LEGRAND bticino RCP User manual

Rev. 02 - 04/2017
Installation for RCP
busbar systems.

RCP INSTALLATION MANUAL
Rev. 02 - 4/2017 2
INDEX
Warnings . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Good reception. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .. 7
Notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Storage of Hardware and Chemical Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Distance and dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Type of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rules for support installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Junction installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Junction IP 68-55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Fire barrier . . . . . . . .. . . . . . . . . . . . . . . . . . . . .. . . . . . . … . . . . . . . . . . . . . . . . . . .. . 31
Switchboard connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . 33
Final test and periodic inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Contact us. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

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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 IEC 11-27 and 50110-1:2004-11 (IEC 11-48)
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.

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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.
1Always pay the utmost attention when opening packages.
2To open wooden cases, in which the materials are dispatched to protect
them, use a claw hammer.
3Handle 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.
4Do 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.
5When not installing the busbar immediately upon receipt, ensure appropriate
storage for the time required before installation, following the storage
instructions.
6Do not drag the busbar along the floor. This could cause irreversible
damage.
7To correctly move busbars, cranes shall be used. These would enable to lift
the busbars from the floor very easily.
8Do not move already assembled busbars, as this would cause stress at the
point of the electric joint.

RCP INSTALLATION MANUAL
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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
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=
=
OK
Correct way to lift the busbar,
equal distance on each side

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GOOD RECEPTION
Upon receipt of the goods check the following:
1integrity of the packaging, and the goods, if delivered in a see-through
package
2consistency of the material with the Delivery Note and the packing list, if
supplied
3consistency 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
[email protected] e-mail address, including the notification form
MODZ017.
Ensure that the MODZ017 form is correctly filled in, as this will enable us to
answer more promptly to your notification. This means that all fields must be
completed, including a detailed description of the disclaim.
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.

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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.
If you require technical support intervention from us, tick the appropriate box
in the MODZ017 form. We remind you that this technical support intervention
may entail a fee (ANIE tariffs, plus out-of-pocket expenses) in case of
installation problems and/or malfunctioning or damage caused by the
customer.
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:
1For the installation only use bracketing systems supplied by BTicino, and
follow the instructions found in the catalogue or enclosed with the item.
2Only use accessories supplied by BTicino.
3Check that the element’s position coincides with what indicated on the project
drawing.
4Check that the system operating current does not exceed the product rated
current, downgrading it if required.
5Check if the busbar capacity must be downgraded (for example due to high
ambient temperature, presence of harmonics, etc.)
6Before 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.

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Distances and dimensions
During the placement of the busbar elements pay attention to distance from the
ceiling, wall and floor. Below the minimum distance:
The minimum distances are important to avoid problems during the pouring of the
cast resin junction.
These distances are applied to every RCP rating ( from 630A to 6300A ).
40mm
*400mm
**100mm
**100mm
100mm
m
Ceiling distance.
Wall distance , horizontal
installation.
Wall distance, vertical
installation.
Floor distance.
*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.
100mm
**100mm

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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:
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
4P - (3P+N) without earth - STANDARD
4P - (3P+N)+Pe1
*For more information contact us or check the RCP catalog
*For more information contact us or check the RCP catalog

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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 contact us or check the RCP catalog
*For more information contact us or check the RCP catalog
*For more information contact us or check the RCP catalog
*For more information contact us or check the RCP catalog

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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
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ASSEMBLY
NOTICE
Tighten the nuts to 50 Nm.
Tie rod

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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

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Rules for supports installation
1A support shall never coincide with a junction
2For easier leveling, always use two supports for each element.
3Always 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.
4The 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 in the corresponding locations before installing the cast resin
busbar trunking system.
6Mark the anchorage holes on the wall, using the support as a template.
7Use the appropriate anchor bolts for the weight to be supported ( see the table
below ).
8Ensure the support has the correct number of springs ( see the table below ).
MAX LOAD PER
BRACKET (KG)

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NOTICE
For the case of 5000 A (Al) and 6300 A (Cu), please, consider the following
indications.
- Vertical solution (only one):
in the picture it is shown how to install a rising main for these two ranges 5000 A (Al)
and 6300 A (Cu);
The minimum distance between two busbars is 100 mm;
- Necessary brackets:
RCP 5000 A (Al) = consider 2 brackets of 2500 A (Al)
RCP 6300 A (Cu) = consider 2 brackets of 3200 A (Cu)
The distance between two elements should be more than 100 mm

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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

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ASSEMBLY
NOTICE
All 3 types of brackets for the vertical solution will be installed as shown in the
previous picture. ( with shelf and springs / with springs / bracket only )
If you use vertical brackets without springs you must fix at first the tie rods and the
collar on the busbar and then fix the collar on the support.
Tighten the nuts to 50 Nm.
100 mm
collar
Support
Tie rod

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Junction installation
WARNINGS
1 Read all the instruction sheet ( attached with mould kit ) before starting the
installation
2Ensure that all contact surfaces are clean and free of impurities.
3Ensure that the monoblock is exactly in-between two elements to be joined.
4Do 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.
5Double check phase sequence on all terminal elements using a voltmeter.
6Before 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.
8Before casting make sure that the element corresponds to the ones shown in the
drawing (check item no. and reference present in the label).
9Do 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°.
15 Delay casting if the required ambient temperatures cannot be maintained for a
minimum of 6 hours.
16 Wash hands thoroughly with soap and warm water after work.