12kV DOUBLE BUSBAR SWITCHGEAR

INSTRUCTION AND OPERATION MANUAL

(HICLAD- 10D)

\li

oorn
-

.,
i

,)

\~
---
--
- -
-
=~~=
-
EPE POWEll CORPORATION BERHAD
(Company No. 12351-K)
! :r
§
LOT 1296, BATU 5, JALAN IPOH, 51200 KUALA LUMPUR
r
J

..
 • OPERATION
&
INSTRUCTION MANUAL

11kV DOUBLE BUSBAR SWITCHGEAR

r.
HICLAD 100
r
!k
f-

•
f .I
,f
)i'
I ,

·-~
EXCLUSIVE RIGHT
; ' The policy of EPE POWER CORPORATION BERHAD.
Is one of continuous Improvement and Development.
The company therefore reserve the right to supply
equipment which may differ slightly from that
described and illustrated in this publication.
VFr-lOD Rev No: 0
if
•~
I
•l CONTENTS
.
t
t ITEM TITLE PAGE

il 1. Introduction
I' 2. Ratings
3. Structure of the cubicle 2
4. Despatch 5
5. Storage 5
6. Installation 6
6-1. Unpacking 6
6-2. Handling 6
6-3. Preparing The Foundation Floor 7
6-4. Erection Procedure 12
·~ 6-5. Extension To Existing Switchgear 14
6-6. Connection Of Earthing Busbars 14
6-7. Connection Of Control Wirings 14
6-8. Power Cable Termination 15
6-9. Protection Against Vermin Entry 17
6-10. Busbar Connections 19a
6-11. Inspection After Installation 20
7. Operation 20
7-1. VCB Operation 20
7-2. Earthing Switch 22
7-3. Interlocks 22
8. Safety Shutters 22
9. Test And Commisioning 23
9-1. General 23
9-2. Physical Inspection 23

" 9-3. Isulation Resistance Test

9-4. Power Frequency Voltage Withstand Test
9-5. Relay Injection Test
9-6. Operation Test
24
24
25
26
9-7. Final Check 26
10. Maintenance 26
10-1. General 26
10-2. Types Of Inspection 27
10-3. Methods Of Inspection 28
10-4. Safety Precautions 29
10-5. Check Of Paintwork 29
11. Troubleshooting 30

VFT-lOD Rev No: 0

 1.0 INTRODUCTION

The purpose of this instruction manual is to provide guidelines for operation and maintenance of
the high voltage metal clad double busbar switchgear (HICLAD lOD). The operation and maintenance
procedures of vacuum circuit breaker (VCB) should be referred to it's instruction manual.

2.0 RATINGS

The standard ratings of the 12kV Double Busbar Metal clad manufactured by EPE switchgear are
shown in Table 2.1.

~
Type HICLAD- lOD

Applicable Standard IEC 298, BS 5227

Rated voltage (kV) 12
Rated Frequency (Hz) 50 or 60
Rated Current (A) 800,1250, 2000
ofVCB
Rated Current (A) up to 2000
of Busbar
Short Time Rating
(a) Current 25 kA
(b) Time 3 sec
~
Insulation Level Insulation Level
(a) Impulse (kV) 75
(b) AC (kV) 28
Type of VCB VFT- 12D
~------

Table 2.1 Standard Ratings

VFf-lOD Rev No: 0

1
3.0 STRUCTURE OF THE CUBICLE

The HICLAD lOD double busbar switchgear is designed and constructed in such a way that it is
a totally enclosed metal clad cubicle and in a compartmentalised pattern with insulated busbars and
utilising the vacuum circuit breaker (VCB). The figure below shows the cross section of a typical
panel.

VACUUM CIRCUIT BREAKER

2 CURRENT TRANSFORMER (RING)

2a CURRENT TRANSFORMER (RING)

2b CURRENT TRANSFORMER (RING)

4
EARTHING SWITCH

CABLE TERMINATION BUSBAR

I e
5 MAIN BUSBAR

5o RESERVE BUSBAR

6 BUSBAR SUPPORTER

7 DROPPER CONNECTION

8 ISOLATING CONTACT

9 METAL SHUTTER

10 OPERATING MECHANISM FOR ES

11 TERMINAL BLOCK

12 CONTROL CIRCUIT CONNECTION FOR VCB

13 EARTH BUSBAR

14 PARTITION

14a

14b
PARTITION

PARTITION I e
15 POWER CABLE CLAMP

16 PRESSURE RELIEF FLAP

17 RELAY COMPARTMENT

18 MULTI CORE CONTROL CABLE BOX

19 5Jmm RAYCHEM TUBULAR CU. BUSBAR

20 CABLE TRUNKING

21 ANTI CONDENSATION HEATER

22 EARTH SWITCH CONNECTION

ll l;;j;z: ~ 'I !1'----... ~-.;;:: 1.t I[ ! ~ I j!::: I I 23 VOLTAGE DETACTOR

Figure 3.1 Cross Sectional View Of A Typical HJCLAD JOD Panel

For Single Three Core Cable Termination Design

VFf-lOD Rev No: 0

2
Figure 3.1, shows the switchgear design for single three core cable but in the case where three single
core cables per phase are used, the termination busbars design is shown in the figure below.

VACUUM CIRCUIT BREAKER

2 CURRENT TRANSFORMER (RING)

2a CURRENT TRANSFORMER (RING)

2b CURRENT TRANSFORMER (RING)

