16 | Electrical Panels

Image courtesy of Schneider Electric

Electrical Panels by Mark Coles

Introduction factory-built switchgear and increase costs but will give maintenance. Such assemblies
At many events in which the controlgear assemblies better operational flexibility normally have lower fault
IET participate, such as the (switchboards, motor control regarding safe working when withstand and it may be
ELEX and InterBuild shows, centres, distribution boards, connecting in additional inconvenient to shut down a
questions are asked about busbar trunking systems, etc.), circuits or carrying out whole plant or system for a
standards to which hand-wired known as type-tested and maintenance. This trade-off simple maintenance or repair
electrical control panels are to partially type-tested must be carefully assessed. operation.
comply. This article looks at assemblies. These forms of The four forms given have
types and forms of electrical separation provide protection basic definitions and Form 2
panels, uses, competency and against contact with live parts applications but Forms 2 to 4 The overall assembly
the standards to which they ( known as basic protection) can be further subdivided into enclosure provides protection
are to comply. belonging to adjacent devices more specific Types against direct contact with live
Electrical panels come in and protection from the (applications) by discussion and parts; separation is provided
many shapes and sizes (of probability of initiating arcing agreement with manufacturers. between the busbar assembly
course) and have many faults and the passage of and switching, isolation,
applications. Consider a simple foreign bodies between units of Form 1 control items and terminations.
empty box which is then firmly the assembly. The Standard This form provides for an There is very little advantage of
fixed to the ground or building also gives guidance on other enclosure to provide protection this over Form 1 and the style
structure, adapted to enclose requirements for protection against direct contact with live is similar. Form 2 can be
electrical equipment and against electric shock. parts but does not provide any subdivided into:
terminations to perform a Four forms of separation are internal separation of
particular function - the empty indicated in the main text of switching, isolation or control n Type 1 - in which the
box becomes an electrical BS EN 60439-1:1999 but items or terminations. These busbars are separated by
panel and issues relating to there is no specific detail given overall assemblies are often insulation of the bars.
electrical safety are to be on how these forms are to be known as wardrobe type with n Type 2 - in which the
considered. achieved. It is stated in the large front opening doors, busbars are separated by
Standard that the form of usually with an integral door- metallic or non-metallic rigid
Factory built panels and Forms separation should be agreed interlocked isolator. Operating barriers.
of Electrical Separation between manufacturer and the isolator interrupts all
BS EN 60439-1:1999 gives designer/user. It shall be functions but allows the door Form 3
guidance on the forms of remembered that higher forms to be opened to gain access to The enclosure provides
separation applicable to of separation specified will the assembly for installation or protection against direct

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 Electrical Panels | 21

contact with live parts and also

separation is provided between
the busbars and switching,
isolation or control items and
between all these items.
Outgoing terminals are not
separated from each other, or
perhaps from the busbars.
Form 3 can be subdivided
into:

n Form 3a - in which outgoing

terminals are not separated
from the busbars.

n Form 3b - in which outgoing

terminals are separated from
the busbars.

Form 3b can be further

subdivided into:

