• Electrical Control Panels
  • Electrical Control Panels

The designing of panel is based on the requirements of Customers.

We consider the following aspect while designing a panel :

  • Location : It is very important to know the location to design the panels for :
    • a) Indoor / outdoor application.
    • b) Space available for length and depth & height
  • Whether back access is available for cable termination work /maintenance etc. This helps to reduce / increase the size of panel
  • Cable entry to be top / bottom to fix the location of Bus bar chambers & cable chambers
  • Out going cable sizes for all the feeders is considered for selection of connectors & cabie chambers designing
  • The bus bar calculation for phase, Neutral, Earth, sizing in done considering current rating short circuits rating ambient temperature, future expansion etc.
  • The panel is designed such that all the switchgears & bus bars installed in it shall be accessible for easy maintenance.
  • After freezing the above point, G.A., S.L.D. & control writing drawings are submitted to the client for approval.
  • On the receipt of approved drawings & manufacturing process resumes.
  • Unless & otherwise specified, all the load bearing members are fabricated in two MM thick CRCA sheet and doors, covers & partitions in 1.6mm CRCA sheets
  • The panel's structure is supported by frame 75 X 40 X 6 mm ISMC.
  • All the heavy components like Air Circuit Breaker, changeover switch are supported on the angle iron structure.
  • The incoming raw material is inspected for quality, thickness etc.
  • All our sheets steel is required from reputed suppliers / manufacturers.
  • All sheets cutting is done by power shearing machine to insure good quality.
  • All the bending work is done by 80-tons power press break.
  • All the fabricated sub assemblies such as channels, doors, and covers are inspected for dimensions, right angles, and strainness & diagonals
  • All the fabrication sub assemblies are joint together by arc welding. We verify that a welding electrode give necessary rigidity to structure.
  • The excess welding material is removed by grinder / sander etc.
  • We confirm that all the feeders are as per requirement of the client.
  • We confirm that necessary mounting arrangement is done for switchgears etc.
  Painting / Powder Coating  
  • Seven-tank process is carried out.
  • All the gaps, welding spots, joints are given a coat of m-seal or equivalent finishing material.
  • Two coats of red oxide are applied across the complete structure
  • The Zinc chromate manufacture by reputed companies like Sigma paints are used (This process is carried out for spray painting only)
  • The painted structure doors & covers are oven baked.
  • The painted structure is inspected & fault if any are rectified.
  • Panels are randomly tested as per peel off test.
  • It is verified that the structure is hard & scratch proof.
  • The thickness of paint is not less than 50-60 microns approximately
After pretreatment the job is baked for about 70-80 degree centigrade, which enabled to remove the moister contents.

After baking the jobs & again baked for about 200 degree centigrade to get the required result.
The powder used is of reputed make like Inter phone, Asian Marpole etc.
  Selection of Busbars  
  • All the busbars & busbar supports are designed to withstand necessary short circuit levels the size of the busbar insulator distance between insulator is designed to carry rated currents at 50 degree centigrade ambient with maximum Temperature rise of 30 degree centigrade.
  • Necessary precaution is taken for busbar just including cleaning by sandpaper & application of petroleum jelly for protection against oxidation (for Aluminum busbar only )
  • The number of hole in the busbar is kept to petroleum jelly for is kept to minimum. The loss in using additional cross selection of busbar completeness area.
  • The joint of busbar have sufficient overlaps or additional strips.
  • The busbar supports are usually of SMC & DMC.
  • The complete busbar system is independently supported so that no load Can transferred to switch gear components.
  • The bending of busbar is done using hydraulic machine so that no cracks are developed & deformation is minimum.
  • Suitable spacing is maintained between the busbars
  • The busbars are insolated with the heat shrinkable sleeves.
  • Wherever necessary the busbar is shrouded to avoided the human touch.
  Assembly and Wiring
  • All the bought out components are verified for quality.
  • All the components shall be easily accusable.
  • Adequate space is provide for cable termination.
  • Switchgear component, wires etc. are as per specification of the client.
  • All the controls wires are of 1 sq. mm / 1.5 sq. mm. Stranded Cu. wires.
  • Ferrules at both the ends identify all the wires.
  • All necessary and suitable wiring accessories such as PVC channel grommets are used.
  • All feeders have name plates indicating name, rating & feeders nos.
  • The rubber gasket is used between 2 metal surfaces of doors, covers etc.
  • All the covers & doors shall have earth connection.
  Testing of Panels
  • The Physical Dimension of Panels Shall match approved drawing.
  • All the doors & enter locks shall operate smoothly.
  • All the doors, covers shall be in perfect alignment .
  • All the components like timers are tested for accuracy.
  • Insulation resistance test is carried out using 1000V.DC insulation tester.
  • High voltage test is carried out using 2.5KV AC H.V. testing kit.
  • All the result are noted is the test certificate.