QCB Rev B May 2013

Quality Code Book for
LV Switchboard Channel Processor

Updated : May 2013
Siemens Ltd.
IC LMV MS O-AIS (LV)
Kalwa Works
s IC LMV MS O-AIS (DS)
Quality Code Book
Contents
Sr.No. Description Page No.
Contents 1
Authorisation 3
Distribution 3
1.0 Busbar Manufacturing & Assembly 4
1.1 Busbar Fabrication 4
1.2 Busbar Marking 4
1.3 Busbar Jointing & Treatment 5
1.4 Busbar Sequence 10
1.5 Busbar Insulation 13
1.6 Power Terminal Fasteners 15
1.7 Vertical Earth Busbar 15
2.0 Equipment mounting & wiring 16
2.1 Mounting & Colour coding of Pushbuttons & Lamps 16
2.2 Mounting of Equipment plates on panel structure 20
2.3 Mounting of Instrument Plate Sub-assembly on Trolley Frame 20
2.4 Mounting of Switches / Drives 21
2.5 Mounting of Equipment 21
2.6 Equipment Marking 22
2.7 Marking of Wires 23
2.8 Colour Coding of Wires 25
2.9 Wiring of Equipment 26
2.10 Wiring routing through Channels 29
2.11 Selection of Wire Sizes 32
2.12 Selection of Lugs 39
3.0 Final Assembly Guidelines 40
3.1 Fixing of Panel nos. & Nameplates 40
3.2 Fixing of Barriers & Guards 41
3.3 Panel Dust-proofing Guidelines 44
3.4 Rubber Lining / Gasketing Precautions 45
4.0 Trolley Assembly Guideline 46
4.1 Trolley Frame Assembly 46
4.2 Mechanical Assembly of Trolley 47
4.3 Handling of Trolleys 50
Document No. Document Description:

LMVLVDS / QA / 12 Valid from Quality Code Book
08-05-2013 Page 1 of 78
Version No. This Supersedes:
B LMVLVDS / QA / 12 Version No. A
The contents of this handbook are the sole property of Siemens Ltd, IC LMV MS O-AIS, Kalwa Works.
The information contained in this page must not be divulged or duplicated in any form to a third party without the
specific consent and written approval of the Head of IC LMV MS O-AIS - Siemens Ltd.
Quality Code Book
5.0 Handling & Transportation of Assembled Panels 51

6.0 Technical Order Processing Guideline 52
6.1 Feeder Layout & Equipment Mounting 52
6.2 Cable Termination 54
6.3 Busbar Design 56
6.4 Other Areas 57
7.0 Packing of Switchboards 60
7.1 Preparation for Packing 60
7.2 Domestic Packing Guidelines 60
7.3 Sea-worthy packing for export 61
7.4 Packed case marking 61
8.0 Inspection & Testing Guidelines 62
8.1 Incoming Inspection 62
8.2 In-process Inspection 62
8.3 Final Inspection & Testing 62
8.4 Quality Records 62
8.5 Testing Instructions 63
9.0 Guideline for higher short circuit level 69
10.0 Intelligent Code Book (ICB) for Simocode 70
11.0 Forms of Separation 77

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Quality Code Book
Authorisation
This Quality Code Book (QCB) provides the basic guideline on several aspects of
Manufacturing / Assembly of Siemens LV switchboards to vendors. The objective of providing
the information to all concerned is to ensure uniform work practices during manufacturing /
assembly. This will also help the vendors to carryout the work as per Siemens manufacturing
norms & ensure Siemens Quality standards.
It is hoped that our vendors will find the enclosed information useful & strictly follow the same in
order to meet the required Quality standards. Further clarifications & guidance, if required, can
always be provided at any point of time during the execution of the jobs. Similarly, order-
specific customer requirements which need to be taken care of will be communicated to them
while loading specific jobs.
The contents of this handbook are the sole property of Siemens Ltd, IC LMV MS O-AIS, Kalwa
Works.
The information contained in this page must not be divulged or duplicated in any form to a third
party without the specific consent and written approval of the Head of IC LMV MS O-AIS -
Siemens Ltd.
Prepared by Checked by
sd/- sd/-
Anil Motwani Karthik Narayanan
Distribution
The soft copy of this QCB is available on Server ( \\inbomt785dat\IND-KALWA-
DEPT\AND\DEPT\ANDCDDM\LVDS\Q-SP ). All employees having valid access can view the
QCB.
One hard copy is distributed to all Manufacturing vendors.
Original is retained by QM.

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1.0 Busbar Manufacturing & Assembly
1.1 Busbar Fabrication

The following general care has to be taken during busbar fabrication:
Busbar cut edges should ensure smoothness, straightness & perpendicularity along the
busbar width.
The cut edges should be properly filed to remove all sharp corners & burrs to prevent
damage of sleeve.
Punching of holes on busbar is preferred. In case of drilled holes, proper chamfering of
holes to be done to remove burrs & sharp edges.
Hole locations should be correct as per drawing. No double-punching of holes on
busbars are allowed. Parts must be accurately positioned by shims & jigs, not by eye
estimation.
For oblong holes, proper punching tool to be used instead of multiple punching/drilling.
Proper bending radius as per drawing to be followed during bending of busbars. Sharp
bending should be avoided to prevent cracking of busbars at bending points. If required,
some preheating of busbars at bend-points is recommended to avoid cracking.
Bending angles must be checked & ensured after bending since these are critical during
assembly for proper surface area contacts at joints.
At all joints, proper brushing & greasing is to be carried out as per guidelines given below
immediately after busbar manufacturing operation.
5 x 6.5 mm dia. holes to be done at cable alley side for control bus 15 x 5 mm copper
aux busbar.
1.2 Busbar Marking

The markings for the busbars & main connections should be as per IS 11353-1985. Clause
2.4.1 of IS 11353 specifies that individual busbars and similar conductors whether
insulated or not, should be identified where appropriate, by a graphical symbol or
alphanumeric notation rather than by colours. The correlation between alphanumeric
notation, graphical symbols & colours are given in Table 1.2.1.
Identification of busbars will be provided:

using alpha-numeric notations on self-adhesive polyester tapes as per details given in
Table 1.2.1.
on main busbars at a convenient location close to the end of every panel which can be
easily visible (view not blocked by joint shroud), by wrapping relevant tape around the
busbar. The wrapping of identification tape should be for at least one complete turn on
each busbar run.
On feeder connections :
marking to be provided at least at two points if length of connections exceeds 1.5
meters,
marking to be done in the approx. centre if length of connections is less than 1.5
meter,
marking to be done on the vertical surface in case of right-angled or bent
connections,
marking should not be covered by equipment like metering & protection CTs,
If busbars are PVC sleeved then marking to be provided over PVC sleeve.

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On outgoing busbar cable connections:

At the edge of busbar protruding out of the FRP Support (applicable for ACB
feeders),
On the outgoing cable connection piece (for higher cables) in case of MCCs in such a
way that the same is not covered by cable connection bolts/nuts / lugs.
In general, marking will be provided on busbars and connections keeping in mind normal
access which is either from front or rear side.
Width of busbar marking tape should be 25mm polyester.
Table 1.2.1
Designation of Conductors Identification by
Alphanumeric Graphical Colour
Notation Symbol
(1) (2) (3) (4)
Supply AC system Phase 1 L1 Red
(Main Power) Phase 2 L2 Yellow
Phase 3 L3 Blue
Neutral N Black
Apparatus AC Phase 1 U Red
System (Aux Bus) Phase 2 V Yellow
Phase 3 W Blue
Neutral N Black
Supply DC System Positive +VE Red
Negative - VE Blue
Midwire M Black
Supply AC System Phase L Red
(1 ph.) Neutral N Black
Protective PE Green & Yellow
conductor (Spiraled)
Earth E Green
Table 1.2.2
Colour RED YELLOW BLUE GREEN BLACK
Material of Polyester Polyester Polyester PVC Polyester

Tape
Colour P.O. Red Golden Azure Blue Grass Green
Name Yellow
IS-5 Shade 538 356 104 218
No.
The shades for colours shall be as per IS 5 – 1961.
1.3 Busbar Jointing & Treatment

Main horizontal busbars (phases & neutral) will be PVC sleeved (black colour) if specified
in DIS. However, the joint surface shall not be covered by sleeves. Joints shall be
shrouded if specified in DIS.
The PVC insulation sleeve should be of 1.1kV grade & should withstand temperatures of
~120 deg.C without any deformation/cracking.
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In case of silver / tin plating on busbars / joints, the minimum plating thickness should be
2 microns for silver and 6-8 microns for tin plating & the same should be carried out on
both the mating surfaces.
The various types of joints that generally occur in switchboards are listed in Tables 1.3.1
& 1.3.2. The methods used for preparation of contact surfaces of parts to be joined have
also been indicated in the table.
The following method to be ensured during preparation / assembly of any joint:

No deformation like burr, bulging & dent should exist on contact surfaces, to avoid higher
temperature rise due to uneven contact surface.
The busbar joint should be done as soon as the contact surfaces are prepared. This is
necessary to avoid the formation of oxide film on the contact surfaces. For all types of
contact surfaces, neutral grease Servogem-2 or Arden 20 should be applied on the area
10 mm more than the actual contact area, on all sides before making the joint and
immediately after preparing the contact surface.
For busbar width upto 25mm, the normal bolts of 4.6 / 4.8 class & nuts of class 4 as per
IS 1367 will be used with plain & spring washers.
For busbar width 30 mm & above, the high tensile M12 bolts / nuts of property class 8.8 /
8 as per IS 1367 will be used with Belleville washers.
Refer Table 1.3.3 for details of tightening torque.
The tightness of joints should be checked with a torque wrench for adherence of the
torque values as per table at sufficient number of joints.
For the hole patterns on Main Busbars for tap-offs, the guidelines given in the Table 1.3.4
for 8PUS1/F4/L4/T3 & 8PUS1.5/F4.5/F4.6/L4.5/T3.5 respectively are to be followed.
For hole patterns on Main Bus for joining fish-plates, the respective standard drawings
should be referred for 8PUS1/F4/L4 & 8PUS1.5/F4.5/L4.5 respectively.
Please refer Siemens drg. no.4-16-10084-001 for 8PUS1.5/F4.5/L4.5.
Star/contact washer to be used for fixing mounting cleat of earth bus to painted panel
structure.
At any bus-joint, the nut is preferred facing the side from which tightening is carried out &
bolt-head on the opposite side. For convenience of access during tightening, the nut on
MBB joints are kept facing rear.
Length of Bolts
For all types of busbar joints, the length of bolts are to be selected such that two (2) or
three (3) threads come out of the nut after proper tightening. This point is to be ensured for
power tap-off points also. As well as clearance is maintained between phases & earth.
Busbar Fishplates
The busbar fishplates for joining between shipping sections should be sent loose with
proper size of nut, bolt & washers mounted on fish plates.
In such cases, the fishplates & fasteners should be coupled together in sets for easy
identification/tracking. Also, the quantity, size of fishplates & fasteners (joining bolts,
washers, nuts) are to be ensured. The details of such loose supply items are to be
recorded separately & submitted along with the other order-related documents. Refer
Fishplate packing guidelines on page no. 59.

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Use of aluminum cleats for control tap-offs

Wherever applicable, control tap-offs for potential / auxiliary supply from busbar
connections must always be done using aluminum cleats fitted at joints using the same
holes. This is required to ensure that removal of control wire for maintenance does not
involve disturbance of the busbar joint.
Table 1.3.1 – Surface Preparation for Busbar Jointing

In the table below, A,B, etc. stands for the details given below :
A - The small surfaces in case of clamped connection to be brushed.
B - To be brushed and greased at once with neutral grease:
Veedal (type Arden 20) or
Indian Oil (Servogem 2).
C - To be wiped by means of clean and dry rag. However, if the surface is covered by
greenish or blackish deposits, then they should be brushed.
F - At contact combinations, Cu to Al intermediate Cupal Sheet to be used. Cupal should
project approx 3 mm beyond contact surface.
BF - B & F to be applied.
** - Only if required specially by client.
Sr. Inside the enclosure / room
Part 1 Part 2
No. Part 1 Part 2
1. Al Bare Al. Bare B B
2. Al Bare Al tin plated B C
3. Al Bare Copper Bare B (F**) C
4. Al Bare Cu tin-plated B C
5. Al Bare Cu Ag-plated BF C
6. Al Bare Struc.Steel bare B B
7. Al Bare Struc.Steel galvanised B C
8. Al tin-plated Al tin-plated C C
9. Al tin-plated Copper Bare C C
10. Al tin-plated Cu tin-plated C C
11. Al tin-plated Cu Ag-plated C C
12. Al tin-plated Struc.Steel bare C B
13. Al tin-plated Struc.Steel galvanised C C
14. Copper Bare Copper Bare C C
15. Copper Bare Cu tin-plated C C
16. Copper Bare Cu Ag-plated C C
17. Copper Bare Struc.Steel bare C C
18. Copper Bare Struc.Steel galvanised C C
19. Cu tin-plated Cu tin-plated C C
20. Cu tin-plated Cu Ag-plated C C
21. Cu tin-plated Struc.Steel bare C B
22. Cu tin-plated Struc.Steel galvanised C C
23. Cu Ag-plated Cu Ag-plated C C
24. Struc.Steel bare Struc.Steel bare B B
25. Struc.Steel bare Struc.Steel galvanised B C
26. Struc.Steel galvanized Struc.Steel galvanised C C

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Table 1.3.2
Applicable for Air Circuit Breakers & Switches for ratings 1000A & above
Busbar / Equipment Terminal Treatment for
Sr.No.
Connections Surfaces Part 1 Part 2
1. Cu Bare Cu Bare B C#
2. Cu Bare Cu Silver/Tin/Nickel plated B C#
3. Al. Bare Cu Bare B C#
4. Al. Bare Cu Silver/Tin/Nickel plated B F
Note: # brushing not allowed.
Table 1.3.3: Tightening torque for Hex. Head Bolts for busbar joints in switchboards
Bolt Size : M8 M10 M12
Class of Bolt 4.6 / 4.8 4.6 / 4.8 8.8
Torque (N-m) 13.2 – 19.8 26.3 – 39.5 71 – 80
Note: Tolerances on above recommended torque values are +5.0 N-m & -0.0 N-m. Torque
Wrenches are to be used for tightening to ensure the above torques.

