HISTORY / CHALLENGE

For years, March & Associates Engineering Ltd., a client of Horner Canada, has delivered high-performing dust collection systems, built around custom filters tailored to their ProDraft units. These filters, manufactured by a trusted supplier, offered exceptional durability and filter performance. That changed when the supplier was acquired and ceased production of custom units. Though a replacement vendor was sourced, their filters failed to meet the same standards. This situation has raised concerns among customers about potential legal and regulatory repercussions due to the unfiltered dust being released into the environment and affecting neighboring businesses. To restore trust and performance, March & Associates turned to Boehm Tech to develop a data-driven solution.

Boehm Tech’s objective was not merely to replace components, but to design for reliability: Measure, Maintain, Scale. Achieving that trifecta requires solving
three interrelated problems:

– Analog precision shortfalls. The existing I/O system lacked the resolution and isolation required to accurately and safely capture key sensor signals, especially from the dust probe and Differential Pressure Transducer (DPT).
– Limited diagnostic visibility. Without high-quality data, maintenance teams could not distinguish gradual filter loading from sudden failure. Problems remained hidden until they triggered production risks.
– Rigid system architecture. The new solution had to work for a 12-filter setup immediately, while remaining flexible enough to support future systems with 40+ filters.

SOLUTION

To tackle the performance and compliance risks, Boehm Tech partnered with Mark Taverner at Horner Canada to evaluate options for expanding the analog I/O capabilities of the Edge Controller: OPTA PLUS. Boehm Tech chose Horner Canada for their reputation in providing reliable, high-quality automation products with excellent technical support (Thank you Mark and team!). The goal was clear: improve sensing precision without introducing a substantial increase in cost or complexity.

After reviewing alternatives, Boehm Tech selected the Horner SmartMod product line. Its modular structure, industrial-grade performance, and integration
support made it the right fit for this application. The FFD PLUS Dust Collection System is an advanced solution designed to optimize the performance and
efficiency of industrial filtration systems. In collaboration with Horner Canada, Boehm Tech integrates Horner’s products to enhance the capabilities of its own
system, delivering precise monitoring, real-time control, and IIoT connectivity.

The first FFD PLUS installation is now operational at a plant manufacturing
doors and mouldings. Even in its initial deployment, the system is delivering high-resolution insights into filter condition, supporting proactive maintenance
and system tuning.

SOLUTION Continued…

The FFD PLUS platform goes beyond basic monitoring to include:
– Precise sensor integration and real-time monitoring
– Native IIoT connectivity for remote dashboards
– A scalable foundation that adapts to both small and large dust collection systems
By making filter performance both measurable and actionable, the system helps operators prevent unfiltered emissions, avoid
shutdowns, and ensure compliance. Failing filters can now be identified early and replaced during scheduled downtime, minimizing
risk and maintaining uninterrupted production. Alan March, P.Eng., of March & Associates Ltd., was instrumental in refining
the concept and successfully delivering the first commercial deployment.

SYSTEM ARCHITECTURE

Key Components:
Edge Controller: OPTA PLUS – The OPTA PLUS serves as the system’s central edge controller. Powered by a dual-core ARM processor (M7 and M4), it runs advanced control logic including
the pulse-cleaning sequence and PID feedback loop. Simultaneously, it supports machine learning and IIoT cloud connectivity. Real-time data is accessible through browser-based and mobile dashboards, enabling remote monitoring and diagnostics.

While the OPTA PLUS alone would have introduced an analog input error margin of up to 10%, the HE359ADC120 module resolves this limitation through high precision analog input. With approximately 16-bit resolution and 0.2% linearity error, the ADC captures accurate signal data with minimal distortion, forming the foundation for reliable diagnostics and control.

Horner SmartMod HE359ADC120 4-channel RS-485 Modbus RTU: The ADC accurately samples the 4-20 mA output signals from the compressed air pressure transmitter, Differential Pressure Transmitter (DPT), and dust detection probe, enabling high-precision data acquisition for monitoring critical system parameters related to filter health.

While the edge controller would have introduced a 10% error margin, the HE359ADC120’s precision eliminated this limitation, providing the necessary data accuracy for the dust collection system. With approximately 16-bit resolution and 0.2% linearity error the ADC module enables them to build a system that provides low overall error in the acquired data samples.

