Why Professional Control Panel Design Matters

A well-designed control panel is the foundation of reliable separator automation. Proper panel design ensures safe operation, regulatory compliance, ease of maintenance, and optimal system performance. For industrial separators operating in pharmaceutical, food processing, or biotechnology applications, control panel quality directly impacts production uptime and product quality.

YES-AL Engineering specializes in custom control panel design and fabrication for all major separator manufacturers, including Alfa Laval, ABB, GEA, and others. Our panels integrate seamlessly with existing plant infrastructure while meeting industry standards and regulatory requirements. We have extensive experience with Alfa Laval separator control systems and ABB automation platforms.

Control Panel Design Process

Our systematic approach to control panel design ensures all requirements are met from concept to commissioning:

1. Requirements Analysis

We begin with a comprehensive analysis of your separator application requirements:

• Separator model and specifications
• I/O count and signal types (analog, digital, safety)
• Motor control requirements (bowl drive, feed pump, discharge)
• Communication protocols (EtherNet/IP, Modbus, Profibus)
• Environmental conditions (NEMA rating, washdown requirements)
• Regulatory compliance needs (UL, CE, FDA 21 CFR Part 11)
• Integration with existing plant systems

2. Component Selection

We select components based on reliability, performance, and long-term supportability:

3. Electrical Design

Our electrical design includes comprehensive documentation:

• Single-line diagrams
• Wiring diagrams with wire numbers and terminal designations
• I/O schematics
• Power distribution layouts
• Grounding and bonding plans
• Panel layout drawings
• Bill of materials

4. Panel Layout & Enclosure Selection

Proper panel layout ensures accessibility, maintainability, and compliance with electrical codes:

• Enclosure selection: NEMA 4X stainless steel for washdown areas, NEMA 12 for general industrial use
• Component spacing: Adequate clearance for heat dissipation and maintenance access
• Wire management: Organized wire routing with proper labeling and segregation
• Safety: Proper arc flash labeling and safety interlocks

Fabrication Standards & Quality

Our fabrication process adheres to industry standards:

Standards Compliance

• UL 508A - Industrial Control Panels
• NFPA 70 (NEC) - National Electrical Code
• NFPA 79 - Electrical Standard for Industrial Machinery
• IEC 61439 - Low-voltage switchgear and controlgear assemblies
• CE marking for European installations
• FDA 21 CFR Part 11 compliance for pharmaceutical applications

Quality Assurance

Every panel undergoes rigorous quality checks:

• Component verification against bill of materials
• Continuity and insulation resistance testing
• Functional testing of all circuits
• PLC I/O verification
• HMI screen validation
• VFD configuration and testing
• Documentation review

Specialized Panel Types

Main Control Panels

Central control panels house the primary PLC, HMI, and motor control equipment. These panels typically include:

• Allen Bradley PLC with I/O modules
• PanelView Plus HMI
• PowerFlex VFDs for bowl drive and feed pump
• Safety relay modules
• Power distribution equipment
• Communication modules (EtherNet/IP switches)

Remote I/O Panels

For distributed installations, remote I/O panels reduce wiring costs and improve maintainability:

• CompactLogix or Point I/O modules
• Local power supplies
• Terminal blocks for field wiring
• EtherNet/IP communication

Motor Control Centers (MCCs)

For facilities with multiple separators, MCCs provide centralized motor control:

• Individual starter buckets for each motor
• VFD compartments with proper ventilation
• Bus bar power distribution
• Control voltage transformers
• Ground fault monitoring

Integration Considerations

Modern separator control panels must integrate with plant-wide systems:

SCADA Integration

• EtherNet/IP connectivity for FactoryTalk View SE
• OPC UA servers for multi-vendor SCADA systems
• Tag naming conventions for consistency
• Historical data logging capabilities

MES/ERP Integration

• Batch record interfaces
• Production data reporting
• Maintenance scheduling integration
• Quality data export

Documentation & Deliverables

Complete documentation ensures smooth installation and long-term maintainability:

• As-built electrical drawings
• PLC program documentation
• HMI screen layouts
• VFD parameter lists
• Spare parts list
• Maintenance procedures
• Commissioning checklist

Installation & Commissioning Support

YES-AL provides comprehensive support throughout installation and commissioning:

• Pre-installation site surveys
• Installation supervision
• Field wiring verification
• System startup and testing
• Operator training
• Performance optimization