Power connections
Connecting with flexible bars
Flexible bar types
Practical rules
Standard: IEC 60332
Examples for Prisma Plus
Flexible bars must comply with standard IEC 60332-1 which guarantees: the electrical characteristics of the conducting core resistance to temperature and fire of the insulation.
To determine the required cross-sections for flexible bars connecting a Merlin Gerin device inside a Prisma Plus enclosure, use the tables below. Circuit-breakers, switches and fuses: b in a Prisma Plus cubicle b temperature inside switchboard: 60 °C. device IN125 IN160 IN250 IN400 IN630 NS100(1) NS160(1)
To determine the cross-sections of flexible bars required for switchboards complying with standard IEC 60439-1, the following parameters must be considered: location of the device within the enclosure sizes of the other circuits ambient temperature around the switchboard heat dissipated by the installed device temperature rise generated by the installed device connection length Standard: IEC 60439
Cutting to length
It is therefore necessary to respect the instructions provided by the electrical equipment manufacturer.
s (mm) 20 x 2 20 x 2 20 x 3 32 x 5 32 x 8 20 x 2 20 x 2
device NS250(1) NS400(1) NS630 Fu250 Fu400 Fu630
s (mm) 20 x 3 32 x 5 32 x 8 24 x 5 32 x 5 32 x 8
(1) the values indicated for circuit-breakers also apply to contactors with the same ratings.
Disconnectors, terminal blocks and busbar/ busbar connections: b in a Prisma Plus cubicle b temperature inside switchboard: 60 °C. I max (60 °C) 200 A 250 A 400 A 480 A 520 A 580 A 660 A
s (mm) 20 x 2 20 x 3 24 x 5 24 x 6 32 x 5 24 x 8 32 x 8
Insulation of the Prisma Plus flexible bars withstands temperature of 125 °C. NB: in all cases, comply with the bar crosssections given in the manuals.
Cutting, using shears if possible, should leave a clean cut, without flash. The cutting length is equal to the required final length of the bar + a safety margin (generally 10 mm) which allows for possible slippage between the individual copper layers when the bar is bent.
Bending Fig. 1
Fig. 2
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Flexible bars should be bent by hand, to avoid damaging the insulation, with a curvature radius equivalent to at least the thickness of the bar (see fig. 1). The copper layers, whose position in relation to each other may have changed during bending, are then cut off flush (see fig. 2).
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Power Connecting with flexible bars connections
Insulation stripping
Practical rules
Examples for Prisma Plus Prisma Plus offers a whole host of prefabricated connections, pre-stripped and drilled.
Stripping should be carried out using a stripper or a sharp tool as close as possible to the connection point, to restrict the amount of live, exposed parts. Avoid damaging the copper layers, which could create the starting points for fractures.
N
Drilling and punching
Merlin Gerin recommends use of a punch fitted with a spring-loaded stripper plate that makes a clean cut and prevents layer deformation as the punch is withdrawn.
This is carried out once the flexible bar has been bent.
If the holes are drilled, use a special drilling template, held in a vice, to guide the bit and hold the flexible bar during the operation.
As a rule, there should be a 0.2 mm clearance between the punch and the die. Ensure that the punch is kept sharp to avoid flash and prevent cuttings from getting between the copper layers.
Drilling diameter depends on the diameter of the nuts and bolts used. bolt diameter M6 M8 M10 M12
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max. drilling diameter 7 10 12 14
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Assembly and installation guide
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Power connections
Busbars in wall- mount and floor- standing enclosures and cubicles Standard: IEC 60439
Practical rules
Examples for Prisma Plus No sharp edges on busbars in Prisma Plus.
According to standards IEC 60439-1 and IEC 60204-1, insulated conductors must not rest up against bare live parts or against sharp edges. Their maintenance must be carried out properly.
Standard: IEC 60204
Powerclip busbar in a wall-mount enclosure
5
Flat busbar at the back of a wall-mount enclosure
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Assembly and installation guide
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Power Connecting with flexible bars connections
Securing the bars
Practical rules
Examples for Prisma Plus According to Merlin Gerin, the fixed ties should be secured to the framework every 400 mm at the most, and the free ties as per the value (x).
Secure the flexible bars to the insulating supports. The distance between the ties depends on the electro-dynamic forces produced in the event of a short-circuit. Recommended distances between ties. tie type width: 9 mm load: 80 kg
max. Ipk (kÂ) 20 25 35 45
distance (x) between ties (in mm) 350 200 100 70
fixed tie loose tie
NB: The last tie should be located as close as possible to the connections.
In the event of stacking, form a separate stack for each circuit. Example: N, L1, L2, L3. To ensure that conductors are properly ventilated, a space should be left between the flexible bars, at each tie, using an insulating, selfextinguishing spacer.
Assembly In order to distribute tightening forces and avoid creep in the copper, locate a u 2 mm thick flat washer between the contact washer and the bar. Care should be taken to avoid pinching the insulation when tightening the connections.
Assembly rules (hardware quality and tightening torque: see pages 45 and 48).
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In order to connect a flexible bar to a device, use the basic hardware delivered with the device and add a flat washer. The flat washer is supplied in all products incorporating prefabricated connections.
Apply the tightening torque specified in the device manual.
