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Installation manual

LVRSys™ - 3-phase systems

Low Voltage Regulation System

Outdoor installation Al

Outdoor installation GRP

Pole mount

Indoor installation

Systems of the series: 180.1000.2xxx

Delivered from III/2019

Содержание Low Voltage Regulation System

Страница 1: ...lation manual LVRSys 3 phase systems Low Voltage Regulation SystemTM Outdoor installation Al Outdoor installation GRP Pole mount Indoor installation Systems of the series 180 1000 2xxx Delivered from III 2019 ...

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Страница 3: ...itch cabinet 9 4 2 2 Switch cabinet GRP 11 4 2 3 Installing the Switch cabinet indoors using a crane and the lifting lugs 12 4 2 4 Pole Mount cabinet with crane lugs 13 4 2 5 Lifting the Transformer with a crane using the lifting lugs 13 4 2 6 Concrete base 14 5 Installation 15 5 1 Fuse protection 16 5 1 1 Fuse protection for systems with switch disconnector fuses 16 5 1 2 Fuse protection for syst...

Страница 4: ...5 4 3 Transformers 41 5 4 4 Mounting the base LVRSys indoor installation on the floor 41 5 4 5 Connecting the low voltage cables 42 5 5 Pole mount Systems 46 5 5 1 Mounting the LVRSys on the pole 46 5 5 2 Connecting the low voltage cables on the grid side 50 5 6 External installations 51 6 Commissioning Decomissioning LVRSys 52 6 1 Lights Switches 52 6 2 Commissioning and decomissioning LVRSys 52 ...

Страница 5: ... 1 2 Warnings Structure of the warnings Warnings are structured as follows SIGNAL WORD Type and source of danger Consequences of non compliance Measures to avoid the danger Gradation of the warnings Warnings differ according to the type of hazard as follows DANGER Warns of an imminent danger leading to death or serious injury if not avoided WARNING Warns of potentially hazardous situation leading ...

Страница 6: ...List level 2 Structure of numbered lists 1 List level 1 2 List level 1 1 List level 2 2 List level 2 1 5 Other applicable documents For safe and correct use of the system also observe the additional documents supplied as well as relevant standards and applicable local regulations 1 6 Storage Keep the installation manual including all applicable documents in close proximity to the LVRSys system ...

Страница 7: ... 0 LVRSys control unit for installation in external control cabinets 0 Transformer block 0 Control cabinet for outdoor or indoor installation or pole mount 0 Base for outdoor installation 0 Operating instructions LVRSys 0 Installation manual LVRSys 0 Circuit diagram of the control cabinet LVRSys 0 Test certificate LVRSys ...

Страница 8: ...ng Figure 3 1 Switch cabinet packed in wood example For special regulations e g export the packaging may differ Figure 3 2 Packaging shock sticker To protect the system the packaging consists of particle board pieces Before opening the crate check the shock sticker ADVICE If the sticker is RED Do not remove packaging Contact A Eberle GmbH Co KG for further information ...

Страница 9: ...on The transformer block is packed in foil cardboard or wood selected order feature lying on pallet 3 3 Concrete GRP base 0 Outdoor installation The base is packed in foil concrete base cardboard GRP base or wood selected order feature lying on pallet ...

Страница 10: ...binets must be transported vertically Pole mounting systems can also be transported horizontally CAUTION Avoid damage to the switch cabinet due to incorrect handling during transport Only Transport the switch cabinet upright Ensure that the switch cabinet cannot tip over while in transit Fasten mounting devices on the board wall Figure 4 1 Cabinet transport on truck ...

Страница 11: ...ION Damage to the system if the control cabinet is dropped Always secure the LVRSys switch cabinet by the lifting lugs Only lift the cabinet vertically deviation up to a maximum of 60 to the lifting lugs Ensure the lift upward of the LVRSys switch cabinet is done smoothly without any jerks 4 2 1 Use of a crane and the lifting lugs of the Aluminum switch cabinet Transport lugs are located under the...

Страница 12: ... of it Figure 4 2 Installing and removing the weather protection roof The screws can be loosened and fastened with a TX 25 screwdriver The tightening torque may not exceed 6 Nm Use all four transport lugs 1 2 3 4 5 6 1 2 7 ...

Страница 13: ...occur through incorrect handling during transit Only transport the switch cabinet in an upright position Ensure that the switch cabinet cannot tip over Ensure fastening of holding devices to the tailboard Use mobile crane lugs Then seal the switch cabinet with blind plugs Figure 4 4 mobile crane lugs ...

