Horizontal Carousel Controller Upgrades
Modernize controls, boost safety, and integrate software, all without replacing your carousels.
Smarter Controls. Safer Operation.
Our Horizontal Carousel Controller (HCB) is a modern controller upgrade for legacy horizontal carousels. Replace aging electronics with a single wall-mounted enclosure that runs up to four carousels, adds VFD motion, safety PLC supervision, and operator-friendly HMIs. Connect to our inventory management solutions and pick-to-light systems for faster, more accurate fulfillment.
Inside the HCB Controls Package
The HCB upgrade combines every core component your carousels need into one compact, wall-mounted enclosure. From motion control and safety logic to intuitive HMIs and service tools, each element below works together to deliver smoother operation and easier maintenance.
Main Control Panel
Smoother starts/stops, reduced wear, and energy-efficient rotation.
Position/PLT Pick Light Tower
Shows shelf, quantity, and a grid for tote location to guide picking.
Safety Controller
Supervises E-Stops and sensors with clear status LEDs and fault messages.
OP3 Soft HMI
Push-button interface with plain-language alerts and carrier status.
Service Tools
Wireless Maintenance Keyboard (or budget Service button-pad) to move equipment safely during maintenance.
Upgrade vs. Replace
Compare the controls-only HCB retrofit with a full carousel replacement
Upgrade with HCB
- Keep your mechanics; replace controls
- Lower CapEx and faster install
- Add HMI, light guidance, ERP links
- Safety PLC + VFD performance
Replace Entire System
- New hardware across the board
- Higher CapEx and more downtime
- Longer training and changeover
- Disruption to existing workflows.
Technical Highlights
Supports up to 4 carousels per enclosure
Ethernet $ RS-232 for ERP/WMS Connectivity
VFD motor control w/ AC motor upgrade available
Programmable Safety Controller for E-Stops
Compatible with legacy Horizontal Carousels
Software & HMI Options
PartPic™ Inventory Control
Windows-based inventory with image support, min/max levels, reorder alerts, and reports that export to Excel/ERP. See Inventory Management Solutions.
OPC Operator Panel (PC HMI)
PC-based diagnostics, parameter backup, error logging, and optional remote support.
Frequently Asked Questions (FAQs)
Will this work with my older Remstar®/Kardex carousels?
Yes. We confirm model and I/O during scoping.
How many carousels can one HCB panel run?
Up to four per enclosure.
Do we need new motors?
An AC motor + VFD upgrade path is available for performance and efficiency.
Can HCB connect to our ERP/WMS?
Yes—via Ethernet/RS-232, host options, and CSV/XLS exports.
How do operators know where to pick?
The Position/PLT light tower shows shelf and quantity with a location grid; the OP3 HMI displays status and errors.
Ready to Upgrade Your Carousel?
Tell us about your system and options you want. We’ll confirm compatibility and send a scoped proposal.
