s

Operation and Maintenance Instructions

Air Insulated Metal-Clad Single Busbar Medium Voltage Switchgear Type 8BK80
On withdrawable circuit-breaker truck upto 24 kV

Table of Contents
Page Nos 1. 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.2 1.2.1 1.2.2 1.2.2.1 1.2.2.2 1.2.2.3 1.2.2.4 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.7.1 1.2.7.2 1.2.7.3 1.2.7.4 1.2.8 1.2.9 1.3 1.4 2. 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.6 2.6.1 2.7 2.7.1 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.9 2.10 2.11 2.11.1 2.11.2 2.11.3 2.11.4 2.11.5 2.12 3. 3.1 3.1.1 3.1.2 3.2 3.3 3.4 Technical Description General Application Specific Standards Ambient Temperature and Humidity Site Altitude Design Features Switchgear Layout Circuit Breaker Compartment Service Position Test Position Isolated Position Removed Position Busbar Compartment Cable & CT Compartment Compartment for Low Voltage Equipment Accessory Items Range of Panels Feeder Panels Bus Sectionalizer Panel Metering Panel Panel with I/C & O/G Connections General Construction Interlocks Technical Data Rating Plate Installation Foundation Electrical Service Room Dimensions Transportation Units Packing Unloading Handling Equipment Required Procedure Examining the Switchgear against damages Storage Transferring the Transport Units Remove the truck from the panel Assembling the Switchboard Bolting the Panels together Fixing the Switchboard to the Foundation Bolting the Busbars together Bolting the Main Earth Busbar section together Making HV Cable Connections Earthing of Switchboard Other Work to be carried out Checking the HV Connection Checking the bolted Joints Cleaning the Switchboard Inserting the withdrawable parts Protecting the panels against Environmental effects Interpanel Wiring Putting the Switchgear into Service Test Operations With Door Open With Door Closed Checking the Accessory Items Revising the Circuit Diagram Space Heaters 3 3 3 3 3 5 5 5 6 6 7 7 7 7 7 7 7 8 8 8 8 8 8 8 9 10 11 11 13 13 13 13 13 13 13 14 14 14 15 15 15 15 16 16 16 16 16 17 17 17 18 18 18 19 19 19 4. 4.1 4.1.1 4.1.2 4.1.2.1 4.1.3 Page Nos Operations Withdrawable Truck Positions of the withdrawable truck Transferring the Withdrawable Part from the test / disconnected position manually Normal Operations Transferring the Withdrawable Part from the Connected position to the test / disconnected position manually Normal Operations Castell Key Operation (Optional) Removing the LV Plug Connecting the LV Plug Circuit Breaker Operating Mechanism Circuit Breaker Operation Charging the closing spring by hand Breaker ON and OFF Mechanically Electrically Switching State Indication Line PT with Drawout Fuse Mechanism Earthing Earthing of Busbars and Cables Direct Earthing of Busbars with Conductors Earthing of Cables with Conductors Removing Earthing Connections Earthing of Busbars / Cables with a Drawout Truck Disconnection of Earthing Drawout Truck Earthing the Busbars / Cables with Earthing Switch Earthing Busbars with Earthing Switch Earthing Cables with Earthing Switch Disconnection of Earthing Switch Earthing of Busbars or Cables with Truck Earthing of Busbars with Bus Earthing Truck Earthing of Cables with Cable Earthing Truck Link Type Earthing Truck Breaker Compartment Door To Open the Door To Close The Door Door to LV Compartment To Open the Door To Close the Door Maintenance Inspection Schedule Cleaning Lubrication Replacement Parts Defeating the Door Interlock of HV Compartment Drawout Unit in Connected Position Drawout Unit in Disconnected Position Restoring the Door Interlock Disposal of Product Summary of Important Instructions Additional Information Reference list of Items Jointing Torque 21 21 21 21

4.1.3.1 4.1.3.2 4.1.4 4.1.5 4.2 4.3 4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.3.2 4.4 4.5 4.5.1 4.5.1.1 4.5.1.2 4.5.1.3 4.5.2 4.5.2.1 4.5.3 4.5.3.1 4.5.3.2 4.5.3.3 4.5.4 4.5.4.1 4.5.4.2 4.5.4.3 4.6 4.6.1 4.6.2 4.7 4.7.1 4.7.2 5. 5.1 5.2 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 6. 7. 8. 8.1 8.2

21 21 22 22 22 22 22 22 22 22 22 23 23 23 23 23 23 23 24 24 24 24 24 24 24 24 25 25 25 25 25 25 25 25 26 26 27 27 27 27 27 27 28 29 30 31

Warning
To Ensure Personnel & Product Safety

This equipment carrries hazardous voltages and moving mechanical parts that shall be controlled remotely. Non observance of the safety instructions will result in death and / or severe personnel injury or damage to property & environment. Only qualified personnel shall work on or around this equipment after becoming thoroughly familiar with all warnings, safety notices and maintenance procedures contained herein. The components labeled with the Danger Sign shall be removed only after ensuring that the supply to the live parts behind them is deenergized & earthed. Successful and safe operation of this equipment is dependent on perfect planning of the system, proper handling (transport, storage), installation, operation and maintenance.

Fig 1: Basic Circuit Diagram

temperature of the air in the switchboard room. At ambient temperatures below -5C prevailing for a longer period the switchboard room has to be heated. The air temperature in the panels should always be about 5C above the ambient temperature to avoid condensation. (Switch on the heater against condensation!) The humidity of upto 95% is permissible. If the truck-type switchboard is exposed to a humid climate and rapid temperature changes, the switchboard room has to be heated. 1.1.4 Site Altitude

1.
1.1

Technical Description
General

8BK80 metal clad switchgear is of .horizontal isolation & horizontal drawout type suitable for easy extension of switchgear in both direction for system voltage upto 24kV. The switchgear is designed for single busbar system & is fully compartmentalized. The design incorporates the set of interlocks for safe operation of switchgear. 1.1.1 Application

The switchgear is suitable for use as distribution unit for switching load at substations of electric supply companies as well as for power stations & industrial plants. 1.1.2 Specific Standards

The rated insulating capacity values (rated impulse withstand voltage, rated power frequency withstand voltage)1) specified for the equipment are, in accordance with the provisions of IEC Publication 71, based on standard atmospheric conditions (1013 h Pa, 20C and 11 g/m3 water content). i.e. sea level. The insulating capacity of an insulation in air decreases with increasing altitude as a result of changes in the air density. Standards promulgated by IEC and other disregard this decrease in insulating capacity for altitude of up to 1000 m, i.e. the decrease of approximately 9% at this altitude is still permissible. The standards provide no guideline for altitudes of more than 1000 m with respect to insulation ratings; they leave this up to an agreement between manufacturer and user. Our own recommendation is as follows: Since this method used for rating insulation up to altitudes of 1000 m has proved to be satisfactory, it should also be applied to higher altitudes. The altitude correction factor a should therefore be based on the insulating capacity at 1000 m, which is lower by 9% (corresponding to 0.91 or 1/1.1) than the capacity at sea level. The following expression thus applies for the selection of the equipment: 3

The metal clad metal enclosed switchgear has been type tested as per all the requirements of IEC 60298 Specification for Rating & testing of insulation of electrical Switchboards & switchgear for AC Voltages above 1 kV & conforms to the standards IS3427, IS12729. The Switchgear is supplied in ready assembled condition. The Switchgear can be installed free standing. 1.1.3 Ambient Temperature and Humidity

Ambient temperature is understood as the

Rated withstand voltage to be selected2) Required withstand voltage2) 1,1 a

Example: Site altitude above sea level .......................... 3000 m Required impulse withstand voltage .................. 75 kV Correction factor a .............................................. 0,73 (according to Fig. 1.1) 75 kV Rated impulse withstand = 93 kV voltage to be selected 1.1 x 0.73 Switchgear with rated voltage of 15 kV, IEC List 2 (rated lightning impulse withstand voltage of 95 kV) meets this requirement. The actual insulating capacity at the site is then withstand voltage 3) = a rated withstand voltage2) of the selected switchgear unit.

