ICP is a short-form of the Industrial Control Panel. It is used to assemble two or more control circuit and power circuit components and a combination of both. ICPs are typical assemblies of equipment, like motor controllers, switches, auxiliary devices, relays, and other control devices. According to the National Electric Code (NEC), ICPs work under 600 voltage.
ICPs are also referred to as Electrical Control Panels. Well-structured and accurately designed control panels help organizations to empower the production process and to automate several tasks. If the control panel is ill-designed, organizations need to frequently repair it and face unnecessary disruptions and downtime in the production process.
While selecting Industrial Control Panel, you must ensure that they are well-designed and neat. Any control panel is referred to as well-designed and uncluttered if it has the following four characteristics:
What are industrial control panels?
Industrial control panels are assemblies of electrical and automation components used to control, monitor, and operate industrial machinery and processes. They house devices like PLCs, circuit breakers, relays, VFDs, and HMIs, ensuring efficient power distribution, automation and safety in industries such as manufacturing, oil and gas, and power systems. These panels streamline operations, enhance system reliability, and integrate with modern industrial networks for seamless control.
Industrial Control Panel (ICP) is used to control circuits and power circuit components and a combination of both. ICPs are typical assemblies of equipment, like motor controllers, switches, auxiliary devices, relays, and other control devices. According to the National Electric Code (NEC), ICPs work under 600 voltages.
ICPs are also referred to as Electrical Control Panels. Well-structured and accurately designed control panels help organizations to empower the production process and to automate several tasks. If the control panel is ill-designed, organizations need to frequently repair it and face unnecessary disruptions and downtime in the production process.
Types of industrial control panels
Industrial control panels come in various types based on their function and application. Motor control panels (MCC, VFD, soft starter panels) regulate motors. Process control panels (PLC, DCS, SCADA) automate industrial processes. Power distribution panels manage electrical loads, while safety panels (E-stop, explosion-proof) ensure protection. HVAC and lighting control panels optimize building system, and custom skidded panels integrate with modular equipment for specialized applications.
Industrial control panels come in various types, depending on their applications, industry standards, and configurations. Here are some common types:
Motor Control Panels:
- Motor Control Center (MCC): Houses multiple motor starters, circuit breakers, and relays to control industrial motors.
- Variable Frequency Drive (VFD) Panel: Controls motor speed and torque by varying frequency and voltage.
- Soft Starter Panel: Gradually increases voltage to reduce inrush current and mechanical stress on motors.
- Direct Online (DOL) Starter Panel: Used for small motors that require direct power application.
- Star-Delta Starter Panel: Reduces starting current for large motors by initially running in a star configuration before switching to a delta.
Power Distribution Panels
- Main Distribution Panel (MDP): Distributes electrical power from the main supply to different loads.
- Sub Distribution Panel: A secondary panel that further divides power distribution.
- Automatic Transfer Switch (ATS) Panel: Switches power supply between the main grid and backup generators.
Process Control Panels
- Programmable Logic Controller (PLC) Panel: Houses PLCs for automation and process control.
- Distributed Control System (DCS) Panel: Used in large-scale industrial processes for centralized control.
- SCADA Control Panel: Integrates Supervisory Control and Data Acquisition (SCADA) systems for remote monitoring.
Safety & Protection Panels
- Fire Pump Control Panel: Controls fire suppression systems.
- Emergency Shutdown (ESD) Panel: Provides emergency stop functions for hazardous industrial processes.
- Explosion-Proof Panel: Designed for hazardous environments like oil & gas plants.
Specialized Control Panels
- HVAC Control Panel: Manages heating, ventilation, and air conditioning systems.
- Lighting Control Panel: Controls industrial and commercial lighting systems.
- Skid-Mounted Control Panel: Integrated with modular skidded equipment for remote sites.
What Are The Key Components Of Industrial Control Panels?
Industrial control panels consist of essential components for power, control, safety, and communication. Key elements include circuit breakers, transformers, and power supplies for power management, PLCs, relays, VFDs and contactors for automation, and push buttons, sensors, and HMIs for user interaction. Safety devices like E-stops and overload relays ensure protection, while network modules and terminal blocks enable seamless communication and wiring organization.
Industrial control panels consist of various components that work together to manage, monitor and control electrical and mechanical systems. Key components include:
Power Components
- Main Circuit Breaker – Disconnects power and protects the panel from overloads.
- Fuses – Protect circuits from excessive current.
- Surge Protectors – Shields sensitive equipment from voltage spikes.
- Power Supplies – Converts incoming power to suitable voltage (e.g., 24V DC for control systems).
- Transformers – Steps down or steps up voltage levels.
