Manual SWGR Blokset

Blokset
Low voltage switchboard
Installation guide
10-2011
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
1
2
General
Safety recommendations 4
Introduction 5
1
3
General Safety recommendations
Note DANGER
You have just received your new Blokset
switchboard. Please read this manual carefully.
It provides all the necessary information
concerning installation, operation and
maintenance of your switchboard.
Please keep this manual on hand for easy WARNING
reference.
The messages opposite are used in this
manual to:
■ Warn of potential hazards;
■ Draw attention to additional information
intended to clarify or simplify a procedure.
CAUTION
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:
□ Qualified to work near live equipment;
□ 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. 11 :: Standard
Fig. Standard packing
packing
set
Blok
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:
v 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).
v 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:
v Reinforce the mechanical connections between sections;
v 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 wen 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°
OFF
ON
TRIP
Mg 500
400
300 V
200
100
0
OFF
ON
TRIP
Mg 500
400
300 V
Mg 60
40
200
100
0
A
20
Mg 60
40
A GERIN
MERLIN
dialpact
ES21
fault
20
I on
0 θ
trip
O off
fault
fault
Fig. 2 : Handling with slings.
OFF
ON
TRIP
ON
UCH
OFF
UCH
Mg 500
400
300 V
200
100
0
OFF OFF
ON ON
TRIP TRIP
ON ON
OFF UCH
OFF
UCH
ON
I
Mg 500
400
tripped ∅5...8
300 V
Mg 60
reset
40
O 200
OFF
OFF 100
0
A
ON
TRIP
ON 20
OFF
0
ON
I
tripped ∅5...8
reset
O
OFF
OFF
ON
TRIP
ON
OFF
Mg 60
40
ON
A GER
IN
M ERLIN
I dialpact
E S21
fault
I on
20
tripped ∅5...8
0 θ
trip
O off
reset fault
fault
O
OFF
OFF
ON
TRIP
ON
OFF
GERIN
MERLIN
dialpact
ON ES21
I
fault
I on
tripped
θ
∅5...8
trip
O off
fault
fault
reset
O
OFF
OFF
ON
TRIP
ON
OFF
ON
I
tripped ∅5...8
reset
O
OFF
OFF
ON
TRIP
ON
OFF
ON
I
tripped ∅5...8
reset
O
OFF
Fig. 3 : Handling joined sections.
10
Delivery Handling
■ Cubicle : Mw2
Side connection Rear connection
A
2
L
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
(A) (L)
- 1500 to 2300mm
650mm 700 to 1000mm
Mw2 cubicle lifting lugs are delivered separately

For handling operation follow the steps herehunder:
■ Remove the side panels
■ Install the 4 captive nuts and the lugs
v IP31 directly on the frame
v 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
■ bush of 13
■ bush of 16
■ bush of 17
■ bush of 18
■ bush of 19
■ 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

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

v bush of 16 and 17 for M10 screw
■ assembling: columns
v bush of 10 for M6 screw
■ floor fixing:
v bush of 16 and 17 for M10 screw
■ fitting the roofs and lifting lugs:
v 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:
v it allows operator inspection, to check that the nut has been tightened and to
verify if others bolts/nuts are untightened.
v 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
■ 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
■ The Blokset installation site must be clean. The floor must be flat and level
deviations (≤ 2 mm/m) (see Fig. 1).
■ Leave at least 1200 mm of free space (see Fig. 1) to enable for opening of the
doors and operator access.
■ 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.
■ Leave space for future extensions.
■ Connection through the top.
v Provide at least 600 mm of free space above Blokset.
■ Connection via the bottom (see Fig. 2).
■ Two possibilities for routing the cables:
v 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;
v 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.
OFF
ON
TRIP
ON
UCH
OFF
UCH
Mg 500
400
300 V
200
100
0
ON
UCH
OFF
UCH
tripp ˘5...8
r
Mg 60
40
20
3
tripp ˘5...8
tripp ˘5...8
tripp ˘5...8
1200 mm. tri
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

450
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.
v 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.
v 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).
v 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.
■ 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
3
Fig. 1
OF F OFF
ON ON
TRIP TRIP
ON ON
OFF OFF
Fig. 2 Fig. 3
Fig. 4 Fig. 5
E34192
E34193
Fig. 6 Fig. 7 Fig. 8
19
■ 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
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.

