PIX High. Installation Operation Maintenance Technical Manual No. AGS Edition 01/2009. Medium Voltage Distribution

Transcription

1 Medium Voltage Distribution PIX High Motor Control Center up to 7.2 kv Installation Operation Maintenance Technical Manual No. Edition 0/2009

2 Schneider Electric 35, rue Joseph Monier CS Rueil-Malmaison Cedex, France Manufacturer: Schneider Electric Sachsenwerk GmbH Service: Should you have any queries as to our service, please contact: Schneider Electric Sachsenwerk GmbH Schneider Electric All rights reserved to this technical manual. Reproduction and making available of this technical manual, or extracts, to third parties are prohibited. Only integral reproduction of this technical manual is permitted with the written permission from Schneider Electric Energietechnik GmbH Sachsenwerk Medium Voltage. Electronic copies in e.g. PDF-format or scanned version have the status for information only. The only valid version of technical manuals are always enclosed directly to the product in question by the factory.

3 Content Remarks on this manual... 5 Purpose and target group... 5 Further applicable documents... 5 Terms and symbols used... 5 Abbreviations used... 5 Do you have questions or suggestions?... 5 Safety Instructions Design and Description Panel design Dimensions and weight Applied standards Environmental and operating conditions Technical data Nameplate Technical data of electrical control and operating devices Utilization in line with the intended purpose Disposal after the end of the panel s service life... 3 Packaging, Transport, Storage Shipping units Transport Delivery Storage Access to the main circuit compartments Safety provisions Access to the cable compartment Removal of the cable compartment cover Re-attachment of the cable compartment cover Access to the switch compartment Removal of the switch compartment cover Re-attachment of the switch compartment cover Removal and connection of the low-voltage connector Removing transport lock for the CVX -truck Racking the truck out of the panel Important: Racking the truck into the panel Access to the busbar compartment Assembly Safety provisions Important information for assembly Requirements regarding the switchgear room Transporting the switchgear panels Mounting the switchgear sidewalls Installation of panels Screw-fastening the panels to one another Busbar assembly Access to the busbar compartment Busbar installation Assembly of the earth bus Mounting deflectors or pressure relief duct on top of the panel High Voltage Connection Low Voltage Connection Connecting the ring circuits in the low-voltage cabinet Connecting the external cables

4 Content (contd.) 8 Final steps/commissioning Final steps Commissioning Voltage Detecting Systems (VDS) Pluggable voltage detection system Integrated Voltage Detection System IVIS Voltage Detection System VOIS Phase comparison devices Operation Operator interface of the panel Vacuum contactor CVX truck Operation accessories Interlocks Intra-panel interlocks Electromagnetic interlocks (optional) Mechanical lock-outs with U lock Interlocks by means of cylinder locks (optional) Supplementary interlocks Switching the vacuum contactor Moving the truck into disconnected/service position Operating the earthing switch manually Fuse tripping Maintenance Safety provisions Maintenance schedule Cleaning Corrosion protection Avoid condensation Lubrication instructions Replacement of components and panels Annex Auxiliary products Treatment of firmly screw-connected contact surfaces Screw fastenings Required tools (not included in the scope of supplies) Operation accessories List of the assembly drawings

5 Remarks on this manual As our products are subject to continuous further development, we reserve the right to make changes regarding standards, illustrations and technical data. All dimensions specified in this manual are in millimeters. Purpose and target group This Technical Manual describes installation, assembly, operation and maintenance of PIX High Motor Control Center It is exclusively intended for use by the manufacturer s staff or by persons certified for the PIX High series (training certificate). This Technical Manual is an integral part of the product and must be stored in such a way that it is at all times readily accessible for and can be used by persons who are to work on the switchgear. If the switchgear is relocated to another site, this Technical Manual must be passed on to the new operators along with the unit. Further applicable documents The following additional documents must be observed for this switchgear: sales agreement with the stipulations regarding the switchgear-specific equipment and the legal details the switchgear-specific circuit diagrams / documentation the operating manuals of the low-voltage devices installed in the switchgear (e.g. voltage indicators, devices in low-voltage compartment) the assembly drawings supplied with the switchgear the assembly instructions of the manufacturer of the cable connection systems to be connected to the switchgear the assembly and operating instructions of the vacuum contactor CVX (No. NTV 32) the assembly, operating and maintenance instructions of PIX High (No. AGS ) Terms and symbols used This Technical manual uses certain terms and symbols. They warn about dangers or provide important information which must be complied with to avoid danger to personnel and damage to equipment. Warning This warning symbol indicates dangerous electrical voltage. Contact with voltage may result in fatal injury! Warning This warning symbol indicates danger of injury. Observe alle instructions that are labeled with this sign to avoid death or serious injury. Warning This symbol warns about the risk of falling. Pay attention to flooring ducts. Important This symbol is used for information which is important to avoid damage. Abbreviations used PIX High CC : CVX : Truck : Motor Control Center for PIX High switchgear Vacuum contactor with high voltage fuse link on a truck withdrawable part Do you have questions or suggestions? Do you have any questions or suggestions regarding this technical manual, or do you need further information? We are always committed to provide the best information for the optimal and safe application of our products. So do not hesitate to contact us if you have recommendations, supplementary suggestions or suggestions for improvement. 5

6 Safety Instructions The work described in this Technical manual may only be performed by specialist electricians who have proved their experience with PIX High MCC panels and all relevant Safety provisions. Read these instructions carefully before you work on the switchgear, and perform the work detailed in them as described. Applicable standards andregulations: Common specifications for high-voltage switchgear and controlgear: IEC the locally applicable accident prevention, operating and work instructions. Installation: IEC 6936-/HD 637 S Operation of electrical installations: EN 500- The national standards applicable in the country where the equipment is to be installed must be complied with. Before performing work on the panel, make sure that you comply with the following instructions: Before starting work on high-voltage components, de-energize the system, verify it for zero voltage and earth the system in accor- dance with the applicable safety rules pursuant to EN After removal of covers, operator safety in accordance with IEC may be restricted if the appropriate part of the switchgear has not been isolated from the power supply. Before performing work on the drive mechanism, switch off the supply voltage and prevent it from reclosing. There is a risk of injury when working on the drive mechanism. Before commencing work, release the energy-storing device by switching OFF the vacuum contactor CVX closing the make-proof earthing switch. Behaviour in case of incidents or accidents PIX High Motor Control Center panels have defined pressure relief ports which prevent compartments in the switchgear panel from bursting in the case of an internal faults. In case of fire or of an internal fault, toxic and caustic decomposition products may develop which are hazardous to health. Comply with the locally applicable accident and safety provisions. In case of personal injury, take first-aid measures or cause them to be taken. 6

