Busbar trunking system
SIVACON 8PS - Installation with BD2 system
Installation Manual • 02/2011
Low-Voltage Power Distribution and
Electrical Installation Technology
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SIVACON 8PS - Installation with BD2
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Low-voltage power distribution and
electrical installation technology
Busbar trunking system
SIVACON 8PS - Installation with
BD2 system
Installation Manual
02/2011
A5E02126899-02
Introduction
1
Planning usage
2
Installation
3
Commissioning
4
Service and maintenance
5
Weights
6
Test reports
7
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG
Industry Sector
Postfach 48 48
90026 NÜRNBERG
GERMANY
A5E02126899-02
Ⓟ 02/2011
Copyright © Siemens AG 2008.
Technical data subject to change
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 3
Table of contents
1 Introduction................................................................................................................................................ 5
2 Planning usage.......................................................................................................................................... 7
2.1 Scope of delivery ...........................................................................................................................7
2.2 Receiving goods ............................................................................................................................7
2.3 Safe handling .................................................................................................................................7
2.4 Storage...........................................................................................................................................8
2.5 Packaging ......................................................................................................................................9
2.6 Handling.........................................................................................................................................9
3 Installation ............................................................................................................................................... 11
3.1 Overview ......................................................................................................................................11
3.2 Installing a busbar run..................................................................................................................12
3.3 Installation recommendations ......................................................................................................14
3.4 Attaching fixing material...............................................................................................................15
3.4.1 Typical procedure ........................................................................................................................15
3.4.2 Overview ......................................................................................................................................15
3.4.3 Bracket for horizontal installations ...............................................................................................16
3.4.4 Spring brackets for vertical installation on walls ..........................................................................18
3.4.5 Floor fixing for spring brackets.....................................................................................................21
3.5 Connecting units ..........................................................................................................................22
3.5.1 Connecting units ..........................................................................................................................22
3.5.2 Mounting the plug-in terminal.......................................................................................................23
3.5.3 Mounting the single-bolt terminal.................................................................................................25
3.6 Expansion unit..............................................................................................................................27
3.7 Flanged end .................................................................................................................................27
3.7.1 Flanged end .................................................................................................................................27
3.7.2 Installation....................................................................................................................................27
3.8 Cable feeder units........................................................................................................................29
3.9 Fire barrier....................................................................................................................................30
3.9.1 Fire barrier regulations.................................................................................................................30
3.9.2 Installing a fire barrier ..................................................................................................................30
3.10 Tap-off unit...................................................................................................................................32
3.10.1 Tap-off units from 10 A to 530 A..................................................................................................32
3.10.2 Lateral mounting of tap-off units BD2-AK04 (05, 06) in runs for horizontal installation...............33
4 Commissioning ........................................................................................................................................ 35
4.1 Steps to be performed prior to electrification of the line ..............................................................35
4.2 Electrifying the line.......................................................................................................................36
Table of contents
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4 Installation Manual, 02/2011, A5E02126899-02
5 Service and maintenance ........................................................................................................................ 37
5.1 Inspections/Expansions .............................................................................................................. 37
5.2 Service and maintenance............................................................................................................ 37
5.3 Dismantling busbar trunking system elements ........................................................................... 38
6 Weights.................................................................................................................................................... 39
7 Test reports ............................................................................................................................................. 45
7.1 Test reports ................................................................................................................................. 45
7.2 Test report for inspecting assembled joint blocks on initial assembly ........................................ 46
7.3 Test report for inspecting assembled joint blocks on subsequent assembly.............................. 47
7.4 Insulation test report.................................................................................................................... 48
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 5
Introduction 1
This manual is designed to assist you in installing, maintaining, and commissioning BD2
systems.
Note
Before installing the system on the site, you must read and follow the instructions on storage,
transport and handling.
WARNING
Only personnel who have been trained in site safety regulations (such as the wearing of
helmets, safety goggles, safety shoes, high-visibility tabards, etc.) may work on
construction sites and install busbar trunking systems. The responsible safety officer must
provide mandatory safety training.
Manual overview
This manual consists of four sections:
● General information: Brief overview of busbar trunking system components and how they
are installed
● Installation: Description of how the busbar trunking system elements are installed
● Inspection, expansions, checks: Description of how to handle the busbar trunking system
once it has been installed
● Checklists and reports
You can find more detailed technical information on BD2 systems in the planning manual
"Planning with SIVACON 8PS" (order number A5E01541017-01) and in Catalogue LV 70.
In addition, observe the installation operating instructions (AWA) for the individual busbar
elements. These contain specific details on how to install the various busbar elements. You
can find an overview of the AWAs at Installing a busbar run (Page 12)
Introduction
SIVACON 8PS - Installation with BD2 system
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SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 7
Planning usage 2
2.1 Scope of delivery
All materials are packaged and sent out together with a delivery note and AWA.
2.2 Receiving goods
● Check that the material and documentation received corresponds to the scope of your
installation project.
● Check the components supplied and ensure that they function as intended and
correspond with the information on the documentation.
● Take particular note of the information on the packaging (symbols, labels, etc.). Observe
the warning notices.
● When ordering a system, you can determine the element's installation location in the
layout on the basis of the item number on the packaging and in the project manual.
● Check that the material has been delivered in perfect condition and with no transport
damage. Use only material that is in a perfect condition.
2.3 Safe handling
Handling material
NOTICE
As with all electrical equipment, this material should be handled with care, following the
instructions listed here.
Proceed with caution and pay attention to personnel safety. Use all equipment necessary
for correct handling of the material.
