s

Air InsulatedMetal-Clad Single BusbarMedium Voltage SwitchgearType 8BK80On withdrawable circuit-breaker truck for 36 kV

Installation, Operation andMaintenance Instructions

2

Table of Contents

4. Operations4.1 Withdrawable Truck 204.1.1 Positions of the withdrawable truck 204.1.2 Transferring the Withdrawable Part from

the test / disconnected position manually 204.1.2.1 Normal Operations 204.1.3 Transferring the Withdrawable Part

from the Connected position to thetest / disconnected position manually 20

4.1.3.1 Normal Operations 204.1.3.2 Castell Key Operation 214.1.4 Removing the LV Plug 214.1.5 Connecting the LV Plug 214.2 Circuit Breaker Operating Mechanism 214.3 Circuit Breaker Operation 214.3.1 Charging the closing spring by hand 214.3.1.1 Breaker ON and OFF 214.3.1.2 Mechanically 214.3.1.3 Electrically 214.3.2 Switching State Indication 224.4 Withdrawable Line PT Truck 224.5 Earthing 224.5.1 Earthing of Busbars and Cables 224.5.1.1 Direct Earthing of Busbars with Conductors 224.5.1.2 Earthing of Cables with Conductors 234.5.1.3 Removing Earthing Connections 234.5.2 Earthing of Busbars / Cables with a

Drawout Truck 234.5.2.1 Disconnection of Earthing Drawout Truck 234.5.3 Earthing the Busbars / Cables with

Earthing Switch 234.5.3.1 Earthing Busbars with Earthing Switch 234.5.3.2 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 244.5.4.3 Link Type Earthing Truck 244.6 Breaker Compartment Door 244.6.1 To Open the Door 244.6.2 To Close The Door 244.7 Door to LV Compartment 244.7.1 To Open the Door 244.7.2 To Close the Door 24

5. Maintenance5.1 Inspection Schedule 255.2 Cleaning 255.3 Lubrication 255.4 Replacement (Spare) Parts 265.5 Defeating the Door Interlock of HV

Compartment 265.5.1 Drawout Unit in Connected Position 265.5.2 Drawout Unit in Disconnected Position 265.5.3 Restoring the Door Interlock 26

6. Disposal of Product 27

7. Summary of Important Instructions 28

8. Additional Information8.1 Reference list of Items 298.2 Jointing Torque 30

Page Nos

Subject to change due to improved designNotes: 1. The item numbers shown in the figures are explained in the fold-out central legend.

2. When ordering the manual, please quote the order no. 4-XXBXX-03-27300-001

1. Technical Description1.1 General 31.1.1 Application 31.1.2 Specific Standards 31.1.3 Ambient Temperature and Humidity 31.2 Design Features 31.2.1 Switchgear Layout 31.2.2 Circuit Breaker Compartment 31.2.2.1 Service Position 31.2.2.2 Test Position 31.2.2.3 Isolated Position 41.2.2.4 Removed Position 41.2.3 Busbar Compartment 51.2.4 Cable & CT Compartment 51.2.5 Compartment for Low Voltage Equipment 61.2.6 Accessories 61.2.7 Range of Panels 71.2.7.1 Feeder Panels 71.2.7.2 Bus Sectionalizer Panel 71.2.7.3 Metering Panel 71.2.7.4 Isolating Panel with I/C & O/G Connections 71.2.8 General Construction 71.2.9 Interlocks 81.3 Technical Data 81.4 Rating Plate 9

2. Installation2.1 Foundation 102.2 Electrical Service Room Dimensions 102.3 Transport Units 122.4 Packing 122.5 Unloading 122.5.1 Handling Equipment Required 122.5.2 Procedure 122.6 Examining the Switchgear against damages 122.6.1 Storage 122.7 Transferring the Transport Units 122.7.1 Removing the truck from the panel 132.8 Assembling the Switchboard 132.8.1 Joining of the Panels 132.8.2 Fixing the Switchboard to the Foundation 132.8.3 Joining of the Busbars 142.8.4 Bolting the Main Earth Bar sections together 142.9 Termination of HV Cable Connection 142.10 Earthing of Switchboard 152.11 Other Work to be carried out 152.11.1 Checking the HV Connections 152.11.2 Checking the bolted Joints 152.11.3 Cleaning the Switchboard 152.11.4 Inserting the withdrawable parts 162.11.5 Protecting the panels against

Environmental effects 162.12 Interpanel Wiring 16

3. Putting the Switchgear into Service3.1 Test Operations 173.1.1 With Door Open 173.1.2 With Door Closed 173.2 Checking the Accessory Items 193.3 Revising the Circuit Diagram 193.4 Space Heaters 19

Page Nos

3

1. Technical Description

1.1 General

8BK80 metal clad switchgear is of horizontal isolation& horizontal drawout type, suitable for easy extensionof switchgear in both directions, for system voltage36kV. The switchgear is designed for single busbarsystem & is fully compartmentalized. The designincorporates the set of interlocks for safe operation ofswitchgear.

