s

Air InsulatedMetal-Clad Single BusbarMedium Voltage SwitchgearType 8BK80On withdrawable circuit-breaker truck upto 24 kV

Operation and MaintenanceInstructions

2

Table of ContentsPage Nos

1. Technical Description1.1 General 31.1.1 Application 31.1.2 Specific Standards 31.1.3 Ambient Temperature and Humidity 31.1.4 Site Altitude 31.2 Design Features 51.2.1 Switchgear Layout 51.2.2 Circuit Breaker Compartment 51.2.2.1 Service Position 61.2.2.2 Test Position 61.2.2.3 Isolated Position 71.2.2.4 Removed Position 71.2.3 Busbar Compartment 71.2.4 Cable & CT Compartment 71.2.5 Compartment for Low Voltage Equipment 71.2.6 Accessory Items 71.2.7 Range of Panels 71.2.7.1 Feeder Panels 81.2.7.2 Bus Sectionalizer Panel 81.2.7.3 Metering Panel 81.2.7.4 Panel with I/C & O/G Connections 81.2.8 General Construction 81.2.9 Interlocks 81.3 Technical Data 81.4 Rating Plate 9

2. Installation2.1 Foundation 102.2 Electrical Service Room Dimensions 112.3 Transportation Units 112.4 Packing 132.5 Unloading 132.5.1 Handling Equipment Required 132.5.2 Procedure 132.6 Examining the Switchgear against damages 132.6.1 Storage 132.7 Transferring the Transport Units 132.7.1 Remove the truck from the panel 142.8 Assembling the Switchboard 142.8.1 Bolting the Panels together 142.8.2 Fixing the Switchboard to the Foundation 152.8.3 Bolting the Busbars together 152.8.4 Bolting the Main Earth Busbar

section together 152.9 Making HV Cable Connections 152.10 Earthing of Switchboard 162.11 Other Work to be carried out 162.11.1 Checking the HV Connection 162.11.2 Checking the bolted Joints 162.11.3 Cleaning the Switchboard 162.11.4 Inserting the withdrawable parts 172.11.5 Protecting the panels against Environmental

effects 172.12 Interpanel Wiring 17

3. Putting the Switchgear into Service3.1 Test Operations 183.1.1 With Door Open 183.1.2 With Door Closed 183.2 Checking the Accessory Items 193.3 Revising the Circuit Diagram 193.4 Space Heaters 19

Page Nos

4. Operations4.1 Withdrawable Truck 214.1.1 Positions of the withdrawable truck 214.1.2 Transferring the Withdrawable Part from the

test / disconnected position manually 214.1.2.1 Normal Operations 214.1.3 Transferring the Withdrawable Part from

the Connected position to the test /disconnected position manually 21

4.1.3.1 Normal Operations 214.1.3.2 Castell Key Operation (Optional) 224.1.4 Removing the LV Plug 224.1.5 Connecting the LV Plug 224.2 Circuit Breaker Operating Mechanism 224.3 Circuit Breaker Operation 224.3.1 Charging the closing spring by hand 224.3.1.1 Breaker ON and OFF 224.3.1.2 Mechanically 224.3.1.3 Electrically 224.3.2 Switching State Indication 234.4 Line PT with Drawout Fuse Mechanism 234.5 Earthing 234.5.1 Earthing of Busbars and Cables 234.5.1.1 Direct Earthing of Busbars with Conductors 234.5.1.2 Earthing of Cables with Conductors 234.5.1.3 Removing Earthing Connections 234.5.2 Earthing of Busbars / Cables with a

Drawout Truck 244.5.2.1 Disconnection of Earthing Drawout Truck 244.5.3 Earthing the Busbars / Cables with

Earthing Switch 244.5.3.1 Earthing Busbars with Earthing Switch 244.5.3.2 Earthing Cables with Earthing Switch 244.5.3.3 Disconnection of Earthing Switch 244.5.4 Earthing of Busbars or Cables with Truck 244.5.4.1 Earthing of Busbars with Bus Earthing Truck 244.5.4.2 Earthing of Cables with Cable Earthing Truck 254.5.4.3 Link Type Earthing Truck 254.6 Breaker Compartment Door 254.6.1 To Open the Door 254.6.2 To Close The Door 254.7 Door to LV Compartment 254.7.1 To Open the Door 254.7.2 To Close the Door 25

5. Maintenance5.1 Inspection Schedule 265.2 Cleaning 265.3 Lubrication 275.4 Replacement Parts 275.5 Defeating the Door Interlock of HV

Compartment 275.5.1 Drawout Unit in Connected Position 275.5.2 Drawout Unit in Disconnected Position 275.5.3 Restoring the Door Interlock 27

6. Disposal of Product 28

7. Summary of Important Instructions 29

8. Additional Information8.1 Reference list of Items 308.2 Jointing Torque 31

3

1. Technical Description

1.1 General

8BK80 metal clad switchgear is of .horizontalisolation & horizontal drawout type suitable for easyextension of switchgear in both direction for systemvoltage upto 24kV. The switchgear is designed forsingle busbar system & is fully compartmentalized.The design incorporates the set of interlocks for safeoperation of switchgear.

1.1.1 Application

The switchgear is suitable for use as distribution unitfor switching load at substations of electric supplycompanies as well as for power stations & industrialplants.

1.1.2 Specific Standards

The metal clad metal enclosed switchgear has beentype tested as per all the requirements of IEC 60298“Specification for Rating & testing of insulation ofelectrical Switchboards & switchgear for AC Voltagesabove 1 kV & conforms to the standards IS3427,IS12729. The Switchgear is supplied in readyassembled condition. The Switchgear can be installedfree standing.

1.1.3 Ambient Temperature and Humidity

Ambient temperature is understood as the

WarningTo Ensure Personnel & Product Safety

This equipment carrries hazardous voltages andmoving mechanical parts that shall be controlledremotely.

Non observance of the safety instructions willresult in death and / or severe personnel injury ordamage to property & environment.

Only qualified personnel shall work on or aroundthis equipment after becoming thoroughly familiarwith all warnings, safety notices and maintenanceprocedures contained herein. Thecomponents labeled with theDanger Sign shall be removed onlyafter ensuring that the supply to thelive parts behind them is de-energized & earthed.

Successful and safe operation of this equipment isdependent on perfect planning of the system,proper handling (transport, storage), installation,operation and maintenance.

temperature of the air in the switchboard room.

At ambient temperatures below -5°C prevailing for alonger period the switchboard room has to be heated.

The air temperature in the panels should always beabout 5°C above the ambient temperature to avoidcondensation. (Switch on the heater againstcondensation!)

The humidity of upto 95% is permissible.

If the truck-type switchboard is exposed to a humidclimate and rapid temperature changes, theswitchboard room has to be heated.

1.1.4 Site Altitude

The rated insulating capacity values (rated impulsewithstand voltage, rated power frequency withstandvoltage)1) specified for the equipment are, inaccordance with the provisions of IEC Publication 71,based on standard atmospheric conditions (1013 hPa, 20°C and 11 g/m3 water content). i.e. sea level.The insulating capacity of an insulation in airdecreases with increasing altitude as a result ofchanges in the air density. Standards promulgated byIEC and other disregard this decrease in insulatingcapacity for altitude of up to 1000 m, i.e. thedecrease of approximately 9% at this altitude is stillpermissible.

The standards provide no guideline for altitudes ofmore than 1000 m with respect to insulation ratings;they leave this up to an agreement betweenmanufacturer and user.

Our own recommendation is as follows:

Since this method used for rating insulation up toaltitudes of 1000 m has proved to be satisfactory, itshould also be applied to higher altitudes. Thealtitude correction factor a should therefore be basedon the insulating capacity at 1000 m, which is lowerby 9% (corresponding to 0.91 or 1/1.1) than thecapacity at sea level.

The following expression thus applies for theselection of the equipment:

Fig 1: Basic Circuit Diagram

4

Rated withstand voltage to be selected2)

Required withstand voltage2)

≥1,1 · a

Example:

Site altitude above sea level .......................... 3000 mRequired impulse withstand voltage .................. 75 kVCorrection factor a .............................................. 0,73(according to Fig. 1.1)

Rated impulse withstand 75 kV

voltage to be selected = 93 kV1.1 x 0.73

Switchgear with rated voltage of 15 kV, IEC List 2(rated lightning impulse withstand voltage of 95 kV)meets this requirement.

The actual insulating capacity at the site is then

withstand voltage 3) = a • rated withstand voltage2) ofthe selected switchgear unit.

2.1. Circuit Breaker compartment (HV Compartment)2.2. Busbar compartment2.3. Cable & CT compartment

Fig 2: Side view of switchgear cubicle

2.3

2.2

2.1

2.4

2.5

Fig. 1.1 Relationship between the correction factor “a” andthe site altitude

The following definitions apply:1) Rated withstand voltage2) = required value corresponding to

the provisions of IEC etc. for sea level.Withstand voltage3) = actual value for the given altitude

2) Rated lightning impulse withstand voltageRated power frequency withstand voltage

3) Lightning impulse withstand voltagePower frequency withstand voltage

2.4. Low Voltage compartment (LV Compartment)2.5. Withdrawable Truck

5

3.1. Vacuum Interrupter3.2. Insulating Switching Rod3.3. LV Plug on the truck3.4. Contact Arm3.5. Truck Handle3.6. Cast Resin Insulator3.7. Guide Roller on truck3.8. PP Tube

Fig 3: Withdrawable Truck with Circuit Breaker

3.1.1 Pole Flange (Upper)3.1.2 Pole Flange (Lower)3.1.3 PT’s on the truck

Fig. 3.1: Rear View of the truck

3.1.1

3.1.2

3.1.3

3.13.2

3.3

3.4

3.5

3.6

3.8

1.2 Design Features

1.2.1 Switchgear layout (Refer Fig. 2)

Metal partitions subdivide each panel into

- Circuit breaker compartment (2.1)

- Cable & CT compartment (2.3)

- Busbar compartment (2.2)

- Low voltage compartment (2.4)

- Withdrawable Truck (2.5)

The outside covers are bolted to the frame and thedoors are hinged.

1.2.2 Circuit breaker Compartment

The circuit breaker compartment contains awithdrawable truck with Vacuum circuit breaker orBus PT Truck. The breaker terminals are fitted withcontact arms (3.4, Fig 3)

The withdrawable truck can be transferred betweenthe service & test positions behind closed doors usinga hand crank.

3.2.1 Mechanical ‘ON’ Push Button3.2.2 Mechanical ‘OFF’ Push Button3.2.3 Spring Charging Opening3.2.4 Spring Charge Indication3.2.5 Mechanical ‘ON’ & ‘OFF’ indication3.2.6 Mechanical Operations Counter3.2.7 Earthing for the Truck

Fig 3.2: Mechanical ON & OFF Push Buttons

3.2.1

3.2.2

3.2.3

3.2.4

3.2.5

3.2.6

3.2.7

3.7

6

1.2.2.1 Service Position (Connected Position)

The position of a Withdrawable Truck in which it isfully connected for its intended function. In thisposition of the truck, the contact arms of the circuitbreaker are connected to the busbars as well as to theout going cables via the fixed mounted isolatingcontacts in the cubicle.

The truck is locked against withdrawing.

The low voltage circuit is connected through the lowvoltage plug & socket connection (3.3, Fig. 3 & 4.5,Fig. 4).

1.2.2.2 Test Position

The position of withdrawable truck in which anisolating distance or segregation is established in themain circuit & in which control circuits are connected.In the test position, the truck with the breaker iswithdrawn so far between busbars & outgoing cablesthat there is isolating distance according to VDE 0670,part 2 / 2.65. The truck is locked against moving. Thelow voltage circuit is connected through low voltageplug connection (4.5, Fig. 4).

The circuit breaker can be switched for testing & allfunctions.

6.1. Main Earth Busbar6.2. Bushings for lower mating contact6.3. Current transformer6.4. Cable connecting pieces6.5. Wiring Cover6.6. Gland Plate for Power Cables

Fig 6: Looking into Cable compartment

6.1

6.2 6.3 6.4

6.56.6

4.1. Door Locking hinge pin4.2. Door close interlock4.3. Viewing window for truck

position4.4. Viewing window for

Spring charge indicatorand Mechanical Counter

4.5. LV Socket4.6. Drive Mechanism housing4.7. Ramp

Fig 4: Withdrawable Truck in Test Position & door open

4.8. Interlocking Plate(Drive Box)

4.9. Holder for LV Plug4.10. Clip for locking LV

Plug to Breaker4.12. Trip mechanism for

operating the breakerin service position

4.13. Rod Lever

5.1. Bushings of upper matingcontact

5.2. Cast resin insulator

5.3. Feeder connections5.4. Busbars

Fig 5: Busbar Compartment

4.1 4.7

4.8

4.13

4.6

4.54.104.2

4.3

4.4

4.9

4.12

5.15.2

5.3

5.4

7

8.18.2 8.38.48.5

1.2.2.3 Disconnected Position (Isolated Position)

The position of withdrawable truck in which anisolating distance or segregation is established in thecircuits of the withdrawable truck, the truckremaining mechanically attached to the enclosure.In this position the truck is withdrawn as in testposition but the LV plug is disconnected.In the test & disconnected position the contact arms &their mating contacts are separated by metallicshutters.

1.2.2.4 Removed Position

The position of withdrawable truck when it is outsidethe panel and electrically & mechanically separatedfrom it. Ramps are provided at the front bottom of thepanel to withdraw the truck out of the panelsmoothly.

Drive Mechanism of the truck is attached to thecubicle frame using Rod Lever.

The Earthing strip at the bottom of the breakercompartment, along with the spring loaded pinprovided at the bottom of the circuit breaker truckensures the earthing of the truck in all the positions.

1.2.3 Busbar Compartment (Refer Fig.5)

The busbar compartment contains:

- The busbars (5.4)

- Bushings with the mating contacts for the uppercontact arms (5.1)

- Feeder Connections (5.3)

The Main Busbars are mounted on cast resininsulators (5.2). The ends of the smaller Main Busbarsare connected with the longer Busbar Links extendingfrom one panel to the next.

1.2.4 Cable and CT compartment (Refer Fig.6)

The Cable compartment contains:

7.1 LV Compartment Door

Fig 7: Looking into LV compartment

8.1. Charging Handle8.2. Cranking Handle8.3. Double Bit Key

Fig 8: Accessories

7.1

- Bushings with the mating contacts for the lowercontact arms of the withdrawable part (6.2)

- Cable termination pieces (6.4)

- A section of the main earth bar (6.1)

- Current transformers (6.3)

The cable termination pieces are accessible from therear.

1.2.5 Compartment for Low Voltage Equipment(Refer Fig 7)

This compartment contains all the low voltagedevices (protective relays, MCB’s, terminals, etc.,)Indicators and relays are accommodated in doorcutouts.

1.2.6 Accessory Item (Refer Fig.8)

Following accessories are supplied with theswitchgear.

- Changing handle for charging the closing spring ofthe vacuum circuit breaker (8.1)

- Cranking handle for truck movement betweenservice and test positioning (8.2).

- Double bit key for locking the truck transferoperating mechanism (8.3)

- Rod Trap key for LV compartment. (8.4)

- Earthing Switch Handle (Optional). (8.5)

1.2.7 Range of Panels

General:

For a metal clad enclosed switchgear there arevarious panel modules available. All the panels areconstructed using identical parts as far as possible.

1.2.7.1 Feeder Panels (Fig 9a)

The feeder panels are suitable for input or output ofelectrical energy.

8.4. Rod Trap Key8.5. Earthing Switch

Handle

8

panels are interchangeable.Trucks are earthedwith panel in both test & service positions.

- Outgoing cables can be earthed by means ofmanually operated earthing switch. (Optional)

- C.T.s are mounted on stationery part in the CableChamber.

- Line P.T.s are available with a drawoutarrangement and with fuses.

