Safesix. ABB Switchgear. 12 kv switchgear manual. Instruction 1VES Edition 97-11

Transcription

1 Safesix Instruction 1VES Edition kv switchgear manual ABB Switchgear

2 CONTENTS Page 0. Access zones General description Standards Cubicle design Personnel safety Dimensions and weights Busbars and downleads PC intermediate wall with shields Earthing Running gear and interlock system Temperature indicators Power circuit breaker cubicle Load disconnector cubicle SFL Load disconnector cubicle NAL/NALF Disconnector cubicle Metering cubicle Sectioning cubicle Contactor cubicle Contactor cubicle Erection requirements Lift truck Floor Space requirements Unloading Moving in Setting up Fitting busbars Fitting busbars, light series Fitting busbars, heavy series Cubicle and system earthing Fitting roof panels Connecting power cables Connecting control cables Post-tightening Post-tightening Post-tightening Commissioning new switchgear Commissioning after stoppage for repair or other action Commissioning after stoppage Operating instructions Circuit breakers HPA and HA Circuit breaker shift Circuit breaker shift to operating position Circuit breaker shift to disconnected position Load disconnector SFL Safesix SFL interlock chain Shifting load disconnector SFL Shifting load disconnector SFL to operating position Switching load disconnector on Shifting load disconnector SFL to disconnected position Switching load disconnector off Load disconnectors NAL 12/630, NALF 12/ Operating NAL/NALF Maintenance rules Switchgear cubicle maintenance Lubricants Cleaning agents Accessories, spares and ancillary equipment Documentation references...60

3 0 Access zones Switchgear is not intended to be accessible to the general population. The access zone for operators is the service entrance at the front of the switchgear. Only servicing personnel are allowed to open switchgear doors. All operation of a withdrawable switching or connecting unit must be with the doors closed. 1 General description ABB's Safesix switchgear series is divided into compartments and intended for indoor locations. It is available in three different voltage versions of 12, 17.5 and 24 kv. This documentation is for the 12 kv version. The cubicles are sized for operating currents of up to 3150 A and maximum 4000 A on the busbars and a short-circuit current of up to 40 ka. Safesix 12 kv switchgear is available in two forms: Light series Max. rated current 1600 A. Max. short-circuit current 31.5 ka. Heavy series Max. rated current 4000 A. Max. short-circuit current 40 ka. The range comprises the following cubicles: Circuit breaker cubicle, with SF 6 -breaker Switch disconnector cubicle, with SF 6 -or air-insulated switch disconnector Disconnector cubicle, with drawer-mounted disconnector Metering cubicle, with measuring transformers Sectioning cubicle, with withdrawable switching or connecting unit Interconnection cubicle Contactor cubicle with vacuum contactor (max. 7.2 kv) The withdrawable switching and connecting units have the following functions: Circuit breaker Can make, carry and break operating current and short-circuit current Switch disconnector Mechanical electrical switch operated manually. Can make, carry and 1

4 break normal operating current. Can carry short-circuit current for a specified period. Can close against shortcircuit current and can be provided with fuses and short-circuit protection. NAL and NALF have visible break points. SFL has mechanical indication. Type of switch used preferably where both switching density and current are low. Disconnector Contactor Operated manually and has visible disconnection distance. Cannot connect current but can carry operating and short-circuit current. Safesix has a disconnector of drawer-mounted design that can be interlocked so that it cannot be shifted when energised. Electrical switch that is operated electrically and has an electrical or mechanical latch. Can make, carry and break normal operating current and carry short-circuit current for a specified period. Can be supplied with fuses as short-circuit protection. Type of switch used preferably where switching density is high and current low. Circuit breaker cubicle Sectioning cubicle 31.5 ka A Sectioning cubicle 40 ka A Disconnector cubicle Metering cubicle Switch disconnector cubicle Inter connection cubicle Contactor cubicle Fig. 1. Examples of cubicle types in ABB Safesix range. 2

5 1.1. Standards Standards complied with: SS-IEC 298. Electrical requirements complied with: Rated voltage: 12 kv SS-IEC 298 Test voltage: Impulse withstand voltage 75 kv 1.2/50 µs. Power frequency voltage 28 kv 50 Hz, 1 min. All voltage levels apply to earth and between phases (max m above sea level). Rated current: Busbars: 630, 800, 1250 and 1600 A for light series. 1250, 2000, 2500, 3150 and 4000 A for heavy series. Circuit breakers and cubicles: 630, 800, 1250 and 1600 A for light series. 800, 1250, 2000, 2500 and 3150 A for heavy series. The above current values apply with enclosure IP3X, max. temperature rise as per SS-IEC 298 table V at max. average ambient temperature 35 C and max. short-time temperature 40 C. Rated short-time current: Rated impulse current peak value: 25, 31.5 and 40 ka in one second. 25 and 31.5 ka in 3 seconds (option). 2.5 x rated short-time current. Mechanical requirements complied with: Enclosure: Outer enclosure IP3X according to SS-IEC 298. Partitions IP2X as seen from withdrawable switching or connecting unit compartment. Environmental requirements complied with: Ambient temperature: As per SS-IEC 298, -5 C to +40 C. Switchgear can be equipped to cope with difficult environments. 3

