GUIDE TO CONTROL

PANEL ENGINEERING
275 Mount Read Blvd. Rochester, NY 14611 | 800.274.6266 | [email protected] | www.simcona.com
Table of Contents

Intro 2

PART 1: What to Include in Your Schematic 3

PART 2: Layout 3

PART 3: Wiring 6

PART 4: Components 10

PART 5: Enclosure 14

PART 6: Navigating Standards & Regulations 19

PART 7: In-House vs. Contract Design & Manufacturing 23

Next Steps 25

WHAT’S INSIDE THIS E-BOOK?

Dreaming up and successfully executing an industrial control panel design is no easy feat.

Electric panel manufacturing is highly engineered and highly manual – it’s more than just
slapping together an enclosure and back panel to house some wires and fuses. A suc-
cessful build requires serious know-how and careful planning to develop an interface that
can efficiently manage an industrial process.

This Guide to Control Panel Engineering will empower you with best practices for quality
and safety, from conceptual design to production, installation, and maintenance. You’ll
learn how the layout, wiring, enclosure, and other factors influence the life cycle of your
panel.

275 Mount Read Blvd. Rochester, NY 14611 | 800.274.6266 | [email protected] | www.simcona.com

PART 1: WHAT TO INCLUDE IN YOUR SCHEMATIC
Any electrical panel project begins with evaluating the electrical load, desired
components, and regulatory requirements. But it’s how you communicate those
specifications that sets your project on the right – or wrong – path.

With your requirements set, create a drawing that addresses both the electrical and
physical needs of the panel. Your schematic must include:

• Functional diagram
• I/O (Input/Output) diagram
• Power distribution
• Enclosure layout, including the back panel
• Bill of materials

Get specific about the configuration of wiring, circuits, controls, and every other
component of the final product.

There’s a lot to cover, so consider including a table of contents for easy reference. Don’t
rush through this stage or make assumptions when communicating – any mistakes can
compound and lead to costly repairs later.

PART 2: LAYOUT
“Keep it simple, stupid,” or KISS, is a mantra many people recommend for building anything
– from websites to war planes. There’s some validity to the idea in electronics, too – simple
panel layouts are cheaper to produce, and often easier to manufacture and maintain.

Industrial-grade control
panels are complex
creatures to lay out, so
simplicity is easier said
than done. To make
simplicity … simple, focus
on these areas of design:

• Grouping
components
• Overcurrent
protection
• Spacing

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2-1. Group Components Wisely
There are three ways to group the components of a control panel: flow, heat consider-
ations, and function.

AC and DC components, as well as their grounding paths, belong on opposite sides of the
panel. By separating these types of current flow, you’ll:

• Minimize short-circuiting
• Reduce electromagnetic interference
• Make troubleshooting & maintenance easier

Arrange AC and DC components in distinct sections, physically separated by partitions or

barriers. Regulations for minimum clearance vary by geographic region.

Heat buildup affects some components more than others, so prioritize the placement of
those at-risk parts first. Arrange components that generate significant heat, such as power
supplies and variable frequency drives, in a way that exposes them to enough airflow. Put
the risky stuff closest to a heat sink, fan, or other cooling device.

Organizing components by function or size is another fundamental aspect of a high-per-

forming panel.

If you can, put devices of similar sizes in a bay together. Also, by grouping similarly func-
tioning components (i.e. contactors and relays), you can:

• Save on wire cost

• Improve accessibility
• Make ID’ing & troubleshooting easy

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2-2. Protect From Overcurrents
The layout phase is also when you consider how to minimize overcurrent risk. Installing
overcurrent protection can happen in two ways:

• Ahead of the panel, which avoids needing to open the enclosure

• Inside the panel, helping users quickly ID & isolate faults

Consider whether you’re OK with needing to access the enclosure for inside-the-panel
protection. But above all else, make sure you do something to deter overcurrent –
otherwise you’ll risk unnecessary damage and downtime.

