Power Conversion System (PCS) and inverter cabinets for grid-connected energy storage. Our PCS cabinets house inverters, transformers, switchgear, and control systems with proper thermal management, EMC shielding, and safety interlocks.
IP55/IP65 Rated
UL 9540A Certified
-40°C to +55°C
1-5 MWh Capacity
The PCS/Inverter Cabinet Enclosure from Leading Top Union is engineered to house power conversion systems from 100 kW to 5 MW, supporting both grid-tied and off-grid configurations. Fabricated from 2.0 mm to 3.0 mm hot-dip galvanized steel per ASTM A653, the enclosure achieves an IP54 rating per IEC 60529 and NEMA 3R compliance, ensuring protection against dust ingress and water spray from any direction. Internal structural reinforcements are welded to AWS D1.1 standards, with all welds verified through visual inspection per ISO 5817 Grade B. The enclosure accommodates forced air cooling with airflow rates up to 12,000 CFM or liquid cooling loops with 2-inch NPT fittings, maintaining internal temperatures below 45°C at ambient conditions up to 50°C.
EMC shielding is integrated into the enclosure design to meet IEC 61000-6-2 (industrial immunity) and IEC 61000-6-4 (emission limits) without requiring external filter cabinets. Conductive gaskets with 95% minimum compression set resistance are installed at all door and panel interfaces, providing attenuation of 60 dB at 100 MHz and 40 dB at 1 GHz. The enclosure is arc flash rated per IEEE C37.20.7, with Type 2 accessibility classification for front-only access. Internal arc containment is achieved through 3.0 mm steel barriers and pressure relief panels rated for 10 kA arc fault currents over 500 ms duration. Safety interlocks on all access doors automatically disconnect control power upon entry, complying with NFPA 70E requirements.
Cable management is optimized for high-density AC and DC power routing, with separate compartments for power cables (up to 500 MCM) and communication cables (fiber optic and Cat6A). The enclosure includes pre-drilled cable entry plates with IP54-rated gland plates accommodating up to 24 cable entries per side. Busbar systems are rated for 2000 A continuous current per IEC 61439-1, with tin-plated copper bars sized for 60°C temperature rise at full load. The enclosure supports both top and bottom cable entry, with removable gland plates for field installation flexibility. All hardware is stainless steel 316 grade, and the enclosure is powder coated to a minimum 80-micron thickness with RAL 7035 texture finish for corrosion resistance in coastal environments.
In utility-scale solar photovoltaic plants, the PCS/Inverter Cabinet Enclosure is deployed at 1.5 MW to 5 MW per unit, typically paired with central inverters from SMA, Sungrow, or KACO. For a 100 MW solar farm, approximately 20 to 30 enclosures are installed in parallel, each handling 3,000 VDC input and 600 VAC output. The enclosure's IP54 rating allows outdoor installation in desert environments with ambient temperatures up to 55°C, while the forced air cooling system maintains IGBT junction temperatures below 125°C. EMC compliance ensures no interference with SCADA communication systems operating at 2.4 GHz, critical for real-time power curtailment and grid frequency response.
In offshore wind energy applications, the enclosure is adapted for liquid cooling to handle 2 MW to 4 MW power conversion from permanent magnet generators. The enclosure is constructed with marine-grade 316L stainless steel and coated with a 120-micron epoxy system per ISO 12944 C5-M for high corrosion resistance. Internal components are protected against salt spray per ASTM B117 for 1,000 hours with no corrosion. The enclosure supports DNV-GL type approval for offshore substations, with vibration testing per IEC 60068-2-6 at 5 to 100 Hz and 2 g acceleration. Cable entries are fitted with EMC glands rated for IP68 submersion, and the liquid cooling loop uses a 30% glycol-water mixture for freeze protection down to -20°C.
