Prisma Plus

Prisma PlusAssembly Guide

System G

Preface

1Assembly guide System G Version 4.0 Merlin Gerin

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 ensuresthat assembling and cabling staff, for whom it is intended, will benefit from theconsiderable experience in this field acquired by Schneider Electric and itscustomers. In short, it is an essential workshop tool.

There are several approaches for assembling Prisma Plus components. In thisguide we propose one approach which you can add to according to yourprofessional organisation and experience.

This guide does not replace the technical manuals supplied in the packing of eachcomponent, but recommends an assembly sequence for the components andprovides information to complement that given in the manuals (assembly tips andtricks, specific assembly recommendations, warnings, etc.).

Contents


Preface ........................................................................................ 1

Presentation of the components ............................................... 4

Instructions for use .................................................................... 6

ToolsAssembling and cabling tools............................................................................... 7Inspection tools....................................................................................................... 7

Identify and sort the components ............................................. 8

Assemble the rear panel of the wall-mount/floorstanding enclosuresAssembling the IP30, IP31 and IP43 wall-mount or floor-standingenclosures ............................................................................................................... 9Assembling the IP55 wall-mount enclosures..................................................... 10

Install the busbarsInstalling the Powerclip 125 to 630 A insulated busbar.................................... 11Installing the 160 to 400 A rear busbar in vertical position.............................. 11Installing the 160 to 630 A multi-stage busbar in the duct ............................... 11

Install the mounting platesInstalling the mounting plates and switchgear.................................................. 12Checking switchgear position............................................................................. 12

Run and cable the power circuitsInstalling the secondary distribution blocks ..................................................... 13Installing the connection terminal blocks and earth bars ................................ 14Installing the wiring running accessories .......................................................... 15Power cables ......................................................................................................... 15Installing the protection devices......................................................................... 18

Run and cable the low power and auxiliary circuitsInstalling the devices on door or front plate...................................................... 19Installing the wiring running accessories .......................................................... 19Cabling the auxiliary circuits ............................................................................... 19Closing the trunking and wiring running accessories...................................... 19

Install the partitionsInstalling the horizontal partition ........................................................................ 20Installing the vertical partition............................................................................. 20

Install the pack wall-mount enclosureDisassembing the enclosure ............................................................................... 21Installing the busbar............................................................................................. 21Installing the switchgear ...................................................................................... 21Cabling ................................................................................................................... 21Finish...................................................................................................................... 22

Inspect the switchboardFinal factory inspection........................................................................................ 23

Finish and fit the switchboard with panelsCleaning the switchboard .................................................................................... 24Finishing the IP30 wall-mount or floor-standing enclosure ............................. 24

Pack the switchboardPacking .................................................................................................................. 25

Presentation of the components


Wall-mount enclosure structure1. Pillar2. Rear panel3. Functional upright4. Top plate5. Bottom plate6. Gland plate7. Side panel

Mounting plates and switchgear8. Horizontal Compact NS incoming unit on mounting plate9. Multi 9 mounting plate: modular rail10. Contactors

Busbars11. Powerclip insulated busbar12. Tap-off blocks

Distribution blocks13. Multiclip14. Comb busbar

Wiring running15. Trunking16. Trunking for fine wiring

Power cables17. Incoming connection block18. Power supply block19. Earthing terminal block

Front panel finish20. Front plate support frame21. Front plate22. Barrier

Cover panels23. Transparent door24. Plain wicket door

Presentation of the components


PD39

0674

2

5

4

7

6

24

22

20

23

18

21

12

17

14

1910

16

13

15

1

9

11

8

6

3

Instructions for use


This manual describes a procedure for assembling the Prisma Plus system G. Itthus indicates the order in which the cubicle components are to be assembled: thetechnical assembly instructions are found in the manuals supplied in the packagingof each componentThe drawings often represent the wall-mount enclosures in vertical position but it isbetter to work horizontally on a table.

A) Before starting to assemble, you must first identify and sort thecomponents.

B) The actual assembly process, divided up into 7 stages, is organised asfollows:

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 assemblymanual. In most cases, the pictogram in the manual can be seen through thepackagings plastic film.

For some configurations of the cubicle in question, you will not have to carry out allthe 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 protectionof the cubicles during transport.

Tools


The recommended tool lists for this section are not complete, but represent theminimum tools required to assemble, cable and inspect the Prisma Plus systemG cubicles.

Assembling and cabling toolsb Individual toolsThe tool kit belonging to the assembling and cabling staff must contain at least thefollowing tools:

Type of assembly ToolsSwitchboard mounting: enclosure,mounting plate and panels exceptfor switchgear

1 ratchet wrench1 extension piece1 x 10 and 13 mm wrench1 wrench bit socket1 screwdriver1 wrench bit for screwdriver1 wrench bit for pozidriv no. 2 recess1 x 8 flat screwdriver1 portable jig-saw

Mounting the switchgear andtightening the connections(Compact NS, etc.)

