User Manual

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SEN Plus low voltage

switchgear
User Manual
Include:
SEN Plus with split main busbar
31T002702_Rev.05
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Table of contents
1. Safety notes . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2. Control Centre and Outgoing Panel (type B60, B185) with plug-in
modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2. General characteristics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.2.1. Main components of a motor starter application. . . . . . . . . . . . . . . . . . . . . 12
2.2.2. Main components of a fused load break switch module SASILplus. . . . . . . . . . . . 13
2.2.3. Main components of a fused load break switch module SlimLine. . . . . . . . . . . . 14
2.3. Opening a door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.1. Opening the door of a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.3.2. Opening the door of a load break switch module SASILplus. . . . . . . . . . . . . . . 16
2.3.3. Mounting the Outgoing Plug in the column. . . . . . . . . . . . . . . . . . . . . . . . 17
2.4. Inserting / removing a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.1. Inserting a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.4.2. Locking the module in the compartment. . . . . . . . . . . . . . . . . . . . . . . . . 19
2.4.3. Inserting a load break switch module SASILplus . . . . . . . . . . . . . . . . . . . . . 20
^
2.4.4. Locking the load break switch module SASILplus in the compartment. . . . . . . . . . 21
2.4.5. Inserting a load break switch module SlimLine. . . . . . . . . . . . . . . . . . . . . . 22 1
2.4.6. Mounting the Outgoing Plug in the column. . . . . . . . . . . . . . . . . . . . . . . . 23
2.4.7. Removing a module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 2
2.4.8. Removing a load break switch module SASILplus. . . . . . . . . . . . . . . . . . . . . 25
2.4.9. Removing a load break switch module SlimLine . . . . . . . . . . . . . . . . . . . . . 26 3
2.5. Connecting a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.5.1. Removing the bottom plate (for small modules). . . . . . . . . . . . . . . . . . . . . . 27 4
2.5.2. Connecting the main cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.5.3. Connecting the auxiliary cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 5
2.5.4. Inserting the bottom plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.6. Replacing a compartment door. . . . . . . . . . . . . . . . . . . . . . . . . . . 30 6
2.6.1. Replacing a compartment door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.6.2. Disconnecting cables from the compartment door. . . . . . . . . . . . . . . . . . . . 31 7
2.6.3. Mounting a compartment door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.7. Removing the IP20 shroud from the vertical busbar. . . . . . . . . . . . . . . . . 33 8
2.8. Change module arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
2.8.1. Example: replacing 2 modules size 5E by 1 module size 10E. . . . . . . . . . . . . . . . 34
9
3. Control Centre with withdrawable modules. . . . . . . . . . . 35
3.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 10
3.2. General characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.2.1. Functional segments of the column. . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 11
3.2.2. Functional parts of the module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
3.2.3. Plugs types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

3.2.4. Main components of a motor starter application. . . . . . . . . . . . . . . . . . . . . 38
3.3. Worm gear mechanism operation. . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.1. Operating the worm gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
3.3.2. Operating positions of the withdrawable module. . . . . . . . . . . . . . . . . . . . . 40
3.4. Opening a door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.4.1. Opening the door of a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
3.5. Inserting / removing a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3
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Table of contents
3.5.1. Inserting a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
3.5.2. Locking / unlocking the module in the compartment. . . . . . . . . . . . . . . . . . . 44
3.5.3. Removing a module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
3.6. Connecting a module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.6.1. Connecting the main cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
3.6.2. Connecting the main cables in cubicles with separation form 4b type 7. . . . . . . . . 47
3.6.3. Connecting the control cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
3.6.4. Inserting the bottom plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
3.6.5. Removing 24-pole auxiliary control plug. . . . . . . . . . . . . . . . . . . . . . . . . . 52
3.6.6. Removing the vertical separation between the cable and equipment compartment. . 53
3.6.7. Mounting the outgoing plug in the column. . . . . . . . . . . . . . . . . . . . . . . . 54
3.7. Change module arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
3.7.1. Example: replacing 2 modules size 5E by 1 module size 10E. . . . . . . . . . . . . . . . 55
4. Outgoing Panel type D. . . . . . . . . . . . . . . . . . . . . 57
4.1. Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
^ 4.2. Functional segments of the column. . . . . . . . . . . . . . . . . . . . . . . . . 58
4.3. Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
1 4.4. Connecting the main cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
4.5. InLine ZHBM operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2 5. Power Centre . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3 5.2. Functional segments of the column. . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3. Table of panel to panel electrical connection cross-sections. . . . . . . . . . . . 64
4 6. Installation of a column. . . . . . . . . . . . . . . . . . . . 66
6.1. Storage of columns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5 6.2. Transport of a column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6.3. Lifting of a breaker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6 6.4. Installation space of a column. . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.5. Erecting a column. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7 6.6. Connecting the base frame to the column. . . . . . . . . . . . . . . . . . . . . . 74
6.7. Connecting two columns. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8 6.8. Connecting the main busbar system. . . . . . . . . . . . . . . . . . . . . . . . . 77
6.9. Torque values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9 6.9.1. Torque values for mechanical connections. . . . . . . . . . . . . . . . . . . . . . . . 80
6.9.2. Torque values for electrical connections. . . . . . . . . . . . . . . . . . . . . . . . . . 82
10 7. Routine testing. . . . . . . . . . . . . . . . . . . . . . . . 83
11 8. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 84
8.1. Use of hand tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
9. End of column service life. . . . . . . . . . . . . . . . . . . 87
10. After sales and service . . . . . . . . . . . . . . . . . . . . 88
11. Contacts details of after Sales & Service Organization. . . . . 90
4
^
10
11
Notes
5
Notes
1. Safety notes
Principle This document is based on information available at the time of

its publication. While efforts have been made to ensure accuracy,
the information contained herein does not cover all details or
variations in hardware and software, nor does it provide for every
possible contingency in connection with installation, operation, and
maintenance. Features may be described herein that are not present
in all hardware and software systems. ABB assumes no obligation
of notice to holders of this document with respect to changes
subsequently made.
ABB makes no representation or warranty, expressed, implied, or
statutory, with respect to, and assumes no responsibility for the
accuracy, completeness, sufficiency, or usefulness of the information
contained herein. No warrantees of merchantability or fitness for
purpose shall apply.
^
Labels WARNING WARNING

1
Warning notices are used to emphasize that hazardous voltage, 3

currents, or other conditions that could cause personal injury are
present in this equipment or may be associated with its use. 4
Warning notices are also used for situations in which inattention or
lack of equipment or knowledge could cause either personal injury or 5
damage to equipment.
6
CAUTION 7
CAUTION
8
Caution notices are used for situations in which equipment might be

9
damaged if care is not taken.
10
11
NOTE

Notes call attention to information that is especially significant to

understanding and operating the equipment.
7
General notes Describe disclaims, purpose of this document, etc.
This manual contains procedures for receiving, handling, storage,
operation, and maintenance of SEN Plus - LV Switchgear.
The SEN Plus is designed to simplify the construction of a LV
switchgear assembly. Typical applications for such equipment are:
• Healthcare – Hospital building, medical equipment.
• Transportation – railways, airports, tunnels, naval.
• Commercial – Retail, Banks, Office & Commercial Buildings,
Hotels, Telecom.
• Water – Desalination Plants, Municipalities.
• Renewable Energies – Wind, Solar, Hydro, Gas, Incinerator Plants.
• Oil&Gas – On & Off Shore Sites, DW-MD-UP Stream Applications.
•
SEN Plus LV Switchgear described in this document is
IEC 61439-2 tested for use with wide range of ABB electrical
apparatus.
^
NOTE: The personnel responsible for installing, operating, and
1 servicing this equipment should be thoroughly familiar with the
contents of this manual.
2 Before any installation work is performed, thoroughly read and
understand the material in this instruction manual. A copy of the
3 instruction manual is shipped with each LV Switchgear assembly in
the control compartment. When requesting additional information
4 from ABB Industrial Solutions, include the complete data appearing
on the equipment nameplate, including requisition number.
5 When requesting information concerning any specific item furnished
with panel/module, refer to that item by description, part number,
6 its location within this manual, and any applicable drawing number.
Any materials, which may be required to meet local codes, such as
7 mats, screens, railings, etc., are not included, and not furnished by
ABB Industrial Solutions.
8 If there are any questions or requirements not covered in this manual
or in the accompanying drawings, please contact the local sales
9 office of ABB Industrial Solutions.
10
Safety notes Describe Dangers, Cautions and Warnings.
for
11
electrical The LV Switchgear has been built in accordance with state-of-the-
equipment art standards and recognized safety rules. However, the use of the