Planning usage
2.4 Storage
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8 Installation Manual, 02/2011, A5E02126899-02
2.4 Storage
1. The material storage area has to meet the following requirements:
– It must be stable, secure and not on a slope.
– It must be protected against damp, extreme temperatures and water penetration.
– Effective protection against dust, water, welding sparks and other factors that could
damage the material supplied must be in place.
– For safety reasons, the area must not serve as a gangway, nor must it be used to
assemble other equipment.
2. Take note of the specific storage and packaging information featured on the packaging
(symbols, labels, etc.).
3. If possible, store the material in its transport packaging. As a rule, the elements are
supplied on pallets that must not be stacked on top of one another.
If the transport packaging is removed, store the elements in their product packaging as
follows:
– Tap-off units, junction units, flanged ends and cable feeder units must not be stacked.
– Straight trunking units:
Depending on the system, you can only stack a specific number of elements flat on
top of one another:
160 ... 400 A 10 elements, max.
BD2 aluminium system
630 ... 1000 A 5 elements, max.
160 ... 400 A 5 elements, max. BD2 copper system
630 ... 1250 A 3 elements, max.
Figure 2-1 Storing trunking units
Planning usage
2.5 Packaging
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 9
2.5 Packaging
The busbar trunking system elements are supplied with protective covers on their ends
These protect conductors, insulators and joint blocks against impact during transport and
storage on the building site. The protective foil/packaging also protects the elements from
dust and damp.
NOTICE
Do not remove the protective covers until the busbar trunking system elements are ready to
be joined. Do not remove all the protective coverings until you install the elements.
Be very careful when removing the strap retainers. The sharp edges on the strap retainers
pose a significant risk of injury when they spring off.
Note
The protective material can be recycled. When disposing of it, refer to the applicable
standards for waste disposal in the installation area.
2.6 Handling
Handling
Busbar trunking system elements can be moved using a forklift and/or suspended from
slings.
Figure 2-2 Transport using a forklift
Planning usage
2.6 Handling
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Suspension from slings
Ensure that the elements do not get damaged when transporting them with a forklift.
Use fabric slings to suspend the busbar trunking system elements.
As a rule, always attach slings to lift the elements.
NOTICE
Never use abrasive or metal slings under any circumstances.
Never suspend the elements by their conductors, as this could potentially damage them
beyond repair.
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Installation Manual, 02/2011, A5E02126899-02 11
Installation 3
3.1 Overview
1. Checking elements:
Inspect all elements on receipt and ensure that neither the conductors nor their insulation
have been damaged during handling and/or storage.
2. Correct installation sequence:
Install the elements in accordance with the planned layout as indicated in the installation
drawings.
3. Connecting elements:
– Ensure that the spacing between adjoining elements is correct.
– Establish the electrical connection between the conductors; do not place the covers on
the junction yet (see Connecting units (Page 22)).
4. Checking the assembled elements:
Check the insulation resistance of the layout. No other equipment (tap-off units, end feed
units, etc.) must be connected at this time. (see chapter Commissioning (Page 35)).
5. Closing the junctions:
Place the covers on the mechanical junctions (see Connecting units (Page 22)).
DANGER
All installation work on the busbar layout must be done before electrifying the system.
Installation
3.2 Installing a busbar run
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3.2 Installing a busbar run
Installation
The steps that must be performed to install the different BD2 system elements are described
below, along with some accessories that have been designed for this purpose.
Although the parts are listed in order of installation, we do recommend that you read the
instructions in full in order to familiarise yourself with the special characteristics of this
installation procedure. Operating instructions (AWA) are also provided with the elements.
These contain specific details on how to install the various busbar elements and must be
followed at all times.
Note
A video clip demonstrating BD2 busbar installation is also available; please contact your
SIEMENS contact for further available.
NOTICE
Plan the installation process carefully, resolving all possible difficulties prior to starting work.
Always pay attention to personnel safety and ensure that material does not become
damaged.
Overview of AWAs
Elements A5E no.
Trunking units
A5E00949701 BD2.-...-. (160 A to 400 A) Straight trunking units, L, Z, K
and T units; junctions; end caps A5E00949710 BD2.-...-. (630 A to 1250 A)
Non-standard lengths (can be
cut to length)
A5E00949750 BD2.-...-WO-AL
Movable junction unit A5E00949736 BD2-...-R
Feeder units
A5E00949738 BD2.-250-VE
A5E00949735 BD2.-400 (1000)-VE
Flanged ends
A5E00949745 BD2.-1250-VE
A5E00949737 BD2.-250-EE, BD2-250-EBAL
A5E00949734 BD2.-400 (1000)-EE, BD2-400 (1000)-
EBAL(-KR)
A5E00949746 BD2.-1250-EE, BD2-1250-EBAL, BD2-
1250-KR
End feeder units
A5E00949748 BD2.-...-EESC
A5E00949739 BD2.-400-ME Centre feeder units
A5E00949740 BD2.-1000-ME
Installation
3.2 Installing a busbar run
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 13
Tap-off units
up to 25 A A5E00949712 BD2-AK1/...
A5E00949711 BD2-AK2M2/..., BD2-AK2X/..
A5E00949713 BD2-AK02M2/..., BD2-AK02X/...
A5E00949743 BD2-AK2X/GB323, .../GB633, /GB1003
A5E00949714 BD2-AK02X/GB323(GB633), BD2-
AK03X/GB1003
A5E00949741 BD2-AK3X/GS00
A5E00949742 BD2-AK3X/GSTZ00
up to 63 A (100 A)
A5E00949715 BD2-AK03X/L.., BD2-AK03X/FS..
