Switchgear LV
Content
LV switchgear
Industry leading technology from Mardix
The UK’s leading provider of switchgear, power distribution and monitoring systems.
LV switchboards: detailed technology from Mardix
Introduction
As the UK’s leader in high power switchboard solutions, Mardix has more than 40 years of cross sector experience. From hospitals to shopping centres, office developments to data centres, our knowledge and expertise is built into every product. Whether you require a 1250A modular switchboard or a 6300A ASTA certified ‘L’ shaped bespoke switchboard, Mardix has a solution to meet your needs. Our uncompromising commitment to high build quality combines with our ‘in‑house’ philosophy, which ensures that every switchboard is designed and manufactured to exacting specifications and is delivered on time, every time.
A collaborative approach
At Mardix we take ongoing product development very seriously. We have committed to extensive research and development and ASTA Type Testing programmes as part of our business investment. The results of this approach are demonstrated in the finished product; fully installed and tested LV switchboards with built-in benefits (Fig.01). We pride ourselves on assisting end users, consultants, and contractors through every step of the design, manufacturing, and installation processes, and are delighted to work with consultants from a project’s inception. In the earliest design stages our input guarantees that any designs issued for tender are fit for purpose, commercially viable, and are of the required specification. We understand the need for specification compliant bids and requirements for value engineering during the tender process and have built excellent relationships with electrical contractors on this basis, offering a safe path rather than a badly engineered alternative. We stand by the principle that a cost effective Mardix quotation should be about more than just our bottom line price, it should be about added value for the client. Ongoing collaboration with all parties and valuable feedback from end users keeps us at the fore of switchgear technology. Our ability to convert client feedback into technological advances has been central to many new initiatives and products, not least our intelligent switchboards (iBoards™) and intelligent Power Distribution Units (iPDUs™) which have set the industry standard. Similarly, our Mardix LV switchboard design is 100% Mardix owned and has been developed in 3 key stages over many years. Our latest offering is the most technically advanced and feature rich offering to date and is only possible due to our in-house 3D solid modeling capability, which has introduced innovations not previously possible with 2D software. We spend a significant amount of time during the design process perfecting the top level assembly which is automatically checked for accuracy, clearance and zero clashing parts. The same attention to detail is witnessed in our manufacturing approach. All switchboards and PDUs are of fully welded construction for maximum rigidity and high tolerance not achievable with bolted flat pack assembly. Door seals remain flush fitting and Ingress Protection (IP) ratings are not compromised. An earthing arrangement running the full length of the switchboard and vertically into each cubicle section forms a high integrity earth bond against the welded enclosure. Whilst a welded, integral, high strength plinth completes the cubicle structure, which is then suitable for slab mounting or on a separate raised plinth assembly. An exacting cubicle fabrication process and a resilient powder coating in any RAL or BS4800 colour ensures the final product looks just as we intended.
Key benefits
ASTA certificates of Type Testing up to 6300A (100kA for 1sec) with unique ventilations systems designed, tested, and incorporated into higher power Mardix switchgear Thermal imaging capability as standard, with strategically positioned pre-punched grids for ease of access and enhanced surveying accuracy Forms of Separation up to Form 4 Type 7 with front and rear access designs Fully welded high strength Mardix cubicle system with high integrity earth bond, which is suitable for slab mounting or bolting onto underfloor plinthwork Standard Ingress Protection to IP31. Higher IP ratings are available, and all Mardix switchboards are suitable for mounting within GRP enclosures High and low level cable spreader boxes to facilitate glanding and termination of large cables All outer doors and busbar chambers are hinged for ease of access. Screw fix covers are not an acceptable alternative and will not be used Bespoke arrangements to meet specific width and height constraints Powder coated to any RAL or BS4800 colour. Our standard colour is BS4800 10 A03 (light grey) with a semi-gloss smooth finish
Fig.01. A top level 3D solid model switchboard assembly.
Fully welded construction
Constructed from individually folded panels, which are fitted and welded together to form the superior Mardix cubicle system with maximum rigidity.
Hinged doors and chambers
Doors, busbar and cable chambers are all hinged for added safety. We do not use screw fix covers.
Ventilation
ASTA Type Tested natural and forced air-cooling assemblies are used on higher current rated switchboards
Switchboard earthing
Copper earth bars run along the entire length of the cubicles and drop vertically into the functional units, busbars and chambers.
Cable spreader and transition boxes Thermal imaging ports
Designed by Mardix and fitted to all MCCB and fuse switch outer doors, our thermal imaging ports are CNC cluster punched directly into the steel. A tamper proof retained fastener mechanism allows the port to be opened to allow efficient and non-invasive thermal imaging. Higher current rating switchboards are fitted with boxes to facilitate glanding and termination of large cables. Transition boxes can be used where cables run perpendicular to the vertical plane of the switchboards.
LV switchboards: it’s what’s inside that really counts
LV switchboards from Mardix have many unique internal features for improved resilience and performance (Fig.02).