6 1.2. Cubicle design Cubicle frames and rear panels made of spot-welded 2 mm Aluzink sheetsteel. Doors of 2.5 mm painted sheet steel. Cubicles may either be backed up against a wall or placed with sufficient clearance to leave the rear accessible. They may also be ordered with exhaust channels designed for minimum roof height 2650 mm. Each cubicle is divided into a number of compartments: Busbar compartment Low-voltage compartment, with contents varying from installation to installation. A detailed description of this compartment appears in the documentation specific to each order Withdrawable switching or connecting unit compartment Cable compartment All HV compartments (busbar compartment, cable compartment and withdrawable switching or connecting unit compartment) have individual upward pressure relief ducts with top covers that opens by any overpressure in the respective compartment. Lead-in duct for external LV cables Low voltage box door and Combiflex framework Instrument space Upper door Busbar compartment LV compartment Compartment for withdrawable switching or connecting unit Racking mechanism PC partitions Lower door Air intake for cubicles with rated current ³ 1600 A Partition wall for compartment division Cable compartment Fig. 2a. Safesix cubicle space distribution. 4

7 The front of cubicles for 1600 A or over is provided at the bottom with a cooling air intake to create sufficient ventilation. This intake is provided with a patented check valve. On 3150 A circuit breaker cubicles the lower door is also provided with ventilation apertures. Each cubicle is provided with lighting. The incandescent bulb can be replaced from the LV compartment and is situated outside the compartment rear wall Personnel safety Personnel safety High voltages and currents can cause serious injuries, so the Safesix range is designed for maximum elimination of accident risks. Contact safety As it is vitally important for servicing personnel to be protected from inadvertent contact with energised parts, Safesix cubicles are divided into compartments. Among other advantages, this prevents access to energised busbars when disconnected circuit breakers are being inspected. The walls between compartments are partly transparent. The advantages of this include being able to view the disconnection distance through the window in the LV compartment. CAUTION! There is no contact protection inside the lower door. The cable side has to be de-energised and be earthed by means of the earthing switch before opening the door. Unauthorised access can be prevented by padlocking the handles of both the upper and lower doors. Arcing safety The outer enclosure has been arc-tested to SS-IEC 298. The front, rear and sides withstand the pressure caused by arcing faults. Safesix cubicles have also been successfully tested to SS-IEC 298 with breaker doors open. Damage caused by arcing faults is extensive and costly, so their causes need to be eliminated despite the high degree of personnel safety built into Safesix switchgear. The following are possible causes of flashover: Small animals, most commonly rats or mice, that make their way into HV spaces Overheating due to bad threaded connections, oxidised 5

8 contacts or overload High overvoltages, e.g. during thunderstorms Objects such as tools inadvertently left behind Faulty or severely fouled components or cable terminations The Safesix design incorporates the following measures to improve the prevention of arcing: Holes in outer enclosure too small for even small animals to make their way into HV spaces Erection instructions give torques for correct tightening of threaded connections Spring washers used in threaded connections of primary conductors to control prestress forces even after a number of temperature cycles and sagging of material Busbar monitoring by SafeGuard (option) Overvoltage limitation by surge arrestor (option) Arcing fault prevention by arc monitor (option) to trip the breaker when it indicates a powerful arc combined with high current. This involves the development of pressure waves that reach their maximum in a hundredth of a second Exhaust gas channels (option) For gathering and leading overpressure and flue gases away so as not to affect switching operations. As the channels lead to outdoor outlets, the switchgear room is not pressurised or polluted by toxic arc gases. Voltage indicator (option) Earthing medium-voltage switchgear is a safety risk. To minimise it, the earthing should be effected inside closed doors by means of earthing switches. Each cubicle is provided with an interlock system to prevent incorrect operation. It may also be provided with voltage indicators that display 1, 2 or 3 if the corresponding phase is energized. Fig. 2b. Voltage indicator SafeGuard (option) SafeGuard is a monitoring system covering, among other things, the temperatures of busbar joints and contacts in the main circuit. The continuous information thus provided helps to eliminate the risk of arcing faults. 6

9 Temporary earthing Safesix switchgear is equipped with a patented earthing switch that has the following features: It can be operated when the doors are closed It has making capacity up to 40 ka rms The window in the lower door makes it possible to see whether the earthing switch is closed or open Illicit operation is prevented by interlocking by means of a blocking disc that closes the operating hole when the breaker is in operating position or being shifted Training It is very important that operators and servicing personnel be trained in handling the equipment Dimensions and weights Weights A 12 kv switchgear cubicle (without circuit breaker) normally weighs 400 to 600 kg depending on equipment, e.g. an 800 A circuit breaker cubicle weights 400 kg. A circuit breaker weighs between 180 and 235 kg, depending on its rated current. Max Series Dimensions mm current A H W D 1600 Light Heavy Heavy Fig. 3. Dimensions of 12 kv switchgear cubicle. 7

