WEEK - 5

DAY- 1

CONTROL PANELS

CONTROL PANELS:

A control panel is a flat, often vertical, area where control or monitoring instruments are displayed
or it is an enclosed unit that is the part of a system that users can access, such as the control panel
of a security system (also called control unit).
They are found in factories to monitor and control machines or production lines and in places such
as nuclear power plants, ships, aircraft and mainframe computers. Older control panels are most
often equipped with push buttons and analog instruments, whereas nowadays in many
cases touchscreens are used for monitoring and control purposes.
Main types of electrical control panels:
Have you ever wondered which types of electrical control panels used in power engineering?
In this article, we are going to talk about various electrical control panels. In process plant one
or more motor control by a piece of equipment that called an electrical control panel. The
electrical control panel starts or stops many equipment's through switchgear and SCADA
automation by using MCCB, Contractor, PLC, Overload relay and plug-in relay, etc.
There are three types of electrical control panels.
1. Power control center (PCC Panel)
2. Motor Control center (MCC Panel)
3. Automation Panel (SCADA PLC Panel)
What is an Electrical Control panel, exactly? Think of an electrical control panel like the human
body. Inside our bodies, We have many vital organs that control & monitor our surroundings.
Similarly, an Electrical control panel is a CRCA ms sheet enclosure that contains electrical
switchgear that controls and monitors a mechanical process electrically.

Power control center (PCC Panel)

Let's get started! First, let's talk about the power control center (PCC Panel),PCC panel
contains all of the electrical switchgear like an air circuit breaker, MCC's, mcb, and suitable size
aluminum or copper busbar. The main circuit breaker is where the power comes into the control
panel for all of the switchgear. This circuit breaker generally has an isolate on the panel that
allows us to shut off the power.
Always remember the incoming side of the breaker will still have power. The power that comes
into the panel can be anywhere from 440 volts to 800V AC.

Motor control center (MCC Panel)

In many commercial and Industry applications, multiple electric motors are required, and it is
often desirable to control some of the motors. The apparatus designed for this type of function is
the motor control center panel (MCC Panel).
When a motor operation runs with the protection of overload relays or solid-state motor
controllers. An MCC Panel manufacturer has a control from a remote or local that is called a
motor control panel. There are combinations of different types of starters like direct online (DOL)
Starter or star-delta starter.
MCC Panel (motor control center) is using for motor control of various electrical power
Industries. Therefore, it is most important in electricity. MCC panel is an Electrical control
panel in LT panels. In other words, it can control the motor from generation to production.

Automation Panel (SCADA PLC Panel)

Automation panel (Scada PLC panel) is a Programmable digital computer also known as PLC
Automation Panel is one of the most important and efficient kinds of control panels. Which are
generally used in a variety of electronic and electrical circuit fittings.Integrated with solid PLC
logic and flawless PLC hardware programming.
Intelligent MCC Panel

Intelligent MCC Panel is a smart IMCC panel to control some or many

electric motors in a central location. Imcc have consisted of multiple
feeders that have a common power busbar and with each section
containing a combination of starters. Intelligent MCC panel is a type
of MCC panel with advanced features and enhanced workability by
using a communication capable motor management device
(SIMOCODE) that monitors the motor's other lead processes by the
process control system.

Intelligent MCC Panel represents the flexible & modular management system
for motors in the low Voltage range which can be easily and directly connected
to superior automation system. It covers all functional requirements, including
safety related disconnection of the motor feeder-automation system.

How to design Electrical control panel

Electric control panels are the best product to control mechanical equipment. When you buy
electric control panels, buy the LT panels that undergo pre-treatment for degreasing, water
rinsing, and de-rusting/ Phosphating. All our LT panels are painted with powder coating or
Synthetic enamel as per the requirements. After that, seven tank process is made by the painter
for improving the reliability of the threw product. Similarly, bus bars / internal wiring uniform
cross-section, support by SMC and DMC bases, and earthing Bus Bars run along with the
Panel. Hence, it is determined that MCC panels are an important aspect of electrical control
panels and LT panels.

Types of Electrical distribution board

There are two main types of electrical distribution boards, first is electrical panels and second
is solar LT panels.

1. Electrical Panels: An electrical panel is also known as the load center. This panel is a
metal electrical service box that accepts the main power to the home and distributes
electrical current to the various circuits within the home
2. Solar LT Panels: Solar LT Panel is an electrical distribution board that receives power
from solar panels and distributes the same to various electronic devices and distribution
boards. These types of panels are used in industries both for internal as well as external
use.