A5E00949716 BD2-AK04(05,06)/FS(LSD,LSM)...
A5E00949747 BD2-AK04(05,06)/SNH.
up to 530 A
A5E00949749 BD2-AK04/GB250J-.
Ancillary equipment units A5E00949744 BD2-GK...
Accessories
Fixing brackets for horizontal
layout
A5E00949709 BD2-...-BB, BD2-DSB, BD2-BD
A5E00949707 BD2-BWV, BD2-BDV
A5E00949704 BD2-BVF
Fixing brackets for vertical layout
A5E00949705 BD2-BVC
Fire barrier mounted at the
factory
A5E00949717 +BD2-S90-B.-., +BD2-S120-B.-.
IP54 covers for trunking units in
horizontal layout
A5E00949708 BD2-F., BD2-...-H.
IP55 covers for trunking units A5E00949702 BD2-FAS,BD2-...-FS(E) (IP55)
IP55 covers for tap-off units A5E00949703 BD2-AK...IP55
Installation
3.3 Installation recommendations
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3.3 Installation recommendations
Installation recommendations
Install either the whole line or parts of it, depending on how accessible and safe the layout is.
1. Start the installation by connecting the board outlets.
2. Once the distribution board has been installed, continue towards the sub-distribution
board and consumers.
3. For vertical installation, use the joint block of the top trunking unit for the feeder unit.
When the vertical laying mode is used, a certain installation position must be kept to. The
PE must always be on the right and the side with the joint block of the trunking unit must
point upwards. This ensures that
– the flange cover is fitted onto the terminal from the front and the screws can be
tightened,
– the tap-off units are not fitted in the forbidden head position.
To simplify handling, on runs between feeder units the last element to be inserted should be
a straight trunking unit. If the run ends with an end cap, fit this last.
NOTICE
Protect all elements from adverse ambient conditions and other potentially damaging
agents until installation has been completed.
Always pay attention to the safety of personnel and ensure that material does not get
damaged.
Note
Deviating from the recommendations
These installation recommendations specify the general assembly sequence for the various
busbar trunking system elements. As local conditions on the building site or within a project
can vary, deviations from these recommendations are possible. In such cases, please get in
touch with your SIEMENS contact.
Installation
3.4 Attaching fixing material
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 15
3.4 Attaching fixing material
3.4.1 Typical procedure
The BD2 busbar trunking system is generally attached to the structure of the building using
supporting structures provided on site (e.g. threaded rods, C-profiles, joists or stands for
intermediate levels) and the system-specific fixing bracket.
3.4.2 Overview
Types of fixing material
● Fixing material not available in the catalogue (plugs, beams, suspension struts, spigots,
etc.) must be provided by installation experts.
● Bracket for horizontal installations (ceiling/wall/floor brackets)
● Bracket for vertical installations (wall and floor brackets)
Mounting
In all cases, proceed as follows:
1. Attach the fixing brackets to the building via the supporting structure.
2. Raise the BD2 element and place it in the brackets without securing it.
3. Move the element until it is inserted in the adjoining joint block and place it in its final
position.
4. Secure the element.
Note
Consulting installation experts
These instructions only refer to accessories manufactured by SIEMENS. For further
information, please refer to the catalogue.
It is beyond the scope of this manual to document the vast number of different on-site
conditions that may arise. Therefore, we recommend that installation experts evaluate on-
site conditions.
WARNING
Always follow the instructions provided in the manual and the AWAs.
Installation
3.4 Attaching fixing material
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3.4.3 Bracket for horizontal installations
Ceiling bracket
● Attach the suspension bracket to the ceiling or another suitable structural support.
● Ensure that the ceiling or structural support is strong enough to hold the weight of the
system.
● Place the element to be suspended in its intended final position on the brackets, leaving
the element in a horizontal position.
● Join the adjacent elements.
Figure 3-1 Ceiling bracket, horizontal flat
Figure 3-2 Ceiling bracket, horizontal on edge
Note
When selecting plugs to use, take the ceiling material and quality as well as the weight to
be supported into account.
The surface finishes of the fixing strut and the screws must be adapted to on-site ambient
conditions.
Installation
3.4 Attaching fixing material
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 17
Trunking weights and bracket distances
Type BD2A 160 250 400 630 800 1000
Horizontal, on edge m 4 4 4 4 3.5 3
Horizontal, on edge with BD2-BD m 4 4 4 2 1.75 1.5
Horizontal, flat m 3.5 3.5 3.5 3.5 3 2.5
Weight without joint block kg/m 5.3 5.8 7.5 12.3 12.4 15.8
Type BD2C 160 250 400 630 800 1000 1250
Horizontal, on edge m 4 4 4 4 3.5 3 2
Horizontal, on edge with BD2-BD m 4 4 4 2 1.75 1.5 1
Horizontal, flat m 3.5 3.5 3.5 3.5 3 2.5 1.5
Weight without joint block kg/m 7.3 7.5 9.5 15.6 18.9 25.1 37.6
● In designing brackets, consider the following:
– The maximum capacity of fixing brackets in terms of supporting at least the weight of
the busbar trunking system plus 90 kg, in accordance with IEC/EN 60439-2
– Fixing points on the structure and suitable accessories (plugs, etc.)
● Please take the particular requirements of vertical trunking, i.e. manoeuvrability,
suspension of elements, execution, etc., into consideration.
Wall bracket
The same maximum permissible values apply to wall brackets as to ceiling brackets.
