safe.inspiring.green. Product manual GEOS - Industrial and Outdoor Enclosures

Transcription

1 safe.inspiring.green. Product manual GEOS - Industrial and Outdoor Enclosures

2 Contents About this Product manual... 4 GEOS-Enclosure... 4 Intended Use... 4 Configuration support according to the standard... 5 Safety information... 5 Meaning of symbols... 5 Areas of application... 6 Application limits according to IEC... 6 Ambient temperature... 6 Humidity... 6 Maximum installation height... 6 Application limits according to UL / CSA... 6 Product features... 7 Insulating material of the enclosure... 7 Level of contamination... 7 Electrical properties... 7 Level of protection... 7 IP level of protection... 7 IK level of protection... 7 Scope of delivery... 8 Fittings... 8 Box... 9 Base of the box... 9 Side walls Threaded inserts Screw points Inner area Cover Cover screws Accessories Set of ventilation elements BEL Air M Mounting plates Standard rails Mounting bracket Partition wall External fixing lugs

3 Mounting Position of use Mounting the box Work preparation Cable entries Knock-outs Drainage holes point mounting within the sealing area point keyhole mounting within the sealing area Mounting outside the sealing area Threaded inserts Mounting the threaded inserts Dismantling the threaded inserts Mounting the cover Quick-thread screw Quick-thread screw Mounting the accessories Mounting plate Standard rail Mounting bracket Mounting the partition wall Dismantling the partition wall Maintenance Design Design according to IEC Name of the standard Original manufacturer / manufacturer of the switchgear assembly Design verification according to section 10 of IEC / Unit verification according to section 11 of IEC / Technical data GEOS-Enclosure Power dissipation details for individually mounted GEOS enclosure Dimensional sheets GEOS GEOS GEOS GEOS GEOS

4 About this Product manual This product manual is a configuration and installation manual and has been written for technicians. Read this product manual to select GEOS enclosures, install them properly, operate, and to use the permissible application options provided by the enclosure. GEOS-Enclosure The GEOS enclosure is part of a series of empty enclosures of different sizes and design versions. The different versions are reflected in the respective extension given to the name. The enclosures meet the requirements of the following standards in consideration with this product manual: IEC IEC IEC IEC (restricted access) UL 50, UL 50E CSA 22.2 Considering their technical features, the enclosures are suitable for use according to: EN Regardless of the information given in this product manual, the technicians are responsible for using the currently applicable standards and the procedures described in them. Intended Use GEOS enclosures are intended for installing: Rail mounted devices, especially protection and control devices Low-voltage and switching devices Control and switching devices Terminals The limits mentioned in this product manual and the limit values specified by the properties of the product have to be followed. The specifications given in this product manual regarding the installation of the enclosure, the wiring and the assembly of the equipment have to be followed. 4

5 Configuration support according to the standard Spelsberg supports proper installation of GEOS empty enclosures according to the standards: IEC Safety information GEOS enclosures should be installed and commissioned only by electricians. Depending on the use of the enclosure, the equipment installed inside may be operated from outside by laymen or authorised persons. In case the enclosure is damaged which hampers the original level of protection, a qualified electrician has to assess if the enclosure needs to be decommissioned. If the enclosure is accessible for laymen and protection level of the enclosure against contact with live parts and ingression of solid bodies is less than IP3x (protection against contact with tools, wires, foreign bodies, etc.> Ø 2.5 mm), then the distribution has be shut down immediately! The M16 and M20 sealing plugs are used exclusively for closing the mounting holes in the base of the enclosure. Due to their reduced sealing ability, they are not suitable for cable entries with a level of protection of IP66 / IP67. Regardless of the information given in this product manual, the currently valid versions of the standards and regulations are applicable. Meaning of symbols Danger Non-compliance will result in death or serious injury. Escape from danger. Warning Non-compliance may result in death or serious injuries. Escape from danger. Caution Non-compliance may result in injuries. Escape from danger. Note Explanation Note Important additional information about the GEOS enclosure. 5

6 Areas of application GEOS-Enclosures are approved for wall mounting. In doing so, the enclosure has to be installed on a closed surface. When installed at other locations, like for example, on poles, a closed stable plate matching the size of the enclosure has to be used as an adapter between the enclosure and the mounting location. In case of open drainage holes, all the mounting surfaces should protrude by at least 20 mm With the appropriate accessories they are also suitable for other types of mounting (e.g. pole mounting). They are suitable for indoor and outdoor installation. Application limits according to IEC GEOS enclosures can be used with the following limits in accordance with the applicable standard without consulting Spelsberg. Ambient temperature Minimum ambient temperature: 25 C Maximum ambient temperature: + 40 C The average temperature in 24 hours should not exceed 35 C. Note Specific operating conditions Please consult the technical sales department of Spelsberg if GEOS enclosures are used outside the temperature limits mentioned above. Phone: / Humidity The permissible humidity depends on the maximum ambient temperature. It is 50 % at a maximum ambient temperature of +40 C. It is 100 % at a maximum ambient temperature of +25 C. Maximum installation height The maximum altitude of the installation site is restricted to 2000 m above sea level due to the reduction of the dielectric strength and cooling effect of ambient temperature at higher altitudes. Note Specific operating conditions Please consult the technical sales department of Spelsberg if GEOS enclosures are used at altitudes exceeding 2000 m above sea level. Phone: / Application limits according to UL / CSA GEOS enclosures meet the following type rating according to UL 50 / CSA 22.2 TYPE 4X TYPE 12K 6

