RITZ SIS BUS BAR SYSTEMS Installation Instructions Manual Download

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SAFETY

Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05

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Improper installation / assembly

……….

WARNING!
Risk of injury due to improper installation /
assembly!

Improperly performed installation and assembly
work can cause serious or even fatal injuries and
considerable material damage.

– Make sure there is sufficient space to work

in before starting work.

– Handle exposed, sharp-edged components

with care.

– Be aware of the dead weight of the

components.

– Keep the work area clean and tidy! Parts or

tools loosely piled or lying about are a

potential source of accidents.

– Install components properly. Adhere to the

stipulated tightening torque values for

bolts.

– Secure components so they cannot fall or

topple over.

– When performing installation and assembly

work, make sure nobody is in the danger

area.

Summary of Contents for SIS BUS BAR SYSTEMS

Page 1: ...INSTALLATION INSTRUCTIONS SIS BUS BAR SYSTEMS GERMANY HAMBURG WIRGES KIRCHAICH DRESDEN AUSTRIA MARCHTRENK HUNGARY KECSKEMÉT CHINA SHANGHAI USA HARTWELL ...

Page 2: ...rmers GmbH Mühlberg 1 97514 Oberaurach Kirchaich Germany Telephone 49 9549 89 0 Fax 49 9549 89 11 E Mail sis service ritz international com Internet www ritz international com Checked by Wolfgang Wessing Approved by Stefan Waldheuser Ritz documentation designation A2MS001EN Supersedes RITZ document SA8520 001 RITZ Instrument Transformers GmbH 2015 2020 ...

Page 3: ...ese instructions before starting any work Adherence to all the safety information and instructions specified in these instructions is a basic requirement to ensure safety whilst working COPYRIGHT The local occupational health and safety regulations and general safety rules for the installation of bus bars also apply The contents of these instructions are protected by copyright They may be used wit...

Page 4: ...AL DAMAGE 19 2 4 RESPONSIBILITY OF THE OWNER 20 2 5 STAFF REQUIREMENTS 22 2 6 PERSONAL SAFETY CLOTHING AND EQUIPMENT 23 2 7 ENVIRONMENTAL PROTECTION 25 3 TRANSPORTATION AND STORAGE 27 3 1 SAFETY INSTRUCTIONS ON TRANSPORTATION AND STORAGE 27 3 2 SYMBOLS ON THE PACKAGING 28 3 3 TYPE OF DELIVERY 29 3 4 TRANSPORT INSPECTION 29 3 5 TRANSPORTATION OF PACKAGES 30 3 6 PACKAGING 31 3 7 UNPACKING 32 3 8 STO...

Page 5: ...ION SLEEVES 72 4 7 1 3 1 ALIGNING THE CONNECTION SLEEVE PIPE 72 4 7 1 3 2 SCREWING THE SEALING FLANGE IN PLACE 73 4 7 1 3 3 EARTHING THE INDOOR CONNECTION SLEEVE 74 4 7 2 INSTALLING OUTDOOR CONNECTION SLEEVES 75 4 7 2 1 PREPARING OUTDOOR CONNECTION SLEEVES 75 4 7 2 1 1 PREPARING THE BELLOWS 75 4 7 2 1 2 PREPARATION ON BOTH SIDES 78 4 7 2 1 3 PREPARING THE CONNECTION SLEEVE PIPE 80 4 7 2 2 ESTABLIS...

Page 6: ...NTHS OR MORE 100 6 DISASSEMBLY AND DISPOSAL 101 6 1 SAFETY FOR DISASSEMBLING AND DISPOSAL 101 6 2 DISASSEMBLY 102 6 3 DISPOSAL 102 7 TECHNICAL DATA 103 8 INDEX 104 APPENDIX 106 A DRAWINGS 108 B TORQUE TABLE 109 C TEST VOLTAGES 111 D TOOL LIST 112 E CHECKING WHETHER EARTHING VIA EARTHING NUT APPLIES 114 F CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE 115 G CHECK LIST FOR ...

Page 7: ...leeve 5 Contact spring 6 Flexible connector Fig 2 Indoor connection sleeve installed example The connection of two bus bar elements Fig 2 2 inside the connection sleeve Fig 2 1 is established using flexible connectors Fig 2 4 which offset small length tolerances during installation and the thermal expansion of the bars during operation The contact springs Fig 2 3 are installed on the flexible conn...

Page 8: ... bus bar to which all bars connection sleeves and fixation must be connected and subsequently to the earth potential Design Dimensions and designs are in line with the valid regulations and standards The drawing and serial number of the respective bus bar is punched in at one end of the long side of the flange connection or on the face of round or pipe shaped connections The bus bar elements are s...

Page 9: ...H on page 129 Check list for one outdoor connection sleeve Appendix I on page 130 If special constructions such as wall penetrations transformer protection boxes tab off boxes etc are required for a project the corresponding installation instructions or installation drawings are included with the delivery as necessary 1 3 SCOPE OF DELIVERY The construction of the bus bar system is specific to the ...

Page 10: ...f the bus bar system They are listed in Appendix Tool List on page 112 1 5 TORQUE VALUES The torque values appropriate for the applications are indicated in the installation instructions in the table of torque values in Appendix B and in the individual drawings A calibrated torque spanner must be used for tightening the bolted connections After tightening the bolted connections they have to be mar...

Page 11: ... CAUTION This combination of symbol and signal word indicates a possibly hazardous situation which may cause minor or light injuries if not avoided NOTICE This combination of symbol and signal word indicates a possibly hazardous situation which may cause material damage if not avoided ENVIRONMENTAL PROTECTION This combination of symbol and signal word indicates possibly hazards for the environment...

