FULLY INSULATED & ARC PROOF

THE ULTIMATE IN SAFETY & RELIABILITY

LOW VOLTAGE SWITCHGEAR AND CONTROL GEAR ASSEMBLIES

Modular Switchgear and Controlgear System

The PI INSULSAFE is fully insulated and arc proof, making it ideal for applications where

continuity of service is of critical importance and safety is paramount.

The PI INSULSAFE brings a new level of safety and reliability to low voltage motor control and power distribution.

Total insulation eliminates the risk of busbar arcing faults and protects against accidental contact with live parts.

The insertion and removal of plug-in motor starters and feeders can be carried out safely with the busbars energised. Even changes in configuration can be completed safely without the need to shut down.

INTRODUCTION

The standard horizontal busbar system is rated at 1400, 2400 or 3000 Amps. Heavy duty busbars rated at 4000 Amps are available to special order. Neutral bars are either half size or full size, depending on specification.

Dropper busbars are rated at 630 Amps for standard flat bar and 1000 Amps for heavy duty “L” shaped bar, with higher ratings available to special order. Dropper neutral bars are generally full size.

All dropper busbars have a short-circuit strength of at least 80kA RMS with 176kA peak.

BUSBAR SYSTEM

Vertical phase and neutral busbars are individually enclosed in a molded support structure made from glass reinforced nylon. Horizontal phase and neutral busbars are individually enclosed in phase coloured, molded nylon covers and phase coloured extruded polycarbonate.

The insulation completely surrounds the live conductors and alone is capable of withstanding the dielectric test voltage of the assembly. This insulation is in addition to clearances in air and other insulating media.

All insulating material is fire retardant and self extinguishing.

BUSBAR INSULATION

Icw Ipk Test Report

MAIN BUSBAR 1400 A 80 kA, 1 sec 176 kA TCA 102247

MAIN BUSBAR 2400 A 80 kA, 3 sec 176 kA TCA 102247

MAIN BUSBAR 3000 A 80 kA, 3 sec 176 kA TCA 102247

MAIN BUSBAR 4000 A 80 kA, 3 sec 176 kA TCA 102740

MAIN BUSBAR 1400 A 100 kA, 1 sec 220 kA TCA 102742

MAIN BUSBAR 2400 A 100 kA, 3 sec 220 kA TCA 102742

MAIN BUSBAR 3000 A 100 kA, 3 sec 220 kA TCA 102742

MAIN BUSBAR 4000 A 100 kA, 3 sec 220 kA TCA 102740

DROPPERS 630 A 80 kA, 0.2 sec 176 kA TCA 102740

DROPPERS 1000 A 80 kA, 1 sec 176 kA TCA 102740

SHORT CIRCUIT STRENGTH

The PI INSULSAFE is constructed from standardised sheetmetal components to form a strong, uniform line-up suitable for low voltage motor control and power distribution.

All structural parts, including doors and covers are manufactured from 2mm steel.

Base plinths are made from 3mm steel.

Interconnecting structural components are located with a dimple on dimple arrangement to add strength and ensure a perfect fit. Doors and covers are folded with a double return on all edges for extra strength and rigidity.

Sheetmetal components are powder coated to a DFT of approximately 80 microns.

STRUCTURE & FINISH

ColourS are aS followS:

Base plinth Black

Structural frame Metallic Charcoal

Internal parts White

Doors and covers Client’s choice (depending on availability)

The PI INSULSAFE is a fully modular system which allows customised switchboards and motor control centres to be manufactured quickly and cost effectively using standard components. The same basic structure and standard components can be configured to accommodate an endless variety of equipment, such as:

• Motor starters• Feeders• VVVF drives• Programmable logic control• Control marshalling• SCADA equipment• 1000V mining switchgear & control gear

MODULAR DESIGN

A representative selection of functional units has been tested to AS/NZS 3439.1 2002 Annex ZD at various prospective fault levels up to 100 kA. More than twenty tests were performed and in every case, the forces were successfully controlled and contained.

ARC FAULT CONTAINMENT

Today’s fast-track projects sometimes require changes to the motor control centre or switchboard layout during the late stages of manufacture, or even on site during commissioning. Quick and easy reconfiguration is delivered by the PI INSULSAFE through its completely modular design with interchangeable components. Even while in service, simple reconfigurations can be done in complete safety.

