0301

Low-voltage switchgear Installation, handling

MNS Light W and operation

ABB LV Systems
MNS Light W switchgear is a flexible system that is primarily designed for
motor control. The rated service voltage is 690 V and the rated current is
max. 1900 A (IP21, IP31).
MNS Light W can be equipped with:
– starters and distribution units of withdrawable design (W units)
– distribution units, MCB boards and fuse boards of removable
design (R units)
For further information see:
– Brochure 1TSC 2110-EN

List of contents
Handling and unpacking 3
Setting up switchgear cubicles 4
Laying of external cables 7
Connection of circuit-breaker cubicle and disconnector cubicle 8
Connection of busbar trunking system 12
Connection of apparatus units
Withdrawable units, main circuits 13
Removable units, main circuits 15
Screw-in fuse boards 17
MCB boards 19
Auxiliary circuits 20
Protective earthing 20
Withdrawable apparatus units, handling
Description 21
Operation 22
Withdrawing 24
Inserting 25
Extension 26
Removable apparatus units, handling
Description 27
Operation 27
Withdrawing 28
Inserting 28
Extension 29
Measures to be adopted before applying voltage
Concluding work 30
Check list upon commissioning 30

2
Handling and unpacking

The switchgear cubicles are delivered in the form of ready assembled completed
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. Transportation can be conveniently effected using
fork-lift trucks.
When hoisting with an overhead travelling crane or other hoists:
1. Use the lifting plate attachments supplied in the installation kit.
2. Fix the lifting slings with shackles in the holes in the lifting plates.
3. Adjust the length of the slings so that the angle between them does not
exceed 60°.
The cubicles are most easily transported
If the cubicles are not to be installed directly, they should be stored in a dry place using a fork-lift truck.
protected from dust. The plastic wrapping 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
60°

When hoisting with a crane, the lifting plate

attachments should be mounted on the
cubicles.

3
Setting up switchgear cubicles

Cubicle types, overview

Circuit-breaker cubicle for ACB min 150
Cubicle width 600 mm.
Circuit-breaker cubicle for MCCB
Cubicle width 500 mm.
Disconnector cubicle
Cubicle width 500 or 600 mm.
Apparatus cubicle W
Cubicle width 600 + 400 or 600 + 600 mm.
Apparatus cubicle F
Cubicle width 500 mm.
The following dimensions are identical for all types of MNS light W cubicles
Height 2126 mm
Height module 50 mm
Depth 650 mm

Free space around cubicles Free space above cubicle.

There should be at least 150 mm clearance above the cubicles.
The distance between each cubicle´s rear panel and the wall, and between the end
panel and the wall should be at least 40 mm.
Apparatus cubicles with operating handles in the panels should be placed at a min 40
distance of at least 150 mm from the left end panel to the wall to allow the panels
to be opened more than 90°.

Drilling of holes min 40 – 150

The drawing shows the maximum permissible holes that can be drilled for external Distance to wall.
cables under the cubicles, in the base plate and in the roof plate.

35 35 35

650 650 650

630 610 630 610 630 610

116

82 82 82
637
116 66 66
600 500 600+400 / 600+600

Holes in floor and base plate: Holes in floor and base plate: Holes in floor and base plate:
Circuit-breaker cubicle ACB Circuit-breaker cubicle in MCCB Apparatus cubicle W
Disconnector cubicle, b = 600 Disconnectror cubicle, b=500

155 155
225

380 380
450

600 615 615

150 99,5 120
250 199,5 220
350 299,5 320
450 399,5 420 *)
599 499 600+600 / 600+400
*) Only for cubicles 600 + 600 wide
Holes in roof plate: Holes in roof plate:
Circuit-breaker cubicle ACB Circuit-breaker cubicle MCCB Holes in roof plate:
Disconnector cubicle, b= 600 Disconnector cubicle, b = 500 Apparatus cubicle W
4
Setting up switchgear cubicles

Alignment of cubicles
The flooring should be flat and even and carefully chosen for cubicle erection
(Swedish House-AMA Tolerance 3B or Class 2) so that several cubicles can be
bolted together without necessitating further measures.
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 under
the attachment lugs.
*)
Bolting together of cubicles
Any height adjustment of cubicles necessary must be carried out before bolting
them together. 35

On the right-hand end panel of the cubicles there are eight clearance holes for M6 Height adjustment is effected by inserting
hexagonal headed bolts and in the left-hand end panel there are corresponding sheet metal shims under the attachment lugs.
threaded holes. Upon delivery, the bolts are screwed into the left end panel.

