STD-CUS-030 Type 298 User Guide for Circuit Breaker Cubicle

STD-CUS-030 Type 298 User Guide for Circuit Breaker Cubicle
Switchgear & Instrumentation
Type298
Medium Voltage IEC Switchgear and Motor Control Centres
User Guide for Circuit Breaker Cubicle
Incorporating PowlVac100TM Circuit Breaker
Issue Date: January 2014
Document Revision 2.3
Doc Ref: STD-CUS-030
REVISION HISTORY
Revision
Date
0.00
07/12/11
1.0
18/12/11
2.0
Description
Prepared
Charlotte Pestell
04/01/12
Original created from several existing IOMs and Technical
Data sheets.
Updated to incorporate comments from collaborative crossdepartment review meeting
Updated to include required branding modifications
2.1
11/01/12
Updated to incorporate comments following review
Charlotte Pestell
2.2
2/1/13
Updated to reference STD/CUS/020 for lifting procedures
Paul Dale
2.3
21/01/14
Updated Sect. 6.6./Added Sect 6.4 for 95kV BIL specific
requirements/ Updated Sect 6.3.4 for Vib & Seismic
Installation requirements.
Ignitius Milomo
Charlotte Pestell
Charlotte Pestell
The Design and Development Department is responsible for the data contained in this standard document.
The relevant departmental managers and team leaders are responsible for ensuring the correct use of this
data within their departments. The Engineering Manager is responsible for the correct use of the data within
the Contract Engineering department.
AUTHORISED BY
SD&D Manager_______________________
P Dale
nd
DATE _28 January 2014
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TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 3 of 53
Contents
1
Getting Started ........................................................................................................... 7
1.1
1.2
1.3
2
Introduction ................................................................................................................. 9
2.1
2.2
3
About this User Guide ................................................................................................... 7
How to Use this User Guide .......................................................................................... 7
Application Notes .......................................................................................................... 8
Overview ....................................................................................................................... 9
Equipment ................................................................................................................... 10
Specifications ............................................................................................................11
3.1
Mechanical Specifications ........................................................................................... 11
3.1.1
3.1.2
3.1.3
3.2
Electrical Specifications ............................................................................................... 13
3.2.1
3.2.2
3.2.3
4
Construction ................................................................................................................ 14
Withdrawable Circuit Breaker Compartment ................................................................ 14
Low Voltage Control Compartment.............................................................................. 14
VT Compartment ......................................................................................................... 15
Busbar Chamber ......................................................................................................... 15
Cable Chamber ........................................................................................................... 15
4.6.1
4.6.2
CT Specifications.............................................................................................................15
Cable Terminations .........................................................................................................15
Dispatch and Storage ................................................................................................16
5.1
5.2
5.3
5.4
5.5
6
Switchboard Specifications .............................................................................................13
Continuous Current Ratings ............................................................................................13
Internal Arc Classification ................................................................................................13
Circuit Breaker Cubicle ..............................................................................................14
4.1
4.2
4.3
4.4
4.5
4.6
5
Enclosure.........................................................................................................................11
Special Climatic Operating Conditions ............................................................................11
Weights and Dimensions .................................................................................................12
Condition on Delivery .................................................................................................. 16
Packing ....................................................................................................................... 16
Export Packing ............................................................................................................ 16
Transport..................................................................................................................... 16
Delivery and Intermediate Storage .............................................................................. 17
Installation .................................................................................................................18
6.1
6.2
6.3
Overview ..................................................................................................................... 18
Switchroom Requirements .......................................................................................... 18
Mounting ..................................................................................................................... 18
6.3.1
6.3.2
6.3.3
6.3.4
6.4
Foundation Frame or Unistrut .........................................................................................18
Switchroom Floor.............................................................................................................18
Raised Plinth ...................................................................................................................18
Installation requirements specific to Vibration and Seismic switchboard ........................18
Requirements specific to 95kV Basic Impulse Level (BIL) Switchboard ....................... 19
6.4.1
6.4.2
6.4.3
6.4.4
Busbar Chamber .............................................................................................................19
700 wide PV100 VCB Requirements ..............................................................................20
100
1000 wide PV VCB Requirement ................................................................................21
Tier Requirements ...........................................................................................................22
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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6.5
Mechanical Assembly.................................................................................................. 24
6.5.1
6.5.2
6.5.3
6.6
Assembly of Busbars................................................................................................... 25
6.6.2
6.7
6.8
Site Requirements ...........................................................................................................24
Assembly of Cubicles ......................................................................................................24
Cubicle Fixing Bolts .........................................................................................................24
Assembly of Arc Ventilation Plenum ...............................................................................28
Torque Settings ........................................................................................................... 29
Electrical Connections ................................................................................................. 31
6.8.1
6.8.2
Connection of Mains Power and Control Cables ............................................................31
Earthing the Switchboard ................................................................................................31
6.9 Final Installation .......................................................................................................... 32
6.10 Extension Cubicles ...................................................................................................... 33
7
Pre-Commissioning ...................................................................................................34
7.1
7.2
Overview ..................................................................................................................... 34
Pre-connection Checks ............................................................................................... 34
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.2.6
7.2.7
7.2.8
7.2.9
7.2.10
7.3
7.4
7.5
7.6
7.7
8
General and Visual Checks .............................................................................................34
Control Wiring Completion Checks .................................................................................34
Low Ohm (Ducter) Tests (Minimum 50A) ........................................................................34
Primary Injection Tests ....................................................................................................34
Secondary Injection Tests ...............................................................................................34
Power Frequency Pressure (Flash) Tests .......................................................................35
Insulation Resistance Tests (Minimum 5kV) ...................................................................35
Electro-Mechanical and Functional Checks ....................................................................35
Protection Relays ............................................................................................................35
Final Checks ....................................................................................................................35
Energisation ................................................................................................................ 35
Standard Tools ............................................................................................................ 36
Special Tools............................................................................................................... 36
Loose Items................................................................................................................. 36
Lubricants and Cleaning Agents .................................................................................. 36
Operation of the VCB Cubicle....................................................................................37
8.1
Insertion and Withdrawal of the Circuit Breaker ........................................................... 37
8.1.1
8.1.2
8.2
8.3
Test/Isolated Position .................................................................................................. 38
Interlocks..................................................................................................................... 39
8.3.1
8.3.2
8.4
8.5
8.6
Maintenance Cradle ........................................................................................................43
Voltage Transformer.................................................................................................... 44
8.7.1
8.7.2
8.8
General Interlocks ...........................................................................................................39
Key Interlocks ..................................................................................................................40
Operating Mechanism ................................................................................................. 40
Earthing Switch ........................................................................................................... 41
Shutters....................................................................................................................... 42
8.6.1
8.7
Insertion ...........................................................................................................................37
Withdrawal .......................................................................................................................38
Insertion ...........................................................................................................................44
Withdrawal .......................................................................................................................44
Busbar Earthing Truck ................................................................................................. 45
8.8.1
8.8.2
8.8.3
Insertion ...........................................................................................................................45
Withdrawal .......................................................................................................................46
Operation .........................................................................................................................46
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 5 of 53
9
Maintenance ..............................................................................................................47
9.1
9.2
Overview ..................................................................................................................... 47
Inspection and Servicing ............................................................................................. 47
9.2.1
9.2.2
9.3
Repairs........................................................................................................................ 49
9.3.1
9.3.2
9.4
Inspection ........................................................................................................................47
Servicing ..........................................................................................................................48
Cubicles ...........................................................................................................................49
Replacement of VT Primary Fuses .................................................................................49
Electro-Mechanical Interlock Checks ........................................................................... 49
9.4.1
9.4.2
Circuit Breaker .................................................................................................................50
Circuit Earthing Switch ....................................................................................................50
Appendix 1: Abbreviations/Glossary of Terms ...................................................................51
