Low-voltage switchgear MNS Installation, handling

and operation

MNS

ABB Installation
Low-voltage switchgear MNS is available with rated currents up to
5000 A (IP 31) and can be equipped with:
– starters and distribution units of withdrawable design (W units)
– distribution units and group boards of removable design (R units)

List of contents
Handling and unpacking page 3
Setting up switchgear cubicles 4
Laying of external cables 6
Connection of circuit-breaker cubicle and disconnector cubicle 7
Disconnector cubicle, cable connection from below 7
Disconnector cubicle, busbar connection from above 7
Circuit-breaker cubicle, cable connection from below 8
Circuit-breaker cubicle, cable connection from above 10
Circuit-breaker cubicle, busbar connection from above 12
Connection of apparatus units
Withdrawable units, main circuits 14
Removable units, main circuits 16
Screw-in fuse boards 17
MCB boards 20
Auxiliary circuits 21
Protective earthing 21
Withdrawable apparatus units, handling
Description 22
Operation 23
Withdrawing 25
Inserting 26
Extension 27
Withdrawable apparatus units, handling
Description 28
Operation 28
Replaceability, MNS – Center 5000/1600 28
Removing a unit 29
Mounting a unit 29
Extension 30
Measures to be adopted before applying voltage
Concluding work 31
Check list upon commissioning 31

2
Handling and unpacking
The switchgear cubicles are delivered in the form of ready
assembled complete units with horizontal busbars. Each
cubicle is protected with plastic wrapping and securely
attached to a loading pallet.
Check the delivery against the accompanying advice note.
Handle the cubicles carefully. They are most easily trans-
ported using fork-lift trucks.
When hoisting with an overhead travelling crane or other
hoists:
1. Use the lifting eye bolts attached to the top of the cubicles.
2. Insert the lifting sling shackles into the holes in the eye The cubicles are most easily Lifting with a hoist or overhead
bolts. transported using a fork-lift truck. travelling crane.
3. Adjust the length of the slings so that the angle between
them does not exceed 60°.
If the cubicles are not to be installed directly, they should be

Fill up between the cubicles

Fill up between the cubicles
stored in a dry place protected from dust. The plastic wrap-
ping should be kept on as a protection.
Avoid fixing adhesive marking labels to painted surfaces. If
they are left on too long, the paint may become discoloured.

Max. 3 mm

Warning! Cubicles may easily tip over when transported with a

hand-pulled truck. The truck must not be raised more than 3 mm
when moving a cubicle on a pallet.

3
Setting up switchgear cubicles

Cubicle types, overview

Circuit-breaker cubicle for ACB min 150
Cubicle widths up to 1200 mm.
Disconnector cubicle
Cubicle width 800 mm.
Apparatus cubicle W/R
Cubicle width 600 + 400 or 600 + 600 mm.
Apparatus cubicle for free equipping
Cubicle width 400, 600 or 800 mm.
The following dimensions are the same for all types of MNS cubicles:
Height 2263 mm
Height module 50 mm
Depth 650 mm

Clear space around cubicles

The area around the cubicles to be left clear should be at least 150 mm.
The distance between the cubicle´s rear panel and the wall, and between end
Free space above cubicle.
panels and the wall, should be at least 40 mm.
Apparatus cubicles with operating handles in the doors should be placed with a
clearance distance of at least 150 mm from the left end panel to the adjacent wall
so that the doors can be opened more than 90°. min 40

Drilling of holes
The drawings show the holes that can be drilled for external cables under the
cubicles, in the base plate and in the roof plate. min 40 – 150

Distance to wall.

50 50
50 50
*) *)
FL 21
FL 21 FL 21

600
100 100 100
270 b – 100 50
100 100 100
D=16

117 150 150 150

75

Front 200 Front Front Front

b 200 216 192 216 216 184

Drilling of holes in floor and base plate: Drilling of holes in Drilling of holes in Drilling of holes in
Circuit-breaker cubicle, b = 600, 800, 1000, 1200 roof plate: roof plate: roof plate:
Disconnector cubicle, b = 600, 800 Apparatus cubicle, b = 400 Apparatus cubicle, b = 600 Apparatus cubicle, b = 800
Apparatus cubicle, b = 400, 600, 800
*) Not to be used when a cubicle is fixed to
a wall.

50 50

50 50
*) *)

FL 21 FL 21

600
100 100
270 300/500 50
100 100

117 150 150

75

Front 200 Front Front

216 130 216 216 130
1000/1200

Drilling of holes in floor and base plate: Drilling of holes in roof plate: Drilling of holes in roof plate:
Apparatus cubicle W, b = 600 + 400, 600 + 800 Apparatus cubicle W, b = 600 + 400 Apparatus cubicle W, b = 600 + 600
*) Not to be used when a cubicle is fixed to
a wall.

4
Setting up switchgear cubicles (cont.)

Alignment of cubicles
The flooring should be flat and even and carefully chosen for cubicle erection
so that several cubicles can be bolted together without necessitating further meas-
ures.
If the floor is not sufficiently flat, this may result in panels and doors jamming.
The height of the cubicles can be adjusted by inserting sheet metal shims between
base plate and floor.

Bolting together of cubicles

Any height adjustment of cubicles necessary must be carried out before bolting Bolting cubicles together.
them together.
At the front, the frames are to be bolted together at four places: There are four
clearance holes for M6 hexagonal headed bolts in the front right-hand frame post *) 25
D=16 31.5
of cubicles, and corresponding threaded holes (ready-mounted threaded bushings)
in the left hand post. The threaded holes are located 112.5 mm, 762.5 mm, 1437.5 mm
and 2087.5 mm above the floor plane.
At the rear, the frames are bolted together at three places: 112.5, 2087.5 and
depending on whether the cubicles are fitted with an upper or lower busbar system,
the frames are bolted together 762.5 mm (upper busbar system) or 1437.5 mm
(lower busbar system) above the floor plane.
The maximum tightening torque is 5 Nm. 2315

Five distance bolts (article no. 1TSA2 21671-90) for bolting cubicles together are
provided in a plastic bag to be found attached in the cable compartment of each
cubicle.

Attachment
Placing against a wall
The cubicle furthest to the left in a row of cubicles is to be fixed to the wall with the
help of two wall attachment brackets and to the floor with a bolt through the front of
its base plate, positioned 200 mm from the right-hand side of the cubicle. Other Placing against a wall.
cubicles in the row are to be fixed to the wall with one wall attachment bracket and *) Only for the cubicle furthest to the left.
to the floor with a bolt through the front of their base plates.
Free-standing arrangement
The cubicle furthest to the left in a row of cubicles is to be fixed to the floor using
two bolts through the rear of its base plate (after removing the rear panel), 50 mm
from the sides of the cubicle, and with a bolt through the front of its base plate,
200 mm from the right-hand side of the cubicle. Other cubicles in the row are to be
fixed with one bolt through the rear of their base plates (after removing the rear
panel), 50 mm from the right-hand side of the cubicle, and with a bolt through the
front of their base plates, 200 mm from the right-hand side of the cubicle.
Recommended screw diameter: 10 mm.

Interconnection ot horizontal busbars

Connection of the horizontal busbars between the cubicle units should take place
from the front of the cubicles.
1. Remove the polycarbonate shields in front of the bars to allow access to the
point of interconnection.
2. Unscrew the bolts in the joint pieces.
3. Move over the joint pieces to the bars in the cubicle alongside.
4. Tighten the bolts with a torque wrench, 20 Nm.
5. Fit the polycarbonate shields back on.
In the case of several parallel phase bars, the joint pieces should be placed as Removal of polycarbonate shields.
shown in the diagram.

Coupling of phase bars. Coupling of N and PE bars.

5
Laying of external cables

Apparatus cubicle
All external cables to apparatus cubicles are to be laid in the area intended for
cables.
Main
cables *)
Control cables
Main cables
In the 400 mm cable compartment there are five rails on the right-hand cubicle Internal wiring
wall, for fixing of main cables using cable hangers. Slimmer cables are best fixed
Main cables
to the rails by crossing two smaller bunching straps.
In the 600 mm cable compartment there are in addition five rails on the rear wall,
for fixing of main cables.
Cable compartment.
Auxiliary cables *) Only with 600 mm cable compartment.
Internal wiring and operating voltage supply cables should be attached using
bunching straps in special attachment holes to the left at the rear of the cable
compartment. Control cables should be attached using strap attachments and
bunching straps on the rear wall. (Bunching straps are delivered with the cubicles.)
For withdrawable units, there is a strap attachment on the right hand side of the
cassette plate for supporting the weight of the operating cables.
Under the top door there is a cable duct intended for connections between
Cable clamping straps.
cubicles. The cable duct also serves as an attachment rail for cubicle terminal
boards.

Strap attachment. Cable duct for operating cables between cubicles. Attachment rail for cubicle terminal boards.

Circuit breaker cubicles, disconnector cubicles, cubicles for extra equipment

Main cables
The main cables are supported with fixing clamps in anchoring rails which
can be attached in depth at different levels and matched to terminal bars and
cables.

Auxiliary cables
Operating cables are supported with bunching straps in the cable brackets
fixed to the ends of the cubicle. Operating cables can be placed on either
side, depending on where the terminal board is placed.

6
Connection of circuit-breaker cubicles and disconnector cubicles

Cable cross-sectional areas, Dimension drawings

main circuits
Disconnector cubicle, cable connection from below
Max. connectable area mm2

Cubicle design A, OETL 1250 A

cable connection from below
Disconnector cubicle
1250 – 1600 A 8//240
2500 – 3200 A 20//240
Circuit-breaker cubicle ACB
1250 – 2000 A 8//240
2500 A 12//240
3200 A 20//240
4000 A 24//240
Cubicle design A,
cable connection from below
Circuit-breaker cubicle ACB
1250 – 1600 A 6//300
2000 – 2500 A 8//300
3200 – 4000 A 12//300

Cable cross-sectional areas,

auxiliary circuits
Auxiliary circuit cables are to be
connected to terminal boards.