electrical equipment can represent a danger to life, or damage to the
plant and other material assets.
The electrical equipment must only be used in technically perfect
condition in accordance with its designated use and the instructions
set out in the Operation and Maintenance Manual, and only by safety-
conscious and qualified persons who are fully aware of the risks
involved in operating the electrical equipment! In particular, any faults
that may compromise the safety of the machine should be rectified
immediately.
The Operation and Maintenance Manual must always be within at the
place of use of the electrical equipment!
8
In addition to the Operation and Maintenance Manual, comply
with and instruct all users in the generally applicable legal and
other mandatory provisions regarding accident prevention and
environmental protection.
Supplement the Operation and Maintenance Manual with any
additional instructions, including supervisory and reporting
obligations, to reflect company-specific procedures, e.g. with regard
to work organization, working procedures.
Use personal protective equipment where necessary or if required by
regulations.
Observe all safety instructions and warnings attached to the electrical
equipment!
Ensure that all safety and danger notices on the electrical equipment
remain clearly legible.
In the event of safety-relevant malfunctions of the electrical
equipment or changes to the behaviour of the electrical equipment
during operation, stop the electrical equipment immediately and ^
report the malfunction to the authorized personnel!
Never make any modifications, additions or conversions which might 1
affect safety without the original manufacturer approval!
Do not make any modifications to the programs (software) on 2
programmable control systems without the original manufacturer
approval! 3
Observe the stipulated periods or the periods given in the Operation
and Maintenance Manual for regular checks / inspections. 4
Make sure appropriate equipment and tools are available for
performing maintenance work. 5
Provide information on the location and operation of fire extinguishers.
Familiarize yourself with the fire alarms and fire firefighting 6
equipment.
Only use original fuses with the specified amperage. Switch off the 7
plant / machine immediately if trouble occurs in the electrical system!
Work on electrical equipment or operating materials should only be 8
carried out by electricians or by trained persons under the guidance
and supervision of an electrician in accordance with electrical 9
engineering regulations.
If specified, plant and machine components that are being inspected, 10
serviced or repaired should be disconnected from the power supply.
First check that the isolated parts are free of voltage, then earth and 11
short-circuit them and insulate adjacent parts still carrying current.
The electrical equipment of plants / machines is to be inspected and
checked at regular intervals.
Faults such as loose connections or scorched cables must be
corrected immediately!
Should it be necessary to work on live parts, have a second person
standing by who can activate the emergency stop switch or a main
switch with shunt tripping in case of an emergency. Secure the
working area using a red and white safety chain and warning sign.
Only use insulated tools.
When working on high voltage modules, first isolate the voltage,
and then connect the power cable to earth and short-circuit the
components, e.g. capacitors, with an earthing rod.
9
2. Control Centre and Outgoing Panel (type B60,
B185) with plug-in modules
2.1. Introduction
Introduction This chapter discusses briefly the general principle of the
Control Centre and Outgoing Panel (type B60, B185).
Principle The Control Centre and Outgoing Panel (type B60, B185) is subdivided
in three functional zones:
• Busbar zone.
• Equipment zone.
• Opening a door.
• Cable zone.
^
Busbar zone The busbar zone is located at the rear of the column and contains
1 the main horizontal and vertical busbar system. Internal separation
sheets are dividing the busbar zone from the equipment and cable
2 zone and are protecting the operator against accidental contact with
hazardous life parts.
3
Equipment The standard equipment zone, is separated from the cable zone by
4 zone means of the individual sides of the module installed. Additional
separation sheets can be provided to segregate the equipment zone
5 from the cable zone in the event of uninstalled modules.
6
Cable zone The cable zone is designed for fast and comfortable cabling.
7
10
11
10
2.2. General characteristics
Introduction This section discusses briefly the main segments of the column and
the main segments of the modules.
Principle The column is subdivided in three functional zones.
Illustration The following illustration shows the three functional zones of

a Control Centre.
6
Busbar zone Equipment zone Cable zone 7
10
11
11
2.2.1. Main components of a motor starter
application
Illustration The following illustration shows the main components of the motor
starter application.
2
^ 1
1 3
2
4
3
5 5
7 6
8
7
9
10 Components The following table gives an overview of the main components of

a motor starter application.
11
Part Function
1 Incoming plug (line side).
2 18 pole plug (optional for door-wiring).
3 Main breaker.
4 Contactor.
5 Frame.
6 Cable entry for main outgoing cables.
7 16 pole plug (control plug).
12
2.2.2. Main components of a fused load break
switch module SASILplus
Illustration The following illustrations show the main components of a load break
switch module.
1
1 2 3
2
9
4 5
10
Components The following table gives an overview of the main components of a

11
load break switch module.

Part Function
1 Load break switch module.
2 Operating handle.
3 Door.
4 16 pole plug (option).
5 Incoming stabs.
13
2.2.3. Main components of a fused load break
switch module SlimLine
Illustration The following illustrations show the main components of a load break
switch module.
1
^
2 3
1
7 4
8 Components The following table gives an overview of the main components of a

load break switch module.
9
Part Function
10 1 Load break switch module.
11 2 Operating handle.
3 Door.
4 Incoming stabs.
14
2.3. Opening a door
Introduction This section describes how to open the door of the different modules.
WARNING The operator must apply all relevant safety precautions including
those mentioned in this book. Take all precautions to prevent
accidental contact with hazardous live parts. Before carrying out any
adjustments, maintenance or repair, switch off the voltage of the
affected module(s).
2.3.1. Opening the door of a module

Principle The door of a module which is provided with a main power switch
can only be opened if the main power switch is turned off.
Illustration The following illustration shows the main power switch and ^
door lock.
1
Main power
switch Door lock 2
10
11

Procedure The following procedure describes the opening of the door.
Step Action
Turn off the module’s main power switch
1
(if provided).
2 Unlock the door lock of the module.
3 Open the door.
15
2.3.2. Opening the door of a load break
switch module SASILplus
Principle The door is locked by means of the main power switch and
a door lock.
Illustration The following illustration shows the switches for opening the door.
Main power
switch Door lock
(double bearded)
5 Procedure The following procedure describes the opening of the door.
6 Step Action Illustration

Turn off the main
7 1 power switch of -
the afected module.
Open the double-
8 2
bearded lock(s).
-
10
Simultaneously pull and
11 3 turn the
main power switch.

4 Open the door. -
16
2.3.3. Mounting the Outgoing Plug in the column
Principle The door is locked by means of the main power switch and
a door lock.
Illustration The following illustration shows the switches for opening the door.
Door lock
Main power (double
switch bearded)
3
Procedure The following procedure describes the opening of the door. 4
Step Action Illustration 5
Turn off the main
power switch of 6
1
the afected module.
7
8
Open the double-
2
bearded lock(s). 9
10
11
3 Open the door.

17
2.4. Inserting / removing a module
Introduction This section describes how to insert and remove the modules.
affected module(s).
2.4.1. Inserting a module

Principle A module can easily be inserted or removed in order to be repaired or
replaced by another type.
^ Procedure The following procedure describes how to insert a module.

2
Slide the module above
3 1 the bottom
plate into the column.
4
6 Push the module

2 completely into the
7 compartment.
9 Make sure that the

module is
10 3 positioned in its
furthermost
backward position.
11
18
2.4.2. Locking the module in the compartment
Principle The module is locked on both sides by two tongues through the
bottom plate and the guides.
Procedure The following procedure describes how to lock a module in a column

compartment.
Step Action Illustration
Loosen the screws on

1
the module.
^
Slide the screws
completely down so
2 that the tongues are 1
positioned
through the cut-out. 2
Tighten the
4
3
screws again.
5
10
11
19
2.4.3. Inserting a load break switch module
SASILplus
Principle The load break switch modules can easily be inserted or removed in
order to be repaired or replaced by another type.
Procedure The following procedure describes how to insert a load

break switch module.
Mount the connector

guide.
Note:
^ 1. Make sure that the
pins are in the
1
1 vertical frame part.
2. Make sure that the
spacer is
2 between the profile
and the
3 connector.
7
Fix the connector
8 2
guide.
10
11
Repeat step one and
two for installing
3 -
the guide on the
opposite site.
20
Procedure
Slide the module into

4
the column.
Push the module

column.
Make sure that the

module is ^
6 positioned in its
furthermost
backward position. 1
2.4.4. Locking the load break switch module 3

SASILplus in the compartment 4
Principle The module is locked on both sides by four locking bolts. 5
6
Illustration The following illustration shows the position of the four locking bolts.
7
10
11
21
2.4.5. Inserting a load break switch module
SlimLine
Principle The load break switch modules can easily be inserted or removed in
order to be repaired or replaced by another type.
Procedure The following procedure describes how to insert a load break

switch module.
Slide the module into

1
the column.
^
Push the module
1 column.
2
Make sure that the
3 module is
3 positioned in its
4 furthermost
backward position.
10
11
22
2.4.6. Mounting the Outgoing Plug in the column
Principle The module is locked on both sides by locking screws.
Illustration The following illustrations shows the position of the locking screws.
10
11
23
2.4.7. Removing a module
Principle This chapter discusses briefly the general principle of the
Control Centre.
WARNING Always disconnect the power before disconnecting power supply

cables.
Procedure The following procedure describes how to remove a module from

a column compartment.

See “Opening the door of a
1 Open the door.
module”
Loosen the mounting

^ screws of the
2 18 pole plug for door
1 wiring and the
16 pole “side” plug.
3
3 Disconnect the plugs.
4
5 Disconnect the main

See “Connecting the main
4 cables from the
cables”.
module.
6
Loosen the modules
See “Removing the bottom
5 mounting
7 screws.
plate ”.
8
Take the module by the
9 6
front plates.
10
11
Pull the module out of

7
the column.
24
2.4.8. Removing a load break switch module
SASILplus
Principle The load break switch module can easily be removed in order
to be replaced.
Special tool The following illustration shows the special tool required for pulling
out the module.
^
Procedure The following procedure describes how to remove a load break switch 1
module from a column compartment.
1 Open the door.
load break switch module SASILplus”. 3
Disconnect the power
2 supply from - 4
the module.
5
6
Screw the four
3 mounting screws 7
loose.
8
10
Shove the special 11
extraction tool over
4
the pin of the door
switch.

5
the column.
25
2.4.9. Removing a load break switch module
SlimLine
Principle The load break switch module can easily be removed in order to be
replaced.
Procedure The following procedure describes how to remove a load break switch
module from a column compartment.
1 Open the door.
load break switch module SlimLine”.
Disconnect outgoing
2 -
cable from module.
^ 3
Unscrew module
mounting srews.
1
2
4
3 the column.
10
11
26
2.5. Connecting a module
Introduction This section describes how to connect the modules.
affected module(s).
2.5.1. Removing the bottom plate

(for small modules)
Principle The module must be unlocked from the bottom plate in order to
remove the plate. ^
Procedure The following procedure describes how to remove the bottom plate. 1
3
Loosen the modules
1 mounting 4
screw.
5
2
Slide the screw 7
upwards.
8
10
3 Tighten the screw.
11
Repeat step 1 to 3 for

4 the other -
screw.
Extract the bottom

5
plate.
27
2.5.2. Connecting the main cables
General rule The main cables are connected directly to the electrical component.
Remark The connection of external cables is easier when the bottom plate
is removed.
Example • The main cables must be connected to the last electrical

component for a motor starter application.
4
• The main cables must be connected directly to the circuit
5 breaker (place indicated by the arrow) for a feeder application.
10
11
28
2.5.3. Connecting the auxiliary cables
General rule The auxiliary cables are connected by means of a 16 pole plug at the
side of the module (see “main components of a module”). The plug-in
is secured by means of two bolts.
Illustration The following illustration shows the securing of the plug-in.
1
2.5.4. Inserting the bottom plate 2
Principle Always insert the bottom plate to make a separation between the 3
different modules.
4
Procedure The following procedure describes how to insert the bottom plate.
5
6
Slide the plate into the 7

column
in such a way that the 8
1 borders of
the plate are between
the guides 9
of the column.
10
11
Push the plate forward
between
2 the conduits until the
tongues are
through the cut-outs.
Make sure that the

plate is
3 positioned in its -
furthermost
backward position.
29
2.6. Replacing a compartment door
Introduction This section describes how to replace a compartment door.
affected module(s).
2.6.1. Replacing a compartment door

Principle A compartment door can easily be replaced by another.
Procedure The following procedure describes how to replace

^ a compartment door.
1
2 1 Open the door.
module”.
Disconnect the plug-in See “Disconnecting cables
3 2
module. from the compartment door”.
5
Disconnect grounding
3
wire.
6
9
Disassemble each
4 hinge from panel
10 frame.
11
Remove compartment
5
door.
Mount the new See “Mounting a compartment

6
compartment door. door”.
30
2.6.2. Disconnecting cables from the compartment
door
Principle The cables from the compartment door (for indicator lamps, controls,
etc.) are connected with the module by means of a 18 pole plug.
Illustration The following illustration is showing the position of the plug.
18 pole ^
plug
1
3
Procedure The following procedure describes how to disconnect the plug.
5
Loosen the 2 tightening
1 screws 6
from the 18 pole.
7
8
Pull out the plug from
2 9
the socket.
10
11
31
2.6.3. Mounting a compartment door
Principle The different types of doors can easily be installed on the column.
Procedure The following procedure describes the mounting of

a compartment door.
Attach door hinges into

1
panel frame.
1 2
Assemble 4 screws on
each hinge.
2
5 Connect grounding
3
wire.
6
10
11
32
2.7. Removing the IP20 shroud from the
vertical busbar
Introduction This section describes how to remove the protective IP20 shroud
from the busbar.
accidental contact with hazardous live parts (busbars in the back!).
Before carrying out any adjustments switch off the voltage.
Principle The vertical busbars is protected against direct contact by means of

a IP20 shroud. If necessary (e.g. for maintenance) the shrouds can be
removed as described below.
^
Procedure The following procedure describes how to remove the IP20 shroud.
1
3
Unlock the 2 latching
tongues 4
from the frame while
1
pulling the
shroud from the
5
busbars.
6
10
11
33
2.8. Change module arrangement
Introduction Modules can have different sizes. The column arrangement can easily
be adjusted for installing another size.
affected module(s).
2.8.1. Example: replacing 2 modules size 5E

by 1 module size 10E
^ Principle The compartment of a module can easily be adjusted to contain a

module of another size.
1
Procedure The following procedure describes how to replace 2 modules size 5E
2 by 1 module size 10E.
Open the door of the 2
“Opening the door of a
4 1 modules size
module”.
5E.
5 Remove the bottom
2 plate of the upper “Removing the bottom plate ”.
module.
6 Disconnect the cables
from the
7 compartment door.
“Disconnecting cables from the
8 3
compartment door”.
If the 16 pole plug is
used
9 this one must also be
disconnected.
10 Disconnect the main
4 and auxiliary -
11 cables.
Remove the 2 modules
5 “Removing a module”.
size 5E.
Remove the 2 guiders
6 of the upper -
module size 5E.
Replace the doors by
“Replacing a compartment
7 the door of a
door”.
10E module.
8 Insert the 10E module. “Inserting a module”.
Connect the 10E
9 “Connecting a module”.
module.
34
3. Control Centre with withdrawable modules
Introduction This chapter discusses the Motor Control Centre and its correct use.
3.1. Introduction
Introduction This chapter discusses briefly the general principle of the
Motor Control Centre.
Principle The Motor Control Centre is subdivided in three functional zones:

• Busbar zone
• Equipment zone
• Cable zone
the main horizontal and vertical busbar system. Internal separation ^
sheets are dividing the busbar zone from the equipment and cable
zone and are protecting the operator against accidental contact with 1
hazardous parts.
2
Equipment The standard equipment zone, is separated from the cable zone 3
zone by means of vertical separation sheets. Additional covers can be
provided to close the contact holes of the auxiliary control terminal 4
in the separation sheet in the event of uninstalled modules.
5
Cable zone The cable zone is designed for fast and comfortable cabling. 6
3.2. General characteristics 7
Introduction This section discusses briefly the main segments of the column and 8
the main segments of the modules.
9
10
11
35
3.2.1. Functional segments of the column
Illustration The following illustration shows the three functional zones of a

Control Centre.
3
Busbar zone Equipment zone Cable zone
4
3.2.2. Functional parts of the module
5
Principle The withdrawable modules have incoming, outgoing and control
6 terminals. The incoming terminal is movable respect the base of the
module. The outgoing and control terminals are fixed to the module.
7 The instrument plate is fixed to the tray.
8
Notice The operations on the worm gear mechanism are only allowed with
9 closed doors.
10 Ilustration Incoming Outgoing

plug (moveable) plug
11
Worm gear Auxiliary

mechanism control plug
36
3.2.3. Plugs types
Principle The Motor Control Centre has three kinds of plugs:
• Incoming plug
• Outgoing plug
• Auxiliary control plug
Incoming The incoming plug is located at the rear left side of the module
plug and allows the connection of the main circuit of the tray to vertical
busbars.
Outgoing The outgoing plug is located at the rear right side of the module
plug and allows the connection of the main circuit of the module to the
outgoing plug in the column. The terminals for cable connection are
located in rear of the cable compartment.
^
Auxiliary The auxiliary control plug is located at the right side of the module
control plug and allows the connection to the female (in the column). The standard 1
plug has 24 pins. An additional 24-pin auxiliary control plug can be
provided if a higher number of pins is required. 2
10
11
37
3.2.4. Main components of
a motor starter application
Illustration The following illustration shows the main components of the motor
starter application.
1 2
4 8
3
6
^ 5
1 9
2
Components The following table gives an overview of the main components of
3 a motor starter application.
4 Step Function
1 Incoming plug.
5 2 Outgoing plug.
3 24 pole aux. control plug.
6 4 Main breaker.
5 Contactor.
7
6 Base plate.
8 7 Side walls.
8 Mounting plate.
9 9 Worm gear mechanism.
10
11
38
3.3. Worm gear mechanism operation
Introduction This section discusses briefly the function of the worm gear
mechanism and the terminals positions.
3.3.1. Operating the worm gear

Principle The mechanism to remove the incoming plug is a worm gear which
moves a slide fixed to the incoming terminal. The movement of the
worm gear provokes the movement of the incoming terminal respect
the tray base, connect or disconnect the incoming plug from the
vertical busbar.
To move the worm gear, one external “T” tool is required. The access
to the worm gear is protected by a cover, which can be locked with
up to 3 padlocks.
^
Illustration The following illustration shows how to operate the worm gear.
1
10
11
39
3.3.2. Operating positions of the
withdrawable module
Introduction The following illustration shows the different positions of the module
respect to the column and terminals positions.
10
11
40
3.4. Opening a door
Introduction This section discusses briefly the function of the worm gear
mechanism and the terminals positions.
affected module(s).
3.4.1. Opening the door of a module

Principle The door of a module that is provided with a main power switch can
only be opened if the main power switch is turned off and the worm
gear is in off position. ^
Illustration The following illustration shows the main power switch and 1
door lock.
2
Worm gear Main power switch Door lock
3
10
11
Procedure The following procedure describes the opening of the door.
Step Action
1 Turn off the module’s main power switch.
2 Remove the padlock from the worm gear cover (if provided).
3 Using the T-tool turn the worm gear to the OFF position.
4 Unlock the door lock of the module.
5 Open the door.
41
3.5. Inserting / removing a module
Introduction This section describes how to insert and remove the modules.
affected module(s).
3.5.1. Inserting a module

Principle A module can easily be inserted or removed in order to be repaired or
replaced by another type.
10
11
42
Procedure The following procedure describes how to insert a module.
Slide the module above

1 the bottom
plate into the column.
Push the module

compartment.
Make sure that the

module is
positioned in its
furthermost ^
backward position
3 (latch on the right 1
hand side of the tray
should be
parallel to the 2
instrument plate) - see
next chapter. 3
4 Close the door. See chapter “opening a door”.
Open the plastic cover 4
of the module
5 interlock and insert the 5
T-tool into
the worm gear.
6
Turn the T-tool
6 clockwise until the 7
ON position.
8
7 Close the plastic cover. See chapter “opening a door”
Close the padlock 9
8 See chapter “opening a door”.
(if provided).
10
11
43
3.5.2. Locking / unlocking the module in
the compartment
Principle The module is locked on one side by one latch through
the bottom plate.
Procedure The following procedure describes how to lock and unlock a module
in a column compartment.

lide the module slowly
above the
bottom plate into the
column until it
reaches the
furthermost backward
^ 1
position - the latch on
the right hand
side of the module
1 snaps into the
second cut-out of the
2 bottom plate –
the module is in
3 standby position.
Make sure that the
module is
4 positioned in its
furthermost
5 backward position - the
2 latch that is
6 situated at the right
hand side of the
tray should be parallel
7 to the
instrument plate.
8 To move the module to
disconnected
9 (isolated) position pull
the latch
towards yourself and
10 3
pull the module
towards yourself until
11 the latch snaps
into the first cut-out of
bottom plate.
To remove the module
out of the
column pull the latch
toward yourself
4
and then pull toward
yourself until
the module is drawn
out of column.
44
3.5.3. Removing a module
Principle A module can easily be removed in order to be repaired or replaced
by another type.
Before opening doors assure that the worm gear is in OFF position.
Procedure The following procedure describes how to remove a module from

a column compartment.
Unlock padlock
1 See chapter “opening a door”.
(if accessible).
Insert the T-tool to
worm gear and
2 turn to the OFF See “Mechanism position”.
position. Afterwards
take out the tool.
^
See “Opening the door of
3 Open the door.
a module”. 1
Take the module by left
hand at the
2
left of the worm gear,
4 3
and the right
hand in the blocking
part. 4
5
5
the column. 6
10
11
45
3.6. Connecting a module
Introduction This section describes how to connect the modules.
affected module(s).
3.6.1. Connecting the main cables

General rule The main cables are not connected directly to the electrical
component. The connection is made to the outgoing terminals
mounted in the cable compartment.
^
Example The main cables must be connected to the outgoing terminals
1 situated in the rear left side of the cable zone (place indicated
by the arrow).
2
10
11
46
3.6.2. Connecting the main cables in cubicles with
separation form 4b type 7
General rule The connection of the main cables of each functional unit is made to
the outgoing terminals mounted in the cable compartment that are
additionally separated from other cable connections by rigid barriers
out of sheet-metal.
Example The main cables must be connected to the outgoing terminals

situated in the rear left side of the cable zone (place indicated by the
arrow) through the cut-outs in the metal barriers.
10
11
47
Procedure The following procedure describes how to connect the cables in
cubicles with separation form 4b type 7.
Unscrew the bolts on

one side
1
cover of the separation
box .
^
Unscrew the bolts on
1 the second
2
side cover of the
2 separation box.
6
Make a hole (holes) in
7 a side
separation cover, and
3
8 pull
through the cable
(cables).
9
10
11
48
Procedure Step Action Illustration
Connect the cables to

the clamps
of the outgoing
1 terminal and
screw the side cover to
the
construction.
^
Screw the second side
2 cover of 1
the separation box
4
Repeat steps 1-5 to the
3 other - 5
separation boxes.
10
11
49
3.6.3. Connecting the control cables
General rule The control cables are connected by means of a 24-pole plug mounted
at the side of the module (see ”main components of the module”)
and the 24-pole socket mounted in the vertical separation.
Illustration The following illustration shows the cable connection to the auxiliary
control terminal.
10
11
50
3.6.4. Inserting the bottom plate
Principle Always insert the bottom plate to make a separation between the
different modules.
Procedure The following procedure describes how to insert the bottom plate.
Slide the plate into the

column
in such a way that the
1 borders of
the plate are between
the guides
of the column. ^
3
Push the plate forward
between 4
2 the conduits until the
tongues are 5
through the cutouts.
6
Make sure that the

9
plate is
positioned in its 10
3 furthermost
backward position and 11
screw it
with the guides.

