Box for control panel. Photo by E. Wilde, 2003 Aug 16.

After determining the physical space constraints for the control panel, and how it will be mounted, where the wiring will enter the box, etc., CAD drawings are prepared and sent for the customer's OK. In this case, the customer specified the box dimensions and door location so that the box would bolt right to the unistrut on the wall of the car's electrical locker. From the drawings, a large, galvanized steel box is fabricated that will house all of the control panel components. The control panel front will be hinged, with a piano hinge, from the tab on the right (or left, if you prefer) of the box, for easy access to all of the components. Photo by E. Wilde, 2003 Aug 16.

Control panel layout. Photo by E. Wilde, 2003 Oct 14.   The customer specified a carbon steel panel that was laid out, punched for all of the components, painted and striped. In this view, lettering is about to be applied, prior to overspaying the entire panel with clear laquer for protection. A number of different treatments can be used for the control panel marking. Photo by Eric Wilde, 2003 Oct 14.
Here, all of the control panel components are mounted on the panel. The customer supplied some of the components used for generator set controls (an existing control panel was disassembled and reused) and the rest were purchased after consulting with the customer as to their preferences. Pilot lights are long-life diode lamps and switches are industrial type controls or heavy-duty toggles. Photo by Eric Wilde, 2003 Oct 19.   Control panel components mounted. Photo by E. Wilde, 2003 Oct 19.
Control panel wiring in progress. Photo by E. Wilde, 2003 Oct 30.   Wiring of the control panel is in progress. All of the panel wiring was done with #18 or #14 Exane wire, supplied by the customer. The lamp test function was implemented by diodes incorporated into the panel wiring. Photo by Eric Wilde, 2003 Oct 30.
The control panel wiring is shown nearing completion. A large bundle of wire is being formed to the left of the panel, where it will be looped down and back up to an attachment point on the box. This will allow the door to easily hinge open. Photo by Eric Wilde, 2003 Nov 3.   Control panel wiring nearing completion. Photo by E. Wilde, 2003 Nov 3.
Control panel attached to its box. Photo by E. Wilde, 2003 Nov 3.

The completed panel is attached to the box and wiring of the terminal strips on the back of the box has begun. Field wiring will enter through the large hole in the bottom right corner of the box and attach to the control panel terminal blocks. Photo by E. Wilde, 2003 Nov 3.

All control panel wiring completed. Photo by E. Wilde, 2003 Nov 4.

All of the control panel wiring is completed. Three control transformers, to provide power to the panel (Standby, HEP, Gen) and three phase failure relays, in addition to a fuse block for the generator controls, can be seen bolted to the box. The proposed unistrut mounting holes are marked where the customer will field drill them. Photo by E. Wilde, 2003 Nov 4.

Assembled control panel. Photo by E. Wilde, 2003 Nov 4.   The completed control panel is assembled and ready for delivery. Power monitoring and selection for the three sources of power (Standby, HEP, Gen) are at the top. Generator controls are in the middle. Below them are HVAC monitoring lamps and a row of toggle switches for car lighting. The lamp test button is at the bottom. Controls for any and all car functions can be included in your control panel. Photo by Eric Wilde, 2003 Nov 4.
The completed panel, crated and ready for shipping. The customer will install the panel in their car and complete the field wiring. Photo by Eric Wilde, 2003 Nov 16.   Control panel ready for shipping. Photo by E. Wilde, 2003 Nov 16.