The construction of electric control panels is the responsibility of a panel builder. The exact process varies depending on the industry in which the panel builder works, but it generally entails designing and building the panel layout. All of the components in the control panel are laid out in a logical order to facilitate maintenance, diagnostic testing, and part replacement during the design process. The panel is prepared and all components are mounted in their designated positions once the design is complete. The wiring of the harness, which connects all of the components, and the testing of the completed circuit are the final steps in the process.
Most manufacturing, industrial, and domestic electrical installations include electrical panels. These can range in size and complexity from massive process controllers to small start/stop stations that control pool motors at home. A panel is essentially an enclosure that houses all of the switch gear and control elements of a circuit or group of circuits. This consolidates all relevant equipment in one location, protects the circuit from contaminants, and simplifies circuit maintenance and repair. These panels are usually built a specialist artisan known as a panel builder, though in some cases, local electricians may construct them themselves.
It’s difficult to define an accurate description of a panel builder’s exact process for constructing panels. The extent of the builder’s involvement in the construction process varies, as do the methods used. The panel builder may be part of a larger team, with each member responsible for only a portion of the work. These groups might even make the enclosures and some of the components themselves. Panels are typically made one or two artisans using off-the-shelf components.
A typical panel construction project will begin with the creation of a brief, which will include the panel’s exact purpose, a description of the machinery it will control, and a list of general specifications. Details on the exact types of equipment and wiring to be used, circuit diagrams, and the type of environment in which the panel will be used are typically included. The panel builder will begin the project creating a component layout based on the enclosure’s specifications and physical dimensions. The physical construction of the panel begins after the diagram has been refined and approved.
During this stage, the panel builder will install all of the components into the panel, including circuit breakers, contactors, and volt and amp meters, in accordance with the approved layout. After that, cable trunking or trays are inserted to hold the wiring harness in place. In the case of one-off panels, the circuit wiring can be done wire wire, or a pre-built harness can be used when standard panels are being built. Making all of the connections between the harness and the installed components completes this step. When the wiring is finished, the panel can be moved to a test bench, where all of the circuit’s components can be tested and the panel can be signed off for delivery.