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Panel Savings using Modular Panel Savings using Modular Technology and Bus Systems Technology and Bus Systems Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 1

Reducing electrical enclosure panels

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Electrical Enclosure panels

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Page 1: Reducing electrical enclosure panels

Panel Savings using Modular Panel Savings using Modular Technology and Bus SystemsTechnology and Bus Systems

Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 1

Page 2: Reducing electrical enclosure panels

Rittal OverviewRittal Overview• World’s Largest Manufacturer ofWorld s Largest Manufacturer of

Enclosures and Climate Control- >$2.1 Billion- > 80 Countries (250 Stocking Locations Worldwide)- > Manufacture 1 million free standing enclosures, 2.3 million

ll t l d 200 000 i ditiwall mount enclosures, and 200,000 air conditioners per year

• Industry Leader in Innovation- 250 to 500 New Products per Year- Pioneered many Innovations

Panel Savings with New Enclosure Technology B. Downing/Marketing/2010 2

Page 3: Reducing electrical enclosure panels

Rittal InnovationsRittal Innovations• Foamed-in-place robotically-applied gasketing• Easily removable doors/interchangeable doors• Modular free-standing industrial enclosures• Unibody enclosure design• E-coat dip-bath primer process• Full usable width bus bar• Articulated arm systemsy• R-134a refrigerant for a/c systems; RiNano; Condensate Evap.• Industrial PC enclosures• Zinc mounting panelsg p• IT Enclosures (Kiosk Systems)• Industrial Workstations• IP69K Enclosures (high pressure/high temp. hose down)Panel Savings with New Enclosure Technology 3

IP69K Enclosures (high pressure/high temp. hose down)

Page 4: Reducing electrical enclosure panels

What is a Modular Enclosure?What is a Modular Enclosure?

• A Frame-based design for free-standing cabinets, allowing for additional sections (doors) to be added side to side, front to rear or on top (“baying”, “suiting” or “joining”).M i t i NEMA i t it ( t ti ti )• Maintains NEMA integrity (protection rating)

• Offers multiple equipment mounting options (d th dj t bl l ti l l(depth adjustable panel; partial panels; chassis bars; 19” racks; door mounting)

Panel Savings with New Enclosure Technology 4

Page 5: Reducing electrical enclosure panels

Modular vs. Traditional design

Traditional

Modular Frame-based Traditional

welded designs (OGB)

designs –Strength from roll formed & welded f(OGB) frame

- vs -All surfaces are load bearing-load bearingstrength from gauge of steel

Panel Savings with New Enclosure Technology 5

Page 6: Reducing electrical enclosure panels

Enclosure FunctionsEnclosure Functions

What are the (3) basic functions of anWhat are the (3) basic functions of an enclosure (why would you buy one)?

Panel Savings with New Enclosure Technology 6

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Enclosure FunctionsEnclosure FunctionsFunction OGB ModularPlace to put White panel, Zinc panel, depthyour stuff fixed to rear wall adjustable; partial (equipment) panels (F-R, S-S); 19”( q p ) p ( , );

swing frames; chassisbars; DIN rail; mounton 360° (incl. Door)on 360 (incl. Door)

Protection/security N3R,12, 4, 4X N3R*,12, 4*, 4X* (also IP)

Aesthetics Old look (WWII) High-Tech (hidden(piano hinge; clamps) hinges, no clamps)

*Rittal only

Panel Savings with New Enclosure Technology 7

Rittal only

Page 8: Reducing electrical enclosure panels

Benefits of Enclosure FunctionsE lEnclosures

Over and beyond a very basic welded-box,

modular enclosures provide:

Much greater range of dimensions in H x W x D

Comprehensive, quick-install accessories

Multiple mounting options within the

same platform

Ease of wiring due to removable skins & doors

Unique configurations with standard inventory

Panel Savings with New Enclosure Technology 8

Page 9: Reducing electrical enclosure panels

Panel Size

Most panel designers only considerp g ythe mounting panel when laying out theirdesign. Thus, enclosure size isdictated by panel size.dictated by panel size.