7 Product features Insulating material of the enclosure GEOS-Enclosures are manufactured from thermoplastics (type-tested branded products). It is an insulating material enclosure and therefore does not have any grounding fixture. Level of contamination GEOS-Gehäuse sind für den Einsatz in Anwendungsgebieten mit dem Verschmutzungsgrad 3 konstruiert. Electrical properties GEOS enclosures may be operated in electrical networks with a rated voltage of up to 1,000V AC / 1,500V DC, where the prospective short circuit current (Icp) does not exceed 10 ka. If a higher Icp is expected at the input, then a current-limiting protection device with a maximum cut-off current of 17kA should be provided (for example AKi T 201, item no made by Spelsberg). Level of protection IP level of protection GEOS enclosures have an IP level of protection IP66/67. The IP level of protection may reduce depending on the cable entry used. Note Using sealing plugs The sealing plug supplied by Spelsberg have an IP level of protection of IP54 as a separate product. When the sealing plugs are used properly to cover the screw heads on the inner fixing points, then the GEOS enclosures achieve an IP level of protection IP66. IK level of protection The IK level of protection is a measure of the durability of enclosures against harmful mechanical stresses, especially impact stress. Front Side walls GEOS-Empty Enclosure IK09 IK09 Stress energy: IK09 10 Joule The IK level of protection has been tested at -25 C. The IK level of protection does not refers to break-out openings. 7

8 Wall mounting fixing points outside Wall mounting fixing points inside the sealing area Montage mural Points de fixation dans la zone d étanchéité Type 4X and 12K, UL 50 / CSA 22.2 culus listed File No. E GEOS xxxx-18 x: min. 130 mm GEOS xxxx-22 x: min. 175 mm tube à connecter est la taille 1. Scope of delivery The GEOS enclosures are supplied with 1 Box 2 Cover (grey or transparent) 3 Set of screws for cover with slotted corners 4 Sealing plug 5 Brief assembly instructions 1 Figure 1: Scope of delivery of GEOS Empty Enclosure Installation der GEOS Gehäuse Installation of GEOS enclosures Installation des boîtiers GEOS Wandbefestigung Befestigungspunkte außerhalb des Dichtbereiches the sealing area Montage mural points de fixation à l extérieur de la zone d étanchéité Screw / Schraube / Vis: A2; AiSi 304 / A4; AiSi 316 b: 8,5 mm - 10,5 mm c: max. 6 mm Click! Wandbefestigung Befestigungspunkte innerhalb des Dichtbereiches Instructions for Installation Use fastening holes located under the retention screws for the cover, which are external to the equipment cavity. Conduit hubs are to be connected to the conduit before connected to the enclosure. Type rating for the hubs 4X and 12K or better. Caution: Use of grounding hubs and jumper wires are required. Refer to pakkaging sheet for instructions, types and sizes. The Myers Electric company ground hub cat. no. STG or STAG followed by 1, 2, 3, 4, or 5 are suitable for use with the above stated enclosures. Enclosure does not provide grounding means between conduit connections. Use of grounding hubs and jumper wires are required. Refer to packing sheet for instructions, type and sizes. Grounding wire sized AWG 10 shall be used except for size ST (A) G5 shall be AWG 8. Grounding screws M4, Cat. No Grounding screws M6, Cat. No The maximum conduit trade size to be connected is trade size 1. Instructions pour l installation Veuillez utiliser les trous situés sous les vis de fixation pour le couvercle, qui sont externes à la partie étanche du boitier. Les raccords des tubes doivent être raccordés d abord aux tubes puis ensuite seulement au boitier. Le degré de protection des raccords doit être: 4X et 12K ou mieux. Attention: L utilisation de raccords avec une prise de mise à la terre et de fils de raccordement à la terre sont nécessaires. Reportez-vous à la feuille d emballage pour les instructions, les types et les tailles. Les raccords de la société Myers Electric avec misse à la terre, types STG ou STAG 1, 2, 3, 4, ou 5 sont adaptés pour une utilisation avec les boitiers indiqués ci-dessus. Le boitier n assure pas la mise à la terre entre les tubes de raccordement. L utilisation d un point de connexion relié à un fil de terre est obligatoire. Reportez-vous à la feuille d emballage concernant les instructions de montage, les différents modèles et les tailles. Un fil de terre de taille AWG 10 est à utiliser, sauf pour la taille STG5 et STAG5 qui doit avoir un fil de terre de taille AWG 8. Vis de mise à la terre M4, Cat. No Vis de mise à la terre M6, Cat. No La taille maximale du 3 Note Disposing of the packaging material Packaging materials have to be recycled. Fittings Box The box consists of the box base, the side walls, 4 or 6 screw points for mounting the cover and the interior Base of the box The box base of the GEOS enclosure is provided with: Knock-outs for fixing points within the sealing area Knock-outs for the cable entry from the back 4 combined entries M40/32 Mounting bosses for fixing the mounting material Screw points for mounting the cover, combined with fixing points outside the sealing area Fixing points for external attachment lugs Drainage holes 8

