Prisma Plus Assembly Guide System G
Preface This guide proposes a procedure for assembling the Prisma Plus System G. 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 Plus 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.). 1
Contents Preface... 1 Presentation of the components... 4 Instructions for use... 6 Tools Assembling and cabling tools... 7 Inspection tools... 7 Identify and sort the components... 8 Assemble the rear panel of the wall-mount/floor standing enclosures Assembling the IP30, IP31 and IP43 wall-mount or floor-standing enclosures... 9 Assembling the IP55 wall-mount enclosures... 10 Install the busbars Installing the Powerclip 125 to 630 A insulated busbar... 11 Installing the 160 to 400 A rear busbar in vertical position... 11 Installing the 160 to 630 A multi-stage busbar in the duct... 11 Install the mounting plates Installing the mounting plates and switchgear... 12 Checking switchgear position... 12 Run and cable the power circuits Installing the secondary distribution blocks... 13 Installing the connection terminal blocks and earth bars... 14 Installing the wiring running accessories... 15 Power cables... 15 Installing the protection devices... 18 Run and cable the low power and auxiliary circuits Installing the devices on door or front plate... 19 Installing the wiring running accessories... 19 Cabling the auxiliary circuits... 19 Closing the trunking and wiring running accessories... 19 Install the partitions Installing the horizontal partition... 20 Installing the vertical partition... 20 Install the pack wall-mount enclosure Disassembing the enclosure... 21 Installing the busbar... 21 Installing the switchgear... 21 Cabling... 21 Finish... 22 Inspect the switchboard Final factory inspection... 23 Finish and fit the switchboard with panels Cleaning the switchboard... 24 Finishing the IP30 wall-mount or floor-standing enclosure... 24 Pack the switchboard Packing... 25 2
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Presentation of the components Wall-mount enclosure structure 1. Pillar 2. Rear panel 3. Functional upright 4. Top plate 5. Bottom plate 6. Gland plate 7. Side panel Mounting plates and switchgear 8. Horizontal Compact NS incoming unit on mounting plate 9. Multi 9 mounting plate: modular rail 10. Contactors Busbars 11. Powerclip insulated busbar 12. Tap-off blocks Distribution blocks 13. Multiclip 14. Comb busbar Wiring running 15. Trunking 16. Trunking for fine wiring Power cables 17. Incoming connection block 18. Power supply block 19. Earthing terminal block Front panel finish 20. Front plate support frame 21. Front plate 22. Barrier Cover panels 23. Transparent door 24. Plain wicket door 4
Presentation of the components PD390674 2 6 4 1 8 18 17 13 20 22 11 9 14 7 12 16 10 3 15 19 5 6 21 23 24 5
Instructions for use This manual describes a procedure for assembling the Prisma Plus system G. 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 The drawings often represent the wall-mount enclosures in vertical position but it is better to work horizontally on a table. A) Before starting to assemble, you must first identify and sort the components. B) The actual assembly process, divided up into 7 stages, is organised as follows: 1 Assembling the rear panel of the wall-mount/floor standing enclosure 2 Installing the busbars 3 Installing the mounting plates 4 Running and cabling the power circuits 5 Running and cabling the low power and auxiliary circuits 6 Installing the partitioning 7 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 60439-1 must be carried out. D) The last stage consists of packing the switchboard to ensure protection of the cubicles during transport. 6
Tools The recommended tool lists for this section are not complete, but represent the minimum tools required to assemble, cable and inspect the Prisma Plus system G cubicles. Assembling and cabling tools b Individual tools The tool kit belonging to the assembling and cabling staff must contain at least the following tools: DD382164 Type of assembly Switchboard mounting: enclosure, mounting plate and panels except for switchgear 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 wrench bit for pozidriv no. 2 recess 1 x 8 flat screwdriver 1 portable jig-saw Mounting the switchgear and tightening the connections (Compact NS, etc.) Socket 7, 8, 10, 13, 16 and 17 mm Hexagon socket bit 4, 5, 6, 8 and 10 Wrench bit for pozidriv no. 1, 2 and 3 recess Cabling the switchboard 1 flat screwdriver 3 mm - 3.5 mm 4 mm 5.5 mm 1 pozidriv no. 2 screwdriver 1 electrician s knife 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 DD382258 b Group tools K 1 torque wrench to tighten all electrical connections to the required torque (max. torque 50 Nm). K 1 set of shears to cut flexible bars. K 1 punching machine for flexible bars. K 1 electrical saw. K 1 drill. K 1 vacuum cleaner for switchboard cleaning. NB: When crimping the lugs, only the pliers recommended by the lug manufacturer must be used. DD382260 DD382263 Inspection tools b Individual 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: K 1 small hinged mirror. K 1 electrical lamp or portable lamp. b Group tools K 1 control console. K 1 dielectrometer. K 1 Multimeter. DD382261 7
