Large-Scale Conveyor Control System for a UK Parcel Handling Facility
Sector:
Materials Handling & Conveying
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed and built a comprehensive conveyor control system comprising a main floor-standing control panel, 27 individual VFD panels, and 45 operator control stations, complete with PLC software, HMI, and a full documentation package for a UK distribution facility.
Challenge
A conveyor systems integrator required a complete electrical control solution for a large-scale parcel handling installation. The system needed to control 27 individual conveyor drives across the facility, with local operator start/stop and emergency stop capability at each conveyor zone.
The control system was required to meet a detailed functional design requirement specification, comply with UK machinery safety standards, and be delivered with a full documentation pack including electrical drawings, a UKCA Declaration of Conformity, a Factory Acceptance Test (FAT) certificate, and an operator manual.
Solution
DelaControl, as a Siemens Solutions Partner, designed and built the system around the Siemens S7-1200 PLC platform and Siemens G120 (PM240-2) variable frequency drives — a combination selected for its conveyor-specific suitability, competitive lead times, and DelaControl's access to enhanced technical support and simulation tools. The main control panel is a multi-bay Rittal VX floor-standing enclosure housing the PLC rack, a Siemens TP2200 21-inch Comfort Pro HMI, power monitoring instrumentation, redundant 24 V DC power supplies, an uninterruptible power supply, and an IXON IXrouter3 for secure remote access. Power distribution is via a Rittal RiLine busbar system with a 250 A SENTRON incomer.
Each of the 27 conveyor motors is served by a dedicated Rittal AX compact enclosure containing a Siemens G120 drive (ranging from 0.55 kW to 7.5 kW depending on the motor duty), a local isolator, motor protection circuit breaker, and — notably — a VFD bypass contactor arrangement. This bypass functionality allows any conveyor to be run direct-on-line in the event of a drive fault, improving operational resilience. Safety in the event of an emergency stop is achieved through Safe Torque Off (STO) on the drives and safety contactors for DOL circuits.
Forty-five operator stations were supplied across the facility, comprising separate start/stop pushbutton enclosures and dedicated emergency stop enclosures, all to IP66/IP67 rating. The PLC I/O rack includes Siemens F-DI and F-DQ safety-rated modules to handle the emergency stop loop.
The full software suite was developed in Siemens TIA Portal and tested thoroughly at DelaControl's Bristol facility prior to delivery, using IO simulation rigs and test motors. A formal FAT was conducted with the customer in attendance. The documentation package includes EPlan schematics, AutoCAD general arrangement drawings, a UKCA Declaration of Conformity (to BS EN 60204, BS EN 61439-1, and BS EN 61439-2), an FAT certificate, and a full operator manual with annotated HMI walkthrough.
Key Facts
• 27 individual VFD control panels, each with a Siemens G120 drive (0.55 kW to 7.5 kW) and drive bypass (DOL) functionality
• Multi-bay Rittal VX main control panel with Siemens S7-1200 PLC, safety I/O modules (F-DI and F-DQ), and Siemens TP2200 21-inch Comfort Pro HMI
• 250 A SENTRON 4-pole incomer with Rittal RiLine busbar power distribution
• 45 operator stations supplied (IP66/IP67-rated separate start/stop and emergency stop enclosures)
• Siemens CU240E-2 PN Profinet control units with STO on all 27 drives
• Redundant 24 V DC power supplies with Siemens SITOP redundancy module
• 2000 VA Riello UPS for control system power resilience
• IXON IXrouter3 4G/Wi-Fi gateway for remote access
• Siemens SENTRON PAC power monitoring device with expansion module
• Full UKCA Declaration of Conformity, FAT schedule and certificate, and operator manual delivered