Appendix A, E and F
Appendix A – Engineering Operating Standard (EOS) 09-0080 LV
Remote Control Equipment
Appendix E – FUN-LV CB Operations Instruction Card
Appendix F – Advanced Use Cases
Document Number: EOS 09-0080
Date: 28/03/2015
ENGINEERING OPERATING STANDARD
EOS 09-0080
LV REMOTE CONTROL EQUIPMENT
Network(s):
EPN, LPN, SPN
Summary:
This standard covers all operational aspects of the system and provides the
required information to safely install, commission, operate and remove the :V
remote control and automation equipment.
Owner:
Peter Lang
Date:
28/03/2015
Approved By:
Barry Hatton
Approved Date:
28/04/2015
This document forms part of the Company’s Integrated Business System and its requirements are mandatory throughout UK
Power Networks. Departure from these requirements may only be taken with the written approval of the Director of Asset
Management. If you have any queries about this document please contact the author or owner of the current issue.
Applicable To
UK Power Networks
External
All UK Power Networks
G81 Website
Asset Management
Contractors
Capital Programme
ICPs/IDNOs
Connections
Meter Operators
HSS&TT
Network Operations
UK Power Networks Services
Other
THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE
Version: 1.0
LV Remote Control Equipment
Document Number: EOS 09-0080
Version: 1.0
Date: 28/03/2015
Revision Record
Version
1.0
Review Date
28/04/2016
Date
28/03/2015
Author
Peter Lang
New document which covers the approval of the LV remote control circuit breakers and link box
switches to be connected to LV networks.
Version
Review Date
Date
Author
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Contents
1
Introduction ............................................................................................................. 9
2
Scope ....................................................................................................................... 9
3
Glossary and Abbreviations ................................................................................... 9
4
Specialised Tools .................................................................................................. 10
5
Definitions .............................................................................................................. 10
6
Background and Overview ................................................................................... 11
6.1
Background ............................................................................................................. 11
6.2
System Overview .................................................................................................... 11
6.3
Tools Required to Install and Remove Link Box Devices ......................................... 15
7
Basic Operational Awareness (local / remote, open close (CBs and
Switches) ............................................................................................................... 16
7.1
Substation Overview................................................................................................ 16
7.2
Gateway (RTU) ....................................................................................................... 17
7.3
CB Operation........................................................................................................... 19
7.3.1
Open CB ................................................................................................................. 20
7.3.2
Close CB ................................................................................................................. 21
7.3.3
CB Series Fuse Replacement ................................................................................. 21
7.3.4
Series Fuse Rating Selector .................................................................................... 23
7.4
CB Indications ......................................................................................................... 23
7.4.1
FPI indication........................................................................................................... 23
7.4.2
Out of phase indicator ............................................................................................. 25
7.4.3
Other indicators, Power, Sys fail, voltage indicators, port and fuse selector ............ 26
7.5
Link Boxes ............................................................................................................... 30
7.5.1
Local Remote .......................................................................................................... 35
7.5.2
Switch Selection ...................................................................................................... 36
7.5.3
Open/ Close ............................................................................................................ 37
7.6
Other indicators, Power, Sys fail, voltage indicators, port and fuse selector ............ 38
7.6.1
FPI indication........................................................................................................... 38
7.6.2
Out of phase indicator ............................................................................................. 39
7.6.3
Other indicators, Power, Sys fail, voltage indicators ................................................ 40
8
Operational Procedures ........................................................................................ 42
8.1
Creating Points of Isolation ...................................................................................... 42
8.1.1
Circuit Breaker Point of Isolation.............................................................................. 42
8.1.2
Link Box Switch Point of Isolation ............................................................................ 44
8.2
Safety Fusing for Live Work ..................................................................................... 44
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8.3
Operation of Devices under Fault Conditions........................................................... 45
8.3.1
Restoring Supplies Remotely after a Fault ............................................................... 45
8.3.2
Restoring Supplies Locally after a Fault................................................................... 47
8.3.3
CB Operation (Fault Conditions) .............................................................................. 48
8.3.4
Link Box Switch Operation (Fault Conditions) .......................................................... 49
8.4
Device Removal and Replacement .......................................................................... 52
8.4.1
CB Removal ............................................................................................................ 52
8.4.2
CB Replacement ..................................................................................................... 54
8.4.3
LB Control Panel Removal ...................................................................................... 58
8.4.4
LB Control Panel Replacement ............................................................................... 61
8.4.5
LB Switch Removal ................................................................................................. 66
8.4.6
LB Switch Replacement .......................................................................................... 68
8.5
Abnormal Operation ................................................................................................ 71
8.5.1
CB Removal (Inoperable) ........................................................................................ 71
8.5.2
LB Switch Removal (Inoperable) ............................................................................. 72
9
Commissioning and Installation Procedure ........................................................ 73
9.1
Onsite installation and commissioning procedure for substation Gateway (RTU)
and Circuit Breakers ................................................................................................ 73
9.1.1
Substation Equipment Overview .............................................................................. 73
9.1.2
Gateway (RTU) Installation / Mounting .................................................................... 75
9.1.3
Power & Data Bus Installation ................................................................................. 75
9.1.4
Gateway (RTU) Installation Connections ................................................................. 76
9.1.5
RTU and CB Installation & Commissioning Process ................................................ 81
9.1.6
Substation Commissioning Flowchart ...................................................................... 90
9.2
Onsite installation and commissioning procedure for Link Box Devices ................... 91
9.2.1
LB Equipment Overview .......................................................................................... 92
9.2.2
LB Commissioning Information ................................................................................ 94
9.2.3
LB Switch and Controller Commissioning Process .................................................. 95
9.2.4
Link Box Commissioning Flowchart ....................................................................... 104
9.2.5
Link Box Switch Installation Flowchart ................................................................... 105
9.3
System Alteration Notice and Asset Registration ................................................... 106
10
References ........................................................................................................... 106
11
Dependent Documents....................................................................................... 106
Appendix A - Asset Registration.................................................................................... 107
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Figures
Figure 1: System Overview ................................................................................................. 11
Figure 2: Circuit Breaker ..................................................................................................... 12
Figure 3: Link Box Switch .................................................................................................... 12
Figure 4: Link Box Switch Dummy Cover ............................................................................ 13
