s

Installation, Operation and Maintenance Instructions

Air Insulated Metal-Clad Single Busbar Medium Voltage Switchgear Type 8BK80
On withdrawable circuit-breaker truck for 36 kV

Table of Contents
Page Nos
1. 1.1 1.1.1 1.1.2 1.1.3 1.2 1.2.1 1.2.2 1.2.2.1 1.2.2.2 1.2.2.3 1.2.2.4 1.2.3 1.2.4 1.2.5 1.2.6 1.2.7 1.2.7 .1 1.2.7 .2 1.2.7 .3 1.2.7 .4 1.2.8 1.2.9 1.3 1.4 2. 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2 2.6 2.6.1 2.7 2.7 .1 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.9 2.10 2.11 2.11.1 2.11.2 2.11.3 2.11.4 2.11.5 2.12 3. 3.1 3.1.1 3.1.2 3.2 3.3 3.4 Technical Description General Application Specific Standards Ambient Temperature and Humidity Design Features Switchgear Layout Circuit Breaker Compartment Service Position Test Position Isolated Position Removed Position Busbar Compartment Cable & CT Compartment Compartment for Low Voltage Equipment Accessories Range of Panels Feeder Panels Bus Sectionalizer Panel Metering Panel Isolating Panel with I/C & O/G Connections General Construction Interlocks Technical Data Rating Plate Installation Foundation Electrical Service Room Dimensions Transport Units Packing Unloading Handling Equipment Required Procedure Examining the Switchgear against damages Storage Transferring the Transport Units Removing the truck from the panel Assembling the Switchboard Joining of the Panels Fixing the Switchboard to the Foundation Joining of the Busbars Bolting the Main Earth Bar sections together Termination of HV Cable Connection Earthing of Switchboard Other Work to be carried out Checking the HV Connections Checking the bolted Joints Cleaning the Switchboard Inserting the withdrawable parts Protecting the panels against Environmental effects Interpanel Wiring Putting the Switchgear into Service Test Operations With Door Open With Door Closed Checking the Accessory Items Revising the Circuit Diagram Space Heaters 3 3 3 3 3 3 3 3 3 4 4 5 5 6 6 7 7 7 7 7 7 8 8 9 10 10 12 12 12 12 12 12 12 12 13 13 13 13 14 14 14 15 15 15 15 15 16 16 16 17 17 17 19 19 19 4. 4.1 4.1.1 4.1.2 4.1.2.1 4.1.3

Page Nos
Operations Withdrawable Truck Positions of the withdrawable truck Transferring the Withdrawable Part from the test / disconnected position manually Normal Operations Transferring the Withdrawable Part from the Connected position to the test / disconnected position manually Normal Operations Castell Key Operation Removing the LV Plug Connecting the LV Plug Circuit Breaker Operating Mechanism Circuit Breaker Operation Charging the closing spring by hand Breaker ON and OFF Mechanically Electrically Switching State Indication Withdrawable Line PT Truck Earthing Earthing of Busbars and Cables Direct Earthing of Busbars with Conductors Earthing of Cables with Conductors Removing Earthing Connections Earthing of Busbars / Cables with a Drawout Truck Disconnection of Earthing Drawout Truck Earthing the Busbars / Cables with Earthing Switch Earthing Busbars with Earthing Switch Earthing Cables with Earthing Switch Disconnection of Earthing Switch Earthing of Busbars or Cables with Truck Earthing of Busbars with Bus Earthing Truck Earthing of Cables with Cable Earthing Truck Link Type Earthing Truck Breaker Compartment Door To Open the Door To Close The Door Door to LV Compartment To Open the Door To Close the Door Maintenance Inspection Schedule Cleaning Lubrication Replacement (Spare) Parts Defeating the Door Interlock of HV Compartment Drawout Unit in Connected Position Drawout Unit in Disconnected Position Restoring the Door Interlock Disposal of Product Summary of Important Instructions Additional Information Reference list of Items Jointing Torque 20 20 20 20

4.1.3.1 4.1.3.2 4.1.4 4.1.5 4.2 4.3 4.3.1 4.3.1.1 4.3.1.2 4.3.1.3 4.3.2 4.4 4.5 4.5.1 4.5.1.1 4.5.1.2 4.5.1.3 4.5.2 4.5.2.1 4.5.3 4.5.3.1 4.5.3.2 4.5.3.3 4.5.4 4.5.4.1 4.5.4.2 4.5.4.3 4.6 4.6.1 4.6.2 4.7 4.7 .1 4.7 .2 5. 5.1 5.2 5.3 5.4 5.5 5.5.1 5.5.2 5.5.3 6. 7. 8. 8.1 8.2

20 20 21 21 21 21 21 21 21 21 21 22 22 22 22 22 23 23 23 23 23 23 24 24 24 24 24 24 24 24 24 24 24 24 25 25 25 26 26 26 26 26 27 28 29 30

Subject to change due to improved design Notes: 1. The item numbers shown in the figures are explained in the fold-out central legend. 2. When ordering the manual, please quote the order no. 4-XXBXX-03-27300-001

Warning
To Ensure Personnel & Product Safety

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

VCB

Fuses

P .T.

Fig 1 : Typical Circuit Diagram

1.2 1.2.1

Design Features Switchgear Layout (refer Fig. 2)

Metal partitions subdivide each panel into a circuit breaker compartment (2.1.) a cable & CT compartment (2.2.) a busbar compartment (2.3.) a low voltage compartment (2.4.)

1.
1.1

Technical Description
General

The outside covers on sides and rear are bolted to the frame and the doors on front are hinged. 1.2.2 Circuit Breaker Compartment

8BK80 metal clad switchgear is of horizontal isolation & horizontal drawout type, suitable for easy extension of switchgear in both directions, for system voltage 36kV. The switchgear is designed for single busbar system & is fully compartmentalized. The design incorporates the set of interlocks for safe operation of switchgear. 1.1.1 Application

The circuit breaker compartment contains a withdrawable truck with Vacuum Circuit Breaker or Bus PT Truck. The breaker terminals are fitted with contact arms (3.7 , Fig 3) The withdrawable truck can be transferred between the service & test positions behind closed doors using a hand crank. 1.2.2.1 Service Position (Connected Position)

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

The metal clad metal enclosed switchgear has been type tested as per all the requirements of IEC 60298 Specification for rating & testing of insulation of electrical switchboards & switchgear for AC Voltages above 1 kV& conforms to the standards IS 3427 and IS12729. 1.1.3 Ambient Temperature and Humidity

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 panel. The truck is locked against withdrawing & earthed. The low voltage circuit is connected through the low voltage plug connection. 1.2.2.2 Test Position

The ambient temperature, the switchboard has been designed for, is stated in the rating plate.