In various industries, electrical consultants design electric distribution boards with a distribution
transformer. After this, they bus duct this board to PCC Panel for more distribution of electrical
panels. Also, electrical contractors supply MCC Panel and APFC Panel to enhance its
functionality. Apart from this, when a client chooses to install a solar power plant, we supply
Solar ACDB and Solar DCDB Feeder Pillar and Junction Box along with synchronizing panels.
 AUTO MAINS FAILURE(AMF) PANELS:

Auto Main Failure (AMF) Panels are designed to restore power during power failures
and are installed in between the generators and main power supply. When the main supply
failure occurs, the panel disconnects the main from the load, activates the generator and
shifts load to generator output. On restoration of main supply, the generator automatically
stops, gets disconnected and the load is again transferred to the mains.

PRODUCT BENEFITS:

 Auto delaying start of Genset.

 Hooter alarm annunciation for start failure.
 Manual start/stop & emergency stop switch for smooth operation.
 Generator starting, stopping and monitoring sequence
 Automatic shutdown during any DG fault.
 Continuous monitoring of three phase voltage/current/frequency of mains, power supply and
DG.
 Continuous monitoring of power supply status from electricity board and DG.
 Available with lightning and surge arresters

APFC panel:

Function of APFC panel is improve the power factor. Most of the electric load is reactive,
resulting in poor power factor. Companies distributing electricity encourage consumers to
improve power factor. For improving power factor, electricity consumers have to connect
capacitors of optimum rating across inductive load. APFC is an automatic power
factor electrical device which is employed to boost the ability factor, whenever required, by
switching ON and OFF the desired capacitor bank units automatically.

APFC Panel has microcontroller based programmable controller which switches the
capacitor banks of suitable capacity automatically in multiple stages by directly reading the
reactive load (RKVA) which works in the principle of VAR sensing tends to keep up the PF
to 0.99 Lag. APFC Relay - Automatic Power Factor Controller Relay. Low Power Factor -
Harms. In industries we've differing kinds of loads viz. resistive, inductive & capacitive. To
improve the facility factor it's required to attach a hard and fast capacitor or capacitor bank
at the LT side of the Transformer. For approximate KVAr of capacitors required. If the
installation has various small loads with the mixture of huge loads then the APFC should be
recommended.

Design factors to be considered:

Control panels contain electrical components and devices that allow for the automation of industrial processes
and equipment. When designing a custom control panel, there are a number of key aspects to consider to
ensure your panel operates properly, is safe to use, and remains reliable. Understanding the basics of what to
consider in industrial control panel design will help ensure your panel meets your specific requirements and
reduces the chances for costly mistakes during your project.

PANEL LAYOUT AND DESIGN

Designing an industrial control panel requires careful consideration of every aspect of your manufacturing
process, equipment, and plant environment. This knowledge is necessary when determining what type of
enclosure is needed, the available space to install the control panel, what the electrical requirements are, and
what hardware and software components are needed to achieve your desired functionality. While a custom
control panel is designed to suit a specific application, most share a similar overall blueprint.

Enclosure Type and Sizing

Determining the enclosure type and size for your control panel is an important step in the design process.
When choosing the enclosure type, we evaluate the environment that the panel will be located in. For example,
a panel that will be exposed to corrosive substances will need a fully sealed stainless-steel enclosure, while a
panel that is installed in an area with high ambient temperature may require a ventilation fan or air conditioner.
Furthermore, a panel that is being mounted to a machine, pedestal, or on a wall will use a different style
enclosure than a panel that will be free-standing.

Once the enclosure type has been selected, we determine the right size based on the space required to install
and wire the intended control panel components. Additionally, the National Electric Code (NEC) includes
requirements for proper wiring space and wire bending radius.

Power and Circuit Protection

Assessing your power requirements is another important step when designing a custom control panel and is
best handled by a qualified controls engineer. Conducting full-load calculations will help you determine how
many amps will need to be supplied to the panel. Furthermore, based on the voltage of the power supplied by
your facility, you may need to include a transformer in your panel to convert the voltage to 120V AC and/or a
power supply to convert to 24V DC.

The types of equipment you will be controlling also must be considered when assessing your panel’s electrical
requirements. For example, if your panel will be controlling motors, you may need to include contactors,
overload relays, or motor starters to protect your motor from pulling too much electrical current and
overheating.

Determining correct wire sizes to ensure delivery of the required load current, as well as adding the necessary
circuit protection are additional aspects that are crucial to the electrical design of your panel. Circuit protection
is essential for creating consistency and preventing damage to your wires and components from excessive
voltages or currents. Circuit protection components may include circuit breakers, surge protectors, and fuses.
Controls Components
Selecting the right components and devices to accomplish the control functionality you need is another step of
designing a custom control panel. Control components such as relays or timers may be used in simple control
applications where you just need the ability to turn something on or off based on an input signal.

