ABB MNS-Up User manual

• Capex and footprint reduction
• Reduced installation time as all
the system is pre-tested
• Flexibility and scalability with
full plug-in UPS modules
• On-premise and cloud base data
collection and analysis with
ABB AbilityTM
—
DISTRIBUTION SOLUTIONS
MNS-Up
Service Manual

—
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.

1217 1116 07 06 05 04 03 02 010914 1015 081318
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Table of contents
01. Introduction 06
02. Safety requirements 08
03. General technical data 12
04. System description 16
05. Packing 18
06. Transport 36
07. Erecting 40
08. MNS-Up configuration 48
09. MNS-Up Module installation 52
10. Handling of EMC boards 56
11. Communication boards 60
12. MNS 3.0 sections 62
13. Commissioning 64
14. Operating of MNS-Up system 66
15. Tightening torques for screw connection 68
16. Spare parts 72
17. Onsite inspection and maintenance 74
18. Maintenance intervals 76

4MNS-UP SERVICE MANUAL
1 Introduction
1 Introduction 07
2 Safety first
2.1 Safety relevance 09
2.2 Understanding and managing the risk 09
2.3 Warning signs and labels 10
2.4 Basic principles and precautions to be observed 10
2.5 Areas of work 10
2.6 Five safety rules 11
2.7 Permit to work 11
2.8 Personal Protection Equipment (PPE) 11
2.9 Special considerations when working on electrical equipment 11
2.9.1 Capacitors 11
2.9.2 CT’s 11
2.9.3 Auxiliary or temporary supply 11
3 General technical data
3 General technical data 13
3.1 MNS-Up UPS General characteristics 14
4 System description
4.1 MNS-Up UPS section 17
5 Packing, storage and transportation
5.1 General 19
5.1 Recommended packing methods 22
5.2.1 The packing for normal road transport 22
5.2.2 The seaworthy packing 23
5.2.3 Horizontal transportation 29
5.2.4 Packaging of switchgear components 30
5.3 Handling of switchgear components 30
5.3.1 Circuit breaker 30
5.3.2 Withdrawable modules 30
5.3.3 MNS-Up UPS modules 30
5.3.4 MNS-Up Filter modules 31
5.4 Unloading and transport at site 31
5.4.1 Ground transport 31
5.4.4 Transport by crane 32
5.4.3 Transport by truck 34
5.5 Intermediate storage 34
5.5.1 Storage of spare modules 35
5.6 Enviromental conditions of transport, storage and installation 35
6 Transport
6.1 MNS-Up section 37
6.1.1 Rolling transport 37
6.1.2 Forklift transport 37
6.1.3 Crane transport 38
6.1.3.1 Guide values for permissible rope loading 38
6.2 MNS-Up Modules 39
6.3 Circuit breakers 39
7 Erecting
7.1 Before installation 41
7.1.1 Ambient conditions 41
7.1.2 Floor cutouts 41

5TABLE OF CONTENTS
7.2 Clearance above MNS-Up system 42
7.3 Clearance behind MNS-Up system, clearance in front of the section 42
7.4 Frame and enclosure 43
7.4.1 EMC measures for enclosure 43
7.4.1.1 EMC seals between sections 43
7.4.1.2 EMC seals for roof plates 43
7.4.1.3 EMC seals for bottom plate 43
7.4.2 EMC seals for shipping splits 43
7.4.3 Rear walls and side walls 43
7.5 Main busbar 44
7.5.1 Busbar connection 44
7.5.1.1 Main busbars 44
7.6 Battery connection 46
7.6.1 Individual batteries 46
7.6.2 Common batteries 46
8 MNS-Up configuration
8.1 Single MNS-Up UPS section configuration 49
8.2 Multiple MNS-Up UPS section configuration 49
8.3 Active, passive and filter module placing 50
8.3.1 Module arrangement 50
8.3.2 Space covers 51
9 MNS-Up Module installation
9.1 Lifting of modules 53
9.2 Adding of module sets 54
9.3 Removing of module sets 54
10 Handling of EMC boards
10.1 Replacing EMC boards 57
11 Communication boards
11 Communication boards 61
12 MNS 3.0 sections
12.1 Handling of ACBs 63
12.2 Earthing of transformer/generator connection 63
12.3 Central manual bypass 63
13 Commissioning
13 Commissioning
65
14 Operating of MNS-Up system
14.1 MNS-Up system operation 67
14.2 Handling/operating ACBs 67
14.3 Other electrical devices 67
15 Tightening torques for screw connection in MNS-Up
15.1 SeIf-tapping screws in plastic material 69
15.2 Thread rolling screws in metal 70
15.3 Screws for busbar connections (Cu) and system connections (steel/steel) 71
16 Spare parts
16 Spare parts 73
17 Onsite inspection and maintenance
17 Onsite inspection and maintenance 75
18 Maintenance intervals
18 Maintenance checklist 78

