Controls · Northwestern Pennsylvania
Integrate PLC, HMI, drives, sensors, and custom panels. Modifications, updates, bench test, and TeamViewer remote help when you cannot wait for a site visit.
What we do
New machines, old processors, a far panel that should have been on Ethernet years ago — the job is the same: integrate it, keep it supportable, leave the documentation behind.
Ladder and related logic on Allen-Bradley and AutomationDirect processors. New programs, changes to a running line, and clean-up of code nobody wants to touch.
Make the PLC, HMI, drives, sensors, and remote I/O talk to each other as one machine — not six boxes that almost work. Build and wire custom control panels when the plant needs a clean enclosure, not a rat’s nest.
VFD setup, scaling, and commissioning — including applications like recoilers, conveyors, and line speed follow.
The machine already runs. You need a new interlock, a speed change, extra I/O, or a screen the operators will actually use. We change what is there without starting over.
Photoeyes, analog, distance, and 24 VDC devices that have to be honest in the program. IFM, Banner, SICK, Keyence, and similar — plus remote I/O when the home run is too far.
Prove the logic on the bench before you cut into production. When the line is down and a visit is hours away, TeamViewer and remote support to get eyes on the processor. AI-assisted diagnostics and documentation when that speeds the handoff.
How a job runs
No slide deck. The drawing, the processor, and the operator who has to live with it — that is the starting point.
Site visit or a detailed call. What the machine is supposed to do, what it actually does, and what “fixed” means to you.
Points, voltages, networks, and the spare that is not really spare. The program is only as good as the field list.
Logic, screens, and panels a maintenance tech can follow. Bench-test when we can, so the first time it sees the machine is not a surprise.
Startup, backups, and a short handoff: how to get in, what to watch, and who to call if it does not behave.
Tools on the truck
Most of the work is Allen-Bradley. DirectSOFT 6 and field sensors are on the truck too. If your plant still runs RSLogix 500, that is a feature, not a problem.
MicroLogix 1400, CompactLogix, ControlLogix. DirectLOGIC with DirectSOFT 6. ENI adapters and Ethernet on the older hardware.
RSLogix 500, Studio 5000, RSLinx, FactoryTalk View / PanelView, DirectSOFT 6. Also Connected Components Workbench (CCW), Python, and CANopen when the job needs them.
PowerFlex VFDs; IFM, Banner, SICK, Keyence, and similar sensors; 24 VDC I/O; Stride remote I/O. Bench test offline. TeamViewer and remote support when you need eyes on the processor tonight.
Also: Delta, Mitsubishi, Fanuc, Yaskawa, Omron, Schneider, and similar — when that is what the plant already runs.
The company
Lybarger Automation is Andrew Lybarger’s controls practice, based in Cochranton, Pennsylvania. The firm is new. The work is the same work plants already know: integrate the processor, the drives, and the sensors so the machine does what it is supposed to, and do not leave a mess for the next shift.
You get one person who programs it, builds the panel when needed, bench-tests it, commissions it, and answers the phone afterward — including TeamViewer and remote support when a visit is not fast enough. AI-assisted diagnostics and documentation when they help. If a job is bigger than that, we say so before anyone buys hardware.
Start a job
Tell me about your project or problem. A processor type, a symptom, and a photo of the panel is enough to start. If it is down, call.
