ALL YOU NEED TO KNOW ABOUT CONTROL PANELS

 

control panel

Control panels are an integral part of the system that controls various pieces of equipment, as they provide power, operator devices, and proper control over the machinery/appliances.

Each company has its own set of rules and regulations they must follow when it comes to selecting control panels. The combinations of devices that must be attached to it determine the selection process and outcome.

Take a look at a few of the primary components that are listed by control panel manufacturers:

 

CONTROL RELAYS

Control relays are devices that have a coil which can be both energized and de-energized through an electrical voltage. The coil state changes the logic state due to the contact. There are various types of relays of which one of the simplest relays is the Timing relays. These are used to control pilot lights, contractors, etc. to switch them on and off at specified times. Their working can be justified with their built-in timers.

·        One-Shot Timer - When the coil is energized, it stays in on state and on time due to the contacts it has.

·        On Timer - These are used to change the contact state to on after the on delay when the coil is energized.

·        Off Timer - As the coil is de-energized off timers are used for the contacts to change to off state after the off delay.

·        Repeat Cycle Timer - The state of contacts keep switching from on to off and vice versa when the coil is energized.

 

Programmable Logic Controllers

The programmable logic controllers are packed with various components such as relays and timers. Their primary function is to send out digital signal and input signal to the MCC panel for the motor to start. This type of control panel works on the principle of the relay logic or the DCS/PLC program. Since all the instruments and types of equipment are connected to the control panel, labels for the interlocks are provided to maintain safety regulations. With the advancement in technology, it has become possible to use a single panel instead of installing separate MCC and control panels.

Motor Control Center

Control panel manufacturers in India now customize the various control panels that are required by industries. Basically, a motor control center (MCC) is a series of fabricated enclosed panels that have a common power bus and contain motor control units. They’re also equipped with feeders for motors, and blowers and a provision from switching them from auto to manual and vice versa, have been given. These feeders have been designed according to the necessary motor ratings. To start the motor in the auto-provision, an external signal is required, which goes through the control panel. For any industry, motor control can be comprised of programmable controllers, frequency drives, metering, and the electrical service entrance.

Low Tension Panels

These control panels are similar to the high-tension panels except for the fact that these are not equipped to handle high voltage current. They’ve been designed to withstand weather and external high temperatures. Along with that, the design makes sure that the panel does not consume more energy and proves to be cost-efficient.

Automatic Power Factor Control Panels

The APFC panels are known to be employed when energy savings are a priority. It just so happens that their design can accommodate the fluctuation in power supply and voltage, and maintain the high-power factor at a stable consistency. The types of machinery used in the industry, along with various devices, and cooling plants shall determine the electrical load required by a unit. In case of the slightest fluctuation, the machines could get damaged. Capacitors are used to safeguard the equipment for fixed loads, while for varied loads capacitors with a switch in and switch out mechanism is used.

High Tension Panels

The design of high-tension panels is such that they can be used to contain and transfer high levels of voltage. Their insulation strength is higher than the control panels provided by a few electrical panel manufacturers. The electrical distribution board distributes the power received from the generator or a transformer to several distribution boards and electronic devices. Industries employee such panels for internal and external use depending on their requirement and the consumption of electricity.

Synchronizing Panel

The power supply reaching the machinery is managed through the synchronizing panel working between power sources such as DG sets. These DG sets are manipulated to act as a single unit to eliminate the subdivision of total load. If and when any unit requires servicing, the load from that particular unit shall be transferred to another unit with the synchronizing panel units, so that it can be shut off. Loss of production can be avoided since the critical load is not interrupted. More units can be synchronized as the load increases and can be disconnected with low loads.

Power Control Center

Comprised of various vertical sections, the power control center or PCC is the common control panel that controls and monitors the predetermined electrical parameters. The panel is capable of handling high levels of current passing through at a low voltage. Essentially, PCC is a power distribution unit that supplies power to transformers, panels, and motors, that are an integral part of the electrical control systems. The design of such panels are robust, and they are constructed rigidly.

Variable Frequency Drive Control Panel

According to the industrial control panel guide, VFD control panels, are essentially used to protect the VFD, and various other electrical types of equipment from dust, humidity, hot, or corrosive environment. The panel is designed so that all the components required for various types of equipment, are kept in a single panel. Line reactors and harmonic filters are a part of the VFD to reduce harmonic distortion by 3% to 5%. In case the VFD fails, it comes with bypass, which enables it to keep working without being interrupted. These panels are waterproof and weatherproof as well. The panel doors are equipped with a frequency control potentiometer, that can transmit command signals to the motor, as assigned by the operator.

Auto Main Failure Panel

AMF, also known as Automatic Transfer Switch (ATS) panels are used in case of a sudden loss of power to switch to the emergency standby generators so that the industry can run uninterrupted. The mains supply source is switched for UPS (Uninterruptible Power Supply) system between the generator and the utility mains supply. The AMF panels come with various sensors that determine the type of loss, i.e. if it is partial, complete, or notes the variations in the utility mains supply. The utility mains failure cover the failing of a single phase of three-phase system failure, in case all the phases fail concurrently.

All of the above-mentioned control panel systems are used for varied purposes and handle numerous types of equipment. The metal box can have multiple sections to hold the electrical devices needed to run the industry and can be customized according to the requirements.

 

The various components of an electrical panel enclosure according to control panel manufacturers are:

·        Surge Arrester

·        Main Circuit Breaker

·        Transformer

·        24-Volt Power Supply

·        Terminal Block

·        Relays and Contactors

and many more.

Control panel can be manufactured in a wide range of sizes, but mostly come equipped with similar devices.