product manual safering / safeplus 12-24kv installation and operating ... · pdf...

SafeRing / SafePlus 12-24kVInstallation and operating instructions

Product manual

2

CONTENTS

1. Safety 4 1.1 For your safety 4 1.2 Skilled personnel 4 1.3 Crucial information 4

2. General description 5 2.1 Outer assembly 6 3. Transport and handling 7 3.1 By receiving inspection 7 3.2 Storage 7 4. Technical data 8 4.1 Electrical data SafeRing 8 4.2 Electrical data SafePlus 8 5. Installation 9 5.1 Standard 3-way switchgear 9 5.2 3-way switchgear with base frame (AFL) 10 5.3 3-way switchgear with base frame (AFLR) 11

6. Dimensions 13

7. Internal arc classification (IAC) 14 8. Cable compartment 17 8.1 Standard cable compartment 17 8.2 Arc proof cable compartment 17 8.3 Cable connection 18

9. Extension of switchgear 19 9.1 External busbar 19 9.2 Side connection 19

10. Current and voltage transformers 19 11. Motor operation 20 12. Relay and current transformers 21 13. Pressure indicator 22 13.1 Gas pressure 22 13.2 Altitude 23 13.2.1 Adjustment of gas pressure 23 14. Operation of the switchgear 24 14.1 Operating conditions 24 14.2 General warnings and precautions 25 14.3 Putting into service 25 14.3.1 Preparatory work 25 14.4 Start-up 25

3

15 Operation 26 15.1 Operation of cable switch 26 15.2 Operation of vacuum circuit-breaker 27 15.3 Operation of vacuum circuit-breaker 12kV/25kA, 24kV/20kA 28 15.4 Operation of fuse-switch disconnector 29 15.5 Installation and replacement of fuses 29 15.6 Fuse selection tables 31 15.6.1 Fuse selection table - CEF 31 15.6.2 Fuse selection table - CEF-S 32

16. Metering module 33 17. Capacitive voltage indicators 34 17.1 Voltage indicators VPIS 34 17.2 Voltage indicators VDS 35 17.3 Voltage indicators VDS-LRM 35 18. Additional equipment 36 18.1 Low-voltage connections 36 18.2 Remote control and monitoring unit 36

19. Cable testing 37 19.1 Procedure for switchgear with test points 37 19.2 Procedure for testing directly on the cable 38 connector with the cable connected to the switchgear 19.3 Procedure for testing directly on the cable 38 connector with the cable disconnected from the switchgear

20. Service and maintenance 39 20.1 General warnings and cautions 39 20.2 Maintenance intervals 39 20.3 Inspection 39 20.4 Servicing 40 20.5 Repairs 40 21. Environmental certification 41 21.1 Life expectancy of product 41 21.2 Recycling capability 41 21.3 End-of-life 41

4

1. SAFETY1.1 For your safety! – Strictly follow these Installation and operating instructions. – Only install switchgear in indoor conditions according to

IEC 62271-1 cl.2.1. – Ensure that installation, operation and maintenance is

only carried out by professional personnel. – Comply fully with the standards in force (IEC or local), the

connection conditions of the local power utility and the applicable safety at work regulations. – Observe the relevant information in the manual for all

actions involving the switchgear. – Use gloves when installing or operating switchgear.

1.2 SKILLED PERSONNELAll the installation, putting into service, running and main-tenance operations must be carried out by skilled personnel with in-depth knowledge of the apparatus.

When carrying out any maintenance work, the regulations in the country of installation must be strictly obeyed.Maintenance work must only be performed in a professional way by trained personnel familiar with the characteristics of the switchgear, in accordance with all the relevant IEC safety regulations and those of other technical authorities, and also respecting other overriding instructions. It is recommended that ABB service personnel be called in to perform the servic-ing and repair work.

1.3 CRUCIAL INFORMATIONPay special attention to the information shown in the manual by the following attention symbol:

After this symbol there are four different explanations indicat-ing what types of injuries or damage can be caused should the recommended precautions not be followed:

– DANGER - identifies the most serious and immediate hazards which can cause serious personal injury or death – WARNING - identifies hazards or unsafe practices which

can result in serious personal injury or death – CAUTION - identifies hazards or unsafe practices which

can result in minor personal injury or product or property damage – NOTE - identifies important procedures or requirements

that, if not followed, can result in product or property damage

WARNINGMake sure that the specified electrical ratings are not exceeded under switchgear operating condi-tions. Keep the manuals accessible to all personnel involved in installation, operation and maintenance.The user’s personnel are responsible for all matters regarding safety in the workplace and correct use of the switchgear.

WARNINGAlways follow the instructions in the manual and respect the rules of good engineering practice (GEP)! Hazardous voltages can cause serious in-jury or death! Disconnect the power and earth live parts before proceeding with any work on the switchgear. Follow the safety regulations in force in the place of installation.

CONTACT USIf you have any further questions about this manual, our fieldservice team will be pleased to help. See the back cover of this manual for contact information.

5

SafeRing 3-way unit CCV

2. GENERAL DESCRIPTIONSafeRing is a SF6-insulated ring main unit and SafePlus is a SF6-insulated compact switchgear for applications in medium voltage distribution networks. SafeRing and SafePlus offer a sealed stainless steel tank which contains all the live compo-nents and switching functions. The transformer is protected either by a switch fuse combination or a vacuum circuit-breaker.

The units are delivered from the factory ready for installation.

SafeRing can be supplied as a 2, 3 or 4-way unit in standard configurations with additional equipment according to custo-mer specification.

Available configurations: DeF, CCF, CCC, CCCF, CCFF, DeV, CCV, CCCC, CCCV, CCVV.

SafePlus has a unique flexibility due to its extendibility and the possible combination of fully modular and semi-modular confi-gurations, with a maximum of 5 modules in one SF6-tank.

The units are delivered from the factory ready for installation.

Routine tests are carried out on all units/ modules before dispatch.

No special tools are required for installing the equipment.

Available modules are :C - Cable switchF - Switch fuse disconnectorD - Direct cable connectionDe - Direct cable connection with earthingV - Vacuum circuit-breakerSl - Busbar sectionalizer, load break switch Busrise needed when SL on right side of SF6 tankSv - Busbar sectionalizer, vacuum circuit-breaker Sv always together with busrise (total width=650 mm)Be - Busbar earthingM - Metering cubicleV20, V25 - Vacuum circuit-breaker 20/25kASv20, Sv25 - Busbar sectionalizer, vacuum circuit-breaker

20/25kA.

SafeRing / SafePlus with switch fuse combination in compliance with IEC 62271-105.With this unit the transformer will be protected by current-limiting HV fuses in combination with a load break switch. The load break switch is equipped with a stored spring energy mechanism which can be tripped by the fuse striker pin. SafeRing / SafePlus with vacuum circuit-breaker in compliance with IEC62271-100With this unit the transformer will be protected by a vacuum circuit-breaker combined with relays and current transformers.The standard relays are based on digital technology and do not require an external power supply.Further information can be found in the product catalogue for SafeRing and SafePlus, 1VDD006104 GB.

6

2.1 OUTER ASSEMBLY

Upper front cover1. Manometer2. Nameplate of module3. Short circuit indicator4. Capacitive voltage indication5. Load break / earthing switch position indicator6. Push buttons close/open operation7. Charged spring indicator8. Self-powered protection relay9. Vacuum circuit-breaker position

Lower front cover10. Nameplate of switchgear11. Fuse blown indicator12. Disconnector / earthing switch position indicator13. Capacitive voltage indication Cable compartment cover14. Cable compartment cover standard15. Cable compartment cover with inspection window16. Support bar (removable) Side cover17. Lifting lug18. Operating handle (suspended on the side wall, by default on the right-hand side wall)

� ��SafePlus

17

1

2

34

10

11

5 6 7 8

9

18

12

13

14

16

15

7

3. TRANSPORT AND HANDLINGThe units are delivered from the factory ready for installation.

3.1 BY RECEIVING INSPECTIONUpon receiving the SafeRing / SafePlus please check that the delivered equipment has not been damaged during transport. If any such damage has occurred, a claim must be submitted to the carrier immediately.