Fig. 1.1 Relationship between the correction factor a and the site altitude
The following definitions apply: 1) Rated withstand voltage2) = required value corresponding to the provisions of IEC etc. for sea level. Withstand voltage3) = actual value for the given altitude 2) Rated lightning impulse withstand voltage Rated power frequency withstand voltage 3) Lightning impulse withstand voltage Power frequency withstand voltage

2.4

2.1

2.2

2.5

2.3

2.1. 2.2. 2.3.

Circuit Breaker compartment (HV Compartment) Busbar compartment Cable & CT compartment

2.4. 2.5.

Low Voltage compartment (LV Compartment) Withdrawable Truck

Fig 2:

Side view of switchgear cubicle

3.3 3.6

3.2.3

3.7

3.2.1 3.8 3.2.4 3.2.5 3.2.6 3.2.2

3.5

3.4

3.2

3.1

3.2.7

3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7. 3.8.

Vacuum Interrupter Insulating Switching Rod LV Plug on the truck Contact Arm Truck Handle Cast Resin Insulator Guide Roller on truck PP Tube

3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7

Mechanical ON Push Button Mechanical OFF Push Button Spring Charging Opening Spring Charge Indication Mechanical ON & OFF indication Mechanical Operations Counter Earthing for the Truck

Fig 3:

Withdrawable Truck with Circuit Breaker

Fig 3.2: Mechanical ON & OFF Push Buttons

1.2 1.2.1
3.1.1

Design Features Switchgear layout (Refer Fig. 2)

Metal partitions subdivide each panel into 3.1.2

Circuit breaker compartment (2.1) Cable & CT compartment (2.3) Busbar compartment (2.2) Low voltage compartment (2.4) Withdrawable Truck (2.5)

The outside covers are bolted to the frame and the doors are hinged. 1.2.2 Circuit breaker Compartment

3.1.3

The circuit breaker compartment contains a withdrawable truck with Vacuum circuit breaker or Bus PT Truck. The breaker terminals are fitted with contact arms (3.4, Fig 3) The withdrawable truck can be transferred between the service & test positions behind closed doors using a hand crank.

3.1.1 Pole Flange (Upper) 3.1.2 Pole Flange (Lower) 3.1.3 PTs on the truck

Fig. 3.1: Rear View of the truck

1.2.2.1

Service Position (Connected Position)

The position of a Withdrawable Truck in which it is fully connected for its intended function. In this position of the truck, the contact arms of the circuit breaker are connected to the busbars as well as to the out going cables via the fixed mounted isolating contacts in the cubicle.
4.9 4.2 4.5 4.10

The truck is locked against withdrawing. The low voltage circuit is connected through the low voltage plug & socket connection (3.3, Fig. 3 & 4.5, Fig. 4). 1.2.2.2 Test Position

4.3

4.12 4.4 4.6 4.13 4.8

4.1

4.7

The position of withdrawable truck in which an isolating distance or segregation is established in the main circuit & in which control circuits are connected. In the test position, the truck with the breaker is withdrawn so far between busbars & outgoing cables that there is isolating distance according to VDE 0670, part 2 / 2.65. The truck is locked against moving. The low voltage circuit is connected through low voltage plug connection (4.5, Fig. 4). The circuit breaker can be switched for testing & all functions.
6.2 6.3 6.4

4.1. Door Locking hinge pin 4.2. Door close interlock 4.3. Viewing window for truck position 4.4. Viewing window for Spring charge indicator and Mechanical Counter 4.5. LV Socket 4.6. Drive Mechanism housing 4.7. Ramp

4.8. Interlocking Plate (Drive Box) 4.9. Holder for LV Plug 4.10. Clip for locking LV Plug to Breaker 4.12. Trip mechanism for operating the breaker in service position 4.13. Rod Lever

Fig 4:

Withdrawable Truck in Test Position & door open

5.4

5.3

5.1

5.2

6.1

6.6

6.5

5.1. Bushings of upper mating contact 5.2. Cast resin insulator

5.3. Feeder connections 5.4. Busbars

6.1. 6.2. 6.3. 6.4. 6.5. 6.6.

Main Earth Busbar Bushings for lower mating contact Current transformer Cable connecting pieces Wiring Cover Gland Plate for Power Cables

Fig 5:

Busbar Compartment

Fig 6: Looking into Cable compartment

Bushings with the mating contacts for the lower contact arms of the withdrawable part (6.2) Cable termination pieces (6.4) A section of the main earth bar (6.1) Current transformers (6.3)

The cable termination pieces are accessible from the rear. 1.2.5 Compartment for Low Voltage Equipment (Refer Fig 7)

7.1

This compartment contains all the low voltage devices (protective relays, MCBs, terminals, etc.,) Indicators and relays are accommodated in door cutouts. 1.2.6 Accessory Item (Refer Fig.8)

7.1

LV Compartment Door

Fig 7: Looking into LV compartment

1.2.2.3 Disconnected Position (Isolated Position) The position of withdrawable truck in which an isolating distance or segregation is established in the circuits of the withdrawable truck, the truck remaining mechanically attached to the enclosure. In this position the truck is withdrawn as in test position but the LV plug is disconnected. In the test & disconnected position the contact arms & their mating contacts are separated by metallic shutters. 1.2.2.4 Removed Position The position of withdrawable truck when it is outside the panel and electrically & mechanically separated from it. Ramps are provided at the front bottom of the panel to withdraw the truck out of the panel smoothly. Drive Mechanism of the truck is attached to the cubicle frame using Rod Lever. The Earthing strip at the bottom of the breaker compartment, along with the spring loaded pin provided at the bottom of the circuit breaker truck ensures the earthing of the truck in all the positions. 1.2.3 Busbar Compartment (Refer Fig.5) The busbar compartment contains: - The busbars (5.4) - Bushings with the mating contacts for the upper contact arms (5.1) - Feeder Connections (5.3) The Main Busbars are mounted on cast resin insulators (5.2). The ends of the smaller Main Busbars are connected with the longer Busbar Links extending from one panel to the next. 1.2.4 Cable and CT compartment (Refer Fig.6) The Cable compartment contains:

Following accessories are supplied with the switchgear. Changing handle for charging the closing spring of the vacuum circuit breaker (8.1) Cranking handle for truck movement between service and test positioning (8.2). Double bit key for locking the truck transfer operating mechanism (8.3) Rod Trap key for LV compartment. (8.4) Earthing Switch Handle (Optional). (8.5) Range of Panels

1.2.7

General: For a metal clad enclosed switchgear there are various panel modules available. All the panels are constructed using identical parts as far as possible. 1.2.7.1 Feeder Panels (Fig 9a)

The feeder panels are suitable for input or output of electrical energy.

8.2

8.5

8.4

8.3

8.1

8.1. 8.2. 8.3.

Charging Handle Cranking Handle Double Bit Key

8.4. 8.5.

Rod Trap Key Earthing Switch Handle

Fig 8: Accessories

Outgoing feeder panels with C.B. on the truck are most frequently used. Alternatively, these panels can also be equipped with an isolating truck. The panel is available with current transformer either with earthing switch or without earthing switch. The earthing switch is always equipped with manual drive. 1.2.7.2 Bus Sectionalizer Panels (Fig 9b) -

panels are interchangeable.Trucks are earthed with panel in both test & service positions. Outgoing cables can be earthed by means of manually operated earthing switch. (Optional) C.T.s are mounted on stationery part in the Cable Chamber. Line P.T.s are available with a drawout arrangement and with fuses. Future extension of existing switchboard is possible Interlocks

In bus sectionalizing panel one panel is used for the truck with the C.B. (alternatively, an isolating truck) & one panel for connection of busbars to the top. Both the panels are usually delivered as one assembled transport unit. 1.2.7.3 Metering Panel (Fig 9c)

1.2.9

The positions of the withdrawable part are described on page 4 State Withdrawable truck in service position, switching device ON Withdrawable truck in service position, switching device OFF Withdrawable truck located between the service and test positions Withdrawable truck in test position, switching device ON Withdrawable truck in disconnected position LV plug pulled off, switching device OFF, door open 1.3 Technical Data 12kV 3150A 4000A 28kV/ 38kV** 24kV 3150A 3150A 50kV 3150A 4000A 20kV 60kV The following operations are not possible Removal of the withdrawable truck Opening of the door Pulling of the LV plug Removal of the withdrawable truck Opening of the door Pulling of the LV Plug Closing of the switching device Opening of the door Pulling of the LV plug Transfer of the withdrawable truck to service position Closing of the door transfer of the withdrawable truck to service position.