Figure 5: Link Box Controller ............................................................................................... 13
Figure 6: Gateway (RTU) .................................................................................................... 14
Figure 7: Power and Data Busbar ....................................................................................... 15
Figure 8: 5mm Allen Key to remove - install Link Box Switches .......................................... 15
Figure 9: Spinner Nut Ins 10mm loosen/tighten the Link Box neutral connector .................. 15
Figure 10: Substation Overview of Connections .................................................................. 16
Figure 11: LV Substation with a Gateway (RTU) ................................................................. 17
Figure 12: Overview of the basic Gateway (RTU) indicators ............................................... 18
Figure 13: Communications Hub ......................................................................................... 18
Figure 14: Data Hub ............................................................................................................ 19
Figure 15: Circuit Breaker showing controls and indicators ................................................. 19
Figure 16: Gateway (RTU) set to local mode ...................................................................... 20
Figure 17: Circuit Breaker Open Procedure ........................................................................ 20
Figure 18: Circuit Breaker Close Procedure ........................................................................ 21
Figure 19: CB Series Fuse Replacement – Internal wiring diagram..................................... 21
Figure 20: Check Voltage between neutral and the cable - Circuit Breaker fuse stalk ......... 22
Figure 21: Check voltage between the busbar CB fuse stalk and the cable CB fuse stalk ... 22
Figure 22: CB Fuse Selector Indicator set to 400A.............................................................. 23
Figure 23: Circuit Breaker FPI Indicator .............................................................................. 24
Figure 24: Out of Phase Indicator ....................................................................................... 25
Figure 25: Power indicators & Sys fail ................................................................................. 26
Figure 26: Voltage indicators............................................................................................... 27
Figure 27: Port & Phase designations ................................................................................. 28
Figure 28: Example Circuit Breaker addressing displayed on a laminated information card 29
Figure 29: Diving Bell Lid Installed ...................................................................................... 30
Figure 30: Link Box Control ................................................................................................. 31
Figure 31: Link Box Switch Dummy..................................................................................... 31
Figure 32: Link Box Switch .................................................................................................. 32
Figure 33: Link Box Switches in Prysmian Box.................................................................... 32
Figure 34: Link Box Control Panel Neutral Connector ......................................................... 33
Figure 35: Link Box Control showing Q1 label on Prysmian ................................................ 33
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Figure 36: Overview Link Box Control Panel ....................................................................... 34
Figure 37: Link Box Local/Remote Selector ........................................................................ 35
Figure 38: Link Box Controller Switch Selection .................................................................. 36
Figure 39: Link Box Local/Remote Selector ........................................................................ 37
Figure 40: FPI indicator ....................................................................................................... 38
Figure 41: Current Direction Indicator ................................................................................. 39
Figure 42: Control Panel System Status Indicators ............................................................. 40
Figure 43: Voltage Indicator ................................................................................................ 41
Figure 44: Circuit Breaker Point of Isolation ........................................................................ 42
Figure 45: Circuit Breaker remove series fuse..................................................................... 43
Figure 46: Circuit Breaker - removing power and data ........................................................ 43
Figure 47: Circuit Breaker Status verification - CB has lost logic and solenoid power ......... 43
Figure 48: Circuit Breaker - Down Fusing for Live Work ...................................................... 44
Figure 49: Remote Switching Fault Scenario ...................................................................... 46
Figure 50: Remote Switching Fault Isolation ....................................................................... 46
Figure 51: Fault location cannot be determined................................................................... 47
Figure 52: Circuit Breaker fault indications .......................................................................... 49
Figure 53: Circuit Breaker Fault Make ................................................................................. 50
Figure 54: Circuit Breaker Out of Phase .............................................................................. 50
Figure 55: CB Removal ....................................................................................................... 52
Figure 56: Remove series fuse ........................................................................................... 52
Figure 57: Circuit Breaker Data and Power Connector ........................................................ 53
Figure 58: Circuit Breaker insulating fuse stalks .................................................................. 53
Figure 59: Procedure - loosen Circuit Breaker thumb screws .............................................. 53
Figure 60: CB fuse stalk insulated covers ........................................................................... 54
Figure 61: Circuit Breaker thumb screws............................................................................. 54
Figure 62: Circuit Breaker port and phase configuration ...................................................... 55
Figure 63: Circuit Breaker open operation ........................................................................... 56
Figure 64: Circuit Breaker confirm switch is open................................................................ 57
Figure 65: Circuit Breaker check voltage - busbar CB fuse stalk and the cable CB fuse
stalk ................................................................................................................... 57
Figure 66: Circuit Breaker fuse selection toggle button ....................................................... 57
Figure 67: Link Box Control Panel Removal ........................................................................ 59
Figure 68: Control Panel Local/Remote button .................................................................... 59
Figure 69: release the plug retaining clip ............................................................................. 60
Figure 70 Link Box switch plug removal .............................................................................. 60
Figure 71: Link Box Controller Plugs ................................................................................... 60
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Figure 72: Link Box Controller Neutral Connection.............................................................. 61
Figure 73: Link Box Control Panel Orientation .................................................................... 62
Figure 74: Positioning Link Box Controller........................................................................... 63
Figure 75: Socket positioning on the controller .................................................................... 63
Figure 76: Connecting switches to the control panel ........................................................... 64
Figure 77: Control Panel displaying the state of the switches .............................................. 64
Figure 78: Control Panel LED TEST button......................................................................... 65
Figure 79: Controller in Remote mode ................................................................................ 65
Figure 80: Select button cycles through available switches for control ................................ 66
Figure 81: Disconnecting the switches plugs....................................................................... 67
Figure 82: Removing link Box Switches .............................................................................. 67
Figure 83: Checking that the switches to be installed are in the open position .................... 68
Figure 84: Installing switches using 5mm Allen Key ............................................................ 69
Figure 85: Showing correct socket on the controller to avoid potential switching errors ....... 70
Figure 86: Remove Series Fuse .......................................................................................... 71
Figure 87: insulated fuse stalk............................................................................................. 71
Figure 88: Circuit Breaker retaining thumb screws .............................................................. 72
Figure 89: Substation Equipment Overview ........................................................................ 73
Figure 90: Substation devices to be installed ...................................................................... 74
Figure 91: Power & Data Bus Installation ............................................................................ 75
Figure 92: Connections to the PDB ..................................................................................... 75
