1

Prisma PPrisma PAssembly Manual

Schneider Electric SA088620 UDirection commerciale5 rue Nadar92506 Rueil-Malmaison CedexFranceTel. : +33 (0)1 41 29 82 00Fax. : +33 (0)1 47 51 80 20

As standards, specifications and designs change from time to time, please ask for confirmation of the informationgiven in this publication.Publication : SchneiderCreated by : SONOVISION-ITEP EybensPrinting by : ColorPress

PREFACE

This manual proposes a procedure for assembling the Prisma P functional system.We have designed it to help you successfully complete your first projects.It ensures that assembling and wiring staff, for whom it is intended, will benefit from Schneider’s considerableexperience in this field. In short, it is an indispensable workshop tool.

There are several approaches for assembling Prisma components. In this manual we propose one approachwhich you can add to according to your professional organisation and experience.

ContentInstructions for use 2

Presentation of the components 4

1 Identify and sort the components 7

2 Assemble the frameworks 11

3 Install the mounting plate cross-members 19

4 Install the busbars 21

5 Install the mounting plates and switchgear 31

6 Check switchgear positioning 37

7 Install the secondary distribution blocks 41

8 Install the wiring routing accessories 43

2

9 Power connections 47

10 Install the form 3 horizontal screens 55

11 Wire the auxiliary circuits 57

12 Install the form 2 partitioning without insertion ofconnections 61

13 Install the cable tie-bars, bracing supports andprotective conductors 63

14 Install the cableway screens 67

15 Clean the switchboard 69

16 Finish the front face 71

17 Fit the panels on the switchboard 73

18 Inspect the switchboard 77

19 Package the switchboard 79

Instructions for useThis manual describes the procedure for assembling the components of the Prisma P functional system. It thusindicates the order in which the components are to be assembled: the technical assembling instructions arefound in the manuals supplied in the packaging of each component.We have divided the procedure into 19 stages. The sorting software supplied enables you to class your project’scomponents by assembly stage. Each stage is organised as follows:

AIntroduction to the stage.

BGeneral procedure of the stagesymbolised in the top righthand corner by the icon .

CDetails of the operations if necessarysymbolised in the top righthand corner by the icon .For some configurations you will not have to perform all the operations proposed.

AIntroduction to the stageStandard switchboard produced at the end of the stageSummary of the work to be performedBGeneral procedure of the stageSequencing of operationsOperation and summary of work to be performed.

3

CDetails of operations

Presentation of the componantsFramework1 Frame2 Top strip3 Bottom strip4 Intermediary upright5 Roof

Mounting plates and switchgear6 Mounting plate cross-member7 Mounting plate8 Multi 9 mounting plate: Multifix rail and fastener9 Compact C incoming unit10 Compact NS devices11 Multi 9 switchgear

Busbars12 Linergy bottom support13 Linergy busbar support14 Linergy busbars15 Linergy prefabricated connections16 Horizontal busbars

Distribution blocks17 Polypact18 Multiclip19 Comb busbar

Wiring routing20 Trunking21 Trunking and terminal block for auxiliary wiring

Power connections22 Form 2 screen and prefabricated connection23 Transfer connection and screen24 Devices mounted on drilled cableway door

Partitioning25 Connection support form 2 screen26 Spare form 2 screen27 Form 3 screen

PE28 Cable tie-bar29 Cable support30 PE protective conductor31 PE connection

Front face finish

4

32 Identification label33 Front plate support (door or fixed front face)34 Front plate

Panels35 Rear panel36 Side panel37 Transparent door38 Plain cableway door

01 Identify and sort the componentsDon’t get carried away: don’t unpack everything...

The components are grouped in families according to their use.

The components and switchgear are grouped by assembly stage in order to optimise work organisation andminimise handling during the assembly procedure. The pallets are clearly identified for each project.Reference documents:� Delivery slip.� Order form.� List of sales references classed by assembly stage:� stage 1 components are consumables that can be used throughout assembly.You can use the sorting software to create this list.Framework components

Panel componentsBusbar functional unit componentsComponents intended for the installation contractorSwitchgear & distribution blocksContent of the pallets� The framework.� The lifting lugs� The gland plates.� The panels� The sealing kits.� The juxtaposition kits.

� The mounting plates.� The front plates.� The busbars.� The protective conductor supports.� The partitioning.� The prefabricated connections.� Small components are grouped in crates or on a raised pallet.

