loadframe 25/63 lv switchboard system · in mind loadframe 25/63 has a wide variety of busbar...

Loadframe 25/63 LV Switchboard System

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Loadframe 25/63 LV Switchboard System

1

FeaturesFully Type Tested in accordance with EN 60439-1

ASTA Certified

Form 1 to Form 4b Type 7

Horizontal busbars up to 6300A

Wide range of busbar fault ratingoptions

Fully extendable at either end

Front or rear access with cable entriestop or bottom to suit application

Compact modular design

ACB, MCCB, Fuse Combination Switchand MCB options

BenefitsImproved stacking densities

Complete range of devices ensuresLoadframe is suitable for any L.V.application

Cost Effective

ApplicationsL.V. Power distribution

Industrial environments

Commercial environments

PFI projects

Public buildings

ApprovalsBS EN 60439-1

EN 60439-1

IEC 60439-1

ISO 9001

EN 60529

IEC 60529

The Loadframe family of factory-assembled switchboards comprehensively covers allLV switchboard requirements up to 6300A (4.5MVA). This range of Type TestedAssemblies is more than capable of satisfying individual customer needs for thecontrol of power in any commercial or industrial application. When fitted withLoadswitch, Loadline or Loadlimiter XS components Loadframe 25/63 ensures thatDorman Smith Switchgear offers a complete system solution.

Loadframe 25/63 fully complies with EN 60439-1 and is available in a variety ofoptions from a simple Form 1 switchboard through to complex Form 4b Type 7installations. Designed with product performance, cost effectiveness and user choicein mind Loadframe 25/63 has a wide variety of busbar arrangements capable ofcarrying many current ratings for a broad range of breaking capacities and withstandtimes. Innovative features can be found throughout Loadframe, from divisible framesthat reduce the number of actual sections required to comprise a switchboard throughto a highly versatile, patented busbar support system. The benefits of such featuresprovide advantages in the simplicity of build and installation.

Contents Page No.

Technical Specification Loadframe 25 2-3

Technical Specification Loadframe 63 4-5

General Information 6-7

Internal Components 8

Forms of Separation 9-11

Ingress Protection 12

Type Testing 13

Dimensional Guide 14-15

Company Profile 16

Loadframe 25 Technical Specification

2

Product: Loadframe 25

Name of Manufacturer: Tyco Electronics/Dorman Smith SwitchgearBlackpool RoadPreston PR2 2DQ UK

Quality Certificate of Manufacturer: ISO9001

Country of Origin: England

Type of Product: L.V. Switchboard (TTA)

Standards: BS EN 60439-1 : 1999EN 60439-1 : 1999IEC 60439-1 : 1999

Form of Separation: Compliance to EN 60439-1 : 1991 Forms 1, 2, 3 & 4 as appropriate to specific project. National Annex accommodated

Designation: Type Tested Assembly

IP Rating: External IP3X as standard to IEC 529 : 1989 and IEC 60529 : 1989Optional IP54 (please check availability)

IP Rating: Internal IP2X minimum to above named standards

Construction: Frame Structure 2mm gauge folded steel

Construction: Cover Plates 1.6mm screw fixed sheet steel

Construction: Internal Segregation Aluzinc, perforated sheet steel or transparent polycarbonate sheet

Cabling Access: Suitable for front or rear access cabling. Entry via provided gland plates that facilitate either top and/or bottom entry

Terminal Identification and Marking: In accordance with IEC 9471 and IEC 60445 : 1988

Busbars: Material HDHC Copper. Multiple laminations per phase

Busbars: Mounting 4-pole air insulated mounted in glass fibre reinforced moulded supports


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Busbars: Shielding Non-conductive rigid insulated barriers or rigid sheet steel barriers

Busbars: Maximum Current and Fault Withstand Ratings 1250 – 2500A: 50kA for 3s (Optional 50kA for 1s)2500A: 80kA for 1s

Switchboard Certification Bodies

Type Testing Independent Certification: ASTA

• Temperature Rise ASTA

• Dielectric Properties ASTA

• Short Circuit withstand Strength ASTA

• Effectiveness of Protective Circuit ASTA

• Clearance and Creepage Distances ASTA

• Mechanical Operation ASTA

• Degree of Protection ASTA

Earthing: Earth bar sized at 300mm2 for 50kA for 1s fault level and 500mm2 for 50kA for 3s and 80kA for 1s fault levels. Earth continuity of cladding is maintained by fixing screws specifically designed for this purpose