Safety is an absolute priority and inside the functional unit compartment it is clearly demonstrated in the mounting of the circuit breakers. Both the live and load sides of the switch are completely shrouded to prevent inadvertent contact with live parts, and copper connections to busbars are insulated and shrouded for added safety. In terms of separation, metallic barriers are used between each functional unit and also between functional units and busbar chambers. This degree of separation provides further safety from live parts, and protects against a fault in one compartment propagating to an adjacent compartment. Horizontal and vertical busbar chambers are positioned and sized to ensure the busbars and connections can be accessed at any time during the life cycle of the switchboard. Each busbar compartment is provided with an outer door and a secondary captive thermal imaging screen. This method allows efficient and safe monitoring of busbars and connections with our infrared thermal imaging cameras. Mardix LV switchboards incorporate Air Circuit Breakers (ACBs), Moulded Case Circuit Breakers (MCCBs) and fuse switches. Typical brands used for these purposes are Schneider, Terasaki, ABB and Socomec, which are recognised as high integrity components. If you have width and height constraints in your plant room you may require double stacking of ACBs and high density stacking of MCCBs. Mardix have Type Tested these arrangements to ensure they perform under temperature rise. Forms of Separation for our LV switchboards are typically Form 4 Type 2, Form 4 Type 5, Form 4 Type 6 and Form 4 Type 7 (please refer to Forms of Separation section). We can accommodate all forms in front and rear access configurations and we always ensure glanding plates and cableways are the correct size and cable boxes can accept the specified cable sizes. Separate compartments are designated for metering, control and BMS terminals. Contacts for BMS are internally wired and taken to a BMS terminal rail with dedicated routes for the external cables. Protection fuses and control components are clearly labelled and cross referenced to our schematic drawings.
Double marking system for all power connections
For nearly a decade Mardix has implemented quality procedures to achieve zero tolerance of errors during busbar installation, and we always invest time in making sure we adhere to those quality procedures. Every connection is tightened with a torque wrench and then marked, initialled, dated, and signed with a coloured pen. A second, independent operative then subjects the same connection to the same procedure. Our Production Manager, Simon Hamer, comments, “This system has moved us ever closer to our original objective of zero errors and every member of our site teams understands what a significant difference it has made to our business, and to levels of client satisfaction. It’s an apparently simple process that offers reassurance whilst improving the end product.”
Example of double marking procedure.
Key benefits
All functional units are protected against inadvertent contact with live parts. Custom made shrouds with laser profiled thermal imaging grids allow efficient thermal imaging of circuit breaker connections All connection points can be thermal imaged including busbar chambers and incoming/outgoing cable boxes All major brands of ACBs, MCCBs and fuse switches can be incorporated, including Schneider, Terasaki, ABB and Socomec Sealed CT chambers with connection links, insulation barriers and shorting links, built to the specification of all Regional Electricity Companies (REC) Integration of tuned and detuned Power Factor Correction (PFC) and Active Harmonic Filters (AHF) Type Tested arrangements for stacked ACBs, and high density stacking of MCCBs Separate compartments with fully labelled components and terminals for metering, control, and prewired BMS contacts Incorporation of protection relays, G59 protection, battery intertripping units, Electronic Surge Protectors (ESP), Castell interlocking arrangements including solenoids and exchange boxes, temperature monitoring and large mimic panels Incorporation of HMI control panels, dual redundant PLC control philosophies, standard PLC control, auto-changeover systems and load shedding Incorporation of high end metering systems with waveform capture facility such as Schneider ION 7650 and ION 7550. Multifunction metering brands include Socomec, Autometers, Schneider. Energy metering to building regulations Part L2. See also the iBoard™ and iPDU™ for our intelligent range of switchgear and PDUs
Fig.02. An intermediate 3D solid model switchboard assembly.
Cable management systems
Attention to detail doesn’t stop at our outgoing connection boxes, cable ways are constructed to ensure cabling can be organised and strapped securely in place.
Sealed REC CT chambers
Mardix build CT chambers to all Regional Electricity Company specifications, ensuring our clients don’t have any issue when the REC comes to terminate the incoming supplies.
Fully shrouded functional units
Careful attention to detail and custom made shrouds with laser profiled thermal imaging slots provide protection against inadvertent contact with live parts, and allow for efficient thermal imaging of the circuit breaker.
Incoming connections far large and multiple cables
High strength busbar support assemblies are used to gland and terminate very large cables such as 500 mm2 single core cables or multiple Steel Wired Amoured (SWA) cables per phase.
Safety - insulated flexible busbars
As standard, we only use insulated flexible connections on circuit breakers up to 630A. This Type Tested arrangement virtually eliminates the possibility of foreign objects settling between live conductors in the most inherently susceptible part of a switchboard.
Mardix busbar systems
The new advanced Mardix busbar system offers space and cost savings and is rated up to 6300A (100kA for 1sec).
Strip away all the other elements of the switchboard (see Fig.03) and we can see perhaps the most important element of a Mardix LV switchboard; our all new, Mardix owned, ASTA Type Tested busbar system, which is rated up to 6300A (100kA for 1 sec). Like many switchgear companies we used a proprietary busbar system, however, in 2006 we began to develop our new system, which we felt was required to enhance the Mardix cubicle system. During development we outlined various criteria that had to be met: • Improved performance with the same cross sectional area of High Density, High Conductivity (HDHC) copper. • Stronger busbar supports allowing higher fault ratings than previous possible. • Increased cooling around horizontal and vertical busbar assemblies for both air natural and forced air cooling options. • Vastly quicker assembly process within the tight spatial constraints of busbar chambers, which would ultimately slash time required onsite connecting LV switchboards. In 2008 we passed our first major test with the new Mardix system, which included a 4000A, 4 pole ACB, a 4000A 4 pole busbar and various outgoing circuit breakers. The switchboard performance exceeded our expectations and during temperature rise passed in an air natural configuration. This was due, in no small part, to the use of our all-new ventilation duct system. Following this early success we went on to achieve the holy grail of type testing at IPH in Berlin, including a heat rise test at 6300A in an air natural configuration. This achievement is believed to be a first on a global scale, and is testament to our ongoing commitment to improved switchgear performance. Commenting on the breakthrough, Mardix Director, Wayne Lewis said: “This achievement is a very positive step forward for Mardix, and reflects the continued success of our ASTA Type Testing programme. We look forward to passing the benefits of this achievement on to our client base, including efficiencies in the switchboard assembly process.” Mardix have invested £250K in the current ASTA Type Testing programme and will continue testing late into 2009.