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 IS 3427and IS12729.

1.1.3 Ambient Temperature and Humidity

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

1.2 Design Features

1.2.1 Switchgear Layout (refer Fig. 2)

Metal partitions subdivide each panel into

– a circuit breaker compartment (2.1.)

– a cable & CT compartment (2.2.)

– a busbar compartment (2.3.)

– a low voltage compartment (2.4.)

The outside covers on sides and rear are bolted to theframe and the doors on front 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 (3.7, Fig 3)

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

1.2.2.1 Service Position (Connected Position)

The position of a withdrawable truck in which it is fullyconnected for its intended function.In this position ofthe truck, the contact arms of the circuit breaker areconnected to the busbars as well as to the out goingcables via the fixed mounted isolating contacts in thepanel.

The truck is locked against withdrawing & earthed.

The low voltage circuit is connected through the lowvoltage plug connection.

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.

Fig 1 : Typical Circuit Diagram

VCB

CT

Fuses P.T.

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 the DangerSign shall be removed only afterensuring that the supply to the liveparts 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.

4

In the test position, the truck with the breaker iswithdrawn so far between busbars & outgoing cablesthat there is isolating distance. The truck is lockedagainst moving. The low voltage circuit is connectedthrough low voltage plug connection. Also metallicshutters drop down and cover the bushing of upper &lower mating contact the circuit breaker truck isearthed via a spring loaded pin in test position.

The circuit breaker can be tested for all functions.

1.2.2.3 Disconnected Position (Isolated Position)

The position of withdrawable truck in which anisolating distance or segregation is established in thecircuits of the withdrawable truck, the truck remainingmechanically attached to the enclosure.

In this position the truck is withdrawn as in testposition but the LV plug is disconnected.

In both the test & disconnected positions the contactarms & their mating contacts are separated bymetallic shutters.

1.2.2.4 Removed Position

The position of withdrawable truck when it is outsidethe panel & electrically as well as mechanicallyseparated from it. Ramps are provided at the frontbottom of the panel to withdraw the truck out of thepanel smoothly.

Fig 2 : Side view of switchgear panel

2.1. Circuit Breaker (CB) compartment2.2. Cable & CT compartment

2.12.2

2.3

2.4

2.3. Busbar compartment2.4. Low Voltage (LV) compartment

Fig 3 : Withdrawable truck with 3AH3 VacuumCircuit Breaker

3.1. Mechanical ‘ON’ Push Button3.2. Mechanical ‘OFF’ Push Button3.3. Spring Charging Opening3.4. Spring Charge Indication3.5. Mechanical ‘ON’ & ‘OFF’ indication3.6. Mechanical Operations Counter3.7. Contact Arms with Tulip Contacts3.8. Truck Handle3.9. End Partition (Truck)

3.1

3.2

3.3

3.4

3.5

3.6

3.73.8

3.9

5

4.1. Door locking hinge pin4.2. Door close interlock4.3. Viewing window for truck position4.4. Viewing window for spring charge indicator and

mechanical counter4.5. LV connection plug4.6. Drive mechanism housing4.7. Ramp4.8. Interlocking plate (Drive Box)4.9. Holder for LV plug

Fig 4 : Withdrawable Truck in Test Position & door open

4.1

4.2

4.3

4.4

4.5

4.64.7

4.8

4.9

4.10

4.11

4.12

4.13

4.14

4.15

4.16

4.11

4.10. Clip for locking LV plug to breaker4.11. Opening for hand crank for charging the closing

spring4.12. Twist grip for operating the breaker in service

position4.13. Rod lever4.14. ‘ON’ push button4.15. ‘OFF’ push button4.16. Plate covering manual spring charge opening

Drive Mechanism of the truck is attached to the panelframe 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 service, test &disconnected position.

