Certificaat Elektro Test Report Cubic

TEST REPORT 2120438.03-QUA/INC Page 2 of 17

Subject The main system of low-voltage switchgear and controlgear assemblies, type CUBIC Modulsystem, for maximum 6300 A with an incoming ACB loaded with 5320 A at a maximum 3-phase voltage of 1000 Vac 50 Hz, including the characteristic elements of the main construction of the modular system, such as the horizontal and vertical busbars, as well as the workmanship of the installed compartments. The whole system is mounted in a closed sheet steel modular enclosure. Note 1: This report does not refer to the testing of the equipment generally mounted in the enclosure, such as switches, fuses etc. Note 2: The values given in this enclosure for the current rating of the busbar systems are valid for

busbar systems loaded over the entire length with these currents and therefore they have to be considered as maxima. In a completely installed switchboard reduction of the current rating due to the temperature rise of the apparatus installed may be necessary. The reduction size shall be determined into practice by the manufacturer / assembler dependent on the number, the nature and the utilization of the apparatus installed. For four configurations with outgoing groups a temperature-rise test was carried out.

Place of examination The tests concerning temperature rise are carried out in the KEMA-laboratories in Arnhem and Ampere laboratories of Groupe Schneider Electric in Grenoble, France. The short-circuit strength tests are carried out in the KEMA-laboratories in Arnhem, Institute for International Product Safety, test laboratory, Bonn, Germany and Prof. Ir. Damstra laboratorium, Hengelo, The Netherlands. For the rest the examination has been carried out in the factory of the manufacturer in Woerden. A description of the design of the modular systems and the test results are given in the enclosure.

Summary - Verification of temperature-rise limits, clause 8.2.1 of IEC 60439-1 - Verification of the dielectric properties, clause 8.2.2 of IEC 60439-1 - Verification of the short-circuit withstand strength, clause 8.2.3 of IEC 60439-1 - Verification of the effectiveness of the protective circuit, clause 8.2.4 of IEC 60439-1 - Verification of clearances and creepage distances, clause 8.2.5 of IEC 60439-1 - Verification of mechanical operation, clause 8.2.6 of IEC 60439-1 - Verification of the degree of protection, clause 8.2.7 of IEC 60439-1 - Verification of the resistance of insulation materials to abnormal heat and fire (glow- wire test),

clause 8.2.9 of IEC 60439-1. Note: EMC tests, clause 8.2.8 of IEC 60439-1, are not applicable.

Remark:The CUBIC low-voltage switchgear and controlgear assemblies of the type Modulsystem are Type Tested Assemblies (TTA).These low-voltage switchgear and controlgear assemblies have the right to use the KEMA-KEUR certification mark if all installed components, such as switch-disconnectors, fuseholders, circuit-breakers etc., bear the KEMA-KEUR certification mark. The main horizontal and vertical busbar systems has the right to bear the KEMA-KEUR certification mark.


1 DESIGN OF THE SYSTEM

The switchgear and controlgear assemblies are intended for indoor installation and normal atmospheric conditions.

1.1 General design

The design of the modular system is based on a system constructed of similar parts, each with dimensions, which are a multiple of 192 mm.

The supporting structure is made of shaped steel and is assembled by means of moulded corners and brackets of various kinds. Three sides are fitted with cover plates, the fourth side the front is provided with doors or removable cover plates.

The material is primarily electro-galvanised or iron phosphated steel plate treated with powder coating.

The construction parts of the ASSEMBLY can be made completely or partly as fixed parts, removable parts (plug-in) or as withdrawable parts (draw-out). Height of the sections : max. 12 times 192 mm.

