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ELECTRICAL PANEL QUALITY

ASSURANCE TEST

I think we can all agree that quality assurance is important. Without it, things probably wouldn’t
be consistent in functionality and you’d always run the risk of getting a shoddy product.

Here at Robinson Engineering, we have in place a test procedure for all of the electrical control
panels that we build, and I wanted to share the first portion of that plan so you catch a glimpse
of the quality that goes into a panel built in our UL-508a listed panel shop.

Before the test begins, we:

1. Print a new copy of the finalized electrical drawing.

2. Ensure that someone other that the person who wired the panel is doing the testing.

3. Connect multi-panel systems if necessary.

When that’s all done, we move on to the test portion that takes place before connecting power
to the panel. This is the stage we’ll discuss today.

First, all wiring and components are inspected for obvious non-conformities. If it looks good, we
move on.
Next, all components are checked to ensure that they match the bill of materials. If lights are
used, correct voltage is checked. If relays with surge suppressors are used, the correct type is
confirmed. Also, all contacts on pushbuttons and switches are checked to make sure they’re
the right ones.

Next, we check that the required component labels are present, correct, and easily visible.

Close behind that is the inspection of all wire labels to ensure that they are correct, facing
outward, and are easily visible.

Some of these are backward, so they have to be fixed before we can move on.

Ta da! Let’s move on.

After the component and wire labels are checked, we check all screw connections for
tightness.

Then, we pull on each wire to ensure that no connections are loose and that wires have the
appropriate amount of slack. You don’t want too much extra wire, but some is good to make
sure that it’s not constantly under stress.
After that, we use a multimeter to do a point-to-point continuity check on all wiring based on the
electrical drawings and we highlight the drawing as each connection is verified.

Make sure any applicable jumpers are properly set and that there is an insulated barrier
between exposed jumper ends and other jumpers. The barrier is really important so the jumpers
don’t accidentally jump to each other and cause big problems.

Using a multimeter, check across all normally open and normally closed contact for proper
continuity and operation. This should include (if applicable) the operation of contactors,
disconnects and switches.

Using a multimeter, check the disconnect handle for correct operation.

Using a multimeter, perform short circuit testing on all power circuits and PLC outputs.
Whew. And that’s just the beginning! All of this takes place before we even think about
connecting power because we want to be sure that the panel is correct and safe to use to
continue testing, and ultimately for our customers.

What other things do you do in your quality assurance tests? Is there anything you would add to
ours? Let us know by leaving a comment or contacting our project manager Cliff at
cclark@robinsonengineeringinc.com or 757-872-7292 ex 210.

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300 D Newsome Drive, Yorktown VA 23692 Phone: 1-866-568-7392
E-mail: contact@robinsonengineeringinc.com

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