40.5kv instruction manual

SecoGear/SecoVac Instruction manual

GE/SecoGear_40.5/IM/2008/001 of 36

40.5kV Instruction Manual



Stakeholders safety first – “Always, forever”!

Important recommendations to begin with focusing on safety:

Installation of switchgear and/or switchboards must be ensured inside closed rooms suitable for electrical equipment as specified by manufacturer Installation, operation and maintenance are allowed to be carried out by certified persons only Complete compliance with the applicable standards (e.g. IEC), connection rules of the relevant utility

and applicable safety laws at installation site needs to be ensured All actions on switchgear needs to be carried inline with instructions in this manual Danger!

Stay alert for activities for which hazard notes are marked in this manual with warning symbol shown above.

Ensure that the specification limits are not exceeded for switchgear normal operating conditions All the personnel involved in installation, operation and maintenance needs to have access for the

latest manual copy Matters affecting safety at installation site needs to be handled responsibly by the user’s personnel

WARNING

Follow the installation manual and respect the safety rules and advised practices! Operating

voltage can result in electrical shocks and burns.

Ensure power is disconnected, ground and short-circuited before proceeding for any work!

For any further questions about this instruction manual, the team members of our field organization will be pleased to update you with the required information.

All installations and foundation plans can be customer specific. Please contact the manufacturer to understand the different options available. Drawings can be provided at the time of the approval.

We reserve all rights to this publication. Wrong use and but not limited to duplication and making this manual –fully or in parts thereof available to third parties is prohibited. We do not accept any responsibility for the information provided, which is subject to alternation.


of 36 GE/SecoGear_40.5/IM/2007/001

Contents

1 General................................................................................................................................................................................................................... 4

1.1 Summary ................................................................................................................................................................................................... 4

1.2 Standard and specification............................................................................................................................................................. 4

1.3 Operating conditions ............................................................................................................................................................................ 4

1.4 Safety and environment protection requirement ............................................................................................................. 6

Panels with basic packing; .................................................................................................................................................................................... 7

Panels without packing;.......................................................................................................................................................................................... 7

2 Technical Specification .................................................................................................................................................................................. 9

2.1 Table 1-Technical specification for SecoGear.......................................................................................................................... 9

2.2 Table 2: - Technical specification for SecoVac (Circuit breaker) ............................................................................... 9

2.3 Table 3-Main circuit resistance of SecoVac 40.5kV....................................................................................................... 10

3 Enclosure design and equipment .......................................................................................................................................................... 10

3.1 Typical modules (Figures 3/1 to 3/2) ...................................................................................................................................... 10

3.2 Enclosure and partitioning (Figure 3/1) ................................................................................................................................ 10

3.3 Switchgear structure ......................................................................................................................................................................... 12

3.4 Cable compartment (Figure 3/1 and 3/5)................................................................................................................................ 14

3.5 Breaker compartment....................................................................................................................................................................... 15

3.6 Main busbar compartment.......................................................................................................................................................... 15

3.7 Instrument compartment ............................................................................................................................................................. 16

3.8 VCB truck................................................................................................................................................................................................. 16

3.9 Hydraulic lifter ..................................................................................................................................................................................... 17

4 Operations and trouble shooting........................................................................................................................................................... 18

4.1 Closed door racking out of SecoVac from Service position to test or withdrawn position................... 18

4.2 Rack in of the circuit breaker from withdrawn position to service position................................................... 20

4.3 Diagnosis and trouble shooting for malfunctioning during operations ........................................................... 21

5 Installation......................................................................................................................................................................................................... 21

5.1 Handling and storage ..................................................................................................................................................................... 21

5.2 Installation.............................................................................................................................................................................................. 24

5.3 Busbar connection ............................................................................................................................................................................ 26

5.4 Connection of earthing busbar ................................................................................................................................................. 28

5.5 Connection of control cables......................................................................................................................................................... 28

5.6 Connection of power cable.......................................................................................................................................................... 28

5.7 Check after mounting ..................................................................................................................................................................... 29

6 Maintenance item and cycle ................................................................................................................................................................... 29

6.1 Routine Inspection............................................................................................................................................................................. 29

6.2 Routine maintenance...................................................................................................................................................................... 30

6.3 Minor repairs......................................................................................................................................................................................... 31

6.4 Items for verification........................................................................................................................................................................ 31

6.5 Performance test ............................................................................................................................................................................... 32

7 Major Repairs ................................................................................................................................................................................................... 32

8 Spare parts........................................................................................................................................................................................................ 33

Appendix A - Onsite service safety instruction......................................................................................................................................... 35



1 General

1.1 Summary

This publication contains the information required for installation, commissioning, operation and maintenance of

SecoGear, an air-insulated switchgear.

SecoGear is three-phase, metal enclosed, air-insulated factory assembled switchgear. SecoGear is type-

tested and suitable for indoor applications up to 40.5 kV. The units are designed with withdrawable modules

and are fitted with a single busbar system. The withdrawable parts are equipped with either circuit breakers

(SecoVac) or voltage transformers..

Details of the technical design and configuration of individual switchgears, such as the technical data, detailed

equipment lists for the individual panels and comprehensive circuit documentation etc, can be found in the

relevant order documents.

For correct usage of the product, please read this manual carefully. It is always advisable to use the manual

for all operations regarding installation, commissioning, operation and maintenance of SecoGear air-

insulated switchgear.

This instruction is also used as references for personnel to carry on regularly maintenance

for switchgear.

1.2 Standard and specification

SecoGear comply with the standards and specifications for factory-assembled, metal enclosed and type tested high

voltage switchgears to IEC publications as given below.