51
3.6.5. Removing 24-pole auxiliary control plug
Principle The 24-pole plug can be removed if the relevant module is removed
and all the control cables are disconnected.
Procedure The following procedure describes how to remove the 24-pole

auxiliary control plug.

Remove the relevant
1 See “Removing a module”.
module.
Open the cable
2 compartment -
door.
Disconnect the control
3 See “Connecting the control cables”.
cables.
1
Screw the two
2 4 mounting screws
loose.
3
10
11
52
3.6.6. Removing the vertical separation between
the cable and equipment compartment
Principle The vertical separation between the cable compartment and the
equipment compartment is required to achieve the degree of
protection of IP 2X.
Procedure The following procedure describes how to remove the vertical

separation.
Open the cable
1 compartment -
door.
Remove the 24 pole
See “Removing the 24 pole aux.
2 aux. control
control plug”. ^
plug.
2
Screw the four
3 mounting screws 3
loose.
4
10
11
53
3.6.7. Mounting the outgoing plug in the column
Principle The outgoing plug in cable compartment can be easily inserted or
removed in order to be repaired or replaced by another type.
Procedure The following procedure describes how to mount the outgoing plug.
Mount the support for

1 the
outgoing plug.
2
Mount the outgoing
3 plug.
4 2
Make sure that the pins
are in the vertical part
5 frame.
9
3 Fix the outgoing plug.
10
11
54
3.7. Change module arrangement
Introduction Always insert the bottom plate to make a separation between the
different modules.
affected module(s).
3.7.1. Example: replacing 2 modules size 5E by

1 module size 10E
Principle The compartment of a module can easily be adjusted to contain a ^
module of another size.
1
Procedure The following procedure describes how to replace 2 modules size 5E
by 1 module size 10E. 2

Open the door of the 2
1 modules size
module”.
4
5E.
2
Remove the 2 modules
See “Removing a module”. 5
size 5E.
Remove the bottom
3 plate of the upper
See “Removing the bottom 6
plate”.
module.
Open the cable 7
4 -
compartment door.
Disconnect the main See “Connecting control cables 8
5 and control “ and “Connecting the main
cables. cables”. 9
Remove the auxiliary See “Removing the 24-pole
6
control plug. aux. control plug“. 10
Remove the cable
7 chanel support (if -
necessary). 11
See “Removing the vertical
Remove the vertical
8 separation between the cable
separation sheet.
and equipment compartment”.
Remove the upper
9 -
module guides.
Remove the outgoing
See “Mounting outgoing plug
10 plug of upper
in the column”.
module.
55
Procedure Step Action Illustration
Cover the opening
above the
11 -
outgoing plug with a
plastic cover.
Replace the vertical
separation sheet See “Remowing the vertical
12 by the vertical separation between the cable
separation of a 10 E and equipment compartment”.
module.
Mount the auxiliary
13 -
control plug.
Replace the doors 5E by
See “Replacing a compartment
14 the door of a
door”.
10E module.
15 Insert the 10E module. See “Inserting a module”.
Connect the 10E
16 See “Connecting a module”.
module.
^
10
11
56
4. Outgoing Panel type D
4.1. Introduction
Introduction This chapter describes briefly the general principle of the Outgoing
Panel type D.
Principle The Outgoing Panel type D is subdivided in three functional zones: 5

• Busbar zone.
• Equipment zone. 6
• Cable zone.
7
Busbar zone The busbar zone is located at the rear of the column and contains 8
the main horizontal busbar system, vertical busbar system and
front horizontal distribution busbar system dedicated for Fuse- 9
switch-disconnector type InLine. Internal separation sheets divide
the busbar zone from the auxiliary equipment zone and protect the 10
operator against accidental contact with hazardous live parts.
11
Equipment The equipment zone is located at front of the column and can be
zone subdivided into:
• Main equipment zone for InLine disconnectors (located in the
middle of panel height).
• Auxiliary equipment zone for auxiliary / control apparatus
(located at the bottom or top of panel depends on cable entry side).
Cable zone The cable zone is designed for fast and comfortable cabling.
57
4.2. Functional segments of the column
Introduction This chapter describes briefly the main segments of the column.
Illustration The following illustrations show example of the three functional

zones of an Outgoing Panel type D for top cable entry.
Segments The following table gives an overview of the functional segments of

the column.
3
2a 1
4
9
2b
10
11

Segment Function
1 Busbar zone.
2a Main equipment zone.
2b Auxiliary equipment zone.
3 Cable zone.
58
4.3. Main components
Illustration The following illustrations show the main components of Outgoing
Panel type D, fuse switch disconnectors InLine ZHBM00/1/2/3.
4
1
5
2 3 6
10
11
Parts The following table gives an overview of fuse Switch disconnector
type InLine.

Part Function
1 Fuse switch disconnector.
2 Operation handle.
3 Incoming terminals.
59
4.4. Connecting the main cables
General rule The main cables are connected directly to the electrical component.
Illustration The following illustrations show the standard cable termination

using bolt terminals and cable lugs acc. to DIN 46329.
• Bolt M8 x 16 for ZHBM00.
• Bolt M12 x 40 for ZHBM1/2/3.
8 Remark After connection of main outgoing cables always add dedicated cable
shrouds available for each version of InLine.
9
10
11
60
4.5. InLine ZHBM operation
Principle Disconnectors can be easily open or close using its operating handle.
Illustration The following illustrations show the position of disconnectors.
3
1 2 3
4
Positions The following table gives an overview of fuse switch
disconnector states. 5
Part Function 6
1 Closed position / ON.
2 Open position / OFF. 7
3 Replacement of fuses position.
8
10
11
61
5. Power Centre
5.1. Introduction
Introduction This chapter discusses briefly the general principle of the Power
Centre.
Principle The Power Centre is subdivided in three functional zones:

• Busbar zone.
• Equipment zone.
• Cable zone.
the main horizontal and vertical busbar system. Internal separation
sheets divide the busbar zone from the equipment zone and protect
^ the operator against accidental contact with hazardous live parts.
Additional separation sheets can be provided to segregate the
1 equipment zone from the cable zone.
2 Equipment The equipment zone is located at front of the column and contains
zone air circuit breaker.
3
4 Cable zone The cable zone is designed for fast and comfortable cabling.
10
11
62
5.2. Functional segments of the column
Introduction This section discusses briefly the main segments of the column.
Illustration The following illustrations show the three functional zones of a

Power Centre:
• The incomer with air circuit breaker type Emax 2 E1.2, E2.2, E4.2.
1
2a
^
3
2b
4
7
3 8
10
Components The following table gives an overview survey of the main components 11
of a Power Centre.
Part Function
1 Busbar zone
2a Equipment zone / other
2b Equipment zone / ACB
3 Cable zone
63
5.3. Table of panel to panel electrical connection
cross-sections
Introduction This section contains a table of panel to panel electrical connection
cross-sections.
Method The cable lugs are clamped by means of bolts.
Cabling zone The following illustrations are showing the cabling zone of an air
circuit breaker (examples).
10
11
64
Emax 2 External connections - standard cable arrangements for air circuit
breaker application type - Emax 2.
Maximal
Risers
Rated Number of cable Bolt
Frame L1, L2, L3
current cable per cross- diameter
size copper type
phase section
[A] [mm x mm] [mm²] [mm]

