Genie Switch Gear

Genie rangeSF6 indoor switchgear

installation, operation and maintenanceinstructionsversion 002 / August 2000

GENIE PDF O&M 11/9/00 10:10 am

generalgeneral descriptionintroductionweights and dimensionsstorage

installationfloor preparationconnection of panelsconnection of busbars installation of pilot cables

connectionmain cable connectionbusend cable box connection

operationoperation of switch - mainoperation of switch - earthoperation of circuit breaker - mainoperation of circuit breaker - earthoperation of busbar earthing switchcable testing main cablephase live indicationoperation of pocket terminalaccessing VT’sdisconnection of V.T.s

commissioningintroductionphysical checksHV. withstand testtest voltagestest connection

maintenance

SF6 gas

endurance characteristics

product support

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Genie rangecontents

1MERLIN GERIN


introduction

circuit breaker/switch

circuit breaker/switch(with bus end cable box)

extendedcircuit breaker(with bus end cable box)

circuit breaker/switch(with busbar VT)

extendedcircuit breaker(with busbar VT)

bus-section

2380hwd

average dimensions(mm) (packed)

unit(s)

approx. weight (kg)(packed)

5301300450

extendedcircuit breaker

23807701300500

2380 2380770 10101300 1300500 550

2380 2380600 8401300 1300550 600

23807701300500

Genie rangegeneral description

the range comprises:-■ CB2 200A circuit breaker■ CB6 630A circuit breaker■ CB12 1250A circuit breaker■ BS6 630A bus section■ BS12 1250A bus section■ SW6 630A switch■ SWE busbar earthing switch

The equipment is suitable for indoor use only. It is therefore necessary to protectthe equipment from the environment before and during erection/commissioning.Should the busbar chamber or cable box become exposed to the elements, theyshould be thoroughly cleaned prior to energising.

2 MERLIN GERIN

weights and dimensions

These instructions cover all operations concerning handling,installation, operation and maintenance of the Genie range of equipment.


All units are delivered on pallets (secured by 2 x M8 screws and nuts). The unitscan be off loaded by forklift truck or by using a lifting kit consisting of 2 lifting barsand can be off loaded using an overhead crane (see above diagrams).

These units are designed for indoor use and must not be left outdoors. They shouldbe stored in a warm, dry switchroom and protected against dust and debris.

Ancillary kits containing busbars, dyscon boots, glands, screws etc. are suppliedloose with each unit or fastened to the panel or secured in the cable box.

offloading

'F'

LIFTINGPOINTS

during lifting of theunit all four liftingpoints must be used.

lifting bars are fixedto unit using existingfixings (marked'F')tightened to a torquevalue of 10Nm(7.4lb/ft).

new fixings and sealsmust be used to re-securethe facia after lifting,tighten to a torquevalue of 5.4Nm(4lb/ft).

important

maximum mass = 350kg

note:lifting chains/ropesshould be positioned@1800mm and 1650mm fromlifting points, as shown.

LIFTINGPOINTS

'F'

1650mm

1800

mm

'F'

LIFTINGPOINTS

during lifting of theunit all four liftingpoints must be used.

lifting bars are fixedto unit using existingfixings (marked'F')tightened to a torquevalue of 10Nm(7.4Ib/ft).

new fixings and sealsmust be used to re-securethe facia after lifting,tighten to a torquevalue of 5.4Nm(4Ib/ft).

important

maximum mass = 300kg

note:lifting chains/ropesshould be positioned@1800mm and 1650mm fromlifting points, as shown.

LIFTINGPOINTS

'F'

1650mm18

00m

m

storage

ancillary kits

Genie rangestorage

3MERLIN GERIN


Please refer to the arrangement drawing for foundation details.floor preparation

erection/connection circuit breaker, switch, busbar earthing panel

The units can be directly bolted to theconcrete floor by use of 2 x 10mmrawlbolts for single width panels or 4 x 10mm rawlbolts for bus-section andextended circuit breaker panels. Thefloor tolerance is ±1mm over 1 metre.

