PIX High. Medium-voltage switchgear. Air-insulated switchgear kv ( 50 ka) Assembly - Operation - Maintenance Technical Manual

Medium-voltage switchgear PIX High Air-insulated switchgear 7.5 kv ( 50 ka) Assembly - Operation - Maintenance Technical Manual No. AGS 53 50-0 Edition /04 www.schneider-electric.com

Manufacturer: Schneider Electric Sachsenwerk GmbH Rathenaustrasse D-93055 Regensburg ( +49 (0) 9 4 46 0-0 7 +49 (0) 9 4 46 0-48 Service: Schneider Electric Sachsenwerk GmbH Rathenaustrasse D-93055 Regensburg ( +49 (0) 9 4 46 0-0 7 +49 (0) 9 4 46 0-48

Contents Remarks on this manual...6 Reference documents... 6 Terms and symbols used... 6 Abbreviations used... 7 Any questions or suggestions?... 7 Safety provisions...8 Design and description...9. Panel design... 9. Panel variants....3 Dimensions and weights... 7.4 Applicable standards... 8.5 Ambient and operating conditions... 8.6 Ratings of the PIX High series... 9.7 Nameplate... 9.8 Technical data for electrical control and operating devices... 0.9 Intended use....0 Disposal at the end of service life... 3 Packaging, transport, storage... 3. Shipping units... 3. Transport... 3.3 Storage... 3 4 Access to the main circuit compartments...4 4. Access to the circuit-breaker compartment... 4 4.. Opening and closing the front door... 4 4.. Removing and connecting the low-voltage connector... 5 4..3 Removing truck from the panel... 5 4..4 Inserting the truck into the panel... 7 4. Access to the cable compartment... 9 4.. Removing the cable compartment cover... 9 4.. Access via the circuit-breaker compartment (optional)... 9 4.3 Access to the busbar compartment... 30 5 Assembly...3 5. Safety provisions... 3 5. Instructions for assembly... 3 5.3 Requirements regarding the switchgear room... 3 5.4 Transport of panels and trucks on site... 36 5.5 Mounting the switchgear end plates... 38 5.6 Aligning and fastening switchgear panels... 39 5.7 Screw-fastening the panels to one another... 4 5.8 Busbar assembly... 43 5.8. Access to the busbar compartment... 43 5.8. Busbar compartment section segregation (optional)... 43 5.8.3 Busbar assembly... 44 5.9 Mounting the earth bar... 50 5.0 Mounting the fan... 5 5. Mounting the deflectors... 5 5. Assembly of the pressure relief duct... 54 6 High-voltage connection...55 6. Overview of cable connection variants... 55 6. Overview for fully insulated busbar connection... 56 6.3 Mounting the high-voltage cables... 58 6.4 High-voltage connection on rear side of switchgear panel (optional)... 60 7 Low-voltage connection...6 7. Connection of the ring circuits in the low-voltage cabinet... 6 7. Placing external cables in the switchgear panel... 6 AGS 53 50-0 Edition /04 3

Contents 8 Commissioning...63 8. Final steps... 63 8. Checking switching functions and interlocks... 64 8.3 Power frequency test of busbar (optional)... 64 8.4 Cable test after assembly... 65 9 Voltage Detecting Systems (VDS)...67 9. Pluggable voltage detecting system... 67 9. Integrated voltage detecting system IVIS (optional)... 67 9.3 Voltage detecting system VOIS+ (optional)... 68 9.4 Phase comparators... 68 0 Operation...69 0. Operating interface of the panel... 69 0. Trucks for PIX High Rating Panels... 70 0.3 Operation accessories... 7 0.4 Interlocks... 73 0.4. Electromagnetic interlocks (optional)... 73 0.4. Internal mechanical interlocks in the panel... 73 0.4.3 Interlock with padlock... 74 0.4.4 Interlock with cylinder lock (optional)... 75 0.5 Operating specifications... 76 0.6 Operating the circuit-breaker... 76 0.6. Charging the circuit-breaker s energy storing device... 76 0.6. Switching the circuit-breaker manually... 77 0.6.3 Switching the circuit-breaker electrically... 78 0.6.4 Position indicators on circuit-breaker and possible operating sequences. 78 0.7 Moving the truck into operating/disconnected position... 79 0.7. Racking-in the truck from disconnected into service position... 79 0.7. Racking-out the truck from service into disconnected position... 80 0.8 Vacuum contactor CVX... 80 0.9 Operating the earthing switch manually... 8 0.9. Switch earthing switch ON... 8 0.9. Switch the earthing switch OFF... 83 0.0 Standard switching operations... 83 0.0. Operating the outgoing feeder cable... 83 0.0. Earthing the outgoing feeder cable... 84 0.0.3 Coupling busbar sections via bus section coupler... 84 0. Earthing the busbar... 85 0.. Earthing a busbar section by means of the bus section coupler... 85 0.. Earthing the busbar with the circuit-breaker of a branch-circuit panel... 86 0..3 Earthing the busbar with busbar earthing switch... 87 0. Panel with fan attachment... 87 Maintenance...89. Safety provisions... 89. Maintenance and maintenance specifications... 89.3 Cleaning... 90.4 Avoid condensation... 90.5 Corrosion protection... 90.6 Replacement of components and panels... 9.7 Lubrication instructions... 9.8 Replace fuses for voltage transformer... 9 Annex...93. Auxiliary products... 93. How to treat the contact surfaces... 93.3 Specifications for screw connections... 94.4 Required tools (not included in the scope of supplies)... 95.5 Transport trolley for truck... 95.6 List of assembly drawings... 97 4 AGS 53 50-0 Edition /04

Remarks on this manual This Technical Manual describes installation, operation and maintenance of airinsulated medium-voltage switchgear units of the series PIX High. It is exclusively intended for use by the manufacturer's staff or by persons certified for the PIX High series (training certificate). The work described in this manual may only be performed by specialist electricians with proven experience in conjunction with the PIX High series (training certificate), all relevant safety provisions. This Technical Manual is an integral part of the product and must be stored so that it is readily accessible at all times 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. This Technical Manual cannot describe every imaginable individual case or every customer-specific version of the product. For information which is not included in this manual, please contact the manufacturer. Reference documents The following additional documents must be complied with: purchase agreement with the stipulations regarding the switchgear-specific equipment and the legal details the appropriate switchgear-specific circuit diagrams / documentation the Operating Manuals of the low-voltage devices installed in the switchgear (e.g. voltage presence detecting systems, devices in low-voltage cabinet) the assembly drawings supplied with the equipment the operating instructions of the trucks being used: Circuit-breaker HVX (No. AGS 53 460-0) Metering truck MTX (No. AGS 53 360-0) Disconnector truck UTX (No. AGS 53 360-0) Vacuum contactor CVX (kv) (NTV 33 D) the Assembly Instructions of the manufacturer of the cable connection systems to be connected to the switchgear PIX Motor Control Center up to 7. kv: AGS 53 500-04 (optional) 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 in order to avoid danger to persons and damage to equipment: DANGER WARNING CAUTION NOTICE indicates an immediate, immanent risk which, if not avoided, will result in death or serious injury indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury warns about material damage This symbol is used to warn you about potential risks of injury. Please comply with all the safety provisions identified by this symbol in order to avoid death or injury. This symbol is used to warn you about hazards due to electrical voltage. Please comply with all the safety provisions identified by this symbol in order to avoid death or injury due to electrical voltage. AGS 53 50-0 Edition /04 5

Remarks on this manual Abbreviations used U r : Rated voltage I r : Rated current As our products are subject to continuous further development, we reserve the right to make changes regarding the standards, illustrations and technical data. All dimensions specified in this manual are in millimeters. Any questions or suggestions? Do you have any questions or suggestions regarding this manual, or do you require further information? We always strive to provide you with the best-possible information for optimum, safe use of our products. Thus, do not hesitate to contact us if you have any recommendations, amendments or proposals for improvement. 6 AGS 53 50-0 Edition /04