10 Busbars and droppers PC-partition with shutters Busbars and droppers are normally supplied uninsulated but can be supplied with insulation to order. Busbars are made of copper with cross-section suited to the rated current. The switchgear is of the drawer-mounted type. The withdrawable units can be cranked into and out of the compartments. The withdrawable unit compartment and the busbar compartment are separated by a partition of polycarbonate to prevent inadvertent contact with live parts when the unit is removed. This partition incorporates six shutters that are opened by the connecting bars when the unit reaches operating position. The PC partition and the shutters provide IP3X as degree of protection. PC partitions Earthing switch shaft with position symbol Shutters Box with earthing switch auxiliary contacts and interlock magnets Fig. 4. PC partitions with shutters (racking mechanism removed) Earthing Fixed earth paths, system earthing Safesix has two alternative earthing arrangements. The first is for each cubicle to be earthed separately, with terminals for connecting external earth conductors to the earth bar in each cubicle. The other alternative has an earth bar running through the whole switchgear, with terminals for connecting external 8

11 earth conductors to the earth bar in each cubicle. The only earth connections of the station are in the outer cubicles. Equipment items incorporated are earthed to the frame, except for the earthing switch and the voltage transformers, which have earthing wires to the earth bar of the cubicle. Temporary earthing A standard fitting for temporary earthing of cable is an earthing switch permanently fitted in the cubicle. Any busbar earthing switch fitted will be on the righthand end cover. An option available is to equip the earthing switch with voltage indicators that display on the cubicle front. The earthing switch is operated from the cubicle front by means of a crank. On earthing switch operation see section 5.1.1, Shifting withdrawable units Racking mechanism and interlocking system Each withdrawable unit is provided with wheels that run along channel sections on the sides of the cubicle. The unit can be pulled out onto the door. A stop mounted on the door prevents its being pulled too far out. For instructions on shifting withdrawable units, see section The racking mechanism has interlocks to prevent incorrect operation. Torsion disc Selector cam Stop Racking mechanism operating hole Selector Earthing switch operating hole Fig. 5. Interlock system. 9

12 The interlock system has active interlocks (preventing access to operating holes) that mechanically make it impossible to: 1. shift a closed circuit breaker (blocking disc covers racking mechanism operating hole, selector rotation breaks control circuit) 2. shift a closed circuit breaker from test position to service position (blocking device on righthand side of circuit breaker hits the stop) 3. close the circuit breaker while it is being shifted (during which it has no control voltage) 4. shift the circuit breaker from disconnected position to service position if the earthing switch is closed (blocking disc covers racking mechanism operating hole) 5. connect the earthing switch if the circuit breaker is in service position or being shifted (blocking disc covers earthing switch operating hole) 6. push the circuit breaker in from disconnected position if the racking mechanism is in the wrong position when the circuit breaker is run in from the door (blocking devices on selector shaft and torsion disc stop the circuit breaker) 7. place the selector in shift position if the circuit breaker is closed (blocking device in circuit breaker prevents selector movement) 8. place the selector in service position if the circuit breaker is not fully run in to service position (selector cam cannot enter recess in torsion disc) 9. run a withdrawable unit into a cubicle intended for a higher rated current (prevented by blocking devices on rails and on withdrawable unit wheel undercarriage) As an option the cubicle may be equipped with motorised racking mechanism. 10

13 Temperature indicators An option with which Safesix cubicles can be provided is temperature indicators consisting of two small self-adhesive markers positioned to detect the temperature at critical points on the conducting path. They replace thermography and are used for preventing malfunctions due to overheating. 1. The 104 C marker is white when unaffected and turns darker when subjected to excessive temperature. Neither time nor temperatures below 104 C affect it. It is placed close to critical points in cases where they are visible from the front of the cubicle. 2. The 70 C marker is reversible. Up to 70 C it is red but beyond that it turns darker and displays the numerals 70. It reverts to red upon cooling. It is placed in a clearly visible position adjacent to the point that may become hottest in cases where the critical point cannot be seen from the front of the cubicle. Fig. 6. Temperature indicators for 12 kv. 11

14 1.3. Circuit breaker cubicle Data Rated current A 630, 800, 1250, 1600, 2000, 2500, 3150 Rated voltage kv 12 Insulation level kv 28/75 Insulation level kv 38/75 (option) Rated short-time current peak value ka 62.5, 79, 100 Rated short-time current, 1 s ka 25, 31.5, 40 Rated short-timecurrent, 3 s ka 25, 31.5 (option) This cubicle contains an SF 6 -circuit breaker (described separately) of the withdrawable type and can be provided with current transformers, voltage transformers, earthing switch and cable fastenings. In the light series (max A) four parallel cables can be connected. In the heavy series there is space for up to six parallel cables. The cubicle incorporates interlocks to prevent the connection of undersized units. The withdrawable unit can be shifted inside the closed door, thereby creating a disconnection distance that can be viewed through the window in the LV compartment (see Fig. 7). Window in low voltage compartment Fig. 7. Circuit breaker cubicle. 12

15 1.4. Switch disconnector cubicle SFL Contains an SF 6 -switch disconnector which is drawer-mounted and placed in the withdrawable unit cell. The rated current is up to 630 A without fuses and up to 100 A with high-power fuses. The switch disconnector is operated manually inside the closed door by means of a control lever. For fuse replacement the unit has to be pulled out onto the door (see separate instructions 1VEH The racking mechanism can be used inside the closed door to shift the withdrawable unit to disconnected position, thereby creating a disconnection distance that can be viewed through the window in the bottom of the LV compartment. This cubicle can be used for up to 20 ka if the withdrawable unit has no HV fuses or for 40 ka with fuses. The upper door is extended by 40 mm, making a total cubicle depth of 1375 mm. Window in low voltage compartment Fig. 8. Switch disconnector cubicle with SFL. 13