04696191 AA 00 Identify and sort the components Aim: Identify and sort components to ensure subsequent proper working organisation and fewer handling operations. DD382267 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 wall-mount/floorstanding enclosure panels b Collect the components that will be used by the contractor, but do not unpack them. DD382291 Prisma Plus 08302 08306 08303 08307 08304 08309 08305 Tip: When you receive your components in your workshop, don t get carried away, don t unpack everything x4 VISSERIE A DETERMINER x4 x4 x2 IP55 8
Assemble the rear panel of the wall-mount/floor-standing enclosures DD382290 Aim: Assemble the rear panels and carry out the various combinations if required. Tip: The wall-mount or floor-standing enclosure must be assembled horizontally on a table that is protected to ensure the paintwork is not damaged. 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. DD382292 Assembling the IP30, IP31 and IP43 wall-mount or floorstanding enclosures b Take the rear panel, pillars, plinth gussets (for a floor-standing enclosure) and the assembly manual out of the packing. b Keep the adhesive shocks placed at the rear of the rear panel to prevent deformation b Store the rest of the packing Tip: The mounting hardware must be carefully associated with each wall-mount or floor-standing enclosure. During storage, take measures to prevent damaging component paintwork. DD382293 DD382294 b Mount the pillars on the rear panel and the gussets for the floor-standing enclosures b Couple the ducts, wall-mount or floor-standing enclosure extensions The ducts, wall-mount or floor-standing enclosure extensions are mounted in a similar way to the basic wall-mount and floor-standing enclosure. Couple the pillars located at the junction of the wall-mount or floor-standing enclosures using the combination kits. b Mount the set of cross-members to rigidify the wall-mount or floorstanding enclosure combinations. NB: Mounting of the set of cross-members is recommended for a wall-mount enclosure / duct combination, but becomes compulsory for a combination of 2 wallmount or floor-standing enclosures. Tip: Do not handle the rear panel of the wall-mount or floor-standing enclosure using the pillars. Take care to ensure the enclosure rear panel remains level during cabling operations. DD382296 DD382295 9
Assemble the rear panel of the wall-mount/floor-standing enclosures DD382297 x4 Assembling the IP 55 wall-mount enclosures b Take the rear panel, pillars and the assembly manual out of the packing b Store the rest of the packing Tip: The mounting hardware must be carefully associated with each wall-mount enclosure. During storage, take measures to prevent damaging component paintwork. DD382298 b Mount the pillars on the rear panel DD382299 b Couple the ducts, additional wall-mount or floor-standing enclosures The combination kit must be used to couple wall-mount enclosures. When coupling the enclosures, ensure that the gaskets are positioned properly. DD382300 Tip: Do not handle the rear panel of the wall-mount or floor-standing enclosure using the pillars. 10
Install the busbars Aim: This stage consists of positioning the supports and bars making up the busbars. Tip: If cutting oil is used, the busbars must be cleaned prior to assembly as oil adversely affects insulation properties. NB: K Busbar overall dimensions do not vary with current strength. K Whatever the busbar type, the order of the bars is always the same: from the front to the rear N, L1,L2 and L3. K With the rear busbar, the Neutral is to the left, then L1, L2, L3. DD382301 Installing the Powerclip 125 to 630 A insulated busbar NB: The busbars are mounted before the mounting plates, except for plates cat. no. 03032, 03073 and 03074 that must be mounted before the Powerclip insulated busbar (for more details on mounting plate installation, refer to the assembly stage "Installing the mounting plates"). To prevent assembly interference between busbar supports and mounting plates, we recommend that you follow the assembly order below: b Position the mounting plates but do not secure them