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MODSTACKIntelligent • Modular • Highly Integrated

Switch Fuse Disconnector System

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Contents Modstack Switch-Fuse Disconnector System

■ Modular■ Compact■ Plug-in■ High degree of operator safety■ Easily installed■ Intelligent■ Highly integrated■ Energy management options■ Communications options■ Promotes savings

TimeMoneySpaceLabour

■ Long term data & event memory■ Current transformers■ Maximum Demand Meters■ Auxiliary Conatacts■ Motor Actuators■ KWh Monitoring■ RS485 Communication■ Three Phase Data Acquisition■ Ammeters■ Electronic Fuse Surveillance

EMS Energy Management Panel

Modstack Switch-Fuse 2-3Disconnector System

Modstack Switch Accessories 4-6

Modstack Mounting Accessories 7

Modstack Mounting System 8-9

Modstack Busbar System 10-11

Modstack Insallation Accessories 12-13

Modstack Switchboards 14-15

Energy Management System 16-17

Integrated EMS Application 18

Modstack Motor Actuator 19

Switch Specifications 20-21

Dimensions 22

Modstack Parts List 23

Installation Information 24-25

Modstack Mounting/Installation 26

Modstack Suggested Specification 27

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Modstack Switch-Fuse Disconnector System

■ Unique self-aligning busbar plugs■ DIN & BS standards■ Up to 630A fused■ Padlockable rotary actuator■ Double break contacts■ Independent manual operation■ Fully comply with IEC947-3■ Rated for motor duty AC23■ Rated up to 690VAC and 440VDC■ Busbar coupling versions■ Integrated options

AmmetersCTs20mA transmittersFuse monitoringAuxiliary contactsCommunicationsMotor actuators

BusbarCouplingSwitch400/630A150mm* 1000A withsolid copperlinks see p10.

Size 2/3400/630A150mm

Size 00160A50mm

Size 1250A75mm

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Modstack Switch Accessories

Transformer Transformer Rating (VA)Ratio CI.1 CI.3

50-5 – 0.6

75-5 1.0 1.3

100-5 1.6 2.0

125-5 2.2 2.6

150-5 2.8 3.8

200-5 4.0 4.6

250-5 5.2 6.2

300-5 3.75 3.75

400-5 5.0 7.5

500-5 5.0 7.5

600-5 5.0 5.0

75-1 0.8 1.1

100-1 1.4 1.8

125-1 2.0 2.4

150-1 2.6 3.0

200-1 3.7 4.0

250-1 5.0 5.4

300-1 3.75 3.75

400-1 5.0 7.5

500-1 5.0 7.5

600-1 5.0 5.0

Plug Connector

The plug connector is needed to bring out the auxiliary circuits for the use of:

■ Auxiliary contacts for switch positions indicators (1M x 1B).■ Current transformers for remote indication.■ Transducers for remote indication.■ The electronic fuse monitoring device.

The plug connector is accommodated in the busbar adapter. It is fitted insuch a way that it automatically makes contact with a socket connector whenthe switch is inserted.

Current Transformer

The current transformers are fittedinside the busbar adapter and areconnected to a meter in the wiringarea of the switch and/or to a 16-poleplug connector in the busbar adapter.

■ Class 1 available as standard■ Class 0.5 available on request■ 0...20mA transmitters available

Meters

Moving-iron ammeters andmaximum demand (bimetal)ammeters are available for fittinginto every size of fuse-combinationunit. Size 48 x 48 meters areequipped with plug-in contacts andare placed in the cable connectionarea of the fuse-combination unit.

When ordering, match CT primaryrating to the fuse rating.

Transformer ratings:

Auxiliary Contacts

Up to 3 changeover contacts canbe installed in the busbar adapterto indicate the switch position.Each c/o contact can be wired asa n/o and/or a n/c contact.The auxiliary contacts are installedat the factory, where they are wiredto the plug connector fitted in thebusbar adapter.

Technical Data: 12A: AC250V

Maximum Demand (bimetal) AmmeterPower consumption: N/1A: 0.9VA

N/5A: 1.6VA

Moving-iron AmmeterPower consumption: N/1A: 0.3VA

N/5A: 0.5VA

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Electronic FuseMonitoring Device

The fuse monitoring device is builtinto the busbar adapter. Indicationof a defective fuse is given by meansof make and break contacts to theplug connector and by the indicatorlights on the front of the device(one per fuse and one event LED).

Technical Data 5A: AC 250V

Versions:

ES: 1 function LED internally powered

ES25A1: 4 LEDs, 1 per phase and1 function LED. Requires 24VDCsupply. Max. consumption 80mA

(see picture below)

Table 1: ES25A1 operating states

No. Operating State Relay State Break Contact N/C Make Contact N/O Function LED Green/Red F1 LED red F2 LED red F3 LED red

