Prisma P. Assembly Guide 2012

Transcription

1 Prisma P Assembly Guide 2012

2 Preface This guide proposes a procedure for assembling the Prisma P. We have designed it to help you successfully complete your first projects. It ensures that assembling and cabling staff, for whom it is intended, will benefit from the considerable experience in this field acquired by Schneider Electric and its customers. In short, it is an essential workshop tool. There are several approaches for assembling Prisma P components. In this guide we propose one approach which you can add to according to your professional organisation and experience. This guide does not replace the technical manuals supplied in the packing of each component, but recommends an assembly sequence for the components and provides information to complement that given in the manuals (assembly tips and tricks, specific assembly recommendations, warnings, etc.). 2

3 Contents Presentation of the components... 4 Instructions for use... 6 Tools... 7 Assembling and cabling tools... 7 Inspection tools... 7 Identify and sort the components... 8 Assembling the frameworks... 9 Assembling the frameworks... 9 Install the busbars...10 Install the horizontal busbar Install the vertical busbar...11 Coupling the busbars Installing the PE and PEN Marking the busbars Mounting the form 2 side barrier for vertical busbar Install the mounting plates...18 Installing the mounting plates and switchgear Checking switchgear position Run and cable the power circuits...20 Power cables Installing the secondary distribution blocks Installing the connection terminal blocks and the earth bars Installing wiring running accessories Fitting the protection devices Run and cable the low power and auxiliary circuits...25 Installing the devices on door or front plate Installing the wiring running accessories Cabling the auxiliary circuits Closing the trunking and wiring running accessories Inspect the switchboard...27 Final factory inspection Install the partitioning...28 Installing the form 2 barriers on the top or bottom horizontal busbar Installing the incoming unit partitions Installing the barriers for the incoming unit connections Installing the form 3 horizontal barriers Installing the bar duct barriers Finish and fit the switchboard with panels...29 Cleaning the switchboard Finishing the front panel Installing the front panel on the framework Roof adaptation to a Compact NS1250 or Masterpact NT1250 circuit breakers Roof adaptation to 800 to 3200 A Masterpact NW circuit breakers Roof adaptation to a Compact NS1600 or Masterpact NT1600 circuit breakers Roof adaptation to 800 to 4000 A Masterpact NW circuit breakers Fitting the switchboard panels Pack the switchboard...33 Packing

4 Presentation of the components Framework 1. Framework upright 2. Top cross-member 3. Bottom cross-member 4. Cable compartment upright 5. Roof Mounting plates and switchgear 6. Mounting plate support 7. Mounting plate 8. Acti 9 mounting plate: Multifix rail 9. Masterpact incoming unit 10. Compact NSX device 11. Acti 9 switchgear Busbars 12. Bottom support for the Linergy channelled busbar 13. Linergy busbar support 14. Linergy busbars and/or Linergy Evolution busbars 15. Insulated flexible bar prefabricated connection 16. Rigid bar prefabricated connection 17. Neutral bar 18. PE protective conductor Distribution blocks 19. Polypact 20. Multiclip 21. Comb busbar Wiring running 22. Trunking 23. Trunking for thin wiring Power cables 24. Connection transfer assembly in cable compartment 25. Protective barrier 26. Tie support Partitioning 27. Form 2 barrier Front panel finish 28. Front plate support frame 29. Front plate Cover panels 30. Rear panel 31. Side panel 32. Transparent door 33. Plain wicket door 4

5 Presentation of the components PD NEW

6 Instructions for use This manual describes a procedure for assembling the Prisma P. It thus indicates the order in which the cubicle components are to be assembled: the technical assembly instructions are found in the manuals supplied in the packaging of each component. A) Before starting to assemble, you must first identify and sort the components. B) The actual assembly process, divided up into 6 stages, is organised as follows: 1 - Assembling the framework 2 - Installing the busbars 3 - Installing the mounting plates 4 - Running and cabling the power circuits, the low power and auxiliary circuits 5 - Installing the partitioning 6 - Finishing the front panel and fitting the switchboard panels Each assembly stage is symbolised by a pictogram also found in the assembly manual. In most cases, the pictogram in the manual can be seen through the packaging s plastic film. For some configurations of the cubicle in question, you will not have to carry out all the operations proposed. C) Testing as per standard IEC must be carried out. D) The last stage consists of packing the switchboard to ensure protection of the cubicles during transport. 6

