Installation

nstallation for RCP

busbar systems.

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INDEX

Warnings ………………………........................................................... 3
Handling ………………………............................................................. 4
Handling for vertical installation…………………………….…………...7
Good reception………………………....................................................... 9
Notification ………………………............................................................. 9
Storage of Hardware and Chemical Components ………………................ 10
Installation instructions ………………………..................................... 11
Distance and dimensions ………………………........................................ 12
Type of supports ……………………….................................................... 15
Rules for support installation …………………………………..…................ 18
Junction installation………………………................................................ 22
Junction IP 68-55 ……………………….................................................... 32
Fire barrier ………………………............................................................. 33
Switchboard connection………………………………………................... 35
Final test and periodic inspections ……………………................... 36

Contact us………………………......................................................... 38

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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
ibed by IEC 11-27 and 50110-1:2004-11 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
mus
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
odifications not authorized in writing by BTicino S.p.A. will
ll 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,
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
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.

1 Always pay the utmost attention when opening packages.

2 To open wooden cases, in which the materials are dispatched to protect
them, use a claw hammer.
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.

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NOT OK

Do not use belts or other system to

lift the busbar in unbalanced
position.

NOT OK

Do not lift the busbars from their

ends

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OK

Correct way to lift the busbar,

equal distance on each side
=

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HANDLING FOR VERTICAL INSTALLATION

Assemble the collar as

shown in the image.

NOTICE

Tighten the nuts to 30 Nm

Position the element at a

height higher than the
distance between one end
and the collar

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Hook the collar (the one

farthest from the wall)
with the slings as in the
zoom

Lift the element slowly

Place the element in the correct

position.

Fix the element to the wall according

to the rules at page 21 ( “Rules for
supports installation”)

Remove the slings.

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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

ITPostVenditaZucchini@bticino.it 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:

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.

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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:

100mm
m

*400mm
**100mm

**100mm 40mm

Ceiling distance. Wall distance , horizontal Wall distance, vertical

installation. installation.
**100mm

100mm

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.

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 ).

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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*

2 x 2500
SINGLE BARS DOUBLE BARS DOUBLE BARS
Rating A 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Weight (RCP Kg/m 29.2 35.4 35.4 37.5 46.9 57.6 72.7 91.2 110.3 72.7 72.7
Standard 4P)
Weight Kg/m 29.9 36.3 36.3 38.4 47.8 58.5 74.4 93 112.1 74.4 74.4
(4P+PE 1)
*For more information contact
tact us or check the RCP catalog

RCP – 4 CONDUCTROS – COPPER*

2 x 3200
SINGLE BARS DOUBLE BARS DOUBLE
BARS
Rating A 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Weight (RCP Kg/m 41.1 50.4 50.4 65.1 71.4 89 127 141 173.6 127 127
Standard 4P)
Weight Kg/m 41.9 51.3 51.3 65.9 72.3 89.9 129 143 175.4 129 129
(4P+PE 1)
*For more information contact
tact us or check the RCP catalog

4P - (3P+N) without earth - STANDARD

4P - (3P+N)+Pe1

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RCP – 5 CONDUCTROS – ALUMINIUM*

2 x 2500
SINGLE BARS DOUBLE BARS DOUBLE BARS
Rating A 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Weight (RCP Kg/m 39 48.2 48.2 52.4 67.1 83.1 102 131 160.5 102 102
Standard 5C)
Weight Kg/m 39.8 49.1 49.1 53.3 68 83.9 104 133 162.3 104 104
(5C+PE 1)
*For more information contact us or check the RCP catalog

RCP – 5 CONDUCTROS – COPPER*

2 x 3200
SINGLE BARS DOUBLE BARS DOUBLE
BARS
Rating A 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Weight (RCP Kg/m 48.2 59.3 59.3 76.7 84.5 105 150 166.6 205.7 150 150
Standard 5C)
Weight Kg/m 49 60.2 60.2 77.6 85.4 106 152 168.4 207.5 152 152
(5C+PE 1)
*For more information contact us or check the RCP catalog

RCP – 3 CONDUCTROS – ALUMINIUM*

2 x 2500
SINGLE BARS DOUBLE BARS DOUBLE BARS
Rating A 630 800 1000 1250 1600 2000 2500 3200 4000 5000
Weight (RCP Kg/m 23.9 28.8 28.8 30.4 38 46.6 59.1 74 89.3 59.1 59.1
Standard 3C)
Weight Kg/m 24.6 29.7 29.7 31.3 38.9 47.5 60.9 75.8 91.1 60.9 60.9
(3C+PE 1)
*For more information contact us or check the RCP catalog

