Prisma P

Assembly Guide
2012
 Preface

This guide proposes a procedure for assembling the Prisma P.

We have designed it to help you successfully complete your first projects. It ensures
that assembling and cabling staff, for whom it is intended, will benefit from the
considerable experience in this field acquired by Schneider Electric and its
customers. In short, it is an essential workshop tool.

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

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

2
Contents

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

Instructions for use...................................................................... 6
Tools................................................................................................... 7
Assembling and cabling tools..................................................................................... 7
Inspection tools.......................................................................................................... 7

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

Assembling the frameworks..................................................... 9

Assembling the frameworks....................................................................................... 9

Install the busbars.......................................................................10

Install the horizontal busbar...................................................................................... 10
Install the vertical busbar...........................................................................................11
Coupling the busbars............................................................................................... 13
Installing the PE and PEN........................................................................................ 16
Marking the busbars................................................................................................. 16
Mounting the form 2 side barrier for vertical busbar................................................. 17

Install the mounting plates......................................................18

Installing the mounting plates and switchgear.......................................................... 18
Checking switchgear position................................................................................... 19

Run and cable the power circuits..........................................20

Power cables............................................................................................................ 20
Installing the secondary distribution blocks.............................................................. 22
Installing the connection terminal blocks and the earth bars.................................... 23
Installing wiring running accessories........................................................................ 23
Fitting the protection devices.................................................................................... 24

Run and cable the low power and auxiliary circuits.......25

Installing the devices on door or front plate.............................................................. 25
Installing the wiring running accessories.................................................................. 25
Cabling the auxiliary circuits..................................................................................... 26
Closing the trunking and wiring running accessories............................................... 26

Inspect the switchboard...........................................................27

Final factory inspection............................................................................................. 27

Install the partitioning...............................................................28

Installing the form 2 barriers on the top or bottom horizontal busbar........................ 28
Installing the incoming unit partitions........................................................................ 28
Installing the barriers for the incoming unit connections........................................... 28
Installing the form 3 horizontal barriers..................................................................... 28
Installing the bar duct barriers.................................................................................. 28

Finish and fit the switchboard with panels........................29

Cleaning the switchboard......................................................................................... 29
Finishing the front panel........................................................................................... 29
Installing the front panel on the framework............................................................... 29
Roof adaptation to a Compact NS1250 or Masterpact NT1250 circuit breakers...... 30
Roof adaptation to 800 to 3200 A Masterpact NW circuit breakers.......................... 30
Roof adaptation to a Compact NS1600 or Masterpact NT1600 circuit breakers...... 31
Roof adaptation to 800 to 4000 A Masterpact NW circuit breakers.......................... 31
Fitting the switchboard panels.................................................................................. 32

Pack the switchboard................................................................33

Packing.................................................................................................................... 33

3
 Presentation of the components

Framework
1. Framework upright
2. Top cross-member
3. Bottom cross-member
4. Cable compartment upright
5. Roof

Mounting plates and switchgear

6. Mounting plate support
7. Mounting plate
8. Acti 9 mounting plate: Multifix rail
9. Masterpact incoming unit
10. Compact NSX device
11. Acti 9 switchgear

Busbars
12. Bottom support for the Linergy channelled busbar
13. Linergy busbar support
14. Linergy busbars and/or Linergy Evolution busbars
15. Insulated flexible bar prefabricated connection
16. Rigid bar prefabricated connection
17. Neutral bar
18. PE protective conductor

Distribution blocks
19. Polypact
20. Multiclip
21. Comb busbar

Wiring running
22. Trunking
23. Trunking for thin wiring

Power cables
24. Connection transfer assembly in cable compartment
25. Protective barrier
26. Tie support

Partitioning
27. Form 2 barrier

Front panel finish

28. Front plate support frame
29. Front plate

Cover panels
30. Rear panel
31. Side panel
32. Transparent door
33. Plain wicket door

4
 Presentation of the components
PD391304 NEW

33 32 28 24 6 31 2 4 5 1 7 30

27

16
25

10

15

19
22

13

20

14

21

12

29 26 11 23 3 18 17

5
 Instructions for use

This manual describes a procedure for assembling the Prisma P. It thus indicates the
order in which the cubicle components are to be assembled: the technical assembly
instructions are found in the manuals supplied in the packaging of each component.

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

B) The actual assembly process, divided up into 6 stages, is organised as

follows:

1 - Assembling the framework

2 - Installing the busbars

3 - Installing the mounting plates

4 - Running and cabling the power circuits, the low power and
auxiliary circuits

5 - Installing the partitioning

6 - Finishing the front panel and fitting the switchboard panels

Each assembly stage is symbolised by a pictogram also found in the assembly

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

For some configurations of the cubicle in question, you will not have to carry out all
the operations proposed.

