PanelMaster MCC Product Catalogue

www.eaeelektroteknik.com

2
Index
Introduction 4

Area of applications 5

Characteristics 6
Features 8

Design 10

Intelligent Motor Control Center 20

Dimensions 21

3
Introduction

Compact and modular design for every function

PanelMaster is a simple and modular switchgear solution that is easy to choose, intuitive to use, cost
effective, and simple to install or upgrade.

It provides complete range to match various needs for power distribution and motor control including
variable speed drives and motor starters.

• Switchgears that comply with standard IEC 61439-1 and 2.

• Guarantee a level of safety that has been 100 % tested.

• Ensure a lasting investment through easy upgrading of the installation in compliance with the standard.

Different standardized solution for incoming and outgoing feeders

Switchgear requirements differ from project to project. PanelMaster easily allows the assembly to be
configured to suit all technical conditions and plant operational procedures and to decrease operational
expenses and when possible general investments. Different types of modules can be combined in
one common switchgear. PanelMaster switchgear with fixed outgoing modules, in which all electrical
connections made with screws and bolts are fixed, has proved to be a reliable solution.

The withdrawable module technique has proved to be the appropriate solution for use in industrial
applications where requirements for high availability are a must particularly in Motor Control Centers. All
electrical connections are realized using sliding contacts, what makes possible fast and easy exchange of
modules under live conditions.

Scalability and Flexibility

PanelMaster provides complete scalability across the entire portfolio with options for front or rear access
designs, this coupled with the portfolio applications that fulfil requirements in all industry segments from final
distribution to high end process control and secure power systems ensures PanelMaster is the definitive
solution for all applications.

All PanelMaster modules equipped with different device types made by diverse device manufacturers
are individually type-tested and certified by DEKRA. Being able to select different device brand enables
enormous flexibility for providing application-specific design capability and supply elasticity for improving
supply management.

4
Area of applications

PanelMaster low voltage switchgears are ideal for variety of applications:

• Petrochemical industries

• Oil and gas

• Metal and mining

• Process industry

• Nuclear power

• Pulp and Paper

• Refineries

• Steelworks

• Cement works

• Water treatment plants

• Food industry

• Infrastructure

• Power stations

5
Characteristics

PanelMaster MCC is withdrawable low voltage switchgear up to 6800 A. EAE’s proven technologies have
been integrated in the design and development of the latest generation PanelMaster MCC switchgear in
order to ensure the complete system quality, safety and reliability.

The system has been verified by testing according to IEC 61439-1 and 2 standards.
The standardized, modular PanelMaster MCC system offers practically unlimited possibilities to satisfy
customers’ demands for high-grade Motor Control Centers whilst providing optimum operational reliability,
personal safety, flexibility and economy.

Process changes, e.g. up rating of motor power, may require on-site modification of motor starter circuits
and accordingly, enlargement of switchgear compartments. PanelMaster MCC design is able to meet this
requirement under live conditions.

In cubicles with a vertical distribution busbar system, provided with separation shutters for insertion of main
double-finger contacts along its entire height, changing of outgoing compartment sizes can be safely carried
out under live conditions. For this purpose, the compartment separation barriers being secured by two bolts
at the front of the cubicle, can be easily and quickly removed and secured at the desired position.

6
Characteristics

Electrical Data Rated voltages Rated operating voltage Ue 690 V AC, 3 Ph.

Rated insulation voltage Ui 1000 V AC

Rated impulse withstand voltage Uimp up to 12 kV

Rated frequency up to 60 Hz

Rated currents Main Busbars:

Rated current ln up to 6800 A

Rated peak withstand current lpk up to 264 kA

Rated short-time withstand current lcw up to 120 kA / 1 s.

Internal Arc Passive, 65 kA / 0,3 s.

Distribution bars (MCC Unit):

Rated current ln 630 A / 1250 A

Rated peak withstand current lpk 105 kA

Rated short-time withstand current lcw 50 kA / 1 s.

Mechanical Dimensions Fixed Module Compartment 690 V AC, 3 Ph.

Characteristics Height 2000, 2200 mm

Width 300, 400, 500, 600, 700, 800, 1000 mm

Depth 600, 800, 1000, 1200 mm

Withdrawable Module Compartment

Height 2000, 2200 mm

Width 600 mm

Depth 600, 800, 1000, 1200 mm

Cable Compartment for MCC

Height 2000, 2200 mm

Width 400, 500, 600, 800 mm

Depth 600, 800, 1000, 1200 mm

Enclosure Frame Pre-galvanized, RAL 7035 painted

Cover, Door Pre-galvanized, RAL 7035 painted

Degrees of
According to IEC 60529 IP31, IP54
protection

Internal
According to IEC 61439-2 up to Form-4b
separation

Environmental Location Type Indoor

Ambient Conditions
Characteristics Ambient Air Temperature (Operation) -5 °C to +40 °C
Maximum Relative Humidity 5 %-90 %
Altitude up to 2000 m
Degree of pollution 3
Standards Low voltage switchgear and controlgear
assemblies IEC 61439-1 and 2
Power switchgear and controlgear assemblies
Internal Arc IEC/TR 61641