Control Components
- Programmable Logic Controller (PLC) – The brain of the panel, automates processes by controlling inputs and outputs.
- Relays & Contactors – Switches electrical loads on/off based on control signals.
- Variable Frequency Drive (VFD) – Controls motor speed and torque by varying frequency and voltage.
- Soft Starters – Reduces inrush current during motor startup.
- Timers – Provides time-based control functions (e.g., delay start/stop).
Input & Output Devices
- Push Buttons & Selector Switches – Manual control for starting/stopping operations.
- Indicators & Pilot Lights – Displays status (e.g., running, fault, or standby).
- Sensors (Proximity, Temperature, Pressure, etc.) – Provides real-time data for process control.
- Encoders & Limit Switches – Monitors position and movement of machinery.
Safety & Protection Devices
- Emergency Stop (E-Stop) Button – Provides an immediate shutdown in case of emergencies.
- Overload Relays – Protects motors from overheating and excessive current.
- Grounding & Earthing Components – Ensures electrical safety and prevents shocks.
- Circuit Protection Devices (RCBOs, MCBs, MCCBs) – Protect circuits from faults, overloads, and short circuits.
Communication & Interface Components
- Human-Machine Interface (HMI) – Touchscreen or panel-mounted displays for operator interaction.
- SCADA System – Supervisory Control and Data Acquisition for remote monitoring.
- Ethernet Switches & Communication Modules – Enables communication between controllers, HMIs, and networks (Modbus, Profibus, Ethernet/IP).
- I/O Modules (Digital & Analog) – Expands control panel connectivity to field devices.
Enclosure & Wiring
- Control Panel Enclosure – Houses all components, rated for environmental protection (e.g., NEMA, IP-rated enclosures).
- Terminal Blocks – Organizes and connects wiring inside the panel.
- DIN Rails – Mounting rails for electrical components.
- Cable Management (Wire Ducts, Glands, Conduits) – Organizes and protects wiring.
Tips for Choosing the Right Industrial Control Panel
Choosing the right industrial control panel requires considering application needs, environmental conditions, and compliance requirements. Ensure the panel has the correct voltage, current capacity and protection ratings (NEMA/IP) for safety. Select reliable PLCs, VFDs and HMIs for automation and efficiency. Factor in expandability, ease of maintenance, and integration with existing systems. Use proper wiring, surge protection, and cooling to enhance durability. Finally, choose a trusted manufacturer that meets industry standards and provides long-term support.
While selecting Industrial Control Panel, you must ensure that they are well-designed and neat. Any control panel is referred to as well-designed and uncluttered if it has the following four characteristics:
Aspect 1: Layout of the Control Panel
The main power switch of the control panel must be located in the top-right corner. It implies that components that have high-voltage ratings are placed at the control panel’s top. The power from the high-rating components will get distributed to low-rating components. Below these components, PCL and I/O terminals are placed.
Aspect 2: Labelling and Documentation
Labelling and clear documentation are crucial for any industrial control panel. Proper labelling of components and wiring simplifies maintenance, reduces the risk of errors, and improves safety during operation. Incorrectly wired or unlabeled panels can lead to severe operational issues, delays in troubleshooting, and safety hazards.
Labelling conventions should be followed consistently throughout the panel. For instance, every wire, terminal, and component should be labelled with unique identifiers. For wiring, labels should be applied to the wire’s end to ensure that every connection is easily traceable. This is especially important in the case of PLC I/O wiring, where labelling should follow the PLC’s address syntax.
Aspect 3: Panel Sizing and Space Utilization
Proper panel sizing is a critical aspect of control panel design. The size of the panel determines how much space each component has to operate effectively. Insufficient space can lead to overheating, poor ventilation, and difficulty accessing components for repairs or upgrades. On the other hand, excessive space may lead to unnecessary material costs.
The sizing of the panel should consider the heat dissipation needs of each component. Different components have varying levels of heat emission, and components that generate more heat should be spaced appropriately to allow air circulation. For example, motors and transformers generate significant heat and must be placed away from heat-sensitive components to prevent damage.
Aspect 4: Wire-way Management
Effective wire-way management is another critical factor in a well-designed control panel. A wire-way refers to the system of pathways used to organize and route wires and cables inside the panel. Proper wire management ensures that wires are not tangled, exposed, or subjected to unnecessary stress, which can lead to system failures or safety hazards.
The key to good wire management is organizing cables in a way that prevents overcrowding and allows for easy access. Cables should be neatly arranged with enough space between them to ensure proper airflow. Using wire ducts or cable trays to route cables can keep them organized and reduce the risk of damage during maintenance.