- Future extension of existing switchboard ispossible

1.2.9 Interlocks

The positions of the withdrawable part are describedon page 4

State The following operationsare not possible

Withdrawable truck in – Removal of theservice position, withdrawable truckswitching device “ON” – Opening of the door

– Pulling of the LV plug

Withdrawable truck in – Removal of theservice position, withdrawable truckswitching device “OFF” – Opening of the door

– Pulling of the LV Plug

Withdrawable truck – Closing of thelocated between the switching deviceservice and test – Opening of the doorpositions – Pulling of the LV plug

Withdrawable truck in – Transfer of thetest position, switching withdrawable truckdevice “ON” to service position

Withdrawable truck in – Closing of the doordisconnected position transfer of theLV plug pulled off, withdrawable truckswitching device “OFF”, to service position.door open

1.3 Technical Data

Rated Voltage, Frequency (50Hz) 7.2kV 12kV 24kV

Rated Current of the Feeders 3150A 3150A 3150A

Rated Current of the Busbar 4000A 4000A 3150A

Rated Power Frequency 20kV 28kV/ 50kVwithstand Voltage (rms) 60 sec. 38kV**

Rated Lighting Impulse 60kV 75kV/ 125kVWithstand Voltage (peak) 95kV**1.2/50 Micro sec.

Rated short circuit 44kA 44kA 26.3kAbreaking current

Rated short time withstand 44kA 44kA 26.3kAcurrent (3 sec)

Rated short circuit 110kA 110kA 66kAmaking current (peak)

** On request upto 31.5 kA

Outgoing feeder panels with C.B. on the truck aremost frequently used.

Alternatively, these panels can also be equipped withan isolating truck.

The panel is available with current transformer eitherwith earthing switch or without earthing switch. Theearthing switch is always equipped with manualdrive.

1.2.7.2 Bus Sectionalizer Panels (Fig 9b)

In bus sectionalizing panel one panel is used for thetruck with the C.B. (alternatively, an isolating truck) &one panel for connection of busbars to the top. Boththe panels are usually delivered as one assembledtransport unit.

1.2.7.3 Metering Panel (Fig 9c)

Basically metering panels are of the sameconstruction as the standard outgoing panels. Themetering truck with voltage transformers & HRC fusesin series is equipped with 3 top contact arms.

1.2.7.4 Panel with I/C & O/G Connections (Fig 9d)

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

1.2.8 General Construction

- Safety devices & interlocks are provided to avoidany malfunctioning. These devices protect theoperating personnel & ensure reliable operations.The interlocks are explained in section 1.2.9.

- The panel is compartmentalized in differentcompartments with metallic partitions.

- Vacuum Circuit Breaker for the panel is mountedon the truck. All the identical trucks in different

Fig 9a Fig 9b

Fig 9c Fig 9d

I/C

VCB

CT

O/G

VCB

CT

VCB

CT

Fuses

P.T.

I/C

O/G

VCB

CT

9

Maximum values indicated

Overall Panel weight: Approx. weight with vacuumcircuit breaker

15 kV (800W) 650 kg approx.

12 kV (600W) 450 kg approx.

24 kV (1000W) 800 kg approx.

Overall Panel Dimensions :

w h h1 d d1 d2 d3mm mm mm mm mm mm mm

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

24 kV 1000 1450 2300 2270 2215 380 1000

1.4 Rating Plate

A Rating Plate containing the particular data is fixedinside each panel. The withdrawable vacuum breakerhas its own rating plate and the rated normal currentstated on it does not apply to the switchgear.

Degree of protection

Basic model IP 4X acc. To IEC 298 orIP 40 acc. To IEC 529

The panels are gasketted to make them dust & verminproof.

IP 41, IP 5X and IP 51 can also be provided.

Fig 11: Rating Plate of a Panel

10.1. End Covers are fitted to the left & right hand end panelsof the switchboard

10.2. Pressure relief channel for the terminationcompartment, 110 mm deep.

10.3 Pressure Relief Flaps

† Minimum from highest pressure relief flap(Part 10.1) after it has opened

All dimensions are in mm and are forthe standard panel

* Single Row of Panels** Double Row of Panel

Fig: 10 Overall Panel Dimensions

750†

10.1

2020.0

800 minon either side

800 min

W

10.2

d3

d2

10.3

d1

d

38

1100* / 2000**

FRONT

h

10

2. Installation

The installation sequence should be planned andprepared with care. Ensure that the erectors and theoperating personnel read the operation, installation &maintenance instructions.

2.1 Foundation

- False Floor

Place a girder in the cutout common to several or allof the switchboards so that it is parallel to theoperating front. The girder is meant to support thepanel bottom rails below the 30mm x 30mm cutouts.

Two girders (depthwise) must be fixed along thewheel tracks of the truck as shown in the foundationplans (Fig. 12a, 12b & 12c).

- Concrete Floor

This should be provided with foundation rails onwhich the panels are to rest. For floor cutouts refer toFig 12a,12b &12c. The foundation should beprepared before the panels arrive. Level differencesbetween the mounting surfaces of the individualpanels should be determined and compensated for byusing a sheet as shown in Fig 16.

Note : All dimensions are in mm

Fig.12a: Foundation Plan for 12 kV (600W) Panel

Note : All dimensions are in mm

Fig.12b Foundation Plan for 12 kV (800W) Panel

Note : All dimensions are in mm

Fig 12c : Foundation Plan for 24 kV (1000 W) Panel

450 450

800

1000

12

15

32

.5

65

75

75

Standard panel

Rear

box

400

30

040 Front

1000

375 375 37

.5

10 45

1140

77

7.5

30

0

45 10 22

1532

.5

30 ø

Rear cover

65.0 670.0 65.0

65.020.0

25.0

310.0

1750.0

300.0

935.0

580.0

45.010.0

300.0

120.0

45.010.0

38.032.5

800.0

450.0175.0 175.0

H.T./L.T. Front door

65.0

Rear cover

65.0470.0

65.020.0

310.0

1750.0

300.0

935.0

580.0

10.0

45.0

300.0

120.0

45.0

10.0

38.032.5

175.0 250.0 175.0

600.0

H.T./L.T. Front door

CUTOUT FORPOWER CABLES

CABLE CHAMBER

C.B. CHAMBER

CUTOUT FORCONTROL CABLES

6x holes for M12 bolts(for fixing to foundation)

FRONT

CUTOUT FORPOWER CABLES

CABLE CHAMBER

6x holes for M12 bolts(for fixing to foundation)

CUTOUT FORCONTROL CABLES

C.B. CHAMBER

FRONT

198.0 198.0Wheel Track

295.0 295.0

WheelTrack

295.0 295.0

Wheel Track

11

- Base Frame (optional)

A solid base frame can be provided. The base framegives a strong support to the panels at their joiningline & also under it along the movement of the truckwheels. It is made up of rolled steel sections.

A reference sketch of the base frame is as shown inFig 13a, 13b & 13c

2.2 Electrical Service Room Dimensions

Min. Clearance to the ceiling 750 mm minabove the top (Refer Fig. 10)

Min.Clearance on the sides 800 mm minof the Panels

Min.Width of control aisle in 1100*/front of the Panel for Single row 1500** mm min

Min.Width of control aisle 2000*/in front of the Panel for 2500** mm mintwo rows facing each other

* For upto 15 kV Panel ** For 24kV Panel

A power source must be available. Work likely toproduce dust or dirt may not be carried out while thepanels are being installed. The floor should belevelled to enable transport units to be moved onroller and/or similar devices.

2.3 Transport Units

A transport unit consists of maximum upto 3assembled switch cubicle with withdrawable truck.

The cubicle should not be lifted from the top withcircuit breaker inside.

Fig 13a: Base Frame Dimensions (12 kV 600W)

Fig 13b: Base Frame Dimensions (12 kV 800 W)

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

40.040.0

75

.0

75

.0

1780.0

1705.0

1027.5

952.5

75

.07

5.0

75

.0

75

.0

75.0

75.0

Ø14.0

Ø14

.0

1780

.0

Ø14.0

ISA 40x40x5

M12 NUTWELDED

0.0

67

.5

14

2.5

17

5.0

42

5.0

45

7.5

53

2.5

600.

0

47.50.0

ISMC 75x40x5

TOP

40.040.0

75

.0

75

.0

1780.0

1705.0

1027.5

952.5

75

.07

5.0

75

.0

75

.0

75.0

75.0

Ø14.0

Ø14

.0

1780

.0

ISA 40x40x5

M12 NUTWELDED

0.0

67

.51

42

.51

75

.0

62

5.0

65

7.5

73

2.5

800.