3 f.ARTHING SWITCH

4 CABLE TERMINATION BUSBAR

5 MAIN Bl.ISBAR

Sa RESERVE BUSBAR

6 BUSBAR SUPPORTER

7 [lRUPPER CONNECTION

8 1'30LATING CONTACT

9 METAL ')HUTTER

10 OPERATING MECHANISM FOR ES

11 TERMINAL BLOCV

12 CONTROL CIRCUIT CONNECTION FOR VCB

1.3 EARTH BUSBAR

14 PARTITION

@I 14a PARTITION

14b PARTITION

15 POWER CABLE CLAMP

Hi PRESSURE F~EUEF FLAP

17 RELAY COMPAr<TMENT

18 MULTI CORE CONTROL CABLE BOX

19 53, nrn RA'fCHEM TUBULAR CU BUS BAR

20 CABLE TRUNKit<G

21 ANTI CONGENSATION HEATER

22 EARTH SWITCH CONNECTION

2J VOLTAGE DETACTOR

23o SUPPORT INSULATOR

24 POTENTIAL TRAtEFORMER

25 PT. CONNECTION

26 PRIMARY FUSE

Figure 3.2 Cross Sectional View Of A Typical Hiclad JOD Panel

For 3 Single Core Per-Phase Cables Termination Design

VFT-lOD Rev No: 0

3
 VACUUM CIRCUIT BREAKER

2
.3

4
5 MAIN BUSBAR

5o RESERVE BUSBAR

6 BUSBAR SUPPORTER

7 DROPPER CONNECTION

8 ISOLATING CONTACT

9 METAL SHUTIER

10
11 TERMINAL BLOCK

@ 12 CONTROL CIRCUIT CONNECTION FOR VCB

13 EARTH BUSBAR

14 PARTITION

14o PARTITION

14b PARTITION

15 POWER CABLE ClAMP

16 PRESSURE RELIEF FlAP

17 RElAY COMPARTMENT

18 MULTI CORE CONTROL CABLE BOX

19
20 CABLE TRUNKING

21 ANT! CONDENSATION HEATER

~ UJ 22
23 VOLTAGE DETACTOR

'
';,

Figure 3.3 Cross Sectional View Of A Bus Section

VFf-lOD Rev No: 0

3a
 VACUUM CIRCUIT BREAKER

2 CURRENT TRANSFORMER (RING)

5 MAIN BUSBAR

So RESERVE BUSBAR

6 8U38AR SUPPORTt:R

7 DROPPER CONNECTION

8 ISOLATING CONTACT

9 METAL SHUTTER

10

11 TERMINAL BLOCK

12 CONTROL CIRCUIT CONNECTION FOR VCB

@lu EARTH BUSBAP

14 PARTITION

14o PARTITION

14b PARTITION

15

16 PRESSURE RELIEF FLAP

17 RELAY COMPARTMENT

18 MULTI CORE CONTROL CABLE BOX

19 S)mm RE ICHEM TUBULAR CU.BUSBAR

20 CABLE TRUNKING

21 ANTI CONDENSATION HEATER

U" 23 SUPPORT INSULATOR

Figure 3.4 Cross Sectional View Of A Hiclad b

VFf-lOD Rev No: 0

3b
 Item Name Qty. Rating & Remark
1 Vacuum Circuit Breaker 1 630A 12kV 20kA 3 sec
2 Current Transformer 3
3 Earthing switch 1 set
4 Cable Termination Busbar 3
5 Main busbar 3 Ph
9 Bushing/Isolating Contact 3 Ph 630A
10 Metal Shutter I set
13 Control Circuit Connection
For VCB I set
23 Heater 2 60 Watt
27 Lifting Eye 4 !

'
28 Screen Plate 1 -----

Table 3.1 Legend For The Cross Sectional View

With reference to the figure shown, the VCB compartment is located on the front of the
cubicle. This compartment houses the circuit breaker which is of vertical isolation and horizontal
withdrawal type with mechanical interlock features. Location of the circuit breaker truck within the
compartment is made by moving the truck along the horizontal base rails. The LV metering, relay
and instrumentation compartment is situated above the VCB compartment.

The busbar and CT compartments are located in the middle of the switchgear cubicle. The CTs
are mounted in between the top reserve busbars and the bottom main busbars. Busbar selection is
made by vertical transfer of the circuit breaker to the appropriate position. Pressure relief flaps are
provided on the top portion of the panel to ensure safety of the operator in the event of an explosion
during fault occurance. These flaps are also provided in the arc conduit at each end of the panel e
for pressure relief of fault in the bottom busbars compartment.

Independently operated safety shutters, cover the fixed isolating contact bushing orifices and
are positively operated by the insertion or withdrawal of the circuit breaker truck. Each of the
busbar or circuit shutters are padlockable at either the closed or for open maintenance or for testing
purpose. Re-insertion of the circuit breaker into the housing automatically unable the catches.

The secondary control wiring isolating contacts are of the plug and socket type. The plug
(male) contacts are ·wired to the VCB control and fixed to the top of the truck. The fixed socket
(female) cont~cts are wired to the control terminal blocks in the LV metering compartment. The
insertion of the plug contacts into the socket contacts is made by moving the VCB into its fully
engaged position. To test the operation of the circuit breaker at the isolated position, a flexible "Test

VFr-lOD Rev No: 0

4
 Cord" is provided. A fully interlocked integral earthing switch is incorporated in the HICLAD 1OD
feeder panel for cable earthing during maintenance.

A circuit connected voltage transformer can be mounted on the top rear portion of the panel.
The VT is normally of the dry epoxy resin insulated type and is protected by primary and secondary
fuses. It is firmly locked in it's service position by a latch. Automatic safety shutters are provided
to cover the live contacts when the VT is isolated. The VT is mounted on a truck and is fully
withdrawable. Fixed VT version is also available upon request.

Interlocks are provided to ensure that the circuit breaker or earthing switch 1s properly and
safely operated. Detailed descriptions of the interlocking features are given in section 7.3. Power
cable entry is from the bottom as a standard. Adequete space is available for cable termination in
: the cable compartment which is accessible through the removable rear covers. A multi-core cable
- ' box is mounted at the rear of the panel. This allows termination of tfie e-xternaTcohtro.tcable~ to
be carried out without interfering with the busbar and power cable compartments.

4.0 DESPATCH

The switchgear panels are despatched in units or sections, depending on the conditions at site, with
all the inter-connecting busbars supplied as loose items. The circuit breaker truck is placed in the
engaged position within its compartment to prevent it from rolling out of the housing to avoid
damage to the isolating contacts.

In accordance to the manufacturer's recommendations, relays' movement are tied and induction
discs are wedged during transportation. Indicating instrument movements are not secured. Each
• switchboard is supplied complete with the following items:
a) Circuit breaker elevating handle(raising!lowering)
b) Manual charging handle
c) Earthing switch operating handle
Test bushings and tool kits are supplied only when requested during placement of order. Note that
these are optional items.

5.0 STORAGE

The HICLAD 1OD switch~ear is meant for indoor operation and should be stored in a clean, dry
'--.:!..

and ventilated environment. Unless otherwise specified, it is not weather proof and should not be
left outdoor where rain and moisture may cause irreversible damage. For prolonged storage, it is
recommended that the panel be energised to prevent moisture condensation. Cover the switchgear
with plastic sheet to protect against dust settling and the surface panel from being scratched. Panel
must be stored in a non-corrosive environment.

VIT-lOD Rev No: 0

i.~'
5
 6.0 INSTALLATION

6.1 Unpacking

Each unit or section is packed according to the type of delivery. On arrival at site, each part of the
consignment should be checked with the relevant shipping document. Any shortage or damages
should be reported within THREE (3) days of receipt to the forwarder AND either to EPE POWER
CORPORATION BHD. or the agent who supplied the switchgear. Detailed descriptions of the part
concerned and any damage incurred during transportation should also be included. Failure to do so
may result in claim(s) not being entertained.

6.2 Handling

After unpacking, care must be taken when handling the switchgear. The switchgear can be moved
by using a crane, lifting hoist or rollers and levers. To facilitate lifting, removable lifting eyes/bolts
are attached on the side panels of each shipping section. Before the panel is being lifted, make sure
that the circuit breaker truck is held securely inside its compartment so that it will not roll out of
'
the housing during lifting operations. A typical method of lifting is shown in Figure 6.2.1. The
slings of the lifting ropes should be of equal lengths to allow easy balancing. When the switchgear
units need to be rolled into their position, move the units carefully on three steel rollers of 25mm
diameter, positioned so as to avoid flexing of the structure.

tl I

I
I
I
6
VFT-lOD Rev No: 0
 AHO!ST

f/ '\___LIFTING ROPE ~,, p

/~ \\ ,,
" '\,, •
I
\ ~
,,I

~ ,, ~
,,
PANEL ,,/ '\ ~

•
I \ ,,
¥ ~
MAX TWO PANELS FOR PLAN
ONE LIFTING (WHEN) COUPLED TOGETHER

Figure 6.2.1 Typical Method Of Lifting

I
lI 6.3 Preparing The Foundation Floor

Every attention is given in the factory to ensure that the switchgear is accurately manufactured and

l .t that it should function properly and satisfactorily, provided it is properly erected at the site. It is jig

I assembled on level floor in the factory and to obtain satisfactory operation, these conditions should
be reproduced at the site.

6.3.1 Switchgear Panels Erected On Substation Floor

j·,t'·~..·';.
i
I. It is essential that the foundation floor level must be fairly flat. If that floor is not level, the

I. switchgear may be deformed during installation. This will cause damage or malfuction to the
equipment. The basic requirements for correct erection are as follows:

1) The bottom plate of the unit must be flat and level as specified.

VFT-lOD Rev No: 0

7
 2) The sides of the basic housing must be vertical and particular attention should be paid to the front
of the unit.

3) The longitudinal alignment and height of the units should be referred to the front of the housing
and instrument panels.

4) The area of the substation floor of the switchgear must be flat and level to ensure that the circuit
breaker truck is standing in a vertical position at the point of entry into the housing.

5) Care should also be taken when tightening down the foundation bolts, since excessive tightening
will distort the bottom plate. It is usual, when cementing the grouting bolts in, to flood a 300
mm diameter pad of concrete, thus supporting the bottom plate.

Provided that the floor level is within t 2mm in 1 meter, no difficulty will be experienced during I
erection.

~f
700
f:_
420 X 340 pro
-"'
0

CUTOUT 2.0 rom Linear

"'
-N-
0
-1----- - SWITCHGEAR

+-- + ...
+
.. .. Cable Trench ..
-
co
c.>
0 610 (MINIMUM) I
""
0
0

'----- + +

""
<Jl
0

b
Figure 6.3.1.1 Floor Erected Switchgear Panel

Notes for tightening the foundation bolts:

1) Insert liners if there is a gap between the foundation and the switchgear.

2) Unreasonable screwing of foundation bolts into bolt holes of the switchgear is absolutely
prohibited if their size does not fit the size of the holes.

1
;
VFT-lOD Rev No: 0
I 8
 3) All four foundation bolts must be used.

Foundation boll

Finished floor Switchgear

surface bottom

<l <(\ <l

<1 <l <(\

Foundation
~ "
<1

<l <1
<1 il\~<(j - <1 4
<(\

~ <1
<(\ <1

<(\
4 <l
<1 4
1;, <l
<1

<1 <(\

Hole in anchor

Figure 6.3.1.2 Fixing The Foundation Bolt

..
."
I I~
_f~=~--'
•j
I =!
Figure 6.3.1.3 Level Adjustment

I
.I 6.3.2 Switchgear Panels Erected On Unistruts

In the case where unistruts are embedded in the floor for the switchgear panels to be mounted on
top of it, care must be taken to ensure that the clearance from the floor level to the switchgear panel
is 5 mm or less.

I 9
VFf-lOD Rev No: 0
 BOLT-SORING NUT

~~ --,-
1 11
1 {"""""'
t
. ..
~~
n "'~
• • •• SWITCHGEAR BASE PLATE

.... . ... ....

;!:: • 1 .
• .. ... .. UN !STRUT
8 I=
8
-
-
= ::o-=
i'-.. ./

41.3 mm

Figure 6.3.2.1 Embedded Unistruts

For erection of more than 1 panels, the unistruts must be embedded horizontally.
~ith Bolt-Spring Nuts

r-----------~-----------,-----------,-----------,-----------~
I I
I I
I I
I I
I I
I I
I I
I I
SWITCHGEAR
PANEL
I I
I J
I I
I I
I I
I I
I I
I I
--r-
1
I
I
I
I
,,
I I
I I
I I
I I
I I
I I
I I
I I I
...;!::
8
8

'
I '
I : I

UNISTRUT 7 I
I
I
I
I
!:
<·
I I I I I I
L-----------~-----------~-----------~-----------~-----------~ 8
8

Figure 6.3.2.2 Plan View Of Panels Erected On Unistruts.

t
The following points should be noted when installing the embedded unistruts:

1) Examine the mutual positioning and dimensions of the embedded bases and foundation bolts for
the cubicle. Check the drawing to confirm that there is no abnormal bending.

VFf-lOD Rev No: 0

10
 2) Arrange the embedded unistruts according to their correct dimensions and positions. They must
be arranged and fixed horizontally. Instruments for horizontal measurement need to be
employed and the horizontal level must be determined precisely.

3) The unistruts must be fixed according to Figure 6.3.2.1 so that the alignment of the switchgear
can be achieved.

f'
700

~
-

0>
.....
0

420 X 340 ~m
CUTOUT 2.0 mm Linear
-1------- - --- SWITCHGEAR
UNISTRUT

.J --------+ -,
--'
~..
.
Cable Trench ..
...
.....
I. 610 (MINIMUM) I
-~

co
"'
0

"'
0
0

---------
... !_ ________
-,
L --'
M12 X 40mm
c..:>
<Jl
0 BOLT - SPRIING NUT

~
Figure 6.3.2.3 Switchgear Panels Erected On Unistruts

.-
6.3.3 Level Adjustment

The horizontal level can be checked with a plumb bob and liners can be inserted to make sure that
l
~,1. distance A and B are equal (Refer Figure 6.3.3.1). This level check is required in all direction, front,

n m
'~
'·i rear, left and right.
'~ '
J~

l
I I
i----" ~

I! ,I THREAD
".

~
i
B
~
I PLUMB BOB
\,.
r---

-'- -'-

Figure 6.3.3.1 Level Check

VFT-lOD Rev No: 0
11
 6.4 Erection Procedure

Units or sections should be erected and coupled in the following manner:

1) Withdraw the circuit breaker from the housing to reduce weight. Refer section 7.3 for
clarification.

VCB

ti

Figure 6.4.1 VCB Truck Withdrawn From Cubicle

2) The lifting eyes can be left on the panels or removed.

3) Bring the units together over the floor mounting holes or unistruts, lining up front edges and
busbar centre. In case of a long switchgear panel, it is recommended to start erection from the
center instead from one end of the panel. Once the correct horizontal level has been established,
a neighbouring panel should be installed as closely as posible to the preceding switchgear. The
horizontal level for this switchgear is also arranged in the same manner.
NO GAP
/

~ ~
PUSH
I
I <=

Figure 6.4.2 Arrangement Of Switchgear

~~ 4) When all the panels have been installed in alignment, they are rigidly tightened with bolts and
!i
't
nuts through their connecting holes provided on their panel sides. Clamping work between
:(
J VFT-100 Rev No: 0
i, 12
rt
~1:.
~!,1
 panels must start from the center to the left and then from the center to the right.

BASIC PANEL

.. ..~ ij ij
.... ....
ij ij

Figure 6.4.3 Panel To Panel Clamping

5) Fix the bolts through the bottom plates of the panels to the floor or to the unistruts. Refer

I Figures 6.3.1.2 or 6.3.2.1.

6) Remove covers from busbar chambers.

7) Install busbar links, ensuring that joint surfaces are clean. Smear with a thin film of vaselin, if
necessary. Tighten the bolts securely.
'

-~
8) Replace covers of busbars chambers.

9) Connect the earth busbars. Refer to section 6.6.

10) Connect inter-panel control wirings. Refer to section 6.7.

l 11) After the power cable termination have been completed, the VCB truck can be pushed into the
cubicle again (refer section 7 .3).

I 13
VFT-lOD Rev -No: 0
 VCB

<:=

Figure 6.4.4 VCB Truck Inserted Into Cubicle

6.5 Extension To Existing Switchgear t

At each end of the panel, the end of the busbar chamber is blanked off using a steel arc conduit
which is fitted with a pressure relief flap at the top. This flap will release the pressure in the event
of any fault in the lower busbar compartment. When an existing switchgear is required to be
extended, the new panel can be erected into position after removal of the conduit.

By switching off the bus section and bus coupler circuit breakers and one of the incomers one
side of the switchgear will be dead. Erection of the new panel can then be carried out on the dead
end. In this way, loss of supply will only effect one half of the loads. Once all the busbar links are
fitted between the existing and new panels, the substation will be ready for full re-energisation.

