Tot Halyester Manual 1.1 ENG PDF

Halyester manual
TABLE OF CONTENTS
1. INTRODUCTION
1.1 Scope 1-2

1.2 Characteristics 1-2
1.3 General system description 1-2
2. BOXES
2.1 Box overview 2-2

2.2 Box accessories 2-2
2.3 Box fittings 2-9
2.3.1 Flanges for increasing depth 2-9
2.3.2 Locking and sealing 2-10
2.3.3 Mounting plates for installing equipment 2-12
2.3.4 Press-in nuts for fixing equipment 2-13
2.3.5 Condensate discharge and ventilation 2-14
2.4 Range of products 2-15
2.5 Overview of busbar boxes 2-22
2.6 Dimensions 2-24
3. BOX ASSEMBLY
3.1 Assembly openings 3-2

3.2 Punching of openings 3-3
3.2.1 Hand-operated punching machine 3-3
3.2.2 Marking-off templates for feed-through openings 3-4
3.3 Box assembly sequence 3-6
3.3.1 Box assembly using intermediate coupling pieces 3-6
3.3.2 End and cable entry covers 3-7
3.4 Assembly sequence for busbar boxes 3-8
3.4.1 Busbar supports 3-8
3.4.2 End caps 3-10
3.4.3 Coupling of main and auxiliary busbars 3-11
3.4.4 Coupling of busbar connection boxes and
group distribution boxes 3-13
3.4.5 Branch of main and auxiliary busbars 3-14
3.5 Busbar systems 3-17
4. SUPPLY MODULE ASSEMBLY
4.1 Supply modules with switch-disconnector 4-2

4.1.1 1000 A supply module for bottom connection 4-3
4.1.1.1 with segmented cable sealing box 4-3
4.1.1.2 without segmented cable sealing box 4-4
4.1.2 1000 A supply module for top connection 4-5
Version 1.1 Table of contents 1

Halyester manual

4.1.7 Detail drawings of busbar connections and cable inlet 4-10
4.2 Supply modules with circuit breaker 4-12
4.2.1 1000 A supply module, with 3 poles + N 4-13
4.2.2 1000 A supply module, with 4 poles 4-14
4.2.3 1000 A/1250 A supply module, with 3 poles + N 4-15
4.2.4 1000 A/1250 A supply module, with 4 poles 4-16
4.2.7 Detail drawings of busbars connections and cable inlet 4-19
5. CABLE SEALING BOXES
5.1 Plastic cable glands 5-2

5.2 Cable sealing box 5-3
5.3 Segmented cable sealing box 5-6
5.4 Special configuration for top connection 5-8
6. FRAME MOUNTING
6.1 Wall mounting 6-2

6.1.1 Single boxes 6-2
6.1.2 Wall mounting for small combinations 6-3
6.2 Floor/wall mounting 6-5
6.3 Free-standing arrangement 6-7
6.4 Wall frame extensions 6-8
6.4.1 Wall frames for small combinations 6-8
6.4.2 Floor/wall frames and frames for free-standing arrangement 6-9
7. SPECIAL CONFIGURATIONS
7.1 Arrangement in corners 7-2

7.2 Back-to-back arrangement 7-5
7.3 Sun/rain cover 7-7
8. TECHNICAL DATA
8.1 Technical specification 8-2

8.1.1 Characteristics of plastics used 8-3
8.1.2 Resistance to chemicals 8-3
8.2 Loads and short-circuit strength of busbar systems 8-4
8.3 Technical data of distribution transformers 8-5
8.4 Tightening torques 8-5
8.5 Standards and certificates 8-6
2 Table of contents Version 1.1

Halyester manual
9. ENCLOSURES
9.1 Test report 9-2

9.2 Certificate 9-6
9.3 EU declaration of conformity 9-7
9.4 KEMA-Keur certificate 9-8
9.5 Revision overview 9-9
Version 1.1 Table of contents 3

Halyester manual
1. INTRODUCTION
1.1 Scope 1-2
1.2 Characteristics 1-2
1.3 General system description 1-3
Version 1.1 Introduction 1-1

Halyester manual
1. INTRODUCTION
1.1 Scope
Halyester was designed as a modular low-voltage system for composing switchgear and controlgear
assemblies for the distribution of electric power and motor control centres. The system is suited for in-
door and outdoor installation and based on the principle of total insulation in accordance with stan-
dard IEC 60439.
This ensures maximum operator safety. The outstanding mechanical and electrical characteristics of the
plastic boxes give the Halyester system a long service life, even under the most prevalent arduous ope-
rating conditions.
Halyester is extensively used in refineries, chemical plants and heavy industry.
Thanks to its compact and modular design, the Halyester system is also eminently suited for being
used in office buildings, greenhouses, department stores and factories. In addition, the separate boxes
accommodating a wide variety of electrical switchgear and controlgear assemblies are a perfect en-
closure for being used in relatively restricted places.
Separate operating areas or buildings are no longer necessary because the Halyester system provides
high operator safety and can be arranged outdoors.
1.2 Characteristics
The boxes and assembling accessories are made from glass mat reinforced polyester; the covers are
made from transparent or non-transparent UV-resistant polycarbonate. The features of the plastics
used are:
• high impact strength

• self-extinguishing
• non-hygroscopic
• resistant to all weather conditions
• resistant to tracking
• immune to large temperature variations
• low weight
• easy to machine
• UV-resistant
1-2 Introduction Version 1.1

Halyester manual
1.3 General system description

Halyester switchgear and controlgear assemblies are designed as movable or stationary systems
for indoor and outdoor installation. The ambient temperature may vary between + 70°C and -
25°C. In the case of outdoor installation it is advised to protect the assembly against direct sun-
light and rainfall under extreme conditions.
Boxes
The Halyester system comprises assembled boxes from heat-resistant glass fibre reinforced polyester,
with covers from polycarbonate.
The system is made up of 10 differently sized boxes.
Each box has a removable cover which is provided with locking screws which can be tightened either
with a screw driver or manually. Manual locking screws are used for boxes which are adequately pro-
tected against contact with live parts which are allowed to be operated by non-technical personnel.
According to the international IEC 60439 standard, low-voltage Halyester switchgear and controlgear
assemblies may be used in places that are accessible to non-technical personnel.
Busbar systems
The main busbars are made from electrolytic copper ECu57 F25. The busbars are supported by glass fi-
bre reinforced polyester busbar supports. All end caps, end covers and cable entry covers are provided
with seamless polyurethane foam sealing.
1
3 2
5 6
1 end cover / cable entry cover

2 busbar support
3 end cap
4 intermediate coupling piece 8
5 casing
6 cover
7 flange for increasing depth
8 cable sealing box 9
9 segmented cable sealing box
Version 1.1 Introduction 1-3

Halyester manual
2. BOXES
2.1 Box overview 2-2
2.2 Box accessories 2-6
2.3 Box fittings 2-9
2.3.1 flanges for increasing depth 2-9

2.3.2 locking and sealing 2-10
2.3.3 mounting plates for installing equipment 2-12
2.3.4 press-in nuts for fixing equipment 2-13
2.3.5 condensate discharge and ventilation 2-14
2.4 Range of products 2-15
2.5 Overview of busbar boxes 2-22
2.6 Dimensions 2-24
Version 1.1 Boxes 2-1

Halyester manual
2. BOXES
2.1 Box overview
box type weight
K 432 1.4 kg
K 433 1.7 kg
K 434 2.5 kg
with flange for
increasing depth 3.7 kg
2-2 Boxes Version 1.1

Halyester manual
box type weight
K 442 1.7 kg
K 444 3.0 kg
K 463 3.5 kg
with flange for

Halyester manual
box type weight
K 464 5.5 kg
with flange for
increasing depth 7.2kg
K 466 7.0 kg
with flange for

Halyester manual
box type weight
K 484 6.0 kg
K 486 11.5 kg

Halyester manual
2.2 Box accessories
Intermediate coupling pieces
For interconnecting boxes with openings 2, 3 or 4.
Busbar supports, end caps
The busbar supports do not only serve as a busbar carrier but also as a con-
necting piece between two busbar boxes. They are provided with sealing
and come with four coupling bolts and nuts. The bolt heads are insulated.
The end caps for sealing the busbar compartment sides consist of a cap and
busbar support. They are supplied with fastener material.
End covers and cable entry covers
The end cover is available in two models:

• for fastening from the inside;
• for fastening from the outside;
The cable entry covers (only suited for outside fastening) come with
knockouts.All end covers and cable entry covers have sealings and are
suited for openings 2, 3 or 4.

Halyester manual
Covers and locking screws
All covers are provided with sealing. The cover locking screws are suited
for wire or band sealing and available for hand or tool operation.
The locking screws may come with a hinge pin.
Plastic nut
For locking screws with hinge pin.
Flanges for increasing depth
Type KB 434, 463, 464 and 466 casings can be equipped with one or more
flanges for increasing depth to obtain a larger mounting depth.
The flanges for increasing depth come with sealing and fastener material.
Cable sealing boxes
The cable sealing boxes suited for openings 3 or 4 are available in two
models:
• blank or with opening(s) having one or more rubber grommets;
including sealing and complete with fastener material
• segmented and complete with segmented cable clamps
Cable glands
Plastic cable glands for cable entry come in 10 models

(sizes Pg 7 thru Pg48).
Segmented adaptor ring
For segmented cable entries having a 40mm passage.

Halyester manual
Press-in nut / self-tapping screws
For fixing equipment to plastic base plate.
grondplaat
base plate
Vent valve
For box ventilation.
Drain valve
To be fitted at the lowest point in the box.
Hinged operating windows
For cover mounting to allow fast and easy operation of MCBs, RCCBs, RCBOs,
etc.