7 Tools The recommended tool lists for this section are not complete, but represent the minimum tools required to assemble, cable and inspect the Prisma P cubicles. Assembling and cabling tools bbindividual tools The tool kit belonging to the assembling and cabling staff must contain at least the following tools: DD DD Type of assembly Switchboard mounting: enclosure, mounting plates and panels except for switchgear Mounting the switchgear and tightening the connections (Compact NSX, etc.) Cabling the switchboard Tools 1 ratchet wrench 1 extension piece 1 x 10 and 13 mm wrench 1 wrench bit socket 1 screwdriver 1 wrench bit for screwdriver 1 x 5 mm hexagon socket bit 1 wrench bit for pozidriv no. 2 recess 1 x 8 flat screwdriver 1 portable jig-saw Socket 7, 8, 10, 13, 16, 17 and 19 mm Hexagon socket bit 4, 5, 6, 8 and 10 Wrench bit for pozidriv no. 1, 2 and 3 recess 1 flat screwdriver 3.5 mm - 4 mm- 5.5 mm 1 pozidriv no. 2 screwdriver 1 electrician s knife 1 x 6 mm hexagon socket bit 1 flat nose pliers 1 stripping pliers 1 cable cutter 1 crimping tool 1 diagonal cutting pliers 1 half round nose pliers 1 bell or tester Ring spanner type terminal ends for torque wrench bbgroup tools vv1 torque wrench with socket and ring spanner type terminal ends to tighten all electrical connections to the required torque (max. torque 50 Nm). vv1 ratchet wrench to tighten all busbar connections and joints using shear nuts. vv1 set of shears to cut flexible bars. vv1 punching machine for flexible bars. vv1 electrical saw. vv1 drill. vv1 vacuum cleaner for switchboard cleaning. NB: When crimping the lugs, only the pliers recommended by the lug manufacturer must be used. Inspection tools bbindividual tools The quality inspector s basic individual tools are the same as for the assembling and cabling staff, with in addition the few tools below: vv1 small hinged mirror. vv1 electrical lamp or portable lamp. bbgroup tools vv1 control console. vv1 dielectrometer. vv1 Multimeter. DD DD DD

8 Identify and sort the components DD Aim: Identify and sort components to ensure subsequent proper working organisation and fewer handling operations. b Identify the assembly stage pictogram shown in the assembly manual. b Group the components, devices and accessories, by assembly stage, from assembling of the rear panel through to fitting the cubicle panels. b Collect the components that will be used by the contractor, but do not unpack them A AA01-1 General assembly manual for cubicle Tip: When you receive your components in your workshop, don t get carried away, don t unpack everything Individual assembly manual for component 8

9 Assembling the frameworks DD Aim: Assemble the structure and carry out the various combinations if required. A variety of framework types are available: bbdepth: 400 or 600 mm. bbwidth: 300,400,650 or 800 mm. Tip: For transport reasons, assemble 2 or 3 cubicles at most according to total weight. Pre-tighten beforehand. Check alignment. Tighten to torque. Assemble side by side back to back Tip: To produce disconnectable-type switchboards, you must use a 600 mm deep and 650 mm wide cubicle and a 300 or 400 mm wide and 600 mm deep cable compartment, placed to the right of the cubicle. DD NB: The cover panels are assembled once the internal components have been mounted and cabled, thus guaranteeing 100% access to components throughout assembly and installation. Assembling the frameworks bbassemble the framework(s) DD Tip: The frameworks must be assembled on a flat surface, protected to ensure the paintwork is not damaged. When assembling the rafters, take care not to damage the gaskets located at the end of the upright. bbinstall the plinth unless its installation is scheduled for on site bbcouple the frameworks If the cubicles have to delivered separately: vvstore the combination kits, vvcouple temporarily using bolts. DD Tip: For IP55 cubicles, do not forget to fit the gasket at the junction of the cubicles to be coupled. Ensure you degrease the surfaces thoroughly before sticking on the gaskets. NB: For an L-shaped combination, the right-angle kit will be assembled on site. b Install the gland plate support frames Tip: For reasons of accessibility, the frames will be mounted immediately, while the gland plates will be mounted before the switchboard panels are fitted. Tip: For reasons of accessibility and according to the position of the horizontal busbars (top or bottom), we recommend that you reverse mounting of the combination kits; Top busbars: long screws + spacers at the top of the framework uprights, Bottom busbars: long screws + spacers at bottom. DD DD DD b b Install the framework stabiliser This device increases cubicle stability and enables it to be lifted using a pallet truck or fork-lift. 9

