METAL-CLAD SWITCHGEAR TYPE SRUP 12, SRP 12 12 kv...1250 A...25 ka Manual for mounting, operation and maintenance ABB Power Distribution
Your safety first - always! WARNING Always observe the instruction manual and follow the rules of good engineering practice! Hazardous voltage can cause electrical shock and burns. Disconnect power, then earth and short-circuit before proceeding with any work on this equipment! That is why our instruction manual begins with these recommendations: Only install switchgear and/or switchboards in enclosed rooms suitable for electrical equipment. Ensure that installation, operation and maintenance are carried out by specialist electricians only. Comply in full with the legally recognized standards IEC, the connection conditions of the local electrical utility and the applicable safety at work regulations. Make sure that under operation condition of the switchgear or switchboard the specified data are not exceeded. Keep this instruction manual accessible to all persons concerned with installation, operation and maintenance. The users personnel are to act responsibly in all matters affecting safety at work and the correct handling of the switchgear. If you have any further questions on this instruction manual, the members of our field organization will be pleased to provide the required information. NOTICE! We can give a guarantee with a correct operation of our equipment only in case when the installation of switchgear cubicles is carried out by verified erecting works with which we have contracted a service agency. Erecting staff of these works is regularly trained in our company and can secure that the installation, setting up and commissioning are carried out in a correct way including a qualified service and if need be repairs. In case that you will decide for other than the erecting works recommended by the manufacturer then it is inevitable to carry out the training of erecting staff in our company on the basis of an agreement. We reserve all rights to this publication. Misuse, particularly including duplication and making available of this manual - or extracts - to third parties is prohibited. The information supplied is without liability. Subject to alternation. 2
Contents: Page 1 Summary... 4 1.1 General... 4 1.2 Standards and specifications... 4 1.3 Operating conditions... 4 1.3.1 Normal operating conditions... 4 1.3.2 Special operating condition... 4 2 Technical data... 5 2.1 Dimensions and weights... 5 2.2 Resistance to internal arc faults... 5 2.3 Electrical data... 5 3 Panel design and equipment... 6 3.1 Basic structure and variants... 6 3.2 Current instrument transformers... 6 3.3 Enclosure and partitioning... 6 3.4 Compartments in the panels... 7 3.4.1 Busbar compartment... 7 3.4.2 Circuit-breaker compartment... 7 3.4.3 Withdrawable circuit-breaker part... 7 3.4.4 Cable compartment... 7 3.4.5 Control cabinet... 8 3.5 Voltage measuring... 8 3.6 Earthing of busbars... 8 3.7 Interlocks/protection against maloperation... 9 3.7.1 Panel internal interlocking... 9 3.7.2 Interlocks between panels... 9 3.7.3 Locking devices... 9 3.7.4 VD4 circuit-breaker run on-block... 9 4 Dispatch and storage... 20 4.1 Condition on delivery... 20 4.2 Packaging... 20 4.3 Transport... 20 4.4 Delivery... 21 4.5 Intermediate storage... 21 5 Erection of the switchgear on site... 22 5.1 Site requirements... 22 5.2 Foundations... 22 5.3 Fixing the cubicles to the foundations... 22 5.4 Installation of the busbars... 23 5.5 Earthing of the cubicles... 23 5.6 Connection of the cables... 24 5.6.1 Power cables... 24 5.6.2 Control cables... 24 6 Operation of the switchgear... 32 6.1 Start-up... 32 6.1.1 Preparatory works... 32 6.1.2 Start-up... 32 6.2 Switching operation... 33 6.2.1 Withdrawable circuit-breaker part... 33 6.2.2 Tee-off earthing switch... 33 6.2.3 Busbar earthing switch... 34 6.2.4 Supplementary box of voltage measuring... 35 7 Maintenance... 41 7.1 General... 41 7.2 Periods of inspection, servicing and repairs... 41 7.3 Inspection... 41 7.4 Servicing... 42 7.5 Repairs... 42 7.5.1 Switchgear in general... 43 7.5.2 Replacement of some switchgear parts... 43 7.6 Spare parts... 43 7.7 List of lubricants and cleaning aids... 43 3
1. SUMMARY 1.1 General The indoor metal-clad switchgear panels from the SRUP/SRP 12 series are air-insulated, factoryassembled and are intended for a rated voltage to 12 kv. They are designed as withdrawable module type panels and fitted with a single busbar system. The withdrawable parts are fitted with vacuum circuit breakers from VD4 series. SRUP/SRP switchgears are designed in such a manner that they can be arranged in a row with the switchgear type SR (busbars are of the same type and in the same connecting places). This makes possible to use e.g. in incoming feeders and busbar sectionalizing panels SR switchgear with higher rating currents and to fit outgoing feeders with SRUP/SRP type. Details of the technical design and configuration of the switchgear, such as technical data, detailed equipment lists, comprehensive circuit documentation etc., can be found in the relevant order documents. 1.2 Standards and specifications The switchgear complies with the specifications of following international standards: IEC 60298 - A.C. metal - enclosed switchgear and controlgear for rated voltages above 1 kv and up to including 52 kv IEC 60694 - Common clauses for high voltage switchgear and controlgear standards All other corresponding IEC publications, the national or local workplace safety regulations and the safety regulations for production materials are to be followed during erection and operation of this equipment. In addition, the order- related data and instructions of ABB are to be observed. 1.3 Operating conditions 1.3.1 Normal operation conditions The switchgear are basically suitable for normal operating conditions for indoor switchgear and controlgear in accordance with IEC Publication 60694. The following limit values, among others, apply: Ambient temperature: - Maximum +40 C - Maximum 24 h average +35 C - Minimum -5 C (acc. to minus 5 indoor class) Humidity: With indoor installation, it is assumed that the humidity within the enclosure can reach high values, but without condensation normally appearing on the installed equipment. Condensation can be prevented by appropriate design of the station building or switchgear room. Site altitude: The maximum site altitude is up to 1000 m above sea level. 1.3.2 Special operating conditions Special operating conditions must be agreed by the manufacturer and operator according to IEC Publication 60694. The SRUP/SRP 12 switchgear provides opportunities to comply, for example, with the following special operating conditions: Increased ambient temperature: Conductors and switching devices to be designed for a higher rated current. Increased humidity: Heaters to be installed in the panels. Site altitudes above 1000 m: Design panels for higher insulation level in consideration of the altitude factor k (see e.g. ABB switchgear manual). 4