Safety provisions Before performing work on the panel, it is essential that you comply with the following instructions: DANGER Risk of fatalities due to electrical voltage! Before removing covers and before performing assembly or maintenance work, make sure that you isolate the system from the high voltage and the supply voltage and that you ground it. Comply with the five safety rules:. Isolate from the power supply,. make sure that unintentional restart (reclosing) is prevented, 3. verify zero voltage, 4. earth and short-circuit, 5. cover or cordon off adjacent live components. WARNING Risk of injury due to movable parts in mechanical drives. Before performing maintenance work, isolate the system from the supply voltage; release the circuit-breaker s energy storing device by OFF-ON-OFF operation; switch make-proof earthing switches ON. Applicable standards and regulations: Behaviour in case of incidents or accidents Metal-enclosed AC switchgear for rated voltages > kv up to including 5 kv: IEC 67-00 The locally applicable accident prevention, operating and work instructions must be complied with. Assembly and maintenance: IEC 6936-/HD 637 S Operation of electrical equipment: EN 500- The national standards applicable in the country where the equipment is to be installed must be complied with. For the case of an internal fault, the switchgear PIX High is equipped with pressure relief ports which prevent the panels and the switchgear from bursting. This Technical Manual does not include information regarding the safety of buildings in case of internal faults (pressure load of the switchgear room and necessary pressure relief ports). Pressure calculations for switchgear rooms incl. recommendations regarding pressure relief ports can be provided on request against a fee. For further details, please contact the manufacturer. In case of fire or of internal faults, toxic and caustic decomposition products may be produced. Comply with the locally applicable accident and safety provisions. Make sure that first-aid measures are taken in case of injury to persons. AGS 53 50-0 Edition /04 7

Design and description. Panel design 4 3 3 4 5 6 0 9 7 8 Fig. Schematic diagram of the panel PIX High with circuit-breaker truck HVX Low-voltage cabinet 8 Voltage transformer (optional) Circuit-breaker truck HVX 9 Cable compartment 3 Front door with nameplate 0 Current transformer 4 Position indicator of the earthing switch Make-proof earthing switch 5 Voltage detecting system Shutter 6 Operator interface of the earthing switch 3 Busbar compartment 7 Cable compartment cover 4 Circuit-breaker compartment 8 AGS 53 50-0 Edition /04

Design and description 5 4 3 3 4 5 6 0 9 7 8 Fig. Schematic diagram of the panel PIX High with circuit-breaker truck HVX (5000 A variant) Low-voltage cabinet 9 Fully insulated conductor bar terminal Circuit-breaker truck HVX 0 Current transformer 3 Front door with nameplate Make-proof earthing switch 4 Position indicator of the earthing switch Shutter 5 Voltage detecting system 3 Busbar compartment 6 Operator interface of the earthing switch 4 Circuit-breaker compartment 7 Cable compartment cover 5 Fan 8 Voltage transformer (optional) AGS 53 50-0 Edition /04 9

Design and description Panel description 0 9 8 7 3 6 5 4 Fig. 3 Schematic diagram of the panel with circuit-breaker truck HVX Busbars 6 Cable connections Earthing switch 7 Door of circuit-breaker compartment 3 Current transformer 4 Voltage transformer (optional with 8 Circuit-breaker truck HVX fuses) 9 Low-voltage cabinet 5 Cable compartment cover 0 Fan Fig. 4 Panel with internal arc classification (IAC) Deflector Pressure relief duct (not for 5000 A variant) 0 AGS 53 50-0 Edition /04

Design and description. Panel variants The illustrations show the panel types with their respective basic equipment without pressure relief duct or deflectors. Customized models or additional equipment are described in the switchgear-specific documentation... Branch-circuit panels with switching devices Block diagram Sectional view Panel Description Branch-circuit panel - circuit-breaker truck HVX () - optional voltage transformer () - with fan for I r = 4000 A (not shown) - optional surge arrester (not shown) Branch-circuit panel - disconnector truck UTX () - earthing switch () - optional current and voltage transformer (not shown) Motor Control Center (U r = kv) - vacuum contactor CVX () - optional current transformer () AGS 53 50-0 Edition /04

Design and description.. Metering panel / bus riser Block diagram Sectional view Panel Description Metering panel - metering truck MTX () - optional busbar earthing switch () Busbar riser - optional earthing switch () - optional current transformer () - optional voltage transformer (3) 3 AGS 53 50-0 Edition /04

Design and description..3 Panels for bus section coupler Block diagram Sectional view Panel Description Bus section coupler panel - circuit-breaker truck HVX () - optional earthing switch () - optional current transformer (3) - with fan for I r = 4000 A (not shown) 3 Bus section coupler panel - disconnector truck UTX () - optional earthing switch () - optional current transformer (3) 3 Bus section coupler panel with bus riser - metering truck MTX () Bus section coupler panel with bus riser AGS 53 50-0 Edition /04 3

Design and description..4 Panels with busbar rated current I r = 5000 A Block diagram Sectional view Panel 3 Description Feeder panel with Ir 5000 A - circuit-breaker truck HVX () - optional voltage transformer () - with two fans (3) Branch-circuit panel - circuit-breaker truck HVX () - optional voltage transformer () - branch-circuit panels can be equipped with additional fans, depending on the switchgear configuration. Metering panel - metering truck MTX () - optional busbar earthing switch () 4 AGS 53 50-0 Edition /04

Design and description..5 Panels for bus section coupler with busbar rated current I r = 5000 A Block diagram Sectional view Panel Description 4 Bus section coupler panel - circuit-breaker truck HVX () - optional earthing switch () - optional current transformer (3) - with fan (4) 3 Bus section coupler panel with bus riser - metering truck MTX () Bus section coupler panel with bus riser AGS 53 50-0 Edition /04 5

Design and description.3 Dimensions and weights 90 90 0 80 840 330/430 900/3000 30/30 Fig. 5 Dimensions of PIX High Panels Panel type Branch current [A] Width B [mm] approx. weight [kg] Panel with circuit-breaker truck HVX Direct bus riser panel without truck Panel with disconnector truck UTX or metering truck MTX Motor Control Center (U r = kv) 3 x voltage transformer (optional) 630 800 000 50 800 000 600 800 00 000 800 00 500 800 300 500 000 400 350 000 500 4000 000 600 5000 000 800 500 800 650 500 000 750 500 800 750 500 000 850 400 800 900 + approx. 0 Busbar rated current 5000 A incl. low-voltage cabinet with average equipment fitted, incl. deflectors or pressure relief duct, incl. fan (if provided) and incl. busbars 6 AGS 53 50-0 Edition /04

Design and description.4 Applicable standards Switchgear units of the PIX High series metal-enclosed; loss of service continuity category acc. to IEC 67-00: LSC B-PM type-tested tested for internal faults (qualification IAC AFLR) dimensioned for indoor installation PIX High switchgear units meet the following standards and regulations: Designation IEC Standard Switchgear IEC 67-00 IEC 67- Internal arc classification (IAC) IEC 67-00 Circuit-breaker IEC 67-00 Earthing switch IEC 67-0 Disconnector truck IEC 67-0 Current transformer IEC 6869- Voltage transformer IEC 6869-3 Voltage detecting systems IEC 643-5 Protection against accidental contact, foreign bodies and water IEC 6059 Vacuum contactor IEC67-06 High-voltage fuse link IEC 60644 IEC 608 Degrees of protection against accidental contact and foreign objects Degrees of protection against accidental contact and foreign objects acc. to IEC 67-00 and IEC 6059 Degree of protection of the switchgear enclosure IP3X Degree of protection of the accessible claddings in the panel IPX other values available on request.5 Ambient and operating conditions PIX High is an indoor switchgear and may only be operated under normal conditions in acc. with IEC 67-. Operation under conditions deviating from these is only admissible upon consultation with and with the written approval of the manufacturer. Ambient conditions in accordance with IEC 67- Temperature class "minus 5 indoors" Ambient temperature min./max. C 5 / + 40 Average value over 4 hours C 35 mean rel. air humidity: 4 hours/ month % 95 / 90 Installation altitude above sea level m 000 other values available on request AGS 53 50-0 Edition /04 7

Design and description.6 Ratings of the PIX High series Rated voltage U r [kv] 7,5 Rated lightning impulse withstand voltage U p [kv] 75 95 Rated power frequency withstand voltage U d [kv] 8 (4) 38 (45) Busbar [A] 350/4000/5000 Rated normal current I r Branch-circuit panel [A] 350/4000/5000 Motor Control Center [A] 400 A Rated peak withstand current I p [ka] 30 Rated short-circuit breaking current I sc [ka] 50 Rated short-time current I k [ka] 50 (3 s) Rated frequency f r [Hz] 50 (60 ) with fan on request.7 Nameplate The type designation of the switchgear panels on the nameplate (Fig. 6) specifies the essential technical data. When submitting enquiries to the manufacturer or ordering spare parts, the following information is required: Type designation Serial number Year of construction 3 4 Fig. 6 Nameplate on the front side of the switchgear panel Type designation Serial number 3 Year of construction 4 Technical data 8 AGS 53 50-0 Edition /04

