US Systems: Your Full-Service Panel Shop

At US Systems, we pride ourselves on being a full-service panel shop with a team of highly skilled industrial controls engineers ready to meet your every need. Our experts are equipped to design, build, and support control panels that keep your operations running efficiently and effectively.

Our Expertise:

Our industrial-duty control panels are designed to automate much of your processes, ensuring your system operates smoothly with minimal downtime. These panels are built to meet the specific needs of your application and can include a variety of features to enhance functionality and reliability.

Key Features of Our Control Panels:

• NEMA-Rated Panels: We offer panels that meet various NEMA ratings, providing the appropriate level of protection for your environment.
• Disconnect Switch: Ensures safety and quick power disconnection when needed.
• Primary Circuit Protection: Protects your system from electrical faults and ensures operational safety.
• Industrial-Duty Buttons, Selector Switches, and Door Devices: Robust components designed for long-lasting performance in industrial environments.
• PLC – Programmable Logic Controller: Essential for automating and controlling your processes with precision.
• Motor Starters: Safely start and stop motors, reducing wear and extending their lifespan.
• HMI – Human Machine Interface: Provides an intuitive interface for operators to interact with the control system.
• LED Indicator Lights: Clearly display the status of various system components for easy monitoring.
• Variable-Speed Controls: Allow precise control of motor speeds to optimize performance.
• Touchscreen: Enhances user interaction with a modern, responsive interface.
• Remote Networking Capability: Enables remote monitoring and control of your system, increasing flexibility and convenience.
• Data Collection: Collects and analyzes data to improve system performance and identify areas for improvement.

Custom Solutions:

In addition to our standard features, we offer customization options to meet your unique requirements:

• Exhaust Fan: For enhanced ventilation and cooling.
• Extreme Cold or Heat Applications: Designed to withstand harsh environmental conditions.
• Portable Units: Available for applications requiring mobility and flexibility.
• Particulate Monitor: Monitors the clean side for particulates, ensuring air quality.
• Support Lugs and Optional Legs: Provides additional stability and support.
• Explosion Mitigation and Venting: Essential for applications with explosion risks.
• Pressure Transmitter: Monitors and transmits pressure data for improved control.
• Power Options: Choose between 24VDC or 120VAC to suit your needs.
• Special Requirements: Have unique needs? We custom-design panels to your specifications.

Click here to download our Automation Guide

Types of Control Panels

At US Systems, we’re dedicated to crafting top-quality industrial control panels that cater to a wide range of applications. Here are the various types of panels we offer, along with a detailed explanation of their functions and features:

1. Motor Control Center (MCC)

Motor Control Centers (MCCs) are essential for managing multiple motors from a centralized location. They contain power distribution busbars and mounting locations for motor controllers. Each motor controller includes:

• Contactor or Motor Starter: Initiates and stops the motor.
• Overload Relay: Protects the motor from overheating and electrical overloads.
• Circuit Protection Devices: Such as circuit breakers and fuses, ensuring safety and preventing damage.
• Power Disconnect Switch: Provides a secure method for isolating power.

Additionally, MCCs can house other components like:

• PLCs (Programmable Logic Controllers): For automation and control.
• VFDs (Variable Frequency Drives): To regulate motor speed and efficiency.
• Pushbuttons and Selector Switches: For manual control.
• Indicator Lights: For status monitoring.
• Metering Devices: To measure electrical parameters.

MCCs ensure efficient and safe control of multiple motors, making them ideal for industrial applications where centralized control is paramount.

2. PLC Control Panels

PLC Control Panels house Programmable Logic Controllers (PLCs), which are industrial computers designed to:

• Receive Inputs: From devices like valves, scales, motors, and sensors.
• Send Outputs: To control various elements of the process.
• Distribute Power and Protect Circuits: Ensuring the electrical integrity of the system.

These panels may also include:

• Ethernet Switch: To connect the PLC to a computer network, HMI, or other networked devices, allowing for seamless communication and control.
• HMI (Human Machine Interface): For operators to interact with the PLC.

