Mounting electrical components in enclosures
Overview
This standard identifies the competences you need to mount electrical components in enclosures, in accordance with approved procedures. The final enclosure could be used for distribution equipment, switchgear or control systems. The rated operating voltage of the completed assembly will not exceed 1,500 volts DC, or 1,000 volts AC, at frequencies not exceeding 1,000 Hertz. You will be required to select the appropriate tools and equipment to use, based on the operations to be performed and type of components to be installed and to check that they are in a safe and serviceable condition.
In carrying out the operations, you will be required to follow laid-down procedures and specific assembly techniques, in order to mount various components into enclosures, such as component panels, isolator switches, fuses/MCBs, contactors, relays, bases for plug-in devices, rail-mounted terminal blocks, trunking, earthing bonding and sub- assemblies such as power supplies, card racks and process controller units. The mounting activities will also include making all necessary checks and adjustments to ensure that components are correctly positioned and free from damage.
Your responsibilities will require you to comply with organisational policy and procedures for the assembly activities undertaken and to report any problems with the activities, components or equipment that you cannot personally resolve, or are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work and will provide an informed approach to applying assembly techniques and procedures to the mounting of electrical components in enclosures. You will understand the distribution equipment, switchgear or control systems being assembled, their application and the assembly techniques used. You know about the components used, in adequate depth to provide a sound basis for carrying out the activities to the required specification.
You will understand the safety precautions required when mounting electrical components in enclosures. You will be required to demonstrate safe working practices throughout and you will understand the responsibility you owe to yourself and others in the workplace.
Performance criteria
You must be able to:
P1 work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
P2 follow the relevant instructions, assembly drawings and any other specifications
P3 ensure that the specified components are available and that they are in a usable condition
P4 assemble, mount and install the components in their correct positions using appropriate methods and techniques
P5 secure the components using the specified connectors and securing devices
P6 check the completed assembly to ensure that all operations have been completed and it meets the required specification
P7 deal with problems within your control and report those that cannot be solved
P8 complete and store all relevant documentation in accordance with organisational requirements
P9 leave the work area in a safe condition on completion of the activities, as per organisational requirements
Knowledge and Understanding
You need to know and understand:
K1 how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
K2 the importance of wearing the appropriate personal protective equipment (PPE), and of keeping the work area clean and tidy
K3 what constitutes a hazardous voltage and how to reduce the risks of a phase to earth shock
K4 how to obtain and interpret drawings, circuit and physical layouts, charts, specifications, graphical electrical symbols, wiring regulations and other documents needed for the electrical component mounting activities
K5 how to effectively deal with emergency situations in relation to electric shock and safe isolation
K6 the assembly methods and techniques to be used when mounting electrical distribution equipment, switchgear or control systems
K7 the type of components and sub-assemblies that are used in the assembly activities
K8 the basic operating principles of the electrical components being assembled
K9 preparations to be undertaken on the components and enclosure, prior to the mounting activities
K10 how the components are to be aligned and positioned prior to securing and the tools and equipment that are used
K11 methods of attaching identification markers/labels during electrical assembly activities
K12 how to conduct any necessary checks to ensure the accuracy and quality of the assembly produced
K13 the visual checks and preparation requirements for components to be used in the electrical assembly activities
K14 how to recognise and identify any orientation requirements for all electrical distribution equipment, switchgear or control system components used in the assembly activities
K15 the methods, tools and equipment used to transport, handle and lift the components into position
K16 how to check that the tools/equipment are within current certification dates, free from damage and defects, in a safe and usable condition, and configured correctly for purpose
K17 the methods and techniques used to prepare enclosures and the electrical distribution equipment, switchgear or control systems equipment to be used in the assembly activities
K18 the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
K19 how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
- Mount the electrical components, by carrying out all of the following activities:
- use the correct assembly drawings, specifications and job/order instructions
- adhere to health and safety regulations, systems and procedures to realise a safe system of work
- ensure that the components are free from damage, foreign objects, dirt or other contamination
- check that all tools and equipment are within calibration date (where appropriate) and serviceable
- prepare the electrical components and enclosures for the assembly operations
- use safe and approved techniques to mount the electrical components in the enclosures
- leave the work area in a safe and tidy condition
- Mount electrical components into enclosures, to include twenty of the following items:
- enclosure partitions
- bases for plug-in devices
- soft starters
- component mounting plates
- switches (push button, toggle)
- variable speed drives
- capacitors
- limit switches
- trunking
- resistors
- sensors
- conduit
- rectifiers
- programmable controllers
- contactors
- timers
- plugs/sockets
- overload protection relays
- relays
- power supplies
- grommets/grommet strip
- transformers/chokes
- circuit boards
- lighting fixtures
- circuit breakers/fuses
- thermistors/thermocouples
- batteries
- panel meters (voltage, current)
- indicators (lamps, LEDs)
- connector rails
- terminal blocks/junction boxes
- thermostats
- solenoids
- safety interlocks
- busbars
- other specific components
- Carry out eight of the following activities during the mounting of the electrical components:
- setting working clearance
- aligning components
- measuring
- applying sealants/adhesives
- drilling
- torque setting
- clamping
- filing
- earth bonding
- crimping
- riveting
- securing using mechanical fasteners/threaded/locking devices
- component marking/labelling
- sawing/cutting
- making belt connections
- forming
- punching
- making screw connections
- Carry out seven of the following quality checks:
- positional accuracy
- alignment
- freedom from damage and foreign objects
- dimensions
- component security
- operating clearance
- orientation
- completeness
- electrical continuity/earthing checks
- Assemble electrical components in enclosures, to one of the following quality and accuracy standards:
- organisational drawings and procedures
- customer drawings and requirements
- wiring regulations
- current industry standards, codes of practice and procedures
- other international standards