C) Testing as per standard IEC 61439-2 must be carried out.

D) The last stage consists of packing the switchboard to ensure protection of

the cubicles during transport.

6
 Tools

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

Assembling and cabling tools

bb Individual tools
The tool kit belonging to the assembling and cabling staff must contain at least the
following tools:

Type of assembly Tools

DD382164

Switchboard mounting: 1 ratchet wrench

enclosure, mounting plates 1 extension piece
and panels except 1 x 10 and 13 mm wrench
for switchgear 1 wrench bit socket
1 screwdriver
1 wrench bit for screwdriver
1 x 5 mm hexagon socket bit
1 wrench bit for pozidriv no. 2 recess
1 x 8 flat screwdriver
1 portable jig-saw
Mounting the switchgear and tightening the Socket 7, 8, 10, 13, 16, 17 and 19 mm
connections (Compact NSX, etc.) Hexagon socket bit 4, 5, 6, 8 and 10
Wrench bit for pozidriv no. 1, 2 and 3 recess
Cabling the switchboard 1 flat screwdriver 3.5 mm - 4 mm- 5.5 mm
1 pozidriv no. 2 screwdriver
1 electricians knife
1 x 6 mm hexagon socket bit
1 flat nose pliers
1 stripping pliers
1 cable cutter
1 crimping tool
1 diagonal cutting pliers
DD382258

1 half round nose pliers

1 bell or tester
Ring spanner type terminal ends for torque
wrench

bb Group tools
vv 1 torque wrench with socket and ring spanner type terminal ends to tighten all
electrical connections to the required torque (max. torque 50 Nm).
vv 1 ratchet wrench to tighten all busbar connections and joints using shear nuts.
vv 1 set of shears to cut flexible bars.
vv 1 punching machine for flexible bars.
vv 1 electrical saw.
vv 1 drill.
vv 1 vacuum cleaner for switchboard cleaning.

NB: When crimping the lugs, only the pliers recommended by the lug manufacturer
must be used.
DD382260

Inspection tools
bb Individual tools
The quality inspectors basic individual tools are the same as for the assembling and
cabling staff, with in addition the few tools below:
vv 1 small hinged mirror.
vv 1 electrical lamp or portable lamp.
DD382263

bb Group tools
vv 1 control console.
vv 1 dielectrometer.
vv 1 Multimeter.
DD382261

7
 Identify and sort the components

Aim: Identify and sort components to ensure subsequent proper

DD382267

working organisation and fewer handling operations.

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 cubicle panels.

b Collect the components that will be used by the contractor, but do not unpack
them.

Tip: When you receive your components in your workshop, dont get carried away,
04696505AA01-1

dont unpack everything

General assembly manual for cubicle

0469600A01

Individual assembly manual for component

8
 Assembling the frameworks

Aim: Assemble the structure and carry out the various combinations
DD382191

if required.
A variety of framework types are available:
bb Depth: 400 or 600 mm.
bb Width: 300,400,650 or 800 mm.

Tip: For transport reasons, assemble 2 or 3 cubicles at most according to total
weight. Pre-tighten beforehand. Check alignment. Tighten to torque.

Tip: To produce disconnectable-type switchboards, you must use a 600 mm deep

Assemble side by side back to back and 650 mm wide cubicle and a 300 or 400 mm wide and 600 mm deep cable
compartment, placed to the right of the cubicle.
DD382192

NB: The cover panels are assembled once the internal components have been mounted and
cabled, thus guaranteeing 100% access to components throughout assembly and installation.

Assembling the frameworks

bb Assemble the framework(s)

Tip: The frameworks must be assembled on a flat surface, protected to ensure
the paintwork is not damaged.
When assembling the rafters, take care not to damage the gaskets located at the
DD382194

end of the upright.

bb Install the plinth unless its installation is scheduled for on site

bb Couple the frameworks

If the cubicles have to delivered separately:
vvstore the combination kits,
vvcouple temporarily using bolts.

Tip: For IP55 cubicles, do not forget to fit the gasket at the junction of the cubicles
to be coupled. Ensure you degrease the surfaces thoroughly before sticking on
DD382193

the gaskets.

NB: For an L-shaped combination, the right-angle kit will be assembled on site.

b Install the gland plate support frames

Tip: For reasons of accessibility, the frames will be mounted immediately, while the
gland plates will be mounted before the switchboard panels are fitted.

