ABB MNS-Up User manual

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MNS-Up Service Manual
MNS-Up
Service Manual

2MNS-Up Service Manual
MNS-Up a registered trademark
Microsoft, Window 2008 and Windows 7 are registered trademark of Microsoft Corporation.
Products names of other products are registered trademarks of their manufacturers.
In no event shall ABB be liable for direct, indirect, special, incidental, or consequential damages of any nature or kind
arising from the us this document, nor shall ABB be liable for incidental or consequential damages arising from use of any
software or hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB’s written permission and the contents
thereof must not be imparted to a third party nor be used of any unauthorized purpose. The software described in this
document is furnished under a license and may be used, copied, or disclosed only in accordance with the terms of such
license.
All rights reserved.
Copyright © 2016 ABB Schweiz Lenzburg, Switzerland

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MNS-Up Service Manual
01 LIST of Symbols 6
02 Safety requirements when working on electrical systems 7
2.1 Understanding and managing the risk 7
2.2 Basic precautions to be observed 8
2.3 Areas of work 8
2.4 Five safety rules 8
2.5 Permit to work 9
2.6 Personal Protection Equipement 9
2.7 Special considerations 9
2.7.1 Capacitors 9
2.7.2 CT’s 9
03 General technical data 10
3.1 MNS-Up UPS General characteristics 11
04 System description 14
4.1 MNS-Up UPS section 15
05 Packing 17
5.1 The standard packaging comprises: 17
5.2 Shipping unit with transport frame or euro pallet 18
5.3 Box packing 18
5.4 Separate packing 19
Table of contents

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06 Transport 20
6.1 MNS-Up section 20
6.1.1 Rolling transport 20
6.1.2 Fork lifter transport 20
6.1.3 Crane transport 20
6.2 MNS-Up Modules 21
6.3 Circuit breakers 21
07 Erecting 22
7.1 Before installation 22
7.1.1 Ambient conditions 23
7.1.2 Floor cutouts 23
7.2 Clearance above MNS-Up system 23
7.3 Clearance behind MNS-Up system, clearance in front of the section 23
7.4 Frame and enclosure 24
7.4.1 EMC measures for Enclosure 24
7.4.2 EMC seals for shipping splits 24
7.4.3 Rear walls and side walls 25
7.5 Main busbar 25
7.5.1 Busbar connection 25
7.6 Battery connection 26
7.6.1 Individual batteries 27
7.6.2 Common batteries 27
08 MNS-Up configuration 28
8.1 Single MNS-Up UPS section configuration 28
8.2 Multiple MNS-Up UPS section configuration 28
8.3 Active, passive and filter module placing 29
8.3.1 Module arrangement 29
8.3.2 Space covers 30
09 MNS-Up Module installation 32
9.1 Lifting of modules 32
9.2 Adding of module sets 32
9.3 Removing of module sets 32
10 Handling of EMC boards 33
10.1Replacing of EMC boards 33

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MNS-Up Service Manual
11 Communication boards 35
12 MNS 3.0 sections 36
12.1Incoming and outgoing feeders 36
12.1.1 Cable / bus duct connection 36
12.1.2 Handling of ACBs 36
12.1.3 Earthing of transformer / generator connection 37
12.2 Central manual bypass 37
13 Commissioning 38
14 Operating of MNS-Up system 39
13.1 MNS-Up System Operation 39
13.2 Handling / operating ACBs 39
13.3 Other electrical devices 39
15 Tightening torques for screw connection in MNS-Up 40
15.1 SeIf-tapping screws in plastic material 40
15.2 Thread rolling screws in metal 41
15.3 Screws for busbar connections (Cu) and system connections (steel/steel) 42
16 Spare parts 43
17 Onsite inspection and maintenance 43
18 Maintenance intervals 44
18.1 Maintenance checklist 45