� The spare parts.� The plinths.� The roofs� The installation file.

� The switchgear.

5

� The secondary distribution blocks.

02 Assemble the frameworks

This stage consists of assembling the structural parts and creating the various combinations.

Store the roofsAssemble the basic frameworkInstall the intermediary uprightsAssemble the extension frameworkFit back to backInstall the lifting lugs

Summary of operations.Details on page 14.

� Place a frame on its edge� Position and assemble the top and bottom strips.� Position the second frame.� Assemble the last two strips.Details on page 14.

� Position the intermediary uprights.� Loosely screw all the bolts on the framework.Details on page 15.

Assembly of the extension framework and its partial uprights (if any) is similar to that of a basic framework. Theextension framework is fixed onto the basic framework.

� Punch out the pre-stamped combination holes of the uprights to be fitted together.� Assemble the second framework.� Check structure alignment and tighten the combination bolts.Details on page 16.

� Install the lifting lugs on the inner side of the frames.� Lock the counternut, taking care to leave the lifting lug its freedom of movement.

Install the handling raftersInstall the functional uprightsThe cubicles are delivered coupledThe cubicles are delivered uncoupledInstall the strip covers on the partial doorsInstall the gland plates and the inter-cubicle partitions

Summary of operations.

� Punch out the lower cutouts on the frames� Fix the rafters.Details on page 16.

6

If a 600 mm deep framework is used, the functional uprights must be assembled. These uprights will be used toinstall the mounting plates supporting the switchgear.

� Couple the cubicles widthways.� Install the juxtaposition kit angle brackets.Details on page 17.

� Store the juxtaposition kits on the contractor’s pallet.� Temporarily bolt together the cubicles.Details on page 1

This operation should be carried out before the gland plates are installed.Keep the leftover parts, which will be used to assemble the front face (stage 6).

Details of operations

Store the roofs:Each roof must be assigned its screws and bolts, and the complete assembly stored for future use, either on thecontractor’s pallet or the panel storage pallet.To avoid damaging the roof paintwork, retrieve the pins supplied and insert them between the roofs.

Assemble the basic framework:Use of a working surface simplifies framework assembly. The frames are then assembled horizontally.The frameworks must be assembled on a flat surface, equipped with suitable protection to prevent damage to thepaintwork� Place a frame on its edge.� Position and assemble the top and bottom strips. To simplify assembly of the intermediary uprights do nottighten the bolts:� Then position the second frame, bringing the screws together:� Assemble the last two strips:To fix the upper face strips on the frames:� Insert the bottom of the strip into the holes shown in the assembly guide.� Bring the two screws together.� Swivel the strip and fit the remaining screws.

Do not tighten the bolts in order to leave sufficient play.This will simplify the rest of the assembly process.

Details of operations

� Assemble the last two strips:To fix the upper face strips on the frames:� Insert the bottom of the strip into the holes shown in the assembly guide.� Bring the two screws together.� Swivel the strip and fit the remaining screws.

Install the intermediary uprights:The uprights are installed in 900 mm or 1100 mm frameworks.� 900 mm = a 700 mm switchgear area with a 200 mm cableway (on the left or right).� 1100 mm = a 700 mm switchgear area with a 400 mm cableway (on the left or right) or two 200 mm cableways.

� Screw on all the bolts and ensure they are properly tightened.

Fit back to back:

7

If 800 mm or 1000 mm deep cubicles are required, the frameworks must be fitted back to back. Therefore, afterthe first framework has been assembled, punch out the pre-stamped combination holes of the uprights to befitted together.The frames of the second framework are then placed edgeways on the frames of the first framework and partiallyscrewed on, ensuring sufficient play is left. The second framework is assembled in the same way as a basicframework. Once the second framework has been assembled, check structure alignment and permanentlytighten the combination bolts.

Install the handling rafters:

The handling rafters, installed beneath the cubicles, enable transport by fork-lift truck. To install the rafters, punchout the lower cutouts on the frames and fix the rafters.The frameworks were assembled horizontally. You now need to lift them upright to continue the assemblyoperations.

Rafters may be prepared beforehand. Let the rafters protrude as this will simplify packing in front of the front faceof the switchboard.

Gripping nuts may prove extremely useful when assembling these parts.We strongly recommend that you create magnetic labels identifying the various cubicles (each cubicle isidentified for each project).

We strongly recommend that you create magnetic labels identifying the various cubicles (each cubicle isidentified for each project).

