Controls & Automation Servicesin Northwest Indiana
Quick overview
SSI integrates and troubleshoots Allen-Bradley programmable logic controller (PLC) systems, control panels, sensors and variable frequency drives (VFDs) for plants across Northwest Indiana and Chicagoland. Because our crews are millwrights too, we trace a fault through the controls and the machine together, so the fix covers both the signal and the equipment it runs.
What do controls and automation services include?
| System | What we do | What you get |
|---|---|---|
| Allen-Bradley PLCs | Troubleshooting, I/O checks, integration of new equipment into existing logic | A machine that runs and faults that make sense |
| Control panels | Panel wiring, terminations, component replacement and tie-ins | Clean, labeled panels that are easier to service |
| Sensors & switches | Prox switches, photo eyes, limit switches, pressure and level devices | Reliable signals to the PLC |
| VFDs & motor control | Drive setup basics, fault diagnosis, replacement and motor checks | Motors that start, stop and run at the right speed |
| Equipment integration | Wiring and commissioning controls on installed or retrofitted machines | One crew for the mechanical and controls side |
- Allen-BradleyControls integration is one of our credentials.
- Mechanical tooWe check the machine, not just the code.
- 24/7Call (219) 386-1506 any time.
How does a controls troubleshooting call work?
Step 1: Gather the story
Talk to operators and maintenance. Note the fault, when it started and what changed.
Step 2: Make it safe
Lockout/tagout and electrical safe work practices before panels are opened.
Step 3: Trace the fault
Check PLC status and I/O, then follow the signal to the sensor, drive or machine.
Step 4: Fix it
Replace the failed device, correct wiring or repair the mechanical cause.
Step 5: Test & hand over
Run the machine with your operators and document what was changed.
Signs of a controls problem
When should you call for controls troubleshooting?
If the machine is fine but won't run, or runs but won't behave, the problem may be in the controls.
- Faults that won't clear or keep coming back
- Sensors reading wrong or dropping out
- Drives tripping on overcurrent or overvoltage
- Intermittent stops with no clear cause
- Damaged or undocumented panel wiring
- New equipment that needs to be tied in
What does SSI do in controls and automation?
We integrate and troubleshoot Allen-Bradley PLC systems, control panels, sensors and VFDs on industrial equipment. Our crews are millwrights first. So when a machine faults, we look at the signal and the steel together. Then we fix the real cause and get the line running again.
Most plants don’t need a controls firm for every fault. They need someone who can open the panel, read the PLC, walk out to the machine and work out why it stopped. That’s the gap we fill.
Why pair controls work with mechanical work?
A large share of “controls” faults start with something mechanical. A sensor bracket gets knocked. A cable chafes against a moving guard. A motor draws high current because the gearbox behind it is failing. A crew that only works the panel will reset the fault. A crew that also works the machine will find the cause.
| Fault you see | Possible controls cause | Possible mechanical cause |
|---|---|---|
| Prox or photo eye dropout | Failed sensor, bad cable | Bent bracket, vibration, buildup |
| VFD overcurrent trip | Drive settings, failed drive | Seizing bearing, jammed load, misalignment |
| Position or limit fault | Switch failed, wiring open | Worn linkage, loose cam, overtravel |
| Intermittent stop | Loose terminal, bad I/O card | Cable flexing at a moving joint |
What does Allen-Bradley PLC work include?
Allen-Bradley controls integration is one of SSI’s listed credentials. In practice that covers:
- Troubleshooting. Reading controller status and fault codes, then checking inputs and outputs while the machine runs.
- Integration. Tying new or retrofitted equipment into the PLC that already runs your line.
- I/O and wiring. Replacing failed modules, correcting wiring and documenting changes.
- Commissioning. Testing sequences with your operators before handing the machine back.
We work with your plant’s controls standards and change practices. If your plant controls who edits logic, we follow that process.
