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The UKs leading provider o switchgear,
power distribution and monitoring systems.
LV switchgearIndustry leading technology rom Mardix
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At Mardix we take ongoing product
development very seriously. We have
committed to extensive research and
development and ASTA Type Testing
programmes as part o our business
investment. The results o this approach are
demonstrated in the nished product; ully
installed and tested LV switchboards with
built-in benets (Fig.01).
We pride ourselves on assisting end users,
consultants, and contractors through every
step o the design, manuacturing, and
installation processes, and are delighted
to work with consultants rom a projects
inception. In the earliest design stages our
input guarantees that any designs issued or
tender are t or purpose, commercially viable,and are o the required specication.
We understand the need or specication
compliant bids and requirements or value
engineering during the tender process and
have built excellent relationships with electrical
contractors on this basis, oering a sae path
rather than a badly engineered alternative.
We stand by the principle that a cost eective
Mardix quotation should be about more than
just our bottom line price, it should be about
added value or the client.
Ongoing collaboration with all parties and
valuable eedback rom end users keeps
us at the ore o switchgear technology.
Our ability to convert client eedback into
technological advances has been central to
many new initiatives and products, not least
our intelligent switchboards (iBoards) and
intelligent Power Distribution Units (iPDUs)
which have set the industry standard.
Similarly, our Mardix LV switchboard design is
100% Mardix owned and has been developed
in 3 key stages over many years. Our latest
oering is the most technically advanced
and eature rich oering to date and is
only possible due to our in-house 3D solid
modeling capability, which has introduced
innovations not previously possible with 2D
sotware. We spend a signicant amount o
time during the design process perecting
the top level assembly which is automaticallychecked or accuracy, clearance and zero
clashing parts.
The same attention to detail is witnessed inour manuacturing approach. All switchboards
and PDUs are o ully welded construction
or maximum rigidity and high tolerance not
achievable with bolted fat pack assembly.Door seals remain fush tting and Ingress
Protection (IP) ratings are not compromised.
An earthing arrangement running the ull
length o the switchboard and vertically intoeach cubicle section orms a high integrity
earth bond against the welded enclosure.
Whilst a welded, integral, high strength plinth
completes the cubicle structure, which is thensuitable or slab mounting or on a separate
raised plinth assembly. An exacting cubicle
abrication process and a resilient powdercoating in any RAL or BS4800 colour ensures
the nal product looks just as we intended.
Key benefts
ASTA certicates o Type Testing up to
6300A (100kA or 1sec) with unique
ventilations systems designed, tested,and incorporated into higher power Mardix
switchgear
Thermal imaging capability as standard,with strategically positioned pre-punched
grids or ease o access and enhancedsurveying accuracy
Forms o Separation up to Form 4 Type 7
with ront and rear access designs
Fully welded high strength Mardix cubicle
system with high integrity earth bond, which
is suitable or slab mounting or bolting ontounderfoor plinthwork
Standard Ingress Protection to IP31. Higher
IP ratings are available, and all Mardixswitchboards are suitable or mounting within
GRP enclosures
High and low level cable spreader boxes toacilitate glanding and termination o large
cables
All outer doors and busbar chambers
are hinged or ease o access. Screw x
covers are not an acceptable alternativeand will not be used
Bespoke arrangements to meet specic
width and height constraintsPowder coated to any RAL or BS4800
colour. Our standard colour is BS4800 10
A03 (light grey) with a semi-gloss smoothnish
As the UKs leader in high power switchboardsolutions, Mardix has more than 40 years o
cross sector experience. From hospitals to
shopping centres, oce developments to data
centres, our knowledge and expertise is builtinto every product.
Whether you require a 1250A modularswitchboard or a 6300A ASTA certied
L shaped bespoke switchboard, Mardix
has a solution to meet your needs. Our
uncompromising commitment to highbuild quality combines with our in-house
philosophy, which ensures that everyswitchboard is designed and manuactured
to exacting specications and is delivered on
time, every time.
