Panel Design
Every control panel begins with careful engineering. Before a single component is installed, the electrical design, panel layout and system architecture are developed to ensure reliable operation, efficient assembly and straightforward future maintenance.
Electrical Design
Every project begins with a structured electrical design developed in EPLAN, forming the foundation for manufacturing, testing and future maintenance. Schematics are produced using clear layouts, logical circuit organisation and consistent labelling to ensure they remain easy to understand throughout the entire lifecycle of the machine. Revision control is maintained throughout the project, allowing every design change to be documented and traced from concept through to commissioning.
Key features
- EPLAN electrical schematics
- Clear, easy-to-read wiring diagrams
- Logical device and wire identification
- Revision control throughout the project
- Designs prepared to support UKCA compliance where applicable
Panel Layout
A well-designed layout simplifies every stage of the project, from assembly through to commissioning and future maintenance. Components are positioned to maximise accessibility, maintain suitable spacing for ventilation and create logical cable routes throughout the panel. Space for future expansion is considered from the beginning, allowing additional hardware to be integrated without unnecessary redesign.
Functional Safety Engineering
Designing functional safety systems requires more than simply adding safety devices. We develop integrated safety architectures that combine Safety PLCs, PROFIsafe communication, safe drives and intelligent field devices into a coordinated system, helping to achieve reliable machine protection, straightforward diagnostics and compliance with current industrial safety standards.
Key features
- Safety PLC programming and system architecture
- PROFIsafe integration with drives and field devices
- Safe Motion and safety device integration
- Functional safety diagnostics and fault tracing
- Support for SIL and Performance Level (PL) requirements
Panel Manufacture & Testing
Once the design has been approved, every control panel is assembled, wired and electrically tested before leaving our workshop. Consistent workmanship, structured assembly methods and thorough testing ensure every panel arrives ready for installation and commissioning.
Cable Management
Well-organised wiring improves reliability, simplifies fault finding and makes future modifications considerably easier. Cables are routed using structured trunking systems with consistent identification and clear segregation between different circuit types to maintain a clean and service-friendly installation.
Key features
- Separation of power and control circuits
- Segregation of AC, DC and data cables
- Consistent conductor colours following recognised UK wiring practices
- Clear wire numbering and identification
- Structured cable routing for future maintenance and expansion
Testing, Installation
& Commissioning
Every control panel undergoes comprehensive electrical and functional testing before leaving our workshop. Continuity checks, hardware verification and PLC software testing are carried out to confirm correct wiring, I/O functionality and overall system performance before delivery. Once installed on site, the control system is commissioned within the complete machine environment, with field devices, communications and safety functions fully validated to ensure reliable operation and a smooth handover from the very first start-up.
Key features
- Continuity and electrical verification
- PLC software and I/O testing
- Factory Acceptance Testing (FAT)
- Site installation and commissioning
- Final validation and operator handover
