Installation Guideline

1 Preparation in BMS

To start the preparation, you will receive a link from Christian Liebhardt (CHL), or Markus Leimer (LEM) for the project TransferSharePoint folder. If the site was started by another supervisor, all current data will be in this SharePoint folder. If this folder is still empty, download the file 'Installation_Site_Docu' from the network 'Q' and save it in the SharePoint.

There is also a separate KIWI article on this topic: Private:Sharepoint EEM Guideline

Send the electrical drawings via DHL to the customer. Supported by EEM-secretary. (It´s normally done by CHL.)

1.1 Preparation of the MFS diagramms

For easier identification and labeling of the electric components at the machine parts it is useful to use the MFS-diagramms in addition to the electrical drawings. Therefore it is advisable to prepare the MFS-diagrams in advance and note the electric device names into the MFS diagrams.

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1.2 Prepare excel cable and cable connection list

Find the cable list "KAB.xlsx" and cable connection list "KAN.xlsx" in the Installation_Sie_Docu in the folders 17 and 18. The original lists contain too much informations, many of them are useless for installation. Therefore they will be prepared form CHL and saved in the file 40-CHL-sitepreparation.

A coloured sorting by voltage level for the KAB is recommended before the start of installation. System-specific and location-dependent sorting is also useful, which can make it much easier to create the individual cable pulling lists on site later.

In the cable connection list (KAN) you have to check if the correct ports are entered for all Profinet- and Profibus-cables. If this is not the case they must be corrected manually.

2 Preparation on site

Access data to the Brückner Site Server (BSS) is assigned by the site manager. Template:Notice bms Drawings and documentations are also helpful for electrical assembly.

• Plant specifications
• Mechanical construction drawings
• Documentation from subcontractors

Printers and scanners work via the BSS. On the BSS all activities and the manpower are entered in the logbook every day. The BSS is also to be used for a weekly backup of work (lists and plans). The BSS is automatically synchronized to the home servers on a daily basis.

2.1 Storage

Approx. 10 meters of shelf with 4 trays are needed.

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Sort installation material and put it on the shelves.

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Check all cables by using the "cable list customer" and "cable list BMS", see "Installation_Site_Docu" folders 16 and 17.

Sort checked cables by type in a suitable storage area.

Unpack control panels and terminal boxes, check for damages and put them in the storage. In case of any demage take photos and report it to the EE-projectmanager.

Checking the installation material by using the packing lists can be done quickly and conveniently in a sorted and organiced storage.

2.2 Foundationcheck

Highlight the cable routings in the foundation drawing for a better guidance.

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Check and compare present foundation according foundation drawing. If necessary correct FU drawing according present situation and inform the EE-projectmanager.

Check pipe distance in cable pits according "Werkblatt WB 49.0", (File:WB49.0 Rev21.pdf) in case of to big difference inform EE-Projectmanager.

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Check steel pipes DN50 grounding connection in cable pits with foundation ground. If grounding connection is missing, correct it.

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Check cable trays and grounding in cabletrenches according foundation drawing and correct it if neccessary.

2.3 Switchboard assambly

• Unpack and check switchbords for possile demages. In case of demages take pictures and inform EE-projektmanager.
• If the switchboard panels are mounted already by mechanic supervisor ensure correctness of position and assambly.
• Fix panels with bolts to the U-profile frames. See Werkblatt WB 179. (File:WB179.0 Rev15.pdf)
• Connect switchboard panel units together with included installation material. File:Rittal Anleitung.pdf
• Busbar conector must be tighten according screwsize with a torque wrench (to find in BMS E-Tools) and mark tightend srews with permanent marker.
• Install vented roof panel, see drawing 622.121A1 und 623.121A1. (mostely on +STD1... cabinets)
• Dismantle switchboard bottom sheets for cable pulling and store them safely in the storage.
• Reconnect (due to transport reasons) disconnected cables and wires inbetween shipping units.
• To avoid possible demages of mainswitch door handles, don`t install them before pre check up.
• Check cable tray assembly below switchbords according "Werkblatt WB 179" and if neccessary arrange e.g. modify it to present site situation.File:WB179.0 Rev15.pdf

Example cable tray assembly in switchboardroom MCC1 and MCC2:

File:Schaltschrankraum.PNG

3 Grouding and shielding

Grounding and shielding are topics that must receive better attention with the change in automation and power electronics.

3.1 Grouding

• Brueckner earthing schema: File:Scheme-of-grounding-system As Designed.pdf

File:Groundingschema.jpg

3.2 Grounding measurement

• The grounding protocol (folder 31 in the Installation_Site_Docu) must be checked by the E-supervisor and adjusted if necessary.
• The grounding measurement must be done by the customer.
• The completed protocol must be handed over to Brückner befor commissioning.

3.3 EMC

For cable and shield installation, see "E-Montage-Kabelabfang+EMV-BMS-Guide-Line.pdf" in folder 40 of the Installation_Site_Docu. File:E-Montage-Kabelabfang+EMV-BMS-Guide-Line.pdf

There is also a separate KIWI article for the topic EMC. Public:EMC Guidelines

4 Installation and safety

4.1 Working under voltage

1. Disconnect completely
2. Secure against reconnection
3. Verify absence of voltage
4. Earth and short-circuit
5. Provide protection against adjacent live parts

4.2 Electrical drawings

Changes in electrical diagrams has to be made with red pen and provided with date and the Brückner short sign. Alternatively a correspondingly marked change in PDF format is also possible. Important changes (concerning the software) must be reported to the EE project manager as soon as possible.