A Modular, frame-based system canoffer up to 30% more panel space inoffer up to 30% more panel space inan equivalent size enclosure vs. awelded box due to the latter’s largeflange support areas (Main panelflange support areas. (Main panelonly- not counting other options).

Panel Savings with New Enclosure Technology 9

Page 10: Reducing electrical enclosure panels

Panel Comparison (Free Standing)Panel Comparison (Free Standing)(Sq. Inches)

Free Standing OGB: TS8:Free Standing OGB: TS8:90x36x24= 78x32 (2496) 86x39x24= 83x35 (2935)

or 79x39x24= 75x35 (2625)

60x24x18= 48x20 (960) 63x24x20= 59x20 (1180)or 55x24x20= 51x20 (1020)or 55x24x20= 51x20 (1020)

72x60x16= 68x56 (3808) 71x63x16= 67x59 (3953)( ) ( )

84x40x18= 72x33.7(2426) 79x39x20= 75x35 (2625)

10

Page 11: Reducing electrical enclosure panels

Assembly Advantages

Door Removal ~ 30 sec (usuallyDoor Removal ~ 30 sec. (usuallynot done on piano hinge box dueto time & difficulty) – avoidshaving to dodge/deal with doorsIn the way of installers.

oror

Panel Savings with New Enclosure Technology 11

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Equipment Mounting Options

Many more options are availablewith Modular Enclosures:with Modular Enclosures:

• Partial panels in x-y-z

• Chassis bar for direct or DINRail mounting (components or wireway)

• Load capacity to 500 lbs. Per oad capac ty to 500 bs echassis bar

Panel Savings with New Enclosure Technology 12

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Equipment Mounting Options

Many more options are availableMany more options are availablewith Modular Enclosures:

Door mounting for devices &Wireway via standard accessories(no drilling or welding)

Panel Savings with New Enclosure Technology 13

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7. Aesthetics…Aesthetics

What kind of impression do you want to make?

Panel Savings with New Enclosure Technology 14

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Common Misperceptions –p pModular Systems

M d l t t t (thi• Modular systems are not as strong (thinner gauge steel) as the traditional style (OGB)

– The TS8 holds 3000 lbs., the same as a fully equipped F150 truck

• Modular systems are more expensive– They are overall more cost competitive than OGB

• Modular systems require a lot of assembly• Modular systems require a lot of assembly work (“erector set”)

– Only the assembly of the side walls is needed to provide a complete enclosureenclosure

• Must order a bunch of part numbers– Only 2 part numbers are needed to provide a complete enclosure, the same

as OGB

Panel Savings with New Enclosure Technology 15

as OGB

Page 16: Reducing electrical enclosure panels

Technological ImprovementsTechnological Improvements

• Most designers have switched to current (2000’s) control technology in PLC’s, Starters, Drives, etc.

• Yet they package these products in 1940’s-1950’s enclosure designs (end product looks like oldenclosure designs (end product looks like old technology)

• Most are unaware of improvements in enclosure designs unless they study the global market– Most enclosure manufacturers don’t have the

technology (esp local fab shops)technology (esp. local fab shops)– Those that do (other than Rittal) don’t lead with it;

they lead with OGBPanel Savings with New Enclosure Technology 16

y

Page 17: Reducing electrical enclosure panels

Technological ImprovementsTechnological Improvements

M d l i d t i l t ff• Modular industrial systems offer:– Multiple mounting options for components

More flexibility in system designs; lower– More flexibility in system designs; lower “Use” costs (thus lower Total cost)

– More flexibility in incorporating jobMore flexibility in incorporating job changes

– Less need for customization (can use pre-(engineered parts)

– Greatly improved aesthetics

Panel Savings with New Enclosure Technology 17

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True Cost AnalysisTrue Cost Analysis(Modular Free-Standing vs. OGB)

P h P i U C t T C tPurchase Price + Use Costs = True Cost-Enclosure & accessories -Time & Space-oriented

tasks: Door removal &tasks: Door removal &replacement, Panel removal& replacement, grounding efforts,ease of access & movement inease of access & movement inshop, time on shop floor (throughput),product mounting options, weight/freightfactors, ease of cutouts, flexibilityyof job changes, range of accessories,ease of installation of accessories,ease of working/wiring inside.

