Solving MODBUS Integration Challenges: Walchem Controller Success Story

The Challenge: Integration Issues with Walchem Controllers

A customer and their end-user were experiencing significant difficulties integrating their Walchem controllers into their existing automation system. The primary issue stemmed from the complexity of MODBUS communication protocols as they struggled to determine which MODBUS registers corresponded to their system’s inputs and outputs.

Configuring the controllers within their SCADA (Supervisory Control and Data Acquisition) system or PLC (Programmable Logic Controller) without a clear register map was inefficient and error-prone. This resulted in extended setup times, inconsistent data flow, and operational bottlenecks.

Our Solution: A Custom MODBUS Mapping Strategy

Recognizing the challenge, Evan Humpert, Application Engineer at Becker Engineered Systems, proactively resolved the issue. He:

✅ Developed a custom MODBUS map that clearly outlined the register assignments for the Walchem controller, providing a direct reference for proper system configuration.
✅ Mapped each input and output to its corresponding MODBUS address, ensuring seamless communication with the customer’s PLC or SCADA system.
✅ Provided a detailed implementation guide to help the customer integrate the controller efficiently, minimizing downtime and eliminating guesswork.

The Outcome: Full Automation Integration

With the MODBUS mapping in place, the customer successfully integrated their Walchem controllers into their existing system, leading to the following:
✔️ Seamless automation with accurate data transmission between the controller and their operating system.
✔️ Reduced troubleshooting time, allowing for faster deployment.
✔️ Improved system efficiency, eliminating manual configuration errors.

Customer Feedback:

✅ “You nailed it, and the customer is taken care of. Thank you for going above and beyond in putting this together.”

Leadership Perspective: Commitment to Innovation & Customer Success

🗣️ Greg Tankersley, President & Owner, Becker Engineered Systems:
"This project highlights the technical expertise and customer dedication that defines Becker. Evan’s ability to step in, diagnose the challenge, and provide a precise solution is a testament to how we go beyond just delivering products—we deliver real solutions that drive automation success."

🗣️ Bryan Jostworth, Vice President of Business Development, Becker Engineered Systems:
"At Becker, we pride ourselves on being more than just a supplier—we’re a trusted partner in automation. This project is a great example of how we help our customers overcome complex challenges with hands-on technical support and customized solutions. The result? A fully integrated system that maximizes efficiency and performance."

We Have the Products & Solutions Ready for You

At Becker Engineered Systems, we provide technical expertise and stock the products you need to keep your systems running efficiently. We have:

✔️ Walchem Controllers are ready to ship and fully compatible with automation systems.
✔️ MODBUS Mapping & Integration Services – Tailored solutions to help you seamlessly integrate automation components.
✔️ SCADA & PLC Programming Assistance – Ensuring your controllers work efficiently within broader industrial automation frameworks.

📧 Have Questions? Contact Us Today!

📞 Call: (513) 874-3372
📧 Email: info@beckerengineered.com
🌐 Visit: www.beckerengineeredsystems.com

Let’s optimize your automation workflow today! 🚀