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The electrical warning icon indicates the presence of hazard that could result in electrical shock.
The warning icon indicates the presence of hazard that could result in personal injury.
The caution icon indicates important information or warnings relates to the concept discussed in the text. It might indicates
the presence of a hazard that could result in corruption of software or damage of equipment/property.
The information icon alerts the reader ro pertinent facts and conditions.
List of Symbols
1.1 Use of Warning, Caution and Information icon
This publication includes Warning, Caution and Information icons where appropriate to point out safety related or other
important information. The corresponding symbols should be interpreted as follows:
1.2 References
– MNS Service Manual
– DPA500 User Manual
Although Warning notices are related to personal injury and Caution notices are asscociated with equipment or property
damage , it should be understood that the operation of damaged equipment could, uncer certain operational conditions, result
in impaired process performance leading to personal injury or dearh. It is, therefore, imperative that you comply fully with all
Warning and Caution notices.
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MNS-Up Service Manual
Safety requirements for working on
electrical systems
2.1 Understanding and managing the risk
Anyone working on or near electrical systems is required to understand the danger and risk to their lives as well as to any
person or property in the vicinity.
It is of utmost importance that the danger of electrical energy is understood, and the following characteristics associated with
electrical energy noted:
– Electrical energy cannot be seen, heard or smelled, with the result that it is not possible to determine whether a circuit is
alive or dead by relying on these senses. Electrical apparatus must always be con-sidered LIVE until it proves to be dead.
– Note: DEAD means zero volts between conductor and earth has been confirmed.
– LIVE or DEAD status is determined and confirmed by equipment specifically designed for the purpose, NEVER by touch.
Persons must keep clear of electrical apparatus until authorized to work thereon and until it has been proved to be safe. In
order to prevent accidental contact access, the following must be controlled:
– Any prohibited area
– Compartments containing potentially live apparatus/conductors/and terminals
Electrical energy will follow the path of least resistance. This may include all metallic and conductive compo-nents, the human
body and many fluids. Conditions that influence the flow of electrical energy are:
– Intact Insulation. Under these conditions, the circuit fulfills its designed function and the flow of ener-gy can be predicted.
– Breached Insulation. Under these conditions, the circuit may be short-circuited, by tools or by human body. This could prove
hazardous to life and property. The flow of energy is random and may not be predictable. Damaged insulation must
always be reported. There are two reasons for accidental con-tact with live parts:
– Apparatus being made live while others are working on it
– Incompetence and unsafe or careless attitudes
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The highest danger to human life and property is in cases of an electrical arc. An electrical arc is a dangerous release of energy
created by an electrical fault or short circuit. It contains thermal energy, pressure waves, acoustic energy and debris. The
intense energy and very short duration of an electric arc flash represents a very unique event. The temperature of an electric arc
can reach up to 20,000 oC (35,000oF), or two to three times the surface temperature of the sun! Exposure to these extreme
temperatures both burns the skin directly and causes ignition of clothing, adding to burn injuries.
An electrical arc flash describes an explosive electrical event that presents an extremely significant hazard to people and
property. It is of vital importance to use suitable tools and instruments, and personal protection equipment for commissioning,
inspection, or any kind of maintenance work on electrical systems.
2.2 Basic precautions to observe
– THINK – The greatest safety asset is an alert, focused mind.
– Maintain strict discipline regarding safety procedures.
– Communicate clearly and ensure all communications are fully understood.
– Query all instructions that are unclear, not understood or that appear to be in breach of
safety re-quirements.
– Prove all circuits to be safe if they have been unattended for a period of time.
– Maintain safety clearance (air insulation) when working in the proximity of live conductors.
– Do not improvise. Use purpose-designed equipment and tools.
– Use the pre-start checklist prior to commencing any work.
2.3 Areas of work
Working on electrical systems may occur at different times and different conditions. Clearly understanding the conditions helps
to perceive and eliminate any risk. For low-voltage switchgear systems, the following work conditions are defined:
– Operation (operation of circuit breaker, main switch or push button while all doors and
compartments are closed – closed door condition)
– Visual inspection (open doors and compartments to perform any visual inspection, no parts
are touched and no physical work is performed on the electrical system - open door condition)
– Any other maintenance and work (e.g. modification, extensions, cable connection) on low
voltage elec-trical system (either open or closed door condition)
The procedure for performing switching operations is defined by the instruction EN50110-1 2012 “Operation of electrical
installations.”
2.4 Five safety rules
The DEAD circuit condition must be established prior to commencement of work and must be ensured at the place of work for
the duration of work in compliance with the five safety rules (EN50110-1 2012 ch 6.2):
– Disconnect completely
– Secure against re-connection
– Verify that the installation is dead
– Carry out earthing and short-circuiting (Note 1)
– Provide protection against adjacent live parts
Safety requirements for working on
electrical systems 02