7 2 Design and Description 2. Panel design Fig. 2. PIX High Motor Control Center Low-voltage cabinet with GEMSTART 5 control unit 2 Voltage indicator (option) 3 Switch compartment cover 4 Operation of the earthing switch 5 Position indicator of the earthing switch 6 Cable compartment cover 7 Current Transformer 8 Cable connection 9 Pressure relief duct for cable compartment 0 Shutter actuation Vacuum contactor CVX with fuses on truck 2 Bushings 3 Busbars 7

8 2 Design and Description (contd.) 2.2 Dimensions and weight / / / Fig. 2.2 Dimensions of a PIX High Motor Control Center panel Weight of a PIX High Motor Control Center panel Max. weight with CVX truck, without packaging [kg] 650 8

9 2 Design and Description (contd.) 2.3 Applied standards PIX High MCC are metal-enclosed Loss of service continuity category in accordance with IEC : LSC 2B-PM type-tested optional: tested for internal faults (qualification IAC) dimensioned for indoor installation PIX series switchgear panels meet the following standards and regulations: Designation IEC standard EN standard Switchgear IEC IEC EN Internal arc classification IEC EN Vacuum contactor IEC EN High voltage fuse link IEC EN Earthing switch IEC EN Vacuum contactor truck IEC EN Current transformer IEC EN Voltage detection systems IEC EN Protection against accidental contact, foreign objects and IEC EN water Erection IEC HD 637 S Operation of electrical equipment - EN 500- Degree of protection provided by enclosures Degrees of protection against accidental contact and foreign objects according to IEC external enclosure of panel IP3X between the compartments of the panel IP2X optional IP4X; other values available on request 2.4 Environmental and operating conditions PIX High is an indoor switchgear that may only be operated under normal operating conditions in accordance with the specifications of IEC Operation outside the specified conditions is only permissible after consultation with and obtaining the written approval of the manufacturer. Ambient conditions according to IEC 227- Temperature class minus 5 indoors Ambient temperature min./max. o C -5 / +40 Average value over 24 hours (max.) o C +35 Average rel. air humidity: 24 hours / month % 95 / 90 Maximum installation altitude above sea level m 000 higher values on request 9

10 2 Design and Description (contd.) 2.5 Technical data Technical data Rated voltage U r [kv] 7.2 Rated lightning impulse withstand voltage U p [kv] 60 Rated power frequency withstand voltage U d [kv] 20 / 32 Rated normal current, busbar I r max. [A] 4000 Rated normal current, feeder panel I r max. [A] 400 Rated short-time current I k, busbar [ka] 50 (3 s) Rated frequency f r [Hz] 50/60 on request (optional) For the technical data of the vacuum contactor CVX, refer to its separate Operating Instructions (no. NTV 32). 2.6 Nameplate The nameplates on the panels (Fig. 2.3) specify essential technical data. In case of queries and orders for spare parts, the following data on the nameplate must be specified: Type designation Serial number Year of construction Fig. 2.3 Nameplate on the operating panel (front side) of the switchgear panel Type designation 2 Serial number 3 Year of construction 4 Technical data 2.7 Technical data of electrical control and operating devices The switchgear panels have been designed on principle so as to permit manual operation. Fixtures in the switchgear panel The drive mechanisms of the individual switching devices can be equipped, depending on the specific customer s model, with additional electrical control and operating devices. These are defined in the switchgear-specific circuit diagram (see switchgear documentation). Component fitting options: Motor-operated drive mechanism for the earthing switch control element 0

11 2 Design and Description (contd.) Blocking coil The blocking coil prevents manual actuation of the earthing switch. If the supply voltage has failed or is shut off, all blocking coils are in blocked position. Auxiliary switches Auxiliary switches are always actuated directly by the truck or by the switch shaft via an intermediate linkage. Their position always corresponds to that of the main contacts. The switching functions have been set in the factory according to the circuit diagram. Micro-switches are used depending on the customized panel models. Overview of rated supply voltages Direct voltage DC [V] Alternating voltage AC [V] (0)/20 (220)/230 Power consumption Device Rated power consumption DC approx. [W] AC 50/60 Hz approx. [VA] Blocking coil 2 Motor for earthing switch Information about the power consumption of solenoids and the motor is available from the manufacturer. The supply voltage data is required to this effect. Truck Electrical control and operating devices of the CVX contactor are described in the Technical Manual NTV Utilization in line with the intended purpose PIX High Motor Control Center panels are exclusively designed for switching and distributing electrical power. They may only be used in the scope of the specified standards and the switchgear-specific technical data. Any other utilization constitutes improper use and may result in dangers and damage. Important: Operating reliability and useful life depend on correct operation. Disclaimer of liability The manufacturer shall not be held responsible for damage which occurs if the switchgear is not operated in accordance with its intended use (see above), the switchgear is assembled, connected or operated improperly, accessories or spare parts are used which have not been approved by the manufacturer, the switchgear is converted without the manufacturer s approval, or if inadmissible parts are attached. No liability is accepted for parts provided by customers, e.g. current transformers. 2.9 Disposal after the end of the panel s service life A material and recycling data sheet can be provided on request for the disposal of series PIX switchgear at the end of its service life. Disposal at the end of the service life is performed as a service by the Service Center at the manufacturer s which is subject to a fee.

