Posted on by Carl Marchese
Don’t Just Design a Control Panel to Fit — Design It to Be Serviced
Getting every component into an electrical enclosure is only part of good panel design.
Eventually, someone will have to build it, troubleshoot it, maintain it, or modify it.
A technician may need to replace a power supply, tighten a terminal, trace wiring, access a PLC, change a fuse, or add equipment years after the panel was originally installed. A layout that looks efficient on a CAD drawing can become frustrating in the field if routine work requires removing unrelated components simply to reach the device that needs attention.
Good panel design should therefore consider not only whether everything fits, but also how easily people can work on it.
Leave Room for People, Not Just Components
Component dimensions tell you whether something physically fits. They don't necessarily tell you whether someone can install, wire, or service it.
Panel builders should consider:
- Space around terminals and connectors
- Screwdriver and tool access
- Wire bend radius
- Wire duct access
- Component removal paths
- DIN rail spacing
- Door- or cover-mounted equipment
- Connector locations
- Access to mounting hardware
Packing components tightly can reduce the enclosure size and potentially lower cost. But there is a point at which those savings can be offset by additional assembly, troubleshooting, and service time.
A few inches of additional space can sometimes be more valuable than a smaller enclosure.
Think About What Will Need to Be Serviced
Not every component requires the same level of accessibility.
Fuses, relays, power supplies, batteries, filters, terminal blocks, and other serviceable components may deserve more accessible positions than equipment that is unlikely to be touched during the life of the panel.
Frequently serviced components should ideally not be located behind equipment that must first be removed.
The same thinking applies to connections. A component may be easy to see but difficult to service if its terminals are inaccessible once neighboring components and wiring are installed.
Consider How the Panel Is Built
Serviceability and assembly efficiency can begin before the panel ever reaches the field.
Traditional fixed mounting plates work perfectly well for many control panels. But depending on the enclosure design, removable or adjustable mounting systems can provide another option.
For example, some adjustable-depth mounting kits allow the mounting plate to be assembled and wired outside the enclosure and then slid into the enclosure base.
That can give panel builders much better access to components and wiring during assembly because technicians aren't constantly reaching into the enclosure.
Once the panel is assembled, the mounting plate can be installed and positioned at the appropriate depth.
This approach won't provide a meaningful advantage for every build. But on more complex panels, repetitive production, or applications with difficult component access, the ability to work on the panel outside the enclosure can simplify assembly.
Make Use of Adjustable Depth
Adjustable-depth mounting can also help solve clearance problems.
Instead of having one predetermined mounting-plate position, the panel can potentially be moved forward or backward within the available enclosure depth.
That can help accommodate:
- Deeper components
- Door-mounted controls
- HMIs and displays
- Wiring and connectors
- Cable-entry requirements
- Components of different heights
The goal isn't simply to maximize depth. It's to put the mounting surface where it makes the most sense for the particular design.
Consider Visibility
Sometimes the easiest equipment to service is equipment that doesn't have to be accessed in the first place.
Where appropriate, windows or transparent covers can allow technicians to see displays, meters, status indicators, and warning lights without opening the enclosure.
This can be useful for routine inspection and troubleshooting, although whether a transparent cover or window makes sense depends on the equipment, environment, security requirements, and application.
Leave Some Room for Tomorrow
Control panels have a habit of changing.
A customer may eventually want another sensor, communications device, terminal block, relay, or power supply.
That doesn't mean every enclosure should be substantially oversized. Larger enclosures cost more, occupy more space, and can increase shipping and installation costs.
But leaving reasonable expansion space can prevent a relatively minor future change from requiring a major redesign.
Think About Where the Finished Panel Will Be Installed
An enclosure mounted comfortably at eye level inside a factory is very different from one mounted on a pole, beneath equipment, beside a pump, or outdoors in a confined area.
Panel builders should consider:
- Door or cover swing
- Hinge orientation
- Mounting height
- Nearby equipment or structures
- Access to fasteners
- Ability to remove the mounting plate
- Space available for technicians and tools
These issues can be easy to overlook when designing a panel on a screen or assembling it on a bench.
Design for the Person Who Comes After You
A successful panel design shouldn't only answer:
“Can we fit everything inside?”
It should also answer:
“Can we build it efficiently, and can somebody work on it five years from now?”
Thinking about accessibility, mounting depth, wiring, component replacement, and future changes during the initial design can make the finished panel easier to assemble and easier to maintain throughout its service life.
Working on a new panel design? Fibox offers fixed and adjustable-depth mounting options for selected enclosure systems, including configurations that allow a panel to be assembled outside the enclosure before installation. Talk to Fibox About Your Application