Attachment
Each cubicle has four external attachment lugs for anchoring to the floor, hole
diameter 16 mm. Drilling should be done after the cubicles have been moved into
their final positions. Check that no cement dust or the like gets into the cubicles
when drilling.
Free-standing cubicles and the first cubicle in a row should be fixed to the floor at
all four attachment lugs. Other cubicles in a row should only be bolted down at one
side of the cubicle (two attachment lugs).
When mounting against a wall, or back to back, the cubicles should be fixed at the
top with wall mountings. Free-standing cubicles and the first cubicle in a row should
be fixed with two wall mountings. Other cubicles in a row should only be fixed with
one wall mounting. The wall mountings are fitted on top of the cubicles and have to
be turned so that the fixing holes face upwards.
When fixing against a wall, or back to back, the cubicles should be bolted to the Bolting together of cubicles.
floor only at the front attachment lugs.

Ø 16

2170

Attachment to floor. 40 80

Attachment to wall. Attachment back to back.

5
Setting up switchgear cubicles

Nut washer or joint

Interconnection of horizontal busbars piece with threaded
bushings
Connection of the horizontal busbars between the cubicle units should take place
from the front of the cubicles. Phase bars, N bars and PE bars are all to be joined
in the same manner.
1. Remove the protection plates in front of the bars to allow access to the point of
interconnection. Joint piece
2. Untight 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 protection plates back on.
In the case of double joint pieces, both should be placed at the front of the bars.
In the case of three joint pieces, two should be placed at the front of the bars and M8, 20 Nm
the joint piece with threaded bushings behind the bars (replacing the nut washer).
Joining of phase bars.

Joining of N and PE bars.

6
Laying of external cables

Apparatus cubicle
All external cables to apparatus cubicles are to be laid in the area intended for
cables.

Main cables
In the cable area there are four rails, at the rear and on the right-hand cubicle wall,
for fixing of main cables using cable hangers. They are provided with holes 50 mm
apart for sturdy bunching straps. Slimmer cables are best fixed to the rails by cross-
ing two smaller bunching straps.

Auxiliary cables
Internal leads and operating voltage supply cables should be drawn along a cable
duct placed to the left at the rear of the cable area.
Cable area.
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.
In the apparatus and cable area there is a cable duct intended for connections
between cubicles.
In the cable area there is an attachment rail intended for cubicle terminal boards
(B50).
Cable clamping straps.

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.
Mounting pieces for connection of PE (N)
conductors to busbars are supplied
strapped onto the cubicle.

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.

7
Connection of circuit-breaker cubicles and disconnector cubicles

Cable cross-sectional areas, Dimension drawings

main circuits
Disconnector cubicle, cable connection
Cubicle designs A and E.
Cable connection from below or above.
OETL 1250 – 1600 A, from below

Max. connectable area mm2

Disconnector cubicle L1, L3 L2

1250 – 1600 A 6//240
2000 A 20//240
25 L1 L2 L3
Circuit-breaker cubicle MCCB (103)

1250 – 1600 A 6//240

113
Circuit-breaker cubicle ACB 21
37 42 42 217

1250 – 2000 A 8//240 Ø 14

250

Cable cross-sectional areas, 475

auxiliary circuits N
/ L4 N
Auxiliary circuit cables are to be / L4
connected to terminal boards.