The position of withdrawable truck in which an isolating distance or segregation is established in the main circuit & in which control circuits are connected. 3

2.3

2.4

2.2 2.1

2.1. Circuit Breaker (CB) compartment 2.2. Cable & CT compartment

2.3. Busbar compartment 2.4. Low Voltage (LV) compartment

Fig 2 : Side view of switchgear panel

3.9

3.3 3.7 3.4 3.5 3.6 3.1 3.8 3.2

In the test position, the truck with the breaker is withdrawn so far between busbars & outgoing cables that there is isolating distance. The truck is locked against moving. The low voltage circuit is connected through low voltage plug connection. Also metallic shutters drop down and cover the bushing of upper & lower mating contact the circuit breaker truck is earthed via a spring loaded pin in test position. The circuit breaker can be tested for all functions. 1.2.2.3 Disconnected Position (Isolated Position)

The position of withdrawable truck in which an isolating distance or segregation is established in the circuits of the withdrawable truck, the truck remaining mechanically attached to the enclosure. In this position the truck is withdrawn as in test position but the LV plug is disconnected.

3.1. 3.2. 3.3. 3.4. 3.5. 3.6. 3.7 . 3.8. 3.9.

Mechanical ON Push Button Mechanical OFF Push Button Spring Charging Opening Spring Charge Indication Mechanical ON & OFF indication Mechanical Operations Counter Contact Arms with Tulip Contacts Truck Handle End Partition (Truck)

In both the test & disconnected positions the contact arms & their mating contacts are separated by metallic shutters. 1.2.2.4 Removed Position

Fig 3 : Withdrawable truck with 3AH3 Vacuum Circuit Breaker 4

The position of withdrawable truck when it is outside the panel & electrically as well as mechanically separated from it. Ramps are provided at the front bottom of the panel to withdraw the truck out of the panel smoothly.

4.11 4.9 4.3 4.16 4.12 4.4 4.5 4.10 4.14 4.15

4.2 4.1

4.11 4.8 4.7 4.6 4.13

4.1. 4.2. 4.3. 4.4. 4.5. 4.6. 4.7 . 4.8. 4.9.

Door locking hinge pin Door close interlock Viewing window for truck position Viewing window for spring charge indicator and mechanical counter LV connection plug Drive mechanism housing Ramp Interlocking plate (Drive Box) Holder for LV plug

4.10. Clip for locking LV plug to breaker 4.11. Opening for hand crank for charging the closing spring 4.12. Twist grip for operating the breaker in service position 4.13. Rod lever 4.14. ON push button 4.15. OFF push button 4.16. Plate covering manual spring charge opening

Fig 4 : Withdrawable Truck in Test Position & door open Drive Mechanism of the truck is attached to the panel frame using Rod Lever. The earthing strip at the bottom of the breaker compartment, along with the spring loaded pin provided at the bottom of the circuit breaker truck ensures the earthing of the truck in service, test & disconnected position. 1.2.3 Busbar Compartment (refer Fig. 6) The main busbars are mounted on cast resin insulators (6.2). The ends of the smaller main busbars are connected with the longer busbar links extending from one panel to the next. 1.2.4 Cable and CT compartment (refer Fig. 8)

The Cable compartment contains: Bushings with the mating contacts for the lower contact arms of the withdrawable part (8.2) Cable termination pieces (8.4) A section of the main earth bar Current transformers (8.3) The cable termination pieces are accessible from the rear.

The busbar compartment contains: The busbars (6.5) Bushings with the mating contacts for the upper contact arms (6.1) Feeder Connections (6.3)

3.7 5.3 6.4 6.5

5.1

6.2

6.2. Cast resin insulator 6.5. Main busbar 6.4. Joint shrouds

Fig 7: Busbar joint 1.2.6 Accessories (refer Fig. 9)

Following accessories are supplied with the switchgear.

5.1. Vacuum interrupter 5.2. Insulated switching rod 5.3. Insulated phase barrier (truck)
5.2

Hand crank for charging the closing spring of the vacuum circuit breaker (9.1) when in service position. Hand crank for truck movement between service and test position (9.2). Double bit key for locking the truck transfer operating mechanism (9.3) Rod trap key for LV compartment.(9.4) Earthing switch handle (Optional).(9.5)
8.3

Fig 5: Side view of withdrawable part of breaker 1.2.5 Compartment for Low Voltage Equipment

LV compartment (2.4, Fig 2) contains all the low voltage devices (protective relays, MCBs, terminals, etc.,) Indicators and relays are accommodated in door cutouts.

6.4 6.5

6.3

6.2 6.1

8.2

8.5

8.1

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

Bushings of upper mating contact Cast resin insulator Feeder connections Joint shrouds Main busbar Explosion rents

8.4

8.1. 8.2. 8.3. 8.4. 8.5.

Phase barrier (Cable chamber) Bushings for lower mating contact Current transformer Cable connecting pieces Bushing cover

Fig 6: Busbar compartment 6

Fig 8: Cable compartment

I/C

O/G

9.5 9.2 9.3 9.4 9.1

VCB VCB

VCB

CT

CT

CT

9.1. 9.2. 9.3. 9.4. 9.5.

Charging handle Cranking handle Double bit key Rod trap key Earthing switch handle

Fig 10a

Fig 10b

Fuses

VCB O/G CT

Fig 9: Accessories 1.2.7 Range of Panels

P .T.

