Industrial control panels consist of power circuits or control circuits (or both) that provide signals directing the performance of machinery or equipment. Industrial control panels don’t include the main power or the controlled equipment; instead, the panel is mounted on a back panel, subpanel, or in an enclosure, depending on the application.
Industrial control panel design begins with weighing design requirements and specifications and preparing schematics. However, in order to meet all applicable regulatory standards and safety requirements, the design process can be quite complex.
Despite its complexity, the need for electric control panels has never been higher. In fact, experts predict the control panel market will be worth $10.3 billion worldwide by 2032.
This guide will help you better understand the types of control panels, key design considerations, and relevant regulatory standards. We’ll also cover best practices and provide troubleshooting tips to help you maximize the safety and value of your investment.
Properly configured industrial control panels ensure your machines operate seamlessly. However, the panels you choose, and how you design them, will play a critical role in ensuring safety, efficiency, and ease of use.
There are many types of industrial control panels on the market, but the most common types include:
Regardless of the type of industrial control panel you choose, following proper design principles is paramount, as a poorly designed control panel can lead to hazardous situations, such as electrical faults or operator errors.
Clear labeling, proper wiring, and following industry standards are essential to prevent accidents. Not only does proper design prevent workplace incidents, but it also speeds up maintenance, reduces downtime, and creates a more professional appearance.
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Control panel design for industrial equipment and machinery is an important undertaking. It’s not a simple matter of selecting an appropriate enclosure and a back panel that houses the electrical hardware.
Proper hardware must be mounted on a back panel and properly wired and integrated into the machine. Any improper configuration can result in malfunctioning machinery, but it’s also likely to pose an unnecessary risk to operators.
The process should always begin with an evaluation of the specifications, requirements, and regulatory standards. After evaluating these considerations, create schematics to outline the specific configuration of wiring, circuits, controls, and every other aspect of the final control panel.
Good design addresses both the electrical and physical requirements. The schematics should include:
A table of contents is also recommended because there are so many elements in a proper schematic. The schematic is the foundation for the subsequent development of an industrial control panel.
Many industrial control panels are still not compliant with industry-wide standards. However, compliance is critical for reducing safety risks associated with installing and operating industrial equipment and machinery.
Below is an overview of the most prominent regulations applicable to the design, manufacture, and installation of industrial control panels. Like all regulatory standards, industrial control panel standards are subject to change over time.
In fact, one of the most relevant standards, UL 508, has recently been phased out and replaced by UL 60947-4-1 — an updated, harmonized international standard.
Because of the changing nature of regulatory standards, it’s important to stay up-to-date on current requirements. Ensure your industrial control panel design adheres to all relevant standards to stay safe and compliant.
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The National Electrical Code (NEC), or NFPA 70, is a widely accepted standard for the safe installation of electrical equipment and wiring. The NEC is adopted by state or region to standardize the enforcement of safe electrical practices.
Article 409 covers industrial control panels and applies to panels intended for general use at 600 volts or less, in ordinary locations.
Article 409 specifies that industrial control panels must be evaluated and marked for their Short Circuit Current Rating (SCCR), which you can establish by evaluating each feeder individually, along with all the branch circuits. The smallest kA value is used as the kA value for the panel as a whole. The kA value must be greater than the kA value of the incoming source to install the panel.
NFPA (National Fire Protection Association) 79 is a section of the NEC that pertains to wiring standards for industrial machinery. The scope of this standard encompasses electrical and electronic elements of all machinery that operates at or below 600V, including:
NFPA 79 provides safeguards for industrial machinery aimed at protecting operators, equipment, facilities, and work-in-progress from fire and electrical hazards.
Portions of NFPA 79 relate to control circuits and control functions, operator interface and control devices, location, mounting, and enclosures for control equipment.
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UL 508 was one of the most important industrial control panel design standards for many years, but this standard has recently been phased out and replaced by UL 60947-4-1.
The transition is meant to harmonize the standards from UL and other entities, including the Canadian Standards Association (CSA) and the International Electrotechnical Commission (IEC) in Europe.
It’s worth noting that UL 508 and UL 60947-4-1 are largely the same in a technical sense, but do incorporate important national differences in order to create an international standard.
The primary effects of the transition relate to how products are tested and qualified to a standard, regardless of the differences in voltages used around the world. For example, industrial voltages in the United States are 480 V at 60Hz, while industrial voltages in Europe are 400 V at 50Hz.
The new UL 60947-4 standard “applies to the types of equipment listed in 1.1.1 and 1.1.2 whose main contacts are intended to be connected to circuits the rated voltage of which does not exceed 1 000 V a.c. or 1 500 V d.c.”
