Published:
17 June 2011
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Power Solutions
Power Solutions ABB is a market leader in medium and low voltage applications
2 ABB power solutions ABB power solutions ABB is a market leader in Medium and Low Voltage applications. We offer one of the largest ranges of high quality products and systems available from any single supplier, backed up by in-depth application know-how. In putting together its portfolio ABB has taken care to address not only the core technology but also the systems and services that support customers across the total life cycle. The ABB range covers the following products: – HV Switchgear– MV Switchgear– Power Transformers– Low Voltage Transformers– Low Voltage Switchgear– Air Circuit Breakers– Moulded Case Circuit Breakers– Miniature Circuit Breakers– Power Factor Correction– Motor Control– Variable Speed Drives– Soft Start Units– Renewable Energy– Service & Maintenance
ABB power solutions 3 MV Switchgear UniGear type ZS1 Air insulated metal-enclosed switchboards for primary distribution – Internal arc proof construction– Circuit-breaker racking-in/out with closed door– Construction with pregalvanized sheet without welding points– Wall standing solution– Cable compartment accessible from the front– Double level solution– Slim fused vacuum contactor units Switchboard UniGear 12 UniGear 17 UniGear 24 Type of construction Metal-clad Metal-clad Metal-clad Rated voltage [kV] 12 17,5 24 Insulation levels [kV] 12/28/75 17,5/38/95 24/50/125 Rated main busbar current (40°C) [A] … 4000 … 4000 … 2500 Rated branch connection current (40°C) [A] … 4000 … 4000 … 2500 Rated short-time current [kA] … 50 … 40 … 25 Arc proof withstand current [kA] … 50 … 40 … 25 Tested according to IEC Standards IEC Standards IEC Standards Overall dimensions of basic cubicle H [mm] 2200/2675 2200/2675 2325/2775 W [mm] 650/800/1000 650/800/1000 800/1000 D [mm] 1340/1390 1340/1390 1560 Design includes: SF6 circuit-breakers • • • Vacuum circuit-breakers • • • Vacuum contactors • • • Integrated capacitor banks • • • Earthing switch • • • Bay computer • • • Measuring transformers • • • Measuring sensors • • • Technical catalogue No. 649424 649424 649424 Technical Data basic cubicle Single level unit Double level unit Slim fused vacuum contractor unit
4 ABB power solutions UniAir – Air insulated metal-enclosed switchboards for secondary distribution – Standard and arc-proof versions– Complete air insulation of all live parts– Circuit-breaker equipped with self-powered protection release– Mechanical safety locks to prevent incorrect operations– Software for switchboard design and estimates– Wall standing solution– Plug-in or withdrawable circuit-breakers– Wide range of functional units– Construction with pregalvanised sheet without welding points– Wide use of recyclable material, production cycle certified ISO 14001 Switchboard Type of construction Metal-enclosed Rated voltage [kV]Insulation levels [kV] Corrente nominale (40 °C)– Main busbars [A] – Circuit-breakers [A]– Switch-disconnectors [A]– Insulation isolators [A] Rated short-time current– Circuit-breakers [kA]– Switch-disconnectors [kA]– Insulation isolators [kA] Arc proof withstand current [kA] Tested according toOverall dimensions of basic cubicle H [mm] W [mm] D [mm] Design includes: SF6 circuit-breakerSwitch-disconnectorDisconnectorEarthing switchBay computerMeasuring transformers Technical catalogue No. UniAir •2424/50/125 400/630/800/1250630/800/1250400-630400/630/800/1250 12,5 - 16 - 20 - 25 (25 kA a/at 12 kV)12,5 - 1612,5 - 16 - 20 - 25 (25 kA a/at 12 kV)16 - 0,5s / a richiesta: 16 - 1s – 25 x 0,5 sIEC1950700/7501190/1290/1385 ••••••649223 Technical Data A B C D E basic cubicle A Instrument compartment B Circuit-breaker C Feeder compartment D Busbar compartment E Earthing switch
ABB power solutions 5 Ring Main Units Flexible – Circuit breaker or fuse switch protection– Integrated remote control and monitoring unit available Economical – Compact– Maintenance free– Standard design Safe and environmental friendly – Simple operation– Arc suppressor available– Recyclable– Manufactured according to ISO 9001 and ISO 14001 C - module Earthing F - module Downstream V - module Earthing switch switch switch earthing Vacuum switch disconnector fuse breaker circuit switch Rated voltage kV 12/24 12/24 12/24 12/24 12/24 12/24 Power frequency withstand voltage kV 28 /50 28 /50 28 /50 28 /50 28 /50 28 /50 Impulswithstand voltage kV 9 5/125 95/125 95/125 95/125 95/125 95/125 Rated current A 630/630 see 200/200 Breaking capacities close loop A 630/630 off load cable charging A 135/135off load transformer A 20/20 earth fault A 200/150 earth fault cable charging A 115/87 short circuit breaking current kV see 21/16 Making capacity kV 52,5/40 52,5/40 see 12,5/12,5 52,5/40 52,5/40 Short time current 1 sec. kV 5/5 21/16 Short time current 2 sec. kV 21/16 21/16 21/16 1) 38 kV on request 2) Depending on the current rating of the fuse 3) Limited by high voltage fuse links Technical specification 1) 2) 3) 3) 1) 1) 1) 1) 1)
6 ABB power solutions Dimensional drawings Available modules C - Cable SwitchF - Switch fuse disconnectorV - Vacuum circuit breakerD - Direct cable connection with earthing If other configurations are required, they can be obtained throughSafePlus, which is ABB´s modular compact switchgear withidentical user interface. NB Fixing bracket NB 100 765 1021 1345 107 107 490 595 1248 64.5 30 66.5 253.5 253.5 668 BC M12 o15 RMU A B C 2-way3-way 4-way 696 1021 1346 622947 1272 661986 1311 DF DV CCF CCV CCFF CCCF CCC CCCV CCCC CCVV
ABB power solutions 7 Junior 100 Outdoor Enclosure – Outdoor Enclosure for SafeRing and SafePlus The outdoor enclosure is designed for SafeRing and SafePlus,up to 4-ways switchgear. The enclosure is designed to bemounted between two poles or on a standard aluminiumfoundation. The housing is assembled together from profiles.The profiles are joined together with one way non-corrosivescrews which are not removable from outside.Both the enclosure and the roof is made of Aluzinc and paintedwith powder epoxy painting. The enclosure has two doors inthe front allowing for easy operation. The doors are securedwith two-point closing device with flush-mounted handle forpadlock and vandal proof cover. The cover beneath the doorscan be dismounted to give free access for cables.The cover on the backside can easily be dismounted too. Dimensions Outdoor enclosure on ground Foundation on the ground Outdoor enclosure - mounted between two poles 1530 1090 1010 1090 1860 300 1530 280 1860 480 1010 1450 SafeRing Front
8 ABB power solutions Dry Type Transformers Dry type transformers are not flammable, they are self-extinguishing and in the event of a breakdown there is no risk of leakage of flammable or contaminating substances. Construction features ABB vacuum cast coil transformers range from 50 kVA up to 30MVA with primary operating voltages up to 36 kV and secondaryoperating voltage up to 6 kV. Customers demand dry type transformers more frequently inorder to minimise environmental contamination and fire hazard.The emission of toxic substances and fumes is minimised. The use of cast resin, combined with our latest manufacturingtechniques allows us to build stronger compact transformerscapable of withstanding severe rolling and vibration. Vacuum cast coil transformers are virtually maintenance free.They do not require any special civil works prior to installation anddue to the particular design they can be repaired on site. ABBvacuum cast coil transformers are manufactured in accordancewith the international quality standard ISO 9001. Vacuum cast coil transformers are moisture-proof, suitable foroperation in humid or heavily polluted environments. They are theideal transformers for operation in environments with a humidityhigher than 75% as well as at temperatures lower than 25°C. Standard features – HV coils vacuum cast in epoxy resin. LV windings pre- impregnated – Casting process utilises high performance filled epoxy– Aluminium windings, copper optional– Step-lap mitered core– 155°C insulation system and 100°C average temperature rise– Four full capacity taps on HV winding rated ± 2 x 2.5% – Provisions for lifting core and coil assembly– Rating plate– Temperature control device– Earthing terminals– Base equipped with bi-directional rollers or designed for skidding Core ABB’s dry type transformers utilise a step-lap mitred coreconstruction to ensure optimum performance and minimumsound levels. The mitred core joint allows efficient flux transferalong natural grain lines between the core legs and yoke. Thestep-lap construction further enhances the efficiency of the jointby reducing joint fringing which reduces corelosses and exciting currents.The core is designed and built to provide the lowest possiblelosses from the effects of magnetic hysteresis and eddy currents.All possible steps are taken to prevent local circulating currentsand to avoid built-in bending stresses.As part of the quality process, ABB uses non-aging highpermeability cold-rolled, grain-orientated silicon steel andconstructs the core with step-lap mitred joints. Magnetic fluxdensities are kept well below the saturation point. The steel isprecision cut to ensure that it will be smooth and burr-free. Forrigidity and support, the upper and lower yokes aresolidly clamped to a sturdy metal frame. The finished core iscoated with a corrosion resistant sealant which provideslamination cohesion and environmental protection.
