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Chandrashekar Shriyan 27-10-2006

N02

WHY THE SAME DOCUMENT IS SUBMITTED


WITH DIFFERENT DOCUMENT Nos.?
s
PLEASE REFER DOC. No. 25194-JGZ-ES0L01-MA-000-B02-0001
FOR COMMENTS
Op er at io n an d M ai n t en an ce
In st r u ct io n s

Air In su l at ed
M et al-Clad Sin g l e Bu sb ar
M ed iu m Vo lt ag e Sw it ch g ear
Typ e 8BK80
On w ithdraw able circuit -breaker t ruck upto 24 kV
Table of Con t en t s
Page Nos Page Nos
1. Tech n i cal Descri pt i o n 4. Op erat io n s
1.1 General 3 4.1 Wit hdraw able Truck 21
1.1.1 Applicat ion 3 4.1.1 Posit ions of t he w it h draw able t ruck 21
1.1.2 Specific St andards 3 4.1.2 Transferring the Wit hdraw able Part from t he
1.1.3 Am bient Tem perat ure an d Hum idity 3 test / disconnected posit ion m anually 21
1.1.4 Site Alt itude 3 4.1.2.1 Norm al Operat ions 21
1.2 Design Feat ures 5 4.1.3 Transferring th e Wit hdraw able Part from
1.2.1 Sw it chgear Layout 5 th e Con nected posit ion t o t he test /
1.2.2 Circuit Breaker Com part m ent 5 discon nected posit ion m anually 21
1.2.2.1 Service Posit ion 6 4.1.3.1 Norm al Operat ions 21
1.2.2.2 Test Posit ion 6 4.1.3.2 Cast ell Key Operation (Opt ional) 22
1.2.2.3 Isolated Posit ion 7 4.1.4 Rem oving t he LV Plug 22
1.2.2.4 Rem oved Posit ion 7 4.1.5 Connect ing th e LV Plug 22
1.2.3 Busbar Com part m ent 7 4.2 Circuit Breaker Operat in g M echan ism 22
1.2.4 Cable & CT Com partm ent 7 4.3 Circuit Breaker Operat ion 22
1.2.5 Compart m ent for Low Volt age Equipm en t 7 4.3.1 Chargin g the closin g spring by hand 22
1.2.6 Accessory Item s 7 4.3.1.1 Breaker ON and OFF 22
1.2.7 Range of Panels 7 4.3.1.2 M echanically 22
1.2.7.1 Feeder Pan els 8 4.3.1.3 Electrically 22
1.2.7.2 Bus Sect ion alizer Panel 8 4.3.2 Sw itch ing St ate Indicat ion 23
1.2.7.3 M etering Panel 8 4.4 Line PT w it h Draw out Fuse M echanism 23
1.2.7.4 Panel w it h I/C & O/G Con nect ion s 8 4.5 Eart hing 23
1.2.8 General Const ruct ion 8 4.5.1 Eart hin g of Busbars and Cables 23
1.2.9 In terlocks 8 4.5.1.1 Direct Earthing of Busbars w it h Conductors 23
1.3 Technical Dat a 8 4.5.1.2 Eart hing of Cables w ith Con duct ors 23
1.4 Ratin g Plate 9 4.5.1.3 Rem oving Eart hing Conn ect ions 23
2. In st allat ion 4.5.2 Eart hin g of Busbars / Cables w it h a
2.1 Foun dat ion 10 Draw out Truck 24
2.2 Elect rical Service Room Dim ensions 11 4.5.2.1 Disconnect ion of Eart hing Draw out Tru ck 24
2.3 Tran sport ation Units 11 4.5.3 Eart hing t he Busbars / Cables w ith
2.4 Packing 13 Earth ing Sw it ch 24
2.5 Unloading 13 4.5.3.1 Eart hin g Busbars w it h Earth ing Sw it ch 24
2.5.1 Handling Equipm ent Required 13 4.5.3.2 Earthing Cables w it h Earthin g Sw it ch 24
2.5.2 Procedure 13 4.5.3.3 Disconnection of Earthing Sw it ch 24
2.6 Exam ining t h e Sw it chgear against dam ages 13 4.5.4 Eart hing of Busbars or Cables w ith Truck 24
2.6.1 Storage 13 4.5.4.1 Eart hing of Busbars w it h Bus Earthin g Truck 24
2.7 Transferring t he Transport Units 13 4.5.4.2 Eart hing of Cables w ith Cable Eart h ing Truck 25
2.7.1 Rem ove t h e t ruck f rom t he panel 14 4.5.4.3 Link Type Eart hing Truck 25
2.8 Assem bling t he Sw it chboard 14 4.6 Breaker Com part m en t Door 25
2.8.1 Bolt ing t he Panels t ogether 14 4.6.1 To Open t he Door 25
2.8.2 Fixing t he Sw itch board t o t he Foun dat ion 15 4.6.2 To Close The Door 25
2.8.3 Bolt ing th e Busbars t oget her 15 4.7 Door to LV Com part m ent 25
2.8.4 Bolt in g the M ain Eart h Busbar 4.7.1 To Open t he Door 25
section t oget her 15 4.7.2 To Close t he Door 25
2.9 M akin g HV Cable Connect ions 15
2.10 Earthin g of Sw itchboard 16 5. M ain t en an ce
2.11 Oth er Work t o be carried out 16 5.1 Inspect ion Schedule 26
2.11.1 Checking th e HV Connect ion 16 5.2 Clean ing 26
2.11.2 Checkin g the bolt ed Joint s 16 5.3 Lubricat ion 27
2.11.3 Cleaning t he Sw it chboard 16 5.4 Replacem ent Part s 27
2.11.4 Insert ing th e w ith draw able parts 17 5.5 Defeatin g t he Door Interlock of HV
2.11.5 Protecting th e panels again st Environm en t al Com partm en t 27
ef fects 17 5.5.1 Draw out Unit in Connected Posit ion 27
2.12 Interpan el Wirin g 17 5.5.2 Draw out Unit in Discon nected Posit ion 27
5.5.3 Restoring t he Door Interlock 27
3. Pu t t i n g t h e Sw i t ch gear in t o Ser v ice
3.1 Test Operat ions 18 6. Disp o sal o f Prod u ct 28
3.1.1 With Door Open 18 7. Su m m ar y of Im p or t an t In st ru ct ion s 29
3.1.2 With Door Closed 18
3.2 Checking the Accessory It em s 19 8. Ad di t io n al In f o rm at io n
3.3 Revising t he Circuit Diagram 19 8.1 Reference list of It em s 30
3.4 Space Heaters 19 8.2 Jointing Torque 31

2
Warn in g
To En su re Per son n el & Produ ct Saf et y

This equipm ent carrries hazardous volt ages and


m oving m echanical part s t hat shall be controlled
rem otely.

Non observance of the safet y inst ruct ions w ill


result in death and / or severe personnel injury or
dam age to property & environm ent .

Only qualif ied personnel shall w ork on or around


this equipm ent af ter becom ing thoroughly fam iliar
w it h all w arnings, safety notices and m aintenance
Fig 1: Basic Circuit Diagram
procedures contained herein. The
com ponents labeled w ith t he tem perat ure of the air in the sw it chboard room .
Dan g er Sig n shall be rem oved only
At am bient tem peratures below -5°C prevailing for a
af t er ensuring that t he supply to the
longer period t he sw it chboard room has t o be heated.
live parts behind t hem is de-
energized & earthed. The air tem perature in t he panels should alw ays be
about 5°C above the am bient tem perat ure to avoid
Successful and safe operation of t his equipm ent is condensat ion. (Sw itch on t he heater against
dependent on perfect planning of the syst em , condensat ion!)
proper handling (t ransport, storage), inst allat ion,
The hum idity of upto 95% is perm issible.
operat ion and m aintenance.
If t he t ruck-type sw itchboard is exposed to a hum id
clim at e and rapid tem perat ure changes, t he
sw it chboard room has to be heated.
1. Tech n ical Descript ion

1.1.4 Sit e Alt it u d e


1.1 Gen eral
The rated insulat ing capacit y values (rated im pulse
8BK80 m et al clad sw it chgear is of .horizont al
w ithstand voltage, rated pow er frequency w ithstand
isolation & horizont al draw out t ype suitable for easy
volt age) 1 ) specif ied for t he equipm ent are, in
extension of sw itchgear in bot h direct ion for system
accordance w ith t he provisions of IEC Publicat ion 71,
volt age upto 24kV. The sw it chgear is designed for
based on st andard at m ospheric condit ions (1013 h
single busbar system & is fully com part m ent alized.
Pa, 20°C and 11 g/m 3 w ater content). i.e. sea level.
The design incorporates the set of interlocks for safe
The insulat ing capacity of an insulation in air
operat ion of sw it chgear.
decreases w ith increasing altitude as a result of
changes in t he air density. Standards prom ulgated by
1.1.1 App licat ion IEC and ot her disregard this decrease in insulating
The sw it chgear is suit able for use as dist ribut ion unit capacit y for alt it ude of up to 1000 m , i.e. t he
f or sw itching load at subst at ions of elect ric supply decrease of approxim ately 9% at t his alt it ude is still
com panies as w ell as for pow er st ations & indust rial perm issible.
plan t s. The standards provide no guideline for alt it udes of
m ore than 1000 m w it h respect t o insulation rat ings;
1.1.2 Specif ic St an d ar d s they leave t his up to an agreem ent betw een
m anufact urer and user.
The m et al clad m et al enclosed sw it chgear has been
t ype test ed as per all the requirem ents of IEC 60298 Our ow n recom m endat ion is as follow s:
"Specif icat ion for Rat ing & test ing of insulat ion of Since this m et hod used for rat ing insulation up to
elect rical Sw itchboards & sw it chgear for AC Volt ages alt itudes of 1000 m has proved to be sat isf actory, it
above 1 kV & conform s to t he st andards IS3427, should also be applied to higher alt it udes. The
IS12729. The Sw it chgear is supplied in ready alt itude correction factor a should therefore be based
assem bled condition. The Sw it chgear can be inst alled on t he insulat ing capacit y at 1000 m , w hich is low er
f ree st anding. by 9% (corresponding to 0.91 or 1/1.1) t han t he
capacit y at sea level.
1.1.3 Am b ien t Tem p erat u re an d Hu m id it y
The follow ing expression t hus applies for t he
Am bient t em perat ure is understood as t he select ion of the equipm ent :