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Table 1.3.4: Bolting pattern for Busbar

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1.4 Busbar Sequence

Unless otherwise specified, the phase sequence of main horizontal busbars will be as
shown below:
Horizontal Busbar Sequence (Sectional Side-view)
L1 L2 L3
Front Side
L1
L2
** Neutral Busbar
applicable only for 4-
pole system
L3
N **
Vertical Busbar Sequence (Top view)
L1 L2 L3
L3
Front Side
L2
L1
Outgoing Cable Terminal Busbar Sequence

(Unless otherwise specified, the following sequence is to be followed)
L3 L2 L1 N
(Rear Sectional View)

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Auxiliary Busbar Sequence

The number of auxiliary busbars is decided by the electrical circuit requirement and is
indicated in the FV drg. The location of busbars B1, B2, etc. is dependent on number of
auxiliary buses required.
For 2 nos. auxiliary buses, locations 2 & 6 are to be used.
For 4 Nos. auxiliary buses, locations 2, 4, 6 & 8 are to be used.
For 6 Nos. auxiliary buses, locations 3, 4, 5, 6, 7, 8 are to be used.
For 7 Nos. auxiliary buses, locations 1, 2, 3, 4, 5, 6, 8 are to be used.
For 8 Nos. auxiliary buses, locations 1, 2, 3, 4, 5, 6, 7, 8 are to be used.
The slots 10 & 11 are to be used for 15x6 Copper control bus for circuits with load
more than 100A (e.g., 24VAC motor winding heating, etc.).
For detailed assembly guideline, please refer to drg.no. 3-03-08496-….
Similarity is to be maintained in locations of respective buses for various shipping
sections of a switchboard.
1
2
3 10
4
FRONT
5
6
7
11
8
9

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When 15 x 6 slot is used for 5 x 5 aux busbar, then fix 2mm thick FRP sheet with self
tapping screws / Araldite on 15 x 6 slot of aux bus support. Drill holes on FRP for 5 x 5 aux
bus. Refer below drawing.

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1.5 Busbar Insulation

Wherever insulation on busbars / connections is given, it should be uniform throughout
and all around the surface. Refer below Busbar insulation process.
Contact overlap areas should be kept free from insulation. Sleeve should be removed
5mm more than the jointing surface.
The insulated surface should withstand a power frequency test voltage as indicated in
order specific Engineering drawing.
For feeder connections, the insulation can be provided by means of heat-shrinkable PVC
sleeves or polyester tapes (thermosetting type), as specified in DIS.
The auxiliary busbars may be insulated as and when required by the client (mentioned in
the Technical Details) by inserting the same through PVC sleeve of suitable size. The
insulation sleeve is to be removed at locations where control wire clamps are connected
for potential tapping.
Busbar Insulation Process

Following are the some measures to be followed strictly during busbar insulation process.
A) Ordering:
At the time of the sleeve ordering CHP has to follow some norms:
1. Approved supplier for purchase of the sleeve is ‘Platec Industries’.
2. Alternately order can be placed on authorized dealer of Platec Industry, named
M/s.Switchgear components situated at 102, Himachal, 1st floor, Juhu lane, Andheri,
Mumbai-400 058.
3. Busbar size should be mentioned by CHP on the Purchase Order.
4. Sleeve should be suitable to withstand temp upto 120 . Same should be mentioned
on the PO.
5. Refer below chart for busbar size and the sleeve size.
Busbar Sleeve
Size(mm) size(mm)
30 x 10 48
40 x 10 61
50 x 10 81
60 x 6 85
60 x 10 85
80 x 10 103
100 x 10 128
120 x 10 150
140 x 10 170
160 x 10 190
180 x 10 210
200 x 10 230
B) Storage:
1. Sleeve has to be stored indoor and should not be exposed to light or heavy light.
2. Sleeve should be kept in roller.
3. Manufacturing date of the sleeve, generally mentioned on one end. That end to be
cut and put it in the roller so one can see the Mfg. date of the same at any time.
4. Sleeve should be used up to one year from the date of Mfg.

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C) Properties:
Working Temp. - 120 C
Dielectric strength - 20KV/mm
Insulation Resistance - 20 x 1010 Ohms at 500V DC
Tensile strength - Min 400 kg/cm
Ultimate Elongation - Min 11 %
Chemical Resistance - Good
Fire Resistance - Self Extinguishing
Shrinking Temp. - 150 C – 170 C for 4-5 minutes
Mechanical Strength - Excellent
Heat Dissipation - Excellent
Colour - Black
D) Sleeving Process:
1. Oven should be heated to the temp of 150 C to 170 C
2. Busbar covered with sleeve should be kept inside the oven.
3. After completion of Sleeving, if there any 90 or obtuse angle, sleeve should be cut at
that portion and to be covered by black polyester tape, with complete turn.
4. If there any joining portion (As shown in the Fig. below) should be covered with black
tape as shown.
Black tape
Joining-portion
Busbar with sleeve
E) Output:
Output should be free from the Wrinkles, blowholes and air tapings.
F) Handling:
1. Handling of the sleeved busbar should be done with care.

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While putting in the panel it should not strike on the panel parts which may result into sleeve
damage.
1.6 Power Terminal Fasteners

The size of fasteners for outgoing power terminals are guided by client’s cable sizes. The
following guidelines should be followed for the size of bolts. The length of bolts is decided
by the number of cable runs per terminal.
Cable size > 2.5 sq. mm. & = 6 sq.mm : M4 Bolt
Cable size > 6 sq. mm. & = 35 sq.mm : M6 Bolt
Note: For Power cable sizes 50 sq.mm & above refer tables in 6.2 (Page no.55)
1.7 Vertical Earth busbar

If Main (Horizontal) Earth busbar is Aluminum / GS, then Aluminum Vertical Earth busbar
to be provided.
If Main (Horizontal) Earth busbar is Copper, then Copper Vertical Earth busbar to be
provided.

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2.0 Equipment Mounting & Wiring
2.1 Mounting & Colour Coding of Pushbuttons & Lamps

The following arrangement gives the general layout & colours of pushbuttons / lamps on
instrument plates / doors unless otherwise specified:
Vertical Mounting & Colour Coding for Pushbuttons For MCC Inst. Plate and
doors up to 10M
Green ON / START
Red OFF / STOP
Green RAISE / FORWARD
Red STOP
Yellow LOWER / REVERSE
Green FAST
Red STOP
Yellow SLOW

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Horizontal Mounting & Colour Coding for Pushbuttons for MCC doors more than
10M
ON OFF STOP / TRIP
Green Red Red (Mushroom)
FORWARD / RAISE STOP REVERSE / LOWER
Green Red Yellow
FAST STOP SLOW
Green Red Yellow
Note:
While mounting of lamps and pushbuttons on the instrument plate of feeders, the layout of
the same given in Order drawing shall be referred. In case of any mismatch between those
mentioned in the Order drawing and the convention followed above, the layout mentioned
in this document will be given overriding importance and be followed. Order drawing must
be corrected accordingly.

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Vertical Mounting & Colour Coding for Pilot Lamps for MCC instr. Plate and doors
upto 10M
Red ON
Green OFF
Amber TRIP
TRIP (Amber) FORWARD (Red)
OFF (Green)
REVERSE (Red)
TRIP (Amber) FAST (Red)
OFF (Green)
SLOW (Red)

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Horizontal Mounting & Colour Coding for Pilot lamps for MCC doors more than 10M
ON OFF
Red Green
ON OFF TRIP
Red Green Amber
RAISE/ OFF LOWER / TRIP

FORWARD REVERSE
Red Green Red Amber
FAST OFF SLOW TRIP
Red Green Red Amber
Lamps & PB’s mounted on Instrument plate & doors of MCC panel to have G6 type of
ring name plate and if mounted on ACB door should have G5 type (longer) ring name
plate. Legend plate should be Black anodized with white letters.

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Indicating lamp in PCC

If phase indicating lamps not used then shift other indicating lamp in place of phase
indicating lamps. These for indicating lamps sequence only.
TRIP
CKT R PH B PH TEST SERVICE
ON OFF TRIP HLTY ON Y PH ON ON POS POS
RED GREEN AMBER BLUE RED YELLOW BLUE WHITE RED
Provide push button below in relation with indicating lamp.
2.2 Mounting of Equipment Plates on Panel Structure

(Applicable for fixed type MCCs & PCCs)
While mounting the equipment plates for the individual feeders on the panel structure after
wiring, care should be taken that earth continuity is maintained between equipment plate &
panel structure. Moreover, the base plates should be openable from front for future
maintenance.
For achieving the above, the following steps should be followed during mounting :
The mounting bolt head should be put from rear side of the trough & locked with a lock-
nut.
The base plate, after mounting on the fixing bolt, should be tightened with a nut from
front.
Star/contact washers are to be provided on both sides (behind trough & in front of base
plate) for achieving earth continuity.
2.3 Mounting of Instrument Plate Sub-assembly on Trolley Frame

(Applicable for Drawout MCCs)
Star/contact washers are to be used at the fixing points between trolley frame
stiffener & IP sub-assembly for achieving earth continuity.

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2.4 Mounting of Switches & Drives

In order to keep uniform practice of operation of handles of circuit breakers, isolators &
toggle switches, the following practice should be adopted for mounting the same on panels
:
Type of Drive Switching ON Switching OFF
Rotary Drive
Switch, MCCB, MPCB Clockwise Direction Anti-clockwise Direction
Straight Vertical Drive
MPCB, MCCB, MCB From Bottom to top From top to bottom
Straight Horizontal Drive
MPCB, MCCB, MCB From Left to Right From Right to Left
Toggle & Tumbler

Switches
From top to bottom From Bottom to top
2.5 Mounting of Equipment

All CT’s are to be mounted after ascertaining the polarity so that the nameplate is clearly
visible.
While mounting equipments, nameplates, self-adhesive labels, etc. the straightness is to
be maintained.
While mounting CT secondary terminals on trolley, care has to be taken so that the same
do not obstruct maintenance approach to other equipment.
While mounting Mushroom Head Push-Button on Instrument Plate, care should be taken
to ensure that the same does not overlap with adjacent lamps / pushbuttons as well as
does not foul with the door IP cutout.
Space heaters should be located centrally depth wise inside the panel for uniform
heating. It is not recommended to place the space heaters at the extreme back of the
panel (near rear cover) in case of single front boards.
Care should be taken that space heaters are not placed close to the outgoing cables to
avoid damage of insulation due to direct heating. Generally, the preferred mounting
orientation of space heaters is vertical with the terminals pointing downwards in order to
have least obstruction with the customer’s cabling space.
The mounting of thermostat & control MCB/fuses for space heater should be done on MS
supporting brackets as per standard design. The mounting of the same should be at a
convenient height from operation / maintenance viewpoint in the cable alley. Also, the

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same should be staggered from the feeders with extended cable termination bus links in
cable alley.
In S1.5 test push button to be mounted on left hand side on bottom bugal and in F4.5 test
push button to be mounted on equipment plate on additional “Z” bracket.
2.6 Equipment Marking

In order to identify the equipment properly, marking is to be provided indicating its
designation in SLD or Wiring Diagram.
For compartmentalized / modular design, where the equipment are grouped /
segregated according to feeder / functional aspect, only the basic designation should be
used for marking the individual equipment. However, in addition, the feeder / group
designation marking should be provided at a prominent place inside the compartment
on the base plate or the module.
For drawout feeder trolleys, the feeder number & type should be identified with printed
self-adhesive labels fixed on the bottom left corner of the trolley frame (bugel). For fixed
type feeders, the feeder number & type identification labels should be fitted at a visible
location on the equipment plate. To the extent possible, the location of these labels on
the equipment plate should be uniform. However, the same will depend on the actual
equipment layout.
In case of non-compartmentalized executions or where the equipment are not grouped
or segregated according to feeder / function (e.g., Relay & Control Panels, non-
compartmentalized MCC/PCC), the basic designation should be prefixed by the feeder
number.
The equipment marking should be done by fixing self-adhesive labels. The labels should
have black letters on yellow background. The marking is to be done by either of the
following methods:
Marking on the baseplate
The marking should be done on the baseplate as close to the equipment as possible.
It should be clearly visible and should not be covered by wires, parts or any
projection of equipment. This method should be preferably used since it helps in
locating the equipment position when the equipment is removed for repairs /
maintenance.
Marking on the equipment
In this method the marking will be done on the equipment itself. In addition to this, the
marking should be done under the equipment, before mounting it on the baseplate.
This will facilitate the re-locating on the position, when the equipment is removed.
This method should be used only if marking by the first method is not possible,
because of space constraint.
In case of Siemens equipment, white tags are provided on the equipment themselves
on which the self-adhesive labels are to be fixed.
For non-drawout type MCC (with rear cable alley), where the outgoing terminals are
grouped together in a common outgoing cable chamber, the feeder number shall be
marked (by self-adhesive labels) for proper identification.
The following points should be noted while marking certain equipment :

