3 wiring mistakes that can cost you

When it comes to electrical field wiring, even small oversights can lead to serious consequences—costing you time, money, and safety. Whether you’re overseeing a new industrial automation project or updating existing systems, avoiding common wiring mistakes is essential to long-term system reliability and performance.

At Designed Electrical Integrators, we’ve seen firsthand how three preventable wiring errors consistently lead to rework, downtime, and system failures. Here’s what you need to know:

1. No Wire Labeling

Skipping wire labeling might seem minor during install, but it slows down future troubleshooting, increases the risk of errors, and leaves future maintenance teams guessing. This oversight can cost hours—or even days—when systems need urgent attention, compromising safety and reliability. Clear, consistent wire labeling ensures your system remains accessible, maintainable, and code-compliant.

2. Undersized Conduit

Choosing conduit that's too small creates major issues. Restricted airflow leads to overheating, which breaks down wire insulation and can cause premature system failure. Undersized conduit also makes future upgrades or maintenance more difficult and expensive. Always design with proper conduit fill percentages in mind to protect your system and extend its lifespan.

3. Rushed Terminations

Taking shortcuts during wire terminations is a recipe for failure. Loose connections often lead to voltage drops, erratic equipment behavior, and unexpected shutdowns. In industrial environments, those interruptions can halt entire production lines. Taking time to properly torque connections and test continuity protects your equipment and keeps operations running smoothly.

Avoid the Rework—Do It Right the First Time

Wiring mistakes don’t just delay projects—they damage reputations, strain budgets, and compromise safety. At Designed Electrical Integrators, we specialize in expert field wiring for industrial systems, with a commitment to doing it right the first time. Contact us today to learn how our team can support your next automation project with safe, reliable, and efficient installations.