Amongst the control panel layout tips out there, some are practical, many are good and some are downright weird. There are is a wealth of it in the /PLC sub-reddit. Some of it is amusingly opiniated:

 

The following is my collection of top tips on control panel layouts. A few of the panel posts from Reddit are embedded below. Will add more pointers as I come across them.

 

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1. Heat rises

Do the heat calculations. Enclosure vendors usually have free tools for this like this .

• • If ventilation is needed, fan at the bottom, exhaust at the top, not the other way around. Hot air rises and leaves the panel, cool air comes in the bottom.

2. Power protection components at the top. Circuit breakers, disconnects. The temperature rating on circuit breakers are usually higher than the average PLC, drive or anything that has electronics for that matter. Example here – 30A breaker from SE has an operational ambient of 158 degF/70 degC. Accessibility and safety is also better with power devices at the top. 

3. Incoming power. This really depends on the install site/location. If you have a choice, some would argue that’s it’s better for incoming power to come in from the bottom. With gravity, holes and inlets at the top of the panel have poor contingencies in the event of condensation or dirt coming in( or even water ingress- say NEMA 4/4X failure situations) . 

4. Wire labels, terminals, and wire markers

• • Avoid putting the label on the device. If the device gets replaced, the label goes with it.
  • Sometimes end users may require label on device also. Check before it gets to the FAT
  • Harmonize labelling such that it can be traced back to schematics. This will help with maintenance folks and any troubleshooting efforts.

5. Wireway

• • Vertical runs should intersect with a horizontal run such that the horizontal run stops the vertical cover from sliding down
  • Plan it out such that control wiring is separated from power wiring. If they intersect, make it perpendicular.
  • Read on to number 6.

6. Electromagnetic interference

• • • Separate 480Vac and  24Vdc ( control and communications) wires. 
    • If they have to cross, it’s best done perpendicularly- ie. they cross at a 90 deg angle. Still avoid having them in proximity. Good explanation of this here
    • Additional sleeving or barriers for EMI mitigation if needed.

 

7. Spacing If the project allows for it, allow for some room between devices, PLC’s, drives, power supplies. This helps with maintenance accessibility. Also, it makes way for future expansions. More I/O if the PLC needs it, another drive …etc..

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8. Ground connections

• • Spec grounding washers installed and properly torqued to bite through the paint

9. Network cabling

• Use pre-terminated cables where possible. From a good vendor, reliability is better. 
• From item 6 above, separate controls communications cables from the power wiring.

10. Maintenance and usability

• Add a rack on door for reference material

 

“I´m tired boss…”
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Will come back and add more as I find it…