3D solid modelling
Every switchboard Mardix produces is designed in-house using 3D design expertise. Once the overall assembly design is complete, it is transferred to the Computer Aided Design/ Computer Aided Manufacture (CADCAM) area where the assembly is analysed and separated into - subassemblies - and parts of varying materials including steel, copper, aluminium, polycarbonates and plastics. All 3D parts are automatically developed into 2D flat parts and then converted into machine code. This code is then sent to the job libraries of the required machine whether that is a laser cutter, a CNC punch, or a press brake. This level of technology and automation means Mardix now consistently produces cost effective and efficient switchgear. Production Director Wayne Lewis explains the benefits of 3D modelling: “Our assembly times have reduced dramatically which saves costs for the client, and the potential to have zero design errors has virtually eliminated incorrectly machined parts, mistakes, and rework which saves time and enables us to keep projects right on schedule”.
Mardix can offer cost effective modular LV switchboard solutions to fit your budget, with lead times from only 7–10 days depending on configuration.
Key benefits
All new 100% Mardix owned, ASTA Type Tested busbar system. Developed in-house since 2006, we have introduced new innovative features that benefit our clients through cost and space savings, and that speed up our LV switchboard assembly process ASTA tested up to 6300A (100kA for 1 sec). Our range of Type Test certificates allows a more flexible approach to busbar sizing, and associated cost savings can be passed onto our clients We have achieved cost savings through the full range of busbar assembly ratings. This ensures we remain competitive whilst still delivering the highest quality LV switchboards Innovative busbar connecting systems, easier access to the individual busbar supports, and much improved 3D assembly drawings have reduced fitting times by up to 30% 200% busbar requirements can be accommodated. (contact us for further details) Free issue busbar flanges, which can be problematic at the final stages of installation, are incorporated with ease using our 3D software. We can fit and test final connections as part of LV switchboard installation. Using our 3D views of complex busbar assemblies, including multiple corner sections and overhead busbar links, our customers benefit from enhanced visualisation, which also simplifies the design process
Fig.03. A 3D solid model complex busbar assembly.
Innovative fishplate connections
Fishplates are now much easier to install as they are accurately sized and positioned to improve access for torque wrenches. A unique Mardix fastening system reduces fixing time by up to 30% and both of these benefits have proved valuable to our onsite teams.
Brand new busbar supports from Mardix
The Mardix busbar system delivers increased performance and strength plus reduced manufacturing and assembly times.
Complex busbar assemblies
We understand plant room space constraints and manufacture irregular shaped boards to fit available space.
Forms of Separation
All of our Forms of Separation are agreed between users and ourselves during specification.
In order to protect against contact with live parts belonging to adjacent functional units, and against the passage of solid foreign bodies from one unit within an assembly to an adjacent unit, we take great care to apply the most appropriate Forms of Separation to each solution we manufacture. Ranging from Form 2 Type 2 through to Form 4 Type 7 our Forms of Separation incorporate industry standard methods such as: non-metallic and metallic rigid barriers and partitions; glanding and termination chambers for cables; busbar separation; insulated coverings and shrouding; and external terminals. Each option is carefully considered and balanced to fit requirements and budgets, so you always know your equipment is well protected and cost effective. And, the probability of initiating arc faults is properly limited when you work with Mardix. We’ve included the following pages as a quick and easy guide to the Forms of Separation offered on Mardix assemblies, and we’ve included an area offering clarity on Ingress Protection (IP) ratings.
3D Solid model demonstrating all Forms of Separation. See next page for detailed information on each Form of Separation.
Form 2 Type 2
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation, whilst terminals are separated from the busbars, but not from each other or functional units.
Incoming units
Outgoing units
Outgoing units
Form 4 Type 2
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation. Cables are terminated in the same compartment as the functional unit, but are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 5
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation. Terminals are external from the functional unit and insulated coverings such as PVC boots are used. Cables are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 6
All separation is achieved by metallic or non-metallic rigid barriers or partitions. Terminals are external from the functional unit compartment and rigid barriers or partitions are used to enclose them in their own compartment. Cables are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 7
All separation is achieved by metallic or non-metallic rigid barriers or partitions. Terminals are external from the functional unit compartment and rigid barriers or partitions are used to enclose them in their own compartment which features integral glanding facility.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Technical specifications
A guide to the technical features behind Mardix LV switchgear.
Enclosure
Mardix LV switchboards usually comprise one or more vertically mounted sections. The sections are generally slab mounted, however, options for mounting on underfloor/raised plinths can be accommodated. Our enclosures are formed from individually folded panels of Zintec sheet steel, which are fully welded and ground to provide clean lines and maximum rigidity. The Mardix high integrity earth bond is standard. An integral 150 mm plinth is then welded to the base of the cubicle to provide a solid support channel which enables the switchboard to be mounted on a separate underfloor plinth. Enclosure finish: Cabinets and doors are powder coated with RAL colours or BS4800 colours with a smooth finish whilst internal compartments feature RAL 9003 (white) with a ripple finish.