Horner SmartMod HE359DAC007 2-channel RS-485 Modbus RTU: The optional DAC module enables closed-loop pressure feedback control via
a Variable Frequency Drive (VFD), maintaining a constant vacuum level in the mainline duct to ensure optimal dust collection performance. The ability to control the vacuum levels in the mainline duct based on data samples from the ADC ensures system efficiency, preventing excessive power consumption while maintaining consistent airflow to ensure the collected dust stays suspended in the airstream.

RS-485 Modbus RTU Communication: The integration of half-duplex RS-485 Modbus RTU allowed them to seamlessly communicate with the ADC module, enabling the system to gather raw analog data from the transmitters.

PR Electronics Isolation Products: The PR Electronics isolation products were integrated to enhance signal integrity and protect the system from electromagnetic interference. These products provided an isolated excitation source for the 2-wire transmitters, significantly improving the system’s performance and reliability.

RESULTS

With high-fidelity sensing and IIoT integration, the system now identifies filter degradation as it happens. This enables proactive scheduling of replacements,
reduces unplanned downtime, and extends maintenance intervals. At the same time, it conserves energy and ensures compliance.

HORNER’S ROLE IN IMPROVING THE APPLICATION

Increased Precision and Reliability: The switch to Horner’s ADC has allowed for far more accurate data acquisition. The near elimination of analog input errors has enabled precise monitoring of differential pressure and particulate loading, ensuring the dust collection system is constantly operating within optimal parameters.

The optional DAC module’s integration to support VFDs has resulted in tighter control of vacuum levels maintaining consistent dust collection airflow and efficiency.

Seamless Integration and Scalability: System components communicate over a half-duplex RS-485 Modbus RTU network, linking the edge controller with the ADC and DAC modules. This setup supports reliable signal transmission and centralized control, while minimizing field wiring and cost. The modular architecture allows straightforward expansion. New features and increased capacity can be added without redesigning the control logic. Relay Expansion Modules support control of up to 40 filters per edge controller, enabling the system to automatically suspend pulse-cleaning for filters identified as failed or degraded. This reduces manual intervention and improves overall system reliability.

Enhanced Remote Monitoring and Control: Cloud connectivity with the edge controller provides real-time monitoring and diagnostics through web and mobile dashboards. This capability allows Boehm Tech to monitor system performance from anywhere, reducing the need for on-site inspections and
enabling proactive maintenance actions.

The OTA (Over-the-Air) update feature ensures that the system stays up-to-date with the latest software improvements, without the need for manual intervention.

Proactive Fault Management and Predictive Maintenance: With the FFD PLUS system, they are looking forward to implementing both local and cloud based algorithms that predict filter maintenance based on real-time sensor data. This reduces unplanned downtime and optimizes the life cycle of the filters providing a fast ROI. This controller implements on-demand cleaning only when required to reduce filter wear/damage. The pulse control differs from standard industrial dust collectors, which use timer based controls and significant amounts of compressed air to clean the filters. Savings of up to 50% of the compressed air being used and an increase in filter life by up to 30% are possible. The automatic identification of filter failures is another key benefit of the system. In the event of a filter failure or heavy dust leakage, the system automatically stops pulsing the affected filter and flags it for inspection, and possible replacement, at the next scheduled shutdown. This ensures continuous operation without manual intervention.

With these improvements, Boehm Tech has changed dust collection from a reactive maintenance task to a proactive and intelligent process. Their controller is not only designed for the ProDraft series of Dust Collectors from March & Associates Engineering Ltd, but can be retrofitted to existing dust collection systems, promptly allowing the savings to start immediately.

CONCLUSION / TESTIMONIAL

“The integration of Horner Canada’s products into the FFD PLUS Dust Collection System has been instrumental in improving both the precision and efficiency of our dust collection operations. With enhanced signal acquisition and control, and the ability to scale the system as needed, Horner’s products have provided us with a robust foundation for future growth. Their reliable and versatile modules, combined with their expert technical support, have allowed us to overcome critical challenges and to implement a highly efficient, low-maintenance dust collection reverse pulse jet filter care solution.”

“We are looking forward to working with Horner Canada and leveraging their innovative products in future iterations of the FFD PLUS system.”
~ Stephen Boehm, Boehm Tech