Figure 1: Form 1 construction

Type 1 - in which the
busbars are insulated for
separation.
Type 1 - in which the busbars associated item of switchgear, external conductors are not in
Type 2 - in which busbar are separated by insulation ff etc., but in separate enclosed the same compartment as the
separation is by metallic or coverings. Terminals for spaces. However, cables may associated item of switchgear,
non-metallic rigid barriers or external conductors are in the be glanded elsewhere. etc., but in separate enclosed
partitions. same compartment as the spaces and the termination for
associated item of switchgear, Type 5 - in which busbars are each item has its own integral
Form 4 etc., but cables may be separated by metallic or non- glanding facility (see Figure 2).
The enclosure provides glanded elsewhere. metallic rigid barriers or Switchboard manufacturers
protection against direct contact partitions. Terminals for therefore cannot give all-
with live parts and internal Type 2 - in which the busbars external conductors are not in embracing assurances for safe
separation of the busbars from are separated by metallic or the same compartment as the working, according to the form
all switching, isolation and non-metallic rigid barriers or associated item of switchgear, of separation with parts of the
control items and outgoing partitions. Terminals or etc., but in separate enclosed assembly energized.
terminations and separation of external conductors are in the spaces and terminals may be Specifying a particular form of
all items and outgoing same compartment as the separated by insulated separation will not guarantee
terminations from each other. associated item of switchgear, coverings. Cables may be this for any given form
This allows for access to any etc., but cables may be glanded in common cabling number.
single item, such as a switch- glanded elsewhere. chambers.
fuse or starter and its outgoing General
terminations, to enable work to Type 3 - in which separation Type 6 - in which all separation Assemblies are to be designed
be carried out whilst the requirements are by metallic or requirements are by metallic or and constructed so as to be
assembly remains operational. non-metallic rigid barriers or non-metallic rigid barriers or able to withstand the thermal
Protection is also provided partitions. Terminals or partitions. Terminals for and dynamic stresses resulting
against an arcing fault in one external conductors are in the external conductors are not in from fault currents up to their
device affecting other items. same compartment as the the same compartment as the rated values.
This is the usual form specified associated item of switchgear, associated item of switchgear, The installation designer
for commercial and industrial etc. and each item has its own etc., but in separate enclosed must specify the prospective
switchgear and controlgear integral cable glanding facility. spaces and cables are glanded fault current conditions at the
assemblies but the designer has in common cabling chambers. point of installation. Busbar
to consider whether, due to the Type 4 - in which the busbars systems for switchgear and
extra cost, such requirements are separated by insulated Type 7 - in which all separation controlgear should be
are necessary or justified. Form coverings. Terminals for requirements are by metallic or adequately rated for the
4 can be subdivided into seven external conductors are not in non-metallic rigid barriers or normal duty and maximum
types: the same compartment as the partitions. Terminals for fault current level expected

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22 | Electrical Panels

supply (Section 411)

(ii) Double or reinforced
insulation (Section 412)
(iii) Electrical separation for the
supply to one item of
current-using equipment
(Section 413)
(iv) Extra-low voltage (SELV
and PELV) (Section 414).

In electrical installations the

most commonly used
protective measure is
automatic disconnection of
supply. Automatic
disconnection of supply is a
protective measure in which:

(i) basic protection is provided

by basic insulation of live
parts or by barriers or
Figure 2: Form 4 construction
enclosures, and
(ii) fault protection is provided
by protective earthing,
and should be well supported aluminium, sometimes that internal heating would be protective equipotential
and braced, as the stainless steel required; high external bonding and automatic
electromechanical stresses temperatures (solar gain) may disconnection in case of a
under fault conditions can be n mechanical impact - if there call for internal cooling fault.
severe. is a mechanical impact issue, Regulation 412.2.4.1 states
such as the risk of being n electromagnetic that the requirements for basic
Bespoke panels struck by moving objects, compatibility and interference and fault protection can be
Many electrical panels are BS EN 62262 provides issues may need to be met if the rated voltage of the
made for bespoke applications information on the IK rating of addressed cable(s) is not less than the
which require much more enclosures nominal voltage of the system
consideration than selecting A concise list of external and at least 300/500 V and
factory built units from a n vandalism - if the panel is influences can be found in that adequate mechanical
catalogue. The environmental susceptible to unauthorised Appendix 5 of BS 7671:2008. protection of the basic
and local conditions will have entry or vandalism a locking insulation is provided.
the greatest influence on the mechanism will need to be Electrical safety Adequate implies the non-
choice of panel. The following considered in addition to When constructing a bespoke metallic sheath of the cable or
issues will need to be vandal-proof fixings electrical panel, the non-metallic trunking or
considered when choosing the requirements of BS 7671 are ducting complying with the
correct panel for the n hazardous locations - panels to be considered. The method BS EN 50085 series, or non-
application: installed in hazardous of protection against electric metallic conduit complying
locations will need to meet the shock will be established with the BS EN 61386 series.
n weather - if the panel is to requirements of BS EN 60079 based on the environment in Note that the where a lid or
be located outdoors, a feeder- suite of standards, e.g. Group which the panel is located and door in an insulating enclosure
pillar or telecommunications I: electrical apparatus for the particular application. can be opened without the use
cabinet for example, the mines susceptible to firedamp; Regulation 410.3.3 requires of a tool or key, all conductive
weather will be a factor in Group II: electrical apparatus that in each part of an parts which are accessible
deciding the overall IP rating of for places with an explosive installation, one or more when the lid or door is open
the cabinet; see BS EN 50529 gas atmosphere other than protective measures are to be must be behind an insulating
mines susceptible to firedamp applied, taking account of the barrier (providing a degree of
n material - the material of with sub-division IIA, IIB or IIC conditions of external protection not less than IPXXB
manufacture is an important influence. BS 7671 generally or IP2X) preventing persons
issue - metallic or a type of n temperature - ambient recognises the following four from coming unintentionally
plastic, for example. Plastic temperature expected and the methods of protection against into contact with those
materials are usually much amount of heat emitted by electric shock: conductive parts. This
lighter than metallic; metallic internal components; external insulating barrier shall be
units are often made from low temperatures may mean (i) Automatic disconnection of removable only by the use of a

