How to Choose the Right Pilot Light for Your Control Panel?

Pilot lights are small but important components in any industrial control panel. They serve as visual indicators that help operators monitor the status of machines and systems in real-time. Whether it's showing that power is on, a motor is running, or there's a fault in the system, choosing the right pilot light makes all the difference in keeping operations safe and efficient.

In this blog, we’ll guide you through how to choose the right pilot light for your control panel, using simple terms and helpful tips along the way.

What Is a Pilot Light?

A pilot light is a visual signal device typically installed on the front panel of control equipment. It lights up to indicate various operating conditions such as "power on," "machine running," "fault occurred," or "emergency stop." These small lights are essential in industrial environments, helping operators quickly understand what's happening with equipment without opening the panel.

Key Factors to Consider When Choosing a Pilot Light

1. Voltage Rating

The first thing to check is the voltage of your control system. Pilot lights are available in different voltage ratings—commonly 24V DC, 120V AC, and sometimes 230V. Using a pilot light that doesn’t match your control voltage can cause the light to fail, burn out quickly, or not turn on at all.

Always match the pilot light’s voltage to your control circuit. If your control panel operates on 24V DC, make sure the pilot light is rated for 24V DC as well.

2. Color and Function

Colors play a crucial role in what pilot lights communicate. Most industrial facilities follow standard color codes for safety and clarity. For example:

- Green: Equipment is running or normal condition

- Red: Fault, stop, or emergency

- Yellow/Amber: Warning or attention needed

- Blue: Optional or user-defined (sometimes for equipment reset)

- White/Clear: General indication or power on

Using consistent color codes throughout your facility helps reduce confusion and ensures quick, accurate responses from operators.

3. Light Source Type

The two main types of pilot lights are LED and incandescent:

- LED Pilot Lights: These are the most common choice today. They last longer, consume less power, and resist vibration—making them perfect for industrial use.

- Incandescent Pilot Lights: These are older and less common. They produce more heat and have a shorter lifespan. However, they may still be used in legacy panels or specific applications.

For most modern control panels, LED pilot lights are the smarter, more energy-efficient option.

Common Mistakes to Avoid

Even though pilot lights seem simple, mistakes can still happen. Here are a few to watch out for:

- Inconsistent color usage: Mixing up meanings for red, green, or yellow across different panels can lead to serious operator errors.

- Wrong voltage rating: Always double-check that the pilot light voltage matches your control system.

- Wrong product for the environment: Even if environmental ratings weren’t discussed earlier, it's still important not to use indoor-rated lights in dirty, wet, or high-vibration settings.

Choosing the right pilot light for your control panel isn’t just about buying a light that fits—it’s about ensuring safety, clear communication, and long-term reliability. By paying attention to the voltage rating, using standard color codes, and selecting the right light source type, you can make sure your control panel is both functional and easy to understand.

The next time you're selecting or upgrading pilot lights in your system, use these guidelines to make smart, informed choices. A small decision like the right pilot light can make a big impact on operator performance and system safety.