The PI INSULSAFE has been designed to accept virtually any type of low voltage switchgear and control gear, including intelligent motor control systems, so client equipment preferences can easily be accommodated.

FLEXIBILITY

Functional Unit Icp Test Report

Schneider 11kW DOL 50 kA TCA 102741

Schneider 37kW DOL 50 kA TCA 102741

Schneider 55kW DOL 50 kA TCA 102741

Schneider 110kW DOL 50 kA TCA 102741

Schneider 11kW DOL 100 kA TCA 102741

Schneider 37kW DOL 100 kA TCA 102741

Schneider 55kW DOL 100 kA TCA 102741

Schneider 110kW DOL 100 kA TCA 102741

Schneider 250A FDR 65 kA TCA 102741

Schneider 400A FDR 65 kA TCA 102741

NHP 11kW DOL 65 kA TCA 102741

NHP 37kW DOL 65 kA TCA 102741

NHP 55kW DOL 65 kA TCA 102741

NHP 110kW DOL 65 kA TCA 102741

NHP 11kW DOL 100 kA TCA 102741

NHP 37kW DOL 100 kA TCA 102741

NHP 55kW DOL 100 kA TCA 102741

NHP 110kW DOL 100 kA TCA 102741

TERASAKI 250A FDR 80 kA TCA 102741

TERASAKI 400A FDR 80 kA TCA 102741

The relatively small number of parts, ease of assembly and compact size, makes the PI INSULSAFE extremely cost effective in applications where safety, continuity of service and quality are major considerations.

ECONOMY

The PI INSULSAFE has the smallest footprint of any MCC available in Australia.

A double sided (back to back) motor control centre is just 650mm deep. It can accommodate up to 60 x form 4 starters per square metre of floor area, while maintaining generous cable access and termination space.

Cable access is top, bottom or both.

Full height cable zones are 300mm wide. Extra wide cable zones are available as an option.

Generous cross wiring spaces are provided at top and bottom, front and rear.

COMPACT

TECHNICAL DATA

Rated Voltage 1000 V

Rated Frequency 50/60 Hz

InsulationPower Frequency Withstand

Voltage3.5 KV

Impulse Withstand Voltage 12kV

Number of Poles 3 or 4 Pole

Degree of Protection

Indoor (Standard) IP 4x

Indoor (Enhanced) IP 53

Outdoor IP 56

Internal > IP 2X

Form of Separation Form 4 (a or b)

Rated Current

Main Busbars 1400 A

2400 A

3000 A

4000 A

Droppers (Standard) 630 A

Droppers (HD) 1000 A

Branch Busbars (Special) < 4000 A

Rated Short-Time Current

Main Busbars (Standard) 80 kA, 3 sec (176 kA Peak)

Main Busbars (HD) 100 kA, 3 sec (220 kA Peak)

Droppers (Standard) 80 kA, 0.2 sec (176 kA Peak)

Droppers (HD) 80 kA, 1 sec (176 kA Peak)

Branch Busbars (Special) < 100 kA, 3 sec (220 kA Peak)

ARC Fault Containment to AS/NZS 3439.1 : 2002 Annex ZD

Schneider 11kW DOL Starter 50 kA prospective

Schneider 37kW DOL Starter 50 kA prospective

Schneider 55kW DOL Starter 50 kA prospective

Schneider 110kW DOL Starter 50 kA prospective

Schneider 250 A FDR 65 kA prospective

Schneider 400 A FDR 65 kA prospective

NHP 11kW DOL Starter 65 kA prospective

NHP 37kW DOL Starter 65 kA prospective

NHP 55kW DOL Starter 65 kA prospective

NHP 110kW DOL Starter 65 kA prospective

Terasaki 250 A FDR 80 kA prospective

Terasaki 400 A FDR 80 kA prospective

Schneider 11kW DOL Starter 100 kA prospective

Schneider 37kW DOL Starter 100 kA prospective

Schneider 55kW DOL Starter 100 kA prospective

Schneider 110kW DOL Starter 100 kA prospective

NHP 11kW DOL Starter 100 kA prospective

NHP 37kW DOL Starter 100 kA prospective

NHP 55kW DOL Starter 100 kA prospective

NHP 110kW DOL Starter 100 kA prospective

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PLUMMERS INDUSTRIES PTY LTD

The PI Insulsafe Modular Switchgear and Controlgear system is designed and manufactured by: