ABB CoreSense M10 Installation Manual

Multi-gas monitoring system
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I N S TA L L AT I O N G U I D E
CoreSense M10
Multi-gas monitoring system

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Summary of Contents for ABB CoreSense M10

  • Page 1 — I N S TA L L AT I O N G U I D E CoreSense M10 Multi-gas monitoring system...
  • Page 2 ABB product catalogs, the latter takes precedence. ABB reserves the right to make changes to the specifications of all equipment and software, and contents of this document, without obligation to notify any person or organization of such changes. Every effort has been made to ensure that the information contained in this document is current and accurate.
  • Page 3: Table Of Contents

    Safety ..............52 3 Preparing for installation Connecting the cable ........53 Considering meteorological conditions ..19 Powering up the CoreSense M10 ..... 56 Siting the analytical unit ........20 Establishing SCADA connections ....56 Clearance requirements ........ 20 Establishing RS-485 connections .....57 Siting the sensor head .........
  • Page 4 Troubleshooting ............. 71 Understanding cabinet LEDs .......72 Understanding sensor head LEDs ....73 Exporting the Events log .......74 Giving access to administrative settings on the SCADA port ..........75 Installing firmware updates .......76 Updating with a web browser ......76 Updating with a USB key........77 Taking an oil sample ..........
  • Page 5: Safety

    CoreSense M10 systems on energized transformers. If you do not fully understand the information contained in this guide, or if the instrument shows any signs of damage, contact ABB. Refer to the back cover of this manual for contact information. Symbol definitions This document uses the following symbols to bring attention to key technical and safety-related information.
  • Page 6 WARNING — HIGH VOLTAGE Indicates the presence of electrical energy at voltages high enough to inflict harm on living organisms. WARNING — LASER R ADIATION Indicates the presence of a laser related hazard. It also indicates the type of laser in use, its wavelength and its safety class.
  • Page 7: Personnel Safety

    ABB assumes no liability for the user’s failure to comply with any of these safety requirements, which may result in personal injuries and/or instrument damages.
  • Page 8: Handling The Analytical Unit

    Handling the analytical unit The CoreSense M10 analytical unit weighs 65 kg (144 lb). It is not designed to be installed by one person. At least two people should be installing this unit. To avoid personal injuries, make sure to follow the proper lifting and carrying instructions when handling the instrument.
  • Page 9: Installation On Energized Transformers

    • Installation must be performed with feet on the ground (no work should be performed off of a ladder or lift of any kind). • The CoreSense M10 sensor head must be installed near ground level. • Plan AC power connection to the analytical unit prior to all other work (connection location, needs for additional fuses, etc.)
  • Page 10: Improper Use

    Repairs, alterations, and enhancements, or the installation of replacement parts, are only permissible as far as these are described in this manual. Approval by ABB must be requested in writing for any activities beyond this scope. Repairs performed by ABB-authorized centers are excluded from this article.
  • Page 11: Introducing The Coresense M10

    C h A p T E r 2 Introducing the CoreSense M10 CoreSense™ M10 continuously monitors dissolved gas levels in transformer oil to provide early warnings for incipient transformer faults. Additionally, CoreSense M10 can also continuously monitor moisture levels, as moisture can accelerate transformer aging. —...
  • Page 12: Analytical Unit

    Analytical unit As part of the CoreSense M10 multi-gas monitoring system, the analytical unit is where gases extracted from the transformer are analyzed. Analysis results allow for prevention of incipient transformer faults. It is also the part of the system equipped for external communication and system configuration.
  • Page 13 — Figure 3 Overview of the CoreSense M10 analytical unit (open) Relay module and power entry terminal block Touchscreen Cable cover Communication ports Status lights (from back) Power entry port External Analytical unit communication bulkhead fitting entry port Introducing the CoreSense M10...
  • Page 14: Analytical Unit Status Leds

    — Figure 4 Analytical unit status LEDs Analytical unit communication ports The purpose of each of these ports is explained in more details in “Connecting the CoreSense M10” on page 43 and “Appendix B” on page 89. — Figure 5...
  • Page 15: Touchscreen