Page 12: ...and other elements Marking Explanation Step by step instructions for actions Results of actions References to sections of these Instructions and other applicable documents Lists without a set order 2 2 PROPER USE The bus bar system is used exclusively for conveying electrical current and insulating touch voltage as per the specification defined in the order documentation Proper use also includes a...

Page 13: ...ulations of these installation instructions Never climb on or walk on the bus bar system Never suspend loads from the installed bus bar system or place objects on the bus bar system Never operate the bus bar system without insulation or earthing Refrain from performing cutting grinding and welding work on or in the vicinity of bus bar systems 2 3 RESIDUAL RISKS 2 3 1 BASIC HAZARDS WHEN PERFORMING ...

Page 14: ...e Make sure there is sufficient space to work in before starting work Handle exposed sharp edged components with care Be aware of the dead weight of the components Keep the work area clean and tidy Parts or tools loosely piled or lying about are a potential source of accidents Install components properly Adhere to the stipulated tightening torque values for bolts Secure components so they cannot f...

Page 15: ...mensions and weight of the load being lifted Do not overload fastening equipment Use edge protectors or a crossbeam when lifting sharp edged loads Position the load hook above the centre of gravity of the load During the lifting procedure observe whether the fastening equipment takes hold in the designated positions whether the transportation position remains unchanged when lifting and make sure t...

Page 16: ...or lifting platform If necessary have a second person secure the ladder Wear a safety harness as necessary Suspended loads WARNING Risk of fatal injury from suspended loads When lifting loads the loads may swing and fall This can cause serious or even fatal injuries Never stand under or in the swinging range of suspended loads Only move loads under supervision Use only approved lifting gear and fa...

Page 17: ...f electrical systems In case of damage to the insulation immediately switch off the power supply and make repairs When performing installation and assembly work on or in the vicinity of bus bars implement measures in the working position so it is and remains isolated from the voltage Follow the five safety rules 1 Isolate from the voltage 2 Secure to prevent from being switched back on 3 Make sure...

Page 18: ...acturer s material safety data sheet Wear protective gloves when applying and removing liquid lubricant Handling acetone WARNING Health hazard from acetone Acetone is highly flammable and can cause fatigue dizziness and serious eye irritation Repeated contact can cause chapped or cracked skin Avoid contact with acetone Do not eat drink or smoke when handling acetone Wash your hands before breaks a...

Page 19: ...r Adhere to the stipulated tightening torque values for bolts Never stand on or load connection sleeves and bus bars in any other way during installation Install bus bars so that they are free from mechanical strain Make sure the system is properly earthed Make sure that all installation work is carried out and completed in accordance with the specifications and information in these instructions a...

Page 20: ...tion or building interferences any change must be coordinated with RITZ Instrument Transformers GmbH beforehand and noted in the drawings Cutting grinding or welding work NOTICE Risk of material damage to the bus bar system from cutting grinding or welding work Sparks or welding spatter can cause considerable damage to the insulation of the bus bar system Welding cutting or grinding angle grinder ...

Page 21: ...er are in line with the respective current applicable rules and standards and he must adjust them if necessary The owner must clearly organize and define the responsibilities for installation and maintenance of the bus bar system The owner must make sure that all personnel involved with the bus bar system are provided with training at regular intervals and informed of the hazards The owner must pr...

Page 22: ...operate cranes on construction sites and has subsequently been assigned in writing the task of operating the crane by the owner Installation staff Installation staffs are the persons given by the owner the task of assembling and installing the bus bar system The owner must make sure the staffs employed are suitable for performing the installation work Installation staff must be able to perform the...

Page 23: ...lfill the requirements described herein are not familiar with the hazards in the installation area Unauthorised persons are therefore at risk of serious or fatal injury Therefore all work must only be carried out by appropriately qualified staff Keep unauthorised persons away from the installation area In case of doubt address the persons and instruct them to leave the installation area Stop work ...

Page 24: ...e work location is not safeguarded with a railing Put on the safety harness so the safety rope is connected to the safety harness and a fixed fastening point Provide a shock absorber as necessary Safety harnesses must only be used by specifically trained personnel Hearing protection Hearing protection is used to prevent hearing damage as a result of noise Industrial safety helmet Industrial safety...

Page 25: ... environmentally hazardous substances If environmentally hazardous substances are accidentally released into the environment take suitable measures immediately If in doubt inform the local authorities about the incident and ask about suitable measures The following harmful substances are used Highly flammable materials Acetone and alcohol are highly flammable and must not be released into the envi...

Page 26: ... Adhere to the adhesive manufacturer s material safety data sheet Lubricants such as grease and oil contain toxic substances They must not be released into the environment Disposal must be carried out by a specialist disposal company Adhere to the lubricant manufacturer s material safety data sheet ...

Page 27: ...frayed lifting gear such as rope or belts Do not place lifting gear such as ropes and belts over sharp edges and corners Do not knot or twist the lifting gear Before leaving the work station set the load down Off centre centre of gravity WARNING Risk of injury due to off centre centre of gravity Packages may have an off centre centre of gravity If fastened incorrectly the package may topple and fa...

Page 28: ...package carefully and observe whether it topples If necessary change the fastening Improper storage NOTICE Risk of material damage due to improper storage Improper storage can cause considerable material damage Always adhere to the instructions for storage as described in chapter 3 8 on page 33 3 2 SYMBOLS ON THE PACKAGING Fasten here Only attach fastening equipment fastening chain lifting belt to...