Assembly and installation guide
Schneider Electric
Power connections
Connection to the busbars
Practical rules
Examples for Prisma Plus For each current, there is a prefabricated connection for the device/busbar connection.
If the busbars have several bars per phase, the connection points must be distributed over the various bars of the same phase.
Insulated flexible prefabricated connection
5
Bare bar prefabricated connection
Flexible bars should be connected without separating the copper layers.
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Assembly and installation guide
Schneider Electric
Power Connecting with cables connections
Principle
Practical rules
Examples for Prisma Plus
Cables may be used for all medium power connections. However, above a certain power rating, cable connections become more difficult on account of requirements such as the crosssection of the cables, the number of conductors, the radius of curvature or the space available inside the enclosure.
Cable characteristics
Cable crosssection
Above 125 A, Merlin Gerin recommends use of flexible bars for connection between the main busbar and the outgoers.
Merlin Gerin recommends use of a U 1000 flexible or semi-rigid cable (1000 V insulation). As a rule, flexible or semi-rigid copper cables are used for wiring the inside of a switchboard. H05VK cables with 500 V insulation or H07VK cables with 750 V insulation can be used. The standard cable has a resistant insulator at 105 °C.
Cable cross-section should be compatible with: b the current to be carried b the ambient temperature surrounding the conductors.
For an operating voltage of less than half the cable insulating voltage, or in other words < 500 V, these cables are treated as belonging to class 2. Consequently, they may be secured directly to metal supports without inserting an insulator. Merlin Gerin recommends black power cables with a blue mark for the neutral and a green/ yellow mark for the protective conductor.
Copper cable cross-sections recommended for connecting circuit-breakers on a switchboard with an external temperature of 35 °C. crosssection (mm2) 1.5 2.5 4 6 10 16 25 35
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permissible current (A) switchboard switchboard IP y 30 (∼ 60°C) IP > 31 (∼ 70°C) separate bundle separate bundle 16 14 14 12 25 22 23 20 32 28 29 24 40 36 39 33 63 55 55 50 90 80 77 70 110 100 100 93 135 125 125 120
Assembly and installation guide
Schneider Electric
Power connections
Bundles
Practical rules
Examples for Prisma Plus Number of cables recommended according to their diameter :
Bundles are normally created circuit by circuit. The number of cables by bundle depends on cable diameter.
cable cross-section (in mm2) y 10 16 to 35
number of cables by bundle 8 4
They must be assembled before being secured to their support. Distance between securing centres: (see page 57).
5 Stripping Use a wire stripper taking care to avoid cutting the strands or damaging the insulation. The length stripped should allow for: b the depth of the lug to be crimped
For u 6 mm2 cross-sections, lugs offer better tightening, without risk of creep in the terminal. For cross-sections < 6 mm2, Merlin Gerin prefers use of direct connection in the device terminal. However, it also proposes a variety of connection types: steel terminals, multi-hole terminals, reduced lugs, etc
b the depth of the connection tunnel on the device.
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Power Connecting with cables connections
Lug crimping
Practical rules
Examples for Prisma Plus
A lug should only contain a single power cable. All the strands of the conductor should be located inside the lug barrel.
Merlin Gerin recommends open barrel lugs which enable the operator to check cable penetration.
Hexagonal crimping distributes the crimping force in a uniform manner around the lug. Use crimping tools, of a suitable size, as recommended by the lug manufacturer. Apply the tightening force specified by the manufacturer of the crimping tool. The tools should be checked at regular intervals.
Merlin Gerin proposes reduced lugs which are ideal for Compact devices from 100 to 1250 A for copper or aluminium cables.
Lugs must not be re-used, bent, reduced in width (space requirements) or countersunk.
Do not bind cables to one another in the vicinity of lugs to avoid damaging insulation and causing flashover.
b Leave a clearance of at least 100 mm.
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Power connections
Cable routing
Practical rules
Examples for Prisma Plus
General rules: Cables should never be in contact with live conductors, or located between them (copper bars, flexible bars, etc.) to avoid temperature rise. Sharp edges on the framework situated close to conductors should be protected to avoid risk of damage to cables. Use gaskets, grommets, etc. Cables must not run over the sheetmetal thickness.
On all metal parts (mounting plates, frameworks, etc.), sharp edges are chamfered, parts are painted and tie devices are built into the plates.
Compact NS mounting plate
Securing the cables
If cables do not satisfy class 2 conditions, they should be secured to the insulating supports. The distance between ties depends on the electro-dynamic forces involved and the type of tie.
1000 V insulation cables are treated as belonging to class 2 if they are used on an electrical switchboard with an operating voltage < 500 V. They may be secured directly to metal cable tiebars. Recommended distances between ties: tie type width: 4.5 mm load: 22 kg width: 9 mm load: 80 kg
max. Ipk (kÂ) 10 15 20 20 25 35 45
distance between ties (in mm) 200 100 50 350 200 100 70
Ties should be locaed as close as possible to connection points. For cable cross-sections u 50 mm2, 9 mm wide ties should be used. They must be secured to the framework at most every 400 mm.