1 Delivery State Low Closed Open Off Off Off Off

2 Phase failure L1 – L3 Low Closed Open Flash Green Off Off Off

3 Fuses OK Low Closed Open Green Off Off Off

4 Fuse F1 defect High Open Closed Flash Green On Off Off

5 Fuse F2 defect High Open Closed Flash Green Off On Off

6 Fuse F3 defect High Open Closed Flash Green Off Off On

7 Fuse F1 and F3 defect High Open Closed Flash Green On Off On

8 Fuse monitor fault Low Closed Open Flash Red Off Off Off

9 Switch in off position Low Closed Open Green Off Off Off

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1 Spring loaded busbar plug2 16 pole plug connector (auxiliary circuits)3 Current transformers4 Electronic modules5 Auxiliary contacts6 Double break contacts7 Insulated switch case8 Rotary actuator9 Cable connections

10 Padlocking facility11 Front cover

The control cables for the integrated switch options areconnected to the socket connector. The socket connectoritself is latched onto the guide. (See diagram)

Terminal range: 0.5-1.5mm2 Rated voltage: AC 400V

1 2

3

4

5

6

7

8

9

10

11

3 3

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Modstack Mounting Accessories

O : off Open front cover I : on

Swicth Actuator

* Switch cover must be locked prior to switching

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Modstack Mounting System

Fitting Dimensions

■ The dimensions details thepositioning of the modstacksupport rails (SRAIL) for install-ation into custom metalwork.

■ Dimensional jig available.Order 2 x 5KB2880-002.

■ For modular panels such asElsteel Techno, fix the verticaland horizontal support barsas per the dimensions shown.

■ For the Techno System, a “Half L”kit will need to be installed onthe left side of the switch tier tomaintain dimensional integrity(due to switch overhang).

■ Insert support rails ■ Fix busbar support, busbarand busbar cover supports

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Modstack Mounting System

■ Attach busbar covers, shroudsand vent brackets

■ Clip in guide rails and fitswitches and vents

Busbar mm a b

40 x 10 290 270

50 x 10 300 280

60 x 10 310 290

80 x 10 330 310

100 x 10 350 330

Top View

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Modstack Busbar System

Short Circuit ratings of Busbar Carrier (kA rms)

Cross-Section 0.1 second 1 second

of Busbar Busbar Carrier Separation

300mm 450mm 600mm 750mm 300mm 450mm 600mm

40 x 10mm 80 65 50 35 65 50 –

50 x 10mm 80 65 50 35 65 50 –

60 x 10mm 80 80 65 40 80 65 –

80 x 10mm 100 80 65 50 80 65 –

100 x 10mm 100 100 80 65 80 65 65

(100+40) x 10mm – – – – 80 65 65

Short Circuit Ratings

Short circuit protection of the busbarcarrier as a function of busbar carrierseparation and busbar cross-section(shown in table above).

Busbar Carriers

The busbar carriers (Fig. 1) can besupplied for each size of metriccopper busbar. The carriers are notadjustable. The fixed style of carrierensures high fault level protection(certificates available).

The busbar carriers can be fixed fromthe rear of the switchboard (BBSFXbracket Fig. 2) or from the front ofswitchboard (BBSB90 bracket Fig. 3).

Fig. 1

Fig. 2

Fig. 3

Fig. 4 Switch side view Fig. 5 Fig. 6

Versions are available with insulatedback plates for use in the lowestsupport position.

Busbar Isolation & Coupling

The vertical busbars that feed theModstack units can be dividedand isolated at any point along theirlength. This is achieved by using themoulded isolating units (Fig. 5, 6) tosplit and isolate the busbar. They arefitted within a 100mm busbar support.

The busbar can be coupled anduncoupled by using the Modstackbusbar coupling switch (Fig. 4).The busbar coupling switch comes in400A and 630A models. The 630Amodel can be rated at 1000A using1000A size 3 copper links (NH3/1000ISM). This switch performs thefunction of a 1000A load break switchin a quarter of the space.

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Modstack Busbar System

Typical Current Carrying Capacities for Copper Busbar

Compact High Current Solution

The diagram to the left details thesolution for applications greater than1500A.1 When the 100 x 10mmbusbar rating is not adequate forthe distribution system, this set-upcan be used to increase the crosssectional area of the busbar to1400mm2 per phase.

By adding the 40 x 10mm busbar tothe 100 x 10mm busbar, a compactring feed is produced.

This configuration is housed insidethe standard 100mm busbar support.The combination has been type testedfor its short circuit rating.

1 At rating 1 in the table above.

Dimensions (mm) Cross-Section (mm2) Rated Current (A)1 Rated Current (A)2

40 x 10 400 715 570

50 x 10 500 852 695

60 x 10 600 985 800

80 x 10 800 1240 1010

100 x 10 1000 1490 1220

(100+40) x 10 1400 2180 1780

1 Rating @ 35°C Ambient, 70°C Rise,Enclosed Factor 0.72

2 Rating @ 40°C Ambient, 50°C Rise,Enclosed Factor 0.72

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Modstack Insallation Accessories

Type Description llustration

SRAIL Panel mounting frame section assembly kit (4 rails 2023mm).

3-pole busbar support,185mm interval between busbar centres.

BBS40 Busbar cross-section 40 x 10BBS50 Busbar cross-section 50 x 10BBS60 Busbar cross-section 60 x 10BBS80 Busbar cross-section 80 x 10BBS100 Busbar cross-section 100 x 10

3-pole busbar support, with backing plate,185mm interval between busbar centres.