Tip: For reasons of accessibility and according to the position of the horizontal
busbars (top or bottom), we recommend that you reverse mounting of the
combination kits; Top busbars: long screws + spacers at the top of the framework
uprights, Bottom busbars: long screws + spacers at bottom.
DD382367
DD382366
DD382195

bbInstall the framework stabiliser

This device increases cubicle stability and enables it to be lifted using a pallet truck
or fork-lift.

9
 Install the busbars

Aim: This stage consists of positioning the supports and bars making
DD384557

up the busbars.
L3
L2 Tip: If cutting oil is used, the bars must be cleaned prior to assembly as oil
L1 adversely affects insulation properties.
N
If the Linergy HVOF copper bars or tracks (Linergy Evolution) have become
oxidised, you can recover the connection or joint contact using a soft micro-
abrasive cloth.

NB:
vv Busbar overall dimensions do not vary with current strength.
vv Whatever the busbar type (flat or channelled), the order of the horizontal and vertical bars is
always the same: from the front to the rear N, L1 ,L2 and L3.
vv With the rear busbar, the Neutral is to the left, then L1, L2, L3.

DD382126

Install the horizontal busbar

bb Install the horizontal busbar at the top or bottom of the cubicle
The dimensions are:
vv 3 modules at the top or bottom for flat copper bars up to 3200 A
(y 100 mm x 10 mm) or Linergy Evolution up to 2500 A.
vv 4 modules at the top and 3 modules at the bottom for copper busbars 4000 A
(120 mm x 10 mm).
vv 4 modules at the top or bottom for Linergy Evolution busbars 3200 A or 4000 A.

If a connection with a rear busbar is provided, dimensions change to 5 modules.

If the busbar is at the bottom, fit a form 2 partition to prevent the risk of falling tools.
DD384520

Tip: Joining should preferably take place in a cable duct to simplify installation.

If cubicles have to be separated for transport, provide horizontal busbar

L3
L2
L1
d joints. The joints will be assembled on site and should preferably be used at
the inter-cubicle connections to simplify replacement. Ensure a 10 mm
space between the bars to be joined, i.e. 5 mm from the edge of the cubicle.
N
Use the neutral joint barrier kit (04624) to join the Linergy Evolution on 4
poles. Linergy Evolution joints are used exclusively with the stud plates and
shear nuts supplied in the enclosed kit. The stud plate design perfectly
centres the joints on each bar ensuring compliance with the 10 mm
distance between the 2 bars to join.

bb Cutting Linergy Evolution for joining

Linergy Evolution is cut with a circular saw, starting from the side with the copper
HVOF contact track. Once it has been cut, make sure there are no shavings or burrs
on the HVOF copper contact track. If cutting oil is used, the bars must be cleaned
prior to assembly.

Tip: When cutting the bars, gloves and protective goggles must be worn to protect
injuries.

Shavings and burrs: not good

Clean contact surfaces: good

10
 Install the busbars

Install the vertical busbar

b Install the single busbar in the 150 mm busbar compartment

DD382199
DD382198
DD382197

Busbar compartment on the right or on the left Linergy channelled busbar Flat busbar up to 2800 A
up to 1600 A or (IP y 31)
Linergy Evolution up to 2500 A

11
 Install the busbars

bb Install the double busbar in the busbar compartment

DD382201
DD382200

Linergy double busbar up to 3200 A Double flat busbar up to 3200 A

3 equipotential bonding connections are required between the busbars. Consult the
manuals to determine the number of supports as a function of installation lcw.
NB: The bottom support for the lateral flat busbar is not considered to be a bar support.

bb Install the busbar at the back of the cubicle

NB: The rear busbar is installed at a depth of 400, but can be installed at a depth of 600. In the
latter case, the assembling and cabling staff must make the busbar connections themselves.
DD382283

DD382284

Linergy rear busbar up to 1600 A Rear flat busbar up to 1600 A

12
Install the busbars

Coupling the busbars

bb Connection between Linergy Evolution busbars and Linergy busbar in
bar compartment.
Tip: It is recommended to use torque nuts to secure the inter-busbar
connections. When using this type of nut, care must be taken to balance
tightening by gradually increasing the tightening of each nut until breakage
occurs.
If you use other nut types, we recommend that you smear Swiss varnish on
each nut tightened to its torque.