2. TECHNICAL DATA 2.1 Dimensions and weights Type SRUP 12 SRP 12 Width mm 650 800 Height mm 2200 2400 Depth mm 1790 2000 Weight kg 800 1200 See also the dimensional drawing on this page below. The minimum ceiling height in the switch room is for SRUP/SRP 12 switchgear 3 m. The corridor of minimum width of 1 m is required on the rear side of switchgear to make possible connection of cables and necessary manipulation with the switchgear. Therefore the switchgear cannot be installed with its rear side to the wall. 2.2 Resistance to internal arc faults The resistance to internal arcing faults is 26,5 ka, 100 ms, at 11 kv. Criteria 1 to 6 acc. to IEC Standard 60298, appendix AA are fulfilled. 2.3 Electrical data Type SRUP 12 SRP 12 Rated voltage kv 12 12 Rated power frequency withstand voltage kv 28 / 38 28 / 38 Rated lighting impulse withstand voltage kv 75 / 95 75 / 95 Rated frequency Hz 50-60 50-60 Rated current of busbars A 630-3150 630-3150 Rated current of tee-offs A 630-1000 1250 Rated short-time withstand current 1-3 s ka 25 1) 25 1) Rated peak withstand current ka 63 2) 63 2) Degree of protection IP 4x IP 4x 1) To 11 kv applies 26,5 ka 2) To 11 kv applies 67,3 ka 5
3. PANEL DESIGN AND EQUIPMENT 3.1 Basic structure and variants (Fig. 3/1a, b, c, d, 3/2) The basis for SRUP/SRP panel is the incoming/outgoing feeder panel using insertion technology. It is divided into busbar compartment A, circuit-breaker compartment B, cable compartment C and secondary equipment compartment D. For a busbar sectionalizing, two panels are necessary, the busbar sectionalizing panel with the withdrawable circuit- breaker part (see Fig. 3/1c), and bus riser panel (Fig. 3/1d). This bus riser panel is equipped with a fixed coupling, which can be completed with current instrument transformers. 3.2 Current instrument transformers (Fig. 3/1, 3/2) Incoming and outgoing feeder panels are equipped with toroidal current transformers of the type BD 00 (see Fig. 3/2, pt. 506), which are used for current range 100-1250 A. Ratings, accuracy classes and number of cores are adjusted according to individual requirements of each order. These data are a part of the order documentation. In case when the rated current of instrument transformers is required to be lower than 100 A, it is possible to use instrument transformers of supporting type TPU 4. But in this case the earthing switch (see Fig. 3/1b) cannot be mounted in the panel. Therefore we recommend this solution only in exceptional cases. 3.3 Enclosure and partitioning The switchgear is designed as metal-clad with separated compartments. This means that single compartments (busbar compartment, circuit breaker compartment, cable compartment) are separated mutually with metal earthed partitions. These partitions are made from the steel sheet of 2,5 mm sheet gauge. The switchgear fulfils requirements according to standard IEC 60298, annex AA with regard to an accidental internal fault (see also chap. 2.2). Therefore each switchgear compartment is equipped with a gas outlet for release of decomposition products caused by arcing in the upwards direction outside of operator devices. On the upper switchgear part gas outlets are equipped with pressure relief flaps (824, Fig. 3/2). These relief flaps are fastened on one longitudinal side with steel screws, on the other longitudinal side with plastic screws. In case of an internal overpressure plastic screws are pulled apart. This precaution increases safety of operating staff considerably. Sidewalls of the panel are made from the steel sheet of 2,5 mm sheet gauge. This means that adjacent switchgear panels are after assembling divided with two walls of thickness 2,5 mm, which provides sufficient safety to prevent them from melting through if an arc fault should occur. The front of the panels is closed off by pressure proof doors, which open to an angle of almost 180. On doors an inspection hole from safety proof glass is through which it is possible to monitor the mechanical indicator of circuit breaker. The control cabinet for the secondary equipment is fully separated from high voltage compartments with a steel sheet covering. Prior assembling all parts of panel coverings are thoroughly cleaned and treated to resist corrosion and then painted with a high quality powder stoved enamel system which is notable after stoving for its particular resistance to mechanical damages and corrosion. The cover painting is in a colour shade RAL 7035, other colour shades are possible after agreement between the customer and manufacturer. 6
3.4 Compartments in the panels 3.4.1 Busbar compartment (Fig. 3/2, 3/4) Busbars have a circular diameter of 70 mm and are made from Cu tubes of different thickness depending on the rated current. Busbars 507 are divided to sections according to the panel width and are fastened on busbar connections 509 and on bushings 508 between panels. Busbars and busbar connections are delivered either bare or insulated with shirk-on sleeves or by means of powder epoxy-resin insulation technology (Komaxit). Screw connections can be optionally protect with insulation covers. The connection of busbars is described in chapter 5/4. 