b Define the busbar support positions b Remove the mounting plates except for those that have to be mounted before the busbar b Secure the supports and clip the Powerclip insulated busbar into the notches NB: Pay attention to the mounting direction of the Powerclip insulated busbar (refer to the assembly manual). When the Powerclip busbar is supplied by a power supply block, ensure that it reaches the top level of the incoming device mounting plate. If busbar length needs to be adjusted, cutting must be extremely accurate and on no account exceed the cutting line. When handling the Powerclip busbar, take care not to break the end of the partitions. For safety reasons (creepage distance, insulation, etc.), do not! install a Powerclip busbar with a broken partition. b Store the covers of the Powerclip insulated busbar. They will be installed once the wall-mount or floor-standing enclosure has been cabled. DD382302 Installing the 160 to 400 A rear busbars in vertical position b Fit the busbar with its supports but do not screw them on as they may be transferred later when laying the power cables. L3 N L1 L2 b Mark the bars (N L1 L2 L3). DD382303 Installing the 160 to 630 A multi-stage busbars in the duct b Fit the multi-stage busbar with its supports b Mark the bars (N L1 L2 L3). N 11
Install the mounting plates DD382304 Aim: This stage consists of defining the position of the mounting plates in the wall-mounted or floor-standing enclosure and installing them with their devices. The order of assembly of the mounting plates and devices depends on the technical features of the devices. NB: 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 is 1 reference m0 at each corner, materialised by a mark and a slot, used to hook up a measuring tape to measure the height to be complied with when installing a mounting plate. DD382307 X DD382305 Installing the mounting plates and switchgear b Mount the devices on their mounting plate Device Fixing Assembly order Compact NS and INS y 630 A Fixed b Place the device on the mounting plate b Install the equipped mounting plate H Withdrawable or plug-in b Place the plinth or rack on the mounting plate b Install the equipped mounting plate b Plug in the device DD382306 Modular devices Modular system b Install the rail b Place the modular devices on the rail b Define the positions of the functional unit mounting plates and install them: K the position of a mounting plate depends on the overall dimensions of the functional unit that is characterised by a number of modules (1 module = 50 mm), K the number of modules is given in the catalogue and in the assembly manual, K install the equipped mounting plates starting at level m0. DD382308 Checking switchgear position This operation allows operator inspection and prevents incorrect positioning of the functional unit with respect to the front panel, once the wall-mount or floor-standing enclosure has been fully cabled. Use of the front panel enables mounting plate and device position to be validated. b Place the necessary front plate mounting parts: K place the functional uprights in the wall-mount/floor-standing enclosure, K place the uprights in the IP55 wall-mount enclosure, K place the sides in the IP30 duct. b Install the front plates to check device position. Also check the depth of the devices mounted on an adjustable modular rail. DD382309 b Remove the front panel without taking the front plates apart, as well as the sides for the IP 30 wall-mount (or floor-standing) enclosure and duct combination. 12
Run and cable the power circuits DD381889 Installing the secondary distribution blocks You need to comply with connection capacities, stripping lengths, the number of cables connected and use the appropriate tools. 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 Connection principle Polybloc 4-10 mm 2 O 4-10 mm 2 6-16 mm 2 4 mm 2 12 _ 5,5 mm 6 mm 2 12 16 10 mm 2 12 16 6-16 mm 2 16 mm 2 _ 16 Additional block 16 mm 2 25 mm 2 35 mm 2 12 pozidriv n 2 Distribloc Power supply ø 6,5 2,5 6 mm 2 ø 5 1,5 4 mm 2 ø 8 4 10 mm 2 ø 8 4 16 mm 2 12 10 12 12 pozidriv n 2 Distribution 5,5 mm Multiclip 200 A 12 Power supply 10 mm 2 n 6 Distribution 4 mm Multiclip 80 A 4 mm 2 10 Power supply pozidriv n 2 12 6 mm 2 Distribution 3,5 mm Tap-off blocks insulated busbar 4 mm 2 10 4 mm 6 mm 2 12 10 mm 2 12 NB: The downstream device connecting cables are delivered with the Multiclip and Distribloc. 13