Rated Operational Voltage: 415V

Rated Insulation Voltage: 690V

Power Frequency Withstand Voltage: 2500V

Rated Operational Current Ie: Project specific

EMC Emissions Compliance with appropriate EN/IEC standards for the design and manufacture of Loadframe 25 and it’s complementary products means we are not required to comply with EN 50081 and EN 50082 as the individual standards make reference to comply with EMC emissions requirements

Labels: Screw fixed traffolyte

Paint Finish: Colour light grey RAL 7035 semi gloss

Paint Depth: 40/60 Microns

Paint Process: 4-stage process of chemical spray degreasing, iron phosphate coating, automatic electro-static epoxy polyester film application and curing in a high temperature controlled oven


4

Product: Loadframe 63

Name of Manufacturer: Tyco Electronics/Dorman Smith SwitchgearBlackpool RoadPreston PR2 2DQ UK

Quality Certificate of Manufacturer: ISO9001

Country of Origin: England

Type of Product: L.V. Switchboard (TTA)

Standards: BS EN 60439-1 : 1999EN 60439-1 : 1999IEC 60439-1 : 1999

Form of Separation: Compliance to EN 60439-1 : 1991 Forms 1, 2, 3 & 4 as appropriate to specific project. National Annex accommodated

Designation: Type Tested Assembly

IP Rating: External IP3X as standard to IEC 529 : 1989 and IEC 60529 : 1989Optional IP54 (please check availability)

IP Rating: Internal IP2X minimum to above named standards

Construction: Frame Structure 3mm gauge folded steel

Construction: Cover Plates 1.6mm screw fixed sheet steel

Construction: Internal Segregation Aluzinc, perforated sheet steel or transparent polycarbonate sheet

Cabling Access: Suitable for front or rear access cabling. Entry via provided gland plates that facilitate either top and/or bottom entry

Terminal Identification and Marking: In accordance with IEC 9471 and IEC 60445 : 1988

Busbars: Material HDHC Copper. Multiple laminations per phase

Busbars: Mounting 4-pole air insulated mounted in glass fibre reinforced moulded supports


5

Busbars: Shielding Non-conductive rigid insulated barriers or rigid sheet steel barriers

Busbars: Maximum Current and Fault Withstand Ratings 2500A: 80kA for 1s4000A: 80kA for 1s6300A: 100kA for 1s

Switchboard: Certification Bodies

Type Testing Independent Certification: ASTA

• Temperature Rise ASTA

• Dielectric Properties Internal Test Laboratory

• Short Circuit withstand Strength ASTA

• Effectiveness of Protective Circuit ASTA

• Clearance and Creepage Distances Internal Test Laboratory

• Mechanical Operation ASTA

• Degree of Protection Internal Test Laboratory

Earthing: Earth bar sized at 300mm2 for 50kA for 1s fault level and 500mm2 for 50kA for 3s, 80kA for 1s and 100kA for 1s fault levels. Earth continuity of cladding is maintained by fixing screws specifically designed for this purpose

Rated Operational Voltage: 415V

Rated Insulation Voltage: 690V

Power Frequency Withstand Voltage: 2500V

Rated Operational Current Ie: Project specific

EMC Emissions Compliance with appropriate EN/IEC standards for the design and manufacture of Loadframe 63 and it’s complementary products means we are not required to comply with EN 50081 and EN 50082 as the individual standards make reference to comply with EMC emissions requirements

Labels: Screw fixed traffolyte

Paint Finish: Colour light grey RAL 7035 semi gloss

Paint Depth: 40/60 Microns

Paint Process: 4-stage process of chemical spray degreasing, iron phosphate coating, automatic electro-static epoxy polyester film application and curing in a high temperature controlled oven

Scope of Available ServicesSwitchboard supply in the modern day market is not simply only the supply anddelivery of a sole piece of equipment. The demand on switchgear suppliers has evolvedand to meet these changes Dorman Smith can now offer a service that includes;

• Installation• Commissioning• Site testing• Free technical support and advice• System design assistance• Source and supply of associated equipment (One Stop Shop for switchgear solutions)

Scope of UseThe versatility of Loadframe 25/63 ensures that the products can be used as the idealsolution for the following applications;

• Main Switchboards• Sub-Main Switchboards• Package Substations• Changeover Systems• PLC Controlled “Intelligent” Switchboards

Available technologies can, when selected, permit communication between theswitchboard and building / energy management systems.