Width of the sections, incoming unit : max. 8 times 192 mm. Outgoing units : max. 4 times 192 mm. Depth of the sections : max. 4 times 192 mm. The sections can be used back to back. 1.2 Busbar-systems

All systems can be used as main and distribution busbars. The systems can be directly connected to each other with standard components and can be fitted vertically as well as horizontally. The horizontal busbars may be placed at choice at the top of the section, at the bottom or in-between sections. The distances between the supports can be adapted to the values of the short-circuit strength. System 2000/2000HD/2000D/S2000HB uses three / four or two parallel copper busbars per conductor in the vertical and horizontal mode. The busbars are as standard 10 mm thick and from 10 to 80 mm high in 10 mm steps. System S2000HI horizontal busbars can be 10x30 mm and 10x50 mm copper and can be fitted up to three parallel copper busbars per conductor. System 7000 uses two, three, four or six parallel copper busbars per conductor. The busbars are always 10 mm thick. The height of the busbars may be either 50 or 100 mm. The table 1 up to and including 6 gives a survey of the cross sections and the current ratings of the busbars, the distances between the supports and between the busbars of the phases and the values of the short-circuit strength given by the manufacturer. The current ratings given in the tables are valid for 50 Hz and a maximum ambient temperature of 35 C.


1.3 Rated values of the system General ratings Trade name : ELEKTRO INTERNATIONAAL Type : CUBIC Modulsystem Rated frequency : 50 Hz Rated insulation voltage (Ui) : maximum 1000 V depending on the used electrical components Rated operational voltage (Ue) : maximum 1000 V depending on the used electrical components Rated operational current (Ie) : busbar maximum 6300 A Configuration maximum 5320 A Rated short-circuit withstand strength : see table 1 up to and including 6 Degree of protection : IP4X standard IP51, when front of ACB is covered by

shielding cover and withdrawable units were secured by screws

The plinth was sealed to the floor.


Short-circuit tables

Table 1

Table 2


Table 3


Table 4


Table 5

Table 6


PE Busbars

PE busbar 2x10x10 mm; short-time withstand current 48 kA 0,5 s with 106 kA peak. PE busbar 2x10x10 mm, support distance 576 mm with one coupling bolt between the supports; short-time withstand current 72 kA 0,1 s with 158,4 kA peak. PE busbar 2 x 20 x 10 mm with a prospective short-circuit current of 30 kA at 240 V, when protected by the withdrawable units with moulded-case circuit-breaker manufacturer ABB, type Tmax T5S 400 (400 A), Tmax T3S 250 (250 A), Tmax T2S 160 (125 A). Protective circuit with moulded case circuit breaker GE D630A; prospective current 3-phases of 35 kA at 415 V.

Inserts

Insert for air circuit-breaker 2000 A; short-time withstand current, three phases, 63 kA 0,2 s with 132 kA peak Insert type OESA 250 with fuses 250 A gG: prospective current 3-phases of 80 kA at 400 V and neutral 48 kA at 242 V. Insert type Electrotech: prospective current 3-phases of 80 kA at 400 V and neutral 48 kA at 242 V. Insert type UA 2x2 with fuses 160 A gG: prospective current 3-phases of 80 kA at 400 V. Insert type plug-in 2x1,5: prospective current 3-phases of 100 kA at 400 V. Insert type plug-in 3x2: prospective current 3-phases of 100 kA at 400 V. Insert type MCS 2x1,5 with fuses 160 A gL: prospective current 3-phases of 100 kA at 690 V. Insert type plug-in 2x1,5 with fuses 160 A gL: prospective current 3-phases of 100 kA at 690 V and neutral 60 kA at 420 V. Insert type MCS 3x3 with fuses 630 A gL: prospective current 3-phases of 100 kA at 690 V and neutral 60 kA at 420 V. Insert type plug-in 3x2 with fuses 630 A gL: prospective current 3-phases of 100 kA at 690 V and neutral 60 kA at 420 V. Insert type UA 2x2 with fuses 630 A gL: prospective current 3-phases of 100 kA at 690 V. Insert type Fuse DIN 3 with fuses 630 A gL: prospective current 3-phases of 100 kA at 690 V. Insert type MPI 2x1x1 with 250A MCCB: prospective current 3-phases of 120 kA at 415V. Insert type MPI 3x1,5x1 with 400A MCCB: prospective current 3-phases of 120 kA at 415V. Insert type MPI 3x2x1 with 630A MCCB: prospective current 3-phases of 120 kA at 415V. Insert type Draw-out DW1x1 with 16A Motor starter: prospective current 3-phases of 120 kA at 415V.