Max. connectable area mm2

Fixed 4
Disconnectable 10 OETL 1250 – 1600 A, from above

OETL 2000 A, from below OETL 2000 A, from above

8
Connection of circuit-breaker cubicles and disconnector cubicles

Dimension drawings
Disconnector cubicle, busbar connection from above

OETL 1250 – 1600 A

OETL 2000 A

9
Connection of circuit-breaker cubicles and disconnector cubicles

Dimension drawings
Circuit-breaker cubicle, cable connection

MEGAMAX 1250 - 1600 A, from below. MEGAMAX 2000 A, from below

MEGAMAX, from above

MCCB. from below MCCB, from above

L1, L3 L2

25 L1 L2 L3
(103)

113
37 42 42 217
21
Ø 14
250

475
N
/ L4 N
/ L4

10
Connection of circuit-breaker cubicles and disconnector cubicles

Dimension drawings
Circuit-breaker cubicle, busbar connection from above
2// busbars ≤ 1600 A
3// busbars 2000 A

MEGAMAX 1250 - 2000 A MCCB fixed 630 - 1600 A, withdrawable 630 - 800 A

PE or PEN

215
PE or PEN
PE or PEN

MCCB withdrawable 630 - 1600 A

PE or PEN

PE or PEN

11
Connection of busbar trunking system

Busbar trunking connections are used for incoming or outgoing supply, or for
connecting rows of switchgear together.
Each trunking unit takes up a height of 6 M in the upper part of the cubicle. Several
apparatus units can therefore not be mounted in this space at the same time.
The trunking units have four conductors and are intended for connection to
busbar trunking terminal units of type LD, enclosure class IP30 or IP54.

PE and N conductors
A common protective earth and neutral busbar (PEN) is connected via the fourth
busbar of the trunking unit.
In the case of separate N and PE bars, the N conductor is connected via the
fourth busbar of the trunking unit, whereas the PE conductor is connected via the
enclosure of the trunking unit.

Note the phase sequence

Busbar trunking units are available in two types; 661 with phase sequence from left
to right and 662 with phase sequence from right to left.
For adjacent rows of cubicles with fronts facing the same way, the one connection
unit should be of type 661 and the other of type 662. The same applies if the
cubicles stand front to front or back to back. If the rows of cubicles stand behind
each other with their fronts facing the same way, both connection units should be
of type 661.

Dimension drawings
Connection units 1250 and 1600 A

L1, L2, L3, PEN(N) L1, L2, L3, PEN(N) PEN(N), L3, L2, L1 PEN(N), L3, L2, L1

6 M (300) 6 M (300)

130 130 370 130

Type 661 for Type 661 for circuit- Type 662 for Type 662 for circuit-
apparatus breaker cubicle, apparatus breaker cubicle,
cubicle W. disconnector cubicle cubicle W. disconnector cubicle
and apparatus and apparatus
cubicle F. cubicle F.

Type 661 Type 662 Type 661 Type 662

930

400 L 650 650 L 650

Min. 2670
185

2420
180 180
2330

160 160 430

2350
2370*) Min. 920 (L + 2 x 160)

2120

Min. 1960 (L + 430 + 930)

*) 2350 for size 1250 A

2700 for size 1600 and 2000 A

12
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 Examples of suitable screwdrivers for the connection unit
Dimension A max 230 mm BACHO 6000/6850 1,0 x 5,5 L = 210 mm
B min 80 mm BACHO Ergo/850 1,0 x 5,5 L = 222 mm
C 1,0 mm BACHO Ergo S/8150 S 1,0 x 5,5 L = 222 mm
D 5,5 mm WERA 35 1,0 x 5,5 L = 223 mm
WERA 1678 A 1,0 x 5,5 L = 220 mm
WERA 335 1,0 x 5,5 L = 223 mm
A
B
E

13
Connection of apparatus units

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. A shield protecting against

inadvertent touching should be mounted over the connection
unit and cable clips.