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Power Distribution blocks connections
Distribution blocks
Practical rules
Examples for Prisma Plus Spring terminal With connection accessories such as Multiclip, Polybloc, Distribloc, a spring terminal rather than a screw is used to tighten the cables. These accessories are all fully comptible with the breaking capacity of the Merlin Gerin devices. Contact pressure of the spring is automatically adapted to conductor cross-section and does not depend on the operator. Tightening is very reliable as it is not sensitive to vibrations or temperature variations, and is guaranteed over time.
Distribution blocks must withstand thermal stresses generated in the event of a short-circuit.
Standard: IEC 60947
Standard: IEC 60439
Tighten taking care not to cut the conductor strands. In the case of terminals with pointed screws, it is advisable to fit ferrules on the ends of multi-strand conductors. The ferrules must be adapted to cable cross-sections and terminal dimensions and crimped using suitable tools for the purpose. For spring terminals, comply with the stripping lengths and tightening torques of the various connection types.
1
3
2 Do not fit ferrules on spring terminals. Each terminal can only take a single wire. Use a flat screwdriver with cylindrical crosssection only to open the spring. Tests have been carried out on terminals both alone and in association with Merlin Gerin devices. They are shown to comply with standards IEC 60947-7 (cable withstand tests) and IEC 60439-1 (temperature rise and electrodynamic tests). Tunnel terminal This connection type such as on additional block or Multiclip allows several cables to be connected. However it is best not to use a ferrule. Tunnel terminals are used mainly for supplying the various distribution blocks and certain circuit-breakers (Multi 9).
L2 L1
12
N
Tunnel terminals on Multiclip distribution block
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Auxiliary and low power circuits
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Auxiliary and Wiring running low power circuits
Principle
Practical rules
Examples for Prisma Plus
Inside the enclosures, the auxiliary and low power circuit cables must run freely in straps or trunking, which provide more effective mechanical protection and cable ventilation than if cables are mounted in bundles. The intermediate connection terminals must be installed outside the wiring conduits. Separate power cables from auxiliary wires: b Bus cables and the other "fine wiring" cables (connected to auxiliary power supplies for relays, contactor controls, PLC inputs/outputs, etc.) can exist side by side, but must be placed in trunking for separation from power cables. b A bus line is "ELSV", thus with double or enhanced insulation with respect to mains. Consequently a bus cable must not touch a bare power bar.
Running through straps
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Cables running through straps must not be tied, in order to encourage heat loss. FIt a sufficiently large number of straps (normally 1 strap every 100 mm) to ensure that wires are properly held in place.
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In Prisma Plus, running and connection of auxiliary and low power circuit cables inside the enclosure is functionalised.
In Prisma Plus, the possibility of installation of horizontal and vertical cable straps ensures optimisation and legibility of wiring running.
Assembly and installation guide
Schneider Electric
Auxiliary and low power circuits
Running in trunking
Practical rules
Examples for Prisma Plus
Use trunking for cables with crosssections y 6 mm2. If cables are used which do not comply with class 2 conditions (cable insulation voltage > twice operating voltage), trunking should be secured using rivets or plastic screws which cannot damage the cables and which preserve the double insulation of the conductors in relation to the metal parts supporting the trunking. The distance between trunking fixing centres must not exceed 600 mm. Trunking packing density must not exceed 70%. Do not tie cables in the trunking. This encourages heat loss. Free rows must be provided for future extensions.
In Prisma Plus, the possiblity of installation of horizontal and vertical cable straps ensures optimisation and legibility of wiring running. The mounting plates include zones specially designed for trunking insertion and fastening.
Horizontal fastening
Vertical fastening
Bundles A bundle should never run in contact with or between copper bars in order to avoid temperature rise and damage to insulation. If cables do not fulfill class 2 conditions, bundles should be secured to insulating supports.
Use of cable straps must be preferrred to bundles as the latter are hard to modify subsequently.
NB: Auxiliary circuit bundles which generally carry low voltages (less than half the insulation voltage of the cable) may be secured directly to metal supports.
The mounting plates for horizontal Compact NS 100/630 and vertical Compact NS 630B/1600 are equipped with cable tie straps.
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Auxiliary and Wiring running low power circuits
Bundles (continued)
Practical rules
Examples for Prisma Plus
A sufficient number of ties should be used. Distances between ties, depending on the diameter of the bundle: bundle diameter D (in mm) < 20 20 to 30 30 to 45 45 to 75
distance between ties L min. L max. (in mm) (in mm) 60 120 70 140 90 180 125 200
Bundles may also be protected using a tubular or spiral plastic conduit. Bundles coming from devices mounted on doors or on wicket doors must allow sufficient freedom of movement for the various panels without there being any risk of damaging the cables.
Flexible trunking for wiring to door
Running to auxiliary devices installed on doors
Cables running to the door run via a bundle. This bundle must be produced to prevent mechanical damage to conductors following panel or door movement.
In Prisma Plus, bundle insertion zones are provided, and zones for installation of switchgear on door or front plate have been predefined.
Trunking for devices on door
Grommet for devices on front plate
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Auxiliary and low power circuits
Running between columns
Practical rules
Examples for Prisma Plus
For wiring running between cubicles (auxiliary supplies, etc.) that must be separable (transport, etc.), preference should be given to use of terminal blocks to connect the various cables.
6 Power supplies The auxiliary power supply and its protection must be clearly identifiable in the switchboard.
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Use of the auxiliary earth bar in the power and regulation equipment for the relay, control and indication automation systems is a means of simplifying distribution of auxiliary voltage for each functional unit. It must be mounted in a cable duct.