Busbars and connections
Mardix busbar assemblies are ASTA certified up to 6300 Amperes (100kA for 1 sec). Busbars are air insulated. The neutral busbars have the same rating and cross sectional area as respective phase busbars. Individual riser busbars are suitably sized for the devices they serve, but are not necessary of the same rating as the main busbars. If required, busbars can be extendable at the ends of the switchboard in order to facilitate easy installation of future cubicle extension sections. Busbars are clad along their entire length. It is not be possible to come into contact with the busbars by opening any compartment doors, including busbar sections. At connection points, the busbars are punched with holes in each adjacent piece, which will then be connected together using fishplates, and suitably sized nuts, bolts, and washers. Edge clamping of busbars i.e. a no holed system is not used for Mardix switchboards. Tap-off connections from the main busbars to individual circuit breakers (up to 630A rating) are manufactured using insulated flexible copper links. This reduces the risk of short circuit at points on the busbar system that may be prone to high short circuit currents. All power connection points, including busbar joints are tightened to the correct torque in accordance with Mardix double marking standards.
Functional units and internal separation
Each functional unit is, in general, separated from each other. By opening the door of the respective functional unit e.g. an Air Circuit Breaker compartment, it isn’t possible to inadvertently touch live parts. All exposed live parts are shrouded using proprietary or custom-made shrouds. • Protection against the passing of solid foreign objects from one function unit to another • Mardix internal separation will generally be achieved using rigid metallic barriers. Unless otherwise specified, busbars will be separated from functional units
Control and BMS section
This section houses the control, indication and protection components, including: • Multi-function metering • Specialist Protection Relays e.g. Restricted Earth Fault Relay • LED indicators • Pushbuttons and Keyswitches • Transformer Temperature Relays • Electronic Surge Protection • Relays and Protection Fuses as applicable • BMS and Control Terminals
In addition:
Separation will be achieved in accordance with BSEN 60439-1:1999. The exact Form of Separation e.g. Form 4 (6) will be as specified. Separation will generally meet the following conditions: • Protection against contact with live parts belonging to adjacent functional units • Limitation of the probability of initiating arc faults
Technical specifications
Thermal imaging
LV switchboards are designed and manufactured in-line with thermal imaging requirements. Thermal imaging ports are punched directly into the steel doors using CNC cluster punching. The ports are fitted with sliding captive covers, fixed and sealed to the door by security screws. A special tool is required to open the port. Polycarbonate custom-made shrouds are fitted over all connection points to prevent inadvertent touching of any live parts and to facilitate safe thermal imaging. The custom-made shrouds are manufactured from polycarbonate sheet, which is folded and tied to form a rigid barrier. Each barrier will be laser profiled with slots positioned in such a way to facilitate efficient thermal imaging of the connection point.
Doors and covers
Switchboard enclosures are IP31 unless otherwise specified. The switchboard has hinged doors, which cover the individual compartments and terminal chambers. 90-degree turn latches are used to lock each compartment and a special tool is required to open the doors. Mardix do not use screw fix external covers. All door hinges are high quality and of sufficient strength that doors stay aligned and square. Where applicable, doors are completed with polycarbonate viewing windows, sealed with rubber profiling strip.
Labelling
Engraved traffolite labels will be fitted to relevant doors and chambers. • General labels – black letters on white background • Voltage warning labels – black letters on yellow background • General warning labels – red letters on a white background All fuses and control components and associated connection terminals will be labelled using adhesive strip labelling.
Ingress Protection ratings
IP Codes classify the degrees of protection provided against intrusion of solid objects in electrical enclosures. This protection includes body parts such as hands and fingers, dust, accidental contact, and water. The standard aims to provide users with more detailed information than terms such as ‘waterproof’ would. Digits are used to express conformity. As an example an ingress protection rating could be stated as IP31. Therefore the switchboard would be protected against solid objects larger than 2.5 mm and vertically falling water droplets.
First characteristic numeral – protected against solid bodies
0 1 2 3 4 5 6
No protection against contact and ingress of objects Protected against solid bodies larger than 50 mm (eg. accidental contact with hand) Protected against solid bodies larger than 12 mm (eg. finger contact) Protected against solid bodies larger than 2.5 mm (eg. tools and wires) Protected against solid bodies larger then 1 mm (eg. fine tools, small wires) Protected against dust (no harmful deposits) Totally dust tight
Second characteristic numeral – protected against liquids
0 1 2 3 4 5 6 7 8
No protection Protected against vertically falling water droplets (condensation) Protected against water droplets deflected at up to 15º from the vertical Protected against water spray at up to 60º from the vertical Protected against water spray from all directions Protected against low pressure water jets from all directions Protected against strong water jets and waves Protected against effects of temporary immersion Protected against effects of prolonged immersion under pressure
Get in touch now
Call now on: 01539 720161 to talk to us about how you can benefit from custom engineered switchgear at Mardix, or email: [email protected]
Delivering peace of mind!
Tailored service packages including emergency call out response, routine maintenance and servicing of non-Mardix equipment.
Worried about power consumption?
Mardix delivers integrated intelligent solutions for optimum energy efficiency, improved power quality, and ongoing critical power provision.
• 24/7/365 emergency assistance • Emergency onsite engineers • Telephone technical support • Non-invasive maintenance • Isolated maintenance • Thermal image surveys
• Industry standard iPDU™ technology • Power quality improvements • Power trending procedures • Citect Facilities and/or PowerLogic ION Enterprise • Energy management to individual racks • Integration with your management systems
Call our Service Division now on 01539 720161
Call our Monitoring Division now on 01539 720161
t. 01539 720161 www.mardix.co.uk Mardix, Service Division, Westmorland Business Park, Kendal, Cumbria, LA9 6NS
Industry leading technology from Mardix
The UK’s leading provider of switchgear, power distribution and monitoring systems.
