A D I V I S I O N O F
Industrial Control Panel
Design Guide
Schematics, Standards, Design
Considerations & More
[Link]
Industrial Control Panel Design Guide
Industrial control panels consist of
power circuits or control circuits (or
both) which provide signals that direct
the performance of machinery or
equipment. Industrial control panels
don’t include the main power, nor do
they include the controlled equipment;
rather, the panel is mounted on a back
panel (or subpanel) or in an enclosure,
depending on the application. Industrial
control panel design begins with
weighing design requirements and
specifications and preparing schematics,
but the design process can be quite
complex in order to ensure that all
applicable regulatory standards and
safety requirements are met.
We’ve created this guide to provide an overview of the key design considerations
applicable to industrial control panel design, including schematics, relevant regulatory
standards, and design considerations relating to every facet of effective control panel
design for industrial equipment and machinery.
Industrial Control Panel Design – Schematics
Control panel design for industrial equipment and machinery is an important
undertaking, resulting in an interface designed to control a machine or process.
It’s not a simple matter of selecting an appropriate enclosure and a back panel
that houses the electrical hardware. So, the proper hardware must be mounted on
a back panel and properly wired and integrated into the machine – any improper
configuration can result in malfunctioning machinery, but it’s also likely to pose an
unnecessary risk to operators.
The process should always begin with an evaluation of the specifications,
requirements, and regulatory standards. After these considerations are evaluated,
drawings are created to outline the specific configuration of wiring, circuits, controls,
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Industrial Control Panel Design Guide
and every other aspect of the final control panel. Good design addresses both the
electrical and physical requirements. These drawings should include:
y Functional diagram
y I/O (Input/Output) diagram
y Power distribution
y Control cabinet and back panel layouts
y Bill of materials
Because there are so many elements in a proper schematic, a table of contents is also
recommended. The schematic is the foundation for the subsequent development of
an industrial control panel.
Regulatory Standards Related to Industrial
Control Panel Design
Despite many Code cycles, many industrial control panels are still not compliant with
the regulatory standards which are accepted industry-wide. Compliance, however,
is critical for ensuring minimal safety risks associated with installing and operating
industrial equipment and machinery.
Below is an overview of the most prominent regulations applicable to the design,
manufacture, and installation of industrial control panels. Like all regulatory standards,
industrial control panel standards are subject to change over time, and in fact, one of
the most relevant standards, UL 508, has recently been phased out and replaced by
an updated, harmonized international standard. Because of the changing nature of
regulatory standards, it’s important to stay up-to-date on current requirements.
NEC
The National Electrical Code (NEC), or NFPA 70, is a widely-accepted standard for the
safe installation of electrical equipment and wiring. The NEC is adopted by state or by
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Industrial Control Panel Design Guide
region to standardize the enforcement of safe electrical practices. Article 409 covers
industrial control panels and applies to panels intended for general use at 600 volts or
less, in ordinary locations. Industrial Control Panel Design Regulatory Standards
Article 409 specifies that industrial
control panels must be evaluated
and marked for their Short Circuit
Current Rating (SCCR), which is
established by evaluating each
feeder individually as well as all
branch circuits. The smallest kA
value is used as the kA value for
the panel as a whole. The kA value
must be greater than the kA value
of the incoming source in order for
the panel to be installed.
NFPA 79
NFPA (National Fire Protection Association) 79 is a section of the NEC that pertains
to wiring standards for industrial machinery. The scope of this standard encompasses
electrical and electronic elements of all machinery that operates at or below
600V, including injection molding machines, assembly machinery, machine tools,
and material handling machinery, among others, as well as inspection and testing
machinery. NFPA 79 provides safeguards for industrial machinery aimed at protecting
operators, equipment, facilities, and work-in-progress from fire and electrical hazards.
Portions of NFPA 79 relate to control circuits and control functions, operator interface
and control devices, location, mounting, and enclosures for control equipment, and
other topics relevant to the design of industrial control panels.
UL 508 and UL 60947-4-1
UL 508 was one of the most important standards to recognize for many years, but this
standard has recently been phased out and has been replaced by UL 60947-4-1.
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Industrial Control Panel Design Guide
y Before January 26, 2012, listed control panels were evaluated to standard UL
60947-4. If a customer specifically requested that a panel be evaluated to UL-
508, this was permissible.
y From January 26, 2012 through January 26, 2017, new industrial control panels
were evaluated to UL 60947-4. However, evaluating revisions to existing control
panels to UL-508 was permissible if requested.
y After January 27, 2017, all listed industrial control panels are required to meet UL
60947-4-1 specifications.
The transition is meant to harmonize the standards from UL and other entities
including the Canadian Standards Association (CSA) and the International
Electrotechnical Commission (IEC) in Europe. It’s worth noting that UL 508 and UL
60947-4-1 are largely the same in a technical sense but do incorporate important
national differences in order to harmonize and create an international standard.