ABB power solutions 9 Windings ABB’s winding design depends on operating voltage, basicimpulse level and the current capacity of the individual winding.ABB’s Low-Voltage windings, insulation class 1.1 kV are usuallywound with sheet conductors.This construction allows free current distribution within the axialwidth of the coil which eliminates the axial forces developed inother types of windings under short-circuit conditions.During the assembly process, each Low-Voltage winding isblocked radially and axially against the core using a combinationof solid and resilient mounts for sound suppression and thermalexpansion compensation.The ABB winding construction is either round or oval up to 2500kVA. Windings on transformers with ratings greater than 2500kVA are generally round.An experienced and dedicated work force ensures the quality ofits work and the customer’s satisfaction with the product. Options and accessories Design options– 80°C average temperature rise (or other according to requirements) – Copper windings– Cast coil LV windings– Increased basic impulse levels– Dual primary-secondary voltage– Loss optimised designs– Retrofit designs– Other designs available on request Accessories – Three-phase electronic temperature monitor– Anti vibration pads– Optional ventilated enclosure with removable front and rear panels (IP20 to IP65) – Electronic screen– Forced cooling package with three-phase electronic temperature monitor – Air-filled terminal chambers– Special paint colours– Plug-in terminals (quick connectors) Standard tests – Transformation ratio at all taps and polarity– Applied voltage– Induced voltage– Partial discharge test– Resistance of all windings– Vector group– No-load loss and no-load current– Load losses and impedance voltage test Type tests – Temperature rise test– Lightning impulse test– Measurement of noise level– Insulation resistance Humid or heavily polluted environments – Use of epoxy resins – not hygroscopic– Conductor protected from corrosion– E2 class certified (tested for ambient 90% humidity and 50°C)– C2 class certified (operation down to -25°C)– Minimum dust accumulation Partial discharge tests – Routine test for partial discharge– Below 5 pC Fire hazards – Neither dioxins nor hydrohalogen compounds– Non toxic materials used– F1 class certified– Self-extinguishing– Light transmission factor of fumes 60% Electrical and mechanical design – Impulse test withstands voltage up to 200 kV– Mechanically stronger, safe against vibrations and earthquakes– Withstands thermal and dynamic short circuit effects Specifications – Self-Cooled Power Rating: 50-25.000 kVA– Primary Voltage: withstands up to 36 kV– Primary Lightning impulse voltage: withstands up to 170 kV– Secondary Voltage: withstands up to 6 kV– Secondary Lightning impulse voltage: withstands up to 60 kV– Temperature Rise: 100/100 C
10 ABB power solutions Oil Filled Transformers MDT transformers are used to step down three-phase high voltage to low voltage for power distribution, mainly in metropolitan areas and for industrial applications. – Undercarriage with bi-directional rollers– Oil drain valve– Off-circuit tap changer handle– Earthing terminals– Sparking gaps for voltages 15 kV and above– Rating plate Additionally, for transformers with conservator (Rated Power ?1000 kVA)– Max thermometer– Magnetic oil-level indicator– Oil filling plug on the conservator– Buchholz relay– Dehydrating breather– Conservator Core The cores of the transformers are made of grain orientedmagnetic, cold-rolled silicon steel laminations with low losses. Construction features The transformers in standard versions are designed for use inmoderate climates and can be installed both outdoors andindoors. The loading is in accordance with IEC 354. MDTtransformers are hermetically sealed (the tank is completely filledwith oil) or equipped with oil conservator. Both types areequipped with flexible corrugated tank walls enabling sufficientcooling of the transformer. They also compensate for the changesin the oil volume during operation. An advantage of thehermetically sealed transformers is that the oil is never in contactwith the atmosphere thus avoiding periodic oil analysis. Standard features Hermetically sealed. (Rated power 100 kVA)– Oil filling plug on the cover– Oil-level indicator– The two lifting lugs on the cover are made for lifting the transformer or its removable part – Corrugated tank
ABB power solutions 11 Windings The windings of the transformers are made of high gradeelectrolytic copper or aluminium. The High Voltage windings arewound either with round, enamel insulated, or shaped, paperinsulated wire. The Low Voltage windings are wound withshaped, paper insulated wire or foil. The winding construction ischaracterised by high dielectric strength and high resistance toatmospheric surges and to the effects of short-circuits. Neutralpoints of the Low Voltage windings are brought to the tank cover. Off-circuit tap changer The off-circuit tap changer is of a 5-position type connected onthe High Voltage side with a handle located on the cover. The tapchanger should be operated only when the transformer isdeactivated. Insulating oil The mineral oil with its electrical and chemical characteristics is incompliance with the IEC Standards and is P.C.B. and P.C.T. free. Tank and cover The cover is bolted to the tank frame. The transformerundercarriage is provided with bi-directional rollers turnable by/2 rad (90°) to allow longitudinal and transverse movement on flatsurfaces. Painting and surface treatment All metal parts are carefully sandblasted. The painting is madewith a single coat of one-pack epoxy paint. The finishing paint ismade with two or three coats. If requested a hot-dip galvanisedcorrugated steel tank can be provided. Options and accessories – Plug-in bushings– Dial type thermometer with two contacts– DGPT2 control device– Pressure relief valve with or without contacts– Tap changer with more than five positions– Cable boxes– Spark gap meter– Air insulated housings– Galvanized tank– Additional thermometer pocket– Dual voltage transformer Specifications – Standards: IEC, DIN, BS, UNE, PN etc.– 301-2000 kVA, three-phase, 65°C maximum windings temperature rise – 50 Hz standard, 60 Hz optional– High voltages 3000 – 35000 V– Low Voltages 100 – 15750 V– Vector group: Dy, Yz, Yy, Dd, Yd– Impedance voltage: 4-7%– Voltage regulation: ±2 x 2.5%; ±2 x 5%; +2.5%, -3 x 2.5%
12 ABB power solutions Resin-encapsulated Transformers RESIBLOC® transformers with encapsulated windings provide the ultimate mechanical strength to withstand thermal and mechanical stresses from severe climates, cycling loads, and short circuit forces. Construction features The ABB resin-encapsulated dry-type transformer, RESIBLOC®,offers specific advantages. For more than a quarter of a centurywe have been using only epoxy resin and fibre-glass toencapsulate the wire layers. Epoxy resin moulding reinforced withfibre-glass rovings is a material of outstanding strength.Furthermore, we manufacture RESIBLOC® transformers withoutthe addition of extenders or plasticisers. Electronically controlledwinding processes ensure uniform distribution of the glass rovingsand precise tracking. The Low Voltage and High Voltage windings are joined adhesivelyby way of bars to form a compact block winding. The favourableimpulse voltage distribution – resulting from the multilayering ofthe High Voltage winding – in conjunction with the outstandingstrength of the coil makes RESIBLOC® resin-encapsulatedtransformers short-circuit proof.The fibre-glass reinforcement of the resin-encapsulatedRESIBLOC® windings is so robust that we have no hesitation inguaranteeing the crack resistance of the High Voltage coil for theentire life of the transformer. We also guarantee that no silicone is used at any time inRESIBLOC® coil manufacture. This is a further key point forthose operators who demand absolutely silicone free manufacturefrom their transformer suppliers. Standard features – Ratings: from 30 kVA to 30 MVA– Primary Voltages: up to 41.5 kV– Secondary Voltages: up to 36 kV – BIL: According to standards– HV Winding: Copper– LV Winding: Aluminium– Step-lap mitred core– Tapping 2 x 2.5%– Temperature device– Fire class F1– Environmental class E2– Climatic class C2– Built-in cooling channels to dissipate heat– Environmentally friendly– Linear distribution of lightning impulse voltage– Base equipped with bi-directional rollers or designed for skidding arrangement Options and accessories – Dimensions adaptable to specific requirements– Loss optimized design– Special designs as traction, rectifier and converter transformer, multiwinding transformers – Enclosure IP20 to IP65, indoor and outdoor, galvanised without painting – Fans for forced cooling (up to 140% of AN rating), including control – Anti-vibration pads, (1 set = 4 pieces)– Earthing bolts (1 set = 3 pieces)– PTC sensors, with relay– Dial type thermometer (with capillary tube 2m)– Thermo-resistor PT100– Copper for LV windings– Reduced temperature rise on request
ABB power solutions 13 Certified test results – Safe to store and transport at -60°C (standard test requirement only -25°C) – Tested with twice rated current at -40°C (standard test requirement only -25°C) – Vibration tested for installation in seismic areas. Acceleration tested to 12.5g – All components tested for non-toxicity– Repeated thermal shock with hot air 120°C and cold air -10°C (over 10 times) Fire proof – Approx. 80% fibreglass in winding insulation– Only non-toxic materials– Max 5% calorific energy of comparable oil type unit– No halogens, nor sulphur (fluorine/chlorine/bromine)– Every unit guaranteed to be self-extinguishing. Fire Class 1 certified Short circuit proof – High mechanical stability of coil structure– Diagonally and radially fibreglass braced (HV-winding)– Turns glued to each other with prepreg (LV winding)– HV and LV windings form a singular coil– Coil structure will withstand radial forces in short circuit conditions Moisture and pollution proof – 100% humidity and condensation proof– Strong presence in off-shore applications– High resistance to chemical pollution– Long-term molecular stability due to absence of flexibilisers Crack proof – Severe thermo-shock tested– Severe hot/cold dip tests– Physical and mechanical properties of coil components optimised – High resistance to extremely low ambient temperatures– Performance stability under extreme load conditions– Not a single crack registered to date Minimal dust accumulation – Vertical cooling channels with chimney effect– Minimum dust settles– No horizontal ducts– Small upper coil surface– Surface structure non-adhesive to dust