3
Rated w it hst and volt age to be selected 2)
Required w it hst and volt age 2 )

1,1 · a
Exam p le:
Sit e altit ude above sea level .......................... 3000 m
Required im pulse w it hstand volt age .................. 75 kV
Correct ion factor a .............................................. 0 ,7 3
(according to Fig. 1.1)
Rated im pulse w ithst and 75 kV
= 93 kV
volt age to be selected Fig. 1.1 Relat ionship betw een the correct ion fact or "a" and
1.1 x 0.73
the site alt it ude
Sw it chgear w it h rat ed volt age of 15 kV, IEC List 2 Th e follow in g def initions apply:
(rat ed light ning im pulse w ithst and volt age of 95 kV) 1)
Rated w it hst and volt age2 ) = required value corresponding to
m eet s t his requirem ent. the provisions of IEC etc. for sea level.
With st and volt age 3 ) = act ual value for the given altitude
The act ual insulat ing capacit y at the site is t hen 2)
Rated light ning im pulse w ithst and volt age
3) 2) Rated pow er f requency w it hst and volt age
w ithst and voltage = a · rated w it hst and volt age of 3)
Lightning im pulse w it hst and voltage
the selected sw it chgear unit . Pow er f requency w it hst and volt age

2.4

2.1

2.2

2.5

2.3

2.1. Circuit Breaker com part m ent (HV Com part m en t) 2.4. Low Voltage com part m en t (LV Com part m ent)
2.2. Busbar com part m ent 2.5. Withdraw able Truck
2.3. Cable & CT com partm ent

Fig 2: Side view of sw itchgear 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 Interrupt er 3.2.1 M echanical `ON' Push But ton


3.2. Insulat ing Sw itchin g Rod 3.2.2 M echanical `OFF' Push Button
3.3. LV Plug on t he truck 3.2.3 Spring Chargin g Opening
3.4. Cont act Arm
3.2.4 Spring Ch arge Indication
3.5. Truck Handle
3.2.5 M echanical `ON' & `OFF' indication
3.6. Cast Resin Insulat or
3.7. Guide Roller on truck 3.2.6 M ech an ical Operat ions Count er
3.8. PP Tube 3.2.7 Eart hing for the Truck

Fig 3 : Wit h draw able Tru ck w it h Circuit Breaker Fig 3.2: M echanical ON & OFF Push But tons

1.2 Desig n Feat u res

1.2.1 Sw it ch gear layo u t (Ref er Fig . 2)

3.1.1 M et al partit ions subdivide each panel int o


- Circuit breaker com partm ent (2.1)
- Cable & CT com part m ent (2.3)
- Busbar com part m ent (2.2)
- Low volt age com partm ent (2.4)
- Wit hdraw able Truck (2.5)
The outside covers are bolted to the f ram e and the
3.1.2
doors are hinged.

1.2.2 Circu it b reaker Com p ar t m en t


The circuit breaker com partm ent cont ains a
3.1.3
w ithdraw able truck w it h Vacuum circuit breaker or
Bus PT Truck. The breaker term inals are fit ted w ith
cont act arm s (3.4, Fig 3)
The w it hdraw able truck can be t ransferred bet w een
the service & test posit ions behind closed doors using
3.1.1 Pole Flange (Upper) a hand crank.
3.1.2 Pole Flange (Low er)
3.1.3 PT's on the t ruck

Fig. 3.1: Rear View of th e truck

5
1.2.2.1 Ser vice Po sit io n (Con n ect ed Posit ion )
The posit ion of a Withdraw able Truck in w hich it is
fully connected for it s intended funct ion. In t his
posit ion of t he t ruck, t he cont act arm s of t he circuit
breaker are connected t o t he busbars as w ell as to the
out going cables via the fixed m ount ed isolating
cont act s in the cubicle.

4.9 The t ruck is locked against w ithdraw ing.


The low volt age circuit is connected through the low
4.5
4.2 4.10 volt age plug & socket connect ion (3.3, Fig. 3 & 4.5,
4.3
Fig. 4).
4.12

4.4 4.6 1.2.2.2 Test Posi t io n


4.13
4.8 The posit ion of w it hdraw able t ruck in w hich an
isolating dist ance or segregat ion is est ablished in t he
m ain circuit & in w hich cont rol circuit s are connected.
In the test posit ion, the t ruck w ith t he breaker is
w ithdraw n so f ar bet w een busbars & out going cables
that t here is isolat ing dist ance according t o VDE 0670,
part 2 / 2.65. The truck is locked against m oving. The
4.7
4.1 low voltage circuit is connect ed through low volt age
plug connect ion (4.5, Fig. 4).
4.1. Door Lockin g h inge pin 4 .8. Int erlocking Plate The circuit breaker can be sw it ched for t esting & all
4.2. Door close interlock (Drive Box) funct ion s.
4.3. View ing w indow for truck 4.9. Holder for LV Plug
posit io n 4 .10. Clip for locking LV
6.2 6.3 6.4
4.4. View ing w indow for Plug to Breaker
Spring charge indicator 4.12. Trip m echanism for
and M ech anical Counter operat ing the breaker
4.5. LV Socket in ser vice posit ion
4.6. Drive M echanism h ousing 4.13. Rod Lever
4.7. Ram p

Fig 4: Wit h draw able Truck in Test Posit ion & door open

5.4

5.3

5.2
5.1

6.1 6.6 6.5

6.1. M ain Earth Busbar


6.2. Bushings for low er m at ing cont act
6.3. Current t ran sform er
5.1. Bushings of upper m atin g 5.3. Feeder connect ions 6.4. Cable connect in g pieces
co nt act 5.4. Busbars 6.5. Wiring Cover
5.2. Cast resin insulat or 6.6. Gland Plat e for Pow er Cables

Fig 5: Busbar Com part m ent Fig 6: Looking into Cable com partm ent

6
- Bushings w ith the m ating cont act s for t he low er
cont act arm s of t he w ithdraw able part (6.2)
- Cable t erm inat ion pieces (6.4)
- A sect ion of t he m ain earth bar (6.1)
- Current t ransform ers (6.3)
The cable t erm ination pieces are accessible f rom t he
rear.

1.2.5 Co m p ar t m en t f or Low Vo lt age Eq u ip m en t


(Ref er Fig 7)
This com part m ent cont ains all t he low volt age
devices (protect ive relays, M CB's, term inals, et c.,)
Indicators and relays are accom m odated in door
7.1 cutout s.

7.1 LV Com part m ent Door


1.2.6 Accessor y It em (Ref er Fig .8)
Fig 7: Looking int o LV com part m ent
Follow ing accessories are supplied w ith the
sw it chgear.
1.2.2.3 Di sco n n ect ed Posit io n (Isolat ed Po sit io n )
- Changing handle for charging the closing spring of
The posit ion of w ithdraw able t ruck in w hich an
t he vacuum circuit breaker (8.1)
isolating dist ance or segregat ion is est ablished in t he
circuit s of the w ithdraw able t ruck, the t ruck - Cranking handle for truck m ovem ent bet w een
rem aining m echanically at tached to the enclosure. service and test posit ioning (8.2).
In this position the t ruck is w ithdraw n as in test
- Double bit key for locking t he t ruck transfer
posit ion but t he LV plug is disconnected.
operating m echanism (8.3)
In the test & disconnected posit ion t he cont act arm s &
t heir m ating cont acts are separated by m et allic - Rod Trap key for LV com part m ent. (8.4)
shut t ers.
- Earthing Sw itch Handle (Opt ional). (8.5)

1.2.2.4 Rem oved Posi t ion


1.2.7 Ran g e o f Pan el s
The posit ion of w it hdraw able t ruck w hen it is out side
t he panel and electrically & m echanically separated Gen eral:
f rom it . Ram ps are provided at t he front bottom of the For a m et al clad enclosed sw it chgear there are
panel to w it hdraw t he truck out of the panel various panel m odules available. All t he panels are
sm oot hly. const ructed using ident ical part s as f ar as possible.
Drive Mechanism of t he t ruck is at t ached t o the
cubicle f ram e using Rod Lever. 1.2.7.1 Feed er Pan els (Fig 9a)

The Earthing st rip at the bott om of the breaker The feeder panels are suit able for input or out put of
com partm ent , along w it h the spring loaded pin elect rical energy.
provided at t he bottom of t he circuit breaker t ruck
ensures t he eart hing of t he t ruck in all t he posit ions.

