Motor Control Centre for a UK Minerals Processing Operation
Sector:
Mining & Minerals Processing
Type:
MCC, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, tested and delivered a fully specified Motor Control Centre (MCC) for a UK minerals processing operation, incorporating a Siemens S7-1500F safety PLC, intelligent soft starters, a variable frequency drive, ET200SP distributed I/O, and bespoke TIA Portal software — all within a Form 4 Type 3 Rittal enclosure rated at 630 A.
Challenge
A minerals processing company required a new Motor Control Centre to control and protect a range of process equipment including 90 kW shredders, shed conveyors, and a chain conveyor. The MCC needed to be of industrial standard to withstand harsh site conditions, comply with Form 4 Type 3 segregation requirements, incorporate intelligent motor control devices communicating over PROFINET, include a safety PLC with fail-safe I/O, and be supplied with two operator HMI screens. A factory acceptance test and site installation support were also required.
Solution
DelaControl took on the full scope of design, manufacture, software generation, testing, and installation support for a single MCC built in a Rittal VX enclosure finished in RAL 7035. The MCC is rated at 630 A incomer and 25 kA fault level at 400 V, with a 630 A busbar system constructed from laminated copper bar. Control intelligence is provided by a Siemens S7-1517F safety PLC programmed in TIA Portal V20, with an ET200SP remote I/O head station carrying a mix of standard and fail-safe digital I/O modules (including F-DI and F-DQ cards) and analogue I/O.
Two Siemens 3RW55 intelligent soft starters — one rated for 90 kW shredder duty and one for 22 kW conveyor duty — communicate to the PLC via PROFINET modules. A Siemens G120 modular VFD (PM240-2 power module with CU240E-2 PN-F safety control unit) drives the 22 kW chain conveyor. A Siemens PAC3220 power monitor with a PROFINET expansion module provides energy metering on the incomer. Two unmanaged 8-port Ethernet switches support the panel network. The operator interface uses a Siemens MTP1500 Unified Comfort HMI — a current-generation platform selected in place of the legacy TP1500 range. A 40 A Phoenix Contact TRIO three-phase power supply provides 24 V DC, and panel services including LED lighting, RJ45 programming sockets, and a 230 V outlet are fitted to the ICA section.
Thermal calculations were performed using Rittal Therm software. Documentation supplied includes a full drawing pack (GA and schematics), Declaration of Conformity, FAT schedule and certificate, thermal calculations, and a SISTEMA report. DelaControl's scope also included site installation labour to position and secure the panel.
Key Facts
630 A incomer and busbar rating, 25 kA/1 s fault rating at 400 V Siemens S7-1517F safety PLC with ET200SP distributed I/O including fail-safe F-DI and F-DQ modules
64 digital inputs (16 fail-safe), 32 digital outputs (16 fail-safe), 8 analogue inputs as specified
Two 3RW55 intelligent soft starters (90 kW and 22 kW) with PROFINET and built-in STO
Siemens G120 modular VFD (PM240-2 + CU240E-2 PN-F) for 22 kW chain conveyor with safety-integrated control
Siemens MTP1500 Unified Comfort HMI — current-generation Unified platform
Siemens PAC3220 power monitor with PROFINET expansion module
Rittal VX enclosure, Form 4 Type 3, 5000 mm × 2325 mm × 600 mm, RAL 7035
Two unmanaged 8-port PROFINET switches supplied • Full documentation pack including SISTEMA report and Declaration of Conformity