Max. connectable area mm2

Fixed 4
Disconnectable 10
Disconnector cubicle, busbar connection from above

OETL 2500 A

7
Connection of circuit-breaker cubicles and disconnector cubicles (cont.)

Dimension drawings
Circuit-breaker cubicle, cable connection from below

MEGAMAX 1250 A 3-P MEGAMAX 1250 A 4-P

MEGAMAX 1600 A 3-P MEGAMAX 1600 A 4-P

MEGAMAX 2000 A 3-P MEGAMAX 2000 A 4-P

8
Connection of circuit-breaker cubicles and disconnector cubicles (cont.)

Dimension drawings
Circuit-breaker cubicle, cable connection from below

MEGAMAX 2500 A 3-P MEGAMAX 2500 A 4-P

MEGAMAX 3200 A 3-P MEGAMAX 3200 A 4-P

MEGAMAX 4000 A 3-P MEGAMAX 4000 4-P

9
Connection of circuit-breaker cubicles and disconnector cubicles (cont.)

Dimension drawings
Circuit-breaker cubicle, cable connection from above

MEGAMAX 1250 A 3-P MEGAMAX 1250 A 4-P

*)

MEGAMAX 1600 A 3-P MEGAMAX 1600 A 4-P

*)

MEGAMAX 2000 A 3-P MEGAMAX 2000 A 4-P

*)

*) Only when connection is made with a 5-conductor system.

10
Connection of circuit-breaker cubicles and disconnector cubicles (cont.)

Dimension drawings
Circuit-breaker cubicle, cable connection from above

MEGAMAX 2500 A 3-P MEGAMAX 2500 A 4-P

*)

MEGAMAX 3200 A 3-P MEGAMAX 3200 A 4-P

*)

MEGAMAX 4000 A 3-P MEGAMAX 4000 A 4-P

*)

*) Only when connection is made with a 5-conductor system.

11
Connection of circuit-breaker cubicles and disconnector cubicles (cont.)

Dimension drawings
Circuit-breaker cubicle, busbar connection from above

MEGAMAX 1250 A 3-P MEGAMAX 1250 A 4-P

*)

MEGAMAX 1600 A 3-P MEGAMAX 1600 A 4-P

*)

MEGAMAX 2000 A 3-P MEGAMAX 2000 A 4-P

*)

*) Only when connection is made with a 5-conductor system.

12
Connection of circuit-breaker cubicles and disconnector cubicles (cont.)

Dimension drawings
Circuit-breaker cubicle, busbar connection from above

MEGAMAX 2500 A 3-P MEGAMAX 2500 A 4-P

*)

MEGAMAX 3200 A 3-P MEGAMAX 3200 A 4-P

*)

MEGAMAX 4000 A 3-P MEGAMAX 4000 A 4-P

*)

*) Only when connection is made with a 5-conductor system.

13
Connection of apparatus units

Withdrawable apparatus units 4 M/4, main circuits

Max connectable area 1 x 10 mm2

Main circuit
terminal boards

Withdrawable apparatus units 2 M, main circuits

Max connectable area 1 x 25 mm2

Connection unit for main circuits.

Phase interval = 18 mm.

Requisite screwdriver size for connection unit's clamp

Dimension A max. 235 mm
B min 80 mm
C 1.0 mm
D 5.5 mm

A
B
D

14
Connection of apparatus units (cont.)

Withdrawable apparatus units 4 M - 12 M ≤ 400 A, main circuits

Connection unit Max. connectable Max. bolt Max. tightening Cable shields
size area dimension torque per phase

3 x 160 A (25 mm) 1 x 120 mm2 M10 x 30 45 Nm 1 x 120 mm2

6 x 160 A (25 mm) 1 x 120 mm2 M10 x 30 45 Nm 1 x 120 mm2
3 x 400 A (40 mm) 2 x 240 mm2 M12 x 35 80 Nm 2 x 240 mm2

Connection unit for main circuits.

The cable shield protecting against inadvertent touching
should be cut to fit the cable area. The shield should be
secured with a clamping strap.

Withdrawable apparatus units 8 M - 12 M > 400 A, main circuits

Connection unit Max. connectable Max. bolt Max. tightening

size area dimension torque

3 x 800 A 4 x 240 mm2 M 12 x 35 80 Nm

Connection unit for main circuits.

The cable shield protecting against inadvertent touching
should be cut to fit the cable area. The shield should be
secured with a clamping strap.

15
Connection of apparatus units (cont.)

Removable apparatus units, main circuits

The main circuits are to be connected direct

to the apparatus terminals using a cable lug
or cable clip. Cable shield protecting against
inadvertent touching.

Apparatus unit Connectable area, copper cable Connectable area, aluminium cable
Type Size Min. area Max. area Max. area Min. area Max. area Max. area
cable lug cable clamp cable lug cable clamp
mm2 mm2 mm2 mm2 mm2 mm2

MCCB ISOMAX N, fixed

S3N 160 19 – 100 A 16 – 25 2//95 120 16 – 35 70 70
S3N 160 88 – 160 A 35 – 50 2//95 120 50 – 70 2//150 120
S3N 250 140 – 250 A 50 – 95 2//95 120 120 – 150 2//150 -
S4N 250 40 – 250 A 25 – 95 2//95 120 120 – 150 2//150 -
S5N 400 130 – 400 A 35 – 240 2//150 300 240 – 300 2//240 300
S6N 630 250 – 630 A 1x95 – 2//150 3//300 2//300 2//240 3//240 2//300
S6N 800 320 – 800 A 1x150 – 2//240 3//300 2//300 2//300 3//240 2//300

MCCB ISOMAX N, plug-in

S3N 160 19 – 100 A 16 – 25 50 - 16 – 35 70 -
S3N 160 88 – 160 A 35 – 50 2//95 - 50 – 70 2//150 -
S3N 250 140 – 250 A 50 – 95 2//95 - 120 – 150 2//150 -
S4N 250 40 – 250 A 25 – 95 2//95 - 120 – 150 2//150 -
S5N 400 130 – 400 A 35 – 240 2//150 - 240 – 300 2//240 -
S6N 630 250 – 630 A 1x95 – 2//150 3//300 2//300 2//240 3//240 2//300
S6N 800 320 – 800 A 1x150 – 2//240 3//300 2//300 2//300 3//240 2//300

MCCB ISOMAX H, fixed

S3H 160 19 – 100 A 25 2//95 120 25 – 35 2//150 120
S3H 160 88 – 160 A 35 – 50 2//95 120 70 2//150 120
S3H 250 140 – 250 A 50 – 95 2//95 120 120 – 150 2//150 -
S4H 250 40 – 250 A 25 – 95 2//95 120 120 – 150 2//150 -
S5H 400 130 – 400 A 35 – 240 2//185 300 240 – 300 2//240 300
S6H 630 250 – 630 A 1x95 – 2//150 3//300 2//300 2//240 3//240 2//300
S6H 800 320 – 800 A 1x150 – 2//240 3//300 2//300 2//300 3//240 2//300

MCCB ISOMAX H, plug-in

S3H 160 19 – 100 A 25 70 - 25 – 35 70 -
S3H 160 88 – 160 A 35 – 50 2//95 - 70 2//150 -
S3H 250 140 – 250 A 50 – 95 2//95 - 120 – 150 2//150 -
S4H 250 40 – 250 A 25 – 95 2//95 - 120 – 150 2//150 -
S5H 400 130 – 400 A 35 – 240 2//185 - 240 – 300 2//240 -
S6H 630 250 – 630 A 1x95 – 2//150 3//300 2//300 2//240 3//240 2//300
S6H 800 320 – 800 A 1x150 – 2//240 3//300 2//300 2//300 3//240 2//300
Continued on page 15

16
Connection of apparatus units (cont.)

Removable apparatus units, main circuits

Continued from page 14

Apparatus unit Connectable area, copper cable Connectable area, aluminium cable
Type Size Min. area Max. area Max. area Min. area Max. area Max. area
cable lug cable clamp cable lug cable clamp
mm2 mm2 mm2 mm2 mm2 mm2

MCCB LN, fixed

LN 125 16 – 125 A 6 – 35 70 70 10 – 50 70 70
LN 200 125 – 200 A 50 – 70 70 70 70 – 120 70 70
LN 320 200 – 320 A 95 – 150 2//185 - 150 – 240 2//240 -
LN 500 320 – 500 A 240 – 300 2//300 - 300 – 2//150 2//240 -
LN 630 500 – 630 A 2//150 3//300 - 2//240 3//240 -
MCCB LN, plug-in
LN 125 16 – 125 A 6 – 35 70 70 10 – 50 70 70
LN 200 125 – 200 A 50 – 70 2//95 120 70 – 120 2//150 120
LN 320 200 – 320 A 95 – 150 2//185 300 150 – 240 2//240 300
LN 500 320 – 500 A 240 – 300 2//300 2//300 300 – 2//150 2//240 2//300

Fuse/switch OESA
160 A 50 120 120 70 120 120
250 A 95 300 300 150 240 300
400 A 240 2//300 2//240 300 240 300
630 A 2//150 3//300 2//300 2//240 3//240 2//300
800 A 2//240 3//300 2//300 2//300 3//240 2//300

Screw-in fuse boards

Continued on page 16

17
Connection of apparatus units (cont.)

Screw-in fuse boards, continued from page 15

Thread II, 25 A
With neutral and protective earth busbars.