A variety of other standards are applicable to certain types of industrial control panels, as shown in the table below:
| Standard | Covers |
| UL 218: Standard for Fire Pump Controllers | Fire pump controllers |
| UL 1203: Standard for Explosion-Proof and Dust-Ignition-Proof Electrical Equipment for Use in Hazardous (Classified) Locations | Equipment intended for use in hazardous locations |
| UL 698A: Standard for Industrial Control Panels Relating to Hazardous (Classified) Locations | Industrial control panels with intrinsic safety barriers intended for connection to circuits in hazardous locations |
| UL 845: Standard for Motor Control Centers | Motor control centers |
| UL 864: Standard for Control Units and Accessories for Fire Alarm Systems | Electrical control unit assemblies or equipment containing electrical control units for fire-protective signaling systems |
| UL 891: Standard for Switchboards | Freestanding assemblies of circuit breakers and related applications |
| UL 924: Standard for Emergency Lighting and Power Equipment | Any equipment necessary for supplying automatic illumination and/or power to critical areas and/or equipment essential for the safety of human life |
| UL 1563: Standard for Electric Spas, Equipment Assemblies, and Associated Equipment | Control equipment for swimming pools and spas |
| UL 1640: Standard for Portable Power-Distribution Equipment | Portable control panels for specific applications |
| UL 1741: Standard for Inverters, Converters, Controllers and Interconnection System Equipment for Use With Distributed Energy Resources | Equipment for controlling fuel cells, photovoltaic systems, or utility interactive systems |
| UL 1773: Standard for Termination Boxes | Enclosures or pedestals that contain terminals for connecting power circuit conductors |
| UL 2017: Standard for General-Purpose Signaling Devices and Systems | Covers control panels that contain emergency alarm equipment, as well as the actual alarm equipment |
| UL 2075: Standard for Gas and Vapor Detectors and Sensors | Equipment for gas or vapor detection |
| UL 60950-1: Standard for Information Technology Equipment – Safety – Part 1: General Requirements | Covers control panels with predominantly communication equipment |
| UL 294: Standard for Access Control System Units | Control equipment for use in physical access control systems |
| UL 1037: Standard for Antitheft Alarms and Devices | Control equipment intended for theft deterrent or warning purposes |
| UL 916: Standard for Energy Management Equipment | Equipment for energizing or de-energizing electrical loads to achieve the desired use of electrical power |
Other bodies have also issued applicable standards, such as IEC 60204-1, which relates to the safety of machinery and electrical equipment of machines.
Given the many standards applicable to specific types of industrial control panels and those intended for use in specific applications, it’s important to identify the appropriate standards at the beginning of the design process.
Identifying proper standards is a crucial first step in designing industrial control panels. Follow these best practices to enhance the reliability and safety of your control panels.
More than 90% of control panel components are now built to be “finger safe,” which reduces the risk of electrical injuries. Still, all control panels need proper grounding to prevent catastrophic accidents.
Standards like NEC 250 are helpful here because they dictate grounding and bonding requirements. However, you can also use dedicated grounding bars to reduce the risk of electrical shock and prevent damage from power surges.
Disorganized wires are a tripping hazard and complicate maintenance. All industrial control panels should have organized wire management to reduce the risk of damage and keep workspaces tidy. Use wire ducts, ties, and labels to manage wires.
Color-coding wires is also helpful for quickly identifying which lines are for power, ground, and control. Ask your maintenance team to regularly check each panel’s wires for organization, damage, and loose connections.
Reduce errors by grouping like components together. For example, related components like switches and power supplies should go together because they share a function. For safety reasons, separating high-voltage and low-voltage areas is also wise.
Industrial control panels need proper heat dissipation, as overheating will lead to component failure and shorten the life of the panel. Calculate the head load for every panel and install fans or filters if necessary. Thermal barriers and heat sinks are also helpful for managing hot spots.
Lastly, avoid crowding components together; space them far apart to allow ample airflow.
When it comes to industrial control panels, safety is the first priority. Follow these safety best practices to protect operators:
Best practices are crucial to maximizing safety and reducing misunderstandings. Once you have a stable foundation built on proven best practices, it’s time to focus on industrial control panel design.
You must weigh various considerations to design a control panel that meets functional requirements, application specifications, and regulatory standards. Run through this primary design checklist to ensure your industrial control panel designs meet your unique needs.
The working environment dictates the appropriate type of enclosure required for an industrial control panel. You’ll need enough space to install and wire components. It’s also wise to plan for several receptacles to reduce the need for extension cords when it becomes necessary to power test equipment or appliances.
Placement is another consideration. For example, depending on the panel’s location, you may need to account for the swing requirements of cabinet doors.
If you’re installing a control panel in a hot area, a ventilation fan or air conditioning may be required to keep the control panel within an ideal operating temperature range. If temperature control applies, it’s necessary to allow easy access to air intakes and exhaust vents (making it easier to access and replace filters).
You must follow both NEC-required clearance around power wiring and UL-required clearance around heat-producing devices to allow adequate room for ventilation.
Space considerations are crucial because using confined control panels is one of the most common NEC violations. In these cases, the panels are too small and don’t have enough space for wiring and wire bending. At this stage, it’s also wise to leave extra space for future needs because restricted space is a common challenge for retrofits.
