Panel production

Electrical Panel Assembly & Control Panel Design for Industrial Automation

Professional electrical panel assembly is a fundamental step in building reliable power distribution systems and process automation solutions for industries, utilities, and commercial facilities. Chastotnik.ua delivers high-level engineering services including custom design, careful component selection, precision manufacturing, and factory acceptance testing of low-voltage switchgear and controlgear assemblies. Our dedicated assembly workshop manufactures custom control panels, PLC-based automation cabinets, automatic transfer switches (ATS), and main distribution boards. All custom assemblies strictly comply with international standards such as IEC 61439, national safety regulations, and industrial electrotechnical norms.

Key Areas of Our Electrical Cabinet Production

We focus on custom solutions tailored to the specific environmental conditions and technological requirements of our clients. The primary categories of electrical cabinets manufactured at our facilities include:

• VFD Control Cabinets (Variable Frequency Drive Cabinets): Designed for automated speed regulation of induction (including frequency converter tuning prior to startup) and synchronous motors in water supply, HVAC, industrial ventilation, and conveyor systems. These panels integrate high-performance VFDs (such as Veichi or other brands), forced ventilation/cooling units, line/motor reactors, harmonic filters, and protection switchgear to eliminate starting current spikes and prevent motor overheating.
• PLC Automation and Control Panels: Designed for continuous data collection from industrial sensors, executing programmable logic control algorithms, and sending control signals to actuators. Built with high-grade programmable logic controllers, analog/digital I/O modules, and human-machine interfaces (HMI touch panels) (we also provide professional controller programming services).
• Main Distribution Boards & Power Distribution Panels: Utilized for receiving, distributing, and metering electrical energy in three-phase AC systems. These boards protect outgoing circuits from overloads, short circuits, and earth fault currents in industrial plants and residential complexes.
• ATS Panels (Automatic Transfer Switches): Provide near-instantaneous automatic switching to a backup power source (secondary independent utility line, diesel generator, or uninterruptible power supply) upon main utility failure, phase imbalance, or voltage drop, ensuring continuous operation for critical loads.

Technical Standards and Component Selection Criteria

Exceptional reliability of our custom control panels is achieved by using original, certified equipment from leading global brands like Schneider Electric, Eaton, ABB, Veichi, and Chint. During enclosure selection, we carefully evaluate the environmental conditions: for dusty, humid, or outdoor installations, we select enclosures with protection ratings of IP54 or IP65. Enclosure options include durable epoxy-polyester powder-coated sheet steel or corrosion-free glass-reinforced polyester (GRP/SMC) structures. Internal wiring is completed using flexible copper wires terminated with insulated wire-end ferrules. Cable identification is executed using professional thermal-transfer printable sleeves to guarantee label legibility throughout the lifetime of the assembly.

Step-by-Step Electrical Panel Assembly Process

We adhere to a standardized, rigorous quality control workflow at every phase of cabinet assembly to eliminate human error and ensure operational safety:

1. Technical Requirements Analysis & CAD Design: Reviewing client specifications, designing electrical schematics, creating 3D cabinet layouts, and securing formal design approval from the customer.
2. Enclosure & Mounting Plate Preparation: Punching necessary cable entries, drilling holes on cabinet doors for HMI screens, buttons, pilot lights, and measuring/marking the mounting plate.
3. DIN Rail & Cable Duct Installation: Mounting high-density slotted plastic wiring ducts, zinc-plated DIN rails, terminal blocks, and installing copper busbars on high-dielectric strength insulators.
4. Switchgear & Electronic Component Mounting: Installing circuit breakers, contactors, relays, VFDs, PLCs, and power supplies on DIN rails with appropriate thermal clearances for optimal heat dissipation.
5. Internal Wiring & Power Bus Connections: Routing power and control cables neatly inside wiring ducts at 90-degree angles with proper bend radii. Wire stripping is done with specialized tools and terminated using precise crimping methods.
6. Identification & Labeling: Printing and placing unique markers on both ends of every conductor according to the electrical schematic, along with distinct tags for each internal component.
7. Quality Control & Terminal Torque Testing: Cross-checking the actual wiring against the approved schematics and verified torque verification of all screw terminals using calibrated torque screwdrivers.
8. Factory Acceptance Testing (FAT): Testing insulation resistance with a megohmmeter, checking ground continuity, applying nominal voltage, and performing complete functional and logic testing of PLCs and ATS systems (after which the equipment is ready for APCS commissioning on-site).
9. Packaging & Technical Documentation: Including original schematics, product passport with quality assurance sign-offs, manuals, and protective packaging (bubble wrap and heavy-duty wooden crates) for safe domestic and international transit.

Comparative Technical Parameters of Our Cabinets

To help you choose the right configuration for your project, the table below summarizes the key technical specifications of our standard and custom-engineered panels:

Warranty and Engineering Support Services

All control panels and automation cabinets manufactured by Chastotnik.ua are backed by an official 12 to 24-month warranty starting from the commissioning date. Our engineering team provides full remote and on-site support for cabinet integration, parameter setup, commissioning, and preventive maintenance and system retrofitting.