14
Connection of apparatus units

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 clip cable lug cable clip
mm2 mm2 mm2 mm2 mm2 mm2

MCCB Type ISOMAX N, fixed

S3N 160 19 – 100 A 16 – 25 50 70 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//195 120 120 – 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 Type 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//195 - 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 Type 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 Type 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 16

15
Connection of apparatus units

Removable apparatus units, main circuits

Continued from page 15

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 clip cable lug cable clip
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 240 300 300 300 240 300
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 17

16
Connection of apparatus units

Screw-in fuse boards, continued from page 16

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 Plug-in Fixed
the requisite single-screw clamps for single-
pole connection of all outgoing groups 18 6 7 7
Connectable area: 9 3 4 4
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 Plug-in Fixed
tral boards for joint and individual disconnection
of the groups. Protective earth bar with single- 18 6 7 7
screw clamp and connection to the main neu- 9 3 4 4
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 Plug-in Fixed
busbars have joint neutral disconnection and
requisite single-screw clamps for connection of - 6 7 7
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 Plug-in Fixed
Connectable area:
max. 10 mm2, min. 1.5 mm2 24 - 7 7
6 6 7 7

Continued on page 18

17
Connection of apparatus units

Screw-in fuse boards, continued from page 17

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 Plug-in Fixed
requisite two-screw clamps for 3-pole connec-
tion of all outgoing groups. - 5 7 7
Connectable area: - 2 4 4
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 Plug-in Fixed
tral boards for joint and individual disconnection
of the groups. A protective conductor bar with - 5 7 7
two-screw clamp and connection the a main - 2 4 4
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 Plug-in Fixed
ductor busbars have joint neutral disconnection
and requisite two-screw clamps for single-pole - 5 7 7
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 Plug-in Fixed
Connectable area:
max. 25 mm2, min. 1.5 mm2 for 3-pole 6 5 7 7
max. 10 mm2, min. 1.5 mm2 for 1-pole

18
Connection of apparatus units

MCB boards
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 MCB apparatuses
of MCB apparatuses

Basic set (PEN)

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

19
Connection of apparatus units

Auxiliary circuits, withdrawable units.

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 screen conductors is best done to an earthing bar located on the left
front post in the cable area (option).
Connection unit for auxiliary circuits for
Auxiliary circuits, removable units withdrawable units 2M – 20M.
For removable units, signal cables are to be connected to plug-in ten-pole
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).

20
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.

21
Withdrawable apparatus units, handling

Operation, normally wide unit

The unit has two fixed positions: connected position and disconnected position.
The operating handle is used both for operating the power switch and for interlock-
ing the apparatus unit. The handle has four different positions.

Handle position Unit funktion when in

connected position
On All electrical circuits connected.
Cover interlocked.
E
T

ST

Off All electrical circuits disconnected.

E
T

ST

Test Main circuits disconnected,

E auxiliary circuits connected.
T

ST

Move All electrical circuits disconnected.

The unit can be moved.
E When withdrawing from the run position,
T

ST
the unit is automatically locked when it
reaches the disconnected position *).
For further movement outwards, the
handle must be moved back to the move
position.
The handle can be locked using up to *) Where the unit is in the disconnected
three padlocks in the positions Off and position (see fig. on page 28) the
Test. position of the handle is of no impor-
tance since both the main and the
auxiliary circuits are disconnected.

22
Withdrawable apparatus units, handling

Operation, compact unit

The unit has three fixed positions: connected position, test position and disconnect-
ed position. The operating handle is used both for operating the power switch and
for mechanical interlocking of the unit. A microswitch with two making and two
breaking contacts is included for electrical interlocking. The handle has five differ-
ent positions.
Handle 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 handle 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 run position, the
unit is automatically blocked when it
reaches the disconnected position
(pulled out 30 mm from the run posi-
tion). For further movement outwards,
The handle can be locked with up to the handle must be turned back to the
three padlocks in the positions Off move position.
and Test.

23
Withdrawable apparatus units, handling

Withdrawing, normally wide unit

The unit is in the run position (pushed right in).
1. Move the handle 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 handle must not be used as a handle when
moving the unit.
When moving the unit, the handle immediately moves back to the 0 position when
the unit starts moving. This is perfectly normal; continue moving without touching
the handle.