Design and description Overview of rated supply voltages.8 Technical data for electrical control and operating devices The panels have been designed on principle for manual operation. 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 drive for actuation of the earthing switch Blocking coil The blocking coil prevents manual actuation of the earthing switch. In case of failure of or switching off the supply voltage, all blocking coils are in their "locked" position. Auxiliary switches Auxiliary switches are always actuated directly in front of the truck 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 customer-specific panel models. Overview of rated supply voltages Direct voltage DC [V] 4 48 60 0 5 0 Alternating voltage AC [V] (0)/0 (0)/30 Power consumption Device Power consumption DC approx. [W] Blocking coil AC 50/60 Hz approx. [VA] Motor for earthing switch 50 Please enquire at the manufacturer s for details of the power consumption for solenoids and motor. The supply voltage data is required to this effect. Technical data, auxiliary switch for the earthing switch Rated supply voltage [V DC] 0 Switching capacity (NC contact) [A] Time factor T = L/R [ms] 0 Truck Electrical control and operating devices of trucks are described in the appropriate Technical Manuals of these devices (see Reference documents on page 6). Circuit-breaker HVX: see Technical Manual AGS 53460-0 Disconnector truck UTX/Metering truck MTX: see Technical Manual AGS 53360-0 Vacuum contactor CVX: see Technical Manual NTV 33-D AGS 53 50-0 Edition /04 9

Design and description.9 Intended use Air-insulated medium-voltage switchgear units of the PIX High series are designed exclusively 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 danger and damage. Disclaimer of liability The manufacturer shall not be held responsible for damage which occurs if instructions in this Technical Manual are not complied with; the switchgear is not operated according to 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 added. No liability is accepted for parts provided by customers, for ex. current transformers..0 Disposal at the end of service life A material and recycling data sheet can be provided on request for the disposal of switchgear units of the PIX High series at the end of their service life. Disposal is performed as a service by the manufacturer s Service Center and is subject to a fee. 0 AGS 53 50-0 Edition /04

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. The panels are delivered individually and are fastened on pallets. The standard accessories are included. In the case of panels with a width of 800 mm, the trucks can be delivered within the panels. They are in "disconnected" position. With 000 mm wide panels, the trucks are delivered in separate packaging. The panels are delivered in vertical position. The weight of the entire transport unit is indicated on the packaging. Packaging If packed exclusively for truck transport, the panels are delivered on a pallet with PE protective film (Fig. 7). For sea transport, the units are packed in sealed aluminium foil with desiccant and in a closed wooden case with tightly closed wooden base (also for container transport, Fig. 8). In case of air transport, the panels are packed 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. 8). Fig. 7 Packaging in PE protective film, on a pallet Fig. 8 Packaging in a wooden case 3. Transport WARNING Risk of injury and risk of serious damage due to tipping load! Transport units must be protected against slipping and tipping during transport. AGS 53 50-0 Edition /04

3 Packaging, transport, storage Transport with forklift truck The panel may only be transported on a pallet. The entire length of the forks must be placed under the transport unit (Fig. 0). Fig. 9 Transport units must not tip over Fig. 0 Transport with forklift truck 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. The consignment must be checked for completeness based on the shipping documents. The supplier must be notified in writing without delay about any possible deviations. 3.3 Storage WARNING Risk of injury and risk of serious damage due to tipping load! Sufficient stability and evenness of the supporting area (floor) must be ensured. Panels must be stored in vertical position only, and must not be stacked. If the panels are not installed immediately after delivery, they can be stored under the following conditions: Panels must be stored in vertical position, and must not be stacked. Storage only admissible indoors. Switchgear panels and accessories must be sealed with desiccant in aluminium foil and be packed in a wooden crate (storage for max. two years after the date of packaging). 40 C -5 C Fig. Schematic diagram of the storage conditions for PIX High panels AGS 53 50-0 Edition /04

4 Access to the main circuit compartments 4. Access to the circuit-breaker compartment DANGER Risk of fatalities due to high voltage! Move the truck in disconnected position before opening the front door (see Chapter 0.7., page 79). The panels can be equipped with additional cylinder locks to lock the cable compartment cover and the front door. In this context, refer also to Chapter 0.4.4 as of page 74 Interlocks with cylinder lock. 4.. Opening and closing the front door Opening the front door. Insert the door handle into the door opening and turn it counter-clockwise upwards (Fig. ). The door is lifted.. To open the door, swing it to the left (Fig. 3). Fig. Insert the door handle and turn it upwards Fig. 3 To open the door, swing it to the left Closing the front door. Close the door completely.. Turn the handle downwards; the door is lowered. 3. Pull door handle off and stow it in the tool tray of the trolley (see Chapter.5 as of page 94). AGS 53 50-0 Edition /04 3

4 Access to the main circuit compartments 4.. Removing and connecting the low-voltage connector The low-voltage connector can only be removed or inserted while the truck is in its disconnected position. Removing the low-voltage connetor. Pull interlocking slide of the low-voltage connector forward and remove connector (Fig. 4).. Stow low-voltage connector in storage tray above the truck (Fig. 5 ). Fig. 4 Interlocking slide Fig. 5 Storage tray Low-voltage connector Connecting the low-voltage connector. Remove low-voltage truck from the storage tray above the truck.. Insert low-voltage connector into the truck and press interlocking slide forward. 4..3 Removing truck from the panel Fig. 6 Coupling the trolley to the panel Adjust the trolley to the appropriate panel width 800/000 (see Chapter.5 as of page 94). Turn the lever on the trolley clockwise in order to lift the table. 3 Push the trolley all the way down to the panel. 4 AGS 53 50-0 Edition /04

4 Access to the main circuit compartments Fig. 7 4 Turn lever counter-clockwise to secure the trolley to the panel. Ensure that it is locked. 5 Turn the interlocking lever on the truck upwards by 90 in order to unlock the truck in the panel. 6 Pull the truck carefully onto the trolley to its stop. AGS 53 50-0 Edition /04 5

4 Access to the main circuit compartments Fig. 8 7 Turn the interlocking lever on the truck back to the right by 90 in order to lock the truck to the trolley. 8 Turn the lever on the trolley clockwise in order to lift the transport table. 9 Remove the trolley from the panel. Now the truck can be raised by means of a crane, if required, and deposited. For additional information, please refer to Chapter 5.4 as of page 35. For further information regarding lifting and transporting the trucks (HVX, UTX, MTX, CVX), please refer to the appropriate Operating Instructions. 4..4 Inserting the truck into the panel NOTICE Optionally, trucks and panels can be given matching coding. This is to prevent a truck from being racked completely into the panel if the ratings do not match. Fig. 9 Moving the truck to the front of the panel using the trolley Turn the lever on the trolley clockwise in order to lift the transport table. Push the trolley all the way down to the panel. 6 AGS 53 50-0 Edition /04

4 Access to the main circuit compartments Fig. 0 3 Turn lever on the trolley counter-clockwise to secure the trolley to the panel. Ensure that it is locked. 4 Move the interlocking lever on the truck upwards by 90 in order to unlock the truck from the trolley. 5 Rack the truck carefully into the panel. Fig. 6 Turn the interlocking lever to the right by 90 in order to lock the truck in the panel. 7 Turn the lever on the trolley clockwise in order to lift the transport table. 8 Pull the trolley away from the panel. AGS 53 50-0 Edition /04 7

4 Access to the main circuit compartments 4. Access to the cable compartment DANGER Risk of fatalities due to high voltage! Switch the earthing switch ON before opening the cable compartment (see Chapter 0.9., page 8). 4.. Removing the cable compartment cover Release the securing bolts and keep them in a safe place (Fig., item 3). Lift and remove the cable compartment cover (4). The cable compartment is now accessible from the front. Mounting the cable compartment cover After completing assembly work, place cable compartment cover onto the panel, lower it and re-fasten it using the securing bolts. 4.. Access via the circuit-breaker compartment (optional). Remove truck from the panel (see Chapter 4..3, page 4).. Remove the base plate from the circuit-breaker compartment: Release all securing bolts of the base plate (). Remove the base plate carefully (). The cable compartment underneath is now accessible from above. 3 Fig. Access to the cable compartment Remove the 5 self-locking screws Remove the base plate 3 Release the bolts from the cable compartment cover 4 Lift and remove the door 4 Re-mounting the base plate After completion of assembly work, re-insert the base plate and fasten it by means of the bolts. 8 AGS 53 50-0 Edition /04

