Low Voltage Switchboards: Quality Inspection Guide

Quality inspection guide
Low voltage switchboards

Preface
Foreword
On the strength of its experience, Schneider Electric
has always sought to produce hight quality equipment,
fully complying with IEC 60439-1 standard.
But what exactly do we mean by Quality ?
The standard ISO 9000 defines the quality as:

“degree to witch a set of inherent characteristics fulfils
requirements”
Although final inspection is in some respects a statement
of failure (as we have not been able to control the necessary
quality throughout the assembly process) it is nevertheless
a vital stage in equipment production.
This stage must be performed with care and rigour,

both with respect to customer specifications (explicit needs),
and proper operating procedures (implicit needs),
in order to satisfy the customer.
The quality is also the willingness of all the staff,

from the manager to the worker to satisfy the customer.
This guide is a good means to help you in this way
and to reach the excellence.
Contents
Quality inspection: means and process 3
Introduction to the quality inspection 4

1.1 Justification of quality inspection 4
1.2 Quality inspection function 6
1.3 Quality inspection responsibility 6
1.4 Quality inspector’s profile 6
1.5 Necessary documents 6
1.6 Required human resources 6
Incoming delivery inspection 7

2.1 Justification of the incoming inspection 7
2.2 Procedures 7
In process inspection 8
3.1 Inspection during manufacturing 8
3.2 Justification of the inspection during manufacturing stage 8
3.3 Process 8
3.4 Means 9
Final inspection 10
4.1 Final inspection process 10
4.2 Operating rules 11
4.3 Non conformity treatment process 12
4.4 Conformity declaration 13
Quality inspection: instructions 15
Performing in-process inspection 16

5.1 Reminder 16
5.2 Composition 16
5.3 Process 16
Performing the final inspection 17

6.1 Conformity check 17
6.2 Mechanical checks 20
6.3 Electrical operations checks 26
6.4 Prior dispatching checks 31
Summarising of final inspection operations 33

7.1 Comprehensive list of points to be checked 33
Summarising of tasks after final inspection stage 38
Quality inspection: follow up 39
Quality dashboard 40
8.1 Purpose 40
8.2 Principles 40
8.3 Produced non quality 40
8.4 Example of a Produced Non Quality index board 42
8.5 Non conformity weight example 42
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Contents
Quality inspection:
facilities and calibration 43
Facilities 44
9.1 The Quality Inspector’s individual tools 44
9.2 Common means of the quality inspection 44
9.3 Quality inspection zone 44
9.4 Necessary documents 44
Control of inspection means 45

10.1 Purpose 45
10.2 Reminders of basic principles 45
10.3 Responsibility 45
10.4 Diagram of operations 46
10.5 Application rules 46
Quality inspection: appendix 49

Follow-up of missing parts 49
Form example 49
Checking program 50
Non quality record board 51
Corrective action request 52
Final inspection record 53
Missing parts list 54
Glossary 55
Abreviations 55
Vocabulary 55
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Quality inspection:
means and process
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Procedure
“ Set of organisational rules of an administrative
nature in order to achieve a certain result
“ Specified way of accomplishing an activity ”
(see ISO 9001).
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Quality inspection: Introduction to the quality
means and process inspection
1.1 Justification of quality inspection

The implementation of the quality process in production plant will entail
to organised the work station on the way to reach the quality target
as per imposed by the standard.
A quality inspection process has always been recommended to all our
partner and subsidiaries.
Part of the quality insurance, it is a normative obligation of the
IEC 60439-1 standards which stipulate that three routine tests should be
perform in the scope of the quality inspection procedures to complete
the type tests:
b giving the equipment the TTA label (Type Tested Assembly)
b and which are bound to the panel builder’s responsibility.
These three Routine tests are
b inspection of the assembly
b dielectric tests and / or measurement of insulation resistance
b checking of protective measures and of the electrical continuity
of the protective circuit.
Human factors
The specificity and complexity of low voltage equipment, the numerous
human interventions, and thus risk of errors are the principal source of
mistakes in our field, so the main reasons of the implementation of the
quality inspection process.
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Each job must be checked.

Cost reduction
The non quality manufactured entails extra cost in term of time and
money due to:
b product examination
b reparation
b scrap
b incidence in term of delivery schedule, brand image
b etc.
A study shows that a fault detected on customer site can cost one
hundred to one thousand times more than if it had been detected during
the switchboard design phase (see graph below).
The in process checking operation and the final inspection also guarantee
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a good economic management of the switchboard manufacturing process.

The Quality inspection therefore contributes
b to guarantee the quality of the equipment:
v by preserving the company’s brand image
v by guiding the staff training according to the anomalies observed.
b to the security of people and equipment
b to the economic results of the company.
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1.2 Quality inspection function

Guarantee the quality level of the service and insure the brand image.
Detect and settle the internal dysfunction and so on increase the plant
profitability.
b perform the inspection with respect to:
v the project file and the customer document
v Schneider and products rules
v IEC standards
b carry out acceptance tests in the customers’ presence
b perform quality follow-up and corrective actions
b ensure the information, preventive action and training to the production
staff
b ensure periodical calibration of inspection and production means.
1.3 Quality inspection responsibility

Quality inspection department
b is directly attached to management and independent from manufacture
b can postpone the delivery of a project and require reworking to ensure
conformity
b in event of a dispute, informs the unit manager who alone has the
power to decide
b is responsible for the safety of all people entering in the quality
inspection zone.
1.4 Quality inspector’s profile

b graduate as electrical technician (technician’s certificate)
b versatile
b good knowledge of Schneider equipment and devices
b authorised to work near electrical current:
v knowledge of the hazards of electrical current
v authorisation by approved training course
v basic notions of first-aid.
1.5 Necessary documents

To carry out the various checks, the quality inspector must possess a
complete, updated production file of the project, including the check list,
missing parts list, etc.
1.6 Required human resources

For an accurate and reliable quality process, the quality inspectors
account for approximately 10 % of workforce,
i.e. 1 quality inspector for 8 to 10 fitters.
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Quality inspection: Incoming delivery inspection
means and process
Applicable to the external and internal goods or assembly.

In the case of sub assembly or internally manufactured goods, an internal
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procedure could be used to perform a final inspection of one process,

joined to the incoming inspection of another one.
2.1 Justification of the incoming inspection

As a final stage before assembly process, this quality inspection is a
sizeable part of the final quality of the job and will ensure his profitability.
The reason to implement the incoming inspection process is to ensure
that the received material and components are conform in regards of:
b the specifications indicated in the ordering form (colours, ...)
b the standard
b the product specifications
b the professional carried out rules.
2.2 Procedures
Verification
The quantity and aspect control of goods could be done
by the receiving agent.
The quality checking should be done by the quality inspector.
In case of large volume of goods, this operation could be done
on a sample.
All the incoming goods should be received and stored in such condition
that they will not be damaged till their final installation.
Non conformity processing

All non conform product will be:
b confined in a separated place
b registered as a non conform product and clearly identified.
All precautions should be taken to prevent their repetitions.
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Quality inspection: In process inspection
means and process
3.1 Inspection during manufacturing

On the way to ensure the conformity of the product or sub assembly to
the expected needs, the quality insurance program may recommend the
implementation of a specific inspection procedure. Done on parts of an
assembly or at the end of various mounting operations.
The following diagram represents the operations on which in-process

inspections are carried out and the main goods concerned by incoming
quality inspection.
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3.2 Justification of the inspection during

