Highlights

Form 4 Solution

Thursday, November 20, 2025

FORM 4 SOLUTION

In industrial settings, workplace safety and efficient operation of facilities are of critical importance. At Tekpan PDS, we provide high-security, modular, and tested panel systems for your facility’s power distribution and control needs.

Our products are fully compliant with IEC 61439-1&2 standards and, with additional testing, comply with UL 891. Thanks to the Form 4 structure, safe maintenance, operational continuity, and fault isolation are ensured.

What is the IEC 61439-1&2 Standard?

  • IEC 61439-1: General rules and performance requirements.
  • IEC 61439-2: Specific rules for power distribution panels.
  • The standard defines the verification tests expected from the manufacturer, including criteria such as mechanical strength, temperature rise, dielectric properties, short-circuit withstand, and protection classes.
  • Purpose: To produce safe, high-quality, traceable, and comparable panel solutions.

Tests and Verifications

  • Temperature rise test
  • Dielectric withstand test
  • Short-circuit withstand test
  • Protection class (IP) test
  • Mechanical impact resistance (IK) test
  • Ground continuity test

Definition of Form 4 Structure

  • Form 4 is a panel design class where functional units (e.g., switches, measuring devices, busbars) are completely separated from each other and from the busbar.
  • It ensures independent operation from live parts during maintenance and faults.

Advantages of Form 4 in Industrial Applications

  • High operational continuity
  • Enhanced personnel safety
  • Easy maintenance and fault isolation
  • Flexible modular structure: adaptable to changing production lines
  • Energy efficiency and optimized cable management

Application Areas

  • Power generation facilities
  • Petrochemical and refinery plants
  • Cement and iron-steel factories
  • Automotive production lines
  • Water treatment and pumping stations
  • Food and pharmaceutical manufacturing facilities

Comparison

  Non-Form Protected Panel Form 4B Panel (Fully Segregated)
DESCRIPTION All components (switches, busbars, cables) are located in the same compartment; there is no physical separation. Each functional unit, busbars, and cable connections are located in separate compartments. All live parts are physically isolated.
SAFETY LEVEL Low – During a fault or maintenance, personnel are at risk of electric shock or short circuit. High – Live parts are inaccessible; other circuits continue to operate during maintenance.
FAULT ISOLATION None – A fault may affect the entire system. Available – A fault is confined to the relevant compartment, while the rest of the system continues to operate.
USER SAFETY Typically low IP protection (below IP20) Compartment-Based High Protection Level:(IP2X–IP4X)
SHORT-CIRCUIT RISK High – Since busbars and functional units are in the same compartment, an arc fault can spread to other circuits. Minimum – Arc faults are limited by metal/plastic barriers between compartments.
CABLE ARRANGEMENT AND SERVICE EASE Confused – Cable and busbar paths are intertwined. Organized – Each compartment’s wiring is independent.
COMPLIANCE WITH OCCUPATIONAL SAFETY REGULATIONS Partially or not compliant with IEC 61439. Fully compliant with IEC 61439-1 and 61439-2; type-tested.
SUITABILITY FOR INDUSTRIAL USE Typically chosen only for low-cost, small facilities. Fully compliant with IEC 61439-1 and 61439-2; type-tested. Ideal for medium and large-scale industrial facilities (power, cement, automotive, petrochemical, etc.).

Tekpan Form 4 Panel Features

  Features Additional Information
STANDARD IEC 61439-1&2 Compliant with UL 845 and UL 489 (with additional testing)
MODULE POWER 4000A ( 4 x 80/10mm Busbar) Total power may vary according to heat calculation
SHORT-CIRCUIT WITHSTAND Icw: 85kA (1sn.) / Ipk: 176kA Values represent maximum limits
INSULATION Ue : 690V AC / Ui : 1000V AC / Uimp: 12kV Overall panel insulation levels are maximum values
PROTECTION CIRCUIT Icw: 60kA (1sn.) / Ipk: 132kA Values represent maximum limits
IP PROTECTION (EN 60529) IP53 Values represent maximum limits
NEMA CATEGORY NEMA 1, 2, 5, 12 Values represent maximum limits

Design

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