Service Manual

MNS R Low Voltage Switchgear

Construction, commissioning, operation and maintenance

Index

1 Technical Description 6

2 Packing and Transport 17

3 Construction 19

4 Start up and Operation 38

5 Maintenance and Spare Parts 44

2 Service Manual MNS R | 1TTS900001M0203
Consequences deriving from non-
compliance
ABB declines all liability for the following
events:
– Negligent handling of the low-
voltage switchgear system and
non-compliance with the safety and
operating regulations as amended
from time to time.
– Insufficient maintenance,
non-compliance with the
recommendations given herein or
makeshift repairs by personnel
without the necessary training or
adequate equipment.
– Damages due to transport.
– Improper use.
– Modifications to the low-voltage
switchgear systems performed by
unauthorized personnel.

1TTS900001M0203 | Service Manual MNS R 3

4 Service Manual MNS R | 1TTS900001M0203
Contents
page
1 - Technical Description 6
1.1 - Technical data 6
1.2 - Basic Structure of the switchgear 7
1.3 - Distribution busbars 8
1.4 - Modular add-on parts 11
2 - Packing and Transport 17
2.1 - General 17
2.2 - Packing 17
2.3 - Delivery and unloading operations 17
2.4 - Storage 18
3 - Construction 19
3.1 - Inspections on delivery 19
3.2 - Installation 19
3.3 - Cable and busbar connection 20
3.4 - Additional information about switchgear
positioning 24
3.5 - Cuts in the floor 25
3.6 - Methods for fastening to foundation 28
3.7 - Cable connections, wiring 30
3.8 - Protective conductor connection 37
3.9 - Neutral conductor connection 37
3.10 - Final Preparations 37
3.11 - Checking Operations 37
4 - Start up and Operation 38
4.1 - Start up 38
4.2 - Operation 39
4.3 - Special information 43
5 - Maintenance and Spare Parts 44
5.1 - General 44
5.2 - Withdrawable technique 44
5.3 - Plug-In technique 45
5.4 - Converting and changing withdrawable
module compartments 46
5.5 - Examination of MNS contact systems within
the scope of plant revisions 48
5.6 - Greasing of contact areas 50
5.7 - Lubrication of withdrawable module interlocks 51
5.8 - Installation of power contacts 51
5.9 - Paintwork damage 52
5.10 - Mechanical damage 53
5.11 - Tightening torque values for screw connections 53
5.12 - Commissioning and maintenance of MNS
reactive power compensation systems 54
5.13 - Insulation resistance measurement 55
5.14 - Maintenance intervals 56
5.15 - Servicing Tmax XT1 and XT2 mechanisms in
MNS R (8E/4 and 8E/2) 57
5.16 - Maintenance and Inspection List 59

1TTS900001M0203 | Service Manual MNS R 5

1 Technical Description
1.1 Technical data
Standards Low-voltage switchgear and controlgear assemblies IEC 61439 -1 and -2
Power switchgear and controlgear assemblies EN 61439-1 and -2
Test certificates ABB SACE
ACAE LOVAG
CESI
Electrical data* Rated voltages Rated insulation voltage Ui 1000 V 3~, 1500 V-
Rated operating voltage Ue 690 V 3~, 750 V-
Rated impulse withstand voltage Uimp 6 / 8 / 12 kV, depending on equipment
Overvoltage category II / III / IV
Degree of pollution 3
Rated frequency up to 60 Hz
Rated currents Main Busbars:
Rated current Ie up to 8000 A
Rated peak withstand current Ipk up to 330 kA
Rated short-time withstand current Icw up to 150 kA
Power Center Distribution busbars:
Rated current Ie up to 4000 A
Rated peak withstand current Ipk up to 264 kA
Rated short-time withstand current Icw up to 120 kA
Motor Control Center Distribution busbars:
Rated current Ie up to 1500 A
Rated peak withstand current Ipk up to 220 kA
Rated short-time withstand current Icw up to 100 kA
Mechanical Dimensions Sections and frames DIN 41488
characteristics Standard height 2200 mm
Standard width 300, 400, 600, 800, 1000, 1200 mm
Standard depth 1025, 1200, 1400, 1600mm
Basic grid size E = 25 mm acc. to DIN 43660
Surface protection Frame Zinc or Alu-zinc coated
Internal subdivision Zinc or Alu-zinc coated
Transverse section Zinc or Alu-zinc coated
Enclosure Zinc or Alu-zinc coated and Powder coated
RAL 7035, light grey
Degrees of protection According to IEC 60529 or VDE 0470 part 1 Up to IP 54
Plastic components Halogen-free, self-extinguishing, flame retardant, IEC 60707, DIN VDE 0304 part 3
CFC-free
Internal subdivision Equipment compartment - equipment compartment
Busbar compartment - cable compartment
Busbar compartment - equipment compartment
Equipment compartment - cable compartment
Compartment bottom plates
Extras Paint finish Enclosure Special colours (standard RAL 7035)
Busbar system Busbars Sheathed
Silver or tin galvanized
Special qualification Test certificates See test certificates listed above
* Design verification by testing: When an assembly has previously been tested in accordance with IEC 60439-1, and the results fulfil the requirements
of IEC61439 -1 / -2, verification of these requirements need not to be repeated.
** Depending on the electrical equipment.

6 Service Manual MNS R | 1TTS900001M0203

1.2 Basic Structure of the switchgear The equipment compartment comprises:
– Main circuit breakers.
1.2.1 Typical side section – Auxiliary devices.
The basic structure of the frame (steel C-sections, 2mm thick, – Terminal boards.
with holes at 25 mm intervals), comprises (see fig.1): The busbar compartment comprises:
– Equipment compartment. – Main busbars.
– Busbar compartment. – Distribution busbars.
– Cable compartment. – Vertical busbar for MCC.
The cable compartment comprises:
– Input and output cables.
– Auxiliary accessories (connectors, auxiliary terminal boards,
etc.).

Cable
compartment

Busbar
compartment

Equipment
compartment

MNS R Power Center MNS R Motor Control Center

Fig. 1 Typical construction for MNS R and MCC

1TTS900001M0203 | Service Manual MNS R 7

MNS R uses up to three busbar systems located in the 1.3 Distribution busbars
busbar compartment. The position of the main busbar in
the cubicle can be center, top and bottom depending on 1.3.1 Distribution busbars
which types of modules are installed in the cubicle. The distribution busbars are the connection between the
There are two types of main busbar systems: standard type or busbars and the outgoing units.
multi-level busbar type (see fig. 2). The busbars can be installed in a single section along the
whole length of the compartment, or at an appropriate level
for particular versions (see fig. 3-4).
– ln fixed and plug-in module versions they are installed
vertically in the busbar compartment.
– ln plug-in and withdrawable module versions, the busbars
are embedded into the multifunctional wall made of insulating
material (degree of protection lP 20), held in place and arc-
proof covered. In this solution, the grid for contacting is 4E.

Multi-level busbar

Standard busbar

Fig. 2 Typical busbar arrangement

8 Service Manual MNS R | 1TTS900001M0203

Connection to busbar

Distribution busbar

Supporting bracket

Frame structure

Fig. 3 MNS R Power Center distribution busbars

Frame structure

Connection to busbar

Multi-functional wall
Detail
Connection cable unit

Detail
Multi-functional wall

Fig. 4 MNS R Motor Control Center distribution busbars

1TTS900001M0203 | Service Manual MNS R 9

1.3.2 Distribution busbar reinforcement
Distribution busbar reinforcement is provided if the rated current
of the distribution busbars is over 750 A, and/or for short circuit
ratings over 65 kA (see fig. 5).

Fig. 5 Distribution busbar reinforcement for MNS R Motor Control Center

10 Service Manual MNS R | 1TTS900001M0203

1.4 Modular add-on parts 1.4.1 Direct connection to busbar
The circuit breaker or the circuit breaker cradle is connected
The equipment beIonging to a functional unit is housed in a to the busbar by the copper cable kit (see fig. 6).
single module.
Standard versions feature:
– Direct connection to busbar
– The withdrawable technique
– The plug-In technique.

Fig. 6 Typical MNS R system ACB solution

1TTS900001M0203 | Service Manual MNS R 11

1.4.2 Withdrawable technique
Withdrawable units comprise: The withdrawable module condapter is the connecting
– the withdrawable module (see fig. 7-8-10-11), link between distribution bars and size 8E/2 and 8E/4
– the frame-mounted module compartment (see fig. 9). withdrawable modules.
Standard sizes are 8E/4, 8E/2, 6E, 8E, 12E, 16E, 24E, The condapter consists of:
(E = 25 mm). – Conductor busbars for the incoming feeder connection of
the withdrawable modules.
One 600 mm width equipment compartment can contain: – Outgoing contacts with connection to the power terminals
– size 8E/4 4 withdrawable modules (in the cable room).
– size 8E/2 2 withdrawable modules – Power terminals including the PE terminals.
– sizes 6E to 24E one withdrawable module – Control terminal for 8E/4 modules: 20 poles.
Empty spaces are closed off by front covers (see spare parts – Control terminal for each 8E/2 module:
list). with one control plug: 20, or 40 poles.

Size 8E/4 and 8E/2 withdrawable compartments comprise Electrical connections to the withdrawable module are the
(see fig. 7-8): plug-and-socket type.
– Compartment bottom pIate.
– Withdrawable module condapter. The front panel for size 8E/4 and 8E/2 withdrawable modules,
– Guide rails. which is fixed to the withdrawable modules themselves, is
– Front posts. made of insuIating material and serves as an instrument panel
for measuring, operating and indicating instruments.

Withdrawable module
Condapter ass'y. Power terminal Control terminal

Compartement
bottom assy

Front post 8E/4

Guide rail 8E/4

Fig. 7 Withdrawable module compartment for 4 units - size 8E/4

12 Service Manual MNS R | 1TTS900001M0203

 20-pole control terminal block

Side wall Micro switch

Rear wall

Mechanical interlocking unit

Instrument panel

Handle

Switch handle
Side wall

Name plate holder Latch-type lock Mounting rail

Fig. 8 Size 8E/4 empty withdrawable unit size (without electrical equipment)

Apparatus plate

Rear wall
Left side wall

Right side wall

Base plate

Instrument panel

Fig. 9 > 6E empty withdrawable unit (without electrical equipment)

1TTS900001M0203 | Service Manual MNS R 13

 Mechanical interlocking unit

Interlock link

Switch handle

Handle

Name plate holder Front cover

Lock

Fig. 10 Withdrawable module door with interlock for 6E ... 24E

Cable connection unit

Compart. Bottom assy

Ctr condapter
Roller

Fig. 11 Withdrawable module compartment for units size 6E ... 24E

14 Service Manual MNS R | 1TTS900001M0203

Size 6E ... 24E withdrawable module compartments 1.4.3 Plug-in technique
comprise(see fig. 9-10-11): Plug-in units comprise:
– Compartment bottom pIate with roller. – rear plug-in compartment (see fig. 12)
– Guide raiI. – rear plug-in module (see fig. 13).
– Sheet metal side wall with the outgoing control plug.
– Outgoing cable connection unit. Standard sizes are 6E, 8E, 12E, 16E, 24E, (E = 25 mm).
One 600 mm width equipment compartment can house:
The uppermost withdrawable module compartment is covered – sizes 6E to 24E one rear plug-in module
by a bottom pIate. The top cover for the lower compartments
is the bottom plate of the compartment above. Sizes 6E ... 24E rear plug-in compartments comprise
(see fig. 12):
The withdrawable module feeder is directly connected to – Compartment bottom pIate
the distribution busbar system via the contact devices of the – Guide
withdrawable modules. Outgoing cables are connected by – Sheet metal side wall with the outgoing control plug
plug-in-contacts to the outgoing cable connection unit (main – Outgoing cable connection unit.
circuit) and by terminal blocks (auxiliary circuit). The outgoing The uppermost rear plug in the module compartment is
cable connection units are fastened directly to the frame. covered by a compartment bottom pIate. The top cover of the
lower compartment is the bottom plate of the compartment
A hinged instrument panel made of insulating material for the above.
measuring, operating and indicating instruments is also
provided for size 6E to 24E withdrawable modules. lt is
installed on the unit itself and protrudes through an opening in
its the hinged front cover.

Consult chapter 4 for details about the operating

components.

Cable connection unit

Compart. bottom ass'y

Guide

Ctr condapter

Fig. 12 Plug-In compartment for units size 6E ... 24E

1TTS900001M0203 | Service Manual MNS R 15

The plug-in modules are fastened directly to the compartment 1.4.4 Capacitor Bank
bottom plate by screws. MNS reactive power compensation in plug-in modules
The plug-in module feeder is directly connected to the complies with the regulations governing type-tested factory-
distribution busbar system by the contact device of the built switchgear and controlgear assemblies in accordance with
plug-in modules. Outgoing cables are connected by plug-in VDE 0660 Part 500, EN 61439-1 and IEC 60439-1 standards.
contacts to the outgoing connection unit (main circuit) and by The standards cover three series of modules for 400 V, 415
terminal blocks (aux circuit). The outgoing cable connection V, 525 V and 690 V ratings. Fuse-disconnectors or -bases,
units are fastened directly to the frame. contactors, control terminals and reactive power controllers are
The modules are racked-in/out with a special tool. installed on the front side if necessary (see fig. 14-15).

Fig. 14 MNS plug-in-modules with CLMD capacitors

Fig. 13 Plug-In Module (fixed MCCB) Fig. 15 MNS plug-in-modules with MKPgG capacitors

16 Service Manual MNS R | 1TTS900001M0203

2. Packing and Transport
2.1 General 2.3 Delivery and Unloading Operations

MNS R switchgear is delivered either in single cubicles or in Cranes or lift trucks must be used for unloading the
shipping units no more than 2.4 meters in length, depending equipment. The load must be placed on a level surface.
on the type of equipment installed and the space available for
handling the switchgear at the construction site. 2.3.1 Unloading
In the absence of special instructions from the customer, the By means of lift trucks (see fig. 16-17).
switchgear is delivered in standard packaging, according to By means of lifting and sliding devices (see fig. 16-17).
ABB internal instructions, and a suitable method of shipping – If necessary, by means of rollers (min. 3 pieces). The
is chosen. wooden crossbeams must be removed for roller transport
(only for units weighing up to 1200 kg) (see fig. 16).
2.2 Packing – The switchgear compartments must only be transported in
the vertical position.
The cubicles are protected by suitable packaging during – Tilting and canting must be avoided.
transport and intermediate storage (if applicable).
The standard packaging comprises:
– PE-sheeting
– pallet
– plastic straps
– wooden crate (if necessary)

Crossbeam Transport frame

(wooden beam 10 x 12 cm)

Fig. 16 Fork-lift transport Fig. 17 Roller transport (only for transporting units weighing up to 1200 kg)

Transporting by manual lift truck is dangerous

as the apparatus can overturn.
For this reason, the distance between the
crossbeams or pallets and the bottom must not
exceed 3 mm (see Figure).

Fig. 18 Transporting by manual lift truck

1TTS900001M0203 | Service Manual MNS R 17

2.3.2 Transporting by crane – costly precision instruments for measuring and indicating,
– When a crane is used to transport the apparatus, the – fluorescent tubes,
compartments and relative units must be equipped with – modules with single phase control power transformers over
lifting profiles. 2 kVA,
– The lifting devices must not be fixed to the frame sections. – spare withdrawable and P-/R-modules,
– The angle between the lifting cable and crane hook must – withdrawable modules weighing ≥ 30 kg.
not exceed 120° (see fig. 19-20).
– The lifting devices can be removed once the apparatus has 2.4 Storage
been installed.
– The fastening holes for the lifting apparatus must be The nature and length of time intermediate storage lasts
covered with GMN 775 502 P18 plugs. depends on the type of packaging.
Standard packaging:
– After arrival, the apparatus must be stored in places where
Approximate acceptable weights of loads lifted by cable no condensation can form.
Cable diameter Acceptable load for a 4-cable device, – Unpack immediately.
angle between cable and crane hook – Leave the door open for several hours so as to acclimatize
Hemp cable Perlon cable Steel cable the equipment.
DlN 83325 DlN 83330 DlN 15060
(160 kg/mm2) – Cover the panels with plastic sheeting for longer storage
mm kg kg kg periods.
8 - - 890 – Check for condensation before installing the equipment.
10 180 400 1440
12 280 600 2100 Packaging for transportation by sea/export (on request):
14 350 820 2900
– Protection against moisture is only guaranteed if the
16 470 1060 -
packaging is undamaged.
18 580 1340 -
– Intermediate outdoor storage is possible.
20 720 1660 -
– 6-12 month storage is possible, depending on the storage
24 1000 2400 -
30 1600 - -
environment conditions, if the goods are wrapped in
36 2400 - - heat sealed protective sheeting and the packaging is
undamaged.
For a 90° angle, the acceptable load is approximately 40% If the storage period is lasts longer, the drying agent must be
more than the values shown in the table. renewed and the plastic covering must be sealed again.

2.3.3 Packaging of switchgear components 2.4.1 Spare Module Storage

The following devices and materials must be delivered packed – In a dry place.
separately from the switchgear, regardless of the transport – Modules must be stored in their undamaged original
method used: packaging.
– withdrawable air circuit breaker, – Modules must not be subjected to sudden temperature
– withdrawable moulded case circuit breaker with over 1,000 changes.
A rated current, – Boxes must be stored with the top side pointing upwards.
– fuses, – Do not store size ≥ 16E modules on top of each other.
– transformers and reactors weighing more than 25 kg, in the
case of floor mounted units weighing more than 100 kg,

Fig. 19 Crane transport, transport unit unpacked Fig. 20 Crane transport, transport unit in box

18 Service Manual MNS R | 1TTS900001M0203

3 Construction
3.1 Inspection on Delivery 3.2 Installation
After the goods arrive, check to make sure that: The best internal conditions, adequate illumination and free
– none of the components is damaged; access to the switchgear must be guaranteed. It is advisable
– the goods are free from damage (otherwise, assess to heat the room so as to avoid sudden temperature changes,
the extent of the damage, the cause and possible a high degree humidity and the formation of condensation.
responsibilities). To correctly install the switchgear, it is important to construct
When damage is discovered, proceed as follows: the frame with care. It must be prepared in advance, before
– Record the visible damage on the delivery note. the installation date, as indicated in the design document.
– Inform ABB Sace (directly or through the supplier or sales
representative). 3.2.1 Construction and Connection of the Cubicles
– Notify the forwarding agent in writing within one week if Proceed as follows to install the switchgear units:
concealed damage is discovered. – The units to be installed must be aligned with care. Check
that they are in the vertical position. Doors and panels must
Following delivery of the apparatus, complaints about damage not be distorted or stressed. Assembly can begin from the
or for other reasons must indicate the year of construction right or left.
of the switchgear and the number of the order confirmation – The frames must be screwed together (see fig. 21). Threaded
sent by ABB Sace, as indicated on the enclosed supply rivets are pre-installed for fixing the C-profiles together.
documents.
Use an electric or pneumatic screwing device to initially fasten
ABB declines all liability for loss of supply the threaded rivets.
documents or failure to lodge claims.

Threaded rivet

Fig. 21 Frame connection

1TTS900001M0203 | Service Manual MNS R 19

3.3 Cable and Busbar Connection The switchgear must be earthed by means of a copper
conductor with a cross-section no less than the earth busbar.
Comply with the tightening torque values given in the table The doors are earthed by means of yellow-green copper
in Sect. 5.11 for all connections, especially those made with conductors (minimum cross-section 2.5 mm2).
standard components. No connection is necessary, if no energized elements are
Circuit breakers and main switching devices are normally connected to the door (≤ 50 V AC or ≤ 120 V DC).
connected by cables or busbars. ln all cases, protective conductor connections screwed onto
– Power and control cables must be fastened to cable painted surfaces should be secured with serrated contact
mounting rails. washers. Any screw locking method is permissible for
– Power and control cables are connected to: fastening screwed connections to gaIvanised surfaces. No
- Terminal boards lock-washers are required for roundhead screws (so-called
- Connection busbars Taptite screws) when screwed into galvanised parts for the
- Outgoing cable connection units. first time.

If the outgoing busbar connections must be disassembled or 3.3.3 Protection Degree

replaced, comply with the following instructions before The sections must be sealed in the place of installation
re-installing: depending on the required protection degree.
– Check that the connection contact surface is flat and clean. – For IP X2 or IP 5X degrees of protection, the bottom plate
– Remove burrs, dents and oxidation with a file or rough covers (flanges) must be sealed, if this has not already been
cloth. In case of busbars with special protective coatings, done by the manufacturer. 15 x 2 mm (GSIN100021P0010)
the coating must be restored after the above-mentioned self-adhesive sealing material must be used to seal the
tools have been used. bottom plate. This must be applied after cleaning (see
– Remove any grease with a cloth and solvent. below), to the inside bend of the flanges, and must overlap
3 mm over the bend (see fig. 22).
3.3.1 Busbar Connection (see fig. 24a-b) – For IP X1 or IP 4X degrees of protection, the frames
Before assembling, carefully clean the busbar contact area between the sections (section/ section) must be sealed
with a cloth soaked in solvent. where divided for transport, unless this has already been
– Make sure that the busbar is properly aligned. done in the factory.
– Match the coupling elements
– Lock the joints by means of the coupling elements, bolts The following measures must be taken:
and nuts supplied. – The connection sides of the frame sections in question must
be cleaned with cleaner and an oil- and grease-free cloth.
Protective and neutral busbars must be screwed together – After the cleaner has dried, 15 x 2 mm self-adhesive sealing
where divided for transportation purposes (connecting tape (GSIN100021P0010) must be applied to the C-sections,
elements are included). 3 mm away from outer edge (see fig. 23).
The busbar points of connection are accessed from the rear. If
installation is performed correctly, the holes will match. Drilling
is not allowed since it produces chips.
The contact surfaces do not need any particular treatment.
Consult Sect. 5.11 for the tightening torque values.

3.3.2 Protective Conductor Connection (see fig. 25)

All switchgear compartments are normally equipped with an
earth busbar the section of which will depend on the short-
circuit level of the switchgear.
The earth busbar is installed in the rear side of the switchgear
(at the bottom). The earth busbar joint of each unit divided for
shipping purposes must be connected in the following way:
– Remove any traces of oxidation from the contact surfaces of
the busbars using a file or emery cloth.
– Remove any grease with a cloth and solvent.
– Join the the earth busbars using the screws, washers and
nuts supplied.

20 Service Manual MNS R | 1TTS900001M0203

Fig. 22 Seals on bottom plate cover

Roof plate Corner sealing

GLBK410048P0001

IP 32, 43...43...54

Seal with17x2
adhesive tape
GSIN100021P0023

IP 32, 43...43...54

Neighbouring
cubicle

Use 17x2 adhesive tape GSIN100021P0023

for sealing cubicle to cubicle and sidewall

Rear wall

Fig. 23 Seals between adjacent compartments and roof

1TTS900001M0203 | Service Manual MNS R 21

Fig. 24a Standard busbar connections

Fig. 24b Multi-level busbar connections

22 Service Manual MNS R | 1TTS900001M0203

 Earth busbar

Fixing screw

Bracket

Interconnection
busbar

Earth busbar

M10 exagon head screw,

spring washer,
exagon head nut

Earth busbar joint

Fig. 25 Earth busbar connection detail

1TTS900001M0203 | Service Manual MNS R 23

3.4 Additional information about The last compartment (right) must be installed 150 mm away
from the wall.
switchgear positioning The last left compartment must be at least 150 mm away from
The distance from the wall (front and rear) should comply with the left wall, so that the doors can be opened at an angle of
the following rules: over 90°.
– it must be more than the width of the largest panel For internal arc-proof cables, the upper edge of the tallest
– it must be at least 800 mm to allow normal operations cubicle end must be at least 500 mm away from the ceiling
– it must comply with the safety regulations for emergency/ (see fig. 26).
evacuation plans (see fig. 26-27).

Side view

Panel width Min space Min space

[mm] Front [mm] * Rear [mm]**
600 1000 800
800 1000 800
1000 1000 800
1200 1200 800
* A lift truck may be required to remove and insert the breaker of the ACB withdra-
wable version.
In this case, the space required for lift truck manoeuvres must also be assessed.
** 2 x 500 width rear doors are provided for 1000mm width panels
2 x 600 width rear doors are provided for 1200mm width panels

Fig. 26 Free space around the frame

24 Service Manual MNS R | 1TTS900001M0203

3.5 Cuts in the floor
If the floor must be cut on-site to accommodate supply
cables and wires, measurements must be taken as shown in
the diagrams below (all measurements in mm).

