LEGRAND Bticino 60280036R User manual

Rev. 13 - 07/2020
Installation for RCP
busbar systems.

RCP INSTALLATION MANUAL
Rev. 13 - 07/2020 2
INDEX
Warnings ………………………........................................................................................................... 3
Handling ………………………............................................................................................................. 4
Good reception……………………..................................................................................................... 7
Notification ………………………........................................................................................................ 7
Storage …………………………………………………………………................................................................ 8
Preliminary Installation instructions ………….................................................................................. 9
Distance and dimensions ………………………......................................................................................... 10
Type of supports ………………………..................................................................................................... 12
Rules for support installation …………………………………..…................................................................. 15
Vertical installation…………………………….………………………………………………..…………….... 20
Junction installation…………………................................................................................................. 20
Disposal kit…………………….…........................................................................................................ 28
Junction IP 68-55 ………………………............................................................................................... 29
Fire barrier ……………………….......................................................................................................... 31
Switchboard connection………………………………………............................................................. 33
Final test and periodic inspections ……………………..................................................................... 34
Contact us………………………............................................................................................................. 36

RCP INSTALLATION MANUAL
Rev. 13 – 07/2020 3
WARNINGS
These instructions are provided to ensure appropriate storage, correct
installation, and efficient use of the system.
Note: carefully read these instructions upon receipt of the material and before
installing the system, and putting it into operation.
The installation must be completed by competent and suitably trained
personnel, as prescribed by CEI 11-27 and EN 50110-1 standards,
corresponding international standards, or specific applicable
standards of the individual countries of installation.
In order to guarantee the safety of personnel, the installation activities must
only be carried out with the power voltage disconnected, unless otherwise
stated.
WARNING
When working with electric systems, pay particular attention to the
risk of electric shock. Electric shocks can cause serious injury, or even
death.
NOTE: Do not tamper or perform modifications to products
manufactured by BTicino S.p.A. without written authorization by
manufacturer.
BTicino S.p.A. does not authorize any kind of repairs. All tampering, or
modifications not authorized in writing by BTicino S.p.A. will void the
product warranty.
WARNING
HAZARD OF CRUSHING, FRACTURES AND CHEMICAL EXPOSURE
 Wear personal protective equipment when handling and installing
the products (long sleeved jacket, trousers, gloves, safety shoes,
helmet, and safety glasses).
 Only personnel who have been trained in safety regulations may
work on construction sites to install cast resin busbar systems.
 Work with extreme caution and follow the instructions provided in
the manual.
 Follow all the safety instructions described in the material safety
data sheets while working with chemicals.
Failure to follow these instructions can result in death, serious
injury, or equipment damage.

RCP INSTALLATION MANUAL
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HANDLING
When handling the material, comply with the regulations for safety in the
workplace pursuant Leg. Decree No. 81 dated 09/04/2008 (Consolidated act
on safety in the workplace).
Follow the indications supplied to prevent damage to materials, or risks to
personnel.
Below are the instructions to follow for a correct material handling.
1 When opening the packaging, always pay the utmost attention and wear the
correct PPE.
2 To open wooden cases, in which the materials are dispatched to protect
them, use a claw hammer and correct personal protective equipment.
3 Handle the busbars with due care and attention. Do not subject busbars to
torsions, dents, violent impact, or sharp movements that may damage their
internal components.
4 Do not lift the busbars from their ends. This could not just damage the
busbar, but also cause injury to the personnel carrying out the operation.
When using a crane to install the busbar, use nylon slings to balance the
weight.
5 When not installing the busbar immediately upon receipt, ensure appropriate
storage for the time required before installation, following the storage
instructions.
6 Do not drag the busbar along the floor. This could cause irreversible
damage.
7 To correctly move busbars, cranes shall be used. These would enable to lift
the busbars from the floor very easily.
8 Do not move already assembled busbars, as this would cause stress at the
point of the electric joint.
9 The information regarding the disposal of the components necessary to make
the junctions are indicated in the paragraph "Disposal kit" on page 31.