RCP – 3 CONDUCTROS – COPPER*

2 x 3200
SINGLE BARS DOUBLE BARS DOUBLE
BARS
Rating A 800 1000 1250 1600 2000 2500 3200 4000 5000 6300
Weight (RCP Kg/m 32.4 40.2 40.2 50 57.8 71.2 97.5 114.4 138.9 97.5 97.5
Standard 3C)
Weight Kg/m 33.2 41.1 41.1 50.9 58.7 72.1 99.3 116.2 139.88 99.3 99.3
(3C+PE 1)
*For more information contact us or check the RCP catalog

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Types of supports

There
re are brackets for vertical and for horizontal suspension, on request we have
brackets solution for aggressive environments.
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

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ASSEMBLY

Tie rod

NOTICE

Tighten the nuts to 30 Nm.

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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.
system

A*: Depending of the quantity of requested conductors

B**: Depending of the rating of busbar

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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.
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 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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NOTICE

For the case of 5000 A (Al) and 6300 A (Cu), please, consider
consider the following
indications.

- Vertical solution (only one):

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:

Standard brackets

vertical brackets

1.Without springs 2.With springs

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.

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ASSEMBLY

collar
Tie rod
100 mm

Support

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 30 Nm.

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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 no. 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°.
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.
17 Before start pouring the junction be sure that all the elements of the line are in
the correct position.

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PROCEDURE

Before starting ensure to have all the materials:

1 Resin and hardener ( ZU-65200002R / ZU-65200003R* ).

2 Filler mix and bucket ( ZU-65200001R ).
3 Mould kit with release agent.
4 Rubber hammer
5 Industrial mixer (rated 750 W or above)
6 Clamping tools ( only for vertical junction)
7 Metallic rasp or grinding stone
8 Silicone/silicone gun

*For junction casting in environment temperature between 5°C to 18°C , you have
to use the code ZU-65200003R
For junction casting in environment temperature between 18°C to 35°C , you have
to use the code ZU-65200002R

One junction kit ( resin + hardener + filler ) could be used for more than a junction,
please check the tables below:

RCP 4 CONDUCTORS JUNCTION

Number of Number of
Material Rating (A) junction per Material Rating (A) junction per
kit kit
630 2,50 800 2,50
800 2,65 1000 2,65
1000 2,65 1250 2,65
ALUMINIUM

1250 2,70 1600 2,20

COPPER

1600 2,30 2000 2,30

2000 1,90 2500 1,90
2500 1,40 3200 1,15
3200 1,15 4000 1,15
4000 1,00 5000 1,00
5000 0,70 6300 0,55

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RCP 3 CONDUCTORS JUNCTION

Number of Number of
Material Rating (A) junction per Material Rating (A) junction per
kit kit
630 3,00 800 3,00
800 3,00 1000 3,00
1000 3,00 1250 3,00
ALUMINIUM

1250 3,00 1600 2,60

COPPER
1600 2,60 2000 2,60
2000 2,15 2500 2,15
2500 1,60 3200 1,30
3200 1,30 4000 1,30
4000 1,25 5000 1,25
5000 0,80 6300 0,65

RCP 5 CONDUCTORS JUNCTION

Number of Number of
Material Rating (A) junction per Material Rating (A) junction per
kit kit
630 2,40 800 2,40
800 2,50 1000 2,50
1000 2,50 1250 2,50
ALUMINIUM

1250 2,60 1600 2,10

COPPER

1600 2,30 2000 2,20

2000 1,85 2500 1,90
2500 1,40 3200 1,10
3200 1,10 4000 1,10
4000 1,10 5000 1,00
5000 0,70 6300 0,55

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Ensure the junction kit and the mould kit are not damaged:
damaged

Apply the sealant and the release agent:

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Ensure the correct position of the RCP elements, the distance between bars must
be 40mm. Clean the bar’s surface, do not remove the surface treatment ( if
applied). Fit the monoblock between the copper or aluminum conductors from
above or below. Align it so that it extends equally on all sides.. If necessary, gently
knock the monoblock into place using a rubber hammer.
When the junction block is aligned, tighten the connecting bolt until braking up
the nut.

NOTICE

Dry possible wet parts with hot air at a temperature not higher than 80 °C and
remove residues with mild reagents (e.g. trichlorethene) not corroding or creating
abrasion on surface treatment (zinc, tin, silver coating) or on contact surface
(copper).

Blocks
locks correctly adhere on bars (use a 0.05mm thickness gauge), i.e. conducting
parts fully make contact.