Horizontal busbar Vertical busbar Connection

Linergy Evolution Linergy

DD384557
or

DD384556
NB: 04603 connections allow vertical connection with the Linergy Evolution y 1600 A and joining
in the same 150 mm duct.

bb Linergy Evolution 3200 A-4000 A

Installation requires 4 high modules. Before connection the Linergy must be cut to
1625 mm (remove 50 mm).

bb Cutting Linergy
Linergy is cut with a circular saw, starting from the side with the copper HVOF
contact track. Once it has been cut, make sure there are no shavings or burrs on the
HVOF copper contact track. If cutting oil is used, the bars must be cleaned prior to
assembly.

Tip: When cutting the bars, gloves and protective goggles must be worn to protect
injuries.

13
 Install the busbars

bb Connection between Linergy Evolution busbars and Linergy Evolution

DD384554 bleu.tif

busbar in bar compartment.

Horizontal busbar Vertical busbar Connection

150 mm duct
Linergy Evolution Linergy Evolution

DD384554 bleu.tif
1600 A

Linergy Evolution Linergy Evolution

DD384559
2000 A - 2500 A

DD384575

Tip: Depending on ease of access to for on-site joining, the 2000 A or 2500 A
rating HVOF copper contact track may be positioned towards the top (access
through the roof) or towards the bottom (access from within). Vertical connections
can thus be short (horizontal Linergy Evolution track at the bottom) or long
(horizontal Linergy Evolution track at the top).

NB: Beyond 1600 A, horizontal/vertical busbar connection and joining in the same duct is no
longer possible.

Horizontal busbar Vertical busbar Connection

300 mm duct
Linergy Evolution Linergy Evolution
PD384624

3200 A-4000 A

bb Cutting length for Linergy Evolution bars for vertical installation.

Rating horizontal busbar Vertical busbar
630 to 1600 A 1675 mm
2000 to 2500 A 1675 mm
3200 to 4000 A 1625 mm

bb Cutting Linergy Evolution

Linergy Evolution is cut with a circular saw, starting from the side with the copper
HVOF contact track. Once it has been cut, make sure there are no shavings or burrs
on the HVOF copper contact track. If cutting oil is used, the bars must be cleaned
prior to assembly.
Linergy Evolution connections are exclusively used with the stud plates and shear
nuts supplied in the connection.

14
 Install the busbars

bb Connection between horizontal busbar and Linergy busbar in the bar

DD382202

compartment
Tip: It is recommended to use torque nuts to secure the inter-busbar
connections. When using this type of nut, care must be taken to balance
tightening by gradually increasing the tightening of each nut until breakage
occurs.
If you use other nut types, we recommend that you smear Swiss varnish on
each nut tightened to its torque.

NB: Connection of a 10 mm thick horizontal busbar requires no holes to be drilled, unlike the
5mm thick horizontal busbar.

Horizontal busbar Vertical busbar Connection

10 mm bar Linergy bar

DD381240
5 mm bar Linergy bar

DD381239
bb Connection between horizontal busbar and vertical flat busbar in
the busbar compartment.
DD382122

Horizontal busbar Vertical busbar Connection

10 mm bar 10 mm bar
DD381499

5 mm bar 5 mm bar
DD383844
DD384611

For this connection type, holes must be drilled on the 5 mm horizontal bars.

bb Connection between horizontal busbar (flat copper or Linergy Evolution)

and Linergy rear busbar.

This connection type must partially be carried out by the assembling and cabling staff.
For the dimensions of the bars to be made, consult the busbar drawing collection.

bb Connection between flat busbar (flat copper or Linergy Evolution) and rear
DD382287

flat busbar.

This connection type must partially be carried out by the assembling and cabling staff.
For the dimensions of the bars to be made, consult the busbar drawing collection.

15
 Install the busbars

Installing the PE and PEN

DD382288

b Install the PE
K for vertical mounting, it is normally installed in the cable compartment,
K for horizontal mounting, it is installed at the top or bottom of the switchboard
opposite the horizontal busbar.

NB: If the cubicles have to be separated for transport, produce PE joints.

DD384616

b Install the PEN

The PEN is mounted vertically, normally in the cable compartment.
It must be connected to the neutral by a removable joint allowing subsequent taking
of insulation measurements.

Marking the busbars

NB: Marking of the protective conductors (neutral, PE and PEN) is compulsory. Phase marking is
strongly recommended.
DD382205

16
 Install the busbars

Mounting the form 2 side barrier for vertical busbar

DD382207

NB: The form 2 side barrier allows insertion of flexible or rigid connections less than 12 mm thick
between 2 flaps.

