OWNER’S MANUAL - Pascal Switchcarepascalswitchcare.com/pdf_file/2. Operation Manual.pdf ·...

OWNER’S MANUAL

12kV Indoor Vacuum Circuit Breaker Panel – Type PSI Installation Operation Maintenance Spares

PASCAL Switchcare India Pvt. Ltd.

P. L. Deuty Road,

P.O.:- Bishnupur,

Dist:- S Parganas,

West Bengal - 743503

PASCAL Switchcare India Pvt. Ltd

CONTENTS PAGE NO

1. INSTRUCTIONS 1

2. BASIC EQUIPMENT DETAILS 2

2.1 APPLICABLE STANDARDS 2

2.2 NAME PLATE DETAILS 2

3. RECEIVING, HANDLING & STORAGE 3

3.1 VISUAL INSPECTION 3

3.2 UNLOADING 3

3.3 UNPACKING 4

3.4 STORAGE 4

4. INSTALLATION 5

4.1 GENERAL 5

4.2 SITE REQUIREMENTS 5

4.3 PREPATORY WORK 5-6

4.4 ERECTING CUBICLES 6

5. ELECTRICAL CONNECTIONS 7

5.1 BUS BARS 7

5.11 GENERAL 7

5.12 BUS BAR JOINTS 7

5.2 PRIMARY POWER CABLES 8

5.3 SECONDARY CONTROL CABLES 8

5.4 GROUND CONNECTIONS 8

6. INSTALLATION OF CIRCUIT BREAKER TRUCK 9

6.1 CIRCUIT BREAKER OPERATION 9-10

6.2 CIRCUIT BREAKER INTERLOCKS 10

7. INSPECTION AND TESTING 11

(PRE-COMMISSIONING)

7.1 INSPECTION PROCEDURES 11

7.2 PRE-COMMISSIONING TEST PROCEDURES 12

8. OPERATION 12

9. MAINTENANCE 13

9.1 INTRODUCTION 13

9.2 MAINTENANCE STEPS 13

9.3 INSPECTION 13

9.4 POTENTIAL TRANSFORMER 13

9.4.1 DRAW OUT PT 14

9.4.2 FIXED PT 14

9.5 CURRENT TRANSFORMER 14-15

9.6 MAINTENANCE TABLE ‘A’ 15

9.7 MAINTENANCE TABLE ‘B’ 16

9.8 REPLACEMENT PROCEDURES 17-18

ANNAXURE MAINTENANCE LOG BOOK 19-20


1. INSTRUCTIONS

This manual describes installation operation handling and maintenance of

PASCAL make Horizontal Isolation Horizontal Draw Out VCB Panels Type PSI.

This manual is not intended to cover all details, combinations, or

variations of the equipment, storage, or installation.

It is also not intended to cover every possible contingency which can arise

during installation, operation or maintenance of the equipment.

If any problem arises which is not sufficiently covered in this Manual to

the satisfaction of the User or any further information is required, the

questions should be addressed to;

This equipment is designed and manufactured in conformance to applicable

safety standards. Unauthorized modifications or use of non-authorized

components can result in malfunctioning of equipment severe injury, death

and property damage.

Only qualified & trained persons are to install, operate, or service this

equipment. He should preferably be trained at manufacturer’s place to

handle the equipment. He should be trained in use of all protective gear /

equipment and should be aware of all hazards.

There is a HAZARD OF ELECTRICAL SHOCK OR BURN whenever working on or near electrical equipment.

Read the entire “Instruction Manual” carefully for important information about safety, handling, installation, operation, maintenance, and parts replacement.

The successful operation of circuit breakers depends upon proper handling, installation, operation, and maintenance. Neglecting fundamental installation and maintenance requirements may lead to personal injury, as well as damage to electrical equipment or other property.

This MANUAL and all accompanying drawings forms an integral part of the Equipment supplied and should be readily available for review and reference.

