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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 Page Nos
1. Technical Description 4. Operations
1.1 General 3 4.1 Withdrawable Truck 21
1.1.1 Application 3 4.1.1 Positions of the withdrawable truck 21
1.1.2 Specific Standards 3 4.1.2 Transferring the Withdrawable Part from the
1.1.3 Ambient Temperature and Humidity 3 test / disconnected position manually 21
1.1.4 Site Altitude 3 4.1.2.1 Normal Operations 21
1.2 Design Features 5 4.1.3 Transferring the Withdrawable Part from
1.2.1 Switchgear Layout 5 the Connected position to the test /
1.2.2 Circuit Breaker Compartment 5 disconnected position manually 21
1.2.2.1 Service Position 6 4.1.3.1 Normal Operations 21
1.2.2.2 Test Position 6 4.1.3.2 Castell Key Operation (Optional) 22
1.2.2.3 Isolated Position 7 4.1.4 Removing the LV Plug 22
1.2.2.4 Removed Position 7 4.1.5 Connecting the LV Plug 22
1.2.3 Busbar Compartment 7 4.2 Circuit Breaker Operating Mechanism 22
1.2.4 Cable & CT Compartment 7 4.3 Circuit Breaker Operation 22
1.2.5 Compartment for Low Voltage Equipment 7 4.3.1 Charging the closing spring by hand 22
1.2.6 Accessory Items 7 4.3.1.1 Breaker ON and OFF 22
1.2.7 Range of Panels 7 4.3.1.2 Mechanically 22
1.2.7.1 Feeder Panels 8 4.3.1.3 Electrically 22
1.2.7.2 Bus Sectionalizer Panel 8 4.3.2 Switching State Indication 23
1.2.7.3 Metering Panel 8 4.4 Line PT with Drawout Fuse Mechanism 23
1.2.7.4 Panel with I/C & O/G Connections 8 4.5 Earthing 23
1.2.8 General Construction 8 4.5.1 Earthing of Busbars and Cables 23
1.2.9 Interlocks 8 4.5.1.1 Direct Earthing of Busbars with Conductors 23
1.3 Technical Data 8 4.5.1.2 Earthing of Cables with Conductors 23
1.4 Rating Plate 9 4.5.1.3 Removing Earthing Connections 23
2. Installation 4.5.2 Earthing of Busbars / Cables with a
2.1 Foundation 10 Drawout Truck 24
2.2 Electrical Service Room Dimensions 11 4.5.2.1 Disconnection of Earthing Drawout Truck 24
2.3 Transportation Units 11 4.5.3 Earthing the Busbars / Cables with
2.4 Packing 13 Earthing Switch 24
2.5 Unloading 13 4.5.3.1 Earthing Busbars with Earthing Switch 24
2.5.1 Handling Equipment Required 13 4.5.3.2 Earthing Cables with Earthing Switch 24
2.5.2 Procedure 13 4.5.3.3 Disconnection of Earthing Switch 24
2.6 Examining the Switchgear against damages 13 4.5.4 Earthing of Busbars or Cables with Truck 24
2.6.1 Storage 13 4.5.4.1 Earthing of Busbars with Bus Earthing Truck 24
2.7 Transferring the Transport Units 13 4.5.4.2 Earthing of Cables with Cable Earthing Truck 25
2.7.1 Remove the truck from the panel 14 4.5.4.3 Link Type Earthing Truck 25
2.8 Assembling the Switchboard 14 4.6 Breaker Compartment Door 25
2.8.1 Bolting the Panels together 14 4.6.1 To Open the Door 25
2.8.2 Fixing the Switchboard to the Foundation 15 4.6.2 To Close The Door 25
2.8.3 Bolting the Busbars together 15 4.7 Door to LV Compartment 25
2.8.4 Bolting the Main Earth Busbar 4.7.1 To Open the Door 25
section together 15 4.7.2 To Close the Door 25
2.9 Making HV Cable Connections 15
2.10 Earthing of Switchboard 16 5. Maintenance
2.11 Other Work to be carried out 16 5.1 Inspection Schedule 26
2.11.1 Checking the HV Connection 16 5.2 Cleaning 26
2.11.2 Checking the bolted Joints 16 5.3 Lubrication 27
2.11.3 Cleaning the Switchboard 16 5.4 Replacement Parts 27
2.11.4 Inserting the withdrawable parts 17 5.5 Defeating the Door Interlock of HV
2.11.5 Protecting the panels against Environmental Compartment 27
effects 17 5.5.1 Drawout Unit in Connected Position 27
2.12 Interpanel Wiring 17 5.5.2 Drawout Unit in Disconnected Position 27
5.5.3 Restoring the Door Interlock 27
3. Putting the Switchgear into Service
3.1 Test Operations 18 6. Disposal of Product 28
3.1.1 With Door Open 18 7. Summary of Important Instructions 29
3.1.2 With Door Closed 18
3.2 Checking the Accessory Items 19 8. Additional Information
3.3 Revising the Circuit Diagram 19 8.1 Reference list of Items 30
3.4 Space Heaters 19 8.2 Jointing Torque 31

2
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
Fig 1: Basic Circuit Diagram
procedures contained herein. The
components labeled with the temperature of the air in the switchboard room.
Danger Sign shall be removed only
At ambient temperatures below -5°C prevailing for a
after ensuring that the supply to the
longer period the switchboard room has to be heated.
live parts behind them is de-
energized & earthed. The air temperature in the panels should always be
about 5°C above the ambient temperature to avoid
Successful and safe operation of this equipment is condensation. (Switch on the heater against
dependent on perfect planning of the system, condensation!)
proper handling (transport, storage), installation,
The humidity of upto 95% is permissible.
operation and maintenance.
If the truck-type switchboard is exposed to a humid
climate and rapid temperature changes, the
switchboard room has to be heated.
1. Technical Description
1.1.4 Site Altitude
1.1 General
The rated insulating capacity values (rated impulse
8BK80 metal clad switchgear is of .horizontal withstand voltage, rated power frequency withstand
isolation & horizontal drawout type suitable for easy voltage)1) specified for the equipment are, in
extension of switchgear in both direction for system accordance with the provisions of IEC Publication 71,
voltage upto 24kV. The switchgear is designed for based on standard atmospheric conditions (1013 h
single busbar system & is fully compartmentalized. Pa, 20°C and 11 g/m3 water content). i.e. sea level.
The design incorporates the set of interlocks for safe The insulating capacity of an insulation in air
operation of switchgear. decreases with increasing altitude as a result of
changes in the air density. Standards promulgated by
1.1.1 Application IEC and other disregard this decrease in insulating
The switchgear is suitable for use as distribution unit capacity for altitude of up to 1000 m, i.e. the
for switching load at substations of electric supply decrease of approximately 9% at this altitude is still
companies as well as for power stations & industrial permissible.
plants. The standards provide no guideline for altitudes of
more than 1000 m with respect to insulation ratings;
1.1.2 Specific Standards they leave this up to an agreement between
manufacturer and user.
The metal clad metal enclosed switchgear has been
type tested as per all the requirements of IEC 60298 Our own recommendation is as follows:
“Specification for Rating & testing of insulation of Since this method used for rating insulation up to
electrical Switchboards & switchgear for AC Voltages altitudes of 1000 m has proved to be satisfactory, it
above 1 kV & conforms to the standards IS3427, should also be applied to higher altitudes. The
IS12729. The Switchgear is supplied in ready altitude correction factor a should therefore be based
assembled condition. The Switchgear can be installed on the insulating capacity at 1000 m, which is lower
free standing. by 9% (corresponding to 0.91 or 1/1.1) than the
capacity at sea level.
1.1.3 Ambient Temperature and Humidity
The following expression thus applies for the
Ambient temperature is understood as the selection of the equipment:

3
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)
Rated impulse withstand 75 kV
= 93 kV
voltage to be selected 1.1 x 0.73 Fig. 1.1 Relationship between the correction factor “a” and
the site altitude
Switchgear with rated voltage of 15 kV, IEC List 2 The following definitions apply:
(rated lightning impulse withstand voltage of 95 kV) 1)
Rated withstand voltage2) = required value corresponding to
meets this requirement. the provisions of IEC etc. for sea level.
Withstand voltage3) = actual value for the given altitude
The actual insulating capacity at the site is then 2)
Rated lightning impulse withstand voltage
Rated power frequency withstand voltage
withstand voltage 3) = a • rated withstand voltage2) of 3)
Lightning impulse withstand voltage
the selected switchgear unit. Power frequency withstand voltage

2.4

2.1

2.2

2.5

2.3

2.1. Circuit Breaker compartment (HV Compartment) 2.4. Low Voltage compartment (LV Compartment)
2.2. Busbar compartment 2.5. Withdrawable Truck
2.3. Cable & CT compartment

Fig 2: Side view of switchgear cubicle

4
3.3 3.2.3
3.6

3.2.1
3.7
3.8

3.2.4 3.2.2
3.5
3.2.5

3.2.6

3.4

3.2 3.1
3.2.7

3.1. Vacuum Interrupter 3.2.1 Mechanical ‘ON’ Push Button


3.2. Insulating Switching Rod 3.2.2 Mechanical ‘OFF’ Push Button
3.3. LV Plug on the truck 3.2.3 Spring Charging Opening
3.4. Contact Arm
3.2.4 Spring Charge Indication
3.5. Truck Handle
3.6. Cast Resin Insulator 3.2.5 Mechanical ‘ON’ & ‘OFF’ indication
3.7. Guide Roller on truck 3.2.6 Mechanical Operations Counter
3.8. PP Tube 3.2.7 Earthing for the Truck

Fig 3: Withdrawable Truck with Circuit Breaker Fig 3.2: Mechanical ON & OFF Push Buttons

1.2 Design Features

1.2.1 Switchgear layout (Refer Fig. 2)


3.1.1 Metal partitions subdivide each panel into
- 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
3.1.2
doors are hinged.

1.2.2 Circuit breaker Compartment


The circuit breaker compartment contains a
3.1.3
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
3.1.1 Pole Flange (Upper) a hand crank.
3.1.2 Pole Flange (Lower)
3.1.3 PT’s on the truck

Fig. 3.1: Rear View of the truck

5
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 The truck is locked against withdrawing.
The low voltage circuit is connected through the low
4.5
4.2 4.10 voltage plug & socket connection (3.3, Fig. 3 & 4.5,
4.3
Fig. 4).
4.12
4.4 4.6 1.2.2.2 Test Position
4.13
4.8 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
4.7
4.1 low voltage circuit is connected through low voltage
plug connection (4.5, Fig. 4).
4.1. Door Locking hinge pin 4.8. Interlocking Plate The circuit breaker can be switched for testing & all
4.2. Door close interlock (Drive Box) functions.
4.3. Viewing window for truck 4.9. Holder for LV Plug
position 4.10. Clip for locking LV
6.2 6.3 6.4
4.4. Viewing window for Plug to Breaker
Spring charge indicator 4.12. Trip mechanism for
and Mechanical Counter operating the breaker
4.5. LV Socket in service position
4.6. Drive Mechanism housing 4.13. Rod Lever
4.7. Ramp

Fig 4: Withdrawable Truck in Test Position & door open

5.4

5.3

5.2
5.1

6.1 6.6 6.5

6.1. Main Earth Busbar


6.2. Bushings for lower mating contact
6.3. Current transformer
5.1. Bushings of upper mating 5.3. Feeder connections 6.4. Cable connecting pieces
contact 5.4. Busbars 6.5. Wiring Cover
5.2. Cast resin insulator 6.6. Gland Plate for Power Cables

Fig 5: Busbar Compartment Fig 6: Looking into Cable compartment

6
- 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)
This compartment contains all the low voltage
devices (protective relays, MCB’s, terminals, etc.,)
Indicators and relays are accommodated in door
7.1 cutouts.

7.1 LV Compartment Door


1.2.6 Accessory Item (Refer Fig.8)
Fig 7: Looking into LV compartment Following accessories are supplied with the
switchgear.
1.2.2.3 Disconnected Position (Isolated Position)
The position of withdrawable truck in which an - Changing handle for charging the closing spring of
isolating distance or segregation is established in the the vacuum circuit breaker (8.1)
circuits of the withdrawable truck, the truck - Cranking handle for truck movement between
remaining mechanically attached to the enclosure. service and test positioning (8.2).
In this position the truck is withdrawn as in test
- Double bit key for locking the truck transfer
position but the LV plug is disconnected.
operating mechanism (8.3)
In the test & disconnected position the contact arms &
their mating contacts are separated by metallic - Rod Trap key for LV compartment. (8.4)
shutters.
- Earthing Switch Handle (Optional). (8.5)

1.2.2.4 Removed Position


1.2.7 Range of Panels
The position of withdrawable truck when it is outside
the panel and electrically & mechanically separated General:
from it. Ramps are provided at the front bottom of the For a metal clad enclosed switchgear there are
panel to withdraw the truck out of the panel various panel modules available. All the panels are
smoothly. constructed using identical parts as far as possible.
Drive Mechanism of the truck is attached to the
cubicle frame using Rod Lever. 1.2.7.1 Feeder Panels (Fig 9a)
The Earthing strip at the bottom of the breaker The feeder panels are suitable for input or output of
compartment, along with the spring loaded pin electrical energy.
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 8.2 8.5 8.4 8.3 8.1
from one panel to the next. 8.1. Charging Handle 8.4. Rod Trap Key
8.2. Cranking Handle 8.5. Earthing Switch
8.3. Double Bit Key Handle
1.2.4 Cable and CT compartment (Refer Fig.6)
The Cable compartment contains: Fig 8: Accessories

7
Outgoing feeder panels with C.B. on the truck are panels are interchangeable.Trucks are earthed
most frequently used. with panel in both test & service positions.
Alternatively, these panels can also be equipped with - Outgoing cables can be earthed by means of
an isolating truck. manually operated earthing switch. (Optional)
- C.T.s are mounted on stationery part in the Cable
The panel is available with current transformer either
Chamber.
with earthing switch or without earthing switch. The
earthing switch is always equipped with manual - Line P.T.s are available with a drawout
drive. arrangement and with fuses.
- Future extension of existing switchboard is
1.2.7.2 Bus Sectionalizer Panels (Fig 9b) possible
In bus sectionalizing panel one panel is used for the
truck with the C.B. (alternatively, an isolating truck) & 1.2.9 Interlocks
one panel for connection of busbars to the top. Both
The positions of the withdrawable part are described
the panels are usually delivered as one assembled
on page 4
transport unit.
State The following operations
1.2.7.3 Metering Panel (Fig 9c) are not possible
Basically metering panels are of the same Withdrawable truck in – Removal of the
construction as the standard outgoing panels. The service position, withdrawable truck
metering truck with voltage transformers & HRC fuses switching device “ON” – Opening of the door
in series is equipped with 3 top contact arms. – Pulling of the LV plug

