those activities and considerations associated with the design, installation and

Transcription

1 : Low Voltage Switchboards d Purpose And Design Guidelines : This standard details those activities and considerations associated with the design, installation and maintenance of.

2 Index: Document History 1. Introduction 1.1 Purpose 1.2 Management Responsibility 2. References 2.1 International and National Standards 3. Glossary of Terms and Definitions 4. Construction 4.1 General 4.2 Electricity Supply 4.3 Discrimination 4.4 Forms of Separation 4.5 Ingress Protection 4.6 Impact Protection 4.7 Pollution Degree 4.8 Busbars 4.9 Outgoing Circuits 4.10 Cable Chambers 4.11 Earthing 4.12 Low Smoke Zero Halogen 4.13 Installation of LV cables 4.14 Labelling and Numbering Systems 4.15 Enclosure Numbering and Labelling 4.16 Electromagnetic Compatibility (EMC) 4.17 Electrolytic Action 5. Components 5.1 Air Circuit Breakers (ACB) 6. Interlocking 6.1 Non Paralleled Supplies 6.2 Paralleled Supplies 7. Fault Rating 8. Diversity 9. Spare Capacity 10. Power Factor Correction 10.1 Power Factor Correction 11. Inspection & Testing 11.1 Manufactures Type Tests 11.2 Particular Board Test 11.3 Energisation 12. Documentation 12.1 Electrical Drawings 12.2 Engineering Drawings 12.3 Device Parameters 12.4 Operation & Maintenance Manuals 12.5 Manuals 13. Component Table 13.1 General components Appendix Attachments 1. Attachment??? Revision: 2 Feb 2012 Noel Corry Page 2 of 27

3 Document History Date Revision Number Revision History Written By: Verified By: Approved By: 04/01/11 1 Text communicating changes and reasons for change (note changes in body text of document must be highlighted) Noel Corry Alain Polycarpe Noel Corry 07/02/12 2 Revised for rev 2. Revised text in Yellow Noel Corry Alain Polycarpe Noel Corry 1. Introduction This standard supplements national, international standards and legal requirements. It does not overrule these and where any conflict exists, national, international standards and legal requirements take precedence. This standard relates to the design, manufacture and works testing of Low Voltage main switchboards and sub distribution boards for supply to CCE Inc. This standard is not intended to be restrictive. Alternate means will be considered. However, proposals that do not address these basic requirements, as a minimum, are not likely to be acceptable. The proposed alternative, clearly indicating any advantages shall be submitted to the CCE responsible person. The written acceptance, of a proposed alternative, by CCE shall be obtained before any work is carried out. The requirements for packing, delivery, off loading, temporary storage and installation will be included in the specific contract documentation. 1.1 Purpose This standard details those activities and considerations associated with the design, installation and maintenance of Low Voltage Switchboards. This standard applies to the supply of the relevant equipment wherever installed on premises controlled by CCE in Belgium, the Netherlands, Norway, Sweden, Great Britain and Continental France. 1.2 Management Responsibility Standard Owner Procedure fulfilled by Managers locally accountable and responsible for: ESC Central Manager Electrical & Automation Manager -Noel Corry Engineering Manager Revision: 2 Feb 2012 Noel Corry Page 3 of 27

4 2. References The following documents contain provisions which, through reference in this text, constitute provisions of this Low Voltage Switchboard standard. 2.1 International and National Standards As this standard is for use in several countries the EN reference is used rather that a particular county version i.e. EN rather than BS EN Where national variations exist in standards the CCE responsible person shall decide which applies to a specific contract. Reference EN :2007 IEC :2007 EN :2007 EN :2006 EN EN :2009 EN 62262:2002 Title Low voltage fuses. General requirements. Insulation coordination for equipment within low-voltage systems Principles, requirements and tests Low-Voltage Switchgear and Control gear Specification for low-voltage switchgear and control gear. Circuit-breakers Specification for low-voltage switchgear and control gear. Switches, disconnectors, switch-disconnectors and fuse-combination units Low-Voltage Switchgear and Control gear Assemblies Degrees of protection provided by enclosures for electrical equipment against external mechanical impacts (IK code) 3. Glossary of Terms and Definitions As used in this standard: Abbreviation or Term ASTA Association of Short-circuit Testing Authorities Definition Circuit Breaker (CB) A mechanical switching device, capable of making, carrying, and breaking currents under normal circuit conditions, and also making, carrying for a specified time and breaking currents under specified abnormal circuit conditions such as those of short circuit. Contactor A mechanical switching device having only one position of rest, carrying and breaking currents under normal circuit conditions including operating overload conditions. Revision: 2 Feb 2012 Noel Corry Page 4 of 27