1.2.3 Bu sb ar Com p ar t m en t (Ref er Fig .5)


The busbar com part m ent cont ains:
- The busbars (5.4)
- Bushings w it h t he m at ing cont act s for the upper
cont act arm s (5.1)
- Feeder Connect ions (5.3)
The M ain Busbars are m ounted on cast resin
insulators (5.2). The ends of t he sm aller M ain Busbars
are connected w it h the longer Busbar Links extendin g 8 .2 8.5 8.4 8 .3 8.1
f rom one panel to t he next. 8.1. Chargin g Handle 8.4. Rod Trap Key
8.2. Cranking Handle 8.5. Eart hin g Sw it ch
8.3. Double Bit Key Handle
1.2.4 Cab le an d CT com p ar t m en t (Ref er Fi g .6)
The Cable com part m ent cont ains: Fig 8: Accessories

7
Out going feeder panels w it h C.B. on t he truck are panels are interchangeable.Trucks are earthed
m ost f requent ly used. w ith panel in both test & service posit ions.
Alt ernat ively, t hese panels can also be equipped w ith - Out going cables can be earthed by m eans of
an isolating t ruck. m anually operated earthing sw it ch. (Opt ional)
- C.T.s are m ounted on stationery part in t he Cable
The panel is available w it h current t ransform er eit her
Ch am ber.
w ith earthing sw it ch or w it hout eart hing sw itch. The
eart hing sw itch is alw ays equipped w it h m anual - Line P.T.s are available w it h a draw out
drive. arrangem ent and w it h fuses.
- Fut ure extension of exist ing sw it chboard is
1.2.7.2 Bu s Sect ion alizer Pan els (Fig 9b ) possible
In bus sect ionalizing panel one panel is used for t he
truck w ith t he C.B. (alt ernat ively, an isolat ing t ruck) & 1.2.9 In t er lock s
one panel for connection of busbars to the t op. Bot h
The positions of t he w ithdraw able part are described
the panels are usually delivered as one assem bled
on page 4
transport unit.
State The follow ing operat ions
1.2.7.3 M et er in g Pan el (Fig 9c) are n ot possible
Basically m etering panels are of t he sam e Withdraw able t ruck in - Rem oval of t he
construct ion as the st andard out going panels. The ser vice position, w it hdraw able t ruck
m etering truck w ith volt age t ransform ers & HRC f uses sw itching device "ON" - Opening of t he door
in series is equipped w it h 3 top contact arm s. - Pulling of the LV plug

Withdraw able t ruck in - Rem oval of t he


1.2.7.4 Pan el w it h I/C & O/G Con n ect io n s (Fig 9d)
ser vice position, w it hdraw able t ruck
These panels are com prising of Incom ing & Out going sw itching device "OFF" - Opening of t he door
Cables in t he sam e panel. - Pulling of the LV Plug

Withdraw able t ruck - Closing of t he


1.2.8 Gen er al Co n st ru ct ion
located bet w een the sw itching device
- Safety devices & interlocks are provided to avoid ser vice and t est - Opening of t he door
any m alfunctioning. These devices protect t he posit ion s - Pulling of the LV plug
operat ing personnel & ensure reliable operat ions.
Withdraw able truck in - Transfer of the
The int erlocks are explained in sect ion 1.2.9.
test posit ion , sw itching w it hdraw able t ruck
- The panel is com partm ent alized in dif ferent device "ON" to service position
com partm ents w it h m etallic part it ions.
Withdraw able t ruck in - Closing of t he door
- Vacuum Circuit Breaker for t he panel is m ounted
disconnected posit ion transfer of t he
on t he t ruck. All t he ident ical t rucks in dif feren t
LV plug pulled of f , w it hdraw able t ruck
sw itching device "OFF", to service posit ion.
I/C O/G
door open

1.3 Tech n ical Dat a


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 upt o 31.5 kA


Fig 9c Fig 9d

8
750†

d2

800 m in d3
on either side

800 m in 10.3 1100* / 2000* *


10.1

h 10.2

FRONT

20 W
20.0 d1 38
d * Single Row of Panels
* * Dou ble Row of Panel
10.1. End Covers are f itted to t he lef t & right h an d end pan els
of th e sw it chboard †
M inim um from h ighest pressure relief flap
10.2. Pressure relief channel for the term inat ion (Part 10.1) af t er it has opened
com part m ent , 110 m m deep. All dim ensions are in m m and are for
10.3 Pressure Relief Flaps th e standard pan el

Fig: 10 Overall Panel Dim en sions

M axim um values indicated

Overall Pan el w ei g h t : Approx. w eight w it h vacuum


circuit breaker
15 kV (800W) 650 kg approx.
12 kV (600W) 450 kg approx.
24 kV (1000W) 800 kg approx.

Overall Pan el Dim en sion s :

w h h1 d d1 d2 d3
mm mm mm mm mm mm mm

Upto 15 kV 60 0/80 0 1600 20 00 1808 1750 38 0 750

24 kV 1 00 0 1450 2300 2270 2215 38 0 1 00 0

1 .4 Rat i n g Plat e

A Rat ing Plate cont aining the par ticular dat a is fixed
inside each panel. The w it hdraw able vacuum breaker
has its ow n rating plate and t he rated norm al current
stated on it does not apply to t he sw itchgear.
Degree of protect ion
Basic m odel IP 4X acc. To IEC 298 or
IP 40 acc. To IEC 529
The panels are gaskett ed to m ake t hem dust & verm in
proof.
IP 41, IP 5X and IP 51 can also be provided.

Fig 11: Rating Plate of a Panel

9
2. In st allat ion
The installat ion sequence should be planned and
prepared w ith care. Ensure t hat t he erectors and th e Rear cover

operat ing personnel read t he operat ion, inst allat ion & 65.0 670.0 65.0

m aintenance inst ructions. 20.0


65.0

25.0

2.1 Fou n d at ion


CUTOUT FOR
310.0
POWER CABLES
- Fal se Fl oo r
Place a girder in t he cutout com m on to several or all
of t he sw itchboards so that it is parallel to the
operat ing f ront . The girder is m eant to support th e CABLE CHAM BER
panel bot tom rails below t he 30m m x 30m m cutouts.
295.0 295 .0
Tw o girders (depthw ise) m ust be fixed along the
w heel tracks of t he truck as show n in t he foundat io n 6x holes for M 12 bolt s
Wheel 1750.0
plans (Fig. 12a, 12b & 12c). Track (for fixing to foundation)

300.0
- Con cr et e Floo r
CUTOUT FOR
This should be provided w ith foundat ion rails on CONTROL CABLES
45.0
w hich t he panels are t o rest. For floor cut outs refer t o 10.0
10.0 935.0
45.0
Fig 12a,12b &12c. The foundation should be
prepared before the panels arrive. Level dif ferences
580.0
300.0
bet w een t he m ount ing surfaces of t he individual C.B. CHAMBER
panels should be det erm ined and com pensat ed for by
using a sheet as show n 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

Not e : All dim ensions are in m m


CUTOUT FOR
POWER CABLES 310.0 Fig.12b Foun dat ion 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 foundat ion)
300.0
1000

CUTOUT FOR
45.0 CONTROL CABLES 295.0 295.0
10.0
400

935.0
10.0
32.5

45.0
2215

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

1140

10 45

120.0
777.5
300

3 2.5
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 dim ension s are in m m Not e : All dim ensions are in m m

Fig.12a: Foun dat ion Plan for 12 kV (600W) Pan el Fig 12c : Foundation Plan for 24 kV (1000 W) Panel

10
- Base Fram e (opt ion al)
A solid base fram e can be provided. The base f ram e
gives a st rong support to t he panels at t heir joining
line & also under it along the m ovem ent of t he t ruck
w heels. It is m ade up of rolled steel sect ions.
A reference sket ch of the base f ram e is as show n in
Fig 13a, 13b & 13c 40.0

ISA 40x40x5
75.0
Ø
14
.0

1780.0
1705.0

75 .0
40.0 40.0
ISA 40x40x5
ISMC 75x40
75.0
.0

M12 NUT
4
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
Ø
14
.0

47.5
0.0
Fig 13c: Base Fram e Dim ension s (24 kV 1000W)
175.0

600.0
0.0
67.5
142 .5

425 .0
457 .5
532.5

2.2 Elect rical Ser vice Ro om Dim en sio n s


Fig 13a: Base Fram e Dim ensions (12 kV 600W)
Min. Clearance to the ceiling 750 m m m in
above t he top (Refer Fig. 10)
75 .0

Min.Clearance on the sides 800 m m m in


Ø
14
.0

1780.0 of the Panels


1705.0
Min.Widt h of cont rol aisle in 1100* /
75.0

40.0 40.0
front of the Pan el for Single row 1500* * m m m in
ISA 4 0x4 0x5

Min.Widt h of control aisle 2000* /


in front of the Panel for 2500* * m m m in
75.0

M 12 NUT tw o row s facing each other


4 .0

WELDED
Ø1

T
102 7.5
1780.0

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

ISM C 7 5x40x5
A pow er source m ust be available. Work likely to
produce dust or dirt m ay not be carried out w hile t he
75.0 panels are being inst alled. The floor should be
75.0 levelled to enable transport unit s t o be m oved on
roller and/or sim ilar devices.
75.0

75.0

47.5 2.3 Tran spo r t Un it s


0.0
A transport unit consist s of m axim um upto 3
175.0

800.0
0.0
67.5
142.5

625.0
657.5
732.5

assem bled sw itch cubicle w ith w ithdraw able t ruck.


The cubicle should not be lif t ed f rom the t op w ith
Fig 13b: Base Fram e Dim ensions (12 kV 800 W) circuit breaker inside.

11
12

th e location of f ixing holes of t he panel for t ightening th e foun dat ion bolt s.
In case foundation rails or f abricated channel f ram es are em bedded in cem ent concrete, care should be t aken t o leave open pockets below

Fig 14 : Dim ension dat a sheet for t he foundat ion .

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


Level 1m m w it hin 1m tr.m easured length.
St raight ness 1m m . Per 1m t r. Length, 2m m . For t otal length
Toleran ce as per DIN 43661:
According t o DIN 4 3 661 , DIN 718 4 an d DIN 18 20 2 , sh eet No . 3, the fo llo w in g steps sh ou ld be adh ered t o:
- For equalizat ion of all irregularities of t he rough floor, th e screed to be applied to the floor shou ld be at least 10 m m higher th an
the h eigh t of the foundation rails.
- Before applyin g the screed t o th e floor, t he fou n dat ion rails should be align ed, leveled and ancho red t o the ro ugh flo or.
- The to p edge o f t he foun dat io n rails shou ld be flu sh w it h th e upper surface of th e fin ish ed flo or, t akin g ceram ic t iles, ston e-
w are t iles or any other flo or coverings into accou nt . Th e su rface of th e screed or of the floor coverin g sh ould not be h igh er th an
the l evel of the top edg e o f t he foun dation rails.
- The p lane defin ed by t he carr ying surfaces of both (or several) p arallel fou n dat ion rails h as to be levelled in tw o d irections 9 0
degrees apart by m eans of a levellin g instrum ent con sisting of tw o w ater filled glass tu bes co n nected by a rubber h ose.
- The level toleran ce, m easured alon g a d ist an ce of o n e m eter, sh all not exceed o ne m illim eter.
m easuring surface

t The st raightness toler ances, as required by DIN


43 661 shall include the level tolerance and
shall now here in the com plete plant to be
inst alled exceed 2 m illim eters.

