Assembly Instructions Manual 06_10_2007.pdf

DEAR PANEL ASSEMBLER

Please use these instructions as a guide when assembling a Techno Module

panel. This will enable you to build a type tested panel.

It is important to follow the assembly sequence page by page in order to fit the

various components. This is because some components need to be fitted

before the other items can be installed.

For more ideas, please visit our picture gallery on our web page

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ISSUED BY: F. P DATE: 01.10.2007 APPROVED BY: A. K DATE: 01.10.2007 REPLACES: 01.04.2005 01

- Take one Plinth Corner and assemble it to thePlinth Profile used for the depth.

- Fix one more Plinth Corner to the other end- Make sure that the blanking plugs of the Plinth

Corners, which are used to lift the panel, are posi-tioned at the front and back.

- 2 sets of completed depth BaseProfiles.

- Connect the two depth Base Profiles with the SideProfiles and tighten to the torque specified.

- It is easy to assemble a complete plinth by followingthe assembly sequence.

- Completed plinth assembly.

- If the plinth needs to be rein-forced, use the StrengtheningBracket with depth BaseProfile.

- The Strengthening Bracketprofile fixing position can bechanged according to thepanel design

- Completed plinth assembly with twosets of strengthening profiles

ISSUED BY: F. P DATE: 01.10.2007 APPROVED BY: A. K DATE: 01.10.2007 REPLACES: 01.04.200502

- Place all the Corners on the assembly table withthe outer 8mm thread facing the tabletop.

- Put the corner bars for the top and bottom frameson the assembly table and turn them with the flatsurface of the cross anchor points facing down-wards.

- Fix the Corners to panel depth Corner Bars

- Make sure that the surfaces described in fig.7are correct after assembling.

- Fix depth Corner Bar assembly to thepanel length Corner Bars.

- This is how the top and bottom frames must look.


- Take one bottom frame and place it on the tableas shown.

- Place the plinth assembly on top of the CornerBar frame and complete the assembly.

- Tighten with the right torque.

Turn the base frame around on the table and fixthe height Corner Bars. Turn the bars so that theflat surface of the Cross Bar anchors pointtowards the adjacent or side panels

- Now, place the assembly on the floor and fix theremaining frame to the top of the structure.

- This is how the correctly assembled TechnoModule structure should look.


- Corner Bars and Cross Bars are provided witha modular indicator at every 200 mm intervalas shown.

- Use the indicators as center points when divid-ing the outside surfaces of the enclosure.

The Cross Bars can be used inside the panel in all directions.


- Fix a few hinges, cam receivers and fixing bracketson the outer framework to get an idea of their posi-tions.

- This is needed to ensure that you do not use theseholes for Busbar Holders and other internal items.

- All the M6 bolts in the system must be tightened to 10 Nm.


These busbar holders are mainly used for small distributionboards and power supply distribution for small fully withdraw-able units.

Connect the cables directly on to the busbars with the tribu-lar screws shown in the catalogue.

Do not use any other type of screws or cut threads.

The maximum distance between holders should be 300mm

The holders can be bolted directly onto the crossbars, between crossbarsor directly on to cable holders.

With PC covers from the top to thebottom of the enclosure you canachieve Form 2 segregation.

Clip away for cable connection.

Torque 9NmBolt quality 8.8

ISSUED BY: F. P DATE: 01.10.2007 APPROVED BY: A. K DATE: 01.10.2007 REPLACES: 01.04.2005 06:1

This picture shows the differentoptions of fixing incoming andout going cables.


The UBH holders can be installed in all 3 direc-tions at 25 mm intervals. The maximum distance between two holders is400 mm. These holders are designed to allow for aslight movement of busbars. All the M6 boltsused must be tightened with 10 Nm

Bolt quality 8.8


The Universal Busbar Holder can beadjusted to hold many different sizes ofbusbars.

2×10×10mm Copper

2×10×15mm Copper

To support 2×10×20mm to 2×10×80copper, the busbar support marked bmust b moved to the correct position. (intervals of 10mm)

To support busbars in the horizontalposition, a support rail must be used asshown.