16 1.5. Switch disconnector cubicle NAL/NALF Contains a drawer-mounted switch disconnector in the withdrawable unit cell. The switch disconnector is operated manually inside the closed door by means of a control lever. It can be provided with high-power fuses up to 100 A. For fuse replacement the withdrawable unit has to be pulled out onto the door. It has a visible disconnection distance at the knives, so it has no disconnected position in the cubicle. It is therefore connected in service position when just inside the door. This cubicle can be used for 40 ka if the withdrawable unit has fuses and for 25 ka without fuses. It can be provided with current and voltage transformers and an earthing switch. Window in low voltage compartment Fig. 9. Switch disconnector cubicle NAL/NALF. 14

17 1.6. Disconnector cubicle Same construction as the circuit breaker cubicle. The withdrawable disconnector has the same contact positions in the conducting path as the corresponding circuit breaker. Disconnection is achieved by shifting the withdrawable unit from service position to disconnected position. Disconnection can be effected by means of racking mechanism inside the closed door. The cubicle can be provided with current and voltage transformers and an earthing switch. The disconnector has no make and break facilities. Interlocks prevent incorrect operation. The disconnection distance can be viewed through the window in the LV compartment. Blocking devices prevent withdrawable units with too small a rated current being run into the cubicle. Window in low voltage compartment Fig. 10. Disconnector cubicle. 15

18 1.7. Metering cubicle This cubicle can measure current or voltage or both. It can be provided with IHBF type current transformers or with transformers to DIN standard (small model). Max. operating voltage Primary rated current: IHBF type, 12C DIN type Secondary rated current Frequency 12 kv Up to 1250 A, two cores Up to 3200 A, three cores 5 A Hz The cubicle can be provided with KRES type voltage transformers, which are single-phase versions intended for connection between phase and earth. All three phases should be fitted. Primary rated voltage Secondary rated voltage Frequency 12 kv 110/Ã3 V for metering and 110/3 V for earth-fault protection Hz The cubicle can be equipped with an earthing switch type NJS 12 with making capacity 40 ka, 1 s. Fig. 11. Light-series metering cubicle measuring both current and voltage. 16

19 1.8. Sectioning cubicle The function of this cubicle is to divide switchgear into two sections. It is mainly constructed in the same way as the circuit breaker cubicle with a circuit breaker or disconnector withdrawable unit. It can be equipped with current and voltage transformers and an earthing switch. In the light series everything is housed in one cubicle. In the heavy series two cubicles are used, one of them containing the withdrawable unit, measuring transformers and earthing switch, the other containing only sectioning busbars. There are two different sectioning combinations, one with current measurement before the withdrawable unit, the other with it after. Light series: Rated current A, max. short-time current 31.5 ka. Heavy series: Rated current A, max. short-time current 40 ka. Fig. 12. Light-series circuit breaker cubicle with sectioning. For the heavy series a two-cubicle combination is used. 17

20 1.9. Contactor cubicle Data Rated voltage kv kv Insulation level /40 kv.20/60 kv Rated current with fuse A A Fuse length mm..442 mm Rated short-time current ka ka Rated short-time current with fuse..40 ka ka This cubicle contains a VRC type vacuum contactor which is drawer-mounted and placed in the withdrawable unit compartment. It is operated electrically and has both electrical and mechanical latch. For fuse replacement the withdrawable unit has to be pulled out onto the door. Racking mechanism can be used to shift the contactor to disconnected position inside the closed door, thereby creating a disconnection distance that can be viewed through the window in the bottom of the LV compartment. The upper door is extended by 40 mm, making a total cubicle depth of 1375 mm. Fig. 13. Contactor cubicle. 18

21 2 Erection instructions CAUTION! Take good care to follow these instructions precisely so that cubicles are not dropped or tipped over during unloading, moving in and setting up. When handling cubicles, take particular care to avoid causing pinching or injuries Erection requirements Trolley A pallet lifter with maximum width 540 mm may be used to move cubicles into the switchgear room. This is catered for by placing two lifting yokes on the cubicle as in Fig. 18. Before moving the cubicle, check that apertures for cables are in accordance with layout drawings and with Figs. 27 and 15. Examine the floor surface and note irregularities so that the cubicle can subsequently be adjusted to the correct level. CAUTION! When using a trolley, the unit concerned must always be carried in the lowered position. Do not leave it in the raised position on the trolley. Removing a withdrawable unit from a cubicle or putting it in involves using a trolley. The trolley will lift the circuit breaker, drawer-type disconnector, switch disconnector or contactor from the floor to the correct height for placing it on the opened upper door. Order no. Description 1VES AAA Trolley 1VES AAB Adaptor for voltage measuring sets Section to front wheel Square tube Section to front wheel Square tube Position for 12 kv Fastening bolt Position for 24 kv Fastening bolt Fig. 14a. Trolley. 19