v The sliding fishplates are sent assembled on the horizontal busbars.
v Tighten all the nuts to the indicated tightening torque using a torque wrench.
v Once tightened, mark each nut with a drop of varnish.
■ Joining with non-sliding fishplate (option) Fig. 3.
v 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 3
the bolts.
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
v Tighten the nuts using a torque wrench as indicated page 22.

v 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
■ Cables must never touch or run between live conductors
(copper bars, etc.).
■ 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.

v Remove the roof or the cable gland plate.
v Drill the holes required to install cable glands or grommets.
v Install the cable glands. They must comply with high IP protection degrees.
v Put the roof or the gland plate back on Blokset.
v Run the cables through the glands.
v 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

v Remove the bottom plate (Fig. 1A).
v Drill the holes required to install cable glands or grommets.
v Install the cable glands. They must comply with high IP protection degrees.
v Remount the bottom plate.
v Run the cables through the glands (Fig. 1B).
v The cables must run in the intended ducts and be secured to cable tie-bars
every 400 mm.
v 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
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
■ Connection of cables to the ends of the copper bars.

v 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).
v 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
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:

v Trunking must be secured at least every 600 mm (see Fig. 1).
v Trunking must not be filled to more than 70% of capacity.
v 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:

v All strands of a conductor must be inserted in the hole of the terminal (see
Fig. 2).
v Tighten securely, taking care not to cut strands.
■ Conductors must be shielded (see Fig. 3):

Connect the cable shielding to earth.
28
Installation Connection of auxiliary circuits
Fig. 1
Fig. 2
Fig. 3
29
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).
v 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).
v Compact
Consult circuit breaker documentation and the operating manuals.
Fig. 1 Fig. 2
Test
Test
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:
v 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.
■ Dielectric tests have already been carried out in the factory (see the factory test
3
report).
■ Final connections and checks
v Reconnect the earth electrodes that were disconnected for the insulation and
dielectric measurements.
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.).
v Check, using a torque wrench, the tightness of all electrical connections,
mechanical connections and anchor bolts.
v 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.
■ 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
v Fit the racking crank (see Fig. 1).

v 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 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:
v Operating sequence;
v Controls, indications, measurements, protection;
v Remote-control mechanism;
v 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.
injury or death, and damage to the switchboard.
Test
Test
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):
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).
Test
Fig. 1
■ 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
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
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:
v green OFF light "B";
v ON push-button "C";
v OFF push-button "D";
v red ON light "E";
v yellow FAULT light "F";
Fig. 2
38
Operation Drawers
Mw2 Network wiring
6 3
15 12 9 2
24 21
18 8 5
17 14 11 4 1
23 20 7
16 13 10
22 19
3
9 6
18 15 12 2
24 21 8 5
23 20
22 19
17
16
14 11
13 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
Bus Ground - - - - - - 1
DeviceNet Bus Ground - - - - - - 3
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:
v main part,
v customer outgoing (for side or rear connection),
v Form 4 (for side or rear connection),
■ The moving parts:
v main part,
v power plugs,
■ The front face:
v handles,
■ Auxiliaries parts complete the functional unit:
v auxiliary connectors,
v 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 ■ General: passing from one position to another

v operation of the drawer impossible apparatus closed: open the apparatus
v seize the drawer by the handles and press and hold the black release button.
■ Withdrawing
v pass from the «connected» to the «test» position, then to the «disconnected»
position
v the positioning mechanism locks the drawer in the selected position.
4
drawer implemented in the lower side of the column
■ Removal
v pull the drawer with the handles to the pre-extraction hard point
v position the hands as indicated on the diagrams and extract the drawer
v be careful with grease present on the mechanisms.
■ Putting into position

v engage the drawer in its cell, positioning the hands as indicated on the
diagrams
v check that the apparatus is in open position
v 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:

v 1 to 3 padlocks on the rotary handle
v 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
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
injury or death.
Maintenance on fixed parts Common maintenance operations for the entire range.
■ Check inside and outside the switchboard for moisture or foreign material.
of the switchboard (Fig. 1) 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:
v Assembly screws for busbars do not need to be tightened as long as the
varnish, guaranteeing correct tightening torque, is intact;
v 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
OFF
ON
TRIP
ON
UCH
OFF
UCH
Mg 500
400
5
300 V
200
100
0
OFF OFF
ON ON
TRIP TRIP
ON ON
OFF UCH
OFF
UCH
ON
I
Mg 500
400
tripped ∅5...8
300 V
reset
Mg 60
40
O
OFF 200
OFF 100 A
ON 0
TRIP
ON 20
OFF
0
ON
I
tripped ∅5...8
reset
O
OFF
OFF
ON
TRIP
ON
OFF
Mg 60
40
ON A
I
20
tripped ∅5...8
0
reset
O
OFF
OFF
ON
TRIP
ON
OFF
GERIN
MERLIN
ON dialpact
I ES21
fault
I on
tripped
θ
∅5...8
trip
O off
fault
fault
reset
O
OFF
OFF
ON
TRIP
ON
OFF
ON
I
tripped ∅5...8
reset
O
OFF
OFF
ON
TRIP
ON
OFF
ON
I
tripped ∅5...8
reset
O
OFF
Ver nish
Va
nis
r
se
Grais
RAL 9002
ase
Gre
Fig. 1
45
Maintenance on fixed parts Additional maintenance for withdrawable Blokset switchboards.

■ Check the condition of the busbars opposite the disconnection contacts (no
of the switchboard (cont.) 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
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.
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

v unscrew the 1/4 turn screw
v unlock the protection device rotary handle
v open the door
v execute thermal monitoring
v close again the door.
Mw2
47
48
Evolution
Extensions 48
49
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:
v the starter input and the vertical busbars;
v 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:
v order of phases;
v elimination of foreign material (cable scraps, nuts and bolts, tools);
v carry out insulation measurements.
■ Energise the system.
DANGER
injury or death.
50
51
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.
v Remove all foreign objects that may disturb switchboard operation (cable
scraps, wires, nuts and bolts, tools, etc.).
v Vacuum the entire switchboard to remove dust.
v 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
v 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.
v Miscellaneous checks: mechanical locking of switchgear devices; markings on
the switchboard, on power and control conductors.
v Visual inspection of outside surfaces and paintwork. Touch up any scratches
or other defects.
■ Then proceed with energising.
52
Fig. 1
53
Adding a section Assembling
Mw2 / Mw2 Mw2 / D D/D
Cubicles are assembled with M6 x 16 screws
54
55
56
ART 838483 © 2011 - Schneider Electric - All rights reserved
Schneider Electric Industries SAS

35 rue Joseph Monier As standards, specification and designs change from time to time. Please, ask for confirmation
CS 30323 of the information given in this document.
F-92506 Rueil Malmaison
RCS Nanterre B 954 503 439

Shared capital 896 313 776 €
http://www.schneider-electric.com
Design: Schneider Electric
Illustrations: Schneider Electric
ESBED397708EN Printing:
10-2011

Manual SWGR Blokset

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Manual SWGR Blokset

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Blokset

Low voltage switchboard

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

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

Fig. 2 : Ship packing

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

Fig. 2 : Handling with slings.

Fig. 3 : Handling joined sections.

Lifting beam + Slings Lifting beam + Slings

Mw2 cubicle lifting lugs are delivered separately

■ Blokset is intended for use indoors. The equipment must therefore

Tools required Usual tools :

Specific tools ■ Torque wrench features

■ Busbar trunking conversion modules special tip

Assembly types ■ splicing: busbars

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

1200 mm. tri

Check that floor is flat and level

opening for cable

600 50 600 50 350 50

150 50 1100 50 350 50

250 250 250

■ Remove any remaining packing and protection.

Fig. 6 Fig. 7 Fig. 8

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

195 205 125 25

Tightening torque for class 8.8 nuts and bolts

Fig. 2 (sliding fishplate)

Fig. 3 : option, non-sliding fishplate

■ Joining with sliding fishplates Fig. 2.

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

■ Connections through the top.

■ Connection through the bottom

A: removal of the bottom plate.

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

■ Connection of cables directly to device terminals.

■ Running cables in trunking:

■ Connections must be made to terminals:

■ Conductors must be shielded (see Fig. 3):

■ Rack in the Masterpact devices.

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

Operation of Masterpact circuit breakers 34

Consult the Masterpact documentation.

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

To open Masterpact (OFF position):

Two types of manual control are possible.

Direct control on the circuit breaker

Extended rotary handle

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

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

Mw2 Network wiring

Downstream power plug

Positions The drawer may be set to any of three positions

input auxiliaries output input auxiliaries output input auxiliaries output

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

■ Putting into position

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

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

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