2-3. Internal Space

When weighing the physical implications of As always, pay special attention to NEC
your design, space is the place to focus first. (National Electrical Code) requirements for
clearance around power wiring, in addition
Electrical safety, for both users and the to UL spacing mandates for heat-producing
public, is dependent on your panel’s layout. devices.
The panel should have enough area for
an operator to install and service each Future modifications might not seem
component safely. important now, but they’ll be easier if you
set aside space today.
High-voltage components need enough
room to work without creating electrical Leave enough space around each
arcs. Follow the component manufacturer’s component for easy access and
instructions for minimum distances modification after the initial install. A
between conductors, energized parts, and replacement component might be larger
nearby surfaces (both grounded and non- than the now-obsolete one you used before.
grounded). A new project using the same control might
require another set of terminal blocks,
Heat buildup becomes a bigger problem forcing you to rearrange the panel.
as you reduce your product’s footprint.
The spacing of the enclosure itself is a huge
If your enclosed control panel will face part of futureproofing, but we’ll cover that in
exposure to high external temperatures, the Enclosure section later.
place cooling functionality near the most
at-risk components. If your box is heavy on
temperature-management features, put
exhaust vents and air intakes in easy-to-
reach spots. This makes filter replacement
smoother.

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PART 3: WIRING
You may have noticed that wiring and workmanship varies wildly from panel to panel.
Every engineer and electrician has “their way” of doing things, but for industrial jobs there
are concrete rules you should follow for:

• Choosing wire
• Laying wire
• Grounding wire
• Service loops & slack
• Ferrules
• Testing early

Hopefully everyone agrees on the end goal: producing an assembly that’s logically
arranged and easy to maintain for a long service life.

3-1. Choosing Wire

While there are many universal rules for laying out and grounding wire, choosing the
product itself is mostly case-by-case.

• Size – Pick the appropriate wire gauge based on load current, The circuit must be
capable of delivering the required current without the wire breaking down.
• Mechanical properties – In certain applications, wires must be able to withstand
crushing and cutting forces. Or, there could be a need for extra flexibility in a
dynamic or compact assembly – this is a great time to use stranded wire.
• Heat, cold, & flame – Temperature ratings determine the maximum how extreme a
wire’s working environment can be without degrading. The designer must account
for not only internal heat sources, but also external heat and cold. Depending on
your application, you may need to also prove your wires won’t catch fire too easily or
emit toxic fumes when burning.
• Corrosion – Your panel’s environment might include moisture, chemicals, oil, or dust.
There are wire types purpose-built for these situations, and they’re well worth the
investment.

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3-2. Laying Wires
(Tip: When designing, use a CAD tool that helps optimize routing. This practice saves
material costs and installation time.)

This is another step where it’s vital to account for both electrical and physical layout.

Electrical Layout Considerations

• Keep sensitive wires away from high-power components, as electromagnetic
noise can hurt transmission ability in some types (i.e. data transmission and process
control wires).
• Split & break down power branches inside the panel when possible.
• Use stranded wire if you can, as it creates less heat than solid wire.

Physical Layout Considerations

One of the most common NEC violations in industrial control panel layout design is
insufficient space for wiring. Don’t skimp on solutions for wire management – in industrial
applications, wire tangling and damage are surprisingly quick to happen. Proactive
management will also
make retrofitting easier,
accommodating all the
bends and turns you need.

• Use proper routing

methods like cable
trays and conduits –
not ties.
• Only use horizontal
and vertical runs, as
they add useful slack
and keep the panel
neat.
• Don’t run wires in front
of devices or ducts
– elevate ducts and
run wires underneath,
bringing the wire to the
front when entering or
leaving ducts.

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3-3. Grounding Wires
Poor electrical grounding is one of the top causes of failure in control devices. It’s a human
safety risk and produces electrical noise that hampers performance.

There are ways your control panel layout can promote safe, effective grounding:

• Route grounding wires separately from power lines. This prevents the current from
leaking between lines and becoming a shock hazard.
• Rethink dedicated grounding busbars. Mount them where they’ll be easily
accessible for connecting all grounding conductors.
• Avoid ground loops. Route grounding conductors in a direct, single-point fashion
with the appropriate length of wire to prevent unwanted noise or voltage differences.

More specific grounding best practices may vary based on your application and industry
standards, so consult with a panel manufacturing expert if you’ve got concerns.

3-4. Service Loops & Slack

It’s not unanimous, but in many situations designers and operators prefer too much wire
over not enough. Not enough could mean rewiring the whole panel later.

