Panel Assembly

About Company

In the realm of industrial manufacturing, electrical control panels serve as the vital nervous system for complex mechanical systems. They play a crucial role in efficiently controlling, monitoring, and safeguarding all electrical systems, devices, and machines. Without these panels, the manufacturing process could easily become chaotic and hazardous.

Given their importance, designing, building, and assembling electrical control panels requires meticulous attention to detail, thorough planning, and expert knowledge. This guide will walk you through the essential steps necessary to construct and assemble an electrical control panel, ensuring the smooth and safe operation of your manufacturing process.

Planning & Design

Before embarking on any electrical control panel project, it is imperative to have a clear understanding of the manufacturing process requirements and safety standards. This knowledge will enable you to design a set of electrical schematics and panel layouts that include crucial details such as power requirements, equipment specifications, signal types, and safety features. The design should be tailored to meet your specific manufacturing process needs and must comply with all relevant Electrical Safety Standards, such as NFPA 70 (NEC), NFPA 79, or UL508A.

Component Assembly

Once the design is finalized, the next step is to assemble all the necessary components of the control panel. Control components are typically mounted on a sub-panel, which will later be installed in an enclosure. The sub-panel layout, as detailed in the electrical schematic design package, specifies the required components and their mounting positions. Many control components mount on a standard size DIN rail for expedited installation. Additionally, wire ducts are installed on the sub-panel to facilitate clean wiring routing between devices, following the manufacturers’ spacing requirements to ensure proper heat dissipation. Some components, such as disconnect handles, air conditioners, push buttons, or stack lights, are also mounted directly on the enclosure.

Installation & Wiring

After assembling all the components, the next step is to wire the control panel according to the electrical schematic package. The wiring diagram specifies which terminal on each control component a wire should be connected to, as well as the required wire gauge. Wire color is also crucial, as it indicates the voltage the wire carries (e.g., 24VDC, 120VAC, or 480VAC), and must adhere to applicable standards. Each wire is labeled uniquely to ensure correct connection and aid in maintenance troubleshooting.

Testing and Quality Control

Following component installation and wiring, the final step is to test and validate the electrical control panel. This step is critical as it checks for any wiring errors, verifies safety features, and tests functionality. The first test is a point-to-point continuity test against the electrical schematics to ensure correct wiring. Once this is completed successfully, the panel can be powered on to verify that all components function as intended. Safety procedures, such as lock-out tag-out, wearing gloves, and eye protection, should be followed when working with live panels. A final checklist should be completed to confirm the panel meets all design criteria, including the presence of informational or warning labels and proper bonding of ground bars.

Compliance and Certification

Finally, it is essential to ensure that your industrial control panel complies with local and national electrical codes and standards. Consulting with a certified electrical safety inspector is advisable if there are any doubts. Undergoing the UL508A certification process is recommended to ensure that your control panel meets all safety standards and requirements.

Consider the following questions, before selecting a panel shop.
It help you address all your substation automation requirements

SAM Analytic Solutions is an expert and professional in distribution panel assembly with over four decades of experience.

They specialize in designing and building highly organized industrial control panels with built-in diagnostic capabilities that meet UL, CSA, or CE safety standards.

For more information, reach out to them at They are happy to assist with any questions you may have.