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MNS-Up Service Manual
Any circuit that has not been proven dead is to be considered LIVE.
1. Earthing and short-circuiting is not mandatory as per EN 50110-1 2012 ch 6.2.5.2. However, earthing becomes mandatory
under the risks described therein and if also requested by local requirements or customer guidelines, and where provision is
made for earthing or other proper means are available.
2.5 Permit to work
Permission to start work shall be given by the nominated person in control of electrical installation (plant-responsible-person
or PrP) to the nominated person in control of any work activity (work-responsible person or WrP). The permit to start working
must be recorded and signed by all parties in a Safety Permit to Work docu-ment.
2.6 Personal Protection Equipment
Personal protection equipment refers to clothing and additional devices that enhance personal protection to a safe level while
working on electrical systems. Depending on the area of work, a certain level of PPE is required (see table).
When working on or near live parts, the minimum standard for clothing is that products shall be capable of withstanding an
electrical arc with an incident energy of 8cal/ cm2. For the majority of work on or near ener-gized systems, this means that the
clothing provided must be manufactured and tested to the following standards:
– For IEC: Class 1 Garments to IEC 61482-1-2 (Formerly ENV 50354 and CLC/TS 50354).
Note:
In accordance with the valid local regulations, all installation and maintenance work involv-ing MNS low voltage switchgear
systems may only be performed by qualified personnel. For work at low voltage electrical system and components, the
component to be modified or worked on must be isolated and confirmed dead.
2.7 Special considerations
2.7.1 Capacitors
The power supply to a capacitor by a remote auxiliary power source, if any, must also be isolated. When the system has been
isolated, allow the voltage stored in the capacitor to be discharged by the discharging resis-tors by waiting for one minute. As an
additional safety measure, the outgoing capacitor circuits must be tested for discharged condition using a voltage measurement
device. The automatic capacitor must be installed in accordance with the standards IEC 60831-1&2 and all national regulations.
Safety requirements for working on
electrical systems 02

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Standards Low-voltage switchgear and control gear assemblies
Power switchgear and control gear assemblies
IEC 61439 -1 and -2
EN 61439-1 and -2
IEC 62040 Class C
Test certificates IPH, Institut für Prüffeld- und Hochspannungstechnik, Berlin / Germany
Electrical
data*
Rated voltages Rated insulation voltage Ui
Rated operating voltage Ue
Rated impulse withstand voltage Uimp
Overvoltage category
Degree of pollution
Rated frequency
690 V 3~
400 V 3~
2,5kV MNS-Up UPS section
6kV / 8kV for MNS modules
12 kV ACB sections and busbar system
II / III / IV
3
50 Hz
Rated current Busbar:
Rated current Ie
Rated peak withstand current Ipk
Rated short-time withstand current Icw
Distribution bars:
Rated current Ie:
Rated peak withstand current Ipk:
Rated short-time withstand current Icw:
up to 5500 A
up to 250 kA
up to 100 kA
up to 2000 A
up to 220 kA
up to 100 kA
Mechanical
character-
istics
Dimensions Sections and frames
Recommended height
Recommended width
Recommended depth
Basic grid size
DIN 41488
2200 mm
400, 600, 800, 1000, 1200, 1400 mm
400, 600, 800, 1000, 1200, 1400, 1600 mm
E = 25 mm acc. to DIN 43660
Surface protection Frame
Internal subdivision
Transverse section
Enclosure
Zinc or Alu-zinc coated
Zinc or Alu-zinc coated
Zinc or Alu-zinc coated
Zinc or Alu-zinc coated and
Powder coated RAL 9011, black
Degrees of protection According to IEC 60529 or VDE 0470 part 1 UPS: IP 20
MNS: IP40/IP41
Plastic components Halogen-free, self-extinguishing,
flame retardant, CFC-free
IEC 60707, DIN VDE 0304 part 3
Internal subdivision - Equipment compartment - equip-ment
compartment
- Busbar compartment - cable com-partment
- Busbar compartment - equipment compartment
- Equipment compartment - cable compartment
- Compartment bottom plates
Extras Paint finish Enclosure Special colours (standard RAL 9011)
Busbar Busbars Bare copper
Special qualification Test certificates See test certificates listed above
*Design verification by testing: acc to IEC61439 -1 / -2,
General technical data 03

