Prisma Plus
Prisma Plus
Prisma Plus
Assembly Guide
System G
Preface
This guide proposes a procedure for assembling the Prisma Plus System G.
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 Plus 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.).
Merlin Gerin
Contents
Preface ........................................................................................ 1
Presentation of the components ............................................... 4
Instructions for use .................................................................... 6
Tools
Assembling and cabling tools ............................................................................... 7
Inspection tools....................................................................................................... 7
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PD390674
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20
8
17
18
22
13
11
9
14
7
16
12
19
10
15
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5
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This manual describes a procedure for assembling the Prisma Plus system G. 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
The drawings often represent the wall-mount enclosures in vertical position but it is
better to work horizontally on a table.
A) Before starting to assemble, you must first identify and sort the
components.
B) The actual assembly process, divided up into 7 stages, is organised as
follows:
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Tools
The recommended tool lists for this section are not complete, but represent the
minimum tools required to assemble, cable and inspect the Prisma Plus system
G cubicles.
DD382258
DD382164
The tool kit belonging to the assembling and cabling staff must contain at least the
following tools:
Type of assembly
Tools
b Group tools
K 1 torque wrench to tighten all electrical connections to the required torque (max.
K
K
K
K
K
torque 50 Nm).
1 set of shears to cut flexible bars.
1 punching machine for flexible bars.
1 electrical saw.
1 drill.
1 vacuum cleaner for switchboard cleaning.
DD382260
NB: When crimping the lugs, only the pliers recommended by the lug manufacturer
must be used.
Inspection tools
b Individual tools
b Group tools
K 1 control console.
K 1 dielectrometer.
K 1 Multimeter.
DD382261
DD382263
The quality inspectors basic individual tools are the same as for the assembling
and cabling staff, with in addition the few tools below:
K 1 small hinged mirror.
K 1 electrical lamp or portable lamp.
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DD382291
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, dont unpack everything
Prisma Plus
08302 08306
08303 08307
08304 08309
08305
x4
x4
ERIE
R
VISS ERMINE
T
A DE
x4
x2
IP55
04696191 AA 00
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DD382290
DD382292
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.
DD382293
Tip: The mounting hardware must be carefully associated with each wall-mount or
floor-standing enclosure.
During storage, take measures to prevent damaging component paintwork.
b Mount the pillars on the rear panel and the gussets for the floor-standing
enclosures
DD382294
DD382296
DD382295
Tip: Do not handle the rear panel of the wall-mount or floor-standing enclosure
using the pillars.
Take care to ensure the enclosure rear panel remains level during cabling
operations.
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DD382297
b Take the rear panel, pillars and the assembly manual out of the packing
b Store the rest of the packing
DD382299
DD382298
Tip: The mounting hardware must be carefully associated with each wall-mount
enclosure.
During storage, take measures to prevent damaging component paintwork.
DD382300
When coupling the enclosures, ensure that the gaskets are positioned properly.
Tip: Do not handle the rear panel of the wall-mount or floor-standing enclosure
using the pillars.
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DD382301
K With the rear busbar, the Neutral is to the left, then L1, L2, L3.
DD382302
b Store the covers of the Powerclip insulated busbar. They will be installed
once the wall-mount or floor-standing enclosure has been cabled.
DD382303
L2
N L1
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DD382304
DD382305
DD382307
Fixing
Fixed
Assembly order
b Place the device on the mounting
plate
b Install the equipped mounting
plate
Withdrawable
or plug-in
DD382306
Modular devices
Modular
system
b Define the positions of the functional unit mounting plates and install them:
K the position of a mounting plate depends on the overall dimensions of the
DD382308
K the number of modules is given in the catalogue and in the assembly manual,
K install the equipped mounting plates starting at level m0.
DD382309
b Remove the front panel without taking the front plates apart, as well as
the sides for the IP 30 wall-mount (or floor-standing) enclosure and duct
combination.