3.4.2 Circuit-breaker compartment (Fig. 3/2, 3/6, 6/2) The circuit-breaker compartment contains all the necessary equipment for the mutual functioning of the withdrawable breaker part and the panel. It is, as the busbar compartment, metally partitioned on all sides. Upper insulated contact arms 1021, which are fitted with the contact system 1008, are inserted in insulated chambers 805 where they are connected with contact pins 809. These contact pins are connected by means of busbar connections 509 with busbars 507. Lower insulated contact arms are inserted in bushings 825 on which are directly put toroidal current transformers 506. Also included are the metal shutters 806 which cover the insertion openings. The shutters are opened by means of the actuating bars 1019 of the withdrawble breaker part using lever 808 when inserting into the service position and are closed when it is removed. In the test/disconnected position of the withdrawable part, a partitioning by separation is established in the main circuit current. The connection of the control wiring is not possible to interrupt in service position. But the plug 807a can remain connected in test/disconnected position for test purposes. The socket 807b for the control wiring is fixed mounted in the circuit-breaker compartment. 3.4.3 Withdrawable circuit-breaker part (Fig. 3/2, 3/3, 3/6, 6/1, 6/2) The withdrawable circuit-breaker forms a complete module consisting of circuit- breaker type VD4, the withdrawable truck 100, the insulated contact arms 1021 with the contact system 1008 and the control wiring plug 807a. The withdrawable truck establishes the mechanical connection between the panel and the circuit-breaker. The truck is connected to the panel by means of blocking pins 1018 on both sides. These pins are actuated by pedal 1009. The movable part with the circuit-breaker is moved manually by way of a spindle, between the service and test/disconnected positions with the front doors closed. Service and test/disconnected positions are exactly registered by means of auxiliary switches which register the final position reached. The earthing connection between the withdrawable part and the panel is established by earthing blade contact 1004 on the truck and earthing strip contact 821 in the panel. Withdrawable parts of the same design are mutually interchangeable. In the case of the withdrawable parts having the same dimensions, but different equipping of the circuitbreaker, its mechanical interlocking is possible. 3.4.4 Cable compartment (Fig. 3/2, 3/7) The cable compartment contains current transformers 506, earthing switch 851 and cable connection 811 according to individual operating requirements. 7
The cable compartment is constructed for the installation of three current transformers. Further information see chapter 3.2. The earthing switch type EK6 is equipped with manual operating mechanism. Its switching position is indicated by means of the auxiliary switches both electrically and mechanically. The earthing switch can be equipped with blocking magnet. In cable compartment a capacitive or resistive divider can also be placed for the voltage indication. The number and cross-sections of cables, which can be connected in the switchgear SRUP/SRP 12, are given in chap. 5.6.1. 3.4.5 Control cabinet (Fig. 3/2, 3/8) The control cabinet 817 is for all matters of control and protection suitable for both conventional or modern control technology. Apart from the usual case, a control cabinet of 700 mm high, there is also a 900 mm high version for especially comprehensive secondary technology. Secondary cables are led through cable glands in the marshalling box 652, which is placed on the panel rear side. They are connected to the terminal strip 661. From this terminal strip wires are led through the duct on the panel right side in the control cabinet. Detailed information about the secondary technology and to the relevant material used in each case can be obtained from the secondary check-list pertaining to the particulary order. 3.5 Voltage measuring (Fig. 3/2, 6/5, 6/6) On feeders or busbars the voltage measuring is carried out by means of an universal tilt-out box of voltage measuring 1040, which is placed on the panel rear side. This box is connected by means of high voltage cables either to the cable feeder 811 or to busbars 507. The box 1040 comprises three singe-pole insulated instrument voltage transformers of type TJC4 (1035), three high voltage fuses 1032 and a mechanism for tipping of fuses with corresponding covers. The replacement of fuses 1032 can be carried out without disconnection of the primary voltage. The working procedure during the replacement of fuses is described in chap. 6.2.4. By request of customers the box with withdrawable voltage transformers can be delivered instead of the universal tilt-out box. 3.6 Earthing of busbars (Fig. 3/9, 3/10, 3/11, 3/12) The earthing of busbars is carried out by the earthing switch of type EK6, which is placed in a special box 862 located on the end panel side in row (on the right or left side). The earthing switch is placed in the steel sheet box and is connected by means of the shaft 854 with the operating mechanism box 863. The Fig. 3/10 and 3/11 show a view in the box with the earthing switch in the open and closed position. If the earthing switch is in its closed position the movable contact 853 is connected with the fixed contact 852 and in this way busbars are safely earthed. The earthing switch is connected by means of the earthing strip 864 with the main switchgear earthing. The dimensional drawing is in the Fig. 3/14. 8
3.7 Interlocks/protection against maloperation 3.7.1 Panel internal interlocking A series of interlocks are provided to prevent fundamentally dangerous situations and any maloperation with possibly serious consequences, thus protection both personnel and switchgear itself. The interlocks which are normally individually effective are as follows: The withdrawable part can only be moved from the test/disconnected position into the service position (and back) with the circuit-breaker open and the earthing switch open (mechanical interlock). The circuit-breaker can only be closed when the withdrawable part is precisly in the defined test/disconnected position or in the service position (mechanical interlock). The circuit-breaker can only be opened manually in the service or test/disconnected position when no control voltage is applied, and cannot be closed (electromechanical interlock - on request). Low voltage plug 807a can only be inserted or removed when