Socket 7, 8, 10, 13, 16 and 17 mmHexagon socket bit 4, 5, 6, 8 and 10Wrench bit for pozidriv no. 1, 2 and 3 recess

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Cabling the switchboard 1 flat screwdriver 3 mm - 3.5 mm 4 mm 5.5mm1 pozidriv no. 2 screwdriver1 electricians knife1 flat nose pliers1 stripping pliers1 cable cutter1 crimping tool1 diagonal cutting pliers1 half round nose pliers1 bell or tester

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58 b Group toolsK 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 manufacturermust be used.

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60 Inspection toolsb Individual toolsThe quality inspectors basic individual tools are the same as for the assemblingand cabling staff, with in addition the few tools below:K 1 small hinged mirror.K 1 electrical lamp or portable lamp.

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b Group toolsK 1 control console.K 1 dielectrometer.K 1 Multimeter.

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Identify and sort the components


Aim: Identify and sort components to ensure subsequent properworking organisation and fewer handling operations.

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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/floor-standing enclosure panels

b Collect the components that will be used by the contractor, but do notunpack them.

Tip: When you receive your components in your workshop, dont get carriedaway, dont unpack everything

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91

04696191 AA 00

Prisma Plus08302 0830608303 0830708304 0830908305

VISSERIE

A DETERMIN

ERx2x4x4

x4

IP55

Assemble the rear panel of thewall-mount/floor-standingenclosures


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90 Aim: Assemble the rear panels and carry out the variouscombinations if required.

Tip: The wall-mount or floor-standing enclosure must be assembled horizontallyon a table that is protected to ensure the paintwork is not damaged.

NB: The cover panels are assembled once the internal components have beenmounted and cabled, thus guaranteeing 100% access to components throughoutassembly and installation.

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92 Assembling the IP30, IP31 and IP43 wall-mount or floor-standing enclosuresb 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 preventdeformation

b Store the rest of the packing

Tip: The mounting hardware must be carefully associated with each wall-mount orfloor-standing enclosure.During storage, take measures to prevent damaging component paintwork.

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93 b Mount the pillars on the rear panel and the gussets for the floor-standingenclosures

b Couple the ducts, wall-mount or floor-standing enclosure extensionsThe ducts, wall-mount or floor-standing enclosure extensions are mounted in asimilar way to the basic wall-mount and floor-standing enclosure.Couple the pillars located at the junction of the wall-mount or floor-standingenclosures using the combination kits.

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94 b Mount the set of cross-members to rigidify the wall-mount or floor-standing enclosure combinations.

NB: Mounting of the set of cross-members is recommended for a wall-mountenclosure / duct combination, but becomes compulsory for a combination of 2 wall-mount or floor-standing enclosures.

Tip: Do not handle the rear panel of the wall-mount or floor-standing enclosureusing the pillars.Take care to ensure the enclosure rear panel remains level during cablingoperations.

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Assemble the rear panel of thewall-mount/floor-standingenclosures


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97 Assembling the IP 55 wall-mount enclosuresb 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-mountenclosure.During storage, take measures to prevent damaging component paintwork.

x4

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b Mount the pillars on the rear panel

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b Couple the ducts, additional wall-mount or floor-standing enclosuresThe combination kit must be used to couple wall-mount enclosures.

When coupling the enclosures, ensure that the gaskets are positioned properly.

Tip: Do not handle the rear panel of the wall-mount or floor-standing enclosureusing the pillars.

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Install the busbars


Aim: This stage consists of positioning the supports and barsmaking up the busbars.

Tip: If cutting oil is used, the busbars must be cleaned prior to assembly as oiladversely 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.

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Installing the Powerclip 125 to 630 A insulated busbarNB: The busbars are mounted before the mounting plates, except for plates cat.no. 03032, 03073 and 03074 that must be mounted before the Powerclip insulatedbusbar (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 mountedbefore the busbar

b Secure the supports and clip the Powerclip insulated busbar into thenotches

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 itreaches the top level of the incoming device mounting plate.If busbar length needs to be adjusted, cutting must be extremely accurate and onno account exceed the cutting line.

When handling the Powerclip busbar, take care not to break the end of thepartitions. For safety reasons (creepage distance, insulation, etc.), do notinstall a Powerclip busbar with a broken partition.

b Store the covers of the Powerclip insulated busbar. They will be installedonce the wall-mount or floor-standing enclosure has been cabled.

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N L1L2 L3

Installing the 160 to 400 A rear busbars in vertical positionb Fit the busbar with its supports but do not screw them on as they may be

transferred later when laying the power cables.

b Mark the bars (N L1 L2 L3).

