MCC Panels

Custom Engineered Panel

Bespoke panel assemblies for non-standard requirements — special ratings, unusual form factors, multi-function combinations.

Custom Engineered Panel

Custom Engineered Panel assemblies are bespoke low-voltage switchgear and controlgear solutions designed for projects where off-the-shelf distribution boards, MCCs, or control panels cannot satisfy the electrical, mechanical, environmental, or functional specification. They are typically engineered as IEC 61439-2 assemblies for power switchgear and controlgear, with design verification completed in accordance with IEC 61439-1. Depending on the scope, the assembly may also incorporate elements governed by IEC 60947 for ACBs, MCCBs, contactors, motor starters, VFDs, soft starters, and protection relays, ensuring the complete system is coordinated from the incomer through to the final load. In practical applications, rated operational voltages are commonly 400/415 V AC, 480 V AC, or up to 690 V AC, with busbar ratings ranging from 400 A to 6300 A and short-circuit withstand values typically from 25 kA to 100 kA for 1 s, subject to the available fault level and protective device coordination. The primary value of a custom engineered panel is integration. A single assembly can combine an incoming air circuit breaker, multiple outgoing MCCB feeders, variable-frequency drives for pumping, HVAC, conveyors, and process equipment, soft starters for high-inertia motors, capacitor banks for power factor correction, power meters and analyzers, PLC I/O modules, HMI/SCADA interfaces, surge protection devices, and protection relays for feeder, motor, transformer, or generator duty. This makes the panel suitable for multi-function installations where power distribution, motor control, monitoring, and automation must coexist in one coordinated enclosure. For engineering teams, this often means careful attention to heat dissipation, cable segregation, harmonics from VFDs, neutral loading, and reserve space for future expansion. Form of internal separation is a key design decision. Depending on maintainability and fault containment requirements, custom engineered panels may be built to Form 2, Form 3, or Form 4 arrangements, with Form 4b frequently selected for better segregation between functional units and busbars. In critical sites, this helps reduce downtime and improves service safety by allowing work on one feeder section without exposing adjacent circuits. Design verification must address temperature rise, dielectric properties, short-circuit withstand, clearances and creepage distances, mechanical strength, and protective circuit continuity as required by IEC 61439-1/2. Environmental and project-specific constraints often drive the enclosure design. Panels can be supplied in IP31 to IP66 ratings, with powder-coated mild steel, stainless steel, or galvanized steel enclosures, anti-condensation heaters, filtered ventilation, forced cooling, or heat exchangers. For harsh industrial and marine environments, corrosion resistance, vibration performance, and EMC behavior per IEC 61000 become essential. Where hazardous locations or adjacent equipment interfaces are involved, ATEX and IECEx considerations may influence the panel architecture, while marine classification approvals, seismic qualification, and internal arc assessment under IEC 61641 may be required for offshore, utility, transport, or emergency power applications. Custom Engineered Panels are widely used in data centers, healthcare, oil and gas, mining, water and wastewater, infrastructure utilities, commercial towers, food and beverage plants, pharmaceuticals, renewable energy plants, and marine offshore assets. They are also often specified for export projects requiring UL 891 or CSA alignment. The engineering objective is consistent across all sectors: deliver a verified IEC 61439 assembly with the right ratings, segregation, protection philosophy, and lifecycle maintainability. For EPC contractors, panel builders, and facility managers, a custom engineered panel provides a reliable way to integrate OEM and third-party equipment into a single compliant solution tailored to the site and the process.

Components for This Panel

Air Circuit Breakers (ACB)

Air Circuit Breakers (ACB) selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Moulded Case Circuit Breakers (MCCB)

Moulded Case Circuit Breakers (MCCB) selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Variable Frequency Drives (VFD)

Variable Frequency Drives (VFD) selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Soft Starters

Soft Starters selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

PLCs & I/O Modules

PLCs & I/O Modules selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Contactors & Motor Starters

Contactors & Motor Starters selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Capacitor Banks & Reactors

Capacitor Banks & Reactors selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Metering & Power Analyzers

Metering & Power Analyzers selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Surge Protection Devices (SPD)

Surge Protection Devices (SPD) selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Busbar Systems

Busbar Systems selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

HMI & SCADA Systems

HMI & SCADA Systems selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Protection Relays

Protection Relays selection, integration, and best practices for Custom Engineered Panel assemblies compliant with IEC 61439.

Applicable Standards

IEC 61439-2 (PSC)

IEC 61439-2 (PSC) compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

ATEX / IECEx Certification

ATEX / IECEx Certification compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

Marine Classification (DNV/Lloyd's/BV)

Marine Classification (DNV/Lloyd's/BV) compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

Seismic Qualification (IEEE 693/IBC)

Seismic Qualification (IEEE 693/IBC) compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

UL 891 / CSA C22.2

UL 891 / CSA C22.2 compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

IP Protection Ratings

IP Protection Ratings compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

Arc Flash Protection (IEC 61641)

Arc Flash Protection (IEC 61641) compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

EMC Compliance (IEC 61000)

EMC Compliance (IEC 61000) compliance requirements, testing procedures, and design considerations for Custom Engineered Panel assemblies.

Industries Using This Panel

Commercial Buildings

Custom Engineered Panel assemblies engineered for Commercial Buildings applications, addressing industry-specific requirements and compliance standards.

Industrial Manufacturing

Custom Engineered Panel assemblies engineered for Industrial Manufacturing applications, addressing industry-specific requirements and compliance standards.

Data Centers

Custom Engineered Panel assemblies engineered for Data Centers applications, addressing industry-specific requirements and compliance standards.

Healthcare & Hospitals

Custom Engineered Panel assemblies engineered for Healthcare & Hospitals applications, addressing industry-specific requirements and compliance standards.

