Control Panel Design: 5 Common Mistakes and How to Avoid Them

Designing an electrical control panel isn’t just about placing components in a box and wiring them up. It’s about functionality, safety, longevity—and making sure the end user can understand and operate it without hassle. At PSL Controls, we’ve seen first-hand how thoughtful design can save time, reduce maintenance, and avoid costly downtime.

Here are five common mistakes in control panel design—and how to avoid them:

1. Poor Layout and Space Planning

The Mistake:

Overcrowding components or placing them without a clear layout can lead to overheating, difficult maintenance, and even electrical faults.

How to Avoid It:

Design your panel with spacing, airflow, and accessibility in mind. Allow room for future modifications, and follow clear layout standards. A clean, logical layout not only looks professional - it makes life easier for anyone maintaining or troubleshooting it.

2. Inadequate Labelling

The Mistake: Wires and components without clear labels make future work a nightmare. It’s a small detail that can cause big delays.

How to Avoid It:

Label everything—wires, terminals, relays, breakers. Use durable labels that won’t wear off over time. This ensures safety, speeds up maintenance, and helps others understand the system at a glance.

3. Ignoring Heat and Ventilation

The Mistake:

Components generate heat, and without proper ventilation or cooling, performance can suffer—sometimes permanently.

How to Avoid It:

Always consider the heat load inside your panel. Use vented enclosures, fans, or air conditioning where needed. Design for efficiency, and always double-check the thermal requirements of your components.

4. Overcomplicating the System

The Mistake:

Trying to include too many features or over-automating a simple system can make the panel confusing and expensive—without adding much value.

How to Avoid It:

Keep the user in mind. Design for what’s needed now, with flexibility for future upgrades. Simplicity often leads to better reliability and usability.

5. Failing to Consider Real-World Conditions

The Mistake:

Building a panel in a clean workshop and forgetting it’ll be installed in a dusty, wet, or high-vibration environment.

How to Avoid It:

Always match the panel’s specification to its intended location. Consider IP ratings, material choices (e.g. stainless steel for corrosive environments), and mounting conditions. A good design works where it’s needed, not just on paper.

Need Help with a Control Panel Design?

At PSL Controls, we specialise in bespoke control panel design and manufacture—tailored to your system, environment, and end users. Whether you’re designing from scratch or refining an existing setup, we’re here to help you get it right.

Designed with Care. Delivered with Commitment.

📩 Ready to talk about your next control panel project?

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