5 Control gear (Also see switchgear) Disconnector A general term covering switching devices and their combination with associated control, measuring, protective and regulating equipment, also assemblies of such devices and equipment with associated interconnections, accessories, enclosures and supporting structures. A mechanical switching device that provides, in the open position, an isolating distance in accordance with the specified requirements. Extra Low Voltage (ELV) Fuse Switch High Voltage (HV) IDMT Insulator Lambar LED Low Voltage (LV) Main Board Main LV Switchgear Voltage not exceeding 50V a.c. or 120V d.c., whether between conductors or to earth. A switch (disconnector) (switch disconnector) in which a fuse link or a fuse carrier with fuse link forms the moving contact. In a general sense, the set of voltage levels in excess of low voltage (1,000V). In a restrictive sense, the set of upper voltage levels used in power systems for bulk transmission of electricity. Inverse Definite Minimum Time. A tripping characteristic that has a variable tripping time inversely related to the fault current with a definite minimum time lag. Components designed to support and insulate a conductive body. Lambar is a unique busbar trunking system; it can be used in various distribution systems such as horizontal power systems and rising mains. Light Emitting Diode A voltage below High voltage (1,000Va.c. between conductors or 600V to earth). A board having connection to the LV side of a distribution transformer. That which is connected to the LV side of distribution transformers (11 kv or 6.6 kv /400 V) and are located in substations. Moulded Case Circuit Breaker (MCCB) A circuit breaker having a supporting housing of moulded insulating material forming an integral part of the circuit breaker. OCR Over current Overload Over current relay A current exceeding the rated current. Operating conditions in an electrically undamaged circuit, which causes an over current. PILC PVC Screen Separation Short Circuit Current Paper Insulated Lead Covered, refers to a type of cable construction. Polyvinylchloride A device used for the protection of cables and circuits against interference of electrical fields on the pulse to be transmitted. Of conductors. An arrangement of conductors with solid insulation interposed in such a manner that disruptive discharges cannot occur between them. An over current resulting from a short circuit due to a fault or an incorrect connection in an electric circuit. Revision: 2 Feb 2012 Noel Corry Page 5 of 27

6 Switch Fuse A switch (disconnector) (switch disconnector) in which one or more poles has a fuse in series in a composite unit. Switchgear (Also see control gear) Switching Device A general term covering switching devices and their combination with associated control, measuring, protective and regulating equipment, also assemblies of such devices and equipment with associated interconnections, accessories, enclosures and supporting structures. A device designed to make or break the current in one or more electric circuits. For the purposes of this specification only, Switching Devices embraces, switches, disconnectors, switch disconnectors and fuse combination units as defined by BS EN XLPE Cross-linked polyethylene refers to a type of cable construction. 4. Construction 4.1 General The switchboard and components shall be designed, constructed, assembled and tested to comply with applicable parts of EN :2009. All live parts on the switchboard shall be fully shrouded to prevent accidental contact with live equipment when the doors are open or cabling is in progress. All doors shall be key lockable with Gull Wing type handles and all openings shall be properly gasketted and vermin proof. Key type shall be specified by the CCE responsible person. Main switchboards shall be suitable for front and rear access, with outgoing cables emanating from above or below. Easily accessible cable terminating and testing facilities shall be provided. Surge protection shall be installed in all low voltage switchboards. Construction shall comprise of multi-fold fully welded outer units manufactured from 2mm CR4 prime quality sheet steel, thus ensuring earth continuity and integrity. This would be inherent Form 4 design and when stacked in the outer units create a minimum steel thickness between incoming / outgoing compartments of 3mm / 4mm ensuring the maximum segregation. Doors shall be returned folded for increased rigidity and have all corners fully welded and ground smooth, and be manufactured fro a minimum 2mm CR4 sheet steel. Doors shall be manufactured to open to a minimum of 90 degrees to allow access for maintenance and adjustment. Gland plates shall be fixed by the use of clamping bolts or tapped bushes. Self tapping screws shall not be used. The paint finish shall be suitable for normal industrial duty with adequate priming/undercoat layers applied. The switchboard shall be painted to a BS or RAL colour as specified in the tender document, the total paint thickness shall not be less than 100 microns. The board shall be easily extendible in either direction. Revision: 2 Feb 2012 Noel Corry Page 6 of 27

7 4.2 Electricity Supply The equipment shall be designed for use in any European country with the nominal voltages of 230V, 1 Phase, 400V, 3 Phase, 50 Hz +/- 10% in accordance with harmonised standards and tolerant of legally permitted supply variations in terms of voltage, frequency and their combined effects at each extreme. Equipment shall be supplied for use with a neutral and earth TN-S system (with separate neutral and earthing conductors throughout). 4.3 Discrimination Discrimination of operation of protective devices shall be assured for all circuits and sub-circuits. MCCB discrimination by current is preferred. Discrimination by time shall only be permitted where discrimination by current is not possible. Where Discrimination by Time is required the agreement of CCE responsible person shall be obtained at the design stage. 4.4 Forms of Separation Unless otherwise stated in the contract, the internal separation of assemblies shall be Form 4b Type 2 (to EN :2009) namely, bus bars, functional units and terminals for external conductors separated from each other by rigid barriers or partitions 4.5 Ingress Protection The switchboard assembly shall be of metal construction dust and damp protected to EN :2007. The degree of protection for the switchboard shall be IP42 as a minimum (i.e. cubicle, multiple cubicle or multi-box assemblies). The internal degree of protection would be to IP2X (any live parts not isolated by the door interlocked isolation device. Additional protection shrouding can be offered id required. 4.6 Impact Protection Impact protection of enclosures shall be appropriate to the location and shall be stated by the supplier in accordance with the rating system (IK rating) defined in EN Pollution Degree Unless otherwise stated in the contract Pollution degree 3 (IEC :2007) shall apply. 4.8 Busbars All busbars and droppers shall be manufactured from Hard Drawn High Conductivity (HDHC) copper, run horizontally and vertically as required. Busbars shall be air insulated and shall be fault rated to carry the rated current of the switchboard. Access to busbar system and busbar connections shall only possible by the removal of covers by using a tool. All covers which, when removed, which give access to live parts will have warning labels firmly fixed, which also state the voltage which will be exposed. Busbars current rating shall be specified on all quotations. Busbar rating shall relate to boards in continuous operation. Busbar rating shall not be varied throughout the length of the switchboard. Busbar systems shall be ASTA certified. Revision: 2 Feb 2012 Noel Corry Page 7 of 27