Depth 1025 mm
Busbar compartment 525 mm

Panel width 200 mm Panel width 300 mm Panel width ≥ 400 mm

FRONT FRONT FRONT

Depth 1025 mm
Width [mm] B.C. B C E F L
200 525 - - - - -
300 525 - - - - -
400 525 220 240 336 385 80
600 525 420 488 347 374 56
800 525 620 688 347 374 56
1000 525 820 888 336 385 56
1200 525 1020 1088 336 385 56

1TTS900001M0203 | Service Manual MNS R 25

Depth 1200 mm
Busbar compartment 525 mm

Panel width 200 mm Panel width 300 mm Panel width ≥ 400 mm

FRONT FRONT FRONT

Depth 1200 mm
Width [mm] B.C. Note B C D E F G H I L M
200 525 - - - - - - - - - - -
300 525 - - - - - - - - - - -
400 525 - 220 240 220 336 440 62 58 117 80 90
600 525 - 420 488 488 347 408 91 55 112 56 56
800 525 - 620 688 688 347 408 91 55 112 56 56
1000 525 - 820 888 820 336 440 62 55 112 56 90
1200 525 - 1020 1088 1020 336 440 62 55 112 56 90
600 525 MCC REAR 420 488 488 440 310 96 55 112 56 90

26 Service Manual MNS R | 1TTS900001M0203

Depth 1400-1600 mm
Busbar compartment 525-650 mm

Panel width 200 mm Panel width 300 mm Panel width ≥ 400 mm

FRONT FRONT FRONT

Depth 1400 mm
Width [mm] B.C. Note B C D1 D2 E F G H l L M N
525 - - - - - - - - - - - 1400
200
650 - - - - - - - - - - - 1400
525 220 240 188 - - - - - 120 - 56 1400
300
650 220 240 188 - - - - - 120 - 56 1400
525 220 240 220 - - 340 440 76 240 80 90 1400
400
650 220 240 220 - - 392 508 76 120 80 90 1400
525 420 488 220 220 48 347 408 96 245 56 56 1400
600
650 420 488 220 220 48 347 533 96 120 56 56 1400
525 620 688 320 320 48 347 408 96 245 56 56 1400
800
650 620 688 320 320 48 347 533 96 120 56 56 1400
525 820 888 420 420 48 340 440 76 240 56 56 1400
1000
650 820 888 420 420 48 392 508 76 120 56 56 1400
525 1020 1088 520 520 48 340 440 76 240 56 56 1400
1200
650 1020 1088 520 520 48 392 508 76 120 56 56 1400
600 525 MCC REAR 420 488 220 220 48 445 310 96 245 56 56 1400

Depth 1600 mm
Width [mm] B.C. Note B C D1 D2 E F G H l L M N
525 - - - - - - - - - - - 1600
200
650 - - - - - - - - - - - 1600
525 220 240 188 - - - - - 320 - 56 1600
300
650 220 240 188 - - - - - 320 - 56 1600
525 220 240 220 - - 340 440 76 440 80 90 1600
400
650 220 240 220 - - 392 508 76 320 80 90 1600
525 420 488 220 220 48 347 408 96 445 56 56 1600
600
650 420 488 220 220 48 347 533 96 320 56 56 1600
525 620 688 320 320 48 347 408 96 445 56 56 1600
800
650 620 688 320 320 48 347 533 96 320 56 56 1600
525 820 888 420 420 48 340 440 76 440 56 56 1600
1000
650 820 888 420 420 48 392 508 76 320 56 56 1600
525 1020 1088 520 520 48 340 440 76 440 56 56 1600
1200
650 1020 1088 520 520 48 392 508 76 320 56 56 1600
600 525 MCC REAR 420 488 220 220 48 445 310 96 445 56 56 1600

1TTS900001M0203 | Service Manual MNS R 27

3.6 Methods for Fastening to If the switchgear is installed on a raised floor, make sure that:
– The tolerance is the same as that of a base frame.
Foundation – The foundation base must be solid, so that the tolerance
Installation of switchgear with cables entering from the bottom values do not change if it settles (especially when insulation
requires a foundation with an opening or a cable duct. layers and adhesives are used).
Compartments can be installed directly on the floor or – The bearing capacxity of the raised floor must be p=20 kN/m2
preferably on a base frame which is: (compression load from top to bottom).
– Embedded in the concrete floor
– Fixed on supports on a raised floor. The switchgear is welded or screwed to the raised floor when
installed.
Comply with the following instructions when constructing the – The length of the welded joint on the front and rear sides
base frame: of each cubicle should not be less than 20 mm. Each weld
– The base frame should be aligned and checked by a should be adequately treated to protect it against corrosion
qualified ABB SACE operator (on customer’s request). (by a coat of paint).
– The horizontal tolerance must not exceed ±1 mm over a
length of 1 m. The switchgear has three available anchor points, see fig. 28.
– The frame must not wobble ( | 2 / 1000 according to The base frame could be a standard UPN profile or a HALFEN
DIN ISO 1101). profile.
Fixing points A and B may be used if the switchgear is
During the installation operations, the switchgear is welded or anchored to the floor or UPN profile. Only fixing point C may
screwed to the base frame. be used if the profile is the HALFEN type.
– The welded joint length on the front and rear sides of each Installation drawings illustrating the different anchor points are
cubicle, should not be less than 20 mm. Each weld should given in figs. 29-30-31.
be adequately treated to protect it against corrosion (by a
coat of paint).

Fig. 28 Switchgear with three anchor

points

28 Service Manual MNS R | 1TTS900001M0203

Fig. 29 Anchoring the switchgear to the floor

Fig. 30 Anchoring the switchgear to the UPN profile

Fig. 31 Anchoring the switchgear to the halfen profile

1TTS900001M0203 | Service Manual MNS R 29

3.7 Cable connections, wiring
3.7.1 Connection to circuit breaker and load-break
switches
Circuit breaker and load break switches are equipped with
standard cable connection sets (see figs. 32, 33, 34).
The outgoing cable must be fastened to the cable support
with a plastic seal.

Cable support

Busbar system

Cable support

Cable

Cable support

Cable support

Cable support

Fig. 32 Typical cable connection from Emax to busbar and cable

30 Service Manual MNS R | 1TTS900001M0203

 Segregation cable way

Frame structure

Cable support

Cable

Fig. 33 Typical cable connection from fixed module

1TTS900001M0203 | Service Manual MNS R 31

 Segregation
cable way

Cable support

Cable

Fig. 34 Typical cable connection from MNS R Motor Control Center

32 Service Manual MNS R | 1TTS900001M0203

3.7.2 Cable connection, wiring Cable section [mm2] B [mm]
Types of cable lugs Normal lugs Contained palm
Two types of cable lugs are considered: normal and contained 16 15 -
palm type, see following table for dimension details. 25 15 -
35 17 -
The maximum number of cables that can be connected to the 50 19 11.5
incoming/outgoing busbar in the standard configuration are 70 21 11.5
given in the following tables. Special cable connections can 95 25 15.5
be designed to comply with specific customer requirements. 120 28.5 19
150 31.5 19
185 35.5 24.5
240 39 31
Make connection between terminal and lug using a screw, spring washer and nut.
300 51 31
Screw size depends on cable section:
Use M8 screws for cable sections up to 70 mm2 400 56.5 -
Use M10 screws for cable sections up to 150 mm2 500 61.6 -
Use M12 screws for cable sections up to 300 mm2 630 72 -
Use M16 screws for 400 mm2 cable sections and over. In this case, standard
800 80 -
busbar hole must be enlarged from 13 mm to 17 mm.

ACB cable connection

Cable Breaker Cable Breaker
section E1 E2 E2 2000 E3 E3 E4 E6 section E1.2 E2.2 E4.2 E6.2
[mm2] 1250 1250 2000 [mm2]
1600 1600 2500
3200
95 14 14 14 14 14 14 14 95 14 14 14 14
120 8 8 8 8 8 8 8 120 8 8 8 8
150 8 8 8 8 8 8 8 150 8 8 8 8
185 8 8 8 8 8 8 8 185 8 8 8 8
240 8 8 4 8 8 8 8 240 8 8 8 8
300 4 4 2 4 4 4 4 300 4 4 4 4
400 4 4 2 4 4 4 4 400 4 4 4 4
500 4 4 2 4 4 2 4 500 4 4 2 4
630 2 2 2 4 2 2 4 630 2 2 2 4
800 2 2 2 2 2 2 2 800 2 2 2 2

Table 1 Max number of cables with standard cable lugs type – Emax Table 2 Max number of cables with standard cable lugs type – Emax.2

Cable Breaker Cable Breaker

section E1 E2 E2 2000 E3 E3 E4 E6 section E1.2 E2.2 E4.2 E6.2
[mm2] 1250 1250 2000 [mm2]
1600 1600 2500
3200
95 14 14 14 14 14 14 14 95 4 14 14 14
120 14 14 14 14 14 14 14 120 4 14 14 14
150 14 14 14 14 14 14 14 150 4 14 14 14
185 14 14 14 14 14 14 14 185 4 14 14 14
240 8 8 4 8 8 8 8 240 4 8 8 8
300 8 8 4 8 8 8 8 300 4 8 8 8

Table 3 Max number of cables with contained palm cable lugs type – Table 4 Max number of cables with contained palm cable lugs type –
Emax Emax.2

1TTS900001M0203 | Service Manual MNS R 33

MCCB cable connection
Breaker Position Type of cable lug Max number of cables and cross section for phase [mm 2]
XT1 Horizontal Normal 2x25(M8)
Contained palm 1x50(M8)
XT2-XT3-XT4 Horizontal Normal 2x70(M8)
Contained palm 2x150(M8)
T2 Horizontal Normal 2x25(M8)
Contained palm 2x50(M8)
T3 Horizontal Normal 2x70(M8)
Contained palm 2x150(M8)
T4 Horizontal Normal 2x70(M8)
Contained palm 2x150(M8)
T4 320 Horizontal Normal 1x95(M8) / 2x70(M8)
Contained palm 2x150(M8)
T5 400 Horizontal Normal 1x185(M10) / 2X150(M10)
Contained palm 1x240(M10) / 2X185(M10)
T5 630 Horizontal Normal 1x240(M12) / 2X185(M12)
Contained palm 1x240(M12) / 2X185(M12)
T6 630 / 800 Horizontal Normal 2x240(M12)
Contained palm 2x240(M12)
T7 / X1 Horizontal Normal 2x240(M12) / 4*240**(M12)
Contained palm 2x240(M12) / 4*240**(M12)
T6 630 / 800 Vertical Normal 2x300(M12) / 3x300***(M12)
T7 / X1 Vertical Normal 2x300(M12) / 4x300***(M12)
(*) T7-X1 800/1000A Copper section 1 (one) 50x10
(*) T7-X1 1250/1600A Copper section 2x50x10 ph/ 50x10 N
(** ) Only for T7-X1 1250/1600A (to be assessed case by case depending on depth/width)
(***) For bottom vertical position

Withdrawable module cable connection

Module size Poles Inc [A] Max number of cables and cross section for phase [mm 2]
8E4 3 45 1x6
8E4 4 45 1x6
8E2 3 63 1x35
8E2 3 63 1x35
8E2 4 63 1x35
8E2 4 63 1x35
8E2 6 45 1x6
8E2 8 45 1x6
8E2 6 45 1x6
8E2 8 45 1x6
6E 3 250 2x120 (M10)
≥8E 3 160 2x120 (M10)
≥8E 3 250 / 400 2x240(M12)
≥16E 3 630 4x240(M12)
6E 4 250 2x120 (M10)
≥8E 4 250 2x120 (M10)
≥16E 4 400 2X240 (M12)
≥24E 4 630 4X240 (M12)
≥8E 6 160 2x120 (M10)

Plug in module cable connection

Module size Poles Inc [A] Max number of cables and cross section for phase [mm 2]
6E 3 250 2x120 (M10)
8E 3 160 2x120 (M10)
8E 3 250 / 400 2X240 (M12)
16E 3 630 4x240 (M12)
6E 4 250 2x120 (M10)
8E 4 250 2x120 (M10)
16E 4 400 2X240 (M12)
24E 4 630 4x240 (M12)