Service loops at entry and exit points provide several potential benefits:

• Accessibility – less likely to become

tangled
• Flexibility – more slack to allow movement
• Maintenance – reduced chance of broken
connections or damaged wires

Over an industrial assembly’s lifetime,

components are bound to fail, and the available
replacement part might be smaller or come
with a shorter wire. Sliding a few components 2”
away from the connection is much trickier when
your wire was cut to exact length.

When creating service loops at entry and exit

points, leave enough slack to avoid strain on the
connection. Running wires like the world’s worst
track athlete – using the duct’s outside lane,
taking corners widely – is a good thing here.

And yes, there is such a thing as too much slack. One balanced option is stripping each
cable’s jacket 2+ cm from its fitting. This facilitates service looping and saves space.

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3-5. Ferrules
A wire ferrule is a crimped tube that holds together stranded wire extending from stripped
insulation. This small feature can make a big impact on layout:

• Relieves strain
• Lowers electrical resistance
• No strand displacement to the sides
• Reduces oxidation from lack of air space

As with all electrical design, there are right and wrong ways to set up ferrules:

• Size: Make sure the connection is strong and they’re easy to insert into terminal
blocks.
• Space: Leave space in the termination area within the panel, around other
components, and wherever the maintenance team needs access.
• Label: To make troubleshooting quicker, clearly ID ferrules with conductor, circuit, and
other key info. Consider color-coding by circuit or function.

3-6. Testing Early

Use a pull test to ensure a connection can withstand force during the control panel’s
installation or operation.

To perform a simple pull test, apply gentle pressure on both ends of the wire until you feel
resistance. Less resistance equals less wire separation from the terminal during vibration or
movement.

The specifics of your ideal pull testing method may vary by wire type and application.
Destructive methods tend to give more useful data.

If you find wires disconnecting too easily, adjust your layout accordingly. You may need to
add slack or a service loop, or perhaps there’s a way to arrange your components more
efficiently.

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PART 4: COMPONENTS
A control panel box might contain 100s of electrical components working in unison. Each
one plays a part in protecting, powering, or processing.

To maintain human and machine safety and maximize the assembly’s efficiency, choose
the components of your control panel based on:

• Size
• Electrical load
• Functionality
• Compatibility with your system

Here’s a little advice on squeezing the most out of various component types.

4-1. Circuit Protection

The ideal circuit protection prevents wire overheating and reduces the chance of a fire.
Choose your circuit protection based on wire size.

TYPE FUNCTION BENEFITS

Circuit breaker Disconnects the circuit when Prevents fires, protects

an overcurrent occurs against both surges & short
circuits, quickly restores
power

Surge protector Absorbs & redirects transient Useful in locations with

voltage spikes frequent lightning

Fuse One-time protection – it Fast, small footprint, variety

melts when the current of application-specific
exceeds its rating options, low price

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The current rating is obviously key to sourcing the correct components, no matter the type.
There are also component-specific performance factors:

When choosing circuit breakers, consider trip characteristics and interrupting capacities
to handle fault conditions.

When choosing surge protectors, consider clamping voltage, response time, and how
they’ll co-exist with other protective components.

When choosing fuses, consider voltage ratings and time-current characteristics.

4-2. Control Components

Here’s another case where the KISS method may work best.

When choosing control components, start by weighting the simplest options first. These
include relays and timers.

If these don’t work out, move to more advanced options, like a smart relay or PLC
(programmable logic controller). These offer a lot more to the user, but only if they know
how to program it. They also require a computer and programming software.

The point is, don’t start at the filet mignon solution (a PLC). Use the simplest controls
possible for the application – a flat-iron steak (relay) may offer enough sizzle to get the job
done.

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4-3. Operator Devices

While simple is typically better, simple may not always be possible.

When speccing out an operator device, shoot for a design that’s straightforward to use, yet
can meet the assembly’s functional requirements.

SIMPLE COMPLEX

Examples Buttons, levels, indicator HMIs (i.e. color touchscreen

lights, digital panel meters displays)

Pros Low cost; easy to use Allow for more complex

functionality

Cons Limited functionality Higher cost; require

computing components and
software development

When a panel concept calls for user input, some designers immediately jump to human-
machine interfaces (HMIs) as the answer. Sometimes an HMI is the way to go, but other
times there’s a simpler device type that’s perfectly suitable for the application.