14 ABB power solutions Rated Currents and Short-Circuit Currents of 3 Phase 400v Transformer Transformer Ratings KVA 1 x 5002 x 5001 x 6302 x 6303 x 6301 x 8002 x 8003 x 8001 x 10002 x 10003 x 10001 x 12502 x 12503 x 12501 x 16002 x 16003 x 16001 x 20002 x 20001 x 2500 A 722722910910910115611561156144414441444180518051805231223122312289028903610 A 722144491018202730115623123468144428884332180536105412231246246936289057803610 KA 18.036.022.745.468.123.146.269.328.957.886.736.172.2108.337.074.0111.046.292.457.7 No of transformers and rated output Current rating of transformer Total available current Maximum prospective short circuit current NOTE: The above ratings do not take into account impedance of busbars, connections to circuitbreakers or cables
ABB power solutions 15 Air Circuit Breakers Air circuit breakers can be used both as circuit-breakers for general protection (of plants and electric lines) and as protection circuit breakers of electrical machines (generators, motors, transformers, capacitors). They are used in all types of plants (civil, industrial, and in theservice sector) as well as in the equipment on-board ships, inmines, in prefabricated substations, and for primary andsecondary distribution in general. Specific characteristics All the SACE Emax circuit-breakers have the same height anddepth both in the fixed and withdrawable version and allowconstruction of compact switchgear. They are fitted with many features which mean that personnelcan always work under conditions of maximum safety, such asracking-out with the door closed, degree of protection towardsthe outside up to IP54, an articulated series of safety locksand double insulation. The innovative structure of the pole guarantees completeinsulation between phases and between phase and neutral andallows for inspection of the arcing chamber and the maincontacts. SD Pocket is an innovative function which means a PC, even ahand-held one, can dialogue with Emax by means of theBluetooth protocol. By means of the PC, and without any cables,the following is now possible, for example: the setting of thevarious protections, display of the measurements including thosestored in the Data Logger, verification of the state of the circuit-breaker, number of operations carried out, etc.. Conformity with Standards The SACE Emax circuit-breakers and their accessories complywith the international IEC 947, EN 60947 (harmonised in 28countries of the CENELEC), CEI EN 60947 and IEC 1000Standards and conform to the EC Directive:– "Low Voltage Directives" (LVD) no. 73/23 EEC– "Electromagnetic Compatibility Directive" (EMC) no. 89/336 EEC Furthermore, a series of SACE Emax circuitbreakers conformingto the UL 1066 Standards are available. Range of apparatus Air circuit breakers are available for a large number ofapplications. The new series of air circuit-breakers consists of fivesizes (E1, E2, E3, E4 and E6) in the fixed and withdrawableversions, with rated uninterrupted currents from 800 to 6300 Aand breaking capacities up to 150 kA at 415 V. Different modelsof circuitbreakers for each size are available, all with the same dimensions, but with various rated currents and with differentbreaking capacities, identified by letters. The series is completed by a range of currentlimiting circuit-breakers, of different construction concept, particularlyrecommended in plants characterised by high short-circuitcurrents. Customisation of the circuit-breaker is carried out by means of acomplete range of accessories - common over the whole range,which can be installed from the front of the circuit-breaker withoutthe need for any internal cabling. For protection in alternating current, the circuitbreakers are fittedwith the new series of electronic releases which offer the followingmain characteristics:– SACE PR121/P, the basic release with the following protection functions: overload(L), selective short-circuit(S), adjustableinstantaneous short-circuit(I) and Earth fault(G) – SACE PR122/P, the intermediate release. It offers, further to protection (L, S, I, G), measuring and communication functions – SACE PR123/P, the advanced release. In addition to the above units, it offers more communication and measuring capabilitiesand other functions like, for example: harmonic analyses,directional protection and phase rotation
16 ABB power solutions E1 E2 E3 E4 E6 Rated current Iu [A] 800-1600 800-2000 800-3200 3200-4000 3200-6300 Iu N (4 poles CB) [%Iu] 100 100 100 50 50 Ue AC (50-60 Hz) [V] 690 690 690 690 690 Ui [V] 1000 1000 1000 1000 1000 Uimp [KV] 12 12 12 12 12 Test voltage (50 Hz, 1 min) [V] 3500 3500 3500 3500 3500 N° of poles [No.] 3-4 3-4 3-4 3-4 3-4 Breaking capacities Icu AC 50-60 Hz 220-415 V [kA] 42-50 42-130 65-130 75-150 100-150 Icu AC 50-60 Hz 440 V [kA] 42-50 42-110 65-130 75-150 100-150 Icu AC 50-60 Hz 500-690 V [kA] 42-50 42-85 65-100 75-100 100 Ics AC 50-60 Hz 220-415 V [kA] 42-50 42-130 65-130 75-150 100-125 Ics AC 50-60 Hz 440 V [kA] 42-50 42-110 65-110 75-150 100-125 Ics AC 50-60 Hz 500-690 V [kA] 36 42-65 6-85 75-100 100 Icw (1s) [kA] 42-50 10-65 15-85 75-100 100 Icw (3s) [kA] 36 42 65 75 75-85 Icm (peak value) Icm AC 50-60 Hz 220-415 V [kA] 88.2-105 88.2-286 143-286 165-330 220-330 Icm AC 50-60 Hz 440 V [kA] 88.2-105 88.2-242 143-242 165-330 220-330 Icm AC 50-60 Hz 500-690 V [kA] 75.6 84-187 143-187 165-220 220 Category of use (IEC 60947-2) B A-B A-B B B Isolation behaviour (IEC 60947-2) X X X X X Overcurrent protectionElectronic releases for AC applications X X X X X Operating times Closing time (max) [ms] 80 80 80 80 80 Trip time for I Icw (max) (1) [ms] 70 70 70 70 70 Trip time for I Icw (max) [ms] 30 12-30 12-30 30 30 Overall dimensionsF.: H= 418mm - D= 302mm - L (3/4 p.) [mm] 296-386 296-386 404-530 566-656 782-908 W.: H= 461mm - D= 396.5 mm - L (3/4 p.) [mm] 324-414 324-414 432-558 594-684 810-936 Weights Fixed 3/4 poles [kg] 45-54 50-63 66-83 97-117 140-160 W 3/4 poles (including fixed part) [kg] 70-82 78-95 104-127 147-190 210-260 Version F-W F-W F-W F-W F-W ACB sizes & ratings (1) without intentional delays Versions caption: F fixed W withdrawable NOTE: For more information please refer to Emax Technical catalogue
ABB power solutions 17 Moulded Case Circuit Breakers The moulded-case circuit-breakers, proposed by ABB SACE, derive from the T-Max family series (Top selection at Intel Design 2003 for their technological content and respect of the environment). In particular, Tmax are characterised by an extremely high level ofperformances with limited overall dimensions, installationsimplicity and an increasingly greater guarantee of safety for theoperator thanks to their reinforced insulation. Tmax circuit-breakers can be used for all distribution and sub-distributionapplication for both AC and DC electrical plants. Specific characteristics of Tmax The Tmax series is characterised by being a product with a hightechnological content - the fruit of the most advanced design andsimulation tools with excellent performances in minimum overalldimensions.Thanks to the new technology used for the arcing chambers andthe speed of contact opening, the circuit-breakers of the Tmaxseries guarantee strong limitation of the specific let-throughenergy and reduction in the peak currents, therefore limitingoverheating of the devices and electro-dynamic stresses. Furthermore, the new Tmax circuit-breakers use a completelycommon and standardised range of accessories withconsiderable advantages in terms of reduced stocks as well asflexibility and ease of use. Then within this range there are alsothe new residual current releases up to 500 A. Field of application The moulded-case circuit-breakers are used in industrial and civillow voltage plants with service currents from 1 to 3200 A. Theyare used in direct and alternating current distribution switchgear,for motor protection (Motor Control Center), generators,capacitors and for end users. The ranges The ABB moulded case circuit-breakers are proposed into eightsizes: T1, T2, T3, T4, T5, T6, T7 and T8. The rated ultimatebreaking capacity under short-circuit, Icu, at 380/415V AC isavailable starting from 16kA up to 200kA. To fulfil the variousapplication requirements, they are available in the followingranges:– Circuit-breakers for AC and DC power distribution– Circuit-breakers for motor protection– Circuit-breakers for applications up to 1000 V AC and DC– Switch-disconnectors For each size, circuit-breakers are available in the three and four-pole versions. They are also equipped with a complete range ofprotection releases: thermomagnetic, magnetic only adjustableand electronic releases of the latest generation. T1, T2, T3, T4,T5 and T6 circuit-breakers fitted with TMD and TMAthermomagnetic releases can also be used in direct currentplants, with a field of application from 1A to 800 A and aminimum operating voltage of 24V DC. Power distribution circuit-breakers The ABB SACE family of moulded case circuit breakers aredivided into different, perfectly integrated, ranges (Tmax T1B 1p,T1, T2, T3, T4, T5, T6 T7 and T8), able to cover a range ofservice currents from 1 to 3200 A. The power distribution circuitbreakers are available in the fixed, plug-in or withdrawable, three-pole and four-pole versions. The Tmax T1 circuit breaker is alsoavailable in the single pole Tmax T1B 1p version, with breakingcapacities of 25 kA at 220/230 V AC. Interchangeability of the releases The Tmax circuit-breakers can be fitted either withthermomagnetic, magnetic only or electronic releases, which areall interchangeable with each other. In fact, thanks to thesimplicity of their installation, the type of release can be replacedrapidly even by the end user, according to theirrequirements and needs: in this case, correct assembly remainsthe responsibility of the user himself. All this means increasing theflexibility of use of the circuit-breakers, with considerable savingsthanks to the better rationalisation of stock management. Conformity with Standards The moulded-case circuit-breakers and their accessories conformto the IEC 60947-2 international Standards and comply with theEC "Low Voltage Directives (LVD) no. 73/ 23 EEC" and"Electromagnetic compatibility Directives (EMC) no. 89/336 EEC".ABB SACE’s Quality System conforms to the ISO 9001International Standard and to the equivalent European EN ISO9001 and Italian UNI EN ISO 9001 Standards. The certifying Bodyis the Italian Shipping Register (RINA - QUACER): ABB SACE hasreached its third qualificationconfirmation. The ABB SACE Test Room is accredited by SINAL.The apparatus conforms to the prescriptions of the on-boardinstallations and approvals by the major Shipping Registers are inprogress.
