Upgrade AB 5/250 to ControlLogix

Rockwell no longer support Allen Bradley 5/250 PLC’s.

5/250 PLC’s were a big ticket item of the early 90’s and considered advanced in their day. These powerful systems ran a whole factory with ease. They were developed with a DOS package, unfortunately the software never advanced beyond this.

Companies running these PLC’s are feeling the heat not only from the risk of the lack of support, but getting left behind in technology especially since the advent of ControlLogix and all its Information / Control might.

“One day running with an AB 5/250 the next a ControlLogix”

These companies have, over the years, optimised their plants and running efficiencies only to realise they are operating on yesteryears technology.

How to upgrade from 5/250 to a ControlLogix platform? As there is no conversion utility as with other AB platform upgrades.

Those with large budgets, restructure/rewrite the whole code “a start again approach.”

We have heard others retyping the whole code with a moderate price tag and a rough plant restart.

Byers Control Systems solution is “Easy 5/250 to Clogix”

“Easy 5/250 to Clogix” entails a systematic approach for the actual upgrade and implementation of the code. Together they ensure a smooth transition literally One day running with an AB 5/250 the next a ControlLogix, all at a value for money option.

The first “Easy 5/250 to Clogix” was presented to a major NZ company who wouldn’t accept downtime or a high price tag. This major NZ customer was so happy with the outcome… well, you can talk to them yourself.

Easy 5/250 to Clogix

Advance operator interface

This project entailed upgrading inefficient CIP (Clean In Place) systems at New Zealand Dairy Foods.

Murray Dench, a prominent Dairy process engineer had clear project goals:- save money by minimizing waste and run time. Murray requested that we make these systems work smarter, not harder. One of the key areas to be improved was the operator’s interface window to the smart yet complex process.

In conjunction with Murray and site operators, Byers Controls developed the CIP Control panel. These operator-focused screens employ many special features which include: Dynamic indicators show only what the operator needs to know, when required, and removing complication; Quick glance format which allows for an answer to “Is it OK?” allowing for CIP to be one of many tasks in process for the operators. The main question asked by operators was “How long till it finishes?” This is now quickly and accurately answered. This feature allows for planning.

The benefits are clear to see - happy operators who understood what was going on and Murray realizing the potential and future of such a philosophy as HMI interfaces.

CIP Control Panel

Milk Cream Pasteurizer NZCP7

A start-again-from-scratch project. Byers Controls electrically engineered, supervised and commissioned this project for Tetra-Pak NZ.

This pasteuriser is a stand-alone system with several stand-alone PID controllers, an Allen Bradley FlexLogix PLC, and a Panelview HMI.

Requirements for this project were: NZCP7 compliant 2002, up and running by a set date with minimal budget.

All requirements were met with ease and customer satisfaction.

Byers Controls has since integrated the key NZCP7 monitoring points into the site Citect SCADA system

Smart flexible Equipment Fault System

Byers Controls have developed a real time mass equipment fault routine that will exceed most customers needs when it comes to plant equipment fault detection systems. Our system is configurable down to the individual customer and equipment’s requirements. Key features include: real time fault monitoring, auto fault acknowledgement, all fault acknowledgement, individual fault acknowledgement and recorded faulted status.

Benefits of such a system are:- real time fault monitoring for those critical processes, intermittent faults are pin pointed and detailed immediately for quick resolution.

Grateful broken-down customers

Byers Controls is especially strong in the URGENT breakdown field. Many customers who have been working on a problem for some time call us for help. Sometimes a fresh pair of skilled eyes can pick up the fault very quickly.

Some of the comments we get afterwards are: “Now we know…we won’t waste so much down-time on the hard ones”, “Thanks for your prompt attention, we were really under pressure”, “We didn’t think of that”, “Now you’ve fixed that how about fixing up this system”

Please note: We provide this service free of any after hours surcharge and promise to give priority to existing long term customers

Machine control systems

In recent times we been involved in many machine control systems, to name just a few:- form filling & sealing, high speed lines, crate packing machines, bagging, blow moulding, sheet metal pressing….. the list goes on.

We believe that our strong electrical and practical skills benefit our customers in this field.