The primary impacts of the transition relate to how products are tested and qualified
to a standard due to differences in voltages used around the world. Industrial voltages
in the United States are 480 V at 60Hz, while industrial voltages in Europe are 400 V
at 50Hz.
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Industrial Control Panel Design Guide
The new UL 60947-4 standard “applies to the types of equipment listed in 1.1.1 and
1.1.2 whose main contacts are intended to be connected to circuits the rated voltage of
which does not exceed 1 000 V a.c. or 1 500 V d.c.”
A variety of other standards are applicable to certain types of industrial control panels,
shown in the table below:
STANDARD COVERS
UL 218: Standard for Fire Pump Controllers Fire pump controllers
UL 1203: Standard for Explosion-Proof and Equipment intended for use in hazardous
Dust-Ignition-Proof Electrical Equipment for locations
Use in Hazardous (Classified) Locations
UL 698A: Standard for Industrial Control Industrial control panels with intrinsic safety
Panels Relating to Hazardous (Classified) barriers intended for connection to circuits in
Locations hazardous locations
UL 845: Standard for Motor Control Centers Motor control centers
UL 864: Standard for Control Units and Electrical control unit assemblies or equipment
Accessories for Fire Alarm Systems containing electrical control units for fire-
protective signaling systems
UL 891: Standard for Switchboards Freestanding assemblies of circuit breakers and
related applications
UL 924: Standard for Emergency Lighting and Any equipment necessary for supplying
Power Equipment automatic illumination and/or power to critical
areas and/or equipment essential for the safety
of human life
UL 1563: Standard for Electric Spas, Equipment Control equipment for swimming pools and spas
Assemblies, and Associated Equipment
UL 1640: Standard for Portable Power- Portable control panels for specific applications
Distribution Equipment
UL 1741: Standard for Inverters, Converters, Equipment for controlling fuel cells, photovoltaic
Controllers and Interconnection System systems, or utility interactive systems
Equipment for Use With Distributed Energy
Resources
UL 1773: Standard for Termination Boxes Enclosures or pedestals that contain terminals
for connecting power circuit conductors
UL 2017: Standard for General-Purpose Covers control panels that contain emergency
Signaling Devices and Systems alarm equipment, as well as the actual alarm
equipment
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Industrial Control Panel Design Guide
UL 2075: Standard for Gas and Vapor Equipment for gas or vapor detection
Detectors and Sensors
UL 60950-1: Standard for Information Covers control panels with predominantly
Technology Equipment – Safety – Part 1: communication equipment
General Requirements
UL 294: Standard for Access Control System Control equipment for use in physical access
Units control systems
UL 1037: Standard for Antitheft Alarms and Control equipment intended for theft deterrent
Devices or warning purposes
UL 916: Standard for Energy Management Equipment for energizing or de-energizing
Equipment electrical loads to achieve the desired use of
electrical power
Other bodies have issued applicable standards as well, such as IEC 60204-1, which
relates to the safety of machinery and electrical equipment of machines. Given the
many standards applicable to specific types of industrial control panels and those
intended for use in specific applications, it’s imperative to identify the appropriate
standards at the beginning of the design process.
Design Considerations for Industrial Control
Panels
A variety of design considerations must be weighed throughout the design process
in order to design a control panel that meets functional requirements, application
specifications, and regulatory standards. The following design decisions represent
the primary design considerations in developing an industrial control panel, although
additional considerations specific to individual applications may apply.
Enclosures and Space Requirements
The intended environment largely dictates the appropriate type of enclosure for an
industrial control panel. You’ll need enough space to install and wire components, and
it’s also wise to plan for several receptacles to reduce the need for extension cords
when it’s necessary to power test equipment or appliances.
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Industrial Control Panel Design Guide
Placement is another consideration
related to enclosures. Depending
on where the panel will be located,
you may need to account for swing
requirements of cabinet doors (if a
cabinet enclosure is being used).
If a control panel will be located
in an area with a high ambient
temperature, a ventilation fan or
air conditioning may be required
to keep the control panel within an
ideal operating temperature range. If
temperature control applies, it’s necessary to allow for easy access to air intakes and
exhaust vents (which makes it easier to access and replace filters). Both NEC required
clearance around power wiring and UL required clearance around heat producing
devices must be considered to allow adequate room for ventilation.
Space considerations are paramount, as one of the most common NEC violations
involves control panels that are too small or too confined to allow for the proper space
for wiring and wire bending. It’s also wise to consider space requirements not only for
the current configuration but possible future needs, as restricted space is a common
challenge for retrofits.