N° of poles No. 1 3-4 3-4 3-4 3-4 3-4 3-4 3-4 3-4 Ue AC 50-60Hz [V] 240 690 690 690 690 690 690 690 690 UeDC [V] 125 500 500 500 750 750 750 - - Uimp [kV] 8 8 8 8 8 8 8 8 12 Ui [V] 500 800 800 800 1000 1000 1000 1000 1000 Testvoltage(50 Hz, 1 min.) [kV] 3 3 3 3 3.5 3.5 3.5 3.5 3.5 18 ABB power solutions Icu AC 50-60 Hz 380/415 V [kA] 25 16 36 36 36 36 36 50 85 (1)(2) 36 85 50 200 200 100 150 130 Icu AC 50-60 Hz 690 V [kA] 3 6 5 20 20 20 30 50 6 10 8 80 80 150 60 80 Icu DC 500 V - 3 p in series [kA] 25 16 36 36 16 16 20 - - (3) 36 85 50 70 70 65 Ics AC 50-60 Hz 380/415 V [kA] 18 16 36 27 36 36 35 50 85/110.5 25 70 200 200 150 60 Category of use (IEC 60947-2) A A A A A B/A B B B Mechanical lifeN. op x [103] No 25 25 25 25 20 20 20 10 10 Electrical life @ 415 VN. op x [103] No 8 8 8 8 8 7 7 2 2.5 6 5 5 3 1.5 TMF X TMD X X X TMA X X X X TMG X X ELT X X X X X X Dimensions (fixed version) Width 1 pole [mm] 25.4 Width 3 poles [mm] 76 90 105 105 140 210 210 427 Width 4 poles [mm] 102 120 140 140 184 280 280 553 Depth [mm] 70 70 70 70 103.5 103.5 103.5 154man/178mot 282 Height [mm] 130 130 130 150 205 205 268 268 382 406 Versions Fixed F F F F F F F F F Plug-in P P P P Withdrawable W W W W MCCB size & rating Breaking capacities Protection releases (1) for In=16 A and In = 20 A Icu = 16 k A(2) Icu @ 230 V AC(3) Icu @ 125 V DC Caption:TMF = themomagnetic fixed releaseTMD = thermomagnetic with adjustable thermal releaseTMA = thermomagnetic with adjustable thermal and magneticreleaseTMG = release for generator protectionELT = electronic release Circuit-breakers for motor protection Starting, switching and protection of three-phase asynchronousmotors are fundamental operations for their correct use. ABBSACE proposes two different solutions for this type of application in the series of moulded-case circuit-breakers:– a traditional system which has a circuit-breaker for protection against the short-circuit, a thermal relay for protection againstoverload and missing or unbalanced phase and a contactor formotor switching – a system of integrated protection, thanks to the PR222MP release, which ensures the following protections: against short-circuit, overload, against missing or unbalanced phase, andagainst rotor locking Field of application Available in six sizes (T2, T3, T4, T5, T6 and T7), they can beused in a vast range of start-ups, from 0.37 kW upto 355 kW at400 V AC. NOTE: For more info please refer to Tmax technical catalogue T1 1p T1 T2 T3 T4 T5 T6 T7 T8 Iu [A] 160 160 160 250 250 400 630 800 2000 320 630 800 1000 2500 1000 1250 3200 1600
ABB power solutions 19 System pro M Compact – Miniature Circuit Breakers, Residual Current Devices & Modular Din Rail Components Miniature Circuit Breakers MCBs protect installations against overload and shortcircuit,warranting reliability and safety for operations. New System pro Mcompact S 200 series satisfies most common requirements interms of MCBs, allowing the usage of them for domestic,industrial and commercial applications. Three series – S 200, S 200 M and S 200 P – with three different breaking capacities upto 25 kA are available, in all characteristics (B, C, D, K and Z) andconfigurations (1P, 1P+N, 2P, 3P, 3P+N and 4P), in all the sizesup to 63 A. A space saving version with an integrated auxiliarycontact is also available. All these MCBs comply to IEC/EN60898 and IEC/EN 60947-2 Standards. Characteristics B, C, D 120 60 40 20 10 64 2 1 40 20 10 64 2 1 0.60.4 0.2 0.1 0.060.04 0.02 0.01 90 45 30 15 8 1 1.5 2 3 4 5 6 8 10 15 20 30 2.55 10 20 30 1.45 1.13 63 63 32 32 IEC-EN60898 Minutes Minutes multiples of rated current Characteristics K, Z 120 60 40 20 10 64 2 1 40 20 10 64 2 1 0.60.4 0.2 0.1 0.060.04 0.02 0.01 1 1.5 2 3 4 5 6 8 10 15 20 30 12 1.2 1.05 IEC-EN60947-2 Minutes Minutes multiples of rated current
20 ABB power solutions RCDs assure a protection to people and installations against fault current to earth. They are divided into three families:– RCCBs , which are sensitive only to earth fault current (therefore they have to be connected in series with a MCB or a fuse toprotect them against overcurrents and short circuits) – RCD-blocks , which are devices to be assembled on an MCB with lower or equal rated current to provide protection againstboth earth-fault currents and overload or shortcircuits – RCBOs , which combines, in a single device, protection against both earth-fault currents and overloads or short-circuits New RCDs System pro M compact range presents a wide offerfor all the three families, respectively F 200 , DDA 200 and DS 200 series. A large offer for standard instantaneous and selective AC and Atypes is completed with some configurations for specialapplications, like AP-R type against perturbations or AE type foremergency stop. Sizes up to 63A with sensitivity thresholds up to 1A are available. Functions and classification criteria for RCDs A residual current operated circuit-breaker is an amperometricprotection device which is tripped when the system leaks asignificant current to earth.This device continuously calculates the vector sum of the single-phase or three-phase system line currents and while the sum isequal to zero allows electricity to be supplied. This supply israpidly interrupted if the sum exceeds a value preset according tothe sensitivity of the device. Residual current operated circuit-breakers can be classedaccording to four parameters:– type of construction– detectable wave form– tripping sensitivity– tripping time Depending on the type of construction, RCDs may be classed as:– RCBOs (magnetothermic with overcurrent protection)– RCCBs (without overcurrent protection releaser incorporated)– RCD blocks RCBOs combine, in a single device, the residual current functionand the overcurrent protection function typical of MCBs. RCBOsare tripped by both current leakage to earth and overloads andshort-circuits and they are self-protecting up to a maximum short-circuit current value indicated on the label. RCCBs are only sensitive to current leakage to earth. They mustbe used in series with an MCB or fuse which protects them fromthe potentially damaging thermal and dynamic stresses of anyovercurrents. These devices are used in systems already equipped with MCBswhich preferably limit the specific energy passing through, alsoacting as the main disconnecting switches upstream of anyderived MCBs (e.g.: domestic consumer unit). RCD blocks are residual current devices suitable for assemblywith a standard MCB. IEC/EN 61009 app. G only allowsassembly of RCBOs once on site, that is to say outside thefactory, using adaptable RCD blocks and the appropriate MCBs.Any subsequent attempts to separate them must leavepermanent visible damage. The residual current operated circuit-breaker obtained in this way maintains both the electricalcharacteristics of the MCB and those of the RCD block. According to the wave form of the earth leakage currents they aresensitive to, the RCDs may be classed as:– AC type (for alternating current only)– A type (for alternating and/or pulsating current with DC components) – B type (for alternating and/or pulsating current with DC components and continuous fault current) AC type RCDs are suitable for all systems where users havesinusoidal earth current. They are not sensitive to impulsive leakage currents up to a peakof 250 A (8/20 wave form) such as those which may occur due tooverlapping voltage impulses on the mains (e.g.: insertion offluorescent bulbs, X-ray equipment, data processing systems andSCR controls). A type RCDs are not sensitive to impulsive currents up to a peakof 250 A (8/20 wave form). They are particularly suitable for protecting systems in which theuser equipment has electronic devices for rectifying the current orphase cutting adjustment of a physical quantity (speedtemperature, light intensity, etc.) supplied directly by the mainswithout the insertion of transformers and insulated in class I (classII is, by definition, free of faults to earth). These devices maygenerate a pulsating fault current with DC components which theA type RCD can recognise. Other modular functions Protective devices Residual current monitors, toroidal transformers, fuseholders,surge protection. Command devices Installation relays, switches, latching relays, push button andindicator lamps, dimmers, time delay and digital timeswitches. Load management devices Light level switches, overload alarms, current/voltage, undervoltage relays and mains disconnecting relays. Other modular functions Bell transformers, bells, buzzers, pushbuttons and power supplyunits.
