Control Panel Boards 

Understanding Control Panel Board Basics

An electrical control panel is an enclosure, usually made of metal or plastic, that houses crucial electrical parts that regulate and observe a variety of mechanical operations. They are powered systems that require maintenance, with condition-based monitoring and planned preventative maintenance being the most efficient approaches. In order to diagnose problems, make modifications, and verify electrical safety, electrical personnel must acquire access to control panels. To run and manage the plant and process, operators will interact with the panel's controls. The control panel's components will make a variety of activities easier. For instance, they may monitor the pressure or flow in a pipe and signal when to open or shut a valve. They are typical and essential to the majority of enterprises. Neglecting them can lead to issues with them.
 

Designing Control Panel Boards for Optimal Performance

Component layout and placement

Components and component groups should be arranged logically and functionally in any control panel. For instance, since the primary incoming power disconnect switch is typically located near the top right of control panels, components with a high voltage rating should be positioned at the top of the panel. Power components will have a reduced voltage level as you descend the control panel.

Power distribution components should have a breaker for the designated power level to the left, followed by distribution breakers, fuses, and terminals in order to make troubleshooting simpler. This will maintain order, consistency, and reflect the schematic hierarchy. Between groups, there should be enough room to facilitate easy expansion.  

Let’s have a look at the strategies for designing control panels 

1. Adopt a different leaner style

Finding strategies to make space available is usually helpful in manufacturing. Even if there aren't any urgent requirements for new equipment right now, they most likely will be in the near future. Narrower and lighter control panels can help free up more space for future expansion and the inclusion of more components.

2. Enhance the dissipation of heat

A control panel's longevity can be severely impacted by improper heat dissipation. The maintenance and/or replacement downtime brought on by defective panels can drastically reduce productivity. The air circulation within control panels must be optimised in order to lessen hot spots.

3. Make wiring easy safe and secure 

Wires are held firmly in place by Omron's Innovative Push-In Plus technology, which offers a strong grip. Even more amazing about this technology is how it combines a strong pull-out force with a remarkably weak insertion force. In fact, putting a wire into a Push-In Plus terminal block requires less effort than plugging in a standard pair of earbuds. 

The function of a control panel boards

PANEL FOR ELECTRICAL CONTROL ELECTRICAL PARTS

Within a utilised electrical panel enclosure, there are eight main sorts of electrical components that define and organise the many functions the panel performs. These elements consist of: 

Circuit breaker in the main- This is comparable to disconnecting the main electrical panel that serves a building's entrance or office. In the majority of industrial applications, miniature circuit breakers handle voltages between 120V and 480V, establishing control over circuit components.

Influx arresters- This part shields the electrical components inside the panel from overvoltage damage caused by lightning strikes or utility power surges.

Transformers- Transformers can step down voltage to 24V when incoming power is 120V or reduce voltage to 120V for various components depending on the incoming voltage. 
 

Safety Tips for Working with Control Panel Boards

Electricity is required for everything from facility lighting to operating gear and equipment. The industrial control panel is at the centre of how the office uses energy. The labelling of the electrical panel is frequently disregarded for unknown reasons. It is crucial that employees are aware of where to go in order to quickly and securely solve any electrical equipment issues.

Observation of Details

According to the Bureau of Labor and Statistics, 154 people died in 2016 as a result of electrical exposure. Shock and arc flash injuries are frequent when dealing with electricity. Employers cannot entirely eliminate dangers unless they stop using electricity. Employee protection can be achieved, nevertheless, by following safety best practises such employing the appropriate personal protective equipment (PPE), lockout/tagout techniques, and current electrical equipment identification.
 

Maintain Current Communications

Control panels are highlighted by floor signs and tape.

Each piece of service equipment, including motor control centers, panels, feeders, substations, and switchboards, needs to be labelled. When equipment that may be unmarked or labelled with outdated information needs to be maintained or repaired, proper labelling impacts the safety of everyone in the facility both now and years from now. In the event that emergency personnel need to access facility equipment during a disaster response, industrial control panel labelling is also helpful. 

