PROJECT / CONTRACT REF: C2011/75 PROJECT NO.

: 280111800

DESIGN & BUILT OF TANKER RECEPTION FACILITY AT DOHA

WEST STW OLD PLANT

DOCUMENT TITLE:

METHOD STATEMENT FOR INSTALLATION OF MCC

CONTRACTOR CONSULTANT

24-Nov-2012 01 Issued for Approval GD MG MG

REV.
DATE REASON FOR REVISION PREPARED BY CHECKED BY APPROVED BY
NO.

METITO DOC. NO. TRFDW-DOC-GEN-00 SUBMITTAL NO. TRFDW-DOC-GEN-0

MCC METHOD STATEMENT
Low voltage switchboard
Contents

General 3
Safety recommendations 4
Introduction 5

Delivery 7
Receiving 8
Packing 9
Handling 10
Storage 12

Installation 13
Tools 14
Site preparation 16
Joining sections 18
Earthing bar connection 22
Main busbar splicing 23
Connection of power cables 24
Connection of auxiliary circuits 28
Final installation procedures 30
Preliminary checks 31
Energising equipment for the first time 32

Operation 33
Operation of Masterpact circuit breakers 34
Operation of circuit breakers 36
Drawers 38
Troubleshooting information 42

Maintenance 43
General maintenance 44
Preventive maintenance 47

Evolution 49
Extensions 50

Organisation 59

1
2
General

Safety recommendations 4
Introduction 5

3
General Safety recommendations

Note DANGER
You have just received your new Blokset Used where there is a hazard of severe bodily injury or death.
switchboard. Please read this manual carefully. Failure to follow a "DANGER" instruction will result in electric shock,
It provides all the necessary information severe bodily injury or death.
concerning installation, operation and
maintenance of your switchboard.
Please keep this manual on hand for easy
reference. WARNING
The messages opposite are used in this manual Used where there is a hazard of bodily injury or death.
to: Failure to follow a "WARNING" instruction may result in bodily injury
b Warn of potential hazards; or death.
b Draw attention to additional information
intended to clarify or simplify a procedure.

CAUTION
Used where there is a hazard of damage to equipment.
Failure to follow a "CAUTION" instruction may result in damage to
equipment.

NOTE
Provides additional information intended to clarify or simplify a
procedure.

4
General Introduction

Blokset is a modular switchboard made up of a number of sections. Modular design

facilitates transportation and installation.
The horizontal busbars are connected between sections by splicing.
Prior to shipping, every Blokset section is inspected visually, mechanically and
electrically by a trained technician of the Quality Inspection department.
1
A test and inspection report may be provided on request.

DANGER
 Correct operation of the Blokset switchboard requires that
handling, installation, operation and maintenance be carried
out exclusively by qualified personnel.
 The system must be de-energised prior to installation and
maintenance operations to avoid exposing personnel to
the risk of electrical shock.
 The purpose of this instruction manual is to familiarise
qualified personnel with Blokset construction, installation
and maintenance as well as the risks encountered.
Personnel must be:
o Qualified to work near live equipment;
o Trained with respect to all applicable safety practices.
Failure to observe these instructions will result in severe bodily
injury, death or damage to the switchboard.

Check the switchboard nameplate located on the incoming section for conformity
with the delivery note.

5
6
Delivery

Receiving 8
Packing 9
Handling 10
Storage 11

7
Delivery Receiving

 On receipt of the equipment and before handling it, check that the
cases and packing materials used for transportation have not been
damaged and that all items on the packing list have been effectively
delivered.
 Even if the packing appears to be in good condition, do not hesitate to
unpack the equipment in the presence of an authorised transport
agent.
 Check consignment contents and weight. Thoroughly check the
equipment to make sure that no damage or shocks have occurred
which may impair insulation or operation.
 If necessary, check that the information given on the switchboard
nameplate, located on the incoming section, conforms to that given
on the delivery slip.
 In case of damage or missing parts, inform the transport agent by
registered mail.

NOTE
We absolutely decline any responsibility for losses or damage during
transportation and any financial liability for said losses and damage.

8
Delivery Packing

Blokset is generally shipped in transport units made up of one or several joined

vertical sections.
Two types of packing are used for shipping.
 Standard packing
The transport unit is wrapped in a sheet of plastic and crated (see Fig. 1).
Blokset

 Ship packing
Desiccant packets are placed inside the equipment which is then wrapped in a
heat-sealed plastic sheet and placed in a ventilated box made of wood or plywood
(see Fig. 2).
2

Fig. 1 : Standard packing

Fig. 2 : Ship packing

9
Delivery Handling

 The equipment is delivered on pallets or skids. Final unpacking of the

equipment should take place, if possible, just before installation.
Equipment dimensions and weights are indicated on the packing.
 The equipment may be handled from:
o The bottom
The equipment may be lifted from the front or back by a pallet-mover or a forklift.
Care must be taken during lifting and the equipment must be secured by a safety
strap during transport (see Fig. 1).
o The top
When overhead cranes are used, slings are required. They must be strong
enough and in good condition. The slings must always be connected to the four
lifting rings on the equipment. Adjust the length of the slings to the size of the
switchboard such that the angle between slings does not exceed 60° (see Fig.
2).
 In special cases where the transport unit includes more than two
interconnected sections, it is necessary to:
o Reinforce the mechanical connections between sections;
o Use a lifting beam with direct connections to the switchboard support
items (see Fig. 3).
Fig. 1 : Handling with a forklift.
WARNING
Use extreme caution when moving the equipment. There is a
tendency for the equipment to tilt due to its high centre of gravity.
Failure to observe these instructions may result in bodily injury
or damage to the equipment.
B=A
2
A

60°

Fig. 2 : Handling with slings.