4 Access to the main circuit compartments 4.3 Access to the busbar compartment DANGER Risk of fatalities due to high voltage! Ground the busbar before opening the busbar compartment (see Chapter 0., page 84).. Open front door and remove truck from the panel (see Chapter 4., page 3).. Remove cladding between busbar compartment and circuit-breaker compartment (Fig. 3) and (Fig. 4). Now the busbar compartment is accessible. Fig. 3 Remove truck () and partition plate () Fig. 4 Posture of worker during busbar mounting and panel fastening Re-inserting the partition plate Fig. 5 De-mounting the cladding between busbar compartment and circuit-breaker compartment Remove all securing bolts. Tilt the cladding and remove it in forward direction. After completion of assembly work, re-insert the partition plate and fasten it by means of the bolts. AGS 53 50-0 Edition /04 9

5 Assembly 5. Safety provisions WARNING Risk of injury due to movable parts in mechanical drives! Do not charge the energy storing devices of the circuitbreakers and earthing switches during assembly. WARNING Risk of falling! Watch out for floor openings in the switchgear room. The tops of the panels are not meant to be walked on. When working on top of panels, protect the workplace. The switchgear panels may only be installed and assembled by the manufacturer s staff or by persons who have been certified for this work. 5. Instructions for assembly PIX High panels are delivered with the earthing switch ON. In the case of panels with a width of 800 mm, the trucks can be delivered within the panels. They are in disconnected position. The circuit breakers are always shipped in open state ( OFF ) with the energy storing device released. NOTICE Condensation, dirt and dust should be avoided during assembly on all accounts, in order to prevent damage to the panels. For assembly, observe the assembly drawings supplied with the equipment. Read them before you commence assembly work. The drawing numbers are specified in this manual in the description of the assembly work in question. For all screw connections, refer to the tightening torques specified in the Annex. 5.3 Requirements regarding the switchgear room Before installing the switchgear panels, make sure that the switchgear room is checked according to the switchgear documentation (Fig. 6). Observe the minimum distance between the switchgear and the wall of the building. The load-bearing capacity of the fastening areas must correspond to the weight of the switchgear (perform a stress analysis of the building). Check base frame (if used) for dimensions and positional tolerances. Check position of floor openings for high-voltage and low-voltage cables. Before the switchgear is positioned at its site of installation, check that the fastening points are level. Unevenness must not exceed ± mm/meter and 6 mm difference in height over the entire switchgear width. NOTICE Observe switchgear-specific space assignment plan. 30 AGS 53 50-0 Edition /04

5 Assembly 00 3 35 35 000 000 800 800 860 Switchgear with rear wallmounting and deflectors Fig. 6 Dimensions in the switchgear room (example) Deflectors Switchgear panels 3 Switchgear room 330 890 3500 00 590 500(900) Fig. 7 900 mm are required for panel replacement. AGS 53 50-0 Edition /04 3

5 Assembly Switchgear for free-standing installation within the room, with deflectors 330 890 3500 000 590 500(900) Fig. 8 900 mm are required for panel replacement. Switchgear with rear wallmounting, deflectors and installation "face-to-face" 300 890 3500 Switchgear with rear wallmounting and pressure relief duct Fig. 9 00 590 000 590 00 330 80 3300 00 590 500 (900) Fig. 30 lower room height on request 900 mm are required for panel replacement. 3 AGS 53 50-0 Edition /04

5 Assembly Switchgear for free-standing installation within the room, with pressure relief duct 80 330 3300 800 590 500(900) Fig. 3 lower room height on request 900 mm are required for panel replacement. AGS 53 50-0 Edition /04 33

5 Assembly 00 7 00 35 5 35 00 80 0 4 50 000 800 3 3 75 75 0 0 05 05 05 34 5 78 05 05 05 3 4 70 0 7 80 70 50 50 550 435 55 8 5 40 50 553 50 40 00 30 0 30 40 00 480 0 30 40 40 000 800 Fig. 3 Dimensions of the floor space in the switchgear room (example) Bore-holes for fastening of panel Opening for routing external low-voltage cables 3 Opening for routing high-voltage cables Further dimensional diagrams for cable or fully insulated bus connector variants are available on request. 4 Switchgear end plate 5 Width of base frame 00 mm 6 Width of base frame 50 mm 7 Rear gap cover 8 Front gap cover 34 AGS 53 50-0 Edition /04

5 Assembly 5.4 Transport of panels and trucks on site WARNING Risk of fatalities due to falling or tipping load! Make sure the ropes or chains are strong enough to bear the weight of the panel and the trucks. Comply with the relevant provisions for hoisting equipment. On lowering the panels and the trucks, make sure that the supporting platform is sufficiently stable and even. WARNING Risk of falling!! Watch out for floor openings in the switchgear room.. the accessories) out of their packaging (Fig. 33).. Remove transport packaging and protective film from the panel. 3. Insert the jack rings on the four fastening points at the top of the panel and secure them with one bolt each (Fig. 33). 4. Attach 4 crane ropes/chains (observing minimum carrying capacity and length, Fig. 34). Lift the panel carefully. Release the screw-fastenings between the lateral fixing brackets on the pallet and the panel. 5. Deposit the panel carefully on the floor at the intended site of installation..5 m Fig. 33 Jack rings for crane transport and fastening points at the panel Fig. 34 The ropes must have the following minimum lengths/release the screwfastenings between the fixing brackets and the panel Fixing brackets Pallet AGS 53 50-0 Edition /04 35

5 Assembly Transport of the panel on the floor. If the panel has to be moved on the floor: Use three rollers with a minimum diameter of 30 mm (Fig. 35). Sufficient stability and evenness of the supporting area (floor) must be ensured.. Move the panel on the rollers to its final site of installation. Fig. 35 Transport on rollers Transport of the trucks Lift the circuit-breaker acc. to Fig. 36. To this effect, three ropes (no metallic steel ropes) of Ø 5 mm or straps are required. Fig. 36 Lifting and depositing the HVX circuit-breaker 36 AGS 53 50-0 Edition /04

5 Assembly 5.5 Mounting the switchgear end plates Assembly drawing: AGS C73040-0 NOTICE If the switchgear is to be placed in the corner of a room, the appropriate end plate must be mounted first. The left-hand and the right-hand end plates are mounted identically. First mount the rear, then the front end plate, as shown in Fig. 37. Fig. 37 Mounting the end plate (shown: mounting the end plates on the left-hand switchgear end) Front switchgear end plate Rear end plate AGS 53 50-0 Edition /04 37

5 Assembly 5.6 Aligning and fastening switchgear panels NOTICE The position of the first panel is decisive for placement of the subsequent panels, thus it is essential that measuring is effected with the utmost precision.. Position first panel on the foundations in accordance with the switchgear-specific space assignment plan.. Remove cable compartment cover (see Chapter 4.3., page 8). 3. Align the panel. Check the panel front for correct horizontal and vertical position. If applicable, lift the panel and place shims in the direct vicinity of the fastening areas, until the horizontal position has been reached. 4. Screw-fasten the panel to the two fastening points provided on the front and to at least one fastening point on the rear (see also Fig. 3 on page 34). Fastening on concrete foundations (Assembly drawing: SEM 0 73-0) Hex. bolt M 0 x 30 + dowel pin Sectional drawing 3 4 5 Top view Fig. 38 Fastening of panels on concrete foundations Hex. bolt M 0 x 30 Lock washer ES 0 3 Washer ES 4 Dowel pin 5 0, or shims 38 AGS 53 50-0 Edition /04

5 Assembly Fastening on base frame Screws, bolts and accessories are not included in the scope of supplies... Drill holes (Ø 8.5 mm) into the base frame at the intended panel fastening points (Fig. 39).. Cut threads M 0 in the boreholes. 3. Screw-fasten panel to the frame. Sectional drawing 3 4 Top view 6 5 Fig. 39 Panel fastening on base frame Hex. bolt M 0 Lock washer ES 0 3 Washer ES 4 0, or shims 5 Base frame 6 Fastening points Additional fastening variants Further fastening variants are available on request. Please contact the manufacturer to this effect. Panel fastening with seismic qualification or vibration-proof characteristics can be supplied on request. For further details, please contact the manufacturer. AGS 53 50-0 Edition /04 39