the withdrawable part is in the test/disconnected position. Earthing switch can only be closed when the withdrawable part is in the test/disconnected position or in the removed position (mechanical interlock). In order to comply with the external blocking conditions the earthing switch can additionally be equipped with a blocking solenoid. The withdrawable part cannot be moved from the test/disconnected position into the service position when the earting switch is closed (mechanical interlock). Details of any additional interlocks, e.g. the links of such systems to the bus ties and links to adjacent systems can be found in order documents for each individual case. 3.7.2 Interlocks between panels The busbar earthing switch can only be on when all withdrawable parts in busbar section, which must be earthed, are out of the panel (electromechanical interlock). When the busbar earthing switch is on, the withdrawable parts in earthed busbar section cannot be moved from the test/disconnection position to the service position (electromechanical interlock). 3.7.3 Locking devices (Fig. 3.2) The shutters 806 can be secured independently of each other with padlocks when the withdrawable circuit-breaker has been removed. Access to the drive shaft of the earthing switch can be restricted by padlock. Acces to the spindle mechanism of withdrawable circuit-breaker is restricted by padlock (on cubicle doors). 3.7.4 VD4 circuit-breaker run on-block In case of any irregularity in the area of the inner control mechanism and of the charging function of the stored-energy spring mechanism, the run-on block disables the immediately subsequent switching operation. This is a protective measure to prevent damage to the circuit-breaker. Release of the run-on block is described in instruction manual BA 383/E. 9
a) Incoming - outgoing feeder b) Outgoing feeder up to 100 A 100-1250 A (without earthing switch omly) c) Busbar sectionalizing d) Bus riser with or without CT Fig. 3/1 Panel variants 10
Legend to the Fig. 3/2. 100 - Withdrawable part with CB 506 - Toroidal current transformer 507 - Busbar 508 - Bushing 509 - Busbar connection 652 - Marshalling box 661 - Terminl strip 805 - Insulated chamber 806 - shutter 807a,b - control wiring plug + socket 809 - Contact pin 811 - Cable connection 812 - Earthing bar 815 - Insulator 817 - Control cabinet 824 - Pressure relief flap 825 - Bushing 851 - Earthing switch 1003 - VD4 circuit-breaker 1008 - Contact system 1021 - Insulated contact arm 1032 - HRC fuse 1035 - Voltage transformer 1040 - Box of voltage measuring 11
817 508 507 509 805 824 1040 1035 809 1032 807a,b 806 1003 661 652 811 1021 100 1008 812 851 815 506 825 Fig. 3/2 Cross-section of the basic model of the panel A - Busbar compartment C - Cable compartment B - Circuit-breaker compartment D - Control cabinet 12
817 807a,b 100 1009 1018 Fig. 3/3 View on the SRUP - panel with opened door 100 - Withdrawable part with CB 1009 - pedal 807 a,b - Control wiring plug + socket 1018 - blocking pin 817 - Control cabinet 13
507 508 509 805 Fig. 3/4 View into the busbar compartment 507 - Busbar 509 - Busbar connection 508 - Bushing 805 - Insulated chamber 506 825 811 Fig. 3/5 View on the toroidal current transformers 506 - Toroidal current transformers 811 - Cable connection 825 - Bushing 14
806 Fig. 3/6 View into the CB - compartment 806 - Shutters 808 - Lever 821 - Earthing strip contact 823 - Guide rail 808 821 823 661 811 652 851 Fig. 3/7 View into the cable compartment 652 - Marshalling box 654 - Cable gland (turned into the panel for transport) 661 - Terminal strip 811 - Cable connection 851 - Earthing switch 654 15
661 Fig. 3/8 View into the control cabinet 661 - Terminal strip 16
862 858 863 854 864 Fig. 3/9 The end panel with equipment for busbar earthing 854 - shaft 858 - lever 862 - additional box for busbar earthing 863 - additional box for driving mechanism 864 - earthing strip 17
852 Fig. 3/10 View to busbar earthing (earthing switch open) 852 - fixed contact 853 Fig. 3/11 View to busbar earthing (earthing switch closed) 853 - Movable contact of earthing switch 18
Fig. 3/12 Dimensioned sketch of busbar earthing 19
4. DISPATCH AND STORAGE 4.1 Condition on delivery At the time of dispatch, the SRUP/SRP panels are factory-assembled, the withdrawable parts inserted into the service position and the doors closed. The factory-assembled panels are checked at the works for completness in terms of the order and simultaneously subjected to routine testing according to IEC 60298, and thus tested for correct structure and function. The busbars are not assembled. The busbar material, fasteners and accessories are packed separately. 4.2 Packaging Two basic arts of packaging exist according to the land of destination and the way of transport: The basic packaging in a polyethylene foil as protection against dust and damage. This art of packaging is used for the transport on short distances mainly in the inland. The packing of panels for an oversee transport. In this case the panels are hermetically welded up in a polyethylene foil and packed into cases. Inside of the packing bags with the drying agent are placed. The case bottom is arranged in such a manner that it damps impacts, which can be caused during the transport manipulation. The art of packaging is carried out according to requirements of the customer. 4.3 Transport The transport units normally comprise individual panels, and in exceptional cases small groups of panels. The panels are each fitted with four lifting lugs. a) Transport of panels with the basic packaging: Transport switchgear panels only standing upright. It is necessary to take into consideration that the centre of gravity of transported panels is relatively high. Only ever carry out loading operations when it has been ensured that all precautionary measures to protect personnel and materials have been taken and using only: - a crane, hang hooks only in the marked lifting lugs, - fork-lift truck and/or - manual trolley jack. b) Transport of panels in cases: Transport the cases with packed switchgear panels only standing upright and lift them with the crane according to instructions on the case. Cases can be also lifted and transported by a fork-lift truck. c) Transport of unpacked panels in rooms at site: The switchgear panels prepared for the installation are transported in the building or the switch room preferably by means of a low-lift truck with an adequate loading capacity. If a truck such this is not at disposal or cannot be used, it is possible to transport panels on an even floor by means of rollers. But this method must be considered to be an emergency transport and can be used only in inevitable cases. Then it is necessary to pay a special attention to this transport and to proceed with care to prevent any damage of panels. Especially it is necessary to put rollers only under side panel walls (longer side), no under the shorter one, where the front door and rear covers are - see the Fig. 4/1. In case, that rollers are put under the panel shorter side a serious damage of mechanical parts (guard rails, blocking devices, door opening) can occur. 20
