Cable Distribution Cabinets Utility Networks ENSTO Group is a privately owned group of companies manufacturing electrical products. Ensto began its operation in 1958 in Porvoo, Finland. Down the years, Ensto has grown from a modest workshop into an international group with subsidiaries in 12 countries. The total turnover of the Ensto group is about 200 USD and total number of personnel 1900. ENSTO UTILITY NETWORKS manufactures accessories for electricity distribution lines to utilities and power companies, as well as, components for railway electrification all over the world. Ensto Sekko Oy has a certified ISO 9001 Quality Standard and an ISO 14001 Environment Management Standard. The Ensto cable distribution cabinet system consists of a full range of products for LV cable network for power distribution including different kinds and sizes of cabinets, fuse-switch disconnectors, connectors and also accessories and tools. 2 KS-DESIGN 2000 We have developed a Windows-based program ”KS-Design 2000” to help the design of cable distribution cabinets. With the program, a designer can easily choose the right cabinet size and components. The program also creates material lists of cabinet and project, circuit diagrams and layout diagrams of the cabinets. The used components, fuse sizes, cable types and sizes and cable addresses can be seen in the circuit diagram. All used components, as well as, material and labour costs can be seen in material lists. It is also possible to add own components, like cables and terminations, to material lists. KS-Design 2000 3 Cable Distribution Cabinets 4 Branch off Cabinets 5 Empty Cabinets 6 Mounting plates for empty cabinets 7 Swicthes and Earthing Covers 8 Connectors 9 Busbars 10 Adapters and tools 11 Accessories 12 Dimension drawings 14 Surface treatment – How and why 15 3 CABLE DISTRIBUTION CABINETS Cable distribution cabinets and bases are made of sendzimirgalvanized 2 mm steel sheet. The roof, which is isolated to prevent condensation of water, is of 2 mm stainless steel. The roof can also be removed when installing mounting plates. The corrosion properties have been improved by polyester powder coating, see page 15. Life expectancy of the cabinets is over 25 years. The standards colour is RAL 7037 grey. The cabinets are suitable also for 5-core system with earthing set EJS5, see page 13. The protection class of the cabinets is IP43 and IP20 for busbars and components, which makes live line work possible without any special tools or working methods. The cabinets also fulfil the requirements of EN 60439-5 standard. Modular system All the components for the busbar, like switches and components, are dimensioned with the modular system. The space needed for the components is stated in the number of modules (a’ 6 mm), which makes it easy to choose the right cabinet size, see page 14. External connections The cabinets can be connected to each other with the connection set. The same fixing points can be used with the marking bar. Temporary current output The cabinets are equipped with a hole on both sides of the cabinet for temporary current output. The holes can also be locked. Identification Inside the cabinet, there is a place for the cabinet form. External identification can be done with identification plates, see page 13. Locking The standard locking of all the cabinets is triangle locking. Other alternatives can be delivered according to agreement. b b d Fixing of the cables Cables are fixed to adjustable fixing bar with standard cable clamps. 4 h h 900 The base of the cabinet is integrated into the construction. The base is locked inside the cabinet during transportation and it is pulled out and locked to the right place during installation. Cabinets without base are also available for pole, concrete base or floor mounting. 