If the switchboard has to be equipped with plinths, but no means of lifting from the top is available, the plinthsmust be assembled immediately.

The cubicles are delivered coupled:� Couple the cubicles widthways:For handling reasons, it is preferable not to couple more than 2 cubicles together.� Install the juxtaposition kit angle brackets:Keep the leftover parts as they will be used in the panel fitting phase.The juxtaposition kits are positioned between two basic frameworks only.

The cubicles are delivered uncoupled:� Store the juxtaposition kits on the contractor’s pallet:The contractor will install the juxtaposition kits.� Temporarily bolt the cubicles together:Temporary bolting together of the cubicles is a good way of determining cable and busbar length.

03 Install the mounting plate cross-members

Installation of the mounting plate cross-members is a means of determining the position of the busbar supports.These supports must be positioned at mounting plate cross-member level in order to simplify insertion of theconnections.

Mark the position of the functional units and install the mounting plate cross-members:

Mark the space taken up by the functional units (dimension H) starting at m 0.

8

1 module = 50 mm.Then mark the position of the mounting plate cross-members (dimensions A, a, b available in the assemblymanual).The position of the vertical busbar supports will thus depend on the position of the cross-members.When marking the space taken up by the functional units, allow for the displacement caused by the presence of amain horizontal busbar at the top or bottom of the cubicle (e.g. 3 modules for form 2).The connecting busbar occupies the same space as the functional unit.The partial door intermediate cross-members occupy modules which can no longer be used to position thefunctional units. The same applies to the boards, shelves and ventilated front plates. This stage must thereforedetermine the position of these components.

� Install the mounting plate cross-members:In the case of mounting plates for compact NS, install the frame on the cableway side.Identify the leftover parts which will be used in stage 5.

04 Install the busbars

This stage consists of positioning the supports and bars making up the busbar. The positions of the screens andcurrent transformers are also determined .

The busbar installation procedure depends on the following factors:� Presence and location of the main horizontal busbar� Position and type of the vertical distribution busbars.

Install the horizontal busbarInstall the vertical busbarJoin the busbarsTighten the countersupports on the horizontal busbarTighten the bars to the required torqueLabel the barsInstall the form 2 partition on the horizontal busbar

Install the vertical busbarDetermine the position of the current transformersFlat busbar mounted laterallyLinergy busbar mounted laterallyBusbar mounted at the back of the cabinetScrew on the vertical busbar countersupports

� Define the distance between supports� Install the supports.� Cut and punch out the bars.� Position the horizontal busbar.� Prepare the splice-bars.� Bring together the screws on the busbar countersupports.

� Define the distances between supports� Install the supports in the cableway.� Install the busbar.� Define the distances between supports.� Install the supports in the cableway.� Install the Linergy busbar.Details and tips on page 27.

9

� Define the distances between supports.� Install the girders and supports in the back of the cabinet.� Install the busbar.

Do not over tighten: the supports are not designed to exert pressure on the bars but to hold them laterally inplace should a short-circuit occur.

� Prepare the combination splice-bars.� Join the busbars.Details on page 30.

Install the horizontal busbarThe general assembly procedure consists of determining the position of the supports and installing thehorizontal busbar if required.� Install the supports:The distances between supports must be checked once short-circuit current values have been taken intoconsideration. The same check must also be performed between the cubicles.� Cut, punch out and bend the bars:If you use a Linergy busbar supplied by a bottom horizontal busbar, install a copper wedge to hold the verticalbars in place.The spacer ref. 07410 can be used as a wedge if a bottom horizontal busbar made up of 50X5 bars is used.Align the horizontal busbar with the Linergy busbar. The relative position of the holes in each bar is the same.� Prepare the fish plates:If the switchboard is dissociable and fitted with a horizontal busbar, the fish plates must be fitted, cut andpunched out.Try out the fish plates; draft an assembly manual mentioning the tightening torques and the necessary screwsand bolts . This manual will be included in the file submitted to the contractor.� Loosely screw the screws on the horizontal busbar countersupports:Once the horizontal busbar is installed, you can install the vertical busbar and its associated current transformers,if any.

Flat busbar mounted laterally:� Install the supports:The distances between supports must be checked once the switchboard’s electrical data have been taken intoconsideration. The supports must be placed between the functional units in order to simplify device connection.Add a support if necessary.When installing the busbar supports, you should determine the position of the various items of switchgear,mounting plates, connecting busbars...

