Do we need to specify tin or silver plating, or does Frigate recommend based on current rating?

Frigate recommends plating specification at DFM review based on your rated current, joint temperature rise target, and contact resistance requirement. Tin plating is standard for configurations up to approximately 2,000 A. Silver plating is recommended above 2,000 A and wherever minimum contact resistance is a specific requirement. The recommendation is included in the written DFM review returned within 5 working days of drawing submission.

Pre-Integrated Enclosure + Busbar

Enclosure and busbar system supplied as a single verified sub-assembly — copper or aluminium conductors installed, torqued, shrouded, and phase-barrier fitted inside the enclosure before dispatch. Connection interface geometry, joint torque values, phase barrier completeness, and thermal performance at rated current are all verified and documented. Arrives at your production line ready for circuit breaker, MCCB, or switchgear connection — no busbar assembly, no torque sequence, no shrouding work on your line.

Conductor Material

ETP copper C11000; Al 1350-H19;

Conductor Cross-Section

Per your rated current and temperature rise calculation; standard range 25×3 mm to 120×10 mm flat bar; multiple parallel bars for high-current configurations

Rated Current

Up to 6,300 A; specific rating confirmed per conductor cross-section, support configuration, and enclosure thermal model

Short Circuit Withstand

Up to 100 kA peak (1 second); confirmed by type test or calculation per IEC 61439-1 Clause 10.11

Plating Coverage

All contact faces at bolted joints and device connection interfaces; plating applied after drilling, before assembly

*First-run lead times include DFM review, jig fabrication for conductor positioning, and first article inspection covering torque verification, CMM connection position, and thermal verification data.

Product Description

Frigate installs busbar conductors to your layout drawing with connection interface positions held to ±0.5 mm from the switchgear interface datum. All bolted joints are torqued to specification using calibrated torque tooling and recorded on a per-joint torque verification sheet supplied with every sub-assembly. Contact face plating — tin or silver — is applied per your specification before assembly and verified by plating thickness measurement before installation. Phase barriers and shrouding are fitted to provide full live part isolation before the sub-assembly is packaged for dispatch.

Fastener Specification

Grade 8.8 steel or A2-70 stainless bolts; M8–M16 per joint current rating; spring or Nord-Lock washers at all busbar joints

Connection Hole Position

±0.5 mm true position from switchgear interface datum; CNC-drilled; CMM-verified at first article

Support Insulator Material

Glass-reinforced polyester (GRP / SMC); UL 94 V-0 rated;

Support Bracket Position

±1.0 mm from drawing position;

Shrouding Coverage

All accessible live surfaces shrouded before dispatch; IPXXB (finger-safe) minimum at all surfaces accessible

Temperature Rise Verification

Per IEC 61439-1 Clause 10.10; by type test for new configurations;

Temperature Rise Limits

Busbar conductor: ≤70 K above 40°C ambient;

Enclosure Material

CRCA steel 2.0–3.0 mm (IS 513 / EN 10130); 304 SS or 316L SS per environment specification;

IP Rating

IP31 / IP41 / IP54 / IP65 per your installation environment; verified on assembled sub-assembly with busbar system installed

Environmental Compliance

RoHS 3; REACH SVHC <0.1% w/w; WEEE compliant;

Technical Advantages

Main distribution board (MDB) and main LV panel sub-assemblies typically carry the highest current ratings in the range — 1,600 A to 6,300 A — with flat copper or aluminium conductor busbars on insulated supports across the full panel width. The connection interface positions for incoming ACB, outgoing MCCB feeders, and inter-panel links are all CNC-drilled to your layout drawing and verified by CMM before dispatch.

Sub-distribution board (SDB) and final distribution sub-assemblies operate in the 100 A to 1,600 A range with smaller cross-section conductors and higher device connection point density — connection position consistency at this density is particularly critical, as small positional errors multiply across a high device count.