A wall bracket consists of a wall beam and a fixing bracket (type BD2-...-BB from BD2
range). The customer must provide the wall beams.
Figure 3-3 Wall bracket for BD2 elements mounted horizontally
Installation
3.4 Attaching fixing material
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3.4.4 Spring brackets for vertical installation on walls
Mounting the bracket for vertical installation
Version a: Vertical installation
bracket, mounted on flange cover
Version b: Vertical installation,
mounted on joint block, adjustable
distance from wall
Version c: Vertical installation, mounted on
trunking unit
1. Mark the anchorage holes on the wall, using the fixing bracket as a template if you so
wish.
2. Drill the holes and insert the plugs into them.
Note
The fixing bracket should be attached to the wall using plugs appropriate to the weight to
be supported and the fixing material used.
3. Attach the bracket for vertical installation with the screws.
4. Install all fixing brackets in the corresponding locations before installing the busbar
trunking run.
Installation
3.4 Attaching fixing material
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Maximum length/height of vertical BD2 busbar runs, supported by 1 fixing element BD2-BWV(-BDV),
Version b
BD2A.-...
Rated current A 160 250 400 630 800 1000 1250
Max. supported length/height at max.
load (see below)
m 11.3 10.9 7.9 5.8 5.8 5.3 —
Max. load per 3.25 m trunking unit fitted
with tap-off units
kg 50 53 74 106 108 108 —
BD2C.-...
Rated current A 160 250 400 630 800 1000 1250
Max. supported length/height at max.
load (see below)
m 10.0 9.9 7.2 5.2 4.8 4.1 3.25
Max. load per 3.25 m trunking unit fitted
with tap-off units
kg 50 53 74 106 108 108 —
Note
For higher BD2 busbar runs, use additional fixing elements.
Vertical fixing elements can support up to 175 kg and should be attached near the terminal.
Installation
3.4 Attaching fixing material
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Mounting the busbar trunking system on a bracket for vertical installation
Version a BD2 - BVF Version b BD2 - BWV Version c BD2 - BVC
AWA: A5E00949704 AWA: A5E00949707 AWA: A5E00949705
1. Position the busbar trunking system element at the desired installation location using
slings or other lifting lugs. Observe the installation instructions. In the case of version "a",
break out the intended knockouts on the flange cover.
2. Ensure that the element is correctly positioned in terms of the adjoining element.
3. Establish an electrical and mechanical connection between adjoining elements, taking
note of the relevant instructions.
4. Mount the busbar trunking system by fastening the screws onto the fixing bracket Use
nuts and washers.
5. Remove the slings or lifting lug used. The element is now supported by the fixing bracket.
Installation
3.4 Attaching fixing material
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3.4.5 Floor fixing for spring brackets
Figure 3-4 Mounting the bracket for vertical installation on the floor 1
Figure 3-5 Mounting the bracket for vertical installation on the floor 2
Perform further vertical installation as described in AWA A5E00949707.
Installation
3.5 Connecting units
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22 Installation Manual, 02/2011, A5E02126899-02
3.5 Connecting units
3.5.1 Connecting units
NOTICE
Ensure that all contact surfaces are free of impurities.
1. Remove the upper junction cover by removing the screws.
2. Depending on the amperage, a plug-in terminal (160 to 400 A) or a single-bolt terminal
(630 to 1250 A) is attached to the system.
Figure 3-6 Dismantling the joint block's flange cover
Installation
3.5 Connecting units
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Installation Manual, 02/2011, A5E02126899-02 23
3.5.2 Mounting the plug-in terminal
1. Slacken the 4 screws and remove the flange cover.
[
Figure 3-7 Slackening screws and removing flange cover
2. Insert the busbar element.
Figure 3-8 Inserting the busbar element
Installation
3.5 Connecting units
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3. Insert the cover at an angle, tighten the two screws, and pull the cover tight with the
screws on the other side. Retighten all four screws.
[
[
Figure 3-9 Attaching the cover
Installation
3.5 Connecting units
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 25
3.5.3 Mounting the single-bolt terminal
1. Slacken the four screws and remove the flange cover.
2. Insert the busbar element.
Installation
3.5 Connecting units
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3. Tighten the single-bolt terminal to the stop. Attach the flange cover.
6723
4. Tighten the four screws on the flange cover.
NOTICE
Ensure that the joint block is centred and aligned between the two elements to be
joined.
Plan the installation of the connections in advance to avoid subsequent problems.
Install the joint block with care, thus avoiding damage due to force.
Installation
3.6 Expansion unit
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3.6 Expansion unit
The BD2 system does not require an additional expansion unit. The system design ensures
expansion compensation through the joint block.
Note
The movements of the building and the fixing structures are not compensated by the BD2
system.
3.7 Flanged end
3.7.1 Flanged end
The flanged end connects the busbar trunking system to external power supplies or outputs,
both mechanically and electrically. These external power supplies are usually distribution
boards for low-voltage main distribution systems.
Figure 3-10 Flanged end
3.7.2 Installation
Preparing the non-Siemens distribution board for the connection of the flanged end
1. Align the distribution board mounting surface so that it is flat.
2. Prepare the cutouts in accordance with the AWA.
3. Reinforce the distribution board mounting surface in accordance with the weight of the
flanged end.
4. The distribution board must contain fixtures for mechanically securing the flanged end.
The flanged end's own weight must be mechanically decoupled from the electrical
connection (copper connection).
5. During this process, observe the flanged end connection dimensions and cross-section
specifications, as well as the distribution board manufacturer's specifications.