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01
Introduction

7INTRODUCTION
This manual id dedicated to the MNS-Up section hosting
the UPS modules; for the other cubicles and the UPS
modules please refer to dedicated Manuals:
• MNS Installation and maintenance manual
1TGC902040B0201
• DPA 500 Operating Manual 04-3275 REV-C
—
Introduction

—
02
Safety first

9SAFETY FIRST
—
Safety first
Safety requirements when working on electrical systems
2.1 Safety relevance
This Service Manual contains further safety relevant aspects in the document. This is highlighted with the following symbol:
!
When working on specific tasks or areas in the switchgear it is mandatory to follow the safety requirements and advises
outlined in this document.
2.2 Understanding and managing the risk
Any person working on or near electrical systems is required to understand the danger and risk such work may impose to
his/her life as well as to any person and property in the vicinity.
It is of utmost importance that the danger of electrical energy is understood and following characteristics associated with
electrical energy should be noted:
• Electrical energy cannot be seen, heard or smelt, with the result that it is not possible to determine whether a circuit is
alive or dead by relying on senses. Electrical apparatus must therefore always be considered LIVE until it is proved to be
DEAD.
• DEAD means zero volts between conductor and earth is confirmed.
• LIVE or DEAD status is determined and confirmed by equipment specifically designed for the purpose, NEVER by touch.
Personnel shall not work on any electrical apparatus until approval has been granted by the responsible authority and the
working environment has been classified as safe, the following must be controlled:
• Any prohibited area,
• Compartments containing potentially live apparatus/conductors/and terminals.
Electrical energy will follow along the path of least resistance. This may include all metallic and conductive components,
the human body and many fluids. Conditions that influence the flow of electrical energy are:
• Intact Insulation. Under these conditions the circuit fulfils its designed function and the flow of energy can be predicted.
• Breached Insulation. Under these conditions a short circuit may occur. 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 contact with live parts:
- Apparatus being made live whilst others are working on it,
-Unsafe working practices.
The highest danger to human life and property is the situation with the occurrence of an electrical arc. An electric arc is a
dangerous release of energy created by an electrical fault or short circuit. It contains thermal energy, pressure waves, acous-
tic 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 °C (35 000 °F), 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, which adds
to the 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 as well as personal protection equipment for com-
missioning, inspection or any kind of maintenance work on electrical systems.

10 MNS-UP SERVICE MANUAL
2.3 Warning signs and labels
Electrical systems shall be labeled according to the hazard risk level. ISO3864 and its ANSI equivalent Z535.4 prescribes the
layout and application of signs. Following sings are typically applied:
High Voltage
ISO3864
Arc Flash Hazard
ISO3864
Warning Sign
ANSI Z535.4
Danger Sign
ANSI Z535.4
WARNING
ARC FLASH and
SHOCK HAZARD
Appropriate PPE and
Tools required when
working on thi
equipment
!
DANGER
Arc Flash Hazard
Follow requirements for
safe work practices and
apporopriate PPE.
Failure to comply can
result in death or injury.
!
Table 2-01 Typical warning signs and labels
2.4 Basic principles and precautions to be observed
In accordance with the valid local regulations, all installation and maintenance work involving MNS low voltage
switchgear systems may only be performed by skilled and 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.
If in doubt of the task to be carried out, ABB Service technicians should be utilized for the work. Never utilize
untrained personnel who are not certified with the system.
The mandatory guideline for working in electrical systems is the instruction EN50110-1 2013. Local country law for work on
electrical systems must also be observed. Minimum precautions are to be observed:
• THINK – The greatest safety asset is an alert, focused mind,
• Maintain strict discipline regarding safety procedures,
• Use appropriate personnel protection equipment and tools,
• 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 requirements,
• 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 starting or commencing any work.
2.5 Areas of work
Working on electrical systems may occur at different times and different conditions. To clearly understand the conditions
helps to understand and eliminate any risk. In low voltage switchgear systems 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 electrical system (either
open or closed door condition)
The procedure for performing switching operations is defined by the instruction EN50110-1 2013 “Operation of electrical
installations”.
!
Keep doors and covers closed & locked whenever possible.
Check if lock couplings are utilised otherwise, each lock must be locked.

