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INDUSTRIAL SOLUTION SYSTEMS

AFCON ENERGON
MCC Draw-out Type
Low Voltage Switchgear System

Geared to the future thanks to innovation and quality


AFCON switchgear systems – safe and versatile

type, arc fault and earthquake tested in accordance with IEC


internal separation up to form 4b
with interlocked operating / diconnected / test position
innovative due to ARC SAFE, DTS and CONTINUOUS LATCH

AFCON low voltage switchgears:


ENERGON is setting new innovative standards
AFCON switchgear systems offer to a new safety level through Low voltage – geared to the
you professional, top quality solu- a withdrawable system that future
tions based on the highest safety had only till then been reached Numerous innovations and con-
standards. In our more than 60 by medium voltage switchgears. stant further developments are
year company history, AFCON has our guarantee for a reliable and
been building and delivering draw- With the patented contact mecha- geared to the future switchgear.
out type switchgears since 1978. nism DTS, we very quickly set the We provide our customers with
standard on the market of MCC- experienced engineering teams.
Innovative developments systems. A globally unique That is how we guarantee an opti-
We are making the distribution of ergonomic latch, the one-handed mal design and the shortest possi-
power in low voltage networks safety latch CONTINUOUS LATCH, ble delivery time.
even safer with our type-tested closes the door "arc safe" without
switchgear assembly (TTA) the use of tools. The certified
certified switchgear system arc fault distribution busbar
ENERGON. ENERGON switchgears ARC SAFE has been built into
have taken low voltage systems the systems as a standard.

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Technical data
Standards and specifications type tested low voltage switchgear IEC 60439-1, DIN EN 60439-1 complain IEC 60439-1,
assembly (TTA) VDE 0660 part 500 61439-1
protection against electric shock DIN VDE 50274, VDE 0660, part 514
testing of the response during internal IEC 61641
faults (arc fault) DIN VDE 0660 part 500, supplement 2
Ue 725V AC, Icw = 65 KA, t=300 ms
testing during ground motion
(earthquake testing) IEC 68 part 2 and 3, DIN EN 60068
Creepage distance and
clearances rated impulse withstand voltage (Uimp) 8 kV (12 kV)
overvoltage category III
degree of pollution 3
Rated insulation voltage (Ui) busbar system 1,000 V
switchgear up to 1,000 V
Rated operational voltage (Ue) up to 690 V
Busbars horizontal main busbars rated current up to 3200 A
installation position: top or rear rated peak withstand current (Ipk) up to 220 kA
blank or coated (insulated)
meterial copper Cu-E-F30 rated short-time withstand current (lcw), 1s up to 100 kA
vertical busbar for the
multifunctional outgoing cubicle MD rated current 1,000 A
single pole, enclosed, rated peak withstand current (Ipk) 176 kA
copper Cu-E-F30 rated short-time withstand current (lcw), 1s 80 kA
Rated currents
circuit breaker (ACB) incoming supply, coupler or outgoing feeder up to In = 3200 A
moulded case circuit breaker (MCCB) incoming supply, coupler or outgoing feeder up to In = 1600 A
motor-starter starter combination type 1 or type 2 IEC 947-4-1 up to In = 630 A
Internal separation form 2b to form 4b IEC 60439-1 / DIN EN 60439-1, 7.7
DIN VDE 0660, part 500, 7.7

Surface treatment pieces of frame, roof and rear panel galvalumed


doors, side panels powder coating
colour of the powder coated parts standard RAL 7035, light grey
(coating thickness 80 μm) (optional all other RAL tones)
Degree of protection IEC 60529, DIN 40050 standard IP41 (optional higher IP)
Dimensions height 2,200 mm
width 500/600/800/1,000 mm
depth single front 500/700 mm
double front 1,000/1,400 mm

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SWITCH
GEARS

Demanding customers have put their faith in


AFCON switchgear systems, and thus also in
SERVICES AUTOMATION
the quality and safety of our solutions.

