The Challenge
Elmleigh was engaged to support the electrical infrastructure and control system integration for our client's new Innovation Centre. The project required the design, manufacture, and installation of a bespoke control system, including field wiring, containment, and safety architecture. The scope included the development of two control panels and the integration of specialist cabling to support automated equipment and drag chain systems.
The Teams
The Solution
The project began with the installation of a new distribution panel and sub main to supply a control panel located beneath a mezzanine floor. A 63A TP+N sub main was installed. All works were tested and certified to BS7671.
In the field, our team installed BZP(Bright Zinc Plated) basket containment for the VTD lift control panel wiring. Containment was mounted above and below the robot access way.
The field wiring scope included power and control connections for motor isolators, Blade stops isolators, and brake mains cables. Elmleigh wired field IO blocks, safety-rated IO block, and Turck IO-Link block, supporting up to 110 sensors and actuators. Specialist cabling was installed for the drag chain system, including 400V, 24V, control, and network cables. A safety-rated encoder was integrated.
Elmleigh designed and manufactured a main control panel using a Rittal VX Series enclosure. The panel included Siemens PLCs (CPU 1518HF-4 PN), MP and ET200SP I/O racks, 8x 0.55kW G120C VSDs, and an 11kW PM250 drive. Network infrastructure included SCALANCE XC216-4C and SC636-2C switches, with Schneider switchgear and a safety-rated PLC architecture.
A second switch panel was also designed and built using a Rittal wall-mounted enclosure. This included 24VDC and 48VDC PSUs, a fibre converter, and a 16-port PoE network switch. Local isolators and circuit breakers were installed to suit the system requirements.
The Outcome
Elmleigh successfully delivered a comprehensive electrical and control system installation for the Innovation Centre. The project demonstrated our ability to integrate complex automation infrastructure while maintaining compliance with safety and design standards.
Our collaborative approach ensured seamless coordination with the client and other contractors, supporting the Innovation Centre’s operational goals and future scalability.
Find out how Elmleigh can help
At Elmleigh, we understand that no two projects are the same. Whether you’re upgrading infrastructure, developing a new centre or needing support with a lighting installation, we deliver tailored solutions that meet your exact needs.
If you're facing challenges with your electrical systems or planning a new development, get in touch today via our contact page or call us on 01455 847045. We’re here to help.