OEM Thyristor Power Control Solutions for Electrical Heating

• Precise phase‑angle or burst‑firing control of resistive and transformer‑coupled loads
• Reduced temperature overshoot and tighter process stability
• Lower RMS current and reduced peak loading
• Improved overall system efficiency and heater life

• Application-specific controller selection and sizing
• Custom control strategies aligned to your heating process
• Electrical and thermal design support including Integration with PLC, PID controllers, and industrial fieldbus systems
• Documentation and support aligned to OEM production and commissioning cycles

CD Automation thyristor power controllers are designed for continuous industrial duty, not intermittent or light-use applications.

Key design considerations include:

• Thermal design optimised for sustained load conditions
• Component derating to improve reliability and lifespan
• Stable performance under fluctuating load and ambient conditions

The CD Automation range is designed with a target MTBF of 10 years under normal industrial operating conditions.

This long-term reliability is achieved through:

• Conservative electrical and thermal design margins
• Selection of high-performance, long-life components
• Controlled, repeatable manufacturing processes

For OEM engineers, this supports:

• Long machine service life expectations
• Reduced warranty risk
• Greater confidence during engineering sign-off and design approval

While low-cost power control solutions may appear attractive initially, they often introduce higher lifetime costs through:

• Increased maintenance and replacement
• Reduced heater life due to electrical and thermal stress
• Energy losses caused by poor control resolution
• Unplanned downtime and service intervention

CD Automation controllers are engineered to minimise total cost of ownership by:

• Extending component and heater lifespan
• Maintaining efficiency over the machine lifetime
• Reducing service requirements and operational risk

The following example is indicative and provided to support engineering and commercial evaluation.

• Electrically heated machine load: 100 kW
• Operating time: 6,000 hours per year
• Energy cost: £0.15 / kWh

Annual energy cost: £90,000

A conservative 3–5% efficiency improvement achieved through improved thyristor power control equates to:

• £2,700–£4,500 saved per year, per machine
• £27,000–£45,000 over a 10-year machine life

These savings are achieved without mechanical redesign and can be validated during factory acceptance testing.

• Engineered specifically for industrial electrical heating
• Proven in continuous-duty OEM applications
• Built with performance margins for long service life
• Designed to integrate cleanly into OEM machine platforms
• Supported by technical expertise focused on OEM requirements

It’s common for OEMs to ask why an industrial-grade thyristor controller costs more than basic alternatives.

The answer is simple: performance over time.

CD Automation controllers are not designed to meet minimum specifications, they are designed to deliver:

• Stable, repeatable performance
• Lower lifetime operating and maintenance costs
• Reduced risk during commissioning and in the field

For OEMs and their customers, this translates into fewer problems, lower long-term costs, and greater confidence in every machine delivered.

• Suitable thyristor power controller technology (phase-angle and/or burst firing)
• Stable, high-resolution power modulation for precise temperature control
• Compatibility with resistive and transformer-coupled heating loads
• Reduced RMS current and peak electrical stress compared to contactor control

• Designed for continuous industrial duty operation
• Conservative electrical and thermal derating applied
• Target MTBF of 10 years under normal industrial operating conditions
• Proven component selection for long service life

• Compatible with PLC- and PID-based control architectures
• Straightforward integration into existing machine designs
• Clear documentation for commissioning, FAT, and SAT

• Demonstrable reduction in energy consumption versus basic control methods
• Quantifiable operating cost savings over machine lifetime
• Improved heater life and reduced maintenance requirements

• Proven use in industrial OEM applications
• Technical support available during design and commissioning
• Long-term product availability aligned with OEM lifecycles

• Control modes: Phase‑angle control, zero‑cross burst firing
• Load types: Resistive loads, infrared heaters, transformer‑coupled heating systems
• Power ratings: Scalable solutions for low‑power zones through to high‑power industrial heating banks
• Stability: High‑resolution power modulation for tight temperature control
• Reliability: Industrial‑grade components designed for continuous operation
• Integration: Compatible with standard industrial control architectures

By optimising power delivery rather than simply switching load on/off, OEMs achieve repeatable efficiency gains that can be quantified during factory testing and demonstrated to end customers.

• Reduced electrical energy consumption per machine
• Lower operating costs for end users
• Improved thermal process stability and repeatability
• Stronger technical justification in tenders and specifications

Efficiency becomes an engineered feature, not a marketing claim.

Our solutions are widely used by UK OEMs in:

• Industrial ovens and furnaces
• Plastics and rubber processing machinery
• Food processing and packaging equipment
• Composite curing and thermal treatment systems
• General industrial electrical heating applications

• Analogue and digital control interfaces
• Compatibility with PID temperature controllers
• Integration with PLC-based control systems
• Support for common industrial communication standards
• Clear documentation for commissioning and validation

• Application-specific power controller sizing and selection
• Engineering input early in the machine design cycle
• Solutions proven in continuous industrial operation
• Predictable performance that can be validated during FAT and SAT
• Long-term technical support aligned with OEM production lifecycles

• Customer technical discussions
• Tender and bid documentation
• Energy efficiency justification
• Internal design reviews

• Technical data sheets
• Performance calculations
• Application notes
• Engineering consultation for customer-specific requirements