9 Figure 2: Box base, front view Figure 3: Box base, rear view Fixing points within the sealing area 2 Fixing points outside the sealing area 3 Screw points (cover mounting) 4 Mounting boss 5 Knock-outs for cable entries 6 Mounting boss for external attachment lugs 7 Drainage holes 7 9

10 Side walls The side walls of the GEOS-Enclosure do not have any knock-outs. Instead there are sections for individual holes and cutouts separated by a small groove. A distance of 4 mm should be maintained from the groove for penetrations and holes of fitted components. Short side wall Long side wall GEOS x 100 mm 212 x 100 mm GEOS x 147 mm 212 x 147 mm GEOS x 100 mm 312 x 100 mm GEOS x 147 mm 312 x 147 mm GEOS x 147 mm 2 sections each 181x 147mm Caution Impermeability The small groove surrounding the section has to be noted when positioning the cable entries. Sealing elements should not be on the groove. Note Use of cable entries and plug systems in size B24 GEOS enclosure xxxx-22 are suitable for vertical mounting of the corresponding systems. Holes are provided for threaded inserts to mount the covers at the corners, and in the middle for larger enclosures. The drain-protect system for draining water is provided on the side walls of the box below the cover. Note The drain protect system has to be checked for contamination during maintenance work 10

11 Figure 4: Side walls 1 Section for holes and cut-outs 2 Opening for threaded inserts 3 Water drainage channel Threaded inserts The threaded inserts in the corners of the boxes are matched to the different versions of mounting the cover. Replacing the cover screws and threaded inserts allows the screw system to be changed, even on existing enclosures. Screw points The screw points are used for screwing the cover to the box with the help of the threaded inserts. At the same time, the channels below are used as fixing points for mounting the enclosure outside the sealing area. The following cover mounting options are available, partly as accessories The following cover mounting options are available, partly as accessories Quick-thread screw Quick-release fastener, ¼ turn Note Mounting the threaded inserts To make it easy to mount the box through the screw channels outside the sealing area, the threaded inserts should be inserted only after installing the enclosure. 11

12 Inner area The inner area of the GEOS enclosure is used for housing the equipment. The following are available as accessories: Mounting plates made of galvanised steel sheet Mounting plates made of insulating material Standard rails They can be screwed directly onto the mounting boss at the base of the box or mounted at different heights using mounting brackets. Cover GEOS enclosures are available with cover versions in grey or transparent blue. The cover with the overlapping, peripheral edge optimally protects the seal. The cover can be placed easily and without jamming on the box. The combination of box and upper part generates a creepage distance, which produces a rated insulation voltage of 1,000V AC / 1,500V DC (IEC 61439) for a contamination level of 3. Cover screws The cover is mounted to the threaded inserts in the box using the cover screws. Sealing the cover The cover can be sealed using a sealing wire if necessary. Figure 5: Cover sealing 12

13 Accessories The following parts and assemblies are not included in the scope of delivery of the GEOS enclosure. Set of ventilation elements BEL Air M40 There may be condensation problems when using enclosures that are not airtight in environments with varying temperature and humidity. The explanation for this is that air can hold only a certain amount of water vapour at a certain temperature and a certain pressure. The higher the temperature and the higher the air pressure, the greater is the maximum possible water content. Compared to a temperature of 55 C, the air can hold only 20% of the water at a temperature of 20 C. Due to the power dissipated by the inbuilt devices, the air inside the enclosure usually gets heated up to 55 C. When appropriate devices and wiring are installed, this temperature can be even higher. The warm air in the enclosure gradually absorbs the water vapour contained in the ambient air. If the outside temperature falls, then the outer walls of the enclosure cool down. When the dew point temperature is reached, the water vapour contained in the air condenses on the inside of the enclosure as condensate. The water collects in the box and may cause damage. The ventilation elements set BEL Air M40 available as accessory can be mounted on the back or on the side walls. The air ventilation element is used to prevent condensate water while maintaining the high IP level of protection of IP65. It also helps in transporting the condensate out of the enclosure very quickly by means of air exchange. The continuous exchange of air allows the inside air to mix constantly with the surrounding air and transports the moisture to the outside. Air exchange also takes place in environments with almost constant air humidity and temperature, as the inside temperature increases due to the installed components. The ventilation element is designed to be maintenance-free. It is provided with a replaceable filter element. The filter element filters particles larger than 10 microns. The filter can be replaced. Figure 6: BEL AIR M40 Note IP and IK levels of protection If changes such as, installation of ventilation elements, cable entries, control and signalling devices, are made to the GEOS enclosure, then the IP level of protection has to be reassessed. 13

14 Mounting plates Mounting plates are available in sizes matched to the dimensions of the enclosure in the following materials: Galvanized steel sheet (2 mm thick) Insulating material (5 mm thick) The mounting plate is intended for installing the individual equipment. It is screwed to the mounting bosses of the box (torque: 2 Nm) using the screws provided. Alternatively, it can be mounted in different positions in the box using the mounting brackets available as accessories. Maximum load on the mounting plates: Description Material Max. load GEOS MPS 3030 Galv. Steel sheet 2 mm 7 kg GEOS MPS 4030 Galv. Steel sheet 2 mm 10 kg GEOS MPS 4050 Galv. Steel sheet 2 mm 12 kg GEOS MPI 3030 Insulating material 5 mm 7 kg GEOS MPI 4030 Insulating material 5 mm 10 kg GEOS MPI 4050 Insulating material 5 mm 12 kg Figure 7: Mounting plate steel sheet Figure 8: Mounting plate insulating material 14