JIGS SUPPLIED

CHANNELS GROUTED INPOSITION USING SETTING

FOOT OF UNIT

M10 CHANNEL FIXING

IN SUBFLOORCHANNELS MADE

CHANNEL NUTSPRING LOADED

698 TO + - 1mm WITHFOUNDATION CHANNEL

NOTE: FLOOR LEVEL FLUSH

41

70

Genie rangeinstallation

Where it is not possible to guaranteethat the floor is within the specified tolerance, we strongly recommend theuse of foundation channels, i.e.Unistrut P3270 or similar.

note: the floor must be 1mm below the topof the Unistrut

Line up the first panel in position(seeUnistrut diagram above). Insert 2channel nuts into the Unistrut asshown and slide into position. Fingerconnect the M10 screws at the frontand rear of the unit (do not tighten).Manoeuvre next panel into positionand repeat.

If the panel is being bolted directly tothe floor, line up the first panel in position and remove the lower panelfront plate. Drill front and back fixingpositions through access holes. Therecommended drill size is 16mm Ø.Install rawlbolts, (shown above). Finger connect the M10 nuts and washers.Manoeuvre next panel into positionand repeat.

4 MERLIN GERIN

access holes


connection of panels

With the busbar chamber coverremoved,bolt the panel busbar chamber flanges together using 10 x m6 screws and nuts via the flangeholes along the lower and front edges.

Repeat until all panels within theswitchboard have been installed andbolted together.


5MERLIN GERIN

Remove the busbar chamber top andrear cover plate. To remove undo the10 x M6 captive screws along the topand rear of the busbar chamber cover.

Remove pilot cable box (if fitted) . Toremove undo the 9 x M6 screws andnuts along the top and rear of the busbar chamber. Place the pilot cablebox on the top of the low voltage cabinet. (Approximate weight of pilotcable box is 10kg.)

multicore pilot cable riser kit(bottom entry cables)

A multicore pilot riser kit is available forswitchboards which require bottomentry multicore pilot cables. This allowseasy fixing and support for all multicore cables associated with the switchboard. It can be supplied loosefor installation onto an existing switchboard, or factory installed via abusbar trunking. An additional pilotcable tray can be supplied for fitting tothe LV compartment to allow the multicores to travel to the relevantpanel.

Full assembly instructions are providedwith the appropriate kits.



6 MERLIN GERIN

wide Genie LV cabinet Geniehousing

standard Genie LV cabinet Geniehousing

1. Using a hoist or similar offer the LVCabinet up to the unit as shown.

2. Locate the LV Cabinet onto the Genie Mecho Cover Plate.

3. Fix the cabinet in place using 6 offM6 x 16 Screws with 1 off M6 Form‘A’ Washer under the head of eachscrew.

1. Using a hoist or similar offer the LV Cabinet up to the unitas shown.

2. Locate the LV Cabinet onto theGenie Mecho Cover Plate.

3. Fix the cabinet in place using 6 offM6 x 16 Screws with 1 off M6 Form‘A’ Washer under the head of eachscrew.

note: standard LV cabinet door not shownfor clarity

note: wide LV cabinet door not shown forclarity


connection of front earth conductors and remaining panel fixings

connection of end panel earthconductor

connection of rear earth conductor and busbar assemblies

completing the installation

bus-section earth conductors

Remove the housing lower front plateby removing 8 x M6 screws. Removethe rear access plates. With the lowerfront and rear access panels removed,secure the panels using 2 x M6screws, washers and nuts at the lowerpanel - panel fixings as illustrated.Connect front panel - panel main earth conductor as illustrated and secureusing 1 x M10 screw, washers and nut.

Secure the low voltage instrument cabinets together using 1 x M5 screw,washers and nut at the fixing pointadjacent to the bus-wiring aperture.

Connect end panel earth conductor asillustrated using 1 x M10 screw, nutand washers at the front and rear fixingpoints.

note: for inverted MV cable boxes theassembly illustrated dashed should beused.