Let's Get Started

Need reliable Enclosure for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Application

Main LV Distribution Panels

High-current busbar sub-assemblies for main LV switchboard and MDB production — 1,600 A to 6,300 A configurations with ACB incoming interfaces and MCCB feeder connection positions pre-drilled and plated. Torque documentation supports IEC 61439 type-tested assembly verification.

Motor Control Centres

Vertical riser and horizontal tee-off busbar sub-assemblies for MCC production. Tee-off connection positions drilled to your starter unit interface drawing; shrouding between positions completed before dispatch. Consistent tee-off geometry across all positions reduces starter unit alignment time on your production line.

Transfer Switch & Changeover Panels

Dual-source busbar sub-assemblies with structural isolation barrier between normal and standby supply zones. Isolation barrier fabricated as a permanent element of the sub-assembly. Both source connection interfaces pre-drilled and plated before dispatch.

Sub-Distribution Boards

Medium-density busbar sub-assemblies for SDB and final distribution panel production — 100 A to 1,600 A range with high device connection point count. Connection position consistency at high device density is maintained through retained jig tooling across all production batches.

Metering & Power Quality Panels

Busbar sub-assemblies with CT primary connection interfaces and CT mounting provisions integrated into the conductor layout. CT primary interface positions drilled to ±0.3 mm from busbar centreline per your CT specification.

Busbar Trunking Interface Panels

Enclosure sub-assemblies with busbar trunking connection flanges pre-installed at the trunking entry position. Connection flanges drilled and plated to the trunking manufacturer’s interface specification — tap-off connection at your facility without enclosure modification.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

Solar Inverter Enclosure

units per month

Bento Boxes for D2C Segment

Units Manufactured Monthly

0 +

Defence-Grade Cable Supply

Cost savings

0 %

Flange Assembly for Pump

Faster Production

0 %

Having Doubts? Our FAQ

Our current supplier's busbar connection positions vary between units. How does Frigate control that in production?

Connection position variation between units almost always traces to conductors being positioned by hand against the drawing rather than against a retained jig. Frigate installs conductors using dedicated jig tooling referenced to the enclosure datum — the jig is retained between production batches, not rebuilt each run. Connection position is verified by CMM at first article and AQL-sampled in production, with measurement data available per batch.

We need torque documentation to support our IEC 61439 assembly verification. What format does Frigate supply?

Frigate supplies a per-joint torque verification sheet with each sub-assembly — identifying every bolted joint by position reference, the specified torque value, and the measured torque value recorded at assembly. The format is aligned to IEC 61439-1 assembly verification documentation requirements and can be formatted to your incoming quality documentation standard on request.

We're transitioning from loose component supply to pre-integrated sub-assembly. What does Frigate need from us to start?

Submit your busbar layout drawing — conductor positions, cross-sections, connection interface dimensions, support positions, and phase barrier requirements — alongside your rated current, rated voltage, and short-circuit withstand requirement. If a current layout drawing doesn’t exist, Frigate’s engineering team can develop one from your panel schedule and device connection data. DFM review and scope confirmation are returned within 5 working days.

We have multiple panel types in our product range. Can Frigate supply pre-integrated sub-assemblies across all of them under one programme?

All panel types are managed under a single programme — consistent conductor material specification, matching plating, unified torque documentation format, and a single documentation package structure across all configurations. Each panel type has its own jig tooling and first article, but the programme management, delivery scheduling, and quality documentation are consolidated. The commercial discussion covers whether all panel types enter the programme simultaneously or are phased in as their respective layouts are confirmed.

We'd love to Manufacture for you!

Submit the form below and our representative will be in touch shortly.

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Components Built for Critical Performance

Engineered Products for Critical Applications

Pre-Integrated Enclosure + Busbar

Product Description

Fastener Specification

Connection Hole Position

Support Insulator Material

Support Bracket Position

Shrouding Coverage

Temperature Rise Verification

Temperature Rise Limits

Enclosure Material

IP Rating

Environmental Compliance

Technical Advantages

Let's Get Started

Industry Application

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Pre-Integrated Enclosure + Busbar

Get Latest Price

Pre-Integrated Enclosure + Busbar

Get Latest Price