General : For a metal clad enclosed switchgear there are various panel modules available. All the panels are constructed using identical parts as far as possible. 1.2.7.1 Feeder Panels (Fig 10a)

I/C

Fig 11 1.2.8

Fig 12 General Construction

The feeder panels are suitable for incoming as well as outgoing supply. Outgoing feeder panels with circuit breaker on the truck are most frequently used. Alternatively, these panels can also be equipped with an isolating truck. The panel is available with current transformer either with earthing switch or without earthing switch. The earthing switch is always equipped with manual drive. 1.2.7.2 Bus Sectionalizer Panels (Fig 10b)

Safety devices & interlocks are provided to avoid any malfunctioning. These devices protect the operating personnel & ensure reliable operations. The interlocks are explained in section 1.2.9. The panel is compartmentalized in different compartments with metallic partitions. Vacuum circuit breaker for the panel is mounted on the truck. All the identical trucks of same rating in different panels are interchangeable.Trucks are earthed with panel in both test & service positions. Busbars are insulated and their joints are shrouded. Outgoing cables can be earthed by means of manually operated earthing switches with withstand capacity (Optional). Earthing trucks instead of in-built earthing switch can be provided. C.T .s are mounted on stationery part in the cable chamber. Line P .T.s are available with an arrangement of drawout fuses. Bus P .T .s with fuses are mounted on withdrawable truck. At a later date extension of existing switchboard is possible. Delivery of completed & tested panels to site consists of single panel section, except the bus sectionalizer panel which consists of two panel section. 7

In bus sectionalizing panel one panel is used for the truck with the C.B. (alternatively, an isolating truck) & second panel for connection of busbars to the top. Both the panels are usually delivered as one assembled transport unit. Both panels are separated by a partition in busbar chamber. The Bus Sectionalizer panel can be combined with a metering panel. 1.2.7.3 Metering Panel (Fig 11)

Basically metering panels are of the same construction as the standard outgoing panels. The metering truck with voltage transformers & HRC fuses in series is equipped with 3 upper contact arms only & therefore three lower fixed isolating contacts are not installed. 1.2.7.4 Panel with I/C & O/G Connections (Fig 12)

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

1.2.9

Interlocks

1.3

Technical Data 36 kV

The positions of the withdrawable truck are described on page 3 & 4 State Withdrawable truck in service position, switching device ON Withdrawable truck in service position, switching device OFF Withdrawable truck located between the service and test positions Withdrawable truck in test position, switching device ON Withdrawable truck in disconnected position LV plug pulled off, switching device OFF, door open The following operations are not possible Removal of the withdrawable truck Opening of the door Pulling of the LV plug Removal of the withdrawable truck Opening of the door Pulling of the LV Plug Closing of the switching device Opening of the door Pulling of the LV plug Transfer of the withdrawable truck to service position Closing of the door transfer of the withdrawable truck to service position.

Rated Voltage

Rated Power Frequency withstand Voltage 70 kV Rated Impulse Withstand Voltage Rated short circuit breaking current Rated short time current (3s) Rated short time making current (peak) Rated current of bus (maximum) Rated current of feeder (maximum) Overall Dimensions : Refer Fig 13
w mm Panel Dimn. (Unpacked) 1100 Panel Dimn. (Packed) 1300 h mm 2250 2500 h1 mm 2250 d2 mm 400 d3 mm 2700 d4 mm 2758 3000

170 kV 31.5 kA 31.5 kA 78.75 kA 3150A 2500A

Panel weight : Approx. 1300 kg with vacuum circuit breaker.

* Single row of panels 13.1. Covers are fitted to the left & right of the switchboard

** Two rows of panels

13.2. Pressure relief channel for the cable termination compartment, 110 mm deep. 13.3. Pressure Relief Flaps
All dimensions are in mm and are for the standard panel.

Fig 13: Overall Panel Dimensions and recommended clearances 8

1.4

Rating Plate

A rating plate containing the particular data is fixed inside LV compartment of each panel. The withdrawable vacuum breaker has its own rating plate and the rated normal current stated on it does not apply to the feeder. Degree of protection Basic model IP 4X acc. to IEC 60298 or IP 40 acc. to IEC 60529

The panels are gasketted to make them dust & vermin proof. IP 41, IP 5X and IP 51 can also be provided.

Un Up Ir Isc Ibusbar Ifeeder f tk

Rated Voltage Rated Lightening Impulse Withstand Voltage Rated Short Ckt. Breaking Current Short Circuit Making Current Busbar Current Feeder Correction Current Rated Frequency Short Ckt. Duration

Fig 14 : Rating Plate of a Panel

2.

Installation

False Floor Place a girder in the cutout common to several or all of the switchboards so that it is parallel to the operating front. The girder is meant to support the panel bottom rails below the 30mm x 30mm cutouts. Concrete Floor This should be provided with foundation rails on which the panels are to rest. For floor cutouts refer to Fig 15. The foundation should be prepared before the panels arrive. Level differences between the mounting surfaces of the individual panels should be determined and compensated for by using a sheet as shown in Fig 16. 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 15a. 2.2 Electrical Service Room Dimensions At least 750 mm At least 800 mm At least 2500 mm

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

Min. clearance to the ceiling above the top of panel Min.clearance on the sides & rear of the panels Min.width of control aisle in front of the panel for single row Min.width of control aisle in front of the panel for two rows facing each other

At least 4000 mm

All dimensions are in mm and are for the standard panel

Fig 15 : Foundation Plan

All dimensions are in mm and are for the standard panel

Fig 15 a: Typical Base Frame Dimensions 10

W
measuring surface

d
t

According to DIN 43 661, DIN 7184 and DIN 18 202, sheet No. 3, the following steps should be adhered to: For equalization of all irregularities of the rough floor, the screed to be applied to the floor should be at least 10 mm higher than the height of the foundation rails. Before applying the screed to the floor, the foundation rails should be aligned, leveled and anchored to the rough floor. The top edge of the foundation rails should be flush with the upper surface of the finished floor, taking ceramic tiles, stoneware tiles or any other floor coverings into account.The surface of the screed or of the floor covering should not be higher than the level of the top edge of the foundation rails. The plane defined by the carrying surfaces of both (or several) parallel foundation rails has to be levelled in two directions 90 degrees apart by means of a levelling instrument consisting of two water filled glass tubes connected by a rubber hose. The level tolerance, measured along a distance of one meter, shall not exceed one millimeter.
The straightness tolerances, as required by DIN 43 661 shall include the level tolerance and shall nowhere in the complete plant to be installed exceed 2 millimeters.

RATED VOLTAGE kV mm mm 2700 1100

36

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

MEASURING POINTS A1 TO B21 ON THE FOUNDATION

Fig 16 : Dimension data sheet for the foundation.

