Designing Control Panels for Safety and Maintainability

As industrial automation systems become increasingly complex, the design of control panels necessitates a more thoughtful approach. Without close attention to ergonomics, panels can become cluttered and confusing, resulting in safety hazards, operational errors, and prolonged maintenance delays. To avoid these problems, designers must prioritize the human factor to help ensure panels are intuitive to operate and easy to maintain.

This article provides a brief overview of the challenges associated with control panel design. It then introduces a suite of solutions from Panduit and shows how they work together to create safer, easier-to-maintain control panels that support reliable system performance.

Why cable management systems matter

Many of the usability challenges within a control panel stem from wiring issues. Common issues include unclear component labels, tangled wiring, and poor access to critical areas.

These issues can be best addressed with a holistic approach that uses comprehensive cable management systems, such as those offered by Panduit. With a variety of components that are designed to work together, including labels, wire ducts, cable ties, and cable mounts, these systems provide clean, secure cable management that supports smooth installation and reliable operation.

Organizing and protecting cables with wiring ducts

Wiring ducts are foundational elements of a well-organized control panel. They provide a structured method for routing and protecting cables, helping technicians understand the overall layout and reducing the risk of accidental disconnections.

These benefits are evident in the Panduct Type F wiring duct family. This product line features a “finger and slot” design, with alternating solid sections (fingers) and open spaces (slots) along the duct sidewalls. The slots are closely spaced at 0.5 inches (in.) to facilitate tidy routing to high-density terminal blocks and tightly-packed components.

The slots in this family are only 0.2 in. wide, providing a snug fit around outbound cables, and feature a protrusion midway down the finger that helps retain wires. This double-restricted design reduces the need for cable ties and wiring duct covers, simplifying installation and maintenance. For situations requiring larger cable exits, individual fingers or larger sidewall sections can be easily removed thanks to integrated scorelines.

The family ranges in size from the 1.25 x 3.13 in. F1X3LG6 (Figure 1) to the 4.25 x 5.1 in. F4X5LG6. These options enable the family to address compact control panels where space is limited, as well as larger installations that require the management of complex cable bundles.

Figure 1: The F1X3LG6 member of the Type F wiring duct family measures 1.25 x 3.13 in. (Image source: Panduit)

Matching covers, such as the C4LG6 (Figure 2) at 4 in. wide, help conceal and protect rarely accessed cables, reducing the risk of accidental disturbances.

Figure 2: The C4LG6 cover for the Type F wiring duct family measures 4 in. wide. (Image source: Panduit)

All Panduct Type F ducts are constructed from lead-free PVC and meet RoHS, UL, CE, and CSA requirements. They are UL94V-0 rated for flammability, providing consistent safety and performance across the entire product range.

Using cable ties to secure and organize cable bundles

Cable bundling is crucial for maintaining a safe and intuitive control panel layout. Proper bundling not only enhances visual clarity but also reduces the risk of accidental disconnections, abrasion, and mechanical strain.

When selecting cable ties, designers must consider factors such as environmental exposure, tensile strength requirements, and material compatibility with other panel components. Compliance with industry standards, such as UL 62275 for cable management systems, also plays a crucial role in ensuring long-term reliability and safety.

Panduit offers a wide range of cable ties to suit various requirements. Two families, the Pan-Ty PLT Series and the Dome-Top Barb Ty BT Series, illustrate the breadth of options available. Both families are offered in multiple sizes and materials to accommodate different bundle diameters and environmental exposures. The primary distinction between them lies in their locking mechanisms.

Pan-Ty cable ties use an integral plastic locking head, a mechanism familiar to many installers. An example is the PLT2I-M (Figure 3). Designed for indoor use, the PLT2I-M is made from Nylon 6.6 and features a curved tip for easy handling and fast installation. It supports bundle diameters up to 2.0 in. and is suited to compact and space-constrained control panel layouts.

Figure 3: The PLT2I-M features an integral plastic locking head. (Image source: Panduit)

For applications requiring enhanced strength, Dome-Top cable ties provide an alternative. These ties, including the BT4S-M0 (Figure 4), feature a stainless steel locking barb that delivers infinite adjustability and superior holding strength. The BT4S-M0 is constructed from UV and weather-resistant black Nylon 6.6, making it suitable for outdoor environments. It accommodates bundle diameters up to 4.0 in. and incorporates smooth, rounded edges to protect cables and improve installer comfort.

