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MNS Content InhaltPower – Low Voltage Switchgear MNS

IT

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Service Manual

Erection, commissioning, operation and maintenance

MNS Service 1

Content

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Folgen bei Nichtbeachtung ABB

:

Consequences in the event of non-compliance ABB shall not assume any liability for any of the following events: Negligent handling of the low-voltage switchgear system and noncompliance with the safety and working regulations as amended from time to time. Insufficient maintenance, non-compliance with the recommendations given herein or inappropriate repairs by personnel without the necessary training or adequate equipment. Transport damages of any kind. Inappropriate use. Modification of the low-voltage switchgear systems which were not made by authorized specialized personnel.

Die Angaben in dieser Druckschrift gelten vorbehaltlich technischer ?nderungen.

Technical reservations The data and figures of this publication are subject to change as required by technical progress.

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MNS Service
MNS / Manual

Erection, Commissioning, Operation and Maintenance

/ Publication No. 1TGC 902006 M0402 / Edition November 2004

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Content

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1
1.1 1.2 1.3 1.4

Technical Description
Technical data Mechanical design Busbar system Modular add-on parts

6
6 8 10 17

2
2.1 2.2 2.3 2.4 2.5 2.6

Packing and Transport
General Packing Handling of switchgear components Unloading and transport at site Intermediate storage Storage of spare modules

24
24 24 27 29 31 32

3
3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12

Erection and Commissioning
Checks on delivery Constructional requirements Removal of the transport frame Erection Fastening methods to foundation Cable connections, wiring Protective conductor connection Neutral conductor connection Special information Final preparations Checks Commissioning

33
33 33 33 34 39 41 47 47 48 49 49 49

4
4.1 4.2 4.3 4.4 4.5 SR 8E/4 8E/2

Operation
Electrical equipment Fixed technique Plug-in, disconnectable and railable technique Fused load-break switch type SR Withdrawable units size 8E/4 and 8E/2

50
50 50 50 53 54

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4.6 4.7

4E 48E

Withdrawable units size 4E up to 48E Special information

56 59

5
5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 5.18 MNS MNS ESLOK threadlocking MNS

Maintenance and Spare Parts
General Plug-in, disconnectable and railable technique Withdrawable technique Conversion and change of withdrawable module compartments Examination of MNS contact systems within the scope of plant revisions Greasing of contact areas Lubrication of withdrawable module interlocks Installation of power contacts Paintwork damage Mechanical damage Spare parts Accessories List of standard screws with ESLOKthreadlocking Tightening torques for screw connections Commissioning and maintenance of MNS reactive power compensation systems Measuring of the insulation resistance Measuring log for MNS reactive power compensation system Maintenance intervals, safety aspects, maitenance and inspection lists

60
60 64 68 70 74 76 78 79 81 81 82 85 86 87 89 94 97 99

6

Appendix
List of figures Index

110
110 113

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Technical Description

1
500 ,

1.1
(TTA)* IEC 60439-1, CEI 60439-1, DIN EN 60439-1, VDE 0660 BS 5486, UTE 63-412

ASTA ( IEC 61641 IEC 60298 AA) DLR IABG Industrieanlagen Betriebsgesellschaft, Vibration und Schock Ui Ue Uimp 1000 VAC 3P, 1500 VDC ** 690 VAC 3P, 750 VDC 6 / 8 / 12 kV, II / III / IV 3 60 Hz

: Ie Ipk Icw : Ie Ipk Icw 6300 A 250 kA 100 kA 2000 A 176 kA 80 kA DIN 41488 2200 mm 400, 600, 800, 1000, 1200 mm 400, 600, 800, 1000, 1200 mm E = 25 mm DIN 43660

RAL 7035, IEC 60529 , CFC VDE 0470 1 IP 00 IP 54 3

IEC 60707, DIN VDE 0304

(

RAL 7035)

* **

TTA:

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Technical Description

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1.1 Technical data
Standards Type-tested switchgear assemblies (TTA)* IEC 60439-1, CEI 60439-1, DIN EN 60439-1, VDE 0660 part 500, BS 5486, UTE 63-412

Test certificates

Germanischer Lloyd, Hamburg (shipping) ASTA, Great-Britain (resist. to accidental arcs acc. to IEC 61641 and IEC 60298, Appendix AA) DLR German Research Institute for Aerospace e. V. Jülich, Earthquake Test for Security Areas in Nuclear Power Stations IABG Industrieanlagen Betriebsgesellschaft, Vibration and shock tests Rated voltages Rated insulation voltage Ui Rated operating voltage Ue Rated impulse withstand voltage Uimp Overvoltage category Degree of pollution Rated frequency 1000 V 3~, 1500 V- ** 690 V 3~, 750 V6 / 8 / 12 kV, depending on equipment II / III / IV 3 up to 60 Hz

Electrical data

up to 6300 A up to 250 kA up to 100 kA up to 2000 A up to 176 kA up to 80 kA Cubicles and frames Recommended height Recommended width Recommended depth Basic grid size Frame Internal subdivision Transverse section Enclosure DIN 41488 2200 mm 400, 600, 800, 1000, 1200 mm 400, 600, 800, 1000, 1200 mm E = 25 mm acc. to DIN 43660 Zinc or Alu-zinc coated Zinc or Alu-zinc coated Zinc or Alu-zinc coated Zinc or Alu-zinc coated and Powder coated RAL 7035, light grey IP 00 up to IP 54

Rated currents

Mechanical characteristics

Dimensions

Surface protection

Degrees of protection Plastic components Internal subdivision

According to IEC 60529 or VDE 0470 part 1

Halogen-free, self-extinguishing, flame retardant, CFC-free Device compartment - device compartment Busbar compartment - cable compartment Busbar compartment - device compartment Device compartment - cable compartment Compartment bottom plates Enclosure Busbars Test certificates

IEC 60707, DIN VDE 0304 part 3

Extras

Paint finish Busbar system Special qualification

Special colours (standard RAL 7035) Insulated Silver or tin galvanized see test certificates listed above

*

Definition TTA: Switchgear assembly corresponding, to a large degree, with the original type or system of switchgear assembly type-tested in accordance with these standards.

** Depending on the electrical equipment

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Technical Description

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1.2

1.2 Mechanical design
The basic mechanical design comprises , , the frame, the enclosure, the internal constructions.

MNS

2mm

25mm .

C

The basic elements of the frames are C-sections of 2 mm thick sheet steel with holes at 25 mm intervals. The parts of the frame are secured with thread-forming screws and require no maintenance. The corner joints are carried out by means of pressure plates,

M10 x 18.

ESLOK-secured hex head screws M 10 x 18. Depending on the type of construction, the cubicle may be enclosed partially or on all sides. Doors, front covers and rear walls can be provided with ventilation louvers. Windows in the doors are made of multilayer safety glass or polycarbonate. : Depending on the requirements or the design the cubicles are divided into functional compartments:

Busbar compartment Equipment compartment

Cable compartment

.

The equipment modules are situated in the equipment compartment. The busbar compartment contains: busbars,

.

distribution bars. The cable compartment contains: , incoming and outgoing cables, cables for interconnecting the modules,

( .

).

auxiliary accessories (cable clamps, outgoing cable connection units, wiring ducts, etc.). The equipment modules, functional compartments and cubicles are separated by separation walls if required. Cubicles can be arranged for front operation or front and rear operation.

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Roof plate Top strip holder Transport lug

End plate

Rear plate M6x10 Self tapp. screw M6x10

Label - clip

Cable compartment door

End plate

Side - strip Parallel coupling

C C - section

Angle with peg

Transverse section

M6 Rivet M6

.1 / Fig. 1 Frame with enclosure
Floor plate

Cont. washer f. earth

Gelenk Stud for hing Scharnier Hinge

Lock

M22 Hex. nut M22

M6x10 Self. tapp. screw M6x10 Module - door Cable compartment door

Side - strip 8E/4 8E Withdrawable module size 8E/4 and 8E

Parallel coupling

16E

24E

Module - door for withdrawable module size 16E and 24E

.2 / Fig. 2 Frontbestückung (Beispiel)

Cover with ventilation louvers

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Technical Description

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1.3
: ( ( 3 4), 5, 6 7), (PE+N/PEN) (

1.3 Busbar system
The following busbar systems can be installed: busbars (see fig. 3 and 4), distribution bars (see fig. 5, 6 and 7), protective and neutral conductor bars (PE+N/PEN) (see fig. 4). 1.3.1 Busbars : The busbars are arranged in the rear section (busbar compartment) of the cubicle horizontally in two selectable levels: Double busbar systems are located at the upper and lower level. Single busbar systems are located at the upper or Iower level, as required. The cross-section of the busbars in both levels can be different. For double busbar systems separate, parallel or coupled operation is possible. Depending on the current 2, 4 or 8 (2 x 4) conductors per phase are used. Cubicles for front and rear operation have a common busbar system. The busbar system can be realised both as 3-pole or 4-pole version. The busbars are divided into sections corresponding to the sizes of the switchgear shipping units. Units having busbars of different cross-sections can be coupled together (required short circuit withstand to be considered).

4).

1.3.1

.

2

4

8

2X4

3

4

1.3. .

1.3.2 Distribution bars They provide the connection link between the busbars and the modules. ln the fixed, plug-in, disconnectable and railable module design they are arranged vertically in the busbar compartment (see fig. 5). As an alternative the use of a multi-function separator (see fig. 6) or a metal separation wall (see fig. 7) is possible for plug-in, disconnectable- and railable modules. If using the metal separation wall (see fig. 7) the openings for contacting are covered by protective covers (degree of protection IP 20). ln the withdrawable module design they are embedded into the multi-function separator made of insulating material (degree of protection lP 20) and held in place and arc prooved covered by distribution bar covers. As an alternative they could be covered by a metal separation wall with protective covers (degree of protection IP 20). The grid for contacting is in this solution 4E. The distribution bars can be installed in one length over the total cubicle height, however, sectionalizing is possible, e.g. for coupling for plug-in, disconnectable, railable and withdrawable technique. As a maximum, two 4-poIe distribution bar systems can be installed for plug-in, disconnectable, railable and withdrawable technique. If using the metal separation wall only one 4-pole distribution bar system can be installed.

(

5). 7

6 IP20

IP20 IP20 4E

.

2 1 4

4 .

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Technical Description

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Busbar holding plate

3 4 Busbar support 3- or 4-pole

Busbar

Busbar holding plate

N N busbar

. 3 / Fig. 3 4 Busbar system with outlined 4th pole

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Technical Description

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4 4-pole busbar support

N N busbar

PE/PEN PE/PEN connection bar

N N connection bar N N bus insulator

PE/PEN PE/PEN connection

N N bar

PE/PEN-Sammelschiene PE/PEN

. 4 / Fig. 4 N (PE) N N-busbars, protective bars (PE) and neutral bars (N)

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. 5 / Fig. 5 Open version of distribution bars

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Technical Description

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Multi function separator

Distribution bar cover

Distribution bars

Bracket for cable connection unit

Cable connection unit

Detail A

. 6 / Fig. 6 2E Cubicle distribution bar embedded in multi-function separator with outgoing cable connection unit and 2E distribution bar covers

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M5x8 Pan-head tap. screw M5x8

M6x10 Pan-head tap. screw M6x10

M6x10 Pan-head tap. screw M6x10

Protective cover

4E Metal seperation wall 4E

Abb. 7 / Fig. 7 Distribution bars embedded in metal separation wall with distribution bar covers

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Technical Description

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Distribution bar Busbar connector

Busbars Bracket Tragbügel Distribution bar holder Mounting rail

Side wall (right)

Bushing side wall

Compartment bottom plate Assembling plate

. 8 / Fig. 8 ( ) Cubicle with fixed technique (without equipment)

1.3.3

1.3.3 Protective and neutral bar The protective bar (PE) is mounted horizontally in the lower front section of the cubicle and is directly connected to the frame. Parallel to this the neutral bar (N) is mounted on insulators. The lengths of the bars correspond to the switchgear shipping unit lengths. The protective connection bar is arranged vertically in the cable compartment. Parallel to this the neutral connection bar is mounted on insulators. PE N PEN All PE+N/PEN-bars and connection bars are punched according to a grid system which permits the bars to be mounted in the cubicle and the outgoing cables to be connected as required.

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Technical Description

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1.4
.

1.4 Modular add-on parts
The equipment beIonging to a functional unit is contained in a single module. Standard designs are: , , , direct connection to the busbar, fixed technique, plug-in, disconnectable and railable technique, withdrawabIe technique, , ( ). control modules or control cubicles, front modules (indicating, measuring, annunciating, operating and control units mounted on the instrument panel of the front cover or the measuring recess). 1.4.1 Direct connection to the busbar Air circuit breaker and moulded-case circuit breaker rated 630 A and higher are connected directIy to the busbars. Withdrawable switches are furnished with an additional plug-in unit as intermediate link to the busbars.

:

1.4.1

9 Ausziehbarer Leistungsschalter Emax (mit Messnische) im Schmalfeld als Einspeisung für MCC 1.4.2 Bei Festeinbaumodulen (Motorstarter bis 450 kW und Energieverteilung bis 800 A) erfolgt die Kontaktierung mit den Feldverteilschienen über feste Schraubverbindungen. Diese Verbindungen k?nnen sowohl mit Kabeln als auch mit Schienen durchgeführt werden. Die Schutzart zu den Verteilschienen betr?gt IP 20 und zum Kabelraum IP 30. Grundelemente der Festeinbau-Technik sind die Montageplatte, linke und rechte Seitenwand, eine Durchführung durch die Seitenwand für Abgangskabel und der Fachboden, der die Module voneinander trennt (siehe Abb. 8).

Fig. 9 Withdrawable circuit breaker type Emax (with measuring recess) in narrow cubicle as feeder for MCC 1.4.2 Fixed technique Fixed modules (motor starters up to 450 kW and feeders up to 800 A) are connected to the distribution bars by means of fixed bolt connections. The connections are realized by using power cables or fixed bars. The degree of protection is IP 20 against the distribution bars and IP 30 against the cable compartment.

Basic parts for fixed modules consist of assembly plate, side walls (left and right), bushing side walls for outgoing cables and compartment bottom plate, which separates the modules from each other (see fig. 8).

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Technical Description

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1.4.3 630A . SR .

1.4.3 Plug-in, disconnectable and railable technique Plug-in, disconnectable and railable modules (up to 630 A) are connected to the distribution bars by means of plug-in contacts.

The LV HRC load break switch type SR constitutes a type of plug-in module. The complete unit is mounted directly on the frame and connected through its own contact elements to the distribution bars. 1.4.3.1 Plug-in modules

1.4.3.1 25mm 9 1800mm 600mm

The plug-in module technology basically consists of supporting plates made of sheet steel with an alu-zinc coating. See fig. 9. Modules of any size may be built in a 25mm grid up to a height of 1800 mm (standard) which comprise one or several supporting plates. The equipment compartment width of standard modules is 600 mm. The modules are fastened directly to the MNS frame using tapping screws secured with a screw cage. If necessary, supporting plates are provided with cut-outs for contact units which serve for contact with the distribution bars. When installed without a multi-function separator, the empty slots will be covered. On the outgoing side of the modules, the connections are made via terminals or directly to the switchgear units.

MNS

.

Depending on their design, modules are operated from inside or from outside if a rotary handle has been fitted.

Abb. 10 : 1 2 ,

Fig. 10 Plug-in modules as motor starters: above 1 fused plug-in module, below 2 fuseless railable modules

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Technical Description

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1.4.3.2 . 11. .

1.4.3.2 Disconnectable modules Disconnectable modules have the same construction as plug-in modules, however, they are equipped with two handles for live insertion and removal of the modules. During this process, the modules are moved on guide rails. See fig. 11. Taking out disconnectable modules under load is not permitted. The load should be disconnected before taking out the modules.

. .

The fastening as well as the electrical equipment installation is the same as for plug-in modules. Disconnectable modules may only be operated from inside.

1.4.3.3

1.4.3.3 Railable modules The base plate of railable modules is identical to that of plug-in modules. Furthermore, side panels are installed which are in touch with guide rails bolted to the frame and are locked to these (see fig. 12). . The electrical equipment installation is the same as for plug-in modules. Railable modules may only be operated from inside. Modules may be withdrawn with the help of a handle.

side part eil

wiring duct BASF inset for interposing relay BASF BAYER inset for control plug BAYER inset for control plug STANDARD

SEF-10 Auxiliary switch SEF-10 for electrical interlock

pressure spring interlocking bolt Support plate

screw for interlock of module in test and duty condition

inset for nameplate and door control plug mounting plate

Hand Protection cover

inset for nameplate

INSUM Cutout for INSUM control plugs handle

Kpl . interlocking device cpl.

11 / Fig. 11 Mechanical design of the disconnectable modules

12 / Fig. 12 Mechanical design of the railable modules

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Technical Description

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1.4.4

1.4.4 Withdrawable technique Withdrawable units comprise: , . the withdrawable module, the frame-mounted module compartment. Standardized sizes are 8E/4, 8E/2, 4E, 6E, 8E, 12E, 16E, 20E, 24E, 36E, 40E, 44E und 48E (E = 25 mm). Modules 36E consist of 2 withdrawable modules interlocked with each other, whereby only the upper module is withdrawable. The lower module is bolted with the frame. : 4 2 1 ( ). One 600 mm wide equipment compartment can contain: for size 8E/4 for size 8E/2 for size 4E to 48E 4 withdrawable modules 2 withdrawable modules one withdrawable module

8E/4, 8E/2, 4E, 6E, 8E, 12E, 16E, 20E, 24E, 36E, 40E, 44E und 48E (E = 25 mm). 36E

600mm 8E/4 8E/2 4E - 48E

Empty space are closed off with front covers (see spare parts list). Withdrawable compartments size 8E/4 and 8E/2 consist of:

8E/4

8E/2

:

Compartment bottom pIate Withdrawable module condapter Guide rails Front posts The withdrawable module condapter is the connecting link between distribution bars and the withdrawable modules size 8E/2 and 8E/4. The condapter consists of:

8E/4

8E/2

.

:

Conductor bars for the incoming feeder connection of the withdrawable modules. Outgoing contacts with connection to the power terminals (in the cable room).

PE 8E/4 8E/2 16, 20, 38 32, 40, 76 16 20 38

Power terminals including the PE terminals. Control terminal per 8E/4 module: 16, 20 or 38 pole Control terminal for each 8E/2 module: with one control plug: 16, 20 or 38 pole with two control plugs: 32, 40 or 76 pole Electrical connections with the withdrawable module are of the plug-and -socket type.

8E/4

8E/2 .

The front panel for withdrawabIe modules size 8E/4 and 8E/2 which is fixed to the withdrawable modules is made of insuIating material and serves as instrument panel for measuring, operating and indicating units.

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Technical Description

1

Withdrawable mod. condapt. assy. M6x10 Pan head tap.screw M6x10

Compartment bottom assy. Guide rail

M6x10 Pan head tap.screw M6x10 Control terminal Front post Bushing B6.4 Washer B6.4 M6x10 Pan head tap.screw M6x10 M6x20 Pan head tap.screw M6x20 PE PE-connecttion for condapter

13 / Fig. 13 4 8E/4 2 8E/2 Withdrawable module compartment for 4 units size 8E/4 or 2 units size 8E/2

(kein Standard) (no standard)

14 / Fig. 14 8E/4

Empty withdrawable unit size 8E/4 (without electrical equipment)

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Technical Description

1

4E ... 48E

:

Withdrawable moduIe compartments size 4E ... 48E consist of: Compartment bottom pIate with roller Guide raiI Sheet metal side wall with the outgoing control plug Outgoing cable connection unit The uppermost withdrawable module compartment is covered by a compartment bottom pIate. The top cover for the lower compartments is the bottom plate of the compartment above. Withdrawable module feeder connection to the distribution bar system is done directly via the contact devices of the withdrawable modules. Outgoing cables are connected via plug-in-contacts to the outgoing cable connection unit (main circuit) and via terminal blocks (auxiliary circuit). The outgoing cable connection units are fastened directly to the frame. A hinged instrument panel made of insulating material for measuring, operating and indicating units is also provided for the withdrawable modules size 4E to 48E. lt is mounted on the unit itself and protrudes through a cut-out in the hinged front cover of the unit. For details concerning operating elements see chapter 4.

.

