Sheet metal, busbar, wiring, test
The production route for a rack PDU runs through four stations, and the last one is a powered test on every single unit.
- Enclosure
- cold-rolled steel
- Conductors
- VDE 2.5mm² / 6mm²
- Termination
- copper busbar
- Testing
- 100% electrical
- Record
- per line
What is checked before a unit leaves
Each station signs off on its own list. A unit that fails any line goes back to the station that owns it, not to the next one.
Test basis: 100% electrical testing · standard basis IEC / NEMA- Chassis dimensions
- per outline drawing
- Outlet type and order
- C13, C19, C19 as drawn
- Busbar joints
- bolted, torque checked
- Conductor size
- VDE VDE 2.5mm² / 6mm²#
- Continuity and polarity
- 100% of units
- Earth bond
- 100% of units
- Insulation
- before power-up
- Breaker operation
- trip and reset
- Metering reading
- ±1% against reference
- Communications
- Ethernet and RS485
- Display and alarms
- OLED, SMTP path
- Labels and documents
- per line, per drawing revision
Each check has one owner
Blanking, forming, busbar, wiring and test are separate stations with separate sign-off. When a line fails, the unit returns to the station that produced it.
Wide-input builds: 180 to 265V with surge and lightning protection
The work you cannot see from the front
The front of a rack PDU is an outlet row. Behind it sit the busbar, the breaker bank and the conductor terminations, and that is where a build is either sound or not.
- Busbar
- copper, bolted joints
- Conductors
- VDE 2.5mm² / 6mm²
- Terminations
- , ferruled
- Protection
- breaker, surge arrestor
Six stations on the shop floor
The route is fixed; the work inside each station follows the drawing. Nothing moves on until the station's own list is signed.
Blanking
Sheet steel is cut to the chassis outline and the outlet apertures. The cut program follows the latest drawing revision.
Checked: outline and aperture positionsForming
The panel is folded to the chassis profile, including the mounting flanges for 1U, 2U, 3U and zero-U builds. Depth is set by the enclosure family.
Checked: fold angles and mounting facesBusbar and breakers
Copper busbar is mounted and the breaker bank is fitted to the drawing. Joints are bolted and checked for torque before wiring begins.
Checked: joint torque and breaker ratingWiring
Conductors run to VDE 2.5mm² or 6mm², and terminate at the outlet blocks. Metering transformers are seated on the reporting lines.
Checked: conductor size and routingPower test
The unit is energised: continuity, polarity, earth bond, insulation and breaker function. Metering is compared against a reference meter.
Checked: ±1% metering against referencePack and document
The outlet row is protected, the unit is packed, and the document set goes inside: specification sheet per line, drawings, certificate titles.
Checked: document set against the dispatchCertificates behind the production route
Quality, environmental and health-and-safety systems are audited on their own cycles. The UL evidence for the product is a component certificate, certified to UL 62368-1.
Send the drawing. We build to it.
Outlet combination, current per feed, metering depth and switching scope. The quotation comes back in English with a specification sheet written per line.
- Reply
- within 12 hours, working days
- Documents
- per line, in English
- Build basis
- drawing or sample