1.2.7.4 Panel with I/C & O/G Connections (Fig 9d) Withdrawable truck in – Removal of the
service position, withdrawable truck
These panels are comprising of Incoming & Outgoing switching device “OFF” – Opening of the door
Cables in the same panel. – Pulling of the LV Plug
Withdrawable truck – Closing of the
1.2.8 General Construction
located between the switching device
- Safety devices & interlocks are provided to avoid service and test – Opening of the door
any malfunctioning. These devices protect the positions – Pulling of the LV plug
operating personnel & ensure reliable operations.
Withdrawable truck in – Transfer of the
The interlocks are explained in section 1.2.9.
test position, switching withdrawable truck
- The panel is compartmentalized in different device “ON” to service position
compartments with metallic partitions.
Withdrawable truck in – Closing of the door
- Vacuum Circuit Breaker for the panel is mounted
disconnected position transfer of the
on the truck. All the identical trucks in different
LV plug pulled off, withdrawable truck
switching device “OFF”, to service position.
I/C O/G
door open

1.3 Technical Data


VCB VCB VCB
Rated Voltage, Frequency (50Hz) 7.2kV 12kV 24kV
Rated Current of the Feeders 3150A 3150A 3150A
CT CT CT
Rated Current of the Busbar 4000A 4000A 3150A
Rated Power Frequency 20kV 28kV/ 50kV
withstand Voltage (rms) 60 sec. 38kV**
Fig 9a Fig 9b
Rated Lighting Impulse 60kV 75kV/ 125kV
Withstand Voltage (peak) 95kV**
1.2/50 Micro sec.
Rated short circuit 44kA 44kA 26.3kA
Fuses VCB breaking current
O/G Rated short time withstand 44kA 44kA 26.3kA
P.T.
CT current (3 sec)
Rated short circuit 110kA 110kA 66kA
I/C making current (peak)

** On request upto 31.5 kA


Fig 9c Fig 9d

8
750†

d2

800 min d3
on either side

800 min 10.3 1100* / 2000**


10.1

h 10.2

FRONT

20 W
20.0 d1 38
d * Single Row of Panels
** Double Row of Panel
10.1. End Covers are fitted to the left & right hand end panels
of the switchboard †
Minimum from highest pressure relief flap
10.2. Pressure relief channel for the termination (Part 10.1) after it has opened
compartment, 110 mm deep. All dimensions are in mm and are for
10.3 Pressure Relief Flaps 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 h h1 d d1 d2 d3
mm mm mm mm mm mm mm

Upto 15 kV 600/800 1600 2000 1808 1750 380 750

24 kV 1000 1450 2300 2270 2215 380 1000

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

9
2. Installation
The installation sequence should be planned and
prepared with care. Ensure that the erectors and the Rear cover

operating personnel read the operation, installation & 65.0 670.0 65.0
maintenance instructions. 20.0
65.0

25.0
2.1 Foundation CUTOUT FOR
310.0
POWER CABLES
- 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 CABLE CHAMBER
panel bottom rails below the 30mm x 30mm cutouts.
295.0 295.0
Two girders (depthwise) must be fixed along the
wheel tracks of the truck as shown in the foundation 6x holes for M12 bolts
Wheel 1750.0
plans (Fig. 12a, 12b & 12c). Track (for fixing to foundation)

300.0
- Concrete Floor
CUTOUT FOR
This should be provided with foundation rails on CONTROL CABLES
45.0
which the panels are to rest. For floor cutouts refer to 10.0
10.0 935.0
45.0
Fig 12a,12b &12c. The foundation should be
prepared before the panels arrive. Level differences 580.0
300.0
between the mounting surfaces of the individual C.B. CHAMBER
panels should be determined and compensated for by
using a sheet as shown in Fig 16. 120.0

32.5
38.0
H.T./L.T. Front door
Rear cover
175.0 450.0 175.0
FRONT
65.0 470.0 65.0
20.0
65.0 800.0

Note : All dimensions are in mm


CUTOUT FOR
POWER CABLES 310.0 Fig.12b Foundation Plan for 12 kV (800W) Panel

CABLE CHAMBER 450 450


32.5

198.0 198.0
65

Wheel Track
Rear box
800

1750.0
75 75

Standard panel
6x holes for M12 bolts
(for fixing to foundation)
300.0
1000

CUTOUT FOR
45.0 CONTROL CABLES 10.0 295.0 295.0
400

935.0
10.0 45.0
32.5
2215

45 10
580.0 Wheel Track 30 ø
300.0
C.B. CHAMBER
300
1215

1140

10 45

120.0
777.5
300

32.5
38.0
H.T./L.T. Front door
40

37.5

375 375 Front


175.0 250.0 175.0
1000

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
Ø1
4.
0

1780.0
1705.0

75.0
40.0 40.0
ISA 40x40x5
ISMC 75x40
75.0
4.0

M12 NUT
Ø1

WELDED
T 75
1027.5
1780.0

952.5
O
P
1AØ
75.0

ISMC 75x40x5

75.0

75.0

875

940
1000
0
60

125
75.0
75.0
Ø1
4.
0

47.5
0.0
Fig 13c: Base Frame Dimensions (24 kV 1000W)
175.0

600.0
0.0
67.5
142.5

425.0
457.5
532.5

2.2 Electrical Service Room Dimensions


Fig 13a: Base Frame Dimensions (12 kV 600W)
Min. Clearance to the ceiling 750 mm min
above the top (Refer Fig. 10)
75.0

Min.Clearance on the sides 800 mm min


Ø1
4.

of the Panels
0

1780.0
1705.0
Min.Width of control aisle in 1100*/
75.0

40.0 40.0 front of the Panel for Single row 1500** mm min
ISA 40x40x5

Min.Width of control aisle 2000*/


in front of the Panel for 2500** mm min
75.0

M12 NUT two rows facing each other


4.0

WELDED
T
Ø1

1027.5
1780.0

O
952.5
P
* For upto 15 kV Panel ** For 24kV Panel
75.0

ISMC 75x40x5
A power source must be available. Work likely to
produce dust or dirt may not be carried out while the
75.0 panels are being installed. The floor should be
75.0 levelled to enable transport units to be moved on
roller and/or similar devices.
75.0

75.0

47.5 2.3 Transport Units


0.0
A transport unit consists of maximum upto 3
175.0

800.0
0.0
67.5
142.5

625.0
657.5
732.5

assembled switch cubicle with withdrawable truck.


The cubicle should not be lifted from the top with
Fig 13b: Base Frame Dimensions (12 kV 800 W) circuit breaker inside.

11
12
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, stone-
ware 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
t The straightness tolerances, as required by DIN
43 661 shall include the level tolerance and
shall nowhere in the complete plant to be
Tolerance as per DIN 43661:

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
Level 1mm within 1mtr.measured length.