. 4E bis 48 E

KA63 Mounting bracket f. KA63

M6x10 Pan head tap.screw M6x10

4E Location auxiliary contacts 4E

M6x10 Pan head tap.screw M6x10

Mounting bracket f. compartment bottomplate

M6x10 Pan head tap.screw M6x10 Roller

M6x10 Pan head tap.screw M6x10

8E Location auxiliary contacts M6x10 Pan head tap.screw M6x10 Cover

8E

Control terminal bracket

15 / Fig. 15 4E ... 24E Withdrawable module compartment for units size 4E ... 24E

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Technical Description

1

Strip Apparatus plate

Left side wall Rear wall

Base plate

Right wall side

Instrument panel

16 / Fig. 16 4E ( ) Empty withdrawable unit > 4E (without electrical equipment)

Mechanical interlocking unit Lock

Interlock link

Handle

Name plate carrier

Switch handle

Lock Front cover

17 / Fig. 17 4E ... 24E Withdrawable module door with interlocking for 4E ... 24E

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Verpackung und Transport

Packing and Transport

2

2.1
,MNS3M , , ( x x ) mm: ABB guidelines .

2.1 General
MNS-switchgears are shipped either in singIe cubicles or in shipping units not exceeding 3 m in length depending on the type of equipment instalIed and on the space available for handIing the switchgear at the erection site. lf no special instructions are given by the customer, packing is carried out based on ABB shipping guidelines and a suitable method of shipping is selected. Maximum size of a shipping unit (length x width x height) in mm: Unpacked Packed in crate 500 700 1000 1800 500 400 300 3100 x 1300 x 2200 3300 x 1500 x 2590

3100 x 1300 x 2200 3300 x 1500 x 2590 kg:

Approximate values for weights per cubicle in kg: 1600 A 2500 A 4000 A 6300 A Operation from one side 500 700 1000 1800 500 400 300 Operation from both sides

900 700 500

Incoming feeder 1600 A Incoming feeder 2500 A Incoming feeder 4000 A Incoming feeder 6300 A Withdrawable module cub. Plug-in/Disconn. mod. cub. Control cubicle

900 700 500

2.2
2.2.1 , t: .

2.2 Packing
2.2.1 Cubicles The cubicles are protected by suitable packaging during transport and possible intermediate storage. The standard packaging comprises: PE, (2,4 x 5 cm) (8 x 10 cm)( : , ( ). . 1200kg . 6 x 12 cm. : . . , ,. , . , , . ( fig.8) , (6 x 12 cm) fig.18) PE-sheeting, transport frame consisting of wooden beams (6 x 12 cm) with wooden fixing ledges (2,4 x 5 cm) and wooden cross beams (8 x 10 cm) for fork-lift transport (see fig. 18) or: euro pallet, plastic strips, wooden crate (if necessary). The cubicles are to be fixed with the plastic strips to the palIets.

Shipping units with transverse section and a total weight of more than 1200 kg are provided with a transport frame (see fig. 18), which is to prevent the cubicle steel sections from bending. consists of wooden beams 6 x 12 cm. has to be fixed in such a way that the front and rear transverse sections and the module supporting frame rest on the transport frame. has to be fastened to the cubicle by means of plastic strips and wooden fixing ledges. The plastic strips have to be bolstered by foam plastic foil. For fastening, the bottom plate may be pierced at the points of attachment. At site these holes must be sealed by pIugs unless they are used for fIoor mounting. There is no connection of the transport frame with the packing material when using crates (see fig. 19) or boxes (see fig. 20).

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Verpackung und Transport

Packing and Transport

2

6 x 12 cm Shipping frame Wooden beams 6 x 12 cm

Abb. 18 / Fig. 18 / Shipping unit with transport frame or euro pallet

Abb. 19 / Fig. 19 / Crating

oder elastische Packmittel als Polster or elastic packing means as pads

Abb. 20 / Fig. 20 / Box packing

MNS Service

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Verpackung und Transport

Packing and Transport

2

, 18) , ( / ( , , (acc. DIN 55474), (8 x 10 cm), . : 13 mm, 24 oder 30 mm, / Feder 28 mm. ). ): , , .

(

fig.

Unpacked shipping units have to be provided directly with wooden cross beams (see fig. 18) for handling by fork-lift trucks. For packed shipping units the wooden cross beams are Iocated underneath the packing material. To protect them against moisture, the switchgear instalIations have to be encased in a foil. A protective drying agent (such as silicagel) has to be provided between the foil and the switchgear. The export/seaworthy packaging (for sea transport and truck or train transport outside continental Europe) comprises: Closed wooden box, heat-sealed foil, drying agent (acc. DIN 55474), wooden cross beams (8 x 10 cm) for fork-lift transport, elastic packing means as pads. As packaging material the following is allowed: Plywood 13 mm,

, .. DIN 55474 . . ,

Cut timber 24 or 30 mm, Slot and feather 28 mm. The switchgear has to be wrapped with foil after upholstering sharp edges and corners. The joints of the foil have to be sealed. A protective drying agent according DIN 55474 has to be provided between the foil and the switchgear. No direct contact of this protective drying agent with the switchgear is allowed.

. . With container traffic no box packing is necessary.

Only remove the packaging after delivery of the switchgear to site. Only remove the transport frames from the cubicle bases at the place of erection. 2.2.2 : , 1000A MCCB, 2.2.2 Packaging of switchgear components The following devices and materials have to be delivered separately packed with the switchgear independent from the kind of transport: withdrawable air circuit breaker, withdrawable moulded case circuit breaker with a nominal current of more than 1.000 A, 100kg fuses, transformers and reactors with a weight of more than 25 kg, in the case of floor mounted units of more than 100 kg, precision instruments of high value for measuring and indication, fluorescent tubes, modules with single phase control power transformers of more than 2 kVA, 3500 A, spare withdrawable and P-/R-modules, top stripe holders, rear walls made of laminate for cubicles withdrawable modules with weight 3500 A, 30 kg.

25 kg ,

reactors ,

, 2 kVA P-/R, ,

top stripe holders, rear walls made of laminate for cubicles 30 kg .

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Verpackung und Transport

Packing and Transport

2

LV HRC . ,

,

With exception of the LV HRC fuses the above mentioned parts have to be marked (label, tag) by the work shop including the statement of the module location. . Withdrawable, plug-in, ( If possible the original packaging material of the manufacturer should be reused for packaging. Withdrawable, plug-in, disconnectable and railable modules as spare parts or as supplementary parts for switchgears have to be marked with the necessary technical data for the use (module location, type, order number). The fuses remain in the modules. Information concerning the procurement of standard boxes can be obtained from the shipping department of the workshop in Ladenburg. The quality of the internal packaging depends on the kind of good to be packaged and has to be choosen by the shipping department. Materials to be used: Padding (chips made of expanded polystyrene), corrugated cardboard, foil, expanded polystyrene board, cardboards. Already in the order the separat shipping of switchgear components should be specified.

disconnectable and railable modules , , ) , Ladenburg .

the kind of good to be packaged, . : . In der Bestellung sind bereits Angaben über den separaten Versand von Anlagenkomponenten zu machen.

2.3 Behandlung von Anlagenkomponenten
2.3.1 : . 1000A . . . , . . .

2.3 Handling of switchgear components
2.3.1 Circuit breaker Circuit breaker have to be treated the following way: Fixed circuit breaker have to be braced additionally. Withdrawable air circuit breaker and withdrawable moulded case circuit breaker with a rated current of more than 1000 A have to be dismounted and packed separately. Heavy busbar constructions have to be supported during transport in an adequate way. It is urgently necessary to attach a caution label demanding the removal of the used transport fixing material during switchgear erection. If possible the original packaging material should be reused for packing the dismounted circuit breaker. The bracing has to be removed prior to commissioning. Separately shipped circuit breakers are to be mounted in accordance with the mounting instructions enclosed.

2.3.2 (ON,OFF . TEST ) , 30 kg

2.3.2 Withdrawable modules Withdrawable modules have to be secured for shipping by their own mechanical interIock operated by the switch handle (ON, OFF or TEST position). Withdrawable modules with weight 30 kg must be shipped separately. In addition, the withdrawabIe modules may be secured by a latchtype lock which works independently from the mechanical interlock and which may be operated by 5 mm double bit key or a cylinder type safety key. Necessary switch positions prior to commissioning: Switch handle must be in position ?OFF“.

In addition, the withdrawabIe modules may be secured by a latch-type lock which works independently from the mechanical interlock and which may be operated by 5 mm double bit key or a cylinder type safety key.

: OFF

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Packing and Transport

2

2.3.3 Plug-in, disconnectable and railable modules 2.3.3.1 Plug-in, disconnectable and railable modules . 2.3.3.2 Railable modules >11E < 31E . 31E fig. 21, 22).

2.3.3 Plug-in, disconnectable and railable modules 2.3.3.1 Plug-in modules and disconnectable modules No additional transport protection has to be provided. 2.3.3.2 Railable modules Modules with a height >11E <31 E should be protected for transport with 2 screws and a screw cage. Modules with a height 31 E should be protected for transport with 4 screws and a screw cage (see fig. 21, 22) Service handle

( Modulgriff

cable straps

(

fig. 23)

The service handle should be secured for transport using cable straps (see fig. 23).

Abb. 21 / Fig. 21 Securing the module with a cage and a screw

Abb. 22 / Fig. 22 Fixing of the cage

cable straps / cable straps

Abb. 23 / Fig. 23 Transport protection of the service handle

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2

2.3.5 , , 25 kg mounted , , , 2 kVA , reactors, 100 kg fIoor

2.3.5 Other switchgear components Separately packed components, such as fuses, transformers and reactors with a weight of more than 25 kg, fIoor mounted units of more than 100 kg, precision instruments of high value, fluorescent tubes, modules with single phase control power transformers of more than 2 kVA, spare withdrawable or plug-in/disconnectable modules are marked with their place of instalIation. The encIosed mounting instructions must be observed.

withdrawable or plug-in/disconnectable . .

2.4
, 2.4.1 ( fig. 24). . , ( ( ( 3 ). 1200 kg ) ( fig. 26). . fig. 24). , ) , , . , 3 mm ( ( , , , .

2.4 Unloading and transport at site
The truck can be unloaded by crane or fork-lift truck. The loads must be lowered onto a flat surface. 2.4.1 Ground transport By fork-lift truck (see fig. 24). By lifting and conveying devices. In an emergency, with rollers (min. 3 pieces). For roller transport the wooden cross-beams must be removed (only for cubicles with transverse sections up to 1200 kg) (see fig. 26). Switchgear cubicles have to be transported only in the vertical position. Tilting and canting must be avoided (see fig. 24). Single cubicles (cubicles without withdrawable modules, circuit breaker cubicles without circuit breakers) may be briefly tilted into the horizontal position if the height of the doorway to the place of erection does not permit vertical transport. ln this case the cubicle sections must be supported over a wide area. Cubicles may easily tip over when transported with a hand-pulled truck. Therefore the distance between the wooden cross beam or the pallet and the underground should not be more than 3 mm (see fig. 24).

fig. 24).

Abb. 24 / Fig. 24 Transport with a hand-pulled truck

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Transportrahmen (Holzbalken 6 x 12 cm) Transport frame (Wooden beam 6 x 12 cm)

Abb. 25 / Fig. 25 Fork-lift transport

Abb. 26 / Fig. 26 ( 1200 kg ) Roller transport (only for weight of transport units up to 1200 kg)

Abb. 27 / Fig. 27 , Crane transport, transport unit unpacked

Abb. 28 / Fig. 28 , Crane transport, transport unit in box

Abb. 29 / Fig. 29 (MNS ) Arrangement of lifting angles (plan view of MNS-cubicles)

Abb. 30 / Fig. 30 Frame corner joint with lifting angle

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2

2.4.2 . . 120° ( , , . GMN 775 502 P18 . fig. 27). ( fig. 29).

2.4.2 Transport by crane For the transport by crane the cubicles resp. the shipping units are equipped with lifting angles (see fig. 29). Fastening of any Iifting device directly to the frame sections is not permitted. The lifting rope angle at the crane hook must not be larger than 120° (see fig. 27). The lifting angles may be removed after the switchgear has been erected. The fastening holes for the lifting angles are to be plugged with plugs GMN 775 502 P18 if removing the lifting angels. Hamp Ropes DlN 83325 mm 8 10 12 14 16 18 20 24 30 36 90° fig. 29 . l. . For a rope angle of 90° the permissible load is approximately 40 % larger than the values given in the table. The arrangements of the lifting angles are shown in fig. 29. Shipping units with one or two cubicIes are equipped with single angles. . , . Shipping units consisting of three or four cubicles are equipped with dual angIes. The sign advertising the tilting danger must not be removed before all cubicles have been secured to the foundation. Don?t put the switchgear down on one edge, because of the danger of a considerable mechanical damage. kg 180 280 350 470 580 720 1000 1600 2400 120° Perlon Ropes DlN 15060 DlN 83330 (160 kg/mm2) kg kg 890 1440 400 2100 600 2900 820 1060 1340 1660 2400 40 %. Guide values for permissible rope loading Rope diam. Permissible Ioad for a four-rope arrangement, Rope angle at crane hook 120° Perlon Hamp Ropes Steel Ropes Ropes DlN 83325 DlN 15060 2 DlN 83330 (160 kg/mm ) kg kg kg 890 1440 400 180 2100 600 280 2900 820 350 1060 470 1340 580 1660 720 2400 1000 1600 2400

mm 8 10 12 14 16 18 20 24 30 36

2.5
. :

2.5 Intermediate storage
The nature and duration of intermediate storage are dependent on the type of packaging. Cubicles in standard packaging: condensation . , . , condensation forming . . , . Store indoors after arrival where no condensation can occur. Unpack immediately. Open the doors for several hours to acclimatize the equipment. Cover the cubicles with plastic sheeting for any subsequent storage periods. Check regularIy for condensation forming under the sheeting until the start of installation.

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2

: t. Possibility of intermediate storage outdoors. 12 PE . 12 , , . r. . 24 PE 24 , , :

Cubicles with export/seaworthy packaging: Moisture protection is only guaranteed if the packaging is undamaged. Possibility of intermediate storage outdoors. Storage period of maximum 12 months if wrapped in heat sealed PE sheeting and the packaging is undamaged. For duration of transport and storage from 12 month up to maximum 24 month and/or if the possibility to check the status of the drying agent is needed, the following can be used instead of heat-sealed PE-sheeting: Heat-sealed aluminium-compound foil with integrated hygroscope which provides moisture protection for at least 24 months. The hygroscope is visible from the outside through a opening in the transport box. When the storage period is exceeded, the drying agent must be replaced and the plastic sheeting has to be resealed.

2.6
. . . . 16E .

2.6 Storage of spare modules
Storage is only allowed in dry rooms. The modules have to be stored in undamaged original packing. Do not expose the modules to bigger temperature variations. Store the boxes with the top side to the top. Do not store modules with sizes 16E one on top of the other.

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3.1

3.1 Checks on delivery
Check the consignment on arrival at site for: , ( ). Completeness, transport damage (if found, determine the extent, cause and originator). When damage is detected it must be proceeded as foIlows: lmmediately write down visible damage in the consignment note. Report hidden damage in writing to the relevant forwarding agent within one week.

When certification is missing or a claim has not been made, the manufacturer can disclaim all Iiability.

3.2

3.2 Constructional requirements
To prevent damage being caused by moisture and dirt the following tasks (only examples) must be carried out before erection of the switchgear: . Walls and ceilings pIastered, painting completed. Doors and windows installed. . Openings in the floor, wall and ceiling for cables, conductors pipes, bars and ventiIation in accordance with the construction drawings provided. Supporting brackets, beams, enclosures and foundation frames assembled and painted. lf necessary, assemble braces appropriate to the basic dimensions of the switchgear installation with cross struts corresponding to the cubicle divisions. Suitable indoor conditions must be maintained. Adequate lighting as well as free access to the switchgear rooms must be provided. Excessive temperature fIuctuations together with high humidity should be prevented by heating the room. Condensation should also be prevented.

Ggf. Aufst?nderungen passend zu den Grundabmessungen der Schaltanlagen mit Querstreben entsprechend der Feldteilung montiert.

3.3

3.3 Removal of the transport frame
The transport frame has to be removed at site as described in the following before installing and connecting the switchgear: Release the rear parts of the transport frame. For this purpose it may be necessary to unscrew the rear walls. Afterwards refit the rear walls correctly.

.

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3.4
3.4.1 : 1. * . 2. 31) . 3. .( 33). M6X10

3.4 Erection
3.4.1 Erection and connection of the cubicles The erection of the cubicles should be carried out, as described in the following: 1. The shipping units which are to be erected in one row have to be aligned accurately and checked that they are vertical. Doors and panels must not be twisted or stressed. The erection can start at the left or at the right. 2. The frames of the shipping units have to be screwed together (see fig. 31). The vertical sections for front operated units are already fitted on the left front and rear with 4 special nuts. For front and rear operated cubicles, the vertical sections at front left and rear right are fitted with the special nuts. 3. The side walls for the end cubicles have to be fastened. For this purpose, taptite or torx screws M6x10 (see fig. 33) have to be used. During fastening the side walls it has to be made sure that at least at one bolted connection a protective conductor connection is realised by placing a contact washer underneath. 4. Additionally to the vertical sections or if the access to the screw joints in the vertical sections is obstructed by installed equipment, the bottom sections can be screwed together using the frame connectors which are encIosed (see fig. 32). For the initial tightening of the thread-forming screws an eIectric or compressed-air operated screw-driver should be used. For tightening torques for bolted frame connections refer to chapter 5.14.

4. Zus?tzlich zu den H?henprofilen oder falls der Zugang zu den Schraubstellen der H?henprofile durch Einbauten behindert ist, k?nnen die Tiefenprofile unter Verwendung der mitgelieferten Gerüstverbindungen miteinander verschraubt werden (siehe Abb. 32). Zum erstmaligen Eindrehen der gewindeformenden Schrauben ist vorzugsweise ein Elektro- oder Druckluftschrauber zu verwenden. Zu den Anzugsdrehmomenten für Schraubverbindungen von Gerüstteilen siehe Kapitel 5.14.

Abb. 31 / Fig. 31 Gerüstverbindung Frame connection

31

Abb. 32 / Fig. 32 Zus?tzliche Gerüstverbindung Additional frame connection

32

34

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Rückwand Rear wall

Taptite/Torx-Schraube M6x10 Self tapping screw M6x10 M6x10

Seitenwand Side wall

Abb. 33 Befestigung von Rück- und Seitenwand

Fig. 33 Mounting of rear and side wall
Rückwand Rear wall

5.

PE 34 35

N ESLOK

45° 6.

+0 -15

,

1

+1

-0,5 mm

5.14

PE PEN PE/PEN

7.

5. The busbars as well as the protective and neutral conductor bars have to be bolted at the transport divisions using the connections provided (see fig. 34/35). Only ESLOK-sealed screws together with one conical spring washer each are to be used. The connecting points for the busbars are accessible through partition wall between the cable and busbar compartments. This partition wall must be closed after the bars have been secured. Elongated holes at the ends of the bars ensure adequate adjustment within the tolerances set. lf the erection is properly carried out the holes will match up as required. Drilling is not permissible, due to the resulting chips. Contact surfaces do not need a special pretreatment. In case of dirt, the contact surfaces should be cleaned with a soft cloth. Do not use a metal brush or chemical liquids. In case of double busbar systems, the bars should be deburred or slightly phased (on both sides +0 +1 45° -15 with 1 -0,5 mm). Refer to chapter 5.14 for tightening torques for bolted connections of busbars, protective and neutral conductor bars. 6. The protective conductor (PE or PEN) is to be connected to the PE/PEN bar. Additional connections to the central earthing system can be made at any point of the perforated PE/PEN bar. Local regulations must be complied with. 7. The lifting angles may be removed and afterwards the fastening holes have to be plugged with plug GMN 775 502 P18.

Seitenwand Side wallM6x10 Taptite/Torx-Schraube Self tapping screw M6x10

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ESLOK-Schraube ESLOK screw ESLOL

Spannscheibe Conical spring washer

Abb. 34 / Fig. 34 Sammelschienenverbindung Busbar connection

Abb. 35 / Fig. 35 PE/N-Verbindung PE/N-connection PE/N

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Erection and Commissioning

3

3.4.2 80 mm 37

3.4.2 Additional information for switchgear positioning The area around the cubicles to be left clear should be at least 80 mm (see fig. 37). To be able to mount the last (right) cubicle, the distance between the end cubicle and the (right) wall must be at least 150 mm (see fig. 37). In case of left-mounted doors, the minimal distance between the (left) wall and the (left) end cubicle should be also 150 mm, such that the doors can be openend in an angle of more than 90° (see fig. 37). The distance from the upper edge of the (highest) cubicle to the ceiling should be at least 500 mm for cubicles which are resistant to accidental arcs (see fig. 36).

150 mm

37 150 mm

90°

37 500mm,

(

36).

Abb. 36 / Fig. 36 Freiraum über dem Schaltschrank Free space above cubicle

Abb. 37 / Fig. 37 Wandabst?nde Walldistances

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3.4.3 ( mm).

3.4.3 Floor cut-outs If floor cut-outs are required at site to supply cables and wires, the measurements must be taken according to the following sketches (all measurements in mm).

Cubicles without busbar compartment

Cubicles with busbar compartment

Cubicles with cable- and busbar compartment; cable entry only to the cable compartment

Cubicles with busbar compartment and two-sided operation

B: Gesamtbreite / total width T: Gesamttiefe / total depth B: T: T1=100 B1=75

B: Gesamtbreite / total width T: Gesamttiefe / total depth

T: Gesamttiefe / total depth

T1=100 B1=75

T2=200

T1=100

T2=200

B: Gesamtbreite/total width T1: Ger?teraumtiefe/depth of equipment compartment T2: Ger?teraumtiefe/depth of equipment compartment T1: T2:

B1=75mm Abb. 38 / Fig. 38 Bodendurchbrüche Floor cutouts

38

Erection and Commissioning

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3.5

3.5 Fastening methods to foundation
The erection of switchgears having the cable entries at the bottom requires a foundation with an opening or a cable duct. The cubicles should preferably be erected on a base frame which is either embedded in the concrete fIoor or rests as false floor on supports. ABB ±1 mm /1m (. DIN ISO1101 2 / 1000 ) When erecting the base frame the following must be observed: The base frame should be aligned and checked under the supervision of an ABB fitter. The horizontal tolerance of the frame must not exceed ±1 mm over a length of 1 m. This is to be ensured by using suitable levelling devices (e.g. spirit level, 1 m long surveyors rod). The frame must not ondulate ( according to DIN lSO 1101) 2 / 1000

Die Nivellierung der Fundamentrahmen kann z. B. mit einstellbaren PRESTOJACK-Nivellierspindeln (siehe Abb. 39) erfolgen. 39 20mm ( ( ) M8 40).

The leveIling of base frames can be performed e.g. with PRESTOJACK levelling spindles (see fig. 39). During erection the switchgear is welded or screwed to the base frame (see fig. 39). The length of the weld seams at the front and rear of each cubicle should not be less than 20 mm. All weldings must be protected against corrosion by a coat of paint (e.g. zinc paint). ( The screwed connection is carried out through the transverse section. The mounting hoIes required for metal straddling dowels M 8 must be drilled during erection (see fig. 40). ). When false floors are used, notice that: Tolerances are the same as for the base frame.

. ). 20 kN/m
2

.(

20mm ( ).

The subsoil must be firm, so that the tolerances are not exceeded by settling of the soil (especially when using insulation layers and adhesives). The false floor has to have a carrying capacity of p=20 kN/m (Compression load from top to bottom). 500 mm During erection the switchgear is welded or screwed to the false floor. The length of the weld seams at the front and rear of each cubicle should not be less than 20 mm. Then a reliable earth connection is provided. All weldings must be protected against corrosion by a coat of paint (e.g. zinc paint). lf welding is not possible, the switchgear can be bolted to the false floor. The necessary mounting holes should be driIled on site. Care should be taken to ensure that the base sections of each cubicle rests evenly on the supports. Taking into account the bending radius of the cables and adequate accessibility, a minimum floor height of 500 mm is recommended.
2

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Befestigen durch Schwei?en Fastening through welding Schwei?en nach Nivellierung Welding after levelling

Oberkante Fertigboden Top of finished floor max. 40 Oberkante Rohdecke Top of unfinished floor max. 55

Befestigung am Querprofil Fastening on the transverse provile

Oberkante Fertigboden Top of finished floor Oberkante Rohdecke Top of unfinished floor

Abb. 39, 40 / Fig. 39, 40 Fundamentbefestigungen (Beispiele) Fastening methods to foundation (examples)

Abb. 41 / Fig. 41 Aufstellung auf Kabel-Zwischenboden Installation on false floor for cables

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Erection and Commissioning

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3.6
3.6.1 Direktanschluss an Leistungs- und Lastschalter Leistungs- und Lastschalter sind mit Standardkabelanschlusss?tzen (Parallelschaltkonstruktion) ausgerüstet. (siehe Abb. 42, 43 und 45)

3.6 Cable connections, wiring
3.6.1 Direct connection to circuit breaker and load-break switches Circuit breaker and load break switches are equipped with standard cable connection sets (for cable connection in parallel). (see fig. 42, 43 and 45).

Abb. 42 / Fig. 42 Kabelanschlusss?tze, max. 8 Kabel Cable connection sets, max. 8 cables

Abb. 43 / Fig. 43 Kabelanschlusss?tze, max. 12 Kabel Cable connection sets, max. 12 cables

Bei gro?en Str?men ( 3500 A), Kabeleisen aus Aluminium verwenden. In case of high currents ( 3500 A), cable mounting rails made of aluminium must be used.

Abb. 44 / Fig. 44 Befestigung der Kabeleisen Fastening of cable mounting rails

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3150 A 12 (16)x300mm
2

1500 A Switch type

/ Rated current up to 2500 A

/ Max. numbers of cables and cross-section per phase Lastschalter OETL 4x300mm
2

8 (12)x300mm

2

(mit Zusatzstück / with supplementary cable connector) / Rated current up to 1600 A / Max. numbers of cables and cross-section per phase 3 (6)x240mm
2

Switch type

leistungsschalter Moulded case circuit breaker S6 / S7

(

/ with supplementary cable connector)

Switch type

/ Rated current up to 800 A 1250 A 1600 A 2000 A 2500 A 3200 A 4000 A 5000/6300 A Max. Anzahl der Leitungen x Leiterquerschnitt pro Phase / Max. numbers of cables and cross-section per phase

Air circuit breaker E1 1250 A E2 2000 A E3 3200 A E4 4000 A E6 6300 A

4x240mm

2

4x240mm 2 4x240mm 2 12x240mm

2

6x240mm 2 12x240mm

2

6x240mm 2 12x240mm

2

12x240mm

2

12x240mm 2 14x240mm 2 16x240mm

2

14x240mm 2 16x240mm

2

24x240mm

2

The control cabIes are led vertically at the side of the cubicIes and are connected directly to the control terminals of the circuit breaker moduIes or if necessary, to the terminaI strips in the control equipment recess. 3.6.2 1. 2. 3. : ( 44). 3.6.2 Cable connection in cubicles with cable compartment 1. Power and control cables are to be attached to the cable mounting rails (slot width 16,5 mm) in the cable compartment (see fig. 44). 2. Power and control cables are to be stripped off their jacket below the connections of each module. 3. Power and control cabIes are connected to: terminals (see fig. 46 or 48) or 49 . connection bars or outgoing cable connection units (see fig. 49). SR 47). ( . 48). ( Bellows providing protection against electrical shock are to be used for: Cable connections to cable clamps for fused Ioad-break switches type SR in the plug-in module design (see fig. 47). CabIe connections to outgoing cable connection units for withdrawable modules (see fig. 48).

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Erection and Commissioning

3

3.6.3

3.6.3 Cable connections at plug-in and withdrawable modules Before fastening the cables at the power terminals of the plug-in modules or the outgoing cable connection unit of the withdrawable modules they must be supported or bended so that no tension or pressure is exerted on the cable connection unit. Connection material and barriers are supplied with the switchgear separately. The frame-mounted cable mounting rails can be moved as required for the module terminals. Cable entrance to the cubicIe can be from above or below under consideration of the specified degree of protection. Control cables with individual conductors to be connected to several different modules are to be stripped within the cable compartment. The individual conductors must be installed inside the verticalIy mounted wiring duct in the cable compartment; likewise control cables for interwiring between modules.

.

.

3.6.4

3.6.4 Cable connections in control cubicles and wiring between shipping units The control cables are installed at the side in the lower part of the cubicle and led to the control modules through the vertical wiring duct. Before positioning the cables it is advisable to secure them with cable straps. Control cables and conductors for the cubicle-to-cubicIe wiring are Ied through the control wiring duct situated in the upper part of the equipment compartment. At the transport divisions the separated cables have to be connected. For this the cables have to be connected to the terminals of the control wiring duct in accordance with the markings.

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Measuring and equipment

Voltage tap

Earthing bolt

Cable connection

Abb. 45 / Fig. 45 Direct connection at a circuit breaker

Abb. 46 / Fig. 46 INSUM Cable connections of a cubicle with railable modules with INSUM

Abb. 47 / Fig. 47 SR Cable connections for fused load-break switch type SR

Abb. 48 / Fig. 48 Klemmenleisten und Kabelanschlüsse eines Einschubfeldes Terminal strips and cable connections for a cubicle with withdrawable module design

44

Erection and Commissioning

3

Cable connection unit

( ) Adapter ring (optional)

M10 M12 Hexagon head screw M10 or M12

DIN 6796 Spring washer DIN 6796 M10 M12 Nut M10 or M12

Bellow (shock protection)

Spannscheibe DIN 6796 DIN 6796

Cut off rings to match the cable cross section

Fix with cable tie

Rated current 160 A 250 A 400 A 630 A

Number of poles 3 6 3 4 4 3 3

Cable connection

M10 x 30

M12 x 35

Withdrawable module size ab/from 8 E ab/from 8 E 6E 6E ab/from 8 E ab/from 8 E ab/from 16 E

Max. tightening torque

45 Nm

80 Nm

Abb. 49 / Fig. 49 6E Cable connection for withdrawable modules from 6E

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1TSA215002P0286 1TGL110046P0011 1TGL110046P0001 9ADA629-54 9ADA629-61

3.6.4 2E 51–52). 4E 6E 8E M 6x10 M 6x40 1TSA215002P0286 1TGL110046P0011 1TGL110046P0001 9ADA629-54 9ADA629-61

3.6.4 Mounting of cable connection units Cable connection units can be used in 2E grids with and without distribution bar covers in the standard as well as in the supplementary distribution bar system (see fig. 51–52). Bracket for cable connection unit 4E Bracket for cable connection unit 6E Bracket for cable connection unit 8E Pan head rolling screw M 6x10 Pan head rolling screw M 6x40

1 x 25 mm 2 Box terminal for max 1 x 25 mm

2

Abb. 50 / Fig. 50 4E ( 63 A) Cable connection unit for 4E-modules (max. 63 A)

l (630A ) Bracket (for the cable connection unit 3x630A two pieces are necessary)

Li-Formschrauben M 6x10 Pan head rolling screws M 6x10

Li-Formschrauben M 6x40 Pan head rolling screws M 6x40

3,5 Nm The max. tightening torque of the pan head rolling screws is 3.5 Nm. Abb. 51 / Fig. 51 1) 2E 1) Mounting of the bracket in 2E-grid Abb. 52 / Fig. 52 2) C 2) Screwed joint of the cable connection unit at the C-section

46

Erection and Commissioning

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3.7
: 63 A: 100 A: 100 A: M6 PE PE (PE PEN ) PE PEN PE

3.7 Protective conductor connection
The protective conductors have to be connected as follows: Up to 63 A: To the PE terminal of the withdrawable module condapter or the plug-in, disconnectable or railable module. To the vertical section located at front right (see fig. 53) with a screw M6. To the vertical PE connection bar, arranged right in the cable compartment (see fig. 4) as screw connection or using a bar mounting terminal.

Up to 100 A: Over 100 A:

The green and yelIow conductor (colour marking over the entire length) may only be used as protective (PE) or PEN conductor. lt must not be used as a voltage carrying conductor by altering the colours at the ends or employed as regulator earth or as a connector for the shield earth. (2.5 mm 50V
2

) 120V

lEC 60439

VDE 0100 Part 540

ln all cases, protective conductor connections screwed on to painted surfaces should be secured with serrated contact washers. Any means of locking the screws is permissible for fastening screwed connections to gaIvanised surfaces. No lockwashers are required for roundhead screws (so-called Taptite screws) when screwed into galvanised parts for the first time. The protective conductors are connected to the doors by fIexible 2 green and yellow copper conductors (cross-section 2.5 mm ). The connections are not necessary if no Iive ( 50 V AC or 120 V DC) equipment is mounted to the doors. The continuous connection of the protective conductor circuits to inactive metal parts of the building (in accordance with lEC 60439 or DIN VDE 0100 Part 540) is to be carried out according to the conditions at the erection site.

3.8 Neutralleiter-Anschlussm?glichkeit
N N

3.8 Neutral conductor connection
The neutral conductors have to be connected to the insulated neutral bar arranged parallel to the protective conductor bar or to the neutral connection bar, as screw connection or using a bar mounting terminal. ln all cases the connection is to be made at the height of the relevant module and allocation must be clearly distinguishable. ln other cases, e.g. for control cables, cross referencing will be necessary. Key to abbrevations

ABB

IEC 60439-1 / VDE 0660 Teil 500 PE N PEN

Object

Protective earth conductor Neutral conductor Neutral conductor with protective function

Abbreviation acc. to IEC 60439-1 / VDE 0660 part 500 PE N PEN

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3.9
3.9.1

3.9 Special information
3.9.1 lnterruption of work lf work is interrupted during erection or connection, measures should be taken to ensure that maximum protection is provided against outside interference like dust, moisture and foreign objects, like: Close the cubicle doors. lf necessary, cover the switchgear with foil. lf necessary, the pIace of erection must be heated

3.9.2 IP IP X2 IP 5X 3mm 15X2mm(GSIN100021P0010) IP X1 IP 4X

3.9.2 Degree of protection Depending on the degree of protection measures are required to be taken at the erection site to seal the cubicles: For degrees of protection IP X2 or IP 5X the bottom plate covers (flanges) have to be sealed, if not already done at the manufacturers site. To seal the bottom plate covers the self adhesive sealing 15 x 2 mm (GSIN100021P0010) has to be used which has to be applied after cleaning (see below) on the inside bending of the flanges with an overlapping distance of 3 mm to the bending. For degrees of protection IP X1 or IP 4X a sealing of the frames between the cubicles (cubicle/cubicle) at the transport division is necessary. Therefore the following measures have to be taken: The connection sides of the affected frame sections have to be cleaned with Terokal R (GSIN100298P0001) cleaner using an oil- and grease-free piece of cloth. After drying of the cleaner the self-adhesive sealing tape 15 x 2 mm (GSIN100021P0010) has to be applied to the Csections at a distance of 3 mm from the outer edge (see fig. 54).

Terokal R (GSIN100298P0001) 15 x 2 mm (GSIN100021P0010) C 3mm 54

Terokal R

The cleaner Terokal R is inflamable. Obeye the use instructions of the manufacturer.

Sealing material is supplied with the cubicle. Use glands for cable entrances.

Dachplatte Roof plate Dichtung 15x2 selbstklebend Sealing 15x2 self-adhesive GSIN100021P0010 Eckabdichtung Corner sealing GLBK410048P0001

Rückwand Rear wall

Nachbarfeld Adjacent cubicle

Dichtung 15x2 selbstklebend GSIN100021P0010 für Feld/Feld- und Seitenwandabdichtung Sealing 15x2 self-adhesive GSIN100021P0010 for cubicle to cubicle and side wall sealing

53 / Fig. 53 C Protective conductor connection at a vertical structural C-section

Abb. 54 / Fig. 54 Ma?nahmen zur Abdichtung Measures for sealing

48

Erection and Commissioning

3

3.9.3 5.9 3.9.4 5.11 5.12 ABB ? “

3.9.3 Damage to paintwork Refer to chapter 5.9 ?Damage to paintwork“ 3.9.4 Supply of material The most important spare parts and accessories are listed in sections 5.11 and 5.12. Other parts and accessories are contained in the relevant lists or are obtainable through the responsible project or sales department of ABB.

3.10

3.10 Final preparations
Remove transport safety devices (wooden bracing) from heavy components. Mount separately shipped equipment, such as withdrawable circuit breaker, fuses, fluorescent tubes, measuring instruments. The equipment is appropriately marked. Enclosed mounting instructions have to be obeyed. Remove any foreign parts, such as tools, packing material or conductor scraps from the switchgear. 4 Clean insulating parts with an anti-static cloth. Do not use any solvents as for example carbon tetrachloride, trichlorethyIene or hydrocarbons. Close the doors. Slide the withdrawable modules into testing position (see chapter 4, Operation).

,

3.11
5.14

3.11 Checks
Check the busbar connections at the shipping unit divisions. (refer to chapter 5.14 for tightening torques) Check the frame connections at the transport divisions. Check the floor fastening (to foundation or false floor). Check the realization of the required degree of protection, particulary with regard to the bottom plates. General visual check; appearance, completeness, markings, foreign parts in the switchgear, dirt. Check for correct and complete cable connections and wiring as far as installed on site. Barriers in place? Check for correct and complete protective conductor connections.

IP

3.12

3.12 Commissioning
Switch on control voltage. Test the control, protection and monitoring equipment and the mechanical and electrical interlocking devices. Apply voltage to the busbars. (insulation test!) Switch on the main circuits individually. Check the indication and measuring equipment for correct readings. Observe the general precautionary rules and regulations.

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Operation

4

4.1

4.1 Electrical equipment
Separate provided operating instructions have to be obeyed for the electrical equipment.

4.2

4.2 Fixed technique
No separate operating instructions are necessary for fixed modules.

4.3

4.3 Plug-in, disconnectable and railable technique
4.3.1 Plug-in modules Depending on their design, modules are operated from inside or from outside if a rotary handle has been fitted. Please note the operating instructions for the electrical components installed in the plug-in module. For outside operation, the symbols shown on the service handle are to be observed.

4.3.1

4.3.2

4.3.2 Disconnectable modules Disconnectable modules may only be operated from inside.

Taking out disconnectable modules under load is not permitted. The load should be disconnected before taking out the modules.

4.3.3 55

4.3.3 Railable modules Railable modules may only be operated from inside. Modules may be withdrawn with the help of a handle. Additional the operating instructions on the inside of the cable compartment door are to be considered (see fig. 55). ) ) The following positions are possible for railable modules: Service position (all main and auxiliary circuits are closed) Test position (the main circuit is isolated from the system, the control circuit is connected). The module is visibly disconnected. Isolating position (all main and control circuits are isolated). The module is visibly disconnected (see fig. 59).

( ( ( 59)

)

(

50

Operation

4

55 / Fig. 55 Open door with service handle and operating instruction.

56 / Fig. 56 Inserting service handle.

The test position is achieved as follows: Switch off main switching device Insert the module handle as described above Lock the module handle to the module Pull out the module up to the first engaged position Lock the module to the guide rail (turning module handle toggle counter-clockwise) Remove the module handle (see fig. 56-59)

.

(siehe Abb. 56-59)

57 / Fig. 57 Locking the service handle when simultaneous unlocking the module.

58 / Fig. 58

Lift module slightly and pull it out up to the first engaged position. Unlock service handle and lock the module at the same time. Remove service handle.

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Operation

4

59

Fig. 59 Test position or isolated position. The module is visibly disconnected. Then the module’s control circuit can be tested. The isolated position is achieved by unplugging the control plug. ( 60 61)

Railable modules can be locked in service position as well as in test and isolated position by means of padlocks (see fig. 60 and 61).

60 / Fig. 60 Interlocking of the railable module

61 / Fig. 61 Securing the railable module using a padlock

52

Operation

4

62

Fig. 62 Removal of a railable module: Lift module slightly and pull it out Lift module out totally by grabbing it on its sides Remove service handle

The module must not be carried by its service handle

4.4 SR
SR

4.4 Fused Ioad-break switch type SR
The LV HRC fused load-break switch type SR is a three pole multi function device covering the switch functions >>load-breaking<< and >>protecting (fuses)<<. The loadbreak switch is provided with a spring assisted mechanism. 45 The toggle must be pulled to the left and latched before operating. For switching on, the handle has to be pushed to the side for 45°. The handle can be locked in the OFF-position with up to three padlocks. The ON-position of the switch is marked 1 (red). The OFF-position of the switch is marked 0 (green). Whether or not fuses are blown can be observed easily since the cover is of transparent material.