LV switchboards: detailed technology from Mardix
Introduction
As the UK’s leader in high power switchboard solutions, Mardix has more than 40 years of cross sector experience. From hospitals to shopping centres, office developments to data centres, our knowledge and expertise is built into every product. Whether you require a 1250A modular switchboard or a 6300A ASTA certified ‘L’ shaped bespoke switchboard, Mardix has a solution to meet your needs. Our uncompromising commitment to high build quality combines with our ‘in‑house’ philosophy, which ensures that every switchboard is designed and manufactured to exacting specifications and is delivered on time, every time.
A collaborative approach
At Mardix we take ongoing product development very seriously. We have committed to extensive research and development and ASTA Type Testing programmes as part of our business investment. The results of this approach are demonstrated in the finished product; fully installed and tested LV switchboards with built-in benefits (Fig.01). We pride ourselves on assisting end users, consultants, and contractors through every step of the design, manufacturing, and installation processes, and are delighted to work with consultants from a project’s inception. In the earliest design stages our input guarantees that any designs issued for tender are fit for purpose, commercially viable, and are of the required specification. We understand the need for specification compliant bids and requirements for value engineering during the tender process and have built excellent relationships with electrical contractors on this basis, offering a safe path rather than a badly engineered alternative. We stand by the principle that a cost effective Mardix quotation should be about more than just our bottom line price, it should be about added value for the client. Ongoing collaboration with all parties and valuable feedback from end users keeps us at the fore of switchgear technology. Our ability to convert client feedback into technological advances has been central to many new initiatives and products, not least our intelligent switchboards (iBoards™) and intelligent Power Distribution Units (iPDUs™) which have set the industry standard. Similarly, our Mardix LV switchboard design is 100% Mardix owned and has been developed in 3 key stages over many years. Our latest offering is the most technically advanced and feature rich offering to date and is only possible due to our in-house 3D solid modeling capability, which has introduced innovations not previously possible with 2D software. We spend a significant amount of time during the design process perfecting the top level assembly which is automatically checked for accuracy, clearance and zero clashing parts. The same attention to detail is witnessed in our manufacturing approach. All switchboards and PDUs are of fully welded construction for maximum rigidity and high tolerance not achievable with bolted flat pack assembly. Door seals remain flush fitting and Ingress Protection (IP) ratings are not compromised. An earthing arrangement running the full length of the switchboard and vertically into each cubicle section forms a high integrity earth bond against the welded enclosure. Whilst a welded, integral, high strength plinth completes the cubicle structure, which is then suitable for slab mounting or on a separate raised plinth assembly. An exacting cubicle fabrication process and a resilient powder coating in any RAL or BS4800 colour ensures the final product looks just as we intended.
Key benefits
ASTA certificates of Type Testing up to 6300A (100kA for 1sec) with unique ventilations systems designed, tested, and incorporated into higher power Mardix switchgear Thermal imaging capability as standard, with strategically positioned pre-punched grids for ease of access and enhanced surveying accuracy Forms of Separation up to Form 4 Type 7 with front and rear access designs Fully welded high strength Mardix cubicle system with high integrity earth bond, which is suitable for slab mounting or bolting onto underfloor plinthwork Standard Ingress Protection to IP31. Higher IP ratings are available, and all Mardix switchboards are suitable for mounting within GRP enclosures High and low level cable spreader boxes to facilitate glanding and termination of large cables All outer doors and busbar chambers are hinged for ease of access. Screw fix covers are not an acceptable alternative and will not be used Bespoke arrangements to meet specific width and height constraints Powder coated to any RAL or BS4800 colour. Our standard colour is BS4800 10 A03 (light grey) with a semi-gloss smooth finish
Fig.01. A top level 3D solid model switchboard assembly.
Fully welded construction
Constructed from individually folded panels, which are fitted and welded together to form the superior Mardix cubicle system with maximum rigidity.
Hinged doors and chambers
Doors, busbar and cable chambers are all hinged for added safety. We do not use screw fix covers.
Ventilation
ASTA Type Tested natural and forced air-cooling assemblies are used on higher current rated switchboards
Switchboard earthing
Copper earth bars run along the entire length of the cubicles and drop vertically into the functional units, busbars and chambers.
Cable spreader and transition boxes Thermal imaging ports
Designed by Mardix and fitted to all MCCB and fuse switch outer doors, our thermal imaging ports are CNC cluster punched directly into the steel. A tamper proof retained fastener mechanism allows the port to be opened to allow efficient and non-invasive thermal imaging. Higher current rating switchboards are fitted with boxes to facilitate glanding and termination of large cables. Transition boxes can be used where cables run perpendicular to the vertical plane of the switchboards.
LV switchboards: it’s what’s inside that really counts
LV switchboards from Mardix have many unique internal features for improved resilience and performance (Fig.02).