8 Busbars in switchboards fed from cast resin transformers capable of being up rated by forced cooling (See HV Standard section 6.3) shall be designed for this higher rating. Connections between busbars and outgoing circuits shall be manufactured from copper bars or suitably rated insulated cables for lower rated circuits. If cables are used a fault free concept with double insulation, shrouded terminals and no crossovers shall be applied. All busbars shall be totally enclosed and braced for the fault level nominated. Neutral busbars shall have an equal cross sectional area to the phase bus bars. Where cable connections are made to busbars, appropriate means (e.g. high temperature insulation) shall be taken to ensure the cable insulation integrity owing to any heat conduction from the busbars. 4.9 Outgoing Circuits Overload protection shall be provided on all three phases. Each outgoing circuit is to have an individual power meter measuring all three phases. Schneider Power Meter PM810 is the CCE preferred type Cable Chambers The cabling chambers shall be segregated to make it possible to cable any outgoing circuit in safety with the switchboard 'live'. Main board incoming sections shall be arranged to accept single core cables with top or bottom entry. If a cable gland plate is used it shall be non-ferrous to prevent eddy current circulation. Suitable cable lugs shall be provided to terminate the conductors. Alternatively the low voltage incoming section shall be arranged to accept busbar connections (Lambar or similar) for interconnection with the low voltage bus bars of the cast resin type transformers, which may form part of the suite Earthing On main switchboards a copper earth bar shall run the full length of the switchboard, be solidly fixed to the framework of each section and compartment and all non-current carrying metalwork shall be bonded to it. Dropper earth bars shall be available at each cable entry point for the connection of external earth conductors. The main earth bar size shall be 150 mm 2 minimum and shall be able to carry the maximum asymmetrical fault current of the board. Terminations shall be provided at both ends to facilitate connection to the earthing bar in the switch room. All gland plates, doors, component plates etc, shall be directly or indirectly earth bonded to the main earth bar. Each gland or gland plate shall be connected to the main earth bar. The neutral conductor shall be isolated from earth Low Smoke Zero Halogen All none metallic containment, equipment, associated items and cables installed in the switchboard shall be of low smoke halogen free materials (LS0H). Revision: 2 Feb 2012 Noel Corry Page 8 of 27

9 4.13 Installation of LV cables Suppliers shall only provide and install cables in compliance with current ISO Standards, national codes of practice, procedures and statutory instruments. All mechanical protection, i.e. cable tray and trunking, shall be both mechanically and electrically sound and complete, before wiring can commence. Suppliers shall provide documented evidence of cable sizing calculations. At all times the utmost care is to be exercised to avoid damaging the protective sheathing of the cable or of causing excessive bending or twisting which may result in bird caging of wire armour and/or damage to core insulation, sheaths etc. When routing cables, care must be taken not to obstruct access to and movement of plant. Cables shall be run in continuous unbroken lengths and joints will not be permitted unless authorised by the CCE Responsible Person. Where cables pass through floors, or rise through covered trenches, they shall be provided with adequate mechanical protection in the form of metallic sleeves or kick plates projecting not less than 75 mm above floor level. Kick plates shall be so positioned as not to constitute a trip hazard. Where vehicular access may be expected, exposed cables less than 4 m from floor level shall be adequately protected against damage. This protection must be sufficiently strong to withstand damage by trucks and shall also be applied to armoured cables where necessary. Steel pipe or suitable tubular guard may be used. Cables shall be handled and installed in accordance with the manufacturer's recommendations. Catenary support of cable will not be permitted unless all other methods of installation are impractical and then only with specific authorisation of CCE Responsible Person. Each cable shall be supported and secured in a manner that ensures that the cable will not sag. Storage and handling of cable before, during, and after installation is to be carried out with due regard to the manufacturers recommendations. Cables shall not be installed on exterior wall faces of buildings without the specific approval of the CCE Responsible Person Small Power Control and Wiring Cables shall be installed in such a way as to prevent entanglement with other cables in the conduit or trunking. All internal wiring shall be carried out using PVC insulated BS 6231 type BK cable neatly secure and loomed and run in PVC trunking where possible. Small wiring for protection and metering should be accessible whilst the board is still energised. All cables shall be fitted with crimped terminations and cable markers at each end, numbered to correspond with the appropriate wiring diagram and colour coded to BSPD 2379, IEC446. Where metering is required all protection shall be via HRC fuse cartridges Standard Wire Colours The following standard wire colours shall be utilised unless specific prior approval to use alternative colours is given in writing by the CCE Responsible Person. For mains voltage circuits of 400 V ac. or 230 V ac.: - Revision: 2 Feb 2012 Noel Corry Page 9 of 27

10 Phase 1 Phase 2 Phase 3 Neutral Earth Brown Black Grey Light Blue Green/Yellow For 230/110 V ac.: - Line Neutral Red Light Blue For 24 V supplies: - Positive Negative Dark Blue Dark Blue and White For PLC Connection (may be required for auto change over purposes): - PLC Input PLC Output Dark Blue Dark Blue All installations: - Interfacing Cabling Instrumentation Current Transformers Inter Tripping Orange White White White DC analogue signals (in shielded cable): - Positive Negative Brown White Power Cables Cable drums shall only be rotated in the direction indicated by drum markings and open cable ends are to be effectively sealed immediately after cutting to prevent the ingress of moisture. Cables shall be continuous and no joints are to be made along the length, reference shall be made to the CCE Responsible Person if this stipulation cannot be fulfilled. Only proprietary devices shall be used for clamping cables. Cable routes in production areas must be approved by the CCE Responsible Person before installation commences. Cables shall be neatly installed either separately or on banks arranged to form a maximum of two layers. The bunching of cables is unacceptable. Where cables require to be installed through or across the edges of tray or other metalwork the edges of the lips shall be made smoothed, painted and lined with protective sleeving to avoid cable damage. Revision: 2 Feb 2012 Noel Corry Page 10 of 27