Connection direct to the riser
800 E1.2 2 x (30 x 10) 2 240 12
1250 E1.2 3 x (30 x 10) 4 240 12
1600 E1.2 3 x (30 x 10) 4 240 12
1000 E2.2 2 x (30 x 10) 4 240 12
1250 E2.2 2 x (40 x 10) 4 240 12
1600 E2.2 2 x (40 x 10) 4 240 12
2000 E2.2 3 x (50 x 10) 6 240 12
2500 E2.2 3 x (50 x 10) 8 240 12 ^
2500 E4.2 4 x (40 x 10) 8 240 12
Connection to auxiliary busbars 1
3200 E4.2 6 x (40 x 10) 6 (12) 300 12
4000 E4.2 8 x (40 x 10) 8 (16) 300 12
2
5000 E6.2 9 x (40 x 10) 12 300 12
6300 E6.2 12 x (40 x 10) 14 300 12
3
10
11
65
6. Installation of a column
6.1. Storage of columns
Introduction This section describes the factors that must be taken into account
for storing a column.
Principle To protect the column during storing certain factors must be taken
into account.
Storing place The switchboards must be stored in dry, ventilated rooms.
CAUTION
^ Storage conditions for electrical components in accordance to the

catalog.
1
Ambient -20°C to +55°C (short term up to +70°C, no longer than 24h).
2 temperature
3
Damage Any damaged packaging shall be renewed in order to protect the
4 packaging assembly against harmful pollution during storage.
5
Relative Min 20%, Max. 90%.
humidity
6
of the
7 atmosphere
10
11
66
6.2. Transport of a column
Introduction This section describes the correct way to transport a column.
How to move A vertical section is to be moved in an upright position. The section

a section? can hang or stand.
Transport • Crane (recommended; please read the safety-notes first).

• Fork-lift truck (optional; please read the safety-notes first).
Limitations The following table describes the limitations that should be taken
into account for transport.
WARNING Max. width Max. weight
Transport section
[m] [kg]
Single column E1.2,
- 1000 ^
E2.2, E4.2
Single column E6.2 - 1500 1
Other single columns - 1000 2

Transport column of 3
Power Centers with
1,5 -
busbars type SMB-14 and
above
4
Other transport sections 2 2000
5
6
Safety notes • The center of the gravity of the column is located in the upper
part (typically in the area marked as „1” or „2” of the illustration
7
WARNING below).
• The special care shall be taken during the transport operation
8
to provide the safety for the Staff and the Equipment.
• Fork-lift optional transport is not recommended (stability of 9
the section during the transport).
• In case of any doubts please consult the ABB Specialist. 10
11

Picture:
center of the gravity
location in a column.
DRW number: 31T002707R170
67
Measures for The following measures must be followed for transporting a Control
transporting a Centre.
Control Centre • Modules for motor Control Centres remain inside the Column
during transport.
WARNING • The withdrawable module incoming terminal shall be in
connected position.
Measures for The following measures must be followed for transporting a Power
transporting a Centre with ACB type Emax 2.
Power Centre • Circuit breaker, fixed type Emax 2, all frame remains inside the
column during transport.
WARNING • Circuit breaker, withdrawable type Emax 2, all frames shall be
shipped separately.
• Circuit breaker type Emax 2, all frames shall be in “OFF” position
and with closing spring completely discharged.
• Detailed information concerning Emax 2 circuit breaker, can be
^ found in document “SACE Emax 2 Installation, operation and
maintenance instructions for the installer and the user”.
1
2 Preparing for The following table gives an overview of the preparations for
transport transport.
3
Step 1 If the transport is
4 Then...
done...
5
The column shall be bolted on a
With a fork-lift truck transport metal feet. Transport on
6 wooden pallets shall be avoided.
7
The column shall have four lifting
latches on top are used with hexagon
8 With a crane head bolts M12 x 50 St 8.8.
In case of raised roof: Remove top roof
9 from the panel.
10
Step 2 The column shall be covered on all sides with foil to protect the
11 surface finish against damage.

68
Transporting The columns shall be bolted with a transport metal system at bottom.
a column The following pictures illustrate the previously described
transportation methods.
Load shall be equally distributed:
• By crane:
Column with circuit breaker type Emax 2 E6.2 use four lifting
ear (eye bolt) on top M12 54 x 53 C15 KIT# 293344.
3
Rope angle >45° Rope angle 90°
4
• By fork-lift truck:
5
10
11
Only for E6.2

Please see the safety notes!
WARNING
Make sure that section is properly / safely prepare to a transport
operation.
69
6.3. Lifting of a breaker
Introduction This section describes the correct way to lift a breaker.
How to move A breaker is to be moved in an upright position. The breaker can be

a breaker? hang only.
10
11
70
6.4. Installation space of a column
Introduction This section describes installation space required for column.
Principle The SEN Plus columns with main incomer up to 4000A (max. depth
800mm) are executed as free standing that means it can be installed
at the wall for non ventilated enclosure, however for ventilated
enclosure it is required to keep minimum distance of 100mm (“X”)
from a wall or an obstacle, and minimum 500mm from the ceiling.
The front gap should be sufficient to open the door (“Z” must be
greater than 400 – 1200mm) but mainly is driven by standards for
the safety paths.
Installation The following illustration shows the possible space requirement for
Space for Installation of column. ^
Column Product dimensions Min required gaps / clearances
Right Left Min 1
WARNING Top Bottom Front
Width Height Depth side side rear
gap gap gap
gap gap gap 2
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
3
600 / 800 500
400 - 1200 2200 - - - X Z
/ 1000 +Y 4
10
11
X, Y, Z - dimensions to be fixed by the installer / customer.
71
6.5. Erecting a column
Introduction This section describes how to erect a column.
Principle The column is erected on a well-aligned foundation Frame or on a

false floor construction.
Maximum fall A maximum fall of 2mm per meter column width is acceptable.
Foundation The following illustration shows the possible components on the

Frame foundation frame, depending on the column depth and arrangement.
1. Only at the end of the switchboard.

3. M10 - screw for a foundation frame.
^ 4 . Column fishplate.
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72
Erecting the The following illustration shows the erection scheme with the
column components for a column.
1. Foundation frame.
2. Column fishplate.
3. Column frame.
4. Load plug for M10.
5. Adjusting plates.
6. Top of composition floor.
7. Top of concrete.
8. Column assembly screw M12 x 50.
10
11
73
6.6. Connecting the base frame to the column
Introduction This section describes the base frame and its correct use.
Procedure A base frame can be added to the column to give more space for the
final cabling.
Procedure The following procedure describes how to connect the base frame to
the column.
Step 1 Assemble the base frame.
4
Step 2 Place the column on the base frame.
5
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11
74
Step 2a Put a bushing between the base frame and the column frame.
Step 2b Make the connection with a hexagonal head screw M12 x 50 St 8.8 2
through the cut-outs in the base frame and the column and the bush.
3
10
11
Step 3 Repeat the step 2 for the other screws.
75
6.7. Connecting two columns
Introduction This section describes how to connect two columns.
Procedure Several columns can be connected to make one panel.
Procedure The following procedure describes how to connect two columns.
Step 1 Remove the side panels.
Step 2 Screw the M6 x 16 metric bolt from one side into the threaded
hexagonal spacer.
6 Step 3 Put the two panels next to each other. Screw the second bolt into the
threaded hexagonal spacer.
7
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76
6.8. Connecting the main busbar system
Introduction This section describes how to connect the busbars of two columns.
Principle The busbars of two or more columns can be connected.
Fishplate Fishplates are used for making the connection. The following
illustration gives an example of such fishplates.
3
Position The following illustrations show the position of fishplates.
fishplate 4
10
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77
Procedure The following procedure describes how to connect the main busbar
system.
Step 1 Loosen fixing bolts (marked „1”) as per illustration below.