ABB power solutions 21 Motor Control Gear ABB Motor Control Gear Contactors: Mini and block contactors. 3 + 4 pole9-1600A AC+DC operated Specificapplications – DC circuit switching,capacitor switching, lighting circuitswitching. Manual Motor Starters: Thermal + electromagnetic protection 0.16 – 100A up to 100kA. Overload Relays: Thermal + Electronic 0.1 – 1250AHeavy duty and ATEX applications. Pilot Devices: Push buttons, pilot lights, selectorswitches, key operated switches,potentiometers and buzzers. Soft Starters: 3-1810 A, Integrated by-passcontactors, LCD display, flexible BWScommunications. Field Bus Plug: Universal bus communication devicefor all common BWS applications. Electronic Protection Electronic timers, measuring and monitoring relays, interface relays,safety relays, switching power Relays: supplies, solid state relays, signalconverters, logic modules. Sensors: Inductive and capacitive, proximity,photoelectric and ultrasonic wirelesssensors. Limit Switches: 30, 40 + 60 in metal and plastic doubleinsulated housings, safety limit switchesand latches. Terminals: Screw clamp, spring clamp, insulationdisplacement, power terminals, quickconnect terminals, pluggable terminals. Motors: Full, comprehensive range for powergeneration, transmission, industrial andrail transportation and distribution. Why not visit our website for the most comprehensive selection of tools available – www.abb.com/lowvoltage ABB offer the most comprehensive range of motor control devices and accessories found on the market today. With acquired years of experience with respect to problems of co-ordination ABB is able to make a complete offer based on tests performed in qualified laboratories. This offer includes 400V, 500V and 690V networks. A complete database of co-ordination tables, according to IEC 60947-4-1 (EN 60947- 4-1) is available on the ABB website (www.abb.com).
22 ABB power solutions The currents given below concern standard three-phase four-pole cage motors (1500 r.p.m. at 50 Hz. 1800 r.p.m. at 60 Hz). These values are given for guidance and may vary according to the motor manufacturer and depending on the number of poles. Motive Power KW Rating 220 V 230 V 240 V 380 V 400 V 415 V 440 V 500 V 660 V 690 V A A A A A A A A A A 0.06 0.37 0.35 0.34 0.21 0.2 0.19 0.18 0.16 0.13 0.12 0.09 0.54 0.52 0.50 0.32 0.3 0.29 0.26 0.24 0.18 0.17 0.12 0.73 0.7 0.67 0.46 0.44 0.42 0.39 0.32 0.24 0.23 0.18 1 1 1 0.63 0.6 0.58 0.53 0.48 0.37 0.35 0.25 1.6 1.5 1.4 0.9 0.85 0.82 0.74 0.68 0.51 0.49 0.37 2.0 1.9 1.8 1.2 1.1 1.1 1.0 0.88 0.67 0.64 0.55 2.7 2.6 2.5 1.6 1.5 1.4 1.3 1.2 0.91 0.87 0.75 3.5 3.3 3.2 2.0 1.9 1.8 1.7 1.5 1.15 1.1 1.1 4.9 4.7 4.5 2.8 2.7 2.6 2.4 2.2 1.7 1.6 1.5 6.6 6.3 6.0 3.8 3.6 3.5 3.2 2.9 2.2 2.1 2.2 8.9 8.5 8.1 5.2 4.9 4.7 4.3 3.9 2.9 2.8 3 11.8 11.3 10.8 6.8 6.5 6.3 5.7 5.2 4.0 3.8 4 15.7 15 14.4 8.9 8.5 8.2 7.4 6.8 5.1 4.9 5.5 20.9 20 19.2 12.1 11.5 11.1 10.1 9.2 7.0 6.7 7.5 28.2 27 25.9 16.3 15.5 14.9 13.6 12.4 9.3 8.9 11 39.7 38 36.4 23.2 22 21.2 19.3 17.6 13.4 12.8 15 53.3 51 48.9 30.5 29 28.0 25.4 23 17.8 17 18.5 63.8 61 58.5 36.8 35 33.7 30.7 28 22.0 21 22 75.3 72 69 43.2 41 39.5 35.9 33 25.1 24 30 100 96 92 57.9 55 53 48.2 44 33.5 32 37 120 115 110 69 66 64 58 53 40.8 39 45 146 140 134 84 80 77 70 64 49.1 47 55 177 169 162 102 97 93 85 78 59.6 57 75 240 230 220 139 132 127 116 106 81 77 90 291 278 266 168 160 154 140 128 97 93 110 355 340 326 205 195 188 171 156 118 113 132 418 400 383 242 230 222 202 184 140 134 160 509 487 467 295 280 270 245 224 169 162 200 637 609 584 368 350 337 307 280 212 203 250 782 748 717 453 430 414 377 344 261 250 315 983 940 901 568 540 520 473 432 327 313 355 1109 1061 1017 642 610 588 535 488 370 354 400 1255 1200 1150 726 690 665 605 552 418 400 500 1545 1478 1416 895 850 819 745 680 515 493 560 1727 1652 1583 1000 950 916 832 760 576 551 630 1928 1844 1767 1116 1060 1022 929 848 643 615 710 2164 2070 1984 1253 1190 1147 1043 952 721 690 800 2446 2340 2243 1417 1346 1297 1179 1076 815 780 900 2760 2640 2530 1598 1518 1463 1330 1214 920 880 1000 3042 2910 2789 1761 1673 1613 1466 1339 1014 970 IEC Motor nominal current: standardised values in blue colour (according to IEC 60947-4-1 Annex G) MotorPowerkW
ABB power solutions 23 Utilisation Categories: A contactor’s duty is characterised by the utilization categorytogether with the rated operational voltage and current indicated. Utilization Categories for Contactors According to IEC 60947-4-1: Alternating current AC-1 Non-inductive or slightly inductive loads, resistancefurnaces. AC-2 Slip-ring motors: starting, switching off. AC-3 Cage motors: starting, switching off runningmotors. AC-4 Cage motors: starting, switching off runningmotors. AC-5a Discharge lamp switching. AC-5b Incandescent lamp switching. AC-6a Transformer switching. AC-6b Capacitor bank switching. AC-8a Hermetic refrigeration compressor motor controlwith manual resetting of overload releases. AC-8b Hermetic refrigeration compressor motor controlwith automatic resetting of overload releases. Direct current: DC-1 Non inductive or slightly inductive loads, resistancefurnaces. DC-3 Shunt motors: starting, plugging, inching, dynamicbreaking of d.c. motors. DC-5 Series motors: starting, plugging, inching, dynamicbreaking of d.c. motors. DC6 Incandescent lamp switching. Types of Co-ordination IEC 60947-4-1 (EN 60947-4-1) defines two types of co-ordinationaccording to the expected level of service continuity. Acceptableextreme damage for the switchgear is divided into two types. Type 1: In short-circuit conditions, the contactor or starter does not endanger persons or installations and will notbe able to then operate without being repaired orhaving parts replaced. Type 2: In short-circuit conditions, the contactor or starter does not endanger persons or installations and will beable to operate afterwards. The risk of contacts lightwelding is acceptable.
24 ABB power solutions Low Voltage AC & DC Drives The Range – Machinery Drives – Standard Drives – Industrial Drives– DC Drives ABB AC drives The ABB AC drives product range is the widest available fromany manufacturer, from 0.18 to 5600 kW. ABB drives is areference for drives users the world over that signifies reliability,simplicity, flexibility and ingenuity, throughout the lifecycle of anAC drive. ABB machinery drives ABB offers machinery builders AC drives from component drivesup to high performance machinery drives. Global support andservice guarantees lifelong satisfaction. ABB machinery drivesprovide speed control of diverse applications from spa bathmotors to treadmill motors, as well as high precisionapplications such as positioning and synchronisation systems. ABB machinery drives ACS55Power range 0.18 to 0.37 kW (1-phase, 100 to 120 V)Power range 0.18 to 2.2 kW (1-phase, 200 to 240 V) ACS150Power range 0.37 to 2.2 kW (1-phase/3-phase, 200 to 240 V)Power range 0.37 to 4 kW (3-phase, 380 to 480 V) ACS350Power range 0.37 to 2.2 kW (1-phase, 200 to 240 V)Power range 0.37 to 11 kW (3-phase, 200 to 240 V)Power range 0.37 to 22 kW (3-phase, 380 to 480 V) ACSM1Power range 0.75 to 160 kW (3-phase, 380 to 480 V) ABB drives bring together a world leading and recognized brand which has carved a niche as global number one supplier for low voltage AC drives and DC drives.
