Why CE Marking Control Panels Matters

When most people think of CE compliance, they either draw a blank, or jump to machinery guards, emergency stops and documentation. Ensuring you design CE compliant control panels and assuring electrical safety is just as important however- and getting it wrong can lead to serious consequences. 

In todays blog, I’ll detail why CE marking control panels is so important, and how you can get it right for your next product design. 

What is A Control Panel?

A control panel within this context is a purposely designed assembly of both electrical and electromechanical components, that are used to control, monitor, and protect both machinery, processes or building systems. 

A control panel usually includes electrical equipment and devices such as over current protection, contactors, relays, PLCs, power supplies, switches, terminals and wiring. 

There are three main types of control panel:

• Automation/Process control, which house control logic and automation hardware that governs how a machine operates,
• Power Control Centres (PCC), which handle distribution, protection and management of electrical power,
• Motor Control Centres (MCC), which manage multiple motors from a central point. 

Legal Background

As you may be aware, CE marking is the legal gateway to placing electrical and electromechanical products on the EU and UK markets. The scope of machines and equipment that must be compliant with CE criteria is vast, and of course includes control panels. 

It’s important to note at this point however that a control panel in isolation does not require CE marking if it is to be incorporated into a wider assembly by a manufacturer before reaching the end user. If it is to be sold to, and put straight into service by the end user, it must be CE marked. 

Applicable Directives

Achieving CE conformity isn’t always straightforward, as the criteria varies according to the applicable design standards relevant to the product in question. So, for example, the standards for an electric bicycle will be different to those for a kettle. 

In the case of control panels, in order to achieve CE compliance, they must conform to the requirements of:

• The Low Voltage directive,
• The EMC directive, (at the discretion of the manufacturer),
• RoHS, if the panel is supplied to the end user. 

Getting It right

Let’s get down to brass tacks/copper tracks. Here’s what you need to know in order to make sure your control panels are CE compliant. 

Design Responsibilities

Getting the design of your control panel right requires a combination of engineering discipline, technical understanding and planning ahead. As a designer, you can’t rely on simply assembling a bunch of CE-marked parts, as the entire assembly must meet the essential requirements of each applicable directive. 

Your key responsibilities involve:

• Choosing compliant and compatible components– they must work safely together within the assembly. 
• Effective segregation– power, control, safety and communication circuits often need to be separated either physically or functionally to avoid EMC issues, and function correctly. 
• Thermal management: designers must determine the expected temperature that will rise within the enclosure and ensure there is adequate means to dissipate it. 
• Correct earthing, bonding and protective measures, aligning with the IEC relevant to control panels, EN 60204-1 (Safety of machinery – Electrical equipment of machines) or EN 61439 (Low-voltage switchgear and control gear assemblies). 
• Safe Operation and Maintenance access, for example via emergency stops, isolation points, and operator devices, which must also be positioned for rapid and intuitive use.

Testing and Verification

It’s one thing to aspire to conform to safety standards. It’s another to prove it. This is why it’s crucial to arrange for your control panel to be tested and verified before it can be CE marked and placed on the market. 

Testing normally includes:

• Functional testing of controls, i.e. start/stop logic, safety interlocks, 
• Protective bonding and continuity checks,
• Insulation resistance and dielectric testing,
• Temperature rise levels,
• EMC assessment.

Technical Documentation

Correctly CE marking control panels relies on, and is proven via, a comprehensive technical file, which demonstrates how the panel meets each and every applicable directive. These are a commonly overlooked aspect of a product design lifecycle yet are a legal requirement in their own right. 

A technical file will typically include:

• Electrical schematics and layout drawings showing wiring, protective devices, component locations and interface points. 
• Bill of Materials (BOM), i.e. a full list of components, including their part numbers and conformity details, which provides traceability and demonstrates that all items used within the design are compliant. 
• Risk assessment of hazards which may cause shock, arc-flash, overheating and EMC interference. 
• Verification and test reports, which may include insulation resistance, continuity testing, functional verification or EMC assessments. 
• Declaration of Conformity (DoC), which is the formal statement that the panel meets all the applicable directives. 
• Instructions and user information, such as installation, operation and maintenance documents. 

Assuring CE Marking Control Panels with Knox Thomas

It’s easy to fall short of CE conformity- whether it’s due to using non-CE marked components, overlooking EMC considerations, compiling poor documentation or inadequate risk assessments, and even not keeping up-to-date with changes to relevant standards. 

Therefore it’s crucial to take a proactive approach to CE marking, rather than reactive; ensuring the criteria are considered early in the design and are accounted for accordingly. 

It’s easy for me to say this, but how do you do this in practice? And what if you’ve already put together your product design and are only now considering the potential compliance gaps? 

The answer is actually simple: you get in touch with us here at Knox Thomas. We’re available to advise on CE marking control panels either at the pre-design stage, to help specify design requirements, during the R&D stage, or even afterwards to review your completed, assembled product and technical file. 

For help navigating the rigours of Control Panel CE marking, and to make sure your machines are both compliant AND safe- contact us today.