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.

A 6 12 7 8 9 10 11 16 15 14 13 17 18 19 20 21 d

Tolerance as per DIN 43661: Straightness 1mm. per 1meter Length, 2mm. for overall length Level 1mm within 1meter measured length. Higher tolerances are to be compensated by laying sheets (below panel)

MEASURE ELEVATION OF POINTS A1 TO B21 WITH A LEVELLING DEVICE 6 12 7 8 9 10 11 13 14

1.DIMENSIONS MAY HAVE TO BE ALTERED IN LINE WITH THE FOUNDATION RAIL CENTERES 15 16 17 18 19 20 21

DIFFERENCE IN ELEVATION BETWEEN THE VARIOUS POINTS AND THE HIGHEST MEASURING POINT. 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

In case foundation rails or fabricated channel frames are embedded in cement concrete, care should be taken to leave open pockets below the location of fixing holes of the panel for tightening the foundation bolts.

11

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

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

A transport unit consists of a single assembled panel (except Bus - Sectionalizer panels), complete with withdrawable truck. The panel should not be lifted from the top with circuit breaker inside. 2.4 Packing

Move each transport unit into the building. Take off the plastic sheet immediately prior to bolting the transport units together and also temporarily to check them for any signs of transport damage. 2.6 Examining the switchgear against damage

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

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

Store the packing cases in upright position only The packing cases must be stored in adequetly covered location such that they are protected from sun, rain, flood waters & other such natural elements It is preferable to open the crates and polythene cover provided on the panel only before installation. 2.7 Transferring the transport units to their points of installation

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

A mobile crane or a chain pulley block for unloading the transport unit. Lifting tackle A fork-lift truck with a fork length of about 3.0 mtr, for handling the switchgear inside the building. Hydraulic jacks or winches & roller pads. The handling/transport gear must meet the site requirements with regard to its construction and load bearing capacity. Refer to the weights (for raising and transporting) stated on the transport or in the covering documents. 2.5.2 Procedure

Transfer the transport units including their wooden pallets to the point of their installation using fork lift rollers. Withdraw the trucks out of the panels using two wooden wedges below the ramps & close the door. (Refer clause 2.7 .1) Put the panels down on the cleaned site or at least immediately in front of it in the correct order, leaving a clearance of about 25 mm between them. To remove the transport units from their wooden pallets Attach four hooks at the four corners to the lifting angles at the top of the panel to lift the panel.

Do not unpack while unloading the transport units. Take care not to damage the plastic sheet because it protects the switchgear against any environmental effects. Use of mobile crane or a forklift truck. 12

 Remove the wooden pallet. Lower the transport unit as far as it will go & place it on two wooden beams if it is located above its site or place on four roller pads if it is in front of the sites In the later case roll the units to their mounting position. If this means changing the direction of travel raise the unit & reposition the roller pads accordingly. Now place the planks & channels in the foundation cutouts that have to be crossed. To raise the panels on their mounting position & removing the roller pads Lower the transport unit as far as possible & place them on two wooden beams. Now, raise the units, first on one side & then on the other side, using roller-type crowbars. Pull out the planks & lower the panels onto the cleaned foundation. Position the crowbars only at the corners of the panels below the vertical frame members.

Fig 17 : Procedure for bolting the panels together 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 (refer Fig 16) and be absolutely vertical. If necessary place shims, under the frame uprights and

2.7.1

Removing the Truck from the Panel

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

under the bottom rails near the 30 mm x 30 mm cutouts for the foundation bolts. Remove the bolts fitted at the left hand end of each panel, as viewed from the front. Move up the second panel. Align this second panel on the foundation, raise it to the correct level and make sure the panels stand vertically. Use shims as for the first panel. Using the nuts & bolts join the adjoining panels. Check to see whether the panels are truly vertical. If necessary slacken the screws and seal the gaps with rubber. Move up the other panels in sequence, align them and bolt them together. 2.8.2 Fixing the Switchboards to the Foundation

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.

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

2.8.1

Joining of the Panels

It is assumed that the first transport unit is in its final position and that the other units are positioned on the foundation rails in the correct order but with an adequate clearance between them.

Embed anchor-bolts in the foundation (through the 30 13

mm x 30 mm cutout) or drill the appropriate holes in the foundation rails (false floor). Insert shims between the foundation and the bottom rails near the cutouts. Tighten the screw without distorting the panels. 2.8.3 Joining of Busbars

6.1 19.1

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 (6.5, Fig 6). 1. Remove the shroud on the busbar joint. 2. Brush the contact faces criss-cross wise until bright & wipe using a clean cloth. (applicable only for bare Aluminium busbars) 3. Square neck, round head, coach bolts are used for busbar joints. These bolts do not rotate in their slots & hence can be tightened from one side. Recommended torque is 70 Nm. (Refer clause 8.2) 4 Allow the joint to settle down in 24 hrs & check the value of the torque with the torque wrench.

8.2 19.2

19.4

19.3

6.1. 19.1. 8.2. 19.2. 19.3. 19.4.

Upper contact bushing Fixed contacts Lower contact bushing Fixed contacts Truck earthing srip Space heater

Fig 19 : View into circuit breaker compartment with shutter held open 5. Before joining the busbars ensure to insert the side caps of the shrouds in the busbar link. (Refer Fig 20) 6. The busbars of adjacent units must be joined together using the busbar links (Fig 20.1, Fig 20) & hardware supplied. While inserting coach bolts ensure that the round head of coach bolt is facing sheet metal structural parts. That means the nuts will always be towards the live parts such as busbars/feeder connections. The busbars (6.5, Fig 6) of the panel forming a transport unit are already bolted. 7 . Fix the shrouds on the joints after the joint is tightened.

18.4

18.2 18.1

18.3 22.3

8. Refix the upper rear cover after the busbars are bolted. 2.8.4 Bolting the Main Earth Bar

The main earth bars of the transport units must be linked together. One of the two parts to be bolted together is already fitted with a link. This must be undone, passed through the partition and bolted to the two adjacent earth bar sections. The cover on the side wall should be properly adjusted after joining the earth bars.
19.6 19.3 4.7

2.9
18.1. Compartment door 18.3. Lower metallic shutter 18.2. Upper metallic shutter 18.4. Thermostat

Terminating HV Cables

Fig 18: View into Circuit Breaker panel after removing the drawout truck 14

The cable connection pieces are provided with Hex. Headed bolts M16 with washers., spring washers & hex. Nuts for mounting the cable lugs of the conductors.

