13 lv switchboard inspection guide

Quality inspection guideLow voltage switchboards

Preface

ForewordOn the strength of its experience, Schneider Electric has always sought to produce hight quality equipment, fully complying with IEC 60439-1 standard.

But what exactly do we mean by Quality ?

The standard ISO 9000 defi nes the quality as:“degree to witch a set of inherent characteristics fulfi ls requirements” Although fi nal inspection is in some respects a statement of failure (as we have not been able to control the necessary quality throughout the assembly process) it is nevertheless a vital stage in equipment production.

This stage must be performed with care and rigour, both with respect to customer specifi cations (explicit needs), and proper operating procedures (implicit needs), in order to satisfy the customer.

The quality is also the willingness of all the staff, from the manager to the worker to satisfy the customer. This guide is a good means to help you in this way and to reach the excellence.

Contents

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Quality inspection: means and process 3

Introduction to the quality inspection 41.1 Justifi cation of quality inspection 41.2 Quality inspection function 61.3 Quality inspection responsibility 61.4 Quality inspector’s profi le 61.5 Necessary documents 61.6 Required human resources 6

Incoming delivery inspection 72.1 Justifi cation of the incoming inspection 72.2 Procedures 7

In process inspection 83.1 Inspection during manufacturing 83.2 Justifi cation of the inspection during manufacturing stage 83.3 Process 83.4 Means 9

Final inspection 104.1 Final inspection process 104.2 Operating rules 114.3 Non conformity treatment process 124.4 Conformity declaration 13

Quality inspection: instructions 15

Performing in-process inspection 165.1 Reminder 165.2 Composition 165.3 Process 16

Performing the fi nal inspection 176.1 Conformity check 176.2 Mechanical checks 206.3 Electrical operations checks 266.4 Prior dispatching checks 31

Summarising of fi nal inspection operations 337.1 Comprehensive list of points to be checked 33

Summarising of tasks after fi nal inspection stage 38

Quality inspection: follow up 39

Quality dashboard 408.1 Purpose 408.2 Principles 408.3 Produced non quality 408.4 Example of a Produced Non Quality index board 428.5 Non conformity weight example 42

Contents

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Quality inspection: facilities and calibration 43

Facilities 449.1 The Quality Inspector’s individual tools 449.2 Common means of the quality inspection 449.3 Quality inspection zone 449.4 Necessary documents 44

Control of inspection means 4510.1 Purpose 4510.2 Reminders of basic principles 4510.3 Responsibility 4510.4 Diagram of operations 4610.5 Application rules 46

Quality inspection: appendix 49Follow-up of missing parts 49

Form example 49Checking program 50Non quality record board 51Corrective action request 52Final inspection record 53Missing parts list 54

Glossary 55Abreviations 55Vocabulary 55

Procedure“ Set of organisational rules of an administrative nature in order to achieve a certain result “ Specifi ed way of accomplishing an activity ” (see ISO 9001).

Quality inspection: means and process

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1.1 Justifi cation of quality inspection

The implementation of the quality process in production plant will entail to organised the work station on the way to reach the quality target as per imposed by the standard.A quality inspection process has always been recommended to all our partner and subsidiaries. Part of the quality insurance, it is a normative obligation of the IEC 60439-1 standards which stipulate that three routine tests should be perform in the scope of the quality inspection procedures to complete the type tests:b giving the equipment the TTA label (Type Tested Assembly)b and which are bound to the panel builder’s responsibility.

These three Routine tests areb inspection of the assemblyb dielectric tests and / or measurement of insulation resistanceb checking of protective measures and of the electrical continuity of the protective circuit.

Human factorsThe specifi city and complexity of low voltage equipment, the numerous human interventions, and thus risk of errors are the principal source of mistakes in our fi eld, so the main reasons of the implementation of the quality inspection process.

Each job must be checked.

Cost reductionThe non quality manufactured entails extra cost in term of time and money due to:b product examinationb reparationb scrapb incidence in term of delivery schedule, brand imageb etc.

A study shows that a fault detected on customer site can cost one hundred to one thousand times more than if it had been detected during the switchboard design phase (see graph below).The in process checking operation and the fi nal inspection also guarantee

Introduction to the quality inspection


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a good economic management of the switchboard manufacturing process.

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

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1.2 Quality inspection function

Guarantee the quality level of the service and insure the brand image.Detect and settle the internal dysfunction and so on increase the plant profi tability.b perform the inspection with respect to:v the project file and the customer documentv Schneider and products rulesv IEC standardsb carry out acceptance tests in the customers’ presenceb perform quality follow-up and corrective actionsb ensure the information, preventive action and training to the production staffb ensure periodical calibration of inspection and production means.

1.3 Quality inspection responsibilityQuality inspection departmentb is directly attached to management and independent from manufactureb can postpone the delivery of a project and require reworking to ensure conformityb in event of a dispute, informs the unit manager who alone has the power to decideb is responsible for the safety of all people entering in the quality inspection zone.

1.4 Quality inspector’s profi le

b graduate as electrical technician (technician’s certificate)b versatileb good knowledge of Schneider equipment and devicesb authorised to work near electrical current:v knowledge of the hazards of electrical currentv authorisation by approved training coursev basic notions of first-aid.

1.5 Necessary documents

To carry out the various checks, the quality inspector must possess a complete, updated production fi le of the project, including the check list, missing parts list, etc.

1.6 Required human resources

For an accurate and reliable quality process, the quality inspectors account for approximately 10 % of workforce,i.e. 1 quality inspector for 8 to 10 fi tters.

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Applicable to the external and internal goods or assembly. In the case of sub assembly or internally manufactured goods, an internal procedure could be used to perform a fi nal inspection of one process, joined to the incoming inspection of another one.

2.1 Justifi cation of the incoming inspection

As a fi nal stage before assembly process, this quality inspection is a sizeable part of the fi nal quality of the job and will ensure his profi tability.The reason to implement the incoming inspection process is to ensure that the received material and components are conform in regards of:b the specifications indicated in the ordering form (colours, ...)b the standardb the product specificationsb the professional carried out rules.

2.2 Procedures

Verifi cationThe quantity and aspect control of goods could be done by the receiving agent.The quality checking should be done by the quality inspector.In case of large volume of goods, this operation could be done on a sample.

All the incoming goods should be received and stored in such condition that they will not be damaged till their fi nal installation.

Non conformity processingAll non conform product will be:b confined in a separated placeb registered as a non conform product and clearly identified.

All precautions should be taken to prevent their repetitions.

Incoming delivery inspectionQuality inspection: means and process

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In process inspectionQuality inspection: means and process

3.1 Inspection during manufacturing

On the way to ensure the conformity of the product or sub assembly to the expected needs, the quality insurance program may recommend the implementation of a specifi c inspection procedure. Done on parts of an assembly or at the end of various mounting operations.

The following diagram represents the operations on which in-process inspections are carried out and the main goods concerned by incoming quality inspection.

3.2 Justifi cation of the inspection during manufacturing stage

The reasons to implement the inspection during manufacturing process are:b the complexity of the some equipment system.It could be necessary to perform a quality inspection process during manufacturing to ensure the conformity of parts or assembly step witch presents:v the access difficulty: current transformer, bars characteristics, connections, installation...v the time (profitability) needed for the final inspector to remove some cover or other partsb the will to involve and motivate the staff for the quality of their workb the workshop organisationb existence of dedicated assembly line for frame, busbars, functional units (withdrawable, disconnectable, plug in, fixed)b presence of a devices adaptation work stationb mass produced manufacturing system.