Page 1

WARNING

FIELD SERVICE DEPT

PASCAL SWITCHCARE INDIA PVT LTD P.L Deuty Road, PO: Bishnupur, Dist: 24 Parganas(S), West Bengal-743503 Telefax: (033) 24809426 Email: [email protected] [email protected] Website: www.pascalswitchcare.com

mailto:[email protected]


2. BASIC EQUIPMENT DETAILS

The PSI range of MV Switchgear is up to 12kV, 1250A, 26.3kA. The Switchgear is metal clad, compartmentalized panel comprising of:

1) Vacuum breaker compartment 2) Incoming/outgoing cable compartment 3) Main Bus Bar chamber 4) Low voltage instrument compartment

The Vacuum Circuit Breaker is of horizontal isolation, & mounted on draw out truck. All compartments are securely earthed

2.1 APPLICABLE STANDARDS

The Switchgear conforms to the following standards;

IS 3427/ IEC 62271-200 for Indoor Panels.

IS 13881/ IEC 62271-100 for Circuit Breakers.

2.2 NAME PLATE DETAILS

The following details are provided on the switchgear panel and vacuum circuit breaker.

Please verify the name plate details with the requirement.

Enclosure type: Serial no: Rated voltage: Reference standards: Phase: Frequency: Rated current: Insulation level: CT type: Ratio: Specification: Purposes: STC Panel main circuit and duration: STC panel earthing circuit and duration: Year of manufacture: Purchase order & date: Full address & contact details:

Type: Specification: Serial no: Mass: Rated voltage: Rated current: Frequency: SC Breaking capacity and duration: Insulation level: Closing: Opening: Operating mechanism: Operating sequence: Year of manufacture: Purchase order & date:

SWITCHGEAR PANEL CIRCUIT BREAKER

Page 2


3. RECEIVING, HANDLING & STORAGE

The panel is completely assembled and tested in the factory prior to shipment.

The equipment is packed and shipped in perfect condition with the Circuit Breaker in

OFF position and closing spring DISCHARGED

The panel is mounted on a pallet and firmly secured with fasteners. This must be

unloaded and / or stored in upright position only.

3.1 VISUAL INSPECTION

Upon receipt of the equipment, make an immediate physical inspection of the packed

consignment for possible transit damage. The recommended procedure for transit visible

damage is;

a) Check for visible damage on the packed consignment upon arrival.

b) Visible damage to be noted on delivery receipt and acknowledged by the

transporter

c) Inform PASCAL office and arrange for insurance inspection. Do not remove

material from unloading point.

3.2 UNLOADING

Unloading of the package units must only be done using crane as shown in fig. 3.2a, forklift

truck and / or transporter trolley jack as shown in below fig.3.2b.

Figure 3.2a Figure 3.2b

Heavy weight,

Improper Lifting or hoisting can result in death, serious injury or property damage.

Obtain the services of a qualified rigger prior to hoisting the panel to assure

adequate safety margins in the hoisting equipment and procedures to avoid damage.

Page 3

WARNING


3.3 UNPACKING

Unpacking should preferably be done near the foundation

In case unpacking is done away from foundation then panels should be transported

to foundation with breaker truck removed & with firm support to base.

DO NOT ROLL THE PANELS. USE AIR CUSHION OR FORK LIFTS FOR TRANSPORTATION

Carefully remove the shipping carton from the panel. If the panel has to be stored

before installing it at final site, do not remove the shipping pallet.

Check the panel for concealed damage. Notify transporter and PASCAL office as

soon as possible.

The panel with vacuum circuit breaker is packed in one container and loose

material such as bus bars; handles; coupling hardware etc. are packed in a separate

box. Please check the completeness of supply against the packing list. In case of any

discrepancy, notify PASCAL office immediately.

3.4 STORAGE

If the panel has to be stored before installing it at final site,

Do not remove the shipping pallet.

The panel is designed for indoor storage in covered area on the pallet provided before it

is moved to its final destination.

The indoor storage environment must be clean, dry and free from dust, corrosive

atmosphere and large temperature variations.

In case indoor storage is not possible, the panel must be completely covered and

protected from rain, dirt and other contaminants.

It is recommended to use space heaters for both indoor and outdoor storage to prevent

condensation and corrosion.