To improve the assembly process the following optionally actions are
allowed as per information below.
Optionally:
• Lubricate the ending of the busbar connection, to improve
the whole procedure. Example of the lubricate to be used:
SHELL Alvania S2.
• Check if there are any burrs on the main rails and remove it if
applicable.
• Loosen (but do not fully unscrew) additional fixing bolts
(marked „2”).
1 2 1
2
9
Step 2 Move the columns together. The fishplate moves between the two
10 busbar layers.
11
78
Step 3 Fix the connection (see “connecting two columns”) when the
fishplates are in the right position. Tighten the busbar fixing bolts
again.
Step 4 • Check if all fixing elements are in a proper place; make sure that 2
there are no loose elements within the switchgear which may
CAUTION lead to s-c / arc event. 3
• Check if the position of the insulators has not been altered.
• Check the torque of fixing elements; make sure that all previously 4
loosen fixing bolts are covered. See “Torque values”.
• Proceed with the connection of the following panel only when 5
the previous ones are properly connected.
6
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79
6.9. Torque values
6.9.1. Torque values for mechanical connections
Introduction This section gives an overview of all torque values for bolt and screw
connections in the column.
Where The torques shall be applied for all mechanical bolted joints.
applied?
Property The stated values relate to property classes 5.8 to 8.8, for ungreased
classes screw and nuts.
Deviating Deviating torques are only admissible if:

torques • Special manufacturer instructions have to be followed.
^ • Special tightening torques are requested in drawings or
manufacturing instructions.
1
2 Torques for The following table gives a survey of the torques for hexagon head
hexagon head screw.
3 bolts
Hexagon head screw
4 Property class 5.8 Property class 8.8
Screw
Min. Min.
5 size Nominal
torques for
Nominal
torques for
torques torques
maintenance maintenance
6
[Nm] [Nm] [Nm] [Nm]
7 < M3 0,40 - 0,45 0,30 0,60 - 0,70 0,50
M3 0,80 - 0,90 0,60 1,10 -1 ,20 0,80
8 M3,5 1,00 - 1,10 0,80 1,70 - 1,90 1,50
M4 1,60 - 1,75 1,10 2,50 - 2,75 2,10
9 M5 3,00 - 3,30 2,30 5,30 ± 6% 3,80
M6 5,60 ± 6% 3,80 9,00 ± 6% 6,50
10 M8 12,60 ± 6% 9,20 21,00 ± 6% 15,00
M10 27,30 ± 6% 18,50 44,00 ± 6% 31,00
11 M12 44,00 ± 6% 32,00 74,50 ± 6% 54,00
M16 105,00 ± 6% 77,00 178,50 ± 6% 123,00

Taptite screws
Screw Min.
Nominal
torques for
size torques
maintenance
[Nm] [Nm]
M3,5 1,70 - 1,90 1,50
M4 2,50 - 2,75 1,50
M5 7,40 ± 6% 2,30
M6 15,80 ± 6% 3,80
M8 21,00 ± 6% 9,20
80
Torques for The following table gives a survey of the torques for self-threading
self-threading screws.
screws Self-threading screws
Screw Nominal
size torques
[Nm]
M5 7,40 ± 6%
M6 15,80 ± 6%*
M8 21,00 ± 6%
* we use torques 9,6 ± 6% for the “metal-plastic” connections of

vertical current paths in the switchgears.
Torques The following table gives a survey of the torques for self-threading
for plastite screws.
screws ^
Plastite screws
Screw
1
Nominal
size torques
2
[Nm]
M3 0,10 3
M5 0,50
M6 0,80 4
5
Unused Unused connection screws (e.g. spare installations) have to be
connection tightened with a tightening torque 50% of nominal torque. 6
screws
7
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81
6.9.2. Torque values for electrical connections
Where The torques shall be applied for all electrical bolted joints.
applied?
Property The stated values relate to property classes 8.8 and A4-80 for screw
classes and nuts that are not greased.
Deviating Deviating torques are only admissible if:

torques • Special manufacturer instructions have to be followed.
• Special tightening torques are requested in drawings or
manufacturing instructions.
Torques for The following table gives a survey of the torques for electrical
^ terminals terminals.
1 Cu - bubsar connections
and air circuit breaker
2 Terminals
type A4-80 (screw with
Screw property class 8.8)
3 size
Nominal Min. torques for Nominal Min. torques for
4 torques maintenance torques maintenance
[Nm] [Nm] [Nm] [Nm]
5
< M3 0,50 - 0,55 0,43 - -
M3 1,00 - 1,10 0,70 - -
6
M3,5 1,10 - 1,20 0,90 - -
M4 1,50 - 1,65 1,30 - -
7
M5 3,00 - 3,30 2,50 - -
M6 6,3 ± 6% 4,00 9,00 ± 6% 6,00
8
M8 14,7 ± 6% 10,00 21,00 ± 6% 14,00
M10 27,6 ± 6% 20,00 44,00 ± 6% 26,00
9
M12 44,0 ± 6% 36,00 74,50 ± 6% 45,00
M16 63,0 ± 6% 50,00 147,00 ± 6% 110,00
10
11 Unused Unused connection bolts (e.g. for supply or outgoing terminals) have
connection to be tightened with a tightening torque 50% of nominal torque.
screws
82
7. Routine testing
Introduction This section gives an overview of tests that should be carried out
before putting the assembly into operation.
Principle Mechanical and electrical function tests should be carried out before
putting the assembly into operation as per IEC 61439-2.
Mechanical The following mechanical function tests should be carried out before
function tests putting the assembly into operation:
• Mechanical function check of electrical components according
the relevant operating instructions.
• Check all connections to the protective conductor.
• Check all protection against electrical shock and integrity of
protective circuits. ^
• Check all internal electrical circuits and connections to the
conductor. 1
• Check if all accessible components are grounded.
• Check if all barriers and obstacles are in place as per degree of 2
protection of column.
• Check correct functioning of the worm gear mechanism. 3
• Check if correct door is used.
• Check correct opening and closing of doors - all doors shall be 4
closed.
• Check correct function of all door locks. 5
• Check interlocking facilities of circuit breakers and doors.
• Check if correct transprotation and installation system is used. 6
• Check correct assembly of breaker in column.
• Check if no tool is left in column. 7
• Check if proper labels are at required place.
• General visual inspection of the assembly. 8
9
Electrical The following electrical function tests should be carried out before
function tests putting the assembly into operation: 10
• Electrical function check of electrical components according to
the relevant operating instructions.
11
• Measure the insulation resistance of the assembly
(The insulation resistance of the assembly should not drop
below 1MΩ).
• Check dielectric properties.
• Check all safety equipment as e.g. emergency off.
• Check the correct functioning of control-, monitoring- and
measuring instrumentation.
• Check all control functions.
83
8. Maintenance
Introduction This section contains a checklist for inspection.
Maintenance The maintenance intervals depend on the intensity of use of the

intervals switchgear installed in the column.
Attention Observe all relevant operating instructions of the electrical

components as well as local requirements and standards.
Inspection A visual inspection as well as a control of mechanical functions (e.g.

