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MODSTACKIntelligent • Modular • Highly Integrated
Switch Fuse Disconnector System
2
Contents Modstack Switch-Fuse Disconnector System
■ Modular■ Compact■ Plug-in■ High degree of operator safety■ Easily installed■ Intelligent■ Highly integrated■ Energy management options■ Communications options■ Promotes savings
TimeMoneySpaceLabour
■ Long term data & event memory■ Current transformers■ Maximum Demand Meters■ Auxiliary Conatacts■ Motor Actuators■ KWh Monitoring■ RS485 Communication■ Three Phase Data Acquisition■ Ammeters■ Electronic Fuse Surveillance
EMS Energy Management Panel
Modstack Switch-Fuse 2-3Disconnector System
Modstack Switch Accessories 4-6
Modstack Mounting Accessories 7
Modstack Mounting System 8-9
Modstack Busbar System 10-11
Modstack Insallation Accessories 12-13
Modstack Switchboards 14-15
Energy Management System 16-17
Integrated EMS Application 18
Modstack Motor Actuator 19
Switch Specifications 20-21
Dimensions 22
Modstack Parts List 23
Installation Information 24-25
Modstack Mounting/Installation 26
Modstack Suggested Specification 27
3
Modstack Switch-Fuse Disconnector System
■ Unique self-aligning busbar plugs■ DIN & BS standards■ Up to 630A fused■ Padlockable rotary actuator■ Double break contacts■ Independent manual operation■ Fully comply with IEC947-3■ Rated for motor duty AC23■ Rated up to 690VAC and 440VDC■ Busbar coupling versions■ Integrated options
AmmetersCTs20mA transmittersFuse monitoringAuxiliary contactsCommunicationsMotor actuators
BusbarCouplingSwitch400/630A150mm* 1000A withsolid copperlinks see p10.
Size 2/3400/630A150mm
Size 00160A50mm
Size 1250A75mm
4
Modstack Switch Accessories
Transformer Transformer Rating (VA)Ratio CI.1 CI.3
50-5 – 0.6
75-5 1.0 1.3
100-5 1.6 2.0
125-5 2.2 2.6
150-5 2.8 3.8
200-5 4.0 4.6
250-5 5.2 6.2
300-5 3.75 3.75
400-5 5.0 7.5
500-5 5.0 7.5
600-5 5.0 5.0
75-1 0.8 1.1
100-1 1.4 1.8
125-1 2.0 2.4
150-1 2.6 3.0
200-1 3.7 4.0
250-1 5.0 5.4
300-1 3.75 3.75
400-1 5.0 7.5
500-1 5.0 7.5
600-1 5.0 5.0
Plug Connector
The plug connector is needed to bring out the auxiliary circuits for the use of:
■ Auxiliary contacts for switch positions indicators (1M x 1B).■ Current transformers for remote indication.■ Transducers for remote indication.■ The electronic fuse monitoring device.
The plug connector is accommodated in the busbar adapter. It is fitted insuch a way that it automatically makes contact with a socket connector whenthe switch is inserted.
Current Transformer
The current transformers are fittedinside the busbar adapter and areconnected to a meter in the wiringarea of the switch and/or to a 16-poleplug connector in the busbar adapter.
■ Class 1 available as standard■ Class 0.5 available on request■ 0...20mA transmitters available
Meters
Moving-iron ammeters andmaximum demand (bimetal)ammeters are available for fittinginto every size of fuse-combinationunit. Size 48 x 48 meters areequipped with plug-in contacts andare placed in the cable connectionarea of the fuse-combination unit.
When ordering, match CT primaryrating to the fuse rating.
Transformer ratings:
Auxiliary Contacts
Up to 3 changeover contacts canbe installed in the busbar adapterto indicate the switch position.Each c/o contact can be wired asa n/o and/or a n/c contact.The auxiliary contacts are installedat the factory, where they are wiredto the plug connector fitted in thebusbar adapter.
Technical Data: 12A: AC250V
Maximum Demand (bimetal) AmmeterPower consumption: N/1A: 0.9VA
N/5A: 1.6VA
Moving-iron AmmeterPower consumption: N/1A: 0.3VA
N/5A: 0.5VA
5
Modstack Switch Accessories
Electronic FuseMonitoring Device
The fuse monitoring device is builtinto the busbar adapter. Indicationof a defective fuse is given by meansof make and break contacts to theplug connector and by the indicatorlights on the front of the device(one per fuse and one event LED).
Technical Data 5A: AC 250V
Versions:
ES: 1 function LED internally powered
ES25A1: 4 LEDs, 1 per phase and1 function LED. Requires 24VDCsupply. Max. consumption 80mA
(see picture below)
Table 1: ES25A1 operating states
No. Operating State Relay State Break Contact N/C Make Contact N/O Function LED Green/Red F1 LED red F2 LED red F3 LED red
1 Delivery State Low Closed Open Off Off Off Off
2 Phase failure L1 – L3 Low Closed Open Flash Green Off Off Off
3 Fuses OK Low Closed Open Green Off Off Off
4 Fuse F1 defect High Open Closed Flash Green On Off Off
5 Fuse F2 defect High Open Closed Flash Green Off On Off
6 Fuse F3 defect High Open Closed Flash Green Off Off On
7 Fuse F1 and F3 defect High Open Closed Flash Green On Off On
8 Fuse monitor fault Low Closed Open Flash Red Off Off Off
9 Switch in off position Low Closed Open Green Off Off Off
6
Modstack Switch Accessories
1 Spring loaded busbar plug2 16 pole plug connector (auxiliary circuits)3 Current transformers4 Electronic modules5 Auxiliary contacts6 Double break contacts7 Insulated switch case8 Rotary actuator9 Cable connections
10 Padlocking facility11 Front cover
The control cables for the integrated switch options areconnected to the socket connector. The socket connectoritself is latched onto the guide. (See diagram)
Terminal range: 0.5-1.5mm2 Rated voltage: AC 400V
1 2
3
4
5
6
7
8
9
10
11
3 3
7
Modstack Mounting Accessories
O : off Open front cover I : on
Swicth Actuator
* Switch cover must be locked prior to switching
8
Modstack Mounting System
Fitting Dimensions
■ The dimensions details thepositioning of the modstacksupport rails (SRAIL) for install-ation into custom metalwork.
