Wash specialists MecWash of Tewkesbury are using Westermo TD-32 PSTN modems to monitor their specialist aqueous washing systems installed at customer sites across Europe. Various types of PLC are used by MecWash systems and a key reason for buying Westermo, says MecWash, “was their ability to provide valuable advice about how to remotely communicate with the many different types of PLC.”  Westermo claims that their ability to provide this type of support sets them apart from their competitors.

The TD-32 DIN rail mounted modem allows MecWash to connect to remote systems worldwide from their headquarters in the UK and diagnose faults reported on the washing systems without the need for site visits. This enables cleaning systems to be returned to production much faster and at less expense after a breakdown.  However, other benefits include the ability to continuously monitor the ultra-critical chemistry. MecWash experts can monitor trends or degradation occurring in the wash fluids and advise how to maintain optimum performance, thereby pre-empting bad wash conditions.  Data can also be obtained about machine usage, reliability and consumption which are valuable for quality and future improvements.

MecWash supplies washing systems for many industrial uses.  Their products are typically used for cleaning components such as car engine parts, percussion caps, small pins and even ventilator grills.   Big changes have taken place in industrial cleaning systems in recent years, mainly in response to environmental issues; for example, water-based washes are now almost universally used.  However, there is also a trend to more flexible manufacturing and, whereas in the past a single large washing unit might serve many sectors of a plant, nowadays each production cell tends to have its own smaller and more specialised washing unit. This means that wash systems are usually highly customised.

Being a true industrial modem the Westermo TD-32 is ideal for building into this type of machine. As well as mounting onto one of the DIN rails in the unit it will also run directly from the cabinet 24V supply without the need for special adapters. The modem is designed with tri-galvanic isolation and has high immunity to noise to help provide reliable communications. Internal watchdog functions also ensure that the modem does not lock up and need to be reset every time a connection is required.

MecWash systems are built and commissioned in Tewkesbury and then shipped to the end user.  Various makes of PLC are used for controlling whatever wash sequence is decided on. However, wash conditions are equally important and a resident chemicals expert employed by MecWash subsidiary MX Systems has the key role of optimising the wash chemistry. After delivery, the remote comms facility is often used during setup and commissioning. In operation, wash systems are usually maintained by local staff, though operations are routinely overviewed from Tewkesbury, particularly the wash conditions.  “Often,” says MecWash, “we can advise the customer of a fault before he realises he has a problem on his hands.”  

The connection between the PLC and modem is made via an RS-232 link. This is where the Westermo expertise comes into its own as no two PLC’s ever seem to have the same pin outs or connectors, not only are the Westermo technical support engineers familiar with the various PLC’s and their programming utilities, but Westermo can also provide specially prepared application sheets for most PLC’s.  

As well as helping maintenance and providing valuable data feedback, the Westermo TD-32 modems are used for updating the PLC programs to take account of new conditions or to improve operational performance in response to actual washing experience.  Remote access plays an increasingly important role in gaining orders in the current economic climate, reports MecWash.