12 3 Packaging, Transport, Storage 3. Shipping units The conditions and types of transport have been stipulated in the contract details. The type of packaging depends on the type of transport and the storage conditions. Delivery is effected in terms of single switchgear panels. One transport unit consists of one PIX High MCC-panel which is screwfastened to the pallet. The vacuum contactor CVX is supplied in assembled condition, already mounted in the panel with an additional transport lock. The standard accessories are included. The panels are delivered in upright position. Important: The weight data of the complete transport unit are indicated on the packaging/ wooden case. Packaging If the panels are transported exclusively on a lorry, they are fastened by wooden bars at the front and rear and packed in PE film (Fig. 3.). For sea transport, the units are packed in sealed aluminium foil with desiccant and in a closed wooden case with tightly closed wooden base (alsofor container transport, Fig. 3.2). In case of air transport, the panels are packaged in wooden crates with a protective PE film hood (dust protection) or in wooden crates, also with closed wooden bases, however without protective hoods (dust protection, Fig. 3.2). Fig. 3. Packed in PE protective film on a pallet Fig. 3.2 Packed in a wooden case 2

13 3 Packaging, Transport, Storage (contd.) 3.2 Transport When transporting the switchgear, it must be ensured that the units do not slip or tip. If necessary, nail down transport pallets to the loading surface (Fig. 3.3). Important: For transporting the trucks, comply with the transport specifications in the appropriate manuals. Transport using a forklift truck For transport, the panels must be packaged completely. The entire length of the forks must be placed under the transport unit (Fig. 3.4) Fig. 3.3 Do not tip the transport units Fig. 3.4 Transport using a forklift truck 3.3 Delivery Handle shipping units carefully when unloading and unpacking them. Shipping units must be checked upon receipt. Any damage which may have occurred in transit must be recorded and reported to the manufacturer immediately. Check completeness of consignment based on the transport documents. The supplier must be notified in writing without delay about any deviations. 3.4 Storage Sufficient stability and evenness of the supporting area (floor) must be ensured. Fig. 3.5 Schematic diagram of storage conditions for PIX High Motor Control Center switchgear panels 25 C +40 C If the panels are not installed immediately after delivery, they can be stored under the following conditions: Panels may only be stored vertically; they must not be stacked. Storage only indoors! Panels and accessories must be packed in sealed aluminium film with desiccant and in a wooden case (storage for max. two years after date of packing). 3

14 4 Access to the main circuit compartments 4. Safety provisions Before opening / removing doors / covers, isolate the compartment in question, check for zero voltage and earth in accordance with the safety provisions in EN After removal of covers, operator safety in accordance with IEC may be restricted if the appropriate part of the switchgear unit has not been isolated from the power supply. 4.2 Access to the cable compartment The cable compartment may only be opened if the earthing switch is ON (see Chapter 0.7). The panels can be equipped with supplementary locks to lock the cable compartment cover. To this effect, see also Chapter 0.4 Interlocks Removal of the cable compartment cover Release the 2xM8 hex. socket screws () and keep them in a safe place. Lift and remove the cable compartment cover (2). Fig. 4. Removing the cable compartment cover Fig. 4.2 Double-bit key Re-attachment of the cable compartment cover Place the cable compartment cover (2) in the cutout on the panel and lower it. Screw-fasten the cable compartment cover to the panel using the 2xM8 hex. socket screws (). Important: Comply with the specified tightening torque (refer to Annex). 4.3 Access to the switch compartment The switching device compartment may only be opened if the truck is in disconnected position (see Chapter 0.6) Removal of the switch compartment cover To unlock the door, insert the appropriate double-bit key into the door lock on the switch compartment cover and turn it to the right by approx. 90 as far as it will go (Fig. 4.2 and Fig. 4.3, item 2). Lift the switch compartment cover () using the two handles (3) and remove it. Remove the double-bit key and keep it in a safe place. 4

15 4 Access to the main circuit compartments (contd.) Re-attachment of the switch compartment cover Pick up the switch compartment cover () using the two handles (3), place it in the cutout on the panel and lower it. To unlock the door, insert the appropriate double-bit key into the door lock (2) on the switch compartment cover and turn it to the left by approx. 90 as far as it will go. Remove the double-bit key and keep it in a safe place. Fig. 4.3 Removing the switch compartment cover Removal and connection of the low-voltage connector Initial situation: Vacuum contactor OFF Truck in disconnected position Switch compartment cover removed (see chapter 4.3.). Removal of the low-voltage connector Unlock the interlock of the low-voltage connector (3) and remove the connector. Store the low-voltage connector in the storage tray above the vacuum contactor CVX (). Fig. 4.4 Vacuum contactor CVX with locked lowvoltage connector Storage tray for low-voltage connector 2 Low-voltage connector 3 2 Fig Low-voltage connector 3 Connector interlock with actuating directions Connection of the low-voltage connector Pick up the low-voltage connector from the storage tray above the vacuum contactor CVX. Insert the low-voltage connector into the vacuum contactor CVX (2) and lock the connector interlock (3). 5

16 4 Access to the main circuit compartments (contd.) 3 3 Fig. 4.6 Transport catch of the vacuum contactor CVX in the panel Removing transport lock for the CVX -truck Remove the switch compartment and cable compartment covers (see chapter 4.2. and 4.3.). Remove the locking mechanism of the vacuum contactor CVX in the switch compartment (Fig. 4.6): Release the 4 front screws of the CVX (). Release the 2 lateral securing bolts M8x25 (2). Remove both support brackets (3). Re-fasten the 4 screws () to the CVX. Remove the vacuum contactor CVX from the panel (see next chapter) Racking the truck out of the panel Important: Important: Observe the description of the transport trolley (see chapter 2.5). Initial situation: Vacuum c ontactor OFF Truck in disconnected position Switch compartment cover removed (see chapter 4.3.) Low-voltage connector removed (see chapter 4.3.3) Move the transport trolley in front of the panel and lock it onto the panel. Unlock the vacuum contactor CVX in the panel (Fig. 4.7) and pull it onto the transport trolley using the handle (Fig. 4.8). Fig. 4.7 Vacuum contactor CVX in the panel Fig. 4.8 Vacuum contactor CVX on the transport trolley 6