11SAFETY FIRST
2.6 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 2013 chapter 6.2):
1. Disconnect completely;
2. Ensure no re-connection is possible;
3. Verify that the installation is dead;
4. Carry out earthing and install any shorting links required1;
5. Ensure that any adjacent live parts are suitably shrouded and provide the required protection.
!
Any circuit that has not been proven dead is to be considered as LIVE.
2.7 Permit to work
Permission to start work shall be given by 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 document.
2.8 Personal Protection Equipment (PPE)
Personal protection equipment refers to clothing and additional devices to enhance personal protection to a safe level while
working on electrical systems. Depending on the area of work certain level of PPE is required.
When working on or near live parts the minimum standard for clothing is that products shall be capable of withstanding
e.g. electrical arc with an incident energy of 8cal/cm2. For the majority of work on or near energised 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).
Specific Risk Assesment and Arc Flash analysis shall be carried out and as per the task the minimum PPE should be decided.
2.9 Special considerations when working on electrical equipment
2.9.1 Capacitors
The power supply to a capacitor by a remote auxiliary power source, if any, shall also be isolated. When the system has
been isolated, allow the voltage stored in the capacitor to be discharged, the outgoing capacitor circuits must be tested for
discharged condition using voltage measurement device. The automatic capacitor must be installed in accordance with the
standards IEC 60831-1&2 and all national regulations.
2 . 9 . 2 C T´s
Ensure that the current transformer secondary circuits have been shorted when no load is connected.
2.9.3 Auxiliary or temporary supply
Ensure that any auxiliary supply that may be required to perform testing or commissioning tasks is securely switched off and
protected against operation while working on the electrical equipment.
—
1 Earthing and shorting is not mandatory as per EN 50110-1 2013 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.

—
03
General technical data

13GENERAL TECHNICAL DATA
—
General technical data
3 General technical data
Standards
Enclosed low-voltage switchgear
and controlgear assemblies
General rules 
Power switchgear and controlgear assemblies 
Testing under conditions of arcing due to
internal fault (internal arc)

Seismic Recommended practices for nuclear generating
station

Vibration Environmental testing Test Fc: Vibration
(sinusoidal)

Shock Environmental testing
Test Ea and guidance: Shock

Protection against electric shock Common aspects for installation and equipment 
General rules 
Test certificates
ASTA / United Kingdom, DEKRA / Netherlands, Germanischer Lloyd, Hamburg / Germany
IPH, Institut für Prüffeld- und Hochspannungstechnik, Berlin / Germany
High Power Laboratory, ABB AG, Ratingen / Germany
Technology center laboratory, ABB s.r.o, Brno / Czech Republic
Electrical data
Rated voltages
Rated insulation voltage Ui
Rated operating voltage Ue
Rated impulse withstand voltage Uimp
Overvoltage category
Degree of pollution
Rated frequency



II / III / IV


Rated currents
Main 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



Arc fault containment
Rated operational voltage
Prospective short-circuit current
Duration





Mechanical
characteristics
Dimensions
Sections and frames
Recommended height
Recommended width
Recommended depth
Basic grid size

*)



Surface protection
Frame incl. Internal subdivision
Cladding, internal, roof and bottom plate
Cladding, external, front, rear and side
Zinc or Alu-zinc coated
Zinc or Alu-zinc coated
Zinc or Alu-zinc coated and

Degree of protection
 

Internal from IP XXB
Separation Form 

External mechanical impact (IK) 
Plastic components Halogen-free, self-extinguishing,
flame retardant, CFC-free

Steel components 

Forms of separation 

Internal subdivision
Equipment compartment
Busbar compartment
Cable compartment
Extras
Paint finish Enclosure 
colours on request)
Busbar system
Busbars Bare copper Insulated with heat shrinkable
sleeving Silver or tin plating Aluminium
busbar systems
Optional Project specific solutions available on request

14 MNS-UP SERVICE MANUAL
3.1 MNS-Up UPS general characteristics
General characteristics
General characteristics - Frame Values Unit
Model: MNS-Up
Power ratings:
Apparent power per section  kVA
Apparent active power per section  kW
Power, range  kW
UPS type: on-line, transformer-free, modular,
decentralized parallel
architecture