IEC62271-100: 2006 …………… High-voltage alternating current circuit breakers.

IEC62271-200: 2003 …………… AC Metal enclosed switchgear and control gear for rated voltages above

1kV and up to 52kV.

IEC60694: 2002 …………… The common specification for high voltage switchgear and control gear

Standards

IEC60529:1989 …………… Degrees of protection as provided by enclosures (IP Code)

The switchgear panels have the following degrees of protection:

IP 4X is for the enclosure and IP 2X for the partitions.

All other corresponding IEC publications, national or local safety regulations must be

followed during the erection and operation of the switchgear. In addition, any project specific

advice from GE must be considered.

1.3 Operating conditions

1.3.1 Normal operating conditions

The switchgears are fundamentally designed for the normal service conditions for indoor switchgears to IEC

Publication 60694. The following limit values, among others, apply.

• Ambient temperature

- - Maximum + 40°C

- - 24h-Medium +35°C



- - Minimum -15°C

• Humidity

- Highest average value measured over 24 hours

o Relative humidity 95 %

- Highest average value measured over 1 month

o Relative humidity 90 %

• The maximum site altitude is 1000 m above sea level

1.3.2 Special operating conditions

This switchgear is suitable for operation in the climate of indoor type according to IEC standard. Special

operating conditions must be discussed with the manufacturer in advance.

For example: At site altitudes above 1000 m, the effects of the reduction in density of the air on the

dielectric properties must be taken into account.

Increased ambient temperatures must be compensated for in the design of the busbar and branch

conductors as well as the withdrawable parts; otherwise the current carrying capacity will be reduced.

Fitting additional ventilation facilities can assist heat dissipation in the switchgear panel.

1.3.3 Note on any special climatic operating conditions

When the switchgears is operated in areas with high humidity and/or major rapid temperature fluctuations,

there is a risk of dew deposits, which must remain an exception in normal operating conditions for indoor

switchgear. Preventive action (e.g. fitting the electric heaters) must be taken in consultation with the

manufacturer to avoid this condensation phenomenon and any resulting corrosion or other adverse

effects. The control of the heaters depends on the relevant project and details can be taken from the order

documents.



1.4 Safety and environment protection requirement

1.4.1 Safety proceeding

• Wear necessary safety uniform according to electric safety regulations before

entering the site

• Comply with industry work procedure, Power supply shall be operated by authorized staff.

Environment protection requirements

The manufacturer has a product recycle policy in accordance with related law and ISO14001.

Local laws shall be observed when the switchgear is due for recycle.

1.5 Handling and storage

1.5.2 Condition on delivery

At the time of dispatch, the factory assembled SecoGear will have withdrawable parts either securely locked in

the service position or separately packed, depending on the rating of the equipment, transport mode and

destination.

The SecoGear panels are verified in the factory for completeness as per order requirement, and also passed routine

testing as per IEC 62271-200:2003.

The busbars are not assembled, and they are separately packed with fasteners and accessories.

1.5.2 Packing

Based on the kind of transportation and country of destination, the packing may vary. To protect against the moisture

a drying agent bag is provided. IEC60694:1996 guidelines are followed.

• Panels with basic or no packing

• Panels with seaworthy or similar packing (including packing for containerized shipments);

o Sealed in polyethylene sheeting

o Transport drying agent bags included

o Moisture indicator included

Observe the directions for use of the drying agent bags. Note the following;

o Drying agent color observed blue means the packaged equipment is dry condition

o Drying agent color observed pink that means the packaging contains moisture (relative

humidity above 40%). Please contact the manufacturer in this case before installation.

1.5.3 Transport (Figure 1/2)

The transport units normally comprise individual panels and, in exceptional cases, small groups of panels. The

panels are equipped with four lifting lugs.

• Only Carry out loading operations when all precautionary measures to protect

personnel and materials have been taken, with the following equipment:

o Crane of suitable capacity

o Fork-lift truck and/or manual trolley

o Fit lifting ropes of appropriate load capacity with spring catches

o Keep an angle of at least 60° from the front for the ropes leading to the crane hook



HANG THE UNITS USING ALL 4 EYEBOLTS!

1.5.4 On Receipt

The responsibilities of the consignee when the switchgear arrives at site include, but are not limited to, the

following:

Checking the consignment for completeness and any damage (e.g. the adverse effect by moisture). In case of

doubt, the packing must be opened and then properly resealed with new drying agent bags (when

intermediate storage is necessary).

If any quantities are short, or defects or transport damage are noted, these must be;

o Documented on the respective shipping document

o Notified to the relevant carrier or forwarding agent immediately in accordance with the

relative liability regulations

Note: Always take photographs to document any major damage.

1.5.5Intermediate storage

Intermediate storage should follow the following practices to avoid any negative consequences:

1. Panels with basic packing or without packing:

• A dry well-ventilated storeroom with a climate in accordance with IEC 60694

• Store the panels upright

• Do not stack panels

Panels with basic packing;

• Open the packing, at least partially

Panels without packing;

• Loosely covered with polythene

Figure 1/2: Handling by crane

1 Lift ing eyebolt



• Ensure that there is sufficient air circulation

Check regularly for any condensation during storage.

2. Panels with seaworthy or similar packing with internal protective covers,

• Store the transport units;

o Protected from the weather

o In a dry place

o Safe from any damage

• Check the packing for damage

• Check the drying agent;

o On arrival of the consignment

o Subsequently at regular intervals

3. When the maximum storage period, starting from the date of packing, has been exceeded;

• The protective function of the packing can no longer be guaranteed

• Take suitable action if intermediate storage needs to be continued

Warning:

Do not walk on the top of the panels (due to rupture points in pressure relief devices) !

The pressure relief devices can be damaged!



2 Technical Specif ication

2.1 Table 1-Technical specification for SecoGear

Rated voltage kV 40.5

Rated power frequency withstand voltage kV 95

Rated lightning impulse withstand voltage kVp 185

Rated frequency Hz 50/60

Rated current A 1250/2500

Rated short time withstand current (3s) kA 31.5

Rated peak withstand current kAp 82


≤100+CT* (≤1250A) Resistance of main circuit µΩ

≤45+CT* (≤2500A)

Enclosure IP4X IP level for weather protection

Intercompartment IP2X

2.2 Table 2: - Technical specification for SecoVac (Circuit breaker)

Rated voltage kV 40.5

Rated operating sequence - O-0.3s-C0-3min-CO O-180s-

CO-180s-CO

Rated power frequency withstand voltage kV 95

Rated lightning impulse withstand voltage kVp 185

Rated frequency Hz 50/60

Rated current A 1250/2500

Rated short circuit breaking current kA 31.5

Rated short time withstand current (3s) kA 31.5


Rated cable charging breaking current A 50

Rated short circuit making current kAp 82

Rated single capacitor bank breaking current A 400

Opening time ms 25-40

Closing time ms 55-80

Rated auxiliary voltages V 48/110/220 DC 110/220 AC

Rated power consumption of spring charging motor VA 90



2.3 Table 3-Main circuit resistance of SecoVac 40.5kV

Item Unit Value

Rated current A 1250 2500

Withdrawable µΩ ≤50 ≤25

Fixed type µΩ ≤35 ≤20

3 Enclosure design and equipment

3.1 Typical modules (Figures 3/1 to 3/2)

With either withdrawable or fixed type SecoVac Vacuum Circuit Breaker installed, SecoGear panels are used as for

incoming or outgoing feeder. Each unit consists of three high voltage compartments i.e. Main bus bar, Circuit breaker,

Cable compartment and Low voltage compartment for instruments and auxiliary circuits. Apart from this, there are

variants for all operating needs.

For busbar sectionalizing, two panels are necessary, the coupling panel with the withdrawable circuit-breaker part

and a bus riser panel (optional with busbar metering ). In equipment without busbar sectionalizing, a direct bar

connection between the busbar will be established.

3.2 Enclosure and partitioning (Figure 3/1)

Enclosure is bent & blended multi-layer structure of 2mm aluminum-zinc steel plate (or quality cooled rolling steel

plate), which is composed of function compartments such as truck compartment, main busbar compartment , cable

compartment, busbar tie compartment, instrument compartment and overhead inlet channel, etc

Each function compartment is separated by metal partition and protection grade in enclosure is IP2X. Main busbar is

partitioned by metal plate and epoxy bushing and every cabin has dependent pressure-release channel.

Pressure relief flaps are provided on the top of the panel for all high voltage compartments. In case of overpressure

due to internal arc inside any of the compartments, these pressure relief flaps are designed to open very fast thus

releasing the pressure. The pressure-relief flaps are secured with steel screws on one longitudinal side and on the

other longitudinal side with plastic screws. In the case of internal overpressure, the plastic screws are the point of

rupture.

The door is set with seal bars and protection grade of enclosure is IP4X.The front doors, which can open up to, an

angle of 130° are pressure resistant. Inspection window made of strong security glass is provided on circuit breaker

compartment door. Lined up adjacent panels are separated by the side walls of each panel and by inherent design the

air gap between two lined up panel exists which works as cushion after joining/bolting.

At the bottom of the cable compartment floor-covering 9, made of non-magnetic material is fitted.

The earthed internal partitioning ensures safe access to the circuit breaker and cable compartment even though the

busbars are energized.

The low voltage compartment is fully protected from the high voltage area with the earthed steel-sheet casing.

On the end panel of the lined up switchboard, end cover plates are provided which ensures better appearance and

provides mechanical and thermal strength to the end panel in case of internal arc in the end panel.



Doors, rear walls and cover plates are treated against corrosion and then coated with high quality paint. The finishing

coat is in the standard RAL 7035 colour (special colours by agreement). The doors for circuit breaker and cable

compartment are pressure resistant and can either be closed with screws or manual locking systems with handles.



3.3 Switchgear structure

Figure 3/1a: Typical feeder panel

A Low voltage compartment

B Circuit-breaker compartment

C Busbar compartment

D Cable compartment

1 Enclosure

1.1 Pressure relief flap

1.2 Partition

1.3 Control wiring duct

2 Branch conductor

3 Busbar

4 Spout bushing (With current

transformer)

5 Cable terminal bar

6 Side Insulate barrier 8 Cable

clamp

9 Floor cover – split

10 Main earthing bar

11 Door for LV Compartment

12.1 Top shutter

12.2 Lower shutter

13 Withdrawable part

14 Spindle mechanism

16 Terminal rack

17 Control wiring plug connector

Figure 3/1b: Typical 2500A panel (Main difference between

1. Ventilation relief plate

2. Ventilation relief plate

3. Top ventilation relief plate

4. Partition plate stainless

5. Partition plate stainless

6. Partition plate bracket stainless

7. lower branch busbar 2-15x70

8. Stainless main busbar compartment cover



Figure 3/2: tie panel Figure 3/3: Typical measuring panel

Description Item Unit Value

Height A mm 2400

Width B mm 1200

Depth C mm 2650

Weight kg 500-1000

Figure 3/4: Typical dimensions and Weights of

SecoGear (including withdrawable circuit-breaker

parts):



3.4 Cable compartment (Figure 3/1 and 3/5)

The cable compartment equipped with spout bushing type current transformers 4, according to case-by-case

operating requirements.