17 4 Access to the main circuit compartments (contd.) Racking the truck into the panel Move the transport trolley in front of the panel and lock it onto the panel. Unlock the vacuum contactor CVX on the transport trolley. Push it into the panel using the handle until it is latched in the panel. 4.4 Access to the busbar compartment The busbar compartment may only be opened if the busbar is earthed (see PIX High manual AGS ). The busbar compartment is accessible from the side and from the top. For top access, the busbar compartment cover must be removed first (Fig. 4.9). Place a sufficiently stable and non-slip cover over the switch compartment to step onto the top of the panels. Release the securing bolts (2) from the busbar compartment cover (). Keep the securing bolts and the cover for the subsequent reassembly. 3 2 Fig. 4.9 Top access to the busbar compartment Busbar compartment cover 2 Securing bolts (6x) 3 sufficiently stable and non-slip cover over the switch compartment 7

18 5 Assembly 5. Safety provisions The switchgear panels may only be installed and assembled by the manufacturer s staff or by persons who have been certified for this work. PIX High MCC panels are delivered with the truck locked in disconnected position, vacuum contactor switched OFF and the earthing switch OFF. Risk of injuries! During assembly, installation and connection, the energy storing devices must not be charged. Risk of accidents Watch out for floor openings in the switchgear room. The top sides of the panels are not meant to be walked on. Persons may fall through them, get injured or may damage the panel. When work has to be performed on the panel top - e.g. assembly of deflectors, fans or pressure relief ducts - temporarily position a solid base plate to step on. The safety provisions of Chapter must be observed. 5.2 Important information for assembly Condensation, dirt and dust during assembly should be avoided on all accounts, in order to prevent damage to the panels. For assembly, observe the assembly drawings supplied with the equipment. The drawing numbers are specified in this manual in the description of the assembly work. For all screw fastenings, comply with the tightening torques specified in Chapter 2.3. Assembly of the switchgear-specific equipment (e.g. sidewalls, deflectors, pressure relief ducts, etc.) is described in the PIX High manual AGS Requirements regarding the switchgear room Before installing the switchgear panels, make sure that the switchgear room is checked according to the switchgear documentation (Fig. 5.): Observe the minimum distance between the switchgear and the wall of the building. The load-bearing capacity of the fastening points must correspond to the weight of the switchgear (perform a stress analysis of the floor). Check base frame (if used) for dimensions and positional tolerances. Check position of floor openings for high-voltage and low-voltage cables. Before the panel is positioned at its site of installation, check that the fastening points are level. Unevenness must not exceed ± 2 mm/meter and 6 mm difference in height over the entire locating surface. Important: Observe switchgear-specific space assignment plan. 8

19 5 Assembly (contd.) / Fig. 5. Switchgear room (top view) PIX High Motor Control Center panels 2 PIX High panel 2 kv 3 Switchgear side wall 4 Rear fixation point 5 Rear base frame 6 Wall of the switchgear room 7 Front base frame 8 Front fixation points 9 Floor openings for high-voltage cables 9

20 5 Assembly (contd.) / / ,5 6,5 Fig. 5.2 Dimension drawing for PIX High Motor Control Center PIX High Motor Control Center panel 2 PIX High 2 kv panel 3 Deflectors 4 Switchgear room wall/ceiling 5 Switchgear side wall 6 Rear fixation point 7 Rear base frame 8 Front fixation points 9 Floor opening for high and low voltage connection 0 Front base frame 20

21 5 Assembly (contd.) m 2 Fig. 5.4 Minimum rope length Fig. 5.3 Lifting eyes and fastening points 2 Transport fixation 5.4 Transporting the switchgear panels Transport by means of a crane Make sure the rope or chain is strong enough to bear the weight of the panel. Minimum lifting capacity of each strap: 500 kg. The specific regulations applicable for hoisting equipment must be complied with. On lowering the panels, make sure that the supporting platform is sufficiently stable and even. Risk of accidents! Pay attention to flooring ducts. Take the 4 lifting eyes (accessories) for the crane straps out of the packaging (Fig 5.3). Remove the panel s transport packaging and protective film and remove the transport fixation (2). Mount the lifting eyes to the 4 fastening points on the panel (). Secure each of the links using a screw. Mount 4 crane straps/chains to the lifting eyes. Comply with the specified minimum rope length and strength (Fig 5.4). Raise the panel carefully via the 4 crane straps. Lower the panel slowly to the floor at its place of destination. Move the panel on the floor, using three cylindrical rollers of 30 mm min. diameter (Fig 5.5). Ensure that the ground is even and able to take the load. Thus move the panel to its final installation place. Fig. 5.5 Cylindrical rollers 5.5 Mounting the switchgear sidewalls Assembly drawing: AGS C The mounting of the sidewalls to PIX MCC panels is identical with the mounting to PIX High panels. For detailed information, please refer to PIX High manual AGS Installation of panels Fixation on the ground / base frame: 2 Standard version: Fig. 5.6 Front fixation points 2 Rear fixation point Assembly drawing: SEM Fasten the panels on the floor by two points in the front cross arm () and one point on the rear side (2). The fixation is identical with the fixation of PIX High panels. For detailed information, please refer to PIX-High manual AGS

22 5 Assembly (contd.) 3 4 Fixation for seismic requirements: Assembly drawing: AGS C Fasten the panels on a base frame by two points in the front cross arm (3) and two points on the rear side (4) (screws M20). For detailed information, please refer to the assembly drawing. Fig Front fixation points 4 Rear fixation points 5.7 Screw-fastening the panels to one another Fixation between PIX High MCC panels and between PIX High MCC panel and PIX High panel: The fixation is identical with the fixation between PIX High panels. For detailed information, please refer to PIX High manual AGS Panel interconnecting points: Assembly drawing: AGS C Top gap cover: Assembly drawing: AGS C Rear gap cover (only necessary in case IAC AFLR is requested) Assembly drawing: AGS C Busbar assembly 5.8. Access to the busbar compartment See chapter Busbar installation Assembly drawings for busbar assembly Panel Busbar type Centre panel End panel Assembly drawing I n (busbar) 250A (2x80x0) EIB AE A I r (busbar) 2500A (3x80x0) EIB AE A I r (busbar) 5000A (4x80x0) EIB AE I r (busbar) 250A (2x80x0) EIB AE A I r (busbar) 2500A (3x80x0) EIB AE A I r (busbar) 5000A (4x80x0) EIB AE Fig. 5.8 Transport fixation 2 Transport spacers 2 Important: Comply with the specifications regarding coating of the contact surfaces and the tightening torques for the busbar links and screw fastenings (refer to Annex). Remove transport spacers and transport fixation (Fig 5.8). Observe specified direction of screws and bolts, and correct position of nut. 22

