medium-voltage switchgear gha - schneider electric...

Medium-voltage switchgear

No. AGS 531 446-01

Edition 04/2014

www.schneider-electric.com

GHAGas-insulated switchgear ≤ 40.5 kV (≤ 40 kA)for single and double busbar panels

Assembly Instructions

Manufacturer:

Schneider Electric Sachsenwerk GmbH Rathenaustrasse 2 D-93055 Regensburg Germany ( +49 (0) 9 41 46 20-0 7 +49 (0) 9 41 46 20-418

Service:

Schneider Electric GmbH MA GIS Rathenaustrasse 2 D-93055 Regensburg Germany ( +49 (0) 9 41 46 20-777 7 +49 (0) 9 41 46 20-776

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3AGS 531 446-01 | Edition 04/2014

Contents

Remarks on this manual .............................................................................5Purpose and target group ........................................................................................... 5Reference documents ................................................................................................ 5Terms and symbols used ............................................................................................ 6Abbreviations used ..................................................................................................... 6Any questions or suggestions?................................................................................... 6

1 Safety provisions ..............................................................................7

2 Design, description, variants ...........................................................82.1 Switchgear panels with single busbar ............................................................. 82.2 Panels with double busbar .............................................................................112.3 Dimensions and weights ............................................................................... 132.4 Applicable standards ..................................................................................... 172.5 Environmental and operating conditions ....................................................... 172.6 Intended use ................................................................................................. 182.7 Disposal after the end of service life ............................................................. 18

3 Packaging, transport, storage........................................................193.1 Shipping units ................................................................................................ 193.2 Transport ....................................................................................................... 193.3 Storage .......................................................................................................... 20

4 Assembly .........................................................................................214.1 Safety provisions ........................................................................................... 214.2 Important instructions for assembly .............................................................. 214.3 Requirements regarding the switchgear room .............................................. 224.4 Transporting the panels on the construction site........................................... 254.4.1 Transport of panel by means of a crane ................................................... 254.4.2 Transport using the transport frame ......................................................... 264.4.3 Transporting the panels onto the base frame ........................................... 274.5 Attachment of pressure relief duct ................................................................ 284.6 Remove cable compartment cover and shutters ........................................... 294.6.1 Cable compartment interlock (optional) .................................................... 294.6.2 Remove cable compartment cover and shutters ...................................... 304.7 Installation of panels ..................................................................................... 324.7.1 Installationofthefirstswitchgearpanel .................................................... 324.7.2 Removal of transport securing device ...................................................... 324.7.3 Pre-coat the high-quality electrical joints of the busbar link ...................... 334.7.4 Preassembling the clamping contacts ...................................................... 344.7.5 Screw-fastening the panels to one another .............................................. 354.8 Compensating shutters for the panel front .................................................... 364.9 Busbar link: B link .......................................................................................... 394.9.1 Press silicone sleeve back ....................................................................... 404.9.2 Connecting the busbar (fasten preassembled clamping contacts) ........... 414.9.3 Contact resistance measurement of busbar screw fastening ................... 424.9.4 Fasten silicone sleeve to adjacent panel .................................................. 434.9.5 Cover of busbar link in case of panels without pressure relief duct .......... 444.9.6 Current transformer on the busbar for fan control .................................... 474.10 Reinforcement ............................................................................................... 504.11 Screw-fastening the panel to the base frame ................................................ 514.12 Mounting the earth bus ................................................................................. 52

5 Busbar attachments ........................................................................535.1 Safety provisions ........................................................................................... 535.2 Assembly of surge arresters ......................................................................... 535.3 Assembly of voltage transformers ................................................................. 54

6 Low-voltage cabinet ........................................................................566.1 Assembly ....................................................................................................... 566.2 Connecting the control lines .......................................................................... 57

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Contents

7 Switchgear termination...................................................................597.1 Attachment of the protective tank to the left-hand / right-hand end of the

busbar ........................................................................................................... 597.2 Switchgear without pressure relief duct ........................................................ 607.2.1 Overview ................................................................................................... 607.2.2 Attachment of the right-hand or left-hand side wall .................................. 617.2.3 Extension of side wall in double busbar switchgear ................................. 637.3 Attachment of fan .......................................................................................... 65

8 Switchgear with pressure relief device .........................................678.1 Overview ....................................................................................................... 678.2 Cover plate ................................................................................................... 698.3 Attachment of pressure relief duct ................................................................ 708.4 Attachment of side walls for pressure relief from the switchgear room ......... 718.5 Attachment of side walls for pressure relief into the switchgear room .......... 72

9 High-voltage connection ................................................................739.1 Cable compartment with base plates (optional) ............................................ 739.2 Outer cone-type bushing ............................................................................... 749.3 Inner cone-type socket .................................................................................. 77

10 Commissioning ...............................................................................8010.1 Final steps ..................................................................................................... 8010.1.1 Attachment of the tool board .................................................................... 8010.1.2 Cleaning and checking assembly ............................................................. 8010.1.3 Remount covers (see Chapter 4.6, page 29) ........................................... 8110.1.4 Damaged paint ......................................................................................... 8110.1.5 Inspection ................................................................................................. 8110.2 Commissioning .............................................................................................. 81

11 Optional high-voltage test on commissioning .............................8211.1 Power frequency withstand test of the busbar .............................................. 8211.2 Cable testing ................................................................................................. 8411.3 Cable jacket test ............................................................................................ 88

12 Replacement of components and panels .....................................89

13 Annex ...............................................................................................9013.1 Auxiliary products .......................................................................................... 9013.2 Required tools (not included in the scope of supplies) ............................... 9013.3 Coating the contact surfaces ...................................................................... 9213.4 Screw locking compound .............................................................................. 9213.5 Specificationsforscrewconnections ............................................................ 93

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For information which is not included in this manual and the assembly drawings sup-plied with the equipment, please contact the manufacturer.As our products are subject to continuous further development, we reserve the right to make changes regarding the standards, illustrations and technical data.Alldimensionsspecifiedinthismanualareinmillimeters.

Purpose and target group

This Technical Manual describes assembly and commissioning of gas-insulated medium-voltage switchgear units of the GHA series.It is an integral part of the product and must be stored so that it is readily accessible at all times for and can be used by persons who are to work on the switchgear. If the switchgear is sold to new owners, they must receive this document along with the switchgear.This Technical Manual is exclusively intended for specialist electricians who havebeencertifiedfortheGHAseries(trainingcertificate).This Technical Manual cannot describe every imaginable individual case or every customer-specificversionoftheproduct.Thus,onlythebasicassemblyprocedureisdescribed. The detailed assembly work for the switchgear model in question is illus-trated for each operation required in the assembly drawings provided to this effect.

Reference documents

■ Purchaseagreementwiththestipulationsregardingtheswitchgear-specificequipment and the legal details

■ Theappropriateswitchgear-specificcircuitdiagrams/documentation ■ GHA Operating Manual ■ The Operating Manuals of the devices installed in the switchgear:

– Voltage detection systems, e. g. IVIS (no. AGS 531 751-01) – Insulating gas monitoring system IDIS (no. AGS 531 691-01) – System for the detection of internal arcs ILIS (optional) (no. AGS 531 761-01) – Devices in the low-voltage cabinet.

■ The Assembly Instructions of the manufacturer – of the cable connection systems to be connected to the switchgear – of the voltage transformers.

■ The assembly drawings supplied with the equipment

The following additional documents must be complied with:

Remarks on this manual

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Remarks on this manual

Terms and symbols used

This Technical Manual uses certain terms and symbols. They warn about dangers or provide important information which must be complied with in order to avoid danger to persons and damage to equipment:

"Danger!"This danger symbol warns about dangerous electrical voltage. Contact with voltage may result in fatal injury!

"Warning!"This danger symbol warns about the risk of injury. Please comply with all the provisions identified by this symbol in order to avoid death or serious injury.

"Warning!"This danger symbol warns about the risk of falling.

"Notice:"This instruction symbol is used for information which is important to avoid material damage.

Abbreviations used

Forreasonsofsimplification,thefollowingabbreviationsareusedinthismanual:ESS = Single busbarDSS = Double busbarSS1 = Busbar 1SS2 = Busbar 2SS-StW = Busbar current transformerTrSS = Disconnector in the busbar run

Ur = Rated voltage Ir = Rated normal current (feeder panel)

Any questions or suggestions?

Do you have any questions or suggestions regarding this manual, or do you require further information?We always strive to provide you with the best-possible information for optimum, safe use of our products. Thus, do not hesitate to contact us if you have any recommen-dations, amendments or proposals for improvement.

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1 Safety provisions

The work described in this manual may only be performed by specialist electricians with proven experience in conjunction with the GHA series and the applicable safety provisions.Please read the whole manual carefully before working on the switchgear.

■ Metal-enclosed AC switchgear for rated voltages > 1 kV up to including 52 kV: IEC 62271-200

■ Useandhandlingofsulphurhexafluoride(SF6) in high-voltage switchgear: IEC 62271-303

■ The locally applicable accident prevention, operating and work instructions must be complied with.

■ Installation: IEC 61936-1/EN 61936-11

■ Operation of electrical equipment: EN 50110-111 The national standards applicable in the country where the equipment is to be installed must be complied with.

Before performing work on the panels, it is essential that you comply with the follow-ing instructions:

Danger!Risk of fatalities due to high voltage. Isolation from high voltage and earthing must always be ensured before performing assembly or maintenance work.