Ensure all insulation and chambers areclean and free from debris.

To complete the installation, tighten allfloor fixings, replace all covers, andcomponents removed

Each panel has an earth conductor fitted at the rear. Bolt these togetherusing 2 x M10 screws, nuts and washers per panel.

Short front and rear earth conductorsfor use on bus-sections are provided.The method of connection remains thesame as for standard panels.

With the busbar fixing studs removed,assemble the busbar system as illustrated opposite. With the busbarsystem assembled, studs inserted andnuts tightened to the torque advisedreplace the busbar chamber coversand pilot cable boxes (if fitted) for thecomplete switchboard.

note: all 20 x M6 screws, nuts and washersshould be fitted to the busbar chamberflanges to ensure a tight seal.

Fit the busbar chamber end coversusing 20 x M6 fixing screws, nuts andwashers.

note: access is required via the busbarchamber top access plates.


7MERLIN GERIN

END PANELEARTH BAR

M10 HEX HEAD BOLTM10 WASHERSM10 LOCK NUT

MAIN EARTH BAR

SIDE SHEET

REAR EARTH BAR

UPRIGHT

SIDE SHEET

FACIA

BUSBARCHAMBER

PANEL TO PANEL LOWER FIXING

REAR EARTH BAR

INVERTED CABLE BOX

STANDARDCABLE BOX

PANEL TO PANELLOWER FIXING

END PANELEARTH BAR

M10 HEX HEAD BOLTM10 WASHERSM10 LOCK NUT

MAIN EARTH BAR

SIDE SHEET

REAR EARTH BAR

REAR EARTH BARCONNECTOR

REAR EARTH BARCONNECTOR



8 MERLIN GERIN

connection of busbarstotally encapsulated and earth screened

connection of busbarstotally encapsulated

Busbar torque 54Nm

Ensure that the environment is cleanand dry.

Clean dyscon boots and bushings.Apply DC4, Dow Corning silicongrease to boots. Fit busbars into bootsas shown above.

note: it is recommended prior to refittingbusbar chamber covers that the busbarsare tested - see page 20 for typical tests.

Please consult us regarding additional testswhich may be required for this busbar system.

refer to accessory kit instructions for fulldetails

note: it is recommended prior to refittingbusbar chamber covers that the busbarsare tested - see page 20 for typical tests

Clean dyscon boots and bushings.Apply DC4, Dow Corning silicongrease to boots. Fit busbars into bootsas shown above.

Busbar torque 54Nm


(LIVE)INTERNAL SCREEN

INSULATION

METALISED COATINGINSULATED BUSBAR WITH

(EARTHED)MOULDED CONDUCTIVE SCREEN

WITH MOULDED METALINSERT

EPOXY END PLUG



9MERLIN GERIN

installation of pilot cables through pilot cable box

standard arrangement optional

Remove the pilot cable box cover by unscrewing the 2 x M6 screws. Pilot cablescan be installed from above or below using individual sliding gland plates or bydrilling the single sliding plate, as shown.

Remove the pilot cable box cover byunscrewing the 4 x M6 screws. Pilotcables can be installed from above orbelow using pre-punched gland plateswith various sized electrical knock-outs.

arrangement of bus-section busbarsconnection of busbars totally encapsulated/earth screened

Busbar torque 54Nm


Remove dyscon boots and clean bushings. Apply DC4, Dow Corningsilicon grease to boots. Fit busbarsinto boots as shown.

refer to accessory kit instructions for full details


Genie rangeconnection

10 MERLIN GERIN

main cable connection

standard cable entry

inverted cable entry

All units are fitted with dry type cableboxes suitable for accepting heatshrink or cold fit termination kits.Accessory kits containing gland platesetc are available.

Cable termination torque = 54NM

note: red phase bushing is on rear left of unit.

note: ensure that cable is supported bygland plate before placing on bushings.


