What are the top mistakes in IEC 61439 panel design and how to avoid them?

[Manon_Chaboud]

Ensuring IEC 61439 compliance is not just about passing a test; it’s about testing the right configurations.
Many manufacturers misunderstand how verification should be planned, which can lead to non-compliant results, rework, and extra costs.
Knowing how to structure verification correctly is key to building safe, efficient, and cost-effective panels.

Verification under IEC 61439 = testing the worst cases.
To certify a complete product range, manufacturers must identify and test multiple worst-case scenarios, especially for temperature rise and short-circuit withstand performance.
The goal is to prove that all configurations within the range meet the required safety and reliability levels,

not just one setup.

Example: PrismaSet (800 A → 4000 A):
Testing only the highest rating is not sufficient.
Several configurations must be selected to represent the most demanding conditions across the range. Those with the most critical combinations of busbars, connections, and mechanical layouts.

Smart verification strategy:
With a well-defined technical approach, testing can be optimized without compromising compliance.
In practice, three to four carefully selected short-circuit configurations are often enough to validate over 100 performance parameters, including busbar cross-sections, support distances, and connection methods.

Don’t over-test; test smart!
Focusing on the most demanding configurations saves time, reduces costs, and ensures your panels stay safe, compliant, and optimized.