How to prepare for electrical switchgear assembly? Installation guide from our engineers

Installing a dozen or more switchgear cabinets is both a design and execution challenge. Here’s what to consider to avoid delays, streamline communication, and ensure top-quality installation.

Accurate Client Data – the foundation of a good design

Every project begins with the design phase, where close collaboration with the client is key. The faster and more precisely data on machines, connections, and operating parameters are delivered, the smoother the design process runs.

As Piotr Grodziski, Senior Automation Engineer at ZW Automation, emphasizes:

“Accuracy and timeliness in data sharing save both time and costs. Ideally, the client defines requirements within clear boundaries and provides access to a unified file repository – this way we avoid duplicate files and lengthy email exchanges.”

It’s also good practice to define data delivery deadlines and mandatory information scope in the contract – this minimizes the risk of late revisions.

Verification of suppliers and components

At every stage – from design to prefabrication – even cooperation with specialists requires verification of supplied components. Always check the validity of used parts and their compliance with the project.

In many of our projects, we use the PrismaSeT switchboard system, which includes Linergy busbars and plug-in modular solutions. This technology works like LEGO blocks – enabling quick reconfiguration and easier maintenance. However, it requires careful preparation: checking cable entries, PE connections, and mounting compatibility. Otherwise, installation may reveal mismatches or the need for extra adaptation.

Michał Chlasta, Senior Automation Engineer coordinating cabinet assembly, points out:

“It’s best when the person responsible for assembling the cabinet reviews the components in advance – it helps identify potential assembly challenges early on.”

It’s equally important to anticipate supply chain issues. Delays or a lack of flexibility from suppliers can seriously affect project timelines. That’s why we work with partners who allow returns and react quickly to changes.

Work organization during assembly – strategy and role division

Efficient prefabrication requires a well-coordinated team and clear role assignment. A strong coordinator is crucial to uphold the schedule – rushing often compromises quality.

Early planning of the assembly and transport sequence is also vital so that cabinets can be easily positioned on-site, minimizing connections made at the client’s facility.

It’s advisable to clarify at the very beginning what kind of flooring is in the facility – raised floor or concrete slab – and whether cabinets will be mounted on plinths with closed or open bases. These decisions directly impact construction preparation, and ignoring them often leads to rework.

Safety and quality control must never be overlooked. We recommend:

• Training the assembly team in advance,

• Assigning separate personnel for electrical tightening and functional testing (to ensure objectivity),

• Delegating two workers to check all connections with a torque wrench and verify labeling.

These simple steps significantly reduce the risk of errors and increase switchgear reliability.

The Client’s role in prefabrication

Preparation on the investor’s side is equally important. Approved documentation, a ready installation site (e.g., raised floor), and proper logistics for switchgear delivery all help speed up the process and prevent downtime.

Thanks to this, our switchgear systems – compliant with EN 61439 and tested according to best engineering practices – can power the facility immediately after installation without unnecessary delays.

Summary – how to build reliable switchgear

Assembling multiple switchgear cabinets requires close cooperation between designers, engineers, suppliers, and the client. The key factors are: accurate data, component verification, efficient workflow, and compliance with standards.

By using the PrismaSeT system, plug-in modularity, and precise technical preparation, our switchgear not only meets formal and safety requirements but also supports long-term standardization in industrial facilities.

See more about this project: 19 main power switchboards for a food processing plant in Lower Silesia.

If you’re planning an investment in electrical switchgear and want to ensure the highest engineering standards – contact us. Our engineers will guide you through the entire process, from design to assembly and final testing.