Wire Sizing and Component Types
When it comes to wire sizing and selecting the appropriate component types, there
are two important rules of thumb:
y Wires should be sized based on load current. In turn, circuit protection should be
based on wire size. Selecting the appropriate wire size is essential for ensuring
that the circuit is capable of delivering the required load current, while selecting
the best circuit protection reduces the risk of fire by preventing wires from over-
heating.
y Component types should be selected based on functional requirements. Select-
ing components of the right size is critical, as well, as voltage and load current
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Industrial Control Panel Design Guide
requirements can mandate minimum size requirements. Components must be
capable of handling the voltage and load current requirements reliably – but they
also must function as required.
UL standards outline specific requirements for wiring, such as wiring materials,
labeling for conductors, sizing for power circuit conductors, and wire sizing.
Control Components and Circuits
What type of controls are appropriate for the application? There are a variety
of options from relays to timers to terminal blocks. Opt for the simplest control
components possible.
Control circuits provide logic for the operation of power circuit components. These
circuits are typically lower-voltage for safety, and components such as control power
transformers (CPTs) and power supplies are utilized to convert the power circuit
voltage to the control circuit voltage.
Supply Conductors
Supply conductors should allow for the highest possible load that may occur.
This is typically calculated by determining the sum of all connected motors and
apparatus (keeping in mind duty cycles and which motors and apparatus will operate
simultaneously), and adding this sum to the full load current for all resistive loads plus
125% of the full load current of the highest rated motor.
Handling Overcurrent Protection
You’ll also need to consider overcurrent protection in the design phase. There are two
options: overcurrent protection can be placed ahead of the panel or incorporating a
single, primary protective device in the panel itself. Depending on the application, it
may not be desirable to integrate the protective device in the panel to minimize the
need to open an enclosure.
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Industrial Control Panel Design Guide
Operator Devices
Operator devices include components
such as push buttons, indicator lights,
digital panel meters, levers, and the
like, but these devices can also be more
complex, touch-screen displays. Such
HMIs (human-machine interfaces) allow
for more complex functionality, but also
require computing components and
software development, which can add to
the cost.
When it comes to controls, the old K.I.S.S. principle (Keep It Simple, Stupid) applies.
Simpler is always better, but simpler may not always be possible. You should, however,
opt for the simplest operator devices appropriate for the functional requirements to
support ease of use.
All industrial control panels should include an emergency stop (which differs from a
cycle stop), typically a self-latching control in a mushroom or palm type. Emergency
stops, or E-stops, are also required by OSHA (Occupational Safety and Health
Administration), and they cannot be buttons on an HMI; they must be a push-button
design which is hard-wired into the safety circuit. Additionally, any start buttons or
switches should be located directly above or to the immediate left of the associated
stop button.
Labeling
It’s imperative to properly label all wires,
terminals, and other components in an industrial
control panel. It’s a time-saving strategy that
also reduces the likelihood of errors in testing,
routine maintenance, and repairs. Labels should
be durable enough to withstand the conditions
of the target environment to avoid fading and
damage that renders them unreadable.
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Industrial Control Panel Design Guide
Front Panels and Faceplates
Front panels and faceplates may seem like an afterthought, but these elements
are equally as important to the overall operation of machinery as the interior
functional components. Front panels should be durable enough to withstand extreme
temperatures, weather conditions, cleaning products, and chemicals to protect the
underlying components.
Front panels and faceplates may include metal or plastic substrates, depending
on the application specifications, and can be mounted with studs, adhesives, or
fasteners. Digital or screen-printed graphics provide visual guidance for operators and
incorporate labeling of operator devices to ensure usability. Therefore, face plates
must have the durability necessary to remain readable for the life of the asset.
There are many, many individual components and elements that go into an industrial
control panel. This guide is meant to provide an overview of the primary design
considerations. Given the depth and complexity of control panel design, as well as
the application specifications and regulatory considerations, partnering with an expert
experienced in designing and developing industrial control panels is a time-saving
and cost-effective option for manufacturers.
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Industrial Control Panel Design Guide
Metalphoto of Cincinnati
A Division of Horizons Incorporated
Metalphoto of Cincinnati has been a leading full-service manufacturer of durable
custom nameplates, panels, overlays, labels and signs for more than 50 years. Our
experience is our strength, providing the knowledge and capability to deliver the
best solution for your product identification needs. From the dedicated graphics,
engineering and customer service teams, to the experienced machine and die
operators in our manufacturing plant, each of our associates is committed to providing
the high quality products and service that consistently delight our customers.
As a manufacturer of custom identification items, equipment front panels and overlays,
MPC offers design support at every turn. Whether you simply need your drawing
refined, or have a concept but need assistance with the development of your product,
MPC’s team includes graphic designers as well as industrial and manufacturing
engineers, who will guide you through each step of taking your product from design,
and through the manufacturing process that is the most cost-effective for you, the
customer.
LET’S TALK
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