ABB power solutions 25 ABB industrial drives ACS800, drive modulesPower range 0.55 to 2000 kW (230 to 690 V) ACS850, drives modulesPower range 1.1 to 500 kW (380 to 500 V) ACQ810, drive modulesPower range 1.1 to 400 kW (380 to 480 V) ACS800, single drivesPower range 0.55 to 5600 kW (230 to 690 V) ACS800, multidrivesPower range 1.1 to 5600 kW (380 to 690 V) ABB DC drives Power range 9 to 18 MW6 pulse or 12 pulse systems DCS400 series3-phase 230 to 500 V AC20 to 1000 A DC DCS800-S series230 to 1000 V AC20 to 5200 A DCS800-A series230 to 1200 V AC20 to 20000 A ABB standard drives ACS310Power range 0.37 to 11 kW (3-phase, 200 to 240 V)Power range 0.37 to 22 kW (3-phase, 380 to 480 V) ACS550-01Power range 0.75 to 75 kW (3-phase, 200 to 240 V)Power range 0.75 to 160 kW (3-phase, 380 to 480 V) ACS550-02Power range 200 to 355 kW (3-phase, 380 to 480 V) ABB standard drives ABB standard drives are simple to buy, install, configureand use, saving considerable time. They are widely availablethrough ABB’s distributors, hence the use of the termstandard. The drives have common user and processinterface with fieldbus, common software tools for sizing,commissioning, maintenance and common spare parts. ABB industrial drives ABB industrial drives are designed for applications such asthose in process industries like pulp & paper, metals,mining, cement, power, chemical, oil & gas and food &beverage. ABB industrial drives are available as completeAC drives and as modules to meet the requirements of theusers, OEMs and system integrators. These highly flexibleAC drives can be tailored to meet the precise needs ofindustrial applications and as such specific configuration ofthe drive can be carried out during ordering. The completedrives and modules cover a wide range of powers andvoltages up to 690 V. ABB industrial drives come with abroad selection of inbuilt options. These drives can be easilyprogrammed which makes adaptation to differentapplications easy. ABB DC drives ABB DC drives offer the highest power to size ratio alongwith onboard field exciters and integrated PLC, makingthem the most suitable DC drive for all new and retrofitapplications. The auto-tuning facility and the self-explanatory intelligent software minimises the start-up time,eases daily operation and increases your productivity andquality. ABB DC drives can be used in most industries such asmetals, cement, mining, pulp & paper, printing, food &beverages, wire drawing, test rigs, ski lifts and cranes. The drives are also suitable for non-motor uses like DCchargers and electromagnetic applications. ABB offers three-phase DC drives ranging from 9 kW (12hp) up to 18 MW (24000 hp). ABB DC drives can be delivered as converter modules,complete cabinets and retrofit kits.
26 ABB power solutions Power Factor Correction – Capacitor Units type CLMD Modular Design The CLMD capacitor is a unit that lends itself easily to modularsystems. Dry Type Design – Low Losses The dielectric of the CLMD capacitor is made of dry type low losspolypropylene, a system that offers very low dielectric losses anddoes not give any risk of leakage. Typical losses less than 0.2Watt/KVAr (excluding discharge resistors). Long Life-Self Healing The self-healing properties of the capacitor elements ensure thelong life of the CLMD capacitor. Protection and Safety The CLMD capacitor incorporates the well known vermiculitefilling of ABB’s capacitors, an efficient means of obtaining a safeprotection. Unique Sequential Disconnector A unique Sequential Protection System ensures that eachindividual element can be disconnected from the circuit at the endof its life. Security and Reliability The CLMD capacitor is equipped with discharge resistors and isready for installation. Ease of Installation The two slots allow easy and speedy installation. Description The ABB CLMD capacitors consist of a number of woundelements made with a dielectric of metallised polypropylene film.These dry windings are provided with a Sequential Disconnectorensuring that each element can be reliably and selectivelydisconnected from the circuit at the end of its life. They receive atreatment under a vacuum in order to ensure perfect electricalcharacteristics. Each winding is placed in aplastic case and encapsulated in thermosetting resin in order toobtain a perfectly sealed element. The elements are placed inside a sheet steel box and connectedin such a way as to supply the single or three phase power at therequired voltage and frequency. The sheet steel box is filled with inorganic, inert and fire proofgranules in order to absorb the energy produced in case of apossible defect at the end of an elements life. The CLMD unitsare also provided with thermal equalisers to ensure effective heatdissipation. Technical Specifications: Voltage range: From 380V-525V standardFrequency: 50Hz standardConnection: 3-phase as standard (single phase on request)Discharge resistors: Permanently connected built-in discharge resistors are sized to ensure safe discharge of the capacitor toless than 50V in 1 minute after switch offTerminals: Threaded, M6 to M12 according to power of thecapacitorEarth: An M8 terminal is included. (M6 on CLMD14)Cable Input: By customerCase Material: Mild steelColour: Light Grey RAL7032Fixing: With two slotsLocation: Well ventilated indoor (outdoor on request)Protection: IP42 (IP54 on request)Maximum Ambient Temperature: +50ºc Class "D" according toIEC831Minimum Ambient Temperature: - indoor: -25°c, outdoor: -40ºcMinimum Distance Between Units and Wall: 50mm(recommended)Losses: (Discharge resistors included): Less than 0.5 Watt/kVArTolerance on Capacitance: -5% + 15% Voltage Test:– between terminal: 2.15 Un for 10 seconds– between terminals and earth: 3kV for 10 seconds The acceptable overloads are those specified in IEC 831 – 1&2:– overvoltage tolerance: 10% max. at intervals– overcurrent tolerance: 30% continuously– maximum overload: stable operation at 135% of the normal rating (generated by overvoltage and harmonics) IMPORTANCE NOTICE The installation of capacitors on networks disturbed by harmonicsmay require special precautions, especially when there is a risk ofresonance.
ABB power solutions 27 Reduction of Harmonic Distortion There are 2 effective ways to reduce or eliminate harmoniccurrents on an electrical system. These are Passive and ActiveFilters. Passive Filters in their basic form comprise a capacitor connectedin series with a reactor tuned to the frequency to be eliminated. Intheory the impedance of the filter is zero and therefore all of theparticular harmonic current is absorbed by the filter. In practicehowever, the capacitor and reactor are usually tuned slightlybelow the harmonic frequency. This together with the naturalresistance of the circuit means that only a small acceptable levelof harmonic current will flow in the network. When it is necessaryto reduce more than one harmonic a multi arm filter may berequired. Passive filters are used where the system has sufficient inductivekvar to be compensated by the capacitor within the filter andwhere a cost effective solution to reactive power compensationand filtering is required. The principle of Active Filtering is fundamentally different from thatof the passive filter. The passive filter is not controlled and thefiltering is a result of the impedance characteristics of the system.The active filter instead measures the harmonic currents andgenerates actively a harmonic current that was measured. Theoriginal harmonic currents are thereby cancelled. The principle isshown in the diagram. Type Rating (KVAR) 400V 50Hz Terminal Weight 415V 50Hz M Packed (KG) CLMD 14 0.9 0.83 16mm block 2.5 1.4 1.3 " " 2.5 2.0 1.8 " " 2.5 2.7 2.5 " " 2.5 star connected 4.2 3.9 " " 2.5 480 Volt Dielectric 5.5 5.0 " " 2.5 Only available 6.2 5.7 " " 2.5 To IPOO 8.5 8.0 " " 2.5 10.0 9.3 " " 2.5 11.0 10.0 " " 2.5 12.5 12.0 " " 2.5 16.3 15.0 " " 2.5 CLMD43 16.0 15.0 M6 4.5 21.0 19.5 M6 5.0 22.0 20.0 M6 5.0 25.0 23.0 M6 5.5 27.0 25.0 M6 5.5 CLMD53 30.0 26.0 M8 9.0 32.0 30.0 M8 9.0 37.5 35.0 M8 10.0 43.0 40.0 M8 11.0 50.0 45.0 M8 11.5 CLMD63 54.0 50.0 M10 15.5 65.0 60.0 M10 17.0 75.0 70.0 M10 18.0 86.0 80.0 M12 23.0 CLMD83 90.0 84.0 M12 25.0 100.0 93.0 M12 25.0 110.0 100.0 M12 25.0 130.0 120.0 M12 27.0 Load Alteration Whenever load expansion is considered, with or withoutadditional power factor correction equipment, the networkimpedance is likely to change and existing filter equipment mustbe re-appraised in conjunction with the new load condition andbe suitably uprated. It is not recommended to have two or morefilters fine tuned to the same busbar system. Slight tuningdifferences may cause one filter to take a much larger share ofthe harmonic distortion, or even cause a harmonic resonancecondition leading to amplification of the very harmonicorder for which the equipment has been designed to reduce.When there is a need to vary the power factor correctioncomponent of a harmonic filter, careful consideration of allparameters is necessary. Active Filters offer considerable flexibility for load expansion orwhere the nature of the load is likely to change. The levels ofharmonic current reduction can be reselected to suit newparameters and with the modular construction used in ABB PQFActive Filters additional power modules can be added to thesystem for more harmonic current elimination. The active filter canbe used for loads that have high power factor and isprogrammable