“1

“0”

SR-M

An interlock prevents the front-cover from being opened in case the switch is in ON-position. When using the SR-M fused load break switch as incoming feeder it must be noted that the fuses are de-energized in the OFFposition of the switch.

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Operation

4

4.5 8E/4
8E/4 8E/2

8E/2

4.5 Withdrawable units size 8E/4 and 8E/2
Withdrawable units size 8E/4 and 8E/2 comprise: One or two profiIe sections for mounting snap-on components, 16 20 38 16 20 8E/4 8E/2 38 a rear waIl with integrated power contacts inclusive wiring and with one 16-, 20- or 38-pole control plug in case of module size 8E/4, one or two 16-, 20- or 38-pole control plug in case of module size 8E/2, a front panel made of insulating material with knockouts for mounting measuring, operating and indicating instruments, the side walls.

2NO

2NC

If using certain standard Ioad-break switches and circuit breakers the handle for operating those devices also activates the electrical and mechanical interIocking. A micro switch with 2 NO and 2 NC contacts is provided for electrical interIocking.

Position of switch ON

Position of module
in cubicle

Main and control circuits
All main- und controlcircuits are closed

3

OFF
Can be locked with 3 padlocks

in cubicle

All main- und controlcircuits are disconnected

3

TEST
Can be locked with 3 padlocks -

in cubicle

All main-circuits are disconnected, the control-circuits are closed

MOVE Position

3

30mm

in cubicle Isolated Position not in cubicle The module is 30 mm drawn out of the cubicle

All main- und controlcircuits are disconnected

ISOLATED Position
Can be locked with 3 padlocks

All main- und controlcircuits are disconnected and the isolating distance is fulfilled

63 8E/4

8E/2

Fig. 63 Description of operating handle positions 8E/4 and 8E/2 modules The switch handle can be moved from position ?OFF“ to position ?ON“ only after the handle has been depressed (push-to-turn feature). The switch handle can be locked in the positions ?OFF“ and ?TEST“ and the isolated position with up to three padlocks (see fig. 67). The withdrawable unit can be prevented from being withdrawn by an additional mechanical Iock (protection against theft) to be installed in the front cover. Switch handIes of withdrawable units that are not used must be in position ?OFF" or ?ISOLATED".

3

67

54

Operation

4

Resetting circuit breakers in withdrawable modules ON OFF When moulded-case circuit breakers are tripped on faults, the switch handle might jump into an intermediate position between "ON" and "OFF“. The function of the circuit breaker can only be re-established by a reset. Reset the fault by turning the switch handle from the intermediate position to the "OFF" position and further to the stop. Then, the circuit breaker can be switched on again. ON OFF OFF 1. Turn switch handle from "ON" position to "OFF" position. 2. Press switch handle down and turn it counter-clockwise to the stop. 3. When released, the switch handle swings back to “OFF“ position. 4. The circuit breaker is ready to be switched on. Note: A clear release tripped indication can only be realized with an electrical signal (e. g. pilot lamp or aural signal).

OFF

1. 2. 3. 4. :

64 / Fig. 64 INSUM 8E/2 Withdrawable module size 8E/2 with INSUM

65 / Fig. 65 INSUM 8E/4 8E/2 Front view of withdrawable modules size 8E/4 and 8E/2 with INSUM

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Operation

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65 / Fig. 66 8E/4 8E/2 Switch operating handle for withdrawable modules size 8E/4 and 8E/2 with position markers

67 / Fig. 67 3 8E/4 Withdrawable module size 8E/4 with 3 padlocks

4.6 4E
4E 48E

48E

4.6 Withdrawable units size 4E up to 48E
Withdrawable units size 4E up to 48E are built-up of sheet steel components which constitute the supporting frame for the electrical components and the contact elements. The hinged front cover offers the advantage of easy accessibility to the built in components from the front side. Opening the front cover with a key is only possible in isolated, test or OFF-position of the withdrawable unit. If a parallel coupling is installed, opening of one lock is sufficient. Opening of the front cover while the operating handle is in ?ON“-position is only possible with a screw driver (see chapter 5, fig. 75).

OFF ON 75)

(

5

ON

If opening the front cover while the operating handle is in ?ON“-position it is possible to touch live parts.

2NO+2NC

The withdrawable unit can be equipped with an instrument panel made of insulating material for the installation of measuring, operating and indicating instruments. The hinged instrument panel is mounted to the withdrawable unit and sticks out through a cutout in the front cover. This panel remains in position when the front cover is opened. If the front cover is open, the instrument panel can be tilted down by unlocking the locking lever on the left and right side of the panel. After tilting down the instrument panel a better access to the equipment both in the withdrawable unit and the instrument panel is provided. The main switch is operated by the operating handle which is also used for the mechanical and the electrical interlocking. A micro switch with maximum 2 NO and 2 NC contacts is provided for the electrical interlocking.

56

Operation

4
Position of module
in cubicle

Position of switch ON

Main and control circuits
All main- und controlcircuits are closed

3

OFF
Can be locked with 3 padlocks

in cubicle

All main- und controlcircuits are disconnected

3

TEST
Can be locked with 3 padlocks -

in cubicle

All main-circuits are disconnected, the control-circuits are closed

MOVE Position
30mm 3

in cubicle Isolated Position not in cubicle The module is 30 mm drawn out of the cubicle

All main- und controlcircuits are disconnected

ISOLATED Position
Can be locked with 3 padlocks

All main- und controlcircuits are disconnected and the isolating distance is fulfilled

68 4E 48E

Fig. 68 Description of operating handle positions 4E to 48E modules

A test function of the control circuit for moulded case circuit breakers with motor operating is not possible in the test position. OFF A secure breaking of the maincircuit is achieved in the OFF-position due to the isolating characteristics of the used main switching devices. In addition it is necessary for working at the consumer to achieve a secure isolation of the main- and control-circuits by moving the withdrawable module to the isolated position.

Resetting circuit breakers in withdrawable modules ON OFF When moulded-case circuit breakers are tripped on faults, the switch handle might jump into an intermediate position between "ON" and "OFF“. The function of the circuit breaker can only be reestablished by a reset. Reset the fault by turning the switch handle from the intermediate position to the "OFF" position and further to the stop. Then, the circuit breaker can be switched on again. 1. Turn switch handle from "ON" position to "OFF" position and further to the stop. 2. When released, the switch handle swings back to “OFF“ position. 3. The circuit breaker is ready to be switched on. Note: A clear release tripped indication can only be realized with an electrical signal (e. g. pilot lamp or aural signal).

OFF

1. 2. 3.

ON

OFF OFF

:

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Operation

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69 / Fig. 69 8E Withdrawable module size 8E

70 / Fig. 70 16E Withdrawable module size 16E

71 / Fig. 71 4E 48E Switch operating handle for withdrawable modules size 4E up to 48E with position markers

“MOVE“

Moving of the withdrawable module The withdrawable unit can only be moved, if the operating handle is in position ?MOVE“. This ensures that it is not possible to move a withdrawable module under load. “MOVE“ For moving a withdrawable unit the operating handle has to be brought to the position ?MOVE“ and the withdrawable module has to be pulled out with the use of the two handles. When the unit starts moving the operating handle immediatly moves back to the position ?OFF“ and the withdrawable unit interlocks after 30 mm in the isolated position. In this position the main and control contacts are disconnected. For further moving of the withdrawable unit the operating handle has to be switched to the position ?MOVE“ again. Afterwards the withdrawable module has to be pulled out further. Before removing the withdrawable unit from the cubicle completely the

“OFF“

30mm

“MOVE“

58

Operation

4

85

withdrawable unit interlocks again to avoid being pulled out from the cubicle uncontrolled. To release this safety stop it is necessary to press down the lever on the left side of the withdrawable unit (see fig. 85). If the withdrawable unit which should be moved is installed in a high position in the cubicle the safety stop can be released by supporting the withdrawable unit with the right hand from below and releasing the lever with the left hand. Afterwards the withdrawable unit can be removed completely from the cubicle. Depending on their size withdrawable units have a high weight. Therefore the following safety measures have to be obeyed by all means:

:

4E 12E

8E

After moving out the withdrawable unit halfway from the withdrawable module compartment the operator has to grasp the withdrawable unit from below under the sides (for withdrawable units size 4E and 8E). 12E For withdrawable units size 12E and bigger the withdrawable unit should only be withdrawn by two persons. For this the operators should be located at one side of the withdrawable unit each and grasp the withdrawable unit from bellow (12E) or at the provided hand grips located at the side walls (> 12E). The withdrawable unit should not be left longer than necessary in the position of the safety stop, because the centre of gravity is already outside the cubicle in this position. Disregarding of this regulation can lead to mechanical damage at the withdrawable unit.

>12E

Withdrawable units in isolated position or in the position of the safety stop are not to be used as help for climbing because persons can be endangered and/or the switchgear can be damaged.

“TEST“

The test position can be achieved without moving the withdrawable unit by turning the operating handle to the position ?TEST“. The operating handle can be locked in the positions ?OFF“ and ?TEST“ by using up to three padlocks. Removing of the unit can be prevented by an additional mechanical lock (protection against theft) which additionally can be installed in the front cover.

“OFF“

“TEST“

3

“OFF“ For withdrawable units that are not being used the operating handle must be in the position ?OFF“.

4.7 Besondere Hinweise

4.7 Special information
When the installation is in operation ensure that the doors and the front covers of the withdrawable modules are closed, the withdrawabIe modules are interlocked, the ventilation louvers are not abstructed or clogged

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5

5.1 Allgemeines

5.1 General
Maintenance work, such as replacing fuses etc., must only be carried out by suitable instructed personnel observing the safety rules. . When working on switchgear cubicles the following regulations must be observed: The national and international safety rules (e.g. VDE 0105, regulations for the operation of power installations). The specific maintenance instructions of the installed devices. When making modifications to cubicles it may be necessary to interrupt the operation of adjacent parts of the installation, depending on the extent of the work and the type of design. For modifications inside the cubicles it is necessary to reconsider the changed heat balance. The allowed limit of temperature-rise inside the switchpanel must not be exceeded. In case of doubt please contact your appropriate ABB branch. The use of ESLOK-secured screws renders maintenance of the bar connections unnecessary. After fault situations the checks are to be carried out just as before commissioning. Pveff 5.1.1 Maximum admittable effective power loss Pveff : The following preconditions are valid for the standard values given under 5.1.1.1 and 5.1.1.2: Cubicle distance from wall at least 8 cm Middle cubicle in multi cubicle arrangement Pveff 5.1.1.1 Standard values of maximum admittable effective power loss Pveff for degrees of protection up to IP 31 and IP41, natural air circulation Roof-plate: Front: Back: stretch lattice 1 ventilation louvre IP30/IP40 1 ventilation louvre IP30/IP40

. : VDE0105, .

ABB . ESLOK

5.1.1 5.1.1.1 5.1.1.2 8cm

5.1.1.1 IP31

IP41,

1 1

IP30/IP40 IP30/IP40 400,600mm ,

For small cubicles (W = 400, 600 mm) 2 ventilation louvres must be used. In case of ventilation from bottom (without bottom plate) i.e. because of cable pits or false floors, there are no ventilation louvres necessary for cubicles, as long as an equivalent air circulation is possible.

5.1.1.2

IP32/IP42( Pveff

)

IP54
2200 mm 1000 mm 600 mm 600 mm

5.1.1.2 Standard values of maximum admittable effective power loss Pveff for protection classes IP 32/IP 42 (nonventilated) and IP 54 Cubicle: H W D W1 = = = = 2200 mm 1000 mm 600 mm 600 mm

= = =

Equipment compartment:

1000mm 800mm 3

3 80 20 8cm

Decrease resp. increase of standard values: For cubicles < 1000 mm curve 3 must be lowered in percentage terms, i.e. for W = 800 mm, lower curve 3 to 80 %. For end cubicles of a switchgear, an increase of the curves by 20 % can be taken into account, due to an additional emmission area of one side wall (Cubicle distance to wall at least 8 cm).

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Explanation of diagram curves:

5

: 60°C 8E/4 8E/4 IP30 – IP42, IP32 – IP54,

The curves correspond to an air temperature of 60°C below the roof plate of the switchgear cubicle. Reduction factors for withdrawable modules size 8E/4 and 8E/2 see next page. IP30 – IP42, ventilated IP32 – IP54, non-ventilated Withdrawable technique Plug-in, disconnectable and railable technique Cubicles without subdivisions, energy distribution, electronics

1500

1400

1300

1200

sige Verlustleistung / Permissible power loss [W] Zul

1100

1000

900

800

700

600

500

400

300

200

100

0 20 30 40 50

Umgebungstemperatur / Ambient temperature [

]

72 Pveff

Fig. 72 Standard values of maximum admittable effective power loss P veff

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5.1.1.3 8E/4,8E/2 8E/2,8E/4

5.1.1.3 Pv Reduction factors for use of withdrawable modules size 8E/4 and 8E/2 The following table gives reduction factors to be multiplied with the permissible power loss for withdrawable modules size 8E/4 and 8E/2 due to additional barriers confining ventilation.

5

.

Rows 3 and 5 relate to the examples given in the table head.

35°C

Given data are valid for an ambient temperature of 35°C.

IP30 – IP42,

/ ventilated /Example Max. Pv = 550 W 550W / per cubicle

IP32 – IP54,

/ non-ventilated /Example Max. Pv = 250 W 550W / per cubicle

Beispiel/ Example

/ No. of occupied rows 1 2 3 4 5 6 7 8 9 73 / Fig. 73

/ Reduction factor 0,77 0,69 0,66 0,63 0,61 0,60 0,59 0,59 0,59

/ Resulting Power loss 424 W 380 W 363 W 347 W 336 W 330 W 325 W 325 W 325 W

/ Reduction factor 0,91 0,87 0,85 0,83 0,81 0,80 0,80 0,79 0,79

/ Resulting Power loss 228 W 218 W 213 W 208 W 203 W 200 W 200 W 198 W 198 W

8E/4,8E/2 Reduction factors, applicable to the permissible power loss for withdrawable modules size 8E/4 and 8E/2 5.1.2 5.1.2 Possibilities for testing the control circuits of withdrawable modules Prior to commissioning of a motor or energy outgoing unit the function of the control circuits must be tested according to the interlocking conditions. . 48E . This can be done as follows: 1. When the withdrawable modules are in test position. 2. For withdrawable modules 8E to 48E by means of a test adapter. 3. With the help of a test cable. . 1. Test position of the withdrawable module This corresponds to the standard design. 1. 2. . 3. . 1. The main switch (fused motor switch, circuit breaker) is switched off. The power and control circuits are disconnected. 2. The switch handle is turned to ”TEST” position. The withdrawable module remains in the contact position. The power circuit is disconnected, the control circuit is operational. 3. In this positino, the internal and external switching conditions can be tested without power.

: 1. 2. 8E 3. 1.

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2. (

) .

2. Testing of the control circuit with the help of a test adapter (refer to table on the next page) For this purpose, the withdrawable module must be pulled out to maintenance position, and an adapter must be plugged into the control plug. Then the module is pushed back to ”isolating position” and secured by turning the switch handle to isolation position. In this position, the control circuit is operational, but the power circuit is not. Thus, testing can be carried out without power. For further information refer to table hereunder.

3.

3. Testing of the control circuit with the help of a test cable 3 16 20 32 The test cable is designed for carrying out the test outside the withdrawable module compartment. The test cables are 3 m long and have 16, 20 or 32 poles. For further information refer to the table hereunder. Control circuit testing by means of a test adapter or a test cable Test adapter resp. test cable will be plugged between control plug (female plug) in the compartment and control plug (male plug) of the withdrawable module. 30mm , The test adapter is used for control voltage testing in the compartment with a 30 mm withdrawn withdrawable module. The test cable is used for control voltage testing outside the withdrawable module compartment (i.e. on a separate work-plate). Test adapter and test cable for withdrawable modules size 4E and 6E on request. / Type TA 8E

4E

6E

Description / test adapter

Order number GILN 220007 R0001 GILN 220007 R0002 GILN 220007 R0003

Application 32 8E - 48E 32-pole for 8E - 48E 16 8E - 48E 16-pole for 8E - 48E 20 8E - 48E 20-pole for 8E - 48E 16 8E/4 und 8E/2 16-pole for 8E/4 and 8E/2 20 8E/4 und 8E/2 20-pole for 8E/4 and 8E/2 38 /4 und 8E/2 38-pole for 8E/4 and 8E/2 32 8E - 48E 32-pole for 8E - 48E 16 8E - 48E 16-pole for 8E - 48E 20 8E - 48E 20-pole for 8E - 48E

/ test cable

TK 2E TK 8E

GILN 220005 R0001 GILN 220005 R0002 auf Anfrage on request HANL 100063 R0001 HANL 100063 R0002 HANL 100063 R0003

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5

5.2

5.2 Plug-in, disconnectable and railable technique
In case of modifications of switchgear cubicles a possible change of the heat balance inside the cubicles has to taken into account. The allowed limit of temperature-rise inside the switchgear cubicle may not be exceeded (see fig. 72, 73). 5.2.1 Plug-in, disconnectable and railable modules The installation and removal of modules is reserved to skilled electrical personnel.

72

73

5.2.1

Plug-in modules : For installing or removing plug-in modules, the switchgear system must be isolated. Proceed as follows to remove a module: 5 Isolating the module Isolating the system (National (VDE0105, five safety rules) and international standards are to be observed).

VDE0105

Isolating the modules Protecting against reclosing Verify isolation from supply Earthing and short-circuiting Barriering adjacent live parts

ABB

Detach outgoing cable and disconnect control cables Remove module fastening screws and carefully pull module out of the cubicle If necessary, empty slots must be covered with blanking plates. (Please contact your ABB supplier) The modules are installed analogously in reverse order.

L?sen / unscrew

74 / Fig. 74 L?sen der Kabel und Steuerleitungen zum Ausbau des Modules (Bsp. Schubeinsatzmodule)

Abb 75 / Fig. 75 L?sen der Kabel und Steuerleitungen zum Ausbau des Modules (Bsp. Schubeinsatzmodule) Detaching the power and control cables prior to removing module (e.g. railable module)

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76 / Fig. 76 Isolating the front wiring (in this case railable module, but without cable) Disconnectable modules : The modules can be removed on live systems. Proceed as follows to remove a disconnectable module: Isolating the module in compliance with the safety rules Detach outgoing cable and disconnect control cables. Modules <=7E: Pull out positioning screws from the right and left of the handles and turn them counter-clockwise by 180°, thus locking the screws in position. Unscrew screw next to them. Module>7E: Remove all fastening screws (cages) from the base plate. Carefully pull out the modules by the handles. The modules are installed analogously in reverse order.

7E 180° 7E

Sicherungsschraube locking screw

Abb. 77 / Fig. 77 Locking screw of disconnectable modules

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Railable modules The modules shall be removed in accordance with the operating instructions (it is always located on the inside of the cable compartment door next to the railable module in question).

78 / Fig. 78 Open door with service handle and operating instruction : Removing a railable module: Lift module slightly and pull it out Lift module out totally by grabbing it on its sides Remove service handle

The module must not be carried by its service handle.

79 / Fig. 79 Inserting the service handle

80 / Fig. 80 . Locking the service handle when simultaneous unlocking the module.

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81 / Fig. 81 Lifting and pulling out the module

82 / Fig. 82 Removing the module

Wiring tool C 83 . In order to facilitate the connection of control cables, a wiring tool is available which is fasted to the front C-section of the cable compartment (see fig. 83).

83 / Fig. 83 Wiring tool

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5.3

5.3 Withdrawable technique
The following description refers to the standard modules. For modules differing from the standard version separate descriptions should be applied for. The multi-function separator is arranged between the busbar and the equipment compartment. lt covers the complete height and width of the equipment compartment and fullfils the following functions: Holding of distribution bars. . Fastening and covering of distribution bars by means of the distribution bar cover. Protection against formation and propagation of arc faults. As an alternative for the multi-function separator the metal separation wall can be arranged between the busbar and the equipment compartment. It covers the complete height and width of the equipment compartment and is used for covering the distribution bars. The contact openings of the distribution bar covers fulfill IP 20 and therefore conversion is made possible without the need of interruption of operation for the cubicle (see fig. 86).