Introduction
LV switchboards: detailed technology rom Mardix
A collaborative approach
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Fully welded construction
Constructed rom individually olded panels, whichare tted and welded together to orm the superior
Mardix cubicle system with maximum rigidity.
Hinged doors and chambers
Doors, busbar and cable chambers are allhinged or added saety. We do not use screw
x covers.
Ventilation
ASTA Type Tested natural and orced air-coolingassemblies are used on higher current rated
switchboards
Switchboard earthing
Copper earth bars run along the
entire length o the cubicles anddrop vertically into the unctional
units, busbars and chambers.
Cable spreader and
transition boxes
Higher current rating
switchboards are tted with
boxes to acilitate glanding andtermination o large cables.
Transition boxes can be usedwhere cables run perpendicular
to the vertical plane o the
switchboards.
Thermal imaging portsDesigned by Mardix and tted to all MCCB anduse switch outer doors, our thermal imaging
ports are CNC cluster punched directly into
the steel. A tamper proo retained astenermechanism allows the port to be opened to allow
ecient and non-invasive thermal imaging.
Fig.01. A top level 3D solid model switchboard assembly.
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Key benefts
All unctional units are protected against
inadvertent contact with live parts. Custommade shrouds with laser proled thermal
imaging grids allow ecient thermal
imaging o circuit breaker connections
All connection points can be thermalimaged including busbar chambers and
incoming/outgoing cable boxes
All major brands o ACBs, MCCBs and use
switches can be incorporated, including
Schneider, Terasaki, ABB and Socomec
Sealed CT chambers with connection links,
insulation barriers and shorting links, builtto the specication o all Regional Electricity
Companies (REC)
Integration o tuned and detuned Power
Factor Correction (PFC) and Active Harmonic
Filters (AHF)
Type Tested arrangements or stacked ACBs,
and high density stacking o MCCBs
Separate compartments with ully labelledcomponents and terminals or metering,
control, and prewired BMS contacts
Incorporation o protection relays, G59
protection, battery intertripping units,Electronic Surge Protectors (ESP), Castell
interlocking arrangements including solenoids
and exchange boxes, temperature monitoring
and large mimic panels
Incorporation o HMI control panels, dual
redundant PLC control philosophies,
standard PLC control, auto-changeoversystems and load shedding
Incorporation o high end metering systems
with waveorm capture acility such asSchneider ION 7650 and ION 7550. Multi-
unction metering brands include Socomec,
Autometers, Schneider. Energy metering to
building regulations Part L2. See also theiBoard and iPDU or our intelligent range
o switchgear and PDUs
Saety is an absolute priority and inside
the unctional unit compartment it is clearly
demonstrated in the mounting o the circuit
breakers. Both the live and load sides o the
switch are completely shrouded to prevent
inadvertent contact with live parts, and copper
connections to busbars are insulated and
shrouded or added saety.
In terms o separation, metallic barriers
are used between each unctional unit and
also between unctional units and busbar
chambers. This degree o separation
provides urther saety rom live parts, and
protects against a ault in one compartmentpropagating to an adjacent compartment.
Horizontal and vertical busbar chambers are
positioned and sized to ensure the busbars
and connections can be accessed at any
time during the lie cycle o the switchboard.
Each busbar compartment is provided with
an outer door and a secondary captive
thermal imaging screen. This method allows
ecient and sae monitoring o busbars and
connections with our inrared thermal imaging
cameras.
Mardix LV switchboards incorporate Air
Circuit Breakers (ACBs), Moulded Case
Circuit Breakers (MCCBs) and use switches.
Typical brands used or these purposes are
Schneider, Terasaki, ABB and Socomec, which
are recognised as high integrity components.
I you have width and height constraints inyour plant room you may require double
stacking o ACBs and high density stacking
o MCCBs. Mardix have Type Tested these
arrangements to ensure they perorm under
temperature rise.