Страница 14: ...d CAUTION Damage to the system will occur if the switch cabinet is dropped Always secure the LVRSys switch cabinet with all lifting lugs Only lift the cabinet up vertically deviation up to a maximum of 60 to the lifting lugs Lift the LVRSys switch cabinet up smoothly avoiding any jerks Systems with more than 800 kg can only be lifted vertically straight up CAUTION Damage to the system will occur i...

Страница 15: ...ransformer blocks must be lifted into the ground base DANGER Risk of fatal injury if the transformer block is dropped Ensure that nobody is standing nearby or under a suspended load CAUTION Damage to the system if the transformer block is dropped Always secure transformer block using all lifting lugs provided Only lift or lower the transformer block in a vertical movement deviation up to a maximum...

Страница 16: ...k with four lifting lugs Use all four lifting lugs 4 2 6 Concrete base DANGER Risk of fatal injury if the concrete base is dropped or falls over Ensure that nobody is standing close by or under a suspended load There are no special transport considerations ...

Страница 17: ...minum con ductor For direct connection terminals With aluminum conductors the oxide layer must be mechanically removed immediately before contacting and treated with acid and alakali free grease The installation location must be kept as free as possible from mois ture or aggressive atmosphere If an aluminum conductor is used the screw in the terminal body of the screw terminal must be tightened to...

Страница 18: ...ces Coordinated fuse protection 400 V L L NH fuse gG NH2 32 A 22 kVA system 63 A 44 kVA system 100 A 70 kVA system 160 A 110 kVA system 200 A 144 kVA system 250 A 175 kVA system 355 A 250 kVA system NH fuse gTr NH3 630 A 400 kVA system 910 A 630 kVA system Table 5 1 Fuse protection of the systems at the switch disconnector fuse block input 400 V L L Protective devices Coordinated fuse protection 2...

Страница 19: ...system 160 A 64 kVA system 200 A 84 kVA system 250 A 101 kVA system 355 A 145 kVA system NH fuse gG NH3 2 x 500 A 400 kVA system Table 5 4 Fuse protection of the systems at the disconnector block input 230 V L L 5 1 3 Fuse protection for systems with automatic circuit breakers Protective devices Coordinated fuse protection 400 V L L Automatic circuit breaker C 32 A 22 kVA system 63 A 44 kVA system...

Страница 20: ...2 1207 X MI5HT25V5 582 1020 05 MI5HT25V2 582 1020 02 355 A 10 to 580 A 8 NH00GR50V80 582 1246 D02GG40V25 582 1205 MI5HT25V8 582 1020 08 MI5HT25V5 582 1020 05 580 A 10 to 910 A 6 NH00GR50V100 582 1247 D02GG40V35 582 1206 MI5HT25V8 582 1020 08 MI5HT25V5 582 1020 05 910 A 8 to 910 A 10 NH00GR50V125 D02GG40V50 582 1208 MI6SA12 5V25 MI5HT25V6 3 582 1020 06 30 Table 5 7 Protection of the systems interna...

Страница 21: ... concrete base and GRP base Generally the base is anchored in the ground so that tilting and sagging can not be caused Work to be carried out Dig a 110 cm to 130 cm deep hole in the ground Use ballast and gravel and concrete of adequate depth to form a solid foundation Level the foundation Install the base and fix it with the foundation stability Figure 5 1 Foundation Special requirements of the G...

Страница 22: ...2x Front and back wall bottom large plate 3 2x Front and back wall top small plate 4 1x Base plate 5 1x Mounting points for control cabinet M12 Mounting material Mounting screws Tabelle 5 8 Explanation of the numbering and delivery scope Two people are required to set up the plinth Required tools 0 Spirit level 0 Spanners 13mm and 19mm with 25 Nm ...

Страница 23: ...llowing illustrations show the plinth assembled on the ground In practice assembly can actually take place in the hole in the ground In the situation of the concrete plinth being assembled above ground then a crane will be required to lift and lower the plinth into position into the hole Align base plate with recesses facing up wards Place the side panels on the base plate with the folds facing up...

Страница 24: ...e larger plate at the bottom with 2 screws and brackets to the side parts Then connect the smaller plate at the top with 2 screws and angle brackets to the side panels The installation depth of the concrete plinth down into the ground should be around 70 cm Figure 5 4 Concrete plinth mounting ...

Страница 25: ...om 3 1x Front wall top without locking slide 4 1x Rear panel top 5 1x Longitudinal stabilization rail no use 6 1x Cable fixing rail 7 2x Mounting rail for standard cable distribution cabinet 8 2x Blanking plugs for construction site closure 9 Gr 1 1x Gr 2 2x Cross stabilization bar 10 2x Fixing nut for PEN bus bar mounting Table 5 9 Explanation of numbering ...

Страница 26: ...anels 2 at an angle into the side panels 1 fold them in and press them down Proceed according to the same principle for the top rear panel 4 and the top front panel Then press two locking slides out wards into each of the side walls Note the top front wall has no locking slides Insert the fixing rail 7 to secure the cabinet in the two holders on the side walls 1 If necessary insert the supplied fa...

Страница 27: ...uded with every size 2 base Figure 5 6 GRP base mounting Installation of the C profile rails to strengthen the side panels both side elements Figure 5 7 installation of the C profile rails Installation of the C profile rail to fix the cable clamp on the right side below the NH switch disconnectors Figure 5 8 Installation of the C profile rail for the cable clamps ...

Страница 28: ...ional On the Transformer block preliminary stage the connection cable LIN is on the left and the connection cable LOUT is on the right Position the transformer block so that it is not touching any of the walls of the plinth or switch cabinet Figure 5 9 Top view of concrete base transformer block the optional preliminary stage 1 Transformer block 2 Connection cable load bar thick cables 3 Connectio...

Страница 29: ...se may be filled with earth Base fillers may only be used above the transformer block 5 3 7 Mounting the switch cabinets for outdoor installation onto a base Figure 5 11 Mounting ducts left aluminium cabinet right GRP cabinet Connect the switch cabinet through four mounting ducts with the base Only use the provided screws M 12 x 25 mm ...

Страница 30: ...and unlock it to the right 2 Unscrew the fastening screw M5 from the locking cylinder 3 Pull out the locking cylinder towards the switch cabinet 4 Push in the new locking cylinder 5 Screw the fastening screw M5 into the locking cylinder 6 Lock the key in the locking cylinder and turn it to the left 7 Close the lock cover to the left 8 Figure 5 12 Installing and removing the locking cylinder 1 2 3 ...

Страница 31: ...the top of the handle 5 3 9 Connection of the transformer block to the control unit For outdoor installations the transformer block and the LVRSys switch cabinet consisting of the control unit and the bypass system must always remain connect ed In complete indoor installation systems the connections are completed during manufacture 5 3 9 1 Transformer contact plug systems 32 A 6 to 160 A 10 Place ...

Страница 32: ...t plug 200 A 6 to 355 A 8 5 3 9 3 Transformer contact plug systems 355 A 10 to 580 A 10 Place the coded plug at the bottom of the case Lock the plug Fix the cables with cable clamps Figure 5 16 Transformer contact plug 355 A 10 to 910 A 5 3 9 4 Transformer contact plug systems 910 A 6 to 910 A 10 For 910 A systems 6 lines must be routed through cable glands The lines must be connected in accordanc...

Страница 33: ...g or Al Cu cable lugs With sector conductors make sure that the conductors nestle in the terminal Figure 5 18 Sector conductors in connection terminals 5 3 10 1 Systems with fuse switch disconnectors Connect local grounding point to PE N rail Connect PEN input transformer grid connection to PE N rail Connect PEN output load grid connection with PE N rail Connect transformer block with PE N rail Co...

Страница 34: ... 19 Overview of terminal points for TN C systems and fuse switch disconnectors TN S TT system The N rail is located behind the covers of the load switch rails Figure 5 20 Overview of clamping points for TN S TT systems and fuse switch disconnectors ...

Страница 35: ...connection points fuse disconnectors 180 mm d2 Centre distance PE N rail to C profile rail cable catch Aluminum housing 215 mm GRP housing 145 mm d3 Centre distance N conductor terminal block to C profile rail Aluminum housing 290 mm GRP housing 190 mm Table 5 11 Explanation of the graphics Torques of the connection points No Explanation IN 160 A 160 A IN 355 A Flat connection Feature D1 Frame cla...

Страница 36: ...lug 43mm NH3 M12 35 40 Nm Cable lug 43mm Table 5 13 Torques and connection technology depending on rated current up to 910 A 5 3 10 2 Systems with terminals The operation of the terminals is described in chapter 5 3 10 3 Connect the local grounding point to the PE N rail Connect PE N input transformer grid connection to PE N rail Connect PE N output grid connection load to PE N rail Connect transf...

Страница 37: ...Page 35 TN C system Figure 5 21 Overview of terminal points for TN C systems and connection terminals TN S TT ystem Figure 5 22 Overview of terminal points for TN S TT systems and terminals ...

