Prisma Plus the tested switchboard, complying with standard IEC 60 439-1

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Prisma Plus the tested switchboard,complyin
g with standard IEC 60 439-1
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Contents

• The low voltage electrical switchboard

• The functions of an electrical switchboard

• The IEC 60439-1standard

• Prisma Plus a structured switchboard based on
  functional units

• Forms partitioning
• Forms separations within an assembly

• The minimum requirements to guarantee the safety
  of a LV switchboard

• The tests of standard IEC 60439-1

• 7 type tests performed by the manufacturer

• 3 routine tests performed by the panelbuilder

• Switchboard builders and manufacturer, together
  for the safety challenge IEC 60439-1

• Prisma Plus and the IEC 60439-1 standard an
  international influence

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The low voltage switchboard

• A vital link for electrical distribution

• To satisfy the increasing needs of safety of
  people and equipment and availability of
  electrical power its realization is not
  improvised

Safety
Reliability
Availability
Maintenability

• and to provide a continual balance between
• the needs of safety and availability
• and the constraints of reliability and
  maintenability of the installation.

Contents
Definitions
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The low voltage electrical switchboard

• Definitions

• The safety is the aptitude of a system not to put
  the people in danger .

• Availibilty is the percentage of time during
  which the system functions correctly. MTBF (Mean
  Time Between Failure) average time between two
  failures of a reparable system is a means of
  characterizing the availibility.

• Reliability is the aptitude of a system to
  function correctly as long as possible. MTTF
  (Mean Time To Failure) average time of good
  working before the first failure is a means of
  characterizing the reliability.

• Maintainability is the aptitude of a system for
  being repaired quickly.La maintenabilité est
  l'aptitude d'un système à être réparé rapidement.
  MTTR (Mean Time To Repair) the average duration
  of repair is a means of characterizing
  maintainability.

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The functions of an electrical switchboard

• To group and protect against external influences
  the protection and control devices and all their
  electrical and mechanical connections.

• To inform the end-user on the state of his
  installation

• To protect the switchboard user against the risk
  of accidents (direct and indirect contact).

• To evolve with the activity.

Contents
Definitions
Cubicles up to 3200 A
Wall-mount and floor standing enclosures up to
630 A
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The functions of an electrical switchboard

• Definitions
• Some of the components or specificities of the
  switchboard realize and/or guarantee its
  finalities,
• in functional term

• The architecture of LV network in centralized
  distribution
• It results in a cutting into various switchboard,
  wall-mount enclosures... Distributed
  geographically, which
• carry out the installation drawing.
• Then various areas are defined within the
  switchboard
• equipment
• busbar
• connection
• auxiliary
• The distances from minimal insulation and safety
  must already be respected.

• The functional units
• allow to realize the electrical functions
  correspondint to the user s
• each unit is intended to cover a function, for
  example
• - the incoming of current in the switchboard
• - the protection of a feeder or a feeders
  whole- the motor control...

• The enclosure
• It materializes electric volume and ensures
  simultaneously
• the protection of electrical materials which it
  contains against the external influences
• the protection of people against electrical
  shocks (direct and indirect contacts).

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The IEC 60439-1 standard

• The IEC 60439-1 standard gives general rules for
  switchboards construction to meet with safety
  and availability needs required by the
  application
• guarantees the minimum level of safety of people
  and equipment
• concerns the low-voltage switchgear and
  controlgear assemblies for the power
  distribution and control.
• states
• - the service conditions (temperature...)
• - the construction requirements (IP, IK,
  forms,...)
• - the tests requirements

• So conformity to the standard is, for the end
  user, an insurance on switchboard realization
  quality.

Contents
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Prisma Plus a structured switchboard based on
functional units

• This modular design brings much clearness to the
  switchboard
• incoming unit
• current distribution units
• feeder units
• distribution units
• connection units
• communication units

Contents
Definitions
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IEC 60439-1 Standard and Prisma Plus a
structured switchboard based on functional units
Definitions

• Incoming units incoming circuit breaker
  (Masterpact, Compact NS, Interpact INS...).

• Current distribution units busbars (Linergy,
  flat bars, Powerclip...).

• Feeder units feeders circuit-breaker and
  contactors (Compact NS, Interpact INS, switch
  INV, modulars devices...).

• Each device is part of a functional unit
  comprising
• a dedicated mounting plate for device
  installation
• a front plate to block direct access to live
  parts
• prefabricated busbar connections
• systems for on-site connections
• running of cables and auxiliary wires

• Connection units insulated flexible bars,
  prefabricated junction

• Distribution units distribution block
  (Polypact, Polybloc, Multiclip, terminal
  block...).

• Communication units measurement devices, BP,
  Powerlogic, Digipact (Human/swichboard Interface).

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Forms partitioning

• In most installations, Prisma Plus cubicles do
  not require partitioning, Schneider Electric
  offering options and features that go well
  beyond the recommendations of the standard
• front plates requiring a tool to be removed
• doors providing access to live parts are
  keylocked
• systematic installation of terminal shields on
  Compact NS circuit breakers and Interpact INS and
  INV switch-disconnectors
• upstream and downstream terminals on the incoming
  device are covered
• The protection of people and equipment is ensured
  on origin
• However, Prisma Plus offers different levels of
  partitioning to create separations inside the
  cubicles and thus create Form 2,3 and 4, as
  defined by the standard.

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Forms separations within an assembly
Prisma Plus

• Form 1

• Form 2a

• Form 3a

• Form 4a

Prisma Plus
Prisma Plus
Prisma Plus

• Form 4b

• Form 2b

Contents

• Form 3b

Definitions
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Forms separations within an assembly
Definitions

• Form 1 no separation within the enclosure.

• Form 2a the functional units are separated from
  busbars, but not the terminals

• Form 2b the functional units and terminals are
  separated from the busbars. The terminals are not
  separated from each other.

• Form 3a the functional units are separated from
  each other and from the busbars , but not the
  terminals.

• Form 3b the functional units are separated from
  each other and from the busbars. Terminals are
  separated from busbars, but are not separated
  from each other

• Form 4a the functional units are separated from
  each other and from the busbars . Terminals which
  are in the same compartment as the associated
  functional unit are separated from each other

• Form 4b the functional units are separated from
  each other and from the busbars. Terminals are
  separated from each other and from the
  functional units.

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The minimum requirements to guarantee the
reliability of a LV switchboard

• First of all, it must comply with standards

• Switchboard construction standard
• IEC 60439-1 low voltage switchgear assemblies.

• Structural standards for incorporated switchgear
  
• IEC 60947-1 general provisions
• IEC 60947-2/3 circuit-breakers/switches
• IEC 60269-1 low voltage fuses.

• Installation standards
• IEC 60364 buildings electrical installation
• specific standards and rules to each country.

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The tests of standard IEC 60439-1
They guarantee that the switchboard complies with
standard and confirm its characteristics

• 7 type tests
• n1 - temperature rise limits
• n2 - dielectric properties
• n3 - short-circuit withstand
• n4 - protective circuit effectiveness
• n5 - clearances and creepage distances
• n6 - mechanical operation
• n7 - degree of protection

• 3 routine tests
• n8 - overall inspection cabling, electrical
  operation
• n9 - insulation/dielectric test
• n10 - protection measures .

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7 type tests performed by the manufacturer

• The aim of these tests is to confirm the
  switchboard characteristics.

• The 7 type tests are carried out on most
  difficult and unfavourable system Prisma Plus
  configurations. The assembled and cabled
  switchboards are made up of their usual
  components, connection system, equipped with
  Merlin Gerin and Telemecanique switchgear and
  assemblied and installed according to inductrial
  standards

• The tests are conducted either in approved
  laboratories (Asefa, Kema, Lcie,), or in
  Schneider Electric ones

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Test n1(8-2-1) Temperature rise limits

• Guarantees the safety and reliability of the
  switchboard, by avoiding problems such as
• connection damages
• reduction in insulation performances
• risk of burn for maintenance operators
• electronic components damages
• faulty operation of the devices inopportune
  release

Conditions
Contents
Results
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Test n1(8-2-1) Temperature rise limits

• Conditions

• Tests progress
• several switchboard configurations
• equipped with Merlin Gerin and Telemecanique
  switchgear
• 10 Clt ambient air temperaturelt40 C
• switchgear loaded to its rated current,
  multiplied by the rated diversity factor

• Complying limits (temperature rise limits)
• when the temperature has stabilised, the
  temperature rise should not exceed limits
  admitted by materials or cause any burn
• 70 C for terminal for external insulated
  conductors
• 15 C or 25 C , according to material type , for
  manual operating means
• 30 C or 40 C for accessible external enclosures
  and covers

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Test n1(8-2-1) Temperature rise limits

• Results

• The tests conducted with Prisma Plus have
  recorded temperature rises less than or equal to
  those stipulated by the standard.

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Test n2 (8-2-2) dielectric properties

• Guarantees the switchboard safety and
  reliability , to avoid problems such as
• electrical arc generation
• insulation performance decreasing
• connection damages

Conditions
Contents
Results
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Test n2 (8-2-2) dielectric properties
Conditions

• Tests progress
• the test voltage is applied between all live
  parts and interconnected exposed conductive parts
  (frame), as well as between each pole and all the
  other connected poles
• dielectric test voltage
• - 3500 V for a rated insulation voltage 1000
  V for busbars in cubicle and rear busbars in
  enclosures
• - 750 V for a rated insulation voltage 3000 V
  according to the type of busbars in enclosure
• - 500 V for a rated insulation voltage 2500 V
  according to the type of busbars in enclosure
• test duration 1 minute.

• Complying limits
• No arc flash-over or insulator perforation are
  observed.

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Test n2 (8-2-2) dielectric properties

• Results

• No arc flashover or insulator perforation for
  the test voltage following the rated voltage of
  busbars

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Test n3 (8-2-3) short-circuit withstand

• This test simulates an incident which could occur
  on site

• Withstanding the short-circuit currents is
• to avoid danger (rupture and projections of
  components, arc generation and propagation
  outside the switchboard,...)
• it also means the installation can be quickly put
  back into operation after the incident

Conditions
Contents
Results
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Test n3 (8-2-3) short-circuit withstand
Conditions

• Tests progress
• the short-circuit tests are carried out by using
  bolted connections at the ends of the main or
  secondary busbars
• 25 kA rms/1 sec. for Prisma Plus System G
• 85 kA rms/1 sec. for Prisma Plus System P

• Complying limits
• the main conductors and the insulating parts must
  retain their insulation and mechanical withstand
  characteristics (lenght, cross-section,
  dielectric properties,).

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Test n3 (8-2-3) short-circuit withstand

• Results

• After a short-circuit test, the Prisma Plus main
  conductors and the insulating parts keep on their
  insulation and mechanical withstand
  characteristics

• maximum rated short-time currents on busbars
• Prisma Plus System G Icw 25 kA rms/1 s
• Prisma Plus System P Icw 85 kA rms/1 s.

• the installation can be quickly put back into
  operation after a simple inspection

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Test n4 (8-2-4) effectiveness of the
protective circuit

• The effectiveness of the protective circuit is
  verified by two tests
• resistance measurement of the connection between
  the exposed conductive parts and the protective
  circuits
• short-circuit withstand performed between the
  protective conductor and the nearest phase
  conductor.

Conditions
Contents
Results
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Test n4 (8-2-4) effectiveness of the
protective circuit
Conditions

• Tests progress
• the short-circuit tests are carried out by using
  bolted connections at the ends of the main or
  secondary busbars
• 15 kA rms/1sec. for Prisma Plus System G
• 51 kA rms/1sec. for Prisma Plus System P.

• Complying limits
• the main conductors and the insulating parts must
  retain their insulation and mechanical withstand
  characteristics (lenght, cross-section,
  dielectric properties,).

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Test n4 (8-2-4) effectiveness of the
protective circuit

• Results

• After the test, continuity and short-circuit
  withstand of the protective circuit, whether it
  consists of a separate conductor or frame, is not
  significantly impaired

• Continuity and short-circuit withstand of the
  Prisma Plus protective circuit comply with the
  standard.

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Test n5 (8-2-5) clearance and creepage
distances

• Clearance control shortest distance between
  two conductive parts.
• Creepage distance control shortest distance
  along the surface of an insulating material
  between two conductive parts.

Conditions
Contents
Results
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Test n5 (8-2-5) clearance and creepage
distances
Conditions

• The values given in the standard apply to bare
  live conductors and the switchgear.

• The minimum clearance in air depends on the rated
  impulse withstand voltage and the degree of
  pollution in the switchboard.

• The minimum creepage distance depends on the
  rated insulation voltage, the degree of pollution
  and the insulating material group separating live
  parts.

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Test n5 (8-2-5) clearance and creepage
distances

• Results

• The tests carried out on typical Prisma Plus
  configurations, equipped with standard main
  busbars, validate compliance with minimum
  clearances and creepage distances for a voltage
  of 1000V, degree of pollotion 3, IIIa material
  group.
• minimum clearance 14 mm
• minimum creepage distance 16 mm.

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Test n6 (8-2-6) mechanical operation

• Endurance of material, guaranteeing the longevity
  of the various mechanisms.

Conditions
Contents
Results
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Test n6 (8-2-6) mechanical operation
Conditions

• The mechanical operation test is carried out on
  an assemblied switchboard.

• The standard requires that 50 operating cycles be
  carried out.

• Verification of locking mechanisms are included
  in this range of tests.

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Test n6 (8-2-6) mechanical operation

• Results

• After 50 operating cycles, the interlocking
  mechanisms and other moving parts of the
  switchboard preserve their initial properties
  - operation, - operating force.
• Some more solicited moving parts of Prisma Plus
  have passed until 10000 operating cycles (door
  handles, hinges).

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Test n7 (8-2-7) degree of protection

• The tests carried out define the capacity of an
  equipped switchboard to
• protect persons against contact with live parts
• protect equipment against penetration of solid
  objects and liquids
• protect equipment against external influences
  such as impacts (shocks).

Conditions
Contents
Results
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Test n7 (8-2-7) degree of protection
Conditions

• Tests for solid objects penetration (test
  finger, stem and wire).
• Tests for water ingress (jets of water, drop
  vaps).

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Test n7 (8-2-7) degree of protection

• Results

• Results of tests confirm the characteristics of
  Prisma Plus switchboard IP30 to IP55 and IK7 to
  IK10 according to the different configurations.

• Prisma Plus system P - IP30/31/55- IK07 with
  fixed panelling frame- IK08 with door IP30-
  IK10 with door IP55.

• Prisma Plus system G
• enclosure - IP30/31/43- IK07 without door -
  IK08 with door
• IP55 enclosure IK10
• Pack enclosure- IP30- IK07 without door -
  IK08 with door.

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The IP degrees of protection (IEC 60529/EN
60529)

• 1st digit
• protection of persons
• protection against solids.

• 2nd digit
• protection against liquids.

• Additional letter (optional) protection of
  persons against contact with live parts
• A protect againts access of the back of the
  hand
• B protect against access of fingers Ø 12 mm
• C protect against access of a tool diameter 2.5
  mm
• D protect against access of a tool diameter 0.1
  mm

Contents
Definitions
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Degree of protection
Definitions

• The IEC 60529 standard (02/ 2001) gives , by the
  IP code, the different degrees of protection
  provided by an electrical enclosure.

• The IP code is described by 2 specific digits
  an additional letter , in option, can complete
  the IP code when the real protection of persons
  against contact with live parts is better than
  the protection given by the first digit
• the 1st digit gives the level of protection of
  equipment against penetration of solid objects
  and protection of persons
• the 2nd digit gives the level of protection of
  equipment against penetration of liquids.

• Additional letter
• it is used only when the effective protection of
  persons is better than the one given bythe
  first IP digit
• in case of only protection of persons is needed,
  the 2 IP digits are replaced by x.
• Example IPxxB.

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Degree of protection IK (IEC 62262)

• IK code 2 digits giving the level of shock
  energy, in Joules
• IK 01 0,14
• IK 02 0,2
• IK 03 0,35
• IK 04 0,5
• IK 05 0,7
• IK 06 1
• IK 07 2
• IK 08 5
• IK 09 10
• IK 10 20.

• The IEC 62262 standard defines a IK code which
  gives the equipment capacity to resist to
  mechanical impacts , on all the enclosure
  surfaces.

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3 routine tests performed by the panelbuilder

• The 3 routine tests, easily and rapidly
  performed, must be carried out by the
  panelbuilder.
• overall inspection according to the mounting
  instructions and technical documents (right
  device ratings, tightening torques)
• insulation checking by a dielectric test
• checking of protective measures and of the
  electrical continuity of the protective circuits.

• They complete the 7 manufacturer type tests and
  guarantee professionnalism and responsability of
  panelbuilder.

• Schneider Electric supplies a full range of tools
  for assistance
• Quality inspection guide
• switchboard assembly and installation guide
• Prisma Plus System P and G assembly guides

Contents
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Test n8 (8-3-1) cabling, electrical operation

• Check of mechanical actuating elements,
  interlocks, ... effectiveness

• Check of proper laying of conductors and cables
  and proper mounting of device

• Check of connections adequate contact, especially
  screwed and bolted connections.

Conditions
Contents
Results
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Test n8 (8-3-1) cabling, electrical operation
Conditions

• Check of conformity with
• drawings, circuit and wiring diagrams
• cabling (power and auxiliary connection)
• cabling quality (cross-section, crimping...)
• information and marking (cables and devices).