Figure 93: LV Board with Power & Data Bus installed ......................................................... 76
Figure 94: PDB fixings - Cable Ties .................................................................................... 76
Figure 95: Gateway (RTU) with cover removed................................................................... 77
Figure 96: Gateway (RTU) Connection Diagram ................................................................. 77
Figure 97: Cable entry locations Gateway (RTU) ................................................................ 78
Figure 98: PDB Power & Data (MODBUS) Connections ..................................................... 79
Figure 99: Power and Data Busbar connections ................................................................. 79
Figure 100: GPRS Antenna cable ....................................................................................... 80
Figure 101: Gateway (RTU) Mains Power Connection ........................................................ 80
Figure 102: Gateway (RTU) Battery Backup Connection .................................................... 81
Figure 103: Gateway (RTU) Installation & Commissioning Process .................................... 82
Figure 104: Circuit Breaker - Fuse Stalk Covers Fitted........................................................ 83
Figure 105: Circuit Breaker thumb screw fixings ................................................................. 83
Figure 106: L1 PLC plug connected to Circuit Breaker ........................................................ 84
Figure 107: PLC connections from the PDB to the CBs ...................................................... 84
Figure 108: Circuit Breaker power and data ........................................................................ 85
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Figure 109: CB power & data cables ................................................................................... 85
Figure 110: Circuit Breaker port number and phase designation ......................................... 86
Figure 111: Test Circuit Breaker in open scenario............................................................... 88
Figure 112: Circuit Breaker in open scenario – CB not back-fed ......................................... 88
Figure 113: Circuit Breaker Fuse Selector........................................................................... 89
Figure 114: Circuit Breaker closing procedure .................................................................... 89
Figure 115: Substation Commissioning Diagram................................................................. 90
Figure 116: Specific tools required to install the LV Automation link box equipment ............ 91
Figure 117: Link Box Installation ......................................................................................... 92
Figure 118: Link Box Switch Dummy................................................................................... 92
Figure 119: Link Box Switch Control Panel ......................................................................... 93
Figure 120: Diving Bell Lid Installed .................................................................................... 93
Figure 121: PowerOn representation .................................................................................. 94
Figure 122: Gateway (RTU) power and local/remote indicators .......................................... 95
Figure 123: Link Box Switch Neutral Connector .................................................................. 96
Figure 124: Link Box - test configuration ............................................................................. 96
Figure 125: Check Link Box Switches are installed are in the open position ....................... 96
Figure 126: Installing OPEN switch into the link box,........................................................... 97
Figure 127: Operating switches to aid installation ............................................................... 98
Figure 128: Neutral connection to Link Box Panel ............................................................... 98
Figure 129: LB Control Panel matches Q1 on Prysmian Box .............................................. 99
Figure 130: Correct Link Box connection procedure ............................................................ 99
Figure 131: Link Box Switch plug/connector installation .................................................... 100
Figure 132: Traffolyte label positioned inside link box to mark the Quadrant 1 location ..... 100
Figure 133: Verify Link Box Control Panel has power and is correctly displaying state of
switches ........................................................................................................... 101
Figure 134: Control board LED diagram ............................................................................ 101
Figure 135: Link Box Control Panel Local – Remote, toggle push button .......................... 102
Figure 136: Link Box Controller Switch Selector................................................................ 102
Figure 137: Modified Bell Cover and Retaining Strap ........................................................ 103
Figure 138: Link Box Switch Commissioning Flowchart Diagram ...................................... 104
Figure 139: Link Box Switch Installation checks Flowchart Diagram ................................. 105
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1
Introduction
This Standard and the associated A5 LV Remote Control Manual dated Autumn 2013 have
been published as UK Power Networks plans to install and operate devices to enable remote
control of Low Voltage networks.
The information provided in this Standard is specific to the installation and operation of
retrofit, single phase remote control LV switching devices, which have been jointly developed
between TE Connectivity, EA Technology Ltd and UK Power Networks.
These include Circuit Breakers (CBs) which retrofit to the majority of LV distribution boards,
in place of existing LV fuse carriers, Link Box Switches which retrofit to the more recent
Prysmian link boxes, and a new Gateway (RTU) unit, which will provide SCADA connectivity
to the devices; allowing LV control engineers to monitor and to remotely reconfigure the LV
network.
This Standard and manual covers all operational aspects of the system, and provides the
required information to safely install commission, operate and remove the LV remote control
& automation equipment.
2
Scope
This standard applies to the use of the LV remote control equipment being used in Smart
Urban LV Network (SULVN) project, Flexible Urban Networks LV (FUNLV) and other
installations where incipient faults occur.
3
Glossary and Abbreviations
Term
Definition
3G/GPRS
3rd Generation/General Packet Radio Service
Back Fed
Supply power from another Transformer – to continue power supply to
network
BAU
Business As Usual
CB
Circuit Breaker
CH
Communications Hub
CI
Customer Interruptions
CML
Customer Minutes Lost
DH
Data Hub
EATL
EA Technology Ltd (Supplier of remote control equipment)
FB
Fault Break
FCU
Fused Connection Unit
FM
Fault Make
FPI
Fault Passage Indicator
FUNLV
Flexible Urban Networks LV
GUI
Graphical User Interface
GW
Gateway
HSS
Health Safety and Sustainability
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HV
High Voltage
LB
Link Box
LBS
Link Box Switches
LCNF
Low Carbon Network Funded
LED
Light Emitting Diode
LV
Low Voltage
MODBUS
A serial communications protocol published by Modicon
PDB
Power & Data Bus
PDB
Power and Data Bus
PH
Abbreviation for Phase – live conductor, eg Phase 1 = Brown coloured
conductor
PLC
Power Line Carrier
POI
Point Of Isolation
PowerOn
Network LV – HV electronic diagram and control software
Quadrant (Pocket)
Link Box section containing links or fuses
RTU (Gateway)
Remote Terminal Unit – remotely accessed, either through a dedicated
version of PowerOn Fusion.
SCADA
Supervisory Control And Data Acquisition
SSL
Secure Sockets Layer
SULVN
Smart Urban LV Network
TC
Transformer Chamber (Distribution substation)
TE
TE Connectivity (Developer of remote control equipment)
4
Specialised Tools
Material code
Description
32103B
ALLEN KEY INSUL T-BAR LONG REACH 5MM - install/remove Link box
switches
33706F
SPINNER NUT INS 10MM - loosen/tighten the Link Box neutral
connector
5
Definitions
Term
Definition
Asset Register
UK Power Networks asset register (formerly Ellipse) which will soon be
integrated into SAP as per Business Transformation.
PowerOn fusion
UK Power Networks network management system.
NetMap
UK Power Networks graphical information system (GIS).
Quadrant 1 (Q1)
The quadrant of a link box on the long side closest to the kerb.
UK Power
Networks
UK Power Networks (Operations) Ltd consists of three electricity distribution
networks:

Eastern Power Networks plc (EPN).

London Power Network plc (LPN).

South Eastern Power Networks plc (SPN).
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6
Background and Overview
6.1
Background
In order to facilitate smarter management of the LV network, UK Power Networks and TE
Connectivity have collaborated to develop a new solid-state switching technology for use on
the LV distribution network.
Following a successful network demonstration, in which prototype devices have been
installed on an LV circuit linking two distribution substations and three link boxes, UK Power
Networks has registered a follow-on Low Carbon Network Funded (LCNF) Tier 1 project.
The Smart Urban LV Network (SULVN) project will enable a large scale trial of the
technology in two feeder groups out of City Rd B Primary substation. Up to 50 secondary
substations will be equipped with circuit breakers (CBs) and 160 link boxes will be fitted with
switches or load monitoring devices.
The Flexible Urban Networks LV (FUN-LV) project will use similar CBs and link box switches
to join distribution substations together to provide capacity sharing. There will be four trial
sites in the interconnected network of Central London, four in the LPN radial networks and
four trials in Brighton.
This document will support the roll out and operation of the new devices throughout the
duration of the trial, and any further deployments should the technology be adopted and
rolled out under BAU.
6.2
System Overview
The main components of the LV remote control and automation system are show in the
system overview diagram (Figure 1).