After unpacking, the following must be checked:1. Operating handle – one piece should be included, normally

fixed on right-hand side.2. Check that the pointer on the pressure indicator is in the

green area.3. Carry out a function test on the mechanical parts.4. Visual check of the switchgear.

Any faults or omissions must be reported immediately to the supplier.

3.2 STORAGESafeRing / SafePlus must be stored under cover in a dry and well ventilated area until it is installed and put into operation.

NOTE: Use only approved slings when lifting. Maximum angle on lifting lugs is set to 60o.

Weight table

Maximum weights for standard SafeRing

2-way DeV 300 kg 2-way DeF 300 kg

3-way CCV 450 kg 3-way CCF 450 kg

4-way CCCV 600 kg 4-way CCCF 600 kg

4-way CCVV 600 kg 4-way CCFF 600 kg

3-way CCC 450 kg

4-way CCCC 600 kg

SafePlus

Standard 1-way 150 kg

2-, 3- and 4-way as for SafeRing

5-way 750 kg

M - metering module incl. trafo 250 kg

Mt - metering tariff module incl. trafo 350 kg

The weights are without additional equipment, except for transformers for M- and Mt-modules

SafeRing / SafePlus is fitted with lifting lugs, but can also be moved on a pallet with a forklift truck. Make sure to secure the switchgear.

Max angle 60o

8

4. TECHNICAL DATA4.1 ELECTRICAL DATA SAFERING

4.2 ELECTRICAL DATA SAFEPLUS

SafeRingC-module F-module V-module

Switch disconnector

Earthing switchSwitch-fuse combination

Earthing switchVacuum

circuit-breakerEarthing switch

Rated voltage kV 12/17,5/24 12/17,5/24 12/17,5/24 12/17,5/24 12/17,5/24 12/17,5/24

Power frequency withstand voltage kV 286)/38/50 286)/38/50 286)/38/50 286)/38/50 286)/38/50 286)/38/50

Impulse withstand voltage kV 95/95/125 95/95/125 95/95/125 95/95/125 95/95/125 95/95/125

Rated current A 630/630/630 2001) 200/200/200

Breaking capacities:

active load A 630/630/630

closed loop A 670/670/670

off load cable charging A 141/141/141

off load transformer A 20/20/20

earth fault A 205/160/160

earth fault cable charging A 117/91/91

short-circuit breaking current kA see 2) 16/16/16

Making capacity kA 52,5/40/40 52,5/40/40 see 2) 12,5/12,5/12,5 40/40/40 40/40/40

Short time current 0,5 sec 3) kA 16/16/16

Short time current 1 sec 4) kA 5/5/5 16/16/16

Short time current 3 sec 5) kA 21/16/16 21/16/16 16/16/16

1) Depending on the current rating of the fuse-link 2) Limited by high voltage fuse-links 3) Maximum rating for bushings Interface A (200 series plug-in) 4) Maximum rating for bushings Interface B (400 series plug-in) 5) Maximum rating for bushings Interface C (400 series bolted) 6) GOST version is available with 42kV power frequency withstand voltage

SafePlus

C-module F-module V-module V20/V25 module

Switch disconnector

Earthing switch

Switch-fuse combination

Earthing switchVacuum circuit-breaker

Earthing switch

Vacuum circuit-breaker

Earthing switch

Rated voltage kV 12/17,5/24 12/17,5/24 12/17,5/24 12/17,5/24 12/17,5/24 12/17,5/24 12/24 12/24

Power frequency withstand voltage kV 281)/38/50 281)/38/50 281)/38/50 281)/38/50 281)/38/50 281)/38/50 281)/50 281)/50

Impulse withstand voltage kV 95/95/125 95/95/125 95/95/125 95/95/125 95/95/125 95/95/125 95/125 95/125

Rated current A 630/630/630 200 2) 630/630/630 630/630

Breaking capacities:

closed loop A 650/650/650

off load cable charging A 140/140/140

off load transformer A 20/20/20

earth fault A 205/160/160

earth fault cable charging A 117/91/91

short-circuit breaking current kA see 3) 21/16/16 25/20 25/20

Making capacity kA 65/52,54)/52,5 62,5/52,54)/50 see 3) 12,5/12,5/12,5 52,5/40/40 52,5/40/40 65/50 62,5/50

Short time current 0,5 sec 5) kA 16/16/16

Short time current 1 sec 6) kA 25/-/- 25/-/- 5/5/5 16/16/16 25/21 25/21

Short time current 3 sec 7) kA 25/214)/21 25/214)/21 21/16/16 21/16/16 25/21 25/21

1) GOST version is available with 42kV power frequency withstand voltage 2) Depending on the current rating of the fuse-link 3) Limited by high voltage fuse-links 4) Tested at 15,2 kV 5) Max. rating for bushings Interface A (200 series plug-in) 6) Max. rating for bushings Interface B (400 series plug-in)7) Max. rating for bushings Interface C (400 series bolted)

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5. INSTALLATION

NOTEThe floor must be well leveled and the unit must be fixed by means of anchor bolts in accordance with the dimensional drawing for the number of modules or units as appropriate.

The tolerance of the evenness is maximum 1 mm per meter.

Unit A B C

1-way 298 337 371

2-way 623 662 696

3-way 948 987 1021

4-way 1273 1312 1346

5-way 1598 1637 1671

5.1 STANDARD 3-WAY SWITCHGEAR

NOTEThe tools required for installation and maintenance of the switchgear are specified in the tool list in chapter 20.6.

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5.2 3-WAY SWITCHGEAR WITH BASE FRAME (AFL)

Unit A B C

1-way NA NA NA

2-way 623 662 696

3-way 948 987 1021

4-way 1272 1312 1346

5-way 1597 1637 1671

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Unit A B C

1-way NA NA NA

2-way 623 662 696

3-way 948 987 1021

4-way 1273 1312 1346

5-way 1598 1637 1671

5.3 3-WAY SWITCHGEAR WITH BASE FRAME (AFLR)

Distance between two units which are connec-ted to each other by means of external busbars

*) Top extension: 8 mm / 81 mm Side extension: 14 mm / 87 mm

indicates cable entry

81/87*

8/14*

12

AFLR baseframe* Dimensions for 290 mm baseframe

Base frame, height 450 mm Base frame, height 290 mm

Standard switchgear installed on cable trench

Low version switchgear installed on cable trench

3938

1786

1045

3938

1626

885

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6. DIMENSIONS

Height (mm) Standard switchgear Lower version switchgear

Non

IAC

/IA

C A

FL

with

out

bas

e fr

ame

Non

IAC

/IA

C A

FL w

ith

290

mm

bas

e fr

ame

Non

IAC

/IA

C A

FL w

ith

450

mm

bas

e fr

ame

IAC

AFL

R w

ith

290

mm

bas

e fr

ame

IAC

AFL

R w

ith

450

mm

bas

e fr

ame

Non

IAC

/IA

C A

FL

with

out

bas

e fr

ame

Non

IAC

/IA

C A

FL w

ith

290

mm

bas

e fr

ame

Non

IAC

/IA

C A

FL w

ith

450

mm

bas

e fr

ame

without low

voltage

compartment or

top entry box

Standard 1336 1626 1786 2002 2002 1100 1390 1550

Top connection without dead ends 1466 1756 1916 2002 2002 1230 1520 1680

Top connection with dead ends 1561 1851 2011 2002 2002 1325 1615 1775

External busbars 1591 1881 2041 2002 2041 1355 1645 1805

Busbar cover 1651 1941 2101 2002 2101 1415 1705 1865

with

top entry box

(124 mm)

Standard 1460 1750 1910 2002 2002 1224 1514 1674




Busbar cover 1651 1941 2101 2002 2101 1415 1705 1865

with low voltage

compartment

(470 mm) *)

Standard 1806 2096 2256 2096 2256 1570 1860 2020




Busbar cover 1806 2096 2256 2096 2256 1570 1860 2020

with low voltage

compartment

(700 mm) *)

Standard 2036 2326 2486 2326 2489 1800 2090 2250




Busbar cover 2036 2326 2486 2326 2486 1800 2090 2250

*) For V-module 12kV/25kA and 24kV/20kA height of low voltage compart-

ment is 570 / 800 mm, so 100 mm has to be added to the total switch-

gear heights in the table

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7. INTERNAL ARC CLASSIFICATION (IAC)

During development of all ABB products, focus is put on personnel safety. This is why the SafeRing/SafePlus portfolio was designed and tested for a variety of internal arc scenarios in order to withstand an internal arc of the same current level as a maximum short circuit current. The tests show that the metal enclosure of Safering/SafePlus switchgear is able to protect personnel standing close to the switchgear during an internal arc fault.

Causes and effects of IACAn internal arc is a highly unlikely fault, although it can theore-tically be caused by various factors, such as:

− Insulation defects due to quality deterioration of the components. The reasons can be adverse environmental conditions and a highly polluted atmosphere.

− Inadequate training of the personnel in charge of the instal-lation, leading to incorrect installation of the cables.

− Breakage or tampering of the safety interlocks. − Overheating of the contact area, e.g. when the connections

are not sufficiently tightened. − Short circuits caused by small animals that have entered

into the cable compartment (i.e. through cable entrance).

The energy produced by the internal arc causes the following phenomena:

− Increase of the internal pressure. − Increase of the temperature. − Visual and acoustic effects. − Mechanical stresses on the switchgear structure. − Melting, decomposing and evaporation of materials.

Tested according to IEC standard 62271-200The capability of SafeRing/SafePlus switchgear to withstand an internal arc is proven by the type test according to Inter-nal arc classification (IAC) as described in the standard IEC 62271-200 as follows:

Accessibility: A, B or C (switchgear)A=Accessible to authorized personnel only B=public accessC=not accessible due to installation

F-Front=Access from the front L-Lateral=Access from sides R-Rear=Access from the rear All test specimens passed the following test criteria according to the standards:

− Correctly secured doors and covers do not open − No fragmentation of the enclosure occurs within the time

specified for the test. Projection of small parts, up to an individual mass of 60 g are accepted

− Arcing does not cause holes in the enclosure of the switch-gear up to a height of 2 m

− Indicators do not ignite due to the effect of hot gases − The enclosure remains connected to its earthing point

Arc duration and damage caused

Melting of Steel

Melting of Copper

Melting of Cables

0 100 200 500 ms

kA2 s

R

L

L

F

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WARNINGDistance from side wall: 20 mm. If installed more than 20 mm from sidewall, an arc shield is re-quired. For easier installation, it is recommended that any switchgear requiring arc shields is in-stalled minimum 300 mm from sidewall.

When installing Ring Main Unit or Compact Switchgear with Internal Arc Classification AFL with ventilation be-hind the switchgear, the following must be considered:

− Unit must be equipped with arc proof cable covers. − Distance from floor to roof must be minimum 2400 mm − Distance from back of unit to wall must be 100 mm − Arc shields with height 650 mm must be mounted − If unit is freestanding (i.e. distance from back of unit to wall

exceeds 100 mm), the area behind the unit must be restric-ted and not accessible.

* Arc shield.Height of arc shield for M-module is 1317 mm

* 1100 mm version available as optional solution

For installation of switchgear with Internal Arc Classi-fication AFL with ventilation down in cable trench, the following must be considered:

− Unit must be equipped with arc proof cable covers − Distance from floor to roof must be minimum 2000 mm − Distance from back of unit to wall must be 100 mm − Cable compartment back plate has to be mounted − Length of cable trench must be 2000 mm, with an opening

of minimum 0,5 m2 − Minimum dimensions of cable trench are 230 x 355 mm

*

Marked area is restricted, but installation is allowed if mount-ing of arc shield is feasible.

20 - 300 mm

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*) 290 mm base frame is available as option

For installation of switchgear with Internal Arc Classifi-cation AFLR with ventilation upwards through exhaust channel, the following must be considered:

− Unit must be equipped with arc proof cable covers − Unit can be installed as free standing − Minimum height of ceiling: 2600 mm − Recommended distance from back wall is 100 mm

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8.1 STANDARD CABLE COMPARTMENT

Removal of cable cover:

1. Loosen the screws on the cable cover, pull out and lift cover off.

2. Removal of front section.

3. Front section removed.

4. The mid-panel can be removed by unscrewing Ax2 and B.

8.2 ARC PROOF CABLE COMPARTMENT

Removal of cable cover:

1. Lift handle to remove the cable cover, pull out and lift cover up.

2. Removal of front section.

3. Front section removed.

4. The mid-panel can be removed by unscrewing Ax2 and B.

8. CABLE COMPARTMENT

CAUTIONIn case of interlocked cable compartment, cover can be opened / closed only when earthing switch is in closed position.


A

B B

A

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8.3 CABLE CONNECTION SafeRing/SafePlus is equipped with external bushings which comply with DIN47636T1 & T2/EDF HN 525-61 for termina-tion of cables.

All bushings are situated in the same height from the floor and are protected by the cable cover.

SafeRing / SafePlus can be supplied with the following bus-hings for the various type of cubicles:

Type of module

Bushings C F V D, De,

V20/25

Interface A X X

Interface C X X X X

Cable adaptersAdapters from following manufacturers are recommended:ABB KabeldonSüdkabelTyco Electronics RaychemPower Systems3MEuromoldNKT cables

Please see supplier documentation for details.

DANGERThe manufacturer’s installation instructions must be followed. Be sure to lubricate the bushings thoroughly with the silicone supplied.Use only isolated cable connections.

Where cables are not connected, the earthing switch must be locked in closed position or the bushings must be fitted with dead end receptacles before the unit is put into operation.

Adjustable cable support bar (additional equipment).

Earthing bar Cable clamp (additional equipment)

Interface C with M16 x 2 metric threads400 series, In = 630A

Interface A with plug200 series, In = 200A

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9. EXTENSION OF SWITCHGEAR

9.1 EXTERNAL BUSBAR SafeRing and SafePlus can be equipped with an externalbusbar. See separate instruction manual:1VDD006006 GB.

9.2 SIDE EXTENSIONSafeRing and SafePlus can be equipped with a side extensi-on. See separate instruction manual 1VDD006106GB.

10. CURRENT AND VOLTAGE TRANSFORMERSSafeRing and SafePlus can be equipped with current and/or voltage transformers.Installation and maintenance manual: 1VLM000610

SafePlus� �� SafePlus� �� SafePlus� ��SafePlusSafePlus

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11. MOTOR OPERATIONSwitches, vacuum circuit-breakers and earthing switches are operated by mechanisms located behind the front panel. The mechanisms for all the switches and breakers are operated manually with the operating lever (standard), or are fitted withmotor operation (additional equipment).

The earthing switch and the disconnectors can only be ope-rated manually. The earthing switches have mechanisms to achieve fault making capabilities.

3PKE mechanism for load break switch (C-module) 1VDD200001

3PAE mechanism for fuse-switch (F-module) 1VDD200003 2PA mechanism for circuit-breaker (V-module) 1VDD200004

3PKSE mechanism for load break switch (C-module) 1VDD200002

Motor operation can be retrofitted. Use the manuals.

All units are delivered with drawings showing the electrical circuits.

Installation instructions cover the following modules:

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12. RELAY AND CURRENT TRANSFORMERS A protection relay is installed in each vacuum circuit-breaker module. The cables from the protection relay to the current transformers are installed from the factory and are terminated in the cable compartment ready for connection to the three current transformers supplied.

CAUTIONBefore installation:Check that the three current transformers have been delivered and that they are all of the same type.Check that the current transformers are of the cor-rect type, with the correctly rated transformer ratio, for the distribution transformer’s rated current and for the adjustment range on the protection relay (see protection relay manual).

Each current transformer must be mounted onto its high voltage cable before the cable termination is fitted.

WARNINGThe earth shield on the cable must be led back through the center hole in the current transformer (see figure on left) and earthed on the earthing bar in the cable compartment. A mounting plate for the current transformers is fitted in the cable compart-ment.

After the current transformers have been installed in the unit, the cables from the protection relay are connected. Consult the manual supplied with the protection relay for a description of the connections.

SafeRing / SafePlus with vacuum circuit-breakers are delivered with self-powered OC / EF protection relay ABB type REJ 603 V.1,5.

Relays with auxiliary voltageSafePlus can be delivered with advanced protection relays:

− REF615 (high LV-compartment with hinged door) − REF630 (high LV-compartment with hinged door) − REF611 (high LV-compartment with hinged door) − REF620 (high LV-compartment with hinged door)

Separate manuals with examples of settingshave been prepared for each of these protection relays.

Installation of current transformersThe cable shielding is led back through the center hole and earthed, as shown in figure.

107

75

60

107

22

WARNINGReplenishment of SF6-gas in SafeRing/SafePlusPotential risk! Operators must be trained and qualified for SF6-gas handling

The following equipment is needed: SF6-gas bottle with manometer and reduction valve, bottle for recovery of SF6/air mixture, adapter and pressure measuring device. It is important that the pressure measuring device shows absolute pressure. If you have a pressure measuring device showing over-pressure, please contact ABB for instructions (NHP 408025).

1. Remove the front cover and if possible the top cover.Unscrew the pressure indicator by unscrewing the hexagon nut as shown on the figure at the right.

2. Screw the adapter to the valve. The tightening torque is max 45 Nm.

3. Before connecting the hose from the gas bottle to the adapter, the air in the hose must be removed by running SF6-gas through the hose. The SF6-gas must be recovered.

4. When gas is flowing into the RMU/switchgear, the mano-meter on the gas bottle has to be observed. When it shows 1,4 bar absolute at ambient temperature 20° Celsius, the gas filling must be stopped. See table for filling pressure on next page.

13. PRESSURE INDICATORSafeRing / SafePlus is usually supplied with a pressure indi-cator in the form of a manometer. Additionally, it is possible to fit a device for an electric signal if the pressure is low. This requires auxiliary voltage supply.

13.1 GAS PRESSURE SafeRing / SafePlus contain SF6-gas with a nominal pressure of 1,4 bar absolute at 20o C.

SafeRing / SafePlus are «sealed for life» and fitted with a temperature-compensated pressure indicator.

Pointer in green area - unit has sufficient pressure. Pointer in red area - pressure is too low.

WARNINGOperation when pressure is too low (pointer in red area):If pointer is in red area, the operation of the switch-gear can not be done under live conditions (voltage on). SF6-gas needs to be topped up according to instruction and the filling table on next page before operation can be done under live conditions. For more detailed description, see instruction ma-nual 1VDD201603

5. Remove the filling hose and connect the pressure device to check the pressure inside the RMU/switchgear.

6. When the correct pressure of 1,4 bar absolute is obtained, remove the adapter, check that the sealing between the pressure indicator and the valve is smooth and clean, and screw the pressure indicator to the RMU/ switchgear with tightening torque max 45 Nm as shown below.

Note! Screw/unscrew on this hexagonal nut only. The pressure indicator can be dismounted from the switchgear with-out SF6 leakage from the SF6 tank

Spring-loaded valve

AirSF6

CAUTION

23

SF6-gas temp Absolute filling

pressureoC mbar

0 1305

5 1328

10 1352

15 1376

20 1400

25 1424

30 1448

35 1472

40 1496

13.2 ALTITUDEMax height above sea level for installation without reducing gas pressure is 1500 meters. In the interval from 1500 to 2500 meters, gas pressure has to be reduced according to the above figure. For installation above 2500 meters, please contact ABB for instructions.

13.2.1 ADJUSTMENT OF GAS PRESSURE IN HIGHER ALTITUDESRemove the front cover in order to get access to the top of the manometer. On top of the manometer, a screw is situa-ted. Open this screw carefully until the arrow starts moving. When the movement stops, tighten the screw again. Now the pressure is equalized and unless there is a leak (which is very unlikely) the arrow will be positioned at the correct level.

Top screw for adjusting pressure in higher altitudes

Altitude

1,45

1,4

1,35

1,3

1,25

1,2

1,15

1,1

1,05

0 500

1000

2000

1500

1

Filin

g p

ress

ure

Bar

ab

s

30oC

20oC

10oC

24

14. OPERATION OF THE SWITCHGEAR14.1 OPERATING CONDITIONSNormal ambient conditions SafeRing / SafePlus is generally equipped for operation/ service in normal indoor conditions in accordance with IEC 62271-1.

The following limitations apply:

Ambient temperatureMax. temperature +40°CMax. temperature (24-hour average) +35°CMin. temperature - 25°C

HumidityMax. average relative humiditymeasured over 24 hours 95%Max. average relative humiditymeasured over 1 month 90%

Special conditionsIn accordance with IEC 62271-1, the manufacturer and end-user must agree about special operating conditions which deviate from operation under normal conditions.

The manufacturer/supplier must be consulted in advance if especially difficult operating conditions are involved. When SafeRing/SafePlus is installed more than 1500 meters above sea level, the atmospheric pressure will be lower and the overpressure inside the tank will have to be reduced.

AirfreightUnits / modules transported by airfreight are delivered with reduced overpressure. For topping up, please see procedure for replenishment of SF6-gas.

WARNINGCONTROL AND MONITORING THE GASSafeRing / SafePlus is a pressure-sealed system that normally does not require special inspections. However, the gas pressure on the manometer should always be checked prior to operation.

Application of the X-ray regulationsOne of the physical properties of vacuum insulation is the possibility of X-ray emissions when the contact gap is open. The specified test performed by the Physikalisch-Technische Bundesanstalt (PTB) in Braunschweig demonstrates that the local dosage output of 1 µSv/h at a distance of 10 cm from the touchable surface is not exceeded when the rated voltage is applied.

The results are as follows: − Testing of the switching device or the vacuum interrupter to

VDE 0671 part 100 or IEC 62271-100 at the relevant rated power frequency withstand voltage may only be performed by trained personnel observing the stipulations of the EU basic standard (Stipulation 96/29/Euratom of the senate from 13 May 1996 (ABI.L 159 from 29 June 1996)).

− Application of the rated power frequency withstand voltage specified for the switching device by VDE 0671 part 100 or IEC 62271-100 is completely safe.

− Higher voltages than the rated power frequency withstand voltage or DC test voltage specified in VDE or IEC stan-dards must not be applied!

− The containment of the above mentioned local dosage output with the vacuum interrupter in the open position is dependent on maintenance of the specified distance between the contacts (which is automatically ensured with correct mechanism function and force transmission).

− Safety clearances must be maintained.

25

14.2 GENERAL WARNINGS AND PRECAUTIONS

DANGERDo not walk on the top of switchgear units!

DANGERSwitchgear operations must be carried out with the doors closed.

WARNINGOperations and any type of work must be carried out by trained and specialized personnel who are familiar with SafeRing/SafePlus and follow all the safety regulations in accordance with the IEC Stan-dards and other regulations in force, as well as any local work regulations and instructions.


14.3 PUTTING INTO SERVICE14.3.1 PREPARATORY WORKBefore connection to the medium voltage networkThe following work must be carried out in preparation for putting into service:

− Check the general condition of the switchgear for any damage or defects.

− Visually inspect the switching devices, cable bushings, insulating parts, etc.

− Check the paintwork for any damage and, where neces-sary, paint over scratches to avoid corrosion

− Remove all residues of materials, foreign objects and tools from the switchgear.

− If necessary, clean the switchgear and remove any traces of greasy or sticky dirt.

− Correctly remount all covers etc. removed during assembly and testing procedures.

− Switch the auxiliary and control voltage on. − Carry out testing operations on switching devices either

manually or using electrical control, simultaneously obser-ving the relative position indicators.

− Check the mechanical and electrical interlocks for effective-ness, without using force.

− Check the SF6 gas pressure of the tank. It needs to be at green level before operating the switchgear.

− Instruct local operators regarding the basic features for correct use of the switchgear.

Other checkpointsDepending on the allocation of responsibilities, it may also be necessary to check the following equipment in the vicinity of the switchgear:

− Power cables − Auxiliary cables − Auxiliary power source − Remote control system − Complete earthing system − Switchgear installation room equipment − Switchgear installation room characteristics:

− Pressure resistance in the case of an arc fault − Ventilation − Temperature − Humidity

14.4 START-UPInstructions

− Comply with all relevant safety regulations. − Ensure that the switch-disconnectors, circuit-breakers or

fuse-switches in the configuration are in the OPEN position. − Energize the power supply feeders. − Connect the switchgear step by step, observing the signals

and indicators. − Where necessary, check that the conductors are in phase

when there are several incoming feeder cables and switch-gear sections.

− Carry out all measurements and check that all functions that depend on the medium voltage power supply are connected.

− Check there are no irregularities of any kind.

26

Switch disconnector:Close: Turn the operating handle clockwise. Open: Turn the operating handle anti-clockwise.

Earthing switch: Close: Turn the operating handle clockwise. Open: Turn the operating handle anti-clockwise.

15. OPERATIONAll switches can be operated with the included operating handle. Internal mechanical interlocking between the switch discon-nector/isolator and the associated earthing switches pre-vents incorrect operation. For detailed interlocking descrip-tion, see dedicated overview for each module in catalogue 1VDD006104 GB.

The operation of the switch disconnector/circuit-breaker and earthing switches can be further interlocked by means of a padlock.

The earthing switches are operated by a snap action mechanism, which ensures fast closing. The earthing switch is closed by turning the operating handle clockwise. Turning the operating handle anti-clockwise opens the switch.

An anti-reflex system, standard on all operating handles, prevents the immediate re-operation of switches.

15.1 OPERATION OF CABLE SWITCH

27

15.2 OPERATION OF VACUUM CIRCUIT-BREAKER

Mechanical position indicators:A: Green push-button closes the switchB: Red push-button opens the switch C: Mechanical position indication, circuit-breaker open D: Mechanical position indication, earthing switch closed

Vacuum circuit-breaker:Charging springs: Turn the operating handle clockwise to charge the closing and the opening spring.Close: Push the green button (A)Open: Push the red button (B)

Switch disconnector:Close: Turn the operating handle clockwise. Open: Turn the operating handle anti-clockwise.

Earthing switch: Close: Turn the operating handle clockwise. Open: Turn the operating handle anti-clockwise.

The isolator in the V-module can only be opened after the circuit-breaker is opened. Then the circuit-breaker can be closed for testing purposes.

A

C

D

B

28

15.3 OPERATION OF VACUUM CIRCUIT-BREAKER - 12kV/25kA, 24kV/20kA

Push button - vacuum circuit-breaker (OFF)

Push button - vacuum circuit-breaker (ON)

Indication - spring charged / discharged

Counter - closing and opening operations

Vacuum circuit-breaker position indicator

Spring-charging lever

Before operating of the vacuum circuit-breaker, check that the spring is charged. If the spring is not charged, it can be charged by means of the charging lever. The spring is fully charged when the indicator turns to charged spring (yellow symbol, about 10 operations needed to fully charge the spring).

CAUTIONIf the vacuum circuit-breaker is equipped with motor operation (optional) it is not necessary to charge the spring by hand. The motor starts charging the spring automatically as soon as the auxiliary volta-ge is switched on.

Close: Push green (ON) button

Open: Push red (OFF) button

Note: the downstream disconnector is mechanically interlocked with the vacuum circuit-breaker.

For operation of the downstream disconnector and earthing switch, see previous page.

29

15.5 INSTALLATION AND REPLACEMENT OF FUSE-LINKSA red indicator below the fuse symbol on the lower front panel indicates that at least one fuse-link has blown. Fuse links are replaced as shown in the sequence of illustrations. Switch- fuse configurations are supplied without fuse-links installed.

When installing fuse-links for the first time, follow the sequence of illustrations 2-9.

1. Blown fuse indicator.

2. Close earthing switch by turning operating handle clockwise.

15.4 OPERATION OF FUSE-SWITCH DISCONNECTOR

Switch-fuse disconnector:Charging springs: Turn the operating handle clockwise to charge the closing and the opening spring. Close: Push the green button (A) Open: Push the red button.(B)

The circuit-breaker can be tripped by the protection relay, while in switch-fuse configurations the fuse switch disconnec-tor can be triggered by the fuse striker pin if an over-current, a short-circuit or an earth-fault occurs.

WARNINGFor correct function of F-module, it is required to use fuses suitable for rating of protected distribution transformer, see fuse selection table on following pages. Use of improper fuse can void the warranty.

B A

30

3. Unscrew the fuse panel. 4. Tilt out the fuse panel to gain access to fuse canisters - If safety wires are installed, make sure they are latched at both ends before continuing to step 5.

5. Applying the operating handle and turning anti-clockwise opens the fuse canisters. - After initial opening with safety wires, reattach the fuse panel for easy detachment of safety wires.

6. Pull out the fuse handle. The fuses are firmly fixed in the fuse cover.

7. Fix the fuses to the fuse cover using the contact screw. This point is not applicable if fuse fastening is spring based.

- The striker must point out from the fuse canister for the fuse to function properly.

8.Turn the handle on the fuse cover clockwise to close and seal the fuse canister. Use the operating handle.

9. Close the fuse panel. The switches are ready for operation.

31

100% Transformer rating (kVA)

Fuse-link

rated

voltage

Un (kV) 25 50 75 100 125 160 200 250 315 400 500 630 800 1000 1250 1600

7,2 kV

3 16 25 25 40 40 50 50 80 100 125 160 160

3,3 16 25 25 40 40 50 50 63 80 100 125 160

4,15 10 16 25 25 40 40 50 50 63 80 100 125 160

5 10 16 25 25 25 40 40 50 50 63 80 100 160 160

5,5 6 16 16 25 25 25 40 50 50 63 80 100 125 160

6 6 16 16 25 25 25 40 40 50 50 80 100 125 160 160

6,6 6 16 16 25 25 25 40 40 50 50 63 80 100 125 160

10 6 10 10 16 16 25 25 25 40 40 50 50 80 80 125 125

12 kV11 6 6 10 16 16 25 25 25 25 40 50 50 63 80 100 125

12 6 6 10 16 16 16 25 25 25 40 40 50 63 80 100 125

13,8 6 6 10 10 16 16 25 25 25 25 40 50 50 63 80 100

17,5 kV15 6 6 10 10 16 16 16 25 25 25 40 40 50 63 80 100

17,5 6 6 6 10 10 16 16 16 25 25 25 40 50 50 63 80

20 6 6 6 10 10 16 16 16 25 25 25 40 40 50 63 63

24 kV22 6 6 6 6 10 10 16 16 16 25 25 25 40 50 50 63

24 6 6 6 6 10 10 16 16 16 25 25 25 40 40 50 63

15.6 FUSE SELECTION TABLE

15.6.1 FUSE SELECTION TABLE - CEF

- The table is based on using fuses type ABB CEF- Normal operating conditions with no overload- Ambient temperature -25oC - +40oC

120% Transformer rating (kVA)

Fuse-link

rated

voltage

Un (kV) 25 50 75 100 125 160 200 250 315 400 500 630 800 1000 1250 1600

7,2 kV

3 16 25 25 40 40 50 63 80 100 125 160

3,3 16 25 25 40 40 50 63 80 80 100 125

4,15 10 16 25 25 40 40 50 63 80 80 100 125

5 10 16 25 25 25 40 40 50 63 80 80 125 160

5,5 6 16 16 25 25 25 40 50 50 80 80 100 125 160

6 6 16 16 25 25 25 40 40 50 63 80 100 125 160

6,6 6 16 16 25 25 25 40 40 50 63 80 80 100 125

10 6 10 10 16 16 25 25 25 40 40 50 63 80 80 125

12 kV11 6 6 10 16 16 25 25 25 25 40 50 50 80 80 100 125

12 6 6 10 16 16 16 25 25 25 40 40 50 63 80 100 125

13,8 6 6 10 10 16 16 25 25 25 25 40 50 50 80 80 100

17,5 kV15 6 6 10 10 16 16 16 25 25 25 40 40 50 63 80 100

17,5 6 6 6 10 10 16 16 16 25 25 25 40 50 50 63 80

20 6 6 6 10 10 16 16 16 25 25 25 40 40 50 63 80

24 kV22 6 6 6 6 10 10 16 16 16 25 25 25 40 50 50 63

24 6 6 6 6 10 10 16 16 16 25 25 25 40 40 50 63

- The table is based on using fuses type ABB CEF- Normal operating conditions with 20% overload- Ambient temperature -25oC - +40oC

32

15.6.2 FUSE SELECTION TABLE - CEF-STr

ansf

orm

er r

ated

volta

ge (k

V)

Transformer rating (kVA)

Fuse

-lin

k ra

ted

volta

ge (k

V)

Fuse

-lin

k le

ngth

„e“

(mm

)25 50 75 100 125 160 200 250 315 400 500 630 Catalogue No. CEF-SCatalogue No.

CEF-S-TCU

Fuse-link rating In (A)

3 16 25 40 50

6/12 292

3.3 16 25 40 50 50

4.15 16 20 40 40 50 10A:1YMB531011M0001 10A:1YMB531861M0001

5 10 20 25 40 40 50 16A:1YMB531011M0002 16A:1YMB531861M0002

5.5 10 20 20 40 40 40 50 20A:1YMB531011M0003 20A:1YMB531861M0003

6 10 16 20 25 40 40 50 25A:1YMB531011M0004 25A:1YMB531861M0004

6.6 10* 16 20 25 40 40 50 50 40A:1YMB531011M0005 40A:1YMB531861M0005

10 10* 10 16 20 20 25 40 40 50 50A:1YMB531011M0006 50A:1YMB531861M0006

11 10* 10 16 20 20 25 40 40 40 50

12 10* 10 16 16 20 20 25 40 40 50

13.8 10* 10* 16 16 16 20 20 40 40 40

10/24 442

15 10* 10* 10 16 16 20 20 25 40 40 10A:1YMB531012M0001 10A:1YMB531862M0001

17.5 10* 10* 10 16 16 20 20 20 40 40 40 16A:1YMB531012M0002 16A:1YMB531862M0002

20 10* 10* 10* 10 16 16 20 20 25 40 40 20A:1YMB531012M0003 20A:1YMB531862M0003

22 10* 10* 10* 10 16 16 20 20 20 40 40 40 25A:1YMB531012M0004 25A:1YMB531862M0004

24 10* 10* 10* 10 16 16 16 20 20 25 40 40 40A:1YMB531012M0005 40A:1YMB531862M0005

Max

.gG

fus

e-lin

k

at L

V s

ide

(A)

40 80 125 160 160 200 250 250 300 400 400 800

The table was calculated according to standards IEC 60787 and IEC 62271-105. The following transformer and switch-gear work conditions were assumed: – Maximum long-lasting transformer overload - 120% – Magnetizing inrush current for transformers up to and

including 630kVA - 12 x In during 100ms – Magnetizing inrush current for transformers above

630kVA - 10 x In during 100ms – Standard ambient working conditions for SafeRing /

SafePlus switchgear (most important: ambient temperature -25 ºC to +40 ºC),

For ratings marked with “*” transformer maximum short-circuit current at LV side, transferred to HV side, is below fuse-link minimum breaking current I3.The table above details the rated current of a particular fuse-link for a given line voltage and transformer rating. For differ-ent criteria, the fuse selection must be recalculated.

33

16. METERING MODULE

DANGER!Make sure there is no voltage in the busbars and cable terminals and that the risk of reconnection is eliminated in all units. Any remote control must also be prevented.

Front door locked:1.1 With padlock: Remove padlock, then turn blocking plates 90°.

1.2 With key lock: Unlock door by using the key for the panel door.

2. Use handles to lift door first up (vertical), then pull the door out (horizontal).

3. Remove plastic cover which is placed behind front door.

DANGERAlways check voltage presence before start of any work inside M-module

4. Pay attention to label placed inside every metering module

NOTEEnsure that HV fuse / dummy fuse is inserted properly into both upper and lower fuse holder

Max. tightening torque: 20 Nm

12kV with HV fuse 24kV with HV fuse,12 and 24kV with dummy fuse

Turn 90o to open

34

17. CAPACITIVE VOLTAGE INDICATORS Each module of switchgears is equipped with a capacitivevoltage indicator in accordance with either IEC 61958 (VPIS) or IEC 61243-5 (VDS).

17.1 VOLTAGE INDICATORS VPISVPIS indicators are used to indicate the presence of service medium voltage.

WARNINGThe indication of VPIS alone is not sufficient to pro-ve that the system is dead: if operating procedures make it mandatory, relevant voltage detectors according to IEC 61243-1, IEC 61243-2 and IEC 61243-5 shall be used.

The energized state of the unit is indicated by a flashing light with frequency of repetition of at least 1 Hz.

NOTEUnder very bright lighting it may be necessary to improve visibility by additional means.

OPERATING TEMPERATUREThe VPIS will operate reliably over a temperature range of –25° to +50°C.

PHASE COMPARISON AND TESTING OF VPISEach phase of the integrated voltage presence indicating system has a connection point on the front panel, which can be used to perform phase comparison and to test the voltage presence indicator.

THRESHOLD VALUES FOR VOLTAGE PRESENCE INDICATIONThe indication corresponding to “voltage present” appears when the actual line-to-earth voltage is between 45% of the nominal voltage and the rated voltage. The indication corres-ponding to “voltage present” does not appear when the actual line-to-earth voltage is less than 10% of the nominal voltage.

35

17.2 VOLTAGE INDICATORS VDSVDS is used to detect the presence or absence of medium voltage according to IEC 61243-5.The VDS are based on the HR system. The system consists of a fixed device, installed in the switchgear, coupled with a mobile device to visually detect the presence or absence of service voltage and phase balance and on which the indicator lights are installed.The state of voltage present is visually indicated with at least 1Hz repetition frequency. The „voltage indicators“ which are recommended are the VIM1 type used as a mobile device and VIM3 type used as a fixed and mobile device. Both are made by Maxeta.The „voltage indicators“ have a maximum operating voltage threshold of 90 V and a maximum current threshold of 2.5 uA at 50Hz.

OPERATING TEMPERATUREThe VDS works reliably with a temperature range from –25°C to +50°C.

PHASE COMPARATORThe phase comparator detects the balance or unbalance of the phases between the interface and/or the test points. De-tection is by means of a luminous indicator.The recommended phase comparator of the VDS is the PCM-HR type, made by Maxeta. It consists of a 1.4 m long test cable.

THRESHOLD VALUES FOR VOLTAGE INDICATIONWhen the line-earth voltage is between 45% and 120% of rated voltage, indication of „voltage present“ must appear. The „voltage present“ indication must not appear when the line-earth voltage is less than 10% of the rated voltage.

17.3 VOLTAGE INDICATORS VDS LRMWith VDS LRM system, the following can be indicated:-Overvoltage-Nominal voltage presence-Isolation problems-No voltage-Broken lead indication (Optional feature)Indication is done visually on the display.Contact the product manufacturer for detailed descriptions and manuals.

Phase sequence test

Capacitive voltage indicator type HR

36

18. ADDITIONAL EQUIPMENT18.1 LOW-VOLTAGE CONNECTIONSAuxiliary contacts (2NO+2NC) can be supplied to indicate switch positions on all switches/breakers. Access to the low-voltage connections is obtained by removing the top front panel. A shunt trip coil (AC or DC) can be fitted on the transformer switch/breaker.

18.2 REMOTE CONTROL AND MONITORING UNITSafeRing can be equipped with an integrated remote control and monitoring unit (see picture left).

This unit is pre-engineered and can be delivered and installed as a retrofit solution or complete from factory.

SafePlus can have the same equipment but needs an additio-nal low voltage compartment on top of the switchgear.