Assembly and installation guide
Schneider Electric
Auxiliary and General remarks low power circuits
Connection to terminals
Practical rules
Examples for Prisma Plus
All the conductor strands must be placed inside the hole on the terminal. Tighten taking care not to cut the conductor strands. In the case of terminals with pointed screws, it is advisable to use ferrules. Power connection distribution blocks, as well as incoming and outgoing distribution blocks should be separated by spacers.
With Merlin Gerin terminals and terminal blocks, a spring system rather than a screw is used to tighten the cables. The contact pressure of the spring is automatically adapted to the crosssection of the conductor. Tightening is very reliable as it is not sensitive to vibrations or temperature variations. Do not fit ferrules on terminal blocks equipped with springs. Each spring terminal may only take a single wire.
Spaces are fitted in the mounting plates to accomodate the terminal blocks.
Use of ferrules
Tunnel terminals on Merlin Gerin devices are designed to accommodate flexible cables without a ferrule. Tests have shown that tunnel terminals used with stripped cables give the best results (pullout resistance and temperature rise). The absence of a ferrule increases the area in contact. The tunnels on Merlin Gerin devices can accommodate two flexible, stripped cables (without ferrules) of identical cross-section. The Telemecanique stirrup terminals require use of ferrules.
To guarantee proper tightening ensuring good contact, choose ferrules to suit the cable crosssection and the space available in the device connection tunnel through which it will run.
Strip the cables to the recommended lengths. All the conductor strands must be placed inside the barrel of the ferrule. The tunnel of the device can only accommodate a single cable with a ferrule.
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Auxiliary and low power circuits
Use of ferrules (continued)
Practical rules
Examples for Prisma Plus
Use of Fast-on clips, ring lugs or spade lugs must be reserved solely for low power auxiliary circuits.
Voltage tap-offs for 6.35 mm Fast-on clips for low power cables or measurement points.
Unless otherwise specified in the specification, Merlin Gerin recommends the following cable cross-sections for auxiliary wiring: b 1.5 mm2 for voltage auxiliary circuits b 2.5 mm2 for current auxiliary circuits.
Cable crosssection
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Auxiliary and Communication circuits low power circuits
Cabling rules
Practical rules
Examples for Prisma Plus To ensure electrical continuity, the mechanical assemblies (front plates, mounting plates, etc.) are made using devices that cut through the paint up to the metal b clips b 1/4 turn screws b self-tapping screws b screws with built-in serrated lock washer with external teeth.
Meshing of frames inside a floor mounting cubicle is an essential parameter. Metal structures must all be interconnected, with electrical contact. Caution: various protective coatings are normally insulating
Sensitivity of the various cable families family cables
Communication equipment must satisfy the requirements of the relevant immunity and emission standards. The following cabling rules are general and do not replace the cabling directives laid down by the manufacturer of the incorporated equipment.
1
type of signal
analog
analog sensor measurement and supply circuits digital digital circuits and Telecom and data bus
2
3
relay
4
power supply
dry contact circuits with re-arcing risk power and power supply circuits
EMC behaviour sensitive signals
these signals are sensitive. They are also disturbing for family 1 these signals are disturbing for famililes 1 and 2 these signals are disturbing
NB: a shielded cable is not disturbing or sensitive.
Earthing terminals with metal fastening system using a DIN rail Use shielded cables or overshielded bundles to protect circuits against radiated disturbances. Metal shielding must be properly earthed. All conductors free in a cable (except for family 1) must be systematically earthed at both ends.
Earthing bar
NO
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Acceptable YES if very short connection
Schneider Electric
Auxiliary and low power circuits
Cabling rules (continued)
Practical rules
Examples for Prisma Plus Schneider Electric devices are immunised.
Keep cables as short as possible and avoid forming loops which may produce interference due to magnetic fields.
The presence of many earthing structures in floor-standing enclosures procures an optimum protective effect. When wires run to a door, run the communication cable near a hinge or an earthing wire.
Protective effect inside a floor-standing enclosure: b all cables must be flattened up against earthing structures b plastic cabling trunking is allowed as installed on DIN rails connected to the enclosure exposed conductive parts. Cables must run close to assembly points (hinges) or be backed up by an earthing wire.
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Earthing wire
Tie
YES
NO
Group the following circuits per cable bundles: b relay, variable speed drives, supply and power b analog, digital and telecommunication signals.
To preserve a protective effect, we recommend that you comply with a ratio of Distance between cables/Radius of largest cable of more than 5. d
d/R>5 R
disturbing cable
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signal cable
Schneider Electric
Auxiliary and Communication circuits low power circuits
Use of toroids
Practical rules
Examples for Prisma Plus
Toroids detect leakage currents and transmit a proportional signal to the associated receiver.
Use a toroid with a diameter considerably larger than the cable passing through it. It should be fitted to a straight length of cable. The cable should be centred in the toroid.
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Placing a soft steel sleeve tube around the cable significantly reduces interference signals caused by the asymmetrical configuration of the conductors in the toroid.
Toroids are used together with Merlin Gerin VIgilohm System products for measurement and monitoring of installations. Earth leakage protection devices of the VIgi module type or residual current circuit-breakers incorporate the insulation monitoring toroid.