SOLUTIONS

The ENERGON-Highlights
ENERGON has taken low voltage switchgears to a new level of safety and technology

ARC SAFE – Safety against arc faults


With this vertical distribution busbar, the replacement and
addition of functional units can take place while the switch-
gear is live. The “Automatic Shutter” is mechanically inter-
locked, is a positively driven contact and can additionally
also be padlocked. The bus duct provides the highest level
of protection through insulated encapsulation and separation
between the phases. Accredited testing laboratories have
certified the bus duct as “arc safe”.

DTS – Double Transfer System


The term Double Transfer System stands for our patented
contact mechanism . The system stands out thanks to the
safe and mechanical separation of the main circuits and con-
trol circuits during the point of disconnection and the testing
point. It also has coloured indicators for the disconnected
position (green), test position (blue) and operating position
(red).

CONTINUOUS LATCH – Design meets functionality


The new door locking mechanism is setting the standard in
safety and ease of use worldwide. This progressive functional
design offers maximum security by means of the easy and
simple one-hand use.

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ENERGON – Types of cubicles
Versatile functions PD-cubicle Cubicle features:
Benefit from the range of low volt- Withdrawable or fixed mounted air circuit breaker (ACB)
age cubicles ENERGON has to offer circuit-breakers (bus-compatible) design/construction according
you. The cubicles have multiple to requests
functions: Used for: measuring technique according
in example for: incoming supply to customer's specifications
- the incoming supply outgoing feeders 3-pole or 4-pole
- the power distribution with coupler up to 6,300 A
air circuit breakers (ACB’s), moulded up to 690 V
case circuit breakers (MCCB’s) separation up to form 4b (IEC)
or fuse blocks cable connection possible from
- the mounting of converters, the top or from the bottom
soft starters or a partially fixed- compact coupler busriser
mounted design for small con- PD-cubicle possible (width of 200 mm)
sumer’s as well as a program-
mable logic controller (PLC)
motor starters either as with-
drawable or semi-withdrawable
units
2,200

cross-wiring compartment
control-circuit voltage compartment
main busbar compartment
circuit-breaker compartment
cable terminal compartment

500
500 - 1,000 700

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main distribution board with high rated
currents and short-circuit currents
electrical equipment make according to
customer’s requests
bus-compatible for the direct integration of
control systems

Construction options for PD-cubicle


rated current
circuit breaker (A)1) cubicle depth cubicle width (mm) 3) main busbar
2)
(mm)
3-pole circuit breaker 4-pole circuit breaker rated current
500 500 600 800 1,000 500 600 800 1,000 (A)
630 1,000
800 1,000
1,000 1,250
1,250 1,250
1,600 1,600
2,000 2,000
2,500 2,500
3,200 3,200

1) derating depends on make, frame size, installation status, degree of protection, ambient temperature
2) if cable department is downwards (if upwards min. 700 mm), without cabinet offset
3) depends on make, frame size and required space in control compartment

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utmost personal safety
operation, test and disconnected
position behind closed doors

ENERGON – Types of cubicles

MD-cubicle Construction withdrawable unit is mechanically


Multifunctional outgoing cubicle the cubicle has 31 units of codable (protection against mix-up
height (U), 27 U can be used of units)
Used for: for modules separation up to form 4b (IEC)
motor starters main busbar: 2 U
power feeder N-Type withdrawable units in dif-
ferent compartments with their Vertical distribution busbar
Design own doors: 2 –10 U ARC SAFE
draw-out type 4 Q-Type withdrawable units in automatic protection (shutter)
semi-withdrawble type the same compartment: 4 U against contact with distribution bus-
Any combination in one cubicle is PE, N, PEN busbar: 2 U bar when withdrawable unit is with-
possible. cabling compartment 400 mm wide drawn, shutter can be padlocked
(optional 600 mm) rated current up to 1,000 A
cable entries from bottom or L1, L2, L3, optionally also with
optionalty top (depth 700 mm) N-busbar (4-pole switching)