0

47.5

ISMC 75x40x5

0.0

TOP

40.0

ISA 40x40x5

ISMC 75x40

75

1AØ

0 60

12

5 87

5

940

10

00

12

Tolerance as per DIN 43661:

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

Level 1mm within 1mtr.measured length.

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

Fig 14 : Dimension data sheet for the foundation.

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

Acc

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to D

IN 4

3 6

61

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13

2.4 Packing

As required :

(a) For shipment to inland destinations each transportunit is fixed on a sturdy wooden pallet andcovered by plastic sheet for surface protection andpacked in normal wooden case.

(b)for shipment overseas each transport unit may beadditionally packed in a seaworthy case. It isenclosed in plastic sheet, which is sealed air-tightand includes bags containing dessicant.

Accessory items are packed separately, or kept in thepanel transport unit (see dispatch advice).

2.5 Unloading

While unloading care must be taken to see that thepanels are not rolled on its sides & they must be keptin upright condition.

2.5.1 Handling equipment required

- A mobile crane or a chain pulley block forunloading 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 siterequirements with regard to its construction and loadbearing capacity. Refer to the weights (for raising andtransporting) stated on the transport or in thecovering documents.

2.5.2 Procedure

- Do not unpack while unloading the transportunits. Take care not to damage the plastic sheetbecause it protects the switchgear against anyenvironmental effects.

- Use of mobile crane or a forklift truck.

• Attach the ropes to the wooden pallet.

• Carefully raise the transport unit and check to seethat it is correctly balanced, if necessary lower thetransport unit and correct any imbalance byrepositioning the ropes on the lifting tackle.

– Unloading the switchgear with a fork-lift truck.Transport units of not more than two panels canbe unloaded with a fork-lift truck if the accessroutes permit this. Make sure the transport unitsare correctly balanced.

• Move the transport units as close as possible tothe switch house and put them down.

• Dismantle and remove the crates.

• Move each transport unit into the building.

• Take off the plastic sheet immediately prior to

bolting the transport units together and alsotemporarily to check them for any signs oftransport damage.

2.6 Examining the switchgear againstdamage

As soon as the switchgear has been unloaded andunpacked examine it to see that it is complete withreference to the relevant documents. Record anydamage and its cause without delay, in the presenceof the forwarding insurance agent, if the damage wascaused en route.

This report is essential for any damage claims.

2.6.1 Storage

- Store the units in upright position only

- The units must be stored in adequetly coveredlocation such that they are protected from Sun,Rain, Flood Waters & other such Natural elements

2.7 Transferring the transport units to theirpoints of installation

- Transfer the transport units including their woodenpallets to the point of their installation using forklift rollers.

- Withdraw the trucks out of the panels using twowooden wedges below the ramps & close thedoor.

- Put the panels down on the cleaned site or at leastimmediately in front of it in the correct order,leaving a clearance of about 25 mm betweenthem.

- To remove the transport units from their woodenpallets

- Place four winches under the floor rails of outerpanels and uniformly raise the panel.

- Remove the wooden pallet.

- Lower the transport unit as far as it will go & placeit on two wooden beams if it is located above itssite or place on four roller pads if it is in front ofthe sites

- In the later case roll the units to their mountingposition. If this means changing the direction oftravel raise the unit & reposition the roller padsaccordingly. Now place the planks & channels inthe 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 & placethem on two wooden beams.

- Now, raise the units, first on one side & then onthe other side, using roller-type crowbars. Pull outthe planks & lower the panels onto the cleanedfoundation. Position the crowbars only at the

14

corners of the panels below the vertical framemembers.

2.7.1 To remove the Truck from the Panel

- Open the door of the panel (Refer clause 4.6.1).

- Bring the truck to the test position by cranking(Refer clause 4.1.3.1)

- Disconnect the LV plug (4.5, Fig. 4) & place it itsholder (4.9, Fig. 4) on the door.

- Mark the truck & their panel numbers foridentification.

- Lift & turn the Levers (4.13, Fig. 4) on the frontinterlocking plate (4.8, Fig. 4) by 90ºanticlockwise. (upto 15kV) OR

- Unscrew the front interlocking plate (for 24kV).

- Slowly move the truck away from the panel. Thetwo ramps drop automatically enabling free &easy withdrawal of the truck.

- Put back the ramps to normal position & close thedoor.

2.8 Assembling the switchboard

Carry out the work described under clauses 2.7.1 and2.8.1 to 2.8.4.

Keep the bolts loose, not fully tightened, till all thebolts for sections are in position. Then tighten thejoining bolts, followed by Busbar bolts, followed byFoundation bolts.

2.8.1 Bolting the panels together

It is assumed that the first transport unit is in its finalposition and that the other units are positioned on thefoundation rails in the correct order but with anadequate clearance between them.

It is always preferable to install the central panel first.This practice should invariably be adopted for a boardwith 20 or more panels. After installing the centralpanel, the other panels can be installed on its left &right in proper sequence.

• Procedure

- Centrally align the first transport unit on itsfoundation. The panels must be at the correct level

(refer Fig. 14) and be absolutely vertical. Ifnecessary place shims.

- under the frame uprights and

- under the bottom rails near the 30 mm x 30 mmcutouts for the foundation bolts.

- Remove the bolts fitted at the left hand end ofeach panel, as viewed from the front.

- Move up the second panel.

- Align this second panel on the foundation, raise itto the correct level and make sure the panels standvertically.

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 gapswith rubber.

- Move up the other panels in sequence, align themand bolt them together.

16.1. Breaker Compartment door16.2. Upper metallic shutter16.3. Lower metallic shutter16.4. Heater4.5 LV socket

Fig16: View into Circuit Breaker cubicle after removing thedrawout truck

Fig 15 : Procedure for bolting the panels together

16.1

16.2

16.3

16.4

4.5

15

2.8.2 Fixing the Switchboards to theFoundation

The panels bottom plate has four 30 mm x 30 mmcutouts (refer Fig 15) for fixing purposes.

• Welding

Weld the bottom plate to the foundation at thecutouts. Insert shims (refer clause 2.8.1) wherenecessary to avoid having to weld across air gaps.

Coat the weld with enamel paint.

• Bolting Down

Embed anchor-bolts in the foundation (through the30 mm x 30 mm cutout) or drill the appropriate holesin the foundation rails (false floor).

Insert shims between the foundation and the bottomrails near the cutouts.

Tighten the screw without distorting the panels.

2.8.3 Bolting the Busbars together

Start working on the busbars only after panel unitshave been adjusted correctly and interconnected.Access to the busbars are from the rear side or fromthe top side by opening the Explosion Vents. Allnecessary hardware is supplied on the the mainbusbars.(5.4, Fig. 5)

1. Brush the contact faces criss-cross wise untilbright, & wipe using a clean cloth. (applicable onlyfor bare Aluminium Busbars)

2. Square neck, round head, coach bolts are used forbusbar joints. These bolts do not rotate in theirslots & hence can be tightened from one side.Recommended torque is 70 Nm.

3. Allow the joint to settle down in 24 hrs & checkthe value of the torque with the torque wrench.

4. The busbars of adjacent units must be joinedtogether using the busbars & hardware supplied.While inserting coach bolts ensure that the roundhead of coach bolt is facing sheet metal structuralparts. That means the nuts will always be towardsthe live parts such as busbars/feeder connections.The busbars (5.4, fig. 5) of the panel forming atransport unit are already bolted.

5. Refix the upper rear cover after the busbars arebolted.

2.8.4 Bolting the Main Earth Bar sectionstogether

The main earth bars of the transport units must belinked together. One of the two parts to be boltedtogether is already fitted with a link. This must beundone, passed through the partition and bolted tothe two adjacent earth bar sections. The cover on theside wall should be properly adjusted after joining theearth bars.

2.9 Making HV Cable connections

The cable connection pieces are provided with Hex.Headed bolts M16 with washers., spring washers &

5.1. Upper Contact Bushing17.1. Fixed Contacts (Upper)6.2. Lower Contact Bushing17.2. Fixed Contacts (Lower)17.3. Truck earthing Srip16.4. Space Heater

Fig 17: View into circuit breaker compartment with shutterheld open

6.1

18.218.16.6

6.1. Earth Busbar18.2. Eathing Strip (from CB

chamber)

Fig 18: Earth Busbar Assembly

5.1

17.1

6.2

17.2

17.3

16.4

18.1. Extension Links6.6. Bottom Covers

16

hex. Nuts for mounting the cable lugs of theconductors.

