GE Industrial Solutions User/Installation Manual for 4.76kV -15kV SecoBloc
Index General Scope...3 Standards...3 Operating conditions...3 Technical specification...3 Basic structure Features...4 Operation...4 Circuit Breaker Compartment...5 Interlocks...6 Transportation and storage Condition on delivery...7 Transport...7 Storage...7 Dimensions and Weight...8 Circuit Breaker Installation and Removal...9 Preparations...9 Move the circuit breaker from test position to connected position...10 Move the truck from connected position to test position...10 Circuit Breaker Operation...10 Trouble Shooting...11 Accessories / Operating Tools...11 Installation details of SecoBloc with switchgear...12 Busbar Installation...13 Recommended Torque Values...13 Ring CT Installation...14
General Scope SecoBloc modules are completely assembled compartments designed to house GE s SecoVac VB2+ vacuum circuit breakers. The modules can be stacked for two-high switchgear configurations, and mounted side-by side to form switchgear lineups. The OEM is responsible for supplying a rear section for main bus and cable connections, as well as the main and riser bus itself. The switchgear is for applications in 4.76-15 kv power systems up to 3000A, with maximum short time withstand current up to 40kA and are compliant with the IEEE C37.20.2 standard for 60Hz. SecoBloc - BM: Breaker compartment enclosure. Standards and specifications The product complies with IEEE C37.20.2 Operating conditions The switchgear is designed for normal service conditions of indoor switchgear as per publication IEEE C37.20.2. The following limit values, among others, apply: Ambient temperature Maximum + 40 C 24h-Medium +35 C Minimum -15 C Humidity Highest average value measured over 24 hours Relative humidity 95% Highest average value measured over 1 month Relative humidity 90% The maximum site altitude is 1000 m above sea level Technical Specification Parameter Unit Rating Rated Voltage kv 4.76/8.25/15 Rated Frequency Hz 60 Rated Power-Frequency Withstand Voltage (1min) kv 36 Rated Lightning Impulse Withstand Voltage (peak) kv 95 Rated Current A 1200/2000/3000 Rated Short-time Withstand Current(3s) ka 31.5/ 40 Rated Peak Withstand Current ka 82/ 104 3
Basic Structure SecoBloc modules are designed for use in constructing MV switchgear arrangements and applications. Each unit of SecoBloc consists of circuit breaker compartment with integrated LV compartment. Features High quality steel sheets of 11 gauge (3 mm) thickness are used for the enclosure. Primary disconnects are supported by high-dielectric epoxy bushings, designed to mount ring-type current transformers. Front compartment doors are supplied as standard. Compartment door can be used for mounting LV equipment. Refer dimensional drawings for space allowance. The grounded internal barriers provide dead-front access to the circuit breaker when the busbars are energized. Doors and cover plates are treated against corrosion and then coated with high quality paint. The finishing coat is ANSI 61 grey color. Operation The circuit breaker can be placed in 3 positions: Connected position->circuit breaker racked in and locked in position, primary circuit connected, control plug connected Test position->circuit breaker racked out and locked in position, primary circuit disconnected, control plug connected Disconnected position->the circuit breaker can be unlocked and removed from the cubicle. Travel between connected and test positions is 200mm (7.87 inches). 1. Breaker Compartment 2. Space for LV Components 3. Metallic Shutter 4. Circuit breaker 5. Top and Bottom primary contact Insulators (Spouts) 6. Fixed contact 7. Ground bus connection 4
Circuit Breaker compartment The circuit breaker compartment contains all the necessary interfaces for the operation of the drawout VCB. Compartment is constructed of grounded metal barriers on all sides. The metallic shutters inside the compartment are moved by an actuating bracket mounted on the drawout VCB. The shutters are opened while racking to connected position, and are closed when the breaker is racked to the Test/Disconnect position or removed from the panel. From the Inspection window on the door, mechanical indicators for ON/OFF and Charged/Discharged and ON/OFF push buttons located on the circuit breaker can be observed. Figure 2: Circuit breaker compartment with and without VCB. 1. Secondary