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 Electrical Panels | 23

tool or key; Regulation required by BS 7671 Part 6 working space and lighting n Guidance Note 1 - Selection
412.2.2.3 refers. should be carried out on the need to be provided where and Erection
Slotted trunking, Figure 3, complete assembly, plus any work is to be carried out on or n BS EN 50529:1992 Degrees
will not meet the IPXXB or other specific tests advised by near equipment, in order that of protection provided by
IP2X requirement of the manufacturer or required persons may work safely. enclosures (IP code)
Regulation 412.2.2.3, by the client, user or engineer. The Memorandum to the n BS EN 62262:2002 Degrees
therefore, if the panel remains It is not usual to carry out a Electricity at work Regulations of protection provided by
fully energised upon opening, repeat of specialist tests, e.g. a 1989, HS(R)25, records that enclosures for electrical
only insulted and sheathed flash test at site; however, in the IEE Wiring Regulations is equipment against mechanical
cables or wiring from SELV or the event of such a widely recognised and impacts (IK code)
PELV sources should be requirement or request, the accepted in the UK and n BS EN 60079 Electrical
installed within the trunking. If manufacturers advice should compliance with them is likely apparatus for explosive gas
non-sheathed cables operating be sought. to achieve compliance with atmospheres suite of
at voltages in excess of the relevant aspects of the 1989 standards
SELV and PELV requirements Competency Regulations in point 7 of the n BS EN 60439-1:1999
of Regulation 414.1.1 are As with all installations, work introduction. n Low-voltage switchgear and
installed in slotted trunking, a must only be undertaken by controlgear assemblies. Type-
further barrier must be competent persons. BS 7671 References and further tested and partially type-tested
installed preventing access. is not a statutory document information assemblies
It should also be realised and it is not a legal n BS 7671:2008 n BS EN 50085-1:2005 Cable
that Regulation 8 of the requirement to follow the Requirements for Electrical trunking systems and cable
Electricity at Work Regulations practices referred to within. Installations, IEE Wiring ducting systems for electrical
places an absolute Primarily, the main piece of Regulations, Seventeenth installations. General
requirement (one that shall be legislation to consider is the Edition requirements
met regardless of cost or any Electricity at Work regulations n Electricity at Work n BS EN 61386-1:2008
other consideration) on 1989 (EWR). The EWR states regulations 1989 - Conduit systems for cable
protective conductor that all systems are to be safe www.opsi.gov.uk/si/si1989/Uks management. General
connections to earth: so as to prevent danger and i_19890635_en_1.htm requirements
prevent the risk of injury. n Memorandum of guidance n BEAMA Guide to verification
a conductor shall be The designer and installer on the Electricity at Work of low voltage power
regarded as earthed when it is must be aware of the statutory Regulations 1989 (HSR25) - switchgear and control gear -
connected to the general mass requirements under the free download - www.beama.org.uk/UserFiles/
of earth by conductors of Electricity at Work Regulations www.hse.gov.uk/pubns/books/ file/publications/installation/
sufficient strength and and the Construction (Design hsr25.htm BAVG.pdf
current-carrying capability to & Management) Regulations n The Construction
discharge electrical energy to 2007 (CDM 2007), etc., for the (Design & Management) Figure 3:
earth. safe design, construction, Regulations 2007 - Slotted trunking

operation and provision for www.hse.gov.uk/construction/

It may be questioned maintenance of electrical cdm.htm
whether the termination of equipment assemblies.
steel or aluminium wire armour Adequate access,
(where used as a protective
conductor) with glands into
metal gland plates, which
themselves may only be bolted
to the switchgear or
controlgear frame, is an
adequate connection. Cable
gland earth tags and
supplementary connections to
the equipment earth terminals
may be necessary. In any case
it should be ensured that any
paint or other surface finish on
the switchgear does not
prevent effective electrical
continuity between the
adjacent parts. During site
installation and
commissioning, tests as

IET Wiring Matters | Winter 09