Basically metering panels are of the same construction as the standard outgoing panels. The metering truck with voltage transformers & HRC fuses in series is equipped with 3 top contact arms. 1.2.7.4 Panel with I/C & O/G Connections (Fig 9d)

These panels are comprising of Incoming & Outgoing Cables in the same panel. 1.2.8 General Construction

Safety devices & interlocks are provided to avoid any malfunctioning. These devices protect the operating personnel & ensure reliable operations. The interlocks are explained in section 1.2.9. The panel is compartmentalized in different compartments with metallic partitions. Vacuum Circuit Breaker for the panel is mounted on the truck. All the identical trucks in different
I/C O/G

VCB

VCB

VCB

Rated Voltage, Frequency (50Hz) 7.2kV

CT

CT

CT

Rated Current of the Feeders Rated Current of the Busbar Rated Power Frequency withstand Voltage (rms) 60 sec. Rated Lighting Impulse Withstand Voltage (peak) 1.2/50 Micro sec.

Fig 9a

Fig 9b

75kV/ 125kV 95kV** 44kA 44kA 110kA 26.3kA 26.3kA 66kA

Fuses P .T.

VCB O/G

Rated short circuit breaking current Rated short time withstand current (3 sec) Rated short circuit making current (peak) ** On request upto 31.5 kA

44kA 44kA 110kA

CT I/C

Fig 9c

Fig 9d

750 d2 800 min on either side 800 min 10.1 h 10.2 d3

10.3

1100* / 2000**

FRONT

20

20.0

d1 d

38 * Single Row of Panels ** Double Row of Panel

10.1. End Covers are fitted to the left & right hand end panels of the switchboard 10.2. Pressure relief channel for the termination compartment, 110 mm deep. 10.3 Pressure Relief Flaps

Minimum from highest pressure relief flap (Part 10.1) after it has opened

All dimensions are in mm and are for the standard panel

Fig: 10 Overall Panel Dimensions

Maximum values indicated Overall Panel weight: Approx. weight with vacuum circuit breaker 15 kV (800W) 650 kg approx. 12 kV (600W) 450 kg approx. 24 kV (1000W) 800 kg approx. Overall Panel Dimensions :
w mm h mm h1 mm d mm d1 mm d2 mm 380 380 d3 mm 750 1000

Upto 15 kV 600/800 1600 2000 1808 1750 24 kV 1000 1450 2300 2270 2215

1.4

Rating Plate

A Rating Plate containing the particular data is fixed inside each panel. The withdrawable vacuum breaker has its own rating plate and the rated normal current stated on it does not apply to the switchgear. Degree of protection Basic model IP 4X acc. To IEC 298 or IP 40 acc. To IEC 529 The panels are gasketted to make them dust & vermin proof. IP 41, IP 5X and IP 51 can also be provided.

Fig 11: Rating Plate of a Panel

2.

Installation
Rear cover 65.0 670.0 65.0 20.0 25.0 65.0

The installation sequence should be planned and prepared with care. Ensure that the erectors and the operating personnel read the operation, installation & maintenance instructions. 2.1 Foundation

- False Floor Place a girder in the cutout common to several or all of the switchboards so that it is parallel to the operating front. The girder is meant to support the panel bottom rails below the 30mm x 30mm cutouts. Two girders (depthwise) must be fixed along the wheel tracks of the truck as shown in the foundation plans (Fig. 12a, 12b & 12c). - Concrete Floor This should be provided with foundation rails on which the panels are to rest. For floor cutouts refer to Fig 12a,12b &12c. The foundation should be prepared before the panels arrive. Level differences between the mounting surfaces of the individual panels should be determined and compensated for by using a sheet as shown in Fig 16.

CUTOUT FOR POWER CABLES

310.0

CABLE CHAMBER
295.0 295.0

Wheel Track

6x holes for M12 bolts (for fixing to foundation) 300.0

1750.0

45.0 10.0

CUTOUT FOR CONTROL CABLES

45.0 10.0 935.0

300.0

C.B. CHAMBER

580.0

120.0 38.0 32.5 H.T./L.T. Front door 175.0 450.0 800.0 175.0

Rear cover 65.0 470.0 65.0 20.0 65.0

FRONT

CUTOUT FOR POWER CABLES

Note : All dimensions are in mm

310.0

Fig.12b Foundation Plan for 12 kV (800W) Panel

75 75

6x holes for M12 bolts (for fixing to foundation) 300.0

1750.0

Rear box

Wheel Track
800

65

198.0

198.0

32.5

CABLE CHAMBER

450

450

Standard panel

32.5

45.0 10.0

45.0

935.0

400

CUTOUT FOR CONTROL CABLES

1000

10.0

295.0

295.0
2215

300.0

1215

300

C.B. CHAMBER

580.0

Wheel Track 10 45

30

45

10

38.0 175.0 250.0 175.0

32.5 H.T./L.T. Front door

40

300

777.5 37.5

120.0

1140

375 1000

375

Front

600.0

FRONT

Note : All dimensions are in mm

Note : All dimensions are in mm

Fig.12a: Foundation Plan for 12 kV (600W) Panel

Fig 12c : Foundation Plan for 24 kV (1000 W) Panel

10

Base Frame (optional)

A solid base frame can be provided. The base frame gives a strong support to the panels at their joining line & also under it along the movement of the truck wheels. It is made up of rolled steel sections. A reference sketch of the base frame is as shown in Fig 13a, 13b & 13c
40.0

ISA 40x40x5
75.0

40.0

ISA 40x40x5

40.0

75.0

1 4.0

75.0

1780.0

ISMC 75x40x5

75.0 75.0
0 60 75.0 75.0 125

75.0

875

940

47.5 0.0
0.0 67.5 142.5 175.0 425.0 457.5 532.5 600.0

Fig 13c: Base Frame Dimensions (24 kV

1000W)

Fig 13a: Base Frame Dimensions (12 kV 600W)

2.2

Electrical Service Room Dimensions 750 mm min 800 mm min 1100*/ 1500** mm min 2000*/ 2500** mm min

Min. Clearance to the ceiling above the top (Refer Fig. 10)
75.0

1780.0 1705.0
75.0

Min.Clearance on the sides of the Panels Min.Width of control aisle in front of the Panel for Single row Min.Width of control aisle in front of the Panel for two rows facing each other * For upto 15 kV Panel

40.0

ISA 40x40x5

40.0

75.0

1 4.0

M12 NUT WELDED

1780.0

1027.5 952.5
75.0

T O P

** For 24kV Panel

ISMC 75x40x5

75.0 75.0
75.0 75.0

A power source must be available. Work likely to produce dust or dirt may not be carried out while the panels are being installed. The floor should be levelled to enable transport units to be moved on roller and/or similar devices. 2.3 Transport Units

47.5 0.0
0.0 67.5 142.5 175.0 625.0 657.5 732.5 800.0

A transport unit consists of maximum upto 3 assembled switch cubicle with withdrawable truck. The cubicle should not be lifted from the top with circuit breaker inside. 11

Fig 13b: Base Frame Dimensions (12 kV 800 W)

1000

0 4. 1 0 4. 1 0 4. 1

1780.0 1705.0

ISMC 75x40

M12 NUT WELDED

1027.5 952.5

T O P
1A

75

Tolerance as per DIN 43661:

Level 1mm within 1mtr.measured length.

Fig 14 : Dimension data sheet for the foundation.