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manufacturing stage
The reasons to implement the inspection during manufacturing
process are:
b the complexity of the some equipment system.
It could be necessary to perform a quality inspection process during
manufacturing to ensure the conformity of parts or assembly step witch
presents:
v the access difficulty: current transformer, bars characteristics,
connections, installation...
v the time (profitability) needed for the final inspector to remove some
cover or other parts
b the will to involve and motivate the staff for the quality of their work
b the workshop organisation
b existence of dedicated assembly line for frame, busbars, functional
units (withdrawable, disconnectable, plug in, fixed)
b presence of a devices adaptation work station
b mass produced manufacturing system.
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3.3 Process
The inspection during manufacturing stage could be described by the
following process:
b inspection during manufacturing stage
This operation consists in carrying out checks at different stage of the
assembly process
v systematic inspection or sampling which is part of quality inspectors
responsability
v inspection done at the end of each key manufacturing step such as
cubicle assembly, devices adaptation, functional units assembly...
N.B.:
non conformity treatment is the same as the one described in the final
inspection chapter.
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Quality inspection: In process inspection
means and process
b continuous inspection
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The assembly operations requires constant carried out

of the professional rules.
Due to that, this procedure consist of carrying out checks throughout
manufacturing in the form of operators or project supervisor check.
It will make them responsible for the quality of their work.
These check should always be validated by the final inspection
inspectors.
Notice:
integral part of the checking operations, the cleaning process should
be performed during and at the end of the manufacturing process and
registered on the check list. (i.e.: Okken or Blokset busbar compartment).
3.4 Means
Presented as a check list form (could be a part of the final inspection
check list), the instructions provided at each manufacturing stage enable
these checks to be formally defined.
One check list is commonly dedicated and located on the cubicle frame,
other check lists can be done for functional units or manufacturing
operation done apart from the cubicles.
The fitter should fill in the check list to allow the quality inspector to verify
that all the points are checked and that the procedures are implemented.
b these follow-up sheets are used to log the status of the inspections
performed.
The same forms are finally authenticate by the quality inspector during the
final inspection stage.
N.B.:
Despite the operator checks performed for each operation, final
inspection is always necessary. As it is stipulated by standard
IEC 60439.1.
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Quality inspection: Final inspection
means and process
Final inspection guarantees operation and conformity of products with

respect to applicable drawings and standards. It is performed by the unit’s
quality inspection department.
A document per project formulating the customer’s requirements and

transcribing the specification is used for the checking phases during
assembly and for final inspection. It forms the first reference document
(production file).
The following table gives you an idea of the average time required to
perform a final inspection according to the type of switchboard to be
inspected.
The following information is given in average % of assembly process.
Simple
Semi-complex Complex
switchboard
PCC 3% <X> 8%
MCC 4% <X> 10 %
4.1 Final inspection process

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The final inspection takes place as follows

b carry out the conformity check
b conduct the tests
b modify the production file by adding any necessary annotations
(throughout testing)
b list all the non conformities:
v by noting all the faults or modifications observed
v by drafting a list of missing parts.
Ensure reworking for conformity.
b if customer acceptance is scheduled, receive the customer and / or his

representative in the quality inspection zone.
Sign the final inspection report after customer acceptance.
b point out any areas of dispute between customer and supplier
b ensure that the design documents have been properly corrected,
by checking final version status and updating
b ensure that all the check list is filled in
b draft and record the final inspection report
b sign the final inspection report and other documents
b archive the documents.
List of the various final inspection tests:

a. conformity checks:
b enclosure:
v appearance
v composition
b the front face layout
b framework
b devices
b busbars
b flexible busbars
b cables
b connections
b PE and (or) PEN protection busbars
b separated equipment.
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means and process
b. mechanical checks
These checks consist of testing proper operation of the mechanisms and
manual controls, the sturdiness of the switchgear, etc.
c. electrical checks
b operating tests
b dielectric withstand
b electric continuity of protection circuits
b insulation resistance.
4.2 Operating rules

The operating rules can be modelled using the following diagram.
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means and process
4.3 Non conformity treatment process

The following diagram describes the various possible cases of treatment
of non conformity.
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During the final inspection operations, any errors detected must be recorded on an
“non quality record board” and all non conformities corrected.
E.g. : type of table.
Non quality record board Corrective action

Location / BB Cabling Performed Time Signature
Type of fault assembly by
Cabling error b Jean 5 min
Busbar support b Alain 1 hour
missing
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means and process
4.4 Conformity declaration

On completion of final inspection, the quality inspector signature declaring
conformity of equipment should be affixed on the identification label
placed on the drawers and cubicles.
Panel builder
“lene “Quality inspection
X0 000 ile Checked by:”
Tel : XX XX XX XX XX
Fax : XX XX XX XX XX”
Conformity
DATE: …..../……./.…… frame Conformity
Job n°: ……….…....….. device Mechanical check
Switchboard: ………… power Electrical test
Cubicle: ………………. auxiliairies Dielectric test
Equipment n° / finishing Protective measures

location: ……………… check
Rating: ……………….. Insulating test
Design n°: …………… Index: ………………
Only fully inspected cubicles can be dispatched.

A label, resembling the one below, is used to identify them before
packaging.
Final inspection sheet

Ready for dispatch
Client: …………………………………… Purchase order n° ………………
Switchboard designation: …………... Design file reference …………...
Final inspection report n°: …………... Issue on: …………
Quality Inspector Date: Quality Manager

Name: …………………… ......./......./....... Name: ……………………
Signature: Signature:
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Quality inspection:
instructions
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Instruction (dictionary definition)

“ Verbal or written explanation intended for
the person responsible for the carrying out of a
specific mission. ”
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Quality inspection: Performing in-process inspection
instructions
5.1 Reminder
The purpose of in-process inspection is to ensure product conformity after
each manufacturing operation.
This process concerns all the manufacturing operations done

by the workshop operators.
5.2 Composition
One assembly follow-up check list sheet is completed for each cubicle
and / or functional unit (according to the manufacturing process).
This document is used both by the operators and the quality inspectors
(see follow up check list example in the appendix).
It is used from the first assembly phase through to final inspection.
This check list should mention:

b the designation of each point to be controlled
b the operator identification and the checking period.
5.3 Process
After each stage, the operator checks and declares product conform
by signing this follow up check list sheet and noting any observations.
On completion of the inspections, a copy of this sheet is archived.
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Quality inspection: Performing the final inspection
instructions
The Quality Inspector must:

b take delivery of the switchboards to be inspected in the dedicated
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zone
b become acquainted with the project production file
b check the observations and information given in the assembly follow-
up sheet (could be a part of the follow up check list)
b perform the final inspection by using the follow up check list.
First routine test / Inspection of the assembly
6.1 Conformity check

6.1.1 Enclosure
Composition and dimension
Number and order of cubicles
Use the drawing of the project front face to ensure that the number and
order of cubicles is respected.
Project, switchboard and cubicles identification label

b check that the information marked on the label match with the project
file
b check the presence of project identification marker on each cubicle.
This is normally shown in the form of a self-adhesive label
(see chapter 4.4)
b ensure that this label contains the registration number, signature,
switchboard number and design update version
On completion of final inspection, the Quality Inspector must place
his registration number (or signature) and indicate the date at which
the inspection was performed.
Dimensions
Check the cubicle dimensions (height, width, length and depth)
by measuring and comparing them with those stated in the project
production file.
Appearance
Paint colour and reference
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Use the colour palette to ensure that the reference of the paint given
in the project file matches the colour of the cubicle.
Verification generally carry out at the incoming delivery inspection stage.
Homogeneity
Perform a visual inspection to check the homogeneity of the colours
of the various switchboard components (doors, panels, etc.).
Finishing
Check external appearance by a visual inspection: no scratches,
deformations, etc.
Front face and mimic diagram

b visually check that the front face of the switchboard matches
the one shown in the drawing of the project
b check conformity of the mimic diagram compared with the power
diagram and front lay out.
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instructions
6.1.2 Framework
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Framework
Panelling
b operation of doors, mechanical accessories and drawers:
v check their operation by manoeuvring them
v ensure that the cubicle equipment is complete and has been installed
properly
b ensure the presence, characteristics (IP, material...) and proper fitting
of:
v ventilation grid, bottom plate
v side and rear cover
v roof, blanking plate, etc.
b conformity of cut outs in the plates:
Using the drawing, check the presence of any cut outs in the roofs,
mounting plate and separation plates allowing fish plating, coupling bars
installation, interlock cables or rods installation, etc.
Checking the locks

Check matching of the lock references and the key numbers with the
references given in the project production file.
Mechanical assembly
Check the overall assembly, frame position (top, bottom), the presence
and location of the screws required for assembling and joining the
cubicles, bottom plate, mounting plate, etc.
Check that all screws, picot washers and earth braids (if required) for
fixing these components are present, and check that screws are properly
tightened.
Ground fixing
Use the project design drawing to check the location of the ground fixing
points.
Handling devices
Check their fixing and their disposition according documentation.
Cable routing area