10 Install the busbars DD Aim: This stage consists of positioning the supports and bars making up the busbars. L3 L2 L1 N Tip: If cutting oil is used, the bars must be cleaned prior to assembly as oil adversely affects insulation properties. If the Linergy HVOF copper bars or tracks (Linergy Evolution) have become oxidised, you can recover the connection or joint contact using a soft microabrasive cloth. NB: vv Busbar overall dimensions do not vary with current strength. vv Whatever the busbar type (flat or channelled), the order of the horizontal and vertical bars is always the same: from the front to the rear N, L1,L2 and L3. vv With the rear busbar, the Neutral is to the left, then L1, L2, L3. DD Install the horizontal busbar bbinstall the horizontal busbar at the top or bottom of the cubicle The dimensions are: vv3 modules at the top or bottom for flat copper bars up to 3200 A (y 100 mm x 10 mm) or Linergy Evolution up to 2500 A. vv4 modules at the top and 3 modules at the bottom for copper busbars 4000 A (120 mm x 10 mm). vv4 modules at the top or bottom for Linergy Evolution busbars 3200 A or 4000 A. If a connection with a rear busbar is provided, dimensions change to 5 modules. If the busbar is at the bottom, fit a form 2 partition to prevent the risk of falling tools. DD Tip: Joining should preferably take place in a cable duct to simplify installation. L3 L2 L1 N d If cubicles have to be separated for transport, provide horizontal busbar joints. The joints will be assembled on site and should preferably be used at the inter-cubicle connections to simplify replacement. Ensure a 10 mm space between the bars to be joined, i.e. 5 mm from the edge of the cubicle. Use the neutral joint barrier kit (04624) to join the Linergy Evolution on 4 poles. Linergy Evolution joints are used exclusively with the stud plates and shear nuts supplied in the enclosed kit. The stud plate design perfectly centres the joints on each bar ensuring compliance with the 10 mm distance between the 2 bars to join. bbcutting Linergy Evolution for joining Linergy Evolution is cut with a circular saw, starting from the side with the copper HVOF contact track. Once it has been cut, make sure there are no shavings or burrs on the HVOF copper contact track. If cutting oil is used, the bars must be cleaned prior to assembly. Tip: When cutting the bars, gloves and protective goggles must be worn to protect injuries. Shavings and burrs: not good Clean contact surfaces: good 10

11 Install the busbars Install the vertical busbar b Install the single busbar in the 150 mm busbar compartment DD DD DD Busbar compartment on the right or on the left Linergy channelled busbar up to 1600 A or Linergy Evolution up to 2500 A Flat busbar up to 2800 A (IP y 31) 11

12 Install the busbars bbinstall the double busbar in the busbar compartment DD DD Linergy double busbar up to 3200 A Double flat busbar up to 3200 A 3 equipotential bonding connections are required between the busbars. Consult the manuals to determine the number of supports as a function of installation lcw. NB: The bottom support for the lateral flat busbar is not considered to be a bar support. bbinstall the busbar at the back of the cubicle NB: The rear busbar is installed at a depth of 400, but can be installed at a depth of 600. In the latter case, the assembling and cabling staff must make the busbar connections themselves. DD DD Linergy rear busbar up to 1600 A Rear flat busbar up to 1600 A 12

