ORIGINAL MANUAL 2CCC444010M0202 REV. 2.0, DATE OF … · Preconfigured Remote Power Panel Assembly...

— ORIGINAL MANUAL 2CCC4 4 4 010M0202 RE V. 2 .0, DATE OF RELE A SE: 0 6/2017

Preconfigured Remote Power PanelAssembly instructions

2 R E M OTE P OW E R PA N E L A SSEM B LY I NS TR U C TI O NS

— Table of contents

003 Unpacking and checking the cabinet

004 – 010 Installation of the devices into the cabinet

011 Installation of the SMISSLINE TP devices into the cabinet

012 Load connections

013 Additional accessories

013 Adaptation of the door for optional devices

014 Mounting

015 Electrical drawing

016 Marking of the cabinet

017 Maintenance

017 Approved SMISSLINE TP devices

018 – 019 Technical data

Pictures in this manual are given for the Remote Power Panel 500A according to the following type code: RPP-500A-P-INT-RTI-BCM-PQ-TS All other cabinets (250A, 750A, 1000A) can be derived from this manual. For operation, please refer to the “Operation instructions” (2CCC444013M0202).

3

—Unpacking and checking the cabinet

Visual control of the packaging • Check the packaging carefully for damage

Unpacking the cabinet • Do not use a knife to cut the package sealing

• After unpacking, the cabinet should look like as shown in Fig. 1, Fig. 2 and Fig. 3 below

• The size of the cabinet can vary depending on your order (width of 550 mm, 800 mm or 1050 mm)

• The empty cabinet has either - a glass door or - a metal door

All devices will be delivered separately and need to be mounted according to this assembly instruction.

—01 Cabinet small – 250/500 A—02 Cabinet medium – 750 A—03 Cabinet large – 1000 A

—01

—02

—03

• There are three different panel sizes: - Fig. 1

- RPP-250A-X3-X4-X5-X6-X7-X8 - RPP-500A-X3-X4-X5-X6-X7-X8

- Fig. 2 - RPP-750A-X3-X4-X5-X6-X7-X8

- Fig. 3 - RPP-1000A-X3-X4-X5-X6-X7-X8


—Installation of the devices into the cabinet

—04 Position of the molded case circuit breakers—05 Connection terminals

—05

—04

Installation of “TMAX XT4N 250A” or"D120/42.ff" connection terminals

There are two possibilities:

Possibility 1: MCCB internalRPP-X2-X3-INT-X5-X6-X7-X8• Unpack the main switch “TMAX XT4N 250A”• Fix the MCCB “TMAX XT4N 250A” with the

screws by assistance of the slot nuts

Possibility 2: MCCB externalRPP-X2-X3-EXT-X5-X6-X7-X8• Instead of MCCBs use connection terminals on

the same position in the cabinet

• Unpack the "D120/42.ff" connection terminals by ABB

• Fix a DIN rail by using screws and slot nuts

• Mount the terminals on the DIN rail. For further information please refer to the next chapters.

5

Connecting load connection by using the MCCB“TMAX XT4N 250A”RPP-X2-X3-INT-X5-X6-X7-X8Connect the load cables in correct order as shown in Fig. 6 (N L1 L2 L3)• Each cable cross section shall be according to

current load of XT4N 250 A: - L1, L2, L3, N: Each 2 x 50 mm²; Cu - PE: 35 mm²; Cu

• Cable shall be according to IEC 60228 Class 5 or Class 6, 105 °C

• All cables shall have the same length, otherwise the current distribution in the cables is not equal and will destroy the parts as a result of the high temperature - The length of every wire shall be between

1500 mm and 1600 mm - This shall ensure a balanced load of every wire

• Use cable lugs according to Fig. 9

• Cable lugs shall be suitable for switchgear connection - For the connection to "D120/42.ff" we recom-

mend to use 106R10 cable lugs by Klauke® - For the connection to the MCCB "TMAX XT4N

250A" we recommend to use 106R8 cable lugs by Klauke®

• To comply with the required minimum force of 3000 N according to IEC 61238 T1, we recom-mend the crimp-type-method “indent crimping” as illustrated in Fig. 7 and 8

• Use for each phase a heat shrinking tube to isolate the cable lug

• Use the mounted central earthing bar with a length of 265 mm, a minimum diameter of 300 mm² (30 x 10) - Apply mounting screws for PE connection as

illustrated in Fig. 9 - Fix the copper busbar by using screws and by

assistance of the slot nuts

• For further information please contact the manufacturer of the cable lugs - Connect both cable lugs with “XT4N 250A”