Appendix 2: Related Documents........................................................................................52
List of Figures
Figure 1 VCB Cubicle Layout
Figure 2 Busbar Barrier
Figure 3 Busbar Joint end Seals
Figure 4 Additional CT Support
Figure 5 V-Rubber Fitted to Busbar Chamber Cut-out
Figure 6 Shrink-wrapped contact Arms
Figure 7 Screw Caps on all Contact Mounting Bolts
Figure 8 Screw Caps on all Contact Mounting Bolts
Figure 9 Standard Inserts replaced by GP03 Blocks
Figure 10 700 mm Wide Tier Shutters
Figure 11 1000 mm Wide Shutters
Figure 12 Locating of Riser and Busbar Joint Plates into cover slots prior to strapping
Figure 13 Busbar Arrangement for Middle Tier (Side View)
Figure 14 Busbar Arrangement for End Tier (Plan View)
Figure 15 Earth Screen Connection
Figure 16 Circuit Breaker Operation
Figure 17 Interlock Box
Figure 18 Earthing Switch Operation
Figure 19 Shutters
Figure 20 Shutter Operating Mechanism
Figure 21 Maintenance Cradle
Figure 22 Voltage Transformer
9
19
19
20
20
20
21
21
22
22
23
25
26
27
31
37
39
41
42
42
43
44
List of Tables
Table 1
Table 2
Table 3
Table 4
Table 5
Table 6
Table 7
Mechanical Enclosure Specifications .........................................................................................................11
Standard Cubicle Dimensions (mm) ...........................................................................................................12
Standard Weights of Loose Mechanical Items (kg) ....................................................................................12
Switchboard Electrical Specifications .........................................................................................................13
Continuous Current Ratings (A) .................................................................................................................13
CT Class .....................................................................................................................................................15
Mounting requirements for Vibration and Seismic Switchboard .................................................................18
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 6 of 53
1 Getting Started
IMPORTANT NOTICE – READ THIS FIRST
This User Guide does not purport to cover every detail of the installation and operation of the switchgear.
Requests for further guidance or information on this or any other product should be directed to Powell UK.
Our switchgear is manufactured in accordance with IEC standards. Powell UK cannot provide any
assurances that this product will comply with the wide variety of local codes, regulations or ordinances that
apply in different areas of the world.
1.1 About this User Guide
This user guide provides user operation, installation and maintenance instructions for the TYPE 298
Switchgear.
The purpose of this user guide is to familiarize the user and maintenance personnel with the basic
capabilities of the switchgear. Only proven safe installation techniques are covered in this user guide.
This user guide was not prepared for inexperienced maintenance personnel. It is not intended to constitute a
training program or to provide sufficient background for personnel, not experienced with this type of electrical
system, to install the system described in this user guide.
The end user is responsible for ensuring that no persons should be authorised to install or carry out
maintenance work on the system without having read this user guide.
All rights reserved. Re-production of any part of this user guide in any form whatsoever without the written
permission of Powell UK is forbidden. Additional copies can be obtained from the After Sales Services Dept.
of Powell UK, Bradford, United Kingdom. The information contained within this user guide is confidential and
cannot be transferred to a third party without the written consent of Powell UK.
All efforts have been made to ensure the accuracy of the contents of this user guide. However should any
errors be detected, Powell UK would greatly appreciate being informed of them.
The above notwithstanding Powell UK can assume no responsibility for any errors in this user guide or the
consequences thereof.
The policy of Powell UK is one of progressive improvement in design, construction and operation. Systems
and equipment referred to in this user guide are subject to changes in keeping with this policy. The
manufacturer, therefore, reserves the right to make any changes without prior notice.
1.2
How to Use this User Guide
This user guide is arranged and subdivided to provide useful information with a minimum of searching.
The key to easy reference is the Table of Contents. Every subject, in the Table of Contents, is listed with a
reference number and the page on which the item can be found. Each subject is numbered by Chapter,
Paragraph and Sub-paragraph, for example:
4.1.2.
“4" - Chapter number.
“1" - Main paragraph topic.
“2" - Breakdown of Main paragraph topic.
The page number, along with the number of pages in this user guide, is located in the outside corner of each
page.
For convenience, all illustrations and tables are numbered in sequential order.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 7 of 53
Familiarity with the Table of Contents will facilitate locating particular information easily.
Personnel responsible for the system should review all of the Table of Contents for future reference and an
overall understanding of the user guide. Then read the user guide and study the illustrations thoroughly.
1.3
Application Notes
MV Switchgear Warranty
Powell UK warrant the switchgear against defects in material or workmanship under normal use for a period of 18
months from the date of shipment from our premises or 12 months from the date the equipment is put into service,
whichever occurs first.
In the event of a failure arising during the warranty, Powell UK will undertake to repair or replace the switchgear at
our option, provided always that it is found to be defective. The warranty obligations of Powell UK will not extend to
defects caused by wrong or negligent operation, accident, overloading, unsuitable operating conditions, or by
failure of the End User to comply with any instruction given by Powell UK with regard to its operation or installation.
Powell UK is not liable under any circumstances for special, economic, financial, indirect or consequential damages
(including loss of profit, loss of use, loss of production, loss of contracts) or for expenses sustained as a result of
switchgear malfunction or incorrect application.
Safety at Work.
The voltages present in certain parts of the switchgear are capable of inflicting a severe electric shock and may be
lethal. It is the responsibility of the owner and / or the End User to ensure that the installation of the switchgear and
the way in which it is operated and maintained complies with the requirements of the Health and Safety at Work Act
in the United Kingdom, and with other applicable legislation and regulations and codes of practice in the UK or
elsewhere.
The manufacturer accepts no liability for any consequences resulting from inappropriate or incorrect installation of
the equipment.
Training
If additional training is required then contact Powell UK or their designated agent.
Type of operating environment
The intended operating environment is limited to being housed within an electrical switchroom or substation that is
suitable for protecting the equipment. Access to the switchroom and switchgear must be prevented except by
trained and authorised personnel.
General Operating Requirements
Users must have electrical experience and be able to interpret control circuit diagrams, electrical schematics and
general arrangement drawings.
Minimum age (years). Eighteen (18), or minimum permissible age required by End User’s national law.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 8 of 53
2 Introduction
2.1 Overview
The Type 298 MV (Medium Voltage) switchgear is a modular construction of metal enclosures incorporating
various arrangements of incomer, feeder, bus tie and motor starter cubicles. The Incomer and bus tie cubicles are
fitted with a Circuit Breaker (CB) and the feeder cubicles can be fitted with either a circuit breaker or a Vacuum
Contactor (VC).
The cubicles that make up the switchboard are connected together via a Hard Drawn High Connectivity (HDHC)
copper bus bar system. HDHC copper risers are used to connect the equipment within each cubicle to the busbar
system.
Figure 1 VCB Cubicle Layout
As can be seen from the above side view, each VCB cubicle contains:
 A withdrawable circuit breaker.
 A Low Voltage (LV) control compartment containing terminals, control relays, MCBs etc.
 A busbar chamber that allows the busbars to run into each cubicle for the risers to connect to.
 A cable chamber for incoming and outgoing connections.
 A voltage transformer in order to provide the control/metering supply (if required). There may not be a VT
in every CB cubicle supplied, but one or two per bus/switchboard. See contract drawings for details.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 9 of 53
2.2 Equipment
The major components that are supplied as standard in the MV Incomer, Bus Tie and CB Feeder cubicles are as
follows:
Component
Circuit Breaker
Earthing Switch
Busbar Earthing Truck
Voltage Transformer
Manufacturer
Powell UK
Contact Powell UK
Powell UK
Transmag
This user guide discusses only the PowlVac
separate user guide.
100
TM
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Model No.
PowlVac
100
TM
breaker. The ABB VD4 and HD4 breakers are discussed in a
Page 10 of 53
3 Specifications
3.1 Mechanical Specifications
3.1.1 Enclosure
IEC Publication
Description
IEC 60470
High Voltage Alternating Current contactors and contactorbased motor starters
IEC60529
Ingress Protection Rating:
 IP 4X (standard enclosure)
 IP 41 (enhanced enclosure)
 IP 42 (enhanced enclosure)
 IP 3X (between compartments)
 IP 2X (inside the compartments with the door open)
IEC 62271
IEC 62271-1
IEC 62271-100
IEC 62271-102
IEC 62271-200
Min
Max
Units
Maximum ambient temperature
-20
+40
°C
Maximum 24 hour average temperature
-20
+35
°C
Storage temperature
-5
+55
°C
Maximum 24 hour average storage temperature
-5
+70
°C
Average relative humidity over 24 hours
95
%
Average value of water vapour over 24 hours
2.2
kPa
Average relative humidity over 1 month
90
%
Average value of water vapour over 1 month
1.8
kPa
Maximum Site Altitude
1000
M
High Voltage switchgear and controlgear
Common specifications
High Voltage switchgear and controlgear
Alternating Current Circuit Breakers
High Voltage switchgear and controlgear
Alternating Current disconnectors and earthing switches
High Voltage switchgear and controlgear
AC metal-enclosed switchgear and controlgear
Table 1
Mechanical Enclosure Specifications
3.1.2 Special Climatic Operating Conditions
For any operating conditions other than those described above, Powell UK must be contacted in advance.
Examples of these are as follows:
 At site altitudes above 1000m the effects of the reduction in dielectric strength of the air on the insulation
level need to be taken into account.
 Increased ambient temperatures must be compensated for in the design on the busbars and tee-off
conductors, otherwise the current carrying capacity will be limited. Heat dissipation can be assisted by
fitting additional ventilation facilities.
 If the switchgear is to be operated in areas with high humidity and/or major rapid temperature fluctuations,
there is a risk of dew deposits. This situation can be exacerbated with low primary currents as internal
heating is not achieved. Anti-condensation heaters can be fitted in order to avoid premature insulation
degradation and corrosion.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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3.1.3 Weights and Dimensions
Description
Current
Rating
Cubicle
Width
Cubicle
Height
Cubicle
Depth
Plenum
Height
Plenum
Depth
Overall
Switchboard
Height
40kA Switchboard
<1600A
700mm
2204
1600/1990
428
1167
2630
50kA Switchboard
<2000A
700mm
2204
1600/1990
428
1167
2803.5
50kA Switchboard
<3150A
1000mm
2204
1600/1990
626
1167
2803.5
63kA Switchboard
<4000A
1000mm
2404
2095
626
1270
3003.5
Table 2
Standard Cubicle Dimensions (mm)
Please note that extended depth is used when the switchboard is required to be top entry.
Cubicle Width
Description
40kA Circuit Breaker
50kA Circuit Breaker
63kA Circuit Breaker
Service Trolley
Shutter Operating Device
Voltage Transformer
Busbar Earth Truck
Earth Switch Operating Handle
Earth Switch Extension Handle
Racking Handle
Door Opening Hand Tool
CB Spring Charging Handle
Table 3
700mm
1000mm
245
245
310
38
30
100
75
1.5
1.5
0.5
0.25
0.25
1000mm
(63kA)
415
TBA
78
50
100
75
100
1.5
1.5
0.5
0.25
0.25
0.5
0.25
0.25
Standard Weights of Loose Mechanical Items (kg)
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 12 of 53
3.2 Electrical Specifications
The specifications detailed below are based on normal operating conditions as detailed in section 3.1 Mechanical
Specifications. If these conditions should differ (e.g. the site is at an altitude greater than 1000m or there is an
increased ambient temperature) then Powell UK should be consulted in advance as it may have an impact on the
specifications detailed below.
3.2.1 Switchboard Specifications
Description
3.6
Short-duration Power Frequency Withstand
Voltage (kV RMS)
Basic Impulse Insulation Level (BIL)
Rated Frequency (Hz)
Rated Busbar Current (A)
Rated Peak Withstand Current (kA)
Rated Short Circuit Breaking Current (kA)
Rated Short Time (3sec) Current (kA)
10
40
50/60
≤4000
≤158
≤63
≤63
Auxiliary voltage (V)
Table 4
Switchboard Voltage Rating (kV)
7.2
12
20
28
60
75
50/60
50/60
≤4000
≤4000
≤158
≤158
≤63
≤63
≤63
≤63
AC Voltages: 110/220
DC Voltages: 48/110/125/220
13.8
38
95
50/60
≤4000
≤158
≤63
≤63
Switchboard Electrical Specifications
3.2.2 Continuous Current Ratings
Description
700mm wide cubicle
1000mm wide cubicle
1000mm wide cubicle
Available Ratings (A)
630
Table 5
1250
2500
1600
3150
3150
2000
1
4000
1
4000
Fault Rating
(kA)
≤50
≤50
≤63
Continuous Current Ratings (A)
3.2.3 Internal Arc Classification
The Internal Arc Classification for the MV298 Switchgear is tested in accordance with IEC 62271-200 Annex A
(Internal Fault – Method for testing the metal-enclosed switchgear and controlgear under conditions of arcing due
to an internal fault). The Internal Arc Classification (IAC) makes allowance for internal overpressure acting on
covers, doors, inspection windows, ventilation openings etc. It also takes into consideration the thermal effects of
the arc or its roots on the enclosure and of the ejected hot gases and glowing particles, but not damage to internal
partition and shutters not being accessible in normal operating conditions.
Please refer to the switchboard rating plate for specific details of the IAC of the switchboard supplied.
1
Forced Ventilation must be used for this rating.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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4 Circuit Breaker Cubicle
4.1 Construction
The Type 298 MV switchgear consists of several segregated compartments:




Withdrawable Circuit Breaker Compartment
Low Voltage Control Compartment
VT Compartment
Busbar Chamber
These compartments are discussed in more detail in the following sections:
The main framework and internal faces of the switchboard are manufactured from Aluzinc. Doors and covers are
manufactured from mild steel and can be painted in any BS or RAL colour.
4.2 Withdrawable Circuit Breaker Compartment
The circuit breaker compartment is fitted with guide rails in order to facilitate insertion and withdrawal of the
breaker. This is done with the use of a Service Trolley (see section 8.1 Insertion and Withdrawal of the Circuit
Breaker for further details).
At the back of the compartment are earthed metal shutters that are automatically operated by the shutter operating
mechanism such that no access can be gained to the primary disconnects when the breaker is in the
“Test/Isolated” position or completely removed from the cubicle. Please refer to Section 8.6 for further details.
Inside the compartment (mounted on the compartment top) is the control socket that the secondary disconnect
(multi-way control wiring plug) on the breaker connects into. This connection can only be made when the breaker
has been inserted into the compartment unless a special tool (CB test umbilical) is used.
When the breaker has been racked from the “In Service” position to the “Test/Isolated” position it is possible to
open the door and manually control the breaker using the Close/Trip buttons on the breaker itself. It is also
possible to perform a manual charge using the handle supplied. The Close/Trip and Charged/Discharged
indicators can be observed through the viewing window in the door when the door is closed.
Anti-condensation heaters (ACH) are also fitted in this compartment as required. These are controlled via a
thermostat which is located in the Low Voltage Control Compartment. Please note that at low loads, the heaters
should be permanently energised. Also, where end tiers draw little or no load, these heaters should also be
permanently energised.
4.3 Low Voltage Control Compartment
This compartment, including the door, accommodates the auxiliary equipment of the switchgear panel. This
includes any protection relays and control relays etc. LV control wiring is situated within plastic trunking and
additional earthed metal trunking to the cubicle sides allows for bottom entry incoming LV connection direct to the
LV compartment. Bus wiring is routed between LV compartments through the cut-outs supplied.
A termination unit (TU) is also fitted into this compartment. This is used to distribute the RS485 cabling around the
switchboard to any intelligent control relays that may be fitted.
A thermostat is also fitted in this compartment. This is used to control the anti-condensation heaters located in the
circuit breaker compartment.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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4.4 VT Compartment
This is situated below the Circuit Breaker compartment and can be equipped to accommodate a cradle mounted
voltage transformer. Guide rails are fitted in order to facilitate insertion and withdrawal of the VT.
At the back of the compartment is an earthed metal shutter that automatically operated by the shutter operating
mechanism such that no access can be gained to the primary disconnects when the VT is withdrawn.
There are no interlocks associated with the VT. The door is padlockable (a padlockable racking boss is available
on request), but after that it is possible to insert and withdraw the VT irrespective of the state of the breaker.
4.5 Busbar Chamber
The busbars are laid in sections from tier to tier and are held in place by post insulators mounted on the steel
frame. Each busbar is constructed from 5mm HDHC copper bar insulted with an epoxy dip coating. Busbars are
used in single, double, triple or quadruple configuration depending on the current rating (refer to contract
documentation). The connections to the 5mm thick dropper busbars are made onto a special joint casting mounted
onto the post insulator and terminated into the busbar spout mouldings. All main circuit conductors are electrotinned or silvered at the joint faces of the bolted joints which are then covered by EPDM covers.
4.6 Cable Chamber
This houses the Current Transformers (CTs), mechanically operated circuit earthing switch, primary cable
terminations and switchboard earth bar. Capacitive dividers and surge arrestors are also contained here if
supplied.
Neon indicators connected to the earth layer of the CT bushings may be fitted as an option to indicate that the
circuit side connections of a cubicle are energised.
Neon indicators for busbar live indication may be provided using busbar sleeving kits, or where possible, by
connecting to the bushing in a bus section cubicle.
Surge arrestors are fitted in this compartment where required. See contract document for details.
4.6.1 CT Specifications
CTs are ring type with 600V insulation mounted onto fully fault rated CT bushings. Each bushing is constructed
with an earth shield between the HV and CT windings. Alternative cast resin insulated wound primary CTs may be
used in special circumstances. CTs are specified as follows:
CT Class
Class 1/0.5/0.2
Class 5P/10P
Class PX
Function
Metering
Protection
Differential & Residual Earth Fault
Table 6
Max.
Rating
≤4000A
≤4000A
≤4000A
CT Class
4.6.2 Cable Terminations
Primary cable terminations are arranged to meet contract requirements with access from above or below. Gland
plates are provided at floor or unit top level with suitable accommodation for either single or multi-core cables as
required by the contract. Joints can be covered with polyurethane moulded covers (boots) if required. Please refer
to contract documentation for glanding details
Secondary cable terminations are made either top or bottom entry. Cables are terminated in the LV Compartment.
Bus wiring is routed directly between LV Compartments.
Internal earth bars and inter-panel earthing is mounted in the lower section of the cable chamber.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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5 Dispatch and Storage
5.1 Condition on Delivery
The factory assembled switchgear cubicles are checked at the factory for compliance with the manufacturing order
and contract documentation.
All routine tests in accordance with all relevant specifications are conducted at the factory. Functional testing and
interlock sequence are checked with the final inspection.
Note: Horizontal busbars are not assembled within the equipment in the factory and are therefore not subjected to
an AC power frequency test on the assembly (this needs to be performed following installation. Please refer to
Section 7.2.6 Power Frequency Pressure (Flash) Tests. Each busbar is however, separately tested for integrity of
insulation by high voltage withstand testing. Busbars are supplied as loose material for completion at site during
installation.
5.2 Packing
The switchgear sections are split and packed in accordance with the contract documentation. Standard packaging
consists of heavy duty welded seam polythene sheeting (minimum grade 500 gauge, micron value 125) applied to
each section. Packaging is often supplied in accordance with specific customer requirements.
Where the panel comprises more than one section, each piece will have an adhesive identification label.
All loose materials are detailed on a dispatch note and packed in a separate carton(s). See “Loose Material List”
supplied with the contract documentation for details.
For further details, please refer to the Packing/Unpacking Specification STD/CUS/008.
5.3 Export Packing
The switchgear sections are split and packed in accordance with contract documentation. Standard domestic
packaging for export consists of a timber-framed, plywood clad case and all equipment is adequately wrapped. For
further details, please refer to the Export Packing Specification STD/CUS/007.
5.4 Transport
The switchboard sections are normally transported as individual panels, or in small groups. Each panel is fitted
with two lifting channels mounted to the upper unit side frames. Please refer to contract drawings for details of the
shipping splits. For recommended methods of lifting, please refer to the Lifting Procedures document
STD/CUS/020.
Always transport switchgear panels upright and avoid sudden shock or jolting.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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5.5 Delivery and Intermediate Storage
The responsibilities of the consignee when the switchgear arrives at the site include, but are not limited to the
following:
 Check the consignment is complete and there is no obvious damage. In cases of doubt, the packaging
may be opened and then properly resealed when intermediate storage is necessary.
 Precisely document any defect/transport damage and report these to the relevant authorities within two
weeks.
Storage is at the discretion of the consignee. Equipment packed according to customer specified documentation
shall be the responsibility of the customer.
Cubicles packed in our standard packing shall be stored as follows:
 A dry, well ventilated and preferably heated storeroom in accordance with IEC 62271 (Please refer to Table
1 Mechanical Enclosure Specifications for details of ambient conditions).
 Store switchgear cubicles in an upright position.
 Do not stack switchgear cubicles.
 Do not remove or damage the packaging.
 Loosely cover unpacked switchgear cubicles with plastic film to prevent dirt and ingress
 Cover all loose equipment with plastic film to prevent dirt ingress.
 Sufficient air circulation must be maintained to prevent corrosion.
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6 Installation
6.1 Overview
Once delivered to site, the switchgear can be assembled. This section details the switchroom requirements and
the mechanical and electrical connections that must be made. We recommend that any installation work is carried
out by Powell UK Site Services personnel. Please contact the Site Services team for further details regarding
installation personnel and activities.
6.2 Switchroom Requirements
The minimum requirement for ceiling height in the switchroom is 3000mm for a standard IEC 62271 construction
switchboard. This will need to be higher for a 63kA switchboard. Please refer to Section 3.1.3 Weights and
Dimensions for further details.
6.3 Mounting
It is recommended that the switchboard be mounted in one of the following ways:
6.3.1 Foundation Frame or Unistrut
The switchgear and controlgear should be erected on a foundation frame or unistrut set into the switchroom floor or
onto a raised plinth. The completed foundation frame must be in accordance with:
 Flatness ± 1mm per 1m
 Straightness 1mm per 1m, but within 8mm over the entire switchboard length
Please refer to contract documentation for details of the foundation layout.
6.3.2 Switchroom Floor
Switchboards with few lightweight cubicles can be fitted directly to the switchroom floor if the floor is level and has
sufficient load bearing capacity. If required, shims may be used to assist with alignment. The completed
switchroom floor must be in accordance with:
 Flatness ± 1mm per 1m
 Straightness 1mm per 1m, but within 8mm over the entire switchboard length
Please refer to contract documentation for details of the foundation layout.
6.3.3 Raised Plinth
The switchboard can be supplied with a mounting plinth for mounting purposes. In order to facilitate the use of
earth trucks and service trolleys, any plinth must include a withdrawal area in front of the switchboard or the
switchroom floor must be screeded to the level of the plinth. Where required specific ramps can be supplied in
order to provide access between different floor levels.
6.3.4 Installation requirements specific to Vibration and Seismic switchboard
The bolts, washers and load spreader bars required for assembling the cubicles are defined in the table below.
The bolt lengths may vary due to site specific installation requirements. Only the minimum length has been
specified in the table. These items are supplied as loose items with each cubicle.
Cubicles
Any cubicle
to Plinth
Description
Qty
Size
Length
Grade 12.9 Cap Screw
1/Mounting Position
M12
≥35mm
Load Spreader
1/Screw
09092P00014012
Locking Washer
1/Screw
M12
Table 7 Mounting requirements for Vibration and Seismic Switchboard
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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6.4 Requirements specific to 95kV Basic Impulse Level (BIL) Switchboard
6.4.1 Busbar Chamber
6.4.1.1 An additional GP03 plate is required. This is fitted to Busbar mounting plate (Ripple Plate) in order
to act as a barrier between the Riserbar of L1 and the horizontal Busbar of L3.GP03 Brackets are
provided and these must be secured using Nylon fasteners
GP03 Barrier between
L3 Busbar and L1
Riserbar, fitted to the
Ripple Plate
Figure 2 Busbar Barrier
6.4.1.2 All main horizontal Busbar are coated with an insulation of between 1.6mm & 2mm thick.
This reduces the gaps between adjacent bars and care must be taken when fitting the
Busbar Joint End Seals which are fitted all round the boot. Replacement Busbar Joint End
Seals which allow for the additional thickness of the insulation on the main Busbars are
required during site installation. Their references are shown below.
Figure 3 Busbar Joint end Seals
Joint End Seals or Joint Plates are fitted to Riser Bars on switchboards specified for Basic
Impulse Level (BIL) application. Detailed procedures for Assembly of Busbars joints are
discussed in Section 6.6.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 19 of 53
6.4.1.1 An additional CT support ring are placed on the CT bushings up against the original CT
support
Additional CT Support
added
Figure 4 Additional CT Support
6.4.1.2 V-rubber edging strip is fitted around the cut out for the interconnecting Busbars on each
tier. Ensure that these are secured.
V-rubber must be fitted
round the edge of the
Cut-out for the Busbar
Chamber
Figure 5 V-Rubber Fitted to Busbar Chamber Cut-out
6.4.2 700 wide PV100 VCB Requirements
6.4.2.1 The contact Arms in the Pole-Moulds have been insulated on the 2000A 50kA 700mm
Wide Vacuum Circuit Breaker and additional insulation shrink-wrapped and protrudes from
the existing Sleeves, see image below
Heat Shrink-wrapped
Insulation over
Contact Arm
Figure 6 Shrink-wrapped contact Arms
6.4.2.2 All fixing screws used for mounting contact arms onto VI’s within a breaker have been
replaced with button head screws and covered using relevant size caps held in place by
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 20 of 53
non-conductive Loctite Sealant 5375. No gaps in insulation should be visible once all caps
and covers are fitted.
Screw Cover Cap
No visible gaps in
Insulation around
Nut Cap
Figure 7 Screw Caps on all Contact Mounting Bolts
6.4.3 1000 wide PV100 VCB Requirement
6.4.3.1 Both upper and lower contact arms are insulated using powder coat insulation Button head
screws are covered using relevant size caps hold in place with non-conductive Loctite
Sealant 5375. Once all caps are fitted no gaps in insulation should be visible
Screw Cover Cap
No visible gaps in the
Insulation around Nut
Cap
Figure 8 Screw Caps on all Contact Mounting Bolts
6.4.3.2 All fixing screws used within fixing of contact arms onto the VI’s have been replaced with
button head screws
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 21 of 53
6.4.3.3 Plastic upper pole mould barrier have been replaced by GP03 barrier firmly fixed in place
using non-conductive Loctite Sealant 5375 in order to ensure no gaps are present down
sides or between barrier and upper contact arms
Plastic Inserts have
been replaced by
GP03 Blocks
Figure 9 Standard Inserts replaced by GP03 Blocks
6.4.4 Tier Requirements
6.4.4.1
700 mm Wide Tier
The shutters including shutter mounting brackets are insulated. In addition, the upper shutter is fitted
with a polycarbonate sheet to the rear of the insulated shutter. Nut caps are also fitted to the Shutter
Mounting screws using Loctite 5375, see images below.
Figure 10 700 mm Wide Tier Shutters
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 22 of 53
6.4.4.2
1000 mm Wide Tier
The shutters including shutter mounting brackets are insulated. The upper shutter is fitted with an
additional polycarbonate plate to both the front and the rear. Nut caps are also fitted to the Shutter
Mounting screws using Loctite 5375, see images below.
Figure 11 1000 mm Wide Shutters
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 23 of 53
6.5 Mechanical Assembly
6.5.1 Site Requirements
Prior to installation at site, the switchroom must be completely finished, provided with lighting and site electricity
supply, lockable, dry and with facilities for ventilation. All the necessary preparations such as wall openings, ducts
etc. for routing of the power and control cables up to the switchboard must be complete.
6.5.2 Assembly of Cubicles
Ensure the cubicles are moved to the prepared installation location in the correct order. Movement can be
accomplished using floor rollers (max. diameter 12mm) between the unit base plate and the site floor. It is
advisable to start assembly in the middle of the switchboard for larger installations i.e. 10 cubicles and above.
The assembly procedure is as follows:






Refer to the General Assembly (GA) drawing for cubicle locations.
Open rear doors and remove vertical partitions from the rear of the busbar chamber.
Fit the neoprene gasket (supplied) to the left hand side of each cubicle (front and top).
Align the cubicles onto the foundations one at a time. Ensure each section is correctly positioned relative
to the neighbouring cubicle. Alignment of the front face of the switchboard is essential.
Fit sections in the order shown on the GA drawing and bolt together
When the switchboard has been correctly assembled, fasten the panels to the foundation fixings.
6.5.3 Cubicle Fixing Bolts
6.5.3.1
Standard: The bolts required for assembling the cubicles are Grade 8.8 and the sizes and lengths
are as detailed in the table below. These are supplied as loose items with each cubicle.
Connecting Cubicles
Description
Qty
Size
Length
Any cubicle to any cubicle
Front verticals
5
M8
35mm
VCB to VCB (any width)
Rear verticals
10
M8
45mm
VCB (any width) to VCU
Rear verticals
5
M8
45mm
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
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6.6 Assembly of Busbars
The procedure for installing the busbars on a panel by panel basis is as follows:
 Clean busbars with a dry, soft cloth and check for insulation damage. Remove all grease and adhesive dirt.
 Slide joint covers to the base of the post insulators to provide access.
 Fit busbars and packers as per contract specific assembly instructions, to the joint castings and riser
connections using fitting pins to provide support during assembly.
 Fit correct length bolts, plain and spring washers into all fixing positions, removing fitting pins to allow bolt
fitting. Do not tighten.
 Fully fit all busbars, packers and riser connections including joint plates to the switchboard prior to
tightening the fixing bolts to the specified torques. Please refer to Section 6.7 Torque Settings for details.
 When all joint bolts are tight, slide joint boxes along the post insulators to final position.
 Close joint boxes ensuring that joint plates correctly locate into the recess in the joint boxes.
 Riser and Busbar Joint Plates must be fitted on all Switchboards. Figure 12 below shows a typical
preparation of the joint box arrangement prior to closing.
Busbar Joint Plate
Riser Joint Plate
Figure 12 Locating of Riser and Busbar Joint Plates into cover slots prior to strapping


Joints at the ends of the busbar run are fitted with blank cover plates.
Fold outer covers into position and clip locating straps through holes in the fixed section and pull to lock in
position.
6.6.1.1 Busbar Fixing Bolts
All fixing bolts are 8.8 Grade, Metric Steel M10 Fixing Bolt Lengths (All dropper sizes)
Single Busbars
30mm
Double Busbars
Triple Busbars
Quadruple Busbars
40mm
50mm
60mm
For bolting together:
Quantity of bolts for 700 Wide Cubicle = 12
Quantity of bolts for 1000 Wide Cubicle = 24
Notes:


M10 plain and spring washer to be fitted under head of bolts into the joint casting.
M10 plain washer to be fitted under head of through bolls with M10 plain and spring washer under M10
full nut.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 25 of 53
6.6.1.2 Busbar Arrangements for Middle Tiers
When the tier is located in the middle of a switchboard, the busbars are arranged as detailed in the diagram below:
%XVEDU
5LVHU
%XVEDUV
5LVHUV
3RVW
,QVXODWRU
%XVEDUV
5LVHUV
%XVEDUV
5LVHUV
%XVEDUV
5LVHUV
%XVEDUV
5LVHUV
%XVEDU
5LVHU
Figure 13 Busbar Arrangement for Middle Tier (Side View)
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 26 of 53
6.6.1.3 Busbar Arrangements for End Tiers
When the tier is located at the end of a switchboard, the busbars are arranged as detailed in the diagram below:
%XVEDUV
5LVHUV
%XVEDU
5LVHU
%XVEDUV
5LVHUV
3RVW
,QVXODWRU
+DOI
3DFNHU
%XVEDUV
5LVHUV
%XVEDUV
5LVHUV
%XVEDUV
5LVHUV
%XVEDU
5LVHU
Figure 14 Busbar Arrangement for End Tier (Plan View)
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 27 of 53
6.6.2 Assembly of Arc Ventilation Plenum
Arc ventilation chambers (plenums) are required in order to comply with the Internal Arc Classification element of
the IEC 62271 specification. Each cubicle has an individual assembly fitted into adjacent chambers. Plenums are
fitted onto cubicle top covers. The assembly procedure is as follows:
 Fit neoprene gasket (supplied) to the plenum.
 Mount plenums from the left hand end of the switchboard (viewed from the front).
 Assemble the plenum. Note: on high current units the plenum fits over output thermal vents on the
cubicle roof.
 Work along the length of the switchboard from the left hand end ensuring that the plenums locate.
Note: Bus section plenums sometimes include dividers. Please check contract documentation and fit if
required.
 When all the plenums are fitted, fit covers to the ends.
 Connect exhaust vent to the appropriate section. See contract documentation for details.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.3
Page 28 of 53
6.7 Torque Settings
The information in contained in this section is as detailed in Torque Settings Technical Document STD/DOC/012.
Description
Torque Settings (Nm)
Interconnections Copper/Copper
M3
M4
M5
M6
M8
M10
M12
M16
M20
-
-
-
9
-
21
21
34
24
54
-
109
-
203
-
-
3.8
1.2
-
5.1
2.6
-
12.7
4.4
-
19.5
10.6
-
27
-
57
-
-
Flush Head Stud
0.74
1.7
3.5
5.9
14.2
-
-
-
-
Brass Bushings
-
-
-
-
-
24
37
-
-
-
-
-
-
-
-
28
-
-
ISO M8.8 Grade Zinc Plated Bolt or Set-Screw
-
-
-
-
-
-
31
76
-
Type 298 MV Switchgear
Type 439 LV Switchgear
-
-
-
-
24
-
-
45
-
-
ISO M8.8 Grade Zinc Plated Bolt or Set-Screw
Set-Screw into Brass Pillar
Interconnections Steel/Steel
Self Clinching Nuts (1)
Self Clinching Studs (1)
Welded Nut
Connections to Self-Clinching Studs (Previously PEM)
Connections to CT Bushings
Connection to ABB Surge Arrester (Aluminium)
ISO M8.8 Grade Zinc Plated Bolt or Set-Screw
Connection to ABB NTGU12A1 Capacitive Dividers
Lifting Beams
(1) Figures shown are 75% of manufacturers’ torque-out data
rd
(2) Torque Application to 3 Party products should be in line with the manufacturers’ installation instructions
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 29 of 53
Description
Type 439 LV Switchgear – Specific Torque Settings
Riser/Busbar Clamp Nut
Busbar Chamber Brass Pillar Nut
Riser Support Cap Head Screw and Nut
Outgoing Connections
Outgoing Socket Connections
Torque Settings (Nm)
M3
M4
M5
M6
M8
M10
M12
M16
M20
-
-
-
-
30
10
10
10
15
-
-
-
-
-
-
-
-
-
14
34
24
-
76
76
76
150
150
-
-
-
-
15
-
24
-
37
37
24
-
76
-
-
-
-
-
-
-
82
-
-
-
-
-
-
-
-
110
-
-
Type 298 MV Switchgear – Specific Torque Settings
Stand-off insulator to support plate
Brass casting to stand-off insulator
Copper Fixing into Stand-off Insulator
Type 298 PV100 MV Switchgear – Specific Torque Settings
Connection from Pole Moulding to Upper Contact
Upper Contact to Vacuum Interrupter Bottle
Insulated Push rod to Vacuum Interrupter Bottle
Guide Pin in the Cluster
Push Rod (L1, L2, L3) Locknut
Seismic Bolting Down of Type 298 MV Switchgear
ISO M8.8 Grade Zinc Plated Bolt or Set-Screw
Seismic Bolting Down of Type 439 LV Switchgear
ISO M12.9 Grade Zinc Plated Cap Head Bolt
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 30 of 53
6.8 Electrical Connections
6.8.1 Connection of Mains Power and Control Cables














Check the contract drawings for position, number, type and direction of access for power and control
cables.
Remove required gland plates, covers etc. and prepare for gland installation (glands may have been
ordered and supplied to contract).
Cut to length and strip power cables for attachment to gland.
Fit gland to cable and gland plate in accordance with gland manufacturer’s instructions.
Fit cable and gland plate assembly to the cubicle.
Prepare and secure the cable sealing ends in accordance with the manufacturer’s instructions.
Pass mains cable through CBCT (where one is fitted. Refer to contract documentation.). Ensure that
the earth screen from each core of the multi-core cable are connected together and passed back
through the CBCT and connected to the switchboard earth bar. See Figure 15 Earth Screen
Connection for details.
Connect the cable cores to the connection points on the end of the current transformer bushing,
ensuring that no undue stress is applied to the bushing.
Fit cable termination covers over the bushings, slot sub-cover in position and attach with rivet clips.
Connect cable earth.
Strip and fasten the control cables to the multi-core box gland plate with glands in accordance with
manufacturer’s instructions.
Fit cable and gland plate assembly to multi core box.
Terminate individual cores in compliance with the circuit diagram.
Make the control wiring connections to adjacent panels via bus wiring access holes in the instrument
chambers.
Figure 15 Earth Screen Connection
6.8.2 Earthing the Switchboard




Ensure the cable earth is connected.
Connect the main earthing bar of the switchgear to the prepared connection links, panel by panel.
Make the earth connection to the foundation frame or the raised false floor.
Connect the earthing conductor from the ground electrode, preferably via a metering point, to the main
earthing bar of the switchboard.
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6.9 Final Installation












Check the paintwork of the switchgear for any damage, and touch up where necessary.
Check bolted connections; especially all those made during on-site assembly in the busbar and
earthing systems, and tighten to the specified torque where necessary.
Carefully clean the switchgear.
Remove all foreign bodies from the switchgear panels.
Properly refit all covers etc., removed during installation and connection.
Fit unit end covers to switchboard end panels. Please ensure that all insulation barriers and additional
barriers for extended depth cubicles are fitted.
Ensure all external holes into the chambers are blanked off with the correct plugs, screws, covers etc.
Check the isolating contacts and interlock mechanisms for smooth operation.
Remove protective caps etc. from circuit breakers (refer to relevant circuit breaker manuals).
Insert the withdrawable elements/power modules into the switchgear and control gear panels, ensuring
that each one is placed in the correct location, according to its rating, and is in compliance with the
general arrangement layout drawing.
Close and lock all front and rear doors.
Carry out full mechanical interlock checks. Refer to Section 9.4 Electro-Mechanical Interlock Checks
for further details.
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Page 32 of 53
6.10 Extension Cubicles
Type 298 equipment is designed to allow extension cubicles to be fitted as required to either end of the
switchboard. The following procedure describes the work that needs to be carried out.















De-energise the busbars in full accordance with the site shutdown and permit to work requirements
Remove the panel end covers on the existing switchboard
If extending on the right hand end: Remove the busbar insulation barrier and replace with appropriate
half high or cut-out barrier.
If extending on the left hand end: Remove the busbar insulation barrier and dispose of as the
appropriate on is already fitted to the extension tier.
Move the extension cubicle(s) onto the prepared foundations in the order detailed on the revised
General Arrangement drawing. Movement can be accomplished using floor rollers (maximum diameter
12mm) between the cubicle base plate and the site floor.
Ensure each section is correctly positioned relative to the neighbouring cubicle. It is essential to ensure
correct alignment of the front face of the switchboard.
Bolt the cubicles together, noting that the insulation retaining strips are to be positioned between the
cubicles to provide partitioning between compartments.
Fasten the extension cubicle(s) to the foundation fixings.
Open the rear cable chamber door of the outer most cubicle on the originally installed Switchgear.
Remove the vertical bus bar chamber cover.
Remove the bolted end plate from within the bus bar chamber to expose the bus bar aperture into the
extension cubicle.
Fit the extension bus bars & busbar seals.
Re-fit the bolted end plate internally within the outer most bus bar chamber cubicle.
Replace all vertical bus bar chamber covers and close the rear cable chamber doors.
Re-fit the insulation barriers (if required) and end covers on the outer most cubicle ends.
Re-commission the bus bar system in accordance with Section 7 Pre-Commissioning of this manual.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
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7 Pre-Commissioning
7.1 Overview
For the purpose of this manual, the term “Pre-Commissioning” refers to the work that is carried out to ensure that
the equipment operates as per the contract requirements. This includes post-installation testing and the set-up of
equipment such as protection relays in order that they functionally operate as intended by the electrical schematics.
More detailed commissioning work that concerns the detailed operation of the plant is not covered by this
document
It is recommended that all pre-commissioning work is carried out by Powell UK personnel and also that Powell UK
personnel assist with the detailed commissioning work. Please contact the Site Services team for further
information regarding both pre-commissioning and commissioning personnel and site activities.
7.2 Pre-connection Checks
In preparation for pre-commissioning, the following work should be carried out prior to connection of the highvoltage power supply:
7.2.1 General and Visual Checks









Check the general condition of the switchgear for damage of any kind.
Remove all material residues, foreign bodies and tools from the switchgear.
Clean the switchgear, rubbing down insulating parts with a clean, soft, non-fraying dry cloth.
Remove greasy or adhesive dirt with a cloth dampened with a slightly alkaline household cleaner.
Wash off with clean water and dry carefully.
Perform a visual examination of the withdrawable elements, power modules, isolating contacts,
insulating parts etc.
For systems with a BIL of 95kV, check the correct fit and location of the additional parts required to
ensure compliance with the rated insulation level of switchgear panels, in line with the contract
documentation.
Visually check the connection of the main earthing bar to the station earthing conductor.
Check all busbar connections have been torqued to the correct level.
Check all busbar joints have been fitted with appropriate boots and shrouds.
7.2.2 Control Wiring Completion Checks


Carry out a point-to-point wiring check of the tier interconnection wiring.
Ensure all connections are tight and that the cable marker is visible.
7.2.3 Low Ohm (Ducter) Tests (Minimum 50A)



Perform a Low Ohm test through all closed and connected circuit breakers.
Perform a Low Ohm test through all closed and connected mechanically operated earth switches.
Perform a Low Ohm test through all busbars.
7.2.4 Primary Injection Tests
 Perform a primary injection test on the current transformers.
 Perform a primary injection test on the voltage transformers.
These tests are optional. Primary injection testing is carried out on all voltage and current transformers in the
factory and it is at the client’s discretion whether these tests should be carried out again on site.
7.2.5 Secondary Injection Tests


Perform a secondary injection test on all protection relays.
Perform a secondary injection test on all metering relays.
Note: Test voltage must match the system voltage
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7.2.6 Power Frequency Pressure (Flash) Tests




Perform flash test on all circuit breakers.
Perform flash test on all voltage transformers.
Perform flash test on all current transformers.
Perform flash test on switchboard.
7.2.7 Insulation Resistance Tests (Minimum 5kV)