In case of contactors, the marking should be such that it will not cover the contact
numbers.
For C.T.s mounted on busbars, the marking must be on the CT body.
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In case of control fuses, the marking must be done on the base plate as well as on the
fuse-carriers.
For door-mounted equipment, if the marking is done on the equipment, then additional
marking should be provided on door (rear side, near wiring) near the same.
The self-adhesive labels shall be affixed in a straight line for proper aesthetics.
Self adhesive sticker material should be “synthetic Paper base”.
D/O Line PTs, D/O Bus PTs mounted at rear of ACB panels shall be identified by a label
with unobstructed view on the trolley front plate.
Whenever more than one D/O PT trolley is mounted at rear of ACB panels, each trolley
shall be identified by a label (e.g. Bus PT Sec-A, Bus PT Sec-B), with unobstructed view
on the trolley front plate as well as on the inside of the top guide channel.
2.7 Marking of Wires

Marking of Main Circuit Wire Connections
The marking of main wires is to be done to identify the different phases. The marking is
not necessary if coloured wires are used. The marking / colour of the wires should be as
per guidelines given in the earlier chapter on busbar marking.
When the grey coloured wire is used for all power wiring, a coloured sleeve should be
provided at the termination point.
Marking of Control / Auxiliary Circuit Wire Connections
The marking of control / auxiliary wiring should be done only if specified by client for the
order. It shall be done by providing yellow V-type ferrules bearing the required marking,
at the termination point of the wire on equipment or clamp terminals.
As per IS 5578 – 1970, the dependent local end marking system should be used for
switchboard wiring unless some special requirement is asked for. This is a system of
marking in which the marking of a conductor end is the same as that of the terminal to
which it is connected. The figure below gives the illustration of this system. In the figure
K11, K12 are two equipment. The marking K11-1 indicates that the conductor is
connected to terminal 1 of equipment K11. Similarly, marking K12-4 indicates a
connection to terminal 4 of equipment K12.
K11-1 K12-3
1 3
K11-2 K12-4
2 4
K11 K12
The marking ferrules should be provided at termination point, indicating equipment
designation and the equipment terminal number to which the wire end is connected.
The ferruling sequence at an equipment terminal should be from left to right or from
bottom to top. This means that, for equipment upper terminal, the ferruling should start
from the termination point & end away from it & vice versa for lower terminal, e.g., for
equipment terminals K11-13 & K11-14, the ferrule K should be towards the terminal 13 &
away from terminal 14.
For MCC, PCC, etc. for the marking of equipment wiring only basic designation should
be considered. Feeder number will not be marked.

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For inter-panel & inter feeder wiring between MCC/PCC feeders the feeder number and
the terminal number must be used.
Unless otherwise specified the ferrules should be of good quality V-notch type with black
printing on yellow background. The letters should be printed properly with permanent ink.
In case of circuit breaker control wiring, if there is inter-panel wiring, the marking should
include the feeder number to which the wire end is connected.
For marshalling feeder wiring, the ferruling should include the feeder number, equipment
& terminal number.
Unless otherwise specified by the customer, the Siemens standard system of dependent
local-end ferruling should be followed.
Coloured sleeves are to be used for identification of control wires of different voltage
systems (AC/DC). The colour coding should be as generally as per Table 1.1.1.
However, customer-specific requirements should be followed for colour-coding of wires
as per order-related instructions.
Terminal marker PVC digits provided on fixed type terminals should be fitted on the
terminal both side. All digits must be pre-printed with good quality indelible ink & easily
readable.
First wire of a set of wires to be identified by feeder no. in terminal row of marshalling
panel.
Sleeve for control wires
1. 110V AC through transformer PH-Red & N Black
2. 240V AC through transformer PH-Red & N-Black
3. 240V AC tapped from phase & neutral PH-Red & N-Black (phase and neutral)
4. 24V AC through transformer PH-Red & N-Black
All these points are applicable from control transformer secondary to aux busbar and upto
feeding point of feeder (whenever feeding points are control terminals or 9 way Male,
female contact (provide on both sides). Rest of the control circuit inside the trolley or feeder
will be with grey sleeve.

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2.8 Colour Coding of Wires

Wires used for main circuit should be of grey colour as per standard unless otherwise
specified. Wires should be identified by coloured sleeves (red, yellow, blue) at both ends
connected to equipment terminals for proper phase identification.
For Star-Delta Starter circuit, the colour coding will be as shown below :
L1
L2
L3
F1 - F3
Red
Yellow
Blue
Yellow
Blue
Red
Q20 Q22 Q21 K31
Yellow
K80 Blue
Red
Red Red
Yellow Blue
Blue Yellow
U1 V1 W1 W2 V2 U2

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For Reversible Direct-on-line Starter circuit, the colour coding will be as shown below :
L1
L2
L3
YELLOW
BLUE
RED
BLUE
YELLOW
RED
YELLOW
BLUE
RED
YELLOW
BLUE
RED
Note: Power wire tap-off should be from fuses to both contactors, wherever power
contactors are with clamp type power terminals.
And for power contactors with bolted terminals – follow above drawing.
2.9 Wiring of Equipment

In order to achieve a neat, stress-free switchboard wiring with minimized wire scrap
generation, the following care shall be taken:
The extra length of wire to be provided at the termination point shall be sufficient for only
one reconnection, in case the conductor breaks.
Unnecessary rounding and awkward shaping of wires shall be avoided so as to prevent
the extra material and labour.
The connection between terminals shall be straight and along the shortest path to keep
the wire length to a minimum.

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The wires shall not be bent at right angles but shall be curved. This prevents damage to
the insulation and conductor. In case of trolley wiring, the connections to plug-in contacts
shall not have sharp bends but should be taken along a curve.
The number of bends along the wiring shall be kept to minimum.
Use 0.75 sq. mm grey cable for auxiliary contacts of MCCB to CST terminals for easy
wiring.
In addition to the above, the following general guidelines are to be followed during wiring of
equipment:
The incoming wires from main/vertical bus to feeders are not protected and hence should
not be bunched together.
In case of trolley wiring, to provide greater resistance to short circuit faults, the incoming
wires from plug-in contacts to main switch (as well as from main switch to fuses) shall not
be bunched together. Each phase wire shall be kept separate from other phase by
proper shaping and clamping.
In case of other executions and non-std. Switchboards, the tapping points on different
phases shall not be in the same vertical line but shall be staggered. However, the wires
tapped from the same phase can be bunched together. Further, the different phase wires
shall not touch each other while crossing.
The bunching of power wires after fuse, contactor and bimetal relay can be done as the
wires are sufficiently protected.
The termination of wires shall not cause undue stress at equipment terminal due to
improper shaping and bending. The conductor shall be parallel to the face terminal.
However, it shall not be bent immediately after connection so as to avoid the stress on
terminal.
In case of clamp terminals, preferably one wire & at most two wires shall be connected to
each side of the terminal. All wire ends with lugs should be provided with insulation
sleeves.
For wiring of 9-way drawout terminals in a trolley, care should be taken to provide
adequate screw-driver maintenance access to terminal row at the rear. Unnecessarily
long wire loops at 9-way front terminals should be avoided.
As per IEC, earthing of equipment is to be carried out using GREEN YELLOW coloured
2.5 sqmm.wire.
The wire bunches inside feeders & on door / instrument plate should be properly
clamped at regular intervals throughout the length of the run.
The potential tapping from feeder busbar connections should always be taken through a
tapping Aluminum cleat so that the busbar joint is not disturbed during connection /
removal of the wire.
Coloured sleeves shall be provided at all potential tapping points, voltage circuit
(voltmeter selector switch), P.T. circuit, kWh meter circuit, etc.
Wherever 1.5 sqmm/2.5 sq mm. Wires are terminated in 6 sq mm. Terminals, grey
sleeves must be provided at terminal end. Wherever double wires (control) are
terminated in a single 6/10 sq mm. terminal, flat type wire lug shall be provided for better
wire gripping. The same is applicable for termination of 2 Nos. wires in a single terminal
of 9-way terminal block.
Whenever control wires are passing through a sheet metal part, e.g., between horizontal
busbar compartment and cable alley in MCC or from one CB panel to adjoining CB panel
in the same shipping section, suitable rubber grommets shall be used. The rubber
grommets used shall be as per IS 5270, blind type 2. These should be punched suitably
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considering the number of wires passing through them and shall have spare capacity for
minimum two wires of 2.5 sq.mm. size. Alternatively, use of ‘U’ profile rubber shall be
made to prevent damage to the insulation of control wires.
While routing & bunching of wires inside feeders, wires for power circuit, auxiliary circuit
& screened wires should be bunched separately.
AC / DC circuit control wires should be bunched separately.
Wire bunches to the door of ACB panel / MCC panel shall be bunched, clamped &
shaped in the form of ‘S’ so that the same is not stressed when the door is fully closed.
Also, all such wire bunches should pass through PVC sleeve / spiral so that the
insulation is not damaged by rubbing against door edge.
Wire bunches on ACB / feeder door should be properly bunched & clamped keeping in
view the aesthetics & functionality. No PVC wire-ways are to be used for such wire
bunches.
Wire bunch to door should not be clamped on the sidewall / partition wall. Clamping
should be done only on panel sidewall / frame edges using P-clips. Fixing of wire-holder
saddle support with self-tapped screws after drilling on sidewall / partition wall is not
allowed.
All wire bunches running inter-panel (between feeders within same shipping section or
between two shipping sections) should be laid on MS/PVC Wireway Channels laid at the
bottom cable chamber & running along the board length. The wire bunch should be tied
at intervals to maintain the routing but not be sleeved. The individual wire should be
identified with proper ferruling at both ends which should indicate the feeder number &
terminal number. This wire bunch should not obstruct client cable entry, refer standard
assembly drawing.
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Jumper wires for joining auxiliary busbars between shipping sections: For 5X5 mm
or 15X6 mm Aux busbar, 6 runs of 2.5 sq.mm wire or 4 runs of 4 sq.mm wire to be used.
Approx length of jumper wire should be 300mm (Incase of adapter panel, length of wire
bunch should be 300mm + Adapter panel width). Grey PVC wires are to be used for
each busbar. These wires are to be bunched into a common black PVC sleeve of
adequate length & the same are to be identified with ferrules indicating busbar
designation, e.g., B1, B2, etc. at both ends. The length of the wire bunch should be
optimized so as to avoid tension on the jumper during coupling as well as excessive
looping due to extra length.
External Resistor for relay to be mounted on equipment plate or on M.S. bracket.
2.10 Wiring Routing through Channels

The layout of insulated conductors in PVC channels for switchboard wiring is
advantageous in view of easy wiring and maintenance. Besides it allows changes in wiring
without any difficulty. Tie belt should not be used inside PVC channel.
Use proper size of PVC trough such that tie belt should not be used for trough cover fixing.
Generally the channels are to be used for laying auxiliary and control wires but can also be
used for power wires in special case.
The dimensional details for channels are given in the table below:
Normal Channel Type Ref. Number of wires accommodated
dimensions (mm) In layout of cross-section
Width Height 1 sq mm. 1.5 sqmm. 2.5 sqmm. 4 sqmm.
25 30 25x30 49 32 23 18
25 45 25x45 72 47 34 27
25 60 25x60 90 60 40 32
45 45 45x45 115 71 55 43
45 60 45x60 173 112 82 64
60 60 60x60 262 170 125 97
The layout of channels

The layout of channels should be designed in such a way that they are arranged around
the equipment terminals / clamp terminals. If an equipment large in size has a small strip
of terminals, then the channels should be laid to cover only the terminals and not the
whole equipment.
The layout should consist of main vertical / horizontal and branch channels. The main
channel shall receive the wires coming through branch channels and also allow
distribution of wires through them at various points.
If one main channel cannot accommodate all the wires, two or more main channels may
be provided. Also the wiring is easy and uniform with two or more main channels, in case
of a crowded layout of equipment.

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In case of shorter or small number of conductors, they shall be taken out of main channel
in round bunches upto the equipment. The side channel is not required in such a case.
The channels should be accessible for maintenance after opening the door or cover.
After deciding the position of channels, the number of wires that will pass through the
channel should be estimated and the suitable channel be selected from the table given
above. The layout and selection of channel should be such that the channel capacity is
fully utilized.
The examples of different typical equipment layouts are given below:
K11 K12 K13

Branch Channel
K56 K28
Main Vertical Channel
K21 K22
Main Horizontal Channel
K11 K12 K13

Branch Channel
K56 K28
Main Vertical Channel
K21 K22
Main Horizontal Channel

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Fixing of Channels
The important points regarding fixing of channels are illustrated below:
The max. distance between adjacent screws for fixing channels ‘a’ should be less than
200mm.
b a
The distance of fixing screw from the end ‘b’ should be less than 50mm.
The channel cover should not be cut to accommodate a side channel. The clearance
should be provided at the joint to facilitate the removal of covers.
The vertical channel should run through the length and horizontal channel should meet it.
RIGHT WRONG
The mounting of channel should be such that the same do not guard any equipment and
its terminal. There should be sufficient gap between the equipment terminal and the PVC
channel so that there is no difficulty in changing the connection, as and when required.
Method of Wiring using Channels

The channel wiring is a substitute for bunching system to avoid the wastage of wire and
reduce the time for wiring. Hence the pre-cutting of wires for a bunch on the basis of
estimated length, which is always on the higher side entailing wastage, should not be
done. For channel wiring, no estimation of length of wire is necessary. The wiring is done
from terminal to terminal and the wires are laid freely in the channel without bunching or
belting the same.
The equipment and channels should be mounted as per layout by the wireman
concerned keeping in view the guidelines given above before starting the wiring.
The following procedure should be followed for channel wiring. One end of the wire coil
shall be connected to equipment terminal. The wire shall then be taken through slot in
channel and laid in it upto the equipment terminal to which its other end is to be
connected. Now the wire shall be cut and taken out through the slot in channel for
connection to equipment terminal. This avoids the checking of connections with battery
tester.

