Control Panel Preventive Maintenance Checklist

1. Preparation

• The maintenance task is permitted and the safe-work procedure is followed
• Last visit's notes and open items are reviewed
• Program and parameter backups are current before any changes
• Tools, spares and cleaning supplies are ready

2. Visual checks (panel closed and open)

• Enclosure, gaskets, latches and hinges are in good condition
• No water, dust build-up, condensation or corrosion inside
• No burn marks, discoloration or unusual smells
• Warning labels and nameplates are legible
• Cable entries are sealed and strain-relieved

3. Cooling and environment

• Fans run freely and are free of dust
• Filters are clean or replaced
• Heatsinks and vents on drives and power supplies are clear
• Panel temperature is normal for the equipment
• Thermal imaging is used where available, and hot spots are noted

4. Connections (with the panel de-energized and locked out)

• Power terminations are checked, retightened where the procedure requires it
• Control terminations and plugs are secure
• Grounding and bonding connections are tight and clean
• Wiring insulation is intact, with no cracks or heat damage

5. Power and protection

• Power supply output voltages are within tolerance
• Fuses, breakers and surge protectors are in good condition
• Overload settings still match the motor nameplates
• UPS or battery status is checked, and batteries are replaced as recommended

6. Controller, drives and network

• Controller status lights and diagnostics are normal
• Fault logs and alarm history are reviewed and explained
• Drive fault history is reviewed
• Network devices show healthy links, with no high error counts
• Memory or backup battery status is checked and replaced as scheduled

7. Safety devices

• Emergency stops and safety relays are tested as scheduled
• Door interlocks and safety devices work
• Safety function test results are recorded

8. Closing out

• Covers, barriers and doors are refitted and secured
• Backups are saved and labeled with the date
• Drawings and documents are updated for any change
• Findings and recommended repairs are recorded, with owners and dates

Notes and punch list