– 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.

Fig 14 : Dimension data sheet for the foundation.


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

the location of fixing holes of the panel for tightening the foundation bolts.
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
2.4 Packing bolting the transport units together and also
temporarily to check them for any signs of
As required :
transport damage.
(a) For shipment to inland destinations each transport
unit is fixed on a sturdy wooden pallet and
2.6 Examining the switchgear against
covered by plastic sheet for surface protection and
damage
packed in normal wooden case.
As soon as the switchgear has been unloaded and
(b)for shipment overseas each transport unit may be
unpacked examine it to see that it is complete with
additionally packed in a seaworthy case. It is
reference to the relevant documents. Record any
enclosed in plastic sheet, which is sealed air-tight
damage and its cause without delay, in the presence
and includes bags containing dessicant.
of the forwarding insurance agent, if the damage was
Accessory items are packed separately, or kept in the caused en route.
panel transport unit (see dispatch advice). This report is essential for any damage claims.

2.5 Unloading 2.6.1 Storage


While unloading care must be taken to see that the - Store the units in upright position only
panels are not rolled on its sides & they must be kept
in upright condition. - The units must be stored in adequetly covered
location such that they are protected from Sun,
Rain, Flood Waters & other such Natural elements
2.5.1 Handling equipment required
- A mobile crane or a chain pulley block for 2.7 Transferring the transport units to their
unloading the transport unit. points of installation
- Lifting tackle - Transfer the transport units including their wooden
- A fork-lift truck with a fork length of about 3.0 mtr, pallets to the point of their installation using fork
for handling the switchgear inside the building. lift rollers.

- Hydraulic jacks or winches & roller pads. - Withdraw the trucks out of the panels using two
wooden wedges below the ramps & close the
The handling/transport gear must meet the site door.
requirements with regard to its construction and load
bearing capacity. Refer to the weights (for raising and - Put the panels down on the cleaned site or at least
transporting) stated on the transport or in the immediately in front of it in the correct order,
covering documents. leaving a clearance of about 25 mm between
them.
2.5.2 Procedure - To remove the transport units from their wooden
pallets
- Do not unpack while unloading the transport
units. Take care not to damage the plastic sheet - Place four winches under the floor rails of outer
because it protects the switchgear against any panels and uniformly raise the panel.
environmental effects. - Remove the wooden pallet.
- Use of mobile crane or a forklift truck. - Lower the transport unit as far as it will go & place
• Attach the ropes to the wooden pallet. it on two wooden beams if it is located above its
site or place on four roller pads if it is in front of
• Carefully raise the transport unit and check to see the sites
that it is correctly balanced, if necessary lower the
transport unit and correct any imbalance by - In the later case roll the units to their mounting
repositioning the ropes on the lifting tackle. position. If this means changing the direction of
travel raise the unit & reposition the roller pads
– Unloading the switchgear with a fork-lift truck. accordingly. Now place the planks & channels in
Transport units of not more than two panels can the foundation cutouts that have to be crossed.
be unloaded with a fork-lift truck if the access
routes permit this. Make sure the transport units - To raise the panels on their mounting position &
are correctly balanced. removing the roller pads
• Move the transport units as close as possible to - Lower the transport unit as far as possible & place
the switch house and put them down. them on two wooden beams.
• Dismantle and remove the crates. - Now, raise the units, first on one side & then on
the other side, using roller-type crowbars. Pull out
• Move each transport unit into the building. the planks & lower the panels onto the cleaned
• Take off the plastic sheet immediately prior to foundation. Position the crowbars only at the

13
corners of the panels below the vertical frame (refer Fig. 14) and be absolutely vertical. If
members. necessary place shims.
- under the frame uprights and
2.7.1 To remove the Truck from the Panel
- under the bottom rails near the 30 mm x 30 mm
- Open the door of the panel (Refer clause 4.6.1). cutouts for the foundation bolts.
- Bring the truck to the test position by cranking - Remove the bolts fitted at the left hand end of
(Refer clause 4.1.3.1) each panel, as viewed from the front.
- Disconnect the LV plug (4.5, Fig. 4) & place it its - Move up the second panel.
holder (4.9, Fig. 4) on the door.
- Align this second panel on the foundation, raise it
- Mark the truck & their panel numbers for to the correct level and make sure the panels stand
identification. vertically.
- Lift & turn the Levers (4.13, Fig. 4) on the front Use shims as for the first panel.
interlocking plate (4.8, Fig. 4) by 90º
- Using the nuts & bolts join the adjoining panels.
anticlockwise. (upto 15kV) OR
- Check to see whether the panels are truly vertical.
- Unscrew the front interlocking plate (for 24kV).
If necessary slacken the screws and seal the gaps
- Slowly move the truck away from the panel. The with rubber.
two ramps drop automatically enabling free &
- Move up the other panels in sequence, align them
easy withdrawal of the truck.
and bolt them together.
- Put back the ramps to normal position & close the
door.
4.5

2.8 Assembling the switchboard


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.
16.2

2.8.1 Bolting the panels together


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
16.3
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

16.1 16.4

16.1. Breaker Compartment door


16.2. Upper metallic shutter
16.3. Lower metallic shutter
16.4. Heater
4.5 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)
1. Brush the contact faces criss-cross wise until
17.1 bright, & wipe using a clean cloth. (applicable only
5.1 for bare Aluminium Busbars)
2. Square neck, round head, coach bolts are used for
6.2
busbar joints. These bolts do not rotate in their
slots & hence can be tightened from one side.
Recommended torque is 70 Nm.
17.2
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.
16.4 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
17.3
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
5.1. Upper Contact Bushing
17.1. Fixed Contacts (Upper) The main earth bars of the transport units must be
6.2. Lower Contact Bushing linked together. One of the two parts to be bolted
17.2. Fixed Contacts (Lower) together is already fitted with a link. This must be
17.3. Truck earthing Srip undone, passed through the partition and bolted to
16.4. Space Heater the two adjacent earth bar sections. The cover on the
side wall should be properly adjusted after joining the
Fig 17: View into circuit breaker compartment with shutter earth bars.
held open

2.9 Making HV Cable connections


2.8.2 Fixing the Switchboards to the
Foundation The cable connection pieces are provided with Hex.
Headed bolts M16 with washers., spring washers &
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 18.1 18.2
30 mm x 30 mm cutout) or drill the appropriate holes 6.1 6.6
in the foundation rails (false floor).
6.1. Earth Busbar 18.1. Extension Links
Insert shims between the foundation and the bottom
18.2. Eathing Strip (from CB 6.6. Bottom Covers
rails near the cutouts. chamber)
Tighten the screw without distorting the panels.
Fig 18: Earth Busbar Assembly