Halyester manual
2.3 Box fittings
2.3.1 Flanges for increasing depth
The flanges for increasing depth, just like the casings, are moulded from glass fibre reinforced
polyester. The flanges come with packing and captive locking screws suited for screwdriver tightening.
Flanges for increasing depth are available for the Halyester boxes listed in table 2.1 below.
This table specifies the flange for increasing depth per box type and the associated effective mounting
depth.If necessary, several flanges can be fitted.
Table 2.1: Flanges for increasing depth
Box Flange for increasing Increasing depth

type depth type in mm
K 434 KR 434 62.5

K 463 KR 463 62.5
K 464 KR 464 62.5
K 466 KR 466 125
Flanges for increasing depth

Halyester manual
2.3.2 Locking and sealing
Locking
Locking screws suited for hand or tool operation are available for securing covers to casings of the Ha-
lyester system.Both models are also available in a hinged configuration. Casings with one or more
flanges for increasing depth can be provided with covers suited for locking screws (manual or screw-
driver models), both with and without hinge pin. The screws to be used for flanges for increasing
depth and the “normal” locking screws differ in that the hinge pin of the former ones has been shor-
tened from abt. 85 mm to abt. 60 mm, because the casings are deeper than the flanges for increasing
depth. To obtain a proper sealing between the cover and casing or flange for increasing depth, the
locking screws must at least be torqued to 1.6 Nm. The different configurations and the fixation of the
locking screws are shown below.
Manual and screwdriver models
1
2
If a hinged locking screw is used,first fit the plastic nut

1 and then tighten the locking screw 2
Manual and screwdriver models

with hinge pin
Manual and screw driver models

with hinge pin for raising frame Attach the casing to the wall or flange before fitting
the locking screws

Halyester manual
Sealing
Wire and band seals can be used on boxes not to be accessed, say for kWh measurement.
18 mm
2 mm
Wire sealing Band sealing

Halyester manual
2.3.3 Mounting plates for installing equipment
The mounting plates for building equipment into Halyester boxes are made from plastic.
They are secured to the bottom of the casing by means of cheese head screws (M6 x 10). Halyester
boxes upwards of type K434 can be provided with more than one mounting plate. Table 2.2 shows the
various options. For fitting and feeding through earth terminals, it is possible to fit an earth strip at
the bottom left and top left holes of the mounting plate.
Table 2.2: Scope of application of the mounting plates
Mounting plate Dimensions Quantity In box

type L x W (mm) type
KG 432 220 x 130 1 K 432
1 K 433
KG 433 220 x 220 2 K 463
4 K 466
1 K 434
KG 434 220 x 310 2 K 464
4 K 486
KG 442 310 x 130 1 K 442
KG 444 310 x 310 1 K 444

2 K 484
Type KG 466 mounting plate KG 463 490 x 270 1 K 463
KG 464 490 x 310 1 K 464

2 K 486
KG 466 490 x 490 1 K 466
KG 484 670 x 310 1 K 484
KG 486 670 x 490 1 K 486

Halyester manual
2.3.4 Press-in nuts for fixing equipment
As already described, the mounting plate is fitted in the box for the fixation of equipment. To allow
the equipment to be secured to the mounting plate, press-in nuts with M4 thru M12 metric thread are
fitted into the plastic mounting plate, as shown in the figure below.
Since the press-in nuts have a knurled rim, they are fixed into the mounting plate.
The holes to be drilled for the various press-in nuts are listed in table 2.3.
Light equipment can be secured direct to the mounting plate, using M4 screws instead of press-in nuts
The holes to be drilled for the M4 screws have a diameter of 3.4 0 mm.
-0.1
Table 2.3: Holes for press-in nuts
Internal thread Holes to be drilled

of press-in nuts (mm)
M4 Ø 5.5 0
-0.1
M5 Ø 6.5 0
-0.1
M6 Ø 8.5 0
-0.1
M8 Ø 10.5 0
-0.1
M10 Ø 12.5 0
-0.1
M12 Ø 14.5 0
-0.1

Halyester manual
2.3.5 Condensate discharge and ventilation
Drain valve
If a Halyester box or a combination of boxes is arranged in a damp room, it is recommended to fit a
drain valve at the bottom of the box, see figure bottom left. This valve cannot be dismounted from
the outside.
The shape of the plastic drain valve prevents foreign objects from being inserted into the box. Insects
cannot enter the box via the valve either. To install the drain valve, it is necessary to drill a 23mm hole
into the casing bottom.
Vent valves
To prevent condensation, 2 vent valves can be fitted together with the drain valve. These valves,
however, are only required in the case of large temperature variations.
The plastic vent valve has a little fine-mesh grate, preventing foreign objects or insects from entering.
To ensure proper venting, two vent valves must be fitted per panel or box, one as high as possible in
the side wall of the box or panel and one as low as possible in the opposite side. If there is no space
for mounting the vent valves in the side walls of the boxes due to the compact design, they can also
be fitted in the rear wall of the casings without any problem. Each vent valve must have two holes to
allow mounting in the boxes, as shown below.
The boxes complete with a drain valve and a vent valve meet IP55.
23 mm
Fixation of drain valve Fixation of vent valve

Halyester manual
2.4 Range of products
415 V switch boxes

Selection from Duco switch-disconnectors: 40 A
63 A
IP56
690 V switch boxes

Selection from Dumeco switch-disconnectors: 125 A
160 A
250 A
400 A
630 A
1000 A
IP56
for feeder panels in TN-S and TN-C current systems

selection from Dumeco switch-disconnectors: 1000 A
1250 A
1600 A
IP56
for feeder panels in TN-S and TN-C current systems

selection from Aeromat circuit breakers:
1000 A
1250 A
1600 A
IP2X
Terminal boxes
terminal box 800 A
IP66

Halyester manual
415 V switch-fuse boxes

selection from Duco switch-disconnectors: 40 A
63 A
IP56

125 A
IP56

250 A
400 A
630 A
IP56
selection from Vemeco switch-disconnector-fuses:100A

160 A
250 A
400 A
IP56
will be replaced with QSA switches in good time

Halyester manual
selection from QSA switch-disconnector-fuses: 63A

125A
160A
250 A
400 A
IP56

selection from FSD fuse-switch-disconnectors: 160A
250A
400A
IP66

Halyester manual
500 V fuse boxes

selection from Isocoupe D-type fuse bases: 3 x 25 A
3 x 63 A
IP66
690 V fuse boxes

selection from Isodin blade contacts-type fuse bases: 3 x 160 A
2 x 3 x 160 A
3 x 250 A
3 x 400 A
3 x 630 A
IP66
Measuring instrument boxes

selection from box types: K 433
K 434
IP56
500 V power group distribution boxes

selection from Isocoupe D-type fuse bases:
2 x 25 A 2 x 63 A
4 x 25 A 3 x 63 A
6 x 25 A 4 x 63 A
8 x 25 A 6 x 63 A
4 x 25 A + 3 x 63 A
IP66
Boxes for kWh measurement
IP66

Halyester manual
230 / 400 V lighting group distribution boxes

selection from number of lighting groups: 2, 3, 6 or 9
IP56
230 / 400 V lighting group distribution boxes

selection from number of lighting groups: 3, 6 or 8
IP66
230 / 400 V lighting group distribution boxes with main switch

selection from number of lighting groups: 3, 4, 7 or 10
IP56
230 / 400 V power group distribution boxes with main switch

selection from number of power groups: 3 or 5
IP56
230 / 400 V lighting and power group distribution boxes with main switch
selection from number of lighting groups: 4 3 4 3 4 6 3
power groups: 1 2 1 2 4 3 5
IP56

Halyester manual
230 / 400 V lighting and power group distribution boxes with main switch
(residual current circuit breaker without overcurrent protection )
selection from number of lighting groups: 3 3 3
power groups: 1 2 2
IP56
Distribution boxes for modular components

suitable for expansion
selection from box types: K 444
K 464
IP56
230 / 400 V switch boxes

with type RSD rotary switches
selection from number of switches: 6 x 25 A

12 x 25 A
18 x 25 A
IP56
415 V switch boxes

with Duco switch-disconnectors
selection from number of switches: 2 x 40 A 2 x 63 A

4 x 40 A 3 x 63 A
6 x 40 A 4 x 63 A
IP56
690 V switch boxes

with Dumeco switch-disconnectors
number of switches: 2 x 125 A
IP56

Halyester manual
415 V - 690 V feeder boxes for side assembly

63 A
IP56
690 V feeder boxes for side assembly

160 A
250 A
IP56
415 V feeder boxes for side assembly

with: Isocoupe D-type fuse bases
63 A
IP56
Busbar connection boxes for side assembly

with 3-phase busbars, neutral busbar and earth busbar
selection from box types: RG 433
RG 434
IP66
Branch strips
L1, L2, L3, N for:
switch boxes
switch-fuse boxes
fuse boxes
Wiring sets
L1, L2, L3, N, PE for:
connections between busbar boxes and distribution boxes

Halyester manual
2.5 Overview of busbar boxes
2
R 432 / 3232
270
3 3
180
3
R 433 / 3333
270
3 3
3
270
4
R 434 / 3434
270
3 3
4
360
4
R 434 / 3432
270
3 3
4
360
4
R 434 / 3232
270
3 3
360

Halyester manual
3
R 463 / 3333
3 3
540
3 3
270
4
R 464 / 3434
3 3
540
3 3
360

Halyester manual
2.6 Dimensions
180 270 360 540

270
K 432 K 433 K 434

360
K 442 K 444
540
K 463 K 464 K 466

720
K 484 K 486

Halyester manual
Box K 432
158
130
270 110
245
200
220
248
3
151
155 126 45
180
Box K 433
248
220
200
270
245
200
220
248
3
151
245 126 45
270

Halyester manual
Box K 434
338
310
290
270
245
200
220
248
3
214
62.5 45
335 126
360
Box K 442
158
130
110
3
290
310
338
360
335
151
155 126 45
180

Halyester manual
Box K 444
338
310
290
290
310
338
360
335
3
151
335 45
126
360
Box K 463
248
220
200
540
515
470
490
518
270
70
3
214
245 62.5 45
126
270

Halyester manual
Box K 464
338
310
290
540
515
470
490
518
70 270
3
217
335 62.5 45
126
360
Box K 466
518
490
470
470
490
518
540
515
70 270
3
70 280
515 126 125 45

540

Halyester manual
Box K 484
338
310
290
720
695
650
670
698
360
70
3
181
335 126 75
360

Halyester manual
Box K 486
518
490
470
650
690
698
720
695
70 360
3
181
70
515 126 75
540

Halyester manual
3. BOX ASSEMBLY
3.1 Assembly openings 3-2
3.2 Punching of openings 3-3

3.2.1 hand-operated punching machine 3-3
3.2.2 marking-off templates for feed-through openings 3-4
3.3 Box assembly sequence 3-6

3.3.1 box assembly using intermediate coupling pieces 3-6
3.3.2 end and cable entry covers 3-7
3.4 Assembly sequence for busbar boxes 3-8

3.4.1 busbar supports 3-8
3.4.2 end caps 3-10
3.4.3 coupling of main and auxiliary busbars 3-11
3.4.4 coupling of busbar connection boxes and group
distribution boxes 3-13
3.4.5 branch of main and auxiliary busbars 3-14
3.5 Busbar systems 3-17
Version 1.1 Box assembly 3-1

