A PLC-based electrical control panel is an integrated system that uses a Programmable Logic Controller (PLC) to monitor and control industrial equipment, machinery, or processes. It replaces traditional relay logic with programmable automation.
These panels are used in:
| Incoming Supply Voltage | 415 V AC, 3-phase, 50 Hz (or 230 V AC single-phase) |
|---|---|
| Control Voltage | 24 V DC (PLC, sensors, actuators) |
| Power Supply Unit (SMPS) | Input: 230 V AC → Output: 24 V DC, 5–20 A |
| Short Circuit Protection | MCCB / MCB rated for 10–25 kA |
| Overload Protection | Thermal overload relay / motor protection circuit breaker |
| Grounding | Dedicated copper busbar; earth resistance ≤ 1 Ω |
| Busbar Material | Electrolytic copper (tinned); rated 200–600 A depending on load |
| Earthing | Class D grounding (100 Ω or less), as per IEC 60204-1 |
| PLC Brand | Mitsubishi / Siemens / Allen-Bradley / Delta / Omron |
|---|---|
| CPU Module | 32-bit or 64-bit microprocessor; 0.1 µs instruction cycle |
| Program Memory | 64 kB – 512 kB flash memory |
| Data Memory | 8 kB – 64 kB RAM |
| Digital Inputs (DI) | 8 – 256 channels (24 V DC, sink/source type) |
| Digital Outputs (DO) | 8 – 256 channels (24 V DC transistor or 230 V AC relay) |
| Analog Inputs (AI) | 2 – 16 channels (0–10 V / 4–20 mA) |
| Analog Outputs (AO) | 2 – 8 channels (0–10 V / 4–20 mA) |
| Communication Ports | RS-232, RS-485 (Modbus RTU), Ethernet, USB, Profibus (optional) |
| Scan Time | < 0.1 µs per instruction |
| Expansion | Up to 8 or more I/O modules |
| Programming Software | GX Works (Mitsubishi) / TIA Portal (Siemens) / RSLogix (AB) |
| Battery Backup | Optional lithium cell or super-capacitor |
| Type | TFT Color Touch Screen HMI |
|---|---|
| Display Size | 4.3″ – 10.4″ (typical) |
| Resolution | 480 × 272 px – 800 × 600 px |
| Communication | Ethernet / RS-232 / USB (depending on model) |
| Software | GT Designer (Mitsubishi), WinCC, FactoryTalk, etc. |
| Mounting | Flush-mounted on panel door |
| Design & Assembly Standards | IEC 60204-1, IEC 61439-2, IS 8623 |