DD382208

To allow insertion of the connection for a large rating device (Masterpact NW/NT
Compact NS 630b - 1600 A, etc.) to a lateral vertical busbar, and if a Polypact with
flexible connections is used (cat. no. 04405 and 04406) with form 2, a side barrier
cut-out must be installed. To identify the position of this interruption, the location of
the power devices must be anticipated on their mounting plate and the following
order complied with: install the interruption kit, then the side shield blades.

Tip: When cutting blades, gloves, protective goggles and a respirator must be worn
to avoid inhaling glass fiber.
DD382209

17
 Install the mounting plates

Installing the mounting plates and switchgear

DD382210

Aim: This stage consists of defining the position of the mounting plates in the
cubicle and installing them with their devices.

The order of assembly of the mounting plates and devices depends on the technical
features of the devices.

To define the position of a mounting plate of a functional unit, you need to know
the overall dimensions of the functional unit, i.e. the number of modules
(1 module = 50mm). This number is given in the mounting plate assembly manual
and the catalogue. The reference m0 is the reference starting point for installation of
the first mounting plate. There are 2 m0 references at the top and bottom of the
cubicle. This reference, in the form of a slot, is used to hook up a measuring tape to
measure the height to be complied with when installing a mounting plate.
Marks located every 50 mm, with a double marking every 100 mm, simplify module
counting.

Table showing assembly order:

Plates for Device fixing Assembly order
Masterpact NW, NT Fixed b Install the mounting plate
Compact NS > 630 A and b Place the device on the
INS > 630 A mounting plate
DD382211

Withdrawable b Install the mounting plate

b Install the cradle
b Plug the device into the
cradle

Compact NSX and Supplied by Polypact b Insert the Polypact,

Interpact INS/INV connections facing forward,
into the cubicle
DD382212

b Slope the Polypact

assembly, connections facing
downwards, while inserting
them between the form
2barrier slats
b Swivel round the Polypact in
the cubicle and put it in the
horizontal position
b Install the 2 mounting plate
supports, with the right-hand
support straddling the first
connection
b Position and hold the
Polypact in place above the
supports
b Secure the mounting plate
(without device) onto its
supports
b Place the Polypact on the
mounting plate
b Assemble the devices
Compact NSX and Fixed b Place the device on the
INS/INV y 630 A mounting plate
b Install the equipped
DD382213

mounting plate
Withdrawable b Place the base or cradle in
or plug-in the mounting plate
b Install the equipped
mounting plate
b Plug in the device

Modular devices Modular system b Install the rail

b Place the modular devices
DD382214

on the rail

18
 Install the mounting plates

Checking switchgear position

This operation allows operator inspection and prevents incorrect positioning of the
functional unit with respect to the front panel, once the cubicle has been fully cabled.
bb Place the front plate support frame for front plate assembly
bb Install the front plates to check device positioning
bb Also check device positioning in depth
bb Disassemble the front plate support frame after checking to simplify
cabling.
PD391304

19
 Run and cable
the power circuits

Power cables
PB105001

Cabling of power devices > 630 A uses rigid bars: bar drawings can be supplied if the
prefabricated connections are not available in the catalogue.

You need to:

b Know the position of the current transformers and partitions and check that they
can be mounted
b Tie the busbar tails onto the framework, and the cables with "1000 V" insulation
onto the device mounting plates
b Install tie supports according to fixing distances.

NB: The tightening torques for connection to the device terminals are given in the device
technical manual.
To avoid the risk of temperature rise, it is essential to comply with the size of the connections or
cables recommended in the assembly manuals or on the devices and to use the screws and
bolts delivered with the devices and connections.
The diameter 8 contact and flat washers must be mounted on hammer screws for
Linergy busbars.

b Upstream connections

Device type Connection type

> 630 A power device Connection by Canalis
DD382217
Connection by cable

DD382216

y 630 A device Prefabricated connection to Connection to the flat busbar

the Linergy busbar
DD382218

DD382219

y 250 A device Connection by Polypact to the Connection by Polypact to the

Linergy busbar flat busbar
DD380548
DD382220

NB: For connection to the flat

busbar, the panel builder must
make the connections himself.

20
Run and cable
the power circuits

Device type Connection type

> 630 A power device Connection by bars to the Connections by bars to the
Linergy busbar flat busbar

DD380649
DD382221
NB: For connection to the flat
busbar, the panel builder
must make the connections
himself.

y 630 A device Connection transfer assembly Universal power supply block

for Powerclip insulated
busbar

DD382223

DD382224
NB: The Powerclip 630 A
insulated busbar is used in
cubicles for distribution over
several device rows.

