Organizing Your Control Panels
You can have the cleanest, most carefully wired control panel in the world but if your signals are glitchy or unreliable, chances are you’re fighting an invisible enemy: electrical noise. Noise problems usually happen when low-level analog or communication signals run too close to high-power wiring. The result? Lost data, false readings, and troubleshooting headaches. That’s why shielding and routing aren’t just about neatness, they’re about performance, reliability, and even safety.
Why Noise Matters
Electrical noise is subtle, but its impact is huge. Inconsistent signals can cause PLCs to misread data, protective devices to trigger incorrectly, or machines to shut down without warning. For critical systems, that translates to costly downtime and unnecessary repairs. The good news: a few best practices in wiring, shielding, and cable management can eliminate most noise-related issues before they start.
Best Practices for Shielding and Routing
- Shielded Cables
- Use shielded cable for analog signals or communication lines.
- Ground the shield at one end only (typically at the panel chassis) to prevent ground loops.
- Never tie shields to signal ground, always use chassis ground.
- Power vs. Signal Separation
- Run power and signal cables in separate ducts or conduits.
- If they must cross, do so at a 90° angle to minimize interference.
- Inside the Panel
- Use wire duct to keep runs organized and seriveable.
- Label wires at both ends for easy troubleshooting.
- Follow colors codes: blue = DC negative, brown = DC positive, green/yellow = ground.
- Terminate wires with ferrules or proper ends, never bare wire into terminals.
- Outside the Panel
- Route cables through strain reliefs or glands to prevent pulling.
- Use liquid-tight flex conduit for moving parts or wet environments.
- Keep AC power and control signals in separate conduits.
- Install junction boxes on long runs to simplify pulling and mainenance.
- Support all cable runs, never leave wires sagging.
Electrical noise may be invisible, but its effects are very real. By shielding correctly, separating power and signal wiring, and using proper cable management inside and outside the panel, you create a system that’s easier to maintain and far more reliable. Do it right the first time, and you’ll avoid the headaches of chasing down noise-related issues later.
Transcript From Video:
[0m:00s] Hey, I’m Mitchell. Welcome to another video in the RSP Education Series. Ever had a perfectly wired control panel that still sends glitchy signals or loses data? It might not be your devices. It’s probably noise. When cables carry low-level analog or communication signals near high power lines, things can get messy fast. That’s why shielding and routing aren’t just about being tidy. They’re about performance, safety, and reliability. In this video, we’re going to cover the best real-world practices for beating electrical noise before it beats you. If you like this content and want more educational videos, like and subscribe. This video is for educational purposes only. Consult a professional for your application. RSP Supply is not liable for any misuse of this information. With that said, let’s dive right in.
[0m:56s] Shielding and routing are key to avoiding electrical noise. When you’re running long cables, especially for analog signals or communication lines, they can pick up interference from nearby motors or power wiring. Shielded cables help prevent this. Only ground the shield at one end, usually at the panel, to avoid ground loops. Use the drain wire and tie it to the chassis ground, not the signal ground. Never connect both ends of the shield unless you’re certain it’s needed. Keep power and signal cables in separate ducts or conduits, and if they have to cross, do it at a 90-degree angle to minimize interference.
[1m:42s] Inside your panel, cable management matters. Use wire ducts to keep things clean and easy to service. Label every wire at both ends so anyone working on the panel can quickly identify connections. Follow color codes: blue for DC negative, brown for DC positive, and green or yellow for ground. Use ferrules or proper terminal ends instead of inserting bare wires into terminals. This improves reliability and makes maintenance safer.
[2m:11s] For cables leaving the panel, always use strain reliefs or cable glands to prevent pulling. In areas with movement or moisture, use liquid-tight flexible conduit. Keep AC power and control signal cables in separate conduits to reduce noise and prevent electrical issues. If the cable runs are long, install junction boxes to make pulling and troubleshooting easier. Always support cable runs properly to prevent sagging, which can cause wear and signal issues.
[2m:41s] The key takeaway is that electrical noise is invisible, but its effects are not. Shield your cables and ground them properly at one end. Keep power and signal wires separated, and when they do cross, make it perpendicular. Inside your panel, stay organized with wire ducts, clear labeling, and correct color coding. Outside, use appropriate conduit, strain reliefs, and junction boxes, and support every cable run. When you do these things right, your signals stay clean, troubleshooting stays easy, and your system runs reliably. Stay tuned, because we’re just getting started making your control panels bulletproof. For hundreds of thousands of other industrial automation products, visit rspsupply.com, the internet’s top source for industrial hardware.