ABB Protecta Power IV Instruction Manual

All pictures shown are for illustration purpose only
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Assembly Guidelines
Protecta Power IV
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All pictures shown are for illustration purpose only

All pictures shown are for illustration purpose only
Table of Contents
Safety Warning.............................................................................................................................................................................1
Tools Needed................................................................................................................................................................................1
Safety Warning.............................................................................................................................................................................2
Bus Stack Assembly......................................................................................................................................................................3
Incoming Pan Assembly ...............................................................................................................................................................4
Incoming Pan Assembly ...............................................................................................................................................................5
Neutral Connection Link ..............................................................................................................................................................6
Incoming Connection Links..........................................................................................................................................................7
Incoming Kit Backplate ................................................................................................................................................................8
Line Side Connector 4P Assembly................................................................................................................................................9
Line Side Connectors Kit 4P .......................................................................................................................................................11
Segregation Kit Assembly ..........................................................................................................................................................12
Vertical Stacking (Top/Bottom Extension Box).........................................................................................................................13
Horizontal Stacking (Side Extension Box)..................................................................................................................................14
Corner Extension Box.................................................................................................................................................................15
Lifting Angles..............................................................................................................................................................................16
Plinth Assembly..........................................................................................................................................................................17
Plain Side Gland Assembly.........................................................................................................................................................18
Top Gland Assembly...................................................................................................................................................................19
Blank Cover Assembly................................................................................................................................................................19
Vented Side Gland Assembly.....................................................................................................................................................20
Door Disassembly.......................................................................................................................................................................21
Wall Mounting Bracket Assembly .............................................................................................................................................22
Door Lock Replacement.............................................................................................................................................................23
Contact us...................................................................................................................................................................................25

1
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Safety Warning
ALL PRODUCT(S) MUST BE INSTALLED BY A SUITABLY COMPETENT ELECTRICIAN CONSIDERING THEIR
INTENDED USE AND IN ACCORDANCE WITH THE CURRENT EDITION OF BS 7671 (IET WIRING REGULATIONS).
Notice:
To prevent potential overheating from loose connections the installer shall check connections are
tightened to the torque levels stated in these instructions prior to energising this board. This check should
include factory made connections which may have loosened in transit.
Tools Needed
PH,PZ,Torx Screw Driver
M5,M6Hexagonal Wrench
M8 Hexagonal Key
Hammer
󱛻󱛼󱛽WARNING
▪Warning! Installation by person with electrotechnical expertise only.
▪Avoid contact with energized electrical circuits.
▪Treat all electrical components as if they are energized.
▪Disconnect all power sources.
▪Use tools with non-conducting handles.
▪Remember PPEs (Personal protective equipment).
▪Make sure that the incoming and outgoing circuit breakers are in the OFF position.
▪Follow instructions for assembly guide.
▪All connections/methods should meet all national/local electrical codes as well as company specific methods
or procedures. Failure to do so may result in damage to the equipment, and or personal injury.

2
 
Safety Warning
ALL PRODUCT(S) MUST BE INSTALLED BY A SUITABLY COMPETENT ELECTRICIAN CONSIDERING THEIR
INTENDED USE AND IN ACCORDANCE WITH THE CURRENT EDITION OF BS 7671 (IET WIRING REGULATIONS).
Notice:
To prevent potential overheating from loose connections the installer shall check connections are tightened
to the torque levels stated in these instructions prior to energising this board. This check should include
factory made connections which may have loosened in transit as shown below.
For all shown screws please check the torque
M8, T=10 Nm
M8, T=10 Nm
M10, T=20 Nm
M8, T=10 Nm
M8, T=10 Nm
M8, T=10 Nm
M10, T=20 Nm

3
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Bus Stack Assembly
1
2
Tighten the busstack to the outgoing pan assembly using the M6 screws already supplied with the panel
6 x M6x10 Posidrive Pan head
T =9 Nm

4
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Incoming Pan Assembly
1
2
Mount the back Plate on the horizontal rails
Make sure to fix the horizontal rail on to the hole that the label designates
3
4
Make sure to align the screw squared neck with the squared hole in the
Copper link
M10 Hex Nut
T = 20 Nm
M10 Spring Washer
M10 Flat Washer
M10x50 Round head square
neck bolt
4 x M5 x 10
T = 5 Nm
4 x M5 x 75
XT4 = 1.1 Nm
XT5 = 2.0 Nm
XT6 = 2.0 Nm
XT7 = 2.0 Nm
4 x M6 x 10
Pozidrive Pan head
T = 12 Nm