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In case the ferruling is required, the ferrules should be put on the wire end before the
connection is made.
After the completion of each connection, the wireman should mark off the same in wiring
chart/circuit diagram to avoid duplication.
2.11 Selection of Wire Sizes

The wiring will be done with PVC insulated multi-strand copper flexible wire of insulation
voltage grade 1100V as a standard unless some special wire is specified by the client.
Wires are to be used of Siemens-approved make. The following are the guidelines for
selection of wire sizes for various ratings.
For Lighting / Heater Feeders (Resistive Load) without Bimetal relay

3-Ph., 4-wire, 415V, 50 Hz, AC1 Duty
Upto kW Line Current (Amp.) Wire Size (sqmm.)

Lighting /
Heater Feeder
16.5 23 2.5
20.8 29 4
26.6 37 6
36.7 51 10
48.8 68 16
62.5 87 25
82.5 115 35
108 151 50
112 156 2 x 25
148 207 2 x 50 or 1 x 70 / Link
175 230 2 x 50 / Link

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For Switch-fuse feeders where the load details are not exactly known, the following wire
sizes should be used:
Switch – Power guard/ Fuse Wire Size (sqmm.)

super switch Rating
3KM/KL 47/ 3KL8111 20 A 4
3KM/KL 48/ 3KL8111 32 A 6
3KM/KL 49/ 3KL8121 50 A 10
3KM/KL 50/ 3KL8151 63 A 16
3KM/KL 51/ 3KL8211 100 A 25
3KM/KL 52/ 3KL8221 125 A 35
3KL8231 160A 2 x 35
3KL 54/ 3KL8311 200 A 2 x 35 Wire OR Links 25 x 6 Al / Cu
3KL 25/ 3KL8321 250 A 2 x 50 Wire OR Links 25 x 6 Al / Cu
315 A 2 x 70 Wire OR Links 30 x 10 Al / Cu

3KL 41/ 3KL8341
400 A 2 x 70 Wire OR Links 40 x 10 Al / 30 x 10 Cu
3KL 61/ 3KL8421 630 A Links 50 x 10 Al / 40 x 10 Cu
3KL8431 800A Links 2 x 40 x 10 Al / 50 x 10 Cu

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For DOL / RDOL Motor Feeders

KW HP Line current Minimum Wire Size

(Amp.) (sqmm.)
Up to 3.7 Up to 5 7.8 2.5
5.5 7.5 11.2 2.5
7.5 10 16 4
9.3 12.5 19 6
11 15 22 6
15 20 29 6
18.5 25 34 10
22 30 41 10
26 35 47 16
30 40 54 16
37 50 67 25
45 60 80 25
55 75 97 35
75 100 131 1 x 70 / 2 x 35
90 125 157 2 x 35
110 147 192 2 x 50
132 177 230 2 x 50
160 211 278 2 x 70 / Links
Note (applicable for all motor feeders):

Whenever there is mismatch between the specifications given in MSLD and those listed
above with reference to kW, the power wire size shall be selected considering the kW
rating of the motor.

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For Automatic Star-Delta Motor Feeders

KW HP Line Phase Wire Size

Current Current
(Amp) (Amp) Line Phase
Connection connection
2.2 3 4.8 2.8 2.5 2.5
3.7 5 7.8 4.5 2.5 2.5
5.5 7.5 11.2 6.5 2.5 2.5
7.5 10 16 9.2 2.5 2.5
9.3 12.5 19 11 2.5 2.5
11 15 22 12.7 2.5 2.5
15 20 29 16.8 4 4
18.5 25 34 19.7 6 6
22 30 41 23.7 10 6
26 35 47 26.9 10 6
30 40 54 31.2 16 10
45 60 80 46.4 25 16
55 75 97 56 35 16
75 100 131 75.6 50 25
90 125 157 90.6 50 35
110 150 191 110 2 x 35 50
132 180 229 132.2 2 x 50 2 x 35
143 192 248 143.2 2 x 50 2 x 35
160 215 270 156 2 x 50 1 x 70
200 270 340 197 2 x 70 2 x 50

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FOR CAPACITOR
Make coil of power wire going to capacitor if reactor is not there in wiring circuit (For
EPCOS Make) (Refer below picture)
Capacitor Rating Turns Approx. Cable cross

Diameter sec
5 KVAr 10 100 mm 2.5 Sq.mm
10 KVAr 10 100 mm 4 Sq.mm
12.5 KVAr 10 100 mm 4 Sq.mm
16.7 KVAr 7 100 mm 6 Sq.mm
50 KVAr 7 100 mm 35 sq.mm
Capacitor connection end should be without lug.

For other make of capacitor refer supplier catalogue.

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Below table may be used to determine cable sizes if not mentioned in supplier’s catalogue.
Capacitor Feeder 415V
7.5KVAR 10.5A
10KVAR 14A
12.5KVAR 18A
20KVAR 28A
25KVAR 34.8A
50KVAR 69.6A

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For single phase Transformer.

Rating KVA Prim. wire Sec. wire Rating KVA Prim.wire Sec.wire
sq. mm sq. mm sq. mm sq. mm
415/240 0.5 2.5 2.5 415/110 0.5 2.5 2.5
415/240 1 2.5 2.5 415/110 1 2.5 2.5
415/240 1.5 2.5 2.5 415/110 1.5 2.5 2.5
415/240 2 2.5 2.5 415/110 2 2.5 2.5
415/240 2.5 2.5 2.5 415/110 2.5 2.5 4
415/240 3 2.5 2.5 415/110 3 2.5 6
415/240 4 2.5 2.5 415/110 4 2.5 10
415/240 5 2.5 4 415/110 5 2.5 10
415/240 7.5 2.5 6 415/110 7.5 2.5 16
415/240 10 4 10 415/110 10 4 25
Rating KVA Prim.wire Sec.wire

sq. mm sq. mm
415/24 0.5 2.5 4
415/24 1 2.5 10
415/24 1.5 2.5 16
415/24 2 2.5 25
415/24 2.5 2.5 35
415/24 3 2.5 35
415/24 4 2.5 2 x 25
415/24 5 2.5 2 x 35

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2.12 Selection of Lugs

The lugs used for wiring should be of tinned copper type suitable for solder-less crimping.
The size of lugs chosen should be in line with the wire size. The following care should be
taken during crimping of power & control wires:
The insulation stripping length of the wire end to be crimped should match the length of
the barrel of the lug.
All the strands of the wire should be inserted into the barrel of the lug before crimping.
Crimping should be done with adequate pressure with proper and calibrated crimping
tools only.
After crimping the barrel length portion of the lug is to be insulated with PVC sleeves
with appropriate colour.
The criteria for selection of type of lugs depend on:

Power & control terminal screw size of the equipment to be wired.
Design of the termination end of the equipment.
Only tubular type lugs shall be provided for termination of control wire at PLC signal
terminals and auxiliary terminals of Siemens 3WN / 3WL type ACBs. For aux. connectors
of 3WL/3WT ACB, only one wire is permitted at one termination point.
In particular, the following applications of lugs shall be noted:
Type of lug Recommended for applications

Ring Current circuits comprising CTs,
ammeters, relays, etc.
Equipment terminals with plain & spring
washers
Stud-type power terminals
Pin Equipment terminals with terminal

washers
Control terminals
Indicating lamps
Fork Equipment terminals with plain & spring

washers
Tubular Control circuits requiring finger-touch-

proof protection, e.g., 9-way terminals
Screw less terminals

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3 Final Assembly Guidelines
3.1 Fixing of Panel Numbers & Nameplates

The panel number stickers/number-plates shall be pasted on the front side of the panel in
case of single front panels (MCCs / PCCs). The sticker/number-plate is to be located
centrally on the top bus chamber cover of each panel. For panels with Siemens / Board
Main Nameplate, the number-plate is to be provided on left corner as shown below.
In case of double-front panels, the panel numbers are to be provided on both front and rear
sides. The panel numbers should be suffixed by “F” & “R” respectively for front & rear. For
single-front panels, only panel numbers are sufficient.
Bus Chamber Cover Bus Chamber Cover

With louvers Without louvers
Board Nameplate / Siemens Board Nameplate / Siemens

Co. Nameplate / Panel No. Co. Nameplate / Panel No.
Bus Chamber Cover

With / without louvers
10F s
Board Nameplate / Siemens Co.
Nameplate / Panel No.
Siemens Company Nameplate shall always be on the last panel in case of boards having
total length less than 5 meters.
It shall be on the first and last panel in case of boards having total length more than 5
meters.
Siemens logo not required for extension panel.
The position of Board Nameplates shall be as shown in the Front / Rear View of order-
related drawings. If Board name plate is on first panel then Siemens logo to be on the
adjacent panel i.e panel 2.
The requirement of covers with ventilation louvers will be indicated in the FV drawing and
the same shall be fitted accordingly.
The Works Order Nameplate which gives the reference Works Order, Item No., Year of
Mfg., etc. should be fixed on the side cable alley door centrally in front of first panel in case
of MCC. For PCC panels, it should be mounted on the ACB upper door of the first panel at
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a suitable location. In case of MCC with rear cable alley, the W.O. nameplate should be
mounted on the incomer feeder door in front at a suitable location.
Feeder name plate to be riveted on the feeder door. Any other name plate provided on
feeder door should also be screwed or riveted. (Name plate on feeder door should not be
fixed with adhesive)
3.2 Fixing of Barriers & Guards

All accessible live parts such as live busbars, live switch / MCCB terminals which remain
live after opening the panel / feeder door need to be guarded against accidental touch by
suitable barriers / guards.
The barriers / guards may be of M.S. blank / polycarbonate sheet, in case of standard, or
made of 1.6mm thick FRP sheet cut to required dimensions for non-std. executions.
The areas which generally require to be guarded with FRP / MS barriers are as follows:
Main Horizontal Busbar Chamber – segregation of main busbars from auxiliary busbars
(fixed & drawout MCCs & PCCs)
Gap between equipment plates – access to vertical busbars from front (in case of 8PU –
F4 & T3)
Cable termination arrangement with busbars extended to cable alley (for drawout & fixed
type MCCs)
Incoming side of switch-fuse / MCCBs inside feeders
Horizontal guard below main busbar chamber at front & rear
Outgoing side of switch-fuse (which act as incoming side) in case of incomer feeders (in
MCCs)
Vertical busbar chamber ( in case of 2-tier PCC panels)
Outgoing cable connection pieces in cable alley at rear (for RCA, PCC DP & T3.5
panels).
Use polycarbonate shroud on incoming side of MCCB.
Shrouds fixed on MCCBs shall be fixed such that fixing & removal of the same can be
done without disturbing the MCCB operating kit.
Yellow polyester insulation tape shall be provided on the inside surface of feeder door in
front of 3KL25/41/61/81 or super switch switch-fuse units mounted inside feeders as a
standard feature. In case of specific customer requirements, FRP sheet may be pasted in
place of self-adhesive PVC tape. Yellow polyester tape also to be provided between
equipment plate and 3KL61/3KL8/3KL10.
Apart from the above, any accessible live part is required to be guarded as per client
special requirement.
To avoid confusion regarding the requirement of guards, please refer to the Table 3.2.1
below which indicates, as a general guideline, product-wise the areas where guards /
barriers are to be provided. For guards for which standard designs exist (as indicated in the
chart), the same are to be followed. For other areas, the same need to be designed during
order-related TOP.