Fig. 3 : Handling joined sections.

10
Delivery Handling

b Cubicle : Mw2
Side connection Rear connection

A
2

Lifting beam + Slings Lifting beam + Slings

(A) (L) (A) (L)
Slings Lifting beam + slings
- 1500 to 2300mm - 1500 to 2300mm

650mm 700 to 1000mm 650mm 700 to 1000mm

L 20°

Slings
Lifting beam + Slings Lifting beam + Slings
(A) (L) (A) (L)
- 1500 to 2300mm - 1500 to 2300mm

650mm 700 to 1000mm 650mm 700 to 1000mm

Mw2 cubicle lifting lugs are delivered separately

For handling operation follow the steps herehunder:
 Remove the side panels retirer les panneaux latéraux
 Install the 4 captive nuts and the lugs
o IP31 directly on the frame
o IP<=54 on the gasket protection part
 Position the columns
 Remove the lugs (and the further gasket protection part)
Lifting gasket protection

11
Delivery Storage

 Blokset is intended for use indoors. The equipment must therefore be stored
upright in a dry and ventilated location, protected from rain, extreme
temperatures, streaming, dust and chemical agents.
 Never store Blokset outside, even under a tarpaulin.
 The columns must preferably remain packed until they are installed. Should
work be in progress nearby or on the premises, cover the columns with a
cover protecting them efficiently against dust, gravel, paint and cement.
 Acceptable storage temperature is -25°C to +70°C.
 To ensure easy, risk-free handling, the columns, in view of their great weight,
must be stored on a stable, rigid floor.

CAUTION
Never store Blokset equipment outdoors, even if covered by a
tarp. Failure to follow this precaution can result in damage to the
equipment.

12
Installation

Tools 14
Site preparation 16
Joining sections 18
Earthing bar connection 22
Main busbar splicing 23
Connection of power cables 24
Connection of auxiliary circuits 28
Final installation procedures 30
Preliminary checks 31
Energising equipment for the first time 32
3

13
Installation Tools

Tools required Usual tools :

 75 N.m torque wrench
 bush ratchet
 bush of 10 b bush of 13 b bush of 16 b bush of 17 b bush of 18 b bush of
19 b Torx 8 bit
 Torx 10 bit
 Torx (8 and 10) and recess screwdriver or screwing/unscrewing machine,
with appropriate bits
 clamps for column alignment
 rubber mallet
 hydraulic jacks that can operate in horizontal position and are used to lift the
columns and, if necessary, move them sideways.

Specific tools  Torque wrench features

o tightening torque : 75 N.m
o reduced thickness for some tightenings on the busbars
 Torque wrench
o A type of torque wrench have the strength and the features
needed for not very accessible tightenings (fishplates ...)
o Tool’s:
- wrench’s shaft, essential
- xtra-thin pawl adapter, mandatory
- pawl for ordinary sockets, optional (to be fitted on the SP3723 shaft)
 Extra-thin sockets for pawl + shaft:
- 13 mm extra-thin low socket
- 13 mm extra-thin high socket
- 16 mm extra-thin low socket
- 16 mm extra-thin high socket
- 17 mm extra-thin low socket
- 19 mm extra-thin high socket
- 19 mm extra-thin low socket

 Busbar trunking conversion modules special tip

Indispensable extended tip for tightening the conversion modules on
the busbar trunking junction blocks.
It fits on an ordinary torque wrench.

Assembly types  splicing: busbars

o bush of 16 and 17 for M10 screw
 assembling: columns
o bush of 10 for M6 screw
 floor fixing:
o bush of 16 and 17 for M10 screw
 fitting the roofs and lifting lugs:
o bush of 19 for M12 screw.

14
Installation Tools

Material  8-8 quality steel. according to ISO 898-1 standard

Recomended tightening torque for mechanical and electrical links with 8.8-class
screws (with nut + contact washer)
diameter of screw tightening torque (N.m)
M3 1.5
M4 3.5
M5 7
M6 13
M8 28
M10
M12
50
75
3
Nut for insulated rod 2

Tightening torque for electrical links on the devices and for their fixing
 Refer to the device’s handbook.

Marking varnish
 After tightening each electrical connection to the appropriate torque, apply some varnish
between the nut and the screw (or else, between the screw’s head and the copper bar or the
device for tightening on a threaded part)
 The varnish isn’t supposed to block the screw:
o it allows operator inspection, to check that the nut has been tightened
and to verify if others bolts/nuts are untightened.
o it facilitates the identification of any loose nuts during the switchboard’s lifetime.

Varnish features:
 Coloured acrylic varnish, indelible and able to resist a 150°C temperature b Schneider
Electric recommends a red varnish as a standard to identify the panelbuilder’s
work
 Other colours can be used by the contractor or any operators entitled to work on the
switchboard after its commissioning.