13 Install the busbars Coupling the busbars bbconnection between Linergy Evolution busbars and Linergy busbar in bar compartment. Tip: It is recommended to use torque nuts to secure the inter-busbar connections. When using this type of nut, care must be taken to balance tightening by gradually increasing the tightening of each nut until breakage occurs. If you use other nut types, we recommend that you smear Swiss varnish on each nut tightened to its torque. Horizontal busbar Vertical busbar Connection Linergy Evolution Linergy DD or DD NB: connections allow vertical connection with the Linergy Evolution y 1600 A and joining in the same 150 mm duct. bblinergy Evolution 3200 A-4000 A Installation requires 4 high modules. Before connection the Linergy must be cut to 1625 mm (remove 50 mm). bbcutting Linergy Linergy is cut with a circular saw, starting from the side with the copper HVOF contact track. Once it has been cut, make sure there are no shavings or burrs on the HVOF copper contact track. If cutting oil is used, the bars must be cleaned prior to assembly. Tip: When cutting the bars, gloves and protective goggles must be worn to protect injuries. 13

14 Install the busbars DD bleu.tif bbconnection between Linergy Evolution busbars and Linergy Evolution busbar in bar compartment. Horizontal busbar Linergy Evolution Vertical busbar 150 mm duct Linergy Evolution 1600 A Connection DD bleu.tif Linergy Evolution Linergy Evolution 2000 A A DD DD Tip: Depending on ease of access to for on-site joining, the 2000 A or 2500 A rating HVOF copper contact track may be positioned towards the top (access through the roof) or towards the bottom (access from within). Vertical connections can thus be short (horizontal Linergy Evolution track at the bottom) or long (horizontal Linergy Evolution track at the top). NB: Beyond 1600 A, horizontal/vertical busbar connection and joining in the same duct is no longer possible. Horizontal busbar Linergy Evolution Vertical busbar 300 mm duct Linergy Evolution 3200 A-4000 A Connection PD bbcutting length for Linergy Evolution bars for vertical installation. Rating horizontal busbar Vertical busbar 630 to 1600 A 1675 mm 2000 to 2500 A 1675 mm 3200 to 4000 A 1625 mm bbcutting Linergy Evolution Linergy Evolution is cut with a circular saw, starting from the side with the copper HVOF contact track. Once it has been cut, make sure there are no shavings or burrs on the HVOF copper contact track. If cutting oil is used, the bars must be cleaned prior to assembly. Linergy Evolution connections are exclusively used with the stud plates and shear nuts supplied in the connection. 14

15 Install the busbars DD bbconnection between horizontal busbar and Linergy busbar in the bar compartment Tip: It is recommended to use torque nuts to secure the inter-busbar connections. When using this type of nut, care must be taken to balance tightening by gradually increasing the tightening of each nut until breakage occurs. If you use other nut types, we recommend that you smear Swiss varnish on each nut tightened to its torque. NB: Connection of a 10 mm thick horizontal busbar requires no holes to be drilled, unlike the 5 mm thick horizontal busbar. Horizontal busbar Vertical busbar Connection 10 mm bar Linergy bar DD mm bar Linergy bar DD DD bbconnection between horizontal busbar and vertical flat busbar in the busbar compartment. Horizontal busbar Vertical busbar Connection 10 mm bar 10 mm bar DD mm bar 5 mm bar DD DD For this connection type, holes must be drilled on the 5 mm horizontal bars. bbconnection between horizontal busbar (flat copper or Linergy Evolution) and Linergy rear busbar. This connection type must partially be carried out by the assembling and cabling staff. For the dimensions of the bars to be made, consult the busbar drawing collection. DD bbconnection between flat busbar (flat copper or Linergy Evolution) and rear flat busbar. This connection type must partially be carried out by the assembling and cabling staff. For the dimensions of the bars to be made, consult the busbar drawing collection. 15

16 Install the busbars DD Installing the PE and PEN b Install the PE K for vertical mounting, it is normally installed in the cable compartment, K for horizontal mounting, it is installed at the top or bottom of the switchboard opposite the horizontal busbar. NB: If the cubicles have to be separated for transport, produce PE joints. DD b Install the PEN The PEN is mounted vertically, normally in the cable compartment. It must be connected to the neutral by a removable joint allowing subsequent taking of insulation measurements. DD Marking the busbars NB: Marking of the protective conductors (neutral, PE and PEN) is compulsory. Phase marking is strongly recommended. 16