Wiring Socket 2. Top Shutter 3. Wiring Duct Cover 4. Bottom Shutter 5. Guide Rail 6. Secondary Wiring Plug 7. Front Facia 8. Racking Mechanism The drawout circuit breaker element consists of 1. Undercarriage Assembly 2. Primary Disconnect 3. Primary Finger Assembly 4. Secondary Disconnect 3 2 4 The under carriage assembly establishes the mechanical connection between the panel and the circuit breaker. The circuit breaker element is moved by a racking handle manually or by a motor (optional feature), between the connected or test/disconnected positions. Auxiliary Switches (TOC) are provided in undercarriage to indicate connected and Test/Disconnected position. 1 Figure 3: SecoVac Drawout Vacuum Circuit Breaker 5
SecoBloc can be used for top or bottom Compartment. In circuit breaker compartment provision for mounting terminal blocks is provided on front as shown below in Figure 4. Suitable to mount terminal blocks type GE EB25, EB27, Marathon 1500 and Phoenix OTTA6 Provision for Terminal Block mounting Figure 4: Provision for mounting terminal blocks in circuit breaker compartment Provision for Terminal Block mounting Interlocks The SecoBloc module is equipped with IEEE required interlocks to block incorrect operations that could put the operator at risk and compromise the efficiency and reliability of equipment. These interlocks inhibit operations as shown in table 2: Table 2: Standard and optional interlocks offered in SecoBloc SecoBloc BM Interlocks Mechanical (M)/ Electrical (E) Standard (S) / Optional (O) Pad Lock of breaker rack in and out (Insertion of the circuit breaker racking-in/out crank lever) (Figure5) M S Circuit breaker secondary disconnect plug removal -truck in connected or undefined position (Figure 6) M S Circuit breaker racking-in - (circuit breaker secondary plug not connected) E O Pad Lock Figure 5: Padlock for breaker rack in/out Interlock lever and Roller Figure 6: Interlock for secondary disconnect pulg removal The secondary disconnect plug cannot be removed in connected position due to the interlock lever shown in Figure 6. Circuit breaker rack-in Interlock is provided in the under-carriage of the circuit breaker. 6
Transport and Storage Condition on delivery At the time of shipment, the factory- assembled SecoBloc module and drawout circuit breaker element are packed separately. The SecoBloc modules and breakers are verified in the factory for accuracy as per order requirement, and compliance with routine testing as per IEEE C37.20.2. Hang the Units Using All 4 Lifting Hooks Transport SecoBloc modules are shipped as individual units. The modules are equipped with four (4) lifting hooks (Figure 7). Only perform loading operations when all precautionary measures to protect personnel and materials have been taken, utilizing the following equipment: Crane with capacity to lift 2 tons (per single module) Fork-lift truck and/or manual trolley Lifting ropes/slings of appropriate load capacity (minimum of 600kg (1322lb) )with shackles Maintain an angle of at least 60 from the front for the ropes leading to the crane hook Figure 7: Lifting Single Panel (1) Lifting hooks (qty.4) Storage It is recommended that the SecoBloc module be immediately placed in its permanent indoor location. If this is not possible, the following precautions must be taken to assure proper storage. 1. The module should be protected against moisture and condensation, by storing indoors in a dry room, with temperatures between as -30 C - +40 C. If modules are to be used for outdoor metalclad switchgear, heaters should be installed and energized to prevent condensation. 2. The modules should be stored in a clean location, free from corrosive gases or fumes; particular care, for example, should be taken to protect the equipment from moisture and cement dust, as this combination is present at construction sites and has a very corrosive effect on many parts. Damage is possible if stored on side/back or top. 7
Dimensions and Weight Table3: Overall dimension different configurations of SecoBloc Width (max) - mm Depth (max) - mm Height (max) - mm Weight (kgs (lbs) 1200A,31.5 ka 914 (36) 1205 (47.45) 1100 (43.31) 514 (1133) SecoBloc BM 1200A, 40 ka 914 (36) 1205 (47.45) 1100 (43.31) 522 (1150) 2000A, 40 ka 914 (36) 1205 (47.45) 1100 (43.31) 574 (1265) 3000A, 40 ka 914 (36) 1205 (47.45) 1100 (43.31) 605(1333) D C A B BM A B C D 1200A,31.5 ka 258 (10.16) 947 (37.28) 275 (10.83) 468 (18.43) 1200/2000/3000A, 40 ka 271 (10.67) 934 (36.77) 310 (12.21) 483 (19.015) Figure 8: general outline diagram of SecoBloc for 1200A/2000/3000, 31.5/40 ka (All dimensions are in mm (inches) 8
