Cooler Room Control System Expansion for a UK Food Production Facility

DelaControl designed and built a new remote I/O junction box based on a  Schneider Electric STB distributed I/O platform, incorporating a network  interface header, digital input and analogue input modules, and  analogue output modules to support 0–10 V speed control of the 230 V  single-phase AHU/evaporator fans in each new cooler room. Eight terminal  boxes were supplied to serve the field connections.

The existing  main control panel was modified to add eight motor protection and  contactor assemblies (Schneider GV2M10 motor circuit breakers with  auxiliary contacts, GVAE11 and GV2AF3 accessories, and LC1D09BL  contactors) for the new cooling fan circuits. Additional Schneider  Modicon digital input and output modules (BMXDDI1602 and BMXDDO1602)  were added to the existing PLC rack to handle the expanded I/O count.

DelaControl  modified the existing PLC software to extend control to the eight new  cooler rooms, working from the customer's existing control software as a  reference. Field equipment — including eight Siemens SDK62 cooling  valves, eight Jumo temperature probes, eight Schneider limit switches,  and eight Schneider motor isolators with auxiliary contacts — was  procured and supplied as part of the package.

The full scope  included electrical design drawings (general arrangements and schematics  produced in AutoCAD Electrical or Eplan), thermal calculations using  Rittal Therm software, a Declaration of Conformity, an Inspection and  Test Schedule and FAT certificate, factory acceptance testing at  DelaControl's Bristol facility, site installation by two industrial  electricians over four days, and commissioning by a controls engineer  over three days.