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Introduction 1 Planning usage 2 SIVACON 8PS Installation 3 BD2 busbar trunking system Installation with BD2 Commissioning 4 Service and maintenance 5 Weights 6 Test reports 7 Installation Manual 03/2008 A5E02126899-01 Safety Guidelines This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are graded according to the degree of danger. DANGER indicates that death or severe personal injury will result if proper precautions are not taken. WARNING indicates that death or severe personal injury may result if proper precautions are not taken. CAUTION with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken. CAUTION without a safety alert symbol, indicates that property damage can result if proper precautions are not taken. NOTICE indicates that an unintended result or situation can occur if the corresponding information is not taken into account. If more than one degree of danger is present, the warning notice representing the highest degree of danger will be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to property damage. Qualified Personnel The device/system may only be set up and used in conjunction with this documentation. Commissioning and operation of a device/system may only be performed by qualified personnel. Within the context of the safety notes in this documentation qualified persons are defined as persons who are authorized to commission, ground and label devices, systems and circuits in accordance with established safety practices and standards. Prescribed Usage Note the following: WARNING This device may only be used for the applications described in the catalogue or the technical description and only in connection with devices or components from other manufacturers which have been approved or recommended by Siemens. Correct, reliable operation of the product requires proper transport, storage, positioning and assembly as well as careful operation and maintenance. Trademarks All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owner. Disclaimer of Liability We have reviewed the contents of this publication to ensure consistency with the hardware and software described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the information in this publication is reviewed regularly and any necessary corrections are included in subsequent editions. Siemens AG Automation and Drives Postfach 48 48 90327 NÜRNBERG GERMANY Ordernumber: A5E02126899-01 Ⓟ 04/2008 Copyright © Siemens AG 2008. Technical data subject to change Table of contents 1 Introduction................................................................................................................................................ 5 2 Planning usage.......................................................................................................................................... 7 3 4 2.1 Scope of delivery ...........................................................................................................................7 2.2 Receiving goods ............................................................................................................................7 2.3 Safe handling .................................................................................................................................7 2.4 Storage...........................................................................................................................................8 2.5 Packaging ......................................................................................................................................9 2.6 Handling .........................................................................................................................................9 Installation ............................................................................................................................................... 11 3.1 Overview ......................................................................................................................................11 3.2 Installing a busbar run..................................................................................................................11 3.3 Installation recommendations ......................................................................................................13 3.4 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 Attaching fixing material...............................................................................................................14 Typical procedure ........................................................................................................................14 Overview ......................................................................................................................................14 Bracket for horizontal installations ...............................................................................................15 Spring brackets for vertical installation on walls ..........................................................................17 Floor fixing for spring brackets.....................................................................................................19 3.5 3.5.1 3.5.2 3.5.3 Connecting units ..........................................................................................................................20 Connecting units ..........................................................................................................................20 Mounting the plug-in terminal.......................................................................................................21 Mounting the single-bolt terminal .................................................................................................22 3.6 Expansion unit..............................................................................................................................24 3.7 3.7.1 3.7.2 Flanged end .................................................................................................................................25 Flanged end .................................................................................................................................25 Installation ....................................................................................................................................25 3.8 Cable feeder units........................................................................................................................26 3.9 3.9.1 3.9.2 Fire barrier....................................................................................................................................27 Fire barrier regulations.................................................................................................................27 Installing a fire barrier ..................................................................................................................27 3.10 3.10.1 3.10.2 Tap-off unit ...................................................................................................................................28 Tap-off units from 10 A to 530 A ..................................................................................................28 Lateral mounting of tap-off units BD2-AK04 (05, 06) in runs for horizontal installation...............29 Commissioning ........................................................................................................................................ 31 4.1 Steps to be performed prior to electrification of the line ..............................................................31 4.2 Electrifying the line.......................................................................................................................32 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 3 Table of contents 5 Service and maintenance ........................................................................................................................ 33 5.1 Inspections/Expansions .............................................................................................................. 33 5.2 Service and maintenance............................................................................................................ 33 5.3 Dismantling busbar trunking system elements ........................................................................... 34 6 Weights.................................................................................................................................................... 35 7 Test reports ............................................................................................................................................. 41 4 7.1 Test reports ................................................................................................................................. 41 7.2 Test report for inspecting assembled joint blocks on initial assembly ........................................ 42 7.3 Test report for inspecting assembled joint blocks on subsequent assembly.............................. 43 7.4 Insulation test report.................................................................................................................... 44 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 1 Introduction This manual is designed to assist you in installing, maintaining, and commissioning BD2 systems. Note Before installing the system on the site, you must read and follow the instructions on storage, transport and handling. WARNING Only personnel who have been trained in site safety regulations (such as the wearing of helmets, safety goggles, safety shoes, high-visibility tabards, etc.) may work on construction sites and install busbar trunking systems. The responsible safety officer must provide mandatory safety training. Manual overview This manual consists of four sections: ● General information: Brief overview of busbar trunking system components and how they are installed ● Installation: Description of how the busbar trunking system elements are installed ● Inspection, expansions, checks: Description of how to handle the busbar trunking system once it has been installed ● Checklists and reports You can find more detailed technical information on BD2 systems in the planning manual "Planning with SIVACON 8PS" (order number A5E01541101-01) and in Catalogue LV 70. In addition, observe the installation operating instructions (AWA) for the individual busbar elements. These contain specific details on how to install the various busbar elements. You can find an overview of the AWAs at Installing a busbar run (Page 11) Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 5 Introduction 6 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Planning usage 2.1 2 Scope of delivery All materials are packaged and sent out together with a delivery note and AWA. 2.2 Receiving goods ● Check that the material and documentation received corresponds to the scope of your installation project. ● Check the components supplied and ensure that they function as intended and correspond with the information on the documentation. ● Take particular note of the information on the packaging (symbols, labels, etc.). Observe the warning notices. ● The item number on the packaging and the project manual will help you to identify where the element is to be installed in the layout. ● Check that the material has been delivered in perfect condition and with no transport damage. 2.3 Safe handling Handling material NOTICE As with all electrical equipment, this material should be handled with care, following the instructions listed here. Proceed with caution and pay attention to personnel safety. Use all equipment necessary for correct handling of the material. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 7 Planning usage 2.4 Storage 2.4 Storage 1. The material storage area has to meet the following requirements: – It must be stable, secure and not on a slope. – It must be protected against damp, extreme temperatures and water penetration. – Effective protection against dust, water, welding sparks and other factors that could damage the material supplied must be in place. – For safety reasons, the area must not serve as a gangway, nor must it be used to assemble other equipment. 2. Take note of the specific storage and packaging information featured on the packaging (symbols, labels, etc.). 3. If possible, store the material in its transport packaging. As a rule, the elements are supplied on pallets that must not be stacked on top of one another. If the transport packaging is removed, store the elements in their product packaging as follows: – Tap-off units, junction units, flanged ends and cable feeder units must not be stacked. – Straight trunking units: Depending on the system, you can only stack a specific number of elements flat on top of one another: BD2 aluminium system BD2 copper system Figure 2-1 8 160 to 400 A 10 elements, max. 630 to 1000 A 5 elements, max. 160 to 400 A 5 elements, max. 630 to 1250 A 3 elements, max. Storing trunking units Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Planning usage 2.5 Packaging NOTICE Do not remove the protective covers from the ends of the busbar trunking until the electrical connection has been made, otherwise material may be damaged and functioning may be impaired following installation. 2.5 Packaging The busbar trunking system elements are supplied with protective covers on their ends These protect conductors, insulators and joint blocks against impact during transport and storage on the building site. The protective foil/packaging also protects the elements from dust and damp. NOTICE Do not remove the protective covers until the busbar trunking system elements are ready to be joined. Do not remove all the protective coverings until you install the elements. Be very careful when removing the strap retainers. The sharp edges on the strap retainers pose a significant risk of injury when they spring off. Note The protective material can be recycled. When disposing of it, refer to the applicable standards for waste disposal in the installation area. 2.6 Handling Handling Busbar trunking system elements can be moved using a forklift and/or suspended from slings. Figure 2-2 Transport using a forklift Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 9 Planning usage 2.6 Handling Suspension from slings Ensure that the elements do not get damaged when transporting them with a forklift. Use fabric slings to suspend the busbar trunking system elements. As a rule, always attach slings to lift the elements. The elements are supplied with special parts for securing the slings in place and for supporting their own weight. The suspended elements can be removed and placed in various positions, depending on their required application (see illustration). NOTICE Never use abrasive or metal slings under any circumstances. Never suspend the elements by their conductors, as this could potentially damage them beyond repair. 10 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 3 Installation 3.1 Overview 1. Checking elements: Inspect all elements on receipt and ensure that neither the conductors nor their insulation have been damaged during handling and/or storage. 2. Correct installation sequence: Install the elements in accordance with the planned layout as indicated in the installation drawings supplied. 3. Connecting elements: – Ensure that the spacing between adjoining elements is correct. – Establish the electrical connection between the conductors; do not place the covers on the junction yet (see Connecting units (Page 20)). 4. Checking the assembled elements: Check the insulation resistance of the layout. No other equipment (tap-off units, end feed units, etc.) must be connected at this time. (see chapter Commissioning (Page 31)). 5. Closing the junctions: Place the covers on the mechanical junctions (see Connecting units (Page 20)). 3.2 Installing a busbar run Installation The steps that must be performed to install the different BD2 system elements are described below, along with some accessories that have been designed for this purpose. Although the parts are listed in order of installation, we do recommend that you read the instructions in full in order to familiarise yourself with the special characteristics of this installation procedure. Operating instructions (AWA) are also provided with the elements. These contain specific details on how to install the various busbar elements and must be followed at all times. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 11 Installation 3.2 Installing a busbar run Note A video clip demonstrating BD2 busbar installation is also available; please contact your SIEMENS contact for further available. NOTICE Plan the installation process carefully, resolving all possible difficulties prior to starting work. Always pay attention to personnel safety and ensure that material does not become damaged. Overview of AWAs Elements AWA no. Trunking units Straight trunking units, L, Z, K and T units; junctions; end caps AWA 3740-1926 BD2.-...-. (160 A to 400 A) AWA 374-1363 BD2.-...-. (630 A to 1250 A) Non-standard lengths (can be cut to length) AWA 3740-2182 BD2.-...-WO-AL Movable junction unit AWA 374-1556 BD2-...-R AWA 374-1656 BD2.-250-VE AWA 374-1321 BD2.-400 (1000)-VE AWA 3740-2029 BD2.-1250-VE AWA 374-1655 BD2.-250-EE, BD2-250-EBAL AWA 374-1084 BD2.-400 (1000)-EE, BD2-400 (1000)-EBAL(-KR) Feeder units Flanged ends End feeder units Centre feeder units AWA 3740-2030 BD2.-1250-EE, BD2-1250-EBAL, BD2-1250-KR AWA 3740-2178 BD2.-...-EESC AWA 374-1661 BD2.-400-ME AWA 374-1662 BD2.-1000-ME up to 25 A AWA 374-1386 BD2-AK1/... up to 63 A (100 A) AWA 374-1663 BD2-AK2M2/..., BD2-AK2X/.. AWA 3740-2013 BD2-AK02M2/..., BD2-AK02X/... AWA 374-1667 BD2-AK2X/GB323, .../GB633, /GB1003 AWA 3740-2014 BD2-AK02X/GB323(GB633), BD2AK03X/GB1003 AWA 374-1665 BD2-AK3X/GS00 AWA 374-1666 BD2-AK3X/GSTZ00 Tap-off units up to 530 A Ancillary equipment units 12 AWA 3740-2015 BD2-AK03X/L.., BD2-AK03X/FS.. AWA 3740-2163 BD2-AK04(05,06)/FS(LSD,LSM)... AWA 3740-2170 BD2-AK04(05,06)/SNH. AWA 3740-2181 BD2-AK04/GB250J-. AWA 374-1669 BD2-GK... Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.3 Installation recommendations Accessories Fixing brackets for horizontal layout AWA 374-1318 BD2-...-BB, BD2-DSB, BD2-BD Fixing brackets for vertical layout AWA 374-1175 BD2-BWV, BD2-BDV AWA 374-1670 BD2-BVF AWA 3740-2177 BD2-BVC Fire barrier mounted at the factory AWA 374-1529 +BD2-S90-B.-., +BD2-S120-B.-. IP54 covers for trunking units in horizontal layout AWA 374-1317 BD2-F., BD2-...-H. IP55 covers for trunking units AWA 3740-2166 BD2-FAS,BD2-...-FS(E) (IP55) IP55 covers for tap-off units AWA 3740-2165 BD2-AK...IP55 3.3 Installation recommendations Installation recommendations Install either the whole line or parts of it, depending on how accessible and safe the layout is. 1. Start the installation by connecting the board outlets. 2. Once the distribution board has been installed, continue towards the sub-distribution board and consumers. To simplify handling, on runs between feeder units the last element to be inserted should be a straight trunking unit. If the run ends with an end cap, fit this last. NOTICE Protect all elements from adverse ambient conditions and other potentially damaging agents until installation has been completed. Always pay attention to the safety of personnel and ensure that material does not get damaged. Note Deviating from the recommendations These installation recommendations specify the general assembly sequence for the various busbar trunking system elements. As local conditions on the building site or within a project can vary, deviations from these recommendations are possible. In such cases, please get in touch with your SIEMENS contact. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 13 Installation 3.4 Attaching fixing material 3.4 Attaching fixing material 3.4.1 Typical procedure The BD2 busbar trunking system is generally attached to the structure of the building using externally provided supporting structures (e.g. threaded rods, C-profiles, joists or stands for intermediate levels) and the system-specific fixing bracket. 3.4.2 Overview Types of fixing material ● Fixing material not available in the catalogue (plugs, beams, suspension struts, spigots, etc.) must be provided by installation experts. ● Bracket for horizontal installations (ceiling/wall/floor brackets) ● Bracket for vertical installations (wall and floor brackets) Attaching fixing material In all cases, proceed as follows: 1. Attach the fixing brackets to the building via the supporting structure. 2. Raise the BD2 element and suspend it on the brackets without securing it. 3. Move the element until it is inserted in the adjoining joint block and place it in its final position. 4. Secure the element. Note Consulting installation experts These instructions only refer to accessories manufactured by SIEMENS. For further information, please refer to the catalogue. It is beyond the scope of this manual to document the vast number of different on-site conditions that may arise. Therefore, we recommend that installation experts evaluate on-site conditions. WARNING Always follow the instructions provided in the manual and the AWAs. 14 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.4 Attaching fixing material 3.4.3 Bracket for horizontal installations Ceiling bracket ● Attach the suspension bracket to the ceiling or another suitable structural support. ● Ensure that the ceiling or structural support is strong enough to hold the weight of the system. ● Place the element to be suspended in its intended final position on the brackets, leaving the element in a horizontal position. ● Join the adjacent elements. ● The surface finishes of the fixing strut and the screws must be adapted to on-site ambient conditions. Figure 3-1 Ceiling bracket Note When selecting plugs to use, take the ceiling material and quality as well as the weight to be supported into account. Trunking weights and bracket distances Type BD2A 160 250 400 630 800 1000 Horizontal, on edge m 4 4 4 4 3.5 3 Horizontal, on edge with BD2-BD m 4 4 4 2 1.75 1.5 Horizontal, flat m 3.5 3.5 3.5 3.5 3 2.5 Weight without joint block kg/m 5.3 5.8 7.5 12.3 12.4 15.8 Type BD2C 160 250 400 630 800 1000 1250 Horizontal, on edge m 4 4 4 4 3.5 3 2 Horizontal, on edge with BD2-BD m 4 4 4 2 1.75 1.5 1 Horizontal, flat m 3.5 3.5 3.5 3.5 3 2.5 1.5 Weight without joint block kg/m 7.3 7.5 9.5 15.6 18.9 25.1 37.6 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 15 Installation 3.4 Attaching fixing material ● In designing supports, consider the following: – The maximum capacity of fixing brackets in terms of supporting at least the weight of the busbar trunking system plus 90 kg, in accordance with IEC/EN 60439-2 – Fixing points on the structure and suitable accessories (plugs, etc.) – Feasibility of fixed points (should be given particular consideration as regards horizontal run layouts) ● Please take the particular requirements of vertical trunking, i.e. manoeuvrability, suspension of elements, execution, etc. into consideration. Wall bracket The same maximum permissible values apply to wall brackets as to ceiling brackets. A wall bracket consists of a wall beam and a fixing bracket (type BD2-...-BB from BD2 range). The customer must provide the wall beams. Figure 3-2 16 Wall bracket for BD2 elements mounted flat Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.4 Attaching fixing material 3.4.4 Spring brackets for vertical installation on walls Mounting the bracket for vertical installation Version a: Vertical fixing bracket, mounted on joint block, adjustable height Version b: Vertical installation, mounted on flange cover Version c: Vertical installation, mounted on trunking unit 1. Mark the anchorage holes on the wall, using the fixing bracket as a template if you so wish. 2. Drill the holes and insert the plugs into them. Note The fixing bracket should be attached to the wall using plugs appropriate to the weight to be supported and the fixing material used. 3. Attach the bracket for vertical installation with the screws. 4. Install all fixing brackets in the corresponding locations before installing the busbar trunking run. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 17 Installation 3.4 Attaching fixing material Maximum length/height of vertical BD2 busbar runs, supported by 1 fixing element, Version a BD2A.-... Rated current A 160 250 400 630 800 1000 1250 Max. supported length/height at max. load (see below) m 11.3 10.9 7.9 5.8 5.8 5.3 - Max. load per 3.25 m trunking unit fitted with tap-off units kg 50 53 74 106 108 108 - Rated current A 160 250 400 630 800 1000 1250 Max. supported length/height at max. load (see below) m 10.0 9.9 7.2 5.2 4.8 4.1 3.25 Max. load per 3.25 m trunking unit fitted with tap-off units kg 50 53 74 106 108 108 - BD2C.-... Note For higher BD2 busbar runs, use additional fixing elements. Vertical fixing elements can support up to 175 kg and should be attached near the terminal. Mounting the busbar trunking system on a bracket for vertical installation 0 1P Version a Version b Version c 1. Position the busbar trunking system element at the desired installation location using slings or other lifting lugs. Observe the installation instructions. For the bracket mounted on the flange cover, remove the knockouts. 18 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.4 Attaching fixing material 2. Ensure that the element is correctly positioned in terms of the adjoining element. 3. Establish an electrical and mechanical connection between adjoining elements, taking note of the relevant instructions. 4. Mount the busbar trunking system by fastening the screws onto the fixing bracket using the nuts and washers. 5. Remove the slings or lifting lug used. The element is now supported by the fixing bracket. 3.4.5 Floor fixing for spring brackets Figure 3-3 Mounting the bracket for vertical installation on the floor Figure 3-4 Mounting the bracket for vertical installation on the floor Please refer to the description in Spring brackets for vertical installation on walls (Page 17) for details on how to attach the vertical line. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 19 Installation 3.5 Connecting units 3.5 Connecting units 3.5.1 Connecting units NOTICE Ensure that all contact surfaces are clean and free of impurities. 1. Remove the upper junction cover by removing the screws. 2. Depending on the amperage, a plug-in terminal (160 to 400 A) or a single-bolt terminal (630 to 1250 A) is attached to the system. Figure 3-5 20 Dismantling the joint block's flange cover Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.5 Connecting units 3.5.2 Mounting the plug-in terminal 1. Slacken the 4 screws and remove the flange cover. [ Figure 3-6 Slackening screws and removing flange cover 2. Insert the busbar element. Figure 3-7 Inserting the busbar element Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 21 Installation 3.5 Connecting units 3. Insert the cover at an angle, tighten the two screws, and pull the cover tight with the screws on the other side. Retighten all four screws. [ [ Figure 3-8 Attaching the cover 3.5.3 Mounting the single-bolt terminal 1. Slacken the four screws and remove the flange cover. 22 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.5 Connecting units 2. Insert the busbar element. 3. Tighten the single-bolt terminal to the stop. Attach the flange cover. 6723 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 23 Installation 3.6 Expansion unit 4. Tighten the four screws on the flange cover. NOTICE Ensure that the joint block is correctly centred between the two elements to be joined. Plan the installation of the connections in advance to avoid subsequent problems. Never knock or hit the joint block when inserting it between the two elements. Instead, insert it carefully, otherwise the elements may get damaged. 3.6 Expansion unit The BD2 system does not require an additional expansion unit. The system design ensures expansion compensation through the joint block. Note The movements of the building and the fixing structures are not compensated by the BD2 system. 24 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.7 Flanged end 3.7 Flanged end 3.7.1 Flanged end The flanged end connects the busbar trunking system to external power supplies or outputs, both mechanically and electrically. These external power supplies are usually distribution boards for low-voltage main distribution systems. Figure 3-9 3.7.2 Flanged end Installation Preparing the non-Siemens distribution board for the connection of the flanged end 1. Align the distribution board mounting surface so that it is flat. 2. Prepare the cutouts in accordance with the AWA. 3. Reinforce the distribution board mounting surface in accordance with the weight of the flanged end. 4. The distribution board must contain fixtures for mechanically securing the flanged end. The flanged end's own weight must be mechanically decoupled from the electrical connection (copper connection). 5. During this process, observe the flanged end connection dimensions and cross-section specifications, as well as the distribution board manufacturer's specifications. 6. When connecting 5-core cables, remove the link between PE and N. Installing the flanged end in the distribution board Following storage and transport to the installation location, you must first mechanically secure the flanged end in the distribution board. After that, you electrically connect the flanged end to the busbars or the circuit breaker. Securing the flanged end mechanically 1. The power cables of the BD2...-VE must be mechanically fixed in the distribution board. The BD2...-VE busbars must not be subjected to any additional forces. 2. Attach the flanged end to the distribution board enclosure. Observe the distribution board specifications relating to the degree of protection. It may be necessary to use additional sealant in order to achieve degrees of protection higher than IP 55. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 25 Installation 3.8 Cable feeder units Connecting the flanged end electrically 1. Remove the protective transportation devices. 2. Perform the electrical connection in accordance with the flanged end specifications (minimum cross-sections) and the information provided by the distribution board manufacturer. Dimension the connecting material in accordance with these specifications. Note You must comply with the required minimum cross-sections for the flanged end, otherwise the maximum permissible limit temperature of 130°C cannot be guaranteed. The design of the electrical connection determines the short circuit strength. The designer, usually the distribution board manufacturer or constructor, is responsible for the temperature and short circuit strength of the electrical connection. 3.8 Cable feeder units Various feeder units are available to supply the busbar trunking system, depending on the requirements. End feeder units connect the system to external power sources at the ends, and centre feeder units connect the system within the run. Phase sequence can be changed on-site by rotating the busbar package. Please refer to the description in Connecting units (Page 20) for details on how to perform the mechanical and electrical connection; the electrical connection is performed as described in Installation (Page 25) . Note Short-circuit and overload protection When a centre feeder unit is used, the left and right runs of the busbar trunking system are supplied with power simultaneously with one supply cable. In this case, you must ensure that the loads are protected against short circuits and overload, either via an upstream protective device or by additional protective measures. 26 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.9 Fire barrier 3.9 Fire barrier 3.9.1 Fire barrier regulations If the busbar run passes through a fire wall or ceiling, you must provide the run with a fire barrier. It is not permissible to mount the fire barrier via the junction (joint block). Note Depending on country-specific regulations, it may be necessary to attach additional fire barrier notices directly at the installation site. Fire barrier signs required directly at the installation site. 3.9.2 Installing a fire barrier The following conditions must be met in order for the fire barrier to be installed (also see illustration): The internal fire barrier must be positioned in the centre of the wall or ceiling. Figure 3-10 Internal fire barrier (left), internal and external fire barrier (right) Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 27 Installation 3.10 Tap-off unit 3.10 Tap-off unit 3.10.1 Tap-off units from 10 A to 530 A 1. These tap-off units are positioned at the tap-off points on the trunking. Power is tapped via the tap-off point. Depending on the relevant national regulations for electrical installations, these tap-off units may either be mounted when live, or this may not be permissible. If the latter is the case, switch the voltage off and safeguard the run against restart in accordance with on-site regulations. 2. See the relevant AWA for more details and instructions on mounting tap-off units. Note You must check the necessary space requirements prior to mounting. These tap-off units cannot be positioned at junctions above a joint block. The necessary space requirements must be taken into account during the project design stage. Figure 3-11 28 Tap-off units up to 530 A and ancillary equipment units for additional installed devices with tap-off units up to 125 A Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Installation 3.10 Tap-off unit 3.10.2 Lateral mounting of tap-off units BD2-AK04 (05, 06) in runs for horizontal installation If the tap-off units are mounted laterally, the mechanical load caused by the weight of the units and the cables to be connected mean that we strongly recommend you use additional supports (beams or brackets). % & ' $ Figure 3-12 Laterally mounted tap-off units should have additional mechanical support A Additional beam for tap-off unit B Tap-off unit C Busbar run D Beam for busbar run Additional beams in line with A and D are not available as BD2 attachment accessories and must be procured externally. Note It is beyond the scope of this manual to document the huge number of different on-site conditions that may arise. Therefore, we recommend that installation experts evaluate on-site conditions. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 29 Installation 3.10 Tap-off unit 30 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Commissioning 4.1 4 Steps to be performed prior to electrification of the line Steps to be performed prior to electrification of the line WARNING Live electrical equipment can cause personal injury or even death. Therefore, proceed with extreme caution and follow these instructions carefully. 1. Check that all connections are fully tightened. Follow the instructions relating to tightening torques (visual inspection with record of results). 2. Check all suspension and fixing elements. All the fixing studs and screws of the fixing brackets must be tightened. 3. Make sure that all tap-off units and tapping equipment is disconnected (OFF). 4. Insulate the busbar trunking system from the connections to transformers, switches, meters, etc. 5. Carry out an insulation resistance test to make sure that there are no short circuits or earth failures in the system (phase - earth, phase - neutral and phase - phase). You will observe that the readings vary depending on the length of the run, the number and size of the conductors and the level of moisture in the atmosphere. Record the measured values in an insulation test report. If you obtain readings lower than 1 MΩ per 100 m (1 MΩ x 100/length of run in metres), please contact technical support. As a rule, you must comply with the relevant country-specific regulations (in Germany, this is a minimum of 0.5 MΩ). 6. Check that the poles on the busbar trunking system and those on the transformers, switches, meters, etc. correspond correctly on electrification. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 31 Commissioning 4.2 Electrifying the line 4.2 Electrifying the line Electrifying the line WARNING Live electrical equipment can cause personal injury or even death. The first time that the busbar trunking system conductors are electrified can be dangerous. Therefore, you must follow these instructions to the letter, along with the relevant applicable country-specific regulations. 1. Qualified personnel must be present the first time the line is electrified. If short circuits or earth failures caused by incorrect installation have not been previously detected, this can lead to serious consequences once voltage is applied. 2. There must be no electrical load connected to the busbar trunking system when it is electrified; the entire system must be checked to ensure that this is the case. 3. You must electrify the line step by step, starting at the power supply and moving towards the loads at the end. The principal elements must be electrified first, followed by the feed equipment and, finally, the secondary element circuits. You must act with purpose and conviction when connecting the line. 4. Once the line has been connected, consumers such as lights, contactors, heaters and motors can be switched on. 5. In normal operation the busbar trunking system will produce a slight buzzing sound. Excessive noise may indicate that components have not been properly secured or metal parts have been incorrectly assembled. 6. Faults caused by short circuits must trigger the protective device for the feeder unit in the manner prescribed by the official regulations. You must ensure that the system is de-energised before you eliminate the cause of the fault. Observe the five safety rules: 1. Disconnect; 2. Safeguard against restart; 3. Ensure the system is de-energised; 4. Earth and short circuit; 5. Cover and safeguard neighbouring live parts. 32 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Service and maintenance 5.1 5 Inspections/Expansions Expansions As a flexible power distribution board, the BD2 busbar trunking system can in principle adapt to meet local needs in terms of loads and can also be expanded for new loads. As a first stage it can be sufficient simply to plug existing or new tap-off units into existing, unused tap-off points. If there are no more tap-off points available or if certain buildings/areas are not supplied by the BD2, it is necessary in a second stage to extend the BD2 run with appropriate trunking units. This involves removing the busbar trunking system element from the BD2 run. 5.2 Service and maintenance The BD2 busbar trunking system is maintenance-free as long as the following conditions are met: ● Assembly was performed in line with the valid guidelines as per AWA and the installation manual. ● Commissioning was performed correctly and then checked and logged with insulation measurements and visual inspections. ● There are no extreme mechanical loads due to external forces or significant impairment due to foreign bodies or dust. ● There are no extreme stresses/loads due to water or liquids. ● There are no extreme stresses/loads due to aggressive media. ● There are no other malfunction-based loads/stresses due to short circuits, fire or gas. This maintenance-free claim does not include devices fitted in tap-off units, feeder units or coupling units. The instructions on their maintenance should be taken from the respective manuals/documentation supplied with the devices. If any of the conditions listed above cannot be guaranteed, you should consult your SIEMENS contact directly. Please also get in touch with your SIEMENS contact for any additional inspections that have to be performed regularly for the erector and operator due to country-specific standards, regulations on accident prevention and safety, as well as for special work areas. Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 33 Service and maintenance 5.3 Dismantling busbar trunking system elements 5.3 Dismantling busbar trunking system elements Dismantling busbar trunking system elements It may sometimes be necessary to dismantle a length of the busbar trunking system for the purposes of expansion or replacement. These instructions indicate the correct procedure to follow in such a case. WARNING Before disconnecting, take the switching capacity of the busbar trunking system protector element into consideration. • All power must be disconnected before you disconnect the busbar trunking system. • The header protection systems must be disconnected in order to insulate the busbar trunking system. WARNING Remember to completely disconnect the line before handling. Observe the five safety rules: 1. Disconnect 2. Safeguard against restart 3. Ensure the system is de-energised 4. Earth and short circuit 5. Cover and safeguard neighbouring live parts NOTICE Only qualified personnel with electrotechnical knowledge may perform the operations indicated in this section. 1. Disconnect all power to the busbar trunking system. 2. Disconnect the busbar trunking system from the supply. 3. Fully insulate the busbar trunking system and safeguard it against restart. 4. Remove the flange cover of the relevant elements. The first element must be removed in a transversal direction. All other elements can be removed in a longitudinal or transversal direction. The busbar trunking system must be handled in accordance with the AWA (see installation instructions). 34 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 6 Weights Trunking units Type (without single-bolt joint block) BD2A[kg/m] BD2C[kg/m] BD2.-.-160-SB-. 5.3 7.3 BD2.-.-160-WB-. 5.3 7.3 BD2.-.-250-SB-. 5.8 7.5 BD2.-.-250-WB-. 5.8 7.5 BD2.-.-400-SB-. 7.5 9.5 BD2.-.-400-WB-. 7,5 9.5 BD2.-.-400-SO-. 7,5 9.5 BD2.-.-400-WO-. 7.5 9.5 BD2.-.-630-SB-. 12.3 15.6 BD2.-.-630-WB-. 12.3 15.6 BD2.-.-630-SO-. 12.3 15.6 BD2.-.-630-WO-. 12.3 15.6 BD2.-.-800-SB-. 12.4 18.9 BD2.-.-800-WB-. 12.4 18.9 BD2.-.-800-SO-. 12.4 18.9 BD2.-.-800-WO-. 12.4 18.9 BD2.-.-1000-SB-. 15.8 25.1 BD2.-.-1000-WB-. 15.8 25.1 BD2.-.-1000-SO-. 15.8 25.1 BD2.-.-1000-WO-. 15.8 25.1 BD2.-.-1250-SB-. - 37.6 BD2.-.-1250-WB-. - 37.6 BD2.-.-1250-SO-. - 37.6 BD2.-.-1250-WO-. - 37.6 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 35 Weights Junction units Type (without single-bolt joint block) BD2A[kg/m] BD2C[kg/m] BD2.