Shock and arc flash injuries are frequent when dealing with electricity. Employers cannot entirely eliminate dangers unless they stop using electricity. Employee protection can be achieved, nevertheless, by following safety best practises such employing the appropriate personal protective equipment (PPE), lockout/tagout techniques, and current electrical equipment identification.

Applications of Control Panel Boards in Various Industries

MCCs

MCCs, often referred to as motor control centers, have one or more vertical cabinet portions that have mounting points for motor controllers and a busbar for power distribution. A contactor or motor starter, an overload relay to safeguard the motor, circuit protection tools such circuit breakers and fuses, and a power disconnect switch are all included in each motor controller in an MCC panel.

MCC panels may also include other controls elements such pushbuttons, indicator lights, programmable logic controllers (PLCs), variable frequency drives (VFDs), and metering devices. Large production plants that require the control of several motors from a central area, such as a mechanical or electrical room, frequently install MCCs.

Panels for PLC Control

PLCs are commercial computers that link and keep an eye on relays, pushbuttons, sensors, and other input devices. The PLC can carry out pre programmed outputs such sounding an alarm, opening or closing a valve, or stopping or starting a motor based on the status of an input device.

VFD Management Panels

VFDs are a form of motor controller that are used to modify the input voltage and frequency to control motor speed. When starting or halting a motor, VFDs can additionally regulate the ramp-up and ramp-down phases. The efficiency of the system is increased, energy consumption is decreased, the motor's speed and torque are matched to the needs of the process, and mechanical stress on a machine is minimised thanks to VFDs.

A single or several VFDs, power distribution components, circuit and motor protection devices, line reactors or harmonic filters, motor starters, and a PLC can all be found in a VFD control panel.
 

Panels for motor starters

Motor starters are tools that start and stop a motor using electromagnetic forces. An overload relay is typically part of a motor starter system to safeguard the associated motor from electrical overload. A motor starter panel may include one or more motor starters that are enclosed, together with pushbuttons or selector switches to control the motor's status, circuit protection devices, power distribution components, and a power disconnect switch.

Troubleshooting Common Problems with Control Panel Boards

If you take your time, control panel troubleshooting can be completed effectively. This doesn't make sense because you're normally debugging a control panel in a production setting where you need to have the issue resolved right away. Prepare your attack. Spend no time or energy in vain. Find the quickest route to the answer. Here are the fundamentals.

Ask for help

Before taking any action, ask for assistance if you can. Sometimes you're fortunate. Speak to anyone who has knowledge of the control panel or the machinery it governs. Contact the maker of the machinery.  You're trying to find someone who understands how the control panel should operate.

Utilize your options

Toolkit for debugging the control panel

MANUALS - Look for the manuals that were initially provided with the control panel. Installation and operating instructions are typically included with control panels. Drawings of electrical schematics are useful. Call the manufacturer to request a copy of the paperwork if you can't find it.

Focus on your efforts

Before you do anything, locate the dedicated power source that is supplying the control panel. In a motor control centre or electrical power distribution panel, it is typically a specialised circuit breaker. Locate it, shut it off, and then look for any field devices that are linked to the panel. The power circuits are a good place to start if you're unsure where. 

FAQs: Control Panel Board

Q. What is a control panel board?

Ans. A control panel board is a device that houses different electric devices for regulating and managing machines and production lines, protecting against anomalies, and operating heaters and electric motors like pumps and motors.
 

Q. What are the different types of control panel boards?

Ans. There are three types of control panels 

• Power Control Center (PCC Panel)
• Motor Control Center (MCC Panel)
• Automation Panel (SCADA PLC Panel)

Q. What are the main components of a control panel board?

Ans. Every automated manufacturing process needs electrical control panels. Basic control panels contain a variety of electrical components that send signals to guide the functioning of machinery and equipment. Even though control systems are a crucial component of electrical engineering, many individuals are unaware of the essential parts that a reliable and safe control panel must include.
 

Q. How do you select the right control panel board for a particular application?

Ans. Printed circuit boards with connections to all nearby peripheral devices are typically housed inside control panels. Door hardware, such as a card reader, door position switch, or door strike, as well as additional inputs and relays as needed, may be included in these peripheral devices. The control panel interfaces with the host computer and hosts the management of the peripheral devices.