RCP INSTALLATION MANUAL
Rev. 13 – 07/2020 5
Do not use belts or other system to
lift the busbar in unbalanced
position.
NOT OK
NOT OK
Do not lift the busbars from their
ends

RCP INSTALLATION MANUAL
Rev. 13 - 07/2020 6
=
=
OK
Correct way to lift the busbar,
equal distance on each side

RCP INSTALLATION MANUAL
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GOOD RECEPTION
Upon receipt of the goods check the following:
1 integrity of the packaging, and the goods, if delivered in a see-through package
2 consistency of the material with the Delivery Note and the packing list, if supplied
3 consistency of the material with the order acknowledgement details
In case of any disclaims, please inform us in writing following the instructions
found in the notifications section.
NOTIFICATIONS
In case of any disclaim, please forward your official complaint to the
[e-mail] e-mail address.
Whenever possible, with each notification, attach photos of the items affected.
When notifying that a wrong item has been received, please indicate the item
code no. found on the packaging, and the item code no. found on the part (if
possible include a photo of the labels).
In case of damaged material, attach photos of the affected part and the
packaging (if present).
In case of hidden damage (outer packing undamaged, material inside
damaged), or if the transport was the responsibility of BTicino, please contact
us immediately so that we may initiate a complaint procedure against the
freight forwarder.
We remind you that the maximum limit for a hidden damage complaint is 7
days from the receipt of goods.
We recommend that upon receiving the goods, the integrity of the packaging is
checked WITH THE FREIGHT FORWARDER PRESENT. If you find that the packaging
has suffered damage and/or collisions of varying degree, please write MATERIAL
RECEIVED DAMAGED on the Delivery Note, to enable us to initiate a complaint
procedure against the freight forwarder. If the freight forwarder stops you from
indicating on the Delivery Note that the goods have been received in damaged
condition, or from performing the visual inspection, we suggest that you DO NOT
ACCEPT THE DELIVERY. This procedure will enable us to immediately initiate the
complaint procedure against the freight forwarder, and to quickly replace any
damaged material received. If the transport is at your charge, we recommend
that you immediately issue a complaint against the freight forwarder.

RCP INSTALLATION MANUAL
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STORAGE
Below are the instructions to follow for a correct storage of the materials.
Failure to comply with the indications supplied may cause damage to the
materials, and make the product warranties void.
Store the material in a dry place, protected from weather conditions such as
rain and humidity, to prevent the formation of condensation inside the
busbars.
Also ensure that the busbars are protected from smoke, water, soil, mud, dust,
or dirt in general. Position the material in a way that prevents a physical
damage to it. We recommend to not store the busbars outside.
It is recommended that the material is stored indoor, in a dry location. In case
of storing the busbars outside for short-medium periods, ensure that it is
appropriately protected, to avoid accidental infiltration of water, which will
result in them being damaged.
The busbars can be transported and stored at a temperature between -25°C
and +55°C. Do not store the cast resin mix in direct sunlight, below 5 °C or above
40 °C. (Prior to casting, store all the junction kit components at a temperature
between 18°C and 25°C for at least 24h.)

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PRELIMINARY INSTALLATION INSTRUCTIONS
Before the installation, all material should be inspected for damage.
When installing the busbars comply with the following:
1 For the installation only use bracketing systems supplied by BTicino, and
follow the instructions found in the catalogue or enclosed with the item.
2 Only use accessories supplied by BTicino.
3 Check that the element’s position coincides with what indicated on the project
drawing.
4 Check that the system operating current does not exceed the product rated
current, downgrading it if required.
5 Check if the busbar capacity must be downgraded (for example due to high
ambient temperature, presence of harmonics, etc.)
6 Before using the junction kit checks that the resin is clear and liquid. Do not use
the resin if it is milky or crystallized. Check that the filler material/sand is dry.
7 The minimal temperature to pour the junction is 5°C.
8 Before start pouring the junction be sure that all the elements of the line are in
the correct position.

RCP INSTALLATION MANUAL
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Distances and dimensions
When positioning the elements, pay attention to the distances from the ceiling,
wall and floor. The minimum distances indicated are essential to avoid problems
when pouring the resin into the joint. The above distances apply to all current
values of the RCP busbars (from 630A to 6300A). Below are the minimum distances
Minimun
distance for
path
elements
Minimun
distance
for
exspansion
*Minimum reccomended distance to be able to pour the resin mixture in the junction
** This distance can be reduced to 80mm if the supports are not installed one beside the
other and NEVER with the solutions 5000A Al and 6300A Cu.