When it comes to wire sizing and selecting the appropriate component types, there are two important rules of thumb:
UL standards also outline specific requirements for wiring, such as wiring materials, labeling for conductors, sizing for power circuit conductors, and wire sizing.
What type of controls are appropriate for the application? There are various options, from relays to timers to terminal blocks. Opt for the simplest control components possible.
Control circuits provide logic for the operation of power circuit components. These circuits are typically lower-voltage for safety, and components such as Control Power Transformers (CPTs) and power supplies convert the power circuit voltage to the control circuit voltage.
Supply conductors should allow for the highest possible load. You can calculate this by determining the sum of all connected motors and apparatus. However, keep in mind which duty cycles, motors, and apparatus will operate simultaneously.
From there, you add this sum to the full load current for all resistive loads, plus 125% of the full load current of the highest rated motor.
You’ll also need to consider overcurrent protection in the design phase. There are two options:
Depending on the application, it may not be desirable to integrate the protective device in the panel to minimize the need to open an enclosure.
Operator devices include components such as tactile push buttons, indicator lights, digital panel meters, and levers, but these devices can also be more complex touch-screen displays.
HMIs (Human-Machine Interfaces) allow for more complex functionality but also require computing components and software development, which can increase costs.
When it comes to controls, the old K.I.S.S. principle (Keep It Simple, Stupid) applies. Simpler is always better, but simpler may not always be possible. You should, however, opt for the simplest operator devices appropriate for the functional requirements to support ease of use.
All industrial control panels should include an emergency stop (which differs from a cycle stop); this is typically a self-latching control in a mushroom or palm type.
Emergency stops, or E-stops, are also required by OSHA (Occupational Safety and Health Administration). They cannot be buttons on an HMI; they must be a push-button design that is hard-wired into the safety circuit. Additionally, any start buttons or switches should be located directly above or to the immediate left of the associated stop button.
It’s imperative to properly label all wires, terminals, and other components in an industrial control panel. It’s a time-saving strategy that also reduces the likelihood of errors in testing, routine maintenance, and repairs.
Labels should be durable enough to withstand the conditions of the target environment to avoid fading and damage that renders them unreadable.
Go with a reputable provider like MPC for all of your control panel labels. Our durable front panels and faceplates shield equipment in even the most extreme environments. With thick substrates and crisp graphic elements, MPC’s durable designs are a must-have for all control panels.
Check out our custom Nameplate Designer tool to build your own labels.
Front panels and faceplates may seem like an afterthought, but these elements are just as important as the interior functional components. Front panels should be durable enough to withstand extreme temperatures, harsh weather conditions, cleaning products, and chemicals to protect the underlying components.
Proper industrial control panel design prevents a lot of issues. However, even the best-planned panels will encounter issues from time to time.
Follow these troubleshooting tips to keep control panels operating efficiently with minimal downtime.
If you suspect there’s an issue with your industrial control panels, provide operators with a pre-vetted checklist of potential fixes. With a ready-made checklist, operators may be able to solve very simple issues without involving maintenance at all, saving everyone time and hassle.
Ensure your troubleshooting checklist addresses these common problems:
Dust, dirt, and chemicals can wreak havoc on control panel substrates. While you shouldn’t expect these controls to be pristine, they need to be clean enough to function.
Ensure both operators and your maintenance team understand when and how to properly clean these control panels. That should include wiping down the panel, removing dust and debris from ventilation areas, and changing filters, if applicable.
Don’t wait for control panel components to fail—this can damage other systems, create safety hazards, and cause unexpected disruptions. Instead, follow either the manufacturer’s recommendations or your own internal replacement data to replace components nearing the end of their lifecycle. It’s also a good idea to stock spare parts for critical components to minimize downtime.
You designed this industrial control panel for a specific environment. However, if the environment’s average temperature increases substantially or suddenly includes caustic chemicals, that can affect the longevity of the control panel. You should verify that temperature and humidity levels are within operational limits.
In a particularly harsh environment, you may need to inspect control panels more frequently for dust accumulation, water, or corrosive materials.
Designing an industrial control panel involves more than assembling components—it requires careful consideration of schematics, regulatory standards, environmental factors, and safety protocols.
From selecting the right control panel type to implementing best practices like proper grounding, wire management, and heat dissipation, every step in the process contributes to functionality, safety, and long-term reliability.
Whether you’re upgrading existing systems or building new ones, this guide provides the essential knowledge you need to navigate the complexities of industrial control panel design.
Of course, the right materials make all the difference, which is why industrial plants rely on MPC. Our durable faceplates, labels, and tags are rated to last the lifespan of your control panels, ensuring long-term performance.
Request your free Identification Evaluation Kit to see MPC’s quality work firsthand.
Good industrial panel design considers:
Industrial control panel design is crucial for both worker safety and organizational efficiency. First, businesses must adhere to regulations like NEC, NFPA, and UL. Next, consider the working environment, which will affect enclosure types, temperature controls, and additional protections required for the panel.
Safety measures like emergency stops and arc flash labeling are also crucial factors to consider.
The three types of industrial control panels are:
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