Industrial Abatement System Control Panel Redesign with NFPA 79 Compliance Pathway
Sector:
OEM & Special Purpose Machinery
Type:
Design Only
Platform:
Certification:
CE / UKCA
Summary
DelaControl undertook the electrical design and documentation for the control system of an industrial abatement unit, redesigning the existing panel to achieve compliance with IEC 60204 and IEC 61439, and providing a clear pathway to NFPA 79 compliance for the US market. The scope included a full drawing pack, compliance documentation, and the supply and build of panel backplates.
Challenge
An industrial abatement system manufacturer needed to redesign the control panel for an existing abatement unit — the NRF714 — to bring it into compliance with IEC 60204 and IEC 61439. The existing design did not meet these standards, and a structured route to achieving compliance needed to be established alongside a full set of supporting documentation.
The customer also required a pathway to NFPA 79 compliance to support the deployment of the system in the US market, and needed the electrical design to account for a complex I/O profile including safety-rated inputs and outputs, thermocouple inputs, and pulse width modulation outputs.
Solution
DelaControl produced a full electrical redesign of the abatement unit's control panel, working from existing schematic drawings, a P&ID, and a preliminary I/O schedule. The design incorporated a proprietary Type 1 controller, a Krinschroeder BCU460 burner control unit, a Weiland SAMOS safety I/O controller, and an HMI, with 25% spare I/O capacity built in as standard. Motor loads — including a direct-on-line water pump and three inverter-driven fans and blowers — were accommodated within the power design.
A complete drawing pack was produced in EPlan, covering general arrangements, schematics, and cable schedules, delivered in both native and PDF formats. A Design Substantiation Report (DSR) was produced to demonstrate conformance with BS EN 60204, BS EN 61439-1, and BS EN 61439-2, along with a dissipated heat calculation to support the customer's wider thermal analysis of the unit.
NFPA 79 compliance for the US market was addressed through a gap analysis identifying the design amendments required to move from the CE-compliant design to a fully NFPA 79-conformant one. DelaControl also supplied and built the panel backplates as part of the overall delivery.
Key Facts
• 49 digital inputs, 42 digital outputs, 23 analogue inputs, 4 analogue outputs
• 6 safety digital inputs, 1 safety digital output, 7 thermocouple inputs, 3 PWM outputs
• 25% spare I/O capacity designed in as standard
• 4 motor loads: 1 DOL water pump, 3 inverter-driven fans/blowers
• Key components: proprietary Type 1 controller, Krinschroeder BCU460 (MK2), Weiland SAMOS safety I/O controller
• Drawing pack produced in EPlan; delivered in native and PDF formats
• Compliance documentation to BS EN 60204, BS EN 61439-1 and BS EN 61439-2
• NFPA 79 gap analysis and conformant design included in scope
• Panel backplates supplied and built by DelaControl