Connection
Tools required to connect the switchboard
List of tools
• Torque wrench.
• Ratchet wrench.
• 10, 13, 16, 17, 19 mm sockets.
• Crimping pliers.
• Clamp pliers.
• Flat and Pozidriv type screwdrivers.
• Colored, indelible and temperature-resistant acrylic varnish.
Note: for the other operations, use the installer’s standard tools.
Connection types
• Power connection:
connection of the busbar trunking to the splicing block,
connection of cables with lugs to the bar tails,
direct connection to devices.
• Connecting the auxiliaries:
-
plug-in terminal blocks, connection terminals.
Special tools
-
• Torque wrench characteristics:
torque: 75 N.m
thin profile for certain tightening operations on busbars.
• Torque wrench (FACOM type) with the power and characteristics required for tightening under difficult access conditions (fishplates, etc.).
wrench handle, essential
extra-flat ratchet adapter, essential
ratchet for ordinary sockets, optional.
• extra-flat sockets for extra-flat ratchet + handle:
-
extra-flat 13, 16, 17 and 19 mm short sockets, extra-flat 13, 16 and 19 mm long sockets.
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Connection
Connecting by busbar trunking
General
• The Prisma SeT P Active switchboard comes equipped with a special interface that allows it to be directly connected to the Canalis KT trunking.
• The electrical connection between the Canalis KT and the Prisma SeT P Active switchboard is just as easy as splicing two busbar trunking sections.
• The Canalis KT interface is totally integrated in the Prisma SeT P Active switchboard volume. It comprises a Canalis KT junction block and interface/circuit breaker connection terminals.
Sealing kit
• To retain the original IP index, use the roof sealing kit ordered with the busbar trunking. This kit guarantees
IP 52 at the trunking passage.
• To install the kit, a cutout must be made in the roof of the Prisma SeT P Active switchboard. This cutout, which is the same size for all Canalis KT busbar trunking ratings, will be made using the template delivered with the sealing kit.
Busbar trunking connection through the top
• Remove the roof.
• Cut out a passage for the busbar trunking.
• Adjust the guides according to the Canalis KT width to be connected.
• Unscrew the junction block nuts.
• Ensure that the busbar trunking section to be connected to the switchboard is correctly supported and that it is not resting on the interface.
• Lower the section until it is in contact with the interface frame, without bearing on it.
• Tighten the shear nuts of the junction. When the head breaks, the torque of 60 N.m. has been reached.
In certain cases, it is recommended to only tighten the 2 middle nuts to 60 N.m and the 2 outer nuts to 10 N.m.
• A red plastic washer, which is ejected when the head breaks, provides visual evidence that the junction tightening operation has been carried out correctly.
• For dismantling or maintenance operations, a second head is available on the nut.
The recommended tightening torque is then 60 N.m.
• Put back the roof.
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PrismaSeT Active installation and maintenance guide
Connection
Power cable connection
General
DANGER
HAZARD OF ELECTRIC SHOCK
To ensure the protection of persons, first connect the switchboard protection cable to the earthing terminal.
Failure to follow these instructions will result in death or serious injury.
Tightening torque
Recommended tightening torque for mechanical and electrical connections with class 8.8 hardware
• Clamp the cables as close as possible to the connections so as not to create any mechanical stresses on the device terminals. When not using cable glands, also clamp the cables as close as possible to the cubicle entry point.
• The cables must never be in contact or routed between uninsulated live conductors (e.g. busbar).
• The sharp edges of the framework where cables are routed must be protected to avoid damaging the conductors.
• Respect with a minimum bend radius of 6 to 8 times the outer diameter of the cable.
• All power connections must be made with class 8.8 fasteners and spring contact washers, and tightened to the torque given in the table below.
• When connecting aluminum cables to copper terminals, use bimetal lugs or interfaces.
• Group the different types of circuit into separate cable bundles (power, control,
48 V, 24 V, direct, alternating, etc.).
Making the bundles
Number of cables per bundle Cable cross-section
(mm²)
S y 10
16 < S y 50
S u 50
8
4
Individual tying
Clamping the bundles
Type of tie
Width: 4.5 mm
Load: 22 kg
Width: 9 mm
Load: 80 kg
20
25
35
45
Maximum Icw
(kA rms/1 s)
10
15
20
Distance between ties
(mm)
200
100
50
350
200
100
70
For cables of cross-section u 50 mm², use 9 mm wide ties.
Screw diameter
M3
M4
M5
M6
M8
M10
M12
Tightening torque (N.m.)
(with nut + contact washer)
1.5
3.5
7
13
28
50
75
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Connection
Connecting the power cables
(cont.)
Connecting cables through the top
• Remove the roof.
• Drill the holes to fit the cable glands or grommets.
• Fit the cable glands or grommets. They must respect the switchboard protection index (IP).
• Put back the roof.
• Feed the cables through the glands or grommets.
• Feed the cables in the compartments provided and attach them to cable tie bars every 400 mm.
• Crimp and connect the lugs.
• When tightness does not require cable glands or when it is obtained using foam, the cables can be routed in a rectangular cutout in the roof. The framework cross-member can be removed so that it is easier to feed the cables into the cubicle.
Connecting cables through the bottom
Using a 2-piece gland plate (IP 30)
• Drilling is not necessary with this type of gland plate.
• The gland plate prevents the creation of induced current.
• The cables are protected by a polyurethane foam seal for sealing purposes.
Using a 1-piece gland plate (IP 55)
• Remove the bottom plate.
• Drill the holes to fit the cable glands or grommets
(1-piece gland plates should be cut at least 30 mm from the edge of the plates).