Page 29: ...en crates For sea freight they are also shrink wrapped in film Delivery is made by a freight forwarder 3 4 TRANSPORT INSPECTION Immediately upon receipt check the delivery for transport damage and to be sure it is complete Fill out the check list for storing and opening one transport box for each transport box see Appendix G on page 124 In case of transport damage which is visible externally or si...

Page 30: ...he bus bars is stated on the respective rating plates Contact RITZ Instrument Transformers GmbH if the weight of a bus bar or any other product can be not determined for some reason before lifting the product 1 Fasten ropes belts multi point harness or crossbeams to suit the installation position 2 Make sure the bus bar hangs straight Be aware it may have an off centre centre of gravity 3 Lift the...

Page 31: ...ing is designed to protect the components from trans port damage corrosion and other damage until they are installed Therefore you must not destroy the packaging and not remove it until shortly before installation How to handle packaging materials Dispose of packaging material in accordance with the valid legal rules and local regulations ENVIRONMENTAL PROTECTION Risk of environmental damage as a ...

Page 32: ...ot subjected to mechanical strain Do not remove the special packaging until shortly before installation Opening crates Personnel Installation Staff Protective Equipment Occupational Safety Clothing Industrial Safety Helmet Protective Gloves Safety Footwear Special Tool Suitable tools pull bar wood saw pliers Cordless screwdriver with Torx bits 1 Adhere to the check list for transport crates that i...

Page 33: ...al shocks or impacts Make sure the components do not become damaged or soiled Storage temperature 5 C to 50 C regarding indoor type systems type SIS and regarding plug in type bus bars e g bus bars for connecting to gas insulated switchgears other storage temperatures by request 25 C to 50 C regarding outdoor type systems type SISES other storage temperatures by request heat by maximum 2 5 C per h...

Page 34: ...Protective Gloves Safety Footwear 1 Fasten suitably dimensioned lifting equipment to the package in accordance with the size of the package Use a safety rope as necessary 2 Before transporting to the installation location check the access doors stairwell other obstruction 3 Take the package to the installation location using suitable aids e g hoist fork lift crane or lift truck 4 Have the package ...

Page 35: ...e national occupational safety measures Improper installation assembly WARNING Risk of injury due to improper installation assembly Improperly performed installation and assembly work can cause serious or even fatal injuries and considerable material damage Make sure there is sufficient space to work in before starting work Handle exposed sharp edged components with care Be aware of the dead weigh...

Page 36: ...he dimensions and weight of the load being lifted Do not overload fastening equipment Use edge protectors or a crossbeam when lifting sharp edged loads Position the load hook above the centre of gravity of the load During the lifting procedure observe whether the fastening equipment takes hold in the designated positions whether the transportation position remains unchanged when lifting and make s...

Page 37: ...ld or lifting platform If necessary have a second person secure the ladder Wear a safety harness as necessary Suspended loads WARNING Risk of fatal injury from suspended loads When lifting loads the loads may swing and fall This can cause serious or even fatal injuries Never stand under or in the swinging range of suspended loads Only move loads under supervision Use only approved lifting gear and...

Page 38: ...the stipulated tightening torque values for bolts Never stand on or load connection sleeves and bus bars in any other way during installation Install bus bars so that they are free from mechanical strain Make sure the system is properly earthed Make sure that all installation work is carried out and completed in accordance with the specifications and information in these instructions and the speci...

Page 39: ...place for installation of bus bars The connection sleeves have been cleaned on the inside The same applies for the surface of the bar in order to ensure the inside of the connection sleeve is free from dust To do so it is recommended to use acetone Take measures to isolate and keep components isolated from the voltage for the installation work o Isolate from the voltage o Secure to prevent from be...

Page 40: ...ation of the connections sleeve remove it as follows 1 Wipe dry 2 Temper to temperature of 20 to 50 C for 24 to 48 h Install sleeve after acclimatising to the ambient temperature of the installation location In case of improper storage contact RITZ Instrument Transformers GmbH immediately In the process you must check whether an electrical follow up inspection is necessary 4 4 INSTALLING FIXATION ...

Page 41: ...plate Fig 9 Overview of a fixation unit example Performing installation Personnel Installation Staff Crane Operator Protective Equipment Occupational Safety Clothing Industrial Safety Helmet Protective Gloves Safety Footwear 1 Check and measure the spacing at the installation point against the installation drawings in the documentation folder 2 Mark the drilling positions 3 Drill the holes 4 Insta...

Page 42: ...ten the fixation units to the floor ceiling or wall according to the installation drawings When installing on reinforced concrete use insulation pipes and insulation washers 7 Secure fixation units to the heavy duty dowel with torque Refer to the dowel package leaflet for torque values 8 After securing with torque usa a continuity tester to check the bolted connetions against the installation draw...

Page 43: ... used and the aluminium bracket is equipped with an insulation plate This ensures that no conductive connection is created between the fixation unit and the building Personnel Installation staff Protective Equipment Occupational safety clothing Hearing protection Industrial safety helmet Protective gloves Safety footwear When installing insulated brackets in conjunction with heavy duty dowels fix ...

Page 44: ...is made of brittle material Therefore if necessary the bolted connection between the bracket and the C profile may need to be loosened so that the insulation pipe can be centered tension free In the process the system has to be secured to prevent it from sagging using ratchet slings for example Fig 15 Tightening the nuts 5 Tighten the nuts with the respective stipulated torque as per the informati...