3.3 Process

The inspection during manufacturing stage could be described by the following process:b inspection during manufacturing stageThis operation consists in carrying out checks at different stage of the assembly processv systematic inspection or sampling which is part of quality inspectors responsabilityv inspection done at the end of each key manufacturing step such as cubicle assembly, devices adaptation, functional units assembly...

N.B.:non conformity treatment is the same as the one described in the fi nal inspection chapter.

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In process inspectionQuality inspection: means and process

b continuous inspectionThe assembly operations requires constant carried out of the professional rules. Due to that, this procedure consist of carrying out checks throughout manufacturing in the form of operators or project supervisor check.It will make them responsible for the quality of their work.These check should always be validated by the fi nal inspection inspectors.

Notice:integral part of the checking operations, the cleaning process should be performed during and at the end of the manufacturing process and registered on the check list. (i.e.: Okken or Blokset busbar compartment).

3.4 Means

Presented as a check list form (could be a part of the fi nal inspection check list), the instructions provided at each manufacturing stage enable these checks to be formally defi ned.One check list is commonly dedicated and located on the cubicle frame, other check lists can be done for functional units or manufacturing operation done apart from the cubicles.The fi tter should fi ll in the check list to allow the quality inspector to verify that all the points are checked and that the procedures are implemented.

b these follow-up sheets are used to log the status of the inspections performed.

The same forms are fi nally authenticate by the quality inspector during the fi nal inspection stage.

N.B.:Despite the operator checks performed for each operation, fi nal inspection is always necessary. As it is stipulated by standard IEC 60439.1.

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Final inspectionQuality inspection: means and process

Final inspection guarantees operation and conformity of products with respect to applicable drawings and standards. It is performed by the unit’s quality inspection department.

A document per project formulating the customer’s requirements and transcribing the specifi cation is used for the checking phases during assembly and for fi nal inspection. It forms the fi rst reference document (production fi le).

The following table gives you an idea of the average time required to perform a fi nal inspection according to the type of switchboard to be inspected.The following information is given in average % of assembly process.

Simple switchboard

Semi-complex Complex

PCC 3 % < X > 8 %

MCC 4 % < X > 10 %

4.1 Final inspection processThe fi nal inspection takes place as followsb carry out the conformity checkb conduct the testsb modify the production file by adding any necessary annotations (throughout testing)b list all the non conformities:v by noting all the faults or modifications observedv by drafting a list of missing parts.

Ensure reworking for conformity.

b if customer acceptance is scheduled, receive the customer and / or his representative in the quality inspection zone. Sign the fi nal inspection report after customer acceptance.b point out any areas of dispute between customer and supplierb ensure that the design documents have been properly corrected, by checking final version status and updatingb ensure that all the check list is filled inb draft and record the final inspection reportb sign the final inspection report and other documentsb archive the documents.

List of the various fi nal inspection tests:a. conformity checks:b enclosure:v appearancev compositionb the front face layoutb frameworkb devicesb busbarsb flexible busbarsb cablesb connectionsb PE and (or) PEN protection busbarsb separated equipment.

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b. mechanical checksThese checks consist of testing proper operation of the mechanisms and manual controls, the sturdiness of the switchgear, etc.

c. electrical checksb operating testsb dielectric withstandb electric continuity of protection circuitsb insulation resistance.

4.2 Operating rules

The operating rules can be modelled using the following diagram.D

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4.3 Non conformity treatment process

The following diagram describes the various possible cases of treatment of non conformity.

During the fi nal inspection operations, any errors detected must be recorded on an “non quality record board” and all non conformities corrected. E.g. : type of table.

Non quality record board Corrective actionLocation / Type of fault

BB assembly

Cabling Performed by

Time Signature

Cabling error b Jean 5 min

Busbar support missing

b Alain 1 hour

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4.4 Conformity declaration

On completion of fi nal inspection, the quality inspector signature declaring conformity of equipment should be affi xed on the identifi cation label placed on the drawers and cubicles.

Panel builder“leneX0 000 ileTel : XX XX XX XX XXFax : XX XX XX XX XX”

“Quality inspectionChecked by:”

ConformityDATE: …..../……./.…… frame Conformity

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

Switchboard: ………… power Electrical test

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

Equipment n° / location: ………………

fi nishing Protective measures check

Rating: ……………….. Insulating test

Design n°: …………… Index: ………………

Only fully inspected cubicles can be dispatched.A label, resembling the one below, is used to identify them before packaging.

Final inspection sheetReady for dispatch

Client: …………………………………… Purchase order n° ………………

Switchboard designation: …………... Design fi le reference …………...

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

Quality Inspector Name: ……………………

Date: ......./......./.......

Quality ManagerName: ……………………

Signature: Signature:


Instruction (dictionary defi nition)“ Verbal or written explanation intended for the person responsible for the carrying out of a specifi c mission. ”

Quality inspection: instructions

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Performing in-process inspectionQuality inspection: instructions

5.1 Reminder

The purpose of in-process inspection is to ensure product conformity after each manufacturing operation.

This process concerns all the manufacturing operations done by the workshop operators.

5.2 Composition

One assembly follow-up check list sheet is completed for each cubicle and / or functional unit (according to the manufacturing process).This document is used both by the operators and the quality inspectors (see follow up check list example in the appendix).

It is used from the fi rst assembly phase through to fi nal inspection.

This check list should mention:b the designation of each point to be controlledb the operator identification and the checking period.

5.3 Process

After each stage, the operator checks and declares product conformby signing this follow up check list sheet and noting any observations.

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


Performing the fi nal inspectionQuality inspection: instructions

The Quality Inspector must:b take delivery of the switchboards to be inspected in the dedicated zoneb become acquainted with the project production fileb check the observations and information given in the assembly follow-up sheet (could be a part of the follow up check list)b perform the final inspection by using the follow up check list.

First routine test / Inspection of the assembly

6.1 Conformity check6.1.1 EnclosureComposition and dimensionNumber and order of cubiclesUse the drawing of the project front face to ensure that the number and order of cubicles is respected.

Project, switchboard and cubicles identifi cation labelb check that the information marked on the label match with the project fileb check the presence of project identification marker on each cubicle. This is normally shown in the form of a self-adhesive label (see chapter 4.4)b ensure that this label contains the registration number, signature, switchboard number and design update versionOn completion of fi nal inspection, the Quality Inspector must place his registration number (or signature) and indicate the date at which the inspection was performed.

DimensionsCheck the cubicle dimensions (height, width, length and depth) by measuring and comparing them with those stated in the project production fi le.

AppearancePaint colour and referenceUse the colour palette to ensure that the reference of the paint given in the project fi le matches the colour of the cubicle.Verifi cation generally carry out at the incoming delivery inspection stage.

HomogeneityPerform a visual inspection to check the homogeneity of the colours of the various switchboard components (doors, panels, etc.).

FinishingCheck external appearance by a visual inspection: no scratches, deformations, etc.

Front face and mimic diagramb visually check that the front face of the switchboard matches the one shown in the drawing of the projectb check conformity of the mimic diagram compared with the power diagram and front lay out.