Incoming units

Incoming air circuit breaker GE S2000A; prospective current 3-phases of 35 kA at 415 V. Vertical busbars 2 x 40 x 10 mm and connection to incoming unit with switch-disconnector manufacturer ABB SACE, type E1N 1250: short-circuit withstand rating of 3-phase 50 kA 1,0 s and neutral 30 kA 1,0 s (ACB unit without protective release (switch-dis-connector) was shorted at their terminals).


Outgoing units

Draw-out fuse-holder with fuses 125 A, 400 A and 630 A: prospective current 3-phases of 50 kA at 690 V and neutral 30 kA at 400 V. Draw-out fuse-holder with fuses 400 A: prospective current 3-phases of 80 kA at 690 V. Switch-disconnector-fuse (QSA 160) with fuses 80 A: prospective current 3-phases of 80 kA at 690 V. Switch-disconnector-fuse (QSA 400) with fuses 400 A: prospective current 3-phases of 80 kA at 690 V. Outgoing moulded case circuit breaker GE D400A; prospective current 3-phases of 35 kA at 415 V Outgoing moulded case circuit breaker GE D630A; prospective current 3-phases of 35 kA at 415 V Outgoing unit with moulded-case circuit-breaker manufacturer ABB, type Tmax T5S 400 (400 A) with a prospective short-circuit current of 3 phase 50 kA at 415 V and neutral 30 kA at 240 V. Outgoing unit with moulded-case circuit-breaker manufacturer ABB, type Tmax T3S 250 (250 A) with a prospective short-circuit current of 3 phase 50 kA at 415 V and neutral 30 kA at 240 V. Outgoing unit with moulded-case circuit-breaker manufacturer ABB, type Tmax T2S 160 (125 A) with a prospective short-circuit current of 3 phase 50 kA at 415 V and neutral 30 kA at 240 V.

Insert type Insert size in modules El. Comp. Short-circuit rating Icc in kA at 415 V

Cu-Flex. Con. Breaker plug

Multi Drawer 1 x 1 x 3 32 A MCB 120 Wire 6 mm

Multi Drawer 1.5 x 1 x 3 200 A MCCB 120 FB50XX

Multi Drawer 1.5 x 1 x 3 160 A MCCB 120 FB50XX

Multi Drawer 3 x 1 x 3 630 A MCCB 120 2 x FB100XX

Multi Drawer 1) 3 x 1 x 3 400 A MCCB 120 FB100XX

Multi Drawer 1) 3 x 1 x 3 250 A MCCB 120 FB50XX

Multi Drawer 3 x 1.5 x 3 630 A MCCB 120 2 x FB100XX

Multi Drawer 3 x 1.5 x 3 400 A MCCB 120 FB100XX

Multi Drawer 3 x 2 x 3 630 A MCCB 120 2 x FB100XX

Neutral tested at 72 kA at 240 V Note:

1) As front cover is used a door


Insert type Insert size in modules Plugs only

In / Out / Adapter Short-circuit rating

Peak / It Cu-Flex. Con. Breaker plug

Multi Drawer 1 x 1 x 3 40 A / 40 A / 40 A 15.4 kA / 1170 kAs Wire 6 mm

Multi Drawer 1.5 x 1 x 3 160 A / 100 A / 200 A 25.4 kA / 4270 kAs Wire 35 mm

Multi Drawer 1.5 x 1 x 3 400 A / 200 A / 200 A 30.4 kA / 6250 kAs Wire 70 mm

Multi Drawer 2) 3 x 1 x 3 400 A / 400 A / 400 A out2 37.9 kA / 11100 kAs FB100XX

Multi Drawer 3 x 1 x 3 630 A / 630 A / 630 A out 2 49.7 kA / 19700 kAs 2 x FB100XX

