Control Panels FAQs

made with
Table of Contents

1. 5 Things You Need to Know Before Designing Your

Motor Control Center

2. Is it Time to Upgrade Your Industrial Control System?

3. Should You Repair or Replace Your Industrial Electrical

Control Panel?

4. What to do if You Have an Electrical Control Problem

5. Troubleshoot Electrical Control Panels with iPhone

Thermal Cameras

6. Industrial Control Panel Contactors: ABB vs. Eaton

7. Industrial Control Panel Contactors: ABB vs. Schneider

Electric

8. Industrial Electric Controls for Businesses in Sarasota,

Florida

9. Mader Electric is truly your one-stop solution.

 u N e e d t o K n o w
5 Things Yo
f o r e D e s ig n in g Y o u r
Be
M ot o r C o n t r o l C e n t e r
by Mader Electric, Inc.

Introduced in 1937, the

motor control center
maximized the use of space
inside industrial facilities.
Even though similar
specifications dictate the
design of today's motor
control centers, well-
designed systems
accommodate a vast
variety of devices required in modern facilities. Therefore, if you want a long
and reliable service life with maximum return on investment, make sure you
address the following five design specifications.

Ampacity
One of the first specifications to consider is the ampacity of the main
horizontal bus of your motor control center. The ampacity represents the
maximum current the main horizontal bus can accommodate before
overheating occurs. The minimum horizontal bus ampacity is 600 A.
Secondly, determine the ampacity for the vertical bus. The minimum vertical
bus ampacity is 300A. Though, many manufacturers use a maximum vertical
bus ampacity of 1,600A, and a maximum ampacity for horizontal bus of
2,000A.

Fault Current Levels

A fault current level is simply the amount of electric current that flows if a short
were to occur between phases. The fault current level rating is determined by
the lowest-rated device in the motor control center. For example, if the bus
structure was designed to withstand 30,000 A and a breaker with a fault-
withstanding rating of 12,000 A is installed, then the entire system rating is
12,000 A.

Bussing Material
Copper has many advantages over aluminum as a bussing material. Firstly,
copper has a higher conductivity rate than aluminum, which allows for a smaller
bus to handle the same current. Additionally, copper doesn't expand and
contract to the degree of aluminum. Though, copper is not a one-size-fits-all
bussing material. Aluminum costs less and is less likely to corrode in some
industrial environments. For example, ammonia gas used in refrigerant systems
or chiller loops attacks copper and cause stress cracking of copper alloys.

Feeder Cables
Careful not to overlook how the main feeder cables enter the control center. If
you determine beforehand how feeder cables enter your system (e.g.
underground or overhead), you may avoid difficult wire bends and potentially
costly field changes. You can design your system to accommodate both
overhead and underground feeds. Though, your costs will increase.

Fire Protection
Make sure cables and components are up to fire code. Motor control centers
generally sit on floors. If your floors (and walls) are required to have a fire-
resistance rating, fire-stops may be necessary for floor- and wall-penetrating
feeder cables.
 im e t o U p g r a d e Y o u r
Is it T
ia l C o n t r o l S y s t e m ?
Industr
by Mader Electric, Inc.

Today's Industrial Control expert ought

to employ products that firmly
automate and centralize Industrial
Control. An Industrial Control System,
aka ICS, contains types of products
which are running in several enterprises.
These kind of products may involve
SCADA, PLC, DCS, and others.

PLC
They can be based upon the Boolean organizational tasks but several types
employ timers. These kind of tools are computer centered to be utilized to
regulate several tasks within an Industrial Control System.

SCADA
Supervisory Control And Data Acquisition identifies a centralized device which
in turn is made of several subsystems like Human Machine Interfaces as well as
PLC and even Telecommunications.

Before switching as well as replacing an ICS, list out pluses and minuses of the
old device and compare it to the updated device.
Here are four reasons for why you may need to upgrade as well as update an
Industrial Control System:

Functionality
Functionality could also be increased by an improvement, still frequently a total
change is a sensible alternative. Although old products may be functioning,
they will continue to work at below an ideal level.