BBS40BP Busbar cross-section 40 x 10BBS50BP Busbar cross-section 50 x 10BBS60BP Busbar cross-section 60 x 10BBS80BP Busbar cross-section 80 x 10BBS100BP Busbar cross-section 100 x 10

Busbar isolator, for lengthwise division distribution bar system,for insertion into BBS100.

SPLIT60 Busbar cross-section 60 x 10SPLIT80 Busbar cross-section 80 x 10SPLIT100 Busbar cross-section 100 x 10

BBSFX Fixing plate assembly kit for securing busbar support to the panelmounting frame section. (Order 1 for each busbar support).

BBSB90 Bracket for securing busbar supports when rear access is limited.(Order 2 for each busbar support).

BBCOVFX Fixing rail assembly kit for securing the busbar cover.

BBCOV Busbar cover, degree of protection IP2x, for clipping ontofixing rail (149mm).

WRCOV Cable connection area cover, degree of protection IP2x,for separating the cable connection area from the busbar area.

Guides for fitting switch units.

GD00 Size 00 - 50 unit height 50mmGD01 Size 00 - 1 unit height 75mmGD23 Size 2 - 3 unit height 150mm

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Type Description Illustration

Cable gland, for separating the component mounting areafrom the cable connection area.

CP00 Size 00 - 50 unit height 50mmCP01 Size 00 - 1 unit height 75mmCP23 Size 2 -3 unit height 150mm Size 00/1 Size 2/31

Mounting frame, for fitting the size 2/3 cable gland into the guide.

CPMF23 Size 2 - 3

Safety interlock can be retrofitted. Device can be energized onlywhen fully inserted and withdrawn only when de-energized.

SINT00 Safety interlock for 50mm switchSINT01 Safety interlock for 75mm switchSINT23 Safety interlock for 150mm switch

SOCONN 16-pole socket connector, for connection of customers’ control cables.

Transparent blanking covers for closing off future switch locations,with 3mm double ward key.

COV00 Size 00 - 50 unit height 50mmCOV01 Size 00 - 1 unit height 75mmCOV23 Size 2 -3 unit height 150mm

Guides required

Transparent blanking covers for closing off future switch locations, eachwith 6 ventilators to IP30, horizontal mounting, 3mm double ward key.

COV01V Size 00 - 1 unit height 75mmCOV23V Size 2 -3 unit height 150mm

Guides required

Steel vented covers.

VENT50UN 50 mm cover unpaintedVENT50BL 50mm cover painted black rippleVENT75UN 75mm cover unpaintedVENT75BL 75mm cover painted black ripple

5KB2890-001 Bracket for fitting steel vent to front rails,2 required per vent.

SWTOOL Puller tool,for removal of switch units from the guides.

1 Can only be used in conjunction with mounting frame

Modstack Insallation Accessories

Modstack Switchboards

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RELEC Switchboards Pty Ltd, Hotel application (NSW)

Mr Noel Tavener, ProjectCoordinator, Nilsen Electric (Vic.).Light and Power application (VIC)

Mechanical Services Pty Ltd,Hospital Application (TAS)

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Example of a servicedistribution boardcompletely protectedagainst contactwith live parts withfuse-combination units

Modstack Switchboards

Mechanical Services Pty Ltd,Hospital Application (TAS)

B.E. Switchcraft Pty Ltd.School/Sport stadium application (SA)

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Energy Management System

The EMS energy management panel can collect and record data from any LVfeeder that is equipped with an EMDE transducer module. The user can define bydialog with the unit, the variables to be cyclically scanned and recorded on aPCMCIA memory card or transmitted via a fieldbus protocol to a higher controllevel. In addition, the EMS system logs events such as faults and the transgressionof preset limits.

■ One EMS panel can monitor up to 60 EMDE modules .■ The EMS panel is the same size as a size 1 switch.■ Standard visualisation software packages available.

EMD Digital Electronic Modules

The EMDE modules are equipped witha microcontroller with which allrelevant variables in an electricalthree-phase AC circuit can bemeasured. The EMDE module usesDigital Signal Processing to measurethe true RMS of any waveform.Transmission to EMS panel is via a2-wire RS485 system.

■ Fuse status (4 LED local readout)■ Voltage■ Current (instantaneous)■ Current (rms)■ Frequency■ Power factor■ Phase failure■ Phase-sequence■ Switch status■ Over/Undervoltage■ Over/Undercurrent■ Min/Max values

EMS Panel

■ Communications gateway■ Actual value display■ Data accumulation■ Power (VA, W, VAr)■ Power factor■ Limiting value monitoring■ Trend analysis■ Status information■ Event list■ Event recognition and prioritisation■ Remote interrogation■ Load analysis


Basic unit

EMS IntelligentMetering Panel

Expansions and Accessories

SystemNetworking

Data CommunicationOption

Signal Input/OutputModule Option

RS-232 InterfaceOption

Profibus FMSOption

Profibus DPOption

Measurement and Control

Drive

ElectronicModules

Withdrawable metering unit for recordingall variables relevant to current andvoltage in the 3-phase system