6. When connecting 5-core cables, remove the link between PE and N.
Installation
3.7 Flanged end
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Installing the flanged end in the distribution board
Following storage and transport to the installation location, you must first mechanically
secure the flanged end in the distribution board. After that, you electrically connect the
flanged end to the busbars or the circuit breaker.
Securing the flanged end mechanically
1. The power cables of the BD2...-VE must be mechanically fixed in the distribution board.
The BD2...-VE busbars must not be subjected to any additional forces.
2. Attach the flanged end to the distribution board enclosure. Observe the distribution board
specifications relating to the degree of protection. It may be necessary to use additional
sealant in order to achieve degrees of protection higher than IP 55.
Connecting the flanged end electrically
1. Remove the protective transportation devices.
2. Perform the electrical connection in accordance with the flanged end specifications
(minimum cross-sections) and the information provided by the distribution board
manufacturer. Dimension the connecting material in accordance with these specifications.
Note
You must comply with the required minimum cross-sections for the flanged end,
otherwise the maximum permissible limit temperature of 130°C cannot be guaranteed.
The design of the electrical connection determines the short circuit strength.
The designer, usually the distribution board manufacturer or constructor, is responsible
for the temperature and short circuit strength of the electrical connection.
Installation
3.8 Cable feeder units
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 29
3.8 Cable feeder units
Various feeder units are available to supply the busbar trunking system, depending on the
requirements.
End feeder units connect the system to external power sources at the ends, and centre
feeder units connect the system within the run. Phase sequence can be changed on-site by
rotating the distribution connection piece or the busbar package.
Establish the mechanical and electrical connections as described in the section entitled
"Joining elements".
Note
Short-circuit and overload protection
When a centre feeder unit is used, the left and right runs of the busbar trunking system are
supplied with power simultaneously. In this case, you must ensure that the loads are
protected against short circuits, either via an upstream protective device or by additional
protective measures, and an overload is avoided.
Installation
3.9 Fire barrier
SIVACON 8PS - Installation with BD2 system
30 Installation Manual, 02/2011, A5E02126899-02
3.9 Fire barrier
3.9.1 Fire barrier regulations
If the busbar run passes through a fire wall or ceiling, you must provide the run with a fire
barrier.
It is not permissible to mount the fire barrier via the junction (joint block).
Note
Depending on country-specific regulations, it may be necessary to attach additional fire
barrier notices directly at the installation site. Fire barrier signs required directly at the
installation site.
3.9.2 Installing a fire barrier
The following conditions must be met in order for the fire barrier to be installed (also see
illustration): The internal fire barrier must be positioned in the centre of the wall or ceiling.
Figure 3-11 Internal fire barrier (left), internal and external fire barrier (right)
Installation
3.9 Fire barrier
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 31
Besides positioning, the following points must also be observed with regard to installation of
the trunking units with fire protection:
● In the case of horizontal installation, the busbar run must be supported with a fixing
bracket at a distance of about 500 mm before and after the component.
● The opening (1) between the busbar trunking element and the component must be filled
with mineral mortar or ZZ fire barrier sealant TS90.
● The gaps between PROMATECT-H(L) plates and the busbar trunking element as well as
the structural part must be closed with ZZ fire barrier sealant TS90 (included in scope of
supply, if plates are required).
● The mortar or the ZZ fire barrier sealant TS90 must comply with the applicable
regulations for producing the fire resistance class or the wall or ceiling.
● The trunking units must be installed by a firm approved for fire protection technology.
● In Germany, the fire protection approval kit BD-2S90-ZUL-D or BD2-120-ZUL-D is
required.
2x (2x 6) = 24x PZ2
PROMATECT-H/L
ZZ
Figure 3-12 Installing fire protection
Installation
3.10 Tap-off unit
SIVACON 8PS - Installation with BD2 system
32 Installation Manual, 02/2011, A5E02126899-02
3.10 Tap-off unit
3.10.1 Tap-off units from 10 A to 530 A
1. These tap-off units are positioned at the tap-off points on the trunking. Power is tapped
via the tap-off point.
Depending on the relevant national regulations for electrical installations, these tap-off
units may either be mounted when live, or this may not be permissible. If the latter is the
case, switch the voltage off and safeguard the run against restart in accordance with on-
site regulations.
Tap-off units for 250 A or higher are fastened with an included mounting aid.
2. See the relevant AWA for more details and instructions on mounting tap-off units.
Note
You must check the necessary space requirements prior to mounting.
These tap-off units cannot be positioned at junctions above a joint block. The necessary
space requirements must be taken into account during the project design stage.
Figure 3-13 Tap-off units up to 530 A and ancillary equipment units for additional installed devices
with tap-off units up to 125 A
Installation
3.10 Tap-off unit
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 33
3.10.2 Lateral mounting of tap-off units BD2-AK04 (05, 06) in runs for horizontal
installation
If the tap-off units are mounted laterally, the mechanical load caused by the weight of the
units and the cables to be connected mean that we strongly recommend you use additional
supports (beams or brackets).
%
&
'
$
A Additional beam for tap-off unit
B Tap-off unit
C Busbar run
D Beam for busbar run
Figure 3-14 Laterally mounted tap-off units should have additional mechanical support
Additional beams in line with A and D are not available as BD2 attachment accessories and
must be procured externally.
Note
It is beyond the scope of this manual to document the huge number of different on-site
conditions that may arise. Therefore, we recommend that installation experts evaluate on-
site conditions.
