Low-voltage Switchgear

Custom Low-voltage Switchgear Manufacturer

We design and manufacture custom low-voltage switchgear for industrial plants, commercial buildings, renewable energy projects, and OEM equipment manufacturers. From engineering design and busbar fabrication to assembly, routine testing, and Factory Acceptance Testing (FAT), we deliver reliable switchgear solutions built to IEC 61439 and international quality standards.

Parameter

Rated Current	630 A, 1250 A, 1600 A, 2000 A, 2500 A, 3150 A, 250A,
Rated Voltage	220V, 380V, 400V, 6600V, 10000V, 13800V, 15000V,
Material	Stainless Steel
Size	1800
Frequency	50/60 Hz

Applications

Data Centers & Mission-Critical Facilities: Main intake switchboards, Tier III/IV dual-feed power distribution setups, automatic transfer switch (ATS) integration, and localized power monitoring.

Industrial & Manufacturing Plants: Main distribution boards (MDBs), Motor Control Centers (MCC) for continuous heavy process automation, VFD bypass panels, and sub-distribution.

Renewable Energy & Battery Storage (BESS): Solar PV inverter AC combiner switchgear, wind turbine tower distribution boards, and high-current battery energy storage system grid-connection switchboards.

Oil, Gas & Chemical Refining: Flame-retardant and arc-resistant switchgear, heavy-duty MCCs for explosive environments, and chemical-resistant powder-coated distribution switchboards.

Commercial & Public Infrastructure: Hospitals, high-rise office towers, shopping centers, municipal water/wastewater pump stations, and airport power intake networks.

Intelligent Low-Voltage Cabinet (iLV Cabinet)

Custom Options

Internal Separation (Form Rating): Configurable internal separation from Form 1 up to Form 4b (per IEC 61439) to isolate busbars, functional units, and external terminals.

Busbar Configurations: Top or bottom busbar entry; high-conductivity copper (bare, tin-plated, or silver-plated) or aluminum busbars rated up to 6300A.

Structure & Access: Fixed, plug-in, or fully withdrawable (drawout) circuit breaker and MCC bucket configurations; front-access or rear-access design.

Enclosure Protection: Indoor (IP30, IP31, IP42, IP54 / NEMA 1, 12) and outdoor weather-proof enclosures (IP55, IP65 / NEMA 3R, 4, 4X) with thermal management options.

Meter & Power Management: Integration of digital power meters, multi-function energy analyzers, thermal monitoring sensors, and Modbus/Profibus/IEC 61850 communication gateways.

Technical Features

Arc Fault Protection

Designed with reinforced structures and optional arc protection solutions to improve operator safety and minimize equipment damage.

High-Conductivity Busbar System

Precision-machined copper or aluminum busbars ensure low resistance, stable current distribution, and reliable long-term performance.

Flexible Internal Separation

Supports Form 1 to Form 4b configurations in accordance with IEC 61439 for enhanced safety and easier maintenance.

Intelligent Power Monitoring

Compatible with multifunction meters, protection relays, and communication protocols such as Modbus and IEC 61850 for real-time monitoring.

Manufacturing Capabilities

01/

CNC Busbar Processing: CNC busbar bending, punching, and shearing machines delivering sub-millimeter precision on copper busbars up to 12mm x 120mm.

02/

Automatic Busbar Sleeving: Heat-shrink tubing and tin/silver plating equipment for high-conductivity joint preparation.

03/

Assembly Capacity: Multi-line switchboard wiring and breaker integration stations supporting parallel production of over 150 low-voltage switchboard bays per month.

04/

Precision Enclosure Fabrication: Laser cutting ±0.05mm tolerance) and CNC press brake bending for 2.0mm–3.0mm galvanized steel or aluminum-zinc coated frame structures.

Manufacturing Process

Engineering Drawing & Approval: CAD generation of single-line diagrams (SLD), 3D cabinet layout, elevation drawings, and schematic diagrams for customer sign-off.

Busbar & Frame Fabrication: CNC punching and bending of structural profiles and main/distribution copper busbars.

Frame & Enclosure Assembly: Mechanical framing, structural torque checking, and powder coating (80–120 µm thickness).

Component Installation: Mounting ACBs, MCCBs, contactors, CTs/PTs, and fitting insulated main copper busbars.

Secondary Wiring & Ferruling: Automated wire cutting, laser-printed sleeve ferruling, and harness routing for control and protection circuits.