RCP INSTALLATION MANUAL
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Applications underground
If the busbars are installed underground, it is mandatory to install them inside a
duct.
The use of solid supports is recommended to support the busbars along its entire
length.
It is also suggested to provide a top cover.
With regard to the distances, it is mandatory to maintain the distances from the
side walls and ceiling previously seen. For ground distances, follow the quotas
below:
Minimum
distances
for path and
expansion
elements
Minimum distances
for path elements
and dilatations 5000A Al
and 6300A Cu
Minimum
distances for
path elements
and
expansions
installed
in parallel
NOTICE
Pay attention to the positioning of the solid supports to prevent them from being
positioned near the junctions where the joining castings must then be made.

RCP INSTALLATION MANUAL
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If the prescribed distances are not respected, the mold of the junctions kit can no
longer be removed after casting.
Types of supports
There are brackets for vertical and for horizontal suspension, on request we have
brackets solution for aggressive environments.
HORIZONTAL SUSPENSION BRACKET
The brackets enable sturdy installation of the busbar to the system support
structures. The recommended installation distance between brackets is 1.5 meters

RCP INSTALLATION MANUAL
Rev. 13 – 07/2020 13
ASSEMBLY
NOTICE
Tighten the nuts to 25 Nm.

RCP INSTALLATION MANUAL
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VERTICAL SUSPENSION BRACKET
In case of rising mains, thanks to pre-load springs (see page 18), these brackets
absorb the forces pressing on the busbar and direct any expansion in a precise
direction. They therefore operate as a limitation, and support the traction and
compression forces of the busbar trunking system.
A*: Depending of the quantity of requested conductors
B**: Depending of the rating of busbar

RCP INSTALLATION MANUAL
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Rules for supports installation
1 A support shall never coincide with a junction
2 For easier leveling, always use two supports for each element.
3 Always maintain a distance of at least 530 mm between the center of junction
and the support on one side of the junction to be able to assemble the junction kit.
4 The minimum distances between the installed elements, walls, and ceilings must
be taken into account while installing the supports, as shown before (
distance and dimension Paragraph ).
5 Mount all supports on the wall in the corresponding locations before installing the
cast resin busbar trunking system.
6 Mark the anchorage holes on the wall, using the support as a template.
7 Use the appropriate anchor bolts for the weight to be supported ( see the table
below ).
8 Ensure the support has the correct number of springs ( see the table below ).
MAX LOAD PER
BRACKET (KG)

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There are two different configurations:
Configuration 1 : use this configuration if the section line is between 2 an 4 meters.
The vertical bracket must be secured to the wall; the standard bracket must be
secured to shelves which can guarantee the load. The normal distance between
standard brackets should be 1.5 meters.
Configuration 2 : use this configuration if the section line is over 4 meters. The
vertical bracket must be secured to the wall; the standard bracket must be
secured to shelves which can guarantee the load. The normal distance between
standard brackets should be 1.5 meters.
Standard brackets
vertical brackets
1.Without springs
2.With springs

RCP INSTALLATION MANUAL
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ASSEMBLY
The brackets with springs for the vertical solution must be installed as shown in the
previous figure and following the indications reported in their instruction sheet. In
case vertical brackets without springs are used, it is first necessary to fix the tie rods
and the collar to the bar and then fix the collar to the support. Tighten the nuts to
30 Nm.
NOTICE
For the 5000 A (Al) and 6300 A (Cu) solutions, please take the following indications
into account.
The minimum distance between two bars is 100 mm.
- Vertical solution:
the figure shows how to carry out a vertical installation for the two solutions 5000 A
(Al) and 6300 A (Cu);
- Necessary brackets:
RCP 5000 A (Al) = consider 2 brackets of 2500 A (Al)
RCP 6300 A (Cu) = consider 2 brackets of 3200 A (Cu)
100
mm
collar
Support
Tie rod