Straightness 1mm. Per 1mtr. Length, 2mm. For total length

Higher tolerances are to be compensated by laying sheets (below panel)

In case foundation rails or fabricated channel frames are embedded in cement concrete, care should be taken to leave open pockets below the location of fixing holes of the panel for tightening the foundation bolts.
According to DIN 43 661, DIN 7184 and DIN 18 202, sheet No. 3, the following steps should be adhered to: For equalization of all irregularities of the rough floor, the screed to be applied to the floor should be at least 10 mm higher than the height of the foundation rails. Before applying the screed to the floor, the foundation rails should be aligned, leveled and anchored to the rough floor. The top edge of the foundation rails should be flush with the upper surface of the finished floor, taking ceramic tiles, stoneware tiles or any other floor coverings into account. The surface of the screed or of the floor covering should not be higher than the level of the top edge of the foundation rails. The plane defined by the carrying surfaces of both (or several) parallel foundation rails has to be levelled in two directions 90 degrees apart by means of a levelling instrument consisting of two water filled glass tubes connected by a rubber hose. The level tolerance, measured along a distance of one meter, shall not exceed one millimeter.
measuring surface

12
t

The straightness tolerances, as required by DIN 43 661 shall include the level tolerance and shall nowhere in the complete plant to be installed exceed 2 millimeters.

The straightness tolerance shall not exceed one millimeter per meter of length of the rails in both the flat and the edgewise position of the rails. U-channel
reference surface t

The top horizontal surfaces of the foundation rails shall be smooth (grind welded joints smooth). Foundation rails embedded in concrete shall be fully grouted for their full length and be able to support a load at any point.

2.4

Packing

As required : (a) For shipment to inland destinations each transport unit is fixed on a sturdy wooden pallet and covered by plastic sheet for surface protection and packed in normal wooden case. (b)for shipment overseas each transport unit may be additionally packed in a seaworthy case. It is enclosed in plastic sheet, which is sealed air-tight and includes bags containing dessicant. Accessory items are packed separately, or kept in the panel transport unit (see dispatch advice). 2.5 Unloading

bolting the transport units together and also temporarily to check them for any signs of transport damage. 2.6 Examining the switchgear against damage

As soon as the switchgear has been unloaded and unpacked examine it to see that it is complete with reference to the relevant documents. Record any damage and its cause without delay, in the presence of the forwarding insurance agent, if the damage was caused en route. This report is essential for any damage claims. 2.6.1 Storage

While unloading care must be taken to see that the panels are not rolled on its sides & they must be kept in upright condition. 2.5.1 Handling equipment required

Store the units in upright position only The units must be stored in adequetly covered location such that they are protected from Sun, Rain, Flood Waters & other such Natural elements Transferring the transport units to their points of installation

A mobile crane or a chain pulley block for unloading the transport unit. Lifting tackle A fork-lift truck with a fork length of about 3.0 mtr, for handling the switchgear inside the building. Hydraulic jacks or winches & roller pads.

2.7 -

Transfer the transport units including their wooden pallets to the point of their installation using fork lift rollers. Withdraw the trucks out of the panels using two wooden wedges below the ramps & close the door. Put the panels down on the cleaned site or at least immediately in front of it in the correct order, leaving a clearance of about 25 mm between them. To remove the transport units from their wooden pallets Place four winches under the floor rails of outer panels and uniformly raise the panel. Remove the wooden pallet. Lower the transport unit as far as it will go & place it on two wooden beams if it is located above its site or place on four roller pads if it is in front of the sites In the later case roll the units to their mounting position. If this means changing the direction of travel raise the unit & reposition the roller pads accordingly. Now place the planks & channels in the foundation cutouts that have to be crossed. To raise the panels on their mounting position & removing the roller pads Lower the transport unit as far as possible & place them on two wooden beams. Now, raise the units, first on one side & then on the other side, using roller-type crowbars. Pull out the planks & lower the panels onto the cleaned foundation. Position the crowbars only at the 13

The handling/transport gear must meet the site requirements with regard to its construction and load bearing capacity. Refer to the weights (for raising and transporting) stated on the transport or in the covering documents. 2.5.2 Procedure

Do not unpack while unloading the transport units. Take care not to damage the plastic sheet because it protects the switchgear against any environmental effects. Use of mobile crane or a forklift truck.

Attach the ropes to the wooden pallet. Carefully raise the transport unit and check to see that it is correctly balanced, if necessary lower the transport unit and correct any imbalance by repositioning the ropes on the lifting tackle. Unloading the switchgear with a fork-lift truck. Transport units of not more than two panels can be unloaded with a fork-lift truck if the access routes permit this. Make sure the transport units are correctly balanced. Move the transport units as close as possible to the switch house and put them down. Dismantle and remove the crates. Move each transport unit into the building. Take off the plastic sheet immediately prior to

corners of the panels below the vertical frame members. 2.7.1 To remove the Truck from the Panel -

(refer Fig. 14) and be absolutely vertical. If necessary place shims. under the frame uprights and under the bottom rails near the 30 mm x 30 mm cutouts for the foundation bolts. Remove the bolts fitted at the left hand end of each panel, as viewed from the front. Move up the second panel. Align this second panel on the foundation, raise it to the correct level and make sure the panels stand vertically. Using the nuts & bolts join the adjoining panels. Check to see whether the panels are truly vertical. If necessary slacken the screws and seal the gaps with rubber. Move up the other panels in sequence, align them and bolt them together.

Open the door of the panel (Refer clause 4.6.1). Bring the truck to the test position by cranking (Refer clause 4.1.3.1) Disconnect the LV plug (4.5, Fig. 4) & place it its holder (4.9, Fig. 4) on the door. Mark the truck & their panel numbers for identification. Lift & turn the Levers (4.13, Fig. 4) on the front interlocking plate (4.8, Fig. 4) by 90 anticlockwise. (upto 15kV) OR Unscrew the front interlocking plate (for 24kV). Slowly move the truck away from the panel. The two ramps drop automatically enabling free & easy withdrawal of the truck. Put back the ramps to normal position & close the door. Assembling the switchboard

Use shims as for the first panel. -

4.5

2.8

Carry out the work described under clauses 2.7.1 and 2.8.1 to 2.8.4. Keep the bolts loose, not fully tightened, till all the bolts for sections are in position. Then tighten the joining bolts, followed by Busbar bolts, followed by Foundation bolts. 2.8.1 Bolting the panels together

16.2

It is assumed that the first transport unit is in its final position and that the other units are positioned on the foundation rails in the correct order but with an adequate clearance between them. It is always preferable to install the central panel first. This practice should invariably be adopted for a board with 20 or more panels. After installing the central panel, the other panels can be installed on its left & right in proper sequence. Procedure Centrally align the first transport unit on its foundation. The panels must be at the correct level

16.3

16.1

16.4

16.1. 16.2. 16.3. 16.4. 4.5

Breaker Compartment door Upper metallic shutter Lower metallic shutter Heater LV socket

Fig 15 : Procedure for bolting the panels together

Fig16:

View into Circuit Breaker cubicle after removing the drawout truck

14

2.8.3

Bolting the Busbars together

Start working on the busbars only after panel units have been adjusted correctly and interconnected. Access to the busbars are from the rear side or from the top side by opening the Explosion Vents. All necessary hardware is supplied on the the main busbars.(5.4, Fig. 5)
17.1 5.1

1. Brush the contact faces criss-cross wise until bright, & wipe using a clean cloth. (applicable only for bare Aluminium Busbars) 2. Square neck, round head, coach bolts are used for busbar joints. These bolts do not rotate in their slots & hence can be tightened from one side. Recommended torque is 70 Nm. 3. Allow the joint to settle down in 24 hrs & check the value of the torque with the torque wrench. 4. The busbars of adjacent units must be joined together using the busbars & hardware supplied. While inserting coach bolts ensure that the round head of coach bolt is facing sheet metal structural parts. That means the nuts will always be towards the live parts such as busbars/feeder connections. The busbars (5.4, fig. 5) of the panel forming a transport unit are already bolted. 5. Refix the upper rear cover after the busbars are bolted. 2.8.4 Bolting the Main Earth Bar sections together

6.2 17.2

16.4

17.3

5.1. 17.1. 6.2. 17.2. 17.3. 16.4.

Upper Contact Bushing Fixed Contacts (Upper) Lower Contact Bushing Fixed Contacts (Lower) Truck earthing Srip Space Heater

Fig 17: View into circuit breaker compartment with shutter held open

The main earth bars of the transport units must be linked together. One of the two parts to be bolted together is already fitted with a link. This must be undone, passed through the partition and bolted to the two adjacent earth bar sections. The cover on the side wall should be properly adjusted after joining the earth bars. 2.9 Making HV Cable connections

2.8.2

Fixing the Switchboards to the Foundation

The panels bottom plate has four 30 mm x 30 mm cutouts (refer Fig 15) for fixing purposes. Welding Weld the bottom plate to the foundation at the cutouts. Insert shims (refer clause 2.8.1) where necessary to avoid having to weld across air gaps. Coat the weld with enamel paint. Bolting Down Embed anchor-bolts in the foundation (through the 30 mm x 30 mm cutout) or drill the appropriate holes in the foundation rails (false floor). Insert shims between the foundation and the bottom rails near the cutouts. Tighten the screw without distorting the panels.

The cable connection pieces are provided with Hex. Headed bolts M16 with washers., spring washers &

18.1

18.2 6.1 6.6 18.1. Extension Links 6.6. Bottom Covers

6.1. Earth Busbar 18.2. Eathing Strip (from CB chamber)

Fig 18: Earth Busbar Assembly

15

hex. Nuts for mounting the cable lugs of the conductors. Three part bottom cable cover is supplied fitted with the switchboard. Of these, the outer most cover has to be removed & cutouts to be made of the size as per the instructions given by cable kit manufacturer. 2.10 Earthing the Switchboard

the core spacing on three core cables and the antimagnetic clips on single-core cables. Checking the Bolted Joints

2.11.2 -

Connect the earth terminals of at least one or two panels to the station earth. This could be done to suit the local guidelines. Termination facility for earth connection is provided on the earth busbar mounted in the cable chamber. 2.11 2.11.1 Other work to be carried out Checking the HV Connections

Check the power and auxiliary circuit connections of the switching devices at random. Examine all the terminal block connections, making sure that the blocks are correctly labeled and replace any missing labels by referring to the circuit diagram. The torque values of all the busbar joints must be checked Cleaning the Switchboard

2.11.3 -

Clean all the post insulators, Bushings and Busbars in all the compartments using soft dry cloth.

On all HV cables, check the bolts for tightness the sealing and earthing

Do not use any abrasive chemicals or detergents to clean installed parts. Use only distilled water if necessary. Ensure that all parts are dried up before applying any voltage.

16.2

16.3

19.2

19.1

19.3

16.2, 16.3. Shutters 19.1. Shutter operating rod 19.2. Roller Guide Angle 19.3. Truck guide

16.1

2.5

16.1. Breaker compartment Door 2.5. Breaker Truck

Fig 19: View inside circuit breaker compartment without withdrawable truck.

Fig 20: Insertion of trolley in the panel

16

2.11.4 -

Inserting the withdrawable parts

2.11.5

open the front door (16.1, Fig. 20) put down the ramps (4.7, Fig. 4) place the breaker truck in front of the corresponding panels. Transfer the truck inside the panel and push it as far as it will go. Fix the racking mechanism / interlocking plate to structure frame by using lift & turn levers (upto 15kV) & by using bolts (for 24kV) Fix the ramps back in the position Close the door (16.1, Fig 20) Insert all other drawout trucks in the same manner.

Protecting the panels against environmental effects

(a) Damaged sections of the paint finish may only be touched up with original paint. (b)Fit the parts supplied to protect against the ingress of reptiles. Check in case they are removed during installation. (c) Close all the doors & covers properly. (d) Any opening that is left open after installation should be closed & sealed to make it truly verminproof. 2.12 Interpanel Wiring

The wire have been left loose in the LV compartment of certain panels. These wires must be connected from panel to panel as per approved wiring diagrams.

17

3.

Putting the switchgear into service

For details of operation refer section 4 3.1 3.1.1 Test operations With door open

7.1

The motor operating mechanism start as soon as the LV plug is inserted and control supply is available (If the VCB is not already charged) Open & close the breaker several times.
4.3 4.12 21.1 4.11 4.12 7.1 4.3 21.6 21.8

21.4 4.11 21.2 21.3 21.5

21.5 21.3 21.4

21.6

16.1

21.7

21.2

4.3. Viewing window for truck position 4.11. Opening for charging handle for charging the breaker closing spring 4.12. Trip mechanism for operating the circuit breaker in the connected position. 7.1. LV compartment door 16.1. Breaker compartment door 21.2. ON & OFF Push Button (On HT Door) 21.3. Window for the indicators of the withdrawable part - Number of operations (Operation Counter) - Closing Spring of the circuit breaker - Charged - Lable with spring symbol - Discharged - Blank Lable - Indicator for circuit breaker switching status - Circuit Breaker Closed - I Tripped - O 21.4. Opening for Double Bit Key for locking the transfer operating mechanism 21.5. Opening for racking handle for racking the breaker truck 21.6. Opening for defeating interlock 21.7. Door Handle

4.3. Viewing window for truck position 4.11. Opening for charging handle for charging the breaker closing spring 4.12. Trip mechanism for operating the circuit breaker in the connected position. 7.1. LV compartment door 16.1. Breaker compartment door 21.1. Ball grip 21.2. ON & OFF Push Button (On HT Door) 21.3. Window for the indicators of the withdrawable part - Number of operations (Operation Counter) - Closing Spring of the circuit breaker - Charged - Lable with spring symbol - Discharged - Blank Lable - Indicator for circuit breaker switching status - Circuit Breaker Closed - I Tripped - O 21.4. Opening for Double Bit Key for locking the transfer operating mechanism 21.5. Opening for racking handle for racking the breaker truck 21.6. Opening for defeating interlock 21.8. Bolts for door locking

Fig. 21a: Opening Elements (for 24kV Panel)

Pull off the LV plug. Charge the breaker closing spring by hand (refer clause 4.2) Operate the circuit breaker Refit the LV cable Plug. With door closed

3.1.2

Each switchpanel should be tested as follows: Transfer the withdrawable truck to the disconnected position (see 4.1). Switch ON the auxiliary and control supply. Transfer the withdrawable part to the connected position.

Fig. 21: Opening Elements (upto 15kV Panel)

18

 Open and close the breaker as long as no high voltage is applied. Without using force check all mechanical and electromechanical interlocks for satisfactory functioning. Check to see whether the switching states are indicated correctly in the control room. Check whether the position of the withdrawable truck is indicated correctly (if the appropriate position switches are fitted refer to the circuit diagrams). 3.2 Checking the Accessory Items

The Hand Crank for transferring the truck is also suitable for all M8 bolts. 3.3 Revising the Circuit diagrams

If circuits have to be modified during installation the existing circuit diagrams are marked up. When work has been completed make sure that the original diagrams are revised. 3.4 Space Heaters

The accessory items required must be easily available in the Switchgear Room or an adjacent room. They include one Hand Crank for transferring the truck and for charging the breaker closing spring, a Double Bit Key for locking the hand-operating mechanism, the basic circuit diagram, Operating Instructions, Castell Lock Key (optional) and Earthing Switch Handle (Optional)

For panels installed in humid atmosphere, space heaters are fitted in the circuit breaker & cable compartments. The thermostat controlled heaters should be switched ON before taking the panels into service. The thermostat shall be set to cut off supply to heaters at about 5 higher than the maximum ambient temperature. Heaters must always be kept ON in all the conditions (even during maintenance)

19

s
BRIEF OPERATING INSTRUCTIONS FOR 8BK80 SWITCHGEAR

FOR DETAILED DESCRIPTION OF ABOVE OPERATIONS &SPRING CHARGING OF CB, OPENING OF DOOR, ETC. REFER CLAUSE 4 OF THIS MANUAL FOR OPERATIONS
Fig 22 : Label on door of breaker compartment

20

4.

Operations

In detail: Make sure that the circuit breaker is open, the LV plug(3.3, fig. 3) and socket connector has been put together and lock it. The breaker compartment door is closed. The castell key can be re,moved in this position also for any interlocked operations which are to be performed with circuit breaker in open position. Fit the hand crank (8.2, fig. 8)to the hexagon shank in opening (21.5, fig. 21) turn it clockwise as far as it will go and pull it off. Insert the castell key if it was removed for interlocked operations. Turn the key clockwise through 90 degrees from position Manual Racking to Connected position(locked) and pull it off. Transferring the withdrawable part from the connected position to the test/ disconnected position manually Normal Operations
3rd Step Turn double-bit key

Each row of cubicles is provided with brief operating instructions. Refer to fig. 22. 4.1 4.1.1 Withdrawable truck Positions of the withdrawable truck

Refer clause 1.2.2 for Circuit breaker Chamber Service position(connected position) The circuit breaker is connected with the busbars and the outgoing circuit Auxiliary circuit is connected through LV plug and socket. Test position The circuit breaker is disconnected from the busbars and the outgoing circuit. Segregation as specified in IEC 60298 is maintained. The LV circuits are connected through LV plug and socket. Disconnected position The circuit breaker is disconnected from the busbars and the outgoing circuit. LV circuits are disconnected by pulling out the LV socket from the plug. When the LV plug and socket are connected the following functions can be carried out. The breaker can be tested / operated, also from the control room. The breaker compartment door can be opened. Functions such as ON / OFF indication and electrical interlocks can be tested. When the LV plug and socket are disconnected. The breaker compartment door cannot be closed. Hence the truck cannot be inserted. 4.1.2 Transferring the withdrawable part from the Test/Disconnected Position manually Normal operation
3rd Step Turn double-bit key

4.1.3

4.1.3.1 In brief

1st Step 2nd Step Turn double-bit key Insert and turn hand crank from by to as far it will go and pull it of

from

by

to

90
Fig. 23b

90

In detail: Make sure that the circuit breaker is open. insert the double bit key in lock (21.4, fig. 21) and turn it anti-clockwise through 90 degrees from connected position (locked) to Manual Racking. The hexagon shank opening (21.5, fig. 21).is now accessible. The hand racking mechanism is unlatched. Fit the hand crank (8.2, fig 8) to the hexagonal shank in opening (21.5, fig. 21) turn it anticlockwise as far as it will go and pull it off. Turn the double-bit key anti-clockwise through 90 degrees from the position Manual Racking to Disconnected position (locked) and pull it off.

4.1.2.1 In brief:

1st Step 2nd Step Turn double-bit key Insert and turn hand crank from by to as far it will go and pull it of

from by to

90
Fig. 23a

90

Opening (21.5, fig. 21) is now closed. The hand racking mechanism is now locked.

21

4.1.3.2

Castell Key Operations (Optional)

2nd Step as far it will go and pull it of 3rd Step Trun castell key from by to

4.2

Circuit-breaker operating mechanism

1st Step Turn castell key from by to

90
Fig. 23c

90

The operating mechanism is of the stored energy type. For electrically operated breakers, motor automatically charges the closing spring after each switching operation. If the motor supply should fail the closing spring can also be charged by hand. The tripping spring is charged each time the breaker is closed. 4.3 4.3.1 Circuit-breaker Operation Charging the closing spring by hand

In detail: Make sure that the circuit breaker is open. Turn the castell key (which is trapped in the mechanism) anti-clockwise through 90 from Connected position (locked) to Manual Racking. In this position the castell key can be removed for any interlocked operations which are to be performed with circuit breaker in open condition. The hexagon shank opening(21.7,fig.21)is now accessible. The hand racking mechanism is unlatched. Fit the hand crank (8.2, fig.8) to the hexagonal shank in opening (21.5, fig.21) turn it anticlockwise as far as it will go and pull it off. Insert the castell key if it was removed for interlocked operations. Turn the double-bit key anti-clockwise through 90 degrees from the position Manual Racking to Disconnected Position(locked) and pull it off. The castell key can also be removed in this position to facilitate the opening of the HT compartment door and / or other interlocked operations. Disconnecting the LV Plug

Procedures If the breaker compartment door is closed (connected position) turn plate (21.6, fig. 21) so that it clears opening (21.7, fig. 21) insert the hand crank and fit it into the breaker is open (disconnected position) fit the hand crank directly to the breaker operating mechanism in opening (21.7, fig. 21).

Operating Mechanism Turn the crank until the symbol spring charge appears in viewing window (21.3, fig.21) on indicator. The operator is not at risk if the motor supply recovers,because the hand crank freewheels and detaches in the anti-clockwise direction. Pull the crank off. Breaker ON and OFF Mechanically (locally by means of push button)

4.3.1.1 4.3.1.2

4.1.4 -

Transfer the withdrawable part to the disconnected position(in accordance with clause 4.1.3) and lock it. Open the breaker compartment door (refer clause 4.6.1). Unlock the LV plug (3.3, fig. 3) and LV socket (4.5, fig. 4 & 16) by turning down the clip. Pull off the plug and attach it to the holder (4.9, fig. 4) which is fixed to the door. Connecting the LV Plug

In the connected position : Trip mechanism (4.12, Fig. 4 & 21) as far as it will go, hold it there, press buttons ON and OFF (21.2, Fig 21) and then release the grip. In the disconnected position with the door closed : Press buttons ONand OFF (21.2, Fig 21) on the breaker compartment door. In the disconnected position with the door open : Press buttons ON(4.14, Fig 4) and OFF (4.15, Fig 4) on the breaker truck 4.3.1.3 Electrically (from the control room or locally)

4.1.5 -

Put the LV plug (3.3, fig.3) and LV socket (4.5, fig. 4 & 16) together and lock it with the clip. Close the breaker compartment door (refer clause 4.6.2).

by means of push button/switches in the control room or on the LV compartment door. If the control supply fails the breaker can always be tripped mechanically (see above)

22

4.3.2

Switching State Indication

In the middle part of viewing window (21.3, Fig 21) O means OFF, I means ON.

Danger
Precautions for Safe Working High Voltage ! Touching live parts will result in severe personnel injury and / or death. This equipment shall be operated only by qualified personnel who have become thoroughly familiar with the operating instructions manual and in particular all the safety instructions. 4.5 4.5.1 4.5.1.1 Earthing Earthing of Busbars and Cables
(Side view)
24.1

Direct Earthing of Busbars with conductors

24.4

24.2

Switch off all breakers feeding to the busbars. Open upper rear bolted cover & inside covers (of busbar chamber). Touch all phases with an earthing conductor mounted on the long insulating pole. Short all the phases with a conductor and bolt it to earth. Place necessary warning plates at all noticeable locations. Earthing of Cables with conductors

4.5.1.2 -

Switch off the breaker in the panel where cable earthing is desired. Ensure that the cables are not getting the supply from the other end. Remove the lower rear cover of the cable chamber. Follow the procedure described for busbar earthing.
(Rear view)

4.5.1.3 -

Removing Earthing Connections

6.1 24.3

Disconnect and remove the shorting and earthing conductors. Close the rear cover and bolt it firmly. Remove the warning plates.
24.1. 24.2. 24.3. 24.4. 6.1.

Fixed Contacts (E switch) Moving Contact (E switch) Earthing Switch Shaft Operating Link Earthing Busbar

Fig 24: Earth switch Arrangement on cable side

23

4.5.2

Earthing of Busbars or cables with a Drawout Truck

4.5.3

Earthing the Busbars or Cables with Earthing Switch Earthing the Busbars with Earthing Switches

Separate drawout Trucks can be supplied optionally for busbar and cable earthing. In case fault making capacity is required, a circuit breaker is mounted on such drawout trucks. Procedure Remove the circuit breaker or the link drawout truck from the panel where earthing is to be done (refer clause 2.8.1) Insert the desired earthing drawout truck i.e. cable or busbar earthing drawout truck in the panel (refer clause 2.11.4) Connect the LV plug and socket (refer clause 4.1.5) Close the panel door (refer clause 4.5.2) Ensure that there is no voltage available on the parts to be earthed when earthing drawout truck without making capacity is used. Transfer the drawout unit to the connected position (refer clause 4.1.3). In case the earhting drawout truck has an electro-mechanical interlock unit mounted on it, the transfer is possible only after all the interlocking conditions are satisfied. Lock it in the connected position. In case the drawout truck has a circuit breaker mounted on it switch ON (refer clause 4.2 & 4.3). Place the warning plates at all necessary locations. Disconnection of Earthing Drawout truck

4.5.3.1 -

Switch off the supply to the main busbars. Ensure that the supply to the main busbars cannot be switched ON from remote points. In case the electro-magnetic interlocks, ensure that all the interlocking conditions are satisfied. Otherwise the earthing switch cannot be closed. Close the earthing switch by inserting the earthing switch handle in position and turning it in the clockwise direction till stop. Withdraw the handle. Place the warning plates at all necessary locations.