6.6 Connection Of Earthing Busbars

~·
Earthing busbar links separately supplied with the switchgear panel are to be installed along the rear
within the cable compartment. Ensure that all joints between the earthing bar sections are accurately
bolted. The connection to the station earthing system should have a cross-section not less than that
of the earth bar mounted on the panels.

6.7 Connection Of Control Wirings

Terminals for the connection of auxiliary control and other external wirings are provided in the
multi-core box mounted at the rear of each panel. Remove the cover of the multi-core box of the
terminal blocks. Complete the termination of the cables according to the relevant wiring diagrams.

VFT-lOD Rev No: 0

14
 Ensure that each cable is firmly and neatly terminated. Drill hole on the plate cover to match
the diameter of the cable gland used to hold the cables. Inter-panel wirings should be made in the
same manner, but the terminal blocks are located inside the LV relay and metering compartment.

6.8 Power Cable Termination

Note: Any high voltage tests to be made on the switchgear should be performed before the power
cables are terminated, otherwise temporary disconnection of the cables may be necessary.

Cable contractors are best experienced in cable jointing. This manual does not gi"ve instructions
relating to cable jointing since the methods varies from contractors to contractors and it also
depends on the type of cable and termination used. For operation or installation procedures of the
termination kits, please refer to the manufacturer's manual of the relevant type of termination kits
~ used.

To acess the cable chamber, firstly remove the rear covers. When cable termination have been
completed, make sure that the cable chamber is cleaned of any debris and that no tool is left in the
chamber. Finally replace the cover and make sure that the cover is tight.

CA~LE TERMINATION

.J POWER CABLE
Ill
Ill
Ill
CABLE SUPPORT Ill
Ill
ill
Ill
Ill

<
.•. GLAND PLATE

'
; CABLE TRENCH

Figure 6.8.1 Power Cable Termination For Single 3 Core Cable

VFT-IOD Rev No: 0

15
 $ $

CUT OUT FOR CABLE

CABLE SUPPORT

$ $
BRACKET
$ $

$ $

Figure 6.8.2 Plan View Of cable Support And Gland Plate For Single 3 Core Cable
•

CABLE TERMINATION

POWER CABLE
t
CABLE SUPPORT

o.-v
r;-;-
"· GLAND PLATE
CABLE TRENCH

Figure 6.8.3 Power Cable Termination For 3 Single Core Per-phase cable

I 16
VFf-lOD Rev No: 0
 + +

+ +
+ +
+ +
+ +
+ +
+ CABLE SUPPORT

+ CUT OUT _FOR CABLE

+
~-- +
/.a. CUT SEMICIRCLE ON EACH HALF
\"' OF GLAND PLATE

Figure 6.8.4 Plan View OfCable Support And Gland Plate For 3 Single Core Per-phase Cables.

6.9 Protection Against Vermin Entry

To prevent the instrusion of vermins like rats, snakes and other insects, cover the main cable entry
I
opening using the gland plate provided. The cable gland plates are divided into two parts per-cable
for easy installation. The procedures for fixing these plates are as follow:

1) Measure the external diameter of the cable.

/t 2) Cut a semicircle on each half of the gland plates to match with the cable diameter as shown in
Figure 6.9.1 for single three core cable. However in the case of three single core per-phase
cable, the gland cutting will be as in Figure 6.9.2.

I 3) Adjust the position of the power cable and mount the cable gland plates into position neatly.
Tighten the fixing nuts securely.

I 4) If there is any gap between the power cable and the gland plate opening, wind some insulting
tape around the cable neatly to close the gap.

I 17
VFf-lOD Rev No: 0
 ~ +

+ +
+ CDI CDI CDI +
+ I I I +
+
+ cD I
cDI
cDI
+
+
+ +
cp. !
II
I
I
I
I

+
$ $
+
•
I CUT OUT FOR CABLE I

+
1 CUT SEMICIRCLE ON EACH HALF
OF GLAND PLATE

Figure 6.9.1 Gland Plate Cutting For One 3 Core Power cable

+ +

I
i

+
+
I

I
i
I
+
+ CUT OUT FOR CABLE
-
+ +
CUT SEMICIRCLE ON EACH HALF
OF GLAND PLATE

Figure 6.9.2 Gland Plate Cutting For 3 Single Core Per-hase Power Cable.

;}

~
\1}1-lOD Rev No: 0
18
a~·
 '

CABLE SUPPORT
''
---

INSULATION TAPE
GLAND PLATE
WINDING (IF NECESSARY)
POWER CABLE
.J ... --- ... '-
.... ___ .....

Figure 6.9.3 Assembly Of Cable Gland Plate For One 3 Core Power Cable

.J CABLE SUPPORT

INSULATION TAPE GLAND fLATE

WINDING (IF NECESSARY)
" \ POWER CABLE"
'~"''
!;
.~
""=''
tr
l Figure 6.9.4 Assembly Of cable Gland Plate For 3 Single Core Per-phase Power Cable
j
~

1
It.
i f
I
1
~

l 19
VFT-IOD Rev No: 0
 6.10 Busbar Connections

6.1 0.1 The main and reserve bus bar can be accessed by loosening the 4 bolts and removing the
bus bar cover as shown in diagram 6.1 0.1

~,

/j

•
BUSBAR ACCESS

6.1 0.2 Remove the insulation cover and metal fitting and clean the contact surface.

6.10.3 Clean the surface of the busbar, bushing and metal fitting by cloth. •
6.1 0.4 Fit the spacer between the main-busbar and connecting conductors of the farthest left or right
switchgears.

6.1 0.5 Ensure that the bolts & nuts are inserted in the correct directions as shown by the arrow in
Figure 6.1 0, 6.1 0.1, 6.10.2, 6.1 0.3.

6.10.6 Cover the connecting joint with the busbar cap.

I 19a
VIT-lOD Rev No: 0

I
·--··-~·L-------------------··-----"----··-··---·-··-------···-·---~-----·------·-···"·---·------·----------·-···--·--------~---- . ·-----··

•
'··~.-.
-~

.!

PROCESS !DESCRIPTION PICTURE OR SKETCH EXPLANATION OR NOTE

NO
Check for
THIS DRAWING SHOWS REAR VIEW)
FIT THE SPACER BETWEEN
supplied parts MAIN-BUSBARS AND CONNECTING
WASHER~ CONDUCTOR.
received.
NUT
2 Fix the Busbar WASHER - - - - - - - , ~ SPRING WASHER ~\.'<-
'<'a'l-
/
I'
supporter on
'"""() / '-..
./
, \ _ SIDE PANEL
~«'-'-""
the left side BUSBAR SPACER----,~ '0\\S'c,Ci
/
/ 1',
'-..
panel MAIN BUSBAR ~ / '-..
3 Mount the
(Rh)(B)
s'-c,
'O..;,S' /
<Jl'<'
/ 1', ""' '-..
Guide pieces
on the
/

/
/1
'i- "'"' / -1(..
bus bars '"'""v,'- / I '---
/
4 Insert the
,_. bus bars ~'-'-':r.:'<- """'/ / -1(_
I . ""'
/
"'
0" through
f-,
the busbar
supporter I
5 Connection of
bus bars "',., /
j
(refer sheet: /

6 Clamp the ,/
SEE DETAIL 'F'

/
Bolts by
using a '-..
\___ SEE DETAIL '8'

torque wrench ""'

~
>-'
(Torque '-..
I
""''\ "-J.I
/
CAUTION
L BE CAREFUL ABOUT INSERTING

---
0 '-.. I ""' '-.. DIRECTION OF BOLTS. OVER-
0 required LAPPING PROCEDURE AND

450kgf.cm)
', I "-J_ / / \ _ _ SEE DETAIL 'D'
POSITION OF WASRERS, ETC.
~
(1J
<
'-..
-....__.-------- __j '
2. ARROWS IIEAN
z0 INSERTING DIRECTION.