21
 Run and cable
the power circuits

Installing the secondary distribution blocks

You need to comply with connection capacities, stripping lengths, the number of
cables connected and use the appropriate tools.

d Do not use ferrules with the spring loaded terminals.

Each terminal may only take a single wire.

On the Multiclip 200 A, cable entry is via the bottom only to allow assembly of the
insulating covers and production of cable straps.

Type Connection capacity Connection principle

Polybloc Distribution
DD382268

Additional block

Distribloc Power supply

Distribution

Multiclip 200 A Power supply

DD382269

Multiclip 160 A (1/2 row) Distribution

Multiclip 80 A Power supply

Multiclip 63 A (1/2 row)

Multiclip 80 A Distribution

Tap-off blocks
insulated busbar

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

22
 Run and cable
the power circuits

Installing the connection terminal blocks and earth bars

DD381512

bb Install the supports for arrangement of the connection terminal blocks and earth
bars

NB: The connection terminal blocks and earth bars are installed:
vv either in the duct that forms a zone that can be completely separated from the devices,
vv or in the switchgear zone, at the top or bottom (or on the sides for the earth bar).

b Install the terminal blocks

DD380867
Installation at top or bottom of a cubicle on

DD382245
depth adjusted rails
DD380776

Disconnectable terminal block for auxiliaries

b Install the earth bars
Type Connection capacity Connection principle
DD382246

DD382247

DD382227
Installation on modular rail turned using
universal angle brackets
DD382248

DD382249

DD382250 convert
DD381513

35 mm2 incoming terminals Screw terminals

DD382251

for flexible or rigid cables

16 mm2 outgoing terminals

for flexible or rigid cables

Installing wiring running accessories

Installation in a lateral compartment b Install the horizontal and vertical cable straps
The straps are used to guide the wires. They are easy and quick to implement and
can be clipped directly onto the mounting plates.
DD382270

DD381631
DD381514

on mounting plate on a modular rail support

DD381622

DD381634

Installation on a device mounting plate

Cover for horizontal cable straps Cover for vertical cable straps

23
 Run and cable
the power circuits

bb Install the trunking for horizontal or vertical wiring

DD382320

The trunking is used to carry wires to the switchgear zone. Trunking is secured:
vv to some mounting plates on specially reserved locations,

vv on the trunking supports by means of clip-on, turn removable screws.

The Polypact distribution block accommodates a trunking as standard to guide the

auxiliary wiring of the NSX circuit-breakers that it supplies.

DD380866

DD382272
Trunking installed horizontally on the rear of
a modular rail

on mounting plate on rail

DD381555

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

bb Install the cable tie-bars

b For an L-shaped installation with corner kit for busbars, an additional corner
kit can be added for wiring and earth conductor running.

Fitting the protection devices

bb Prepare the various protective covers (cut-out, drilling, etc.)
bb Fit the various protective covers:
vv upstream and downstream terminal shields are compulsory for all Compact NSX
circuit-breakers and INS/INV switches with vertical or horizontal mounting,
vv cover for power supply block,
vv connection cover for cable,
vv cover for busbar,
vv tooth-caps, etc.
DD382252

DD382253

Longitudinal and lateral cable-tie supports

DD383425

NB: For connection by insulated flexible bars equipped with built-in terminal shields, there is no
point equipping Compact NSX circuit-breakers with terminal shields.

bb Fit the puffing chamber barriers on the Masterpact NT
Compact NS u 630 A circuit-breakers if bare copper connections are used.

C-shaped cable-tie supports

DD382365

24
 Run and cable the low power
and auxiliary circuits

Installing the devices on door or front plate

DD382273

d
For safety reasons, it is forbidden to mount devices on the bar duct door.
We recommend that devices be transferred to the cable duct door.
DD382274

b Install the partial doors with cut-outs or front plates with cut-outs
accommodating devices

NB: The devices can be installed on conventional plain doors by making a cut-out.

b Install the mounting plates and devices on the doors or front plates
b Install an earthing braid when the door accommodates non-class 2 devices.


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

Installing the wiring running accessories

DD382275

bb Install the trunking and the wire-guide straps

b Install the terminal blocks for auxiliary wiring
DD382254

NB: Holes are drilled in the mounting plates for rear insertion of cables.

bb Install the auxiliary disconnectable terminal blocks

b Install the 4P auxiliary bus ducts
b Install the voltage tap-offs at the device exit.