11 Single Core Cables for 3 Phase Supplies When single core cables are used for three phase power distribution circuits (e.g. off main 400 V transformers), both ends shall be earthed and bonded together. Special attention shall be given to de-rating the cable to account for circulating currents owing to induced voltages in the armour. Under such circumstances: - a separate protective conductor shall be provided. insulated glands for cable terminations shall be fitted at one end. triangular formation shall be used for each three phase group of single core cables. contractors shall provide evidence of ability of cleats to withstand the axial forces. protection from contact with the cable armour shall be provided Labelling and Numbering Systems All elements of an installation, whether they are electric, or other means of control will be clearly identifiable with a reference mark and reproduced on plans and diagrams. Each component of an electrical installation shall be labelled according to the CCE E&A standard: each component, wire, terminal, cable, etc shall have a unique number. All numbers shall relate to the electrical drawings and shall be visible in the electrical drawings. Labels and signs shall comply with the relevant national and international standards. Labels shall be durable and remain clearly legible for minimum 10 years, appropriate for the physical environment. All labels shall be printer generated (handwritten labels or labels composed of pre-printed signs are not accepted). Label designations shall relate to those on drawings, which identify the items of equipment. Identification of all electrical equipment shall be unique, for a complete listing contact the CCE responsible person. Warning labels i.e. bus bar chambers shall be Yellow/Black/Yellow engraved laminate (Traffolyte). Enclosures labels shall be manufactured from Red/White/Red engraved laminate (Traffolyte). Labels shall be permanently fixed next to the equipment. The CCE numbering system is based on IEC The use of Group and Place structure for electrical drawings and numbering is mandatory. Explanation Group and Place: Group: Functional part of the machine. Indicated by symbol = Line number and machine number (= machine abbreviation) shall be included in the group number Machine abbreviation shall be taken from Industrial Network and Communication Standard. Place: Physical location of a component. Electrical cabinet or zone in the installation. Indicated by symbol +. Important notes: If a machine or installation is not subdivided in functional groups, the complete electrical drawing shall be in 1 group, the name of this group shall be the machine number. Example: =2FBC1 Line 2 Full Bottle Conveyors The indication of the physical location of each component by using the place indicator + is mandatory. The choice for a Group and Place project is a setting in Eplan, and is incorporated in the CCE Eplan P8 standard. Revision: 2 Feb 2012 Noel Corry Page 11 of 27

12 4.15 Enclosure Numbering and Labelling Each enclosure, electrical cabinet, panel, distribution board and junction box shall be uniquely numbered. The complete number of each cabinet shall be composed following the Group and Place syntax below: Syntax: =[LineNumber][MachineAbbreviation] + [CabinetNumber] Line Number: Number of the production line. Machine abbreviation: To be taken from Industrial Network and Communication Standard Cabinet number: Mandatory abbreviations for cabinets to be used see below: Main cabinet: +MP1, +MP2 Junction box: +JB1, +JB2 Control box: +CB1, +CB2 (cabinet containing operator control) Examples: =2FIL1 +MP1 =2FBC1 +MP1 =2FBC1+JB1 The supplier shall ascertain the required numbers from CCE for every contract. Electrical enclosure labels shall be manufactured from red/white/red engraved laminate (Traffolyte, Resopal) Main Panel Each enclosure will have unique number existing of number main panel plus index *.01,*.02, Example: =2FIL1 +MP1 =2FIL1 +MP2 Note: Main panels with more than 2 compartments shall be split up in different main panels to simplify finding components: +MP1, +MP2, etc. Nameplate of main panel shall indicate: Source of power supply (Supplied from) Description Panel No Location Rating Cable type Network Type Icc 3 value Definitions: Supplied from: Source of electrical supply to the equipment, including source panel number and source switch number. Description: Name of the equipment being supplied. Panel No.: Reference number of panel composed of machine number and location. Location: Area or place where panel being supplied is situated. Rating: Circuit breaker / Main disconnect maximum rating (maximum allowable current). Cable type: Description of what type of cable installed (No of cores x core size + cable type). Network Type: Type of distribution system (TNC/TNS). Icc 3 Short circuit rating Revision: 2 Feb 2012 Noel Corry Page 12 of 27

13 Supply Panel Label When the dimensions of the panel do not allow the application of a label with the dimensions prescribed above, a label with appropriate dimensions can be fixed. Edges to be chamfered to 45 0 Nameplate of the sub panel, powered must indicate: Description of the equipment. Cabinet number. Figure 1 Enclosure label main panel When the dimensions of the panel do not allow the fixture a label with the dimensions prescribed above, a label with appropriate dimensions can be fixed. Nameplate of sub enclosure, powered with power bus must indicate: Description of the equipment. Enclosure number. Each compartment or switchgear unit shall carry a label to identify circuit description together with plant reference number. On Main boards labels shall be fitted on the front and the rear of each compartment and on any moving carriages. All labels shall be fixed with non-ferrous rivets or screws. Covers to Busbar chambers shall have labels engraved with black text on a yellow background with 6 mm high letters DANGER LIVE BUSBARS. The switchgear shall have a main designation label to EN :2007, and include the following information: - Manufacturer's name or trademark. Type, designation and serial number. Rated voltage, frequency, and short circuit capability and certification authority. Rated current of each circuit. Revision: 2 Feb 2012 Noel Corry Page 13 of 27