Three part bottom cable cover is supplied fitted withthe switchboard. Of these, the outer most cover hasto be removed & cutouts to be made of the size asper the instructions given by cable kit manufacturer.

2.10 Earthing the Switchboard

Connect the earth terminals of at least one or twopanels to the station earth. This could be done to suitthe local guidelines. Termination facility for earthconnection is provided on the earth busbar mountedin the cable chamber.

2.11 Other work to be carried out

2.11.1 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 anti-magnetic clips on single-core cables.

2.11.2 Checking the Bolted Joints

- Check the power and auxiliary circuit connectionsof the switching devices at random. Examine allthe terminal block connections, making sure thatthe blocks are correctly labeled and replace anymissing labels by referring to the circuit diagram.

- The torque values of all the busbar joints must bechecked

2.11.3 Cleaning the Switchboard

- Clean all the post insulators, Bushings and Busbarsin all the compartments using soft dry cloth.

Do not use any abrasive chemicals or detergents toclean installed parts.

Use only distilled water if necessary. Ensure that allparts are dried up before applying any voltage.

16.2, 16.3. Shutters19.1. Shutter operating rod19.2. Roller Guide Angle19.3. Truck guide

Fig 19: View inside circuit breaker compartment withoutwithdrawable truck.

16.1. Breaker compartment Door2.5. Breaker Truck

Fig 20: Insertion of trolley in the panel

16.2

16.3

19.119.2 19.3

16.1 2.5

17

2.11.4 Inserting the withdrawable parts

- open the front door (16.1, Fig. 20)

- put down the ramps (4.7, Fig. 4)

- place the breaker truck in front of thecorresponding panels.

- Transfer the truck inside the panel and push it asfar as it will go.

- Fix the racking mechanism / interlocking plate tostructure frame by using lift & turn levers(upto 15kV) & by using bolts (for 24kV)

- Fix the ramps back in the position

- Close the door (16.1, Fig 20)

- Insert all other drawout trucks in the samemanner.

2.11.5 Protecting the panels againstenvironmental effects

(a) Damaged sections of the paint finish may only betouched up with original paint.

(b)Fit the parts supplied to protect against the ingressof reptiles. Check in case they are removed duringinstallation.

(c) Close all the doors & covers properly.

(d)Any opening that is left open after installationshould be closed & sealed to make it trulyverminproof.

2.12 Interpanel Wiring

The wire have been left loose in the LV compartmentof certain panels.

These wires must be connected from panel to panelas per approved wiring diagrams.

18

3. Putting the switchgear into service

For details of operation refer section 4

3.1 Test operations

3.1.1 With door open

- The motor operating mechanism start as soon asthe LV plug is inserted and control supply isavailable (If the VCB is not already charged)

- Open & close the breaker several times.

- Pull off the LV plug. Charge the breaker closingspring by hand (refer clause 4.2)

- Operate the circuit breaker

- Refit the LV cable Plug.

3.1.2 With door closed

Each switchpanel should be tested as follows:

– Transfer the withdrawable truck to thedisconnected position (see 4.1).

– Switch ON the auxiliary and control supply.

– Transfer the withdrawable part to the connectedposition.

4.3. Viewing window for truck position4.11. Opening for charging handle for charging the breaker

closing spring4.12. Trip mechanism for operating the circuit breaker in the

connected position.7.1. LV compartment door16.1. Breaker compartment door21.2. ON & OFF Push Button (On HT Door)21.3. Window for the indicators of the withdrawable part

- Number of operations (Operation Counter)- Closing Spring of the circuit breaker

- Charged - Lable with spring symbol- Discharged - Blank Lable

- Indicator for circuit breaker switching status- Circuit Breaker Closed - “ I “

Tripped - “ O “21.4. Opening for Double Bit Key for locking the transfer

operating mechanism21.5. Opening for racking handle for racking the breaker truck21.6. Opening for defeating interlock21.7. Door Handle

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

16.1

4.12

21.2

21.3

4.11

21.4

21.5

7.1

21.6 21.7

4.3

4.3. Viewing window for truck position4.11. Opening for charging handle for charging the breaker

closing spring4.12. Trip mechanism for operating the circuit breaker in the

connected position.7.1. LV compartment door16.1. Breaker compartment door21.1. Ball grip21.2. ON & OFF Push Button (On HT Door)21.3. Window for the indicators of the withdrawable part

- Number of operations (Operation Counter)- Closing Spring of the circuit breaker

- Charged - Lable with spring symbol- Discharged - Blank Lable

- Indicator for circuit breaker switching status- Circuit Breaker Closed - “ I “

Tripped - “ O “21.4. Opening for Double Bit Key for locking the transfer

operating mechanism21.5. Opening for racking handle for racking the breaker truck21.6. Opening for defeating interlock21.8. Bolts for door locking

Fig. 21a: Opening Elements (for 24kV Panel)

21.1

4.3

4.12

21.2 21.34.11

21.4

21.5

7.1

21.6

21.8

19

– Open and close the breaker as long as no highvoltage is applied.

– Without using force check all mechanical andelectromechanical interlocks for satisfactoryfunctioning. Check to see whether the switchingstates are indicated correctly in the control room.

– Check whether the position of the withdrawabletruck is indicated correctly (if the appropriateposition switches are fitted refer to the circuitdiagrams).

3.2 Checking the Accessory Items

The accessory items required must be easily availablein the Switchgear Room or an adjacent room. Theyinclude one Hand Crank for transferring the truck andfor charging the breaker closing spring, a Double BitKey for locking the hand-operating mechanism, thebasic circuit diagram, Operating Instructions, CastellLock Key (optional) and Earthing Switch Handle(Optional)

The Hand Crank for transferring the truck is alsosuitable for all M8 bolts.

3.3 Revising the Circuit diagrams

If circuits have to be modified during installation theexisting circuit diagrams are marked up. When workhas been completed make sure that the originaldiagrams are revised.

3.4 Space Heaters

For panels installed in humid atmosphere, spaceheaters are fitted in the circuit breaker & cablecompartments. The thermostat controlled heatersshould be switched “ON” before taking the panels intoservice. The thermostat shall be set to cut off supplyto heaters at about 5º higher than the maximumambient temperature.

Heaters must always be kept “ON” in all the conditions(even during maintenance)

20

s

BRIEF OPERATING INSTRUCTIONS FOR 8BK80 SWITCHGEAR

Fig 22 : Label on door of breaker compartment

FOR DETAILED DESCRIPTION OF ABOVE OPERATIONS &SPRING CHARGING OF CB,OPENING OF DOOR, ETC.

REFER CLAUSE 4 OF THIS MANUAL FOR OPERATIONS

21

In detail:

- Make sure that the circuit breaker is open, the LVplug(3.3, fig. 3) and socket connector has beenput together and lock it. The breaker compartmentdoor is closed.

- The castell key can be re,moved in this positionalso for any interlocked operations which are to beperformed with circuit breaker in open position.

- Fit the hand crank (8.2, fig. 8)to the hexagonshank in opening (21.5, fig. 21) turn it clockwiseas far as it will go and pull it off.

- Insert the castell key if it was removed forinterlocked operations. Turn the key clockwisethrough 90 degrees from position “ManualRacking” to “Connected position(locked)” and pull itoff.

4.1.3 Transferring the withdrawable part fromthe connected position to the test/disconnected position manually

4.1.3.1 Normal Operations

In brief

1st Step 2nd Step 3rd StepTurn double-bit key Insert and Turn double-bit key

turn handcrank

as far it willfrom by to go and pull from by to

it of

90° 90°

Fig. 23b

In detail:

- Make sure that the circuit breaker is open.

- insert the double bit key in lock (21.4, fig. 21) andturn it anti-clockwise through 90 degrees from“connected position (locked)” to “Manual Racking”.The hexagon shank opening (21.5, fig. 21).is nowaccessible. The hand racking mechanism isunlatched.

- Fit the hand crank (8.2, fig 8) to the hexagonalshank in opening (21.5, fig. 21) turn it anti-clockwise as far as it will go and pull it off.