5 Assembly 5.7 Screw-fastening the panels to one another Assembly drawing: AGS C73038-0. Position the next panel next to the previous one in accordance with the assignment plan and align it. Connecting points. Screw-fasten the two rear connecting links from the inside of the busbar compartment to the two panels (Fig. 40). Access to the busbar compartment: see Chapter 4.4, page 9. 3. Screw-fasten the panels to one another at the front using 7 self-locking screws M 8. 4. Screw-fasten the low-voltage cabinets to one another using self-locking screws M 8. 3 4 Fig. 40 Panel fastening Thread-cutting screw 8 Coupling part 3 Hex. bolt M 6 with locking ring 4 Hex. bolt M 8 40 AGS 53 50-0 Edition /04

5 Assembly Upper gap cover Rear gap cover (only if IAC AFLR is to be ensured) Assembly drawing: AGS C73 479-0 Fasten one cover plate on the top between the panels with 6 bolts M 6 respectively (Fig. 4). Assembly drawing: AGS C73 483-0 Fasten one cover plate on the rear between the panels with 4 bolts M 8 respectively. 3 Fig. 4 Gap cover between panels Upper gap cover Rear gap cover 3 Bolt M 6 AGS 53 50-0 Edition /04 4

5 Assembly 5.8 Busbar assembly 5.8. Access to the busbar compartment See Chapter 4.4, page 9. 5.8. Busbar compartment section segregation (optional) The section segregation for the busbar compartment and for the bus section coupler is mounted to the right-hand panel side (except for the right-hand end panel) (Fig. 4 and Fig. 43). Normally, the busbar segregation plate is pre-assembled in the factory. Mounting the bushings: Type of busbar Assembly drawing I r (busbar) 50 A ( x 80 x 0) AGSC73044-0 600 A I r (busbar) 500 A (3 x 80 x 0) AGSC73044-0 350 A I r (busbar) 4000 A (4 x 80 x 0) AGSC73044-03 I r (busbar) 5000 A (x00x5) (x60x5) AGSC74680-0 3 4 3 5 4 6 5 Fig. 4 Schematic diagram of busbar compartment section segregation Lock ring Fastening 3 Partition plate 4 Bushing 5 Right-hand panel side wall Fig. 43 Schematic diagram of busbar compartment section segregation (5000 A variant) Nut M8 Cover 3 Partition 4 Bushing 5 Cover 6 Plastic bolt M8x30 4 AGS 53 50-0 Edition /04

5 Assembly 5.8.3 Busbar assembly Assembly drawings for busbar assembly Panel variant Center panel End panel Bus section coupler Bus riser; bus riser with UTX or MTX Branch-circuit panel Busbar Assembly drawing I r (panel) 50 A or metering panel 600 A I r (panel) 350 A I r (busbar) 50 A (x80x0) AGSC7303-0 600 A I r (busbar) 500 A (3x80x0) AGSC7303-0 350 A I r (busbar) 4000 A (4x80x0) AGSC7303-03 600 A I r (busbar) 500 A (3x80x0) AMT00346-0 350 A I r (busbar) 4000 A (4x80x0) AMT00346-03 4000 A I r (panel) 350 A I r (busbar) 4000 A (4x80x0) AGSC7303-07 I r (panel) < 600 A AGSC7303-600 A I r (panel) 500 A AGSC7303-4 I r (busbar) = 5000 A (x60x5/x00x5) 500 A < I r (panel) 350 A AGSC7303-6 350 A < I r (panel) 5000 A AGSC7303-0 I r (busbar) 50 A (x80x0) AGSC7303-04 I r (panel) 50 A or metering panel 600 A I r (busbar) 500 A (3x80x0) AGSC7303-05 350 A I r (busbar) 4000 A (4x80x0) AGSC7303-06 600 A I r (panel) 350 A 600 A I r (busbar) 500 A (3x80x0) AMT00346-08 350 A I r (busbar) 4000 A (4x80x0) AMT00346-09 4000 A I r (panel) 5000 A 350 A I r (busbar) 4000 A (4x80x0) AGSC7303-08 Ir (panel) < 600 A AGSC7303-600 A I r (panel) 500 A AGSC7303-3 I r (busbar) = 5000 A (x60x5/x00x5) 500 A < I r (panel) 350 A AGSC7303-5 350 A < I r (panel) 5000 A AGSC7303-09 I r (busbar) 50 A (x80x0) AMT00346-07 AGSC73753-0 600 A I r (busbar) 500 A (3x80x0) AMT00346-08 AGSC73753-0 350 A I r (busbar) 4000 A (4x80x0) AGSC7303-08 AGSC73753-0 I r (busbar) = 5000 A (x60x5/x00x5) AGSC7303-7 I r (busbar) 50 A (x80x0) AMT00346-07 600 A I r (busbar) 500 A (3x80x0) AMT00346-08 350 A I r (busbar) 4000 A (4x80x0) AGSC7303-08 NOTICE Comply with the specifications on treatment of contact surfaces and the tightening torques for busbar screw fastening in the Annex. Remove transport spacers (Fig. 44). Comply with the position and direction of screws and nuts as shown in the diagram (Fig. 45 up to Fig. 48). AGS 53 50-0 Edition /04 43

5 Assembly Removing transport spacers Fig. 44 Removing transport spacers Arrangement of busbars in branch-circuit panels Number of busbars per phase 3 4 Number of outgoing feeder bars per phase L 350 A - 4000 A 5000 A L/L3 350 A 4000 A 5000 A 44 AGS 53 50-0 Edition /04

5 Assembly Busbar link L 6 4 4 5 3 L L3 7 Fig. 45 Busbar link in a center panel I r Busbar: 350 4000 A I r Branch-circuit panel: 600 350 A Busbar Copper interlayer 3 Hex. socket bolt M 0 4 Washer 5 Lock washer 6 Nut M 0 7 Outgoing feeder bar AGS 53 50-0 Edition /04 45

5 Assembly L3 L L 6 4 5 Fig. 46 Busbar assembly in a bus section coupler Example: I r Busbar: 350 4000 A Busbar Copper interlayer 3 Hex. socket bolt M 0 4 Washer 5 Lock washer 6 Outgoing feeder bar 3 46 AGS 53 50-0 Edition /04

5 Assembly End panels L L L3 Fig. 47 Shown: Busbar fastening in the left-hand end panel I r Busbar: 600 500 A I r Branch-circuit panel: 600 350 A L L L3 Fig. 48 Shown: Busbar fastening in the left-hand end panel I r Busbar: 5000 A I r Branch-circuit panel: 5000 A AGS 53 50-0 Edition /04 47

5 Assembly L L L3 L L L3 Fig. 49 Busbar link in a center panel (for details, refer to assembly drawing) I r Busbar: 5000 A I r Branch-circuit panel: 5000 A L L L3 L L3 L L L3 L Fig. 50 Busbar link for bus section coupler (for details, refer to assembly drawing) I r Busbar: 5000 A 48 AGS 53 50-0 Edition /04

5 Assembly 5.9 Mounting the earth bar (Assembly drawing: AGS C73 030-03) The earth bars are screw-fastened from panel to panel by means of connecting bars (Fig. 49 and Fig. 50). NOTICE Comply with the specifications on treatment of contact surfaces and the tightening torques for screw fastenings in the Annex. Observe the specific standards referring to earthing systems which apply in the country in question.. Clean all contact areas of the connecting bar and the appropriate earth bar in the switchgear panels and coat them with synthetic lubricant (see Chapter., page 90).. Slip the connecting bar into the adjacent panel's supporting structure through the cutout in the panel. 3. Screw-fasten connecting bar on both sides to the earth bar in question. 4. Connect earth bus to the earthing system of the switchgear building. (Connecting lines and screw accessories are not included in the scope of supplies). Fig. 5 Connecting the earth bars Connecting bar Screw fastening: Bolt M 0 + lock washer + washer 3 Fig. 5 Connecting the earth bus of the switchgear to the building earth Connecting bar Connecting points for building earth 3 End plate with marked cutout AGS 53 50-0 Edition /04 49