    CoreSense M10 analytical unit touchscreen (Dashboard panel) Alarms and Dashboard Instrument IP CoreSense M10 events screen screen address system general 4 – 20 mA information input screen — Figure 7 CoreSense M10 analytical unit touchscreen (4 – 20 mA input panel) Introducing the CoreSense M10...
  • Page 16: Sensor Head And Communication Cable

    CoreSense M10 analytical unit touchscreen (Alarms and events panel) Sensor head and communication cable As part of the CoreSense M10 multi-gas monitoring system, the sensor head extracts gases from the transformer and routes them through its permanently attached conduit for analysis inside the analytical unit.
  • Page 17: Sensor Head Status Leds

    — Figure 10 Overview of the CoreSense M10 sensor head (front) LEDs NOTICE The length of the conduit attached to the sensor head is 10 meters (33 feet). Make sure that the distance between the sensor head and analytical unit is at most 10 meters.
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  • Page 19: Preparing For Installation

    • that will allow for the analytical unit touchscreen to be positioned at eye level. • where the sensor head will be exposed to maximal oil flow and minimal oil temperature fluctuations. Considering meteorological conditions Installation of the CoreSense M10 monitoring system should not be performed under the following meteorological conditions: • In rain •...
  • Page 20: Siting The Analytical Unit

    Siting the analytical unit Since the CoreSense M10 analytical unit can be installed on the transformer wall or a wall adjacent to the transformer, there are a few physical limitations to take into account before installing the CoreSense M10 analytical unit.
  • Page 21: Siting The Sensor Head

    Siting the sensor head The CoreSense M10 sensor head can be installed at various locations on the transformer. — Figure 13 Possible locations for sensor head on a transformer Acceptable installation location Acceptable installation location Good installation location Best installation...
  • Page 22: Clearance Requirements

    Clearance requirements First, you need to make sure that you have enough room to install the head. Below are the clearance requirements for the unit. — Figure 14 CoreSense M10 sensor head dimensions (in millimeters) (392.9) (158.1) ThrEADED 1 1/2″ NPT (264.1)
  • Page 23: Planning Your Cabling

    Planning your cabling Select cabling according to your communication needs. Refer to the table below for recommended cable gauge or type. NOTICE Table 2 gives a general description of the necessary cables. More detailed information is found in Appendix B on page 89. Always comply with national codes and electrical standards.
  • Page 24: Planning Your Communications

    (Ethernet) port at startup use, the Ethernet SCADA port IEC61850 MMS port must not be used. 102/tcp Default static Ip address for ABB remote access can be SErVICE CoreSense: 10.126.126.126 enabled or disabled using the (Ethernet) web interface. NOTICE For best results it is recommended to configure the Modbus or DNP3 master with a timeout of 10000 ms and 5 retries.
  • Page 25: Gathering The Installation Tools

    Gathering the installation tools Once you have finished planning your installation, you need to assemble a set of all the equipment necessary to perform the installation. Supplied tools • Metric hex (Allen) key set: 2.5 mm, 4 mm, 5 mm •...
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  • Page 27: Installing The Analytical Unit

    Installing the CoreSense M10 multi-gas monitoring system requires at least a team of two. WARNING The CoreSense M10 analytical unit weighs over 65 kg (144 lb). It could cause serious injuries or even death if it were to tip over and/or fall on someone.
  • Page 28 — Figure 15 Analytical unit installation template Screw holes (×8) 3 With a drill powerful enough, and appropriate drill bits, drill the eight screw holes. 4 Screw in the four mounting posts as shown below (screws, washers and lock washers not provided). —...
  • Page 29: Installing The Shock Absorbers

    Installing the shock absorbers Once the mounting posts are properly installed, you need to install the shock absorbers that are designed to counter system and environmental vibrations. To do so: 1 Position a shock absorber on a mounting post. 2 Position the nuts and washers. 3 Tighten the provided M8 screw by hand, and then up to the required torque (21.1 N·m [15.6 lb.ft]).
  • Page 30: Placing The Unit On The Shock Absorbers