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MNS-Up Service Manual
General technical data
3.1 MNS-Up UPS general characteristics
GENERAL CHARACTERISTICS
General characteristics - Frame Values Unit
Model: MNS-Up
Power ratings:
Apparent power per section 500 kVA
Apparent active power per section 500 kW
Power, range 100 - 3000 kW
UPS type: on-line, transformer-free, modular, decentralized parallel
architecture
Parallel capability: up to 6 MNS-Up sections
Battery: not included
Performance classification: VFI-SS-111
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Mechanical
Dimensions (width × height × depth) 1400x2200x1400 or
1400x2200x1600
mm
Mass, approx. per MNS-Up section (500kW system, with / without 5 mod-
ules)
1450 /
950
kg
Acoustic noise at 1 m:
in normal mode (at <=25°C) at 100% load 84,9 dBA
in normal mode (at <=25°C) at 50% load av. at later stage
Safety
IEC 62040-1 Access: operator/restricted
Electromagnetic compatibility
IEC 62040-2 compliant
Emission UPS Cat/Immunity UPS Cat C3
Environmental
Storage temperature range -25 - +70 °C
Operative average temperature range 0 - +35 °C
Max. continuous operating temperature +30 °C
Relative humidity range (non-condensing) ≤ 95 %
Max. altitude without de-rating 1000 m
General characteristics of active and passive module
Model: Conceptpower DPA500
Active submodule
Passive submodule
Power ratings:
apparent 100 kVA
active 100 kW
UPS type: on-line, transformer free, modular, decentralized parallel architecture
Parallel capability: up to 6 frames
1For higher ambient temperatures, there is a restriction in the operating time in battery mode.
General technical data 03

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MNS-Up Service Manual
Mechanical
Dimensions (width × height × depth):
active sub-module/passive sub-module 710x178x750 mm
Mass, approx.:
active sub-module/passive sub-module 55 / 54 kg
Additional useful information
Back feed protection: included
Color: black (RAL 9005)
General characteristics of filter module
Filter module
Power ratings:
apparent 100 kVA
active 100 kW
Mechanical
Dimensions (width × height × depth): 346x382x650 mm
Mass, approx.: 41 kg
General technical data 03