IP20 86

84 / Fig. 84 Unlatching the front cover of a withdrawable module by means of a screw driver

If opening the front cover while the operating handle is in ?ON“-position it is possible to touch live parts.

85 / Fig. 85 Draw out of a withdrawable module

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5

The withdrawable module can be exchanged or removed and replaced in the compartment during maintenance without isolation. 8E/4 48E 8E/2 4E With the interIocking switch handle in the move position, withdrawable modules size 8E/4 and 8E/2 can be withdrawn without stop. The modules size 4E up to 48E have to be withdrawn up to the stop position, released and then removed completely. Main fuses in withdrawable modules with hinged front cover are accessibIe after the main switching device has been turned OFF and after the front cover has been unlatched. Unlocking the front cover with the module in the operating position can only be achieved by means of a tooI, e.g. a screw driver (see fig. 84). The interlocking mechanism can be found at the side of the switch handle. For conversion or modification of complete withdrawable module units, e.g. replacement of one large unit through several smaller units or vice versa, the frame-mounted compartment has to be exchanged, too (see fig. 86/87).

84

86/87

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5.4

5.4 Conversion and change of withdrawable module compartments
Before the conversion and/or change of withdrawable module compartments the withdrawable module below the affected withdrawable module compartments has to be removed from the cubicle. By using a appropriate cover for the compartment bottom plate of the withdrawable module compartment below small parts have to be prevented from falling through. 72 73 In case of modifications of switchgear cubicles a possible change of the heat balance inside the cubicles has to be taken into account. The allowed limit of temperature-rise inside the switchgear cubicle may not be exceeded (see fig. 72/73).

86 / Fig. 86 8E 2E

Withdrawable module compartment size 8E with outgoing cable connection unit, 2E-distribution bar cover

87 / Fig. 87 8E/4 8E/2 Conversion to withdrawable module compartments size 8E/4 and 8E/2

70

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5.4.1

1

16E 200mm

2

400mm 8E/2

4 8E/4 200mm

5.4.1 Example 1: Conversion of one unit size 16E (height 400 mm) into 4 units each of size 8E/4 (height 200 mm) and two units each of size 8E/2 (height 200 mm) The conversion has to take place in the following sequence:

86 . 49

Disassembly (see fig. 86) Pull out the withdrawable unit. Disconnect power cables after protective cover (bellows) has been removed. Due to the protective covers on the adjacent cable connection units work inside the cable compartment can be performed without danger (see fig. 49). Disconnect control wiring. Remove control terminal block and its support located at the lower right hand side of the compartment (in the cable compartment). The left guide rail on the Iower compartment bottom plate has to be removed. Remove cable connection unit (see fig. 49). Reassembly (see fig. 13 and 87) 13 Install a new compartment bottom plate (item 72) 200 mm from top and bottom of the old compartment and fix it by screws. In the back of the newly created two compartments install one withdrawable unit condapter each (see fig. 13), one for four withdrawable units size 8E/4, one for two withdrawable units size 8E/2. During mounting of a withdrawable unit condapter it has to be made sure that a earthing connection is established at the lower right screw connection using a bushing (GLBL210021P0001) and a washer A 6,4 (9ADA312-6) (see fig. 13). 8 plastic guide rails have to be mounted, four for each compartment bottom plate. 2 8E/2 Install 3 front posts between two compartment bottom plates for 8E/4 modules and one front post for 8E/2 modules in the other compartment. Connect power cables and control wiring. Insert four withdrawable modules size 8E/4 into the upper compartment and two withdrawable units size 8E/2 into the lower compartment. Should new material be required contact the nearest ABB-sales office or representative.

49 . 13 87 200mm

4

8E/4

2

8E/2

A6 6 13 .

4

9ADA312-

8 8E/4 8E/2 . . 4 8E/4 3

4

ABB

5.4.2

2 200mm

24E

600mm

3

8E

5.4.2 Example 2: Conversion of one unit size 24E (height 600 mm) into three units size 8E (height 200 mm each) The conversion has to take place in the following sequence: Disassembly Pull out withdrawable unit.

8E 8E

lf required exchange power cable or leave for one of the units size 8E if suiting. Disconnect control wiring or Ieave for one of the units size 8E if desired. The compartment bottom plate with the guide rail and the top compartment bottom plate remain unchanged. Reassembly

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2 2 8E

49 . . . 1 2 16-/20 lnstall 2 outgoing cable connection units (details see fig. 49). Insert two new compartment bottom plates with a distance of 8E each and fix them with screws. The newIy installed bottom plates must be equipped with the left guide rail and the rollers and covers have to be mounted. Between the newly installed compartment bottom plates one control terminal block support per withdrawable module compartment with one or two 16-/20-pole terminal blocks must be mounted on the right hand side (in the cabIe compartment). lf only one terminal block per support is required it must be mounted in the upper part of the cut-out of the support. The lower part has to be covered with a cover plate. Connect power cabIes with their protective covers (bellows) (see fig. 50) and also the control wiring. lnsert three new withdrawable units size 8E. Should new material be required contact the nearest ABB saIes office or representative.

50 8E .

ABB

5.4.3

3 600mm

6

8E/2

200mm

24E

5.4.3 Example 3: Conversion of 6 units size 8E/2 (height 200 mm) into one unit size 24E (height 600 mm) The conversion has to take place in the following sequence: Disassembly

6

.

Pull out the 6 withdrawable units. Disconnect power and control cables and wiring. 13 . . DisassembIe the two middIe compartment bottom plates with front posts and guide rails (see fig. 13). 13 . Remove guide rail and front post from the lower compartment bottom plate (see fig. 13/15). Take out the 3 withdrawable module condapters with their terminal blocks (see fig. 13).

2

50 . 2 15 . . 1 2 16-/20

Reassembly InstalI one outgoing cable connection unit (details see fig. 50) depending on the module design. Depending on the current or whether a star-delta unit is used two outgoing cabIe connection units can be mounted. Install guide rail left on the lower compartment bottom plate (see fig. 15).

49 24E

2

Mount roller and cover in the compartment bottom plate (see fig. 15). lnstall control terminal block support with one or two 16-/20-pole control terminal blocks. When only one 16-/20-pole control terminal block is required mount it in the upper part of the support and use a cover for the lower part of the support. Connect power cable including protective cover (bellows, see fig. 49) and control wiring. For parallel connection of two outgoing cable connection units an additional bellow is required. lnsert new withdrawable unit size 24E.

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5.4.4

4 600mm

3

8E

200mm

1

24E

5.4.4 Example 4: Conversion of 3 units size 8E (height 200 mm) into one unit size 24E (height 600 mm) The conversion has to take place in the following sequence: Disassembly

3

. 49

Pull out the 3 withdrawable units. Disconnect power cables after protective cover (bellows) has been removed (see fig. 49). Due to the protective covers on the adjacent outgoing cable connection units working inside the cable compartment can be performed without danger. 2 16-/24 Take out the two upper control terminal bIock supports with their control terminal blocks. The Iower support may remain unchanged or, if necessary, can be converted to one or two 16-/ 20-pole control terminal blocks. When converting from two to one control terminal block the remaining one must be at the top of the support while the space below has to be covered with a cover. Dismantle the two middle compartment bottom plates with their guide rails The lower bottom plate remains unchanged (see fig. 15). Depending upon module design remove one or two outgoing cable connection units. When necessary exchange outgoing cable connection unit (details see fig. 50). Depending upon current or whether a star-delta unit is required two outgoing cable connection units have to remain or must be exchanged. Reassembly Connect power cable including protective cover (bellows) and control wiring (see fig. 49). lnsert new withdrawable unit size 24E. Should new material be required contact the nearest ABB sales office or representative.

1 2 1

15 1 50 2 2

. 24E ABB

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5.5

MNS
DIN57 105 1 /VDE

5.5 Examination of MNS contact systems within the scope of plant revisions
According to the applicable national and international standards and provisions (e.g. DlN 57 105 part 1/ VDE 0105 part 1; BGV A2), electrical plants must be maintained in an orderly condition by their operator. For all works in connection with the activities required for this purpose, all relevant determinations of the MNS manufacturing instructions and MNS product information sheets must be observed and complied with in addition to the valid safety regulations and all relevant provisions. The former include the following:

0105

1

BGV A2 MNS

MNS :

.

. / SR

?Installation of power contacts" ?Greasing of power contacts“ ?Tightening torques of bolted connections" which you will find in this chapter, too. Each module (withdrawable / plug-in module, fused SR elements, or withdrawable module condapter) is subject to the following mandatory visual inspections prior to installation in the cubicle (before first installation in the workshop as well as after each revision). The visual inspection of the contact system should include the following items resp. their observation is strongly recommended: 8E/4 8E/2 Damages (e.g. worn silver resp. tin layer, signs of inadmissible heating, etc.) at the contacting surfaces of the MNS contacts and their counterparts (distribution bars, withdrawable module condapter, outgoing cable connection unit). Contacts movable and properly snaped into position in the withdrawable module rear wall or contact apparatus housing. Deformation of contacts (bent), mechanical damages. Medium-force fit of the contact spring (withdrawable modules 8E/4 and 8E/2) in its specified position. lnsulation behind crimping swollen. Contacts greased.

MNS

. . . .

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.

In cases of doubt, the contact force may be measured using a special testing device. In the event of doubts additionally measure the contact clearance with a slide gauge or standard gauge. The specified values of 4.7 +0,05 -0,2 mm must not be exceeded or left short.

.7

+0,05 -0,2

mm

: 4

8E/2 8E/4 ABB

Please note: The size of the contact opening need not be checked for the contact 4E (e.g. using a gauge block), because this check does not make sense due to construction.

lf irregularities are detected, we recommend replacing contacts, complete withdrawable module rear wall for 8E/2 and 8E/4 modules or the entire contacting system and/or informing the respective ABB Service department in order to determine and coordinate further measures.

Before checking the distribution bars or the withdrawable module condapters disconnect the cubicle from the power supply!

/ Contact type Specification/ application Contact force

A Contact opening A

after production 1TGB 100101 R... 4E...8E Power contact of withdrawable modules 4E...48E and plug-in modules 50...90 N

during normal operation min . 40 N * not applicable

GLBS 200520 R... 8E/4 8E/2 4E Power contact of small withdrawable modules 8E/4 and 8E/2 and of withdrawable modules 4E (outgoing)

40...100 N

Min

. 33 N *

4.7

+0,05 -0.2

mm

GLBS 200502 R... ( )/

/ reinforced

90...120 N

min

. 73 N *

4.7

+0,05 -0.2

mm

values for earlier types on request)

4E...8E Power contact of withdrawable modules 4E...48E and plug-in modules

88 / Fig. 88 Check of contact force and contact opening * * Contact to be exchanged if contact force is below the given value

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5.6
5.6.1

5.6 Greasing of contact areas
5.6.1 Greasing of power contacts Greasing the contacts is a mandatory prerequisite for reaching the operating cycles to which the unit is certified through type test as the grease reduces the wear of the contact area finish. Furthermore, the force needed for withdrawing the modules is reduced. Contact areas of the power contacts are to be cleaned and greased whenever the following conditions apply: the assembly works and testing routines have been completed in the workshop after a revision or after 100 plug-in cycles or after 2 years, whichever is earlier immediately before installing the module in the cubicle. Grease to be applied: Contact grease Klüberlectric KR44-102 Use a brush to apply the grease. Avoid excess grease on the contacts. If modules are supplied as loose parts, they should be greased at the building site. For contact areas to be greased, see figures 89 and 90

100

2

.

Klüberlectric KR44-102 .

89

90

areas to be greased

areas to be greased 89 / Fig. 89 8E/4 8E/2 4E Power contacts for withdrawable modules size 8E/4 and 8E/2 as well as the outgoing power contacts of the 4E-withdrawable modules SR 90 / Fig. 90 4E 48E Power contacts for withdrawable modules size 4E to 48E

Contacts of the withdrawable module condapter as well as of SR switch disconnectors are to be treated similarily.

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7 8

Withdrawable modules which are to be supplied separately, the contacts should only be greased on site. The following quantities of 7 g (8 ml) tubes are to be supplied together with the modules for this purpose: For 1 up to 4 modules of size 8E/4 and 8E/2 1 tube each For module sizes 4E up to 48E 8 contacts each For plug-in modules up to 400 A, 4 contacts each over 400 A, 4 contacts each

1

4

8E/4,8E/2 1

4E

48E 8 0.5

0.5 tubes

400A 400A,

4 4

0.25 1

0.25 tubes 1 tube

: 8E 2 3 8E 8E 250A 8 8 8 1 1 2 250A 250A

Prior to transport packaging the appropriate number of tubes has to be fixed to the modules by the manufacturing department (tubes are fixed to the withdrawable module handle, at least one tube per packaging unit, in case of major deliveries to one customer the grease can also be supplied in tins). Example: 1 module size 8E, 250 A (8 contacts) 1 tube 2 modules size 8E, 250 A (8 contacts) 1 tube 3 modules size 8E, 250 A (8 contacts) 2 tubes Ident numbers of the contact grease

1KG

1TGB000172R1000 7g(8 ) 1TGB000172R0008

Tin containing 1 kg of grease Tube containing 7 g (8 ml) of grease

1TGB000172R1000 1TGB000172R0008

5.6.2 HRC OS/OESA,SLP/XLP,SR 0.5

5.6.2 Greasing the fuse links The contact lugs of the LV HRC fuses must also be greased every time before being inserted into the fuse holder of any type of switching device (OS / OESA, SLP/ XLP, SR elements, etc.). If the fuses are supplied loosely, 0.5 tubes of contact grease are required for each module (1 set = maximally 4 fuses for all sizes).

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5.7
8E/2 8E/4 1

5.7 Lubrication of withdrawable module interlocks
When the withdrawable modules have been in use for some time, it may be necessary to lubricate the interlocks of the withdrawable modules size 8E/2 and 8E/4 (dependent on the environmental conditions and the tightness). For this purpose the mobile parts must be sprayed with a lubricant (approx. 1 sec.). Thereafter a functional test must be carried out. Lubricant to be used: Molycote Omnigliss Spray, Liquid high-pressure lubricant in 300 ml tins Manufacturer: Dow Corning GmbH D-65201 Wiesbaden/Germany 4E 48E Lubrication of withdrawable module interlocks for module sizes 4E up to 48E is not necessary during maintenance works.

Molycote Omnigliss Spray, : Dow Corning GmbH D-65201 Wiesbaden/Deutschland

300ml

Withdrawable module interlock

ON

OFF

Spray in lubricant here several times, move switch handle between ON and OFF position hereby.

91 / Fig. 91 MNS 8E/4 8E/2 Lubrication of MNS-withdrawable module interlocks 8E/4 and 8E/2

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5.8

5.8 Installation of power contacts

/ Contact forms: A: bis / up to 2 x 16 mm 2 B: bis / up to 35 mm 2 C: bis / up to 70 mm
2

92 / Fig. 92 4E ... 48E Power contacts for withdrawable modules 4E ... 48E

5.8.1 1TGB120050P001 1TSA233000P0007 1TGB120048P0001

5.8.1 Installation Once inserted in the withdrawable module rear wall 1TGB120050P0001, or the contact housings 1TGB120048P0001 and 1TSA233000P0007, the contact must be properly engaged. Successful engagement is indicated by a single, audible click, and can be verified by pulling the cable. Please note! The new contact type does not click a second time once it has passed the engagement hook like the old contact type.

,

In case the contact does not properly engage, it has to be checked whether the engagement hook has the proper shape (and does not, e.g., have any extrusion edges), or whether the engagement hook is broken. Parts whose engagement hook is not properly shaped, or broken, have to be replaced.

Rastnasen Engagement hooks

93 / Fig. 93 Contact apparatus housing, cross-section

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5.8.2

5.8.2 Testing The withdrawable module assembly must be tested as follows prior to installation in the cubicle (first installation and after revisions): MNS ). Visual inspection (The contacts must not have any visible damages). Contact opening size (refer to: Examination of MNS withdrawable module design contact systems within the scope of plant revisions). Snapping in (It must not be possible to press the contacts back manually). Contact float (The contacts must not sit firmly in the chamber, they must be mobile in all directions in order to ensure a tolerance adjustment).

( (

).

5.8.3

5.8.3 Contact plating Contact plating with silver or tin Application of different platings -> -> Silver (Ag) Tin (Sn) -> Standard -> Option on customer request

Identification The type of plating is visually not distinguishable. That is why contacts are marked: ” on the contact fingers: impression of “Ag” or “Sn” Combination of differently plated parts in one switchgear It applies in principle for the withdrawable and railable technique: Es ist nicht zul?ssig, Schienen und Kontaktsysteme mit unterschiedlicher Oberfl?chenvergütung miteinander zu kombinieren! It is not permitted to combine busbars and contact systems with different coatings!

: 30 SR RPC 8E/4 :

Exceptions: The mix of contact material for the following systems, where the contacts are not moved more than 30 times. SR- Switch disconnectors Plug-in modules (not railable modules) RPC modules Module condapters 8E/4 and 8E/2 (only the connection between distribution bar and condapter) tin-plated busbars and contacts at the incoming side of a system and silver-plated busbars and contacts at the outgoing side.

8E/2

MNS For clear verification also all parts of the MNS busbar system are marked with “Ag” or “Sn”.

80

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5.9
5.9.1

5.9 Paintwork damage
5.9.1 Preparation of the damaged Iocation Surfaces or locations soiled by grease/oil shall be cleaned with an aliphatic cleaning agent using a linen cloth.

5.9.2

5.9.2 Execution The paintwork repair set whose colour matches that of the plant to which it is attached (if ordered) shall be used for paintwork repairs. The hardening agent in the small container shall be completely added to the Iarger container filled with paint. The quantity of hardening agent exactly matches the quantity of the paint. After hardening agent and paint have been thoroughly mixed the mixture shall be appIied using a brush or a lambskin paint roller to the surface to be repaired. Small marks may be repaired isolated; but the success depends on the surface preparation and/or the ?handling".

5.10
5.10.1 400

5.10 Mechanical damage
5.10.1 Preparation of the damaged Iocation When major damage to Iarge areas has occurred the respective surfaces shalI be ground with abrasive paper (grade 400). The damaged area has then to be wiped with a linen cloth or cleaned with compressed air to remove the dust. 5.10.2 Execution A filler material (aIkyd resin basis) shalI be applied flush with the surface using a drawing scraper. The filler shall be left to set over night. The filled-in location has again to be slightIy ground. Thereafter the paint has to be appIied as described above.

5.10.2

5.10.3 :

5.12 RAL .... ( (2 RAL .... ( ) : : ( . 7035, ) )

5.10.3 Materials (see also section 5.12) Colour: Repair paint: Filler: Cleaning agent: RAL .... (e.g. 7035, light-grey) (2-component synthetic resin varnish) RAL .... and hardener (paint repair set) Alkyd resin base Aliphatic (e.g. white spirit)

)

5.10.4 : 400 : :

5.10.4 Tools For cleaning: For painting: For repair: Linen cIoth (lint-free) Abrasive paper (grade 400) Brush or lambskin paint rolIer Scraper

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/ Ident no.

5.11

5.11 Spare parts

Designation Frame, cladding and front Side wall Rear waIl Roof plate lP 40 Supporting angle Top stripe holder, standard Top stripe holder, halogen free PIug Closure rail AngIe bracket with peg Frame connection Threaded rivet M 6-St. SpIice bar Seal 15 x 2 (self adhesive) ) Busbar mounting parts : 30 mm 40 mm 60 mm Clamp strap for busbar mounting: 30 mm busbars 40 mm busbars 60 mm busbars Insulating cover for busbar connection lnsulating angle lnsulator Fastening bracket Plug-in design Wiring duct Cage Name plate carrier Cover for spare spaces Supporting plates without mounting holes for devices: Supporting plate without contact Supporting plate 3-pole Supporting plate 4-pole Supporting plate 2x3-pole Supporting plate 2x4-pole Supporting plates with mounting holes for devices: Supporting plate without contact Supporting plate 3-pole Supporting plate 4-pole Supporting plate 2x3-pole Supporting plate 2x4-pole Disconnectable design Handle assy.

lP 40 Kopfleiste, Standard Kopfleiste, halogenfrei

M6 15 x 2 (

1TGB110011P.... 1TGB110012P.... GLBK410044P.... GLBK400005P0001 1TGB120051P.... 1TGB120000P.... GMN 775502P0018 GLBK500007P.... GLBK400007P0001 GLBK300003R0001 GZN 490012P0032 GLBK400011P0001 GSlN100021P0010

1TGB110211P0001/P0011 1TGB110211P0002/P0012 1TGB110211P0003/P0013 1TGL100024R0001 1TGL120007P0001 GZN 560103P0003 GLBS300210P0001

K?fig

1TGB120026P0460 1TGB120030P0001 1TGB110159P0001 GLBL100032R....

