A well-structured control panel intake form is the difference between a project that runs smoothly and one that’s plagued by delays, redesigns, and cost overruns.
In our last post, we covered the biggest mistakes companies make when starting a control panel project—most of which stem from missing or incomplete information at the beginning. Now, let’s break down the essential sections every intake form should include to ensure a seamless design process.
Project Overview: Setting the Foundation
A strong intake form starts with the big-picture details. Without a clear understanding of the project’s purpose and scope, teams may misinterpret requirements, leading to costly rework.
- Project Name & ID – Ensures all stakeholders are referring to the same project.
- Brief Project Description – Defines the intent of the panel (e.g., motor control, process automation, machine integration).
- Key Contacts – List of responsible engineers, project managers, and client representatives.
Why This Matters: Establishing who is involved and what the panel is supposed to do prevents confusion from the start.
Scope of Work: What’s Included (and What’s Not)
Many projects suffer from scope creep because there’s no written agreement on what’s included. Clearly outlining expectations prevents this.
- New Panel or Modification? – Is this a brand-new design or an upgrade to an existing panel?
- Specific Functional Requirements – What does the panel need to control? Are there special features required?
- Exclusions – What is NOT included in the scope (e.g., field wiring, programming, installation)?
Why This Matters: A clearly defined scope reduces misalignment between the customer, engineers, and panel shop.
Environmental & Compliance Requirements
Selecting the wrong enclosure or failing to meet industry standards can result in non-compliance, equipment failure, or costly modifications.
- Indoor or Outdoor? – Define exposure conditions (dust, moisture, vibration, heat, chemicals).
- Temperature Ranges – Minimum and maximum ambient temperature the panel will be exposed to.
- Required NEMA or IP Rating – Ensures the enclosure provides adequate protection.
- Compliance Standards – UL 508A, NFPA 70 (NEC), NFPA 79, CE, ATEX, etc.
Why This Matters: Avoids safety hazards, environmental failures, and last-minute redesigns to meet regulatory standards.
Power Requirements: Avoiding Costly Electrical Mismatches
Incorrect power assumptions lead to major design errors that delay projects.
- Supply Voltage – Single-phase or three-phase? 120V, 240V, 480V? Verify, don’t assume.
- Frequency – 50Hz or 60Hz?
- Short Circuit Current Rating (SCCR) – Must align with the available fault current at the installation site.
- Power Conditioning Needs – UPS, surge protectors, transformers required?
Why This Matters: Ensuring the panel is designed for the available power prevents equipment failures and safety issues.
Integration & Communication: Ensuring the Panel Plays Nicely with Other Systems
Modern control panels rarely operate in isolation—they must communicate with existing systems.
- PLC, DCS, or SCADA System? – Define the existing control architecture the panel will integrate with.
- Communication Protocols – Ethernet/IP, Modbus TCP, Profibus, DeviceNet, etc.
- IP Addressing & Network Configuration – Avoid conflicts by confirming subnet and VLAN requirements upfront.
Why This Matters: Prevents integration failures and last-minute control system rework.
Physical & Component Preferences
A panel that doesn’t fit its allocated space creates installation nightmares. Additionally, using non-preferred components can cause compatibility and supply chain issues.
- Available Space – What are the height, width, and depth restrictions?
- Mounting Requirements – Wall-mount, floor-standing, or integrated into an MCC?
- Preferred Manufacturers & Part Numbers – Are specific brands required for breakers, relays, or PLCs?
- Customer-Supplied Components – Will the customer provide any parts?
Why This Matters: Ensures the panel is physically compatible with its installation site and meets customer expectations for components.
Documentation & Drawing Standards
Standardized drawings reduce confusion for panel builders, field technicians, and maintenance teams.
- CAD Drawing Format – AutoCAD, EPLAN, or another format?
- Titleblock & Symbol Standards – Ensures consistent documentation across projects.
- Wiring & Terminal Labeling Requirements – Defines wire colors, numbering conventions, and label types.
Why This Matters: Standardized documentation makes it easier to build, troubleshoot, and maintain the panel.
Final Thoughts: A Strong Intake Form Saves Time & Money
By covering these must-have sections, your intake form ensures:
- No missed details that lead to rework
- A streamlined design and approval process
- Fewer delays and last-minute surprises
A well-structured intake process doesn’t just help the design team—it improves efficiency, cost control, and customer satisfaction.
Next Up: How a Well-Structured Intake Process Saves Time and Money
We’ve now covered what should be in your intake form—but how does this actually translate into cost savings and project efficiency?
In the next post, we’ll break down the tangible benefits of a strong intake process and how it prevents wasted time, budget overruns, and scope creep.