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System description
The MNS-Up system is an integrated low-voltage switchgear
system comprised of incoming and central manual bypass
feeders, MNS-Up UPS sections and MNS 3.0 outgoing
sections. The system is based on the well-known MNS
system, in which the MNS-Up UPS is integrated.
The MNS-Up system uses both MNS main busbar systems.
The upper main busbar is used as the input busbar to which
the incoming feeders and the non-critical load are connected.
The lower main busbar system is used as output main busbar
to which the critical load is connected. The output main
busbar is fed by the MNS-Up UPS modules. The central
manual bypass breaker is connected to both the input and
output main busbars. This breaker is normally open. In case
Output line
UPS n x
5x100kW
Input line
Transformer
Distribution
Feeder
Generator
Cable or
Busbar
Gen Incomer Main Incomer
Central Bypass Non- critical
load
of maintenance on the MNS-Up UPS section or modules, the
central manual bypass can be closed and the MNS-Up UPS
system can be turned OFF and isolated. During maintenance,
the critical load is fed from the input busbar via the bypass
breaker.
The MNS-Up UPS section can be equipped with 1-5 UPS
module combinations of 100kW each. A module com-bination
consists of one MNS-Up active module 1 MNS-Up passive
module and one MNS-Up filter module.
In the MNS-Up system, up to 6 MNS-Up UPS sections (6 x 5
x 100 kW= 3000 kW) can be combined in one system.
MNS-Up system overview and interfaces
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MNS-Up Service Manual
System description
4.1 MNS-Up UPS section
MNS-Up UPS SECTION OVERVIEW
1 Input main busbar 3 pole 10 Common battery connection bars
2 Output main busbar 3 pole 11 Ventilation chanel
3 Input and output neutral conductor 12 Partition wall 3 to main busbar area
4 PE main busbar 13 EMC filter board input line
5 Active MNS-Up UPS module 14 EMC filter board output line
6 Passive MNS-Up UPS module 15 Multifunction wall
7 MNS-Up UPS Filter module 16 Bottom plates
8 Active and passive module compartment 17 Communication interfaces
9 Filter module compartment
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The MNS-Up is used to protect sensiwtive equipment and prevent
loss of valuable electronic information, mini-mize equipment
downtime, and minimize the adverse effect on production
equipment due to unexpected power problems.
The MNS-Up system continually monitors incoming electrical
power and removes the surges, spikes, sags, and other
irregularities that are inherent in commercial utility power. Working
with a building‘s electrical system, the MNS-Up system supplies
clean, consistent power that sensitive electronic equipment
requires for reliable operation. During longer blackouts and other
power interruptions, batteries provide emergency power to safe-
guard operation.
Hot Swappable Modules
The unique hot swappable feature of the modules provides the
ability to insert and extract the electron-ic/power modules from
a larger assembly while it is powered (hot). The hot swappable
design allows live powered modules to be attached to and
removed from a powered set without causing disturbance to the
operation of the load and without need to go to bypass.
Flexible Battery Management (FBM)
Flexible battery management (FBM) has been designed in all
MNS-Up products, with the goal to avoid the dete-rioration of
battery age. The FBM – Key Features protect the battery from
negative environmental impacts (high temperature and false
manipulations) and avoid deterioration of battery life through
advanced man-agement of battery charging and preventive failure
diagnostics. The implemented features result in benefits not only
for the end user, but also to the environment. The battery user is
required to replace batteries less often.
DPA Technology - Decentralized Parallel Architecture
The MNS-Up product features DPA paralleling technology that
provides N+X redundancy without introducing a single-point-
of-failure. Products using the DPA technology are completely
autonomous by means of individual power units, bypasses, CPUs,
control panels and separate battery configuration for each single
module.
DPA technology is more reliable than traditional paralleling
techniques. A parallel MNS-Up system means the linking together
of two or more MNS-Up units in parallel, so that in the unlikely
event that one fails, the other can automatically take up the load.
Traditionally, a parallel redundancy configuration is achieved by
having a random or fixed master-slave relationship among the
MNS-Up units. This master logic gives out individual commands
to all the slave units. Unfortunately, this can lead to a single-
point-of-failure for the whole system, because if the master logic
or communication to slaves fails, it causes trouble for the whole
MNS-Up system.
DPA technology was developed as a multi-master logic concept,
with separated independent regulation and logic buses to allow
parallel capacity system and to maintain the highest system
availability. An industry lead-ing paralleling technology in its own
right, DPA technology enables setup of a parallel redundant
system, providing 100% conditioned power at all times. Its unique
decentralized design eliminates the system level single-point-
of-failure inherent in traditional parallel UPS, and exponentially
increases the reliability of the overall system.
DPA technology allows up to 30 MNS-Up modules to cover the
same load in parallel and redundant configura-tion. No vulnerable
master logic is needed in this design. It provides automatic load
sharing and module level redundancy with nothing other than the
power connecting to the Conceptpower DPATM 100kW modules.
System description 04

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MNS-Up Service Manual
Shipping frame
Wooden beams 8x10cm Wooden beams 8x10cm
handing by forklift truck
Nails for fastening of
wooden cross beams
Sections are protected by suitable packaging during transport and possible intermediate storage.
5.1 The standard packaging is comprised of:
– PE-sheeting
– transport frame consisting of wooden beams (6 x 12 cm) with wooden fixing ledges (2, 4 x 5 cm) and wooden cross beams (8 x 10
cm) for forklift transport, or
– Euro pallet, plastic strips, wooden crate (if necessary)
The sections are to be fixed with the plastic strips to the pallets.
Shipping units with transverse section and a total weight of more than 1200 kg are provided with a transport frame, which:
– prevents the section steel sections from bending
– consists of wooden beams 6 x 12 cm
– is fixed in such a way that the front and rear transverse sections and the module supporting frame rest on the transport frame
– is fastened to the section by means of plastic strips and wooden fixing ledges. The plastic strips must be bolstered by foam plastic
foil. For fastening, the bottom plate may be pierced at the points of attach-ment. At the site, these holes must be sealed by plugs
unless they are used for floor mounting.
– There is no connection of the transport frame with the packing material when using crates.
Packing
Box packing with cross beams
05