Figure 1: System Overview
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The LV Remote Control & Automation system consists of the following components:
Circuit Breakers
The circuit breakers (CB) have been designed to fit to the majority of UKPN LV distribution
boards, in place of BS J-type fuse carriers. Each CB accepts a standard 315A or 400A JPU
fuse, which is connected in series, and is easily removable from the front panel of the CB.
The CBs are Fault Break (FB)/Fault Make (FM) single-phase switching devices.
Figure 2: Circuit Breaker
The CBs will isolate a network fault where the fault current is less than 6kA RMS. For a fault
current above 6kA the in series JPU fuse will clear the fault. Where the fuse clears a fault,
restoration of supply will require that the fuse is manually replaced.
Link Box Switches
Link Box Switches (LBS) are a single phase Load Break/Fault Make device that can be
retrofitted to existing Prysmian Link Boxes, currently used on the LV network. The LBS
replaces the standard links; therefore to fully populate a four-way link box requires the
installation of 12 switches.
Figure 3: Link Box Switch
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A controller sits above the switches, providing remote comms to the box, and local control of
the switches. One controller can operate and control up to 12 switches, in a 4-way link box.
The controller for a 2-way link box controls three switches. Switches must be installed in
three’s, on a per quadrant/pocket basis, i.e. all phases on a quadrant (pocket) must
have a LBS installed.
The standard link box bell lid will not accommodate the additional height of the new Link Box
equipment, so is replaced with a deeper bell lid, supplied as part of the system.
Where not all quadrants (pockets) in a link box are to be fitted with switches, the remaining
links or empty ways are covered by a dummy blanking switch body, of the same dimensions
as the switches.
Figure 4: Link Box Switch Dummy Cover
Fitment of the dummy switches provide a stable flat base for the LB control panel to sit on,
and ensure that the volume of air under the diving bell cover, remains consistent.
Link Box Switch Control Panel
The control panel sits above the switches and provides remote comms to the link box and
local control of the switches. The status of each switch is provided by an LED mimic panel,
which also provides FPI indication for each device, and the comms status of the controller.
The control panel is connected directly to the switches, via flexible cables (one per switch),
plus a neutral cable, which is connected to the neutral stalk in the link box. It utilises Power
Line Carrier (PLC) to communicate over the LV network to a Gateway (RTU) unit located at
the distribution substation.
Figure 5: Link Box Controller
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Gateway (RTU)
The Gateway (RTU) enclosure houses a Communications Hub module, a Data Hub module,
and a power supply module. The Gateway (RTU) controls the remote operation of the link
box switches, and the distribution board circuit breakers. One Gateway (RTU) is installed per
substation.
Figure 6: Gateway (RTU)
The Gateway (RTU) is a wall mounted unit, and should be installed as close as possible to
the substation LV board, to ensure the comms cables between the Gateway (RTU), and the
LV board are as short as possible (the range of the Power Line Carrier comms can be
adversely affected by cable runs greater than 3m, between the LV board and the Gateway).
In extreme situations the RTU could be mounted up to 10 metres away due to substation
accessibility.
The Gateway (RTU) requires connection to a 3A fused spur (via an unswitched FCU), and
also accepts a 24V DC supply for backup power, to be taken from the 24V separate backup
battery and charger system withits own neutral connection.
The Gateway (RTU) connects to UKPN’s SCADA network, via 3G/GPRS and enables LV
control centre to connect and remotely control, the CBs and LBSs. In standard form each
Gateway (RTU) can support a 5-way LV board with a maximum of 15 CBs. The DC backup
must be connected to operate all 15 CBs.
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Power & Data Busbar
This is a small unit that provides the interface, between the Gateway (RTU) and up to 15
CBs. It provides the data and power connections for each CB (one connector/lead per CB),
and the Power Line Communication (PLC) connection between the Gateway (RTU) and the
LV board busbars (one three phase PLC connector per LV board).
Figure 7: Power and Data Busbar
6.3
Tools Required to Install and Remove Link Box Devices
All tools required to work on the system are approved for use and available from the UKPN
materials e-catalogue.
The following tools are required to install or remove the link box switches and neutral
connector:
Allen Key Insul T-Bar Long Reach 5mm
Material Code – 32103B
Figure 8: 5mm Allen Key to remove - install Link Box Switches
This tool is required to loosen/tighten the Link Box Switch retaining clamps.
NOTE: Link box switches cannot be installed or removed without this tool.
It is recommended that all operational engineers likely to encounter the LV Automation
system ensure that they carry this tool, and that the tool is modified by cutting back the
insulation and only then used for the purpose of installing LBS.
Spinner Nut Ins 10mm
Material Code – 33706F
Figure 9: Spinner Nut Ins 10mm loosen/tighten the Link Box neutral connector
This tool is required to loosen/tighten the Link Box neutral connector, which clamps on to the
link box neutral stalk.
The neutral connector can be left in place once installed; therefore it is recommended that all
operational staff responsible for installing the Link Box devices carry this tool.
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7
Basic Operational Awareness (local / remote, open close (CBs and
Switches)
This section will provide basic operating instructions for the LV automation equipment being
installed; Circuit Breakers, Link Box Switches, Controllers, and Gateways (RTUs). This
section is aimed at those needing a better understanding of the system, such as engineers
working with the equipment, and personnel involved in working on the LV network.
NOTE: Where practical all operations shall be performed remotely by LV Control.
If it is necessary to perform operations locally, LV Control shall be contacted prior to any
local switching being undertaken.
7.1
Substation Overview
The following equipment will be installed to the distribution substation:



Circuit Breaker;
Gateway (RTU);
Power & Data Busbar.
These are show in the below diagram, with their connections.
Figure 10: Substation Overview of Connections
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Figure 11 shows an LV Substation with a Gateway (RTU), Power & Data Bus, and one LV
way populated with Circuit Breakers.
Figure 11: LV Substation with a Gateway (RTU)
7.2
Gateway (RTU)
The Gateway (RTU) connects to UKPN’s SCADA network via 3G/GPRS, and enables the
LV control centre to connect, and remotely control the CBs. It also provides comms from the
substation, to the linkbox equipment using Power Line Carrier (PLC) over the LV cables,
enabling LV control to remotely reconfigure the LV network, and isolate faulted sections of
network, in the event of a LV cable fault.
In standard form each Gateway (RTU) can support a 5-way LV board with a maximum of 15
CBs, and can control up to 10 link boxes.
LV Control can connect to the Gateway (RTU) remotely, through a dedicated version of
PowerOn Fusion (ENMAC). A web interface on the RTU (used for set-up/configuration of the
Gateway (RTU)) can also be accessed locally by connecting a laptop to one of the two
Ethernet ports on the bottom of the unit.
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An overview of the basic Gateway (RTU) indicators and controls is shown in Figure 12:
Power LEDs
Local / Remote Selector
Indicates there is Power on the Gateway
module. (Should always be illuminated)
Rotating the selector
button, will alternate
between local and
remote settings.
Set to Local to enable
local control of CBs.