Installation
3.10 Tap-off unit
SIVACON 8PS - Installation with BD2 system
34 Installation Manual, 02/2011, A5E02126899-02
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 35
Commissioning 4
4.1 Steps to be performed prior to electrification of the line
Steps to be performed prior to electrification of the line
WARNING
Live electrical equipment can cause personal injury or even death. Therefore, proceed with
extreme caution and follow these instructions carefully.
1. Insulate the busbar trunking system from the connections to transformers, switches,
meters, etc.
2. Check that all connections are fully tightened. Follow the instructions relating to tightening
torques (visual inspection with record of results).
3. Check all suspension and fixing elements. All the fixing studs and screws of the fixing
brackets must be tightened.
4. Make sure that all tap-off units and tapping equipment is disconnected (OFF).
5. Carry out an insulation resistance test to make sure that there are no short circuits or
earth failures in the system (phase - earth, phase - neutral and phase - phase). You will
observe that the readings vary depending on the length of the run, the number and size
of the conductors and the level of moisture in the atmosphere. Record the measured
values in an insulation test report.
If you obtain readings lower than 1 MΩ per 100 m (1 MΩ x 100/length of run in metres),
please contact technical support. As a rule, you must comply with the relevant country-
specific regulations (in Germany, this is a minimum of 0.5 MΩ).
6. Check that the poles on the busbar trunking system and those on the transformers,
switches, meters, etc. correspond correctly on electrification.
Commissioning
4.2 Electrifying the line
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36 Installation Manual, 02/2011, A5E02126899-02
4.2 Electrifying the line
Electrifying the line
WARNING
Live electrical equipment can cause personal injury or even death. The first time that the
busbar trunking system conductors are electrified can be dangerous. Therefore, you must
follow these instructions to the letter, along with the relevant applicable country-specific
regulations.
1. Qualified personnel must be present the first time the line is electrified. If short circuits or
earth failures caused by incorrect installation have not been previously detected, this can
lead to serious consequences once voltage is applied.
2. There must be no electrical load connected to the busbar trunking system when it is
electrified; the entire system must be checked to ensure that this is the case.
3. You must electrify the line step by step, starting at the power supply and moving towards
the loads at the end. The principal elements must be electrified first, followed by the feed
equipment and, finally, the secondary element circuits. You must act with purpose and
conviction when activating the line.
4. Once the line has been connected, consumers such as lights, contactors, heaters and
motors can be switched on.
5. Faults caused by short circuits must trigger the protective device for the feeder unit in the
manner prescribed by the official regulations. You must ensure that the system is de-
energised before you eliminate the cause of the fault. Observe the five safety rules:
1. Disconnect;
2. Safeguard against restart;
3. Ensure the system is de-energised;
4. Earth and short circuit;
5. Cover and safeguard neighbouring live parts.
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 37
Service and maintenance 5
5.1 Inspections/Expansions
Expansions
As a flexible power distribution board, the BD2 busbar trunking system can in principle adapt
to meet local needs in terms of loads and can also be expanded for new loads.
As a first stage it can be sufficient simply to plug existing or new tap-off units into existing,
unused tap-off points. If there are no more tap-off points available or if certain
buildings/areas are not supplied by the BD2, it is necessary in a second stage to extend the
BD2 run with appropriate trunking units.
5.2 Service and maintenance
The BD2 busbar trunking system is maintenance-free as long as the following conditions are
met:
● Assembly was performed in line with the valid guidelines as per AWA and the installation
manual.
● Commissioning was performed correctly and then checked and logged with insulation
measurements and visual inspections.
● There are no extreme mechanical loads due to external forces or significant impairment
due to foreign bodies or dust.
● There are no extreme stresses/loads due to water or liquids (observe the degree of
protection).
● No exposure to aggressive media (acids, etc.).
● There are no other malfunction-based loads/stresses due to short circuits, fire or gas.
This maintenance-free claim does not include devices fitted in tap-off units, feeder units or
coupling units. The instructions on their maintenance should be taken from the respective
manuals/documentation supplied with the devices.
If any of the conditions listed above cannot be guaranteed, you should consult your
SIEMENS contact directly.
Please also get in touch with your SIEMENS contact for any additional inspections that have
to be performed regularly for the erector and operator due to country-specific standards,
regulations on accident prevention and safety, as well as for special work areas.
Service and maintenance
5.3 Dismantling busbar trunking system elements
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38 Installation Manual, 02/2011, A5E02126899-02
5.3 Dismantling busbar trunking system elements
Dismantling busbar trunking system elements
It may sometimes be necessary to dismantle a length of the busbar trunking system for the
purposes of expansion or replacement.
These instructions indicate the correct procedure to follow in such a case.
WARNING
Before disconnecting, take the switching capacity of the busbar trunking system protector
element into consideration.
All power must be disconnected before you disconnect the busbar trunking system.
The header protection systems must be disconnected in order to insulate the busbar
trunking system.
WARNING
Remember to completely disconnect the line before handling.
Observe the five safety rules:
1. Disconnect
2. Safeguard against restart
3. Ensure the system is de-energised
4. Earth and short circuit
5. Cover and safeguard neighbouring live parts
NOTICE
Only qualified personnel with electrotechnical knowledge may perform the operations
indicated in this section.
1. Disconnect all power to the busbar trunking system.
2. Disconnect the busbar trunking system from the supply.
3. Fully insulate the busbar trunking system and safeguard it against restart.
4. Remove the flange cover of the relevant elements.
The first element must be removed in a transversal direction. All other elements can be
removed in a longitudinal or transversal direction.
The busbar trunking system must be handled in accordance with the AWA (see installation
instructions).