These holders require bolts of the cor-rect length to clamp and tighten the bus-bars.


Ex : Main busbar - 2×10×80mmDropper busbar - 2×10×20mm

Torque 47NmBolt quality 8.8


These holders are availablewith Alu-zink frames for bus-bars up to 3200 Amps, and instainless steel frames forbusbars 3200-5000 Amps.

Due to the eddy currents,avoid mild steel parts within80mm distance of busbars(above 3200 Amps)

Bolt quality 8.8

1. Place the two rails in the approximate center of the panel (consider the

connection from the ACB) and place the bottom plate.

2. With the bottom plate in the right position the stack the busbars.

3. Bolt the top plate and retighten all the bolts with 10Nm.


he rear module “200mm” of the panelis always used for main busbars anddropper busbars.With the main busbars fitted towardsthe rear of the panel and the electricalinserts in the front, there is limitedroom for the droppers.The table below indicates the maxi-mum dropper size that can beinstalled.


When assembling Busbar systemsalways use bolt and nut of minimum8.8 quality and a torque of 49Nm.

Clean the surfaces before joiningand do not use any type of greaseor contact agent.

The connection between the main busbars and the drop-pers are made with “Horizontal To Vertical Connectors”.

They are available in different sizes according to the num-ber of main busbars used (2-3-4) and the current rating.Please refer to the table below.

Horizontal to vertical connector

ORDER NO X NO OF MAINBARS

AMPS DROPPERS

20910 30 2 0-120020900 50 2 0-200020920 50 3 0-200020930 50 4 0-2000


Larger panels are often made in separatesections for ease of transportation. Alwaysmake the main busbar joint at the rear of acable section. When the panels are pushedtogether the busbars should almost toucheach other. With the clamping bracket shownhere you can join the busbars from the frontof the panel.

Please note the copper plate positionedbetween the bars. Tighten with a torque of100Nm.

Other types of joints are available. Pleaserefer to the Constructors Manual page 2:09


CLEARANCE DATA FOR BUSBAR SYSTEMS (TOP VIEWS)



These plates are the best way of installingequipment in Techno Module.

They are quick and easy to install and provideinstant Form 2 segregation.

Start by placing the UBH holdersbetween 2 cross bars from top to bottom. Make sure to note the modular indicatorpoint.

It is important to fix the mounting platecorrectly in relation to the modularindicator.


Follow thisassemblysequence

1. Universal busbar holder2. Form 2 Separation plate3. Mounting studs4. Earth clip5. Units


Follow thisassemblysequence

1. Universal busbar holder2. Form 2 Separation plate3. Mounting studs4. Earth clip5. Units


Compartments are provided with glandplates as shown to ensure proper cableconnections.

Use these separation plates toachieve Form 3+4 segrega-tion. These separation platesfit both fixed type mountingplates and removable units.


The insert can be mountedfrom top to bottom.


The steel DIN-rail insert is availablefor preset heights only and cannotbe mounted continuously from thetop to the bottom.

They can also be wired on the work-bench before installation.


These inserts are suitable if you onlyneed a few in a panel. They can beturned in 2 directions. With the helpof the PC plates from page 6 Form 3and 4 segregation can be achieved.

These units can comes in withNFTC/CNFTC for Form4 mountingplates adjustable posibilities.


Mounting plates can be placed anywhere inany direction. They can at the same time beused as Form 2 separation plates. Whenplaced horizontally, they can serve as traysfor batteries, transformers and capacitors.

Mounting plates should not be fitted flushinside the rear frame, as they will block thespace used for fixtures when mounting rearcovers.

Combine separation plates with mounting platesfor large size compartments. (see page 20)


Separation plates are used for internal parti-tioning.

They can be assembled horizontally, verti-cally or longitudinally in the Techno Modulestructure.

The flaps of the separation plates are straight butcan bent once if it suits the construction.

The oval holes will allow the builder to offset theplates by 5 mm in relation to the framework toincrease the IP rating


These come as flat sheets andare easily folded and riveted toform compartments. They areinserted from the rear andshould be put into place beforemounting busbar holders. Themounting plates can be removedfrom the front for drilling andmounting of equipment.