Circuit Breaker Installation and Removal Preparations: Before start up, the following work should be completed. a. Visually inspect the overall condition of the module for damage. b. Ensure there are no unnecessary materials or tools inside of the compartment. c. Wipe the compartment body and the insulation parts, clean with a soft cloth d. Inspect and test the VB2+ circuit breaker per Instruction Book DEH-50001 Lift Truck Guide Arms Cell Mounted Guide Rails Lift Truck Locking Lever Insert circuit breaker truck into the switchgear a. Check the interlocking mechanism on the lift truck and apply lubricant on the moving parts to ensure smooth operation. b. Place the circuit breaker on lifting truck guide arms and ensure the locking tabs on the sides of the circuit breaker engage the slots on the lifting truck. (See Figure 9). Figure 11: Unlock circuit breaker from lifting truck Figure 9: Circuit breaker element on the lifting truck c. Move the lifting truck to the front of the switchgear; rotate the handle to adjust the height of the lifting truck platform (clockwise for up, counterclockwise for down), (See Figure 10). Figure 12: Lock circuit breaker in switchgear d. Release the lifting truck locking lever, and then remove the lifting truck. Alignment of the lifting truck rail with the bloc. Figure 10: Lifting truck lock with switchgear 9
Move the circuit breaker from test position to connected position a. Insert the secondary plug of the truck into the socket at the top of the circuit breaker compartment and lock it. (See Figure 13 and Figure 14). b. Make sure the circuit breaker is in open position (if it is not open, press breaker manual open push button). d. Turn the handle clockwise (approximately 20 turns) until it cannot be rotated any further, at the same time a click sound will be heard, then the breaker is in the connected position. The breaker position indicator will change the status from TEST to CONNECTED (Figure 16). Figure 13: Release secondary plug from VCB Move the truck from connected position to test position a. Make sure the circuit breaker is in open position (if it is not in open position, open by pressing the trip pushbutton). b. Reverse steps of moving the breaker to service position. c. The breaker position indicator will chang the status from CONNECTED to TEST (Figure 16). Figure 14: Insert secondary plug into cell-mounted socket c. Close the door and insert the racking handle into the racking access hole located at the bottom of the door (Figure 15) until the racking socket is engaged with the racking drive screw CONNECTED Position INTERMEDIATE Position DISCONNECTED Position Figure 16: Position indicator on SecoBloc -BM CONNECTED Position INTERMEDIATE Position DISCONNECTED Position Figure 15: Racking handle insertion on door 1. Circuit breaker door 2. Racking handle insertion hole 3. Racking handle Circuit breaker operation For operation instructions refer SecoVac VB2+ instruction manual. 10
Trouble shooting Diagnosis and trouble shooting for malfunctioning during operations Malfunction Reason Resolution The circuit breaker cannot be racked into connected position from test position The circuit breaker cannot be racked out to test position from connected position The circuit breaker cannot be closed The circuit breaker cannot be opened 1. The locking handles on the circuit breaker are not in position. 2. The circuit breaker is closed 3. Shutter is not completely open 4. Secondary plug is disconnected 1. Adjust the frame and handles 2. Open the circuit breaker 3. Visually check shutter drive mechanism 4. Insert in the secondary plug 1. The circuit breaker is closed 1. Open the circuit breaker 1. The secondary plug is not inserted 2. No control power supply 3. The circuit breaker is not fully in test /connected position 4. The closing spring has not been charged 1. No control power supply 2. Opening coil not working 1. Insert and lock secondary plug 2. Turn on control power supply 3. Rack circuit breaker to test or connected position 4. Charge the closing spring 1. Turn on control power supply 2. Check power supply for opening release **See VB2+ Instruction Book for additional circuit breaker opening and closing Trouble Shooting information.** Accessories / operating tools The accessories / operating tools are list as below: Name Unit Comments Rack in/out handle Piece Used to rack the breaker in or out though opening in bloc door. 11
