Projects
Retrofits, installations and the jobs that started as a breakdown call.
Retrofit · Completed
Relay logic on ten bell annealers replaced with a Siemens S7-1500 and ET200SP remote I/O — 200 digital and 20 analog inputs per machine. Every signal mapped to a custom WinCC Unified Comfort Panel for diagnostics, maintenance run-hours and gas valve and pressure switch monitoring, and fed directly into Iba data acquisition for external trace and monitoring.
Siemens S7-1500 · ET200SP · WinCC Unified · Iba
Retrofit · Completed
An old relay control system replaced with an affordable Siemens S7-1200 driving integrated soft starts, so the pumps ramp more efficiently and last longer. Push-button control with automatic and manual selection, a PROFIsafe e-stop system, and everything from the design philosophy and electrical schematics to the PLC program and full commissioning.
Siemens S7-1200 · Soft start · PROFIsafe
HMI retrofit · Completed, next phase underway
A legacy Lauer annunciator replaced with a Horner XL6 operator panel while the existing Siemens S5 and its alarm logic stay in place — read through the S5's 8-bit alarm output, with alarm text, acknowledge, reset and history on screen. Now extending to speed, run/ready/fault status and current on 14 DC drives, with factory MES integration to follow.
Siemens S5 · Horner XL6 · Horner OCS I/O
Steel & metals
Lubrication control on a Horner X4 PLC: pump control and flow monitoring, pressure and temperature supervision, alarms and safety interlocks — built for reliable operation in a demanding environment.
Horner X4
Plastics
Control of three 120 kW chillers, with flow and pressure control, optimised energy-efficient cooling performance, data monitoring and system alarms.
Greenhouse technology
Hot water heating control with pumps and inverters, heat exchanger and temperature management, data collection and remote monitoring — for lower energy use and stable growing conditions.
