Cressall Resistors Ltd,

Evington Valley Road, Leicester, LE5 5LZ,

United Kingdom
Tel: +44 (0)116 273 3633, Fax: +44 (0)116 273 7911
Email: info@cressall.com, Web: www.cressall.com

CRESSALL RESISTORS

TECHNICAL MANUAL

FOR

NEUTRAL EARTHING RESISTORS

Page 1 TDS015A
 CONTENTS

Section Title

0 Safety Instructions

1 General Description

2 Unpacking

3 Site Installation

4 Maintenance

5 Replacement Parts

Page 2 TDS015A
 Section 0

Safety Instructions

1 Compliance with Instructions in this Manual

The Purchaser/User should comply with the instructions and information given in
this manual and ensure that all personnel to be associated with the apparatus
supplied under this contract are made familiar with the information contained
herein.

2 Installation

The Purchaser/User should ensure that technically qualified and competent

persons correctly install the apparatus supplied under this contract in a suitable
location.

Apparatus supplied as loose components, devices or sub-assemblies could, when

energised, constitute a safety hazard. The Purchaser/User should ensure that
such apparatus is installed in a secure location and that adequate safety
information about the installation is provided to all personnel to be associated with
it.

3 Operation & Maintenance

3.1 Guidance Notes for Users on the Safety of Personnel

The rules for ensuring the safety of personnel can be summarised as follows: -

(a) During Normal Use ensure that the plant operators:

- Are fully conversant with all controls, particularly those for emergency shutdown

- Comply with safety warning notices and keep all enclosures shut

- Are trained to recognise signs of malfunction and know what action to take in
the event of trouble or difficulty

(b) During Maintenance, Testing etc. ensure that only technically competent and
authorised persons are permitted to carry out work and that they:

- Comply with statutory requirements

- Are fully conversant with the apparatus and the system of which it is a part, and
recognise the safety hazards which could arise, e.g. back feed.

Page 3 TDS015A
 - Electrically isolate the apparatus completely and prove it to be dead before
starting work. If an isolator is not provided with the Neutral Earthing Resistor
it must be isolated elsewhere before any work is carried out
Precautions must be taken to ensure that the isolated apparatus cannot be
re-energised whilst work is being carried out.

- Comply with safe working procedures for the safety of yourself and of others
working on the equipment. Use temporary barriers and warning notices
where appropriate.

- Are conversant with the information provided, particularly on matters relating

to safety

- Recognise the hazards that can arise when working on live apparatus and
take all the necessary precautions

- Functionally check the apparatus and then mechanically and/or electrically

test it in accordance with this manual and good working practice before
putting the apparatus back in service

- Take account of the possibility that the apparatus may have been modified
without proper reference to the manufacturer and take extreme caution at all
times before, during and after any work is carried out

If there is any doubt as to the correct and safe method of working then further
assistance should be sought from the supplier.

3.2 Skills Required for Specific Tasks

To ensure that the apparatus is safe for use under normal healthy plant operating
conditions: -

- It has been designed and tested in accordance with relevant British European
and International Standards i.e. IEEE 32, BSEN 60529, BSEN ISO9001 &
IEC60071-1 & -2

- Information is provided in this manual about the conditions necessary for safety
and about any hazards which are reasonably foreseeable during normal use,
together with precautions to be taken to counteract them.

The Purchaser/User should ensure that the apparatus is maintained in a safe

condition. If technically competent and authorised personnel have to gain access to
apparatus that is not made completely safe as recommended, everyone under
whose authority these persons act should ensure that appropriate safety
procedures are generated and are complied with.

The apparatus covered by this manual has been allocated the Apparatus Grade
stated below. Reference to the Apparatus/Task/Skill Level Schedule enables the
user to select personnel to carry out specific tasks requiring access to the
apparatus.

Page 4 TDS015A
APPARATUS/TASK/SKILL LEVEL SCHEDULE FOR WORKING ON THE APPARATUS

APPARATUS MINIMUM SKILL LEVEL REQUIRED FOR

GRADE DEGREE OF INTEGRAL 100% SETTING, SETTING, SPECIAL

ISOLATION PROVIDED FOR ISOLATION & CLEANING, CLEANING, TESTING,
PROVING DEAD ROUTINE ROUTINE COMMISSIONING
MAINTENANCE MAINTENANCE, FAULT FINDING
ROUTINE
TESTING

With Power On With Power On

100% Isolated or Not 100% or Not 100%
& Proved Dead Isolated Isolated

1 100% isolation by operation C A C C

of the isolators provided

2 Partial isolation only by C A C C

operation of the Isolators
provided. The Purchaser/
User is responsible for 100%
isolation elsewhere

