Replacement Motor Control System for an Industrial Processing Facility
Sector:
General Manufacturing
Type:
New Build - Control System, Software
Platform:
Siemens
Certification:
CE / UKCA
Summary
DelaControl designed, built, programmed, and commissioned a complete replacement control system for an industrial electric motors panel, migrating to a modern Siemens S7-1500F PLC platform. The scope covered everything from electrical design and panel build through to PLC and HMI software, factory acceptance testing, site installation, and a subsequent panel upgrade to accommodate a higher-rated mixer motor.
Challenge
The customer operated an ageing electric motors control panel that required full replacement. The existing system needed to be replicated and modernised, with new PLC and HMI software developed to match the current control philosophy.
The control system needed to manage a large number of motor circuits — including DOL starters, a soft starter, and multiple variable speed drives — alongside safety functions, operator interface, and remote support capability. Following commissioning, an additional requirement arose to accommodate a new, higher-rated mixer motor, requiring a further upgrade to the panel.
Solution
DelaControl designed and built a new control panel based on a three-bay Rittal VX25 enclosure system. The control platform chosen was a Siemens SIMATIC S7-1511F-1 PN safety CPU — a fail-safe variant of the S7-1500 range — supported by a full complement of digital and analogue I/O modules. A Siemens TP1200 touch-screen HMI was supplied for operator interaction, and five Panel Pilot 4–20 mA process meters were included for local indication. Remote access was provided via an IXON industrial router, allowing engineering support to be carried out remotely without the need for a site visit.
Motor control was provided through a combination of Siemens SIRIUS motor protection circuit breakers, contactors, a SINAMICS G120 variable speed drive (with power module and PROFINET control unit) for the primary drive circuit, and five Siemens SINAMICS G120C compact drives for additional variable speed duties. A Pilz PNOZ s4 dual-channel safety relay was incorporated for emergency stop monitoring. Door-mounted operator controls, pilot lights, selector switches, and illuminated push buttons were fitted throughout the panel.
Electrical schematics were produced in EPlan and supplied to the customer in both PDF and native formats, alongside a full drawing pack, Declaration of Conformity, and a signed Inspection and Test Certificate. PLC software was written to replicate the existing control logic; HMI software was developed from scratch to DelaControl's standard practices. The complete system was fully functionally tested at DelaControl's Bristol facility before delivery, with motor and drive simulation carried out using purpose-built test boxes.
Following installation and commissioning, DelaControl subsequently supplied and fitted a 22 kW Siemens SINAMICS G120C drive and associated motor protection components to support an upgraded mixer motor, including all necessary panel modifications carried out by a DelaControl electrician.
Key Facts
• Three-bay Rittal VX25 enclosure system (800W × 2000H × 500D per bay)
• Siemens SIMATIC S7-1511F-1 PN fail-safe PLC CPU with PROFINET
• Siemens TP1200 12.1-inch touch-screen HMI (1280 × 800 px)
• 64 digital inputs, 64 digital outputs, 5 analogue input modules, 1 analogue output module (S7-1500 I/O complement)
• 1 × Siemens SINAMICS G120 drive (with PM230 power module and CU230P-2 PN PROFINET control unit)
• 6 × Siemens SINAMICS G120C 7.5 kW variable speed drives
• 1 × Siemens SINAMICS G120C 22 kW drive (mixer motor upgrade)
• Multiple Siemens SIRIUS motor protection circuit breakers across a range of ratings (1.1 A to 50 A)
• Pilz PNOZ s4 dual-channel safety relay for emergency stop monitoring
• 5 × Panel Pilot 4–20 mA process meters for local indication
• IXON router for remote connection and engineering support
• EPlan electrical schematics supplied in PDF and native formats
• Full FAT carried out at DelaControl's Bristol facility with IO simulation test boxes
• Scope included PLC software (recreated from existing code) and new HMI software
• Site installation by DelaControl electricians included in scope