25
 Run and cable the low power
and auxiliary circuits

Cabling the auxiliary circuits

DD382276

bb Six cabling rules must be applied by the contractor:

vv Rule no. 1:
The outgoing conductor and the return conductor must always be adjacent.
vv Rule no. 2:
It is preferable to flatten all connections up against equipotential frame structures to
benefit from a HF protective effect.
vv Rule no. 3:
In the switchboard run the power circuits, control circuits and communication/
network circuits in three separate groups, ensuring compliance with a ratio of
distance between cables over radius of the largest cable that is greater than 5.
Only analog, digital and telecommunication signal pairs can be placed right up
against one another in the same bundle or laid in the same grouping cable.
vv Rule no. 4:
We recommend against using the same connector for connections of different
families (except for relay, supply and power circuits).
vv Rule no. 5:
All free conductors in cables must systematically be connected to the chassis frame
at both ends (except for analog cables).
vv Rule no. 6:
Power cables do not need to be shielded if they are filtered.

bb Mark the wires to simplify on-site connection and maintenance of cubicles,

thus avoiding laborious switchboard reworking that could cause errors.
It is important to obtain customer approval of the marking technique. The marks must
be placed at the extremities of the conductors and, if necessary, along their routes.

d

bb Separate power cables from auxiliary wires:
vv Bus cables and the other "fine wiring" cables (connected to auxiliary power
supplies for relays, contactor controls, PLC inputs/outputs, etc.) can exist side
by side, but must be placed in trunking for separation from power cables.
vv A bus line is "ELSV", thus with double or enhanced insulation with respect to

mains. Consequently a bus cable must not touch a bare power bar.

Tip: Thoroughly secure cables onto the door to avoid disconnecting the devices
when opening. We recommend you use protection devices for wiring through the
front panel or to the doors.
DD382278
DD382277

Flexible trunking Grommet

Closing the trunking and wiring running accessories

Tip: Trunking packing density must not exceed 70 %.

26
 Inspection the switchboard

Final factory inspection

DD382263

On completion of assembly, the wall-mount or floor-standing enclosure must

undergo a variety of inspections and tests. At the very least the 3 routine tests must
be carried out as per standard IEC 61439-2 mentioned below:
bb 1st test: overall inspection including examination of cabling, checking
connection tightening and, if necessary, an electrical operating test
bb 2nd test: checking insulation via a dielectric test
bb 3rd test: checking direct contact protection measures and electrical
continuity of protection circuits
bb Drafting test reports.
For more details concerning inspections, consult the switchboard assembly and
installation guide.
DD382261
DD382266

27
 Install the partitioning

Installing the form 2 barriers on the top or bottom horizontal

busbar
DD384521

NB: The barrier does not modify busbar dimensions.

Installing the incoming unit partitions

DD382279

Tip: Before assembling the partition, remove the pre cut-outs required for

cable insertion.

Installing the barriers for the incoming unit connections

Installing the form 3 horizontal barriers

DD382280

Tip: Before assembling the partition, remove the pre cut-outs required for busbar
or cable insertion.
Follow the order given in the manual.

Installing the bar duct barriers

DD382255

bb Install the front barrier

bb Install the rear barrier for 600 deep cubicles

bb In event of insertion of a PEN conductor through the front barrier, remove

the pre cut-out provided (compliance with clearances) and fit an insulating
plate (Polycarbonate T > 960C) to guarantee IP2X (consult the front barrier
assembly manual).

28
 Finish and fit the switchboard
with panels

Cleaning the switchboard

E68280

bb Remove dust from the inside using a vacuum cleaner

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

bb Dust the outside

Tip: Use a neutral dissolvent that will not damage the paint. The switchboard
panels can be cleaned using liquid soap, methylated spirits, F oil or isopropyl
alcohol.

bb Touch up paintwork if necessary

bb Check absence of foreign matter inside the switchboard (tools, screws and
bolts) that could prevent it from operating properly.

Finishing the front panel

DD383950

bb Secure the front plate support frame to the cubicle framework

bb Install the markers: fit the label holders

bb Install the blanking plates on the front plates

DD384091

OK

Mode

OK

Mode

OK

Mode

Front plate hinge kit

bb Install the front plate hinge kit (optional)

DD381208

bb Fix the adhesive drawing holder.

Drawing holder

Installing the front panel on the framework

DD382355a

bb On the front of the switchboard

A name plate should indicate at least:
vv the name and address of the panel builder,
vv the identity of the project.

bb Device marking
This enables installation users to identify clearly the type of circuits used.
Marking should be fully legible, durable and properly attached next to the device.
There are 3 label formats that can be printed or engraved.
DD381715

Adhesive labels

29
 Finish and fit the switchboard
with panels
by Canalis interface

Roof adaptation to a Compact NS1250

DD202306

or Masterpact NT1250 circuit breakers

bb Enclosure 400 mm deep, access through the front.