PLC Control Panels are vital for automating processes, enhancing efficiency, and ensuring precise control.

3. VFD Control Panels

Variable Frequency Drive (VFD) Control Panels are designed to:

• Vary Input Frequency and Voltage: To control motor speeds.
• Control Motor Ramp-Up and Ramp-Down: During starting and stopping to prevent wear and tear.
• Improve Efficiency and Reduce Energy Consumption: By matching motor speed to process requirements.

These panels can house:

• Single or Multiple VFDs: Depending on the application.
• Power Distribution Components: To manage power flow.
• Circuit Protection Devices and Motor Protection Devices: For safety.
• Harmonic Filters and PLCs: For additional functionality and control.

VFD Control Panels are crucial for applications requiring precise motor speed control and energy efficiency.

4. HMI Panels – Operator Stations

HMI Panels feature displays that provide visual representations for operators to:

• Interact with the System: Execute commands and monitor processes.
• Standalone Enclosures or Integrated Designs: Can be placed near machines or within control panel doors.
• Intuitive Interface: For real-time monitoring and control.

HMI Panels enhance operator interaction with the control system, improving usability and process oversight.

5. Motor Starter Panels

Motor Starter Panels are equipped with:

• Electromagnetically Operated Devices: To start and stop motors.
• Selector Switches or Pushbuttons: For motor control.
• Circuit Protection and Power Distribution: Ensuring electrical safety.
• Power Disconnect Switch: For secure isolation.

These panels protect motors from electrical faults and allow for safe and efficient operation.

6. Pneumatic Control Panels

Pneumatic Control Panels house components that:

• Make Up Control Logic: For pneumatic systems.
• Direct Air Through Components: To determine control outputs.

These panels are essential for applications involving air-powered systems, providing reliable and efficient control.

Why Choose US Systems:

• Customization: We tailor our control panels to meet your specific application needs, ensuring optimal performance.
• Quality Components: We use industrial-duty components designed for durability and reliability, ensuring long-term operation.
• Comprehensive Support: From design to installation and maintenance, we provide full support to ensure your system operates seamlessly and efficiently.

At US Systems, our commitment to excellence ensures you receive the best control panels for your industrial needs. Contact us today to discuss how we can enhance your operations with our superior control panels!

What is an Industrial Control Panel?

An industrial control panel is a critical component in the world of automation and process control, serving as the brain of industrial machinery and systems. These panels are assemblies of electrical devices that manage and regulate the operations of equipment and machinery within industrial settings. Let’s delve into the details to understand the significance and functionality of industrial control panels.

Components of an Industrial Control Panel:

1. Power Distribution Devices:
   • Circuit Breakers and Fuses: These components protect the system from overcurrent conditions, preventing damage to equipment.
   • Busbars: These metallic strips or bars conduct electricity within the panel, distributing power to various devices.
2. Control Devices:
   • Programmable Logic Controllers (PLCs): These industrial computers receive input signals from sensors and other devices, process the data, and send output signals to control equipment.
   • Relays and Contactors: Electromagnetic switches used to control high-power devices like motors and heaters.
   • Motor Starters: Devices that provide the necessary current to start and stop motors, often incorporating overload protection.
3. Human-Machine Interface (HMI):
   • Touchscreens and Displays: These interfaces allow operators to interact with the control system, monitor processes, and execute commands.
   • Pushbuttons and Selector Switches: Simple input devices for manual control of machinery.
4. Protection and Safety Devices:
   • Overload Relays: Protect motors from overheating by disconnecting power if current exceeds safe levels.
   • Disconnect Switches: Enable safe isolation of electrical power during maintenance or emergency shutdowns.
5. Communication Devices:
   • Ethernet Switches and Routers: Facilitate communication between the PLC and other networked devices, ensuring seamless data exchange and control.