1.2.3 Busbar Compartment (refer Fig. 6)

The busbar compartment contains:

– The busbars (6.5)

– Bushings with the mating contacts for the uppercontact arms (6.1)

– Feeder Connections (6.3)

The main busbars are mounted on cast resininsulators (6.2). 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. 8)

The Cable compartment contains:

– Bushings with the mating contacts for the lowercontact arms of the withdrawable part (8.2)

– Cable termination pieces (8.4)

– A section of the main earth bar

– Current transformers (8.3)

The cable termination pieces are accessible from therear.

6

6.1. Bushings of upper mating contact6.2. Cast resin insulator6.3. Feeder connections6.4. Joint shrouds6.5. Main busbar6.6. Explosion rents

Fig 6: Busbar compartment

6.2. Cast resin insulator6.5. Main busbar6.4. Joint shrouds

Fig 7: Busbar joint

8.1. Phase barrier (Cable chamber)8.2. Bushings for lower mating contact8.3. Current transformer8.4. Cable connecting pieces8.5. Bushing cover

Fig 8: Cable compartment

8.18.2

8.3

8.48.5

6.1

6.2

6.3

6.46.5

6.2

6.5

6.4

1.2.6 Accessories (refer Fig. 9)

Following accessories are supplied with theswitchgear.

– Hand crank for charging the closing spring of thevacuum circuit breaker (9.1) when in serviceposition.

– Hand crank for truck movement between serviceand test position (9.2).

– Double bit key for locking the truck transferoperating mechanism (9.3)

– Rod trap key for LV compartment.(9.4)

– Earthing switch handle (Optional).(9.5)

5.1. Vacuum interrupter5.2. Insulated switching rod5.3. Insulated phase barrier (truck)

Fig 5: Side view of withdrawable part of breaker

5.1

5.2

5.3

3.7

1.2.5 Compartment for Low VoltageEquipment

LV compartment (2.4, Fig 2) contains all the low voltagedevices (protective relays, MCBs, terminals, etc.,)

Indicators and relays are accommodated in doorcutouts.

7

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 10a)

The feeder panels are suitable for incoming as well asoutgoing supply.

Outgoing feeder panels with circuit breaker on thetruck are most 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 manual drive.

1.2.7.2 Bus Sectionalizer Panels (Fig 10b)

In bus sectionalizing panel one panel is used for thetruck with the C.B. (alternatively, an isolating truck) &second panel for connection of busbars to the top.Both the panels are usually delivered as oneassembled transport unit. Both panels are separatedby a partition in busbar chamber. The BusSectionalizer panel can be combined with a meteringpanel.

1.2.7.3 Metering Panel (Fig 11)

Basically metering panels are of the sameconstruction as the standard outgoing panels. Themetering truck with voltage transformers & HRCfuses in series is equipped with 3 upper contact armsonly & therefore three lower fixed isolating contactsare not installed.

1.2.7.4 Panel with I/C & O/G Connections (Fig 12)

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 the operating 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 mounted onthe truck.

All the identical trucks of same rating in differentpanels are interchangeable.Trucks are earthed withpanel in both test & service positions.

– Busbars are insulated and their joints are shrouded.

– Outgoing cables can be earthed by means ofmanually operated earthing switches withwithstand capacity (Optional). Earthing trucksinstead of in-built earthing switch can be provided.

– C.T.s are mounted on stationery part in the cablechamber.

– Line P.T.s are available with an arrangement ofdrawout fuses.

– Bus P.T.s with fuses are mounted on withdrawabletruck.

– At a later date extension of existing switchboard ispossible.

– Delivery of completed & tested panels to siteconsists of single panel section, except the bussectionalizer panel which consists of two panelsection.

Fig 10a Fig 10b

Fig 11 Fig 12

I/C

VCB

CT

O/G

VCB

CT

VCB

CT

Fuses

P.T.

I/C

O/G

VCB

CT

9.1. Charging handle9.2. Cranking handle9.3. Double bit key9.4. Rod trap key9.5. Earthing switch handle

Fig 9: Accessories

9.1

9.2

9.39.4

9.5

8

1.2.9 Interlocks

The positions of the withdrawable truck are describedon page 3 & 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

13.2. Pressure relief channel for the cabletermination compartment, 110 mm deep.

13.3. Pressure Relief Flaps

1.3 Technical Data

Rated Voltage 36 kV

Rated Power Frequency withstand Voltage 70 kV

Rated Impulse Withstand Voltage 170 kV

Rated short circuit breaking current 31.5 kA

Rated short time current (3s) 31.5 kA

Rated short time making current (peak) 78.75 kA

Rated current of bus (maximum) 3150A

Rated current of feeder (maximum) 2500A

Overall Dimensions : Refer Fig 13

w h h1 d2 d3 d4mm mm mm mm mm mm

Panel Dimn.(Unpacked) 1100 2250 2250 400 2700 2758

Panel Dimn.(Packed) 1300 2500 - - - 3000

Panel weight : Approx. 1300 kg with vacuum circuitbreaker.

