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How is Control Panel Installation Performed?

• The Control Panel should be mounted on the position decided by the General Contractor according to the Interconnect Drawings.
• The Control Panel is indicated by a ( ) on the Interconnect Drawing. If there are several Control Panels for the installation, they will be marked with their selected location and labeled to match with the Interconnect Drawings.
• Before mounting the Control Panel to the wall, be sure enough clearance is provided to install the Trunk Line and Power Insert cables as required.
• Firmly place the Control Panel onto the wall according to industry standard mounting routines.
• Open the front panel to reveal the inside of the Control Panel. Configure the AC Power wiring as shown on the silver panel.
• Once the AC Power is installed, turn the Control Panel on.
• Confirm the green light is lit on the front of the Control Panel and then turn the Control Panel off.
• An overlooked issue with larger control panels is the need to power test equipment and appliances, such as vacuums used for maintenance. Add adequate receptacles at suitable locations, rather than ensuring the need for extension cords, and permit these in your rough layout.
• The NEC requires marking every panel with its short circuit current rating (SCCR) [409.110]
• Grounding: Ensure there’s no change of potential between enclosure parts and any close by metallic objects. Install an equipment grounding (bonding) conductor or grounding (bonding) bus sized.
• Workmanship: In a cabinet installed with good workmanship, the wires are neatly bundled, run in gutters or similar supports, and routed with smooth radius bends — and all terminals, wires, and components have identification labels.
• A good labeling strategy conserves time and decreases mistakes in testing, terminating, maintenance and repair. Don’t use handwritten labels. You can choose from many available labeling solutions to produce legible, durable labels in an efficient, cost-effective manner.

Precaution to be Taken During Installation

Given below are additional factors need to be considered when approving the installation of an open industrial control panel, some of which include:

• Study and obey manufacturer’s installation guidelines, which might define a particular application necessity
• Verify suitability for installation and use in conformity with the provisions of the NEC
• Confirm the mechanical durability and strength of the required enclosure is satisfactory to guard the open industrial control panel
• Make sure the enclosure does not intrude in the necessary wire bending and conductor termination area required for a safe installation

Any other features that add to the shielding of persons handling or probable to come in contact with the open industrial control panel, like exposure to live parts, arch flash hazards, and proper grounding or bonding-just to name a few. 

Regular Maintenance of Control Panel

There is no standardized protocol for the maintenance of control panels, however we tend to live by the old adage prevention rather than the cure.

• Pest control: This may consist of a rodent trap in one corner. Whatever method, ensure it is inspected periodically.
• Dust control: Clear out the gathered dust from the cabinet floors by vacuuming, remembering it’s an energized cabinet — follow the applicable procedures.
• Connection control: Retightening terminal screws leads to lose connections. As a replacement for unintentionally over-tightening terminal screws, utilise an infrared gun to find out which terminals have high resistance. Disassemble, clean, and reassemble.
• Insulation: An insulation resistance testing program is the best way to prevent wiring failures.

Where is Control Panel Installation Necessary?

When it comes to the industrial workshop electrical supply or overall control in your commercial business the control panel is the heart of each machine, tool, and operation. If you want to reduce the expenses and time consumption and technologically develop your facility, install a control panel. Industries (small or large) huge flats, etc. would need control panel installation.

But a badly designed or incompatible panel can make the act of running operations effortlessly a terrifying ordeal. It is always advisable to take proper care of control panel and hand over the installation and maintenance routines to expert hands.

What Exactly is an Industrial Control Panel?

Industrial control panels are defined by the NEC section 409.2 as an assembly of two or more power circuit components, control circuit components, or any combination of power and control circuit components.

For NEC purposes, an industrial control panel operates at less than 600V and consists of power circuits and/or control circuits. A control circuit provides the signals directing the performance of the controlled equipment but doesn’t carry the main power or include the controlled equipment. The “panel” part means the control system is mounted on (or in) an enclosure or subpanel.

What is Done During Control Panel Installation?

The installation must be in accordance with the all applicable national (NEC, IEC, EN, etc.) and local electrical codes and ordinances.