The cable compartment is also suitable for installation of three post type current transformers. When all three current

transformers are not required, then dummies can be installed in their place, using the same installation and

connection procedures.

The disconnecting type of voltage transformers truck are fitted with HRC fuses.

Both mechanical indications mounted on driveshaft and the auxiliary switch operated by driving shaft is used to

identify the switch position.

Cable clamps and cover plates on the bottom of cable compartment can provide for passing and fix MV cables.

Height to cable terminals is approx. 680mm. Generally, cable clamps and rubber cable cover to be match-drilled as

actual dimension of cable to isolate cable compartment with cable duct. Normally, there will install 35KV, single core

cable 180mm2, 4 strings per phase and 12 strings in total; 35KV three cores, cross-linked cable 400mm2, 2 strings per

phase and 6 strings in total.

Zinc lightening arrestor are also equipped inside of cable compartment as required.. Main circuit adopts capacity

sensor type voltage display device. On the bottom of compartment, there sets main earthing bar and earthing

terminal (M12) connecting with siding earthing of truck compartment.

Cable connection:

Rated voltage

Panel width

Max. number of parallel cables

Max. cross section of cables

Range of cable clamp

Range of reducer ring

(kV) (mm ) Per Phase (mm2) (mm) (mm)

40.5 800 4 400 70 100

Figure 3/5: Cable compartment,

Max. four parallel cables possible 9 Floor cover, split 8 Cable clamp 9.1 Reducer ring 5 Cable connection bar

10 Main earthing bar 20 Surge arrester



3.5 Breaker compartment

Breaker compartment is located in front middle of enclosure. Top of compartment is equipped with pressure relief

channel and 6 pieces of equalizing electric field type epoxy contactor bushing are mounted on the back of

compartment (or install contactor bushing type current transformer). Center distance of cabinet is 275mm. On both

sides of compartment, there are truck mid-mount working guide rail and shutter hoist mechanism. Shutter is the

structure of metal folding to use chains to drive sprocket open or close shutter. Both sides of truck compartment are

equipped with secondary cable channels directly to instrument compartment. View window, driving operation hole of

truck and emergent opening device are set on the door.

3.6 Main busbar compartment

This compartment is located above the enclosure and pressure relief window is set on top of compartment. Adjacent

compartment are partitioned by metal plate and epoxy wall bushing and rubber shims for main busbars.

To adopt tube type copper busbars with even electric field distribution and max current is 2500A. Distance between

main busbars is 360mm to form triangular arrangement and composition insulation with smart structure, good

insulation performance and easy installation is used. Joints of Busbars are covered by Silicon rubber insulation

shroud.

Figure 3/6: Breaker compartment, 17 Control wiring plug connector 4 Contactor bushing 17.1 Plug lock 12.2 Lowe shutter

22 Guide rail 12.3 Shutter drive mechanism



3.7 Instrument compartment

Instrument compartment is located on front upper of the enclosure, where there is set swing grid-hole mounting

plate for ease of inspection and replacement of relay.

Connection terminals and auxiliary busbar terminals can be mounted on the bottom of compartment. Two rows are

separately in front and rear and mounting length of every row shall not exceed 900mm. There are round holes

between L/R side plates and terminals for auxiliary busbar. In the right side of compartment door, there are mounting

indicating device for indicate status of breaker O/C, truck position, as well as composition protection device to realize

remote control, measuring, adjustment and communication of system.

Figure 3/8: Instrument compartment

3.8 VCB truck

Breaker adopts solid insulate pole and vacuum arc-extinguishing chamber are poured by epoxy materials to insulate.

Operation mechanism is module spring mechanism. Refer to User’s Guide of VB-40.5 indoor HV vacuum breaker for

detailed operation.

Figure 3/7: Main busbar compartment 2 Branch conductor 4 Contactor bushing 3 Busbar 21 Epoxy wall bushing



1. hanging arm

2. upper contact arm 3. closed contact 4. lower contact arm 5. solid-seal pole

Figure 3/9 breaker truck

1. secondary insert 6. closing module

2. closing electromagnetic 7. chassis

3. energy storing spring 8. opening module

4. opening spring 9. aux. switch

5. main shaft 10. opening electromagnetic

3.9 Hydraulic lifter

Movement of breaker truck inside or outside of cabinet should make use of special hydraulic lifter This lifter

adopts hydraulic lifting mechanism with locking device for ease of operation, labor-saving, smooth and

safety.



Figure 3/10 Hydraulic lifter

1. Truck body 6. Bucket

2. Hydraulic handle 7. Guide rail

3. Double sprocket lift system 8. Lock block

4. Hydraulic cylinder 9. Braking board

5. Knob of drainage valve 10.

4 Operations and trouble shooting

4.1 Closed door racking out of SecoVac from Service position to test or withdrawn position

4.1.1 Open the SecoVac by pressing the push button on LV compartment door for OPEN.

4.1.2 Open the racking operation hole’s cover.

4.1.3 Insert the racking handle into operation hole, turn the handle anticlockwise around 20 turns, this will bring the

circuit breaker to TEST position see figure 4-1.

Figure 4/1: Position of handle insertion cut out in VCB



Hange

r Bolt

4.1.4 Open circuit breaker compartment door.

4.1.5 Open control plug locking handle, (see figure 4/2). Push the control plug out of socket, hang the control plug on

hanger bolt fixed on VCB truck (see figure 4/3).

