Mains panels and distribution panels are usually used in a building’s electrical system, and they are a complementary combination usually used together. However, they are not nearly the same electrical panels, this article will bring you the differences between main and distribution panels in 9 aspects so that you can understand their differences in detail.

What is the Main Panel and the Distribution Panel

Before describing their differences, we need to understand the basic information about main panels vs. distribution panels:

MAIN PANEL: Main panels are the first step in getting electricity into a building and also protect against overloads and short circuits in electrical equipment. They are usually connected directly to the power company’s grid or transformer and are usually controlled by a main circuit breaker with a main switch.

DISTRIBUTION PANEL: The distribution panel is responsible for distributing the power brought in by the main panel to every place in the building that needs electricity. Simply put, without a distribution panel, the provision of electricity would be very dangerous and may require dozens or even hundreds of circuits to reach each point of use, but with a distribution panel, these wires can be eliminated and the distribution panel can be operated directly to complete the distribution of power more efficiently and safely.

What are the Differences They Have?

In the next article, we will bring you the differences between main panels and distribution panels in 10 different aspects, so that you can better understand how they differ from structure to function.

#1 Functional

MAIN PANEL: The main panel’s primary function is to bring external power into the building, so it would be called the first step in the entry of power into the building, the point of entry of power.

DISTRIBUTION PANEL: The main function of the distribution panel is to distribute the power coming into the building to the areas that need it, so it can be said that the distribution panel is the second step of power coming into the building.

#2 Structure

MAIN PANEL: The main panel consists of FIVE components accompanied by different functions, which are:

• Incoming Terminals: The incoming terminal is the interface device used by the main panel to connect to the external power supply and can be considered the first step in the first step.
• Main Circuit Breaker: The core component of the main panel is the switch used to control the current to the main panel itself, preventing overloads and short circuits.
• Branch Circuit Breakers: A branch circuit breaker would be responsible for a separate circuit such as lighting, outlets, etc.
• Bus bars:  The busbars are the key to power distribution at the main panel and work similarly to the incoming terminals, distributing power to individual circuits.
• Grounding System: The grounding system consists of a neutral wire and grounding bar to ensure that the main panel is connected to the grounding system and to protect the equipment from fault currents.

DISTRIBUTION PANEL: The structure of the distribution panel exists in similar parts to the main panel, including the incoming terminals, the main circuit breaker, the bus bars, the branch circuit breakers, and the grounding system. The following is a list of the main parts that differ from the main panel:

• Mains Link: The main link ensures that incoming terminals and bus bars ensure that power goes from the correct to the individual circuits.
• Load Terminals: Load terminals are the electrical contacts at the distribution panel that distribute power to each branch circuit.
• Meter: Meter is a basic metering device used to measure and record the consumption of electricity for tracking power usage.

#3 Materials

MAIN PANEL: The main panel is made of galvanized steel, stainless steel, copper, and aluminum, with different materials used for different components.

• Aço galvanizado: Used in the enclosure or as grounding material, generally used in industrial and outdoor environments.
• Aço inoxidável: 304 and 316 stainless steel are commonly used for the housing.
• Cobre: Used in conductive and grounding systems.

DISTRIBUTION PANEL:  The main materials used for distribution panels are galvanized steel, aluminum alloy, polycarbonate, copper, and aluminum, of which galvanized steel, copper, and aluminum are used for similar purposes as the main panels, and the following discussion focuses on the parts that are different from the main panels:

• Aluminum alloy: Often used for lightweight distribution panel enclosures, it is lighter than steel and has better corrosion resistance.
• Polycarbonate: Used for the enclosure of small distribution panels that can cope with low current loads.

#4 Installation

MAIN PANEL: They are typically installed at building entrances, electrical service entry and in electrical rooms. Common installation methods are listed below:

• montado na parede
• Floor standing

In outdoor or harsh environments, the main panel also needs to have a high rating, in general, IP54 is the most basic level of protection, in some cases, IP65 or IP66 or higher.