    Once the mounting posts and shock absorbers are properly installed, you need to position the analytical unit. ABB recommends using a sling and a crane to lift the unit up on to the mounting posts. To this end, slots are designed in the unit mounting frame to help lift up the unit.
  • Page 31 — Figure 19 Positioning the unit on the shock absorbers Mounting screw Shock absorber Mounting post 3 Insert the screw through the mounting frame and in the shock absorbers. Shock absorbers minimize the effects of vibrations, shocks, and bumps on the analytical unit, and provide a certain amount of protection against seismic activity (Class 1 of IEC 60255, part 21).
  • Page 32: Earthing The Analytical Unit

    Earthing the analytical unit Safety ONLY qualified personnel may perform the electrical installation of the monitoring system. In accordance with international safety standards, the monitoring system uses a three-wire power cord or line typically connected to an electrical panel that provides grounding for the monitor chassis. •...
  • Page 33 — Figure 20 Cabinet earthing lug Cabinet earthing lug with earthing wire Earthing lug To earthing Installing the analytical unit...
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  • Page 35: Installing The Sensor Head

    Do not expose sensor head innards to rain or snow. The CoreSense M10 sensor head is delivered with the thermal pump turned OFF. When installation is complete and the sensor head is in contact with oil, make sure to enable the thermal pump (see "Activating the thermal pump"...
  • Page 36: Connecting The Sensor Head

    Connecting the sensor head The sensor is designed to be installed on a 1.5 NPT transformer valve. 1 Remove the black rubber cap covering the sensor head male fitting. Make sure that both the sensor head male fitting and the transformer valve female fitting are clean. NOTICE Do not expose the sensor head innards to rain or snow.
  • Page 37 Rotate the head as necessary. NOTICE Failure to position the CoreSense M10 sensor head horizontally, with the access panel pointing upwards, will cause the thermal pump to malfunction and may result in erroneous readings.
  • Page 38: Purging The Sensor Head

    7 Tighten all rotating flange screws by hand. 8 With the 5 mm hex key, tighten the rotating flange screws to 8.1 N·m (6.0 lbf.ft) according to the tightening pattern below. NOTICE The rotating flange screws must be tightened to 8.1 N·m (6.0 lbf.ft) to prevent oil leaking from the rotating flange.
  • Page 39 To purge the sensor head: 1 Remove the external sampling port cover located on top of the sensor with the 4 mm hex key. 2 Connect the provided bleeding hose (ID 3.18 mm [0.125 in]) to the sampling adapter. 3 Direct the other end of the bleeding hose in an oil container to collect all the purged oil. 4 Slowly open the transformer valve and wait until oil comes out of the sensor (about 20 seconds;...
  • Page 40 5 Tighten the bleed screw to a maximum torque of 2.26 N·m (20 lbf.in). NOTICE Do not apply excessive torque. 6 Wipe excess oil with a clean cloth. 7 Re-install the external sampling port cover and secure it with the 4 mm hex key. Installation Guide...
  • Page 41: Earthing The Sensor Head

    (for grounding wire gauge, see Table 2 on page 23). 2 Attach the other end of the earthing wire to the sensor head earthing lug located underneath the head. — Figure 21 Overview of the CoreSense M10 sensor head (back) To earthing rod Earthing wire Installing the sensor head...
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  • Page 43: Connecting The Coresense M10

    ABB assumes no liability for user failure to comply with any of these safety requirements, which may result in personal injuries and/or instrument damages.
  • Page 44: Routing The Sensor Head Conduit To The Analytical Unit

    • In accordance with IEC61010-1 edition 3.0, to prevent contamination of the electronics by outside elements, the analytical unit cabinet cover shall be opened only under controlled environmental conditions defined as: – Temperature: between 5 °C (41 °F) and 40 °C (104 °F) –...
  • Page 45 9 Screw the nut to the sensor head conduit connector head coming though to the analytical unit bulkhead fitting. NOTICE To ensure that the analytical unit retains its environmental protection rating, make sure that the cable connector is pressed hard against the fitting gasket. Connecting the CoreSense M10 45...
  • Page 46: Connecting The Gas Lines

    Connecting the gas lines Gas lines route gases from the sensor head to the analytical unit. They are made from semi-rigid stainless steel tubing. NOTICE You can connect any of the gas lines to any of the two gas connectors inside the unit. To connect the gas lines: 1 Stretch out the gas line tubing slightly to bring its tip to a gas connector inside the cabinet.
  • Page 47: Connecting The Internal Communication Cable