Figure 4: The BT4S-M0 cable tie features a stainless-steel locking barb. (Image source: Panduit)

To streamline installation and ensure consistent tensioning of larger ties, Panduit recommends the GTH-E cable tie gun (Figure 5). It improves installation quality by cutting ties flush and eliminating sharp edges that could damage neighboring cable bundles. It also aids ergonomics by minimizing worker fatigue and reducing labor time.

Figure 5: The GTH-E cable tie gun streamlines the installation process. (Image source: Panduit)

Anchoring cable bundles with cable tie mounts

Cable mounts provide secure anchor points for cable ties, ensuring that the bundles remain firmly in place. They are especially useful where cables need to exit a duct and run to their final connection point, helping maintain a tidy layout and supporting long-term reliability.

Choosing the right cable mount involves assessing the panel environment, expected mechanical stress, and installation preferences. Adhesive-backed mounts are ideal for retrofits or space-constrained areas where drilling is not feasible, while screw-mounted options offer superior load-bearing capacity and vibration resistance.

Panduit offers a range of cable tie mounts in various sizes, materials, and fastening methods to meet diverse mechanical and environmental requirements. One representative option is the ABMM-A-C (Figure 6). Made of ABS plastic, it features a four-way entry that simplifies cable tie positioning and installation. This mount is designed for lighter loads and uses a rubber-based adhesive for attachment, making it well-suited for applications where drilling or mechanical fastening is impractical.

Figure 6: The ABMM-A-C cable tie mount features four openings for flexible mounting. (Image source: Panduit)

For higher load requirements or areas where maximum stability is essential, designers can opt for a mechanically fastened alternative, such as the TM3S10-C (Figure 7). This mount is secured using a #10 (M5) screw and is made from durable Nylon 6.6, making it suitable for more demanding environments.

Figure 7: The TM3S10-C cable tie mount can be screwed into place for rugged installations. (Image source: Panduit)

Addressing safety and compliance issues with clear labeling

Clear and durable labeling is essential for ensuring safe operation and efficient maintenance of control panels. Proper identification of wires and components reduces the risk of errors, supports compliance with industry standards, and speeds up troubleshooting during maintenance activities.

In many industries, clear labeling is not only a best practice but also a regulatory requirement. Standards such as NFPA 79 mandate proper identification of control circuits to prevent accidents and ensure safe operation, underscoring the need for durable, legible labels.

Panduit offers a range of labeling solutions specifically designed for the unique challenges of control panel environments. One versatile option is the Turn-Tell labeling system (Figure 8), which includes the R100X150V1T. These labels are designed to rotate around wires and cables, allowing for repositioning to achieve optimal visibility, even in dense or space-constrained layouts. The self-laminating design also provides added durability, protecting printed information from abrasion, moisture, and other environmental hazards.

Figure 8: Turn-Tell labels can rotate around a cable for better visibility. (Image source: Panduit)

For applications where a fixed-position label is preferred, the S100X150VATY (Figure 9) thermal transfer label offers a reliable alternative. This label features a self-laminating design with a white printable zone and a clear tail that wraps around the cable, sealing and protecting the printed area. Measuring 1.0 x 1.5 in., the S100X150VATY is well-suited for medium diameter wires and cables. Its vinyl material offers strong resistance to oils, water, and mild solvents, ensuring that critical identification remains legible over time, even in harsh industrial settings.

Figure 9: The S100X150VATY thermal transfer labels are made of durable vinyl that can withstand harsh conditions. (Image source: Panduit)

To streamline label creation and installation, Panduit offers a comprehensive thermal transfer printing solution with the TDP43ME-KIT (Figure 10). The kit includes the TDP43ME printer, Panduit Easy-Mark Plus Labeling Software, a black hybrid ribbon (RMEH4BL), and essential accessories such as a roll stand, protective case, and a starter roll of S100X150VATY labels. This system enables technicians to produce high-quality, durable labels on demand, ensuring consistency and accuracy across installations.

Figure 10: The Panduit TDP43ME printer kit provides a complete labeling solution, including software, ribbon, and accessories. (Image source: Panduit)

Conclusion

User-centric design plays a critical role in safety and maintainability in modern control panels. The integrated Panduit system, encompassing high-visibility labeling, versatile wiring ducts, secure cable ties and mounts, and ergonomic installation tools, directly addresses these needs. Implementing these solutions leads to control panels that are not only safer and more reliable but also significantly easier and faster to install and maintain.