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 39
Weights 6
Trunking units
Type
(without single-bolt joint block)
BD2A-
[kg/m]
BD2C-
[kg/m]
BD2.-.-160-SB-. 5.3 7.3
BD2.-.-160-WB-. 5.3 7.3
BD2.-.-250-SB-. 5.8 7.5
BD2.-.-250-WB-. 5.8 7.5
BD2.-.-400-SB-. 7.5 9.5
BD2.-.-400-WB-. 7.5 9.5
BD2.-.-400-SO-. 7.5 9.5
BD2.-.-400-WO-. 7.5 9.5
BD2.-.-630-SB-. 12.3 15.6
BD2.-.-630-WB-. 12.3 15.6
BD2.-.-630-SO-. 12.3 15.6
BD2.-.-630-WO-. 12.3 15.6
BD2.-.-800-SB-. 12.4 18.9
BD2.-.-800-WB-. 12.4 18.9
BD2.-.-800-SO-. 12.4 18.9
BD2.-.-800-WO-. 12.4 18.9
BD2.-.-1000-SB-. 15.8 25.1
BD2.-.-1000-WB-. 15.8 25.1
BD2.-.-1000-SO-. 15.8 25.1
BD2.-.-1000-WO-. 15.8 25.1
BD2.-.-1250-SB-. — 37.6
BD2.-.-1250-WB-. — 37.6
BD2.-.-1250-SO-. — 37.6
BD2.-.-1250-WO-. — 37.6
Weights
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40 Installation Manual, 02/2011, A5E02126899-02
Junction units
Type
(without single-bolt joint block)
BD2A-
[kg/m]
BD2C-
[kg/m]
BD2.-400-L.. 7.5 9.5
BD2.-400-Z.. 7.5 9.5
BD2.-1000-L.. 15.8 —
BD2.-1000-Z.. 15.8 —
BD2.-1250-L.. — 37.6
BD2.-1250-Z.. — 37.6
BD2.-400-T.. 7.5 9.5
BD2.-400-K.. 7.5 9.5
BD2.-1000-T.. 15.8 —
BD2.-1000-K.. 15.8 —
BD2.-1250-T.. — 37.6
BD2.-1250-K.. — 37.6
Feeder units
Type
(without single-bolt joint block)
BD2A-
[kg]
BD2C-
[kg]
BD2.-250-EE 6.6 8.9
BD2.-250-VE 2.1 4.4
BD2.-400-EE 13.3 16.3
BD2.-400-ME 28.0 36.6
BD2.-400-VE 3.5 6.5
BD2.-1000-EE 14.9 22.1
BD2.-1250-EE — 27.1
BD2.-1000-VE 4.7 11.8
BD2.-1250-EE — 16.3
BD2.-1000-ME 47.0 75.5
Cable compartments
Type
(without single-bolt joint block)
[kg]
BD2-400-KR 3.1
BD2-1000-KR 5
BD2-1250-KR 5
Weights
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 41
Tap-off units
Type [kg]
BD2-AK1/S14 1.1
BD2-AK1/S18 1.15
BD2-AK1/A163 1.3
BD2-AK1/CEE165S14 1.2
BD2-AK1/CEE165A163 1.5
BD2-AK1/2CEE163S14 1.2
BD2-AK1/2CEE163A161 1.4
BD2-AK1/3SD163S14 1.4
BD2-AK1/3SD163A161 1.3
BD2-AK1/A161/1 1.1
BD2-AK1/A162 1.2
BD2-AK1/A163N 1.4
BD2-AK1/2CEE163A162 1.5
BD2-AK1/A201 1.1
BD2-AK1/A202 1.2
BD2-AK1/A203 1.3
BD2-AK1/A203N 1.4
BD2-AK1/2PC163A162 1.5
BD2-AK1/3DKS103S14 1.2
BD2-AK1/3DKS103A131 1.2
BD2-AK1/F1038-3 1.1
BD2-AK1/F1038-3-N 1.2
BD2-AK1/F140-162 1.6
BD2-AK1/A133 1.1
BD2-AK1/T25-A163 1.4
BD2-AK1/3T23-3A161 1.6
BD2-AK.2X/S18 4.1
BD2-AK.2X/S27 3.9
BD2-AK.2X/S33 4.2
BD2-AK2X/CEE325S33 5.1
BD2-AK.2M2/A323 4.4
BD2-AK2M2/CEE325A323 4.9
BD2-AK2X/CEE635S33 5.7
BD2-AK2X/2CEE165S14 4.8
BD2-AK2X/2CEE165S27 4.9
BD2-AK2M2/2SD163CEE165A163 5.6
BD2-AK2M2/2CEE165A163 5.4
BD2-AK.2M2/A323N 4.8
BD2-AK.2M2/A633 4.9
BD2-AK.2M2/A633N 5.2
Weights
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42 Installation Manual, 02/2011, A5E02126899-02
Type [kg]
BD2-AK2X/3BS133GB131 5.4
BD2-AK2X/3BS133A131 5.6
BD2-AK.2X/GB323 5.5
BD2-AK.2X/GB633 5.6
BD2-AK.2X/F1451-3(N) 5.5
BD2-AK.2X/F2258-3(N) 5.7
BD2-AK03X/LSD-DC40-N 8.5
BD2-AK03X/LSD-DC(AE)63-N 8.5
BD2-AK03X/LSD-DC80-N 8.5
BD2-AK03X/LSD-DC(AE)100-N 8.5
BD2-AK03X/LSD-DC125-N 8.5
BD2-AK03X/LSD-EM40-N 9.0
BD2-AK03X/LSD-EM63-N 9.0
BD2-AK03X/LSD-EM80-N 9.0
BD2-AK03X/LSD-EM100-N 9.0
BD2-AK03X/LSD-EM125-N 9.0
BD2-AK.3X/GS00 5.4
BD2-AK.3X/GST.00 6.7
BD2-AK.3X/GB1003 7.8
BD2-AK03X/FS125...-3 7.9
BD2-AK03X/FS125...-4 8.3
BD2-AK03X/F2258...-3N 7.5
BD2-AK03M2/A1253(N) 6.0
BD2-AK04/SNH1 30.0
BD2-AK04/FS...-3 30.0
BD2-AK04/FS...-4 30.0
BD2-AK05/SNH2 35.0
BD2-AK05/FS...-3 35.0
BD2-AK05/FS...-4 35.0
BD2-AK06/SNH3 40.0
BD2-AK04/LS.-DC(AE)... 30.0
BD2-AK04/LS.-EC... 30.0
BD2-AK05/LS.-DC(AE)... 35.0
BD2-AK05/LS.-EC... 35.0
BD2-AK06/LS.-DC(AE)... 40.0
BD2-AK06/LS.-EC... 40.0
Weights
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 43
Ancillary equipment units
Type
(without single-bolt joint block)
[kg]
BD2-GKX/F 0.4
BD2-GKM2/F 1.5
Additional equipment