Note: The cable lugs shall be fully faced to each other and to the XT4 as shown in Fig. 10

- Fix the screws with a torque of 8 Nm (Fig. 9)

—06 Cable connec-tion of XT4N 250A—07 Indent crimping—08 Indent crimping, practical example—09 Details on connection of XT4

—07

—08

—06

—09


—10 Details on con-nection of XT4—11 SMISSLINE TPparallel end feed-in

—10

—11

RPP-X2-X3-INT-X5-X6-X7-X8Connect the cable in correct order as shown in Fig. 6 on p. 5 (N L1 L2 L3 PE)


1500 mm and 1600 mm - This shall be ensured for a balanced load of

every wire

• Cable lugs should be especially construed for 50 mm² and switchgears

• We recommend “6SG8” by Klauke®

• To reach the minimum torque according to IEC 61238 T1, we recommend the crimp-type-method “indent crimping” as illustrated in Fig. 7 and 8

• Use for each phase a heat shrinking tube to isolate the cable lug

• Connect both cable lugs with "XT4N 250A" Note: The cable lugs shall be entirely faced to each other and to the XT4 as shown in Fig. 10

• Fix the screws with a torque of 8 Nm (see Fig. 9 on p. 5)

• Finally mount the protection housing of the MCCB (see p. 9)

7

—12 Connection terminal"D120/42.ff" for onephase

—12

Connecting load by using the connectionterminal "D120/42.ff"RPP-X2-X3-EXT-X5-X6-X7-X8Connect the load connection in correct order (same as using MCCB) see Fig. 6 on p. 5 (N L1 L2 L3)

• For each SMISSLINE TP busbar 4 terminals are neccessary to connect L1, L2, L3 and N

• Each cable cross section shall be according to a maximum current load of 250A: - L1, L2, L3, N: Each 2 x 50 mm²; Cu - PE: 35 mm²; Cu



1500 mm and 1600 mm - This shall be ensured for a balanced load of

every wire!

• To connect the wires to the terminals follow the instructions on page 8

• This is required for each phase and neutral


—13 Use an M10 socket spanner

—13

RPP-X2-X3-EXT-X5-X6-X7-X8Connect the cables according to Fig. 13

• The load cable cross section shall be: - L1, L2, L3, N: 2 x 50 mm²; Cu - PE: 2 x 35 mm²; Cu


• All cables shall have the same length, otherwise the current in the cables are not equal and will destroy the parts as a result of the high temperature - The length of every wire shall be between - 1500 mm and 1600 mm - This shall be ensured for a balanced load of

every wire!

• This is required for each phase and neutral

9

—14 Fixing position of the cables—15 Cable connection for the MCB on the DIN rail, MCCB internal—16 Protection housingof MCCB "XT4N 250A"

Fixing of the cables in the cabinet• To protect the 50 mm² load cables (L1, L2, L3, N)

from damage, due to a short circuit or while transportation, the wires shall be fixed as shown in Fig. 14

• The wires shall be placed behind the SMISSLINE TP busbar and fixed at minimum 5 positions (marked in blue)

Connecting load connection of MCBfor accessoriesRPP-X2-X3-INT-X5-X6-X7-X8• To connect the 4-pole MCB on the DIN rail

use CU cables with a minimum diameter of 4 mm²

• On MCCB connection side use cable lugs

• On MCB connection side use a wire end ferrule

• The “small” cable lug with a minimum cross section of 4 mm² should be above the other “big” cable lugs with a cross section of 50mm² or 95 mm² as visualized in Fig. 15

Mounting of the protection housing of MCCB• Assemble the electrical shock protection

- Fix the protection housing - “High terminal cover” - using the tiny screw

- For further information please refer to the assembly manual provided with the “High terminal cover”

—14

—15

—16


—17

—17 MCCB external

Connecting load connection of MCBfor accessoriesRPP-X2-X3-EXT-X5-X6-X7-X8• To connect the 4-pole MCB on the DIN rail use

CU cables with a minimum diameter of 4 mm²

• To connect the cable with the terminals use cable lugs

Mounting of the protection housing of MCCB• Assemble the electrical shock protection

- Fix the protection housing - “High terminal cover” - using the tiny screw

- For further information please refer to the assembly manual provided with the “High terminal cover”

