Control and Secondary Wiring Verification

Pre-energization inspection for point-to-point control wiring, terminal terminations, and accessory device function against the approved schematic.

Inspection Details

• Equipment or panel identification recorded
  Record the gear, panel, machine, or assembly identifier being inspected.
• Approved schematic or wiring diagram available at point of inspection
  Verify the latest approved schematic, wiring diagram, or control drawing is available and matches the assembly under inspection.
• Inspection date and time recorded
  Document when the verification was performed.
• Inspector name and qualification recorded
  Record the inspector and confirm they are a qualified person or competent person as required by site procedure.

Point-to-Point Wiring Verification

• Control conductors match schematic point-to-point
  Verify each control conductor is landed on the correct terminal and matches the schematic from source to destination.
• Terminal numbers and wire markers legible and correct
  Verify terminal designations and wire markers are present, legible, and correspond to the wiring schedule.
• No crossed, reversed, or omitted control connections
  Check for crossed wires, reversed polarity where applicable, omitted terminations, or incorrect landing points.
• Continuity test results documented for verified circuits
  Record the number of circuits tested and verified by continuity or equivalent point-to-point method.
• Unintended continuity or shorts detected
  Confirm no unintended continuity, short circuit, or cross-connection exists between unrelated control circuits.

Terminal Connections and Termination Quality

• Terminal screws, lugs, and ferrules properly secured
  Verify all terminations are mechanically secure and installed per manufacturer instructions.
• No exposed conductor beyond termination limits
  Check that conductor insulation is stripped to the correct length and no bare conductor is exposed outside the terminal.
• Conductor routing and bend radius acceptable
  Verify conductors are routed neatly, protected from abrasion, and not strained at terminals.
• Terminal torque verified to specification
  Confirm terminal torque was applied per manufacturer specification or documented torque procedure.
• Loose strands, damaged insulation, or pinched conductors observed
  Inspect for loose strands, nicked insulation, pinched conductors, or other termination defects.

Accessory Device Function Checks

• Relays, contactors, and interposing devices operate correctly
  Verify accessory devices actuate as intended when the control circuit is tested.
• Pilot lights, indicators, and annunciators function as intended
  Verify visual indicators illuminate or clear according to the control logic.
• Pushbuttons, selector switches, and limit devices operate correctly
  Confirm manual and field-operated devices change state properly and are wired to the correct terminals.
• Auxiliary contacts and interlocks match schematic logic
  Verify auxiliary contacts, permissives, and interlocks perform the intended logic and do not bypass safety or control functions.

Safety, Documentation, and Release to Energize

• Lockout-tagout applied during inspection as required
  Confirm lockout-tagout controls were used where required before any testing or access to energized parts, consistent with site procedure and OSHA 1910.147.
• Test instruments suitable and functioning
  Verify meters, continuity testers, or other instruments are appropriate for the task and in good working order.
• Deficiencies documented and tagged for correction
  Record all non-conformances, corrective actions, and any components removed from service or held for rework.
• Assembly approved for energization
  Final disposition confirming the control wiring verification passed and the assembly may be energized.
• Inspector signature
  Inspector signs to confirm the verification was completed and findings are accurate.