Most plants don’t notice control panel issues until something breaks. By then, it’s already costing you.In our recent webinar, What to Look for in Custom Control Panels, Spark Power’s Chris Minvielle outlined the most common — and preventable — mistakes he sees inside industrial panels across Canada. These red flags are easy to miss but hard to recover from once downtime starts.

1. Poor or Missing Documentation

When wiring diagrams or updated schematics are missing, even simple fixes can take hours. Technicians are forced to trace wires manually and guess at connections, increasing downtime and risk.

Fix it: Every panel should ship with a complete, accurate documentation package — and it must stay updated over time.

2. Cheap or Misrated Components

Inexpensive, uncertified components might save money upfront — but often fail faster, especially in harsh or high-demand environments. The result: more breakdowns, harder replacements, and unreliable operation.

Fix it: Use only CSA/UL-certified parts, and make sure they’re properly rated for your plant’s temperature, humidity, and load profile.

3. Inadequate Factory Testing

Some vendors skip or rush factory acceptance testing (FAT), leaving key issues undetected. Without proper simulation and point-to-point verification, problems surface later — during commissioning or live production.

Fix it: Demand a detailed FAT process. Ideally, you should be able to witness it in person or virtually before the panel ships.

4. Messy or Unlabeled Wiring

Disorganized wiring isn’t just cosmetic — it leads to electromagnetic interference, false triggers, and slow fault isolation. Bad cable management can turn a 10-minute fix into a multi-hour headache.

Fix it: Ensure cables are routed cleanly, labeled at both ends, and separated by signal type and voltage level.

5. Wrong Enclosure for the Environment

Too many panels are installed without proper sealing, heating, or protection for their location. In washdown areas, cold climates, or dusty outdoor sites, this leads to corrosion, condensation, or even full shutdowns.

Fix it: Choose enclosures that match the actual environment — NEMA 4X, IP69K, heaters, fans, drip shields — whatever your site conditions demand.

6. No Post-Delivery Support

Some vendors disappear after delivery. That leaves your team on their own during install, startup, or when something needs to change. The result? More guesswork. More downtime.

Fix it: Choose a panel partner who offers support beyond shipping — including documentation, install coordination, and long-term upgrade options.

Don’t Wait Until It Fails

These red flags don’t always show up right away. But when they do, the damage is costly. Unplanned downtime, production loss, and safety risks can often be traced back to avoidable panel design and install issues.

Want a second set of eyes on your control panels?

Schedule a control panel review with Spark Power

The best time to fix it was before it failed. The second-best time is now.