Electrical Panels Verification and testing

The verification, once the panel wiring and other construction tasks (assembly of parts,
components labeling, etc.) are finished (totally or partially according to building
strategy and panel complexity: part by part, etc.), has three stages in essence:
1. Visual.
2. Electrical (functional) Test,
3. Advanced Testing for compliance with standards.
In the Visual, it will be observed that the panel is clean of shavings of material, pieces
of cables, marks of markers, damaged material, unconnected cable, lack of some
elements, some strange material inside the picture, twisted signs, erroneous
connections and much more, according to exhaustive internal procedures based on
cumulated experience.

The Electrical Test is basically a functional one, at different levels. Basically, the
different elements forming circuits are to be checked to ensure that there are effective
electrical connections, no line crossings (correspondence), proper function or circuits
and sections, and so forth; in sum, the circuits have been wired and they operate as its
expected. At very first level, its included here non-live checking, that is continuity or
wires, proper function of opening and closing contacts, control components
mechanically operated, etc. At a higher level, it includes checking of differential and
thermal trip of protection elements; (if present) programmers are programmed,
watches, inverters, starters, network switching, voltage free contacts, automatisms
complete cycles of operation. Connection to loads is not always necessary. However,
as a final step, the panel could be tested simulating real operating conditions:
magnitude ratings as in real use, modes of operation, operation times (to check
thermal behavior, etc.).
1

Advanced testing consists in applying rigorous tests, electrical and non electrical, in
order to ensure quality and conformity with design specifications and/or panel building
standards. Often, more sophisticated test equipment is used (Multifunction devices for
safety tests on electric boards and machines. See example below) and several tests are
carried out intended to verify:

Dielectric strength.
Protection against indirect contact.
Continuity of protective conductors.
RCD tripping.
Measurement of Non-trip earth resistance.
Coordination of magneto-thermal protections.
Insulation resistance.
Residual voltage on capacitive elements.
Leakage current in the outlet and through clamp.
Equipotential Resistance (all the metallic mass of the enclosure forms a single unit).
Others.

FULLTEST HT 4050 (HT-Instruments)

These data, will accompany the panel folder, and will be delivered a sheet with the
results to the client.
VERIFICATION SHEET
CLIENT: ------------------------------------------------------------------------------------------------------WORK: -------------------------------------------------------------------------------------------------------PANEL: -------------------------------------------------------------------------------------------------------WORKER: ---------------------------------------------------------------------------------------------------DATE: ---------------------------------------------------------------------------------------------------------2

ENCLOSURE ELEMENTS
DO NOT MATCH WITH THE BOM
DO NOT MATCH THE SCHEMATIC
CONCEPT
1.0 ENCLOSURE

2.0 DUCTING

3.0 WIRING

4.0 POWER BUSBAR

5.0 PROTECTION OF
MEASUREMENT

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
2.1
2.2
2.3
2.4
2.5
2.6
2.7.
2.8
2.9
2.10
3.1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
5.1
5.2

CONTROL ELEMENTS
DEFECTIVE TIGHTENING (SCREWS)
BAD PLACED MOUNTING PLATES
DAMAGED PLATES
DIRTY PLATES
PAINTED PLATES
PLATES WITHOUT LABELS
TWISTED LABELS
EARTH CONNECTIONS
DOOR WITHOUT TRIANGLE
PILOT LIGHTS BAD FIXED
DEFECTIVE FIXATION
SATURATED CABLE CONDUITS (TRUNKS, etc.).
OPEN BENDS OF CABLES AND CONDUITS
DISCONTINUED TRUNKS OR CABLE CONDUITS
CONDUITS OF DIFFERENT HEIGHTS
DIRTY TOPS
SHORT COVERS
PAINTED COVERS
RESTS OF WIRE LACING AND OTHERS IN TRUNKS
RIVETS BAD FINISHED AND/OR METALIC RESTS
INCORRECT SECTION
INCORRECT PHASE
INCORRECT IDENTIFICATION
INCORRECT TERMINATION AND CONNECTIONS
CABLES WITHOUT FERRULES
BROKEN FERRULES
WIRES AND CABLE OUTPUTS WITHOUT NUMBERS
DAMAGED CABLES
DEFECTIVE TIGHTENING
POWER BUSBAR BAD CALCULATED
POWER BUSBAR BAD STRAIGHTHENED
POWER BUSBAR BAD CONNECTED
BAD SPACING OF FIXING PARTS
BAD SHEET SPACING
BAD SCREWS SPACING
LACKING METACRYLATE SCREEN
BAD LAID METACRYLATE
DIRTY METACRYLATE
SCREWS WITHOUT MARKING
INCORRECT IDENTIFICATION
TRANSFORMERS BAD PLACED
WITHOUT PROTECTION
3

