TECHNO system

TECHNOModular Switchboard System

Compartments

Structures

Busbar Systems

Accessories

Software

IPD INDUSTRIAL PRODUCTS Phone: 1300 556 601 www.ipdgroup.com.au

2 TECHNO Modular Switchboard System 2010

IPD Group Ltd. © Copyright 2010

IPD Distributes the following brands:»»»»»»

ELSTEEL TECHNO Modular Switchboard System is the result of years in research, development and testing to create a cost effective and easy to assemble system suited to meet the most demanding of applications.

TECHNO is a fully modular system that enables switchboard builders assemble type-tested boards with user-friendly estimation & design software. Being truly modular, it offers absolute flexibility in switchboard construction enabling changes and modifications to be done easily with little cost impact.

TECHNO offers training and accreditation to switchboard builders so that the switchboards comply with type test requirements. IPD also offers technical and engineering support in every state.

TECHNO is made by Elsteel a Danish company with factories in Denmark, Poland and Sri Lanka, accredeted to ISO 9001:2008 (DNV) and all relevant IEC text certification.

IPD and ELSTEEL have jointly conducted testing and certification to AS/NZ standards with full compliance. Visit us at:

www.ipdgroup.com.au

Schedule of Tests 0

References Page 18

Constructors Manual Page 16

Design & Estimation Software Page 14

Switchboard Accessories Page 12

Compartments Page 8

Busbar System & Accessories Page 6

Internal Plates Page 5

Framework Page 4

Technical Data Page 22

CONTENTS:»»»»»»

TECHNO Modular Switchboard System 2010 3


CONTENTS:»»»»»»

FrameworkPage 4

Internal PlatesPage 5

Busbar System & AccessoriesPage 6

Compartments Page 8

Switchboard AccessoriesPage 12

Design & Estimation SoftwarePage 14

Constructors ManualPage 16

ReferencesPage 18

Schedule of TestsPage 20

Framework



CROSS BAR

CORNER & CORNER BARS

PLINTH & CORNER BARARRANGEMENT

The framework is made up of:

- Base corners- Plinth profiles- Corners- Corner bars- Cross bars

Structure members range from 200mm up to 2400mm.

The structure is made from 2mm cold rolled electrogalvanised powder coated steel profiles with tapped holes at every 25mm forming a 25mm grid.

Untapped holes are located at every 12.5mm

The base profiles include pre-cut holes to facilitate lifting of the switchboard.

All structural members of the framework are screwed together with captive screws to ensurerigidity & earth continuity.

Modular indicators are provided at every 200mm for easy identification during assembly.

Internal Plates + Cladding



Internal separation up to Form 4b can be achieved using standard parts;

- Mounting plates- Separation plates- Standard compartments

Internal separation plates and mounting plates are modular, metallic and offer IP2X protection. A range of insulated separation plates are also available.

All internal parts are painted white.

FINISH:

Doors and covers are dished and made of 1.5mm mild steel with an epoxy polyester powder coated smooth finish.

2mm doors and covers are available onrequest.

Flat covers are available as an option.

The framework and cladding is stocked in Grey RAL 7032 & Orange RAL 2000.

Doors may be hinged left or right.

Gaskets are continuous and are formed from high grade polyurethane to ensure good sealing & a high degree of protection up to IP55.

SEPARATION & MOUNTING PLATES

COVERS

DOOR

Busbar System

The busbar system is designed around 10mm wide flat bars and has been tested extensively for ratings up to 7100A / 100kA.

Busbars can be mounted at the top or bottom & can be arranged for front or back access.

The busbar holders have a unique clamping method that negates the need for drilling holes.

The holders are modular in size to suit all tier widths.

The system includes a wide variety of busbar holders from 250A-7100A that offers flexibility to design various switchboard arrangements.



BUSBAR ARRANGEMENT WITH MAB& UBH SUPPORT

MAB SUPPORTS

UBH BUSBARSUPPORTS

BUSBAR SYSTEMWITH BH SUPPORTS

BUSBAR SYSTEMWITH UBH SUPPORTS

Busbar System Accessories

Connections from main horizontal to vertical busbars can be made using standard HTVC connectors or cylindrical copper spacers.

Connections to devices from dropper busbars are achieved using busbar tap-off sets. These connections may be of cable, flexible copper or solid copper bars.

A choice of fish plates allows busbars to be extended easily.

Insulated Flexibars with nominal ratings up to 400A allow for easy connections between dropper busbars and circuit breakers.



HORIZONTAL TOVERTICAL CONNECTOR

FISH PLATES

BUSBAR TAP-OFF SETS

FLEXIBAR

COPPER SPACERS

Fixed type compartments to Form 3a, 3b & 4a are available in modular sizes from 400w x 200h x 200d up to 600w x 600h x 400d.