■ Dimensional jig available.Order 2 x 5KB2880-002.
■ For modular panels such asElsteel Techno, fix the verticaland horizontal support barsas per the dimensions shown.
■ For the Techno System, a “Half L”kit will need to be installed onthe left side of the switch tier tomaintain dimensional integrity(due to switch overhang).
■ Insert support rails ■ Fix busbar support, busbarand busbar cover supports
9
Modstack Mounting System
■ Attach busbar covers, shroudsand vent brackets
■ Clip in guide rails and fitswitches and vents
Busbar mm a b
40 x 10 290 270
50 x 10 300 280
60 x 10 310 290
80 x 10 330 310
100 x 10 350 330
Top View
10
Modstack Busbar System
Short Circuit ratings of Busbar Carrier (kA rms)
Cross-Section 0.1 second 1 second
of Busbar Busbar Carrier Separation
300mm 450mm 600mm 750mm 300mm 450mm 600mm
40 x 10mm 80 65 50 35 65 50 –
50 x 10mm 80 65 50 35 65 50 –
60 x 10mm 80 80 65 40 80 65 –
80 x 10mm 100 80 65 50 80 65 –
100 x 10mm 100 100 80 65 80 65 65
(100+40) x 10mm – – – – 80 65 65
Short Circuit Ratings
Short circuit protection of the busbarcarrier as a function of busbar carrierseparation and busbar cross-section(shown in table above).
Busbar Carriers
The busbar carriers (Fig. 1) can besupplied for each size of metriccopper busbar. The carriers are notadjustable. The fixed style of carrierensures high fault level protection(certificates available).
The busbar carriers can be fixed fromthe rear of the switchboard (BBSFXbracket Fig. 2) or from the front ofswitchboard (BBSB90 bracket Fig. 3).
Fig. 1
Fig. 2
Fig. 3
Fig. 4 Switch side view Fig. 5 Fig. 6
Versions are available with insulatedback plates for use in the lowestsupport position.
Busbar Isolation & Coupling
The vertical busbars that feed theModstack units can be dividedand isolated at any point along theirlength. This is achieved by using themoulded isolating units (Fig. 5, 6) tosplit and isolate the busbar. They arefitted within a 100mm busbar support.
The busbar can be coupled anduncoupled by using the Modstackbusbar coupling switch (Fig. 4).The busbar coupling switch comes in400A and 630A models. The 630Amodel can be rated at 1000A using1000A size 3 copper links (NH3/1000ISM). This switch performs thefunction of a 1000A load break switchin a quarter of the space.
11
Modstack Busbar System
Typical Current Carrying Capacities for Copper Busbar
Compact High Current Solution
The diagram to the left details thesolution for applications greater than1500A.1 When the 100 x 10mmbusbar rating is not adequate forthe distribution system, this set-upcan be used to increase the crosssectional area of the busbar to1400mm2 per phase.
By adding the 40 x 10mm busbar tothe 100 x 10mm busbar, a compactring feed is produced.
This configuration is housed insidethe standard 100mm busbar support.The combination has been type testedfor its short circuit rating.
1 At rating 1 in the table above.
Dimensions (mm) Cross-Section (mm2) Rated Current (A)1 Rated Current (A)2
40 x 10 400 715 570
50 x 10 500 852 695
60 x 10 600 985 800
80 x 10 800 1240 1010
100 x 10 1000 1490 1220
(100+40) x 10 1400 2180 1780
1 Rating @ 35°C Ambient, 70°C Rise,Enclosed Factor 0.72
2 Rating @ 40°C Ambient, 50°C Rise,Enclosed Factor 0.72
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Modstack Insallation Accessories
Type Description llustration
SRAIL Panel mounting frame section assembly kit (4 rails 2023mm).
3-pole busbar support,185mm interval between busbar centres.
BBS40 Busbar cross-section 40 x 10BBS50 Busbar cross-section 50 x 10BBS60 Busbar cross-section 60 x 10BBS80 Busbar cross-section 80 x 10BBS100 Busbar cross-section 100 x 10
3-pole busbar support, with backing plate,185mm interval between busbar centres.
BBS40BP Busbar cross-section 40 x 10BBS50BP Busbar cross-section 50 x 10BBS60BP Busbar cross-section 60 x 10BBS80BP Busbar cross-section 80 x 10BBS100BP Busbar cross-section 100 x 10
Busbar isolator, for lengthwise division distribution bar system,for insertion into BBS100.
SPLIT60 Busbar cross-section 60 x 10SPLIT80 Busbar cross-section 80 x 10SPLIT100 Busbar cross-section 100 x 10
BBSFX Fixing plate assembly kit for securing busbar support to the panelmounting frame section. (Order 1 for each busbar support).
BBSB90 Bracket for securing busbar supports when rear access is limited.(Order 2 for each busbar support).
BBCOVFX Fixing rail assembly kit for securing the busbar cover.
BBCOV Busbar cover, degree of protection IP2x, for clipping ontofixing rail (149mm).
WRCOV Cable connection area cover, degree of protection IP2x,for separating the cable connection area from the busbar area.
Guides for fitting switch units.
GD00 Size 00 - 50 unit height 50mmGD01 Size 00 - 1 unit height 75mmGD23 Size 2 - 3 unit height 150mm
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Type Description Illustration
Cable gland, for separating the component mounting areafrom the cable connection area.
CP00 Size 00 - 50 unit height 50mmCP01 Size 00 - 1 unit height 75mmCP23 Size 2 -3 unit height 150mm Size 00/1 Size 2/31
Mounting frame, for fitting the size 2/3 cable gland into the guide.
CPMF23 Size 2 - 3
Safety interlock can be retrofitted. Device can be energized onlywhen fully inserted and withdrawn only when de-energized.
SINT00 Safety interlock for 50mm switchSINT01 Safety interlock for 75mm switchSINT23 Safety interlock for 150mm switch
SOCONN 16-pole socket connector, for connection of customers’ control cables.
Transparent blanking covers for closing off future switch locations,with 3mm double ward key.
COV00 Size 00 - 50 unit height 50mmCOV01 Size 00 - 1 unit height 75mmCOV23 Size 2 -3 unit height 150mm
Guides required
Transparent blanking covers for closing off future switch locations, eachwith 6 ventilators to IP30, horizontal mounting, 3mm double ward key.
COV01V Size 00 - 1 unit height 75mmCOV23V Size 2 -3 unit height 150mm
Guides required
Steel vented covers.
VENT50UN 50 mm cover unpaintedVENT50BL 50mm cover painted black rippleVENT75UN 75mm cover unpaintedVENT75BL 75mm cover painted black ripple
5KB2890-001 Bracket for fitting steel vent to front rails,2 required per vent.
SWTOOL Puller tool,for removal of switch units from the guides.
1 Can only be used in conjunction with mounting frame
Modstack Insallation Accessories
Modstack Switchboards
14
RELEC Switchboards Pty Ltd, Hotel application (NSW)
Mr Noel Tavener, ProjectCoordinator, Nilsen Electric (Vic.).Light and Power application (VIC)
Mechanical Services Pty Ltd,Hospital Application (TAS)
15
Example of a servicedistribution boardcompletely protectedagainst contactwith live parts withfuse-combination units
Modstack Switchboards
Mechanical Services Pty Ltd,Hospital Application (TAS)
B.E. Switchcraft Pty Ltd.School/Sport stadium application (SA)
16
Energy Management System
The EMS energy management panel can collect and record data from any LVfeeder that is equipped with an EMDE transducer module. The user can define bydialog with the unit, the variables to be cyclically scanned and recorded on aPCMCIA memory card or transmitted via a fieldbus protocol to a higher controllevel. In addition, the EMS system logs events such as faults and the transgressionof preset limits.
■ One EMS panel can monitor up to 60 EMDE modules .■ The EMS panel is the same size as a size 1 switch.■ Standard visualisation software packages available.
EMD Digital Electronic Modules
The EMDE modules are equipped witha microcontroller with which allrelevant variables in an electricalthree-phase AC circuit can bemeasured. The EMDE module usesDigital Signal Processing to measurethe true RMS of any waveform.Transmission to EMS panel is via a2-wire RS485 system.
■ Fuse status (4 LED local readout)■ Voltage■ Current (instantaneous)■ Current (rms)■ Frequency■ Power factor■ Phase failure■ Phase-sequence■ Switch status■ Over/Undervoltage■ Over/Undercurrent■ Min/Max values
EMS Panel
■ Communications gateway■ Actual value display■ Data accumulation■ Power (VA, W, VAr)■ Power factor■ Limiting value monitoring■ Trend analysis■ Status information■ Event list■ Event recognition and prioritisation■ Remote interrogation■ Load analysis
Energy Management System
Basic unit
EMS IntelligentMetering Panel
Expansions and Accessories
SystemNetworking
Data CommunicationOption
Signal Input/OutputModule Option
RS-232 InterfaceOption
Profibus FMSOption
Profibus DPOption
Measurement and Control
Drive
ElectronicModules
Withdrawable metering unit for recordingall variables relevant to current andvoltage in the 3-phase system
Support of the"PROFIBUS DP" field bus
Support of the"PROFIBUS FMS" field bus
Serial data transmission
Event-controlled relay contacts forprocessing external input signals
Data communication module
System networking on PC-basedon-line visualising system
EMDE intelligent measuring sensorfor system data acquisition
Fuse combination blockswith SASIL-MOT motor drive
SystemAccessories
EMS statistics programfor Windows
17
Energy Management System
■ On screen data display■ Long term data store (PCMCIA)■ Communications gateway - fieldbus
Modstack Units
With integrated energy data acquisition,consisting of:
■ Basic unit with or without motor actuator■ EMDE built-in measuring sensor■ Built-in current transformers (3-phase)■ Built-in switch position display■ 3-phase voltage taps■ Data bus interface
EMS EnergyManagement Panel(24VDC supply)
EMDE Transducer
The EMDE transducer collects, buffers and transmits allrelevant three-phase parameters. The units can either beintegrated into the Modstack switchunit or mountedexternally on DIN rail to monitor MCCBs, ACBs, striptype fuse switches etc. The addressing is accomplishedvia the EMS panel during commissioning. One EMSpanel can monitor up to 60 EMDE transducers. Eachunit requires a 24VDC supply. The 3 auxiliary contacts(1 n/o, 2 n/c) indicate for fuse status, phase failure or ageneral alarm and are rated at 5A/250VAC.