The neutral and protective earth busbars are

N PE Number of groups Height, modules
provided with joint neutral disconnection and
1-pole 3-pole
the requisite single-screw clamps for single-
pole connection of all outgoing groups 18 6 8
Connectable area: 9 3 6
max. 10 mm2, min. 1.5 mm2

Thread II, 25A

With row of terminal boards.

The groups are connected to a row of terminal Number of groups Height, modules
boards which also contain disconnectable neu- 1-pole 3-pole
tral boards for joint and individual disconnection
of the groups. Protective earth bar with single- 18 6 8
screw clamp and connection to the main neu- 9 3 6
tral board are included.
Connectable area:
max. 6 mm2, min. 1.5 mm2 for 3-pole
max. 4 mm2, min. 1.5 mm2 for 1-pole

Thread II, 25 A
With group circuit-breaker 40 A

Each group is provided with a three-pole group

Number of groups Height, modules
circuit-breaker. The neutral and protective earth
1-pole 3-pole
busbars have joint neutral disconnection and
requisite single-screw clamps for connection of - 6 8
outgoing groups.
Connectable area:
max. 10 mm2, min. 1.5 mm2

Thread II, 25 A
With extra row of fuses.

6 fuse sockets 25 A mounted on a phase bar Number of groups Height, modules

alongside the normal three rows.
1-pole 3-pole
Connectable area:
max. 10 mm2, min. 1.5 mm2 24 - 8
6 6 8

Continued on page 17

18
Connection of apparatus units (cont.)

Screw-in fuse boards, continued from page 16

Thread III, 63 A
With neutral and protective earth busbars

The neutral and protective earth busbars are

N PE Number of groups Height, modules
provided with joint neutral disconnection and
1-pole 3-pole
requisite two-screw clamps for 3-pole connec-
tion of all outgoing groups. - 5 8
Connectable area: - 2 6
max. 25 mm2, min. 1.5 mm2

Thread III, 63 A
With row of terminal boards

The groups are connected to a row of terminal

Number of groups Height, modules
boards which also contain disconnectable neu-
1-pole 3-pole
tral boards for joint and individual disconnection
of the groups. A protective conductor bar with - 5 8
two-screw clamp and connection the a main - 2 6
neutral board are included.
Connectable area:
max. 16 mm2, min. 1.5 mm2

Thread III, 63 A
With group circuit-breaker 80 A

Each group is provided with a three-pole group

Number of groups Height, modules
circuit-breaker. The neutral and protective con-
1-pole 3-pole
ductor busbars have joint neutral disconnection
and requisite two-screw clamps for single-pole - 5 8
connection of outgoing groups.
Connectable area:
max. 16 mm2, min. 1.5 mm2

Thread III, 63 A
With extra row of fuses

6 fuse sockets 25 A mounted on a phase bar

Number of groups Height, modules
along side the normal three rows.
1-pole 3-pole
Connectable area:
max. 25 mm2, min. 1.5 mm2 for 3-pole 6 5 8
max. 10 mm2, min. 1.5 mm2 for 1-pole

19
Connection of apparatus units (cont.)

MCB terminals
Internal cables from back-up circuit-breaker
Cable duct for external cable or from main busbar

Neutral bar

PE bar

Disconnector board N-PE

Connection of external cables direct to terminals Internal distribution busbar for

of MCB apparatuses MCB apparatus

Basic set (PEN)

PE + N placed in 5-conductor system PEN/PE +N placed in 4-conductor system (neutral bar optional)

20
Connection of apparatus units (cont.)

For withdrawable units, operating and signal cables are connected to terminal units
(sliding contact units).
Max. connectable area: 1 x 2.5 mm2 screw clamp + 2 x flat pin terminal 2.8 x 0.8.
Max. rated current/voltage: 10 A/500 V.
Connection of screened conductors is best done to an earthing bar located on the
left front post in the cable area (option).

Auxiliary circuits, removable units

Connection unit for auxiliary circuits for
For removable units, signal cables are to be connected to plug-in ten-pole withdrawable units 2M – 20M.
connection blocks.
Max. connectable area: 1 x 4 mm2 screw clamp.
Max. rated current/voltage: 10 A/500 V.

Plug-in connection block for auxiliary

circuits for removable units.

Protective earthing
The vertical protective earth busbar (PE) has holes 50 mm apart for cable lug
connection down to 4 mm2 conductor area. Conductors with areas of 1 – 10 mm2
are to be connected to a smaller bar mounted on the large bar.
The PE busbar is located right at the back of the cable area to the left.

Vertical protective earth busbar (PE).

21
Withdrawable apparatus units, handling

Description
The withdrawable apparatus units have plug-in connection both for the incoming
supply from the vertical busbar system and for outgoing cables. The units can be
pulled out without having to unscrew any bolts. Interlocking takes place via the
group´s operating handle. The auxiliary circuits are connected via multi-pole plug-in
contact units. Unoccupied apparatus seats are screened off to minimise the risk of
unintentional touching of live parts.

Withdrawable unit in disconnected position.

Withdrawable starter.

Unoccupied apparatus seat for withdrawable unit.