• An ignored matter with bigger control panels is the necessity to power test appliances and equipment, for instance vacuums utilised for maintenance. Working with the electrical distributor to see what standard offerings are closest to what you need can produce significant savings in cost and delivery.
• After the panel is designed, next step is to figure out where to place it. Determine the outside dimensions and the swing requirements of cabinet doors. To reduce maintenance inefficiencies and other hidden costs during operation, it is ideal to allow enough room for a test cart to roll across the area with those doors open.
• Control panels often are near the process area. An elevated ambient temperature might need a air conditioning or ventilation fan on the cabinet, both of which will have filters that need maintenance. Other circumstances may dictate adding a heater or dehumidifier.
• Find the air exhaust and intakes vents for simple filter spare and make sure there is no process meddling; having a cabinet vent suck in air off an aluminum melting pot is generally not helpful.
• Figuring out the ampacity for the supply conductors can be confusing unless you break down the requirements into discrete steps
• You can either put a single main overcurrent protective device (OCPD) in the panel or put overcurrent protection ahead of the panel.
• The NEC requires marking every panel with its short circuit current rating (SCCR)
• Look for the grounding measures.

Why  Choice CoreSystem for Control Panel Installation?

Our Team

CoreSystem team is rich with skilled professionals who have numerous experiences to be able to give you proper advice. All our instructors are approved by a number of accrediting bodies. Making sure they are up to date with relevant regulations and industry best practices.

Our Aim

We believe in delivering a quality, honest, straight forward and professional service. Our customers need straight forward and honest advice when it comes to their training and rely on ourselves to separate fact from fiction and cut through the jargon that can surround the Health & Safety industry.

Our Work

A cabinet installed with quality workmanship should have neatly organised wires run in gutters or channels, laid-out with only smooth bends to the wire radii, no sharp bends or kinks.

Perfection

All wires, components and terminals should be clearly labelled. We cannot stress the importance of a sound labelling strategy upon installation, when maintenance and troubleshooting is necessary it will save time in testing for errors, saving money therein and ultimately saving you the stress.

Hard working

Our team will work tirelessly to get the training you require, when you require it. Although we cannot always work miracles, our team will do everything we can to get you what you need.

You are bankrolling a new control panel installation, upgrading your company to the era of automation. The designs and the parts are ready, all that is left is to install your system correctly. This is the stage where CoreSystems comes into play.

What is an Industrial Control Panel?

” The NEC section 409.2 describes industrial panels as an association of two or more control circuit components, power circuit components or any combination of circuit or power and control components.”

For NEC purposes, an industrial control panel operates at less than 600V and consists of power circuits and/or control circuits. A control circuit offers the signals leading the performance of the controlled equipment but does not include the controlled equipment or carry the main power. The “panel” part means the control system is mounted on (or in) an enclosure or subpanel

What are the Advantages of Control Panel?

• No air compressor and associated machinery required.
• High efficiency since there is no leakages.
• Instantaneous response.
• Very little affected by normal temperature variations.
• Very accurate.
• Electric cables are cheap and easy to lay.
• Increases “up time”
• Increases overall efficiency
• Optimizes use of electrical power
• Conserves valuable resources
• Minimizes space requirements
• Reduces unscheduled service
• Emphasizes simplicity
• Anticipates future requirements
• Easy to troubleshoot or modify

Standards other than the NEC also apply to industrial control panels. The standards that always apply are

• UL 508AStandard for Industrial Control Panels
• NFPA 79Electrical Standard for Industrial Machinery

Why CoreSystem is the Best Choice in Control Panel Installation?

Our Team

CoreSystem team is rich with skilled professionals who have numerous experiences to be able to give you proper advice. All our instructors are approved by a number of accrediting bodies. Making sure they are up to date with relevant regulations and industry best practices.

Our Aim

We believe in delivering a quality, honest, straight forward and professional service. Our customers need straight forward and honest advice when it comes to their training and rely on ourselves to separate fact from fiction and cut through the jargon that can surround the Health & Safety industry.

Our Work

A cabinet installed with quality workmanship should have neatly organised wires run in gutters or channels, laid-out with only smooth bends to the wire radii, no sharp bends or kinks.

Perfection

All wires, components and terminals should be clearly labelled. We cannot stress the importance of a sound labelling strategy upon installation, when maintenance and troubleshooting is necessary it will save time in testing for errors, saving money therein and ultimately saving you the stress.