Perform insulation resistance test on all circuit breakers.
Perform insulation resistance test on all voltage transformers.
Perform insulation resistance test on switchboard.
7.2.8 Electro-Mechanical and Functional Checks




Turn on the auxiliary and control voltage.
Carry out test operations of switching devices manually or by electrical control, and simultaneously
observe the relevant position indicators.
Check mechanical and electrical interlocks for effectiveness, without using force. Please refer to
Section 9.4 Electro-Mechanical Interlock Checks for further details.
Set the protective devices in the switchboard to the required values and check their function with test
equipment.
7.2.9 Protection Relays



Configure protection settings in protection relays
Configure control and functional settings in protection relays
Configure communications settings in protection relays if required.
7.2.10 Final Checks
Following completion of checks and tests, ensure that:
 All test equipment and tools are removed from the switchroom or sub-station.
 All temporary connections are removed and permanent connections are reinstated.
 All covers removed to facilitate testing are reinstated.
 All test results are documented on appropriate test sheets.
7.3 Energisation
The following procedure describes the connection of the switchboard to the 3 phase mains power. Please note
that this activity is normally undertaken by the client with the assistance and supervision of our Site Services
Personnel. The following description serves only to provide an idea of what is required and a detailed procedure
provided by the client will take precedence over this.
 Ensure that the circuit breakers in the switchboard are in the OFF position.
 Remove any existing earthing and short circuiting connections in the critical switching area.
 Energise the feed cables.
 Connect the switchgear step-by-step, observing the signals and indicators.
 Check the conductors are in phase as far as necessary when several incoming feeder cables and
switchgear sections are connected.
 Carry out all measurements and check all functions dependent on the high-voltage power supply being
connected.
 Pay careful attention to irregularities of any kind.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 35 of 53
7.4 Standard Tools
Standard tools that are supplied on each contract are as detailed below. Please refer to contract documentation for
any other special tools that may be supplied.
 VCB Service Trolley
 VCB Racking Handle
 Door Handle/Rear Cover Handle
 Earth Switch Handle
 Busbar Earth Truck Extension Rod
 VT Ramp
 Manual Charging Handle
7.5 Special Tools
Special tools that can be supplied if a requirement of the contract are detailed as below. Please refer to contract
documentation for details.
 Maintenance Cradle
 Test plugs & links
 VCB test umbilical
 Earth Truck Operating Handle
7.6 Loose Items
Loose items that are supplied on each contract are as detailed below. Please refer to contract documentation for
any other loose items that may be supplied.
 Cubicle Fixing Bolts
 Busbar Fixing Bolts
 Neoprene gasket
7.7 Lubricants and Cleaning Agents
Contact Lubricant -
Contact Treatment Grease (For VT Contacts)
RS Components Ltd – Part No 503-335
Mobile Grease 28 (For Breaker Primary Contacts)
Mechanical Lubricant - Rocol MTS 1000 (For Tier)
RS Components Ltd – Part No. 691-397
Rheolube 368A (For Breaker)
Contact Cleaner -
Electrical Cleaner
RS Components Ltd – Part No 203-0750
Insulation Cleaner -
Electro Mech.
RS Components Ltd – Part No 268-2115
If RS Components Ltd products are not available locally, please contact Powell UK for an approved equivalent
supplier.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 36 of 53
8 Operation of the VCB Cubicle
8.1 Insertion and Withdrawal of the Circuit Breaker
ŽŶƚƌŽůtŝƌŝŶŐ
WůƵŐ
ŝƌĐƵŝƚƌĞĂŬĞƌ
^ŚƵƚƚĞƌKƉĞŶŝŶŐ
ƌĂĐŬĞƚ
ŶƚŝZŽůůͲŽƵƚ
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dƌŽůůĞLJ,ĞŝŐŚƚ
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^ĞƌǀŝĐĞdƌŽůůĞLJ
>ĞǀĞƌ
tŚĞĞůƐ
Figure 16 Circuit Breaker Operation
8.1.1 Insertion
The circuit breaker is inserted into the switchgear cubicle with the use of a service trolley (a service trolley is
provided for each cubicle width). The procedure for inserting the circuit breaker is as follows:
 Unlock and open the compartment door.
 Position the service trolley (with the breaker on) at the correct height facing the panel front. The height of
the trolley may need some adjustment and this can be done by winding the trolley adjusters up or down the
threaded bar as required.
 Move the trolley up to the cubicle and ensure that it automatically latches to the cubicle such that it can’t be
moved away.
 Operate the anti-rollout lever to release the breaker from the trolley.
 Move the breaker forwards until it is fully inside the cubicle and the anti-rollout lever has latched onto the
anti-rollout bracket on the compartment mid pan.
 The breaker is now inserted into the compartment and is in the “Test/Isolated” position.
 Remove the breaker control wiring plug (secondary disconnect) from the storage position on the breaker
and connect it to the socket on the top of the compartment above the breaker.
 Detach the trolley from the cubicle by moving the lever on the trolley (at the front and underneath the bench
top) to the right and pulling the trolley away.
 Close and lock the compartment door. The breaker can now be racked into the “In Service” position using
the provided racking handle assuming all other interlocks will allow it.
 Fit the racking handle to the hexagonal spigot of the racking mechanism through the access hole in the
compartment door.
 Turn the handle clockwise until the stop is reached. It will take approximately 20 turns to achieve this.
NOTE: The circuit breaker must not be stopped at any position in the travel range between the “Isolated”
position and the “In Service” position.
 Remove the racking handle.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 37 of 53
8.1.2 Withdrawal
The circuit breaker is removed from the switchgear cubicle with the use of a service trolley (a service trolley is
provided for each cubicle width). The procedure for withdrawal of the circuit breaker is as follows:
 Ensure that the circuit breaker is open.
 Fit the racking handle to the hexagonal spigot of the racking mechanism through the access hole in the
compartment door.
 Turn the handle anti-clockwise until the stop is reached. It will take approximately 20 turns to achieve this.
NOTE: The circuit breaker must not be stopped at any position in the travel range between the “In Service”
position and the “Isolated” position.
 Unlock and open the compartment door ensuring that the door retaining catch is disengaged before
opening.
 Disconnect the breaker control wiring plug (secondary disconnect) from the socket on the top of the
compartment above the breaker and attach it to the storage position on the breaker.
 Position the service trolley at the correct height facing the panel front. The height of the trolley may need
some adjustment and this can be done by winding the trolley adjusters up or down the threaded bar as
required.
 Move the trolley up to the cubicle and ensure that it automatically latches to the cubicle such that it can’t be
moved away.
 Operate the anti-rollout lever to release the breaker from the cubicle.
 Move the breaker backwards until it is completely on the service trolley and the anti-rollout lever latches on
the trolley.
 Detach the trolley from the cubicle by moving the lever on the trolley (at the front and underneath the bench
top) to the right and pulling the trolley away.
 The breaker is now completely removed from the compartment.
8.2 Test/Isolated Position
This is the position in which the breaker can be operated without actually energising the bus and is used for testing
and commissioning purposes. When in the “In Service” position, the breaker will operate and energise/de-energise
the bus.
When in this position it is possible to open the compartment door and manually open and close the breaker using
the Close/Trip button and to manually charge the breaker using the handle provided. A remote Open and Close (if
configured) will also operate the breaker in this position. For commissioning purposes a temporary supply will be
used to allow closure of the VCB to be tested.
This is the position from which it is also possible to completely remove the breaker from the cubicle.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 38 of 53
8.3 Interlocks
A series of mechanical and electro-mechanical interlocks are provided to prevent mal operation of the breaker that
could result in damage to the equipment or be dangerous to the operating personnel. These are as follows:
 General Interlocks
 Key Interlocks
8.3.1 General Interlocks
These are a series of mechanical interlocks that are provided as standard to:
 Ensure that the compartment door can only be opened when the breaker is in the “Test/Isolated Position”
or completely removed from the cubicle.
 Prevent the breaker being racked into the “In Service” position with the door open.
 Prevent the breaker from being operated when the door is open unless it has been racked into the
“Test/Isolated Position”.
 Ensure that the breaker cannot be closed unless it is racked into either the “Test/Isolated” or “In Service”
position.
 Ensure that the earthing switch cannot be closed when the breaker is in the “In Service” position.
There is also a series of mechanical interlocks that are provided via the Interlock Box (located under the VCB door)
and these are detailed below:
Figure 17 Interlock Box



Prevent breaker from being racked from the “Test/Isolated position to the “In Service” position.
Ensure that the breaker cannot be racked to the “In Service” position when the earthing switch is closed.
Prevent access to the earthing switch operating mechanism. This is done by blocking off the access hole
for the earth switch handle (see Figure 17 Interlock Box) using the padlock knob or key switch. Please
note that this is entirely operator-driven and is controlled only by turning the padlock knob or key switch
and padlocking it in the required position.
The following procedure details how to rack the breaker in and out of service.
 Ensure the breaker is in the “Test/Isolated” position or is completely removed from the cubicle.
 Full depress push rod.
 Turn the key or wing knob (depending what has been ordered on the contract)
 Remove key (if supplied).
 It is now not possible to rack the breaker to the “In Service” Position.
Please refer to the following section for further details regarding key interlocks
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 39 of 53
8.3.2 Key Interlocks
If required, a key interlocking system can be provided. This inhibits busbar earthing unless all incoming sources
are isolated. This section details some of the options in terms of operation but please refer to contract
documentation for exact details of the operation of this system.
A series of keys can be used to prevent actions being undertaken unless certain other conditions have first been
met. An example of this is busbar earthing. For example, in order to earth Bus A, Incomer A and the Bus Tie must
be racked out and the racking interlock applied. This ensures that the busbar earth switch cannot be racked onto a
live bus. This frees those 2 keys which then go onto an exchange box to release the busbar earth racking interlock
key.
Key Free Off
If a key free off system is selected, it means that access to the circuit earth switch is normally blocked. The key for
this is held elsewhere (usually upstream). When the upstream breaker has been isolated then the key can be
removed and placed in the interlock box. This in turn allows access to the key for the circuit earth switch and traps
the key from the upstream breaker, thus preventing it from being re-energised.
Key Free On
If a key free on system is selected, it means that the key which is normally trapped can only be removed when the
circuit earth switch is applied. Once applied, the key can then be removed and taken to a downstream breaker (as
detailed in the Key Free Off description above) or a transformer house.
8.4 Operating Mechanism
The circuit breaker is fitted with a spring charging handle and open/close buttons on the front of the breaker.
These can only be operated with the door open, which means that the breaker must be in the “Test/Isolated”
position. A mechanical “push to trip” button can be fitted to the door if required to allow a local “Trip” command in
the “In Service” position.
Once the breaker is closed, the spring discharges and needs to be re-charged before another close operation can
be actioned. This is achieved via a motor charged spring charging mechanism which is fitted to the circuit breaker
to enable the spring to automatically recharge following a close operation. This can also be done manually using
the charging handle on the front of the breaker when the breaker is in the “Test/Isolated” position. Mechanical
indicators show “Spring Charged” or “Spring Discharged” status.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 40 of 53
8.5 Earthing Switch
The circuit earthing switch is located in the cable chamber has an independent manual closing mechanism which is
operated using the earth switch handle via the access hole in the interlock box on the front of the cubicle (refer to
Figure 17 Interlock Box). There is a user-operated mechanical interlock on the interlock box that blocks off the
access hole when the padlockable knob is turned. This prevents the earth switch handle from being inserted and
would be mainly used when the breaker is in the “Test/Isolated” position or completely removed from the cubicle.
An automatic mechanical interlock ensures that the earthing switch cannot be operated when the breaker is in the
“In Service” position.
DĞĐŚĂŶŝĐĂů
WŽƐŝƚŝŽŶ/ŶĚŝĐĂƚŽƌ
ĂƌƚŚŝŶŐ^ǁŝƚĐŚ
,ĂŶĚůĞ
/ŶƚĞƌůŽĐŬŽdž
Figure 18 Earthing Switch Operation
The procedure for closing the earthing switch is as follows:
 Ensure the breaker is in the “Test/Isolated” position or completely removed from the cubicle.
 Ensure the door is closed.
 Ensure the padlock has been removed from the padlockable knob and turned such that the access hole is
clear.
 Insert earthing switch handle such that it engages with the hexagonal shaft of the switch itself.

Turn the handle anti-clockwise through approximately 180° until the stop is reached. Complete the
operation in one smooth action.
 Observe the position of the switch via the mechanical position indicator. This should be red to indicate that
the switch is closed. Ensure that the position indicator does indicate that the switch is closed.
 Remove the handle from the access hole.
The procedure for opening the earthing switch is as follows:
 Observe the position of the switch via the mechanical position indicator. This should be red to indicate that
the switch is closed.

Turn the handle clockwise through approximately 180° until the stop is reached. Complete the operation in
one smooth action.
 Observe the position of the switch via the mechanical position indicator. This should be yellow to indicate
that the switch is open.
 Remove earthing switch handle.
 Operate padlockable knob such that the access hole is blocked off and put padlock on.
 The breaker is now available to be returned to the “In Service” position.
Please note that this applies to the earthing of this circuit only. For busbar earthing, please refer to Section 8.8
Busbar Earthing Truck.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 41 of 53
8.6 Shutters
Figure 19 Shutters
Shutters are provided to shroud the primary contacts when the breaker is in the “Test/Isolated” position or
completely removed from the cubicle. These shutters are automatically operated via the shutter operating
mechanism as the breaker is racked in and out. The details of this are as follows:

As the breaker is racked from the “Test/Isolated” position to the “In Service” position, the shutter drive
bracket on the circuit breaker (see Figure 16 Circuit Breaker Operation) makes contact with the shutter
operating mechanism, which in turn opens the shutters and allows the breaker to be connected to the
busbars.

As the breaker is racked from the “In Service” position to the “Test/Isolated” position, the shutters close
thus preventing access to the primary contacts.

With the breaker completely removed from the cubicle it is possible to padlock the shutter operating
mechanism to prevent accidental operation of the shutters during maintenance of the circuit breaker
compartment. Please note that the bottom padlock position is used to lock the top shutter and the top
padlock position is used to lock the bottom shutter.
Figure 20 Shutter Operating Mechanism
Note:
The shutter colours (as depicted in Figure 19 Shutters) relate to a bus tie. The bottom shutter on an
incomer/feeder is yellow and where a tier is a designated busbar earthing tier, there is only a single red shutter.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 42 of 53
8.6.1 Maintenance Cradle
^ŚƵƚƚĞƌƐ
ĚũƵƐƚĂďůĞ
^ŚƵƚƚĞƌKƉĞŶŝŶŐ
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DĂŝŶƚĞŶĂŶĐĞ
ƌĂĚůĞ
dŽƉ^ŚƵƚƚĞƌ
KƉĞƌĂƚŝŶŐ
DĞĐŚĂŶŝƐŵ
'ƵŝĚĞ
ZĂŝůƐ
Figure 21 Maintenance Cradle
Where access to the spout bushings is required for maintenance purposes, it is possible to operate the shutter
operating mechanism via a maintenance cradle. This is inserted into the compartment in the same way as the
circuit breaker, but because it is only a base frame construction, access can still be gained to the compartment and
thus the shutters and primary contacts.
The maintenance cradle can operate only one shutter at a time and the height of the shutter drive bracket on the
cradle determines which shutter is opened. This height is altered by turning the opening bracket round prior to
inserting it into the compartment.
When the maintenance work is complete and the maintenance cradle is removed and the compartment is ready for
normal use with a circuit breaker.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 43 of 53
8.7 Voltage Transformer
Figure 22 Voltage Transformer
The Voltage Transformer (VT) is a 3 phase, cradle mounted, cast resin withdrawable element.
8.7.1 Insertion
The procedure for inserting the VT into the compartment is as follows:
 Unlock and open the compartment door.
 Wheel the VT into the compartment using the ramp provided, such that it connects in the “Isolated”
position.
 Close and lock the compartment door
 Fit the racking handle to the hexagonal spigot of the racking mechanism through the access hole in the
compartment door.
 Turn the handle clockwise until the stop is reached. It will take approximately 20 turns to achieve this.
NOTE: The VT must not be stopped at any position in the travel range between the “Isolated” position and
the “In Service” position.
 Remove the racking handle.
 The VT is now in the “In Service” position and is connected to the system.
8.7.2 Withdrawal
The procedure for withdrawing the VT from the compartment is as follows:
 Fit the racking handle to the hexagonal spigot of the racking mechanism through the access hole in the
compartment door.
 Turn the handle anti-clockwise until the stop is reached. It will take approximately 20 turns to achieve this.
NOTE: The VT must not be stopped at any position in the travel range between the “In Service” position
and the “Isolated” position.
 The VT is now in the “Isolated” position and ready to be removed from the compartment if required.
 Remove the racking handle.
 Unlock and open the compartment door.
 Wheel the VT from the compartment using the ramp provided.
 Close and lock the compartment door.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 44 of 53
8.8 Busbar Earthing Truck
The busbar earthing truck is 3 phase, cradle mounted and withdrawable. These trucks can be accommodated in
the incomer and bus tie sections in place of the circuit breakers or in designated earthing cubicles.
8.8.1 Insertion
The busbar earthing truck is inserted into the switchgear cubicle with the use of a service trolley (a service trolley is
provided for each cubicle width). The procedure for inserting the earthing truck into the compartment is as follows:
 If an incomer or bus section is to be used, ensure the breaker has been removed. (See Section 8.1
Insertion and Withdrawal of the Circuit Breaker for further details).
 Unlock and open the compartment door
 Position the service trolley (with the earth truck on) at the correct height facing the panel front. The height
of the trolley may need some adjustment and this can be done by winding the trolley adjusters up or down
the threaded bar as required.
 Move the service trolley up to the cubicle and ensure that it automatically latches to the cubicle such that it
can’t be moved away.
 Operate the anti-rollout lever to release the earth truck from the trolley.
 Move the earth truck forwards until it is fully inside the cubicle and the anti-rollout lever has latched onto the
anti-rollout bracket on the compartment mid pan.
 The earth truck is now inserted into the compartment and is in the “Isolated” position.
 Detach the trolley from the cubicle by moving the lever on the trolley (at the front and underneath the bench
top) to the right and pulling the trolley away.
 Close and lock the compartment door.
 Fit the racking handle to the hexagonal spigot of the racking mechanism through the access hole in the
compartment door.
 Turn the handle clockwise until the stop is reached. It will take approximately 20 turns to achieve this.
NOTE: The earth switch must not be stopped at any position in the travel range between the “Isolated”
position and the “In Service” position.
 Remove the racking handle.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 45 of 53
8.8.2 Withdrawal
The earth switch is removed from the switchgear cubicle with the use of a busbar earthing truck. The procedure for
withdrawal the earth switch is as follows:
 Fit the racking handle to the hexagonal spigot of the racking mechanism through the access hole in the
compartment door.
 Turn the handle anti-clockwise until the stop is reached. It will take approximately 20 turns to achieve this.
NOTE: The earth switch must not be stopped at any position in the travel range between the “In Service”
position and the “Isolated” position.
 Open the door.
 Position the earthing truck at the correct height facing the panel front. The height of the trolley may need
some adjustment and this can be done by winding the trolley adjusters up or down the threaded bar as
required.
 Move the truck up to the cubicle and ensure that it automatically latches to the cubicle such that it can’t be
moved away.
 Operate the anti-rollout lever to release the earth truck from the trolley.
 Move the earth truck forwards until it is fully inside the cubicle and the anti-rollout lever has latched onto the
anti-rollout bracket on the compartment mid pan.
 Detach the truck from the cubicle by moving the lever on the truck (at the front and underneath the bench
top) to the right and pulling the truck away.
 The earth switch is now completely removed from the compartment and the circuit breaker can be inserted.
(See Section 8.1 Insertion and Withdrawal of the Circuit Breaker for further details).
8.8.3 Operation