14 Voltage warning labels shall also be fixed, at all appropriate positions on each enclosure Sub Panels in the Field Each sub panel shall have a unique number consisting of main cabinet number plus index 1, 2 Example: =2FIL1 +JB1 =2FIL1 +CB1 Nameplate of sub panel shall indicate: Source of power supply (Supplied from) Description Panel No composed of machine number and location. Location Rating Cable type Sub Panel Label Label - Sub Panel Revision: 2 Feb 2012 Noel Corry Page 14 of 27

15 Component Numbering and Labelling Component numbers have to identify each component with a unique number, indicating the group, the place, the page, symbol and the path where the component can be found in the electrical drawings and in the installation. Symbols used must be according to IEC Composition of component number: Syntax: =[Group]+[Place] [Page][Symbol][Consecutive Number] Example: =2FIL1.PS +MP1-8K3 Project subdivided in groups =2FBC1 +MP1-100U1 Total project is 1 group PLC cards shall be numbered to the page number of the page containing the PLC rack overview. Note: Sub division of the machine in functional groups is not mandatory. The complete machine can be in 1 general group Use of Group and Place syntax (IEC ) is mandatory Cabinet Internal Component Labelling Component labels in control panels and electrical cabinets shall be permanently fixed on the component and to the backplane next to the component. Wire channel covers (lids) shall be labelled with identification markings to aid replacement after removal. Numbering shall start upper left side and end lower right side. Syntax to be used: On each crossing of covers, a 2 digit number shall be put on both covers. Label inside the electrical cabinet shall be yellow background with black lettering Field Component Labelling Labels shall not be fixed directly on components but to a permanent support next to the component in such a manner as to avoid any device ambiguity. Component labels shall be manufactured from white/black/white engraved laminate (Traffolyte, Resopal). Component numbers in the field shall be permanently fixed next to the equipment. Each label shall be positioned so that it can be clearly read from a normal observation position, and will unambiguously relate to the item that it describes Wire Numbering Wire numbers shall uniquely identify each wire, indicating the group and the page where the wire can be found in the electrical drawings. Label colour shall be white background with black lettering. Composition of wire numbering shall be done according to syntax below: Syntax: =[Group] [Page]/[Consecutive Number] Group number: Example: =2FIL1.PS =2FBC1 Page number Consecutive number Number to be reset for each page Example: =2FIL1.PS-05/01 =2FBC1-25/01 Visibility in the electrical drawings: The wire numbers shall be visible in the electrical drawing. As a minimum, the wire numbers from the example above shall be minimum visible as follows: Wire number Wire number visible in the drawing =2FIL1.PS-05/01-05/01 Project subdivided in groups =2FBC1-25/01-25/01 Total project is 1 group Revision: 2 Feb 2012 Noel Corry Page 15 of 27

16 : Low Voltage Switchboards d Printed wire number visible in the cabinet: Wire number shall be the same on both sides of the wire The part of the actual wire number to be printed depends if the project consists of 1 general group or if the project is divided into functional groups Minimum the syntax below shall be printed on the wire number: Wire number Printed wire number visible in the cabinet =2FIL1.PS-05/01 PS-05/01 Project subdivided in groups =2FBC1-25/01-25/01 Total project is 1 group Cores of a cable shall have a unique wire number. Core numbers printed on the cable cores shall be visible in the electrical drawing. Wire numbering shall be sequential. Numbering shall re-start for each page. Material wire numbers: Phoenix PATG. For wires connected to PLC-cards, shall be used Terminal the supplier shall assure that the doors of the PLC cards can be closed. When necessary, extended covers Wiring Each terminal row shall be labelled with a unique number, to be put at the left side of the terminal block. Each physically separated block of terminals is consideredd as a terminal row. A terminal row should not consist of more than 30 terminals. Symbols to be used: Power terminals: XP Control voltage terminals: XC Each terminal must be labelled with a unique number within the terminal block Cable Numbering Cable numbers shall uniquely identify each cable, indicating source and destinationn of the cable. Label colour shall be yellow background with black lettering. Cable numbers shall be placed inside the cabinet (between floor plate and terminal row) for floor mounted cabinets. Cable numbers shall be placed outside the cabinet for wall mounted (sub)-cabinets with sufficient freee space below. Network cables shall be numbered on entering the electrical cabinet and where connected to the network component. The division between source and destination in the cable number will be made by a slash sign ( / ). The cable number has to be engraved on 2 lines to improve legibility of the number. First line shall contain source of the cable followed by the slash sign. Second line shall contain the destination of the cable. Syntax: Source/ =[Group]+[Place] [Component Number]/ Destination =[Group]+[Place] [Component Number] Example =2FBC1+F3-300M1/ =2FBC1+F3-301M1 Laser engraved cable markers shall be used. Labels must be legible for a minimumm period of 10 years. Following label brands are approved by CCE: Murr Plastic, Elmaro. All other material must be approved by the CCE responsible person before use. Example Cable Number Material / Syntax For floor standing cabinets, the cable markers shall be fixed inside the cabinet. SC Procedure Revision: 2 Feb 2012 Author: Noel Corry Low Voltage Switchboard Standard Page 16 of 27