Hard working

Our team will work tirelessly to get the training you require, when you require it. Although we cannot always work miracles, our team will do everything we can to get you what you need.

Our Control Panel Assembly Expertise Includes: 

• Control panel assembly and installation
• Integration with existing technologies
• Allen-Bradley PLC-based control solutions, including programming and training
• Assistancefor other main component brands and manufacturers including Square D, GE, ABB, Automation Direct and more
• Expansions of current control systems
• Stainless steel, NEMA 4X, washdown-rated enclosures
• Total process assessments as they relate to plant automation

What is Done During Control Panel Installation?

The installation must be in accordance with the all applicable national (NEC, IEC, EN, etc.) and local electrical codes and ordinances.

• An ignored matter with bigger control panels is the necessity to power test appliances and equipment, for instance vacuums utilised for maintenance. Discussing with the electrical distributor to understandwhat standards are nearest to your requirement and thus make major savings in delivery and cost.
• After the panel is designed, next step is to figure out where to place it. Determine the outside dimensions and the swing requirements of cabinet doors. To reduce maintenance inefficiencies and other hidden costs during operation, it is ideal to allow enough room for a test cart to roll across the area with those doors open.
• Control panels are usually close to the processzone. An elevated ambient temperature might need a air conditioning or ventilation fan on the cabinet, both of which will have filters that need maintenance. Other situations might state inserting a dehumidifier or heater.
• Find the air exhaust and intakes vents for simple filter spare and make sure there is no process meddling; having a cabinet vent suck in air off an aluminum melting pot is generally not helpful.
• Findingthe requirements for the supply conductors can be puzzling until you divide it into different steps.
• You can either put a single main overcurrent protective device (OCPD) in the panel or put overcurrent protection ahead of the panel.
• NEC needsevery panel to be marked with its short circuit current rating.
• Look for the grounding measures.

How is Control Panel Installation Performed?

• The Control Panel should be mounted on the position decided by the General Contractor according to the Interconnect Drawings.
• The Control Panel is indicated by a ( )on the Interconnect Drawing. If there are several Control Panels for the installation, they will be marked with their selected location and labeled to match with the Interconnect Drawings.
• Before mounting the Control Panel to the wall, be sure enough clearance is provided to install the Trunk Line and Power Insert cables as required.
• Firmly place the Control Panel onto the wall according to industry standard mounting routines.
• Open the front panel to reveal the inside of the Control Panel. Configure the AC Power wiring as shown on the silver panel.
• Once the AC Power is installed, turn the Control Panel on.
• Confirm the green light is lit on the front of the Control Panel and then turn the Control Panel off.

Precautions to be Taken

Given below are additional factors need to be considered when approving the installation of an open industrial control panel, some of which include:

• Study and obey manufacturer’s installation guidelines, which might define a particular application
• Verify suitability for installation and use inconformity with the provisions of the NEC
• Verify the mechanical strengthand durability of the required enclosure necessary to protect the open industrial control panel
• Make sure the enclosure does notintrude in the necessary wire bending and conductor termination area required for a safe installation

Any other factors that contribute to the practical safeguarding of persons using or likely to come in contact with the open industrial control panel, such as exposure to live parts, proper grounding or bonding and arch flash hazards, just to name a few.

Regular Maintenance of Control Panel

There is no standardised protocol for the maintenance of control panels, however we tend to live by the old adage prevention rather than the cure.

• Pest control:This may consist of a rodent trap in one corner. Whatever method, ensure it is inspected periodically.
• Dust control: Vacuum the accumulated dust off the cabinet floors. If conditions require vacuuming anything else, remember it’s an energized cabinet — follow the applicable procedures.
• Connection control: Retightening terminal screws leads to lose connections. Instead of inadvertently over-tightening terminal screws (consequently diminishing their clamping power), use an infrared gun to see which terminals high resistance are. Disassemble, clean, and reassemble.
• Insulation:An insulation resistance testing program is the best way to prevent wiring failures.

By taking a few extra steps in the selection, design, and installation of an industrial control panel, you can ensure it will have no failure time bombs ticking away. By performing a humble maintenance course, the panel will be nearly problem free for its lifespan.