Figure 4/2: Control plug locking Figure 4/3: Control plug location on VCB

4.1.6 Move the hydraulic lifter for circuit breaker near to the circuit breaker compartment , Operate hydraulic

handle to make bucket of lifter up to 650mm and push in front of the cabinet. Align dowel pins in front of

lifter bucket and insert positioning holes on both sides of front of cabinet, paddle brake is locked by step on it

then adjust position of lifter bucket to make guide rails parallel with guide rails inside of cabinet.

Figure 4/4: The position of paddle brake Figure 4/5: Hydraulic handle of the hydraulic

lifter

! Limit rise height of bucket is 1000mm.

! Maximum loading of lifter is 750kg

! Total depth of lifter including breaker truck is 1560mm.

! Personnel can not stand on or under the lifter bucket.

4.1.7 Move the VCB on the lifter slowly , push guide rail of truck along wheels of VCB truck in then dowel pins of

truck of VCB slides into slot along locking block. (see figure 4/4 / see figure 4/5).

Paddle

brake

Hydraulic

Handle

Locking

block Guide

rail



4.1.8 Unlock the paddle brake to unlock lifter , move away lifter from switchgear.

4.1.9 Can falling down the bucket for moving, The speed of lifter bucket during falling down should be controlled.

4.2 Rack in of the circuit breaker from withdrawn position to service position.

！Ensure circuit breaker compartment in order and clean.

4.2.1 Move circuit breaker truck into test position of switchgear.

Attention: Once circuit breaker truck is at defined position, its pilot pin can be released to outside

limiting position (see figure 4/6), otherwise, VCB truck cannot be inserted in the VCB

compartment.

4.2.2 Control plug shall be inserted in the socket of switchgear, move the control plug bracket to lock the control plug

in the inserted position.

4.2.3 Close circuit breaker compartment door.

4.2.5 Turn the racking handle in clockwise direction to move the circuit breaker truck to service position, VCB truck

indicator which is on the low voltage compartment door will show an indication once it is in complete service position.

4.2.6 Now circuit breaker closing spring can be charged according to operating instructions and, keep watch on

indications for correct operation.

Figure 4/6: Handle position

when VCB is in test position

VCB

handle



4.3 Diagnosis and trouble shooting for malfunctioning during operations

Abnormal phenomena

Reason Treatment measures

VCB can not be moved to Service position from test position

1. Bar pilot pin is not in proper position. 2. Circuit breaker is switched CLOSE 3.VCB electromagnetic Y0 is not unlock 4. Shutter is not open completely

1. Reposition bar pilot pin 2. OPEN the circuit breaker 3. Check electromagnetic Y0 4. Check shutter drive unit

VCB can not be moved to test position from service position

1. Circuit breaker is CLOSE 2. VCB electromagnetic Y0 is not unlock

1. OPEN the circuit breaker 2. Check electromagnetic Y0

VCB can not be switched ON

1. If auxiliary power supply is OFF 2. If control plug is not locked 3. If circuit breaker is not in test or service position completely 4. If closing spring has not been charged 5. VCB CLOSE locking Electromagnet takes no action 6. Closing release not working

1. Auxiliary power is ON 2. Plug in and lock control plug fully 3. Move the VCB to proper test or service position completely 4. Charge the closing spring 5. Check auxiliary power source 6. Check if closing release and its connections

Circuit breaker can not be switched off automatically

1. If auxiliary power is OFF 2. Opening release not functioning

1. Ensure auxiliary power source 2.Check opening release and its connections

5 Installation

5.1 Handling and storage

5.1.1 Condition on delivery

The SecoGear panels, which are factory assembled, are with withdrawable parts in the service position locked

properly and the doors closed at the time of dispatch. Sometimes withdrawable part can be shipped

separately packed based on the rating of the equipment ,transport mode and destination for delivery.

The SecoGear panels are inspected at the works for completeness in terms of the order and also subjected to

routine testing as per IEC 62271-200:2003, This ensures correct assembly and function.



The units are dispatched without busbar in assembled condition. The busbar, fasteners and required accessories

are packed separately.

5.1.2 Packing

Based on the kind of transportation and country of destination, the packing may vary. To protect against the moisture

a drying agent bag is provided. IEC60694:1996 guidelines are followed.

• Panels with basic or no packing

• Panels with seaworthy or similar packing (including packing for containerized shipments);

o Sealed in polyethylene sheeting

o Transport drying agent bags included

o Moisture indicator included

Observe the directions for use of the drying agent bags. Note the following;

o Drying agent color observed blue means the packaged equipment is dry condition

o Drying agent color observed pink that means the packaging contains moisture (relative

humidity above 40%). Please contact the manufacturer in this case before installation.

5.1.3 Transport (Figure 5/1)

The transport units normally comprise individual panels and, in exceptional cases, small groups of panels. The panels

are equipped with four lifting lugs. Truck and cabinets must be lifted and mounted separately. Normally, cabinet

weight (excluding truck) dose not exceed 1000kg, truck weight dose not exceed 500kg. Safety hanging tackles must

be used during operation. including angle of lifting wire rope forming mutual force shall not be more than 55 degrees.

Switchgear can be lifted with lifting angle steel on the top of cabinet. Truck has two lifting holes so it should be lifted

with small size hanging hook (see figure 5/2). After the truck is located on the floor, lifting plates can be removed and

the truck can be transferred with special hydraulic lifter.