Run and cable the power circuits DD382310 Installing the connection terminal blocks and earth bars b Install the supports for arrangement of the connection terminal blocks and earth bars NB: The connection terminal blocks and earth bars are installed: K either in the duct that forms a zone that can be completely separated from the devices, K or in the switchgear zone, at the top or bottom (or on the sides for the earth bar). b Install the terminal blocks DD382245 b Install the earth bars Type Connection capacity Connection principle DD382246 DD382247 4 mm 2 12 DD382227 DD382311 6 mm 2 12 5,5 mm 10 mm 2 12 16 mm 2 12 DD382248 DD382249 10 DD382250 4 mm 2 3 mm DD382251 35 mm 2 incoming terminals for flexible or rigid cables 16 mm 2 outgoing terminals for flexible or rigid cables Screw terminals 14
Run and cable the power circuits Installing wiring running accessories 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. DD382342 DD382343 b Install the trunking for horizontal or vertical wiring The trunking is used to carry wires to the switchgear zone. Trunking is secured: K to some mounting plates on specially reserved locations, K on the trunking supports by means of clip-on, ¼ turn removable screws. DD382344 NB: Trunking is assembled onto its support simply by clipping on from the front. DD382312 Power cables You need to: b know the position of the partitions and check that they can be mounted, b tie the "1000 V" insulation cables to the device mounting plates, b install the tie supports complying with 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. b Install the upstream connections Device type u 1600 A power device DD382313 Connection in switchgear zone Incoming connection block DD382315 Connection in duct Connection transfer assembly Connection by cable Connection by cable DD382314 DD382316 15
Run and cable the power circuits Device type Modular device Connection in switchgear zone Connection from a Powerclip busbar Connection in duct DD382318 DD382317 Connection from a rear busbar Connection from a busbar DD382320 DD382319 DD382321 16
Run and cable the power circuits b Install the downstream connections DD382322 Device type u 160 A power device Connection in wall-mount/floorstanding enclosure Power supply block to the Powerclip busbar Connection in duct Connection by flexible bars to the busbar in the duct DD382323 DD382327 Universal power supply block to the Powerclip busbar DD382325 DD382345 Connection by cable to Polybloc DD382324 DD382346 Connection by cable to additional block DD382326 Modular device Connection to the terminal blocks DD382328 DD382328 17
Run and cable the power circuits Fitting the protection devices b Prepare the various protective covers (cut-out, drilling, etc.) b Fit the various protective covers: K upstream and downstream terminal shields are compulsory for all Compact NS circuit-breakers and INS/INV switches with vertical or horizontal mounting, K cover for power supply block, K connection cover for cable, K cover for busbar, K tooth-caps, etc. DD382329 DD382330 l 18
200 310 400 V 500 200 31 0 400 V 500 20 0 310 400 V 500 500 400 310 200 V Route and cable the low power and auxiliary circuits DD382331 Install the devices on door or front plate 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. Installing the wiring running accessories b Install the trunking for doors and the grommets Tips: We recommend that you use protection devices for wiring through uprights or to doors: DD382277 DD382278 Flexible trunking Grommet Cabling the auxiliary circuits DD382276 b Mark the wires to simplify on-site connection and maintenance of wallmounted and floor-standing enclosures, 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. 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. Closing the trunking and wiring running accessories Tip: Trunking packing density must not exceed 70 %. 19
Install the partitions DD381418 Installing the horizontal partition Before mounting the partition, remove the pre cut-outs required to insert the cables and wires through the busbar. DD381421 Installing the vertical partition Before mounting the partition, pierce or cut out the pre cut-outs required to insert the cables and wires. 20
Assemble the pack enclosure DD382332 Disassembling the enclosure The enclosure of the pack enclosure comes equipped with blanking plates for the front plates. b To ensure total access to components during the enclosure assembly and installation process, we recommend that you remove the front panel, the sides and the top and bottom plates b Store the parts removed with their associated mounting hardware and the front plate blanking plates. DD382333 Installing the busbar Install the Powerclip 125 A or 160 A busbar. NB: With the Powerclip 160 A busbar, Multiclip distribution blocks cannot be installed. DD382334 DD382335 Installing the switchgear Device Illustration Comments NSA 125/160 INS 40/160 To install an NSA, an enclosure modular rail must be replaced by an adjustable modular rail (rail recommended in the catalogue). DD382306 Modular device DD381818 DD382231 Cabling b Installing the distribution blocks Distribution block Distribloc 125 A et 160 A Illustration Comments Refer to the table on page 13 for the connection principle of these distribution blocks. DD381200 DD382238 Multiclip 80 A Position the Distribloc 160 so that its power supply is at the top of the enclosure to save space DD382336 Multiclip 63 A DD382337 DD382242 Tap-off blocks 21