Page 4

CAUTION


4. INSTALLATION

4.1 GENERAL

In the interest of safe and proper functioning of the equipment, local erection should be

carried out or managed and supervised by trained skilled personnel.

4.2 SITE REQUIREMENT

Before commencement of installation please ensure;

a) Switchgear room is ready in all aspects with lighting, site electricity supply and

planned ventilation

b) Wall openings, ducts etc. for laying of power cables and control cables must be

complete.

c) Foundation should be properly leveled & must provide firm support to base plate. The

power & control cable cut outs should be as per foundation plan provided. Channels

should be embedded as per drawing for smooth removal of breaker truck. For ease of

maintenance following clearances from wall are recommended:

At rear – 750 mm

On sides – 750 mm

On front – 1500 mm

On top – 2000 mm

d) Recommended light intensity is 500lux

e) Ventilation: Switchgear should have adequate air flow.

4.3 PREPARATORY WORK

The following items should be readily available before starting the installation,

a) Tools and Accessories

OGA and Foundation drawings

Torque wrenches 0-150Nm

Torque screw drivers 0-10Nm

Allen Keys size 3-9 (1 set)

Flat nose plier with side cutter

Cir clip plier

Extractor plier

Grease

Cleaning cloth

Breaker Rack IN/OUT Handle

Page 5


b) Technical Documents

OGA and Foundation drawings

Scheme drawings

O&M manual

Other drawings

4.4 ERECTING CUBICLES

a) Sweep the mounting surface and clear it of all the debris and dust. Mark the location of

the panels as per the line up on this surface. The GA drawing will indicate the location of the

panel within the lineup. Determine and match the correct location of the panel to be erected

with the mounting surface.

Panels /shipping sections are to be installed on the foundation with breaker truck

removed.

VCB trucks are shipped along with the Panel with main contacts OPEN and springs

DISCHARGED. Perform the following tests before removing the VCB truck from the panel

Push the trip push button

Push the close push button

Push the trip push button again

Verify Spring CHARGE/ DISCHARGE indicator shows DISCHARGE

Verify ON/OFF indicator shows OFF

b) Take out the breaker using Lock – Free handle and remove the low voltage connection

between the VCB trolley and Panel by opening the multi pin connector on the top of the

breaker.

c) Mount the panels without VCB on the mounting surface. The four anchor bolts location

in each panel must freely rest in firm contact with the mounting surface. There must not be

any projection or obstruction in other areas as this may distort the cubicle. Do not force

cubicles in firm contact by drawing down anchoring bolts as this will distort the cubicle. Once

this position is achieved, tighten all the anchor bolts.

d) After the installation is complete remove the lifting bars.

e) When erecting adjacent panel, surfaces of panels at each anchoring bolt location must be

level and in the same plane with a maximum tolerance of 1.6mm.

f) Move the next panel into position following the Process defined in Point c and d; with the

front of the units in line against the adjacent group. Check the panel is in firm contact with

the surface at each corner and the coupling holes are in alignment. Bolt the adjacent panels

together Using M8 bolts supplied in the loose material Box. Place all the panels as per the

General Arrangement drawings in the similar manner.


5 ELECTRICAL CONNECTIONS 5.1 BUSBARS

5.11 General

Inter panel Bus bar links and connection hardware are supplied as loose item and packed

separately. Please check the loose items against the packing list for both the size and

completeness of supply. Bus bar links are of copper or aluminum as specified on the drawing.

5.12 Bus bar – Joints

The procedure for bus bar jointing:

Joint preparation:

Collect all the hardware for bus bar joints as supplied & tightening tools along with

torque wrench Do not substitute with smaller of lower grade hardware.

For silver plated joints use soft lint free cloth to clean the joint surface. Do not use

any hard brush or chemicals.

For Aluminum bus bars use soft wire mesh brush to clean joint surface by lightly

brushing & then wiping the surface with lint free cloth.

Bus bar joints are to be assembled immediately after cleaning.

The bus bar is to be assembled parallel to the line of the switchboard running on the inner

side of the spouts as shown in the fig below.

Please note that the bus bars for end panels are different from the other panels.