• Transport the panels in upright position only

• Carry out loading operations only when it has been ensured that all precautionary measures to

protect

personnel and materials have been taken and use of one of the following equipment is recommended;

o Crane of suitable capacity

o Fork-lift truck and/or manual truck

o Fit lifting ropes of appropriate load capacity with spring catches

o Keep an angle of at least 60° from the front for the ropes leading to the crane hook

HANG THE UNITS USING ALL 4 EYEBOLTS!



Figure 5/2: VCB Truck hanging

1. hanging hook 2. hanging arm 3. breaker

5.1.4 On Receipt

The responsibilities of the consignee when the switchgear arrives at site include, but are not limited to, the

following:

Checking the consignment for completeness and lack of any damage (e.g. also for moisture and its detrimental

effects). In case of doubt, the packing must be opened and then properly resealed, putting in new drying agent

bags, when intermediate storage is necessary

If any quantities are short, or defects or transport damage are noted, these must be;

o Documented on the respective shipping document

o Notified to the relevant carrier or forwarding agent immediately in accordance with the

relative liability regulations

Figure 5/1: Handling by crane

1 Lift ing eyebolt



Note: Always take photographs to document the major damage if any.

5.1.5 Intermediate storage

Intermediate storage, where it is necessary, without any negative consequences depends on;

a. Panels with basic packing or without packing:

• A dry well-ventilated storeroom with a climate in accordance with IEC 60694

• Store the panels upright

• Do not stack panels

Panels with basic packing;

• Open the packing, at least partially

Panels without packing;

• Loosely covered with polythene

• Ensure that there is sufficient air circulation

b. Panels with seaworthy or similar packing with internal protective covers,

• Store the transport units;

o Protected from the weather

o In a dry place

o Safe from any damage

• Check the packing for damage

• Check the drying agent;

o On arrival of the consignment

o Subsequently at regular intervals

c. When the maximum storage period, starting from the date of packing, has been exceeded;

• The protective function of the packing can no longer be guaranteed

• Take suitable action if intermediate storage needs to be continued

Warning:

Do not walk on the top of the panels (rupture points in pressure relief devices

can be damaged!)

5.2 Installation

5.2.1 Mounting base This switchgear is installed away from wall. Please refer to figure 5/3 for structure construction of installation of basic frame.



Note: Planeness of basic channel steel frame should be 1mm, channel steel should be 1～3 mm higher than concrete terrace.

Figure 5/3: mounting base reference

Planeness of basic frime is 1mm/m and lineal within total length of frame is 2mm. Construction of basic terrace shall

comply with relative regulations stipulated in ”Construction and Acceptance of Power Engineering ”. Double / single

row arrangement of switchgear refers to figure 5/4, 5/5 and fix holes of cabinet body and MV cable/Control wire

access holes refers to figure 5/6.

Figure 5/4: Double rows reference Figure 5/5: Single row reference



Figure 5/6: Cable /Wire access hole

5.2.2 Mounting procedure

Fix the enclosure on C channel steel (or fix it directly on fix holes by welding) with M12 fastens (match fix screw as

per figure 5/3 to base C channel steel) after the panel is in place. Use M10 bolts to tighten between panels. Connect

leads of main circuit, earthing circuit (see connection of earthed busbar), auxiliary circuit (see connection of control

cable and connection of power cable). Regarding to connection of main circuit (see notices for mounting of busbar),

linking locations of conductors of every phase, adopt special silicon-rubber insulation bush to wrap. Cover plates for

unloading pressure of function units on the cabinet top adopt M6 nylon screw to fix evenly. Clean inside of cabinets

and every elements of truck. (It is prohibited to use methylchoroform, trichlene or telluricchloride) Push the truck into

the cabinet correctly as per specifications under the Contract and this Instruction and check performance of each

part. Before entering the cabinet, dub vaseline on surfaces of all isolate static contacts then place the truck from

“operation position” to “move position”. Check engagement track of dynamic / static contacts (see figure 5/7) and

push the truck into the cabinet again to “testing position”. Perform electrifying and operation test as per wiring

diagram of auxiliary circuit, finally place truck in “operation position” and carry out regular site test as per

requirements on the Contract and technical parameters of relative product.

`

5.3 Busbar connection

Figure 5/8: Busbar after opening the rear cover

Figure 5/7: Contactor in the bushing



5.3.1 Before new main busbar mounting, clean busbar with clean soft cloth to remove dirty and check

whether insulation layer of busbar are damaged. Check whether conduct spring is deformed and

stop installation if there is any severe distortion.

5.3.2 Use M5 screw as per figure to fix conduct spring on the main busbar. Pay attention to tighten the

screw.

1.induct spring 2.main Busbar

5.3.3 Installing main busbar, pass through sleeve of epoxy body in parallel to avoid deformation of

contact spring.

1.induct spring 2.equalizing ring 3. sleeve 4.rubber shim 5. main busbar

5.3.4 In case center of Busbar is more offset with that of insulation sleeve after mounting of Busbar to

make induct spring away from equalizing ring, the main Busbar can be rotate 180 degree to install.

5.3.5 In case center of Busbar is less offset with that of insulation sleeve after mounting of Busbar and

contact between induct spring and equalizing ring is not well, connect bolts between main Busbar

and branch Busbar can be loosed to make a little adjustment.

5.3.6 Note: Don’t knock induct spring while passing through main Busbar. Keep contact between induct

spring and equalizing ring in sleeve well after installation otherwise air gap between induct spring

and , equalizing ring will discharge due to worse contact after electrifying and produce abnormal

noise or damage on the device.

5.3.7 Overlaps of Busbar adopts wallet-type silicon-rubber shroud to insulate. There are two

types shroud: T type (3501) and L type (3502) (inside and outside in set).