22 The same trolley is used for both 12 and 24 kv switchgear and is normally supplied in the 12 kv position. If it is in the 24 kv position, it can still be used if there is space beside the outer cubicle. The trolley can be made about 100 mm narrower (12 kv position) by slackening the bolts (two on each side) that fasten the sections on which the front wheels are mounted to the fixed square tube in the truck frame. Adjust the position of the sections in the square tubes and retighten the bolts (see Fig. 14 a). Lifting voltage measuring sets requires the use of a special lifting adaptor which is suspended on the trolley forks by placing the front ends of the forks in the two slots in the square sections that act as guides in the lifting adaptor. Inset the pin in the hole in the movable spacer tube, then insert one end of the spacing tube in the lowest square tube in the lifting adaptor. Push out the two guided stays and push the screws at their bottom ends in through the holes in the side panels of the voltage measuring set and lift as in Fig. 14b. Pin Spacer tube Fig. 14b. Adaptor for lifting voltage measuring sets Floor Cubicles can be erected on various types of floor. The maximum permitted variation in level is 10 mm over the whole length of the switchgear. 20

23 Concrete floor: Should incorporate the smallest possible holes for the power cables. Note that single-phase cables should not be run through their respective holes if there are steel reinforcements between holes. The reason for this is to prevent reinforcements forming magnetic loops that might cause heating and losses. After cable erection, the holes should be sealed against fire and small animals. Alternatively the cubicle bottom may be provided with a cable seal plate. Cable holes should be aligned with cable fastening points as in Fig. 27. For cubicle fastening to floor, see section 2.5, Setting up. Switchgear floor on framework: Should be constructed so that cubicle feet stand on the longitudinal square tubes. No height adjustments are required on floors of this type. Fastening by bolts through the square tube as in Fig. 20b. Floor with longitudinal cable channel: A 500 mm cable channel maybe used. Place the cubicle so that its bottom hole is over the centre of the cable channel, the front adjusting feet are in front of the channel and the rear feet behind it. With this kind of arrangement the cubicle should be provided with a cable seal plate to keep out small animals by being clamped tight to the cubicle bottom Space requirements Cubicles may be positioned with their rear as close to a wall of the building as the construction tolerances allow (about 20 mm). Figs. 15 and 16 show the space requirements around a cubicle. Fig. 15. Dimensional drawing for cubicle bottom. 21

24 Right-hand end cover with earthing switch on busbar Switchgear with end covers Right-hand end cover without earthing switch min 2650 Circuit breaker door folded out N.B. According to SS and the Electrical Safety Authority's heavy current regulations (ELSAK-FS 1994:7), if there is another row of switchgear opposite, the space between the cubicle fronts must be at least 1920 mm. 700 min min min 1500 min 150 min 150 Fig. 16. Space requirements for Safesix switchgear. 22

25 2.3. Unloading Cubicles are supplied wrapped in plastic, banded to pallets or packed in boxes. Withdrawable units are locked in disconnected position inside their cubicle. The easiest way to unload cubicles is by fork truck. If they are unloaded by crane, the four lifting eyes should be used (see Fig. 17). Check that there is no transport damage. Fig. 17. The lifting weight of cubicles is normally kg Moving in CAUTION! If the transport protection was broken during loading, the cubicle enclosure will have sharp edges on the sides and top. Be particularly careful when handling or touching these areas. Keep cubicle packaging as long as possible. Use a pallet lifter to remove the cubicle from the shipping pallet by inserting it in the cubicle and placing two lifting yokes as in Fig. 18. The cubicle can only be transported in this way with the Lifting tackle Fig. 18. Pallet lifter positioning. 23

26 circuit breaker removed. Before inserting the pallet lifter in the cubicle, lift off the lower door and keep it well protected during the erection period, e.g. on a pallet. The measuring transformer unit is sized for possible use as a rear yoke. NB! If the cubicle cannot be transported upright, e.g. because of doorways being too low, it may be placed on its back on a pallet and carried by pallet lifter to the erection site. Remove the withdrawable unit before placing the cubicle on its back. CAUTION! Keep in mind the risk of pinching or injury between doorways and equipment and between trucks and equipment. To remove the withdrawable unit, place the selector in position 2 (removal onto door). The unit is thus released and can be rolled out onto the door. This may be done with the cubicle standing on a pallet. CAUTION! Only in the lowered position should a unit be carried by lift truck. Do not leave it in the raised position on the truck. The safest way to run a lift truck carrying a withdrawable unit is in the lowered position. Roof panels and busbars are supplied packed separately in the respective cubicle. Check the materials sent with them against the accompanying specification. Complaints about missing or damaged items must be raised as soon as possible Setting up CAUTION! Cubicle enclosures have sharp edges on the sides and roof. Take particular care when handling these areas. Figu.19. Positions of bolted connections. 24

27 Setting up commences with the cubicle standing on the highest part of the floor. Use the four adjusting screws as necessary to adjust the cubicle to the correct level (this does not apply to switchgear floors with framework). Check the distance between the set-up cubicle and sidewalls (distance = number of cubicle widths + side arrangements) as in Fig. 16. If the cubicle is to stand with its rear against a wall, check that all the screws in the rear panel are tightened before positioning the cubicle against the wall. Place the next cubicle and adjust to the correct position. See that its front is in line with the first cubicle. Bolt the cubicles together with four M8x16 as per Fig. 19. Fasten cubicles to the floor as per Figs. 20a and 20b. In a row of up to four cubicles, fasten only the outer ones. Where there are more than four, fasten every third. Drill holes in the floor, using the square holes of the adjusting screws as jigs. For Hilti HKDM10 type expanders drill to diameter 12, depth 50. Washers should be used (see Fig. 20a). The bellows for control lines between cubicles is permanently mounted on the lefthand side of each cubicle and should be inserted in the respective hole in the cubicle to the left (multipole contacts with bellows are optional). For erection of busbars, see section 2.6. Erect the other cubicles in the row by the same procedure. CAUTION! Beware the risk of pinching when closing doors. When all the cubicles in the row have been set up, check that their fronts are in line and that their doors and locking devices function properly. It is important that the doors be closed and the handles folded into them in order that they should withstand the pressure caused by any arcing fault. The handles should be easy to operate. Check the movement of the withdrawable units by shifting them from door to operating position and back. Adjust the threshold in each cubicle downwards towards the floor. When handling an upper door, the handle should be grasped with both hands. To open an upper door, raise the handle and the door will fold out downwards. To close it, raise the handle and close the door, then press the handle down against the 25

