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PASSION FOR POWER.

Guide
Design and assembly
according to IEC 61439 / EN 61439
ENYSTAR Distribution Boards up to 250 A and
Mi Power Distribution Boards up to 630 A

Download at www.hensel-electric.de/61439
2
GUIDE
Design and assembly
in accordance with
IEC 61439 / EN 61439
ENYSTAR Distribution Boards up to 250 A and
Mi Power Distribution Boards up to 630 A

Basics 4-6

IEC 61439 / EN 61439 7

Mi Power Distribution Step 1: Collecting all the project data


Boards
Interface characteristics of assemblies 8
Checklist to design switchgear assemblies according to IEC 61439 / EN 61439 9
Interface: Installation and ambient conditions 10
Interface: Operation and maintenance 11
Interface: Connection to the public power supply system 12
Interface: Electrical circuits and consumers 13

Step 2: Design of an assembly and design verication


Example: Checklist to design switchgear assemblies
according to IEC 61439 / EN 61439 14
Project design using the data from the checklist 15
HENSEL Planning tools at a glance 16-17
Verications supplied by the system manufacturer 18
Verications to be created by the panel builder 19

Determining the rated short-time withstand current (Icw) of a circuit of an assembly 20-21
Feed: Determining the rated current (InA) of an assembly 22
Rated current of an outgoing circuit (InC) 23
Determining the operating current (IB) 24
Calculation of the power dissipation (PV) 25
Determining the rated diversity factor (RDF) 26
Design verication of permissible temperature rise
according to IEC 61439-1 / EN 61439-1 Section 10.10 27

Step 3: Assembly / manufacture of the distribution board


Assembly instructions for distribution board systems 28-29
Routine verication / inspection (routine test report) 30-31

Step 4
Manufacturer's marking 32

Step 5
Declaration of EC conformity (check lists for the manufcturer of an assembly) 33

Documentation 34

3
Why a guide to practice?

There is a precise conformity on the content of the new Standard Guide 61439 for the practice:
61439 in the IEC and EN world of standards. Consequently this 5 steps to a standard-conforming switchgear assembly
document uses the writing IEC 61439 / EN 61439 in the following.
The guide lists the process of design, assembly and documentation
IEC 61439 / EN 61439 - of a low-voltage switchgear assembly in the order of the necessary
New tasks and responsibilities for the electrician steps and at the same time assigns to these steps the relevant
sections from the standard IEC 61439 / EN 61439.
IEC 61439 / EN 61439 shows how a low-voltage switchgear
The application of the guide is focused on the manufacturing
assembly, which is safe for the user, can be built. In addition to
of distribution boards up to 630 A and in addition to checklists
changes affecting the design of an assembly, the manufacturer of a
and instructions regarding the verication of compliance with the
switchgear assembly is faced with new tasks and responsibilities.
maximum temperature rise.
Denes which documents belong to a low-voltage switchgear
assembly and which verications need to be maintained. Makes
statements regarding the rating of the assembly so that a design
verication can be maintained.

The guide can be downloaded from:

w
www.hensel-electric.de/61439

Step 1
Collecting all the project data

Step 2
Assembly design and design verification

Step 3
Assembly / manufacture of the distribution board

Step 4
Manufacturer's marking

Step 5
Declaration of CE conformity (check lists)

HENSEL, as the system manufacturer, supports panel builders with this guide
to design and assemble safe low-voltage switchgear assemblies according to
IEC 61439 / EN 61439.

4
Basics of IEC 61439 / EN 61439

Legal Basis of LVD 2014/35 EU

In the European Union, the Compliance with this legal basis is conrmed by the declaration
Low Voltage Directive of conformity by the manufacturer of a switchgear assembly.
LVD2014/35EU forms the legal Reference to EN 61439 implies that the basic requirements of
EU only basis for all electrical equipment the law have been met. If the legal requirements are not met, the
between 50 and 1000 V a.c., or purchaser has no liability protection!
75 and 1500 V d.c.
If harmonized standards are not applied, the manufacturer of the
This directive pursues the pro- switchgear assembly has a duty to establish compliance with the
tection objective that electrical above protection objectives by appropriate means.
equipment must not jeopardize
the safety of persons, livestock,
and the preservation of property,
and refers to the harmonized
standards, which are published
in the Ofcial Journal of the EU.

Structure of IEC 61439 / EN 61439

IEC/TR 61439-0
Planning guide for low-voltage switchgear assemblies

IEC 61439-1 / EN 61439-1


General requirements for low-voltage switchgear assemblies

IEC 61439-2 / EN 61439-2 IEC 61439-3 / EN 61439-3 IEC 61439-4 / EN 61439-4


Power switchgear and Distribution boards intended to Construction
Constr
Construct
uction
ion si
site
te dis
distri
distributors
tribut
butors
ors
controlgear assembly (PSC) be operated by ordinary persons
(DBO)

IEC 61439-5 / EN 61439-5 IEC 61439-6 / EN 61439-6 IEC/TS 61439-7


Cable
Cable Dis
Distri
Distribution
tribut
bution
ion Ca
Cabin
Cabinets
binets
ets Busbar
Busbar di
distr
distributors
stribu
ibutor
tors
s Distribut
Distributor
Distributor
or for ca
campi
camping,
mping,
ng, ma
marke
market
rkett
places, marinas and charging
stations for electric vehicles

IEC 61439-1 / EN 61439-1


is a general part which must New terminology of product responsibility:
be read in conjunction with Original manufacturer (system manufacturer) and manufacturer
the product section of switchgear assembly (panel builder) with new regulation for
IEC 61439-2 to -7 / product responsibility.
EN61439 -2 to -7.
Does not include product- More safety through the denition of requirements
specic requirements. for switchgear assemblies that affect the construction of the
Describes operating conditions, system, e.g. rated short-time withstand current, current carrying
assembly requirements, capacity, resistance to temperature rise.
technical properties and
requirements, as well as More safety by determining the rating data
verication options for low- that are essential for the function of a switchgear assembly
voltage switchgear assemblies under operating conditions. For this purpose, the switchgear is
and lists the terms used. considered as a BLACK BOX.
5
Basics of IEC 61439 / EN 61439

Manufacturer's product responsibility

The manufacturer is primarily responsible for compliance with the law and the safety of a distribution board! He must provide evidence that
the distributor was free of design, manufacturing and instruction errors when brought on the market.

Thereby he must prove the safety of the system according to the appropriate documents (risk analysis and assessment).
These documents must be retained. He must create a declaration of conformity and affix the CE marking visibly.
EU only

Who is the manufacturer of a switchgear assembly?

The new standard clearly regulates the responsibility for a distribution board placed on the market. It distinguishes between the original
manufacturer (system manufacturer) and the manufacturer of the switchgear assembly (panel builder).

Panel builder

Panel builder

Panel builder
System manufacturer, e.g. HENSEL

Original manufacturer (system manufacturer) Manufacturer of the switchgear assembly


(Panel Builder)

Responsible for: Responsible for:


the distribution board system the rating of the switchgear assembly according to the
the verification of the design by testing, calculation customer/operator requirements
or construction rules the compliance with the design verification of the original
the documentation of this design verification, manufacturer
e.g. test documentation, derivations, calculations the declaration of conformity to the customer
thecreation of tools to design and appropriate instructions for (Declaration of Conformity)
assembling and testing EU only
the marking and documentation of the assembly
the performance of the design verification and documentation

The original manufacturer (system manufacturer) already Panel builders who have no distribution board system of their
provides the respective verications for its distribution board own and assemble veried systems into ready-to-connect
system. switchgear assemblies thus decide for themselves about their
own verication efforts, as they can use the documents of the
original system manufacturer.

6
PORTAL|61439
All about design and assembly
according to IEC 61439 / EN 61439

With this portal, HENSEL supports you to implement the require-


ments of IEC 61439 / EN 61439 from the first step - collecting
all project data - via the design of standard-complying HENSEL
distribution board systems, up to the provision of the necessary
design verification and routine test verification.

Here you will find:


Checklists and forms
Configurator ENYGUIDE design software
ONLINE calculation tool
for the verification of the permissible temperature rise
Instructions for determining design values (InA, Inc, ICW)
Technical data

ALL ABOUT
IEC 61439 /
EN 61439!

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7
7
Step 1: Collecting all the project data

The user species the operational requirements and conditions for a The correct rating of the key interfaces in the switchgear assembly
low-voltage switchgear assembly. is crucial for its function under operating conditions. For this
Where special operating conditions exist that are not covered by the purpose, the switchgear assembly is considered a BLACK-BOX
standard, in addition also the applicable special requirements have with four interfaces for which the manufacturer of the switchgear
to be met or special agreements between the manufacturer of the assembly must dene the correct design values when designing the
switchgear assembly and the user must be made. The user must assembly.
inform the manufacturer if such extraordinary conditions exist. The design of the switchgear assembly is dependent on the
conditions and data such as:
1.1 Installation and ambient conditions
1.2 Operation and maintenance
1.3 Connection to the public power supply system
1.4 Electrical circuits and consumers

Interface characteristics of assemblies

Switchgear assembly as BLACK BOX with the 4 interfaces according to IEC 61439 / EN 61439
1.1 1.2 Operation and maintenance
Conditions at place of - (Device) operation by ordinary
installation/environment persons (DBO) - unskilled persons
- Installation site - Access and operation only by
- Special requirements for skilled persons (electricians)
use in commercial and
industrial applications

BLACK BOX

ENYSTAR Mi Distributor
Combinable enclosure Combinable enclosure
system, insulation- system, insulation-
enclosed, totally enclosed, totally
insulated, IP 66, insulated, IP 65,
for the assembly of for the assembly of
distribution boards power switchgear and
up to 250 A intended to controlgear assemblies
be operated by ordinary (PSC) to 630 A
persons (DBO) according in accordance with
to IEC/EN61439-3 IEC/EN61439-2

1.3 1.4
Connection to the public Electrical circuits and consumers
power supply system
- Rating of outgoing circuits
- Rated voltage of the feed - Determination of the thermal
- Nominal values transformer power dissipation
- Rated short-time withstand
- Determination of the rated diversity
current
factor (RDF)

8
Step 1: Collecting all the project data

HENSEL checklist to design switchgear assemblies according to IEC 61439 / EN 61439

This editable checklist supports you in step 1 when collecting all The checklist to design switchgear assemblies according to
data for the design of a distribution board on site. IEC 61439 / EN 61439 can be quickly and easily downloaded.
It reects the determination of the correct design values for the four
interfaces of the assembly.

w
www.hensel-electric.de/61439

Checklist to design switchgear assemblies


in accordance with IEC 61439 / EN 61439
Request/Offer Hensel expert: ___________________________ Date: _______________

Client: Project:
Name:
Address:

Phone:

E-Mail:

1. Installation and ambient conditions


1.1 Installation and Type of business: ___________________________ Indoor/ambient temperature (C): _______________
ambient conditions Installation
- indoors: in the locked electrical operation room in production area
Page 10
- outdoors: protected outdoors unprotected outdoors
Available wall surface in mm: Width: __________ Height: __________ Depth: __________
Assembly type: wall-mounted oor-standing
Degree of protection: IP 44 IP 54 IP 55 IP 65 IP _______________

2. Operation by skilled persons (electricians) by unskilled persons


1.2 Operation and maintenance
Doors/lids: opaque/without inspection pane transparent/with inspection pane _______________
Page 11
3. Connection to the public power supply system
1.3 Connection to the public Main distribution board: Outgoing device: ______________________
power supply system Transformer: Rated power (kVA): _____________________ Impedance uk (%): 4 6
Page 12 Rated voltage _______________ V a.c. V d.c. _____ Hz __________ Rated current (A): _______
Conductor designation: L1, L2, L3 N PE PEN
Protection class: I II
Incoming device: __________________________

Connection incoming:
from top from bottom from left from right _______________
copper aluminum
with cable lug with terminal
conductor single conductor cross section (mm): _______________

4. Electrical circuits and consumers


1.4 Electrical circuits and Connection outgoing:
consumers from top from bottom from left from right _______________
connected to device via terminal blocks cross section (mm): _______________
Page 13
Equipped with:

Rated values of the


Quan- Type of protective device
consumer Comments
tity (fuse, circuit breaker, ...)
(current, power, ...)
Consumer

Consumer

Consumer

Consumer

Consumer

Gustav Hensel GmbH & Co. KG Industrial Electrical Power Distribution Systems D 57368 Lennestadt Germany www.hensel-electric.de/61439

9
Step 1: Collecting all the project data

1.1 Installation / ambient conditions

The checklist queries these installation and ambient conditions on


site, which need to be provided by the planner. The manufacturer
considers this information and assembles the distribution
board according to these requirements. The measures and
recommendations given must be considered for the safe operation
of the distribution board.

