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Engineering - Controls

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Calvary utilizes CAD and Excel to document our complete Controls Hardware Design solution. CAD drawings are provided for Electrical Power Distribution Schematics, Safety Schematics, Device Connection Schematics, Network Connection Diagrams, I/O Schematics, Cabinet Layouts, Panel Layouts, Pneumatic Schematics, and Hydraulic Schematics. Separate Excel files are provided for Electrical, Pneumatic, and Hydraulic Bill of Materials.

Calvary makes extensive use of Industrial Networks for I/O and communications to reduce machine and control cabinet footprints, shorten wiring time, and improve diagnostic capability. Modern open networks such as:

  • EtherNet/IP
  • ProfiNet
  • Modbus/TCP
  • DeviceNet
  • ControlNet
  • Profibus
  • ASI

Integral with all Calvary designs is the appropriate use of domestic and global industry standards including:

  • NFPA79
  • NEC
  • CE
  • ANSI
  • RIA
  • CSA
  • UL


At the heart of every custom machine is either a PLC or PC based controller. Calvary is experienced with all major brands of PLCs and their associated programming software including:

  • Allen-Bradley (ControlLogix, CompactLogix, SLC, MicroLogix, Pico, PLC5)
  • Siemens (S7, S5)
  • Modicon/Telemecanique (Premium, Quantum, Momentum, Compact984)
  • GE-Fanuc (RX3i, 90-30, 90-70)
  • Omron
  • Automation Direct
  • B & R

For PC-based control and test, Calvary is experienced with:

  • National Instruments (LabView, Measurement Studio)
  • Microsoft (Visual Basic, C)
  • Entivity (Steeplechase)

Industrial HMI
The operator’s control and status of the machine is through a single purpose industrial HMI and/or a SCADA system.
Calvary is experienced with all major brands of industrial HMIs and their associated programming software including:

  • Allen-Bradley (PanelView Plus via RSViewStudio For ME, PanelView via Panelbuilder32)
  • Siemens (OP, TP via WinCCFlex and ProTool)
  • Modicon/Telemecanique (Magelis via Vijeo)
  • GE-Fanuc (QuickPanel via QuickDesigner)

Other brands such as CTC, Omron, Automation Direct, and CutlerHammer:

  • For SCADA systems, Calvary is experienced with software such as:
  • Allen-Bradley RSViewStudio for SE
  • Siemens WinCC
  • CTC InteractX
  • Invensys Wonderware
  • GE Fanuc Intellution iFIX

Machine Vision
Machine Vision is applied extensively from simple applications such as part presence/absence to more complex applications such as gauging, pattern matching, and surface inspection. Calvary is experienced with:

  • Cognex (insight, Checker, VisionPro)
  • DVT (intellect, Framework)
  • Acuity
  • Banner
  • Keyence

Robotics & Motion Control
Calvary makes extensive use of Cartesian, SCARA, Gantry and Articulated Robots for pick and place, dispensing, and welding. Many robots are fitted with Machine Vision to guide or correct their motion. Calvary is experienced with many different robotic systems including but not limited to:

  • Fanuc
  • Epson
  • ABB
  • Adept
  • Denso
  • Intelliegent Actuator

As part of our complete traceability solutions, Calvary has provided many custom designed SQL and Access databases and the communication links necessary to extract data out of and send data to system controllers and devices.


As a turnkey supplier, Calvary is accustomed to integrating many devices into safe, easy to operate, robust, fault tolerant machines. We are experienced users of Transducers (pressure, flow, level, temperature, displacement, force, torque); Servo and Stepper Motors; Heaters; Chillers; Temperature Controllers; Leak Testers; Label Printers and Applicators; Chip Programmers; Magnetizers; Laser and Pinstamp Markers; Laser, Electron Beam, Resistance, and Plasma Welders; Signature Analyzers; Dispensers, and many other devices.

Test machines are programmed with a Recipe structure to allow easier modification to existing models and addition of future models. End of Test Results are stored in various formats (CSV, Excel, ODBC, Access, SQL, etc.).

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 Calvary Automation Systems · 855 Publishers Parkway. · Webster, NY 14580 · Tel:585-347-6127 · Fax:585-347-6125 ·