Halyester manual
3. BOX ASSEMBLY
3.1 Assembly openings

For proper assembly, the boxes to be coupled must have identical feed-through openings. Shown be-
low are the dimensions and number of feed-through openings punched in the boxes.
opening 2
opening 3
opening 4
Figure 3.1: Overview of feed-through openings
3-2 Box assembly Version 1.1

Halyester manual
3.2 Punching of openings
3.2.1 Hand-operated punching machine

Openings in the casings of Halyester boxes can be made in different ways. One of the options is pun-
ching, using the hand-operated punching machine described below.
Punching machine description

- height including removable handle 1150 mm, and without handle 470 mm
- maximum width 390 mm
- overall depth excluding handle 350 mm
- weight 80 kg
The frame plate has four 12mm dia. openings for fixation of the punching machine.
The machine is equipped with a fixed punching tool for opening 2.
The stop strip has 4 centring pins, allowing the required openings to be punched in all casings.
Punching machine operation

- place the casing (with the fixing holes for the cover) onto the centring pins under the punching
machine
- punch the four fixing holes in the casing by pulling the handle
- the machine is suited for punching opening 2 in one go. Openings 3 and 4
require several punching operations.
Figure 3.2: Hand-operated punching machine

Halyester manual
3.2.2 Marking-off templates for feed-

through openings
For making openings in casings, not only a pun-

ching machine but also a saw can be used.
The openings to be sawn out can be marked off
by means of templates, which are available for
openings 2, 3 and 4.
Hand tools can be used to simply make openings
in the casings which are easy to work on.
Figure 3.3: Marking-off templates
Work instruction:
- place the template on the casing

- mark off the openings to be sawn out along
the inside of the template
Figure 3.4: Marking off
- drill 7mm dia. holes in the casing through the

template drill bushes 1 and inside the template
2 before sawing out
1
2
Figure 3.5: Drilling

Halyester manual
- remove the template and saw the opening in

the casing along the marking-off line
Figure 3.6: Sawing out openings
- the saw cuts made in the template for openings

3 and 4 can be used as a size for sawing out the
front post
- this is necessary if the casing is provided with a
cable sealing box
Figure 3.7: Sawing out front posts

Halyester manual
3.3 Box assembly sequence
3.3.1 Box assembly using intermediate coupling pieces
Open intermediate coupling pieces

For proper assembly, the boxes to be coupled must have identical feed-through openings. They can
be coupled both horizontally and vertically. The open intermediate coupling pieces are available in
three sizes: for openings 2, 3 and 4.
Table 3.1: Overview of intermediate coupling pieces
open blank f eed-through

intermediate coupling intermediate coupling opening
piece piece
type type
U 420 UB 420 2
U 430 UB 430 3
U 440 UB 440 4
‘Blank’ intermediate coupling pieces

In addition to the above open intermediate coupling pieces, also ‘blank’ intermediate coupling pieces
are available to ensure dust-tight feed-through of lines etc. They are fitted in the same way as the
‘open’ intermediate coupling pieces. Type UB 420 for opening 2, type UB 430 for opening 3 and type
UB 440 for opening 4.
Mounting
- mount the intermediate coupling piece with the marking towards the rear 1
- fit the bolts with plastic head by tightening the nuts only.
1 1
Figure 3.8:Fitting of open intermediate coupling piece Figure 3.9:Fitting of ‘blank’ intermediate coupling piece

Halyester manual
3.3.2 End and cable entry covers
Function
End covers are applied to seal unused vertical and horizontal openings.
They are available in three models:
• for mounting from the inside: type U

• for mounting from the outside, type UE
• cable entry covers with knockouts for fitting cable glands: type UE .../.
In situations where it is advised not to open the box from the outside (for example, in the case of se-
aling), it is possible to use end covers which are fixed from the inside.
Table 3.2: Overview of end covers
opening end cover

type
2 U 402 UE 402
3 U 403 UE 403
4 U 404 UE 404
Table 3.3: Overview of cable entry covers
cable entry covers opening knockouts

type type
UE 402 / 7 2 7 x Pg16
UE 402 / 4 2 x Pg16 + 2 x Pg29
UE 403 / 16 3 16 x Pg16
4 x Pg16 + 2 x Pg29
UE 403 / 7 + 1 x Pg29 / 42
UE 404 / 25 4 25 x Pg16
6 x Pg16 + 2 x Pg29
UE 404 / 10 + 2 x Pg29 / 42
Figure 3.10: End cover fixed from the inside
Figure 3.11: End cover fixed from the outside. Figure 3.12: Cable entry cover with knockouts
Special clips are supplied for that purpose 1

Halyester manual
3.4 Assembly sequence for busbar boxes
3.4.1 Busbar supports

Function
Four types of busbar supports for different busbar sections are available for coupling busbar boxes in
horizontal direction and for feeding through the main busbars without causing short circuits. There
are openings for 3-phase busbars, a neutral busbar and an earth busbar. In addition, four insulated
auxiliary busbars (6 x 6 mm) can be fitted. The busbar supports can be used for opening 3 only.
The maximum support distance between two busbar supports is 360 mm in view of the short-circuit
strength of the busbar system.
Table 3.4: Busbar supports with associated busbar load and busbar sections
busbar support supply L1, L2, L3 (PE)N*) PE

type single-side central mm mm mm
R 430/ 4 315 A 500 A 15x 4 15x 4 15x 3

R 430/ 8 500 A 800 A 15x 8 15x 4 15x 4
R 430/16 630 A 1000 A 15x16 15x 8 15x 6
R 430/24 800 A 1000 A 15x24 15x12 15x 6
R 430/24 1500 A 1600 A 2(15x24) 2(15x12) 2(15x6)
*) If the section of the neutral conductor should be identical with that of the phase, it is possible to enlarge the
opening. This adjustment has no consequences for the short-circuit strength.
When using a double-busbar system, it is necessary to fit equalising busbars on both ends of the bus-
bar system. With larger installations, every third box and every following third box - starting from the
power supply - must be equipped with equalising busbars.
PE
L1
L2
L3
PE
(PE)N
PE
L1
L2 L1
L3
(PE)N
L2
auxiliary
busbars
L3
Figure 3.13: Double-busbar system with equalising busbars
(PE)N
Figure 3.14: Busbar support

Halyester manual
Mounting
- mount the busbar supports between the busbar boxes in such a way that the feed-through openings
of the main busbars are located at the rear side.
- fit the bolts with plastic head by tightening the nuts only.
Figure 3.15: Busbar support mounting

Halyester manual
3.4.2 End caps
Function
End caps are used to close the busbar system.
A complete end cap consists of a busbar support, a ‘recessed end cover’ and fastener material.
Mounting
Fix the end cap from the busbar box, using hexagonal head bolts (M6 x 25) and flat washers.
Just like the end covers, the end caps are provided with press-in nuts.
Table 3.5: Overview of end caps with associated busbar

sections
end cap L1, L2, L3 (PE)N PE

type mm mm mm
UR 403/ 4 15x 4 15x 4 15x 3

UR 403/ 8 15x 8 15x 4 15x 4
UR 403/16 15x16 15x 8 15x 6
UR 403/24 15x24 15x12 15x 6
Busbar length
The length of the main busbars can be determined on the basis of the following data:
busbar length = length of the busbar compartment + 2 x 24 mm
On either side the busbars extend 16.5 mm into the end caps, see figure 3.16. This allows the main
busbar to be coupled to the busbar box to be attached when the busbar system is extended.
Figure 3.16: Distance between the busbars when mounting the end cap

Halyester manual
3.4.3 Coupling of main and auxiliary busbars
Main busbar coupling

If main busbars must be coupled, one or more busbar couplings may be used. In determining the bus-
bar length, it should be considered that for each coupling 6 mm space is required between the busbars
to be coupled.
The busbar coupling clamps consist of two clamping pieces and fastening screws.
With type A 70/16 and A 70/24 clamps, pointed screws are also used to optimize the current transfer.
The busbars are coupled at a distance of 16.5 mm from the busbar support, see figure 3.17.
Table 3.6: Overview of busbar coupling clamps
main busbar busbar coupling

clamp
15 x 3 mm
15 x 4 mm A 70 / 8
15 x 6 mm tightening torque 9 Nm
15 x 8 mm A 70 / 8
15 x 12 mm
15 x 16 mm A 70 / 16
2 x (15 x 8 mm)
15 x 24 mm A 70 / 24
3 x (15 x 8 mm)
16.5 mm
Figure 3.17: Minimum distance for busbar coupling

Halyester manual
Auxiliary busbar coupling

When coupling auxiliary busbars, the same distance must considered as with main busbar coupling, i.e.
16.5 mm from the busbar support. The auxiliary busbars (6 x 6 mm) must be insulated with glass fibre
sleeves in view of the limited ventilating path and creepage distance between auxiliary and branch
busbars, if any. For coupling purposes, it is necessary to remove the insulation. The branch busbars
must therefore be taken into consideration when determining the coupling location.
To enable the main busbar couplings to be checked, they should be fitted to another side of the casing
or in an adjacent box.
Figure 3.18: Coupling clamp for auxiliary busbar

Halyester manual
3.4.4 Coupling of busbar connection boxes and group distribution boxes
Mounting
All group distribution boxes accommodate
3-phase busbars, 1 neutral busbar and 1 earth
busbar. M = 4,5 Nm
The connection to these box busbars may take
place at the side, top or bottom. To this end,
there are threaded holes for terminal screws at
the end of the busbars.
To enable connection to the busbars, each bus-
bar can be provided with a terminal having a
16 mm2 or 35 mm2 section.
For connection to the power supply (single-side

160 A or central 250 A) there are type RG 433
and RG 434 busbar boxes accommodating 3-
phase busbars, 1 neutral busbar and 1 earth bus-
bar. The busbars are mounted in the boxes in
such a way that they can be connected using
type AA 400 or AM 400 branch terminals. These
terminals are also used in type R busbar boxes.
Figure 3.19: Busbar coupling
Coupling strips according to figure 3.19 must be
fitted to allow busbars in group distribution
boxes and busbar boxes to be coupled.
There are power supply boxes suitable for being

mounted to the side of group distribution boxes.