4.5.3.2 Earthing Cables with Earthing Switch (fig.24) Move the truck to test / disconnected position. Earthing switch cannot be closed until this position is reached. Ensure that the cables cannot be energized from the other end. Follow the procedure for Busbar earthing switch.

4.5.3.3 Disconnection of Earthing Switches Insert the earthing switch handle in position. Turn it in the anti-clockwise direction till stop. Withdraw the handle. Remove warning plates from all the locations Earthing the Busbars or Cables with Truck

4.5.2.1 -

Switch OFF the breaker in case of earthing drawout truck with making capacity (refer clause 4.3). Transfer it to the disconnected position (refer clause 4.1.3) Disconnect the LV plug (refer clause 4.1.4) Open the HT compartment door (refer clause 4.6.1) Remove warning plates. Insert the original drawout truck of the circuit breaker or link drawout truck in the panel (refer clause 2.11.4) Connect the LV plug (refer clause 4.1.5) Close the door (refer clause 4.5.2) The original drawout truck is now ready for transfer to connected position.

4.5.4

4.5.4.1 Earthing the Busbars with Bus Earthing Truck Switch off the supply to the main busbars. Ensure that the supply to the main busbars cannot be switched ON from remote points. Rack ou the breaker to diconnected position. Diengage the LV plug & socket. Drawout the nreaker truck completely out of the panel. Insert the Bus earthing truck in the panel to diconnected position. Connect the LV plug to socket. Rack in the truck to service position. Place the warning plates at all necessary locations.

24

4.5.4.2 Earthing the Cables with Cable Earthing Truck Move the truck to test / disconnected position Ensure that the cables cannot be energized from the other end. Follow the procedure for Busbar earthing switch.

Unscrew the door closing bolts of HT compartment door. The bolts are captive (for 24kV Panel) Open the door. To close the door

4.6.2 -

Shut the door. Rotate the handle clockwise till it gets closed. (For upto 15kV) Tighten the captive screw in case of bolted door. Door to LV Compartment To open the door

4.5.4.3 Link Type Eathing Truck Switch off the supply to the main busbars. Ensure that the supply to the main busbars cannot be switched ON from remote points. Ensure that the cables cannot be energized from the other end. Follow the procedure for Busbar earthing switch. Breaker Compartment Door -

4.7 4.7.1 -

Rotate the turnlocks with a key in anti-clockwise direction or unscrew the captive bolts in case of bolted door. Open the door. To close the door

4.6

The door can be opened & closed when the truck is in the disconnected position and the plug & socket connector for LV cables has been connected together. The door interlock can be defeated as described under clause 5.5 below. 4.6.1 To open the door

4.7.2 -

Shut the door. Rotate the turnlock in clockwise direction or tighten the bolts in case of bolted door.

Rotate the handle anti-clockwise to open the door. (For upto 15kV)

25

5.

Maintenance

Check the switchpanel functions and put the board back into service. If work has to be carried out in the panels; isolate the board, make sure that it cannot be made live again, check its isolated state and earth and short-circuit the feeders and where applicable, the busbars. Adhere to all regulations and safety measures, maintain and service the built-in equipment, e.g. circuit-breakers, voltage transformers, current transformers, relays, meters, protective devices, etc. in accordance with their operating instructions. Before removing the front plate of the breaker operating mechanism discharge the closing and tripping springs. Follow the instructions given on the mechanism housing. Only standard tools are required. Put the switchgear back into service as described under clause 3 above. Service the switchgear at shorter intervals if the air is very moist or full of dust or is otherwise polluted. The cause of any disturbance or shortcircuit must be determined immediately and damaged parts replaced, irrespective of whether an inspection is due or not. 5.2 Cleaning

Danger
Precautions for Safe Working Maintenance, repair and subsequent conversion or extension work shall be carried out only by specially trained personnel in accordance with the operating instructions and/or special conversion instructions. Training and information sessions for personnel will be provided by the competent Siemens department. Before starting any work on the panels references must be made to local regulations for high voltage switchgear. Switch off the power supply, close/ open the breaker manually to ensure that the closing spring of the breaker is discharged. Then rack out the truck from service to test position. Control terminals in the LV compartment must not be touched if the control supply is not disconnected. Non observance will result in death and / or severe personnel injury or substantial damage to property. 5.1 Inspection Schedule

Each year Make a general visual check. Check whether the accessories are complete and in proper order. Clean and lubricate the wheels as well as moving parts of the truck and interlocking plate. Relays to be tested for their functionality. Clean the Panels (refer clause 5.2)

Caution
For Safety For safety reasons, cleaning of panels shall be taken up only when the shutdown of Main & Auxilliary Power supply is taken, the breaker is in the open state, closing spring of the breaker is discharged & the breaker truck is removed out of the panel. Cleaning Agents Perchlorethylene, 1.1.1 trichloroethane, small brushes, dusters and vacuum cleaner for sheet metal parts. Note: Trichlorethylene, perchloroethylene and tetrachloroethylene have a harmful effect on cast resin parts and must not come into contact with them. Cast resin parts should be cleaned with distilled water only. Silver plated and other contact surfaces to be cleaned with clean cloth.

Every five years Transfer the withdrawable truck to the disconnected position. Test-operate the circuit-breakers. Remove the withdrawable trucks (refer clause 2.7.1) and carry out all maintenance work, also on the switching devices. Clean the panels (refer clause 5.2) and check the connections. Lubricate all bearing surfaces, bearings and articulated joints. Reinsert the withdrawable trucks.

26

5.3 -

Lubrication

5.5

Immediately after cleaning: Lubricate the isolating contacts and their mating contacts with neutral grease. apply a film of neutral grease to the bearings and articulated joints of the operating mechanisms, to the withdrawable parts and shutters, and to the door hinges and locks.

Defeating the Door Interlock of HV Compartment

Caution : Take utmost care while defeating any interlock as the defeat operation leads to access to the areas / parts which are likely to be live. 5.5.1 Drawout Unit in Connected Position

Recommended neutral greases are: (i) (ii) (iii) SERVOGEM 2 (multipurpose) of Indian Oil Corporation make Multipurpose grease H of Hindustan Petroleum Ltd. make Any other chemically neutral grease which can withstand temperature up to 15 C.

The breaker compartment door interlock should only be cancelled if the truck cannot be transferred to the disconnected position and the situation cannot be cleared in any way. Switch off the circuit-breaker. Make sure that the busbars are not live. Insert a small screw driver in the opening (21.6, fig. 21) and screw-in the grub screw visible through the opening.till it falls out inside the panel. Open the door by turning the door handle.(refer clause 4.5.1). Drawout Unit in disconnected position

5.4 Replacement Parts Items such as post insulators, bushings mating contacts, measuring instruments, current transformers etc., can be replaced. If replacement is likely to prove difficult ask the nearest Siemens representative in good time for deputation of suitable personnel. The representative will also assist you in deciding what spare parts to keep in stock. When ordering spare parts and units give the following details: Type and Serial No. of the switchboard (see nameplate). Exact description of the unit or part, referring to the appropriate operating instructions where applicable, or to a drawing; sketch or circuit diagram. Use reference list of items in Section 8.

5.5.2 -

Press the interlocking lever on interlocking plate by hand. Insert the double-bit key in lock(21.4, fig.21) and turn it (locked) to Manual Racking. Fit the hand crank (8.2, fig. 8) to the hexagon shank in opening turn it clockwise as far as it will go and pull it off(21.5, fig.21).

Turn the double-bit key clockwise through 90 from position Manual Racking to Connected Position(locked) and pull it off. 5.5.3 Restoring the Door Interlocks

Danger
Precautions for Safe Working High Voltage ! Touching live parts will result in severe personnel injury and / or death. This equipment shall be operated only by qualified personnel who have become thoroughly familiar with the operating instructions manual and in particular all the safety instructions.

After carrying out the operations to defeat the door interlock as described in clause 5.5.1 or clause 5.5.2, the door of the HV compartment can be closed and interlocks can be restored by following the procedures in clause 5.5.1 in the reverse sequence.

27

6.