Forms o Separation or our LV switchboardsare typically Form 4 Type 2, Form 4 Type 5,
Form 4 Type 6 and Form 4 Type 7 (please
reer to Forms o Separation section). We
can accommodate all orms in ront and rearaccess congurations and we always ensure
glanding plates and cableways are the correct
size and cable boxes can accept the specied
cable sizes.
Separate compartments are designated
or metering, control and BMS terminals.
Contacts or BMS are internally wired andtaken to a BMS terminal rail with dedicated
routes or the external cables. Protection usesand control components are clearly labelled
and cross reerenced to our schematicdrawings.
LV switchboards rom Mardix have many unique internal eatures or
improved resilience and perormance (Fig.02).
LV switchboards: its whats inside that really counts
Double marking system or all power connections
For nearly a decade Mardix has implemented
quality procedures to achieve zero tolerance
o errors during busbar installation, and we
always invest time in making sure we adhereto those quality procedures. Every connection
is tightened with a torque wrench and then
marked, initialled, dated, and signed with
a coloured pen. A second, independentoperative then subjects the same connection
to the same procedure.
Our Production Manager, Simon Hamer,
comments, This system has moved us
ever closer to our original objective o zero
errors and every member o our site teamsunderstands what a signicant dierence it
has made to our business, and to levels o
client satisaction. Its an apparently simple
process that oers reassurance whilstimproving the end product.
Example o double marking procedure.
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Fully shrouded unctional unitsCareul attention to detail and custom madeshrouds with laser proled thermal imaging
slots provide protection against inadvertent
contact with live parts, and allow or ecientthermal imaging o the circuit breaker.
Cable management systems
Attention to detail doesnt stop at our outgoing
connection boxes, cable ways are constructedto ensure cabling can be organised and
strapped securely in place.
Incoming connections ar largeand multiple cables
High strength busbar support assemblies are
used to gland and terminate very large cables
such as 500 mm2 single core cables or multipleSteel Wired Amoured (SWA) cables per phase.
Sealed REC CT chambers
Mardix build CT chambers to all Regional
Electricity Company specications, ensuringour clients dont have any issue when the REC
comes to terminate the incoming supplies.
Saety - insulated exible busbarsAs standard, we only use insulated fexible
connections on circuit breakers up to 630A. ThisType Tested arrangement virtually eliminates the
possibility o oreign objects settling between live
conductors in the most inherently susceptiblepart o a switchboard.
Fig.02. An intermediate 3D solid model switchboard assembly.
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Key benefts
All new 100% Mardix owned, ASTA Type Tested
busbar system. Developed in-house since2006, we have introduced new innovative
eatures that benet our clients through cost
and space savings, and that speed up our LV
switchboard assembly process
ASTA tested up to 6300A (100kA or 1 sec).
Our range o Type Test certicates allows a
more fexible approach to busbar sizing, andassociated cost savings can be passed onto
our clients
We have achieved cost savings through the
ull range o busbar assembly ratings. Thisensures we remain competitive whilst still
delivering the highest quality LV switchboards
Innovative busbar connecting systems, easier
access to the individual busbar supports, andmuch improved 3D assembly drawings have
reduced tting times by up to 30%
200% busbar requirements can beaccommodated. (contact us or urther
details)
Free issue busbar fanges, which can
be problematic at the nal stages oinstallation, are incorporated with ease
using our 3D sotware. We can t and test
nal connections as part o LV switchboard
installation. Using our 3D views o complex
busbar assemblies, including multiplecorner sections and overhead busbar links,
our customers benet rom enhanced
visualisation, which also simplies thedesign process
Strip away all the other elements o the
switchboard (see Fig.03) and we can see
perhaps the most important element o a
Mardix LV switchboard; our all new, Mardix
owned, ASTA Type Tested busbar system,
which is rated up to 6300A (100kA or 1 sec).