Halyester manual
3.4.5 Branch of main and auxiliary busbars
Main busbar branch

A branch of the phase, neutral and earth busbar up to a thickness of 6 mm with a maximum branch of
25 x 7 comprises the following components:
• 1 washer AA 400
• 1 spacing clip
• 2 hexagon socket head screws M6
• 2 flat washers
When main busbars with a thickness of over 6 mm and a branch of at least 30 x 10 mm are involved,
the busbar branch terminal will comprise the following components:
• 1 washer AA 401
• 2 spacing clips
• 4 hexagon socket head screws M6
• 4 flat washers
AA 400
AA 401
1
12 ÷ 25
30 ÷ 40
Figure 3.20: Branch strip dimensions Figure 3.21: Mounting of busbar branch
Figure 3.22: If there is no sub-branch, a Figure 3.23: If there is a sub-branch with a

clamping bracket 1 cable < 10 mm2 , a clamping bracket 1
may be used for the purpose of mounting may be used for the purpose of mounting

Halyester manual
The length of the hexagon socket head screws is determined by the b

thickness of the main busbar and branch strips, see table below.
a
Please refer to chapter 8 when determining the sections of the main

and branch busbars.
The hexagon socket head screws for fixing the busbar branch termi-
15
nals must be torqued to 9 Nm.
The busbar branch terminals are suited for branching both strips and
c
cables.7mm holes must be drilled in the branch strips.
main busbar
b branch strip
Figure 3.24: Busbar branch terminal
A large number of branch strips are available for being mounted

between busbar systems and switch boxes, switch-fuse boxes and
fuse boxes.
Table 3.7: Busbar branches
main busbar (a) branch strip (b) hexagonal socket head screw (c)
M = 9 Nm
15 x 3 mm
15 x 4 mm
15 x 6 mm
7 mm max. M6 x 30
15 x 8 mm
0 - 5 mm M6 x 30
5 - 15 mm M6 x 40
15 x 12 mm
15 x 16 mm
0 - 7 mm M6 x 40
7 - 15 mm M6 x 50
15 x 24 mm
0 - 7 mm M6 x 50
7 - 15 mm M6 x 60

Halyester manual
For a general overview of the available branch strips and wiring sets, please consult the relevant cata-
logue on low-voltage switchgear and controlgear assemblies.
PE
L1
L2
L3
(PE)N
PE
L1 L1 L2 L3 N
L2
L3
(PE)N L1 L2 L3 N
Figure 3.25: Busbar branch examples
Threaded connections
Standard branch strip sets are available for all boxes that are placed under or above the busbar boxes.
Threaded connections are used between lighting/power group distribution boxes and the main busbar
system. These are also available as standard sets in 3 current ratings. One side of the wiring sets comes
with cable sockets, whereas the other side must be finished by the assembly department. All wires are
black, whereas the neutral conductor and PE conductor must be marked blue and yellow/green respec-
tively.
Auxiliary current branch

An auxiliary current branch terminal comprises the following components:
• 1 fixing brace
• 1 terminal strip
• 1 clamping screw
• 1 terminal screw M5 x 8
When using auxiliary current branch terminals, the insulation local to the auxiliary busbar must be
removed.
Figure 3.26: Auxiliary current branch terminal

Halyester manual
3.5 Busbar systems
Table 3.8: Busbar load in relation to busbar sections
power supply busbar section
single-side central L1, L2, L3 N*) PE PEN

In In mm mm mm mm
315 A 500 A 15 x 4 15 x 4 15 x 3 15 x 4
500 A 800 A 15 x 8 15 x 4 15 x 4 15 x 4
630 A 1000 A 15 x 16 15 x 8 15 x 6 15 x 8
800 A 1000 A 15 x 24 15 x 12 15 x 6 15 x 12
*) If the section of the neutral conductor should be identical with that of the phase, it is possible to enlarge the opening. This
adjustment has no consequences for the short-circuit strength.
Table 3.9: Busbar branches
cable, section in mm2 strip, W x H (mm)

temperature resistance of insulated
wire 105°C
In ambient temperature 35°C ambient temperature 35°C
L1,L2,L3 N PE PEN L1,L2,L3 N PE PEN

16 A 1,5 1,5 1,5 10
25 A 2,5 2,5 2,5 10
32 A 4 4 4 10
40 A 6 6 6 10
63 A 10 10 10 10
80 A 16 16 16 16
100 A 16 16 16 16
125 A 25 16 16 16 12x2 1) 12x2 1) 12x2 1
) 12x2 1)
160 A 35 16 16 16 12x3 1) 12x2 1) 12x2 1
) 12x2 1)
200 A 50 25 25 25 20x2 12x2 1) 12x2 1
) 12x2 1)
250 A 70 35 35 35 20x3 12x2 1) 12x2 1
) 12x2 1)
315 A 95 50 50 50 20x4 12x3 1) 12x3 1
) 12x3 1)
400 A 50 50 50 20x6 20x2 20x2 20x2
500 A 70 50 70 30x6 20x3 20x3 20x3
630 A 95 75 95 30x8 20x4 20x3 20x4
800 A 40x10 30x4 30x3 30x4
1250 A 50x15 50x15 40x6 50x15
1600 A 2x50x15 50x15 40x6 50x15
1) Given the section of the terminal bolts of switches etc., a 12mm strip width was chosen for practical reasons;
however, 10 x 2 mm or 10 x 3 mm is already sufficient.

Halyester manual
4. SUPPLY MODULE ASSEMBLY
4.1 Supply modules with switch-disconnector 4-2

4.1.1.1 with segmented cable sealing box 4-3
4.1.1.2 without segmented cable sealing box 4-4

4.2 Supply modules with circuit breaker 4-12
4.2.3 1000 A/1250 A supply module, with 3 poles + N 4-15
4.2.4 1000 A/1250 A supply module, with 4 poles 4-16
Version 1.1 Supply module assembly 4-1

Halyester manual
4 SUPPLY MODULE ASSEMBLY
4.1 Supply modules with switch-disconnector
Introduction
The Halyester system can also be equipped with a double-busbar system suited for a maximum 1600 A
load if central supply is involved.
The switch boxes come with top or bottom connection.

With top connection, the terminal strips can be connected direct to copper busbars protruding
through the wall from the low-voltage compartment.
All models are available for TN - C or TN - S systems. *)
*) TN - C = L1, L2, L3, PEN

TN - S = PE, L1, L2, L3, N
If the switchgear and controlgear assembly is used in a TN-C system, the opening marked (PE)N in the
busbar support must be used for the PEN conductor.
Mounting
This chapter shows the detail drawings for mounting busbar connections and grommets.
Equalising busbars for double-busbar system

power supply - must be equipped with equalising busbars (see figure 3.13).
4-2 Supply module assembly Version 1.1

Halyester manual
4.1.1 1000 A supply module for bottom connection

with single-busbar system (15 x 24 mm) in 270 mm high box
4.1.1.1 with segmented cable sealing box

for connection of multi-core cables
see chapter 3 for busbar system data detail, see pages 4-10/4-11
busbar box
switch box
(DMV 1000)
3
maximum
phase 3x185 mm2 terminal box
N 3x185 mm2
PE 3x185 mm2
segmented cable sealing box
A
section A - A

Halyester manual
4.1.1.2 without segmented cable sealing box

with single-core cables through grommets
see chapter 3 for busbar system data detail, see page 4-10/4-11
busbar box
switch box
(DMV 1000)
3
terminal box
maximum
11x1x185 mm2
11
view C C
aanzicht
A section A - A
C

Halyester manual
4.1.2 1000 A supply module for top connection

see chapter 3 for busbar system data detail, see page 4-10
switch box
(DMV 1250)
busbar bux
A section A - A

Halyester manual

with double-busbar system (2x15 x 24 mm) in 540 mm high box
A
5
busbar box
switch box
assembly
montage (DMV 1250)
sequence
volgorde
a b
b a a b 9
B B
terminal box
maximum 24x1x240 mm2
11
A section A - A
3poles + solid neutral
C 4mm shim4 mm
opvulring
section B - B view C

Halyester manual

with double-busbar system (2 x15 x 24 mm) in 540 mm high box
switch box
(DMV1250)
busbar box
A section A - A

Halyester manual

with double-busbar system (2x15 x 24 mm) in 540 mm high box
see chapter 3 for busbar system data detail, see page 4-10/4-11
busbar box
switch box
assembly
montage (DMV1600)
sequence
volgorde
a b
10
b a a b
B B
maximum 24x1x240 mm2 terminal box
11
A 3 poles + solid neutral section A - A
C 22 shims
opvulplaten
section B - B view C

Halyester manual

switch box
(DMV 1600)
busbar box
section A -A
A

Halyester manual
4.1.7 Detail drawings of busbar connections and cable inlet
M12
M6 M12
1
2 3
M6
4 M6
5 M6
M6 9 Nm
M10 28 Nm
M12 40 Nm
M16 60 Nm
M16
M16
M12
7 8

Halyester manual
M6 9 Nm
M12 M12 40 Nm
M16 60 Nm
9
M12
M12
10
M12
11
M6

Halyester manual
4.2 Supply modules with circuit breaker
Introduction
The Halyester system is also suited for accommodating circuit breakers for maximum loads of up to
1500 A if central supply is involved. Depending on the load, type Aeromat AE 1000-SS, AE 1250-SS and
AE 1600-SS can be used.
The different configurations are shown in this manual.
The switch boxes complete with fixed part come with bottom connection.
Circuit breakers are supplied separately because of their weight.
The terminal box is suited for 6 x 1 x 240 mm2 per phase or neutral.
All models are available for TN - C or TN - S systems. *)
*) TN - C = L1, L2, L3, PEN

TN - S = PE, L1, L2, L3, N
If the switchgear and controlgear assembly is used in a TN-C system, the opening marked (PE)N in the
busbar support must be used for the PEN conductor.
Mounting
This chapter shows the detail drawings for mounting busbar connections and cable inlet.
Equalising busbars for double-busbar system

power supply - must be equipped with equalising busbars.
. Important
Do not transport pre-assembled circuit breakers in boxes

Halyester manual
4.2.1 1000 A supply module, with 3 poles + N

busbar box
5 e
A f f f f A
d c b a
switch box
(AE 1000-SS)
maximum 24x1x240 mm2 7
terminal box
B section B - BB - B
doorsnede
C
viewaanzicht
C C
assembly sequence a b c d e f
montagevolgorde
section A - AA - A
doorsnede

Halyester manual
4.2.2 1000 A supply module, with 4 poles

busbar box
e
A f f f f A
d c b a
switch box
(AE 1000-SS)
terminal box
B section B B- B- B
doorsnede
C
view C
aanzicht C
montagevolgorde
section A -AA- A
doorsnede