Check the special facilities provided for cable (top or bottom) routing
or bus way links.
b fixing of mounting plates, protection screens and partitioning or cowling
parts:
v check that all the screws for fixing these parts are present, and properly
secured
v check the quality of the riveted assembly, type of rivets, direction,
pressure.
Check the connection facilities space and equipment
Checking the degree of protection:

b this check is performed by checking the presence of the components
guaranteeing the IP level stated in the project production file.
Needs vary according to the required IP degree: awning, seal, front plate,
cable glands, etc. (information given in the product catalogues or guides).
If a seal is used, ensure it is properly positioned and continuous
b be sure that the IP degree of the equipment located on the door or
the device manoeuvring mode (cut out on doors or presence of specific
cover), matches with the switchboard requirement.
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instructions
6.1.3 Switchgear
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Conformity of devices
Location / identification
Use the layout diagrams in the project production file to ensure that the
devices are properly located and identified (QF1, QF2, etc.).
At the same time, the nature of the labels associated with the devices
and the content of the text can be checked.
Characteristics
b devices characteristics:
v type, rating
v breaking capacity and number of poles
v Masterpact terminal pads characteristics and installation (according
product). Inspection to be done prior the installation in the cubicle
(Inspection during manufacturing process).
Check or carry out the settings such as thermal and magnetic releases,
time delays, etc.
b associated devices
Check presence and technical data of circuit breaker’s associated
devices (Vigi, fault signal switch, trip unit, etc.).
Check the supply voltages for:
v switchgear motor mechanisms
v coils (contactors, relays, impulse relays, under voltage or shunt coils of
the Compact, Masterpact and multi 9)
v indicator lights
v all the electronic devices
v soft started, capacitor bank....
b toroïds
Check the technical data of each toroïd, their compatibility with the
customer connection cables. Also ensure the correct mounting direction:
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the arrow shows current direction.
b current transformer
v check the technical data of the current transformers together with the
installation direction
v check the correspondence between the current transformer and the
associated device, ammeter, etc. Ensuring that the current delivered by
its secondary circuit is compatible with the associated device
v check the respect of the clearances between the fixing and the
secondary connecting screws of the current transformer versus live
conductors or metal parts.
Check if the current transformer are well secured on the conductor.
Shunt
Check the connection between the shunt and the measuring instrument.
Safety perimeters
Check the circuit-breaker safety perimeters referring to their installation
guides.
No devices, equipment or bundle should be located in the safety
perimeter.
Accessories
Visual checking of the presence of :
b crank handles for circuit-breaker and / or drawers extraction
b doors stop, light
b clamps for fuse extraction
b pins for fixing certain relays
b etc.
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instructions
6.2 Mechanical checks

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Consult the switchboard assembly and installation guide.
6.2.1 Mechanical check and setting

Mechanical check
Equipment manual operation
b manoeuvre the manual mechanism of devices, to ensure their proper
operation
b check the operation of the functional units based on drawers,
disconnectable, plug in on base or chassis version.
Check the operating safety margin of the drawers, ease of operation,

inserting or extracting the drawers should be done without damaging the
internal component or wiring.
Equipment fixing
b check the fixing of the devices on the drawers, on Polyfast (Inspection
during manufacturing process), on mounting plates, on doors...
b check that they are correctly fitted and that all the necessary screws or
additional miscellaneous are present.
b a particular attention should be paid in regards of:
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v the respect of the assembly to the functional dimensions tolerances

v the jaws installation and validated in the check list
v check whether the auxiliary block are correctly identified, assembled
and that the mechanical assembly remain free of movement
Mechanical operation
b to be checked:
v the installation and operations of the position contact, door, drawer
position, extended rotary handle, etc
v the operation of the limit contact travel, drawers position, circuit
breakers, contact located on door
v the functional units (drawers, plug in, disconnectable...) operating
margin.
Mechanical setting and grease

Jaws
Check the power jaws plug-in penetrations and installation.
With Blokset, use the specific jig to control the bars position (jaws
operation).
Presence of electrical and mechanical grease

b the jaws lubrication
b mechanical parts lubrication.
Consult the technical product documentation.
Freedom of the power clamp fingers, contact pressure

Make sure that during the functional units manoeuvre, the various type of
power and command control clamp will not be damage.
Check carefully whether the contact pressure looks well spread off.
Accessibility
Accessibility of functional units or devices
Check accessibility of:
b the terminal, current transformer, etc.
Always check the ease access of:
v pivoting front face locking devices.
If stipulated in the project specifications, check also the access facilities
for thermography control.
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instructions
Installation and maintenance access

Check accessibility of:
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b joint, cubicle coupling accessories

b settings, HPC fuses for replacement, contactors coils, interlocking
mechanism, arc chute chamber.
In some particular case, (e.g. plug in auxiliary terminal block), check the
ease of removing them from their support in regards of the screws access
for modifications and maintenance.
The associated bundle should be long enough to have access to the
screw without difficulties.
6.2.2 Mechanical safety and locking system

Mechanical check of safety and locking system.
To be checked all mechanism making the different
manoeuvre (possible or impossible)
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Functional units pre tripping and lock

Check that during plug in or out operation of the functional units,
(withdrawable, disconnectable, plug in on base or chassis version) are
impossible when the device is closed.
(Pre tripping accessories, mechanical lock and / or micro switch)
Check pre-tripping of the devices, on plug-in and plug-out operations.
Devices on chassis, plug on base, drawers, disconnectable on strip,
contactors, etc..
Check the fuse blowing mechanical operation.
Fault trip and position indicator

Position of the mechanical indicators after operation, a fault trip, drawers
manoeuvre.
Check that the circuit-breaker is reset after an electrical fault trip or after
pressing the tripping test button. Check the position of the handle.
Be sure of the correct resetting of the devices and drawers after fault trip
or manoeuvre.
Safety systems
Ensure sturdiness of the various locking and mismatching systems.
a. interlocking
Check that closing of one device prevents closing of the other associated
one.
b locking by rods:
v check their mechanical fasteners and adjustment.
b locking by cables:
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v check its radius of curvature using the installation guide and ensure
that they are not running near exposed live parts
b locking by key-locks, check:
v the type and references of the key-locks
v that the key-lock prevents the device from operating.
b. Mismatching
Check that the code of the polarising slots matches the specifications
(drawers, devices on chassis).
c. Padlocking
Check the operation of padlocking (devices, drawers...).
b inter change:
v check the possibility of inter change of circuit-breakers or drawers
of the same type.
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instructions
6.2.3 Checking electrical link / Busbar

Conformity of electrical links
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Busbar
Type and characteristics
Check the bars characteristics according to the type of equipment,
the project specifications, the project design.
b cross-section:
according to nominal current (In), short-circuit current and / or peak
current, IP, circuit-breaker breaking time, etc.
Check that the cross-section corresponds to that shown in the project
production file and product documentation.
b coating:
check the type of busbars coating (bare copper, tin-coated, sheathed
busbars, epoxy paint, silver-plating, nickel, etc.).
Marking and phase order

b check phase labelling type conformity
b check that phase order (phases 1, 2, 3, neutral and PE) is respected
according to the product specifications.
Layout and installation

b check their position (horizontal, vertical, top, etc)
b check that the layout or arrangement of the busbars does not obstruct
the routing of client cable
b ensure the extension possibilities of the busbars according to specific
features
b spacing, fastening, characteristics and number of busbar supports.
Refer to technical documents, switchboard characteristics, etc.
b type of supports:
v check their type and characteristics (material) referring to the
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switchboard characteristics
v check the alignment of the support, presence of deformation due to
extra torque apply on the fixing bolt.
Bending radius and bar alignment

a minimum bending radius must be respected that is equal to r = 1.5 x e.
If the copper is of excellent quality (Cu ETP), we accept: r = e.
Check the perfect alignment of the different bar assembly:

b ensure a good positioning in the support
b make easier the insertion of the connection bolt
b avoid trouble (flexion, torsion...) on devices or terminal pads
connections.
Busbar joints
Joints cross-section
Characteristics and number
Check positioning and accessibility of the joints screws
Insulating distances versus frame, form partition, etc.
Cleanness
After busbars installation, ensure that no foreign body are lost in the bars
compartment.
In particular in the case of access difficulties.
According to the installation system and the procedure in use, this

verification should be authenticate using the check list.
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instructions
6.2.4 Checking electrical link / Flexible bars