MD-Cubicle MD-Cubicle MD-cubicle double front MD-cubicle double front


single front single front (busbars on top) (busbars on rear)

cross-wiring compartment
main busbar compartment
withdrawable unit compartment
2,200
2,200

2,200

2,200

cable terminal compartment

500 500 700


500
1,000 500 1,000 700 1,000 1,000 1,000 1,400

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powder coating in
accordance with RAL
colour palette (80 μ m) busbars L1, L2, L3 on the top
up to 3 x 100 x 10 mm per
phase bare or coated

compartment for busbar supports with


Q-Type withdrawable an arc fault barrier
units
compartment for
N-Type withdrawable
units
27 modules
available

double-walled compartment

inner corpus made of


galvalumed metal and
stainless steel components

minimum metal
sheet thickness busbar N / PE (PEN)
of 2 mm

sturdy construction of bottom module


with 3 mm material thickness

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ENERGON – Types of cubicles
FD-cubicle
The mounted cubicle is
a multifunctional cubicle that
provides the reception of the
following:
control voltage distribution
outgoing feeders in
mounting
soft starter
frequency converter
automation equipment
2,200

cross-wiring compartment
main busbar compartment
switching devices compartment
cable terminal compartment

500
500 - 1,000 700

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ENERGON – Types of withdrawable units


N-Type withdrawable unit disconnection contact for incom- Disconnected and test position
ing and outgoing circuits on both Closed door operating / discon-
Patented contact mechanism sides nected / and test position. The
DTS: compartments can be padlocked required isolating distance is pro-
safe connection, user-friendly, bus- to prevent insertion of withdraw- vided, besides by the main
compatible able units switch, by the mobile, patented
main switch can only be operat- both withdrawable units and sub- contact mechanism (DTS)
ed when the door is closed sections can be exchanged or control connector adapts to
cubicle door only opens in the converted while the board is live changing needs: up to 40 poles,
disconnected position (can be mechanical encoding ensures with additional bus contacting
overridden) protection against mix-up of units
unit can only be withdrawn in coloured display that can be
disconnected position seen through a window on the
unit can only be withdrawn if the units door indicates the switch-
main switch is disconnected ing status

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N-Type

Switching status of the withdrawable units

Contacting Contacting
Disconnected position
module display
main plug control plug The patented contact mecha-
nism ensures that the withdraw-
ble unit can only be withdrawn
Disconnected
position in the disconnected position –
this maximises the user-friend-
liness.

Test position
Contacting Contacting module display
main plug control plug You can safely configure and
test the control circuit while the
circuit breaker is disconnected in
Test position
the test position.

Operating position
Contacting Contacting module display
main plug control plug Main circuit and control circuit are
contacted while the withdrawable
unit is mechanically secured
Operating
position against extraction.

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Q-Type

Q-Type withdrawable unit

Small, space saving withdrawable unit can only be withdrawn in the main switch with motor switch-
unit up to 11 KW or 32 A disconnected position (without ing capacity
has the same operating and lock- overriding insertion forces) operating mechanism can be
ing logic as the N-Type compartments can be padlocked padlocked in disconnected mode
mechanical operating / discon- to prevent insertion of withdraw- (maximum of three padlocks)
nected / test position able units common door for 4 Q-Type
disconnection contact for incom- mechanical encoding ensures pro- withdrawable units
ing and outgoing circuits tection against mix-up of units coloured display that can be
control connector adapts to seen through a window on the
changing needs: up to 40 poles, units front panel indicates the
with additional bus contacting switching status

Control elements on the switchgear The following control elements are installed on the switchgear door
door of Q-type small plug-in
modules, with sliding bolt

Item Denomination Function

1 Main switch Works as a breaker to cut off main


circuit.

2 Display Mode of module is displayed using


three different symbols (see
chapter 4.2.1).