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N

Installing the 160 to 630 A multi-stage busbars in the ductb Fit the multi-stage busbar with its supports

b Mark the bars (N L1 L2 L3).

!

Install the mounting plates


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Aim: This stage consists of defining the position of the mountingplates in the wall-mounted or floor-standing enclosure and installingthem with their devices.The order of assembly of the mounting plates and devices depends on thetechnical features of the devices.

NB: To define the position of a mounting plate of a functional unit, you need toknow 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 manualand the catalogue. The reference m0 is the reference starting point for installationof the first mounting plate. There is 1 reference m0 at each corner, materialised bya mark and a slot, used to hook up a measuring tape to measure the height to becomplied with when installing a mounting plate.

Installing the mounting plates and switchgearb Mount the devices on their mounting plate

Device Fixing Assembly orderFixed b Place the device on the mounting

plateb Install the equipped mounting

plate

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Compact NS and INSy 630 A

Withdrawableor plug-in

b Place the plinth or rack on themounting plate

b Install the equipped mountingplate

b Plug in the device

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X

H

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Modular devices

Modularsystem

b Install the railb 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.

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Checking switchgear positionThis operation allows operator inspection and prevents incorrect positioning of thefunctional unit with respect to the front panel, once the wall-mount or floor-standingenclosure 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.

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b Remove the front panel without taking the front plates apart, as well asthe sides for the IP 30 wall-mount (or floor-standing) enclosure and ductcombination.

Run and cable the power circuits


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89 Installing the secondary distribution blocksYou need to comply with connection capacities, stripping lengths, the number ofcables connected and use the appropriate tools.Do not use ferrules with the spring loaded terminals. Each terminal may only take asingle wire.On the Multiclip 200 A, cable entry is via the bottom only to allow assembly of theinsulating covers and production of cable straps.

Type Connection capacity Connectionprinciple

Polybloc 4 - 10 mm2

6 - 16 mm2

6 mm2

10 mm2

16 mm2

12

12

12

16

4 - 10 mm2

4 mm2

16

16

O

_

_

6 - 16 mm2

5,5 mm

Additional block 16 mm225 mm235 mm2

12

pozidriv n2

Distribloc

8 4 16 mm2

6,5

5 8

2,5 6 mm2

1,5 4 mm2

4 10 mm2

10

12

12

12

Power supply

pozidriv n2

Distribution

5,5 mm

Multiclip 200 A Power supply

n6

10 mm2

12

Distribution

4 mm

Multiclip 80 A Power supply

pozidriv n2

104 mm2

126 mm2

Distribution

3,5 mm

Tap-off blocksinsulated busbar 4 mm2

6 mm2

10

12

10 mm2 12

4 mm

NB: The downstream device connecting cables are delivered with the Multiclip andDistribloc.



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10 Installing the connection terminal blocks and earth barsb Install the supports for arrangement of the connection terminal blocks

and earth barsNB: 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

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b Install the earth bars

Type Connection capacity Connection principle

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11

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46

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474 mm2

6 mm2

12

12

10 mm2 12

16 mm2 12

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5,5 mm

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48

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4 mm2

10

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503 mm

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51 35 mm2 incoming terminalsfor flexible or rigid cables

16 mm2 outgoing terminalsfor flexible or rigid cables

Screw terminals



Installing wiring running accessoriesb Install the horizontal and vertical cable strapsThe straps are used to guide the wires. They are easy and quick to implement andcan be clipped directly onto the mounting plates.

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b Install the trunking for horizontal or vertical wiringThe 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, turn removable screws.

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NB: Trunking is assembled onto its support simply by clipping on from the front.

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12 Power cablesYou 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 thedevice technical manual.To avoid the risk of temperature rise, it is essential to comply with the size of theconnections or cables recommended in the assembly manuals or on the devices.

b Install the upstream connections

Device type Connection in switchgearzone

Connection in duct

u 1600 A powerdevice

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Incoming connection block

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Connection transferassembly

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Connection by cable

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Connection by cable



Device type Connection in switchgearzone

Connection in duct

Modular device

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Connection from a Powerclipbusbar

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Connection from a rearbusbar

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Connection from a busbar

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b Install the downstream connections

Device type Connection in wall-mount/floor-standing enclosure

Connection in duct

u 160 A powerdevice

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Power supply block to thePowerclip busbar

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Connection by flexible barsto the busbar in the duct

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Universal power supply blockto the Powerclip busbar

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Connection by cable toPolybloc

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Connection by cable toadditional block

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Modular device

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Connection to the terminalblocks

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Fitting the protection devicesb 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.

l

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Route and cable the low powerand auxiliary circuits


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31 Install the devices on door or front plateb Install the partial doors with cut-outs or front plates with cut-outs

accommodating devicesNB: 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 2devices.