Battery: not included

Mechanical
Dimensions (width × height × depth) 

mm
mm
Mass, approx. per MNS-Up section

 kg

 
 

av. at later stage
dBA
dBA
Safety
 Access: operator/restricted
Electromagnetic compatibility
 compliant
Emission UPS Cat/Immunity UPS Cat 
Environmental
Storage temperature range  °C
Ambient temperature  °C
Relative humidity range (non-condensing) ≤ 
Max. altitude without de-rating  m

15GENERAL TECHNICAL DATA
General characteristics of active and passive module
Model: Conceptpower DPA500 Values Unit
Active submodule
Passive submodule
Power ratings:
apparent  kVA
active  kW
UPS type: on-line, transformer free,
modular, decentralized parallel architecture

1For higher ambient temperatures, there is a restriction in the operating time in battery mode.
Mechanical
Dimensions (width × height × depth)
active sub-module/passive sub-module 
mm
mm
Mass, approx:
active sub-module/passive sub-module  kg
Additional useful information
Back feed protection: included

General characteristics of filter module
Filter module
Power ratings:
apparent  kVA
active  kW
Mechanical
Dimensions (width × height × depth):  mm
Mass, approx.:  kg

—
04
System description

17SYSTEM DESCRIPTION
—
System description
4.1 MNS-Up UPS section
1 Input main busbar 10 Common battery connection bars
2 Output main busbar 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 compartmen

—
05
Packing, storage and transportation

19PACKING, STORAGE AND TRANSPORTATION
—
Packing, storage and transportation
5.1 General
MNS switchgear is shipped either in singIe section or in shipping units not exceeding 3 m in length depending on the type
of equipment instalIed and on the space available for handIing the switchgear at the erection site.
Maximum size of a shipping unit (length × width × height) in mm:
• Unpacked 3100 x 1300 x 2300
• Packed in crate 3300 x 1500 x 2590 (see also “3.1.1 Container shipment”)
The MNS-Up sections must be shipped as individual sections, due to their dimensions and weight.
In all cases the ACB must be transported separately from the section. It is not allowed to transport it within the section.
The ACB requires special attention during transport and handling. Please refer to original manuals 1SDH000999R0002 and
1SDH001000R0002, Chapter 2: Transport and checking on receipt.
Note: Shipping dimensions and weights here are approximate. These are meant to be used a guide only. Please refer to
project specific documentation.
!
Remove all ACBs from sections and transport them separately!
Module type Protection circuit Type Module size
Withdrawable modules
Motor starters
Fuse
TOL / EOL



Circuit breaker
TOL / EOL


Energy distirbution
Fuse SFU

Contactor feeder
Circuit breaker MMS / MCCB
Contactor feeder
Plugin modules Energy distirbution
Fuse
SFU

Contactor feeder
SlimLine
Circuit breaker MMS / MCCB
Contactor feeder
Table 5-01 General overview of standard module solutions (customer specific solutions not mentioned)
If no special instructions are given by the customer, packing is carried out based on ABB shipping guidelines and a suitable
method of shipping is selected. Approximate weights for calculation are listed in below tables.
All weights for incoming feeders configured as below:
• Section weights are defined based on IP30-IP40 internal protection with bottom plate
• Section weight for EQ400 / EQ600 contains 200 mm main busbar area
• Section weight for EQ800 contains 400 mm main busbar area
• Section weights are defined with all possible CTs (measuring and protection), REF relay and SPD
• Section weights do not contain internal devices (except CTs, REF, SPD) and wiring
• Section weights do not contain side walls and main busbar end covers
All weights for couplers configured as below:
• Coupler weights do not contain internal devices (except CTs and REF) and wiring
• Coupler weights do not contain side walls and main busbar end cover
• The type of coupler with CTs utilizes different angle set (with more copper) to create place for CTs. If you use coupler
without CTs, the overall weight might be significantly lower.

20 MNS-UP SERVICE MANUAL
Approximate weight of one front access section without ACB
Type of section Type of ACB
Section width
[mm]
Weight of ACB
[kg]
Standard
(EQ400,EQ600)
High current
(EQ800)
     –
     –
     –
     
     
     
     –
     –
     
     
     –
     –
     –
     
     
     
     –
     –
     
     
Empty module section – – –
Table 5-02 Approximate weights per 3 and 4 pole ACB sections (incomming feeders and couplers)
Approximate weight of MNS-Up section
Section type Approximate weight [kg]
MNS-Up empty section (without UPS modules) 
Table 5-03 Approximate weights of MNS-Up section
Approximate weight of UPS modules
Module type UPS components Approximate weight [kg]
Plugin modules
 
 
 
Table 5-04 Approximate weights of USP modules