Support of the"PROFIBUS DP" field bus

Support of the"PROFIBUS FMS" field bus

Serial data transmission

Event-controlled relay contacts forprocessing external input signals

Data communication module

System networking on PC-basedon-line visualising system

EMDE intelligent measuring sensorfor system data acquisition

Fuse combination blockswith SASIL-MOT motor drive

SystemAccessories

EMS statistics programfor Windows

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■ On screen data display■ Long term data store (PCMCIA)■ Communications gateway - fieldbus

Modstack Units

With integrated energy data acquisition,consisting of:

■ Basic unit with or without motor actuator■ EMDE built-in measuring sensor■ Built-in current transformers (3-phase)■ Built-in switch position display■ 3-phase voltage taps■ Data bus interface

EMS EnergyManagement Panel(24VDC supply)

EMDE Transducer

The EMDE transducer collects, buffers and transmits allrelevant three-phase parameters. The units can either beintegrated into the Modstack switchunit or mountedexternally on DIN rail to monitor MCCBs, ACBs, striptype fuse switches etc. The addressing is accomplishedvia the EMS panel during commissioning. One EMSpanel can monitor up to 60 EMDE transducers. Eachunit requires a 24VDC supply. The 3 auxiliary contacts(1 n/o, 2 n/c) indicate for fuse status, phase failure or ageneral alarm and are rated at 5A/250VAC.

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Integrated EMS Application

MODSTACK System

Functional Structure

Higher Control Levels

High integration inthe control cabinet

Low-voltage switchgearcabinet with EMS EnergyManagement System

Voltage

Current

On/Off

PCCard

EMSMeasuring

Panel

EMDEModule

Relays LEDs Control Level

JM Bus

DP Profibus

Application Software

JeanVis Client (Visualisation)JeanVis Server (Profibus data server)

EMS metering panel

JM Bus

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Modstack Motor Actuator

DIN 500V 690V Module Height

00 160A 100A 50mm

1 250A 200A 75mm

2 400A 315A 150mm

3 630A 500A 150mm

Latest Generation Switch-fuse Technology

The new generation of fuse combination units with motor drive, SASIL-MOT, can be

■ integrated in all common switchgear cabinet systems■ combined with all Modstack system products

and satisfies all modern requirements in terms of energy management andautomation in low voltage systems.

The front-mounted electric drive unit replaces the previous manual drive system forour switch-disconnector-fuses in the Modstack system format and contains all themotor-drive and electrical components required for control and monitoring.

General

■ Absolute shock-hazard and operating safety. In the activated state,the front cover with the drive unit cannot be opened.

■ Electronic and mechanical switch position display.■ Operating mode selectable by keyswitch (MAN, OFF, AUTO).■ Integrated fuse monitor/display LEDs■ Terminal block on the back panel for 24V remote control and bus system

(JM bus) for connection to the EMS System.■ Motor switching capacity.■ High load factors.■ Hazard-free replacement of LV HRC fuse-links, due to all pole safety

disconnection of incoming and outgoing circuits.■ Automatic switching when fuse blows.■ Can be operated manually if auxiliary supply fails. (With hex key).■ 24V DC, can be used on battery supply.

SASIL-MOT fuse combination units areavailable in the following DIN sizes:

Picture of motor actuator attached to size 00 switch

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Switch Specifications

Switch size 00 1

Electrical Current Type VAC VAC DC DC VAC VAC DC DC Parameters

Rated operating voltage Ue V 500 690 220 440 500 690 220 440

Rated operating current Ie A 160 100 160 100 250 200 250 250

Conventional free air thermal current with fuse Ith A 160 100 160 100 250 200 250 250

Conventional free air thermal current with copper link Ith A 250 250 250 250 400 400 400 400

Rated frequency – Hz 40-60 40-60 – – 40-60 40-60 – –

Rated insulation voltage Ui V AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000

Rated impulse withstand voltage Uimp kV 8 8 8 8 8 8 8 8

Number of poles – – 3 3 2(1) 2(1) 3 3 2(1) 2(1)

Power loss Ith (equipment with no fuse) Pv W 48 19 32 13 66 45 44 44

Utilisation category – – AC-23B AC-23B DC-22B DC-21B AC-23B AC-23B DC-22B DC-21B

cos.ø/L/R t ms 0.35 0.45 2.5 1 0.35 0.35 2.5 1

Rated making capacity – A 1600 1000 640 150 2000 1600 1000 375

Rated breaking capacity – A 1280 800 640 150 1500 1200 1000 375

Electrical durability (operating cycles) – – 300 300 300 300 200 200 50 50

With fuse - conditional rated short circuit current (effective) – kA 65(2) 65 25 25 65(2) 65(2) 25 25

- conditional rated short circuit current (peak) – kA 143 143 – – 143 143 – –

- cos.ø/L/R t ms 0.25 0.2 15 15 0.25 0.25 15 15

With solid link - rated short time withstand current (1 second) Icw kA 8 7 – – 12 9 – –

- rated short circuit making capacity Icm kA 14 13 – – 24 16 – –

Fuse Links Size in accordance with DIN43620 – – 00 00 00 00 1 1 1 1

Max. rated current (operating class gL/gG) IN A 160 100 160 100 250 200 250 200

Max. allowable power loss of HRC fuse link Pv W 12 10 12 7.5 23 23 23 23

Mechanical Mechanical durability (operating cycles) – – 1700 1700 1700 1700 1000 1000 1000 1000