Copper/Al Spacers must be used for Bus bars joints as shown in the fig Above

Assemble all joints before tightening. Use torque wrench to tighten the joints with 25Nm

Torque. Always tighten the hardware diagonally for proper grip.

Page 7


5.2 PRIMARY POWER CABLES

Recommendations of cable supplier should be followed.

Power cables must be firmly supported using suitable cable glands at the gland

plates provided. Suitable termination hardware must be used as per recommendations

of cable manufactures. While terminating cables on the connection links provided in the

cable compartment care must be exercised so that

• The phase to phase clearance is maintained.

• Phase to earth clearance is maintained.

• There is no undue stress on the joints.

5.3 SECONDARY CONTROL CABLES

1) Secondary control wiring is installed and tested at the factory.

All wiring diagrams needed for installation are furnished in advance.

Wires can be easily traced on wiring diagrams furnished for the switchgear.

Each device is illustrated and identified with a letter.

Each terminal on each device is identified by an alphanumeric code.

2) Inter Panel wiring can be readily connected by referring to Bus Wiring diagram

provided with the Drawings. These wires are not terminated and are of sufficient length

to be routed to their termination point after cubicles are bolted together

3) For the multi core cables entry please refer to the GA & Foundation Drawing.

For the standard panel the Multi core cable entry is from the front of the cubicle at

the base of the housing on the left hand and / or right hand frame. All user wiring is to

be routed behind the cable retainer, which is removable for installation purposes. Use

plastic or nylon ties to secure all field installed wires to the cubicle structure.

5.4 GROUND CONNECTIONS

• All equipment’s, doors –etc. are firmly earthed with earth bus provided in each unit

at the bottom of circuit breaker chamber.

• The inter unit Copper Links (with 4 Holes) and Bolts are provided in each panel

mounted on the inner side. After coupling the panels open the links and bolt it with the

earth bus of the two adjacent panels such that 2 holes of the link are bolted in each

panel. For the ease of assembly, install bottom bolts first.

• For the connection to plant earth; bolt the Inter Unit Link at the two end panels such

that 2 holes are bolted with Earth bus and remaining 2 holes are connected firmly with

the plant earth.

Page 8


6. INSTALLATION OF CIRCUIT BREAKER TRUCK

6.1 CIRCUIT BREAKER OPERATION

The Circuit breaker compartment houses the vacuum circuit breaker and power and

control connections between VCB and the panel.

To establish VCB Connections;

1) Establish low voltage connections between VCB truck and panel through multi pin plug as

shown in the Figure 6.1a below

2) Align the VCB truck in front of the circuit breaker compartment and gently push it on the

Truck rail inside the Panel as shown in the Figure 6.1b below

3) Inserting the truck in the panel:

a) Hold the truck with handles provided as shown in Figure 6.1d below.

b) Move the handles in the direction of arrow marked in Figure 6.1e below.

c) Slide the truck in the Test position in the panel & release the handle, it will move

automatically in the direction marked Lock & truck will be locked with frame in the

slots provided as shown in Figure 6.1f below.

4) Close the front door. Insert the operating handle through the slot provided on the front

door till it fits into identified slot on VCB truck. By operating this handle clockwise, the

breaker is MOVED from TEST position to SERVICE position as shown it the figure 6.1c below.

Do this operation until the indicator shows SERVICE

Even in electrically de-energized condition, the circuit breaker may have stored energy in form

of energized springs.

Ensure all springs are in discharged condition before starting any work.

Do not insert VCB of rating different from the rating for which CB compartment is designed.

Verify that VCB and CB compartments have matching ratings

CAUTION

Page 9

Fig. 6.1a Fig. 6.1b Fig. 6.1c


5) Movement of truck will cause the safety shutters on both the bus side and cable side to

open automatically. Both shutters have independent mechanism. If the safety shutter was

locked earlier using a padlock, please ensure the padlock is removed. The shutters are fully

in closed position when the VCB truck moves to TEST position.

6) A contact assembly for grounding the circuit breaker truck frame is mounted under the

truck. This is used to earth the carriage by engaging with the ground connections mounted

in the CB compartment.