    For more information on the various communication cables used, see Table 4 on page 24 and “Connector definitions” on page 89. For more information on configuring the communication protocols, refer to the CoreSense M10 Monitoring System User Guide. Connecting the CoreSense M10...
  • Page 48: Connecting The Sensor Head Dc Power Cable

    Connecting the sensor head DC power cable The sensor head DC power cable sends low voltage power to the sensor head for almost every electrical task except the heating element. 1 Of the cables coming from the sensor head conduit, identify the one with the red and black internal wires.
  • Page 49 2 Loosen the two screws holding the terminal block cover in place (see Figure 28). — Figure 28 Loosening the two screws holding the terminal block cover 3 Slide out the terminal block cover, exposing the terminals. — Figure 29 Removing the terminal block cover System electronics grounding cable Connecting the CoreSense M10 49...
  • Page 50: Connecting The Cable

    Connecting the cable NOTICE All terminals are properly identified in the instrument itself to simplify installation. 1 Of the cables coming from the sensor head conduit, identify the one with green, blue and brown internal wires. This is the AC power cable. —...
  • Page 51 — Figure 32 Routing the sensor head AC power cable to the terminal block Protection rail top cover 4 Connect each wire in the appropriate terminal. — Figure 33 Connecting the sensor head AC wires Connecting the CoreSense M10...
  • Page 52: Connecting The Mains Ac Power Cable

    Connecting the mains AC power cable Once all internal connections have been completed, you need to bring power to the analytical unit from the power distribution panel. NOTICE It is the user’s responsibility to provide a power cord that fits local electrical requirements. Safety ONLY qualified personnel may perform the electrical installation of the monitoring system.
  • Page 53: Connecting The Cable

    1 Insert the cable through the power entry port and route it under the cable guide found on the left- hand side of the analytical unit cabinet (see Figure 35 on page 53). — Figure 35 Routing the mains power cord toward the power entry terminal block Power entry port Connecting the CoreSense M10...
  • Page 54 NOTICE Once the installation is complete, it is strongly suggested to use tie wraps (in white on Figure 35) to secure the cables to the cable guides. Remove the protection rail top cover and continue routing the wire through the upper protection rail all the way to the appropriate terminal, as illustrated in Figure 35.
  • Page 55 3 Once both AC power cables are properly connected, put back the terminal block cover. — Figure 38 Putting back the terminal block cover 4 Tighten the screws that hold the terminal block cover. — Figure 39 Tightening the two screws holding the terminal block cover Connecting the CoreSense M10...
  • Page 56: Powering Up The Coresense M10

    — Figure 40 Pulling the breaker switches to power up the monitoring system Establishing SCADA connections ABB recommends using a Cat5 Ethernet cable. NOTICE Do not use the optical Ethernet port when using the copper-based SCADA Ethernet port. Installation Guide...
  • Page 57: Establishing Rs-485 Connections

    For more information on the various communication cables used, see Table 4 on page 24 and “Connector definitions” on page 89. For more information on configuring the communication protocols, refer to the CoreSense M10 Monitoring System User Guide. Connecting the CoreSense M10...
  • Page 58: Establishing Analog 4-20 Ma Connections

    For more information on the various communication cables used, see Table 4 on page 24 and “Connector definitions” on page 89. For more information on configuring the communication protocols, refer to the CoreSense M10 Monitoring System User Guide. Installation Guide...
  • Page 59: Inputs

    For more information on the various communication cables used, see Table 4 on page 24 and “Connector definitions” on page 89. For more information on configuring the communication protocols, refer to the CoreSense M10 Monitoring System User Guide. Connecting the CoreSense M10...
  • Page 60: Installing Relays

    Installing relays This is the diagram to install the communication relays between external sensors and the CoreSense M10. These relays are underneath the terminal box (see Figure 3 on page 13). For more information, see “Power and relays” on page 91.
  • Page 61: Establishing Optical Ethernet Connections