18
Integrated EMS Application
MODSTACK System
Functional Structure
Higher Control Levels
High integration inthe control cabinet
Low-voltage switchgearcabinet with EMS EnergyManagement System
Voltage
Current
On/Off
PCCard
EMSMeasuring
Panel
EMDEModule
Relays LEDs Control Level
JM Bus
DP Profibus
Application Software
JeanVis Client (Visualisation)JeanVis Server (Profibus data server)
EMS metering panel
JM Bus
19
Modstack Motor Actuator
DIN 500V 690V Module Height
00 160A 100A 50mm
1 250A 200A 75mm
2 400A 315A 150mm
3 630A 500A 150mm
Latest Generation Switch-fuse Technology
The new generation of fuse combination units with motor drive, SASIL-MOT, can be
■ integrated in all common switchgear cabinet systems■ combined with all Modstack system products
and satisfies all modern requirements in terms of energy management andautomation in low voltage systems.
The front-mounted electric drive unit replaces the previous manual drive system forour switch-disconnector-fuses in the Modstack system format and contains all themotor-drive and electrical components required for control and monitoring.
General
■ Absolute shock-hazard and operating safety. In the activated state,the front cover with the drive unit cannot be opened.
■ Electronic and mechanical switch position display.■ Operating mode selectable by keyswitch (MAN, OFF, AUTO).■ Integrated fuse monitor/display LEDs■ Terminal block on the back panel for 24V remote control and bus system
(JM bus) for connection to the EMS System.■ Motor switching capacity.■ High load factors.■ Hazard-free replacement of LV HRC fuse-links, due to all pole safety
disconnection of incoming and outgoing circuits.■ Automatic switching when fuse blows.■ Can be operated manually if auxiliary supply fails. (With hex key).■ 24V DC, can be used on battery supply.
SASIL-MOT fuse combination units areavailable in the following DIN sizes:
Picture of motor actuator attached to size 00 switch
20
Switch Specifications
Switch size 00 1
Electrical Current Type VAC VAC DC DC VAC VAC DC DC Parameters
Rated operating voltage Ue V 500 690 220 440 500 690 220 440
Rated operating current Ie A 160 100 160 100 250 200 250 250
Conventional free air thermal current with fuse Ith A 160 100 160 100 250 200 250 250
Conventional free air thermal current with copper link Ith A 250 250 250 250 400 400 400 400
Rated frequency – Hz 40-60 40-60 – – 40-60 40-60 – –
Rated insulation voltage Ui V AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000
Rated impulse withstand voltage Uimp kV 8 8 8 8 8 8 8 8
Number of poles – – 3 3 2(1) 2(1) 3 3 2(1) 2(1)
Power loss Ith (equipment with no fuse) Pv W 48 19 32 13 66 45 44 44
Utilisation category – – AC-23B AC-23B DC-22B DC-21B AC-23B AC-23B DC-22B DC-21B
cos.ø/L/R t ms 0.35 0.45 2.5 1 0.35 0.35 2.5 1
Rated making capacity – A 1600 1000 640 150 2000 1600 1000 375
Rated breaking capacity – A 1280 800 640 150 1500 1200 1000 375
Electrical durability (operating cycles) – – 300 300 300 300 200 200 50 50
With fuse - conditional rated short circuit current (effective) – kA 65(2) 65 25 25 65(2) 65(2) 25 25
- conditional rated short circuit current (peak) – kA 143 143 – – 143 143 – –
- cos.ø/L/R t ms 0.25 0.2 15 15 0.25 0.25 15 15
With solid link - rated short time withstand current (1 second) Icw kA 8 7 – – 12 9 – –
- rated short circuit making capacity Icm kA 14 13 – – 24 16 – –
Fuse Links Size in accordance with DIN43620 – – 00 00 00 00 1 1 1 1
Max. rated current (operating class gL/gG) IN A 160 100 160 100 250 200 250 200
Max. allowable power loss of HRC fuse link Pv W 12 10 12 7.5 23 23 23 23
Mechanical Mechanical durability (operating cycles) – – 1700 1700 1700 1700 1000 1000 1000 1000
ParametersModule height – mm 50 50 50 50 75 75 75 75
Busbar thickness – mm 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2
Interval between busbar centres – mm 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5
Weight – kg 4.75 4.75 4.75/4.35(3) 4.75/4.35(3) 8.1 8.1 8.1 8.1
Cable Bolt diameter – – M8 M8 M8 M8 M10 M10 M10 M10 Connections
Cable lug (DIN46235) – mm2 1*10-95(4) 1*25-150 OR 2*25-70
Busbar – mm 24*5 30*10
Tightening torque – Nm 10 10 10 10 15 15 15 15
Protection Operating state – – IP41 IP41 IP41 IP41 IP41 IP41 IP41 IP41
Front cover open – – IP20 IP20 IP20 IP20 IP20 IP20 IP20 IP20
Operating Ambient temperature Tu °C -25 to +35°C, 55°C (5) -25 to +35°C, 55°C (5)
ConditionsDuty cycle – – Continuous duty Continuous duty
Actuation – – Independent manual operation Independent manual operation
Fitting position – – Horizontal / Vertical Horizontal / Vertical
