The design and manufacture of electrical panels forms the backbone of any electrical system, both in industrial and civil environments. These complex devices are engineered to ensure safety, efficiency and full control over power distribution. They can support highly specialised applications, such as electric heating and temperature control systems, which require bespoke equipment to guarantee optimal performance and full compliance with current regulations. Specialised companies like Parma ST, operating in consultancy, distribution and installation of heating cables and leak detection systems, enhance the implementation of efficient, high-performance plant solutions through their expertise and tailored services.
What is an electrical control panel?
An electrical panel, also known as distribution board or switchboard, is the central hub of any electrical installation. From this unit, power is distributed to all connected loads: cables lead to main junction boxes, from which electricity is then supplied to sockets, lighting systems and electrical equipment.
In civil applications, the control panel manages the entire power supply while also providing protection against overheating and preventing accidental electric shocks. Typically housed in a metal or plastic enclosure, it is installed downstream of the electricity meter, often near the building entrance or in another suitable location.
Industrial electrical panels, on the other hand, are significantly larger and more complex, as they must handle much higher power levels. Their design and construction are governed by stringent CEI standards due to the increased operational risks involved.
Types of electrical panels and their functions
The configuration of an electrical panel varies considerably depending on its intended use and application.
Electrical panels’ classification based on technical characteristics
Installation method is one of the first criteria used to classify electrical panels. Flush-mounted panels are integrated directly into masonry walls and are often preferred in industrial settings where space is limited. Wall-mounted panels, by contrast, are more common in civil installations and are typically fixed with anchors, featuring a box-shaped enclosure with a hinged door. Another key distinction concerns the degree of protection. Indoor panels are designed for enclosed environments, while outdoor panels must be protected against water ingress, humidity and adverse weather conditions.
With regard to voltage levels, panels are classified according to the power they manage. There are low voltage systems below 1 kW (typical of civil applications), medium voltage systems ranging from 1 to 30 kW, and very high voltage systems exceeding 150 kW. These are essential in industrial contexts where power demands are significantly higher.
Distribution panels are primarily responsible for supplying and protecting individual circuits, ensuring that electricity is safely allocated across the installation. They are widely used in residential buildings, offices and commercial premises, acting as the central point for power distribution.
Types of electrical panels based on operational function
Automation and control panels are designed to manage mechanised equipment and complex industrial processes. These systems integrate control, regulation and signalling components such as relays, thermostats, control units and monitoring devices. For example, panels used for heating cable systems must supply power to the cables while automatically regulating temperature via thermostats, ensuring optimal conditions in pipes, tanks or surface heating applications.
Machine-mounted control panels are typical in industrial environments and are installed directly on machinery to allow operators to control and manage all functions locally. Their defining feature is the control interface, from which power distribution, command functions and system monitoring are handled.
An even more specialised category includes diagnostic panels, which are used to test and verify the correct operation of equipment, components or wiring. These panels can interface with multiple systems to perform functional tests and identify faults or anomalies.
A final important distinction must be made between panels designed for standard environments and those intended for ATEX-classified areas (explosive atmospheres). In high-risk industrial sectors such as petrochemical, chemical or pharmaceutical industries, electrical equipment must comply with specific certifications to ensure safe operation in the presence of potentially explosive gases, vapours or dust.
Electrical panels’ construction process
The development of an electrical control panel begins with a thorough analysis of the functional and logistical requirements of the operating environment. This includes defining the intended application, evaluating the electrical load, assessing installation conditions and identifying the certifications required by regulations.
In industrial installations involving temperature control—such as maintaining process fluids at a specific temperature or providing frost protection for pipework—this analysis must also consider integration with automation systems and specialised devices.
The next step is the design stage, during which electrical schematics, component sizing and system integration methods are defined. For instance, a panel designed to control self-regulating heating cables requires different design choices compared to one used for constant wattage systems. Self-regulating cables automatically adjust their output based on temperature changes, while constant wattage systems require more precise control through thermostats and regulators.
Assembly, internal wiring and installation must be carried out by qualified professionals with in-depth knowledge of electrical schematics and components. Proper grounding is essential to ensure long-term system reliability, although thorough and regular monitoring remains necessary.
The process concludes with testing and certification. Each panel must undergo functional testing and compliance checks in line with applicable regulations. The technical documentation provided at this stage—electrical diagrams, certificates of conformity and user manuals—accompanies panels throughout their entire operational life.
Essential components and their integration
A complete electrical control panel integrates multiple components, each serving a specific purpose. The main switch allows the entire system to be disconnected from the power supply, ensuring safety during maintenance operations. Thermal-magnetic circuit breakers and residual current devices protect individual circuits against overloads, short circuits and earth leakage.
In automation and control applications, more complex components are required. These include thermostats and temperature controllers for managing electric heating systems, control units that coordinate multiple devices simultaneously, as well as monitoring and alarm systems that signal faults or abnormal conditions. In highly advanced applications such as fluid leak detection, the control panel may integrate dedicated control units that manage sensor cables capable of detecting water, hydrocarbons, acids or solvents with high precision, triggering alarms and emergency procedures when necessary.
Modern solutions also allow electrical panels to be managed through cutting-edge interfaces, ranging from traditional push-button controls to touchscreen displays, as well as Wi-Fi remote monitoring systems that enable plant supervision via smart applications.
Standards and certifications
The construction of electrical panels is regulated by a comprehensive framework of standards designed to ensure safety and reliability. CEI EN 61439-1 and 61439-2 are the main reference standards for low-voltage assemblies, defining general construction requirements, component selection criteria and testing procedures. The CEI 64-8 standard further specifies design and installation requirements for electrical systems as a whole.
For domestic and similar applications, CEI 23-51 provides more specific guidelines that simplify inspection and certification processes. When panels are intended for ATEX-classified environments (with risks associated with potentially explosive atmospheres) or for use outside the EU, additional certifications such as ATEX, EAC or FM are required, confirming compliance with rigorous international safety standards.
Configuration, monitoring, and after-sales support
For electrical panels designed to manage complex systems, such as heating cable installations, this phase also includes configuration of operating parameters, thermostat calibration and verification of overall system performance. These activities require specialised expertise, such as that provided by Parma ST technicians, who offer consultancy and installation services across both civil and industrial sectors.
Commissioning is a critical stage and involves on-site functional testing as well as user training on correct operation and alarm management procedures, where necessary. Qualified after-sales support ensures rapid intervention when required and may include preventive maintenance programmes that extend panels’ operational lifespan and reduce the risk of unexpected failures.
High-performance, efficient systems are achieved through the correct integration of thermal control systems, monitoring devices and custom-designed electrical control panels. Rely on Parma ST’s know-how for a project managed through every stage, from design to installation of cables and components. We ensure optimal system performance with reliable, regulation-compliant solutions. Contact us for a consultation to identify the most suitable system for your operational requirements.