Like many switchgear companies we used a
proprietary busbar system, however, in 2006
we began to develop our new system, which
we elt was required to enhance the Mardix
cubicle system. During development we
outlined various criteria that had to be met:
Improvedperformancewiththesamecross sectional area o High Density, High
Conductivity (HDHC) copper.
Strongerbusbarsupportsallowinghigher
ault ratings than previous possible.
Increasedcoolingaroundhorizontaland
vertical busbar assemblies or both air
natural and orced air cooling opt ions.
Vastlyquickerassemblyprocesswithin
the tight spatial constraints o busbar
chambers, which would ultimately slash
time required onsite connecting LV
switchboards.
In 2008 we passed our rst major test with
the new Mardix system, which included a
4000A, 4 pole ACB, a 4000A 4 pole busbar
and various outgoing circuit breakers. The
switchboard perormance exceeded ourexpectations and during temperature rise
passed in an air natural conguration. This
was due, in no small part, to the use o our
all-new ventilation duct system.
Following this early success we went on to
achieve the holy grail o type testing at IPH in
Berlin, including a heat rise test at 6300A in
an air natural conguration. This achievement
is believed to be a rst on a global scale, and
is testament to our ongoing commitment to
improved switchgear perormance.
Commenting on the breakthrough, MardixDirector, Wayne Lewis said: This achievement
is a very positive step orward or Mardix, and
refects the continued success o our ASTA
Type Testing programme. We look orward to
passing the benets o this achievement on
to our client base, including eciencies in theswitchboard assembly process.
Mardix have invested 250K in the current
ASTA Type Testing programme and will
continue testing late into 2009.
The new advanced Mardix busbar system oers space and cost
savings and is rated up to 6300A (100kA or 1sec).
Mardix busbar systems
3D solid modelling
Every switchboard Mardix produces isdesigned in-house using 3D design expertise.
Once the overall assembly design is complete,
it is transerred to the Computer Aided Design/
Computer Aided Manuacture (CADCAM)
area where the assembly is analysed and
separated into - subassemblies - and parts
o varying materials including steel, copper,
aluminium, polycarbonates and plastics.
All 3D parts are automatically developed into2D fat parts and then converted into machine
code. This code is then sent to the job libraries
o the required machine whether that is a laser
cutter, a CNC punch, or a press brake.
This level o technology and automation
means Mardix now consistently produces
cost eective and ecient switchgear.
Production Director Wayne Lewis explainsthe benets o 3D modelling: Our assemblytimes have reduced dramatically which saves
costs or the client, and the potential to have
zero design errors has virtually eliminated
incorrectly machined parts, mistakes, andrework which saves time and enables us to
keep projects right on schedule.
Mardix can oer cost eective modular LV switchboard solutions
to ft your budget, with lead times rom only 710 days dependingon confguration.
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3D Solid model demonstrating all Forms o Separation. See next page or detailed inormation on each Form o Separation.
Forms o Separation
In order to protect against contact with live
parts belonging to adjacent unctional units,
and against the passage o solid oreign
bodies rom one unit within an assembly to an
adjacent unit, we take great care to apply the
most appropriate Forms o Separation to each
solution we manuacture.
Ranging rom Form 2 Type 2 through to
Form 4 Type 7 our Forms o Separation
incorporate industry standard methods such
as: non-metallic and metallic rigid barriers and
partitions; glanding and termination chambers
or cables; busbar separation; insulated
coverings and shrouding; and external
terminals.
Each option is careully considered and
balanced to t requirements and budgets,
so you always know your equipment is
well protected and cost eective. And, the
probability o initiating arc aults is properly
limited when you work with Mardix.
Weve included the ollowing pages as a quick
and easy guide to the Forms o Separation
oered on Mardix assemblies, and weveincluded an area oering clarity on Ingress
Protection (IP) ratings.
All o our Forms o Separation are agreed between users and
ourselves during specifcation.