5.3.8 Before overlapping, Clean insulate cover inner and outer to make sure no dirty on cover. It is

difference cover for A\C and B phase, Be careful when mounting.

5.3.9 Inner shrouds of T/L on branch Busbar as needed then select engaged Busbar clamp board as

specification form in the Contract to clamp and fix overlap head of Busbar, and outer shroud to

cover overlap head, finally tighten with insulation retaining screw. Mounting of Busbar in place

Figure 5/9: Busbar conduct spring

Figure 5/10: Busbar conduct spring with sleeve



should be carried out after rubber liners are covered. Check the insulation shield covered all busbar,

No bare parts can be found.

5.3.10 The shrouds need insert wall spouse>=20mm per fig 5.11

5.3.11 For the requirements of bolts and torque, standard bolt with 8.8 grade of mechanical performance.

Details are as follows:

5.3.12 Reassemble the cover for the busbar compartment

5.4 Connection of earthing busbar

5.4.1 Connection line of busbar in switchgear is supplied with the cabinet. Connect all earthing busbar in

switchgear to ensure all surfaces of joints are clean and tighten bolts as required.

5.4.2 Connect earthed Busbar of switchgear with earthing system of transformation station. Section of

earthing busbar of earthing system of transformation station should not be less than earthing

busbar of switchgear.

5.5 Connection of control cables

Control cables enter switch cabinet via cable slots on both sides of cabinet body, mounting sequences are as follows:

5.5.1 Pass control cable into cable slots and cover the slots.

5.5.2 Strip out cable coat and fix the cables on the top of slots, then pull the control cable into LV room.

5.5.3 As per diagram, connect control lines to terminals.

5.6 Connection of power cable

Inlet of power cable is located on the bottom of cable compartment of switch cabinet. If the seal plate is removed, cable can enter it . Standard inlet method of cable adopts down-inlet or up-inlet as required by user. The following is mounting procedures of cable:

Bolt specification M8 M10 M12 M16 M20 No lubricant: Nm 25 45 85 170 300 Inject lubricant: Nm 15 25 45 80 120

Figure 5/11: Busbar shrouds mounting detail



5.6.1 Pull power cable in and peel shield from rated length.

5.6.2 Open round hole of enough size on seal by cable diameter.

5.6.3 Prepare cable head as per Cable Instruction from manufacturer and mount on cable core.

5.6.4 Connect cable head to connection line of cable.

5.6.5 Connect cable earthing.

5.7 Check after mounting

• Check whether the door is open / close freely. • Check the bolts especial on busbar and earthing systems mounting at site are tighten. • Check all bare parts have been covered by insulate shield. • Check and install the removed cover plates during mounting and connection. • Seal any openings what are useless again. • Check running parts and interlocking mechanism are running flexibly and paint lubricants if necessary. • Remove all foreign articles. • Clean switch cabinet carefully. • Mount base plate, fasten seal and fix the cables on the bracket of base plate with cable clips.

6 Maintenance item and cycle

SecoGear is used in distribution system to measure, control and protect the load. It is equipped with the SecoVac

withdrawable and fixed type vacuum circuit breaker. SecoGear is with complete interlocking in different functional

units for safe and reliable operation. This also helps in servicing of the switchgear.

Only the trained personnel shall carry out maintenance of the switchgears. During

servicing manufacturers instruction, guidelines from IEC and local safety standards shall

be followed.

It is recommended to carry any major repairing if required with the help of

manufacturers representative.

6.1 Routine Inspection

Safety method: Routine inspection is to ensure smooth operation of the switchgear. It does

not require power shutdown, but shall be done without any wrong operations.

The function for routine inspection is to detect an abnormality in advance so that it will not create any defect.

Routine inspection includes:

• Check compartment doors are closed properly

• Voltage check in all phases

• VCB position and relevant indications as required

• Check ammeter and voltmeter are functioning properly

• Check relay for power indication is on and no malfunction indication is ON. Based on malfunction light and

code inspects the related area if required. In case of ambiguity and suspect that relay is faulty contact the

Relay manufacturer

• Ensure alarm and pre alarm indication is functioning



• Check for any abnormal sound, odor and light in the switchgear; report to manufacturer if there is any

• Check for proper function of Heater (optional item). Separate current relay in the low voltage compartment

checks the current of the heater. The red light will off to indicate that the heater is not functioning

• In this case please check the heater circuit

Figure 5/1: Indicating relay for heater

6.2 Routine maintenance

Safety method: Switchgear demands the maintenance as scheduled with power shut down and

isolated work area. Make sure that power will not be switched on unintentionally or by

miscommunication. Ensure proper earthing and padlocks in place. Routine maintenance needs the

specially trained person to supervise.

The purpose for the routine maintenance is to guarantee the operation quality of the SecoGear and avoid any

possible malfunctions. This increases the life of the switchgear.

The contents include the works below:

• Check: Confirmation for the actual switch and circuit breaker operational status and eliminate the potential

malfunction

• Maintenance: By doing operations as per manufacturers instruction ensures the best state of the switchgear

• Repair: Repair if anything abnormal observed during the operations done as per manufacturers instruction

Frequency for the routine maintenance of the switchgear should be decided based on operating environment and

the operation frequency of the equipment in service along with other factors that can influence the performance of

switchgear.

Indicator of the heating machine



6.2.1 Schedule the routine maintenance after minimum 2 years if the installation is in normal operating

conditions without pollutants and salty environment. In this case the number of operations shall be

less than 10 numbers per month.

6.2.2 Schedule the routine maintenance every year is if the operations on the panel are more than 10

times in a month.

