AutomationDirect has created an extensive portfolio of professional-grade control panel products, tools, and test equipment, all readily available at reasonable cost so that shops can equip their technicians to deliver high-quality results.
By Zach Ganster, AutomationDirect
The “good/better/best” concept is familiar to most people. When it comes to obtaining anything we use in our daily lives, we need to make choices between necessity, performance, price, and even safety. For example, an inexpensive pair of shoes is good enough for walking around the block, but someone tackling a significant mountain hike is more focused on their boot’s grip, comfort and support than they are on price. Similarly, a shade-tree mechanic may get by with a cheap good-enough tool for a one-off job, but a master auto technician will pay for durable high-quality specialty tools they use all the time.
For companies operating an electrical and control panel fabrication and/or assembly shop, superior tools, test equipment, and supplies are essential for ensuring the work is performed correctly. These items are also critical for preserving the safety of those initially building the panels, and those who will work in and around them in the future.
Begin with the Basics
When a company first gets their panel-building capabilities off the ground, they may just have one or two techs fulfilling a variety of roles. Eventually, these shops may grow their staff to encompass several skill levels, similar to other trades. Beginners start off as apprentices, and as each grows in skill they will become a journeyman. Once they gain experience in most aspects of the work, they will become a master. While all levels will use basic hand tools, those with greater experience will use more advanced products and test equipment.
Simple hand tools
All worker levels will rely on basic hand tools like slotted, Phillips, and Torx screwdrivers, and nut drivers. Simple consumer-grade options will provide inferior results. Professional versions of these tools feature precision-ground and machined designs and heat-treating, which closely fit standard fasteners to reduce the chance of slipping out or stripping the fastener head (camout), or marring nearby hardware. Likewise, handles will provide a good ergonomic grip for comfort, even after extended periods of use, and safe torque transfer.
More advanced workers will add insulated versions of these tools to their kit. The handles and shanks of these tools should feature a 1,000V insulation rating, necessary for those trained to work on live equipment, yet they should be slim enough to fit into recessed areas (Figure 1).
Depending on the work task, other specialty screwdriver versions—such as multi-bit, small precision, and heavy-duty chisel screwdrivers—may be needed. One other tool crucial for any control panel shop worker is a calibrated torque screwdriver, which is a much more advanced version of a simple screwdriver. It is required so that technicians can properly tighten wiring terminations in accordance with specifications to provide optimal connection integrity and electrical continuity.
There are many other types of basic hand tools (Figure 2a/b/c). Some examples are:
- Pliers: Long nose, tongue-and-groove, linesman, and many other configurations
- Bit drivers, standard bits, impact bits, and adapters
- Wrenches: adjustable, combination, ratcheting
- Ratchets and socket sets
- Hex keys: fold-out, L-type, T-handle, each in standard- and ball-end
- Hole cutting, knockouts, drill bits, and step drill bits
Figure 2a/b/c: Professional electrical and control panel fabrication staff require high-performance tools to safely perform top-quality work.
It can be tempting to pick up low-cost tools, but quality versions exist because of professional needs and demands for performance, durability, and safety.
Electrician tools
While some control panels may contain mechanical-only components, like hydraulics or pneumatics, most will have some kind of wiring. Wire cutters, wire strippers, and sheathing strippers are used many thousands of times by control panel workers to cut wire to length, and to then strip back the insulation and prepare the conductor for termination. Consumer-grade tools will simply not last in this service.
Expert wire tools will have hardened and sharpened cutting edges, with long-lasting profiles. Wire strippers will be carefully gauged to remove just the insulation without damaging any of the conductors. Workers will appreciate a range of models, with professional-grade options such as:
- Soft-touch, ergonomic designs requiring lower hand force
- Hardened and tempered steel
- Replaceable blades
- Sizes for common solid and stranded conductors, and multi-conductor cable jackets
As shop throughput increases, workers will appreciate more advanced automatic cutting/stripping tools, with an adjustable strip length (Figure 3a/b). This minimizes the time to prepare conductors and maximizes consistency.
Figure 3a/b: Specialty electrical tools such as wire strippers, sheathing strippers, crimpers, cable tie tensioners/cutter, and more help technicians speed up task execution, improve consistency, and lead to overall efficiency improvements.
Many wiring operations require fork, ring, spade, or ferrule connectors to be crimped on to the end of the bare conductor to provide a better mechanical connection with the receiving end. Basic crimping tools are a form of pliers, but most professionals will opt for ratcheting and self-adjusting wire crimping tools to ensure the proper force is applied to the crimp, with inherent leverage to minimize their effort.
One other installation product used heavily throughout control panels is the humble cable tie, available in a wide range of sizes and configurations. While a casual user may simply install these by hand, a professional will prefer a specific cable tie tool to perform this work. This tool will pull the tie to a proper tension and then cut it off cleanly to prevent leaving a sharp exposed edge. Almost every panel worker likely knows the pain of cutting themselves on a poorly trimmed cable tie, and the right tool will eliminate this hazard.
Quality Tools are Fundamental for a Safe and Efficient Shop
The list goes on-and-on, but the theme repeats. Quality tools cost more but are designed for a hardworking lifetime of safe and effective use. Workers can accumulate these tools one at a time from trusted suppliers, or save by obtaining sets.
AutomationDirect’s website and catalog contains an extensive range of professional-grade control panel tools and test equipment, so users can quickly obtain the high-quality items they need at a superior price/performance ratio than is possible from other sources. The AutomationDirect portfolio provides a head start for control panel shops, whether they are just entering the discipline, or if they are growing and better equipping their operation.
All figures courtesy of AutomationDirect and Agape Collaborations, Inc., a Georgia-based industrial automation control systems manufacturing and engineering company with a UL508A control panel shop, https://www.agape-inc.com/manufacturing
About the Authors
Zach Ganster is the Product Engineer for Hand Tools Products at AutomationDirect. He has over 12 years’ experience with control panel products, electrical safety products, and hand tools. He previously worked at a large industrial manufacturing company as a business development manager of electrical safety products. Zach holds a Mechanical Engineering degree from Southern Polytechnic State University and a Masters in Business Administration from Kennesaw State University.