900 Bases CABINETS WITH 630 A, IP20 BUSBAR AND BASE Grey RAL 7037 cable distribution cabinets Type E-KSEA 6-26 E-KSEA 6-44 E-KSEA 6-50 E-KSEA 6-72 E-KSEA 6-94 E-KSEA 6-117 E-KSEA 6-183 EAN-no. 5702665985818 5702665985979 5702665986082 5702665986297 5702665986501 5702665986716 5702665987133 Modules Width/mm Height/mm Depth/mm Weight/kg 26 198 850 198 18 37 264 850 198 21 48 330 850 198 24 70 460 850 198 34 92 595 850 198 38 116 795 850 198 60 182 1190 850 198 74 Green cable distribution cabinets Type E-KSEC 6-26 E-KSEC 6-44 E-KSEC 6-50 E-KSEC 6-72 E-KSEC 6-94 E-KSEC 6-117 E-KSEC 6-183 EAN-no. 5702665985788 5702665985795 5702665986099 5702665986303 5702665986518 5702665986723 5702665987140 Modules Width/mm Height/mm Depth/mm Weight/kg 26 198 850 198 18 37 264 850 198 21 48 330 850 198 24 70 460 850 198 34 92 595 850 198 38 116 795 850 198 60 182 1190 850 198 74 BRANCH OFF CABINETS The branch off cabinets are designed for branching of cables with branching connectors without fuse-switches or busbar. In the E-KSE_ 26.2 cabinet the branching (max. 50 mm2) is done with a connector set SV50, when it is possible to branch two cables in a ring network and three cables in an ending cabinet. If more branches are needed, the branching is done with KE 10.506 connectors. There is the M8 earthing screw in the cabinet. In the E-KSE_ 44.2 cabinet the branching (max. Al 95 mm2) is done with SL19.4 connectors and SP24 protective covers. There is a separate earthing bar with an earthing connector in the cabinet. In the earthing bar, there is place for three KG50 earthing connectors, which have to be ordered separately. If the used cables are max 50 mm2, the branching is done with the SV 50 connector set. Ordering of connectors, see page 11. 264 198 E-KSE_26 2 + SV50 E-KSE_44 2 M=10 Nm SL 19 4+SP24 SL 19 4+SP24 SL 19 4+SP24 Place for 3 x KG50 connectors To be ordered separately Earthing connector is included maxl 4x50mm2 max 4x50mm2 max 4x50mm2 max Al 4x95mm2 max Al 4x95mm2 max Al 4x95mm2 Empty branch off cabinets with base. Type E-KSEA 26.2 E-KSEC 26.2 E-KSEA 44.2 E-KSEC 44.2 EAN-no. 5702665985757 5702665985580 5702665986013 5702665985597 Colour Grey Green Grey Green Width/mm Height /mm Depth/mm Weight/kg 198 850 198 15 198 850 198 15 264 850 198 18 264 850 198 18 5 EMPTY CABINETS The empty cabinets are suitable for tele- or instrument cabinets, e.g. a street lighting or a measuring cabinet. The empty cabinets are externally similar to the cabinets with busbar, see page 4 and 14. It is possible to install a mounting plate or a C-mounting bracket into the mounting bars inside the cabinet. The roof of the cabinet can be removed during installation of the mounting plate or the C-bar bracket. Mounting plates have to be ordered separately. EMPTY CABINETS WITH BASE Grey RAL 7037 cabinets Type E-KSEEA 44 E-KSEEA 60 E-KSEEA 94 E-KSEEA 117 E-KSEEA 183 EAN-no. 5702665990003 5702665990065 5702665990126 5702665990157 5702665987188 Width/mm 264 392 595 795 1190 Height/mm 850 850 850 850 850 Depth/mm 198 198 198 198 198 Weight/kg 15 26 32 52 64 EAN-no. 5702665990027 5702665990089 5702665990140 5702665990171 5702665990201 Width/mm 264 392 595 795 1190 Height/mm 850 850 850 850 850 Depth/mm 198 198 198 198 198 Weight/kg 15 26 32 52 64 Green cabinets Type E-KSEEC 44 E-KSEEC 60 E-KSEEC 94 E-KSEEC 117 E-KSEEC 183 6 MOUNTING PLATES INTO EMPTY CABINETS The mounting plates are delivered separately. An earthing set with connectors is included in every mounting plate. Mounting plates and C-mounting bracket are mounted on the mounting place of the cabinet. Mounting plates, LSA+ cross connection frame E-MPKR mounting plates