15 Standard rails The 35 x 7.5 mm standard rail can be screwed to the mounting bosses of the box using the screws provided. It can also be mounted at different heights in the enclosure using 2 mounting brackets. Enclosure side Length of standard rail Maximum load of the standard rail 300 mm 250 mm 3 kg 400 mm 350 mm 3 kg 500 mm 450 mm 3 kg Figure 9: Standard rail Figure 10: Standard rail, Sample installation Mounting bracket The mounting brackets help in assembling the mounting plates and standard rails at different heights. At least 4 brackets are required for mounting plates and 2 brackets are required for standard rails. It consists of a base support and the slideable mounting brackets for mounting plates and standard rails. Figure 11: Mounting bracket for standard rails and mounting plates Figure 12: System structure Mounting system 15

16 Distance standard rail - Cover plate Distance standard rail - Cover Distance mounting plate (MPS) - Cover plate Distance mounting plate (MPS) - Cover Distance Mounting plate (MPI) Cover plate Distance mounting plate (MPI) - Cover 1 48 mm 99,5 mm 49 mm Cover 47 mm 94,5 mm 2 60 mm 107,5 mm 61 mm 108,5 mm 59 mm 106,5 mm 3 75 mm 122,5 mm 76 mm 123,5 mm 74 mm 121,5 mm 4 92,5 mm 140 mm 93,5 mm 141 mm 91,5 mm 139 mm mm 157,5 mm 111 mm 158,5 mm 109 mm 156,5 mm mm 175,5 mm 129 mm 176,5 mm 127 mm 174,5 mm Figure 13: Distances Standard rails to the cover plate / cover Figure 14: Distances Mounting plate to the cover plate / cover 16

17 Partition wall: The partition wall can be used to divide the inside space vertically or horizontally. Enclosure side Enclosure height Partition wall 300 mm 180 mm GEOS TW mm 226 mm GEOS TW mm 180 mm GEOS TW mm 226 mm GEOS TW mm 226 mm GEOS TW Figure 15: Partition wall, incl. bracket. Mounting plate - Cover plate The mounting plate - cover plate made of insulating material (4 mm thick) can be mounted in the upper part of the box and is suitable for installing control and signalling devices, measuring devices etc. It can also be used as a cover plate for protection against accidental contact with the installed devices. Figure 16: Mounting plate - Cover plate 17

18 External fixing lugs The external fixing lugs made of plastic can be fixed in different positions at the back of the enclosure. Wall clearance Description 10 mm GEOS ABL mm GEOS ABL-40 Figure 17: External fixing lugs GEOS ABL-10 Figure 18: External fixing lugs GEOS ABL-40 18

19 Mounting The GEOS-Enclosure has to be mounted using suitable mounting material. The mounting materials that are necessary should be selected based on the mounting surface. If the wall unevenness is more than 2 mm, a compensation is necessary between the fixing points to avoid deformation of the enclosure. Position of use The GEOS enclosures are designed for vertical and horizontal wall mounting and floor mounting. Ceiling mounting is permitted only if the mounting plate or standard rail is firmly screwed in place. Danger Ceiling mounting position The mounting bracket should not be used for ceiling mounting. In this type of mounting, parts may fall out when the cover is opened. Note Position of equipment The permissible position of the equipment and their attachment in the enclosure should be noted. Mounting the box Required mounting material: Screws, dowels, etc. The box of the GEOS enclosure can be mounted in four different ways: 4-point mounting within the sealing area 3-point keyhole mounting within the sealing area Mounting using external fixing lugs Mounting outside the sealing area below the cover screws Please refer to the dimensional sheets (starting from page 48) for the exact mounting dimensions. Note Rated voltage Using the fixing points within the sealing area is suitable for electrical equipment having a rated voltage of up to 690V AC / DC Using the fixing points outside the sealing area or the external fixing lugs is suitable for electrical equipment having a rated voltage of up to 1000V AC / 1500V DC Note Instruction as per UL 50 / CSA 22.2 file: Installation instructions Use fastening holes located under the retention screws for the cover, which are external to the equipment cavity 19

20 Work preparation The side walls of the GEOS-Enclosure do not have knock-outs for cable entries. Corresponding holes or notches should be made before mounting the box. Cable entries Accessories for the cable entry are not supplied with the GEOS-Enclosures. Various types of cable entries are available as accessories. Overview of sealing options for the cable entries and the associated sealing areas from the Spelsberg range of accessories: Cable screw coupling KVR, IP68 Double membrane seals DMS, IP66 Stepped nipple SNI, IP55 Attachment bush AST, IP54 Size Sealing area [mm] Rated torque [mm] Sealing area [mm] Sealing area [mm] Sealing area [mm] M12 2 6,5 mm 2 Nm M mm 2,5 Nm 5 9 mm mm M mm 4 Nm 7 12 mm 5 16 mm 8 13,5 mm M20 GDB 7 14 mm 4 Nm M mm 6 Nm 9 16 mm 5 21 mm 9 18,5 mm M mm 7 Nm mm 13 26,5 mm mm M mm 7,5 Nm mm mm mm M ,5 mm 8 Nm M ,5 mm 9 Nm Note IP level of protection The IP level of protection of the GEOS enclosure reduces to the IP level of protection of the cable entry depending on the cable entry used. Note IK level of protection The IK level of protection of the GEOS enclosure may decrease depending on the cable entry used. 20