15
hex. Nuts for mounting the cable lugs of the - the core spacing on three core cables and the anti-
conductors. magnetic clips on single-core cables.
Three part bottom cable cover is supplied fitted with
the switchboard. Of these, the outer most cover has 2.11.2 Checking the Bolted Joints
to be removed & cutouts to be made of the size as
- Check the power and auxiliary circuit connections
per the instructions given by cable kit manufacturer.
of the switching devices at random. Examine all
the terminal block connections, making sure that
2.10 Earthing the Switchboard the blocks are correctly labeled and replace any
missing labels by referring to the circuit diagram.
Connect the earth terminals of at least one or two
panels to the station earth. This could be done to suit - The torque values of all the busbar joints must be
the local guidelines. Termination facility for earth checked
connection is provided on the earth busbar mounted
in the cable chamber. 2.11.3 Cleaning the Switchboard
- Clean all the post insulators, Bushings and Busbars
2.11 Other work to be carried out
in all the compartments using soft dry cloth.
Do not use any abrasive chemicals or detergents to
2.11.1 Checking the HV Connections
clean installed parts.
On all HV cables, check
Use only distilled water if necessary. Ensure that all
- the bolts for tightness parts are dried up before applying any voltage.
- the sealing and earthing

16.2

16.3

19.2 19.1 19.3

16.1 2.5
16.2, 16.3. Shutters
19.1. Shutter operating rod
19.2. Roller Guide Angle 16.1. Breaker compartment Door
19.3. Truck guide 2.5. Breaker Truck

Fig 19: View inside circuit breaker compartment without Fig 20: Insertion of trolley in the panel
withdrawable truck.

16
2.11.4 Inserting the withdrawable parts 2.11.5 Protecting the panels against
environmental effects
- open the front door (16.1, Fig. 20)
(a) Damaged sections of the paint finish may only be
- put down the ramps (4.7, Fig. 4)
touched up with original paint.
- place the breaker truck in front of the
(b)Fit the parts supplied to protect against the ingress
corresponding panels.
of reptiles. Check in case they are removed during
- Transfer the truck inside the panel and push it as installation.
far as it will go.
(c) Close all the doors & covers properly.
- Fix the racking mechanism / interlocking plate to
(d) Any opening that is left open after installation
structure frame by using lift & turn levers
should be closed & sealed to make it truly
(upto 15kV) & by using bolts (for 24kV)
verminproof.
- Fix the ramps back in the position
- Close the door (16.1, Fig 20) 2.12 Interpanel Wiring
- Insert all other drawout trucks in the same The wire have been left loose in the LV compartment
manner. of certain panels.
These wires must be connected from panel to panel
as per approved wiring diagrams.

17
3. Putting the switchgear into service
7.1
For details of operation refer section 4

3.1 Test operations

3.1.1 With door open


- 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)
4.3
- Open & close the breaker several times.
4.12

21.1

21.6
4.11 4.12 7.1 4.3
21.8

21.4

4.11 21.2 21.3 21.5

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 “
21.5 21.6 16.1 21.7 21.2
Tripped - “ O “
21.3 21.4
21.4. Opening for Double Bit Key for locking the transfer
operating mechanism
4.3. Viewing window for truck position 21.5. Opening for racking handle for racking the breaker truck
4.11. Opening for charging handle for charging the breaker 21.6. Opening for defeating interlock
closing spring 21.8. Bolts for door locking
4.12. Trip mechanism for operating the circuit breaker in the
connected position.
Fig. 21a: Opening Elements (for 24kV Panel)
7.1. LV compartment door
16.1. Breaker compartment door
21.2. ON & OFF Push Button (On HT Door)
- Pull off the LV plug. Charge the breaker closing
21.3. Window for the indicators of the withdrawable part spring by hand (refer clause 4.2)
- Number of operations (Operation Counter) - Operate the circuit breaker
- Closing Spring of the circuit breaker
- Charged - Lable with spring symbol - Refit the LV cable Plug.
- Discharged - Blank Lable
- Indicator for circuit breaker switching status
3.1.2 With door closed
- Circuit Breaker Closed - “ I “
Tripped - “ O “ Each switchpanel should be tested as follows:
21.4. Opening for Double Bit Key for locking the transfer
operating mechanism – Transfer the withdrawable truck to the
21.5. Opening for racking handle for racking the breaker truck disconnected position (see 4.1).
21.6. Opening for defeating interlock
21.7. Door Handle – Switch ON the auxiliary and control supply.

– Transfer the withdrawable part to the connected


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

18
– Open and close the breaker as long as no high The Hand Crank for transferring the truck is also
voltage is applied. suitable for all M8 bolts.

– Without using force check all mechanical and


electromechanical interlocks for satisfactory 3.3 Revising the Circuit diagrams
functioning. Check to see whether the switching If circuits have to be modified during installation the
states are indicated correctly in the control room. existing circuit diagrams are marked up. When work
has been completed make sure that the original
– Check whether the position of the withdrawable
diagrams are revised.
truck is indicated correctly (if the appropriate
position switches are fitted refer to the circuit
diagrams). 3.4 Space Heaters
For panels installed in humid atmosphere, space
3.2 Checking the Accessory Items heaters are fitted in the circuit breaker & cable
compartments. The thermostat controlled heaters
The accessory items required must be easily available should be switched “ON” before taking the panels into
in the Switchgear Room or an adjacent room. They service. The thermostat shall be set to cut off supply
include one Hand Crank for transferring the truck and to heaters at about 5º higher than the maximum
for charging the breaker closing spring, a Double Bit ambient temperature.
Key for locking the hand-operating mechanism, the
basic circuit diagram, Operating Instructions, Castell Heaters must always be kept “ON” in all the conditions
Lock Key (optional) and Earthing Switch Handle (even during maintenance)
(Optional)

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:

Each row of cubicles is provided with brief operating - Make sure that the circuit breaker is open, the LV
instructions. Refer to fig. 22. plug(3.3, fig. 3) and socket connector has been
put together and lock it. The breaker compartment
door is closed.
4.1 Withdrawable truck
- The castell key can be re,moved in this position
also for any interlocked operations which are to be
4.1.1 Positions of the withdrawable truck
performed with circuit breaker in open position.
Refer clause 1.2.2 for Circuit breaker Chamber
- Fit the hand crank (8.2, fig. 8)to the hexagon
shank in opening (21.5, fig. 21) turn it clockwise
• Service position(connected position)
as far as it will go and pull it off.
The circuit breaker is connected with the busbars and
- Insert the castell key if it was removed for
the outgoing circuit Auxiliary circuit is connected
interlocked operations. Turn the key clockwise
through LV plug and socket.
through 90 degrees from position “Manual
Racking” to “Connected position(locked)” and pull it
• Test position
off.
The circuit breaker is disconnected from the busbars
and the outgoing circuit. Segregation as specified in
4.1.3 Transferring the withdrawable part from
IEC 60298 is maintained. The LV circuits are
the connected position to the test/
connected through LV plug and socket.
disconnected position manually
Disconnected position
4.1.3.1 Normal Operations
The circuit breaker is disconnected from the busbars
and the outgoing circuit. LV circuits are disconnected In brief
by pulling out the LV socket from the plug. 1st Step 2nd Step 3rd Step
- When the LV plug and socket are connected the Turn double-bit key Insert and Turn double-bit key
following functions can be carried out. turn hand
crank
• The breaker can be tested / operated, also from
as far it will
the control room. from by to go and pull from by to
• The breaker compartment door can be opened. it of