• Fit the cable glands or grommets. They must respect the protection indexes (IP).
• Put back the bottom plate.
• Feed the cables through the glands or grommets.
• Feed the cables in the compartments provided and attach them to cable tie bars every 400 mm.
• If cable glands are not used, it may be easier to prepare the cable heads outside the switchboard (e.g. lug crimping) and then move them into the cubicle after removing the bottom removable cross-member.
Covering a MasterPacT and ComPacT incomer
For MasterPacT MTZ2, MTZ1,
ComPacT NS1600b-3200, NS630b-1600
• Remove the part of the cover to access the device connection terminals.
• Connect the cables, respecting the insulation distances.
• Make a cutout for the cables in the cover in such a way as to preserve the required protection index.
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PrismaSeT Active installation and maintenance guide
Connection
Connecting the power cables
(cont.)
Connecting to bar tails
• Check the consistency between circuit and device identifications.
• When connections are made to bar tails comprising several bars per phase, position the lugs opposite one another and insert copper spacers.
• Respect the insulation distances between phases. Comply with standard
IEC 60439-1.
• Mark all nuts and bar tails with a spot of varnish after tightening to the recommended torque.
• Remove the cubicle upper cross-member to connect the cables to the terminals more easily.
• Tie the cables together by phase. (see
“"Power cable connection", page 43 )
Removable upper cross-member
Connecting directly to device terminals
• When connections are made directly to the device terminals, respect the tightening torque given by the device manufacturer.
• Check that the length of the screws delivered with the device is compatible with the thickness of the lugs to be connected.
• Respect the safety perimeter around the devices, defined by the manufacturer and guaranteeing their correct operation.
• If necessary, put back the phase separators and the terminal covers after making the connections.
• In the special case of connection with shielded wires, please consult us.
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Connection
Connecting the auxiliary circuits
Routing the cables
Cable straps
• Cables routed through straps must comply with the following rules:
cables routed through the straps must not be tied in bundles,
a sufficient number of straps must be used: generally 1 strap every 100 mm.
Cable ducts
• The following rules apply to cable ducts:
cable ducts must be secured at least every 600 mm,
cable ducts must not be filled to more than 70 % capacity,
cables must not be tied into bundles inside cable ducts
cable ducts must be secured using plastic screws to avoid any risk of damaging the cables,
do not route auxiliary cables directly in contact with power cables,
Connection
Connecting to terminals
• Terminals are either installed on the device mounting plate or on rails
• All conductor strands must be placed in the terminal hole.
• Tighten properly making sure the strands are not cut. It is recommended to use cable ferrules.
• It is recommended to use cable ferrules with the cables for set screw terminals.
• Some Schneider Electric switchgear and junction blocks use spring terminals. This type of connection is very reliable since it is insensitive to vibrations and thermal variations. With this type of spring terminal, it is recommended to insert only insert one wire in each terminal.
• Identify the cables using markers that are consistent with those in the switchboard to make future work easier.
Routing auxiliary wiring between cubicles
• Connect the plug-in junction terminals for auxiliary wiring.
Routing towards auxiliary door-mounted switchgear
• Route the cables through self-adhesive door ducts and/or flexible trunking to the door.
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PrismaSeT Active installation and maintenance guide
Connection
Connecting the antenna
Antenna on the roof
• Place the magnetic antenna on the roof at the most suitable position.
• Respect the bend radius if you need to wind the cable (see diagram below).
• The antenna must always be installed vertically.
Prisma
SeT
G Active
• The antenna is stored inside the roof.
• Open the gland plate to access it.
Antenna on the roof
• Feed the antenna and its cable through the opening provided.
• Make sure to respect the antenna cable bend radius.
R u 50 mm R < 50 mm
Ø > 100 mm
RISKS OF EQUIPMENT DAMAGE
• All bends in the antenna cable must have a bend radius greater than 50 mm.
• It is prohibited to wind the cable in a figure of 8.
• Remove the antenna from the roof to transport the equipment.
Failure to follow these instructions may result in equipment damage.
• Connect the cable to its connector on the top of the green strip: tightening torque 0.8 N.m.
Remote antenna
• In this case, the antenna must have already been installed: see
“"Antenna installation", page 23
• Simply connect the antenna cable extension (5 m) ref. SMT10011 on the connector at the top of the green strip: tightening torque 0,8 N.m
Note: to avoid damaging the connector, it is recommended to tighten by hand “up to contact”.
• Put back the gland plate.
• Position the magnetic antenna vertically on a metal part of the roof.
Remote antenna
• Remove the green strip to access the antenna cable connector.
• Unscrew the antenna cable.
• Route the extension along the same path as the antenna cable.
• Screw the extension instead.
• Put back the green strip and the cable gland-plate.
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Connection
Finishing
General
• Work carried out on the cubicles to allow or simplify cable routing must not affect the original protection index.
Note: if a panel has been cut to route cables for example, the edge should be repainted to avoid corrosion and fitted with a protective sleeve (U-section seal, grommet) to avoid damaging the insulation of the conductors.
Paneling
• Put back the shields and partitions protecting the connections and busbars.
• Put back the roof (check that the self-adhesive seal is present on the roof for protection index IP 31).
• Put back the gland plates.
• Put back the rear panels.
• Put back the side panels.
• Put back the door. If necessary, do not forget to connect the earth braid when devices are installed on the door.
• Touch up the paintwork as required.
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PrismaSeT Active installation and maintenance guide
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Commissioning
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PrismaSeT Active installation and maintenance guide