Life ExpectancyThe life expectancy of a Switchboard is inherently dependant on the frequency of use ofthe devices installed within it.

Frequent use is usually defined as less than 5 times a day for a small device (i.e. up to100A) and once a week for a larger device. Therefore, for example, a 200A fuse switchbeing switched once a day would have a life expectancy of at least 22 years.

The switchboard and devices installed in it require no maintenance other than theactions recommended below.

Storage and TransportationWe would not anticipate any degradation of components in the event of theswitchboards being transported or placed into storage prior to installation providing thatthe storage area was reasonably dust and damp free and maintained, as stated inEN60439-1: 1999 Section 6.3.1 at a temperature between -25°C and +55°C. The averagetemperature over short periods should not exceed 24 hours up to +70°C. In the event ofthis being the case we would recommend that the switchboard sections are wrapped inhigh-grade PVC sheaths (which would be supplied by ourselves) and protected againstany further accidental damage by rigid barriers i.e. wood casings. In addition to theabove it would be preferable if the anti-condensation heaters (if fitted) were powered upand thermostatically set if the period of storage was to be prolonged. This would ensurethat the switchboards are stored in an environment very similar to operating conditionsAs an alternative to anti-condensation heaters fitted within the switchboards theprovision of a thermostatically controlled wall heater located within the storage areawould assist with the temperature regulation within the switchboards. In the event ofany switchboard being designated for prolonged storage containing lead acid batterieswe would advise that all necessary precautionary measures in line with the batterymanufacturer's recommendations are taken.

Loadframe 25

Utilising Loadswitch Devices

Fault Rated Busbars

Unclad Panel End Veiw

Loadframe 25/63 General Information

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Loadframe 25/63 General Information

7

InstallationA major benefit of the Loadframe 25 / 63 design is it’s physical strength. A typicalsection is capable of carrying over 1200kg without distortion. The practical benefit of thisis that it can be shipped to site in multiple sections, where site conditions permit, toreduce installation times.

As part of our complete service solutions we are able to undertake the wholeswitchboard installation aspect of the project if required. This service can range from asimple final installation to a comprehensive installation project involving craneage,testing, commissioning and client training. All site work undertaken by Dorman Smith iscarried out in full compliance with HSE guidelines and, where required, preceded by adetailed method statement.

PositioningWhen positioning the assembled switchboards into their final position Dorman Smithrecommend that the floor level should have a tolerance of +/- 2mm per metre.

Atmospheric ConditionsSection 6.1.2.1 of EN60439-1:1999 states that for indoor installations the air should beclean and have relative humidity not exceeding 50% at a maximum temperature of+40°C. Higher relative humidities may be permitted at lower temperatures, for example90% at +20°C. Care should always be taken to moderate condensation which mayoccasionally occur due to variations in temperature.

Routine MaintenanceWe would recommend that all switchboards are periodically inspected for the tightnessof all current carrying connections (i.e busbar links). Additionally, the switchboard coverplates can be cleaned with a light solvent such as is typically found in ordinarydetergents. This action would reduce the long term build up of dust and dirtsurrounding the unit. Specific information relating to the maintenance of ourswitchboards is contained within the main O&M manual that is supplied post order.Routine maintenance recommendations for individual component parts will be asdetailed in the relevant documentation relating to the particular product.

24hr Emergency CoverDorman Smith operate an emergency call out service that is permanently manned 24hours a day 365 days a year. The service is manned by a rota of duty managers who areall capable of responding to any type of enquiry.

In and emergency situation simply call the main switchboard, telephone number (+44 1772 325400) and follow the instructions.

SeminarsEN60439-1 can seem a complicated standard to understand as it covers a wide range oftopics that relate to switchboard design. To assist in understanding specific topicsDorman Smith offers a wide range of free technical seminars and training which coverall aspects of the standard from Type Testing through to an explanation of the Forms ofSeparation. If you wish to arrange any of these seminars please contact either your localsales contact or the main office.

Interconnecting Sections Step 1



Loadframe 25/63 Internal Components

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Dorman Smith Circuit Protection DevicesLoadframe 25/63 has been designed to utilise Tyco products for all aspects of control,protection, monitoring and communications. All devices are designed to comply withthe appropriate IEC standard and manufactured to ISO 9001 procedures. A briefsynopsis of the available control and protection devices is given below;

MCBs: Loadlimiter XSA comprehensive range of MCBs, featuring B, C & D characteristics, with a current rangespanning from 6A to 63A. In addition to the single pole, double pole, triple pole and fourpole devices a complete range of complementary RCBOs and RCCBs is available. Fullycompliant with EN 60898 the Loadlimiter XS range is the ideal choice for final circuitprotection within any switchboard or distribution scheme. Note that a detailed range ofenclosure systems are also available for instances where final circuit distribution boardsare sited remote from the actual switchboard.

