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bluebear asked how difficult can it be to build my first electrical panel?
i've been doing industrial electrical for over 7 years. i'm going to get my chance to build my first control panel. any advise?any secrets? mostly start and stop and a few safety switches.
And got the following answer:
If you not using a PC controller, the concept of "motor control" utilizing relay logic is quite simple. But you do have to understand the basic "magnetic interlock", commonly referred to as "holding contacts". Once you fully understand that one simple principle, the rest is easy. If you do not understand the concept, it may be quite difficult, if not impossible. If you do, it is so simple a child could do it. I found it extremely easy, my best friend struggled with it for years, others never could understand it. Do not be afraid of it. I think some think it is very hard and do not allow themselves to "get it." You should be working from a line diagram that is like a road map of how to terminate every wire so the finished product works as intended. Make sure there is a wire for every line on the diagram, and that every point of each component on the diagram gets a wire terminated to it. If you are building the panel from scratch, as in cutting the holes for all the lights and switches, and mounting all relays, motor starters, breakers, wire terminal strips, etc. on the back panel, you must install all equipment first - before the first wire. Keep it clean. Others may judge the panel by its appearance, whether or not it works well. They do not understand how electricity works, they only know what looks good, so make it "look like" you are good at what you do, even if you are not confident. Make every mechanical connection tight. Get the correct tool for the job. Do not use a channel-lock for tightening the connecting nuts on door mounted switches. Make it look like a new car. No rounded edges on nuts, no stripped our phillips screw slots, etc. Do it right with the right tools. Sometimes the most difficult job is only difficult because you do not use the right tool. Plan ahead, so that you make plenty of room for all components and the wire bundles. I like to use wire racks between each component on the back panel. It holds the wire in place while you wire the entire panel, and provides for a clean finished look, since all of the wire runs are hidden behind covers. I also lay everything in its intended position before I drill the first hole, to make sure everything will fit. I also like to drill and then tap each hole for mounting everything that mounts with screws. Use pan heads, they are larger diameter heads, so they do not need washers and hold securely. You can also buy self-tapping screws, which save you the time of tapping the hole first. Use wire numbers and attach a number securely to each end of every wire. If it is necessary to trace a problem now, or anytime in the future, it is easy if the wires are numbered. They usually call the guy that built the panel when there is a problem in the future. If you can easily trace the problem, you can prevent down time and be the hero they call for all their service needs. Service calls equal "good money". Do not pull the wires too tight from point to point. Leave a little slack to avoid pressure that will accumulate as additional wires are added. Pressure can pull a wire out of a loose connection. Sometimes connections can loosen after installation, especially with slight vibrations, and if the wire is under pressure, it might slip out of the connection and cause the system to fail. Remember, it will have your name on it (whether or not it really does - people will know you are the one that built it). Use only a very high grade of wire within the panel, it will be more flexible and easier to use - and larger is better. I also like to twist the strands and tin the end of each wire before connecting it. It ensures a tighter fit under a screw or terminal, and prevents loose strands that might accidentally short circuit against another terminal, wire, or ground. It is also the highest standard of quality you can provide for the customer. Take your time, and double-check your work. Like an old carpenter would say, "Measure twice and cut once." Make sure you are right the first time. Take advantage of what others have done before you. Go to one or two of the industrial sites that have existing control panels and look at what they did. Sometimes it is much smarter to copy the way the other guy did it that to try to "re-invent the wheel." After threading, bending, and installing tens of thousands of feet of rigid conduit of all sizes, and then pulling millions of feet of wire, the panel building was the most fun and rewarding. I wish I were doing it for you. Good luck.
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