23 5 Assembly (contd.) Busbar and busbar feeder arrangement Number of busbars per phase 2 busbars 3 busbars 4 busbars Busbar arrangement to the feeder View X View X 3 Fig. 5.9 Busbar link in a center panel with 3 busbars (example) Screws M0 with washers and lock washers 2 feeder bar 3 Copper intermediate layer 4 busbars 23

24 5 Assembly (contd.) 5.9 Assembly of the earth bus (Assembly drawing AGS C ) Earth bars are screw-fastened from panel to panel using connecting bars. The connecting bars are included in the accessories. First remove the transport spacers (Fig. 5.0). The assembly of the connecting bars in PIX MCC panels is identical with PIX High panels. For detailed information, please refer to PIX High manual AGS Fig. 5.0 Earth bus Earth bar 2 Transport spacers 5.0 Mounting deflectors or pressure relief duct on top of the panel Deflectors or a pressure relief duct are necessary to ensure personal safety in case of internal faults in accordance with IEC The mounding to PIX MCC panels is identical with the mounting to PIX High panels. For detailed information, please refer to PIX High manual AGS

25 6 High Voltage Connection Preparation Access to the cable compartment see chapter 4.2. Remove the clamps from the floor of the cable compartment and take out the rubber sleeves (Fig. 6.). 2 Fig. 6. Bushings for high-voltage cables in the floor of the cable compartment Clamps 2 Rubber sleeves Mount cable lugs Route the high-voltage cable from the cable basement to the cable compartment through the vacant cut-outs in the metal sheet of the panel. Cut the rubber sleeves to fit the cable outside diameter and slip them over the cable ends. Do not use aluminium cable lugs for the cable connection. Inadmissible matching of materials. Mount the cable lugs and insulations to the cable ends according to the instructions specified by the cable manufacturer. Connect cables to the Panel Screw-fasten the cable lugs to the cable connections of the panel (Fig. 6.4). Screw fastening M2 In case of multi-cable connection (max. 2 per phase), mount the cables according to Fig Fig. 6.2 Cut rubber sleeves to size and slip them onto the cables Fig. 6.3 Mount cable lug 25

26 6 High Voltage Connection (contd.) 4 Important: Comply with the tightening torques specified by the cable manufacturer. Precoat the contact surfaces (refer to Annex). Place the rubber sleeves again on the bottom plate and fix the highvoltage cable using the clamps (5). Screw-fasten the earthing screens of the high-voltage cables to the earthing cable of the panel (3). 5 3 Fig. 6.4 Cable compartment with high-voltage cables mounted (plastic screens not represented) 3 Earthing connection of the cable screen 4 High-voltage connection 5 Clamps with rubber sleeves 2 If two cables are connected per phase, arrange and mount the cables as shown in Fig Fig. 6.5 Assembly of 2 cables per phase High-voltage cable 2 Cable connection 3 2 Cable fastening for 3-conductor cable Maximum of two 3-conductor cables can be fastened using the clamps. The fastening insert is screwed in instead of the standard model, increasing the cable connection area by another 50 mm towards the cable basement (Fig. 6.6). 50 Fig. 6.6 Cable fastening for 3-conductor cable Clamps 2 Earthing bar 3 Screw-fastening to the panel (8 screws) 26

27 7 Low Voltage Connection 2 7. Connecting the ring circuits in the low-voltage cabinet Open the door of the low-voltage cabinet using a double-bit key. Route the cables to the adjacent panel through the lateral openings (Fig. 7., item 2) of the low-voltage cabinet. Connect the ring circuits to the terminal strip according to the circuit diagram. 2 Fig. 7. Laying and connection of the ring circuits in the low-voltage cabinet Terminal strip 2 Bushings to the adjacent panel Fig Connecting the external cables External cables supplied by the customer may be routed upwards to the low-voltage cabinet through the right-hand cable duct in the inside of the panel (Fig. 7.2). Remove the protective cover of the cable duct in the panel (Fig. 7.3) (3x nuts M6, wrench size: 0 mm). Open the four cut-outs required for the cable bushings (Fig. 7.4). Route the cable through the cable duct to the low-voltage cabinet (Fig. 7.5). Fig. 7.3 Fig. 7.4 Fig. 7.2 Placing external connections 27

28 7 Low Voltage Connection (contd.) Fig. 7.3 Remove the protective cover 4 cut-outs Fig. 7.4 Cut-outs for cable bushings 2 3 Fig. 7.5 Low-voltage cabinet 2 Cable duct for secondary lines 3 External cable 28

29 8 Final steps/commissioning 8. Final steps Clean and check assembly Clean the switchgear, removing contamination resulting from assembly work. Remove all the attached information tags, cards, brochures and instructions no longer needed. Check the tightening torques of all screw fastenings and connections established on the site of installation: High-voltage connection Earth bus Panel screw fastenings Busbar connections Special attachments (deflectors, pressure relief duct) Rack in the vacuum contactor CVX Rack the vacuum contactor CVX into the panel (see chapter 4.3.6). Re-mount the covers Cable duct cover of the secondary lines (see chapter 7.2) Cable compartment cover (see chapter 4.2.2) Switch compartment cover (see chapter 4.3.2) Damaged paint The panels are powder-coated. Minor damage to the paint can be repaired using commercially available paint (standard colour RAL 7044 or customer specific colour). Inspection The high-voltage supply must not be connected. All active parts must be earthed. Check the switchgear for damage which might be due to transport or assembly work. Compare data on nameplate to the required ratings. 8.2 Commissioning Checking switching functions and interlocks The high-voltage supply must not be connected. All active parts must be earthed. Important: For switching operations, comply with Chapter 0 (Operation). In case supply voltage is not available: blocking coils are in locked position, thus blocking manual switching operations. Apply supply voltage. Perform several manual test operations with each switching device. Check switch position indicators. Check electrical functions of control and operating devices: Closing and opening of the vacuum contactor Optional motor-operated drives for the truck and the earthing switch Check switch position indicators and interlocks (see Chapter 0). 29