Note: 2) As front cover is used a door


2 TEST RESULTS The low-voltage switch and distribution boards were tested in the arrangement as in normal use.

2.1 Temperature-rise test of the low-voltage switchgear and control gear assembly (IEC / EN 60439-1 clause 8.2.1)

HORIZONTAL BUSBARS The horizontal busbar, cross section 3 x 50 x 10 mm, were loaded with a three-phase 50 Hz current equal to their rated current of 2000 A until steady temperature was reached. The temperature rise of the supporting insulating material was measured by means of thermo-coules. The maximum temperature rise was 99 K. This value complies with the standard which is 105 K in this respect for the copper busbar. Further the horizontal busbar 2 x 100 x 10 mm for 2500 A was subjected to a temperature rise tests. The tested values are laid down in KEMA Report 2107832.01-QUA/INC. The other horizontal busbars ratings given by the manufacturer comply in comparison with the rating tables for copper rails according to DIN 43671. The values given in these tables are based on free placed copper busbars with their greatest width vertical, the load being ac 50 Hz and the temperature rise 30 K at ambient temperature of 35 C. In the present system the horizontal busbars are placed as mentioned in the table 1 up to and including 6. In this disposition the temperature rise of the busbars will be more than the above mentioned 30 K, but the maximum allowable temperature rise of 105 K for copper busbar will not be reached under the load of the busbars.

VERTICAL BUSBAR The vertical busbar 2//2 x 50 x 10 mm for 2500 A, vertical busbar 2 x 60 x 10 mm for 2000 A, vertical busbar 2 x 50 x 10 mm for 1600 A, vertical busbar 2 x 40 x 10 mm for 1350 A and vertical busbar 2 x 30 x 10 mm for 1100 A were subjected to a temperature rise tests. The tested values are laid down in KEMA Report 2107832.02-QUA/INC. The other values of the current rating of the vertical busbars given by the manufacturer comply in comparison with the rating tables for copper rails according to DIN 43671. The values given in these tables are based on free placed copper busbars with their greatest width vertical, the load being ac 50 Hz and the temperature rise 30 K at ambient temperature of 35 C. In the present system the vertical busbars are placed as mentioned in the table 1 up to and including 6. The centre distances are as given in the table 1 up to and including 6. In this disposition the temperature rise of the busbars will be more than the above mentioned 30 K, but the maximum allowable temperature rise of 105 K for copper busbar will not be reached under the load of the busbars.


CONFIGURATION For three configurations the temperature-rise tests reference is made to the KEMA report 2001975.01-KRQ\COM. Panel has a degree of protection of IP51

Type of Unit rated current (A) Load (A) Incoming Unit

Air circuit breaker Merlin Gerin type NW63H1 6300 5320 Outgoing units

6 times moulded-case circuit-breaker Merlin Gerin type NS630N

630 420

2 times air circuit-breaker Merlin-Gerin type NW20H1

1400 1400

Panel has a degree of protection of IP20

Type of Unit rated current (A) Load (A)

Incoming Unit

Air circuit breaker Merlin Gerin type NW63H1 6300 4000

Outgoing units

5 times

moulded-case circuit-breaker type NS630

630 280

2 times

air circuit-breaker type NW20H1

1400 1300

Panel has a degree of protection of IP20


Incoming Unit

Air circuit breaker Merlin Gerin type NW63H1 6300 4550

Outgoing units

6 times

moulded-case circuit-breaker type NS630

630 300

2 times

air circuit-breaker type NW20H1

1400 1375


For one configuration the temperature-rise test reference is made to the KEMA report 2095425.02-QUA/INC.


Incoming Unit

Switch-disconnector Merlin Gerin type E1N 1250 1000 1000

Outgoing withdrawable units Rated current

A

Test current A

Diversity Factor

MCCB type Tmax T5S 400 400 320 0,8



MCCB type Tmax T2S 160 63 50,4 0,8

MCCB type Tmax T2S 160 32 25,6 0,8

The remaining current 304 A was loaded on left side of the horizontal busbars.

2.2 Dielectric properties (IEC / EN 60439-1 clause 8.2.2)

The low-voltage switch and distribution boards were subjected during 1 minute to a high-voltage test with an ac voltage of 2500 V applied in the prescribed connections.