Innovative technology
Advancements in technological know-how nowadays can increase device
effectiveness or make the modern products much easier to employ. The benefit
of alternative technologies is one, among a number of good reasons, for
updating an old device.

Assistance
Updating the device could expand the technical assistance lifetime. Still,
replacing it with a different device offers you the latest technical assistance
deals, so it normally comes with more desirable technical help. Each and every
device offers a fixed assistance lifetime. An upgrade is a chance to update the
device in the event that future technical help will not be available to choose
from, or maybe if current assistance is lousy.

Organization Requirements
Updating an existing device may possibly permit you to insert device functions
which may be required according to the desired device specifications. As time
passes the device specifications may have change.

Paying for something offering you less of a specification you require is a waste
of hard earned money. A device change will certainly often present the ability
to get just about all the functions you will require from an Industrial Control
System. Regardless of whether you are ready to upgrade as well as update a
Industrial Control System, the target should be to get something that satisfies a
facility's effectiveness, lowers your costs, and encourages productivity.
S h o u ld Y o u R e p a ir o r
Y o u r In d u s t r ia l
Replace
t r ic a l C o n t r o l P a n e l?
Elec
by Mader Electric, Inc.

Industrial electrical
control panels fall
under two
categories:
1. Units that contain components that control major industrial production
systems, such as presses, cranes, conveyors and refrigeration units

2. Units that contain components that control necessary nearby environmental

systems, such as lighting, HVAC and pumps

When power or control components, such as motor controllers, wires, relays

and switches, fail to work properly, production immediately slows or screeches
to a halt resulting in lost revenues and high on-site emergency repair call costs.
For these reasons, it's critical that you hire a trained technical professional to
perform a preventative inspection and repair work if any of the following
conditions currently exist in your factory.
Precursor Events
Many workers fail to order control panel inspections after seemingly non-
related emergency events, such as power surges, roof leaks and floods. Some
factory employees also fail to seek assistance when they notice warning signs,
such as an unusually warm enclosure, low performance, metal corrosion,
component wear, strange smells or noises, even though these warnings often
occur before electrocution and fire events. Causes of some signs vary -- for
example, defective and worn wire insulation and current leaks can cause
performance problems and strange odors.

Disorganized Units
Many factories have custom, D-I-Y patched and junction box control panels
designed to fit their unique industry, product and/or environment needs. These
units usually have messy and overcrowded interiors that create unnecessary
repair and safety problems and allow noise interference. Users and technicians
also often find it difficult to determine the purpose of components in
disorganized units.

Non-Compliance Issues
Many older and customized control panels fail to meet National Electric Code
requirements. As a result, they also fail to meet some of the National Fire
codes. Obviously, older units with worn and/or damaged parts are fire hazards.
Disorganized units can also fail to provide enough required space. Many units
simply fail to provide appropriate printed markings, such as part labels and
system diagrams.

Bad Location
When a control panel is located near anything that blocks air vents or certain
industrial byproduct and environmental conditions, such as corrosive vapors,
oil, dirt, vibrating equipment, moisture and heat or cold, the unit is more likely
to suffer damage. Additionally, higher labor-related costs often occur if
technicians can't access a control panel with ease because it's located in a
partially inaccessible spot.
 t o d o if Y o u H a v e a n
W hat
a l C o n t r o l P r o b le m
Electric
by Mader Electric, Inc.

When running a business it can seem like

electric motors fail regularly and
unfortunately, they end up needing to be
replaced. But in many situations, full
motor or pump replacement can be
prevented with proper care and
maintenance.

While it may seem like motor failure is very common, often times the real issue
is an incorrect application or control circuit problem. In many cases, motor
failure can be an indication of more serious issues down the line. Luckily, with
the help of an experienced technician, troubleshooting and repairs can be easy
and stress-free.

How to Handle an Electrical Control Problem

Safety First
First things first, unless you are an experienced repair technician, it is a good
idea to schedule a service appointment if you are dealing with electrical issues
affecting a pump or motor. It is important to put your safety and the safety of
your employees first when troubleshooting electrical issues. If dealing with a
conveyor belt, watch where you are placing your hands and be aware of any
boxes or other materials that may be coming down the conveyor belt.
Listen, Look and Feel
Take the time to visually assess any damage to the system and be careful to
feel for any catch points that could prevent the conveyor belt from working
properly. If there are any abnormal sounds coming from the system be sure to
take note and give this information to the repair technician, especially if the
noise is intermittent. When possible, it may be necessary to shut down all
power to the system to prevent further problems.

