Automation Products

Low Voltage Switchgear MNS System Overview

Inroduction to the MNS System

ABB is the global leader for production of a wide range of low voltage energy distribution systems. In 1992 ABB started operations in Baltic States. Low voltage systems factory in Keila (Estonia), offers to its customers a wide choice of switchgear systems inclusive of the MNS system. Permanently developing the product range, ABB draws wealth of background experience in project management and low voltage switchgear manufacturing for its customers, as well as offers a great command of state-of-the-art technologies. The MNS low voltage switchgear system is designed and built to be the heart of any modern, highly automated motor control or power distribution system. The consistent application of the modular principle both in electrical and mechanical design as well as the use of standardized components allows its flexible and compact design. Depending on customer requirements, operating and environmental conditions different design levels are available.

System safety is confirmed with plenty of type-tests according to IEC 60439-1 such as: verification of temperature rise limits, verification of dielectric properties, verification of the short-circuit withstand strength, verification of the effectiveness of the protective circuit, verification of clearances and creepage distances, verification of mechanical operation, verification of the degree of protection. In addition ABB adopted as a standard IEC 61641 for testing under conditions of arcing due to an internal fault. Earthquake-, vibration- and shock-proof designs are available. It is no surprise that the MNS system is the benchmark for operational safety, reliability and quality. MNS proves to have the approved solutions for pulp and paper, metal and petrochemical industry, power stations, shipbuilding industry and marine applications, and also for infrastructure objects (such as waste water treatment plants, airports, hospitals, data centres, etc.) Safety, unique design and innovativeness of the MNS system, as well as global service and support network ensure that the choice of MNS will be the right decision.

2 Inrod u ction to the MNS System | LV Switchgear MNS

Switchgear Design

The MNS switchgear is divided into separate equipment, busbar and cable compartments. The design solutions used clearly decrease the possibility of damages occurring to components inside the switchgear. In the unlikely event of arcing, damage is localized in the compartment where the arc occurred. This allows fast repair and recommissioning of the switchgear. The basic elements of the MNS frame construction are C shaped steel profiles with a 25 mm (=1) hole pitch according to DIN 43660. The profiles are galvanic protected (Zn or Al/Zn) against corrosion. The assembly is maintenance free. MNS switchboard enclosure is made of sheet steel protected by galvanic coating and powder coating for maximum durability. Final construction varies depending upon the required degree of protection (IP) In accordance with the general safety philosophy followed with MNS, each compartment and sub-compartment which requires access for commissioning, operation or maintenance, has its own door. The MNS main busbar system is arranged in the rear of the switchgear in the busbar compartment. This assures a maximum distance between the busbars and the operator and maintenance staff. Special fastening method guaranties safe connections during the whole life cycle without the need of additional tightening. Main busbars are divided into sections depending on transportation units. Main busbars can be ma-

nufactured from aluminium or copper. As option fully insulated solution utilizing heat shrinkable sleeving is available. Copper or aluminium (optional) distribution busbars run vertically the full height of the cubicle and are used for feeding of outgoing modules. In case of withdrawable module solution distribution busbars are manufactured from silver plated copper and embedded into a multifunction wall. The multifunction wall is a unique MNS design. It constitutes a complete barrier between the main busbars and the equipment compartment. The distribution bars are fully phase segregated and insulated. This design makes it virtually impossible for an arc to pass between distribution bar phases or between main busbars and equipment compartment. System highlights: Maintenance free busbar construction Easy switchgear extension Main busbar arrangement at the rear thus assuring maximum safety to personnel effective withstand against highest stresses in case of short circuit optimum heat dissipation Gas tight seals for connection from the equipment compartment to the main busbars system Option for Form 4 separation for both incoming and outgoing assemblies Active and passive arc fault prevention tested according to IEC 61641 Isolating materials are free of CFC and halogens

MNS frame with copper main busbars and L-shaped silver coated distribution busbars for withdrawable modules

Installation of busbars (from left to right: busbar cover, distribution busbars, multifunctional wall, main busbars) LV Switchgear MNS | Switchgear Design 3

Different Module Application

The MNS system offers different standardized solutions for incoming and outgoing feeders.

