procedure for manufacturing of electrical panels

Sistema Gestione Qualità Aziendale

Company Quality Management System

Doc. no. 097GQ

Rev. 4 of 29.01.2009

1- PURPOSE AND APPLICATION FIELD

This procedure is aimed at defining the standard for the manufacturing of Electrical Panels

(here below E.P.) in compliance with the norms/laws in force that can be applied and to

inhouse technical-quality specifications by Emerson Network Power Srl (here below ENP).

Such prescriptions, contained in the wiring diagrams, make the manufacturing specification to

which the qualified suppliers must comply while manufacturing the E.P.

Note: possible changes to this must be univocally agreed upon with the technical

departments of Emerson Network Power Srl caring for the electrical

design of the machines.

2 - GENERAL SPECIFICATIONS ON THE COMPONENTS

The electrical systems, in its single components and as a whole, must comply with the norms

CEI EN60204-1 (IEC 204-l), CEI 64-8 , CEI1-13/1 (EC 60439-l), in the last current revision.

Further, each component must have the initials/mark of obtained approval by at least one of the

following reliable certification bodies acknowledged in Europe:

- VDE;

- IMQ;

- SEMKO;

- NEMKO;

- DEMKO;

- others.

If there is no mark, the approval certificate of the component released by one reliable

certification bodies acknowledged in Europe must be available.

3 - COMPONENT MARKING

The electrical components must be identified by adhesive labels in PVC applied on the bottom

of the plate/panel and on the body of the component; they shall have a grey (or yellow)

background and indelible black initials, made by using automatic writing systems.

Note: E.P.s with labels having a different colour or with hand-written initials shall not be

accepted.

4 - POWER SUPPLY

4.1 - SUPPLY VOLTAGE AND FREQUENCY

All components must be suitable for the correct operation as for supply voltage and frequency,

as indicated in relevant wiring diagram.



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4.2 - POWER SUPPLY DISCONNECTING DEVICE

The power supply disconnecting device must enable to disconnect the unit:

for cleaning the machine;

for maintenance or repair works;

for long inactivity.

If there are several supply networks, each one must be equipped with individual disconnecting

switch, namely linked with the general supply device.

Note:

a) the general disconnecting switch must have a red door-locking handle on

yellow background, unless the wiring diagram shows differently;

b) the handle must feature holes for fitting at least no. 3 locks inside it to lock the

switch in the position "0" (open), unless the wiring diagram shows differently;

c) the cable inlet and outlet terminals must be protected against possible

accidental contacts;

d) the device must disconnect all cables entering the unit, including the neutral

one.

4.3 - UNIT START/STOP DEVICE

This device is usually installed on the electronic control on the unit front.

It is possible to disable the device through the control menu and to arrange its switching-on/off

only by remote control: in this case, a label with the suitable instructions shall be applied on the

unit front.

5 - PROTECTION MEASURES

5.1 - PROTECTION AGAINST DIRECT CONTACT

The electrical system must ensure the protection for people against hazards due to a direct

contact with live parts.

As for the electrical system of the ENP units, the protection must be guaranteed through:

a) interlock between protection cover and power supply disconnecting device;

b) use of components with protection degree IP2X.

The following must be protected with polycarbonate covers or screens featuring a protection

degree IP2X:

- visible extended and quite projecting live surfaces;

- inlet/outlet terminals on the main switch and power terminals with protection degree

lower than IP2X;

- exposed remote relays and straps;

- transformer inlet and outlet terminals;



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The protection cover or the possible plexiglass must be supported by spacers fastened and

protected according to the enclosed drawing VC55.

5.2 - PROTECTIONS FOR THE CONDITIONER

5.2.1 - PROTECTION OF THE POWER BRANCHES

Each power circuit branched from the main switch must be protected on all phases by an

automatic-magnetothermal switch (M.C.B.) with short circuit disconnection power not lower

than 6 kA or by fuses.

The neutral conductor, if any, cannot be protected (see norm CEI 64-8).

6 - CONTROL CIRCUIT

6.1 - CONTROL CIRCUIT POWER SUPPLY

All control circuits are supplied through a transformer with separate windings manufactured

according to the norm CEI 14-6 (EN 61558-1) in the last current revision.

