Working with low voltage switchgears isn’t just about turning on power it’s about ensuring safety, reliability, and long-term performance. Over the years, we’ve seen countless avoidable errors that cost businesses thousands and even put lives at risk. So, we decided to put together this guide to highlight the most common mistakes professionals make and how you can avoid them. Because in the world of electricity, a small mistake can have a shocking impact.
One of the biggest blunders is treating low voltage switchgears as “install-and-forget” equipment. In reality, even high-quality components degrade over time. Dust, moisture, vibration, and thermal stress all take a toll on performance.
Example: A facility experienced a critical power outage due to corroded busbars — something that could’ve been prevented with a simple annual inspection.
Every switchgear is designed to handle a specific electrical load. Exceeding that limit, even occasionally can cause overheating, component damage, or complete failure.
Overloads may not always trip the system but can slowly degrade internal components, leading to dangerous failures.
Electrical safety is non-negotiable. Mistakes such as bypassing lockout/tagout procedures, using incorrect PPE, or operating under load without proper clearance can cause serious injuries or even fatalities.
Case Study: A technician suffered burns after servicing a live panel with no arc-flash protection , a costly and avoidable mistake.
Dust, humidity, corrosive vapors, and high temperatures can all compromise switchgear performance. Failing to account for the installation environment can reduce the lifespan of your equipment dramatically.
Poor ventilation or proximity to industrial chemicals can cause switchgear enclosures to corrode or overheat prematurely.
When problems occur, clear documentation and labeling are your best tools. But many facilities fail to maintain updated schematics, single-line diagrams, or breaker labels — turning troubleshooting into guesswork.
Delays caused by poor documentation can cost hours of downtime and even risk misdiagnosis or accidental energization.
When it comes to electrical safety, cutting costs upfront can mean paying double later. Low-cost switchgears may lack proper certifications, use substandard materials, or fail under fault conditions.
Substandard components might save money short-term but often result in increased failure rates, lower efficiency, and non-compliance penalties.
Not every application is the same. Using standard switchgear panels for specialized facilities like data centers, factories, or hospitals can cause serious compatibility and layout issues.
A factory once faced cable routing challenges and overheating due to lack of space all because they chose off-the-shelf switchgear with no customization.
Low Voltage Switchgears installation isn’t complete until testing and commissioning are thoroughly carried out. Skipping or rushing this step can lead to hidden wiring issues, undervoltage, phase faults, or even short circuits.
Today’s system might work perfectly, but what about next year? Adding new machinery or increasing building loads without considering switchgear limitations can create bottlenecks and require expensive rework.
Everyone makes mistakes. But when it comes to low voltage switchgears, even small errors can have big consequences. The good news? They’re all avoidable. By following the tips we’ve shared here, you’re already ahead of the curve. Keep learning, keep inspecting, and always aim for safety first.
Need help choosing the right Low Voltage switchgears? Looking for a custom solution or technical advice?
Contact Stefan Switchgears Today
www.stefanelectric.com.com
Email: info@stefanelectric.com
Providing high-quality, reliable switchgear solutions with a commitment to excellence, safety, and customer satisfaction.
Providing high-quality, reliable switchgear solutions with a commitment to excellence, safety, and customer satisfaction.