30 9 Voltage Detecting Systems (VDS) Important: Observe the manufacturer s operating manual of the voltage detecting system in use. 9. Pluggable voltage detection system The presence or absence of the operating voltage is detected via a separate voltage detecting system in accordance with IEC Socket-contacts for the indicator units are located on the panel front (Fig 9.2). Capacitive voltage indicators of all the approved manufacturers can be used (Fig 9.). Fig 9. Voltage indicator unit (Type HR-ST, Manufacturer: Horstmann GmbH) Important: Observe the manufacturer s Operating Manual of the voltage indicators used. Important: All three phases L, L2 and L3 must always be checked together. Close non-used socket-contacts using a cap. Fig 9.2 Socket-contacts for HR system Fig 9.3 IVIS display 9.2 Integrated Voltage Detection System IVIS IVIS is an integrated voltage detecting system with an integrated display unit used to determine zero voltage according to IEC The IVIS system has been designed for maximum operating reliability. It does not require supply from an external source. It features climateproof encapsulated electronics and is maintenance-free, due to permanent monitoring of the indication thresholds. Flash arrow symbols on the indicators display the mains voltage still existing within the defined response thresholds (Fig 9.3). The IVIS system does not require the electrical repeat tests common for voltage detection systems. Important: For a description of all functions and messages of the IVIS system, refer to the separate Operating Manual IVIS (No. AGS ). 30

31 9 Voltage Detecting Systems (VDS) (contd.) 9.3 Voltage Detection System VOIS+ VOIS+ is a three phase capacitive voltage detecting system with an integrated display unit used to detect the presence or absence of operating voltage in accordance with IEC For voltage detecting no battery or external power supply is required. Flash arrow symbols on the indicators display the operating voltage still existing within the defined response thresholds (Fig 9.4). The device includes a 3-phase connecting point which is adapted to the LRM conditions according to IEC for phase comparison and phase sequence test. Fig 9.4 Voltage Detecting System VOIS+ (Manufacturer: Kries-Energietechnik GmbH & Co. KG) 9.4 Phase comparison devices Important: Whenever connecting live switchgear components for the first time, always check phase coincidence. If IVIS is used, phase comparison can be performed by means of the phase comparator MS 00 (Fig 9.6). Fig 9.5 Phase comparator for HR system, type ORION 3.0 (Manufacturer: Horstmann GmbH) Fig 9.6 Phase comparator MS 00 3

32 0 Operation 0. Operator interface of the panel Combined panel control and protection device GEMSTART 2 Voltage indicator (option) 3 Attached frontplate with handle 4 OFF push-button (optional) * 5 Vacuum contactor CVX 6 Inspection port 7 Interlock slide for manual actuation of the truck 8 Switch compartment cover locking mechanism via double-bit key 9 Insertion opening for manual racking in/out the truck 0 Position indicator of the earthing switch Interlock slide for manual actuation of the earthing switch 2 Insertion opening for manual actuation of earthing switch * only in case of CVX truck with manual tripping (drive mechanically latched) Fig. 0. Operator interface of PIX High MCC panels 0.2 Vacuum contactor CVX truck Moving contacts 2 Fuses 3 Low-voltage connector 4 Manual tripping (optional) 5 Fuse trip indicator: green-red 6 Counter (optional) 7 Position indicator I Handle * Drive is mechanically latched Fig. 0.2 Vacuum contactor CVX 32

33 0 Operation (contd.) 0.3 Operation accessories Important: These accessories are supplied together with the panel. The panel may only be operated by means of these accessories. Designation Item no. Illustration Double-bit key for the front door SEM037-0 Double-bit key for the low-voltage compartment SEM Operating rod to switch the vacuum contactor off manually (option) Operating lever for earthing switch AGS H AGSC Hand crank for CVX truck AGSH Interlocks 0.4. Intra-panel interlocks Interlock Between truck and low-voltage connector Between truck and earthing switch Between truck and operating state of the vacu-um contactor Between the cable compartment cover and the earthing switch (optional) Function of interlock The truck cannot be racked in unless the low-voltage connector is inserted and locked The low-voltage connector can only be inserted or re-moved while the truck is in its disconnected position The truck cannot be racked in while the earthing switch of the switchgear panel is in "ON" position The earthing switch cannot be switched on once the truck has left its disconnected position The truck cannot be racked in or out while the vacuum contactor is switched on The vacuum contactor cannot be switched on unless it is completely in its disconnected or service posi-tion and the operating crank for the rack-in mechanism has been removed The cable compartment cover can only be removed if the earthing switch is ON Method of operation of interlock The opening for the moving crank handle is locked The interlock for the low-voltage connec-tor on the drive end has been activated The moving crank handle is uncoupled au-tomatically The earthing switch cannot be switched on. Do not apply force! The opening for the moving crank handle is locked The vacuum contactor cannot be switched on or off The cable compartment cover ist locked mechanically by means of a sheet metal plate 33

34 0 Operation (contd.) Electromagnetic interlocks (optional) Electromagnetic blocking coils can be used for inter-panel as well as intrapanel interlocks: Manual actuation of the disconnector truck is blocked. Manual actuation of the earthing switch is blocked. Complete switchgear interlocking can only be ensured with complete locking devices to avoid malfunctions. Important: In case of failure of the supply voltage, all electrical interlocks are in their locked position. Measure: Re-establish supply voltage. Please note the purchase contract and the switchgear-specific circuit diagram as regards the design of the interlocking systematics Mechanical lock-outs with U lock Actuation of the earthing switch and the truck can be blocked by means of U locks (lock Ø 8 mm) (Fig. 0.3 and 0.4, not included in the scope of supplies). Fig. 0.3 Padlock on earthing switch Fig. 0.4 Padlock on truck Interlocks by means of cylinder locks (optional) Fig. 0.5 Cylinder lock mechanism of earthing switch Interlocking of earthing switch in closed condition 2 Interlocking of earthing switch in open condition 2 3 Fig Rack-in interlock Supplementary interlocks Further mechanical lock-outs and additional interlocks can be provided as specified in the contract.