DISTRIBUTION PANEL: Distribution panels are usually installed in load centers and may also be centralized in electrical rooms or set up at a centralized control point on each floor or in a different area, mainly to avoid power losses, load management and more. There are various ways of installing power distribution panels:

• Montado na parede
• Floor-standing enclosures
• Panelboard-mounted

It should be noted that the distribution panel will need expansion and maintenance, and needs to be installed in a location that is convenient for operation, while avoiding high temperatures and humid environments.

#5 Power Capacity and Magnitude

MAIN PANEL: Main panels are primarily used to carry high currents, typically with current capacities up to 4000 A or higher in industrial settings. However, in residential and small commercial settings it is common to find them in the 100 A to 400 A range. The current capacity of the main panel depends specifically on the environment in which it is used. Common types of loads are:

• Large motors 
• High power equipment

DISTRIBUTION PANEL: Distribution panels are usually connected to a low-voltage distribution system and there are usually multiple panels distributed at different load centers. Capacities range from 50A to 200A, which is lower than the main panels, they can also reach 800A or more in industrial or commercial environments. Common load types for distribution panels are:

• Power distribution 
• Lighting circuits
• Production machinery
• Specialized equipment

#6 Safety

MAIN PANEL: The safety of the main panel, which is at the heart of power distribution, is critical, and is usually accomplished through a main circuit breaker that monitors the current and cuts it off in the event of overloads and short circuits. The earthing system ensures that fault currents can be directed to ground without any problems, and the level of protection ensures that the electrical components are protected from external aggression. Common safety protections for the main panel are:

• main circuit breaker
• Grounding system
• Main panel enclosure, not less than IP54 rated
• Fusíveis

DISTRIBUTION PANEL: Since distribution panels are oriented to low-voltage circuits, safety is more evident in the protection of the components, including the use of branch circuit breakers, grounding systems, and the use of up-to-date levels of protection. The safety and protection installation measures of the distribution panel are similar to those of the main panel, and the different parts are mainly shown below:

• Branch circuit breakers
• High enclosure ratings, depending on the use scenario, between IP20 and IP65
• Operating instructions

#7 Application

MAIN PANEL: Main panels are used in almost every situation where power is required, as they are the first step in connecting the external power supply to the place where the electricity is used. Including commercial settings, industrial environments, residential settings, data centers, and more.

DISTRIBUTION PANEL: Distribution panels and main panels are a common combination of relationships, so they can also be used in the above sections, although more commonly in various areas of them, such as lighting systems in commercial and residential settings; air conditioning systems in office areas; production equipment, machinery in industrial environments, and more.

#8 Cost

MAIN PANEL: The cost of a main electrical panel is higher than a distribution panel due to materials, design, installation, and maintenance, mainly in the form of:

• Additional components
• Larger material sizes
• More complex construction
• Higher levels of protection
• Maintenance by specialized technicians
• Higher component costs
• Larger space requirements

DISTRIBUTION PANEL: Distribution panels will cost less than mains panels in all aspects, but may be equal to or higher than mains panels in terms of total cost due to the higher quantities available. The cost of the distribution panels is mainly in:

• Materiais
• maintenance cost
• Periodic Inspection
• Component replacement
• Instalação

#9 Benefits

MAIN PANEL: The main panel, as the core of the power system, has long-term stability, eliminating the need for frequent maintenance and reducing system downtime.

DISTRIBUTION PANEL: They not only bring flexibility in power distribution, but also allow for careful management of power. In addition, distribution panels are characterized by small size and flexible installation, which can maximize space saving. In terms of design, distribution panels are often modular, allowing for flexible expansion and adjustment of components, which is also convenient for regular maintenance.

Conclusão

Overall, mains electrical panels appear to be superior to distribution panels in all respects. However, you should note that mains and distribution panels are not in competition, but are a combination, usually used in a building or an area, so they support each other in different applications.