for changing loads. ABB have a wealth ofexperience in designing, manufacturing and supply filter systemsof both passive or active types and hybrid solutions embodyingboth technologies for cost efficient reactive power compensationand reduction of harmonic distortion. Harmonic Analysis To determine capacitor and filter requirements to meet specificharmonic conditions, it is necessary to establish with accuracythe impedance of the supply network and the value of eachharmonic current experienced at the point of intended connectionof any filter or power factor correction capacitor. ABB is theleading manufacturer and supplier of Harmonic Filter Systems atall voltages. Site analysis and scheme design are undertaken onan individual basis to utilise our technical expertise to the bestadvantage of our customer in each case. Information Required In considering the application of power factor correctionequipment where harmonics are evident or suspected, detailedsite information will assist design of the most economic andtechnically acceptable scheme.Such information should always include:– Simplified line diagram of system– Supply Transformer(s) rating and impedance– Summary of system load including– Source of harmonics (AC Drives-DC Drives)– Type of harmonic generating equipment (e.g. 6 pulse)– Details of additional proposed harmonic current generating equipment – Ratings of existing capacitors– Rating of proposed power factor correction capacitors CT PQF
28 ABB power solutions Type Tested Assembles Introduction to Type-Tested & Partially Type-Tested Assembles IEC 60439-1-1999-09,EN60349-1 and BS EN60439-1 is part 1of the 439-series of standards and is the main part covering thegeneral requirements for type-tested assemblies. Parts 2, 3,and 4 of the standards deal with the particularrequirements for certain specialised forms of assemblies (seebelow). Low-voltage switchgear and controlgear assemblies -439-1: Specification for type-tested and partially type-tested assemblies. -439-2: Particular requirements for busbar trunking systems.-349-3: Particular requirements for assemblies intended to be installed where unskilled persons have access to theiruse. -439-4: Particular requirements for assemblies for construction sites. The need to conform to standards Low-voltage switchgear and controlgear come under the EU LowVoltage Directive, and since January 1st 1997, all new assembliesintended for use within the EU member states must be CE-marked to indicate that they conform with the essential safetyrequirements of this Directive. The Directive requires electrical equipment to be safe andconstructed in accordance with the principles generally acceptedwithin the member states of the EU as constituting goodengineering practice in relation to safety matters. It requires thatthe electrical equipment (assembly), together with itscomponents, is made in a way that ensures it can be safely andproperly assembled and connected. It also requires thatmeasures are taken to ensure that protection is assured againstvarious hazards which might arise from the electrical equipmentor by external influences on it. Some of the hazards listed by the directive include:– Direct and indirect contact with live parts– Dangerous temperatures, arcs or radiation– Overloading– Insulation failures– Mechanical failures– Expected environmental conditions– Non-electrical dangers caused by the assemblyThere is, of course, the proviso that an assembly is used in anapplication for which it was made, and that it is properly installed. Type-Tested Assembly (TTA) IEC 60439-1-1999-09 CLAUSE 2.1.1.1 A low- voltage switchgear and controlgear assembly conformingto anestablished type or system without deviations likely to significantlyinfluence the performance, from the typical assembly verified tobe in accordance with this standard. Notes: For various reasons, for example transport or production, certainsteps of assembly may take place outside the factory of themanufacturer of the TTA. Such an assembly is considered as aTTA provided the assembly is performed in accordance with themanufacturers instructions in such a manner that compliance ofthe established type or system with this standard is assured,including submission to applicable routine test. Partially Type-Tested Low-Voltage Switchgear & Controlgear asembly (PTTA) IEC 60439-1-1999-09 Clause 2.1.1.2 A low- voltage switchgear or controlgear assembly, containingboth typetested and non-type-tested arrangements provided thatthe latter are derived (e.g. by calculation) from type testedarrangements which have complied with the relevant tests.
ABB power solutions 29 Enclosure & Distribution Systems Our Range: Thanks to our innovative products, ABB has become the leadingmanufacturer of electrical distribution systems found on themarket today. We develop and produce custom electricaldistribution systems for all types of buildings including domestic,commercial and industrial. All our systems are fully type tested tonational and international standards. MNS: MNS Fully Type Tested Switchgear Assemblies (TTA) up to 6300Aand up to IP54, Special Colours, Fixed or Withdrawable fordistribution and motor control centres. Striebel & John: A comprehensive range of electrical distribution systems coveringconsumer units surface and flush, wall and floor standing systemsup to IP54 and Fire Protection Cabinets. Form 4 Tri Line-R TTAup to 4000A. Smissline: A Plug in distribution system rated up to 200A. Rated up to IP54in wall and floor standing systems. MCB Pan Assembly: A range of Pan Assembly Systems for miniature circuit breakerapplications up to 250A incoming. A full and comprehensiverange of incoming and outgoing devices and accessories areavailable, side, top and bottom extension boxes. MCCB Pan Assembly: A full and comprehensive range of TTA systems in MCCBarrangements. Incoming devices up to 800A and outgoingdevices from 10A up to 630A. Customised to customerrequirements. Mirage Pan Assembly: A 50KA miniature circuit breaker Pan Assembly TTA. Incomingdevices up to 630A, outgoing devices MCB’s up to 125A 50KA. Turati Sub & Main Distribution: A full range and comprehensive range of sub and maindistributions wall and floor standing TTA from 100A up to 4000A.ArTu K,L & M. IP rated up to IP65. Turati Automation Enclosures: A full range and comprehensive range of wall and floor mountedenclosures in wall, floor standing, control consoles and 19” racksystems for all control application areas. Rated up to IP65. Thereare also a full and comprehensive range of accessories available. Luca Plastic Enclosure Systems: A full range and comprehensive range of plastic enclosures fordistribution and control application for domestic, commercial andindustrial applications. IP rated up to IP65. Kabeldon IP Systems: IP distribution system for outdoor applications up to 1600Aincoming and outgoing up to 630A. Enclosures are hot dipgalvanised and fully TTA to IEC standards and Arctic weatherconditions.
30 ABB power solutions Forms of Separation Forms of Separation Main criteria No separation Separation of busbars fromthe functional units. Separation of busbars from thefunctional units and separationof all functional units from oneanother. Separation of the terminals forexternal conductors from thefunctional units, but not fromeach other. Separation of busbars from thefunctional units and separationof all functional units from oneanother, including the terminalsfor external conductors whichare an integral part of thefunctional unit. Sub-criteria Terminals for external conductors notseparated from busbars. Terminals for external conductorsseparated from busbars. Terminals for external conductors notseparated from busbars. Terminals for external conductorsseparated from busbars. Terminals for external conductors insame compartment as associatedfunctional unit. Terminals for external conductors not inthe same compartment as theassociated functional unit, but inindividual, separate, enclosedprotected spaces or compartments. Form Form 1 Form 2a Form 2b Form 3a Form 3b Form 4a Form 4b Type of construction Type 1 Busbar is achieved by insulated covering, e.g.sleeving, wrapping or coatings. Type 2 Busbar separation is by metallic or nonmetallic rigidbarriers or partitions. Type1 Busbar separation is achieved by insulated coverings,e.g sleeving, wrapping or coatings. Type 2 Busbar separation is by metallic or nonmetallic rigidbarriers or partitions. Type 1 Busbar separation is achieved by insulated coverings,e.g. sleeving, wrapping or coatings.Cables may be glanded elsewhere. Type 2 Busbar separation is by metallic or nonmetallic rigidbarriers or partitions Cables may be glanded elsewhere. Type 3 Busbar separation is by metallic or non-metallic rigidbarriers or partitions. The termination for each functional unithas its own integral glanding facility. Type 4 Busbar separation is achieved by insulted coverings,e.g. sleeving, wrapping or coatings.Cables may be glanded elsewhere. Type 5 Busbar separation is by metallic or nonmetallic rigidbarriers or partitions.Terminals may be separated by insulatedcoverings and glanded in common cablingchamber(s). Type 6 All separation requirements are bymetallic or non-metallic rigid barriers orpartitions. Cables are glanded in commonchamber(s). Type 7 All separation requirements are bymetallic or non-metallic rigid barriers orpartitions. The termination for each functionalunit has its own integral facility.