These compartments also come as flat sheets andare easily folded and riveted to form compart-ments. They are inserted from the rear and shouldbe put into place before mounting busbar holders.The back plates are detachable. The mountingplates can be removed from the front for drillingand mounting of equipment.

To achieve Form 4a, use cable boxes (page : 24)


Bolt cable boxes directly to the compart-ments. Ensure to install gland plates.Keep in mind the space required for ter-minating cables when designing thecable compartment. These cablesshould not bend more than 7 × thediameter of the cable.

Install cable holders to bring law andorder in the cable compartment.


This cable box design facilitates the mounting ofthe din-rail or fiber holders.

These holders can be fixed either horizontally orvertically in the rear of the cable box. Differentgland available on request


Many types of glands are available to construct cable-entry, airflowand release of arc pressure. Please see the illustrations on this pageas well as page : 26.



Press in the cable entry frame to the structure andtighten it using the M6 allen bolts.

Insert cable entry plates one by one. Note that theplates can be fixed horizontally or longitudinallyand that there are several types of plates tochoose from.


The units are delivered fully assembled asshown in this picture Please follow the assembly sequence startingwith 1.

1. Mount the back conduit holder profileand side PC holder profile as shown inthe pic:1 and fix the conduit betweenthe two rails.

2. Knockout the slot on the outer casingon the side that faces the cablechamber.

FRONT VIEW

BACK VIEW

The power and control plugs cancarry maximum 42 amps. Please notethe different length of the earth pin -auxiliary and power plugs.

3. Insert the outer casing and fix it withscrews.


5. Insert the pre-wired control plug assembly inthrough the side slot and screw in. Break theflaps of the PC plates as required in order to takethe cables out.

4. Slide the outer casing in and tighten thescrew.

Run the power cable from the back to thecable chamber through the conduit.

Fix the cable box.

6. Bend the PC retaining plate along the slottededge as shown. Make sure to bend it in the cor-rect direction.

7. Break the flaps of the PC plates on the lid asrequired and fix the lid.


The units are delivered fully assembled asshown in this picture.Please follow the assembly sequence startingwith 1.

1. Mount the back conduit holder profileand side PC holder profile as shown inpic:1 and the conduit between the tworails.


FRONT VIEW

BACK VIEW

Power plugs rated up to 80 ampsare available.




4. Run the power cable from back to the cablechamber through the conduit.

Insert the outer casing and fix it with screws.

Fix the cable box.


7. Break the flaps of the PC plates on the lid asrequired and fix the lid.


The units are delivered fully assem-bled as shown in this picture Please follow the assemblysequence starting with 1.

1. Mount the back conduit holder profileand side PC holder profile togetherwith the outgoing copper as shown inpic:1



Mount the 2 busbar holders asshown.

FRONT VIEW

BACK VIEW



4. Mount the incoming and outgoing copper usingthe set of busbar holders provided as shown.(torque - 10 Nm)Connect the outgoing copper bars to the outgo-ing copper links with the M10 hexagon bolts pro-vided. (torque - 49 Nm)


8. Break the flaps of the PC plates on the lid asrequired for outgoing cables and fix the lid.

5. Mount the cable box with 04 screws




Doors are supplied with IEC doublewing locks in polyamide.

Other types of locks are availableon request

The doors can be fittedleft or right as required.All doors are suppliedwith oil and chemicalresistant gasket. Themaximum door opening is120º

1 Fix the top hinge tothe cross bar asshown.

2 Hang the door on thetop hinge.

3. Insert bottom hinge pininto the hinge bush inthe door and fix thehinge to the cross bar.


All covers are suppliedwith oil and chemicalresistant gasket.

