Control panel tester

Control panel testers test the electrical control panels. They read blueprints to check if the wiring is connected correctly. Control panel testers use electrical measuring and testing equipment to detect malfunctions and may correct faulty wiring and components.

Control panel testers do the following tasks, among others (list not exhaustive)

• Inspects and tests electrical panels used to control machinery, equipment, and systems for conformance with specifications, following blueprints and wiring schematics, and using electrical testing equipment and instruments
• Compares wiring and location of control devices on panel with blueprints and wiring diagrams to verify assembly.
• Examines wiring for loose or faulty connections.
• Connects leads from panel onto power source leads to prepare for testing activities.
• Turns rheostat to impose and regulate current loads onto panel controls and observes action of relays, cut-outs, and other devices for conformance with specifications.
• Tests wiring circuits and controls to isolate and locate causes of malfunctions, using electrical instruments, for example voltmeter, ammeter, and ohmmeter.
• Records causes of malfunctions on test sheet and routes defective panels for rework.
• May also change defective control devices on panel, using handtools, and solder loose or faulty wiring.

Control panel testers generally have a schedule each week. They usually work 40 hours a week. However, overtime is common, especially when meeting project deadlines.

Control panel testers work indoors. They often share the same office space with other engineers. They are occasionally exposed to hazardous conditions.

The following job titles also refer to control panel tester:

electrical test technician
control panel inspection technician
electrical inspection and test technician
electric control panel repairer
control tester
panels tester
inspector of control panels
technician expert in electrical control panels
electric control panel tester and repairer
tester of control panels
controls tester
panel tester
control panel testing technician
control panel testing technologist
panel wireman
electro-mechanical test technician
control panel test technician
electric control panel fault-finder
tester of electrical control panels
electrical control panel test technician
panel builder
control panel testing technology expert
control panel inspector
electric control panel tester
electrical control panel tester
electric control panel inspector and tester
control panel testing technology specialist

A high school diploma is generally required to work as control panel tester; although some companies require some form of technical or vocational education training, such as an associate’s degree or certificate in electronics technology or a similar discipline.

Common topics covered in a degree or certificate program in this field include semiconductor or electromechanical devices, electrical or industrial motor controls or circuitry, digital or analog circuits, soldering techniques, fundamentals of electronics, or blueprint reading. These programs typically take one to two years to complete and can also provide or require students to complete an internship, or prepare individuals for entering an apprenticeship program.

A prior experience of electrical equipment assembly is a serious asset, as well as the knowledge of specific tools such as National Instruments LabVIEW, SAP, or Sage 100 ERP.

ISCO skill level is defined as a function of the complexity and range of tasks and duties to be performed in an occupation. It is measured on a scale from 1 to 4, with 1 the lowest level and 4 the highest, by considering:

• the nature of the work performed in an occupation in relation to the characteristic tasks and duties
• the level of formal education required for competent performance of the tasks and duties involved and
• the amount of informal on-the-job training and/or previous experience in a related occupation required for competent performance of these tasks and duties.

Control panel tester is a Skill level 2 occupation.

These occupations, although different, require a lot of knowledge and skills similar to control panel tester.

electrical equipment inspector
electronic equipment inspector
battery test technician
electrical equipment assembler
control panel assembler

These occupations require some skills and knowledge of control panel tester. They also require other skills and knowledge, but at a higher ISCO skill level, meaning these occupations are accessible from a position of control panel tester with a significant experience and/or extensive training.

computer hardware test technician
calibration technician
electrical engineering technician
electromechanical engineering technician
avionics inspector

This knowledge should be acquired through learning to fulfill the role of control panel tester.

• Quality assurance procedures: The procedures to inspect a product or system to ensure that it is according to specifications and requirements.
• Electricity principles: Electricity is created when electric current flows along a conductor. It entails the movement of free electrons between atoms. The more free electrons are present in a material, the better this material conducts. The three main parameters of electricity are the voltage, current (ampère), and resistance (ohm).
• Electrical equipment regulations: The national and international regulations with regards to the use and manufacture of electrical equipment on the workfloor. These regulations provide rules and guidelines on topics such as general risk management, electrical equipment manufacture, electrical equipment testing, electrical equipment installation, warning labels, and certificates.
• Electromechanics: The engineering processes that combine electrical and mechanical engineering in the application of electromechanics in devices that need electricity to create mechanical movement or devices that create electricity by mechanical movement.
• Electrical wire accessories: Electrical wire and cable products and accessories, such as electrical connectors, splices, and wire insulation.
• Instrument performance elements: Elements that indicate or influence instrument performance. A first indication of the performance of the instrument is the accuracy or precision of the instrument, such as its response time, resolution, and range. A second indication of performance is the technical performance of the instrument, such as its power level, the electromagnetic interference, and transient voltages. A third indication of performance are environmental factors that can influence instrument performance, such as humidity, operating temperatures, or dust.
• Power electronics: The functioning, design, and usage of electronics that control and convert electric power. Power conversion systems are usually categorised as AC-DC or rectifiers, DC-AC or inverters, DC-DC converters, and AC-AC converters.
• Switching devices: Devices that are able to open and close electrical circuits, such as disconnecting switches, interrupter switches, and circuit breakers.
• Electricity: Understand the principles of electricity and electrical power circuits, as well as the associated risks.
• Electrical testing methods: Test procedures performed on electrical equipment and machinery in order to check the performance and quality of the electrical equipment and their adherence to specifications. During these tests electrical properties, such as voltage, current, resistance, capacitance, and inductance, are measured using electrical measuring equipment, such as multimeters, oscilloscopes, and voltmeters.
• Power engineering: Subdiscipline of energy and electrical engineering which specialises in the generation, transmission, distribution, and usage of electrical power through the connection of electrical devices to motors, generators, and transformers, such as an AC-DC power adapter.
• Electrical wiring diagrams: The visual schematic representation of an electrical circuit, its components, and the connections between these components.
• Control panel components: The elements present in control panels, such as wires, circuit breakers, DIN rails, switches, programmable logic controllers (PLC), contactors, and transformers.