13.1. Covers are fitted to the left & right of theswitchboard

Fig 13: Overall Panel Dimensions and recommended clearances

* Single row of panels ** Two rows of panels

All dimensions are in mm and are for the standard panel.

9

Fig 14 : Rating Plate of a Panel

1.4 Rating Plate

Un Rated VoltageUp Rated Lightening Impulse Withstand VoltageIr Rated Short Ckt. Breaking CurrentIsc Short Circuit Making CurrentIbusbar Busbar CurrentIfeeder Feeder Correction Currentf Rated Frequencytk Short Ckt. Duration

A rating plate containing the particular data is fixedinside LV compartment of each panel.

The withdrawable vacuum breaker has its own ratingplate and the rated normal current stated on it doesnot apply to the feeder.

Degree of protection

Basic model IP 4X acc. to IEC 60298 orIP 40 acc. to IEC 60529

The panels are gasketted to make them dust &vermin proof.

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

10

2. Installation

The installation sequence should be planned andprepared with care. Ensure that the erectors and theoperating personnel are aware of 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.

– Concrete Floor

This should be provided with foundation rails onwhich the panels are to rest. For floor cutouts refer toFig 15. The foundation should be prepared before thepanels arrive. Level differences between themounting surfaces of the individual panels should bedetermined and compensated for by using a sheet asshown in Fig 16.

– 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 15a.

2.2 Electrical Service Room Dimensions

Min. clearance to the ceilingabove the top of panel At least 750 mm

Min.clearance on the sides& rear of the panels At least 800 mm

Min.width of control aisle infront of the panel for single row At least 2500 mm

Min.width of control aisle infront of the panel for two rows At least 4000 mmfacing each other

Fig 15 : Foundation Plan

Fig 15 a: Typical Base Frame Dimensions

All dimensions are in mm andare for the standard panel

All dimensions are in mm andare for the standard panel

11

Tolerance as per DIN 43661:

Straightness 1mm. per 1meter Length, 2mm. for overall length

Level 1mm within 1meter measured length.

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

Fig 16 : Dimension data sheet for the foundation.

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

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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 be plane toenable transport units to be moved about on rollerand/or similar devices.

2.3 Transport Units

A transport unit consists of a single assembled panel(except Bus - Sectionalizer panels), complete withwithdrawable truck.

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

2.4 Packing

As required :

(a) For shipment to inland destinations each transportunit is fixed on a sturdy wooden pallet and coveredby plastic sheet for surface protection and packedin 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.

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

Packing cases to be opened immediately prior toinstallation only.

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 transport units.Take care not to damage the plastic sheet becauseit 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 tobolting 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.Record any damage and its cause without delay, inthe presence of the forwarding insurance agent, if thedamage was caused en route.

This report is essential for any damage claims.

2.6.1 Storage

– Store the packing cases in upright position only

– The packing cases must be stored in adequetlycovered location such that they are protected fromsun, rain, flood waters & other such naturalelements

– It is preferable to open the crates and polythenecover provided on the panel only beforeinstallation.

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. (Refer clause 2.7.1)

– 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

– Attach four hooks at the four corners to the liftingangles at the top of the panel to lift the panel.

13

– Remove the wooden pallet.

– Lower the transport unit as far as it will go &place it on two wooden beams if it is locatedabove its site or place on four roller pads if it isin front of the 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 & channelsin the foundation cutouts that have to becrossed.

– To raise the panels on their mounting position &removing the roller pads

– Lower the transport unit as far as possible &place them on two wooden beams.

– Now, raise the units, first on one side & then onthe other side, using roller-type crowbars. Pullout the planks & lower the panels onto thecleaned foundation. Position the crowbars onlyat the corners of the panels below the verticalframe members.

2.7.1 Removing the Truck from the Panel

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

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

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

– Mark the truck & their panel numbers foridentification.

– Lift & turn the Levers on the front interlocking plateby 90º anticlockwise.