Page 45: ...80 mm or 100 mm depending on the specific order tolerance 20 mm In order to make a perfect connection between the bars possible the flat terminals must be aligned on both axis The spacing between bars has to be 80 mm or 100 mm depending on the specific order The exact spacing is stated in the specific order documents RITZ Instrument Transformers GmbH allows a maximum tolerance of 20 mm Fig 18 for ...

Page 46: ... to for reasons related to the performance of the installation or building interferences any change must be coordinated with RITZ Instrument Transformers GmbH beforehand and noted in the drawings 4 5 2 TIGHTENING TORQUE VALUES Adhere to the tightening torque values as per Appendix B for stainless steel bolts and nuts NOTICE Conical spring washers as per DIN 6796 must not be re used after being rem...

Page 47: ...d in the fixation clamp without being able to slip Adhere to the correct torque 4 5 5 SETTING SLIDING BEARINGS When setting the floating bearings adhere to the corresponding drawing in the documentation folder Floating bearings are marked in the drawing as Bg Set sliding bearings which are marked Bg in the installation drawing so the bus bar can slide axially in the fixation clamp without play Adh...

Page 48: ...ble Preparing one earthing cable Personnel Installation staff Protective Equipment Occupational safety clothing Protective gloves Safety footwear 1 Cut the earthing cable to the desired length using the side cutter Fig 20 Stripping the cable at one end 2 Strip the cable at one end of the cable using the cable stripper see Fig 20 Fig 21 Aligning the stripped cable and the cable lug 3 Put the stripp...

Page 49: ... to the stripped cable using the crimping tool for cable lugs Crimp one cable lug 2 to 3 times Rotate the cable after each crimp in manner that the angle is different to the crimp before see Fig 27 and Fig 28 Fig 24 Cable lug covered by shrinking sleeve 5 Shrink the shrinking sleeve for the earthing cable using a hot air gun over the cable lug like shown in Fig 29 6 Repeat steps 2 to 5 for the oth...

Page 50: ...Before closing the connection sleeves the bus bar system must be correctly aligned 4 7 1 INSTALLING INDOOR CONNECTION SLEEVES Fill out the check list for indoor connection sleeves for each indoor connection sleeve see Appendix H on page 129 4 7 1 1 PREPARING INDOOR CONNECTION SLEEVES 4 7 1 1 1 PREPARATION ON BOTH SIDES Required tools and components Fig 25 Overview of the individual parts The follo...

Page 51: ...de of the flange Fig 26 4 bevel facing away from the connection towards the O ring and the seal Fig 26 2 Fig 27 Thread for earthing 1 Drilled hole with thread 2 Drilled hole without thread The aluminium rings each have two drilled holes for the earthing one of which is threaded 2 Make sure the flanges are positioned correctly to one another so a drilled hole with thread outside flange away from th...

Page 52: ... Personnel Installation staff Protective Equipment Occupational safety clothing Industrial safety helmet Protective gloves Safety footwear Safety goggles Materials Acetone Lint free rag or paper towel NOTICE Risk of Material Damage due to Improper Cleaning Dust or metal particles in the connection sleeves can cause flashovers This can compromise safe operation of the overall system The lettering o...

Page 53: ...onnection sleeve on both sides aligning the holes in the ring over the thread holes on the ends of the connection sleeves and secure them with adhesive tape or super glue Fig 31 6 Slide the connection sleeve onto the bar positioning the connection sleeve so there is sufficient space for installation of the flexible connectors Fig 32 Fig 32 Connection sleeves on bar 7 If necessary remove the parts ...

Page 54: ...in order to ensure the inside of the connection sleeve is free from dust Use acetone and a lint free rag The following describes how flexible connectors bolts nuts washers conical spring washers and contact springs are installed The contact springs must be installed on the flexible connectors underneath the conical spring washers For Al Cu connections contact grease compound filled Al elast contac...

Page 55: ...lso 18 mm as necessary Torque spanner calibrated Grinding sponge or grinding fleece 3M red The following consumables are required for installation Acetone and a lint free rag Gleitmo 815 high performance grease paste PFISTERER contact grease compound P1 Preparing the flange connections Personnel Installation staff Protective Equipment Occupational safety clothing Safety goggles Protective gloves S...

Page 56: ...connections with a lint free rag Fig 35 Cleaning the flange connections 4 Clean the surface of flange connections with a grinding sponge or grinding fleece Fig 35 5 Remove residue from grinding and dust with acetone and a lint free rag 6 Make a note of the serial numbers and enter them into the general drawing The serial numbers of the bars are engraved on the flange connections 7 Clean all connec...

Page 57: ... grease compound 8 Using a clean brush brush the connection s contact surfaces evenly with a thin layer of PFISTERER contact grease compound P1 Fig 36 Alternatively to the clean brush fingers covered by protective gloves can be used Make sure the entire contact surface is covered The contact grease compound must not be used as mechanical grease ...

Page 58: ...ble connectors with a grinding fleece and remove any dust with acetone and a lint free rag Fig 37 2 Clean the rest of the flexible connectors with a lint free rag Applying contact grease compound Fig 38 Applying contact grease compound 3 Apply a small amount layer of PFISTERER contact grease compound P1 to the contact areas Fig 38 Fig 39 Spreading the contact grease compound 4 Use a clean brush to...

Page 59: ... contact grease compound P1 Personnel Installation Staff Protective Equipment Occupational Safety Clothing Safety Goggles Protective Gloves Safety Footwear Fig 40 Al elast contact discs filled on both sides Fill the Al elast contact discs with contact grease compound on both sides Fig 40 In the process make sure no dirt gets onto the surface and that the applied contact grease compound remains fre...