Functions of an Industrial Control Panel:

1. Automation and Control: Industrial control panels automate processes by receiving input data from sensors, processing it through the PLC, and sending commands to actuators and other devices. This automation enhances efficiency, accuracy, and consistency in industrial operations.
2. Monitoring and Diagnostics: These panels enable real-time monitoring of equipment and processes. HMIs display crucial information, such as temperature, pressure, and motor speed, allowing operators to make informed decisions and identify potential issues early.
3. Safety and Protection: Control panels incorporate multiple safety features to protect both equipment and personnel. Overload relays, circuit breakers, and disconnect switches ensure that machinery operates within safe parameters and can be quickly shut down in emergencies.
4. Data Collection and Communication: Modern industrial control panels are equipped with communication devices that collect and transmit data to central monitoring systems. This data can be used for performance analysis, predictive maintenance, and process optimization.

Applications of Industrial Control Panels:

Industrial control panels are used across various sectors, including manufacturing, energy, water treatment, and transportation. They play a pivotal role in:

• Assembly Lines: Coordinating the movement and operation of machinery.
• Chemical Processing: Regulating the flow of materials and controlling reactions.
• Energy Management: Monitoring and controlling power distribution systems.
• HVAC Systems: Automating heating, ventilation, and air conditioning processes.

Programmable Logic Controllers

Programmable Logic Controllers (PLCs) are the cornerstone of modern industrial automation. These rugged digital computers are designed to control manufacturing processes, machinery, and various automated systems. Here’s an in-depth look at what PLCs are, how they work, and their significance in the industry.

What is a PLC?

A Programmable Logic Controller (PLC) is an industrial digital computer that has been ruggedized and adapted for the control of manufacturing processes, such as assembly lines, robotic devices, or any activity that requires high-reliability control and ease of programming and process fault diagnosis.

Key Components of a PLC:

1. Central Processing Unit (CPU):
   • The brain of the PLC that executes control instructions based on the program loaded into its memory.
   • Manages communication with other devices and performs diagnostics.
2. Input/Output (I/O) Modules:
   • Input Modules: Receive signals from sensors and other input devices (e.g., switches, sensors).
   • Output Modules: Send control signals to actuators and output devices (e.g., motors, valves).
3. Power Supply:
   • Converts incoming power to the voltage levels required by the PLC and its components.
4. Programming Device:
   • Used to create and load the control program into the PLC. This can be a dedicated console or a computer with PLC programming software.

How PLCs Work:

1. Input Scan:
   • The PLC reads the status of input devices connected to its input modules.
2. Program Execution:
   • Based on the input status, the PLC executes the control program stored in its memory. This program is typically written in a specialized programming language (e.g., Ladder Logic, Function Block Diagram).
3. Output Scan:
   • After processing the program, the PLC updates the status of its output devices by sending signals through its output modules.
4. Communication:
   • Modern PLCs can communicate with other PLCs, computer systems, and smart devices, enabling advanced control and data exchange.

Applications of PLCs:

1. Manufacturing:
   • Controlling machinery on factory assembly lines, coordinating tasks, and ensuring efficient operation.
2. Building Automation:
   • Managing HVAC systems, lighting, and security systems in commercial buildings.
3. Process Control:
   • Monitoring and controlling continuous processes such as chemical manufacturing, water treatment, and oil refining.
4. Material Handling:
   • Controlling conveyor belts, sorting systems, and automated storage and retrieval systems.

Advantages of Using PLCs:

1. Reliability:
   • Designed to withstand harsh industrial environments, including extreme temperatures, dust, and vibration.
2. Flexibility:
   • Easily reprogrammable to adapt to changing process requirements without needing extensive rewiring.
3. Scalability:
   • Capable of controlling a few inputs and outputs to thousands, making them suitable for small to large-scale applications.
4. Real-time Processing:
   • Can handle complex processes in real-time, ensuring timely and accurate control.
5. Diagnostics:
   • Built-in diagnostic capabilities help detect and troubleshoot issues quickly, minimizing downtime.

Conclusion: