Improving Safety and Performance in Electrical Assemblies. a Guide to lEC 61439-2

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    I P oving sa e yan performa cein elec ical assembliesA guide to lEe 61439-2

    S C ~ l 1 e i d e r u-Elec t r ic

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    Intra uctianSince i t was first published over 35 years ago,IEC 60439 has provided the basis for specification andtesting of low-voltage electrical assemblies. As was the casefor many early IEC standards, it was a compromise betweendifferent national approaches, some of which were verystringent. even prescriptive, and others that were moresubjective.Where consensus could not be achieved. the subject was ignored. or somevague olause was added that could be interpreted to SUIt the readers pOint of View,

    These weak foundations have made It d fficu lt to evolve the standard IfI line with market needsand pressures. [V(\ry assembly manufactured should meet minimum performance and safetycriteria, in s p ~ e of ever increasing demands to optimise manufacture and re:!uGe costs.

    Application needs, however, make It mpr actlcal to type test every variant that IS prO\'lded,Some frequently used desogn concepts, such as modular systems, are not adequately coveted,rurthermore, many assemblies produced do not fit neatty into the Type Tested Assembty (ITA)or Partially Type Teste:! Assembly (PTTA) categories.Some smaller assemblies may not be covered by either TTA or PTTA and are thereforeeffectively outside the scope of lEe 60439. In the case or a PTIA, the standards'requirements fo r proving a design are very subjective and entirely dependent onthe knowledge and in tegrity of the particular manufacturer.

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    Schneider Electric, along with other leading UK assemblymanufacturers, long recognised the limitations of lEe60349. Some 10 years ago the company proposed, viathe Manufacturers' Associations and British Standards,that the IEC carry out a radical review of the IEC 60349series of standards.

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    I also suggest9cl, if practical. that the ICC restructul-e and improvethe series of standards to reflect the present and future applicationsand requirements tor assembhes

    A fundamental revteW has questioned every aspect of IEC 60439and has been a long and tortuous task. Despite there hailing beenan Interna -anal standard for many years and. atthough majormanufacturers ha\l'e attempted to promote international designsor assemblies, views differ markedly around the world about basicpelfor ma oa and requ aments,

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    A c h i e ~ ' i n g consensus has once again been very difficult. However, the first parts of the new serieso standards have been published. The approach to specifying an assembly, pfOlling capability,and the format 01 the 5tandard Itself, have all fundamentally changed.

    In due coarse , the tvvo patts of the selles that have been publlsl ed by lEG wI be Issued as ENStandards and then subsequently automaticafly as British Standards. The [N Standards wm beidentical to the lEG Standards. The only difference in the British Standard is that it is expectedto contain addrtional detail on form5 of separatiOl1. These are gl\len In annex NA of 8S E 60439-1and wi be transferred to the new 5enes. again as an Informative annex.

    Users, purchasers, builders and specifiers of assemblies will need to familiarise themselveswith the new approach. This guide provides all easy transition from the old to the newstandards, IdelltJfying the fundamental changes and the parameters that need to be definedin al l a55emb y speCification.

    .-.-.-".

    "

    o r own Pnsmapanels" e certifiedcompilan \ " l i tIEC61439

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    Newse lesThe new series of low-vo tage assembly standards willbe numbered lEe 61439, a single digit change that beliesfundamental changes 'n the structure and format of thestandards.

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    HistoricaKy ICC 6 0 ~ ~ 9 - 1 has been a comple e s andard that defined the requirements ofassemblies not otherwise covered by prcductspecific assembly standards. In addition.IEC 604391 was a reference for the product-specific assembly standards, EC 00439Part 2 to 5 inclusive, WIth ill the requirements of lEe 00439-1 applying to the product-specificparts. unless specifically e ~ c l u d e d ,

    This approach to the strocture of a series of standards leads to d ' f f C t J ~ i e s when standardsare revIsed. A change to lEe 60439-1 can inadvertently pase changes on specificproducts unless their part of the senes of standards IS rel'lsed at the same time.

    The I[ C 61439 series of s andat'ds will use the same structure as other series .....ithin CC,Part 1 is General Rules. detailing requirements that are common to two Cf more generictypes of assembly. Each genenc type of assembly then has a product-specific Part withinthe series 01 standards.

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    RecognitionAssemblies are very multifaceted, They consist of a numberof components closely connected together in an almostinfinite number of possible combinations,Interactions bet\ ..een the ....anous elernents of an assembly, thermal , magnetic, etc" all affect theperformance of inoioJidua l circuits and the assembly as a whole. This is a "'ery different scenariofrom that presented by an individual comlXInent. such as a circuit breaker. The performance ofa component is usually wen defined in its product standard. but it assumes operation alone andunder Specific operating condrtions, thus making feasibl e to readily pro\'e the componentscapability by type test.

    IM th assemblies, the permutations and configurations are effectively imitless. Fu lly type testingevery manufactured variant within a modular system and each bespoke assembly or part of anassembly is simply not practical. C06tS and time preclude thIS

    While lEe has recognisecl this fundamental issue, it is equally clear tha t there ml,lst be away of ensuring all assemblies meet defined performance and safety cnter-ia. Accept ingthat the design of some assemblies is only 'partially' proven, or perhaps only routinetested, is no longer an op t ion.

    * For more information call us on 0870 608 8 608or dick on www.schneider-electric.co.uk11

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    New approachMarket trends and requirements for assemblies may evolve,but they will not suddenly change. Assemblies will continueto be manufactured in a wide range of volumes fromone-off bespoke arrangements, through adaptedstandards, to mass-produced units with defined options.The pressure on operators of electrical distribution networks to imprOlla the utmsation of their assets\ ~ q U continue. Manufacturers are also continuously optimi&ing their designs. Taking all of this intoa=unt , together with the need to ensure increasingly demanding safety requirements are met.rt IS clear that the approach to specifying and demonstratlflg the capability of assemblies isout-dated and must ohange radically.

    After much debate and deliberation, lEe has taken a practical and pragmatic approach to prmqngthe capability of assemblies. The capability of each assembly will be verified, effectIVely In twostages: design verification, to prove the design performance of the assembly is in accordancewith lEe 61439; and, { i ~ routIne verificatIOn. to oonfinn the matenals and workmanshIp are Inaccordance with the design specification. Tha lattar verification is mora oofinad, but otherwise,the requirements are generally as the routine test requi-ements in the previous standard.

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    Desgn verification. however, uses a radical n(#!.' approach, Where volumes Justify It, type testingwill remain the preferred option for design verification. since it can, and ooes, lead to material andlabour optimiza ion. VVhen adaptations or bespoke arrangements are required. the s andardoffers other equivalent routes to design verifK::ation.

    T ese olude oomparlson to a verified reference deslg n, calculation, and terpolatlon from averified design. measurement, e c . The 'n uttiple option' route to verification is S 'ietty contro 00-When. where and how each is used is defined. While' is possible to b u ~ d a small assembly. of theorder of 200A, with the only type tests being an earth continuity measurement and a dielectric test.the standard etlectlVely mits the deSign venficallon of assembl es of the higher ratings to type test,

    When design verification, other than by type test is used, the standard insists on margins beingadded to the design, tor example; {i) 5O'Jc added to clearance an impulse test is not carned out,{in components are de-rated by 20% when the assembly IS not temperature tested

    These design margins ensure the alternatives to type testing provide a minimum level ofperformance in a=rdance with the standard. Inevitably adding margins has an adverse effecton the physical size ot the assembly, the quantity ot materials used and it it is an applicationwhere a standard destgn could have beet'! used, oommerolal mplloatlons,

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    u a e tachangesIn order to meet its objectives, the review of the lEe 60439series of standards had to make changes and indeed, ithas made radical changes. A number of the foundationsof the old standard have been discarded in order to havea standard that better meets the low-voltage assemblymarket's needs and the way it operates.

    In some instances, the changes are so tundamen af that it may ake users some time to acljl.lst 0the new order and the benefits it brings. The categories of TTA and PTTA have been discardedIn favour of a design 'verified assembly', This 15 a classless deSigna en where demonstration ofdesign cap.:iliility can be achie\

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    For the first time the standard recognises that more than one party may be irwowed beMieen concept and deHveryof an assembly. The standard identifies the original manufacturer as the one responsible for the basiC design andIts verification and possibly, the s u p p ~ of a kit of parls. 11 then designates the rnanufacturet who completes ttleassembly and conducts the routine tests as the assembly manufacturet

    The original and assembly manufacturer can be the same, or, a transition may take place somewherebetween concept and delivery, for some or all of the assembly. In any event, all parts of the assembliesmust be design and routine verified by a manufacturer. See figure 1 for a typical assembly supply chaIn.

    Figure 1: Typical supply chain for a low-voltage assembly

    OriginalManufacturer

    Contr i lctor

    J,

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    Responsibi litiesThe new standard, so far as any standard is able to do so,attempts to focus all parties involved in the provision of alow-voltage assembly on their respective responsibilities.Purchasers and specifiers are encouraged to view anassembly as a 'black box'.T h e ~ prime functKln IS to specit',' the Inputs and outputs to the assembly and to define theinterfaces between he assembly and the outside world. See figure 2.

    How the assembly is configured internally and the performance of the assembly. relative to theel(ternal parameters as defined by the purohaser or speoifier, is clearly the responsibility of themanufacturer(s). They ate responsible for the correct Incorporation of the Indlvodual componentsand must ensure the design meets the specifICation, is fully verified and it is fit for purpose. Themanufacturer, or combination of manufacturers (original manufacturer and assembly manufacturer).isfare regarded as the expert and they must have sufficient knowledge of assemblies to satisfythIS role,

    Figure 2: Responsibilities

    InCOl11ing SUpply(e.g.

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    .........esgn verfcafonDesign verification is a prerequisite for all assembliesprovided. It is fundamental to ensuring every assemblymeets its defined design requirements. There is flexibilityin the way in which this is achieved within the new standard.and some new concepts have been introduced, but theoptions are defined and where necessary their use isrestricted and a design margin applied.Examples of the limitatiOIlS and margins applied to verificatioll without type test include;

    > All assemblies connected to a supply with a prospectIVe short oirelilt ClJrrent In e)(ooss of 10kArms or haYIng a cut-off ourrent of 17kA peak must be of a type-tested design or the venficationmust be an Interpolation from a referenoe design . Under no olrcumstances can the asstgnedshort olrcult current ratIng be highe i than that of the referenoe destgn.> So as to take accoun of the ai temperature \o\Iithin the enclosure, thennal interactions andpo&Sible hot spots: components within a circuit hat has not been temperature rise tested.must be de-rated to 80% of thell' free air currerlt ral1ng> Com par isorl of the powe loss of the components wlth[l an assembly with the known heatdissipation capability of an enolosu e, IS restncted to assemblies ~ ) a v l n g a rating of 630A> Confirmation of temperature rise performance by calculation is limited 0 assemblies \ ~ ~ t h arating not e:

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    New concepts in ver if ication

    In addition to the fundamental change from type testing (or perhaps tumlng a blindeye in the case of PITAs) to design verification. a number of new approactles toprov ing design capability of assemb lies have been recogn ised and included in thestandard. In summary these ate:> Modular systems - a means of ensuring aJ antJdpated arrangements within a modular

    a s s . e m b ~ 1 can be temperature l ise vetlfled, without the need to test every possiblepermutatlOtl

    > Criti ca l variants - the testing of the most onerous arrnngement, as determined bycriteria given in the standard, and then assigning ratings to lower rated arrangementswithln defined rules. As an example, it the se::;tion of a tempemt ure rise tested busbarha""ed, then the current rating of the busbar IS also halved, assuming all other oonditlonsremw n the same> Comparison to a reference design -using a prescribed checklist to ensure that designis at least equivalent n all respects to a pr6\liously ~ ' 9 r i f i e d design.> Simplified verification - options within the standard enable low rating assemblies:where the prospective short circurt current of the incommg supply is less than 1akArmslHkA cut oft, and a type tested enclosure is used. allow the assembly to be designvenfed without a type test, other than tt1e carr'jlng out of a power frequency dielectnctest and an earth continll ity measurement.

    Additional verificationlEG 604391 was delicjent in a number of respects.A number ot these ISSues have been addressed and In line with goed standards' practise,for eacll new performance measure, a new I"9rlncatlon has been Introduced.These incl ude:

    > Two levels of venfloation of oorrosion resistanoe; one for internal/Indoor parts and a seoond .rrore onerous requ rement for outdoor parts.> Verification of resistance to lJI/ radiation for outdoor plastic enclosures.> Gonfinnation that the assembly, via its lifting points. is capable of being f t e d without dangeror damage.> Mandatory declaratIon and confirmation of an impulse ral'ng.> The use of an Insulation resistance measurement as the only means of connrmll'lg dielectrICparformance is no longer parmitted. All assembfies mllst be dasign varifJeod by means of apower frequancy dielectric test.> Labels that are not engraved or similar must be subject to a test to confinn their legibdityand durabilrty.

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    1111111 mil

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    Ambiguities clarifiedAs part of the review of the lEe 60439 series of standardsa number of hitherto imprecise requirements have beenclarif ied. Previously a manufacturer had to assign a currentrating to each circuit, but they were never required by thestandard to prove its rating.This has been rectified and manufacturers, In accordance IMth tt1e ne .... standard, have to venfy therating of each type of circuit. All the pr9'Jious concerns about the rating of a device once it has beeninstalled in an assembly are overcome.

    In the old standard, diversity was defined. The d e f l T l i ~ o n albwed, subject to the maximum ratingof the Incoming circUit; a m a ~ l m u r T 1 number of cltcults to be loaded to their rated current muttlplledby the diversity factor. or, a smaffer number of adjacent circuits to be loaded to their rated current;or any loading arrangement between the /1.'10 extremes. Clearly these extremes led to \'91)' differenttemperatures and performance and so this lack of clarity has been addressed.

    Each type of CIrCUIt Will have Its rating ver lfied within the assembly and the c ~ b i l l t y of tt1e assemblyas a whole will be proven by loading adjacent outgoing circu ts to their rated cun-ent, multiplied bythe diversity factor.

    Historically It has been assumed that If nothing was said, the neutral oould have a current ratingequal to 50% of that of Its associated phase. However, because this has not been stipulated In anylowvoltage standards for many years, any query oould only be answered by it's custom andpractise'. ICC 61113-9 includes a default current rating in accordance with custom and practise forcircuits with conductors alcove 16mm'. but a specifier can ask for a higher rating to suit the needsof his application.

    In addition tl'le ongoing question in respect of forms of separation has been answered.A device's integral enclosure, for example the case of a moulded case circuit breaker, isdefined as a means of providing separation from an adjacent circuit.

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    S ecific issuea ressedThe substitution of a device within a type tested assemblywithout re-testing has always been a contentious issue.Apart from the physical issues, all the design criteria withinthe standard must be considered if, after substitution, safetyis to be assured. In particular, there are serious difficultiesand concerns in respect of temperature rise and short circuitperformance.It is not sufficient to assume that, because the 1VV'() devices comply with the same standard. theycan be exchanged in respect of temperature rise. The device used in the assembly verification mayoperate well below the temperature limit; in rts product standard, while the alternative may approachthe limit. Replacing the cool runrwlg devlOe WIth the alternative one may potentially lead to problemsIn the assembly.

    To overcome this d ~ e m m a lEe 61439 has determined in respect of temperature rise. that devicescan only be substituted wrthout repeating the design verification the altemative devioe has: til apower loss equal to or less than the original devioe; and (ii) lhe temperature rise 01 the alternativedevloe's terminals Is less than Or equal to that of the Original devloe, when bott1 are testOOIl'laccordance with the same pi"oduct standard.

    When cOfl5ldering short cirouit perlcrmanoe the difficulties are even more acute. The Interruptingcharaoteristic and performance of swrtchlf"og de\qces differ markedly between types and makes.Even If the energy let through and the out off CUrrent of two devloes IS the same, the e.tent anddirection of the emissions may vaf)'- Some devices emit gases at the top only, some emit top andbottom. some restrict the emissions with mechanical filters. while others dont

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    Clearty when considemg short Clrcurt performance It IS not a SIITlple matter of ccmpanng valuesfrom catalogues. Much mOle detal ed knowledge or both the OI'lglt1a1 and alter native devIce ISrequired,

    For the 'me being. lEG has concluded that in respec of short circuit performance. substitutionoan only be carried out wrthout new venfloation ; (0 the anginal and alternative devces are fromthe same manuracturer; and ( l ~ tt1at the deVIce man ufactu er IS prepated to cert fy tha In allrelevan respects the a emative device is equal to or better han he original device,This enables Schneioor Dectril;, for e ~ m p l e , to confirm that ' s NSX cirwit breaker canbe substituted for its NS model withou an assembty b u ~ d e r having to repeat their designverificatIOns. However, exchanging bet ....een different makes of devioe is precluded.

    Specifying an assemblyA s s e m b ~ e s are complicated and so is the standard that defines their performance, As thestandard defines all the needs and performam::e requirements of an assembly as a whole, andVvlthout any conSideration of any pattlcular stakeholder's perspeoctlve, It IS difficutt for a reader toIdentify the parts tl1at are Interest to them. To assist speoclfiers of assembl 68 , an annex has beeninclvded in I[C 6 1439- 2_ This identifies the parameters hat should be specified; he o o f a u ~ values that v . ~ 1 be assumed in the absence of any other information: and information thatmust be given in order to obta 1 the correct a5.'1embiy tor the particular app loation.

    Much of the specifiers guide In 1he annex is self eJo:planatory.However the guidance notes in Table 2 may avoid the need to delve into the standardto o d eeply

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    S mmaryandconclusionWith the ever-increasing pressures of demand for highernetwork utilisation, assembly design optimisation and morestringent safety, the changes included in the assemblystandard lEe 61439-2 are important and overdue.All assemblies that do not have a specific product standardare covered and there is no opportunity to avoid compliance.In the new standard, the methods of confirrl'llng design pelformance are praot,cal and pragmatic,reflecting the different market needs and ways in which assemblies are produced. Several alternativeand equivalent means of verifying a particular characteristic of an assembly are inchJdoo. These aredeflfled and their use restricted . Where alternatives to rype tests are used, a compensatoty approachis taken and margins are added to ensure equNalence. Overal., the standard is per10rmance based,but If'\ SOr"1'le Instances where deSign rules are used, has to be prOSCriptive.

    In due COLlrse lEG 61439-2 w il l become a European and therefore a British Standard.In the process of th is the European Standards should be listed in the Official Journalof the European Un ion. Meeting Ihis standard in full will then be the simplest route 10a 'presumpllon of comp liance ' with the EMC DireC1lve and the Low-voltage Directive.compliance Will'l bQth is, for the majority of applications, essential in order to apply theGE mark to a low -voltage assembly.

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    Technical specificationGuidance on producing an assembly specification

    E ~ r l l l l f t 8 ,houltl Do! I d ~ n t i / i 4 ! d ~ . S J .

    I!ated VQlt"!JII Un (Volt.s)

    Over vcltage category

    lInusual voltage tT'ansients,vcltage .tT' ..... t e m p < W i l ~

    I!->:ceptlol'lally high ' l r 2 l n 5 l B 1 t ~ [ h ~ shou ld dl!fu' lI! {hI!: p ~ d O l ' m 2 l n c : ~ ~ u l n ! < : l .. . {hl!:lr .5.pt!(;ltlc.!i[JOr'I.

    St;ttr. thr. nominrl l frcqurnc:y 0 ' rlrc;triort circuit current in the neutfal

    A m.antItac.turer m a ~ prO'tllde a current Ilrtlltlng device CIS tl)e II\COMIt19CirCUit torr Circuit~ U l f i ! m t ! ! l i [ to r rol!mblr'tdl!:r o.f [ ~ M . S . l ! : m b l y . If [h13 b no f a l X l ! ! p [ ~ b l ~

    to U'i.e, they should " d " " ~ aooo,dlngly in t h ~ I ' 'p"" l f.c.!IlJOn.

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    I

    C < > - o r < l i , , ~ " o n of .,,r!-d .. . t"",,lectlve ~ " ' " ino ludi"9e : l ~ m : l .short-cin:uit P l " " l ! l t ~ t ...edevice detOliils:tliItii " ' ...... ed "; Ih lQads l i ~ oto conlribute to t he 5hort-c:irc:uitcurr-ent.

    ArYi 3pt!c::lfic c.:o-.CIrdln.!llJOr'I q u . l ! ! m l ! ! n ' l S w ~ [ h . ' I ' lhl! . ! i ~ ~ b l y ~ r ' l d wt [h'43 Or down ~ t r l ! - l I m dl!vlces should be dl!f.::ulo!d In fh!. ~ s ~ l ! m ~ y 'Ilr"!tJfiCOlition

    The 5pec,fier 5hOlJld ,,,elude in their specification detail, f anv large1oiKl5, .. g , motOf5, .,h'ch miI'Y, in th e event 1 a lault, add t t .. . 5hOftClrc.utt current from th . 5upply Th e m a n u t ~ c t u r e r ",II then take thIS illt o n i o ~ 1 " ' I ' ~ o t (IIooiliod otheoftse)

    He5hunee te> cotl'Q51on

    ....

    B w I ~ < : protr.c:tlon

    OutdoOf': IP 1(l~ o o r -

    St.ndMd

    Standard

    Brlo;i

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    Ambient ai r te mpet'"i! t ....... - lower m i t Indoor -5OUtdoor -2 5I\mblent ai r te mpe!'il t ure - up per Ilm ft 40 'CAmbient ollar l'em p.er.,t LM'i!- - daily 35 liel N S l J . rnaxim LJl'nM.Dimum r r!! la ti\ll! h...-nicity lndoor 'ij) 40 lie

    Outdoor: 1000j, 01 25 c!>""'ution degree

    Au lru" .. s 2000m

    EMC erJvi ronm!:!nt

    Special 5eMce oondl ions

    28

    S e I I - e ~ p I a o a t O l Y , ,"'-e the cO

    t " " ' P O ~ r y conducltvlty "",,-""t lon Is [ b .. .xp

    4 C.cntlrlUClU!I: I;Qnductivl ty D(;l;Ur!l: d ue to d u c t ~ d u ~ . rain or at ........'l'ol'9t conditions

    (} r industria l app licabons u t i n g degree 3 is the default cndibonWhere a -dlf le ,ent I""e l 01 pollut ion ISantic ipated, appropriate -detailsshould be g l" " " ' " the a s s e l 1 ' l ~ y specificatIOn.Th . """,,,I ~ h o u l d ..ly " [ 10"" to.d ...,""'"200cm.A. ..... r.m b!1C"';'I:i CAn emit ;;;!nd 'thr m u ~ br Il1'IIl'IIU"'Ir to C1cfern ;:J1electromagnetic dlsturban""s 1[1;; def i""" (l>I(} (ateg""ie5. ) &rvirQf1ll\'Oeflt A - relates to low-voltage non-pubhc or indust ....... WOrks' locat ions, .nsrallatlot15 Itlclu

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    \.

    MOIl:imum Q v e . dimr!nsionsilOO ..nd weight

    IlIrectfon(s) of ".:te.n.aI condUC'lors

    E1iter ... pha .. cond",tg r.cross 6 4 ! C - t and terminations

    E l < t ~ . t \ I I l PE:. N. PEN .ondu"t.ors d . of tr an..., .. (0.11. f" 'klilt.< r " " ~ )

    --

    -Star>dardSt.ndard

    ---

    T h ~ Ot..ndbrd o < I ~ n t l r l M ............ 1g the ..recog.. ed .rrangements.

    Tht! ml!ljorit)' or ass@mblil!s . 8 ~ stbicionary. h ~ . thl! l i ~ t ! I ' .;I\Ould . a ~ t : ~ r whl!-'lhl!r [hl!-&!.I!:mbl), [0 bI!- ~ ( l I t l o n a r y Qr Iii ~ m l ! ! ~ por[lI1:Ji1!. _If thrm .. .r (J r wr.19hr ri:!!t.trl(;OOno; for fnr. ;:t,,'I:;n mbiy thC!!m ..hou'=lbor. d r : t ~ r d in thr. :o:;prr;ificaticnThe speCifier should detail conductor t.",es. e g. cable Of' busbarIn order to ensu,e t ... e"te"",1conductorS can be accommodated th e",eofler shoold

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