28 Use a small-diameter hose to blow drill cuttings away Hilti type expander Fig. 20a. Cubicle fastening to concrete floor. Fig. 20b. Cubicle fastening to "switchgear floor". door panel. To open a lower door, pull the handles out towards you, then turn them upwards. The door will move upwards and outwards. To close the lower door, fold the handles out from the door and turn them upwards. Use the guide pins on the door to raise it into position, then press the door downwards, turn the handles downwards and fold them in. The gap between cubicle front side-panels is a nominal 3 mm and should not be reduced, as cubicles are tight together in middle part. 26

29 2.6. Fitting busbars CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas Light series Supplied with busbars mounted on their insulators and tilted so as not to protrude from the sides of cubicles. Torquing as per section Right-hand outer cubicle Intermediate cubicle Left-hand outer cubicle View from rear Right-hand outer cubicle Front Intermediate cubicle Busbars for sectioning cubicle, as seen from above Rear Fitting busbars and droppers A - A A - A A - A A - A A - A Busbars for: Droppers for: 1250, 1600 A 1250, 1600 A 1250, 1600 A 800 A 1250, 1600 A 630 A 800 A 630, 800 A 630 A 630 A Fitting busbars B - B B - B B - B Busbars for: 1250, 1600 A 800 A 630 A Fig. 21. Fitting light-series busbars and droppers. 27

30 Heavy series Delivered with busbars mounted against the panel in the busbar compartment. Torquing as per section CAUTION! Shipping screws must be removed from switchgear before energisation. The black plastic shipping interlay is intended to facilitate busbar fitting and should be removed. Fit these busbars in each cubicle as it is set up. Bolting together and torquing in the case of outer cubicles and during retightening should be carried out from above. Intermediate cubicle Outer cubicle Busbars Droppers A A Intermediate cubicle Outer cubicle Busbars Droppers A A Intermediate cubicle Outer cubicle Busbars Droppers A A Fig. 22a. Fitting heavy-series busbars and droppers. 28

31 Intermediate cubicle Outer cubicle Busbars Droppers A A Intermediate cubicle Outer cubicle Busbars Droppers A A Fig. 22b. Fitting heavy-series busbars and droppers. Intermediate cubicle Outer cubicle Busbars Droppers A A Fig. 22c. Fitting heavy-series busbars and droppers. 29

32 2.7. Cubicle and system earthing CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas. In the case of cubicles with single earth bars, connect an external earth cable to each cubicle as in Fig. 23. Make the connection either with a spare loop or with a cable lug and an M10 bolt in the hole in the copper bar. In the case of cubicles with earth bars running right through, link the bars up as in Fig. 24. Make sure that the bushings between cubicles seat properly. Only connect the external earth cable to the outer cubicles in the row, following the procedure described above. Copper bars connected directly to Aluzink panels should be lubricated in with grease "G" (see section 6.2, Lubricants) as protection against galvanic corrosion. Fig. 23. Single earth bar Fig. 24. Through earth bar. 30

33 2.8. Fitting roof panels CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas. Roof panels are supplied in cartons placed in the respective cubicles. CAUTION! To prevent pressure relief via front doors on the occasion of any arcing faults, roof panels must be fitted as follows: Panels made of 0.7 mm Aluzink sheet should be fitted from above and fastened at the front edge with bolts and clamping sections. The rear edge should only be fastened with plastic rivets so as to allow the pressure due to any arcing fault to be reliefed by the rivets at the rear edge sliding and the rear edge of the panel bending upwards. The position of the front edge of the panel will remain unchanged Connecting power cables CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas. Connect incoming/outgoing cables in the cable compartment. There are facilities for connecting up to six parallel singlephase cables, depending on the rated current. Before connecting power cables, remove withdrawable units, racking mechanism and doors. The PC partition may remain in place, it is transparent. When working on cable connections, the fitter may sit in the cable cell or on the threshold. If space allows, the rear panel may be removed, using a long-handled socket wrench. Connection facilities depend on rated current and cubicle type (Fig. 27 shows a standard selection). Cable connection procedure: 1. Remove withdrawable units. See section Remove doors. Release the hinge pins by turning the screws through 90 as per instructions on the door. Release the swivel arms on the upper door. Fold the door upwards about 15 and lift it out obliquely upwards. 31