2. The unit is now in the disconnected position.

3. For further movement, turn the handle to the move position.

4. The unit is now ready to be pulled completely

out of the cubicle.
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 straight out if it is located at a level below chest
height. If it is at a higher level, keep one hand on the handle and place
the other underneath the unit on the guide plate.
For units bigger than 4 M, there should be two persons pulling the unit out of the
cubicle. When the unit is withdrawn half-way, one person on each side takes hold of
the handles on the sides and then the unit can be pulled completely out of the cubi-
cle. Be careful when large, heavy units are handled so as to avoid injuries to per-
sons nearby and damage to mechanical parts.
To make handling of large units easier, and also from the ventilation point of view,
they should be placed as far down in the cubicle as possible.
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).
When temporarily storing the unit, it should be placed with its left side (seen from
the front) on the table or floor. The surface should be flat and smooth so as not to
scratch the paintwork on the unit.
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 damage the
front cover and mechanism.

Withdrawing, compact unit

The unit is in the run position (pushed right in).
Move the handle to the Move position.
The unit is now ready to be pulled out of the cubicle completely. Use the handle (the
handle must not be used as a handle when pulling out the unit).

When moving to the disconnected position, turn the handle 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 handle to the Move position, whereupon
the unit is free to be pulled out.
24
Withdrawable apparatus units, handling

Inserting, 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. Move the handle 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, move the handle to the Move position.

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

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

Inserting, 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. Move the handle to the Move position.

Push the unit in to the Run position.

3. Move the handle to the Test position or Off position.

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

25
Withdrawable apparatus units, handling

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.

2. Insert and mount a new cassette plate and guide rail.

Pos. Typ
3. Mount connection units for main and auxiliary circuits. 1 M6 x 20 Torx
2 Distance 20 mm
3 M6 x 40 Torx
4 M6 x 10 Torx

4. Connect up cables for main

and auxiliary circuits.
Follow instructions for connecting up
apparatus units.

5. Fit the panel below the new unit Terminal bracket

back in and push the unit into place. Snap-in
Follow instructions for inserting units.
Check that the snap-in has
full engagement in the ter-
minal bracket

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.
26
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 operating position.

Operation
The operating handle has two positions.

Handle 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.

27
Removable apparatus units, handling

Withdrawing
1. Set the handle 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.

Inserting
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.

28
Removable apparatus groups, handling

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.

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. Close 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 30.
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.

29
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 Carry out a visual inspection to ensure voltages and circuits that were
a directly earthed system. that the bolts in busbar joints between disconnected during the
the cubicles are tight. insulation tests.
In the case of indirectly earthed
systems, a check must always be made
8. ❐ Check phase sequence and 11. ❐ Energising the equipment
that all metallic parts are correctly
earthed. Check the earth fault protec- marking 11.1 Check that incoming and
tion signal as well. outgoing circuit-breakers and
disconnectors are off.
Apart from this check-list, local and
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.
11.4 Check the phase sequence of a
2. ❐ Checking of fuses 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 11.5 Check the units one at a time
Set instantaneous and thermal tripping 9. ❐ Check internal connections by:
of MCCB units, based on load and Check all internal connections between - switching on the circuit-breaker
selectivity. the cubicles.
The instantaneous protection for inco- - checking the main circuit to
ming 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 10.2 Check that all operating with the circuit diagram.
circuit during commissioning. 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 12.2 Check that all instantaneous
(under load). Otherwise the secondary disconnected. protections that have been
windings must be short-circuited. 10.5 Check the insulation on the turned down during
main busbars using a megger commissioning work are reset to
5. ❐ Setting of starters with 1 or 0.5 kV. The insulation their operating positions.
Set the thermal over load protection at resistance should be ≥ 1 Mohm. 12.3 Check that no vibrations or
the rated current of the motor. noises occur in the busbar.
Phase Insulation resistance
NB. Setting above or below the scale Mohm
range is not permitted.
L1 – N
6. ❐ Check the main busbars L2 – N
Make a visual inspection to see that L3 – N
the bolts in busbar joints between the
L1 – L2
cubicles are tight.
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.

30
 1TSC 2314-EN

ABB LV Systems AB
SE-721 62 Västerås, Sweden.
Telephone +46 21 346000
Telefax +46 21 346110
www.abb.se/lvs
REKLAMCENTER AB 99026