6.2

20.6 20.3

20.7 20.2 6.5 20.4 20.1

20.7 20.5

6.3

6.5. 20.1. 20.2. 6.2. 20.3.

Main busbars Busbar link Coach bolt Resin cast insulator Rear cap (Shroud)

20.4. 20.5. 6.3. 20.6. 20.7 .

Side cap (Shroud) Front cap (Shroud) Feeder connections Nylon bolt Hex bolt

Fig 20 : Assembly of Busbar joining Three part bottom cable cover is supplied fitted with the switchboard. Of these, the outer most cover has to be removed & cutouts to be made of the size as per the instructions given by cable kit manufacturer. 2.10 Earthing of the Switchboard 2.11 2.11.1 Other work to be carried out Checking the HV Connections

On all HV cables, check the bolts for tightness the sealing and earthing the core spacing on three core cables and the antimagnetic clips on single-core cables. 2.11.2 Checking the Bolted Joints

Connect the earth terminals of at least one or two panels to the station earth. This could be done to suit the local guidelines. Termination facility for earth connection is provided on the earth busbar mounted in the cable chamber.

19.3 21.1 21.2 21.3

Check the power and auxiliary circuit connections of the switching devices at random., but examine all the terminal block connections, making sure that the blocks are correctly labeled and replace any missing labels by referring to the circuit diagram. The torque values of all the busbar joints must be checked (Refer clause 8.2). 2.11.3 Cleaning the Switchboard

21.1. Earth Busbar 21.2. Extension Links

19.3. Truck eathing Strip 21.3. Bottom Covers

Clean all the post insulators, bushings and busbars in all the compartments using soft dry cloth. Do not use any abrasive chemicals or detergents to clean installed parts. 15

Fig 21 : Earth Busbar Assembly

18.2 22.2 22.3

place the withsrawable truck (23.1, Fig 23) in front of the corresponding panels. Transfer the truck inside the panel and push it as far as it will go. Fix the racking mechanism / interlocking plate to structure frame by using lift & turn levers. Fix the ramps back in the position

18.3

Close the door Insert all other withdrawable trucks in the same manner. 2.11.5 Protecting the panels against environmental effects

22.1

(a) Damaged sections of the paint finish may only be touched up with original paint.
18.2, 18.3. Metallic earthed shutters 22.1. Shutter operating rod 22.2. End insulating partition (Breaker chamber) 22.3. Truck guide

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

Fig 22: View inside circuit breaker compartment without withdrawable truck. Use only distilled water if necessary. Ensure that all parts are dried up before applying any voltage. 2.11.4 Inserting the withdrawable truck

open the front door (18.1, Fig 23) put down the ramps

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

18.1

23.1

18.1. HT compartment door

23.1. Breaker truck

Fig 23: Insertion of truck in the panel 16

3.

Putting the switchgear into service

3.1.2

With door closed

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

Each panel should be tested as follows: Transfer the withdrawable truck to the disconnected position (see 4.1). Switch ON the auxiliary and control supply. Transfer the withdrawable part to the connected position. Open and close the breaker as long as no high voltage is applied. Without using force check all mechanical and electromechanical interlocks for satisfactory functioning. Check to see whether the switching states are indicated correctly in the control room.

The motor operating mechanism start as soon as the LV plug is inserted and control supply is available (If the VCB is not already charged) Open & close the breaker several times. Pull off the LV plug. Charge the breaker closing spring by hand (refer clause 4.2) Operate the circuit breaker Refit the LV cable plug.

24.6

18.1 24.1 24.2 24.8 4.12 4.11 24.2 24.3 24.7 24.4 24.5

4.11. Opening for Hand Crank for charging the breaker closing spring 4.12. Twist grip for operating the circuit breaker in the connected position. 18.1. Door of circuit breaker compartment 24.1. Window for inspecting the withdrawable truck 24.2. ON & OFF button (On CB door) 24.3. Window for the indicators of the withdrawable truck Number of operations (Operation Counter) Closing spring of the circuit breaker Charged - Lable with spring symbol

Discharged - Blank Lable Indicator for circuit breaker switching status Circuit Breaker Closed - I Tripped - O 24.4. Opening for double bit key for locking the transfer operating mechanism 24.5. Opening with hexagon shank for fitting the hand crank for racking the withdrawable part 24.6. Door of compartment for LV equipment 24.7 . Opening for defeating interlock 24.8. Handle for operating the CB door.

Fig 24: Opening Elements 17

s
BRIEF OPERATING INSTRUCTIONS FOR 8BK80 SWITCHGEAR

FOR DETAILED DESCRIPTION OF ABOVE OPERATIONS &SPRING CHARGING OF CB, OPENING/CLOSING OF DOOR, ETC. REFER CLAUSE 4 OF THIS MANUAL Fig 25 : Label on door of breaker compartment 18

 Check whether the position of the withdrawable truck is indicated correctly (if the appropriate position switches are fitted refer to the circuit diagrams). 3.2 Checking the Accessory Items

3.3

Revising the Circuit diagrams

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

The accessory items required must be easily available in the Switchgear Room or an adjacent room. They include one hand crank for transferring the truck and for charging the breaker closing spring, a double bit key for locking the hand-operating mechanism, the basic circuit diagram, operating instructions, castell lock key (optional), earthing switch handle (Optional) and rod trap Key for opening of LV compartment door. The hand crank for transferring the truck is also suitable for all M8 bolts.

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

19

4.