- The straigh tn ess to leran ce sh all n ot exceed o ne m illim eter per m eter of leng th of t he rails in bo th t he flat an d th e edgew ise
position of th e rails. U -channel
reference surface
t

- The to p h orizon tal surf aces of t he f oundat io n rails shall be sm o oth (grind w elded join ts sm ooth).
- Foun dation rails em bedded in concrete shall b e fully gro ut ed for th eir fu ll len gth an d be able to support a load at any point .
2 .4 Pack in g bolt ing t he t ransport units together and also
t em porarily to check t hem for any signs of
As required :
t ransport dam age.
(a) For shipm ent to inland dest inat ions each transport
unit is f ixed on a st urdy w ooden pallet and
2.6 Exam in in g t h e sw it ch g ear ag ain st
covered by plast ic sheet for surf ace protect ion and
d am age
packed in norm al w ooden case.
As soon as t he sw itchgear has been unloaded and
(b) for shipm ent overseas each t ransport unit m ay be
unpacked exam ine it t o see that it is com plete w ith
additionally packed in a seaw orthy case. It is
reference to the relevant docum ent s. Record any
enclosed in plast ic sheet, w hich is sealed air-tight
dam age and it s cause w it hout delay, in t he presence
and includes bags cont aining dessicant .
of t he forw arding insurance agent , if the dam age w as
Accessor y item s are packed separately, or kept in t he caused en route.
panel t ransport unit (see dispatch advice). This report is essent ial for any dam age claim s.

2 .5 Un loadin g 2.6.1 St o rag e


While unloading care m ust be t aken to see t hat t he - Store t he unit s in upright position only
panels are not rolled on it s sides & they m ust be kept
in upright condit ion. - The units m ust be stored in adequet ly covered
locat ion such t hat they are protected from Sun,
Rain, Flood Waters & ot her such Natural elem ent s
2.5.1 Han d lin g equ ip m en t requ ired
- A m obile crane or a chain pulley block for 2.7 Tran sf er rin g t h e t ran sp o r t u n it s t o t h eir
unloading t he transport unit . p oin t s o f in st allat io n
- Lif t ing tackle - Transfer t he t ransport unit s including t heir w ooden
- A fork-lif t t ruck w it h a fork lengt h of about 3.0 m tr, pallet s t o t he point of t heir inst allation using fork
for handling t he sw it chgear inside t he building. lif t rollers.

- Hydraulic jacks or w inches & roller pads. - Wit hdraw the t rucks out of t he panels using tw o
w ooden w edges below the ram ps & close the
The handling/transport gear m ust m eet t he site door.
requirem ents w it h regard to it s construct ion and load
bearing capacity. Refer to the w eight s (for raising and - Put t he panels dow n on the cleaned site or at least
t ransport ing) st ated on t he transport or in the im m ediately in front of it in t he correct order,
covering docum ent s. leaving a clearance of about 25 m m bet w een
t h em .

2 .5.2 Pro ced u r e - To rem ove the t ransport unit s from t heir w ooden
pallet s
- Do not unpack w hile unloading t he t ransport
unit s. Take care not to dam age the plast ic sheet - Place four w inches under the f loor rails of outer
because it protect s the sw it chgear against any panels and uniform ly raise the panel.
environm ent al ef fects. - Rem ove the w ooden pallet .
- Use of m obile crane or a f orklif t t ruck. - Low er the transport unit as far as it w ill go & place
· At tach t he ropes to the w ooden pallet . it on tw o w ooden beam s if it is located above it s
site or place on f our roller pads if it is in f ront of
· Carefully raise the t ransport unit and check to see t he sites
t hat it is correct ly balanced, if necessar y low er the
t ransport unit and correct any im balance by - In the lat er case roll t he unit s to t heir m ount ing
reposit ioning the ropes on t he lif t ing tackle. posit ion. If this m eans changing the direction of
t ravel raise t he unit & reposition t he roller pads
- Unloading t he sw itchgear w it h a fork-lif t t ruck. accordingly. Now place the planks & channels in
Transport unit s of not m ore t han t w o panels can t he foundat ion cutout s t hat have to be crossed.
be unloaded w ith a fork-lif t t ruck if the access
routes perm it this. M ake sure the transport unit s - To raise t he panels on t heir m ounting posit ion &
are correct ly balanced. rem oving the roller pads

· M ove t he t ransport units as close as possible to - Low er t he t ransport unit as far as possible & place
t he sw it ch house and put them dow n. t hem on t w o w ooden beam s.

· Dism ant le and rem ove the crates. - Now , raise t he unit s, f irst on one side & t hen on
t he ot her side, using roller-t ype crow bars. Pull out
· M ove each transport unit into the building. t he planks & low er t he panels onto the cleaned
· Take of f t he plast ic sheet im m ediat ely prior t o foundat ion. Posit ion t he crow bars only at t he

13
corners of the panels below the vert ical f ram e (refer Fig. 14) and be absolut ely vert ical. If
m em bers. necessar y place shim s.
- under the fram e upright s and
2.7.1 To rem ove t h e Tru ck f rom t h e Pan el
- under the bot tom rails near the 30 m m x 30 m m
- Open t he door of t he panel (Refer clause 4.6.1). cutout s for t he foundation bolt s.
- Bring the t ruck to t he test posit ion by cranking - Rem ove t he bolts fit ted at the lef t hand end of
(Refer clause 4.1.3.1) each panel, as view ed from t he f ront.
- Disconnect t he LV plug (4.5, Fig. 4) & place it its - M ove up the second panel.
holder (4.9, Fig. 4) on t he door.
- Align this second panel on the foundat ion, raise it
- M ark t he t ruck & t heir panel num bers for to the correct level and m ake sure the panels stand
ident if ication. vert ically.
- Lif t & t urn t he Levers (4.13, Fig. 4) on t he f ront Use shim s as for the f irst panel.
interlocking plate (4.8, Fig. 4) by 90º
- Using t he nut s & bolts join the adjoining panels.
ant iclockw ise. (upt o 15kV) OR
- Check to see w hether the panels are t ruly ver tical.
- Unscrew t he f ront interlocking plate (for 24kV).
If necessary slacken the screw s and seal t he gaps
- Slow ly m ove t he t ruck aw ay from t he panel. The w ith rubber.
t w o ram ps drop autom at ically enabling free &
- M ove up t he other panels in sequence, align them
easy w ithdraw al of t he t ruck.
and bolt them toget her.
- Put back t he ram ps t o norm al posit ion & close t he
door.
4.5

2.8 Assem b lin g t h e sw it ch b oard


Carry out the w ork described under clauses 2.7.1 and
2.8.1 to 2.8.4.
Keep t he bolt s loose, not fully tightened, t ill all the
bolt s for sect ions are in posit ion. Then t ighten t he
joining bolts, follow ed by Busbar bolts, follow ed by
Foundat ion bolt s.
16.2

2.8.1 Bolt in g t h e p an els t o g et h er


It is assum ed t hat the f irst t ransport unit is in it s f inal
posit ion and that the ot her unit s are posit ioned on the
foundat ion rails in t he correct order but w it h an
16.3
adequate clearance betw een them .
It is alw ays preferable to inst all the central panel f irst .
This pract ice should invariably be adopted for a board
w ith 20 or m ore panels. Af t er inst alling t he central
panel, the other panels can be installed on it s lef t &
right in proper sequence.

· Pr o ced u r e
- Cent rally align t he f irst t ransport unit on it s
f oundat ion. The panels m ust be at t he correct level

16.1 16.4

16.1. Breaker Com partm ent door


16.2. Upper m et allic shut t er
16.3. Low er m et allic shut ter
16.4. Heater
4.5 LV socket

Fig 15 : Procedure for bolt in g t he panels t ogether Fig16: View int o Circuit Breaker cubicle aft er rem oving th e
draw out t ruck

14
2.8.3 Bo lt in g t h e Bu sb ar s t o g et h er
St art w orking on the busbars only af t er panel unit s
have been adjusted correct ly and interconnect ed.
Access to t he busbars are f rom t he rear side or f rom
the top side by opening the Explosion Vent s. All
necessary hardw are is supplied on t he t he m ain
busbars.(5.4, Fig. 5)
1 . Brush t he cont act faces criss-cross w ise unt il
17.1 bright , & w ipe using a clean clot h. (applicable only
5.1 for bare Alum inium Busbars)
2 . Square neck, round head, coach bolts are used for
busbar joint s. These bolt s do not rotate in their
6.2
slot s & hence can be t ightened f rom one side.
Recom m ended torque is 70 Nm .
17.2
3 . Allow the joint to set t le dow n in 24 hrs & check
t he value of t he torque w it h t he torque w rench.
4 . The busbars of adjacent units m ust be joined
t ogether using the busbars & hardw are supplied.
16.4 While insert ing coach bolt s ensure that t he round
head of coach bolt is f acing sheet m et al struct ural
part s. That m eans t he nuts w ill alw ays be tow ards
t he live parts such as busbars/feeder connect ions.
The busbars (5.4, f ig. 5) of the panel form ing a
17.3
t ransport unit are already bolted.
5 . Refix t he upper rear cover af ter the busbars are
bolt ed.

2.8 .4 Bol t in g t h e M ain Ear t h Bar sect ion s


t o g et h er
5.1. Upper Cont act Bushing
17.1. Fixed Cont acts (Upper) The m ain earth bars of t he t ransport unit s m ust be
6.2. Low er Cont act Bushing linked toget her. One of the t w o part s t o be bolted
17.2. Fixed Cont act s (Low er) together is already f it ted w it h a link. This m ust be
17.3. Truck ear thing Srip undone, passed through t he part it ion and bolted to
16.4. Space Heater the t w o adjacent eart h bar sections. The cover on the
side w all should be properly adjust ed af ter joining t he
Fig 17: View int o circuit breaker com part m ent w ith shut ter eart h bars.
held open

2.9 M akin g HV Cab le co n n ect io n s


2.8.2 Fix in g t h e Sw it ch b o ard s t o t h e
Fou n d at io n The cable connect ion pieces are provided w it h Hex.
Headed bolt s M 16 w it h w ashers., spring w ashers &
The panels bot tom plat e has four 30 m m x 30 m m
cutouts (refer Fig 15) for f ixing purposes.