Danger!Risk of fatalities due to supply voltage. Isolation from supply voltage must always be ensured before performing assembly or maintenance work.

Warning!Risk of injury due to movable parts in mechanical drives. For maintenance work,

► isolate the system from the supply voltage ► release the circuit-breaker’s energy storing device by OFF-

ON-OFF operation and make-proof earthing switches by the appropriate ON-operation.

Warning!After removing covers from a switchgear unit, operator safety may be reduced regarding internal arcs unless the switchgear is isolated from the power supply. Optimum operator safety is only ensured if the switchgear is completely disconnected from the power supply and grounded during assembly.

For the case of an internal fault, the GHA switchgear features pressure relief ports which prevent the panels and the switchgear from bursting.This Technical Manual does not include information regarding the safety of buildings in case of internal faults (pressure load of the switchgear room and necessary pres-sure relief ports). Pressure calculations for switchgear rooms incl. recommendations regarding pressure relief ports can be provided on request against a fee. For further details, please contact the manufacturer.Incaseoffireorofinternalfaults,toxicandcausticdecompositionproductsmaybeproduced. Comply with the locally applicable accident and safety provisions.Incaseofpersonalinjury,takefirst-aidmeasuresorcausethemtobetaken.

Applicable standards and regulations:

Behaviour in case of incidents or accidents

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2 Design, description, variants

2.1 Switchgear panels with single busbar

1

2

3

4

56a

7

8

9

10

1213

14

15

16

17

1 Busbar tank with three-position switch

2 Jack rings3 Busbar link4 Circuit-breaker tank with vacuum

interrupter chambers5 Toroidal-core current transformer6a Outer cone-type bushing6b Inner cone-type socket7 Voltage transformer (optional)8 Cable support9 Cable compartment cover10 Disconnecting device for voltage

transformer (optional)11 Test sockets for cable test12 Capacitive voltage testing system13 IDIS indicator for insulating gas

monitoring14 Hinged front frame15 Manual operator interface16 Low-voltage cabinet17 IDIS gas density switch

Fig. 1Circuit-breaker panel with outer cone-type bushing

1

2

3

4

5

7

11

16

17

18

10

6b

8 9

11

6b

8

7

5

10

Fig. 2Circuit-breaker panel with inner cone-type socket

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123

4

5

6

9

12

10

11

87

13

14

1 Right-hand busbar tank with three-position switch

2 Left-hand busbar tank with three-position switch

3 Jack rings4 Busbar link5 Circuit-breaker tank with vacuum

interrupter chambers6 Toroidal-core current transformer

(optional)7 Voltage transformer (optional)8 Cable compartment cover9 Test sockets (optional)10 IDIS indicator for insulating gas

monitoring11 Hinged front frame12 Manual operator interface13 Low-voltage cabinet14 IDIS gas density switch

Fig. 3Bus section coupler, shown for rated current Ir≤2000A

6

8

Fig. 4Bus section coupler, shown for rated current Ir≤2500A

L R

L R

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Busbar attachments

Fig. 5Busbar voltage transformers (2 variants available)

Fig. 6Busbar surge arresters (2 variants available)

Fig. 7Busbar earthing switch

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2.2 Panels with double busbar

1

2

7

3

4a

5

6

171819 16

8

9

10

12

13

14

15

11

1 Gas density switch of the IDIS sys-tem for busbar 1 (rear busbar)

2 Busbar link SS13 Circuit-breaker tank with vacuum

interrupter chambers4a Outer cone-type bushing4b Inner cone-type socket5 Toroidal-core current transformer6 Voltage transformer (optional)7 Cable support8 Cable compartment cover9 Disconnecting device for voltage

transformer (optional)10 Capacitive voltage testing system11 IDIS indicator for insulating gas

monitoring 12 Hinged front frame13 Manual operator interface14 Low-voltage cabinet15 Gas density switch of the IDIS sys-

tem for busbar 2 (upper busbar)16 Busbar link SS217 Tank, busbar 2 (upper busbar) with

three-position switch18 Jack rings19 Tank, busbar 1 (rear busbar) with

disconnector20 Test sockets for cable test

Fig. 8Circuit-breaker panel with outer cone-type bushing

1

2

3

4

5

7

20

16

17

18

10

6b

8 9

5

11

10

7

8

6b

Fig. 9Circuit-breaker panel with inner cone-type socket

12

12

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Fig. 10Bus section coupler, busbar 2 (busbar 1 analogous)

Fig. 11Bus coupler

Fig. 12Metering panel with busbar voltage transformer or with bus-bar surge arrester (not shown)

Fig. 13Bus section coupler, busbar 2 (busbar 1 analogous)

12 12

12 1

2

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2.3 Dimensions and weightsSwitchgear panels with single busbar (see Fig. 14, page 16)

Panel type Rated current Ir1

[A]Panel width A

[mm]Depth2 [mm]

Depth3 [mm]

Approx. weight [kg]4

Feeder panel

≤ 1250 6001330

2400/2780(Height of low-voltage

cabinet: 800/1200)

7001600

600/8005800

2000 1380/13305 900

2500 900 1330 1100

L R

Bus section coupler

≤ 1250800

1330 9001600/2000 1380 1100

2500 1000 1330 1300

Bus sectionalizer with disconnector ≤ 2500 600 1330 300

Busbar measure-ment with current transformer

≤ 2500 600 1330

2600/2780 (Height of low-voltage

cabinet: 800/1200)

300

Attached busbar earthing switch +70

Disconnecting device attached to the busbar (for voltage transformer or surge arrester) (panel height depending on the attachment design, see Chapter 2.1, page 10)

24006/25007 +70

Voltage transformer for outgoing feeder cable / busbar +120 (3 x 40)

1 In the case of feeder panels, the rated current Ir refers to the feeder (max. busbar nominal current: 2500 A)2 The values listed in the Tables are referred to a panel depth without pressure relief duct on the rear.

Depth of panels with rear pressure relief duct: 1595 mm3 –Dampingresistor(foroptionalvoltagetransformer)onthelow-voltagecabinet:specifiedheight+150 – Height of pressure relief duct: 2400 – Height of pressure relief duct with fan: 26004 including the low-voltage cabinet, without voltage transformer and for feeder panels with outer cone-type bushing

feeder panels with inner cone-type socket: max. + 200 kg Panels with rear pressure relief duct: max. + 100 kg

5 The dimensions depend on the cable connection system; inner cone-type socket / outer cone-type bushing system6 Voltage transformer on the busbar can be removed by pulling it laterally (see Fig. 5, page 10)7 Voltage transformer on the busbar can be removed by pulling it upwards (see Fig. 5, page 10

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Switchgear panels with double busbar (see Fig. 15, page 16)


[A]

Panel width A

[mm]

Depth2 [mm]

Depth3 [mm]


12

Feeder panel

≤ 1250 6001700

2400/2780(Height of low-voltage

cabinet: 800/1200)

9001600

600/8005900

2000

1860

1200

2500 900 1400

12

Bus section coupler≤ 1250/1600

8001700 1100

2000 1980 14002500 1000 2030 1300

12

Bus section coupler

≤ 1250/1600800 1700

11002000 1400

2500 1000 1850 1300

12

Bus coupler

≤ 1250/1600600

1700 9002000

1860

1100

2500 900 1600

12

Bus sectionalizer with disconnector

≤ 1600 ≤ 2500

600 600

1700 1970

400 450

12 Busbar measurement

with current trans-former ≤ 2500 600 1700 2600/2780 600

1 In the case of feeder panels, the rated current Ir refers to the feeder (max. busbar nominal current: 2500 A).2 The values listed in the Tables are referred to a panel depth without pressure relief duct on the rear. Technicaldetailsandthedesignfortherearpressurereliefductmustbeclarifiedwiththemanufacturerasrequired.3 –Dampingresistor(foroptionalvoltagetransformer)onthelow-voltagecabinet:specifiedheight+150 – Height of pressure relief duct: 2400 – Height of pressure relief duct with fan: 26004 Thespecifiedweightsapplyincludingthelow-voltagecabinetandwithoutthevoltagetransformer;theyrefertofeederpanels

with outer cone-type bushing. - Feeder panels with inner cone-type socket: max. + 200 kg

– Panels with rear pressure relief duct: max. + 150 kg5 The dimensions depend on the cable connection system; inner cone-type socket / outer cone-type bushing

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[A]

Panel width A

[mm]

Depth2 [mm]

Depth3 [mm]


12 Metering panel for volt-

age transformer ≤ 2500 600 1700 24006/25007 400

12 attached busbar earth-

ing switch ≤ 2500 600 1700 2400/2780 400

attached voltage transformer for outgoing feeder cable / busbar + 120 (3 x 40)

1 In the case of feeder panels, the rated current Ir refers to the feeder (max. busbar nominal current: 2500 A).2 The values listed in the Tables are referred to a panel depth without pressure relief duct on the rear. Technicaldetailsandthedesignfortherearpressurereliefductmustbeclarifiedwiththemanufacturerasrequired.3 –Dampingresistor(foroptionalvoltagetransformer)onthelow-voltagecabinet:specifiedheight+150 – Height of pressure relief duct: 2400 – Height of pressure relief duct with fan: 26004 Thespecifiedweightsapplyincludingthelow-voltagecabinetandwithoutthevoltagetransformer;theyrefertofeederpan-

els with outer cone-type bushing. - Feeder panels with inner cone-type socket: max. + 200 kg