Fig. 4/1 Transport of the cubicle by means of rollers 4.4 Delivery The responsibilities of the consignee when the switchgear arrives at the site include, but are not limited, the following: Checking the consignment for completeness and freedom from damage (e.g. also for moisture and its detrimental effects). If any short quantities, defects or transport damages are noted: - to be documented on the respective shipping documents, - notify the relevant carrier or forwarding agent immediately in accordance with the relevant liability regulations. Always take photographs to document any major damage. 4.5 Intermediate storage Optimum intermediate storage-as far as this is necessary at all - without detrimental consequences depends on compliance with a number of minimum conditions for the panels and assembly materials. a) Panels with basic packaging or without packaging: - A dry well-ventilated store room with a climate in accordance with IEC 60694. - The room temperature must not fall below -5 0 C. - There must not be any other unfavourable environmental influences. - Store the panels upright. - Do not stack panels. - Panels with basic packaging: Open the packaging, at least partially. - Panels without packaging: Loosely cover with protective sheeting. Ensure that there is sufficient air circulation. b) Panels with seaworthy or similar packaging with internal protective sheeting: - Store the transport units: protected from the weather, in a dry place, safe from damage. - Check the packaging for damage. 21
5. ERECTION OF THE SWITCHGEAR ON SITE In the interests of the best possible erection sequence, and in order not to endanger the high quality standard of the switchgear, local erection should only be carried out, or at least responsibly managed and supervised, by specially trained skilled personnel. See too the notice on page 2. 5.1 Site requirements On commencement of installation at site, the switchroom must be completely finished, provided with lighting and site electricity supply, lockable, dry and with facilities for ventilation. All the necessary preparations such as wall openings, ducts, etc. for laying of the power and control cables up to the switchgear must already be complete. Compliance with the conditions for indoor switchgear to IEC 60694, including the condition for minus 5 indoor temperature class must be ensured. 5.2 Foundations (Fig. 5/1,5/2) The floor surface has to be prepared accordingly, with foundations for the installation of switchgear cubicles. It is recommended to use a foundation frame that consists of two rails, to which the cubicles are fastened (see Fig. 5/1).The dimensions are shown in the floor ground plan. The flatness of the foundations has to comply with permitted tolerance range values. Foundations on all sides of the floor have to be levelled horizontally and, in case of necessity, shim blocks under the cubicles are used in order to achieve the required levelling. The floor covering has to provide for an easy cleaning, the flooring is to prevent slipping and must be pressure and abrasion resistant. After the installation of the switchgear, and where required, the areas in front of the cubicles are to be covered with an insulation carpet of thickness up to 8 mm. 5.3 Fixing the cubicles on the foundations - Place down the cubicles onto the foundations. - Unscrew the lock screws and open the front door. - Pull out all the withdrawable parts from the cubicles and store them at a place where these shall be protected against damage. Follow the instructions of chapter 6. - Position the cubicles on the floor foundations. - Align the cubicles and level them horizontally by using water level and the guide rails as a reference level. - By using hexagonal screws (M12x30) join the adjacent cubicles each to the other. - Push in all the withdrawable parts into the cubicle. - After positioning the cubicles secure each of the cubicles by using spot welds to the guide rails (from the front and also from the rear, if needed). Note: Another methods of assembly can also be used, providing these shall be agreed with the manufacturer in advance. For local erection of the switchgear bolts of tensile strength class 8.8 are used im all cases. The following table contains the recommended rated tightening torques. Recommended tightening torque (Nm) 1)2) Lubricant 3) Thread Without Oil or grease M6 10,5 4,5 M8 26 10 M10 50 20 M12 86 40 M16 200 80 1) The rated tightening torques for fasteners without lubrication are based on a coefficient of friction for the thread of 0,14 (the actual values are subject to an unavoidable, partly not inconsiderable, spread). 2) Rated tightening torques for fasteners with lubrication are in accordance with German standard DIN 43 673. 3) Thread and head contact surface lubricated. 22
