ABB PC30 1 23-11-2009, 8:12 General

MNS R - Main distribution switchgear System Guide

MNS R main low voltage distribution switchgear

Index

General Introduction ...... 2 Technical data ...... 3

Construction and functional characteristics Switchgear frame ...... 4 Earthing ...... 4 Circuit-breakers used ...... 5 Circuit-breaker compartment ...... 5 Instrument compartment ...... 6 Busbar compartment ...... 7 Main busbars ...... 7 Distribution busbars ...... 8 Cable compartment ...... 9 Segregation forms ...... 10 Construction forma type ...... 10 Typical units and cross-sections ...... 12 Ventilation ...... 13

Standardisation Typical configurations ...... 14 Switchgear depth ...... 16

Versions Available versions ...... 17 Arc-proof ...... 17 Power Motor Control Center integrated solutions ...... 17 Intelligent switchgear ...... 20

Installation Fixing the units to the floor ...... 22

Tests and certifications ...... 23

ABB SACE 1

ABB PC30 1 23-11-2009, 8:12 General

Introduction currents involved and the effective these requirements. In addition to The MNS R main low voltage distri- short-circuit levels require high per- that, due to a perfect integration with bution switchgear with rear access formances switchgears. Furthermore, all the latest generation of ABB appa- had been studied for installation in must be guaranteed personnel safety, ratus, it easily meets all market re- large electrical plants, such as petro- service continuity, easy inspection, quirements. chemical plants, steel works, rolling maintenance, erection and installa- mills, power stations, oil rigs, ships, tion. Easy extension applications as etc. well as compact overall dimensions The service conditions on these plants are a must. The Power Center MNS are often extremely severe: the high R switchgear fully complies with all

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ABB PC30 2 23-11-2009, 8:12 Technical data

Reference Standards ABB SACE L.V. MNS R switchgear

Standards conformed to CEI EN 60439-1, IEC 439-1

Test certification Test certificates ABB SACE, ACAE LOVAG and SINAL

Electrical Data Rated voltages Rated insulation voltage up to 1000 V AC 1500 V DC

Rated service voltage Ue up to 690 V AC 750 V DC

Rated frequency 50 - 60 Hz

Impulse withstand voltage 12 kV

Rated currents Main busbars:

Rated current up to 6300 A

Rated peak withstand current up to 220 kA

Rated short-time withstand current (1s) up to100 kA

Distribution busbars:

Rated current 630÷4000 A Rated peak withstand current 220 kA

Rated short-time withstand current (1s) 100 kA

Arc-proof Values 100 kA, 0,3 s. at 415 V IEC 61641 (on request)

Mechanical Dimensions Height 2200 mm characteristics Widht 300, 400, 600, 800, 1000, 1200 mm

Depth 1025, 1200, 1400, 1600 mm

Module base (height) E = 25 mm DIN 43660

Surface protection Frame Al-Zn galvanisation

Internal divisions Galvanised sheet UNI EN 10130

Transversal section Electrolytic galvanisation UNI ISO 4520

Housing (doors and external curtain panels) Painting RAL 7035

Degrees of protection With door open IP20 IEC 529, EN 60529 Standards With door closed IP30 standard, up to IP 54

Construction form 3a, 3b, 4b

Normal conditions Installation internal for service

Ambient temperature -5 °C; +40 °C

Relative humidity max. 50% at 40 °C

Max. altitude ) 2000 m Extra options Paint External protection colour on request

Busbar system Main and branch busbars sheathed busbars, treated busbars (Ag/Sn)

Forms of segregation According BS 60439-1 4b type 1÷7

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ABB PC30 3 23-11-2009, 8:12 Construction and functional characteristics

Switchgear frame All compartments are meccani- The MNS R frame is based on cally segregated from the others. modular 2 mm thick still C sec- The switchgear is pre set for tions, pre-drilled at a pitch of 25 easy extensions on both sides. mm. Each unit is based on modular elements and consists of: – circuit-breaker compartments – instruments compartments – busbar compartment – cable compartment.

Earthing The switchgear is provided with a continuous electrolytic copper earthing busbar, with a cross-section suitable for the proper switchgear short- circuit rating and pre-set on both sides for connection to the earthing network.

Are connected to the earthing busbar - all the metallic structures of the indi- vidual units; - all not live metallic parts of the circuit-breakers; - all CTs and VTs secondary earthing connections. All others not live metallic parts of the apparatus are connected to the earthing busbar by means of the unit metallic structure.

The doors with apparatus installed are connected to the structure by means of flexible copper braids. All the ground connections are made with screws or bolts provided with gripping washers.

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ABB PC30 4 23-11-2009, 8:13 Circuit-breakers used

System Pro M modular circuit-breakers (MCBs) Tmax moulded-case circuit-breakers (MCCBs)

SACE Emax air circuit-breakers (ACBs) SACE Isomax S moulded-case circuit-breakers (MCCBs)

Circuit-breaker compartment The compartment is suitable to accept both air and moulded-case circuit-breakers and it is accessible from the front side by means of a locked hinged door. The circuit- breakers can be installed in all the available versions, fixed, plug-in and withdrawable. With all the widrawable circuit- breakers, in order do guarantee the maximum safety level to the operator, the apparatus handling can be carried out with the door closed.

Circuit-breaker compartment with Isomax Circuit-breaker compartment with Emax

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ABB PC30 5 23-11-2009, 8:13 Construction and functional characteristics

Instrument compartment The instrument compartment as well is located in the front side of the switchgear and it is accessible by means of a locked hinged door. It can be dedicated to each functional unit or be common to several ones. The measuring instruments, protection re- lays, control and signalling devices are normally mounted on the door, whereas any other auxiliary apparatus, such as miniature circuit-breakers, protection fuses and auxiliary re- lays are placed inside the compartment. Apparatus wiring is made with flexible copper cables and arranged Instrument compartment with protection relay mounted on the door in dedicated wiring channels. Each circuit-breaker terminal blocks are separated from the others and prop- erly identified.

Internal compartment with auxiliary apparatus and terminal boxes

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ABB PC30 6 23-11-2009, 8:13 Busbar compartment The busbar compartment is located in the middle section of the switchgear. Main busbars can be located at the top, in the centre or at the bottom of the panel depending on the selected design and they distrib- ute the power to the various switchgear panels. In some of the ex- isting configurations main busbars can be directly connected to a circuit- breaker as well. Distribution busbars are located into the single column and positioned vertically to feed panel circuit-breakers. The busbar system can be composed by 1, 2 or 3 busbars per phase, according to requested rated current, short-circuit level and operational ambient conditions in terms of temperature, altitude and humidity. Busbars are normally bare copper made, on request can be suit- ably treated with tinning, silver-plating and/or sheathing.

Main busbar system with connections for incoming busbars and bus-tie from the top

Main busbars MNS R main busbars are available for currents up to 6300 A. Main busbars, as well as distribution busbars, can be completely segregated. Each MNS R panel can be fitted with three busbar systems at the same time (top-centre-bottom) each segregated from the others.

Detail of a compartment with entry from the top and connection on the main busbar system

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ABB PC30 7 23-11-2009, 8:13 Construction and functional characteristics

Distribution busbars MNS R distribution busbars are available for currents up to 4000 A. Distri- bution busbars, branched directly from main busbars, are vertically installed either on the right or on the left in the column. They are feeding outgoing circuit-breakers, and are connected to them by means of rigid or flexible copper busbars, or cables. In any case, all the connections are suit- ably sized to withstand the thermody- namic stresses of the fault currents.

Cable connections

Copper busbar Busbar distribution system with connections to the outgoing circuit-breakers made with copper connections busbars and cables.

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ABB PC30 8 23-11-2009, 8:13 Distribution busbars

Connection terminals

Removable sheets Cable compartment for cable The cable compartment is located in entry the rear side of the panel and and it is accessible by means of a locked hinged door or a removable bolted door. Its purpose is to contain: – power terminals – outgoing cables – current reducers – auxiliary terminal boxes (if any).

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ABB PC30 9 23-11-2009, 8:13 Construction and functional characteristics

Segregation forms The MNS R segregation forms are compliant with the relevant standard IEC 60439-1 annex D. The purpose of the segregations is mainly to allow safety access to the internal parts of the switchgear to operational personnel and to minimize propagation of any faults it may happen in the circuits and in the adjacent compartments, to the benefit of service continuity of the installation.

Form 4b, rear side. Both main and distribution busbars are metallically segregated, plastic covers are used for cable connections.

Construction forms type

Form 1 No segregation

Form 2a Segregation of the busbars from the functional units; terminals are not separated from the busbars

Form 2b Segregations of the busbars from the functional units; the terminals are separated from the busbars

Form 3a Segregations of the busbars from functional units and between functional units; segregation of the terminals from the functional units, but not from the busbars; terminals not separated from each other

Form 3b Segregations of the busbars from the functional units and between functional units; segregation of the terminals from the functional units and from the busbars, but not from each other

Form 4a Segregations of the busbars from the functional units and between functional units; segregation of the terminals from the functional units and from the busbars; the terminals for external conductors are in the same compartment as the associated functional unit

Form 4b Segregations of the busbars from the functional units and between functional units; segregation of the terminals from the functional units and from the busbars; the terminals for external conductors are not in the same compartment as the associated functional unit

Form 4b, rear side Both main and distribution busbars are metallically segregated, plastic covers are used for cable connections.

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ABB PC30 10 23-11-2009, 8:14 MNS R form 3a, 3b and 4b construction solutions

Form 3a

Construction solution of one unit with moulded-case View from the top of a column with moulded-case circuit-breaker in form 3a segregated circuit-breaker in form 3a

Form 3b

Construction solution of one unit with moulded-case View from the top of a column with moulded-case circuit-breaker in form 3b segregated circuit-breaker in form 3b

Form 4b

Construction solution of one unit moulded-case View from the top of a column with moulded-case circuit-breaker in form 4b segregated circuit-breaker in form 4b

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ABB PC30 11 23-11-2009, 8:14 Construction and functional characteristics

Typical units and cross-sections Construction solutions with ABB The ABB MNS R switchgear is de- Emax air circuit-breakers and ABB signed for the installation of ABB Isomax and Tmax moulded-case cir- Emax air circuit-breakers as well as cuit-breakers ABB Tmax and Isomax moulded- Emax air circuit-breakers panels are case circuit-breakers, in all the avail- available with both top and bottom able versions, fixed, plug-in and with- entry design. drawable. It allows installation of the For modules sizing, please refer to ta- main ABB apparatus and of the bles at page 15. measuring and protection instruments Tmax and Isomax moulded-case cir- available on the market, according to cuit-breakers are installed horizontally different design requirements. and vertically as well in the unit. For modules sizing, please refer to ta- bles at page 14.

Typical section with two superimpo- sed Emax air circuit-breakers. The circuit-breaker placed in the bottom is an incoming/outgoing feeder that can be provide with cable as well as bus-duct connection. The circuit-breaker placed on top of the feeder is a bus-tie and it connects the two main busbar systems

The switchgear allows the installation of bus ducts with various current carrying capacities

The bus-duct can easily be connected to the busbar system of the circuit-breakers in the switchgear.

Typical realisation of a structure with Emax circuit-breaker connected in the top part to a bus-duct.

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ABB PC30 12 23-11-2009, 8:14 Ventilation The ABB MNS R switchgear have A= Apparatus area been studied to create separated air B= Busbar area flows for all the internal compartments C= Cable area in order to guarantee an efficient natural ventilation to all the installed com- ponents. Ventilation grides for natural cooling are placed on the front and rear side of the the panel on both, top and bottom positions, and on the roof as well.