are equipped with an LSA+ cross connection frame, earthing connectors and 6mm holes for cable guides. Type E-MPKR 200 E-MPKR 400 E-MPKR 600 E-MPKR 800 EAN-no 5702662518149 5702662518200 5702662518262 5702662518323 Pairs For cabinet Height Width 200 E-KST_44 700 252 2x200 E-KST_60 700 380 3x200 E-KST_94 700 583 4x200 E-KST_117 700 781 Mounting plates, Al 2 mm Type E-MPAL 44 E-MPAL 60 E-MPAL 94 E-MPAL 117 E-MPAL 183 EAN-no 5702662518156 5702662518217 5702662518279 5702662518330 5702662518385 For cabinet E-KST_44 E-KST_60 E-KST_94 E-KST_117 E-KST_183 Height 700 700 700 700 700 Width 252 380 583 781 1177 Height 700 700 700 700 700 Width 252 380 583 781 1177 Galvanised mounting plates, 1,5 mm Type E-MPZ 44 E-MPZ 60 E-MPZ 94 E-MPZ 117 E-MPZ 183 EAN-no 5702662518163 5702662518224 5702662518286 5702662518347 5702662518392 For cabinet E-KST_44 E-KST_60 E-KST_94 E-KST_117 E-KST_183 C-MOUNTING BRACKETS The mounting brackets are made of C-form aluminium profile. The mounting bracket includes vertical and horizontal bars, fixing parts and an earthing set with connectors. E-CKV bar set includes 2 pcs of fixed length horizontal bars and fixing parts into the cabinet. C-mounting brackets Type E-CKS 44 E-CKS 60 E-CKS 94 E-CKS 117 E-CKS 183 EAN-no. 6418677410413 6418677410420 6418677410437 6418677410444 6418677410451 For cabinet E-KST_44 E-KST_60 E-KST_94 E-KST_117 E-KST_183 EAN-no. 6418677410468 6418677410475 6418677410482 6418677410499 6418677410505 For cabinet E-KST_44 E-KST_60 E-KST_94 E-KST_117 E-KST_183 Height 700 700 700 700 700 Width 252 380 583 781 1177 C-bar sets Type E-CKV 44 E-CKV 60 E-CKV 94 E-CKV 117 E-CKV 183 For bracket Width E-CKS 44 252 E-CKS 60 380 E-CKS 94 583 E-CKS 117 781 E-CKS 183 1177 7 SWICTHES AND EARTHING COVERS The E-DZ2x63A fuse-switch disconnector includes two outputs (max 63 A DZ II-III fuses) with spring operated fuse holders. The breaking operation of the load is made with knives, not with fuses. The EDZ2x63A is ideal for renewing projects and private house areas because each consumer can be connected with one’s own output. Connectors are integrated into the construction, so there no need for separate connectors. The right fuse size is limited with fuse adapters, see page 11. The E-KLB00 160 A fuse-switch disconnector can be used with one max 95 mm2 cable or two max 35 mm2 cables having the same cross-section, when E-KK25-95 connectors are used. Connectors, which are delivered in sets of 4, have to be ordered separately for E-KLB00 and E-KLB2 switches. The E-KLB2 400 A fuse-switch disconnector can be used with one max 300 mm2 cable with E-KK240300 connectors or with two 50...185 mm2 cables having the same cross-section with E-KK2x50-185 connectors. The E-FSD disconnector unit includes visible clearance between open contacts. The switch is one pole operated. The utilisation category of the unit is AC21 with rated values of 500 V, 400 A. The cabinet can be bypassed by connecting two E-FSDs together. The unit can be used as a disconnecting device in a ring network instead of e.g. short circuiting knives. Switching positions of the unit are shown on the next page. The connectors have to be ordered separately. Every disconnector unit is voltage tested at the factory. All phases of the cable including the PEN conductor are connected directly to all the switches in the same level, which makes the installation easy. There is no need to bend the PEN conductor into a separate earthing bar. All the switches and components are suitable for live line work without any special tools or working methods. The installation of all the components and switches is done with 5 mm allen key E-IN5 or E-MIN5. The busbar and cables can be earthed with earthing covers. Switches