Operations

Each row of panel is provided with brief operating instructions. Refer Fig 25. 4.1 4.1.1 Withdrawable truck Positions of the withdrawable truck

and locked up with the clip(4.10, Fig 4). The breaker compartment door is closed. The castell key can be removed in this position also for any interlocked operations which are to be performed with circuit breaker in open position. Fit the hand crank (9.2, Fig 9) to the hexagon shank in opening (24.5, Fig 24) turn it clockwise as far as it will go and pull it off. Insert the castell key if it was removed for interlocked operations. Turn the key clockwise through 90 degrees from position Manual Racking to Connected position(locked) and pull it off. 4.1.3 Transferring the withdrawable part from the connected position to the test/ disconnected position manually Normal Operations

Refer clause 1.2.2 for circuit breaker chamber Service position(connected position)

The circuit breaker is connected with the busbars and the outgoing circuit Auxiliary circuit is connected through LV plug and socket. Test position

The circuit breaker is disconnected from the busbars and the outgoing circuit. Segregation as specified in IEC 60298 is maintained. The LV circuits are connected through LV plug and socket. Disconnected position The circuit breaker is disconnected from the busbars and the outgoing circuit. LV circuits are disconnected by pulling out the LV socket from the plug. When the LV plug and socket are connected the following functions can be carried out. The breaker can be tested / operated, also from the control room. The breaker compartment door can be opened. Functions such as ON / OFF indication and electrical interlocks can be tested. When the LV plug and socket are disconnected. The breaker compartment door cannot be closed. Hence the truck cannot be inserted. 4.1.2 Transferring the withdrawable part from the Test/Disconnected Position manually Normal operation

4.1.3.1 In brief

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

3rd Step Trun double-bit key

from by

to

90 Fig 25b In detail:

90

Make sure that the circuit breaker is open. Insert the double bit key in lock (24.7 , Fig 24) and turn it anti-clockwise through 90 degrees from connected position (locked) to Manual Racking. The hexagon shank opening (24.5, Fig 24).is now accessible. The hand racking mechanism is unlatched. Fit the hand crank (9.2, Fig 9) to the hexagonal shank in opening (24.5, Fig 24) turn it anti-clockwise as far as it will go and pull it off. Turn the double-bit key anti-clockwise through 90 degrees from the position Manual Racking to Disconnected position(locked)and pull it off.

4.1.2.1 In brief:

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

3rd Step Trun double-bit key

from

by

to

Opening (24.5, Fig 24) is now closed. 90 The hand racking mechanism is now locked.

90 Fig 25a In detail:

Make sure that the circuit breaker is open, the LV plug (4.5, Fig 4) and socket has been put together 20

4.1.3.2

Castell Key Operations

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

4.2

Circuit-breaker operating mechanism

1st Step Turn castell key from by to

90 Fig 25c In detail:

90

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

Make sure that the circuit breaker is open. Turn the castell key (which is trapped in the mechanism) anti-clockwise through 90 from Connected position (locked) to Manual Racking. In this position the castell key can be removed for any interlocked operations which are to be performed with circuit breaker in open condition. The hexagon shank opening (24.5, Fig 24) is now accessible. The hand racking mechanism is unlatched. Fit the hand crank (9.2, Fig 9) to the hexagonal shank in opening (24.5, Fig 24) turn it anticlockwise as far as it will go and pull it off. Insert the castell key if it was removed for interlocked operations. Turn the double-bit key anticlockwise through 90 degrees from the position Manual Racking to Disconnected Position(locked) and pull it off. The castell key can also be removed in this position to facilitate the opening of the CB compartment door and / or other interlocked operations. 4.1.4 Removing the LV Plug

Procedures

If the breaker compartment door

is closed (connected position) turn plate (24.7 , Fig 24) so that it clears opening (24.5, Fig 24) insert the hand crank and fit it to the breaker is open (disconnected position) fit the hand crank directly to the breaker operating mechanism in opening (24.5, Fig 24).

Operating Mechanism

Turn the crank until the symbol spring charge appears in viewing window (24.3, Fig 24) on indicator. The operator is not at risk if the motor supply recovers,because the hand crank freewheels and detaches in the anti-clockwise direction. Pull the crank off. 4.3.1.1 4.3.1.2 Breaker ON and OFF Mechanically (locally by means of push button)

Transfer the withdrawable part to the disconnected position (in accordance with clause 4.1.3 ) and lock it. Open the breaker compartment door (refer clause 4.6.1). Unlock the plug (4.5, Fig 4) and socket connector by turning down the clip (4.10, Fig 4). Pull off the plug and attach it to the holder (4.9, Fig 4) which is fixed to the door.

In the connected position : Turn the twist grip (4.12, Fig 4) as far as it will go, hold it there, press buttons ON and OFF (24.2, Fig 24) and then release the grip.

In the disconnected position with the door closed : Press buttons ONand OFF (24.2, Fig 24) on the CB compartment door. In the disconnected position with the door open : Press buttons ON(24.2, Fig 24) and OFF (4.15, Fig 4) on the withdrawable truck.

4.3.1.3 4.1.5 Connecting the LV Plug

Put the plug (4.5, Fig 4) and socket connector together and lock it with the clip (4.10, Fig 4). Close the breaker compartment door (refer clause 4.6.2).

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

21

4.3.2

Switching State Indication

In the middle part of viewing window (24.3, Fig 24) O means OFF, I means ON. 4.4 Withdrawable Line PT Truck

As an option, the Line PT would be mounted on a separate withdrawable trucks along with a primary fuses in the rear box of the panel. The connections for the same are factory set. To disengage, push the locking levers (26.5, Fig 26) inside, turn the ramps down and pull the truck out of the panel. There are two positions possible for Line PT truck i.e., connected & withdrawn positions. After the truck is withdrawn, all the live parts of the truck must be earthed using an earthing rod. The rear cover of the compartment must be fitted back. The advantages of this kind of system are : the metering of the panel is possible even if the breaker is in test mode or disconnected position. the PT fuses can be replaced without switching off the breaker.
26.1. Drawout fuse truck 26.2. HT fuses 26.3. Upper moving contact 26.4. Lower moving contact

26.3 6.2 26.1 3.8 26.5 26.2 26.4

3.8. Truck handle 6.2. Resin cast insulator 26.5 Locking lever (PT truck)

Fig 26: Line PT truck rear view

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

27 .4 27 .2

26.1 26.2 27 .3

27.1

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.