With bottom horizontal busbar:� Install the busbar:When installing the busbar, lean on a bottom support in order to align the slots on the various devices (verticaland horizontal bars, fish plates).The vertical busbars, which are floating, must be held in place.

Without bottom horizontal busbar:� Install the bottom support:If the switchboard does not have a main bottom busbar, install an insulating bottom support for laterally mountedflat bars.� Install the busbar:Use the bottom support to bear the busbar.The vertical busbars, which are floating, must be held in place.

Linergy busbar mounted laterally:

10

Without bottom horizontal busbar:� Install the bottom support.� Define the distances between supports:The table defining distances between supports can be found in the assembly manual.

Make sure that you place the supports between the functional units in order to simplify connection of theswitchgear to the busbar.� Install the supports.� Install the Linergy busbar:Use the bottom support to bear the busbar.

With bottom horizontal busbar:� Define the distances beween supports:The table defining distances between supports can be found in the assembly manual.

Make sure you place the supports between the functional units in order to simplify connection of the switchgearto the busbar.

� Install the supports.� Install the Linergy busbar:The copper wedges placed on the horizontal busbars act as a bottom support for the Linergy busbar (verticalblocking). The spacer ref. 07410 can be used as a wedge if a bottom horizontal busbar made up of 50X5 bars isused.

Busbar mounted at the back of the cabinet:� Define the distances between supports:The distances between supports are given in the assembly manual.� Install the girders and supports at the back of the cabinet:The maximum allowed spacing must be respected when installing the girders and supports.� Bear on a bottom support to install the busbarIf the busbar is of the Linergy type, bear on the bottom support (ref. 07499) when installing it. If a flat busbar isused, a special wedge will be made to align the bottom of the bars during assembly.The spacers (ref. 07410) can be used to wedge the flat bars on the busbar supports.

Join the busbars:� Prepare the combination fish plates and join the busbars:Cut, punch out and bend the fish plates as required (horizontal busbar current greater than 1600 A), or useprefabricated connections (ref. 07407, 07408) and join the busbars.When fitting oblong hole connections (connections ref. 07407 and 07408), a flat washer must be used to ensureeven distribution of tightening force.

05 Install the mounting plates and switchgear

In this stage, the mounting plates and switchgear are assembled and installed in the enclosure. The order ofassembly depends on the technical features of the devices.Switchboard assembly can continue even if functional unit components (e.g. mounting plate, front plate,switchgear) are missing!

Compact NS, Interpact ≤ 630 A.Multi 9Masterpact, Compact CM, Compact C, Interpact > 630A.

11

Other mounting plates� Prepare the mounting plates.

Fixed device:� Install the Polypact.� Fit the device on the mounting plate.� Install the equipped mounting plates.

Draw-out device:� Fit the plug-in base or chassis on the mounting plate.� Install the equipped mounting plates.Details on page 34.� Install the Multifix rails.� Install the switchgear on the rails.Details on page 35.Fixed device:� Install the mounting plates.� Fit the devices on the mounting plates.Draw-out device:� Install the mounting plates.� Fit the chassis on the mounting plates.Details on page 33.� Install the perforated plates.� Install the shelves.The spaces reserved for wiring routing can thus be marked out.

Masterpact, Compact CM, Compact C, Interpact > 630 A.Fixed device:� Install the mounting plates:During this stage, the assembly guide must be carefully consulted in order to define the depth at which themounting plates should be positioned. This depends not only on the switchgear but also on the type of frontface chosen.

� Fit the device on the mounting plate:The device is fitted on the mounting plate to enable the connections to be made.As there is a small amount of play, make sure the device is properly aligned on the mounting plate.

Draw-out device:� Install the mounting plates:During this stage, the assembly guide must be carefully consulted in order to define the depth at which themounting plates should be positioned.This depends not only on the switchgear but also on the type of front facechosen.

� Fit the chassis on the mounting plate:The chassis is fitted on the mounting plate to enable the connections to be made.As there is a small amount of play, make sure the chassis is properly aligned on the mounting plate.

Compact NS, Interpact ≤ 630 A.Identification labels for the devices are placed on the mounting plates, thus making it easy to locate the devicesonce the front plates have been removed.

For simplified power connections, you can now install the prefabricated connections on the frames of themounting plates on which horizontal devices are fitted.