Seismic Verification IEC 60068-3-3 and IEEE-693/2005

7
Features

System flexibility Personal safety

• Assemblies with combined motor control and • Safe operation of the withdrawable units
high current distribution functions Withdrawable units of all sizes are equipped
with integrated operating error protection
• Back-to-back or face-to-face mounting features via mechanical interlocks and a uniform, clear
main busbar interconnection modules indication of all withdrawable unit positions.

• Operating the withdrawable unit to connected

position takes place when the cover is closed
and without eliminating the degree of protection.

• Full internal separation of all functional units

• Enclosure protection IP31 minimum, higher

ratings are available when required. (up to IP54)

• Internal separation including for disconnected

units are IPXXB (maintained even when units
removed).

• Cable connection terminals positioned at the • Automatic cover interlocking of all outgoing
back of withdrawable unit sections where feeder sections prevents access or removal
rear door application is possible eliminate cable when the main circuit breaker is in the ON
connection section and reduce footprint. position.

• Corner section for angular mounting • Motor starters and circuit breakers can only
be replaced when the withdrawable unit is fully
• Cable connection section can be positioned removed.
on left or right side of withdrawable units section.
Common wider cable connection section • Shutters guard the distribution busbars when
shared by two withdrawable unit section. withdrawable units are removed.

• Wide range of options, such as soft starters, • Safe connection of outgoing cables is feasible
frequency converters, PLC-controlled under live conditions of the busbar by means of
synchronization and changeover equipment, respective protection measures.
units for power factor improvement, harmonic
filtration, etc.

8
Features

Operational reliability Maintenance

• Vertical distribution busbars are completely • Double-finger isolating contacts render

enclosed by double layer insulated busbar maintenance on distribution busbars
chamber. unnecessary.

• Withdrawable unit sections can be modi­fied • Double-finger contact holders can be quick­ly and
without process interruption. easily changed if necessary.

• Cable connection to withdrawable units can be

accomplished under live conditions.

• Optional additional insulation by thermo­plastic

coating of main busbars.

• Unique main isolating double-finger con­tacts

between distribution busbars and withdrawable
units prevent contact wear or welding to busbars
and counteract the risk of contact repulsion
under short-circuit conditions.

9
Design

Main components

PanelMaster MCC switchgears are of a self-supporting structure, consisting of profiles and sheet-steel
sidewalls. The outer sidewalls and front covers are made of zinc coated sheet steel and epoxy polyester
coated.

Corrosion-resistant zinc coated sheet-steel plates are used for the rear and inner walls and for compartment
separation.

Main Busbar
Wireways

Main Busbar - Distribution

Busbar Connection

Withdrawable
Unit

Neutral Distribution
Busbar

Vertical Distribution
Busbar

Cable
Neutral Busbar Section

Protective Earth
Busbar

Withdrawable Unit Section

10
Design

Main busbar system

Main busbars are located in a separate compartment of the switchgear. The compartment has a degree of
protection of IP 2X with respect to the lower situated switchgear and the vertical cable-entry compartment.

Busbars, phase bars and neutral bar, have a standard thickness of 10 mm and are available for current
ratings up to 6800 A. They are secured by type-tested busbar supports which allow easy, on-site changing
of the busbars if uprating of the system is necessary. This can be done without having to alter the busbar
supports.

On-site extension of busbars can be easily and quickly accomplished.

Busbars are arranged in upper, mid or lower height of sections horizontally. Phase conductors are
positioned horizontally side by side. The cross section of busbars can be found in the busbar selection table
which is inside the “PanelMaster Design and Application Rulebook” documentation

Distribution busbar duct with connection bars to main busbar system. Rear view

11
Design

Vertical distribution busbar system for withdrawable units

For sections with withdrawable outgoing units vertical busbars are branched from the main busbar system
by means of connection bars. The vertical busbars are insulated with double-layer solid insulation material at
the back of the section. The busbar duct is partitioned into four sections with double-layer separation wall,
each section accommodating a phase or neutral busbar consisting of special shaped conductors. The front
of the duct is screened by finger proof (IPXXB) shutters, so that each busbars is fully enclosed, preventing
the occurrence of arcs between busbars or between busbars and earth. Busbar shutters have a module
height of 75 mm and are each provided with contact openings for busbar branching.

Shutters are blanking all busbar openings

automatically when withdrawable units are removed
or unused to provide IPXXB protection.