Page 60: ...t the bolts through the drilled hole in the flexible connector Fig 43 1 In the process make sure the hole for the contact springs Fig 42 5 remains free Installing the Al elast contact discs Fig 43 Flexible connector with Al elast contact disc 3 Fasten the Al elast contact discs to the underside of the flexible connectors Fig 43 2 Fig 44 Position of the Al elast contact discs 4 In the process fit t...

Page 61: ...s indicated in the drawings specific to the respective project The normal procedure of installing the flexible connectors is to assemble one side of the connector s complete with bolts washers Al elast contact discs as needed and contact springs with associated hardware and then to insert onto the flange connections of the bus bar with the contact spring mounted on the side of the flexible contact...

Page 62: ...f contact grease 10 Apply and brush on a thin even layer of contact grease compound to all contact areas on the contact springs but not on the curved tip of the contact spring the part of the spring that will make contact with the contact tube within the connection sleeve Fig 49 Preparing the bolted connection Fig 50 Inserting the conical spring washer for the contact spring 1 Conical spring washe...

Page 63: ... pushed on In the example shown in Fig 51 the connection sleeve is positioned on the left thus both contact springs are mounted on the left side of the flexible connectors It is not possible to push against the contact springs as would be the situation in the figure on the right Installing the flexible connectors from the other side Fig 52 Greasing or brushing the threads 13 From the other side of...

Page 64: ...ashers and contact springs are installed The contact springs must be installed on the flexible connectors underneath the conical spring washers For the copper to copper connection the Al elast contact discs are not used The required tools and material are shown in the following Required Tools and Material Fig 53 Overview of the individual components The following tools are required for installatio...

Page 65: ...connections Preparing the flange connections in chapter 4 7 1 2 1 on page 54 2 Prepare the flexible connectors Preparing the flexible connectors in chapter 4 7 1 2 1 on page 54 Preparing the bolts 3 Push the conical spring washers onto the bolts For the conical spring washer to properly transfer the pressure onto the bolted component the domed side of the washer must always face the bolt head or n...

Page 66: ...e connectors onto the bolts 7 Apply with a clean brush a thin layer of Gleitmo 815 grease to all of the bolt threads Fig 55 Bolted connection for the copper copper connection 8 Install the washers and nuts onto the bolts Fig 55 do not tighten Preparing the contact springs Fig 56 Grinding the contact springs 9 Clean the contact spring s contact areas with a grinding fleece Fig 56 Fig 57 Cleaning th...

Page 67: ...l spring washers into the drilled holes on the flexible connector In the process make sure that the conical spring washers are properly in place Fig 59 For the conical spring washer to properly transfer the pressure onto the bolted component the domed side of the washer must always face the bolt head or nut with the concave side of the washer towards the object s being fastened Fig 59 Installing t...

Page 68: ...lt threads 15 Slide the opposite side contact spring onto the proper bolts parallel to the first contact spring 16 Slide the conical spring washers over the threads of the bolts through the contact springs dome towards the nut concave towards the contact springs and the other appropriate washers over the remaining bolts When viewed from the side the one side will be a near mirror image of the othe...

Page 69: ... page 64 Aluminium Aluminium Al Al connections are installed like Cu Cu connections as described in chapter 4 7 1 2 2 on page 64 except that the Al connection surfaces must be grinded using a steel brush instead of a grinding fleece 4 7 1 2 4 TIGHTENING THE TORQUING Personnel Installation Staff Protective Equipment Occupational Safety Clothing Industrial Safety Helmet Protective Gloves Safety Foot...

Page 70: ...olt exposed bolt threads top and face of the nut top and side of the washer and onto the flexible connector Fig 63 Fig 64 Checking the marking 1 Verify all bolted connections have been properly torqued by checking for the markings Fig 64 The marking can be used to check for a later disconnection 4 7 1 2 6 CLEANING THE CONTROLLED SYSTEMS Personnel Installation Staff Protective Equipment Occupationa...

Page 71: ...INSTALLATION Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 71 130 Fig 65 Cleaning the controlled systems Clean the controlled systems with acetone and a lint free rag Fig 65 ...

Page 72: ...ot be turned along their own axes If this is desired e g to turn the rating plate into a visually better position the connection sleeve must be first moved away from the contact springs along the bus bars to be able to turn the connection sleeve Fig 66 Positioning 1 Clean the bus bar elements in the area of the connection sleeve before moving it to prevent contaminants dirt debris from getting ins...

Page 73: ...unthreaded hole on one flange lines up with the threaded hole on the other flange Fig 68 Fig 69 Sealing flange open 2 Push the inner aluminium ring onto the aligned connection sleeve on both sides 3 Carefully push the O ring into the bevel without shifting the connection sleeve 4 Put on the outer ring with the bolts and conical spring washers and finger tighten in an alternating sequence applying ...

Page 74: ...n can cause damage during operation which can lead to injuries and even death Never stand or tread on the connection sleeve during installation Personnel Installation Staff Protective Equipment Occupational Safety Clothing Protective Gloves Safety Footwear Fig 71 Earthing on the flange 1 Attach the earthing as per the installation drawing Fig 71 2 Tighten the earthing with a bolted connection M10 ...

Page 75: ...ic drawings All the dimensions specified in the drawings must be adhered to prevent insulation damage Vertical connection sleeves must be supported by an insulated bracket If the dimensions from drawings cannot be adhered the procedure must be discussed with RITZ Instrument Transformers GmbH with regard to possible deviations before installing the connection sleeves Changes must be documented 4 7 ...