EAN-code Nominal current In Nominal voltage Un Insulation level Ui Fuse type Utilisation category IEC 408 (1985) EN 60947-3 (1992) Protection class Al/Cu (mm2) Connectors. Delivered in a set of 4 pcs. Modules a’ 6mm Weight 8 E-DZ2x63A Fuse-switch disconnector 5702665959383 2 x 63 A 500 V 660 V DZ II-III AC 23B IP 20 2,5–50 Integrated connectors 11 2.1 kg E-KLB 00 Fuse-switch disconnector 5702665959291 160 A 500V 1000 V DIN 00 AC 23B IP 20 10–95 / 2x16-35 E-KK10-35 E-KK25-95 9 2.0 kg E-KLB 2 Fuse-switch disconnector 5702665959321 400 A 500 V 660 V DIN 0-2 E-FSD Disconnector unit 5702665959314 400 A 500 V 660 V — AC 23, AC 22 AC 21 IP 20 IP 20 50–300 / 2x50-185 50–300 E-KK50-95 E-KK50-95 E-KK95-240 E-KK95-240 E-KK240-300 E-KK240-300 E-KK2x50-185 25 12 6.4 kg 3.2 kg E-FSD BYPASS E-FSD CLOSED Earthing covers EAN-no. Nominal voltage Un Insulation level Ui S.c. current, 1s Dyn Ik Test Standard Protection class For Switch Weight E-FSD OPEN E-JL 00 5702665977547 500 V 1000 V 8,4 kA 18,7 kA EN 60947-3 IP 20 E-KLB 00 0.5 kg E-JL 2 5702665977547 500V 660 V 8,4 kA 21,1 kA IEC 408 IP 20 E-KLB 2 1.0 kg CONNECTORS FOR SWITCHES Connectors are delivered in a set of 4 pcs. The protection class of the connectors is IP20 and they are suitable for live line work. Connector EAN-no. E-KK10-35 E-KK25-95 E-KK50-95 E-KK95-240 E-KK240-300 E-KK2x50-185 5702665959178 5702665959185 5702665959192 5702665959208 5702665959215 5702665959262 Cross-section Al/Cu (mm2) 10-35 25-95/2x16-35 50-95 95-185 240-300 2x50-185 for Switch Weight kg E-KLB00 0.2 E-KLB00 0.2 E-KLB2, E-FSD 0.6 E-KLB2, E-FSD 0.6 E-KLB2,E-FSD 0.6 E-KLB2 0.6 BUSBAR CONNECTORS Connectors are delivered in a set of 4 pcs. The protection class of the connectors is IP20 and they are suitable for live line work. Busbar Connector E-AK10-35 E-AK25-95 E-AK120-300 EAN-no. Al/Cu Mod. (mm2) 5702665959239 10-35 6 5702665959246 25-95 6 5702665959277 120-300 14 Nominal Weight current In. kg 200A 0.5 200 A 0.5 400 A 1.5 CONNECTORS FOR BRANCH OFF CABINETS Type KE10.504 KE10.506 KG 50 SL19.4 SP24 SV50 EAN-no. 6418677400087 6418677400094 6418677400278 6418677403583 6418677405259 6418677405808 Cross-section (mm2) Al/Cu 4x16-50/2,5-35 Al/Cu 6x16-50/2,5-35 Al/Cu 1x95/2x35 Al 4x16-95 Protective cover 3xKE10.504+KE10.506 9 BUSBARS The renewing busbars are ideal for renewing of old, existing cable distribution cabinets and transformer substations. If an old cabinet body is in good condition, there is no need to change the whole cabinet and a lot of money and time is saved. The busbar is mounted into an old cabinet and old switches and open fuse bases can be replaced with new ones. The protection class of the busbars is IP20. E-SS busbars are suitable for old cable distribution cabinets, E-SS1600 busbars for LV side of transformer substations and E-STS busbars for the branch off cabinets. COVERED BUSBARS (630 A, IP20) FOR RENEWING OF OLD CABLE DISTRIBUTION CABINETS. Type EAN-no. E-SS 6-50 E-SS 6-61 E-SS 6-72 E-SS 6-83 E-SS 6-94 E-SS 6-117 E-SS 6-183 5702665989885 5702665989878 5702665989892 5702665989915 5702665989939 5702665989946 5702665989953 Height Width Length of busbar Weight mm mm mm / mod kg 580 330 300 / 50 4,5 580 395 367 / 61 4,8 580 460 433 / 72 5,2 580 526 499 / 72 7,2 580 595 565 / 94 9,8 580 795 763 / 127 12,5 580 1190 1159 / 193 18,0 COVERED BUSBARS (630 A, IP20) FOR THE BRANCH OFF CABINETS Type E-STS 6-26 E-STS 6-44 EAN-no. 5702665989601 5702665989618 For Cabinet E-KSE 26.2 E-KSE 44.2 Weight kg 2,5 3,0 COVERED BUSBARS (1600 A, IP20) FOR RENEWING OF TRANSFORMER SUBSTATIONS Bars are made of HL-profile. The same components as with cable distribution cabinets can be used. The feeder cable can be connected to the backside of the busbar with cable lugs, flexible joints or busbar connectors. The busbar can be equipped with earthing balls. 