Case Study 6192: Industry Served | HVAC & Water Heater Manufacturing

Is your critical machinery running on outdated controls? Legacy systems can be a ticking time bomb for downtime, posing risks to both production and safety. Here's how we're helping a major American manufacturer of HVAC and water heating solutions mitigate that risk.

Our client relied on a key custom assembly machine with an obsolete control system. This legacy platform created significant challenges, including the growing unreliability of aging components, the difficulty of sourcing spare parts, and safety systems that didn't meet modern standards. They needed a comprehensive upgrade to ensure the machine's long-term viability and safety.

The J+H Automation team designed a complete controls modernization. We replaced the entire core of the system with a state-of-the-art Allen-Bradley ControlLogix PLC and programming it in the modern Studio 5000 environment. The upgrade includes new Allen-Bradley Panelview Plus® HMIs for an improved operator experience and a Powerflex® DC drive for precise motor control. To bring the machine up to the highest safety standards, we are integrating new Keyence light curtains, providing enhanced protection for their team.

This turnkey retrofit will breathe new life into their valuable machinery, significantly boosting system reliability and eliminating the risks associated with obsolete hardware. The client will benefit from a robust, future-proofed platform that enhances operator safety, improves system performance, and provides a foundation for future connectivity and data integration.

We solve problems by building world-class automation. If you're ready to modernize your legacy systems and engineer your success, let's talk about your next project.