ParametersModule height – mm 50 50 50 50 75 75 75 75

Busbar thickness – mm 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2

Interval between busbar centres – mm 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5

Weight – kg 4.75 4.75 4.75/4.35(3) 4.75/4.35(3) 8.1 8.1 8.1 8.1

Cable Bolt diameter – – M8 M8 M8 M8 M10 M10 M10 M10 Connections

Cable lug (DIN46235) – mm2 1*10-95(4) 1*25-150 OR 2*25-70

Busbar – mm 24*5 30*10

Tightening torque – Nm 10 10 10 10 15 15 15 15

Protection Operating state – – IP41 IP41 IP41 IP41 IP41 IP41 IP41 IP41

Front cover open – – IP20 IP20 IP20 IP20 IP20 IP20 IP20 IP20

Operating Ambient temperature Tu °C -25 to +35°C, 55°C (5) -25 to +35°C, 55°C (5)

ConditionsDuty cycle – – Continuous duty Continuous duty

Actuation – – Independent manual operation Independent manual operation

Fitting position – – Horizontal / Vertical Horizontal / Vertical

Altitude – m up to 2000 up to 2000

Pollution degree – – 3 3

1 Phase L2 not connected AC22 versions available2 At 125A (00), 224A (500V, S1), 160A (690V, S1) fused rating3 2 pole version has centre pole removed4 Max lug width = 24mm5 With reduced operational current

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Switch Specifications

Switch size 2 3

Electrical Current Type VAC VAC DC DC VAC VAC DC DC Parameters

Rated operating voltage Ue V 500 690 220 440 500 690 220 440

Rated operating current Ie A 400 315 400 400 630 500 630 630

Conventional free air thermal current with fuse Ith A 400 315 400 400 630 500 630 630

Conventional free air thermal current with copper link Ith A 630 630 630 630 1000 1000 1000 1000

Rated frequency – Hz 40-60 40-60 – – 40-60 40-60 – –

Rated insulation voltage Ui V AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000 AC 1000

Rated impulse withstand voltage Uimp kV 8 8 8 8 8 8 8 8

Number of poles – – 3 3 2(1) 2(1) 3 3 2(1) 2(1)

Power loss Ith (equipment with no fuse) Pv W 126 81 84 84 270 195 180 180

Utilisation category – – AC-23B AC-23B DC-22B DC-21B AC-23B AC-23B DC-22B DC-21B

cos.ø/L/R t ms 0.35 0.35 2.5 1 0.35 0.35 2.5 1

Rated making capacity – A 3200 2520 1600 600 5040 4000 2520 945

Rated breaking capacity – A 2400 1890 1600 600 3780 3000 2520 945

Electrical durability (operating cycles) – – 200 200 50 50 200 200 50 50

With fuse - conditional rated short circuit current (effective) – kA 80 80 25 25 80(6) 80 25 25

- conditional rated short circuit current (peak) – kA 176 176 – – 176 176 – –

- cos.ø/L/R t ms 0.2 0.2 15 15 0.2 0.2 15 15

With solid link - rated short time withstand current (1 second) Icw kA 16 13 – – 20 18 – –

- rated short circuit making capacity Icm kA 33 27 – – 41 37 – –

Fuse Links Size in accordance with DIN43620 – – 2 2 2 2 3 3 3 3

Max. rated current (operating class gL/gG) IN A 400 315 400 400 630 500 630 630

Max. allowable power loss of HRC fuse link Pv W 34 34 34 34 48 48 48 48

Mechanical Mechanical durability (operating cycles) – – 1000 1000 1000 1000 1000 1000 1000 1000 Parameters

Module height – mm 150 150 150 150 150 150 150 150

Busbar thickness – mm 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2 10 +/- 0.2

Interval between busbar centres – mm 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5 185 +/- 1.5

Weight – kg 15.5 15.5 15.5 15.5 16.5 16.5 16.5 16.5

Cable Bolt diameter – – M12 M12 M12 M12 M12 M12 M12 M12

ConnectionsCable lug (DIN46235) – mm2 1*35-300 OR 2*35-240 1*35-300 OR 2*35-240

Busbar – mm 40*10 40*10

Tightening torque – Nm 30 30 30 30 30 30 30 30

Protection Operating state – – IP41 IP41 IP41 IP41 IP41 IP41 IP41 IP41

Front cover open – – IP20 IP20 IP20 IP20 IP20 IP20 IP20 IP20

Operating Ambient temperature Tu °C -25 to +35°C, 55°C (5) -25 to +35°C, 55°C (5)