MCCBs: Loadline Y-FrameThe Loadline Y-Frame MCCB range spans current ratings from 20A to 1600A and iscomplemented by a comprehensive range of accessories. All devices comply with IEC60947-2 and EN 60947-2. The Y-Frame series has been introduced to meet increasingmarket demands for higher breaking capacities with the option of thermal / magnetic orelectronic trip unit protection. The electronic variants feature selectivity utilisationcategory B throughout and can read up to the 19th harmonic. The thermal / magneticdevices are unaffected by harmonic distortion. The range is completed by a series ofgenerator MCCBs and a range of temperature calibrated thermal / magnetic devices foruse in tropical climates

ACBs: Loadline Z-FrameThe Z-Frame is the latest step in development of the Dorman Smith product portfolio.The Z-Frame range utilises unique technologies and features a high number of patentedinnovations that make this family of ACBs one of the leaders in it’s class. All devicescomply with IEC 60947-2 and EN 60947-2. The range spans a current rating spectrumfrom 800A to 4000A in just 3 Frame sizes. A 6300A variant is available for use withinLoadframe 63. The units are available as 3-Pole and 4-Pole variants and offer the userthe choice of fixed or withdrawble pattern chassis’. The ACBs are complemented with awide range of accessories ranging from simple key locks to intelligent trip units offeringdata measuring and communication facilities.

Fuse Combination Units: LoadswitchLoadswitch has been designed to exceed the requirements of BS EN 60947-3 and tooffer solutions demanded by our customers where ease of installation and everincreasing cable sizes are required. A full-uninterrupted duty ensures that the unit canmaintain full rated load indefinitely. A utilisation category of AC23A and short-circuitcapacity of 80kA enables Loadswitch to be installed with confidence on any inductive orresistive load. The robust steel enclosure of the housed variant is finished in epoxypowder coating light grey RAL 7035 and has a door that will open through 180 degreesfor ease of access with padlocking off as standard. Up to three padlocks can be attachedwith ease. Cable spreading room (which can easily be reversed by the installer) isallowed for at the bottom of the housed unit.

Further details of these products can be found in the appropriate product catalogues.

Loadlimiter XS MCBs

Loadline Y-Frame MCCBs

Loadline Z-Frame ACBs

Loadswitch Fuse Combination Switches

Loadframe 25/63 Forms of Separation

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Form 4B Type 7

Form 1

Form 4A Type 2

Form 4B Type 6

Form 4 Internal Shielding Form1 Internal Shielding

Fundamentals of SeparationIn accordance with EN60439, separation of the various elements of an Assembly:busbars, functional units, terminals, can be claimed providing one or more of thefollowing criteria are met:

1. Protection against contact with live parts belonging to adjacent functional units. The

degree of protection shall be at least IP2X or IPXXB.

As a minimum, finger contact with live parts in adjacent functional units is prevented.With Assemblies supplied by Dorman Smith Switchgear this is extended to includeprotection against finger contact between: functional units, adjacent busbars and busbarconnections, and terminals as required for the particular form of separation beingconsidered.

The requirement is proven with the standard test finger.

2. Protection against the passage of solid foreign bodies from one unit of an Assembly

to an adjacent unit. The degree of protection shall be at least IP2X.

The minimum requirement is proven by the standard test finger not being able to touchlive parts in adjacent units and a 12mm ball not being able to pass between units.

In practice, a higher degree of protection may be required for horizontal partitions toprevent small objects from falling between compartments and should be identified inthe contract specification.

These two fundamental criteria are interrelated. Dorman Smith Switchgear will thereforeensure all these are fully met in respect of the particular form of separation offered.

Typical ApplicationsForm 1 - No separation

Typical applications are places where the switchboard is in a secure location and wherefailure of the switchboard will cause little or no additional disruption to other areasbeing fed by the switchboard.

Form 2 - Separation of busbars from functional units.

Applications may well be the same as Form 1 but where it is important that a fault in theswitchboard need not affect all functional units being fed from the same busbar system.

Form 3 - Separation of busbars from functional units and the functional units from one

another but not their terminations.