1. Installation / ambient conditions


Type of business: ___________________________ Indoor / ambient temperature (C): _______________
Installation
Indoor: in locked electrical operating room in production area
Outdoors: protected outdoors unprotected outdoors
Available wall surface in mm: Width: __________ Height: __________ Depth: __________
Assembly type: wall-mounted oor-standing
Degree of protection: IP 44 IP 54 IP 55 IP 65 IP _______________

Type of business Take into account special requirements for use in commercial and industrial applications, such as strong
mechanical and chemical stress on assembly material.
Room / ambient Temperature range: -5C to +35 C, max. +40C
temperature(C) according Humidity: 50% at 40C, 100% at 25C
toIEC 61439 / EN 61439 Measures: Specify power dissipation of the assembly for the rating of the ventilation / room size.
Higher ambient temperatures must be considered in planning.
Installation indoors In locked electrical operating room: Only accessible by skilled persons (electricians)
During operation: Accessibility by unskilled persons
IP degree of protection
Protection against foreign bodies: dust-proof IP 6X
Water protection: waterproof IP X6 / IP X5 (deected water without high pressure)
Installation outdoors Direct sunlight
- Protected outdoors The material has been tested for UV resistance.
- Unprotected outdoors UV-resistant according to IEC 61439-1 / EN 61439-1 paragraph 10.2.4.
If necessary, protect with additional measures against direct sunlight, for example with canopy
Temperature and humidity
Higher ambient temperatures, possibly due to direct sunlight have to be considered in the planning
stage.
IP degree of protection for protected or unprotected outdoor installation
Where appropriate, consider measures against occasional condensation forming as a result of
temperature variations, such as venting, heating, air-conditioning (also with unprotected installation).
Type of installation Specify the system type for wall-mounting or oor-standing installation
Available sizes Consider installation conditions on site and specify restrictions as needed.

For details, see HENSEL main catalogue or www.hensel-electric.de.

10
Step 1: Collecting all the project data

1.2 Operation and maintenance

The checklist queries the necessary requirements for the switchgear


assembly for the operation, maintenance and expansion, taking
into account the qualications of persons who require access to the
respective areas or must operate equipment.

2. Operation by skilled persons (electricians) by unskilled person

Doors/lids: opaque/without inspection pane transparent/with inspection pane _______________

Operation by Electrician (skilled person) IP XXB


Devices which must be operated by a qualied electrician only,
shall be installed behind separate doors or lids which can be
opened with a tool only.
Tool-operated areas for feeding-in, back-up fuse and outgoing
terminals.
Here, merely a qualied electrician must have access!
Electrically trained person IP XXB, see qualied electrician

Electro-technical unskilled IP XXC: Protection against direct contact with hazardous live parts
person For ENYSTAR distribution boards, IEC 61439-3 / EN 61439-3
Selection of equipment for requires special protective measures for areas to which unskilled
unskilled persons! persons have access:
Only installation devices such as - Live parts should be covered with a protection cover.
series built-in equipment, fuses - Devices which may be operated by a qualied electrician only,
up to 63A, circuit-breakers and shall be installed behind separate lids or doors, which can be
IT components permitted. opened only with a tool.
Hand-operation for the access areas of unskilled persons or use of
hinged lids allowing easy control of equipment.
Devices operated Behind the door / lid Protection measures must be observed
Doors / covers Lock available for retrotting
Conversion kits for door or lid fasteners from hand to tool operation
available

For details, see HENSEL main catalogue or www.hensel-electric.de.

11
Step 1: Collecting all the project data

1.3 Connection to the public power supply system

The checklist describes the required features of the network


(nominal data). These must be compared with the design data of
the low-voltage switchgear assembly.
For the planning of a switchgear assembly, the necessary rated
values of the grid must be determined and specied.

3. Connection to the public power supply system


Main distribution board: Outgoing device: ______________________
Transformer: Rated power (kVA): _____________________ Impedance uk (%): 4 6
Rated voltage ________ V a.c. V d.c. ________ Hz _______________ Rated current (A): _______________
Conductor designation: L1, L2, L3 N PE PEN
Protection class: I II
Incoming device: ______________________

Connection incoming:
from top from bottom from left from right _______________
copper alumini
with cable lug with terminal
conductor single conductor cross section (mm): ____________

Rated voltage of the feed in VAC a.c., Hz


Grid system TN-C, TN-C-S, TN-S, TT, IT Protection class II, protection by protective insulation
Rated current Infeed current (rated current Determine InA, see step 2, design of a distribution board, page 22
transformer / upstream protective
device)
Short-circuit resistance Derive value from the size of the Example calculation see pages 20-21.
transformer or use the information Icp
from the local power supplier IK"
For detailed information about
- determination of the rated current (InA) Page 22
- determination of the rated short-time
withstand current (ICW) Page 20-21
Overvoltage Overvoltage category III, IV
Incoming cable connection Type of incoming cable
Type of cable
Type of connection

12
Step 1: Collecting all the project data

1.4 Electrical circuits and consumers

Outgoing circuits in a switchgear assembly can be distinguished


into distribution circuits (protective device and incoming cable to
downstream distribution) and nal circuits (protection device and
incoming cable and consumers).
For a correct rating of the circuits, all information regarding
the expected power demand and consumers must be known.
Therefore, the technical data of the device manufacturer with
information on derating, but also the rated current of a circuit and
the rated diversity factor RDF must be considered.

4. Electrical circuits and consumers


Connection outgoing:
from top from bottom from left from right _______________
connected to device via terminal block cross section (mm): _______________
Equipped with Quan- Type of protective device Rated values of the consumer Comments
tity (fuse, circuit breakers, ...) (current, power, ...)
Consumer
Consumer
Consumer
Consumer
Consumer

Incoming cable Type of incoming cable


connection Type of cable
Type of connection
Equipping
Type of protective device Fuse, miniature circuit breaker, For detailed information about
circuit breaker - Rating of an outgoing circuit (InC) Page 23
Rating data of the Current - Determination of the operating current (IB) Page 24
consumer Power - Calculation of the power dissipation (PV) Page 25
Type (ohmic, inductive or capacitive - Creating the design verication of the
load) cos permissible temperature rise according to
IEC 61439-1 / EN 61439-1 Section 10.10. Page 26

13
Step 2: Design of an assembly and design verification

Example: Checklist to design switchgear assemblies according to IEC 61439 / EN 61439

Collecting the data on-site


with the completed checklist
Checklist to design switchgear assemblies
forms the basis to design a in accordance with IEC 61439 / EN 61439
distribution board. Hoffmann 05.03.2015
Request/Offer Hensel expert: ___________________________ Date: _______________

Client: Project:
Name: Metal working shop Brands Extension to the production facility
Address: Musterstrae 10 Section II
50000 Musterstadt
Phone:

E-Mail: info@ brands-metalworkingshop.de

1. Installation and ambient conditions


Metal working shop Indoor/ambient temperature (C): _______________
Type of business: ___________________________ 25
Installation
- indoors: in the locked electrical operation room X in production area

- outdoors: protected outdoors unprotected outdoors
Available wall surface in mm: 1500
Width: __________ 1400
Height: __________ 500
Depth: __________
Assembly type: X wall-mounted oor-standing

X IP 55
Degree of protection: IP 44 IP 54 IP 65 IP _______________

2. Operation by skilled persons (electricians) X


by unskilled persons

Doors/lids: X opaque/without inspection pane X


transparent/with inspection pane _______________

3. Connection to the public power supply system


Main distribution board: Outgoing device: ______________________
Transformer: Rated power (kVA): _____________________ Impedance uk (%): 4 6
Rated voltage 230/400
_______________ 50 Hz
X V a.c. V d.c. _____ __________ 400
Rated current (A): _______
X
Conductor designation: L1, L2, L3 X
N X
PE PEN
Protection class: I X
II
Incoming device: Circuit
__ breaker
________________________

Connection incoming:
from top X from bottom
from left from right _______________
X copper
aluminum
with cable lug X with terminal

conductor single conductor 4x150/70
cross section (mm): _______________

4. Electrical circuits and consumers


Connection outgoing:
from top X from bottom
from left from right _______________
X connected to device via terminal blocks
cross section (mm): _______________

Equipped with:

Rated values of the


Quan- Type of protective device
consumer Comments
tity (fuse, circuit breaker, ...)
(current, power, ...)
Consumer 1 MCCB 200 A Machine I
Consumer 1 MCCB 128 A Machine II
Consumer 1 MCCB 128 A Internal fuse
Consumer 1 RCBO 63 A Internal protection for MCBs
Consumer 14 MCB 12 A Light and socket outlets

Gustav Hensel GmbH & Co. KG Industrial Electrical Power Distribution Systems D 57368 Lennestadt Germany www.hensel-electric.de/61439

D
Download editable checklist:
www.hensel-electric.de/61439
w

14
Example: Project design using the data from the checklist

The design is realized on basis of documents, catalogues, and By complying with the information from catalogues, technical
technical data provided by HENSEL, as the original manufacturer manuals and installation instructions, the effort required by the panel
(system manufacturer). builder for providing the design verication is minimized.

1
A circuit diagram results from
-Q1
400A
L1-L3,N,PE - 400/230V 400A

I>
3

-Q2
250A I>
3

-Q3
160A I>
3

-Q4
100A I>
3

2
Selection of
products for
the electrical
functions.
the determined data from the
checklist, which denes the -F5
63/0,03A
4 -F6
B16A
1 -F7
B16A
1

electrical functions.
A1
Controller
-F5.1 1 -F5.12 1 -K6 t -K7 heating
B16A B16A A2
L1-L3,N,PE

L1-L3,N,PE

L1-L3,N,PE

L,N,PE

L,N,PE

L,N,PE

L,N,PE
12x

3
Mi Distribution Board Mi Distribution Board
HRC fuse boxes with fuse switch disconnectors HRC fuse boxes with fuse switch disconnectors
with fuse switch disconnectors in accordance with IEC 60 947-3 with fuse switch disconnectors in accordance with IEC 60 947-3
nologien
n

enn
Mi 6266 Mi 6426

Technologie
ie
3 5
2 Wall 2 2 Wall 3
eue

Neue
2 x fuse switch disconnector 160 A, 3 2 x fuse switch disconnector 160 A, 5
Ne
echn

HRC 00, 3-pole HRC 00, 3-pole


ec
Te

Rated current of busbars 400 A Rated current of busbars 250 A


only for combination Terminals for incoming cables: 25-70 mm, Cu, round conductors 600 170
N
Terminals for outgoing cables: 4-35 mm, Cu, round conductors 300 170 Connection of wiring strip Mi VS 100/160/250/400
DK

DK
300
per PE and N terminal: 2 x 4-35 mm, Cu, round conductors Terminals for outgoing cables: 4-35 mm, Cu, round conductors
300

D
without supply cable per PE and N terminal: 2 x 4-35 mm, Cu, round conductors PE

N conductor with the same current carrying capacity as the phase N conductor with the same current carrying capacity as the phase

conductors conductors
Cable connections from the top, changeable to bottom connections Cable connections from the top, changeable to bottom connections

with cover with cover

Lid fasteners for tool operation Lid fasteners for tool operation

Rated voltage Un = 690 V a.c. Rated voltage Un = 690 V a.c.


