Client Challenge
A new hockey and ice sports arena needed a centralized control system to manage a highly specialized refrigeration process. The system had to support multiple chillers, pumps, and fans across a large facility footprint, and accommodate a mix of control technologies provided by different vendors. Reliable uptime, efficient motor control, and remote access were non-negotiable due to the strict operating standards required for ice quality and spectator safety.
The client sought a turnkey solution partner who could manage procurement, fabrication, programming, and testing—all while collaborating with their team to integrate third-party-supplied components. DSI was tasked with delivering a control system that was scalable, supportable, and ready for rapid commissioning in a tight timeframe.
Our Solution
- Custom Panel Design & Fabrication: DSI built a main enclosure (84″ x 118″) equipped with cooling fans, industrial service lighting, and standardized power distribution. All panels were fabricated at DSI headquarters and met UL certification standards.
- Integrated Motor Control: The system featured 4 VFDs (50 HP each) for surface pumps, 3 soft starters (200 HP each) for compressors, and across-the-line starters for fans and support equipment. Smart control strategies were programmed to balance power usage with process demand.
- Ignition HMI with Secure Remote Access: An industrial PC running Ignition provided real-time system visualization, alarming, and historical data logging. Remote access was enabled through Tosibox VPN hardware to allow off-site diagnostics and commissioning.
- Collaborative PLC Programming: DSI developed logic for a Wago PLC platform to interface with American Arena-supplied components. The system included over 50 relays, 35 circuit breakers, and multiple transformers, all integrated and tested in-house.
- Factory Testing & Remote Support: DSI conducted a 5-day FAT at its facility to verify wiring, PLC-HMI communication, and motor spin-up. Post-delivery, 4 days of remote support were provided during system startup.
The Results
- Reliable System Operation: The centralized refrigeration control platform enabled consistent and precise management of ice conditions, ensuring an optimal environment for athletes and spectators alike. Operators gained confidence in the system’s stability and performance.
- Energy Efficiency Gains: The integration of VFDs, soft starters, and intelligent PLC logic reduced electrical demand, extended equipment life, and lowered long-term energy costs. System responsiveness also allowed for smarter scheduling and load balancing.
- Remote Support & Future Scalability: With Tosibox-enabled secure remote access, DSI’s engineering team can assist with diagnostics, updates, and future system expansions without requiring on-site intervention. The modular panel design also supports future additions or layout changes as facility needs evolve.
- Enhanced Operational Visibility: Real-time monitoring and historical data logging through Ignition allow for proactive maintenance and faster response to system alerts. The arena now benefits from a modern, data-driven platform that supports both daily operations and long-term asset management.
