Panel Design Basics:

Control panel design for industrial equipment & machinery is an important undertaking. Cost is always importent, first priority is simple operator controls and then reliable operation. In simple way design of panels are less expensive to produce and easy to operate and maintain.

Resulting in designed panel to control a machine or a process. It’s not a straightforward matter of picking a proper exterior casing and internal electrical hardware. So, any improper wiring of panel and configurations of electrical components lead to malfunction of machinery and unnecessary risk to operators.

List the design requirement, it may be unorganized way at starting. Evaluate the technical specifications and regulatory standards, then a question and answer session to fill in all gaps. Design is a process and it takes time to get it right. After these considerations are evaluated, drawings are prepared for physical & schematic layouts. Good panel design include:

·      Functional Diagram

·      Input/output Diagram

·      Power Distribution

·      Control Distribution

·      General Arrangement (GA) Drawing

·      Bill of Material

Design Considerations:

The following design discussions shows the primary considerations in developing an industrial control panel and the consideration includes in maintenance point of view also.

3. Power Cable: size should allow highest possible load that may occur.

Usually determined by estimating sum of all connected motors and apparatus (keeping in mind- type of motor, Duty cycles and simultanious operation of apparatus), adding this sum to F.L.C for all resistive loads + 1.25 times of F.L.C of highest rated motor.

4. Simplest Operating Devices are always used with front panel faceplates. such as push buttons, pilot lamps, knob switches, degital meters, E-stop(Emergency-stop) pushbutton, joysticks, RRC (Radio Remote Control), etc,.

5. Control panel should equip with primary protective device, over current protection can be provided ahead of panel.

Earthing (or grounding) is a crucial aspect of electrical and electronic systems, particularly incommercial and industrial sectors. It involves establishing a connection between an electrical circuit or equipment and the Earth (ground) through a conductor.

1. Earthing (Grounding):

• Definition: Earthing is the process of connecting electrical systems and equipment to the Earth, creating a low-resistance path for electrical current to flow safely into the ground in the event of a fault.

• Purpose: The primary purpose of earthing is to ensure safety by preventing electrical shocks, fires, and damage to equipment. It also helps in maintaining a stable electrical reference point for the system.

2. Importance of Earthing:

• Safety: In commercial and industrial settings, electrical systems can be complex and powerful. Proper earthing minimizes the risk of electric shock to personnel, reducing the chances of accidents and injuries.

• Equipment Protection: Earthing helps prevent damage to sensitive electronic equipment from lightning strikes, power surges, or faults in the electrical system.

• Fire Prevention: Effective earthing reduces the risk of electrical fires by providing a path for fault currents to safely dissipate into the ground.

• System Stability: In industrial processes, maintaining a stable electrical reference point is critical for the proper functioning of control systems and machinery. Earthing helps achieve this stability.

• Compliance: Many electrical codes and standards require proper earthing for commercial and industrial installations. Compliance with these standards is essential to ensure safety and legal requirements are met.

3. Earth Pit Resistance Validation & Certification:

• Earth Pit: An earth pit (also known as a ground pit or grounding electrode) is a dedicated structure or enclosure in which grounding electrodes are installed. These electrodes facilitate the connection between electrical systems and the ground.

• Earth Pit Resistance: Earth pit resistance refers to the electrical resistance between the grounding electrode system and the Earth. It measures how effectively electrical current can be safely discharged into the ground.

• Validation: Earth pit resistance validation involves testing the resistance of the grounding system to ensure that it meets safety and performance standards. This is typically done using specialized equipment, such as ground resistance testers.

• Certification: After validation, a certification or compliance report is issued to confirm that the earth pit resistance is within acceptable limits. Certification is often required by regulatory authorities and may need to be periodically updated to ensure ongoing safety and compliance.

• Acceptable Limits: The acceptable limit for earth pit resistance varies by region and standards but is generally in the range of a 1Ω to 5Ω. Lower resistance values are preferred, as they provide better safety and performance.

• Maintenance: Earth pit resistance can change over time due to environmental factors and corrosion. Regular maintenance and testing are essential to ensure that the grounding system continues to provide effective protection.

In summary, earthing is a critical safety measure in commercial and industrial sectors. It helps protect personnel, equipment, and facilities from electrical hazards, ensures system stability, and facilitates compliance with safety standards. Validating and certifying earth pit resistance is an integral part of ensuring that the grounding system functions as intended and remains in compliance with safety regulations.