– Panels with rear pressure relief duct: max. + 150 kg5 The dimensions depend on the cable connection system; inner cone-type socket / outer cone-type bushing6 Voltage transformer can be removed by pulling it laterally (see Fig. 12, page 12)7 Voltage transformer can be removed by pulling it upwards

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1340/13803

15954

2380

/278

01

2400

A

2100

- 23

00

+150 +20056

1 with low-voltage cabinet 800/1200 mm

2 Height depends on the busbar cooler attachments

3 Panel depth depending on rated current Ir of the panel (without/with cooler, see Table)

4 Depth of panel with pressure relief duct

5 Damping resistor6 Fan attachment

Fig. 14Dimensions of a series GHA single busbar panel

2100

- 23

00

2380

/278

01

1700/1960

19906/22107A

2400

+150 +2005 4

1 with low-voltage cabinet 800/1200 mm

2 Height depends on the busbar cooler attachments

3 Panel depth depending on rated current Ir of the panel (see Table)

4 Damping resistor5 Fan attachment6 Depth of panel with pressure relief

duct 7 Depth of panel with pressure relief

duct and bus section coupler of the rear busbars (Ir = 2500 A)

Fig. 15Dimensions of a series GHA double busbar panel

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2.4 Applicable standards

■ metal-enclosed ■ SF6-insulated ■ type-tested and prefabricated ■ testedforinternalfaults(qualificationIAC) ■ dimensioned for indoor installation

Designation Standards

Switchgear IEC 62271-1 IEC 62271-200Circuit-breaker IEC 62271-100Earthing switch IEC 62271-102Disconnector IEC 62271-102Current transformer IEC 61869-2Voltage transformer IEC 61869-3Voltage detection systems IEC 61243-5Protection against accidental contact, foreign bodies and water IEC 60529Installation IEC 61936-1Operation of electrical equipment EN 50110-11

InsulatinggassulphurhexafluorideSF6 IEC 60376 Useandhandlingofsulphurhexafluoride(SF6) IEC 62271-303

1 The national standards applicable in the country where the equipment is to be installed must be complied with.

Degrees of protection against accidental contact and foreign objects accord-ing to IEC 60529Main electric circuits IP65

Drive mechanisms IP2X1

Low-voltage cabinet IP3X1

Cable compartment IP3X1

1 optional IP5X

2.5 Environmental and operating conditions

GHA is an indoor switchgear and may only be operated under normal conditions in acc. with IEC 62271-1. Operation under conditions deviating from these is only admissible subject to consultation with and written approval from the manufacturer.

Ambient conditions (in accordance with IEC 62271-1)Temperature class "Minus 5 indoors”

Min./max. ambient temperature °C –51/+401

Average value over 24 hours °C ≤ 351

mean rel. air humidity: 24 hour/1 month % ≤ 95/≤ 90Installation altitude above sea-level m ≤ 10001

1 other values available on request

Type GHA switchgear units are:

GHA switchgear units meet the following standards and regulations:

Degree of protection against accidental contact and foreign objects:

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2.6 Intended use

Gas-insulated GHA medium-voltage switchgear units are exclusively intended for switching and distributing electrical energies. They may only be used in the scope of thespecifiedstandardsandtheswitchgear-specifictechnicaldata.Anyotherutiliza-tion constitutes improper use and may result in dangers and damage.

The manufacturer shall not be held responsible for damage which occurs if ■ instructions in this Technical Manual are not complied with; ■ the switchgear is not operated according to its intended use (see above); ■ the switchgear is assembled, connected or operated improperly; ■ accessories or spare parts are used which have not been approved by the

manufacturer; ■ the switchgear is converted without the manufacturer’s approval, or if inadmis-

sible parts are added.No liability is accepted for parts provided by customers, e.g. current transformers.

2.7 Disposal after the end of service life

TheoperatingequipmentcontainsthefluorinatedgreenhousegasSF6 covered by the Kyoto Protocol with a global warming potential (GWP) of 22 200.SF6 must be recovered and must not be released into the atmosphere. When trans-porting and handling SF6,thespecificationsinIEC62271High-VoltageSwitchgearandControlgear–Part303UseandHandlingofSulphurHexafluoride(SF6), must be complied with.A material and recycling data sheet can be provided on request for the disposal of series GHA switchgear units at the end of their service life.Disposal is performed as a service by the manufacturer’s Service Center and is subject to a fee.

Liability Disclaimers

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3 Packaging, transport, storage

3.1 Shipping units

Delivery is effected in terms of prefabricated single switchgear panels. One transport unit consists of max. 2 individual switchgear panels which are fastened to the pallet. The busbar compartment with three-position switch, the circuit-breaker compart-ment, the drive mechanisms and the supporting structures are mounted ready for connection and routine-tested. The individual busbar links are mounted on site. The low-voltage cabinets are assembled in the factory or supplied as accessories, depending on the customer’s wishes.

■ If packed exclusively for truck transport, the panels are delivered on a pallet withPEprotectivefilm.

■ For sea transport, the units are packed in sealed aluminium foil with desiccant and in a closed wooden case with tightly closed wooden base (also for con-tainer transport).

■ In case of air transport, the panels are packaged in wooden crates with a protectivePEfilmhood(dustprotection)orinwoodencrates,alsowithclosedwooden bases, however without protective hoods (dust protection).

Notice:The weight of the entire transport unit is indicated on the packaging.

3.2 Transport

Warning!Danger due to tipping load.

► Transport units must be protected sufficiently against slipping and tipping during transport.

Warning!Sufficient stability and evenness of the supporting area (floor) must be ensured.

■ Handle shipping units carefully when unloading and unpacking them ■ Shipping units must be checked upon receipt. Any damage which may have

occurred in transit must be recorded and reported to the manufacturer immedi-ately.

■ The consignment must be checked for completeness based on the shipping documents.

■ Thesuppliermustbenotifiedinwritingwithoutdelayaboutanypossibledevia-tions.

Packaging

Abb. 16Do not tip the transport units

Transport using a forklift truck

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3 Packaging, transport, storage

The panel may only be transported on a pallet. The entire length of the forks must be placed under the transport unit (Fig. 17).

Fig. 17Transport with forklift truck

3.3 Storage

Warning!Sufficient stability and evenness of the supporting area (floor) must be ensured.

If the panels are not installed immediately after delivery, they can be stored under the following conditions:

■ Panels must be stored in vertical position, and must not be stacked. ■ Storage only admissible indoors ■ Panels and accessories must be packed in a wooden crate with a dessicant

and sealed in aluminium foil (storage period max. 2 years after date of packaging).

– 5 ºC

+ 40 ºC

Fig. 18Diagram showing the storage conditions

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4 Assembly

4.1 Safety provisions

The switchgear panels may only be installed and assembled by the manufacturer’s stafforbypersonswhohavebeencertifiedforthiswork.The GHA series switchgear panels are delivered with the circuit-breaker set to “OFF”, the energy storing device released and the disconnector and earthing switch set to “OFF”.

Warning!Risk of injury due to movable parts in the mechanical drive. The energy storing device of the circuit-breakers and the earthing switches must not be charged during assembly.

Warning!Risk of accidents! Watch out for floor openings in the switchgear room.

Danger!Danger due to insufficient dielectric strength of high-voltage con-nections in case of assembly under aggravated ambient condi-tions. During assembly of the busbar link and the high-voltage connections, it is essential to avoid condensation, dirt and dust deposits. At the time of installation, the ambient temperature must amount to ≥ 10 °C.

Warning!The top sides of the panels are not meant to be walked on. Per-sons may fall through them, get injured or may damage the panel. When work has to be performed on the panel top - e.g. assembly of deflectors, fans or pressure relief ducts - temporarily position a solid mounting rack to step on.

Warning!Risk of injury due to non-respect of the safety provisions in Chap-ter 1, on page 7.

4.2 Important instructions for assembly

Notice: ● Switchgear with pressure relief duct (see Chapter 8, as of page

67): The pressure relief duct must be mounted before the panel is positioned on the base frame.

● Condensation, dirt and dust should be avoided during assembly on all accounts, in order to prevent damage to the panels.

● For assembly, observe the assembly drawings supplied with the equipment. Read them before you commence assembly work. The drawing numbers are specified in this manual under the de-scription of the assembly work in question.

● For all screw connections, refer to the tightening torques specified in the Annex.

● The transport securing device on the busbars must not be re-moved before assembly of the busbar link acc. to Chapter 4.7 on page 32.

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4 Assembly

4.3 Requirements regarding the switchgear room

Notice:Before installing the switchgear panels, make sure that the switchgear room is checked according to the customer-specific switchgear docu-mentation.

■ Observe the minimum distance between the switchgear and the wall of the building.

■ The load-bearing capacity of the fastening areas must correspond to the weight of the switchgear (perform a stress analysis of the building).

■ Check base frame for dimensions and tolerances in position. ■ Checkpositionofflooropeningsforhigh-voltageandlow-voltagecables.

Before the switchgear is positioned at its site of installation, check that the base frame dimensions are precisely correct.