You have to remember that cutting corners really impacts on the future reliability of all that investment, financially and hourly. Imagine redecorating your entire house without first fixing the hole in the roof and the creeping threat of rising damp. It won’t take long for all your fresh walls to be completely ruined. Well, the same premise can be applied to control panels, in a cabinet installed with shoddy workmanship it will not take long before errors start piling up until servicing will be rendered useless, leaving repair or replacement as the only option. Which will obviously impact reliability, impacting on time and ultimately cost to you.

Current control systems employ a PLC or Programmable Logic Controller as a way to control motors, valves and many other gears used in a procedure. Computer based Human Machine Interface(HMI) products offer the measures by which process personnel interact with the PLC control system. A well-designed combination of PLC’s and HMI’s can be a solid foundation for your process automation needs. 

A basic PLC system consists of the following sections:

• Input/ Output Section: The input section or input module consists of devices like sensors, switches and many other real-worldinput sources. The input from the sources is linked to the PLC via the input connector rails. The output section or output module can be a motor or a solenoid or a lamp or a heater, whose functioning is controlled by varying the input signals. 
• CPU or Central Processing Unit: It can be a hexagonal or an octal microprocessorand is said to be the brain of the PLC. It carries out all the processing related to the input signals in order to control the output signals based on the control program. 
• Programming Device: The program of control logic is written in this platform.It can be a handheld device or a laptop or a computer itself. 
• Power Supply: It generally works on a power supply of about 24 V, used to power input and output devices.
• Memory: The memory is divided into two parts- The data memory and the program memory. The program information or the control logic is stored in the user memory or the program memory from where the CPU fetches the program instructions. The output and input signals and the counter signals and timer are saved in the input and output external image memory respectively. 

Why Chose PLC and HMI Programming?

Programmable Logic Controllers propose businesses the chance to really modify their mechanical processes. PLC delivers automated solutions by initiating operation based on a system of inputs and outputs, and thus performing as the “brain” of the control system. Other common programming languages used include: 

• Structured Text
• Sequential Flow Chartor SFC, very similar to a traditional flowchart 
• Instruction List
• Function Block Diagram

PLC programming is extremely valuable. Advantages or benefits of PLC are: 

• Minimize the monotony of simplistic work tasks
• Simplify wiring and reduce material costs
• Generatedynamic and complex procedures that out-of-date techniques like mechanical relay-based control just cannot control 
• Offercost effective solutions to even the minor and major manufacturers looking for solutions to process control, complex assembly, manufacturing and testing  

HMI is the best choice because of its user-friendliness of the graphical interface. The graphical interface contains color coding that allows for easy identification. Advantage or benefits of HMI are: 

• Alarms/Warnings
• Reliable Messaging
• Easier Overall Management of Plant
• Accurate Testing with Simulation
• Cost Reduction
• Improved Communications

CoreSystems blends the right components with customized design to build quality automation solutions.  Our aim is to generate successful and well documented programs that merge well with present system logic.  Our widespread system control knowledge of current development platforms and our history permits us to offer proven technologies that can progress your process efficiencies.

What is Done During PLC and HMI Programming?

PLC or Programmable Logic Controller from the I / O signals is responsible for the control of the entire machine or equipment. Its programming, in addition to meeting production requirements, must also be structured and accessible to provide fault diagnostics quickly and accurately. 

A Programmable Logic Controller program is generally written on a computer and then downloaded to the controller Most PLC programming software offers programming in Ladder Logic. Ladder Logic is the traditional programming language. Due to its visual nature Ladder Logic is simpler to employ than many other programming languages. Some PLC manufacturers supply control programming software. 

When operators don’t have easy access to a PC nor laptop close to the installation or the machine, is hard to face the task of creating some backups by downloading or uploading the PLC program or modification. For this reason, there’s a method to upload/download the PLC program directly from or to a USB through the Human Machine Interface.  

There are a few key features that set PLCs apart from industrial PCs, microcontrollers, and other industrial control solutions: 

• Input and Output– The PLC’s CPU stores and processes program data, but input and output modules connect the PLC to the rest of the machine; these I/O modules are what provide information to the CPU and trigger specific results. Input output can be digital or analog. Users can match and mix a PLC’s Input output in order to obtain the correct configuration for their application. 
• Communications – APLC is also connected with other types of systems. Users might want to export application data recorded by the PLC to a supervisory control and data acquisition (SCADA) system, which monitors multiple connected devices. PLCs propose a range of communication protocols and ports to make sure that the PLC can communicate with these other systems. 
• HMI – In order to intermingle with PLC in real time, users need a Human Machine These operator interfaces enable users to review and input information to the PLC in real time, by providing interfaces with simple displays, with a text-readout and keypad, or large touchscreen panels. 