Installation details of SecoBloc with Switchgear Installation with Switchgear SecoBloc BM can be mounted on top or bottom, and customer can connect to the rear, top, bottom and foundation plan (as shown in Figure 17, 18 and 19) Bottom mounting Grounding contact detail Figure 19: Foundation plan of SecoBloc BM (All dimension are in mm (inches) Bolt location for stacking modules Figure 17: SecoBloc stacking details Bolting locations for rear attachment of OEM furnished rear section While coupling the SecoBloc with OEM furnished rear section, be sure to maintain relief holes of min dia of 25 mm(1 in.) for A and 16.5mm (0.65 in.) for B( in Figure19), to avoid interference with the bolt head at locations shown in Figure 20. Connection-1 and 2: Bolt M10x25, M10 Spring washer, M10 washer/ quantity: 18(8+10) NOs. Figure18: Mounting details Rear, Top and Bottom of SecoBloc BM (All dimension are in mm (inches)) Figure 20: Hole/Relief details of switchgear - BM (All dimensions are in mm) 12
Figure 21: Mounting details Busbar and ground bus of SecoBloc BM (All dimension are in mm (Inches) Figure 22: Shows the critical dimensions to be maintained from breaker locking lever slot on frame to fixed contact surface Figure 23: Engagement of fix contact and moving contact Busbar Installation Customer shall design the main horizontal and riser bus bars for the panel to be assembled with the accessories and spout. Recommended branch busbar sizes are described in table 4. Bus shall be constructed of electrical grade copper, and silver or tin plated at all connecting joints. All bus must be insulated per IEEE C37.20.2. (Figure 20) using M10 (location A in Figure 21) and M16 (location B in Figure 21), 8.8 Grade MS hardware with the recommended torque values in table 5. Use M10 hardware for grounding connection (location C in Figure 21) Rating Material Busbar size In inches In mm 1200A Copper 0.19X6, 1/phase 5X150, 1/phase 2000A Copper 0.38X6, 1/phase 10X150, 1/phase Figure 22 and Table 6 shows the critical dimension to be maintained from breaker locking lever slot on frame to fixed contact surface, Figure 23 shows the engagement between fix contact of SecoBloc and moving contact of Breaker. Engagement dimension 20±5mm must be ensured when breaker is in connected position. Rating A (in mm) B (in mm) 1200A, 31.5kA SecoBloc BM 764 (30.1 in.) 1052 (41.42 in.) 1200A, 40kA SecoBloc BM 752 (29.61 in.) 1052 (41.42 in.) 2000A, 40kA SecoBloc BM 752 (29.61 in.) 1052 (41.42 in.) Recommended torque values Following table indicates torque values to be used for tightening the fasteners indicated in these documents. Table 6: Recommended torque Limits in N -m (ft-lb) Without Bolt size lubrication(oil) With lubrication(oil) M8 25(18.44) 10(7.37) M10 45(33.19) 25(18.44) M12 85(82.69) 45(33.19) M16 170(125.39) 94(69.33) 13
Ring type CT Installation SecoBloc can accommodate a maximum 4 ring type, standard accuracy class, CT s per phase (2 on each spout/bushing). CT s must be ordered separately or furnished by the OEM. To mount these CT s on the spout bushing, shutters must be open or removed (as shown in in Figure 25), tighten the bolt with M10 x100(for 1 CT/Spout) or M10x185 (for 2 CT/Spout) hardware and move the shutter down. Standard CTs offered by GE ITI for the rating 1200/2000/3000A Ring type CT is shown in Figure 25 and 26. 1. Shutter Assembly 2. Spout Bushing 3. Ring Type CT 4. Fixing Hardware Figure 24: Ring CT Mounting on Spout bushing of SecoBloc - BM Figure 25: Ring CT Rating and Mounting details for the SecoBloc for 1200 /2000A Figure 26: Ring CT Rating and Mounting details for the SecoBloc for 3000A 14
GE Industrial Solutions 41 Woodford Avenue Plainville, CT 06062 1-800-431-7867 www.geindustrial.com * Trademark of General Electric Company These instructions do not purport to cover all details or variations in equipment nor, to provide contingency to be met in connection with installation, operation, or maintenance. Should further information be desired, or should particular problems arise which are not covered sufficiently for the purchaser s purposes, the matter should be referred to GE. 12.14 DEH-50002