Compact unit with two units in operating position, one unit in

disconnected position and one unoccupied apparatus seat.

22
Withdrawable apparatus units, handling (cont.)

Operation, normally wide unit

The unit has two fixed positions: connected position and disconnected position.
The operating knob is used both for operating the power switch and for interlocking
the apparatus unit. The knob has four different positions.

Knob position Unit function when in

connected position
On All electrical circuits connected.
Cover interlocked.
TE
T
ST

Off All electrical circuits disconnected.

TE
ST

Test Main circuits disconnected,

auxiliary circuits connected.
TE
ST

Move All electrical circuits disconnected.

The unit can be moved.
TE
ST
When withdrawing from the connected
position, the unit is automatically locked
when it reaches the disconnected posi-
tion *).
The knob can be locked using up to For further movement outwards, the
three padlocks in the positions Off and knob must be moved back to the move
Test. position.
*) Where the unit is in the disconnected
position (see the figure on page 20) the
position of the knob is of no importance
since both the main and the
auxiliary circuits are disconnected.

23
Withdrawable apparatus units, handling (cont.)

Operation, compact unit

The unit has three fixed positions: connected position, test position and disconnect-
ed position. The operating knob is used both for operating the power switch and for
mechanical interlocking of the unit. A microswitch with two making and two break-
ing contacts is included for electrical interlocking. The knob has five different posi-
tions.

Knob position Unit function when in Unit function when in

the connected position disconnected position
On All electrical circuits connected. –
The unit interlocked in the connected
position.

Off All electrical circuits disconnected. –

To turn from ”0” to ”1”, The unit interlocked in the connected
the knob must be position.
pressed in.

Test Main circuits disconnected, auxiliary –

circuits connected.
The unit interlocked in the connected
position.

Move All electrical circuits disconnected. All electrical circuits disconnected.

The unit can be moved. The unit can be moved.

Disconnected – All electrical circuits disconnected.

The unit can be moved.
When withdrawing from the connected
position, the unit is automatically
blocked when it reaches the discon-
nected position (pulled out 30 mm from
the run position). For further movement
The knob can be locked with up to outwards, the knob must be turned
three padlocks in the positions Off back to the move position.
and Test.

24
Withdrawable apparatus units, handling (cont.)

Withdrawing, normally wide unit

The unit is in the run position (pushed right in).
1. Turn the knob to the Move position.
Pull (jerk) the unit out so far that it is automatically locked by the interlocking
mechanism. Use the two handles. The operating knob must not be used as a
handle when moving the unit.
When moving the unit, the knob immediately moves back to the 0 position
when the unit starts moving. This is perfectly normal; continue moving without
touching the knob.
2. The unit is now in the disconnected position.
3. For further movement, turn the knob to the Move position.
4. The unit is now free to be pulled out to the safety stop.
Since the weight of the unit can prove to be too heavy if the hands remain on
the handles, shift your grip when the unit is half-way out. For 2M and 4M units,
grasp under the sides about half way along and pull the unit out
against the safety stop. For 6M units and bigger, there should be
two persons pulling the unit out of the cubicle. When the unit is
withdrawn half-way, one person on each side should grasp the
side of 6M units, or the handle on the sides of larger units, and
pull the unit out against the safety stop. Since the unit now has its
centre of gravity outside the cubicle the unit cannot be left in this
position. Be careful when large, heavy units are handled so as to
avoid injuries to persons nearby and damage to mechanical parts.
To make handling of large units easier, and also from the ventila-
tion point of view, they should be placed as far down in the cubicle
as possible.
5. Before removing the unit from the cubicle, release the safety stop by
pressing down the catch at the bottom of the left-hand side of the of
the unit.
The catch is so placed that the correct balance is obtained when
pulling out 2M and 4M units alone. For larger units, it is located
so that it is easily accessible for the person standing on the left.
For 2M and 4M units located at a level below chest height grasp
under the sides about half way along and release the catch with
your left thumb. If they are at a higher level, grasp under the unit
on the guide plate with your right hand and release the catch
with your left hand.
6. The unit is now ready to be pulled completely out of the
cubicle
When using the special apparatus hoist available for ABB’s apparatus units,
this instruction should be followed up to point 3, after which the instructions
supplied with the apparatus hoist should be complied with (1TSC 232-SE).
If a hoisting trolley is used for depositing the unit on, the unit can be placed on
its guide plate, inserting wooden slats or similar underneath so as not to dam-
age the front door and mechanism. When temporarily storing the unit on the
floor, it should be placed with its left side (seen from the front) on the floor so
as not to damage the unit´s withdrawal mechanism. The floor surface should
be flat and smooth so as not to scratch the paintwork on the unit. For perma-
nent storage on the module bottom plate, the unit should be blocked up so as
not to damage the unit´s withdrawal mechanism and the underneath of the
panel.

