All electrical panel enclosures can keep dust and moisture out, but the real performance test happens inside. Component placement, wire routing, heat management, and service access all influence system reliability, which is why electrical control panel layout deserves as much attention as the schematic itself.
Fralo Industries has been fabricating custom enclosures and backplanes for industrial manufacturers since 1979, giving us deep insight into the layout traits that help a panel deliver lasting performance. Below, we break down the five top strategies we use when collaborating with clients on their panel layouts. Explore our practical insights and reach out to our team for electrical enclosures backed by proven sheet metal fabrication and electrical control panel expertise as well as cutting-edge capabilities.
1. Begin With Thermal Planning
Every electrical panel layout plan begins with a conversation about thermal management. We ask our customers questions like “which device runs hottest?”, “how warm does your facility get in the summer?”. Getting answers to questions is essential as even a slight increase in operating temperature can greatly reduce the life of electrical components.
Once we have an understanding of the heat load, we start planning around where drives and power supplies are going to be positioned within the panel. Because warm air rises, we typically place these heat-generating components near the top of the electrical panel enclosure and more sensitive equipment, such as programmable logic controllers, lower down. We also incorporate cutouts for cooling fans.
2. Map Out Power and Control Zones Together
Electrical noise is one of the most common challenges our clients face after heat management. For example, erratic sensor readings often indicate that power wiring is routed too close to low-voltage signal wiring. Fralo Industries provides engineering support for electrical panel layouts, helping clients establish separate power and control zones on the backplane.
3. Consider Safe Service Access
Clients usually focus on how a panel looks on paper, but with our experience we encourage them to picture real-life situations like troubleshooting the electrical system during a line shutdown.
That’s why we review all electrical panel enclosures for an accessible reach height, hinged inner doors, swing out panels, and adequate working room around thermal blocks, since a crowded or hard to get to panel can impede repairs.
4. Planning for Growth
Data centers and other high-tech industries are only going to continue to grow as technology advances. We plan for scalability and recommend reserving around 20 to 25 percent of the backplane as spare space because we’ve seen clients that have been burned by a panel that filled up long before its equipment wore out.
Custom fabrication makes future-proofing the layouts of electrical panel enclosures easy because we build to exact dimensions and can leave room for expansion without wasting a single millimeter.
5. Matching Panel Layouts to Their Environment
Electrical panel enclosures can have vastly different layout requirements. An outdoor enclosure at a remote pump station, for instance, has unique considerations compared to one in an indoor clean control room. In wet locations, we often recommend bottom cable entries since water tends to follow cables that enter through the top.
For sites where condensation is a concern, we discuss enclosure heaters and other features that help ensure sensitive electronics are clear of areas where moisture is likely to collect.
Get Electrical Panel Enclosures Built Around Your Needs from Fralo Industries
By having thermal management, accessibility, and future growth guiding the layouts of electrical panel enclosures, Fralo Industries helps data center suppliers and OEMs in other high-tech industries avoid frustration and costly surprises down the road.
If you have an upcoming project, let our team of experts be part of the process. We have the capabilities and electrical control panel expertise needed to create custom assemblies centered around your unique requirements. Give us a call today to get started.