3 Open Use the square key to switch from


Idle / Operation operating to idle mode or vice
versa. Insert square key here and
turn.

4 Open Use the square key to switch from


Idle / Test test to idle mode or vice versa.
Place square key here and turn.

5 Sliding bolt Service opening cover, locking the


cover
4

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Structure and function

Padlocks There are various possibilities to place padlocks on the module racks.

Padlock on the sliding bolt


The door of the module rack can be padlocked when the sliding
bolt is pushed completely to the right. This will prevent any access
to the service openings, and the locking mechanism is covered by
the bolt. The door cannot be opened.
Padlock on the sliding bolt

Padlock on the module rack


There is a possibility to place a padlock at the front of module
racks. With a padlock in place, it is not possible to insert a plug-in
module anymore.

Padlock on the module rack

Padlock on the shutter


There is a possibility to place padl ocks on the shutters at the back
of the module rack. Shutters cannot be opened anymore.

Padlock on the shutter

Control elements on switchgear N-type standard modules have the following control elements on
door, with sliding bolt the switchgear door.

Control elements on switchgear door

Item Denomination Function

1 Open Use the square key to switch from operating to idle mode or vice versa.
Idle / Operation Insert square key here and turn (Max rotatory force when operating plug-in
modules: 10 Nm).

2 Display Mode of module is displayed using three different symbols

3 Open Use the square key to switch from test to idle mode or vice versa. Place square
Idle / Test key here and turn (Max rotatory force when operating plug-in modules: 10 Nm).

4 Sliding bolt Service opening cover, locking the cover.

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Structure and function
Mechanical encoding
Modules with identical features and properties are interchangeable.
To make sure that modules with different features are not
interchanged, Q-type small modules and N-type standard module
can be optionally equipped with a mechanical encoding system.
Such encoding makes inadmissible mixing and matching of
modules and boards impossible. If the mechanical encoding of the
module (bushings) does not correspond with that of the rack (pins),
it is not possible to insert the plug-in.

Mechanical encoding of Q-type


small plug-in modules

Changing mechanical encoding

CAUTION!
Hazard of material damage due to faulty
encoding.
Inadmissible mixing and matching of modules
within the switchgear can damage the switchgear
and/or other downstream equipment.
Therefore:
– Make sure there are no critical overlaps with
existing encodings.

The encoding pins sit on little rubber cushions so they can be


pushed to the back.
1. Loosen encoding pins (1) on the rack to the point where you
can push them back.
2. Hold the casing with the pins (1) in one hand. Use the other
hand to push the pins back until they snap and the desired
encoding pattern is generated. Make sure the little rubber
1 2 cushions at the back of the pins are in the right position.
You can encode each pin with a number from 0 to 9.
Encoding bushings and pins
3. Screw down the encoding pins (1).
4. Take the casing with the bushings (2) and use a 6.5 mm ÀDW
screwdriver to push back the encoding part at the back and
set it so its corresponds with the pins (1).
Make sure the bushings snap into position when adjusting.

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Typical configurations
Motor Protection - DOL Type 2-Normal starting
Example - Manufactured by ABB 50KA/400V/415VAC

Power Rated Circuit breaker for Contactor Thermal release Cable Size of
Current motor protection 400V/415V cross withdra
section wable
up to units type
KW A mm2
3

up to 7.5 15A up to MS325-16 up to A26 up to TA25DU19 16 Q4


up to 11 22A up to MS325-25 up to A30 up to TA42DU25 16 N2
I>

up to 11 22A T2S 160 MA52 up to A30 TA42DU25 2x95 N3


up to 37 68A T2S 160 MA80 up to A75 TA75DU80 2x95 N3
3
up to 55 98A up to T4S 250 MA160 up to A110 TA110DU110 2x95 N4
up to 75 135A T4S 250 TMA 200 up to A145 TA200DU175 2x240 N6
up to 90 158A T4S 250 TMA 200 up to A185 TA200DU200 2x240 N6
M
up to 160 282A T5S400PR221-I In=400 up to A300 E320DU320 2x240 N8
3
up to 250 430A T6S630PR221-I In=630 up to AF460 E500DU500 4x240 N10
Cable feeders, fuseless