15
Installation Site preparation

 b The Blokset installation site must be clean. The floor must be flat and level
deviations (y 2 mm/m) (see Fig. 1).
 b Leave at least 1200 mm of free space (see Fig. 1) to enable for opening of the
doors and operator access.
 b At least 1200 mm (or 1600 mm for 6300A) of free space (see Fig. 1) must be left
in front of Blokset to allow complete opening of the doors, maintenance or, where
applicable, use of a lifting device.
 b Leave space for future extensions.
 b Connection through the top.
 v Provide at least 600 mm of free space above Blokset.
 b Connection via the bottom (see Fig. 2).
 Two possibilities for routing the cables:
o Through a trench located under the equipment. The depth must be at
least 600 mm to take into account the minimum bending radius of the
cables;
o or under a false floor. In this case, a hole must be made in the floor for
cable routing.

DANGER
HAZARD OF ELECTRIC SHOCK, BURNS OR EXPLOSION.
A hazard of electric shock, burns or explosion exists both inside and
outside the equipment. Turn off all power supplying the equipment
before working on it.
Failure to observe these instructions will result in electric shock,
severe personal injury or death!

16
Installation Site preparation

600 mm.

r
3

1200 mm.

Check that floor is flat and level

600
min.
2
max.
1000
Fig. 1

Openings for cable routing via the bottom

opening for cable
Fig. 2: Blokset type D, Mf, Ms
routing
Depth of section 400 or 600 mm
Section width 700 Section width 900 (200 + 700) Section width 1100 (700 + 400) A: 250 for a depth of 400 mm
450 for a depth of 600 mm

A A A

75 75 75

600 50 600 50 350 50

Section width 1100 (200 + 700 + 200) Section width 1200 Section width 1300 (200 + 700 + 400)

A A A

75 75 75

150 50 1100 50 350 50

Blokset type Mw2
Section depth 600mm Section depth 1000mm B: 175 for a width of 800
275 for a width of 900
Section width 800, 900 or 1000mm Section width 800, 900 or 1000mm Section width 600mm 375 for a width of 1000
550 550 25
75 75

250 250 250

45

75
B 25 450

75

B 25

17
Installation Joining sections

 Position the sections on the installation site in the desired order of assembly.

 Remove any remaining packing and protection.

 Remove the cover panels and parts to facilitate access for switchboard
assembly. Note the position of the various parts.
o Remove the side panels (see Fig. 1):
- Remove the screws securing the panel;
- Lift the panel to free it from its supports and pull it away.
o Remove the upper and lower ventilation grates :
- First tilt the grate forward to unclip it from the frame (see
Fig. 2);
- Now pull it forward to free it completely(see Fig. 3).
o Remove the doors (see Fig. 4): Fig. 4 and 5: open the
door;
Fig. 6: free the blocking stud by pulling it down;
Fig. 7: pivot the blocking stud a quarter-turn
with respect to the door; Fig. 8: Remove the door.

 b The sections can be installed starting from right to left, or left to right
or beginning with a central section.

WARNING
Use extreme caution when moving the equipment. There is a
tendency for the equipment to tilt due to its high centre of gravity.
Failure to observe these instructions may result in bodily injury
or damage to the equipment.

18
Installation Joining sections

3
Fig. 1

Fig. 2 Fig. 3

Fig. 4 Fig. 5
E34192

E34193

Fig. 6 Fig. 7 Fig. 8

19
Installation Joining sections

 Position the first section and secure it to the floor using three M10 anchor bolts
(see Fig. 1 and 2).
Figure 3 shows the locations of the holes that must be drilled for the anchor bolts.
 Position the second section next to the first.
 Secure the second section to the floor using two M10 anchor bolts at diagonally
opposite corners (see Fig. 1).
 Interconnect the two sections using eight HM6 x 16 bolts and 6 mm
diameter barbed washers. Use class 8.8 nuts and bolts.
 Proceed in the same manner for the other sections.

NOTE
If the floor is not perfectly flat, chock the sections before securing
them.

Fig. 1

20
Installation Joining sections

Fig. 2

Joining sections A : 350 mm for a depth of 400 mm

Fig. 3 : Depth of section 400 or 600 mm 550 mm for a depth of 600 mm
950 mm for a depth of 1000 mm
Section width 700 Section width 900 (200 + 700) Section width 1100 (200 + 700 + 200)

A
A A

122,5 455 125 125

25 25 197,5 25
322,5 455 322,5 455
Section width 1100 (700 + 400) Section width 1200 Section width 1300 (200 + 700 + 400)

A A A

195 205 125 25

122,5 455 25 25
122,5 955 195 205
322,5 455
Side connection Rear connection
Section width 800 Section width 900 Section width 1000 Section width 600

180 25 25122,5
687,5 737,5 697,5 355

350
550

625

21
Installation Earthing bar connection

 The earthing bars of the various sections are connected together using class 8.8
nuts and bolts (see Fig. 1).
Assemble the bars using HM10 x 30 bolts with contact washers and tighten the
nuts as indicated hereunder using a torque wrench. Once tightened, mark each nut
with a drop of varnish (see Fig. 1).