ConditionsDuty cycle – – Continuous duty Continuous duty

Actuation – – Independent manual operation Independent manual operation

Fitting position – – Horizontal / Vertical Horizontal / Vertical

Altitude – m up to 2000 up to 2000

Pollution degree – – 3 3

6 At 500A fused rating AC22 versions available

22

Dimensions

Size 00

Size 1

Size 3

23

Modstack Parts List

Part Number Description

SASDN003 size 00 DIN cfs 160A 50mm profile AC23 @ 500v


SASDN223 size 2 DIN cfs 400A 150mm profile AC23 @ 400v, AC22 @ 500v


SASDN233 size 3 DIN cfs 630A 150mm profile AC23 @ 400v, AC22 @ 500v


SASDN002 size 00 DIN cfs 160A 50mm profile 2 POLE DC21/22





SASDNBC3 size 3 DIN 630A 150mm profile, bus bar coupling unit AC23 @ 500v

SASBS003 size 00 BS cfs 100A 75mm profile AC23 @ 500v




SASBS002 size 00 BS cfs 100A 75mm profile 2 POLE DC21/22




GD00 installation guides (pair) for size 00 switch

GD01 installation guides (pair) for size 1 switch

GD23 installation guides (pair) for size 2/3 switch

CP00 cable partitions for size 00 switch (3 pieces)

CP01 cable partitions for size 1 switch (3 pieces)

CPMF23 mounting frame for putting cable partitions in size 2/3 switches

CP23 cable partitions for size 2/3 switch (3 pieces)

COV00 blanking covers for closing off unoccupied locations,size 00, transparent

COV01 blanking covers for closing off unoccupied locations,size 1, transparent

COV23 blanking covers for closing off unoccupied locations,size 2, 3, transparent

COV01V blanking covers for closing off unoccupied locations,+ horizontal vent slots, size 1, transparent

COV23V blanking covers for closing off unoccupied locations,+ horizontal vent slots, size 2-3, transparent

VENT50UN 50mm blanking covers for closing off unoccupied locations,size 00, steel, vented, unpainted

VENT50BL 50mm blanking covers for closing off unoccupied locations,size 00, steel, vented, painted black

Part Number Description

VENT75UN 75mm blanking covers for closing off unoccupied locations,size 1, steel, vented, unpainted

VENT75BL 75mm blanking covers for closing off unoccupied locations,size 1, steel, vented, painted black

5KB2890-001 steel bracket for fixing steel vent, 2 required per vent

SRAIL panel mounting frame section assembly kit (4 rails)

5KB2880-002 support pan to maintain dimensional integrity with SRAIL installation

BBS40 40 x 10mm bus bar support





BBS40BP 40 x 10mm bus bar support with backing plate





BBSFX fixing plate assembly kit for securing bus bar support to framework

BBSB90 busbar support bracket for front connect switchboards

BBCOV busbar cover (150mm)

WRCOV shroud for wiring area

BBCOVFX fixing rail assembly kit for securing the busbar covers (2 rails)

SPLIT60 busbar isolator assembly kit 60



SINT00 safety interlock 00

SINT01 safety interlock 1

SINT23 safety interlock 2/3

SWTOOL switch removal tool

INSKIT installation kit, M6, M5 screws and 2 bit key with instructionsfor mounting

SASCOV00 spare front cover with handle 00 50mm, standard RHS cable zone




SASCOV00L spare front cover with handle 00 50mm, standard LHS cable zone



SOCONN 16 pole socket connector

24

Installation Information

For an effective MODSTACKinstallation, attention should be paidto stack layout, switch de-rating andbusbar loading. The de-rated currentcapacities as detailed in Graph 1 areconservative when used with the stacklayout instructions. If the guidelines asdetailed in the stack layout section areused in conjunction with the switchde-rating method, the MODSTACKdesign will be optimised with respectto maximum current carrying capacity,permissible temperature limits andheat dissipation.

Stack Layout

■ For effective loading and heatdissipation install switches inup to 400mm blocks.

■ Install vent sections (50/75mm)between the 400mm blocks.

■ Install the largest switches in thelowest positions.

■ See page 10 for busbar supportkA ratings for various spacing.

Switch De-rating

The MODSTACK system physical switch sizes are expressed in modules.MODSTACK is based on a 25mm module. The modules are detailed in Table 2.Apply the following switch de-rating method to each “stack” (tier) of switches.

1. Enter the number of switches of each size (00,1,2,3) in column 3.

2. Calculate the modular height (column 4 = column 2 x column 3).

3. Enter the diversity factor for the total number of main circuits according toeither AS3439.1 part 4.7 (table 1 below) or the customers value (for example,based on the size of the main switch/total fused rating of stack) in column 5.

Table 1

No. of main circuits 2 & 3 4 & 5 6 - 9 10+

Diversity factor (a) 0.9 0.8 0.7 0.6

4. Calculate the effective modular height (column 6 = column 4 x column 5).

5. Total the effective modular heights per switch (sum column 6).

6. Apply the total effective modular height (from step 5) to graph 1 and read offthe effective current carrying capacity for each switch size at the intersection ofthe curves (enter into column 7).

Table 2

COLUMN 1 COLUMN 2 COLUMN 3 COLUMN 4 COLUMN 5 COLUMN 6 COLUMN 7

Swich Module Number of Modular Diversity Effective Modular Effective CurrentType per unit Switches Height Factor Height Carrying Capacity

HE N HE * N a HE * N * a (A)

00/160A 2

1/250A 3

2/400A 6

3/630A 6

TOTAL

If the average ambient temperature varies from 35°C, the current carrying valuesfrom the de-rating curve (graph 1) should be multiplied by the following factors:

Table 3

Ambient Temp °C 20 25 30 35 40 45 50 55

Factor 1.15 1.10 1.05 1 0.95 0.90 0.85 0.80

25

Installation Information

Test Cubicle

Width: 1000mmHeight: 2200mmDepth: 600mmProtection: IP30Material: SteelVertical Bars: 1600A CU

The de-rating information andcorresponding current values areintended to be a guide only.Specific installations may requireindividual solutions dependingon layout, venting, IP rating etc.