7) It is not possible to operate the circuit breaker in any intermediate position.

8) To withdraw circuit breaker from service position to withdrawn position, these steps

should be reversed

6.2 CIRCUIT BREAKER INTERLOCKS

To ensure operators safety following interlocks are provided for breaker operation.

Ensure good understanding of these interlocks before installation of breaker truck in

the panel. No efforts should be made to bypass these interlocks

Low voltage connections must be established firmly before truck is moved from

ISOLATED TO TEST POSITION.

VCB has to be in OFF position to move from TEST to SERVICE position.

If efforts are made to rack in the truck while breaker in ON condition breaker will

TRIP

Where operation behind closed door is provided following sequence is

applicable

VCB cannot be inserted from TEST position to SERVICE position unless

the front door is closed.

Once VCB is in SERVICE position, the front door cannot be opened

unless the VCB is tripped and brought to TEST position.

Page 10

Fig. 6.1d Fig. 6.1e Fig. 6.1f


7 INSPECTION AND TESTING

After the electrical connections are made and before the panel are energized, it must be cleaned and then inspected and testes as per procedure defined below. 7.1 INSPECTION PROCEDURES:

Check panel is clean and free of shipping and construction material

In withdrawn position perform 5 closing and 5 opening operations of VCB using hand charged procedure for spring charging. Ensure no abnormality

Establish low voltage connections through multi pin plug and socket and insert the VCB in test position. Perform 5 closing and 5 opening operations of VCB using electrical procedure for spring charging. Ensure no abnormality.

Check the following interlocks properly. a. When a VCB in ON position is Racked In from Test to Service position it

should trip. b. Similarly when a VCB in ON position is Racked Out from Service to Test

position it should trip.

c.

Check incoming and outgoing primary connections are properly made and rechecked for shorts or undesired ground

Check grounding/earthing connections are properly made

All temporary wiring jumpers’ ties to external devices are removed.

Proper coordination of protective relays in the panel with other protective relays and devices in the system to which this panel will be connected

Check all fuses of correct rating are in place

Check all high voltage connections are properly installed

Rack in and rack out breaker from SERVICE to TEST position 3 times and check no abnormality in operation of safety shutters.

Page 11

If any abnormality is found please inform to our Service Department at the address given above.

Do not Charge the panel till the problem is resolved.


7.2 PRE-COMMISSIONING TEST PROCEDURES:

Perform Megger test / insulation resistance test on the high voltage circuit to ensure all connections are correctly insulated. This test is also advisable on control circuit.

Perform dielectric test on high voltage circuit for 1 minute at voltage corresponding to values specified in IEC 62271-200. Surge arrestor and surge capacitor if connected must be disengaged during this test.

Switch on the space heaters for sufficient time to remove moisture. With the VCB in test position, perform the following checks

I. Trip and close the VCB using the control switch II. Trip the VCB by passing sufficient current through protective relay coils

III. Trip and close the VCB from remote location in case Local Remote selector switch option is provided.

IV. Operate auxiliary devices V. Check proper functioning of indicating lamps, push buttons, alarm and

annunciation as well as mechanical indicators for Spring Charging and VCB ON/OFF.

8 OPERATION

Before placing equipment into service for the first time, the procedure should involve, A. Energise the control circuit while the VCB is open in OFF position. B. Connect incoming power source. C. Switch ON the feeders in sequential operation & observe proper operation of all

feeders. D. Observe instruments, meters, and protective relays at this time. E. Switch OFF the incoming supply & discharge any residual voltage using earth rod. F. Connect outgoing cables to the load circuit G. Switch on the feeders sequentially

For the first week of operation, carefully observe signs of heating of primary and secondary circuits and also observe instrument and meters operation.

Page 12


9 MAINTENANCE

9.1 INTRODUCTION

Vacuum Interrupter is a sealed unit & requires no maintenance.

Periodic inspection and maintenance is recommended for breaker drive mechanism & to check tightness of connections.