Panel Savings with New Enclosure Technology 18

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Use Cost: Door removal (f )Use Cost: Door removal (free standing)

• OGB: 30-45 minutes on/off, so most leave door on. Cutouts done on door while enclosure is on its back.

• Shavings go in enclosure, require cleaningC t b ki i l t ti• Cannot be working in enclosure at same time

• TS8: Door removal 30 sec ; cutouts at bench• TS8: Door removal 30 sec.; cutouts at bench• No cleaning in enclosure; can also work in enclosure

while door is being cut

• No dodging, moving or working around doors.• Similar for Wall Mount doors vs. OGBPanel Savings with New Enclosure Technology 19

Page 20: Reducing electrical enclosure panels

Use Cost: Panel Insertion (free standing)

• OGB: Use crane or fork lift to put enclosure on it’s back, then drop panel in over studs, then raise enclosure back up (Takes up additional spaceenclosure back up. (Takes up additional space –sometimes in aisle). Panel in fixed location.

• Approximately 10 min. / enclosure• Usually staged due to limited crane availability• 10 enclosures = 100 minutes total

• TS8: 1-2 minutes / enclosure; 10-20 minutes total for 10 enclosures- 80/90 min. savingsfor 10 enclosures 80/90 min. savings

• No added space required (for laying down)• Panel depth adjustable in 1” increments

Panel Savings with New Enclosure Technology 20

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Use Cost: Grounding (Earthing)Use Cost: Grounding (Earthing)

• White panel: Drive ground screw; test for ground; if no ground scrape to bare metal;ground; if no ground, scrape to bare metal; then test again for ground; touch up.

• Potentially 4 labor steps per panel• Potentially 4 labor steps per panel• 50 panels / 200 labor steps /100+ minutes

possible (vs zinc panels – no added time)possible (vs. zinc panels no added time)

Panel Savings with New Enclosure Technology 21

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Use Cost: Freight (f t di )Use Cost: Freight (free standing)

• OGB 2-door: 300 lbs. (136 kg.) heavier thanOGB 2 door: 300 lbs. (136 kg.) heavier than TS8 2-door (Single door to 185 lbs. heavier)

• 10 Enclosures = 3000 lbs. (1360 kg.) savings on freight / shippingg g

Panel Savings with New Enclosure Technology 22

Page 23: Reducing electrical enclosure panels

Weight ComparisonsWeight Comparisons (Freight; ease of handling)

WEIGHT COMPARISONS (lbs.)- FREE STANDING CABINETS

OGB TS8

SINGLE DOORSize Enclosure Panel Total Size Enclosure * Sidewalls (Pr) Total %TS to OGB Savings/Cab.

72x25x18 250 45 295 71x24x20 206 24 230 0.78 65

72x31x24 290 57 347 71x32x24 265 26 291 0.84 56

90x24x20 313 56 369 87x24x24 249 35 284 0.77 85

90x36x24 440 88 528 87x32x24 307 35 342 0.65 186

DOUBLE DOORDOUBLE DOOR

72x48x18 575 119 694 71x47x20 382 24 406 0.59 288

72x48x24 600 119 719 71x47x24 396 26 422 0.59 297

90x48x20 650 144 794 87x47x24 458 35 493 0.62 301

FMD (1 DOOR)

84x40x18 642* - 642 79x40x20 346 28 374 0.58 268

Note: (*)= Weight includes mounting panel. If Plinth is necessary, weights would be 8 to 12 lbs.(47x24= 12 lbs.) for complete Plinth.

Panel Savings with New Enclosure Technology 23

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Use Cost: Adding CutoutsUse Cost: Adding Cutouts• OGB: Cutouts done while enclosure is standing or on

it b kits back • Shavings go in box, requires cleaning• Cutouts done wrong must be welded overCutouts done wrong must be welded over• Cannot work in enclosure at same time• Cutting 10 or 12 ga. Steel – hard on tools

• TS8: Cutting can be done at work bench – no internal cleaning. Errors easily fixed.cleaning. Errors easily fixed.