(Note: OSHA requires that all industrial control panels include an emergency stop [separate from any
cycle stop]. This e-stop can’t be a button on an HMI; it must be a push button hard-wired into the
safety circuit. For optimal safety, place start buttons and switches immediately above or left of the
stop button.)

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4-4. Supply Conductors

No matter your panel’s application, proper design and installation of the power supply and
distribution system are essential to meeting electrical load requirements. A reliable power
source ensures that all electrical components receive enough voltage to remain healthy.

The supply conductor you choose should allow for the highest possible load your panel
might endure. One way to calculate this is:

+ + =
All connected The full load 125% of the full Recommended
motors and current for all load current of capacity of
mechanisms resistive loads the highest rated supply conductor
motor

Other best practices include:

• Use proper grounding techniques
• Futureproof for load size – insufficient transformers and branch circuits may face
early onset of thermal issues, overloaded equipment, and sudden shutdowns.

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PART 5: ENCLOSURE
Whether you insource or outsource panel manufacturing, it’s important for the installer
and end user to understand the “why” behind the enclosure’s design.

Don’t think of enclosures as trivial, interchangeable parts – what works for a server rack
may fail horribly for mining equipment. These enclosure design guidelines address both
electrical and physical needs so your precious equipment reaches its life expectancy:

1. Ratings & standards

2. Environment
3. Heat
4. Space – now and later
5. Integration & accessibility
6. Installation

5-1. Ratings & Standards

Organizations worldwide have built strict standards and regulations to ensure that
enclosures protect people and equipment from hazardous devices.

By following UL panel standards and National Electrical Manufacturers Association

enclosure ratings (see Part 6), you can make wiser design choices that reduce expensive
customizations later.

No matter your classifications, make sure they’re printed on a metal plate and attached to
the enclosure for quick identification.

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5-2. Working Environment
An unprotected control panel installed near moisture or particles is at risk of damage or
worse.

Any UL safety rating or NEMA classification your enclosure has should influence your
material and design choices. Much of that comes down to the product’s need for:

• Outdoor use
• Water resistance
• Dust & solid contaminants-proofing
• Hazardous-conditions rating
• Explosion-proof rating

If the overall installation will reside in a hazardous or classified location included in Articles
500-506 of NEC installation requirements, the enclosure must offer additional protection.
The long and short is that your assembly should stay dry, clean, and isolated from
interference. Material choice goes a long way toward that:

Painting a plain steel enclosure offers cheap protection, but it won’t last long in many
industrial uses. Aluminum enclosures may be more cost-efficient for protecting industrial
control panel components that’ll be subject to a low-to-moderate moisture or dust levels.

To extend your industrial enclosure’s life span, specify a custom finish like anodizing (for
aluminum) or powder coating (for any of the above).

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5-3. Heat
Creating an enclosure that effectively regulates temperature – accounting for both
internal and outside factors – can make all the difference in a control panel’s operability.

There are many ways to manage heat with your enclosure

• Material selection – aluminum alloys dissipate heat better than stainless steel
• Exterior color
• Sun shield
• Back panels with internal vents.
• Increased enclosure size – see Part 5-4 for more
• Keeping it away from other heat-generating equipment

Temperature needs depend on the panel’s proximity to natural and machine-made heat.
Warming features may be necessary for cold locations, or for humid locations where you
need to increase the interior temperature just enough to stop moisture buildup.

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5-4. Space & Future-Proofing
We often call them safety enclosures, but when it comes to spacing, safety is far from the
only quality an enclosure’s design influences. Proper spacing is also essential for:

• Accurate readings
• Heat efficiency
• Installation & access
• Expansion

The number of doors necessary (usually 1-2) often determines the overall size of an
industrial enclosure. However, you’ll also have to consider the minimum and maximum
dimensions for meeting the supplier’s (even if it’s you) design-for-manufacturability
requirements. Modeling the box build with 3D software helps stamp out space and
interference concerns.

Obviously, the enclosure must be big enough to fit the components inside, and the
enclosure itself must fit in your available installation area. Some manufacturers
recommend that 20% of the enclosure’s area goes to spare space, depending on your
application.