Safety is an absolute priority and inside the functional unit compartment it is clearly demonstrated in the mounting of the circuit breakers. Both the live and load sides of the switch are completely shrouded to prevent inadvertent contact with live parts, and copper connections to busbars are insulated and shrouded for added safety. In terms of separation, metallic barriers are used between each functional unit and also between functional units and busbar chambers. This degree of separation provides further safety from live parts, and protects against a fault in one compartment propagating to an adjacent compartment. Horizontal and vertical busbar chambers are positioned and sized to ensure the busbars and connections can be accessed at any time during the life cycle of the switchboard. Each busbar compartment is provided with an outer door and a secondary captive thermal imaging screen. This method allows efficient and safe monitoring of busbars and connections with our infrared thermal imaging cameras. Mardix LV switchboards incorporate Air Circuit Breakers (ACBs), Moulded Case Circuit Breakers (MCCBs) and fuse switches. Typical brands used for these purposes are Schneider, Terasaki, ABB and Socomec, which are recognised as high integrity components. If you have width and height constraints in your plant room you may require double stacking of ACBs and high density stacking of MCCBs. Mardix have Type Tested these arrangements to ensure they perform under temperature rise. Forms of Separation for our LV switchboards are typically Form 4 Type 2, Form 4 Type 5, Form 4 Type 6 and Form 4 Type 7 (please refer to Forms of Separation section). We can accommodate all forms in front and rear access configurations and we always ensure glanding plates and cableways are the correct size and cable boxes can accept the specified cable sizes. Separate compartments are designated for metering, control and BMS terminals. Contacts for BMS are internally wired and taken to a BMS terminal rail with dedicated routes for the external cables. Protection fuses and control components are clearly labelled and cross referenced to our schematic drawings.
Double marking system for all power connections
For nearly a decade Mardix has implemented quality procedures to achieve zero tolerance of errors during busbar installation, and we always invest time in making sure we adhere to those quality procedures. Every connection is tightened with a torque wrench and then marked, initialled, dated, and signed with a coloured pen. A second, independent operative then subjects the same connection to the same procedure. Our Production Manager, Simon Hamer, comments, “This system has moved us ever closer to our original objective of zero errors and every member of our site teams understands what a significant difference it has made to our business, and to levels of client satisfaction. It’s an apparently simple process that offers reassurance whilst improving the end product.”
Example of double marking procedure.
Key benefits
All functional units are protected against inadvertent contact with live parts. Custom made shrouds with laser profiled thermal imaging grids allow efficient thermal imaging of circuit breaker connections All connection points can be thermal imaged including busbar chambers and incoming/outgoing cable boxes All major brands of ACBs, MCCBs and fuse switches can be incorporated, including Schneider, Terasaki, ABB and Socomec Sealed CT chambers with connection links, insulation barriers and shorting links, built to the specification of all Regional Electricity Companies (REC) Integration of tuned and detuned Power Factor Correction (PFC) and Active Harmonic Filters (AHF) Type Tested arrangements for stacked ACBs, and high density stacking of MCCBs Separate compartments with fully labelled components and terminals for metering, control, and prewired BMS contacts Incorporation of protection relays, G59 protection, battery intertripping units, Electronic Surge Protectors (ESP), Castell interlocking arrangements including solenoids and exchange boxes, temperature monitoring and large mimic panels Incorporation of HMI control panels, dual redundant PLC control philosophies, standard PLC control, auto-changeover systems and load shedding Incorporation of high end metering systems with waveform capture facility such as Schneider ION 7650 and ION 7550. Multifunction metering brands include Socomec, Autometers, Schneider. Energy metering to building regulations Part L2. See also the iBoard™ and iPDU™ for our intelligent range of switchgear and PDUs
Fig.02. An intermediate 3D solid model switchboard assembly.
Cable management systems
Attention to detail doesn’t stop at our outgoing connection boxes, cable ways are constructed to ensure cabling can be organised and strapped securely in place.
Sealed REC CT chambers
Mardix build CT chambers to all Regional Electricity Company specifications, ensuring our clients don’t have any issue when the REC comes to terminate the incoming supplies.
Fully shrouded functional units
Careful attention to detail and custom made shrouds with laser profiled thermal imaging slots provide protection against inadvertent contact with live parts, and allow for efficient thermal imaging of the circuit breaker.
Incoming connections far large and multiple cables
High strength busbar support assemblies are used to gland and terminate very large cables such as 500 mm2 single core cables or multiple Steel Wired Amoured (SWA) cables per phase.
Safety - insulated flexible busbars
As standard, we only use insulated flexible connections on circuit breakers up to 630A. This Type Tested arrangement virtually eliminates the possibility of foreign objects settling between live conductors in the most inherently susceptible part of a switchboard.
Mardix busbar systems
The new advanced Mardix busbar system offers space and cost savings and is rated up to 6300A (100kA for 1sec).
Strip away all the other elements of the switchboard (see Fig.03) and we can see perhaps the most important element of a Mardix LV switchboard; our all new, Mardix owned, ASTA Type Tested busbar system, which is rated up to 6300A (100kA for 1 sec). Like many switchgear companies we used a proprietary busbar system, however, in 2006 we began to develop our new system, which we felt was required to enhance the Mardix cubicle system. During development we outlined various criteria that had to be met: • Improved performance with the same cross sectional area of High Density, High Conductivity (HDHC) copper. • Stronger busbar supports allowing higher fault ratings than previous possible. • Increased cooling around horizontal and vertical busbar assemblies for both air natural and forced air cooling options. • Vastly quicker assembly process within the tight spatial constraints of busbar chambers, which would ultimately slash time required onsite connecting LV switchboards. In 2008 we passed our first major test with the new Mardix system, which included a 4000A, 4 pole ACB, a 4000A 4 pole busbar and various outgoing circuit breakers. The switchboard performance exceeded our expectations and during temperature rise passed in an air natural configuration. This was due, in no small part, to the use of our all-new ventilation duct system. Following this early success we went on to achieve the holy grail of type testing at IPH in Berlin, including a heat rise test at 6300A in an air natural configuration. This achievement is believed to be a first on a global scale, and is testament to our ongoing commitment to improved switchgear performance. Commenting on the breakthrough, Mardix Director, Wayne Lewis said: “This achievement is a very positive step forward for Mardix, and reflects the continued success of our ASTA Type Testing programme. We look forward to passing the benefits of this achievement on to our client base, including efficiencies in the switchboard assembly process.” Mardix have invested £250K in the current ASTA Type Testing programme and will continue testing late into 2009.
