Control Panels

Denca has been designing and building Form 2 MCCs (sometimes referred to as wardrobe style) for our customers for many years, this has given us a good knowledge of the requirements and layout of this style of MCC panel.    Before presenting our finalised design solution, our pre-manufacture design meetings would consider access restrictions, cable routing, equipment specification, and maintenance needs.

This style of MCC has long been popular in such industries as Automotive, Food manufacturing, Brewing, Logistics etc where the ease and speed of maintenance are essential.    We are able to manufacture these styles of panels in a standard off the shelf enclosure or a custom design, colour can also be specified at the time of order.

Bespoke distribution control panels can be a very efficient way to supply your plant with electric power, our distribution systems are built to protect your vital machinery and equipment.    

Choosing the correct protection device is very important and there are various methods which you can choose from, such as Fuse, MCB, MCCB or ACB.  Designing the system and sizing the devices correctly will prevent common problems like nuisance tripping or equipment malfunction. 

When space is at a premium, we can design bespoke distribution boards to fit on walls or in other specific locations, leaving precious floor space for production needs. 

Whether your needs are better isolation or more protection, in a fixed or withdrawable compartment style, we can manufacture to your specification. 

We can also offer a modular solution which is more off-the-shelf and widely recognised as a Mini-Form Board.   These boards can be built to order but using a modular steelwork system, and are usually supplied with fuse switches. 

All our Mini-form boards meet current standards BSEN 60439-1 and BSEN 60947-1 for fuse switches. 

Denca has been designing and manufacturing Motor Control Centre (MCC) panels for over 20 years, working closely with our customers and suppliers to obtain the most efficient and cost-effective solutions.   Our pre-manufacture design meetings would consider access restrictions, cable routing and maintenance needs before presenting our finalised design solution.

We have seen a sharp increase in demand for these Form 4 MCCs in recent years, these large capacity panels are sometimes termed as traditional MCCs or compartment MCCs,  which we can manufacture to the Form 4 Type 2 standard or higher.   We are also able to custom design and manufacture extensions to your existing systems.

The increased floor area of our new manufacturing base together with its 5 tonne overhead crane has meant we are able to undertake larger and more complex Form 4 MCCs.

Programmable Logic Controller (PLC) systems are a great solution to control and monitor a complex process, the decision on whether to use a PLC is usually evident in the early stages of the project design.

The PLC connects to all of the process equipment including Motors, Valves and Sensors which often means the panel has to be capable of marshalling a significant number of cables for the various input/outputs (I/O). Denca has over 25years experience in the design and implementation of these systems and we will be happy to assist with your specification and design process.

We are also able to offer a variety of remote I/O marshalling solutions when a centralised system is not appropriate.

HMI Panels (Human-Machine Interface) can be mounted within a remote standalone control panel. This gives the flexibility to be located and installed near your workspace and machine.  

Operators can monitor the state of a process and modify control settings to change the control objective. They can manually override automatic control operations in an emergency. 

We can connect your HMI panel using various hardware links, such as industrial ethernet, Profibus, and Profi Net. The links can then communicate to your PLC. 

Please get in touch with Denca directly with any HMI enquires. Our engineers have a wealth of knowledge covering both new and legacy HMI systems. 

Remote I/O Control panels are an ideal solution for controlling multiple systems across a large area. The remote panels are connected onto a local process network which links to a centralised controller, usually a PLC.

The advantage of this design concept is seen within industries that are expanding or often need to make changes to local processes.  A local I/O panel reduces cost of initial installation and also allows for cost-effective changes.   A local I/O panel can also help with fault diagnosis by allowing maintenance technicians to easily check sensor status.

Since our 2019 move to a much larger manufacturing facility, we have seen an increase in the number of container-based solutions that we are providing.    We have the in-house capability to handle these 40-foot containers, the space and overhead cranage make delivery and handling a lot easier.

These solutions have mainly been built for the water and chemical industries.

The containers are purchased as empty structures and then fabricated to a bespoke internal design. The walls and floor can be insulated to the customer’s requirements with other changes including concealed cable access, and additional mounting rails for securing equipment and services such as heat and light.   The containers can contain system controls, motor controls or even small processes.

Due to the modular nature of these solutions, they can also be built and tested in the UK and shipped overseas for installation in remote projects.   These solutions also lend themselves to easy expansion as they can be cost-effectively stacked and interconnected.

Denca designs and manufactures control panels with full EMC compliance. With expanding technologies and multiple systems working within a single environment, it is paramount to correctly install components to the manufacturer’s specifications.

Of course, component suppliers each recommend different installation guidelines to meet the requirements for operation within an EMC environment! 

Denca engineers regularly undertake training to stay up to date with changing guidelines. These continuing updates help us work to the best ability and knowledge to deliver a fully compliant EMC control system. 

Variable Speed Motor Panels are probably our most frequently ordered panel. Customers see the benefit in energy savings and increased lifespan on equipment.

A Variable Speed Drive (VSD) allows motor equipment to be run at their optimum speed, which is usually less than the 100% rate that a fixed speed motor would require. This reduced energy and decrease in wear and tear often brings significant cost savings.

If you feel a VSD would benefit your system, please ask our engineers and we will be happy to advise on how best to proceed.

PLC/Motor Control panels are a popular option for controlling process equipment. A PLC is dedicated to controlling and monitoring the process whilst electrical distribution and motor control is needed for the power requirements.

It is often a good idea to house all of this equipment in a suite of suitably sized panels, with the benefits including simplified interconnection between motor equipment and controls, efficient use of floor space and ease of maintenance.

When appropriate, operator controls can be installed on the front of the enclosures, which could include a Human Machine Interface (HMI) or pushbutton control.

If you think this type of arrangement would suit your process our engineers will be happy to help with both design and specification.

An instrument control panel is a highly efficient and user-friendly interface that enables operators to manage and monitor various automated processes with ease. Designed with cutting-edge technology and advanced features, it offers a centralised and streamlined approach to control and monitor various instruments and equipment in real-time, ensuring smooth operation and maximum productivity. This cost-effective solution offers complete control and visibility into critical processes, making it an indispensable tool for modern industries looking to streamline their operations and achieve higher levels of efficiency.

A push-button station is a compact, user-friendly device that can be installed remotely. It is possible for the station to control its peripherals from as many locations as there are stations. This can be done by using more than one push-button station.

This type of panel provides signals to your VSD, PLC or a hardwired control circuit using normally open or closed contacts.

When installing a push-button station with an emergency stop, we recommended that it is of easy access to the operator(s).

A pneumatic control panel is an efficient, reliable and safe solution for industrial process control. By utilizing compressed air to activate control elements, this type of control panel provides fast and precise control over various process variables. Pneumatic control panels are ideal for applications where electrical controls are not feasible or safe, and are designed to meet the demands of demanding industrial environments, making them an essential component in many manufacturing and production processes. With a focus on durability, accuracy and ease of use, a pneumatic control panel is the ideal solution for process control and automation.