ABB power solutions 31 Form 1 Requirements Form 1 covers overall Assemblies which are enclosed so as toprovide protectionagainst contact with any internal live parts or components, butwhere no internalseparation is provided for functional units or terminations. For Form 1 i) Busbars are not separated from the functional units.ii) Functional units are not separated from other functional units.iii) Functional units are not separated from any incoming or outgoing termination. iv) Busbars are not separated from any incoming or outgoing terminations. Form 2 Requirements Form 2 defines overall Assemblies which are enclosed to provideprotection againstcontact with any internal live parts or components, and wherethere is internalseparation of the busbars from functional units.The following general conditions apply;i) Busbars are separated from functional units.ii) Functional units are not separated from other functional units.Compliance with the requirements of Form 2 may be offered byEIEMA manufacturersby any of the three methods. Specifiers and Users should clearlystate their preference. Form 1 Form 2 (form 2a) Basic form as a above. However, with this method terminals arenot separated from the busbars, or each other. The actual meansof separation is not defined in the standard. Form 2 Type1 (form 2b type 1) Main criteria as Form 2. Busbar separation is achieved byinsulated coverings, e.g. PVC sleeving, wrapping or coating.Terminals are therefore separated from the busbars, but not fromfunctional units or each other. Form 2 Type 2 (form 2b Type 2) Main criteria as Form 2. Busbar separation is achieved by metallicor non-metallic rigid barriers or partitions. Terminals are thereforeseparated from the busbars, but not from the functional units oreach other. Form 3 Requirements Form 3 defines overall Assemblies which are enclosed to provideprotection against contact with internal live parts andcomponents, and in which there is internal separation of allfunctional units from each other. Form 2a Form 2b Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit
32 ABB power solutions Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit Insulation The following general conditions apply; i) Busbars are separated from functional units.ii) Functional units are separated from each other.iii) Functional units are separated from incoming and outgoing terminals. iv) Incoming and outgoing terminals are not separated from each other. Compliance with the requirements of Form 3 may be offered byEIEMA manufacturers by any of the three methods. Specifiersand users should clearly state their preference. Form 3a Basic form as above. Terminals are not separated from thebusbars or each other. The actual means of separation is notdefined in the Standard. Form 3b Type 1 As basic Form 3. Busbar separation is achieved by insulatedcoverings, e.g. PVC sleeving, wrapping or coating. Terminals aretherefore separated from the busbars, but not from each other. Form 3a Form 3b Type 2 As basic Form 3. Busbar separation is achieved by metallic ornon-metallic rigid barriers or partitions. Terminals are thereforeseparated from the busbars, but not from each other. Form 4 Requirements Form 4 covers overall Assemblies which are so enclosed as toprovide protection against contact with internal live parts andcomponents, and in which there is internal separation of thebusbar system from functional units, and separation of allfunctional units from each other. Incoming and outgoing terminalsare also required to be separated from the busbars and fromeach other. The following general conditions apply; i) Busbars are separated from functional units.ii) Functional units are separated from each other.iii) Terminations to functional units are separated from each other.Compliance with any of the requirements of Form 4 may beoffered by EIEMA manufactures by any of the following sevenmethods. Specifiers and users should clearly indicate theirpreference. Form 4 Type 1(form 4a type 1) As basic Form 4. Busbar separation is achieved by insulatedcoverings, e.g. PVC sleeving, wrapping or coating. Cables areterminated within the same compartment as the associatedfunctional unit. Cables may be glanded elsewhere, e.g. in acommon cabling chamber. Form 4 Type 2 (Form 4a Type 2) As basic Form 4. Busbar separation is achieved by metallic ornon-metallic rigid barriers or partitions. Cables are terminatedwithin the same compartment as the functional unit. Cables maybe glanded elsewhere, e.g. in a common cabling chamber. Form 4a Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit Form 3b Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit Insulation
ABB power solutions 33 Form 4 Type 3 (Form 4a Type 3) As basic Form 4. Busbar separation is achieved by metallic ornon-metallic rigid barriers or partitions. Cables are terminatedwithin the same compartment as the functional unit. Thetermination for each functional unit has its own integral glandingfacility. Form 4 Type 4 (Form 4b Type 4) As basic Form 4. Busbar separation is achieved by insulatedcoverings, e.g. PVC sleeving, wrapping or coating. Terminals areextended to the functional unit and separated by insultedcoverings, e.g. PVC boots. Cables may be glanded elsewhere,e.g. in a common cabling chamber. Incoming Unit Outgoing Unit Outgoing Unit OutgoingUnit Insulation Form 4b Type 4 Incoming Cable Outgoing Cables Outgoing Cables Note: Where connections between the terminals and the functional unit pass through the same general compartment asthe busbar, busbar separation may be achieved by insulatedcovering of these connections only. Form 4 Type 5 (Form 4b Type 5) As basic Form 4. Busbar separation is achieved by metallic ornon-metallic rigid barriers or partitions. Terminals are external tothe functional unit compartment and separated by insultedcoverings, e.g. PVC boots. Cables may be glanded elsewhere,e.g. in a common cabling chamber. Form 4 Type 6 (Form 4b Type 6) As main criteria for Form 4. All separation is achieved by metallicor non metallic rigid barriers or partitions. Terminals are external tothe functional unit compartments and enclosed in their owncompartment by means of rigid barriers or partitions. Cables maybe glanded elsewhere, e.g. in a common cabling chamber. Form 4 Type 7 (Form 4b Type 7) As main criteria for Form 4. All separation requirements areachieved by metallic or non-metallic rigid barriers or partitions.Terminals are external to the functional unit compartment andenclosed in their own compartment by the means of rigid barriersor partitions complete with integral glanding facility. As indicated in the following table, the IP degree of protection isexpressed by two characteristic numbers depending on the behaviour of the product to which it refers according to theprescriptions of CEI 70-1 and IEC 60529 Standards. IP Ratings IP 0 No protection 1 Protection against the penetration of solid bodies witha diameter of over 50mm 2 Protection against the penetration of solid bodies witha diameter of over 12mm or a length of over 80mm 3 Protection against the penetration of solid bodies witha diameter or thickness of over 2.5mm 4 Protection against the penetration of solid bodies witha diameter or thickness of over 1.0mm 5 Protection against the penetration of dusts 6 Total protection against the penetration of dusts IP 0 No protection 1 Protection against the penetration of drops of waterfalling vertically 2 Protection against the penetration of drops of waterfalling at an angle of up to 15° from vertical 3 Protection against the penetration of drops of waterfalling at an angle of up to 60° from vertical 4 Protection against the penetration of splashes ofwater from all directions 5 Protection against the penetration of water sprayedby a hose from all directions 6 Protection against the penetration of sea water 7 Protection against the penetration of water duringtemporary immersion 8 Protection against the penetration of water duringcontinual immersion First number: protection against the penetration of solid bodies Second number: protection against the penetration of water Additional Letter Letter A Protected against access with the backof the hand B Protected against access with a finger C Protected access with a toole D Protected access with a wire
34 ABB power solutions ABB – the biggest supplier of electrical components, systems and services to the wind power industry Experience plays an important role when customers choose ABBfor their products, systems and services. Over 100 years ofexperience and collaboration with power utilities, the process andautomation industry and OEMs enables ABB to convert know-how and application understanding into products and solutions tobenefit the wind power industry. Sustainable solutions, reliabilityand knowledge of industry-specifics, such as grid codes, havemade ABB the leading partner for wind power. Renewable Energy ABB – present where you are ABB is close to its customers everywhere in the world. Our globalpresence offers customers easy access to leading electricalengineering products, systems and services everywhere in theworld.Innovation and quality, the key characteristics of our offering, arereinforced by our knowledge and understanding of localrequirements and needs, and of local manufacturing, service andlogistics. ABB companies operate in around 100 countries andemploy about 110,000 people.
ABB power solutions 35 Grid code knowledge for power quality, grid stability and improved control Grid codes have existed for decades, mainly as nationalregulations for connecting all types of large power generators toAC grids. The grid manages the reactive power supply to keepthe grid voltage within operational limits and recover voltageimmediately after a fault. Wind power generation, from large windfarms as well as a number of small turbine groups, now supplyhundreds of megawatts to several regional AC power grids. Theinternational harmonisation of national grid codes toaccommodate the growing contribution of renewable energygenerated from wind is ongoing. ABB supplies its customers witha variety of solutions and also participates in many internationalgroups addressing grid code issues. Reactive Power Compensation With advanced power electronics, ABB offers STATCOM systemknowledge. With its selection of compensator products such asPCS6000, SVC Light® and SVC, ABB also offers expertise forimplementing the functions for connecting wind farms to the grid.FACTS is an acronym for flexible AC transmission systems. ABB’ssystems based on power electronics offer dynamic reactivepower compensation based on voltage source convertertechnology. The solutions offer farm operators fast control,continuous compensation, low harmonics and low costs withincreased efficiency. Grid code compliant converters Converters, both low and medium voltage, are based onpremium frequency converter technology and are grid codecompliant. They can be single turbine installations with virtualdirect-torque-control towards the grid. Our converters ensurecontinuous operation even during times of grid fault. Theconverter control principle enables fast control, robustness,increased availability and a high quality of generated power.For wind farms and their reactive power compensation, we offertwo STATCOM solutions, depending on the ratings. PCS6000and SVC Light® are products based on, and equipped with,pulse-width-modulated control. They are particularly well adaptedto enhance grid code compliance of wind power applications ona large scale. Power stations are now built and operated by agrowing number of wind farm developers, increasing the supplyof wind-derived electricity. Grid connections in remote areas ABB’s HVDC Light® underground transmission system offersreliable grid connection and can be connected to any type ofwind power concept
Contact Us ABB Ltd.Belgard Road,Tallaght,Dublin 24.Tel: + 353 1 405 7300 Fax: + 353 1 405 7327 Email: [email protected] Web: www.abb.ie ABB Ltd.Blaris Industrial Estate,Lisburn,Co. AntrimBT27 5QBTel: + 44 28 9260 3500 Fax: + 44 28 9260 3484 Email: [email protected] Web: www.abb.ie © Copyright 2009 ABB. All rights reserved No part of this publication may bereproduced or transmitted in any form or bymeans, electronic, mechanical, photocopying,recording or otherwise without prior writtenpermission of ABB.