Power control panel

temperaturemulti-channelwith touchscreen

General
Glass Service process control board manages the glass production line and associated equipment (batch plant, melting furnace, distributors, forehearths). The system is engineered for operator safety and provides an intuitive HMI for real-time operation and monitoring.

Design
Design uses industrial-grade hardware and proven software platforms. Components are selected from reputable suppliers (Siemens, Schneider, ABB, Honeywell). Engineering includes process control procedures and multidisciplinary risk analysis involving control, electrical, combustion and production experts.

Design includes

• Process control analysis
• Electrical diagrams and cable/equipment sizing
• DCS/PLC selection and sizing
• DCS/PLC software engineering
• HMI/SCADA software design and graphics
• Cold FAT tests, on-site tests and start-up support

Main performances
The control board delivers:

• Reliable continuous control of glass melting and distribution
• Safety functions compliant with applicable standards
• Full automatic process control with PID regulation
• Operator-friendly HMI and clear manageability
• Real-time process variables and historical trends
• Alarm management with historical alarm database
• Automatic diagnostic and troubleshooting aids
• Remote access and support capabilities

Loops controlled

• Temperature (thermocouple or pyrometer inputs)
• Gas/air ratio
• Oil/air ratio
• Gas/oxy ratio
• Furnace pressure
• Combustion air temperature

Alarms
Alarms are shown on touchscreens and logged. Main alarm groups:

• High/low temperature
• Device faults (fans, motors)
• Incorrect fuel/air ratios
• Cooling system faults (e.g. batch charger)

Trends and data
Process trends and historical data are stored locally and available on HMI/SCADA for real-time and post-analysis, with database export for reporting.

DCS and PLC controller
Standard controller options include Honeywell ControlEdge HC900 and Siemens SIMATIC S7-1500 / S7-400. Configurations support single or dual CPUs and multiple redundancy strategies to match availability requirements.

HC900 key features

• Hot software upgrade with furnace in operation
• Hot-swap I/O modules (where supported)
• SIL2-capable options
• Remote I/O via Ethernet TCP/IP
• Touchscreen connectivity typically via Modbus RS485
• CPU and power supply redundancy options
• I/O health monitoring for thermosensors

Siemens S7-1500 key features

• SIL2 / SIL3 capable configurations
• Remote I/O via Profinet
• Independent touchscreen communication
• CPU and power supply redundancy options

Redundancy strategy
Redundancy options ensure 24/7 continuity. Typical strategies:

• Solution 1 — dedicated loop controllers per PID with a redundancy PLC for ON/OFF electromechanical devices
• Solution 2 — redundant CPUs, redundant HMI, redundant network and redundant SCADA server/database

Safety integration
System design follows safety standards (EN746/2, ANSI/NFPA86) and SIL methodology with LOPA assessments. Glass Service can deliver SIL2–SIL3 capable solutions for combustion and other critical functions.

HMI / SCADA and Touch screen HMI
HMI is designed for clear operator interaction and data collection:

• Operator-centric screens and navigation
• Stable, industrial-grade solutions
• Comprehensive data logging for historical analysis
• Alarm management and historical alarm retrieval
• HMI/SCADA software engineering by Glass Service

HMI families:

• PC SCADA (Windows-based PC hardware and SCADA such as WinCC, Citect, Ignition)
• Touch screen HMI (Siemens panels 12.1"–21.5", Honeywell 10.4"–15", ASEM 12"–24")

PC SCADA considerations
Recommendations for PC SCADA include industrial PC hardware (fanless preferred), server/client redundancy, database storage of all furnace variables, trend analysis tools and secure remote access via firewall/VPN.

Remote control
Remote features cover software assistance, upgrades, troubleshooting and secure connections (industrial VPN such as EWON Talk2M) for worldwide access and support.

Images and galleries
Product page includes multiple photos and schematic/monitor images showing layouts, wiring and HMI screens.

Caractéristiques / spécifications techniques

• Supported controllers: Honeywell ControlEdge HC900, Siemens SIMATIC S7-1500 / S7-400
• SIL capability: SIL2 / SIL3 (configuration dependent)
• Operator interfaces: PC SCADA (Windows), Touch HMIs (Siemens, Honeywell, ASEM)
• HMI software examples: WinCC, Citect, Ignition, Honeywell Station Designer
• Communication: Ethernet TCP/IP, Profinet, Modbus RS485
• Remote I/O: supported via Profinet/Ethernet
• Data storage: internal historical memory, database storage, trend analysis
• Alarm handling: on-screen display and historical alarm database
• Redundancy options: CPU, power supply, HMI/SCADA, networks
• Hot maintenance: hot software upgrade, hot-swap I/O (where supported)
• Typical loops: temperature, gas/air, oil/air, gas/oxy, furnace pressure, combustion air temperature
• Design components: selected from Siemens, Schneider, ABB, Honeywell