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On-Site Controls Commissioning Support — Automated Warehouse, Costa Rica

Warehouse Automation Allen-Bradley Controls Commissioning Logistics

A global warehouse-automation and material-handling integrator brought Exxerpro in as specialized on-site controls support for the commissioning of a large automated distribution center in Costa Rica — validating and troubleshooting Allen-Bradley PLC control across two plant control zones, a multi-level spiral sorter, and ground-floor conveyor systems, through to live production. Client and end-site names are withheld at the integrator's request.

Scope of Work

  • On-site diagnostics, programming support and fault resolution across the project's control programs and installations.
  • Validation of I/O, safety conditions, motor rotation direction, and VFD (variable-frequency drive) synchronization.
  • Validation and tuning of start/stop sequences.
  • Validation of system alarms and fault handling.
  • Validation and tuning of system communications.
  • Control-network startup validation.
  • Support spanned electrical installation, installation validation, control commissioning for two plant zones, a multi-level spiral conveyor, and a ground-floor conveyor system, plus integration validation against the site's Warehouse Control System (WCS) for both zones, client validation, internal mass-movement testing, and live production assistance.

Technology

  • Allen-Bradley PLC platform
  • Variable-frequency drives, safety I/O
  • Warehouse Control System (WCS) integration

Engagement Model

A specialized controls engineer was deployed on-site for the duration of the commissioning phase, working directly within the integrator's project timeline and reporting structure — the kind of embedded technical support role that complements in-house delivery teams during a complex multi-system startup.