TECHNICAL NOTE

Pages: 1 Datum
Subject LV JUNCTION REPAIR INSTRUCTIONS version 3 29/07/2016
To Installation personnel By RCE
Phase 1: PREPARATION & SAFETY

- Preparation:

a) Check whether a grinder with diamond blade can be used (spark and/or dust restrictions)
If necessary, cover switch boards and other sensible equipment with plastic sheeting or similar to avoid
precipitation of dust on sensitive equipment.
If necessary, provide a cover to avoid rain and water on the elements during and after removing the
junction.
b) Tools :
A diamond disc grinder reaching a depth of 30 mm is required
Concrete drills of 8 and 10 and 15 mm and length equivalent to the height of the busduct
Big chisel and small (8 mm) chisel and hammer
Clamps (wood or preferably steel) and threaded rods to secure the element on both sides of the junction.
This avoids splitting of the insulation close to the junction.

Phase 2: SAFETY

- Always wear gloves, goggles and adequate clothing (long sleeves) when using grinder
- Use respiratory protection
- If the system is situated at more than 1.5 m above ground suitable scaffolding must be provided
- Always make sure you work according local regulations (work permits, PPE, tooling, )

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Phase 3: understanding the geometry of the low voltage junction

Junction without resin

insulation isometric view
Pressure strips Phase Insulation

busduct insulation

busduct insulation

Section view of junction Junction insulation surface

+ Busduct insulation Busduct insulation surface
surface
+ junction insulation
17.5

37.5
surface

17.5
Junction insulation heigth

Conductor heigth

junction heigth
busduct heigth

element insulation width

Junction insulation width

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 Side view of junction

Junction insulation heigth

busduct heigth

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Phase 4: Removal low voltage busduct junctions

This section explains how you should remove the insulation around the junction.

1 Make sure the junction is accessible from

all sides

2 Use a grinder with diamond disc and

sufficient grinding depth to make cuts in
all sides of the junctions.

For LA busduct type use the grinding

depths defined in annex 1

For LB busduct type use the grinding

depths defined in annex 2

Important: Cuts must remain 40 mm from

the extremities of the junction to preserve
insulation of the element itself. These
areas are indicated with .

For information: cuts with a depth of

19mm should be sufficient to get the job
done.

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 3. Use a grinder with diamond disc and
sufficient grinding depth to make cuts in
all sides of the junctions.

For LA busduct type use the grinding

depths defined in annex 1
Area of metal pressure strips
For LB busduct type use the grinding
depths defined in annex 2

For information: cuts with a depth of

19mm should be sufficient to get the job
done.

4 Continue with the cutting all sides of the

junction insulation. For information: cuts
with a depth of 19mm should be sufficient
to get the job done.

5 Continue with the cutting all sides of the

junction insulation perpendicular to the
former cuts. For information: cuts with a
depth of 19mm should be sufficient to get
the job done.

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 6 Use a big chisel and hammer to chip off
piece by piece of the insulation.

7 Once the position of pressure plates and

bolts is known, cut the bolts with the
diamond tool. After this, the laterals and
pressure plates can be removed.

Cut bolts Remove pressure plates

Remove outer junction

Remove pressure plates conductor and insulation

Both sides of the junction removed

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 8 Once the exact position of junction plates
and conductors is known, the remainder
of the BIM insulation can be removed.

Drill holes in the spacing between

conductors to facilitate removal of BIM
insulation and junction plates between the
conductors.

Do not damage the busduct conductors !

Cut away the resin between Drill holes between element

element conductors conductors

Cut away the insulation Use small chisel & hammer

between elements to chip off the insulation

Use big chisel & hammer to push out the junction plates
between all element conductors
9 Finally remove the 40 mm remaining on
both sides taking care to have the clamps
in place. This to avoid splitting of the
busduct beyond the junction area.

Use clamps to avoid cracks

remove the 40 mm edges
in the elements while
removing the 40mm edges !

10 Be sure to remove all traces of insulation

in the contact area up to 75 mm of the
ends of the conductors to assure a good
75mm 75mm
electrical connection when replacing the
junction.
Use the scourer tape to remove oxidation
and resin in case copper conductors are
used.
remove remains of insulation in the 75mm areas for all element conductors

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Phase 5: Replacement of the junction by a new junction + resin mixture

See Installation manual modules F +G +H +I.

Phase 6: Junction resistance test + test report

See Installation manual Annex A + B to perform the test and fill in the test report. In case the junction resistance is
below the limit set by Eta-com, make sure the report is signed by the client and sent to Eta-com.

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Annex 1: grinding depths for LA type busducts