· Weld in g
Weld t he bottom plate to t he foundat ion at t he
cutouts. Insert shim s (refer clause 2.8.1) w here
necessary to avoid having t o w eld across air gaps.
Coat t he w eld w it h enam el paint .

· Bo lt in g Dow n
Em bed anchor-bolt s in t he foundat ion (through the 18.1 18.2
30 m m x 30 m m cutout ) or drill the appropriat e holes 6.1 6.6
in t he foundat ion rails (false f loor).
6.1. Ear th Busbar 18.1. Ext ension Links
Insert shim s bet w een t he foundation and the bott om
18.2. Eathing St rip (from CB 6.6. Bottom Covers
rails near t he cutouts. ch am ber)
Tighten the screw w it hout distorting t he panels.
Fig 18: Eart h Busbar Assem bly

15
hex. Nut s for m ount ing t he cable lugs of the - the core spacing on t hree core cables and the ant i-
conduct ors. m agnet ic clips on single-core cables.
Three part bott om cable cover is supplied f itted w it h
the sw itchboard. Of these, t he outer m ost cover has 2.11.2 Ch eckin g t h e Bo lt ed Jo in t s
to be rem oved & cut outs t o be m ade of the size as
- Check t he pow er and auxiliary circuit connect ions
per t he instructions given by cable kit m anufact urer.
of the sw it ching devices at random . Exam ine all
the t erm inal block connections, m aking sure that
2.10 Ear t h in g t h e Sw it ch b o ard the blocks are correct ly labeled and replace any
m issing labels by referring to the circuit diagram .
Connect t he eart h term inals of at least one or tw o
panels to the st at ion eart h. This could be done to suit - The torque values of all t he busbar joint s m ust be
the local guidelines. Term inat ion f acility for earth checked
connect ion is provided on the earth busbar m ount ed
in t he cable cham ber.
2.11.3 Cl ean in g t h e Sw it ch b oar d
- Clean all the post insulators, Bushings and Busbars
2.11 Ot h er w o rk t o b e carried ou t
in all t he com partm ents using sof t dry cloth.
Do n ot u se an y ab r asive ch em icals or d et ergen t s t o
2.11.1 Ch eckin g t h e HV Co n n ect io n s
clean in st alled par t s.
On all HV cables, check
Use on ly d ist ill ed w at er if n ecessar y. En su re t h at all
- t he bolt s for t ight ness p ar t s ar e dr ied u p b ef o re ap p lyin g an y vo lt ag e.
- t he sealing and earthing

16.2

16.3

19.2 19.1 19.3

16.1 2.5
16.2, 16.3. Sh ut ters
19.1. Shut ter operat ing rod
19.2. Roller Guide Angle 16.1. Breaker com part m ent Door
19.3. Truck guide 2.5. Breaker Truck

Fig 19: View inside circuit breaker compart m ent w ith out Fig 20: Insert ion of trolley in t he panel
w it h draw able t ruck.

16
2.11.4 In ser t in g t h e w it h d raw ab le p ar t s 2.11.5 Prot ect in g t h e p an els ag ain st
env iron m en t al ef f ect s
- open the front door (16.1, Fig. 20)
(a) Dam aged sect ions of t he paint finish m ay only be
- put dow n the ram ps (4.7, Fig. 4)
t ouched up w ith original paint.
- place t he breaker t ruck in front of the
(b) Fit t he parts supplied to protect against the in gress
correspon ding pan els.
of rept iles. Check in case they are rem oved during
- Transfer t he t ruck inside the panel and push it as in st allat ion .
f ar as it w ill go.
(c) Close all the doors & covers properly.
- Fix t he racking m echanism / interlocking plate to
(d) Any opening that is lef t open af ter inst allation
struct ure f ram e by using lif t & turn levers
should be closed & sealed to m ake it t ruly
(upt o 15kV) & by using bolts (for 24kV)
verm inproof .
- Fix t he ram ps back in t he position
- Close t he door (16.1, Fig 20) 2.12 In t erp an el Wir in g
- Inser t all ot her draw out t rucks in t he sam e The w ire have been lef t loose in the LV compartm ent
m anner. of certain panels.
These w ires m ust be connected from panel to panel
as per approved w iring diagram s.

17
3. Put t in g t h e sw it ch gear in t o serv ice
7.1
For det ails of operat ion refer sect ion 4

3.1 Test op er at ion s

3.1.1 Wi t h d o or o pen
- The m otor operat ing m echanism st art as soon as
t he LV plug is inserted and cont rol supply is
available (If t he VCB is not already charged)
4.3
- Open & close t he breaker several t im es.
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. View ing w indow for truck posit ion


4.11. Opening for charging h an dle for charging t he breaker
closin g spring
4.12. Trip m echan ism for operat ing the circuit breaker in the
con nect ed posit ion.
7.1. LV com par t m ent door
16.1. Breaker com partm en t door
21.1. Ball grip
21.2. ON & OFF Push But ton (On HT Door)
21.3. Window for t he in dicators of the w it hdraw able part
- Num ber of operat ions (Operat ion Counter)
- Closing Spring of t he circuit breaker
- Charged - Lable w it h spring sym bol
- Discharged - Blank Lable
- Indicator for circuit breaker sw it chin g stat us
- 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 t he transfer
operat ing m echanism
4.3. View in g w in dow for t ruck position 21.5. Opening for rackin g handle for rackin g t he breaker t ruck
4.11. Openin g for charging handle for charging t he breaker 21.6. Opening for defeat ing int erlock
closing sprin g 21.8. Bolt s for door locking
4.12. Trip m ech anism for operat ing the circuit breaker in the
con nect ed posit ion .
Fig. 21a: Openin g Elem ent s (for 24kV Panel)
7.1. LV com part m ent door
16.1. Breaker com part m ent door
- Pull off the LV plug. Charge the breaker closing
21.2. ON & OFF Push But ton (On HT Door)
21.3. Window for the indicat ors of t he w ithdraw able part
spring by hand (refer clause 4.2)
- Num ber of operat ions (Operat ion Counter) - Operate the circuit breaker
- Closing Spring of t he circuit breaker
- Charged - Lable w ith sprin g sym bol - Refit the LV cable Plug.
- Discharged - Blank Lable
- Indicator for circuit breaker sw it ch ing status
3.1.2 Wit h d oo r clo sed
- Circuit Breaker Closed - " I "
Tripped - " O " Each sw itchpanel should be tested as follow s:
21.4. Opening for Double Bit Key for locking the t ran sfer
operat in g m echan ism - Transfer the w it h draw able truck to t he
21.5. Opening for racking han dle for racking the breaker truck disconnected position (see 4.1).
21.6. Opening for defeatin g in terlock
21.7. Door Han dle - Sw it ch ON t he auxiliary and cont rol supply.

- Transfer t he w ithdraw able part t o t he connected


Fig. 21: Open ing Elem ent s (upto 15kV Panel) posit ion.

18
- Open and close t he breaker as long as no high The Hand Crank for t ransferring t he t ruck is also
volt age is applied. suit able for all M 8 bolts.

- Without using force check all m echanical and


elect rom echanical interlocks for satisfactory 3.3 Revisin g t he Circu it d iagram s
f unctioning. Check t o see w het her the sw itching If circuits have to be m odif ied during inst allation t he
states are indicated correctly in the cont rol room . existing circuit diagram s are m arked up. When w ork
has been com pleted m ake sure t hat the original
- Check w het her the position of the w it hdraw able
diagram s are revised.
t ruck is indicat ed correctly (if t he appropriat e
posit ion sw itches are f itted refer to t he circuit
diagram s). 3 .4 Space Heat ers
For panels inst alled in hum id at m osphere, space
3 .2 Ch eckin g t h e Accessor y It em s heaters are f itt ed in t he circuit breaker & cable
com partm ent s. The therm ost at cont rolled heat ers
The accessory it em s required m ust be easily available should be sw itched "ON" before t aking the panels int o
in the Sw itchgear Room or an adjacent room . They service. The t herm ostat shall be set to cut of f supply
include one Hand Crank for t ransferring t he t ruck and to heat ers at about 5º higher t han t he m axim um
f or charging the breaker closing spring, a Double Bit am bient tem perature.
Key for locking t he hand-operat ing m echanism , t he
basic circuit diagram , Operat ing Instruct ions, Castell Heaters m ust alw ays be kept "ON" in all the condit ions
Lock Key (opt ional) and Earthing Sw itch Handle (even during m aint enance)
(Opt ional)

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 M AN UAL FOR OPERATIONS

Fig 22 : Label on door of breaker compart m en t

20
4. Operat ions In det ail:

Each row of cubicles is provided w ith brief operating - M ake sure t hat t he circuit breaker is open, the LV
instruct ions. Refer to fig. 22. plug(3.3, fig. 3) and socket connector has been
put toget her and lock it . The breaker com part m ent
door is closed.
4 .1 Wit h d raw ab l e t r u ck
- The castell key can be re,m oved in this posit ion
also for any int erlocked operations w hich are t o be
4.1.1 Po sit i on s o f t h e w i t h d raw ab le t ru ck
perform ed w it h circuit breaker in open posit ion.
Refer clause 1.2.2 for Circuit breaker Cham ber
- Fit t he hand crank (8.2, fig. 8)to t he hexagon
shank in opening (21.5, fig. 21) turn it clockw ise
· Ser vice p osit ion (con n ect ed p osit ion )
as f ar as it w ill go and pull it of f.
The circuit breaker is connected w ith t he busbars and
- Insert the castell key if it w as rem oved for
t he out going circuit Auxiliary circuit is connect ed
interlocked operat ions. Turn t he key clockw ise
t h rough LV plug and socket.
t h rough 90 degrees f rom posit ion "M anual
Racking" t o "Connected position(locked)" and pull it
· Test p o sit io n
of f .
The circuit breaker is disconnect ed from t he busbars
and t he outgoing circuit . Segregat ion as specified in
4.1.3 Tran sferrin g t h e w it h d raw ab le p ar t f r om
IEC 60298 is m aint ained. The LV circuit s are
t h e co n n ect ed p o sit ion t o t h e t est /
connect ed through LV plug and socket .
d iscon n ect ed p osit ion m an ually
Discon n ect ed p osit ion
4.1.3.1 No rm al Op erat io n s
The circuit breaker is disconnect ed from t he busbars
and the out going circuit . LV circuits are disconnected In brief
by pulling out t he LV socket from t he plug.
1 st St ep 2n d Step 3rd Step
- When t he LV plug and socket are connect ed t he Turn double-bit key In sert and Turn double-bit key
follow ing functions can be carried out. turn hand
crank
· The breaker can be tested / operated, also from
as far it w ill
th e control room .
f rom by to go and pull from by to
· The breaker com partm ent door can be opened. it of

· Funct ions such as ON / OFF indication and 90° 90°


elect rical interlocks can be tested.