Withdrawable unit compartment, showing from left

to right: finger proof sockets of auxiliary contacts,
double finger contacts shutter of distribution
busbars, outgoing terminal conductors.

Short-circuit capacity
Maximum Busbar cross-section (Cu)
permissible Phase and Neutral bar
load current (A) (mm2) lcw lpk
kA-1 s kA

630 400 mm2 50 105

1250 800 mm2 50 105

Top view of distribution busbar system in double layer

insulated duct.

12
Design

Contacts

Withdrawable units utilize double-finger main The double-finger contacts (patent granted)
contacts. When a withdrawable unit is being have a number of important advantages: They
fully inserted and operating handle turned to ON prevent wear on the vertical busbars, normally
position, both power circuit contact fingers slide resulting from the in and outward movement of the
on distribution busbar and apply force by means of withdrawable unit.
U-shaped contact spring. As a result an excellent-
low resistance, contacting is obtained on both Risk of contact welding to the busbars in the
busbar and withdrawable unit. event of high starting or short-circuit currents
is eliminated by fine-tuned contact pressure.
If required, the finger-contact holder can be Through-going currents on parallel double-finger
removed or replaced easily and quickly. Shutters construction cause increased contact pressure
are blanking all busbar openings automatically on the vertical busbars and on the units contact
when withdrawable units are removed or unused conductor, consequently preventing contact
to provide IPXXB protection. repulsion under short-circuit conditions.

Forces created by current flowing from parallel

Double-finger contact conductors

Increasing through-going (short-circuit)

currents cause increased contact
pressure on the vertical busbars and
on the unit’s contact conductors,
consequently preventing contact
repulsion under short-circuit conditions.

13
Design

Withdrawable outgoing units

Withdrawable outgoing units are provided with contact conductors connecting the unit to distribution
busbars and cable terminals via the corresponding double-finger main contacts. Since the full phase
segregation of the busbar branching points is also continued at the contact conductors, the possibility of
phase-to-phase, phase-to-neutral and phase-to-earth faults are excluded.

Operating of withdrawable units is made very simple and fault-free. Integrated front face marked with easy-
to-perceive instructions require no tools to handle operations. Tests and maintenance operations are safer,
simpler and quicker.

Operating the withdrawable unit to “connected” position takes place when the unit is engaged, door is
closed and without eliminating the degree of protection. Withdrawable units of all sizes are equipped
with integrated operating error protection via mechanical interlocks and a uniform, clear indication of all
withdrawable unit positions.

Each withdrawable unit comprises the following locking means:

• Mechanical interlock between main contacts and main circuit breaker. Main contacts can only be
switched when main circuit breaker is in OFF position.

• Independent mechanical interlock between withdrawable unit position and mechanism for main
contacts.

• Mechanical lock preventing insertion or removal when main contacts or main circuit breaker is in
ON position.

• Latch to prevent the unit from being dropped accidentally if removed too quickly.

For local signaling and operation, each withdrawable unit is provided with a front mounted button set cover
for testing during service showing up to six operating and signaling functions. An auxiliary contact block
(12,24,36,48 poles) has been incorporated to enable remote control and signaling.

Withdrawable unit compartment

Double-finger main contacts

Distribution busbar

Auxiliary contacts

Cabling terminal

Withdrawable unit

Fixed unit

14
 Design

The outgoing units are available in the following heights based on a 75 mm height pitch.

Withdrawable Max. Motor Feeder Outgoing Feeder

Unit
Height Direct On-Line Forward-Reverse Star-Delta Motor Starter
MCCB
Motor Starter (DOL) Motor Starter (FR) (SD)

75 mm 0-15 kW 0-15 kW --- 0-32 A

150 mm 0-45 kW 0-45 kW 0-15 kW 0-100 A

225 mm 0-75 kW 0-75 kW 0-22 kW 0-250 A

300 mm 0-90 kW --- 0-55 kW 0-250 A

450 mm 0-160 kW --- --- 0-400A

75
75 75

Module height:

300
600

75 mm

300 300
600
600
150

Module height:
150 150

150 mm 600

600
600
600

600
600

Module height:
225

225 mm
225 225

450
450 450

PanelMaster MCC cubicle showing partly withdrawn motor

starter withdrawable unit
600

600
600
75
75

600

Module height: 600

300

0
300

300 mm 600
150
150

Front view of withdrawable unit (module height 225 mm).

600
600

Module height:
225
225

450 mm
450
450

Rear view of withdrawable unit

600
600
15
Design

Hybrid operation method (PATENTED)

Safe and simple operation with two different operating action

Operating main contacts:

Main contacts can be moved to OFF or ON position with rotatable handle located at front of the unit only,
when withdrawable unit is engaged in IN position. Operation can be done without using a removable part or
tool that can be lost like key, lever etc.