A manufacturing line must first be working with a Programmable Logic Controller (PLC) so as to be integrated with an HMI. It is the PLC that takes the information from the sensors, and transforms it to Boolean algebra, so the HMI can decipher and make decisions. This is where PLC and HMI interface. 

The programming of HMI as its name says, is responsible for the provision of interface with the machine. Thus, from network communication with the CLP, Programming of HMI provides a series of information to operators and other users of the system, such as: fault diagnosis; Production reports; Status of equipment; Manual controls etc. An HMI Programming application need an intuitive and friendly function and its resources must be rightly employed according to the customer needs. 

Choosing an HMI:

An HMI is a considerable purchase thus it is vital to know correctly what is needed of it. An HMI is used for three primary roles: 

• The place of LEDs, On/ Off buttons,  is replaced by the pushbutton replacer. The elimination of these mechanical devices is possible because the HMI can provide a visual representation of all these devices on its LCD screen, while performing all the same functions.
• The Data Handler is utilized for applications thatneed monitoring and stable feedback. Most of the times these Data Handlers come arranged with large capacity memories.  
• The overseeris the last of the HMI three types. These are centralized systems that watch and regulate whole sites or complexes of large systems expanded over vast areas 

At CoreSystems we create programming solutions for HMI and PLC devices separately designed for every customer. CoreSystem team with numerous years of experience in creating solutions in cutting-edge sectors such as the cooling, chemical and machinery industries, offers each project with fresh characteristics to make sure a straightforward and visual user communication with the process.  

Features like remote connectivity that is through mobile, tablet or PC or the sending of alarms makes it simple to obtain the control and analyze various processes anyplace and at any time. Technical support services are also provided. This support, along with our connectivity solutions, ensures assistance is provided instantly and remotely in the event of any incident. We work with PLC brands which offer a guarantee of reliability and robustness over a long period of time.  

How is HMI PLC Programming Done?

PLC programming is done mostly with the help of ladder language. Procedure for PLC programming using ladder language is given below: 

• Analyze and Get the Idea of Control Application: The primary step to program the PLC is to get the idea for which you are going to develop an application-based program.
• List All the Conditions and Get the Design using Flowchart
• Open and Configure the PLC Programming Software: Open the programming software installed in the PC that comes with PLC hardware.After selecting the hardware model of the PLC, configure it with proper output and input  From the listing of the programming languages, chose ladder language and provide a name for the program after selecting the hardware processor. 
• Add the Required Rungs and Address Them: Add the required rungs based on the control application logic and give the address to the each and every input and outputs.
• Verify if there are anyErrors and Simulate It: Locate the Online section in the menu bar and select Online. Check for the errors and make necessary changes after selecting Offline.  
• Download the Program to PLC CPU Memory: After the successful simulation of the program, download the program to CPU by selecting the Download option through a network or communication cable.

HMI-PLC Programming

Given here are the steps through which a PLC and HMI interface or communicate: 

• Copy the PLC program into an USB memory stick
• Insert the memory stick into the USB port of the HMI
• Enter the system menu of the HMI
• Enter the “Up/Download” sub menu
• Select “HMI <->PLC” transfer mode by navigating through the “LEFT” and “RIGHT” buttons at the bottom
• PressUSB on left side of the screen and chose the PLC program file you need to download 
• On the right part of the screen, select the port that is connected to the PLC
• After selecting the port, HMI will search PLC automatically
• After the PLC is detected by the HMI user can now download the program by clicking Download button                                  

An example of HMI-PLC interface 

The requirements for data exchanges between a PLC and an HMI station are basically: 

• This first part of basic requirements is the components for data exchange.
• A physical link that is obtainableto PLC as well as HMI like an Ethernet cable or a RS-485 connection with the adequate ports on both. 
• A common protocol that can exist on the selected physical connection.
• Protocol drivers that will bind the communication interface to the protocol.
• The parttwo is what is switched between the HMI and the PLC.