The above torque values do not apply for the assembly of busbars of 70 mm. In this case follow the procedures described in section 5.4. In addition, these value do not apply for mounting the fixed contacts 809 into the 805 chambers see the section 7.5.2. 5.4 Installation of the busbars (Fig. 5/3, 5/4, 5/5) In all the cubicles you have to provide access and open the busbar area. Remove the rear and front covers of the busbar area and the partition wall. All the covers are secured with M6 screws. Assembly procedure for the installation of busbars into the cubicles: - Insert the busbars 570 through the inlet bushings into the adjacent cubicles. The bushings now are loosely clamped to the partition wall. Turn round the busbars in a way that the larger of the two openings is turned to the front side of the cubicle. - Mount the busbars to the busbar branches in the following way: Slide on the clamp 540 onto the busbar branch 509 - see the Fig. 5/3, 5/4, 5/5 - and slide on the busbar 507 onto each of the branch end parts. Through the busbar opening insert the plate 541, introduce three pieces of disk springs 542 onto each of the sides of the clamp and tighten slightly the nut 543. - Make the same connection of busbars with the busbar branches in the adjacent cubicle. Proceed in the same way as described above. - Install all the remaining busbars in the described way, including the busbar end pieces 535 in the extreme cubicles (Fig. 5/4) of the switchgear system and install insulating end cover 537. - Check and make sure that busbars and either the end pieces 535 fit into the recess which serves for the support of the busbars, and that busbars are aligned over the whole length of the system (with a distance of approx. 10 mm between the individual busbar pieces). - After finishing the alignment retighten all the nuts. Torque to be applied: 30 Nm - After the installation of busbars incl. the busbar end pieces fit on the two-parts insulating covers 536 (if required by the purchase order). Notes: 1. The interconnection between the busbars is to be carried out in a proper way which would provide for a stable quality of the connection (contact resistance) during the switchgear operating period. Through testing and long-term monitoring it was evidenced that this type of connection for copper busbars does not require any maintenance during the whole service life of the switchgear system. One of the pre-requisitions for this type of connection, however, is the correct assembly of the busbars. Therefore it is essential to follow the assembly procedures as described above and as shown in Fig.5/3, 5/4, 5/5. Especially it is necessary to tighten all the screw connections with a defined torque. 2. After each disassembly of the system do use new clamps 540, the disk springs 542 and the nuts 543 because of damaging these assembly components during the disassembly. 5.5 Earthing of the cubicles (Fig. 3/2, 3/6, 5/6, 6/2) - The earthing busbar 812 (Fig. 3/2) are installed in the bottom rear part of the cubicles in the circuitbreaker area. - Earthing busbar pertaining to a specific cubicle, through an opening in the side cubicle wall, is connected to the earthing busbar of the adjacent cubicle. In such a way the cubicles can be interconnected and linked as a whole to the main earthing system. Screws for this connection you can find in the cubicles. - The interconnection of the withdrawable truck with the cubicle earthing busbar occurs automatically by means of blade earthing contact 1004 mounted on the truck and the earthing strip contact 821 which is linked with the earthing busbar of the cubicle 812. - Connection of the whole switchgear system to the main earthing occurs by means of earthing clamp 522 installed in the end cubicle of the system - see Fig. 5/6. 23
5.6 Connection of the cables 5.6.1 Power cables (Fig. 3/7) The power cables are led in the switchgear from below through cable glands 654 (see also chap. 3.4.4). Note: In the Fig. 3/7 the cable gland 654 is depicted in the position for transport ie. turned inside the panel. In operation this cable gland will be turned through 180 and will be directed into the cable compartment. In type panels SRUP/SRP 12 the connection of following types of cables is supposed: Panels SRUP 12 (width 650 mm): 1x three-core all-plastic cable to the maximum cross section of 400 mm 2. Panels SRP 12 (width 800 mm): 6x one-core all-plastic cable to the maximum cross section of 400 mm 2. Other ways of connections and use of other cable types is possible. In these cases the agreement between the user and manufacturer is necessary. The working procedure for mounting of power cables in type panels: Dismount the rear part of cable compartment and the cable gland 654. With cutting adjust the cable gland according to the cable diameter. Remount the cable gland turned through 180 0, so that it is directed into the cable duct. Lead power cables through glands in the switchgear. Assemble the cable termination according to instructions of their manufacturer. Connect cables on cable terminals 811. Remount the rear wall of cable compartment. 5.6.2 Control cables (Fig. 3/2, 3/7) The control cables are led into the switchgear from the rear side. They are directed through packing cable glands into the marshalling box 652 and are connected on terminal strip 661. In the marshalling box a detachable cover is prepared for mounting of cable glands. Working procedure: Dismount the marshalling box cover. Mount cable glands (if they are not mounted in production works). Pull through cables into the marshalling box and connect them on the terminal strip 661. Remount the marshalling box cover. 24
Fig. 5/1 Supporting frame 25
Fig. 5/2 Cable duct 26
Legend to fig. 5/3, 5/4, 5/5: 507 - Busbar 509 - Busbar branch 509a - Busbar branch 509b - Busbar branch 535 - Busbar end piece 536 - Connecting point cover (consisting of two parts) 537 - Insulation end cover 540 - Clamp 541 - Plate 542 - Disk spring 543 - M10 nut 805 - Insulated chamber 809 - Contact pin 1071 - Partition wall 1072 - Cover 1073 - M10 bolt (hexagonal socket head screw) 1074 - M8 bolt (hexagonal socket head screw) 1076 - Spring washer 27
Fig. 5/3 Assembly of busbars 28
Fig. 5/4 Assembly of busbars - end cubicle 29
Fig. 5/5 Assembly of busbars 30
522 Fig. 5/6 Earthing of the switchgear 522 - Earthing clamp 31