RCP INSTALLATION MANUAL
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ACCESSORIES
If you do not use supports supplied by Bticino to fix the busbar, you must verify the
support capacity load of your supports. You can use the following technical data:
4P - (3P+N) without earth - STANDARD
4P - (3P+N)+Pe1
RCP – 4 CONDUCTROS – ALUMINIUM*
SINGLE BARS DOUBLE BARS
2 x 2500
DOUBLE BARS
Rating A 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Weight (RCP
Standard 4P)
Kg/m
29.2 35.4 35.4 37.5 46.9 57.6 72.7 91.2 110.3 72.7 72.7
Weight
(4P+PE 1)
Kg/m
29.9 36.3 36.3 38.4 47.8 58.5 74.4 93 112.1 74.4 74.4
RCP – 4 CONDUCTROS – COPPER*
SINGLE BARS DOUBLE BARS
2 x 3200
DOUBLE
BARS
Rating A 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Weight (RCP
Standard 4P)
Kg/m
41.1 50.4 50.4 65.1 71.4 89 127 141 173.6 127 127
Weight
(4P+PE 1)
Kg/m
41.9 51.3 51.3 65.9 72.3 89.9 129 143 175.4 129 129
*
For more information con
tact us or check the RCP catalog
*
For more information con
tact us or check the RCP catalog

RCP INSTALLATION MANUAL
Rev. 13 – 07/2020 19
RCP – 5 CONDUCTROS – ALUMINIUM*
SINGLE BARS DOUBLE BARS
2 x 2500
DOUBLE BARS
Rating A 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Weight (RCP
Standard 5C)
Kg/m
39 48.2 48.2 52.4 67.1 83.1 102 131 160.5 102 102
Weight
(5C+PE 1)
Kg/m
39.8 49.1 49.1 53.3 68 83.9 104 133 162.3 104 104
RCP – 5 CONDUCTROS – COPPER*
SINGLE BARS DOUBLE BARS
2 x 3200
DOUBLE
BARS
Rating A 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Weight (RCP
Standard 5C)
Kg/m
48.2 59.3 59.3 76.7 84.5 105 150 166.6 205.7 150 150
Weight
(5C+PE 1)
Kg/m
49 60.2 60.2 77.6 85.4 106 152 168.4 207.5 152 152
RCP – 3 CONDUCTROS – ALUMINIUM*
SINGLE BARS DOUBLE BARS
2 x 2500
DOUBLE BARS
Rating A 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Weight (RCP
Standard 3C)
Kg/m
23.9 28.8 28.8 30.4 38 46.6 59.1 74 89.3 59.1 59.1
Weight
(3C+PE 1)
Kg/m
24.6 29.7 29.7 31.3 38.9 47.5 60.9 75.8 91.1 60.9 60.9
RCP – 3 CONDUCTROS – COPPER*
SINGLE BARS DOUBLE BARS
2 x 3200
DOUBLE
BARS
Rating A 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Weight (RCP
Standard 3C)
Kg/m
32.4 40.2 40.2 50 57.8 71.2 97.5 114.4 138.9 97.5 97.5
Weight
(3C+PE 1)
Kg/m
33.2 41.1 41.1 50.9 58.7 72.1 99.3 116.2 139.88 99.3 99.3
*
For more information con
tact us or check the RCP catalog
*
For more
information con
tact us or check the RCP catalog
*
For more information con
tact us or check the RCP catalog
*
For more
information con
tact us or check the RCP catalog

RCP INSTALLATION MANUAL
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VERTICAL INSTALLATION
It’s possible install busbars in vertical position
JUNCTION INSTALLATION
WARNINGS
1 Read all the instruction sheet (attached with mould kit) before starting the
installation
2 Ensure that all contact surfaces are clean and free of impurities.
3 Ensure that the monoblock is exactly in-between two elements to be joined.
4 Do not knock or hit the junction block hard when you insert it. Instead, insert it
carefully to avoid damaging the elements. A rubber hammer can be used as an
aid.
5 Double check phase sequence on all terminal elements using a voltmeter.
6 Before casting, check the insulation resistance using an insulation tester with 1000
V rating. The insulation resistance for each element should be ≥ 100 MΩ.
7 Prior to casting, store all the junction kit components at a temperature between
18°C and 25°C for at least 24h.
8 Before casting make sure that the element corresponds to the ones shown in the
drawing (check item and reference present in the label).
9 Do not eat, drink, or smoke on the work site.
10 Use protective overalls, gloves, glasses, and masks.
11 In the event of unintentional spillage, clean with inert absorbent material (sand)
and store the contaminated material in an appropriate container before disposal.
12 Ensure good ventilation of working areas and avoid inhalation of vapor.
13 Before mixing resin and hardener be sure resin is clear and without
crystallization.
14 Do not cast at ambient temperature below 5°c or above 35°c.