17 Install the busbars DD Mounting the form 2 side barrier for vertical busbar NB: The form 2 side barrier allows insertion of flexible or rigid connections less than 12 mm thick between 2 flaps. DD DD To allow insertion of the connection for a large rating device (Masterpact NW/NT Compact NS 630b A, etc.) to a lateral vertical busbar, and if a Polypact with flexible connections is used (cat. no and 04406) with form 2, a side barrier cut-out must be installed. To identify the position of this interruption, the location of the power devices must be anticipated on their mounting plate and the following order complied with: install the interruption kit, then the side shield blades. Tip: When cutting blades, gloves, protective goggles and a respirator must be worn to avoid inhaling glass fiber. 17

18 Install the mounting plates DD Installing the mounting plates and switchgear Aim: This stage consists of defining the position of the mounting plates in the cubicle and installing them with their devices. The order of assembly of the mounting plates and devices depends on the technical features of the devices. To define the position of a mounting plate of a functional unit, you need to know the overall dimensions of the functional unit, i.e. the number of modules (1 module = 50 mm). This number is given in the mounting plate assembly manual and the catalogue. The reference m0 is the reference starting point for installation of the first mounting plate. There are 2 m0 references at the top and bottom of the cubicle. This reference, in the form of a slot, is used to hook up a measuring tape to measure the height to be complied with when installing a mounting plate. Marks located every 50 mm, with a double marking every 100 mm, simplify module counting. Table showing assembly order: Plates for Device fixing Assembly order Masterpact NW, NT Compact NS > 630 A and INS > 630 A DD Fixed Withdrawable b Install the mounting plate b Place the device on the mounting plate b Install the mounting plate b Install the cradle b Plug the device into the cradle Compact NSX and Interpact INS/INV DD Compact NSX and INS/INV y 630 A DD Modular devices DD Supplied by Polypact Fixed Withdrawable or plug-in Modular system b Insert the Polypact, connections facing forward, into the cubicle b Slope the Polypact assembly, connections facing downwards, while inserting them between the form 2 barrier slats b Swivel round the Polypact in the cubicle and put it in the horizontal position b Install the 2 mounting plate supports, with the right-hand support straddling the first connection b Position and hold the Polypact in place above the supports b Secure the mounting plate (without device) onto its supports b Place the Polypact on the mounting plate b Assemble the devices b Place the device on the mounting plate b Install the equipped mounting plate b Place the base or cradle in the mounting plate b Install the equipped mounting plate b Plug in the device b Install the rail b Place the modular devices on the rail 18

19 Install the mounting plates Checking switchgear position This operation allows operator inspection and prevents incorrect positioning of the functional unit with respect to the front panel, once the cubicle has been fully cabled. bbplace the front plate support frame for front plate assembly bbinstall the front plates to check device positioning bbalso check device positioning in depth bbdisassemble the front plate support frame after checking to simplify cabling. PD

20 Run and cable the power circuits PB Power cables Cabling of power devices > 630 A uses rigid bars: bar drawings can be supplied if the prefabricated connections are not available in the catalogue. You need to: b Know the position of the current transformers and partitions and check that they can be mounted b Tie the busbar tails onto the framework, and the cables with "1000 V" insulation onto the device mounting plates b Install tie supports according to fixing distances. NB: The tightening torques for connection to the device terminals are given in the device technical manual. To avoid the risk of temperature rise, it is essential to comply with the size of the connections or cables recommended in the assembly manuals or on the devices and to use the screws and bolts delivered with the devices and connections. The diameter 8 contact and flat washers must be mounted on hammer screws for Linergy busbars. b Upstream connections Device type Connection type > 630 A power device Connection by Canalis Connection by cable DD DD y 630 A device Prefabricated connection to the Linergy busbar Connection to the flat busbar DD DD y 250 A device Connection by Polypact to the Linergy busbar Connection by Polypact to the flat busbar DD DD NB: For connection to the flat busbar, the panel builder must make the connections himself. 20

21 Run and cable the power circuits Device type Connection type > 630 A power device Connection by bars to the Linergy busbar Connections by bars to the flat busbar DD DD y 630 A device Connection transfer assembly DD NB: For connection to the flat busbar, the panel builder must make the connections himself. Universal power supply block for Powerclip insulated busbar DD NB: The Powerclip 630 A insulated busbar is used in cubicles for distribution over several device rows. 21