35 0 Operation (contd.) CVX 0.5 Switching the vacuum contactor General information The switchgear may only be switched by specialist electricians. Specialist electricians in terms of this provision are persons who, due to their electro- technical training, have knowledge in the handling of mediumvoltage switchgear according to EN Check whether the supply voltage is ON. Position indicator Whether the vacuum contactor CVX is switched on or off is indicated directly on the device (Fig. 0.7 and 0.8). Fig. 0.7 I Vacuum contactor switched ON CVX Fig. 0.8 Vacuum contactor switched OFF Switching The vacuum contactor CVX is switched on and off only by means of a remote control device or the control and protection device GEMSTART. There is a separate documentation for GEMSTART. Fig. 0.9 Switching OFF the vacuum contactor by means of an operating rod Switching OFF manually (optional) This feature is only available for mechanically latched vacuum contactors CVX. In this case, the vacuum contactor CVX can be switched off directly on the panel (Fig. 0.9 and 0.0). Put the operating rod (see chapter 0.3) through the guide hole in the switch compartment cover until the vacuum contactor switches off automatically (Fig. 0.9). Check the position indicator (Fig. 0.8). Alternatively: Switching off by means of a push-button (Fig. 0.0). To this effect, move the push-button extension () downwards to its stop and press the OFF push-button (2). Check the position indicator (Fig. 0.8). 2 Fig. 0.0 Switching OFF the vacuum contactor by means of a push-button Push-button extension 2 OFF push-button 35

36 0 Operation (contd.) 0.6 Moving the truck into disconnected/ service position Trucks may on principle only be moved into service or disconnected position when de-energized. Switch vacuum contactor OFF. Important: Do not pull the crank out before the truck has reached its end position; do not pull it out in an undefined intermediate position. Initial situation: Vacuum contactor OFF Earthing switch OFF Moving the truck from service into disconnected position Push the interlock slide () to the left to open the crank insertion opening. Insert operating crank incl. the integrated slip coupling (2) and move it counter-clockwise to its stop or until the slip coupling reacts (3); the vacuum contactor moves to its disconnected position. Check the position of the vacuum contactor in the panel through inspection port (4). Remove crank Fig. 0. Moving the truck from service into disconnected position Moving the truck from disconnected into service position Push the interlock slide () to the left to open the crank insertion opening. Insert operating crank incl. the integrated slip coupling (2) and move it clockwise to its stop or until the slip coupling reacts (3); the vacuum contactor moves to its service position. Check the position of the vacuum contactor in the panel through inspection port (4). Remove crank Fig. 0.2 Moving the truck from disconnected into service position 36

37 0 Operation (contd.) Operating the earthing switch manually Initial situation: Vacuum contactor OFF Truck in disconnected position Fig. 0.3 Closing the earthing switch 4 Closing the earthing switch Push the interlock slide () upwards to open the insertion opening for the operating lever. Insert the operating lever (see chapter 0.3) (2). Swing the operating lever downwards by 90 (3). The position indicator of the earthing switch indicates CLOSED condition (ON) (4). Remove operating lever. Fig. 0.4 Position indicator: earthing switch ON 2 Opening the earthing switch 3 Push the interlock slide () upwards to open the insertion opening for the operating lever. Insert the operating lever (2). Swing the operating lever upwards by 90 (3). The position indicator of the earthing switch indicates OPEN condition (OFF) (4). Remove operating lever. Fig. 0.5 Closing the earthing switch 4 Fig. 0.6 Position indicator: earthing switch OFF 37

38 0 Operation (contd.) CVX 0.8 Fuse tripping The inspection port of the vacuum contactor on the panel front indicates the status of the fuses (Fig. 0.7): CVX 3 2 Fig. 0.7 Fuse trip indicator green: fuses OK 2 red: one or several fuses have tripped 3 Vacuum contactor has switched off automatically Measures to be taken in case of fuse tripping Remove the vacuum contactor from the panel (see chapter 4.3.5). Always exchange all 3 fuses. Fuse replacement is described in the Operating Manual of the vacuum contactor CVX (no. NTV 32). 38

39 Maintenance. Safety provisions Only specialist electricians certified by the manufacturer for maintenance work and who have the required knowledge regarding handling of series PIX High medium-voltage switchgear are permitted to perform maintenance and cleaning work. Refer to the safety provisions in chapter..2 Maintenance schedule We recommend performing a visual inspection of the panels at least every four years, depending on the strain to which they are subjected during operation and the operating conditions. Important: In case of humidity and condensation or air pollution (dust, smoke or corrosive gases), the maintenance intervals must be adapted to the actual conditions. For cleaning and maintenance work, please refer to Chapter 4 Access to the main circuit compartments. In case of ambiguities or irregularities, please contact the manufacturer s Service Center immediately. Maintenance interval for ambient conditions according to IEC 60694* Every 4 years or depending on the actual ambient conditions After 2 years After.000 actuations of the truck or the earthing switch Vacuum contactor CVX.3 Cleaning Work to be performed Check panels for contamination, condensation and damage If necessary, clean the panels (see chapter.3) and perform switching tests of the drive mecha-nisms Clean and lubricate the drive mechanisms and per-form switching tests Replace the function unit Qualification / Work performed by Staff who have been certified for this work Manufacturer's Service Center See the Operating Manual (no. NTV 32) To ensure the specified insulating level, the insulating components must be clean and dry. On principle, cleanliness deserves utmost attention. When deposited dirt and humidity are detected, the panels must be cleaned in an expert fashion. When performing cleaning, make sure that the lubrication in the drive mechanisms is not removed. If the drive mechanisms are no longer sufficiently lubricated, new lubrication must be applied. Risk of injuries: The drives must not be disassembled for service and maintenance work. 39

