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Switchgear - LV Form 4 Type
Switchgear - LV Form 4 Type
The UKs leading provider of switchgear, power distribution and monitoring systems.
A collaborative approach
At Mardix we take ongoing product development very seriously. We have committed to extensive research and development and ASTA Type Testing programmes as part of our business investment. The results of this approach are demonstrated in the nished product; fully installed and tested LV switchboards with built-in benets (Fig.01). We pride ourselves on assisting end users, consultants, and contractors through every step of the design, manufacturing, and installation processes, and are delighted to work with consultants from a projects inception. In the earliest design stages our input guarantees that any designs issued for tender are t for purpose, commercially viable, and are of the required specication. We understand the need for specication compliant bids and requirements for value engineering during the tender process and have built excellent relationships with electrical contractors on this basis, offering a safe path rather than a badly engineered alternative. We stand by the principle that a cost effective Mardix quotation should be about more than just our bottom line price, it should be about added value for the client. Ongoing collaboration with all parties and valuable feedback from end users keeps us at the fore of switchgear technology. Our ability to convert client feedback into technological advances has been central to many new initiatives and products, not least our intelligent switchboards (iBoards) and intelligent Power Distribution Units (iPDUs) which have set the industry standard. Similarly, our Mardix LV switchboard design is 100% Mardix owned and has been developed in 3 key stages over many years. Our latest offering is the most technically advanced and feature rich offering to date and is only possible due to our in-house 3D solid modeling capability, which has introduced innovations not previously possible with 2D software. We spend a signicant amount of time during the design process perfecting the top level assembly which is automatically checked for accuracy, clearance and zero clashing parts. The same attention to detail is witnessed in our manufacturing approach. All switchboards and PDUs are of fully welded construction for maximum rigidity and high tolerance not achievable with bolted at pack assembly. Door seals remain ush tting and Ingress Protection (IP) ratings are not compromised. An earthing arrangement running the full length of the switchboard and vertically into each cubicle section forms a high integrity earth bond against the welded enclosure. Whilst a welded, integral, high strength plinth completes the cubicle structure, which is then suitable for slab mounting or on a separate raised plinth assembly. An exacting cubicle fabrication process and a resilient powder coating in any RAL or BS4800 colour ensures the nal product looks just as we intended.
Key benets
ASTA certicates of Type Testing up to 6300A (100kA for 1sec) with unique ventilations systems designed, tested, and incorporated into higher power Mardix switchgear Thermal imaging capability as standard, with strategically positioned pre-punched grids for ease of access and enhanced surveying accuracy Forms of Separation up to Form 4 Type 7 with front and rear access designs Fully welded high strength Mardix cubicle system with high integrity earth bond, which is suitable for slab mounting or bolting onto underoor plinthwork Standard Ingress Protection to IP31. Higher IP ratings are available, and all Mardix switchboards are suitable for mounting within GRP enclosures High and low level cable spreader boxes to facilitate glanding and termination of large cables All outer doors and busbar chambers are hinged for ease of access. Screw x covers are not an acceptable alternative and will not be used Bespoke arrangements to meet specic width and height constraints Powder coated to any RAL or BS4800 colour. Our standard colour is BS4800 10 A03 (light grey) with a semi-gloss smooth nish
Ventilation
ASTA Type Tested natural and forced air-cooling assemblies are used on higher current rated switchboards
Switchboard earthing
Copper earth bars run along the entire length of the cubicles and drop vertically into the functional units, busbars and chambers.
Key benets
All functional units are protected against inadvertent contact with live parts. Custom made shrouds with laser proled thermal imaging grids allow efcient thermal imaging of circuit breaker connections All connection points can be thermal imaged including busbar chambers and incoming/outgoing cable boxes All major brands of ACBs, MCCBs and fuse switches can be incorporated, including Schneider, Terasaki, ABB and Socomec Sealed CT chambers with connection links, insulation barriers and shorting links, built to the specication of all Regional Electricity Companies (REC) Integration of tuned and detuned Power Factor Correction (PFC) and Active Harmonic Filters (AHF) Type Tested arrangements for stacked ACBs, and high density stacking of MCCBs Separate compartments with fully labelled components and terminals for metering, control, and prewired BMS contacts Incorporation of protection relays, G59 protection, battery intertripping units, Electronic Surge Protectors (ESP), Castell interlocking arrangements including solenoids and exchange boxes, temperature monitoring and large mimic panels Incorporation of HMI control panels, dual redundant PLC control philosophies, standard PLC control, auto-changeover systems and load shedding Incorporation of high end metering systems with waveform capture facility such as Schneider ION 7650 and ION 7550. Multifunction metering brands include Socomec, Autometers, Schneider. Energy metering to building regulations Part L2. See also the iBoard and iPDU for our intelligent range of switchgear and PDUs
3D solid modelling
Every switchboard Mardix produces is designed in-house using 3D design expertise. Once the overall assembly design is complete, it is transferred to the Computer Aided Design/ Computer Aided Manufacture (CADCAM) area where the assembly is analysed and separated into - subassemblies - and parts of varying materials including steel, copper, aluminium, polycarbonates and plastics. All3D parts are automatically developed into 2D at parts and then converted into machine code. This code is then sent to the job libraries of the required machine whether that is a laser cutter, a CNC punch, or a press brake. This level of technology and automation means Mardix now consistently produces cost effective and efcient switchgear. Production Director Wayne Lewis explains the benets of 3D modelling: Our assembly times have reduced dramatically which saves costs for the client, and the potential to have zero design errors has virtually eliminated incorrectly machined parts, mistakes, and rework which saves time and enables us to keep projects right on schedule.