34 Fig. 25. Racking mechanism bolts. 3. Remove racking mechanism. This is done by slackening the bolts arrowed in Fig. 25. Pull the racking mechanism straight out. 4. Remove voltage transformers (option). If the cubicle has a set of voltage transformers, two screws at the front edge have to be slackened. Pull the set out as far as it will go. Release the safety screws on the guides. The adaptor can then be removed, using a trolley (see section 2.1.1). 5. Remove lower PC partition. For good access, remove also the lower PC partition after slackening the screws all round. 6. Run the cable upwards into the cubicle. 7. Terminate the cable as per manufacturer's instructions. CAUTION! Make sure that the cable screen reaches the earth bar. Where necessary, insert earth line with at least the same cross-section as the cable screen. Make sure that the clearance between the XLPE insulation and the field guide of cables in the same phase is at least 10 mm. The field guides on all three phases must be at the same height if they are close to one another. 8. Run cable up through cable current transformer (option). If necessary, this transformer may be loosened from its 32

35 mounting. Note how the transformer has to be positioned in relation to the cable (see Fig. 26). The earth conductor has to be run back insulated through the transformer. The transformer mounting is adjustable relative to the cable. 9. Contact-press the cable lugs and connect. If cupped spring washers are used on bolted connections, apply torque as per section 2.11, otherwise M12 connections should be tightened at 80 Nm. 10. Use suitable clips to straighten and destress the cable. For example, use cable clips type UKR 90, order no. E Fasten with available bolts and nuts (see Fig. 26). Cable positions are illustrated in floor plan in Fig. 15 and connection points in Fig Apply transparent protective flexible tubing to screen connections. Connect the screen to the earth bar of the cubicle. Insulated earth conductor Cable clip type UKR 90 Fig. 26. Fitting a cable current transformer. 33

36 800 A Current transformer IHBF 12 A Cables Cable lugs Pattern Holes 663 from front Circuit breaker cubicle Primary reconnectable Position 1 1 x 3 phase mm 2 D= from floor A IHBF 12 A 663 from front 90 Circuit breaker cubicle Primary reconnectable Position 1 2 x 3 phase mm 2 D= from floor A Circuit breaker cubicle IHBF 12 A Primary reconnectable Position 2 4 x 3 phase 300 mm 2 4 x 1 core mm 2 D= A Circuit breaker cubicle DIN-TRAFO Primary not reconnectable Position 2 4 x 3 phase 300 mm 2 4 x 1 core mm A Circuit breaker cubicle DIN-TRAFO Primary not reconnectable Position 3 6 x 1 core mm A Circuit breaker cubicle DIN-TRAFO Primary not reconnectable Position 3 6 x 1 core mm A Cable cubicle DIN-TRAFO Primary not reconnectable 6 x 1 core mm Fig. 27. Safesix 12 kv cable fastening points. 34

37 2.10. Connecting control cables CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas. Control cable connections are made in the LV compartment. If control cables come up through the floor, they can be run inside the side panels in a space measuring about 65 x 340 mm (see Fig. 28). These ducts have openings at their bottom and top ends and via a cover on the inside halfway up the lefthand side of the cubicle. Run control cables to each cubicle via the cable duct above the LV compartment, then into the connection box via a 30 mm wide gap at the rear of the duct. Fig. 28. Cable run from floor to LV compartment. 35

38 Control cables may also be run from the basement beneath the switchgear up into each cubicle division in which there is a duct (external lines) (see Fig. 15). In the LV compartment, run the cables to the group of terminal blocks to which most of the strands are to be connected. Use stripe to fasten the cables to the fixed bars situated at the rear, and fasten any protection conductors to overhead earth bars (see Fig. 29). An option for making linking connections between cubicles is to use a connector which includes a fixed element situated on the lefthand side of the LV compartment and mounted in a bellows, while its movable element is situated in the cubicle to the left and has to be inserted in the bellows and screwed to the fixed element with a centre screw. Terminal blocks for current measurement Terminal blocks for control voltage Terminal blocks for relay protection Terminal blocks for auxiliary contacts and earthing switch Cubicle lighting Cable duct Terminal blocks for cubicle lighting Sliding terminal blocks Terminal blocks for voltage measurement Fig. 29. Connecting control cables. 36

39 2.11. Posttightening of busbar CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas. The final step in cubicle erection is to check the primary current paths. The post-tightening of bolts on busbar connections requires the following torques to an accuracy of + 10%. They apply in cases where the spring washers that form part of the supply are used. M8 M10 M12 M16 Nm dry Nm lubricated If washers of some other kind are used, e.g. in the erection of power cables, larger torques have to be applied. In such cases the torque for M12 connections is 80 Nm in the dry state. N.B. Connections at voltage transformer terminals and at other terminals that have brass threads potted in epoxy should only be subjected to the following torques: M8 M10 M12 M16 Nm IMPORTANT! When all erection work has been completed, clean the cubicles thoroughly. Wipe clean all insulators, measuring transformers and screens. 37