• Functions such as ON / OFF indication and 90° 90°


electrical interlocks can be tested.
- When the LV plug and socket are disconnected. Fig. 23b
• The breaker compartment door cannot be
closed. Hence the truck cannot be inserted. In detail:
- Make sure that the circuit breaker is open.
4.1.2 Transferring the withdrawable part from - insert the double bit key in lock (21.4, fig. 21) and
the Test/Disconnected Position manually turn it anti-clockwise through 90 degrees from
“connected position (locked)” to “Manual Racking”.
4.1.2.1 Normal operation The hexagon shank opening (21.5, fig. 21).is now
accessible. The hand racking mechanism is
In brief: unlatched.
1st Step 2nd Step 3rd Step - Fit the hand crank (8.2, fig 8) to the hexagonal
Turn double-bit key Insert and Turn double-bit key
shank in opening (21.5, fig. 21) turn it anti-
turn hand
crank
clockwise as far as it will go and pull it off.

as far it will - Turn the double-bit key anti-clockwise through 90


from by to go and pull from by to degrees from the position “Manual Racking” to
it of “Disconnected position (locked)” and pull it off.
Opening (21.5, fig. 21) is now closed.
90° 90°
The hand racking mechanism is now locked.
Fig. 23a

21
4.1.3.2 Castell Key Operations (Optional) 4.2 Circuit-breaker operating mechanism

1st Step 2nd Step 3rd Step


The operating mechanism is of the stored energy
Turn castell key Trun castell key type. For electrically operated breakers, motor
automatically charges the closing spring after each
as far it will switching operation. If the motor supply should fail
from by to go and pull from by to
the closing spring can also be charged by hand. The
it of
tripping spring is charged each time the breaker is
90° 90° closed.

Fig. 23c 4.3 Circuit-breaker Operation

In detail:
4.3.1 Charging the closing spring by hand
- Make sure that the circuit breaker is open. • Procedures
- Turn the castell key (which is trapped in the If the breaker compartment door
mechanism) anti-clockwise through 90º from
“Connected position (locked)” to “Manual Racking”.
is closed (connected is open (disconnected
- In this position the castell key can be removed for position) turn plate position) fit the hand
any interlocked operations which are to be (21.6, fig. 21) so that it crank directly to the
performed with circuit breaker in open condition. clears opening (21.7, breaker operating
The hexagon shank opening(21.7,fig.21)is now fig. 21) insert the hand mechanism in opening
accessible. The hand racking mechanism is crank and fit it into the (21.7, fig. 21).
unlatched. breaker

- Fit the hand crank (8.2, fig.8) to the hexagonal


shank in opening (21.5, fig.21) turn it anti- • Operating Mechanism
clockwise as far as it will go and pull it off.
- Turn the crank until the symbol “spring charge”
- Insert the castell key if it was removed for appears in viewing window (21.3, fig.21) on
interlocked operations. Turn the double-bit key indicator. The operator is not at risk if the motor
anti-clockwise through 90 degrees from the supply recovers,because the hand crank free-
position “Manual Racking” to “Disconnected wheels and detaches in the anti-clockwise
Position(locked)” and pull it off. direction.

- The castell key can also be removed in this - Pull the crank off.
position to facilitate the opening of the HT
compartment door and / or other interlocked 4.3.1.1 Breaker ON and OFF
operations.
4.3.1.2 Mechanically (locally by means of push
4.1.4 Disconnecting the LV Plug button)
- Transfer the withdrawable part to the • In the connected position :
disconnected position(in accordance with clause Trip mechanism (4.12, Fig. 4 & 21) as far as it will
4.1.3) and lock it. go, hold it there, press buttons “ON” and “OFF”
- Open the breaker compartment door (refer clause (21.2, Fig 21) and then release the grip.
4.6.1). • In the disconnected position with the door closed :
- Unlock the LV plug (3.3, fig. 3) and LV socket (4.5, Press buttons “ON”and “OFF” (21.2, Fig 21) on the
fig. 4 & 16) by turning down the clip. breaker compartment door.
- Pull off the plug and attach it to the holder (4.9, • In the disconnected position with the door open :
fig. 4) which is fixed to the door. Press buttons “ON”(4.14, Fig 4) and “OFF” (4.15,
Fig 4) on the breaker truck
4.1.5 Connecting the LV Plug
4.3.1.3 Electrically (from the control room or
- Put the LV plug (3.3, fig.3) and LV socket (4.5,
locally)
fig. 4 & 16) together and lock it with the clip.
by means of push button/switches in the control room
- Close the breaker compartment door (refer clause or on the LV compartment door. If the control supply
4.6.2). 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.
24.1
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 Earthing

4.5.1 Earthing of Busbars and Cables


(Side view)
4.5.1.1 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.

4.5.1.2 Earthing of Cables with conductors


- 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.
24.1. Fixed Contacts (E switch)
- Close the rear cover and bolt it firmly. 24.2. Moving Contact (E switch)
24.3. Earthing Switch Shaft
- Remove the warning plates. 24.4. Operating Link
6.1. Earthing Busbar

Fig 24: Earth switch Arrangement on cable side

23
4.5.2 Earthing of Busbars or cables with a 4.5.3 Earthing the Busbars or Cables with
Drawout Truck Earthing Switch
Separate drawout Trucks can be supplied optionally
for busbar and cable earthing. In case fault making 4.5.3.1 Earthing the Busbars with Earthing
capacity is required, a circuit breaker is mounted on Switches
such drawout trucks.
- Switch off the supply to the main busbars.

• Procedure - Ensure that the supply to the main busbars cannot


be switched ”ON” from remote points.
- Remove the circuit breaker or the link drawout
truck from the panel where earthing is to be done - In case the electro-magnetic interlocks, ensure that
(refer clause 2.8.1) all the interlocking conditions are satisfied.
Otherwise the earthing switch cannot be closed.
- Insert the desired earthing drawout truck i.e. cable
or busbar earthing drawout truck in the panel - Close the earthing switch by inserting the earthing
(refer clause 2.11.4) switch handle in position and turning it in the
clockwise direction till stop. Withdraw the handle.
- Connect the LV plug and socket (refer clause 4.1.5)
- Place the warning plates at all necessary locations.
- Close the panel door (refer clause 4.5.2)

- Ensure that there is no voltage available on the


4.5.3.2 Earthing Cables with Earthing Switch
parts to be earthed when earthing drawout truck
(fig.24)
without making capacity is used.
- Move the truck to test / disconnected position.
- Transfer the drawout unit to the connected Earthing switch cannot be closed until this position
position (refer clause 4.1.3). In case the earhting is reached.
drawout truck has an electro-mechanical interlock
unit mounted on it, the transfer is possible only - Ensure that the cables cannot be energized from
after all the interlocking conditions are satisfied. the other end.

- Lock it in the connected position. - Follow the procedure for Busbar earthing switch.