Halyester manual
4.2.3 1000 A/1250 A supply module, with 3 poles + N

with double-busbar system (2 x 15 x 24 mm) in 540 mm high box
busbar box
4
5
e
A A
f f f f
d c b a
switch box
(AE 1000-SS/AE 1250-SS)
terminal box
B C section B-B
doorsnede B - B
view aanzicht
C C
montagevolgorde
section A-A-A
doorsnede

Halyester manual
4.2.4 1000 A/1250 A supply module, with 4 poles

busbar box
e
A f f f f A
d c b a
switch box
(AE 1000-SS/AE 1250-SS)
terminal box
B C section B-B
doorsnede B-B
view C C
aanzicht
montagevolgorde
section A -AA- A
doorsnede

Halyester manual
4.2.5 1600 A supply module, with 3 poles + N

busbar box
4
5
e
A A
f f f f
d c b a
switch box
(AE 1600-SS)
maximum 24x1x240 mm2

7
terminal box
B C section B-BB-B
doorsnede
view C
aanzicht C
montagevolgorde
section A A- A
doorsnede -A

Halyester manual
4.2.6 1600 A supply module, with 4 poles

with double-busbar system (2 x 15 x 24 mm) in 540 mm high box
busbar box
4
5
e
A f f f f A
d c b a
switch box
(AE 1600-SS)
maximum24x1x240 mm2 7
terminal box
B C section B -BB- B
doorsnede
view aanzicht
C C
montagevolgorde
section A-A-A
doorsnede

Halyester manual
4.2.7 Detail drawings of busbar connection and cable inlet
1
5
M6 M16
2
M8
M6
M16
M12
M6
M6 9 Nm
M8 14 Nm
4 M12 40 Nm
M16 M16 60 Nm
M8
L1 L2 L3 N
M12 460-L1-1 464-L2-1 468-L3-1 472-N-1

461-L1-2 465-L2-2 469-L3-2 473-N-2
462-L1-3 466-L2-3 470-L3-3 474-N-3
463-L1-4 467-L2-4 471-L3-4
coding of strips

Halyester manual
6 M12
M12
475-L1-1
476-L1-2 478-L2-1
477-L1-3 479-L2-2 478-L2-1
480-L2-3 479-L2-2 478-L2-1
coding of strips
480-L2-3 479-L2-2
480-L2-3
M12 40 Nm

Halyester manual
5.1 Plastic cable glands 5-2
5.2 Cable sealing box 5-3
5.3 Segmented cable sealing box 5-6
5.4 Special configuration for top connection 5-8
Version 1.1 Cable sealing boxes 5-1

Halyester manual
5.1 Plastic cable glands
According to standard IEC 60439 plastic boxes are not allowed to be interconnected by conductive
parts, in order to limit a possible fault voltage to the relevant box. Nor is it permitted to feed any con-
ductive parts from the inside to the outside. This means that metal parts which have to be fed through
the box, must be insulated on the inside or outside. That’s why the Halyester product range includes
plastic cable glands for cable diameters from 3.5 to 40 mm. Listed in the table below are the cable
glands, associated cable diameters and holes to be drilled.
The lock nut of a cable gland has the largest diameter. This diameter should be taken into account
when fitting a cable gland in the casing or end cover.
Table 5.1: Overview of cable glands
size cable diameter drill type

(mm) (mm)
Pg 7 3,5 - 6 13 E 407
Pg 9 6 - 8 16 E 409
5
Pg 11 8 - 10 19 E 411
4 Pg 13,5 10 - 12 21 E 413
3 Pg 16 12 - 14 23 E 416
2 Pg 21 14 - 18 29 E 421
Pg 29 18 - 24 38 E 429
1
Pg 36 24 - 30 48 E 436
Figure 5.1: Exploded view of cable gland Pg 42 30 - 35 55 E 442
1 cable gland follower Pg 48 35 - 40 60 E 448
2 thrust washer
3 cable gland ring
4 cable gland housing
5 lock nuts
5-2 Cable sealing boxes Version 1.1

Halyester manual
5.2 Cable sealing box
Type E 403 and E 404 cable sealing boxes

Cable sealing boxes can be fitted to boxes with openings 3 and 4.
They are available in “blank’ configuration and with 60mm or 80mm dia. holes.
These holes are provided with rubber grommets from which the diameter of the cable(s) to be fed
through can be cut out. For this purpose, various nicks are made in the grommets, in line with the
most prevalent cable diameters. Before the cable sealing box with the accompanying fastener material
is fitted to the casing, the front post must be cut out of the casing which has markings for that pur-
pose. The cable sealing boxes are provided with sealing and locking screws.
Mounting
- saw the front post from the casing at the markings (see chapter 3)
- cut the rubber grommet to the correct size
- fit the grommet around the cable
- slide the bushing over the cable core and then connect the cores
- fit the cable sealing box to the casing, using four hexagon head bolts M6x8
- place the rubber grommet in the cable sealing box
Figure 5.3: Rubber grommet
Table 5.2: Holes to be drilled in the cable sealing box for the
grommet
max. cable diameter drill application

mm mm
60 75 E 403/160 E404/360
E 403/260
80 95 E 404/180
E 404/280
Figure 5.2: Mounting of cable sealing box

Halyester manual
Dimensions
type B B’ E
opening 3
167
E 403 223 165 196
E 403/160 223 165 196
E 403/260 223 165 196
opening 4
B' M6 E 404 313 255 286
E 404/180 313 255 286
E 404/280 313 255 286
118 68 97 E 404/360 313 255 286
59
E
B
Figure 5.4: Cable sealing box dimensions
opening 3 opening 4
type type
E 403 E 404
ø60 ø80
E 403 / 160 E 404 / 180

ø60 ø80
E 403/ 260 E 404 / 280

85 120
ø60
E 404 / 360
85 85
Figure 5.5: Cable sealing box configurations

Halyester manual
Top connection
If the cable is fed from the top, silicone sealant
must be applied at the front local to the saw
notches. This is done to obtain a proper seal.
Figure 5.6: Sealing of the cable sealing box
Cable attachment
For terminal boxes having a width of 270 mm2
and 360 mm2 there are braces to which cables
can be fitted, using Pohl clamps or tyraps. The
braces must be fitted with the fastening screws
of the mounting plates. The height of the braces
is such that the cables can be fastened at about
the same height as the connection points of
switches, fuse holders, etc.
Figure 5.7: Fitting of brace for Pohl clamp or tyraps

Halyester manual
5.3 Segmented cable sealing box
Type EG 403 and EG 404 segmented cable sealing boxes

A maximum of two 60mm dia. cables can be fed through the segmented cable sealing box. The cable
sealing boxes can be fitted under a box with opening 3. Type EG 404 cable sealing box for opening 4 is
suited for three 60mm or two 80mm dia. cables. For the segmented cable sealing box with cable clip
there are filling pieces reducing the inlet from 60 to 40 mm. In addition, the clips for the 60mm dia.
cable can be provided with a segmented rubber ring, from which openings can be cut for cable diame-
ters of 41 - 46 and 55 mm.
Mounting
- saw the front post from the casing along the markings
- fit the rear half of the cable sealing box to the casing, using the hexagon head bolts
M6 x 16 supplied.
- if the cable diameter is too small for the relevant clip, a filling piece can be fitted
- if the cable size deviates from the size of the half clips or filling pieces, fill the cable
clip with tape
- fit the half cable clip at the front in such a way that at least a space of 0.5 mm remains between
both half clips
- complete the cable sealing box by fitting its front half by means of four cheese head screws
(M5 x 25) and safety rings
detail of band sealing
Remark:
Segmented cable sealing boxes can be provided
0 - 0.5mm with a wire or band seal. This requires the fastening
screw (M5 x 25) to be replaced with a special seal
screw and seal plate.
Figure 5.8: Mounting of cable sealing box

Halyester manual
Dimensions
type A B C
opening 3
EG 403/160 200 226 196
A EG 403/260 200 226 196
opening 4
EG 404/180 270 316 286
EG 404/280 270 316 286
EG 404/160 270 316 286
B EG 404/260 270 316 286
EG 404/360 270 316 286
C
25 7
120 68
Figure 5.9: Dimensions of segmented cable sealing box
opening 3 opening 4
type type type

60 60 80
EG 403/160 EG 404/160 EG 404/180
60 60 60 80
EG 403/260 EG 404/260 EG 404/280

50.5 50.5
50.5 50.5 61 61
60
EG 404/360
100.5 100.5
Figure 5.10: Segmented cable sealing box configurations

Halyester manual
5.4 Special configuration for top connection
Top connection caps

If cables come from below and must be connected at the top in the switchgear and controlgear assem-
bly, top connection caps can be used.
A top connection cap can be provided with cable glands or a cable sealing box.
If a cable sealing box is used in combination with a top connection cap, another opening must be
made in the bottom of the casing. In this case, only type K 434 box can be used.
The hexagon head bolts M6 for fixing the cap must have a 50mm minimum length and need not be
provided with an insulated head because no voltage can be transferred from one box to the other.
Because of the additional intermediate coupling piece, the fastener material for the cable sealing box
must be about 16 mm longer than the fastener material supplied.
When top connection caps are used, the depth of the assembly will increase, which implies that exten-
ded spacers must be fitted to the frame uprights in the case of floor/wall mounting.
When the supporting frame is assembled, the uprights must be placed so that the top connection caps
do not stand in the way. For assembly of the supporting frames please refer to chapter 6.
50 mmmin.
Note!marking
to the rear
Figure 5.11: Top connection cap with cable sealing box Figure 5.12: Exploded view of top connection cap

Halyester manual
Dimensions of openings in top connection cap
Type K 433 box
space for
cable glands
opening 3
87± 0.5
Type K 434 box for type E 403 or EG 403

cable sealing box
opening 3
248 ± 0.5
opening 3
87± 0.5
Type K 434 box
space for
cable glands
opening 4
87± 0.5
Figure 5.13: Configurations
Remark: For the dimensions of opening 3 and 4 please refer to chapter 3.