– Flatness: ±1 mm/meter – Straightness: ±1 mm/meter – Parallelism: ±1 mm/meter – Height difference over the entire length of the switchgear: ±2 mm

Design data of GHA switchgear: Examples for various switchgear panel variants

500

1194

41

180 600/800 600/800

5050

7

2

50

6

8

14

2 3

50

900800

900800

100

460/660 660

175

35

5

Fig. 19Location of base frame and ceiling ducts (example: double busbar switchgear)1 Rear gap cover2 Steel base frame3 Ceiling duct for high-voltage connections4 Wall of building5 Possible cross-bracings 6 Cooler attachments7 Side wall8 Side wall extension for double busbar switchgear

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4 Assembly

≥100

≥1700

1000

1340

2400/2780

Fig. 20Example of panels with single busbar in the switchgear room

≥500 ≥2100

1000

2380/2780

1700

Fig. 21Example of panels with double busbar in the switchgear room

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≥5001 ≥17001595

1000

2400

Fig. 22Example of panels with single busbar and pressure relief duct in the switchgear room 1Switchgearaccessiblefromtherear:≥800

≥5001 ≥21001990

1000

2400

Fig. 23Example of panels with double busbar and pressure relief duct in the switchgear room 1Switchgearaccessiblefromtherear:≥800

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4.4 Transporting the panels on the construction site

Warning!Make sure the rope or chain is strong enough to bear the weight of the panel and the trucks. Comply with the relevant provisions for hoisting equipment.

Warning!On lowering the panels, make sure that the supporting platform is sufficiently stable and even.

Warning!Risk of tipping over. During transport, pay attention to the weight distribution. The center of gravity is at gas tank level in the upper part of the switchgear panel. Never move panels without using transport aids.

Warning!Risk of accidents. Pay attention to floor openings!

4.4.1 Transport of panel by means of a crane1. Removetransportpackaging(protectivefilms).2. Attach rope/chains to the jack rings located on the busbar tank (Fig. 24).

Notice:The ropes must have the following minimum lengths: L ≥ 900 mm

3. Release transport fastening device of the panel from the transport pallet (Fig. 24, item 1).

4. Lift the panel carefully with the crane.5. If necessary, mount transport rollers (Fig. 26). Description of assembly, see

following page.6. Lowerthepanelslowlytotheflooratitsplaceofdestination.

1

L ≥ 900

Fig. 24When lifting, make sure that at least the minimum rope length L is used.1 Transport fastening

1

Fig. 25Panels with cooler and busbar attach-ments1 Use an additional frame for crane

transport.

Fig. 26Mounting the transport rollers (see Chap. 4.4.2, page 26)

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4.4.2 Transport using the transport frameFortransportonthefloor,aframemustbemountedtotheleftandrightoftheswitchgear panel (not included in scope of supplies).

1. Insert locating pins of transport frame into the lateral bore-holes in the support-ing structure of the switchgear panel, and secure them by means of the two knurled screws (Fig. 27, item 2).

2. Actuate front toggle lever (3) to its stop in the direction of the arrow. Press the button on the rear lifting device (4) and actuate lever to its stop in the direction of the arrow till it reaches its stop.

3. The panel is lifted.

1 2

3 4

5

Fig. 27Mounting the transport rollers1 Transport frame2 Knurled screws3 Front toggle lever4 Rear lifting device with push-button5 Switchgear panel

Thesepanelsaredeliveredfromthefactorywithadditionalsupportingprofilesmounted.Thesupportingprofilesmustnotberemovedduringassembly.Fortransportonthefloor,thetransportrollersmustbesecuredtothesupportingprofilestotheleftandrightofthesupportsprovidedtothiseffect(Fig. 28).Removeasupportingprofilebeforescrew-fasteningthepaneltoanadjacentpanel.Asupportingprofile-left-handorright-hand-mustalwaysbeleftmountedtothepanel as long as the panel is not screw-fastened to the adjacent panel. Remove sup-portingprofileafterhavingscrew-fastenedthepanels.

Fig. 28Panelwithpre-assembledsupportingprofilesandattachedtransportrollers

Assembly

Panels with center of gravity located in the rear part (e. g. single busbar panel with bus section coupler on the rear busbar)

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4.4.3 Transporting the panels onto the base frame1. PlacetwoUprofiles(notincludedinscopeofsupplies)onthebaseframeas

traversing aid and block them by (lower) stops against slipping in the base frame (Fig. 29, item 1).

2. AdjustthedistancebetweenthetwoUprofilesinaccordancewiththepanelwidth. When positioning the panels, make sure that the transport rollers are locatedintheUprofiles.

3. Move panel onto the base frame, align front edge (see space assignment plan) and lower the panel.

4. RemovetransportrollersandUprofiles.

1

2 3

Fig. 29Moving the panel on the base frame1 Uprofileswithstopedgesastraversingaid2 Transport frame3 Switchgear panel

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4 Assembly

4.5 Attachment of pressure relief duct

Switchgear units are provided with pressure relief duct, if the following is required: ■ Accessibilityinacc.withIEC62271-200:QualificationIACAFLR(accessibility

from all sides) and/or ■ QualificationIACAFL(R)internalarc40kA/1s

Notice:The pre-assembled pressure relief duct supplied with the equipment must be mounted before the panel is positioned on the base frame. After installation of the panels, mounting may no longer be possible in part.

L

2

L

3

Fig. 30Switchgear panel with single busbar and pressure relief duct

Fig. 31Switchgear panel with double busbar and pressure relief duct

The attachment of the pressure relief duct is described in the assembly drawing in question:

Panel width [mm]

Busbar system

Pressure relief from the switchgear room with customized duct

Pressure relief into the switchgear room

for fan attach-ment

TrSS SS-Stw 600 800 900 1000

Sin-gle

bus-bar

Dou-ble

bus-bar

Internal arc qualification IAC AFLR, ≤25 kA/1 s

Internal arc qualification IAC AFLR, ≤40 kA/1 s

■ ■ AGS002105-02 AGS003379-012

■ ■ AGS002105-04 AGS002105-04■ ■ AGS002105-06 AGS002105-06 AGS002105-151

■ ■ AGS002105-07 AGS002105-07 AGS002105-161

■ ■ AGS003216-01 AGS003216-01■ ■ AGS002105-08 AGS003379-08

■ ■ AGS002105-10 AGS002105-10■ ■ AGS002105-12 AGS002105-12

■ ■ AGS002105-14 AGS002105-14■ ■ AGS003216-02 AGS003216-02

■ ■ AGS002105-08 AGS002105-08 AGS002105-183

1 Optional fan attachment2 only to be used for panels without busbar top structure, in this case AGS002105-02 3 only in case of Ir = 2500 A

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4.6 Remove cable compartment cover and shutters4.6.1 Cable compartment interlock (optional)An additional interlock prevents the cable compartment cover from being removed if the earthing switch is not switched ON.1. Charge spring mechanism of the circuit-breaker (Fig. 32, item 3). Earth the

outgoing feeder cable (see Operating Manual).2. Push interlocking slide of cable compartment cover (2) upwards.At the same time, the cable compartment cover is unlocked and actuation of the earthing switch (1) interrupted mechanically and electrically.

Notice:After removing the cable compartment cover, it is impossible to push the slide (Fig. 32, item 2) down. The earthing switch remains locked.

1

2

3

00346

Fig. 32Unlock/lock cable compartment cover1 Insertion opening for manual actuation of the earthing switch2 Slide for locking/unlocking the cable compartment cover3 Charge the spring mechanism of the circuit-breaker drive manually (as long no

supply voltage is applied).

Interlocking matrix Earthing switch Cable compartment cover

Cable compart-ment cover

screw-fastened unlocked –

removed locked –

Earthing switchON – unlockedOFF – locked

After assembly of the cable compartment cover, press interlocking slide (Fig. 32, item 2) down. The earthing switch (1) can be switched off mechanically and electrically.

Unlocking the cable compartment cover

Locking the cable compartment cover

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4.6.2 Remove cable compartment cover and shutters

Notice:Store screws, bolts and shutters carefully for subsequent reuse.

1. Open front frame: – Operating shutter without inspection glass:

Release the two securing bolts (Fig. 33, item 1). – Operating shutter with inspection glass:

Open interlocking mechanism using the double-bit key (Fig. 34, item 2).Then, open the front frame by swinging it to the left.

2. Unscrew the two securing bolts from the cable compartment cover (3).3. First pull the cable compartment cover up, then forwards to remove it.

1

1

3

4

Fig. 33Operating shutter without inspection glass1 Securing bolts of the front panel3 Securing bolts of cable compart-

ment cover4 Hinged front frame

3

4

2

Fig. 34Operating shutter with inspection glass2 Lock and double-bit key3 Securing bolts of cable compart-

ment cover4 Hinged front frame

Removing cable compartment cover

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Notice:Identify panel in accordance with the nameplate on the operating shut-ter to avoid confusion.

1. Release screw connection of the operating shutter (Fig. 35, item 5) from the 4 fastening points and remove shutter

2. Release the fastening of the two lateral covers (4) of the right-hand cable tray and remove covers.

1 2

34

5

Fig. 35Removal of shutters1 Hinged front frame2 Operating shutter3 Cable compartment cover4 Cable tray cover5 Screw connection of operating shutter (4 x)

Unscrewing the shutters

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4.7 Installation of panels

4.7.1 Installation of the first switchgear panel

Notice:The position of the first panel is decisive for placement of the subse-quent panels, thus it is essential that measuring is effected with the utmost precision!