Assembly and installation guide
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Labelling and marking
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Labelling Switchboard and device marking and marking
General
Standards: IEC 60439 IEC 60617
On the front of the switchboard
Practical rules
Examples for Prisma Plus
Standards IEC 60439-1 and IEC 60617 specify the markings which are compulsory: b on the front of the switchboard b on the devices inside the switchboard.
Manufacturer’s name plate: A name plate should indicate, at least: b the name and address of the panel-builder b the identity of the project. The standards permit electrical specifications such as the voltage, current, frequency, Isc withstand, system earthing arrangement, etc. and mechanical characteristics such as switchboard weight or its degree of protection, to be marked on the documents supplied to customer.
Device marking: This enables users of the system to identify clearly the various circuits involved. Marking should be fully legible, durable and properly attached to the device.
Manufacturer’s name plate
There are 3 sizes of label with transparent cover, which may be printed or engraved. They are clipped directly to the openings on the front plate using the holes provided. Also available are self-adhesive label holders equipped with transparent covers and paper labels, or symbol sheets printed on clip-on or self-adhesive labels.
Clip-on labels
Self-adhesive labels
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Labelling and marking
Inside the switchboard
Practical rules
Examples for Prisma Plus
Marking identifies the devices, thus avoiding all risk of confusion when working inside the switchboard. The marks on the devices must be identical to the ones on the project wiring diagram.
A device with live downstream terminals (supplied via the bottom terminals) must be marked with a label which is visible from the outside and aligned with the device: b on the door b on the back panel, for rear access installations.
NB: Barriers preventing access to live parts should be marked with a "DANGER" sign. The devices are identified by clip-on markers (AB1) for marking either on the front of the device or above the downstream terminals.
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Labelling Conductor marking and marking
General
Standard: IEC 60439
Power circuits (cables and bars)
Practical rules
Examples for Prisma Plus
Standard IEC 60439-1 specifies the markings which are compulsory: b on power circuits b on auxiliary circuits.
The phases and polarities, at least, must be marked L1, L2, L3, L+, L-, at their extremities and points of connection. No colour requirements are specified.
The neutral must be marked in light blue: b either along its full length, for cables b or in all cases (cables, bare bars or insulated, flexible bars) at the extremities and points of connection.
The main protective conductor (PE) and the PEN must carry a double marking: b green/yellow at the extremities b a PE or PEN mark, as appropriate.
The earthing connection point or stud on the floor-standing enclosure must be marked with a standardised earth mark.
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Labelling and marking
Auxiliary circuits
Practical rules
Examples for Prisma Plus
Proper marking is essential for onsite connections and switchboard maintenance. As there are several possible solutions, it is important to obtain customer approval for the marking technique. Subsequent changes to switchboard marking are laborious and likely to cause mistakes. Marking may be alphabetical, numerical or alpha-numerical. The markers, which are usually overlapping rings, must be placed at the ends of conductors and, if necessary, along their path.
Main marking: b Case 1: dependent on terminal at the same end: the end of the wire and its terminal are given the same name b Case 2: dependent on terminal at the opposite end: the end of the wire and the terminal at the opposite end are given the same name b Case 3: dependent on both terminals: the end of the wire is marked with the name of both terminals b Case 4: independent: a wire number, unrelated to the terminals, is assigned. b Case 5: composite: this method combines dependent and independent marking.
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Labelling Conductor marking and marking
Auxiliary circuits (continued)
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Practical rules
Examples for Prisma Plus
Additional marking: This is used to provide additional marking, such as phase or polarity, for example.
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Final factory inspection
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Final factory Facilities inspection
Principle
Practical rules
Examples for Prisma Plus
At the end of the manufacturing process, a LV switchboard must undergo various routine inspections and tests in the factory, following an established programme. The switchboard must comply with: b the appropriate standards b the design file (drawings, diagrams and specific requirements) b manufacturer mounting instructions b in-house instructions.
Test conditions Tests must be carried out in a clearly defined area, in compliance with applicable legislation or regulations, by qualified personnel.
Inspection facilities
Reference documents
Standards: IEC 60439 IEC 60529
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The necessary parts should be suitable for the purpose, correctly calibrated and in good working order: b control console b dielectrometer b megohmmeter b multimeter b bell tester b torque wrench, etc.
Inspection is carried out in a special area referred to as the test platform which is set aside for final testing. All inspectors must first attend a special training course and must be qualified for working in the proximity of live parts.
Megohmmeter
In addition to those items which are specific to the switchboard: drawings, diagrams and specific specifications, quality inspectors should refer to upto-date documents: b integrating revisions and updates: b to technical files b to in-house rules, etc. b keeping track of changes in standards in order to have the most recent version at all times. The main international standards are: b IEC 60439-1, IEC 60529.
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Final factory inspection
Tests
Inspections and tests
Practical rules
Standard: IEC 60439
1st routine test: inspection of the assembly, including inspection of wiring and, if necessary, an electrical operation test
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Examples for Prisma Plus
Carry out all the compulsory inspections and tests and in particular the three routine tests specified by the IEC 60439-1 standards. They complement any type tests which may have been carried out previously by the manufacturer.