Quality Control

Incoming Material Inspection (IQC)

Conductivity testing on incoming copper busbars, steel gauge verification, and brand authentication checks on all circuit breakers.

In-Process Quality Checks (IPQC)

Busbar bolt torque checks using calibrated torque wrenches (marked with tamper-evident paint), creepage and clearance distance verification (per IEC 61439).

Wiring Verification

100% point-to-point wire continuity checking against approved schematic drawings.

Factory Acceptance Testing (FAT) & Routine Test

Dielectric Power Frequency Withstand Test: High-voltage insulation testing applied between phases, phase-to-neutral, and phase-to-earth (typically 2.5kV AC for 1 second / 1 minute).

Insulation Resistance Measurement: 1000V DC megohmmeter insulation resistance checking before and after dielectric tests.

Mechanical & Interlock Checks: Manual operation tests of all circuit breaker drawout mechanisms, door interlocks, padlocking devices, and shutter mechanisms.

Electrical Operational Test: Control circuit energization test, trip/close simulation for ACBs and MCCBs, protection relay functional verification, and meter display calibration checks.

Factory Acceptance Test (FAT) Documentation: Full test report package provided with the shipment, including calibrated instrument certificates.

Engineering Services

Pre-Sale Engineering

SLD review, busbar sizing calculations, short-circuit current calculation, and 2D/3D CAD layout creation (AutoCAD, SolidWorks, Revit BIM models).

Value Engineering (VE)

Cost optimization suggestions without compromising thermal rating, breaking capacity, or safety standards.

FAT Remote Inspection

Live video-streamed Factory Acceptance Testing (FAT) for overseas customers unable to conduct on-site factory visits.

Documentation Package

Comprehensive documentation provided, including O&M manuals, as-built schematic diagrams, bill of materials (BOM), type test certificates, and FAT reports.

Packaging, Fastening & Export Shipping

Protective Wrapping

PE stretch film with anti-moisture VCI (Volatile Corrosion Inhibitor) wrap and heavy-duty desiccant packs placed inside each panel compartment.

Crate Construction

Heavy-duty, fumigation-free plywood crates (18mm minimum thickness) reinforced with internal timber bracing and EPE foam cushioning.

Base & Center of Gravity Securing

Switchboard bays bolted directly to heavy timber skids or steel bases with reinforced lifting eyes for crane hoisting. Center of gravity clearly marked on outer packaging.

Shipping Methods

FCL (Full Container Load) via 40ft High Cube or Open Top containers with heavy-duty ratchet tie-down straps.

Certifications

Manufactured under ISO 9001 quality management, with CQC certification and other certifications available according to project requirements.

FAQ

Q: What standards do your low-voltage switchgear and switchboards comply with?

A: Our switchgear is manufactured and tested in accordance with IEC 61439-1/2, IEC 60947, and UL 891 / UL 1558 design guidelines. We supply certified short-circuit, temperature rise, and degree of protection test documentation.

Q: What forms of internal separation can you provide?

A: We offer all forms of internal separation from Form 1 up to Form 4b (per IEC 61439). Form 4b ensures complete isolation between busbars, functional units (circuit breakers), and outgoing cable terminals for maximum operator safety during maintenance.

Q: Can we specify our preferred brands for ACBs, MCCBs, and meters?

A: Yes. We frequently build switchboards using customer-specified components from Schneider Electric, ABB, Siemens, Eaton, or LS Electric. We can also source components based on your target budget and project delivery schedule.

Q: Do you provide Type Test reports for your switchgear design?

A: Yes. We maintain Type Test certifications and Design Verification documentation per IEC 61439-2, covering temperature rise limits, dielectric properties, short-circuit withstand capability, effectiveness of protective circuits, and clearance/creepage distances.

Q: Can you provide 3D BIM or STEP files for our building coordination design?

A: Yes. Our engineering team provides 3D STEP files, Revit BIM models, and 2D AutoCAD drawings (elevation, floor plan, single-line diagrams) during the engineering submittal stage for seamless integration into your building layout.

Q: How are withdrawable (drawout) units tested during FAT?

A: All withdrawable circuit breaker buckets and MCC units undergo 100% mechanical racking tests (Connected, Test, Disconnected positions), shutter operation verification, secondary control plug alignment checks, and electrical interlock testing during FAT.

As one of the most professional low-voltage switchgear manufacturers and suppliers in China, we also support customized service. Please feel free to wholesale discount low-voltage switchgear in stock here from our factory. Quality products and low price are available.