4.3 Jira Points (Mantis Points)

In case of changes (Jira/Mantis) the relevant drawing pages must be exchanged and after completing the points, the old plans must be disposed of.

All changes are saved in the Installation_Site_Docu in folder 30, as well as in folder 29 with additional information of the claim number and NL in the List of Open Points (LOP).

Extensive points include:

• Circuit diagrams (new and old)
• Cable pulling lists
• Cable connection lists
• Required labels

4.4 Cabletray assambly

• Cable trays can only be installed after the completion of the mechanical work (e.g. pipe welding work of the HCUs) to avoid collisions.
• If holes have been drilled incorrectly in the cable trays, they must be closed with blind fasteners.
• Cable trays must be cleaned before cable pulling, as concrete residues or metal shavings, for example, can damage the cables.
• Sharp corners and edges must be filed down or alternatively provided with edge protection to prevent damaged cables.

Due to EMC- reasons close trays are prefered:

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4.4.1 Separators in cable trays

Separators are used do avoid induction currents when power and data cables are lying parallel in the same cabletray.

4.5 Installation of protective hoses

• Fix the protective hose fastened in the appropriate size with the provided clips.
• Mounting the protective hose with cable ties is not a permanent solution.
• Free-hanging protective hose has to be avoided.
• Take care not to build tripping hazards.
• When inserting the protective hose, the correct hose-fittings must be used. Clamping a hose in a cable gland is not professional and wrong.

4.6 Installation of junction boxes

• Terminal boxes should be mounted at a reachable hight (~30cm – 160cm above the ground).
• Incorrect drilled holes must be closed with blind fasteners to ensure IPXX protection class.
• Do not cut large openings in the terminal boxes. This also means that the protection class certification of the terminal boxes is lost.
• All terminal boxes of our system are certified at least protection class IP54.
• All subcontractor terminal boxes must be marked with the black labels. The sign must be fixed by rivets!

4.7 Labeling the devices

• Nearby the nameplate or the cable entrance
• On a vertical surface
• Not on removable parts like covers

5 Cable pulling

The cable laying should be done in sections after the mechanical assembly has been completed. The prepared lists are handed over to the customer (installation company) and returned by the customer after marking the cables. This is used to maintain the KAB list, so it is easy to see which cables have already been laid and which are still open.

In order to make it easier to lay the cables, which are separated by voltage, it is advisable to mark the routes with colour (same colours as in the KAB).

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Template:Notice bmsTemplate:Notice bms

Unwinding of cables

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5.1 power supply

Arangement of conductors if multiple power supply.

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5.2 High voltage cables

For some parts of the line are equiped with generator that generate high voltage up to 20kV.

For this keep a look in the seperate KIWI articles:

• Pinning Generator Casting Unit Public:Installation Guide Pinning HV-Cable
• Corona Generator Pull Roll Public:Corona Grounding

6 Cable connection

For connecting the cables you have to pay attention the following points:

• Do not leave extra lengths in the cabinets or terminal boxes, this is not professional, damages the clarity and does not look clean. If necessary some reserve length can be placed in the cabletray leading to the connection point.
• All conductive material of the cables, wires and bus bars must not tbe visible and touchable.
• Check that the conductive material has been clamped correctly and not the insulation of the core. Poor contact leads to fire hazard!
• For fine and ultra-fine wire cables all strands must be clamped. If this is not the case, or if strands were removed during stripping, this is a reduction in the cross-section of the core and will be a risk of fire.
• In case of shielded cables copper tape can be wrapped around to get some good connection to the EMC rail.

6.1 Cable end sleeves and cable lugs

For all cross sections < 0,75mm2 are cable end sleeves mandatory!

• Wire endsleeves are required with a cross section of 0,5mm2 and smaller. All push- terminals form WAGO used by BRÜCKNER (no sub-suppliers) are approved for connection without endsleeves. Just use the endsleeves for screw connection.
• In case of aluminium power cables the correct cable lugs has to be used. It affects screw connections. There is a own KIWI article for this topic:

6.2 Cable connection in switchboard panel

Keep a look at: File:E-Montage-Kabelabfang+EMV-BMS-Guide-Line.pdf

You can always check in the Fotopedia on the Transfer Sharepoint for some good example pictureshttps://bruecknergroup.sharepoint.com/sites/Transfer_SharePoint_M365_BMS_C/Freigegebene%20Dokumente/Forms/CHL.aspx

7 End of installation

Fill out the "IBN-Data" and send it two weeks before the check up starts to EEC IBN or the EE-projectmanager. Frequency controlled motors and line drives are priority.

Template:Notice bms

7.1 Checklist

The Checklist File:Checklist E-Montage de-en V231102.pdf from the E-Installation_Site_Docu in folder 40 has to be filled out and sent to Markus Leimer and the EE-prjectmanager.

Take some photos of the line and the switchboards and upload them to the network "Q". The link must be sent to Markus Leimer and the EE project manager.