B A

Diagram of natural ventilation of the unit

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ABB PC30 13 23-11-2009, 8:14 Standardisation

Typical configurations The ABB MNS R switchgear has great application flexibility. Several assembly configurations are possible, for incoming, outgoing and bus-ties. Some examples are given below:

Typical Incoming/Outgoing solutions A1 A4

PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0

SACE

MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE

Typical Incoming/Outgoing solutions Depth: 1200-1400-1600 Depth: 1200-1400-1600 for main busbar system up to 4000 A

PC 3.0 PC 3.0 B1PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 B4 PC 3.0 PC 3.0 PC 3.0

SACE SACE

SACE

MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE

Depth: 1400-1600 Depth: 1400-1600

Typical Incoming/Outgoing solutions for 5000/6300 A main busbar system

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ABB PC30 14 23-11-2009, 8:14 Typical Incoming and Bus-tie C1 C4 solutions

PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0

SACE SACE SACE SACE

SACE SACE

MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE

Typical Incoming and Bus-tie solu- Depth: 1200-1400-1600 Depth: 1200-1400-1600 tions for main busbar system up to 4000 A

D1 D4 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0 PC 3.0

SACE SACE SACE SACE

SACE SACE

MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE MORSETTIERE

Depth: 1400-1600 Depth: 1400-1600

Typical Incoming and Bus-tie solutions for main busbar system from 5000 to 6300 A

For customised solutions, please contact ABB SACE S.p.A. directly

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ABB PC30 15 23-11-2009, 8:14 Standardisation

Switchgear depth The switchgear can have different depths. Selection mainly depends on the rated current of the main busbar system, on the short-time withstand current and on the space needed for feeder connections.

Depth PABC 1025 450 525 50 400 350 1200 450 525 225 525 425 1400 450 650 300 525 625 1600 450 650 500

FRONT

Switchgear depth in relation to the main busbars rated current Amperes Depth Max. 50 kA 400 1200 630 1200 800 1200 1000 1200 1250 1200 1600 1200 2000 1200 2500 1200 Max. 75 kA 400 1025-1200 630 1025-1200 800 1025-1200 1000 1025-1200 1250 1025-1200 1600 1025-1200-1400 2000 1025-1200-1400 2500 1025-1200-1400 3200 1025-1200-1400-1600 Max. 100 kA 3200 1400-1600 4000 1400-1600 5000 1400-1600 6300 1400-1600

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ABB PC30 16 23-11-2009, 8:14 Versions

Available versions Arc-proof Version according to UL Standards The ABB MNS R switchgear is avail- On request, in order to achieve the ABB MAX SG is the solution available able in the following versions/types: maximum safety level, is available a in accordance with the American - For indoor installation version tested in conformity with the Standards UL 1558. Please refer to the - Top and bottom entry power cables technical report IEC 61641. The arc relevant technical documentation for - Top and bottom entry bus-duct proof ABB MNS R switchgear can details. - Top and bottom entry auxiliary cables withstand the stresses caused by any - Standard painting internal arcs for short-circuit - Special painting cycle for aggressive currents up to 100 kA for 300 ms at environments 415 V, still keeping the voltage value - Bare busbars at 415 V unaltered. - Sheathed busbars - Busbars with protective electrolytic treatment - Flame-proof cables and wiring - Flame-proof and alogen free cables and wiring - Arc-proof - Degree of protection IP30…54 - IEC segregation forms 3a, 3b and 4b.

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ABB PC30 17 23-11-2009, 8:14 Versions

Power Motor Control Center integrated solutions By means of a busbar transition panel, it is possible to make Power Motor Control Centers to supply widrawable motor control feeder units.

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ABB PC30 18 23-11-2009, 8:15 Furthermore it is possible to make Power Motor Control In this solution, the auxiliary connections are always Centerx with withdrawable drawers without transition accessed from the front, whereas the power connections panels by using MCC columns with rear access. are available on the rear.