3 4 2×3 2x4

1TGB110111P0003-P0010 1TGB110110P0033-P0040 1TGB110110P0043-P0050 1TGB110110P0233-P0240 1TGB110110P0243-P0250

3 4 2×3 2x4

1TGB105034R0004-R0010 1TGB105033R0013-R0016 1TGB105033R0024-R0026 1TGB105033R0034-R0036 1TGB105033R0044-R0046

1TGB105017R0011

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Identnummer / Ident no. 1TGB105019R0001 1TGB110123R0001 1TGB110123R0011 1TGB105018R0011 1TGB105018R0012 1TGB105020R0011 1TGB120029P0001 1TGB110158P0001 1TGB105053R0001 1TGB105024R0001 1TGB110136P.... 1TGB120028P0001 1TGB120028P0002 1TGB120027P0001 1TGB120039P0001 1TGB120039P0002

Designation Railable design Service handle Lateral guide rail, left Lateral guide rail, right Sidepanel assy., left Sidepanel assy., right Parking position assy., for 180° door Hand safety guard Spacing frame for control plug Wiring tool assy. Lock assy. Lock coupling Label for operating instruction, German Label for operating instruction, English Label for service handle Label insert for handle, German Label insert for handle, English

. l

1 1

250…400 A 630 A 32 ... 250 A 32 ... 250 A 00/1 2/3

Contacting with distribution busbars Contact. device housing 1-pole 250 ... 400 A Contacting device 1-pole 630 A Power contacts with wires with standard-wires 32 ... 250 A with halogenfree wires 32 ... 250 A Cable connection Bellow size 00/1 Bellow size 2/3 Cable support cpl. Withdrawable design Module compartment Compt. bottom plate (top cover) Guide rail Guide raiI, left Front post Space cover 8E/4

1TGB120048P0001 HANL150000R0001

1TGB100051A/S.... 1TGB100052A/S....

1TGB120070P0001 1TGB120071P0001 GLBL100014R....

8E/4 16-/20 38 38 UMC 4E, 4E, 6E, 6E, 8E, 4E - 24E 2E 12 12 24 24 32 ( ( ) ) INSUM INSUM

1TGB110026P0001 HANL200001P0001 1TSA090001R0044 HANL200002P0002 HANL200122P0001 GLBS200516R.... 1TGB100085R.... 1TGB369004R.... 1TGB250003R.... 1TGL110054P0001 1TSA215001P0160 1TSA010011P0098 1TSA010011P0093 1TGL110054P0002 GILN100115R.... HANL200063P.... GLBS300555P0001

Withdrawable module condapter 16-/20-pole Withdr. mod. condapter 38-pole, Ag-cont., INSUM Withdr. mod. condapter 38-pole, Sn-cont., INSUM Withdrawable module condapter for UMC Control terminal bracket 4E, 12-pole, (front) Control terminal bracket 4E, 12-pole, (back) Control terminal bracket 6E, 24-pole Control terminal bracket 6E, 24-pole Control terminal bracket 8E, 32-pole Control terminal 4E - 24E Cover plate Distribution bar cover 2E

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Identnummer/ Ident no. HANL200008P0010 1TSA030009P0061 HANL200056P0001 GILN100117R0001 GILN220012R0001 1TGB363000P0238 GILN100116R.... HANL100024R0001 1TGB120005P.... HANL200059P0010 HANL200060P0010 1TSA275003R0004 1TSA060001R0003 1TSA060011R0006 1TSA060011R0016 1TSA060011R0007 1TSA060011R0017 1TSA060011R0001 1TSA060011R0011 1TSA060011R0005 1TSA060011R0015 1TSA060011R0003 1TSA060011R0013 1TSA060011R0002 1TSA060011R0012 1TSA060011R0004 1TSA060011R0014

Designation Withdrawable modules Handle for 8E/4 and 8E/2 Handle for 4E Name plate carrier 8E/4, 8E/2 , , 8E/4, 8E/2 8E/4, 8E/2 ControI terminal block 16-poIe, for 8E/4, 8E/2 ControI terminal block 20-poIe, for 8E/4, 8E/2 ControI terminal block 38-poIe, for 8E/4, 8E/2 Control terminal block for 4E - 48E Latch-type lock 8E/4, 8E/2 lnstrument panels for withdrawable modules size: 4E ... 24E 8E/4 8E/2
2

8E/4 4E

8E/2

16 , 20 38

4E - 48E 8E/4, 8E/2 4E ... 24E 8E/4 8E/2 3 3 3 3 4 4 3 3 4 4 6 6 3 3 3 3 25mm /63 A, 25mm /63 A, M 10/250 A, M 10/250 A, M 10/250 A, M 10/250 A, M 10/160 A, M 10/160 A, M 10/160 A, M 10/160 A, M 10/160 A, M 10/160 A, M 12/400 A, M 12/400 A, M 12/630 A, M 12/630 A, 4E 6E 8E : M 10 M 12 160/250 A 400 A
2

4E, 4E, 6E, 6E, 6E, 6E, 8E, 8E, 8E, 8E, 8E, 8E, 8E, 8E, 16, 16, . . . . .

Cable connection units 2 3-pole 25mm /63 A, for 4E, Ag-cont. 2 3-pole 25mm /63 A, for 4E, Sn-cont. 3-pole M 10/250 A, for 6E, Ag-cont. 3-pole M 10/250 A, for 6E, Sn-cont. 4-pole M 10/250 A, for 6E, Ag-cont. 4-pole M 10/250 A, for 6E, Sn-cont. 3-pole M 10/160 A, for 8E, Ag-cont. 3-pole M 10/160 A, for 8E, Sn-cont. 4-pole M 10/160 A, for 8E, Ag-cont. 4-pole M 10/160 A, for 8E, Sn-cont. 6-pole M 10/160 A, for 8E, Ag-cont. 6-pole M 10/160 A, for 8E, Sn-cont. 3-pole M 12/400 A, for 8E, Ag-cont. 3-pole M 12/400 A, for 8E, Sn-cont. 3-pole M 12/630 A, for 16, Ag-cont. 3-pole M 12/630 A, for 16, Sn-cont.

Brackets for cable connection units Bracket for 4E Bracket for 6E Bracket for 8E BelIows for: Connecting bolts M 10 for 160/250 A Connecting bolts M 12 for 400 A

1TSA215002P0286 1TGL110046P0011 1TGL110046P0001

1TGB120070P0001 1TGB120071P0001

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/ Ident no.

5.12

5.12 Accessories

/ Accessories RAL 7035 * Paintspray, Shade RAL 7035 , RAL 7035 (Verdünner + H?rter) * Two component paint, Shade RAL 7035 ( )
* *

/ Supplier

Cromadex D-71636

/Germany

Filling compound , Klüberlectric KR44-102 Contact grease, Klüberlectric KR44-102Topas NB 52

Klüber Lubrication KG D-81379 München /Germany Dow Corning GmbH D-65201 /Germany

1TGB000172R1000 (1 kg Dose / 1 kg tin) 1TGB000172R0008 (7 g Tube / 7 g tube)

Molycote Omnigliss (300 ml Dose) Liquid high-pressure lubricants Molycote Omnigliss (300 ml tin)

* *

Other colours on request

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5.13
M8 GILN 200125 P...

ESLOK
MNS ESLOK GILN 200123 P..., GILN 200124 P... and

5.13 List of standard screws with ESLOKthreadlocking
For screwed joints M8 the MNS-system uses for screwed joints at the busbars and at the frame screws with ESLOKthreadlocking according to GILN 200123 P..., GILN 200124 P... and GILN 200125 P... . Under standard conditions bolt connections with ESLOKthreadlocking are maintenance-free (e.g. with a max. busbar temperature 130°C). Screw type Hexagon head bolt DIN 931 (ISO 4014) 8.8-A.G /Dimensions M10 x 50 M10 x 60 M10 x 70 M10 x 80 M12 x 40 M12 x 50 M12 x 60 M12 x 70 M12 x 80 M12 x 90 M12 x 100 M12 x 110 M12 x 120 M12 x 130 /Ident.-no. GlLN200123P0366 GlLN200123P0368 GlLN200123P0370 GlLN200123P0372 GlLN200123P0414 GlLN200123P0416 GlLN200123P0418 GlLN200123P0420 GlLN200123P0422 GlLN200123P0424 GlLN200123P0425 GlLN200123P0426 GlLN200123P0427 GlLN200123P0428

ESLOK 130°C

DIN 931 (ISO 4014) 8.8-A.G

DIN 933 (ISO 4017) 8.8-A.G

Hexagon head screw DIN 933 (ISO 4017) 8.8-A.G

M 8x M10 x M10 x M10 x M10 x M10 x M10 x M10 x M10 x M10 x M10 x M10 x M12 x M12 x M12 x M12 x M12 x M16 x M16 x M16 x

25 16 18 20 25 30 35 40 45 50 55 60 30 35 40 50 60 20 60 70

GILN200125P0311 GILN200125P0359 GILN200125P2312 GILN200125P0360 GILN200125P0361 GILN200125P0362 GILN200125P0363 GILN200125P0364 GILN200125P0365 GILN200125P0366 GILN200125P0367 GILN200125P0368 GILN200125P0412 GILN200125P0413 GILN200125P0414 GILN200125P0416 GILN200125P0418 GILN200125P0460 GILN200125P0468 GILN200125P0740

DIN 912 (ISO 4762) 8.8-A.G

Hex socket head cap screw DIN 912 (ISO 4762) 8.8-A.G

M 8 x 30 M 8 x 40 M 8 x 50 M 8 x 60 M 8 x 80 M10 x 35 M10 x 40 M10 x 50 M10 x 70 M10 x 80 M10 x 100 M10 x 120

GILN200124P0312 GILN200124P0314 GILN200124P0316 GILN200124P0318 GILN200124P0322 GILN200124P0363 GILN200124P0364 GILN200124P0366 GILN200124P0370 GILN200124P0372 GILN200124P0375 GILN200124P0377

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5.14
5.14.1 MNS , AlMgSi 0,5)
02

5.14 Tightening torques for screw connections
5.14.1 Scope of application 70 N/mm (
2

,

/

The figures quoted apply to system screw connections and busbar 2 screw connections on busbars with 02 70 N/mm (Cu, Cu/Al, AlMgSi 0,5) in the switchgear system MNS.

The values are not applicable to electrical equipment connections and mountings. 8.8 Exception: They do however apply to the mountings of equipment with sheet steel bases and the connections of electrical equipment when this is made with flat copper terminals and bolts and nuts of tensile class 8.8. Note: For equipment connections and mountings see the technical data sheets of the manufacturers. 5.14.2 5.14.2 Exactness of Screwing/Bolting High-accuracy torque tightening equipments should be used. These are adjusted so that the maximum torquing value ( including tolerance ) of each adjustment step does not exceed the given tightening torques in the tables.

5.14.3 85%

5.14.3 Testing torque The testing torque is the preset vaIue of the tightening equipment minus 15 %. 5.14.4 Tightening torques SeIf-tapping screws in plastic material

5.14.4

Max. tightening torque PUR Dimension Ident.-no of the screw Screw type mm 1TGB 000 116 P.... und/ and 1TGB 000 117 P.... TORX TORX pan head tapping screws Linsenblechschrauben mit TORX TORX pan head tapping screws 4.2 5.5 6.3 Duroplaste Thermoplastics Duroplastics Nm 2.0 4.5 5.5

Nm 3.5 3.5

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Max. tightening torque

Thread rolling screws in metal

Sheet steel Ident.-no of the screw Screw type Dimension

Al-sheet -

Cu-bars

Material thickness mm 1.5 1.5 1.5 2.0 3.0

Nm 1.0 2.0 4.5 5.5 9.5

Material thickness mm 3.0 3.0 3.0 3.0 3.0

Nm 1.0 2.0 4.5 5.5 5.5

Material thickness mm 5.0

Nm 9.5

9ADA 629-... 9ADA 633-... GILN 100 082 P....

TORX TORX pan head thread rolling screws TORX TORX counters. head thread roll. screws Cheese head thread rolling screws

M3 M4 M5 M6 M8

1TGB 000 118 P.... GZN 490 181 P.... 1TGB 000 002 P....

TORX TORX pan head thread rolling screws 6 Hex head thread rolling screws Cross recess. pan head rolling screws

1TGB 000 003 P.... Cross recess. pan head rolling screws 1TSA 273 000 P.... 6 Cross recess. hex head thread rolling screws

Are self-tapping and thread rolling screws loosened, then they later be only tightened no more with a machine equipment, but with the handscrewdriver. Screws for busbar connections (Cu) and system connections (steel/steel)

Ident.-no of the screw GILN 200 124 P... GILN 200 123 P.... GILN 200 125 P.... 9ADA 183-... 9ADA 56-... 9ADA 120-...

Screw type DIN 912 ESLOK Hex socket head cap screws DIN 912, with ESLOK DIN 931, ESLOK Hex head bolts DIN 931, with ESLOK DIN 933, ESLOK Hex head screws DIN 933, with ESLOK ISO 4762 (DIN 912) Hex socket head cap screws ISO 4762 (DIN 912) ISO 4014 (DIN 931) Hex head bolts ISO 4014 (DIN 931) ISO 4017 (DIN 933) Hex head screws ISO 4017 (DIN 933)

Dimension M6 M8 M10 M12 M16

Max. tightening torque Nm 8 20 40 70 140

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5.15

5.15 Commissioning and maintenance of MNS reactive power compensation systems
5.15.1 Commissioning and maintenance In the worst case, compensation systems are permanently operated with their maximum power. Therefore, good ventilation is to be ensured in the place of installation in order to prevent the ambient temperature from exceeding the max. admissible limit of 35°C (mean value over 24 hours). Malfunctions or an insufficient compensation power can be best determined (although too late) by checking the reactive power demand (electricity bill). If the following points are noted during commissioning and the regular maintenance works, a loss in compensation power can be detected at an early stage.

5.15.1

35°C

24

1. 2. a) b) 4 c) d) e) IP 32 .

1. Check ventilation in the place of installation. 2. Check the construction: a) Above and below each individual module (or the modules), an air supply and air discharge must be available. b) If the cubicle bottom plate is closed (no air supply through bottom plate), there must be at least 4 ventilation slots. c) No compartment bottom plates or other installations may be present in the cubicle which might adversely affect ventilation. d) For protection class > IP 32 or installations which deviate from c) above, forced ventilation (or a reduced amount of equipment) is required. e) A transverse partitioning must be installed between the cable compartment and the equipment compartment. 3. Check the settings and the functioning of the controller (switching outputs). 4. Check contactors for sparking when switching and for faultless making and breaking operations. The maintenance intervals of the contacts of the capacitor contactors depending on their number of ? switching operations (can be read off ESTAmat RPR) are subject to the manufacturer?s instructions.

3. 4.

Do not operate capacitor-contactors by hand!

5. 5. The current consumption of the system and the modules serves as an indication for a loss in capacitance if a capacitance test (which requires safety disconnection of the compensation system) is not possible; in this case, the currents and voltages in each phase must be measured simultaneously. (However, current measurement is only a rough criterion in view of possible current distortions caused by harmonic waves!) 6. a) b) c) d) e) 7. 7. : 1 . . . 6. Before touching the capacitors: a) Wait for at least one minute until the capacitor is discharged. b) Protect the system against reclosing. c) Verify safe isolation from supply. d) Short-circuit the capacitor terminals among each other and with the housing in order to compensate for differences in potential. e) Protect neighbouring live parts against accidental contact. Perform a visual inspection of the electrical equipment. (Leaks such as oil leakages, bulging of the capacitor lid or housing,

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condition of terminals, switches, protective devices, reactors, discharge resistors, conductors.) 8. 9. 10. 11. 9. Clean the modules as well as the air supply and air discharge regions of each cubicle (ventilation louvers, filter mats).

8.

Check protective devices and switches for faultless operation.

10. Check bolted connections and clamping units. 11. Measure capacitances and log measured values. (The capacitances of the compensation capacitors may change due to inadmissible heat rise, expiry of the useful life, overvoltages, etc. Experience has shown that the inductance values are not subject to major changes.) Please note: Before measuring capacities discharge resistors must be disconnected from capacitors. Setpopint values are given on the module nameplates.

5.15.2

5.15.2 Correction of faults In the event of malfunctions during commissioning, the cubicle wiring (especially in the area of the transport partition) should be checked first. Other possible faults include the following: Controller display remains dark: Check control voltage. Controller does not switch in additional steps (although request is available): Measuring voltage or current not or improperly connected. Check fuses. Wrong transformer ratio. Lowest step power is too high. C/K / Inappropriate C/k value setting / value too low. Controller switches very often: Switching time (too) short with quick load changes. Step power too low. Wrong C/k value setting. C/K cos . setpoint is not reached: Lowest step power is too low. Inductive current too low. All steps are permanently active: Undercompensation, i.e. installed leading reactive power is not sufficient. Check control voltage. Check LV HRC fuses of the modules. 5A 1A 5 A transformer connected to 1 A controller measuring input.

Too many steps active (overcompensation): Check transformer installation. Check controller settings.

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(

N

).

(

N

)..

Wrong measuring voltage connection (phase-phase and phaseN exchanged). cos display does not coincide with additional power factor meter reading: wrong voltage measuring connection (phase-phase and phase-N exchanged). slight deviations may be due to inaccurate measuring units and/or different measuring points.

(

)

DIP-switch programming of ESTAmat RPR (adjustment after removing the frontplate)

?

