GDA - GDR 63 - 2500 A
ASSEMBLY INSTRUCTIONS
GDA - GDR
GDA/GDR Joint part list
1 GDR straight element
2 Aluminium joint cover (IP50 or IP55)
3 Monobolt joint
4 Lateral cover
5 fixing screw
6 Hex nut
7* GDA5/GDR5 ONLY: PE continuity
8** IP55 ONLY: Plug outlet cover (to be fitted by installer)
a) Fix the hangers to the wall or channel support system etc. We suggest positioning hangers as indicated in the above diagram. Each 4m straight element will have at least 2 hangers (for elbows and Tees one hanger near the joint). WARNING: When considering the position of the busbar run in relation to walls etc you must take into account the dimensions of the end feed box being used
b) Install the 2 busbar elements (1) and bring the two together whilst ensuring the conductors are lined up (L1, L2, L3, N, PE).
c) Insert the tap off cover (4).
d) Install the aluminium joint cover (2) onto the closed part of the case, inserting the fixing screws (5).
e) Insert monobolt joint (3) and tighten with a torque wrench.
f) Cover the joint with the remaining aluminium joint cover (2) and tighten the hex nuts (6). Different covers can be supplied to provide rating of IP55.
g) Here is how the completed joint should look.
a) Fix the support and mount the feed unit adjacent to the first busbar element as explained above —we suggest you support the feed unit body with another fixing hanger and also appropriate support.
b) Unscrew four screws (1) and remove the lid.
c) Unscrew four screws (3) and remove plate (2) (when the plate is installed).
d) Terminate your cables with cable lugs (4).
e) Connect the lug to the bars (5) and to the PE contact (6) by means of screws, nuts and washers. The busbar ends are terminated in a staggered array to assist in access to bolts etc.
f) Close the lid and tighten the four screws (1).
g) Fix the end cap (7) and tighten the four screws (8).
a) Fix the hanger and mount the center feed unit adjacent to the two busbar elements as explained above. We suggest you support the center feed unit box with two fixing hangers as shown in the above diagram.
b) Unscrew four screws (1) and remove the lid.
c) Terminate your cables with cable lugs (4) after deciding your entry point into the centre feed unit and drilling the correct sized hole.
d) Connect cable lug to the bar (5) and to the Pe contact (6) by screws, nuts and washers.
e) Close the lid and tighten four screws (1).
a) Always start the assembly of rising busbar systems from the bottom (after the end feed unit or the switchboard feed unit). Mount the first element with the internal busbar clamp device and attach the hanger for vertical risers to the busbar element..
b) Fix the other part of the hanger for vertical risers to the building.
c) Insert the straight element between the two hangers and screw the four self tapping screws (2) supplied.
d) Position the hangers and remaining busbar as outlined above, using at least 2 hangers per 4m length with each hanger approx 500mm from the end of each length. CARE MUST BE TAKEN TO INSTALL THE BUSBAR LENGTHS IN THE CORRECT SEQUENCE WHEN FIRE BARRIERS HAVE BEEN FITTED. THE POSITION OF THESE IS CLEARLY INDICATED BY A RED MARK ON THE BUSBAR ELEMENT. IF FIRE BARRIERS ARE FITTED AS PART OF THE DESIGN OF A RISING MAIN EACH LENGTH WILL BE LETTER CODE (A USUALLY NEAREST TO THE END FEED UNIT).
e) For every 150 Kg of busbar, install another hanger for all vertical risers and in any event for every 12 meters of busbar. Larger rated busbars will require more vertical riser hangers.
f) Assemble the tap off boxes and the end cap to finish the installation.
c) Close the cover (2).
d) Tighten the screws (1) and check if cover (2) is well fixed to the tap off box body (7).
e) Insert tap off box in tap off unit positioned on straight element (10). Check that PE is well connected.
f) Bring the two hooks (5) close the to the busbar and fix with screws (9) to the tap off unit body (7).
a) Unscrew the cover screw (1) to open cover.
b) Drill the tap off body to accept your cable gland.
c) insert cable and carry out all electrical connections. Check that the internal tap off box must be clean and check that there is not copper filaments or other conductive objects.
d) Open the cover and insert carefully the tap off box into the tap off unit and check that PE contact (3) correspond with line PE contact (4).
e) Push the tap off box until the two lateral plastic hooks has released. The lateral hooks must hook up to the busbar edges (5).
f) Close cover and screw to secure (1).
a) Unscrew the cover screws (1) to open the cover.
b) Drill the tap off body gland plate with the hole required for your cable gland (2).
c) Insert the cable and carry out all electrical connections. Check that the internal tap off box is clean and check that there is not copper filaments or other conductive objects.
d) Open the cover, open the hooks and insert carefully the tap off box into the tap off unit and check that PE contact (4) correspond with line PE contact (5).
e) Push in the tap off box and hook up the hooks to the bus duct (6) and tighten the screws.
f) Close cover and screw to fix it (1).
FINAL INSTRUCTIONS
When the installation is completed you must check:
1) The bolts are correctly tightened
2) The line is assembled with no stress on the joints, which means keeping a maximal deviation of 3 cm from the axis per 4m length (both vertically and horizontally)
3) Carry out the necessary testing in accordance with current regulations.