FRONT VIEW LATERAL SECTION

MAIN BUSBARS COMPARTMENT 2200 2200

600 200/300 EARTHING 800/900BUSBAR 1025/1200/1400/1600

POWER CABLE ENTRY

INTERNAL DIVISIONS

Drawers/apparatus area Auxiliary cable area Power cable connection area (form 4b) 1025/1200/1400/1600 Power cable entry/exit Vertical busbar area

600 200/300 800/900

FRONT

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Intelligent switchgear Thanks to the use of electronic releases with dialogue func- tion, the air and moulded-case circuit-breakers mounted inside the switchgear can be controlled and managed by a supervision system. To integrate the moulded-case and air circuit-breakers fitted with electronic releases into correct installation management, ABB SACE supplies SD-View 2000, a “ready to use” system consisting of software which, when installed on a personal computer with standard configuration, allows full control of the low voltage electrical installation. Modbus® RTU, the recognised standard in the electrical distribution sector, is supplied as the communication pro- tocol. Applications SD-View 2000 is a system specially studied for application in those electrical distribution installations which require efficient management without the need to use complex and costly systems. It is able to dialogue and control all the protection units of the installation and, in particular, low voltage Tmax, Isomax and Emax series of circuit-breakers in the following configurations: – Tmax T4 and T5 series of moulded-case circuit- breakers fitted with PR222DS/PD release – Isomax S from S4 to S7 series of moulded-case circuit-breakers fitted with PR212/P release and PR212/D-M communication unit – Emax E1 to E6 air circuit-breakers fitted with PR112/PD or PR113/PD Modbus releases.

Tmax T4 and T5 Isomax S4…S7

Emax E1…E6

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ABB PC30 20 23-11-2009, 8:15 SD-View 2000 is the ideal tool available to managers in In particular it is possible to: order to have the situation of the plants under control at all – send opening and closing commands to the times and to be able to control all their functions simply circuit-breakers and immediately. – read the electrical values of the installation (current, The operator station (personal computer) allows informa- voltage, power factor, etc.) tion to be received from the installation and to control the – read and modify the trip characteristics of the protection circuit-breakers and relative releases. unit – determine the status of the apparatus (open, closed, number of operations, trip for fault, etc.) – determine abnormal operating situations (e.g. overload) and, in the case of releases tripping, the type of fault (short-circuit, ground fault, value of the interrupted currents, etc.) – log the history of the installation (energy consumed, most highly loaded phase, any warnings of anomalies or faults, etc.) – illustrate evolution of the installation over time by means of graphic diagrams.

Access to the various functions of the system can be ena- bled by means of a password with different levels of au- thorisation. Putting the SD-View 2000 system into service is simple and rapid: in fact, the software itself guides the user in rec- ognition and configuration of the protection unit. The user only needs to know the characteristics of the installation.

Operator use is extremely simple: the graphic pages of SD- View 2000, based on Internet Explorer, make management of the installation as simple as surfing the Internet. The graphic pages relative to each circuit-breaker are particularly intuitive and easy to use.

Modbus RTU on RS-485

RS232-RS485 Converter

Tmax T4-T5 Isomax S4-S7 Emax E1-E6 with PR222DS/PD with PR212/P with PR112/PD or PR113/PD and PR212/D-M

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ABB PC30 21 23-11-2009, 8:15 Installation

Fixing the units Column with lateral descent. Column Dim. Installation for moulded-case Type D x W Model A B C D E c.bs. in horizontal position. to the floor 1 1025x400 VS.525 220 – 270 638 110 (L) 1 1025x600 VS.525 420 – 270 638 210 1 1025x800 VS.525 620 – 270 638 410 = A = VS.400 220 170 250 563 110 1 1 1200x400 50 VS.525 220 58 370 593 110 48 VS.400 420 170 250 563 210 1 1200x600

50 VS.525 420 58 370 593 210 117 VS.400 620 170 250 563 410

B 1 1200x800 NB.2 VS.525 620 58 370 593 410 VS.525 220 240 270 697 110 1 1400x400 VS.650 220 120 438 649 110

C VS.525 420 240 370 697 210 1 1400x600

Depth (D) VS.650 420 120 438 649 210 VS.525 620 240 270 697 410 45 E E 45 1 1400x800 VS.650 620 120 438 649 410 D VS.525 220 440 270 697 110 1 1600x400 70 VS.650 220 320 438 649 110 117 50 VS.525 420 440 270 697 210 1 1600x600 = A = VS.650 420 320 438 649 210 VS.525 620 440 270 697 410 1 1600x800 FRONT VS.650 620 320 438 649 410