6.2 - GROUNDING

A ground terminal with suitable section for the unit power supply cable must be installed on the

electrical panel; this terminal shall be positioned next to the power supply input.

A single ground-cable must be connected to each ground terminal.

The panel bottom plate shall be grounded by a suitable screw, marked with the ground symbol,

using a suitable toothed washer;

The graphic symbol must comply with IEC 60417-5019 (DB:2002-10)

Note: to ensure a suitable safety of the protection circuit, one of the following solutions must be

implemented:

• grounding of the terminal of control transformer not protected by switch or fuse.

• Protection of both terminals of the control transformer through fuses or automatic

switch.

The connection of the transformer with the general ground terminal must be made with a

flexible copper conductor insulated with yellow/green sheath with the same section as the one

of the control circuit conductor, min. 5 mm².



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6.3 - SIZE OF THE GROUNDING TERMINAL (PE)

SECTION OF THE

PHASE CONDUCTOR

SUPPLYING THE

MACHINERY

(mm²)

SECTION FOR WHICH THE

INLET GROUNDING

TERMINAL MUST BE

SIZED

(mm²)

S≤ 16 same as the one of the supply

conductors

16 <S≤35 = 16

S>35 Equal at least to 50% of the

supply ones, min. 16 mm²

7 - CONDUCTORS AND CABLES

7.1 - CONDUCTOR TYPES

Fire non-propagating cables must be used on the cables, in compliance with the norm CEI 20-22

(TEST II)/ IEC332-3A; IEC332-3B; IEC332-3C; (in the last current revision), unless the wiring

diagram indicates differently.

The main features of single-pole or multi-pole cables are the following:

• Uo/U=450/750 V

• Max. working temperature: +70°C

• Max. short circuit temperature: 160°C

• Insulation in PVC

• Test voltage 2000 V for 5 min.

• Conductors of class 5 or class 6.

The active conductors branched from the main switch, that necessarily have a section lower than

the main distribution cables, must have one of the specifications indicated in table 5 of the norm

EN60439-1, page 44, enclosed here below.



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7.2 - CONDUCTOR SECTION

The min. allowed section for the conductors of the control circuits is 1 mm², while lower sections are

allowed when the connectors require so (as indicated in the wiring diagram), while the min. allowed

section for the ones of the power circuits is 1.5 mm².

The max. allowed current values in permanent operation are indicated in the table below depending

on the conductor section:

MAX. ALLOWED CURRENT

(no. 3 multi-pole conductors inside a tube or raceway)

Note: the max. allowed current has been sized for a max. temperature around the cables of 30°C.

7.3 - CABLE INSULATION

The cable insulating material must be suitable for their environmental conditions (heat, chemicals,

etc.).

The mechanical resistance and the insulation thickness must ensure they are not damaged during the

productive steps, both for manufacturing the E.P. or for assembling it in the ENP units.

As for the part of the E.P. operating at 24-110-230 V, the cables must have insulation equal to the

higher voltage on it.

The E.P. must have an insulation resistance not lower than 1 MEGAOHM to ground; this is

measured by an equipment generating a continuous voltage of 500 V, applying such voltage

separately between:

a) each main conductor and each of the control conductors;

b) all the above conductors individually and the ground.

Note: during the test, low level circuits must be disconnected or short-circuited.

The complete E.P. must further bear, for T=60 seconds, the test voltage applied between all

conductors of the main circuits reciprocally connected (including the conductors of the control

circuits directly connected with the mains) and the ground of the grounded E.P.

NOMINAL SECTION

(mm²)

MAX. ALLOWED

CURRENT (A)

NOMINAL SECTION

(mm²)

MAX. ALLOWED

CURRENT (A)

1 12 35 111

1.5 16 50 134

2.5 21 70 171

4 28 95 207

6 36 120 239

10 50 150 275

16 68 185 314

25 89 240 369



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Such voltage must be equal to 85% of the lower voltage among all the tests ones under which the

different E.P. components have been tested during the dielectric test before being incorporated in the

equipment, with a min. of 1500 V, and must be supplied by a transformer with apparent power equal

to or higher than 500 VA.

Note:

• the devices that are damaged by high voltages, that can accidentally be supplied to their

terminals during the applied voltage tests, must be short-circuited during these tests;

• all above tests must be documented and the relevant certificates must be enclosed by the

supplier.