Should be applied where it is important to provide protection from internal live partsand where failure of functional units being fed from the same busbar would causeunacceptable disruption.

Form 4 - Separation of busbars from functional units and the functional units from one

another including their terminations.

Should be applied where it is important to provide protection from internal live partsand where failure of functional units being fed from the same busbar would causeunacceptable disruption. Because all the terminations are separated it is possible toisolate and work on a single functional unit.


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UK National AnnexThe internal separation of Assemblies by barriers or partitions is specified in Section 7.7 of EN60439-1: 1999 and is subject toagreement between the manufacturer and the user.

The table below gives additional information regarding different types of construction, based on typical practice in the UnitedKingdom. Other types of construction are not precluded, and it is not essential to adopt any of the listed types in order to comply withthe requirements of the Standard.

However, in order to achieve agreement between manufacturers and users, it is recommended to adopt one of the listed types ofconstruction..

Main Criteria

No separation

Separation of busbars from the functional units.

Separation of busbars from the functional units and separation of all functional units from one another. Separation of the terminals for external conductors from the functional units, but not from each other.

Separation of busbarsfrom the functional units and separation of all functional units from one another, including the terminals for external conductors which are an integral part of the functional unit.

Form

Form 1

Form 2a

Form 2b

Form 3a

Form 3b

Form 4a

Form 4b

Sub Criteria Type of Construction

Type 1 Busbar separation is achieved by insulated covering,e.g. sleeving, wrapping or coatings

Type 2 Busbar separation is by metallic or non-metallic rigidbarriers or partition.

Type 1 Busbar separation is achieved by insulated coverings,e.g. sleeving, wrapping or coatings

Type 2 Busbar separation is by metallic or non-metallic rigidbarriers or partitions.

Type 1 Busbar separation is achieved by insulated coverings,e.g. sleeving, wrapping or coatings. Cables may be glanded elsewhere.

Type 2 Busbar separation is by metallic or non-metallic rigidbarriers or partitions. Cables may be glanded elsewhere.

Type 3 Bushbar separation is by metallic or non-metallic rigid barriers or partitions. The termination for each functionalunit has its own integral glanding facility.

Type 4 Busbar separation is achieved by insulated coverings, e.g. sleeving, wrapping or coatings. Cables may beglanded elsewhere.

Type 5 Busbar separation is by metallic or non-metallic rigid barriersor partitions. Terminals may be separated by insulated coverings and glanded in common cabling chamber(s).

Type 6 All separation requirements are by metallic ornon-metallic rigid barriers or partitions. Cables are glanded in common cabling chamber(s).

Type 7 All separation requirements are by metallic or non-metallicrigid barriers or partitions. The termination for each functional unit has its own integral glanding facility.

Terminals for external conductors not separated from busbars.

Terminals for external conductors separated from busbars.

Terminals for external conductors not separated from busbars.

Terminals for external conductors separated from busbars.

Terminals for external conductors in the same compartment as the associated functional unit.

Terminals for external conductors not in the same compartment as associated functional unit, but in individual, separate, enclosed protected spaces or compartments.


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Form 4a Type 2

Form 4b Type 5

Form 4b Type 6

Form 4b Type 7

IncomingUnit

OutgoingUnits

OutgoingUnits

OutgoingUnits

IncomingCable

OutgoingCables

OutgoingCables

IncomingUnit

OutgoingUnits

OutgoingUnits

OutgoingUnits

IncomingCable

OutgoingCables

OutgoingCables

IncomingUnit

OutgoingUnits

OutgoingUnits

OutgoingUnits

IncomingCable

OutgoingCables

OutgoingCables

Compartment

IncomingUnit

OutgoingUnits

OutgoingUnits

OutgoingUnits

IncomingCable

OutgoingCables

OutgoingCables

Compartment

Loadframe 25/63 Ingress Protection

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External Shielding to IP3X Minimum

Internal Segregation of Z-Frame ACB

Where some degree of protection against ingress of water is required the following tablegives the preferred IP combination numbers:-

Second Number – Protection Against Liquids

IP Example Protection Against Protection From

Liquids - Tests Water

0 No protection. Non-protected

Protection against verticallyProtection against

1falling drops of water.

vertically falling dropsof water

Protection against vertically Dripping up to 15° from2 falling drops of water with enclosurethe verticaltilted 15° from the vertical.

Protection against sprays to 60°3 from the vertical - limited Limited spraying

ingress permitted.Protection against water splashed

Splashing from all4 from all directions - limited directionsingress permitted.