-400-L.. 7.5 9.5 BD2.-400-Z.. 7.5 9.5 BD2.-1000-L.. 15.8 - BD2.-1000-Z.. 15.8 - BD2.-1250-L.. - 37.6 BD2.-1250-Z.. - 37.6 BD2.-400-T.. 7.5 9.5 BD2.-400-K.. 7.5 9.5 BD2.-1000-T.. 15.8 - BD2.-1000-K.. 15.8 - BD2.-1250-T.. - 37.6 BD2.-1250-K.. - 37.6 Type (without single-bolt joint block) BD2A[kg] BD2C[kg] BD2.-250-EE 6.6 8.9 BD2.-250-VE 2.1 4.4 BD2.-400-EE 13.3 16.3 BD2.-400-ME 28.0 36.6 BD2.-400-VE 3.5 6.5 BD2.-1000-EE 14.9 22.1 BD2.-1250-EE - 27.1 BD2.-1000-VE 4.7 11.8 BD2.-1250-EE - 16.3 BD2.-1000-ME 47.0 75.5 Feeder units Cable compartments 36 Type (without single-bolt joint block) [kg] BD2-400-KR 3.1 BD2-1000-KR 5 BD2-1250-KR 5 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Weights Tap-off units Type [kg] BD2-AK1/S14 1.1 BD2-AK1/S18 1.15 BD2-AK1/A163 1.3 BD2-AK1/CEE165S14 1.2 BD2-AK1/CEE165A163 1.5 BD2-AK1/2CEE163S14 1.2 BD2-AK1/2CEE163A161 1.4 BD2-AK1/3SD163S14 1.4 BD2-AK1/3SD163A161 1.3 BD2-AK1/A161/1 1.1 BD2-AK1/A162 1.2 BD2-AK1/A163N 1.4 BD2-AK1/2CEE163A162 1.5 BD2-AK1/A201 1.1 BD2-AK1/A202 1.2 BD2-AK1/A203 1.3 BD2-AK1/A203N 1.4 BD2-AK1/2PC163A162 1.5 BD2-AK1/3DKS103S14 1.2 BD2-AK1/3DKS103A131 1.2 BD2-AK1/F1038-3 1.1 BD2-AK1/F1038-3-N 1.2 BD2-AK1/F140-162 1.6 BD2-AK1/A133 1.1 BD2-AK1/T25-A163 1.4 BD2-AK1/3T23-3A161 1.6 BD2-AK.2X/S18 4.1 BD2-AK.2X/S27 3.9 BD2-AK.2X/S33 4.2 BD2-AK2X/CEE325S33 5.1 BD2-AK.2M2/A323 4.4 BD2-AK2M2/CEE325A323 4.9 BD2-AK2X/CEE635S33 5.7 BD2-AK2X/2CEE165S14 4.8 BD2-AK2X/2CEE165S27 4.9 BD2-AK2M2/2SD163CEE165A163 5.6 BD2-AK2M2/2CEE165A163 5.4 BD2-AK.2M2/A323N 4.8 BD2-AK.2M2/A633 4.9 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 37 Weights 38 Type [kg] BD2-AK.2M2/A633N 5.2 BD2-AK2X/3BS133GB131 5.4 BD2-AK2X/3BS133A131 5.6 BD2-AK.2X/GB323 5.5 BD2-AK.2X/GB633 5.6 BD2-AK.2X/F1451-3(N) 5.5 BD2-AK.2X/F2258-3(N) 5.7 BD2-AK03X/LSD-DC40-N 8.5 BD2-AK03X/LSD-DC(AE)63-N 8.5 BD2-AK03X/LSD-DC80-N 8.5 BD2-AK03X/LSD-DC(AE)100-N 8.5 BD2-AK03X/LSD-DC125-N 8.5 BD2-AK03X/LSD-EM40-N 9.0 BD2-AK03X/LSD-EM63-N 9.0 BD2-AK03X/LSD-EM80-N 9.0 BD2-AK03X/LSD-EM100-N 9.0 BD2-AK03X/LSD-EM125-N 9.0 BD2-AK.3X/GS00 5.4 BD2-AK.3X/GST.00 6.7 BD2-AK.3X/GB1003 7.8 BD2-AK03X/FS125...-3 7.9 BD2-AK03X/FS125...-4 8.3 BD2-AK03X/F2258...-3N 7.5 BD2-AK03M2/A1253(N) 6.0 BD2-AK04/SNH1 30.0 BD2-AK04/FS...-3 30.0 BD2-AK04/FS...-4 30.0 BD2-AK05/SNH2 35.0 BD2-AK05/FS...-3 35.0 BD2-AK05/FS...-4 35.0 BD2-AK06/SNH3 40/0 BD2-AK04/LS.-DC(AE)... 30.0 BD2-AK04/LS.-EC... 30.0 BD2-AK05/LS.-DC(AE)... 35.0 BD2-AK05/LS.-EC... 35.0 BD2-AK06/LS.-DC(AE)... 40.0 BD2-AK06/LS.-EC... 40.0 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Weights Ancillary equipment units Type (without single-bolt joint block) [kg] BD2-GKX/F 0.4 BD2-GKM2/F 1.5 Additional equipment Type [kg] BD2-400-SK 3.5 BD2-400-FE 0.98 BD2-400-BB 0.44 BD2-400-HF 0.3 BD2-400-HFE 0.18 BD2-400-VF 0.2 BD2-1250-EK 6.48 BD2-1250-FE 1.28 BD2-1250-BB 0.54 BD2-1250-HF 0.52 BD2-1250-HFE 0.26 BD2-1250-VF 0.5 BD2-FFE 0.32 BD2-FF 0.6 BD2-FAS 0.22 BD2-AK...-IP55 0.07 BD2-400-FS 1.9 BD2-1250-FS 2.6 BD2-SD163 0.28 BD2-CEE163 0.26 BD2-CEE165 0.31 BD2-CEE325 0.35 BD2-AG 0.15 BD2-APO 0.09 BD2-APM 0.06 BD2-BD 0.44 BD2-BDV 4.5 BD2-BVC 0.5 BD2-BVF 0.5 BD2-BVW 1.56 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 39 Weights 40 Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Test reports 7.1 7 Test reports The following test reports are available for commissioning and for maintenance/expansion purposes: ● Test report for inspecting assembled joint blocks on initial assembly ● Test report for inspecting assembled joint blocks on subsequent assembly ● Insulation test report Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 41 Test reports 7.2 Test report for inspecting assembled joint blocks on initial assembly 7.2 Test report for inspecting assembled joint blocks on initial assembly Test report For inspecting assembled joint blocks on initial assembly for SIEMENS BD2 busbar systems Customer: Type of installation: Contact: Site: Street: Manufacturer/Type: City/Post code: Year of manufacture: Consignment no.: Run number/designation: Date: Run length: Test starts at position no.: Drawing coord.: Date of drawing: Sheet no.: Drawing coordinates Place: 42 Position Joint block initial assembly New bolt joint(s) Date: Tester's signature: Other remarks Test as a whole Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Test reports 7.3 Test report for inspecting assembled joint blocks on subsequent assembly 7.3 Test report for inspecting assembled joint blocks on subsequent assembly Test report For inspecting assembled joint blocks on subsequent assembly for SIEMENS BD2 busbar systems Customer: Type of installation: Contact: Site: Street: Manufacturer/Type: City/Post code: Year of manufacture: Consignment no.: Run number/designation: Date: Run length: Test starts at position no.: Drawing coord.: Date of drawing: Sheet no.: Drawing coordinates Place: Position Joint block subsequent assembly Bolt joint(s) Date: Tester's signature: Installation with BD2 Installation Manual, 03/2008, A5E02126899-01 Other remarks Test as a whole 43 Test reports 7.4 Insulation test report 7.4 Insulation test report Insulation test report For inspecting assembled joint blocks on initial assembly for SIEMENS BD2 busbar systems Customer: Type of installation: Contact: Site: Street: Manufacturer/Type: City/Post code: Year of manufacture: Consignment no.: Run number/designation: Date: Run length: Meter data: Meter manufacturer: Type: Direct measuring circuit voltage: Climate data: Time: Air temperature: Humidity: !! There must be no loads connected when the insulation resistance is tested !! !! The insulation resistance must be at least 1 megohm !! System design: 4-pole ❒ 5-pole ❒ Specify measured values in megohms. Component N-PE L1-L2 L2-L3 L3-L1 L1-PE L2-PE L3-PE L1-N L2-N L3-N L1PEN L2PEN L3PEN We hereby confirm that the measurements given above were performed correctly. Place: 44 Date: Tester's signature: Installation with BD2 Installation Manual, 03/2008, A5E02126899-01
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