0
_ _ _ _,"_L,__ c_e,_, _ _ __
------------~ .... ---------- ---~~-·--- ---~---~--------- --~-- '··-·-~·----~·-----·--~------.........-.....-- .............·-----·- ·---· ·-----~--_.~ .............. , _ ,__
,~lff~l!i~l'9'~·~-~--·J·-··'

PROCESS NO DESCRIPTION PICTURE OR SKETCH EXPLANATION OR NOTE

Connection of
busbars (refer
sheet: No: 1 Detail A)

/
/

~'~~
I

F I ' D~OPPER BUSBAR

_.
1.0
('")

FIXING BOLT & NUT

~
DETAIL "A'
,_.
0
t:l

~
<:
z0
0

• •
·!.'.:.::_.·,,

~- ....-,·-~--~-.,.--~"-~--·

DESCRIPTION
• PICTURE OR SKETCH
• EXPLANATION OR NOTE
PROCESS NO

Connection of
busbars (refer
sheet: No: 1 Detail B)

"\ \

~i~~ \
~f@~"'-...1
@~= J
/

~
--- /
-
\D
0..

DETAIL "8"

~
......
0
t:1

~
z
~
0
 "'-"---·-'---~------------·-··-····--·--------·---·------·-·-····---·-----..··-·----·-··--------·--··-----------·-"""·--·--· ----.. ···---·----------·-··---·----
V¥'"':;:;;:;;;.;.,_.,..,. __ a•. ' '·'*"""'"''""'""''""'·*!i""'"'!~il( •• Af41iMf7qul m ;;;;:;;;;;;cw:;:a:: g;;; ,;;;:;:;;::;;:;;;:;;:::;:;:;.......,..... ~""-"""•'·"···iA~..,,L;t~,,wH'~~·""· ·.' ,,,_,..;r_:...-;;;::;;:,::.:·_,,: ·.~;·.~;::;-::;:;::->,:.'Sl;:'.:;l'..:;-.,:.:1...,_,-"""-''•

'··~-·

PROCESS NO DESCRIPTION PICTURE OR SKETCH EXPLANATION OR NOTE

Connection of
busbars (refer
sheet: No: 1 Detail C)

(/{~ ISOLATOR

----MAIN BUSBAR

--+-~--- BUSBAR SUPPORT

~

......
I I I
DETAIL "c"
\.----- - ---
'""
\0

/~
(1)

~~ /miT \
(-'®,~I~Y'/ \
\ '-,~~
@~-
l@ ~'
~-
J
~ /
/
'
~ I
I I I ~
- - -/
'-'
0
0
.,:;d<:
z0
0

•• •
·-------·····---------------------··----··---··-""_____.....--.-......- ..- ...- .......-.....
~---- ............... _......--
...................

~· "-"
PROCESS NO DESCRIPTION PICTURE OR SKETCH EXPLANATION OR NOTE

Connection of
busbars (refer
sheet: No: I Detail D)

DROPPER ~USBAR - - - - - ,

$""'
" ' "-.,FIXING BOLT & NUT
MAIN BUSBAR

+---- BUSBAR SUPPORT

.....,
\0

DETAIL "D"

---- ___....

~
......
0
0
ld
!1l
<
z0
0
£.£££&&£12 2 g;g; iSS. I I,,, , ;;, , -"'"''''"""'''

PROCESS NO DESCRIPTION PICTURE OR SKETCH EXPLANATION OR NOTE

Connection of
busbars (refer
sheet: No: 1 Detail E)

DROPPER BUSBAR

"""-c---1- BUSBAR SUPPORT

FIXING B!>L T & NUT

\0
(JQ
DETAIL "E"

~.....
0
t:1

~
z0
0

•• •
~-..!--,·--·----· ·--">"'........ ~··~·--·----·~· .......... -·--·-~---~-----~--·-·-~-·--~··-··~~·~~~- - - - - ·

)
..)
"""'
PROCESS NO DESCRIPTION PICTURE OR SKETCH EXPLANATION OR NOTE

Connection of
busbars (refer
sheet: No: 1 Detail F)

FIXING BOLT &: NUT

ISOLATOR

TO REYCHAM BUSBAR WITH C.T•

-
\0
::r

EARTH SWITCH BUSBAR

CABLE TERMINATION BUSBAR

DETAIL 'F'

~
.......
0
t:l

~
z
~
0
 6.11 Inspection After Installation

Door
Check the door to ensure that it can be opened and closed smoothly.

Tightness Of Joints
1) Check that no bolts and nuts are loosely connected.

2) Note: Bolts and nuts are marked using black during manufacture to enable detection of loose
connection. Check that these markings are aligned. Retighten nut if necessary to restore the
marking.

>-~- Busbar Connection

Check that all busbar connecting joints are tight. Insulation covers must be provided wherever
necessary.
•
Cleaning
1) Look out for any tools or loose parts that have been left inside any compartment.

2) Clean any debris and dust inside and outside the cubicle.
I
7.0 OPERATION

7.1 VCB Operation

The double bus bar VCB type utilised in this HICLAD I OD switchgear is of motorised spring
charged, electrical closing mechanism. The charging motor starts immediately upon connection of
I
control DC supply and it stops when closing spring is fully charged. This charging operation repeats
I automatically when the VCB is tripped, making it ready for the next closing operation. In the event
I of motor failure, manual charging is possible by using the manual charging handle provided.

I The VCB is of vertical isolation, horizontal withdrawal type on truck. At the service position,
l the main contacts of the moving truck are fully engaged with the main contacts of the fixed cubicle.
These contacts are disengaged when the VCB is at the disconnected position. To select either the
top or bottom busbar position of the switchgear, the arms of the VCB contact fingers can be raised
or lowered manually using an elevating handle or by an electrical elevating motor (optional). To
l raise the VCB, turn the handle clockwise; to lower, turn it anti-clockwise. The status of the selected

I busbar position whether it is on the RAISED or LOWERED position is shown by a level indicator
on the front of the VCB.
111\
!

II r{ 20
VFf-lOD Rev No: 0

l ;l'
 +~{
I
I
o11lj 1 -
i
r 1!..,.__._, I
!
I Ii ! I

1
~
i
I ';
.'

II II:' -i ' -!-:

~ ,,
I ::
I
:-

:
I___, .

I 'X
~~~~oci!
I '-

1·1 (I
:i I
I

.• ::
l Jf.
I' •

l~
i ~ •

0 i [1-t:

-
'• I

fj_
'
;_.._

CIRCUIT BREAKER AT
CIRCUIT BREAKER AT
RESERVE BUS POSITION
MAIN BUS POSITION

Figure 7.1.1 Vacuum CirciJ.it Breaker At Main And Reserve Bus Position

Operation of the VCB can be done either locally or from a remote control panel by selecting the
LOCAL/REMOTE (LR) switch mounted on the front of the metering door. By selecting "LOCAL,"

L the VCB can be closed and opened using the TRIP/NORMAL/CLOSE (TNC) switch located on the

- metering door. Both the LR and TNC switches may be of lockable type (optional) to provide
unauthorised operation of the VCB.

The status of the VCB operation is indicated by a mechanical flag through a small opening on
the front panel to show whether it is in the ON (RED) or OFF (GREEN) position. In addition to
the mechanical indicators on the truck, two transparent openings are provided on the VCB

I
r
compartment door to allow checking of the VCB status without opening the door.

To operate the anti-condensation heater, turn the heater switch located inside the relay
compartment to the ON position. An indicating light will turn on to show the status of the heater.
Detailed description on the operation and maintenance of the VCB are given in another manual.
Reference should be made to the relevant drawings whenever necessary.

VFI-lOD Rev No: 0

21
;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;;z Raising And Lowering The Busbar

The vacuum circuit breaker can be elevated or lowered to the "Main" or "Reserve."

••• u -- ---u"~c=Xeserve bus bar is in the upper position and Main bus bar is at the lower position.

he elevating mechanism cannot be operated when the vacuum circuit breaker is in the "Test"
or "Service" position.

- - - - - 3 MANUAL RAISING & LOWERING VACUUM CIRCUIT BREAKER (FROM LOWER

TO UPPER) Refer to figure 7 .1.3

·- LOCKING AND t
f.l1lii7 •+ POSITION INDICATOR

IIANLI'L
CHARGING

C>'AAG(
4-
+
+ DISCHAAGE
-$-
ON-0ff INDICATOR

• MANU"- CB KNOB
OPERATING

$
COUNTt:R MANUAL CB
OPERATING KNOB
RESET

lifT TO UNLOCK
e
~

Trip the VCB manually or electrically.

Tum the interlock handle to the released position having handle kept .at released position.

When the vacuum circuit breaker is withdrawn, the interlock handle is automatically engaged
in the locked position. Vacuum circuit breaker is located at isolated position.

Remove the socket cover for elevating handle.

VFT-lOD Rev No: 0

21a
 5) Move· the interlock lever to raise (item )

6) Insert manual elevating handle socket to the operating shaft.

7) Turn the manual elevating handle clockwise.

8) Ensure that the elevating indicator meet the red line. This is the upper position.

9) Pull out the elevating handle socket from operation shaft.

10) Install cover socket for elevating handle on the front panel.

11) When the vacuum circuit breaker is set from the upper busbar to the lower busbar position, use
~- the same procedure.

;.~,

VFf-lOD Rev No: 0

2lb
 .7.2 Earthing Switch

The operating mechanism of the earthing switch is accessible from the front. By opening the VCB
compartment door, the earthing switch mechanism is located on the left of the VCB. It can only be
operated using handle provided. To close the earthing switch, insert the handle into the slot opening
and push it downwards until a hard-knocking sound is heard when the earth switch is fully closed.

Note that an interlock is provided between the earthing switch and the VCB as outlined in
section 7.3. To open the earthing switch, the same operating handle is used. Push the handle
upwards until the earthing switch is fully opened. The status of the earthing switch operation is
indicated by a mechanical flag indicator attached to the operating mechanism to show whether it
is ON or OFF. An indicating light may be provided on the front metering door as optional.
-------·
7.3 Interlocks ttl
Several interlocking facilities have been incorporated to ensure safety of operation of the high
voltage metalclad switchgear. These include the following:

1) The VCB truck cannot be inserted into its engaged or connected position when
i) it is in the CLOSED condition.
ii) the earthing switch is in the CLOSED position.
2) The VCB truck cannot be withdrawn or diconnected from its engaged position when it is in the
CLOSED condition.
3) The VCB cannot be closed when
i) it is not properly inserted into its engaged position.
-,,
ii) it is not properly withdrawn to its disconnected or test position.
Note: Items (3)(i) and (3)(ii) indicated that the VCB is in the intermediate position i.e. between t
the connected and the disconnected positions.
i 4) The earthing switch cannot be closed when the VCB truck is not fully withdrawn to its
disconnected position.
j 5) The VCB truck can only be inserted into its engaged position when it's selected busbar matches
with the selected shutters of the fixed cubicle. Otherwise the shutter plates may be damaged if
excessive .force is exerted.

8.0 SAFETY SHUTTERS

Automatic safety will close to cover the main fixed contact stabs when the VCB. truck is
withdrawn from its engaged position. The top and bottom shutters are both labelled "BUSBAR"
f

-i whil~ the middle one as "CIRCUIT" shutter. Operation of these shutters are independent of one

f
l
another.

'i VFf-lOD Rev No: 0

i 22
.1
 When the VCB is located on the upper busbar positon, only the top two shutters will operate,
while the bottom one remains stationary. When the VCB is engaged to the lower busbars, only the
bottom two shutters will operate, while the top one stays stationary. Independant catches are fitted
to enable the shutters to be held open for maintenance or testing purposes. Re-insertion of the VCB
truck into the housing automatically cancels the catches. Each shutter can also be padlocked at the
closed position for safety during maintenance.

9.0 TESTS AND COMMISIONING

9.1 General

Prior to the delivery of the switchgear, routine factory tests would be carried out to detect any
fault on materials and workmanship. These include check on cubicle dimensions, paintwork, wiring,

'--- insulation, resistance tests, power frequency voltage withstand test, relay injection test and general
operation or functional test.

Sitt! tests should be carried out before commisioning to ensure that the switchgear has been
installed correctly and to detect any defect that may have been sustained during transportation. It
is absolutely essential that tests and commissioning be performed only by competent persons to
avoid damage or accident. Testing contractors are best experienced in site commissioning test. The
following descriptions are given to serve as a guide only.

Note: Test on the external power cables are not included here. Reference should be made to the
relevant standards whenever necessary.

9.2 Physical Inspection

~
1) Check that the switchgears are installed in accordance with drawings. They should be securely
bolted to the floor and all the external control and power cables are correctly terminated.
2) Remove rear covers and check that the interconnecting busbars are securely fitted. Insulation
,. covers should be fitted wherever necessary.
3) Check that the earthing busbars and terminations are installed correctly.
4) All dessicants should be remove.
5) Inspect all relays and meters and remove any packing. Check for zero setting for all indicating
instruments.
l
.I 6) All external and inter-panel control wirings should be checked for correct termination and
continuity.
l.
l l
~'
t
I~ !'.f
I~
i 23
VFT-lOD Rev No: 0

1
 9.3 Isulation Resistance Test

WARNING! Any solid state relay must be isolated during this test.

9.3.1 Power Circuit

1) This test should be carried out before power cable termination. Disconnect the cables temporarily,
if neccessary.
2) Remove all PT and control fuses.
3) All CTs should be bridged using the CT shorting links terminals provided.
4) With all VCBs in open condition, measure the insulation resistance of ERYB-RYB using a
suitable megger test set; usually 1kV or higher.
) 5) Engage all VCB's and manually close all circuits.
6) Repeat the measurement of the insulation resistance for R-E, Y-E, B-E, R-Y, Y-B and B-R. The til
value of the insulation resistance varies depending on the number of sections and the megger
set used. But normally, the value should exceed 100 MegaOhm.

9.3.2 Control Circuit

WARNING! Do not megger any solid state relay.

Insulation resistance test for control circuit is optional. If necessary, use a 500V megger to measure
the insulation resistance to earth. The insulation resistance should normally be greater than 1
MegaOhm.

9.4 Power Frequency Voltage Withstand Test

WARNING! Any solid state relay must be isolated during this test.

PRECAUTIONS:
I) During this test, the surrounding area must be cordoned off and warning notice clearly
'
positioned.
2) It is essential to earth the equipment under test after each and very test that has been performed.

9.4.1 Power Circuit

1) With all VCB's open, set up the same conditions as in iterris 9.3.1 (1) to (3).

2) Apply a high voltage to ERYB-RYB for 1 minute in accordance with IEC 298 and 694
standards. For service voltage of llkV, apply a test voltage of 28kV. The test is considered
passed if there is no flash-over occurs.

1 24
VFf-lOD Rev No: 0
 3) Now, close all VCBs and repeat item (2) forE IB-R, ERB-Y and ERY-B.

4) Megger test should be repeated as described in item 9.3.1(4) and (6). The value of insulation
resistance may be slighty lower than that was recorded during the first megger test.

NOTE: The frequency of the test voltage should be in the range of 25Hz to 1OOHz. If it is not
practical to perform the test at the specified voltage, then voltages reduced according to the
following table may be used for longer period as recommended by the BS 162 standard.

Duration of Test Precentage of 1 minute_

(minutes) Test Voltage
1 100.0
2 8.3.5
II
J 3 75.0
4 70.0
5 66.6
10 60.0
15 57.7 I
J

Table 9.4.1.1 Power Frequency Test For Durations Exceeding 1 Minute

9.4.2 Control Circuit

,,
Pressure test on the control circuit if required, should be performed at a voltage equal to 2000V.
The test is considered passed if no flash over occurs. Where electronic components are used in the
control circuits, different testing procedures and values may be adopted subject to the agreement
between the manufacturer and user.

9.5 Relay Injection Test

,«-

Primary injection test on most relays are usually carried out before the switchgear leaves the factory.
1 ~ If internai wirings are not disturbed, the relays should function satisfactorily once they are set up
I "
Ig for commissioning. It may be necessary to perform primary or secondary injeCtion t~st on site to
I f.fit- establish that no CTs, relays and wirings are damaged during transportation .
!l f,
'.·
ji!;

I
i
~
-~
1) Return alL CT shorting links to normal position.

'
1 )
l
l
Il !
l
-I
VFT-lOD Rev No: 0
25
 2) Perform primary/secondary current injection test on all relays wherever possible to establish that
the tripping time corresponds to that shown on the manufacturer's tripping characteristic curve.

9.6 Operation Test

1) Manually trip each VCB and withdraw it from its cubicle housing. Attach the Test Cord
provided.
2) Set all relays according to the coordination data.
3) Select the REMOTE/LOCAL switch to "LOCAL."
4) Connect the test control supply and test the VCB for motor charging, electrical closing and
tripping operations.
5) Check that the indicating lights function properly.

-
/~

6) Repeat tripping test by operating the indication disc relays manually and bridge contacts if
necessary. Reset all flag indicators.
7) Check operation of the earthing switch.
8) Check operation of the shutters.
9) Check that all interlock features function satisfactorily.

9. 7 Final Check

1) Check and ensure that no tools have been left inside the switchgear. Replace all covers.
2) Reconnect all power cables.
3) Inser. all PTs and control fuses.
4) Insert all VCBs into the fully engaged position.

The switchgear is now ready for energisation.

I
10.0 MAINTENANCE
I

lI 10.1 General
I

I To ensure reliable and satisfactory service of the switchgear, it is recommended that through
maintenance be performed regularly. It will also serve to check that the switchgear is maintained
in the safe operating conditions. Inspec;:tion should be made as soon as possible after the occurence
of a fault on the circuit. The switchgear should not be placed into operation without a complete .
check and tests after the clearance of the fault. A general guide is to refrain from changing exi.sting
adjustments, unless absolutely necessary.

I
i
I
·,
¥
-1. ~;~,:
l ;;i;~ '''·
26
VFT-lOD Rev No: 0
 ':_ ~-~
r:.:~.~

>·~~
·.f
'·,··1.''···.
:~

2) Perform primary/secondary current injection test on all relays wherever possible to establish that
:;1
;~
the tripping time corresponds to that shown on the manufacturer's tripping characteristic curve. ~
•.,"!
'i

9.6 Operation Test

1) Manually trip each VCB and withdraw it from its cubicle housing. Attach the Test Cord
provided.
2) Set all relays according to the coordination data.
3) Select the REMOTE/LOCAL switch to "LOCAL."
4) Connect the test control supply and test the VCB for motor charging, electrical closing and
tripping operations.
5) Check that the indicating lights function properly.
6) Repeat tripping test by operating the indication disc relays manually and bridge contacts if
necessary. Reset all flag indicators. e
7) Check operation of the earthing switch.
8) Check operation of the shutters.
9) Check that all interlock features function satisfactorily.

9. 7 Final Check

I) Check and ensure that no tools have been left inside the switchgear. Replace all covers.
2) Reconnect all power cables.
3) Insert all PTs and control fuses.
4) Insert all VCBs into the fully engaged position.

) The switchgear is now ready for energisation.

e
10.0 MAINTENANCE

10.1 General

To ensure reliable and satisfactory service of the switchgear, it is recommended that through
maintenance be performed regularly. It will also serve to check that the switchgear is maintained
in the safe operating conditions. Inspection should be made as soon as possible after the occurence
of a fault on the circuit. The switchgear should not be placed into operation without a complete
check and tests after the clearance of the fault. A general guide is to refrain from changing existing
adjustments, unless absolutely necessary.

VFf-lOD Rev No: 0

26
 Routine inspection should be conducted at regular intervals, normally not exceeding 6 months
and at more frequent intervals in the case of important circuits. A maintenance program schedule
should be planned to assist the personnel monitoring the service of the equipment. The frequency
of the maintenance should be adjusted to take into account the environment, operating conditions,
fault history and service liability. A brief sample of the maintenance program schedule is shown in
Table 10.1.1.

Frequency Circuit Service Check Point

1 Daily General Indication Visual Inspection
2 Monthly Control supply Healthy Test
Relay and Fuses Inspection

-,. 3. Half Yearly

~· :y~arly ______ -
Circuit Breaker and Meters
Trip Circuit
Relay and PTs
·-- -
Operation Check
Tripping Test
Injection Test
-

Table 10.1.1 Sample Maintenance Schedule

For detailed maintenance of each component, reference should be made to the respective
manufacturer's manual. The following sections describe the general procedures for routine
maintenance.

10.2 Types Of Inspection

10.2.1 Daily Check

I - 1) In daily inspection, no doors and covers are to be opened. The switchgear is checked from the
outside for noise, smell or physical damage accordance with inspection schedule.

I
I
l
lI
t
j
l

-j VFT-lOD Rev No: 0

27
 2) When something abnormal is detected, identify the location and the degree of fault by opening
the door of the the switchgear, if necessary.

3) Except when the trouble is expected to lead to an immediate malfunction of the switchgear, the
trouble is recorded as a reference data for the periodical or detailed inspection.

10.2.2 Periodical Check

1) Periodical check is carried out at intervals in accordance with the maintenance schedule.