The type of maintenance and period for maintenance defined in this section is for normal operations. Normal operation means the panel is not subjected to excessive dust, acid fumes, damaging chemicals, salt air, rapid or frequent changes in temperature, vibration and prolonged high humidity.

The maintenance schedule defined in this section should be increased based on operator experience for abnormal conditions. 9.2 MAINTENANACE STEPS As per IEC 61208, maintenance is divided into 3 broad activities.

1. Inspection – determination of the actual condition 2. Servicing – measures to maintain the specified conditions 3. Repair – measures to restore the specified conditions

It is recommended, PASCAL field service persons should be called for certain servicing and repair work as explained in the Table below. 9.3 INSPECTION In addition to Inspection Procedures defined in the Table below, experience is required to

spot abnormal conditions caused by grime, corrosion and moisture. This results in high

temperature on main circuit; reduction in insulation level; abnormality on surface of contact

systems etc.

9.4 POTENTIAL TRANSFORMER

Where required, PT is mounted on top rear of the panel. The PT can be of fixed type or

draw out type; Please follow the instructions below for replacement of PT fuse.

The panel is high voltage equipment

With high speed moving parts and is also heavy. Un-authorised or improper maintenance can cause death, serious injury and

damage to property. Always de-energize and ground the equipment before starting any

maintenance. Maintenance work must only be carried out by trained persons familiar with the characteristics of high voltage switchgear panel.

CAUTION

Page 13


9.4.1 DRAW OUT TYPE PT

The draw out PT arrangement has a fixed portion which is the housing where

connections from Bus bars are terminated. The PT itself is mounted on a draw out carriage

along with HRC fuses and this carriage moves on a rail arrangement. The front panel of the

truck cannot be opened to gain access to the fuses until the rollout truck is in the

DISCONNECT position.

Rack out the PT truck in a smooth and continuous manner from the CONNECT to the

DISCONNECT position.

During racking, audible sound will be heard as the truck primary contacts

disconnects from the housing fixed contacts. This is normal and do not stop the

racking

Once the truck is in DISCONNECT position, fuses are accessible by opening the front

knob of the draw out truck.

Replace the PT fuse and close the knob.

Rack in the PT truck in a smooth and continuous manner from the DISCONNECT to

the CONNECT position. During racking, audible sound will be heard as the truck

primary contacts connect from the housing fixed contacts. This is normal and do not

stop the racking

If the PT carriage is in between DISCONNECT and CONNECT position, the front knob

of the truck cannot be opened and the fuses are not accessible

9.4.2 FIXED TYPE PT

SWITCH OFF the Main Incomer and ensure that the panel is dead before accessing

the PT.

Open the rear cover of the fixed PT box using a spanner.

Open the knob and replace the PT fuse.

Close the knob and close the rear cover of the fixed PT box using a spanner.

Switch ON the main Incomer.

9.5 CURRENT TRANSFORMER

CT supplied can be bar primary or wound type depending upon the requirement. All CT

connections are made in the panel and tested before dispatch.

Page 14

CT secondary must be shorted to prevent High voltage and risk to operator against electrical shock.

For fixed type PT extra care should be taken to replace the PT Fuse.


CT can be accessed by removing the rear cover of the CT and cable compartment. In

case more than 3 CTs are used, the CT mounted on the inner side of the panel can also

be accessed through the circuit breaker compartment by removing bolted cover

9.6 MAINTENANCE TABLE ‘A’

Item Period Inspection / Abnormality Action Operating mechanism

Yearly Presence of dust Dust/clean with dry brush or cloth

In 3 Years Check springs for distortion or oxidation

Replace damaged spring. Call our Field Service Dept.(contact details provided in this Manual)

In 3 Years Check for loose nuts or screws. Check if locking nut is out of place

Tighten nuts and screws and reaffix the locking rings in their position

In 3 Years Check for fasteners and wires if they are detached

Reconnect wires correctly and replace fasteners

Pole Assembly and connections

Yearly Presence of dust on insulating parts

Dust/clean with dry brush or cloth


Tighten nuts and screws and reaffix the locking rings in their position

Yearly Distortion or cracking of insulating parts

Replace the insulating parts. Call our Field Service Dept. (contact details provided in this Manual)

In 3 Years Oxidized isolating contacts Clean with rough cloth soaked in suitable solvent and lubricate moderately with neutral / contact grease

In 3 Years Check connections on circuit breaker terminal for signs of overheating and loose screws

Clean with rough cloth soaked in suitable solvent and lubricate moderately with neutral grease and tighten the screws.