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6.1.2 FrameworkFrameworkPanellingb operation of doors, mechanical accessories and drawers:v check their operation by manoeuvring themv ensure that the cubicle equipment is complete and has been installed properlyb ensure the presence, characteristics (IP, material...) and proper fitting of:v ventilation grid, bottom platev side and rear coverv roof, blanking plate, etc.b conformity of cut outs in the plates:Using the drawing, check the presence of any cut outs in the roofs, mounting plate and separation plates allowing fi sh plating, coupling bars installation, interlock cables or rods installation, etc.

Checking the locksCheck matching of the lock references and the key numbers with the references given in the project production fi le.

Mechanical assemblyCheck the overall assembly, frame position (top, bottom), the presence and location of the screws required for assembling and joining the cubicles, bottom plate, mounting plate, etc.

Check that all screws, picot washers and earth braids (if required) for fi xing these components are present, and check that screws are properly tightened.

Ground fi xingUse the project design drawing to check the location of the ground fi xing points.

Handling devicesCheck their fi xing and their disposition according documentation.

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

Check the connection facilities space and equipment

Checking the degree of protection:b this check is performed by checking the presence of the components guaranteeing the IP level stated in the project production file. Needs vary according to the required IP degree: awning, seal, front plate, cable glands, etc. (information given in the product catalogues or guides).If a seal is used, ensure it is properly positioned and continuousb be sure that the IP degree of the equipment located on the door or the device manoeuvring mode (cut out on doors or presence of specific cover), matches with the switchboard requirement.

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6.1.3 SwitchgearConformity of devicesLocation / identifi cationUse the layout diagrams in the project production fi le to ensure that the devices are properly located and identifi ed (QF1, QF2, etc.).At the same time, the nature of the labels associated with the devices and the content of the text can be checked.

Characteristicsb devices characteristics:v type, ratingv breaking capacity and number of polesv Masterpact terminal pads characteristics and installation (according product). Inspection to be done prior the installation in the cubicle (Inspection during manufacturing process).

Check or carry out the settings such as thermal and magnetic releases, time delays, etc. b associated devicesCheck presence and technical data of circuit breaker’s associated devices (Vigi, fault signal switch, trip unit, etc.).Check the supply voltages for:v switchgear motor mechanismsv coils (contactors, relays, impulse relays, under voltage or shunt coils of the Compact, Masterpact and multi 9)v indicator lightsv all the electronic devicesv soft started, capacitor bank....

b toroïdsCheck the technical data of each toroïd, their compatibility with the customer connection cables. Also ensure the correct mounting direction: the arrow shows current direction.

b current transformerv check the technical data of the current transformers together with the installation directionv check the correspondence between the current transformer and the associated device, ammeter, etc. Ensuring that the current delivered by its secondary circuit is compatible with the associated devicev check the respect of the clearances between the fixing and the secondary connecting screws of the current transformer versus live conductors or metal parts. Check if the current transformer are well secured on the conductor.

ShuntCheck the connection between the shunt and the measuring instrument.

Safety perimetersCheck the circuit-breaker safety perimeters referring to their installation guides.No devices, equipment or bundle should be located in the safety perimeter.

AccessoriesVisual checking of the presence of :b crank handles for circuit-breaker and / or drawers extractionb doors stop, lightb clamps for fuse extractionb pins for fixing certain relaysb etc.


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6.2 Mechanical checks

Consult the switchboard assembly and installation guide.

6.2.1 Mechanical check and settingMechanical checkEquipment manual operationb manoeuvre the manual mechanism of devices, to ensure their proper operationb check the operation of the functional units based on drawers, disconnectable, plug in on base or chassis version.

Check the operating safety margin of the drawers, ease of operation, inserting or extracting the drawers should be done without damaging the internal component or wiring.

Equipment fi xingb check the fixing of the devices on the drawers, on Polyfast (Inspection during manufacturing process), on mounting plates, on doors...b check that they are correctly fitted and that all the necessary screws or additional miscellaneous are present.b a particular attention should be paid in regards of:v the respect of the assembly to the functional dimensions tolerancesv the jaws installation and validated in the check listv check whether the auxiliary block are correctly identified, assembled and that the mechanical assembly remain free of movement

Mechanical operationb to be checked:v the installation and operations of the position contact, door, drawer position, extended rotary handle, etcv the operation of the limit contact travel, drawers position, circuit breakers, contact located on doorv the functional units (drawers, plug in, disconnectable...) operating margin.

Mechanical setting and greaseJawsCheck the power jaws plug-in penetrations and installation. With Blokset, use the specifi c jig to control the bars position (jaws operation).

Presence of electrical and mechanical greaseb the jaws lubricationb mechanical parts lubrication. Consult the technical product documentation.

Freedom of the power clamp fi ngers, contact pressureMake sure that during the functional units manoeuvre, the various type of power and command control clamp will not be damage.Check carefully whether the contact pressure looks well spread off.

AccessibilityAccessibility of functional units or devicesCheck accessibility of:b the terminal, current transformer, etc.Always check the ease access of:v pivoting front face locking devices.If stipulated in the project specifi cations, check also the access facilities for thermography control.

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Installation and maintenance accessCheck accessibility of:b joint, cubicle coupling accessoriesb settings, HPC fuses for replacement, contactors coils, interlocking mechanism, arc chute chamber.In some particular case, (e.g. plug in auxiliary terminal block), check the ease of removing them from their support in regards of the screws access for modifi cations and maintenance. The associated bundle should be long enough to have access to the screw without diffi culties.

6.2.2 Mechanical safety and locking systemMechanical check of safety and locking system. To be checked all mechanism making the different manoeuvre (possible or impossible)Functional units pre tripping and lock Check that during plug in or out operation of the functional units, (withdrawable, disconnectable, plug in on base or chassis version) are impossible when the device is closed.(Pre tripping accessories, mechanical lock and / or micro switch)Check pre-tripping of the devices, on plug-in and plug-out operations.Devices on chassis, plug on base, drawers, disconnectable on strip, contactors, etc..Check the fuse blowing mechanical operation.

Fault trip and position indicatorPosition of the mechanical indicators after operation, a fault trip, drawers manoeuvre.Check that the circuit-breaker is reset after an electrical fault trip or after pressing the tripping test button. Check the position of the handle.Be sure of the correct resetting of the devices and drawers after fault trip or manoeuvre.

Safety systemsEnsure sturdiness of the various locking and mismatching systems.

a. interlockingCheck that closing of one device prevents closing of the other associated one.b locking by rods:v check their mechanical fasteners and adjustment.b locking by cables:v check its radius of curvature using the installation guide and ensure that they are not running near exposed live partsb locking by key-locks, check:v the type and references of the key-locksv that the key-lock prevents the device from operating.

b. MismatchingCheck that the code of the polarising slots matches the specifi cations (drawers, devices on chassis).

c. PadlockingCheck the operation of padlocking (devices, drawers...).b inter change:v check the possibility of inter change of circuit-breakers or drawers of the same type.


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6.2.3 Checking electrical link / BusbarConformity of electrical links

BusbarType and characteristicsCheck the bars characteristics according to the type of equipment, the project specifi cations, the project design.

b cross-section:according to nominal current (In), short-circuit current and / or peak current, IP, circuit-breaker breaking time, etc.Check that the cross-section corresponds to that shown in the project production fi le and product documentation.

b coating:check the type of busbars coating (bare copper, tin-coated, sheathed busbars, epoxy paint, silver-plating, nickel, etc.).

