Segregation of switchgear

Segregation of switchgear
There are several forms of segregation for Switchboards , Form 1 up to Form 4. All of them have their
justification in applications. However, ABB Low Voltage Systems has chosen to stay in the high end with their
technical solutions.
Some MCC users are of the understanding that if they purchase Type tested segregated switchgear to Form 3
or Form 4 to AS/NZS 3439.1:2002 that this provides greater safety and protection and specifying Form 3/4 will
protect the operators against an internal arcing fault.

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Article author:

David Stonebridge

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General information:
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While Form 3/4 segregation does provide increased safety in that it provides protection against contact with
any live components or busbars in against compartments it will not necessarily provide protection against an
internal arc fault. Segregation maybe required to achieving arc fault containment, however the additional metal
barriers can increase the risk of an arcing fault being initiated. There is probable less risk in having an arcing
fault initiated in a big non-segregated panel compared to a small compartment surrounded by metal. Similarly a
big non-segregated panel has a better chance of dissipating the ionised gas and pressure.
Internal Separation
The Internal separation is subject to agreement between the manufacturer and the user refers AS/NZS
3439.1:2002 clause 7.7 Assemblies are divided by means of barriers (metallic or non-metallic) into separate
compartments.
Form 1. There is no internal separation. The busbars are in the same compartment as the functional units.
Form 2. Separation of the busbars to the functional units.
Form 3. Separation of the busbars to the functional units, separation of the functional units from each other
and separation between the outgoing terminals and the functional units.
Form 4. Separation of the busbars to the functional units, separation of the functional units from each other
and separation of the outgoing terminals with the functional units and of another functional unit.
The degree of separation of the outgoing terminals is further defined by the addition of sub criteria a and b. The
above broad definitions are basically the same in IEC 60439.1 and BS EN 60439-1 the difference comes in
AS/NZS 3439.1:2002 Annex ZF with the further sub criteria i and h for the materials used to separate the
outgoing terminals.
ABB MNS Switchgear
Generally ABB do not manufacture Form 1 switchgear. Form 2, 3 and 4 are available. Standard MNS
withdrawable functional units comply with Form 4bih and Standard MNS Incomer ACB cubicles comply with
Form 4a
MNS Main Busbar System
The horizontal busbars are located within a separate bus bar compartment at the rear of the switchgear
complying with Form 2, 3 and 4. MNS has the facility of utilising two bus bar systems, located in the upper and
lower section of this compartment. The busbar system has a unique design utilising bolts coated with ESLOK
(a Loctite type compound), conical spring washers and threaded plates once tensioned utilising a torque
wrench, and the busbar system is certified maintenance free. Once installed there is no need to access this
compartment.

The rear cover has been removed. The main busbars are fully segregated from the distribution busbars making it impossible for a fault to
transfer to the main bus from the distribution bus of functional units.

The top bus cover has been removed. The distribution bars mounted within the multifunction wall. The distribution bars are phase
segregated.

The MNS withdrawable Functional Units

The functional units are located in the own Form 3/4 compartment and can be removed for safe inspection and
maintenance. There is no requirement to work in live compartments.

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Segregation of switchgear

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MNS 8E Starter module

The MNS cable compartment and outgoing motor terminal comply with Form 4bih, and are suitable for
front cable access.
A 400mm wide cable compartment is provided, cable entry maybe from the top or bottom of the cubicle. Cable
straps are supplied within each compartment together with cable shrouds, where required, (8E modules and
above). A blank undrilled 3mm Alu-zinc coated mild steel gland plate is provided.

MNS cable compartment, fully shrouded terminal for small starters and slip on bellows for cable lug terminations on large starters.

Segregated power cable connections are provided for each outgoing functional unit, cable sizes can be
accommodated as follows.
Outgoing functional module type

Cable size

Termination Method

8E/4
150mm wide
4 modules located size by side

6mm2

Cable terminal

8E/2
150mm wide
2 modules located size by side

35mm2

Cable terminal

Full width modules

Height in mm

4E

100

25mm2Cable terminal

6E

125

25mm2Cable terminal

8E up to 160A

200 and above

M10Cable lug

12E up to 400A

300 and above

M12Cable lug

Summary MNS Internal separation

The Busbars are located in the own compartment at the rear of the switchgear well away from the operators.
The bus compartment is maintenance free. The Functional units are located in there own compartment and
can be removed to the safety of a workshop for service. The motor cable terminations are located in a separate
400mm wide cable compartment.
With MNS the Form 4b motor starter are arc fault contained. Arc fault contained incoming breaker cubicles and
bus systems are available in MNS.

The withdrawable motor starters on the right comply with an Internal separation to Form 4bih the circuit breaker panels on the left comply with
Form 4a to AS/NZS 3439.1:2002.

For more information contact david.stonebridge@au.abb.com

Last edited 2006-08-22

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