os ABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 1 ‘Docum:1TFL291002C Installation Instructions CONTENTS 1. Installation instructions for jointings 1.1 General jointing instructions 1.2 Extensions 2.1 Connection of frame parts of busbar bridge 1.2.2 Busbar connections 1.2.3 Mounting of connection boxes 1.2.4 Extension of bridge unit with flexible extension parts Connection of busbar bridge to switchboard 2.1 — Connection of the busbar bridge to the switchboard from above 22 Connection of the busbar bridge to the switchboard from below Connection of busbar bridge to transformer Support and suspension of busbar bridge Nominal currents and the dimensions of busbar bridges ing of busbar b ge 6.1 Lifting of horizontal bridge 6.2 Lifting of vertical bridgeABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Docum:1TFL2910026 Installation Instructions Poge: 2 1. Installation instructions for jointings 4.1 General jointing instructions For the connection of busbars to aluminium or copper bars (feeder bars, transformer poles and busbar bridge extentions) the following instructions apply: Jointing aluminium to aluminium bar shall be performed as follows: Picture 1; jointing aluminium to aluminium Al-bar Bolt Spacer Spring washer arenas Nut In dry and humid environment the aluminium bar can be connected directly to another aluminium bar using jointing mastic. Surfaces to be connected are cleaned by rubbing and brushing them with a wire brush. Aluminium surfaces are cleaned using jointing mastic and a short bristle wire brush.ABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 3 ‘Dooum:1TFL2910026 Installation Instructions Jointing copper to copper shall be performed as follows’ Picture 2; jointing copper to copper 1 Cu-bar 2 Bolt 3 Washer 4 Spring washer 5 Nut Copper surfaces can be connected to each other without rubbing or brushing them. Jointing copper bar to an aluminium bar shall be performed as follows: Picture 3; jointing copper to aluminiumABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 4 Docu: 1TFL.2910020 Installation Instructions 1 Cu-bar 2 Al-bar 3 Bolt 4 Spacer 5 Spring washer 6 Nut In dry environment an aluminium bar can be connected directly to a copper bar using jointing mastic. Aluminium surfaces to be connected are cleaned by rubbing and brushing with a wire brush. In addition aluminium surfaces are brushed using jointing mastic. In humid environment a tinned copper plate is to be added between the joints. Note! When the tinned jointing plates are used, do not brush them with scratching tools.ABB Oy Low Voltage Systems Date 21.05.2002 MDY-BUSBAR BRIDGE Page: 5 Docu 17F1.2910020 Installation Instructions 1.2 Extensions The connection of busbar bridge units is performed in the following ordi 7 frame parts of busbar bridges are mounted (1) - busbars of the units are connected with each other (2) - connection boxes are mounted and, ifnecessary, sealed (3) Picture 4; busbars, connection boxes, bridge frames 1.2.1 Connection of frame parts of busbar bridge For the extensions of frame parts of the busbar bridge, the PE-circuit of the frame is connected with each other and cover plates of the extension are mounted. PE-circuit is connected as shown in the assembly drawing, PE-busbar to be connected is jointed to the next transport unit. Before this the inner surface of the frame must be cleaned by rubbing and brushing it with a wire brush. The surface is cleaned using jointing mastic. The bolts are tightened as shown in the assembly drawings. The cover plate is fastened to the busbar bridge frame with self-drilling screws as shown in assembly drawings.ABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Docu TLZa1002¢ Installation Instructions a SURERCES age 10 BE gDinecttDN BOLTS 4 pes FASTENING SCREWS OF COVER PLATES <4pcs> Picture 5; connection of frameABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Docum: TFL.2910026 Installation Instructions Page: 7 1.2.2. Busbar connections Busbars of the busbar bridge units are connected with each other as shown in the attached assembly drawings. The length of the units can be adjusted + 40 mm by means of connection pieces. The material of the connection pieces is aluminium, copper or tinned copper. = when aluminium busbar bridges are used, the busbars are rubbed and greased = connection pieces, screws and nuts are fastened - busbar joints are tightened according to the torque shown in the table below size [_Nm m0 | 404-5 m2 | 704-5, As for the rest, chapter 1.1 "General jointing instructions" are followed for the busbar connections.ABB Oy Low Voltage Systems (ate: 21.05.2002 MDY-BUSBAR BRIDGE Page Dooum:1TFL.2910026 Installation Instructions SAS CREadIS VEN AEShcscun rs use Picture 6; busbar connectionsABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page