Rated current of a circuit Inc = 128 A Rated current of a circuit Inc = 128 A
Number of circuits 2 Number of circuits 2
Rated short-time withstand ICW = 15 kA / 1 s Rated short-time withstand ICW = 15 kA / 1 s
current with fuse links utilisation current with fuse links utilisation
category gG/gL category gG/gL
Busbar system - polarity 5 Busbar system - polarity 5
Busbar thickness L1-L3, N: 10 mm Busbar thickness L1-L3: 10 mm
PE: 5 mm N, PE: 5 mm
Mi

Mi
Centreline spacing of busbars 60 mm Centreline spacing of busbars 60 mm
Tightening torque for terminal terminal 6.0 Nm Tightening torque for terminal terminal 6.0 Nm

Mi 6267 3 Mi 6427 5
2 Wall 2 2 Wall 3
2 x fuse switch disconnector 160 A, 3 2 x fuse switch disconnector 160 A, 5

HRC 00, 3-pole HRC 00, 3-pole


Rated current of busbars 630 A Rated current of busbars 400 A
only for combination Terminals for incoming cables: 25-70 mm, Cu, round conductors 600 170
N
Terminals for outgoing cables: 4-35 mm, Cu, round conductors 300 170 Connection of wiring strip Mi VS 100/160/250/400

300
Terminals for outgoing cables: 4-35 mm, Cu, round conductors
per PE and N terminal: 2 x 4-35 mm, Cu, round conductors
300

without supply cable per PE and N terminal: 2 x 4-35 mm, Cu, round conductors PE

N conductor with the same current carrying capacity as the phase


N conductor with the same current carrying capacity as the phase
conductors conductors
Cable connections from the top, changeable to bottom connections
Cable connections from the top, changeable to bottom connections
with cover
with cover
Lid fasteners for tool operation
Lid fasteners for tool operation

Rated voltage Un = 690 V a.c. Rated voltage Un = 690 V a.c.


Rated current of a circuit Inc = 128 A Rated current of a circuit Inc = 128 A
Number of circuits 2 Number of circuits 2
Rated short-time withstand ICW = 21 kA / 1 s Rated short-time withstand ICW = 15 kA / 1 s
current with fuse links utilisation current with fuse links utilisation
category gG/gL category gG/gL
Busbar system - polarity 5 Busbar system - polarity 5
Busbar thickness L1-L3, N, PE: 10 mm Busbar thickness L1-L3, N: 10 mm
PE: 5 mm
Centreline spacing of busbars 60 mm
Centreline spacing of busbars 60 mm
Tightening torque for terminal terminal 6.0 Nm
Tightening torque for terminal terminal 6.0 Nm

330 331

Selection of products for the electrical functions from manufacturers'


catalogues or with the planning tool ENYGUIDE.

4
At the end of the design,
a dimensional drawing and a
parts list must be created for the
distributor.

HENSEL provides
comprehensive planning tools
that simplify the planning.

15
Step 2: Design of an assembly and design verification

Plan quickly and easily with the HENSEL planning tools

Your planning is signicantly simplied by the use of the HENSEL planning tools.
The functions of the different planning tools are provided here in comparison.

Techical Data
Mounting Plate
Installation Device on
Techical Data Power Dissipation

Technologien
on Mounting Plate
Installation Devices Size of fuse Rated Power

Neue
Power Dissipation link current of dissipation
Installation devices of the instal-
Power installation
Size of Rated mounted in products lation device
dissipation device
fuse link current of per pole at

Technologien
Installation devices of the instal-
installation rated current
mounted in products

DK
lation device

Neue
device
per pole at
rated current 4,6 W
160 A
Fuse base on busbar NH 00
Mi 8030, Mi 8035, Mi 8040,
Mi 6461, Mi 8020, Mi 8025,
Mi 6212, Mi 6422, Mi 6432, Mi 8085, Mi 8090, Mi 8095 4,6 W
160 A 4,2 W Mi 8070, Mi 8075, Mi 8080, NH 00
160 A
Fuse base on mounting
plate NH 00 Mi 8045, Mi 8050, Mi 8055, 4,6 W
4,4 W Mi 6462 160 A
NH 1
250 A Mi 6213, Mi 6423, Mi 6433, NH 00
7,3 W
7,0 W Mi 6463 250 A
NH 2
400 A Mi 6214, Mi 6424, Mi 6436, NH 1
7,3 W
Mi Distribution Board Mi Distribution Board Mi 8333, Mi 8336 250 A
Mi 6474, Mi 8322, Mi 8326, NH 1
18,6 W
HRC fuse boxes with fuse switch disconnectors HRC fuse boxes with fuse switch disconnectors NH 2
400 A
mounting plate 125 A 1,7 W Mi 6475
with fuse switch disconnectors in accordance or on 18,6 W
Fuse switchwith IEC 60
disconnect 947-3 NH 00C with fuse switch disconnectors
W 4,7
in accordance with IEC 60 947-3 NH 2
400 A
250 A Mi 6476
NH 1
160 A 2,6 W Mi 6477
Technologien

o ien
NH 00 4,6 W
Mi 6266 3 Mi 6426250 A 4,7 W ne
conn orr o
o
to
ctor
cto
c
ec onn bus ar
ar
sba
bar
b
busbar 5 125 A

Technologi
2 Wall 2
sc
sconne
Fuse switch disconnect 2 Wall 3
NH 00C
NH 1
Neue

Neue
Mi 5... 160 A 5,9 W
2 x fuse switch disconnector 160 A, 2 x fuse switch disconnector
7,3 W 160 A,

u
3
FP 3226, FP 34266 5 NH 00

Mi
Mi 5... NH 2 Mi 6642, Mi 8 24, Mi 8125,
M 8124,
HRC 00, 3-pole HRC 00, 3-pole Mi 6436, Mi 6465, Mi 6632,
NH 3 Mi 6226, Mi 6265, Mi 6426, 5,9 W
Rated current of busbars 400 A Mi 5... Rated current of busbars 250 A Mi 8835 160 A

T
Mi 8824, Mi 8825, Mi 8834, Mi 6644
NH 00
5,9 W
only for combination Mi 5... Terminals for incoming cables: 25-70 mm, Cu, round conductors Mi 6437, Mi6006466, Mi 6634,
170 160 A
Mi 6227, Mi 6266, Mi 6427, NH 00
Mi 6467, Mi 6636, Mi 6646 8,6 W
N
Terminals for outgoing cables: 4-35 mm, Cu, round conductorsdisconnector 300 170 Connection of wiring strip Mi VS 100/160/250/400 250 A
Switch - Mi 6267, Mi 6428, Mi 6438, NH 1

300
per PE and N terminal: 2 x 4-35 mm, Cu, round conductors Mi 6228,
Terminals for outgoing cables: 4-35 mm, Cu, round conductors
Mi

300
5101, FP 5103 15,0 W
without supply cable Mi 7103, Mi 7104, FP - per PE and N terminal: 2 x 4-35 mm, Cu, round Mi
conductors
6478, Mi 6479 PE NH 2
400 A
5104
N conductor with the same current carrying capacity asMi
the Mi 7214, FP 5102, FP
phase
7213, - N conductor with the same current carrying capacity as the phase
conductors Mi 6476, Mi 6477
conductors
FP 5201, FP 5202 -
Cable connections fromMi Distribution Boards
the top, changeable to bottom connections 25 A MiWDistribution
0,4 Boards
Cable connections from the top, changeable to bottom connections busbar
Mi 7256, Mi 7257, Mi 7456,
Mi 7457 - with cover Screw-type fuses on 7
427
3427
Mi 3423, Mi 34
DII
0,4 W
with cover Technical Details Mi 3426, Mi 3226, Mi 3221, 25 A Technical Details
Lid fasteners for tool operation - Lid fasteners for tool operation Mi 3225, Mi 3220, Mi 3425, DII
FP 5211, FP 5213 Power Dissipation of Empty Boxes Mi 3428 63 A W
Power
3,3 Dissipation of Empty Boxes
Mi 7454, FP 5312 - Mi 3227, Mi 3222, Mi 3424, DIII
3,3 W
Rated voltage Un = 690 V a.c.Mi 7455, Rated voltage Un = 690 V a.c. Mi 3264, Mi 3261, Mi 3464 63 A
- Temperature 3263, Mi 3260, Mi 3463,
Mi A DIII
Inc = 128 A Mi 7445, Mi 7846 Rated current
rise of a circuit
( ) with Mi-Distribution boards Inc = 128 2,0 W

(450 x 600 x 170 mm)


Rated current of a circuit Temperature rise63(-)
A with Mi-Distribution boards
3262, Mi 3465 D02
Number of circuits 2 Mi 7665, Mi 7865, Mi 7866
by powerNumber
dissipation of electrical devices
of circuits 2 Mi 3265, Mi by power dissipation of electrical
2,0 Wdevices
63 A
Rated short-time withstand ICW = 15 kA / 1 s Rated short-time withstand ICW = 15 kA / 1 s D02

Mi 0600 / Mi 0601 (450 x 600 x 170 mm)


2,0 W
current Changeover switch
with fuse links utilisation current with fuse links utilisation D02
63 A
category gG/gLMi 7481 category gG/gL
Busbar system - polarity 5 Busbar system - polarity 5 3,5 W
Mi 7882 63 A
External enclosures
Busbar thickness L1-L3, N: 10 mm Busbar thickness L1-L3: 10 mm D02
PE: 5 mm Circuit-breaker N, PE: 5 mm
Mi

Mi
Centreline spacing of busbars 60 mm Mi 7431 Centreline spacing of busbars 60 mm Power
Size Rated
Tightening torque for terminal terminal 6.0 Nm FP 5216 Tightening torque for terminal terminal 6.0 Nm dissipation
current of
Mi 7432 busbars of busbars at
Mi 6427 rated current
Mi 6267 5
FP 5325 3
2
5
3
2 Wall 2
2 x fuse switch disconnector 160 A, 4
Mi 7434 3 2 x fuse switch disconnector 160 A, 5

HRC 00, 3-pole Mi 7836 HRC 00, 3-pole 42,7 W/m


250 A
Rated current of busbars 630 A Rated current of busbars 400 A 63,8 W/m
400 A
only for combination Terminals for incoming cables: 25-70 mm, Cu, round conductors 600 170
102,3 W/m
Connection of wiring strip Mi VS 100/160/250/400 N 630 A
Terminals for outgoing cables: 4-35 mm, Cu, round conductors 300 170

300
Terminals for outgoing cables: 4-35 mm, Cu, round conductors
per PE and N terminal: 2 x 4-35 mm, Cu, round conductors
300

without supply cable per PE and N terminal: 2 x 4-35 mm, Cu, round conductors PE

N conductor with the same current carrying capacity as the phase


N conductor with the same current carrying capacity as the phase
conductors conductors
Cable connections from the top, changeable to bottom connections
Cable connections from the top, changeable to bottom connections
with cover
Tightening torque for terminal terminal 6.0 Nm
with cover
Lid fasteners for tool operation
Lid fasteners for tool operation
701
Rated voltage Un = 690 V a.c. Rated voltage Un = 690 V a.c.
Rated current of a circuit Inc = 128 A Rated current of a circuit Inc = 128 A Mi 6427
Number of circuits 2 Number of circuits 2
Rated short-time withstand ICW = 21 kA / 1 s Rated short-time withstand ICW = 15 kA / 1 s 2 x fuse switch disconnector 160 A,
Mi

Mi
current 700
with fuse links utilisation current with fuse links utilisation
category gG/gL category gG/gL HRC 00, 3-pole
Busbar system - polarity 5 Note!
Busbar system - polarity
Busbar thickness
5
L1-L3, N, PE: 10 mm Busbar thickness L1-L3, N: 10 mm Rated current of busbars 400 A The maximally permissible operating temperature inside the enclosures (Jimax) is determined by:
PE: 5 mm 1st Maximally permissible ambient temperature of the installed electrical devices (please consider data of the equipment manufacturers)
Centreline spacing of busbars 60 mm Terminals for incoming cables: 25-70 mm, Cu, round
Centreline spacing of busbars 60 mm conductors
Tightening torque for terminal terminal 6.0 Nm 2nd Category temperature of the internal wiring and the inserted cables
Central enclosures
Tightening torque for terminal terminal 6.0 Nm Connection of wiring strip Mi VS 100/160/250/400
3rd Temperatur resistance of the enclosure materials and the cable entries etc.
Terminals for outgoing cables: 4-35 mm, Cu, round conductors
LES

LES
Example: Computation of the maximum rated power dissipation (P )
per PE and N terminal: 2 x 4-35 mm, Cu, round conductors V

Maximally permissible operating temperature inside the enclosure(s) (- ): e.g. 55 C


N conductor with the same current carrying capacity as the phase imax

Ambient temperature of the enclosure(s) (- ): U


25 C
conductors Maximally permissible heating up inside the enclosure: - = -Lmax - -U = 55 C - 25 C = 30 K
Cable connections from the top, changeable to bottom connections
Maximum permissible power dissipation of the installed equipment inclusive wiring
Enclosure size 3 (540 x 270 x 163 mm)
(P ) in accordance with diagram:
with cover V
T chnical Data

Technical Data
Single enclosure: PV = 53 W
Lid fasteners for tool operation
Central enclosure: PV = 45 W
330 331
Extermal enclosure: PV = 48 W
Un = 690 V a.c.
Tec

5Inc Inncc = 122Example:


128 8 A Computation of tthe operating temperature inside the enclosure (- )
Ambient temperature of the enclosure(s)
nc
2Rated power dissipation of the
(- ): U
25 C
i

Number of he installed electrical equipment (P ): 30 W


5circuits ICW = 15 Heating
kkAA/1 up s
inside the enclosures
ur in accordance with diagram over:
V

-
Enclosure size 3 (540 x 270 x 163 mm) single enclosure: '- = 17 K; - = - + - = 25 C + 17 K = 42 C
with fusse linkss utilis
fuse sation
utilisation n
Types

Types
From now on, all values are taken into account in the products 5 ICW
i U

Enclosure size 3 (540 x 270


0 x 163 mm) central enclosure: '- = 20 K; - = - + - = 25 C + 20 K = 45 C
cate
category
egoryEnclosure
g
gG/gL
G/g gsize
L 3 (540 x 270 70 x 163 mm) external enclosure: '- = 19 K; - = -
i U

+ - = 25 C + 19 K = 44 C
i U

336 Busbar system - polarity 5 337


Busbar thickness L1-L3, N: 10 mm

needed by the electrician for the rating of a switchgear assembly Centreline spacing of busbars
PE: 5 mm
60 mm
Tightening torque for terminal terminal 6.0 Nm

according to IEC 61439 / EN 61439:


Rated current of a circuit,
Number of circuits and
Rated short-time withstand current.