Tightening torque for class 8.8 nuts and bolts

Bolt diameter Tightening torque (m.daN) nut with contact washer
HM6 1.3
HM8 2.8
HM10 5

Fig. 1

Fig. 2 (sliding fishplate)

Fig. 3 : option, non-sliding fishplate

22
Installation Main busbar splicing

 Joining with sliding fishplates Fig. 2.

o The sliding fishplates are sent assembled on the horizontal busbars.
o Tighten all the nuts to the indicated tightening torque using a torque wrench.
o Once tightened, mark each nut with a drop of varnish.
 Joining with non-sliding fishplate (option) Fig. 3.
o Connect the bars in the order indicated below.
- Position the fishplate starting from the bottom and sliding them up between
the busbars (see Fig. 3).
- Align the holes for bolting.
- Fit the bolts, contact washers and nuts (see Fig. 3).

NOTE
The non- sliding fishplate are supplied in a box inside the section.
Begin connections on the bars for phase 3 to ensure easy mounting
of the bolts.
3
Fig. 4

The length of the bolts depends on the number of bars to be joined as indicated
hereunder.
Recommended bolt length
Number of bars to be joined Bar thickness: 5 mm
Minimum Maximum
2 25 30
4 35 40
6 50 60
8 60 60
10 65 70

o Tighten the nuts using a torque wrench as indicated page 22.

o Once tightened, mark each nut with a drop of varnish.

In some cases, for an easier contractor access during the busbars fishplating
Fig. 5 process, the busbars supporting cross members (aluminium) can be temporarily
removed. After actual fishplating, they must be re-installed at the same position
and re-tightened with torques indicated on figures 4 and 5.

23
Installation Connection of power cables

DANGER
Turn off the power supplying the equipment before working on it. A
hazard of electric shock, burns or explosion exists whenever working
in or around the equipment.
Failure to observe these instructions will result in severe bodily
injury or death.

NOTE
b Cables must never touch or run between live conductors
(copper bars, etc.).
b When bending cables, observe the minimum bending radius
(six to eight times the cable diameter).

 First connect the Blokset earthing bar to the earth electrode to ensure the
protection of the personnel.

 Care must be taken when installing the cables to avoid placing any mechanical
strain on the connection terminals of the equipment.

 Connections through the top.

o Remove the roof or the cable gland plate.
o Drill the holes required to install cable glands or grommets.
o Install the cable glands. They must comply with high IP protection
degrees.
o Put the roof or the gland plate back on Blokset.
o Run the cables through the glands.
o The cables must run in the intended ducts and be secured to cable tie-
bars every 400 mm (see Fig. 1).
Bundle cables circuit by circuit. The number of cables in each bundle depends on
the diameter of the cables (see Fig. 1).
Cable cross-sectional area (mm2) Number of cables per bundle
≤ 10 8
16 to 50 4
> 50 Tie individually

The distance between the cable ties depends on the electro-dynamic forces and
the type of tie used.

Type of tie Maximum Isc (kA rms) Distance between ties (mm)
Width: 4.5 mm 10 200
Max. load: 22 kg 15 100
20 50
Width: 9 mm 20 350
Max. load: 80 kg 25 200
35 100
45 70

 Connection through the bottom

o Remove the bottom plate (Fig. 1A).
o Drill the holes required to install cable glands or grommets.
o Install the cable glands. They must comply with high IP protection
degrees.
o Remount the bottom
plate.
o Run the cables through the glands (Fig. 1B).
o The cables must run in the intended ducts and be secured to cable
tie-bars every 400 mm.
o If the bottom plate is not used, the cables must be secured to a tie-bar
at the bottom of the section (see Fig. 1C).

24
Installation Connection of power cables

Fig. 1

A: removal of the bottom plate.

B: incoming cables through the bottom with bottom plate and cable glands.
C: incoming cables through the bottom without bottom plate.

25
Installation Connection of power cables

 Connection of cables to the ends of the copper bars.

o Lugs are used for connections to the ends of the copper bars (see
Fig. 1). If connections are made with aluminium cables, use bi-metal lugs.
- When connections are made to several bars for each phase, position the lugs
opposite one another and insert the copper spacers supplied with Blokset (see
Fig. 1).
o All connections must be made with class 8.8 hardware and
tightened as indicated hereunder.
Tightening torque (m.daN)
Nominal diameter of bolt nut with contact wash
HM3 0.15
HM4 0.35
HM5 0.7
HM6 1.3
HM8 2.8
HM10 5
HM12 7.5
HM14 12
HM16 18.5
HM18 26
HM20 37
Once tightened, mark each nut with a drop of varnish.

 Connection of cables directly to device terminals.

When connections are made directly to the terminals of devices, different
tightening torques must be observed, depending on the various devices as
indicated hereunder.
Tightening torque (m.daN)
Circuit breaker nut with contact washer
Compact NS80 0.45 (≤ 6 mm2)
0.56 (> 6 mm2)
Compact NS100 1
Compact NS160/250 1.5
Compact NS400/630 5

NOTE
Respect the safety clearances for devices as defined by the
manufacturer to guarantee correct operation.

26
Installation Connection of power cables

Fig. 1

27
Installation Connection of auxiliary circuits

NOTE
 Auxiliary circuits must be separated from power circuits.
 Cables should, wherever possible, be run in trunking.

 Running cables in trunking:

o Trunking must be secured at least every 600 mm (see Fig. 1).
o Trunking must not be filled to more than 70% of capacity.
o Cables must not be tied inside trunking.