6. OPERATION OF THE SWITCHGEAR Requirements of occupational safety All the respective works and procedures to be done must be performed by trained personnel who has been thoroughly informed about the installation steps, while acting in accordance with the respective safety regulations and other operating instructions. 6.1 Start-up 6.1.1 Preparatory works Before connecting the operating voltage (medium voltage level) the following works have to be done: - Verify the general state of the switchgear and check for deviations and offsets of all kind (if any). - Make visual inspection of switching devices, withdrawable parts and modules, breaking contacts, insulation parts etc. - Check the connection of the earthing clamp 522 at the station earthing conductor. - Check the paintwork for damage and touch up as described in section 7.5.1 where necessary. - Remove all foreign matters form the switchgear, such as the pieces of installation material, tools or other items. - Clean the switchgear insulation parts by using a clean, dry, soft and non-fluffy cloth. - Remove any grease and sticky dirt by wiping the switchgear with a cleaning cloth soaked in solvent - see chapter 7.7. - Reinstall properly all the covers which were dismounted during the assembly and testing. - Transport covers on the circuit-breaker poles - if still mounted - have now to be dismounted. - If necessary or required, perform the AC voltage test on main circuits according to the IEC 694 standard. In the course of this testing monitor the state of voltage transformers, cables and other design parts. - Connect the auxiliary and control voltage. - Perform test manipulations with the switching devices, both manually and by using electric control elements, and monitor simultaneously the respective switching state indicators. - Check the function of mechanical and electrical blocking systems (don t use any excessive force). - Adjust the protective relays to the defined operation values and check for their proper function. - Check the switching state, the functionality and readiness of upstream (higher level) and downstream systems connected to the switchgear. - Instruct the operating personnel about the handling principles with the switchgear. Check and verify also the following devices and equipment, installed in areas next to the switchgear: - power cables, - auxiliary cables, - additional power supply units, - remote control system, - complete earthing system, - equipment installed at the switching station, - operating state of the switching station. 6.1.2. Start-up - Follow all the respective safety regulations and procedures. - Make sure that all the circuit-breakers installed in the switchgear are in OFF position. - Disconnect all links to the earthing system and disconnect all short-circuit jumpers. - Connect the feeding lines. - Subsequently in steps connect the switchgear outlets by simultaneous monitoring of the indication lamps. - If necessary verify the phase sequence, especially in case of more than one inlet feeding line and several switchgear sections. - Perform all measurements and check all functions in dependence of feeding lines connected. - Pay attention to all deviations and irregularities of any kind. 32
6.2 Switching operation It is assumed that withdrawable parts of the switchgear are equipped with VD4 vacuum circuit-breakers. Because of safety reasons all handling with and operations done on the switchgear under voltage must be performed with closed doors of the circuit-breaker compartment, which means that when switching the circuit-breakers ON or OFF, the pushing in or out from the test/disconnected into service position must be done with closed doors. 6.2.1 Withdrawable circuit breaker part (Fig. 6/1, 6/2, 6/3) A detailed description of handling steps carried out on the VD4 circuit-breaker during the making and breaking operations, and all the service and maintenance works are described in the service and maintenance manual for VD4 breakers - see the document No. BA 352/E and BA 359/E. Procedure for putting the withdrawable part into the cubicle (to the test/disconnected position): Grip the holders 110 with both hands and start to push the withdrawable part into the cubicle. Just before reaching the test/disconnected position press the pedal 1009 and push the withdrawable part till stop inside the cubicle. Loosen the pedal 1009. In this way the withdrawable part is fixed in test/disconnected position by means of blocking pins 1018. Grip the holder of control wiring plug 807a and engage it into socket 807b. Now the secondary circuits of the withdrawable part and those of the cubicle are interconnected. When the withdrawable part is in test/disconnected position, the circuit-breaker and the earthing switch can both be switched on and off. (The circuit-breaker and earting switch are mutually interlocked - see chapter 3.7.1.) Procedure for putting the withdrawable parts from test/disconnected position into service position and vice versa: This procedure is to be carried through with cubicle doors closed, circuit-breaker and earthing switch must be open. Engage the cranking handle 1006 into the opening of cubicle doors. By turning the cranking handle 1006 clockwise the withdrawable part 100 is moved to service position. Withdrawable part to be inserted completely necessitates about 20 turns of the handle 1006. After reaching the service position of the truck you have to check whether the circuit-breaker is inserted completely (check the indicator). After finishing this procedure remove the cranking handle 1006. In this position you can control the circuit-breaker both locally and remotely. The earthing switch cannot be controlled, because of its mechanically interlocking in OFF position. Transfer of the withdrawable part from the service into test/disconnected position is carried out in the same way, by turning the cranking handle anticlockwise. During this procedure the breaker has to be withdrawn completely into the test/disconnected position. Procedure for withdrawing the withdrawable part from the test/disconnected position out from the cubicle: Open the front doors of the cubicle (by meeting all the conditions for blocking). Disengage the control wiring plug 807a from the socket 807b. In this way the secondary circuits have been disconnected. Grip the both holders 110 on the front panel and simultaneously press the pedal 1009 in the lower part of the truck and pull the truck out of the cubicle. After pulling it out by about 5 cm you may leave the pedal 1009 and continue with pulling the withdrawable part by using only the holders 110 on the panel. 6.2.2 Tee-off earthing switch. (Fig. 3/2, 3/7, 6/3, 6/4) The earthing switch at the switchgear tee-offs can be operated only with withdrawable parts being in test/disconnected or in disengaged position. Switch ON the earthing switch only after closing the switchgear doors! 33