• Cutting 16 or 14 ga. Steel- easier on tools• Can work in enclosure while cutouts are done on bench

Panel Savings with New Enclosure Technology

24

Page 25: Reducing electrical enclosure panels

Consider this…Cutouts / Modifications

When the installer cuts into the panel, will metal filings fall on my electrical equipment?

How easy is it to do the cutouts?

How do I ensure that the equipment is protected during installation?installation?

Do I have enough room inside the enclosure for wire bending (per NEC), wire bundles, termination points, tie-off points and spares?

Is there enough room around my enclosure for the installer to work?

Vs

Panel Savings with New Enclosure Technology 25

Page 26: Reducing electrical enclosure panels

8. Cable Cutouts / Modifications, cont.and M tManagement

How are panel builders and field installers going to work p g gwith the enclosure? This impacts how components are installed and how the enclosure is modified, not only inside but outside the enclosureinside but outside the enclosure.

Which method saves time and money, is safer and ensures greater quality?ensures greater quality?

or

Panel Savings with New Enclosure Technology 26

Page 27: Reducing electrical enclosure panels

Use Cost: Job Changes (f )Use Cost: Job Changes (free standing)

• OGB: If panel is full and job requires• OGB: If panel is full and job requires additional equipment installed, a new and larger enclosure is usually required; removal g y qand reinstallation of product follows.

• TS8: Optional panels, chassis bars, 19” rack possible for new equipment mounting

• Worst case: Add new section (baying) for new• Worst case: Add new section (baying) for new equipment. No rework of product.

Panel Savings with New Enclosure Technology 27

Page 28: Reducing electrical enclosure panels

Modular System vs. OGBISSUE MODULAR OGB ADVANTAGE

Strength From closed frame From heavy walls Lighter system; easier(Rittal; open for comp.) to handle; lower freight( ; p p ) ; g

Panel insert Slide out on feet Put on back; lift in Easier in/out; less use(in vertical position) in/out with crane cost; easier on paint

Panel size Full Ht /Width Partial coverage ~15% more spacePanel size Full Ht./Width Partial coverage ~15% more space

Door removal Captive hinges; on/ Piano hinge; 45min- Easy to work on; allows off in 20 seconds 1hr. On/off access (esp. multidoor)

Sid ll R bl Fi d E t i idSidewalls Removable Fixed Easy access to inside;ease of cutouts

Roof, Rear wall Removable Fixed “ “ “

Suiting Easily joined N/A Accommodate jobchanges/add’l. equip.

Weight (2-Dr.) 300 lbs. Less Heavy steel Less freight; easier to move

Panel Savings with New Enclosure Technology 28

Page 29: Reducing electrical enclosure panels

Modular System vs. OGBISSUE MODULAR OGB ADVANTAGE

Mounting on Panels, door bars, None More mountingInside of doors DIN rail surface; flexibilityInside of doors DIN rail surface; flexibility

Mounting panel Zinc plated; C-fold Painted steel, Stronger; immediateDesign (Rittal) L-fold ground/no scraping

Internal mounting Bars; panels; DIN None More mountingOptions rail; swing frames surface; flexibility

Gasketing Foamed in place Strip tape Better seal; memory( )(Rittal) retention

Adding cutouts At workbench, on In place, on 12/ Easier to cut; less wear16/14 ga. Steel 10 ga. Steel on tools; no shavings

Paint Finish E-Coat/Powder Coat Powder Coat Longer lasting,(Rittal) scratch-resistant

Accessories Very wide range Limited Flexibility/less custom

Panel Savings with New Enclosure Technology 29

Page 30: Reducing electrical enclosure panels

Total Cost – MOD vs. OGB Summary

Issue MOD OGBIssue MOD OGBGlobal SupportPanel SizeDoors On/OffCutoutsPanel In/OutPanel AdjustmentGroundingWeight/FreightAdd'l. Mounting spaceWi iWiring accessJob change flexibilityRange of accessoriesAesthetics

Panel Savings with New Enclosure Technology 30

Aesthetics

Page 31: Reducing electrical enclosure panels

Modular Enclosures –Trending Factors

• Globalization– Mergers/Acquisitions (US/EU/Asian)Mergers/Acquisitions (US/EU/Asian)– Modular already standard / multiple countries– Certifications (UL, CE, TUV, DIN, IEC, etc.)– No local Fab/ OGB support– No local Fab/ OGB support