Genie rangeconnection

11MERLIN GERIN

standard cable entry

inverted cable entry

Dyscon elbow adaptors

bus end cable box connection

Dyscon dry - type cable terminationsare standard on 1250A panels andoptional on 200A/630A panels.

note: the hole size in the dyscon palm forconnecting the main cable is 14mmø forM12 fixing.


Genie rangeoperation

12 MERLIN GERIN

operation of switchmain

operation of switchearth

Check that the gas indicator is in thegreen healthy condition. Check thefacia diagram for the service condition.Remove padlocks if fitted. Move selectto main switch position.

Insert handle as shown and pull downfirmly until the switch closes. Theselector lever will be locked into themain switch position.

Fit padlock into the handle socketpadlock bracket if required. Toopen, rotate the handle through180° and reverse the procedure.

Check that the gas indicator is in thegreen healthy condition. Check thefacia diagram for the service condition.Remove padlocks if fitted. With theswitch in the open position, move theselector lever to earth switch position.

Insert handle as shown and pull downfirmly until the switch closes. Theselector will be locked in the earthswitch position.

Fit padlock into the handle socket padlock bracket if required. To open,rotate the handle through 180° andreverse the procedure.



13MERLIN GERIN

operation of circuit breaker main

Check that the gas indicator is in thegreen healthy condition. Check thefacia diagram for the service condition.Remove padlocks if fitted. Move selectto main circuit breaker position. Inserthandle as shown and pull down firmlyto charge springs.

Pull down on lever firmly.The selectorwill be locked into the main circuitbreaker position. Fit padlock into thecircuit breaker closed in service position if required.

To store an additional charge on thesprings, rotate the handle through 180°and insert as shown. Move handle up to reset and earth off position.

The handle can then be reversed oncemore and pulled down to store an additional charge. See indicator flag ontop of unit.

To open the circuit breaker press thepush circuit breaker off button. Fit padlock into the circuit breaker openposition if required.



14 MERLIN GERIN

operation of circuit breakerearth

operation of busbar earthing switch

Check that the gas indicator is in thegreen healthy condition. Check thefacia diagram for the service condition.Remove padlocks if fitted. With the circuit breaker in the open position,move the selector lever to earth switchposition. Insert handle as shown andpull down firmly to charge springs.

Check that the gas indicator is in thegreen healthy condition. Check thefacia diagram for the service condition.Remove padlocks if fitted.

Fit padlock into the handle socket padlock bracket position if required.To open rotate the handle through 180°and reverse the procedure.

Pull down on lever firmly to close to theearth on position. The selector will belocked in the earth position.

Fit padlock into the handle socket padlock bracket position if required.To open rotate the handle through 180°and insert and move handle up to resetand earth off position.

note: the circuit breaker off button will notoperate.

Insert handle as shown and pull downfirmly until the switch closes.

important note: the busbar earthing switch should only be operated when the busbars are de-energised.



15MERLIN GERIN

cable testing main cable

Ensure that the main earth switch is“earth on”. This will open the key way.Push in and rotate test access keycover lever 90° clockwise and removecover.

Insert test access key into the key way(as shown). Push lever in and rotate90° anti-clockwise. The test accesskey can be padlocked in position ifrequired.

Remove the earth star points as shownto provide access for cable testing.The test access key will be locked inposition until the earth star point isfirmly replaced.Reverse the procedure to return to service condition.

note : ensure cables are dischargedbefore touching bushings.

Unit shown with earth star point connected.



16 MERLIN GERIN

operation of TSM2001 pocket terminal

Open the facia of the Sepam 2000 andconnect the TSM20001 pocket terminalas shown.

Refer to Sepam 2000 commissioningmanual for further details.

phase live indication

To test for phase live condition, insertneon indicator lamp into the relevantphase socket as shown. The indicatorlamp will illuminate if the phase is live.

note : the neon indicator lamp can beproved before and after insertion using aneon verification box (Kit Ref. RMR-A24).