FORM 4b can be achieved using cable boxes.Compartments are made up of 1.2mm mild steel, painted white and include mounting plates.

Larger size compartments are formed using separation plates.

Compartments come flat and are bent into shape using a simple bending tool.

Knock outs are included for incoming & outgoing connections along with a set of insulated + metal gland plates.

Compartments - Fixed Type



FIXED TYPE COMPARTMENTS

CABLE BOX

Compartments - Fully Withdrawable

Fully withdrawable compartments are available rated up to 630A.

Compartment sizes range from 200W x 200H x 400D up to 600W x 1000H x 400D mm.

Compartments provide 3 distinct positions - IN-SERTED, TEST/ISOLATED and FULLY WITHDRAWN with position indicators and padlocking features.

Earth contacts that make first and break last are provided as a safety feature. Main switch shaft interlocks and compartment interlocks are also provided for added safety.

Heavy duty stainless steel handles and mechanism offer years of reliable operation.

Internal segregation of up to Form 4b is maintained to ensure the highest level of material safety.

DEMOUNTABLE UNITS

Demountable cells are in all sizes from 400w x 200H up to 600w x 600h.

Earth contacts that make first and break last are provided.

Doors may be hinged to the structure or as an option, may be fixed to the demountable cell itself. The cell design suits outgoings to the left or right as needed.



6.2.4 FULLY WITHDRAWABLECOMPARTMENT

4.2.4 FULLY WITHDRAWABLECOMPARTMENT

DEMOUNTABLE UNITS

6.4.4 DEMOUNTABLE CELL

Compartments - Demountable

Power Cassette



The POWER CASSETTE is Elsteel’s latest innovation to provide a heavy duty & high tech solution for Removable/Demountable and Fully Withdrawable applications. This patented design allows for functional cells to be rated for power distribution up to 630A or for motor control up to 200kW.

The cassette offers fool proof mechanical and electrical interlocking systems. Defective units can be replaced in a few seconds when both incoming & outgoing power connections are of the plug-in type. The design provides three positions – Connected-Test/Disconnected Lockable/Removable. The units have been tested for internal arcing fault containment to ASS3439.1:2002 Annex ZD.

WITHDRAWABLEPOWER CASSETTE

DEMOUNTABLE POWERCASSETTE

Internal Arcing Fault Containment



TECHNO has been successfully tested for Internal Arcing Fault Containment to AS/NZS 3439.1:2002 Annex ZD. These tests have been carried out on Fixed, Demountable and Fully Withdrawable compartments using GE devices. Tests have been done at 415V and at 690V on circuit breakers, fuse switches and air circuit breakers with the highest rated device being an ACB rated 2000A. Tests have also been done within the busbar chamber in accordance with IEC1641.

All tests were carried out with stock standard components. The parts are designed in a way to release the overpressure within the compartments away from the front and to the top of the switchboard thus providing operator safety in the event of a fault.

Chimney

Switchboard Accessories

A wide variety of accessories are available for the TECHNO system. These include: - A choice of locks- Internal doors & plates- Tools- Equipment mounting accessories- Gland plates- Louvres- Cable supports- Seals



ESCUTCHEONDOORS

SUPER FLEXINSERTS

CABLE HOLDER RAILS(BENDING TOOL)

DOOR STAY

KNOB LOCK

PADLOCK COVER

TOOLS

Switchboard Accessories



BLANK FRONT PLATES

DOORINTERLOCK

LOUVRE COVERS

DOOR CABLEHOLDERS

COVER SEAL

MODULAR GLANDPLATE

Design & Estimation Software

The ELSTEEL PANEL DESIGNER is a revolutionary Windows based software program for designing switchboards of just about any size in only a matter of minutes.

This software is very user friendly and allows boards to be designed and laid out quickly.

Changes and modifications to designs are easily done.

The software provides switchboard layout draw-ings along with the TECHNO parts list. It can also provide a complete list of the electrical components selected for the switchboard.



ELCAD is an Auto Cad based software program used in the design + estimation of TECHNO switchboards. This software allows designers to generate isometric drawings along with parts lists.

Design & Estimation Software

The latest version of GE’s “Selection Plus” software, which was designed + produced in Australia now offers the engineering consultant, switchboard manufacturers or electrical contractors a set of design tools to optimize the performance of a lowvoltage installation using GE equipment.

The new software now features the ability to;

1. Draw a single line diagram of the installation.2. Select and print the selectivity curves including user defined values including voltage reflection for comparing GE HV fuses and GE LV protective devices.3. Temperature rise calculations for enclosures.