Graph 1 IP30600

550

500

450

400

350

300

250

200

150

100

SASIL 3

SASIL 2

SASIL 1

SASIL 003 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60

Effective Modular Height

A

Table 4

COLUMN 1 COLUMN 2 COLUMN 3 COLUMN 4

Switch Type Fuse Ratings Fitted Quantity per Rating Diversity Factor Connected Load

00/160A

1/250A

2/400A

3/630A

TOTAL

Table 5 - Typical current carrying capacity of copper busbar

Dimensions (mm) Cross Section (mm2) Rated Current (A)1 Rated Current (A)2

40 x 10 400 715 570

50 x 10 500 852 695

60 x 10 600 985 800

80 x 10 800 1240 1010

100 x 10 1000 1490 1220

(100+40) x 10 1400 2180 1780

(1Rating @ 35°C Ambient temperature, 70°C rise, enclosed factor 0.72)

(2Rating @ 40°C Ambient temperature, 50°C rise, enclosed factor 0.72)

Busbar Loading

Carry out the following steps to calculatethe size of the vertical copper busbarrequired to supply the stack.

1. Enter the “fused rating” of eachswitch size in column 1.

2. Enter the quantity of each fusedswitch rating in column 2.

3. Enter the diversity factor (as perTable 2, column 5) in column 3.

4. Calculate the connected load.Column 4 = column 1 x 2 x 3.

5. Total the connected loads, sumcolumn 4. Use Table 5 to chooseappropriate busbar size.

26

Modstack Mounting/Installation

STEP 1 – Metalwork

Ensure SRAIL's are cut to the required length.Rear rails should be cut to 150mm multiplesi.e. 600, 750, 900, 1050, 1200, etc. to ensureshrouds and busbar supports can be easilyfitted. Add an additional 100mm to these lengthsif the mounting jigs are to left in the job.

Dimensional jigs are available (5KB2880-002).The jigs are fitted within the four rails at the topand the bottom positions. The assembly is thenfitted into the board. Weld or screw in the railsas required. The mounting jigs can be removedor left in the job depending on the supportstructure provided.

Install the busbar support brackets (BBSFX = 2brackets per support) onto the back of the rearrails. If rear access is not possible, use the 90degree bracket (BBSB90) and fix to the side ofthe rear rails. The vertical spacing of the busbarsupports depends on the short circuit rating ofthe bars and their size (p10). Busbar supportspacings should always be made at intervals of300, 450, 600mm. These spacings ensure thatthe busbar covers will always fit.

** A 50mm steel vent (VENT50xx) should befitted in front of each busbar support. Screw thetwo brackets onto the front rails ready for thevented cover. The brackets can be fitted beforeor after powder coating.

STEP 2 – Copper

If the MODSTACK is fed from the top, fix thebusbar support with the insulated back plate inthe lowest position, this provides an insulatedstop for the bars.

Fix the front half of the standard busbarsupports onto the busbar support brackets.Hold the nut in the support and tighten thesocket head studs. If busbar covers are beingused, fix the busbar cover support rails(BBCOVFX) to the front half of the busbarsupports once they have been cut to thecorrect length (distance from top support tobottom support).

Fit the 10mm copper busbar. Fit the rearsections of the busbar supports to the frontsections to clamp the copper in place. A 6mmhex key is required to tighten the support bolts.

STEP 3 – Busbar Covers (option)

Clip the 150mm busbar cover section (BBCOV)onto the support rails.

When a busbar support is between two busbarcovers, break off the top edge of the lowercover and the bottom edge of the higher coverwith a pair of pliers. The edges are designed tosnap off.

With good access to the cable side of theModstack, the wiring zone separators (WRCOV)can be clipped in. The WRCOV section helps tosegregate the cable zone from the busbar zone(i.e. for 3b or 4 type segregation).

STEP 4 – Switch Guides

Install the switch mounting guides as per therequired layout. Fit the rear mounting pins andthen bring the front of the guide from the insideof the equipment zone toward the target railand push home. Screw them in if necessary(M6 TT screw into rear rail). If required, thesafety interlocks can be installed in themounting guides opposite from the cable zone(just clip in).

STEP 5 – Switches

Slide the switches into the guides, push homeonto the busbars. Fix each switch to the guideswith four M5*20 pan head screws (one in eachcorner). The switches are now ready for cablingand fuse installation.

Note: While working on an open switch, thecovers can be clipped off by thumbing theblack tab at the hinge and moving the coveraway from the switch.

The Modstack switch systemlends itself to numerous mountingarrangements. Switches can bemounted horizontally or vertically.In the horizontal position, the switchescan be oriented so that the cablezone is located at either the left orthe right side of the switch. In thevertical position, the switches can beoriented so that the cable zone islocated either above or below theswitch. The phase rotation shouldbe checked in each case. Installationmay be performed by either:

1. Installing the mounting rails (SRAIL)as per the layout on pages 8 and 9in custom metalwork. The width ofthe cable zone would depend onthe size of the cables used.