Altitude – m up to 2000 up to 2000
Pollution degree – – 3 3
1 Phase L2 not connected AC22 versions available2 At 125A (00), 224A (500V, S1), 160A (690V, S1) fused rating3 2 pole version has centre pole removed4 Max lug width = 24mm5 With reduced operational current
21
Switch Specifications
Switch size 2 3
Electrical Current Type VAC VAC DC DC VAC VAC DC DC Parameters
Rated operating voltage Ue V 500 690 220 440 500 690 220 440
Rated operating current Ie A 400 315 400 400 630 500 630 630
Conventional free air thermal current with fuse Ith A 400 315 400 400 630 500 630 630
Conventional free air thermal current with copper link Ith A 630 630 630 630 1000 1000 1000 1000
Rated frequency – Hz 40-60 40-60 – – 40-60 40-60 – –
Rated insulation voltage Ui V AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000
Rated impulse withstand voltage Uimp kV 8 8 8 8 8 8 8 8
Number of poles – – 3 3 2(1) 2(1) 3 3 2(1) 2(1)
Power loss Ith (equipment with no fuse) Pv W 126 81 84 84 270 195 180 180
Utilisation category – – AC-23B AC-23B DC-22B DC-21B AC-23B AC-23B DC-22B DC-21B
cos.ø/L/R t ms 0.35 0.35 2.5 1 0.35 0.35 2.5 1
Rated making capacity – A 3200 2520 1600 600 5040 4000 2520 945
Rated breaking capacity – A 2400 1890 1600 600 3780 3000 2520 945
Electrical durability (operating cycles) – – 200 200 50 50 200 200 50 50
With fuse - conditional rated short circuit current (effective) – kA 80 80 25 25 80(6) 80 25 25
- conditional rated short circuit current (peak) – kA 176 176 – – 176 176 – –
- cos.ø/L/R t ms 0.2 0.2 15 15 0.2 0.2 15 15
With solid link - rated short time withstand current (1 second) Icw kA 16 13 – – 20 18 – –
- rated short circuit making capacity Icm kA 33 27 – – 41 37 – –
Fuse Links Size in accordance with DIN43620 – – 2 2 2 2 3 3 3 3
Max. rated current (operating class gL/gG) IN A 400 315 400 400 630 500 630 630
Max. allowable power loss of HRC fuse link Pv W 34 34 34 34 48 48 48 48
Mechanical Mechanical durability (operating cycles) – – 1000 1000 1000 1000 1000 1000 1000 1000 Parameters
Module height – mm 150 150 150 150 150 150 150 150
Busbar thickness – mm 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2
Interval between busbar centres – mm 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5
Weight – kg 15.5 15.5 15.5 15.5 16.5 16.5 16.5 16.5
Cable Bolt diameter – – M12 M12 M12 M12 M12 M12 M12 M12
ConnectionsCable lug (DIN46235) – mm2 1*35-300 OR 2*35-240 1*35-300 OR 2*35-240
Busbar – mm 40*10 40*10
Tightening torque – Nm 30 30 30 30 30 30 30 30
Protection Operating state – – IP41 IP41 IP41 IP41 IP41 IP41 IP41 IP41
Front cover open – – IP20 IP20 IP20 IP20 IP20 IP20 IP20 IP20
Operating Ambient temperature Tu °C -25 to +35°C, 55°C (5) -25 to +35°C, 55°C (5)
ConditionsDuty cycle – – Continuous duty Continuous duty
Actuation – – Independent manual operation Independent manual operation
Fitting position – – Horizontal / Vertical Horizontal / Vertical
Altitude – m up to 2000 up to 2000
Pollution degree – – 3 3
6 At 500A fused rating AC22 versions available
22
Dimensions
Size 00
Size 1
Size 3
23
Modstack Parts List
Part Number Description
SASDN003 size 00 DIN cfs 160A 50mm profile AC23 @ 500v
SASDN013 size 1 DIN cfs 250A 75mm profile AC23 @ 500v
SASDN223 size 2 DIN cfs 400A 150mm profile AC23 @ 400v, AC22 @ 500v
SASDN023 size 2 DIN cfs 400A 150mm profile AC23 @ 500v
SASDN233 size 3 DIN cfs 630A 150mm profile AC23 @ 400v, AC22 @ 500v
SASDN033 size 3 DIN cfs 630A 150mm profile AC23 @ 500v
SASDN002 size 00 DIN cfs 160A 50mm profile 2 POLE DC21/22
SASDN002 size 00 DIN cfs 160A 75mm profile 2 POLE DC21/22
SASDN012 size 1 DIN cfs 250A 75mm profile 2 POLE DC21/22
SASDN022 size 2 DIN cfs 400A 150mm profile 2 POLE DC21/22
SASDN032 size 3 DIN cfs 630A 150mm profile 2 POLE DC21/22
SASDNBC3 size 3 DIN 630A 150mm profile, bus bar coupling unit AC23 @ 500v
SASBS003 size 00 BS cfs 100A 75mm profile AC23 @ 500v
SASBS013 size 1 BS cfs 200A 75mm profile AC23 @ 500v
SASBS023 size 2 BS cfs 400A 150mm profile AC23 @ 500v
SASBS033 size 3 BS cfs 630A 150mm profile AC23 @ 500v
SASBS002 size 00 BS cfs 100A 75mm profile 2 POLE DC21/22
SASBS012 size 1 BS cfs 200A 75mm profile 2 POLE DC21/22
SASBS022 size 2 BS cfs 400A 150mm profile 2 POLE DC21/22
SASBS032 size 3 BS cfs 630A 150mm profile 2 POLE DC21/22
GD00 installation guides (pair) for size 00 switch
GD01 installation guides (pair) for size 1 switch
GD23 installation guides (pair) for size 2/3 switch
CP00 cable partitions for size 00 switch (3 pieces)
CP01 cable partitions for size 1 switch (3 pieces)
