All cables are number/letter ferruled corresponding with the unique wire number on the drawings and then suitably crimped relating to the size of cable and component connection. Crimping tools are regularly calibrated to ensure the torque strength of the crimp is consistent no matter who makes the connection and what tool is used.
Once the gearplates have been wired on the bench the sprayed panel sections can be assembled and fitted out with the pre-wired gearplates, doors and door equipment, to allow the door wiring loom to be connected. Engraved traffolyte labels are fitted to the doors with either plastic rivets or stainless steel tapped screws depending on the requirements of the specification.
If the panel has a busbar system the copper-work is cut to length, punched and fitted into the panel and all joints are Torque tightened and marked with indelible paint to demonstrate every bolt has been tightened correctly. Once the busbar system has been fitted the Mains Cabling or Copper-Work can be fitted to each functional unit to complete the main power distribution system.
The earth bar is installed and all metalwork and equipment earth bonding is connected back to the main earth bar.
With the panel sections fully assembled all interconnection cables are fitted to complete the assembly of the panel ready for testing.
Quality is paramount during the assembly process to ensure that wiring is ‘right first time’ and all connections are correctly terminated using the correct crimping tools and techniques. The works manager constantly monitors the build process along with the Design Engineer who is always available for any technical issues or design queries experienced during the assembly process.