Operating auxiliary contacts:

Auxiliary contacts can be switched ON or OFF positions by pulling or pushing the withdrawable unit IN or
OUT while pressing unlocking button located besides left handle.

Withdrawable outgoing unit positions

CONNECTED Position TEST Position ISOLATED Position

Main contacts handle is in ON Main contacts handle is in OFF Main contacts handle is in OFF
Main switching device is in ON or OFF Main switching device is in OFF Main switching device is in OFF
Auxiliary contacts are in ON Auxiliary contacts are in ON Auxiliary contacts are in OFF
Withdrawable unit is IN Withdrawable unit is IN Withdrawable unit is OUT

TEST
CONNECTED ISOLATED

16
Design

Options

• Additional insulation by thermoplastic coating of main busbars

• Tin or silver coating of main busbars

• Corner sections for U or L shaped configurations.

• Interconnection of main busbar systems, enabling back-to-back arrangements

• Cubicles with reduced height for application in packaged substations, offshore and on board ships

• Special locking facilities

• Separate foundation frame

• Seismis connection accessories

• Internal arc modules

• Auxiliary switches for withdrawable units

• Mutually insulated busbar sections

• Fully insulated main busbar system

Auxiliary switch - 1 Auxiliary switch - 2

ON-OFF position of main contacts Withdrawable unit IN-OUT position

Padlocking option - 1 Padlocking option - 2 Padlocking option - 3

17
Design

Cable entry compartment

If several incoming and outgoing feeder sections are mounted in one cubicle, and cable connection is made
from the front, a separate, lockable cable-entry compartment, along the entire height of the switchgear
compartment, is provided at the right or left-hand side.

On the side wall, mounting strips are available for cable clamps or cable glands. Cable connections to
withdrawable units are made in the switchgear compartment without the use of cable lugs. The terminals
are fully enclosed in a cable connector block, together with the cable sided scissor-shaped isolating double-
finger contacts. The cable- entry compartment is isolated from the switchgear compartments by means
of screening plates (IP 2X). The standard cable-entry compartment width is 400 mm (500, 600 or 800 mm
optional available). The compartment is provided with an undrilled, removable gland plate at the bottom of
the cubicle.

Fixed mounting plate

for auxiliary circuit Depth adjustable
terminals mounting plate
for main circuit
terminals

Main Outgoing
Cable
Connection
Terminal Cover
Spiral Conduit
for cross
over of cables

Rear View
Auxiliary Circuits
Terminal

18
Design

Cable terminals for main circuit

If the application requires form of internal separation Form-4b, other than Type 6 or 7 then outgoing cable
terminals must be selected IPXXB or IP2X class.

Form 4b Form 4b Type 6 Form 4b Type 7

Separation is achieved by Separation is achieved by Separation is achieved by
metallic or non-metallic metallic or non-metallic metallic or non-metallic
rigid barriers or partitions. rigid barriers or partitions. rigid barriers or partitions.
Terminals are external to the Terminals are external to the Terminals are external to the
functional unit compartment functional unit compartment functional unit compartment
and separated by insulated and enclosed in their own and enclosed in their own
coverings. compartment by means of rigid compartment by means of rigid
barriers or partitions. barriers or partitions complete
IPXXB or IP2X finger-proof with integral glanding facility.

IPXXB finger-proof barriers at cable Cable glands at cable terminals

terminals covering entry. covering entry.

19
Intelligent Motor 6 Control MOTOR CONTROL AND PROTECTION UNIT M10X

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Main benefits of PanelMaster MCC with motor management
M10x has become the number one choice of our motor management.
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• Increasing plant availability qualities make M10x a trademark ABB intelligent process involved, including time
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regions where the most reliable and proven conditions.
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• Reliable solution customers and end users.

• Flexibility in a standardized solution

• Less spare starter module types

• Rapid fault detection and rectification

• Easy integrate and access to digital service

Modbus TCP, Profibus or Modbus RTU

(*Profinet via addtional converter)

20

Process control system,

Dimensions

IP31 Version IP54 Version

Number of withdrawable units per section

Max. Number of Withdrawable Units

Switchgear
Withdrawable Unit Height
Height

75 mm 150 mm 225 mm 300 mm 450 mm

2000 mm 16 8 5 4 2

2200 mm 18 9 6 4 3

Note: All dimensions are in mm.

21
Notes:

22
23
Ikitelli Organize Sanayi Bolgesi
Eski Turgut Ozal Caddesi
Ziya Gokalp Mahallesi No: 20
34490 Basaksehir / ISTANBUL
Phone: +90 212 549 26 39
Fax: +90 212 549 37 91
panelmaster@eaegroup.com

www.eaeelektroteknik.com

PM-MCCPC-ENG-2023-0001