– Slowly move the truck away from the panel. Thetwo ramps drop automatically enabling free & easywithdrawal 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 Joining of the Panels

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.

Fig 17 : Procedure for bolting the panels together

It is always preferable to install the central panel first.This practice should invariably be adopted for a 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 16) and be absolutely vertical. Ifnecessary place shims,

• under the frame uprights and

• under the bottom rails near the 30 mm x 30mm cutouts 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 panelsstand vertically.

Use shims as for the first panel.

– Using the nuts & bolts join the adjoining panels.

– Check to see whether the panels are truly vertical.If necessary slacken the screws and seal the gapswith rubber.

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

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 the 30

14

18.1. Compartment door 18.3. Lower metallic shutter18.2. Upper metallic shutter 18.4. Thermostat

Fig 18: View into Circuit Breaker panel after removingthe drawout truck

6.1. Upper contact bushing19.1. Fixed contacts8.2. Lower contact bushing19.2. Fixed contacts19.3. Truck earthing srip19.4. Space heater

Fig 19 : View into circuit breaker compartment withshutter held open

18.1

18.4

18.2

18.3

22.3

19.619.3 4.7

6.1

19.1

8.219.2

19.3

19.4

mm x 30 mm cutout) or drill the appropriate holes inthe 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 Joining of Busbars

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 (6.5, Fig 6).

1. Remove the shroud on the busbar joint.

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

3. 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. (Refer clause 8.2)

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

5. Before joining the busbars ensure to insert theside caps of the shrouds in the busbar link. (ReferFig 20)

6. The busbars of adjacent units must be joinedtogether using the busbar links (Fig 20.1, Fig 20) &hardware supplied. While inserting coach boltsensure that the round head of coach bolt is facingsheet metal structural parts. That means the nutswill always be towards the live parts such asbusbars/feeder connections. The busbars (6.5, Fig6) of the panel forming a transport unit are alreadybolted.

7. Fix the shrouds on the joints after the joint istightened.

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

2.8.4 Bolting the Main Earth Bar

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 Terminating HV Cables

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

15

6.5. Main busbars 20.4. Side cap (Shroud)20.1. Busbar link 20.5. Front cap (Shroud)20.2. Coach bolt 6.3. Feeder connections6.2. Resin cast insulator 20.6. Nylon bolt20.3. Rear cap (Shroud) 20.7. Hex bolt

Fig 20 : Assembly of Busbar joining

21.1. Earth Busbar 19.3. Truck eathing Strip21.2. Extension Links 21.3. Bottom Covers

Fig 21 : Earth Busbar Assembly

21.1

19.3

21.221.3

6.2

20.6

20.3

20.7

6.5

20.4 20.120.2

6.3

20.5

20.7

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 of 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., but examineall the terminal block connections, making surethat the blocks are correctly labeled and replaceany missing labels by referring to the circuitdiagram.

– The torque values of all the busbar joints must bechecked (Refer clause 8.2).

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 detergentsto clean installed parts.

16

18.2, 18.3. Metallic earthed shutters22.1. Shutter operating rod22.2. End insulating partition (Breaker chamber)22.3. Truck guide

Fig 22: View inside circuit breaker compartmentwithout withdrawable truck.

– place the withsrawable truck (23.1, Fig 23) in frontof the corresponding 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.

– Fix the ramps back in the position

– Close the door

– Insert all other withdrawable 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 theingress of reptiles. Check in case they areremoved during installation.

(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 wires 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

22.1

22.2

22.3

Use only distilled water if necessary. Ensure thatall parts are dried up before applying any voltage.

2.11.4 Inserting the withdrawable truck

– open the front door (18.1, Fig 23)

– put down the ramps

18.1. HT compartment door

Fig 23: Insertion of truck in the panel

23.1. Breaker truck

18.1

23.1

18.2

17

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 panel 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.

– 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.