Earthing isolating contact

In 3 Years Check for traces of oxidation suitable solvent and lubricate moderately with neutral grease

Earthing connection

In 3 Years Check for traces of oxidation and also for loose nut

Clean with rough cloth soaked in suitable solvent. Tighten the earthing connections and cover it with neutral grease

Auxiliary circuit supply voltage

In 3 Years Check the supply voltage of operating mechanism operating accessories

Devices must operate in the voltage range as defined in IS.

Page 15


9.7 MAINTENANCE TABLE ‘B’

Item Period Inspection / Abnormality Action Operating and control elements Spring charging motor

Yearly Carry out functional tests Replace damaged motor as per Replacement Procedure 1.0

Trip coil Yearly Check operation at specified voltage range and also check signs of sluggishness

Replace damaged trip coil as per Replacement Procedure 3.0

Closing coil Yearly Check operation at specified voltage range and also check signs of sluggishness

Replace damaged closing coil as per Replacement Procedure 2.0

Auxiliary switch

Yearly Ensure connections are tight at the terminals and change over contacts tested with continuity tester

Replace damaged auxiliary switch as per Replacement Procedure 5.0

Vacuum interrupter vacuum integrity

5 Years Conduct Hi-Pot test by applying 20kV ac voltage across each pole with interrupter OPEN and other side earthed for 5 seconds. VI is healthy in case there is no break down

To replace faulty interrupter, please call our Field Service Dept. (contact details provided in this Manual)

Vacuum interrupter life

5 Years after every 10 short circuit interruptions & /or after each 5000 mechanical operations

Check the contact wear as per Replacement Procedure 4.0 to ensure if VI replacement is required.

To replace faulty interrupter, please call our Field Service Dept.(contact details provided in this Manual

Interlocking, actuating, monitoring devices Interlocks 5 Years Check performance of all

interlocks as per Section 6.2. For non-conformity please call our Field Service Dept. (contact details provided in this Manual

Actuating devices

3 Years Perform functional tests on all push buttons, lamps, alarm circuit, switches, annunciators, contactors. Observe for sluggishness.

Tighten connections and replace equipment if necessary

Relays 3 Years Perform functional tests Inform our Field Service Dept. (contact details provided in this Manual) for non-conformance.

It is recommended that entire breaker should be replaced after 100 short circuit operations or after 10,000 mechanical operations

Page 16


9.8 REPLACEMENT PROCEDURES

PROCEDURE 2.0 – CLOSING COIL

1) Open the closing coil connection (2 nos.) from the 4 way Terminal using screw driver 913 (see A).

2) Open the 2 nos. M4X10 Hex Head bolts from back side of closing coil fixing bracket using 6-7 flat spanner (see B).

3) Remove defective coil and replace it by fixing it using 2 nos. M4X10 Hex Head bolts (see B).

4) Connect the closing coil wiring to the 4 way terminal using 913 screw driver (see A).

PROCEDURE 1.0 – SPRING CHARGING MOTOR

1) Cut ties using wire stripper and open 2 nos. motor coil Connection from the 2 way terminal (see A) using 913 screw driver.

2) Open 2 nos. M6 Hex Head Bolts (see B) at the Bottom using 10-11 flat spanner.

3) Open M6 nut on top (see C) using 10-11 flat and ring spanner 4) Remove damaged motor and put replacement motor in the same position. 5) Fix M6 Hex nut on top (see C) and bolt using 10-11 spanner 6) Fix the outer M6 Hex Head Bolts (see B) and tighten the 2 bolts using 10-11

flat spanner. 7) Connect 2 nos. motor coil connection (see A) from 2 way terminal using 913

screw driver.