Mounting of other MCCB accessoriesRPP-X2-X3-INT-X5-X6-X7-X8

Mounting of the padlock• For further information please refer to the

assembly manual provided with the padlock

Mounting of the “EKIP LED Meter”• For further information please refer to

the assembly manual provided with the “EKIP LED Meter”

Mounting of the “EKIP COM Display”• For further information please refer to

the assembly manual provided with the “EKIP COM Display”

11

—Installation of the SMISSLINE TP devices into the cabinet

Mounting of the SMISSLINE TP starter pack including socket end piece• Unpack both starter packs with 72 modules

• Mount the socket end piece on both sides (two pieces, left and right)

• Check if the cap rail is mounted correctly - The distance between the cap rails (end-

to-end) shall be at least 1350 mm - If the distance is too short, it will not be

possible to fix the SMISSLINE TP starter pack correctly

- In this case, adjust the cap rail by choosing another position

• Take the SMISSLINE TP and snap it easily onto the cap rail

• Tighten each screw at both socket end pieces

Mounting of the additional socket for external N and PE busbars• Unpack the parts of the additional socket

• Mount all bottom parts

• Insert both delivered busbars

• Mount the upper part of the busbar socket and ensure that the busbar is closed correctly and thus touch proof

Mounting of the standard incoming terminal block “ZLS224LAB”• Unpack all four standard incoming terminal

blocks

• Each SMISSLINE TP starter pack will be equipped with two incoming blocks, respectively end feed

Mounting of the incoming terminal component for additional socket• Unpack all feeder components

• Feeder component PE construed for max. 35 mm²

• One component of the PE type shall be mounted to each side of the additional socket, directly to the back of one “ZLS224LAB”

• Feeder component N is construed for max. 95 mm²

• One component of the N type shall be mounted to each side of the additional socket directly to the back of every “ZLS224LAB”

Connecting of the standard incoming terminal block “ZLS224LAB”• Remove the protection housing

• Connect the cables according to Class 5 or Class 6 with a cross section of 50mm² and crimped with an end sleeve - L1, L2, L3 can be connected normally - N shall be installed to the “ZLS224LAB”

if 2-pole devices will be used - Fix all screws with a tightening torque of 4 Nm

• Reassemble the dismounted electrical shock protection

Connecting of the incoming terminal component for additional socket• The PE component shall be connected on each

side once with 35 mm² (end feed) - End sleeves are always helpful to connect the

wire

• If 1-pole devices are installed, the N component will be connected on each side twice (once at each end) with 50 mm² - End sleeves are always helpful to connect the

wire

12 R E M OTE P OW E R PA N E L O PER ATI O N I NS TR U C TI O NS

—Load connections

For detailed information please contact ABB or download the specific instruction manual for SMISSLINE TP on the ABB homepage:http://new.abb.com/low-voltage/products/system-pro-m/smissline-tp

Devices shall only be installed if the cabinet is at the installation site. Otherwise the busbar can be damaged due to the heavy weight of the MCBs and the vertical installation.

Installation of SMISSLINE TP devices • Ensure that each powerbus does not exceed

250 A rated current referring to the consump-tion of the servers - Load connection of SMISSLINE TP devices

according to Fig. 18

• To ensure that the devices are connected properly please check the position of the fixing clip of each MCB

• The fixing clip shall be in the upper position as in Fig. 19

Position of the plug-in connector• First: Lift contact gate (Fig. 20)

• Second: Bring the plug contacts to the required position (L1, L2 or L3) (Fig. 20)

—18 Assembly of a SMISSLINE TP device—19 Plug-in position of the fixing clip—20 Position of the plug-in connector

—18

—19

—20

13

—Additional accessories

—Adaptation of the door for optional devices

RPP-X2-X3-X4-RTI-X6-X7-X8• With the option "Remote Tripping Indication"

RPP-X2-X3-X4-OVR-X6-X7-X8• With the option "Overvoltage Protection"

RPP-X2-X3-X4-X5-BCM-X7-X8• For the option "Branch Circuit Monitoring" a

CMS-700 Control Unit will be delivered

RPP-X2-X3-X4-X5-MID-X7-X8• For the option "Billing Meters" a B23 312-100

(three phase meter up to 65A) or a B21 312-100 (single phase meter up to 65A) is delivered depending on your configuration

Possible devices are:

RPP-X2-X3-X4-X5-X6-PQ-X8• Power Quality Analyzer ANR96 (ABB)• Optional: UMG512 (Janitza)

RPP-X2-X3-X4-X5-X6-NET-X8• Network Analyzer M2M (ABB)• Optional: UMG96RME (Janitza)

RPP-X2-X3-X4-X5-X6-X7-TS• Panel PC with Touchscreen EL2 PPC12.1

(Phoenix Contact)

For detailed information on the CMS-700 please contact ABB or download the specific technical instructions manual on the ABB homepage:https://goo.gl/JpqEM5 Document Number: 2CCC481011M0201

Additional devices are available within the CB-Certificate. Please contact your local sales organization (LSO) to ask for these devices or other special solutions.