7.4 - CONDUCTOR IDENTIFICATION

All conductors, to mark the belonging circuit, must be identified by the colour of the insulating

material (see 7.5) and marked at both ends by the number of the voltage point.

Note:

a) each voltage point must be marked by a single number, also indicated on the terminal boards

through a suitable indelible label and indicated in the function wiring diagram

b) conductors and cables must be permanently marked by non-metal sleeves or collars, resistant

to hydrocarbons, white and with indelible marking;

Adhesive labels are not accepted.

7.4 - CONDUCTOR COLOUR

The colours to be used on the units for all coated single-pole electrical conductors, according to their

belonging circuit, must be:

a) for control circuits (branched from transformer):

- RED: for AC circuits (24 V AC), including the common grounded phase;

- DARK BLUE: for DC circuits; if the polarity must be indicated, it will be marked

with the signs “+” and “-” in the use points and in the possible check

points.

- GREY: for AC circuits with 230 V AC, if such voltage is used together with

the 24 V voltage (to distinguish the two circuits).

b) for the user circuits (branches from the line even if through transformers, excluding the

transformers of the control circuits):

- BLACK for phase conductors

- LIGHT BLUE (see 3.2.2 of IEC 60446) for the neutral wire

c) for the (protection) ground connections in E. P. containers, remote cases;



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- YELLOW/GREEN.

d) when the auxiliary circuits are branched between a phase and the neutral:

- BLACK for phase conductors

- LIGHT BLUE for the neutral (see 3.2.2 of IEC 60446), common for coils.

Note: multipolar cables, both for control and power circuits, must comply with the norm IEC 332.1

CEI 20-20 CEI-UNEL 00722 (in the last current revision), specifying:

for cables containing

• up to 5 cores, a different colour for them;

• two-pole: brown, blue,

• three-pole: brown, black, grey

• three-pole: brown, blue, yellow/green

• four-pole: brown, black, grey, yellow/green

• four-pole: brown, black, grey, blue

• five-pole: brown, black, grey, blue, yellow/green

• five-pole: brown, black, grey, blue, black

For cables with more than 5 cores, the black colour with their numbering, otherwise follow the

colours of the cores indicated in the wiring diagram of the machine.

Cables with cores of a different colour according to the standard DIN 47100 are accepted.

If the cables are not available according to the indicated standard, cables with colour in compliance

with the norm VDE0293 can be used.

8 - WIRING

8.1 - CONNECTION TYPES

All connections, including those for the grounding conductors, must be made with terminals.

The connections with the terminals must be made so as to prevent inner and outer wirings from

passing over the terminals.

Further care for the wirings not to pass close to or in contact with heat sources such as transformers

or heater, or with cutting parts.

The number of wires referred to each single terminal must be limited to at most 2 for each inlet.

A single wire for terminal must be arranged for ground terminals.

The terminals arranged for the connections of devices installed by ENP or optional devices installed

by the customer must have a free available inlet.

8.2 - TERMINAL TYPES



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All terminals, including those for ground conductor, must be screw-type with indirect tightening

(namely with a platelet between screw and nut and conductor) or spring-type (according to the

specifications of the functional wiring diagram).

Such tightening is mandatory even if tubular and ring cable terminals are used.

Different terminals cannot be used, if not previously authorized by ENP technical department.

Each terminal must be clearly identified (obtained through automatic identification systems) in

compliance with the wiring diagram through legible and indelible labels.

E.P.s with terminals identified by hand-written initials shall not be accepted.

8.3 - CABLE TERMINAL TYPES

Cable terminals must be clamped on all cables by suitable pincers and the clamped part must be

protected by an insulating sheath.

Required electrical features:

• no halogens

• Working temperature: 115°C

• Pre-insulated terminal

• Self-extinguishing according to the norm V0 (UL94), class 1

Note: only tubular or ring insulated or pre-insulated cable terminals are allowed.

Tubular terminals, are not necessary on spring terminals.

8.4 - RACEWAYS

The cable passage raceways and their covers must have the following electrical features:

Material: self-extinguishing PVC according to the norm V0 (UL94), class 1.

Colour: grey RAL7030

Reference norms CSA, UR, IMQ.