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Table 3.2.1 : General Guideline for Guards & Barriers
Std.(S)/
Order-
related
Product Area of fitment Orientation Material (O)
Between Main Busbar & Control Busbar in
8PUS1/ S1.5 front Vertical Perf. M.S. S
In front of Vertical Busbar trough Vertical SMC S
In cable alley in front of extended busbar
cable terminals Vertical FRP S
Below o/g fixed power terminals behind
middle tray Horizontal M.S. S
Below MBB Chamber behind top tray (SF) or
between two top trays (DF) Horizontal M.S. S
Below MBB in case of Full Feeder (where top
Tray is absent) Horizontal FRP O
Live busbar terminals inside fdr.after opening
fdr.door Vertical FRP S
Behind fdr.door in front of power fuse links of
3KL25/41/61 Vertical FRP/Tape S
8PUS1 (TCE) Above Control Busbars in Cable Alley Hor.&Vertical M.S. S
In front & behind MBB Vertical M.S. S
8PUS1.5 (TCE) Above Main Bus at bottom in C/A Horizontal M.S. S
Above Main Bus at bottom at rear Horizontal M.S. S

8PUF4 front Vertical M.S. S
Below MBB in case of Full Feeder (where top
Tray is absent) Horizontal FRP O
fdr.door Vertical FRP S
Behind fdr.door in front of power fuse links of
3KL25/41/61 Vertical FRP/Tape S
(TCE) Above Control Busbars in Cable Alley Hor.&Vertical M.S. S
(TCE) In front & behind MBB Vertical M.S. S
In front of approachable live busbars at rear
after opening door (in case of hinged doors at
rear) Vertical FRP O/S

8PUF4.5 front Vertical M.S. S
fdr.door Vertical FRP O/S
Behind fdr.door in front of power fuse links of Vertical FRP/Tape S
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3KL25/41/61
Below Main Bus Hor. M.S. S
Between Vertical Busbar & feeder
compartment Vertical M.S./FRP S
8PUF4.5(TCE) Above Main Bus at bottom in C/A Horizontal M.S. S
Above Main Bus at bottom at rear Horizontal M.S. S
Above ACB in front (1-tier ACB) upto top tray

8PUL4 / middle edge Vertical FRP O
Beside ACB in front (in case of B/C only) in
the upper compt. Vertical FRP O
Below MBB above ACB in front (in case top
tray is absent) Horizontal FRP O
In front of Cable conn. Busbar terml. edges at
rear Vertical FRP O
Vertical Busbar Trough in 2-tier ACBs Vertical FRP O
In front of approachable live busbars at rear
after opening door (in case of hinged doors at
rear) Vertical M.S. O/S
Behind the MBB (Top cable Entry) Vertical M.S. O
Between live busbars & equipment mounted
at rear (if applicable) with rear door Horizontal FRP O
Between two sets of outgoing busbar
8PUL4.5 terminals in DP Panels Hor. & Vertical M.S. S
8PUL4(TCE) Above Control Busbars in front Hor.&Vertical M.S. S/O
Above Main Busbars in front & rear(M B
8PUL4.5(TCE) Busbar) Horizontal M.S. O
8PUT3 Above & below 3KL FSU / MCCB inside fdr. Vertical FRP S
In front of VBB between eqpt. plates Vertical FRP S
In front of VBB looking from rear Vertical M.S. S
Above o/g cable busbar terminals Hor.&Vertical M.S. S
Compartment barriers between fdrs. Horizontal M.S. S
Below MBB at rear Horizontal M.S. S/O
8PUT3.5 Between VBB & FSU/MCCB incoming side Vertical M.S./FRP S/O
Incoming live terminals of FSU/MCCB inside
fdr. Vertical FRP S/O
Vertical Bus Chamber from rear Vertical M.S. O
Below MBB at rear Horizontal M.S. O
Above o/g cable busbar terminals Hor.&Vertical M.S. S
Compartment barriers between fdrs. Horizontal M.S. S
Vertical guard between feeder and cable
termination Vertical FRP S

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3.3 Panel Dust-proofing Guidelines

The following dust-proofing arrangement is required to be incorporated in the panels as per
the required degree of protection:
Use of neoprene (synthetic rubber)

gasket on
Remarks
DOP VL / VB 8PU Top
Relays (Addl.Measures)
Covers Sheet VB on
&
/ Doors of top
meters
panel
L4, L4.5
IP 41 With VL
T3, T3.5 N.A.
L4, L4.5 Bolts at intervals

With VL
IP 42 of 80 to 120 mm
& / or VB
T3, T3.5 N.A. on D.P. for doors.
L4, L4.5 1. Self-adhesive

gasket inside
door for IP
Panels cutout
T3, T3.5
IP 52 without N.A. 2. Bolts at
VL / VB intervals of 80
to 120mm on
S1, S1.5, D.P. Channel
N.A.
F4, F4.5 for doors
L4, L4.5
1. Same as
above (1) & (2)
Panels T3, T3.5 N.A.
2. Self-sticking
IP 54 without
gasket
VL / VB S1, S1.5,
between
F4, F4.5, N.A.
panels
F4.6
Legend:
= Gasket required 5 = Self sticking gasket = Gasket not required
N.A. = Not Applicable VB = Ventilation Box VL = Ventilation Louver

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3.4 Rubber Lining / Gasketting Precautions

The following precautions need to be adopted during gasketting operation for good quality
of workmanship:
The powder on the rubber profile needs to be wiped off using semi wet cloth. Traces of
powder if remaining in the groove will cause poor adhesion.
Traces of oil / dust, if any should be removed from MS parts edges before application of
rubber lining.
Clean dust-free workplace & clean pair of hands are required to achieve good aesthetic
finish.
The adhesive on the door edge should be uniformly applied. Care should be taken to
avoid smearing of adhesive on the door surface. Once dried, these marks cannot be
removed & gives a dirty appearance.
The rubber profile needs to be cut at 45 degrees (V-shape) at the corners of doors /
covers to avoid bulging. This is very important as bulging of rubber profile at door corners
will lead to fouling of adjacent doors after assembly & also ultimately damage the rubber
lining.
The application of adhesive should start from one end of the door & should be
simultaneous with the fixing of profile on the door edge.
Good quality adhesive (araldite) to be used to ensure proper durability of adhesion.
At the hinge end of the door, the rubber lining should be extended till 12 mm from the
door edge to ensure proper dust-proofing after closing door.
The self-adhesive flat gasket behind door should be pasted vertically straight & it should
be ensured that the same sits on the Dust-proof Channel after door closing. No joining of
gasket should be done.
The self-adhesive flat gasket behind IP should be pasted straight & it should be ensured
that there is no gap between the IP & door-cutout after closing door.
Inside portion of door gasket where the door lifter overlaps should be cut.
After gasketting the doors / covers should be kept untouched for at least 6 hours for
curing. The doors or covers during curing to be stacked in such a way that the gasket
edges are not subjected to any pressure whatsoever. Small wooden block may be placed
in between 2 doors or covers during stacking to achieve free gasketting edges during
curing.

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4.0 Trolley Assembly Guideline
4.1 Trolley Frame Assembly ( This is applicable if trolley fixture is available)

The trolley frame is to be assembled on Bugel Assembly Fixture. The sequence is given
below:
Insert lever guide (bottom) into the slot

provided on fixture
Insert lever guide (top) into the slot

provided on fixture
(not required for 2M)
Insert bugel at its locating pin (bottom) &

clamp (press toggle clamp)
Insert bugel at its locating pin (top) &

clamp (press toggle clamp)
(Note: Top Bugel required for 3M – 10M.
Addl. middle bugel required for 8M & 10M)
Put stiffener (RH) & (LH) with pep rivets in

their respective positions.
Rivet stiffeners with hydra-pneumatic pep

riveting gun (air pressure: 6kg/sqcm.)
(Note: No moisture content allowed in
pressurized air line).
Remove assembled trolley frame from the

fixture after releasing toggle clamp.
The frame is now ready for mounting
on rear plate.

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4.2 Mechanical Assembly of Trolley

The assembly steps are given below :
Place power & auxiliary equipment on rear plate

and mark drilling details as per fixing locations on
the plate
Drill holes on rear plate as per marked locations

(Note : For identical / similar trolleys, similar layout
of equipment to be maintained)
Touch-up with paint at the drilling locations
Mount the equipment on DIN rail or with self-

tapping screws directly on rear plate as per
instructions of individual equipment type
Mount the Trolley Frame Assembly on rear plate

and fix with 4 Nos. screws on tapped holes on rear
plate
Mount Instrument Plate Sub-assembly

(drg.no.4-16-02811-001/002)
(without / with fuse support)
on Trolley Frame Assembly
(Ref. Drg. 3-16-02812-001 / 002)
Put spacer 2 Nos. between rear plate & centre

guide (top) and rivet with pep-riveting gun
A
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Put spacer 2 Nos. between rear plate & centre

guide (bottom) and rivet with pep-riveting gun
Assemble Terminal Support on Trolley
Assemble Earthing Spring & Support on trolley at

the incoming lyra contact cutout
Insert Lifter End on Earthing Spring ( 2 Nos.)
Mount 9-way terminal plug on terminal support

Note : No. of blocks & type as per drawing
(normal / test-service). ***
(Ref. Drg. 4-03-08198-… & 4-03-08105-…)
Fix self-adhesive stickers for terminal numbers on

9-way terminal plug as required by circuit drawing
Mounting of Outgoing Lyra Assembly as per rating

required. (125/250/400A)
Mounting of Assembly of Control Transformer

(applicable in case of control trafo feeders only)
(Ref. Drg. 4-03-08671-001)

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Assemble TEST/SERVICE limit switch on bottom

centre-guide of trolley, if applicable
(Ref. Drg. 4-03-08117-001 / 002)
Fix self-adhesive delta sticker on bottom centre-

guide for indication of TEST/SERVICE position.
(The corresponding TEST/SERVICE/ISOLATE
sticker will be put on middle tray of feeder.)
Assemble Locking Lever assembly for

TEST/SERVICE position, if required as per drawing
(Ref. Drg. 4-03-15881-001)
*** The terminal blocks (9-way plugs on terminals) on trolley are numbered as shown
below :
FOR SIZE
2M
Nos. Nos.
21 - 11 - FRONT
29 19 SIDE OF
TROLLEY
FOR SIZE
Nos. Nos. 3M
41 - 21 -
49 29 FRONT
SIDE OF
TROLLEY
Nos. Nos.
31 - 11 -
39 19 BOTTOM
SIDE OF
TROLLEY

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FOR SIZES 4M – 10M ( please refer drg.no.4-03-08105-..)
Nos. Nos.
61 - 31 -
69 39
FRONT
Nos. Nos. SIDE OF
51 - 21 - TROLLEY
59 29
Nos. Nos.
41 - 11 - BOTTOM
49 19 SIDE OF
TROLLEY
4.3 Handling of Trolleys

Trolleys, after assembly, have to be handled carefully to avoid damages to mechanical
parts / equipment. The following specific care need to be taken :
Trolleys should be stored on a level and dry surface free of dust away from sunlight.
They should be preferably covered with polyethylene sheet to avoid accumulation of
dust.
Trolleys must always be stored upside up, i.e., the way they are placed in the panel.
They should never be stored sideways / upside down / rear side down to avoid damage
to power / control terminals & equipment.
Top / Bottom Levers must never be used for lifting the trolleys as they are not designed
to take the load of the trolley. Lifting of trolleys should be done only with top / middle
bugel.
The extended portion behind rear plate comprising of incoming and outgoing lyra
contacts, earthing spring & shutter lifter should not be damaged during storing / transit.
Trolleys should be properly identified with the self-adhesive labels which shall be pasted
on the rear side of the base plate. The label should mention the order & item reference,
feeder number, module type and wiring scheme number.

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5.0 Handling & Transportation of Assembled Panels

Assembled panel structures are often required to be transported to & from partners’
premises in unpacked/semi-packed condition for completion of various assembly jobs in
our Works. Adequate care is to be taken during such movement of panels in order to
ensure that there is no damage to any panel part or electrical equipment.
The following general points are required to be ensured:
All hinged doors for feeders & bolted covers are to be tightly closed.
No busbar / metal parts should be projected outside the panel outside perimeter.
All mechanical parts & equipment should be mounted with proper tightening. (for
example, tightness of ACB Guide frame mounting bolts/nuts to be ensured).
All busbars / busbar supports are to be properly tightened.
All C.T.s (busbar mounted) should be properly clamped to avoid damage due to
vibrations / jerking.
The following are to be packed in separate wooden boxes and transported a) Above
5KVA transformer, b) BG3 ACB, c) Soft Starters d) UNISTAR Capacitor of 50 KVA &
above and VFD etc.
During loading / unloading of panels, proper slinging with steel ropes of adequate
strength should be used. Panels must always be lifted by slinging from bottom
including the wooden platform below the panels. Lifting angles should not be used as
they are not designed to withstand all the dynamic loads during movement.
The T.U.s should be placed on the truck lengthwise as shown below in order to minimize
impact on the panels during sudden braking of trucks.
PLACING OF PANELS ON TRUCK (PLAN VIEW)
RIGHT WRONG
The panels should be tightly tied with rope with the transport vehicle to ensure that there
is no relative movement during transportation.
The panels shall be covered with tarpaulin completely from all sides to ensure that they
are not directly exposed to sunlight or rain during transit.

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6.0 Technical Order Processing – General Guidelines

Based on observations during testing / quality checks as well as customer feedback, the
need was felt to lay down certain basic guidelines which are to be followed during technical
order processing. Over & above the specific order-related requirements as mentioned in
the engineering drawings, the following general points should be taken care of during
processing:
6.1 Feeder Layout & Equipment Mounting
1. For feeder arrangement in a panel, it is desirable that the bigger or heavier feeders are
taken in the bottom side and the smaller feeders in the topside for convenience in
handling. Although the General Arrangement Drawing is finalized during engineering /
drawing approval, any discrepancy in this regard should be pointed out at the time of
contract review during TOP and necessary changes should be made in the GA in
concurrence with Sales / Execution Engineer.
2. While making the equipment layout in the equipment plate, care to be taken to place
the equipment for:
(a) economic wire routing (specially for power wire),
(b) all equipment to be properly accessible for maintenance,
(c) sufficient space to be kept for routing of power & control wire bunches avoiding
sharp bends on power wires,
(d) CT secondary terminals mounted on the left hand stiffener plate should not obstruct
approach to any equipment (except CTs, PTs, Control Trafo) mounted on the rear
plate,
(e) Sufficient space to be kept adjacent to terminal rows for ferruling of wires
(f) In case of feeders with CBCT, it is preferable to mount the same in the trolley to
avoid the crowding in the cable alley. The CBCT dimensions are to be selected as
per power wire size of the trolley.
(g) For fixed type feeders, the equipment mounting on baseplate should be either on
DIN Rail or with self-tapped screws or on tapped holes.
For heavy equipment mounting in fixed type feeders, e.g., power contactors –
3TF56/57, etc. which requires fixing with bolt size of M8 or higher, welded nut should
be provided on the rearside of equipment plate to ensure rigid mounting as well as
maintenance access from front only.
Transformer to be mounted with largest size hardware (suitable for the mounting slot /
hole size).
3. While designing a corner panel for a board having two wings at 90 degrees, care
should be taken that the equipment projection in case of door-mounted equipment
does not foul with the other side.
4. For drawout MCCs with L-Shaped layout, care should be taken to ensure the feeder
doors of corner panels open adequately for trolley insertion/withdrawal. Necessary
dummy adapter panels should be considered suitably.
5. For panels with capacitor / soft starter / variable frequency drives, suitable ventilation
louvers, Ventilation boxes are to be considered on the panel. For higher ratings of such
equipment, ventilation fans may also be required. The relevant equipment catalogue
should be referred while designing mounting of such equipment.