—Mounting

Dimensions Network Analyzer ANR 96, M2M and Touchscreen / Panel PC EL2 PPC12.1 1000• For further information please refer to the

user and operator manual provided by ABB or Phoenix with each device

• The cut-out size for the devices are displayed in Fig. 21 – 24

• All devices listed above/below should be installed in parallel in the front door

• The devices should be mounted at a height of 1800 mm (measured from the bottom to the top edge of the devices)

• Please consider that each panel base/socket adds 100 mm to the height of the cabinet

• If more than one device is delivered, they are to be installed in the front door one above the other

Mounting of Janitza devices• For further information please refer to the user

and operator manual provided by Janitza

—21 Cut-out size dimensions of Network Analyzer M2M—22 Cut-out size dimensions of Network Analyzer ANR 96—23 Cut-out size dimensions of Touchscreen/Panel PC EL2 PPC12.1 1000—24 Cut-out size dimensions of Touchscreen/Panel PC EL2 PPC12.1 1000

—21

—22

—23

—24

15

—Electrical drawing

The electrical drawing (Fig. 27) shows the connection between 4-pole MCCB or terminal blocks for copper conductors and one busbar.• RPP-X2-X3-INT-X5-X6-X7-X8

MCCB is inside the enclosure• RPP-X2-X3-EXT-X5-X6-X7-X8

Terminals are inside the enclosure

• Depending on the order and the devices delivered, the panel builder shall provide an electrical diagram which corresponds to the wiring of the electrical cabinet

—25 1-pole and 3-pole MCB needs additional sockets for connect-ing the neutral line—26 By using 2-pole and 4-pole devices there is no need for additional sockets—27 Electrical drawing between 4-pole MCCB and incoming terminal block ZLS224

—27

—25

—26


—Marking of the cabinet

Each cabinet shall be marked with a label according to the following standard: • The assembly manufacturer shall put his own

name or trademark on the label according to IEC 61439-1

• X1 = - RPP Remote Power Panel

• X2 = - 250 A 2 vertical modules - 500 A 2 vertical modules - 750 A 3 vertical modules - 1000 A 4 vertical modules

• X3 = - P 1-pole device - KP 1-pole device, tripping characteristic

tolerant - NP 2-pole device, protected neutral - KNP 2-pole device, protected neutral,

tripping characteristic tolerant - 3P 3-pole device - K3P 3-pole device, tripping characteristic

tolerant - 3NP 4-pole device, protected neutral - K3NP 4-pole device, protected neutral,

tripping characteristic tolerant

• X4 = - INT Internal MCCB - EXT External MCCB - SINT Single cabinet with internal MCCB - SEXT Single cabinet with external MCCB

• X5 = - … Not selected - RTI Remote tripping indicators - OVR Overvoltage protection - RTIOVR Combination of RTI & OVR

• X6 = - … Not selected - BCM Branch circuit monitoring

(ABB CMS-700)

• X7 = - … Not selected - NET Network analyzer (e.g. ABB M2M) - PQ Power quality analyzer

(e.g. ABB ANR96)

• X8 =• … Not selected• TS Panel PC with touchscreen

—28 Example of label

—28

17

No maintenance is necessary.

Only the listed devices may be used in combination with the RPP panel.

MCB 1-pole

Rated current Product ID Catalog description

16A 2CCS571001R0164 S401 M-C16

16A 2CCS571001R0467 S401 M-K16

32A 2CCS571001R0324 S401 M-C32

32A 2CCS571001R0537 S401 M-K32

MCB 2-pole (with protected neutral)


16A 2CCS571103R8164 S401 M-C16NP

16A 2CCS571103R8467 S401 M-K16NP

32A 2CCS571103R8324 S401 M-C32NP

32A 2CCS571103R8537 S401 M-K32NP

MCB 3-pole


16A 2CCS573001R0164 S403 M-C16

16A 2CCS573001R0467 S403 M-K16

32A 2CCS573001R0324 S403 M-C32

32A 2CCS573001R0537 S403 M-K32

MCB 4-pole (with protected neutral)


