Batch Charger Control Panel Build and Software Modernisation for a Glass Processing OEM
Sector:
Glass, OEM & Special Purpose Machinery
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built and tested two control panels for a specialist glass processing OEM, covering the full scope from hardware procurement and panel build through to a complete redevelopment of the HMI and PLC software. The project delivered a modernised operator interface, restructured and modularised PLC code, and a full documentation pack including a SISTEMA safety assessment.
Challenge
A glass processing machine OEM required a complete control panel for its OBC Saver batch charger, including all associated machine wiring and field devices. The panel needed to be built, fully tested prior to delivery, and supported by a comprehensive documentation pack.
Separately, the existing HMI and PLC software for the batch charger had accumulated issues over time — including software bugs, poor code organisation, and a structure that required significant rework for every new machine variant supplied to different end customers. The OEM needed the software modernised to reduce commissioning time, improve operator usability, and make supporting multiple customer-specific configurations far more efficient.
Solution
DelaControl built two control panels at its Bristol facility, based on a Siemens S7-1200 CPU 1214C platform with a KTP700 Basic 7" touchscreen HMI. Each panel was equipped with a Sinamics V20 2.2 kW inverter drive, digital and analogue I/O expansion modules, a Siemens safety relay, motor protection circuit breakers, a Scalance industrial Ethernet switch, and a 24 V DC SITOP power supply. Operator interface hardware included Schneider Harmony XB4 push buttons, selector switches, an emergency stop, a key switch, and a potentiometer.
Alongside the panel build, DelaControl procured and supplied all associated field installation equipment, including proximity switches, flexible conduit, a junction box, and interconnecting cables. Two engineers completed on-site machine wiring, connecting the field devices to the control panels.
A full documentation pack was produced, comprising electrical schematics, a SISTEMA report to ISO 13849-1 identifying the achieved Performance Level of the safety functions, a Declaration of Conformity to the Low Voltage and EMC Directives, and a signed Inspection and Test Certificate. Prior to delivery, each panel underwent a thorough pre-delivery test programme — including I/O simulation, drive testing, and a full functional run-through of the control system.
Concurrently, DelaControl undertook a complete redevelopment of the batch charger HMI and PLC software. The HMI was redesigned with updated animations and an improved ergonomic layout, and a real-time I/O diagnostic page was added to aid commissioning without requiring a laptop connected to the PLC. The PLC code was restructured to industry-standard naming conventions, with data blocks replacing memory tags to ensure data retention across power cycles, and all networks commented throughout. Crucially, the code was made modular — machine options and customer-specific I/O configurations can now be selected directly from a password-protected HMI screen, activating the relevant control routines automatically and significantly reducing the engineering effort required to configure each new machine variant. The completed software was demonstrated and accepted at a Factory Acceptance Test.
Key Facts
• Siemens S7-1200 CPU 1214C with KTP700 Basic 7" HMI per panel
• Sinamics V20 2.2 kW inverter drive per panel
• Digital I/O, analogue I/O and 8-port Scalance Ethernet switch per panel
• Siemens safety relay with SISTEMA ISO 13849-1 PL assessment
• Full documentation pack: schematics, SISTEMA report, Declaration of Conformity, I&T certificate
• Machine wiring by 2 engineers over 2 days, including proximity switches, conduit and junction box
• HMI fully redesigned with real-time I/O diagnostic page
• PLC code modularised to support multiple customer variants via password-protected HMI selection