Switchgear requirements differ from project to project. The MNS system easily allows the assembly to be configured to M S S s i p e c t M N S S D s i n A s p c M Ni S iD Se D e sn ig gA ns A s p e ct ts s MN N S i Si D e se ig g n A s p e ce ts s suit all technical conditions and plant operational procedures M S S s i n A p e c t M N S S D s i n A s p c M Ni S iD Se D e s ig g ns A s p e ct ts s MN N S i Si D e se ig g n A s p e ce ts s M N S i S D e s i g n A s p e c t s Interlocking System/Operating Handle Position and to decrease operational expenses and when possible Interlocking System / Operating Handle Position Interlocking System / Operating Handle Position Interlocking System / Operating Handle Position Interlocking System / Operating Operating Handle Position general investments. Interlocking System / Handle Position Interlocking System / Operating Handle Position Interlocking System / Operating Handle Position Interlocking System / Operating Handle Position Position Mechanical Electrical status Interlocking System / Operating Handle Position Different types of modules can be combined in one common switchgear. The MNS switchgear with fixed outgoing modules , in which all electrical connections made with screws and bolts are fixed, has proved to be a reliable solution. The front door is locked, when the main switch is on. The door can be opened for visual inspection of the equipment without interrupting the supply by using a specially designed method. Fixed modules are used for power distribution feeders with circuit breakers or fuse switches or for motor starters. The withdrawable module technique has proved to be the appropriate solution for use in industrial applications where requirements for high availability are a must particularly in Motor Control Centres (MCC). All electrical connections are realized using sliding contacts, what makes possible fast and easy exchange of modules under live conditions.
6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2 6E/4, 6E/2

Withdrawable modules are operated with the multifunction operating handle. This handle also activates the electrical and mechanical interlocking of the module and the module door. No further tools or unlocking devices are necessary to withdraw a module. Thus replacing a module takes less then a minute.

Position Position Position Position Position Position Position Position Position 8E/4, 8E/2 4E40E Designation

status Mechanical status statusMechanical Mechanical status

Module Padlock Module Padlock Module drawPadlock Withdrawable Mai Designation Designation 6E24E inter-interlocked possible switchWithdrawable circuit 6E24E Module Padlock Designation possible contacts swit 6E24E Designation interlocked possible contacts s Module Padlock Mai 6E24E Module Padlock Withdrawable interlocked possible contacts s Module able Padlock Withdrawable Withdrawable locked interlocked possible contacts swit Designation 6E24E Module Padlock Withdrawable Mai Designation 6E24E Module Padlock Withdrawable Designationinterlocked 6E24E Designation possible contacts switc interlocked possible contacts s 6E24E Designation interlocked possible contacts s 6E24E contacts interlocked possible contacts switc interlocked possible contacts s ON ON position position g g position ON ON ON position g g ON ON position g g position ON position (I) g position ( I ) ON ON position g position ( I ) g (I) (I) ( I ) (( II )) ( I )( I )

Mechanical status status Mechanical Mechanical status Mechanical status Mechanical status Mechanical status Module Padlock WithMain

Electrical Electri Electri Electrical Electrical Electric Electri Electrical Electric Control Withdrawable Withdrawable Mai

3 3 33 3 3 33 3 3 3 33 3 3 33 3 3 3 33 3 3 33 3 3 3 33 3 3 33 3

OFF position OFF position OFF position OFF OFF position OFF position OFF position OFF position position (position O) ( OFF OFF position (O O) ) ( O ) (O) (O) (( O O )) (O) (O)

3 3 33 3 3 33 3 3 3 33 3 3 33 3 3 3 33 3 3 33 3
or or or or or or or or or

Test Test position position Test position Test position Test position Test position Test position Test position Test position Test position

Thanks to the specially constructed power contacts and use System Highlights: System Highlights: System Highlights: of the multifunction wall, full phase segregation is assured Withdrawable modules are mostly used for motor starters up System Highlights: System Highlights: System Highlights: System Highlights: System Highlights: Highlights: prior to the connection of the power contacts to the distributi-x System to 355 kW. MStart can be replaced while switchboard is energized x M can be while switchboard is MStart Start can be replaced replaced while switchboard is energized energized x xMStart can be replaced replaced while switchboard is energized energized M Start can be while switchboard x x Integrated contact system and sensors x Integrated system and sensors M can be while switchboard is x MStart Start can be replaced replaced while switchboard is energized energized on bars. That design minimizes the possibility of an accidentalx Integrated contact system and sensors is x x M Start can becontact replaced while switchboard is energized Integrated contact system and sensors M Start can be replaced while switchboard is energized x Integrated contact system and sensors x x Power loss reduction due to separation of control components permits high-density x Power loss reduction due to separation of control components permits high-dens Integrated contact system and sensors Integrated contact system and sensors x Power loss reduction due to separation of control components permits high-densm x Integrated contact system and sensors Power loss reduction reduction due to separation separation ofare control components permits high-density m arc occurrence. control diagrams available on request. xStandard Integrated contact circuit system and sensors x xPower loss due to of control components permits high-density m ment in the switchboard ment in the switchboard Power loss reduction due to separation of control components permits high-densi
ment in the switchboard ment in switchboard ment in the the switchboard ment in the switchboard ment in the switchboard

Disconnected Disconnected Disconnected Disconnected Disconnected position position Disconnected position Disconnected position Disconnected 30 mm position Disconnected Disconnected position position (isolated position (Isolated 30 with- 30 mm (Isolated position position 30 mm mm (Isolated 30 mm (Isolated position) withdrawn position) withdrawn position) drawn 30 mm (Isolated 30 mm (Isolated withdrawn position) 30 mm (Isolated withdrawn position) 30 mm (Isolated 30 mm (Isolated withdrawn position) withdrawn position) withdrawn position) Moving Moving withdrawn Moving position) withdrawn position) Moving Moving g g g g Position position Position Moving g Moving Position Moving g g g Position Moving removal g or g Moving (withdrawn Position g g Position g g Position removal removal (Withdrawn g (Withdrawn g Position g possible g removal Position (Withdrawn position) removal (Withdrawn possible possible position) position) removal (Withdrawn removal (Withdrawn possible position) removal (Withdrawn possible position) removal (Withdrawn removal (Withdrawn position) possible position) possible position) possible possible position) possible position)

x Power loss reduction due to separation separation of control control components permits high-densm ment in the switchboard x x Power loss reduction due to separation of control components permits high-density ment in the switchboard Power loss reduction due to of components permits high-densi

MNS withdrawable modules:

Module Connection to Distribution Bars Module Connection to Bars Module Connection to Distribution Distribution Bars Module Connection to Distribution Distribution Bars Module Connection to Bars Module Connection to Distribution Bars Module Connection to Distribution Bars Module Connection to Distribution Bars A Module condaptor unit facilitates the horizontal A condaptor unit facilitates the horizontal Connection to Distribution Bars condaptor unit facilitates horizontal A A condaptor unit facilitates thethe horizontal A condaptor unit facilitates the horizontal distribution of power from thethe vertical distribution distribution of power from vertical distribution A condaptor unit facilitates the horizontal A condaptor unit facilitates the horizontal distribution of power from the vertical distribution A condaptor unit facilitates the horizontal distribution of power from the vertical distribution A condaptor unit facilitates the horizontal distribution of power from the vertical distribution bars for for 6E/4 and 6E/2 modules. The condaptor bars 6E/4 and 6E/2 modules. The condaptor distribution of from the vertical distribution distribution of power power from the vertical distribution bars for 6E/4 and 6E/2 modules. The condaptor distribution of power from the vertical distribution bars for 6E/4 and 6E/2 modules. The condaptor distribution of power from the vertical distribution bars for for 6E/4 and 6E/2 modules. The condaptor enables the modules to be located adjacently enables the modules to be located adjacently bars 6E/4 and 6E/2 modules. The condaptor bars for 6E/4 and 6E/2 modules. The condaptor enables the modules to be located adjacently bars for for 6E/4 and 6E/2 modules. The condaptor enables the modules to be located adjacently bars 6E/4 and 6E/2 modules. The condaptor enables the modules to be located adjacently within the same horizontal position of the cubicle. within the same horizontal position of the cubicle. enables the modules to be located adjacently enables the modules to be located adjacently within the same horizontal position of the cubicle. enables the modules to be located adjacently within the same horizontal position of the cubicle. enables the modules to be located adjacently within thethe same horizontal position of the cubicle. within same horizontal position of cubicle. within the same horizontal position of the the cubicle. within thethe same horizontal position of the cubicle. within same horizontal position of the cubicle.

Modules of size 6E 6E and above a Modules of and abov Modules of size size 6E and abov Modules of size size 6E and and above a Modules of 6E above a directly to the vertical distribution directly to the vertical distribu Modules of size 6E and abov Modules of size 6E and abov directly to the vertical distribu Modules of size 6E and above a directly to the vertical distribution Modules of size 6E and abov directly to the vertical distribution directly to vertical distribu directly to the the vertical distribu directly to the vertical distribution directly to the vertical distribu

8E/4 module up to 18,5 kW

8E/2 module up to 30 kW

8E module up to 75 kW

4 Different Module Application | LV Switchgear MNS

14 1 4 14 14

ABB MNS iS System Guide ABB MNS iiS Guid ABB MNS S System System Guid ABB MNS iS System Guide

Different Module Application

Thanks to its inherent modular design MNS can easily be adapted to house the ABB range of AC Industrial Drives. The switchgear can accommodate multiple drives in a single section. Each drive compartment has an individual isolator; options are available for auxiliary relays, filters and breaking choppers to be installed in the same switchgear. It is also possible to mount the drive control panel on the door for parameters overview and modification. This solution excludes the need for cabling between a drive and a feeder, and streamlines commissioning, as well as creates a suitable environment for sensitive equipment. Standard solutions are available for installation of ABB frequency converters range ACS800 into the MNS low voltage switchgear system.

MNS also offers the possibility of integrating reactive power compensation modules into its standard design. The standard range covers: Network voltages up to 690 V 50 or 60 Hz All common reactor rates (if required) Modules 12,5, 25 and 50 kVar Controllers available for 6 or 12 step regulation The MNS system has standardized solutions for incoming modules. A load break switch or a circuit-breaker can be used as a main switch. If required, it is possible to install an earthing switch. Cable entry solutions or entry solutions with busducts are available.

Incomer 3200A with air Emax circuit breaker and two earthing switches

Switchboard example with withdrawable modules. One partly withdrawn, others in TEST position

Frequency converters integrated into the MNS system

LV Switchgear MNS | Different Module Application 5

Integration into the Process Contol System

More than thirty years ago, ABB introduced MNS as the first arc contained Low Voltage switchboard design based on separated functional areas. In 1983, the first modular designed fully withdrawable MNS switchboard was delivered. Seven years later, in 1990, the Intelligent Motor Control system with INSUM was the first switchboard including electronic protection and control devices and communication interfaces. Following the long series of innovations during the past years, ABB offers the fully integrated Low Voltage Motor Control center platform, the MNS iS . MNS iS platform offers the basic characteristics of an intelligent motor control system: micro processor protection, monitoring and control of motor and distribution circuits, and interfacing to upper plant-wide control systems via fieldbus communications. MNS iS is one integrated MCC system configurable for all possible customer specifications. It can be provided based on conventional up to sophisticated Intelligent Motor Control System requirements. MNS iS makes modifications and enhancement of control and protection functions possible at any time and at any project stage during the complete project life cycle. Thus it provides much needed flexibility for engineers, system integrators and end users.