Page 76: ...Special Tool Knife The raised numbers on the outside of the bellows indicate the inner diameter of the respective step Fig 73 Bellows 1 The raised numbers on the outside of the bellows indicate the inner diameter of the respective step Fig 74 Cutting the bellows to size 2 Cut off the bellows approximately 5 mm short of the required size Fig 74 Fig 75 Bellows with protruding part 3 Remove protrudin...

Page 77: ... the knife to cut the bellows to size with a clean cut Fig 76 Fig 77 Sealing surface The result is a flat sealing surface that is free of burrs Fig 77 Fig 78 Checking the contour 5 Check that the contour of the cut is perfect Fig 78 Fig 79 Bellows fully insulated example If the contour of the bellows has been selected correctly the bellows can be installed ...

Page 78: ... are required Washers Sealing ring Bolts and nuts Personnel Installation Staff Protective Equipment Occupational Safety Clothing Protective Gloves Safety Footwear Two ring seal units are required for each outdoor connection sleeve Fig 81 Ring seal unit assembled 1 Assemble the ring seal unit as per the installation drawing In the process grease the bolts with Gleitmo 815 When assembling make sure ...

Page 79: ...t onto the bar Fig 82 Fig 82 and Fig 83 show the left hand side of the outdoor connection sleeve In this case the nuts are on the left and the earthing on the right so that the earthing for the ring seal unit is subsequently situated on the inside of the connection sleeve pipe and the ring seal unit can be secured by tightening the nuts which compresses and expands the rubber of the ring seal unit...

Page 80: ...ion sleeves can cause flashovers This can compromise safe operation of the overall system Clean all components properly before installation Principally the outdoor connection sleeve only differs from the indoor connection sleeve in that it has an additional stainless steel pipe and the associated additional earthing Fig 85 1 Fig 84 Inside view of connection sleeve pipe 1 Use acetone and a lint fre...

Page 81: ... earthed using 16 mm earthing cables Fig 86 Pressure compensation element 4 Position the pressure compensation elements in the highest possible position see also detailed drawing in the documentation folder There are two pressure compensation elements Fig 86 1 installed on each outdoor connection sleeve They serve to prevent the formation of condensate inside the connection sleeve Fig 87 Securing ...

Page 82: ... this is desired e g to turn the rating plate into a visually better position the connection sleeve must be first moved away from the contact springs along the bus bars to be able to turn the connection sleeve Fig 88 Positioning the connection sleeve pipe 1 Clean the bus bar elements in the area of the connection sleeve before moving it to prevent contaminants dirt debris from getting inside the c...

Page 83: ...door connection sleeve as per the installation drawing in the documentation folder Fig 90 It is imperative to install the earthing cable before the connection sleeve is pushed onto the bar The 50 mm earthing cable inside of the sleeve is only necessary when earthing of the bus bar via earthing nut applies to check this see Appendix E on page 114 The two ring seal units are always earthed using 16 ...

Page 84: ...el Installation Staff Protective Equipment Occupational Safety Clothing Safety Goggles Protective Gloves Safety Footwear Fig 94 Ring seal unit open 1 After connecting the inner earthing on the bar Fig 94 2 only when earthing of the bus bar via earthing nut applies to check this see Appendix E on page 114 push the connection sleeve into its final position 2 Push the ring seal units Fig 94 3 into th...

Page 85: ...the width of the visible sealing ring around the bus bar is consistent Fig 96 Marking 6 Mark the bolts with a red paint pen Fig 96 Fig 97 Protective caps 7 Put on the plastic caps This will prevent the protruding thread of the mushroom head bolts from damaging the bellows Fig 97 Fig 98 Hose clamps 8 Pull the bellows over the connection sleeve pipe and secure with the hose clamps Fig 98 One small h...

Page 86: ... during installation Aluminium conductors achieve a good contact between the connection surfaces if the non conductive oxide layer is removed crossways with a clean fine wire brush or Scotch Brite immediately before bolting in place and the oxidation is prevented from returning with a thin layer of contact grease neutral petroleum jelly 4 8 2 INSTALLATION WITH AL ELAST CONTACT DISCS In addition to...

Page 87: ...ck washers must not be used 7 Install the bolted connections as per the installation drawing 8 Tighten the bolted connection with a torque spanner When doing so adhere to the tightening torque values in Appendix B 9 Mark the checked bolts with a red paint pen 4 8 3 INSTALLATION WITH CONICAL SPRING WASHER Also adhere to the installation drawing in the documentation folder The contact grease compoun...

Page 88: ...alled earthing Errors when installing the earthing can cause serious or even fatal injuries and considerable material damage The forming of loops within the earthing can cause induction voltage within the earthing system If the bus bar system earthing is incomplete the bus bar system will be destroyed Only allow trained installation staff to carry out earthing work Only connect the earthing as per...

Page 89: ...00 1 which is installed as a transport securing device in the earthing bolt connection on the bus bar must not be removed until shortly before installation of the earthing connection on the bus bars The bolt is only used as a transport securing device and must not be used to bolt the earthing connections in place 2 Remove the protective bolt from the earthing Fig 100 1 3 Earth the bus bar fixation...

Page 90: ...c illustration of the earthing options Fig 102 Protective bolt for the bus bar earthing connection point during shipping The red protective bolt Fig 102 1 which is installed as a transport securing device in the earthing bolt connection on the bus bar must not be removed until shortly before installation of the earthing connection on the bus bars The bolt is only used as a transport securing devic...

