What is Electrical Control Panel?
A metallic box known as an electrical control panel enables users to mechanically control all electric devices, appliances, and circuits using electricity. It provides full access to the entire electrical system from a single location within a sizable electric board, enabling operators to monitor and manage the entire electrical system. The quickest and simplest way to diagnose and fix problems is using an electrical control panel, and the many protection systems contained inside an electrical control panel ensure the safety of a given power system’s entire power system.
Structural components of electrical control panel
The electrical control panel is constructed with the most electric equipment feasible within its walls, keeping all operating systems protected. The basic structural elements of this kind of panel are
- The Enclosure
- The Back Panels
- Wire Ducts and Din Rail
1). The Enclosure
The control panel’s enclosure serves as its body, which is the metallic box primarily composed of either aluminium or stainless steel.
Its purpose is to house all equipment inside of it and protect the equipment’s electrical system from outdoor elements; the size of the enclosure depends on the function that has to be done.
The enclosures contain a printed plate that details the electric control panel’s usage restrictions, including whether it may be used for indoor or outdoor applications, if it is waterproof, dustproof, hazardous condition-rated, and whether it is explosion-proof-rated.
After safety and IP testing, the electrical control panel’s NEMA classification determines these ratings.
2). The Back Panels
An electrical control panel’s back panel is the metallic sheet that is housed inside the enclosure and serves as an actual housing & connectivity for the electrical equipment. For fitting in electrical equipment, mounting holes are either present or can be drilled. The back panel’s DIN rails are an essential component because they provide housing & fitting structure for the electrical equipment that supports the enclosure’s stability. Wire ducts, another essential part of back panels, allow for the proper connection of equipment to electrical power and facilitate maintenance and troubleshooting by providing a clear view of the conductor lines.
3). Wire Ducts and Din Rail
Typically, wire ducts are composed of plastic. On the sides, they have either thick or thin fingers that enable wire for exiting and connect to an electrical equipment. To cover and conceal the wire runs underneath and give the electrical panel a polished appearance, a detachable lid is attached to the top.
Electrical Components in Electrical Control Panel
The components mentioned below combine to form the structure of the electrical control panel, which provides secure housing for each of the electrical components including:
1). Main Circuit Breaker
2). Branch Circuit Breaker
3). Power supply or a transformer
4). PLC (programmable logic controller)
5). HMI, or human-machine interface
6). Network Switch
7). Relays
9). Terminal Block
1). Main Circuit Breaker
It serves as a junction between the electric control panel and the incoming power line. The electrical control panel (or) power system can be connected to or disconnected from the power line using a mechanical device.
Depending on the type of circuit breaker being used, the main circuit breaker’s usage or application will differ, but typically it serves as a point of contact for protecting the electric panel system from the power line fault currents by quickly disconnecting the system.
Depending on the load application, the power line to main circuit breaker might have any distribution level voltage.
2). Branch Circuit Breaker
It serves as a junction between a branch circuit and a feeder circuit breaker. An operator can mechanically connect or separate electrical equipment from the power line that supplies them.
Depending on the circuit breaker type used, a branch circuit breaker may be utilized in a variety of ways, but frequently it serves as an intermediary to protect electric materials from the power line fault currents by instantly cutting the circuit.
In the rare circumstance that a higher than intended current is being pulled through the wires but not at the level of the short circuit, certain types may also provide protection against thermal heat.
3). Power supply or a transformer
Step-down transformers in the electrical control panel reduce the voltage of the incoming power line to the level needed by the electrical component. In such cases, step down transformers (or) DC power supplies step down the voltage to required level of electrical control panel in order to run the system safely and at the levels the control devices are designed to use, even though the distribution line may be between 575v and 120v and the required electric voltage may be even lower than that, such as 24v.
Sometimes separate electric equipment has to operate at different voltage levels. To accurately supply voltage to the particular electric equipment in the situation, numerous step-down transformers (or) DC power supplies are installed.