Mardix can offer cost effective modular LV switchboard solutions to t your budget, with lead times from only 710 days depending on conguration.
Key benets
All new 100% Mardix owned, ASTA Type Tested busbar system. Developed in-house since 2006, we have introduced new innovative features that benet our clients through cost and space savings, and that speed up our LV switchboard assembly process ASTA tested up to 6300A (100kA for 1 sec). Our range of Type Test certicates allows a more exible approach to busbar sizing, and associated cost savings can be passed onto our clients We have achieved cost savings through the full range of busbar assembly ratings. This ensures we remain competitive whilst still delivering the highest quality LV switchboards Innovative busbar connecting systems, easier access to the individual busbar supports, and much improved 3D assembly drawings have reduced tting times by up to 30% 200% busbar requirements can be accommodated. (contact us for further details) Free issue busbar anges, which can be problematic at the nal stages of installation, are incorporated with ease using our 3D software. We can t and test nal connections as part of LV switchboard installation. Using our 3D views of complex busbar assemblies, including multiple corner sections and overhead busbar links, our customers benet from enhanced visualisation, which also simplies the design process
Forms of Separation
All of our Forms of Separation are agreed between users and ourselves during specication.
In order to protect against contact with live parts belonging to adjacent functional units, and against the passage of solid foreign bodies from one unit within an assembly to an adjacent unit, we take great care to apply the most appropriate Forms of Separation to each solution we manufacture. Ranging from Form 2 Type 2 through to Form 4 Type 7 our Forms of Separation incorporate industry standard methods such as: non-metallic and metallic rigid barriers and partitions; glanding and termination chambers for cables; busbar separation; insulated coverings and shrouding; and external terminals. Each option is carefully considered and balanced to t requirements and budgets, so you always know your equipment is well protected and cost effective. And, the probability of initiating arc faults is properly limited when you work with Mardix. Weve included the following pages as a quick and easy guide to the Forms of Separation offered on Mardix assemblies, and weve included an area offering clarity on Ingress Protection (IP) ratings.
3D Solid model demonstrating all Forms of Separation. See next page for detailed information on each Form of Separation.
Form 2 Type 2
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation, whilst terminals are separated from the busbars, but not from each other or functional units.
Incoming units
Outgoing units
Outgoing units
Form 4 Type 2
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation. Cables are terminated in the same compartment as the functional unit, but are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 5
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation. Terminals are external from the functional unit and insulated coverings such as PVC boots are used. Cables are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 6
All separation is achieved by metallic or non-metallic rigid barriers or partitions. Terminals are external from the functional unit compartment and rigid barriers or partitions are used to enclose them in their own compartment. Cables are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 7
All separation is achieved by metallic or non-metallic rigid barriers or partitions. Terminals are external from the functional unit compartment and rigid barriers or partitions are used to enclose them in their own compartment which features integral glanding facility.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Technical specications
A guide to the technical features behind Mardix LV switchgear.
Enclosure
Mardix LV switchboards usually comprise one or more vertically mounted sections. The sections are generally slab mounted, however, options for mounting on underoor/raised plinths can be accommodated. Our enclosures are formed from individually folded panels of Zintec sheet steel, which are fully welded and ground to provide clean lines and maximum rigidity. The Mardix high integrity earth bond is standard. An integral 150mm plinth is then welded to the base of the cubicle to provide a solid support channel which enables the switchboard to be mounted on a separate underoor plinth. Enclosure nish: Cabinets and doors are powder coated with RAL colours or BS4800 colours with a smooth nish whilst internal compartments feature RAL 9003 (white) with a ripple nish.
In addition:
Separation will be achieved in accordance with BSEN 60439-1:1999. The exact Form of Separation e.g. Form 4 (6) will be as specied. Separation will generally meet the following conditions: Protection against contact with live parts belonging to adjacent functional units Limitation of the probability of initiating arc faults
Technical specications
Thermal imaging
LV switchboards are designed and manufactured in-line with thermal imaging requirements. Thermal imaging ports are punched directly into the steel doors using CNC cluster punching. The ports are tted with sliding captive covers, xed and sealed to the door by security screws. A special tool is required to open the port. Polycarbonate custom-made shrouds are tted over all connection points to prevent inadvertent touching of any live parts and to facilitate safe thermal imaging. The custom-made shrouds are manufactured from polycarbonate sheet, which is folded and tied to form a rigid barrier. Each barrier will be laser proled with slots positioned in such a way to facilitate efcient thermal imaging of the connection point.
Labelling
Engraved traffolite labels will be tted to relevant doors and chambers. General labels black letters on white background Voltage warning labels black letters on yellow background General warning labels red letters on a white background All fuses and control components and associated connection terminals will be labelled using adhesive strip labelling.
24/7/365 emergency assistance Emergency onsite engineers Telephone technical support Non-invasive maintenance Isolated maintenance Thermal image surveys
Industry standard iPDU technology Power quality improvements Power trending procedures Citect Facilities and/or PowerLogic ION Enterprise Energy management to individual racks Integration with your management systems
t. 01539 720161 www.mardix.co.uk Mardix, Service Division, Westmorland Business Park, Kendal, Cumbria, LA9 6NS