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13 lv switchboard inspection guide

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13 lv switchboard inspection guide

  1. 1. Quality inspection guide Low voltage switchboards
  2. 2. Preface Foreword On 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 defines the quality as: “degree to witch a set of inherent characteristics fulfils requirements” Although final 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 specifications (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.
  3. 3. Contents 1 Schneider Electric Quality inspection: means and process 3 Introduction to the quality inspection 4 1.1 Justification of quality inspection 4 1.2 Quality inspection function 6 1.3 Quality inspection responsibility 6 1.4 Quality inspector’s profile 6 1.5 Necessary documents 6 1.6 Required human resources 6 Incoming delivery inspection 7 2.1 Justification of the incoming inspection 7 2.2 Procedures 7 In process inspection 8 3.1 Inspection during manufacturing 8 3.2 Justification of the inspection during manufacturing stage 8 3.3 Process 8 3.4 Means 9 Final inspection 10 4.1 Final inspection process 10 4.2 Operating rules 11 4.3 Non conformity treatment process 12 4.4 Conformity declaration 13 Quality inspection: instructions 15 Performing in-process inspection 16 5.1 Reminder 16 5.2 Composition 16 5.3 Process 16 Performing the final inspection 17 6.1 Conformity check 17 6.2 Mechanical checks 20 6.3 Electrical operations checks 26 6.4 Prior dispatching checks 31 Summarising of final inspection operations 33 7.1 Comprehensive list of points to be checked 33 Summarising of tasks after final inspection stage 38 Quality inspection: follow up 39 Quality dashboard 40 8.1 Purpose 40 8.2 Principles 40 8.3 Produced non quality 40 8.4 Example of a Produced Non Quality index board 42 8.5 Non conformity weight example 42
  4. 4. Contents 2 Schneider Electric Quality inspection: facilities and calibration 43 Facilities 44 9.1 The Quality Inspector’s individual tools 44 9.2 Common means of the quality inspection 44 9.3 Quality inspection zone 44 9.4 Necessary documents 44 Control of inspection means 45 10.1 Purpose 45 10.2 Reminders of basic principles 45 10.3 Responsibility 45 10.4 Diagram of operations 46 10.5 Application rules 46 Quality inspection: appendix 49 Follow-up of missing parts 49 Form example 49 Checking program 50 Non quality record board 51 Corrective action request 52 Final inspection record 53 Missing parts list 54 Glossary 55 Abreviations 55 Vocabulary 55
  5. 5. Procedure “ Set of organisational rules of an administrative nature in order to achieve a certain result “ Specified way of accomplishing an activity ” (see ISO 9001). Quality inspection: means and process 3 Schneider Electric PE50638
  6. 6. 1.1 Justification 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 are b inspection of the assembly b dielectric tests and / or measurement of insulation resistance b checking of protective measures and of the electrical continuity of the protective circuit. Human factors The specificity and complexity of low voltage equipment, the numerous human interventions, and thus risk of errors are the principal source of mistakes in our field, so the main reasons of the implementation of the quality inspection process. Each job must be checked. Cost reduction The non quality manufactured entails extra cost in term of time and money due to: b product examination b reparation b scrap b incidence in term of delivery schedule, brand image b 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 final inspection also guarantee Introduction to the quality inspection Quality inspection: means and process 4 Schneider Electric DD383150
  7. 7. Introduction to the quality inspection Quality inspection: means and process a good economic management of the switchboard manufacturing process. The Quality inspection therefore contributes b to guarantee the quality of the equipment: v by preserving the company’s brand image v by guiding the staff training according to the anomalies observed. b to the security of people and equipment b to the economic results of the company. DD383153 5 Schneider Electric
  8. 8. Introduction to the quality inspection Quality inspection: means and process 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 profitability. b perform the inspection with respect to: v the project file and the customer document v Schneider and products rules v IEC standards b carry out acceptance tests in the customers’ presence b perform quality follow-up and corrective actions b ensure the information, preventive action and training to the production staff b ensure periodical calibration of inspection and production means. 1.3 Quality inspection responsibility Quality inspection department b is directly attached to management and independent from manufacture b can postpone the delivery of a project and require reworking to ensure conformity b in event of a dispute, informs the unit manager who alone has the power to decide b is responsible for the safety of all people entering in the quality inspection zone. 1.4 Quality inspector’s profile b graduate as electrical technician (technician’s certificate) b versatile b good knowledge of Schneider equipment and devices b authorised to work near electrical current: v knowledge of the hazards of electrical current v authorisation by approved training course v basic notions of first-aid. 1.5 Necessary documents To carry out the various checks, the quality inspector must possess a complete, updated production file 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 fitters. 6 Schneider Electric
  9. 9. 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 final inspection of one process, joined to the incoming inspection of another one. 2.1 Justification of the incoming inspection As a final stage before assembly process, this quality inspection is a sizeable part of the final quality of the job and will ensure his profitability. 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 standard b the product specifications b the professional carried out rules. 2.2 Procedures Verification The 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 final installation. Non conformity processing All non conform product will be: b confined in a separated place b 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 PE50642 7 Schneider Electric
  10. 10. 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 specific 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 Justification 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 parts b the will to involve and motivate the staff for the quality of their work b the workshop organisation b existence of dedicated assembly line for frame, busbars, functional units (withdrawable, disconnectable, plug in, fixed) b presence of a devices adaptation work station b mass produced manufacturing system. 3.3 Process The inspection during manufacturing stage could be described by the following process: b inspection during manufacturing stage This operation consists in carrying out checks at different stage of the assembly process v systematic inspection or sampling which is part of quality inspectors responsability v 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 final inspection chapter. DD383169 DD383321 PE50643 8 Schneider Electric
  11. 11. In process inspectionQuality inspection: means and process b continuous inspection The 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 final 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 final inspection check list), the instructions provided at each manufacturing stage enable these checks to be formally defined. 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 fitter should fill 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 finally authenticate by the quality inspector during the final inspection stage. N.B.: Despite the operator checks performed for each operation, final inspection is always necessary. As it is stipulated by standard IEC 60439.1. PE50644 9 Schneider Electric
  12. 12. 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 specification is used for the checking phases during assembly and for final inspection. It forms the first reference document (production file). The following table gives you an idea of the average time required to perform a final 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 process The final inspection takes place as follows b carry out the conformity check b conduct the tests b 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 observed v 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 final inspection report after customer acceptance. b point out any areas of dispute between customer and supplier b ensure that the design documents have been properly corrected, by checking final version status and updating b ensure that all the check list is filled in b draft and record the final inspection report b sign the final inspection report and other documents b archive the documents. List of the various final inspection tests: a. conformity checks: b enclosure: v appearance v composition b the front face layout b framework b devices b busbars b flexible busbars b cables b connections b PE and (or) PEN protection busbars b separated equipment. PE50639 10 Schneider Electric
  13. 13. Final inspectionQuality inspection: means and process b. mechanical checks These checks consist of testing proper operation of the mechanisms and manual controls, the sturdiness of the switchgear, etc. c. electrical checks b operating tests b dielectric withstand b electric continuity of protection circuits b insulation resistance. 4.2 Operating rules The operating rules can be modelled using the following diagram. DD383151 11 Schneider Electric
  14. 14. Final inspectionQuality inspection: means and process 4.3 Non conformity treatment process The following diagram describes the various possible cases of treatment of non conformity. During the final 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 action Location / Type of fault BB assembly Cabling Performed by Time Signature Cabling error b Jean 5 min Busbar support missing b Alain 1 hour DD383154 12 Schneider Electric
  15. 15. Final inspectionQuality inspection: means and process 4.4 Conformity declaration On completion of final inspection, the quality inspector signature declaring conformity of equipment should be affixed on the identification label placed on the drawers and cubicles. Panel builder “lene X0 000 ile Tel : XX XX XX XX XX Fax : XX XX XX XX XX” “Quality inspection Checked by:” Conformity DATE: …..../……./.…… frame Conformity Job n°: ……….…....….. device Mechanical check Switchboard: ………… power Electrical test Cubicle: ………………. auxiliairies Dielectric test Equipment n° / location: ……………… finishing 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 sheet Ready for dispatch Client: …………………………………… Purchase order n° ……………… Switchboard designation: …………... Design file reference …………... Final inspection report n°: …………... Issue on: ………… Quality Inspector Name: …………………… Date: ......./......./....... Quality Manager Name: …………………… Signature: Signature: 13 Schneider Electric
  16. 16. 14 Schneider Electric
  17. 17. Instruction (dictionary definition) “ Verbal or written explanation intended for the person responsible for the carrying out of a specific mission. ” Quality inspection: instructions PE50640 15 Schneider Electric
  18. 18. 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 first assembly phase through to final inspection. This check list should mention: b the designation of each point to be controlled b the operator identification and the checking period. 5.3 Process After each stage, the operator checks and declares product conform by signing this follow up check list sheet and noting any observations. On completion of the inspections, a copy of this sheet is archived. 16 Schneider Electric
  19. 19. Performing the final inspectionQuality inspection: instructions The Quality Inspector must: b take delivery of the switchboards to be inspected in the dedicated zone b become acquainted with the project production file b 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 check 6.1.1 Enclosure Composition and dimension Number and order of cubicles Use the drawing of the project front face to ensure that the number and order of cubicles is respected. Project, switchboard and cubicles identification label b check that the information marked on the label match with the project file b 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 version On completion of final inspection, the Quality Inspector must place his registration number (or signature) and indicate the date at which the inspection was performed. Dimensions Check the cubicle dimensions (height, width, length and depth) by measuring and comparing them with those stated in the project production file. Appearance Paint colour and reference Use the colour palette to ensure that the reference of the paint given in the project file matches the colour of the cubicle. Verification generally carry out at the incoming delivery inspection stage. Homogeneity Perform a visual inspection to check the homogeneity of the colours of the various switchboard components (doors, panels, etc.). Finishing Check external appearance by a visual inspection: no scratches, deformations, etc. Front face and mimic diagram b visually check that the front face of the switchboard matches the one shown in the drawing of the project b check conformity of the mimic diagram compared with the power diagram and front lay out. PE50645PE50641 17 Schneider Electric
  20. 20. Performing the final inspectionQuality inspection: instructions 6.1.2 Framework Framework Panelling b operation of doors, mechanical accessories and drawers: v check their operation by manoeuvring them v ensure that the cubicle equipment is complete and has been installed properly b ensure the presence, characteristics (IP, material...) and proper fitting of: v ventilation grid, bottom plate v side and rear cover v 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 fish plating, coupling bars installation, interlock cables or rods installation, etc. Checking the locks Check matching of the lock references and the key numbers with the references given in the project production file. Mechanical assembly Check 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 fixing these components are present, and check that screws are properly tightened. Ground fixing Use the project design drawing to check the location of the ground fixing points. Handling devices Check their fixing and their disposition according documentation. Cable routing area Check 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 secured v 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 continuous b 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. DE50646 18 Schneider Electric
  21. 21. 6.1.3 Switchgear Conformity of devices Location / identification Use the layout diagrams in the project production file to ensure that the devices are properly located and identified (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. Characteristics b devices characteristics: v type, rating v breaking capacity and number of poles v 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 devices Check 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 mechanisms v coils (contactors, relays, impulse relays, under voltage or shunt coils of the Compact, Masterpact and multi 9) v indicator lights v all the electronic devices v soft started, capacitor bank.... b toroïds Check 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 transformer v check the technical data of the current transformers together with the installation direction v 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 device v 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. Shunt Check the connection between the shunt and the measuring instrument. Safety perimeters Check the circuit-breaker safety perimeters referring to their installation guides. No devices, equipment or bundle should be located in the safety perimeter. Accessories Visual checking of the presence of : b crank handles for circuit-breaker and / or drawers extraction b doors stop, light b clamps for fuse extraction b pins for fixing certain relays b etc. Performing the final inspectionQuality inspection: instructions PE50647DD383152 19 Schneider Electric
  22. 22. Performing the final inspectionQuality inspection: instructions 6.2 Mechanical checks Consult the switchboard assembly and installation guide. 6.2.1 Mechanical check and setting Mechanical check Equipment manual operation b manoeuvre the manual mechanism of devices, to ensure their proper operation b 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 fixing b 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 tolerances v the jaws installation and validated in the check list v check whether the auxiliary block are correctly identified, assembled and that the mechanical assembly remain free of movement Mechanical operation b to be checked: v the installation and operations of the position contact, door, drawer position, extended rotary handle, etc v the operation of the limit contact travel, drawers position, circuit breakers, contact located on door v the functional units (drawers, plug in, disconnectable...) operating margin. Mechanical setting and grease Jaws Check the power jaws plug-in penetrations and installation. With Blokset, use the specific jig to control the bars position (jaws operation). Presence of electrical and mechanical grease b the jaws lubrication b mechanical parts lubrication. Consult the technical product documentation. Freedom of the power clamp fingers, contact pressure Make 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. Accessibility Accessibility of functional units or devices Check 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 specifications, check also the access facilities for thermography control. PE50648PE50649 20 Schneider Electric
  23. 23. Installation and maintenance access Check accessibility of: b joint, cubicle coupling accessories b 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 modifications and maintenance. The associated bundle should be long enough to have access to the screw without difficulties. 6.2.2 Mechanical safety and locking system Mechanical 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 indicator Position 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 systems Ensure sturdiness of the various locking and mismatching systems. a. interlocking Check 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 parts b locking by key-locks, check: v the type and references of the key-locks v that the key-lock prevents the device from operating. b. Mismatching Check that the code of the polarising slots matches the specifications (drawers, devices on chassis). c. Padlocking Check 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. Performing the final inspectionQuality inspection: instructions PE50650PE50651PE50652 21 Schneider Electric
  24. 24. Performing the final inspectionQuality inspection: instructions 6.2.3 Checking electrical link / Busbar Conformity of electrical links Busbar Type and characteristics Check the bars characteristics according to the type of equipment, the project specifications, 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 file 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 order b check phase labelling type conformity b check that phase order (phases 1, 2, 3, neutral and PE) is respected according to the product specifications. Layout and installation b 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 features b 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 characteristics v check the alignment of the support, presence of deformation due to extra torque apply on the fixing bolt. Bending radius and bar alignment a 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 support b make easier the insertion of the connection bolt b avoid trouble (flexion, torsion...) on devices or terminal pads connections. Busbar joints Joints cross-section Characteristics and number Check positioning and accessibility of the joints screws Insulating distances versus frame, form partition, etc. Cleanness After busbars installation, ensure that no foreign body are lost in the bars compartment. In particular in the case of access difficulties. According to the installation system and the procedure in use, this verification should be authenticate using the check list. DD383438PE50653 22 Schneider Electric
  25. 25. Performing the final inspectionQuality inspection: instructions 6.2.4 Checking electrical link / Flexible bars Flexible bars Characteristics Cross-section To be checked according to the device and switchboard characteristics. Installation Radius of curvature of the flexible bars (at least once bar thickness). Bending manual operations are recommended to avoid damage on the bar insulator. In the event of a superimposed flexible bar installation, ensure that insulating spacers are placed between the conductors to provide proper ventilation. Binding Check 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 fit an insulating wedge. Check the connections: presence of the thick flat washer and the contact washer. 6.2.5 Checking electrical link / Cables Cables Characteristics Cross-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 fulfil the class 2 requirement, so these cables may be secured directly on metal supports. Installation Protection 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 fixing 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 fixing: b make sure that the conductor are fastened in accordance with their characteristics, size and network short circuit withstand. Check the collar characteristic. DD383164DD383165DD383171 23 Schneider Electric
  26. 26. Performing the final inspectionQuality inspection: instructions 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 conductors Ensure 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 assembly Connections / Screws and assembly Tightening torque In accordance with bolt, devices and other parts characteristics. Consult the product and devices documentation. Bolt characteristics and installation Check the bolt type (in accordance with the product specifications), 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 length v 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 finish (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 fitter, 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 connections Three 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 section v of the position of the conductor core in the lug shaft, and proper cable insertion v of the bolt diameter versus the lugs fixing hole v 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 washers v presence of varnish certifying tightening to the right torque (on visible connections) or use of torque nuts. DD383166 24 Schneider Electric
  27. 27. Performing the final inspectionQuality inspection: instructions 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 inspection C = checking presence and positioning. Connections Power Other circuits Jaws 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 fastening Check 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 facilities Accessibility 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 supports b 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 distances Shortest 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. DD383439DD383182DD383440 25 Schneider Electric
  28. 28. Performing the final inspectionQuality inspection: instructions 6.3 Electrical operations checks 6.3.1 Electrical tests Operating sequences Equipment preparation Connect 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 circuits Carrying out the operations: Open all the devices. b check the order of the phases b check correspondence of the circuit and conductor identification b 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 circuits Check 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 lights b 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). DD383157 26 Schneider Electric
  29. 29. Performing the final inspectionQuality inspection: instructions Check the information supplied on the connection terminals: b contact status b remaining information (voltage, current, etc.). Motor mechanisms Close the relevant protection devices. Activate the operating mechanism of the devices according to the command diagram, local, remote, automation... Electrical locking Check that it is impossible to close a device equipped with a locking contact. Metering circuits Check 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 voltage v adjust the maximum value of the current to be injected in the secondary circuit v inject the current in one of the circuits or in all three at once to check cabling. Checking the test function Circuit-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-breaker v press the test button of the Vigilohm part. This test is used to regularly check device tripping by simulating an earth fault b trip unit test (NS and Masterpact range): this test is performed using an external electronic tripping box v close the circuit-breaker v make it trip using the box by connecting its cord to the specially provided socket on the front face of the trip unit part v 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 devices For the voltage relays, check that the contacts are in the status defined 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 file. 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 characteristics b make the resistance vary by reducing its value. When the resistance is adjusted below the pre-set value, the device must indicate the fault. DD383189DD383436 27 Schneider Electric
  30. 30. Performing the final inspectionQuality inspection: instructions 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 file). 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. Check b that the protective conductors are identified by the two colours green / yellow marking plus PE or PEN lozenges b the accessiblility of the terminals for external conductors b the contact efficiency between section or parts of the protective circuit b 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 inspection N.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 DD383168 DD383162 DD383183 28 Schneider Electric
  31. 31. Performing the final inspectionQuality inspection: instructions 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 final inspection record list 6.3.3 Operator safety Protection of persons During normal operations b devices adjustment b operating handle access b drawer operation. Be sure that the persons are protected during the following operations: b pre-tripping of devices on plug in and plug out operation b operating safety b 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 door b etc. No live part nearby the operating handle, adjustment screw, etc. Plug-in protection flaps Check the presence of the plug-in flap: chassis, etc. Insulation screen / phase separator / terminal shield Check they are fitted (if required), firmly fixed and linked to earth for the metallic one. Conformity of partitions and form Check the presence of all the screen, form partitioning, protection cover of the devices located on the door (direct contact). Protection against contact This inspection is performed by checking the presence of component parts such as: b picot washers b 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. PE50654PE50655 29 Schneider Electric
  32. 32. Performing the final inspectionQuality inspection: instructions Third routine test Dielectric test 6.3.4 Dielectric withstand (Standard IEC 60439-1 paragraph 8.3.2) Dielectric test Preparation 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 NS b the electrical control motors b 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 A b 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 mode Perform 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 operations Example of the phase live part test: b all switching devices shall be closed b interconnect the exposed conductive parts and earth them b interconnect the live parts to one another and then to the assembly conductive parts b connect the measuring instrument earthing wire to the assembly frame b connect the injection cable to the circuit to be monitored and gradually increase voltage up to the required value PE50656 30 Schneider Electric
  33. 33. Performing the final inspectionQuality inspection: instructions b the test voltage should be applied for 1 second b gradually reduce voltage before disconnecting b once this check is complete, repeat it for the other live circuits. Result The tests are satisfactory if there is no puncture or flashover. Register the result on the final inspection record list 6.3.5 Insulation resistance Insulation resistance measurement Preparation Before performing the test, make sure that you disconnect: b the surge arrestor (if any) b the covers from the Vigi modules of the Compact NS b the electrical control motors b 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 mode Using 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. Result The 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 final inspection record list. 6.4 Prior dispatching checks Prior dispatching checks 6.4.1 Cleaning Prior the packing, check that the equipment is clean: b no dust b no foreign body forgotten in the equipment. Remind: See chapter 3.2 about the assembly for witch the access is difficult at the final inspection stage. 6.4.2. Miscellaneous From a detailed check list establish by the design office, perform the inspection of: b all the equipment to be delivered separately, spare parts, devices dismantled for transportation, etc b roof, coupling screws b busbar joints, etc. 31 Schneider Electric
  34. 34. Performing the final inspectionQuality inspection: instructions Documentation Presence of the name plate and / or the “as built design”. Make sure that all the documentation associated to the quality inspection procedure are fulfil: b missing part list b final inspection report b checking program b corrective action form b non quality record board b delivery note b etc. Associated documentation delivered with the equipment: b devices and switchboard technical documentation b maintenance documentation b missing part list and 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 carried b the transportation means b the destination b the condition of storage b the climate conditions. PE50657 32 Schneider Electric
  35. 35. Summarising of final inspection operations Quality inspection: instructions 7.1 Comprehensive list of points to be checked This non exhaustively list contains a description of the various verifications to be carry out during the final 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’s Product: ......................................................................................................................................................................... Client reference: ......................................................................................................................................................................... Project name: Project identification: ......................................................................................................................................................................... ......................................................................................................................................................................... Drawing number: Index ......................................................................................................................................................................... Quality inspector ......................................................................................................................................................................... Date: ......................................................................................................................................................................... Technical information’s Ambient temperature Degree of protection ......................................................................................................................................................................... Form Withstand Operational rated voltage ..............................................................................................................................................................kA/sec ......................................................................................................................................................................... Cable entry / exit Top Bottom Other IEC 60439-1 reference standards 33 Schneider Electric
  36. 36. Summarising of final inspection operations Quality inspection: instructions 1. Composition Number of cubicles Order of cubicles Project and switchboard identification markers Cubicles identification Dimensional inspection – Switchboard – Length – Width – Height – Depth – Fixing points. 2. Appearance Paint colour and reference Homogeneity Finishing Front face and mimic diagram 3. Framework Panelling / Operation of doors and mechanical accessories Inspecting key lock and number Frame mechanical assembly Handling device Check the degree of protection 4. Conformity of the devices installed Location and identification Conformity of the devices installed Their type and rating Device breaking capacities Devices accessories conformity Safety perimeters 5. Mechanical check Manual operation of mechanism Operating safety (jamming – safety margin) Devices accessibility Equipment fixing Limit travel contacts: circuit-breaker - drawer - etc. Jaws installation Grease 6. Accessibility Functional units or devices Access for installation, joint, junction kit, floor fixing bolt Access for maintenance operations 7. Mechanical setting Power plug-in penetrations Freedom of the power clamp fingers – of contact pressure Auxiliary block installation 8. Checking mechanical safety and locking system Fault 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 operations Correct resetting of devices after a fault trip (circuit-breaker, relay, etc.) Impossibility of plugging in a drawer when the device is closed Impossibility of plugging out a drawer when the device is closed Sealing flaps on the power circuits Sturdiness of the locking systems by key-locks or padlocks 34 Schneider Electric
  37. 37. Summarising of final inspection operations Quality inspection: instructions 9. Checking the electrical conductors and links Busbars Checking the busbars: b type and characteristics b phase order and identification b layout and installation b bending radius and bar alignment b supports characteristics and installation (conformity with product technical file) b busbar joint characteristics b cleanness Flexible bars Checking the flexible bars: b type and characteristics b installation Cables Protection of cables Separation of strands for auxiliary U u 500 V DC – AC EMC compatibility installation rules Wiring trunking (reserve in trunking: 20 %) Type and characteristics Power conductors Auxiliary conductors Phase order and identification Installation Protected from sharp edges or moving parts Non protected active conductor installation rules 10. Conformity of the electrical connections Checking Tightening torque Busbar overlapping / Contact surfaces Bolt characteristics and installation Checking crimping Power cables Control cables Connection stresses and fastening 11. Conformity of connections facilities Possibility of connecting cables to pads or terminals Client power incoming and outgoing route with respect to cross-section: b from the top b from the bottom. Client auxiliary incoming and outgoing route Cable fixing: b number of cable supports and sturdiness of tightening. Proximity of PEN / Earth connection facilities. 12. Clearances Inspection Clearance:14 mm Creepage distances: b 14 mm for rated insulation voltage 750 V AC and DC b 16 mm for rated insulation voltage 1000 V AC and DC. 35 Schneider Electric
  38. 38. Summarising of final inspection operations Quality inspection: instructions 13. Operating inspection Wiring and the various operating sequences Power circuit conformity Electrical 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 circuits Visual Cross-section of the protection conductor. Electrical 15. Protection of persons During normal operation During safety operations Pre tripping: b contactors b fuse blowing b drawers operation b devices tripping accessories. Presence of flaps, cable head outlet pads (as per Specification) Phase separator, terminal shield Rigidity 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 plate IP of the device located on or through door. 16. Interchangeability of drawers Polarisation Electrical interchangeability between drawers and circuit-breakers 17. Measuring dielectric withstand Circuit tested ϕ1 ϕ2 ϕ3 N Aux Nominal voltage Applied voltage Result (1) (1) Passed / not passed. 18. Insulation resistance measurement Circuit tested ϕ1 ϕ2 ϕ3 N Aux Nominal voltage Insulation resistance Result 36 Schneider Electric
  39. 39. Summarising of final inspection operations Quality inspection: instructions 19. Inspection prior to dispatch Roofs, seal covers and fixing screws. End panels and fixing screws. Sealing flaps (+ 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 Specification). Devices dismantled for transportation. Door handle keys: key-locking. The list of equipment not delivered (missing). Cleanness. Associated documentation. 37 Schneider Electric
  40. 40. Summarising of tasks after final inspection stage Quality inspection: instructions After final 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 specifications have been respected. N.B.: The procedures mentioned in this guide are given as per indication. After final 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 final inspection should be signed by the client or his representative after client acceptance inspection. PE50658 38 Schneider Electric
  41. 41. Quality inspection: follow up PE50659 39 Schneider Electric
  42. 42. Quality dashboardQuality inspection: follow up 8.1 Purpose This dashboard allows the measurement of the quality performance and reveal the necessary corrective actions to implement. 8.2 Principles The quality assurance manager issues a monthly quality report entitled “Quality indicator report”. Performance is evaluated according to the four indicators below: b purchased non quality b produced non quality b non service quality b external non quality. The non quality index: b is an indicator used to measure changes in non quality b defines the target aims b reveals the weaknesses of the various operations and allows the relevant actions to be taken. These non quality indices can be calculated using specific formulas (see chapter 9.3). The index witch is directly associated to the final inspection is “produced non quality”. Purchased non quality can be monitored by different indicators depending on the supplies origin: b global ratio b ratio of the supplies purchased b internal manufactured supplies ratio. External non quality: b taking clients complaints into account (intermediate or end users). 8.3 Produced non quality This index is calculated after the final 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 conformity b major: a fault risking a considerable reduction of the achievement of a function in the switchboard. DD383161 40 Schneider Electric
  43. 43. Quality dashboardQuality inspection: follow up 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. Weighting The weighting applied to these three types of faults is: b minor fault = 1 b major fault = 3 b 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 cubicle v < 12 m (1) drawers or functional units = 0.1 cubicle v 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) = 0.3 2 drawers 250 A 6 modules (2 x 0.1) = 0.2 Total = 0.5 Cubicle equivalent = 0.5. 41 Schneider Electric
  44. 44. Quality dashboardQuality inspection: follow up 8.4 Example of a Produced Non Quality index board Product Number Non conform Faults Responsibilities Weighting version Nbr % 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 handled b the complexity of certain projects (complicated operating sequence) b insufficient personnel training b insufficient sensitivity of personnel b poor control of supplies b poor quality of the project production file. 8.5 Non conformity weight example Item Description / Description Poids / Weight 1 Labelling 1 2 Wire marking 1 3 Wiring aspect 1 4 Accessibility of equipment 1 5 Fixation of apparatus 1 6 Space for customer connection 1 7 Bad crimping 3 8 Auxiliary wire section 3 9 Auxiliary protection rating 3 10 IP degree 3 11 Earth connection 3 12 Phase polarity 3 13 Electrical sequence operation 3 14 Auxiliary wire damages 3 15 Power wire damages 10 16 Insulating distance 10 17 Power cable or bus bars cross section 10 18 Protection devices conformity 10 19 Number and clearance of busbars supports 10 20 Interlocking 10 DD383160 42 Schneider Electric
  45. 45. Quality inspection: facilities and calibration PE50660 43 Schneider Electric
  46. 46. FacilitiesQuality inspection: facilities and calibration 9.1 The Quality Inspector’s individual tools These are the switchboard fitter’s tools (screwdriver, wrenches, etc.) with in addition: b a small rule or measuring rods to check clearances b a lamp b an articulated mirror b a set of crocodile clips b a bell tester b set of probe fingers 9.2 Common means of the quality inspection b 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 test b earth continuity tester b phase order tester b drawers test equipment b test cords and a variety of plugs, supply cords and other connection systems b steps, pallet-mover or other transportation facilities. 9.3 Quality inspection zone b is independent from production b must be physically separated from the other departments: v for reasons linked to the hazards of electrical current v for protection of people and equipment b 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 documents b to carry out the various checks, the quality inspector must have: v a complete, updated production file of the project, check list v a missing parts list v update procedures and associated document v updated products documentations (devices, equipment system...) v standards. PE50661PE50662PE50664 44 Schneider Electric
  47. 47. Control of inspection meansQuality inspection: facilities and calibration 10.1 Purpose The 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 principles Inspection means List and identify the inspection means. Have them checked at specific 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 Office). 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 means Torque wrenches. Crimping means. 10.3 Responsibility The inspection and production means responsible appointed by the quality manager is in charge of: b listing and identifying these means b implementing and monitoring the checks b decision-making after checking b archiving the documents. 45 Schneider Electric
  48. 48. Control of inspection meansQuality inspection: facilities and calibration 10.4 Diagram of operations 10.5 Application rules 10.5.1 Choice of means Inspection and production means are chosen according to: b the type of measurement b the theoretical values to be measured b the required accuracy b the type of process to be done. 10.5.2 Classification of means For checking follow-up: b all the inspection and production means identified and monitored. The items of equipment identified 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 means The 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 means Torque wrenches: b must be calibrated once a year at least. Crimping means: b must be checked once a year. DD383159 DD383187 46 Schneider Electric