Marking and phase orderb check phase labelling type conformityb check that phase order (phases 1, 2, 3, neutral and PE) is respected according to the product specifications.

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

Bending radius and bar alignmenta minimum bending radius must be respected that is equal to r = 1.5 x e.If the copper is of excellent quality (Cu ETP), we accept: r = e.

Check the perfect alignment of the different bar assembly:b ensure a good positioning in the supportb make easier the insertion of the connection boltb avoid trouble (flexion, torsion...) on devices or terminal pads connections.

Busbar jointsJoints cross-sectionCharacteristics and numberCheck positioning and accessibility of the joints screwsInsulating distances versus frame, form partition, etc.

CleannessAfter busbars installation, ensure that no foreign body are lost in the bars compartment.In particular in the case of access diffi culties.

According to the installation system and the procedure in use, this verifi cation should be authenticate using the check list.

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6.2.4 Checking electrical link / Flexible bars

Flexible barsCharacteristicsCross-sectionTo be checked according to the device and switchboard characteristics.

InstallationRadius of curvature of the fl exible bars (at least once bar thickness). Bending manual operations are recommended to avoid damage on the bar insulator.In the event of a superimposed fl exible bar installation, ensure that insulating spacers are placed between the conductors to provide proper ventilation.BindingCheck that the characteristics and number of bindings used matches with the electro-dynamic force supposed to affect the assembly in case of short circuit.No direct binding on metal parts. If necessary fi t an insulating wedge.

Check the connections: presence of the thick fl at washer and the contact washer.

6.2.5 Checking electrical link / Cables

Cables

CharacteristicsCross-section of power and auxiliary conductors:b check cross-section referring to the switchboard specifications and product documentation.Type and colours.

Nature of cables:b Schneider recommends use of U 1000 V insulation and with an insulation temperature resistance of < 105 °C (self-extinguishing).By using these cables, we fulfi l the class 2 requirement, so these cables may be secured directly on metal supports.

InstallationProtection of cables:b check that the cables do not run near sharp edges, moving parts, against or between exposed live parts, blowing area, etc.No cables must be inserted in ventilation grid hole or mechanical fi xing hole.

Radius of curvature:b ensure that the cable radius of curvature is roughly 6 to 8 times cable diameter.

Number of cables per strand:b refer to the switchboard assembly and installation guide.

Separating the strands:b check that the power and control strands are separated as well as the strands receiving an auxiliary voltage of more than 500 V AC as well as DC circuit and communication network.

Cable fi xing:b make sure that the conductor are fastened in accordance with their characteristics, size and network short circuit withstand. Check the collar characteristic.

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Wiring in cable trunking:b maximum cable size 6 mm² in cable trunking. Ensure that the reserve in the cable trunking is approximately 30 % and that their fasteners are preferably made of insulating accessories (e.g. polycarbonate screws or rivets).

b the maximum centre distance between two trunking fasteners must not exceed 600 mm.

Non protected active conductorsEnsure that the cable not protected by short circuit devices are installed safely throughout their entire way.Bundle separated, no risk of mechanical damage, safe connection, etc.

6.2.6 Connections / Screws and assemblyConnections / Screws and assembly

Tightening torqueIn accordance with bolt, devices and other parts characteristics. Consult the product and devices documentation.

Bolt characteristics and installationCheck the bolt type (in accordance with the product specifi cations), quality: class 8/8, stainless steel, etc.Bolt insertion way (insulating distance), length of bolt…Check the Linergy sliding bolt position.Presence, position and type of washer.Presence of varnish certifying-tightening to the right torque.In event of doubt: v number of threads protruding from the nut, for connections of the same type, differs on screws of the same lengthv contact washers excessively crushed or moving, carry out a sampling check. If a number of faults are detected, ask the person responsible for assembling it to verify all the connections of the switchboard.

Contact surfaces Quality of drillings / punching and surface fi nish (no burr or cutting deformations on the conductors, no oil stains, etc.).Correspondence between the hole diameter and bolt.The bar overlapping surfaces: H = e x n.For all the non standard bar connections done under supervision of the fi tter, an overlapping height equal to 5 times the thickness of the derived busbar must be counted in order to obtain a suitable connection.

6.2.7 Cables connections

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

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The following table gives the inspections to be performed according to the type of connection used:

b where A, B, C stand for the various inspection types.A = visual inspection B = mechanical inspectionC = checking presence and positioning.

Connections Power Other circuitsJaws and auxiliaries pins A + B A + B

Lugs A + C B + C

Clips - A + B

Cable connectors A B

Terminals B + C B

Screws C C

Connection stresses and fasteningCheck that the lugs match with the connector type.Be sure that the cable are well inserted in the terminal.Remind: make sure that the crimping tools are calibrated.

Accessibility and client connections facilitiesAccessibility of power connection points on devices, and terminal blocks:b within the respect of the cable curvature radius, of the cable routing way (entry from the top / bottom) b by checking the length of pads and number of connecting holes in consideration with the size and number of cables (check the devices or product information).

Check that:b the number and cross-section of cables ensure compliance with clearances (lugs)Remind: arrange it on the way to ensure the safety of the operators (maintenance).b the number and sturdiness of the cable supportsb the ease of connection of client cable on earth or PEN bar nearby the functional unit.

6.2.8 Clearances and creepage distance

Clearances Shortest distance in the air between two live conductors or between live conductors and exposed conductive parts. b 14 mm for 12 kV impulse voltage (main busbar Masterpact)b 8 mm for 8 kV impulse voltage (Compact)b 5.5 mm for 6 kV impulse voltage (Multi 9).The IEC 60439-1 stipulate the minimum clearances required to withstand impulse voltage up to 2000 m above sea level.Pollution degree 3.

Creepage distancesShortest distance along an insulated material surface between two live conductors or between live conductors and exposed conductive part.b 16 mm for rated insulation voltage 1000 V AC and DC (main busbar Masterpact)b 12,5 mm for rated insulation voltage 750 V AC and DC (Compact)b 8 mm for rated insulation voltage 500 V AC and DC (Multi 9).See IEC 60439-1 table 16.Pollution degree 3, Material group 3a.

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6.3 Electrical operations checks6.3.1 Electrical testsOperating sequences

Equipment preparationConnect the equipment circuit and be sure of the earth link between section.Before energising, open the auxiliary control devices (relays, measuring instruments, coils, etc.).Supply the switchboard with the control desk, ensuring that voltage and phase rotation direction is respected.

Checking the power circuitsCarrying out the operations:Open all the devices. b check the order of the phasesb check correspondence of the circuit and conductor identificationb check the correspondence of the phases at each devices by closing them one by one from line side to load side (see example below).Testing is always performed downstream of the devices in order to check its poles at the same time. However a different method can be used.

b example:

When the devices are link to terminals or pads, perform the tests on them.

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

Remote / local operating mechanisms:b check their operation. If necessary use accessories (pin tip, small box equipped with pushbuttons, indicator lights, etc.).

Supply circuits:b systematically check the electronic switchgear supply circuits and the DC circuits using a tester (voltmeter).

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Check the information supplied on the connection terminals:b contact statusb remaining information (voltage, current, etc.).

