How to Avoid LV Switchgear Mistakes

An LV Switchgear Panel is a key component in modern electrical distribution systems, responsible for safely controlling and protecting circuits across industrial and commercial installations. However, mistakes in design, installation, and maintenance can compromise performance, safety, and reliability. When partnering with a Low Voltage Switchgear Manufacturer, understanding common pitfalls and how to avoid them helps ensure your system operates dependably from day one.

Many users have raised concerns about recurring problems — such as unexpected failures, premature wear, or operational errors — that stem from avoidable mistakes.

1. Skipping Installation Guidelines

One frequent error arises when installers overlook or improperly follow the manufacturer’s installation instructions. Each switchgear model comes with detailed manuals that specify torque values, connection diagrams, grounding requirements, and environmental considerations. Ignoring these guidelines can cause loose connections, miswired circuits, and poor grounding — all of which amplify risks of overheating, arcing, or fault conditions. Proper adherence to manuals and standards during installation is essential to achieve safe and reliable operation.

better practice is to prepare a comprehensive installation checklist based on the LV switchgear panel’s technical documentation and verify each step before energizing the system.

2. Neglecting Site Preparation and Environment

The physical environment in which a switchgear panel is installed also matters a great deal. Problems such as high humidity, dust, corrosive fumes, or inadequate ventilation can accelerate component degradation and create unsafe conditions inside the cabinet. For example, an enclosure installed in a dusty or poorly ventilated space may trap heat and contaminants, reducing insulation effectiveness and increasing the likelihood of failures.

Before installation, ensure the site:

Meets ventilation and airflow requirements.

Offers sufficient clearance for maintenance access.

Minimizes exposure to moisture, dust, and corrosive elements.

Implementing proper environmental controls protects both the hardware and personnel.

3. Poor Grounding and Earthing Practices

Adequate grounding is not just a regulatory requirement but a safety imperative. Poor grounding can cause erratic breaker behavior, dangerous fault currents, and increased risk of electrical shock. Many installers underestimate the importance of low-resistance earth connections, resulting in inconsistent performance and potential hazards.

To avoid grounding mistakes:

Use certified grounding conductors sized per applicable standards.

Test earth resistance to verify low resistance paths.

Maintain clear documentation of grounding locations for future reference.

Thorough grounding practices help reduce transient and fault-current risks.

4. Inconsistent Testing and Commissioning

Too many projects rush into energization without comprehensive testing and commissioning. Skipping critical tests — such as insulation resistance, continuity, functional breaker tripping, phase sequence checks, and relay validation — can mask hidden wiring errors or defective components.

Standards-based pre-commissioning ensures that each system element works as intended:

Conduct both visual and electrical tests before power-on.

Include functional simulations to verify protective device responses.

Document all results to support future troubleshooting and compliance audits.

Complete testing exposes issues early and builds confidence before handing over to operations.

5. Ignoring Maintenance and Monitoring

Once the panel goes live, ongoing maintenance is crucial to avoid later failures. Treating a switchgear installation as a one-time task leads to deteriorated connections, insulation breakdown, and undetected wear.

A structured maintenance plan should include:

Routine thermal imaging to detect hotspots.

Check and retighten connections periodically.

Clean dust and contaminants from busbars and terminals.

Inspect wear on mechanical components and contact surfaces.

A documented maintenance log helps track patterns and anticipate future issues.

6. Poor Labeling and Documentation

Another common oversight is inconsistent labeling and lack of accurate documentation. Without clear labels on breakers, circuits, and cabling, troubleshooting becomes guesswork and increases the risk of human error during operation or servicing.

Always maintain:

Clear, durable labels for all electrical components.

Up-to-date single-line diagrams and schematics.

Digital archives of manuals, certificates, and test reports.

Good documentation helps technicians quickly diagnose issues and minimizes service time.

7. Underestimating Safety Protocols

Safety cannot be an afterthought. Mistakes like bypassing lockout/tagout procedures, inadequate use of personal protective equipment, or entrusting work to unqualified personnel put people at risk and can cause to serious accidents.

Ensure safety by:

Applying lockout/tagout for all work on energized or potentially energized equipment.

Requiring arc-rated PPE for all panel access activities.

Training all staff on electrical hazard recognition and response.

A safety-initial mindset reduces risks and protects operators.

At Qinghang Electric Co., Ltd., we emphasize a complete lifecycle approach — from installation planning through testing, maintenance, and documentation — so clients enjoy reliable performance without common pitfalls.