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Complete Guide to DCS/PLC Panel Wiring Materials | Explained with Pictures One by One | Indurstrial

Whether you are an Instrumentation Engineer, Electrical Engineer, Automation Student, or Technician, this video will help you understand the essential materials required for Control Panel Wiring, DCS/PLC Installation, and Instrumentation Projects.
✅ Topics Covered in This Video:

DCS & PLC Panel Wiring Materials

Cable Glands, Terminals, Ferrules, and Tags

Wiring Accessories (Lugs, Connectors, Ducts, Sleeves)

Junction Boxes & Termination Accessories

Power Supply & Control Components

Instrumentation Wiring Tools & Consumables

Cable Laying Materials and Earthing Essentials
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Explore each material in detail to enhance your understanding of electrical wiring. Don't forget to like, share, and subscribe for more informative content on electrical work and materials!
PLC (Programmable Logic Controller)
DCS Controllers / I/O Cards
Remote I/O Modules
Power Supply Modules (24V DC, 230V AC, redundant PSUs)
CPU Module
Communication Modules (Profibus, Modbus, Ethernet/IP, Profinet, etc.)
Terminal Blocks (feed-through, fuse type, ground type)
End Clamps for Terminal Blocks
Din Rails (Aluminium / Steel)
Wiring Ducts / Trunking with covers
Ferrules (PVC & Heat Shrink)
Lugs (pin type, ring type, fork type, bootlace ferrules)
Power Cables (PVC/XLPE)
Control Cables (multi-core, shielded)
Twisted Pair Signal Cables
Instrumentation Cables (screened, armoured, paired)
Patch Cords (Ethernet, Fibre optic, RS485, RS232)
Cable Glands (brass, nickel plated, polyamide)
Cable Lugs & Ferrules
Relay Modules (interposing relays, contactors)
Surge Protectors / Signal Isolators
MCBs / MCCBs
SMPS (Switch Mode Power Supply)
Industrial Switches / Media Converters
HMI / SCADA Terminals
Industrial PC / Engineering Station
Earthing Busbar & Strips
Panel Indicators (LED lamps, pilot lamps)
Push Buttons (ON/OFF, emergency stop)
Selector Switches
Annunciator Windows / Alarm Panels
Namplates, Labels, Tagging Material
Cable Marking Sleeves
Field Instruments (Transmitters: Pressure, Flow, Level, Temperature)

Control Valves & Positioners
Local Gauges (Pressure gauge, Temperature gauge)
Junction Boxes (Weatherproof, Flameproof, SS, FRP)
Glanding & Termination Accessories
SS Tubing (¼”, ½”)
Tube Fittings (Ferrule type – Elbow, Tee, Union, Reducer)
Impulse Tubes & Manifolds (2-way, 3-way, 5-way)
Instrument Valves (Needle, Ball, Gauge, DBB)
Capillary Tubes & Diaphragm Seals
Thermowells
RTD & Thermocouple Sensors
Cable Trays (Ladder, Perforated, Wire Mesh)
Cable Tray Accessories (Bends, Tees, Reducers, Covers)
Gaskets, Sealing Compounds, Thread Sealant (PTFE tape, Loctite)
Earthing Wire / Strip for Instruments
Instruent Supports (Mounting stands, brackets, clamps)
Junction Box Canopy / Sunshade
Desiccant Breathers
🔌 Cable Laying Materials
LT Power Cables (1.1kV, XLPE, Armoured)
Control Cables (Shielded / Unshielded)
Instrument Cables (Overall shield, Pair/triad, armoured)
Fibre Optic Cables
GI Wire for Cable Tracing
Cable Cleats & Clamps
Cable Glands (Double Compression, Single Compression)
Heat Shrink Sleeves for Terminations
Cable Lugs (Copper/Aluminium, Tinned, Crimping type)
Cable Identification Tags (SS tags, PVC tags)
Cable Ties (Nylon, SS)
Cable Tray Supports (Channel, Angle, Cantilever)
Pulling Socks / Grips
Cable Drums & Rollers
Cable Jointing Kits (Heat Shrink, Cold Shrink, Resin type)
Cable Sealing Material (Fire-stop putty, Sealing compound)
Sand, Bricks, Cable Route Markers (for underground laying)
Cable Spacers & Spreader Boards
🛠️ Tools & Consumables
Crimping Tools (Hand, Hydraulic, Pneumatic)
Wire Strippers
Screwdrivers (Insulated set)
Allen Keys
Line Tester / Digital Multimeter
Clamp Meter
Loop Calibrator (mA/Volt simulator)
HART Communicator / Field Communicator
Megger (Insulation Tester)
Earth Resistance Tester
Oscilloscope (for troubleshooting)
Drill Machine & Bits
Blades, Hacksaw, Wire Cutter
Insulation Tape / Self-amalgamating tape
Cable Pulling Lubricant / Jelly
WD-40 / Contact Cleaner

Nut-Bolts, Washers, Fasteners (SS/ GI)
By the end of this video, you will know exactly what materials are required for DCS/PLC panel installation and instrumentation wiring projects.

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