26.1. Drawout fuse truck 27 .1. Line PT 27 .2. Upper fixed contacts

27 .3. Lower fixed contacts 27 .4 Rear box complete 26.2 Fuses

Fig 27: Drawout fuse truck in service

22

 Ensure that there is no voltage available on the parts to be earthed when earthing drawout truck without making capacity is used.
28.5 28.4

Transfer the drawout unit to the connected position (refer clause 4.1.2). In case the earhting drawout truck has an electromechanical interlock unit mounted on it, the transfer is possible only after all the interlocking conditions are satisfied. Lock it in the connected position.
28.6 21.1

28.3 28.7 28.2 28.1

28.1. Fixed contacts 28.2. Moving contact 28.3. Earthing switch shaft 28.4. Operating link

28.5. Operating rod 21.1. Earthing busbar 28.6. Earth connection 28.7 . Flexible connection

In case the drawout truck has a circuit breaker mounted on it switch ON (refer clause 4.2 & 4.3). Place the warning plates at all necessary locations. 4.5.2.1 Disconnection of Earthing Drawout truck

Fig 28 : Earth switch Arrangement on cable side 4.5.1.2 Earthing of Cables with conductors

Switch OFF the breaker in case of earthing drawout truck with making capacity (refer clause 4.3). Transfer it to the disconnected position (refer clause 4.1.3) Open the HT compartment door (refer clause 4.6.1) Disconnect the LV plug (refer clause 4.1.4) Insert the original drawout truck of the circuit breaker or link drawout truck in the panel (refer clause 2.11.4) Connect the LV plug (refer clause 4.1.5)

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. 4.5.1.3 Removing Earthing Connections

Close the door (refer clause 4.6.2) The original drawout truck is now ready for transfer to connected position. Remove warning plates. 4.5.3 Earthing the Busbars or Cables with Earthing Switch Earthing the Busbars with Earthing Switches

Disconnect and remove the shorting and earthing conductors. Close the rear cover and bolt it firmly. Remove the warning plates. 4.5.2 Earthing of Busbars or cables with a Drawout Truck

4.5.3.1

Separate drawout Trucks can be supplied optionally for busbar and cable earthing. In case fault making capacity is required, a circuit breaker is mounted on such drawout trucks. Procedure

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

Remove the circuit breaker or the link drawout truck from the panel where earthing is to be done (refer clause 2.7 .1) Insert the desired earthing drawout truck i.e. cable or busbar earthing drawout truck in the panel (refer clause 2.11.4) Connect the LV plug and socket (refer clause 4.1.5) Close the panel door (refer clause 4.6.2)

23

4.5.3.2

Earthing Cables with Earthing Switch (Fig 28)

4.5.4.3

Link Type Eathing Truck

Switch off the supply to the main busbars. Ensure that the supply to the main busbars cannot be switched ON from remote points. Ensure that the cables cannot be energized from the other end. Follow the procedure for Busbar earthing truck. 4.6 Breaker Compartment Door

Move the truck to test / disconnected position. Earthing switch cannot be closed until this position is reached. Ensure that the cables cannot be energized from the other end. Follow the procedure for Busbar earthing switch. 4.5.3.3 Disconnection of Earthing Switches

Insert the earthing switch handle in position. Turn it in the anti-clockwise direction till stop. Withdraw the handle. Remove warning plates from all the locations 4.5.4 Earthing the Busbars or Cables with Truck Earthing the Busbars with Bus Earthing Truck

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

4.5.4.1

Rotate the handle (24.8) anti-clockwise to unlock the door. Open the door. 4.6.2 To close the door

Switch off the supply to the main busbars. Ensure that the supply to the main busbars cannot be switched ON from remote points. Rack out the breaker to diconnected position. Disengage the LV plug & socket. Withdraw the breaker truck completely out of the panel. Insert the Bus earthing truck in the panel to diconnected position. Connect the LV plug to socket. Rack in the truck to service position. Place the warning plates at all necessary locations.

Shut the door. Rotate the handle (24.8) clockwise till it gets locked. 4.7 4.7.1 Door of the LV Compartment To open the door

Rotate the turnlocks with a key in anti-clockwise direction. Open the door. 4.7.2 To close the door

4.5.4.2

Earthing the Cables with Cable Earthing Truck

Shut the door. Rotate the turnlocks in clockwise direction.

Move the truck to test / disconnected position Ensure that the cables cannot be energized from the other end. Follow the procedure for Busbar earthing truck.

24

5.

Maintenance

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

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

Caution
5.1 Inspection Schedule For Safety For safety reasons, cleaning of panels shall be taken up only when the shutdown of Main & Auxilliary Power supply is taken, the breaker is in the open state, closing spring of the breaker is discharged & the breaker truck is removed out of the panel. Cleaning Agents Relays to be tested for their functionality. Clean the Panels (refer clause 5.2) Every five years Transfer the withdrawable truck to the disconnected position. Test-operate the circuit-breakers. Remove the withdrawable trucks (refer clause 2.7 .1) and carry out all maintenance work, also on the switching devices. Clean the panels (refer clause 5.2) and check the connections. Lubricate all bearing surfaces, bearings and articulated joints. Reinsert the withdrawable trucks. Check the switchpanel functions and put the board back into service. Perchlorethylene, 1.1.1 trichloroethane, small brushes, dusters and vacuum cleaner for sheet metal parts. Note: Trichlorethylene, perchloroethylene and tetrachloroethylene have a harmful effect on cast resin parts and must not come into contact with them. Cast resin parts should be cleaned with distilled water only. Silver plated and other contact surfaces to be cleaned with clean cloth. 5.3 Lubrication Each year Make a general visual check. Check whether the accessories are complete and in proper order. Clean and lubricate the wheels as well as moving parts of the truck and interlocking plate.

Immediately after cleaning: Lubricate the isolating contacts and their mating contacts with neutral grease.

25

 apply a film of neutral grease to the bearings and articulated joints of the operating mechanisms, to the withdrawable parts and shutters, and to the door hinges and locks. Recommended neutral greases are: (i) SERVOGEM 2 (multipurpose) of Indian Oil Corporation make (ii) Multipurpose grease H of Hindustan Petroleum Ltd. make (iii) Any other chemically neutral grease which can withstand temperature up to 150 C. 5.4 Replacement (Spare) Parts

5.5

Defeating the Door Interlock of HV Compartment

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

The breaker compartment door interlock should only be cancelled if the truck cannot be transferred to the disconnected position and the situation cannot be cleared in any way. Switch off the circuit -breaker. Make sure that the busbars are not live. Insert a small screw driver in the opening (24.7 , Fig 24) and screw-in the grub screw visible through the opening till it falls out inside the panel. Open the door by turning the door handle.(refer clause 4.6.1). 5.5.2 Drawout Unit in disconnected position

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

Press the interlocking lever on interlocking plate by hand. Insert the double-bit key in lock (24.4, Fig 24) and turn it (locked) to Manual Racking. Fit the hand crank (9.2, Fig 9) to the hexagon shank in opening turn it clockwise as far as it will go and pull it off (24.5, Fig 24). Turn the double-bit key clockwise through 90 from position Manual Racking to Connected Position (locked) and pull it off. 5.5.3 Restoring the Door Interlocks

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

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

26

6.