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Flexible bars
Characteristics
Cross-section
To be checked according to the device and switchboard characteristics.
Installation
Radius of curvature of the flexible bars (at least once bar thickness).
Bending manual operations are recommended to avoid damage on the
bar insulator.
In the event of a superimposed flexible bar installation, ensure that
insulating spacers are placed between the conductors to provide proper
ventilation.
Binding
Check that the characteristics and number of bindings used matches with
the electro-dynamic force supposed to affect the assembly in case of
short circuit.
No direct binding on metal parts. If necessary fit an insulating wedge.
Check the connections: presence of the thick flat washer and the contact
washer.
6.2.5 Checking electrical link / Cables

Cables
Characteristics
Cross-section of power and auxiliary conductors:
b check cross-section referring to the switchboard specifications and
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product documentation.
Type and colours.
Nature of cables:
b Schneider recommends use of U 1000 V insulation and with an
insulation temperature resistance of < 105 °C (self-extinguishing).
By using these cables, we fulfil the class 2 requirement, so these cables
may be secured directly on metal supports.
Installation
Protection of cables:
b check that the cables do not run near sharp edges, moving parts,
against or between exposed live parts, blowing area, etc.
No cables must be inserted in ventilation grid hole or mechanical fixing
hole.
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Radius of curvature:
b ensure that the cable radius of curvature is roughly 6 to 8 times cable
diameter.
Number of cables per strand:

b refer to the switchboard assembly and installation guide.
Separating the strands:

b check that the power and control strands are separated as well as the
strands receiving an auxiliary voltage of more than 500 V AC as well as
DC circuit and communication network.
Cable fixing:
b make sure that the conductor are fastened in accordance with their
characteristics, size and network short circuit withstand. Check the collar
characteristic.
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instructions
Wiring in cable trunking:

b maximum cable size 6 mm² in cable trunking.
Ensure that the reserve in the cable trunking is approximately 30 %
and that their fasteners are preferably made of insulating accessories
(e.g. polycarbonate screws or rivets).
b the maximum centre distance between two trunking fasteners must not
exceed 600 mm.
Non protected active conductors

Ensure that the cable not protected by short circuit devices are installed
safely throughout their entire way.
Bundle separated, no risk of mechanical damage, safe connection, etc.
6.2.6 Connections / Screws and assembly

Connections / Screws and assembly
Tightening torque
In accordance with bolt, devices and other parts characteristics. Consult
the product and devices documentation.
Bolt characteristics and installation

Check the bolt type (in accordance with the product specifications),
quality: class 8/8, stainless steel, etc.
Bolt insertion way (insulating distance), length of bolt…
Check the Linergy sliding bolt position.
Presence, position and type of washer.
Presence of varnish certifying-tightening to the right torque.
In event of doubt:
v number of threads protruding from the nut, for connections of the same
type, differs on screws of the same length
v contact washers excessively crushed or moving, carry out a sampling
DD383166
check. If a number of faults are detected, ask the person responsible for
assembling it to verify all the connections of the switchboard.
Contact surfaces
Quality of drillings / punching and surface finish (no burr or cutting
deformations on the conductors, no oil stains, etc.).
Correspondence between the hole diameter and bolt.
The bar overlapping surfaces: H = e x n.
For all the non standard bar connections done under supervision of the
fitter, an overlapping height equal to 5 times the thickness of the derived
busbar must be counted in order to obtain a suitable connection.
6.2.7 Cables connections

Cable connections
Three types of inspection are performed according to the connections:
b visual inspection (A):
v of the crimping recess (quality, pressure, etc.)
v of the correspondence of the lug or terminal and the cable section
v of the position of the conductor core in the lug shaft, and proper cable
insertion
v of the bolt diameter versus the lugs fixing hole
v of the quality of the cable insulation and the strands (no damage during
cable installation or wire bare operation)
b mechanical inspection (B) by manual traction (performed by random
sampling)
b verification (C) of:
v presence and direction of contact washers
v presence of varnish certifying tightening to the right torque (on visible
connections) or use of torque nuts.
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instructions
The following table gives the inspections to be performed according to the

type of connection used:
DD383439
b where A, B, C stand for the various inspection types.

A = visual inspection
B = mechanical inspection
C = checking presence and positioning.
Connections Power Other circuits

Jaws and auxiliaries pins A+B A+B
Lugs A+C B+C
Clips - A+B
Cable connectors A B
Terminals B+C B
Screws C C
DD383440
Connection stresses and fastening

Check that the lugs match with the connector type.
Be sure that the cable are well inserted in the terminal.
Remind: make sure that the crimping tools are calibrated.
Accessibility and client connections facilities

Accessibility of power connection points on devices, and terminal blocks:
b within the respect of the cable curvature radius, of the cable routing
way (entry from the top / bottom)
b by checking the length of pads and number of connecting holes in
consideration with the size and number of cables (check the devices or
product information).
Check that:
b the number and cross-section of cables ensure compliance with
clearances (lugs)
Remind: arrange it on the way to ensure the safety of the operators
(maintenance).
b the number and sturdiness of the cable supports
b the ease of connection of client cable on earth or PEN bar nearby the
functional unit.
6.2.8 Clearances and creepage distance

Clearances
Shortest distance in the air between two live conductors or between live
conductors and exposed conductive parts.
b 14 mm for 12 kV impulse voltage (main busbar Masterpact)
b 8 mm for 8 kV impulse voltage (Compact)
b 5.5 mm for 6 kV impulse voltage (Multi 9).
DD383182
The IEC 60439-1 stipulate the minimum clearances required to withstand

impulse voltage up to 2000 m above sea level.
Pollution degree 3.
Creepage distances
Shortest distance along an insulated material surface between two live
conductors or between live conductors and exposed conductive part.
b 16 mm for rated insulation voltage 1000 V AC and DC (main busbar
Masterpact)
b 12,5 mm for rated insulation voltage 750 V AC and DC (Compact)
b 8 mm for rated insulation voltage 500 V AC and DC (Multi 9).
See IEC 60439-1 table 16.
Pollution degree 3, Material group 3a.
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instructions
6.3 Electrical operations checks

6.3.1 Electrical tests
Operating sequences
Equipment preparation
Connect the equipment circuit and be sure of the earth link between
section.
Before energising, open the auxiliary control devices (relays, measuring
instruments, coils, etc.).
Supply the switchboard with the control desk, ensuring that voltage and
phase rotation direction is respected.
Checking the power circuits

Carrying out the operations:
Open all the devices.
b check the order of the phases
b check correspondence of the circuit and conductor identification
b check the correspondence of the phases at each devices by closing
them one by one from line side to load side (see example below).
Testing is always performed downstream of the devices in order to
check its poles at the same time. However a different method can be
used.
b example:
DD383157
When the devices are link to terminals or pads, perform the tests on them.
Checking the control circuits

Check the power supply of the auxiliary circuits by examining phase order
at their associated control devices.
Remind: a particular attention should be done on the non protected circuit
(see chapter 7.5.5 IEC 60439-1).
Electrical indicator light and command button:

b check the function of the indicator lights
b ensure the correspondence of the command button with associated
devices.
Remote / local operating mechanisms:

b check their operation. If necessary use accessories (pin tip, small box
equipped with pushbuttons, indicator lights, etc.).
Supply circuits:
b systematically check the electronic switchgear supply circuits and the
DC circuits using a tester (voltmeter).
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instructions
Check the information supplied on the connection terminals:

b contact status
DD383189
b remaining information (voltage, current, etc.).
Motor mechanisms
Close the relevant protection devices.
Activate the operating mechanism of the devices according to the
command diagram, local, remote, automation...
Electrical locking
Check that it is impossible to close a device equipped with a locking
contact.
Metering circuits
Check the winding direction, the inlets and outlets characteristics of the
current transformers.
To check the metering circuits, the CT secondary must be supplied using
DD383436
a phase shift box (failing this, you can use any other calibrated device
offering the same possibilities).
b example of carrying out the operations:

v select the supply voltage
v adjust the maximum value of the current to be injected in the secondary
circuit
v inject the current in one of the circuits or in all three at once to check
cabling.
Checking the test function

Circuit-breaker operation is checked by a variety of tests according to
device type:
b earth leakage module test (Multi 9 range, NS range):
v close the circuit-breaker
v press the test button of the Vigilohm part. This test is used to regularly
check device tripping by simulating an earth fault
b trip unit test (NS and Masterpact range):
this test is performed using an external electronic tripping box
v close the circuit-breaker
v make it trip using the box by connecting its cord to the specially
provided socket on the front face of the trip unit part
v for increased dependability, repeat this operation.
If the circuit-breaker opens for each test, the device operates correctly.
Voltage relays, time delay relays, fault tracking devices