10 Product Type EAN-no. Busbar 1600 A Busbar 1600 A Busbar 1600 A Connection bar, 4 pcs Earthing balls 4 pcs E-SS 1600.1 E-SS 1600.2 E-SS 1600.3 E-SST 1600 E-SSJ 1600 5702665964837 5702665964851 5702665964875 5702665965032 5702665965049 Length mm/mod 961/160 1357/226 1687/281 ADAPTERS AND TOOLS Adapters for the fuse-switch disconnector E-DZ2x63A Adapters are mounted with a fuse to the fuse holder. The adapter prevents from installing a wrong fuse size. Type E-PI10 E-PI16 E-PI25 E-PI35.1 E-PI50.1 EAN-no. 5702667077108 5702667077115 5702667077122 5702667074572 5702667074589 Fuse size 10 A 16 A 25 A 35 A 50 A Packing 50 50 50 50 50 E-HP 2 BRACKET Bracket is used to connect two switches E-KLB2 parallel to each other. Product Bracket Type E-HP2 EAN-no. 5702668486138 Packing 10 FUSE TONGUES FOR E-DZ2x63A SWITCH Fuse tongues are used for breaking operating of E-DZ2x63A switch. E-PH1 is for 1-pole operation and E-PH3 for 3-pole operation. Product Fuse Tongue Fuse Tongue Type E-PH1 E-PH3 EAN-no. 5702668486114 5702668486121 Packing 10 10 KEYS Insulated allen keys are used for installation of all the switches and connectors. The keys are approved for live line work up to 1000 VAC and they fulfil EN 60900 standard requirements. E-MIN5 allen key can be used with 3/8” torque wrench. Triangle key E-TN is used for opening and closing the door. Product Triangle key Allen key 5 mm Allen key 5 mm Type E-TN E-IN5 E-MIN5 EAN-no. 5702668486145 5702668486091 5702668486060 Packing 25 25 25 POLE MOUNTING BOXES Cabinets can be mounted into poles with pole mounting boxes. The pole mounting boxes are RAL 7037 grey. Protection tubes for cables are also available. Type EAN-no. For Cabinet E-SF6-44 E-SF6-50 E-SF6-72 E-SF6-94 5702665987591 5702665987607 5702665987614 5702665987621 E-KS_ 44 E-KS_ 50 E-KS_ 72 E-KS_ 94 Tubes Weight max/pcs kg 3 12 5 15 7 21 9 26 11 CABLE PROTECTIVE COVERS In pole mounting, cables can be protected with protective covers. Cable coming from a pole can be protected with plastic E-NRL protective tubes. A set includes two pcs of a’ 2,4 m tubes and a joint. Underground cable can be protected with E-KK cable ducts. All the covers are grey. Type EAN-no. E-KK44 E-KK50/72 E-NRL 5702665987690 5702665987706 For Pole Mounting Box E-SF 44 E-SF 50 and 72 E-SF_ Weight kg 10 14 4 BRACKETS The protective tubes can be fixed into a pole with bracket E-RH3 (place for 3 tubes) or with E-RH7 (place for 7 tubes). Product Bracket Bracket Fuse Bracket Type E-RH3 E-RH7 E-SHL EAN-no. 5702665987652 5702665987676 5702665989748 Weight kg 1,5 2,5 0,5 CONNECTION SETS The cabinets can be mounted together with E-SK connection sets or by connecting the roofs together. Type E-SKS E-SKR EAN-no. 5702667305508 5702667305515 For Cabinets All models, side by side All models, against each other MARKING RODS Marking rod can be fixed to the side of the cabinet. Type EAN-no. SKK 121 6418677403477 SKK 121.2 6418677403484 Length (m) 1.2 2.0 CABLE CLAMPS Cables are fixed with standard cable clamps to the adjustable fixing bar inside the cabinet. 12 INDENTIFICATION PLATES External identification can be done with identification plates. The identification plates are fixed to an identification bar, in which there is place for 8 plates. Product Id. bar Id. plate Id. plate Id. plate Id. plate Id. plate Id. plate Id. plate Id. plate Id. plate Id. plate Id. plate Type E-SNS 10 E-SNS 10.0 E-SNS 10.1 E-SNS 10.2 E-SNS 10.3 E-SNS 10.4 E-SNS 10.5 E-SNS 10.6 E-SNS 10.7 E-SNS 10.8 E-SNS 10.10 E-SNS 10.11 EAN-no. Plate no. 5702665410259 5702665410112 0 5702665410419 1 5702665410426 2 5702665410433 3 5702665410440 4 5702665410457 5 5702665410464 6 