    CoreSense M10 Monitoring System User Guide. Closing the analytical unit door The CoreSense M10 analytical unit complies with the IP66 and NEMA 4X standards. To ensure that the unit remains compliant when you close the unit door, you must tighten the unit latch screws to 9 N·m (80 lbf.in) according to the sequence indicated below:...
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  • Page 63: Configuring Coresense M10

    ABB and its affiliates are not liable for damages and/or losses related to such security breaches, any unauthorized access, interference, intrusion, leakage and/or theft of data or information.
  • Page 64: Establishing Communications

    (see “Analytical unit communication ports” on page 14). 2 Open your web browser and point it to the default IP address http://10.127.127.127 This address points to the CoreSense M10 dashboard. — Figure 47 CoreSense M10 dashboard Installation Guide...
  • Page 65: Modifying Default Passwords

    The default operator and administrator passwords are: • Operator • Administrator Admin To modify passwords: 1 From the CoreSense M10 dashboard (see Figure 47), click Settings. The Settings page appears. — Figure 48 CoreSense M10 Settings page 2 Click Administration settings.
  • Page 66 — Figure 49 Settings section 4 At the bottom of the page (depending on the size of your screen, you might have to scroll down), click Apply to save the new passwords that meet the security criteria set by your company, and confirm these.
  • Page 67: Setting The Date And Time

    Setting the date and time To set the system date and time: 1 From the CoreSense M10 dashboard (see Figure 47), click Settings. The Settings page appears. — Figure 51 CoreSense M10 Settings page 2 Click Administration settings and enter your password (for more information on setting passwords, see page 65).
  • Page 68 — Figure 53 Setting the system date and time 4 Browse to select the appropriate date. 5 From the drop-down menus at the bottom of the calendar, select the appropriate time. 6 At the bottom of the page (depending on the size of your screen, you might have to scroll down), click Apply to save the selected date and time.
  • Page 69: Activating The Thermal Pump

    OFF. The CoreSense M10 sensor head is delivered with the thermal pump turned OFF. When installation is complete and the sensor head is in contact with oil, make sure to activate the thermal pump.
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  • Page 71: Maintenance And Troubleshooting

    • Make sure that all enclosures and the connecting cable are properly secured. Troubleshooting Most problems that could happen within the CoreSense M10 monitoring system will be recorded as events in the Events log. You will be informed of these problems either with alarms or by looking at the...
  • Page 72: Understanding Cabinet Leds

    An event is or experimenting a fault condition. Consult the created accordingly and a service call should be event log and contact ABB. made. NOTE: The blinking blue LED can be lit at the same time as other LEDs since the...
  • Page 73: Understanding Sensor Head Leds

    YELLOW This indicator light will remain Gas level of at least one gas Moisture levels Or 24-hour on while the CoreSense M10 Or 24-hour rate-of-change rate-of-change are above is booting up. If the sensor of at least one gas is above...
  • Page 74: Exporting The Events Log

    Should you need to call ABB’s after-sales service (contact information on the back cover of this manual), you will be asked to provide the event log file of your CoreSense M10. To provide this file, you need to export it from the instrument.
  • Page 75: Giving Access To Administrative Settings On The Scada Port

    To enable this feature: 1 From the CoreSense M10 dashboard (see Figure 47 on page 64), click Settings. The Settings page appears (see Figure 51). 2 Click Administration settings and enter your password if necessary (for more information on passwords, see “Modifying default passwords”...
  • Page 76: Installing Firmware Updates

    Figure 60 Firmware update page 5 Click Choose File. 6 In the Open window that appears, locate and select the firmware file (.zip) sent to you by the ABB service representative. 7 Click Open. You return to the firmware update page. The name of the file that you selected appears next to the Choose File button and the Update button is now active.
  • Page 77: Updating With A Usb Key

    Your system reboots once the firmware is updated. 9 After the system has been automaticaly rebooted, return to the web page and click About Coresense™ M10 to make sure that the application version is the one given to you by the ABB service representative.
  • Page 78 — Figure 63 Instrument USB port 5 Turn on the instrument using the main power switch (see Figure 4). The update process will start automatically and take a few minutes. Messages will appear on the local screen during the update process. Also, the instrument may reboot two or three times depending on the required updates for your system.
  • Page 79: Taking An Oil Sample