22 Run and cable the power circuits Installing the secondary distribution blocks You need to comply with connection capacities, stripping lengths, the number of cables connected and use the appropriate tools. d Do not use ferrules with the spring loaded terminals. Each terminal may only take a single wire. On the Multiclip 200 A, cable entry is via the bottom only to allow assembly of the insulating covers and production of cable straps. Type Connection capacity DD Polybloc Connection principle Distribution Additional block Distribloc Power supply Distribution Power supply Multiclip 160 A (1/2 row) Distribution Multiclip 80 A Power supply DD Multiclip 200 A Multiclip 63 A (1/2 row) Multiclip 80 A Distribution Tap-off blocks insulated busbar NB: The downstream device connecting cables are delivered with the Multiclip and Distribloc. 22

23 Run and cable the power circuits DD Installing the connection terminal blocks and earth bars bb Install the supports for arrangement of the connection terminal blocks and earth bars NB: The connection terminal blocks and earth bars are installed: vv either in the duct that forms a zone that can be completely separated from the devices, vv or in the switchgear zone, at the top or bottom (or on the sides for the earth bar). DD DD Installation at top or bottom of a cubicle on depth adjusted rails DD b Install the terminal blocks b Install the earth bars DD DD DD DD DD convert Connection principle DD Connection capacity DD Type Disconnectable terminal block for auxiliaries 35 mm2 incoming terminals for flexible or rigid cables Screw terminals DD Installation on modular rail turned using universal angle brackets 16 mm2 outgoing terminals for flexible or rigid cables Installing wiring running accessories DD DD b Install the horizontal and vertical cable straps The straps are used to guide the wires. They are easy and quick to implement and can be clipped directly onto the mounting plates. DD Installation in a lateral compartment on a modular rail support DD DD on mounting plate Installation on a device mounting plate Cover for horizontal cable straps Cover for vertical cable straps 23

24 Run and cable the power circuits DD bb Install the trunking for horizontal or vertical wiring The trunking is used to carry wires to the switchgear zone. Trunking is secured: vv to some mounting plates on specially reserved locations, vv on the trunking supports by means of clip-on, ¼ turn removable screws. DD Trunking installed horizontally on the rear of a modular rail DD The Polypact distribution block accommodates a trunking as standard to guide the auxiliary wiring of the NSX circuit-breakers that it supplies. DD on mounting plate on rail NB: Trunking is assembled onto its support simply by clipping on from the front. bb Install the cable tie-bars b For an L-shaped installation with corner kit for busbars, an additional corner kit can be added for wiring and earth conductor running. Fitting the protection devices DD DD Longitudinal and lateral cable-tie supports DD bb Prepare the various protective covers (cut-out, drilling, etc.) bb Fit the various protective covers: vv upstream and downstream terminal shields are compulsory for all Compact NSX circuit-breakers and INS/INV switches with vertical or horizontal mounting, vv cover for power supply block, vv connection cover for cable, vv cover for busbar, vv tooth-caps, etc. NB: For connection by insulated flexible bars equipped with built-in terminal shields, there is no point equipping Compact NSX circuit-breakers with terminal shields. C-shaped cable-tie supports 24 DD bb Fit the puffing chamber barriers on the Masterpact NT Compact NS u 630 A circuit-breakers if bare copper connections are used.

25 Run and cable the low power and auxiliary circuits DD Installing the devices on door or front plate dfor safety reasons, it is forbidden to mount devices on the bar duct door. We recommend that devices be transferred to the cable duct door. DD b Install the partial doors with cut-outs or front plates with cut-outs accommodating devices NB: The devices can be installed on conventional plain doors by making a cut-out. b Install the mounting plates and devices on the doors or front plates b Install an earthing braid when the door accommodates non-class 2 devices. Tip: If there is not enough space between the door and the front plates, use the visor. DD Installing the wiring running accessories bbinstall the trunking and the wire-guide straps b Install the terminal blocks for auxiliary wiring DD NB: Holes are drilled in the mounting plates for rear insertion of cables. bbinstall the auxiliary disconnectable terminal blocks b Install the 4P auxiliary bus ducts b Install the voltage tap-offs at the device exit. 25