1. Placethepanelonthebaseframeaccordingtotheswitchgear-specificspaceassignment plan (see Chapter 4.4.3, page 27).

2. Align panel. Check the panel front for correct horizontal and vertical position. If applicable, lift the panel and place shims in the direct vicinity of the fastening areas, until the horizontal position has been reached.

3. Positionthefollowingpanelonthebaseframenexttothefirstpanelaccordingtotheswitchgear-specificspaceassignmentplan.

4. Remove shutters from the panels as described in Chapter 4.6 as of page 29.

4.7.2 Removal of transport securing deviceRemove transport securing device above the high-quality electrical joints of the busbar link.

– Remove plastic cover from the busbar bushing (Fig. 36). – The plastic hood above the silicone sleeve is attached laterally and on top of

the retaining clip (Fig. 37). Remove plastic hood carefully applying little force only.

Fig. 36Plastic cover on the busbar bushing

Fig. 37Plastic hood above the silicone sleeve

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4 Assembly

4.7.3 Pre-coat the high-quality electrical joints of the busbar link

Notice: ● Make sure the high-quality electrical joints are absolutely clean. ● Special grease (art. no. AGS 003371-01) and the sponge element

(art. no. S 065969) are either included in the scope of supplies or must be purchased separately, depending on the agreement concluded. In case of doubt, please contact the manufacturer as required.

1. Clean the high-quality electrical joints of the busbar link (Fig. 40) using white spirit(art.no.S009002)andalint-freecloth(alsomicro-fibrecloths).

2. For each side of a high-quality electrical joint, press a length of approx. 10 mm substance out of the tube and apply it using the sponge element (Fig. 40). In the beginning, apply slightly more (approx. 15 mm), as the sponge also absorbs grease. Onetube(90g)issufficientforapprox.36completehigh-qualityelectricaljoints(72 high-quality joint surfaces).

Abb. 38Special grease (art. no. AGS 003371-01)

Abb. 39Sponge element (art. no. S 065969)

10-15

1

Fig. 40High-quality electrical joint at the bus-bar bushing1 Make sure that the inner diameter

is greased thoroughly!

10-15

1

Fig. 41High-quality electrical joint on the sili-cone sleeve1 Make sure the electrode ring is

clean!

3. Usethespongeelementtospreadauniformthinfilmofthethespecialgreaseover the entire surface. Blank spots not covered by grease should be avoided on all accounts. Once treated, do not touch the surfaces of the high-quality electrical joints any longer.

Notice: ● Busbar bushing (Fig. 40): Check especially the inner diameter

of the high-quality electrical joint for non-greased areas and, if necessary, re-coat.

● Check the electrode ring in the silicone sleeve (Fig. 41, item 1) for cleanness and the absence of grease and, if necessary, clean.

Apply special grease and spread it uniformly by means of the sponge element.

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4.7.4 Preassembling the clamping contacts1. The following factory setting of the clamping contacts (Fig. 42) must be checked

prior to assembly: Turn the two screws until the two clamping contacts are in loose contact, then turn the screws back by a half turn of the thread.

2. Clean and grease busbar contact surfaces and contact points on the clamping contact (see Chapter 13.3, page 92).

3. Carefully slip the clamping contacts into the busbar tubes of the left-hand panel.

3 2

1

Fig. 421 Check the clamping contact screws.2 Clean and grease the contact surfaces3 Insert the contact tips

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4.7.5 Screw-fastening the panels to one another1. Push panels carefully together. Clearance between busbar tanks: 153 ± 2 mm

(Fig. 43, item 1).2. Connect panels to one another

(assembly drawing AGS 000913-01): – front panel screw connection:

9 x self-locking screw M8 to its stop (Fig. 43, item 3). Panels with a width of 900 or 1000 mm are screw-fastened using compen-sating shutters (see Chapter 4.8, page 36).

– rear panel screw connection: Screw-fasten connecting link to the jack ring plate 2 x self-locking screw connection M8 (Fig. 43, item 2).

Panel types Pressure relief duct Mat. no.without with

All panel variants, except busbar current transformers

■ AGS000913-03■ AGS000913-01

Busbar current transformer■ AGS000913-02

■ AGS000913-05

3

2

1

9x

153±2

2

Fig. 43Screw-fastening the panels to one another1 Check setting 153 ± 2; measuring location: Edge shown on the busbar tank2 Rear panel screw connection: fasten connecting link3 Screw-fasten panels on the front.

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4.8 Compensating shutters for the panel front

Compensating shutters are only required for panels with a width of 900/1000 mm (seealsoswitchgear-specificdocumentation),panelswithawidthof600/800mmdonot require compensating shutters in-between each other. The shutters are always supplied in preassembled condition as accessories. The compensating shutter vari-ants are subdivided in accordance with the following dependencies:

– Height of low-voltage cabinet 800 mm or 1200 mm – Nominal width of compensating shutter 50 mm or 100 mm, depending on panel

arrangement (see Table)

Panel with panel width [mm]

Panel width, adjacent panel (left-hand or right-hand)

[mm]

Rated width, compensating shutter (left-hand or right-

hand) [mm]

900/1000600/800 50

900/1000 100

A

1

2

3

4

5

50 100

4 4 1/23/5

900/1000

A

Fig. 44Compensating shutters in the panel front1 Upper compensating shutter, width

100 mm 2 Lower compensating shutter, width

100 mm

3 Lower compensating shutter, width 50 mm

4 Screw connection M8 (12 x per shutter)

5 Upper compensating shutter, width 50 mm

Required nominal width of the compensating shutter depending on the panel arrangement:

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4 Assembly

In-line panel, left-hand

Panel width

LV cabinet height End panel, left-hand

600/800 mm

In-line panel, right-hand

Panel width800 1200

■ ■ not required 600/800■ AGS003372-01

900/1000■ AGS003372-02


Panel width


900/1000 mm


Panel width800 1200

■ AGS003372-01600/800/900/1000

■ AGS003372-02In-line panel, left-

hand Panel width

LV cabinet height Center panel 600/800 mm


Panel width800 1200

600/800■ ■ not required 600/800■ AGS003372-01

900/1000■ AGS003372-02

900/1000

■ AGS003374-01600/800

■ AGS003374-02

■ AGS003372-01 +AGS003374-01900/1000

■ AGS003372-02 +AGS003374-02In-line panel, left-

hand Panel width



Panel width800 1200

600/800/900/1000■ AGS003372-01 +AGS003374-01

600/800/900/1000■ AGS003372-02 +AGS003374-02


Panel width

LV cabinet height End panel, right-hand

600/800 mm


Panel width800 1200

600/800 ■ ■ not required

900/1000■ AGS003374-01


hand Panel width

LV cabinet height End panel, right-hand 900/1000

mm


Panel width800 1200

600/800/900/1000■ AGS003374-01


hand Panel width


900 mm


Panel width800 1200

■ AGS002596-01600/800

■ AGS002596-02■ AGS002597-01

900/1000■ AGS002597-02

Front compensating shutter, attachment to panel

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Panel width



Panel width800 1200

600/800

■ AGS002598-01600/800

■ AGS002598-02■ AGS002599-01

900/1000■ AGS002599-02

900/1000

■ AGS002596-01600/800

■ AGS002596-02■ AGS002597-01

900/1000■ AGS002597-02


Panel width

LV cabinet height End panel, right-hand 900 mm


Panel width800 1200

600/800■ AGS002600-01

■ AGS002600-02900/1000 ■ ■ not required

Front compensating shutter, attachment to panel

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4 Assembly

4.9 Busbar link: B link

L1

L2

L3

L1L2

L3

SS1

SS2

Fig. 45Overview of designations for busbars and phase angle– Upper busbar = SS2 – Rear busbar = SS1

1 2 3 4 5 67Fig. 46

Overview of busbar link1 Busbar support with high-quality

electrical joint2 Busbar3 Spacer pin

4 Retaining clip5 Busbar clamping contacts6 Silicone sleeve with securing

half-shells

Detail drawing of a B-link

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4 Assembly

4.9.1 Press silicone sleeve back

Fig. 47Tool for compressing the silicone sleeve - fork

Fig. 48Tool for compressing the silicone sleeve (alternative) - claw fastener

To get access to the pre-assembled clamping contacts and to complete the busbar link, it is necessary to press the silicone sleeve back.To this effect, only the auxiliary equipment approved by the manufacturer may be used, e.g. the fork Fig. 47 and the claw fastener Fig. 48.Position the tool according to the illustration and press the silicone sleeve back.Relieve the silicone sleeve. To do so, slowly release the silicone sleeve using the tool being used, and remove the tool.

Notice:Switchgear units with fan are equipped with a current transformer on the busbar link for fan control. Before mounting the busbar link, refer to Chapter 4.9.6, page 47.

Tool for pressing the silicone sleeve back (see also Annex, Chapter 13.2, page 85)

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4.9.2 Connecting the busbar (fasten preassembled clamping contacts)

Notice:The two lugs of the upper clamping contact must be located between the busbar tubes.

Assembly drawing for single and double busbar: AGS 002 268-011. Position the preassembled clamping contacts (see Chapter 4.7.4, page 34) acc.

to Fig. 49, item 2. The two lugs of the upper clamping contact must be located between the busbar tubes (see Fig. 49, item 4).

