Design & Build
Full-service panel design and fabrication. You describe the process. We deliver a finished, tested, UL 508A labeled panel with complete documentation.
Who This Service Is For
- OEMs without in-house controls engineering who need custom panels for their equipment
- Facility managers and plant engineers who need motor control centers, pump station panels, or process controls as a turnkey deliverable
- Electrical contractors who win projects requiring control panels but lack panel design or fabrication capability in-house
What Is Included
- Requirements gathering and scope definition
- Electrical design and schematic creation
- Component selection from UL-listed manufacturers
- Bill of materials (BOM) creation with lead-time verification
- Panel layout and enclosure selection
- Enclosure fabrication (cutouts, drilling, mounting plates)
- Component mounting and wiring
- PLC and HMI programming (when applicable)
- Hipot testing per UL 508A Section 60
- SCCR calculation per UL 508A Supplement SB
- 48-point final QC inspection
- UL 508A nameplate and labeling per Section 55
- Complete document package (as-built drawings, BOM, test records, SCCR worksheet)
- Optional: field commissioning and startup support
Process Timeline
| Phase | Activity | Timeline |
|---|
| 1 | Requirements review and scope confirmation | Day 1–2 |
| 2 | Design proposal with schematic, layout, and BOM | Day 3–5 |
| 3 | Customer design approval | Customer-dependent |
| 4 | Component procurement | Week 1–2 after approval |
| 5 | Panel fabrication, mounting, and wiring | Week 2–3 |
| 6 | Testing, QC inspection, documentation, and shipping | Week 3 |
Total turnaround from drawing approval to shipment: 3 weeks.
What You Receive
- As-built electrical schematics (PDF and native format)
- Panel layout drawing
- Complete bill of materials with manufacturer part numbers
- SCCR calculation worksheet per UL 508A Supplement SB
- Hipot and ground continuity test records
- 48-point QC inspection checklist (signed)
- UL 508A nameplate with all required data per Section 55
- Component data sheets for all major devices
- PLC program backup (if applicable)
Example Projects
Municipal Pump Station VFD Panel
A Massachusetts water utility needed a variable frequency drive panel to control three 25-HP submersible pumps with SCADA integration. Sterling Made designed a 480V 3-phase panel in a NEMA 4X stainless steel enclosure with three Yaskawa GA800 VFDs, an Allen-Bradley CompactLogix PLC, Ethernet/IP communication to the existing SCADA system, and hand-off-auto selector switches for each pump. SCCR rated at 65 kAIC per Supplement SB.
Packaging Line Motor Control Panel
A food and beverage manufacturer in New England needed a motor control panel for a new packaging line with eight conveyor drives and two pneumatic zone controls. Sterling Made designed a 208V panel with eight ABB ACS380 micro drives, a CompactLogix L16 PLC, PanelView Plus 7 HMI, and safety-rated E-stop circuit per ISO 13849. NEMA 12 enclosure with panel-mount HMI and door-mounted operator switches.