Motor mechanismsClose the relevant protection devices.Activate the operating mechanism of the devices according to the command diagram, local, remote, automation...

Electrical lockingCheck that it is impossible to close a device equipped with a locking contact.

Metering circuitsCheck the winding direction, the inlets and outlets characteristics of the current transformers.To check the metering circuits, the CT secondary must be supplied using a phase shift box (failing this, you can use any other calibrated device offering the same possibilities).

b example of carrying out the operations:v select the supply voltagev adjust the maximum value of the current to be injected in the secondary circuitv inject the current in one of the circuits or in all three at once to check cabling.

Checking the test functionCircuit-breaker operation is checked by a variety of tests according to device type:b earth leakage module test (Multi 9 range, NS range):v close the circuit-breakerv press the test button of the Vigilohm part. This test is used to regularly check device tripping by simulating an earth faultb trip unit test (NS and Masterpact range):this test is performed using an external electronic tripping boxv close the circuit-breakerv make it trip using the box by connecting its cord to the specially provided socket on the front face of the trip unit partv for increased dependability, repeat this operation.

If the circuit-breaker opens for each test, the device operates correctly.

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

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Second routine test Protective measures & protective circuit

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

Mechanical inspection (Visual)PE and / or PEN protection bars.Check the presence of all the constituent elements of the assembly which guarantee the electrical continuity between the metal part and the earth bar (see technical fi le).

Cross-section in accordance with electrical characteristics.

Presence and cross-section of the joints between the cubicles, they should be at least equal to the cross-section of the PE / PEN bar to be connected.

Depending of Earth/Neutral link systems, check presence of the PEN / PE disconnecting link and access. Ensure that its cross-section is the same as that of the earth bar.

Checkb that the protective conductors are identified by the two colours green / yellow marking plus PE or PEN lozengesb the accessiblility of the terminals for external conductorsb the contact efficiency between section or parts of the protective circuitb the presence of only one conductor per connection on the protective bar.

If, for maintenance reasons, a part of the equipment is removed from the enclosure, the protective circuit of the other parts should not be interrupted.

Electrical inspectionN.B.:There is some electrical measuring devices enable to perform this test. The above method is given only for information.

Example of operating mode:b a DC source is used, with an electromotive force of less than 6 V / 2 A current is injected between the inlet of the earth busbar and the parts to be inspected (doors, front face, frame, etc.)

Measured resistance: R = U/I

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Result:b the inspection is satisfactory if the measured resistance between the circuits and exposed conductive parts is below 0.1 Ohm.

Register the result on the fi nal inspection record list

6.3.3 Operator safetyProtection of persons

During normal operations b devices adjustmentb operating handle accessb drawer operation.

Be sure that the persons are protected during the following operations:b pre-tripping of devices on plug in and plug out operationb operating safetyb drawers mechanical locking.

During maintenance and safety operations (emergency stop, padlocking...)Warning plate:b check the presence of the different warning plate such as “do not step”, “danger”, “danger supply side”, advertising plate for voltage equal or over 660 V or form doorb etc.

No live part nearby the operating handle, adjustment screw, etc.

Plug-in protection fl aps Check the presence of the plug-in fl ap: chassis, etc.

Insulation screen / phase separator / terminal shield Check they are fi tted (if required), fi rmly fi xed and linked to earth for the metallic one.

Conformity of partitions and formCheck the presence of all the screen, form partitioning, protection cover of the devices located on the door (direct contact).

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

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Third routine test Dielectric test

6.3.4 Dielectric withstand (Standard IEC 60439-1 paragraph 8.3.2) Dielectric testPreparation The dielectric test is always performed before the insulation test.

Before performing the test, make sure that you disconnect:b the surge absorbers (if any)b the covers from the Vigi modules of the Compact NSb the electrical control motorsb and any other device not withstanding the applied voltage (electronic switchgear, contactor coils, indicator lights, miniature relays, horn, measuring instruments, etc.).

The interference suppression capacitors installed between the live parts and the frames must not be disconnected, but be able to withstand the test voltage.

This test does not need to be made on auxiliary circuits which are connected to the main busbar if it:b is protected by a device of rating < 16 Ab has previously undergone the operating tests (IEC 60439-1 chapter 6.3.2).

N.B.: Check that no unprotected connections are left.For example: remove the neutral connection wire for the permanent insulation measurement.

Operating modePerform this test using a dielectrometer (or dielectrimeter) designed to deliver a variable voltage 0-5000 V AC.

Voltage to be applied:Rated insulation voltage Ui Dielectric test voltage

Main circuit 300 V < Ui y 690 V 2500 V

800 V < Ui y 1000 V 3500 V

Ui y 60 V 1000 V

Auxiliary circuit Ui > 60 V (2 Ui + 1000) V with 1500 V min.

Apply voltage in turn on each phase and on the other phases which are inter-connected and brought back to the switchboard frame.

The standard stipulates that this test voltage must be maintained for one second.

N.B.: If, for any reason, the dielectric test must be repeated, it will be done with voltage lowered to 85 % of the previous value.

Carrying out the operationsExample of the phase live part test:b all switching devices shall be closedb interconnect the exposed conductive parts and earth themb interconnect the live parts to one another and then to the assembly conductive partsb connect the measuring instrument earthing wire to the assembly frameb connect the injection cable to the circuit to be monitored and gradually increase voltage up to the required value

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b the test voltage should be applied for 1 secondb gradually reduce voltage before disconnectingb once this check is complete, repeat it for the other live circuits.

ResultThe tests are satisfactory if there is no puncture or fl ashover.

Register the result on the fi nal inspection record list

6.3.5 Insulation resistanceInsulation resistance measurementPreparationBefore performing the test, make sure that you disconnect:b the surge arrestor (if any)b the covers from the Vigi modules of the Compact NSb the electrical control motorsb the current consuming devices, so as not to create connections between the live conductors and the loads such as measuring instruments, coils, relays, indicator lights, contactor electromagnets, etc.).

Operating modeUsing an insulation measuring instrument (megohm-meter), measure insulation at a voltage of 500 V DC. This measurement is apply between each live parts and the other interconnected parts of the assembly.

Carrying out the operations: The procedure is the same as the one used for testing dielectric withstand.

ResultThe test is correct if insulation resistance between the circuits and the frame is at least 1000 Ω/V with respect to the nominal voltage of this circuit.

Register the result on the fi nal inspection record list.

6.4 Prior dispatching checksPrior dispatching checks

6.4.1 CleaningPrior the packing, check that the equipment is clean:b no dustb no foreign body forgotten in the equipment.Remind:See chapter 3.2 about the assembly for witch the access is diffi cult at the fi nal inspection stage.

6.4.2. Miscellaneous

From a detailed check list establish by the design offi ce, perform the inspection of: b all the equipment to be delivered separately, spare parts, devices dismantled for transportation, etcb roof, coupling screwsb busbar joints, etc.



DocumentationPresence of the name plate and / or the “as built design”.Make sure that all the documentation associated to the quality inspection procedure are fulfi l:b missing part listb final inspection reportb checking programb corrective action formb non quality record boardb delivery noteb etc.

Associated documentation delivered with the equipment:b devices and switchboard technical documentationb maintenance documentationb missing part listand on demand b final inspection report.