interval interlocks etc.) of the assembly should be done every 4 years as a
minimum.
An interval of <= 1 year is recommended.
^
10
11
84
Inspection The following checklist can be applied as a guideline during inspection.
# Inspection Corrective action
1 Inspection of service conditions -
2 Inspection of the assembly -
Inspection of the ventilation Clean ventilation openings / change dust
3
openings filters
Inspection of measures to
4 -
achieve IP rating
Inspection of cables &
5 -
glandings
Clean with dry piece of cloth or use
Inspection on the effects of
6 vacuum cleaner / do not use high-
pollution
pressure air!
7 Inspection for damages -
Inspection on the effects of Repair failures on surface / make dry if
8
corrosion necessary
9
Inspection of sub-assemblies & Maintenance in accordance with relevant ^
electrical components component manuals
10
Inspection of connectors &
- 1
terminals
11
Check correct protection of
Change fuses if necessary 2
electrical components & cables
Check settings of electrical Correct settings according the 3
12 components ( e.g. overload & documentation of the electrical
short circuit protection) component
4
13 Inspection of plug-in contacts Remove old grease, put new grease on*
Inspection of measures against 5
14 electrical shock (PE conductor, -
PE connections)
6
Check torque values for (see torque values for electrical
15
electrical connections connections)
7
* grease type: 8
• Silver plated contact: Shell - Gadus S2 V100 3.
• Tin plated contacts: Mobil - Mobilgrease 28. 9
Spare parts: For spare parts and extensions, contact your local ABB service: 10
https://new.abb.com/low-voltage/service/services-for-switchgear
11
85
8.1. Use of hand tools
Introduction Generally the use of hand tools shall be limited to those tools that
are common and readily available in the market. The following list
describes the minimum solution.
• Torx screwdrive size 30 : - Used for removal of internal cover and
structural members.
• Flat wrenches of sizes 7, 8, 10, 13, 16, 18 and 24: - Used for removal
/ tighten of structural members and busbar connection.
• English and Metric compatible nut drives for hexagon head
hardware and Phillips, Sloted screws.
• Cluster pliers: - Used for removal of primary contacts during
inspection and maintenance.
• Screwdriver - 8mm: - Used for removal of front panel fixing
screws and operation of racking shutter drive. And for removal
of Rogowski Coil and Power CT cover plate at the rear of the ACB
^
moving portion.
• Allen hex key - 5mm A/F: - Used for removal of arc chutes
1
during inspection and maintenance. Also used for removal or
adjustment of fixed and moving arcing contacts.
2
• Allen hex key 4mm A/F: - Used for removal of 3 off motor and
3 gearbox 5mm - fixing screws.
• Metric Feeler Gauges: - Used for checking and adjusting arcing
4 contact gap.
• Flat screwdriver: - Used for removal of mechanical & electronic
5 components fixing screws and connection of wiring to secondary
isolating contact terminals.
6 • Ring type pliers: - Used for removing the trip unit and mechanism
from shaft during maintenance.
7 • Spanners: - Used to remove conductors during inspection and
maintenance.
8
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11
86
9. End of column service life
Introduction This section contains end of column service life.
Dismantle of • The column are constructed of recyclable material.

the column • All electrical components must be removed.
• While dismantle, the material to be separated and processed to
the appropriate recycling procedures.
• The following figure gives types of material and their application.
Aluminium and aluminium
based alloys
E.g.: corners
Composites
E.g.: Insulators,
busbar supports ^
Copper and copper based 1
alloys
E.g.: conductors
2
Steel
E.g.: frame
3
4
Air circuit breaker
5
8
Plastics
E.g.: internal separation
9
External connection point 10
Incomer 4000A 4 pole column with air circuit breaker type

11
Emax 2 E4.2.

87
10. After sales and service
After Sales ABB’s goal is to ensure the assets’ maximum performance and
and Service availability. ABB has supplied over 1.5 million MNS cubicles from its
worldwide manufacturing locations. Each of these locations operates
with an After Sales and Service department, offering unparalleled
global support.
On completion of commissioning, the switchgear is at the peak of

its performance. To maintain this condition, it is essential to adopt a
service and maintenance plan for this asset. If the switchgear does
not receive maintenance, this could result in downtime. In production
the availability of the switchgear ensures productivity, and any down
time is a lost opportunity for profit. Down time can be attributed to
the following maintenance practices.
• Reactive maintenance is costly for both production and
^
unplanned downtime.
• Preventive or Continuous maintenance is usually performed on
1
an annual basis, during a scheduled shutdown.
• By evaluating information from the intelligent switchgear, it is
2
possible to adopt a Predictive maintenance schedule.
3 • Utilizing an ABB expertise can help to increase the life cycle of
the switchgear.
4
Regular ABB offers comprehensive service and support during the whole life
5 services time of the switchgear:
• Engineering assistance.
6 • Product training.
• Spares holding.
7 • Installation and commissioning.
• Service planning.
8 • Hardware and software support.
• Upgrades, expansions and modifications.
9
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88
Contract ABB can offer comprehensive maintenance contracts designed
services specifically for each particular process. Through preventive
maintenance programs unscheduled outages can be reduced and
maintenance workflows are streamlined.
Utilization of integrated switchgear enables the maintenance

to be taken into an even predictive maintenance practice, where
information available from the switchgear can further assist with
maintenance workflow.
10
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89
11. Contacts details of after Sales & Service
Organization
Contacts Contact us via website for Sales & Service Organization:

https://new.abb.com/low-voltage/service/services-for-switchgear
10
11
90
^
10
11
Notes
91
^
10
11
Notes
92
Additional information
We reserve the right to make technical
changes or modify the contents of this
document without prior notice. With
regard to purchase orders, the agreed
particulars shall prevail. ABB AG does
not accept any responsibility whatso-
ever for potential errors or possible lack
of information in this document.
We reserve all rights in this document

and in the subject matter and illustra-
tions contained therein. Any reproduc-
tion, disclosure to third parties or
utilization of its contents – in whole or
in parts – is forbidden without prior
written consent of ABB AG.
—
ABB Electrification products
Publication Editor:
ABB Industrial Solutions (Bielsko-Biała) sp. z o.o.
Rudawka 96
43-382, Bielsko-Biała, Poland
Local Contacts on
abb.com/contact
Note
This document is applicable to
SEN Plus Switchgear
in accordance with IEC 61439-2
© Copyright 2021 ABB. All rights reserved.

Specifications subject to change without notice.

User Manual

Uploaded by

User Manual

Uploaded by

—

SEN Plus low voltage

Principle This document is based on information available at the time of

Labels WARNING WARNING

Warning notices are used to emphasize that hazardous voltage, 3

Caution notices are used for situations in which equipment might be

Notes call attention to information that is especially significant to

Principle The column is subdivided in three functional zones.

Illustration The following illustration shows the three functional zones of

10 Components The following table gives an overview of the main components of

Components The following table gives an overview of the main components of a

8 Components The following table gives an overview of the main components of a

2.3.1. Opening the door of a module

5 Procedure The following procedure describes the opening of the door.

6 Step Action Illustration

4 Open the door. -

2.4.1. Inserting a module

^ Procedure The following procedure describes how to insert a module.

6 Push the module

9 Make sure that the

Procedure The following procedure describes how to lock a module in a column

Step Action Illustration

Loosen the screws on

Procedure The following procedure describes how to insert a load

Step Action Illustration

Mount the connector

Slide the module into

Push the module

Make sure that the

2.4.4. Locking the load break switch module 3

Principle The module is locked on both sides by four locking bolts. 5

Procedure The following procedure describes how to insert a load break

Step Action Illustration

Slide the module into

WARNING Always disconnect the power before disconnecting power supply

Procedure The following procedure describes how to remove a module from

Step Action Illustration

Loosen the mounting

5 Disconnect the main

﻿ Pull the module out of

Pull the module out of

2.5.1. Removing the bottom plate

Repeat step 1 to 3 for ﻿

Extract the bottom

Example • The main cables must be connected to the last electrical

Illustration The following illustration shows the securing of the plug-in.

Slide the plate into the 7

Make sure that the

2.6.1. Replacing a compartment door

Procedure The following procedure describes how to replace

Mount the new See “Mounting a compartment

Illustration The following illustration is showing the position of the plug.

Procedure The following procedure describes the mounting of

Step Action Illustration

Attach door hinges into

Principle The vertical busbars is protected against direct contact by means of

2.8.1. Example: replacing 2 modules size 5E

^ Principle The compartment of a module can easily be adjusted to contain a

Principle The Motor Control Centre is subdivided in three functional zones:

3.2. General characteristics 7

Illustration The following illustration shows the three functional zones of a

10 Ilustration Incoming Outgoing

Worm gear Auxiliary

3.3.1. Operating the worm gear

3.4.1. Opening the door of a module

Procedure The following procedure describes the opening of the door. ﻿

3.5.1. Inserting a module

Step Action Illustration

Slide the module above

Push the module

Make sure that the

Step Action Illustration

Procedure The following procedure describes how to remove a module from

3.6.1. Connecting the main cables

Example The main cables must be connected to the outgoing terminals

Step Action Illustration

Pull the module out of

Repeat step 1 to 3 for

Procedure The following procedure describes the opening of the door.