Projects

CCS has experience working on a variety of processes in many industries. We can provide solutions for all of your industrial automation needs. Our success can be found in our solutions, such as these recent projects.

Power Drying System

Power Drying System

We were brought into the project in the design phase and were tasked with finding the best solution for the customer, while integrating our controls with another supplier’s controls.

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Scrap System

Scrap System

CCS outperformed the competition on a recent scrap material control system. It all started when we were called in to review the functional requirements of the facility.

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Custom Machine

Custom Machine

CCS was involved with this custom machine from the quoting phase all the way to the end-user training. The initial machine design was simple; however, after further design and analysis, the project grew greatly in scope.

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Passive Isolation Explosion Protection Valve

Passive Isolation Explosion Protection Valve

This project started out with a simple, out of the box solution. After submitting the design criteria to the end user, it was identified that the out of the box solution would not meet the corporate specification.

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Power Drying System

Power Drying System

We were brought into the project in the design phase and were tasked with finding the best solution for the customer while integrating our controls with another supplier's controls. The control system consisted of (4) PowerFlex 525 VFDs fully controlled over EtherNet/IP, (10) local motor starters, (4) existing motor starters in an existing MCC, (14) level sensors, (3) E-Stop Zones, multiple analog inputs, multiple PID loop outputs, and various field mounted sensors.

We oversaw the control panel design, construction, and assembly. While the panel was being built, we converted the RSLogix 500 PLC program to the RSLogix 5000 program loaded into the Allen Bradley 1769-L33ER processor. We also converted the HMI application that was loaded into the 10" PanelView Plus.

The panel was integrated into the customer's existing MCC, which minimized the control panel requirements. Installation support was provided by CCS to the installing contractor.

Once the panel was installed, we provided onsite commissioning, startup, and training support, while customizing the application to the customer's requirements. All inputs and outputs were confirmed while making any required field wiring changes. The PID loop was also tuned for proper operation.

This control system has since been upgraded with a Dell SonicWALL NetExtender VPN connection for remote program changes and troubleshooting assistance. The VPN connection has proven to be essential for the long-term support of this control system.

Scrap System

Scrap System

CCS outperformed the competition on a recent scrap material control system. It all started when we were called in to review the functional requirements of the facility. We quickly identified how we could save the customer time and money.

We were involved from the initial meeting to the final hand off.

The system had two PowerFlex 400 VFDs that were fully controlled over EtherNet/IP. We could read and/or write any parameter in the drive. The system also had (6) additional motors with zero speed switches monitored by the PLC to confirm proper operation.

The control panel was controlled by a CompactLogix PLC and operator interface was provided by a 10" PanelView Plus. The operator interface included all required controls for normal operation, maintenance of the system, and operator troubleshooting.

Once the commissioning and startup was complete, end-user training was completed. After proper training of the system functions and controls, the end-user was able to take ownership of the control system.

CCS has since been contracted to make expansions to this system.

Custom Machine

Custom Machine

CCS was involved with this custom machine from the quoting phase all the way to the end-user training. The initial machine design was simple; however, after further design and analysis, the project grew greatly in scope. The final machine design included electrical, hydraulic, and pneumatic power systems. The purpose of the machine was to cut a cylindrical tube of plastic with a dynamic diameter, which ranged from 4" to 24".

We assisted the customer in proper selection of the PLC, HMI, VFD, and I/O hardware. We also tailored our design around the customer's existing communication protocol specification. The final selection was a full Siemens automation solution from the S7-1200 FC Safety PLC, to the Comfort Panel operator interface. This was a custom solution through and through; from the G120 VFD with STO being controlled over PROFIBUS, to the PROFIBUS remote I/O rack, we met the customer's requirements.

Once the machine was functional, the customer was brought in to review the custom machine. All requested changes were implemented after final review. The customer requested that we provide a full machine manual and onsite training, which was provided. Following this training, additional changes were requested and these changes were implemented in the field.

The customer has requested additional services from CCS.

Passive Isolation Explosion Protection Valve

Passive Isolation Explosion Protection Valve

This project started out with a simple, out of the box solution. After submitting the design criteria to the end user, it was identified that the out of the box solution would not meet the corporate specification. After further communication with the end user, it was identified that a Safety PLC would be required. Based on the application requirements we specified a 1768-L43S safety processor with an in chassis EtherNet/IP communication bridge to facilitate communication to the 1734 POINT I/O modules. This design allowed a safety rated solution, while allowing the I/O to be distributed.

The control panel design, construction, and assembly were closely monitored. Once assembled and ready for testing, the safety PLC program was loaded into the GuardLogix safety controller. The proper operation of the control panel was tested prior to shipment and the safety signature was applied.

At startup, we confirmed the proper operation of all field devices and made the required adjustments. Once the system was fully commissioned, end user training was held.

The customer has requested additional services from CCS.