- Turn the double-bit key anti-clockwise through 90degrees from the position “Manual Racking” to“Disconnected position (locked)” and pull it off.

Opening (21.5, fig. 21) is now closed.

The hand racking mechanism is now locked.

4. Operations

Each row of cubicles is provided with brief operatinginstructions. Refer to fig. 22.

4.1 Withdrawable truck

4.1.1 Positions of the withdrawable truck

Refer clause 1.2.2 for Circuit breaker Chamber

• Service position(connected position)

The circuit breaker is connected with the busbars andthe outgoing circuit Auxiliary circuit is connectedthrough LV plug and socket.

• Test position

The circuit breaker is disconnected from the busbarsand the outgoing circuit. Segregation as specified inIEC 60298 is maintained. The LV circuits areconnected through LV plug and socket.

Disconnected position

The circuit breaker is disconnected from the busbarsand the outgoing circuit. LV circuits are disconnectedby pulling out the LV socket from the plug.

- When the LV plug and socket are connected thefollowing functions can be carried out.

• The breaker can be tested / operated, also fromthe control room.

• The breaker compartment door can be opened.

• Functions such as ON / OFF indication andelectrical interlocks can be tested.

- When the LV plug and socket are disconnected.

• The breaker compartment door cannot beclosed. Hence the truck cannot be inserted.

4.1.2 Transferring the withdrawable part fromthe Test/Disconnected Position manually

4.1.2.1 Normal operation

In brief:

1st Step 2nd Step 3rd StepTurn double-bit key Insert and Turn double-bit key

turn handcrank

as far it willfrom by to go and pull from by to

it of

90° 90°

Fig. 23a

22

4.2 Circuit-breaker operating mechanism

The operating mechanism is of the stored energytype. For electrically operated breakers, motorautomatically charges the closing spring after eachswitching operation. If the motor supply should failthe closing spring can also be charged by hand. Thetripping spring is charged each time the breaker isclosed.

4.3 Circuit-breaker Operation

4.3.1 Charging the closing spring by hand

• Procedures

If the breaker compartment door

is closed (connectedposition) turn plate(21.6, fig. 21) so that itclears opening (21.7,fig. 21) insert the handcrank and fit it into thebreaker

is open (disconnectedposition) fit the handcrank directly to thebreaker operatingmechanism in opening(21.7, fig. 21).

• Operating Mechanism

- Turn the crank until the symbol “spring charge”appears in viewing window (21.3, fig.21) onindicator. The operator is not at risk if the motorsupply recovers,because the hand crank free-wheels and detaches in the anti-clockwisedirection.

- Pull the crank off.

4.3.1.1 Breaker ON and OFF

4.3.1.2 Mechanically (locally by means of pushbutton)

• In the connected position :

Trip mechanism (4.12, Fig. 4 & 21) as far as it willgo, hold it there, press buttons “ON” and “OFF”(21.2, Fig 21) and then release the grip.

• In the disconnected position with the door closed :

Press buttons “ON”and “OFF” (21.2, Fig 21) on thebreaker compartment door.

• In the disconnected position with the door open :Press buttons “ON”(4.14, Fig 4) and “OFF” (4.15,Fig 4) on the breaker truck

4.3.1.3 Electrically (from the control room orlocally)

by means of push button/switches in the control roomor on the LV compartment door. If the control supplyfails the breaker can always be tripped mechanically(see above)

4.1.3.2 Castell Key Operations (Optional)

1st Step 2nd Step 3rd StepTurn castell key Trun castell key

as far it willfrom by to go and pull from by to

it of

90° 90°

Fig. 23c

In detail:

- Make sure that the circuit breaker is open.

- Turn the castell key (which is trapped in themechanism) anti-clockwise through 90º from“Connected position (locked)” to “Manual Racking”.

- In this position the castell key can be removed forany interlocked operations which are to beperformed with circuit breaker in open condition.The hexagon shank opening(21.7,fig.21)is nowaccessible. The hand racking mechanism isunlatched.

- Fit the hand crank (8.2, fig.8) to the hexagonalshank in opening (21.5, fig.21) turn it anti-clockwise as far as it will go and pull it off.

- Insert the castell key if it was removed forinterlocked operations. Turn the double-bit keyanti-clockwise through 90 degrees from theposition “Manual Racking” to “DisconnectedPosition(locked)” and pull it off.

- The castell key can also be removed in thisposition to facilitate the opening of the HTcompartment door and / or other interlockedoperations.

4.1.4 Disconnecting the LV Plug

- Transfer the withdrawable part to thedisconnected position(in accordance with clause4.1.3) and lock it.

- Open the breaker compartment door (refer clause4.6.1).

- Unlock the LV plug (3.3, fig. 3) and LV socket (4.5,fig. 4 & 16) by turning down the clip.

- Pull off the plug and attach it to the holder (4.9,fig. 4) which is fixed to the door.

4.1.5 Connecting the LV Plug

- Put the LV plug (3.3, fig.3) and LV socket (4.5,fig. 4 & 16) together and lock it with the clip.

- Close the breaker compartment door (refer clause4.6.2).

23

4.3.2 Switching State Indication

In the middle part of viewing window (21.3, Fig 21)‘O’ means “OFF”, ‘I’ means “ON”.

DangerPrecautions for Safe Working

High Voltage !

Touching live parts will result in severe personnelinjury and / or death.

This equipment shall be operated only by qualifiedpersonnel who have become thoroughly familiarwith the operating instructions manual and inparticular all the safety instructions.

4.5 Earthing

4.5.1 Earthing of Busbars and Cables

4.5.1.1 Direct Earthing of Busbars withconductors

- Switch off all breakers feeding to the busbars.

- Open upper rear bolted cover & inside covers (ofbusbar chamber). Touch all phases with anearthing conductor mounted on the longinsulating pole.

- Short all the phases with a conductor and bolt it toearth.

- Place necessary warning plates at all noticeablelocations.

4.5.1.2 Earthing of Cables with conductors

- Switch off the breaker in the panel where cableearthing is desired.

- Ensure that the cables are not getting the supplyfrom the other end.

- Remove the lower rear cover of the cable chamber.

- Follow the procedure described for busbarearthing.

4.5.1.3 Removing Earthing Connections

- Disconnect and remove the shorting and earthingconductors.

- Close the rear cover and bolt it firmly.

- Remove the warning plates.

24.1. Fixed Contacts (E switch)24.2. Moving Contact (E switch)24.3. Earthing Switch Shaft24.4. Operating Link6.1. Earthing Busbar

Fig 24: Earth switch Arrangement on cable side

(Side view)

(Rear view)

6.1 24.3

24.1

24.224.4

24

4.5.2 Earthing of Busbars or cables with aDrawout Truck

Separate drawout Trucks can be supplied optionallyfor busbar and cable earthing. In case fault makingcapacity is required, a circuit breaker is mounted onsuch drawout trucks.

• Procedure

- Remove the circuit breaker or the link drawouttruck from the panel where earthing is to be done(refer clause 2.8.1)

- Insert the desired earthing drawout truck i.e. cableor 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 4.5.2)

- Ensure that there is no voltage available on theparts to be earthed when earthing drawout truckwithout making capacity is used.

- Transfer the drawout unit to the connectedposition (refer clause 4.1.3). In case the earhtingdrawout truck has an electro-mechanical interlockunit mounted on it, the transfer is possible onlyafter all the interlocking conditions are satisfied.

- Lock it in the connected position.

- In case the drawout truck has a circuit breakermounted 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

- Switch “OFF” the breaker in case of earthingdrawout truck with making capacity (refer clause4.3).

- Transfer it to the disconnected position (referclause 4.1.3)

- Disconnect the LV plug (refer clause 4.1.4)

- Open the HT compartment door (refer clause4.6.1)

- Remove warning plates.

- Insert the original drawout truck of the circuitbreaker or link drawout truck in the panel (referclause 2.11.4)

- Connect the LV plug (refer clause 4.1.5)

- Close the door (refer clause 4.5.2)

- The original drawout truck is now ready fortransfer to connected position.

4.5.3 Earthing the Busbars or Cables withEarthing Switch

4.5.3.1 Earthing the Busbars with EarthingSwitches

- Switch off the supply to the main busbars.

- Ensure that the supply to the main busbars cannotbe switched ”ON” from remote points.

