Upgrading From CRTs to LCDs in Industrial Control Systems

Your old CRT displays are almost certainly costing you money. These displays use old electron beam technology to create images on a screen. They’re bulky, very heavy, operate at high voltages, and give off a lot of heat. What’s more, their low-resolution images limit what can be displayed.

CRT displays also suffer from what’s called “burn-in.” This is where, after many hours of the same image being projected onto the screen, a permanent ghostly image remains. This effect prevents viewers/equipment operators from seeing important information, and it can be a safety hazard, too.

Additionally, if your old CRT display has unreliable keyboards and pointers, an LCD upgrade can be beneficial, as most of the latest industrial LCDs are available as touchscreens.

Understanding Costs: Is Upgrading to an LCD Worth It?

If your old CRTs are still working, you may wonder why you should spend money on an LCD upgrade. One reason is that it will save you money.

As mentioned earlier, industrial LCD monitors draw less power than their CRT equivalents and last up to five times longer. For a display that’s turned on 24×7, that’s a considerable saving in energy and replacement costs.

A bigger issue might be the lack of replacement CRT monitors. They aren’t being made anymore, and while specialists can repair most faults, they will eventually die. That could lead to a machine or process being shut down until a new LCD monitor has been sourced, purchased, and installed. In a situation like that, the cost of lost production can dwarf the price of a CRT upgrade.

Why You Need a Professional for an Upgrade

Having accepted that a proactive approach is the right approach, what’s involved in making the switch? The first step is to consult a specialist like K+S Services, who can evaluate your current system, find the right LCD, and guide you through the implementation process. The upgrade process is complex, and there are safety risks, especially if you don’t have experience handling these types of projects.

As mentioned earlier, CRT monitors operate at extremely high voltages. Even after being powered off, capacitors and other components can retain a charge, and without proper training, you won’t know how to follow the right protocols for de-energizing and discharging components.

Second, industrial systems use specialized hardware. If you select a monitor that isn’t compatible with your current system, you risk damaging both the new monitor and the control system. And, mistakes in mounting or connecting the monitor can cause mechanical stress, electrical shorts, and overheating.

Other issues with DIY upgrades include signal conversion problems (CRT monitors and LCDs may use different signal formats, so a converter may be needed), resolution errors, configuration issues, and potential warranty voids.

It’s much more time-efficient and cost-effective to have a specialist do it for you.

Understanding the Implementation Process

1. Evaluating Your Current System

Replacing an industrial CRT display is rarely as simple as switching a PC over to an LCD monitor. A specialist always starts the evaluation process by establishing how the existing controller or source sends video to the CRT.

Then, the specialist considers what’s being displayed and the size and resolution required. They also look at how the CRT is mounted or housed (and if the new monitor should be mounted differently), whether there are any environmental challenges (bright sunlight, dust, moisture, a need for washdown protection, etc.,) and if a touchscreen would be useful for your operators.

2. Selecting an LCD

When you consult a specialist, they will consider quite a few technical and performance factors when selecting an LCD for your facility. These factors include:

• Screen Size: This refers to physical dimensions and aspect ratio. Screens have become wider in recent years, limiting the choices of whether the new screen is going into an existing housing. However, going bigger allows the display of more data and a longer viewing distance.
• Resolution: This is defined in pixels, making a direct comparison with a CRT display difficult. However, any modern monitor will offer far higher resolution than the screen being replaced. The benefit of higher resolution is the ability to display more data.
• Readability & Brightness: Modern factories are generally well-lit, and this can make it difficult to read an LCD screen. Brightness is measured in terms of nits: a specialist will look for a minimum of 400, and if the screen will be used outdoors, they will look for 1,000 nit units.
• Power Consumption/Power Efficiency: An LCD monitor will almost certainly be more efficient. However, going to a larger, higher-resolution screen and touch capabilities could negate much of this saving. A specialist will choose the most efficient option based on your current setup.
• Hardware Compatibility: The specialist will evaluate the available connection ports and source outputs to see whether you need a converter.
• Mounting Options: Most monitors adhere to the VESA standard for mounting, so a specialist will verify that this will work for your upgrade.
• Durability: Industrial environments can be hard on electronics, so specialists will look for IP65 or IP66 protection and check the specs for vibration and temperature limits.
• Touchscreen Capabilities: Touchscreen can boost productivity by making equipment easier to use. However, a specialist will identify if this is needed and if your existing system can even support screen input.

The Installation Process

Once an expert has found the right LCD monitor for your setup, the next step is installation, which actually comprises two steps: installation and configuration. The specific details for each step depend on the type of LCD monitor that’s being installed and what it’s being installed into. Only a specialist can determine the specific details required for a safe and effective installation.

Installation

If the monitor is a direct replacement for a CRT, the specialist will remove the old screen first. Because these monitors use high voltages, some residual charge may remain in the components, which is why it’s important to have an expert install the monitor for you.

The specialist will install the monitor based on your specific operational needs (with extending arms, on a panel or rack mount, etc.) and ensure it’s securely in place.

If the new monitor does not fit exactly in the housing, the specialist may need to fabricate and mount additional filler pieces.

Configuration

The specialist will assess the existing video output and configure any necessary converters to ensure the monitor is compatible with the new display. PLCs and other sources may have more complex setup procedures, so always turn to a professional for configuration assistance.

Upgrade Your Monitor Today With Help From K+S Services

There are many advantages of an LCD monitor upgrade, but depending on the equipment you have, this may not be as straightforward as you might think. In these situations, K+S Services can help.

We can perform complete CRT to LCD upgrades. Whether you’re using Allen-Bradley, FANUC, Siemens, Hitachi, Mitsubishi, Modicon, or equipment from other manufacturers, we have the experience and skills needed for a fast and cost-effective switch.

And, if you’re not ready to make an upgrade just yet, we provide reliable CRT monitor repair services. K+S Services is one of the only remaining service providers offering CRT repairs. We follow a strict ISO-certified process and thoroughly test every monitor we repair to ensure quality.

Our repair capabilities include display quality assessment to identify screen burn-in, discoloration, and geometry distortion, CRT-specific component analysis (cathode ray tubes, control circuits, etc.), specialized cleaning, and performance testing to verify resolution, contrast, and response time accuracy. We can even resolve unique CRT issues, such as electron gun misalignments and phosphor wear.

Contact us today for a service quote, and avoid display problems in the future.