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Incomingunits
Incomingcable Outgoing cables
Outgoingunits
Outgoingunits
Incomingunits
Incomingcable Outgoing cables
Outgoingunits
Outgoingunits
Incomingunits
Incomingcable Outgoing cables
Outgoingunits
Outgoingunits
Incomingunits
Incomingcable Outgoing cables
Outgoingunits
Outgoingunits
Form 4 Type 5
Metallic and non-metallic rigid barriersor partitions are used to achieve busbar
separation. Terminals are external
rom the unctional unit and insulatedcoverings such as PVC boots are used.
Cables are glanded elsewhere e.g. in a
common cabling chamber.
Incomingunits
Outgoingunits
Outgoingunits
Form 2 Type 2
Metallic and non-metallic rigid barriersor partitions are used to achieve
busbar separation, whilst terminals are
separated rom the busbars, but not romeach other or unctional units.
Form 4 Type 2
Metallic and non-metallic rigid barriersor partitions are used to achieve busbar
separation. Cables are terminated in the
same compartment as the unctionalunit, but are glanded elsewhere e.g. in a
common cabling chamber.
Form 4 Type 6
All separation is achieved by metallic ornon-metallic rigid barriers or partitions.
Terminals are external rom the unctionalunit compartment and rigid barriers
or partitions are used to enclose them
in their own compartment. Cables areglanded elsewhere e.g. in a common
cabling chamber.
Form 4 Type 7
All separation is achieved by metallic or
non-metallic rigid barriers or partitions.
Terminals are external rom the unctionalunit compartment and rigid barriers or
partitions are used to enclose them in
their own compartment which eaturesintegral glanding acility.
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Technical specifcations
Enclosure Busbars and connections
Edge clamping o busbars i.e. a no holed
system is not used or Mardix switchboards.
Tap-o connections rom the main busbarsto individual circuit breakers (up to 630A
rating) are manuactured using insulated
fexible copper links. This reduces the risk o
short circuit at points on the busbar systemthat may be prone to high short circuit
currents.
All power connection points, includingbusbar joints are tightened to the correcttorque in accordance with Mardix double
marking standards.
Mardix LV switchboards usually
comprise one or more vertically mountedsections. The sections are generally slab
mounted, however, options or mounting
on underfoor/raised plinths can be
accommodated.
Our enclosures are ormed romindividually olded panels o Zintec sheet
steel, which are ully welded and ground to
provide clean lines and maximum rigidity.The Mardix high integrity earth bond is
standard.
An integral 150 mm plinth is then welded
to the base o the cubicle to provide a
solid support channel which enables theswitchboard to be mounted on a separate
underfoor plinth.
Enclosure nish: Cabinets and doors
are powder coated with RAL colours or
BS4800 colours with a smooth nish whilstinternal compartments eature RAL 9003
(white) with a ripple nish.
Functional units and internal separation
Each unctional unit is, in general,
separated rom each other. By opening the
door o the respective unctional unit e.g.an Air Circuit Breaker compartment, it isnt
possible to inadvertently touch live parts.
All exposed live parts are shrouded using
proprietary or custom-made shrouds.
In addition:Separation will be achieved in accordance
with BSEN 60439-1:1999. The exact Formo Separation e.g. Form 4 (6) will be as
specied.
Separation will generally meet the ollowing
conditions:
Protectionagainstcontactwithlivepartsbelonging to adjacent unctional units
Limitationoftheprobabilityofinitiating
arc aults
Mardix busbar assemblies are ASTA certied
up to 6300 Amperes (100kA or 1 sec).
Busbars are air insulated. The neutral busbarshave the same rating and cross sectional area
as respective phase busbars.
Individual riser busbars are suitably sized or
the devices they serve, but are not necessary
o the same rating as the main busbars.
I required, busbars can be extendable at theends o the switchboard in order to acilitate
easy installation o uture cubicle extension
sections.
Busbars are clad along their entire length. It isnot be possible to come into contact with the
busbars by opening any compartment doors,
including busbar sections.
