Good control panel design is rooted in four fundamental elements: layout and component placement, labeling, panel sizing and component spacing, and wireway design. These aspects combine to ensure that panels are not only aesthetically neat but also functionally scalable and easy to troubleshoot. Here is a closer look at each aspect:
1. Layout and Component Placement
Components should be organised logically and functionally. There is usually a principal power disconnect switch on incoming mains power, typically on the upper right side of panels. It makes sense to locate the highest voltage components towards the top and power distribution components in a left-to-right, hierarchical bottom-to-top order with all lower voltage levels being distributed at the bottom-most rows (e.g. the 24Vdc).
Best practices include:
- Arrange the power components in consistent layouts beginning from the left, which has main breakers, then distribution breakers, followed by fuses, and at the end terminals.
- Provision of sufficient space between groups for further extension.
- Installation of Programmable Logic Controllers (PLCs) and input/output (I/O) terminals below power components to keep sensitive electronics away from heat.
- Field instrument I/O wiring is usually brought into the panel from the bottom, which makes termination easier when I/O terminals are located at the bottom. Heat dissipation mechanisms should also be included at the top of the enclosure.
2. Labeling
Clear, consistent labeling is important for effective troubleshooting and maintenance. All components and wires should be labeled in a logical syntax:
- Cable labeling: Label both ends. Power distribution cables tend to match terminal numbers and I/O wiring should match PLC addresses.
- Component labeling: Use standard abbreviations as well as corresponding line numbers from schematics to name power supplies, breakers, etc.
Good labels will quickly identify components as well as wiring in the panel and corresponding schematics.
3. Panel Sizing and Component Spacing
A control panel of an adequate size allows for:
- Ample horizontal room to allow for easy expansion of parts such as breakers, terminals, and PLC racks.
- Enough vertical space to provide for neat terminations, dissipation of heat, and prevention of overcrowding.
- Room at the bottom of the panel to coil spare field wiring.
Sizing is proper because this makes sure that the panel remains tidy, expandable, and thermally efficient.
4. Wireway Design
Wireways shall be designed to accommodate plenty of room for both field I/O and internal wiring.
- Internal wiring: Wireways shall provide neat and accessible routing to internal components with easily readable labels. Size wireways to accommodate future wiring.
- Field I/O wiring: Wireways to the I/O terminals shall be sized to accommodate connections to every terminal with capacity to add more in the future.
Proper design of wireways not only allows for easy wiring but also makes the panel more open to future changes.
Following these principles, control panels can be made to have a clean and organized appearance while offering scalability, easy troubleshooting, and efficient operations. A well-designed panel is not only aesthetically pleasing but also very valuable to any project.
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