Column Dim. Type D x W Model A B C D E 2 1025x400 VS.525 220 – 370 538 Column for incoming 2 1025x600 VS.525 420 – 370 538 cables and for installation 2 1025x800 VS.525 620 – 370 538 of moulded-case VS.400 220 170 250 563 c.bs. in Vertical pos. 2 1200x400 VS.525 220 58 370 593 VS.400 420 170 250 563 (L) 2 1200x600 VS.525 420 58 370 593 = A = VS.400 620 170 250 563 2 1200x800 VS.525 620 58 370 593 50 2 50 VS.525 220 240 370 597 48 2 1400x400 VS.650 220 120 438 649 50

117 VS.525 420 240 370 597 2 1400x600

B VS.650 420 120 438 649 NB.2 VS.525 620 240 370 597 2 1400x800 VS.650 620 120 438 649 VS.525 820 240 370 597 C 2 1400x1000 VS.650 820 120 438 649 Depth (D) VS.525 1020 240 370 597 2 1400x1200 VS.650 1020 120 438 649 = A =

D VS.525 220 440 370 597

70 2 1600x400 VS.650 220 320 438 649 VS.525 420 440 370 597 117 50 2 1600x600 VS.650 420 320 438 649 = A = VS.525 620 440 370 597 2 1600x800 VS.650 620 320 438 649 FRONT VS.525 820 440 370 597 2 1600x1000 VS.650 820 320 438 649 VS.525 1020 440 370 597 2 1600x1200 VS.650 1020 320 438 649 Column for busbar riser

(L) Column Dim. 3 Type D x W A

50 50 3 1025x200 100 3 1025x300 120 50 3 1025x400 220 3 1025x600 420 NB.2 3 1200x200 100 3 1200x300 120 Distances valid for standard 3 1200x400 220 columns with busbar compartment: 3 1200x600 420 - 525 mm size for columns with Depth (D) 3 1400x200 100 1025-1200-1400- 600 mm depth 3 1400x300 120 - 650 mm size for columns with 3 1400x400 220 1400 and 1600 mm. depth 200 3 1400x600 420 3 1600x200 100 117 50 For other overall dimensions, please 3 1600x300 120 contact ABB SACE – L.V. = A = 3 1600x400 220 Switchgear and Systems Division 3 1600x600 420 Ø15 mm holes for M12 expansion dowels FRONT

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ABB PC30 22 23-11-2009, 8:15 Tests and certifications

The Power Center MNS R switchgear have been tested according to relevant IEC standards, among which the following stand out:

– Test report n° 100310: Short-circuit 50 kA 1s – Test report n° 100397: Short-circuit 75 kA 1s – Test report n° 100398: Short-circuit 100 kA 1s – Test report LBRP n° 5193: Arc-proof 50 kA 0.3 s 726 V – Test report LBRP n° 5203: Arc-proof 75 kA, 0.5 s 726 V – Test report n° 0117/B: verification of temperature rise limits 3000/5000 A – Test report LOVAG-ACAE n° IT 01.044: verification of temperature rise limits (6300 A) and verification of dielectric

properties (Uimp = 12 kV)

ABB SACE 23

ABB PC30 23 23-11-2009, 8:15 ABB PC30 24 23-11-2009, 8:15 www.abb.com/mns [email protected] Fax: +390371453251-453265 Tel.: +3903714531 26817 S.MartinoinStrada(LO)-Italy Frazione CàdeBolli Low Voltage Systems A divisionofABBS.p.A. ABB SACE Contact us Copyright 2009ABB.Allrightreserved. without priornotice. the basisoftechnicaldevelopmentproducts, the righttomodifycontentsofthisdocumenton The dataandillustrationsare notbinding.We reserve

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