3D solid modelling
Every switchboard Mardix produces is designed in-house using 3D design expertise. Once the overall assembly design is complete, it is transferred to the Computer Aided Design/ Computer Aided Manufacture (CADCAM) area where the assembly is analysed and separated into - subassemblies - and parts of varying materials including steel, copper, aluminium, polycarbonates and plastics. All 3D parts are automatically developed into 2D flat parts and then converted into machine code. This code is then sent to the job libraries of the required machine whether that is a laser cutter, a CNC punch, or a press brake. This level of technology and automation means Mardix now consistently produces cost effective and efficient switchgear. Production Director Wayne Lewis explains the benefits of 3D modelling: “Our assembly times have reduced dramatically which saves costs for the client, and the potential to have zero design errors has virtually eliminated incorrectly machined parts, mistakes, and rework which saves time and enables us to keep projects right on schedule”.
Mardix can offer cost effective modular LV switchboard solutions to fit your budget, with lead times from only 7–10 days depending on configuration.
Key benefits
All new 100% Mardix owned, ASTA Type Tested busbar system. Developed in-house since 2006, we have introduced new innovative features that benefit our clients through cost and space savings, and that speed up our LV switchboard assembly process ASTA tested up to 6300A (100kA for 1 sec). Our range of Type Test certificates allows a more flexible approach to busbar sizing, and associated cost savings can be passed onto our clients We have achieved cost savings through the full range of busbar assembly ratings. This ensures we remain competitive whilst still delivering the highest quality LV switchboards Innovative busbar connecting systems, easier access to the individual busbar supports, and much improved 3D assembly drawings have reduced fitting times by up to 30% 200% busbar requirements can be accommodated. (contact us for further details) Free issue busbar flanges, which can be problematic at the final stages of installation, are incorporated with ease using our 3D software. We can fit and test final connections as part of LV switchboard installation. Using our 3D views of complex busbar assemblies, including multiple corner sections and overhead busbar links, our customers benefit from enhanced visualisation, which also simplifies the design process
Fig.03. A 3D solid model complex busbar assembly.
Innovative fishplate connections
Fishplates are now much easier to install as they are accurately sized and positioned to improve access for torque wrenches. A unique Mardix fastening system reduces fixing time by up to 30% and both of these benefits have proved valuable to our onsite teams.
Brand new busbar supports from Mardix
The Mardix busbar system delivers increased performance and strength plus reduced manufacturing and assembly times.
Complex busbar assemblies
We understand plant room space constraints and manufacture irregular shaped boards to fit available space.
Forms of Separation
All of our Forms of Separation are agreed between users and ourselves during specification.
In order to protect against contact with live parts belonging to adjacent functional units, and against the passage of solid foreign bodies from one unit within an assembly to an adjacent unit, we take great care to apply the most appropriate Forms of Separation to each solution we manufacture. Ranging from Form 2 Type 2 through to Form 4 Type 7 our Forms of Separation incorporate industry standard methods such as: non-metallic and metallic rigid barriers and partitions; glanding and termination chambers for cables; busbar separation; insulated coverings and shrouding; and external terminals. Each option is carefully considered and balanced to fit requirements and budgets, so you always know your equipment is well protected and cost effective. And, the probability of initiating arc faults is properly limited when you work with Mardix. We’ve included the following pages as a quick and easy guide to the Forms of Separation offered on Mardix assemblies, and we’ve included an area offering clarity on Ingress Protection (IP) ratings.
3D Solid model demonstrating all Forms of Separation. See next page for detailed information on each Form of Separation.
Form 2 Type 2
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation, whilst terminals are separated from the busbars, but not from each other or functional units.
Incoming units
Outgoing units
Outgoing units
Form 4 Type 2
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation. Cables are terminated in the same compartment as the functional unit, but are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 5
Metallic and non-metallic rigid barriers or partitions are used to achieve busbar separation. Terminals are external from the functional unit and insulated coverings such as PVC boots are used. Cables are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 6
All separation is achieved by metallic or non-metallic rigid barriers or partitions. Terminals are external from the functional unit compartment and rigid barriers or partitions are used to enclose them in their own compartment. Cables are glanded elsewhere e.g. in a common cabling chamber.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Form 4 Type 7
All separation is achieved by metallic or non-metallic rigid barriers or partitions. Terminals are external from the functional unit compartment and rigid barriers or partitions are used to enclose them in their own compartment which features integral glanding facility.
Incoming units
Outgoing units
Outgoing units
Incoming cable
Outgoing cables
Technical specifications
A guide to the technical features behind Mardix LV switchgear.
Enclosure
Mardix LV switchboards usually comprise one or more vertically mounted sections. The sections are generally slab mounted, however, options for mounting on underfloor/raised plinths can be accommodated. Our enclosures are formed from individually folded panels of Zintec sheet steel, which are fully welded and ground to provide clean lines and maximum rigidity. The Mardix high integrity earth bond is standard. An integral 150 mm plinth is then welded to the base of the cubicle to provide a solid support channel which enables the switchboard to be mounted on a separate underfloor plinth. Enclosure finish: Cabinets and doors are powder coated with RAL colours or BS4800 colours with a smooth finish whilst internal compartments feature RAL 9003 (white) with a ripple finish.