MNS iS secures customer investments as it provides stepup possibilities with future technology developments with the same system. MNS iS enables flexible usage of spare parts as a results of the system standardization. A very few standard motor starter variants are needed for a complete plant. MNS iS is uniquely safe and simple to operate. Power modules and control devices are physically separated and situated in separate compartments; installation of power cables is possible without adverse effect on control and communication equipment. On the other hand all installation jobs in the control compartments can be carried out without the danger of touching live power cables. This unique design is now a standard in MNS iS. MNS iS promotes predictable plant maintenance. Online information at any time and any point of the plant helps to ensure maximum plant operational flexibility. Predictive maintenance will become integral part of plant operation to ensure reliability of the process.

MNS iS system architecture

MNS iS cubicle

6 Integration into the Process Contol System | LV Switchgear MNS

MNS Technical Data

Standards Test certificates

Type-tested switchgear assemblies (TTA)

IEC 60439-1, CEI 60439-1, DIN NE 60439-1, VDE 0660 part 500, UTE 63-412

ASTA, Great-Britain (resist. to accidental arcs acc. IEC 61641 and IEC 60298, Appendix AA), DLR German Research Institute for Aerospace e. V. Julich, Earthquake Test for Security Arears in Nuclear Power Stations IABG Industrieanlagen Betriebsgessellschaft, Vibration and shock tests Complying with Germanisher Lloyd, Hamburg

Electrical data

Rated voltages

Rated insulation voltage Ui Rated operating voltage Ue Rated impulse withstand voltage Uimp Overvoltage category Degree of pollution Rated frequency

1000 V 3~, 1500 V 690 V 3~, 750 V 6 / 8 / 12 kV II / III / IV 3 up to 60 Hz up to 6300 A up to 250 kA up to 100 kA up to 2000 A up to 176 kA up to 100 kA 690 V 100 kA 300 ms 1 to 5 Up to Form 4 DIN 41488 2200 mm 400, 600, 800, 1000, 1200 mm 400, 600, 800, 1000, 1200 mm E = 25 mm acc. to DIN 43660 External from IP 30 to IP 54 Internal from IP 2X 2,0 / 2,5 mm Minimum 1,5 mm Minimum 2,0 mm Zinc or Alu-zinc coated Zinc or Alu-zinc coated Zinc or Alu-zinc coated Powder coated RAL 7035 (light grey) IEC 607070 DIN VDE 0304 part 3 Fully insulated Silver plating Tin plating

Rated current

Main busbars: Rated current Ie Rated peak withstand current Ipk Rated short-time withstand current Icw Distribution busbars: Rated current Ie Rated peak withstand current Ipk Rated short-time withstand current Icw

Arc fault Containment

Rated operational voltage Prospective short-circuit current Duration Criteria

Forms of separations Mechanical characteristics Dimensions Cubicles and frames Height Panel width Depth Basic grid size Degrees of Protections Steel components According to IEC 60529 Frame, incl. internal subdivisions Cladding, internal Cladding, external Surface protection/ Paint Frame, incl. internal subdivisions Cladding, internal Cladding, external Plastic components Halogen-free, self-extinguishing, flame retardant, CFC-free Optional Extras available on request Special qualification Paint Test certificates Enclosure Busbar system Busbars

See test certificates listed above Special colors on request

LV Switchgear MNS | MNS Technical Data 7

Contact us

ABB AS Paldiski mnt. 21 76601 Keila Estonia Phone: +372 671 2700 Fax: +372 674 7463

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www.abb.com

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