34 Service Manual MNS R | 1TTS900001M0203

Spring washer Nut M10

Hexagon head screw M10

Cable connection unit

Cable terminal

Side segregation

Bottom segregation

Cable
Segregation cable way

Fig. 35 Typical cable connection

1TTS900001M0203 | Service Manual MNS R 35

 Plug-in module

Cable connection unit

Segregation cable way

Vertical busbar interior segregation

Segregation cable way

Cable

Hexagon head screw

Spring washer

Fig. 36 Typical cable connection for plug-in modules and Mcc modules

36 Service Manual MNS R | 1TTS900001M0203

3.8 Protective conductor connection 3.9 Neutral conductor connection
Protective conductors must be connected as follows: The neutral conductors must be connected to the insulated
– Up to 63 A: neutral busbar installed parallel to the protective conductor
- To the PE terminal of the withdrawable module condapter busbar or to the neutral connection busbar, by screws or
or the plug-in, disconnectable or railable module. using a terminal mounting rail.
– Up to 100 A: ln all cases the connection must be made at the height
- To the vertical section located at front right (see fig. 37) of the relevant module and allocation must be clearly
using an M6 screw. distinguishable. ln other cases, e.g. for control cables, cross
– Over 100 A: referencing will be necessary.
- To the vertical PE connection busbar, installed front right
in the cable compartment as a screw connection or using Key to abbreviations
a terminal mounting rail.
Component Abbreviation acc. to
IEC 60439-1 / VDE 0660
The green and yelIow conductor (colour marking over part 500
entire length) may only be used as a protective (PE) or Protective earth conductor PE
PEN conductor. lt must not be used as a voltage carrying Neutral conductor N
conductor by altering the colours at the ends or employed as Neutral conductor with protective function PEN
earthing regulator or as a connector for the shielded earth.
ln all cases, protective conductor connections screwed
onto painted surfaces should be secured with serrated
contact washers. Any means of locking the screws is
permissible for fastening connections screwed into gaIvanised
surfaces.
No lock-washers are required for roundhead screws (so-called
Taptite screws) when screwed into galvanised parts for the
first time.

The protective conductors are connected to the doors by

fIexible green and yellow copper conductors (cross-section
2.5 mm2).
The connections are not required if no Iive (≤ 50 V AC or
≤ 120 V DC) equipment is installed on the doors.
Continuous connection of protective conductor circuits
to inactive metal parts of the building (in accordance with Fig. 37 Protective conductor connection to C-section vertical structural bar

lEC 60439 or DIN VDE 0100 Part 540) must be made in

accordance with the conditions in the construction site. 3.10 Final Preparations
– Remove the safety devices used for transporting the heavy
components of the apparatus.
– Assemble the equipment, i.e. circuit breakers, fuses, lamps,
meters. The various components are labelled. Comply with
the enclosed assembly instructions.
– Remove foreign materials, such as tools, packaging
material and residuals.
– Clean the insulating parts with an antistatic cloth. Do not
use carbon tetrachloride, trichlorethylene or hydrocarbon
solvents.
– Close the doors.

3.11 Checking Operations

– Check busbar connection to units separated for
transportation purposes. Tightening torque, Sect. 5.11.
– Check base frame fastening.
– Check that the required protection degree is obtained,
especially for the bottom closing part.
– General visual inspection: appearance, completeness,
labels, foreign materials in the switchgear, and dirt.
– Check that the cable and wiring connections have been
completely and correctly made.

1TTS900001M0203 | Service Manual MNS R 37

4. Start up and Operation
4.1 Start up
Follow the detailed inspection instructions before energizing
the switchgear.

Item Operation Note

1. Compartment – Visually inspect internal and external parts for
possible damage; remove any foreign material
(i.e. test tools left after assembly)
– Carefully clean the insulating parts, remove any
trace of moisture
– Remove dust or dirt from the air-intake grilles
2. Power circuit connections Check tightening and continuity
3. Earth busbar and relative connections Check tightening and continuity
4. Insulation Measure the insulation resistance of the power – The insulation resistance value is strongly
circuit (phase-phase and phase-earth), auxiliary influenced by environmental conditions
circuit and anticondensate heater The value – The switchgear must NOT be put into service if
measured must be at least > 100 Mohm the insulation resistance is too low, for example
lower than 1 Mohm
– If the low insulation resistance value is due to
humidity, turn on the anticondensate heater
(after having performed the inspections
described in step 8, and set the thermostat
to a higher value). Use provisional heaters if
necessary
5. Circuit breakers – Before putting into service, perform all
the necessary operations described in the
instructions of each circuit breaker
– Check the devices and accessories required
for operation. In the case of key-locked circuit
breakers (open or closed), each circuit breaker
must be equipped with only one key.
Put the circuit breakers into the service position
6. Protective release device Make sure that calibration is correct according to
the selective diagrams of the installation
7. Auxiliary circuits According to the diagram, check the functionality Check the setting of each switchgear relay before
and operation logic sequences of the auxiliary performing this inspection
circuits
8. Anticondensate heater – Energize the circuit
– Adjust the thermostat to the highest
temperature allowed
– Check that the heater temperature rises
– Adjust the thermostat so that the temperature
inside the switchgear is always higher than the
outside ambient temperature (approximately
35 °C)

38 Service Manual MNS R | 1TTS900001M0203

– In the case of particular apparatus configurations, the 4.2 Operation
previous inspections may need to be integrated with others
suggested by the technician responsible for the apparatus 4.2.1 Size 8E/4 and 8E/2 withdrawable units
itself. Size 8E/4 and 8E/2 withdrawable units comprise:
– Check that the secondary winding of the current – One or two profile sections for mounting snap-on
transformer is connected to the relative protective and/or components,
measuring current circuit, then remove any possible short- – a rear waIl with integrated power contacts inclusive of wiring
circuit connections. and with one 20-pole control plug in the case of size 8E/4
– If the secondary winding of the voltage transformer must be modules, one or two 20- or 40-pole control plugs in case of
connected to external equipment of the switchgear, check size 8E/2 modules,
for the following conditions so as to avoid overloads or – a front panel made of insulating material with knockouts for
short-circuits in the voltage transformers: mounting measuring, operating and indicating instruments,
- Make sure that the total comsumption of the equipment is – side walls.
not higher than the transformer capacities. If certain standard Ioad-break switches and circuit breakers
- Check for incorrect connections (also provisional) in the are used, the handle for operating them also activates the
measuring circuit or connections that fail to comply with electrical and mechanical interIocks. A microswitch with 2 NO
the connection of the switchgear and other units (supply and 2 NC contacts is provided for electrical interIocking.
switchgear, subswitchgear, control or operating consoles,
etc.).
Position of Position of Main and control
- Check that only one phase of the secondary winding of switch module circuits
the voltage transformer is earthed. ON in section All main- and
– At the end of the preliminary test, proceed with the following control-circuits are
closed
operations:
- Open and isolate all the circuit breakers
- Remove any testing connections OFF in section All main- and
Close all doors of the circuit breakers and measuring cells control-circuits are
Check for internal metal segregations (according to Can be locked disconnected
with 3 padlocks
the segregation form of the construction design) of the
external closing panels
TEST in section All main-circuits
- Check that the different mechanical and electrical are disconnected,
interlocks (which may have been deactivated to perform Can be locked the control-circuits
with 3 padlocks are closed
the starting test with the switchgear de-energized) have
been restored.
MOVE Position in section All main- and
– Energize the control circuit - control-circuits are
– Close the circuit breakers (according to the system), and Isolated Position disconnected
-
ensure that any related function operates properly not in section
– Make sure that the auxiliary instruments operate correctly
ISOLATED The module is All main- and
Position drawn 30 mm out control-circuits
Comply with the general safety rules Can be locked of the section are disconnected
with 3 padlocks and the isolating
distance is
obtained

Fig. 38 Description of operating handle positions for 8E/4 and 8E/2
modules

The switch handle can only be moved from the “OFF” to “ON”
position after the handle has been depressed (push-to-turn
operation).
The switch handle can be locked in the “OFF” and “TEST”
positions and the isolated position with up to three padlocks
(see fig. 40). The withdrawable unit can be prevented from
being withdrawn by an additional mechanical Iock (protection
against theft) to be installed in the front cover.
Switch handIes of withdrawable units that are not used must
be moved to the “OFF” or “ISOLATED” position.

1TTS900001M0203 | Service Manual MNS R 39

Resetting circuit breakers in withdrawable modules 4.2.2 Sizes 6E to 24E withdrawable units
When moulded-case circuit breakers are tripped by faults, the Sizes 6E to 24E withdrawable units are made of sheet steel
switch handle may turn to an intermediate position between components which form the supporting frame for the electrical
“ON” and “OFF”. components and contact elements. The hinged front cover
The function of the circuit breaker can only be re-established allows easy access to the built-in components from the front
by a reset. Reset the fault by turning the switch handle from side. The front cover can only be opened with a key in the
the intermediate position to the “OFF” position and further to isolated, test or OFF-positions of the withdrawable unit. Only
the stop point. one lock need be opened if a parallel coupling is installed. The
After this, the circuit breaker can be switched on again. front cover can only be opened with a screwdriver when the
1. Turn the switch handle from “ON” to “OFF”. operating handle is in the “ON” position.
2. Press the switch handle down and turn it counter-
clockwise to the stop point. Live parts could be touched if the front cover is
3. When released, the switch handle swings back to the opened while the operating handle is in the “ON”
“OFF” position. position.
4. The circuit breaker is ready to be switched on.
The withdrawable unit can be equipped with an instrument
Note: panel made of insulating material where measuring, operating
A clear release tripped indication can only be achieved by an and indicating instruments can be installed. The hinged
electrical signal (e. g. pilot lamp or audible signal). instrument panel is installed on the withdrawable unit and
projects through a cutout in the front cover. This panel
remains in position when the front cover is opened. If the
front cover is open, the instrument panel can be tilted down
by unlocking the locking lever on the left and right side of the
panel. Tilting down the instrument panel improves access
to the equipment in both the withdrawable unit and the
instrument panel.
The main switch is operated by the operating handle, which
is also used for mechanical and the electrical interlocking. A
microswitch with up to 2 NO and 2 NC contacts is provided
for electrical interlocking.

Position of Position of Main and control

switch module circuits
ON in section All main- and
control-circuits are
Fig. 39 Switch operating handle for size 8E/4 and 8E/2 withdrawable closed
modules with position markers

OFF in section All main- and

control-circuits are
Can be locked disconnected
with 3 padlocks

TEST in section All main-circuits

are disconnected,
Can be locked the control-circuits
with 3 padlocks are closed

MOVE in section All main- and

Position - control-circuits are
Isolated Position disconnected
-
not in section

ISOLATED The module is All main- and

Position drawn 30 mm control-circuits
Can be locked out of the section are disconnected
with 3 padlocks and the isolating
distance is
obtained
Fig. 40 Size 8E/4 withdrawable module with 3 padlocks
Fig. 41 Description of operating handle positions for 6E to 24E
modules

40 Service Manual MNS R | 1TTS900001M0203

In the test position, a test function of the control circuit of
moulded case circuit breakers cannot be performed with the
motor operating.
Secure breaking of the main circuit is achieved in the OFF-
position due to the isolating characteristics of the main
switching devices used. In addition, it is necessary to ensure
that the customer achieves secure isolation of the main- and
control-circuits by moving the withdrawable module to the
isolated position.

Resetting circuit breakers in withdrawable modules

When moulded-case circuit breakers trip due to faults, the
switch handle may set to an intermediate position between
“ON” and “OFF”.
The circuit breaker function can only be re-established by a Fig. 42 Size 8E withdrawable module
reset. Reset the fault by turning the switch handle from the
intermediate position to the “OFF” position and further to the
stop point.
After this, the circuit breaker can be switched on again.
1. Turn the switch handle from “ON” to “OFF”, and then to
the stop point.
2. When released, the switch handle will swing back to the
“OFF” position.
3. The circuit breaker is ready to be switched on.

Note:
A clear release tripped indication can only be achieved by an
electrical signal (e. g. pilot lamp or audible signal).

Moving the withdrawable module

The withdrawable unit can only be moved if the operating
handle is in the “MOVE” position. This ensures that a Fig. 43 Size 16E withdrawable module

withdrawable module cannot be moved under load.