17 Power supply Cable Source: Destination: Cabinet number (=2LVB+MP1) and component number of the circuit breaker with number of the page in the electrical drawing (101) that shows the circuit breaker. =Group (including machine number)+place Component Number of the Main Disconnect Note: Example: =2LVB1+MP1-101F5 / =2FBC1+MP1-100Q1 (2LVB1 = First low voltage board of line 1) When supplying new machines from existing low voltage boards, the origin of the power cable shall not always be in =Group+Place-Component format. Existing cabinet number and component number of the circuit breaker shall be taken as source of the cable Cables Between Cabinets (between 2 machines OR between Main Cabinet and Sub Cabinet to Terminals) Source: =Group+Place Terminal row / Destination: =Group+Place Terminal row Example: =2FIL1.PS+MP1-XP101 / =2FIL1.PS+JB2-XP101 Project subdivided in groups =2FBC1+MP1-XC20 / =2FBC1+JB2-XC40 Total project is 1 group Actuator/ Sensor Cables Source: Destination: =Group+Place Terminal row or Component Number/ =Group+Place Sensor or Actuator Number Example: =2FIL1.PLC+MP1-XC50 / =2FIL1.PLC+JB2-2B1 Project subdivided in groups =2FBC1+MP1-XC20 / =2FBC1+F2-150B1 Total project is 1 group If the destination is a sensor or actuator, the page number in the electrical drawings is indicated by the component number, which includes the page number. In the first example above the reference 2B1, 2 is the page number, B is the symbol, and 1 is the consecutive number, to be restarted for each page Cable between Components in different cabinets (e.g. Network Cabling) Source: Destination: =Group+Place Component Number/ =Group+Place Component Number Note: Component number contains page number of the electrical drawing. Example: From PLC Filler to PLC Bottle Conveyors: =2FIL1.PLC+MP1-3A2 / =2FBC1+MP1-50U1 Where several connections are required from one unit to another i.e. Power, Control & Network the numbering of the cable should reflect this by adding an identifier to define the connection point. Example: From drive motor 300M1 to drive motor 301M1 =2FBC1+F3-300M1.2 / =2FBC1+F3-301M1.2 Revision: 2 Feb 2012 Noel Corry Page 17 of 27

18 Example Numbering =2LVB1+MP1 Low Voltage Board Line 2 Cable Number: =2FBC1+MP1-10XP1 / =2FBC1+JB2-10Q1 Cable Number: =2LVB1+MP1-101F5 / =2FBC1+MP1-100Q1 =2FBC1+MP1 Conveyors Main Panel 1 Cable Number: =2FIL1.PLC+MP1-3U2 / =2FBC1+MP1-50U1 =2FIL1+MP1 =2FBC1+MP2 Cable Number: =2FBC1+MP2-10XP1 / =2FBC1+F3-300M1 =2FBC1+JB2 Sub-enclosure in the field Cable Number: =2FBC1+F3-300M1 / =2FBC1+F3 =2FBC1+F3-301M1-300M1 =2FBC1+F3-301M1 Motor 300M1 Motor 301M1 Example of Numbering 4.16 Electromagnetic Compatibility (EMC) The manufacturer shall confirm compliance with the EMC statutory legislation Electrolytic Action Every precaution shall be taken to prevent chemical or electrolytic action where dissimilar metals are used in close proximity. This is particularly important where aluminium or aluminium alloys are used. Revision: 2 Feb 2012 Noel Corry Page 18 of 27

19 5. Components 5.1 Air Circuit Breakers (ACB) General The circuit breakers shall comply with EN , and shall be certified by an approved testing station for the rated short circuit capacity. The operating handle shall be lockable in the OFF position. The circuit breaker ON - OFF state shall be indicated by a flag or other means of positive indication. Air Circuit Breakers shall be of the Withdrawable type / design of metal clad construction. The protection relay shall be of the self diagnostic type incorporating a watchdog circuit for internal checking; indication of this shall be displayed via an alarm CPU LED. Volt free contacts and LED s shall be provided for overload and short circuit fault functions. An in built OCR check with trip / non trip feature shall be provided to allow calibration settings to be checked on site. Fault and thermal ratings of circuit breaker shall be related to the specific enclosure in which they are installed. Free Air ratings are not acceptable Main Boards Incoming circuits and bus sections shall be 4 pole air circuit breakers (ACB's). Manual closing and tripping shall be independent of operator effort. The circuit breaker closing operation shall be at least independent manual closing as defined in EN :2006. ACB tripping circuits other than integral protection circuits shall be designed for shunt operation from an independent power supply. ACB's designed for shunt tripping operations shall not be closed unless the shunt tripping supply and system mains is available. Such ACB's shall remain closed unless opened by integral protection and/or shunt trip operation. System mains supply failure shall not cause such circuit breakers to open. Facilities shall be provided for testing the circuit breaker closing and tripping mechanisms when the circuit breakers are in the isolated position. It shall not be possible to withdraw or insert a circuit breaker unless it is in the OFF position. The busbar and circuit shutters shall be provided with suitable padlocking facilities Inter-Tripping Inter-tripping circuits shall be designed for shunt trip operation from an independent power supply. Either: - Main board incoming circuit breakers shall be equipped with inter-tripping from HV circuit breaker with cross interlock facilities provided. Revision: 2 Feb 2012 Noel Corry Page 19 of 27