5 Assembly 5.0 Mounting the fan Assembly drawing: AGSC73488-03 (x fan) / AGS C73488-04 (x fan) The fans with capacitor, air flow sensor and supporting frame are pre-assembled. The pre-assembled fan is included in the standard accessories. Depending on the switchgear configuration, fans can be provided both on incoming feeder panels and branch-circuit panels. Refer to the switchgear-specific documentation.. Fasten the pre-assembled fan above the opening in the panel top by means of self-locking screws, as shown in Fig. 53.. Connect the cabling in the low-voltage cabinet, as shown in the assembly drawing. 5 4 3 Fig. 53 Fan Securing bolts 3 Supporting frame 4 Air flow sensor (in the supporting frame) 5 Cabling Fig. 54 Incoming feeder panels with one / two fans 50 AGS 53 50-0 Edition /04

5 Assembly 5. Mounting the deflectors Deflectors are required to ensure operator safety in the case of internal faults in acc. with IEC 67-00. IAC: Internal arc classification Fig. 55 Example : the switchgear is positioned in the left-hand corner of the switchgear room. It is accessible on the front and on one side (in this case: the right-hand side). IAC: AFL Fig. 56 Example : the switchgear is positioned at the wall of the switchgear room, accessible on the front and on both sides. IAC: AFL Fig. 57 Example 3: the switchgear is positioned in the center of the switchgear room, accessible on the front, on the rear and on both sides. IAC: AFLR AGS 53 50-0 Edition /04 5

5 Assembly Assembly drawings for mounting the deflectors: Switchgear front and rear side: AGS C73 566-0 Switchgear side: AGS C73 566-0 Gap covers between switchgear and building wall: AGS C73 566-0 Lateral deflector adjustment in the case of elevated low-voltage cabinet: AGS C73 566-03 NOTICE Check the correct position of deflectors and the gap covers in the switchgear documentation before mounting them. The deflectors and gap covers are mounted identically on the left-hand and the righthand sides. Fig. 58 Lateral gap cover on a switchgear without lateral access (illustrated showing the left-hand side) Fig. 59 Lateral deflector and gap cover on a laterally accessible switchgear (in this example: on the right side) 5 AGS 53 50-0 Edition /04

5 Assembly 5. Assembly of the pressure relief duct The pressure relief duct on the upper side of the panel ensures operator safety in accordance with IEC 67-00 in the case of internal faults. With a pressure relief duct installed, the switchgear can be accessible on general from the front, the rear and both sides. IAC (= Internal arc classification): AFLR (not available for 5000 A variant). NOTICE Before mounting the pressure relief duct, comply with the appropriate specifications in the customer-specific switchgear documentation.. Each panel must be equipped with the pressure relief duct matching the panel width (800 or 000 mm). Assembly drawings: AGS C73 475-0. Connection between two channel sections: AGS C73 478-0 3. Left-hand or right-hand channel end plate: AGS C73 476-0 Extension of the pressure relief duct (identical on the left and right): 4. Left-hand or right-hand connecting piece: AGS C73 480-0 5. Mounting the extension duct (depending on the length: 400/800/000 mm): AGS C73 48-XX 6. Pressure relief flap at the end of the pressure relief duct: AGS C73 0-03 or connecting piece for connection of a customer-specific pressure relief duct: AGS C74 00-0 AGS C 74 00-0 (optional) AGS C 73 476-0 AGS C 73 475-0 AGS C 73 478-0 Extension duct (400, 800, 000 mm) Bottom of the extension duct AGS C 73 0-03 AGS C 73 48-XX AGS C 73 480-0 Fig. 60 Assembly of the pressure relief duct AGS 53 50-0 Edition /04 53

6 High-voltage connection 6. Overview of cable connection variants Fig. 6 Schematic diagram of cable compartment, panel PIX High I n panel Panel width [mm] Cables per phase [A] 630 800 / / 3 / 4 50 800 / 3 / 4 600/000 800 3 / 4 500 800 / / 3 / 4 (5-8) 000 6 / 8 350 000 6 / 8 4000 000 8 Special attachment Overview of connecting brackets available for cable connection -4 cables per phase max. 500 mm cable 50 6-8 cables per phase max. 500 mm cable 50 50 6-8 cables per phase max. 630 mm cable 5 7 7 7 0 0 0 3 (534.5) 3 (534.5) 50 3 (534.5) 75 54 AGS 53 50-0 Edition /04

6 High-voltage connection 6. Overview for fully insulated busbar connection For a fully insulated connection to busbar in customized technical design, please consult the manufacturer. Assembly is effected in accordance with the specifications of the manufacturer of the fully insulated busbars. Fig. 6 Busbar connection in the front of the cable compartment Fig. 63 Busbar connection in the front of the cable compartment (5000 A variant) AGS 53 50-0 Edition /04 55

6 High-voltage connection Panel width: 800 mm; rated current 500 A Panel illustration Connecting brackets Base plate 80 00 00 9 4 45 48 40 70 (5) 60 745 745 Panel width:,000 mm; rated current 4000 A Panel illustration Connecting brackets Base plate 00 75 75 9 4 0-40 48 40 30 (5) 55 75 75 Panel width:,000 mm; rated current 5000 A Panel illustration Connecting brackets Base plate 75 75 6.5 (450) 0 450.5.5 5 5 90 00 59.5 59.5 56 AGS 53 50-0 Edition /04

6 High-voltage connection 6.3 Mounting the high-voltage cables Clamping assemblies for high-voltage cables, screws, bolts and plastic sleeves are included in the accessories. Access to the cable compartment Preparation See Chapter 4., page 8 Remove the base plates (Fig. 64). 67 Fig. 64 Base plates in the cable compartment Mounting the cable box NOTICE Danger due to contact corrosion in case of inadmissible matching of materials! Do not use aluminium cable lugs for the cable connection. Route the individual cables outwards through the cable compartment of the panel to enable assembly of the cable ends (Fig. 65).. Cut the plastic sleeves to fit the cable diameter, and slip them onto the cables.. Strip cable ends and assemble the cable box as specified by the cable manufacturer. Fig. 65 Cable routing AGS 53 50-0 Edition /04 57

6 High-voltage connection Connecting the cables NOTICE Unless otherwise specified by the cable manufacturer: Comply with the specified tightening torques and pre-coat contact areas (see Chapter., page 9). Observe the phase grouping of the switchgear panel.. Fasten the individual cables to the appropriate connection surfaces (Fig. 66, item ).. Re-mount the base plates (3). 3. Fasten high-voltage cables to the floor opening using clamping assemblies (Fig. 66, item and Fig. 67/Fig. 68). 4. Connect the ground wires to the panel rack (4). 3 4 Fig. 66 High-voltage connection Cable connection on the panel Clamping assembly for the cables 3 Base plates 4 Connection of the ground wires to the panel Clamping assembly for the cables Fig. 67 Clamping assembly for cables with a diameter of 40 mm Fig. 68 Clamping assembly for cables with a diameter of < 40 mm 58 AGS 53 50-0 Edition /04

6 High-voltage connection 6.4 High-voltage connection on rear side of switchgear panel (optional) Panels can be extended optionally by a metal-clad rear cable compartment (Fig. 69 to Fig. 7). NOTICE Current transformers may not be capable of conducting the short-circuit current of the earthing switch for 3 s. Observe ratings of current transformers. This rear connection compartment permits connection to high voltage behind the panel. High-voltage cables or external conductor bars can be routed in from the top or from the bottom alike. The variants of the cable connection options (depending on the rated nominal current) correspond to the explanations in Chapter 6., page 54. NOTICE Please clarify further technical details and design specifications with the manufacturer, as required. A dimensional drawing (AGSC73653-05) can be provided on request. Basic design of the rear cable compartment Fig. 69 Rear connection module (example: high-voltage cable routed from the top) High-voltage cables 4 Terminal contacts Rear cable compartment 5 Conductor bars 3 Cable connections 6 Current transformer The connection of the rear cable compartment to the panel was designed symmetrically and, on principle, does not depend on whether cables or fully insulated busbars are routed from the top or from the bottom. In both versions, turning by 80 on site is possible, if required. The preassembled sheet metal housing of the rear cable compartment is screwfastened to the panel on the construction site. The current transformers in the cable compartment (Fig. 69, item 6) are located in the same position as they are in the standard panel. The conductor bars (5) are routed from the current transformer to the rear and coupled to the appropriate terminal contacts (4) for the high-voltage connection in the rear cable compartment. The front earth bus has an outgoing feeder to the rear into the rear cable compartment, where a separate earth bar for earth connectors is located. In the case of several adjoining rear cable compartments, these rear earth bars must be connected to one another. AGS 53 50-0 Edition /04 59

6 High-voltage connection Further variants: Fig. 70 Rear cable compartment with high-voltage cables routed from the bottom Fig. 7 Rear cable compartment with fully insulated conductor bar connection from the top Conductor bar connection from the rear Rear metal housing and supply conductor bars are not included in the scope of supplies. A dimensional drawing incl. the specified connecting points for conductor bars and metal housings can be provided on request. Fig. 7 Rear cable compartment with conductor bar connection. Only schematic illustration, as the components specified are not included in the standard range of products Metal housing Supply conductor bars 60 AGS 53 50-0 Edition /04

7 Low-voltage connection 7. Connection of the ring circuits in the low-voltage cabinet Connecting of the ring circuits. Route the ring circuits for the interpanel wiring through the lateral openings of the low-voltage cabinet (Fig. 73).. Connect ring circuits to the appropriate terminal strips in the lowvoltage cabinet according to the circuit diagram. Fig. 73 Terminal strip Openings for ring circuits in the low-voltage cabinet 7. Placing external cables in the switchgear panel Connecting external cables Customized low-voltage cables for control and measuring purposes can be placed for each panel on the left inside of the panels to the low-voltage cabinet (Fig. 74).. Remove the metal cable duct covers on the left inside of the panel (3, 4).. Route external cables (5) from the cable basement through the cutout in the panel floor (6) and route them in the cable duct to the lowvoltage cabinet. Fasten cables to the panel using cable clamps (). 3. Connect external cables to the terminal strip in the low-voltage cabinet according to the circuit diagram (). 4. Reposition cable compartment covers. NOTICE If the cables are to be routed into the low-voltage cabinet from above, the cable fastening and protection equipment must be provided by the customer. 3 4 5 Fig. 74 Placing external cables in the switchgear panel Connection to terminal strip in the low-voltage cabinet Cable clamp 3,4 Cable duct covers 5 Bus riser in cable duct 6 Cutout in the panel floor AGS 53 50-0 Edition /04 6

8 Commissioning 8. Final steps DANGER Risk of fatalities due to high voltage! High voltage must not be connected. Isolate the switchgear from the power supply, and earth it. NOTICE Whenever you detect anomalies, faults or malfunctions, do not commission the switchgear, but inform the manufacturer. Cleaning the panel and checking panel assembly Damaged paint Re-mounting the covers Inspection Racking-in the trucks 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 conductor Panel screw fastenings Busbar links Deflector fastening Special attachments The panels are powder-coated. Minor damage to the paint can be repaired using commercially available paint (standard colour RAL 7044 or corresponding colour). Secondary cable duct cover (see Chapter 7., page 6) Remove cable compartment cover (see Chapter 4.., page 8). Remove temporary base from the panel top, if such a base has been used. Re-mount cladding between busbar compartment and circuit-breaker compartment. Check the switchgear for damage which might be due to transport or assembly work. Compare data on nameplate to the required ratings. Check the connected cables for phase coincidence (see Chapter 9.4, page 67). Rack the following components into the panel: Circuit-breaker truck HVX Disconnector truck UTX Metering truck MTX Vacuum contactor CVX Close front doors (see Chapter 4.., page 3). 6 AGS 53 50-0 Edition /04

8 Commissioning 8. Checking switching functions and interlocks NOTICE For switching operations, comply with Chapter 0 as of page 68 (Operation). In case supply voltage is not available, blocking coils (optional; lock circuit-breaker button and/or truck in disconnected position) are in locked position, thus blocking manual switching operations; there is a dropped-out undervoltage release in the circuit-breaker (optional). The energy-storing device of the circuit-breaker drive is charged autonomously as soon as the supply voltage is applied.. Apply supply voltage.. Perform several manual test operations with each switching device. 3. Check switch position indicators. 4. Check electrical functions of control and operating devices: Closing and opening releases for circuit-breaker Optional motor-operated drives for the truck and the earthing switch 5. Check switch position indicators and interlocks (see Chapter 0 as of page 68). 8.3 Power frequency test of busbar (optional) DANGER Risk of fatalities due to high voltage! No high-voltage cables must be connected in the panel used for the voltage test and on the busbar. Mount test cables securely to the high-voltage terminal. During the test, close all accessible high-voltage terminals in a surge-proof fashion. Earth the residual phases using a commercially available earthing device. A test unit and a test adapter (not included in scope of supplies) are required for the power frequency test. Preparation. All panels must be isolated from the power supply and earthed (see Chapter 0.0, page 8).. Busbar: Disconnect voltage transformer (MTX) and surge arrester. Earth voltage detecting systems. 3. Incoming feeder panel for voltage test: Remove cable compartment cover and disconnect voltage transformer and surge arrester. Earth voltage detecting systems. NOTICE Observe the assembly and operating instructions for the test unit and the test adapter. Observe admissible test values for the switchgear and the admissible test values for power-frequency tests after installation of the switchgear in accordance with IEC 67-00. AGS 53 50-0 Edition /04 63

8 Commissioning 4. Perform the power frequency test of the busbar on the feeder panel: Connect test unit to the test cable. Switch the earthing switch OFF. Move circuit-breaker truck HVX into service position and switch circuitbreaker ON. Perform the power frequency test successively for all three phases (L, L, L3) in accordance with the specifications of the test unit manufacturer. 3 5 4 Fig. 75 Switch position during the power frequency test (example: five panels) Branch-circuit panels Incoming feeder panel for test voltage 3 Busbar 4 Test unit (e g. high-voltage source, test transformer) 5 Test cable After the power frequency test 5. After the power frequency test: Switch circuit-breaker OFF and put circuit-breaker truck into disconnected position; switch earthing switch ON. Remove test unit and test cables. Reconnect disconnected voltage transformers and surge arresters. 8.4 Cable test after assembly DANGER Risk of fatalities due to internal arc! Due to the open cable compartment cover, internal arc protection only exists to a limited extent. Thus, panels with service voltage existing on the busbar are under maintenance conditions during the cable test. Determine safety clearances and cordon off the area in question before the cable test. Comply with the safety clearances during the cable test. The switchgear operating company is responsible for appropriate implementation of the cable test. A test unit and a test adapter (not included in scope of supplies) are required for cable testing. NOTICE The assembly, operating and testing instructions for cable fittings and connectors and the test unit must be taken into consideration. During the cable test, the busbar can be operated at rated voltage (see nameplate). For qualification of the current transformers for cable tests, enquire at the appropriate manufacturer's. 64 AGS 53 50-0 Edition /04

8 Commissioning Preparation Performing the cable test. Isolate outgoing feeder cable of the panel to be tested (see Chapter 0.0., page 8).. Isolate outgoing feeder cable in remote station. 3. Earth outgoing feeder cable of the panel to be tested (see Chapter 0.0., page 83). 4. Remove cable compartment cover (see Chapter 4.., page 8). 5. Disconnect voltage transformer and surge arrester; earth voltage detecting systems. 6. Connect the test adapter to a free cable connection in the panel and on the test unit. To this effect, observe the specifications of the test unit's manufacturer. NOTICE Make sure that the metallic components of the test adapter are at a sufficient distance from the earthed switchgear components (e.g. housing). 7. Set switchgear panel to test position: Switch earthing switch OFF. Circuit-breaker: OFF Truck: in disconnected position Earthing switch: OFF 8. Perform cable test according to the cable manufacturer's specifications. When doing so, do not exceed the admissible limits (see Table below). After the cable test Admissible limits for the switchgear in case of cable tests with high-voltage cables connected: 9. Earth outgoing feeder cable again. 0. Remove test set.. Reconnect voltage transformer, surge arrester and voltage detecting systems or de-earth them.. Reposition cable compartment cover. DC test voltage [kv] max. 5 min DC test voltage [kv] 0. Hz (60 min) Rated voltage U r = kv 34 9.8 Rated voltage U r =7 kv 4 6. AGS 53 50-0 Edition /04 65

