PAC Automation, in collaboration with PAC Control Panels & MCCs, manufactured 14 back-plates off-site, which were designed to fit the existing control sections. This would save time on the customer’s site and minimise disruptions.

Heating controls where provided by Eurotherm EPack analogue thyristor stacks. The EPack controller uses innovative technology to manage the process and provides higher energy efficiency.

The functionality of the EPack controller, coupled with the heat treatment knowledge of PAC Automation Engineers, means we can monitor the element current against voltage in each heating zone. This allows for early detection of a failing element, helping to reduce production downtime and ensure product quality.

We used the new Omron NX PLC with modular I/O and safety throughout the machine. The system has a total of 46 temperature control loops, which were needed to control to +/-1°C. Omron’s new state-of-the art and dedicated PID control modules eliminated the need to have multiple controllers located around the machine.

All controls are monitored via a Eurotherm 6180XIO video chart recorder and a GE Cimplicity SCADA system, which all ties into the client’s network, allowing their critical process to be monitored anywhere, anytime.