If the busbar earthing truck is used in a circuit breaker cubicle, ensure that the circuit breaker has been
removed from the cubicle.
Insert the earth truck into the cubicle.
Close and lock the cubicle door.
Ensure that all interlocks have been safely removed and rack earth truck into the “In Service” position.
Take the handle used for operating the circuit earthing switch and fit the extension handle provided.
Turn wing knob on the circuit breaker door to open the earthing switch handle access hole.
Insert earthing switch handle such that it engages with the hexagonal shaft of the switch itself.
Turn the handle clockwise through approximately 180° until the stop is reached in order to closed the
switch.
Observe the position of the switch via the mechanical position indicator through the window in the door.
This should be red to indicate that the switch is closed.
To open the earth switch, turn the handle anti- clockwise through approximately 180° until the stop is
reached.
Remove the operating handle.
Turn wing knob to close access hole.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
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9 Maintenance
9.1 Overview
Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of the
switchgear. It is recommended that routine maintenance be carried out at regular intervals in order to reduce the
number of repairs and the unplanned shutdown time. The Planned Preventative Maintenance (PPM) intervals are
as follows and comprise the activities detailed below:
1. 6 month period – Inspection
2. 12 month period – Inspection and service
3. 2-5 year period – Inspection, service and full test
4. Repairs to be carried out as required during inspection and servicing.
Maintenance work may only be performed by trained personnel familiar with the characteristics of the individual
switchgear, in accordance with all relevant safety regulations and with other overriding instructions. It is
recommended that Powell UK service personnel carry out any servicing and repair work. Please contact the Site
Services team for further information regarding maintenance personnel and activities.
9.2 Inspection and Servicing
The inspection and servicing intervals for some of the equipment/components (e.g. parts subject to wear) are
determined by fixed criteria such as switching frequency, length of service and number of short-circuit breaking
operations. For other parts, the length of the intervals may vary, depending on the different modes of operation, the
degree of loading, and also environmental influences (including humidity, extreme cold, pollution and aggressive
air).
In addition to this document, it may be necessary to refer to the operating instructions for the individual
components, such as:
 Circuit Breaker
 Earthing Switch
 Voltage Transformer
 Low Voltage Equipment
9.2.1 Inspection
The inspection should include but not be limited to the following:
 Isolate the area where work is to be performed in accordance with the relevant safety regulations, to
IEC/HSE and other authorities, and secure it against reconnection.
 Check the installation for abnormalities of any kind, dirt and the effects of other environmental
influences.
 Check the function of the switching devices and the controls, interlocks, protection, annunciation and
other devices.
 Check the surface condition of the isolating contact system (the shutters can be opened and secured
with the shutter operating mechanism for visual examination of the fixed contacts with the breaker
removed). If the silver plating on the contact parts is worn to such an extent that the copper conductor
material below becomes visible, or if their surfaces are corroded, or shown signs of other damage, or
overheating (discoloured surface), contact the Site Services Team.
 Where thermographic windows are fitted, check busbar connections for hotspots. If any are found,
contact the Site Services Team.
 Check all switchgear accessories and the auxiliary equipment (e.g. storage batteries, operating
handles, service trolleys, shutter operating devices etc.).
 Check there is no external discharge on the surfaces of equipment at operating voltage. This can be
detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing in the dark.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 47 of 53
9.2.2 Servicing
Basic servicing activities, and those which may be found necessary during inspections, include the following:
 Carefully clean the unit (in particular the insulating material surfaces) when they are found to be dirty as
contamination may be caused by salt, mould formations, insects or conductive materials in conjunction
with frequent condensation when the switchgear is operated in a tropical climate. Remove dry dust
deposits which do not adhere strongly using a soft dry cloth. Remove more strongly adhering, e.g.
sticky/greasy dirt, with a cloth dampened in a slightly alkaline household cleaner. Wash off with clear
water and dry carefully.
 Use halogen-free cleaner Electro Mech (268-2115) for insulating material components and for major
contamination. Do not use 1.1.1-trichloroethane, trichloroethylene or carbon tetrachloride, etc.!
 Should there be evidence of external discharges occurring as a result of condensation, clean the area
thoroughly as above and apply a thin silicone film on the surface concerned as a temporary remedy.
Please contact the Site Services team to discuss a permanent solution to this problem.
 Check that the bolt connections at the contact points in the busbar system and the earth connections
are tight. For the torque settings refer to Section 6.7 Torque Settings.
 Thoroughly clean all contacts using electrical cleaner (203-0750) and re-grease using contact treatment
grease (505-335). Ensure the isolating contact system functions correctly.
 Re-grease the mechanism of the breaker insertion system as necessary, or, when lubrication is
inadequate or missing, thoroughly clean the areas concerned and re-grease with Rocol MTS 1000 (691397)
 Top up the grease on all sliding and bearing surfaces in the panels. For example; the shutters, the
interlock and guide systems, the spindle mechanism and the circuit breaker wheels. Where necessary
thoroughly clean and re-grease with Rocol MTS 1000 (691-397).
 Observe the maintenance instructions in the manuals for the individual circuit breaker and switch
elements.
Note:
In installation areas prone to problems caused by airborne silicone agents, insulation components can be cleaned
and sealed using a mixture of one part white spirit to one part transformer oil sparingly applied to insulation
surfaces.
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
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9.3 Repairs
This section describes the minimum repairs that are likely to be carried out.
9.3.1 Cubicles
Repair work on cubicles must be carried out immediately after a defect has been discovered. The following
procedures describe how to repair:
1) Painted Surfaces
Lightly grind the surrounding paint coat and carefully degrease the entire area. Then immediately apply an antirust primer and, after an appropriate hardening time, apply the top coat. The total dry film thickness should be
approximately 60 microns. Only use suitable and compatible paint products.
The top coat should be in the relevant contract specific colour.
2) Coated Steel Surfaces
Lightly grind the surrounding coated area and carefully degrease the entire area. Immediately apply a coat of
aerosol zinc plate.
3) Mechanical Plated Parts
Remove any rust deposits from zinc plated or tuftrided mechanism parts with a wire brush. Clean loose parts with a
clean dry cloth and degrease where appropriate. Re-grease linkages and bare surfaces with Rocol MTS 1000
(691-397).
9.3.2 Replacement of VT Primary Fuses
The primary fuses are located within the contact arms and the procedure for replacing them is as follows:
 Unlock and open VT compartment door.
 Withdraw the VT from the compartment. (See Section 8.7 Voltage Transformer for further details.)
 Remove the contact shroud and moving contact revealing the primary fuse.
 Pull the primary fuse from the contact arm and remove the rubber centralisation bung.
 Fit rubber centralisation bung to the new fuse, replace the primary fuse and refit the contact shroud
assembly ensuring that the contacts are horizontal and that the fixing screws are tight.
 The VT may be fitted with either secondary fuses or MCBs depending upon contract requirements.
These will be located in the LV compartment. Reset or replace as necessary.
Note: For further protection of the system, additional secondary fuses or MCB s may be fitted within the LV
chamber. Check before re-energising the VT.
9.4 Electro-Mechanical Interlock Checks
Before the cubicle can be put back into service, the interlock functions must be tested as follows:
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
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9.4.1 Circuit Breaker
It should only be possible to rack the breaker from the “Test/Isolated” position to the “In Service” position when the
circuit breaker is open and the earthing switch is open. This is tested as follows:
 With the circuit breaker closed, rack the breaker towards the “In Service” position. This should be
blocked after half a clockwise turn of the handle.
 With the earthing switch closed, rack the breaker towards the “In Service” position. This should be
blocked after only two clockwise turns of the handle.
It should only be possible to rack the breaker from the “In Service” position to the “Test/Isolated” position with the
circuit breaker open. This is tested as follows:
 With the circuit breaker closed, withdraw the breaker. This should be blocked after half an anticlockwise turn of the handle.
It should only be possible to close the circuit breaker when in the “Test/Isolated” position or in the “In Service”
position. This is tested as follows:
 Attempt to close the breaker in between the two positions. This should not be possible.
Ensure that it is possible to open and close the breaker in the “Test/Isolated” position and the “In
Service” position.
When the breaker is closed in either the “In Service” or “Test/Isolated position and the control voltage has failed; it
should only be possible to trip the circuit breaker manually. This is tested as follows:
 Attempt to close the breaker. This should not be possible.
 Attempt to trip the breaker. The breaker should open.
9.4.2 Circuit Earthing Switch
Operation of the circuit earthing switch must only be possible when the circuit breaker is in the “Test/Isolated”
position or completely removed from the cubicle (subject to any additional electromagnetic solenoid interlocks fitted
to meet contract requirements). Check these conditions as follows:
 When the circuit breaker is in the “Test/Isolated” position and is being racked to the “In Service”
position, the earthing switch access hole must be blocked after only 1 ½ clockwise turns of the handle.
 When the circuit breaker is in the “Test/Isolated” position or completely removed from the cubicle, it
should be possible to insert the earth switch operating handle through the access hole and onto the
hexagonal shaft of the earth switch.
 It should now not be possible to rack the breaker into the “In Service” position and this action should be
blocked after only two clockwise turns of the handle.
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Appendix 1: Abbreviations/Glossary of Terms
Abbreviation
ACH
BES
BIL
CB
CT
EDPM
ES
HDHC
HV
IAC
IR
LV
MCB
MV
VC
VCB
VT
Full Description
Anti-Condensation Heater
Busbar Earthing Switch
Basic Impulse Insulation Level
Circuit Breaker
Current Transformer
Ethylene Propylene Diene Monomer (M-class rubber)
Earthing Switch
Hard Drawn High Conductivity
High Voltage
Internal Arc Containment
Insulation Resistance
Low Voltage
Miniature Circuit Breaker
Medium Voltage
Vacuum Contactor
Vacuum Circuit Breaker
Voltage Transformer
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
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Appendix 2: Related Documents
Document Reference
STD/CUS/003
STD/CUS/007
STD/CUS/008
STD/CUS/009
STD/CUS/015
STD/DOC/012
STD/CUS/031
Document Title
Shipping, receiving, handling and storage procedure
Export Packing Specification
Packing/Unpacking Specification
Lifting Procedure
Current Transformer
Torque Settings
100
MV298 PowlVac TM Circuit Breaker
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Document
Origin
Powell UK
Powell UK
Powell UK
Powell UK
Powell UK
Powell UK
Powell UK
Page 52 of 53
TYPE 298 PV100 Cubicle User Guide Doc Rev 2.2
Page 53 of 53
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