Sensors, switches and instruments
Sensors are where controls meet the real world. We replace and set up proximity switches, photo eyes, limit switches, and pressure and level devices. We mount them so they survive the environment they’re in. On weighing systems, see our scales and load cells page.
VFDs and motor control
We diagnose drive faults, check motor and cable condition, set basic parameters and replace failed drives. When a drive keeps tripping, we look at the load too. A laser alignment or a gearbox rebuild is sometimes the real fix.
Controls on new and retrofitted equipment
When we handle equipment installation or an equipment retrofit, we can carry the controls work as well. That means panel tie-ins, sensor mounting and wiring, and startup testing. One contractor on both sides means fewer handoffs and a tighter schedule. Our steel mill retrofit project in Gary shows how we run a retrofit from assessment to testing.
Controls support for environmental and process systems
Collectors, scrubbers and process skids all depend on instruments and timers. We check pressure transmitters, pulse timers and PLC signals on environmental systems. Then we repair the mechanical side as well.
How do you work safely inside a control panel?
Every panel job starts with a JHA and lockout/tagout. Our crews follow electrical safe work practices before any enclosure is opened. Live troubleshooting is kept to the readings that truly need power, done with the right protective equipment. When a fix needs logic changes, we work through your plant’s controls owner. Nothing gets edited on the fly without sign-off.
Before we leave, we tell your maintenance team what we changed and why. Replaced devices, wiring corrections and settings are written down. That way the next person who opens the panel isn’t starting from scratch. A safe worksite is a productive worksite.
When should you call?
Call when a fault won’t clear, a sensor won’t hold, or new equipment needs tying in. We serve plants across Northwest Indiana and Chicagoland. For a line that’s down right now, our emergency repair crews answer 24/7 at (219) 386-1506. When downtime isn’t an option.
Controls & Automation across the Region
Tell us about the equipment
Send the make, model and what you're seeing. A crew lead will call you back with next steps.
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welders
Controls & Automation FAQs
Do you work on Allen-Bradley PLCs?
Yes. Allen-Bradley controls integration is one of our credentials. We troubleshoot Allen-Bradley PLC systems, check inputs and outputs, and integrate new or retrofitted equipment into existing control systems. If your plant runs another platform, call us and we will tell you straight whether it's a fit.
What is PLC troubleshooting?
PLC troubleshooting means finding why a machine controlled by a programmable logic controller isn't doing what it should. We check the controller's status and faults, watch inputs and outputs while the machine cycles, and follow the signal out to the sensor, drive or device that's causing the problem.
Why does it matter that your controls techs are also millwrights?
Many controls faults have a mechanical cause. A prox switch reads wrong because a bracket bent. A drive trips because a bearing is seizing. A crew that understands both the panel and the machine finds those faster, and fixes the cause instead of just resetting the fault.
Do you work on variable frequency drives?
Yes, at a practical level. We diagnose drive faults, check motor and wiring, set up basic parameters, and replace drives when one has failed. For complex drive engineering or system-wide power studies, we will tell you up front and work alongside the right specialist.
Can you wire and commission controls on new equipment?
Yes. When we install or retrofit a machine, we can handle the controls side too: panel work, sensor mounting and wiring, and tie-ins to your existing PLC. One contractor carrying the mechanical and controls work keeps the startup on schedule.
Do you build or modify control panels?
We do panel wiring, component replacement, terminations and modifications to existing panels, and we label what we touch. For new panels that need a listed shop build, tell us your requirements and we will talk through how to meet them.
Can you help with an intermittent fault?
Yes. Intermittent faults are some of the hardest to find. We start with the fault history and when it happens, then check connections, cable runs, sensors and the mechanical condition of the machine. Loose terminations and damaged cables in high-vibration areas are common causes.
Do you offer emergency controls support?
Yes. If a machine is down on a fault, call (219) 386-1506 any time, day or night. We will ask what you're seeing and what the PLC is reporting, then tell you how fast a crew can get there. If the fault turns out to be mechanical, the same crew can fix that too.
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