Withdrawing, compact unit

The unit is in the run position (pushed right in).
Turn the knob to the Move position.
The unit is now ready to be pulled out of the cubicle completely. Use the handle
(the operating knob must not be used as a handle when pulling out the unit).
When moving to the disconnected position, turn the knob by hand to the discon-
nected position while pulling (jerking) the unit out of the Run position. Pull outwards
until the unit is blocked in the disconnected position. To pull the unit out completely
from the disconnected position, return the knob to the Move position, whereupon
the unit is free to be pulled out.
25
Withdrawable apparatus units, handling (cont.)

Insertion, normally wide unit

From the handling point of view, insertion of the unit into the
cubicle takes place in the same manner as withdrawing it.
1. Check that the guiding edge of the unit
fits into the slot in the guide rail.
Push in the unit carefully until it is stopped
by the interlocking mechanism.
The unit must not be left in this position
since it is unblocked.

2. Turn the knob to the Move position.

Push in the unit until it is blocked by the interlocking mechanism.

3. The unit is now in the disconnected position.

4. For further movement inwards, turn the knob to the Move position.

5. The unit can now be pushed into the connected position.

Check that the unit is properly blocked by trying to pull it out without touching
the knob. The knob should now be in the horizontal position.

Insertion, compact unit

From the handling point of view, insertion of a unit into a cubicle takes place in
the same manner as when withdrawing it.
1. Check that the unit´s guiding edge fits into the slot in the control rail.

2. Turn the knob to the Move position.

Push the unit in to the connected position.

3. Turn the knob to the Test position or Off position.

Check that the unit has been properly blocked by trying to pull it out without
touching the knob.

26
Withdrawable apparatus units, handling (cont.)

Extension
Extension of the equipment can take place with the switchgear live, but it is
naturally preferable to work with the voltage switched off.
1. Remove the panel in question as well as the panel immediately below it.
Remove the panel bar as well (only at higher degree of protection).

2. Insert and mount a new cassette

plate and guide rail.

4. Mount connection units for main and

auxiliary circuits.

5. Connect up cables for main

and auxiliary circuits.
Follow instructions for connecting up
apparatus units.
6. Fit the panel below the new unit
back in and push the unit into place.
Follow instructions for inserting units.

Since the units are protected against adjacent units via cassette plates, and the ter-
minals are provided with cable shields, no further measures need be adopted when
carrying out extensions with the equipment live.
Before energising the equipment, see the instructions under ”Concluding work” and
”Check-list upon commissioning”.
In general, it is important when extending equipment that the relevant regulations
regarding measures that are to be adopted, such as marking with sign-plates, etc.,
are complied with. 27
Removable apparatus units, handling

Description
The removable apparatus units have plug-in connection for the incoming supply
from the vertical busbar system, whereas the outgoing cables are connected per-
manently direct to the apparatus terminals. The units can be taken out after the
outgoing cables have been disconnected and four fixing bolts removed. The auxil-
iary circuits are connected via multi-pole plug-in contact units.

Removable R unit. Removable unit in connected position.

Operation
The operating knob has two positions.

Knob position Unit function

On All electrical circuits connected.
Panel interlocked.
T

Off All electrical circuits disconnected.

The unit can be removed after
disconnecting cables and removing
fixing bolts.

Replaceability, MNS – Center 5000/1600

Removable apparatus units (R units) supplied before Week 40, 1995 do
not fit and should not be used in MNS cubicles. Their apparatus plates have
the wrong dimensions for MNS, leading to plug-in contacts not fitting properly.
The mark of a non-replaceable R unit is that the plug-in holder consists of 3 or 4
single-pole holders.
R units supplied after Week 40, 1995 can be used in both MNS and
Center 5000/1600 if proper spacing using spacer set 1TSA2 21518-A is applied
in Center 5000/1600. (Standard design for Center 5000/1600 after Week 40, 1995.)
No spacing is allowed in MNS cubicles.
The mark of a replaceable R unit (with the aid of spacers) is that the plug-in holder
Marking label for a replaceable R unit.
consists of a 4-pole holder and that the apparatus plates are marked with a label.

28
Removable apparatus units, handling (cont.)

Removing a unit
1. Set the knob in the 0 position (breaker off).

2. Open the panel and remove any fuses.

3. Check that there is no voltage at the apparatus

terminals (that the equipment is not live).

4. Detach the main cables.

Pull out the cables through the hole in the group’s end panel.
(Remove any screens and cable shields.)
Protect the cable ends against any live parts in the cable
area.

5. Disconnect any connection units for operating cables.

6. Remove the four fixing bolts.

7. The unit is now free and can be taken out.

8. Close the panel.

Mounting a unit
1. Open the panel.

2. Set the handle in the 0 position (breaker off) and

remove any fuses.

3. Insert the unit and bolt it fast (four fixing bolts).

3. Test that there is no voltage at the apparatus terminals

(that they are not live).

4. Connect up the connection units for the operating

cables.

5. Connect the main cables, fit screens and cable

shields.