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6. In case of lamps with built-in trafo's & Mushroom P.B., care should be taken to mount
them with proper gap as the standard gap for normal lamps will not be suitable in view
of bigger size & heat losses within the units.
7. For mounting of TEST Pushbuttons inside feeders, the standard design of Siemens
should be followed. For drawout trolleys, these Pushbuttons are mounted on MS
Supports fitted on the LHS of bottom bugel. For fixed-type feeders, the TEST
Pushbuttons should be located on the equipment plate with standard support.
Preferably similar location to be maintained.
8. The MS support used for mounting equipments on equipment plate or in cable alley
should not have sharp corners / edges which could lead to operator injury.
9. For MCC feeders with IP having combination of lamps/pushbuttons, Selector switch,
etc., care is to be taken for the following:
While mounting Mushroom-head pushbutton, the pushbutton is to be so located such
that the edge of the mushroom-head does not foul with the IP door gasket.
The Mushroom head should not overlap with adjacent lamps / pushbuttons.
The handle of the selector switch should be such that the same is within the IP cutout
on door and there is no problem while opening / closing of the door. Normally, the
wing knob or double wing knob type handle for 96X96 frame size is accomodable.
The mounting location of Ammeter / Voltmeter Selector Switches (ASS/VSS) should
be so as to allow space for routing the wire connection to them. Care should be taken
to maintain sufficient clearances from switch terminal to IP body as well as for
maintenance access.
Three nos. lamps with built in trafo in one vertical line is not accomodable properly in
standard IP. In such case, the equipment layout should be revised.
In case of control transformer feeder with IP, it is to be checked that the equipment
mounted in the IP does not foul with the equipment (transformer) mounted inside.
Additional length of bimetal relay reset cord, if required is to be considered while
designing the trolley layout.
Separate mounting bracket as per standard design should be used for mounting
SIF96 meters on IP.
Wire bunch to IP should not be clamped at the lower edge (upper edge in case of 2nd
IP) of IP to avoid fouling of the same with the bugel.
10. All equipment mounting cutouts on door / IP & mounting holes should be preferably
pre-punched during fabrication stage itself. Except for nameplate fixing, manual drilling
/ cutout on painted parts is not allowed. Moreover, for all manually-drilled holes on
painted parts, proper paint touch-up to prevent rusting should be carried out.
11. In PCC panels with top cable entry (control bus bar at bottom), suitable cutout on
equipment base plate (in metering chamber) to be provided for entry of control cable to
the outgoing control terminals.
12. For mounting of lamp / P.B. on IP care should be taken so that the lamp row is on L.H
& P.B. on R.H.
13. Care should be taken for mounting lamp / P.B. such that relation between is
maintained. e. g. START PB should be horizontally adjacent to ON lamp.
14. Meters or Relays of SIF 96 which needs to be operated from front facia (e.g. Proke
Device relays) needs to have a wider IP. The width of IP and door cutout has to be
increased by 12 mm to mount the meter / relay directly on IP.
15. In F4.5 execution, mount control terminal rail (in cable alley) with 3 nos. Z cleats for
feeder size 6M onwards.

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16. In F4.5 / F4.6, more than 2 busbar tap-off’s from the same point on vertical busbar is
not allowed. GA to be reviewed & corrected if required, with respect to this point.
17. 3KL82 / 3VL with busbar tap-off from vertical busbar, shall not be provided in 3M &
below size as bottom-most feeder, to prevent fouling of tap-off. GA to be reviewed &
corrected if required, with respect to this point.
18. 3KL82 / 3VL with busbar tap-off from vertical busbar, shall not be provided as top-most
feeder, to prevent fouling of tap-off. GA to be reviewed & corrected if required, with
respect to this point.
6.2 Cable Termination

1. The guideline for the minimum height for cable termination & other relevant parameters
are enclosed in the Sketch & Tabular Chart below. However this is applicable for single
run of power cable. When the no. of cables are more than one, this minimum height is
to be more because of two vertical heights corresponding to 12xD (D = dia of the cable
) – this is normally 1.5 times the cable size as asked by the various consultants/clients.
Critical Dimensions during Cable Termination

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Cable Dimensions Dowell Cu Dowell Al

Size Lug Type Lug Type
sqmm. D A B C d- E-Cu d-Al E-Al
Cu
50 9.00 108 36 144 10.2 16 12.7 23 CUS 15 ALS 224
70 11.20 134 43 177 12.7 20 12.7 22.6 CUS 18 ALS 226
95 12.50 150 45 195 12.7 23 12.7 24.6 CUS 20 ALS 229
120 14.42 173 48 221 12.7 26 12.7 28.2 CUS 22 ALS 231
150 15.68 188 55 243 16.2 28 16.2 30.9 CUS 26 ALS 233
185 17.50 210 66 276 16.2 32 16.2 34.6 CUS 28 ALS 235
225 19.60 235 77 312 16.2 35 16.2 39.0 CUS 231 ALS 320
240 21.00 255 77 332 16.2 38 16.2 41.2 CUS 29 ALS 237
300 22.50 270 84 354 20.3 42 20.3 46.3 CUS 32 ALS 259
400 27.00 325 89 414 20.3 49 20.3 54.1 CUS 33 ALS 260
500 29.15 350 93 443 20.3 53 20.3 58.7 CUS 34 ALS 296
625 33.00 395 109 504 20.3 61 20.3 66.6 CUS 35 ALS 261
800 36.85 440 128 568 ** 67 ** 73.3 CUS 062 ALS 318
1000 41.25 500 165 665 ** 76 ** 81.9 CUS 076 ALS 319
** Available on request only.
Note:
d-Al & d-Cu are the hole diameter of Aluminum & Copper lugs respectively.
E-Al & E-Cu are the widths of the connecting strips corresponding to Aluminum &
Copper lugs.
For various lug hole diameters, the hole diameter on connecting strip & corresponding
bolt sizes are given below :
Lug diameter (mm) Hole size on strip (mm) Bolt Size
10.2 12 M10
12.7 14 M12
16.2 18 M16
20.3 20 M18

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For single core cables, the following points are to be considered while designing the
termination arrangement:
Normally for higher current rating single core cables are selected and in majority of
the cases they are at least two or more in numbers in each phase. The termination
arrangement should be such that the cable can be taken straight to the bus bar
terminal from the gland plate. If two holes are provided side by side in the bus bar
terminal then the distance between the holes are to be decided by the location of the
corresponding gland positions in the gland plate. This point is to be considered as far
as practicable to avoid difficult in bending of the higher size single core cables.
Aluminum Gland Plate of 3mm thickness is to be considered in panels wherever
single-core cables are terminated to avoid heating due to eddy-current losses.
Moreover, all the cores must be terminated on the same gland plate without any
metallic separation between them.
2. For non drawout the minimum power and control terminal size is 6 sq.mm.
3. The cable support for the bottom most termination arrangement for PCC/T3
panels should be a cross support and not the usual cable support fixed on the side.
4. In case of double front MCCs with top cable Entry, the size of rectangular cutout on top
tray is to be checked for adequacy keeping in view the combined diameters of all the
cable cores for both power and control cables.
5. In case double front MCCs with top cable Entry where the incomer feeder is located at
top, care should be taken to provide sufficient space & termination height particularly for
higher cable sizes e.g.300sq mm.
In this regard, the feeder with higher cable sizes should be placed at rear of DF keeping
in view of our location of MBB which is more towards front.
6. Availability of adequate size & numbers of holes for termination of client’s cable should
be ensured at the bus bar terminals.
7. In case of termination of cables of sizes - two runs of 95 sq. mm, and 120 sq. mm and
above cable(in case of MCC) , suitable extension bus bar pieces are provided as per
Siemens standard design. While selecting the size of such extension pieces, care
should be taken such that the palm of the lug sits entirely on these bus bars. Also,
adequate supporting arrangement for extension pieces to be provided on equipment
plate / panel structure as per standard design to prevent load of cables getting
transferred to the outgoing fixed power terminals.
8. In fixed type feeders, all power & control terminals have to be provided on equipment
plate. If the same is not accomodable in some cases, then only the excess terminals are
to be provided in the cable alley with additional support.
6.3 Busbar Design

1. Spacers provided between bus bars of multiple runs generally have two different
applications:
Maintain specified gaps for multiple runs at supporting points.
Current transfer points at joints / tap-offs with multiple runs.
To the extent possible, the second application should be avoided during busbar design.
In case the same is inevitable, the material of the spacer must be the same as that of
the busbars on either side of the joint.
In case of the first application, the spacer is only acting as a packing piece for
mechanical support & can be of a different material. For boards with fully copper
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busbars, FRP shall be used as packing piece. For boards with fully Aluminum busbars
or Aluminum board with Copper feeder connections, FRP / Al packing piece shall be
used.
2. In PCC panels, the spacing between holes on bus bar terminals for termination of
outgoing cables should be more than the palm width of the power cable lug for the
cables. This will facilitate termination of cables by providing additional space for
tightening the bolts at the cable lugs. (Typically for 300sq.mm cable, spacing between
the holes may be maintained as 60mm). For 2-tier PCC panels, suitable cutout on the
horizontal guard between the outgoing terminals shall be provided for the routing of
power cables for the upper tier feeder.
3. Care should be taken to maintain adequate clearance between control bus bars and
the MS perforated guard separating them. This may be achieved by providing control
busbar support at intermediate position as spacer. Alternatively FRP spacer (10mm
thick) may be used between control bus bars and the perforated guard at regular
interval.
Refer below table for additional control busbar support guideline:
5X5 Control busbar 15X6 Control busbar
Panel Width Additional Support
Qty (Nos.) Qty (Nos.)
<= 4 2 No
Upto & <= 6 - No

Including 850 6 2 Yes
>6 - Yes
<= 4 - No
More than 850 <= 4 2 Yes
>= 6 - Yes
4. Suitable bus bar support to be provided within 250mm from the CB terminals on either
side as per guideline / standard design.
5. In case of Bus Trunking Execution (DBT) of ACB, Non std. Busduct Flange Details
(giving details of flange cutout & bus trunking connection) must be furnished during
TOP stage to the customer since the same is very critical from the viewpoint of
matching of busduct. Care should be taken during manufacturing to match the details
furnished even for panels with standard Bus duct. These details should be checked
during final inspection & the same be recorded in the Check List with reference to the
drawing number & revision index of the Flange Details Drawings referred during
checking.
6. For non standard busbar drawing – clearance of at least 20mm (Except where order
specific higher clearance are asked for) to be maintained between phase to phase &
phase to earth. If the same cannot be achieved then phase separator, insulating
material or PVC sleeves to be provided.
6.4 Other Areas

1. Suitable door stiffener should be provided on equipment-mounted door of bigger size.
As a general practice, stiffener shall be provided on the metering chamber of CB
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feeders where relays, meters are mounted. Such stiffener (thickness of which should
be more than sheet steel thickness of door) has a dual purpose of clamping the control
cable bunch. Stiffener frame to be welded in case of ACB lower door with more
equipments / relays of door above 600 width panel. Door lifter shall be provided of
module size 10M and above as per standard design. Proper care should be taken (by
proper adjustment of door hinges) to avoid sagging of metering chamber door of circuit
breaker feeders. Door gasket to be cut where the door lifter touches.
2. Restriction of usage of 9-way terminal block (test and service) should be considered
during contract review. It should be noted that not more than 2 Nos. extended terminal
blocks are allowed in a trolley in order to ensure smooth withdrawal / insertion.
3. In empty trolleys or trolleys W/O incoming top lyra, earthing facility along with guard for
incoming Lyra cutout (without incoming Lyra contact) should be provided.
4. The incoming / outgoing power lyra in trolley is to be selected considering the feeder
rating as well as the power wire size. It should be noted that up to 25 sq. mm. can be
terminated in 125A Lyra contact. For higher power cable sizes, 400A Lyra is to be
used, cutout size of which is different than that of 125A Lyra. The module size is also
sometimes affected due to this consideration.
5. In case of drawout trolleys with equipment mounted on door, the control wires for the
same should be routed via 9-way terminal block & the feeder door has to be earthed.
6. In case of L4.5 joining with F4.5 or S1.5, plain sheet with CSK screw should be
provided at the extended rear portion of the L4.5 panel. Similarly, for a double-front
S1.5 panel joining with L4.5 panel, the addl. Depth of S1.5 (800mm depth) w.r.t. the
depth of L4.5 (560mm depth) has to be blocked with a blanking plate (refer std. drgs).
7. Siemens standard drawings are to be strictly followed while carrying out the following
assembly operations:
Equipment plate mounting in fixed type panels 8PUF4/ F4.5/ F4.6
Door earthing arrangement
Control and power terminal mounting
Shrouding of vertical bus bars
Mounting arrangement of guard in empty compartment.
Shrouding of live parts after opening of doors
Phase identification, colour coding, equipment marking
Busbar assembly & supporting arrangement.
8. Door having equipment mounted should be earthed with std. Earthing wire through
earthing bolt welded inside door towards hinge.
9. Care to be taken to place equipments on ACB lower door such that the rows of lamps /
PB, switches, relays are in same horizontal line with adjacent feeder doors as far as
possible.
10. All supports for mounting aux. equipment in feeders or in cable alley should not have
sharp corners.
11. M.S support (4-16- 10622-008) to be provided below main bus bottom support for main
bus size 2x180x10 & 2x200x10 per phase for aluminum. 1 x 160 x 10mm, 2 x 120 x 10
mm and above for copper.
12. Door limit switch (if required) to be provided at hinge side of door.
13. Rolled “C” channel to be provided at four corners of all shipping section of size – 3 ACB
panels with copper busbar. These channels to be removed at site. Accordingly the
wooden platform / packing width will increase.

