Why Does LV Switchgear Overheat

In modern electrical distribution systems, an LV Switchgear Panel plays a critical role in managing and protecting circuits in commercial, industrial, and residential installations. When this equipment overheats, it can compromise operational safety, reduce service life, and result in unplanned downtime. For anyone sourcing reliable products or technical support from a Low Voltage Switchgear Manufacturer, understanding the factors behind overheating is essential to preventing issues before they escalate.

Overheating doesn’t just happen out of nowhere — there are multiple root causes that installers, operators, and maintenance teams should proactively address. Many users have raised concerns about sudden temperature rises inside their LV panels and what the underlying reasons might be.

Improper Cable Termination and Loose Connections

One of the more frequent contributors to excessive heat in a switchgear panel is poor connections at terminals or busbars. Loose or improperly torqued connections increase electrical resistance, which in turn generates heat during normal current flow. In fact, high resistance at connection points can cause temperatures to rise significantly and even present fire hazards if left unaddressed. Regular inspection and correct torque practices during installation are crucial.

Thermal imaging during maintenance cycles is a useful tool for identifying hotspots inside switchgear before they damage components. Incorporating this preventive practice into routine checks can reveal trouble spots early.

Overloading Beyond Rated Capacity

Every LV switchgear unit is engineered to handle a specific load based on design ratings. When loads exceed these limits — whether due to improper load calculation or subsequent increases in demand — internal components can become thermally stressed. Overloading not only raises temperatures within the panel but also accelerates insulation degradation and can trigger protective devices prematurely or erratically.

Good practice is to allocate appropriate load margins and to review current distribution periodically, especially if your facility’s electrical demand has shifted since the original panel was installed.

Inadequate Ventilation and Environmental Restrictions

Another often overlooked factor is site conditions. LV switchgear panels dissipate heat as part of normal operation; if they are installed in poorly ventilated spaces, near other heat-generating equipment, or in areas subject to high ambient temperatures, heat buildup is almost inevitable. Restricted airflow contributes to stagnant heat pockets inside the panel, which can worsen the overheating cycle.

Planning installation spaces with enough clearance, good ventilation, and, where necessary, auxiliary cooling or airflow fans can help maintain stable operating temperatures.

Component Wear and Maintenance Gaps

Wear and tear on components such as breakers, contactors, and bus bars can also generate heat over time. As parts age or lose mechanical integrity, resistance increases and so does thermal output. Scheduled maintenance — including cleaning, lubrication of moving parts, and replacement of worn items — is key to maintaining efficient operation and avoiding hotspots.

Poor Installation Practices or Commissioning Errors

Sometimes the root cause lies in how the panel was originally installed or commissioned. Improper phasing, incorrect wiring, or skipped commissioning tests can result in abnormal current paths and unexpected heating later in service. Following the manufacturer’s installation guide carefully and conducting thorough commissioning checks are fundamental steps that a responsible Low Voltage Switchgear Manufacturer will emphasize.

At Qinghang Electric Co., Ltd., for example, we recommend that professional electricians conduct initial wiring inspections and full functional testing before energizing any LV switchgear assembly.

Operational Tips to Minimize Overheating Risks

To reduce the risk of overheating in your LV switchgear panel, consider adopting these better practices:

Routine Thermal Imaging: Identify hotspots early.

Torque Verification: Check terminal connections against manufacturer spec sheets.

Load Monitoring: Balance circuits to prevent overload conditions.

Maintain Ventilation: Ensure adequate airflow around all switchgear cabinets.

Periodic Service: Replace worn components and clean dust from internal surfaces.

Overheating in an LV switchgear panel signals that something in the electrical distribution chain isn’t functioning optimally. Whether it’s loose connections, overloading, environmental conditions, or maintenance gaps, taking a proactive approach is fundamental to ensuring long-term reliability and safety. For anyone working with or procuring electrical distribution systems, collaborating with an experienced low-voltage switchgear manufacturer can provide the technical guidance and product support necessary to mitigate these issues and maintain steady performance.