18.1

24.1

24.2

24.3

4.11

24.8

24.4

24.5

24.6

24.7

4.12

4.11. Opening for Hand Crank for charging the breakerclosing spring

4.12. Twist grip for operating the circuit breaker in theconnected position.

18.1. Door of circuit breaker compartment24.1. Window for inspecting the withdrawable truck24.2. ON & OFF button (On CB door)24.3. Window for the indicators of the withdrawable

truck– Number of operations (Operation Counter)– Closing spring of the circuit breaker

– Charged - Lable with spring symbol

– Discharged - Blank Lable– Indicator for circuit breaker switching status

– Circuit Breaker Closed - “ I “Tripped - “ O “

24.4. Opening for double bit key for locking the transferoperating mechanism

24.5. Opening with hexagon shank for fitting the handcrank for racking the withdrawable part

24.6. Door of compartment for LV equipment24.7. Opening for defeating interlock24.8. Handle for operating the CB door.

Fig 24: Opening Elements

24.2

18

s

BRIEF OPERATING INSTRUCTIONS FOR 8BK80 SWITCHGEAR

Fig 25 : Label on door of breaker compartment

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

REFER CLAUSE 4 OF THIS MANUAL

19

– 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), earthing switch handle (Optional)and rod trap Key for opening of LV compartment door.

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 panelsinto service. The thermostat shall be set to cut offsupply to heaters at about 5º higher than themaximum ambient temperature.

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

20

and locked up with the clip(4.10, Fig 4). The breakercompartment door is closed.

– The castell key can be removed in this positionalso for any interlocked operations which are to beperformed with circuit breaker in open position.

– Fit the hand crank (9.2, Fig 9) to the hexagonshank in opening (24.5, Fig 24) turn it clockwise asfar 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 pullit off.

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 Trun double-bit key

turn handcrank

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

it of

90° 90°

Fig 25b

In detail:

– Make sure that the circuit breaker is open.

– Insert the double bit key in lock (24.7, Fig 24) andturn it anti-clockwise through 90 degrees from“connected position (locked)” to “Manual Racking”.The hexagon shank opening (24.5, Fig 24).is nowaccessible. The hand racking mechanism isunlatched.

– Fit the hand crank (9.2, Fig 9) to the hexagonal shankin opening (24.5, Fig 24) turn it anti-clockwise as faras 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 (24.5, Fig 24) is now closed.

The hand racking mechanism is now locked.

4. Operations

Each row of panel is provided with brief operatinginstructions. Refer Fig 25.

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 Trun double-bit key

turn handcrank

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

it of

90° 90°

Fig 25a

In detail:

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

21

4.1.3.2 Castell Key Operations

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 25c

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 “ManualRacking”.

– 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 (24.5, Fig 24) is nowaccessible.

The hand racking mechanism is unlatched.

– Fit the hand crank (9.2, Fig 9) to the hexagonalshank in opening (24.5, Fig 24) 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 key anti-clockwise through 90 degrees from the position“Manual Racking” to “DisconnectedPosition(locked)” and pull it off.

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

4.1.4 Removing the LV Plug

– Transfer the withdrawable part to the disconnectedposition (in accordance with clause 4.1.3 ) and lockit.

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

– Unlock the plug (4.5, Fig 4) and socket connectorby turning down the clip (4.10, Fig 4).

– Pull off the plug and attach it to the holder (4.9, Fig4) which is fixed to the door.

4.1.5 Connecting the LV Plug

– Put the plug (4.5, Fig 4) and socket connectortogether and lock it with the clip (4.10, Fig 4).

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

is closed (connectedposition) turn plate (24.7,Fig 24) so that it clearsopening (24.5, Fig 24)insert the hand crank andfit it to the breaker

is open (disconnectedposition) fit the handcrank directly to thebreaker operatingmechanism in opening(24.5, Fig 24).

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

• Operating Mechanism

– Turn the crank until the symbol “spring charge”appears in viewing window (24.3, Fig 24) 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 :

Turn the twist grip (4.12, Fig 4) as far as it will go,hold it there, press buttons

“ON” and “OFF” (24.2, Fig 24) and then releasethe grip.

• In the disconnected position with the door closed :Press buttons “ON”and “OFF” (24.2, Fig 24) onthe CB compartment door.

• In the disconnected position with the door open :Press buttons “ON”(24.2, Fig 24) and “OFF” (4.15,Fig 4) on the withdrawable truck.

4.3.1.3 Electrically (from the control room orlocally)

by means of push button/switches in the controlroom or on the LV compartment door. If the controlsupply fails the breaker can always be trippedmechanically (see above)

22

4.3.2 Switching State Indication

In the middle part of viewing window (24.3, Fig 24)‘O’ means “OFF”, ‘I’ means “ON”.

4.4 Withdrawable Line PT Truck

As an option, the Line PT would be mounted on aseparate withdrawable trucks along with a primaryfuses in the rear box of the panel.

The connections for the same are factory set. Todisengage, push the locking levers (26.5, Fig 26)inside, turn the ramps down and pull the truck out ofthe panel. There are two positions possible for Line PTtruck i.e., connected & withdrawn positions.

After the truck is withdrawn, all the live parts of thetruck must be earthed using an earthing rod.

The rear cover of the compartment must be fittedback.

The advantages of this kind of system are :

– the metering of the panel is possible even if thebreaker is in test mode or disconnected position.

– the PT fuses can be replaced without switching offthe breaker.

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 an earthingconductor mounted on the long insulating pole.

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

– Place necessary warning plates at all noticeablelocations.

26.1. Drawout fuse truck26.2. HT fuses26.3. Upper moving

contact26.4. Lower moving

contact

3.8. Truck handle6.2. Resin cast insulator26.5 Locking lever (PT

truck)

Fig 26: Line PT truck rear view

26.1. Drawout fuse truck 27.3. Lower fixed contacts27.1. Line PT 27.4 Rear box complete27.2. Upper fixed contacts 26.2 Fuses

Fig 27: Drawout fuse truck in service

26.1

26.2

26.3

26.4

3.8

6.2

26.1

27.2

27.1

27.3

27.4

26.2

26.5

23

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.

4.5.2 Earthing of Busbars or cables with aDrawout Truck

Separate drawout Trucks can be supplied optionally forbusbar 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 2.7.1)

– Insert the desired earthing drawout truck i.e. cableor busbar earthing drawout truck in the panel (referclause 2.11.4)

– Connect the LV plug and socket (refer clause 4.1.5)

– Close the panel door (refer clause 4.6.2)

– 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 4.1.2).

In case the earhting drawout truck has an electro-mechanical interlock unit mounted on it, the transferis possible only after all the interlocking conditions aresatisfied.

– 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 earthing drawouttruck with making capacity (refer clause 4.3).

– Transfer it to the disconnected position (referclause 4.1.3)

– Open the HT compartment door (refer clause 4.6.1)

– Disconnect the LV plug (refer clause 4.1.4)

– Insert the original drawout truck of the 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 4.6.2)

– The original drawout truck is now ready for transferto connected position.

– Remove warning plates.

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, ensurethat all 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.

Fig 28 : Earth switch Arrangement on cable side

28.1. Fixed contacts28.2. Moving contact28.3. Earthing switch shaft28.4. Operating link

28.5. Operating rod21.1. Earthing busbar28.6. Earth connection28.7. Flexible connection

28.128.2

28.3

28.4

28.5

28.6

28.7

21.1

24

4.5.3.2 Earthing Cables with Earthing Switch(Fig 28)

– 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. Turn itin the anti-clockwise direction till stop. Withdrawthe handle.

– Remove warning plates from all the locations

4.5.4 Earthing the Busbars or Cables withTruck

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 out the breaker to diconnected position.

– Disengage the LV plug & socket.

– Withdraw the breaker 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.

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 truck.

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 truck.

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 (24.8) anti-clockwise to unlockthe door.

– Open the door.

4.6.2 To close the door

– Shut the door.

– Rotate the handle (24.8) clockwise till it getslocked.

4.7 Door of the LV Compartment

4.7.1 To open the door

– Rotate the turnlocks with a key in anti-clockwisedirection.

– Open the door.

4.7.2 To close the door

– Shut the door.

– Rotate the turnlocks in clockwise direction.

25

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 to property.

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 interlocking plate.

• 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 theair is very moist or full of dust or is otherwisepolluted. The cause of any disturbance or short-circuitmust be determined immediately and damaged partsreplaced, irrespective of whether an inspection is dueor 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, small brushes,dusters and vacuum cleaner for sheet metal parts.

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 distilledwater only.

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

5.3 Lubrication

Immediately after cleaning:

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

26

– 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 150 C.

5.4 Replacement (Spare) 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.

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 accessto the 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 (24.7,Fig 24) and screw-in the grub screw visible throughthe opening till it falls out inside the panel.

– Open the door by turning the door handle.(referclause 4.6.1).

5.5.2 Drawout Unit in disconnected position

– Press the interlocking lever on interlocking plate byhand.

– Insert the double-bit key in lock (24.4, Fig 24) andturn it (locked) to “Manual Racking”.

– Fit the hand crank (9.2, Fig 9) to the hexagonshank in opening turn it clockwise as far as it willgo and pull it off (24.5, Fig 24).

Turn the double-bit key clockwise through 90º fromposition “Manual Racking” to “Connected Position(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 CB 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 any hazardousmaterials 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 the ozonelayer. Therefore, PVC must be recycled throughauthorized contractors.