insulation
grinding grinding insulation thickness
Number of
conductor conductor depth depth top + thickness TOP + mould mould
LA conductors
thickness height sidewise bottom SIDE BOTTOM width height
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
LA04 3 4 40 < 47,5 < 37,5 47,5 37,5 139 115
LA04 3 5 40 < 46 < 37,5 46 37,5 139 115
LA04 3 6 40 < 44,5 < 37,5 44,5 37,5 139 115
LA08 3 4 80 < 47,5 < 37,5 47,5 37,5 139 155
LA08 3 5 80 < 46 < 37,5 46 37,5 139 155
LA08 3 6 80 < 44,5 < 37,5 44,5 37,5 139 155
LA12 3 4 120 < 47,5 < 37,5 47,5 37,5 139 195
LA12 3 5 120 < 46 < 37,5 46 37,5 139 195
LA12 3 6 120 < 44,5 < 37,5 44,5 37,5 139 195
LA16 3 4 160 < 47,5 < 37,5 47,5 37,5 139 235
LA16 3 5 160 < 46 < 37,5 46 37,5 139 235
LA16 3 6 160 < 44,5 < 37,5 44,5 37,5 139 235
LA20 3 4 200 < 52,5 < 37,5 52,5 37,5 149 275
LA20 3 5 200 < 51 < 37,5 51 37,5 149 275
LA20 3 6 200 < 49,5 < 37,5 49,5 37,5 149 275
LA04 4 4 40 < 40,5 < 37,5 40,5 37,5 139 115
LA04 4 5 40 < 38,5 < 37,5 38,5 37,5 139 115
LA04 4 6 40 < 36,5 < 37,5 36,5 37,5 139 115
LA08 4 4 80 < 40,5 < 37,5 40,5 37,5 139 155
LA08 4 5 80 < 38,5 < 37,5 38,5 37,5 139 155
LA08 4 6 80 < 36,5 < 37,5 36,5 37,5 139 155
LA12 4 4 120 < 40,5 < 37,5 40,5 37,5 139 195
LA12 4 5 120 < 38,5 < 37,5 38,5 37,5 139 195
LA12 4 6 120 < 36,5 < 37,5 36,5 37,5 139 195
LA16 4 4 160 < 40,5 < 37,5 40,5 37,5 139 235
LA16 4 5 160 < 38,5 < 37,5 38,5 37,5 139 235
LA16 4 6 160 < 36,5 < 37,5 36,5 37,5 139 235
LA20 4 4 200 < 45,5 < 37,5 45,5 37,5 149 275
LA20 4 5 200 < 43,5 < 37,5 43,5 37,5 149 275
LA20 4 6 200 < 41,5 < 37,5 41,5 37,5 149 275
LA04 5 4 40 < 33,5 < 37,5 33,5 37,5 139 115
LA04 5 5 40 < 31 < 37,5 31 37,5 139 115
LA04 5 6 40 < 28,5 < 37,5 28,5 37,5 139 115
LA08 5 4 80 < 33,5 < 37,5 33,5 37,5 139 155
LA08 5 5 80 < 31 < 37,5 31 37,5 139 155
LA08 5 6 80 < 28,5 < 37,5 28,5 37,5 139 155
LA12 5 4 120 < 33,5 < 37,5 33,5 37,5 139 195
LA12 5 5 120 < 31 < 37,5 31 37,5 139 195
LA12 5 6 120 < 28,5 < 37,5 28,5 37,5 139 195
LA16 5 4 160 < 33,5 < 37,5 33,5 37,5 139 235
LA16 5 5 160 < 31 < 37,5 31 37,5 139 235
LA16 5 6 160 < 28,5 < 37,5 28,5 37,5 139 235
LA20 5 4 200 < 38,5 < 37,5 38,5 37,5 149 275
LA20 5 5 200 < 36 < 37,5 36 37,5 149 275
LA20 5 6 200 < 33,5 < 37,5 33,5 37,5 149 275

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Annex 2: grinding depths for LB type busducts
insulation
grinding grinding insulation thickness
Number of
LB conductor conductor depth depth top + thickness TOP + mould mould
conductors
thickness height sidewise bottom SIDE BOTTOM width height
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
LB04 6 or 7 4 40 < 36,5 < 37,5 36,5 37,5 173 115
LB04 6 or 7 5 40 < 33 < 37,5 33 37,5 173 115
LB04 6 or 7 6 40 < 29,5 < 37,5 29,5 37,5 173 115
LB08 6 or 7 4 80 < 36,5 < 37,5 36,5 37,5 173 155
LB08 6 or 7 5 80 < 33 < 37,5 33 37,5 173 155
LB08 6 or 7 6 80 < 29,5 < 37,5 29,5 37,5 173 155
LB12 6 or 7 4 120 < 36,5 < 37,5 36,5 37,5 173 195
LB12 6 or 7 5 120 < 33 < 37,5 33 37,5 173 195
LB12 6 or 7 6 120 < 29,5 < 37,5 29,5 37,5 173 195
LB16 6 or 7 4 160 < 36,5 < 37,5 36,5 37,5 173 235
LB16 6 or 7 5 160 < 33 < 37,5 33 37,5 173 235
LB16 6 or 7 6 160 < 29,5 < 37,5 29,5 37,5 173 235
LB04 8 or 9 4 40 < 37,5 < 37,5 37,5 37,5 203 115
LB04 8 or 9 5 40 < 33 < 37,5 33 37,5 203 115
LB04 8 or 9 6 40 < 28,5 < 37,5 28,5 37,5 203 115
LB08 8 or 9 4 80 < 37,5 < 37,5 37,5 37,5 203 155
LB08 8 or 9 5 80 < 33 < 37,5 33 37,5 203 155
LB08 8 or 9 6 80 < 28,5 < 37,5 28,5 37,5 203 155
LB12 8 or 9 4 120 < 37,5 < 37,5 37,5 37,5 203 195
LB12 8 or 9 5 120 < 33 < 37,5 33 37,5 203 195
LB12 8 or 9 6 120 < 28,5 < 37,5 28,5 37,5 203 195
LB16 8 or 9 4 160 < 37,5 < 37,5 37,5 37,5 203 235
LB16 8 or 9 5 160 < 33 < 37,5 33 37,5 203 235
LB16 8 or 9 6 160 < 28,5 < 37,5 28,5 37,5 203 235

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