40 Maintenance (contd.) Slight contamination Clean using a dry, lint-free cloth. Depending on the degree of soiling, replace cloth as often as necessary. Serious contamination Use cleaning agent, litre can (see Chapter 2.). The use of other cleaning agents is not admissible. Wear protective gloves Use cleaning agent according to manufacturer s instructions Soak the cloth thoroughly and wipe the insulating components. Keep duration of exposure as short as possible. Expose the cleaned surface to the air for at least two hours..4 Corrosion protection Drive mechanisms and covers have a long-term protection against corrosion. Any damage to the paint, scratches and other damage must be repaired immediately to avoid corrosion. Contact the manufacturer s Service Center..5 Avoid condensation To ensure the specified insulating level, the panel especially its insulating components must not be exposed to condensation. Measures to take in case of condensation If condensation of the panel or the vacuum contactor CVX is detected, the affected equipment must be cleaned according to chapter.3. Installation or inspection of the appropriate heating. It must provide a sufficient heating performance to prevent condensation on the panel..6 Lubrication instructions Risk of injuries: Vacuum contactors and drives must not be disassembled for lubrication. Important: Only approved lubricants may be used (see Chapter 2.). The following elements must not be lubricated: Motor Ball bearings Auxiliary releases Push switches Blocking coils Auxiliary switches Preparation Remove truck from the panel (see Chapter 4.3.5). Clean lubrication points using a lint-free cloth; use cleaning agent in case of serious contamination (see Annex). 40

41 Maintenance (contd.) Lubrication Points of lubrication Sliding contact surfaces All accessible fric-tion points and slid-ing surfaces Bearings and joints Lubricant Lubrication procedure KL KL FL Clean by means of lint-free cloth; use cleaning agent in case of serious con-tamination. Apply a thin and uniform film of lubricant. Clean lubricating points using a lint-free cloth or a soft paint-brush, if nec-essary using cleaning agent (use spar-ingly, just moisten points of lubrica-tion). Apply a thin coat of lubricant (using e.g. a paintbrush). Pour drops of liquid lubricant (oil can, drip feed lubricator) into the bearing gap. Liquid lubricant gets between the bearing surfaces due to the capillary effect. In case of inaccessible lubrication points, use an extension tube or spray. 2 Fig.. Lubrication points in the switch compartment Guide bars of the shutters 2 Fixed contacts in the bushings 4

42 Maintenance (contd.) 3 4 Fig..2 Lubrication points on the earthing switch 3 Contact blades 4 Strike contacts.7 Replacement of components and panels The drive mechanisms and the current transformers as well as the testing and monitoring systems can be replaced if necessary. Also, entire panels can be replaced. The following data on the nameplate are relevant for replacement of components or panels or in case of any queries (see chapter 2.6): Type designation Serial number Year of construction 42

43 2 Annex 2. Auxiliary products The auxiliary products are available from the manufacturer. The use of alternative auxiliary products is not permissible. Risk of injury in case of inappropriate handling. Observe the safety data sheets of the manufacturers of the auxiliary products. Auxiliary product Item no. Cleaning agent S Lubricant KL, 0.5 kg can ST Liquid lubricant FL, 0.5 kg can S Touch-up pen RAL 7044 silk-grey, 50 ml S Touch-up pen, special paint (specify colour shade) S Treatment of firmly screw-connected contact surfaces Important: Caution when handling bars insulated by heat-shrinkable sleeves: The heatshrinkable sleeve must not get into contact with lubricant (swelling). Contact areas coated with lubricant KL should not be touched, if possible. Contact areas must be subjected to preliminary treatment before screwfastening (see Table). Immediately after the preliminary treatment, coat contact surfaces completely with a thin and uniform film of lubricant KL. Material of contact surfaces Pre-treatment Silver-plated contact surfaces Clean Nickel-plated contact surfaces Remove passivation layer 4 Copper or copper alloy Clean, expose metallic surface 2 Aluminium Clean, expose metallic surface 2 Steel Clean, expose metallic surface 2 Zinc-plated steel Hot-galvanized sheet-metal Clean by means of lint-free cloth; use cleaning agent in case of serious contamination (see above) 2 Expose metallic surface by treating the entire surface with emery cloth or a rotating grinding tool (grain size 00 or 80) or using a wire brush which is clearly marked for use exclusively for aluminium or exclusively for copper 3 using a brass brush, steel brush 4 rub slightly by hand using Scotchbrite abrasive agent (Ni layer must not be reduced) 2.3 Screw fastenings Remove passivation, not the zinc layer 3 Clean, passivation need not be removed The following elements must be used for all screw fastenings: Screws and bolts: Grade 8.8 Nuts: Grade 8 43

44 2 Annex (contd.) Important: Do not grease screws or nuts. Thread size Tightening torque [Nm] min. max. M4 2 3 M M6 7 9 M M M Table : Hex. bolts and socket-head capscrews (except slotted screws) and nuts (except self-locking nuts) Thread size Tightening torque [Nm] min. max. M M8 5 9 M M Table 4: Screw fastening for current transmission, conductor material: copper 2.4 Required tools (not included in the scope of supplies) Cutter Nail puller approved torque wrenches with different bits for hexagon socket screws and socket-head screws and nuts; bits for screw and nut grades M 5, M 6, M 8, M 0, M 2 Screwdriver and Philips screwdriver Cutting pliers 4 crane straps/chains of L 2000 mm lint-free, clean rags 44

45 2 Annex (contd.) Operation accessories Transport trolley for truck Item number of trolley: EIB AE07-02 Handle of the transport trolley 2 Bar to unlock the truck on the transport trolley 3 Bracket to lock and unlock the transport trolley on the panel 4 Handle to unlock the racked-in truck 5 Tray for accessories (lever, keys, handle) 6 Locking/unlocking mechanism of the wheels Fig. 2. Transport trolley for racking in/out the truck into / from the panel Fig. 2.2 Locking the transport trolley on the panel: press the bracket downwards Unlocking the transport trolley from the panel: pull the bracket upwards Fig. 2.3 Unlocking the truck from the transport trolley: push the bar to the front Fig. 2.4 Unlocking the truck from the panel: press the black handle to the front 45