Conformity: b conformity of the finished switchboard to the drawings, part lists and diagrams: v number, type and rating of devices v conformity of cabling: auxiliary and power circuit connections v quality of cables: conductor crosssection, crimping and tightness v marking of conductors and devices. Visual inspection: b check clearances and creepage distances at connections or part of busbars b check the degree of protection. Presence of protective elements, according to requirements (canopy, gasket, front plate, etc.). No enclosure infractions (cut-outs, holes, etc.) that might compromise the original degree of protection. b check the presence of a name plate or technical documentation showing the manufacturer’s name, the project identity number and all the technical specifications relevant to the switchboard (voltage, current, system earthing arrangement, Isc, IP, protection of persons, switchboard dimensions and weight, etc.). Electrical operation: b inspect the cables and check the proper operation of the switchboard: relays, measurement and monitoring functions, mechanical and electrical interlocks, etc.
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Standard IEC 60439-1 defines 10 tests to be carried out on electrical switchboards: b 7 type tests b 3 routine tests. The 7 type tests have been carried out in laboratories and test platforms on Prisma Plus floor-standing enclosures, using real working configurations: complete enclosures fitted with standard components and Merlin Gerin circuitbreakers. The assembly instructions and the 3 routine tests (described below) provide the necessary proof that the switchboard is of the Type Tested Assembly (TTA) or Partially Tested Assembly (PTA) type, and in compliance with standards.
The control console recommended by Merlin Gerin enables the main circuits to be energised and the auxiliary circuits to be tested. It comprises a voltage variator and a number of switching and indicating facilites, for simulation of various operating sequences.
Assembly and installation guide
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Schneider Electric
Final factory Tests inspection
2nd routine test:
Practical rules
Examples for Prisma Plus
insulation testing Dielectric test: All devices must be connected, with the exception of those incapable of withstanding the test voltage. For a switchboard with a 230/400 V rated operational voltage, a 2500 V 50 Hz test voltage should be applied for 5 seconds: b between all the live parts and the interconnected exposed conductive parts of the assembly b between each pole and all the other poles connected for this test to the interconnected exposed conductive parts of the assembly. The tests are satisfactory if there is neither puncture nor flashover between the various parts being tested.
Dielectrometer
Alternative solution: If the switchboard is not subjected to a dielectric test, an insulation measurement must be taken using an insulation tester, with a voltage of at least 500 V(DC). The minimum insulation resistance value must be equal to 1000 ohms/V. Multimeter
3rd routine test: protective measures
Check for the presence of barriers to protect against direct and indirect contacts with live parts. Visually check that: b contact washers have been used on all assemblies b earthing wires have been fitted to doors b the PE conductor is present.
Finishing Clean the inside of the switchboard. Check for switchboard identity markers. Check the external finish: scratches, paintwork, etc.
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Final factory inspection
Reports
Practical rules
Examples for Prisma Plus
Conformity of production: b draw up a list of missing items b draw up a list of equipment which will be dispatched separately from the switchboard.
Create a quality problem report form in order to quantify defects, assess their importance and allocate them to the appropriate service, who will carry out the necessary changes to bring the switchboard up to the required level of quality.
Conformity of operation: b issue a test report b this report notes any anomalies detected and the required corrective measures b establish with the customer, a check list of all the points to be checked (example enclosed) b issue a test report that remains in the panel-builder’s possession but that can be supplied on request b this report certifies that all the tests have been carried out and avoids repeating all tests a second time once on site. Each panel-builder has his own test documents.
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Final factory Check list inspection
customer.........................................................
project no ...........................................................
order no.............................
inspection carried out by ..............................
signatures...........................................................
QI .......................................
equipment.......................................................
inspection operations
date....................................
marking/switchboard/cubicle
tests carried out by QI
LV switchgear and controlgear conformity winding directions CT and ratio VT individual control operation protection indication metering heating measurement overall interlocks operation automatic control power circuit rating tightness secondary circuit rating tightness earthing circuit viewport connections tightening torques marking of wires and devices LV dielectric tests voltage presence mechanical mismatch system interchangeability earthing continuity degree of protection general locking systems mimic diagram name plates presentation, finish reference documents general specifications single line diagram no. layout drawing and front panel no. exploded diagrams no.
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Final factory inspection
Declaration of conformity
marking (European Conformity)
Practical rules
Examples for Prisma Plus The Prisma Plus system conforms and carries marking on its packing.
The declaration of conformity for a switchboard is the responsibility of the panel-builder. For this purpose, the panel-builder must prepare a technical file attesting to the conformity of the equipment. You can greatly facilitate preparation of the declaration of conformity and the necessary attestations by: b using a tested switchboard system as per IEC 60439-1 standards b complying with the corresponding assembly and installation instructions b creating an ISO 9000 type quality organisation.
Remark It is not essential to apply marking to the equipment or the packing. Conformity may simply be indicated in the accompanying documents. A declaration informing the customer of compliance with applicable European directives should be attached to these documents. b prepare and archive a copy of a declaration of conformity for each project (see example below) b prepare a technical file comprising the following: v a description of the equipment v proof of compliance with directives (equipment inspection and test reports, including those pertaining to routine tests, list of products using marking, etc.) b keep a copy of these documents specifically for inspection authorities for a period of 10 years after sale of the equipment..