For the voltage relays, check that the contacts are in the status defined in
the electric design.
For the time delay relays, check correct operation of the time delays.
If mentioned, check that these settings comply with the project design file.
For the fault tracking devices, create a fault and check that the device
detects and indicates its presence.
In order to create a fault, a resistance box can be supplied:
b pre-set the value of the resistance required to create a fault according
to fault tracking devices characteristics
b make the resistance vary by reducing its value. When the resistance is
adjusted below the pre-set value, the device must indicate the fault.
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instructions
Second routine test

Protective measures & protective circuit
6.3.2 Protective measures and electrical continuity

of the protection circuits (standard IEC 60439-1
paragraph 8.3.3)
Monitoring protection circuits
The inspection is either visual and / or electrical as required
by the customer.
DD383168
Mechanical inspection (Visual)

PE and / or PEN protection bars.
Check the presence of all the constituent elements of the assembly which
guarantee the electrical continuity between the metal part and the earth
bar (see technical file).
Cross-section in accordance with electrical characteristics.
Presence and cross-section of the joints between the cubicles, they

should be at least equal to the cross-section of the PE / PEN bar to be
connected.
Depending of Earth/Neutral link systems, check presence of the PEN / PE

disconnecting link and access.
Ensure that its cross-section is the same as that of the earth bar.
DD383183
Check
b that the protective conductors are identified by the two colours
green / yellow marking plus PE or PEN lozenges
b the accessiblility of the terminals for external conductors
b the contact efficiency between section or parts of the protective circuit
b the presence of only one conductor per connection on the protective bar.
If, for maintenance reasons, a part of the equipment is removed from

the enclosure, the protective circuit of the other parts should not be
interrupted.
Electrical inspection
N.B.:
There is some electrical measuring devices enable to perform this test.
The above method is given only for information.
Example of operating mode:

b a DC source is used, with an electromotive force of less than 6 V / 2 A
current is injected between the inlet of the earth busbar and the parts to
be inspected (doors, front face, frame, etc.)
DD383162
Measured resistance: R = U/I
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instructions
Result:
b the inspection is satisfactory if the measured resistance between the
circuits and exposed conductive parts is below 0.1 Ohm.
Register the result on the final inspection record list
6.3.3 Operator safety

Protection of persons
During normal operations

b devices adjustment
b operating handle access
b drawer operation.
Be sure that the persons are protected during the following operations:
b pre-tripping of devices on plug in and plug out operation
b operating safety
b drawers mechanical locking.
During maintenance and safety operations (emergency stop,

padlocking...)
Warning plate:
PE50654
b check the presence of the different warning plate such as “do not step”,
“danger”, “danger supply side”, advertising plate for voltage equal or over
660 V or form door
b etc.
No live part nearby the operating handle, adjustment screw, etc.
Plug-in protection flaps

Check the presence of the plug-in flap: chassis, etc.
Insulation screen / phase separator / terminal shield

Check they are fitted (if required), firmly fixed and linked to earth for the
metallic one.
Conformity of partitions and form

PE50655
Check the presence of all the screen, form partitioning, protection cover of
the devices located on the door (direct contact).
Protection against contact

This inspection is performed by checking the presence of component
parts such as:
b picot washers
b earthing braids, doors, devices chassis (according to type and
installation mode)
b barriers, front plate, etc.
For earthing braids, check their withstand by exerting a slight pressure on
their connections.
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instructions
Third routine test

PE50656
Dielectric test
6.3.4 Dielectric withstand (Standard IEC 60439-1

paragraph 8.3.2)
Dielectric test
Preparation
The dielectric test is always performed before the insulation test.
Before performing the test, make sure that you disconnect:

b the surge absorbers (if any)
b the covers from the Vigi modules of the Compact NS
b the electrical control motors
b and any other device not withstanding the applied voltage (electronic
switchgear, contactor coils, indicator lights, miniature relays, horn,
measuring instruments, etc.).
The interference suppression capacitors installed between the live parts

and the frames must not be disconnected, but be able to withstand the
test voltage.
This test does not need to be made on auxiliary circuits which are
connected to the main busbar if it:
b is protected by a device of rating < 16 A
b has previously undergone the operating tests (IEC 60439-1
chapter 6.3.2).
N.B.:
Check that no unprotected connections are left.
For example: remove the neutral connection wire for the permanent
insulation measurement.
Operating mode
Perform this test using a dielectrometer (or dielectrimeter) designed
to deliver a variable voltage 0-5000 V AC.
Voltage to be applied:
Rated insulation voltage Ui Dielectric test voltage
Main circuit 300 V < Ui y 690 V 2500 V
800 V < Ui y 1000 V 3500 V
Ui y 60 V 1000 V
Auxiliary circuit Ui > 60 V (2 Ui + 1000) V with 1500 V min.
Apply voltage in turn on each phase and on the other phases which are
inter-connected and brought back to the switchboard frame.
The standard stipulates that this test voltage must be maintained for one
second.
N.B.:
If, for any reason, the dielectric test must be repeated, it will be done with
voltage lowered to 85 % of the previous value.
Carrying out the operations

Example of the phase live part test:
b all switching devices shall be closed
b interconnect the exposed conductive parts and earth them
b interconnect the live parts to one another and then to the assembly
conductive parts
b connect the measuring instrument earthing wire to the assembly frame
b connect the injection cable to the circuit to be monitored and gradually
increase voltage up to the required value
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instructions
b the test voltage should be applied for 1 second

b gradually reduce voltage before disconnecting
b once this check is complete, repeat it for the other live circuits.
Result
The tests are satisfactory if there is no puncture or flashover.
Register the result on the final inspection record list
6.3.5 Insulation resistance

Insulation resistance measurement
Preparation
Before performing the test, make sure that you disconnect:
b the surge arrestor (if any)
b the covers from the Vigi modules of the Compact NS
b the electrical control motors
b the current consuming devices, so as not to create connections
between the live conductors and the loads such as measuring
instruments, coils, relays, indicator lights, contactor electromagnets, etc.).
Operating mode
Using an insulation measuring instrument (megohm-meter), measure
insulation at a voltage of 500 V DC.
This measurement is apply between each live parts and the other
interconnected parts of the assembly.
Carrying out the operations: The procedure is the same as the one used
for testing dielectric withstand.
Result
The test is correct if insulation resistance between the circuits and the
frame is at least 1000 Ω/V with respect to the nominal voltage of this
circuit.
Register the result on the final inspection record list.
6.4 Prior dispatching checks

Prior dispatching checks
6.4.1 Cleaning
Prior the packing, check that the equipment is clean:
b no dust
b no foreign body forgotten in the equipment.
Remind:
See chapter 3.2 about the assembly for witch the access is difficult at the
final inspection stage.
6.4.2. Miscellaneous
From a detailed check list establish by the design office, perform the
inspection of:
b all the equipment to be delivered separately, spare parts, devices
dismantled for transportation, etc
b roof, coupling screws
b busbar joints, etc.
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instructions
Documentation
Presence of the name plate and / or the “as built design”.
Make sure that all the documentation associated to the quality inspection
procedure are fulfil:
b missing part list
b final inspection report
b checking program
b corrective action form
b non quality record board
b delivery note
b etc.
Associated documentation delivered with the equipment:

b devices and switchboard technical documentation
b maintenance documentation
b missing part list
and on demand
b final inspection report.
Be sure that all internal devices or other parts are well secured,
inserted or locked in the switcboard
6.4.3. Packaging
Inspection of the packaging before delivery according to:
b the type of good to be carried
b the transportation means
b the destination
b the condition of storage
b the climate conditions.
PE50657
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Quality inspection: Summarising of final inspection
instructions operations
7.1 Comprehensive list of points

to be checked
This non exhaustively list contains a description of the various

verifications to be carry out during the final inspection stage.
She can be usefull to help you to draw up your own checking programme
according to the product implemented in your workshop or manufacturing
process.
Example: list dedicated for functional units (drawers).
General information’s
Product: .........................................................................................................................................................................
Client reference: .........................................................................................................................................................................
Project name: .........................................................................................................................................................................
Project identification: .........................................................................................................................................................................
Drawing number: .........................................................................................................................................................................