- When the LV plug and socket are disconnect ed. Fig. 23b
· The breaker com part m ent door cannot be
In det ail:
closed. Hence the truck cannot be inserted.
- M ake sure t hat the circuit breaker is open.
4.1.2 Tran sf er rin g t h e w it h d raw ab le p ar t f rom - insert the double bit key in lock (21.4, f ig. 21) and
t h e Test /Discon n ect ed Posit io n m an u all y t urn it ant i-clockw ise t hrough 90 degrees f rom
"connected posit ion (locked)" t o "M anual Racking".
4.1.2.1 N orm al o p er at io n The hexagon shank opening (21.5, f ig. 21).is now
accessible. The hand racking m echanism is
In brief : u nlatched.
1st Step 2nd Step 3rd Step - Fit t he hand crank (8.2, fig 8) t o the hexagonal
Turn double-bit key Insert and Turn double-bit key
shank in opening (21.5, fig. 21) turn it anti-
t urn han d
clockw ise as f ar as it w ill go and pull it of f .
crank

as f ar it w ill - Turn the double-bit key anti-clockw ise through 90


from by to go and pull from by to degrees from t he posit ion "M anual Racking" to
it of "Disconnected position (locked)" and pull it of f .
Opening (21.5, fig. 21) is now closed.
90° 90°
The hand racking m echanism is now locked.
Fig. 23a

21
4.1.3.2 Cast el l Key Op erat i on s (Opt io n al) 4 .2 Circu it -b reaker op erat in g m ech an ism
The operat ing m echanism is of t he st ored energy
1st Step 2nd St ep 3rd Step
Turn cast ell key Trun cast ell key type. For elect rically operat ed breakers, m otor
autom at ically charges t he closing spring af ter each
as f ar it w ill sw it ching operat ion. If the m otor supply should fail
from by to go and pull f rom by to
the closing spring can also be charged by hand. The
it of
tripping spring is charged each tim e t he breaker is
closed.
90° 90°

Fig. 23c 4 .3 Circu it -b reaker Operat io n

In det ail:
4.3.1 Ch arg in g t h e closin g sp rin g b y h an d
- M ake sure t hat the circuit breaker is open. · Proced u res

- Turn the cast ell key (w hich is trapped in t he If the breaker com part m ent door
m echanism ) ant i-clockw ise through 90º from
"Connected posit ion (locked)" to "M anual Racking".
is closed (connect ed is op en (disconnect ed
- In this position t he castell key can be rem oved for posit ion) t urn plate position) fit the hand
any interlocked operat ions w hich are to be (21.6, fig. 21) so that it crank direct ly to t he
perform ed w ith circuit breaker in open condit ion. clears opening (21.7, breaker operating
The hexagon shank opening(21.7,f ig.21)is now fig. 21) inser t the hand m echanism in opening
accessible. The hand racking m echanism is crank and fit it into the (21.7, f ig. 21).
un latched. breaker

- Fit t he hand crank (8.2, f ig.8) to the hexagonal


shank in opening (21.5, fig.21) t urn it anti- · Operat in g M ech an ism
clockw ise as far as it w ill go and pull it of f .
- Turn the crank unt il t he sym bol "spring charge"
- Inser t t he castell key if it w as rem oved f or appears in view ing w indow (21.3, f ig.21) on
interlocked operat ions. Turn t he double-bit key indicator. The operator is not at risk if the m otor
ant i-clockw ise th rough 90 degrees from t he supply recovers,because the hand crank f ree-
posit ion "M anual Racking" to "Disconnected w heels and detaches in t he anti-clockw ise
Position(locked)" and pull it of f . direct ion.

- The castell key can also be rem oved in this - Pull t he crank off .
posit ion t o f acilit at e the opening of t he HT
compartm ent door and / or other interlocked 4.3.1.1 Breaker ON an d OFF
operat ion s.

4.3 .1.2 M ech an ical ly (locally by m eans of push


4.1 .4 Disco n n ect in g t h e LV Plu g butt on)

- Transfer t he w ithdraw able part to the · In the connected position :


disconnected position(in accordance w it h clause
Trip m echanism (4.12, Fig. 4 & 21) as f ar as it w ill
4.1.3) and lock it .
go, hold it there, press but tons "ON" and "OFF"
- Open the breaker com part m ent door (refer clause (21.2, Fig 21) and then release the grip.
4 .6.1).
· In the disconnect ed posit ion w ith t he door closed :
- Unlock the LV plug (3.3, f ig. 3) and LV socket (4.5, Press buttons "ON"and "OFF" (21.2, Fig 21) on t he
f ig. 4 & 16) by turning dow n the clip. breaker com part m ent door.

- Pull of f t he plug and at t ach it to the holder (4.9, · In the disconnected posit ion w it h the door open :
f ig. 4) w hich is fixed t o t he door. Press butt ons "ON"(4.14, Fig 4) and "OFF" (4.15,
Fig 4) on t he breaker t ruck

4.1.5 Con n ect in g t h e LV Plu g


4.3 .1.3 Elect ri cally (f rom the con trol room or
- Put t he LV plug (3.3, f ig.3) and LV socket (4.5,
locally)
f ig. 4 & 16) toget her and lock it w it h t he clip.
by m eans of push but ton/sw it ches in t he control room
- Close t he breaker com part m ent door (refer clause or on the LV com part m ent door. If the cont rol supply
4 .6.2). fails t he breaker can alw ays be t ripped m echanically
(see above)

22
4 .3 .2 Sw it ch in g St at e In d icat io n
In the m iddle part of view ing w indow (21.3, Fig 21)
`O' m eans "OFF", `I' m eans "ON".

Dan ger
Precau t ion s f o r Saf e Worki n g

High Volt age !

Touching live part s w ill result in severe personnel


injury and / or death.
24.1
This equipm ent shall be operat ed only by qualified
personnel w ho have becom e thoroughly f am iliar
w it h the operat ing instruct ions m anual and in
part icular all t he safet y inst ruct ions.

4 .5 Ear t h in g

4.5.1 Ear t h in g of Bu sb ar s an d Cab les


(Side view )
4.5.1.1 Direct Ear t h in g of Bu sb ars w i t h
co n d u ct o rs 24.4 24.2

- Sw itch of f all breakers feeding to t he busbars.

- Open upper rear bolt ed cover & inside covers (of


busbar cham ber). Touch all phases w ith an
earthing conductor m ounted on the long
insulat ing pole.

- Shor t all t he phases w it h a conductor and bolt it to


eart h.

- Place necessary w arning plat es at all not iceable


locat ions.

4.5.1.2 Ear t h in g o f Cab les w it h con d u ct or s


- Sw itch of f the breaker in the panel w here cable
earthing is desired.

- Ensure that t he cables are not get ting t he supply


f rom t he other end.

- Rem ove the low er rear cover of the cable cham ber.

- Follow t he procedure described for busbar


eart hing.

(Rear view )
4 .5.1.3 Rem ov in g Ear t h in g Con n ect ion s
6.1 24.3
- Disconnect and rem ove t he short ing and earthing
conduct ors.
24.1. Fixed Cont act s (E sw it ch )
- Close the rear cover and bolt it f irm ly. 24.2. M oving Cont act (E sw itch )
24.3. Eart hing Sw itch Shaf t
- Rem ove t he w arning plates.
24.4. Operating Link
6.1. Eart hing Busbar

Fig 24: Eart h sw it ch Arran gem ent on cable side

23
4.5 .2 Ear t h in g o f Bu sb ar s or cab les w it h a 4.5 .3 Ear t h in g t h e Bu sbar s or Cab les w it h
Draw ou t Tru ck Ear t h in g Sw it ch
Separate draw out Trucks can be supplied opt ionally
for busbar and cable eart hing. In case f ault m aking 4.5.3.1 Ear t h in g t h e Bu sb ar s w it h Ear t h in g
capacit y is required, a circuit breaker is m ounted on Sw it ch es
such draw out trucks.
- Sw it ch of f t he supply to the m ain busbars.