YES

NO

YES

NO

INSTRUMENTS

6.0 TERMINALS

5.3
5.4
5.5
6.1
6.2
6.3
6.4
6.5
6.6
6.7
6.8
6.9
6.10
6.11
6.12

VALIDATION

WRONG FUSE SIZE

BAD CONNECTION
INCORRECT FIXATION
INCORRECT TERMINALS
TERMINALS BAD PLACED
BENDED TERMINALS
TERMINALS WITHOUT LABELS
PAINTED TERMINALS
TERMINALS BLOKCS WITHOUT SPACERS
TERMINALS WITHOUT COVERS
DEFECTIVE FIXATION OF TERMINALS OR BLOCKS
LABELS ORIENTED BADLY
ILLEGIBLE LABELS
DAMAGED CARRIL
DIFFICULT ACCESS

SIGNATURE

DATE

DESCRIPTION OF SOME CONTROL ELEMENTS

1.1 DEFECTIVE TIGHTENING:
A defective tightening of all the elements that make up the enclosure implies that all the metal
parts of the frame do not form a secure equipotential bonding. In addition, it deforms the
entire structure of the painting.

1.2 BAD PLACED MOUNTING PLATES:

Regarding mounting plates, many options are available, some of them with specific
requirements. In general, look for bad placed and bad laid-out or distributed components, wire
conduits and mounting rails or input and output terminals blocks.

1.3 DAMAGED PLATES:

1.4 DIRTY PLATES:
1.5 PAINTED PLATES:
Aesthetics criteria

1.6 PLATES WITHOUT LABELS:

On the general switches, the switching switches and the output switches the signs will be set
to one centimeter in order to identify unambiguously the different circuits and controls.

1.7 TWISTED LABELS:

Aesthetics criteria

1.8 EARTH CONNECTION:

Its key for assurance of an equipotential union between all the metallic parts composing the
enclosure, and for prevention of possible indirect electrical contacts.

1.9 DOOR WITHOUT (Danger sign)TRIANGLE:

Normally, the door and the methacrylate screens must carry the danger triangle.

2.1 DEFECTIVE FIXATION:

The cable conduit must be firmly fixed to the mounting plate, directly or indirectly.

2.2 SATURATED CABLE CONDUITS:

The dimensions of the cable conduits will be calculated for a given number of circuits. A
saturated conduit involves greater risk or wire overheating and, anyway, more heat to
dissipate.

2.3 OPEN BENDS OF CABLES AND CONDUITS:

The cables located inside conduits must have proper curvature radios, so that they do not
exert tensions in the wall of the channel.

2.4 DISCONTINUED CABLE CONDUITS:

The point of attachment of the conduit will be correctly measured and leveled for functional
and aesthetic correspondence with other ones.

2.5 CONDUITS WITH DIFFERENT HEIGHTS:

Once the dimensions of the conduits are calculated, the height will be taken as the standard for
the remaining others.

2.6 DIRTY TOPS:

2.7 SHORT COVERS OR TOPS:
2.8 PAINTED COVERS:
Aesthetics criteria

2.8 RESTS ON THE WIRE CONDUITS:

Aesthetics criteria. And, for possible difficulties when working on possible reforms and repairs.

2.9 RIVETS BAD FINISHED:

Rivet rests, such as rings or pins are metallic and therefore conductors; they can lead to shunts
or to ground leaks if they break the insulation of the cable.

3.1 INCORRECT SECTION:

Section in the head, is determined by the size of the apparatus having first. For example, if we
have a RCD rated 40A 30 mA and then a circuit breaker rated at 20A, wire section installed will
be 10 mm2. The section to be used will be the following:
With insulation 750 v:
1.5 mm2 (control circuits).
2.5 mm2 to 10 A
4 mm2 to 20 A
6 mm2 up to 25 A
10 mm2 to 40 A (32 A)
16 mm2 up to 63 A

With 1000 V insulation:

16 mm2 up to 80 A
25 mm2 to 100 A
35 mm2 up to 125 A
50 mm2 up to 160 A
70 mm2 up to 200 A
95 mm2 to 250 A
These sections are considered without correction factors being applied. The insulation will be
free of halogens. The connection section of the surge protector will be the same as the input
2
2
section. The section of the earthing cable will be between 16 mm and 25 mm . The surge
protector, will have a magnetothermal 20 A rated.