40 3 Functional testing Only servicing personnel are allowed to open cubicle doors. The following points are to be checked before commissioning switchgear: CAUTION! DANGER TO PERSONNEL 1. While switchgear is being worked on, it must be earthed to eliminate any risk of its being energised by mistake. CAUTION! When operating the earthing switch, no-one must be in the cubicle, to avoid the risk of being pinched by the switch. Effect earthing by closing the earthing switch and connecting the temporary earthing to a through earth bar or to each cubicle separately. Only during phase identification and insulation testing may the temporary earthing be temporarily removed. For safety measures before and after energisation, see ABB publications 1WAT and 1WAT In some cases the earthing switch is electrically interlocked so that if there is no control voltage the contact cannot be released. 2. Unfasten and disconnect connected power cables. 3. Check the phase identify of the busbars. Connect a battery box as follows: Earth: - 0 V L1-4.5 V L2-9 V L V Check in every cubicle that the voltages measured on the various busbars are correct. Busbar positioning in ABB indoor switchgear is as follows: a) From top to bottom: L1, L2, L3 b) From left to right: L1, L2, L3 Note: A diagram is provided in cases where any other phase sequence is used. 4. Check the following on all withdrawable units: 38

41 a) that the busbar main contacts engage the connection bars properly, minimum overlap 17 mm (see Fig. 34) b) that the units are in the correct cubicles c) that the interlocks work d) that there are control voltages to the units and that control can be exercised e) that local control works when the selector is on [DISCONNECTED] and the unit is in disconnected position f) that the emergency trip works in operating position g) that a closed circuit breaker cannot be run into or taken out of service position h) that the sliding contacts are undamaged 5. Insulation test. Use a megger to measure the switchgear insulation resistance. N.B. Before doing so, check: that all voltage transformer primaries are disconnected that any surge arrestors are disconnected that all current transformer secondary circuits are closed In cases where switchgear is not subjected to a HV test, the insulation resistance should be measured with a 5 kv megger. In other cases a 1 kv or 0.5 kv megger will suffice. Measure insulation resistance as follows: a) L1 -, L2 -, L3 - b) L1 - L2, L2 - L3, L3 - L1 Measured insulation values should amount to at least 1 Mohm per kv of rated voltage of the switchgear. 6. Reconnect the power cables and the components disconnected in item 5 above. Apply correct torque to all connections that have been slackened. 7. In the case of units with fuses, check on the equipment list that all the high-power fuses tally. 8. Check the settings of all relays against the installation documentation. 39

42 9. Check control circuits in all cubicles against the installation documentation. 10. Check the control circuit transitions between cubicles. 11. Check that all screws on terminal blocks are tight and that no insulation is pinched. 12. Check that units cannot be connected in bays intended for ones with a higher rated current. The mechanical blocking devices must prevent any such mistakes. 13. Check that units cannot be shifted while they are closed. Where there is disconnector, check the interlock system. 14. Check that selector and racking mechanism works. 15. Check that the black bushings on through earth bars seat properly and provide a seal between cubicles. 16. Open the earthing switch so that the indicator displays either "0" or "OPEN". 17. Check that the doors are properly closed and the handles folded down/in towards the door. CAUTION! Beware door pinch risk. It is important that the handle should be easy to fold down when the door to the withdrawable unit cell is closed, so that the door lock will work as intended, i.e., so as to withstand pressure due to any arcing fault. 40

43 4 Commissioning Safesix 12 kv switchgear CAUTION! Before taking action, follow the safety instructions on page 41. The operator access zone is the aisle in front of the switchgear. Only servicing personnel are allowed to open cubicle doors. CAUTION! There is no contact protection inside the lower door. The cable side must be de-energised and be earthed by closing the earthing switch before opening the lower door. When operating the earthing switch, no-one must be in the cubicle, to avoid the risk of being pinched by the switch. Unauthorised access inside the doors may be prevented by padlocking the handles of both the lower and upper doors. CAUTION! Beware risk of being pinched when closing doors. CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas Commissioning new switchgear Carry out functional tests as per chapter 3 and maintenance points as per chapter Commissioning after stoppage for repaire or other action Carry out appropriate parts of functional tests as per chapter 3 and maintenance points as per chapter Commissioning after stoppage Carry out checks as per section 3.17 and instructions as per 6.1. Also maintenance as necessary. 41

44 CAUTION! Before taking action, follow the safety instructions on page Operating instructions The operator access zone is the aisle in front of the switchgear. Only servicing personnel are allowed to open cubicle doors. CAUTION! There is no contact protection inside the lower door. The cable side must be de-energised and be earthed by closing the earthing switch before opening the lower door. When operating the earthing switch, no-one must be in the cubicle, to avoid the risk of being pinched by the switch. Unauthorised access inside the doors may be prevented by padlocking the handles of both the lower and upper doors. CAUTION! Beware risk of being pinched when closing doors. CAUTION! Cubicle enclosures have sharp edges on their sides and roof. Be particularly careful when handling these areas Circuit breaker HPA and HA Interlock chain in Safesix cubicles with HPA or HA circuit breaker. Conditions to be fulfilled to make connection possible: 1. The selector has to be in service position (position 4) or test position (position 1). The circuit breaker interlock rod must be in its topmost position, use the microswitch in the "make" circuit to check that it is. 2. The control voltage must be % of nominal. 3. The circuit breaker "make" springs must be tensioned, use the microswitch in the "make" circuit to check that they are. Closing results in: 1. Mechanical blocking of the racking mechanism selector. 2. Links coming out on the righthand side of the circuit breaker so that the closed circuit breaker cannot shift while in service position (applies to HPA). Conditions to be fulfilled to make opening possible: 1. The circuit breaker must be closed, use auxiliary contacts to check that it is. 2. The control voltage must be % of nominal DC or % of nominal AC. 42