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5.2 Shipping unit with transport frame or euro pallet
5.3 Box packing
Unpacked shipping units have to be provided directly, with wooden crossbeams for handling by forklift trucks. For packed shipping
units, the wooden crossbeams are located beneath the packing material.
To protect them against moisture, switchgear installations must be encased in a foil. A protective drying agent (such as silica gel) must
be provided between the foil and the switchgear.
The export/seaworthy packaging (for sea transport and truck or train transport outside continental Europe) is comprised of:
– Closed wooden box
– Heat-sealed foil
– Drying agent (acc. DIN 55474)
– Wooden cross beams (8 x 10 cm) for forklift transport
– Elastic packing means as pads
As packaging material, the following is allowed:
– Plywood (13 mm)
– Cut timber (24 or 30 mm)
– Slot and feather (28 mm)
The switchgear must be wrapped with foil after upholstering sharp edges and corners. The joints of the foil must be sealed.
A protective drying agent according to DIN 55474 must be provided between the foil and the switchgear. No direct contact of this
protective drying agent with the switchgear is allowed.
With container traffic, no box packing is necessary.
Packing 05

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MNS-Up Service Manual
6.1 MNS-Up section
– The MNS-Up sections must be shipped as individual sections,
due to their dimensions and weight.
– ACB sections and MNS 3.0 sections may be shipped in
sections of max 3 m in length or 3 sections. Shipping sections
shall only be transported in upright position
– For single empty sections, it is possible the to tilt the section
carefully to side for transport, if the door height on site does not
allow upright transport
6.1.1 Rolling transport
Rolling transport of shipping sections up to 1200kg in weight with
min. 3 rollers is possible. In case of higher weight, the transport
must be done with a forklift.
5.4 Separate packing
The following devices and materials must be delivered separately packed with the switchgear, independent from the method of
transport:
Withdrawable air circuit breakers and MCCBs
Withdrawable circuit breakers must be packed in the original transport boxes and shipped separately.
MNS-Up UPS modules
Active and passive MNS-Up modules must be removed from the MNS-Up section and packed in the original boxes before
shipping.
MNS-Up Filter modules
MNS-Up filter modules must be removed from the MNS-Up section and packed in the original boxes before shipping.

Only remove the packaging after delivery of the switchgear to site. Only remove the transport frames
from the section bases at the place of erection.



6 Transport
Transport frame
(wooden beam 10x12cm)
Packing 05

20 MNS-Up Service Manual
6.1.3 Crane transport
For transport by crane, the shipping units are equipped with lifting
angles.
Fastening of any lifting device directly to the frame sections is not
permitted.
The lifting rope angle at the crane hook must not be larger than
120°. The lifting angles may be removed after the switchgear has
been erected.
The fastening holes for the lifting angles are to be plugged with
plugs GMN 775 502 P18, if removing the lifting angles.
Sections may easily tip over when transported with
a hand-lift truck. Therefore the distance between the
wooden cross beam or the pallet and the ground
should not be more than 3 mm (see fig. 24).
Permissible Ioad for a four-rope arrangement,
rope angle at crane hook 120°
Rope diam.
mm
Hamp ropes
DlN 83325
kg
Perlon ropes
DlN 83330
kg
Steel ropes DlN 15060
(160 kg/mm2)
kg
8 - - 890
10 180 400 1440
12 280 600 2100
14 350 820 2900
16 470 1060 -
18 580 1340 -
20 720 1660 -
24 1000 2400 -
30 1600 - -
36 2400 - -

6.1.3.1 Guide values for permissible rope loading
6.1 MNS-Up section
– The MNS-Up sections must be shipped as individual sections,
due to their dimensions and weight.
– ACB sections and MNS 3.0 sections may be shipped in
sections of max 3 m in length or 3 sections. Shipping sections
shall only be transported in upright position
– For single empty sections, it is possible the to tilt the section
carefully to side for transport, if the door height on site does not
allow upright transport
6.1.1 Rolling transport
Rolling transport of shipping sections up to 1200kg in weight with
min. 3 rollers is possible. In case of higher weight, the transport
must be done with a forklift.
Transport frame
(wooden beam 10x12cm)
6.1.2 Forklift transport
The transport pallets are supported with cross beams to allow the transport with a forklift or hand-lift truck
Transport 06