Name: Rittal PLC & Automation Control Panel
Brand: Rittal

Question 1

What is Ri4Power and how does it enable IEC 61439-2 compliance for PLC control panels?

Accepted Answer

Ri4Power is Rittal’s type-tested power distribution busbar system designed for VX25/TS 8 enclosures. It provides factory-engineered busbar stacks, tap-offs and accessories that simplify meeting IEC 61439-2 requirements for panel assemblies. Because Ri4Power is type-tested, many of the design-verification calculations—busbar temperature-rise, dielectric clearances and short-circuit withstand—are already characterized for defined configurations up to rated currents of 5,500 A. For PLC panels this reduces onus on bespoke busbar calculations; however, final assembly still requires IEC 61439 verification for any deviations and routine tests (dielectric, insulation, temperature-rise) per IEC 61439-1/2.

Question 2

Can VX25 and TS 8 enclosures meet the IP and thermal requirements of modern PLC/HMI installations?

Accepted Answer

Yes. VX25 and TS 8 offer modular depth and accessory integration to achieve ratings commonly used in automation panels (IP31 to IP54). For thermal management Rittal TopTherm air conditioning and filtered ventilation modules control internal temperatures for PLCs, PACs and Ethernet switches, maintaining vendor-specified temperature-rise limits required by IEC 61439 temperature verification. Specify appropriate filter classes, redundancy for critical systems and account for heat dissipation from drives and power supplies in the thermal balance to ensure continuous operation in industrial environments.

Question 3

How do you implement Form 4b separation inside a Rittal PLC & Automation Control Panel?

Accepted Answer

Form 4b requires segregation of busbars, functional units and outgoing circuits so that functional units can be accessed without exposure to live parts of other units. In Rittal VX25 assemblies this is achieved using Ri4Power busbar segregation, insulated barriers, partition panels and dedicated cable ducts. Use modular mounting plates and shielded compartments to separate power distribution from control wiring and I/O racks. Documentation and verification to IEC 61439-1/2 must show clearances, barriers and mechanical interlocks meet separation criteria; routine verification includes inspection and dielectric testing after assembly.

Question 4

What short-circuit ratings can a Rittal-based PLC panel achieve and how are they verified?

Accepted Answer

Short-circuit withstand rating depends on busbar cross-section, material, jointing method and panel layout. Ri4Power systems are engineered to support high RMS symmetrical fault levels; many installations achieve short-circuit ratings in the tens of kA range (site-specific designs sometimes target ~50–100 kA). IEC 61439 requires calculation or test evidence for internal arc and short-circuit withstand; type-tested Ri4Power data can be used as part of the design verification. Final short-circuit ratings must be declared in the design-verification report and validated with routine tests and appropriate protective device coordination per IEC 60947.

Question 5

How are redundant PLC controllers and 24 VDC power supplies integrated into these Rittal panels?

Accepted Answer

Redundancy is implemented with physically separated controller racks and redundant 24 VDC power feeds mounted on duplicated DIN rails or redundant power distribution modules (RiLine or sub-distribution blocks). Redundant controllers (hot standby or sync-redundant PACs) are mounted on separate backplanes with isolated I/O domains or mirrored I/O; redundant power supplies are arranged with OR-ing diodes or static redundancy modules and monitored by supervisory alarms. Ensure separation boundaries and fault-containment follow IEC 61439 guidelines and that electrical clearances and protective device coordination comply with IEC 60947 for reliable failover.

Question 6

Can Rittal PLC panels be used in hazardous (IEC 60079) areas?

Accepted Answer

Use in hazardous locations requires compliance with IEC 60079 series. Standard VX25/TS 8 enclosures are not intrinsically certified for explosion-proof installations without modification. For hazardous areas, options include locating the panel in a safe zone with remote I/O in certified Ex enclosures, using certified Ex components, or applying purpose-built Ex-certified housings. Any Ex solution must be certified by an approved body, and the integration of devices (PLCs, power supplies, cooling) must follow the specific IEC 60079 construction and certification rules for the intended gas/dust zone.

Question 7

How does Rittal's Ri4Power compare to Siemens SIVACON, ABB MNS and Schneider Prisma Set for PLC panels?

Accepted Answer

Ri4Power focuses on modular, enclosure-integrated busbar systems optimized for machine and automation panels with strong enclosure accessory ecosystems (VX25/TS 8, TopTherm). Siemens SIVACON and ABB MNS are broader low-voltage distribution platforms aimed at distribution and MCC applications with different type-testing scopes and mechanical architectures. Schneider Prisma Set targets compact distribution and industrial control. Choice depends on rated current, short-circuit needs, modularity, and installer familiarity; Ri4Power’s advantage is tight integration with Rittal enclosures and accessory availability for PLC-centric designs.

Question 8

What documentation and factory tests are delivered with a Rittal IEC 61439-2 PLC assembly?

Accepted Answer

Deliverables typically include a complete documentation pack: IEC 61439 design-verification report, component certificates (Rittal enclosure, Ri4Power datasheets), wiring diagrams, cable schedules, Bill of Materials, and routine test records (dielectric test, insulation resistance, power-on checks, temperature-rise test results where applicable). Additional factory tests such as functional PLC validation, Ethernet switch VLAN configuration validation, and IP protection verification may be performed per contract. All testing and documentation should reference IEC 61439-1/-2 clauses and applicable IEC 60947 device certificates.

Controller	PLC / PAC
I/O Points	16–10,000+
Communication	PROFINET, EtherNet/IP, Modbus TCP
Power Supply	24VDC redundant
IP Protection	IP31–IP54
IEC Standard	IEC 61439-2
Component Brand	Rittal

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