· Pr o ced u r e - Ensure t hat t he supply to t he m ain busbars cannot


be sw it ched "ON" from rem ote point s.
- Rem ove the circuit breaker or the link draw out
t ruck f rom the panel w here eart hing is t o be done - In case t he elect ro-m agnet ic interlocks, ensure th at
(refer clause 2.8.1) all t he interlocking conditions are sat isfied.
Otherw ise the earthing sw it ch cannot be closed.
- Insert t he desired earthing draw out t ruck i.e. cable
or busbar earthing draw out t ruck in the panel - Close the ear thing sw it ch by insert ing the earthing
(refer clause 2.11.4) sw itch handle in posit ion and t urning it in the
clockw ise direct ion t ill stop. Wit hdraw the handle.
- Connect the LV plug and socket (refer clause 4.1.5)
- Place t he w arning plates at all necessar y locat ions.
- Close t he panel door (refer clause 4.5.2)

- Ensure t hat there is no voltage available on t he


4.5 .3.2 Ear t h in g Cab les w it h Ear t h in g Sw it ch
parts to be eart hed w hen eart hing draw out t ruck
(f ig .24)
w ithout m aking capacity is used.
- M ove the t ruck t o test / disconnected posit ion.
- Transfer the draw out unit to the connect ed Eart hing sw it ch cannot be closed unt il t his posit ion
posit ion (refer clause 4.1.3). In case the earhting is reached.
draw out t ruck has an elect ro-m echanical interlock
unit m ounted on it , t he t ransfer is possible only - Ensure t hat t he cables cannot be energized from
af ter all the interlocking condit ions are sat isfied. the other end.

- Lock it in t he connected position. - Follow t he procedure for Busbar earthing sw it ch.

- In case the draw out t ruck has a circuit breaker


m ounted on it sw it ch "ON" (refer clause 4.2 & 4.3). 4.5 .3.3 Discon n ect io n o f Ear t h in g Sw it ch es
- Insert the earthing sw it ch handle in position. Turn
- Place t he w arning plates at all necessary locations.
it in t he ant i-clockw ise direct ion till stop. Wit hdraw
the handle.
4.5.2.1 Disco n n ect io n of Eart h i n g Draw o u t t ru ck
- Rem ove w arning plates f rom all the locat ions
- Sw it ch "OFF" t he breaker in case of earthing
draw out truck w it h m aking capacit y (refer clause
4 .3 ). 4 .5 .4 Ear t h in g t h e Bu sb ars or Cab les w it h Tru ck

- Transfer it to t he disconnected posit ion (refer


4.5 .4.1 Ear t h in g t h e Bu sb ars w it h Bu s Ear t h in g
clause 4.1.3)
Tru ck
- Disconnect the LV plug (refer clause 4.1.4) - Sw it ch of f t he supply to the m ain busbars.
- Open t he HT com part m ent door (refer clause - Ensure t hat t he supply to t he m ain busbars cannot
4 .6.1) be sw it ched "ON" from rem ote point s.
- Rem ove w arning plates. - Rack ou t he breaker t o diconnected posit ion.
- Inser t t he original draw out t ruck of the circuit - Diengage t he LV plug & socket.
breaker or link draw out truck in the panel (refer
clause 2.11.4) - Draw out t he nreaker t ruck com pletely out of the
panel.
- Connect the LV plug (refer clause 4.1.5)
- Insert t he Bus eart hing t ruck in the panel t o
- Close t he door (refer clause 4.5.2) diconnected posit ion.
- The original draw out truck is now ready for - Connect t he LV plug to socket.
t ransfer to connect ed position.
- Rack in t he truck t o ser vice posit ion.

- Place t he w arning plates at all necessar y locat ions.

24
4 .5 .4 .2 Ear t h in g t h e Cab les w it h Cab le Ear t h in g - Unscrew t he door closing bolt s of HT com part m ent
Tru ck door. The bolts are capt ive (for 24kV Panel)
- M ove the t ruck t o test / disconnect ed posit ion - Open the door.
- Ensure that t he cables cannot be energized f rom
t he other end. 4.6 .2 To close t h e d o or

- Follow t he procedure for Busbar eart hing sw itch. - Sh ut t he door.

- Rot at e t he handle clockw ise till it get s closed. (For


4 .5 .4 .3 Lin k Ty p e Eat h in g Tru ck upto 15kV)
- Sw itch of f t he supply to t he m ain busbars. - Tighten the capt ive screw in case of bolted door.
- Ensure t hat t he supply to t he m ain busbars cannot
be sw itched "ON" f rom rem ote point s. 4 .7 Do o r t o LV Com p ar t m en t

- Ensure that t he cables cannot be energized f rom


t he other end. 4.7.1 To o p en t h e d oor

- Follow t he procedure for Busbar eart hing sw itch. - Rot at e t he t urnlocks w ith a key in ant i-clockw ise
direct ion or unscrew t he capt ive bolt s in case of
bolt ed door.
4 .6 Breaker Co m p ar t m en t Doo r
- Open the door.
The door can be opened & closed w hen t he t ruck is in
t he disconnected posit ion and the plug & socket
connect or for LV cables has been connected together. 4.7 .2 To close t h e d o or

The door int erlock can be defeated as described - Sh ut t he door.


under clause 5.5 below .
- Rot at e t he t urnlock in clockw ise direct ion or
t ighten t he bolt s in case of bolt ed door.
4.6.1 To op en t h e d oo r
- Rotate the handle ant i-clockw ise t o open the door.
(For upto 15kV)

25
5. M ain t en an ce · Check t he sw itchpanel f unctions and put the
board back into service.

If w ork has t o be carried out in t he panels; isolate t he


Dan ger board, m ake sure that it cannot be m ade live again,
check its isolated st ate and eart h and short-circuit the
Precau t ion s f o r Saf e Work in g
feeders and w here applicable, the busbars. Adhere to
all regulat ions and safety m easures, m aint ain and
M aintenance, repair and subsequent conversion or
service the built -in equipm ent , e.g. circuit -breakers,
extension w ork shall be carried out only by
volt age t ransform ers, current t ransform ers, relays,
specially trained personnel in accordance w it h t he
m eters, protect ive devices, etc. in accordance w it h
operating instruct ions and/or special conversion
their operating inst ruct ions.
inst ructions. Training and inform at ion sessions for
personnel w ill be provided by the com petent Before rem oving the front plat e of t he breaker
Siem ens depart m ent . operat ing m echanism discharge the closing and
tripping springs. Follow t he instruct ions given on t he
Before st arting any w ork on the panels references
m echanism housing.
m ust be m ade t o local regulat ions for high volt age
sw itchgear. Sw it ch of f the pow er supply, close/ Only st andard tools are required. Put the sw it chgear
open the breaker m anually to ensure that t he back into service as described under clause 3 above.
closing spring of t he breaker is discharged. Then Ser vice t h e sw it ch gear at sh o r t er in t er v als if t h e ai r
rack out the truck from ser vice t o test posit ion. is ver y m o ist or f u ll o f d u st o r is ot h er w ise
p oll ut ed . The cause of any dist urbance or short-
Control term inals in the LV com part m ent m ust not
circuit m ust be determ ined im m ediately and
be touched if t he cont rol supply is not
dam aged part s replaced, irrespect ive of w hether an
disconnected.
inspect ion is due or not.
Non obser vance w ill result in death and / or severe
personnel injury or subst antial dam age to
5.2 Clean ing
proper t y.

5.1 In sp ect ion Sch edu le


Cau t ion
- Each year
Fo r Saf et y
· M ake a general visual check.
For safet y reasons, cleaning of panels shall be
· Check w hether t he accessories are com plete taken up only w hen the shutdow n of M ain &
and in proper order. Auxilliary Pow er supply is taken, the breaker is in
the open st ate, closing spring of the breaker is
· Clean and lubricate the w heels as w ell as
discharged & the breaker t ruck is rem oved out of
m oving part s of the truck and interlocking
the panel.
plate.

· Relays to be tested f or t heir funct ionality. Cleaning Agent s

· Clean t he Panels (refer clause 5.2) Perchloret hylene, 1.1.1 t richloroethane, sm all
brushes, dusters and vacuum cleaner for sheet m et al
part s.
- Every five years
· Transfer t he w it hdraw able t ruck t o t he Note:
disconnect ed posit ion.
Trichlorethylene, perchloroethylene an d
· Test-operate the circuit-breakers. tet rachloroethylene have a harm f ul ef fect on cast
resin part s and m ust not com e into cont act w ith
· Rem ove t he w it hdraw able t rucks (refer clause them .
2.7.1) and carry out all m aint enance w ork, also
on the sw it ching devices. Cast resin part s should be cleaned w ith dist illed w ater
on ly.
· Clean t he panels (refer clause 5.2) and check
t he connect ions. Silver plated and other cont act surfaces t o be cleaned
w ith clean cloth.
· Lubricat e all bearing surfaces, bearings and
articulated joints.

· Reinsert the w ithdraw able t rucks.

26
5 .3 Lu b ricat io n 5.5 Def eat in g t h e Doo r In t erlo ck o f HV
Com p ar t m en t
Im m ediat ely af ter cleaning:
Cau t io n : Take u t m o st care w h i le d ef eat in g an y
- Lubricate t he isolating cont act s and their m at ing
in t erlo ck as t he def eat o p erat ion lead s t o access t o
cont acts w ith neutral grease.
t h e areas / p ar t s w h ich are likely t o b e live.
- apply a film of neut ral grease to the bearings and
articulat ed joint s of t he operating m echanism s, to 5.5.1 Draw o u t Un it in Con n ect ed Posit ion
t he w it hdraw able part s and shutt ers, and t o t he
door hinges and locks. The breaker com partm ent door interlock should only
be cancelled if t he truck cannot be transferred to t he
disconnected posit ion and t he sit uation cannot be
Recom m ended neutral greases are:
cleared in any w ay.
(i) SERVOGEM 2 (m ult ipurpose) of Indian Oil
- Sw itch of f the circuit -breaker.
Corporat ion m ake
- M ake sure that t he busbars are not live.
(ii) M ult ipurpose grease `H' of Hindust an Pet roleum
Lt d. m ake - Insert a sm all screw driver in t he opening (21.6,
f ig. 21) and screw -in t he grub screw visible
(iii) Any ot her chem ically neut ral grease w hich can t h rough t he opening.t ill it falls out inside t he
w it hstand t em perat ure up to 15° C. panel.
- Open the door by t urning t he door h andle.(refer
5 .4 Rep lacem en t Par t s clause 4.5.1).