The switchgear cubicle is equipped with a three-pole earthing switch 851,type EK6, the frame of which is connected with that of the switchgear.. The switching ON and OFF of the earthing switch is carried out by an independent spring-type, hand operated mechanism. Operation of the earthing switch: Switching ON: - By pushing down the sliding cover 859 uncover the opening for the earthing switch operating lever (see Fig. 6/4). Fit on the lever 858 onto the hexagonal shaft 860 with the lever handle pointing down. - Turn round the lever clockwise, by 180. The earthing switch is making instantaneously. - The ON position of earthing switch is indicated by the switching state indicator 861 located in an opening below the hexagonal shaft end 860. - Pull out the lever 858. Switching OFF: - In the way as described above uncover the opening for fitting in the operating lever. Fit on the lever 858 onto the hexagonal shaft end 860, with lever handle pointing up. - Turn round the lever in anticlockwise direction, by 180. The earthing switch disconnects. - The earthing switch OFF position is indicated by the switching state indicator 861 which can be seen in the opening below the 860 hexagonal shaft end. - Remove the 858 lever from the cubicle. Interlocking of the earthing switch as a protective measure against faulty manipulation: The switchgear is equipped with an interlocking system that prevents the making of the earthing switch when the circuit-breaker truck is in service position. Further on, the pushing-in of the circuit-breaker truck into service position is prevented when earthing switch finds itself in making position. Other details about the interlocking system can be found in chapter 3.7. WARNING! Before switching the earthing switch ON you are requested to check the voltage-free state of that circuit which is to be short circuited. Additionally, prior each operation to the earthing switch the position of circuit-breaker truck is to be checked (whether in test/disconnected or disengaged position). Prior pushing the truck into the cubicle you have to check for disconnected position of the earthing switch, regardless of the fact that there is a mechanical interlocking of the earthing switch. In case of using the lower short-circuited contacts as the current inlet into the switchgear, also the OFF position of an upstream circuit-breaker is to be checked. Any manipulation to the earthing switch is always to be fully completed, i.e. the control lever turned by 180. 6.2.3 Busbar earthing switch (Fig. 3/9 to 3/12, 6/4) The earthing of busbars is carried out by the earthing switch EK6, which is placed in a special box 862, located on the end panel side in the row (on the right or left side). The earthing switch is placed in the steel sheet box and is connected by means of the shaft 854 with the operating mechanism box 863 of earthing switch. The operation of the busbar earthing switch is carried out in the same manner as it is described in chap. 6.2.2. 34
In addition before operation it is necessary to press the black unblocking push button on the upper part of operating mechanism box 863. If all interlocking conditions are fulfilled, the locking relay releases the sliding cover 859. Before the busbar earthing switch is closed, all withdrawable parts in the busbar section, which should be earthed, must be switch off and draw out of the panels. For details regarding interlocks against maloperation see chap. 3.7.2. 6.2.4 Supplementary box of voltage measuring (Fig. 3/2, 6/5, 6/6) This supplementary box is placed on the rear panel side (see Fig. 3/2) and comprises three single-pole insulated measuring voltage transformers of type TJC 4 (1035), three high voltage fuses 1032, fitted on a tilt-out frame 1039, and a mechanism for tipping of fuses. The supplementary box can be used for voltage measuring either on busbars or on the cable inlet (outlet). The construction of supplementary box is arranged so that transformers 1035 are firmly fixed and their connection to voltage is carried by means of the tilt-out frame 1039 on which the fuses 1032 are located. The working procedure during the replacement of fuses: Open the door of supplementary box. Disconnect the control wiring plug 662a from the control wiring socket 662b a hand it in the support on door. Release the tilt-out frame by turning the interlocking handle 659 anti-clockwise through approx. 45 0. By means of the holders 110 withdraw the frame 1039 in your direction and tip it downwards. Now you have access to fuses 1032, which can be replaced. The fuses are safely separated from high voltage circuits so that the replacement of fuses can be carried out without disconnection of the supply voltage. Tip the frame 1039 upwards and insert it into the box 1040 up to the stop. Close the door of supplementary box. 35
110 807b 807a 1013 1014 1009 1015 1018 1019 100 203 Fig. 6/1 Withdrawable part with CB out of the cubicle 100 - Withdrawable part with CB 110 - Holder 203 - Roller 807a - Control wiring plug 807b - Control wiring socket 1009 - Pedal 1013 - Push-buttons ON-OFF 1014 - Indicator of CB operating state 1015 - Indicator of energy accumulated in the springs 1018 - Blocking pin 1019 - actuating bars 36
1021 1008 1003 Fig. 6/2 Circuit-breaker on the truck 100 - Withdrawable part with CB 1003 - Circuit-breker VD4 1004 - Earthing blade contact 1008 - Contact system 1021 - Insulated contact arm 1004 100 1006 858 Fig. 6/3 Operating handle and lever 858 - Earthing switch operating lever 1006 - Truck inserting cranking handle 37
860 861 859 Fig. 6/4 State indicator for earthing switch 859 - Sliding cover 860 - Hexagonal shaft 861 - State indicator 38
662a,b 659 1040 1039 110 Fig. 6/5 Supplementary box for voltage measuring - closed 110 - Holder 659 - Interlocking handle 662a,b - Control wiring plug + socket 1039 - Tilt-out frame 1040 - Box of voltage measuring 39
662a 662b 1035 1040 1039 1032 Fig. 6/6 Supplementary box for voltage measuring - opened 662a - Control wiring plug 662b - Control wiring socket 1032 - HRC fuse 1035 - Voltage transformer 1039 - Tilt-out frame 1040 - Box of voltage measuring 40