2. Tighten the clamped connection with a torque of 8 ± 1 Nm.3. Aftertighteningtheclampedconnectionapplyingthespecifiedtorque,remove

theredfilmfromthesandwichlabel(5).Agreenstripeappearswhichindicatesthat the busbar link has been established correctly.

1

8 ± 1 Nm

0-3 mm

2

3

4

5 4

Fig. 49Busbar link1 Tool2 Clamping contacts3 Busbar4 Locating lugs5 Sandwich label

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4.9.3 Contact resistance measurement of busbar screw fastening

Notice:Comply with the manufacturer’s specifications regarding the contact resistance measuring unit.

1. Set the feeder panel for resistance measurement in testing position (A) (Fig. 50): Switch disconnector and circuit-breaker ON, refer also to operating manual.

2. Connect the clip-on ammeter probes of the contact resistance measuring unit to the high-voltage cable connection in the right-hand panel (B). Illustrated: Outer cone-type bushing. Use suitable current probes for the inner cone-type bushing.

3. On the lined-up panel, connect clip-on ammeter probes of the contact resis-tance measuring unit to the busbar tube by means of inner cone-type current probes (C).

4. Apply test current 100 A DC (D).5. Measure contact resistance R between the busbar tube and the lug of the

clampingcontact(E).SetvalueR:≤5μΩ. Ifthemeasuredvalueexceedsthespecifiedvalue:

– Undo busbar screw fastening. – Clean contact surfaces carefully and repeat the mounting and measuring

procedure.In this way, check the contact resistance of all phases between all panels.

100 A DC

00243

C

D

E A

B

R ≤ 5 µΩ

Fig. 50Contact resistance measurement

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4.9.4 Fasten silicone sleeve to adjacent panel

Notice:Check pre-coated high-quality electrical joints again for absolute clean-ness. The surfaces of the high-quality electrical joint must be coated com-pletely and uniformly with a thin layer of special grease. Check high-quality electrical joints for non-greased areas and, if neces-sary, coat again, see Chapter 4.7.3, page 33.

6. Relieve the silicone sleeve. To do so, slowly release the silicone sleeve using the tool being used, and remove the tool.

7. Clean spacer pins (accessories, Fig. 46, item 3, page 39) and welding studs and coat them with a screw locking compound (see Chapter 13.3, page 92). Screw-fasten spacer pin onto the welding studs.

8. Slip retaining clip onto the two pins. The sides of the retaining clip must butt against the retaining lugs of the securing half-shells. Subsequently, position the cage with the cup springs and fasten retaining clip by means of a M8 self-locking nut. The surfaces of the high-quality electrical joint must be compressed by the retaining clip.

1

(10 ± 1,5 Nm)

23

4(12 ± 1,5 Nm)

Fig. 51Fastening the silicone sleeve to the adjacent panel1 Spacer pin2 Retaining clip3 Cup spring package4 Nut

Checking high-quality electrical joints

Mounting the retaining clips

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4.9.5 Cover of busbar link in case of panels without pressure relief duct

Panel width, adja-cent panel, left-hand

[mm]

Panel width [mm]

Assembly drawing

Single busbar Double busbar

600/800 600 AGS003202-01 AGS003202-02600/800 800 AGS003202-01 AGS003203-02

900/1000 600/800 AGS003204-01 AGS003204-02600/800 900 AGS003205-01 AGS003205-02

900/1000 900 AGS003206-01 AGS003206-02600/800 1000 AGS002609-02 AGS003205-02

900/1000 1000 AGS002610-02 AGS003206-02SS-StW 600/800 AGS003215-03 AGS003215-07SS-StW 900 AGS003215-04 AGS003215-08600/800 SS-StW AGS003215-01 AGS003215-05

900 SS-StW AGS003215-02 AGS003215-06

1

2

Fig. 52Cover of busbar link1 Cover of upper busbar link2 Cover of rear busbar link

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Cover of busbar link in case of panels with pressure relief duct

Fig. 53Cover of busbar link in case of panels with pressure relief duct

Panel width [mm]

adjacent panel, right-hand Panel width

[mm]

Busbar sys-tem

Mat. no.

SS-Stw 600 800 900 1000 SS-Stw 600 800 900 1000Single bus-bar

Dou-ble

bus-bar

■ ■ ■ ■ ■ AGS002115-05■ ■ ■ ■ ■ AGS002115-03■ ■ ■ ■ AGS003217-01

■ ■ ■ ■ ■ AGS002115-04■ ■ ■ ■ AGS002115-06■ ■ ■ AGS003217-02

■ ■ ■ AGS002115-06■ ■ ■ ■ ■ AGS002115-02■ ■ ■ ■ AGS002115-07■ ■ ■ ■ AGS003217-05

■ ■ ■ ■ AGS002115-08■ ■ ■ AGS002115-09■ ■ ■ AGS003217-06

■ ■ ■ ■ AGS003217-03■ ■ ■ ■ AGS003217-04■ ■ ■ ■ AGS003217-07■ ■ ■ AGS003217-08■ ■ ■ AGS003217-09■ ■ ■ AGS003217-10

■ ■ ■ ■ AGS002115-10■ ■ ■ ■ AGS002115-11H O ■ AGS002115-14

O = Bus section coupler with upper busbar separation (SS2) H = Bus section coupler with rear busbar separation (SS1)

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Panel width [mm]

adjacent panel, right-hand

Panel width [mm]

Busbar system

LV cabinet Height [mm]

Cover Pressure

relief device

Cover SS (to the right-hand

adjacent panel)

Cover LV cabinet

SS-S

tw

600

800

900

1000

SS-S

tw

600

800

900

1000

Sing

le b

usba

r

Dou

ble

busb

ar

800

1200

■ ■ ■ ■ ■ ■ ■ AGS002113-01 AGS003386-03 -■ ■ ■ ■ ■ ■ AGS002113-03 AGS003386-01 AGS003416-02■ ■ ■ ■ ■ ■ AGS002113-03 AGS003386-01 AGS003416-04■ ■ ■ ■ ■ ■ ■ - - -

■ ■ ■ ■ ■ ■ AGS002113-03 AGS003386-02 AGS003416-02■ ■ ■ ■ ■ ■ AGS002113-03 AGS003386-02 AGS003416-04■ ■ ■ ■ ■ AGS002113-04 AGS003386-05 AGS003416-03■ ■ ■ ■ ■ AGS002113-04 AGS003386-05 AGS003416-05■ ■ ■ ■ ■ - - AGS003416-02■ ■ ■ ■ ■ - - AGS003416-04

■ ■ ■ ■ AGS002113-04 AGS003386-05 AGS003416-03■ ■ ■ ■ AGS002113-04 AGS003386-05 AGS003416-05

■ ■ ■ ■ ■ ■ ■ AGS002113-02 AGS003386-03 -■ ■ ■ ■ ■ AGS002113-05 AGS003386-01 AGS003416-02■ ■ ■ ■ ■ AGS002113-05 AGS003386-01 AGS003416-04

■ ■ ■ ■ ■ AGS002113-05 AGS003386-02 AGS003416-02■ ■ ■ ■ ■ AGS002113-05 AGS003386-02 AGS003416-04■ ■ ■ ■ AGS002113-06 AGS003386-05 AGS003416-03■ ■ ■ ■ AGS002113-06 AGS003386-05 AGS003416-05

■ ■ ■ ■■ ■ ■ ■

■ ■ ■ ■ ■ ■ - - -■ ■ ■ ■ ■ ■ - - AGS003416-02■ ■ ■ ■ ■ ■ - - AGS003416-04

■ ■ ■ ■ ■ - - AGS003416-02■ ■ ■ ■ ■ - - AGS003416-04

■ ■ ■ ■ ■ - - AGS003416-02■ ■ ■ ■ ■ - - AGS003416-04■ ■ ■ ■ - - AGS003416-03■ ■ ■ ■ - - AGS003416-05

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4.9.6 Current transformer on the busbar for fan control

To control fans for disconnectors on the busbar, a toroidal-core current transformer is factory-mounted for each busbar; this transformer is positioned as follows:Single busbar: an der hinteren Phase (on the rear phase (normally designated as L3)Double busbar: Upper busbar (SS2): on the rear phase (L3) Rear busbar (SS1): on the upper phase (L1)

1

2

3

4

3 4

Fig. 54The illustration shows a panel in double-busbar design.The busbar curent transformer is mounted to the single busbar panel in analogy to the upper busbar.1 Busbar current transformer SS22 Busbar current transformer SS13 Silicone sleeve4 Retaining plate for current transformer

Description and variants overview

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1

2

3

4

5 6

7

Fig. 551 Retaining clip2 Securing half-shells, rear3 Current transformer4 Securing half-shells, front

5 Silicone sleeve 6 Retaining plate for current trans-

former7 Wiring of current transformer

Toensurethatthesiliconesleevecanbepressedbacksufficientlyduringbusbaras-sembly, the current transformer must be disconnected and displaced previously. The current transformer as such must not be disassembled.

1. Unscrew the retaining clip of the B link (Fig. 55, item 1).2. Remove the securing half-shells (item 2).3. Detach the current transformer from the retaining plate (item 6).4. Push the current transformer into the position of the removed securing half-

shells.5. Assemble the busbar link acc. to Chapter 4.9 as of page 39.6. After having completed the busbar link, push the current transformer back to its

initial position and re-fasten it to the retaining plate.

Mounting current transformers to the busbar for fan control

Assembly workflow for busbar link (B link)

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49AGS 531 446-01 | Edition 04/2014 49

4 Assembly

7. Remount the two securing half-shells (Fig. 56, item 2) to the silicone sleeve (3).

Notice:Make sure that the securing half-shells are positioned correctly! The bead of the silicone sleeve (Fig. 56, item 5) must be in the groove of the securing half-shell (8).

Comply with the tightening torque 12 ± 1.5 Nm for screw-fastening the securing half-shells.8. Push retaining clip (Fig. 56, item 1) onto the two bolts (6). The sides of the

retaining clip must butt against the retaining lugs of the securing half-shells.Subsequently, position the cup spring package (7) and secure it to the retaining clip using a self-locking nut M8 (6). The surfaces of the high-quality electrical joint must be compressed by the retaining clip.

1234

5

6

7

8

9

5

(12 + 1.5 Nm)

Fig. 56Re-fastening the silicone sleeve to the panel side from which it was previously detached 1 Retaining clip2 Securing half-shells, rear3 Silicone sleeve4 Securing half-shells, front5 Bead

6 Threaded pin M8 with self-locking nut M8

7 Spring cup package8 Groove of securing half-shell9 Hex. socket-head screw M8

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50 AGS 531 446-01 | Edition 04/201450

4 Assembly

4.10 Reinforcement

Required in case of ■ internalarcstrengthacc.toIEC62271-200,qualificationIACAFL(R),internal

arc 40 kA/1 s ■ Seismic design / vibration-resistance

Fan attachment

Panel width adjacent panel,

left-hand

Panel width

Assembly drawing

with-out

with Single busbar Double busbar

■ 600/800 600 AGS003389-01 AGS003389-02■ 600/800 800 AGS003389-01 AGS003389-02■ 900/1000 600/800 AGS003389-03 AGS003389-04■ 600/800 900/1000 AGS003389-05 AGS003389-06■ 900 900 AGS003389-07 AGS003389-08■ 900 1000 AGS003389-09 AGS003389-10■ 1000 900 AGS003389-09 AGS003389-10■ SS-StW 600/800 AGS003389-11 AGS003389-12■ SS-StW 900 AGS003389-13 AGS003389-14■ 600/800 SS-StW AGS003389-15 AGS003389-16■ 900 SS-StW AGS003389-17 AGS003389-18

Fig. 57Reinforcements

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51AGS 531 446-01 | Edition 04/2014 51

4 Assembly

4.11 Screw-fastening the panel to the base frame

Notice:The switchgear panels may not be screw-fastened to the base frame before they have all been installed and adjusted.

Cut thread M8 in the base frame at the securing points provided to this effect (Fig. 58). To this effect, drill initial holes of Ø 6.8. Screw-fasten the panels 2 x each on the front and rear.

1 14

2 3

Fig. 58Fastening points in the base frame

If the rear fastening points are not accessible, e. g. due to voltage trans-formers, fastening links (Fig. 59) can be mounted.Screw-fasten both fastening links to the panel's supporting structure. Cut a thread M8 in the base frame on thespecifiedfasteningpoints.Tothiseffect, drill initial holes of Ø 6.8.

Panel width [mm]

Seismic design / vibration-resistance

Mat. no.

600 800 900 1000 without with■ ■ ■ ■ ■ AGS002206-01■ ■ AGS002206-02

■ ■ ■ AGS002206-03■ ■ AGS002206-04

The base frame must be designed in view of the seismic design. The panels are fastened to the base frame by means of screws M12.

Additional securing points (optional)

1

2

3

Fig. 59Rear fastening links1 Rear base frame2 Fastening link3 Screw connection

GHA

52 AGS 531 446-01 | Edition 04/201452

4 Assembly

4.12 Mounting the earth bus

Notice:Observe the specific standards referring to earthing systems which ap-ply in the country in question.

1. Clean all contact areas of the connecting bar and the appropriate earth bar in the switchgear panels and coat them with lubricant (KL) (see Chapter 13.3, page 92).

2. Slip the connecting bar into the adjacent panel's supporting structure through the cutout in the panel.

3. Screw-fasten the connecting bar with the support brackets on both sides, to the earth bar in question and screw-fasten the support brackets to the panel.

4. Mount the connecting piece for switchgear earthing (Fig. 60, item 6). Connect the earth bus to the earthing system of the switchgear building. Connecting lines and screw accessories are not included in the scope of supplies. Connecting piece for switchgear earthing: AGS 000294-03 Panels with base plates: Observe Chapter 9.1, page 73.

The earth bus should be connected to the earth conductor of the building's earth connectionatleastatthefirstandateachtenthpaneloftheswitchgear.

Panel width [mm]

Panel width Adjacent panel

[mm]Assembly drawing

600 (also for end panel right-hand)600/800

AGS 000294-01

800 (also for end panel right-hand) AGS 000294-02600 900 AGS 000294-04

900 (also for end panel right-hand) 600/800 AGS 002510-01900 900 AGS 002510-02

1000600/800 AGS 002510-03

900 AGS 002510-04

1

2

34

5

6 ( 13 mm)

Fig. 60Mounting the earth bar and connecting bar1 Earth bar2 Support brackets3 Connecting bar4 Screw-fastening the support brackets to the earth bar and the connecting bar5 Screw-fastening the support brackets to the panel6 External point of connection for the earth bus of the panel

The earth bars are screw-fastened from panel to panel by means of connecting bars (Fig. 57, item 3).

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53AGS 531 446-01 | Edition 04/2014

5 Busbar attachments

5.1 Safety provisions

Warning!When performing assembly work on busbar attachments, the ap-propriate disconnecting device must be in earthed position (see Operating Manual).

Warning!Please comply with the safety provisions in Chapter 1, page 7.

5.2 Assembly of surge arresters

Notice: ● Remove grease and silicone from the contact surfaces and insu-

lating areas on the inner cone-type sockets in the tank and on the surge arresters before assembly.

● Comply with the assembly instructions of the surge arrester.

1. Clean and grease contact surfaces on the surge arrester and inside the inner cone-type socket (see Chapter 13.3, page 92).

2. Clean the insulating areas of the surge arrester and in the inner cone-type socketcarefullyandapplyauniformfilmofspecialpaste(seeinstructionsforassembly of the surge arrester).

3. Slip surge arrester in correct axial position into the inner cone-type socket and screw-fasten it.

4. Screw-fasten the earthing cable of the surge arrester on the busbar tank.

Fig. 61Surge arrester

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54 AGS 531 446-01 | Edition 04/201454


5.3 Assembly of voltage transformers

Rated voltage Ur [kV] Assembly drawing≤ 24 AGS 001861-02

> 24 AGS 001861-01

Notice: ● Remove grease and silicone from the contact surfaces and insu-

lating areas on the inner cone-type sockets in the tank and on the voltage transformers before assembly.

● Observe the instructions for assembly of the voltage transformers. ● The weight of the transformers must be taken into consideration!

Support the transformer or secure it by attaching a crane hook to the transformer jack rings.

1. Clean and grease contact surfaces on the transformer connector and inside the inner cone-type socket (see Chapter 13.3, page 92).

2. Clean the insulating areas of the transformer connector and inside the inner cone-typesocketcarefullyandapplyauniformfilmofspecialpaste(seeas-sembly instructions for voltage transformer).

3. Push voltage transformer into inner cone-type socket in correct axial direction and screw-fasten it (Fig. 62, item 2); 4 x M8 self-locking nut. Fasten transformer additionally to angle bracket (4). 2 x M8 self-locking screw

4. Connect the transformer secondary lines (plug-in contacts) (6). Comply with themarking!Fastentheprotectivehose(tightennutbyhandandfixcablesbymeans of cable clamps, 7 and 8).

5. Mount cover plate (5) above the transformer cables. 2 x M5 Torx screw

12 4

5

3

3

7

68

Fig. 62Assembly / disassembly of busbar voltage transformer1 Attachment with disconnecting device on busbar2 Connectingsocketandflangefastening3 Voltage transformer4 Angle bracket5 Cover plate for transformer wiring6 Terminal connection of transformer cables7 Fastening by means of cable clamp8 Fastening the protective hose

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55AGS 531 446-01 | Edition 04/2014 55


The voltage transformers are inserted from above into the inner cone-type socket in the busbar tank (optional, Fig. 63).Assembly is effected as described above.

Fig. 63Voltage transformer attachment from above

Rated voltage Ur [kV] Assembly drawing≤ 24 AGS 002260-02

> 24 AGS 002260-01

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56 AGS 531 446-01 | Edition 04/2014

6 Low-voltage cabinet

6.1 Assembly

The low-voltage cabinets are either supplied as accessories or already mounted to the panel, depending on the transport requirements.1. Remove transport protection covers from the interface between drive compart-

ment and low-voltage cabinet. All the wiring with terminals for the low-voltage cabinet must be located in the drive area below the upper sheet metal edge.

2. Assign the low-voltage cabinet to the appropriate panel. Remove the packag-ing of the low-voltage cabinet and place the cabinet on the lifting table (Fig. 64). Raise lifting table until the low-voltage cabinet is above the drive area.

3. Carefully push the low-voltage cabinet onto the panel above the drive area, align it and screw-fasten it to the panel. To this effect, open the switch cabinet door using the double bit key. Lower screw fastening (1): 4x M8 self-locking screw; rear screw fastening (2): 4x M8 self-locking screw.

