An electrical panel is a set of electrical devices enclosed in a housing or panel, which use power to switch on and control various electromechanical equipment and machines in industrial processes. Although complex, the panel structure required for industries is much like a breaker box used in homes and offices. These panels are responsible for distributing the power feed into smaller circuits, and are protected by circuit breakers. In an overload situation, the circuit breaker trips, thus preventing catastrophes such as fire and protecting machines, human resources, and property. This is the significance of installing an electrical panel in industrial setups.
This post introduces you to different electrical panels for industrial facilities, helps you understand the importance of choosing the right control panels, and offers tips on choosing the right electrical panel and many more.
Importance of Choosing the Right Electrical Control Panel
A circuit breaker panel typically includes components such as the main switch or the circuit breaker, transformer, relays, terminal blocks, programmable logic controllers (PLCs), network switches and connectors. Together, these components enable the panel to function efficiently. Installing these panels in industrial units is crucial because of the increasing use of automation equipment in manufacturing. These panel components manage various industrial controls and help achieve production goals. However, choosing the right industrial electrical panel is essential to achieve operational safety and efficiency. Here are some pointers in this regard.
- Enhanced Safety: The right control panel helps minimize the risk of electrical hazards, such as overloads, equipment failure, short circuits, etc. It allows users to comply with industry regulations while protecting assets and personnel.
- Improved System Efficiency: A properly chosen industrial electrical panel optimizes power distribution and functionality. They help ensure the smooth and efficient operation of different systems and minimize energy waste.
- Efficient Monitoring and Control: Electrical control panels are widely used for industrial automation. They enable manufacturers to define, organize, and achieve their production objectives by providing a high level of monitoring and control of the functions of production machinery.
- Extended Equipment Lifespan: A right industrial electrical panel ensures optimal operation and protection of electrical components. By doing so, it contributes to the equipment’s longevity and reduces the replacement needs.
Different Types of Electrical Control Panels
Here are some commonly used types of electrical control panels.
- Motor Controls: These electrical control panels can manage a single motor or multiple motors in industrial settings. They come with breakers, relays, and motor starters, and can be automated using programmable logic controllers (PLCs). Motor control panels are used in industrial production lines and conveyor systems.
- Lighting Panels: As the term implies lighting panels are installed to manage the lighting systems installed in industrial environments and outdoor areas. They have motion sensors to detect occupancy and shut the lights off if no one’s around. Also, lighting panels can control luminosity levels and even light color through dimmers. They help save energy by sensing and using the available natural light optimally.
- Warehouse Controls: These are centralized systems that manage and coordinate automated warehouse operations. They integrate and control various equipment, such as robots, conveyors, and sorters ensuring efficient workflows. These panels help streamline material handling and inventory management.
- Automation Equipment Controls: These panels are installed to facilitate the integration of advanced controls to automate equipment and machines. They enable remote monitoring and control of an industrial process or system, and come with PLCs and human-machine interfaces (HMIs).
- Emergency Alarm Equipment: Also called alarm control panel, this setup has sensors that receive information regarding exceeding or falling levels and more, depending on the application. It is widely used in fire alarm systems, gas detection equipment, and so on. Alarms are usually LED indicators that flash in a certain color and accompany a sound.
- Crane Controls: These control panels come with power backup to ensure uninterrupted crane functioning. This is a core, centralized component that controls and manages the crane movements. These movements include hoisting, long travel, and angular movements that are controlled by a single panel in a housing.
- Elevator Controls: This is a central panel that controls all the elevator operations including power supply, car calls, car call cancellations, speed, maximum payload, and door control.
- HVAC and Refrigeration Controls: These control panels have temperature sensors to make the necessary adjustments. They manage the range of temperature and airflow in an indoor environment based on temperature.
- Fire Protection Controls: These are centralized systems monitor and manage fire detection and suppression equipment in buildings. They are connected to sensors, sprinklers, duct detection systems, smoke alarms, and more via electric signaling circuits. If fire is detected the control unit issues alerts to the authorities and trigger water sprinklers.
- Pump Controls: Pump control panels help pumps work on an autopilot mode ensuring automatic starts and shutdowns. They also help manage the other functions of the pump such as transferring of fluids or gases at certain intervals, dosing, and issuing alerts in case of pump malfunctioning.
- Swimming Pool Controls: A swimming pool control panel is especially suitable for private pools, wherein you can manage the electrical controls of the pool, such as on & off, timers, and switching of the heater and lights, from a single equipment installed outside a swimming pool wall.