6. Fit fuses, where applicable.

8. Close the panel.

29
Removable apparatus groups, handling (cont.)

Extension
Extension of the equipment can take place with the switchgear live, but it is
naturally preferable to work with the voltage switched off.
1. Remove the panel in question as well as the panel immediately below it.
Remove the panel bar as well (only at higher degree of protection).

2. Insert and mount a new cassette plate.

3. Fit the panel below the new unit back on.

4. Check that no main fuses are mounted in the new unit.
5. Mount the unit in the cubicle.
Follow instructions for mounting units.
6. Check that there is no voltage at the terminals after the first apparatus.
7. Connect up cables for main and auxiliary circuits.
Follow instructions for connection of apparatus units.
8. Fit on the panel and the lock shackle.
9. Adjust the shaft so that the door interlocking in the ’1’ position works.
[Link] the panel.

Since the units are protected against the adjacent units via cassette plates, and
the terminals are fitted with screens against the cable cubicle, no further measures
need be adopted when extending the equipment in live conditions.
Before energising the equipment, see the instructions under ”Measures to be
adopted before energising”, page 29.
In general, it is important when extending equipment that the relevant regulations
regarding measures that are to be adopted, such as marking with sign-plates etc.,
are complied with.

30
Measures to be adopted before energising

Concluding work
Remove wire ends and debris from cable stripping, etc.
Wipe off any grease and dirt.
Check that tools and assembly material have not been left in the cubicles.
Vacuum-clean the cubicles.

Check-list upon
commissioning
There follows a list of points to be 7. ❐ Check the PE and N bars 10.6 Reconnect all relays , operating
observed when inspecting and testing voltages and circuits that were
a directly earthed system. Carry out a visual inspection to ensure
that the bolts in busbar joints between disconnected during the
In the case of indirectly earthed the cubicles are tight. insulation tests.
systems, a check must always be made
that all metallic parts are correctly 8. ❐ Check phase sequence and 11. ❐ Energising the equipment
earthed. Check the earth fault protec- marking 11.1 Check that incoming and
tion signal as well. outgoing circuit-breakers and
Apart from this check-list, local and disconnectors are off.
current national regulations and 11.2 Check that all doors and covers
instructions must be complied with. in the switchgear are closed.
11.3 Switch on the supply and
1. ❐ Insertion of fuses connect in the switchgear, if
Insert all necessary fuses in the main possible one cubicle or section
and auxiliary circuits. at a time.
2. ❐ Checking of fuses 11.4 Check the phase sequence of a
unit. It is enough to check one
Check that all fuses agree with the
unit since the phase sequence
apparatus list and the circuit diagram.
has already been checked
(point 8).
3. ❐ Setting of MCCBs
Set instantaneous and thermal tripping 11.5 Check the units one at a time
9. ❐ Check internal connections by:
of MCCB units, based on load and
selectivity. Check all internal connections between - switching on the circuit-breaker
the cubicles.
The instantaneous protection for incom- - checking the main circuit to
ing circuit-breakers and large distribu- 10. ❐ Carry out insulation tests the connected load
tion breakers can be temporarily set at 10.1 Check that incoming supply is - checking that all important
the lowest value to ensure the fastest switched off. interlocking measures agree
possible tripping in the event of a short with the circuit diagram.
circuit during commissioning. 10.2 Check that all operating
voltages are switched off.
12. ❐ Final inspection
4. ❐ Checking of current 10.3 Check that all relays are 12.1 Check that all voltmeters,
transformers switched off. ammeters and wattmeters are
Check that the secondary winding in all 10.4 Check that all large MCCBs in working order.
current transformers is connected (incoming circuit-breakers) are
(under load). Otherwise the secondary 12.2 Check that all instantaneous
disconnected. protections that have been
windings must be short-circuited.
10.5 Check the insulation on the turned down during
5. ❐ Setting of starters main busbars using a megger commissioning work are reset
with 1 or 0.5 kV. The insulation to their operating positions.
Set the thermal overload protection at resistance should be ≥ 1 Mohm.
the rated current of the motor. 12.3 Check that no vibrations or
Phase Insulation resistance noises occur in the busbar
N.B. Setting above or below the scale systems.
range is not permitted. Mohm
L1 – N
6. ❐ Check the main busbars L2 – N
Make a visual inspection to see that
the bolts in busbar joints between the L3 – N
cubicles are tight. L1 – L2
L2 – L3
L3 – L1

Warning - high currents

A short-circuit current in low-voltage switchgear is normally very high. Depending on the set tripping time, selectivity,
etc., high short-circuit currents with relatively long duration can occur.
A short circuit can cause serious injuries to personnel and damage to material. It is therefore essential to use properly
insulated tools and secured instruments in commissioning work.

31
 97414 ReklamCenter Västerås 1997 11/DocuTech 400ex
1TSC 234-EN

ABB Installation AB
Low Voltage Systems Division
S-721 62 Västerås, Sweden
Telefon: +46 21 34 60 00
Telefax: +46 21 34 61 10