Provide cutouts in the screen to insert the wiring in the duct.

12

� Prepare the mounting plates:Remove the pre-cutouts and touch up the paintwork.

Fixed device:� Install the Polypact and its connections on the mounting plates using the screws and bolts supplied:The Polypact is only installed on mounting plates on which fixed devices are fitted.

� Fit the devices on the mounting plates:Devices supplied by a Polypact can be installed once the mounting plate has been fitted in the framework.� Install the equipped mounting plates:During this stage, the assembly guide must be carefully consulted in order to define the depth at which themounting plates should be positioned. This depends not only on the switchgear but also on the type of frontface chosen.

Draw-out device� Fit the plinths or chassis on the mounting plates.� Install the equipped mounting plates:During this stage, the assembly guide must be carefully consulted in order to define the depth at which themounting plates should be positioned. This depends not only on the switchgear but also on the type of frontface chosen.

Multi 9:� Install the Multifix rails on the framework:During this stage, the assembly guide must be carefully consulted in order to define the depth at which themounting plates should be positioned. This depends not only on the switchgear but also on the type of frontface chosen.

� Install the switchgear on the rails:An 8 mm space must be left free at both ends of the Multifix rail to enable insertion of the front plate.

06 Check switchgear positioningThis stage allows assemblers to inspect their work. The front plate support (door or frame) is placed so as to checkthe position of the switchgear. The busbar connecting bars can then be bent without risk of error due to incorrectpositioning of the functional units.

Install the front plate support doors� Install the hinges.� Install the sliding bolt locks.� Fit the door on the hinges.� Mount the handle.

Install the front plate support fixed frameTo simplify disassembly after checking do not tighten the fasteners.

Install the uprights for the front plate support fixed front face� Install the hinges.� Install the sliding bolt locks.� Install the uprights for the front plate support fixed front face.

Install the partial door cross-members

Install the front plates to check switchgear positioning

13

Remove the front face� The front face is removed to allow easy access to internal components.� The front face will be used again in stage 15.

07 Install the secondary distribution blocksPolybloc 160 / 250 A.Distribloc 125 / 160 A.Multiclip 180 A.Comb busbars 100 / 125 A.

08 Install the wiring routing accessoriesThis stage consists of installing the trunkings, wiring routing straps and, in the case of a double depth cubicle withrear busbar, the form 2 screen supports.

Install the wiring routing straps and trunkingsDetails on page 45.

Install the form 2 screen supports for double depth cubicles Install the wiring routing straps andtrunkingsThe leftover parts will be used in stage 12.

Details of operationsInstall the wiring routing straps and trunkings:

If the switchboard is form 2 and fitted with vertical trunking at the Multifix rail, install the form 2 partitioning beforeyou fit the trunking.If the switchboard contains form 3 separation, the trunking must not exceed the limits of each functional unit inorder to enable installation of form 3 separation.The trunking must be fixed with nylon screws.The wiring routing straps are used to guide the wires, and are easy and quick to mount. The wiring covers usedensure a neat, tidy finish. A set of 5 straps guides the wires on a modular row

The fine wiring trunking is designed to route the wiring (circuit-breaker auxiliaries...) to the left or right of theswitchgear area, and is fixed to the horizontal NS mounting plates (Ref: 07323). This wiring may be connected toa junction block clipped onto an adapter (Ref: 07324).The support (Ref: 07422) is used to fix the horizontal trunking to a Multifix rail.

09 Power connectionsThis stage consists of installing the power connections for the distribution switchgear. Several possibilities areproposed which depend on the power of the switchgear used and the destination of the connection.

Install the upstream connectionsThis stage includes:� Connection of the incoming unit to the incoming cables� Connection of the other devices to the busbar.By barsBy prefabricated connections

14

Multi 9 switchgearBy transfer connectionsBy barsNo downstream connection before installationLabel the conductorsBy flexible barsBy cables

� Install cross-members and supports.� Cut, punch out and bend the bars.� Position the bars in the supports.� Install and tighten the countersupports.� Tighten the connections.Details on page 50.

� Install the support screen.� Pass the connections through the screen.� Tighten the distribution block’s supply connections.� Brace the connections.� Connect the switchgear to the distribution block.Details on page 52.

� Install the support screen and its connections.� Pass the connections through the screen.� Tighten the connections.� Brace the connections.Details on page 50.