The raceway fastening to the sheet must be made with suitable plastic rivets; steel screws or rivets

are not allowed for fastening the raceway.

8.5 - CONNECTION MARKING

Each terminal must feature an indelible mark (see par. 8.2)

All connections of the electronic equipment, including those between pre-mounted elements, must be

marked (e.g. electronic board connectors, remote control relays, switches, transformers, terminal

boards).

8.5.1 – BOTTOM PLATES, CASES, OMEGA GUIDES

The bottom plates and cases must be manufactured according to the drawings specified in the

electrical panel code/layout and according to the last revision.

Omega guide features:

Material: steel

Dimensions: DIN OMEGA 3F (35x7.5 thck. 1 mm) or OMEGA 3AF (35x15 thck. 1.5 mm)

Reference norm: DIN EN50022

Current/section: 65 A/10 mm² (35x7.5 thck. 1 mm)



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Current/section: 125 A/25 mm² (35x15 thck. 1.5 mm)

8.6 - WIRING INSIDE THE ELECTRICAL PANELS

Supply conductors, depending on the unit type, can be connected:

directly on the main switch;

through line inlet terminals.

Anyway, the supply cable shall enter from the upper terminals of the main switch and the outlet of

the cable from the same shall be connected with the upper terminals of the automatic switches

(fuses) installed on the E.P., unless the wiring diagram specifies differently.

A power bar (min. section 16 mm²) can be fastened on the automatic switches (fuses) in order to aid

the wiring; suitable protection caps must be arranged at its ends to prevent possible accidental

contacts.

If the line inlet terminals are not present, a grounding terminal identified by the initials PE must be

arranged next to the main switch and sized so as to enable the connection of a ground conductor

with the section specified in the following table:

SECTION OF THE PHASE CONDUCTOR

SUPPLYING THE CONDITIONER

(mm²)

SECTION FOR WHICH THE INLET

GROUNDING TERMINAL MUST BE

SIZED

(mm²)

LOWER THAN OR EQUAL TO 16 EQUAL TO THE ONE OF THE SUPPLY

CONDUCTORS

HIGHER THAN 16 EQUAL TO AT LEAST 50% OF THE

SUPPLY CONDUCTORS, MIN. 16 mm²

Note

The ground terminal must be

- protected against corrosion and loosening;

- marked indelibly with the symbol "Grounding socket".

The power terminals must

- be separate from the auxiliary ones;

- be protected against possible accidental contacts;

- show the hazard symbol "live"; the graphic symbol must comply with IEC 60417-5019 (DB:2002-

10)



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The neutral terminal, if installed, must be light blue;

The ground terminal, yellow-green.

8.7 - CABLE AND WIRE ROUTE

All cable/wires must be routed directly from terminal board to terminal board and from contactor to

relevant connector without intermediate junctions.

Sections of cables/wires with sufficient length to aid disconnecting and reconnecting must be left

inside the raceways.

8.8 – ELECTROMAGNETIC COMPATIBILITY

In order to reduce the emission of electromagnetic waves from the equipment as much as possible

and to improve its immunity, the following indications must be followed:

a) the ground conductor connecting the ground terminal of the equipment (E.P.) with the

ground collectors ("ground bar") must be as short as possible and have the same section as

the ground conductor of the equipment.

b) The ground connections of the conductors supplying the utilization points outside the

equipment (compressors, fans, heaters, etc.), when required, must be as short as possible and

have a suitable section (also see table in 8.5).

c) The ground connections of the metal bottom plate of the equipment must be made with a

ground conductor with the same section as the one of the equipment ground conductor.

d) Shielded cables must be prepared carefully to prevent wire fraying and to enable and easy

disconnecting; pay special attention following the example of the enclosed drawing:

(SX3669/A).

9 – ELECTRICAL SAFETY TESTS (PSE test for CE marking)

Electrical safety tests are carried out by Emerson Networkpower, during the final test of the unit,

checking the whole electrical systems of the unit after the installation of the E.P. and the connection

of the different utilization points.

The tests are the following:

- insulation test;

- voltage test;

- check of the protection conductor continuity;

according to the specifications of the procedure no. 047GQCCAC utilized on ENP.

Details on the test extent/mode are given here below.