Index
Quality inspector .........................................................................................................................................................................
Date: .........................................................................................................................................................................
Technical information’s
Ambient temperature
Degree of protection .........................................................................................................................................................................
Form
Withstand ..............................................................................................................................................................kA/sec
Operational rated voltage .........................................................................................................................................................................
Cable entry / exit Top Bottom Other
IEC 60439-1 reference standards
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1. Composition
Number of cubicles
Order of cubicles
Project and switchboard identification markers
Cubicles identification
Dimensional inspection – Switchboard – Length – Width – Height – Depth
– Fixing points.
2. Appearance
Paint colour and reference
Homogeneity
Finishing
Front face and mimic diagram
3. Framework
Panelling / Operation of doors and mechanical accessories
Inspecting key lock and number
Frame mechanical assembly
Handling device
Check the degree of protection
4. Conformity of the devices installed

Location and identification
Conformity of the devices installed
Their type and rating
Device breaking capacities
Devices accessories conformity
Safety perimeters
5. Mechanical check
Manual operation of mechanism
Operating safety (jamming – safety margin)
Devices accessibility
Equipment fixing
Limit travel contacts: circuit-breaker - drawer - etc.
Jaws installation
Grease
6. Accessibility
Functional units or devices
Access for installation, joint, junction kit, floor fixing bolt
Access for maintenance operations
7. Mechanical setting
Power plug-in penetrations
Freedom of the power clamp fingers – of contact pressure
Auxiliary block installation
8. Checking mechanical safety and locking system

Fault trip and position indicator
Tripping on fuse blowing
Devices interlock mechanism assemblies (Normal/Standby Source
Changeover devices)
Pre-tripping of devices on plug-in and plug-out operations
Correct resetting of devices after a fault trip (circuit-breaker, relay, etc.)
Impossibility of plugging in a drawer when the device is closed
Impossibility of plugging out a drawer when the device is closed
Sealing flaps on the power circuits
Sturdiness of the locking systems by key-locks or padlocks
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9. Checking the electrical conductors and links

Busbars
Checking the busbars:
b type and characteristics
b phase order and identification
b layout and installation
b bending radius and bar alignment
b supports characteristics and installation (conformity with product
technical file)
b busbar joint characteristics
b cleanness
Flexible bars
Checking the flexible bars:
b type and characteristics
b installation
Cables
Protection of cables
Separation of strands for auxiliary U u 500 V DC – AC
EMC compatibility installation rules
Wiring trunking (reserve in trunking: 20 %)
Type and characteristics

Power conductors
Auxiliary conductors
Phase order and identification
Installation
Protected from sharp edges or moving parts
Non protected active conductor installation rules
10. Conformity of the electrical connections

Checking
Tightening torque
Busbar overlapping / Contact surfaces
Bolt characteristics and installation
Checking crimping
Power cables
Control cables
Connection stresses and fastening
11. Conformity of connections facilities

Possibility of connecting cables to pads or terminals
Client power incoming and outgoing route with respect to cross-section:
b from the top
b from the bottom.
Client auxiliary incoming and outgoing route
Cable fixing:
b number of cable supports and sturdiness of tightening.
Proximity of PEN / Earth connection facilities.
12. Clearances
Inspection
Clearance:14 mm
Creepage distances:
b 14 mm for rated insulation voltage 750 V AC and DC
b 16 mm for rated insulation voltage 1000 V AC and DC.
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13. Operating inspection

Wiring and the various operating sequences
Power circuit conformity
Electrical controls and mechanisms
Local and remote controls
IT inlets and outlets
Winding direction
Electro mechanical indications
Electrical locking
Protection and metering circuits
14. Monitoring protection circuits

Visual
Cross-section of the protection conductor.
Electrical
15. Protection of persons

During normal operation
During safety operations
Pre tripping:
b contactors
b fuse blowing
b drawers operation
b devices tripping accessories.
Presence of flaps, cable head outlet pads (as per Specification)
Phase separator, terminal shield
Rigidity of plates, protection grids.
Presence of door earthing braids
“Man struck by lightning” plates for U u 660 V on form door
“Danger” supply side plate
“Do not step” or other advertising plate
IP of the device located on or through door.
16. Interchangeability of drawers

Polarisation
Electrical interchangeability between drawers and circuit-breakers
17. Measuring dielectric withstand

Circuit tested ϕ1 ϕ2 ϕ3 N Aux
Nominal voltage
Applied voltage
Result (1)
(1) Passed / not passed.
18. Insulation resistance measurement

Circuit tested ϕ1 ϕ2 ϕ3 N Aux
Nominal voltage
Insulation resistance
Result
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19. Inspection prior to dispatch

Roofs, seal covers and fixing screws.
End panels and fixing screws.
Sealing flaps (+ screws), openings for access to the cubicle anchoring
points.
Cubicle coupling screws.
Conformity of cut-outs in the separation plates for insertion of the transfer
busbars (or cables).
Seals according to the IP (those mounted after installation).
Joints (nature) and associated screws.
Circuit-breaker extraction crank handles: - Masterpact – NS/NT, etc.
Device lifting handles.
Extraction clamps for L fuses.
Accessories for protecting wires between cubicles.
Separate equipment.
Cubicle anchoring bolting (if stipulated in Specification).
Devices dismantled for transportation.
Door handle keys: key-locking.
The list of equipment not delivered (missing).
Cleanness.
Associated documentation.
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Quality inspection: Summarising of tasks after final
instructions inspection stage
After final inspection and according to contract clauses, the Quality

inspector may run a check of the project accompanied by a sales
engineer and the client or his representative. During acceptance
procedure, the client ensures that the specifications have been respected.
N.B.:
The procedures mentioned in this guide are given as per indication.
After final inspection, the followings are required:

b check that all the boxes of the checking program have been filled in
b check any reworks noted on the “non quality record board” and sign in
the relevant boxes
b record and draft the final inspection report
b note the final inspection report registration number on the checking

program
b ask the quality manager to validate the report (1)
b draft and record the delivery sheet.
(1) The final inspection should be signed by the client or his

representative after client acceptance inspection.
PE50658
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Quality inspection:
follow up
PE50659
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Quality inspection: Quality dashboard
follow up
8.1 Purpose
This dashboard allows the measurement of the quality performance and
reveal the necessary corrective actions to implement.
8.2 Principles
The quality assurance manager issues a monthly quality report entitled
“Quality indicator report”.
Performance is evaluated according to the four indicators below:
b purchased non quality
b produced non quality
b non service quality
b external non quality.
DD383161
The non quality index:

b is an indicator used to measure changes in non quality
b defines the target aims
b reveals the weaknesses of the various operations and allows the
relevant actions to be taken.
These non quality indices can be calculated using specific formulas (see
chapter 9.3).
The index witch is directly associated to the final inspection is “produced
non quality”.
Purchased non quality can be monitored by different indicators

depending on the supplies origin:
b global ratio
b ratio of the supplies purchased
b internal manufactured supplies ratio.
External non quality:

b taking clients complaints into account (intermediate or end users).
8.3 Produced non quality

This index is calculated after the final inspection process using
the “non quality record board”.
It is calculated using this formula:

Non quality index = Sum of weighted faults
Total number of cubicles*
The faults revealed by the quality inspection are assigned according

to their origin to the production, the project design department or sales.
The faults are classed in 3 categories:

b minor: a fault corresponding to a non conformity
b major: a fault risking a considerable reduction of the achievement
of a function in the switchboard.
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follow up
b critical: a fault which, according to judgement and experience, is likely

to result in a lack of safety or risk of accidents for the user. It presents a
real danger for persons and equipment.
Weighting
The weighting applied to these three types of faults is:
b minor fault = 1
b major fault = 3
b critical fault = 10
Produced non quality is monitored by means of indicators for each

type of product and a global indicator.
Remarks:
Note 1: in the distribution switchboards (PCC), the number of cubicles
indicated corresponds to the number of cubicles produced.
Note 2: in the motor control panel (MCC), the rules are as follows:
v Framework = 0.3 cubicle
v < 12 m (1) drawers or functional units = 0.1 cubicle
v u 12 m (1) drawers = 0.2 cubicle
(1) Modules.
b example of a MCC cubicle made up of:

1 framework (1 x 0.3) = 0.3
2 drawers 250 A 6 modules (2 x 0.1) = 0.2
Total = 0.5
Cubicle equivalent = 0.5.
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follow up
8.4 Example of a Produced Non Quality

index board
Product Number Non conform Faults Responsibilities Weighting version
Nbr % A B C Weight. total Prod. Project Ext.
design dept.
Equip. 1 12.0 3 25 5 2 0 11 4 2 1 0.92
Equip. 2 5.0 4 80 3 3 1 22 3 1 3 4.4
Equip. 3 8.0 4 50 4 0 1 14 4 0 1 1.75
Total 25.0 11 44 12 5 2 47 11 3 5 1.88
Equipment 1: Prisma Plus A: Minor = 1.