26 Run and cable the low power and auxiliary circuits DD Cabling the auxiliary circuits bbsix cabling rules must be applied by the contractor: vvrule no. 1: The outgoing conductor and the return conductor must always be adjacent. vvrule no. 2: It is preferable to flatten all connections up against equipotential frame structures to benefit from a HF protective effect. vvrule no. 3: In the switchboard run the power circuits, control circuits and communication/ network circuits in three separate groups, ensuring compliance with a ratio of distance between cables over radius of the largest cable that is greater than 5. Only analog, digital and telecommunication signal pairs can be placed right up against one another in the same bundle or laid in the same grouping cable. vvrule no. 4: We recommend against using the same connector for connections of different families (except for relay, supply and power circuits). vvrule no. 5: All free conductors in cables must systematically be connected to the chassis frame at both ends (except for analog cables). vvrule no. 6: Power cables do not need to be shielded if they are filtered. bbmark the wires to simplify on-site connection and maintenance of cubicles, thus avoiding laborious switchboard reworking that could cause errors. It is important to obtain customer approval of the marking technique. The marks must be placed at the extremities of the conductors and, if necessary, along their routes. b d b Separate power cables from auxiliary wires: vvbus cables and the other "fine wiring" cables (connected to auxiliary power supplies for relays, contactor controls, PLC inputs/outputs, etc.) can exist side by side, but must be placed in trunking for separation from power cables. vva bus line is "ELSV", thus with double or enhanced insulation with respect to mains. Consequently a bus cable must not touch a bare power bar. Tip: Thoroughly secure cables onto the door to avoid disconnecting the devices when opening. We recommend you use protection devices for wiring through the front panel or to the doors. DD DD Flexible trunking Grommet Closing the trunking and wiring running accessories Tip: Trunking packing density must not exceed 70 %. 26

27 Inspection the switchboard Final factory inspection On completion of assembly, the wall-mount or floor-standing enclosure must undergo a variety of inspections and tests. At the very least the 3 routine tests must be carried out as per standard IEC mentioned below: bb1 st test: overall inspection including examination of cabling, checking connection tightening and, if necessary, an electrical operating test bb2 nd test: checking insulation via a dielectric test bb3 rd test: checking direct contact protection measures and electrical continuity of protection circuits bbdrafting test reports. For more details concerning inspections, consult the switchboard assembly and installation guide. DD DD DD

28 Install the partitioning DD Installing the form 2 barriers on the top or bottom horizontal busbar NB: The barrier does not modify busbar dimensions. DD Installing the incoming unit partitions Tip: Before assembling the partition, remove the pre cut-outs required for cable insertion. Installing the barriers for the incoming unit connections DD Installing the form 3 horizontal barriers Tip: Before assembling the partition, remove the pre cut-outs required for busbar or cable insertion. Follow the order given in the manual. DD Installing the bar duct barriers bb Install the front barrier bb Install the rear barrier for 600 deep cubicles bb In event of insertion of a PEN conductor through the front barrier, remove the pre cut-out provided (compliance with clearances) and fit an insulating plate (Polycarbonate T > 960 C) to guarantee IP2X (consult the front barrier assembly manual). 28

29 Finish and fit the switchboard with panels E68280 Cleaning the switchboard bbremove dust from the inside using a vacuum cleaner Tip: Do not use blow cleaning as this may cause shavings and detritus to accumulate in a live area. bbdust the outside Tip: Use a neutral dissolvent that will not damage the paint. The switchboard panels can be cleaned using liquid soap, methylated spirits, F oil or isopropyl alcohol. bbtouch up paintwork if necessary bbcheck absence of foreign matter inside the switchboard (tools, screws and bolts) that could prevent it from operating properly. DD Finishing the front panel bbsecure the front plate support frame to the cubicle framework bbinstall the markers: fit the label holders bbinstall the blanking plates on the front plates DD Mode OK Mode OK Mode OK Front plate hinge kit DD bbinstall the front plate hinge kit (optional) bbfix the adhesive drawing holder. Installing the front panel on the framework bbon the front of the switchboard A name plate should indicate at least: vvthe name and address of the panel builder, vvthe identity of the project. bbdevice marking This enables installation users to identify clearly the type of circuits used. Marking should be fully legible, durable and properly attached next to the device. There are 3 label formats that can be printed or engraved. DD Drawing holder DD382355a Adhesive labels 29