Planning tool Congurator ENYGUIDE Dimensional drawings and parts lists are automatically created
HENSEL supports you with the free planning software ENYGUIDE. by ENYGUIDE.
Representation of the distribution board as a detailed 3D-image
Allows the quick and easy conguration of distribution boards.
or a 2D-drawing.
Various view planes show the equipment, covers and doors.

ENYGUIDE determines the necessary accessories such as the

number of wall separators independently.


o ine or online via internet
of No time-consuming program installation is needed.
www.enyguide.de
w

16
HENSEL website te with the package of
services for electricians:
ctricians:
Everything for planning
anning according to
IEC 61439 / EN 61439 ONLINE for download!

HENSEL
WEBSITE

www.hensel-electric.de

ONLINE calculation tool from HENSEL


for the design verication of the permissible temperature rise

Design verication of permissible temperature


rise according to IEC 61439-1 / EN 61439-1
The tool automatically calculates the power dissi-
pation and installed power dissipation, and where
appropriate, the RDF.
O
Online via Internet
www.hensel-electric.de/61439
w

Main HENSEL Calculation tool


HENSEL planning tools at a glance Catalogue website
ENYGUIDE
power dissipation
Product information + product image
Detailed technical data on products
Dimensional drawing for products
Reference to appropriate accessories, such as mounting flanges
Reference to appropriate rail-mounted devices, such as residual
current protection device and terminal blocks
Information regarding the option to combine with other enclosures

Creating dimensional drawings (with dimensions)

Automatic creation of project documentation


Automatic creation of parts and order lists (PDF, Excel or ASCII
format)
Automatic completion of compellingly required accessories
(e.g. wall sealings)
Product depiction in DXF format (after export or download)
Product presentation in 3D format
Power dissipatoin calculation according to IEC 61439 / EN 61439

17
Step 2: Design of an assembly and design verification

Verications supplied by the system manufacturer

Before design starts:


Does the selected distribution system meet the requirements on site?
HENSEL - as product provider and responsible party for the distribution system - has already provided a wealth of verications supporting
its distribution systems. These relate to the construction and behaviour of the switchgear assembly during operation and must include the
following criteria.

These tests have already been performed by HENSEL.


Verications which were already provided by HENSEL VERIFICATION
Standards section
(system manufacturer) provided by HENSEL
Strength of materials and parts 10.2
- Resistance to corrosion 10.2.2
Properties of insulating materials 10.2.3
- Thermal stability of enclosures 10.2.3.1
- Resistance of insulating materials to abnormal heat and re due to 10.2.3.2
internal electric effects
- Resistance to ultra-violet (UV) radiation 10.2.4
- Lifting 10.2.5
- Mechanical impact 10.2.6
- Marking 10.2.7

Degree of protection of assemblies 10.3

HENSEL confirms the properties of its


distribution board system according to
EN 61439 with a declaration of conformity.
EU only

The compliance to the Low voltage directive LVD2014/35EU Technische Information


Konformittserklrung
Technische Information
Konformittserklrung
ENYSTAR Mi-Verteiler

as the legal basis has to be conrmed by a declaration of Erklrung Erklrung


der EG-Konformitt Nr./No. K 2010b
der EG-Konformitt Nr./No. ENY 2009b
Declaration of EC-Conformity Declaration of EC-Conformity

conformity. Das Produkt,


The product
Das Produkt,
The product
Typ / Type: Mi-Verteiler
Typ / Type: ENYSTAR
Mi-Distributor
Typ / type: FP ....
Typ / type: Mi ....

HENSEL (system manufacturer) conrms the carried out tests with Hersteller:
Manufacturer.
Gustav Hensel GmbH & Co. KG
Gustav-Hensel-Strae 6
57368 Lennestadt
Hersteller:
Manufacturer
Gustav Hensel GmbH & Co. KG
Gustav-Hensel-Strae 6
57368 Lennestadt

Beschreibung: Installationsverteiler bis 250 A DBO Beschreibung: Niederspannungs-Schaltgertekombination PSC

a declaration of conformity. This proves that the distribution system Description: Distribution boards up to 250 A DBO Description: Low-voltage switchgear and controlgear assemblies PSC

auf das sich diese Erklrung bezieht, stimmt mit folgenden Normen oder normativen Dokumenten berein:
auf das sich diese Erklrung bezieht, stimmt mit folgenden Normen oder normativen Dokumenten berein: to which this declaration relates is in conformity with the following standard(s) or normative document(s):

has the properties listed and complies with the requirements of the to which this declaration relates is in conformity with the following standard(s) or normative document(s):

Norm / Standard: DIN EN 61439-3


Norm / Standard: DIN EN 61439-2
IEC 61439-2
EN 61439-2
IEC 61439-3
EN 61439-3

applicable standard EN 61439. und entspricht den Bestimmungen der folgenden EG-Richtlinie(n):
und entspricht den Bestimmungen der folgenden EG-Richtlinie(n):
and is in accordance with the provisions of the following EC-directive(s)

and is in accordance with the provisions of the following EC-directive(s)


Niederspannungs-Richtlinie 2006/95/EG
Low voltage directive 2006/95/EC
Niederspannungs-Richtlinie 2006/95/EG

If the panel builder uses resources that have already been tested Low voltage directive 2006/95/EC

Diese Konformittserklrung entspricht der Europischen Norm EN 17050-1 Allgemeine Anforderungen fr Konformittserklrungen von
EMV-Richtlinie (EMC) 2004/108/EG
Electromagnetic Compatibility (EMC) Directive 2004/108/EC

Anbietern. Das Unternehmen Gustav Hensel GmbH & Co. KG ist Mitglied von ALPHA im VDE. Diese Erklrung gilt weltweit als Erklrung Diese Konformittserklrung entspricht der Europischen Norm EN 17050-1 Allgemeine Anforderungen fr Konformittserklrungen von

by the system manufacturer through design verication, there is no


des Herstellers zur bereinstimmung mit den oben genannten internationalen und nationalen Normen. Anbietern. Das Unternehmen Gustav Hensel GmbH & Co. KG ist Mitglied von ALPHA im VDE. Diese Erklrung gilt weltweit als Erklrung
des Herstellers zur bereinstimmung mit den oben genannten internationalen und nationalen Normen.
This Declaration of Conformity is suitable to the European Standard EN 17050-1 General requirements for suppliers declaration of confor-
mity. The company Gustav Hensel GmbH & Co. KG is member of ALPHA at VDE. The declaration is world-wide valid as the manufacturers This Declaration of Conformity is suitable to the European Standard EN 17050-1 General requirements for suppliers declaration of confor-
declaration of compliance with the requirements of the a.m. national and international standards. mity. The company Gustav Hensel GmbH & Co. KG is member of ALPHA at VDE. The declaration is world-wide valid as the manufacturers
declaration of compliance with the requirements of the a.m. national and international standards.

obligation to test for himself. Jahr der Anbringung der


CE-Kennzeichnung:
Year of affixing CE-Marking
2013
Jahr der Anbringung der
CE-Kennzeichnung: 2012
Year of affixing CE-Marking.

Ausstellungsdatum: 31.03.2015
Ausstellungsdatum: 31.03.2015

The panel builder must enclose the declaration of conformity of the Date of issue:

Gustav Hensel GmbH & Co. KG


Date of issue:

Gustav Hensel GmbH & Co. KG

system manufacturer with the documentation of the self-assembled O. Gutzeit O. Gutzeit


- Technische Geschftsleitung - - Technische Geschftsleitung -

distribution board. - Technical Managing Director - - Technical Managing Director -

For everything about the documentation of an assembly see step 5.


H
HENSEL declarations of conformity for download:
www.hensel-electric.de/61439
w
18
Verications to be created by the panel builder

During design process and after assembly:


Provide verification of the self-assembled distribution board.
If the panel builder complies with the information from the The panel builder as manufacturer of an assembly must also test
catalogues, technical manuals and assembly guides when the work which was performed by himself and document the safety
assembling a distribution board, the efforts for providing design of the assembly according to IEC 61439 / EN 61439 with a routine
verication are minimized. test report (Sheet 1), for tests see pages 30-31.

The panel builder checks his own work ...


Verications Panel builder must provide
Standards section
which the PANEL BUILDER is required to perform himself VERIFICATION
Clearances and creepage distances 10.4 by routine testing
Protection against electric shock and integrity of protective cirduits 10.5
- Effective earth continuity between the exposed conductive parts by routine testing
of the assembly and the protective circuit 10.5.2
IIncorporation of switching devices and components 10.6 by routine testing
Internal electrical circuits and connections 10.7 by routine testing
Terminals for external conductors 10.8 by routine testing
Dielectric properties 10.9
- Power-frequency withstand voltage 10.9.2 by routine testing
- Impulse withstand voltage 10.9.3
Verication of temperature rise 10.10 by calculating
during design process
Short-circuit withstand strength 10.11 by calculating
during design process
Electromagnetic compatibility (EMC) 10.12 by calculating
during design process
Mechanical operation 10.13 by routine testing

... and documents the safety of his assembly according to


IEC 61439 / EN 61439 with a routine test report.
The panel builder must enclose the report for the routine verica- Routine Test Report Sheet 1

tion (routine test report) (Sheet 1) with the documentation of his Power switchgear and controlgear assembly (PSC),
Verication according to IEC 61439-2/EN 61439-2 X
Distribution boards intended to be operated by ordinary persons (DBO),
Verication according to IEC 61439-3/EN 61439-3

self-assembled distribution board. Metalworking shop Blechner


Customer: ................................................................................. Order number: .............................................................

27 01 045
Project: ..................................................................................... Workshop: ...................................................................

Testing performed:

Type of
IEC 61439
No. test- Content of routine test Result of routine test Test engineer
Section
ing*

For everything about routine verication / inspection see step 3. 1

2
S

S/P
Degree of protection of cabinets /enclosures
(sealings, protection covers)

Creepage and clearance distances


11.2

11.3
O.K.

O.K.
Protection against electric shock and
3 S/P
integrity of protective circuits
11.4 O.K.

4 S Incorporation of built-in components 11.5 O.K.


5 S/P Internal electrical circuits and connections 11.6 O.K.
6 S Terminals for external conductors 11.7 O.K.

The assembly of the distributor is controlled and veried by routine 7 P


Mechanical operation
(actuating elements, lockings)
11.8 O.K.

M
8 P Dielectric properties 11.9

testing. A power-frequency withstand test shall be performed on all circuits in


accordance with IEC 61439-1 Section 10.9.2 for a duration of 1 s. The
test voltage for power switchgear and controlgear assemblies with a rated
Test voltage values
insulation voltage between 300-690 V a.c. is 1,890 V. The test values for
different rated insulation voltages are given in Table 8 of IEC 61439-1. V a.c.