    Taking an oil sample Occasionally, you might need to take an oil sample from the transformer to send to laboratories for analysis. Oils samples are gathered from the sensor head. To do take an oil sample: 1 Remove the external sampling port cover located on top of the sensor with the 4 mm hex key. 2 Connect the provided bleeding hose (ID 3.18 mm [0.125 in]) to the sampling adapter.
  • Page 80 4 Loosen the bleed screw with the 4 mm hex key and wait until oil comes out of the sensor. 5 Once you have gathered enough sample oil, tighten the bleed screw to a maximum torque of 2.26 N·m (20 lbf.in). NOTICE Do not apply excessive torque.
  • Page 81 7 Re-install the external sampling port cover and secure it with the 4 mm hex key. Maintenance and troubleshooting...
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  • Page 83: Technical Specifications

    — C h A p T E r 9 Technical specifications The following pages indicate the CoreSense™ M10 technical specifications. NOTICE While the initial (cold start) accuracy of the sensor is likely to be within specifications, a settling period of approximately 12 hours is strongly recommended to allow electronic components to fully warm up and the internal temperature to stabilize.
  • Page 84: Environmental Specifications

    Maximum switching (breaking) power 1500 VA, 250 V AC (AC1 [resistive]) Contact resistance 100 mΩ (at 1 A/6 V DC) Rated insulation voltage 250 V AC between coil and 4 kV 1 min Rated impulse contacts withstand voltage U between open contacts 1 kV 1 min Environmental specifications Operating ambient temperature...
  • Page 85: Laser

    Carbon Monoxide (CO) Range (ppm) 2 to 5,000 Repeatability (%) ±5 (or ±LDL, whichever is greater) Carbon Dioxide (CO₂) Range (ppm) 5 to 20,000 Repeatability (%) ±5 (or ±LDL, whichever is greater) Methane (CH₄) Range (ppm) 1 to 10,000 Repeatability (%) ±5 (or ±LDL, whichever is greater) Acetylene (C₂H₂) Range (ppm)
  • Page 86: Communication

    Communication Digital interfaces rS-485 serial port 2 × rJ45 100Base-T Ethernet ports 100base-FX fiber optic Ethernet port USB port Protocols Modbus rTU over rS-485 and Modbus TCp over Ethernet DNp3 over rS-485 and Ethernet IEC 61850 over Ethernet Analog interfaces 4 dry-contact relays for alarms 8 analog 4–20 mA outputs for publishing values 4 analog 4–20 mA inputs for reading external sensors...
  • Page 87: Physical Installation Checklist

    — A p p E N D I X A Physical installation checklist □ The system date is set properly using the CoreSense™ M10 web interface. □ The thermal pump is enabled (see “Activating the thermal pump” on page 69). While the thermal pump is disabled, the SYSTEM LED is yellow.
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  • Page 89: Connector Definitions

    — A p p E N D I X B Connector definitions Inputs and outputs NOTICE You must use copper wires only. Using other types of conductors could damage the instrument AND void the warranty. — Figure 65 Analytical unit communication ports Connector Connection Type...
  • Page 90 Connector Connection Type Wire Max. length Screwdriver rS485 1. TX+ rS-485 Stranded 1220 m (4003 ft) Flat Ø 3.5 mm (SCADA) 2. TX– AWG #24 to AWG #16 3. rX– WITh FErrULE 4. rX+ 5. rET hU485 1. TX+ rS-485 precabled 10 m (33 ft) Flat Ø...
  • Page 91: Power And Relays

    Power and relays — Figure 66 Power and relay connections (front view) B D F A C E G H Connector Connection Type Wire Screwdriver 14 - NO Alarm 1 11 - COM Maintenance 12 - NC 14 - NO Copper only wire Alarm 2 11 - COM...
  • Page 92 Connector Connection Type Wire Screwdriver hU AC live 120–240 V AC Copper only wire hU AC neutral 50/60 hz Flat screwdriver Ø 3.5 mm Stranded AWG #18 WITh FErrULE 3.15 A max. hU AC earth Copper only wire AC earth Flat screwdriver Ø...
  • Page 96 We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

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