17MERLIN GERIN

important note: before accessingVT’s (during commissioning or replacing fuses) ensure that the mainearth switch is padlocked in the earthon position. If the unit is a bus-sectionensure that the bars are earthed orcompletely isolated.See page 12 for operation instructions.

Remove the lower circuit breaker frontcover access panel for access to solidlink and fused type connection.

Open VT cover on lower front of unitand remove racking handle from itsstorage position.Insert the racking handle into the topposition of the slot.Turn in an anti-clockwise direction asfar as it will go and remove handle.The VT’s are now disconnected. Thehandle can now be replaced in the VTcover flap and this can be closed andthe panel can be returned to servicecondition.To re-connect the VT’s, the above procedure should be reversed remembering to ensure that the mainswitch is in the Earth ON position.

accessing VT’s

isolation of VT’s

Ensure that the main switch is in the Earth On position

isolatedin service



18 MERLIN GERIN

disconnection of VT’s - solid link

disconnection of VT’s - fused link

Pull back the VT insulating boot andloosen the VT connection using a 6mmallen key as shown.

Remove the fuse completely from theunit to disconnect the VT.

Grasp the grey fuse tube and push upuntil the bottom is clear of the black insulation boot.

Disconnect the VT as shown. Reverse the procedure to connect theVT’s

Reverse the procedure to connect theVT’s

note: ensure the circuit is earthed

note: ensure the circuit is earthed


Genie rangecommissioning

19MERLIN GERIN

commissioning

physical checks

high voltage withstand test toBS/IEC

All equipment is subject to stringentquality and operational checks prior todespatch, however it is the ownersresponsibility to ensure that commissioning tests have been completed to IEC60694. The followingis a resume of these tests.

Connect the H. V. test set and carry outthe withstand tests in accordance withthe following tables.

note: ensure VT’s are disconnected priorto carrying out any HV pressure tests

Check operation of auxiliary switchcontacts and remote indication inaccordance with the schematic diagram. Confirm the phase relationship of the neon indicator sockets.

Check the pick up voltage of auxiliarycoils if fitted. Closing coils should operate between 85% and 110% of therated voltage. Opening coils shouldoperate between 70% and 110% of therated voltage.

note: all voltages should be appliedinstantaneously unless otherwise specified

Refer to Sepam commissioning guideor relay manufacturer’s data.

Remove all packaging and transitlabels from the equipment. Check thedata plate details against the specification. Check the operation ofthe switches/circuit breaker, testaccess and various interlocks.

functional checks protection and control system

B2Y2R2

B1Y1R1


Genie rangecommissioning

20 MERLIN GERIN

test voltages

test connection - circuit breaker / switch

3.6 8 50 1 (AC) 15 (DC) 7.5

7.2 16 50 1 (AC) 15 (DC) 15

12 23 50 1 (AC) 15 (DC) 25

13.8 32 50 1 (AC) 15 (DC) 32

rated voltage(kV)

AC test voltage(kV)

frequency(Hz)

duration(minutes)

(d.c. test voltage - current practice)

test number

1

2

3

4

5

6

CB / switch

closed

closed

closed

closed

open

open

live terminals

R, Y, B

R, Y

Y, B

B, R

R1, Y1, B1

R2, Y2, B2

earthed terminals

frame

B, frame

R, frame

Y, frame

R2, Y2, B2, frame

R1, Y1, B1, frame

The following tests should also be carried out. If additional information and/or assistance is required please consult us.