In mining and mineral processing operations, the enclosure is deployed for regenerative braking systems on conveyor drives and hoists, handling power ratings from 500 kW to 3 MW. The enclosure is designed for underground installation with a 1.5 mm thick steel construction and a 100-micron anti-static powder coating per IEC 60079-14 for hazardous area compliance. Arc flash rating per IEEE C37.20.7 Type 2B provides protection during maintenance in confined spaces. The enclosure includes integrated dust filters with MERV 8 rating for forced air cooling, and all doors are fitted with pressure relief dampers to manage internal pressure from arc events. Cable management accommodates 4/0 AWG power cables and 18 AWG control cables in separate raceways.
In petrochemical and oil & gas facilities, the enclosure is used for variable frequency drives (VFDs) on pump and compressor applications from 250 kW to 2 MW. The enclosure is built to NEMA 4X standards with a 3.0 mm 304L stainless steel body and a 150-micron epoxy coating for chemical resistance. Internal cooling uses a closed-loop liquid system with a plate heat exchanger rated for 100 kW heat rejection at 40°C ambient. The enclosure is certified for Zone 2 gas groups IIC per IEC 60079-15, with all electrical components rated for -20°C to +60°C operation. Cable entries are sealed with explosion-proof glands per IEC 60079-14, and the enclosure includes a purge system for positive pressure maintenance.
Leading Top Union holds ISO 3834-2 certification for fusion welding of metallic materials, ensuring all structural welds on the PCS/Inverter Cabinet Enclosure meet the highest quality standards for fatigue resistance and load-bearing capacity. EN 1090-2 EXC3 certification guarantees execution class 3 for steel structures, with traceability for all materials from mill to final assembly. AWS D1.1 certification is maintained for all welding procedures, with certified welders qualified per AWS QC1. Each enclosure undergoes 100% dimensional inspection using CMM equipment with ±0.1 mm accuracy, and all welds are inspected via ultrasonic testing per ISO 17640 for internal defects. This multi-standard approach ensures consistent quality across production batches.
The manufacturing facility in Suzhou operates with a 15,000-square-meter production floor dedicated to custom enclosure fabrication. CNC turret punch presses with 30-ton capacity and 32-station tooling are used for precise sheet metal forming, achieving tolerances of ±0.2 mm on hole patterns and ±0.5 mm on overall dimensions. Laser cutting capabilities handle material thicknesses from 1.5 mm to 6.0 mm with ±0.1 mm accuracy. The powder coating line includes a 5-stage pretreatment process with zinc phosphate conversion coating, followed by electrostatic application of polyester powder to a minimum 80-micron thickness. Each enclosure is tested for coating adhesion per ASTM D3359 and salt spray resistance per ASTM B117 for 500 hours minimum.
Complete customization is offered for PCS/Inverter Cabinet Enclosures, including custom dimensions from 600 mm to 2,400 mm width, 600 mm to 1,200 mm depth, and 1,800 mm to 2,400 mm height. Internal mounting rails are adjustable in 25 mm increments for flexible component placement. Pre-installed busbar systems rated up to 3,000 A with copper cross-sections from 50 mm² to 200 mm² are provided. Cable management options include cable trays, ladder racks, and wire duct with custom cutouts per your wiring diagram. All enclosures are delivered with full documentation, including material test certificates per EN 10204 3.1, welding procedure specifications (WPS), and inspection reports per ISO 9001:2015 quality management system.
Technical support for integration with any inverter platform, including SMA, Sungrow, KACO, Dynapower, and others, is provided by the engineering team. The enclosure design can be modified to accommodate specific cooling requirements, such as increased airflow for high-altitude installations above 2,000 meters or derated for ambient temperatures up to 55°C. Optional features like anti-condensation heaters rated at 200 W, door position sensors for remote monitoring, and integrated surge protection devices (SPDs) per IEC 61643-11 for Type 1 and Type 2 applications are also available. Lead times for custom enclosures range from 4 to 8 weeks depending on complexity, with sample units available for pre-production validation within 2 weeks.
| Parameter | Specification |
|---|---|
| Power Range | 100 kW - 5 MW |
| Enclosure Rating | IP54 / NEMA 3R |
| Cooling | Forced air / Liquid cooling |
| EMC | IEC 61000-6-2/6-4 |
| Arc Flash | Rated per IEEE C37.20.7 |
| Dimensions | Custom per inverter platform |
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