Страница 38: ...hick cables of the transformer block L1IN L2IN L3IN 5 F2 Customer connection input side direction local grid transformer 7 F4 Customer connection output side direction load 8 F5 3x connecting cable thick cables of the transformer block L1OUT L2OUT L3OUT d1 Centre distance PEN rail to connection points fuse switch disconnector block 180 mm d2 Centre distance PEN rail to C profile rail cable catch A...

Страница 39: ...ors of the same cross section as shown in Figure 5 24 Insert conductors in sector version according to Figure 5 24 Assemble terminal according to Figure 5 24 Tighten terminal to torque as shown in Figure 5 23 Install the cover as shown in Figure 5 25 Figure 5 23 Photo instruction use of terminal block 1 ...

Страница 40: ...Page 38 We take care of it Figure 5 24 Photo instruction use of terminal block 2 ...

Страница 41: ...il Feed the transformer cable LVRSysOUT through the transformer Connect the transformer cable LVRSysOUT to the NH00 Safety Edge Fix transformer with screw from above and transformer cable with cable tie to transformer cable LVRSysOUT Figure 5 26 Cable routing of the transformer cables LVRSysOUT through the walls and fixing to the cable 5 3 10 5 Current transformers for NH00 switch disconnectors th...

Страница 42: ...mer block connection cables LVRSys OUT through the current transformer 5 3 10 6 Current transformers for NH2 NH3 safety edges Current transformers are integrated in the LVRSysIN F1 input current measurement or LVRSysOUT F5 output current measurement safety edges ...

Страница 43: ...r area 5 4 2 Base mounting Systems for indoor installation are supplied with a pre assembled base 5 4 3 Transformers Systems for indoor installation are supplied with pre assembled transformers 5 4 4 Mounting the base LVRSys indoor installation on the floor Figure 5 28 Fixing passages for socket Prepare holes and dowels for fixing the base to the floor Connect the base to the floor using four fixi...

Страница 44: ... copper lines Aluminum conductors may only be connected in the sector conductor version TN C system connection terminals Figure 5 29 Overview of the terminal points for TN C systems and connection terminals TN C system flat connection Figure 5 30 Overview of the terminal points for TN C systems and flat connection ...

Страница 45: ...m connection terminals Figure 5 31 Overview of terminal points for TN S TT systems and connection terminals TN S TT system flat connection Figure 5 32 Overview of the terminal points for TN S TT systems and flat connection ...

Страница 46: ...fixing the cables d1 Centre distance C profile rail to connection points 300mm Table 5 15 Designation of the figures Figure 5 29 Figure 5 30 Figure 5 31 Figure 5 32 No Frame clamp Flat connection 1 5 UKH 70 Feature D31 16 70 mm Cu 50 70 mm Al se RBO 10 Feature D51 M10 6 150 mm UKH 95 Feature D32 25 95 mm Cu 70 95 mm Al se RBO 12 Feature D52 M12 25 240 mm UKH 150 Feature D33 35 150 mm Cu 120 150 mm...

Страница 47: ... plastic ferrule 50mm 150mm Stripping length 40 mm Screw thread M10 Tightening torque 25 Nm 30 Nm UKH 240 IN 415 A Rigid 70mm 240mm Flexible 70mm 240mm Flexible with wire end ferrule without plastic ferrule 70mm 185mm Stripping length 40 mm Screw thread M10 Tightening torque 25 Nm 30 Nm RBO 10 IN 309 A Screw thread M10 Cable lug connection 6mm 150mm Maximum cable lug width 30 mm Tightening torque ...

Страница 48: ...rewing 5 5 1 1 Mounting on a round pole Special mounting clamps are available for round poles which are individually manufactured according to the diameter of the pole Connect the flat bar of the mounting clamp to the switch cabinet M10 45 Nm Lifting and aligning the system with a crane Connect round bracket with counterpart M 12 75 Nm Positioning the pole clamps 3 phase Upper clamp at height 1165...

Страница 49: ...on switch cabinet 5 5 1 2 Mounting on an rectangled pole The mounting system will be delivered with 0 3 mounting rails on the back of the cabinet 0 3 mounting rails for fixation 700 mm long 0 7 threaded rods 700 mm long M12 0 7 movable pipe ring saddels 0 Fixing nuts and washers ...