4). PLC (programmable logic controller)
The PLC, which operates on logical input, is what controls the electrical control panel. The PLC, which controls the entire industrial electric system, receives these preset inputs. It connects to a number of inputs from various terminal blocks & has a number of outputs that are dependent on power signals. On assembly lines in many industries, sensing devices of various types, such as proximity switches & sensors, are installed. These devices give the PLC the necessary feedback, allowing it to alter the logical output in order to maintain system efficiency and within limitations.
5). HMI, or Human-Machine Interface
The interior structure of the electrical control panel is complex and is made up of a lot of electric equipment, making it complicated for the operator to learn about the current condition, decide how to respond appropriately, and input the system. HMI makes it easier to grant direct inputs and gives the operator a space to understand the logical workings of the PLC & electric control panel. The operator can keep control over the power system and electrical control panel with the help of HMI, which serves no other purpose.
6). Network Switch
Network switch is in charge of controlling the 24V communication connection that connects the PLC to every other piece of equipment that has to adhere to predetermined rules and instructions from operators. The network switch regulates communication between the PLC and other electrical equipment in the panel.
7). Relays
Electric equipment is connected to and disconnected from power line using relays, which are safety measures. The ability to turn power ON & OFF as well as establish and destroy electrical circuits is assigned to the operator. Within electrical control panels, there are three different kinds of relays. Small relays that manage the power line to portable electrical devices like lights and fans come first. The motors functionality is controlled by the second type, which are significant relays known as contactors. The emergency stop circuit uses the third type, known as master control relays (MCR), which cut off all power to the output devices if the user activates an emergency device.
8). Pilot Lights (or) Push Buttons
9). Terminal Block
In heavy-duty electrical control panels where several power sources or voltage levels are needed, terminal blocks are a key electrical component. These terminal blocks are where power lines are connected to the appropriate equipment surrounding the electrical control panel. They also hold a specific voltage power source.
Advantages of Electrical Control Panel
- It makes it simpler to learn and keep track of how the electric system is operating inside a certain space, which helps operators in the automation industry control work and accomplish targets.
- They are flexible enough to fit in to according to the needs of the company because there are no design restrictions, allowing them to be made to fit each sector’s requirements.
- By providing real-time information about every change occurring in the power system and the ability to make changes to make them into equipment-suitable circumstances, the electrical control panel increases the reliability of the electric system.
- The operation of the intricate (complex) industrial system is controlled very simply and more affordably by a single electric control panel.
- These electric panels can be used indoors or outdoors, making them weather-resistant outside and enabling field operators to provide emergency or necessary inputs.
- These are safe for use by operators since they are hazard- and fireproof and have complete protection gear to protect the system in the case of an emergency.
- By enabling administration, control, & inspection from a single panel which needs fewer technicians and skilled engineers to handle the entire company, it reduces the overall running costs of any industry.
- The probability of any process system disturbance is reduced because professionals may regulate the entire process within an industry by merely watching the electric control panel indications.
- By simply ensuring that all of the equipment & lines at electrical control panel are operational, problems within the entire system can be tracked and troubleshooting can be performed easily.
Maintenance of an Electrical Control Panel
Giving operators a continuous overview and control over every particular electric system application is the responsibility of the electrical control panel. It’s complicated construction and labour-intensive electric machinery necessitate periodic maintenance to maintain peak performance. The following tasks are necessary for the electrical control panel system’s maintenance.
- To help new operators understanding the working circumstances, all parts, cables, and terminals must have legible labels.
- To make monitoring easier, all electrical connections must be distinct from one another and be clearly visible.
- To thoroughly clean the back panels and enclosure of all dust.
- Measures need to be followed to avoid the control panel’s body against rusting or being attacked by pests.
Conclusion
An electrical control panel is a complicated electrical board that includes numerous power supplies or step-down transformers built on a single line power source to provide the operator with dependable administration and control over a particular building or companies.