NOTE
Trunking must be secured using plastic screws to avoid any risk of
damaging cables.

 Connections must be made to terminals:

o All strands of a conductor must be inserted in the hole of the
terminal (see Fig. 2).
o Tighten securely, taking care not to cut strands.

 b Conductors must be shielded

(see Fig. 3): Connect the cable
shielding to earth.

28
Installation Connection of auxiliary circuits

Rg.1
•

Fig.3
Installation Final installation procedures

 Reinstall the ventilation grates, the side panels at each end and the doors in
their initial position.
 Create an equipotential connection for the doors using a green/yellow wire (see
Fig. 1).
 Install the withdrawable devices (Masterpact, Compact).
o Masterpact
- unpack the devices.
- check that they have suffered no damage that might inhibit correct operation.
- remove the two securing brackets (see Fig. 2).
- before racking in the Masterpact, check that the chassis corresponds to the
device.
- pull on the rail extraction handles (see Fig. 3).
- position Masterpact on the rails (see Fig. 4).
- make sure the device rests on all four supports.
- push on the extraction handles to insert Masterpact in the chassis
(see Fig. 5).
o Compact
Consult circuit breaker documentation and the operating manuals.

Fig. 1 Fig. 2

Fig. 3 Fig. 4

Fig. 5

30
Installation Preliminary checks

 Remove all foreign objects that may disturb switchboard operation (cable
scraps, wires, nuts and bolts, tools…).
 Vacuum the entire switchboard to remove dust.
 Check the insulation of auxiliary circuits using an electromagnetic generator.
 Check operation of the auxiliary circuits in the switchboards:
o energise and carry out operating tests for the various sequences.
 Carry out overall insulation measurements.
If a TNC earthing arrangement is used, disconnect the earth electrodes before
carrying out the insulation measurements.
Measurements should be carried out using an insulation tester and with the system
supplied by a voltage of at least 500 V DC.
The insulation-resistance value must be equal to at least 1 000 ohms/V. If the
overall insulation value is low, preheat the switchboard using a source of heat
(resistor, light bulb) for at least 24 hours to remove humidity, then carry out the
overall insulation measurements again.
b Dielectric tests have already been carried out in the factory (see the factory test
3
report).
 Final connections and checks
o v Reconnect the earth electrodes that were disconnected for the
insulation and dielectric measurements.
o v Check the electrical continuity of the various exposed conductive
parts of the assembly (presence of contact washers, presence of
equipotential connectors for doors, etc.).
o v Check, using a torque wrench, the tightness of all electrical
connections, mechanical connections and anchor bolts.
o Miscellaneous checks:
- mechanical locking of switchgear devices;
- markings on the switchboard, on power and control conductors;
- visual inspection of outside surfaces and paintwork.
Touch up any scratches or other defects.
 b Lightly grease the electrical contacts (according to breakers
manufacturer's instructions .

CAUTION
Dielectric tests subject equipment to certain stresses (ageing…) and
should not be carried out overly frequently.

31
 Installation Energising equipment for the first
time

 Rack in the Masterpact devices.

E32367

o Fit the racking crank (see Fig. 1).

o Turn the crank (see Fig. 2) until "connected" position be
indicated (see Fig. 3).
CAUTION
At the end of insertion, considerable effort is required on the crank.
This is because the device terminals must be pushed into the fixed
contacts. The required torque may be as high as 25 Nm.
Fig. 1 o v Put the crank back into its lodging (see Fig. 4).
 Insert any disconnectable circuit breakers.
 Check that all protective circuit breakers are in the open (off) position.
 Set the control units of the Masterpact devices (see the Masterpact manual) to
protect the network and, if applicable, the low-voltage distribution outgoers.
 Set the trip units on the protective circuit breakers, depending on the rating of
each outgoer.
 Set the magnetic release on each of the motor-protection circuit breakers after
examining the nameplate of the motor to be protected.
E32368

 Check that the phase rotation or index is in conformity with that of the circuits
supplying Blokset.
 One after the other, energise the power circuits in the switchboard, checking
each time that the loads are supplied and operate correctly.
 Carry out operating tests:
o Operating sequence;
o Controls, indications, measurements, protection;
o Remote-control mechanism;
o Electrical interlocks.

DANGER
Fig. 2
HAZARD OF ELECTRIC SHOCK, BURNS OR EXPLOSION
Energising the switchboard for the first time is potentially dangerous.
Therefore only qualified personnel may carry out the energising
procedure because faults, caused by shocks or incorrect installation
and not detected during the preliminary checks, may result in bodily
E32370

injury and serious damage to the equipment when the power is turned
on.
Failure to observe these instructions will result in severe bodily
injury or death, and damage to the switchboard.

Fig. 3
E32371

Fig. 4

32
Operation

Operation of Masterpact circuit breakers 34

Operation of circuit breakers 36
Drawers 38
Troubleshooting information 40

33
Operation Operation of Masterpact circuit
breakers

Consult the Masterpact documentation.

To close Masterpact (ON position):
b Charge the Masterpact operating mechanism by pulling down on the lever
seven times until a «Clack» is heard. The «charged» indication is displayed (see
Fig. 1).

Fig. 1

b If the device tripped due to an electrical fault, reset the indicator on the control
unit by pushing it (see Fig. 2).