3 No Isolator provided. The C B C C

Purchaser/User is
responsible for any necessary
isolation elsewhere

4 100% Isolation not possible Not Applicable Not Applicable C C

because: Impracticable,
Unreasonable, & or
Undesirable

5 Apparatus supplied as loose C Skill level is C C

items, sub-assemblies etc. to be
for which the Purchaser/User determined by
is responsible for wiring Purchaser/
assembly etc. User

Page 5 TDS015A
Skill levels as referred to in the Schedule above

SKILL JOB DESCRIPTIONS

LEVEL
PROPOSED BY SUPPLIER USER
Operating and maintenance
staff with NO electrical knowledge
A but fully conversant with the
operation and maintenance of
the apparatus

Maintenance staff with SOME

electrical knowledge and fully
conversant with the operation
B and maintenance of the apparatus
and the system of which it is a
part.

Authorised and competent staff

(e.g Electrician, Commissioning
Engineer) with HIGH degree of
electrical expertise: trained to
C work on live apparatus and
fully conversant with the
apparatus and the system of which
it is a part.

Page 6 TDS015A
 SECTION 1

GENERAL DESCRIPTION

Based on the information provided in your order the resistor provided has been designed
to meet the requirements of IEEE 32 when operated at the rating specified in your order.

The resistor is built up from a number of individual, replaceable coils arranged in banks to
meet your specified details.

RP resistors are manufactured from continuous stainless steel alloy strip wound edgewise
into elliptical coils. Ceramic insulators mounted on a stainless steel centre support with
stainless steel terminals welded to each end support each coil. The arrangement freely
allows expansion and contraction of the resistor elements without imposing strain on the
coils or terminals.

CC resistors are manufactured from continuous stainless steel alloy wire wound into
coiled coils. A ceramic insulator mounted on a stainless steel centre support with stainless
steel terminal bands at each end supports each coil. The arrangement freely allows
expansion and contraction of the resistor elements without imposing strain on the coils or
terminals.

The coils are assembled in bank formation for duty at high working temperature.

The coil and bank design distributes specified working voltage across the various levels of
insulation and is fully tested in accordance with the routine test requirements of IEEE-32
1972 before despatch.

If an enclosure is provided it will have sufficient creepage and clearances for the voltage
specified in your order. Where you provide the enclosure, you must ensure that
clearances are allowed to meet these requirements and to allow cooling in the event of
operation of the resistor. The construction must allow for the resistor reaching a
temperature of 800°C during a full Earth fault.

Cable connections (For enclosed NERs)

Incoming Cable: -

This is terminated in an air insulated cable box. An M12 through bushing is provided
between the box and the resistor enclosure.

A removable undrilled gland plate is provided.

A ring type Current Transformer may be mounted inside the Cable Box above the gland
plate. The incoming cable will pass through this.

Page 7 TDS015A
Outgoing Cable: -

This is terminated at an insulated M12 terminal on the outside of the enclosure.

Enclosure Earth Connection: -

Two separate M12 terminals are provided on the exterior of the enclosure for bonding the
enclosure to earth.

N.B. When removing covers and gland plates etc. ensure all screws, nuts, washers etc.
are refitted to ensure earthing continuity.

Page 8 TDS015A
 SECTION 2

UNPACKING / LIFTING

NOTE: THE RESISTOR MAY COME COMPLETE WITH INTERNAL WOODEN

BRACING FOR TRANSPORT PURPOSES WHICH MUST BE REMOVED
COMPLETELY BEFORE OPERATION

2.1 Shipping
Unit is shipped in ready to use state.

2.2 Storage
Storage in the original packing is recommended particularly where equipment is in
a sealed bag inside a packing case. Most equipment is suitable for storage
outdoors.

2.3 Receiving
Once received, the unit should be unloaded and moved by forklift or crane taking
care that it does not receive any mechanical shock. A preliminary inspection of the
unit should be made to ensure it was correctly handled during transit. More
information is given on inspection procedures in the “Site Installation” section of this
manual.

2.4 Lifting
Top mounted eyebolts are provided for easy handling by crane. A forklift can be
used providing that extra precaution is taken to ensure the forks rest against the
steel angles of the enclosure and not the bottom screening.

LIFTING SLING ANGLE DATA

MAXIMUM LIFT FOR 4 EYE NUTS = 700 X SINE φ X 4 KG

φ
φ

ANGLE φº MAX LIFT (KG)

90 2800
85 2790
80 2760
75 2700
70 2630
65 2540
60 2420
55 2290
50 2140
45 1980

Page 9 TDS015A
 SECTION 3

SITE INSTALLATION

3.1 Location on Site

The following points should be taken into consideration when locating the equipment: -

a) Access

For access at least 1000mm is required around all removable covers. Local or site
regulations may specify greater clearances.