9.1 - INSULATION TEST

The insulation resistance measured at 500 V in direct current between the conductors of the power

circuits reciprocally connected (including all control and signalling circuits connected with the



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power circuits) and the protection conductor (machine frame included) must not be lower than 1

mΩ (1 Megaohm) to ground.

When the control and signalling circuits are not connected with the power supply circuit, separate

tests must be carried out:

· between the power circuits and the protection conductor;

· between the power circuits and the control and signalling circuits;

between the control and signalling circuits and the protection conductor.

Note:

for large-sized electrical systems separate tests are allowed for each component;

the components and the devices that can be damaged by the voltage during this test can be short-

circuited during this test;

the control and signalling circuits with rated voltage lower than 50 V, including the circuits with very

low operating or machine voltage, must be subject to this test if they do not include electronic

components;

the circuits that are not final-tested must be connected with the protection conductor during the test of

the other circuits.

Note: while applying the test voltage all intentional connections between power, control, signalling

circuits and the protection conductor must be open.

After the test these connections must be restored.

9.2 - VOLTAGE TEST

The electrical systems must be subject to the voltage test for a duration of 60 seconds, applying a

test voltage as follows:

- between the conductors of the power circuits, including all control and signalling circuits

connected with the power circuits, and the protection conductor, machine frame included;

- if applicable, between the control and signalling circuits with rated voltage higher than or equal

to 50 V, that are not connected with the power circuits, and the protection conductor.

Note:

a) the test voltage must be equal to 85% of the lower test voltage under which all components

and devices have been tested already before the assembling, with a min. value of 1500 V AC,

and must be supplied by a transformer with rated power of at least 500 VA;

b) for large-sized electrical systems separate tests are allowed for each component;

c) the components and devices that have not been designed to bear a test voltage of the above

mentioned value (rectifiers, condensers, electronic equipment, etc.) can be disconnected

during the test;

9.3 - PROTECTION CONDUCTOR CONTINUITY

Check:

a) the continuity of the protection conductor by a visual check;



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b) that the resistance between the terminal for the outer protection conductor and the grounds of

the electrical system and of the unit (frame) does not exceed 0.1 Ω (0.1 ohm).

Note: all tests must be certified and the relevant documents must be supplied with the electrical

panel.

10 – CONFORMITY CHECKS/FINAL TESTS FOR THE ELECTRICAL PANELS

Each E.P., before being supplied to Emerson Networkpower, is subject to manufacturing check and

operating final test procedures in compliance with the specifications in:

a) Emerson Networkpower wiring diagrams;

b) material/component detailed lists, manufacturing and test plans and inhouse check-lists defined

by each supplier with Emerson Network Power;

c) “Electrical panel check/final test Check List to be carried out by the supplier” (Quality certificate

of the supplier) defined by Emerson Network Power (Doc. CLC no. 09) that must be

enclosed/fitted inside each E.P.

d) “Remote electrical panel check/final test Check List to be carried out by the supplier” (Quality

certificate of the supplier) defined by Emerson Network Power (Doc. CLC no. 22) that must be

enclosed/fitted inside each remote E.P.

e) Further, spare fuses and connectors for the electronic boards (ICOM/Microface/Powerface) not

wired on the cable must be fitted inside the electrical panel.

11 – ELECTRICAL PANEL IDENTIFICATION PLATE

On the panel bottom plate/wall, in an accessible and well visible (legible) area, an adhesive label with

grey/white background must be applied ( Dimension: 60mm x 30mm) , indicating in capitals and

indelible black ink, the following rating data (see details on par.7 on Supply Technical

Specification 147GQ) :

ELECTRICAL PANEL CODE

CERTIFICATE NO.:

ORDER:

POS.: DATE:

ELECTRICAL PANEL MODEL

DRAWING/REVISION:

MANUFACTURER:

PRODUCTION DATE:

Electrical panels could be supplied inside a cardboard box or without cardon box, suitable to protect

the panel from any possible impact/damage it could be subject to during the different transfer/storage

steps.

A copy of the same label applied to the E.P. shall be applied outside the cardboard package or

electrical panel. (see details on par.8 on Supply Technical Specification 147GQ) :



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Enclosure ; Drawing VC-55



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Enclosure; Drawing SX-3669

Enclosure; Check List 09



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Enclosure ; Check List 22

procedure for manufacturing of electrical panels

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