20 Or: - On switchboards with bus couplers, a fault trip on an incoming circuit breaker shall also trip the closed bus coupler. The particular design of the installation shall dictate the interlocking requirements. It is the responsibility of the supplier to obtain approval from the CCE Ltd Site Electrical Representative for each installation. The supplier shall co-operate with the CCE Ltd Site Electrical Representative in developing suitable written procedures for operation of the system. Power supply equipment for shunt tripping circuits shall be rated at 30 V d.c. with a short term capacity rating of XX 1 ampere hours available with or without the system mains supply available, where 1 is the required battery capacity Protection for Main Low Voltage Switch Boards Main Incomer Overload protection shall be provided on all three phases. The LV main switchboard manufacturer shall arrange a facility to trip the main incoming circuit breaker from an over temperature trip signal. Transformer over temperature alarm and trip volt free contacts shall be provided by the transformer manufacturer. Restricted earth fault protection shall be provided with arrangements to trip low voltage incoming and high voltage circuit breakers. In order to ensure compatibility, the LV main switchboard manufacturer shall include for providing a suitable current transformer as a free issue to the power transformer manufacturer for installation on the neutral busbar of the transformer 5.2 Moulded Case Circuit Breakers (MCCB) Withdrawable or Plug in 4-Pole Moulded Case Circuit Breakers up to and including 630A shall comply with the construction and operating requirements as stipulated by EN :2006. Cascade rating and operation between circuit breakers is not acceptable and absolute selectivity is required. MCCB s shall be rated at 500 volts minimum and will be ASTA certified. MCCB s shall incorporate circuit protective features. MCCB's shall be capable of withstanding prevailing fault levels or shall be protected by appropriately rated back-up fuses. MCCB's shall be pad lockable door interlocked handle and be lockable in the OFF position. Each MCCB shall be mounted within individual compartments and be of plug in pattern up to 630 A current rating, above this rating MCCB s shall be of the fixed pattern. The live side of the MCCB shall be fully shrouded and phase colours for connections shall be clearly identified. All relevant circuit breaker manufacturers' tabulated test data shall be provided. 5.3 Switching Devices All switching devicess shall comply with EN Utilisation categories for switching and disconnecting devices shall be AC23B (infrequent operation of motor or other highly inductive loads) as a minimum. Revision: 2 Feb 2012 Noel Corry Page 20 of 27

21 Switching devices shall not be used as the normal means of motor starting and stopping (i.e. contactors shall be the normal means of motor starting and stopping). The ON or OFF state of the switching device shall be indicated by a flag or other means of positive indication. The mechanism shall be interlocked with the door so that the latter can only be opened when the switching device is in the OFF position. The switching device must be capable of being padlocked in the OFF position. All live parts are to be shrouded (IP20) when the door is open. 5.4 Fuses and Fuse Equipment Fuse and fuse equipment shall comply with the relevant parts of EN :2007 All fuses shall be of the HRC type of class gg utilisation category and comply with EN IEC :2007, for protection against overload and short circuit currents. Class gm fuses for motor protection shall not be used for distribution purposes. All fuse links shall be provided by the switchgear manufacturer. A full set of spare fuse links shall be supplied. 5.5 Metering Energy Meters Where metering is required all protection shall be via HRC fuse cartridges. Instrumentation shall be of the flush pattern type and shall be included on all outgoing circuits, and shall be provided with: Current Display per phase Voltage display per phase / phase and phase / neutral. Power Factor Correction Incomers A kwh meter for 3 phase 4 wire unbalanced loads shall be provided on each main board incoming circuit, complete with facilities to transmit by Ethernet and Pulse Type energy usage signals, at 1 pulse equal to 1Kw to a remotely mounted supervisory computer system. All main incomers shall be provided with a multi function auto meter with a digital display unless otherwise stated. Maximum demand shall be indicated on each incoming circuit Outgoing Circuits Each outgoing circuit is to have an individual 3 phase 4 wire power meter, complete with facilities to transmit by Ethernet and Pulse Type energy usage signals at 1 pulse equal to 1Kw to a remotely mounted supervisory computer system. 5.6 Cables & Wiring Types All wiring shall be carried out in one or more of the following types of cable or as otherwise agreed with the CCE Responsible Person. Wires: Single core stranded copper PVC insulated wires in conduit and trunking to IEC Revision: 2 Feb 2012 Noel Corry Page 21 of 27

22 Cables: PVC insulated PVC sheathed copper conductor multi core cable to IEC This is to be used in general control circuit applications. All power cables must be shielded cables, excluding cables from low tension distribution board to machine. Every shielded cable shall be connected to an earth bar at the entrance of the cabinet. Care shall be taken that the shielding is resistant to the chemicals used in the area. All feed cables must consist of 4 cores (3 phases and earth conductor). For cable types see section 13.1 if these cables are not suitable for the area / installation / equipment then a different Lapp Group cable shall be used, this shall be agreed with the CCE responsible person. 5.7 Tools Any special tools, equipment or test leads required for testing and maintenance shall be provided by the manufacturer. 6. Interlocking Interlocks should be mechanical in nature and shall be preventative rather than corrective in operation. For with more than one source of supply the following will apply. 6.1 Non Paralleled Supplies Standard Castell interlocking facilities shall be incorporated between each incomer and the relevant bus section to prevent parallel supplies, which could prevent a source of energy to an isolated transformer. The engraving of the locks shall be as specified by the CCE Inc. Responsible Person. 6.2 Paralleled Supplies Operation and interlocking shall give due consideration to:- Isolation of transformer for maintenance Isolation of Low Voltage Switchboard sections for maintenance Fault level of paralleled supplies Standard Castell type interlocking facilities shall be incorporated between incomers and bus section circuit breakers to prevent supplies being paralleled. The engraving of the locks shall be specified by the CCE Inc. Responsible Person. Circuit breaker interlocks shall be provided to prevent: - the circuit breaker being inserted into its housing unless it is in the isolated position. the circuit breaker being closed unless it is in its service or isolated position. the circuit breaker being inserted or withdrawn unless it is open. the circuit breaker cannot be inserted into any position other than that that has been selected on the selector mechanism. Revision: 2 Feb 2012 Noel Corry Page 22 of 27