Leave the Hard Work to the Professionals

Whether your system is in need of a few minor repairs or you need to install a
brand new motor and controls, it is best to leave the difficult work up to the
professionals. If you are experiencing an electrical control problem, be sure to
contact the expert team at Mader Electric to get fast, efficient and friendly
service when you need it the most!
 le s h o o t E le c t r ic a l
T ro u b
l P a n e ls w it h iP h o n e
C o n tro
T h erm a l C a m era s
by Mader Electric, Inc.

A new trend in the manufacturing industry is

proving to be very helpful: infrared cameras. Many
facilities regularly use thermal imaging cameras in
order to inspect electrical and mechanical
components. These cameras give users crucial
information about the condition of various
different types of equipment, as well as help
workers optimize the production process and
monitor quality control. Check out some of the
best thermal camera options here!

While thermal cameras are incredibly useful in the manufacturing industry,

they can also be very expensive. There is now a much cheaper alternative to
buying a thermal camera, and it comes in the form of an accessory you attach
to your iPhone. This device turns your normal iPhone camera into a thermal
camera and allows you to use it anywhere, anytime. It is much easier to
transport than a full-sized camera that only has one function, and much more
convenient.

Check out Flir One here!

Thermal cameras can be helpful in the following equipment:

Electrical
Transformers
Fuse Panels
Motor Control Centers
Electrical Cabinets
Switchgear

Mechanic
Pumps
Storage Tanks
Conveyor Belts
Motors
Process Valves
Pipelines

Infrared thermography is used to find areas of excess heat so you are able to
correct any problems before a component fails, causing damage, safety hazards
and productivity loss. You can read more on how infrared cameras are helping
manufacturing industries in this article.
 t r ia l C o n t r o l P a n e l
Indus
t o r s : A B B v s . E a t o n
C o n ta c
by Mader Electric, Inc.

When choosing the contactors for

your control panel, there are plenty
of reliable names on the market
offering products. However, not all
of the parts offer the same benefits
due to design variations and small
improvements that make a big
difference in the long run. Figure
out whether ABB vs. Eaton
contactors are a better choice for your industrial motor control hardware
needs.

Comparable Models
First, you need to understand what models are being compared between the
two manufacturers. Every contactor offered by ABB comes from the same line,
all various model numbers with the AF prefix, like the AF2650. The similar
models available from Eaton are the DILH and DILM collections.
Energy Demands
One of the most marked differences between the two sets of contactors
involves the amount of energy required to modulate electricity flow with AC
equipment. The two lines remain evenly matched in terms of DC use, but ABB
wins in the AC performance category. An Eaton contactor requires about four
times as much energy to close and hold contact when operated under 100A.
This makes a huge difference in energy use, operation costs, and wear and tear
throughout the control panel.

Long-Term Reliability
The higher end of the Eaton lines, which run up to 2000A, include the usual
protections to keep the contactors working properly for months and years on
end. However, the lower end of the lines are missing many of these features.
For example, none of the contactors under 115A include surge suppression
inside the unit. In contrast, every ABB contactor in this line includes this
feature.

Aside from protection from long-term damage, don't forget about the
importance of electronic coils when you need to maintain even power to
protect sensitive equipment. When comparing ABB vs. Eaton in this category,
ABB takes the lead by including this feature on the entire line. Eaton only adds
the feature to models above 185A.

Space Requirements
Finally, check how much space is available on your control panel. In crowded
industrial configurations, the difference of half an inch can make a big
difference in whether the contactor fits or sticks out like a sore thumb. Both
Eaton and ABB parts are compact and designed to minimize width, but the
largest Eaton model is 80mm wider. With similar coil configurations and power
loads, both should fit equally well when open space is minimal.
 t r ia l C o n t r o l P a n e l
Indus
Co n t a c t o r s : A B B v s .
Schneider Electric
by Mader Electric, Inc.