1. Mount the cover bracketsto the framework at correctpositions in line with theholes in the cover.

2. Ensure that the acces-sories of the cover are inorder and fix as shown. Fixthe cover.

International DistributorsEUROPE MIDDLE EAST - Contd. ASIA - Contd.Elsteel UK - England Neka Novin Co., - Iran Elsteel Ltd. - ChinaTel: ++44 197 885 5909Fax: ++44 197 885 5824Mail: [email protected]

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Elsteel Ltd. - Poland N. N. Control Panels Ltd. - Cyprus Elsteel Ltd. - IndiaTel: ++48 77 465 4666Fax: ++48 77 465 4674Mail: [email protected]



Elsteel Ltd. - Ireland Al Bonian International - Lebanon Elsteel Techno - Singapore & MalaysiaTel: ++44 289 077 4041Fax: ++44 289 078 3197Mail: [email protected]



Elsteel Iberica S. A. - Spain & Portugal Electronic & Electrical Industries - Saudi Arabia Flux Engineering - MaldivesTel: ++34 95 567 5128Fax: ++34 95 567 5987Mail: [email protected]

Tel: ++966 1 294 1458Fax: ++966 1 265 2443Mail: www.abunayyangroup.com


EFA Elektro AS - Norway Ahamed Ramadhan Jumar Est - U.A.E. Upright Electrical Engineering Services - Hong KongTel: ++47 6 681 2400Fax: ++47 6 680 0478Mail: [email protected]



RS Components Ltd. - England CIMAC Automation - U.A.E. East Link Engineering - Sri LankaTel: ++44 1536 20 1234Fax: ++44 1536 20 1501Mail: www.rsweb.com



BMC Manufacturing - Ireland Prisma Electric Inductries LLC - U.A.E. KIK Engineering Company - Chennai, IndiaTel: ++353 1 835 1744Fax: ++353 1 835 2359Mail: [email protected]



TMS GmbH - Germany Malisco Switchgear Industry - U.A.E. Fudo Automation Systems - Hydrabad,indiaTel: ++49 4554 705 6500Fax: ++49 4554 705 6503Mail: [email protected]



Kulik Telecom B. V. - Holland Deutsche Babcock Energie - U.A.E. Control Infotech - IndiaTel: ++31 182 61 8777Fax: ++31 182 61 6064Mail: [email protected]



IML International Ltd - Malta Masseera Electrical - U.A.E. Syspro Automation - IndiaTel: ++356 2 141 5642Fax: ++356 2 143 0384Mail: [email protected]



Rafmiolun Ehf - Iceland Arabian Gulf Switchgear Ltd. - U.A.E. Proficon Electronics - Bombay, Pune, IndiaTel: ++354 540 3509Fax: ++354 540 3501Mail: [email protected]



Vav Union Kft - Hungary Jawad Electric Switchgear Mfg. - Jordan Maxwell Electrical Asia - Hong KongTel: ++36 1 310 5150Fax: ++36 1 310 5163Mail: [email protected]



Culic Electro Centar - Croatia Power & Control Fzco - Dubai Hitech JSC Company - VietnamTel: ++38 5 2120 4333Fax: ++38 5 2120 4343Mail: [email protected]



Coelco Trade SRL - Romania Schneider Electric - Israel MIAC Automation- ThailandTel: ++40 21 411 9621Fax: ++40 21 411 9781Mail: [email protected]



AUSTRALASIA AFRICAIPD Ind. Products - Australia & New Zealand Bitech W.L.L - Baharain Elsteel Ltd. - South AfricaTel: ++61 2 9645 0777Fax: ++61 2 9645 2365Mail: [email protected]



MIDDLE EASTElsteel Ltd. - Egypt Powercon Switchgear Factory - Dubai M & E Commercial Industries - MauritiusTel: ++20 2 260 0658Fax: ++20 2 261 4337Mail: [email protected]



National Electric & Co. LLC - Omaniya Unicorn Ltd. - Qatar Specialised Power Systems Ltd. - KenyaTel: ++968 2 445 4951Fax: ++968 2 445 3721Mail: [email protected]



ASIA CISVoltamp Manufacturing - Oman Elsteel Ltd. - Sri Lanka JSC Electronmash - RussiaTel: ++968 2 444 9140Fax: ++968 2 444 6584Mail: [email protected]



Sharikat Fanniya - OmaniyaTel: ++968 2 481 5970Fax: ++968 2 481 0706Mail: [email protected]

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