Alternatively, for switchgear assemblies with a protective device in the


power supply and a rated current up to 250 A applies:
Measurement of the insulation resistance with an insulation tester at a volt- Insulation resistance
age of at least 500 V d.c. The test is passed with an insulation resistance of
at least 1000 / V. /V

Wiring, operational
9 P 11.10
performance and function

S - Visual inspection
P - Testing with mechanical or electrical test equipment

Installer: ............................................................................. Test inspector: ........................................................

W. Hess
Date: ................................................................................. Date: .......................................................................

09.07.2013

Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439

R
Routine test report for download as editable checklist:
www.hensel-electric.de/61439
w
19
Step 2: Design of an assembly and design verification

Determining the rated short-time withstand current (Icw) of a circuit of an assembly

A switchgear assembly must be designed such that it Example:


withstands the thermal and dynamic stresses resulting from the
short-circuit current. The maximum short circuit current at the IK"
connection point of an assembly must be determined on site. Trans-
The panel builder must specify the rated short-time
withstand current Icw of the connection point in his
former UN = 400 VAC
documentation, e.g. in the circuit diagram or technical
document.
The original manufacturer of the switchgear system,
e.g. HENSEL, is responsible for the verication of the short
circuit withstand capacity of the system components, e.g. the Icw Step 1:
value of the busbars. Determining the transformer power and
Rated short-circuit withstand current is determined by the values determining the value IK"
IK", Icw, Icp, Icu. The IK" can be determined by reading table 1.

Transformer
Sr = 250 kVA see identier plate
UN = 400 VAC see identier plate
IN = 360A see table 1
IK" = 9.025kA see table 1

Alternatively, the IK is calculated using the formula:


IK in kA
Sr 100 Sr in kVA
HV = Main Distribution board IK" =
3 UN uK UN in V
UV = Sub-distribution board uK in %

Table 1: Table 2: Rated short-circuit withstand current of installation device


Excerpt from HENSEL main catalogue in HENSEL distribution boards
Rated Rated cur- Initial short- Initial short- Installation device Short-circuit
power of rent at rated circuit cur- circuit cur- in HENSEL distribution boards withstand capacity
the trans- voltage rent at rent at Busbar 250A / 400A ICW =15kA / 1s
former Un=400 V a.c. uk = 4% uk = 6%
Sr IN IK" IK" NH fuse switch disconnector 250A ICC = 50kA
in kVA in A in kA in kA Circuit breaker 250A / 400A ICU = 50kA
100 144 3.610 2.406 Switch disconnector 160A ICC = 50kA
160 230 5.776 3.850 ICS = ICU = 8 kA / 690 V a.c.
MCCB 160 A / 250 A
250 360 9.025 6.015 ICS = ICU = 36 kA / 415 V a.c.

315 455 11.375 7.583 Other values can be obtained from the device manufacturers or
400 578 14.450 9.630 in the HENSEL main catalogue!

20
Path of the short-circuit current from the transformer to the short-circuit

Main Distribution Board (MDB) Sub-Distribution Board (SDB)


400A 250A

Icp ICW Icp ICW


M

MDB SDB
Step 2: Step 3:
Determining the rated short-time withstand current ICW of the Determining the rated short-time withstand current ICW of
main distribution board (MDB) the sub-distribution board (SDB)
Determining the lowest rated short-time withstand current ICW of the Determining the lowest rated short-time withstand current ICW of
device installed in the main distribution board. the device installed in the in the sub-distribution board.

MDB installed devices ICW or ICU SDB installed devices ICW


Circuit breaker 400A ICU = 50kA * Circuit breaker 250A ICU = 50kA *
Busbars 400A Icw = 15kA / 1s * Busbar 250A Icw = 15kA / 1s *
Ics = Icu = 8 kA / 690 V a.c. Ics = Icu = 8 kA / 690 V a.c.
MCCB 250A MCCB 160A
Ics = Icu = 36 kA / 415 V a.c.* Ics = Icu = 36 kA / 415 V a.c.*
Lowest value of the devices: ICC / ICU = 50kA *see table 2 Lowest value of the devices: ICC / ICU = 50kA *see table 2
Lowest value of the busbars: ICW = 15kA Lowest value of the busbars: ICW = 15kA
ICW(MDB) = 15kA it follows: ICW(SDB) = 15kA
ICW(MDB) IK"
15kA 9.025kA ICW(SDB) IK"
15kA 9.025kA
MDB Determining the rated short-time
withstand current ICW SDB Determining the rated short-time
withstand current ICW

The rated short-time withstand current ICW of the MDB must Icp is the prospective short-circuit current at the installation site of
be equal to or greater than the short-circuit current IK" of the the assembly at the incoming terminals. It (Icp) is calculated from
transformer: transformer and cable data (length, cross section). Here, the cable
attenuation due to distance and associated cable length between
Icw (MDB) IK" (transformer)
the transformer and sub-distribution board (SDB) is considered.
In this analysis, the cable attenuation between the transformer
The cable attenuation reduces the IK" of the transformer.
and MDB is not considered. The cable attenuation can mean a
reduction of the short-circuit current IK". The prospective short- Icw(UV) Icw(HV) > Icp IK" (transformer)
circuit current Icp at the installation site of the MDB is smaller If a calculation is not possible, Icp = IK" can be assumed.
because of the cable attenuation than IK" of the transformer.
The rated short-time withstand current of the assembly results from The rated short-time withstand current (ICW) must satisfy the
the rated short-time withstand current of the installed equipment following requirements:
and busbars. ICW(UV) Icp(UV)
The original manufacturer, such as HENSEL, species these values
The rated short-time withstand current (ICW) of the sub-distribution
in the technical data.
board is determined the same way as for the main distribution board.
The respective lowest value determines the maximum rated The respectively lowest value of the devices also determines
short-time withstand current ICW of the main distribution board. the maximum rated short-circuit withstand current ICW of the
The panel builder must specify this value in the documentation of sub-distribution board. The panel builder must specify this value
the assembly! in the documentation of the assembly!

21
Step 2: Design of an assembly and design verification

Determining the rated current (InA) of an assembly

The rated current of the switchgear assembly (InA) is determined on


the basis of the rated current of the built-in device in the infeed or
the busbar.
The rated current of the infeed (InA) is, in accordance with
IEC/EN61439-1 section 10.10.4.2.1c, 80% of the rated current of
the built-in device in the infeed or the busbar.

Example
Determination of the rated current of the switchgear assembly InA:
Rated current of MCCB = 400A
thereof 80%: (400A x 0.8) = 320A
Rated current of the switchgear assembly: InA = 320A

IEC 61439 / EN 61439-1 section 5.3.1


Rated current of the switchgear assembly (InA)
The rated current of the switchgear assembly (InA) is the maximum
permissible load current for which the switchgear assembly is
designed and it can distribute. It is the smaller of the sum of
the rated currents of the incoming circuits whithin the assembly
operated in parallel and the total current which the main busbar is
capable of distributing in the particular assembly arrangement.
InA
Transformer ratings

Rated voltage UN 230/400 V 400/690 V


Short-circuit
voltage UK 4% 6% 4% 6%
Rated power SN Rated Short-circuit current IK" Rated current IN Short-circuit current IK"
current IN
(kVA) (A) (A) (A) (A) (A) (A)
50 72 1805 - 42 1042 -
100 144 3610 2406 84 2084 1392
160 230 5776 3850 133 3325 2230
200 280 7220 4860 168 4168 2784
250 360 9025 6015 210 5220 3560
315 455 11375 7583 263 6650 4380
400 578 14450 9630 336 8336 5568
500 722 18050 12030 420 10440 7120
630 910 22750 15166 526 13300 8760

Rated currents and short-circuit currents of standard transformers: SN IN


SN (kVA) = apparent power of the transformer IN = IK = 100
3xUN UK(%)
UN (V) = rated voltage of the transformer
IN (A) = rated current of the transformer
UK (%) = short-circuit voltage of the transformer
IK (A) = short-circuit current of the transformer
22
Step 2: Design of an assembly and design verification

Rated current of an outgoing circuit (InC)

First, the installation device of the outgoing circuits is selected


based on the electrical function, e.g. fuses, circuit breakers, switch
disconnectors, etc.
Then the short list is based on the rated current of the circuits (Inc).
The rated current of the circuit (Inc) must not exceed 80% of the
rated current of the installed device, IEC 61439-1 / EN 61439-1
section 10.10.4.2.1c.

IEC 61439 / EN 61439-1 section 5.3.2


Rated current of a circuit Inc
"The Inc is the value of the current that can be carried by this circuit
loaded alone, under normal service conditions."

Example: Selection of the installed device of outgoing circuits


MCCB
based on the rated current of the circuits InC

Example 1: Example 2: WITHOUT specifying the


WITH specied operating current operating current
If an operating current (IB) is specied, the
rated current of the installed device must be
If no operating current (IB) is specied, an
calculated.
installation device is selected and the rated
It results from the division of the operating
current of the circuit (Inc) is calculated.
current and the factor 0.8 according to
IEC 61439 / EN 61439
Example Operating current: 180A Example Device selection:
180 A: 0.8 = 225A MCCB: 250A
The rated current of the installed device 250A x 0.8 = 200A
must be at least 225A. The next size for The maximum rated current of the circuit Inc
MCCB is 250A. is 200A.

The rated current of the circuit Inc is 200A.

23
Step 2: Design of an assembly and design verification

Determining the operating current (IB)

Inc x assumed load factor = IB


The operating current IB is necessary to detect the permissible
thermal rise (power dissipation).
The operating current (IB) can be specied.
If no operating current (IB) is specied, it is calculated according to
the formula.
Thereby, in addition to the already determined rated current of the
circuit (Inc), also the number of circuits is taken into account. As
shown in Table 101, an assumed load factor for the calculation of
the operating current (IB) may be used depending on the number of
circuits.
The operating current IB is calculated according to the formula:
IB = Inc x assumed load factor

Table 101 from IEC 61439 / EN 61439


InA
Mi distribution board ENYSTAR distribution
IEC 61439-2 / EN 61439-2 board
Number of outgoing circuits IEC 61439-3 / EN 61439-3
assumed load factor assumed load factor
2-3 0.9 0.8
4-5 0.8 0.7
6-9 0.7 0.6
10 or more 0.6 0.5

Determination of the operating current IB

Example 1: Example 2: WITHOUT specifying the


WITH specied operating current operating current
The IB is calculated according to the
formula:
The customer species the rated
IB = Inc x assumed load factor
operating current IB.
The assumed load factor from Table 101
may be used.
Example Example
Operating current: 180 A Number outgoing circuits: 3
Assumed load factor: 0.9
Inc = 200A
200A x 0.9 = 180A

The operating current IB is 180A. The operating current IB is 180A.


IB = 180A IB = 180A

24
Step 2: Design of an assembly and design verification

Calculation of the power dissipation (PV)

The permissible power dissipation PV for the entire assembly is


calculated from the difference of
- installed power dissipation through installed device, busbars and
wiring and
- power dissipation of the enclosures in the form of heat emission.

The determination of the power dissipation is quick and easy with


the HENSEL calculation tool.
ONLINE at www.hensel-electric.de/61439

ONLINE calculation tool HENSEL "Design verication of


permissible temperature rise".
Design verication of permissible temperature rise according
to IEC 61439-1 / EN 61439-1 Section 10.10
The tool automatically calculates the installed and dissipated
power dissipation, and where appropriate, the RDF.
ONLINE at www.hensel-electric.de/61439

After entering the data for installed device, busbar system and
used enclosures, the calculation tool automatically determines the
installed and dissipated power and, where appropriate, the RDF.

The result is the difference of installed and dissipated power


dissipation. It can be positive or negative.

With a positive difference, the permissible temperature rise of


the assembly is veried.

In case of a negative difference, there is a risk of overheating.

This can be prevented by selecting larger or additional enclosures


and thus the dissipated power dissipation is increased.

A further possibility is the reduction of the installed power


dissipation.

Since the number of installed device cannot be reduced,


a computational reduction of the power dissipation can be
performed by applying the rated diversity factor (RDF).

Online
O via internet
www.hensel-electric.de/61439
w

25
Step 2: Design of an assembly and design verification

Determining the rated diversity factor (RDF)

Specied operating current With a positive difference of installed and dissipated power
If the operating current (IB) is specied and not calculated, dissipation, the rated diversity factor (RDF) is equal to the
formula 1 can be used to determine the rated diversity factor (RDF). assumed load factor.

Calculated operating current Witha negative difference, the HENSEL calculation tool
If the operating current (IB) is calculated, the rated diversity factor automatically calculates the rated diversity factor (RDF)
(RDF) is determined via the power dissipation (PV). according to formula 2.