If you require maintenance and setting up of

devices, then Mader will offer the
components, as well as assistance, to get rid
of any problems. They will also help you to
keep your facilities functioning at peak
efficiency. Industrial control panel contactors
are an essential part of any facility. The
following compares ABB vs. Schneider Electric industrial control panel
contactors to help you decide between the two.

ABB vs. Schneider Electric

ABB: ABB offers one continual array of contactors available, AF09 to AF2650.

Schneider: Schneider offers several varieties of contactors available. The LC10

assortment competes with AF09-AF140. The LC1F assortment competes with
AF116-AF2050. Schneider contactors are of a typical design and style.
Schneider has zero products akin to the AF2650.
Safe Performance Credibility
ABB: Constant tracking of voltage and even current makes certain there will be
distinct performance of the contactor by the electrical coil. Internal surge
suppression is common in all varieties of ABB contactors.

Schneider: A lack of an electrical coil results in the contactor being at the

mercy of sags and even decreases in the network as well as load, which can all
have an impact on the contactor's performance. Zero in-built surge
suppression for any portion of all their varieties of contactors.

Enhanced Installation
ABB: Four coils. AC and DC coil for all of their contactors. PLC from 9A to
2650A. Both of the contactor and even an assembled starter are intended to
be as compact as can be. Components are intended to be as small as they can
be.

Schneider: 15-51 coils. A lack of an AC and DC coil for all of their contactors.
PLC from 9A to 38A. The Schneider contactors are approximately 50% wider
when compared with AF contactors. For the assembled starter, Schneider is
akin to AF up to approximately 80A. Any level above that, Schneider is wider
when compared with AF.

Advanced Productivity
ABB: AF technological know-how cuts down on required electrical power for
closing and even holding the contactor, both for AC and even DC performance.
Minimal probable chattering, humming, welding, and even burnt coils resulting
from electrical coil.

Schneider: Schneider contactors typically call for twice as much electricity for
AC performance and even 70% extra for DC performance when compared to
the AF assortment. Schneider contactors are not equipped with electrical coils
and are prone to chatter, hum, weld, and even burn coils when compared to AF
contactors.
 t r ia l E le c t r ic C o n t r o ls
Indus
in e s s e s in S a r a s o t a ,
fo r B u s
Florida
by Mader Electric, Inc.

Your business is important

to you. You want the best
for it to continue to thrive,
and offer your customers
superlative service at the
same time. Unfortunately,
as with any operation,
things break down. If your
business uses electric
controls to function
(practically all do), then you should call on the services of Mader Electric.

Mader Electric is a front​runner for mechanical and electrical repairs. In 1983,

with only six employees, Mader started repairing electric motors and pumps in
a 5,000 sq. ft. building. Since then, we have grown into a new 33,250 sq. ft.
facility on 7.5 acres of land with additional room for expansion. Our current
capabilities allow us to repair motors and pumps up to 4000 horsepower and
4160 volt. We'll send our highly qualified technicians to your business to get
you up and running again quickly. You can also trust us for generator repair,
welding, custom shaft fabrication, and more.
If, for instance, you need a repair on equipment such as:

Generators
Blowers
Servo Motors
Gear Reducers
Fork truck motors
Welders
Printing press motors

Mader Electric has you covered. We have a high​tech rewind and re​design
facility for AC and DC motors up to 4000 horsepower. We can also take care
of your needs on​site. On​site services include:

Troubleshooting all electric motors

Laser alignment
Balancing
Motor and pump installation
Generator service and installations
Predictive and preventive maintenance
Inverter troubleshooting and repair
Core Repair

Not only can you get repairs on​site, our facility also has a state of the art
training center to provide customers with classes from motor and pump
maintenance, renewable energy devices to programmable logic controls, and
energy savings for manufacturing. We are U.L. certified to repair explosion
proof motors and pumps, and have a U.L. certified custom control panel
department. We also have a general contractor and plumbing license, as well as
a licensed electrician on staff available 24/7 for customers.
 Mader Electric is truly your
one-stop solution.
For more information about industrial control panels or to schedule an
appointment, contact Mader Electric today!

CLICK HERE TO CONTACT US!

made with