Determine the position of the current transformers.� Define the distances between supports.� Install the supports.� Cut, punch out and bend the bars.� Position the bars in their supports.� Install and tighten the counter supports.� Install the transfer device/current transformer connecting bars.� Tighten the connections to the required torqueDetails on page 53.

For Compact NS 100 to 630 A devices:� Install the prefabricated connection (ref: 07200 or 07201).� Tighten the connections to the required torque.For Multi 9 switchgear:� Install the power terminal blocks.� Connect the downstream connections to the terminals.

For Compact NS 100 to 630 A devices:� Install the prefabricated connection (ref: 07200 or 07201).� Tighten the connections to the required torque.For Multi 9 switchgear:� Install the power terminal blocks.� Connect the downstream connections to the terminals.

� Provide the necessary switchgear documents for site connection.

15

Detail of operations

Install the upstream bar connections:

� Incoming unit:The electrical supply connections are made of «bar tails» secured by supports enabling limitation of incomingcable tensile load on the device terminal pads.

You should anticipate installation of the partitioning at this stage (see stage 12).Provide cutouts in the screen for insertion of wiring.

Connection to an incoming unit may either use «bar tails» or be made directly on the device terminal pads.Preference should be given to edgeways pads in order to limit temperature rise at the connection points.Cable supports should be provided to prevent the cables from exerting excessive mechanical stress on thedevice terminal pads.

The «bar tails» must be held together and the supports attached to the framework. Place supports as close aspossible to the device terminal pads. Whenever necessary follow the instructions given in the device’s technicaldocumentation (Masterpact…).

The space available in the 300 mm and 400 mm cableways allows a whole host of possibilities for incomingcables.

� Outgoing units:High power units connected to the busbar by custom-made copper bars.

Install the prefabricated upstream connections, connections custom-made fromflexible bars or cables:

Whenever possible, the busbar connection is made by prefabricated connections (up to 630 A), custom-madeflexible bars (up to 800 A), or cables.Provide cutouts in the screen for insertion of wiring in the cableway.

Details of operations

� Install the support screen or the prefabricated connection with screen.

� Pass the connections through the support screen.� Tighten the connections to the required torque:In order to ensure even distribution of tensile load and prevent copper flow, install a flat ≥ 2 mm thick washer withan outer diameter equal to steel strip width, between the contact washer and the steel strip.Do not squeeze the insulator when tightening.

� Brace the connections:� Support screen.The supplied plugs are used for bracing.� Prefabricated connection.The screen is used for bracing.� Flexible bars without screen.

Bindings are used for flanging. Spacers are inserted between the conductors to limit temperature rise.

16

Details of operations

Install the upstream connections of the Multi 9 devices:� Incoming unit:The electrical supply connections are made of «bar tails» secured by supports enabling limitation of incomingcable tensile load on the device terminal pads.

Whenever possible, the busbar connection is made by prefabricated connections (up to 630 A), custom-madeflexible bars (up to 800 A), or cables.

For Multi 9 switchgear, connect the distribution block (e.g. Multiclip) supply using custom-made connections(flexible bars or cables). The procedure is then the same as for cable supply.� Install the support screen:Provide cutouts in the screen for insertion of wiring in the cableway.� Pass the connections through the screen:Install insulators on the Multiclip terminals.� Tighten the distribution block’s supply connections to the required torque.� Brace the connections� Connect the switchgear to the distribution block.

Install the downstream bar connections:

Linergy section with continuous groove:� Position the screw over the full length of the section.� A standardised M8 screw, class 8/8, is used for all the Prisma connections.� Determine the position of the current transformers

� Install the supports:Determine the distances between supports to ensure they are compatible with the short-circuit current.As far as the installation of supports is concerned, the procedure is the same as for installation of a flat busbar.

� Cut, punch out and bend the bars:Linergy busbar directly supplied by a fixed Compact C 1251 circuit-breaker.Linergy busbar supplied by a draw-out Compact C 1251 circuit-breaker using a transfer busbar.Linergy busbar supplied by a draw-out Masterpact 1600 A circuit-breaker using a transfer busbar.2000 A busbar supplied by a draw-out Masterpact circuit-breaker.

2500 A busbar supplied by a Compact CM circuit-breaker.3200 A busbar supplied by a draw-out Masterpact circuit-breaker� Position the bars in their supports.� Install and tighten the countersupports.� Install the connecting bars and the current transformers.� Tighten the connections to the required torque.

