Allen Bradley PLC and HMI software development for control system upgrade, Indiana, USA

David Tye

Phase one of a controls upgrade on a Goss Metroliner press in Munster Indiana. We have provided our PLC and HMI software design services to the OEM replacing obsolete Harland Simon Intella PLCs with Allen Bradley 1769 Compactlogix PLCs, and replacing the Goss unit facia with Panelview Plus HMIs.

Writing all the bespoke code for both the HMIs and PLCs, maintaining all the functionality and providing diagnostic enhancements. At the same time changing the main press communication protocol from Profibus FDL to Ethernet.

          

Controls Upgrade on a Goss Colorliner Printing Press, San Juan, Puerto Rico, USA

David Tye

Working for the Machine OEM providing commissioning and site management services, we started the changeover and commissioning process on a Goss Colorliner printing press located in San Juan, Puerto Rico. The machine has the outdated and obsolete Goss APCS control system and is being replaced with an Allen Bradley Control Logix and Compact Logix control system communicating on Ethernet/IP instead of the original 4 wire RS422 communication.

Allen Bradley SLC500 to Controllogix Migration, New Zealand.

David Tye

We Provided our PLC programming service to the OEM to convert several Allen Bradley SLC500/4 PLCs and combing them into one central 1756-L82E Controllogix, removing some DeviceNet and RIO networks.  Rewriting code to make it more readable, converting the comments from French to English to aid the maintenance technicians in fault finding after the code has been commissioned.

Press Line Reconfiguration and Extension, New York, USA

David Tye

Working for the Machine OEM providing commissioning and site management services, one on the seven press lines at the largest newspaper manufacturer in the USA was reconfigured to give more colour capacity and a backup press for the larger modern Goss Colorliner 80 press line.  Replacing two Mono units with 2 four colour units and adding missing couples to a 4+1 print tower allowed and extra 20 colour pages straight and 40 pages collect.

Using local labour from the IBEW Local 3 Electrical Union in New York to provide all electrical modifications to the print units and the addition of an extra 150HP Allen Bradley PowerFlex 700 drive to assist the other 10 x 150HP Allen Bradley PowerFlex 700 drive running the line shaft.

CT50 Reelstand Upgrade, Arizona, USA

David Tye

Working for the Machine OEM providing software and hardware commissioning of a Drive Side control panel upgrade to improve the reliability and procurement of Spares for multiple CT50 Goss reel stands. This modification removed the drive side control plate from the reelstand and replaced it with a new control plate with new Allen Bradley PowerFlex DC drive, Allen Bradley Compact Logix PLC and new Motor control gear. The modification was quick, only requiring the reelstand to be out of service for two days.

Before         After

Drive System Upgrade, New York, USA

David Tye

Working for the Machine OEM providing commissioning and site management services, we successfully upgraded 50 x Allen Bradley 1336 150HP (112Kw) Variable Speed AC Lineshaft drives with the modern PowerFlex 700 AC Drives equivalent. The Associated Allen Bradley PLC 5 rack was replaced with a Control Logix PLC and Pilz safety relays utilising the STO (Safe Torque Off) feature of the new drives. Each printing press has 10 x 150HP AC motors with Encoder feedback to provide motion to the printing press.

Print Unit Upgrade, New York, USA

David Tye

Working for the Machine OEM providing commissioning and site management services, we oversaw the conversion project replacing the obsolete Goss APCS control system with a new B&R x20 PLC Control system. The DRINK and MAC racks were replaced with new racks containing B&R x20 remote I/O on a Power Link Ethernet network.

Using Local IBEW Local 3 Union labour for the physical conversion and wiring and us providing the recommissioning of the print unit on the new system

Reelstand Upgrade, New York, USA

David Tye

Working for the Machine OEM providing commissioning and site management services, we oversaw the conversion of 50 x Goss CT45 reel stands. Moving from the old APCS single board computers to New B&R x20 PLC and B&R Servo drives for the reel running belts. Once converted we would recommission the RTP and bring them back into production with production monitoring.

DGM Upgrade

David Tye

Working for the newly formed Prima Group in Manroland Goss, we provided commissioning and software services to upgrade a shaftless DGM web offset printing press at Action Printing in Fond du Lac, Wisconsin USA. The press has three DGM 440 units, two DGM 1030 Folders, with Jardis Reelstands, infeeds and web guides.
The upgrade involved replacing the GE Fanuc PLCs with Allen Bradley Compact Logix controllers, whilst retaining the Profibus Wago IO, and indramat Diax04 drives and PPC controllers.
For information on Press Controls Upgrades Please Contact us.

Controls Upgrade Management and System Commissioning USA

David Tye

Starting Printing Press Conversion, Number 5 of 5 presses.
As part of an Ongoing Contract we are working with ManrolandGoss, we are providing our conversion management and commissioning services for a large press upgrade project in New York, USA.
Replacing the old Goss Colorliners MAC and DRINK controllers with the latest B&R X20 PLCs, and replacing ten Allen Bradley 1336 150HP AC Drives with the latest Allen Bradley Powerflex 755 AC Drives.
For information on Press Controls Upgrades Please Contact us at info@p3controls.com

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