More complex applications such as those requiring the ability to control a sequence of events may require a
programmable logic controller (PLC), which is a microprocessor specially designed to operate in harsh
industrial environments.

If you are controlling a motor, depending on the application, you may need a variable frequency drive (VFD),
servo drive, or soft starter in your panel. A VFD is used in situations where you need to control motor speed.
Alternatively, servo drives are used with servo motors and can control multi-axis movements. Finally, soft
starters are used to gradually increase the voltage supplied to a motor during start-up to prevent a high rush of
current and torque that can damage the motor and the equipment being driven.

Operator Interfaces
The control panel’s operator interface can take many different forms, including pushbuttons, switches,
indicator lights, digital meters, or human-machine interface (HMI) display. Each of these interfaces can be
used on their own or in conjunction with one another, depending on the level of functionality you need. The
advantage of using an HMI in your design is the ability to combine all your pushbuttons, switches, and meters
into one digital touch screen display. Additionally, when integrated with SCADA software, HMIs also provide
an overview and control of your facility and ongoing processes, as well as alarm indicators, visualization of
machine metrics, and production reports.

Safety and Regulations

Process Solutions, as well as any other control panel builder, must comply with certain control panel and
electrical regulations to ensure safety. The main industrial control panel codes and standards include:

 UL 508A – Standard for Industrial Control Panels intended for general use.
 UL 698A – “Standard for Industrial Control Panels Relating to Hazardous (Classified) Locations.”
 NFPA 70 – “Standard for safe installation of electrical wiring and equipment.”
 NFPA 79 – “Electrical Standard for Industrial Machinery to protect operators, equipment, facilities, and
work-in-progress from fire and electrical hazards.”
Safety is a top concern when designing a control panel. Implementing a disconnect switch to completely shut
off power before performing maintenance or during an emergency is just one way to promote safety.
Furthermore, using the lowest practical voltages, touch-safe components, and following NEC and UL
regulations also helps make the control panel safer to use.

Control Panel Maintenance

Once your custom control panel has been designed, built, and installed, it is important to perform continued
maintenance to ensure safety and reliability. Simple maintenance practices that can be performed to prolong
the life of your control panel include:

 Keeping pests away from panel wiring and out of the enclosure.
 Regularly clearing out dust build-up. Be careful not to vacuum near circuit boards without following
electrostatic discharge (ESD) rules.
 Periodically checking terminal connections to ensure they remain properly tightened.
 Always keep the enclosure door closed.
 Contacting your systems integrator to perform any necessary software updates.
ApplicableISandIECstandards:

Delimitation of IEC 60204-1 and IEC 61439-1/2

Because of growing uncertainty on the market as to which standard should be

considered most important for a machine control panel, the German Commission for
Electrical, Electronic and Information Technologies of DIN and VDE (DKE) has
published a statement on this subject.
Various standards have to be observed for the construction of control panels for
machinery. IEC 60204-1 is the relevant standard, but it is the manufacturer's
responsibility to ensure the best possible electrical safety of the control panel.
This is why we recommend that a risk analysis be carried out. For the European
market, this is even stipulated in the relevant directives. If further risks are identified
during the risk analysis that, in the opinion of the manufacturer, are not covered by
IEC 60204-1, then IEC 61439-1/-2 and, if necessary, other standards may also be
consulted as an additional design aid. The DKE (German Commission for Electrical,
Electronic & Information Technologies) has also published a recommendation in this
regard.
Study and read simple control paneldrawings
ELECTRICAL CONTROL PANEL ELECTRICAL
COMPONENTS:
Eight types of electrical components exist within an electrical panel enclosure which
define and organize the several different functions carried out by the panel. These
components include:

 Main circuit breaker. This is like the disconnect of the main electrical panel
leading into a home or office. Main circuit breakers handle between 120V–
480V in most industrial applications.
 Surge arresters. This component prevents lightning strikes or utility power
surges from damaging the electrical components inside the panel due to
overvoltage.
 Transformers. Depending on the incoming voltage, transformers may reduce
voltage to 120V for various components or step down voltage to 24V in
instances where incoming power is 120V.
 Terminal blocks. These blocks help to organize and distribute the array of
wires coming from various sources to different electrical devices.
 Programmable Logic Controller (PLC). This is essentially a CPU contained
inside the control panel. This unit is the brains of the control panel, providing
monitoring and control of the various mechanical processes. In will include
various inputs and outputs to and from mechanized functions of the production
equipment.
 Relays and contactors. These on/off switches control mechanized functions
based on commands from the PLC. Smaller relays control functions like lights
and fans. Larger relays, called contacts, control more advanced functions like
motors.
 Network switches. The communication hub of the control panel, network
switches facilitate communication between the PLC and the various network
compatible devices on the production line.
 Human Machine Interface (HMI). These components allow an operator to
monitor or control certain functions of the machinery. Common HMIs include
video monitors, joysticks, buttons, switches, and keyboards.

