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#114377 - 02/22/03 07:45 PM Another Scary Control Panel
Webmaster Offline


Registered: 10/07/00
Posts: 3142
Loc: NY, USA
Here's another scary control panel. This was controlling a critical cooling water system for forging and heat treating furnaces. I replaced this system about a year ago with a PLC. As you can see it was a bear to try to work on.


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#114378 - 02/22/03 09:48 PM Re: Another Scary Control Panel
circuit man Offline

Registered: 11/05/01
Posts: 287
Loc: saluda,s.c.
what a mess! now that's scary. can't tell where anything goes. this is supposed to be a neat & workman like manner. don't think so!

#114379 - 02/23/03 08:57 AM Re: Another Scary Control Panel
Mike Wescoatt Offline

Registered: 06/17/01
Posts: 164
Loc: Cedar City, Utah
Although red wire is a nice color, they do make more colors...
When I finish a controller it looks like a rainbow inside so you can tell what goes where even if the label should fall off. It also makes tracing wires quick when they enter a bundle. I have probably 40 different color combinations of
MTW wire in stock...
Oooh... look at the pretty colors...
Mike Wescoatt

#114380 - 02/23/03 03:34 PM Re: Another Scary Control Panel
sparky Offline

Registered: 10/18/00
Posts: 5545
no din rail, wire channel, or so much as a tie wrap?

#114381 - 02/24/03 03:14 AM Re: Another Scary Control Panel
Trainwire Offline

Registered: 03/15/02
Posts: 364
Loc: Strasburg,PA,USA
IMHO it looks like it started off nice and neat, and somewhere along the line someone needed to add,troubleshoot and undid it.


#114382 - 02/24/03 05:30 AM Re: Another Scary Control Panel
Joe Tedesco Offline

Registered: 10/07/00
Posts: 3325
Loc: Boston, Massachusetts USA
RED is often used for ungrounded ac control conductors at less than line voltage.

This is a common practice when wiring Industrial Machinery.

See NFPA 79 for more on Identification of Colors in Chapter 14.
Joe Tedesco, NEC Consultant

#114383 - 02/24/03 12:38 PM Re: Another Scary Control Panel
MikeW Offline

Registered: 06/03/02
Posts: 39
Loc: Michigan
I agree with trainwire. Often times, a nice neat panel, turns into a rat’s nest when machinery/equipment malfunctions. Sometimes, in industrial setting, it has to be fixed as fast as possible and more often than not there are no prints available. So to troubleshoot the maintenance person starts cutting ty-raps and pulling on wires to see what powers what and where the wires go. When the equipment is back up and running everyone is happy and time is not taken to redress panel as it originally was. The result is a mess as pictured above.

#114384 - 02/24/03 01:39 PM Re: Another Scary Control Panel
Crowbar Offline

Registered: 01/13/03
Posts: 34
Loc: Pittsburgh, PA,USA
Unfortunatly this enclosure started out that bad, it looks a little better since it had been disconnected already and one ball of wiring passing through the box was removed also. Even though only about half the wires were tagged at least the relays were labeled, but the print was yet another disaster. Good thing for the plant that "electrician" doesn't work here anymore.


[This message has been edited by Crowbar (edited 02-24-2003).]

#114385 - 03/04/03 07:24 PM Re: Another Scary Control Panel
spkjpr Offline

Registered: 12/01/00
Posts: 226
Loc: Sedalia,MO, USA
I work around stuff like this all the time. 25 Year old plant and many hands in the panels, some of dubious experience and caring.

#114386 - 03/07/03 04:49 AM Re: Another Scary Control Panel
electure Offline


Registered: 12/24/00
Posts: 4226
Loc: Fullerton, CA USA
I'm sure it didn't start out looking like this mess. Looks like a troubleshooter ended up being a troublemaker.
Red? I modified an amusement park ride at Knott's Berry Farm (So CA) in the late '70s.
We used 31 miles of #16 TFFN for AC control wiring...every inch was red.


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