Main Control Panel for a Multi-Motor Conveyor System
Sector:
Materials Handling & Conveying
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, programmed, tested, and commissioned a main control panel to manage a multi-motor conveyor system, with all variable frequency drives housed within a single enclosure and full operator control provided from the panel door.
Challenge
A conveyor systems manufacturer required a new main control panel to manage seven motors ranging from 0.55 kW to 4.0 kW across a conveyor installation. Each motor needed to be operable in both forward and reverse, selectable between VFD and direct-on-line (DOL) starter modes.
All operator controls — including start/stop push buttons, MPCB trip indicators, a power monitor, and an AM/PM selector switch — were to be consolidated on the main panel, along with a 7-inch HMI. The system also needed to integrate e-stop links into an existing conveyor installation on site.
Solution
DelaControl designed and built a Rittal VX25 enclosure system housing a Siemens S7-1515F safety PLC (CPU 1515F-2 PN) with a Siemens ET 200SP distributed I/O island, providing both standard and safety-rated digital inputs and outputs. Seven Siemens SINAMICS G120C variable frequency drives — covering motor ratings from 0.75 kW to 4.0 kW — were mounted within the main panel, each paired with a Siemens SIRIUS motor protection circuit breaker and reversing contactor arrangement. A Siemens SIMATIC TP700 Comfort 7-inch HMI on the panel door provides operator visibility, including bypass switch status.
The panel was built to DelaControl's standard design practices in accordance with BS EN 60204-1, BS EN 61439-1, and BS EN 61439-2. The documentation package included a full drawing pack produced in AutoCAD Electrical or Eplan, a Declaration of Conformity, thermal calculations using Rittal Therm software, a SISTEMA report (ISO 13849-1), and a signed FAT certificate.
Software was developed by DelaControl to match a proven control philosophy from an earlier equivalent system, already commissioned and accepted. All native software files were provided to the customer for their ownership. The customer was invited to a Factory Acceptance Test at DelaControl's Bristol facility prior to delivery.
Following FAT, DelaControl supplied site support for electrical termination, testing, training, and handover, with one industrial electrician and one control systems engineer each attending site for up to seven days.
Key Facts
• Seven motors controlled: 3× 0.55 kW, 2× 1.1 kW, 1× 2.2 kW, 1× 4.0 kW
• Seven Siemens SINAMICS G120C VFDs (0.75 kW to 4.0 kW) housed within the main panel
• Siemens S7-1515F safety PLC (CPU 1515F-2 PN) with ET 200SP I/O including safety-rated F-DI and F-DQ modules
• Siemens SIMATIC TP700 Comfort 7-inch HMI on panel door
• Rittal VX25 bayed enclosure system (1800H × 1800W combined, two bays)
• Documentation includes SISTEMA report (ISO 13849-1), thermal calculations, FAT certificate, and Declaration of Conformity
• Site support: 1 industrial electrician + 1 control engineer, up to 7 days each
• 8–10 week lead time from order placement