Robinson Engineering, Inc.

Wiring a Door full of Pilot Devices

I’ve said it before and I’ll say it again: electrical wiring can be an art. Wiring a door full of pilot devices is an opportunity for great wiring style to really shine, so that’s what we’re going to look at today.

Electrical enclosures and panels are all different (unless they are part of an identical set) so the methodology our lead technician Trace Haskin follows may not be fitting for every circumstance.

Here is the door we’re working with today

Panel with Contactors

Before the major wiring begins:

If there are jumpers between the contacts of one button, wire them first.

  • If there are multiple jumpers needed, cut template wires and make a set so they are all uniform.

Wire Jumpers in Place

Mount the cable tie mounts so you have your route set. Manufacturers may say that the mounts are strong enough to stick by themselves, but it’s good practice to apply a drop of super glue before placing them on the enclosure so they really stay where they should. Also, make sure they are in line left to right and up and down.

Cable Tie Mounts

Use two cable tie mounts right before the transition to the door to make sure the hold is strong enough and doesn’t tear off.

Now the Wiring Begins:

First, route the signal wires from the contacts, following the cable tie mounts to the edge of the door and then give enough leftover to get to where they need to go on the panel (for this panel, Trace left five extra feet of wire)

Signal Wires in Place

Wire all of the signal wires and begin routing with zip ties. Guide the wires so they are uniform, flow well, and aren’t too tight.

Route Wires with Zip Ties

Wire the neutral and power wires. These should follow the same bends as the signal wires. As a side note, the emergency stop always gets its own power wires.

Power wires on Pilot Devices

Make sure that all wires and wire groups fall neatly in line and that bends are clean and fluid. Doing so will set you apart from people who just make wires connect and don’t care how they look.

The finished product:

Wired Control Panel Door

Whew. There’s a lot of work there, but it’s functionally and aesthetically worth it. What is your experience with wiring so many pilot devices on a door? What do you do differently?Leave us a comment to let us know, and check out our other blog posts and videos while you’re at it!

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