CASEMASTERTM FURNACE CONTROLLER
The New Standard for Furnace Control
 CaseMasterTM is a microprocessor-based system capable of controlling furnace process variables and mechanical motion in a single integral quench batch furnace (BIQ). The system centers on a 15" TFT active, Pentium III industrial computer and an Allen Bradley SLC 5/05 programmable logic controller. When coupled with three discrete control instruments, one for carbon control, and one each for quench and furnace temperature control, this system represents the state-of-the-art in BIQ furnace control and monitoring systems. CaseMasterTM provides you with consistent, repeatable and reliable furnace control.
Programming
An advanced multi-step programming language features intelligent commands such as: ramp, setpoint, soak and compare. This easy-to-use recipe language uses English language commands and represents the ultimate flexibility in furnace process control. CaseMasterTM accommodates up to 100, ten-step programs. Recipes can be chained together using the GOTO and JUMP commands. Access to every input and output provides complete control of each batch run in a furnace controlled by the CaseMasterTM system.
Control
Digital outputs control critical furnace functions like ammonia addition, fast cool down and probe burnout. Three programmable event outputs allow you to customize the CaseMasterTM system to meet your specific furnace control requirements. This furnace control system is designed to react to furnace conditions as well. Recipe execution can depend on the status of three event inputs. By using these input events, the user can delay program execution until a specific event occurs on the furnace.
CaseMasterTM also includes four programmable 4-20mA analog outputs and four 4-20mA analog inputs. The analog outputs may be used to control variable speed quench agitation or motor-controlled process gas flowmeters using recipe commands. The analog inputs can be used to record process gas flows, fan speed, or other analog signals. The analog input signals may be used for decision making in program execution.
Information Management
The CaseMasterTM Furnace Controller displays and manages furnace process data in an intuitive and functional manner. The active matrix color touch screen displays vivid and precise graphics. Real-Time and Historical Trending screens provide you with a detailed view of the furnace process. Ideal curves, a chart that displays the 'perfect' cycle, can overlay cycles in progress, providing instant confirmation that the batch is running correctly. Data screens display critical information related to control instrument performance and configuration. Batch reports provide detailed listings of furnace process variables, statistical calculations and a real-time graph of the batch process.
Our maintenance tracking screens allow you to track the life of furnace alloy, remind the user of scheduled maintenance tasks and record the frequency of parts replacement. The CaseMasterTM information management features provide you with an accurate view of furnace conditions.
Flexibility
The CaseMasterTM Furnace Controller can operate in one of two modes. When operating in stand-alone mode, the controller operates using the library of 100 user programmable recipe cycles. The user enters batch information and selects a recipe. Once complete, CaseMasterTM creates the batch report, available for review on the furnace controller, a network computer, or for printing on a network printer.
The second mode of operation utilizes the BatchTraxTM Supervisory Control System and allows the user to define batch information from a central location. This Supervisory Control System features operation via batch number. This definition includes essential load data and includes part number, part description, part piece weight, part quantity, and total batch weight. A part number database facilitates the entry of the batch information. The desired recipe cycle is also selected and associated with the batch number. In operation, the user defines a batch, assigns a furnace to that batch, and loads the furnace using either an automated or manual charge car.
Options
CaseMasterTM can control the mechanical motions of a batch IQ. By using distributed I/O, a communications module and additional programs, the furnace control system will control, monitor and alarm all BIQ furnace motion sequences. Detailed graphic screens display the status of all field devices and provide diagnostic and troubleshooting tools that direct the user to the source of electromechanical problems.
The CO analyzer interface gives you the tools to dynamically adjust the CO compensation used in carbon potential calculation. Control of sample, zero and span gas automates the gas sampling process. Configured for up to three gases, this option provides all the tools required for complete atmosphere monitoring.
A barcode reader interface provides quick and detailed access to all load related information. If your plant uses barcodes for production tracking and control, this option can link the heat treatment department to the rest of the production facility.
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