Tip: If there is not enough space between the door and the front plates, use thevisor.

200

310

500400

V

200

310

500400

V

200

310

500400

V

200

310

5004 00

V

Installing the wiring running accessoriesb Install the trunking for doors and the grommets

Tips: We recommend that you use protection devices for wiring through uprightsor to doors:

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Flexible trunking

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Grommet

Cabling the auxiliary circuits

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76 b Mark the wires to simplify on-site connection and maintenance of wall-mounted and floor-standing enclosures, thus avoiding laboriousswitchboard reworking that could cause errors.

It is important to obtain customer approval of the marking technique. The marksmust be placed at the extremities of the conductors and, if necessary, along theirroutes.

Tip: Thoroughly secure cables onto the door to avoid disconnecting the deviceswhen opening. We recommend you use protection devices for wiring through thefront panel or to the doors.

Closing the trunking and wiring running accessories

Tip: Trunking packing density must not exceed 70 %.

Install the partitions


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Installing the horizontal partitionBefore mounting the partition, remove the pre cut-outs required to insert the cablesand wires through the busbar.

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Installing the vertical partitionBefore mounting the partition, pierce or cut out the pre cut-outs required to insertthe cables and wires.

Assemble the pack enclosure


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32 Disassembling the enclosureThe enclosure of the pack enclosure comes equipped with blanking plates for thefront plates.b To ensure total access to components during the enclosure assembly and

installation process, we recommend that you remove the front panel, thesides and the top and bottom plates

b Store the parts removed with their associated mounting hardware and thefront plate blanking plates.

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Installing the busbarInstall the Powerclip 125 A or 160 A busbar.

NB: With the Powerclip 160 A busbar, Multiclip distribution blocks cannot beinstalled.

Installing the switchgearDevice Illustration Comments

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34 NSA 125/160 To install an NSA, an enclosuremodular rail must be replacedby an adjustable modular rail(rail recommended in thecatalogue).

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35 INS 40/160

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06 Modular device

Cablingb Installing the distribution blocksDistributionblock

Illustration Comments

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31 Distribloc 125 Aet 160 A

Refer to the table on page 13 forthe connection principle of thesedistribution blocks.

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38 Multiclip 80 A Position the Distribloc 160 sothat its power supply is at the topof the enclosure to save space

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36 Multiclip 63 A

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42 Tap-off blocks

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Assemble the pack enclosure


PD39

0551 b Installing the connection terminals and the earth terminal blocks

K Connection terminalsFor some terminal block types, it may be necessary to replace one of the packenclosure modular rails by an adjustable modular rail.K Earth terminal blocksThere are 2 earth bar types (the same as those for the IP30 wall-mount and floor-standing enclosures).

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b Installing the horizontal cable straps and trunking (30x60)

PD39

0550 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 theconnection terminals.

Finishingb Clean the switchboard : the procedure is the same as for the IP30 wall-

mount 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.

Inspect the switchboard


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Final factory inspectionOn completion of assembly, the wall-mount or floor-standing enclosure mustundergo a variety of inspections and tests. At the very least the 3 routine testsmust 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 electricalcontinuity of protection circuits

b Drafting test reportsFor more details concerning inspections, consult the switchboard assembly andinstallation guide.

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Finish and fit the switchboardwith panels


Cleaning the switchboardb Remove dust from the inside using a vacuum cleaner

E682

80

Tip: Do not use blow cleaning as this may cause shavings and detritus toaccumulate in a live area.

b Dust the outside

Tip: Use a neutral dissolvent that will not damage the paint.

b Touch up paintwork if necessaryb Check absence of foreign matter inside the switchboard (tools, screws

and bolts) that could prevent it from operating properly..

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38 Finishing the IP30 wall-mount or floor-standing enclosureb Fit the sides, the top plates (and bottom plates for the wall-mount

enclosure) the corner parts and the plinths (only for the floor-standingenclosures)

b Install the markers and fit the label holders

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.

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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.

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NB: Door mounting is reversible.It is advisable to install barrels and inserts before fitting the handle on the door andbefore 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 standingenclosures and extension ducts: Maximum acceptable surface evenness defectwithout affecting installation of panelling is 6 mm.

Pack the switchboard


Packingb 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 thetechnical 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 panelprotections (angle brackets, polystyrene, etc.).b Pack the wall-mount or floor-standing enclosure.

Schneider Electric Industries SAS89 boulevard Franklin RooseveltF-92500 Rueil Malmaison (France)tel : +33 (0)1 41 29 85 00http://www.schneider-electric.com

As standards and equipment change from time to time, always ask for confirmation of the information given in thisdocument.

This document has been printed onecological paper.

Published by: Schneider ElectricProduced by: HeadLines

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