Features:Systems Design software for;- Fault level / Volt Drop / Circuit impedance / cableand switchgear selection / backup and discrimination selection.

GE PROCERA PLUS SOFTWARE GE SELECTION PLUS SOFTWARE

PROCERA PLUS SOFTWARE ENGINEERING, DESIGN AND ESTIMATION CAPABILITY

The CONSTRUCTORS MANUAL is a comprehensive guide in full colour that includes all TECHNO parts listed with part numbers, description, weights and pack quantities.

Constructors Manual



The ASSEMBLY INSTRUCTIONS MANUAL provides step-by-step instructions on the assembly of TECHNO switchboards.

The manual provides precise assembly methods along with clear pictures and is a useful tool for switchboard builders, mainly for new users.

ASSEMBLY INSTRUCTIONS MANUAL

The manual also includes assembly pictures, technical specifications, selection guides, inspections and check lists necessary for consultants, engineers and switchboard builders.

To ensure that TECHNO switchboards are built to standards and are in accordance with the type test requirements, IPD Industrial Products offers training and accreditation to switchboard builders. Refresher courses and updates are provided to ensure that Techno users are kept abreast of product developments and changes.

The training provides in-depth information on the various parts and accessories available within the Elsteel modular enclosure range, effective and practical design methods, exposure to the extensive type testing done on the TECHNO system and simplified estimating using EPD & ELCAD softwares.

IPD also offer technical and engineering support nationally to ensure that customers receive adequate assistance during design and assembly.

Accreditation / Training



References

TECHNO is used in over 30 countries around the world. Over the last few years, TECHNO has built up several impressive references. In Australia and New Zealand, hundreds of TECHNO ModularSwitchboards have been supplied for every possible application.