Equipment 2: Prisma Plus B: Major = 3.
Equipment 3: Okken C: Critical = 10.
DD383160
Example of a graph showing the ‘‘non quality index’’.
The peaks shown on the graph may be due to:

b the number of projects handled
b the complexity of certain projects (complicated operating sequence)
b insufficient personnel training
b insufficient sensitivity of personnel
b poor control of supplies
b poor quality of the project production file.
8.5 Non conformity weight example

Item Description / Description Poids /
Weight
1 Labelling 1
2 Wire marking 1
3 Wiring aspect 1
4 Accessibility of equipment 1
5 Fixation of apparatus 1
6 Space for customer connection 1
7 Bad crimping 3
8 Auxiliary wire section 3
9 Auxiliary protection rating 3
10 IP degree 3
11 Earth connection 3
12 Phase polarity 3
13 Electrical sequence operation 3
14 Auxiliary wire damages 3
15 Power wire damages 10
16 Insulating distance 10
17 Power cable or bus bars cross section 10
18 Protection devices conformity 10
19 Number and clearance of busbars supports 10
20 Interlocking 10
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Quality inspection:
facilities and calibration
PE50660
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Quality inspection: Facilities
9.1 The Quality Inspector’s individual tools

PE50661
These are the switchboard fitter’s tools (screwdriver, wrenches, etc.)

with in addition:
b a small rule or measuring rods to check clearances
b a lamp
b an articulated mirror
b a set of crocodile clips
b a bell tester
b set of probe fingers
9.2 Common means of the quality

inspection
b control desk:
PE50662
enables to energised the main and auxiliary circuits. Equipped with a

voltage variator and a number of selector switches and indicators, to
make easier the various operating sequences.
b dielectrometer:
to perform the dielectric test followed by the insulation resistance one.
b megohmmeter:
to perform the insulation resistance test
b earth continuity tester
b phase order tester
b drawers test equipment
b test cords and a variety of plugs, supply cords and other connection
systems
b steps, pallet-mover or other transportation facilities.
9.3 Quality inspection zone

b is independent from production
b must be physically separated from the other departments:
v for reasons linked to the hazards of electrical current
v for protection of people and equipment
b is clearly marked out (tapes, partitions, etc.)
b is clearly indicated (warning beacon, flashing light, sign, etc.).
This area should be equipped in compliance with applicable legislation

and local regulations.
PE50664
9.4 Necessary documents

b to carry out the various checks, the quality inspector must have:
v a complete, updated production file of the project, check list
v a missing parts list
v update procedures and associated document
v updated products documentations (devices, equipment system...)
v standards.
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Quality inspection: Control of inspection means
10.1 Purpose
The purpose of these operations consist in controlling the inspection and
production means used in the unit for maintenance and calibration.
To get a mark out of the tools on the way to perform possible correctives
actions on the delivered equipment.
10.2 Reminders of basic principles

Inspection means
List and identify the inspection means.
Have them checked at specific intervals, according to the accuracy

of the measurements to take, by an approved international or national
organisation.
(For example, the organisation for France is the B.N.M. – National
Metrology Office).
Identify by a label “not followed up in calibration”, the devices not

assigned to measurement (e.g. power on detection devices).
Store, use and transport these means in conditions guaranteeing their

proper operation and level of accuracy.
Rule on the project equipment delivered and inspected using non conform
measuring instruments.
Production means
Torque wrenches.
Crimping means.
10.3 Responsibility
The inspection and production means responsible appointed by the
quality manager is in charge of:
b listing and identifying these means
b implementing and monitoring the checks
b decision-making after checking
b archiving the documents.
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10.4 Diagram of operations
DD383159
10.5 Application rules

10.5.1 Choice of means
Inspection and production means are chosen according to:
b the type of measurement
b the theoretical values to be measured
b the required accuracy
b the type of process to be done.
10.5.2 Classification of means

For checking follow-up:
b all the inspection and production means identified and monitored.
The items of equipment identified by a label “not followed up in
calibration” and listed on the associated document are used as indicators
only.
10.5.3 Checking frequency

DD383187
Inspection means
The normal frequencies chosen are:
b 1 check once a year for normally used inspection means
(type: dielectric-meter, etc.)
b 1 check once every 2 years for seldom used inspection means.
Production means
Torque wrenches:
b must be calibrated once a year at least.
Crimping means:
b must be checked once a year.
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10.5.4 Listing and monitoring the inspection and

production means
A list of inspection and production means, plus a checking schedule are
updated by the quality manager.
Each inspection and production means has a life sheet, which is opened
for each acquisition and completed after each check by the manager.
A label is placed on tools by an authorised organisation.
It gives the check date and the date of the next one to be carried out.
The checking reports, measurement readings and non conformity sheets
transmitted by the organisation are filed with the life sheet.
10.5.5 Occasional checks

These checks must be performed after:
b acquisition of a new inspection and production means (without
verification or conformity certificate)
b an impact
b a repair
b a loan
b a long period of inactivity.
10.5.6 Devices outside the accuracy class

Should the calibration organisation declare the inspection means to
fall outside the accuracy class, it is up to the manager to isolate it and
implement one of the decisions listed below:
b repair
b downgraded to an operation means not assigned to measurement
(indicator only),
b scrapping (most of case for production means).
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The calibration manager must also decide whether to initiate a notification

of non conformity (NNC) used to rule on project equipment delivered
which was inspected using the defective device in question as follows:
DD383158
(*) See the example of Notification of Non Conformity.
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Quality inspection:
appendix
DD383437
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Quality inspection: Form example
appendix
Follow-up of missing parts

2. Follow-up of missing parts at end of project
Project no.: .................................................. Date received by client

or factory availability lead time .........................................................
1 - Missing at end of assembly
Issued by: .................................................... (copy) V Q.I.

Date: .............................................................
Items Project co-ordinator Quantities Supplies

References Lead time announced
2 - Missing parts at end of inspection/customer acceptance
Issued by: .................................................... (copy) V Q.I.

Date: ............................................................. (copy) V Warehouse
Items Project co-ordinator Quantities Supplies

References Lead time announced
3 - Sales department notification
Can the project be dispatched with missing parts? Yes No
Can the missing parts be partially dispatched? Yes No
Which ones? ..............................................................................................................................................................................
Missing parts dispatch address: ............................................................................................................................................
....................................................................................................................................................................................................
Project site delivery date: ........................................
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appendix
Checking program
Checking program
Product : .................................................................... Final inspection registration n° : ................................

Drawing n° : .................................................................... Index : .......................... Client : .......................................................................
Tendering : .................................................................... Project n° : .................................................................
Design : ....................................................................
Assembly : ....................................................................
Quality : ....................................................................
Cubicle identification : Continuous inspection Quality inspection
Observations (1) Checked by Checked by Repair Conform Nb of faults
1 Number, identification and dimension of cubicle
2 Paint - aspect -
3 Framework assembly - handling devices - keys
4 Protection index
5 Devices location and identification
6 Devices label conformity, circuit identification
7 Devices accessories
8 Current transformer characteristics and installation
9 Fault trip - mechanical pre-tripping function
10 Clamps installation and grease
11 Bus bars characteristics
12 Bars and supports installation
13 Connection conformity
14 Tightening - varnish
15 Conductors identifications
16 Insulating and creepage distances
17 Cleaning
18 Devices mechanical function
19 Devices characteristics
20 Operating and maintenance access
21 Terminal pads conformity (cable entry and size)
22 Devices safety perimeter
23 Conductors characteristics and installation
24 Monitoring of the protection circuit
25 Electrical operating inspection
26 Insulating test
27 Dielectric test
28 Form partitionning
29 Final inspection record
30 Customer acceptance report
31
32 Missing part list
33 Drawing “as built”
34
35 “Non quality” record board
36 Devices specification sheet
37 Packaging
38 Separate equipment delivery
39
Checking during process: fulfil the grey box