Busbars and connections
Mardix busbar assemblies are ASTA certified up to 6300 Amperes (100kA for 1 sec). Busbars are air insulated. The neutral busbars have the same rating and cross sectional area as respective phase busbars. Individual riser busbars are suitably sized for the devices they serve, but are not necessary of the same rating as the main busbars. If required, busbars can be extendable at the ends of the switchboard in order to facilitate easy installation of future cubicle extension sections. Busbars are clad along their entire length. It is not be possible to come into contact with the busbars by opening any compartment doors, including busbar sections. At connection points, the busbars are punched with holes in each adjacent piece, which will then be connected together using fishplates, and suitably sized nuts, bolts, and washers. Edge clamping of busbars i.e. a no holed system is not used for Mardix switchboards. Tap-off connections from the main busbars to individual circuit breakers (up to 630A rating) are manufactured using insulated flexible copper links. This reduces the risk of short circuit at points on the busbar system that may be prone to high short circuit currents. All power connection points, including busbar joints are tightened to the correct torque in accordance with Mardix double marking standards.
Functional units and internal separation
Each functional unit is, in general, separated from each other. By opening the door of the respective functional unit e.g. an Air Circuit Breaker compartment, it isn’t possible to inadvertently touch live parts. All exposed live parts are shrouded using proprietary or custom-made shrouds. • Protection against the passing of solid foreign objects from one function unit to another • Mardix internal separation will generally be achieved using rigid metallic barriers. Unless otherwise specified, busbars will be separated from functional units
Control and BMS section
This section houses the control, indication and protection components, including: • Multi-function metering • Specialist Protection Relays e.g. Restricted Earth Fault Relay • LED indicators • Pushbuttons and Keyswitches • Transformer Temperature Relays • Electronic Surge Protection • Relays and Protection Fuses as applicable • BMS and Control Terminals
In addition:
Separation will be achieved in accordance with BSEN 60439-1:1999. The exact Form of Separation e.g. Form 4 (6) will be as specified. Separation will generally meet the following conditions: • Protection against contact with live parts belonging to adjacent functional units • Limitation of the probability of initiating arc faults
Technical specifications
Thermal imaging
LV switchboards are designed and manufactured in-line with thermal imaging requirements. Thermal imaging ports are punched directly into the steel doors using CNC cluster punching. The ports are fitted with sliding captive covers, fixed and sealed to the door by security screws. A special tool is required to open the port. Polycarbonate custom-made shrouds are fitted over all connection points to prevent inadvertent touching of any live parts and to facilitate safe thermal imaging. The custom-made shrouds are manufactured from polycarbonate sheet, which is folded and tied to form a rigid barrier. Each barrier will be laser profiled with slots positioned in such a way to facilitate efficient thermal imaging of the connection point.
Doors and covers
Switchboard enclosures are IP31 unless otherwise specified. The switchboard has hinged doors, which cover the individual compartments and terminal chambers. 90-degree turn latches are used to lock each compartment and a special tool is required to open the doors. Mardix do not use screw fix external covers. All door hinges are high quality and of sufficient strength that doors stay aligned and square. Where applicable, doors are completed with polycarbonate viewing windows, sealed with rubber profiling strip.
Labelling
Engraved traffolite labels will be fitted to relevant doors and chambers. • General labels – black letters on white background • Voltage warning labels – black letters on yellow background • General warning labels – red letters on a white background All fuses and control components and associated connection terminals will be labelled using adhesive strip labelling.
Ingress Protection ratings
IP Codes classify the degrees of protection provided against intrusion of solid objects in electrical enclosures. This protection includes body parts such as hands and fingers, dust, accidental contact, and water. The standard aims to provide users with more detailed information than terms such as ‘waterproof’ would. Digits are used to express conformity. As an example an ingress protection rating could be stated as IP31. Therefore the switchboard would be protected against solid objects larger than 2.5 mm and vertically falling water droplets.
First characteristic numeral – protected against solid bodies
0 1 2 3 4 5 6
No protection against contact and ingress of objects Protected against solid bodies larger than 50 mm (eg. accidental contact with hand) Protected against solid bodies larger than 12 mm (eg. finger contact) Protected against solid bodies larger than 2.5 mm (eg. tools and wires) Protected against solid bodies larger then 1 mm (eg. fine tools, small wires) Protected against dust (no harmful deposits) Totally dust tight
Second characteristic numeral – protected against liquids
0 1 2 3 4 5 6 7 8
No protection Protected against vertically falling water droplets (condensation) Protected against water droplets deflected at up to 15º from the vertical Protected against water spray at up to 60º from the vertical Protected against water spray from all directions Protected against low pressure water jets from all directions Protected against strong water jets and waves Protected against effects of temporary immersion Protected against effects of prolonged immersion under pressure
Get in touch now
Call now on: 01539 720161 to talk to us about how you can benefit from custom engineered switchgear at Mardix, or email: [email protected]
Delivering peace of mind!
Tailored service packages including emergency call out response, routine maintenance and servicing of non-Mardix equipment.
Worried about power consumption?
Mardix delivers integrated intelligent solutions for optimum energy efficiency, improved power quality, and ongoing critical power provision.
• 24/7/365 emergency assistance • Emergency onsite engineers • Telephone technical support • Non-invasive maintenance • Isolated maintenance • Thermal image surveys
• Industry standard iPDU™ technology • Power quality improvements • Power trending procedures • Citect Facilities and/or PowerLogic ION Enterprise • Energy management to individual racks • Integration with your management systems
Call our Service Division now on 01539 720161
Call our Monitoring Division now on 01539 720161
t. 01539 720161 www.mardix.co.uk Mardix, Service Division, Westmorland Business Park, Kendal, Cumbria, LA9 6NS