16A 2CCS573103R8164 S403 M-C16NP

16A 2CCS573103R8467 S403 M-K16NP

32A 2CCS573103R8324 S403 M-C32NP

32A 2CCS573103R8537 S403 M-K32NP

Other devices for SMISSLINE

Product ID Catalog description

Auxiliary switch and signal contacts

Signal contact, 1NO(right side mounting)

2CCS500900R0216 SK40010-R SA

Signal contact, 1NO(left side mounting)

2CCS500900R0141 SK40010-L SA

Surge Protection Device

Universal adapter SMISSLINE TP/DIN-Rail

2CCA180550R001 ZLS964

Surge arrester OVR typ 2 pluggable

2CTB803873R5200 OVR T2 4L 40-275 P TS QS

Circuit breaker for surge arrester OVR

2CCS573103R8324 S403M-C32NP

—Maintenance

—Approved SMISSLINE TP devices


—Technical data

RPP-250A-X3-X4-X5-X6-X7-X8

Rated voltage (Un) 240/415 V

Rated insulation voltage of a circuit (Ui) 440 V

Rated impulse withstand voltageof the assembly (Uimp)

Line/input 8 kVLoad/output 4 kV

Rated frequency (fn) 50/60 Hz

Rated current assembly (InA) max. 250 A

Rated current of each circuit/powerbus (Inc) max. 250 A

Number of outgoing circuits max. 128

Rated current of all outgoing circuits (Inc) max. 32 A

Rated peak withstand current (Ipk) 52.5 kA(with internal MCCB)

max. 17 kA(with external MCCB)

Rated conditional short-circuit currentassembly (Icc)

25 kA(with internal MCCB)


Rated diversity factor (RDF) 0.8

Type of current AC

Ambient air temperature -5° … +40°

Storage temperature -25° … +70°

Pollution degree 3

Material group III

Protection against mechanical impact IK07 (with steel door)

Protection against mechanical impact IK06 (with glass door)

Degree of protection (vertical planes) IP55

Degree of protection (top and bottom) IP20B

Earthing system TN-S

Assembly is intended for use by Skilled persons

Weight without SMISSLINE TP devices 150 kg

Climatic compatibility IEC 61439-2

Vibration IEC 61439-2

Dimensions

Depth 350 mm

Height (min. with one socket) 1950 mm

Height of socket 100 mm

Maximum height (max. three sockets) 2150 mm

Width 550 mm

RPP-500A-X3-X4-X5-X6-X7-X8








Number of outgoing circuits 128








Type of current AC



Pollution degree 3

Material group III










Dimensions

Depth 350 mm




Width 550 mm

Recommended packaging to transport the RPP• Open the door of the RPP and cover all sides of the

SMISSLINE busbars with sufficient packaging material. Protect especially the vertical SMISSLINE busbars so that they remain centered and do not slip to either side.

• Use a big pallet (2000 mm x 1000 mm) and coat it with cardboard.

• Place the RPP horizontally on the pallet with the door turned upwards.

• Cushion the glass door and all edges of the RPP to avoid shock damage.

• Secure the RPP on the pallet by using strapping band.

19

RPP-750A-X3-X4-X5-X6-X7-X8








Number of outgoing circuits max. 192








Type of current AC



Pollution degree 3

Material group III










Dimensions

Depth 350 mm




Width 800 mm

RPP-1000A-X3-X4-X5-X6-X7-X8








Number of outgoing circuits 256








Type of current AC



Pollution degree 3

Material group III










Dimensions

Depth 350 mm




Width 1050 mm

Additional informationWe reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB AG does not accept any responsibility whatso-ever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustra-tions contained therein. Any reproduc-tion, disclosure to third parties or utilization of its contents – in whole or in parts – is forbidden without prior written consent of ABB AG.

—ABB Switzerland Ltd.Low Voltage Products Fulachstrasse 1508201 Schaffhausen, SwitzerlandPhone: +41 58 586 41 11Fax: +41 58 586 42 22

new.abb.com/data-centers/rpp

For technical questions please refer to:[email protected]

2CC

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© Copyright 2017 ABB. All rights reserved. Specifications subject to change without notice.

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ORIGINAL MANUAL 2CCC444010M0202 REV. 2.0, DATE OF … · Preconfigured Remote Power Panel Assembly...

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