• Visual inspection
• degree of protection, creepage distances and
  clearancess
• technical data document (diagrams,
  characteristics...).

• Mechanical and electrical functioning test
• check of cabling and most sensitive parts of the
  switchboard (mechanical control
  facilities,interlocks...).

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Test n8 (8-3-1) cabling, electrical operation

• Results

• The design of the switchboard , a structure based
  on functional units, insures conformity to this
  test.

• Schneider Electric gives the basic rules of
  assembly and installation in its documentation
  for assistance

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Test n9 (8-3-4) insulation resistance /
(8-3-2) dielectric test

• No arc flash-over or insulator perforation must
  be observed between the live parts each other and
  between the live parts and the conductive
  structural parts.

Conditions
Contents
Results
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Test n9 (8-3-4) insulation resistance /
(8-3-2) dielectric test
Conditions

• 2 possibilities of test depending on the
  panelbuilder s means
• either insulation measuring (8-3-4)
• or dielectric test (8-3-2).

• all electrical equipment shall be connected for
  the test, except those apparatus which are
  designed for a lower test voltage
• the test voltage is applied
• - between each pole and interconnected exposed
  conductive parts - between each pole of main
  circuit and the other poles
• - between each auxiliary control circuit and
  main circuit and exposed conductive parts
• - between supply and withdrawable part of a
  switchgear .

• Insulation test (8-3-4)
• insulation measurement using an insulation
  measuring device at a voltage of at least 500V.

• Dielectric test (8-3-2)
• for a rated operational voltage of 240/400 V, the
  dielectric test voltage of 2500 V must be applied
  during 1 s.

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Test n9 (8-3-4) insulation resistance /
(8-3-2) dielectric test

• Results

• Verification of insulation resistance (8-3-4)
• The test is passed if there is no perforation or
  flashover between the different tested parts

• Dielectric test (8-3-2)
• The test is passed if the insulation resistance
  between circuits and exposed conductive parts is
  at least 1000 Ohms/V..

• The standardization of the distribution and
  conenctions is the best guarantee.

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Test n10 (8-3-3) protective measures

• Checking of protective measures and of the
  electrical continuity of the protective circuits
  for metallic assemblies

Conditions
Contents
Results
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Test n10 (8-3-3) protective measures
Conditions

• Visual inspection
• Checking of protective measures against direct
  and indirect contacts
• Checking of the electrical continuity of the
  protective circuits for metallic assemblies
  (screwed and bolted connections shall be checked
  for adequate contact) possibly by random tests.

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Test n10 (8-3-3) protective measures

• Results

• Compliance of mechanical and electrical assembly
  instructions guarantees good electrical
  continuity of protection circuits.

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Panelbuilder and manufacturer, together to offer
maximum safety and realibility

• Manufacturer
• products tested in real configurations
• detailed instructions for fautless construction.

• Installer
• it has to its disposal informations, by means of
  tools of switchboard assembly and installation
  guide (catalogs, internet)
• confidence in products and swichboards systems,
  the result of many years of experience

• A shared success
• this complementarity must fall under the duration
  to consolidate our professionalism.

Contents
Customers advantages
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Panelbuilder and manufacturer, together to offer
maximum safety and realibility
Customers advantages

• Panelbuilders (and installators workshops)
• they complete a work of quality, simply
• they minimize the risk related to their
  responsibility for realization of a switchboard
  of which they know and ensure the level of safety
• they carry out very simply the conformity to the
  standard, therefore CE marking
• they develop their professionalism by making
  known it
• they are different from the other panelbuilders
• they profit from the transfer of Schneider
  Electric s experiment and tools

• Installators
• for them, a certified switchboard is the
  guarantee of the safety of installation and the
  good completion of work
• it is also the certainty to fulfill the user s
  requirements
• they minimize the risk related to their
  responsibility for installation
• they show professionalism.

• Users
• They have the certainty to have a switchboard
  ensuring
• - the safety and whose the quality is proven
• - maintenance and evolutivity easy thanks to the
  prefabrication and the standardization of the
  components
• They are ensured of the equipment and components
  perennity.
• They minimize the risks related to their
  responsibility for exploitation

• Specifiers/consultants
• For them it is the certainty to prescribe a
  switchboard which ensures the level of safety
  required by the user.

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Prisma Plus and IEC 60439-1 standard an
international influence

• IEC 60439-1 the same standard for all the
  professionals of switchboards

IEC
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IEC
IEC
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