CPMF23 mounting frame for putting cable partitions in size 2/3 switches
CP23 cable partitions for size 2/3 switch (3 pieces)
COV00 blanking covers for closing off unoccupied locations,size 00, transparent
COV01 blanking covers for closing off unoccupied locations,size 1, transparent
COV23 blanking covers for closing off unoccupied locations,size 2, 3, transparent
COV01V blanking covers for closing off unoccupied locations,+ horizontal vent slots, size 1, transparent
COV23V blanking covers for closing off unoccupied locations,+ horizontal vent slots, size 2-3, transparent
VENT50UN 50mm blanking covers for closing off unoccupied locations,size 00, steel, vented, unpainted
VENT50BL 50mm blanking covers for closing off unoccupied locations,size 00, steel, vented, painted black
Part Number Description
VENT75UN 75mm blanking covers for closing off unoccupied locations,size 1, steel, vented, unpainted
VENT75BL 75mm blanking covers for closing off unoccupied locations,size 1, steel, vented, painted black
5KB2890-001 steel bracket for fixing steel vent, 2 required per vent
SRAIL panel mounting frame section assembly kit (4 rails)
5KB2880-002 support pan to maintain dimensional integrity with SRAIL installation
BBS40 40 x 10mm bus bar support
BBS50 50 x 10mm bus bar support
BBS60 60 x 10mm bus bar support
BBS80 80 x 10mm bus bar support
BBS100 100 x 10mm bus bar support
BBS40BP 40 x 10mm bus bar support with backing plate
BBS50BP 50 x 10mm bus bar support with backing plate
BBS60BP 60 x 10mm bus bar support with backing plate
BBS80BP 80 x 10mm bus bar support with backing plate
BBS100BP 100 x 10mm bus bar support with backing plate
BBSFX fixing plate assembly kit for securing bus bar support to framework
BBSB90 busbar support bracket for front connect switchboards
BBCOV busbar cover (150mm)
WRCOV shroud for wiring area
BBCOVFX fixing rail assembly kit for securing the busbar covers (2 rails)
SPLIT60 busbar isolator assembly kit 60
SPLIT80 busbar isolator assembly kit 80
SPLIT100 busbar isolator assembly kit 100
SINT00 safety interlock 00
SINT01 safety interlock 1
SINT23 safety interlock 2/3
SWTOOL switch removal tool
INSKIT installation kit, M6, M5 screws and 2 bit key with instructionsfor mounting
SASCOV00 spare front cover with handle 00 50mm, standard RHS cable zone
SASCOV01 spare front cover with handle 1 75mm, standard RHS cable zone
SASCOV02 spare front cover with handle 2 150mm, standard RHS cable zone
SASCOV03 spare front cover with handle 3 150mm, standard RHS cable zone
SASCOV00L spare front cover with handle 00 50mm, standard LHS cable zone
SASCOV01L spare front cover with handle 1 75mm, standard LHS cable zone
SASCOV02L spare front cover with handle 2 150mm, standard LHS cable zone
SOCONN 16 pole socket connector
24
Installation Information
For an effective MODSTACKinstallation, attention should be paidto stack layout, switch de-rating andbusbar loading. The de-rated currentcapacities as detailed in Graph 1 areconservative when used with the stacklayout instructions. If the guidelines asdetailed in the stack layout section areused in conjunction with the switchde-rating method, the MODSTACKdesign will be optimised with respectto maximum current carrying capacity,permissible temperature limits andheat dissipation.
Stack Layout
■ For effective loading and heatdissipation install switches inup to 400mm blocks.
■ Install vent sections (50/75mm)between the 400mm blocks.
■ Install the largest switches in thelowest positions.
■ See page 10 for busbar supportkA ratings for various spacing.
Switch De-rating
The MODSTACK system physical switch sizes are expressed in modules.MODSTACK is based on a 25mm module. The modules are detailed in Table 2.Apply the following switch de-rating method to each “stack” (tier) of switches.
1. Enter the number of switches of each size (00,1,2,3) in column 3.
2. Calculate the modular height (column 4 = column 2 x column 3).
3. Enter the diversity factor for the total number of main circuits according toeither AS3439.1 part 4.7 (table 1 below) or the customers value (for example,based on the size of the main switch/total fused rating of stack) in column 5.
Table 1
No. of main circuits 2 & 3 4 & 5 6 - 9 10+
Diversity factor (a) 0.9 0.8 0.7 0.6
4. Calculate the effective modular height (column 6 = column 4 x column 5).
5. Total the effective modular heights per switch (sum column 6).
6. Apply the total effective modular height (from step 5) to graph 1 and read offthe effective current carrying capacity for each switch size at the intersection ofthe curves (enter into column 7).