Page 91: ...ce more visual inspection 4 9 2 WHEN EARTHING VIA EARTHING NUT DOES NOT APPLY 4 9 2 1 REGARDING INDOOR BUS BAR SYSTEMS Parallel Earthing Personnel Installation Staff Protective Equipment Occupational Safety Clothing Safety Goggles Protective Gloves Safety Footwear The earthing is stipulated in the respective earthing diagram However the earthing ultimately has to be laid to adapt the local conditi...

Page 92: ...ix B on page 109 for the torque list Mark the connection that it was tightened with torque see Fig 105 7 Check the bolt connections for earthing to make sure they are firmly locked and mark them with a red paint pen to indicate they have been tightened with torque see Fig 105 Individual Earthing Personnel Installation Staff Protective Equipment Occupational Safety Clothing Protective Gloves Safety...

Page 93: ...om the general drawings in the documentation folder 2 Earth the bus bar fixation as per the earthing diagram 3 Earth outdoor connections sleeves as described in the chapter 4 7 2 4 EARTHING THE OUTDOOR CONNECTION SLEEVE on page 83 4 Make sure that the accessories flanges protective cabinets etc are earthed in accordance with the earthing diagram Fig 106 Positioning the earthing clamp 5 Position th...

Page 94: ... 10 FINAL INSPECTION 4 10 1 VISUAL INSPECTION AND FILLING OUT THE CHECK LISTS Personnel Installation Staff Protective Equipment Safety Goggles Protective Gloves Safety Footwear 1 Once installation of the entire bus bar system has been completed perform a visual inspection In the process the following is particularly important Damage to the bus bar surface All earthing connections are correct indiv...

Page 95: ...d Insulated bushings for alternating voltages above 1000 V This test is performed at the Ritz factory for all bus bar elements and connection sleeves Personnel Qualified Electrician Protective Equipment Safety Goggles Protective Gloves Safety Footwear The following routine tests are performed as per IEC 60137 1 Measurement of dielectric dissipation factor tan δ and capacitance at ambient temperatu...

Page 96: ... a high voltage test as per the valid standard Because it is a repeated test only perform this test at 85 of the standard AC power frequency test voltage 4 10 2 2 PERFORMING AN AC OR VLF VOLTAGE TEST Personnel Qualified Electrician Protective Equipment Safety Goggles Protective Gloves Safety Footwear Special Tools Test devices Barrier Duration of AC test 1 minute at rated frequency 50 or 60 Hz Dur...

Page 97: ...10 3 ATTACHING THE RATING PLATES Personnel Installation Staff Protective Equipment Protective Gloves Safety Footwear Every bus bar is fitted with a rail or the rating plate is included loose with the delivery On completion of installation glue the rating plate to the bus bar in a visible position ...

Page 98: ...connections can be tested on different temperature rise compared to the other phases using an infrared camera If connections are opened due to any reason please refer to the SIS Installation Instructions for correct torques Attention Generally do not torque Pfisterer Al elast contact discs and screw connections twice 5 2 OFFSHORE Personnel Installation Staff Protective Equipment Safety Goggles Pro...

Page 99: ...he two opposite openings of the two pressure release valves of every outdoor connection sleeve using a water injection with water containing salt equal or less than drinking water like shown in Fig 108 and Fig 109 The water flow of the water injection should be min 1 ml sec and max 3 ml sec when using an injection with an inner diameter of the die of 1 mm When using injections with smaller or bigg...

Page 100: ...ained in chapter 4 7 1 on page 50 There are two options to perform this check for outdoor connection sleeves SISES First option is to remove the pressure compensation element highlighted red in Fig 110 and to perform the check by means of an endoscope Reassemble the pressure compensation element after the check Second option is to release the bellow and the ring seal unit on one side of the sleeve...

Page 101: ...ve with voltage 4 Earth and short circuit 5 Cover or section off neighbouring parts which are live with voltage Improper Disassembly WARNING Risk of injury from improper disassembly Stored residual energy sharp edged components points and corners on bus bar systems or the tools required can cause injuries Before starting work make sure there is sufficient space Handle exposed sharp edged component...

Page 102: ...th safety and environmental protection 6 3 DISPOSAL Recycle dismantled components Scrap metals Recycle plastic elements Sort other components by material properties and dispose of them separately ENVIRONMENTAL PROTECTION of environmental damage as a result of incorrect disposal Incorrect disposal can cause environmental hazards Have electric waste and electronics components disposed of by approved...

Page 103: ...TECHNICAL DATA Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 103 130 7 TECHNICAL DATA Refer to the order documents for the technical data of the bus bar system ...

Page 104: ...door connection sleeve Parallel see Parallel earthing see Parallel earthing see Parallel earthing Electrical tools 112 Environmental Protection Adhesives 25 Highly flammable materials 25 Insulation system 25 Lubricants 26 F Final Inspection Check lists 94 Performing a high voltage test see High voltage test Visual inspection 94 Fixation unit 42 Fixed bearings 47 Flange connections 55 Flexible conn...

Page 105: ...ad bearing and fastening equipment 15 Scope of Delivery 9 Service 3 Short Description 7 Sliding bearings 47 Staff 22 Storage 33 Subassembly drawing 9 Symbols in these instructions 11 on the packaging 28 System of bills of material 10 T Technical Data 103 Tools Auxiliary see Auxiliary tools Electrical see Electrical tools Hand held see Hand held tools List 40 112 Measurement see Measuring tools Tor...

