ProSense and Coolmay Integration: Automation in Australian Industries
- Feb 3
- 3 min read
Automation plays a crucial role in improving efficiency and reducing costs across various Australian industries. ProSense’s integration of Coolmay’s all-in-one PLC + HMI platforms offers a compact, industrial-grade solution that combines multiple automation functions into a single device. This approach enables smarter control systems for water treatment, pump management, manufacturing, HVAC, irrigation, and OEM machinery, all while cutting down on the expense and complexity of separate controllers and modules.
Combining Multiple Automation Functions in One Device
ProSense’s use of Coolmay platforms brings together PLC control, HMI visualisation, digital and analog I/O, and high-speed functions into a single unit. This integration simplifies system design and reduces hardware costs. For example, a water treatment plant can monitor tank levels, control dosing valves, and manage pump stations all from one device. This eliminates the need for multiple controllers and wiring, making installations cleaner and easier to maintain.
Key features include:
Up to 30 digital inputs and outputs for managing pumps, valves, and alarms
16 analog inputs and 8 analog outputs for sensors like flow meters and temperature probes
High-speed counting and pulse outputs for precise control of packaging lines and conveyors
PID self-tuning for stable process control in dosing and pressure regulation
This versatility suits distributed sites such as wastewater treatment plants, farm irrigation systems, small treatment skids, and industrial machinery.
Upgrading Older Equipment with Compatibility
Many Australian facilities still operate older PLC systems such as Mitsubishi’s FX3G, FX3U, and FX3S. ProSense’s compatibility with these programs allows quick upgrades without costly re-engineering. This means clients can modernise their automation performance while preserving existing wiring and hardware layouts.
For example, a regional pump station using FX3U PLCs can be upgraded with ProSense devices to add HMI visualisation and remote monitoring capabilities. This approach extends the life of existing assets and improves operational reliability.
Flexible Communication Options for Diverse Environments
ProSense supports multiple communication ports and protocols, including:
Dual PLC ports for device networking
HMI download port for easy programming updates
Optional RS485 for remote regional sites with limited infrastructure
CAN bus for industrial device communication
WiFi and Ethernet for seamless integration with SCADA systems and IoT gateways
This flexibility allows ProSense to connect with variable speed drives (VSDs), meters, and other field devices. For example, a wastewater plant can use Ethernet to integrate ProSense with its SCADA system for real-time monitoring, while a remote farm irrigation site might rely on RS485 for reliable long-distance communication.
Advanced Control Features for Precise Automation
ProSense offers a 32K program capacity, retentive registers, and interrupt logic, enabling complex control strategies. Its PID self-tuning feature helps maintain stable conditions in processes such as cooling towers, dosing systems, and pressure stabilization.
High-speed counting and pulse output capabilities make ProSense suitable for applications requiring fast response and accuracy, such as:
Packaging equipment automation
Conveyor belt speed control
Flow meter pulse counting
Stepper and servo motor control
These features allow industries to improve product quality and reduce waste by maintaining tighter process control.
Security and Remote Monitoring
Security is a growing concern in industrial automation. ProSense includes enhanced PLC and HMI encryption to protect client systems and OEM intellectual property. This is especially important for government projects, utilities, and exported machinery where data integrity and confidentiality are critical.
Paired with Coolmay network modules, ProSense enables remote monitoring and control. This reduces the need for onsite service visits, saving time and travel costs. For example, operators can monitor pump performance or adjust dosing parameters remotely, improving response times and reducing downtime.
Practical Examples of ProSense Integration
Water Treatment Plants: ProSense manages multiple pumps, tank levels, flow and pressure sensors, dosing valves, and alarms from one device. This reduces hardware complexity and improves system reliability.
Agricultural Irrigation: Farmers can automate irrigation schedules, monitor soil moisture sensors, and control pumps remotely using ProSense with RS485 communication.
Manufacturing Lines: Packaging machines benefit from ProSense’s high-speed counting and pulse output to synchronise conveyors and packaging cycles.
HVAC Systems: Cooling towers and environmental monitoring systems use ProSense’s PID control and analog I/O for precise temperature and pressure regulation.
Summary
ProSense’s integration of Coolmay’s all-in-one PLC + HMI platforms offers Australian industries a cost-effective, compact, and versatile automation solution. By combining multiple control and monitoring functions in one device, ProSense simplifies system design, reduces costs, and improves operational efficiency. Its compatibility with older PLC programs allows quick upgrades, while flexible communication options support diverse industrial environments. Enhanced security and remote monitoring capabilities further protect assets and reduce maintenance needs.
