Industrial control panels – the unsung heroes of the manufacturing world. They keep our production lines, machinery and process control systems ticking over, safely and efficiently. You’ll find them controlling everything from packaging lines to pumps, conveyors and HVAC systems.
The thing is these panels are a vital part of the electrical infrastructure – they’re responsible for doling out the power and telling the machinery what to do. This means they need to be designed and built to a set of recognised standards – not just to keep people safe, but also to avoid installations falling foul of UK legislation.
If you’re in the market for a new control panel, or you’re deciding on a supplier, knowing your way around the main standards can make all the difference.
Why Bother With Standards?
Industrial control panels live in a world where reliability is everything. A dodgy design or a wiring job that’s gone wrong can cause all sorts of problems – from equipment failures and downtime, to electrical hazards, fire risks and damage to the machinery itself. Not to mention increased maintenance costs and the worry of putting people’s health and safety at risk.
But follow the recognised standards and you can be pretty sure that your panels are going to be built using tried and tested engineering practices, thoroughly tested and up to the job. And once they’re installed, you can have confidence they’ll keep on working safely throughout their working life.
The Main Standards That Industrial Control Panels Need to Follow
There are a few key British and international standards that govern how industrial control panels are designed and made. Some focus on electrical safety, while others cover testing, construction, documentation and quality management. And which ones you need to follow will depend on the type of panel you’re building and the industry it’s being used in.
BS EN IEC 61439 – Low Voltage Switchgear and Controlgear Assemblies
One of the most important standards for industrial control panels is BS EN IEC 61439. This one replaced the older BS EN 60439 series, and it demands that manufacturers verify each new assembly meets the required performance criteria – rather than just relying on what’s been done before.
The standard covers all the basics – temperature rise, short-circuit strength, mechanical construction, electrical clearances and so on. And if you’re working in many industrial applications, compliance with BS EN IEC 61439 is pretty much a given.
BS EN 60204-1 – Safety of Machinery
Another key standard is BS EN 60204-1 – this one focuses specifically on the electrical side of things, and applies when control panels are part of industrial machinery.
It covers everything from electrical protection and emergency stop circuits to protective bonding, cable identification and operator safety. And if you’re a machine builder, you’re probably pretty keen on getting compliance with this one.
UKCA and CE Marking
Since the UK left the EU, a lot of industrial products now need UKCA marking for the GB market. And depending on your application, you may also need CE marking for products going into European markets. This mark shows that your equipment meets the relevant legislation and regulations.
But you need to work out which legislation applies to your products before you can apply these marks.
The Electricity at Work Regulations 1989
These regulations are aimed at employers and duty holders rather than manufacturers – but they do have an influence on how industrial control panels are designed and installed.
Essentially, the regulation requires that electrical systems are: safe to construct, properly maintained, suitable for their purpose and protected against danger. And if your panels have been designed using recognised engineering standards, it makes it a lot easier to comply.
BS 7671 – IET Wiring Regulations
BS 7671 is the electrical installation standard for the whole of the UK. While it doesn’t specify how industrial control panels should be made, it does influence how they get connected in buildings and industrial facilities.
So if you’re an electrical contractor installing panels, you need to make sure the whole installation meets these regulations.
EMC Requirements
Industrial control panels often contain things like PLCs, variable speed drives and industrial computers – all of which generate electromagnetic emissions and can be affected by interference from other kit.
So manufacturers need to think about EMC requirements to ensure reliable operation. That means proper enclosure design, cable routing, shielding and earthing all contribute to EMC compliance.
Low Voltage Regulations
Industrial control panels working within low-voltage limits need to comply with the relevant electrical safety legislation.
Manufacturers need to make sure components are correctly rated, properly protected and installed according to the manufacturer’s guidelines. And choosing quality components from reputable suppliers makes for long-term reliability.
Ingress Protection (IP) Ratings
The environment that your control panels are going to operate in plays a big part in the design process. Enclosures are chosen according to how much protection is needed against things like water, dust and other contaminants.
So, for example, an IP65 rating means that the enclosure can withstand being sprayed with water and has no openings that can let dust in. And so on.* Dust (think about it spoiling electronics, fan blowing it away, etc.)\
- Water (imagine splashing it on a circuit board, someone dropping their coffee on a live component, etc.)\
- Moisture (picture it seeping into a junction box, corroding metal)\
- Oils (see it dripping on a delicate mechanism, or a motor guts getting all gunked up)\
- Chemicals (envision some toxic substance eating away at a PCB)\
- Outdoor weather conditions (-think construction sites, or industrial installations exposed to the elements)
Common ratings you’ll come across include:
*IP54
*IP55
*IP65
*IP66
Food production pharmaceutical manufacturing and outdoor installations often call for higher levels of environmental protection to keep their products or equipment safe.
Component Standards
Every industrial control panel is made up of several certified components including:
- Circuit breakers that can be swapped out easily\
- Contactors which have undergone rigorous testing\
- Relays that work in perfect harmony\
- Power supplies that are rock solid reliable\
- PLCs( programmable logic controllers) to get the job done\
- Terminal blocks that secure all the cables\
- Motor starters which are tried and true\
- Safety relays that prevent accidents
By using tried and tested components from established manufacturers you can rest assured that your panel will be reliable and a breeze to maintain over its lifespan
Functional Safety Standards
Some applications require more than just standard control functions.
When machinery poses a higher risk, standards such as IEC 62061 or ISO 13849 may need to be adhered to.
These standards cover safety-related control systems which include things like:
- Emergency stop systems so you can shut down quickly\
- Safety interlocks to prevent accidents\
- Light curtains to avoid a moving component\
- Two-hand controls to give you a secure grip\
- Safety PLCs which can handle complex operations
The required Performance Level (PL) or Safety Integrity Level (SIL) depends on the machine’s risk assessment.
Factory Acceptance Testing (FAT)
Just building a compliant control panel is only half the battle.
Before shipment, many industrial control panels undergo Factory Acceptance Testing.
Testing usually involves:
- A good old-fashioned visual check over
- A close inspection of the mechanicals
- Tightening all the screws to the correct torque
- Checking for continuity
- Making sure the insulation is up to spec
- Testing every function
- Verifying the PLC software
- Checking out the HMI
- Running I/O tests
- Simulating real-world operating conditions
This thorough testing can spot issues before the panel even reaches site, saving you hours of commissioning time.
Documentation Requirements
A professionally built industrial control panel should come with all the right documentation to get it installed and up and running.
Typical documentation includes:
- Schematics of the electrical layout\
- Wiring diagrams to follow\
- Component layouts for easy assembly\
- Cable schedules so you can get the right ones\
- The Bill of Materials to research any components\
- Test certificates to prove compliance\
- Inspection reports to put your mind at ease\
- Operating instructions for end-users\
- Maintenance guidance for technicians
Having all the right documentation means installers have a much easier job, and future modifications are a breeze
Quality Management Standards
Many leading control panel manufacturers operate under ISO 9001.
Although ISO 9001 doesn’t specify what makes a good control panel, it shows the manufacturer follows documented procedures to cover:
- Buying parts\
- Designing the panel\
- Manufacturing\
- Inspection\
- Correcting mistakes\
- Continuous improvement
This ISO 9001 status can give you extra confidence in the manufacturer’s ability to consistently produce top-notch panels.
Industry-Specific Requirements
Some industries have their own unique standards or customer requirements.
For example:
Food manufacturing
Might call for stainless steel enclosures, hygienic designs and washdown protection to meet food safety regulations.
Pharmaceutical production
Often requires detailed documentation, traceability and validation procedures to ensure compliance with pharma regulations.
Water Treatment
May require the panels to be super resilient, environmentally friendly and have a long lifespan to keep water treatment plants running smoothly.
Marine Applications
Can require vibration resistance, corrosion protection and marine-approved components to withstand the rigours of the sea.
Oil and Gas
May need hazardous area equipment certified for explosive atmospheres to ensure safety in oil and gas operations.
Understand the intended operating environment is just as important as meeting the core electrical standards.
Choosing a Manufacturer That Understands Compliance
When picking an industrial control panel manufacturer, compliance should be a key factor in your evaluation.
Ask them some questions like:
- Which standards do your panels comply with?
- Do you manufacture to BS EN IEC 61439?
- Can you build to BS EN 60204-1?
- Is Factory Acceptance Testing included in your process?
- Can you provide all the necessary documentation?
- Are your panels individually tested?
- Do you hold ISO 9001 certification?
- Can you support a custom design?
- Have you worked within our industry before?
A seasoned manufacturer should be able to tell you how they achieved compliance, rather than just stating that the standards were followed.
Common Misconceptions
“All control panels are built to the same standard.”
Nope, the standards and testing requirements vary depending on what you’re using the panel for, the environment it’ll be in, and the customer’s requirements.
“Standards only matter for big manufacturers.”
Even small machines need to meet applicable safety requirements. Compliance is just as important for one-off bespoke panels as it is for high-volume production.
“Buying cheap will save you money in the long run.”
Panels built without proper engineering standards can lead to costly downtime, modifications and safety concerns later down the line.
Industrial control panel standards exist to improve safety, reliability and long-term performance. From BS EN IEC 61439 and BS EN 60204-1 to UKCA requirements, EMC considerations and comprehensive Factory Acceptance Testing, each standard plays an important role in building equipment that can operate safely in demanding environments.
When specifying a new control panel, understanding these requirements helps ensure you’re investing in equipment that will perform reliably today, and won’t give you any headaches when it comes to maintenance, compliance or operational efficiency. Working with a seasoned UK manufacturer that knows these standards inside out from the design stage to final testing can make all the difference to the success of any automation or electrical engineering project.
