FeedForward successfully completed a Spectrum Migration to Foxboro I/A on the paper machine and additives area on PM#5 in Cantonment, FL. The scope included building and configuring 40 graphic displays and 800 faceplates for monitoring and control of the machine. Approximately 1000 analog and digital I/O points were included in the migration. FeedForward conducted a thorough testing program to confirm that all I/O points and controls were configured properly, and that the new MMI met operational requirements. This testing allowed the control system cutover from Spectrum to I/A to be successfully completed in a few days.

FeedForward implemented a new ControlLogix processor to control a new additive process, integrating the new with the old processes seamlessly. The ControlLogix processor is integrated to the existing Foxboro I/A via a MVI Modbus Communications module connected to a Foxboro termination assembly and a Foxboro FBM 224 for Modbus communications. This will allow all new ControlLogix digital I/O to be available in Foxboro I/A for graphic display and operator commands to the new control system. Analogue I/O is being configured directly into the DCS. The HMI was designed to replicate existing operator screens for ease of transition to the new mill configuration. A Factory Acceptance Test was completed in June.

Champion asked FeedForward to provide the Foxboro I/A controls for a new Paper Machine Gap Former installed in 1999 at their Sartell, MN facility. The project includes Allen-Bradley PLC and I/A controls with a gateway to the Foxboro MMI to accommodate new FoxView displays for all analog and discrete controls. The project scope included regulatory control functions in I/A for a Neat Dye Addition System, Headbox calculations and control and calculations for nozzle static head, flow rate onto the wire, jet speed and retention. The discrete control was implemented in PLC 5/40 ladder logics. Fifteen process graphic displays were required along with group displays and interlock displays.