Страница 50: ...gure 5 37 Installation thread rods in ring saddle Needed tool Spanner with SW 19mm Tinst 31 Nm 24 ft lb On upper installation channel have to be 3 thread rods The middles thread rod has to be installed through the pole therefore is a hole in the middle of the pole necessary min 30 mm diameter Lift cabinet to the pole Fixation of the cabinet through installation channels with washers and nuts see F...

Страница 51: ...Page 49 Figure 5 37 Installation thread rods in ring saddle Figure 5 38 Top view pole installation ...

Страница 52: ...C system connection terminals Figure 5 39 Overview of terminal points for TN C systems and connection terminals TN S TT system connection terminals Figure 5 40 Overview of terminal points for TN S TT systems and terminals No Explanation 1 Connection for customer input cable L1IN L2IN L3IN 2 Connection for customer cable N TN S TT System 3 Connection for customer cable PEN TN C System 4 Connection ...

Страница 53: ...ool Internal hex SW 5 5 6 External installations You must select characteristic P1 during the ordering process The installation space is also required This may change the size of the housing By default an installation space of W D H 400 mm 100 mm 300 mm is available ...

Страница 54: ...ys OUT 0 The controller is in the Off state DANGER Risk of fatal injury from electric shock Ensure that the LVRSysTM is only operated and put into operation by qualified electricians or persons trained in electrical engineering who are either certified in accordance with VDE 0105 100 or certified with respect to the local wiring and safety regulations applicable in your country Never partially ope...

Страница 55: ...LVRSys Decommissioning LVRSys BYPASS Sequence 1 Set the system switch to OFF position Wait until secondary electronics is de energised Display goes out after approx 10 s 2 Close BYPASS F3 with knives 3 Open LVRSys OUT F5 remove knives fuses 4 Open LVRSys IN F1 remove knives fuses The LVRSys is completely disconnect ed from the network The BYPASS is active The network is supplied via the BYPASS Che...

Страница 56: ...tch disconnector with respect to PEN PE busbar Systems with LV fuse switch disconectors Check that there is NO VOLTAGE meaured on L1 L2 L3 directly on the outgoing fuse switch disconnector with respsect to PEN PE busbar 6 4 Current transformer N PEN rail DANGER Danger of electric shock Short circuit the disconnect terminal blocks In bypass operation the 3 phases are bypassed The neutral conductor ...

Страница 57: ...dance with VDE 0105 100 or certified with respect to the local wiring and safety regulations appli cable in your country Only operate the circuit breaker using the operating handle Fast operation of circuit breakers Figure 6 4 Connection and BYPASS function 1 Circuit breaker for LVRSysIN F1 2 Terminal block for external input cables mains connection transformer 3 Circuit breaker for BYPASS F3 4 Te...

Страница 58: ... respect to the local wiring and safe ty regulations applicable in your country When switching the devices the following must be observed Ensure that commissioning decommissioning and operation are only carried out by qualified electricians or persons trained in electrical engineering in accordance with VDE 0105 100 or certified with respect to the local wiring and safety regulations appli cable i...

Страница 59: ...Page 57 Figure 6 6 Operation switch disconnector 1 2 3 4 5 Figure 6 7 NH switch disconnectors ...

Страница 60: ...for LVRSysIN F1 internal transformer block secondary line input 2 Connection of switch disconnector for external input cables mains connection transformer F2 3 Coupling strip BYPASS F3 4 Connection of switch disconnector for external output cables mains connection load F4 5 Connection switch disconnector for LVRSysOUT F5 internal transformer block secondary line output Table 6 3 Explanation of num...

Страница 61: ...licable in your country When switching the devices the following must be observed Ensure that commissioning decommissioning and operation are only carried out by qualified electricians or persons trained in electrical engineering in accordance with VDE 0105 100 or certified with respect to the local wiring and safety regulations appli cable in your country Ensure that only fuse links with silver p...

Страница 62: ...ate BYPASS fuse switch disconnector according to instructions See chapter 6 2 Commissioning and decomissioning LVRSys 1 Connection fuse switch disconnector for LVRSysIN F1 internal transformer block secondary line input 3 Fuse switch disconnector BYPASS F3 5 Connection fuse switch disconnector for LVRSysOUT F5 internal transformer block secondary line output Table 6 4 Explanation of numbering ...

Страница 63: ...Notes ...

Страница 64: ...Nürnberg Tel 49 0 911 62 81 08 0 Fax 49 0 911 62 81 08 96 E Mail info a eberle de http www a eberle de Last updated 11 04 2019 Version 180 1000 2xxx_Installation_manual_LVRSys_Standard_en_V_1_10_RC2 docx Copyright 2013 2019 von A Eberle GmbH Co KG ...

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