Disposal of Product

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

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

27

7
DOs

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

During Installation & Commissioning Stages :-

(1)

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

(2)

(3)

During service life of the panel-

(4) (5) (6)

Keep door & covers firmly closed to prevent entry of dust, moisture, insects etc. Ensure spring charging handle & manual handle are available easily. Decide maintenance schedule based upon (a) no. of short circuit operations, (b) frequency of breaker ON/OFF operations, (c) pollution level (d) humidity, etc. Isolate & earth the breaker before carrying out maintenance & ensure it is in OFF position & springs are discharged completely before cleaning. Ensure that the shutters are close and pad locked before starting the maintenance or cleaning of the panels. Depending on site conditions, inspect the interior of the panels for dust, cobwebs etc. & clean them. porcelain insulators & clean them, operating mechanism parts such as plungers of releases, moving joints etc. & clean them, and functioning of space heaters. Lubricate moving parts with lubricants provided for the breaker. Check insulation resistance with a megger before putting the breaker back into service. Keep a log-book for each panel. Follow instructions given in the operating manual. Ensure panel operations, maintenance etc. is done by trained persons. Operate the defeat interlock of CB door only in case of emergency.

(7)

(8)

(9)

(10) (11) (12) (13) (14) (15)

28

8
8.1
Item No. 2.1 2.2 2.3 2.4 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 4.1. 4.2. 4.3. 4.4.

Additional Information
Reference List of Items
Description Fig. 2 2 2 2 3 3 3 3 3 3 3 3, 26 3 4, 24 4 4 4 4 4 4 4 4 4 4, 24 4 4 4 4 4 5 5 5 6, 19 6,7 , 20, 26 6, 20 6,7 6 8 8,19 8 8 8 9 9 9 9 9 13 13 Item No. 13.3. 18.1. 18.2. 18.3. 18.4 19.1. 19.2. 19.3. 19.4. 20.1. 20.2. 20.3. 20.4. 20.5. 20.6. 20.7 21.1. 21.2. 21.3. 22.1. 22.2. 22.3. 23.1. 24.1. 24.2 24.3 24.4 24.5 24.6 24.7 . 24.8. 26.1. 26.2. 26.3. 26.4. 26.5 27 .1. 27 .2. 27 .3. 27 .4 28.1. 28.2. 28.3. 28.4. 28.5. 28.6. 28.7 . Description Pressure relief flaps HT Compartment door Upper metallic shut Lower metallic sh Thermost Fixed Contacts (Upper) Fixed Contacts (Lower) Truck earthing Strip Space Heater Busbar Link Coach Bolt Rear Cap (Shroud) Side Cap (Shroud) Front Cap (shroud) Nylon Bolt Hex Bolt Earth Busbar Extension Links Bottom Covers Shutter operating rod End Insulating Partition (Breaker Chamber) Truck guide Breaker Truck Window for inspecting the withdrawable part ON & OFF Button (On HT Door) Window for the indicators of the withdrawable part Double Bit Key for locking the transfer operating mechanism Opening for the hand crank for racking the withdrawable part Door of compartment for LV equipment Opening for defeating interlock Handle for operating the HV door. Drawout fuse Truck HT Fuses Upper Moving Contact Lower Moving Contact Locking lever (PT truck) Line PT Upper Fixed Contacts Lower Fixed Contacts Rear Box Complete Fixed Contacts (E. Switch) Moving Contact (E. Switch) Earthing Switch Shaft Operating Link Operating Rod Earth Connection Flexible Connection Fig. 13 18, 23, 24 18, 22 18, 22 18 19 19 19, 21 19 20 20 20 20 20 20 20 21, 28 21 21 22 22 22 23 24 24 24 24 24 24 24 24 26, 27 26, 27 26 26 26 27 27 27 27 28 28 28 28 28 28 28

Circuit Breaker Compartment Cable & CT Compartment Busbar Compartment Low Voltage Compartment Mechanical ON Push Button Mechanical OFF Push Button Spring Charging Opening Spring Charge Indication Mechanical ON & OFF indication Mechanical Operations Counter Contact Arms with Tulip Contacts Truck Handle End Partition (Truck) Door Locking hinge pin Door close interlock Viewing window for truck position Viewing window for Spring charge indicator and Mechanical Counter 4.5. LV connection Plug 4.6. Drive Mechanism housing 4.7 . Ramp 4.8. Interlocking Plate (Drive Box) 4.9. Holder for LV Plug 4.10. Clip for locking LV Plug to Breaker 4.11. Opening for hand crank for charging the closing spring 4.12. Twist Grip for operating the breaker in service position 4.13. Rod Lever 4.14. ON Push Button (On the breaker) 4.15. OFF Push Button (On the breaker) 4.16. Plate Covering manual spring charge opening 5.1. Vacuum Interrupter 5.2. Insulating Switching Rod 5.3 Insulating Phase Barrier (Truck) 6.1. Bushings of upper mating contact 6.2. Cast resin insulator 6.3. Feeder connections 6.4. Joint shrouds 6.5. Main Busbars 8.1. Phase Barrier (Cable Chamber) 8.2. Bushings for lower mating contact 8.3. Current transformer 8.4. Cable connecting pieces 8.5. Bushing Cover 9.1. Charging Handle 9.2. Cranking Handle 9.3. Double Bit Key 9.4. Rod Trap Key 9.5. Earthing Switch Handle 13.1. End Covers 13.2. Pressure relief channel for Rear Frame (110 mm)

29

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

8.2 Sr. No.

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

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

30

Notes

31

Siemens Ltd. PowerTransmission & 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-03-27300-001

'Product development is a continuous process. Consequently, the data indicated in this Booklet is subject to change without prior notice. For the latest information please contact our Sales Offices.' 030001

Siemens Ltd.
PTD-03-152-011