Final inspection and test: fulfil the white box
(1) N.B.: tick the box and annotate the observation on the event record sheet Date. : ........ /........ / ........
Fulfil the box with NA for “not applicable mention”.
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appendix
Non quality record board

Non quality record board
Quality inspector: Manufacturing: Project name: Date:
Product: Quantity: Job number:
Number of faulty column: Client:
Number of drawer: Repair action
A: minor fault B: major fault C: critical fault A B C A B C Repaired Checked by
Localisation and type of fault Design / tendering Manufacturing By: Duration Q.I.
Sum of faults Page:
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appendix
Corrective action request

Corrective action request
Action request of: ..............................................................
Date: ...................................................................................
From: ................................................................................. To: .................................................................................
Copy to: ........................................................................
Non conformity detected by customer Detected internally
Concerned product: ............................................ Project no: ..........................................
Issued by: ............................................................. Date : .................................................. Customer: ...........................................
Description of the non conformity
Any sugestions
Answer
Corrective actions Perfomed by Date
Corrective action settled Date: .................................................. Quality insurance. signature
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appendix
Final inspection report

Procès verbal de contrôle final / Final inspection report
Client : ................................................. PV n° / Registration Nr ....................…............................….......
Affaire / Project : ................................................. N° Cde client / Client ref. : ...............................……....……....…
Nom du tableau / Switchboard identification ............................ ....................……....................…….....................……....……....…
.......…………….........…………….........…………............................
N° affaire / Job ref. : ....................……........................……....…
Produit / Product : .................................................
Quantité / Qty : ................................................. final check delivery
Plan n° / Drawing n° : ................................................. Indice / Index:
Gamme de contrôle / Checking program

1. Contrôle de conformité / Conformity checking
- Les enveloppes / Enclosures ...........................................................
- L’appareillage / Switchgear ...........................................................
- Les conducteurs / Conductors ...........................................................
2. Vérifications mécaniques/ Mechanical checking ...........................................................
3. Essais electriques / Performances electric test ...........................................................
4. Continuité électrique des masses mécaniques Visuel / Visual

Exposed conductive parts electrical continuity
Electrique / Electrical
Réf. Appareil / Measuring device ref. ...........................................................
Valeur / Value ...........................................................
5. Essais diélectriques / Dielectric test Réf. Appareil / Measuring device ref. ....................
Circuit / Circuit Auxiliaires / Auxiliaries Puissance / Power

Tension nominale / Nominal volt V
Tension injection / Injection volt V
6. Essais d’isolement / Insulating test Réf. Appareil / Measuring device ref. ....................
Circuit / Circuit Auxiliaires / Auxiliaries Puissance / Power

Tension d’applicat. / Applied voltage V
Valeur d’isolement / Insulation value V
Observation / Comment:
...................................................................................................................................................................................................
...................................................................................................................................................................................................
Inspecteur client / Client représentative Inspecteur qualité / Quality inspector Respons. I.Q /
Quality manager
.......................................................................... ....................................................................
.......................................................................... .................................................................... .....................................
Date ...................................... Date ...................................... Visa
......................................
Visa ...................................... Visa ......................................
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appendix
Missing parts list

Entity Plant
Tel : 00.00.00.00.00.
Fax: 00.00.00.00.00.
1. Missing parts list / Liste des composants non expédiés avec l’affaire
Project number / N° d’affaire : .................................................
Item / Poste Designation / Désignation Quantity / Quantité
Quality control / Contrôle qualité
...................................................................................................................................................................................................
Quality inspector / Inspecteur qualité
...................................................................................................................................................................................................
Date ......................................
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Quality inspection: Glossary
appendix
Abreviations
B.N.M.: National Metrology Office.
L.V.: Low Voltage.
I.E.C.: International Electro-technical Commission.
Dielectrimeter: A device used only to perform dielectric tests.
Dielectrometer: A device used for withstand testing. It measures
dielectric withstand and insulation resistance.
I.P.: Degree of Protection.
Q.I.: Quality Inspection.
N.N.C.: Notification of Non Conformity.
I.T.P.: Inspection and Test Programme.
P.E.: Electrical Protection.
P.E.N.: Electrical Protection and Neutral.
C.T.: Current Transformer.
MCC: Motor Command and Control
PCC: Power Command and Control
Vocabulary
Main definitions
(Standard ISO 9000)
Quality
Degree to witch a set of inherent characteristics fulfils requirement
Quality audit
Methodical examination of all the measures described in the quality
manual and his relevant procedures, in co-operation with the involved
parties. This on the way to evaluate whether the real statement of the
plant is in harmony with the description of the quality manual.
Quality management
Co-ordinated activities dedicated to direct and control an organisation
with regard to quality.
Also include the evaluation of the results and the correspondent cost.
Quality manual
Written documents specifying information about the quality management
system of an organisation.
Quality plans
Documents describing how the quality management system specify witch
procedures and associated resources shall be applied by whom and
when, on the way to obtain the quality level of the considered project,
product, process or contract.
Also called “quality insurance program”.
Procedures
Specified way to carry out an activity or process.
Written document describing the organisation and manufacturing method,
control, inspection, checking, assessment, corrective actions intended to
be strictly applied on the way to reach the predefine quality level.
Inspection
Conformity evaluation done in the scope of defined process by
observation, measurement, testing or gauging.
Non conformity
Non fulfilment or deviation of a need or expectation with respect of the
specified requirement.
Traceability
Ability from registered identification, to trace the history process and the
location of the product after delivery.
Schneider Electric
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DESW048EN © 2006 - Schneider Electric - All rights reserved
Schneider Electric Industries SAS

89, boulevard Franklin Roosevelt As standards, specifications and designs change from time to time, please ask for confirmation
F - 92500 Rueil-Malmaison (France) of the information given in this publication.
Tel : +33 (0)1 41 29 85 00
Printed on recycled paper.
http://www.schneider-electric.com
http://www.merlin-gerin.com
Design: Schneider Electric
Photos: Schneider Electric
Printed:
DESW048EN 04-2006

Low Voltage Switchboards: Quality Inspection Guide

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Quality inspection guide

Low voltage switchboards

But what exactly do we mean by Quality ?

The standard ISO 9000 defines the quality as:

This stage must be performed with care and rigour,

The quality is also the willingness of all the staff,

Quality inspection: means and process 3

Introduction to the quality inspection 4

Incoming delivery inspection 7

Quality inspection: instructions 15

Performing in-process inspection 16

Performing the final inspection 17

Summarising of final inspection operations 33

Summarising of tasks after final inspection stage 38

Quality inspection: follow up 39

Control of inspection means 45

Quality inspection: appendix 49

1.1 Justification of quality inspection

Each job must be checked.

a good economic management of the switchboard manufacturing process.

1.2 Quality inspection function

1.3 Quality inspection responsibility

1.4 Quality inspector’s profile

1.5 Necessary documents

1.6 Required human resources

Applicable to the external and internal goods or assembly.

procedure could be used to perform a final inspection of one process,

2.1 Justification of the incoming inspection

Non conformity processing

All precautions should be taken to prevent their repetitions.

3.1 Inspection during manufacturing

The following diagram represents the operations on which in-process

3.2 Justification of the inspection during

The assembly operations requires constant carried out

Final inspection guarantees operation and conformity of products with

A document per project formulating the customer’s requirements and

4.1 Final inspection process

The final inspection takes place as follows

Ensure reworking for conformity.

b if customer acceptance is scheduled, receive the customer and / or his

List of the various final inspection tests:

4.2 Operating rules

4.3 Non conformity treatment process

Non quality record board Corrective action

4.4 Conformity declaration

Job n°: ……….…....….. device Mechanical check

Switchboard: ………… power Electrical test

Cubicle: ………………. auxiliairies Dielectric test

Equipment n° / finishing Protective measures

Rating: ……………….. Insulating test

Design n°: …………… Index: ………………

Only fully inspected cubicles can be dispatched.

Final inspection sheet

Switchboard designation: …………... Design file reference …………...

Final inspection report n°: …………... Issue on: …………

Quality Inspector Date: Quality Manager

Instruction (dictionary definition)

This process concerns all the manufacturing operations done

It is used from the first assembly phase through to final inspection.

This check list should mention:

On completion of the inspections, a copy of this sheet is archived.

The Quality Inspector must:

First routine test / Inspection of the assembly