Be sure that all internal devices or other parts are well secured, inserted or locked in the switcboard

6.4.3. Packaging

Inspection of the packaging before delivery according to:b the type of good to be carriedb the transportation meansb the destination b the condition of storageb the climate conditions.

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Summarising of fi nal inspection operations


7.1 Comprehensive list of points to be checked

This non exhaustively list contains a description of the various verifi cations to be carry out during the fi nal inspection stage.She can be usefull to help you to draw up your own checking programme according to the product implemented in your workshop or manufacturing process.Example: list dedicated for functional units (drawers).

General information’sProduct: .........................................................................................................................................................................

Client reference: .........................................................................................................................................................................

Project name:

Project identifi cation:

.........................................................................................................................................................................

.........................................................................................................................................................................

Drawing number:Index

.........................................................................................................................................................................

Quality inspector .........................................................................................................................................................................

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

Technical information’sAmbient temperature

Degree of protection .........................................................................................................................................................................

Form

Withstand

Operational rated voltage

..............................................................................................................................................................kA/sec

.........................................................................................................................................................................

Cable entry / exit Top Bottom Other

IEC 60439-1 reference standards




1. CompositionNumber of cubicles Order of cubicles Project and switchboard identifi cation markersCubicles identifi cation Dimensional inspection – Switchboard – Length – Width – Height – Depth – Fixing points.

2. AppearancePaint colour and referenceHomogeneityFinishingFront face and mimic diagram

3. FrameworkPanelling / Operation of doors and mechanical accessoriesInspecting key lock and numberFrame mechanical assembly Handling device Check the degree of protection

4. Conformity of the devices installed Location and identifi cationConformity of the devices installedTheir type and ratingDevice breaking capacities Devices accessories conformitySafety perimeters

5. Mechanical checkManual operation of mechanismOperating safety (jamming – safety margin)Devices accessibilityEquipment fi xingLimit travel contacts: circuit-breaker - drawer - etc.Jaws installationGrease

6. AccessibilityFunctional units or devicesAccess for installation, joint, junction kit, fl oor fi xing boltAccess for maintenance operations

7. Mechanical setting Power plug-in penetrationsFreedom of the power clamp fi ngers – of contact pressureAuxiliary block installation

8. Checking mechanical safety and locking systemFault trip and position indicator Tripping on fuse blowing Devices interlock mechanism assemblies (Normal/Standby Source Changeover devices)Pre-tripping of devices on plug-in and plug-out operationsCorrect resetting of devices after a fault trip (circuit-breaker, relay, etc.)Impossibility of plugging in a drawer when the device is closedImpossibility of plugging out a drawer when the device is closedSealing fl aps on the power circuitsSturdiness of the locking systems by key-locks or padlocks




9. Checking the electrical conductors and linksBusbarsChecking the busbars:b type and characteristicsb phase order and identificationb layout and installationb bending radius and bar alignmentb supports characteristics and installation (conformity with product technical file)b busbar joint characteristicsb cleanness

Flexible barsChecking the fl exible bars:b type and characteristicsb installation

CablesProtection of cables Separation of strands for auxiliary U u 500 V DC – ACEMC compatibility installation rulesWiring trunking (reserve in trunking: 20 %)

Type and characteristicsPower conductorsAuxiliary conductorsPhase order and identifi cationInstallationProtected from sharp edges or moving partsNon protected active conductor installation rules

10. Conformity of the electrical connections Checking Tightening torqueBusbar overlapping / Contact surfacesBolt characteristics and installation

Checking crimping Power cables Control cablesConnection stresses and fastening

11. Conformity of connections facilitiesPossibility of connecting cables to pads or terminalsClient power incoming and outgoing route with respect to cross-section:b from the topb from the bottom.Client auxiliary incoming and outgoing routeCable fi xing:b number of cable supports and sturdiness of tightening.Proximity of PEN / Earth connection facilities.

12. Clearances Inspection Clearance:14 mmCreepage distances: b 14 mm for rated insulation voltage 750 V AC and DCb 16 mm for rated insulation voltage 1000 V AC and DC.




13. Operating inspection Wiring and the various operating sequencesPower circuit conformityElectrical controls and mechanisms Local and remote controls IT inlets and outlets Winding direction Electro mechanical indications Electrical locking Protection and metering circuits

14. Monitoring protection circuitsVisualCross-section of the protection conductor.Electrical

15. Protection of personsDuring normal operation During safety operations Pre tripping:b contactorsb fuse blowingb drawers operationb devices tripping accessories.Presence of fl aps, cable head outlet pads (as per Specifi cation)Phase separator, terminal shieldRigidity of plates, protection grids.Presence of door earthing braids “Man struck by lightning” plates for U u 660 V on form door“Danger” supply side plate“Do not step” or other advertising plateIP of the device located on or through door.

16. Interchangeability of drawers Polarisation Electrical interchangeability between drawers and circuit-breakers

17. Measuring dielectric withstandCircuit tested ϕ1 ϕ2 ϕ3 N Aux

Nominal voltage

Applied voltage

Result (1)

(1) Passed / not passed.

18. Insulation resistance measurementCircuit tested ϕ1 ϕ2 ϕ3 N Aux

Nominal voltage

Insulation resistance

Result




19. Inspection prior to dispatchRoofs, seal covers and fi xing screws.End panels and fi xing screws.Sealing fl aps (+ screws), openings for access to the cubicle anchoring points.Cubicle coupling screws.Conformity of cut-outs in the separation plates for insertion of the transfer busbars (or cables).Seals according to the IP (those mounted after installation).Joints (nature) and associated screws.Circuit-breaker extraction crank handles: - Masterpact – NS/NT, etc.Device lifting handles.Extraction clamps for L fuses.Accessories for protecting wires between cubicles. Separate equipment.Cubicle anchoring bolting (if stipulated in Specifi cation).Devices dismantled for transportation.Door handle keys: key-locking.The list of equipment not delivered (missing). Cleanness.Associated documentation.


Summarising of tasks after fi nal inspection stage


After fi nal inspection and according to contract clauses, the Quality inspector may run a check of the project accompanied by a sales engineer and the client or his representative. During acceptance procedure, the client ensures that the specifi cations have been respected.

N.B.:The procedures mentioned in this guide are given as per indication.

After fi nal inspection, the followings are required:b check that all the boxes of the checking program have been filled in

b check any reworks noted on the “non quality record board” and sign in the relevant boxes

b record and draft the final inspection report

b note the final inspection report registration number on the checking program

b ask the quality manager to validate the report (1)

b draft and record the delivery sheet.

(1) The fi nal inspection should be signed by the client or his representative after client acceptance inspection.

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Quality inspection:follow up

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Quality dashboardQuality inspection:follow up

8.1 PurposeThis dashboard allows the measurement of the quality performance and reveal the necessary corrective actions to implement.

8.2 PrinciplesThe quality assurance manager issues a monthly quality report entitled “Quality indicator report”.Performance is evaluated according to the four indicators below:b purchased non qualityb produced non qualityb non service qualityb external non quality.

The non quality index:b is an indicator used to measure changes in non qualityb defines the target aimsb reveals the weaknesses of the various operations and allows the relevant actions to be taken.

These non quality indices can be calculated using specifi c formulas (see chapter 9.3). The index witch is directly associated to the fi nal inspection is “produced non quality”. Purchased non quality can be monitored by different indicators depending on the supplies origin:b global ratiob ratio of the supplies purchasedb internal manufactured supplies ratio.

