Decorator Control System Rebuild and Safety Substantiation for a Packaging Manufacturer

DelaControl designed and built a replacement control system around an  Allen-Bradley ControlLogix 5580 platform (1756-L81ES), housed in a  Rittal VX25 bayed enclosure arrangement. The panel included a 90 kW  Allen-Bradley PowerFlex 755 drive with embedded EtherNet/IP, an AMCI  resolver module, front and rear remote I/O panels using Point I/O  EtherNet/IP adapters, and a 10-inch PanelView Plus 7 operator console  mounted on the machine. A Pilz PNOZmulti 2 configurable safety  controller formed the basis of the safety system, with dedicated input  and output expansion modules and a standstill monitor relay. Six  lockable guard switches, a pull-cord, and a Castell key exchange unit  completed the safety field equipment.

Full documentation was  produced including electrical schematics and general arrangement  drawings, a SISTEMA assessment to ISO 13849-1, thermal calculations, a  Factory Acceptance Test schedule and certificate, and a Declaration of  Conformity. Pre-delivery testing was carried out at DelaControl's  Bristol facility before the panels were delivered and installed on site  by two industrial electricians.

Following installation,  DelaControl produced a Safety Design Substantiation Report (DSR)  assessing the as-installed hardware and Pilz PNOZmulti 2 configuration  against seventeen defined safety functions (SF1–SF17), confirming  achieved performance levels of PLd for SF1–SF16 and PLe for SF17 under  ISO 13849-1:2023. On-site functional validation was then carried out by a  senior engineer, covering pre-commissioning verification, functional  testing of all seventeen safety functions, fault injection,  reset/restart verification, and jog mode verification, with results  formally recorded and signed off. Proof test documentation defining test  intervals and routines was handed over to the site maintenance team.