Page 106: ...APPENDIX Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 106 130 APPENDIX ...

Page 107: ...9 C TEST VOLTAGES 111 D TOOL LIST 112 E CHECKING WHETHER EARTHING VIA EARTHING NUT APPLIES 114 F CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE 115 G CHECK LIST FOR STORAGE AND OPENING OF A TRANSPORT BOX EXAMPLE 124 H CHECK LIST FOR ONE INDOOR CONNECTION SLEEVE EXAMPLE 129 I CHECK LIST FOR ONE OUTDOOR CONNECTION SLEEVE EXAMPLE 130 ...

Page 108: ...PENDIX Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 108 130 A DRAWINGS See installation drawings specific to the respective project which are included in the scope of delivery ...

Page 109: ...M8 16 M10 30 M12 60 M14 100 M16 120 M20 420 Fixation Clamps MA Nm See order documentation Heavy Duty Dowel MA Nm See packaging or packaging leaflet Lindapter Beam Clamp MA Nm M12 80 T bolt MA Nm M12 60 Sealing Flange MA Nm M8 16 Electrical connections All electrical connections except for earthing MA Nm M10 43 M12 75 M14 100 M16 120 M20 275 ...

Page 110: ...S Bus Bar Systems A2MS001EN revision R05 110 130 Electrical connections Earthing except for earthing nut MA Nm M8 16 M10 30 Earthing earthing nut MA Nm M10 20 See Appendix E on page 114 to check whether earthing via earthing nut applies or not ...

Page 111: ...st voltage Upr kV RMS values Specifications are based on IEC 3 6 8 5 60071 1 7 2 17 50 60 Hz Duration 1 min 12 23 8 0 1 Hz Duration 15 min 17 5 32 3 24 42 5 36 59 5 40 5 72 3 52 80 6 72 5 119 DC test voltage Highest voltage for equipment Um kV RMS values DC test voltage Upr kV Specifications are based on IEC 3 6 12 60502 2 7 2 24 Duration 15 min 12 33 7 17 5 45 7 24 60 1 36 84 1 40 5 102 52 114 72...

Page 112: ...or marking 8 Chalk line 9 Plump bob 10 Fastening bracket 11 Continuity tester Electrical tools No Designation Comment 1 Hammer drill a Drill for stone concrete 2 Drill a Drill bit set for steel 3 Angle grinder a Cutting discs grinding disc 4 Jigsaw alternatively cordless saw a Saw blades 5 Industrial vacuum cleaner 6 Cordless screwdriver with bits 7 Cable drum extension 8 Hot air gun 9 Work lamps ...

Page 113: ... 16 mm 11 Cable stripper For wire 50 mm 16 mm 12 Vice mobile 13 Screw clamps 14 Pipe cutter for plastic PVC reinforced pipe 15 Plastic hammer 16 Rubber hammer 17 Steel hammer 18 Mallet 19 Screwdriver set 20 Cross head screwdriver set Auxiliary tools No Designation Comment 1 Pulley or chain hoist min up to 500 kg 2 Slings 3 Ratchet Slings Various sizes 4 Work and assembly bench 5 Grinding sponge or...

Page 114: ...30 E CHECKING WHETHER EARTHING VIA EARTHING NUT APPLIES Fig 111 unearthed earthing nut at a bus bar Fig 112 earthed earthing nut at a bus bar When the earthing via earthing nut applies every bus bar features one M10 thread directly applied to the bus bar like shown in Fig 111 and Fig 112 ...

Page 115: ...ructions for SIS Bus Bar Systems A2MS001EN revision R05 115 130 F CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE The project check list is included with the documents specific to the respective project ...

Page 116: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 116 130 ...

Page 117: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 117 130 ...

Page 118: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 118 130 ...

Page 119: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 119 130 ...

Page 120: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 120 130 ...

Page 121: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 121 130 ...

Page 122: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 122 130 ...

Page 123: ...CHECK LIST FOR INSPECTING INSTALLATION OF ONE SIS BUS BAR SYSTEM EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 123 130 ...

Page 124: ...G OF A TRANSPORT BOX EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 124 130 G CHECK LIST FOR STORAGE AND OPENING OF A TRANSPORT BOX EXAMPLE A transport box check list is attached to every transport box ...

Page 125: ...CHECK LIST FOR STORAGE AND OPENING OF A TRANSPORT BOX EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 125 130 ...

Page 126: ...CHECK LIST FOR STORAGE AND OPENING OF A TRANSPORT BOX EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 126 130 ...

Page 127: ...CHECK LIST FOR STORAGE AND OPENING OF A TRANSPORT BOX EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 127 130 ...

Page 128: ...CHECK LIST FOR STORAGE AND OPENING OF A TRANSPORT BOX EXAMPLE Installation Instructions for SIS Bus Bar Systems A2MS001EN revision R05 128 130 ...

Page 129: ...tions for SIS Bus Bar Systems A2MS001EN revision R05 129 130 H CHECK LIST FOR ONE INDOOR CONNECTION SLEEVE EXAMPLE A check list for an indoor connection sleeve is attached to the project documentation Make a copy at site of this check list for each indoor connection sleeve ...

Page 130: ...ions for SIS Bus Bar Systems A2MS001EN revision R05 130 130 I CHECK LIST FOR ONE OUTDOOR CONNECTION SLEEVE EXAMPLE A check list for an outdoor connection sleeve is attached to the project documentation Make a copy at site of this check list for each outdoor connection sleeve ...

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