Model 6 MCC

Insulated Bus Installation

Training Document
July 10, 2013
Denise Robertson, LV MCC Sr. Design Engineer
 Step 1: OE Modifies BOM

● Add Formex box assemblies to BOM as required to cover areas of

horizontal bus that do have insulation. These assembly numbers can
be found on 80466-520-CFG.

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Step 2: Manufacturing Builds section per
modified OE BOM
● Add insulated Formex boxes to bus joints and other exposed areas of
bus that are not fully covered.

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5 Types of Insulated Formex Boxes

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 Riser Box
(800A PP-M breaker in top shown)

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5 Types of Insulated Formex Boxes
●1. Vertical boxes (80466-701-5X)
●2. End caps (80466-703-5X)
●3. Splices (80466-702-5X)
●4. Patches (80466-709-5X)
●5. Riser boxes
80466-700-5X 80466-705-5X 80466-706-5X
800A Top PP-M 800,1200 & 2000A MLO Top 1200A PP-P Tie
1200A Top NT 2000A PP-R Tie
1200A Top PP-P Bkr & Switch
2000A PP-R Top & Bottom

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Vertical Bus Boxes 80466-701-5X

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Tips for vertical box installation

●Two are required per section

●Box covers joint between horizontal bus and horizontal bus
support
●Left and right are usually the same box (exception occurs
with 20” wide high amp vertical bus)
●Asy number for box is lamination and bus width dependent
for all cases with the exception of high amp vertical bus.
●Boxes have additional cutouts on the left hand side to allow
clearance for the vertical bus.

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Slide rear parts behind horizontal bus
(may be easier to install parts flat then fold after part is behind the
horizontal bus due to the tight space)

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Fold rear part around horizontal bus supports with
additional folds for riveting to front parts.

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Fold front Formex part and rivet to tabs on rear
Formex part

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Repeat same steps to assemble the other vertical box

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End Cap Series 80466-703-5X

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Fold end-caps prior to sliding on bus or fold around ends of bus. Then
lace wire tie thru holes in front and rear of part (fish thru horizontal bus).

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Tighten the wire ties snuggly. Cut wire tie to desired length after installation.

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Horizontal Bus Patch Series 80466-709-5X

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Fold formex patches around any bare spots on the horizontal bus that are
not covered by another Formex box or epoxy (such as with 25” wide bus)

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Add rivets to secure patches to bus

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Riser Box Series 80466-700-5X
800A Top PP-M, 1200A Top NT, 1200A Top PP-P Breaker & Switch, 2000A PP-R Top & Bottom

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Slide rear part behind horizontal bus

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Add sides on horizontal box and rivet side to rear

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Rivet combined front and top piece to sides

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Splice Series 80466-702-5X
Commonly will be field installed by customer using instruction bulletin 80466-521-01

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If splice box must be installed at the factory, then add one
rear Formex part at a time to the horizontal bus.
Splice bars will need to be removed
Don’t fasten tabs of box yet to provide more flexibility for splice connection

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Add splice and splice connection hardware

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Fold tabs on all 3 boxes after all the splices boxes and
splices are added

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Fasten clear “U” shaped lexan part to front of all 3
splice boxes with wire ties to complete the assembly

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Field installed splice requirements:

● Place in box and ship to customer: (similar to offset horizontal splices

today)
● Copper splice assemblies generated from ACE
● Insulated Splice box parts (Splice assembly number to be added to BOM by
OE)
● Instruction Bulletin 80466-521-01

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 Variations of Riser Boxes provided with
initial release of insulated bus

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 1200A P frame Tie (has 2 sets of horizontal bus in same section)
riser box 80466-706-51
splice boxes do not insert into riser box on either side

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 2000A PP-R Tie
Riser box 80466-706-50 (qty 2)
splice boxes do not touch riser boxes

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 Hi Amp vertical bus in 20” wide section
requires special vertical boxes on left and right and a special splice box
on right that inserts into the vertical box.

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 High Amp Vertical bus in 25” wide
Standard Vertical boxes and splice boxes (no specials)

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 1200A Main Switch Top
Riser Box 80466-700-54
Riser box and splice boxes do not touch

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 2000A PP-R Main breaker bottom
Riser box 80466-700-57
splice boxes do not insert into riser box on either side

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 1200A NT Main Top
Riser box 80466-700-58
both splice boxes insert into riser box

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 800A MLO Top
Riser box 80466-705-50
(splice box on right outside riser box but splice box on left inside riser box)

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 1200A MLO top
riser box 80466-705-51
(splice boxes are special and insert into riser box on both sides)

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 1200A Main Breaker top 4W (25 wide)
Riser box 80466-700-52
splice boxes do not touch riser box

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 800A Main Breaker Top
Riser Box 80466-700-51
splice boxes do not touch riser box

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 1200A Main breaker top 3W
Riser box 80466-700-53
splice boxes do not touch riser box

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