Oil & Gas

Custom Engineered Panel assemblies engineered for Oil & Gas applications, addressing industry-specific requirements and compliance standards.

Water & Wastewater

MCC, VFD panels, PLC automation, APFC, generator control, soft starters

Mining & Metals

Custom Engineered Panel assemblies engineered for Mining & Metals applications, addressing industry-specific requirements and compliance standards.

Renewable Energy

Custom Engineered Panel assemblies engineered for Renewable Energy applications, addressing industry-specific requirements and compliance standards.

Marine & Offshore

Custom Engineered Panel assemblies engineered for Marine & Offshore applications, addressing industry-specific requirements and compliance standards.

Infrastructure & Utilities

Custom Engineered Panel assemblies engineered for Infrastructure & Utilities applications, addressing industry-specific requirements and compliance standards.

Food & Beverage

Custom Engineered Panel assemblies engineered for Food & Beverage applications, addressing industry-specific requirements and compliance standards.

Pharmaceuticals

Custom Engineered Panel assemblies engineered for Pharmaceuticals applications, addressing industry-specific requirements and compliance standards.

Related Knowledge Articles

Modular vs Custom Panel Assembly: How to Choose

Comparing modular type-tested systems with custom-built panels.

Complete Guide to the IEC 61439 Standard Series

Comprehensive overview of all IEC 61439 parts, their scope, and how they apply to different panel types.

IEC 61439 Compliance Checklist for Panel Builders

Practical checklist for achieving IEC 61439 compliance.

Panel Nameplate and Documentation Requirements

What must appear on the panel nameplate and in documentation.

Frequently Asked Questions

A custom engineered panel is a purpose-built low-voltage assembly designed to meet a project-specific electrical and mechanical brief that standard switchboards cannot satisfy. It is normally built and verified as an IEC 61439-2 power switchgear and controlgear assembly, with design verification per IEC 61439-1 covering temperature rise, short-circuit withstand, dielectric performance, clearances and creepage, and mechanical strength. These panels frequently integrate ACBs, MCCBs, VFDs, soft starters, contactors, metering, PLC I/O, and protection relays into one coordinated lineup. For EPCs and panel builders, the key benefit is flexibility without losing compliance or traceability.
Typical integrations include an incoming air circuit breaker, outgoing moulded-case circuit breakers, variable-frequency drives, soft starters, motor contactors, capacitor banks, multifunction meters, PLC and remote I/O modules, HMI/SCADA hardware, surge protection devices, and feeder or motor protection relays. In industrial and utility projects, these may also include automatic transfer or load management functions. Component selection should follow IEC 60947 for switching and controlgear, while the panel assembly itself remains within IEC 61439. Proper thermal zoning and harmonic management are especially important when VFDs and capacitor banks share the same enclosure.
Custom engineered panels are commonly specified from 25 kA up to 100 kA for 1 second, though the actual rating depends on the prospective fault level, protective device coordination, and busbar design. Under IEC 61439, the assembly must be verified for short-circuit withstand either by testing, calculation, or reference to a verified design. The incoming ACB or MCCB, outgoing feeders, and busbar system must all be coordinated so that the assembly can withstand and, where required, conditionally limit the fault energy. This is particularly important in utility substations, data centers, and heavy industrial facilities.
Custom engineered panels are often built with Form 2, Form 3, or Form 4 internal separation, depending on the maintenance and continuity-of-service requirements. Form 4, including Form 4b arrangements, is selected when the objective is to segregate busbars, functional units, and terminals so that work on one feeder does not force shutdown of adjacent circuits. IEC 61439 allows the form to be defined by the assembly design, but the manufacturer must verify the barriers, partitions, and cable compartments. This is common in hospitals, process plants, and data centers where downtime is costly.
Higher IP ratings such as IP65 or IP66 are selected when the assembly will be exposed to dust, washdown, spray, or corrosive atmospheres, such as food and beverage, wastewater, or offshore projects. Marine-classification requirements are common for vessels and offshore platforms where vibration, salt fog, and EMC performance are critical. ATEX and IECEx considerations apply when the panel is installed in or connected to hazardous areas, or where associated interfaces must be evaluated for explosive atmospheres. In all cases, the enclosure and internal layout must still satisfy IEC 61439 thermal and dielectric requirements.
Yes, but the design must address harmonics, heat dissipation, and control coordination. VFDs generate losses and electrical noise, while capacitor banks can be affected by harmonic distortion if they are not detuned or properly staged. In many custom engineered panels, VFD sections are segregated from metering and control compartments, with filtered ventilation, heat exchangers, or dedicated cooling paths used to maintain temperature rise limits under IEC 61439. EMC measures aligned with IEC 61000 are also important. For larger systems, harmonic studies and reactive power calculations should be completed before final component selection.
Before delivery, the assembly should undergo IEC 61439 design verification and routine verification. Design verification covers temperature rise, dielectric properties, short-circuit withstand, protective circuit continuity, creepage and clearance distances, and mechanical operation. Routine verification includes wiring checks, insulation tests, functional checks, and verification of nameplate data and protective device settings. If the project calls for it, internal arc considerations may be evaluated to IEC 61641, and export projects may also require alignment with UL 891 or CSA. A complete test dossier is essential for EPC handover and lifecycle maintenance.
Custom engineered panels are widely specified in data centers, healthcare, oil and gas, water and wastewater, mining and metals, commercial high-rise buildings, renewable energy plants, marine and offshore assets, food and beverage, pharmaceuticals, and infrastructure utilities. These sectors often need mixed loads, redundancy, special segregation, environmental protection, or integration with automation and monitoring systems. The panel is engineered to match the site-specific load profile, available fault level, maintenance strategy, and enclosure environment while remaining compliant with IEC 61439 and the relevant product and application standards.

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