- primary injection

- secondary injection

- CT spill test

- CT polarity test

- relay secondary injection

- relay timing and functionality tests


Genie rangemaintenance

21MERLIN GERIN

routine maintenance recommendations toBS6626:1985

environmental conditionsUnit installed and commissioned in accordance with the manufacturers instructionsIndoors, completely protected from the weather. Humidity below 40% and no dripping water. Minimal dust and air circulation. Ambient temperature between -5oC and +40oC. No contact with any chemical agents (eg. salt). No infestation of any animal life (eg. insects). No contact with any plant life (eg. mould). No earth movements. No damage to the unit of any kind.

operational conditionsNo mal-operation of any kind. No abnormally high number of operations - refer to the graph. No abnormally high number of faults - refer to the graph. No over-voltage or over-current (above rating).

environmental conditionsUnit installed and commissioned in accordance with the manufacturer’s conditions. Humidity below 60%. Unit may be indoors or outdoors within enclosures, but must not be subjected to regularextremes of weather eg. heavy rain storms, dust storms, heavy snow and ice, flooding, temperature cycles greater than 40oC or less than -5oC, dense coastal fog or acid rain. No regular or thick covering of debris. No contact with any chemical agents (eg. salt). No infestation of animal or plant life. No earth movements. No damage to the unit of any kind.

operational conditionsNo mal-operation of any kind. No abnormally high number of operations - refer to the graph. No abnormally high number of faults - refer to the graph. No over-voltage or over-current (above rating).

Any environmental or operational conditions which do not satisfy either of the above twodescriptions must be deemed aggressive.

ideal conditions

standard conditions

aggressive conditions

Routine maintenance will depend onthe conditions to which the unit is subjected and to the relevant codesand practice. Periodic inspection of the

substation and equipment will be necessary to establish the conditions towhich the units are subjected to.

ideal conditions

gas enclosure

mechanism

housing

standard conditions aggressive conditions

no attention no attention no attention

no attention

no attention

no attention

every 10 years

every 10 years

every 5 years

note: local legislation may dictate maintenance be carried out with greater frequency, irrespective of site conditions. Please contact your localMerlin Gerin representative for further details.


Genie rangemaintenance

22 MERLIN GERIN

If the gas pressure indicator needle iswithin the red zone or in the extremelyunlikely event of a gas leak contactyour local Merlin Gerin office immediately.

In the unlikely event of a mechanismfailure, please contact SchneiderServices.

maintenance

general operation

Check that the gas indicator is in thegreen zone.

For circuit breaker panels check theelectrical protection system.

Check the operation of the unit and allmechanical interlocks.

housing

Check all external fixings, labels andearth connections are present andtight.

Check inside the MV cable box, busbarsystem LV cabinet and pilot cable boxfor heavy deposits of dust, ingress ofwater or contamination by animal orplant life.

Clean the units thoroughly and touchup paint work as necessary.

leakage of SF6 mechanism


Genie rangeendurance characteristic

23MERLIN GERIN

product support■ after sales

■ for products within warranty (12 monthsfrom date of commissioning or 18 monthsfrom date of dispatch - whichever is thesooner), please contact our customer service department onTel: 0113 290 3500Fax: 0113 290 3710■ for products outside the warrantyplease contact our Services division on Tel: 0113 284 8900Fax: 0113 284 8910■ Services division are also able to offer- full spare parts service- maintenance contracts including

protection and testing- erection and commissioning of new

equipment- system design- training

Endurance Characteristics

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Schneider Electric is the leading UK and world expert in the development and manufacture of products for the distribution and industrial applications ofelectricity. In the UK, Schneider Electric operates from 16 industrial and commercial sites, with 2,500 people, and achieves an annual turnover in excessof £270 million.

Schneider offers a full range of products and services for panel builders, OEMs,contractors, specifiers and the electrical supply industry for commercial and industrial applications.

Schneider Electric is committed to supporting its customers at every stage of aproject. Our 180 sales engineers, is the largest dedicated sales force in the UKelectrical industry.

Sales engineers are skilled at assessing individual requirements and combinedwith the expert support of it’s product specialists, will develop the most effectiveand economical solution.

in electrical distribution,

ExpertiseSchneider Electric

control and automation


Merlin Gerin Medium Voltage, 123 Jack Lane, Leeds LS10 1BSTel: 0113 290 3500 Fax: 0113 290 3710 Internet address: http://www.schneider.co.uk P

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Genie Switch Gear

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