2) It is done in principle with no voltage being applied and without dismantling the internal
components. Devices are checked from the outside by visual and touch in accordance with the
inspection schedule. IJ
CAUT!ON!
If the main bus power supply is not shut down during inspection, use utmost caution for safety.
l
10.2.3 Detail (Extraordinary) Check
Detail inspection should be performed when it becomes necessary as a result of daily or periodical
check or when a fault has occured.

10.3 Methods Of Inspection

10.3.1 Using A Check List

~ 1) Prepare a check list as shown in Table 10.3.1.1. Perform inspection on each item listed.
2) Mark or tick the "good" or "poor" column of check list depending on the result of the
inspection.
3) When action is done to remedy fault or when it is necessary to do so, record it on the "Remedy/
Re.narks" column.
"
I
Name of Service Date Weather Temperature Checked By

Result
Item Part Check Point Remedy!Remarks
Good Poor
Cubicle External · Loose?
part Damaged?
I (door, Noisy ?
--
ext cover)
- -·-- -~-
Stained ?
Table 10.3.1.1 Inspection Check List

VFT-lOD Rev No: 0

28
 10.3.2 Recording of Checks
When during daily inspection, periodical inspection or detail inspection, some action was done to
remedy the fault and the date. This record serves as reference data for the next maintenance and
inspection or for future modification work.

10.4 Safety Precautions

10.4.1 Confirmation Of Power Voltage Shutdown

Before checking the main, the following steps should be taken to ensure safety during inspection.
l) Open/trip the relate circuit breaker to de-energise the circuit to be inspected.
2) Draw out the circuit breaker to the disconnected position and attach a warning sign "UNDER
__..
~.
INSPECTION" to the breaker.
. 3) Check using a voltage detector to ensure that no voltage is present and ground the circuit
concerned by closing the earthing switch.
4) Lock the operation of the disconnecting switch, if any. If necessary padlock the safety shutter
at the "CLOSED" position.
5) When there is a posibility of power being fed from the incoming panel or the bus-tie panel, take
steps (2) to (4) for the bustie panel and the Incomer panel.

10.4.2 Precaution Against Residual Charges

Before checking the cable connections or consider, if any, discharge the residual charges and ground
them.

10.4.3 Removal Of Earthing Cable

.-/~
After inspection is completed, the earthing cable that was temporarily removed for safety should be
restored to the original condition.

10.5 Check On Paintwork

The degree of rusting and peeling of paint surfaces depends on the site of installation, environment,
the service condition and duration of use. During the periodical check, attention should be taken of
the following points.

10.5.1 Rusting Of Metal Parts

1) Moving parts which, when rusted, would not rotate or slide smoothly.

'[.,
~¥"

l
~1 VFFIOD Rev No: 0
i 29
I
 2) Those conducting parts which, when rusted, would change in contact resistance resulting in mal-
operation.
3) Springs and welded portions which, when rusted or eroded, would deteriorate in their mechanical
strength.
4) Those portions which, when rusted, would lose beauty in appearance.

10.5.2 Peeling Of Paint or Coating

Where the ambient conditions are severe, the painwork will deteriorate after within a few years
of service. It is recommended that those portions where the paint is found to have been peeled off
or the surface has become scorched, be touched-up or repainted as soon as possible.

11.0 TROUBLESHOOTING
~"""'

The swithgear was manufactured under strict quality control and has undergone various verification
tests before despatch from the factory. However, should any trouble be found during daily or
periodical inspection, investigate the cause of trouble and take the necessary action according to the
-
recommendations in Table 11.1.

Table 11.1 Troubleshooting Check List

Part Trouble Possible Cause Remedy

Shutters 1. Shutters damaged. 1. Repair damaged shutters.
do not 2. Moving parts poorly 2. Adjust moving parts &
close adjusted & lubricating apply lubricating oil.
oil deteriorated. 3. Clean moving parts.
3. Foreign matter trapped
SHUTTERS in moving parts. e
Shutters 1. Padlock left locked. 1. Unlock the padlock.
do not 2. Shutters deformed. 2. Repair deformed shutters.
open 3. Moving parts adjusted 3. Adjust moving parts &
& lubricating oil deteriorated. apply lubricating oil.

Conductor 1. Bolts on connections loose. I . Retighten bolts.

connections 2. Overcurrent. 2. Limit current to rated
MAIN overheated value.
CONDUC- Ground 1. Insulators cracked. I. Replace insulators.
TORS fault or 2. Insulators stained with 2. Clean & dry insulators.
insulation foreign matter or rain 3. Plug small gaps & opening.
resistance water leaking.
drop 3. Instrusion of small animals.
- - - - - - - L_

VFT-lOD Rev No: 0

I 30
 Part Trouble Possible Cause Remedy
Handle 1. Wrong Key (if any) I. Check key on
cannot be 2. Handle Internal 2. Lubricate key hole
unlocked 3. Handle internal 3. If in emergency, cut
mechanism faulty off handle by saw.

DOOR Loose I. Fixing screws loose. l. Retighten the screws

handle 2. Internal mechanism worn out. 2. Replace the handle
I. Loose screws on hinge l. Readjust the door
Door 2. Hinge pin bent & tighten.
warped and 3. Door deformed by external force 2. Rectify the hinge pin.
loose. 3. Repair the
)
~~,
deformed portion.
-

Internal I. Partition plates I. For srewsfixed partition

n01se vibrating due to plates, retighten
electromagnet induction screws.
(i) Loose screws For welded partition
on partition plates. plates, reweld the I

(ii) Welded partition broken or parted

plates dislocated.
STRUCTURE 2. Partition discharge due to
stainted surface of insulating
material or moisture.
--)
Extinction 1. Bulb filament broken.
of indicating 2. Fuse or resistor burnt.
lights 3. Poor contact of VCB
auxiliary switch contacts.
CONTROL 4. Auxiliary supply switch
CIRCUIT open circuited.
5. Auxiliary switch
contacts shifted
i or faulty.
!
portions.
(i) After shutting down power
clean the surface of
insulating material
(ii) Turn on the heater to dry the
air inside the cubicle.
1. Replace bulb.
2. Replace fuse or resistor.
3. Clean the auxiliary
switch contacts.
4. Check MCB or
fuse and wire terminal.
5. Check limits
switch contact
and operation.

-~

VFT-lOD Rev No: 0

I 31
 Part Trouble Possible Cause Remedy
Continued I. Poor contact of VCB 1. Clean auxiliary contacts.
simultaneou auxiliary switch contacts. 2. Operated the auxiliary
lighting of 2. Contact resistance switch several time. I
I

both "ON" increased due to dust

& "OFF" contamination or
indicating oxidation of contacts
lights. (especially when they
CONTROL are not operated for a
CIRCUIT long period of time.)
Poor 1. Loose screws on 1. Retighten screws on
operation terminal blocks. terminal blocks.
~-
of control
circuit in
general.
Poor
2. Control circuit plug not
properly connected.

1. Auxiliary switch
2. Reinsert the control
circuit plug.

1. Clean the contacting portions.

operating of contacts damaged by arc.
instruments 2. Contacts resistance increased
and relays. due to oxidation or dust
contamination.
1. VCB not fully inserted
Does not 2. Remote/Local selector
close switch not at right selection.
3. Auxiliary supply MCB open
4. Control circuit plug position
left unconnected.
5. Control circuit voltage drop
6. Closing coil burnt.
VACUUM Does not 1. Local/Remote selector
CIRCUIT open switch left unoperated.
2. Auxiliary supply MCB open.
3. Control circuit voltage drop.
4. Trip coil burnt.
Cannot be 1. Wrong rating of VCB.
inserted into 2. Lock fever does not
cubicle lift up due to closed VCB.
3. Shutter operation
imperfect:
-
2. Operate contacts several
time or replace contacts
I
if necessary.
1. Insert completely to
the connected position.
2. Change the switch to
selected position.
3. Close MCB.
4. Connect control plug.
5. Restore voltage.
I
I
e
6. Replace coil.
1. Change the switch to
selected position.
2. Close MCB.
3. Restore voltage.
4. Replace coil.
1. Insert the VCB of
correct rating.
2. Tum off VCB.
3. Adjust the shutter mechanism
lubricate moving parts.

VFT-lOD Rev No: 0

32