Position of the jointing unit

Circuit breaker Dimensions(1) (mm)
A B C
Fixed, 3P/4P(2) NS800/1250 236 325 160
NT08/12 260 325 160
Drawout, 3P/4P(2) NS800/1250 260 325 170
or 08/NT12
(1) Dimensions measured from switchboard framework.
(2) For order refer to catalogue.
DD210765

Front connection with Canalis (400 mm depth)

Reference point

Roof adaptation to 800 to 3200 A Masterpact NW

DD202304

circuit breakers
bb Enclosure 600 mm deep, access through the front.

Position of the jointing unit

Circuit breaker Dimensions(1) (mm)
A B C
Fixed, 3P/4P(2) NW08/16 185 325 264
NW20/25 185 325 289
NW32 185 325 264
Drawout, 3P/4P(2) NW08/16 185 344 164
NW20/25 185 344 214
NW32 185 344 214
(1) Dimensions measured from switchboard framework.
(2) For order refer to catalogue.
DD210767

Front connection with Canalis (600 mm depth)

Reference point

30
 Finish and fit the switchboard
with panels
by Canalis interface

Roof adaptation to a Compact NS1600

DD202307

or Masterpact NT1600 circuit breakers

bb Two enclosures combined:
vv 1 enclosure, 400 mm deep, for the circuit breaker
vv 1 enclosure, 400 mm deep, for the Canalis KT/switchboard interface.

Position of the jointing unit

Circuit breaker Dimensions(1) (mm)
A B C
Fixed, 3P/4P(2) NS800/1600 638 325 160
or NT08/16
Drawout, 3P/4P(2) NS800/1600 638 325 170
or NT08/16
(1) Dimensions measured from switchboard framework.
(2) For order refer to catalogue.
Rear connection (RC)
DD210769

Reference point

Roof adaptation to 800 to 4000 A Masterpact NW

DD202305

circuit breakers
bb Two enclosures combined:
vv 1 enclosure, 600 mm deep, for the circuit breaker
vv 1 enclosure, 400 mm deep, for the Canalis KT/switchboard interface.

Position of the jointing unit

Circuit breaker Dimensions(1) (mm)
A B C
Fixed, 3P/4P(2) NW08/16 815 325 264
NW20/25 757 325 414
NW32 774 325 414
NW40 790 325 439
Drawout, 3P/4P(2) NW08/16 815 317 414
NW20/25 815 342 414
NW32 815 317 439
Rear connection (RC) NW40 790 325 439
(1) Dimensions measured from switchboard framework.
(2) For order refer to catalogue.
DD210771

Reference point

31
 Finish and fit the switchboard
with panels

Fitting the switchboard with panels

DD382257

bb Install the gland plates

bb Fit the rear and side panels

NB: For L combinations, there is a specific assembly order: refer to the right-angle kit assembly
manual.

b Install the ventilation system, the resistors and the switchboard lighting,
if necessary
b Fit the roof

NB: For IP31 cubicles, do not forget to fit the gasket. Take care to degrease surfaces thoroughly
DD382281
before sticking on the gaskets.

bb Fit the doors or fixed frames

vv door assembly is reversible,
DD382282

Tip: For safety reasons, ensure that the door opening direction will not obstruct on
site access to an evacuation corridor or passageway. The door must open in the
direction of the evacuation.

vv it is advisable to install barrels and inserts before fitting the handle on the door and
before mounting on the framework.

bb Fit the lifting rings for lifting from the top (do not forget to fit the plugs).

32
 Pack the switchboard

Packing
E20551

bb Uncouple the cubicles electrically and mechanically if necessary

bb Provide the contractor with the necessary accessories (joints, fixing

screws, etc.)

bb Provide an installation guide for cubicle on-site coupling

bb Compile a technical file containing a set of drawings, the device operating

manuals and the cubicle assembly manuals

bb Attach the adhesive drawing holder to the back of the door with the
technical file

bb Ensure cubicle protection for transport, particularly on the surface-mount

HSI surfaces

NB: Use the stabilisers to increase packing volume and re-use cover panel protections (angle
brackets, polystyrene, etc.).

bb Pack the cubicles.

DD381208

Drawing holder

33
 ART805336 2012 - Schneider Electric - All rights reserved

Schneider Electric Industries SAS As standards, specifications and designs change from time to time, please ask for confirmation
35, rue Joseph Monier of the information given in this publication.
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DESW045EN 03-2012