At connection points, the busbars are
punched with holes in each adjacent piece,which will then be connected together using
shplates, and suitably sized nuts, bolts,
and washers.
Control and BMS section
This section houses the control, indication
and protection components, including:
Multi-functionmetering
SpecialistProtectionRelayse.g.
Restricted Earth Fault Relay
LEDindicators
PushbuttonsandKeyswitches
TransformerTemperatureRelays
ElectronicSurgeProtection
RelaysandProtectionFusesas
applicable
BMSandControlTerminals
Protectionagainstthepassingofsolid
oreign objects rom one unction unit to
another
Mardixinternalseparationwillgenerallybe achieved using rigid metallic barriers.
Unless otherwise specied, busbars will
be separated rom unctional units
A guide to the technical eatures behind Mardix LV switchgear.
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LV switchboards are designed andmanuactured in-line with thermal imagingrequirements.
Thermal imaging ports are punched
directly into the steel doors using CNC
cluster punching. The ports are tted with
sliding captive covers, xed and sealed tothe door by security screws. A special tool
is required to open the port.
Polycarbonate custom-made shrouds are
tted over all connection points to preventinadvertent touching o any live parts and
to acilitate sae thermal imaging.
The custom-made shrouds are
manuactured rom polycarbonate sheet,which is olded and tied to orm a rigidbarrier. Each barrier will be laser proled
with slots positioned in such a way to
acilitate ecient thermal imaging o the
connection point.
Thermal imaging Doors and covers
Technical specifcations
Labelling
Switchboard enclosures are IP31 unlessotherwise specied.
The switchboard has hinged doors, whichcover the individual compartments and
terminal chambers. 90-degree turn latches
are used to lock each compartment and
a special tool is required to open thedoors. Mardix do not use screw x external
covers.
All door hinges are high quality and o
sucient strength that doors stay alignedand square.
Where applicable, doors are completed
with polycarbonate viewing windows,
sealed with rubber proling strip.
Engraved traolite labels will be tted torelevant doors and chambers.
Generallabelsblacklettersonwhitebackground
Voltagewarninglabelsblackletterson
yellow background
Generalwarninglabelsredlettersona
white background
All uses and control components and
associated connection terminals will belabelled using adhesive strip labelling.
IP Codes classiy the degrees o protection provided against intrusion o solid objects in electrical enclosures. This protection includes body partssuch as hands and ngers, dust, accidental contact, and water. The standard aims to provide users with more detailed inormation than terms such
as waterproo would. Digits are used to express conormity. As an example an ingress protection rating could be stated as IP31. Thereore the
switchboard would be protected against solid objects larger than 2.5 mm and vertically alling water droplets.
Ingress Protection ratings
First characteristic numeral protected against solid bodies
0
1
2
3
4
5
6
No protection against contact and ingress o objects
Protected against solid bodies larger than 50 mm (eg. accidental contact with hand)
Protected against solid bodies larger than 12 mm (eg. nger contact)
Protected against solid bodies larger than 2.5 mm (eg. tools and wires)
Protected against solid bodies larger then 1 mm (eg. ne tools, small wires)
Protected against dust (no harmul deposits)
Totally dust tight
Second characteristic numeral protected against liquids
0
1
2
34
5
6
7
8
No protection
Protected against vertically alling water droplets (condensation)
Protected against water droplets defected at up to 15 rom the vertical
Protected against water spray at up to 60 rom the verticalProtected against water spray rom all directions
Protected against low pressure water jets rom all directions
Protected against strong water jets and waves
Protected against eects o temporary immersion
Protected against eects o prolonged immersion under pressure
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t. 01539 720161 www.mardix.co.uk
Mardix, Service Division, Westmorland Business Park, Kendal, Cumbria, LA9 6NS
Get in touch now
Call now on: 01539 720161 to talk to us about how you can benet rom custom
engineered switchgear at Mardix, or email: [email protected]
Deliveringpeace o mind!
Call our Service Division now on 01539 720161
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