  49. 49. Control of inspection meansQuality inspection: facilities and calibration 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 filed 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 impact b a repair b a loan b 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 repair b downgraded to an operation means not assigned to measurement (indicator only), b scrapping (most of case for production means). 47 Schneider Electric
  50. 50. Control of inspection meansQuality inspection: facilities and calibration The calibration manager must also decide whether to initiate a notification 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 Notification of Non Conformity. DD383158 48 Schneider Electric
  51. 51. Quality inspection: appendix DD383437 49 Schneider Electric
  52. 52. 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-ordinator References Quantities Supplies Lead time announced 2 - Missing parts at end of inspection/customer acceptance Issued by: .................................................... (copy) V Q.I. Date: ............................................................. (copy) V Warehouse Items Project co-ordinator References Quantities Supplies Lead time announced 3 - Sales department notification 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 50 Schneider Electric
  53. 53. Form exampleQuality inspection: appendix Checking program Product : .................................................................... Final inspection registration n° : ................................ Drawing n°: .................................................................... Index : .......................... Client : ....................................................................... Tendering : .................................................................... Project n° : ................................................................. Design : .................................................................... Assembly : .................................................................... Quality : .................................................................... Cubicle identification : Continuous inspection Quality inspection Observations (1) Checked by Checked by Repair Conform Nb of faults 1 Number, identification and dimension of cubicle 2 Paint - aspect - 3 Framework assembly - handling devices - keys 4 Protection index 5 Devices location and identification 6 Devices label conformity, circuit identification 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 identifications 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 31 32 Missing part list 33 Drawing “as built” 34 35 “Non quality” record board 36 Devices specification sheet 37 Packaging 38 Separate equipment delivery 39 Checking during process: fulfil the grey box Final inspection and test: fulfil the white box (1) N.B.: tick the box and annotate the observation on the event record sheet Fulfil the box with NA for “not applicable mention”. Date. : ........ /........ / ........ Checking program 51 Schneider Electric
  54. 54. Form exampleQuality inspection: appendix Non quality record board Quality 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 52 Schneider Electric
  55. 55. Form exampleQuality inspection: appendix 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 53 Schneider Electric
  56. 56. Form exampleQuality inspection: appendix Procès verbal de contrôle final / Final inspection report Client : ................................................. PV n° / Registration Nr ....................…............................…....... Affaire / Project : ................................................. N° Cde client / Client ref. : ...............................……....……....… Nom du tableau / Switchboard identification ............................ .......…………….........…………….........…………............................ ....................……....................…….....................……....……....… N° affaire / Job ref. : ....................……........................……....… Produit / Product : ................................................. Quantité / Qty : ................................................. final 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. Vérifications mécaniques/ Mechanical checking ........................................................... 3. Essais electriques / Performances electric test ........................................................... 4. Continuité électrique des masses mécaniques Exposed 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 54 Schneider Electric
  57. 57. Form exampleQuality inspection: appendix Entity Plant Tel : 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 55 Schneider Electric
  58. 58. GlossaryQuality inspection: appendix Abreviations B.N.M.: National Metrology Office. 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.: Notification 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 Control PCC: Power Command and Control Vocabulary Main definitions (Standard ISO 9000) Quality Degree to witch a set of inherent characteristics fulfils requirement Quality audit Methodical 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 management Co-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 manual Written documents specifying information about the quality management system of an organisation. Quality plans Documents 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”. Procedures Specified 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 predefine quality level. Inspection Conformity evaluation done in the scope of defined process by observation, measurement, testing or gauging. Non conformity Non fulfilment or deviation of a need or expectation with respect of the specified requirement. Traceability Ability from registered identification, to trace the history process and the location of the product after delivery. 56 Schneider Electric
  59. 59. Schneider Electric Industries SAS 89, boulevard Franklin Roosevelt F - 92500 Rueil-Malmaison (France) Tel : +33 (0)1 41 29 85 00 http://www.schneider-electric.com http://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 Electric Photos: Schneider Electric Printed: DESW048EN 04-2006 DESW048EN©2006-SchneiderElectric-Allrightsreserved

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