4. Screw-fasten the low-voltage cabinets laterally to one another (3). Screw-fasten by means of a M8 self-locking screw connection, depending on the height of the low-voltage cabinet 800/1200: 2x/3x. Assembly drawing: AGS 003252-02

1

33

2

4

5

1

2

2x/3x

6Top view

3

4x 4x

Fig. 64Mounting the low-voltage cabinet1 Lower screw fastening (4x)2 Rear screw fastening (4x)3 Lateral screw fastening (2x/3x)

4 Lifting table5 Low-voltage cabinet6 Spacer

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57AGS 531 446-01 | Edition 04/2014 57


6.2 Connecting the control lines

1. Slip the terminals of the drive box wiring onto the terminal strips in the low-volt-age cabinet according to the marking on the connector (Fig. 65).

2. Close opening in the base of the low-voltage cabinet to the drive area by means of a cover plate (2). 5 x M6 self-locking screw connection.

1

2

3

Fig. 651 Drive wiring to terminal strip in low-voltage cabinet2 Cover plate3 Fastening the cover plate

1. Route the secondary lines for the intra-panel wiring through the lateral rubber sleeves of the low-voltage cabinet (Fig. 66).

2. The ring circuits are designed with connectors and are connected to the ap-propriate terminal strips in the low-voltage cabinet according to the connector designations (or the circuit diagram) (2).

1

2

Fig. 661 Ring circuits between panels2 Connection of the ring circuits to terminal strips

Connecting internal control lines of panel:

Connecting the ring circuits:

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58 AGS 531 446-01 | Edition 04/201458


Customized low-voltage lines for control and measuring purposes can be routed on the right-hand inside of each panel (Fig. 67).1. Route external cables from the cable basement into the cable compartment of

the panel (1) and place them in the right-hand cable tray of the panel to the low-voltage cabinet (3). Fasten cables to the panel by means of cable clamps (2).

2. Connect external cables to the terminal strip in the low-voltage cabinet ac-cording to the circuit diagram. Additionally, ground shielded lines on the cable supports.

3. Re-fasten metallic cable tray covers in the supporting structure (4). 4 x M8 self-locking screw

1

1

2

3

4

Fig. 67Placing external control cables1 External control lines2 Cable clamp3 Low-voltage cabinet4 Metallic cable tray covers

Placing external control lines in the switchgear panel:

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59AGS 531 446-01 | Edition 04/2014

7 Switchgear termination

7.1 Attachment of the protective tank to the left-hand / right-hand end of the busbar

On the busbar end, a protective tank must be mounted on the left and right sides of the voltage-proof busbar caps.

Panel width [mm] End panel


600/800

left-hand side 1 x AGS001760-01

AGS001760-05 +AGS001760-03

right-hand side

1 x AGS001760-02 AGS001760-02 +AGS001760-04

900/1000

left-hand side AGS002570-05

AGS002570-01 +AGS002570-03

right-hand side

AGS002570-02 AGS002570-02 +AGS002570-04

Panel width [mm] End panel


600/800


AGS001760-35 + AGS001760-20

right-hand side

AGS001760-31 AGS001760-31 + AGS001760-21

900/1000


AGS001760-32 + AGS001760-22

right-hand side

AGS001760-33 AGS001760-33 + AGS001760-23

1

2

Fig. 68Protective tanks at the busbar end (example) for1 upper busbar2 rear busbar (in case of

double busbar switchgear)

Models without pressure relief duct

Models with pressure relief duct

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60 AGS 531 446-01 | Edition 04/201460


7.2 Switchgear without pressure relief duct

(Accessibility in acc. with IEC 62271-200: IAC AFL)

7.2.1 OverviewVariants:

– The switchgear is accessible from the front and from the right-hand side (the switchgear is located in the left-hand corner of the room, Fig. 69).

– The switchgear is accessible from the front and from both sides (Fig. 70). – The switchgear is accessible from the front and from the left-hand side (the

switchgear is located in the right-hand corner of the room, without illustration).

Notice:Comply with the appropriate documentation for the switchgear. It de-fines the applicable variant in accordance with the customer's require-ments.

All individual parts are included in the accessories. Design is identical for the right-hand and left-hand sides.

≥1700

1

2≥800

3

100+30 -0

100+30 -0

3

Fig. 69Design example: Switchgear located in the left-hand corner of the room1 Rear gap cover (see page 64)2 Operating area3 Side wall (see Chapter 7.2.2, page 61)

GHA

61AGS 531 446-01 | Edition 04/2014 61


1

3

1

2

≥800

≥800

≥1700 ≥1700

100+30 -0

100+30 -0

Fig. 70Design example: The switchgear is accessible from the front and from both sides1 Gap cover (see page 64)2 Operating area3 Side wall (see Chapter 7.2.2)

7.2.2 Attachment of the right-hand or left-hand side wall

Height of low-voltage cabinet [mm]

Assembly drawing of side wallleft-hand side right-hand side

800 AGS 000630-01 AGS 000630-031200 AGS 000630-02 AGS 000630-04

GHA

62 AGS 531 446-01 | Edition 04/201462


If applicable, remove the covers of the lateral cable ducts in the cable compartment (Fig. 71, item 3).1. Screw-fastenfire-protectionboard(2)andbaseplate(1)tooneanother(11);

2 x M8 self-locking screws.2. Screw-fasten (10) base plate (1) to the last panel (8);

2 x M8 self-locking screws.3. Fasten base plate to the spacer bar (9). 2 x M8 self-locking screws. Cut thread

M8 in the base frame.4. Screw-fasten top and bottom side wall sections (4) to one another (6);

6 x M8 self-locking screw connections.5. Mount complete side wall. To this effect, screw-fasten:

– side wall to base plate (1); 5 x M8 self-locking screw. – side wall to panel (8); 9 x M8 self-locking screws. – side wall to low-voltage cabinet (7) (see also Chapter 6.1); 3 x M8 self-

locking screws. – rear side wall fastening (5) with the retaining plate on the panel;

3 x M8 screw fastening (only required for ESS, not for DSS).

9

2

5

6

8

7

3

5

4

2

11

1

11

110

6

Fig. 71Attaching the right-hand side wall1 Base plates 2 Fire-protection plates3 Cable tray cover4 Top and bottom side wall sections5 Rear screw fastening of the side wall to the panel6 Screw fastening of the two side wall sections7 Screw fastening the side wall to the low-voltage cabinet8 Screw fastening the side wall to the panel supporting

structure

9 Screw fastening the base plate to the base frame10 Screw fastening the base plate to the panel11 Screwfasteningthefire-protectionboardtothebaseplate

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63AGS 531 446-01 | Edition 04/2014 63


7.2.3 Extension of side wall in double busbar switchgear

Height of low-voltage cabinet [mm]

Assembly drawing of side wallleft-hand side right-hand side

800 AGS 000633-01 AGS 000633-031200 AGS 000633-02 AGS 000633-04

In double busbar switchgear, the side wall (Chapter 7.2.2, page 61) is extended to the rear (Fig. 72). 1. Mount side wall acc. to Chapter 7.2.2, page 61.2. Screw-fasten upper and lower cover bracket (Fig. 72, item 5) and upper and

lower termination plates (1 and 2) to the side wall (4).3. Mount the rear fastening link (3).

1

2

3

5

4

Fig. 72Side wall extension for double busbar switchgear1 Upper termination plate2 Lower termination plate 3 Fastening link with screw fastening4 Screw-fasten the termination plates and cover bracket to the side wall5 Upper and lower cover bracket

GHA

64 AGS 531 446-01 | Edition 04/201464


Rear gap cover

Wall clear-ance [mm]

Height of LV cabinet

[mm]

Busbar system Mat. no. in case of side wall side

800 1200 ESS Attachment on the front to

end wall or at the ear to end wall

DSS Attachment only at the rear

to end wall

left-hand side right-hand side

100 ■ ■ AGS001967-01 AGS001967-02

500 ■ ■ AGS001967-07 AGS001967-08100 ■ ■ AGS001963-01 AGS001963-02500 ■ ■ AGS001963-07 AGS001963-08

The rear gap cover is installed between the mounted side wall and the rear wall of the building (Fig. 73).Thenominalwidthofthegapcoveris100mmforsinglebusbarand500(≥300)mmfor double busbar. Assembly is performed identically.1. Screw-fasten upper and lower gap covers (1) to the side wall.

11 x M8 hex. bolt2. Apply gap cover (2) on wall side as shown in the drawing and mark securing

bore-holes on the wall of the building and on the mounted gap cover.3. Remove gap cover on wall side. Provide securing bore-holes for the mounted

gapcover(Ø4.5)andforthebuildingwall(Ø10).Subsequently,fitdowelpinsin the wall of the building.

4. Screw-fasten gap cover on building wall. 9 x M8 hex. bolt

5. Screw-fasten both gap covers to one another. 9 x M5 hex. bolt.

Fig. 73Rear gap cover (shown for left-hand switchgear end, 100 mm wall clearance)1 Front gap cover2 Gap cover on the wall side3 M5 hex. bolt4 M8 hex. bolt5 Fastening to building wall: Dowel and M8 hex. bolt

3

5

2

1

4

100+30≥ 50

105

1

2

34

5A

GHA

65AGS 531 446-01 | Edition 04/2014 65


7.3 Attachment of fan

1

23

4

Fig. 74Fan attachment1 Cover plate2 Fan

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