Type [kg]
BD2-400-SK 3.5
BD2-400-FE 0.98
BD2-400-BB 0.44
BD2-400-HF 0.3
BD2-400-HFE 0.18
BD2-400-VF 0.2
BD2-1250-EK 6.48
BD2-1250-FE 1.28
BD2-1250-BB 0.54
BD2-1250-HF 0.52
BD2-1250-HFE 0.26
BD2-1250-VF 0.5
BD2-FFE 0.32
BD2-FF 0.6
BD2-FAS 0.22
BD2-AK...-IP55 0.07
BD2-400-FS 1.9
BD2-1250-FS 2.6
BD2-SD163 0.28
BD2-CEE163 0.26
BD2-CEE165 0.31
BD2-CEE325 0.35
BD2-AG 0.15
BD2-APO 0.09
BD2-APM 0.06
BD2-BD 0.44
BD2-BDV 4.5
BD2-BVC 0.5
BD2-BVF 0.5
BD2-BVW 1.56
Weights
SIVACON 8PS - Installation with BD2 system
44 Installation Manual, 02/2011, A5E02126899-02
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 45
Test reports 7
7.1 Test reports
The following test reports are available for commissioning and for maintenance/expansion
purposes:
● Test report for inspecting assembled joint blocks on initial assembly
● Test report for inspecting assembled joint blocks on subsequent assembly
● Insulation test report
Test reports
7.2 Test report for inspecting assembled joint blocks on initial assembly
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46 Installation Manual, 02/2011, A5E02126899-02
7.2 Test report for inspecting assembled joint blocks on initial assembly
Test report
For inspecting assembled joint blocks on initial assembly
for SIEMENS BD2 busbar systems
Customer: Type of installation:
Contact: Site:
Street: Manufacturer/Type:
City/Post code: Year of manufacture:
Consignment no.: Run number/designation:
Date: Run length:
Test starts at position no.: Drawing coord.:
Date of drawing: Sheet no.:
Drawing
coordinates
Position Joint block initial
assembly
New bolt joint(s) Other remarks Test as a whole
Place: Date: Tester's signature:
Test reports
7.3 Test report for inspecting assembled joint blocks on subsequent assembly
SIVACON 8PS - Installation with BD2 system
Installation Manual, 02/2011, A5E02126899-02 47
7.3 Test report for inspecting assembled joint blocks on subsequent
assembly
Test report
For inspecting assembled joint blocks on subsequent assembly
for SIEMENS BD2 busbar systems
Customer: Type of installation:
Contact: Site:
Street: Manufacturer/Type:
City/Post code: Year of manufacture:
Consignment no.: Run number/designation:
Date: Run length:
Test starts at position no.: Drawing coord.:
Date of drawing: Sheet no.:
Drawing
coordinates
Position Joint block subsequent
assembly
Bolt joint(s) Other remarks Test as a whole
Place: Date: Tester's signature:
Test reports
7.4 Insulation test report
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48 Installation Manual, 02/2011, A5E02126899-02
7.4 Insulation test report
Insulation test report
For inspecting assembled joint blocks on initial assembly
for SIEMENS BD2 busbar systems
Customer: Type of installation:
Contact: Site:
Street: Manufacturer/Type:
City/Post code: Year of manufacture:
Consignment no.: Run number/designation:
Date: Run length:
Meter data:
Meter manufacturer: Type: Direct measuring circuit voltage:
Climate data:
Time:
Air temperature:
Humidity:
!! There must be no loads connected when the insulation resistance is tested !!
!! The insulation resistance must be at least 1 megohm !!
System design: 4-pole ❒ 5-pole ❒
Specify measured values in megohms.
Component N-PE L1-L2 L2-L3 L3-L1 L1-PE L2-PE L3-PE L1-N L2-N L3-N L1-
PEN
L2-
PEN
L3-
PEN
We hereby confirm that the measurements given above were performed correctly.
Place: Date: Tester's signature:
www.siemens.com/lowvoltage
Subject to change without prior notice
Order No.: A5E02126899-02
© Siemens AG 2011
Siemens AG
Industry Sector
Building Technologie Division
Low Voltage Distribution
Postfach 10 09 53
93009 Regensburg
GERMANY
Service & Support
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