Insulation test at 1000V, with minimum value of 100 MOhm, for each element. The
insulation test has to be carried out between phases, between phases and neutral,
and between every single phase and the earth ( when required ). If results are
unsuccessful, identify the element and in case replace it or carry out further tests.

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Place the mould on the mechanical connection and secure it with the two C-
C
profiles.

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In vertical junction use a bracket to keep the mould in the correct position (
horizontal suspension bracket - edgewise installation )

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If you do not have a bracket or you prefer it, you can use two blocks
block and one
clamping tool to keep the mould
mou in the correct position (in the second case make
sure that the blocks do not damage the busbar's surface. We recommend using
wooden blocks for this solution.):
solution.)

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Mix all the component, checks the correct sequences in the following pictures.
pictures If
the
e temperature is below 18°C you must add an additive ( ZU-65200003R
65200003R ) to the
resin during the operation 1.

During this process use mask with protection grade FFP1.

Pour the mix into the mould carefully. Use a rubber hammer to help the air bubbles bubble
go away.. Check after 20 mins.
mins If the resin has settled and it is not in the correct
level (it is visibly underneath the brim of the cast molds), pour again up to the brim.

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Allow
ow the cast resin mix to harden then, remove the mould and use
u a metallic rasp
to clean the edges.

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Junction IP68-IP55
The RCP busbar system is compatible with SCP
busbar system.
When you connect RCP with SCP the
protection grade becomess IP55. The junction is
very easy to install:

1 Check the correct position of RCP and SCP

( see the picture below ).
2 Check that the monoblock is the one
already preassembled in the SCP element. It is
very important to check this due to the fact
that the SCP's monoblock might be bigger
than the RCP monoblock for the same rating.
3 Fit the monoblock between the copper or
aluminum conductors from above or below.
below If
necessary, gently knock the monoblock into
place using a rubber hammer.
4 When the junction block is aligned, tighten
the connecting bolt until break up the nut.
5 Place the metallic caps to adapt the SCP’s
shape
6 Place the metallic cover over the junction and then tighten the screws.
screws

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Fire barrier
The fire barrier kit is composed of one part, through the wall.
The total length is 550 mm.

In the fire barrier kit there are 12 panels of fire resistant material, screw and mastic
to fix the fire resistant sheet to the wall and to the RCP.

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Once the barriers are assembled with screws, fill all the joints between panels with
the promaseal paste and then work it with a putty knife to obtain a smooth and
homogeneous aspect.

*Check the RCP catalog for L and H dimensions

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Switchboard connection
On switchboard connections verify that:

1 the air distances between bars with different potentials are over 40 mm wide. If it
is not the case, contact Eng. Dept. Zucchini Brand to evaluate the employment of
correct insulating material.
2 the torque moment of connecting screws is correct (required values: 85 Nm
for M12, 100 Nm for M14, 120 Nm for M16, 170 Nm for M18, 25 Nm for M8
and 50 Nm for M10).

The above mentioned inspections have to be carried out by personnel with a

proper technical background and with controlling function/responsibility in the
installation activities.

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Final test and periodic inspections

FINAL TEST

Insulation test at 1000V, with minimum value of 1 MOhm, for the line. The insulation
test has to be carried out between phases, between phases and neutral, and
between every single phase and the earth ( when required ).

After having run the plant at the maximum working current, and let it work for at
least 6 hours, carry out a thermal test. Stick labels on the hottest parts and mark
them with progressive numbers to identify the element. Carry out the thermal test
again on the labels. Fill the attached form with the measured values, together with
ambient temperature and working current.
Thermal tests can be carried out with contact temperature sensors, with optical
pyrometers or thermal cameras.

PERIODIC INSPECTIONS

After having run the plant at the maximal working current for at least 6 hours,
carry out a thermal test, taking in particular consideration the points where
labels had been sticked during installation. Fill in the attached
form with the measured values, together with ambient temperature and
working current. If the measured temperature (DT) is 55 K or 15 K higher than the
temperature measured during installation, get in contact with Customer Care
Zucchini.
This thermal test can be carried out with contact temperature sensors, optical
pyrometers or thermal cameras.

Perform a visual inspection of the entire line and verify the absence of cracks and
crevices.

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Temperature form

PERSON IN CHARGE OF INSPECTION

COMPANY ( if different from installing company )
INSPECTION DATE
SIGNATURE

Check point n. Measured T Ambient T Dt Ib

Dt = Measured T - Ambient T
Ib = Working current

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For further information or explanation please get in contact

with Customer CareZucchini.

Tel: 0365 332811 Fax: 0365 31934

E-mail: IT-PostVenditaZucchini@bticino.it

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