Fig. 2

 Press the ON button. The ON indication is displayed (see Fig. 3).

Fig. 3

34
Operation Operation of Masterpact circuit
breakers

To open Masterpact (OFF position):

 Press the OFF button. The OFF indication is displayed (see Fig. 4).

Fig. 4

DANGER
HAZARD OF ELECTRIC SHOCK, BURNS OR EXPLOSION
A hazard of electric shock, burns or explosion exists whenever
working in or around the equipment. Blokset must be operated only by
qualified personnel, familiar with the installation.
4
Failure to observe these instructions will result in severe bodily
injury and damage to the switchboard.

35
Operation Operation of circuit breakers

Two types of manual control are possible.

Direct control on the circuit breaker

 Open the door to access the devices (see Fig. 1).
 The device is controlled by pushing the toggle up or down, or right or left,
depending on how the device is mounted and according to the I and O
markings engraved on the case (see Fig. 2).
I = closed (ON)
O = open (OFF)

Extended rotary handle

The control mechanism is a rotating handle (see Fig. 3 and 4).
To close a Compact circuit breaker or TeSys series :
 Turn the handle toward I (clockwise) to close the circuit breaker.
To open a Compact circuit breaker or TeSys series :
 Turn the handle toward O (counter-clockwise) to open the circuit breaker.

Recharging
If tripping is automatic or due to a circuit-breaker fault (indicated by the position of
the handle), the mechanism must be recharged prior to closing. Turn the handle
completely to the open position (1). The circuit breaker can now be closed (2) (see
Fig.5).

36
Operation Operation of circuit breakers

Fig. 1
Fig. 2
4

Fig. 3 Fig. 4

Fig.5

37
Operation Drawers

Mw2
Each functional unit is a real drawer (see Fig. 1), made up of:
 a withdrawable moving part with power plugs for busbar connection and
auxiliary contacts connector
 a fixed part for interfacing with the busbar and customer's connections (power
and auxiliaries).

Fig. 1

Identification Each unit is identified by an engraved plate mounted on the door, an

identification plate on the drawer and a mismatch-prevention system
(optional).

Description of a motor-feeder unit Door (see Fig. 2)

 Rotary handle for the circuit breaker "A".
 Optional elements:
o green OFF light "B";
o ON push-button "C";
o OFF push-button "D";
o red ON light "E";
o yellow FAULT light "F";

Fig. 2

38
Operation Drawers

Mw2 Network wiring

6 3
12 9
21 18 15 8 5 2
24
14 11 1
23 20
17 7 4
16 13 10
22 19
6 3
12 9
21 18 15 8 5 2
24
23 20
22 19
17 14

16 13
11
10 7
4 1
4
Contact no. 24 21 18 15 12 9 6 3
No network - - - - - - - - 3
- - - - - - - - 2
- - - - - - - - 1
Profibus Bus Ground - - - - - - 3
Ground Ground - - - - - - 2
Bus Ground - - - - - - 1
Modbus Bus Ground - - - - - - 3
Ground Ground - - - - - - 2
Bus Ground - - - - - - 1
DeviceNet Bus Ground - - - - - - 3
Ground Ground - - - - - - 2
Bus Ground - - - - - - 1
Modbus TCP-Star Bus Bus Ground - - - - - 3
Ground Ground Ground - - - - - 2
Bus Bus Ground - - - - - 1
Modbus TCP-Daisy chain Bus Bus Ground Bus Bus Ground - - 3
Ground Ground Ground Ground Ground Ground - - 2
Bus Bus Ground Bus Bus Ground - - 1

39
Operation Drawers

Drawers parts Drawer functional units are composed with 3 sets of pieces (see Fig. 1):
 The fixed parts:
o main part,
o customer outgoing (for side or rear connection),
o Form 4 (for side or rear connection),
 The moving parts:
o main part,
o power plugs,
 The front face:
o handles,
 Auxiliaries parts complete the functional unit:
o auxiliary connectors,
o accessories:
- compulsory: index mechanism,
- optional: mismatching system, microswitches.

Customer outgoing
Form 4 for rear connection Form 4 for side connection

Downstream power plug

Fixed part

Handle
Upstream power plug

Auxiliary connector

Moving part
Fig. 1
Front face
Index mechanism

Positions The drawer may be set to any of three positions

 Connected position (see Fig. 2a)
Power and auxiliary circuits are all connected.
 Test position (see Fig. 2b)
Power circuits are disconnected (upstream and downstream),
auxiliary circuits remain connected.
 Disconnected position (see
Fig. 2c) All circuits are
disconnected.

input auxiliaries output input auxiliaries output input auxiliaries output

plugs plug plugs plugs plug plugs plugs plug plugs

< <<
Fig. 2a Fig. 2b Fig. 2c
40
Operation Drawers

Manipulation of a drawer  b General: passing from one position to another

o operation of the drawer impossible apparatus closed: open the apparatus
o seize the drawer by the handles and press and hold the black release button.

 Withdrawing
o pass from the «connected» to the «test» position, then to the «disconnected»
position
o the positioning mechanism locks the drawer in the selected position.

4
drawer implemented in the lower side of the column

 Removal
o pull the drawer with the handles to the pre-extraction hard point
o position the hands as indicated on the diagrams and extract the drawer
o be careful with grease present on the mechanisms.