Figure 12: Overview of the basic Gateway (RTU) indicators
Communications Hub Module
This handles all communications to CBs and Link Boxes. Power and Modbus cables
connected from the Hub facilitate power and communication to the CBs. Three PLC modems
(1 per phase) are used to communicate with the Link Boxes via the LV cable.
Power LED, Indicates coms hub has power
Comms LED, Indicates that comms hub
has PLC connectivity (PLC is used to
provide comms between the RTU and Link
Boxes via the LV cables)
Sys Fail LED, Indicates that the comms hub
module has detected a fault – note will
illuminate for a period of approximately 2
minutes on initial power-up, but should
not be illuminated in normal operation.
Figure 13: Communications Hub
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Data Hub Module
This controls the Gateway (RTU), handles Ethernet and remote GPRS communications
(providing connectivity to UKPN SCADA systems and LV control) and provides the user
control interface.
Power LED, Indicates data hub has power
Comms LED, Indicates data hub has GPRS connectivity
(GPRS is used to provide SCADA connectivity to the RTU)
Sys Fail LED, Indicates data hub module has detected a
fault – note will illuminate for a period of approximately
2 minutes on initial power-up.
Local / Remote LEDs, Provides local indication on the Local /
Remote state of the Gateway.
Figure 14: Data Hub
7.3
CB Operation
The following section covers local operation of the CBs, the below diagram shows the CB
control panel with a description of each CB function or indication.
Figure 15: Circuit Breaker showing controls and indicators
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7.3.1
1.
Open CB
Set Gateway (RTU) in substation to local mode.
Local / Remote Selector
Rotating the selector button, will alternate between
local and remote settings.
Set to Local to enable local control of CBs.
Local LED will illuminate when RTU is in Local mode
Figure 16: Gateway (RTU) set to local mode
2. Press and hold open button for 5 seconds; when the flashing frequency of the open LED
increases, the open button can be released.
Figure 17: Circuit Breaker Open Procedure
3. LED will continue to flash, and after a 10 second delay CB will operate. On successful
operation, the CB open LED will light and then close LED will be extinguished.
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Note: it is possible to cancel an operation during the stand clear delay. If CB is performing a
close operation, pressing the open button will cancel it, and vice versa. Remember to return
the Gateway (RTU) to the remote mode when the local manual operations have been
completed.
7.3.2
Close CB
The Close operation is the same as the Open operation – follow the same steps as
described for the ‘Open’ operation, only pressing the Close button instead of Open.
Press and hold Close
button for 5 seconds.
When close LED flashes
quickly release button
and stand clear of
device.
Figure 18: Circuit Breaker Close Procedure
7.3.3
CB Series Fuse Replacement
When a fault current >6kA flows the series fuse will operate to isolate the fault. If a fault
causes the CB series fuse to operate, it must be replaced before supplies are restored. The
following steps should be followed when replacing the series CB:
1. Set Gateway (RTU) to local mode as shown in section 7.2.
2. Ensure CB is open, by checking that the open LED is lit, if not follow the steps for opening the
CB in section 7.3.1.
3. Remove series fuse (providing access to fuse stalks), fuse stalk connection with internal
wiring diagram is shown below.
Internal CB Wiring
In-series
JPU Fuse
Mechanical
Switch / CB
LV Board
Busbar
LV Circuit
To LV
Board
Busbar
To Outgoing
Circuit
Figure 19: CB Series Fuse Replacement – Internal wiring diagram
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4. Check using an approved testing device, that there is no voltage between neutral, and the
cable CB fuse stalk.
No light between the cable fuse
stalk, and the neutral, confirms
the switch is open, in the
scenario where the circuit is
back-fed, the cable LED should
also be lit to indicate the circuit
is back-fed
Figure 20: Check Voltage between neutral and the cable - Circuit Breaker fuse stalk
5. Check using an approved testing device, that there is no voltage between the CB fuse stalk to
the LV busbar and the fuse stalk to the outgoing LV circuit.
No light confirms the switch
is open, in the scenario
where the circuit is not
back-fed, the cable LED
will not be lit if the circuit is
not back-fed
Figure 21: Check voltage between the busbar CB fuse stalk and the cable CB fuse stalk
6. Insert replacement fuse and tighten fuse thumbscrews.
7. Ensure that CB fuse selection matches rating of series fuse (see section 7.3.4 for series fuse
rating selection)
8. Close CB (follow close instructions in section 7.3.2.)
9. Set Gateway (RTU) to remote mode.
The series fuse has an important fault limiting characteristic (max current 32kA peak)
which prevents the CB and Switch exceeding their rated short circuit values.
Important Note: Never use anything other than standard 82mm centre JPU 400A
or 315A fuse. Links must NOT be used, they are not a suitable replacement for a fuse
in the CB, and if installed present a significant safety risk.
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7.3.4
Series Fuse Rating Selector
The CB has three fuse rating indicators, 315A, 400A, and 500A. The fuse rating can be
changed by pressing the F button. The 500A setting is currently not supported and cannot
be selected.
Figure 22: CB Fuse Selector Indicator set to 400A
NOTE: It is essential that the correct fuse rating is selected
The CBs are designed to a standard fuse I/t curve (CB time fuse curve will ensure CB
operates just before a standard fuse), therefore for the correct operation of the CB under
fault and overload conditions, it is essential that the correct fuse rating is selected,
matching the installed series fuse.
7.4
CB Indications
7.4.1
FPI indication
When a fault occurs on a section of network with CBs, and Switches installed, any devices
that see fault current will display an FPI indication. The indication will be available both
locally and remotely at LV Control.
The Circuit Breaker FPI indication is used for two separate functions depending on whether
the CB is open or closed.
Fault Current when Closed (CB Closed)
When the CB is closed, the FPI is turned on when a fault current passes through the CB.
By default the FPI threshold is 700A peak (approx. 495A RMS), if turned on, the indicator
remains on for at least 5 seconds. If, after a period of 5 seconds, busbar and cable voltages
are both present, then the indicator is turned off.
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If the breaker trips, resulting in loss of bus voltage, the indicator will remain on until cleared
remotely, or until the CB is closed again.
NOTE: Always contact LV control prior to performing any local operations, to restore
supplies if a CB has tripped, or has an FPI indicator illuminated.
Fault on Make (CB Open)
When the CB is open, the FPI is turned on when an attempt to close, is aborted due to
excessive current.
The indicator remains on until the fault is cleared remotely, or until the CB is told to close
again.
The CB will not close onto a fault; this is prevented by the intelligent fault make technology,
within the Circuit Breaker, when a device attempts to close, thyristors energise the LV
network with short pulses of current, of increasing magnitude, and duration, these pulses
check the network impedance, before activating the mechanical switch.
If a fault is present, the operator will receive an indication of this (FPI LED will be
illuminated), and the CB mechanical Switch, will be prevented from closing. Note that it is
only necessary to briefly press the close button to turn off/reset the indicator.
The FPI is illuminated in the
following circumstances:
- When the CB trips on fault or
overcurrent
- When the CB sees transient
fault current (does not
necessarily trip)
- When an attempt to close is
aborted due to excess current
(fault on make)
Figure 23: Circuit Breaker FPI Indicator
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7.4.2
Out of phase indicator
1.
If the CB is installed across two sources that are not in phase (default threshold 15 degrees)
then the phase error indicators will be displayed (see below).
2.
It is not possible to close a device across two out of phase sources.
3.
Phase error indicators may illuminate with the FPI indicator, in the case of a ph-ph fault.
Out of phase indicator
- CB is installed across 2 out of
phase sources
- In the case of a ph-ph fault the
FPI and out of phase indicators
may be illuminated
Figure 24: Out of Phase Indicator
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7.4.3
Other indicators, Power, Sys fail, voltage indicators, port and fuse selector
Power indicators & Sys fail
The power LED, lights when the CB
comms cable is connected to the
Gateway (RTU), and the Gateway
is powered up.
The CB sys fail indicator, will light
when a failure is detected with the
CB.
Figure 25: Power indicators & Sys fail
If the Sys Fail LED is illuminated contact LV Control to find out the cause of the problem (LV
Control will be able to interrogate the Gateway (RTU) to determine the cause).
In some cases resetting the CB by removing the data (Modbus) cable and reinserting it, will
clear the Sys Fail indication.
If (a) resetting the CB, and (b) ensuring that the series fuse is intact, does not result in the
Sys Fail indication disappearing, then the CB will have to be removed, and returned to the
manufacturer for inspection.
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Voltage indicators
The Circuit Breaker Busbar Voltage indicator, illuminates when the voltage on the busbar
side of the CB, is at least 50V RMS.
The Cable Voltage indicator illuminates when the voltage on the cable side, is at least 50V
RMS.
Figure 26: Voltage indicators
Either of these indicators may flash from time to time, which is normal behaviour and shows
that the CB is synchronising with the 50Hz AC voltage. When the CB is initially powered on,
it may take a few seconds to synchronize fully.
Port & Phase designations
The port number (1-5) is displayed on a 7 segment display on the front of the CB. It is set
when installing and commissioning the CBs, and should be common to all CBs installed to
the same LV way.
The phase designation (L1, L2, and L3) should match the phase that the CB is installed to.
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Figure 27: Port & Phase designations
Combining CB port number and phase designation provides a CB with a unique address (on
the LV board). No two CBs installed to the same LV board should have the same phase
designation and port number.
The CB address can only be changed during a 30 second period after the CB is powered up,
after which time it is locked. The address is changed by pressing the address (A) button,
which toggles through all available CB addresses (Port 1, L1 -> Port 5, L3)
NOTE - It should not be necessary to change the port number or phase designation under
normal operating conditions, as they should not change after commissioning. If the CBs on
an LV board are addressed correctly, the following will be true:



All CBs on the same way should have the same port number;
The phase indicator LED (L1, L2, L3) must match the phase that the CB is installed to;
The addresses on the CBs will match the CB address info card by the Gateway (RTU).
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The correct CB addressing will be displayed on a laminated information card placed next to
the Gateway (RTU), see Figure 28 example:
Figure 28: Example Circuit Breaker addressing displayed on a laminated information card
To ensure the CB addressing remains correct, if a CB is removed, it shall be reinstalled to
the same position on the LV board from where it was removed.
If for any reason the phase designation is incorrect or the port numbers on an individual way
are inconsistent, prior to any remote operation of the CBs:
1.
2.
3.
4.
The Gateway (RTU) shall be placed in local mode.
LV control shall be notified immediately.
CB addressing shall be verified and if necessary rectified.
Once the CB addressing is rectified the Gateway (RTU) can be returned to remote mode
For more information on setting the phase and port numbers, see the installation and
commissioning instructions in section 9.1.5 parts 7 & 8.
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7.5
Link Boxes
A link box with LV remote control and automation technology installed will contain the
following equipment:
A new modified plastic bell cover
The LB switches and control panel sit significantly higher than the original cast iron LB lid,
and a new Diving Bell lid is supplied, to accommodate this additional height.
Figure 29: Diving Bell Lid Installed
Picture above shows the new diving bell lid prior to installation. The modified
diving bell lid is flexible and non-load supporting. Do not stand on, or place excessive
weight on top of the diving bell lid, as damage to the lid, and control board could
occur.
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A Link Box Control Panel
The control panel sits directly under the LB lid and modified bell cover - Upon lifting the LB
lid and bell cover, the Control Panel will be visible and accessible. The control panel displays
the state of the switches installed to the link box, on an LED mimic panel, and enables local
control of the switches, from easily accessible push buttons.
`
Figure 30: Link Box Control
The 4-way Link Box control panel, installed under the Link Box bell housing, has connections
for four quadrants – Q1, Q2, Q3, and Q4. Quadrant Q1 is closest to the kerb edge.
Each quadrant provides connections for three switches; one per phase – L1, L2 and L3.
Where a link box is not fully populated with switches, the missing switches are replaced by
dummies. These sit loosely over the links and provide flat, stable base for the LED control
panel to sit on. They also ensure that the volume of air under the diving bell cover remains
consistent.
Figure 31: Link Box Switch Dummy
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Link Box Switches
The Link Box Switch (LBS) is a Load Break/Fault Make device that can be retrofitted to the
existing Prysmian link box designs, currently in use on the LV network (82mm centre-centre
spacing). The LBS is designed to fit in place of the existing link box links, or fuse carriers.
Figure 32: Link Box Switch
The switches can be remotely operated from LV Control, or locally via the LB control panel.
Figure 33: Link Box Switches in Prysmian Box
Figure 33 shows a fully populated link box, with the control panel removed, providing access
to all switches.
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Link Box Control Panel Neutral Connector
The LB Control Panel requires a neutral connection, and this is provided by a brass wedge
clamp which is secured to the LB neutral stalk.
Neutral connector
to control panel.
Brass wedge clamp
to provide neutral
connection to link
box neutral stalk.
Figure 34: Link Box Control Panel Neutral Connector
Link Box Control Panel Orientation
The control panel can be rotated 180o in the link box, but once commissioned, the control
panel orientation cannot be changed. Therefore the location of Quadrant (Pocket) one, will
be clearly marked with a traffolyte label, on the inside of the Prysmian box.
The Q1 label on the control must always line up with the Q1 label on the inside of the link
box.
Quadrant 1
label on LB
LB controller Q1
must line up
with LB Q1 label
Note:
Link Box switches in
Q1 must be
connected to the Link
Box controller, for the
PLC communications
to be possible.
Figure 35: Link Box Control showing Q1 label on Prysmian
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It is possible to operate all link box switches locally via the Link Box Control Panel located
under the LB bell cover.
The Control panel draws power directly from the link Box switches, (powered from the cable
side of the link box) therefore only one live incoming phase is required to enable local
operation of the switches.
The Link box control panel must be set to local mode, before any local operations on the link
box switches, are attempted and all Quadrants to be operated must have 3 switches
installed.
NOTE: Where practical all operations shall be performed remotely by LV Control.