Halyester manual
6. FRAME MOUNTING
6.1 Wall mounting 6-2

6.1.1 single boxes 6-2
6.1.2 wall mounting for small combinations 6-3
6.2 Floor / wall mounting 6-5
6.3 Free-standing arrangement 6-7
6.4 Extensions of wall frames 6-8

6.4.1 wall frames for small combinations 6-8
6.4.2 floor/wall frames and frames for free-standing arrangement 6-9
Version 1.1 Frame mounting 6-1

Halyester manual
6. FRAME MOUNTING
6.1 Wall mounting
6.1.1 Single boxes
Depending on their size, Halyester boxes have

four or six holes for wall mounting.
Mounting
- mark off the holes to be drilled in the wall,

using a pencil
- drill 6mm dia. holes in the wall Figure 6.1: Wall mounting
Boxes can also be mounted to a wall, using ex-

ternal fixing brackets. The advantage of this type
of mounting is that completely assembled boxes
(complete with cover) can be mounted to the
wall. In addition, boxes with fixing brackets can
be moved easily, for instance in the case of con-
struction work.
- remove the cover and any hinge pins Ø7 mm

- now fit the fixing bracket, using a cheese head
screw (M6 x 16), at an angle of 45° to the
bottom of the casing.
Remark:
When boxes with more than four fixing holes are
involved, only the upper and lower holes can be
provided with an ear. Figure 6.2: Mounting of fixing bracket
With coupled boxes, not all fixing holes can be
provided with a fixing bracket. The fixing brack-
ets come in sets of 4 pieces complete with faste-
ning screws.
6-2 Frame mounting Version 1.1

Halyester manual
6.1.2 Wall mounting for small combinations
This mounting frame at least comprises two horizontal C sections, whose dimensions are shown in the
figure below.
Mounting
- fit the C sections at the level of the upper box fixing holes
- using the braces fitted to the ends of the C section, the assembly can be mounted to the wall.
The required minimum length of the C sections corresponds with the length of the combination of
boxes measured over the widest part of the installation. The largest bridging between two sections
should not exceed 2x270 mm = 540 mm.
If the combination length exceeds the maximum supporting distance, several C sections and/or various
supporting braces must be fitted. Data on the fixing distances of the frame also apply to Halyester
boxes with a “normal” contents.
If the boxes are equipped with transformers or other heavy equipment, the supporting distances must
be reduced, at customer’s own discretion.
1350 mm max.
540 mm max.
Figure 6.3:Wall mounting of small combinations

Halyester manual
- slide square nuts M6 into the C section; the

actual number of nuts should correspond with
the number of box fixing points on the
section.
square
nuts
Figure 6.4: C section with square nuts
- fit the required number of filling pieces to the

C section, when two adjoining fixing points filling piece
are involved.
- now fit the boxes with cheese head screws

(M6 x 25) on the section, after the boxes have
been interconnected.
Figure 6.5: Mounting of filling piece
- fit the braces. In this way, extensions are Ø14 mm

possible.
- now mount the combination of boxes to the

wall. The braces with 14mm dia. holes provide
sufficient clearance between fixing bolts M12
and the actual braces to mount the
combination horizontally to the wall.
Figure 6.6: Fixing brace at the corner of the box

Halyester manual
6.2 Floor / wall mounting
Switchgear which is too heavy or too large for a Ø14 mm

supporting frame for wall mounting can be pro-
vided with a frame for floor/wall mounting. Up-
rights for a floor/wall frame are available in four
heights: 1530 mm, 1800 mm, 2070 mm and
spacing bracket
2340 mm.
90 mm
The upright can be secured with a spacing
bracket. If the distance between the rear side of
the installation and the wall is too small, for in-
stance because top connection caps are used,
one or more spacing strips can be fitted for each
upright (see figure 6.8). When using spacing
strips, the distance between the wall and the
rear side of the installation is approximately 200
mm. The number of uprights to be fitted de-
pends on the length of the installation. The up-
rights are spaced at 1350 mm as a maximum and
the C sections at 540 mm.
Mounting
- level the uprights 53 mm
- anchor the uprights, both to the floor and to
the wall (see figure 6.7)
- fit the spacing bracket in the upper slotted Ø14 mm
hole, using the clamping bracket with which
the upper C section is also fixed to the frame 110 mm
(see figure 6.9)
Figure 6.7: Mounting of uprights
To allow future extensions, the centre of the ou-

ter uprights is levelled with the outside of the in-
stallation.
The frame upright in between can be placed
both at the transition between two boxes and
centrally behind a box, if top connection caps are
used or if the symmetry of the assembly calls for
such an arrangement. Ø 14 mm M6
Figure 6.8: Spacing strip at upright

Halyester manual
The required C section length corresponds with

2 3 4
the length of the installation, i.e. the sum of the
busbar boxes measured across the widest part of
the casing, or n x 90 mm.
If the length of the controlgear exceeds the stan-
dard length of the C section (abt. 5 m), all sec- M8x16
tions to be coupled must be secured to the
upright by one clamping bracket.
To allow future extensions, only half of the C sec- 1

tion must be fitted to the outer uprights.
Mounting of boxes on a C section, using square

nuts and a filling piece, is identical to wall frame
mounting.
1 upright
staander
afstandsbeugel
2 spacing bracket
3 CC-profiel
section
4 clamping bracket
klembeugel
Figure 6.9: Floor/wall frame mounting

Halyester manual
6.3 Free-standing arrangement
Switchgear and controlgear assemblies which

cannot be mounted to or against a wall can be
provided with a supporting frame for free-stan-
ding arrangement.
This frame can also be used for installations in
back-to-back arrangement and assemblies arran-
ged in corners.
In addition, it is possible to provide this frame
with a sun/rain cover (see chapter 7).
The frame standard for free-standing arrange-
ment consists of two uprights which must be
mounted back to back, using two spacers. Up-
rights with a length of 2340 mm require three
spacers.
A complete standard for free-standing arrange-

ment comprises the following parts:
• 2 uprights (for floor/wall mounting)
• 2 or 3 spacers
• 8 or 12 hexagon head bolts M8x20
• 8 or 12 spring washers
• 8 or 12 flat washers
• 8 or 12 hexagon nuts M8
When spacers are fitted, it should be taken into

account that no C sections must be secured at
the place reserved for these spacers.
Otherwise, the positioning of a frame for free-
31
0
standing arrangement and the installation of

m
m
controlgear to a frame do not differ from the

mounting of a frame to the floor/wall. Figure 6.10: Frame standard for free-standing arrangement

Halyester manual
6.4 Wall frame extensions
6.4.1 Wall frames for small combinations
Wall frames can be extended both to the left

and right. In addition, it is readily possible to ex-
tend an installation both in upward and down-
ward direction.
Mounting
C sections are extended to the left and right as
coupling strip
follows:
- determine the length of the sections to be

extended; their length is identical to the width
Figure 6.11: C section extension
of the combination to be built on, measured
across the widest part of the boxes
- remove the square nuts (used to secure the

fixing braces to the C sections) from the
installation side to be extended
- fit half of the coupling strip in the existing

section, as shown in figure 6.11
- fit the fixing brace and the existing box to the

coupling strip
- extend the frame by sliding the extension

section onto the coupling strips and fixing it
For subsequent frame mounting please refer to

the rules set out in this chapter.

Halyester manual
6.4.2 Floor/wall frames and frames for free-standing arrangement
Frames for floor/wall mounting and free-stan-

ding arrangement can be extended at both sides
of the installation.
In this case the distance between the new frame
uprights and the outer existing standard is not
allowed to exceed 1350 mm either.
The required C section length corresponds with
the length of the extension, measured across the
widest part of the busbar box(es).
Figure 6.12: C sections bracketed to upright
The new sections on the outer upright of the

existing installation and the section already fit-
ted are secured as follows by one clamping
bracket:
- loosen the hexagon bolt a little and slide the

C section under the bracket. Then re-tighten
the bolt.
If the extension requires one or more sections to

be mounted on the upright of the existing instal-
lation, the required clamping brackets and
sections can be fitted in those places without
C section. This is not only true of floor/wall frame
extensions but also of free-standing frame
extensions.

Halyester manual
7.1 Arrangement in corners 7-2
7.2 Back-to-back arrangement 7-5
7.3 Sun/rain cover 7-7
Version 1.1 Special configurations 7-1

Halyester manual
7.1 Arrangement in corners

If a wall in a particular room is too short for arrangement of a switchgear and controlgear assembly,
the equipment can be arranged in a corner (recessed), using one or more angular busbar boxes.
An angular busbar box combination comprises:

1 type KB 432 casing provided with a plastic feed-through plate and 1 type R 432 busbar box.
Required for mounting the feed-through plate on the casing are:

• four threaded sleeves (from hexagon bolts M16)
• four countersunk cap screws (M6x20)
The space required for a corner box when using various supporting structures is shown in the figure
below.
The main busbars are coupled in both boxes next to the type KB 432 casing.
B 180
uprights
staanders
feed-through plate
doorvoerplaat
A KB 432
type of frame A B
(mm) (mm)
floor/wall 275 230
free-standing 375min. 330 min.
wall 210 165
Figure 7.1: Corner arrangement
7-2 Special configurations Version 1.1

Halyester manual
2.5±0.5
M6
12+2
16+2
26±1
M16
1.5+0.5
Figure 7.2: Type KB 432 casing with feed-through plate Figure 7.3: Threaded sleeve
12,5±0.5 155±0.5
68±0.5 68±0.5
24.5±0.5
40±0.5 14±0.5
8±0.2
42±0.5 34±0.5
a = for main busbars

a
b = for auxiliary busbars
b
98±0.5
120±0.5
20+1
182±0.5
270±0.5
245±0.2
196±0.2
30+1
44±0.5
42±0.5
72±0.5
10±0.5
113±0.5
180±0.5
Ø7±0.2 90°±1°
Ø12.5+1
Figure 7.4: Feed-through plate for type KB 432 casing

Halyester manual
Interconnection busbar for main busbar Interconnection busbar for auxiliary busbar
53±1 53±1
45° 154±1
20+5
20+5
113±1
105±1
180±1 67±1
busbar dimensions in line with the busbar system used (see chapter 3)
Figure 7.5: Mounting of interconnection busbars

Halyester manual
7.2 Back-to-back arrangement
With the switchgear and controlgear assembly in back-to-back arrangement, the busbar systems must
be interconnected using two type K 433 and one type K 432 boxes.
The bottom of the type K 433 boxes must have an opening 3.
In view of the short-circuit strength the boxes in the side walls as well as in the relevant bottoms must
be provided with a busbar support.
To ensure a proper sealing between the interconnection boxes and the assembly, a type U 430 connec-
ting piece is fitted to the bottom of the type K 433 boxes.
The main busbars must be coupled in the interconnection boxes using busbar coupling clamps.
For the dimensions of the coupling busbars please refer to table 7.1.
In determining the required space, allowance must be made for any flanges for increasing depth,
protruding handles etc.
A back-to-back arrangement can only be realised by using a supporting structure for free-standing ar-
rangement, see chapter 7.
K 433 K 432 K 433
720 mm
Figure 7.6: Back-to-back arrangement of controlgear assembly with interconnection box