30 Finish and fit the switchboard with panels by Canalis interface DD Roof adaptation to a Compact NS1250 or Masterpact NT1250 circuit breakers bbenclosure 400 mm deep, access through the front. Position of the jointing unit Circuit breaker Dimensions (1) (mm) A B C Fixed, 3P / 4P (2) NS800 / NT08 / Drawout, 3P / 4P (2) NS800 / 1250 or 08 / NT (1) Dimensions measured from switchboard framework. (2) For order refer to catalogue. DD Front connection with Canalis (400 mm depth) Reference point DD Roof adaptation to 800 to 3200 A Masterpact NW circuit breakers bbenclosure 600 mm deep, access through the front. Position of the jointing unit Circuit breaker Dimensions (1) (mm) A B C Fixed, 3P / 4P (2) NW08 / NW20 / NW Drawout, 3P / 4P (2) NW08 / NW20 / NW (1) Dimensions measured from switchboard framework. (2) For order refer to catalogue. Front connection with Canalis (600 mm depth) DD Reference point 30

31 Finish and fit the switchboard with panels by Canalis interface DD Roof adaptation to a Compact NS1600 or Masterpact NT1600 circuit breakers bbtwo enclosures combined: vv 1 enclosure, 400 mm deep, for the circuit breaker vv 1 enclosure, 400 mm deep, for the Canalis KT/switchboard interface. Rear connection (RC) DD Position of the jointing unit Circuit breaker Fixed, 3P / 4P (2) NS800 / 1600 or NT08 / 16 Drawout, 3P / 4P (2) NS800 / 1600 or NT08 / 16 (1) Dimensions measured from switchboard framework. (2) For order refer to catalogue. Dimensions (1) (mm) A B C Reference point DD Roof adaptation to 800 to 4000 A Masterpact NW circuit breakers bbtwo enclosures combined: vv 1 enclosure, 600 mm deep, for the circuit breaker vv 1 enclosure, 400 mm deep, for the Canalis KT/switchboard interface. Rear connection (RC) Position of the jointing unit Circuit breaker Dimensions (1) (mm) A B C Fixed, 3P / 4P (2) NW08 / NW20 / NW NW Drawout, 3P / 4P (2) NW08 / NW20 / NW NW (1) Dimensions measured from switchboard framework. (2) For order refer to catalogue. DD Reference point 31

32 Finish and fit the switchboard with panels DD Fitting the switchboard with panels bbinstall the gland plates bbfit the rear and side panels NB: For L combinations, there is a specific assembly order: refer to the right-angle kit assembly manual. b Install the ventilation system, the resistors and the switchboard lighting, if necessary b Fit the roof NB: For IP31 cubicles, do not forget to fit the gasket. Take care to degrease surfaces thoroughly before sticking on the gaskets. DD DD bbfit the doors or fixed frames vvdoor assembly is reversible, Tip: For safety reasons, ensure that the door opening direction will not obstruct on site access to an evacuation corridor or passageway. The door must open in the direction of the evacuation. vvit is advisable to install barrels and inserts before fitting the handle on the door and before mounting on the framework. bbfit the lifting rings for lifting from the top (do not forget to fit the plugs). 32

33 Pack the switchboard Packing bbuncouple the cubicles electrically and mechanically if necessary bbprovide the contractor with the necessary accessories (joints, fixing screws, etc.) bbprovide an installation guide for cubicle on-site coupling bbcompile a technical file containing a set of drawings, the device operating manuals and the cubicle assembly manuals bbattach the adhesive drawing holder to the back of the door with the technical file bbensure cubicle protection for transport, particularly on the surface-mount HSI surfaces NB: Use the stabilisers to increase packing volume and re-use cover panel protections (angle brackets, polystyrene, etc.). bbpack the cubicles. DD E20551 Drawing holder 33

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36 Schneider Electric Industries SAS 35, rue Joseph Monier CS F Rueil Malmaison Cedex RCS Nanterre Capital social DESW045EN As standards, specifications and designs change from time to time, please ask for confirmation of the information given in this publication. This document has been printed on ecological paper Published by: Schneider Electric Layout: Sedoc ART Schneider Electric - All rights reserved