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Final factory inspection
Final inspection record report
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Packing
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Packing
Cleaning
Switchboard preparation
Practical rules
Examples for Prisma Plus
Clean the switchboard prior to packing: b remove any dust from the inside using a vacuum cleaner: blow cleaning may cause shavings and detritus to accumulate in an area that will subsequently be live. b dust the outside. b if necessary, use a neutral solvent which will not damage the paint b repaint, where necessary b check that there are no foreign objects inside the switchboard (tools, nuts and bolts) which could prevent it from operating properly.
Accessories Include the following on the inside of the switchboard: b any joints for the busbars b additional mounting hardware b panels for installation after on-site connection: roof panel, gland plates b a set of drawings b the device technical manuals.
Precautions Check that all withdrawable or plugin devices are inserted and locked.
Heavy equipment can be dispatched separately. This prevents the risk of the cradle being damaged in the event of shocks and ensures greater enclosure stability during transport.
Large draw-out circuit-breakers (Masterpact) installed in the top part of a floor-standing enclosure are generally delivered separately.
a Prism
Ma ste r
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Packing
Packing definition
Type of packing
Practical rules
Examples for Prisma Plus
Packing depends on the following factors: b switchboard weight b the conditions under which it will be stored (temperature, humidity, weather, dust, shocks) b storage duration b lifting techniques (fork-lift, cranes, etc.) b transport type and conditions (lorry, container, ship, etc.) and transit countries. Packing must provide optimum protection of the the front panel and bear the following essential information: b fragile (glass) b not waterproof (umbrella) b position: top, bottom (arrows) and if appropriate: b centre of gravity (G) lifting points (chains).
Two main types of packing are normally used for packing electrical switchboards: b overland packing: The enclosure is protected by a plastic cover and housed in a crate.
b seaworthy packing: The enclosure, which contains bagged desiccants, is protected by a plastic cover and housed in a ventilated, wooden or plywood case.
The packing has also been tested: b wood for impact strength b plastic covers for their ability to withstand ingress of water and dust.
Important Check with the transporter that packing is compatible with the lifting system in use: points for attaching slings, rafters, etc. (see chapter 10 "handling").… Check with the customer that the switchboard, once packed, can access the site (height and width of doors, etc.). If necessary, pack each cubicle separately and identify each package with respect to the overall switchboard layout.
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Packing
General
Dispatch file
Practical rules The dispatch file should be sent by post to the customer. It includes: b a copy of the delivery slip b a duplicate copy of the set of drawings updated at the end of inspection b the assembly manauls: v for the switchgear v for the enclosure bthe inspection and test reports will be supplied on request. NB: Before dispatch, check that the customer is ready to receive the equipment and choose the appropriate delivery and acceptance procedure (location, on-site facilities, delivery date, name of person to be contacted, his telephone number, email address, etc.).
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Handling and transport
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Handling and transport
Principle
Handling
Practical rules
Examples for Prisma Plus
The frameworks and supports for the devices have been designed for switchboard operation in an upright position. To avoid abnormal mechanical stresses during transport, the floor-standing enclosures must remain upright under all circumstances.
Lifting from the bottom
As a rule, a pallet-mover or fork-lift is used for handling. Packing should include rafters or the like to allow lifting by the forks.
On the Prisma Plus floor-standing enclosure, rafters are attached directly to the base of the framework or to the plinth. They contribute to the stability of the enclosure during movement in the factory and are also used to secure the packing panels.
Move wall-mount enclosures either flat down on a wooden pallet or using a 2-wheeled truck.
The enclosures should be lifted at resistant points selected according to the centre of gravity of the enclosure.
For a Prisma Plus floor-standing enclosure (W = 900) with a bar duct, the lifting points are shifted towards the busbars.
G G
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Handling and transport
Lifting from the bottom (continued)
Lifting from the top
Practical rules
Examples for Prisma Plus
Floor-standing enclosures moved using a fork-lift should be lifted with care and steadied by hand or strapped to the fork-lift during transport.
The maximum load that can be withstood by lifting rings is given in the assembly manuals. If a crane or overhead hoist is used requiring lifting from the top, only slings which are both strong enough and in good condition should be uesd. They must be attached to the lifting rings, specific to the enclosure, and laid out as specified by the manufacturer. Slings should be adjusted to suit the size of the switchboard, in such a way as to ensure that the resulting angle between them does not exceed 60°.
Schneider Electric recommends a combination of 2 cubicles maximum. As a rule, lifting is for one cubicle at a time. When adjacent cubicles cannot be separated, check the strength of the mechanical connections between the two and use a lifting beam.
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Handling and transport
Lifting from the top (continued)
Handling
Practical rules
Examples for Prisma Plus
For switchboards containing a number of cubicles: b mechanical connections between cubicles must be reinforced using angle irons or stiffeners b wherever possible, use a lifting beam directly attached to the switchboard base, after first checking that the base is sufficiently rigid.
The lifting cross-member allows slinging-up of the enclosures while also increasing overall rigidity. Moreover, it offers a latching system for floor-standing enclosures only.
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Handling and transport
Transport
Practical rules After loading the enclosure, check that it is properly chocked and attached on the lorry, to avoid all risk of damage during transport.
The wall-mount and floor-standing enclosures should preferably be laid flat for transport.