Docu: tTFL.2810026 Installation Instructions 1.2.3 Mounting of connection boxes Connection boxes for the busbars are mounted as shown in the assembly drawing Picture 7; mounting of the connection boxABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 10 Docu: tTFL.2910020 Installation Instructions 1.2.4 Extension of bridge unit with flexible extemsion parts Flexible extension parts are mounted in the busbar bridge with a distance of about 20 m. Extension parts are mounted according to the assembly drawing undemeath. The extensions are covered with boxes as in normal extensions. Picture 8; flexible extensionABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 11 Doan: TFLz@t0020 Installation Instructions 2. Connection of busbar bridge to switchboard 2.1 Connection of the busbar bridge to the switchboard from above ‘The busbar bridge and switchboard are connected with each other by means of connections which are located inside the feeder unit. The busbars of the bridge and the feeder busbars of the switchboard are connected with each other by means of square bars according to the attached drawing. Square bars are delivered with the busbar bridge. Picture 9; connection of the busbar bridge to the switchboard from above Connection method ~ remove the connection bars brom the busbar bridge - brush and grease the connection bars, connection bars of the switchboard and the ends of the bars of the bridge (if the busbar material is aluminium) - lift the busbar bridge to its place - fasten the sheet-metal part of the bushing with self-drilling screws to the ceiling of the ‘switchboard - adjust the connection bars and tighten the bolts - connect the frame of the busbar bridge to the PE-circuitABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 12 Docum:1TFL291002¢ Installation Instructions Connection of the busbar bridge to the switchboard from below ‘The connection of the busbar bridge to the switchboard from below is similar to that from above. Picture 10; connection of the busbar bridge to the switchboard from below. Connection method ~ remove the connection bars brom the busbar bridge - brush and grease the connection bars, connection bars of the switchboard and the ends of the bars of the bridge - lift the busbar bridge to its place on the base plate - fasten the sheet-metal part of the bushing with self-drilling screws to the floor of the switchboard ~ adjust the connection bars and tighten the bolts = connect the frame of the busbar bridge to the PE-circuit - seal the bushing opening and fix the bushing frameABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 13 Docun:tTFLz@ "0020 Installation Instructions 3. Connection of busbar bridge to transformer The busbar bridge is connected to the transformer by means of copper and flexible spacers according to the drawings. The cross section of the spacer is 1x40 mm and there must be enough of them to correspond to the rated current fed by the busbar bridge. transformer connection Picture 11; connection to transformer, three busbarsABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 14 Docu 71.2910026 Installation Instructions 4. Support and suspension of busbar bridge The busbar bridge can be installed in a horizontal, vertical or rear position, In a horizontal position the busbar bridge can be supported either from the rear by fixing the frame of the bridge with bolts to the bearing wall or it can be suspended from the ceiling using threaded rods. All methods are shown in the pictures underneath. Picture 13; suspending the busbar bridgeABB Oy Low Voltage Systems Date: 21.05.2002 MDY-BUSBAR BRIDGE Page: 18 Docu TFL2910026 Installation Instructions Ina vertical position the busbar bridge is always fixed to the bearing wall as shown in the picture. Ye suPRT Picture 14; supporting the busbar bridge from the wall, vertical position 5. Nominal currents and the dimensions of busbar bridges [Dimensions Al cu Busbarsiphase | In [A] | height | width | in[Al | height | wiath 2x40x10 1600 | 163 [400/600] 2000 | 163 | 400/600 4x40x10 2100 | 163 | 600 | 2700 | 163 600 Gxd0x10 2700 | 163__| 600 | 3400 | 163 600 8x40x10 3400_[ 163 | 800_| 4300 | 163 800ABB Oy Low Voltage Systems Date: 21.05 2002 Docu: 4TFL.2910020 Picture 15; Picture 16; Picture 17; MDY-BUSBAR BRIDGE Installation Instructions Page: 16 2x40x10 4x40x10 6x40x10ABB Oy Low Voltage Systems Date: 24.08.2002 MDY-BUSBAR BRIDGE Page: 17 Docum:1TFLz810020 Installation Instructions 6. Lifting of busbar bridge Lifting of the busbar bridge must be carried out directly upwards from the lifting hooks. 6.1 Lifting of horizontal bridge Picture 18; horizontal bridgeABB Oy Low Voltage Systems Date 21.05.2002 MDY-BUSBAR BRIDGE Page: 18 Docum:1TFL291002C Installation Instructions 6.2 _ Lifting of vertical bridge Picture 19; vertical bridge