- In case the electro-magnetic interlocks, ensure thatall the interlocking conditions are satisfied.Otherwise the earthing switch cannot be closed.

- Close the earthing switch by inserting the earthingswitch handle in position and turning it in theclockwise direction till stop. Withdraw the handle.

- Place the warning plates at all necessary locations.

4.5.3.2 Earthing Cables with Earthing Switch(fig.24)

- Move the truck to test / disconnected position.Earthing switch cannot be closed until this positionis reached.

- Ensure that the cables cannot be energized fromthe other end.

- Follow the procedure for Busbar earthing switch.

4.5.3.3 Disconnection of Earthing Switches

- Insert the earthing switch handle in position. Turnit in the anti-clockwise direction till stop. Withdrawthe handle.

- Remove warning plates from all the locations

4.5.4 Earthing the Busbars or Cables with Truck

4.5.4.1 Earthing the Busbars with Bus EarthingTruck

- Switch off the supply to the main busbars.

- Ensure that the supply to the main busbars cannotbe switched ”ON” from remote points.

- Rack ou the breaker to diconnected position.

- Diengage the LV plug & socket.

- Drawout the nreaker truck completely out of thepanel.

- Insert the Bus earthing truck in the panel todiconnected position.

- Connect the LV plug to socket.

- Rack in the truck to service position.

- Place the warning plates at all necessary locations.

25

4.5.4.2 Earthing the Cables with Cable EarthingTruck

- Move the truck to test / disconnected position

- Ensure that the cables cannot be energized fromthe other end.

- Follow the procedure for Busbar earthing switch.

4.5.4.3 Link Type Eathing Truck

- Switch off the supply to the main busbars.

- Ensure that the supply to the main busbars cannotbe switched ”ON” from remote points.

- Ensure that the cables cannot be energized fromthe other end.

- Follow the procedure for Busbar earthing switch.

4.6 Breaker Compartment Door

The door can be opened & closed when the truck is inthe disconnected position and the plug & socketconnector for LV cables has been connected together.

The door interlock can be defeated as describedunder clause 5.5 below.

4.6.1 To open the door

- Rotate the handle anti-clockwise to open the door.(For upto 15kV)

- Unscrew the door closing bolts of HT compartmentdoor. The bolts are captive (for 24kV Panel)

- Open the door.

4.6.2 To close the door

- Shut the door.

- Rotate the handle clockwise till it gets closed. (Forupto 15kV)

- Tighten the captive screw in case of bolted door.

4.7 Door to LV Compartment

4.7.1 To open the door

- Rotate the turnlocks with a key in anti-clockwisedirection or unscrew the captive bolts in case ofbolted door.

- Open the door.

4.7.2 To close the door

- Shut the door.

- Rotate the turnlock in clockwise direction ortighten the bolts in case of bolted door.

26

5. Maintenance

DangerPrecautions for Safe Working

Maintenance, repair and subsequent conversion orextension work shall be carried out only byspecially trained personnel in accordance with theoperating instructions and/or special conversioninstructions. Training and information sessions forpersonnel will be provided by the competentSiemens department.

Before starting any work on the panels referencesmust be made to local regulations for high voltageswitchgear. Switch off the power supply, close/open the breaker manually to ensure that theclosing spring of the breaker is discharged. Thenrack out the truck from service to test position.

Control terminals in the LV compartment must notbe touched if the control supply is notdisconnected.

Non observance will result in death and / or severepersonnel injury or substantial damage toproperty.

5.1 Inspection Schedule

- Each year

• Make a general visual check.

• Check whether the accessories are completeand in proper order.

• Clean and lubricate the wheels as well asmoving parts of the truck and interlockingplate.

• Relays to be tested for their functionality.

• Clean the Panels (refer clause 5.2)

- Every five years

• Transfer the withdrawable truck to thedisconnected position.

• Test-operate the circuit-breakers.

• Remove the withdrawable trucks (refer clause2.7.1) and carry out all maintenance work, alsoon the switching devices.

• Clean the panels (refer clause 5.2) and checkthe connections.

• Lubricate all bearing surfaces, bearings andarticulated joints.

• Reinsert the withdrawable trucks.

• Check the switchpanel functions and put theboard back into service.

If work has to be carried out in the panels; isolate theboard, make sure that it cannot be made live again,check its isolated state and earth and short-circuit thefeeders and where applicable, the busbars. Adhere toall regulations and safety measures, maintain andservice the built-in equipment, e.g. circuit-breakers,voltage transformers, current transformers, relays,meters, protective devices, etc. in accordance withtheir operating instructions.

Before removing the front plate of the breakeroperating mechanism discharge the closing andtripping springs. Follow the instructions given on themechanism housing.

Only standard tools are required. Put the switchgearback into service as described under clause 3 above.Service the switchgear at shorter intervals if the airis very moist or full of dust or is otherwisepolluted. The cause of any disturbance or short-circuit must be determined immediately anddamaged parts replaced, irrespective of whether aninspection is due or not.

5.2 Cleaning

CautionFor Safety

For safety reasons, cleaning of panels shall betaken up only when the shutdown of Main &Auxilliary Power supply is taken, the breaker is inthe open state, closing spring of the breaker isdischarged & the breaker truck is removed out ofthe panel.

Cleaning Agents

Perchlorethylene, 1.1.1 trichloroethane, smallbrushes, dusters and vacuum cleaner for sheet metalparts.

Note:

Trichlorethylene, perchloroethylene andtetrachloroethylene have a harmful effect on castresin parts and must not come into contact withthem.

Cast resin parts should be cleaned with distilled wateronly.

Silver plated and other contact surfaces to be cleanedwith clean cloth.

27

5.3 Lubrication

Immediately after cleaning:

- Lubricate the isolating contacts and their matingcontacts with neutral grease.

- apply a film of neutral grease to the bearings andarticulated joints of the operating mechanisms, tothe withdrawable parts and shutters, and to thedoor hinges and locks.

Recommended neutral greases are:

(i) SERVOGEM 2 (multipurpose) of Indian OilCorporation make

(ii) Multipurpose grease ‘H’ of Hindustan PetroleumLtd. make

(iii) Any other chemically neutral grease which canwithstand temperature up to 15° C.

5.4 Replacement Parts

Items such as post insulators, bushings matingcontacts, measuring instruments, currenttransformers etc., can be replaced. If replacement islikely to prove difficult ask the nearest Siemensrepresentative in good time for deputation of suitablepersonnel. The representative will also assist you indeciding what spare parts to keep in stock.

When ordering spare parts and units give thefollowing details:

- Type and Serial No. of the switchboard (seenameplate).

- Exact description of the unit or part, referring tothe appropriate operating instructions whereapplicable, or to a drawing; sketch or circuitdiagram. Use reference list of items in Section 8.

DangerPrecautions for Safe Working

High Voltage !

Touching live parts will result in severe personnelinjury and / or death.

This equipment shall be operated only by qualifiedpersonnel who have become thoroughly familiarwith the operating instructions manual and inparticular all the safety instructions.

5.5 Defeating the Door Interlock of HVCompartment

Caution : Take utmost care while defeating anyinterlock as the defeat operation leads to access tothe areas / parts which are likely to be live.

5.5.1 Drawout Unit in Connected Position

The breaker compartment door interlock should onlybe cancelled if the truck cannot be transferred to thedisconnected position and the situation cannot becleared in any way.

- Switch off the circuit-breaker.

- Make sure that the busbars are not live.

- Insert a small screw driver in the opening (21.6,fig. 21) and screw-in the grub screw visiblethrough the opening.till it falls out inside thepanel.

- Open the door by turning the door handle.(referclause 4.5.1).

5.5.2 Drawout Unit in disconnected position

- Press the interlocking lever on interlocking plate byhand.

- Insert the double-bit key in lock(21.4, fig.21) andturn it (locked) to “Manual Racking”.

- Fit the hand crank (8.2, fig. 8) to the hexagonshank in opening turn it clockwise as far as it willgo and pull it off(21.5, fig.21).

Turn the double-bit key clockwise through 90º fromposition “Manual Racking” to “ConnectedPosition(locked)” and pull it off.

5.5.3 Restoring the Door Interlocks

After carrying out the operations to defeat the doorinterlock as described in clause 5.5.1 or clause 5.5.2,the door of the HV compartment can be closed andinterlocks can be restored by following theprocedures in clause 5.5.1 in the reverse sequence.