To move a withdrawable unit, the operating handle must
be set to the “MOVE” position, after which the unit can be
pulled out by means of the two handles. When the unit starts
moving, the operating handle immediately switches back to
the “OFF” position and the withdrawable unit interlocks after
30 mm in the isolated position. In this position the main and
control contacts are disconnected.

To move the withdrawable unit further, the operating handle

must be switched to the “MOVE” position again. After this, the
withdrawable module can be pulled out further.
Before the withdrawable unit has been completely removed
from the section, it interlocks again to avoid being pulled out
from the section in an uncontrolled way. Press down the lever
on the left side of the withdrawable unit (see fig. 46) to release Fig. 44 Switch operating handle for size 4E to 24E withdrawable
this safety stop. If the withdrawable unit to be moved is modules with position markers
installed in a high position in the section, the safety stop can
be released by supporting the unit with the right hand from
below and releasing the lever with the left hand.

1TTS900001M0203 | Service Manual MNS R 41

After this, the withdrawable unit can be completely removed Please refer to the instruction label affixed to the special tool
from the section. and the steps illustrated here for instructions on how to use
the special tool and perform the plug-in module extraction
Depending on their size, withdrawable units are procedures:
very heavy. Comply with the safety regulations STEP 1
at all times. Switch off the breaker

– After the withdrawable unit has been moved halfway from

the withdrawable module compartment, the operator must
take hold of it from below, under the sides (applicable to
size 4E and 8E withdrawable units).
– Size 12E withdrawable units and larger should be
withdrawn by two persons. To do this, the operators must
each stand at one side of the unit and take hold of it from
below (12E) or by the hand grips on the side walls (> 12E).
– Withdrawable units should not be left longer than necessary
in the safety stop position because the centre of gravity
is already beyond the section in this position. Failure to
comply with this instruction can cause mechanical damage
to the withdrawable unit.

Withdrawable units in the isolated position or

in the safety stop position must not be used
as climbing aids since this could endanger
persons and/or damage the switchgear itself. STEP 2
Open Door
The test position can be obtained without moving the
withdrawable unit by turning the operating handle to the
“TEST” position.
The operating handle can be locked in the “OFF” and “TEST”
positions by using up to three padlocks. Removal of the unit
can be inhibited by an additional mechanical lock (protection
against theft) which can be installed in the front cover.
The operating handle must be in the “OFF” position when
withdrawable units are not being used.

4.2.3 8E to 24E plug-in units

Plug in modules are fastened directly to the compartment
bottom plate using a screw.
The plug in module feeder connection to the distribution
busbar system is made directly via the contact device of the STEP 3
plug-in modules themselves. Outgoing cables are connected Unscrew highlighted screws
via plug-in contacts to the out-going connection unit (main
circuit) and via terminal blocks (aux circuit). The outgoing
cable connection units are fastened directly to the frame.
A special tool is used to rack the modules in/out (see fig. A)

Fig. A Special tool for racking-out the module

42 Service Manual MNS R | 1TTS900001M0203

STEP 4 STEP 6
Unscrew highlighted screws and unplug the terminal block Screw the knobs into the fixing points specified in step 5

STEP 5 STEP 7
Position the removal tool near the highlighted fixing points Extract the plug-in module

4.3 Special information

When the installation is operating, make sure that:
– the doors and the front covers of the withdrawable modules
are closed,
– the withdrawabIe modules are interlocked,
– the ventilation louvers are not obstructed or clogged.

1TTS900001M0203 | Service Manual MNS R 43

5. Maintenance and Spare Parts
5.1 General 5.2 Withdrawable technique

Maintenance work, such as replacing fuses The following description refers to the standard modules.
etc., must only be carried out by suitably Ask for a separate description if the modules differ from the
trained personnel in compliance with the safety standard version.
rules.
The multi-functional wall is installed between the busbar and
The following regulations must be observed when working on the equipment compartment. lt covers the complete height
switchgear sections: and width of the equipment compartment and performs the
– The national and international safety rules (e.g. VDE 0105, following functions:
regulations for the operation of power installations) and – It houses the distribution busbars.
specific maintenance instructions of the installed devices. – It fastens and covers the distribution busbars by means of
the distribution busbar cover.
– It protects against the formation and propagation of arc
When making modifications to sections it may faults.
be necessary to interrupt the operation of
adjacent parts of the installation, depending on The contact openings of the distribution bar covers comply
the extent of the work and the type of design. with protection degree IP 20, thus conversion is possible
The heat balance may change when without having to interrupt the operation of the section (see
modifications are made inside the sections. Do fig. 52).
not exceed the permissible temperature-rise The withdrawable module can be changed or removed and
limit inside the switch panel. Please contact replaced in the compartment during maintenance without
your ABB branch if in doubt. isolation.
With the interIocking switch handle in the move position,
After fault situations, checks are to be carried out just as size 8E/4 and 8E/2 withdrawable modules can be withdrawn
before commissioning. without stopping. Size 6E to 24E modules must be withdrawn
up to the stop position, released and then removed completely.

Fig. 45 Unlatching the front cover of a withdrawable module by

means of a screwdriver

Live parts could be touched if the front cover

is opened while the operating handle is in the
“ON” position.

Fig. 46 Withdrawal of a withdrawable module

44 Service Manual MNS R | 1TTS900001M0203

The main fuses in withdrawable modules with hinged front Proceed as follows to remove a module:
covers are accessibIe after the main switching device – Isolate the modules
has been turned OFF and after the front cover has been – Open the breaker
unlatched. The front cover can only be unlocked by means of – Protect against reclosing
a tool, e.g. a screwdriver (see fig. 45) when the module is in – Verify isolation from supply
the operating position. – Perform earthing and short-circuiting
The interlocking mechanism is situated at the side of the – Provide a barrier between adjacent live parts
switch handle. – Disconnect control cables
The frame-mounted compartment must also be changed – Remove module fastening screws and
(see figs. 52/53) in order to convert or modify complete carefully pull module out of the section
withdrawable module units, e.g. replacement of one large unit – If necessary, empty slots must be covered
with several smaller units or vice versa. with blanking plates (please contact your
ABB supplier).
5.3 Plug-in technique
Work through the above steps in reverse order to install the
The heat balance may change when modifications modules.
are made inside the switchgear sections. Do not If a plug-in module has been removed, grease the guide
exceed the permissible temperature rise inside the before insertion to facilitate the operation.
switchgear section (contact ABB).

Plug-in modules
Plug-in modules can be changed or removed and replaced in
the compartment during maintenance without isolation (see
figs. 47-48-49-50-51).

Fig. 47 Switch off the breaker

Fig. 48 Open Door Fig. 49 Unscrew highlighted screws and unhook terminal block

1TTS900001M0203 | Service Manual MNS R 45

 5.4 Converting and changing
withdrawable module
compartments
Before converting and/or changing a
withdrawable module compartment, the
withdrawable module below the withdrawable
module compartment in question must be
removed from the section. Prevent small parts
from falling through by applying an appropriate
cover as a bottom plate for the withdrawable
module compartment.

The heat balance may change when modifications

are made inside the switchgear sections. Do not
exceed the permissible temperature rise inside the
switchgear section (contact ABB).

Fig. 50 Screw in the tool knobs

Fig. 51 Extract the plug-in module

Fig. 52 Size 8E withdrawable module compartment with outgoing Fig. 53 Conversion to size 8E/4 and 8E/2 withdrawable module
cable connection unit, 2E-distribution busbar cover compartments

46 Service Manual MNS R | 1TTS900001M0203

5.4.1 Example 1: Conversion of one size 16E unit Re-assembly
(height 400 mm) into four 8E/4 size units (height – lnstall 2 outgoing cable connection units (see fig. 35 for
200 mm) and two 8E/2 units (height 200 mm) details).
Conversion must be performed in the following sequence: – Insert two new compartment bottom plates with a distance
Disassembly (see fig. 52) of 8E each and fix them with screws.
– Pull out the withdrawable unit. – The newIy installed bottom plates must be equipped with
– Disconnect the power cables after the protective cover the left guide rail and rollers, and covers must be installed.
has been removed. Thanks to the protective covers on – Between the newly installed compartment bottom plates,
the adjacent cable connection units, work inside the cable one control terminal block support for withdrawable module
compartment can be performed without danger (see fig. 35). compartments with one or two 16-/20-pole terminal blocks
– Disconnect the control wiring. must be installed on the right hand side (in the cabIe
– Remove the control terminal block and its support, situated compartment). lf only one terminal block per support is
in the lower right hand side of the cable compartment. required, it must be installed in the upper part of the cut-out
– The left guide rail on the Iower compartment bottom plate in the support. The lower part must be covered by a cover
has to be removed. plate.
– Remove the cable connection unit (see fig. 35). – Connect the power cabIes with their protective covers and
Re-assembly (see figs. 7 and 53) also the control wiring.
– Install a new compartment bottom plate 200 mm from – lnsert three new size 8E withdrawable units.
the top and bottom of the old compartment and fix it with Contact the nearest ABB saIes office or representative should
screws. new material be required.
– Install a withdrawable unit condapter in the back of each
of the two newly created compartments (see fig. 7), one 5.4.3 Example 3: Conversion of 6 size 8E/2 units (height
for four size 8E/4 withdrawable units, one for two size 8E/2 200 mm) into one size 24E unit (height 600 mm)
withdrawable units. Conversion must be performed in the following sequence:
Disassembly
When installing a withdrawable unit condapter, – Pull out the 6 withdrawable units.
make sure that an earthing connection is – Disconnect the power and control cables and wiring.
established at the lower right screw connection – DisassembIe the two middIe compartment bottom plates
by using a bushing (GLBL210021P0001) and a with front posts and guide rails (see fig. 7).
washer A 6.4 (9ADA312-6) (see fig. 7). – Remove the guide rail and front post from the lower
compartment bottom plate (see fig. 7/9).
– 8 plastic guide rails must be installed, four for each – Take out the 3 withdrawable module condapters with their
compartment bottom plate. terminal blocks (see fig. 7).
– Install 3 front posts between two compartment bottom Re-assembly
plates for 8E/4 modules and one front post for 8E/2 – InstalI one outgoing cable connection unit depending on the
modules in the other compartment. module design. Two outgoing cabIe connection units can be
– Connect the power cables and control wiring. installed, depending on the current and whether a star-delta
– Insert four size 8E/4 withdrawable modules into the upper unit is used.
compartment and two size 8E/2 withdrawable units into the – Install the left guide rail on the lower compartment bottom
lower compartment. plate (see fig. 9).
Contact the nearest ABB-sales office or representative should – Install the roller and cover in the compartment bottom plate
new material be required. (see fig. 9).
– lnstall the control terminal block support with one or two
5.4.2 Example 2: Conversion of one size 24E unit 16-/20-pole control terminal blocks. When only one 16-/20-
(height 600 mm) into three size 8E units (height pole control terminal block is required, install it in the upper
200 mm each) part of the support and use a cover for the lower part of the
Conversion must be performed in the following sequence: support.
Disassembly – Connect the power cable and protective cover (see fig. 35)
– Pull out the withdrawable unit. and control wiring. An additional protective cover is required
– lf required,change the power cable or leave it for one of the for parallel connection of two outgoing cable connection
size 8E units if suitable. units.
– Disconnect the control wiring or Ieave it for one of the size – lnsert the new size 24E withdrawable unit.
8E units if desired.
– The compartment bottom plate with the guide rail and the
top compartment bottom plate remain unchanged.