10 Install the form 3 horizontal screens

Install the form 3 partitioningForm 3 is made up of:� Upstream and downstream partitioning of the incoming unit, or a front screen in front of the incoming unitconnections on the busbar.� Form 2 partitioning of the busbar.� Upstream terminal shields on the switchgear.

17

� Form 3 horizontal screens.

11 Wire the auxiliary circuits

Auxiliary and low power circuitsThe wires for the remote controls, signals and front face devices must run in the trunkings and wiring straps. Lowpower conductors may be provisionally marked at this stage in order to prevent wiring errors and simplifypermanent marking.

Door mounted devicesWire the auxiliary circuitsClose the trunkings and wiring routing accessories

� Install the doors or front plates on which devices will be fitted.� Install the devices on the doors or front plates.� Prepare cable routing.� Make the cable strand hole in the cableway screen.Details on page 59.

Provide for wire insertion through the form 2 screens.� When wiring circuits, ensure you label the wires.

If devices are assembled on a cableway door in front of a busbar trunking fitted with a form 2 front face screen, thepartitioning (ref. 07432 ; 07440 ; 07443) must be positioned in order to allow the cutouts for cable strandinsertion.� Install the doors or front plates on which devices will be fitted.

� Install the devices on the doors or front plates.

� Prepare cable routing through the cableway screen:If the switchboard is fitted with a cableway screen, the auxiliary wires should run out of the screen in the pre-cutouts. This requires presentation of the partitioning in order to determine wire position.Protect the wiring loom using a tubular or spiral plastic duct.

Wire the auxiliary circuits:

� Wire the devices.

� Label the wiring: Auxiliary circuitsAuxiliary circuits must be clearly labelled for site connection and maintenance of the switchboard.As you have a choice of solutions, ask the customer to confirm the type of labelling he requires. Switchboardreworks are extremely fastitious and a source of errors.Labelling may be alphabetical, numerical or alphanumerical.The labels, which are generally imbricated rings, must be placed at the ends of the conductors and, if necessary,along their length.

18

12 Install the partitioningThis stage consists of installing the form 2 partitioning without insertion of connections, for both the incomingunit partitioning and the internal switchboard partitioning.

Install the incoming unit partitioningInstall the transfer busbar screensInstall the lateral partitioning

Install the form 2 lateral partitioning without insertion of connections and the double depth partitioning. Thesupports were installed in stage 8.

13 Install the cable tie-bars, bracing supports and protectiveconductors

In this stage the cable tie-bars and protective conductors are installed, enabling cable bracing, earth bar fixing andconnection of the various devices to the protective conductor.Routing of the protective conductors in the switchboard depends on both the presence and location of thehorizontal busbar and on the position of the outgoing cables.

Install the bracing supportsAdvantages of the supports (Ref: 07210-07213): No mechanical stress on device terminal pads, and attractiveswitchboard finish. A label is placed on the bracing supports for clear identification of the outgoing cables.

Install the cable tie-barsThe cable tie-bars must be installed in the cableway, if the cubicle has one. Otherwise, the cable supports areinstalled behind the outgoing units.In this case rear access to the switchboard is compulsory.

Install the protective conductors on the cable tie-barsThe protective conductors are installed on the cable tie-bars or on angle brackets (ref. 09915) fixed to theframework. The conductors should preferably be positioned near the outgoing cables.

Make the protective conductor liaison bars

Tighten to the required torque

Label the protective conductors

14 Install the cableway screensInstall the cableway screens.

15 Clean the switchboardCleaning must be thorough to ensure that no metal parts or bits are left in the switchboard.

Clean the switchboardClean the switchboard before packaging:� Use an extractor to remove dust inside the switchboard.Use of a blower could cause cut-offs and other such waste to accumulate in live areas.

19

� Remove external dust.Use a neutral solvent, if necessary, that will not damage the paintwork.� Touch up the paintwork as required.� Ensure that there is no foreign bodies in the switchboard (tools, screws and bolts) as this could interfere withoperation.

16 Finish the front faceThis stage consists of installing the front face on the framework, the labels on the front plates, and the blankingplates.

Install the labels on the front plates� Install the fixed frame or the front plate support door.� Place the front plates in front of the devices, and fit the labels.� Screw on the front plates.

Install the front face on the frameworkOn the front face of the switchboard:An identification plate must contain at least:� The panel builder’s details.� The identity of the project.Labelling the devices:Installation users need to be able to clearly identify the circuits. Labelling must be legible, durable and correctlyplaced next to the switchgear.Labels come in 3 formats and can be either printed or engraved.