Protected against low pressure jetsHosing jets from all5 of water from all directions - limiteddirectionsingress permitted.

Protected against strong jets of Strong hosing jets from6 water, eg. for use on shipdecksall directionslimited ingress permitted.

Protected against the effects of7immersion between 15cm and 1m.

Temporary immersion

Protected against long periods of8immersion under pressure.

Continuous immersion

15cm min.

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII

IIIIIIIIIIIIIIIIIIIIIIIII IIIIIIIIIII

50

IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII IIIIIIIIIIIIIIII IIIIII

IIII

IIIIIIIIIIIIIIIIIIIIII I IIIIIIIIIIIIIIII

12.5

IP RatingsEN 60529 : 1991 describes a system for classifying degrees of protection provided byenclosures of electrical equipment with a rated voltage not exceeding 1000V ac and1500V dc.

First Number – Protection Against Solids

IP Example Protection Against Solid Protection of Persons

Foreign Objects - Tests Against Access To

Hazardous Parts With:

0 No protection. Non-protected

Full penetration of 50mm

1diameter sphere allowed.Contact with hazardous parts

Back of hand

not permitted.Full penetration of 12.5mm diameter sphere not allowed.

2 The jointed test finger shall Fingerhave adequate clearance from hazardous parts.

The access probe of 2.5mm3diameter shall not penetrate.

Tool

The access probe of 1.0mm 4diameter shall not penetrate.

Wire

Limited ingress of dust permitted5(no harmful deposit).

Wire

Totally protected against6ingress of dust.

Wire

The markings used to indicate the degreeof protection consist of the letter IP(Ingress Protection) followed by twocharacteristic numerals. The firstcharacteristic numeral designates thedegree of protection with regards to solidobjects. The second numeral designatesthe degree of protection against theingress of liquid.

It is intended to provide indication of:

a) Protection of persons against access to hazardous parts inside enclosures and protection of the equipment inside the enclosure against the ingress of solid foreign objects.

b) Protection of the equipment inside the enclosure against harmful ingress of water.

For switchboard assemblies intended forindoor use EN60439-1 : 1999 states thatthere is no requirement for protectionagainst ingress of water (clause 7.2.1.1)and that the IP references preferred forassemblies designated for indoor use are:

IP00 IP2X IP3X IP4X IP5X

Loadframe 25/63 Type Testing

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LV Switchboard StandardsThe standard to which LV Switchboards should be manufactured to is EN60469-1. Thestandard is non prescriptive and allows for manufacturers to be innovative while fullymeeting the standard and, most importantly, providing the user with the equipmentrequired. The standard details two categories of assembly, Type Tested (TTA) andPartially Type Tested (PTTA).

The definitions for these are as follows;

An Assembly: “A combination of one or more low voltage switching devices togetherwith associated control, measuring, signalling, protective, regulating equipment etc.,completely assembled under the responsibility of the manufacturer with all the internalelectrical and mechanical interconnections and structural parts”

Assemblies are likely to be produced for specific customers and who may specifyequipment to their own specifications and requirements. Hence the phrase “byagreement between manufacturer and user” is used throughout the standard.

Type Tested Assembly: “A low voltage switchgear and controlgear assemblyconforming to an established type or system without deviations likely to significantlyinfluence the performance, from the typical ASSEMBLY verified to be in accordance withthis standard”

Partially Type Tested Assemblies: “A low voltage switchgear and controlgear assembly,containing both type-tested and non-type-tested arrangements provided the latter arederived (e.g. by calculation) from type-tested arrangements which have complied withthe relevant tests”

Why Type-Test?EN60439-1 States:

“Type tests are intended to verify compliance with the requirements laid down in thisstandard for a given type of ASSEMBLY.

Type tests are carried out on a sample of such an ASSEMBLY or on such parts ofASSEMBLIES manufactured to the same or similar design.

They shall be carried out on the initiative of the manufacturer”

The standard also requires switching devices and other components to comply withtheir own relevant standards.