PROCEDURE 3.0 – TRIPPING COIL

1) Open the tripping coil connection (2 nos.) from the 4 way terminal using screw driver 913 (see A).

2) Open 2 nos. M5X15 Hex Head nut using 8-9 flat and ring spanner (see B). 3) Remove defective coil and replace it by fixing it using 2 nos. M5X15 Hex Head

bolts and nuts (see B) 4) Connect the tripping coil wiring to the 4 way terminal using 913 screw driver

(see A).

Page 17


Page 18

Page 18

PROCEDURE 5.0 – AUXILIARY SWITCH

1) Remove auxiliary switch drive link from Bracket-2 by opening split pin using nose plier.(See A)

2) Remove the auxiliary switch snap on socket connection by pushing it upwards using 923 Screw driver. (See B)

3) Open the auxiliary switch bracket by opening 4 nos. M6 studs from Inside of breaker using 10-11 flat spanner (See C). Take out the auxiliary switch along with the bracket

4) Open 2 nos. MS Hex nuts using 8-9 flat spanner. (See D) 5) Open 4 nos. MS M5X15 Hex Head Bolts using 8-9 flat spanner. (See E) 6) Remove and replace Auxiliary switch and connect it to auxiliary switch bracket using

4 nos. MS M5X15 Hex Head Bolts (See E) 7) Fix 2 nos. MS Hex nut using 8-9 flat spanner (See D) 8) Complete auxiliary switch wiring. Refer circuit breaker wiring diagram supplied with

the panel 9) Fix the auxiliary switch bracket in position using 4 nos. M6 studs (See C) 10) Connect the auxiliary switch drive link with Bracket-2 by using Split pin.(See A)

PROCEDURE 4.0 – VACUUM INTERRUPTER

1) Life of vacuum interrupter is determined by wearing of contacts. 2) 2mm Contact wear gauge is provided as accessory with each breaker. 3) Insert the gauge between lower end of the drive shaft and drive insulator

spacer in Breaker ON condition (see A). The gauge should move freely in this space.

4) If the gauge does not move freely it indicates wearing of contact and vacuum interrupter needs to be replaced.

5) Please contact Field Service Department and details are provided in Page 1 of this manual.


ANNAXURE MAINTENANCE LOGBOOK

Date of installation:

Item Period Inspection / Abnormality Observations Action By/Date

Operating mechanism

Yearly Presence of dust

In 3 Years Check springs for distortion or oxidation


In 3 Years Check for fasteners and wires if they are detached

Pole Assembly and connections

Yearly Presence of dust on insulating parts


Yearly Distortion or cracking of insulating parts

In 3 Years Oxidized isolating contacts

In 3 Years Check connections on circuit breaker terminal for signs of overheating and loose screws

Earthing isolating contact

In 3 Years Check for traces of oxidation

Earthing connection

In 3 Years Check for traces of oxidation and also for loose nut

Auxiliary circuit supply voltage

In 3 Years Check the supply voltage of operating mechanism operating accessories

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Item Period Inspection / Abnormality Observations Action by/date Operating and control elements Spring charging motor

Yearly Carry out functional tests

Trip coil Yearly Check operation at specified voltage range and also check signs of sluggishness

Closing coil Yearly Check operation at specified voltage range and also check signs of sluggishness

Auxiliary switch Yearly Ensure connections are tight at the terminals and change over contacts tested with continuity tester

Vacuum interrupter vacuum integrity

5 Years Conduct Hi-Pot test by applying 20kV ac voltage across each pole with interrupter OPEN and other side earthed for 5 seconds. VI is healthy in case there is no break down

Vacuum interrupter life

5 Years after every 10 short circuit interruptions & /or after each 5000 mechanical operations

Check the contact wear as per Replacement Procedure 4.0 to ensure if VI replacement is required.

Interlocking, actuating, monitoring devices Interlocks 5 Years Check performance of all

interlocks as per Section 6.0.

Actuating devices 3 Years Perform functional tests on all push buttons, lamps, alarm circuit, switches, annunciators, contactors. Observe for sluggishness.

Relays 5 Years Perform functional tests

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