9 Voltage Detecting Systems (VDS) NOTICE Refer to the operating manual of the voltage detecting system concerned. 9. Pluggable voltage detecting system The system voltage or the zero voltage state of the outgoing feeders is detected via a separate voltage detecting system according to IEC 643-5. Socket-contacts for the indicator units are located on the panel front (Fig. 77). Capacitive voltage indicators in accordance with IEC 643-5 can be used for highresistance measuring systems. (Fig. 76). NOTICE All three phases L, L and L3 must always be checked together. Close non-used socket-contacts using caps. Fig. 76 Voltage indicator (Type HR-ST, Horstmann GmbH) 9. Integrated voltage detecting system IVIS (optional) IVIS is an integrated voltage detecting system with an integrated display unit used to verify zero voltage according to IEC 643-5. The IVIS system has been designed for maximum operating reliability. It does not require supply from an external source. It features climate-proof encapsulated electronics and is maintenancefree due to permanent monitoring of the indication thresholds. Fig. 77 Socket-contacts for HR system on the panel front Fig. 78 IVIS display unit Flash arrow symbols on the indicators display the mains voltage still existing within the defined response thresholds (Fig. 78). The IVIS system does not require the electrical repeat tests common for voltage detecting systems. For a description of all functions and messages of the IVIS system, please refer to the separate Operating Manual IVIS (No. AGS AGS 53 750-0). 66 AGS 53 50-0 Edition /04

9 Voltage Detecting Systems (VDS) 9.3 Voltage detecting system VOIS+ (optional) VOIS+ (Fig. 79) is a capacitive three-phase voltage detecting system with an integrated display unit used to determine voltage or zero voltage in accordance with IEC 643-5. It does not require a battery or external power supply. Flash arrow symbols on the display indicate the applied voltage within the defined response thresholds. VOIS+ has a 3-phase measuring point geared to the LRM conditions in acc. to VDE 068 part 45 for phase comparison and determining the rotary field direction. 9.4 Phase comparators Fig. 79 Voltage detecting system VOIS+ (Manufacturer: Kries Energietechnik GmbH & Co. KG) NOTICE Before 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 DEHNcap / PC-LRM (Fig. 78, ref. no. AGS C630-0). Phase comparators are optionally available and not included in the scope of supplies. Fig. 80 Phase comparator DEHNcap / PC-LRM AGS 53 50-0 Edition /04 67

0 Operation 0. Operating interface of the panel 8 7 3 4 5 6 L L L3 6 5 4 3 0 9 8 7 Switching circuit-breaker OFF (shown with operating rod; optionally: via push-button) Opening for door handle 3 Interlocking slide for the actuating port, for racking the truck in/out manually 4 Cylinder lock mechanism of cable compartment cover (optional) 5 Earthing switch position indicator 6 Voltage detecting system 7 Cable compartment cover 8 Interlocking lever for the actuation port of the earthing switch 9 Insertion opening for manual actuation of earthing switch 0 Cylinder lock mechanism of truck (optional) Cylinder lock mechanism of earthing switch (optional) Opening for racking the truck in/out manually 3 Truck position indicator 4 Opening for manual charging of the circuit-breaker's energy storing device 5 Inspection port 6 Switching circuit-breaker ON (shown with operating rod; optionally: via push-button) 7 Nameplate 8 Low-voltage cabinet Fig. 8 Operating interface of a PIX High panel 68 AGS 53 50-0 Edition /04

0 Operation 0. Trucks for PIX High Rating Panels Fig. 8 Circuit-breaker truck HVX Pole partitions Moving contacts 3 Vacuum interrupter chamber 4 Thrust rod (transfer of ON/OFF switching movement) 5 Truck 6 Truck rollers 7 Slide for opening the insertion opening (8) for racking the truck in and out manually 8 Insertion opening for racking the truck in/out manually 9 Lever for locking/unlocking the truck in the panel 0 Position indicator - truck in disconnected position Position indicator - truck in service position Operator interface 3 Low-voltage connection Fig. 83 Disconnector truck UTX Moving contacts Truck 3 Truck rollers 4 Slide for opening the insertion opening (5) for racking the truck in and out manually 5 Insertion opening for racking the truck in/out manually 6 Lever for locking/unlocking the truck in the panel 7 Position indicator - truck in disconnected position 8 Position indicator - truck in service position 9 Cover plate with nameplate 0 Low-voltage connection Fig. 84 Metering truck MTX Moving contacts High-voltage fuse 3 Voltage transformer 4 Truck 5 Truck rollers 6 Slide for opening the insertion opening (7) for racking the truck in and out manually 7 Insertion opening for racking the truck in/out manually 8 Lever for locking/unlocking the truck in the panel 9 Position indicator - truck in disconnected position 0 Position indicator - truck in service position Cover plate with nameplate Low-voltage connection AGS 53 50-0 Edition /04 69

0 Operation Fig. 85 Vacuum contactor CVX (only for kv version) Moving contacts Fuse 3 Vacuum interrupter chambers with magnetic drive 4 Truck 5 Truck rollers 6 Slide for opening the insertion opening (7) for racking the truck in and out manually 7 Insertion opening for racking the truck in/out manually 8 Lever for locking/unlocking the truck in the panel 9 Position indicator - truck in disconnected position 0 Position indicator - truck in service position Indicator - vacuum contactor ON/ OFF Fuse status indicator 3 Handles for racking out/in 4 Operations counter (optional) 5 Low-voltage connection Fig. 86 Truck with jumper Moving contacts Truck 3 Truck rollers 4 Slide for opening the insertion opening (5) for racking the truck in and out manually 5 Insertion opening for racking the truck in/out manually 6 Lever for locking/unlocking the truck in the panel 7 Position indicator - truck in disconnected position 8 Position indicator - truck in service position 9 Cover plate with nameplate 70 AGS 53 50-0 Edition /04

0 Operation 0.3 Operation accessories NOTICE These accessories are supplied together with the panel. The panel may only be operated by means of these accessories. Fig. 87 Handle for opening and closing the door Item no. SEM 00-0 Fig. 88 Standard double-bit key to lock/unlock the door of the low-voltage cabinet Item no. SEM 037-0 Fig. 89 Crank to charge the circuit-breaker's energy-storing device Item no. AGS H30498-0 Fig. 90 Lever for racking the truck in/out manually Item number AGS C669-0 Fig. 9 Control lever for actuation of the earthing switch Item number AGSC7470-0 Fig. 9 Operating rod to switch the circuitbreaker ON and OFF Item no. AGS H35446-0 AGS 53 50-0 Edition /04 7

0 Operation 0.4 Interlocks NOTICE Complete switchgear interlocking can only be ensured with complete locking devices. 0.4. Electromagnetic interlocks (optional) Electromagnetic blocking coils can be used for inter-panel as well as intra-panel interlocks: The circuit-breaker s ON and OFF pushbuttons are blocked. Manual actuation of the disconnector truck is blocked. Manual actuation of the earthing switch is blocked. NOTICE In case of failure of the supply voltage, all electrical interlocks are in their "locked" position. Measure: Re-establish power supply. Please note the purchase contract and the switchgear-specific circuit diagram as regards the design of the interlocking systematics. Fig. 93 Symbol for blocking coil on the earthing switch 0.4. Internal mechanical interlocks in the panel Interlock Function of interlock Method of operation of interlock Between truck and low-voltage connector Between truck and earthing switch Between the circuit-breaker and the truck Between the cable compartment cover and the earthing switch (optional) Switch cannot be racked in unless the low-voltage connector is inserted and locked The low-voltage connector can only be inserted or removed while the truck is in its disconnected position The truck cannot be moved into service position 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 Circuit-breaker cannot be racked in or out while it is switched on Circuit-breaker cannot be switched on unless it has completely reached its disconnected or service position 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. The opening for the moving crank handle is locked The interlock for the low-voltage connector on the drive end has been activated The opening for the moving crank handle is locked. The opening for the earthing switch lever is locked. The opening for the moving crank handle is locked The circuit-breaker cannot be switched ON or OFF The cable compartment cover is locked mechanically by means of a sheet metal plate. 7 AGS 53 50-0 Edition /04

0 Operation 0.4.3 Interlock with padlock The holes are designed so that the shackles of padlocks with a diameter of max. 8 mm can pass through them. Fig. 94 Earthing switch locked by padlock with short shackle Fig. 95 Manual racking-in of truck locked by padlock Fig. 96 Manual switching ON of circuit-breaker locked by padlock Fig. 97 Manual switching OFF of circuit-breaker locked by padlock Fig. 98 Padlocks blocking opening of shutters Opening the upper shutter is blocked. Opening the lower shutter is blocked. Fig. 99 Optional: Cover flaps on ON/OFF pushbutton for circuit-breaker can be locked by means of a padlock. AGS 53 50-0 Edition /04 73