- Communication Equipment Controls: These systems are used to manage and monitor communication devices and networks, such as data transmission systems, intercoms, and radios. Communication equipment control panels help centralize controls, streamline operations, and ensure reliable connectivity. They ensure reliable communication in critical environments like transportation hubs, industrial facilities, and emergency response systems.
- Phase Conversion: A phase converter converts a single phase of electricity into three-phase power. Phase converter control panels have start and run circuits and are used to help balance a generate a third line of voltage with the single-phase input.
Factors to Consider When Choosing an Industrial Electrical Panel
Here are some key considerations to help you choose the right electrical panel, taking into account your power and load requirements as well as application or process-specific requirements.
- Understand Your Industrial Needs: Analyzing power requirements and load capacities for your industrial setup is crucial when choosing an electrical panel. In addition, you must focus on the following factors:
- Scalability: While knowing the current requirements in terms of power and load capacities is necessary, you should also consider the scope for expansion and scalability aspects.
- Process automation: If your industrial process is partially automated and you are contemplating complete automation of the unit, your requirements would change. However, ensure the panel you choose is scalable enough to meet these future expansion needs.
- Check Feature compatibility: While checking voltage and current requirements is necessary when choosing the right panel, compatibility aspects are also important. For instance, you can choose PLCs, based on the level of equipment automation. Ensure the panel components have LED indicators on alert for any issues. In remote monitoring, ensure touch screens, memory and data logging features, and more.
- Ensure Compliance and Certifications: Ensure the panel you choose is designed in compliance with OSHA, UL, NEC, or other relevant standards in terms of safety. Also, check the specifications for your industry type. Check the UL rating for your industry. For instance, UL 508A is a standard intended for general use. Likewise, specific UL standards need to be followed in case of installation in hazardous locations and so on.
- Focus on Panel Design: When designing the panel, you must consider the equipment, process and operating environment. This will help determine the type of enclosure you require. Also, determine your electrical requirements, which will help identify the software and hardware components you need. Depending on your application requirements, area available, and so on, you can choose either a modular or fixed design. If there are space constraints, ensure the panel size is compact. Also, it must be installed where workers can move freely and operate it with ease.
- Address Environmental Factors: If you need to install the panel outdoors, consider enclosure materials that are resistant to dust, moisture, and extreme hot or cold temperatures. In the case of indoor installation, you need to consider the operating environment, and what all the panels and enclosure will be exposed to. This may include anything from elevated temperatures and chemicals to heavy machine vibration, dirt, and corrosion. In such cases, choose stainless steel enclosures, and ensure proper ventilation systems.
- Check Customization Options: Always check the custom option a manufacturer or supplier of panel’s offers. Custom panels help meet specific application requirements and add to system efficiency and better control as well as physical fitment.
Tips for Installation and Maintenance of Electrical Control Panels
Installation
Here are some general tips for the installation of electrical control panels:
- Plan the layout carefully: Begin with a detailed layout of your control panel setup. Organize all the components logically, leaving sufficient space for future upgrades.
- Choose the right location: Install the electrical control panel in a dry, well-ventilated, and accessible location, away from the sources of heat, dust, or moisture.
- Follow Manufacturer’s Guidelines: Adhere to manufacturer guidelines on installations. You can refer to the wiring diagrams, mounting instructions, and ensure safety precautions.
- Ensure Proper Grounding: Ensure to ground the equipment properly, as this will help protect the personnel and equipment from hazards.
- Label Components: Neatly label all components, including wires and switches inside the panel. This will enable future troubleshooting.
Maintenance
Ensuring the installed electrical panels are maintained and properly functioning is essential. Here are some maintenance tips.
- Schedule periodic inspections to check loose connections, wear, or overheating components.
- Perform visual inspection of switchboards, circuit breakers, panel boards, and components such as capacitors, transformers, and more.
- Dust and debris may accumulate over time. Use a low-pressure air blower or dry cloth to clean the exterior or interior of the panel. Vacuum clean the area surrounding the panel.
- Check for any frayed and loose wires; mend them if necessary.
- Periodically test overload relays, circuit breakers, and other safety features to check they function as intended.
- Check the batteries and replace them if they are tripping.
- Ensure insulation among all the panel boards.
- Update the wiring diagrams and other control panel documents. Any upgrades or modifications should be documented for future reference.
Secure Your Equipment with Reliable Electrical Panel Solutions
If you are looking for custom electrical panels designed for industrial units, contact no other than North America Phase Converters. We provide high-quality, reliable solutions that help increase the safety and efficiency of your industrial unit. Do not wait for an overload situation to occur, take proactive steps to protect your assets, and increase the safety and efficiency of your equipment. Contact us today to learn more about our electrical panel offerings and how they can control and safeguard your systems.