1TTS900001M0203 | Service Manual MNS R 47

5.4.4 Example 4: Conversion of three size 8E units 5.5 Examination of MNS contact
(height 200 mm) into one size 24E unit (height 600
mm)
systems within the scope of plant
Conversion must be performed in the following sequence: revisions
Disassembly
– Pull out the 3 withdrawable units. According to the applicable national and international
– Disconnect the power cables after the protective cover has standards and provisions (e.g. DlN 57 105 part 1/ VDE 0105
been removed (see fig. 35). Thanks to the protective covers part 1; BGV A2), electrical plants must be maintained in an
on the adjacent outgoing cable connection units, work orderly condition by their operator.
inside the cable compartment can be performed without All the relevant MNS manufacturing instructions and MNS
danger. product information sheets must be observed and complied
– Take out the two upper control terminal bIock supports with with during work in connection with the tasks required for
their control terminal blocks. The Iower support may remain the aforementioned purpose, as well as all the relevant safety
unchanged or, if necessary, can be converted into one or regulations and provisions in force.
two 16-/ 32-pole control terminal blocks. When converting These include:
from two control terminal blocks to one, the remaining one – "Installation of power contacts"
must be at the top of the support while the space below – "Greasing of power contacts"
must be covered with a cover. – "Tightening torques of bolted connections"
– Dismantle the two middle compartment bottom plates which are also described in this chapter.
with their guide rails. The lower bottom plate need not be
changed (see fig. 9). Each module (withdrawable / plug-in module, fused SR
– Remove one or two of the outgoing cable connection units, elements, or withdrawable module condapter) is subject to
depending on the module design. Change the outgoing the following mandatory visual inspections prior to installation
cable connection unit when necessary. Two outgoing in the section (before first installation in the workshop as well
cable connection units must either remain or be changed, as after each revision).
depending on the current or whether a star-delta unit is Visual inspection of the contact system should include the
required. following items:
Re-assembly – Damage (e.g. worn silver or tin plating, signs of over-
– Connect the power cable and protective cover, and the heating, etc.) to the contacting surfaces of the MNS
control wiring (see fig. 35). contacts and their counterparts (distribution busbars,
– lnsert the new size 24E withdrawable unit. withdrawable module condapter, outgoing cable connection
Contact the nearest ABB sales office or representative should unit).
new material be required. – Contacts, movable and correctly fitted into position in the
rear wall of the withdrawable module or contact apparatus
housing.
– Misshapen contacts (bent), mechanical damage.
– Medium-force fitting of the contact spring (withdrawable
modules 8E/4 and 8E/2) into its specified position.
– Swollen insulation behind crimping.
– Contacts greased.

48 Service Manual MNS R | 1TTS900001M0203

If in doubt, measure the contact force using a special testing lf faults are detected, it is advisable to replace the contacts,
device. complete with the real wall for withdrawable modules 8E/2
Also if in doubt, measure the contact clearance with a slide and 8E/4 or the entire contacting system and/or to inform the
gauge or standard gauge. The value should be no more or ABB Service department in order to establish and coordinate
less than 4.7 +0.05-0.2 mm. further measures.

Please note: Disconnect the section from the power supply

Due to construction, the size of the contact opening for ≥ 4E before checking the distribution busbars or the
contacts need not be checked (e.g. using a gauge block). withdrawable module condapters!

Contact type Specification/ application Contact force Contact opening A

after production during normal operation
1TGB 100101 R... 50...90 N min. 40 N * not applicable

Power contact of withdrawable modules 4E...48E

and plug-in modules

GLBS 200520 R... 40...100 N min. 33 N * 4.7 +0.05

-0.2 mm

Power contact of small withdrawable modules 8E/4

and 8E/2 and of withdrawable modules 4E (outgoing)

GLBS 200502 R... reinforced 90...120 N min. 73 N * 4.7 +0.05

-0.2 mm
(values for earlier types on request)

Power contact of withdrawable modules 4E...48E

and plug-in modules

* Contact to be changed if contact force is below the given value

Fig. 54 Contact force and contact opening check list

1TTS900001M0203 | Service Manual MNS R 49

5.5.1 Maintenance procedure 5.5.1.3 Additional checks in case of doubt:
5.5.1.1 Regular visual inspection: If there is no visible damage but one of the following situations
It is advisable to visually check the MNS power contacts is discovered:
after every 100 mechanical movements of the withdrawable – The power contact has been in use for more than 1000
modules or every 2 years, whichever occurs earlier. operating cycles or more than 10 years.
If any of the faults described below is detected, it is advisable – No grease on the power contacts. Dark, discoloured (red-
to change the power contacts including, the connected brown to black), burnt or visibly melted contact grease.
cables. Counter-parts need only to be changed if specific – It is advisable to measure the contact pressure according to
damage is visible, as below. ABB guidelines. Please contact ABB Service for assistance
if measurement is required.
5.5.1.2 Checking procedure:
– Before performing visual checks: Note:
- Check the colour of the contact grease. Discoloured Contact pressure measurement is not a mandatory part of
contact grease (red-brown to black) is a first sign of the regular maintenance procedure. If the contact pressure is
overheating damage. below 40N, the power contact and the connected cable must
- Clean the grease from the power contacts. be changed.
– Check for visible damage to the power contact system, its
contact surface and their counter parts. Damage includes:
- Discoloured contact grease (red-brown to black).
- Worn silver or tin plating / visible bare copper on contact
5.6 Greasing of contact areas
tips or tracks.
- Melted spots on contact tips or in contact tracks. 5.6.1 Greasing of power contacts
- Signs of overheating, such as discolouring due to Greasing the contacts is a mandatory requirement if the
heat. operating cycles for which the unit is certified are to be
- Insulation of connected cables broken, melted or swollen. obtained, as grease reduces the wear on the contact area
Any other signs of overheating. finish. In addition, less force is required to withdraw the
- Plastic parts broken, melted or swollen. Any other signs of modules.
overheating. The contact areas of the power contacts must be cleaned
– Check that the contacts are movable and properly fitted in and greased whenever the following conditions apply:
position in the contact housing. – the assembly work and testing routines have been
– Check that the contacts have not become misshapen, bent completed in the workshop
or damaged. – after a revision or after 100 plug-in cycles or after 2 years,
– Check that the power contact spring is still in its original whichever is earlier
position, properly fixed and not loose. – immediately before installing the module in the section.
– Check that the connected cables are smoothly routed and
that the correct bend radii have been maintained. – Grease to be applied:
After the visual inspections or replacements have been made, Klüberlectric KR44-102 contact grease
the power contacts must be greased as described in sect. – Use a brush to apply the grease.
5.6. – Avoid excess grease on the contacts.
– If the modules are supplied as loose parts, they should be
greased at the building site.
– See figures 55 and 56 for the contact areas to be greased.

The contacts of the withdrawable module condapter are to be

treated similarily.

areas to be greased areas to be greased

Fig. 55 Power contacts for size 8E/4 and 8E/2 withdrawable modules Fig. 56 Power contacts for size 4E to 48E withdrawable modules
as well as the outgoing power contacts of 4E-withdrawable
modules

50 Service Manual MNS R | 1TTS900001M0203

The contacts of withdrawable modules supplied separately 5.7 Lubrication of withdrawable
should only be greased on site. The following numbers of 7 g
(8 ml) tubes must be supplied together with the modules for
module interlocks
this purpose: It may be necessary to lubricate the interlocks of size 8E/2
For 1 to 4 size 8E/4 and 8E/2 modules and 8E/4 withdrawable modules when they have been in use
– 1 tube each for some time (depending on the environmental conditions
For module sizes 4E to 48E and tightness). This is done by spraying the movable parts
– 8 contacts each 0.5 tubes with a lubricant (approx. 1 sec.). A functional test must be
For plug-in modules performed after this.
– up to 400 A, 8 contacts each 0.25 tubes Lubricant required:
– over 400 A, 8 contacts each 1 tube Molycote Omnigliss Spray, Liquid high-pressure lubricant in
300 ml tins
Prior to packaging for transport, the appropriate number of Manufacturer:
tubes must be fixed to the modules by the manufacturing Dow Corning GmbH
department (the tubes should be fixed to the handle of the D-65201 Wiesbaden/Germany
withdrawable module, at least one tube per packed unit. In the
case case of major deliveries to one customer, the grease can Lubrication of withdrawable module interlocks for module
also be supplied in tins). sizes 4E to 48E is not necessary during maintenance
Example: work.
– 1 size 8E module, 250 A (8 contacts) 1 tube
– 2 size 8E modules, 250 A (8 contacts) 1 tube 5.8 Installation of power contacts
– 3 size 8E modules, 250 A (8 contacts) 2 tubes
5.8.1 Installation
Identification numbers of the contact grease Once inserted into the rear wall of the withdrawable
Tin containing 1 kg of grease 1TGB000172R1000 module (1TGB120050P0001), or contact housings
Tube containing 7 g (8 ml) of grease 1TGB000172R0008 1TGB120048P0001 and 1TSA233000P0007, the contact
must be properly engaged. Successful engagement is
5.6.2 Greasing the fuse links indicated by a single, audible click, and can be checked by
The contact lugs of LV HRC fuses must also be greased each pulling the cable.
time, before being inserted into the fuse holder of any type of
switching device (OS / OESA, SLP / XLP, SR elements, etc.). Please note! The new contact does not click a second time
If the fuses are supplied loose, 0.5 tubes of contact grease like the old type once it has passed the engagement hook.
are required for each module (1 set = maximum 4 fuses for all
sizes). If the contact fails to engage properly, make sure that the
engagement hook is the right shape (e.g. free from burrs)
and that it is not broken. Parts with a misshapen or broken
engagement hook must be replaced.

Withdrawable module interlock

Spray lubricant several times in this point

and move switch handle ON and OFF.

Fig. 57 Lubrication of MNS 8E/4 and 8E/2 withdrawable module interlocks

1TTS900001M0203 | Service Manual MNS R 51

5.8.2 Testing Exceptions:
The withdrawable module assembly must be tested as follows A combination of contact material for the following systems,
prior to installation in the section (first installation and after where the contacts are not moved more than 30 times.
revisions): – SR- Switch disconnectors
– Visual inspection (the contacts must be free from visible – Plug-in modules (not railable modules)
damage). – RPC modules
– Contact opening size (refer to: Examination of MNS – Module condapters 8E/4 and 8E/2 (only the connection
withdrawable module design contact systems within the between the distribution busbar and condapter)
scope of plant revisions). – tin-plated busbars and contacts on the incoming side of
– Snapping in (it must not be possible to press the contacts a system and silver-plated busbars and contacts on the
back manually). outgoing side.
– Contact float (the contacts must not sit firmly in the
chamber, they must be able to move in all directions in All parts of the MNS busbar system are clearly marked “Ag” or
order to ensure tolerance adjustment). “Sn”.

5.8.3 Contact plating 5.9 Paintwork damage

Contact plating with silver or tin
Application of different platings 5.9.1 Preparation of the damaged area
– Silver (Ag) -> Standard Surfaces or areas soiled by grease/oil must be cleaned with
– Tin (Sn) -> Optional, if requested by the customer. an aliphatic cleaning agent using a linen cloth.

Identification 5.9.2 Repair

The type of plating cannot be distinguished visually. This is The paintwork repair set whose colour matches that of the
why the contacts are marked: installation to which it is attached (if ordered) must be used for
– on the contact fingers: impression of “Ag” or “Sn”. paintwork repairs.
All the hardening agent in the small container must be added
Combination of differently plated parts in one switchgear to the Iarger container filled with paint. The quantity of
hardening agent exactly matches the quantity of paint. After
Applies in principle to the withdrawable and hardening agent and paint have been thoroughly blended
railable technique: together, the mixture must be appIied by brush or lambskin
paint roller to the surface to be repaired.
It is not possible to combine busbars and Small marks can be touched-up, but the success of the
contact systems with different coatings! operation depends on surface preparation and/or "handling".