21 Knock-outs The GEOS-Enclosures have combination knock-outs with nominal sizes of M40 / M32 only at the back. Note Base of the box If the knock-outs in the box base are used, they have to be removed before mounting. If double membrane seals are used to seal the cable entries then additional spacers are not needed for wall mounting. Tools required: Hammer, Slot screwdriver Place the screwdriver at an angle of to the edge of the mark and facing the centre point Remove the knock-out using the hammer Avoid damage to the sealing contour Cable entry Insert the desired cable entry. Note Instruction as per UL 50 / CSA 22.2 file: Installation instructions Use suitable UL Listed devices having an environmental rating equal to or better than the enclosure rating to close all unfilled openings. Type rating for the devices 4X and 12K or better. Suitable for use with 2 1/2 in or smaller conduits in enclosures XXXX-18 and 3 in or smaller conduits in enclosures XXXX-22 When used as a pull box, installation shall be in accordance with Section of Mexico s Electrical Installations, NOM-001-SEDE, and Section of the National Electrical Code, ANSI/NFPA 70. Caution: Enclosures does not provide grounding means between conduit connections. Use of grounding hubs and jumper wires are required. Refer to packaging sheet for instructions, types and sizes. The Myers Electric company ground hub cat. no. STG or STAG followed by 1, 2, 3, 4, or 5 are suitable for use with the above stated enclosures. Grounding wire sized AWG 10 shall be used except for size ST(A)G5 shall be AWG

22 Drainage holes The GEOS-Enclosures have drainage holes on all the sides of the box base. The drainage holes can be opened if necessary before or after the installation. Note IP level of protection Opening the drainage holes reduces the level of protection of the enclosure. When mounted on a surface with an overlap of 20 mm to IP43. For wall mounting, all the drainage holes at the bottom should be opened if necessary. When used in horizontal position, all the drainage holes should be opened if needed. For ceiling mounting, the drainage holes should not be opened. Tools required: Hammer, Slot screwdriver width max. 5.5 mm Place the screwdriver inside the box on the knock-outs of the drainage hole Remove the knock-out using the hammer Figure 19: Drainage hole 22

23 4-point mounting within the sealing area The box is mounted using the four slotted holes. Suitable mounting material: Slotted holes: Maximum M6 screws or screws having a diameter of 5.5 mm. The head of the screw may have a maximum diameter of 12 mm. Figure 20: Fixing points 4-point mounting Tools required: Hammer, screwdriver Open the mounting holes Align the box Mark the fixing points Drill the holes if necessary and insert suitable dowels Insert the screws into the slotted holes Seal all the fixing holes using the sealing plugs The installation is complete 3-point keyhole mounting within the sealing area The box is mounted using the top keyhole and the two bottom slotted holes. Suitable mounting material: Slotted holes: Maximum M6 screws or screws having a diameter of 5.5 mm. The head of the screw may have a maximum diameter of 12 mm. Keyhole: Maximum M5 screws or screws having a diameter of 5 mm. The head of the screw may have a maximum diameter of 10 mm for using the keyhole. Figure 21: Fixing points 3-point mounting, keyhole mounting 23

24 Tools required: Hammer, screwdriver. Open the mounting holes Drill the hole for keyhole mounting if necessary, insert a suitable dowel and tighten the upper screw at the desired position Mount the box with the keyhole on the pre-assembled upper screw Align the box Mark the lower fixing points Drill the holes if necessary and insert suitable dowels Insert the screws into the lower slotted holes Seal all the fixing holes using the sealing plugs The installation is complete Installation with external fixing lugs Note External fixing lugs The external fixing lugs are not part of the delivery. The box is mounted using the external fixing lugs which are fixed to the box using the stainless steel screws provided. The external fixing lugs can be mounted vertically, diagonally or horizontally. Suitable mounting material: Maximum M6 screws Screws having a diameter of 5.5 mm. The head of the screw may have a maximum diameter of 12 mm. Figure 22: Mounting external fixings lugs ABL-10 Figure 23: Mounting external fixings lugs ABL-40 24

25 Tools required: Hammer, screwdriver (PZ2) Position the external fixing lug in the desired direction and press the expansion element into the screw boss Knock in the pin using the hammer For the ABL 40 use the screwdriver as a tool Fix the external fixing lugs using the supplied stainless steel screw in the mounting boss Align the box Screw the box at the desired position using the external fixing lugs Installation is complete. Mounting outside the sealing area The box is mounted using the screw channels on the corners outside the sealing area. Mounting outside the sealing area is suitable for flat surfaces or mounting profiles (such as Z profiles). In case of pre-wired systems, the advantage is that fixing is not necessary in the interior section. Note Mounting larger enclosures Mounting options are not available below the screw channels in the middle of the side walls Suitable mounting material: Maximum M6 screws Srews having a maximum diameter of 5.5 mm. The screw head should have a diameter between 8.5 mm and 10.5 mm. Figure 24: Mounting outside the sealing area Tools required: Hammer, screwdriver (Min. AF 130 mm for GEOS enclosures xxxx-18) (AF of min. 175 mm for enclosures GEOS xxxx-22) Align the box Mark the fixing points. Drill the holes if necessary and insert suitable dowels Insert the screws through the screw channels The installation is complete Note Threaded inserts If the threaded inserts are already assembled, then please remove them before mounting 25