37

19. CABLE TESTING Cable testing and locating cable faults are preformed inthree ways:1. Directly on the testing points if they are fitted on the unit.2.1 Directly on the cable connectors with the cable connected to the switchgear.2.2 Cable connector dismounted from the switchgear.

CAUTIONCable testing must be carried out in accordance with the cable manufacturer’s recommendedpractice.

DANGERRemember that the cable has two ends. Both ends of the cable need to be isolated. This is typically done by opening the disconnectors of SafeRing SafePlus switchgears connected to the cable. The free end of the tested cable needs to be secured against accidental access.

CAUTIONSometimes cable testing through the busbar of the switchgear is preferred. This way several sections of cable can be tested at the same time. This is feasable, but remember the following limitations:

− DC and VLF voltages must not be applied to voltage transformers and surge arresters.

19.1 PROCEDURE FOR SWITCHGEAR WITH TEST POINTS1. Open switch disconnector.2. Check voltage status.3. If voltage is not present, close the earthing switch.4.Connect the testing equipment on top of the testing points which hold the earth bar (B).5. Remove the earth triangle and perform the test. Respect maximum test voltage levels as detailed in table below.6. Refit the earth triangle. Tightening torque: 25 Nm.7. Disconnect test equipment.

Maximum cable test voltages when testing cables using the cable test points of the switchgear

Rated voltage of the switchgear Ur (kV rms) 12kV 17,5kV 24kV Time

Power frequency cable test voltage Uct(ac) (kV rms) 12kV 17,5kV 24kV 15 min.

DC cable test voltage Uct(dc) (kV peak) 24kV 34,8kV 40kV 15 min.

VLF cable test voltage (Sine-wave, 0,1Hz) Uct(VLF) (kV rms) 18kV 26,1kV 28kV 15 min.

VLF cable test voltage (Cosine-rectangular, 0,1Hz Uct(VLF) (kV peak) 25,5kV 36,9kV 40kV 15 min.

38

19.2 PROCEDURE FOR TESTING DIRECTLY ON THE CABLE CONNECTOR WITH THE CABLE CONNECTED TO THE SWITCHGEAR1. Open switch disconnector.2. Check voltage status.3. If voltage is not present, close the earthing switch.4. Open cable compartment cover.5. Connect test rod or test lead to cable connector, keeping the cable connected to the switchgear.6. Open earthing switch and perform the test. Respect maximum test voltage levels as detailed in table below.7. Close the earthing switch.8. Disconnect the test equipment.9. Complete the cable connector with insulating plugs.10. Refit cable compartment cover.

19.3 PROCEDURE FOR TESTING DIRECTLY ON THE CABLE CONNECTOR WITH THE CABLE DISCONNECTED FROM THE SWITCHGEAR1. Open switch disconnector.2. Check voltage status.3. If voltage is not present, close the earthing switch.4. Open cable compartment cover.5. Remove cable connector from the switchgear.6. Connect test rod or test lead to cable connector.7. Perform the test respecting maximum test voltage levels as detailed in instructions from cable supplier and cable connector supplier. When the cables are disconnected at both ends, the cable testing is independent from the switchgear. Procedures and test values are determined by the cable, cable terminations and test equipment. Test procedure and methods must follow recommendations and limitations related to the cable, cable terminations and test equipment.8. Disconnect test equipment.9. Refit cable connector to switchgear.10. Refit cable compartment cover.

Maximum cable test voltages when testing directly on the cable connector with the cable connected to the switchgear

Rated voltage of the switchgear Ur (kV rms) 12kV 17,5kV 24kV Time

Power frequency cable test voltage Uct(ac) (kV rms) 12kV 17,5kV 24kV 15 min.

DC cable test voltage Uct(dc) (kV peak) 24kV 34,8kV 48kV 15 min.

VLF cable test voltage (Sine-wave, 0,1Hz) Uct(VLF) (kV rms) 18kV 26,1kV 36kV 15 min.

VLF cable test voltage (Cosine-rectangular, 0,1Hz Uct(VLF) (kV peak) 25,5kV 36,9kV 51kV 15 min.

39

20 SERVICE AND MAINTENANCE20.1 GENERAL WARNINGS AND CAUTIONS

WARNINGPay attention to the following safety warnings:Preparing the switchgear for safe assembly1. For each case, set safe working conditions with the utility safety officer.2. Make sure that national safety regulations are followed.3. Make sure there is no voltage in the busbars and cable terminals and that the risk of reconnec-tion is eliminated in all units. Any remote control must also be prevented.4. Make sure that auxiliary circuits are also dis-connected from all possible power supply sources (including instrument transformers)

TOOLS REQUIRED − Tool list as specified under chapter 20.6 − Vacuum cleaner − Cleaning cloths − Mild alkaline cleaning agent- Do not use trichloroethane, carbon carbotetrachloride or any kind of alcohol, etc. for cleaning

− Clean water − Silicone liquid

- In special cases, insulating surfaces can be covered with a thin layer of silicone liquid such as DC200/100CS or similar

− Instruction manuals − Test equipment

MAINTENANCE INSTRUCTIONSMaintenance serves for preserving trouble-free operation and achieving the longest possible working life of the switchgear.It comprises the following closely related activities:

− Inspection: Determination of the actual conditions − Servicing: Measures to preserve the specified conditions − Repairs: Measures to restore the specified conditions

The time intervals for maintenance work to be carried out always depend on the operating conditions of the switchgear and, above all on the mode of operation, the number of rated and short-circuit current switching operations, ambient tem-perature, pollution, etc.The maintenance intervals and measures to be taken that are given in table below are recommended for SafeRing/SafePlus under normal service conditions. Three year intervals are re-commended for all maintenance measures in more demanding conditions (such as areas with high pollution levels).

OTHER IMPORTANT INSTRUCTION MANUALSThe operation of all protection relays should be checked in accordance with the manufacturer’s instructions.All components in the SF6 tank are maintenance-free for the declared life expectancy of the product. The tank is made of stainless steel.

20.2 MAINTENANCE INTERVALSWe recommend carrying out the maintenance work at the following intervals:

Activity performed According to section Time interval in years

Inspection 19.3 5 2)

Service 19.4 As required 3)

Repairs 19.5 As required

2) Under more demanding service conditions, we recommend shortening

this interval appropriately.3) According to the results of the inspection.

Other services may be required, as when max number of ope-rations is reached, please contact ABB to order inspection.

NOTEUnder abnormal operating conditions (including adverse climatic conditions) and/or particular environmental conditions (among which, heavy pollution and aggressive atmosphere), inspection at shorter intervals may be necessary.

20.3 INSPECTIONGENERAL ASPECTSWhere necessary, the working area must be isolated and secured against accidental re-connection before inspection, in accordance with the “Safety Regulations” specified by IEC standards and corresponding national standards. The switch-gear condition must be monitored by regular inspections. Under normal operating conditions, inspections should be carried out once every fifth year by suitably trained personnel.

INSTRUCTIONSCarry out the following inspections:

− Visually check for dirt, corrosion and moisture. − Check for traces of discharges on insulating material parts. − If there are test points:

− Visually check the contact points and surrounding earthed surfaces.

− If there are signs of pollution or dust, please clean the area.

− Check the operating pressure of the gas-insulated switching devices where possible. Follow gas-chapter for further instructions.

− Check condition and life time of installed accessories and auxilliary devices; change if necessary according to com-ponent data sheet.

− If corrosion is observed on mechanisms, motors or other accessories please contact ABB to evaluate if anything needs to be replaced.

− Check that there are no visible signs of, or damage from, partial discharges.

− There should not be any visible signs of overheated connections.

− All components should perform perfectly and any faulty components must be replaced.

40

No discharge should occur on the surfaces of equipment at the operating voltage. This can, for example, be detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing in the dark.

NOTEShould partial discharges occur as a result of condensation, application of a thin silicone film over the surface concerned is often effective as a temporary remedy. It is advisable to ask the ABB after-sales service department for advice regarding permanent solutions to this uncommon type of problem.