Contact forms:
A: up to 2 x 16 mm2
B: up to 35 mm2
C: up to 70 mm2

Fig. 58 Power contacts for 4E ... 48E withdrawable modules Fig. 59 Contact apparatus housing, cross-section

52 Service Manual MNS R | 1TTS900001M0203

5.10 Mechanical damage 5.11.4 Tightening torques
– SeIf-tapping screws in plastic material.
5.10.1 Preparation of the damaged area Max. tightening torque
When major damage to Iarge areas has occurred, the relative Screw Part Screw type Dimension Thermoplastics Pur
surfaces must first be ground with abrasive paper (grade 400). Number Duroplastics
mm Nm Nm
The damaged area must then be wiped with a linen cloth or
cleaned with compressed air to remove the dust. 1TGB 000 116 P.... TORX pan 4.2 2.0 -
and head tapping 5.5 4.5 3.5
1TGB 000 117 P.... screws
5.10.2 Repair 6.3 5.5 3.5

A filler material (aIkyd resin basis) must be applied flush with the
surface using a scraper. Leave the filler set over night. Lightly Bolt and Nuts, and Tightening Torque
grind the filled-in area then apply the paint as described above. – Insulating self-tapping screws.
Max. tightening torque
5.10.3 Materials
Screw Part Diameter Thermoplastics Pur
Colour: RAL .... (e.g. 7035, light-grey) Number Duroplastics
(2-component synthetic resin varnish) mm Nm Nm

Repair paint: RAL .... and hardener (paint repair set) GSIN 100073 P... 4.2 2.0 -
and
Filler: Alkyd resin base GILN 100107 P....
5.5 4.5 3.5
Cleaning agent: Aliphatic (e.g. white spirit) 6.3 5.5 3.5

5.10.4 Tools
– Metal self-tapping screws.
For cleaning: Linen cIoth (lint-free)
Max. tightening torque
Abrasive paper (grade 400)
Screw Part Diameter Steel plate Aluminium plate Copper busbar
For painting: Brush or lambskin paint rolIer Number
For repair: Scraper Thre- Thre- Thre-
ading ading ading
height height height
mm mm Nm mm Nm mm Nm
5.11 T ightening torques for screw HZN 451307 P... M3 1.5 1.0 3 1.0 - -
GILN 100082 P... M4
connections 1.5 2.0 3 2.0 - -
M5 1.5 4.5 3 4.5 - -
M6 2.0 5.5 3 5.5 - -
5.11.1 Scope of application M8 3.0 9.5 3 5.5 5.0 9.5
The figures given apply to system screw connections and
busbar screw connections on busbars with σ02 ≥ 70 N/mm2
(Cu, Cu/Al, AlMgSi 0,5) in the MNS switchgear system. – Busbar (Cu) and system (steel-steel) connecting screws.
The values are not applicable to electrical equipment Screw type Diameter Max. tightening torque
Nm
connections and mountings. mm

}
DIN 931 hexagonal-head screw
Exception: DIN 933 hexagonal-head screw
DIN 912 cheese-headed screw M6 8
They do however apply to the mountings of equipment with M8 20
With or without ESLOK safety,
sheet steel bases and the connections of electrical equipment Resistance class 8.8 A2G M10 40
M12 70
when this is made with flat copper terminals and bolts and Hammer-head screw
GMN 325 116 P... M16 140
nuts in tensile class 8.8.
Screw with SR adapter

Note:
Consult the manufacturer's technical data sheet for the
equipment connections and mountings.

5.11.2 Screwing/Bolting accuracy

High-accuracy torque tightening equipment should be used.
This must be adjusted so that the maximum torquing value
(including tolerance) of each adjustment step does not exceed
the given tightening torques in the tables.

5.11.3 Testing torque

The testing torque is the preset vaIue of the tightening
equipment minus 15%.

1TTS900001M0203 | Service Manual MNS R 53

5.12 Commissioning and maintenance 7. Perform a visual inspection of the electrical equipment.
(Leaks such as oil leakages, bulging of the capacitor lid
of MNS reactive power or housing, condition of terminals, switches, protective
compensation systems devices, reactors, discharge resistors, conductors.)
8. Check protective devices and switches for faultless
5.12.1 Commissioning and maintenance operation.
In the worst case, compensation systems are permanently 9. Clean the modules as well as the air supply and air
operated at their maximum power. This means that good exhaust regions of each section (ventilation louvers, filter
ventilation must be ensured in the installation site in order to mats).
prevent the ambient temperature from exceeding the max. 10. Check bolted connections and clamping units.
admissible limit of 35 °C (mean value over 24 hours). 11. Measure capacitances and log measured values. (The
Faulty operation or insufficient compensation power can be capacitances of the compensation capacitors may
best determined (although too late) by checking the reactive change due to inadmissible heat rise, expiry of useful
power demand (electricity bill). If the following points are life, overvoltages, etc. Experience has shown that the
noted during commissioning and regular maintenance work, inductance values are not subject to major changes).
a loss in compensation power can be detected at an early Please note:
stage. Before measuring capacities, discharge resistors must be
1. Check ventilation in the place of installation. disconnected from capacitors. Setpoint values are given on
2. Check the construction: the module name-plates.
a) Air must be supplied and exhausted above
and below each individual module (or modules). 5.12.2 Correction of faults
b) There must be at least 4 ventilation slots if the bottom If faulty operation occurs during commissioning, the section
plate of the section is closed (no air supply through wiring (especially in the area of the transport partition) should
bottom plate). be checked first.
c) There may be no compartment bottom plates or other Other possible faults include the following:
installations in the section that could adversely affect – Controller display remains dark:
ventilation. - Check control voltage.
d) Forced ventilation (or less equipment) is required for – Controller does not switch in additional steps (although
protection class > IP 32 or installations which deviate request is available):
from c) above. - Measuring voltage or current not, or wrongly, connected.
3. Check the settings and operation of the controller - Check fuses.
(switching outputs). - Wrong transformer ratio.
4. Check contactors for sparking when switching and - Lowest step power too high.
for faultless making and breaking operations. The - Inappropriate C/k value setting / value too low.
maintenance intervals of the contacts of the capacitor – Controller switches very often:
contactors, depending on their number of switching - Switching time (too) short with quick load changes.
operations (can be read off ESTAmat® RPR), are subject - Step power too low.
to the manufacturer´s instructions. - Wrong C/k value setting.
– cosϕ setpoint not reached:
- Lowest step power too low.
Do not operate capacitor-contactors by hand! - Inductive current too low.
– All steps are permanently active:
5. The current consumption of the system and the modules - Undercompensation, i.e. installed leading reactive power
provides an indication of loss in capacitance if a is not sufficient.
capacitance test (which requires safety disconnection - Check control voltage.
of the compensation system) is not possible. In this - Check LV HRC fuses of the modules.
case, the currents and voltages in each phase must - 5 A transformer connected to 1 A controller measuring input.
be measured simultaneously. (However, current – Too many steps active (overcompensation):
measurement is only a rough criterion, in view of possible - Check transformer installation.
current distortions caused by harmonic waves!) - Check controller settings.
6. Before touching the capacitors: - Wrong measuring voltage connection (phase-phase and
a) Wait for at least one minute until the capacitor is phase-N exchanged).
discharged. – cosϕ display does not coincide with additional power
b) Protect the system against reclosing. factor meter reading:
c) Verify safe isolation from supply. - wrong voltage measuring connection (phase-phase and
d) Short-circuit the capacitor terminals among each phase-N exchanged).
other and with the housing in order to compensate for - slight deviations may be due to inaccurate measuring
differences in potential. units and/or different measuring points.
e) Protect neighbouring live parts against accidental
contact.

54 Service Manual MNS R | 1TTS900001M0203

5.13 Measuring of the insulation For which protective measures do you have to measure the
insulation resistance?
resistance
Insulation measurement is of fundamental importance to The insulation resistance must be measured for all
an electrical system. Furthermore, it is the only type of protective measures! This refers to protective measures
measurement that serves for preventive fire protection. without protective conductor and with protective conductor.
The insulation resistance is a complex resistance in the
form of a parallel connection of an ohmic resistor RW and a Insulation measurement is required according to
capacitance C. DIN VDE 0100, but also to other standards, such as
The equivalent resistance is a variable quantity that is – IEC 61439-1, Section 11.9,
influenced by various parameters. – EN 60204,
This is illustrated by the following equivalent circuit diagram: – DIN VDE 0105,
– VDE 0110.

5.13.1 Which insulation measurements have to be perfor-

med?
DIN VDE 0100 part 610 specifies insulation measurement
between the conductors in Section 5.3:

If the circuits contain electronic components,

such as semiconductors, these sensitive
components must by no means be damaged by
the high measuring voltages.

R W: constant equivalent resistance Measurement may also be performed with the consumer
R D: dielectric resistance equipment connected. If the insulation resistance is too low in
R U: voltage-dependent resistance this case, the consumer equipment must be isolated, and the
R i: current-dependent resistance system and consumer must be measured separately.
Rt time-dependent resistance Prior to commissioning, the following circuits must be
measured:
– All line sections between any 2 overcurrent protection
devices.
– The section following the last overcurrent protection device
without any connected consumer equipment.

Procedure Required measurement Remarks

1. Between the outer conductors and the L1
L2
protective conductor L3
N

RIsol RIsol R Isol

PE

2. Between the neutral conductor and the L1 Separate the PE and N conductors!
L2
protective conductor L3 This measurement is not required in the TN-C network.
( ) N

Offen
RIsol

PE

3. Between the outer conductors L1 This measurement is not required:

L2
L3 - if the cable includes an earthed conductor or an
N earthed sheath;
- for switch leads in lighting circuits.
R Isol R Isol R Isol

L1-L2 L1-L3 L2-L3

PE

4. Between the outer conductors and the L1

L2
neutral conductor L3
N

R Isol R Isol R Isol

PE

1TTS900001M0203 | Service Manual MNS R 55

5.13.2 Which minimum insulation resistance must be tests without, however, detailing concrete terms for the test
available? cycles. Repetitive tests allow the proper condition of electrical
In order to exclude the influence of the capacitive reactance, systems and equipment to be assessed.
the measurements must be performed with DC voltage. Repetitive tests include:
For the values of the measuring voltage and the minimum – a visual inspection
insulation resistance, please refer to the table below. – trial runs
Protective measure Measuring-circuit Minimum insulation
– measurements
and rated voltage voltage DC [V] voltage value [MΩ] – other tests.
Extra-low safety voltage, extra- 250 ≥ 0.25
low functional voltage with safe
5.14.2 Maintenance of MNS switchgear systems
isolation
Protective separation 500 ≥1 5.14.2.1 General safety instructions
Rated voltage ≤ 500 V, and extra- 500 ≥ 0.5
low functional voltage without The system or component must be
safe isolation
disconnected from the circuit before the
Rated voltage > 500 V, ≤ 1000 V 1000 ≥1
switchgear can be cleaned inside. It is
inadvisable to use compressed air for cleaning
5.14 Maintenance intervals dusty systems.

5.14.1 General Safety at work:

5.14.1.1 Legal conditions The procedure for performing switching operations is
Electrical switchgear and controlgear systems require prescribed by the implementing instructions in BGV A2, §6.
permanent preventive maintenance not only for technical The off-circuit condition must be established prior to
and economic reasons. In an effort to define due order in commencement of the work and must be ensured at the
the energy sector, the government dictated a number of place of work for the duration of the work itself, in compliance
legal provisions from which the requirements of preventive with the following five safety rules, which must be applied as
maintenance can be derived. a standard:

5.14.1.2 Preventive maintenance Five safety rules

At the moment, no technical standard provides
comprehensive guidance on the preventive maintenance of Before starting to work:
electrical distribution networks and equipment. – Safety isolation
The principles require electrical systems and equipment to be – Protection against re-closing
operated in accordance with the rules of electrotechnology, – Verify off-circuit condition
which include preventive maintenance. – Earthing and short-circuiting
– All defects must be immediately remedied. – Apply a cover or barrier to adjacent live parts.
– In the event of imminent danger, electrical systems must no
longer be operated. These five safety rules must be observed as safety measures
for work on electrical systems and equipment.
Even the provisions of DIN 57105 part 1/VDE 0105 part 1
do not contain any specific requirements beyond general 5.14.2.2 Health and safety
information about the preventive maintenance of electrical Please note the following information:
systems. The most important information on preventive – In accordance with the regulations in force, installation and
maintenance is summarized in item 5, "Preservation of proper maintenance work involving MNS-switchgear systems must
condition and repetitive testing". This item stipulates that only be performed by qualified personnel.
high-current systems must be kept in proper conditions in – Before low-voltage switchgear system components can be
accordance with the standards governing their installation. handled, the component in question must be isolated!!!
Power supplied to the capacitor by a remote auxiliary power
Defects in electrical systems must always be source, if any, must also be isolated.
remedied immediately, i.e. without any culpable – When the system has been isolated, wait for one minute to
delay. If danger to persons, property or the allow the voltage stored in the capacitor to be discharged
environment is imminent, defective electrical by the discharging resistors. As an additional safety
systems or equipment must be immediately measure, the outgoing capacitor circuits must be tested for
put out of operation. They must not be used in the discharged condition using an insulated cable.
defective conditions. – Make sure that the current transformers were short-circuited
before they were isolated or connected.
A switchgear system is defective if safety is jeopardized by its – Automatic capacitors must be installed in accordance with
operation. IEC 60831-1&2 standards and all national regulations.
In order to be able to promptly recognize any defects that – A short-circuit may pose dangers to human life and
may have occurred after electrical systems have been destroy equipment! Therefore, it is of vital importance to
commissioned, repaired or modified, DIN 57105 part 1 / use suitable tools and instruments for commissioning or
VDE 0105 part 1 requires the performance of repetitive inspecting electrical systems.