Local Siemens office can answer any questionsconcerning disposal.

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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 connected tothese 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, cobwebsetc. & 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.

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.

7 Summary of Important Instructions-

29

8 Additional Information

8.1 Reference List of Items

ItemDescription Fig.No.

2.1 Circuit Breaker Compartment 22.2 Cable & CT Compartment 22.3 Busbar Compartment 22.4 Low Voltage Compartment 23.1 Mechanical ON Push Button 33.2 Mechanical OFF Push Button 33.3 Spring Charging Opening 33.4 Spring Charge Indication 33.5 Mechanical ON & OFF indication 33.6 Mechanical Operations Counter 33.7 Contact Arms with Tulip Contacts 33.8 Truck Handle 3, 263.9 End Partition (Truck) 34.1. Door Locking hinge pin 4, 244.2. Door close interlock 44.3. Viewing window for truck position 44.4. Viewing window for Spring charge

indicator and Mechanical Counter 44.5. LV connection Plug 44.6. Drive Mechanism housing 44.7. Ramp 44.8. Interlocking Plate (Drive Box) 44.9. Holder for LV Plug 44.10. Clip for locking LV Plug to Breaker 44.11. Opening for hand crank for

charging the closing spring 4, 244.12. Twist Grip for operating the

breaker in service position 44.13. Rod Lever 44.14. ‘ON’ Push Button (On the breaker) 44.15. ‘OFF’ Push Button (On the breaker) 44.16. Plate Covering manual spring

charge opening 45.1. Vacuum Interrupter 55.2. Insulating Switching Rod 55.3 Insulating Phase Barrier (Truck) 56.1. Bushings of upper mating contact 6, 196.2. Cast resin insulator 6,7, 20, 266.3. Feeder connections 6, 206.4. Joint shrouds 6,76.5. Main Busbars 68.1. Phase Barrier (Cable Chamber) 88.2. Bushings for lower mating contact 8,198.3. Current transformer 88.4. Cable connecting pieces 88.5. Bushing Cover 89.1. Charging Handle 99.2. Cranking Handle 99.3. Double Bit Key 99.4. Rod Trap Key 99.5. Earthing Switch Handle 913.1. End Covers 1313.2. Pressure relief channel for

Rear Frame (110 mm) 13

ItemDescription Fig.No.

13.3. Pressure relief flaps 1318.1. HT Compartment door 18, 23, 2418.2. Upper metallic shut 18, 2218.3. Lower metallic sh 18, 2218.4 Thermost 1819.1. Fixed Contacts (Upper) 1919.2. Fixed Contacts (Lower) 1919.3. Truck earthing Strip 19, 2119.4. Space Heater 1920.1. Busbar Link 2020.2. Coach Bolt 2020.3. Rear Cap (Shroud) 2020.4. Side Cap (Shroud) 2020.5. Front Cap (shroud) 2020.6. Nylon Bolt 2020.7 Hex Bolt 2021.1. Earth Busbar 21, 2821.2. Extension Links 2121.3. Bottom Covers 2122.1. Shutter operating rod 2222.2. End Insulating Partition

(Breaker Chamber) 2222.3. Truck guide 2223.1. Breaker Truck 2324.1. Window for inspecting the

withdrawable part 2424.2 ON & OFF Button (On HT Door) 2424.3 Window for the indicators of

the withdrawable part 2424.4 Double Bit Key for locking the

transfer operating mechanism 2424.5 Opening for the hand crank for

racking the withdrawable part 2424.6 Door of compartment for

LV equipment 2424.7. Opening for defeating interlock 2424.8. Handle for operating the HV door. 2426.1. Drawout fuse Truck 26, 2726.2. HT Fuses 26, 2726.3. Upper Moving Contact 2626.4. Lower Moving Contact 2626.5 Locking lever (PT truck) 2627.1. Line PT 2727.2. Upper Fixed Contacts 2727.3. Lower Fixed Contacts 2727.4 Rear Box Complete 2728.1. Fixed Contacts (E. Switch) 2828.2. Moving Contact (E. Switch) 2828.3. Earthing Switch Shaft 2828.4. Operating Link 2828.5. Operating Rod 2828.6. Earth Connection 2828.7. Flexible Connection 28

30

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 above valuesare 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.

31

Notes

Siemens Ltd.PTD-03-152-011

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-03-27300-001

'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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