IEC 61439 / EN 61439 -1 Section 5.4 Formula 1: Formula 2:


Rated diversity factor RDF (Rated Diversity Factor)
"The rated diversity factor is the per unit value of the rated current, assigned
RDF = IB dissipated power dissipation
Inc RDF =
installed power dissipation
by the assembly manufacturer, to which outgoing circuits of an assembly can
be continuously and simultaneaously loaded taken into account the mutual
thermal influences."
Determining the rated diversity factor RDF

Example 1: Example 2: WITHOUT specifying the


WITH specied operating current operating current


With a positive difference, the RDF
corresponds to the assumed load factor.


With a negative difference, the RDF
The customer species the operating
must be determined by means of
current IB.
a calculation. For this purpose, the
This value is used in Formula1. values from the calculation tool for
dissipated power dissipation and
RDF = IB
according to customer specication
Inc installed power dissipation are used.
dissipated power dissipation
RDF =
installed power dissipation

Example: IB =180A and Inc = 200A Example:


Result from the calculation table is 0.9.
RDF = 180A = 0.9
200A
RDF = 0.9 RDF = 0.9

O
Online via internet
www.hensel-electric.de/61439
w

The ONLINE calculation tool


from HENSEL provides the
design verication of permissible
temperature rise in a safe, fast
and easy way. The tool automatic-
ally calculates the installed and
dissipated power dissipation and,
where appropriate, the RDF.
The tool provides the design
verication of permissible
temperature rise according to
IEC 61439-1 / EN 61439-1
Section 10.10 as a PDF le.
26
Step 2: Design of an assembly and design verification

Design verication of permissible temperature rise


according to IEC 61439-1 / EN 61439-1 Section 10.10

1. Type / temperature
(Installation and ambient
conditions)

2. Installed power
dissipation of the ONLINE calculation tool from HENSEL:
installed equipment Simply enter the values of the assembly and
(Connection to the public read the results!
power supply system)

The values determined with the HENSEL


calculation tool must be included in the
documentation in the circuit diagram.
3. Installed power
dissipation of the busbars
1 4 5 6 7 8

(circuits and consumers)


A

-Q1
B 400A

4. Dissipated power
dissipation of the C
1

enclosures
D

5. Optional object data

6. Determination of RDF: Gustav Hensel GmbH & Co. KG

Guide 61439

The calculation tool


determines the RDF.

7. Design verication of permissible temperature rise


according to IEC 61439-1 / EN 61439-1 Section 10.10
The calculation tool provides the
design verication as a PDF le. Online
O via internet
www.hensel-electric.de/61439
w
27
Step 3: Assembly / manufacture of the distribution board

Assembly instructions for distribution board systems

HENSEL supports the manufacture and assembly of a distribution


board with extensive assembly instructions.
PASSION FOR POWER.

ENYSTAR distribution boards up to 250 A with doors


intended to be operated by ordinary persons (DBO)
Assembly instruction according to IEC 61439-3 / EN 61439-3
ENYSTAR Distribution Boards
up to 250 A
Intended to be operated by ordinary persons (DBO)
in accordance with IEC 61439-3

ENYSTAR ENYSTAR
System design Assembly

The modular structure of Enclosure depth Positioning of enclosures


enclosures in grid of 90 mm with hand operation Assembly of enclosures
1
allows a free conguration of according to layout
the outer form.

186
Combinable in all directions
to follow given requirements 2 4
on site.
with tool operation

Different enclosure depths


allow the installation of equip-
ment of different heights.
Extension frame
With an extension frame the
for extending installation depths
depth of the enclosure sizes 3 by 50 mm with hand operation
3 and 4 can be extended by
50 mm.

50

236
213

with tool operation


Removal of the frames
with door
Unscrew and remove the frame
from the bottom part together
with the door.

Operation
Clear separation of the
operation areas for unskilled
persons and access/opera-
tion areas for skilled persons
(electricians).

Hand operated doors in areas to which Locking facilities with keys prevent the
unskilled persons have access for oper- unauthorized opening of doors
ating devices

Download at www.hensel-electric.de/61439

Standard tool operation for slotted


screwdrivers and triangle
(option square, double bit)

8 9

ENYSTAR ENYSTAR ENYSTAR ENYSTAR


Assembly Assembly Wiring Wiring
Closing Plates, Flanges, Cable Insert Cable inserts, Box Fin Terminals

Closing walls via closing Installation of cable inserts Direct connection of Wiring Strip
plates Saw the box n. conductors to busbars Strip at the connection point by
Insert closing plates into Afterwards the cable insert a suitable length.
Capacity of terminals for direct ENYSTAR For busbar boxes with
covers for the combination

openings of outer walls of the is mounted and xed via Accessories Width with fusegear
and blanking strips

busbar connection see Hensel Terminals for direct busbar connections for cables and laminated wiring strip
PE

distribution board and x them enclosure connectors and the Hint: For observance of insulation resistance clearances of 10 mm are necessary between different potentials
and of 15 mm between conductive metal parts.
1
2
N
L1
L2
L3

Catalogue.
3

PE PE
PE N N
N L1

rubber entries can be inserted.


L1
11 mm L1 L2
Type Cable cross- Type of Wiring strip For busbars Tightening L2 L2 L3

with enclosure connectors.


L3 L3
section conductor torque

16 mm
PE
N
L1
L2
L3
PE
N
L1
L2
L3
PE
N
L1
L2
L3
Right:
PE

First bend forward wiring


PE
PE N N
N L1 L1
21 mm L1
L2
L2
L2 L3
L3 L3

KS 16 F 1,5-16 mm2 Cu ... x 5 mm 4 Nm


PE

strip by 180 and then


N
34 mm L1
L2
L3

KS 35 F 4-35 mm2 Cu 100 A: Mi VS 100 ... x 5 mm 6 Nm


160 A: Mi VS 160

Direct connection of copper KS 70 F 10-70 mm2 Cu


34 mm

100 A: Mi VS 100 ... x 5 mm 10 Nm 90 to the side.


160 A: Mi VS 160

conductor with terminal KS 150 F 35-150 mm2 Cu/Alu* 250 A: Mi VS 250 12 x 5 mm /


12 x 10 mm
12 Nm PE
N
L1
L2
PE
N
L1
L2
PE
N
L1
L2
L3
144 mm L3 L3
-L3, N

KS 150 KS 240/12 35-240 mm2


E

Cu/Alu* 12 x 5 mm /
12 x 10 mm
40 Nm

ti nal short
ation s forms of types of conductors
In rna
Intern
International f (exible)

or connection module AM RK 150 Connection module 35-150 mm (rig


r (rigid)
 for the installation in busbar boxes with covers s (stranded)
 5-pole sol (solid) exible
round sector-type
 space units: 8 sector-type conductors
round conductors conductors
conductors conductors
L1-L3, N: 250 A: Mi VS 250 12 x 5 mm 12.0 Nm L1-L3, N

AM RK 150 to busbar.
35-150 mm Cu 160 A: Mi VS 160 10.0 Nm PE
PE: 10-70 mm Cu RM (round SM (sector,
RE (round SE (sector,r stranded)
solid) stranded)
single)

Wiring strip
* Prior to connection, aluminium conductors must be prepared according to the appropriate technical re-

Cable entry - opening


commendations, see technical information Aluminium conductors.

In order to adjust differences in


Adjust stepped grommet xx-xx
knockouts in anges height, bend a step.
on the cable diameter.
Knock out the appropriate Wiring
cable entries within anges Assignment of terminals for
with screwdriver. Insert cable and x it with
direct busbar connection to
the cable ties.
cross sections and enclosures
with electrical functions
Electrical connections 100 A
up to 250 A from busbars to
Insert the cable into the electrical equipment
box from the front.

Insulation cover for busbars


Cable glands Attach cover for insulating
Insert cable gland into the Box n busbars if necessary.
appropriate knockout and provides an easier wiring
across two boxes. Wiring strip
fasten with lock nut.
Mi VS ...
Connection of wiring strip
Saw out n in box wall.
Mi VS ... with terminal for
direct busbar connection
Insert box n and x via xing
KS ...
wedges.
Terminals for direct
connection on busbars
Mi SA 1210
Direct connection of wiring
strip Mi VS ... to electrical
equipment with at contact
M 10 with wiring terminal Terminal for connection of
Closing of enclosure walls VA 400 wiring strips Mi VA ...
with anges for cable entry
Insert anges for cable entry
into open outer walls of the N P
Connection of cables to
distribution board and x them
devices with at contact
with enclosure connectors.
M 10 with terminal for direct
Terminal for direct
connection DA 185
A wide range of anges for the connection DA 185
cable entry is available. Example:
Wiring with wiring strip Mi VS 250, terminals for direct connection on busbars and strip-
connection terminals VA 400.

12 13 26 27

A
Assembly instruction ENYSTAR for download:
www.hensel-electric.de/61439
w

28
Installation and ambient HENSEL supports the
conditions manufacture and assembly of a
PASSION FOR POWER.
Installation areas and degree distribution board with extensive
of protection, condensation, assembly instructions.
system design
Assembly instruction Mi Power switchgear and
Assembly Mi Power Distribution Boards controlgear assembly (PSC)
lid hinges, wall openings, according to IEC 61439 -2 /
up to 630 A
assembly of enclosures, Power switchgear and controlgear assemblies (PSC)
EN 61439-2
anges, cable entry, cable in accordance with IEC 61439-2
insertion, extension frame,
box n

Mounting
wall mounting, oor-standing,
measures against condensation
forming, canopy

Device installation
mounting plate, DIN rails, PE
and N terminals, protection
against access to hazardous
parts/covers

Wiring
busbar systems, connecting
Download at www.hensel-electric.de/61439
terminals, wiring, bending
wiring strips, feed-in terminals,
FIXCONNECT plug-in
terminals, connection of
aluminum conductors
Mi Distribution Boards Mi Distribution Boards Mi Distribution Boards
Assembly Assembly Wiring
Routine tests of switchgear Assembly of Mi distribution
Wall Opening, Assembly of enclosures

Connections of cables
Flanges, Cable Entry

Direct connection of
Terminals

Mi-Verteiler Mi-Verteiler
Zubehr Zubehr

boards according to assem- Connect cables strain-relieved conductors to busbars

assemblies
Sammelschienen-Direktanschlussklemmen fr Leiter und lamelliertes Verdrahtungsband Mi-Sicherungsgehuse Diazed/Neozed Mi-NH-Sicherungsgehuse, Sicherungs Mi-Sammelschienengehuse
elemente und Sicherungslasttrennschalter
DK

DK

Hinweis: Zur Einhaltung der Isolationsfestigkeit sind zwischen unterschiedlichen Potentialen 10 mm und zu inaktiven, leitfhigen
Metallteilen 15 mm Luftstrecke einzuhalten. NH00
NH00 NH00 NH00

bly draft and pressure-relieved. Capacity of terminals for direct


Typ Leiter-
querschnitt
Leiterart Verdrahtungs-
band
fr Sammel-
schienen
Anzugs-
dreh-
Breite 250 A
N: 12x5
400 A
N: 12x10
630 A
N: 25x10
250 A
N: 12x5
400 A
N: 12x10
630 A
N: 25x10
250 A
N: 12x5
400 A
N: 12x10
630 A
N: 25x10
KV

KV

moment L1-L3: 12x10 L1-L3: 20x10 L1-L3: 30x10 L1-L3: 12x10 L1-L3: 20x10 L1-L3: 30x10 L1-L3: 12x10 L1-L3: 20x10 L1-L3: 30x10
PE: 12x5 PE: 12x5 PE: 12x10 PE: 12x5 PE: 12x5 PE: 12x10 PE: 12x5 PE: 12x5 PE: 12x10

KS 16 F 1,5-16 mm2 Cu - ... x 5 mm 4 Nm 11 mm 1) N 1) N N


NH00 NH00

Pre-assembled and tested busbar connection see HEN- KS 16 Z 1,5-16 mm2 Cu - ... x 10 mm 4 Nm 11 mm
PE