2. Using modular switchboardsystems such as ELSTEEL Techno.

27

Modstack Suggested Specification

1. Switch System

1.1 Switch Properties

1.1.1 Cassette style switch fuse units shall be ofmodular construction and shall have acommon width throughout the range.

1.1.2 They shall be AC22 or 23 in accordancewith the relevant standards.

1.1.3 Operating handles shall be of the rotarytype and must be padlockable with at leastthree 8mm shank padlocks. The handle mustretract to a low profile automatically to ensure itcannot catch the clothing of an operator.

1.1.4 Guide rails must be provided to ensurecorrect alignment of switch fuses in stackconfigurations, and enable simple installationof a spare unit when the switchboard is inservice.

1.1.5 Switch fuse units shall have self-aligningbusbar plugs to ensure optimum plug/coppercontact.

1.1.6 Switch fuse units shall have removablefront covers to allow easy access under serviceconditions.

1.2 Safety

1.2.1 Access to terminals and fuses shall be viaa single interlocked door.

1.2.2 Switch fuse units must have interlockeddoors to ensure access to fuses is only possiblewhen switch units are in the 'OFF' position.

1.2.3 Switch fuse units must have a doublebreak mechanism to ensure that both the lineand load terminals of the fuse link are isolatedfrom the supply and the load when the switch isin the 'OFF' position.

1.2.4 A safety mechanism (safety interlock)must ensure the switch fuse cannot be actuatedunless the switch fuse unit is fully engaged intothe line side busbars. This mechanism mustalso ensure that switches cannot be disengagedfrom the busbar when in the 'ON' position.

1.3 Busbar System

1.3.1 The busbar system must be type tested inaccordance with the relevant standard andshall be able to withstand the thermal anddynamic stresses of a 63 or 80kA short circuitfor 1 second duration minimum.

1.3.2 The busbar system shall use 10mmsquare edge copper on 185mm centres.

1.4 Installation

1.4.1 Temperature derating information mustbe made available, if required, to ensureoptimum performance.

1.4.2 Ensure adequate ventilation isincorporated in to the stack design, wherenecessary, to ensure performance of the switchfuses is optimised in stack configurations.Consideration must also be given to thelocation of the switch fuses in stacks, ensuringthat higher rated devices are installed lowest.

1.5 Options

1.5.1 Switch fuse units shall be available withintegral current transformers (up to three class1 or class 0.5), for metering/measurementpurposes that do not restrict cable connection inany way. The installation of currenttransformers in close proximity to the load sideterminals is unacceptable.

1.5.2 All auxiliary circuit connections (i.e.transducers, fuse monitoring, remote statusindication, parameter metering etc.) shall beconnected via a connector plug system (i.e. nohard wiring to individual switches) enabling easyservice, replacement or upgrading of switch fuses.

1.5.3 Load side terminal shrouds must beavailable to ensure that live terminals areproperly protected and must provide IP2Xsegregation in accordance with AS3439.1.

1.5.4 IP2X busbar covers and cable zone/busbar zone partitions must be available toprovide the required degree of switchboardsegregation (form 3a, 3b, and 4) in accordancewith AS3439.1.

1.5.5 Switch fuse units shall be available withultra compact electronic motor drives whichenable the switch units to be operated inautomatic/remote/manual modes.

2. Energy Management System

2.1 Parameter Monitor Transducers

2.1.1 The three phase parameter monitoringtransducers shall be available as integrateddevices inside the switch fuse units and must beable to monitor instantaneous voltage,instantaneous current, mean current, powerfactor, frequency, fuse status and switch status

2.1.2 The monitoring transducers shall analysea true RMS indication of the actual waveform.

2.1.3 The three phase parameter monitoringtransducers shall communicate to thecommunications gateway via a 2-wire system.

2.2 Communications Gateway

2.2.1 The communications gateway shall beable to communicate with up to 60 three phaseparameter monitoring transducers.

2.2.2 The communications gateway shall beable to be slaved into a block of 32 gatewaysthus potentially monitoring up to 1920transducer units.

2.2.3 The communications gateway shall be ofa modular construction including its own LCDdisplay and keypad. The gateway shall be ableto be installed in the same guide system as thesize 1 switch fuse units.

2.2.4 The communications gateway shall allowconnection to external peripheral devices (bussystems, serial links).

2.2.5 The communications gateway shalldisplay all measured parameters includingvoltage, current, phase, power and powerfactor for individual phases, switches andgroups of switches. The gateway shall monitorlimiting values, analyse trends, provide statusalarms and produce an event list.

2.2.6 The communications gateway shallsupport data accumulation with a useraccessible flash memory card (PCMCIA).

2.2.7 The communications gateway shallconnect to the power supply and transducernetwork via a plug connector (no direct hardwiring) thus allowing easy access for installationor maintenance.

TAN

5285

3/0

0

INDUSTRIAL PRODUCTS 25 Princes Road Regents Park NSW 2143 Telephone (02) 9645 0777 Fax (02) 9645 1608 www.alstom.com

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