23 7. Fault Rating LV switchboard bus bars shall be ASTA Certified as follows: Board Rating Short Circuit Rating 800 A 26 ka for 1 second > 2,000 A 50 ka for 1 second 2,000 A > 80 ka for 1 second Certificates for the tested assemblies shall be provided prior to installation. The fault rating, making and breaking capacity of distribution boards and control gear shall be appropriate to the system fault level at the point of installation. It is the contractor's responsibility to ascertain relevant parameters. Fault and thermal ratings shall be related to the specific enclosure in which the circuit breaker is installed. Free Air ratings are not acceptable. 8. Diversity Where not otherwise specified in the contract or obvious from known loading conditions Diversity factors applied to switchboards shall be as recommended in EN : Spare Capacity A minimum of 20% additional equipped spare capacity shall be provided. The configuration of the spare capacity shall be agreed with the CCE responsible person at the design stage. 10. Power Factor Correction 10.1 Power Factor Correction Design of power factor correction equipment shall take into account present and likely harmonic content. Power factor equipment shall form an integral part of the LV main switchboard. Power factor correction cubicles shall be equipped with incoming fuse switches interlocked with the cubicle door. 300 kvar (maximum) capacitor banks shall be divided into six groups of 50 kvar each. De Tuning capacitor banks shall be considered. Each group shall be provided with a set of suitable fuses and a contactor. Indication for each group shall be viewable at the PFC controller / meter. Power factor correction equipment shall be fully automatic and controlled from six stage automatic power factor correction relays. Revision: 2 Feb 2012 Noel Corry Page 23 of 27

24 A loss of supply volts facility shall be incorporated, so that if the supply is lost for any reason, the capacitors will be automatically de-energised, and when the supply is restored, they will be re-energised in sequence with suitable time delay between stages. A suitable current transformer shall be included in the Phase 1 supply of the incoming main switchboard bus bars for PFC control reference. 11. Inspection & Testing 11.1 Manufactures Type Tests Switchgear suites shall be completely assembled, wired and tested at the manufacturer's premises. The following type tests shall be undertaken and recorded: - Verification of temperature rise limits. Verification of dielectric properties. Verification of short-circuit capacity. Verification of continuity of protective circuits. Verification of creep distances. Verification of mechanical operations. Verification of degree of protection Particular Board Test The following routine tests shall be conducted. In all cases, test results shall be furnished on completion. Inspection of the switchboard including all wiring and interlocks. Electrical operational tests. Dielectric tests. Checking of all metering, protective devices and continuity of circuits. Routine inspection and tests shall be repeated before commissioning on site Energisation Prior to Energisation of the switchboard on site, it shall be demonstrated that it is safe to be put into service. This shall include, but not be limited to, proving that all protection relay, safety and control devices have been correctly set and that the installation complies with this specification and any other relevant requirements. Test certificates shall be provided and accepted before energisation. Revision: 2 Feb 2012 Noel Corry Page 24 of 27

25 12. Documentation 12.1 Electrical Drawings Electrical engineering drawings shall be made in the latest version of Eplan, following the guidelines described in the CCE Eplan P8 standard (CCE_Eplan_P8_Standard_Issue_2011.doc). Structure of electrical drawing shall be according to IEC61346 (group and Place). Symbols shall be according to IEC Electrical drawings shall contain only components present in the cabinet and shall be drawn in landscape. Electrical drawings shall be delivered as-built: they shall be a perfect reproduction of the installation. On all electrical drawings, each symbol (sensor-actuator-device- ) must have a comment at the bottom of the page which explains functionality. This comment must be identical to the comment in PLC-program. For modifications to an existing project, the latest version of electrical drawings and PLC-program shall be requested from the CCE responsible person. Each electrical component shall be linked with manufacturer details, visible in properties of the component. All components shall be listed in a table comprising of: component number, location in electrical drawing, supplier, manufacturer and manufacturer reference number. Electrical drawings shall contain an overview of the physical location of the electrical cabinets used in the electrical drawing (indicated by + ). All + codes shall be indicated on a layout of the machine. Electrical drawings shall contain an overview of all networks (ASI Profibus Ethernet), including the cabinet number in which the network component is built-in / including the electrical component number of all network components / including a cross reference between overview drawing and electrical drawing. Supplier shall provide a preliminary version of the electrical drawings before starting the construction of the panels. CCE responsible person will advise/comment, but the responsibility remains with the supplier. The electrical drawing shall be fully documented in English and the language specified by the table below. France Belgium Gent/Antwerp Belgium Chaudfontaine The Netherlands Great-Britain Norway Sweden French OR English Dutch OR English French OR English Dutch OR English English Norwegian OR English Swedish OR English It is the Supplier s responsibility to ensure that an up to date set of drawings are left on site whilst the as built drawings are finalised. As Built electrical drawings shall be delivered in electronic format and on paper, no later than 2 months after commissioning. The verification procedure done by the drawing software shall result in a set of error free drawings (empty error list). The supplier shall deliver 1 x Electronic copy & 1 x Hard copy (paper). Interfacing between machines: The terminal block and terminal numbers and I/O addresses of destination cabinet have to be drawn in the electrical drawing of the originating cabinet. Machine interface signals have to be exchanged before installation on-site. Revision: 2 Feb 2012 Noel Corry Page 25 of 27