Furnace Control System Modernisation: Dual Obsolescence Upgrade with Safety PLC and HMI
Sector:
General Manufacturing
Type:
Obsolecence Upgrade, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
A UK manufacturing business needed to replace the obsolete control systems on two industrial furnaces. DelaControl designed, built, programmed, and commissioned two new Siemens-based control panels — one for each furnace — incorporating a Safety PLC, touchscreen HMI, remote access capability, and a formal risk assessment, with site installation and commissioning carried out by DelaControl engineers.
Challenge
Two industrial furnaces on site were operating with long-established control systems that had become obsolete. Replacement parts were no longer available, making continued reliable operation a significant risk.
No formal documentation was available for either furnace: one had only outdated, unverified drawings, and the other had no drawings or manual at all. The customer required full modernisation of both control systems, including updated safety provisions in line with current standards.
Solution
DelaControl conducted an on-site survey of the existing control systems to establish the as-installed configuration, using this as the basis for a full redesign. A new Siemens-based control panel was engineered for the first furnace, housing a Siemens S7-1200F Safety PLC, a 10.1" Siemens Unified Comfort Panel HMI, a Siemens SINAMICS G120C variable speed drive, a Eurotherm EPower power controller, and JUMO temperature limiters. Remote access was provided via an IXON IXrouter3 4G/LTE and Wi-Fi enabled gateway. A second panel of equivalent specification — adapted to control two heating loops rather than one — was built for the second furnace.
A formal risk assessment was carried out in accordance with BS EN ISO 12100, with safety functions assessed and documented to ISO 13849-1 (SISTEMA report). The control software was developed in-house to DelaControl's standard software design specification, with all native files handed over to the customer. The full documentation package included electrical schematics, general arrangement drawings, thermal calculations, Declaration of Conformity, FAT schedule and certificate, and an HMI operating manual.
Both panels were factory-tested at DelaControl's Bristol facility before a Factory Acceptance Test was held with the customer. DelaControl's engineers then carried out the site electrical installation and commissioning of both furnace control systems.
Key Facts
• Two Rittal VX modular enclosures (800W × 2000H × 600D) supplied and built
• Siemens S7-1200F Safety PLC (CPU 6ES7214-1AF40) with digital I/O and safety F-DQ expansion modules
• Safety functions assessed to ISO 13849-1; F-DQ module rated up to PL E / SIL 3
• Siemens SIMATIC HMI MTP1000 Unified Comfort Panel — 10.1" touchscreen
• Siemens SINAMICS G120C 0.75 kW inverter drive included
• Eurotherm EPower 2-phase 400 A/600 V power controller for furnace heating
• JUMO STB/STW temperature limiters for over-temperature protection
• IXON IXrouter3 IX2415 gateway providing 4G/LTE, Wi-Fi, and wired remote access
• 400 A Siemens fuse switch disconnector and 400 A NH fuse protection on incoming supply
• 1 kW Rittal TopTherm enclosure cooling unit fitted
• Site installation: 2 electricians × 4 days (first furnace), 2 electricians × 3 days (second furnace)
• Site commissioning: 1 engineer × 6 days (first furnace), 1 engineer × 2 days (second furnace)
• BS EN ISO 12100 risk assessment included in scope
• Full documentation package: schematics, GAs, thermal calculations, SISTEMA report, Declaration of Conformity, FAT certificate, HMI operating manual