Plant Control

The system control unit is the heart of every electric heating system. It not only performs regulation and control functions, but also ensures continuous monitoring and reliable protection of the entire system. Klöpper-Therm develops, designs, and implements system control units for industrial electric heating systems—from electrical design and switchgear construction to integration into higher-level control systems. The result: heating systems that can be operated efficiently, safely, and with long-term reliability.

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Matthias Wilking

project engineer

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What is a plant control system?

A plant control system is the overarching control and regulation system of a technical plant. It integrates individual components—sensors, actuators, controllers, and switching devices—into a single functional system and ensures that all subprocesses run in a coordinated and reliable manner.

In an industrial setting, this goes far beyond simply maintaining individual operating points. A plant control system continuously monitors process variables, evaluates them, and intervenes when necessary—in the event of temperature fluctuations, overload conditions, or safety-related incidents. It thus differs fundamentally from individual components such as a simple temperature controller or a manual control panel: it forms the connecting, intelligent backbone of the entire plant.

Components of a plant control system at Klöpper-Therm

An industrial plant control system consists of several components that are designed to work together. At Klöpper-Therm, these components are not purchased as individual parts, but are planned, designed, and commissioned as an integrated system.

Switchgear

Switchgear forms the electrical foundation of any building control system. Depending on the heating system, it distributes electrical power to various heating circuits or heating zones. It is designed to manage loads efficiently and distribute them as evenly as possible.

Our switchgear comes in a variety of sizes, ranging from small switch boxes and switch panels in wall cabinets to switchgear systems with multiple panels. Switchgear designed in accordance with standards is essential for precise and safe system control.

Heating Controls

The primary function of the heating control system is to regulate the heating output. For high-power electric heaters, contactors or thyristor controls are used, depending on the customer’s requirements and the specific application.

For heating control systems, Klöpper-Therm relies on its proprietary UNIPLEX heating controller. It combines a temperature controller, a safety temperature limiter, and a current controller into a single, space-saving unit.

For systems consisting of multiple individual electric heating systems, the UNIWIN visualization software provides a clear overview. The software gives you direct access to your UNIPLEX III controllers, allowing you to monitor their current status.

Temperature Controllers and Sensors

Precise measurement technology is the foundation of any effective control system. With appropriately designed and integrated sensors, monitoring functions such as temperature and power monitoring can be implemented. This enables real-time tracking of fault diagnostics and the visualization of operating conditions.

At Klöpper-Therm, temperature controllers and sensors are specifically tailored to the requirements of your system. We seamlessly integrate the technology into your overall system.

Security Systems & Emergency Call Solutions

Safety measures such as overcurrent protection, overtemperature protection, and ground-fault circuit interrupters protect the heating system from damage and users from potential hazards. Personal safety also plays an important role, for example, in cold storage construction.

For these situations, Klöpper-Therm offers special emergency alarm systems. These systems operate reliably even during temporary power outages. This allows people in distress to call for help.

Functions of Modern Plant Control Systems

A modern control system for electric heating systems performs a wide range of tasks necessary for stable, safe, and efficient operation.

Heating Power Control: The system controller maintains defined process temperatures within specified limits. Heating power is controlled precisely and according to demand via contactors or thyristor controls.
Monitoring & Troubleshooting: Operational data is continuously recorded. Temperature and performance monitoring, as well as troubleshooting, can be tracked in real time. This provides the foundation for rapid responses to anomalies and comprehensive documentation.
Visualization of operating conditions: A clear visualization shows operators the current system status. They can see temperatures, switch statuses, and process trends at a glance.
The UNIWIN visualization software makes it easy to operate even complex systems with multiple heating circuits.
Safety & Incident Management: In the event of an incident, the plant control system reacts automatically: safety functions are activated, alarms are triggered, and defined safety procedures are initiated. Safety systems can operate independently of the main control system.
Integration into higher-level control systems: For centralized control and monitoring, Klöpper-Therm control panels can be integrated into plant control systems. This is particularly advantageous for complex heating systems and large-scale facilities.

Applications of Plant Control Systems

Control systems for electric heating systems are used wherever thermal processes need to be reliably controlled, monitored, and documented.

Industrial heating systems:

Electrical heating systems in manufacturing and industry require precise process monitoring. System controls ensure that target temperatures are maintained at a stable level and that heating processes are carried out in a reproducible manner.

Thermal processing systems:

Process systems and drying systems operate using defined temperature profiles. Their control systems must precisely control heating phases, holding phases, and cooling processes and monitor them continuously.

Cold Storage Facilities & Refrigeration Systems:

In cold storage construction, in addition to protection against freezing, personal safety through emergency call systems plays a central role. Klöpper-Therm integrates these requirements directly into the system control.

Custom Systems:

We develop customized system controls for client-specific heating systems with special requirements regarding control logic, interfaces, or safety technology. From design through commissioning.

Integrated plant control – Klöpper-Therm

Klöpper-Therm provides plant control systems as a comprehensive engineering service. Planning, electrical design, switchgear construction, and commissioning are all handled by a single provider.

Customized solutions are developed through a thorough understanding of process requirements. Our team of experts handles the design of the switchgear to suit the specific heating system—in compliance with standards, tailored to the project, and drawing on years of experience in thermal process systems. All components are designed based on your system requirements and form the foundation for reliable switchgear construction.

Our support doesn’t end with commissioning. Throughout the entire lifecycle of a system, Klöpper-Therm is available to assist you with maintenance, upgrades, and modifications—ensuring that the system control continues to operate reliably and efficiently for years to come.