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nominal current [A] 14,4 28,9 57,7 18,0 36,1 72,2 11,5 23,1 46,2 8,4 16,7 33,5 10,5 20,9 41,8 14,4 28,9 57,7 18,0 36,1 72,2 11,5 23,1 46,2 8,4 16,7 33,5 10,5 20,9 41,8 14,4 28,9 57,7 18,0 36,1 72,2 11,5 23,1 46,2 8,4 16,7 33,5 10,5 20,9 41,8 14,4 28,9 57,7 11,5 23,1 46,2 8,4 16,7 33,5

5.15.3

1TGR43100x (14E,

)

5.15.3 Setpoint values for capacitance measurements series 1TGR43100x (14E, dry-type)

ident.-no. [V] 1TGR431000R4410 1TGR431000R4320 1TGR431000R4140 1TGR431000R4413 1TGR431000R4325 1TGR431000R4150 1TGR431000R5410 1TGR431000R5320 1TGR431000R5140 1TGR431000R6410 1TGR431000R6320 1TGR431000R6140 1TGR431000R6413 1TGR431000R6325 1TGR431000R6150 1TGR431002R4210 1TGR431002R4220 1TGR431002R4140 1TGR431002R4213 1TGR431002R4225 1TGR431002R4150 1TGR431002R5210 1TGR431002R5220 1TGR431002R5140 1TGR431002R6210 1TGR431002R6220 1TGR431002R6140 1TGR431002R6213 1TGR431002R6225 1TGR431002R6150 1TGR431003R4210 1TGR431003R4220 1TGR431003R4140 1TGR431003R4213 1TGR431003R4225 1TGR431003R4150 1TGR431003R5210 1TGR431003R5220 1TGR431003R5140 1TGR431003R6210 1TGR431003R6220 1TGR431003R6140 1TGR431003R6213 1TGR431003R6225 1TGR431003R6150 1TGR431004R4210 1TGR431004R4220 1TGR431004R4140 1TGR431004R5210 1TGR431004R5220 1TGR431004R5140 1TGR431004R6210 1TGR431004R6220 1TGR431004R6140 400 400 400 400 400 400 500 500 500 690 690 690 690 690 690 400 400 400 400 400 400 500 500 500 690 690 690 690 690 690 400 400 400 400 400 400 500 500 500 690 690 690 690 690 690 400 400 400 500 500 500 690 690 690

capacitors

nominal capacitance [ F]

connection /Y

/nominal terminal capacitance [ F] 100 199 398 125 249 498 58 116 232

R0209 R0010 R0010 R0228 R0029 R0029 R0215 R0016 R0016 R0207 R0008 R0008 R0226 R0027 R0027 R0224 R0025 R0025 R0213 R0014 R0014 R0220 R0021 R0021 R0222 R0023 R0023 R0211 R0012 R0012 R0224 R0025 R0025 R0213 R0014 R0014 R0220 R0021 R0021 R0222 R0023 R0023 R0211 R0012 R0012 R0203 R0004 R0004 R0220 R0021 R0021 R0201 R0002 R0002

R0110 R0110 R0129 R0129 R0116 R0116 R0108 R0108 R0127 R0127 R0125 R0125 R0114 R0114 R0121 R0121 R0123 R0123 R0112 R0112 R0125 R0125 R0114 R0114 R0121 R0121 R0123 R0123 R0112 R0112 R0104 R0104 R0121 R0121 R0102 R0102

2 x 3 x 66,4 6 x 66,4 6 x 66,4 2 x 3 x 83 6 x 83 6 x 83 2 x 3 x 38,5 6 x 38,5 6 x 38,5 2 x 3 x 66,4 6 x 66,4 6 x 66,4 2 x 3 x 83 6 x 83 6 x 83 2 x 3 x 64,5 6 x 64,5 6 x 64,5 2 x 3 x 77 6 x 77 6 x 77 2 x 3 x 111 6 x 111 6 x 111 2 x 3 x 64,5 6 x 64,5 6 x 64,5 2 x 3 x 77 6 x 77 6 x 77 2 x 3 x 64,5 6 x 64,5 6 x 64,5 2 x 3 x 77 6 x 77 6 x 77 2 x 3 x 111 6 x 111 6 x 111 2 x 3 x 64,5 6 x 64,5 6 x 64,5 2 x 3 x 77 6 x 77 6 x 77 2 x 3 x 58 6 x 58 6 x 58 2 x 3 x 111 6 x 111 6 x 111 2 x 3 x 58 6 x 58 6 x 58 Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y Y

33 66 132 42 83 166 97 194 388 116 232 464 56 111 222 32 65 129 39 77 154 97 194 392 116 232 464 56 111 222 32 65 129 39 77 154 87 174 348 56 111 222 29 58 116

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/ nominal current [A] 14,4 28,9 57,7 11,5 23,1 46,2 8,4 16,7 33,5 14,4 28,9 57,7 11,5 23,1 46,2 8,4 16,7 33,5 28,9 57,7 23,1 46,2 16,7 33,5 28,9 57,7 23,1 46,2 16,7 33,5 87 174 348 56 111 222 29 58 116 87 174 348 56 111 222 29 58 116 97 87 194 174 2 x 56 2 x 111 32 29 65 58 97 87 194 174 2 x 56 2 x 111 32 29 65 58

/ Ident no.

/ nominal voltage [V]

/ capacitors

/ nominal capacitance [ F]

/ connection /Y

/nominal terminal capacitance [ F]

1TGR431005R4210 1TGR431005R4220 1TGR431005R4140 1TGR431005R5210 1TGR431005R5220 1TGR431005R5140 1TGR431005R6210 1TGR431005R6220 1TGR431005R6140 1TGR431006R4210 1TGR431006R4220 1TGR431006R4140 1TGR431006R5210 1TGR431006R5220 1TGR431006R5140 1TGR431006R6210 1TGR431006R6220 1TGR431006R6140 1TGR431007R4120 1TGR431007R4140 1TGR431007R5120 1TGR431007R5140 1TGR431007R6120 1TGR431007R6140 1TGR431008R4120 1TGR431008R4140 1TGR431008R5120 1TGR431008R5140 1TGR431008R6120 1TGR431008R6140

400 400 400 500 500 500 690 690 690 400 400 400 500 500 500 690 690 690 400 400 500 500 690 690 400 400 500 500 690 690

R0203 R0004 R0004 R0220 R0021 R0021 R0201 R0002 R0002 R0203 R0004 R0004 R0220 R0021 R0021 R0201 R0002 R0002 R0024 R0025 R0220 R0021 R0022 R0023

R0104 R0104 R0121 R0121 R0102 R0102 R0104 R0104 R0121 R0121 R0102 R0102 R0103 R0104 R0121 R0101 R0102

R0024 R0103 R0025 R0220 R0021 R0022 R0023 R0102 R0104 R0121 R0101

2 x 3 x 58 6 x 58 6 x 58 2 x 3 x 111 6 x 111 6 x 111 2 x 3 x 58 6 x 58 6 x 58 2 x 3 x 58 6 x 58 6 x 58 2 x 3 x 111 6 x 111 6 x 111 2 x 3 x 58 6 x 58 6 x 58 3 x 64,5 3 x 58 6 x 64,5 6 x 58 2 x 3 x 111 6 x 111 6 x 64,5 3 x 58 6 x 64,5 6 x 58 3 x 64,5 3 x 58 6 x 64,5 6 x 58 2 x 3 x 111 6 x 111 6 x 64,5 3 x 58 6 x 64,5 6 x 58

Y Y Y Y Y Y

Y Y Y Y Y Y

Y Y Y Y Y Y

Y Y Y Y Y Y

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5.16
RW C

5.16 Measuring of the insulation resistance
Insulation measurement is of fundamental importance to an electrical system. Furthermore, it is the only type of measurement that serves for preventive fire protection. The insulation resistance is a complex resistance in the form of a parallel connection of an ohmic resistor R W and a capacitance C. The equivalent resistance is a variable quantity that is influenced by various parameters. This is illustrated by the following equivalent circuit diagram:

C

Rw

RD

Ru

Ri

Rt

C

Rw

RD

Ru

Ri

Rt

RW : RD: RU: Ri : Rt

RW : RD: RU: Ri : Rt

constant equivalent resistance dielectric resistance voltage-dependent resistance current-dependent resistance time-dependent resistance

For which protective measures do you have to measure the insulation resistance? The insulation resistance must be measured for all protective measures! This refers to protective measures without protective conductor and with protective conductor. Insulation measurement is required according to DIN VDE 0100, but also to other standards, such as IEC 60439-1, Section 8.3.4, EN 60204, DIN VDE 0105, VDE 0110.

DIN VDE0100 IEC 60439-1, 8.3.4 EN 60204, DIN VDE 0105, VDE 0110.

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5.16.1 DIN VDE 0100 610 5.3

5.16.1 Which insulation measurements have to be peformed? DIN VDE 0100 part 610 specifies insulation measurement between the conductors in Section 5.3: If the circuits contain electronic components, such as semiconductors, these sensitive components must by no means be damaged by the high measuring voltages.

/ Procedure 1. / Between the outer conductors and the protective conductor

/ Required measurement
L1 L2 L3 N

/ Remarks

RIsol

RIsol

RIsol

PE

2. Between the neutral conductor and the protective conductor
offen RIsol

L1 L2 L3 N

PE N TN-C / Separate the PE and N conductors! This measure is not required in the TN-C network

PE

3. Between the outer conductors

L1 L2 L3 N

: -

RIsol L1 - L2

RIsol L1 - L3

RIsol L2 - L3 PE L1

if the cable includes a grounded conductor or a grounded sheath for switch leads in lighting circuits

4. Between the outer conductors and the neutral conductor
RIsol

L2 L3 N

RIsol

RIsol

PE

: 2

Measurement may also be performed with the consuming equipment connected. If the insulation resistance is too low in this case, the consuming equipment must be isolated, and the system and consumer must be measured separately. Prior to commissioning, the following circuits must be measured: All line sections between any 2 overcurrent protection devices. The section following the last overcurrent protection device without any connected consumer equipment.

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5.16.2

5.16.2 Which minimum insulation resistance must be available? In order to exclude the influence of the capacitive reactance, the measurements must be performed with DC voltage. For the values of the measuring voltage and the minimum insulation resistance, please refer to the table below. DC [V] Measuring-circuit voltageDC [V] 250 [M ] Minimum insulation voltage value [M ] 0,25

Protective measure and rated voltage / Safety extra-low voltage, functional extra-low voltage with safe isolation / Protective separation 500 V, / Rated voltage 500 V, and functional extra-low voltage without safe isolation > 500 V, 1000 V / Rated voltage > 500 V, 1000 V

500 500

1 0,5

1000

1

5.16.3 30%. DIN VDE 0413

5.16.3 Required measuring accuracy The operating error within the marked measuring range must not exceed 30 % with respect to the value reading. This error range permitted by DIN VDE 0413 part 1 initially seems to be very high. From the equivalent circuit diagram above, however, it becomes obvious that the insulation resistance is composed of a fixed component and four other components which may vary according to different parameters. This results in the large variation range. 5.16.4 Minimum readings (Note recommended operating error of - 30 %!)

5.16.4

30

[M ] 0,36 500 V 500V, 1000V 0,7 1,4

Protective measure or rated voltage Extra-low voltage Rated voltage Rated voltage Remark: 500 V 500V, 1000V

Reading [M ] 0.36 0.7 1.4

The assessment of the measured values has to take into account the overall condition of the system!

5.16.5

5.16.5 Capacitive charges For longer leads and cables, first allow the capacitive charging process to be completed and the indicator of the measuring device to come to a standstill before performing the reading.

If a capacitive charging process was observed, the leads must be discharged after measurement in order to prevent electric shock.

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5.17

5.17 Measuring log for MNS reactive power compensation system

r cos C/k DIP 1 2 RPR12 3 4 5 6 7

R A : B : / ?F / ?F /A / ?F R / ?F /A

x

kvar

x

kvar

U (L1) 1 L1 L2 L3 8 L1 L2 L3 : Iact = Imeas · Unom? / Umeas? 9 10 2 3

U (L2) 4 5

U (L3) 6 7

11

12

13

14

/

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Plant Customer Order no. Plant Plant section Room temperature Ripple control Remarks

Controller Controller module Target-cos C/k Switching time

automatic Factor

Controller type DIP-switch ON OFF

1

2

RPR12 3

4

5

6

7

Compensation modules Type A Capacitor Step: Nom. capacitance / ?F Type B Capacitor Step: Nom. capacitance / ?F Capacitance measurement Current measurement U (L1) Step Setpoint Phase L1 Phase L2 Phase L3 Step Setpoint Phase L1 Phase L2 Phase L3 1 2

R

Number Terminal capacitance / ?F Number Terminal capacitance / ?F

R

Stepping x Manuf. year Nom. current / A Stepping x Manuf. year Nom. current / A

kvar

kvar

U (L2) 3 4 5

U (L3) 6 7

8

9

10

11

12

13

14

Conversion of measured current values to nominal voltage by: I act = Imeas · Unom? / Umeas? Performed by Name/Department

Date

Signature

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5.18
5.18.1 5.18.1.1

5.18 Maintenance intervals
5.18.1 General 5.18.1.1 Legal conditions Electrical switchgear and controlgear systems require permanent preventive maintenance not only for technical and economic reasons. In an effort to define the due order in the energy sector, the government dictated a number of legal provisions from which the requirements of preventive maintenance can be derived.

5.18.1.2

5.18.1.2 Preventive maintenance At the moment, no technical standard provides comprehensive guidance on the preventive maintenance of electrical distribution networks and equipment. The principles require, i.a., that the electrical systems and equipment must be operated in accordance with the rules of electrotechnology, which includes preventive maintenance. All defects must be immediately remedied. In the event of imminent danger, electrical systems must no longer be operated.

DIN 57105

1

/VDE 0105

1 5

Even the provisions of DIN 57105 part 1/VDE 0105 part 1 do not contain any specific requirements beyond general information on the preventive maintenance of electrical systems. The most important information on preventive maintenance is summarized in item 5, "Preservation of proper condition and repetitive testing". This item stipulates, i.a., that high-current systems must be kept in proper conditions in accordance with the standards governing their installation. Defects of electrical systems must always be remedied immediately, i.e. without any culpable delay. If danger to persons, property or the environment is imminent, defective electrical systems or equipment must be immediately put out of operation. They must not be used in defective condition. A switchgear system is defective if safety is jeopardized by its operation. DIN In order to be able to timely recognize any defects that might have occurred after commissioning of the electrical systems or after a repair or modification thereof, DIN 57105 part 1 / VDE 0105 part 1 demands the performance of repetitive tests, however, without detailing concrete terms for the test cycles. Repetitive tests serve for the evaluation of the proper condition of electrical systems and equipment. Repetitive tests include: a visual inspection trial runs measurements other tests

57105

1

/VDE0105 :

1

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5.18.2 5.18.2.1

MNS

5.18.2 Maintenance of MNS switchgear systems 5.18.2.1 General safety instructions

: BGV A2, §6 5 :

For cleaning the switchgear system inside, the system or component must be off circuit. It is not recommended to use compressed air for purging dusty systems.

Safety at work: The procedure for performing switching operations is prescribed by the implementing instructions on BGV A2, §6: The off-circuit condition must be established prior to commencement of the work and must be ensured at the place of work for the duration of the work in compliance with the following five safety rules which must be applied as a standard:

5 : – – – – –

:

Five safety rules Prior to commencement of work: – Safety isolation – Protection against re-closing – Verify off-circuit condition – Earthing and short-circuiting – Cover or barrier adjacent live parts

5

These five safety rules must be observed as safety measures for work at electrical systems and equipment. 5.18.2.2 : MNS . 5.18.2.2 Health and safety Please note the following information: In accordance with the valid regulations all installation and maintenance work involving MNS-switchgear systems may only be performed by qualified personnel. For manipulations at low-voltage switchgear system components, the component to be manipulated must be isolated!!! The power supply to the capacitor by a remote auxiliary power source, if any, must also be isolated. When the system has been isolated, allow the voltage stored in the capacitor to be discharged by the discharging resistors by waiting for one minute. As an additional safety measure, the outgoing capacitor circuits must be tested for discharged condition using an insulated cable. Check whether the current transformers have been short-circuited before they are isolated or connected. The automatic capacitor must be installed in accordance with the standards IEC 60831-1&2 and all national regulations. A short-circuit may pose dangers to human life and destroy equipment! Therefore, it is of vital importance to use suitable tools and instruments for commissioning or inspection of electrical systems.

1 . . IEC 60831 1&2 .

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Maintenance and Spare Parts

5

5.18.3

MNS

5.18.3 Maintenance and inspection of MNS switchgear systems 5.18.3.1 General Especially in the case of systems associated with a higher risk (e.g. nuclear power plants) the operation and maintenance must be handled extremely carefully in order not to exceed the acceptable limit risk. For information on the mechanical and electrical life of electrical equipment, please refer to the relevant product documentation. All maintenance work and the required tightening torques relating to the electrical equipment in use must also be carried out in accordance with the binding manufacturer?s instructions.

5.18.3.1

5.18.3.2 1. 1.1 1.2 1.3 (

( )

5.18.4)

5.18.3.2 Maintenance intervals (incl. item no. acc. to 5.18.4) 1. 1.1 1.2 1.3 General visual inspection (repetitive tests) External inspection Completion of the interior Switchgear and controlgear assemblies (withdrawable or plug-in modules) Additional inspections Withdrawable technique Plug-in, disconnectable, railable technique Direct connection of incoming and outgoing power feeders with circuit breakers, e.g. Emax, ISOMAX or Tmax

(

)

2. 2.1 2.2 2.3 Tmax Emax,ISOMAX

2. 2.1 2.2 2.3

5.18.3.3 : m: a: n: x: (l )

5.18.3.3 Notes on the inspection lists on the following pages The frequency refers to time intervals (monthly, annually, etc.), service hours, starting frequency, etc. The following abbreviations are used to denote the frequency: m: monthly a: annually n: insertion cycles of modules x: test in the event of a fault (e.g. after a short-circuit)

A: B: C: , ( )

"Installation category" column A distinction is made between the following installation categories, because the frequency of maintenanceor inspection depends on the operating conditions: Installation category A: Normal operation Installation category B: Heavy-duty operation, e.g. cement factory Installation category C: Short circuit (fault)

MNS Service

101

MNS Service 103

5.18.4

Wartung und Ersatzteile

A

B

C

1.0 (
1.1 1.1.1 35°C Relative humidity Dust 1.1.2 ( ) : 1.1.3 / / / / 60°C 1a 6m X , 50 % at 40°C 1a 6m X

)

1a

6m

X ,

/

.

1.1.4 1.2 1.2.1

( ) Cable / equipment compartment doors closed / open 650 mm

1a

6m

X

Maintenance and Spare Parts

1a , 1.2.2 / / / / ) ( / 1a

6m 6m

X X

/ 1.2.3 1a 3 6m X

5

MNS Service 105

1.3 ) 1.3.1 1.3.2

(

,

, 2a , arc splitter, , 12,5 mm , ionization chamber, 1a X

Wartung und Ersatzteile

1.3.5 1.3.6 1.3.7 1.3.8

EN 60529 2a 2a 2a 1a 1a 1a X X X .

2.0
2.1 2.1.1 (8E/4 + 8E/2) Omnigliss 2 - 3a 2 - 3a 1 2a 1a 1a 1 1a X X X 5.5 5.6

Maintenance and Spare Parts

2.1.2

4E

1

100

5

Wartung und Ersatzteile

Maintenance and Spare Parts

5
A
2a
1

B
1a
1

C
X 5.5 5.6

;

2.2 2.2.1 2.2.2 1a X01 6m X

1.3

Klüberlectric KR44-102

: 3 : 1

5.15 : IB 1,3 x In

5.17

50 V

1

100

.

106

MNS Service

Wartung und Ersatzteile

Maintenance and Spare Parts

5

1.3

" " X

,

C

6m

X

B

1a

6m

A

1a

1a

6m

X

,

60 s

)

C/k cos

MNS Service

2.3

(

:

(

)

,

,

107

Wartung und Ersatzteile

Maintenance and Spare Parts

5

MNS Service

109

Wartung und Ersatzteile

Maintenance and Spare Parts

5
Frequency Install. category A B C Remarks

5.18.5 Maintenance and Inspection List

Item no.

Work to be performed

Measured, test and limit values, operating and auxiliary materials

1.0
1.1 1.1.1

General visual inspection (repetitive tests)
External inspection Verify ambient conditions Room temperature 35°C Air, aggressive gases such as SO2 , H2S etc. Relative humidity 50 % at 40°C Dust 1a 6m X Unpleasant smell Auxiliary heating possibly required

1.1.2

Check ventilation system (efficiency) Operating room Switchgear system

1a Air supply to and air discharge from cubicle not obstructed max. temperature inside the cubicle: 60°C

6m

X Touch fronts with hand surface, check cubicle if hand-warm spots are found

1.1.3

Check condition of enclosure / outside paint

1.1.4 1.2 1.2.1

Accessibility Completion of the interior Equipment compartment Check filling factor and equipment Internal conditions Cable compartment / cable terminal compartment

Damaged / corroded Missing parts such as module doors or covers Ventilation louver dusty / covered Roof plate contaminated / covered / obstructed / etc. Fastening of cable compartment doors, side and back panels Position of withdrawable modules in the cubicle (operating or isolated position) Cable / equipment compartment doors closed / open Escape route 650 mm

1a

6m

X

1a

6m

X

1.2.2

1.2.3

Personal protection / protective bellows Busbar compartment Check transport connections

Arrangement of modules in accordance with engineering documents Contamination, e.g. dust Incoming feeder in accordance with documents (busbar / cable laterally / top / bottom) Sufficient room / strain relief Cable routing; bending radii Protective bellows Color changes at bolted connections Proper installation of cover in partition wall 3 Contamination or flashover

1a

6m

X Clean

1a

6m

X

1a

6m

X

Check using thermovision exposures

Check busbar supports

110

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MNS Service 111

Visual inspection of the condition of the busbar insulation

Formation of cracks or creeping paths Shrink-on tube brittle

Wartung und Ersatzteile Maintenance and Spare Parts

5

MNS Service 113

1.3

1.3.1 1.3.2

General inspection of the switchgear assembly (withdrawable or plug-in, disconnectable, railable technique) Design of conductors and conductor installation Condition of insulation Check electrical equipment installed Bracing Check contact corrosion, contact gaps, ionization chamber, arc splitter, rated currents, settings and tripping Minimum creepage distance 12,5 mm Check minimum clearance for arcing space

Wartung und Ersatzteile

2a

1a

X

Measure the insulation resistance For the complete maintenance work, observe the instructions of the equipment manufacturer Cf. equipment manufacturer

1.3.5 1.3.6 1.3.7 1.3.8

Required protection class Check efficiency of protective conductor connection Function test of the control device Check measuring loops

EN 60529 Check continuity with signal test apparatus In accordance with circuit diagram In accordance with circuit diagram

2a 2a 2a

1a 1a 1a

X X X

Control connection cable.

