Panel construction with redundant power supply & UPS integration
- Custom panel construction
- Reliable power supply
- Fully tested
Reliable panel construction with redundant power supply
Panel construction with redundant power supply offers companies a solution to keep processes stable in the event of a power failure or malfunction. This approach is suitable for organizations that require continuity, safety and reliable control. By duplicating power supplies or using UPS integration in the control cabinet, critical systems remain functional. It is a widely used technique in sectors such as mechanical engineering, logistics, food and water management. Gerbin Control designs and builds these control panels according to relevant standards and provides clear schematics, extensive testing and professional delivery.
Paneelbouw Pioniers voor Machinebouw
Met de precisie van een horlogemaker en de souplesse van een acrobaat, zet Gerbin Control zich in voor het creëren van maatwerk elektrotechnische panelen voor de machinebouw. Als veerkrachtige speler in de paneelbouw, schakelen we snel, zonder in te boeten op kwaliteit of duurzaamheid. Stap in onze wereld van innovatie en ontdek hoe we uw machinebouw-projecten naar een hoger niveau kunnen tillen.
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What is panel construction with redundant power supply
Panel construction with redundant power supply focuses on realizing control panels that continue to function in the event of failure of a primary power source. By duplicating power supplies or applying UPS integration in the control cabinet, the installation continues to run stably and safely. Redundant power supply panel construction is used primarily in processes where availability is a hard requirement, such as machine controls, transportation systems and critical infrastructure. The combination of hardware engineering, safe layout, correct cabling and clear schematics in EPLAN P8 forms the basis for a reliable solution.
UPS integration in a control cabinet provides additional security. A UPS captures power loss and gives systems enough time to continue running in a controlled manner. This increases the operational reliability of PLCs, HMIs and sensor networks working with protocols such as Profinet, Modbus TCP or OPC UA.
Important standards and guidelines
NEN-EN 61439
This standard applies to distribution devices and provides the framework for design, construction and testing. In panel building with redundant power supply, it is the basis for safe construction, selectivity and heat management.
NEN EN 60204 1
Machine controllers must comply with this standard for electrical safety and proper integration of components. This is relevant when redundant power supplies or a UPS become part of a machine panel.
NEN 1010
This standard covers low-voltage installations and applies to situations where panels are integrated into wider installations. Consider power supplies, cable selection and protections.
ATEX compliant ATEX 114
For installations in hazardous areas, redundant power supplies can be used in explosion-proof cabinets. Here the design must conform to ATEX 114, depending on the zone and the medium gas or dust.
PL and SIL methodology
When the redundant power supply can directly affect a safety function, the PL or SIL methodology can be applied according to EN ISO 13849 1 or EN IEC 62061. This methodology is used but not positioned as certification.
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Applications in industry
Redundant power supply and UPS integration occur in a variety of industries. Machine builders use it to keep critical shafts and sensors stable. In water management, it prevents shutdowns of pumps and valves when power is lost. In logistics and robotics, communications remain intact so systems do not generate error messages. Reliability also plays a central role in food, climate systems, bulk handling and vacuum technology. Wherever processes are controlled continuously, there is a need for a stable panel design with dual power supply.
Advantages of panel construction with redundant power supply
The biggest benefit is higher availability. Outages are minimized and processes keep running. Other benefits include:
- Better protection of PLC and HMI
- Less interference with voltage drop
- Higher efficiency of critical facilities
- Safe feeding of sensors and actuators
- Greater certainty for operators and maintenance
UPS integration control cabinet solutions additionally provide controlled shutdown or temporary bridging in the event of mains power loss. This prevents data loss and damage to components.
The process from design to commissioning
Gerbin Control starts with a technical design based on specifications, environment and desired autonomy. Hardware engineers work out the design in EPLAN P8, including cabinet layout, power distribution and selectivity. This takes into account heat dissipation, IP value, cable runs and separation of AC and DC circuits.
During panel construction, power supplies, UPS systems and protections are assembled according to NEN EN 61439 and NEN EN 60204 1. Field wiring and connection of industrial protocols are carefully performed. Construction is followed by a FAT with functional tests, load tests and verification of all safety aspects. At commissioning, everything is checked, tested and delivered with declaration of conformity and test report.
Years of experience in the field of industrial automation
Efficiency and reliability in industrial automation
With Gerbin Control as your partner, you benefit from several specific advantages. We strive for reduced Total Cost of Ownership (TCO) and offer electrical components that meet the highest standards. In addition, we combine flexibility with competitive pricing, increase the efficiency of your systems and machines, and have an international network and UL/CSA certification.
Gerbin Control as your partner for panel construction with redundant power supply
Gerbin Control supports companies in developing and building control panels with redundant power supply and integrated UPS solutions. Thanks to our expertise in panel construction, hardware engineering and execution according to NEN EN 61439, we deliver reliable systems for sectors such as machine construction, logistics, water management and climate control installations. For international projects, we can build panels according to UL 508A and provide complete test reports and declarations of conformity. Our specialists supervise the entire process from design to FAT, SAT and commissioning. Want to know what this means for your project? Contact us for specific technical advice.
Frequently asked questions about Panel construction with redundant power supply and UPS integration
When to choose redundant power supply in panel building
Redundant power supply is used when an installation must not fail in the event of failure or loss of voltage. Think of processes that must run continuously, such as pumps, robots, transport systems or machine controls. By applying dual power supplies or UPS integration, the panel continues to function even when one source fails. This increases operational reliability and prevents damage or downtime. The choice depends on the criticality of the process, the environment and the desired availability.
What is the difference between redundant power supply and a UPS
Redundant power supply consists of two or more power supplies that can take over from each other. The system continues to operate when one power supply fails. A UPS provides temporary emergency power in the event of grid voltage loss and offers controlled shutdown. Redundancy prevents component failure within the panel while a UPS absorbs voltage loss from the grid. In many projects, both are combined for maximum reliability.
How to determine the autonomy of a UPS
The required autonomy of a UPS depends on the load, the duration of critical processes and the time operators need to intervene safely. When determining autonomy, the total power draw of PLCs, HMIs and communication modules is considered. Startup currents and operating temperature are also taken into account. Correct sizing prevents unexpected shutdowns and extends the life of battery modules.
Can you integrate a UPS into an existing control cabinet
In many cases, it is possible to add a UPS to an existing control cabinet, provided adequate space, ventilation and safe cable routes are available. An engineer assesses the load, heat generation and incorporation of protections. Sometimes a partial reconfiguration of the cabinet is required to meet standards. Testing the complete circuit after integration is also important to ensure stable operation.
What standards apply to panel construction with redundant power supply
For panel building with redundant power supply, NEN EN 61439 for distribution devices and NEN EN 60204 1 for machine controllers apply in particular. For low-voltage installations, NEN 1010 can be relevant. In hazardous areas, the cabinet must meet the requirements of ATEX 114, depending on zone and application. When a safety function is powered, the PL or SIL methodology can be used. These standards ensure safe assembly, correct protection and reliable operation.
