Low Risk, Minimal Downtime GEM80 Upgrades Delivered in a 2 day Shutdown

Home > Case Studies > Transicon successfully upgrades complex GEM80 PLC and SCADA system for food manufacturer

Transicon's Unique Solution to create Low-Risk GEM80 Upgrades

  • Our customer needed to upgrade their GEM80 PLC due to obsolescence in a 2-day shutdown.
  • Replacing the GEM80’s was never going to be an easy task – there were 2 main controllers - one talking to an old “IMAGEM” graphics system the other to an “iFix” Scada system with remote I/O stations in various locations around the Mill.
  • The systems comprised of over 9,000 rungs of code, around 2,000 I/O points and 120 graphics pages.
  • All previous solutions to upgrade needed a minimum of 12 / 14-day shutdown, due to the amount of remote I/O and complexity of the two SCADA systems.

Transicon’s solution

  • Using their unique GEM80 code converter and extensive library of proven GEM80 functions the conversion was seamless to a Rockwell ControlLogix PLC.
  • Our in-depth knowledge of IMAGEM and iFix graphics enabled us to modernise the graphics to the latest ISA101 HMI standards to FT View SE client server.
  • Our Tscan Scanner card enables the GEM80 I/O to be retained when the GEM80 PLC is changed to a modern leading PLC solution. This greatly reduces RISK. Our customers feel this unique solution is a “Game changer”.
  • Transicon installed and commissioned the new system in just 1 weekend, leaving the existing GEM80 Digital I/O running off the new Rockwell PLC. Existing IO will now be changed out piecemeal on maintenance / outage days.
  • Transicon have also successfully carried out conversions to Siemens PLC’s
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Testimonials

Andy and his team were a pleasure to work with. The project met all deadlines and targets. Good communication throughout. The installation and commissioning on site went extremely well with very little downtime. I would definitely recommend Transicon to anyone else looking to replace their GEM80 PLCs with a modern solution.

Controls & Automation Engineer - Aluminium Processor

Very happy with the upgrade and especially the time taken to complete the job. Would also like to give credit to the Apprentice that was brought to site with the team. I was very impressed with his skill level and must be receiving excellent training.

Section Engineer - Metals Sector

Atritor has worked with Transicon for over 20 years and that speaks volumes in itself. Transicon is far more than a supplier of electrical control equipment and software, we work with them in partnership, and they are important to the quality of the solutions we provide to our clients. They understand our processes and provide innovative and proactive electrical and installation resources. The fact that Transicon works across a broad range of sectors in automotive and manufacturing means that they not only have the depth of experience that we require, but our clients also know and trust them too. The key reason for the length of our relationship is their willingness to develop solutions with us and problem-solve on-site when required.

Background: Atritor Ltd has provided drying and milling solutions to the mineral, chemical, and mineral industries worldwide since 1980 and has over 90 years of experience in equipment manufacture to draw upon.

www.atritor.com

Simon Cheesmore – Technical Director Atritor Ltd

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