08-05-2013 Page 58 of 78
Quality Code Book
14. Powder coating thickness should be 70-0, 70+20 micron, powder should be semi
glossy, structure finish, should be verified with RAL shade card or IS – 5 shade.
Whichever applicable.
15. Fish plates Packing Guideline
Aluminum: Fishplates of MCC and PMCC boards should be packed in carton and
keep the carton inside the panel with proper marking on front door of that panel.
Copper: Fishplates should be packed in separate wooden box.

08-05-2013 Page 59 of 78
Quality Code Book
7.0 Packing of Switchboards

7.1 Preparation for Packing
(a) The panels shall be thoroughly cleaned from inside & outside using dry compressed air
as well as clean dry rag cloth. Lubricated surfaces should not be wiped away.
(b) All necessary loose supply items like busbar fishplates with proper fasteners,
ventilation box, operation manuals, racking handles, blanking plates, panel keys, etc.
must be ensured as per Final Release Check List.
(c) All feeder doors & bolted covers are to be tightly closed.
(d) In ACB panels, the ACB should be racked in SERVICE position.
(e) Cloth Paper Label with TESTED stamp is to be tied on the front side.
(f) Heavy equipment (e.g., BG3 and above, Control Trafo > 5kVA,Soft starter of higher
rating) shall be removed from the panel & packed separately.
(g) Projected parts such as door lock keys, keys for Selector Switches/Pushbuttons should
be removed & packed separately & kept inside the panel (with suitable identification).
7.2 Domestic Packing Guidelines
Material Requirements:
1. Timber used for packing shall be any of the grades I / II under Appendix A of IS:6662-
A980 or good quality fresh rubber wood. The wood shall be free from attack of
insects/fungi, any kind of decay, warping or any other defect reducing the strength &
usefulness of the packing case.
2. Through cracks upto 100mm in planks & shooks are acceptable provided they are
sealed adequately with fasteners suitable to arrest propagation. No through cracks will
be acceptable in battens.
3. The lengthwise battens used in the wooden foundation should be of one piece & not
have any intermediate joints and size of wooden battens should be ¾ inch.
4. Countersunk nails confirming to IS:723 shall be used in the assembly of the packing
case. The shank diameter of the nails shall not be less than 3 mm. The length of the
nails shall not be less than sum of the thickness of boards & battens plus 12mm. There
should be battens (2/3 inch) length wise and depth wise in all four sides at middle height
of panel.
5. The panel sections should be properly wrapped with black plastic sheet. Over this
stretch-plast PVC film (Flexo-film stretch PVC film 40 micron thick 40cm x 200m
roll) to be put from all sides before packing.
6. The black plastic sheet should have sufficient strength (of min. thickness 200 gauge)
not to get torn off during wrapping / handling.
7. Bubble sheet to be provided only on the front side of all ACB panels.
Assembly Requirements :
1. Siemens standard drawing for Wooden foundation dimensions & design for panel
sections should be strictly followed.
2. The clearance from floor-level for the wooden platform base should be minimum 102mm
so that the battery-operated fork-trucks can be inserted freely.
3. While placing the panel section on the wooden foundation, care should be taken so that
the projected portion of equipment, e.g., switch drive handles, etc. remain within the
periphery of wooden foundation.
08-05-2013 Page 60 of 78
Quality Code Book
4. The panel structures should be properly secured to the wooden foundation with couch-
screws fitted on the foundation holes of the panels & the same should not project below
(to prevent fouling during fork-truck insertion).
5. The wooden shooks should have continuous planks (corresponding to full case packing)
on the front side of panels in case of single-front panels & both front & rear sides in case
of double-front panels. The top cover of the panels must always be of continuous planks
in line with full case packing.
6. The sides & rear (for single-front) can be provided with alternate planks (corresponding
to crate packing). For shooks with alternate planks, proper tar-cloth lining is to be
ensured from inside.
7. The shooks should have horizontal reinforcement battens at two levels height-wise.
These reinforcement battens should be provided with jute-felt pads & the same should
lock the panel sections from all sides to prevent movement inside the packed case
during transportation.
8. Siemens std. drg. no. 4-16-00171-… is to be followed as an indicative general guideline
for packing.
7.3 Sea-worthy packing for export

Over & above the requirements as mentioned above, the following need to be followed
additionally in case of export packing:
Instead of standard rubber-wood shooks, 6-ply normal commercial plywood minimum
6mm thick suitably reinforced with wooden battens is to be used.
Adequate quantity of sealed silica-gel packets (@ 3 kg. per cubic meter volume) are to
be provided in each panel cable-alley / LT Chamber.
Total height of packed cases should normally not exceed 2550mm for domestic
transportation. For export packing involving container transportation, special instructions
regarding restrictions in case dimensions to be followed.
Fumigation treatment should be done for Export packing case.
7.4 Packed case marking

Each panel section has to be properly identified with Customer Name, Consignee
Address, Customer Order Number (SAP no.), Item Number, Panel Number as well as
“Front” & “Rear”.
For export orders, additional markings of “THIS SIDE UP”, “FRAGILE”, “KEEP DRY” &
SLINGING LOCATION are to be put on each packed case.
Over & above the standard markings as mentioned above, specific marking as per
customer requirements are to be provided as per Client’s Despatch Instructions.

08-05-2013 Page 61 of 78
Quality Code Book
8.0 Inspection & Testing Guidelines
8.1 Incoming Inspection

All bought-out items are to be procured from sources pre-approved by Siemens.
For critical bought-out materials / finished components, regular checks at incoming stage
during receipt need to be carried out & records to be maintained for the same.
Raw Material (Sheet Metal, Busbars): Apart from routine visual checks, periodic checks
of material properties such as tensile strength, hardness, chemical composition, grade &
conductivity, etc. has to be checked on samples by sending to independent laboratories
& the report furnished for review.
Finished Components (Supports, Insulators, Wires, Rubber Profiles, Fasteners): Visual,
physical & dimensional checks are to be performed as per Siemens Control Plan /
Guidelines & records maintained. For critical finished components such as HT Bolts,
Belleville Washers, etc., the physical properties like hardness also are to be checked
periodically from external laboratories to ensure consistency of supplies.
FRP / SMC / Moulded parts if found to be defective or not as per std drawing then the
same to be rejected / destroyed to avoid reuse.
8.2 In-process Inspection

Critical process parameters of pre-treatment, powder coating need to be monitored on a
regular basis & records maintained.
During fabrication, the critical dimensions of parts (MS & Busbar) need to be checked
after each operation, e.g., cutting, punching, bending, welding, to avoid more rework at a
later stage.
During each assembly stage, the relevant check-lists of Structure, Busbar, and Wiring
should be filled up by the Assembly Supervisor at the appropriate stage to control,
monitor & ensure that all relevant points are taken care of at that stage itself. This also
ensures that the rework at final testing stage is minimized.
8.3 Final Inspection & Testing

Visual & Electrical Checks are to be carried out on completed panels as per Siemens
Electrical Testing Check-Lists & all observations / non-conformances are to be attended
before final release for packing.
The compliance of all earlier assembly-stage check-list points are also to be ensured at
this stage.
8.4 Quality Records

The following documents / records have to be compiled & furnished to Siemens on a
regular basis:
Process-related:
Lab Test Records of Raw Materials / Critical Components : Once in 3 months.
Calibration Records of Testing Instruments / Gauges : Once a year.
Product-related:
Assembly & Final Testing Check-List: For every customer order.
Bought-out items test reports : For every customer order.
Operation Manuals / Instructions for Major Equipment : For every customer order.
As-built drawings / Shop-corrected drawings : For every customer order.

08-05-2013 Page 62 of 78
Quality Code Book
8.5 Testing Instructions

TESTING
s 1.0 LAYOUT INSTRUCTIONS
PAGE - 1/8
TYPE OTHER
DETAILS OF TEST / INSPECTION TO BE CARRIED REFERENCE
SL.NO. OF RELATED
OUT STD
TEST INFORMATION
Check layout of panels, feeders & outside equipment
1.1 C Front view drg.
as per drg.
Check position of transportable unit separation as per
drg.
Top bolted covers with / without louvers & panel nos.
provided
1.4 Top bolted covers with / without louvers provided C Front view drg.
1.5 Panel joining nuts, bolts provided as reqd. V Front view drg.
Door fixing screws are properly aligned with
1.6 V
corresponding cage nut.
1.7 Proper cutouts have been provided for missing eqpts. C Layout drg.
Ref.ERM or
Sufficient space is provided for mounting of missing
dimensional
1.8 equipments, so that, when mounted they should not V
drg. Of the
foul with guards, supports or come near live parts
eqpt.
Positioning of indicating lamps & pushbuttons are as
1.9 C Layout drg.
per drgs.
1.10 Equipment cutouts on doors are smoothly finished. V
1.11 Feeder doors are not twisted. V
1.12 Lifting arrangement provided as per drg. C Tech. Details
1.13 Additional base frame provided (If reqd.) C Tech. Details
1.14 Refer to special notes on front view drg. (If any) C Front view drg.
Doors are smoothly closing & opening without fouling
1.15 with each other or door gasket rubbing with the panel V
body.
Siemens emblem, W.O. nameplate, caution sticker
1.16 C QCB
provided on the panel.
IS Shade
1.17 Check inside & outside paint shade & finish. C
Tech. Details
Card
TYPES OF INSPECTION : T = TESTING / MEASURING; C = COMPARING; V = VISUAL INSPECTION
PREP. BY : Anil Motwani CHKD. BY : Shouvik
s Bhattacharyya ISSUE : 01 / 07
TESTING
s 2.0 BUSBARS INSTRUCTIONS
PAGE - 2/8
TYPE OTHER
SL.NO. OF RELATED
OUT STD
TEST INFORMATION
Front view drg.
2.1 Check busbar size & material as per FV drg. C
/ Tech. Details
Main busbar or vertical busbar isolation provided as Refer Layout &
2.2 V
shown in FV drg. / Ckt. Drg. (If reqd.) Ckt. Drg.

08-05-2013 Page 63 of 78
Quality Code Book
Busbar supports with bigger size slots provided at

2.3 V
busbar joining positions in 8PU design.
2.4 Busbar interconnections are properly supported. V
Busbar mounted CT's are properly clamped &
2.5 V
supported
Bolt length for connecting links provided correctly : - (I)
2.6 Single busbar per phase - 40 mm. (ii) Two busbar per V
phase - 60 mm. (iii) Three busbar per phase - 80 mm.
Earthbus in 8PU - F4 - 600mm Width panel to be fitted
2.7 inside (looking from rear) for greater cable termination V
space at rear cable alley.
TESTING
s 3.0 CABLE TERMINATION ARRANGEMENT INSTRUCTIONS
PAGE - 3/8
TYPE OTHER
SL.NO. OF RELATED
OUT STD
TEST INFORMATION
Correct type cable termination provided as per the cable
3.1 C
size mentioned.
3.2 Outgoing terminal hole nut-bolts are correctly provided. V
3.3 Outgoing terminal is properly accessible. V
Terminal links for bustrunking terminals are provided (If Bustrunking
3.4 C
applicable) layout drg.
Correct size / position of cable gland cutout / cable Cable gland
3.5 T
glands provided (If reqd.) cutout drg.
3.6 Cable supports are provided. V
Proper space is available for connection of cables (Also
3.7 V
when direct termination at equipment terminals)
Cable termination should not obstruct access to any
3.8 V
equipment e.g. space heater, thermostat etc.
Suitable arrangements are provided for cable entry /
3.9 T Std. Drg.
bustrunking connection at top or bottom of the panel.
3.10 Outgoing terminal marking are correctly provided. V Circuit drg.
Outgoing terminal colour identification marking / colour
3.11 V
sleeves provided.
Clamp terminal
3.12 Outgoing terminals are provided as per clamp diagram. V
diagram
Terminal drg.,
3.13 Spare terminals are provided as reqd. V Ckt. drg., Tech.
Details
3.14Identification marking for terminal groups are provided. V
Power cable termination height adequate for the cable
3.15 T QCB
size mentioned.

08-05-2013 Page 64 of 78
Quality Code Book

TESTING
s 4.0 EARTHING INSTRUCTIONS
PAGE - 4/8
TYPE OTHER
SL.NO. OF RELATED
OUT STD
TEST INFORMATION
Earth continuity / star washers are used at various
4.1 V
places as reqd.
Earth busbar extension terminals are provided on each
4.2 V Tech. Details
side (If reqd)
Equipments for which earthing terminals provided, are
4.3 V
properly earthed.
Doors mounted with potential carrying equipments are
4.4 V
properly earthed.
4.5 CT secondary winding is earthed as reqd in drg. V Ckt. Drg.
TESTING
s 5.0 DEGREE OF PROTECTION INSTRUCTIONS
PAGE - 5/8
TYPE OTHER
SL.NO. OF RELATED
OUT STD
TEST INFORMATION
Gaskets have been properly fixed so that no gaps are
5.1 V
visible after closing of the doors.
Dust proofing of instrument plate cutouts are properly
5.2 V
done.
Round holes in the hinge side of door are blocked with
5.3 V
PVC tape.
Parts which remain live after opening of door are
5.4 V
guarded.
In buscoupler feeder, both incoming & outgoing sides
5.5 V
are guarded.
Busbar power terminals exposed in cable alley are
5.6 V
guarded.
Main phase busbars at the bottom are properly
5.7 V
covered from the top.
Rubber gaskets for equipment cutouts are provided as
5.8 V
reqd.
5.9 Clearance between live parts, live part & earth. T QCB
Door mounted equipments, wires, supports, etc. are
5.10 not fouling with or very close to live parts inside the V
panel.