6.2.3 Schedule the routine inspection and maintenance once per half a year for those locations with bad

corrosive, salty or extreme environments and with frequent switching operations.

Verify the Circuit breaker functioning every 6 months if it is stored as spare for

long time.

6.3 Minor repairs

Minor repairs are required in case of following situation emerges:

• Damaged insulation resulting in discharges, flashing and breakdown of voltage

• Broken component in the switchgear or breaker

• Any other abnormal observation which may affect the safety

6.4 Items for verification

6.4.1 Check all the compartments internally along with the visually accessible components for dampness,

rust and dirt.

6.4.2 Tightening check for main busbar bolted joints (please use torque wrench).

6.4.3 Open the busbar compartment and remove the insulation shield (See fig 5/2). Check the torque on

the exposed hardware whether it is 86 N-m by the torque wrench.

6.4.4 Check the insulation shield covered all busbar, No bare parts can be found.

Figure 5/2: Insulation shield of the busbar joint

Insulation

shield



6.4.5 Check the fixed contact including its profile for any sign of sparking or chattering because of

discharges also check the scoring or abrasion marks on the contact that they are not exceeding the

expectations.

6.4.6 Check the operation for the shutters in VCB compartment.

6.4.7 Check the bolted connection between the power cable and terminal if it is accessible.

6.4.8 Ensure proper functioning of the interlock between the VCB truck and the VCB compartment door.

6.4.9 Ensure correctness of all light indicators and labels.

6.4.10 Insure normal functioning of the heater.

6.5 Performance test

The reason of the performance test is to ensure the electric performance of the equipment. This can be done after

the scheduled maintenance.

Performance test includes:

• Make five times VCB OPEN/CLOSE operations, and check the circuit whether it is normal

• Check the functioning of all the interlocks

• Power frequency withstand test for 1 min based on the rating of the panel and guidelines from IEC60694

for on field testing

• Measure the contact resistance for the circuit breaker

• Verify mechanical characteristic for breaker

7 Major Repairs

Comply with the related safety regulation strictly when preceding the repairing work.



7.1.1 Open the main busbar compartment and check all hardware.

7.1.2 Check the main busbar and branch busbar for any dampness and oxidation.

7.1.3 Check all the side walls for any dampness, oxidation and rust.

7.1.4 Check the main busbar compartment for any entry of foreign material.

7.1.5 Re-install the insulation shield, and restore the pressure flaps on the top of the panel.

7.1.6 Check the fastening of the fixed contact and the surface condition.

7.1.7 Open the cable compartment and check the cable connection to ensure no color change of

termination.

7.1.8 Check the sealing condition of the first and second cable hole.

7.1.9 Check the heater condition.

7.1.10 Check the cable compartment for any foreign material.

7.1.11 Check the secondary connections of the current transformer and see it is properly tightened.

7.1.12 Check the current terminals in the low voltage compartment and ensure that secondary current loop

is continuous. Assure the protection relay, ammeter and secondary terminals of the current

transformer are functional.

8 Spare parts

S/N Name Unit Quantity Remarks

1 Insulating shield on bus bar joints Piece 5

2 Fixed contact assembly kit Set 3 Screw washers inclusive

3 Tulip contact kit Set 3

4 SecoVac truck position indicator Piece 1

5 SecoVac status indicator Piece 1

6 Closing Coil Piece 1

7 Opening Coil Piece 1

8 Circuit board AC/DC for 220V/110V as applicable

Set 1



9 Auxiliary Contactors Piece 1

10 Micro Active Switch LXW20-11 Piece 1

11 Electromagnet 110/ 220V Piece 1

12 Over current Electromagnet 5A Set 1

13 Blocking Electromagnet DC220V-13500Ω-20mA Piece 1

14 Blocking Electromagnet DC110V-2520Ω-44mA Piece 1

15 Motor 90W DC110/220V Set 1

16 Mechanical Counter Set 1

17 Pole for Secondary Plug (50 pieces/package) Package 1

18 Jack for Secondary Plug (50 pieces/package) Package 1

19 Manual Charging Lever Piece 1

20 Dolly 40.5-210 bottom earthing Piece 1

21 Operating lever for dolly Piece 1

22 50W heater Set 1

23 100W heater Set 1

24 Current terminal Set 10

25 Voltage terminal Set 20

26 M 6 Washer Piece 24




30 M6×15 self tapping screw Piece 12

31 M8×30bolt Piece 12

32 M10×35 bolt Piece 12

33 M12×50 bolt Piece 12



Appendix A - Onsite service safety instruction

Before start working, please check and make sure all item listed in “list of onsite service safety checking”.

For some reasons if the work is interrupted, please make sure site safety procedure is integral when restarting the

work.

1. Before work, please check site layout, with and without electric area, earthing line layout, ON or OFF of the

control power, state of the temporary power, if supervisor is on his/her position and safety exits.

2. Ensure if safety procedures on working sheet are well implemented, recheck if safety procedures comply with

requirements, if isolation procedure between live equipment and test equipment is established, if there is a clear

instructions on labels.

3. Once equipment is in power off phase, it is strictly forbidden to operate the circuit breaker or switch. Please

switch OFF circuit breaker and move VCB to test or withdrawn position. Instrument and power transformer to

power of the equipment shall be switched off in order to avoid any charging of the equipment by mistake.

4. Please ensure the switchgear reference and number to avoid working on the wrong equipment.

5. All current transformer and voltage transformer secondary winding shall only have one permanent and reliable

protective earthing.

6. If there is a necessary that person has to get into switchgear to give proper service, must make sure this person’s

safety.



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40.5kv instruction manual

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