Disposal of Product

This product is environmentally compatible. The following materials have been used to make up the device : Steel, Copper, Aluminium, Cast-resin glass-fibre-reinforced thermoplastics, rubber, porcelain, greases & similar materials. PVC is used as an insulation material for control wires. In disposal, priority must be given to re-use of the materials which can be recycled. In as-supplied-condition, the product does not incorporate any hazardous substances. In operation, the product does not emit any hazardous materials or gases. During disposal of the product, care must be taken to dismantle as far as possible in more environmentally accepted way as Recyclable & Non-cyclable scraps i.e

steel, copper, aluminium, rubber, PVC, cast-resin & glass-fibre-reinforced materials to be segregated properly. The Re-cyclable materials like Steel, Copper, Aluminium can be reused. Non cyclable materials like Cast-resins, glass-fibrereinforced etc can be broken in to pieces & can be used as secured land filling materials. Rubber being biodegradable material must be recycled through authorized contractors. PVC material should not be burnt as they may release Halogenated hydrocarbons which can affect the ozone layer. Therefore, PVC must be recycled through authorized contractors. Local Siemens office can answer any questions concerning disposal.

28

7
DOs

Summary of Important InstructionsDONTs (1) (2) (3) (4) Do not leave any equipments or tools in the panel. Do not put hands or tools in operating mechanism when electrically operated. Do not operate the breaker during cleaning process. Do not use any other chemical or grease for clearing or lubricating other than mentioned in these instructions.

During Installation & Commissioning Stages :-

(1)

Brush the contact surfaces properly before bolting busbars. Also grease the joints & apply proper torque on the bolts. Check rated voltages of equipments such as motor, closing & tripping releases mounted in the operating mechanism with the available auxiliary supply to be connected to these equipments in the substation. Ensure that all the foundation bolts are tightened along with the square washer and also seal of all control and power cable cutouts to prevent vermin entry.

(2)

(3)

During service life of the panel-

(4) (5) (6)

Keep door & covers firmly closed to prevent entry of dust, moisture, insects etc. Ensure spring charging handle & manual handle are available easily. Decide maintenance schedule based upon (a) no. of short circuit operations, (b) frequency of breaker ON/OFF operations, (c) pollution level (d) humidity, etc. Isolate & earth the breaker before carrying out maintenance & ensure it is in OFF position & springs are discharged completely before cleaning. Ensure that the shutters are close and pad locked before starting the maintenance or cleaning of the panels. Depending on site conditions, inspect the interior of the panels for dust, cobwebs etc. & clean them. porcelain insulators & clean them, operating mechanism parts such as plungers of releases, moving joints etc. & clean them, and functioning of space heaters.

(7)

(8)

(9)

(10) Lubricate moving parts with lubricants provided for the breaker. (11) Check insulation resistance with a megger before putting the breaker back into service. (12) Keep a log-book for each panel. (13) Follow instructions given in the operating manual. (14) Ensure panel operations, maintenance etc. is done by trained persons. (15) Operate the defeat interlock of CB door only in case of emergency.

29

8
8.1
2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8

Additional Information
Reference List of Items
Circuit Breaker Compartment Cable & CT Compartment Busbar Compartment Low Voltage Compartment Breaker Truck Vacuum Interrupter Insulating Switching Rod LV Socket on truck Contact Arm Truck Handle Cast Resin Insulator Guide Roller on truck PP Tube Fig 2 Fig 2 Fig 2 Fig 2 Fig. 2, 20 Fig 3 Fig 3 Fig 3 Fig 3 Fig 3 Fig 3 Fig. 3 Fig. 3 Fig 3.1 Fig 3.1 Fig. 3.1 Fig. 3.2 Fig. 3.2 Fig 3.2 Fig 3.2 Fig 3.2 Fig 3.2 Fig 3.2 Fig 4, 21 Fig 4 6.2 6.3 6.4 6.5 6.6 7.1 8.1 8.2 8.3 8.4 8.5 Bushings of lower mating contact Current Transformer Cable Connection Pieces Wiring Cover Gland Plate for Poer Cables LV Compartment Door Charging Handle Cranking Handle Double Bit Key Rod Trap Key Earthing Switch Handle Fig 6, 17 Fig 6 Fig 6 Fig 6 Fig 6, 18 Fig 7, 21, 21a Fig 8 Fig 8 Fig 8 Fig 8 Fig 8 Fig 14 Fig 14 Fig 14 Fig 16, 20, 21, 21a Fig 16, 19 Fig 16, 19 Fig 16, 17 Fig 17 Fig 17 Fig 17 Fig 18 Fig 18 Fig 19 Fig 19 Fig 19 Fig 21a Fig 21, 21a Fig 21, 21a Fig 21, 21a Fig 21, 21a Fig 21, 21a Fig 21 Fig 24 Fig 24 Fig 24 Fig 24

10.1 End Covers 10.2 Pressure relief channel for cable termination compartment 10.3 Pressure Relief flaps 16.1 Breaker Compartment door 16.2 Upper metallic shutter 16.3 Lower metallic shutter 16.4 Space Heater 17.1 Fixed Contacts (Upper) 17.2 Fixed Contacts (Lower) 17.3 Earthing Strip Truck 18.1 Extension Links 18.2 Earthing strip from CB Chamber 19.1 Shutter operating rod 19.2 Roller Guide Angle 19.3 Truck guide 21.1 Ball grip 21.2 ON & OFF Push Button (On HT Door) 21.3 Window for the indicators of the breaker truck 21.4 Opening for Double Bit Key 21.5 Opening for the cranking handle for racking the breaker truck 21.6 Opening for defeating interlock 21.7 Door Handle 24.1 Fixed Contacts (E. Switch) 24.2 Moving Contact (E. Switch) 24.3 Earthing Switch Shaft 24.4 Operating Link

3.1.1 Pole Flange (Upper) 3.1.2 Pole Flange (Lower) 3.1.3 PT on the truck 3.2.1 Mechanical ON Push Button 3.2.2 Mechanical ON Push Button 3.2.3 Spring Charging Opening 3.2.4 Spring Charge Indication 3.2.5 Mechanical ON & OFF Indication 3.2.6 Mechanical Operation Counter 3.2.7 Earthing Pin for Truck 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 Door Locking hinge pin Door close interlock

Viewing window for truck position Fig 4 Viewing window for Spring charge Indicator and Mechanical Counter Fig 4 LV connection Plug Drive Mechanism housing Ramp Interlocking Plate (Drive Box) Holder for LV Socket Fig 4 Fig 4 Fig 4 Fig 4 Fig 4 Fig 4 Fig 4 Fig 4 Fig 5 Fig 5 Fig 5 Fig 6, 18

4.10 Clip for locking LV Plug to Breaker 4.12 Trip mechanism for operating the breaker in service position 4.13 Rod Lever 5.1 5.2 5.3 5.4 6.1 Cast resin insulator Feeder connections Busbars Main Earth Busbar

Bushings of upper mating contact Fig 5, 17

21.8 Door locking bolts (for 24kV Panel) Fig 21a

30

When ordering spare parts state the following: 1. Type designation, Rating, Year of manufacturing of the panel as stated on the rating plate. 2. The designation of part, as located from the photograph or sketch given in this manual. 3. The description of the part as given in the reference list on page 29. 4. In case the item is not listed below or is not shown in any of the photograph or sketch, please communicate with, brief description of the part and its location in the panel. 5. Alternatively, a sample may be submitted.

8.2 Sr. No.

Jointing Torques Type of Joint Size of Bolt Property Class 1 2 3 4 Steel to Steel Steel with Insulator Busbar Joint Busbar with Steel M8 6.6 32 16 20 20 Torque (Nm) 10% M10 8.8 65 32 40 40 M12 8.8 115 77 70 70 M20 8.8 170

Note: The Values given in the table above are for Tightening Torques. For testing the joint 70% of above values are to be considered as Checking Torque.

31

Siemens Ltd. Power Transmission & Distribution Division Medium Voltage Switchgear Thane Belapur Road, Thane 400 601. Tel. : +91-22-760 0135 Fax : +91-22-760 0134

Order No. 4-XXBXX-03-17231-101

030001

Siemens Ltd.
PTD-03-152-015 This replaces PTD-03-152-003

'Product development is a continuous process. Consequently, the data indicated in this Booklet is subject to change without prior notice. For the latest information please contact our Sales Offices.'