L1
L2
L3
PE

N
L1
L2
L3
N
L1
L2
L3
NH00
PE

L1
L2
L3
NH00
PE

N
L1
L2
L3
NH00
N
L1
L2
L3
PE

L1
L2
L3
PE

N
L1
L2
L3
N
L1
L2
L3

Cable entry
PE PE PE

enclosures with electrical SEL Catalogue. KS 35 F 4-35 mm2 Cu 100 A: Mi VS 100


160 A: Mi VS 160
... x 5 mm 6 Nm 16 mm 1) N 1) 1)
NH00
N 1)
NH00
N
Mi

Mi

PE PE PE PE PE PE

Close knockouts/openings KS 35 Z 4-35 mm2 Cu 100 A: Mi VS 100 ... x 10 mm 6 Nm 16 mm 1) 1) N 1) N N N N N


L1 L1 L1 NH00 L1 NH00 L1 NH00 L1 L1 L1 L1
160 A: Mi VS 160

functions
L2 L2 L2 L2 L2 L2 L2 L2 L2
L3 L3 L3 L3 L3 L3 L3 L3 L3
PE PE PE

KS 70 F 10-70 mm2 Cu 100 A: Mi VS 100 ... x 5 mm 10 Nm 21 mm 1) N 1) N N


NH00 NH00
160 A: Mi VS 160

for the cable entry accord- PE PE PE PE PE PE

routine verication / inspection /


KS 70 Z 10-70 mm2 Cu 100 A: Mi VS 100 ... x 10 mm 10 Nm 21 mm 1) 1) N 1) N N N N N
L1 L1 L1 NH00 L1 NH00 L1 NH00 L1 L1 L1 L1
160 A: Mi VS 160 L2 L2 L2 L2 L2 L2 L2 L2
L2
L3 L3 L3 L3 L3 L3 L3 L3 L3
PE PE PE

ing to the specied degree of KS 120 F 25-120 mm2 Cu 250 A: Mi VS 250


400 A: Mi VS 400
... x 5 mm 20 Nm 25 mm 1)
NH00
N

PE
1)
NH00

PE
N

PE PE

KS 120 Z 25-120 mm2 Cu 250 A: Mi VS 250 ... x 10 mm 20 Nm 25 mm 1) 1) N 1) N N N


L1 L1 L1 L1 L1 L1

protection.
NH00 NH00 NH00
400 A: Mi VS 400 L2 L2 L2 L2 L2
L2
L3 L3 L3 L3 L3 L3
PE PE

KS 240/12 Cu 35-240 mm2 Cu / Alu* - 12 x 5 mm / 40 Nm 34 mm N


L1
N
12 x 10 mm L2
Alu 35-185 mm2 L3
PE PE PE

2
KS 150 35-150 mm Cu 630 A: Mi VS 630 12 x 5 mm / 20 Nm 34 mm N
L1
N
12 x 10 mm L2
L3
PE PE

Right:
PE

KS 185 95-185 mm2 Cu/Alu* - 20 x 10 mm / 30 Nm 38 mm N


L1 L1
25 x 10 mm / L2 L2
30 x 10 mm L3 L3
1) Klemmen im Lieferumfang der Funktionsgehuse, siehe Gehusebeschreibungen.

Covering of cable entry with KS 240 V - - 630 A: Mi VS 630 20 x 10 mm /


25 x 10 mm /
30 Nm 38 mm
L1
L2
N
L1
L2

report, marking, initial inspection


30 x 10 mm L3 L3

cable entry cover KS 300 120-300 mm2 Cu/Alu* - 20 x 10 mm /


25 x 10 mm /
30 x 10 mm
30 Nm 38 mm
Internationale Kurzbezeichnung der Leiterarten

sol (solid) = eindrhtig


runde Leiter
r (rigid) = starr

sektorfrmige Leiter
s (stranded) = mehrdrhtig
runde Leiter sektorfrmige Leiter
f (exible) = exibel
mit gasdicht verpresster
Aderendhlse
L1
L2
L3
N
L1
L2
L3

* Aluminiumleiter mssen vor dem Anschlieen entsprechend den einschlgigen technischen Empfehlungen vorbereitet
werden, siehe technische Information Aluminiumleiter.
346 347

Knock out of box walls for Flanges


electrical connection and Attach anges by means of
cable entry 4 wedge links and 1 clamp Wiring

before putting installation Box walls are knocked out for


the electrical connection within
the distribution board.
to the box wall. Assignment of terminals for
direct busbar connection to
cross sections and enclosures
For the assembly of the enclo- with electrical functions.
sures, the appropriate open-

into operation and inspection


Electrical connection 100 A
ings of the wedge joints are up to 630 A from busbars to
knocked out as well. electrical equipment.
Wiring strip from laminated
copper, insulated,

periods, declaration of Assembly of boxes


For sealing the boxes in posi-
Cable entry
Knock out the appropriate
supplied length 2 meters.

tion, a self-adhesive gasket is cable entries within anges or

conformity
stuck to the box wall (applies box walls with screwdriver.
Wiring strip
to closed box walls, too).
Mi VS ...
Connection of wiring strip
The box assembly is carried
Mi VS ... with terminal for
out by a wedge connection.
direct busbar connection
KS ...
To increase stability, press wall
clamps onto the box ns. Terminals for direct
connection on busbars
Use a wall separator for sub-
Direct connection of wiring
dividing 300 mm box walls into Cable glands strip Mi VS ... to electrical
two 150 mm walls for ange or Insert cable gland into the equipment with at contact
box mounting. appropriate knockout and M 10 with wiring supply ter- Terminal for connection of
fasten with lock nut. minal for direct connection of wiring strips Mi VA ...
laminated copper wiring strip
Mi VA ...

Connection of cables to
devices with at contact
M 10 with terminal for direct
Terminal for direct
connection DA 240.
connection DA 240

Example:
Wiring with wiring strip Mi VS 400, terminals for direct connection on busbars and wiring strip
connection terminals VA 400.

10 11 21

Assembly instruction Mi for download:


A
www.hensel-electric.de/61439
w

29
Step 3: Assembly / manufacture of the distribution board

Routine verification / inspection (routine test report) sheet 1


The panel builder checks his work
Inspection test by the manufacturer of the assembly (panel builder). He documents the safety of the self-made assembly based on
Herby, the panel builder inspects and veries the assembly of his IEC 61439 / EN 61439 by this routine test report (Sheet 1).
distribution board.

Verications Panel builder must provide


Standards section
which the PANEL BUILDER is required to perform himself VERIFICATION
Clearances and creepage distances 10.4 by routine testing
Protection against electric shock and integrity of protective cirduits 10.5
- Effective earth continuity between the exposed conductive parts by routine testing
of the assembly and the protective circuit 10.5.2
IIncorporation of switching devices and components 10.6 by routine testing
Internal electrical circuits and connections 10.7 by routine testing
Terminals for external conductors 10.8 by routine testing
Dielectric properties 10.9
- Power-frequency withstand voltage 10.9.2 by routine testing
- Impulse withstand voltage 10.9.3
Verication of temperature rise 10.10 by calculating
during design process
Short-circuit withstand strength 10.11 by calculating
during design process
Electromagnetic compatibility (EMC) 10.12 by calculating
during design process
Mechanical operation 10.13 by routine testing

The panel builder must enclose the report for the routine verication
Routine Test Report Sheet 1
(routine test report) (Sheet 1) with the documentation of his self-
Power switchgear and controlgear assembly (PSC),
Verication according to IEC 61439-2/EN 61439-2 assembled distribution board.
Distribution boards intended to be operated by ordinary persons (DBO),
Verication according to IEC 61439-3/EN 61439-3

Customer: ................................................................................. Order number: .............................................................

Project: ..................................................................................... Workshop: ...................................................................

Testing performed:

Type of
IEC 61439
No. test- Content of routine test Result of routine test Test engineer
Section
ing*
Degree of protection of cabinets /enclosures
1 S 11.2
(sealings, protection covers)

2 S/P Creepage and clearance distances 11.3


Protection against electric shock and
3 S/P 11.4
integrity of protective circuits

4 S Incorporation of built-in components 11.5

5 S/P Internal electrical circuits and connections 11.6

6 S Terminals for external conductors 11.7


Mechanical operation
7 P 11.8
(actuating elements, lockings)

8 P Dielectric properties 11.9 M

A power-frequency withstand test shall be performed on all circuits in


accordance with IEC 61439-1 Section 10.9.2 for a duration of 1 s. The
test voltage for power switchgear and controlgear assemblies with a rated
Test voltage values
insulation voltage between 300-690 V a.c. is 1,890 V. The test values for
different rated insulation voltages are given in Table 8 of IEC 61439-1. V a.c.

Alternatively, for switchgear assemblies with a protective device in the


power supply and a rated current up to 250 A applies:
Measurement of the insulation resistance with an insulation tester at a volt- Insulation resistance
age of at least 500 V d.c. The test is passed with an insulation resistance of
at least 1000 / V. /V

Wiring, operational
9 P 11.10
performance and function

S - Visual inspection
P - Testing with mechanical or electrical test equipment

Installer: ............................................................................. Test inspector: ........................................................

Date: ................................................................................. Date: .......................................................................

Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439


R
Routine test report for download as editable checklist:
www.hensel-electric.de/61439
w

30
Routine verification / inspection
Example: Mi Distribution Board

1. Degree of protection of cabinets / enclosures 5. Internal electrical circuits and connections

The manufacturer must specify measures that must be implement- Conductors must be checked for consistency with circuit diagrams
ed to maintain the designated degree of protection. and bolted connections have to be checked at random.
Check that seals and covers have been installed according to the
manufacturer's instructions.

2. Creepage and clearance distances 7. Mechanical operation (actuating elements, lockings)

The clearances between different potentials should be greater than The effectiveness of mechanical actuating elements, interlocks and
the values given in Table 1 of the standard. We recommend a mini- locks including those associated with removable parts must be
mum distance of 10mm. checked.

3. Protection against electric shock and integrity of the pro- 8. Dielectric properties
tective circuits

The protective circuits must be subjected to a test for integrity of A power-frequency withstand test must be performed on all circuits
electrical connection. for a period of 1 second, as per IEC/EN61439-1 section 10.9.2.
The test voltage for switchgear assemblies with a rated insulation
voltage between 300-690 V a.c. is 1.890 V. The test values for
different rated insulation voltages are given in Table 8 of
IEC/EN61439-1.

31
Step 4: Marking

The company / panel builder that is responsible for the ready-for- HENSEL adds a manufacturer's marking to all circuit breaker
use switchgear assembly is considered the manufacturer boxes.
(IEC 61439-1 / EN 61439-1).
Upon completion and assessment of the switchgear assembly
by means of a routine verication, a manufacturer's label must be
afxed.
It must be legible when the system is connected.

Manufacturer's marking Example

- Manufacturer's name or trademark


Installation note:
- Type, name or ID number
System manufacturer Complete label.
- Date of manufacture Affixvisibly on the exterior of the assembly.
- Applied Standard Protect with enclosed protective film.


98 01 994

IEC 61439-2/-3 / EN 61439-2/-3


Manufacturer:
M f O
Order
d
Elektro Meister 20130815
Musterstrae 123
IEC 61439 -
58764 Musterhausen DIN EN 61439 - 2 Date 01/15

HENSEL adds a manufacturer's marking to all circuit breaker boxes.

32
Step 5: Declaration of EC conformity

The manufacturer of a switchgear


assembly nally performs a Declaration of Conformity
conformity assessment according to
LVD2014/35EU.
EU only

This can be done with the checklist for conformity assessment Finally, the CE Declaration of Conformity (Sheet 3) can be created.
procedure (Sheet 2). Both forms are editable and are made available for download at
www. hensel-electric.de/61439.

Checklist for conformity assessment procedure Sheet 2 Declaration of EC conformity Sheet 3

Company: Herby, we (name of manufacturer)


Stamp Stamp

Order:

Project:

Type:

Low-voltage switchgear and controlgear assembly


declare under our sole responsibility that the following product
Power Switchgear and Controlgear Assembly (PSC), Distribution board, intended to be operated by Low voltage switchgear and controlgear assemblies (PSC)
Design verication according to EN 61439-2 ordinary persons (DBO)
Design verication according to EN 61439-3 (Designation, type, catalogue- or order number)

1. Technical documentation
Scope of Low Voltage Directive LVD 2014/35 EU to which this declaration releates is in conformity with and is manufactured according to the following
standard(s).
Catalogues or other documentation of the original manufacturer of low-voltage switchgear assemblies
(Important Contents: Name and address of the original manufacturer and type designation, applicable
standard. Description of the product) Low-voltage switchgear and controlgear assembly

Assembly and installation instructions of the original manufacturer. Power Switchgear and controlgear Assembly (PSC) according to EN 61439-2
Circuit diagram, assembly drawing, parts list Distribution Board intended to be operated by ordinary persons (DBO) according to EN 61439-3
Carrying out the routine test according to EN 61439-1
Report for routine verication (sheet 1) is part of the documentation.
The designated product corresponds to the requirements of the following European directives:

Scope of Electromagnetic Compatibility (EMC) Directive 2004/108/EC Low Voltage Directive LVD 2014/35 EU
Supplementing the technical documentation by the manufacturer documents for all electronic equipment Electromagnetic Compatibility (EMC) Directive 2004/108/EC
and devices that include electronic (Assembly and Installation Instructions). for example in electronic equipment, installed in switchgear assemblies according to EN 61439-1
Declaration of conformity of the equipment manufacturer, that conrms the compliance of the product with
the requirements of the EMC Directive. A note in the accompanying documents must be kept equal and
accordingly. (Afxing of CE marking*): (Date)

*) Afx visibly in combination with the manufacturers marking on the low-voltage assembly or distribution board,
2. Declaration of Conformity (see sheet 2) if necessary, readable after opening the door.