Cable feeders Example - Manufactured by ABB 50KA/400V/415VAC


Rated Circuit Cable cross Size of withdra
Current breaker/starter section up to wable units type
mm2
25A up to MS325-25 16 Q4
3

25A up to MS325-25 16 N2
up 160A up to T2S160 2x95 N3
I>
up 250A up to T3S250 2x95 N3
3
up 320A up to T4S320 2x240 N3
up 400A up to T5S400 2x240 N4
up 630A up to T5S630 4x240 N6
up 800A up to T6S800 4x240 N8

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Transport, packing
Transport
Concerning transport:
For weights of packing units: consult technical data sheets
contained in documentation.
Concerning the location of lugs and other points for lifting and
hoisting: consult transport and loading plans in documentation.
Avoid shocks and impacts during transport and setup.
Be sure not to warp, distort or deform equipment when taking it
down from the wooden transport blocks.

Using a crane to move Cranes may be used for packing units that are equipped with crane
packing units lugs. Conditions:
Cranes, lifting gear, slings etc. must be suitable for the weight
of the packing unit.
The operator must be trained and authorised to use a crane.
Loads must be evenly distributed for lifting.
Slinging loads:
1. Ropes, slings, belts etc must be attached to at least
four crane lugs.
2. Make sure the packing unit is suspended properly.
Compensate, if the centre of gravity is off-centre.
3. Move the load.

Using a fork lift truck to Packing units on pallets may be moved using a fork lift truck,
move packing units provided the following conditions are fulfilled:
The fork lift truck must be suitable for the weight to be lifted.
The operator must be trained and authorised to use a fork lift
truck.
The forks must be long enough to protrude on the opposite
side.

Slinging loads:
1. Drive the forks of the fork lift truck under the packing units.
2. Retract the forks until they protrude on the opposite side.
3. Make sure the packing unit cannot tilt if the centre of gravity is
off-centre.
4. Lift the packing unit up and start moving it.

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Storage and maintenance
Storage
Storing packing units
Conditions for storing packing units:
Indoor storage only
Storage must be dry and dust-free
Avoid contact with aggressive gases, liquids etc.
Protect against direct sun exposure
Protect against mechanical shocks, shaking etc.
Temperature: -5 to 40 °C
Relative humidity: 50 % max. at 40°C max.
When storing for longer than 3 months, check the state of parts and packing units at regular intervals If necessary,
repeat conservation measures.

NOTE
Packing units may display instructions and information for storage going beyond details mentioned
above. Be sure to take good note and comply.

Tightening torques
For tightening torques of screwed connections on electrical equipment see the following table. Values stated apply
to hex screws and bolts with angular thread (V-thread) accor. ISO, toughness 8.8, friction coeI¿FLHQt 0.10 - 0.14,
chromised yellow.

Dimensions Tightening torque [Nm]

M8 20

M10 39

M12 65

M16 163

Measures after maintenance


After servicing and/or maintenance and before re-start, carry out the following:
1. Check all screws, bolts and nuts you loosened or unscrewed. Tighten, if necessary.
2. Check whether you have properly replaced any and all safety and protective equipment, covers etc.
you may have removed before.
3. Make sure you do not forget any tools, equipment etc. in the work area.

CAUTION!
Short circuits
Objects not belonging there, e.g. tools, may cause short circuits in the switchgear.
Therefore:
– Be sure not to forget any objects in thes witchgear after servicing and maintenance.

4. Clean your work area.

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AFCON Manufacturing & Contracting Darom LTD.
A member of the Afcon Industries Group - Electro Mechanics Division
Itzhak Nafha 85, P.O.B 1369, Beer Sheva 84113, Israel. Tel. 972-8-6250500, Fax 972-8-6282432