The document provides instructions for installing insulation boxes on horizontal bus bars in low voltage motor control centers. It describes adding insulated boxes to joints and exposed areas of the bus according to a modified bill of materials. Five types of insulated boxes are described: vertical boxes, end caps, splices, patches, and riser boxes. Detailed steps are provided for installing each type of box. Variations for different bus configurations are also outlined.
The document provides instructions for installing insulation boxes on horizontal bus bars in low voltage motor control centers. It describes adding insulated boxes to joints and exposed areas of the bus according to a modified bill of materials. Five types of insulated boxes are described: vertical boxes, end caps, splices, patches, and riser boxes. Detailed steps are provided for installing each type of box. Variations for different bus configurations are also outlined.
The document provides instructions for installing insulation boxes on horizontal bus bars in low voltage motor control centers. It describes adding insulated boxes to joints and exposed areas of the bus according to a modified bill of materials. Five types of insulated boxes are described: vertical boxes, end caps, splices, patches, and riser boxes. Detailed steps are provided for installing each type of box. Variations for different bus configurations are also outlined.
Training Document July 10, 2013 Denise Robertson, LV MCC Sr. Design Engineer Step 1: OE Modifies BOM
● Add Formex box assemblies to BOM as required to cover areas of
horizontal bus that do have insulation. These assembly numbers can be found on 80466-520-CFG.
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- Step 2: Manufacturing Builds section per modified OE BOM ● Add insulated Formex boxes to bus joints and other exposed areas of bus that are not fully covered.
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- 5 Types of Insulated Formex Boxes
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- Riser Box (800A PP-M breaker in top shown)
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- 5 Types of Insulated Formex Boxes ●1. Vertical boxes (80466-701-5X) ●2. End caps (80466-703-5X) ●3. Splices (80466-702-5X) ●4. Patches (80466-709-5X) ●5. Riser boxes 80466-700-5X 80466-705-5X 80466-706-5X 800A Top PP-M 800,1200 & 2000A MLO Top 1200A PP-P Tie 1200A Top NT 2000A PP-R Tie 1200A Top PP-P Bkr & Switch 2000A PP-R Top & Bottom
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- Vertical Bus Boxes 80466-701-5X
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- Tips for vertical box installation
●Two are required per section
●Box covers joint between horizontal bus and horizontal bus support ●Left and right are usually the same box (exception occurs with 20” wide high amp vertical bus) ●Asy number for box is lamination and bus width dependent for all cases with the exception of high amp vertical bus. ●Boxes have additional cutouts on the left hand side to allow clearance for the vertical bus.
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- Slide rear parts behind horizontal bus (may be easier to install parts flat then fold after part is behind the horizontal bus due to the tight space)
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- Fold rear part around horizontal bus supports with additional folds for riveting to front parts.
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- Fold front Formex part and rivet to tabs on rear Formex part
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- Repeat same steps to assemble the other vertical box
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- End Cap Series 80466-703-5X
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- Fold end-caps prior to sliding on bus or fold around ends of bus. Then lace wire tie thru holes in front and rear of part (fish thru horizontal bus).
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- Tighten the wire ties snuggly. Cut wire tie to desired length after installation.
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- Horizontal Bus Patch Series 80466-709-5X
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- Fold formex patches around any bare spots on the horizontal bus that are not covered by another Formex box or epoxy (such as with 25” wide bus)
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- Add rivets to secure patches to bus
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- Riser Box Series 80466-700-5X 800A Top PP-M, 1200A Top NT, 1200A Top PP-P Breaker & Switch, 2000A PP-R Top & Bottom
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- Slide rear part behind horizontal bus
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- Add sides on horizontal box and rivet side to rear
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- Rivet combined front and top piece to sides
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- Splice Series 80466-702-5X Commonly will be field installed by customer using instruction bulletin 80466-521-01
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- If splice box must be installed at the factory, then add one rear Formex part at a time to the horizontal bus. Splice bars will need to be removed Don’t fasten tabs of box yet to provide more flexibility for splice connection
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- Add splice and splice connection hardware
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- Fold tabs on all 3 boxes after all the splices boxes and splices are added
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- Fasten clear “U” shaped lexan part to front of all 3 splice boxes with wire ties to complete the assembly
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- Field installed splice requirements:
● Place in box and ship to customer: (similar to offset horizontal splices
today) ● Copper splice assemblies generated from ACE ● Insulated Splice box parts (Splice assembly number to be added to BOM by OE) ● Instruction Bulletin 80466-521-01
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- Variations of Riser Boxes provided with initial release of insulated bus
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- 1200A P frame Tie (has 2 sets of horizontal bus in same section) riser box 80466-706-51 splice boxes do not insert into riser box on either side
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- 2000A PP-R Tie Riser box 80466-706-50 (qty 2) splice boxes do not touch riser boxes
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- Hi Amp vertical bus in 20” wide section requires special vertical boxes on left and right and a special splice box on right that inserts into the vertical box.
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- High Amp Vertical bus in 25” wide Standard Vertical boxes and splice boxes (no specials)
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- 1200A Main Switch Top Riser Box 80466-700-54 Riser box and splice boxes do not touch
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- 2000A PP-R Main breaker bottom Riser box 80466-700-57 splice boxes do not insert into riser box on either side
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- 1200A NT Main Top Riser box 80466-700-58 both splice boxes insert into riser box
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- 800A MLO Top Riser box 80466-705-50 (splice box on right outside riser box but splice box on left inside riser box)
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- 1200A MLO top riser box 80466-705-51 (splice boxes are special and insert into riser box on both sides)
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- 1200A Main Breaker top 4W (25 wide) Riser box 80466-700-52 splice boxes do not touch riser box
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- 800A Main Breaker Top Riser Box 80466-700-51 splice boxes do not touch riser box
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- 1200A Main breaker top 3W Riser box 80466-700-53 splice boxes do not touch riser box
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