26 Threaded inserts Mounting the threaded inserts Note Threaded inserts If the fixing points outside the sealing area are used to mount the box, then the threaded inserts should be assembled only after mounting the enclosure Place the threaded inserts in the cutout on the box such that the word TOP is visible Press the threaded inserts into the box until they lock into place. The threaded inserts should be flush with the box. Repeat these steps on all the four corners and on the side walls as well if required for larger enclosures The installation is complete Figure 25: Mounting the threaded inserts GEOS 3030, GEOS 3040 GEOS 4050 Figure 26: Dismantling the threaded inserts Side GEOS 4050 Dismantling the threaded inserts Tools required: Screwdriver Place the screwdriver at a slight angle into the hole beside the screw thread Push the screwdriver towards the centre of the box and pry the threaded insert out Repeat these steps on all the four corners and on the side walls as well if required for larger enclosures The dismantling is complete. Figure 27: Dismantling the threaded inserts GEOS 3030, GEOS 3040, GEOS 4050 Figure 28: Dismantling the threaded inserts / Seitenwand GEOS

27 Mounting the cover Quick-thread screw Tools required: Screwdriver Note Tool The upper part should be opened and closed using a slotted screwdriver (AF from 4 to 6.5 mm). For ensuring proper sealing, a torque of 1.2 Nm should be applied when closing. Sealing Check if the threaded inserts are mounted for quick-thread screws Insert the screws provided as accessories into the cover Place the cover on the box Screw the cover into place using the cover screws The installation is complete Figure 29: Mounting Quick-release fastener Opening Loosen the screws Remove the cover from the box The box is open 27

28 Quick-release fastener Tools required: Screwdriver Note Tool The upper part should be opened and closed using a slotted screwdriver (AF from 4 to 6.5 mm). Sealing Check if the threaded inserts are mounted for quick-release fasteners Insert the quick-release fasteners into the cover Note the direction of the quick-release fasteners Place the cover on the box Slightly turn the quick-release fastener until the two tabs on the screw point diagonally from the corner towards the centre of the box. The screw locks into the threaded insert in this position. opening Figure 30: Locking the quick-release fastener Then turn the quick-release fastener by ¼ turn to the right to lock it. The two tabs at the top of the quick-release fastener and the remaining contour of the screws now merge harmoniously with the contour of the cover. Repeat these steps on all the other quick-release fasteners The installation is complete Opening Turn the quick-release fastener by ¼ turn to the left until the two tabs on the head of the quick-release fastener point diagonally from the corner towards the centre of the box. The quick-release fastener is now unlocked. Repeat these steps on all the other quick-release fasteners Remove the cover from the box The box is open Locking Unlocking Figure 31: Locking the quick-release fastener 28 Figure 32: Unlocking the quick-release fastener

29 Note If the ambient temperature significantly drops after mounting the cover, it may happen that the cover sits firmly on the box. Owing to the high level of protection of the GEOS enclosure, the vacuum inside the enclosure is not equalised. This may make it difficult to remove the cover after loosening the cover locks. The properties of the enclosure are not affected by this. Mounting the accessories Mounting plate The mounting plate can be screwed directly onto the mounting bosses of the box base using the screws provided Tools required: Screwdriver (PH2) Screw the mounting plate to the mounting bosses using the screws provided. Recommended torque: 2 Nm The installation is complete Standard rail The standard rail can be screwed directly onto the mounting bosses of the box base using the screws provided. Tools required: Screwdriver (PH2) Slightly turn the screws into the mounting bosses Place the standard rail with the keyholes over the screws Tighten the screws properly. Recommended torque: 1.8 Nm The installation is complete Mounting bracket The mounting bracket is installed in two steps. In the first step, the base support is mounted on the box base. In the second step, the mounting bracket is inserted on the standard rail or mounting plate. Then, this combination is pushed into in the pre-assembled base support. Figure 33: Base support Figure 34: Mounting bracket Figure 35: Locking hook 29

30 Mounting the base support Position the base support on a mounting boss in the box base Press the base support against the side wall till it snaps into place The installation of the base support is complete Figure 36: Mounting base support Note Mounting the base support for mounting plates Before mounting the base support check the position of the support with the selected mounting plate. Dismantling the base support Tools required: Screwdriver (Slot screwdriver 4-5 mm) Remove the mounting bracket before dismantling the base support Insert the screwdriver into the opening on the base support and push the driver slightly towards the box base At the same time, tilt the base support up in the direction of the box centre Remove the base support Figure 37: Dismantling the base support 30

31 Mounting the standard rail / mounting plate on the mounting bracket Insert the standard rail or mounting plate at the desired height in the mounting bracket Inserting the mounting bracket into the base support Push the mounting bracket along with the standard rail / mounting plate evenly into the pre-assembled base support until all the mounting brackets lock into place Dismantling the mounting bracket Pull the locking hooks inwards until it locks Repeat this process on all the mounting brackets Remove the rail / mounting plate evenly from the base bracket Figure 38: Dismantling the mounting bracket Note Dismantling the mounting bracket When removing the mounting bracket from the base support, snap back the locking hooks to their original position. 31