A checklist for proper sizing:

Does it allow proper space between components without overheating or

hampered functionality?
Are wire ducts big enough?
Is there enough space around the panel’s edge?
Is it easy to access key components?
Can you group signals by type?
Does it account for touch safety of 50V (AC) and 60V (DC) parts?

All that advice is great for today, but what about when you want to adapt or expand your
enclosure to meet new needs? If there’s room for it to grow, leave room for the enclosure –
and its heat output – to grow too.

Besides creating more heat by adding more parts, another example of expansion issues is
the Industrial Internet of Things (IIoT). Not all machine connectivity is software-based – you
may want to leave room in the control panel to include new “smart” hardware, too.

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5-5. Integration & Accessibility
What (and who) is going in and out of the enclosure?

Entry and exit points matter to both installers and operators. The budget manager will care,
too, if tough-to-access panels drive up labor costs.

Your enclosure’s size and purpose will influence the success of the installation method:

• Floor-mounted – common for large or heavy enclosures

• Wall-mounted – for small designs and saving floor space
• Wall standoffs and floor-mount legs – for cleaning access in sanitary applications

Best Practices for Installation

It’s not time to celebrate just yet. Poor configuration can cause the machine to
malfunction and put users at risk.

• Properly mount the hardware on a back panel and wire it into the machine.
• Most applications need sufficiently sized cable-access holes on the top and bottom
of the box. For power cables, knockouts in the front and back of the frame are also
wise.
• If switches and buttons will penetrate the enclosure, you’ll likely need to seal the
area.
• When using air conditioners or fans, direct warm air out the top of the enclosure and
bring cool air in from the bottom. This aids the natural convective transfer of heat.
• Don’t block air vents!

Design-for-Use Best Practices

A panel’s layout impacts operational efficiency. Consider how your design can save time
and money for the user.

• Handles, through-door disconnects, and interlocks can provide tagout points for
extra safety. They prevent the door from opening until the user turns off the external
power.
• Lift-off and reversible doors that move out of the way can speed up equipment
installation. Beyond that, access to interior parts will be easier if the operator can
remove the enclosure’s side panels from the outside.
• An assembly that doesn’t require forklifts and multiple workers to manage is a huge
time- and money-saver.

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PART 6: NAVIGATING REGULATIONS & STANDARDS
From a remote-controlled Hot Wheels car to a $400,000 robotic arm station, all electronics
must be safe for those who handle them. The difference between a child’s toy and an
industrial process is that the latter is much riskier. That’s why panel standards exist.

6-1. UL 508A
For industrial-grade control panels, the UL508A certification standard serves as official
proof that a manufacturer has made a safe, reliable product. It’s the gateway to your
products passing inspection and maximizing operational uptime.

UL standards outline specific requirements for wiring, such as materials, wire thickness,
power circuit conductor size, and labels. There are many other UL standards that relate
to control panels; most are hyper-specific (i.e. UL 218: Standard for Fire Pump Controllers). A
few others we’ll cover in a moment are specific to hazardous areas.

What Does UL 508A Mean to a Designer?

UL 508A standards cover industrial-use control panels operating at 1,000V or less. The
ambient temperature must not exceed 104°F unless otherwise marked on the box.

Internally, the design must follow requirements for:

• Enclosures
• Overcurrent protection
• Interconnects
• Motor drives
• Switches
• Terminal blocks
• Transformers
• Contactors

All electrical ratings and instructions must be directly on the panel for safe installation and
use.

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The UL508A Certification Process
UL puts each panel through its paces to ensure it works properly despite exposure to
vibration, power level fluctuations, and extreme temperatures. UL tests industrial
controls for:

• Temperature
• Overvoltage & undervoltage
• Overload
• Calibration
• Dielectric voltage
• Short-circuiting
• Standard & high fault currents
• Transient voltage surge suppression
• Breakdown of components

What If You Fail?

If your control panel assembly doesn’t pass UL standards, the agency will send
the manufacturer a report detailing each feature and test result that didn’t meet
requirements. From there, it’s up to your design and engineering squads to modify the
product according to guidelines. This points to another perk of working with a turnkey
control panel manufacturer – it can optimize your design to pass testing on the first try.

Does UL508A Cover Hazardous Materials?

Panels must pass additional criteria if they’re for use in hazardous environments. Their
designs require enclosures and components that are extra-resistant to catastrophic
failure.