3.2 INCORRECT PHASE:

The equilibrium between phases L1, L2, L3 will be guaranteed; they will be distributed in all
circuits of the frame.

3.3 INCORRECT IDENTIFICATION:

The cables, insulated 1000 v, will be identified with colors corresponding to their phase:
NEUTRAL - BLUE
L1 - BLACK
L2 - MARRON
L3 - GRAY

3.4 INCORRECT CONNECTIONS:

Correct connections of the components will be ensured.

3.5 CABLES WITHOUT FERRULES:

3.6 BROKEN FERRULES:
For security

3.7 WIRES AND CABLE OUTPUTS WITHOUT NUMBERS:

The output cables shall bear a number identifying them on the terminal block and shall be
attached to the output cable of the device and to the terminal.

3.8 DAMAGED CABLES:

3.9 DEFECTIVE TIGHTENING:
For security.

4.1 POWER BUSBARS BAD CALCULATED:

For security.

4.2 POWER BUSBARS BAD STRAIGHTHENED:

For security, for presence, for aesthetics.

4.3 POWER BUSBARS BAD CONNECTED:

4.4 BAD SPACING OF FIXING PARTS:

4.5 BAD SHEET SPACING:

4.6 BAD SCREWS SPACING:
4.7 LACKING METACRYLATE SCREEN:
4.8 BAD LAID-OUT METACRYLATE:
For security.

4.9 DIRTY METACRYLATE:

Aesthetics criteria.

4.10 SCREWS WITHOUT MARKING:

For security.

4.11 IDENTIFICATION INCORRECT:

Copper bars must be of the color that identifies them.

5.1 CURRENT TRANSFORMER BAD PLACED

The current transformers will be oriented from P1 to P2. In these transformer the polarity is
determinant.

5.2 LACKING PROTECTION:

5.3 WRONG FUSE SIZE:
The measuring devices shall be protected by fuses, calibrated according to the manufacturer.

5.4 BAD CONNECTION:

The correct connection will be ensured through the schematic provided by the manufacturer. In
digital ammeters, and other similar devices, the scale will be adjusted according to the installed
devices. When the current transformers are connected to terminals, a bridge will be made
between S1 and S2, for these devices must not operate in a vacuum.

6.1 INCORRECT TERMINALS:

The size of the terminals will correspond to the thermal protection, and the customer can
request a higher size, never lower.

6.2 TERMINALS BAD PLACED:

The terminals will be placed in the rail, oriented in such a way that the tab is on the side of the
customer.
Correct positioning of the terminals shall be ensured. The terminals of a three-phase circuit
shall be of the same size. The neutral terminals will be placed in the same order than the
neutral has been placed in the protection devices.

6.3 BENDED TERMINALS:

It will be checked that the terminals are not deformed when crimped, in order to ensure the
best electrical connection.

6.4 TERMINALS WITHOUT TAGS or LABELS:

Correct identification of the different circuits at the terminals shall be ensured.

6.5 PAINTED BORDERS:

Aesthetic criteria.

6.6 TERMINALS BLOCKS WITHOUT SPACERS:

For security.

6.7 TERMINALS WITHOUT COVERS:

Circuit terminals belonging to a switch header will have a lid on the last circuit.

6.8 DEFECTIVE FIXATION:

The terminals rail will be firmly attached to the chassis or mountin plate.

6.9 LABELS ORIENTED BADLY:

The labels shall be fixed to the terminals in such a way that the identification can be read by
placing the visor on the right side. The labels shall be placed on the terminals, at their top.

6.10 ILLEGIBLE LABELS:

Clear and readable label identification shall be guaranteed.

6.11 BAD CALCULATED RAIL:

The robustness of the terminals rail will be guaranteed, especially if they are for power supply
or distribution.

6.12 DIFFICULT ACCESS:

Sufficient space shall be provided for connecting terminals, testing and repairs.