and 9 5702665410471 7 5702665410488 8 5702665410501 None 5702665410495 – Packing 20 50 50 50 50 50 50 50 50 50 50 50 EARTHING SET FOR 5-CORE CABINETS All the cable distribution cabinets are prepared for 5 core system and they can be modified with E-JS earthing set so that they are suitable for 5 core system. Type E-JS5-26 E-JS5-44 E-JS5-50 E-JS5-72 E-JS5-94 E-JS5-117 E-JS5-183 EAN-no. 6418677410567 6418677410574 6418677410581 6418677410598 6418677410604 6418677410611 6418677410628 For Cabinets E-KSE_6-26 E-KSE_6-44 E-KSE_6-50 E-KSE_6-72 E-KSE_6-94 E-KSE_6-117 E-KSE_6-183 EXTRA EARTHING SET FOR MOUNTING PLATES Type EAN-no. E-JS5x16.1 6418677410635 For Cables max 5x16 mm2 Cu 13 How to choose the right cabinet ? The right cabinet size can be calculated with the number of modules needed for each component. 1. List the number of modules of each component. 2. Calculate the sum of modules of all components. Choose the right cabinet size in which there are enough modules. For example : 1. E-DZ2x63A fuse-switch disconnector E-KLB 00 fuse-switch disconnector E-FSD disconnector unit 2. Total number of modules 14 2 pcs 2 pcs 2 pcs a’ a’ a’ 11 modules = 22modules 9 modules = 18modules 12 modules = 24modules = 64modules SURFACE TREATMENT – HOW AND WHY STEEL QUALITY All the cabinets are manufactured of high grade galvanised steel, which has a low content of carbon and an extremely smooth “skin passed surface”. The steel sheet is coated with 20 m zinc followed by polyester coating of min. 80 m, which ensures a long durability under varying climatic conditions. Life expectancy is over 25 years. SURFACE TREATMENT The polyester powder coating consists of premidbased saturated polyester powder. The quality of the coating on finished products is mainly determined by 2 factors: Pre-treatment prior to the application of polyester powder. A perfectly cured protective coat free from pores. Pre-treatment prior to the application of polyester powder: Galvanised steel sheets undergo 6 preparatory processes including application of phosphate and washing. This careful pre-treatment is necessary to obtain maximum adhesion of the polyester coat. A perfectly cured protective coat free from pores: After the preparatory baths, the manufactured items are dried in a drying oven. Crossbars in the spraying cabin apply electrostatically charged polyester powder to clean and dry items, and finally the polyester powder is melted and cured in a burn-in oven, to form a surface free from pores. Galvanised steel: Cleaning of the items and the application of phosphate takes place in 6 baths of the pretreatment system. Bath 1 - Alkaline degreasing, cleaning and cutting up the surface Bath 2 - Washing in water Bath 3 - Phosphating Bath 4 - Washing in water Bath 5 - Chromating Bath 6 - Chrome passivation Bath 7 - Washing in demineralised water 8 - Drying oven 9 - Spraying cabin for polyester powder 10 - Burn-in oven Process checking: To ensure that the desired quality is obtained, the process is currently supervised/checked and following facts are recorded: Condition of the preparatory baths (titration) Oven temperatures Results of grid cuts Thickness of the coatings Results of bending tests Results of boiling water tests The following procedure takes place: The manufactured items are attached to a conveyor taking them to a cleaning zone (see picture), further to a drying oven, then to a spaying cabin, where crossbars apply electrostatically charged polyester powder to form a surface free from pores, and finally in the burn-in oven, melting the polyester at a temperature of 200 ºC. 15 ENSTO SEKKO OY P.O. Box 51, Kipinätie 1 06101 Porvoo, Finland Tel. +358 204 76 21, Fax +358 204 76 2771 ensto@ensto.com, www.ensto.com