External non quality:b taking clients complaints into account (intermediate or end users).

8.3 Produced non qualityThis index is calculated after the fi nal inspection process using the “non quality record board”.

It is calculated using this formula:Non quality index = Sum of weighted faults

Total number of cubicles*

The faults revealed by the quality inspection are assigned according to their origin to the production, the project design department or sales.

The faults are classed in 3 categories:b minor: a fault corresponding to a non conformityb major: a fault risking a considerable reduction of the achievement of a function in the switchboard.

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b critical: a fault which, according to judgement and experience, is likely to result in a lack of safety or risk of accidents for the user. It presents a real danger for persons and equipment.

WeightingThe weighting applied to these three types of faults is:b minor fault = 1b major fault = 3b critical fault = 10

Produced non quality is monitored by means of indicators for each type of product and a global indicator.

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

b example of a MCC cubicle made up of:1 framework (1 x 0.3) = 0.32 drawers 250 A 6 modules (2 x 0.1) = 0.2Total = 0.5

Cubicle equivalent = 0.5.



8.4 Example of a Produced Non Quality index board

Product Number Non conform Faults Responsibilities Weighting versionNbr % A B C Weight. total Prod. Project

design dept.Ext.

Equip. 1 12.0 3 25 5 2 0 11 4 2 1 0.92

Equip. 2 5.0 4 80 3 3 1 22 3 1 3 4.4

Equip. 3 8.0 4 50 4 0 1 14 4 0 1 1.75

Total 25.0 11 44 12 5 2 47 11 3 5 1.88

Equipment 1: Prisma Plus A: Minor = 1.Equipment 2: Prisma Plus B: Major = 3.Equipment 3: Okken C: Critical = 10.

Example of a graph showing the ‘‘non quality index’’.

The peaks shown on the graph may be due to:b the number of projects handledb the complexity of certain projects (complicated operating sequence)b insufficient personnel trainingb insufficient sensitivity of personnelb poor control of suppliesb poor quality of the project production file.

8.5 Non conformity weight exampleItem Description / Description Poids /

Weight1 Labelling 1 2 Wire marking 13 Wiring aspect 14 Accessibility of equipment 15 Fixation of apparatus 16 Space for customer connection 17 Bad crimping 38 Auxiliary wire section 39 Auxiliary protection rating 310 IP degree 311 Earth connection 312 Phase polarity 313 Electrical sequence operation 314 Auxiliary wire damages 315 Power wire damages 1016 Insulating distance 1017 Power cable or bus bars cross section 1018 Protection devices conformity 1019 Number and clearance of busbars supports 1020 Interlocking 10

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Quality inspection:facilities and calibration

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FacilitiesQuality inspection:facilities and calibration

9.1 The Quality Inspector’s individual tools

These are the switchboard fi tter’s tools (screwdriver, wrenches, etc.) with in addition:b a small rule or measuring rods to check clearancesb a lampb an articulated mirrorb a set of crocodile clipsb a bell testerb set of probe fingers

9.2 Common means of the quality inspectionb control desk:enables to energised the main and auxiliary circuits. Equipped with a voltage variator and a number of selector switches and indicators, to make easier the various operating sequences.b dielectrometer:to perform the dielectric test followed by the insulation resistance one.b megohmmeter:to perform the insulation resistance testb earth continuity testerb phase order testerb drawers test equipmentb test cords and a variety of plugs, supply cords and other connection systemsb steps, pallet-mover or other transportation facilities.

9.3 Quality inspection zoneb is independent from productionb must be physically separated from the other departments:v for reasons linked to the hazards of electrical currentv for protection of people and equipmentb is clearly marked out (tapes, partitions, etc.)b is clearly indicated (warning beacon, flashing light, sign, etc.).

This area should be equipped in compliance with applicable legislation and local regulations.

9.4 Necessary documentsb to carry out the various checks, the quality inspector must have:v a complete, updated production file of the project, check listv a missing parts listv update procedures and associated documentv updated products documentations (devices, equipment system...)v standards.

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Control of inspection meansQuality inspection:facilities and calibration

10.1 PurposeThe purpose of these operations consist in controlling the inspection and production means used in the unit for maintenance and calibration.To get a mark out of the tools on the way to perform possible correctives actions on the delivered equipment.

10.2 Reminders of basic principlesInspection meansList and identify the inspection means.

Have them checked at specifi c intervals, according to the accuracy of the measurements to take, by an approved international or national organisation. (For example, the organisation for France is the B.N.M. – National Metrology Offi ce).

Identify by a label “not followed up in calibration”, the devices not assigned to measurement (e.g. power on detection devices).

Store, use and transport these means in conditions guaranteeing their proper operation and level of accuracy.

Rule on the project equipment delivered and inspected using non conform measuring instruments.

Production meansTorque wrenches.Crimping means.

10.3 ResponsibilityThe inspection and production means responsible appointed by the quality manager is in charge of: b listing and identifying these meansb implementing and monitoring the checksb decision-making after checkingb archiving the documents.



10.4 Diagram of operations

10.5 Application rules10.5.1 Choice of means

Inspection and production means are chosen according to:b the type of measurementb the theoretical values to be measuredb the required accuracyb the type of process to be done.

10.5.2 Classifi cation of meansFor checking follow-up:b all the inspection and production means identified and monitored.The items of equipment identifi ed by a label “not followed up in calibration” and listed on the associated document are used as indicators only.

10.5.3 Checking frequency

Inspection meansThe normal frequencies chosen are:b 1 check once a year for normally used inspection means (type: dielectric-meter, etc.)b 1 check once every 2 years for seldom used inspection means.

Production meansTorque wrenches:b must be calibrated once a year at least.Crimping means:b must be checked once a year.

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10.5.4 Listing and monitoring the inspection and production means

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

10.5.5 Occasional checks

These checks must be performed after:b acquisition of a new inspection and production means (without verification or conformity certificate)b an impactb a repairb a loanb a long period of inactivity.

10.5.6 Devices outside the accuracy class

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



The calibration manager must also decide whether to initiate a notifi cation of non conformity (NNC) used to rule on project equipment delivered which was inspected using the defective device in question as follows:

(*) See the example of Notifi cation of Non Conformity.

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Quality inspection:appendix

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Form exampleQuality inspection:appendix

2. Follow-up of missing parts at end of project

Project no.: .................................................. Date received by client or factory availability lead time .........................................................

1 - Missing at end of assembly

Issued by: .................................................... (copy) V Q.I.Date: .............................................................

Items Project co-ordinatorReferences

Quantities SuppliesLead time announced

2 - Missing parts at end of inspection/customer acceptance

Issued by: .................................................... (copy) V Q.I. Date: ............................................................. (copy) V Warehouse

Items Project co-ordinatorReferences

Quantities SuppliesLead time announced

3 - Sales department notifi cation

Can the project be dispatched with missing parts? Yes No

Can the missing parts be partially dispatched? Yes No

Which ones? ..............................................................................................................................................................................

Missing parts dispatch address: ............................................................................................................................................

....................................................................................................................................................................................................

Project site delivery date: ........................................

Follow-up of missing parts



Checking program

Product : .................................................................... Final inspection registration n° : ................................

Drawing n° : .................................................................... Index : .......................... Client : .......................................................................

Tendering : .................................................................... Project n° : .................................................................

Design : ....................................................................

Assembly : ....................................................................

Quality : ....................................................................

Cubicle identifi cation : Continuous inspection Quality inspection

Observations (1) Checked by Checked by Repair Conform Nb of faults1 Number, identifi cation and dimension of cubicle

2 Paint - aspect -

3 Framework assembly - handling devices - keys

4 Protection index

5 Devices location and identifi cation

6 Devices label conformity, circuit identifi cation

7 Devices accessories

8 Current transformer characteristics and installation

9 Fault trip - mechanical pre-tripping function

10 Clamps installation and grease

11 Bus bars characteristics

12 Bars and supports installation

13 Connection conformity

14 Tightening - varnish

15 Conductors identifi cations

16 Insulating and creepage distances

17 Cleaning

18 Devices mechanical function

19 Devices characteristics

20 Operating and maintenance access

21 Terminal pads conformity (cable entry and size)

22 Devices safety perimeter

23 Conductors characteristics and installation

24 Monitoring of the protection circuit

25 Electrical operating inspection

26 Insulating test

27 Dielectric test

28 Form partitionning

29 Final inspection record

30 Customer acceptance report

3132 Missing part list

33 Drawing “as built”

3435 “Non quality” record board

36 Devices specifi cation sheet

37 Packaging

38 Separate equipment delivery

39

Checking during process: fulfi l the grey box

Final inspection and test: fulfi l the white box

(1) N.B.: tick the box and annotate the observation on the event record sheetFulfi l the box with NA for “not applicable mention”.

Date. : ........ /........ / ........

Checking program



Non quality record boardQuality inspector: Manufacturing: Project name: Date:

Product: Quantity: Job number:

Number of faulty column: Client:

Number of drawer: Repair action

A: minor fault B: major fault C: critical fault A B C A B C Repaired Checked by

Localisation and type of fault Design / tendering Manufacturing By: Duration Q.I.

Sum of faults Page:

Non quality record board



Corrective action request

Action request of: ..............................................................

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

From: ................................................................................. To: .................................................................................

Copy to: ........................................................................

Non conformity detected by customer Detected internally

Concerned product: ............................................ Project no: ..........................................

Issued by: ............................................................. Date : .................................................. Customer: ...........................................

Description of the non conformity

Any sugestions

Answer

Corrective actions Perfomed by Date

Corrective action settled Date: .................................................. Quality insurance. signature

Corrective action request



Procès verbal de contrôle fi nal / Final inspection report

Client : ................................................. PV n° / Registration Nr ....................…............................….......

Affaire / Project : ................................................. N° Cde client / Client ref. : ...............................……....……....…

Nom du tableau / Switchboard identifi cation ...................................…………….........…………….........…………............................

....................……....................…….....................……....……....…

N° affaire / Job ref. : ....................……........................……....…

Produit / Product : .................................................

Quantité / Qty : ................................................. fi nal check delivery

Plan n° / Drawing n° : ................................................. Indice / Index:

Observation / Comment:

...................................................................................................................................................................................................

...................................................................................................................................................................................................

Inspecteur client / Client représentative Inspecteur qualité / Quality inspector Respons. I.Q /Quality manager

.......................................................................... ....................................................................

.......................................................................... .................................................................... .....................................

Date ...................................... Date ...................................... Visa

......................................

Visa ...................................... Visa ......................................

Gamme de contrôle / Checking program

1. Contrôle de conformité / Conformity checking

- Les enveloppes / Enclosures ...........................................................

- L’appareillage / Switchgear ...........................................................

- Les conducteurs / Conductors ...........................................................

2. Vérifi cations mécaniques/ Mechanical checking ...........................................................

3. Essais electriques / Performances electric test ...........................................................

4. Continuité électrique des masses mécaniquesExposed conductive parts electrical continuity

Visuel / Visual

Electrique / Electrical

Réf. Appareil / Measuring device ref. ...........................................................

Valeur / Value ...........................................................

5. Essais diélectriques / Dielectric test Réf. Appareil / Measuring device ref. ....................

Circuit / Circuit Auxiliaires / Auxiliaries Puissance / Power

Tension nominale / Nominal volt V

Tension injection / Injection volt V

6. Essais d’isolement / Insulating test Réf. Appareil / Measuring device ref. ....................

Circuit / Circuit Auxiliaires / Auxiliaries Puissance / Power

Tension d’applicat. / Applied voltage V

Valeur d’isolement / Insulation value V

Final inspection report



Entity PlantTel : 00.00.00.00.00.Fax: 00.00.00.00.00.

1. Missing parts list / Liste des composants non expédiés avec l’affaire

Project number / N° d’affaire : .................................................

Item / Poste Designation / Désignation Quantity / Quantité

Quality control / Contrôle qualité

...................................................................................................................................................................................................

Quality inspector / Inspecteur qualité

...................................................................................................................................................................................................

Date ......................................

Missing parts list


GlossaryQuality inspection:appendix

AbreviationsB.N.M.: National Metrology Offi ce.L.V.: Low Voltage.

I.E.C.: International Electro-technical Commission.

Dielectrimeter: A device used only to perform dielectric tests.Dielectrometer: A device used for withstand testing. It measures dielectric withstand and insulation resistance.

I.P.: Degree of Protection.Q.I.: Quality Inspection.N.N.C.: Notifi cation of Non Conformity.

I.T.P.: Inspection and Test Programme.P.E.: Electrical Protection.P.E.N.: Electrical Protection and Neutral.

C.T.: Current Transformer.

MCC: Motor Command and ControlPCC: Power Command and Control

VocabularyMain defi nitions(Standard ISO 9000)

QualityDegree to witch a set of inherent characteristics fulfi ls requirement

Quality auditMethodical examination of all the measures described in the quality manual and his relevant procedures, in co-operation with the involved parties. This on the way to evaluate whether the real statement of the plant is in harmony with the description of the quality manual.

Quality managementCo-ordinated activities dedicated to direct and control an organisation with regard to quality.Also include the evaluation of the results and the correspondent cost.

Quality manualWritten documents specifying information about the quality management system of an organisation.

Quality plansDocuments describing how the quality management system specify witch procedures and associated resources shall be applied by whom and when, on the way to obtain the quality level of the considered project, product, process or contract.Also called “quality insurance program”.

ProceduresSpecifi ed way to carry out an activity or process.Written document describing the organisation and manufacturing method, control, inspection, checking, assessment, corrective actions intended to be strictly applied on the way to reach the predefi ne quality level.

InspectionConformity evaluation done in the scope of defi ned process by observation, measurement, testing or gauging.

Non conformityNon fulfi lment or deviation of a need or expectation with respect of the specifi ed requirement.

Traceability Ability from registered identifi cation, to trace the history process and the location of the product after delivery.


Schneider Electric Industries SAS89, boulevard Franklin RooseveltF - 92500 Rueil-Malmaison (France)Tel : +33 (0)1 41 29 85 00

http://www.schneider-electric.comhttp://www.merlin-gerin.com

As standards, specifications and designs change from time to time, please ask for confirmation of the information given in this publication.

Printed on recycled paper.

Design: Schneider ElectricPhotos: Schneider ElectricPrinted:

DESW048EN 04-2006

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