• Standardization- Ability to move equipment globally & match up- No local Fab/ OGB meets all standards

• Smaller Footprint- Plant Floor / Real Estate Savings / Lower Cost- Plant Floor / Real Estate Savings / Lower Cost

• Flexibility- Design Changes/ Time to Market/ Plant Floor Appearance

Panel Savings with New Enclosure Technology 31

Page 32: Reducing electrical enclosure panels

OEMUsers and Specifiers of Modular Enclosures

OEM

Panel Savings with New Enclosure Technology 32

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Sample Application: Heavy Industry

Panel Savings with New Enclosure Technology 33

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Sample Application: Process Control

Panel Savings with New Enclosure Technology 34

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Sample Application: Drives and Controls

Panel Savings with New Enclosure Technology 35

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Small Bus Systems

•May be used in Modular or non-Modular enclosures

•Offer numerous advantages over traditional wiring and mounting methods

•Cost savings can exceed 25% for a system•Cost savings can exceed 25% for a system

Panel Savings with New Enclosure Technology 36

Page 37: Reducing electrical enclosure panels

Definition of a Busbar System

Solid copper bars that act as a conductor of electricity.

•Interlocking bars for various lengths/configurations

•Standardized power connections or taps

•Standardized connection and mounting of electrical components.

•May be enclosed or exposed in some cases

Modular approach to traditional power distribution

Panel Savings with New Enclosure Technology 37

Page 38: Reducing electrical enclosure panels

Benefits of using a busbar system

Reduction in enclosure or mounting panel size

•Elimination of distribution blocks

•Elimination of large parallel cable runs with large bend radii

•Elimination of line-side wire duct

•Use of smaller internationally accepted components

Panel Savings with New Enclosure Technology 38

Page 39: Reducing electrical enclosure panels

Benefits of using a busbar system

Reduction in assembly time

•Reduction in number of component mounting holes that must be drilled and tapped in mpl

•Elimination of line-side wiring (stripping, labeling and routing)

•Bus-mounted adaptors allow for quick power taps and mounting of components (pre-assebly)mounting of components (pre-assebly).

•Simplified future expansion options

•Elimination of having to cut, bend or drill custom busbar

Panel Savings with New Enclosure Technology 39

Page 40: Reducing electrical enclosure panels

What is an ideal busbar application?

Multiple power distribution blocks

Large parallel wire runs

Lots of grounding

Motor starters (as few as 4)

Lots of three-phase fusing

Multiple circuit breakersMultiple circuit breakers

High amperage distribution

•Drives

•Switchgear

Panel Savings with New Enclosure Technology 40

Page 41: Reducing electrical enclosure panels

Multiple power distribution blocks

High cost

Not always touch safe

Labor intensive

Wire bend space

Panel space

Wire size constraintsWire size constraints

Limited or no future expansion

Panel Savings with New Enclosure Technology 41

Page 42: Reducing electrical enclosure panels

Multiple power distribution blocks

Mounting holes – locate, drill and tap

Wiring – cut, strip, route, i.d., terminate (line/load)

Wire duct – mounting, bending space

4-5” Wire Duct

Panel Savings with New Enclosure Technology 42

Page 43: Reducing electrical enclosure panels

Multiple power distribution blocks – Using busbar as a distribution block

Install busbar system – 4 screws for complete system

Main attaches to bus with single, flexible busbar feed

Numerous tap options along bus for any wire size

Future Expansion

Touch safe

Ri-STARTER Ri-STARTER

800A 1600A250A3x 63A

Panel Savings with New Enclosure Technology 43

800A 1600A250A3x 63A

Page 44: Reducing electrical enclosure panels

Large parallel wire runs

Cable routing and labeling

Wire duct

Lugs

Multiple terminations

Wire bend space

Panel Savings with New Enclosure Technology 44

Page 45: Reducing electrical enclosure panels

Large parallel wire runs – Using busbar and flexible busbar in place of large parallel cables