AUSTRALIA & NEW ZEALAND

- Stadium Australia, Sydney

- M5 East Tunnel, NSW

- Emirates Wolgan Valley Resort, NSW

- Parramata Rail Link, NSW

- Lane Cove tunnel, NSW

- Westmead Hospital, NSW

- Tamworth Hospital, NSW

- Citipower, VIC

- Eastlink Freeway, VIC

- Melbourne Water, VIC

- BAE Systems, VIC

- Perth Metro Rail, WA

- BHP Billiton Yandi III Ore Handling Facility, WA

- Playford Power Station, SA

- Western Mining Company, SA

- Brisbane Harbour Cruise Ship Terminal, QLD

- Queensland Emergency Operations Centre, QLD

- Australian Super Hornets Base Amberley

(RAAF), QLD

- Merimac Waste Water, QLD

- Townsville Waster Water Treatment Plant, QLD

- HMAS Waterhen, ADI

- Comalco, TAS

- Newmont Granite Gold Mine, NT

- Dreamworld Water Park, Gold Coast

- Telstra

- Woolworths

- Bluescope Steel

- Onesteel



References

OVERSEAS

- Telecom, NZ

- Clandeboye Milk Dryer Facility, NZ

- Vodafone, NZ

- Superyachts, NZ

- Huntley Power Station, NZ

- Te Roha Waste Water Treatment Plant, NZ

- Norfolk Southern Cross Hospital, NZ

- Westlands Dairy, NZ

- New Zealand Post

- Watercare Services Ltd, NZ

- EDS, NZ

- Mighty River Power, NZ

- Hamilton City Council, NZ

- London Underground

- Heathrow Airport

- Hongkong Airport

- Singapore Motor Train Lines

- New Delhi Metro, India

- Northern Telephones, China

- Norway Seafoods

- Cyprus International Airport

- Crowne Plaza Lebanon

- Siemens Germany





TEST PERFORMED TESTING AUTHORITY CERTIFICATE REF. 1. Full type test on 1600A IPH – Berlin ASTA Certificate No. TECHNO MODULE SYSTEM Landsberger Allee 376 16149 with GE Circuit Breaker 12681 Berlin, Germany 2. Type Test on 1600A ASTA ELSTEEL TECHNO MODULE Power Testing & Technology ASTA Certificate No. Institute 17011 Korea 3. Type Test on 2000A IPH – Berlin ASTA Certificate No. ELSTEEL TECHNO MODULE Landsberger Allee 378 A 16783 12681 Berlin, Germany 4. Full type test on 2500A IPH – Berlin ASTA Certificate No. TECHNO MODULE SYSTEM Landsberger Allee 376 16150 with GE Circuit Breakers 12681 Berlin, Germany 5. Full Type Test on 2500A IPH – Berlin 513.228.6.384 TECHNO MODULE SYSTEM Landsberger Allee 376 12681 Berlin, Germany 6. Type Test Report on 2500A IPH – Berlin 170.265.2.230 TECHNO MODULE SYSTEM Landsberger Allee 376 12681 Berlin, Germany 7. Type Test Report on 3200A ASTA Certification Service ASTA Certificate No. TECHNO MODULE SYSTEM ASTA House 12798 Chestnut Field, Rugby CV21 2TL England 8. Type Test Report on 4000A Verification of 1819.1206.5.668 TECHNO MODULE SYSTEM IPH – Berlin Landsberger Allee 378 12681 Berlin, Germany 9. Type Test Report on 5000A ASTA Certification Service ASTA Certificate No. TECHNO MODULE SYSTEM ASTA House 12890 Chestnut Field, Rugby CV21 2TL England 10. Full Type Test on 5000A IPH – Berlin 1513.832.0.468 TECHNO MODULE SYSTEM Landsberger Allee 376 12681 Berlin, Germany 11. Full type test on 7100A IPH – Berlin 1819.1061.3.434 TECHNO MODULE SYSTEM Landsberger Allee 376 12681 Berlin, Germany

Schedule of Tests



TEST PERFORMED TESTING AUTHORITY CERTIFICATE REF. 12. Short Circuit Strength Tests in a TECHNO MODULE SYSTEM Testing & Certification Australia 101740-1 - Conditional Short Circuit Strength Tests on outgoing units 18 Mars Road o GE MCCB Units – 63kA rms Lane Cove NSW 2066 o GE Motor Starter Unit – 50kA rms Australia - Conditional Short Circuit Strength Tests on o 2x10x30 & 2x10x40 – 50kA 1s / UBH & BH Bus Holders o 2x10x40 & 1x80x6.3 – 63kA 1s / BH & Kentan Bus Holders 13. Short Circuit Strength Tests in a TECHNO CHASSIS SYSTEM Testing & Certification Australia 102014 - Conditional Short Circuit Strength Tests on outgoing units 18 Mars Road o GE MCCB Units – 50kA rms Lane Cove NSW 2066 - Prospective Short Circuit Strength Tests on phase busbars Australia o 2x10x60 – 50kA 1s / BH Bus Holders o 2x10x40 & 2x10x30 – 63kA 1s / BH Bus holders 14. Standard Internal Arcing Fault test on ELSTEEL TECHNO Testing & Certification Australia 102378 - Fixed Compartments 18 Mars Road - Demountable Compartments Lane Cove NSW 2066 - Fully withdrawable compartments. Australia 63kA rms at 415V tested in accordance with AS/NZS 3439.1: 2002 Annex ZD. Apparatus – outgoing units of a 415V/690V (Ue/Ui) three phase switchgear assembly.

15. Internal Arcing Fault Test in the busbar compartment of a TECHNO Testing & Certification Australia 102380 Module Switchboard System at a prospective fault level of 63kA for 110ms 18 Mars Road in accordance with IEC61641:1996 Lane Cove NSW 2066 Australia 16. Standard Internal Arcing Fault test on ELSTEEL TECHNO Testing & Certification Australia 102601 - Fixed Compartments with MCCB’s, Fuse Switches & ACB 18 Mars Road 50kA rms at 690V tested in accordance with AS/NZS 3439.1: 2002 Lane Cove NSW 2066 Annex ZD. Australia Apparatus – outgoing units of a 690V three phase switchgear assembly. 17. Standard Internal Arcing Fault test on ELSTEEL TECHNO Testing & Certification Australia 102601 - Removable & Withdrawable Power Cassette Compartments with MCCB’s 18 Mars Road 50kA rms at 415V tested in accordance with AS/NZS 3439.1: 2002 Lane Cove NSW 2066 Annex ZD. Australia Apparatus – outgoing units of a 415V three phase switchgear assembly.

18. Degree of Protection test (IP test) and Internal Separation Test TESTSAFE Australia 29540 The Techno System complied with the requirements of AS 60529-2004 for 919 Londonderry Road “Degree of Protection” IP55 Category 2 and with the requirements of Londonderry NSW 2753 AS/NZS 3439.1:2002 Form 4b for internal separation. Australia

19. Vibration testing of an ELSTEEL TECHNO MODULE SYSTEM VIPAC Engineers & Scientists Ltd. Report No. 302649-01 Australia 20. Seismic Vibration testing of an ELSTEEL TECHNO MODULE SYSTEM VIPAC engineers & Scientists Ltd. Report No. 302649-02 Australia