Floor-standing or wall-mount enclosure
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Standards and technical documentation
Applicable standards for the assembly and installation of LV switchboards
IEC 60439-1 These are the basic standards that define and specify in detail the following: b the rules for fixed and withdrawable type tested assemblies (TTA) or partially tested assemblies (PTA) b assembly classification according to: v connection mode v protection against direct contact, v partitioning. b electrical characteristics of Fixed or Withdrawable Functional Unit Assemblies b information to be provided for Fixed or Withdrawable Functional Unit Assemblies b conditions for use b constructive measures b test specifications. IEC 60529-1 Degrees of protection procured by enclosures: b two digits for the following characteristics: v first digit (from 1 to 6): protection against solid bodies, v second digit (from 1 to 8): protection against liquids b two optional letters for the following characteristics: v first additional letter ( A, B, C or D): protection of persons, v second additional letter (H, M, S or W): operation or test conditions. IEC 60447 Direction of movement of actuators of electrical devices. NF C 20-070 or NF EN 60073 Colours of indicators and pushbuttons. IEC 60152, IEC 60391 and IEC 60446 Conductor markings.
Technical documentation (Merlin Gerin)
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Electrical installation guide 07/91. "Cahiers techniques" publications: b no. 145 : Thermal analysis of LV switchboards b no. 149 : Electromagnetic compatibility b no. 156 : Dependability of LV switchboards b no. 162 : Electrodynamic strength of LV switchboard busbars b no. 166 : Enclosures and degrees of protection b no. 172 : LV system earthing arrangements.
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Index
Description pages A Assembling the bars .....................................................................................................................45 Assembling the structure ................................................................................................................6 Assembly hardware ......................................................................................................................45 Auxiliaries .....................................................................................................................................59 Auxiliary bundles ..........................................................................................................................61 Auxiliary circuits ...........................................................................................................................59 Available space ............................................................................................................................35 B Binding (see Securing the bars) ...................................................................................................52 Bolts..............................................................................................................................................45 Busbars ........................................................................................................................................11 C Cable ............................................................................................................................................54 Cable routing ................................................................................................................................57 Cable straps .................................................................................................................................60 Clearance .....................................................................................................................................13 Communication circuits ................................................................................................................66 Connection volume .......................................................................................................................31 Contact pressure ..........................................................................................................................47 Copper bars bending ....................................................................................................................43 Copper bars hole punching ..........................................................................................................43 Creepage distance .......................................................................................................................14 Current transformer ......................................................................................................................24 Cutting flexible bars ......................................................................................................................49 D Degree of protection .......................................................................................................................9 Dielectric test ................................................................................................................................78 Direct contact................................................................................................................................36 Dispatch file ..................................................................................................................................88 Distance between devices ............................................................................................................32 Distribution blocks ........................................................................................................................58 Drilling flexible bars ......................................................................................................................50 E Earthing (see Electrical continuity) .................................................................................................7 Earthing wire...................................................................................................................................8 Electrical connections of functional units ......................................................................................38 Electrical continuity .........................................................................................................................7 Equipotential bonding ...................................................................................................................17 Ergonomy .....................................................................................................................................31 F Ferrules ........................................................................................................................................64 Final factory inspection .................................................................................................................75 Flexible bars .................................................................................................................................49 Flexible bar bending .....................................................................................................................49 Flexible bars hole punching ..........................................................................................................50 Form .............................................................................................................................................19 Frameworks ....................................................................................................................................6 H Handling .......................................................................................................................................90 High power toroid .........................................................................................................................55 I Incoming power supply .................................................................................................................39 Installing the devices ....................................................................................................................27 Insulation stripping........................................................................................................................50 L Labelling .......................................................................................................................................69 Low power toroid ..........................................................................................................................68 Lug................................................................................................................................................56 M Marking .........................................................................................................................................69
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Description pages P Packing ........................................................................................................................................ 85 Partitioning ................................................................................................................................... 19 PEN conductor ............................................................................................................................. 18 Power connections ....................................................................................................................... 37 Protective conductor PE............................................................................................................... 17 R Rigid copper bars ......................................................................................................................... 43 Routine test .................................................................................................................................. 77 S Safety clearances......................................................................................................................... 32 Securing the cables...................................................................................................................... 57 Securing the flexible bars ............................................................................................................. 52 Storage........................................................................................................................................... 4 Switchboard ventilation ................................................................................................................ 28 T Temperature devices ................................................................................................................... 28 Terminals ..................................................................................................................................... 64 Tests report .................................................................................................................................. 79 Tightening torque ......................................................................................................................... 48 Toroid ........................................................................................................................................... 68 Transport...................................................................................................................................... 93 Trunking ....................................................................................................................................... 61 Type tests..................................................................................................................................... 77 W Wiring ........................................................................................................................................... 60
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Merlin Gerin Alpes BP 18 F - 73804 Montmélian cedex Tel : +33 (0)4 79 75 48 00
As standards, specifications and designs change from time to time, please ask for confirmation of the information given in this publication. This document has been printed on ecological paper.
http://www.schneider-electric.com http://www.schneider-electric.co
DESW043EN
Publication: Schneider Electric Production: Sedoc Printing: 11-2004
ART805343 © 2004 - Schneider Electric - All rights reserved
Schneider Electric Industries SAS