08-05-2013 Page 65 of 78
Quality Code Book
TESTING
S 6.0 GENERAL INSTRUCTIONS
PAGE - 6/8
TYPE OTHER
SL.NO. OF RELATED
OUT STD
TEST INFORMATION
6.1 Check nameplates as per nameplate list C Nameplate list
Nameplates are provided for similar equipments
mounted on door, to differentiate one from the other.
6.2 V
(e.g. same relay for two feeders mounted on the same
door.)
6.3 Different parts fixing nut / bolt are tightened properly V
Any special requirement, if mentioned in the special
6.4 V
notes, are taken care of.
Horizontal perforated guard below main bus chamber
6.5 fitted at rear (applicable for single front 8PU S1 / F4 V
panels)
The Z - support for 3KL 25 / 41 is of correct length : -
6.6 T
T3 panel : 77mm & F4 panel : 83mm.
Yellow insulation tape on trolley / equipment baseplate
6.7 V
& inner wall of door provided as per standard.

S Bhattacharyya ISSUE : 01 / 07
TESTING INSTRUCTIONS
s 7.0 EQUIPMENT MOUNTING & WIRING PAGE - 7/8
TYPE
DETAILS OF TEST / INSPECTION TO BE REFERENCE OTHER RELATED
SL.NO. OF
CARRIED OUT STD INFORMATION
TEST
Check various equipment details as per
7.1 C Equipments list & MSLD
MSLD & equipment list
All equipments mounted are in good
7.2 V
condition.
Equipment terminals, where connections are
7.3 V
made are cleaned.
7.4 Operation tests are performed by :-
a) Energising the board with reqd. main &
control voltages.
b) Interlocking connections & external
connections are simulated by shorting as
reqd.
T Circuit diagram
c) Continuity of the main circuit is checked
with the test lamp.
d) Control circuit functions are checked by
switching ON / OFF of various eqpts. of the
main circuit without load, in the desired
sequence.

08-05-2013 Page 66 of 78
Quality Code Book
e) Checking of interlocking schemes of

various feeders for their proper functioning.
f) Functioning of signaling / annunciation
circuits are checked.
7.5 Correct lugs & ferrules are used. V
Spare contacts are wired up as per ckt.
7.6 Continuity checking for contacts make / T Circuit diagram
break.
Jumper terminals interconnection wires are
7.7 V Ckt. Drg. / Terminal Plan
provided as per drg.
Sufficient length of inter - connection wires for
7.8 V
missing equipment are provided.
7.9 Check tightness of connections. V
7.10 Cupal washers are provided where reqd. V QCB
Wire size / inter connecting busbar sizes are
7.11 T QCB
correct.
Correct rating of lyra contact arrangement
7.12 V
provided as reqd. for the feeder type & rating.
Correct equipment identification marking &
7.13 V Circuit diagram
feeder no. marking provided.
7.14 Wiring is clear of sharp edges. V
Birelay has been made hand reset or self
7.15 V
reset as per requirement.
7.16 Lugs are properly crimped on wires. V
Check operating sequence of switches tally
7.17 with corresponding position on the nameplate T
provided for the same.
Wires or parts of the trolley are not fouling
7.18 with panel body while drawing out of the V
trolley.
7.19 Wires are properly bunched & clamped. V
CT mounting is polarity wise correct &
7.20 T Circuit diagram
secondary winding continuity is OK.
Space heater is mounted clear of wires &
7.21 V
FRP guard.
Check switch drive alignments, interlock &
7.22 V
defeat interlock operations.
Switch padlocking / castle locking Eqpt.list/Spl.Notes/Layout
7.23 V
arrangement provided (If reqd.) drg
7.24 Megger & HV test T
HV test to be carried out as per 'Guidelines
IS 8623 :
7.25 for High Voltage Testing'. Refer chart in next T
1993
page.

08-05-2013 Page 67 of 78
B
GUIDE LINES FOR HIGH VOLTAGE TESTING - ROUTINE TEST TESTING INSTRUCTIONS
s AS PER IS : 8623, CLAUSE 8.3 PAGE - 8/8
Version No.
Document No.
Values of Test Voltages for High Voltage Test
No. & Description of IS Circuit / Apparatus
s
For rated insulation Dielectric Test Duration of application of

To be applied between
voltage, Ui Voltage, V rms test voltage
LMVLVDS / QA / 12
Upto & including 60 1000 60 seconds
61 to 300 2000 60 seconds
Valid from
R phase & YBNE
300 to 660 2500 60 seconds
08-05-2013
Y phase & RBNE
a) Main Circuits
B phase & RYNE
661 to 800 3000 60 seconds
N&E
IS : 8623 - 1993 801 to 1000 3500 60 seconds

Factory Built
Assemblies for 1001 to 1200 DC 3500 60 seconds
This Supersedes:
Voltages upto &
b) Control & Auxiliary Ckts.
Document Description:
including 1000V AC &
Quality Code Book

1200V DC
Upto & including 60 1000 60 seconds
1.Direcltly
Between live parts &
Connected to main 61 to 300 2000 60 seconds
the frame of the FBA
ckt.
300 to 660 2500 60 seconds
LMVLVDS / QA / 12 Version No. A

2. Unsuitable for Upto & including 60 1000
Between live parts &
connection to main
the frame of the FBA Where Ui exceeds 2Ui + 1000 with a
ckt. 60V minimum of 1500
Acceptance Guideline:
Page 68 of 78
Upto 20 fronts - Megger value should be minimum 2 Megaohms and leakage current should not be more than 25 milliamps.
Above 20 fronts - Megger value should be minimum 1 Megaohms and leakage current should not be more than 25 milliamps.
Quality Code Book
IC LMV MS O-AIS (DS)
s PREP. BY : Anil Motwani CHKD. BY : Shouvik Bhattacharyya ISSUE : 10 / 10

Quality Code Book
9.0 Guideline for higher short circuit level

Additional Arrangement on panel for short circuit 65KA/ 80KA
For panels suitable for 65KA the following are to be taken care:
1. In old 8PU, Main bus support shall be double for R & B phase as shown
B
R
PH
PH
2. In old 8PU, Minimum bus size shall be 2x100x10 AL.

3. In old 8PU, Floating main bus support required for panel width 800mm and above and For
600 width with single main bus upto 160x10.
4. 8PU S1- vertical bus shall be copper ‘ P ‘ profile with Non standard trough & vertical bus
support
15
22
51
5. 8PUF4 vertical bus shall be minimum 50x10 copper and with 8 (eight) sets of support
instead of 6 (six) sets.
6. 8PUL4 – Increase the number of support for feeder connection busbar.
7. 8PUS1.5 –
(a) Vertical busbar 60 x 6 copper, connecting link 50 x 10 mm copper.
(b) Vertical bus support 3mm thick, white colour.
(c) Additional 10mm FRP support for vertical bus at top.
(d) Maximum 21M can be used for Modules.
8. 8PU F4.5 –
(a) Vertical busbar 80 x 10mm aluminum, Vertical bus link 80 x 10 mm.
(b) Vertical bus support – 10mm FRP with 8 sets.
9. 8PUL4.5 –
(a) Size – 2, 3WT ACB
(b) Upper connection with 2 x 100 x 10mm and lower connection with 1 x 140 x 10mm.
10. Main Busbar for 65KA should be minimum 80 x 10mm aluminum.
11. Main Busbar for 80KA should be minimum 140 x 10mm aluminum.
12. Main Busbar for 65 kA & 80 kA should be with floating support for single run of main
busbar.

08-05-2013 Page 69 of 78
Quality Code Book
10.0 Intelligent Code Book (ICB) for Simocode

10.1 Mounting & Wiring
1. While mounting Simocode & expansion modules inside the trolley, the total length of all
connecting Cables should not exceed 3 meters per system.
2. A sticker must be provided on the bugel of drawout trolley which reads as follows:
"UNPLUG THE PROFIBUS CONNECTOR FROM SIMOCODE UNIT BEFORE
ISOLATING THE TROLLEY FROM THE FEEDER" (see attached photo)
3. The termination of Profibus on each connector should be done with the help of a tool
(MLFB : 6GK 1905 6AA00). The detailed procedure is as follows:
Tighten the tool on profibus.
Roll it around twice or thrice.
Pull it.
The above gives a two-stage cut on the upper insulation & the shield.
Directly clamp on the connector without stripping since the process of connecting to
the connector automatically eats out into the insulation.
For more clarity, see attached photos.

08-05-2013 Page 70 of 78
Quality Code Book
4. Care must be taken to bunch Profibus separately, away from the Power & Control
cables. Also, panel to panel looping of Profibus should never be done from the busbar
chamber. This is a must to avoid electromagnetic interference.
Pls. refer to sketch below for Profibus looping route to be followed inside the
panel.

08-05-2013 Page 71 of 78
Quality Code Book
5. Trolley layout should be such that the location of Simocode basic unit is chosen so as
to put minimum pressure on Profibus cable terminating on the Basic Unit of Simocode.
Also, use saddles to fix the wires. Trolley layouts worked out for MECON A/c NLC
project are attached herewith as reference. When operator panel is mounted and 0.5m
flat cable is used, use a stopper to avoid IP opening more than 90 deg.
DOL
RDOL

08-05-2013 Page 72 of 78
Quality Code Book
6. The Profibus laying in the cable alley should be as much away as possible from the
power & control wires. It is suggested to bunch it behind the 9-way terminal blocks as
looking into the cable alley. (see attached photo)
7. Repeater module to be mounted on insulator.
12.2 For Simocode

a) Control transformer secondary should be 220 VAC.
b) Control and power contactor should be with surge suppressor.
c) Control and power contactor coil voltage should be 220 VAC.
d) Simocode basic and expansion module should be earthed.
e) Basic and expansion module should be mounted side by side.

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Quality Code Book

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Quality Code Book

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Quality Code Book
11.0 Forms of Separation
The following are the typical forms of separation by barriers or partitions (please also refer the
figures below)
Typical arrangements of internal separation
Main Criteria Sub Criteria Form
No separation Form 1
Terminals for external conductors not
Form 2a
Separation of busbars from the functional separated from busbars.
units. Terminals for external conductors
Form 2b
separated from busbars.
Separation of busbars from the functional Terminals for external conductors not
units and separation of all functional units separated from busbars. Form 3a
from one another. Separation of the
terminals for external conductors from the Terminals for external conductors Form 3b
functional units, but not from each other. separated from busbars.
Terminals for external conductors in the
same compartment as the associated Form 4a
Separation of busbars from the functional functional unit.
units and separation of all functional units
Terminals for external conductors not in
from one another, including the terminals for
the same compartment as the associated Form 4b
external conductors which are an integral
functional unit, but in individual, separate,
part of the functional unit.
enclosed protected spaces or
compartments.
The form of separation and higher degrees of protection shall be the subject of an agreement
between manufacturer and user.

08-05-2013 Page 77 of 78
Quality Code Book

08-05-2013 Page 78 of 78

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Quality Code Book for

LV Switchboard Channel Processor

Document No. Document Description:

5.0 Handling & Transportation of Assembled Panels 51

Document No. Document Description:

Document No. Document Description:

1.0 Busbar Manufacturing & Assembly

1.1 Busbar Fabrication

1.2 Busbar Marking

Identification of busbars will be provided:

Document No. Document Description:

On outgoing busbar cable connections:

Material of Polyester Polyester Polyester PVC Polyester

1.3 Busbar Jointing & Treatment

The following method to be ensured during preparation / assembly of any joint:

Document No. Document Description:

Use of aluminum cleats for control tap-offs

Table 1.3.1 – Surface Preparation for Busbar Jointing

Document No. Document Description:

Note: # brushing not allowed.

Document No. Document Description:

Table 1.3.4: Bolting pattern for Busbar

Document No. Document Description:

1.4 Busbar Sequence

Vertical Busbar Sequence (Top view)

Outgoing Cable Terminal Busbar Sequence

(Rear Sectional View)

Auxiliary Busbar Sequence

Document No. Document Description:

Document No. Document Description:

1.5 Busbar Insulation

Busbar Insulation Process

Document No. Document Description:

Busbar with sleeve

Document No. Document Description:

1.6 Power Terminal Fasteners

1.7 Vertical Earth busbar

Document No. Document Description:

2.0 Equipment Mounting & Wiring

2.1 Mounting & Colour Coding of Pushbuttons & Lamps

Red OFF / STOP

Green RAISE / FORWARD

Yellow LOWER / REVERSE

Document No. Document Description:

ON OFF STOP / TRIP

Green Red Red (Mushroom)

FORWARD / RAISE STOP REVERSE / LOWER

Green Red Yellow

FAST STOP SLOW

Green Red Yellow

Document No. Document Description:

TRIP (Amber) FORWARD (Red)

TRIP (Amber) FAST (Red)

Document No. Document Description:

Red Green Amber

RAISE/ OFF LOWER / TRIP

Red Green Red Amber

FAST OFF SLOW TRIP

Red Green Red Amber

Document No. Document Description:

Indicating lamp in PCC

RED GREEN AMBER BLUE RED YELLOW BLUE WHITE RED

Provide push button below in relation with indicating lamp.

2.2 Mounting of Equipment Plates on Panel Structure