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6. Disposal of Product

This product is environmentally compatible.

The following materials have been used to make upthe device : Steel, Copper, Aluminium, Cast-resinglass-fibre-reinforced thermoplastics, rubber,porcelain, greases & similar materials. PVC is used asan insulation material for control wires.

In disposal, priority must be given to re-use of thematerials which can be recycled.

In as-supplied-condition, the product does notincorporate any hazardous substances.

In operation, the product does not emit anyhazardous materials or gases.

During disposal of the product, care must be taken todismantle as far as possible in more environmentallyaccepted way as Recyclable & Non-cyclable scraps i.e

steel, copper, aluminium, rubber, PVC, cast-resin &glass-fibre-reinforced materials to be segregatedproperly.

The Re-cyclable materials like Steel, Copper,Aluminium can be reused.

Non cyclable materials like Cast-resins, glass-fibre-reinforced etc can be broken in to pieces & can beused as secured land filling materials.

Rubber being biodegradable material must berecycled through authorized contractors.

PVC material should not be burnt as they may releaseHalogenated hydrocarbons which can affect theozone layer. Therefore, PVC must be recycled throughauthorized contractors.

Local Siemens office can answer any questionsconcerning disposal.

29

7 Summary of Important Instructions-

DON’Ts

(1) Do not leave any equipments or tools in thepanel.

(2) Do not put hands or tools in operatingmechanism when electrically operated.

(3) Do not operate the breaker during cleaningprocess.

(4) Do not use any other chemical or grease forclearing or lubricating other than mentionedin these instructions.

DOs

During Installation & Commissioning Stages :-

(1) Brush the contact surfaces properly beforebolting busbars. Also grease the joints &apply proper torque on the bolts.

(2) Check rated voltages of equipments such asmotor, closing & tripping releases mountedin the operating mechanism with theavailable auxiliary supply to be connectedto these equipments in the substation.

(3) Ensure that all the foundation bolts aretightened along with the square washer andalso seal of all control and power cablecutouts to prevent vermin entry.

During service life of the panel-

(4) Keep door & covers firmly closed to prevententry of dust, moisture, insects etc.

(5) Ensure spring charging handle & manualhandle are available easily.

(6) Decide maintenance schedule based upon(a) no. of short circuit operations,(b) frequency of breaker ON/OFF operations,(c) pollution level (d) humidity, etc.

(7) Isolate & earth the breaker before carryingout maintenance & ensure it is in OFFposition & springs are dischargedcompletely before cleaning.

(8) Ensure that the shutters are close and padlocked before starting the maintenance orcleaning of the panels.

(9) Depending on site conditions, inspect

– the interior of the panels for dust,cobwebs etc. & clean them.

– porcelain insulators & clean them,

– operating mechanism parts such asplungers of releases, moving joints etc. &clean them, and

– functioning of space heaters.

(10) Lubricate moving parts with lubricantsprovided for the breaker.

(11) Check insulation resistance with a meggerbefore putting the breaker back into service.

(12) Keep a log-book for each panel.

(13) Follow instructions given in the operatingmanual.

(14) Ensure panel operations, maintenance etc.is done by trained persons.

(15) Operate the defeat interlock of CB door onlyin case of emergency.

30

8 Additional Information

8.1 Reference List of Items

6.2 Bushings of lower mating contact Fig 6, 17

6.3 Current Transformer Fig 6

6.4 Cable Connection Pieces Fig 6

6.5 Wiring Cover Fig 6

6.6 Gland Plate for Poer Cables Fig 6, 18

7.1 LV Compartment Door Fig 7, 21, 21a

8.1 Charging Handle Fig 8

8.2 Cranking Handle Fig 8

8.3 Double Bit Key Fig 8

8.4 Rod Trap Key Fig 8

8.5 Earthing Switch Handle Fig 8

10.1 End Covers Fig 14

10.2 Pressure relief channel forcable termination compartment Fig 14

10.3 Pressure Relief flaps Fig 14

16.1 Breaker Compartment door Fig 16, 20,21, 21a

16.2 Upper metallic shutter Fig 16, 19

16.3 Lower metallic shutter Fig 16, 19

16.4 Space Heater Fig 16, 17

17.1 Fixed Contacts (Upper) Fig 17

17.2 Fixed Contacts (Lower) Fig 17

17.3 Earthing Strip Truck Fig 17

18.1 Extension Links Fig 18

18.2 Earthing strip from CB Chamber Fig 18

19.1 Shutter operating rod Fig 19

19.2 Roller Guide Angle Fig 19

19.3 Truck guide Fig 19

21.1 Ball grip Fig 21a

21.2 ON & OFF Push Button(On HT Door) Fig 21, 21a

21.3 Window for the indicators ofthe breaker truck Fig 21, 21a

21.4 Opening for Double Bit Key Fig 21, 21a

21.5 Opening for the cranking handlefor racking the breaker truck Fig 21, 21a

21.6 Opening for defeating interlock Fig 21, 21a

21.7 Door Handle Fig 21

21.8 Door locking bolts (for 24kV Panel) Fig 21a

24.1 Fixed Contacts (E. Switch) Fig 24

24.2 Moving Contact (E. Switch) Fig 24

24.3 Earthing Switch Shaft Fig 24

24.4 Operating Link Fig 24

2.1 Circuit Breaker Compartment Fig 2

2.2 Cable & CT Compartment Fig 2

2.3 Busbar Compartment Fig 2

2.4 Low Voltage Compartment Fig 2

2.5 Breaker Truck Fig. 2, 20

3.1 Vacuum Interrupter Fig 3

3.2 Insulating Switching Rod Fig 3

3.3 LV Socket on truck Fig 3

3.4 Contact Arm Fig 3

3.5 Truck Handle Fig 3

3.6 Cast Resin Insulator Fig 3

3.7 Guide Roller on truck Fig. 3

3.8 PP Tube Fig. 3

3.1.1 Pole Flange (Upper) Fig 3.1

3.1.2 Pole Flange (Lower) Fig 3.1

3.1.3 PT on the truck Fig. 3.1

3.2.1 Mechanical ‘ON’ Push Button Fig. 3.2

3.2.2 Mechanical ‘ON’ Push Button Fig. 3.2

3.2.3 Spring Charging Opening Fig 3.2

3.2.4 Spring Charge Indication Fig 3.2

3.2.5 Mechanical ‘ON & ‘OFF’ Indication Fig 3.2

3.2.6 Mechanical Operation Counter Fig 3.2

3.2.7 Earthing Pin for Truck Fig 3.2

4.1 Door Locking hinge pin Fig 4, 21

4.2 Door close interlock Fig 4

4.3 Viewing window for truck position Fig 4

4.4 Viewing window for Spring chargeIndicator and Mechanical Counter Fig 4

4.5 LV connection Plug Fig 4

4.6 Drive Mechanism housing Fig 4

4.7 Ramp Fig 4

4.8 Interlocking Plate (Drive Box) Fig 4

4.9 Holder for LV Socket Fig 4

4.10 Clip for locking LV Plug to Breaker Fig 4

4.12 Trip mechanism for operating thebreaker in service position Fig 4

4.13 Rod Lever Fig 4

5.1 Bushings of upper mating contact Fig 5, 17

5.2 Cast resin insulator Fig 5

5.3 Feeder connections Fig 5

5.4 Busbars Fig 5

6.1 Main Earth Busbar Fig 6, 18

31

8.2 Jointing Torques

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

Size of Bolt M8 M10 M12 M20

Property Class 6.6 8.8 8.8 8.8

1 Steel to Steel 32 65 115 –

2 Steel with Insulator 16 32 77 170

3 Busbar Joint 20 40 70 –

4 Busbar with Steel 20 40 70 –

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

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 communicatewith, brief description of the part and its location in the panel.

5. Alternatively, a sample may be submitted.

Siemens Ltd.PTD-03-152-015This replaces PTD-03-152-003

Siemens Ltd.Power Transmission & Distribution DivisionMedium Voltage SwitchgearThane Belapur Road,Thane 400 601.Tel. : +91-22-760 0135Fax : +91-22-760 0134 Order No. 4-XXBXX-03-17231-101

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

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