The busbar systems of the low-voltage switch and distribution boards were subjected during 1 minute to a high-voltage test with an ac voltage of 3500 V applied in the prescribed connections. These tests passed.

The insulation resistance was measured in the same connections on the supports and the terminal blocks after a 48 h humidity test.

The insulation resistance reached a value greater that the required minimum value of 2 megohm.

2.3 Short-circuit strength

The results of the tests concerning the short-circuit strength of the busbar systems and the standard connections between the vertical busbars and the outgoing groups are given in KEMA Certificate No. 934-81, No. 161-94 and 99.7163, KEMA reports Nos. 907-81, 327-82 and 2075018.01, 2095425.02-QUA/INC, 2107832.02-QUA/INC and 2107557.01-QUA/INC.

From the test results of the short-circuit tests can be concluded that the short-circuit strength of the systems mentioned in Table 1 up to and including Table 6 complies with the specifications.


2.4 Effectiveness of the protective circuit

The examination of the electrical continuity of the construction of the assembly has given the result that the resistance between the various exposed parts of the assembly and the PE-circuit is sufficiently low (< 0,1 ohm).

2.5 Clearances and creepage distances

The creepage distances are investigated with respect to: - tracking index of the used insulation material - pollution degree 3 - rated insulation voltage 1000 V The clearances and creepages are in accordance with the requirements.

2.6 Mechanical operation

The test has been carried out on doors, draw-out units and plug-in units. From the test results it is concluded that the mechanical operation of doors, apparatus, interlocks, etc. not in any way has been impaired, and that the effort required for the operation is the same as before the test.

2.7 Degree of protection

The tests were made according to EN/IEC 60529. The degree of protection was determined on representative enclosures. The degree of protection for the assembly is IP4X or IP51.

2.7.1 Degree of protection IP4X

TEST FOR FIRST NUMERAL 4

The test was made with a straight rigid wire of 1 mm diameter, applied with a force of 1 N. It was not possible to enter the panel.

2.7.2 Degree of protection IP51

A special panel with a shielding cover covering the front of the ACB and withdrawable units are secured by screws. The socle of bottom was done with wooden plate in place. Details of the tests are laid down in 2095425.02-QUA/INC.


2.8 Construction

The examination of the construction of the systems included the following points: - earthing of accessible metal parts - provisions for the interconnection of the earth conductors of the outgoing groups - workmanship of the electrical connections - marking.

The examined switchgear and controlgear assemblies met the construction requirements.

N.B. The construction of switchgear and controlgear assemblies has to comply with the following points.

a Doors provided with electrical parts having a working voltage between the poles or between

the poles and earth of more than 50 V, have to be connected suitably to the earthed supporting structure by means of an earth conductor.

b Opening of compartment doors may be possible only by means of tools or a special key,

unless the switch and distribution boards are placed in such a way that they are only approachable for expert persons, or when the compartments have to be opened by non-expert persons for the operation of switches and D-type fuses and therefore are fixed up in such a way that live parts cannot be touched.

c The manufacturer's / assemblers name and the type designation are placed on the switch-

and distribution boards. In the incoming unit a fabrication number, corresponding with the number of the drawings will be places, making it possible to get relevant information about that particular switch and distribution board.

d In consultation with the client the marking of the busbars and the terminals shall be fixed (i.e. colour coding or marking L1, L2, L3, N). The earth busbar shall always be marked with the

earth symbol or with the colour combination green/yellow.

2.9 Resistance of insulating materials to abnormal heat and fire (glow-wire test)

All parts of insulating material necessary to retain current carrying parts were subjected to a glow-wire test according to IEC 60695-2-1, at 960 C.

Other insulating materials were subjected to a glow-wire test at 650 C.

These tests comply with the requirements.


Contents2.1 Temperature-rise test of the low-voltage switchgear and control gear assembly(IEC / EN 60439-1 clause 8.2.1)2.2 Dielectric properties2.9 Resistance of insulating materials to abnormal heat and fire (glow-wire test)

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