electric wire ferrule :

An electric wire ferrule (sometimes electric end terminal) is a metal tube crimped over stranded
wire to secure the strands within a screw terminal. Electrical insulation may be included to protect
any exposed portion of the wire not completely inside the screw terminal post.
Stranded wire is preferred for most electrical applications because it is more reliable than solid wire.
It is more flexible and durable because repeated bending will not cause it to break. Stranded wire
can be more difficult to terminate, because the individual strands tend to separate after insulation is
removed.

Selection of control panel components,theirratingsandwire sizes:

1. Transformer - Transformers are used to convert one AC voltage

to another AC voltage. Most popularly would be converting 480VAC
to 120VAC for creating control power.

2. Programmable Logic Controller (PLC) - This is the "brains" of

the control panel. It reads inputs and executes code based off of
them, then adjust the outputs of the control panel. Details of what
inputs and outputs are plus further details of how a PLC operates are
in later lessons

3. DC Power Supply - Where as a transformer converts an AC

voltage to another AC voltage, a power supply converts AC or DC to
a DC voltage. Most commonly it converts 120VAC to 24VDC

4. Ethernet Switch - Just like the Ethernet switch that you probably
have at your house, many control panels have Ethernet switches for
connecting PLCs, HMIs, networked I/O, and information systems.

5. Circuit Breaker - Circuit breakers protect loads from pulling too

much current.

6. Disconnect Switch - The disconnect switch will usually

disconnect all electrical power from the control panel.
Using Lockout Tagout procedures, this should be isolated when
working on the control system.

7. Wire Duct - Wire duct is usually ran around the perimeter of the
panel and in between rows of electrical components to house the
wires that interconnect the electrical components

8. Terminal Blocks - Terminal blocks are connection points to tie

wires together. Some are for internal connections and some are for
connecting field components to terminal blocks.

9. Breakout Boards - Breakout boards are specialized terminal

blocks that can be used to simplify wiring of components that have
connectors that would normally need soldering or reduce the labor of
internal wiring.

10. Fuses - Fuses, like circuit breakers protect loads from pulling too
much current but are only good for one use. That doesn't mean that
circuit breakers are better since they can be reset and reused. Each
has its place.

11. Relays - A relay is an electronically or magnetically operated

switch. Power is applied to the coil which creates a magnetic field
that switches the relay contacts.

12. DIN Rail - Is a metal rail that allows the mounting of many
industrial control components. It stands
for DeutschesInstitutfürNormung which is who published the original
specifications for it. A note to instructors, don't make
DIN=DeutschesInstitutfürNormung a test question. I, along with
every other Systems Integrator, has to look that fact up. Most of us
don't even know that DIN is a German acronym.

13. Overload - An overload protects loads, usually motors, from

pulling more amps that the overload allows. They usually monitor
three motor phases.

14. Contactor - A contactor is the same as a relay but is usually

larger in size for a motor and consist of three poles.

15. Terminal Ground Blocks - A terminal block ground is usually

internally grounded to the panel. You should learn to identify them,
they are usually green or green/yellow.

Design a simple AMF panel- Prepare the GAdiagram,

SLD and control wiring drawings asperstandardpracticeusingCAD:

Automatic Main Failure (AMF) System is a system which can automatically transfer the switch from
Mains power supply to Auxiliary when anomaly such voltage drop, over-voltage and outage or blackout
is occurred at the main power & any Power Quality problem regarding the supply will also cause the
system to operate. [2]AMF continuously monitor the level of voltage and the output is given to the
Control Circuit. Feedback from the Overload relay, Low voltage monitoring relay will generate the signal
for both the ACB to be operates corresponding and switch the supply accordingly. A. Objectives. The
objectives of this project is to: i) Design a system that allows switching from mains power to backup
power when anomaly is detected. ii) Design an automatic system using Relay Operating Control system.

DESIGN CONSIDERATIONS:

In the designing of AMF panel for 250 KVA load, Active power & Maximum Rated current are calculated
to determine rating of contactor to be used as well as cable size.(Assume PF=0.8 & Balanced Load)