Type tests for assemblies are carried out for;

• Verification of Temperature Rise• Verification of Dielectric Properties• Verification of Short Circuit Withstand Strength• Verification of the Effectiveness of the Protective Circuit• Verification of Clearances and Creepage Distances• Verification of Mechanical Operation• Verification of the Degree of Protection

They are intended to;

• Prove the design capability• Be conducted on representative samples for the design of Assembly, but are not

intended to be undertaken on an Assembly which is subsequently put into service• Be undertaken at the instigation of the manufacturer. It is recognised that it is

impractical to test every conceivable configuration of circuit within an Assembly• Be tested either in the manufacturer’s own laboratory or at an independent facility• Have results recorded in reports or certificates that are available for examination

Loadframe 25

Typical Arrangement Showing Available

Cabling Space

Loadswitch Cabled to EN60439-1

Form 4A Type 2

Detail Illustrating Vertical and

Horizontal Busbar Arrangement

Loadframe 25 Dimensional Guide

14

600

H.BAR 1600A

INTEGRA M-100

MF

DRAWOUT

1600A TPN ACB

OCRLSI

MANUAL

630A

800AMCCB Y6H

400AMCCB Y5H

125A

MCCB Y2HX125A

MCCB Y2H

20A

MCCB Y2H

250A

MCCB Y3H

315A

VE

RT

BB

VE

RT

BB

160A

63A

H.BAR 1600A H.BAR 1600A

600500

IncludesHorizontal Busbars

IncludesHorizontal Busbars

TYPICAL EXAMPLE FRONT ELEVATION

PLAN VIEW

TOP BUSBARS FRONT ELEVATIONNote: Busbars can be mounted at the top or bottom of cubicles

BOTTOM BUSBARS FRONT ELEVATIONNote: Busbars can be mounted at the top or bottom of cubicles

SIDE ELEVATION

500 500

2500ABUSBARS

1600ABUSBARS

1600ABUSBARS

800 600 500 800 600 500

600 600500 500 500

410 410 410 510510

Cubicle Depth B

Cub

icle

Dep

th B

4545

1984

45

2500ABUSBARS 1600A

BUSBARS1600A

BUSBARS

30Modules

Usable Space

27 Modules

24 Modules

21 Modules

Usable Space

30 Modules

27 Modules

24 Modules

Usable Space

30 Modules

27 Modules

24 Modules

Usable Space

27 Modules

24 Modules

21 Modules

Usable Space

30 Modules

27 Modules

24 Modules

Usable Space

30 Modules

27 Modules

24 Modules

Cubicle Heights

2356mm

2170mm

1984mm

45

Cubicle Heights

2356mm

2170mm

1984mm

45

15

Loadframe 25 Dimensional Guide

750mm Deep (B) 1000mm Deep (B)

Cubicles 2356, 2170, 1984mm High 500mm Wide 600mm Wide 800mm Wide 500mm Wide 600mm Wide 800mm Wide

Rear Access * * * * * *Fuse Switch 200A-800A * * * * * *Y Frame MCCBs Y2-Y5 * * * *Y Frame MCCBs Y6 * *Z Frame ACBs Z2 up to 2000A * *Z Frame ACBs Z3 up to 2500A * *Horizontal Busbars 1250, 1600, 2500A * * * * * *

500mm Deep (B) 750mm Deep (B)

Cubicles 2356, 2170, 1984mm High 500mm wide 600mm wide 800mm wide 500mm wide 600mm wide 800mm wide

Front Access * * * * * *Fuse Switch 200A-800A * * * * * *Y Frame MCCBs Y2-Y5 * * * *Y Frame MCCBs Y6 * *Z Frame ACBs Z2 up to 2000A * *Z Frame ACBs Z3 up to 2500A *Horizontal Busbars 1250, 1600, 2500A * * * * * *Cableways * * * *

Vertical Busbars Front/Rear Access Height 500mm wide 600mm wide 800mm wide

1250/1600A 6 Mod to 30 Mod * * *2500A 6 Mod to 27 Mod * *

Cubicles

Devices

Y2 Y3 Y5 MCCBs asstandard are mountedin 500w cubicles LH orRH side

MCCBs 1 Mod = 62mm A filler plate is requiredfor 600w mounting

Y6 MCCBs 600w cubicleonly

Y2 Frame 3 ModY3 Frame 3 ModY5 Frame 6 ModY6 Frame 6 Mod

ACBs 1 Mod = 62mm

Z2 Frame 800/2000A 10 Mod 600 wide sections onlyZ3 Frame 2500A 10 Mod 800 wide sections only

Notes: • For dimensional information on Loadframe 63 please contact Dorman Smith.

• All quotations for switchboards are supported with detailed dimensioned sales sketches.

