Automated Control System Installed on Bucket Wheel Excavators and Combined Rotary Equipment at Mini Maritsa Iztok, Mini Maritsa Iztok EAD, TPP Maritsa East 2, TPP Maritsa East 3, and TPP Maritsa 3 – Dimitrovgrad
As part of a large-scale modernization effort, an automated control system (ACS) has been successfully implemented on key energy and mining equipment at Mini Maritsa Iztok EAD, TPP Maritsa Iztok 2, TPP Maritsa Iztok 3, and TPP Maritsa 3 – Dimitrovgrad. The project included the complete overhaul of legacy control software and drive systems on rotary excavators and coal-handling equipment.
Industrial Strength with Rockwell Automation
The system leverages advanced technologies from Rockwell Automation, integrating:
-
ControlLogix L71 PLCs for reliable and modular control;
-
PowerFlex 755 frequency inverters, optimized for industrial drives;
-
Ethernet/IP communication architecture with DLR topology;
-
High-precision position feedback with 842E encoders;
-
Seamless integration with FactoryTalk View SCADA platforms.
This ensures precise control over movement systems (travel, rotation, hoist), full fault tracking, and visualization of operational data in real time.
Engineering Expertise by Rotek Ltd.
The design, installation, and commissioning were led by Rotek Ltd., a trusted Bulgarian systems integrator and Rockwell Automation partner. Their responsibilities included:
-
Replacement of PLC-5 controllers with modern ControlLogix systems;
-
Retrofitting and wiring of new communication modules;
-
Development and migration of control logic via Studio 5000;
-
Mounting and programming of advanced frequency drives;
-
Configuration of the new user interface using PanelView 1500 and FactoryTalk View.
Thanks to Rotek’s technical depth and precision, the solution achieved full compatibility with existing infrastructure while meeting stringent safety, reliability, and performance standards.