Install the blanking plates on the front platesFor a front plate support door, adjust the position of the Multifix rail, align it with the modular font plate, then lockthe rail fasteners in place.

17 Fit the panels on the switchboard

Assemble the plinthsFor handling reasons (lorry height, passage through doors on site,...), we strongly advise you not to assemblethe plinths in the workshop

Fit the cubicle gaskets� Fit the cubicle gaskets if required by the cubicle IP rating.Remove all grease from surfaces before fixing the gaskets.

Fit panels on the back and sides� Fit panels on the back and sides.� Before fitting the panels, install the ventilation accessories (make cutouts and touch up the paintwork asrequired).If the frameworks are delivered coupled:� Install the juxtaposition kits.

Install the doors� Fit the door on the hinges.� Mount the handle.Screw the earth connection onto the framework.

20

Assemble the roofs� Roofs should preferably be delivered separately so that the cabinet can be handled by its lifting lugs.If the roofs are already assembled, the cabinet must be handled from the bottom only as the lifting lugs are nolonger accessible.

18 Inspect the switchboard

At the end of the assembly process, test and inspect the LV switchboard.The three tests described below are a strict minimum. The person inspecting the switchboard will be issued withappropriate, calibrated tools in proper working order. In addition to the specific switchboard documents(diagrams, drawings, front face drawing, special specifications), the inspector must consult updated documentssuch as technical documents and internal rules.

� 1st test:Conformity and operation including inspection of switchboard conformity (switchgear, wiring, marking,...) and theelectrical operation tests.

� 2nd test:Dielectric test.

� 3rd test:Checking the measures taken to protect against direct contact and electrical continuity of the protective circuits.

� Test report:A test report, stored in the contractor’s file, is issued at the end of this stage.

19 Package the switchboard

Packaging� Electrically and mechanically uncouple the cubicles.� Issue the contractor with the necessary accessories.� Provide an assembly guide for site coupling of the cubicles.� Compile a component assembly manual.� Package the switchboard.

SUIVTravellerProject n° :

Order form no.Delivery slip no.Single wire diagram referenceEarthing systemOperating voltageRated currentShort-circuit currentFront face drawing reference

21

Degree of protection

Stage Assembly phase Assembler Time spent1 Identify and sort the components

2 Assemble the frameworks

3 Install the mounting plate cross-members

4 Install the busbars

5 Install the mounting plates and switchgear

6 Check switchgear positioning

7 Install the secondary distribution blocks

8 Install the wiring routing accessories

9 Power connections

10 Install the form 3 horizontal screens

11 Wire the auxiliary circuits

12 Install the form 2 partitioning without insertion ofconnections

13 Install the cable tie-bars, bracing supports andprotective conductors

14 Install the cableway screens

15 Clean the switchboard

16 Finish the front face

17 Fit the panels on the switchboard

18 Inspect the switchboard

19 Package the switchboard

This traveller ensures project follow-up and traceability in order to accurately evaluate the assembling times offuture projects.

SOM 21 Identify and sort the components2 Assemble the frameworks

22

3 Install the mounting plate cross-members4 Install the busbars5 Install the mounting plates and switchgear6 Check switchgear positioning7 Install the secondary distribution blocks8 Install the wiring routing accessories9 Power connections10 Install the form 3 horizontal screens11 Wire the auxiliary circuits12 Install the form 2 partitioning without insertion of connections13 Install the cable tie-bars, bracing supports and protective conductors14 Install the cableway screens15 Clean the switchboard16 Finish the front face17 Fit the panels on the switchboard18 Inspect the switchboard19 Package the switchboard

Key to the icons used on the pages«General procedure of the stage».

This icon denotes: General procedure of the stage.

This arrow marks the start of the stage (first operation to be performed).

This arrow means that the operations must be performed one after the other.If your cubicle’s configuration makes one of these operations unnecessary, move to the next operation.

This arrow means that at least one of the operations must be performed according to your configuration.

This symbol marks the summary of operations to be performed, and refers you to the detailed pages giving moreinformation.Details on page 19.

Key to the icons used on the pages«Details of operations».

This icon denotes: Details of operations.

Information simplifying your task.

Warning: important information.

When the detailed operation is over, this symbol refers you to the next operation: «General procedure of thestage».