Table 2
COLUMN 1 COLUMN 2 COLUMN 3 COLUMN 4 COLUMN 5 COLUMN 6 COLUMN 7
Swich Module Number of Modular Diversity Effective Modular Effective CurrentType per unit Switches Height Factor Height Carrying Capacity
HE N HE * N a HE * N * a (A)
00/160A 2
1/250A 3
2/400A 6
3/630A 6
TOTAL
If the average ambient temperature varies from 35°C, the current carrying valuesfrom the de-rating curve (graph 1) should be multiplied by the following factors:
Table 3
Ambient Temp °C 20 25 30 35 40 45 50 55
Factor 1.15 1.10 1.05 1 0.95 0.90 0.85 0.80
25
Installation Information
Test Cubicle
Width: 1000mmHeight: 2200mmDepth: 600mmProtection: IP30Material: SteelVertical Bars: 1600A CU
The de-rating information andcorresponding current values areintended to be a guide only.Specific installations may requireindividual solutions dependingon layout, venting, IP rating etc.
Graph 1 IP30600
550
500
450
400
350
300
250
200
150
100
SASIL 3
SASIL 2
SASIL 1
SASIL 003 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60
Effective Modular Height
A
Table 4
COLUMN 1 COLUMN 2 COLUMN 3 COLUMN 4
Switch Type Fuse Ratings Fitted Quantity per Rating Diversity Factor Connected Load
00/160A
1/250A
2/400A
3/630A
TOTAL
Table 5 - Typical current carrying capacity of copper busbar
Dimensions (mm) Cross Section (mm2) Rated Current (A)1 Rated Current (A)2
40 x 10 400 715 570
50 x 10 500 852 695
60 x 10 600 985 800
80 x 10 800 1240 1010
100 x 10 1000 1490 1220
(100+40) x 10 1400 2180 1780
(1Rating @ 35°C Ambient temperature, 70°C rise, enclosed factor 0.72)
(2Rating @ 40°C Ambient temperature, 50°C rise, enclosed factor 0.72)
Busbar Loading
Carry out the following steps to calculatethe size of the vertical copper busbarrequired to supply the stack.
1. Enter the “fused rating” of eachswitch size in column 1.
2. Enter the quantity of each fusedswitch rating in column 2.
3. Enter the diversity factor (as perTable 2, column 5) in column 3.
4. Calculate the connected load.Column 4 = column 1 x 2 x 3.
5. Total the connected loads, sumcolumn 4. Use Table 5 to chooseappropriate busbar size.
26
Modstack Mounting/Installation
STEP 1 – Metalwork
Ensure SRAIL's are cut to the required length.Rear rails should be cut to 150mm multiplesi.e. 600, 750, 900, 1050, 1200, etc. to ensureshrouds and busbar supports can be easilyfitted. Add an additional 100mm to these lengthsif the mounting jigs are to left in the job.
Dimensional jigs are available (5KB2880-002).The jigs are fitted within the four rails at the topand the bottom positions. The assembly is thenfitted into the board. Weld or screw in the railsas required. The mounting jigs can be removedor left in the job depending on the supportstructure provided.
Install the busbar support brackets (BBSFX = 2brackets per support) onto the back of the rearrails. If rear access is not possible, use the 90degree bracket (BBSB90) and fix to the side ofthe rear rails. The vertical spacing of the busbarsupports depends on the short circuit rating ofthe bars and their size (p10). Busbar supportspacings should always be made at intervals of300, 450, 600mm. These spacings ensure thatthe busbar covers will always fit.
** A 50mm steel vent (VENT50xx) should befitted in front of each busbar support. Screw thetwo brackets onto the front rails ready for thevented cover. The brackets can be fitted beforeor after powder coating.
STEP 2 – Copper
If the MODSTACK is fed from the top, fix thebusbar support with the insulated back plate inthe lowest position, this provides an insulatedstop for the bars.
Fix the front half of the standard busbarsupports onto the busbar support brackets.Hold the nut in the support and tighten thesocket head studs. If busbar covers are beingused, fix the busbar cover support rails(BBCOVFX) to the front half of the busbarsupports once they have been cut to thecorrect length (distance from top support tobottom support).
Fit the 10mm copper busbar. Fit the rearsections of the busbar supports to the frontsections to clamp the copper in place. A 6mmhex key is required to tighten the support bolts.
STEP 3 – Busbar Covers (option)
Clip the 150mm busbar cover section (BBCOV)onto the support rails.
When a busbar support is between two busbarcovers, break off the top edge of the lowercover and the bottom edge of the higher coverwith a pair of pliers. The edges are designed tosnap off.
With good access to the cable side of theModstack, the wiring zone separators (WRCOV)can be clipped in. The WRCOV section helps tosegregate the cable zone from the busbar zone(i.e. for 3b or 4 type segregation).
STEP 4 – Switch Guides
Install the switch mounting guides as per therequired layout. Fit the rear mounting pins andthen bring the front of the guide from the insideof the equipment zone toward the target railand push home. Screw them in if necessary(M6 TT screw into rear rail). If required, thesafety interlocks can be installed in themounting guides opposite from the cable zone(just clip in).
STEP 5 – Switches
Slide the switches into the guides, push homeonto the busbars. Fix each switch to the guideswith four M5*20 pan head screws (one in eachcorner). The switches are now ready for cablingand fuse installation.