If it is necessary to perform operations locally, LV Control shall be contacted prior to any
local switching being undertaken.
The LB control panel is shown in Figure 36 with a description of each indication / function.
Figure 36: Overview Link Box Control Panel
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7.5.1
Local Remote
When the LB controller is in remote mode, LV Control engineers are able to remotely
operate all switches in the Link Box (communication to the box is via the substation RTU
over Power Line Carrier (PLC)).
To operate switches locally, the LB Controller must be switched to Local mode.
To switch the LB Controller to local mode, press the L/R button on the controller keypad.
Local / Remote
toggle push
button.
Local LED –
illuminated when LB
is in local mode.
Remote LED –
illuminated when LB
is in remote mode.
Figure 37: Link Box Local/Remote Selector
When link box control panel is in Local mode, LV control cannot open or close any link box
switches in the link box.
Note: when the LB Controller is in local mode, a buzzer will sound constantly, this is normal
and is a feature built in, to ensure that the operative does not replace the LB lid, leaving the
control panel in local mode.
Link box control panel Remote / Local selector button is marked “L/R” and is located on the
operations keypad. The Remote or Local LED is lit to indicate current control status.
Pressing L/R toggles between local and remote mode.
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7.5.2
Switch Selection
Before operating a switch locally, it must be selected for control.
To select a switch for control, repeatedly press the Select button on the control panel until
the select indicator on the switch to be operated is illuminated (amber LED).
NOTE: Only one switch can be selected for control at a time.
Switch selected for control Q4, L3
Pressing select
button, cycles
through switch
selection for
local control.
Figure 38: Link Box Controller Switch Selection
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7.5.3
Open/ Close
1.
The Link Box must be in local mode, and must be selected before any switch operations can
be performed.
2.
Press the “Switch select” button repeatedly, on the operations keypad, until the selected LED
is illuminated for the switch to be opened or closed.
3.
After selecting the switch press and hold either the open or close button for 5 seconds.
4.
E.g. Press the close button and the corresponding LED will flash.
Figure 39: Link Box Local/Remote Selector
5.
The frequency of the flashes will increase after the switch has been held down for more than
5 seconds.
6.
Remove your finger from the switch and it will close after a stand clear delay of 10 seconds.
7.
When the switch completes its operation a short audible noise will be heard from the switch
solenoid, the flashing (open/close) LED will stay lit, and the remaining (open/close) LED will
switch off.
8.
To cancel the switching operation press the opposite control button during the stand clear
delay.
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7.6
Other indicators, Power, Sys fail, voltage indicators, port and fuse selector
7.6.1
FPI indication
There is one FPI indicator per switch, shown on the LED mimic panel as shown below:
FPI – Indication,
illuminated when
switch sees
overcurrent/fault
current.
Fault current
direction – LED
lights to show
direction of fault
current passage.
Figure 40: FPI indicator
The FPI is used for two separate functions, depending on whether the Link Box Switch is
open or closed.
Fault current on make (switch open)
When the Link Box Switch is open, the FPI is turned on when an attempt to close is aborted
due to excessive current. The sequence of operations for this scenario is as follows:
1.
An operation to close a switch is initiated (either locally on site or remotely from LV Control)
2.
The switch attempts to close, but detects excess current and aborts the close operation
3.
The switch remains open and the FPI LED for the switch being operated illuminates
The indicator remains on until the fault is cleared remotely, or until the Link Box Switch is
told to close again. Note that it is only necessary to press the close button briefly, to turn off
the indicator.
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Fault current when switch closed
When a switch is closed, the FPI LED is illuminated when a fault current is detected.
By default the FPI threshold is 700A peak (approx. 495A RMS).
If the FPI triggered, the indicator will remain on for at least 5 seconds. If after a period of 5
seconds, bus and cable voltage are both present and the current measured by the switch
reduces to below the FPI threshold, then the FPI indicator is turned off.
If, when the FPI is triggered, there is a loss of voltage, the indicator will remain on until
cleared remotely, or until the voltage is restored again.
NOTE: Always contact LV control prior to performing any local operations, if any FPI
indicators are illuminated. Whenever an FPI indicator is illuminated, an alarm will be raised
in the LV control centre.
7.6.2
Out of phase indicator
If an open Link Box switch is installed across two sources that are out of phase (default
threshold 15 degrees) then the phase error indicators will be displayed.
When the Link Box Switch is open a phase error is indicated by the two ‘Current Direction’
LEDs flashing.
Out of phase –
Switch current
direction
indicators flash
Figure 41: Current Direction Indicator
NOTE: It is not possible to close a switch between two out of phase sources.
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7.6.3
Other indicators, Power, Sys fail, voltage indicators
System Status Indicators
Three LED indicators provide local information on the status of the LB Controller, and
connected switches. See below for a description of what each LED indicates.
supply
The power indicator lights when logic powerPower
is available
onindicator
the Link
Box
controller.
The Sys Fail Indicator will light, when a failure is detected with the Link
Box controller, or any one of the switches. NOTE: this indicator will turn
onThe
during
of light
the controller,
and will
turn off, ifwith
no fault
Sys the
Fail initialisation
indicator will
when a failure
is detected
the is
detected
after
approximately
1
minute.
Link Box controller or any one of the switches. NOTE: This indicator
will turn on during the initialisation of the controller, and will turn
The comms indicator illuminates, when the LB controller is
off (if no faultwith
is detected).
communicating
substation Gateway (RTU) over the LV circuit, (Via
Power Line Carrier). NOTE: indicator flashes to indicate comms traffic.
The comms indicator illuminates when the LB controller is
communicating with the substation Gateway (RTU) over the LV circuit
(via Power Line Carrier). NOTE indicator flashes to indicate comms
traffic.
Figure 42: Control Panel System Status Indicators
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Voltage indicators
The Circuit Voltage indicator
illuminates when the voltage on
the cable side of the Link Box
Switch is at least 50V RMS.
There is one Circuit Voltage
indicator per Switch
Figure 43: Voltage Indicator
The Circuit Voltage indicator may flash from time to time, if the Link Box Switch timesynchronisation to the zero crossing of the voltage drifts, by more than 50 microseconds.
When the Link Box Switch is initially powered on, it may take a few seconds to synchronise
fully.
Noise on the voltage due to network faults, may also interfere with the zero crossing
synchronisation.
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8
Operational Procedures
This section is aimed at personnel and engineers, requiring a good working knowledge of
the operational procedures, for the Automated LV System; outlining the basic operational
procedures, and methodology, needed to control the Breakers, Link Boxes, and Gateways
(RTUs). Discussed will be the LV System under fault and abnormal conditions, removal and
replacement of equipment, and restoring supplies on the LV Network.
8.1
Creating Points of Isolation
If isolation of a section of the LV network is required, to enable Engineers to work on the
dead apparatus, then the procedures shown below, for each piece of LV Automated
Equipment, shall be followed.
8.1.1
Circuit Breaker Point of Isolation
NOTE: A circuit breaker in the open position does not constitute a point of
isolation.
