PLC programming

Our core business

PLC programming is central to RS Automation’s work. Our published experience includes Rockwell ControlLogix and RSLogix, with applications in recycling, manufacturing, water treatment, mining, warehousing and conveyor systems.

Control built around your process

A useful starting point is the operating sequence: what the machine must do, what allows it to run and what happens when a condition changes. We work through that process with your team before discussing the control solution.

• Conveyor sequence control and coordinated plant operation
• Food, beverage and packaging line applications
• Warehousing, inventory tracking and multilane sortation
• Barcode scanning and database-connected processes
• Servo and motion control applications
• Staff training and operator understanding

Working with an existing system

For an upgrade, the starting point is what is already installed. Controller models, software versions, available backups and the surrounding equipment influence how the work should be approached. A clear picture of the current installation helps define the change.

• Existing controller and network information
• Current programs, drawings and equipment lists
• The behaviour you want to change
• Production windows and commissioning arrangements

Start with a focused brief

Tell us which machine or process you are working on, what the present system does and what you need it to do differently. If you have a functional description, program backup or equipment list, let us know what is available.

Specify automatic and manual behaviour

For each part of the process, describe the sequence, the conditions that permit it to start and the feedback that confirms completion. Include the expected behaviour when equipment becomes unavailable. A clear description of manual operation and recovery helps the team understand what operators actually need.

• Automatic sequence steps and completion feedback
• Manual controls and operating-mode transitions
• Permissives and interlocks that affect the sequence
• Stop, restart and interruption handling

Include settings, recipes and interfaces

A control change can affect more than the visible sequence. Adjustable values, recipes, counts and communications with other equipment need to be identified. Agree which settings are available to operators and which need controlled access. Check the impact on any connected screen, historian or database.

• Setpoints, allowable ranges and engineering units
• Retained settings and reset requirements
• Upstream and downstream machine communications
• Data used by alarms, reports or external applications

Agree the acceptance and final records

Turn the required behaviour into a test plan before commissioning. Include normal operation and the relevant fault cases. Final backups should represent the commissioned installation. Record the changes and hand over the information agreed for operations and maintenance.

• Expected results for each operating mode
• Tests for the interfaces included in the scope
• Final program backups and version information
• Operating notes, training and outstanding items