Note: While working on an open switch, thecovers can be clipped off by thumbing theblack tab at the hinge and moving the coveraway from the switch.
The Modstack switch systemlends itself to numerous mountingarrangements. Switches can bemounted horizontally or vertically.In the horizontal position, the switchescan be oriented so that the cablezone is located at either the left orthe right side of the switch. In thevertical position, the switches can beoriented so that the cable zone islocated either above or below theswitch. The phase rotation shouldbe checked in each case. Installationmay be performed by either:
1. Installing the mounting rails (SRAIL)as per the layout on pages 8 and 9in custom metalwork. The width ofthe cable zone would depend onthe size of the cables used.
2. Using modular switchboardsystems such as ELSTEEL Techno.
27
Modstack Suggested Specification
1. Switch System
1.1 Switch Properties
1.1.1 Cassette style switch fuse units shall be ofmodular construction and shall have acommon width throughout the range.
1.1.2 They shall be AC22 or 23 in accordancewith the relevant standards.
1.1.3 Operating handles shall be of the rotarytype and must be padlockable with at leastthree 8mm shank padlocks. The handle mustretract to a low profile automatically to ensure itcannot catch the clothing of an operator.
1.1.4 Guide rails must be provided to ensurecorrect alignment of switch fuses in stackconfigurations, and enable simple installationof a spare unit when the switchboard is inservice.
1.1.5 Switch fuse units shall have self-aligningbusbar plugs to ensure optimum plug/coppercontact.
1.1.6 Switch fuse units shall have removablefront covers to allow easy access under serviceconditions.
1.2 Safety
1.2.1 Access to terminals and fuses shall be viaa single interlocked door.
1.2.2 Switch fuse units must have interlockeddoors to ensure access to fuses is only possiblewhen switch units are in the 'OFF' position.
1.2.3 Switch fuse units must have a doublebreak mechanism to ensure that both the lineand load terminals of the fuse link are isolatedfrom the supply and the load when the switch isin the 'OFF' position.
1.2.4 A safety mechanism (safety interlock)must ensure the switch fuse cannot be actuatedunless the switch fuse unit is fully engaged intothe line side busbars. This mechanism mustalso ensure that switches cannot be disengagedfrom the busbar when in the 'ON' position.
1.3 Busbar System
1.3.1 The busbar system must be type tested inaccordance with the relevant standard andshall be able to withstand the thermal anddynamic stresses of a 63 or 80kA short circuitfor 1 second duration minimum.
1.3.2 The busbar system shall use 10mmsquare edge copper on 185mm centres.
1.4 Installation
1.4.1 Temperature derating information mustbe made available, if required, to ensureoptimum performance.
1.4.2 Ensure adequate ventilation isincorporated in to the stack design, wherenecessary, to ensure performance of the switchfuses is optimised in stack configurations.Consideration must also be given to thelocation of the switch fuses in stacks, ensuringthat higher rated devices are installed lowest.
1.5 Options
1.5.1 Switch fuse units shall be available withintegral current transformers (up to three class1 or class 0.5), for metering/measurementpurposes that do not restrict cable connection inany way. The installation of currenttransformers in close proximity to the load sideterminals is unacceptable.
1.5.2 All auxiliary circuit connections (i.e.transducers, fuse monitoring, remote statusindication, parameter metering etc.) shall beconnected via a connector plug system (i.e. nohard wiring to individual switches) enabling easyservice, replacement or upgrading of switch fuses.
1.5.3 Load side terminal shrouds must beavailable to ensure that live terminals areproperly protected and must provide IP2Xsegregation in accordance with AS3439.1.
1.5.4 IP2X busbar covers and cable zone/busbar zone partitions must be available toprovide the required degree of switchboardsegregation (form 3a, 3b, and 4) in accordancewith AS3439.1.
1.5.5 Switch fuse units shall be available withultra compact electronic motor drives whichenable the switch units to be operated inautomatic/remote/manual modes.
2. Energy Management System
2.1 Parameter Monitor Transducers
2.1.1 The three phase parameter monitoringtransducers shall be available as integrateddevices inside the switch fuse units and must beable to monitor instantaneous voltage,instantaneous current, mean current, powerfactor, frequency, fuse status and switch status
2.1.2 The monitoring transducers shall analysea true RMS indication of the actual waveform.
2.1.3 The three phase parameter monitoringtransducers shall communicate to thecommunications gateway via a 2-wire system.
2.2 Communications Gateway
2.2.1 The communications gateway shall beable to communicate with up to 60 three phaseparameter monitoring transducers.
2.2.2 The communications gateway shall beable to be slaved into a block of 32 gatewaysthus potentially monitoring up to 1920transducer units.
2.2.3 The communications gateway shall be ofa modular construction including its own LCDdisplay and keypad. The gateway shall be ableto be installed in the same guide system as thesize 1 switch fuse units.
2.2.4 The communications gateway shall allowconnection to external peripheral devices (bussystems, serial links).
2.2.5 The communications gateway shalldisplay all measured parameters includingvoltage, current, phase, power and powerfactor for individual phases, switches andgroups of switches. The gateway shall monitorlimiting values, analyse trends, provide statusalarms and produce an event list.
2.2.6 The communications gateway shallsupport data accumulation with a useraccessible flash memory card (PCMCIA).
2.2.7 The communications gateway shallconnect to the power supply and transducernetwork via a plug connector (no direct hardwiring) thus allowing easy access for installationor maintenance.
TAN
5285
3/0
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