3. Afxing CE marking (see sheet 2)

Conformity assessment procedure has been carried out: (place and date of issue): (name and signature or equivalent marking of authorized person)

With this declaration of conformity the manufacturer ensures conformity with the mentioned directives and standards.

(place/date of issue) (name and signature or equivalent marking of authorized person) This declaration of conformity complies with DIN EN 17050-1 "General Criteria for Suppliers Declaration of Conformity".

_ Please tick as appropriate _ Please tick as appropriate


Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439 Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439

CE marking Afx CE marking


The laws for the safety of electrical equipment stipulate that
Manufacturer: Order
a conformity assessment procedure has to be performed for 20130815
Elektro Meister
assemblies as well. It is to prove that the assembly complies with
Musterstrae 123
the applicable regulations and conforms to the respectively valid 58764 Musterhausen IEC 61439 -
01/15
DIN EN 61439 - 2 Date
safety standards.
Subsequently, a declaration of conformity must be created and the
CE marking shall be afxed to the distributor.
Producing a new manufactured product from already existing
manufactured goods, constitutes a manufacturer!

w
www.hensel-electric.de/61439

33
Step 5: Documentation

What is part of the documentation of a self-assembled distribution board?

Documentation of an assembly Verication required See also

1 Wiring diagram/circuit diagram using the determined values InA, InC, RDF, and Icw Page 27

2 Verication of permissible heating according to IEC 61439-1 / EN 61439-1 Section 10.10 Page 27

3 EU only: Declaration of conformity by the system manufacturer Page 18

4 Protocol for part verication (routine test protocol) (Sheet 1) Page 30

5 EU only: Checklist for conformity assessment procedures (Sheet 2) Page 33

6 EU only: Declaration of Conformity (Sheet 3) Page 33

1
3~400/230V - 25
HSS-L1 L1
2.8/ L1 HSS-L2
2.8/ L2 HSS-L3 L2
2.8/ L3 L3
2.8/ N N

2.8/ 1L1
2.8/ 1L2

2
2.8/ 1L3
2.8
2.8// 1N
2

6
-F5.7 -F5.8 -F5.9 -F5.10 -F5.11 -F5.12
B16A B16A B16A B16A B16A B16A
1

Declaration of EC conformity Sheet 3

2.8
2.8// PE PE
Herby, we (name of manufacturer)
Stamp

-X10 7 NT PE 8 NT PE 9 NT PE 10 NT PE 11 NT PE 12 NT PE Electro-Strom
2,5mm Musterstrae 123
Electro STROM
58765 Musterhausen
Musterstrae 123, 58765 Musterhausen
Bezeichnung
Steckdosen -X10 Reserve
Steckdosen
S 7 NT PE Reserve Reserve Reserve
2,5mm
I nc : 12,8 A 12,8
1 A 12,8 A 12,8 A 12,8 A 12,8 A
declare under our sole responsibility that the following product
RDF : 0,6 0,6
0 0,6 0,6 0,6 0,6
Datum 07.02.2014 Kunde Name 1 Steckdosen S Endkunde Name 1 = N01
Low voltage switchgear and controlgear assemblies (PSC)

(Designation, type, catalogue- or order number)


Kunde Name 2 Endkunde Name 2
Bearb. K.Schuppert + F01
Kunde Strasse Endkunde Strasse Mi Power distribution board (PSC)
Gepr. Sachbearbeiter Gustav Hensel GmbH & Co. KG

nderung Datum Name Stand


Kunde Wohnort
11.02.2014 Urspr.
Wohno
I nc :
Ers. f.
12,8Ers.Ad. 1 Endkunde Wohnort
Verteilerbezeichnung Schaltplan
Projekt-Nr.
Datenaufnahme Be to which this declaration releates is in conformity with and is manufactured according to the following

RDF : 0,6 0
standard(s).

Low-voltage switchgear and controlgear assembly


Datum 07.02.2014 Kunde Name
X
Power Switchgear and controlgear Assembly (PSC) according to EN 61439-2
Kunde Name 2
Bearb. K.Schuppert Distribution Board intended to be operated by ordinary persons (DBO) according to EN 61439-3
Kunde Strasse
Gepr. Sachbearbeiter Kunde Wohno The designated product corresponds to the requirements of the following European directives:
Stand 11.02.2014 Urspr. X Low Voltage Directive LVD 2014/35 EU

X Electromagnetic Compatibility (EMC) Directive 2004/108/EC

for example in electronic equipment, installed in switchgear assemblies according to EN 61439-1

Elektro-Strom 08.01.2015
(Afxing of CE marking*): (Date)

*) Afx visibly in combination with the manufacturers marking on the low-voltage assembly or distribution board,
if necessary, readable after opening the door.

Musterhausen, 08.01.2015 Electro-Strom


(place and date of issue): (name and signature or equivalent marking of authorized person)

With this declaration of conformity the manufacturer ensures conformity with the mentioned directives and standards.

This declaration of conformity complies with DIN EN 17050-1 "General Criteria for Suppliers Declaration of Conformity".

_ Please tick as appropriate


Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439
EU only

3 5
Technische Information
Konformittserklrung
Mi-Verteiler

Erklrung Checklist for conformity assessment procedure Sheet 2


der EG-Konformitt Nr./No. K 2010b
Declaration of EC-Conformity
Company: Electro-Strom, Musterhausen
Das Produkt, Stamp
The product
Order:
Typ / Type: Mi-Verteiler Electro STROM
Mi-Distributor
Typ / type: Mi .... Project: Carpenter Workshop Mueller Musterstrae 123, 58765 Musterhausen

Hersteller: Gustav Hensel GmbH & Co. KG


Manufacturer Gustav-Hensel-Strae 6 Type: 6359
57368 Lennestadt

Beschreibung: Niederspannungs-Schaltgertekombination PSC Low-voltage switchgear and controlgear assembly


Description: Low-voltage switchgear and controlgear assemblies PSC
X
Power Switchgear and Controlgear Assembly (PSC), Distribution board, intended to be operated by
Design verication according to EN 61439-2 ordinary persons (DBO)
auf das sich diese Erklrung bezieht, stimmt mit folgenden Normen oder normativen Dokumenten berein: Design verication according to EN 61439-3

4
to which this declaration relates is in conformity with the following standard(s) or normative document(s):

Norm / Standard: DIN EN 61439-2 X


1. Technical documentation
IEC 61439-2
EN 61439-2 Scope of Low Voltage Directive LVD 2014/35 EU

X
Catalogues or other documentation of the original manufacturer of low-voltage switchgear assemblies
und entspricht den Bestimmungen der folgenden EG-Richtlinie(n): Routine Test Report Sheet 1 (Important Contents: Name and address of the original manufacturer and type designation, applicable
and is in accordance with the provisions of the following EC-directive(s) standard. Description of the product)

Niederspannungs-Richtlinie 2006/95/EG
Power switchgear and controlgear assembly (PSC),
X
Assembly and installation instructions of the original manufacturer.
Low voltage directive 2006/95/EC
Verication according to IEC 61439-2/EN 61439-2 X X
Circuit diagram, assembly drawing, parts list
EMV-Richtlinie (EMC) 2004/108/EG Distribution boards intended to be operated by ordinary persons (DBO),
X
Carrying out the routine test according to EN 61439-1
Electromagnetic Compatibility (EMC) Directive 2004/108/EC Verication according to IEC 61439-3/EN 61439-3
Report for routine verication (sheet 1) is part of the documentation.

Diese Konformittserklrung entspricht der Europischen Norm EN 17050-1 Allgemeine Anforderungen fr Konformittserklrungen von Metalworking shop Blechner
Customer: ................................................................................. Order number: ............................................................. Scope of Electromagnetic Compatibility (EMC) Directive 2004/108/EC
Anbietern. Das Unternehmen Gustav Hensel GmbH & Co. KG ist Mitglied von ALPHA im VDE. Diese Erklrung gilt weltweit als Erklrung
des Herstellers zur bereinstimmung mit den oben genannten internationalen und nationalen Normen.
27 01 045
Project: ..................................................................................... Workshop: ...................................................................
X
Supplementing the technical documentation by the manufacturer documents for all electronic equipment
and devices that include electronic (Assembly and Installation Instructions).
This Declaration of Conformity is suitable to the European Standard EN 17050-1 General requirements for suppliers declaration of confor-
mity. The company Gustav Hensel GmbH & Co. KG is member of ALPHA at VDE. The declaration is world-wide valid as the manufacturers Testing performed: Declaration of conformity of the equipment manufacturer, that conrms the compliance of the product with
declaration of compliance with the requirements of the a.m. national and international standards. the requirements of the EMC Directive. A note in the accompanying documents must be kept equal and
Type of
IEC 61439
No. test- Content of routine test Result of routine test Test engineer accordingly.
Section
Jahr der Anbringung der ing*
CE-Kennzeichnung: 2012 Degree of protection of cabinets /enclosures
Year of affixing CE-Marking. 1 S
(sealings, protection covers)
11.2 O.K. X
2. Declaration of Conformity (see sheet 2)

EU only Ausstellungsdatum:
Date of issue:

Gustav Hensel GmbH & Co. KG


31.03.2015 2

3
S/P

S/P
Creepage and clearance distances

Protection against electric shock and


integrity of protective circuits
11.3

11.4
O.K.

O.K.
X 3. Afxing CE marking (see sheet 2)

4 S Incorporation of built-in components 11.5 O.K.


Conformity assessment procedure has been carried out:
5 S/P Internal electrical circuits and connections 11.6 O.K.
6 S Terminals for external conductors 11.7 O.K.

EU only
Musterhausen, 08.01.2015 Electro-Strom
O. Gutzeit Mechanical operation 
- Technische Geschftsleitung - 7 P
(actuating elements, lockings)
11.8 O.K. (place/date of issue) (name and signature or equivalent marking of authorized person)
- Technical Managing Director -
8 P Dielectric properties 11.9 M
 _ Please tick as appropriate
A power-frequency withstand test shall be performed on all circuits in Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439
accordance with IEC 61439-1 Section 10.9.2 for a duration of 1 s. The
test voltage for power switchgear and controlgear assemblies with a rated
Test voltage values
insulation voltage between 300-690 V a.c. is 1,890 V. The test values for
different rated insulation voltages are given in Table 8 of IEC 61439-1. V a.c.

Alternatively, for switchgear assemblies with a protective device in the


power supply and a rated current up to 250 A applies:
Measurement of the insulation resistance with an insulation tester at a volt- Insulation resistance
age of at least 500 V d.c. The test is passed with an insulation resistance of
at least 1000 / V. /V

Wiring, operational
9 P 11.10
performance and function

S - Visual inspection
P - Testing with mechanical or electrical test equipment

Installer: ............................................................................. Test inspector: ........................................................

W. Hess
Date: ................................................................................. Date: .......................................................................

09.07.2013

Available by Gustav Hensel GmbH & Co. KG, download at www.hensel-electric.de/61439

34
35
Gustav HENSEL GmbH & Co. KG
Industrial Electrical Power Distribution Systems

Altenhundem
Gustav-HENSEL-Strae 6
D-57368 Lennestadt
Germany
P.O. Box 1461
D-57344 Lennestadt, Germany

Phone: +49 (0)27 23/6 09-0


Fax: +49 (0)27 23/6 00 52
E-Mail: info@hensel-electric.de
www.hensel-electric.de

98 17 1000 06.15/1/11
made in GERMANY
since 1931