 Putting into position

o engage the drawer in its cell, positioning the hands as indicated
on the diagrams
o check that the apparatus is in open position
o using the two handles, push the drawer to the «disconnected» position

NOTE
If the drawers are equipped with mismatching device, check the
consistence of drawer and cell.

Secure a funcional unit  Each functional unit can be secured with:

o 1 to 3 padlocks on the rotary handle
o 1 padlock on the push-button
Using the GV2V03, the push-button can be secured with up to 6 padlocks.

41
Operation Troubleshooting information

In the event of any switchgear device problems, consult the corresponding

manuals:
 Blokset switchboard - consult the section on "operation".
 Masterpact circuit breakers: consult the corresponding manuals.
 Compact NS circuit breakers: consult the corresponding manuals.
 TeSys series circuit breakers, consult the corresponding manuals.
 TeSys series contactors and relays, consult the corresponding manuals;
 If the fault persists, contact your local Schneider Electric office.

DANGER
Turn off the power supplying the equipment before working on it. A
hazard of electric shock, burns or explosion exists whenever working
in or around the equipment.
Failure to observe these instructions will result in severe bodily
injury or death.

42
Maintenance

General maintenance 42
Preventive maintenance 45

43
Maintenance General maintenance

Periodic checks on Blokset must be carried out in accordance with applicable

regulations.
Periodic maintenance must be carried out once a year or more, depending on the
stipulations in the servicing conditions and the maintenance contract.

DANGER
HAZARD OF ELECTRIC SHOCK, BURNS OR EXPLOSION
Turn off the power supplying the equipment before working on it. A
hazard of electric shock, burns or explosion exists whenever working
in or around the equipment.
Failure to observe these instructions will result in severe bodily
injury or death.

Maintenance on fixed parts Common maintenance operations for the entire range.
 Check inside and outside the switchboard for moisture or foreign
of the switchboard (Fig. 1) material. Remove any foreign material and clean the switchboard.
 Use a vacuum cleaner to clean. If necessary, clean the ventilation system and
change the filters.
 Clean old grease off all mechanical parts and regrease lightly (ref. 87635).
 Examine the outer finish of the switchboard. If necessary, touch up any paint
scratches and replace any damaged or rusted parts.
 Check the insulation monitoring devices.
 Run tests on the indication systems.
 Visually check the busbars:
o Assembly screws for busbars do not need to be tightened as long as the
varnish, guaranteeing correct tightening torque, is intact;
o The check on busbar connections is, therefore, strictly visual to detect any
hot points (change in colour).
If a hot point is detected, the assembly must be dismounted. Clean and sand the
contact surfaces (sand paper grade 400). When remounting:
- use identical (class 8.8) new hardware (bolts, nuts and washers);
- tighten as indicated in the table below;
- apply varnish.
 Visually check the condition and tightness of the busbar supports.
 Check the tightness of customer cables.
 Run a check on the switchgear devices.
 Consult the corresponding manuals.
Table indicating tightening torques
The table below indicates the correct tightening torque for class 8.8 hardware
with nuts and contact washers.
Diameter of bolt Tightening torque (m.daN)
nut with contact washer
HM3 0.15
HM4 0.35
HM5 0.70
HM6 1.3
HM8 2.8
HM10 5
HM12 7.5
HM14 12
HM16 18.5
HM18 26
HM20 37

NOTE
 Do not clean using compressed air to avoid blowing contaminants to
other surfaces.
 For cleaning purposes, use dry cloths or cloths dipped in
denaturated alcohol. All other products are forbidden.
 Never allow plastic parts (supports for busbars and disconnecting
contacts) to come into contact with grease or detergents.

44
Maintenance General maintenance

tripped ON

reset
O
OFF

tripped
ON
I

O tr∅5...8
ipped
OFF
TRIP
OFF

∅5...8

OFF ON
ON
ON

TRIP ON
OFF

∅5...8
5
ON

reset
O
OFF

ON
I

tr∅5...8
ipped

ON
I

tr∅5...8
ipped

RAL 9002

Fig. 1

45
Maintenance General maintenance

Maintenance on fixed parts Additional maintenance for withdrawable Blokset switchboards.

 Check the condition of the busbars opposite the disconnection contacts
of the switchboard (cont.) (no corrosion or pitting). Remove any grease from plastic parts.
 Check the correct position of auxiliary contacts and their condition.
 Clean the rails and remove any trace of grease. Then lightly regrease (ref.
87635).

Maintenance on drawers  Check the connection/disconnection mechanism for correct operation.

Lightly grease the cam ramp and the connection roller (ref. 87635).
 Clean the disconnecting contacts. Lightly grease those elements that
make electrical contact (ref. 87635).
 Check that the auxiliary contact blocks on the fixed part move freely.
 Check the position of the auxiliary contacts on the drawer.
 Check the condition of the auxiliary contacts.
 Check all connections.
 Check the tightness of connections to the devices (presence of the varnish).
If necessary, retighten according to torque values in the tables.
 Check the switchgear devices (consult the corresponding manuals).

Checks prior to energising  Check the earthing of all exposed conductive parts.
 Check equipotential connections.
 Carry out insulation measurements.

Maintenance after a fault has occurred The high currents resulting from a fault cause damage to structures, components,
busbars and cables.
Following a fault, contact your local Schneider Electric office.

DANGER
HAZARD OF ELECTRIC SHOCK, BURNS OR EXPLOSION
To prevent accidental contact with live parts, all equipment must
be de-energised, disconnected and isolated. Before working on
the equipment, check that there is no voltage present on any of the
incoming and outgoing terminals of the circuit breakers, contactors
or starters in the switchboard. Only qualified personnel may carry out
inspection and repair procedures and all safety procedures must be
observed.
Failure to observe these instructions will result in severe bodily
injury or death.

46
Maintenance Preventive maintenance

Frequency of preventive maintenance The frequency of preventive maintenance depends primarily on the operating
conditions of the electrical switchboard.
For operating conditions found in normal environments, the frequency at which
maintenance should be carried out is indicated in the table below.
The frequency may be lower if the switchboard is used in a particularly clean
environment and not in an intensive manner. On the other hand, if the switchboard
is used in a particularly aggressive environment (dust, humidity, corrosive vapours,
heat) or is used intensively, the frequency of maintenance must be higher.
Type Action Frequency
General inspection  General check Once a year
 General cleaning
 Greasing of mechanical parts

Maintenance on
main
busbars
 Check on contacts Every two years
(or during a break
in production)
5
Maintenance on According to operating
switchgear devices manuals of manufacturers

Maintenance on  Remove all the drawers. This Once a year

drawers operation will eliminate any fretting
corrosion on the electrical contacts.
 Visually check the contacts and Once a year
disconnecting contacts.
 Apply a grease (ref. 87635).
 Lubricate all moving parts. Once a year
 Retighten all connection points. Once a year
 Check visual appearance and Once a year
securing of the output connection
block on the fixed part.
 Check the tightness of all power and Once a year
control connections.

NOTE
By cleaning, we mean elimination of dust and excess grease using a
brush or a dry cloth.
By lubricating, we mean applying grease with a brush to the
articulations and the guides of the drawer.

 Thermal monitoring for Mw2

o unscrew the 1/4 turn screw
o unlock the protection device rotary handle
o open the door
o execute thermal monitoring
o close again the door.

Mw2

47
48
Evolution

Extensions 48

49
0Eiectric
Evolution Extensions

Cubicle evolution The modular design of Blokset switchboards makes possible the addition of
extensions or modification of functional units.

Installing a new drawer in a Mw2

 Remove front plates to free the space for the new drawer
 Install the parts to make the fixed part functional (metal parts, proof falling,
 position guide, index mechanism stop and customer outgoing parts)
 Insert the new drawer.

NOTE
In any case, it is recommended to wire auxiliary contacts as soon as possible
In case of half drawer, it is recommended to equip the left one first.

Fig. 1

Fixed starter

 Open the door of the mounting space chosen for the extension.
 Install the mounting plate with its starter and the control and indication
devices in the frame.
 Make connections between:
o the starter input and the vertical busbars;
o the starter output and the load.
 If applicable, wire the auxiliaries to the customer terminal block
(position indication contacts, fault-indication contact, shunt trip).
 Set the protective devices.
 Prior to energising, make a preliminary check:
 order of phases;
 elimination of foreign material (cable scraps, nuts and bolts, tools);
 carry out insulation measurements.
b Energise the system.

DANGER
Turn off the power supplying the equipment before working on it. A
hazard of electric shock, burns or explosion exists whenever working
in or around the equipment.
Failure to observe these instructions will result in severe bodily
injury or death.

50
 s1
0Eiectric
Evolution Extensions

Adding a section NOTE

The procedure presented below is for the addition of a section on the
right-hand side of Blokset switchboard. For additions on the left-hand
side, the procedure is the same, simply interchange the words left and
right.

Fig. 1
 Remove the right side panel of the Blokset switchboard.
 Remove the hooks holding the panel.
 Position the new section next to the switchboard.
 Secure the new section to the floor using M10 anchor bolts.
 Make connections between the two sections using HM6x16 bolts.
 Splice the earthing bars.
 Splice the horizontal busbars.
 Connect the outgoers.
 Connect the auxiliaries.
 Refit the panels.
 Prior to energising, make a preliminary check.
o Remove all foreign objects that may disturb switchboard
operation (cable scraps, wires, nuts and bolts, tools, etc.).
o Vacuum the entire switchboard to remove dust.
o Carry out overall insulation measurements.
If a TNC earthing arrangement is used, disconnect the earth electrodes before
carrying out the insulation measurements.
Measurements should be carried out using an insulation tester and with the system
supplied by a voltage of at least 500 V DC. The insulation-resistance value must be
equal to at least 1000 ohms/V
o Check the electrical continuity of the various exposed conductive
parts (presence of contact washers, presence of equipotential
connectors for doors, etc.).
 Check the tightness of all electrical connections, mechanical connections
and the anchor bolts.
 Miscellaneous checks: mechanical locking of switchgear devices;
markings on the switchboard, on power and control conductors.
o Visual inspection of outside surfaces and paintwork. Touch up
any scratches or other defects.
 Then proceed with energising.

52
 Evolution Extensions

Fig. 1

53
0Eiectric
Evolution Extensions

Adding a section  Assembling

Mw2 / Mw2 Mw2 / D D/D

Cubicles are assembled with M6 x 16 screws

54