• UL 698A – For panels in ordinary locations, but with circuit barrier extensions into
locations with gas, vapor, dust, or fiber hazards
• UL 1203 – For panels in locations with gas, vapor, or dust that could cause ignition or
explosion
• UL 121201 – For nonincendive equipment in locations with gas, vapor, dust, or fiber
hazards

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6-2. NEC/NFPA
In the United States, panel requirements generally come from the NEC – National Electric
Code. The NEC is part of a fire code series published by the National Fire Protection Agency
(NFPA).

NFPA 70 is for installation. It lays out the design practices that lead to safe installation:

• Wire size
• Spacings
• Permissible exterior equipment

NFPA 79 applies to what’s inside the equipment. This standard covers:

• Wiring
• Electrical controls
• Other components

UL requires documented proof that each panel meets applicable NEC requirements. The
NEC is an essential tool for electronics manufacturers because it gives specific instructions
on proper design and avoiding safety risks.

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6-3. NEMA
NEMA Enclosure Ratings (Non-Hazardous Applications)

NEMA Enclosure Ratings (Hazardous Applications)

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PART 7: IN-HOUSE VS. CONTRACT DESIGN &
MANUFACTURING
Producing an industrial control panel is a highly manual, complex process. Success
may pivot on whether your company engineers and manufactures them in-house vs.
outsourcing to a panel specialist.

We’re not here to judge your decision, but here’s some firsthand wisdom about the design
implications of insourcing or outsourcing your panel.

7-1. The Cost of Business

Insourcing panel work may be a higher hurdle than you think. If your design
requirements are demanding or custom, costs may add up:

• More skilled laborers

• Special testing equipment
• Unique components

If a panel design looks cost-prohibitive to handle in-house, you have two options: Redesign
for manufacturability and sourceability, or offload the hassle.

Third-party suppliers already have sourcing, production, and quality processes in place.
Where a good panel specialist separates itself is how cost-efficiently it executes all that:

• Spots waste & optimization opportunities

• Quickly sources unique & scarce parts
• Zero-defect production

7-2. Lead Time

No matter your in-house capabilities, there’s a 90% chance your lead time will be shorter
if you outsource production.

Think about your company’s and buyer’s timeline expectations. Is your concept simple
enough to efficiently insource with your existing talent and tech? If it’s a complex or risky
build, consider outsourcing to a dedicated team and production cells.

If you’re replacing an existing panel, there may be a simpler path. See if your company
still has the initial drawings and bill of materials, and whether you can replicate them in-
house.

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7-3. Quality
Poking fun at Elon Musk’s intelligence has become a national pastime, even for fellow
engineers. Nonetheless, very few could develop a better spacecraft than his SpaceX
Falcon 9.

An outside expert’s voice is a loud-and-clear benefit to panel design.

Because panels are highly engineered products, there’s only so much that automated
processes can solve for you in-house. A purpose-built team and facility will probably get
better results.

You might be a great designer. But say your concept requires a 10-year service life in an
aerospace application. … Is your overwhelmed team going to deliver?

7-4. A Highly Custom Customer?

If the product doesn’t need a complex build, it might be cheaper to insource.

The more your design pushes the boundaries past “commodity,” the more you’ll invite risk
by going full DIY. Your design’s potential ends where your team’s ability ends – are you
missing out on a creative solution?

If you can tell your model will be a pain to make, it probably will be for a contractor too. But
at least a contractor will have the deftness to make it work (and improve it).

7.5 Building to Standards

Do you plan to build to UL 508A or equivalent baselines? Consider your group’s ability to do
so:
• Is anyone experienced in building to UL508A regulations?
• How much testing will your idea require?
• If it fails testing, is there time & money to spare for a redesign?

An outside manufacturer with UL 508A experience can recommend design improvements

specific to the testing criteria. The builder can also design to standards based on end
user market and location.

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NEXT STEPS
A winning control panel design takes skill, capacity, and understanding of the user’s
industry. It’s a lot of engineering, manual sweat, and trial-and-error.

Start with a schematic that demonstrates your understanding of the specs, industry
standards, and environmental factors most relevant to your project. From there, choose
and arrange components, wires, and the enclosure in a way that manages heat and
current effectively – today and for future expansions.

With the right mindset (and, depending on your capacity, the right partner), you can
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