REPAIR MEASURESIf any irregular conditions are detected, appropriate servicing or repair measures must be taken.

20.4 SERVICINGINSTRUCTIONSIf the need for servicing measures is established during the course of an inspection, proceed as follows:1. Clean all parts (e.g motors and mechanisms) with a

vacuum cleaner and visually inspect them. Clean the surfaces in general:

− Lightly settled dry dust deposits: clean with a soft dry cloth.

2. Perform a closing/opening operation on all disconnectors and circuit-breakers, fuse switches, and earthing switches.

3. Connect the auxiliary control voltage, but ensure that no remote signals can activate the components. Perform one electrical operation sequence on all motor-operated de-vices and tripping mechanisms.

4. For maintenance of gas-pressure, follow gas-chapter for further instructions.

5. Completely remove all rust from damaged paint work areas on steel sheet and other steel parts by mechanical means, e.g. with a wire brush, and apply appropriate anti-corrosion treatment.

20.5 REPAIRS

NOTEIf the switchgear is damaged, contact ABB to eva-luate necessary repairs. Some advanced repairs/operations should be carried out only by ABB service personnel.

Carry out repair work immediately after a defect has been discovered.

CAUTIONFollow the maintenance instructions in the manuals for the relative components.

20.6 TOOL LIST SAFERING/SAFEPLUS

Tools Required

Drill tools

14,4 Volt Drill with battery LSV 034

Extra 14,4V battery

Charger - DC18RA

Drill heads Ø 1 -13 mm

Bits-set 59/S31

First Aid minikit

M4 tap

M5 tap

M6 tap

M16 tap

Adapter piece 7mm hex to 1/4“



1/2“ Extender, L = 10“ ( 25 cm )

1/2“ Long pipe - 17 mm



Hand tools

1/2“ Long ratchet L = 42 cm X

1/2“ Pipe set - Content:

1/2“ ratchet L = 24 cm

1/2“ extender, L = 1 3/4“ ( 4,5 cm )

1/2“ extender, L = 2 1/2“ ( 6 cm )

1/2“ extender, L = 6“ ( 15 cm ) X

1/2“ universal joint L = 7 cm

10 mm 1/2“ pipe X

11 mm 1/2“ pipe

12 mm 1/2“ pipe

13 mm 1/2“ pipe X

14 mm 1/2“ pipe X

15 mm 1/2“ pipe

16 mm 1/2“ pipe

17 mm 1/2“ pipe X

18 mm 1/2“ pipe

19 mm 1/2“ pipe X

21 mm 1/2“ pipe X

22 mm 1/2“ pipe X

24 mm 1/2“ pipe X

27 mm 1/2“ pipe

30 mm 1/2“ pipe

32 mm 1/2“ pipe

NOTEThe following list of tools does NOT cover tools needed for HV or LV cable work/handling or testing.

The tools marked with an “X“ in the column “Required“ are needed for installation and regular maintenance work as described in chapter 20.

41

20.6 TOOL LIST SAFERING/SAFEPLUS Tools Required

Adjustable wrench 10“

Side cutting plier - ergo X

Strippling plier X

Universal plier

Bits set with screwdriver handle X

3/8“ Long ratchet L = 50 cm X

3/8“ Pipe set - Content:

3/8“ ratchet L = 24 cm

3/8“ extender, L = 3“ ( 7,5 cm )

3/8“ Bits holder

8 mm 3/8“ pipe

10 mm 3/8“ pipe

11 mm 3/8“ pipe

12 mm 3/8“ pipe

13 mm 3/8“ pipe

14 mm 3/8“ pipe

15 mm 3/8“ pipe

17 mm 3/8“ pipe

19 mm 3/8“ pipe

Bits PH 1 X

Bits PH 2 X

Bits FT 4

Bits FT 5,5

Bits PZ 1

Bits PZ 2 X

Bits HEX 5 X

Bits HEX 6

Bits TX 10

Bits TX 15

Bits TX 20 X

Bits TX 25 X

Bits TX 30 X

7 mm combination wrench X

8 mm combination wrench











Screwdriver - Flat 1,2 x 8 x150

Screwdriver - Flat 1,2 x 6,5 x100

Screwdriver - Flat 0,5 x 3 x75 X

Screwdriver - Flat 1,2 x 5,5 x38

Screwdriver - Star PZ 2 - 38

Screwdriver - Star PZ 2 - 75

Hex key set 1,5 - 10 mm

Extra tools

Head lamp - LED

Flashlight LED

Multi-purpose service spray 5-56

Permanent Marker

Small cable ties L=203 x 2,5mm

Large cable ties L=375 x 7,6mm

Multimeter - UT58B

Insulation tape - Tesaflex 53948

Working Gloves

Specialist Cloth

Scotch-Brite

Silicon handling glove - Nitrile powder free

Hammer 12 oz

Clamp 300 x 100 mm

Bow saw nr. 10 12““ 300 mm

Extra bow saw blades bi-metal 24T

Flat file

Round file

Knife

42

Raw Material Weight (kg) % of total weight

Recycle Environmental effects & recycle/reuse processes

Iron 132,80 42,53 Yes Separate, utilise in favour of new source (ore)

Stainless steel 83,20 24,93 Yes Separate, utilise in favour of new source (ore)

Copper 43,98 14,09 Yes Separate, utilise in favour of new source (ore)

Brass 2,30 0,74 Yes Separate, utilise in favour of new source (ore)

Aluminium 8,55 2,74 Yes Separate, utilise in favour of new source (ore)

Zinc 3,90 1,25 Yes Separate, utilise in favour of new source (ore)

Silver 0,075 0,024 Yes Electrolysis, utilise in favour of new source

Thermoplastic 5,07 1,63 Yes Make granulate, re-use or apply as energy superioradditive in refuse incineration

Epoxy incl. 60% quartz 26,75 8,35 Yes Grind to powder and use as high-grade energy additive in cement mill

Rubber 1,35 0,42 Yes High-grade energy additive in refuse incineration

Dielectric oil 0,21 0,066 Yes Reclaim or use as high-grade energy additive in refuse incineration

SF6 gas 3,24 1,04 Yes ABB AS in Skien reclaims used SF6 gas

Total recyclables 311,42 97,81

Unspecified* 9,00 No *Stickers, film foils, powder coating, screws, nuts, grease....

Total weight ** 320 100

Packing foil 0,20 Yes High-grade energy additive in refuse incineration

Wooden pallet 21,50 Yes Re-use or use as energy additive in refuse incineration

21.2 RECYCLING CAPABILITY

**) All figures are collected from CCF 3-way unit with fuse canisters

21. ENVIRONMENTAL CERTIFICATION21.1 LIFE EXPECTANCY OF PRODUCTThe product is developed in compliance with the requirements denoted by IEC 62271-200. The design incorporates a life span under indoor service conditions exceeding 30 years (IEC 62271-200 annex GG).The switchgear is gas-tight with an expected diffusion rate of

less than 0.1 % per annum. Referring to the reference-pressu-re of 1.4 bar, the switchgear will maintain gas-tightness and a gas-pressure better than 1.3 bar* throughout its designed life span. *) at 20oC.

21.3 END-OF-LIFEABB AS, Electrification Products division, is committed to the protection of the environment and adhere to ISO 14001 standards. It is our obligation to facilitate end-of-life recycling for our products.

There exist no explicit requirements for how to handle dis-carded switchgears at end-of-life. ABB’s recycling service is according to IEC 1634 edition 1995 section 6: «End of life of SF6 filled equipment» and in particular 6.5.2.a: «Low decom-position»: «No special action is required; non-recoverable parts can be disposed of normally according to local regulati-ons.»

We also recommend ABB’s website : http://www.abb.com/sf6

ABB AS, Electrification Products division in Skien is equipped to reclaim SF6 gas from discarded switchgears.

1VD

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5976

GB

Feb

ruar

y 20

16For more information please contact: ABB ASElectrification Products divisionP.O. Box 108, SentrumN-3701 Skien, NorwayPhone: +47 35 58 20 00www.abb.com

Text and illustrations are not binding. The right to make alterations is reserved

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