The equipment must be located in a secure environment as panel removal gives

access to live metal.

b) Ventilation

Neutral Earthing Resistors may become very hot during operation. Free-air flow is
required around the resistor enclosure. A recommended minimum of distance of
250mm should be allowed.

c) Safe Working

High Temperature - Both the issuing air temperature and the enclosure surface
temperature may exceed 100°C during normal operation.

Other equipment or combustible materials must not be placed on top of the

enclosure or be in contact with the side panels.

3.2 Installation

A level foundation is required.

The Neutral Earthing Resistor is supplied ready assembled.

No special tools are required.

The safe working load of any lifting equipment used must be in excess of the weight
given on the rating plate of the NER.

Place the Neutral Earthing Resistor on the prepared base.

Remove front and back covers.

Check fixing integrity of resistors

Page 10 TDS015A
Examine for signs of damage during transit i.e. Check that the enclosure and support
structure are undamaged, that there are no broken insulators and that the resistor
elements are secure on their mountings.

Secure the Neutral Earthing Resistor onto its base. For a concrete base, use expanding
bolts or rag bolts which penetrate at least 100mm into solid ground.

Ensure that all connections are tight.

Refit front and back covers.

Remove cable box covers.

Drill gland plate as required.

Connect incoming cable.

Carry out commissioning checks as detailed below.

Refit cable box cover.

Connect outgoing cable. (Resistor Earth).

Connect enclosure earth bonding cables as required.

Check all enclosure bolts are tight.

Tightening Torques
For Stainless Steel Bolts and Screws

Size Torque N - m
M6 7.2
M8 17.6
M10 35.0
M12 61.2
M16 152.0
M20 296.4
M24 512.8

Tightening Torques
For Bushing Stems & connections to Bushing Stems
e.g. Cable Lugs

Size Torque N - m
M10 14
M12 20
M16 25
M20 35
M24 45

Page 11 TDS015A
3.3 Commissioning

i) Check resistance value is the same as that on the rating plate.

ii) Check insulation resistance with earth connection disconnected. This should be
greater than 100MΩ (but is dependent on humidity levels)

Alternatively: Carry out an applied potential test.

Maximum applied voltage = ( 2.25 x phase voltage ) + 2000V at 50 Hertz.

N.B. If the Earth Bushing is on the outside of the enclosure then the maximum
applied potential should be 10kV.

Do not energise Current Transformers with the Secondary Winding open

circuit.

iii) Reconnect earth cable

3.4 De-commissioning

i) Ensure the equipment is isolated and that the remainder of any electrical system
it forms part of can function safely without the Neutral Earthing Resistor in circuit.

ii) Remove Cable box cover and disconnect and remove incoming cable.

iii) Remove outgoing earth and bonding earth cables.

iv) Remove foundation bolts.

Page 12 TDS015A
 SECTION 4
MAINTENANCE

The equipment must be completely isolated from the power supply before carrying
out any form of maintenance.

Routine:

Very little maintenance is required on this equipment but maintenance inspections should
be carried out at regular periods to ensure that the equipment is in a good and reliable
condition. The frequency of the inspections is dependant upon site conditions i.e.
atmospheric pollution, safe access to the equipment etc. but initially could be on a 6
monthly basis.

Access to the resistor units is by removing either the front or back cover.

Remove cable box cover and:

(a) Remove all dirt from cable terminations and porcelain insulators.

(b) Check that all connections are sound and that fixings are tight.

(c) Inspect the enclosure for damage and make good any damaged areas.

After inspection ensure that the enclosure covers are securely fastened in position.

After a System Fault:

Remove the enclosure covers and check:

a) That the support insulators are not broken.

b) That the Resistor Elements are undamaged. Whilst they will show signs of having been
very hot, they should not be distorted and the ceramic supports should not be cracked.

c) That the incoming cable connection is sound.

d) Check the earth connections from the resistor and the frame are sound.

e) Check that all fastenings are tight

f) Refit covers.

Page 13 TDS015A
 SECTION 5

REPLACEMENT PARTS

Should it be necessary to replace any part of this equipment contact Cressall Resistors
quoting the serial number of the equipment that is found on the rating plate and give a
description of the part required.

The principal electrical components are:-

Resistor element

Resistor element end insulator

Inter-bank insulator

Foot insulator

Neutral bushing

Resistor ground terminal

Page 14 TDS015A