When a critical refrigeration system became inoperable due to a failed universal controller, the system’s operator turned to Hale Engineering for a swift and effective resolution. With operations reliant on maintaining precise refrigeration settings, the failure posed an immediate risk to productivity and system integrity. The challenge was not only to replace the outdated controller but also to upgrade the system to accommodate new signal requirements and ensure seamless functionality through an enhanced user interface.
Challenge
The failed controller was central to the refrigeration system, managing key operational parameters. Its failure rendered the system inoperative, leaving the operator unable to maintain critical cooling functions. The complexity of the task lay in sourcing a suitable replacement for the outdated controller, retrieving and adapting its programme for a modern setup, and addressing the added requirement of converting some signals from digital to 4-20mA analogue formats. Ensuring these updates worked seamlessly with the existing HMI was crucial to restoring full system functionality.
Our Approach
Hale Engineering’s team of experts promptly assessed the situation, identifying the controller failure as the primary issue. Leveraging an identical controller still operational within the system, we retrieved the original programming as a baseline. However, integrating the updated controller required significant modifications to accommodate the new signal requirements and ensure compatibility with the existing infrastructure.
Solution
- Sourced and installed a compatible replacement universal controller.
- Reprogrammed the controller to incorporate updated signal types, ensuring seamless integration of 4-20mA analogue inputs into the system.
- Reconfigured the HMI to display new parameters, enabling users to view, adjust, and monitor key refrigeration system settings with ease.
- Conducted thorough testing to confirm reliable operation and alignment with the system’s requirements.
Results
Hale Engineering successfully restored the refrigeration system, minimising disruption and delivering a modernised solution tailored to future operational needs. The system now benefits from enhanced functionality, an intuitive user interface, and improved reliability, ensuring uninterrupted performance.
Contact Us
At Hale Engineering, we specialise in solving complex technical challenges while improving and future-proofing your systems. Contact us today to learn how we can support your operational needs.
Phone: +44 20 8154 6102
Email: info@hale-eng.co.uk