All fuse switches asstandard are mountedin 500w cubicles LH orRH side

Fuse Switches 1 Mod = 62mmA filler plate is requiredfor 600w mounting

63/200A 3 Mod315/400A 6 Mod630/800A 12 Mod

Company Profile

16

Dorman Smith SwitchgearPedigree

Since 1878 Dorman Smith products have been associated with high qualitydevelopments in all aspects of electrical switchgear. Historically, the company was apioneer in the introduction of both fuse switch and moulded case circuit breakertechnologies. Latterly, Dorman Smith was at the forefront of the utilisation of PLCcontrol systems that provided intelligent switching of control circuits.

Product Portfolio

The Dorman Smith product portfolio caters for a wide range of applications covering acurrent span of 6A to 6300A. The range which encompasses MCBs, MCCBs, FuseCombination Units, ACBs and all associated enclosure systems caters for the distributor,contractor, end client and OEM markets. The range offers proven reliability across adiverse array of industries including power generation, process control, industrial,commercial, utility, defence and energy management applications.

Design and Development

To meet the challenges of ever decreasing lead times and industry developments ourdesign and manufacturing processes are constantly reviewed and updated. DormanSmith is committed to continual product development and improvement. In addition tothe mainstream product developments the company has been involved in thedevelopment of strategic customer partnerships for the supply of bespoke designsolutions.

Global Reach

Under the Tyco banner, Dorman Smith now has a global presence enabling promptresponse to customer requirements and regional specific technical expertise andapplication advice. The combination of local knowledge and over 120 years of researchand product development ensures Dorman Smith products continue to provide thehighest standards of performance and user convenience.

ManufacturingThe quality and reliability of Dorman Smith products is achieved through highlyinnovative manufacturing techniques, implemented by a multi skilled and flexibleworkforce.

Quality Systems

Dorman Smith design and manufacturing processes have ISO 9001 accreditation and allproducts carry the appropriate BS, EN and IEC approvals. Computer technology aidsDorman Smith designers to develop new products in harmony with customerrequirements and to exceed the demands of international standards.

Product Control

All aspects of the manufacturing processes are vigorously controlled. To obtainconsistently high levels of productivity and service the company operates Kanbancontrol systems in conjunction with a fully integrated business computer system. Thissystem provides the opportunity to delegate routine material transactions in themanufacturing cells and ensures a fast, reliable and cost effective method ofmanufacture.

All the above disciplines enable Dorman Smith to provide the customer with atechnically capable product at a competitive market rate.

About Tyco Electronics Energy DivisionThe Energy Division, a global manufacturer of products and systems for the electricalpower industry, is an operating unit of Tyco Electronics. Today, the Energy Divisionemploys more than 3000 people and has total annual sales of over $500 million. Powerutilities and equipment manufacturers extensively employ our products, in rail transportsystems and in industry around the world.

Our global network of technical and sales representatives provides expert applicationand engineering assistance, hands–on field training and strong after sales support.Expertise in materials science, product design and process engineering goes into theinvention, development, manufacture and marketing of high performance products thathelp our customers successfully master the challenges of their businesses. Our widerange of reliable and cost-effective solutions is continuously expanded through newproduct developments and the integration of new product lines from companies thatmake up the Energy Division.

Sheet Metal Facility at Dorman Smith

Dorman Smith Y-Frame MCCBs

System Loadbank Panelboard Systems

Tyco Energy Division HQ,

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Tyco Electronics UK, Dorman Smith SwitchgearBlackpool Road, Preston, PR2 2DQ, UKPhone: +44(0) 1772 325 400 Fax: +44(0) 1772 726 276

Energy Division – a pioneer in the development of economical solutions forthe electrical power industry. Our product range includes: Cable accessories, connectors & fittings, electrical equipment, instruments, lighting, insulators &insulation enhancement and surge arresters.

For more information and your country contact person, please visit us at: http://energy.tycoelectronics.com

All of the above information, including drawings, illustrations and graphic designs, reflects our present understanding and is to the best of our knowledge and belief correct and reliable.Users, however, should independently evaluate the suitability of each product for the desired application. Under no circumstances does this constitute an assurance of any particularquality or performance. Such an assurance is only provided in the context of our product specifications or explicit contractual arrangements. Our liability for these products is set forthin our standard terms and conditions of sale. ALR, AMP, AXICOM, B&H, BOWTHORPE EMP, CROMPTON INSTRUMENTS, DORMAN SMITH, DULMISON, GURO, HELLSTERN, LA PRAIRIE, MORLYNN, RAYCHEM, and SIMEL are trademarks.

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