These skills are necessary for the role of control panel tester.

• Inspect quality of products: Use various techniques to ensure the product quality is respecting the quality standards and specifications. Oversee defects, packaging and sendbacks of products to different production departments.
• Measure electrical characteristics: Measure voltage, current, resistance or other electrical characteristics by using electrical measuring equipment such as multimeters, voltmeters, and ammeters.
• Apply coating to electrical equipment: Prepare and apply coating, such as conformal coating, to electrical equipment and its components to protect the equipment against moisture, high temperature, and dust.
• Read assembly drawings: Read and interpret drawings listing all the parts and subassemblies of a certain product. The drawing identifies the different components and materials and provides instructions on how to assemble a product.
• Test electrical equipment: Test electrical systems, machines, and components and check electrical properties, such as voltage, current, resistance, capacitance, and inductance, using electrical testing and measuring equipment, such as a multimeter. Gather and analyse data. Monitor and evaluate system performance and take action if needed.
• Perform test run: Perform tests putting a system, machine, tool or other equipment through a series of actions under actual operating conditions in order to assess its reliability and suitability to realise its tasks, and adjust settings accordingly.
• Read standard blueprints: Read and comprehend standard blueprints, machine, and process drawings.
• Use testing equipment: Use equipment to test performance and operation of machinery.
• Analyse test data: Interpret and analyse data collected during testing in order to formulate conclusions, new insights or solutions.
• Communicate test results to other departments: Communicate testing information such as testing schedules, samples testing statistics and test results, to the relevant departments.
• Meet deadlines: Ensure operative processes are finished at a previously agreed-upon time.
• Report defective manufacturing materials: Maintain required company records and forms in order to report any defective materials or questionable conditions of manufacturing machinery and equipment.
• Read engineering drawings: Read the technical drawings of a product made by the engineer in order to suggest improvements, make models of the product or operate it.
• Use measurement instruments: Use different measurement instruments depending on the property to be measured. Utilise various instruments to measure length, area, volume, speed, energy, force, and others.
• Interpret electrical diagrams: Read and comprehend blueprints and electrical diagrams; understand technical instructions and engineering manuals for assembling electrical equipment; understand electricity theory and electronic components.

This knowledge is sometimes, but not always, required for the role of control panel tester. However, mastering this knowledge allows you to have more opportunities for career development.

• Waste removal regulations: Know and understand the regulations and legal agreements governing the performance of waste removal activities.

These skills and competences are sometimes, but not always, required for the role of control panel tester. However, mastering these skills and competences allows you to have more opportunities for career development.

• Apply soldering techniques: Apply and work with a variety of techniques in the process of soldering, such as soft soldering, silver soldering, induction soldering, resistance soldering, pipe soldering, mechanical and aluminium soldering.
• Resolve equipment malfunctions: Identify, report and repair equipment damage and malfunctions. Communicate with field representatives and manufacturers to obtain repair and replacement components.
• Inspect electrical supplies: Check electrical supplies for damage, moisture, loss or other problems.
• Carry out measurements of parts: Operate measurement instruments to measure parts of manufactured objects. Take into consideration specifications of manufacturers to perform the measuring.
• Remove defective products: Remove defective materials from the production line.
• Maintain electrical equipment: Test electrical equipment for malfunctions. Take safety measures, company guidelines, and legislation concerning electrical equipment into account. Clean, repair and replace parts and connections as required.
• Use specialised tools in electric repairs: Use of a variety of specialised tools, instruments and machines, such as presses, drills and grinders; employ them to carry out repairs in a safety manner.
• Wear appropriate protective gear: Wear relevant and necessary protective gear, such as protective goggles or other eye protection, hard hats, safety gloves.
• Research equipment needs: Research equipment or required machine parts; compare sources, prices and delivery times.
• Calibrate electromechanical system: Correct and adjust the reliability of an electromechanical system by measuring output and comparing results with the data of a reference device or a set of standardised results. This is done in regular intervals which are set by the manufacturer.
• Maintain test equipment: Maintain equipment used for testing the quality of systems and products.
• Adjust voltage: Adjust voltage in electrical equipment.
• Repair wiring: Find faults in wires or cables by using specialised equipment and repair these faults depending on type of wiring.
• Liaise with engineers: Collaborate with engineers to ensure common understanding and discuss product design, development and improvement.
• Send faulty equipment back to assembly line: Send equipment that didn’t pass inspection back to the assembly line for re-assembly.
• Keep records of work progress: Maintain records of the progress of the work including time, defects, malfunctions, etc.
• Write inspection reports: Write the results and conclusions of the inspection in a clear and intelligible way. Log the inspection’s processes such as contact, outcome, and steps taken.
• Maintain electromechanical equipment: Diagnose and detect malfunctions in electromechanical components and systems and remove, replace, or repair these components when necessary. Execute preventative equipment maintenance tasks, such as storing the components and machines in clean, dust-free, and non-humid spaces.
• Write records for repairs: Write records of the repairs and maintenance interventions undertaken, of parts and materials used, and other repair facts.
• Write calibration report: Report on the instrument calibration measurements and results. A calibration report includes the objectives and approach of the test, descriptions of tested instruments or products, test procedures, and test results.

7543 – Product graders and testers (excluding foods and beverages)

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References

1. ESCO
2. U.S. Bureau of Labor Statistics
3. Control Panel Tester: A description for the control panel tester job – Job Descriptions
4. Featured image: Photo by Aizat Ramlan