56 Service Manual MNS R | 1TTS900001M0203

5.14.3 Maintenance and inspection of MNS switchgear 5.15 Servicing Tmax XT1 and XT2
systems
5.14.3.1 General
mechanisms in MNS R (8E/4 and
– To prevent the acceptable risk limit from being exceeded, 8E/2)
operation and maintenance must be performed with the
utmost care, especially in the case of systems associated The apparatus must be checked (condition, function, damage)
with a higher risk (e.g. nuclear power plants). and greased after 1000 operation cycles or once a year.
– Please refer to the relevant product documentation for ABB recommends Liqui Moly® (TYPE LM 47) with ABB ID
information about the mechanical and electrical life of 1TGB000235P0001. After greasing, make sure that there
electrical equipment. is no dust or dirt on the modules as this may impair the
– All maintenance work and the required tightening torques switching mechanism.
for the electrical equipment in use must also be carried
out in accordance with the manufacturer´s mandatory Step 1: Removal of the top cover
instructions. Remove module from switchgear and place it on a flat work
surface.
5.14.3.2 Maintenance intervals Remove the side walls of the module according to the
instructions on the back walls and remove the top cover of
1. General visual inspection (repetitive tests) the Tmax XT mechanism as shown in figure 1 and 2 with a
1.1 External inspection tool.
1.2 Completion of the interior Note: Please ensure that none of the four location fasteners is
1.3 Switchgear and controlgear assemblies (withdrawable damaged when the cover is removed.
or plug-in modules)
Step 2: Greasing
2. Additional inspections As shown in Figure 3, the apparatus must be greased with
2.1 Withdrawable technique a brush in the following points: with the MCCB in the “Off”
2.2 Plug-in, disconnectable, railable technique position (see figures 4 and 5) and with the MCCB “On”
2.3 Direct connection of incoming and outgoing power position (see figures 6 and 7).
feeders to circuit breakers Use approximately 0.5 g of grease for each of the four
positions.
5.14.3.3 Notes about the inspection lists on the following
pages Step 3: Top cover fixing
– The frequency refers to time intervals (monthly, annually, The top cover must be correctly positioned on the Tmax XT
etc.), service hours, starting frequency, etc. apparatus. Check that all fixing hooks fit into their positions.
The following abbreviations are used to denote the
frequency: Step 4: Inspection before putting into service:
m: monthly – Visually check that the unit is in a good condition
a: annually – Check that the unit functions correctly by performing about
n: insertion cycles of modules five operations before switching in the load: opening,
x: test in the event of a fault (e.g. after a short-circuit) closing, relay or MCCB tripped
– Check that the test button of the MCCB is free and
– “Installation category” column accessible. It must be possible to use the test function of
A distinction is made between the following installation the Tmax XT breaker with a tool, e.g. a screwdriver.
categories, since maintenance or inspection frequency
depends on the operating conditions: Part Numbers:
Installation category A: Normal operation Module side walls HANL200009P0001 (MNS)
Installation category B: Heavy-duty operation, e.g. XT top cover 1TGB120132P0001
cement factory
Installation category C: Short circuit (fault)

1TTS900001M0203 | Service Manual MNS R 57

Figs. 1 and 2: Cover removal

Fig. 3: Grease on the tip of brush

MCCB switched to the

Off position

Grease the bowden wire

on the cable in the channel
on the pull on side

Grease the bowden wire

on the right side of the rotary
unit

Figs 4 and 5

MCCB switched to the

On position

Grease the bowden wire in

the channel on the pull off
side

Grease the bowden wire on

the left side of the rotary unit

Figs. 6 and 7

test button

Fig. 8: Test button

58 Service Manual MNS R | 1TTS900001M0203

5.16 M aintenance and Inspection List
Frequency
Install. category
Item Work to be performed Measured, test and limit values, operating and A B C Remarks
no. auxiliary materials
1.0 General visual inspection
(repetitive tests)
1.1 External inspection
1.1.1 Check ambient conditions – Room temperature ≤ 35 °C
– Air, aggressive gases etc. 1y 6m X Unpleasant smell
– Relative humidity ≤ 50% at 40 °C Auxiliary heating
possibly required
– Dust
1.1.2 Check ventilation system (efficiency) 1y 6m X
– Operating room – Unobstructed air supply to and air exhaust from section
– Switchgear system – max. temperature inside the section: ≤ 60 °C Touch front surfaces
with hand. Check
section if hand-warm
spots are found
1.1.3 Check condition of enclosure / – Damaged / corroded 1y 6m X
external paint – Missing parts such as module doors or covers
– Ventilation louver dusty / covered
– Roof plate dirtied / covered / obstructed / etc.
– Fastening of cable compartment doors, side and back
panels
– Position of withdrawable modules in the section (operating
or isolated position)
– Cable / equipment compartment doors closed / open
1.1.4 Accessibility – Escape route ≥ 650 mm 1y 6m X
Inspection of insulation resistance
Measure the insulation resistance in accordance with the procedures indicated for starting. Measured values should not be very different from those
detected at the start.
If the insulation level is notably less, perform voltage tests. It is better to measure the insulation resistance before the voltage tests. If the insulation
resistance has decreased, identify the crush point.

1TTS900001M0203 | Service Manual MNS R 59

 Frequency
Install. category
Item Work to be performed Measured, test and limit values, operating and A B C Remarks
no. auxiliary materials
1.2 Completion of the interior
1.2.1 Equipment compartment
– Check filling factor and equipment – Position of modules in accordance with engineering 1y 6m X
documents
– Internal conditions – Contamination, e.g. dust Clean
– Blackened contact surface Clean with a cloth and
solvent
– Loosened screw Tightening torque
indicated in sect. 5.11
Circuit breakers – See the relative installation, operation and maintance Perform the suggested
instructions maintenance
procedures
1.2.2 Cable compartment / cable terminal – Incoming feeder in accordance with documents (busbar / 1y 6m X
compartment cable laterally / top / bottom)
– Sufficient room / strain relief
– Cable routing; bend radii
Personal protection / protective – Protective cover
cover
1.2.3 Busbar compartment
– Check transport connections – Loosened screw Tighten to indicated
tightening torque
– Color changes at bolted connections 1y 6m X Check using thermo-
vision exposures
– Proper installation of cover in partition wall 3
– Check busbar supports – Contamination or flashover
– Formation of cracks or splits
– Visual inspection of the condition – Shrink-on tube brittle
of the busbar insulation
– Insulating busbar holders – Dust Remove the dust
– Cracks Replace the damaged
busbar
– Discharge marks Holders
1.2.4 Earth busbar joints and relalated – Copper Oxide Remove the oxide by
connections means of file or an
emery cloth and clean
with cloth and solvent
– Loosened screw Tighten according to
indicated tightening
torque
1.2.5 Main power feeding busbars, – Discharge or smoke marks Clean with solvent. If
distribution busbars, connections necessary replace the
between busbars and circuit damaged part
breakers
Inspection of insulation resistance
Measure the insulation resistance in accordance with the procedures indicated for starting. Measured values should not be very different from those
detected at the start.
If the insulation level is notably less, perform voltage tests. It is better to measure the insulation resistance before the voltage tests. If the insulation
resistance has decreased, identify the crush point.

60 Service Manual MNS R | 1TTS900001M0203

 Frequency
Install. category
Item Work to be performed Measured, test and limit values, operating and A B C Remarks
no. auxiliary materials
1.3 General inspection of
the switchgear assembly
(withdrawable or plug-in,
disconnectable, railable
technique)
1.3.1 Design of conductors and conductor Condition of insulation 2y 1y X Measure the insulation
installation resistance
1.3.2 Check electrical equipment installed – Bracing Comply with
– Check contact corrosion, contact gaps, ionization chamber the equipment
arc splitter, rated currents, settings and tripping manufacturer‘s
instructions for
full maintenance
indications
– Minimum creepage distance ≥12.5 mm
– Check minimum clearance for arcing space See equipment
manufacturer
1.3.5 Required protection class – EN 60529
1.3.6 Check efficiency of protective – Check continuity with signal test apparatus 2y 1y X
conductor connection
1.3.7 Functional test of the control device – In accordance with circuit diagram 2y 1y X Control connection
cable.
1.3.8 Check measuring loops – In accordance with circuit diagram 2y 1y X
2.0 Additional checks
2.1 Withdrawable technique
2.1.1 Compact modules (8E/4 + 8E/2)
– Make sure that module moves – Remove dust and grease from guide rail if necessary 2-3y 1y X
easily
in compartment
– Functional test of mechanical – Lubricate with Omnigliss 2-3y 1y X
interlock
– Check electrical contact-making 2y 1y(1) X
- Main contacts – Visual inspection Consult
– In case of doubt check contact clearance Sect. 5.5
- Control plugs
- Visual inspection of module – Remove dust from guide rail with vacuum cleaner
compartment
– Operate limit switch rocker (if available)
– Check condition of mating contacts Artificial light source
– Check efficiency of protective – Check cam condition at supporting rail
conductor con-nection
Compact modules (8E/4 + 8E/2 +
6E/4 + 6E/2) with Tmax XT
– Clean the module – Remove dust
– Check the mechanism – Visual inspection and switching test without load
– Lubricate mechanism – Greasing 1y 6m X Consult sect. 5.19
2.1.2 4E withdrawable modules
– Make sure that module moves
easily in compartment
– Functional test of mechanical
interlock
– Check electrical contacts
- Main contact – Visual inspection 2y(1) 1y(1) X Refer to
– Check contact force Sect. 5.5
– Greasing Consult sect. 5.6
- Control plug
– Fastening of outgoing cable unit – Position; the outgoing cable unit could have been pressed
out of its normal position by strong cable forces
– Protective conductor connection – Condition of the roller in the compartment bottom plate
1)
Check the main contact either according to the indicated the mentioned time intervals or after 100 cycles at the latest.

1TTS900001M0203 | Service Manual MNS R 61

 Frequency
Install. category
Item Work to be performed Measured, test and limit values, operating and A B C Remarks
no. auxiliary materials
2.2 Plug-in Also see item
No. 1.3: General
inspection
2.2.1 MCC’s and outgoing energy
distribution feeders
2.2.2 Compensation modules with and
without reactor
Check electrical equipment in every 1y 6m X Check contact gaps,
module contact condition and
whether lubrication is
necessary
– Visual inspection of main
contacts X01
– Condition of short-circuit Control connection
protection cable.

- LV HRC fuse – Fuse continuity Consult sect. 5.6

– Fuse tripped Signs of overload by
mains
- Circuit breaker – Contact condition Resonance in
accord-ance
– Lubricate contact blades – Klüberlectric KR44-102 with manufacturer´s
of LV - HRC fuses
– Check capacitor contactor instructions
- Check for contact corrosion – Contact condition
- Switching performance – No humming, bouncing or chattering of reactor
– Visual inspection of filter circuit
reactor
Connections and windings – Condition
– Capacitor – See sect. 5.15 for the setpoints Use measuring log
- Design without reactor: – Limit value: IB ≤ 1.3 x In according sect. 5.17
measure all step currents
3-phase or capacitance values
- Design with reactor: measure
the terminal capacitance
– Discharging device
- Reactor – Residual voltage after 1 min ≤ 50 V
- Resistor bank – Color change, missing elements
– Cable connection – Insulation melted or even corroded
– Screwed connection at electrical – See manufacturer‘s instructions for tightening torque
equipment
- Insulation
Check controller module
– Check controller settings
- C/k value – In accordance with manufacturer´s operating instructions
- cosϕ setpoint Power circuit open,
i.e.
- response time – Approximate value 60 s fused switch discon-
– Check step triggering nector removed
1)
Check the main contact to be checked either according to the indicated the time intervals or after 100 cycles at the latest.

62 Service Manual MNS R | 1TTS900001M0203

1TTS900001M0203 | Service Manual MNS R 63
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Service Manual - 1TTS900001M0203 - 2016.07 (gs)

The data and illustrations in this publication are subject
A Division of ABB S.p.A. to change on the basis of technical progress.
Low Voltage Systems
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