Halyester manual
for size of
opening 3
see chapter 3
opening 3
94 ± 0.5
Figure 7.7: Type K 433 interconnection box with opening 3 in bottom
for dimensions
see table 7.1
B
5-5 A
Figure 7.8: Coupling busbars for interconnection box
Table 7.1: Overview of coupling rails

load copper strip number destined for dimensions
(mm) (mm)
A A B
315 15 x 4 8 L1,L2,L3, N 35 245

15 x 3 2 PE 35 245
500 15 x 8 6 L1,L2,L3 35 245

15 x 4 4 N en PE 35 245
630 15 x 16 6 L1,L2,L3 35 245

15 x 8 4 N 35 245
15 x 6 2 PE 35 245

Halyester manual
7.3 Sun/rain cover
Types of arrangement
To protect switchgear and controlgear assemblies from direct sun light and rain, it can be provided
with a sun/rain cover.
This cover is available in three versions:
• free-standing arrangement
• back-to-back arrangement
• floor/wall arrangement
These arrangements are shown diagrammatically below.
free-standing back-to-back floor/wall
Figure 7.9: Sun/rain cover arrangements
Parts for mounting the sun/rain cover come as a standard package with one frame standard. The cor-
rugated plates have a 900mm working width and are available in 1000mm and 1300mm lengths.
Free-standing arrangement
U-bracket
A free-standing cover is assembled as follows:
C section
- fit the support strip to the inside of the up support strip
rights, using the hexagon head bolt (M8 x 25) M6x20
in the upper slotted hole of the upright
- if the upper slotted hole in the upright is also
M8x25 clamping bracket
used to fit the C section to the upright, the
support strip must be fixed by means of a upright
hexagon head bolt and a clamping bracket
- fix the C section (with the opening pointing Figure 7.10: Fixation of C section
downwards) to the support strip with U
bracket, using two hexagon head bolts
(M6x20).

Halyester manual
- insert half of the coupling spindle into the

ends of the C section that has been fitted. M6x20
- interconnect the sections using bolts M8 x 10
- fit three supports per aluminium corrugated coupling spindle
support
plate to the C sections, fix these supports with
U brackets to the sections, using two hexagon
bolts (M6x20) per bracket
M8x10
Figure 7.11: Mounting of coupling spindle
- fit the corrugated plates with sufficient over

lap to the supports
- mark off the fixing holes in line with the holes sealing caps M6x20
in the supports
- drill the holes at the top of the corrugation
- secure the plates using bolts M6x20 and
sealing caps
Figure 7.12: Mounting of corrugated plates
1000-13
0 0
2000
1900 min.
1800
Figure 7.13: Dimensions of free-standing arrangement

Halyester manual
Back-to-back arrangement
Sun/rain cover for switchgear and controlgear as- M6x20

sembly in back-to-back arrangement is twice the
cover for free-standing arrangement
- couple the supports back to back using

hexagon bolts (M6x20)
Figure 7.14: Back-to-back coupling of supports
1000-13
1000-1300 00
2000
1900 min.
1800
Figure 7.15: Dimensions of back-to-back arrangement

Halyester manual
Figure 7.16: Back-to-back arrangement including mounting details

Halyester manual
Floor / wall arrangement 1000-13

00
Assemblies with frame for floor/wall arrange-
ment can also be equipped with a sun/rain cover.
This cover is mounted as follows:

- fix the uprights 60 mm from the wall, measured
from the centre of the fixing holes in the foot
- fit the support strip between the spacer at th
2000
bottom of the upright and the wall
1900 min.
1800
- anchor the whole to the wall
Further, the fitting and mounting procedure for

the C sections, supports, corrugated plates etc. is
identical to the one specified under “free-stan-
ding arrangement”.
The height of a sun/rain cover depends on the
Figure 7.17: Dimensions of floor/wall arrangement
controlgear assembly to be installed.
It is advised to stick to the minimum heights
shown in the drawings in view of the length of
the operating personnel.

Halyester manual
8. TECHNICAL DATA
8.1 Technical specification 8-2

8.1.1 characteristics of plastics used 8-3
8.1.2 resistance to chemicals 8-3
8.2 Loads and short-circuit strength of busbar systems 8-4
8.3 Technical data of distribution transformers 8-5
8.4 Tightening torques 8-5
8.5 Standards and certificates 8-6
Version 1.1 Technical data 8-1

Halyester manual
8. TECHNICAL DATA
8.1 Technical specification
Rated operational voltage max. Ue 1000 V
Rated insulation voltage max. Ui 1000 V
Rated impulse withstand voltage max. Uimp 12 kV
Rated current
supply max. 1600 A
busbar system max. 1500 A
Rated short-time withstand current max. Icw 50 kA - 1s
Rated peak withstand current max. Ipk 110 kA
Degree of protection to BS EN 60529 max. IP66
Type of protection total insulation
Impact strength according to BS EN 50102

casings IK 09
covers IK 10
Ambient temperature -25° C ... + 70° C.
Application indoor or outdoor installation
Cable connection at the top and/or bottom
Operation at the front
Arrangement free-standing
wall
back-to-back
Extension horizontal and vertical
Standards BS EN 60439-1
EN 60439-1
IEC 60439-1
BS EN 60529
BS EN 50102
Certification KEMA-Keur
8-2 Technical data Version 1.1

Halyester manual
8.1.1 Characteristics of plastics used
characteristics testing procedure unit polycarbonate glasmat-

reinforced
DIN other polyester*)
mechanical
tensile strength 53455 ASTM D638 N/mm2 63 85
E-modulus 53457 ASTM D638 kN/mm2 2,3 9
flexural strength 53452 ASTM D790 N/mm2 90 175
notched impact strength 53453 - kJ/m2 25 60
thermal
flammability class - UL94 - 94 V2 (1.5 mm) 94 V1 (2 mm)
heat resistance VICAT B/120 53460 - °C 100 -
Martens degree 53458 - °C - >142
operating temperature - UL764 °C - >200
glow-wire test - IEC 695-2-1 °C/mm 850/1.0 960/1.0
physical
water absorption 7708T2 - mg - 50
water absorption equilibrium - ASTM D570 % 0.35 -
elektrical
volume resistivity 53482 ASTM D527 ohm.cm >1015 >1012
surface resistance 53482 IEC 93 ohm.cm - >1011
tracking resistance 53480 IEC 112 V/KC 250 >600
*) glass compound: 36% by weight, 60% by volume
8.1.2 Resistance to chemicals
chemicals polycarbonate glasmat reinforced

polyester
acetone - -
10 %ammonia - +
25 %ammonia vapour - +
33 %liquid sodium hydroxyde - x
acetic acid - +
40 %hydrogen fluoride vapour + x
15 %potassium bisulphide vapour + +
sodium sulphide + +
glycerol, liquid + +
mixture of 3 parts of propyl alcohol and 1 part
of methyl benzene + +
benzene - +
toluene - x
xylene - +
dichloride ethylene - +
synthetic oil - +
+ = resistant; x = resistant (limited) ; - = non-resistant

Halyester manual
8.2 Loads and short-circuit strength of busbar systems
Busbar boxes
load rail data* short-circuit strength
dimensions without fuses with fuses

single-side central (mm) short-time peak
L N PE PEN withstand withstand In Ieff
Icw Ipk
15x4 12 kA - 0.5 s 24 kA 400 A 50 kA

315 A 500 A
15x4 15x3 15x4 12 kA - 0.5 s 24 kA
630 A 30 kA
15 kA - 0.3 s 30 kA
15x8 20 kA - 1 s 50 kA
630 A 50 kA
24 kA - 0.75 s 50 kA
500 A 800 A
15x4 15x4 15x4 12 kA - 0.5 s 24 kA
630 A 30 kA
15 kA - 0.3 s 30 kA
15x16 32 kA - 1 s 67 kA 630 A 50 kA
630 A 1000 A
15x8 15x6 15x8 19.2 kA - 1 s 40 kA 630 A 30 kA
15x24 32 kA - 1 s 67 kA 630 A 50 kA
800 A 1000 A
15x12 15x6 15x12 19.2 kA - 1 s 40,2 kA 630 A 30 kA
2(15x24) 50 kA - 1 s 110 kA
1500 A 1600 A
2(15x12) 2(15x6) 2(15x12) 30 kA - 1 s 66 kA
* Maximum rail support distance : 360 mm
Busbar connection boxes
load busbar data short-circuit strength
single - side central dimensions without fuses
(mm) short-time withstand peak withstand
L N PE Icw Ipk
160 A 250 A 15x4 15x4 15x4 10 kA - 0.3 s 17 kA

Halyester manual
8.3 Technical data of distribution transformers
rated rated short-circuit short-circuit

output current current current
(kVA) at In (A) Ik (kAeff) Ik (kAeff)
400 V Uk = 4% Uk = 6%
400 578 14,5 9,5

500 722 18 12
630 910 23 15
800 1156 29 19
1000 1444 36 24
1250 1805 45 30
8.4 Tightening torques
For electrical connections
hexagonal bolt connections, quality at least 5.6
thread diameter M5 M6 M8 M 10 M 12 M 16
spanner width mm sw 10 sw 13 sw 17 sw 19 sw 24
tightening torque Nm 7.0 14.0 28.0 40.0 60.0
hexagonal socket head bolt connections with large head, quality at least 8.8
spanner width mm sw 4 sw 5 sw 6 sw 8 sw 10
tightening torque Nm 7.0 9.0 20.0 40.0 60.0
hexagonal socket head bolt connections with small head, quality at least 8.8
spanner width mm sw 4 sw 5 sw 6 sw 8
tightening torque Nm 7.0 9.0 20.0 40.0
hexagonal socket head bolt connections without head, quality at least 8.8
spanner width mm sw 4 sw 5 sw 6 sw 8
tightening torque Nm 7.0 9.0 20.0 40.0

Halyester manual
8.5 Standards and certificates
Standards
The Halyester system meets the following standards:
• national: BS EN 60439-1
• European: EN 60439 - 1
• international: IEC 60439 - 1
The Halyester system can be used in TN-S, TN-C, TN-C-S and TT current systems.
It is a TTA (Type-Tested-Assembly)
BS EN 60439 - 1 Specification for: type-tested and partially type-tested assemblies

Low-voltage switchgear and controlgear assemblies
BS EN 60529 Specification for:

Degrees of protection provided by enclosures (IP code)
BS EN 50102 Degrees of protection provided by enclosures for electrical equipment against

external mechanical impacts (IK code)
Certificates
KEMA-Keur

Halyester manual
9. ENCLOSURES
9.1 Test report 9-2
9.2 Certificate 9-6
9.3 EU declaration of conformity 9-7
9.4 KEMA-Keur certificate 9-8
9.5 Revision overview 9-9
Version 1.1 Enclosures 9-1

Halyester manual
9. ENCLOSURES
9.1 Test report
Test report
Test report number:
Test report relating to low-voltage switchgear and controlgear assemblies

according to BS EN 60439-1, EN 60439-1 and IEC 60439-1
Make: Eaton Holec
System: Halyester
Assembled by:
Date:
Signature:
Enclosure:
9-2 Enclosures Version 1.1

Halyester manual
Test report
Item to be tested Approved NA Remarks
1 Name plate
1.1 Visible
1.2 Type designation / identification number
2 Connections
Conductors between main busbar
systems and outgoing components
2.1 Strip connections:
in line with Eaton Holec table
2.2 Section of wire connections:
in line with Eaton Holec table
If deviating dimensions have been used,
they are shown in the relevant drawing(s)
3 Designation of conductors of
main and auxiliary current paths
3.1 Numbers/letters
3.2 Colours
3.3 Symbols
4 Designation of protective conductor

PE and neutral conductor
4.1 Via marking, colour, location
4.2 PEN designation on PEN conductor in
the case of a TN-C system
5 Functional test
5.1 Necessary
If so:
5.2 Mechanical actuating elements /

interlocks etc.