21. Lloyd’s Register of Shipping of all Elsteel parts The test was carried Lloyd’s Register of Shipping 02/70003 out according to LR1 to 10, 14, 15 for TM, 19” MBOX, MTNB, Strandgrade 4C SSBOX (AISI 304/316), STNB (AISI 304/316). The requirements for DK–1401 Copenhagen K RL1 to 10, 14, 15 were fulfilled. Denmark

22. Verification test in accordance with IEC61439-1 IPH - Berlin 17541 on switchboards rated 800A, 1600A, 2500A, 4000A & 6300A. Lands Berger Alle E-376 17542 12681, Berlin 17543 Germany 17544 17545

Schedule of Tests



Technical Data

Base Frame 2mm mild steel powder coated in black (RAL 9005)

Corners Aluminium die cast powder coated in grey (RAL 7032) or Orange (RAL2000)

Corner Bar / Cross Bar Electro galvanised 2mm powder coated in grey (RAL 7032) or Orange (RAL2000)

Doors / Covers Mild steel 1.5mm powder coated in grey (RAL 7032) or Orange (RAL2000). 2mm available as an option.

Door Stabiliser Mild steel 20 x 20 x 1.5 square pipe powder coated in grey (RAL 7032) or Orange (RAL2000)

Mounting Plate Mild steel 2mm powder coated in white (RAL 9010)

Separation Plate Mild steel (2 x 2, 2 x 4, 2 x 6, 4 x 4, 4 x 6) 1mm. All other sizes 1.2mm. Painted white RAL 9010

Flat Cover Mild steel 1.5mm painted in grey (RAL 7032) or Orange (RAL2000)

Panel Assembly Kit Mild steel 3mm zinc plated

Cable Holder Mild steel 1.5mm to 2mm painted white (RAL 9010)

Lifting Eyes Mild steel 3mm powder coated in black (RAL 9005)

Wall Mounting Brackets Mild steel 3mm powder coated

Busbar Holder Self-extinguishing fibre material / reinforced PC

Fish Plate Copper 10mm

H to V Connectors Copper 10mm

Busbar Tap-Off - 21000 Dia 10mm zinc plated

- 21010 Copper 5mm

- 21020 Copper 5mm

- 21030 M.S. 3mm zinc plated

Bracket for Earth Conductor Mild steel 3mm zinc plated

Copper Spacers Copper, 30mm diameter, 5 to 50mm in width

MATERIAL SPECIFICATION

TECHNICAL DATA OF TECHNO MODULE SYSTEM GENERAL DATA Applications Low voltage power distribution, motor control centres, PLC & DCS panel boards Installation Indoor Mounting possibilities Floor standing / Wall mounting Panelling standard colour RAL7032/2000 (inquire for non-standard colours) Coating Epoxy/polyester powder, thickness >50μm

MECHANICAL DATA Field/Tier Arrangement Front connected / back to back Cable Entry Top / Centre / Bottom Access Front/Rear IP Rating IP41, IP42, IP54, IP55 Form of Segregation 1, 2a, 2b, 3a, 3b, 4a, 4b / Form 4 Type 1-7 Max. dimensions of a transport section (basic module 200 x 200 x 200) Width - 2200 Height - 2400 (can be extended) Depth - 2200

ELECTRICAL DATA Rated operations voltage (Ue) 415 / 690 / 1000V Rated insulation voltage (Ui) 690V / 1000V Rated frequency (f) 50Hz Rated impulse voltage (Uimp) 6-8kV Rated current (In) for TM panels Up to 7100A (see pg. 9.05 for more info.) Rated short time current (Icw) Up to 100ka / 1s & 50kA / 3s Pollution degree 3 Earthing systems TN-C, TN-S, TN-C-S, TT, IT

TEST / APPROVALS Type test Fully type tested according to IEC/EN 60439-1 Internal Arcing Fault test According to IEC61641 & AS/NZS 3439.1:2002 Vibration test According to IEC68-2-6 & IEC68-2-36 Seismic test According to IEC68-3-3 EMC verified According to IEC60439-1 clause 8.2.8 Lloyd’s Registered Certificate No. 02/70003



Applications

HOSPITALS & SCHOOLS STADIUMS & COMMERCIAL INSTALLATIONS

ROADS & TUNNELS MINING & METALS

POWER STATIONS OIL & GAS PLANTS

ADF INSTALLATIONS SEAPORTS, AIRPORTS & RAILWAY

BRISBANE

NEWCASTLE

SYDNEY

HOBART

ADELAIDE

MELBOURNE

PERTH

AUCKLAND

WOLLONGONG

National Customer Support CentreTel: 1300 556 601 Fax: 1300 550 187 www.ipdgroup.com.au

TECHNO system

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