Item s such as post insulators, bushings m ating


cont act s, m easuring inst rum ent s, current 5.5.2 Draw o u t Un it in discon n ect ed p o sit i on
t ransform ers et c., can be replaced. If replacem ent is - Press the interlocking lever on interlocking plat e by
likely to prove dif ficult ask the nearest Siem ens h an d.
represent ative in good t im e f or deput at ion of suitable
personnel. The representat ive w ill also assist you in - Insert t he double-bit key in lock(21.4, fig.21) and
deciding w hat spare part s to keep in stock. t urn it (locked) to "M anual Racking".
- Fit t he hand crank (8.2, fig. 8) to the hexagon
When ordering spare parts and unit s give the
shank in opening t urn it clockw ise as far as it w ill
f ollow ing details:
go and pull it of f(21.5, f ig.21).
- Type and Serial No. of t he sw it chboard (see
Turn t he double-bit key clockw ise t hrough 90º f rom
n am eplate).
posit ion "M anual Racking" to "Connected
- Exact description of the unit or part , referring to Posit ion(locked)" and pull it of f .
t he appropriate operat ing instruct ions w here
applicable, or t o a draw ing; sket ch or circuit 5.5.3 Rest o rin g t h e Do o r In t erlo ck s
diagram . Use reference list of item s in Sect ion 8.
Af ter carr ying out the operat ions t o defeat the door
int erlock as described in clause 5.5.1 or clause 5.5.2,
the door of t he HV com part m ent can be closed and
Dan ger int erlocks can be rest ored by follow ing the
procedures in clause 5.5.1 in t he reverse sequence.
Precau t ion s f o r Saf e Worki n g

High Volt age !

Touching live part s w ill result in severe personnel


injury and / or death.

This equipm ent shall be operat ed only by qualified


personnel w ho have becom e thoroughly f am iliar
w it h the operat ing instruct ions m anual and in
part icular all t he safet y inst ruct ions.

27
6. Disp osal of Produ ct steel, copper, alum inium , rubber, PVC, cast-resin &
glass-fibre-reinforced m aterials to be segregated
This product is environm ent ally com pat ible. properly.
The follow ing m aterials have been used to m ake up The Re-cyclable m aterials like Steel, Copper,
the device : Steel, Copper, Alum inium , Cast-resin Alum inium can be reused.
glass-fibre-reinf orced th erm oplast ics, rubber,
porcelain, greases & sim ilar m aterials. PVC is used as Non cyclable m aterials like Cast -resins, glass-fibre-
an insulat ion m at erial for control w ires. reinforced et c can be broken in to pieces & can be
used as secured land filling m aterials.
In disposal, priorit y m ust be given to re-use of th e
m aterials w hich can be recycled. Rubber being biodegradable m at erial m ust be
recycled through authorized cont ractors.
In as-supplied-condit ion, t he product does not
incorporate any hazardous subst ances. PVC m at erial should not be burnt as t hey m ay release
Halogenat ed hydrocarbons w hich can af fect t he
In operat ion, t he product does not em it any ozone layer. Therefore, PVC m ust be recycled t hrough
hazardous m aterials or gases. aut horized contractors.
During disposal of the product , care m ust be t aken to Local Siem ens of f ice can answ er any questions
dism antle as f ar as possible in m ore environm ent ally concern ing disposal.
accepted w ay as Recyclable & Non-cyclable scraps i.e

28
7 Su m m ar y of Im p or t an t In st ruct ion s-

DOs DON'Ts

Du rin g In st al lat ion & Co m m ission in g St ag es :- (1) Do not leave any equipm ents or tools in t he
(1) Brush t he cont act surf aces properly before panel.
bolt ing busbars. Also grease t he joints & (2) Do not put hands or tools in operat ing
apply proper torque on the bolts. m echanism w hen electrically operated.
(2) Check rated volt ages of equipm ent s such as
(3) Do not operate the breaker during cleaning
m otor, closing & tripping releases m ounted
process.
in the operat ing m echanism w ith the
available auxiliar y supply to be connect ed (4) Do not use any other chem ical or grease f or
to these equipm ent s in the substat ion. clearing or lubricat ing other t han m entioned
in t hese inst ruct ions.
(3) Ensure t hat all the foundation bolt s are
t ightened along w it h the square w asher and
also seal of all cont rol and pow er cable
cutouts t o prevent verm in ent ry.

Du rin g ser v ice lif e of t h e p an el-

(4) Keep door & covers firm ly closed to prevent


ent ry of dust, m oisture, insects etc.
(5) Ensure spring charging handle & m anual
handle are available easily.
(6) Decide m aintenance schedule based upon
(a) no. of short circuit operat ions,
(b) frequency of breaker ON/OFF operations,
(c) pollution level (d) hum idity, et c.
(7) Isolat e & earth the breaker before carrying
out m aintenance & ensure it is in OFF
position & springs are discharged
com plet ely before cleaning.
(8) Ensure that t he shut t ers are close and pad
locked before start ing t he m aintenance or
cleaning of t he panels.
(9) Depending on site conditions, inspect
- t he interior of the panels for dust ,
cobw ebs et c. & clean t hem .
- porcelain insulators & clean t hem ,
- operat ing m echanism part s such as
plungers of releases, m oving joint s etc. &
clean them , and
- f unctioning of space heaters.
(10) Lubricate m oving par t s w it h lubricant s
provided f or t he breaker.
(11) Ch eck in sulat ion resist an ce w it h a m egger
bef ore putt ing the breaker back int o service.
(12) Keep a log-book for each panel.
(13) Follow inst ructions given in the operat ing
m an ual.
(14) Ensure panel operations, m aintenance et c.
is done by t rained persons.
(15) Operat e the defeat int erlock of CB door only
in case of em ergency.

29
8 Ad dit ion al In f orm at io n

8.1 Ref eren ce List o f It em s

2.1 Circuit Breaker Com partm ent Fig 2 6.2 Bushings of low er m ating cont act Fig 6, 17
2.2 Cable & CT Com partm ent Fig 2 6.3 Current Transform er Fig 6
2.3 Busbar Com part m ent Fig 2 6.4 Cable Connect ion Pieces Fig 6
2.4 Low Voltage Com part m ent 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 Compart m ent Door Fig 7, 21, 21a
3.2 Insulating Sw it ching 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 Cont act 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 Sw it ch Handle Fig 8
3.7 Guide Roller on t ruck Fig. 3 10.1 End Covers Fig 14
3.8 PP Tube Fig. 3 10.2 Pressure relief channel for
cable term inat ion com part m ent Fig 14
3.1.1 Pole Flange (Upper) Fig 3.1
10.3 Pressure Relief flaps Fig 14
3.1.2 Pole Flange (Low er) Fig 3.1
16.1 Breaker Com part m ent door Fig 16, 20,
3.1.3 PT on the truck Fig. 3.1
21, 21a
3.2.1 M echanical `ON' Push Button Fig. 3.2
16.2 Upper m etallic shutter Fig 16, 19
3.2.2 M echanical `ON' Push Button Fig. 3.2
16.3 Low er m et allic shut ter Fig 16, 19
3.2.3 Spring Charging Opening Fig 3.2
16.4 Space Heater Fig 16, 17
3.2.4 Spring Charge Indicat ion Fig 3.2
17.1 Fixed Contacts (Upper) Fig 17
3.2.5 M echanical `ON & `OFF' Indication Fig 3.2
17.2 Fixed Cont act s (Low er) Fig 17
3.2.6 M echanical Operat ion Counter Fig 3.2
17.3 Eart hing 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 Cham ber Fig 18
4.2 Door close interlock Fig 4
19.1 Shutter operating rod Fig 19
4.3 View ing w indow for truck position Fig 4
19.2 Roller Guide Angle Fig 19
4.4 View ing w indow for Spring charge
19.3 Truck guide Fig 19
Indicator and M echanical 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 Ram p Fig 4
21.3 Window for the indicators of
4.8 Interlocking Plate (Drive Box) Fig 4 t he 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 m echanism for operat ing t he for racking t he breaker truck Fig 21, 21a
breaker in service position Fig 4 21.6 Opening for defeat ing interlock Fig 21, 21a
4.13 Rod Lever Fig 4 21.7 Door Handle Fig 21
5.1 Bushings of upper m ating 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. Sw itch) Fig 24
5.3 Feeder connections Fig 5 24.2 M oving Cont act (E. Sw itch) Fig 24
5.4 Busbars Fig 5 24.3 Earthing Sw itch Shaf t Fig 24
6.1 Main Earth Busbar Fig 6, 18 24.4 Operating Link Fig 24

30
When ordering spare part s st at e t he follow ing:
1 . Type designat ion, Rat ing, Year of m anuf acturing of t he panel as stat ed on t he rat ing plate.
2 . The designat ion of part , as located from the phot ograph or sket ch given in t his m anual.
3 . The descript ion of t he part as given in t he reference list on page 29.

4 . In case the item is not list ed below or is not show n in any of the photograph or sket ch, please com m unicate
w ith, brief descript ion of the part and it s locat ion in t he panel.
5 . Alternat ively, a sam ple m ay be subm it ted.

8 .2 Join t in g To rq u es

Sr. No. Typ e of Join t To rq u e (Nm ) ± 10%

Size of Bolt M8 M 10 M 12 M 20

Propert y Class 6.6 8.8 8 .8 8.8

1 Steel to Steel 32 65 115 -

2 Steel w it h Insulat or 16 32 77 170

3 Busbar Joint 20 40 70 -

4 Busbar w it h Steel 20 40 70 -

Note: The Values given in t he t able above are for Tig h t en in g To rqu es. For test ing t he joint 70% of above
values are to be considered as Ch eckin g Torq u e.

31
Siem ens Lt d.
Pow er Transm ission & Distribut ion Division
M edium Volt age Sw it chgear
Thane Belapur Road,
Than e 400 601.
Tel. : +91-22-760 0135
Fax : +91-22-760 0134 Order No. 4 -XXBXX-03-17231-101

Siem ens Lt d. 'Product developm en t is a con tinuous process. Consequent ly, t he 030001
dat a in dicated in t his Booklet is subject t o change w ith out prior
PTD-03-152-015
not ice. For t he latest inform at ion please con tact our Sales Of fices.'
This replaces PTD-03-152-003
s
s