2.0
2.1 2.1.1

Additional checks
Withdrawable technique Compact modules (8E/4 + 8E/2) Check easy movement of module in compartment Function test of mechanical interlock Check electrical contact-making Main contacts Remove dust and grease from guide rail if necessary Lubricate with Omnigliss Visual inspection In case of doubt check contact clearance Greasing Remove dust from guide rail with vacuum cleaner Actuate limit switch rocker (if available) Check condition of mating contacts Check cam condition at supporting rail 2 - 3a 2 - 3a 1 2a 1a 1a 1 1a X X X Refer to Chapter 5.5 Refer to chapter 5.6

Control plugs Visual inspection of module compartment

Maintenance and Spare Parts

Artificial light source

2.1.2

Check efficiency of protective conductor connection Withdrawable modules 4E Check easy movement of module in compartment Function test of mechanical interlock

1

Main contact to be checked either according the mentioned time intervals or latest after 100 cycles.

5

Wartung und Ersatzteile

Maintenance and Spare Parts

5
Frequency Install. category A B C
1 1

Item no.

Work to be performed
Check electrical contacts Main contact

Measured, test and limit values, operating and auxiliary materials
Visual inspection Check of contact force Greasing Position; the outgoing cable unit might be pressed out of its normal position by strong cable forces Condition of the roller in the compartment bottom plate

Remarks

2a

1a

X

Refer to Chapter 5.5 Refer to chapter 5.6

Control plug Fastening of outgoing cable unit Protective conductor connection 2.2 2.2.1 2.2.2 Plug-in, disconnectable, railable technique MCC’s and outgoing energy distribution feeders Compensation modules with and without reactor Check electrical equipment in every module Visual inspection of main contacts X01 Condition of short-circuit protection LV HRC fuse

Cf. also item no. 1.3: General inspection

1a

6m

X

Check of contact gaps, contact condition and lubrication not necessary

Fuse continuity Fuse tripped Contact condition Klüberlectric KR44-102 Contact condition No humming, bouncing or chattering of reactor Condition Setpoints see chapter 5.15 Limit value: IB 1,3 x In

Circuit breaker Lubricate contact blades of LV HRC fuses Check capacitor contactor Check for contact corrosion Switching performance Visual inspection of filter circuit reactor Connections and windings Capacitor Design without reactor: measure all step currents 3-phase or capacitance values Design with reactor: measure the terminal capacitance Discharging device Reactor Resistor bank
1

Signs of overload by mains resonance in accordance with manufacturer?s instructions

Use measuring log according chapter 5.17

Residual voltage after 1 min 50 V Color change, missing elements

Main contact to be checked either according mentioned the time intervals or latest after 100 cycles.

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MNS Service

Item no.

Work to be performed
Cable connection Screwed connection at electrical equipment Insulation Check controller module Check controller settings C/k value cos setpoint response time Check step triggering

Measured, test & limit values, operating & auxiliary materials
Insulation molten or even corroded For tightening torque, cf. manufacturer?s instructions

Frequency Install. category A B C

Wartung und Ersatzteile

Remarks

In accordance with manufacturer?s operating instructions Approximate value 60 s Power circuit open, i.e. fused switch disconnector removed Analogous to item 1.3 "Gen. inspection of switchgear assembly" Visual inspection of main connections Color change at switch main connections Condition of main and eroded contacts Function test Fastening of transformers Secondary cable routing Condition of transformer housings Check screwed connections Mechanical condition of supporting plate Formation of creepage paths Check screwed connections Check cable strain relief Cable routing, min. bending radii, edge protection, etc. 1a 6m X Procedure in accordance with manufacturer?s instructions

2.3

Direct connection (incoming and outgoing feeders with circuit breaker) Additional checks: Check main switching device

1a

6m

X

Check current transformer arrangement

Check supports at angle and connection sets Condition of partitioning (if available) Check external connections

Maintenance and Spare Parts

1a

6m

X

5

115

Appendix

6
/page

/ List of figures
/ Fig. 1 2 3 4 5 6 2E 4 N (PE) N ( ) Description Frame with enclosure Front mounted equipment (example) Busbar system with outlined 4th pole N-busbars, protective bars (PE) and neutral bars (N) Open version of distribution bars Cubicle distribution bar embedded in multi-function separator with outgoing cable connection unit and 2E distribution bar covers Distribution bars embedded in metal separation wall with distribution bar covers ) Emax ( ) Cubicle with fixed technique (without equipment) Withdrawable circuit breaker type Emax (with measuring recess) in narrow cubicle as feeder for MCC Plug-in modules as motor starters: above 1 fused plug-in module, below 2 fuseless railable modules Mechanical design of the disconnectable modules Mechanical design of the railable modules 4 8E/4 2 8E/2 Withdrawable module compartment for 4 units size 8E/4 or 2 units size 8E/2 Empty withdrawable unit size 8E/4 (without electrical equipment) Withdrawable module compartment for units size 4E ... 24E Empty withdrawable unit > 4E (without electrical equipment) Withdrawable module door with interlocking for 4E ... 24E Shipping unit with transport frame or euro pallet Crating Box packing Securing the module with a cage and a screw Fixing of the cage protection of the service handle Transport with a hand-pulled truck Fork-lift transport ( , , (MNS ) 1200 kg) Roller transport (only for weight of transport units up to 1200 kg) Crane transport, transport unit unpacked Crane transport, transport unit in box Arrangement of lifting angles (plan view of MNS-cubicles) Transportwinkel Frame corner joint with lifting angle Frame connection Additional frame connection Mounting of rear and side wall 9 9 11 12 13 14

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33

15 16 17 18 19 19 21 21 22 23 23 25 25 25 28 28 28 29 30 30 30 30 30 30 34 34 35

8E/4 4E ... 24E 4E 4E ... 24E

116

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Appendix

6
/page 36 36 37 37 38 40 40 41 41 41 44 44 44 44 45 46 46 46 48 48 51 51 51 51

/ Fig. 34 35 36 37 38 39/40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 . 6E 4E 1)2E 2) C C ( 63 A) INSUM SR , , 8 12 ( ) PE/N

Description Busbar connection PE/N-connection Free space above cubicle Walldistances Floor cutouts Fastening methods to foundation (examples) Installation on false floor for cables Cable connection sets, max. 8 cables Cable connection sets, max. 12 cables Fastening of cable mounting rails Direct connection at a circuit breaker Cable connections of a cubicle with railable modules with INSUM Cable connections for fused load-break switch type SR Terminal strips and cable connections for a cubicle with withdrawable module design Cable connection for withdrawable modules from 6E Cable connection unit for 4E-modules (max. 63 A) 1) Mounting of the bracket in 2E-grid 2) Screwed joint of the cable connection unit at the C-section Protective conductor connection at a vertical structural C-section Measures for sealing Open door with service handle and operating instruction Inserting service handle Locking the service handle when simultaneous unlocking the module Lift module slightly and pull it out up to the first engaged position. Unlock service handle and lock the module at the same time. Remove service handle Test position or isolated position. The module is visibly disconnected. Interlocking of the railable module Securing the railable module using a padlock Removal of a railable module
8E/4 8E/2

59 60 61 62 63 64 65 66 67 68 4E

52 52 52 53 54 55 55 56 56 57

Description of operating handle positions 8E/4 and 8E/2 modules Withdrawable module size 8E/2 with INSUM INSUM Front view of withdrawable modules size 8E/4 and 8E/2 with INSUM Switch operating handle for withdrawable modules size 8E/4 and 8E/2 with position markers 8E/4 Withdrawable module size 8E/4 with 3 padlocks Description of operating handle positions 4E to 48E modules

8E/2

INSUM

8E/4 und 8E/2 8E/4 3 48E 8E/2

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117

Anhang

Appendix

6
/page 58 58 58 61 62 64 64 65 65 66 66 66 67 67 67 68 68 70 70 75 76

/ Fig. 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89
8E/4 8E/2 4E 8E 2E . 8E 16E 4E 48E

Description Withdrawable module size 8E Withdrawable module size 16E Switch operating handle for withdrawable modules size 4E up to 48E with position markers Standard values of maximum admittable effective power loss Pveff Reduction factors, applicable to the permissible power loss for withdrawable modules size 8E/4 and 8E/2 Detaching the power and control cables prior to removing module (e.g. railable module) Detaching the power and control cables prior to removing module (e.g. railable module) Isolating the front wiring (in this case railable module, but without cable) Locking screw of disconnectable modules Open door with service handle and operating instruction Inserting the service handle Locking the service handle when simultaneous unlocking the module. Lifting and pulling out the module Removing the module Wiring tool Unlatching the front cover of a withdrawable module by means of a screw driver Draw out of a withdrawable module Withdrawable module compartment size 8E with outgoing cable connection unit, 2E-distribution bar cover Conversion to withdrawable module compartments size 8E/4 and 8E/2 Check of contact force and contact opening Power contacts for withdrawable modules size 8E/4 and 8E/2 as well as the outgoing power contacts of the 4Ewithdrawable modules Power contacts for withdrawable modules size 4E to 48E
8E/4 8E/2

Pveff

8E/4,8E/2

8E/4 8E/2

90 91 92 93

4E

48E MNS

76 78 79 79

Lubrication of MNS-withdrawable module interlocks 8E/4 and 8E/2 Power contacts for withdrawable modules 4E ... 48E Contact apparatus housing, cross-section

4E ... 48E

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Appendix

6
Seite 6, 39 10, 14 16, 17 50 75, 76, 103 77 31, 33, 39, 40

Stichwortverzeichnis / Index
Stichwort Seite Stichwort

Abdichtung Siehe Dichtung
Anzugsdrehmoment Aufstellung 34, 87, 88, 105 34, 37

Farbanstrich
Feldfunktionswand Feldverteilschiene Siehe Verteilschiene Festeinbautechnik Bedienung Fetten der Leistungskontakte der Sicherungseins?tze Fundament

Belüftung
Bemessungsspannung Bemessungsstrom Besch?digung Siehe auch Sch?den bei Transport Blindleistungskompensation Inbetriebnahme Messprotokoll Boden Durchbrüche Zwischen-

60, 89 6 6, 42 31 89 97 38 39, 40

Ger?tetableau
Gerüst

17, 20, 22, 54, 56, 84 8

Hilfsstoffe

85

Daten, technische
Dichtung

6 48, 82

Inbetriebnahme
Inspektion Inspektionslisten Instandhaltung Isolationswiderstand Messung

49, 89 101 101, 102 99 94, 103

Einsatzmodule Siehe Einsatztechnik
Einsatztechnik Bedienung Ersatzteile Kabelanschluss Konstruktion Kontrollen Verpackung und Transport Wartung Einschubkondapter Erdverbindung Ersatzteile Kontrolle Einschubmodule Siehe Einschubtechnik Einschubtechnik Bedienung Kabelanschluss Konstruktion Kontrollen Umrüsten Verpackung und Transport Wartung Einspeisung Ersatzteile Einsatztechnik Gerüst, Verkleidung Schienenbefestigung Schubeinsatztechnik Steckeinsatztechnik 50 82 43 18 104 28 64 20 71 83 75 71 54, 56 43 10, 20 103 70 27 68, 78 17, 24, 53 82 82 82 82 83 82

Kabel
anschluss anschlussraum anschlusss?tze Einführung von unten Kapazit?tsmessungen Kondapter Siehe Einschubkondapter Kontakt einbau fett finger, Pr?gung kraft, Messung ?ffnungsma? prüfung system, ?berprüfung vergütung Kontrolle bei Lieferung nach Aufstellung 41, 42, 43, 44, 45 8, 16, 38 41 39 92

79 76, 77, 85 80 75, 104 75, 80, 104 79, 80 74 80 80 33 49

Lackierung Siehe auch Farbanstrich
Reparatur 81

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119

Appendix

6
Seite 10, 38 6, 10 86 78 47 87 88 8, 18, 34, 88 87 8, 35, 60, 86 50 83 44 103, 104 19 66 28 6, 17, 48, 60 10, 16, 35 34, 35, 47, 48 103, 104 35 34 82 2, 100 104 50 82 19 103 65 28

Stichwort Lagerung von Reservemodulen ZwischenLastschalter Anschluss Lasttrennschalter SicherungsLeistungsschalter Anschluss Kontaktzustand Kontrolle Quittierung Transport Verpackung und Transport

Seite

Stichwort Schienen Siehe auch Sammelschiene

32 24, 31 42 18, 44, 53 26 17, 41, 42, 44 104 105 55, 57 29 27

M essprotokoll
Blindleistungskompensation Modultypen 97 17 10, 12, 16, 35, 47 6, 74

Neutralleiter
Normen

Prüfung
von Kontakten Prüfungen absolvierte wiederkehrende 79, 80 6 99, 101, 102

Reservemodule
Rückwand Befestigung Ersatzteil

26, 29, 32 35 82

raum system verschraubungen Schmierstoff Schrauben an Schutzleiterverbindungen Anzugsdrehmoment für Schienenverbindungen gewindeformend gewindeschneidend mit ESLOK-Sicherung Schubeinsatztechnik Bedienung Ersatzteile Kabelanschluss Kontrollen Technische Daten Umbau Verpackung und Transport Schutzart Schutzleiter anschluss kontrolle Seitenwand Befestigung der Endfelder Ersatzteil Sicherheit Steckeinsatztechnik Bedienung Ersatzteile Konstruktion Kontrollen Modulwechsel Verpackung und Transport

Sammelschiene
Anordnung Bemessungsstrom Transportteilung Verbindung Vergütung Sch?den am Kontakt mechanische Sch. nach Versand Umhüllung Schaltknebel Positionen

8 10, 11 6 35 36 6 74, 80 81 33 102 56, 58 54, 57

Technische Daten
Teststellung Transport BaustellenBoden-einheiten -einheiten, Verdrahtung Kran-rahmen -rahmen, Entfernung -teilung -winkel -winkel, Entfernung

6 50, 51, 54, 57, 58, 62 28 29 29, 30 10, 16, 24, 34 43 30, 31 24, 25, 26 33 10 31 35

120

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Appendix

6

Stichwort Trennstellung Trennwand Feldfunktionswand Metallschottwand

Seite

50, 52, 54, 57, 58 8, 35 10 15

Umbauten
Umhüllung Umrüsten Siehe Umbauten Untergrund

60, 65, 70, 73 8 29

Verdrahtung
Feld-zu-Feld VerIustleistung zul?ssige effektive V. Verkleidung Siehe Umhüllung Verlustleistung Reduktionsfaktoren Verpackung ausgebauter Leistungsschalter Verriegelung Einschubtür Funktionskontrolle Schmieren Schubeinsatzmodul Versand -sch?den Verteilschiene Anordnung Bemessungsstr?me in Feldfunktionswand in Metallschottwand Kontaktierung Kontrolle 43 61 60 62 24, 25, 26 27 23 103 78, 103 51 33 8, 10, 46 13 6 14 15 18, 20 75

Wandabstand
Wartung Siehe auch einzelne Modultechniken Checklisten H?ufigkeit pro Einsatzklasse Intervalle

37, 60 60, 100, 101 102 101 99, 101

Zubeh?r Siehe Hilfsstoffe

MNS Service

121

Appendix

6
10, 35 Page 80, 107, 108, 109 75 76, 77, 85 76 79 Compare contact clearance 75 80 18 22 70 7 31, 33 81 74 80 106 81 6, 48, 60 8 17 108 19 107 65 50 28 82 37 10 13 20 70, 83 8, 10 15 14 75 7 8

Index word accessories air circulation See ventilation busbar Compartment connection inspection mounting plating rated current surface treatment system transport busbars Cable Compartment connection connection sets connection unit entry from bottom number per phase spare parts capacitance measurement certificates See test certificates check See also inspection after erection during commissioning and maintenance of contact system on delivery check list See inspection list circuit breaker cable connection connection fixed type inspections packing and transport reset Commissioning of reactive power compensation modules of switchgear condapter earthing connection inspection spare part Conductor connection of protective c. inspection 108 neutral protective

Page 85

protective and neutral Index word Contact check

7 10, 38 36 106 82 80 7 7 10, 11 35 8 8 41, 42, 43, 44 41 14, 22, 43, 46, 70 39 42 83, 84 92

clearance grease greasing installation opening plating plug-in modules withdrawable modules Conversion of withdrawable module compartment Current, rated Damage during transport mechanical d. of contact plating of contacts of enclosure of paintwork degree of protection Design mechanical

49 89 74 33

standard modules disconnectable modules check Construction inspection maintenance operation

44 17, 41, 42 27 108, 109 26, 27, 29 55, 57 89 49 21 71 75 83 35, 48 107 47 34, 47

packing and transport spare parts Distance to wall distribution bar arrangement contacting cover design in metal separation wall in multi function separator inspection Rated current enclosure

122

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Appendix

6

Feeder check of incoming or outgoing f . incoming 109 17

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123

Appendix

6
Page 16 Page

Index word fixed modules floor cut-outs false f. foundation frame base f. connection spare parts standard screws transport f.

Page 16, 17, 50 33, 38 39, 40, 60 31, 33, 39, 40 8 39 34 82 86 24

Index word module types

Index word Modules disconnectable See disconnectable modules fixed See fixed modules plug-in See plug-in modules railable See railable modules withdrawable See withdrawable modules multifunction separator

10, 14

Greasing contacts fuse links 76, 85, 107, 108 77 neutral bar N neutral conductor N incoming feeder inspection list of contact system of the switchgear system instrument panel insulation resistance measurement Interlock lubrication Interlocking of module doors isolated position 23 50, 52, 54, 57, 58 78, 107 94, 107 17, 53 75 101, 106 80, 107 101 17, 20, 22, 54, 56 Packing of circuit breakers of switchboards of components Paintwork repair plug-in modules cable connection check inspection maintenance Operation lifting angles removal load break switch Connection lubricant maintenance frequency per installation category intervals list of reactive power compensation modules preventive m. measuring log reactive power compensation 97 35 18, 53 41, 42, 44 78 reduction factors 60, 100, 101 101 99, 101 106 89 99 railable modules check Construction Inspection maintenance operation 83 108 19 107 66 50 protective bar protective conductor 63 10, 12, 16, 35 47 packing and transport spare parts power loss maximum admittable effective p. 61, 62 81 18 43 108 107 64 50 28 82 27 24, 25 26 operating handle handle see also switch 56, 58 10, 12, 16, 35 47

124

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Appendix

6

Index word packing and transport replacement spare parts reactive power compensation system commissioning measuring log

Page 28 65 83

89 97

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125

Appendix

6
Page 30, 31 24, 25, 26 33 29, 30 29

Index word

Page

Index word

safety Screws ESLOK secured ESLOK for busbar connections for galvanized surfaces thread-forming thread-rolling tightening torque Sealing separation wall See also multifunction separator metal s. shipping unit spare modules storage spare parts busbar mounting disconnectable modules frame plug-in modules standards Storage Intermediate period switch handle Operation Positions

2, 100 8, 35, 60, 86 88 47 8, 18, 34 87, 88 87 48, 82 8 15 10, 16, 24, 25, 31, 34, 43 26, 29 32 82 82 82 82 82 7, 74 24, 31 31 56 58 54, 57

Transport by crane frame frame removal on ground on site

Ventilation voltages, rated

60, 89 7

Wall distance to w. partition w. rear w. separation w. side w. weight wiring field-to-field tool withdrawable modules cable connection commissioning condapter See condapter Construction conversion distribution bar connection inspection maintenance operation packing and transport test prior to installation 20 70 10 107 68, 78 54, 55, 56 27 80 43 44 37, 60 35 35 8, 15 34, 35 24, 29, 30 41 43 83

technical data test certificates test position Testing of contacts tests repetitive tightening torque

7 7 50, 51, 52, 54, 57, 58, 62 79, 80 99, 101, 106 45, 46, 87, 88

126

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ABB Schaltanlagentechnik GmbH Wallstadter Str. 59 D - 68526 Ladenburg / Germany

Editor / : DEAST/T Publication no./ . 1TGC902006M0402

Related Products, News, Local Contacts / Weitere Produkte, Neuigkeiten, Kontakte: www.abb.com/mns


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