32 Mounting the partition wall Mount the base support in the box (see base support mounting) Insert the partition wall with the openings facing up into one of the two guides of the base support Slide the partition wall into the box till it locks into place Figure 39: Dismantling the partition wall Dismantling the partition wall Tools required: Screwdriver (Slot screwdriver 4-5 mm) Unlock the partition wall at the first base support and slightly pull the partition wall out Unlock the partition wall at the second base support and slightly pull the partition wall out Remove the partition wall Figure 40: Dismantling the partition wall 32

33 Maintenance The drain protect system has to be checked for contamination during maintenance work. If exposed to a lot of dust, the drain protect system has to be checked at regular intervals for contamination and be cleaned. The time intervals depend on the degree of contamination. Figure 41: Drain-Protect-System Design Design according to IEC Name of the standard Low-voltage switchgear assemblies - Part 2: Energy switchgear assemblies Original manufacturer / manufacturer of the switchgear assembly The EN standards distinguish the terms original manufacturer and Manufacturer of the switchgear assembly. Original manufacturer As the original manufacturer, Spelsberg is responsible for the original design of the GEOS enclosure and has the related certificates according to the IEC standard. Manufacturer of the switchgear assembly Manufacturer of the switchgear assembly is the organisation that is responsible for the finished switchgear assembly. This includes the standardised planning and wiring of the mini distributor based on the electrical conditions, installation environment and ease of use, documented by the design and unit verification. Design verification Spelsberg supports the preparation of the design verification below. The specifications given in this product manual regarding the installation of the enclosure, the wiring and the assembly of the equipment have to be followed. The manufacturer of the switchgear assembly is responsible for using the currently applicable standards and the procedures described in them, regardless of the information provided in this product manual. The electrical conditions, installation environment and ease of use has to be defined by the user. Application areas according to standard operating conditions GEOS enclosures are intended for use under the following operating conditions: 33

34 Indoor installation Ambient temperatures from - 5 C to +40 C Not exceeding +35 C for more than 24 hours. Relative humidity less than 50% at a maximum temperature of 40 C, a higher humidity is allowed at lower temperatures. Outdoor installation Ambient temperatures from - 25 C to +40 C Not exceeding +35 C for more than 24 hours. Relative humidity of up to 100% at a maximum temperature of +25 C. Corrosion resistance / UV radiation The corrosion resistance of the metal parts in the enclosure has been proven according to of the standard and the resistance to UV radiation according to Level of contamination GEOS enclosures have been designed for the contamination level of 3. Maximum installation height The maximum height of the installation site is 2000 m above sea level. 34

35 Note Electrical properties Note the supply limits mentioned in the chapter Electrical properties, page 7. Design verification according to section 10 of IEC /2 The chapter details mentioned in brackets below refer to Chapter 10 of the IEC /2. Supporting documents provided by the original manufacturer Corrosion resistance (Chapter ) The metal parts inside the GEOS enclosure pass the Level A test and are suitable for outdoor installation. Properties of insulating materials (Chapter ) The tests for demonstrating the heat resistance of enclosures was successfully passed. The resistance of insulating materials against extreme heat and fire caused by internal electrical effects was demonstrated using specimens taken out and subjecting them to a temperature of 850 C using a glow-wire tip. Resistance to ultraviolet (UV) radiation (Chapter ) Representative test specimens were successfully subjected to UV testing according to ISO , method A, cycle 1 for a total duration of 500 hours. This confirmed the suitability for outdoor installation. Lifting (Chapter ) The GEOS enclosures are suitable for use in vertical and horizontal wall mounting, horizontal floor mounting as well as, under certain circumstances, for ceiling mounting. The maximum installable loads are specified in chapter Mounting plates, Page 14 and Standard rails. Impact tests (Chapter ) GEOS enclosures meet the requirements of the impact tests, see chapter IK level of protection. Labels (Chapter ) The affixed labels were successfully tested for abrasion resistance. Level of protection of enclosures (Chapter 10.3) GEOS enclosures meet the requirements for outdoor installation according to IEC as well as the requirements of Humidity and wet areas and rooms and Outdoor systems according to DIN VDE The GEOS enclosures meet the IP level of protection IP66 and IP67, see Chapter IP level of protection. Note IP and IK levels of protection If changes such as, installation of cable entries, control and signalling devices, are made to the GEOS enclosure, then the IP level of protection has to be reassessed. 35

36 Creepage distances (Chapter ) Additional measures (such as fixing the cables) are not required for the GEOS enclosures due to their high rated insulation voltage. Rated insulation voltage, see chapter Installation. Protection against electric shock and continuity of protective conductor circuits (Chapter 10.5) The basic protection should prevent direct contact with hazardous live parts. The GEOS enclosures provide the required protection with the mentioned IP level of protection when installed properly. Continuity of connection between bodies of the switchgear assembly and protective conductor circuit (Chapter ) GEOS enclosures do not have any connection for protective conductor as they are insulated enclosures. Hence, the test need not be carried out. The protection against the consequences of a fault in the switchgear assembly is provided by the Protective insulation. Short-circuit resistance of the protective conductor (Chapter ) GEOS enclosures are designed for use in electrical networks, where the prospective short circuit current Icp does not exceed 10 ka. Alternatively, GEOS enclosures may be used on a current-limiting protective device with a maximum cut-off current of 17kA. The short-circuit resistance of the protective conductor need not be tested in this case. Testing enclosures made of insulating material (Chapter ) GEOS enclosures are suitable for rated insulation voltages of 1,000V AC and 1,500V DC. The corresponding tests have been successfully passed. External handles made of insulating material (Chapter ) This test is not necessary because GEOS enclosures do not have any external handles. Short circuit resistance (Chapter 10.11) GEOS enclosures are designed for use in electrical networks, where the prospective short circuit current Icp does not exceed 10 ka. Alternatively, GEOS enclosures may be used on a current-limiting protective device with a maximum cut-off current of 17kA. Short-circuit resistance test is hence not required for design verification. Electromagnetic compatibility (Chapter 10.12) GEOS enclosures behave passively as a pure enclosure with regards to EMC. The components installed inside are not protected against electromagnetic interferences arising in the surroundings and the surroundings are not protected against electromagnetic interference arising in the enclosure. 36

37 General (Chapter J.9.4.1/2). EMC distinguishes between two environments. Environment A: These are primarily industrial environments, where the power supply network is fed by a separate transformer. Environment B: This environment includes residences, offices and commercial areas as well as small businesses, which are directly connected to the public low-voltage grid. For further details please refer to EN , Annex J. EMC interference resistance and EMC interference emission tests are not required on the finished switchgear assembly, if the following two conditions are met: The components installed inside are listed for the specified environment (A or B) in accordance with the applicable EMC product or generic standards. The internal layout and the wiring is done according to the instructions of the equipment manufacturer. Mechanical function (Chapter 10.13) The GEOS enclosures with assembled hinge (accessories were tested for proper mechanical functioning. Supporting documents to be provided by the manufacturer of the switchgear assembly Clearance distances (Chapter ) The clearance distance between active parts depends on the rated impulse resistance voltage (Uimp). This in turn depends on the installation area and the mains voltage as well as the configuration of the electrical network. Protection against electric shock and continuity of protective conductor circuits (Chapter 10.5) Devices and circuits have to be arranged such that it is easy to operate and maintain them, and the required protection is ensured at the same time. Effectiveness of the protective conductor (Chapter ) The effectiveness of the protective conductor has to be demonstrated for protection against the consequences of a fault in the switchgear assembly according to The effectiveness of the protective conductor has to be demonstrated for protection against the consequences of a fault in the external circuits supplied by GEOS enclosures according to

38 Installation of equipment (Chapter 10.6) GEOS enclosures are not suitable for Inserts and Removable parts according to IEC standard. The equipment has to meet the applicable standards and be suitable for the specific application. The following should be particularly noted: Rated voltage Rated currents Rated frequency Life Making and breaking capacity Short-circuit resistance If the short-circuit resistance and / or the breaking capacity of the installed equipment are not adequate for the loads arising at the installation site, then the equipment has to be protected using current-limiting devices. Appropriate coordination between the equipment has to be ensured to prevent unwanted shut-downs. The equipment has to be installed in accordance with the manufacturer s specifications. The power dissipated by the devices heats up the air in the enclosure. Therefore, temperature-sensitive equipment should always be installed at the bottom of the enclosure. The user should be able to access the equipment easily. Unless otherwise agreed, the IEC standard specifies the following requirements: Connections, excluding protective conductor connections, should be at least 0.2 m above the ground and arranged such that the cables and wires can be easily connected, Gauges that need to be read should be installed 0.2 to 2.2 m above the standing surface of the operator, EMERGENCY OFF switches should be installed 0.8 to 1.6 m above the standing surface of the operator. Internal electric circuits and connections (Chapter 10.7) The conductors used in the AK mini distributor should be suitable for the specific application. The use of bare conductors is not planned in the AK mini distributor. The conductor has to be suitable for the rated insulation voltage, the rated current and for connecting to the equipment. When laying the conductors, make sure that they are not routed over sharp edges. The installed standard rails and the optional mounting plates are not critical. The cross-section of the conductor should be chosen depending on the rated current of the respective circuit (Inc). The high temperature in the enclosure may negatively affect the current carrying capacity of the conductor. Connections for conductors routed from outside (Chapter 10.8) GEOS-Enclosures do not have any connections for conductors routed from outside in the delivered condition. Insulation properties (Chapter 10.9) General (Chapter ) Every circuit of the switchgear assembly has to withstand temporary and transient over-voltages. This has to be ensured by testing the dielectric strength. In the process, any current-consuming devices (such as windings, measuring equipment, over-voltage protection devices) present in the switchgear assembly, which would cause a current to flow when the test voltage is applied, have to be disconnected. Similarly, devices that are not designed for the test voltage have to be disconnected. All other equipment have to be connected. 38

39 Dielectric strength during operation (Chapter ) Main circuits as well as auxiliary and control circuits that are connected to the main circuit, have to be tested with the following test voltages. Rated insulation voltage U i (conductor to conductor, AC or DC) Test voltage (AC RMS value) Test voltage (DC) U i U i U i U i U i U i Figure 8 of the standard AC or DC auxiliary and control circuits that are not connected to the main circuit, have to be tested with the following test voltages. Rated insulation voltage U i (conductor to conductor, AC or DC) Test voltage (AC RMS value) U i U i U i see DIN EN , table 8 Figure 9 of the standard For further details on the test, please refer to the IEC standard. 39