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DD381889
4 - 10 mm
4 - 10 mm
5,5 mm
12
12
16
12
16
6 mm
10 mm
6 - 16 mm
6 - 16 mm
4 mm
Additional block
Connection
principle
Connection capacity
16 mm
16
16 mm2
25 mm
2
35 mm
pozidriv n2
12
Distribloc
Power supply
6,5
2,5
6 mm2
12
1,5
4 mm2
10
10 mm2
12
16 mm2
12
pozidriv n2
Distribution
5,5 mm
Multiclip 200 A
Power supply
12
10 mm2
n6
Distribution
4 mm
Multiclip 80 A
Power supply
2
10
12
4 mm
pozidriv n2
6 mm
Distribution
3,5 mm
Tap-off blocks
insulated busbar
10
12
4 mm
4 mm
6 mm
10 mm
12
NB: The downstream device connecting cables are delivered with the Multiclip and
Distribloc.
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DD382310
devices,
K or in the switchgear zone, at the top or bottom (or on the sides for the earth
bar).
DD382245
12
6 mm2
12
5,5 mm
10 mm
12
16 mm 2
12
DD382249
DD382248
DD382250
DD382311
4 mm2
Connection principle
DD382227
Connection capacity
DD382247
DD382246
Type
10
4 mm2
DD382251
35 mm incoming terminals
for flexible or rigid cables
3 mm
Screw terminals
16 mm outgoing terminals
for flexible or rigid cables
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DD382343
DD382342
The straps are used to guide the wires. They are easy and quick to implement and
can be clipped directly onto the mounting plates.
The trunking is used to carry wires to the switchgear zone. Trunking is secured:
K to some mounting plates on specially reserved locations,
DD382344
DD382312
NB: Trunking is assembled onto its support simply by clipping on from the front.
Power cables
You need to:
b know the position of the partitions and check that they can be mounted,
b tie the "1000 V" insulation cables to the device mounting plates,
b install the tie supports complying with 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.
b Install the upstream connections
Device type
Connection in duct
DD382315
u 1600 A power
device
Connection in switchgear
zone
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Connection by cable
DD382316
DD382314
Connection by cable
Connection transfer
assembly
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Device type
Connection in switchgear
zone
DD382318
DD382317
Modular device
Connection in duct
DD382321
DD382320
DD382319
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u 160 A power
device
Connection in duct
Device type
DD382323
DD382322
DD382345
DD382325
DD382346
DD382324
Connection by cable to
Polybloc
DD382326
Connection by cable to
additional block
DD382328
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DD382328
Modular device
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DD382330
DD382329
K
K
K
K
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b Install the partial doors with cut-outs or front plates with cut-outs
accommodating devices
500
310
400
310
500
400
310
500
4 00
200
200
500
200
NB: The devices can be installed on conventional plain doors by making a cut-out.
310
200
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.
DD382278
DD382277
Tips: We recommend that you use protection devices for wiring through uprights
or to doors:
Flexible trunking
Grommet
DD382276
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DD381421
DD381418
20
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DD382332
DD382334
DD382335
INS 40/160
Modular device
DD381818
NSA 125/160
DD382306
Device
Illustration
Comments
Cabling
b Installing the distribution blocks
DD382238
Multiclip 80 A
DD382336
Multiclip 63 A
Tap-off blocks
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Illustration
Comments
DD382337
DD382231
Distribloc 125 A
et 160 A
DD382242
DD381200
Distribution
block
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PD390551
For some terminal block types, it may be necessary to replace one of the pack
enclosure modular rails by an adjustable modular rail.
K Earth terminal blocks
PD390550
DD381819
DD382251
DD382248
There are 2 earth bar types (the same as those for the IP30 wall-mount and floorstanding enclosures).
connection terminals.
Finishing
b Clean the switchboard : the procedure is the same as for the IP30 wallmount and floor-standing enclosures
b Fit the sides, top and bottom plates and front panel
b Fit the blanking plates
b Install the markers and fit the label holders
b Fit the doors.
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DD382263
For more details concerning inspections, consult the switchboard assembly and
installation guide.
DD382266
DD382261
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DD382338
enclosure,
K adjust the position of the front panel so that the front plate openings are
DD382339
b For degrees protection IP 31 and IP43, install the canopy with the top
terminal
DD382340
b Fit the doors that were not already fitted with the switchgear on the door.
DD382341
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Packing
b Compile a technical file containing a set of drawings, the device operating
manuals and the wall-mount/floor-standing enclosure assembly manuals
b Attach the adhesive drawing holder to the rear panel of the door with the
technical file
b Ensure wall-mount/floor-standing enclosure 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.).
b Pack the wall-mount or floor-standing enclosure.
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As standards and equipment change from time to time, always ask for confirmation of the information given in this
document.
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