Assemble the pack enclosure PD390551 b Installing the connection terminals and the earth terminal blocks K Connection terminals For some terminal block types, it may be necessary to replace one of the pack enclosure modular rails by an adjustable modular rail. K Earth terminal blocks There are 2 earth bar types (the same as those for the IP30 wall-mount and floorstanding enclosures). DD382248 DD382251 DD381819 b Installing the horizontal cable straps and trunking (30x60) PD390550 b Cabling the power circuit K connect the incoming device to teh Powerclip busbar or the dsitribution blocks, K connect the modular outgoing devices to the distribution blocks and the connection terminals. Finishing b Clean the switchboard : the procedure is the same as for the IP30 wallmount and floor-standing enclosures b Fit the sides, top and bottom plates and front panel b Fit the blanking plates b Install the markers and fit the label holders b Fit the doors. 22
Inspect the switchboard DD382263 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 60439-1 mentioned below: b 1st test: overall inspection including examination of cabling, checking connection tightening and, if necessary, an electrical operating test b 2nd test: checking insulation via a dielectric test b 3rd test: checking direct contact protection measures and electrical continuity of protection circuits DD382261 b Drafting test reports For more details concerning inspections, consult the switchboard assembly and installation guide. DD382266 23
Finish and fit the switchboard with panels E68280 Cleaning the switchboard b Remove 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. b Dust the outside Tip: Use a neutral dissolvent that will not damage the paint. b Touch up paintwork if necessary b Check absence of foreign matter inside the switchboard (tools, screws and bolts) that could prevent it from operating properly.. DD382338 Finishing the IP30 wall-mount or floor-standing enclosure b Fit the sides, the top plates (and bottom plates for the wall-mount enclosure) the corner parts and the plinths (only for the floor-standing enclosures) b Install the markers and fit the label holders DD382339 b Install the front panel on the wall-mount or floor-standing enclosure: K screw but do not tighten the front panel on the wall-mount or floor-standing enclosure, K adjust the position of the front panel so that the front plate openings are properly positioned with respect to the devices, K tighten the fixing screws. b For degrees protection IP 31 and IP43, install the canopy with the top terminal b Install the blanking plates on the front plates. DD382340 b Fit the doors that were not already fitted with the switchgear on the door. b Fit the door gasket to ensure the degree of protection IP43. DD382341 NB: Door mounting is reversible. It is advisable to install barrels and inserts before fitting the handle on the door and before installation on the wall-mount or floor-standing enclosure. Tip: Take care to degrease surfaces thoroughly before sticking on the gaskets. Installation tips for wall mount enclosures, Pack enclosures, floor standing enclosures and extension ducts: Maximum acceptable surface evenness defect without affecting installation of panelling is 6 mm. 24
Pack the switchboard Packing b Compile a technical file containing a set of drawings, the device operating manuals and the wall-mount/floor-standing enclosure assembly manuals b Attach the adhesive drawing holder to the rear panel of the door with the technical file b Ensure wall-mount/floor-standing enclosure 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.). b Pack the wall-mount or floor-standing enclosure. 25
Schneider Electric Industries SAS 89 boulevard Franklin Roosevelt F-92500 Rueil Malmaison (France) tel : +33 (0)1 41 29 85 00 http://www.schneider-electric.com As standards and equipment change from time to time, always ask for confirmation of the information given in this document. This document has been printed on ecological paper. Published by: Schneider Electric Produced by: HeadLines xxxx version A 2003 Schneider Electric all rights reserved