Busbar system replaces parallel cables and blocks

Flexible busbar for feeding large loads without the needs for lugs

Wire bending space reduced with less terminations

1600A360A 1600AMain CBSystem

400A CB’s

250ACB’s

Panel Savings with New Enclosure Technology 45

Page 46: Reducing electrical enclosure panels

Lots of Grounding

Mount load center bus or terminal blocks

Attach individual panel grounds

Daisychain panel grounds and house ground

PanelGrounds

PanelGrounds

PanelGrounds

House Ground

Panel Savings with New Enclosure Technology 46

Page 47: Reducing electrical enclosure panels

Lots of Grounding – Using a 1-pole busbar system

Continuous ground conductor

Easy clamping of wires with conductor connection clamps

No drilling or bolting... even when splicing

00 - 350 MCM 20 - 12 AWGNo-DrillSplice kitsSplice kits(if needed)

1 00 AWGPanel Savings with New Enclosure Technology 47

1 - 00 AWG

Page 48: Reducing electrical enclosure panels

Motor Starters

Locate and mount DIN rail (Worse for panel mounted devices)

Cut, route, strip, i.d., terminate L1/L2/L3

Line-side wire duct

Distribution2 4” Wire DuctBlock!

2-4 Wire Duct

Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER

Panel Savings with New Enclosure Technology 48

Page 49: Reducing electrical enclosure panels

Motor Starters – Using a busbar system

Single power feed for complete system

Line-side adaptor wires stripped and ready for device

Easy expansion and touch safe

Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTER Ri-STARTERRi-STARTER

Panel Savings with New Enclosure Technology 49

Page 50: Reducing electrical enclosure panels

Ways to reduce your system cost

•Reduction of...

•Engineering and design time

•Due to pre-engineered busbar systems

•Due to pre-engineered enclosures

•Quantity of enclosures or enclosure size

•Due to elimination of distribution blocks•Due to elimination of distribution blocks

•Due to elimination of line-side wiring & wiring duct

•Due to elimination of separate DIN rail

•Due to elimination of large parallel cable runs

•Due to elimination of multiple grounding systems

Panel Savings with New Enclosure Technology 50

Page 51: Reducing electrical enclosure panels

Ways to reduce your system cost

Reduction of...

•Integration time

•Due to reduction in drilled tapped mouting holes

•Due to elimination of line side wiring

•Due to quick mounting and connection of components

•Due to quick interconnection or power drops

•Due to pre-engineered switchgear connection kits

•Required testing and certificationRequired testing and certification

•SCCR pre-determined (holder spacing)

•Global certifications – UL, cUL, CE, etc...

Panel Savings with New Enclosure Technology 51

Page 52: Reducing electrical enclosure panels

Ways to reduce your system cost

Reduction of...

•Maintainence and repair time

•Easier to trouble shoot, no tracing line-side wires

•Quick change bus-mounted components

•Availability of replacment parts worldwide

Total System Savings:

25-35% dependingp g

on labor rates

Panel Savings with New Enclosure Technology 52

Page 53: Reducing electrical enclosure panels

Application Photos – MCCB’s, Flexible Busbar

Panel Savings with New Enclosure Technology 53

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Application Photos – Miniature CBs, Contactors

Panel Savings with New Enclosure Technology 54

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Application Photos – MCCBs, MSP

Panel Savings with New Enclosure Technology 55

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Application Photos – MCCBs, Fusing and Flexible Busbar

Panel Savings with New Enclosure Technology 56

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SummaryModular Advantages•Larger panels

Bus System Advantages•Labor savings (less drilling,

i i )•Flexibility in mounting

•Easier wiring access

wiring)

•Space savings (no line side wireway, smaller bend radius)

•Job change flexibility •Baying S-S, F-R

•Lower Use/Assembly

•Eliminate components (DIN rail, wireway, lugs, distribution blocks)•Lower Use/Assembly

costs•Panel insertion/removal

•Panel depth adjustability

blocks)

•Easier grounding solutions

•Job change flexibility•Panel depth adjustability

•Cutouts

•Door removal

•Freight etc

g y

•Future expansion easy

Panel Savings with New Enclosure Technology 57

•Freight, etc.