- In case the drawout truck has a circuit breaker


mounted on it switch “ON” (refer clause 4.2 & 4.3). 4.5.3.3 Disconnection of Earthing Switches

- Place the warning plates at all necessary locations. - Insert the earthing switch handle in position. Turn
it in the anti-clockwise direction till stop. Withdraw
the handle.
4.5.2.1 Disconnection of Earthing Drawout truck
- Remove warning plates from all the locations
- Switch “OFF” the breaker in case of earthing
drawout truck with making capacity (refer clause
4.3). 4.5.4 Earthing the Busbars or Cables with Truck

- Transfer it to the disconnected position (refer


4.5.4.1 Earthing the Busbars with Bus Earthing
clause 4.1.3)
Truck
- Disconnect the LV plug (refer clause 4.1.4) - Switch off the supply to the main busbars.
- Open the HT compartment door (refer clause - Ensure that the supply to the main busbars cannot
4.6.1) be switched ”ON” from remote points.
- Remove warning plates. - Rack ou the breaker to diconnected position.
- Insert the original drawout truck of the circuit - Diengage the LV plug & socket.
breaker or link drawout truck in the panel (refer
clause 2.11.4) - Drawout the nreaker truck completely out of the
panel.
- Connect the LV plug (refer clause 4.1.5)
- Insert the Bus earthing truck in the panel to
- Close the door (refer clause 4.5.2) diconnected position.
- The original drawout truck is now ready for - Connect the LV plug to socket.
transfer to connected position.
- 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 - Unscrew the door closing bolts of HT compartment
Truck door. The bolts are captive (for 24kV Panel)
- Move the truck to test / disconnected position - Open the door.
- Ensure that the cables cannot be energized from
the other end. 4.6.2 To close the door
- Follow the procedure for Busbar earthing switch. - Shut the door.

- Rotate the handle clockwise till it gets closed. (For


4.5.4.3 Link Type Eathing Truck upto 15kV)
- Switch off the supply to the main busbars. - Tighten the captive screw in case of bolted door.
- Ensure that the supply to the main busbars cannot
be switched ”ON” from remote points. 4.7 Door to LV Compartment
- Ensure that the cables cannot be energized from
the other end. 4.7.1 To open the door

- Follow the procedure for Busbar earthing switch. - Rotate the turnlocks with a key in anti-clockwise
direction or unscrew the captive bolts in case of
bolted door.
4.6 Breaker Compartment Door
- Open the door.
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. 4.7.2 To close the door

The door interlock can be defeated as described - Shut the door.


under clause 5.5 below. - Rotate the turnlock in clockwise direction or
tighten the bolts in case of bolted door.
4.6.1 To open the 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


Danger board, make sure that it cannot be made live again,
check its isolated state and earth and short-circuit the
Precautions for Safe Working
feeders and where applicable, the busbars. Adhere to
all regulations and safety measures, maintain and
Maintenance, repair and subsequent conversion or
service the built-in equipment, e.g. circuit-breakers,
extension work shall be carried out only by
voltage transformers, current transformers, relays,
specially trained personnel in accordance with the
meters, protective devices, etc. in accordance with
operating instructions and/or special conversion
their operating instructions.
instructions. Training and information sessions for
personnel will be provided by the competent Before removing the front plate of the breaker
Siemens department. operating mechanism discharge the closing and
tripping springs. Follow the instructions given on the
Before starting any work on the panels references
mechanism housing.
must be made to local regulations for high voltage
switchgear. Switch off the power supply, close/ Only standard tools are required. Put the switchgear
open the breaker manually to ensure that the back into service as described under clause 3 above.
closing spring of the breaker is discharged. Then Service the switchgear at shorter intervals if the air
rack out the truck from service to test position. is very moist or full of dust or is otherwise
polluted. The cause of any disturbance or short-
Control terminals in the LV compartment must not
circuit must be determined immediately and
be touched if the control supply is not
damaged parts replaced, irrespective of whether an
disconnected.
inspection is due or not.
Non observance will result in death and / or severe
personnel injury or substantial damage to
5.2 Cleaning
property.

5.1 Inspection Schedule


Caution
- Each year For Safety
• Make a general visual check.
For safety reasons, cleaning of panels shall be
• Check whether the accessories are complete taken up only when the shutdown of Main &
and in proper order. Auxilliary Power supply is taken, the breaker is in
the open state, closing spring of the breaker is
• Clean and lubricate the wheels as well as
discharged & the breaker truck is removed out of
moving parts of the truck and interlocking
the panel.
plate.

• Relays to be tested for their functionality. Cleaning Agents

• Clean the Panels (refer clause 5.2) Perchlorethylene, 1.1.1 trichloroethane, small
brushes, dusters and vacuum cleaner for sheet metal
parts.
- Every five years
• Transfer the withdrawable truck to the Note:
disconnected position.
Trichlorethylene, perchloroethylene and
• Test-operate the circuit-breakers. tetrachloroethylene have a harmful effect on cast
resin parts and must not come into contact with
• Remove the withdrawable trucks (refer clause them.
2.7.1) and carry out all maintenance work, also
on the switching devices. Cast resin parts should be cleaned with distilled water
only.
• Clean the panels (refer clause 5.2) and check
the connections. Silver plated and other contact surfaces to be cleaned
with clean cloth.
• Lubricate all bearing surfaces, bearings and
articulated joints.

• Reinsert the withdrawable trucks.

26
5.3 Lubrication 5.5 Defeating the Door Interlock of HV
Compartment
Immediately after cleaning:
Caution : Take utmost care while defeating any
- Lubricate the isolating contacts and their mating
interlock as the defeat operation leads to access to
contacts with neutral grease.
the areas / parts which are likely to be live.
- apply a film of neutral grease to the bearings and
articulated joints of the operating mechanisms, to 5.5.1 Drawout Unit in Connected Position
the withdrawable parts and shutters, and to the
door hinges and locks. The breaker compartment door interlock should only
be cancelled if the truck cannot be transferred to the
disconnected position and the situation cannot be
Recommended neutral greases are:
cleared in any way.
(i) SERVOGEM 2 (multipurpose) of Indian Oil
- Switch off the circuit-breaker.
Corporation make
- Make sure that the busbars are not live.
(ii) Multipurpose grease ‘H’ of Hindustan Petroleum
Ltd. make - Insert a small screw driver in the opening (21.6,
fig. 21) and screw-in the grub screw visible
(iii) Any other chemically neutral grease which can through the opening.till it falls out inside the
withstand temperature up to 15° C. panel.
- Open the door by turning the door handle.(refer
5.4 Replacement Parts clause 4.5.1).
Items such as post insulators, bushings mating
contacts, measuring instruments, current 5.5.2 Drawout Unit in disconnected position
transformers etc., can be replaced. If replacement is - Press the interlocking lever on interlocking plate by
likely to prove difficult ask the nearest Siemens hand.
representative in good time for deputation of suitable
personnel. The representative will also assist you in - Insert the double-bit key in lock(21.4, fig.21) and
deciding what spare parts to keep in stock. turn it (locked) to “Manual Racking”.
- Fit the hand crank (8.2, fig. 8) to the hexagon
When ordering spare parts and units give the
shank in opening turn it clockwise as far as it will
following details:
go and pull it off(21.5, fig.21).
- Type and Serial No. of the switchboard (see
Turn the double-bit key clockwise through 90º from
nameplate).
position “Manual Racking” to “Connected
- Exact description of the unit or part, referring to Position(locked)” and pull it off.
the appropriate operating instructions where
applicable, or to a drawing; sketch or circuit 5.5.3 Restoring the Door Interlocks
diagram. Use reference list of items in Section 8.
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
Danger interlocks can be restored by following the
procedures in clause 5.5.1 in the reverse sequence.
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.