Halyester manual
Test report
Item to be tested Approved NA Remarks
6 Insulation test
Tick applicable insulation test according to 6a or 6b.
6a High-voltage test
(At Ui ≤ 690 V 2.5 kV 1 s)
6a.1 Switchgear switched on

or
6a.2 Per current path component
6b Visual inspection
7 Protective conductors
7.1 Check on protective conductors and
electrical conducting parts by means of
inspection or measurement in accordance
with IEC 60439-1, art. 8.2.4
8 Creepage distances,
clearances and clearances in air
8.1 In accordance with EN-IEC 60439-1,
table 14 and table 16
9 Terminals
9.1 Suited for:
Copper
Aluminium
Copper and aluminium*
* To be specified in drawing.
10 Short-circuit strength of
busbar system*
10.1 315 A 12 kA 0.5 s 24 kA peak
10.2 500 A 20 kA 1s 50 kA peak
10.3 630 A 32 kA 1s 67 kA peak
10.4 800 A 32 kA 1s 67 kA peak
10.5 1500 A 50 KA 1s 67 kA peak

* Tick busbar system used.
11 Thermal test
11.1 Temperature rise verification by
extrapolation or test (in accordance with
IEC 60439-1, art. 8.2.1)
12 Degree of protection
12.1 IP degree

Halyester manual
Test report
11 Remarks

Halyester manual
9.2 Certificate
Certificate
The undersigned,
Name:
Company:
Registered office:
declares that the low-voltage switchgear and controlgear assembly
Make: Eaton Holec
System: Halyester
Type- designation:
Identification Number:
has been assembled in line with manufacturer’s instructions and tested

in accordance with the requirements set out in standard IEC 60439-1
This certificate is accompanied by a test report featuring:
Test report number:
Electrical characteristics:
Rated operational voltage in V:
Rated current in A:
Short-circuit strength of busbar

system: See test report, item 10
Degree of protection: IP 56
Date:
Signature:
Enclosure: Test report

Halyester manual
9.3 EU declaration of conformity
Declaration of conformity DOC 95 -220 /E
We, Eaton Electric N.V.,

Europalaan 202, 7550 AA Hengelo, The Netherlands
declare that the product:
Halyester, Switchgear and controlgear assemblies

(including accessories)
provided that it is installed, maintained and used in the application

for which it is made, with respect of the ‘’professional practices‘’
relevant installation standards and manufacturers instructions,
complies with the provisions of Council Directive(s):
73 / 23 / EEC of 19 February 1973 (L 77)

modified by
93 / 68 / EEC of 22 July 1993 (L 220)
Y
so called: Low Voltage Directive
It is in conformity with the following harmonized standard(s) or
P
other normative document(s).
Low voltage switchgear and controlgear assemblies
O
Type-tested and partially type-tested assemblies
C
EN 60439 - 1
January 1994
S. Castelein
Data of affixing marking: 95 Director Eaton Electric N.V.

Halyester manual
9.4 KEMA-Keur certificate

Halyester manual
9.5 Revision overview
Page Version Date Page Version Date
Chapter 1 3-13 1.0 98 - 02

1-1 1.0 98 - 02 3-14 1.0 98 - 02
1-2 1.0 98 - 02 3-15 1.0 98 - 02
1-3 1.0 98 - 02 3-16 1.0 98 - 02
3-17 1.0 98 - 02
Chapter 2
2-1 1.0 98 - 02 Chapter 4
2-2 1.0 98 - 02 4-1 1.0 98 - 02
2-3 1.0 98 - 02 4-2 1.0 98 - 02
2-4 1.0 98 - 02 4-3 1.0 98 - 02
2-5 1.0 98 - 02 4-4 1.0 98 - 02
2-6 1.0 98 - 02 4-5 1.0 98 - 02
2-7 1.0 98 - 02 4-6 1.0 98 - 02
2-8 1.0 98 - 02 4-7 1.0 98 - 02
2-9 1.0 98 - 02 4-8 1.0 98 - 02
2-10 1.0 98 - 02 4-9 1.0 98 - 02
2-11 1.0 98 - 02 4-10 1.0 98 - 02
2-12 1.0 98 - 02 4-11 1.0 98 - 02
2-13 1.0 98 - 02 4-12 1.0 98 - 02
2-14 1.0 98 - 02 4-13 1.0 98 - 02
2-15 1.0 98 - 02 4-14 1.0 98 - 02
2-16 1.0 98 - 02 4-15 1.0 98 - 02
2-17 1.0 98 - 02 4-16 1.0 98 - 02
2-18 1.0 98 - 02 4-17 1.0 98 - 02
2-19 1.0 98 - 02 4-18 1.0 98 - 02
2-20 1.0 98 - 02 4-19 1.0 98 - 02
2-21 1.0 98 - 02 4-20 1.0 98 - 02
2-22 1.0 98 - 02
2-23 1.0 98 - 02 Chapter 5
2-24 1.0 98 - 02 5-1 1.0 98 - 02
2-25 1.0 98 - 02 5-2 1.0 98 - 02
2-26 1.0 98 - 02 5-3 1.0 98 - 02
2-27 1.0 98 - 02 5-4 1.0 98 - 02
2-28 1.0 98 - 02 5-5 1.0 98 - 02
2-29 1.0 98 - 02 5-6 1.0 98 - 02
2-30 1.0 98 - 02 5-7 1.0 98 - 02
5-8 1.0 98 - 02
Chapter 3 5-9 1.0 98 - 02
3-1 1.0 98 - 02
3-2 1.0 98 - 02 Chapter 6
3-3 1.0 98 - 02 6-1 1.0 98 - 02
3-4 1.0 98 - 02 6-2 1.0 98 - 02
3-5 1.0 98 - 02 6-3 1.0 98 - 02
3-6 1.0 98 - 02 6-4 1.0 98 - 02
3-7 1.0 98 - 02 6-5 1.0 98 - 02
3-8 1.0 98 - 02 6-6 1.0 98 - 02
3-9 1.0 98 - 02 6-7 1.0 98 - 02
3-10 1.0 98 - 02 6-8 1.0 98 - 02
3-11 1.0 98 - 02 6-9 1.0 98 - 02
3-12 1.0 98 - 02

Halyester manual
Page Version Date Page Version Date
Chapter 7
7-1 1.0 98 - 02
7-2 1.0 98 - 02
7-3 1.0 98 - 02
7-4 1.0 98 - 02
7-5 1.0 98 - 02
7-6 1.0 98 - 02
7-7 1.0 98 - 02
7-8 1.0 98 - 02
7-9 1.0 98 - 02
7-10 1.0 98 - 02
7-11 1.0 98 - 02
Chapter 8
8-1 1.0 98 - 02
8-2 1.0 98 - 02
8-3 1.0 98 - 02
8-4 1.0 98 - 02
8-5 1.0 98 - 02
8-6 1.0 98 - 02
Chapter 9
9-1 1.0 98 - 02
9-2 1.0 98 - 02
9-3 1.0 98 - 02
9-4 1.0 98 - 02
9-5 1.0 98 - 02
9-6 1.0 98 - 02
9-7 1.0 98 - 02
9-8 1.0 98 - 02
9-9 1.0 98 - 02
9-10 1.0 98 - 02

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Halyester manual

1.1 Scope 1-2

2.1 Box overview 2-2

3.1 Assembly openings 3-2

4. SUPPLY MODULE ASSEMBLY

4.1 Supply modules with switch-disconnector 4-2

Version 1.1 Table of contents 1

4.1.3 1250 A supply module for bottom connection 4-6

5. CABLE SEALING BOXES

5.1 Plastic cable glands 5-2

6.1 Wall mounting 6-2

7.1 Arrangement in corners 7-2

8.1 Technical specification 8-2

2 Table of contents Version 1.1

9.1 Test report 9-2

Version 1.1 Table of contents 3

1.1 Scope 1-2

1.2 Characteristics 1-2

1.3 General system description 1-3

Version 1.1 Introduction 1-1

• high impact strength

1-2 Introduction Version 1.1

1.3 General system description

1 end cover / cable entry cover

Version 1.1 Introduction 1-3

2.1 Box overview 2-2

2.2 Box accessories 2-6

2.3 Box fittings 2-9

2.3.1 flanges for increasing depth 2-9

2.4 Range of products 2-15

2.5 Overview of busbar boxes 2-22

2.6 Dimensions 2-24

Version 1.1 Boxes 2-1

2.1 Box overview

box type weight

2-2 Boxes Version 1.1

box type weight

Version 1.1 Boxes 2-3

box type weight

2-4 Boxes Version 1.1

box type weight

Version 1.1 Boxes 2-5

2.2 Box accessories

Intermediate coupling pieces

For interconnecting boxes with openings 2, 3 or 4.

Busbar supports, end caps

End covers and cable entry covers

The end cover is available in two models:

2-6 Boxes Version 1.1

Covers and locking screws

For locking screws with hinge pin.

Flanges for increasing depth

Cable sealing boxes

Plastic cable glands for cable entry come in 10 models

Segmented adaptor ring

For segmented cable entries having a 40mm passage.

Version 1.1 Boxes 2-7

Press-in nut / self-tapping screws

For fixing equipment to plastic base plate.