Modular Multi-Filter Filtration Control System for an Industrial OEM
Sector:
Water Treatment, OEM & Special Purpose Machinery
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, and programmed a Siemens-based main control panel for a modular industrial liquid filtration machine. The system was engineered to manage up to four filter skids from a single control enclosure, with VFD-controlled pumps, safety PLC, HMI, UPS, and integrated power monitoring — all factory-tested before delivery.
Challenge
The customer required a complete control system for a new multi-filter industrial filtration machine, capable of managing up to four filter skids in two phased deployments. The system needed to coordinate inlet, regeneration, and sludge pumps across all filters from a single control point, with automatic flow balancing, filter hour tracking, and a flushing procedure.
The architecture also needed to be future-ready for external MES communication via OPC UA or Modbus TCP, and had to operate reliably in an elevated ambient temperature environment of 40°C. A UPS was required to allow the PLC to shut down safely in the event of a power outage.
Solution
DelaControl designed and built a main control panel based on a Siemens S7-1500F safety PLC (CPU 1513F-1 PN), accommodating both standard and safety-rated I/O modules. The panel includes a 10.1-inch Siemens SIMATIC Unified Basic HMI for local operator interaction, a Siemens SENTRON PAC3220 power monitor with PROFINET expansion, and a SITOP 24 V DC power supply with a SITOP UPS500S uninterruptible power supply to ensure safe PLC shutdown on power loss.
Thirteen Siemens SINAMICS G120C variable frequency drives are housed within the panel, covering motor duties from 1.1 kW to 7.5 kW across inlet, regeneration, and sludge pump circuits. The main incomer is protected by a 200 A Siemens 3VA MCCB, with individual motor circuit protection provided by Siemens MPCBs. A Rittal RiLineX busbar system distributes power internally. Enclosures are Rittal VX baying units finished in RAL 7035, with an integrated cooling unit to manage the 40°C ambient condition. An IXON IXrouter3 4G/LTE gateway with Wi-Fi is included for remote access capability.
Software was developed by DelaControl in accordance with their in-house Software Design Specification, implementing control loops for multi-filter flow balancing, system valve sequencing, filter hour tracking, flushing routines, and emergency stop and alarm handling. A SISTEMA report (ISO 13849-1) was produced to document the achieved performance level of the safety functions. The full documentation package includes electrical schematics, general arrangement drawings, thermal calculations, inspection and test schedule, and a Declaration of Conformity to LVD and EMC directives.
Pre-delivery testing was carried out at DelaControl's Bristol facility using I/O simulation test boxes and test motors, followed by a Factory Acceptance Test to which the customer was invited before shipment.
Key Facts
• Siemens S7-1500F safety PLC (CPU 1513F-1 PN) with safety DI and safety DQ modules
• 13 × Siemens SINAMICS G120C VFDs rated from 1.1 kW to 7.5 kW
• 200 A MCCB main incomer; individual 40 A MPCB protection per filter circuit
• 10.1-inch Siemens SIMATIC Unified Basic HMI
• SITOP UPS500S 24 V DC / 15 A UPS for safe PLC shutdown on power loss
• Siemens SENTRON PAC3220 power monitor with PROFINET expansion
• IXON IXrouter3 4G/LTE and Wi-Fi gateway for remote access
• Rittal VX baying enclosure system (1200 mm and 600 mm bays), RAL 7035
• Integrated cooling unit rated for 40°C ambient environment
• 20% spare I/O capacity designed in throughout
• SISTEMA report (ISO 13849-1) produced for safety functions
• Full documentation pack including schematics, GA drawings, thermal calcs, FAT schedule, and Declaration of Conformity