27
6. Disposal of Product steel, copper, aluminium, rubber, PVC, cast-resin &
glass-fibre-reinforced materials to be segregated
This product is environmentally compatible. properly.
The following materials have been used to make up The Re-cyclable materials like Steel, Copper,
the device : Steel, Copper, Aluminium, Cast-resin Aluminium can be reused.
glass-fibre-reinforced thermoplastics, rubber,
porcelain, greases & similar materials. PVC is used as Non cyclable materials like Cast-resins, glass-fibre-
an insulation material for control wires. reinforced etc can be broken in to pieces & can be
used as secured land filling materials.
In disposal, priority must be given to re-use of the
materials which can be recycled. Rubber being biodegradable material must be
recycled through authorized contractors.
In as-supplied-condition, the product does not
incorporate any hazardous substances. PVC material should not be burnt as they may release
Halogenated hydrocarbons which can affect the
In operation, the product does not emit any ozone layer. Therefore, PVC must be recycled through
hazardous materials or gases. authorized contractors.
During disposal of the product, care must be taken to Local Siemens office can answer any questions
dismantle as far as possible in more environmentally concerning disposal.
accepted way as Recyclable & Non-cyclable scraps i.e

28
7 Summary of Important Instructions-

DOs DON’Ts

During Installation & Commissioning Stages :- (1) Do not leave any equipments or tools in the
(1) Brush the contact surfaces properly before panel.
bolting busbars. Also grease the joints & (2) Do not put hands or tools in operating
apply proper torque on the bolts. mechanism when electrically operated.
(2) Check rated voltages of equipments such as
motor, closing & tripping releases mounted (3) Do not operate the breaker during cleaning
in the operating mechanism with the process.
available auxiliary supply to be connected (4) Do not use any other chemical or grease for
to these equipments in the substation. clearing or lubricating other than mentioned
(3) Ensure that all the foundation bolts are in these instructions.
tightened along with the square washer and
also seal of all control and power cable
cutouts to prevent vermin entry.

During service life of the panel-


(4) Keep door & covers firmly closed to prevent
entry of dust, moisture, insects etc.
(5) Ensure spring charging handle & manual
handle are available easily.
(6) Decide maintenance schedule based upon
(a) no. of short circuit operations,
(b) frequency of breaker ON/OFF operations,
(c) pollution level (d) humidity, etc.
(7) Isolate & earth the breaker before carrying
out maintenance & ensure it is in OFF
position & springs are discharged
completely before cleaning.
(8) Ensure that the shutters are close and pad
locked before starting the maintenance or
cleaning of the panels.
(9) 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.
(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 Additional Information

8.1 Reference List of Items

2.1 Circuit Breaker Compartment Fig 2 6.2 Bushings of lower mating contact Fig 6, 17
2.2 Cable & CT Compartment Fig 2 6.3 Current Transformer Fig 6
2.3 Busbar Compartment Fig 2 6.4 Cable Connection Pieces Fig 6
2.4 Low Voltage Compartment Fig 2 6.5 Wiring Cover Fig 6
2.5 Breaker Truck Fig. 2, 20 6.6 Gland Plate for Poer Cables Fig 6, 18
3.1 Vacuum Interrupter Fig 3 7.1 LV Compartment Door Fig 7, 21, 21a
3.2 Insulating Switching Rod Fig 3 8.1 Charging Handle Fig 8
3.3 LV Socket on truck Fig 3 8.2 Cranking Handle Fig 8
3.4 Contact Arm Fig 3 8.3 Double Bit Key Fig 8
3.5 Truck Handle Fig 3 8.4 Rod Trap Key Fig 8
3.6 Cast Resin Insulator Fig 3 8.5 Earthing Switch Handle Fig 8
3.7 Guide Roller on truck Fig. 3 10.1 End Covers Fig 14
3.8 PP Tube Fig. 3 10.2 Pressure relief channel for
cable termination compartment Fig 14
3.1.1 Pole Flange (Upper) Fig 3.1
10.3 Pressure Relief flaps Fig 14
3.1.2 Pole Flange (Lower) Fig 3.1
16.1 Breaker Compartment door Fig 16, 20,
3.1.3 PT on the truck Fig. 3.1
21, 21a
3.2.1 Mechanical ‘ON’ Push Button Fig. 3.2
16.2 Upper metallic shutter Fig 16, 19
3.2.2 Mechanical ‘ON’ Push Button Fig. 3.2
16.3 Lower metallic shutter Fig 16, 19
3.2.3 Spring Charging Opening Fig 3.2
16.4 Space Heater Fig 16, 17
3.2.4 Spring Charge Indication Fig 3.2
17.1 Fixed Contacts (Upper) Fig 17
3.2.5 Mechanical ‘ON & ‘OFF’ Indication Fig 3.2
17.2 Fixed Contacts (Lower) Fig 17
3.2.6 Mechanical Operation Counter Fig 3.2
17.3 Earthing Strip Truck Fig 17
3.2.7 Earthing Pin for Truck Fig 3.2
18.1 Extension Links Fig 18
4.1 Door Locking hinge pin Fig 4, 21
18.2 Earthing strip from CB Chamber Fig 18
4.2 Door close interlock Fig 4
19.1 Shutter operating rod Fig 19
4.3 Viewing window for truck position Fig 4
19.2 Roller Guide Angle Fig 19
4.4 Viewing window for Spring charge
19.3 Truck guide Fig 19
Indicator and Mechanical Counter Fig 4
21.1 Ball grip Fig 21a
4.5 LV connection Plug Fig 4
21.2 ON & OFF Push Button
4.6 Drive Mechanism housing Fig 4
(On HT Door) Fig 21, 21a
4.7 Ramp Fig 4
21.3 Window for the indicators of
4.8 Interlocking Plate (Drive Box) Fig 4 the breaker truck Fig 21, 21a
4.9 Holder for LV Socket Fig 4 21.4 Opening for Double Bit Key Fig 21, 21a
4.10 Clip for locking LV Plug to Breaker Fig 4 21.5 Opening for the cranking handle
4.12 Trip mechanism for operating the for racking the breaker truck Fig 21, 21a
breaker in service position Fig 4 21.6 Opening for defeating interlock Fig 21, 21a
4.13 Rod Lever Fig 4 21.7 Door Handle Fig 21
5.1 Bushings of upper mating contact Fig 5, 17 21.8 Door locking bolts (for 24kV Panel) Fig 21a
5.2 Cast resin insulator Fig 5 24.1 Fixed Contacts (E. Switch) Fig 24
5.3 Feeder connections Fig 5 24.2 Moving Contact (E. Switch) Fig 24
5.4 Busbars Fig 5 24.3 Earthing Switch Shaft Fig 24
6.1 Main Earth Busbar Fig 6, 18 24.4 Operating Link Fig 24

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 Jointing Torques

Sr. No. Type of Joint Torque (Nm) ± 10%


Size of Bolt M8 M10 M12 M20
Property Class 6.6 8.8 8.8 8.8
1 Steel to Steel 32 65 115 –
2 Steel with Insulator 16 32 77 170
3 Busbar Joint 20 40 70 –
4 Busbar with Steel 20 40 70 –

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
Siemens Ltd. 'Product development is a continuous process. Consequently, the 030001
data indicated in this Booklet is subject to change without prior
PTD-03-152-015
notice. For the latest information please contact our Sales Offices.'
This replaces PTD-03-152-003

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