5
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Incoming Pan Assembly
5
6
7
8
4 x M6 x 10
Pozidrive Pan head
T = 12 Nm
M6 x 35
T = 9 Nm
M5 x 10
T = 5 Nm
M6 x 10 Pozidrive Pan
head
T = 12 Nm

6
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Neutral Connection Link
1
2
Remove the Incoming Links Shroud
Pass the flexibar underneath the incoming backplate
3
4
Connect the Flexibar to the bustack
Connect the Flexibar to the neutral bridge and insert the shroud back.

7
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Incoming Connection Links
1
XT4
2
XT5
3
XT6
4
XT7

8
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Incoming Kit Backplate
1
XT4
2
XT5
H:171.8 mm, W:140 mm, D:110.7 mm
H:209 mm, W:180 mm, D:88.2 mm
3
XT6
4
XT7
H:269 mm, W:270 mm, D:86.7 mm
H:269 mm, W:280 mm, D:41.8 mm
Breaker Fixing Holes
Breaker Fixing Holes
Breaker Fixing Holes
Breaker Fixing Holes

9
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Line Side Connector 4P Assembly
1
2
Only 4 Screws can be used for XT1, XT2, A1
XT4, XT5 fixing shall be done with 6 screw
Stacking is recommended to be started either from top or bottom
3
4
6 x M6x10 Posidrive Pan head
T =9 Nm
2 x M5x10 Posidrive Pan head
T =5 Nm

10
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Line Side Connectors Kit 3P
1
XT1 3P
2
XT2 3P
W:79 mm
W:99 mm
3
XT4 3P
4
XT5 3P
W:109 mm
W: 140 mm

11
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Line Side Connectors Kit 4P
1
XT1 4P
2
XT2 4P
W: 109 mm
W: 119 mm
3
XT4 4P
4
XT5 4P
W: 139 mm
W: 189 mm

12
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Segregation Kit Assembly
1
2
The standalone holes before and after the pattern
3
4
4 x M5 x 10
T = 5 Nm
8 x M5 x 10
T = 5 Nm
12 x M6 x 10
T = 12 Nm

13
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Vertical Stacking (Top/Bottom Extension Box)
1
2
Make sure the Gasket on Panel Top/ Bottom is pressed before tightening the
screws
3
4
Insert Plugs and Tighten the Gland Plate
Plugs can be
removed using a
screw driver
Hex Head
Screw M6x16
T = 9 Nm
Hex Serrated Nut M6
Flat Washer M6
Hex Serrated Nut M6
T= 9 Nm

14
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Horizontal Stacking (Side Extension Box)
1
2
Untighten the side gland plate
Make sure the Gasket on Panel Side is pressed before tightening the screws
3
4
Hex Head
Screw M6x16
T = 9 Nm
Hex Serrated Nut M6
Flat Washer M6
Hex Serrated Nut M6
T= 9 Nm
Hex Serrated Nut M6

15
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Corner Extension Box
1
2
Remove the top gland plate of side extension box
Remove the side gland plate of top extension box
3
4
Make sure the Gasket on Panel Side is pressed before tightening the screws
4 Screws for connecting the bottom of corner box and another 4 screws are
needed for connecting the side of corner box, total of 8 screws M6x16
Hex Serrated Nut M6
Hex Serrated Nut M6
Hex Serrated Nut M6
Flash Washer M6
Hex Head Screw
M6x16
T= 9 Nm

16
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Lifting Angles
1
Please ensure all the studs are aligned with the holes while assembling.
2
Make sure that Single lifting angles are on 45⁰from the vertical as shown above
Sealing Plugs shall be removed
using a screwdriver
Hex Nut M16
Flat Washer M16
Hex Head
Screw M16x40
T = 248 Nm

17
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Philips Head Self
tapping Screw M4
T = 2.3 Nm
Plinth Assembly
1
2
Use Screwdriver with diameter less than 7 mm
3
4
Plinth could be double stacked
Use a Mallet and
screwdriver to punch
the fixation knockout
Hex Head
Screw M6x20
Flat Washer
M6
Hex Serrated
Nut M6
T = 9 Nm
M12 Nut
M12 Flat Washer
M12 Bolt
Floor