Plastics process control panel upgrade, CompactLogix CPU, Eurotherm solid state heat controls.

A portable asphalt plant needed a control system upgrade due to their failing obsolete hardware. We migrated their control system which consisted of an Allen-Bradley SLC 5/04 controller and PLC-5 Rack I/O on a Remote I/O link, to a CompactLogix controller with an Ethernet link to a CompactLogix I/O remote rack. The system also uses a PC running RSView 32 for the operator and process control, which required I/O tag conversion to the new platform.

A portable asphalt plant needed to upgrade their obsolete variable frequency drives. We replaced the AB 1305 and PowerFlex 40 drives with PowerFlex 523 VFD's in their electrical control room (Very dusty electrical control room, that is).

We assembled a new Variable Frequency Drive panels for a plastics extrusion process. Replacing AB1336 drives with 25hp Allen-Bradley PowerFlex drives in a Hoffman enclosure, Listed UL508A.

A manufacturer of consumer plastic products needed to upgrade their extruder heat controls. We provided a solution that replaced individual PID controllers with a CompactLogix processor and Panelview Plus HMI. The process for the extruder heat control can now be integrated seemlessly with the rest of the process.

Pallet Repair Systems Inc. (Jacksonville, IL)

PRS needed a UL 508A control panel designed and built within three weeks for one of their pallet sortation systems.

We delivered a complete control panel with drawings and documentation. The panel included a 100 amp main with NFPA 79 disconnect handle, six motor starter contactors, CompactLogix controller, operator touch screen, and bulkhead quick-connects for field devices.

Stratas Foods, LLC. (Quincy, IL)

When Stratas Foods needed to upgrade their process control and operator interface (HMI), they also wanted to leverage the benefits of Virtual Machine(VM) technology.

We provided a turn-key project, upgrading their HMI from FactoryTalk View SE version 5.1(32bit) to 7.0(64bit) and implemented within a virtual environment.

Utilizing a new Dell Power Edge VRTX with two VMware vSphere 5.5 Hosts, ten virtual Windows 7 stations run FactoryTalk View SE Clients that allow connections by any device capable of a Remote Desktop (RDP) session.

Two FactoryTalk View SE Server VM's handle the HMI, Data, and Alarm Servers while providing redundancy during IT software updates and patches.

The vSPhere server allows fast VM creation, duplication, and backup using templates and server data storage.

Previously if an operator station PC failed on the plant floor, several software packages had to be installed on a replacement PC before the HMI was operational again. This took an unnecessary amount of time and resources. Now, if an operator station PC fails, any PC or device capable of a Remote Desktop Session can be placed online and connect to the VM that is always running the FTView Client.

Zoetis (White Hall, IL)

Zoetis, a global manufacturer of animal health and pharmaceutical products, wanted a way to reliably trend process data in a centralized system.

We developed a system with Rockwell Software FactoryTalk View SE to collect data from several isolated processes and provide a central point for historical trending and logging.

Operators can now monitor processes located in several areas of the facility from a single PC. Critical data points are logged and displayed in trends on the HMI, which are also stored in an Access database. The data can be queried by other software systems and used in reports for management and quality control.

Below are some sample screenshots of the application during development.

E&M Electrical (Beardstown, IL)

After an automobile accident knocked out a raw water lift station control panel, E&M Electrical needed a panel built with a control system pre-programmed and ready to install for the City of Beardstown.

We designed, built and delivered a complete pump station control panel configured for two pumps with automatic alternating run sequence, lead / lag pump, manual control, and four float levels with alarm beacon.

The system utilized a lockable enclosure with 60 amp main disconnect, runtime meters, Hand-Off-Auto control with lighted indicators, phase sensing relay, two motor contactors, and an Allen-Bradley Micro850 PLC for control.

Federal Mogul (Skokie, IL)

Automotive parts manufacturer Federal Mogul Motorparts needed to upgrade an obsolete PC based control system on a Rhodes 250 Ton Press Machine.

We provided a solution utilizing an Allen-Bradley CompactLogix processor and Panelview Plus operator interface. A remote operator console was removed and a terminal junction was also relocated to the side of the press machine. See videos below...