The CB series fuse, power/data and PLC connectors, if connected, must be removed (while
the CB is in the open position) to create a point of isolation.
If the power and data cable is connected to the circuit breaker, the CB shall be treated as
live.
To isolate the LV circuit fed via a CB:
1.
Open the CB
Press and hold open
button for 5 seconds.
The flashing frequency of
the open LED will increase
and the open button can
be released.
A loud audible click from
the CB solenoid will be
heard when the CB
completes the open
operation and the open
LED will be illuminated.
Figure 44: Circuit Breaker Point of Isolation
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2.
Remove series fuse
Figure 45: Circuit Breaker remove series fuse
3.
Remove CB power & data cable (and PLC connection, if connected)
Data & CB Power
Connector
PLC Connector
Figure 46: Circuit Breaker - removing power and data
4.
Verify CB LEDs are off indicating the CB has lost logic and solenoid power.
Figure 47: Circuit Breaker Status verification - CB has lost logic and solenoid power
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8.1.2
Link Box Switch Point of Isolation
NOTE: A link box switch installed on the network and set to open does NOT
constitute a point of isolation.
Isolation of a section of network fed via a link box switches is only achieved by removing all
switches from the Link Box quadrant/pocket supplying the section of network to be isolated.
NOTE: A switch must be in the open position before it can be removed from the Link
Box.
8.2
Safety Fusing for Live Work
Where live work is to take place on a circuit fed from multiple sources (e.g. on the
interconnected network) or when it is considered necessary to fuse down the network to
enable live work to be carried out safely, the following steps must be taken prior to work
commencing:
1. 315A fuses shall be placed between any connected supply source and the circuit to be
worked on.
2. Where fusing down involves replacement of the CB fuse, CB fuse replacement must only be
undertaken with CBs in the open position.
3. When changing the CB fuse, ensure fuse selection on CB reflects size of fuse installed (press
fuse selection toggle button to switch between 315A and 400A settings).
Figure 48: Circuit Breaker - Down Fusing for Live Work
4. Gateway (RTUs) connected to devices directly affecting the circuit to be worked on shall be
set to Local.
5. Any link box switches providing open points connected to circuits to be worked on shall be
removed.
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8.3
Operation of Devices under Fault Conditions
Under most fault conditions, when the devices are functioning as expected, there should be
no reason to remove them. The CBs and Link Box Switches provide a safer method for
locating, and switching out faulted sections of the LV network, in order to restore supplies to
healthy sections of network.
Under fault conditions, providing there is one healthy phase between the substation, and the
Link Box (to maintain PLC comms), FPIs will provide the control engineer with information on
which section of network, the fault is located. This information can be used to remotely
switch out the faulted section of network, and enable supplies to be restored to the
remaining customers.
For local operation of devices under fault conditions the same applies, providing there is one
phase providing power to a Link Box, switches can be operated to reconfigure the LV
network safely, avoiding the need to manually link and fuse.
In the event that a device fails, and there is no suitable replacement, LBS can be replaced
temporarily with a standard link, and CBs can be replaced with standard fuse carriers.
8.3.1
Restoring Supplies Remotely after a Fault
Should the Circuit Breaker operate, LV Control should be contacted, as they will, where
possible attempt to restore supplies remotely.
Remote restoring of supplies after LV CB tripping should follow these guidelines:


If the fault magnitude is judged to be at a level consistent with overloading, the LV
control engineer can attempt to restore supplies by closing the tripped breaker. In this
case there is little danger of re-energising damaged sections of the network.
If the fault magnitude is high enough that it may have been caused by cable damage or
some other network fault, then attempts to restore supplies can only occur after the
faulted section of network has been sectionalised.
NOTE: If the fault location cannot be identified using link box switch, FPI indications,
or a faulted section of network cannot be switched out remotely, attempts to restore
supplies remotely are not permitted.
After a CB trips, any attempt to close it remotely should only be made if:


The control engineer judges that the CB trip was caused by overloading (fault magnitude
considered); OR
The faulted section of network can be identified using the link box FPIs and then
switched out remotely using the link box switches.
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Scenario 1: In the following scenario, the FPI indicators allow the control engineer to identify
the fault position, switch out the faulted section of network, and restore supplies to the
remaining healthy section of network.
CB Trips due to fault out of LB2:
Figure 49: Remote Switching Fault Scenario
Control engineer uses LB FPI to locate the fault, and opens L2 switch in quadrant of LB2
leading to fault. Fault isolated and CB closed, restoring supplies to remaining customers.
Figure 50: Remote Switching Fault Isolation
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Scenario 2: If a fault occurs in the location shown in Figure 51, the CB should not be closed
remotely, as there would be no information on the cause of the fault. In this case a Field
Engineer should attend site, to ascertain the fault cause.
Figure 51: Fault location cannot be determined
If isolation of the faulted section of network does not succeed, and an attempt to close either
a CB or switch onto the faulted section of network is made, a ‘Fault on make’ error message
will be displayed.
8.3.2
Restoring Supplies Locally after a Fault
If an attempt to restore supplies remotely has not been possible, or proven unsuccessful, it
shall be necessary to attend site and attempt to restore supplies locally.
All supply restoration work shall comply with current UKPN LV Operational Policies and
Procedures.
These include:







Compliance with procedure HSS 40 017 ‘Low Voltage Re-Energising Devices’.
Compliance with HSS 40 023 ‘Energisation of Networks following Faults and
Emergencies’.
Compliance with HSS 40 045 ‘Basic Requirements for Live Working on Low Voltage
Apparatus’.
Mandatory wearing of Approved LV electrical gloves (HSS 01 069 ‘Personal Protective
Equipment’).
Use of Approved Flame retardant coveralls (HSS 01 069)
Use of Full face protection when operating devices locally.
If the cause of the fault is unknown, the LV route shall be patrolled to identify any
possible cause for the CB tripping, and ensure third party risks are managed, prior to any
attempt to restore supplies.
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If the route patrol results in the identification of the fault cause, take steps to rectify the cause
before restoring supplies, by closing the relevant CB/Link Box Switch.
If the fault cause is not identified by the route patrol, an attempt to re-energise the dead
section of network can be attempted, before closing either a CB or a Link Box switch; both
CBs and Link Box switches will not close onto a faulted section of network, and can be used
as LV re-energising devices in conjunction with the procedures detailed in HSS 40 017.
NOTE: Whenever practical any attempt to restore supplies onto a suspected faulted
section of network shall be executed remotely by LV control.
8.3.3
CB Operation (Fault Conditions)
Fault Break
For fault currents up to 6kA the CB will trip in accordance with the operating time
characteristic selected, i.e. 315A or 400A. Remote restoration of supply is possible when the
network fault is isolated. For faults above 6kA the fuse will blow and clear the fault current. If
the fuse operates, it will have to be replaced before supply can be restored.
Fault Make
The CB will not close onto a fault; this is prevented by the intelligent fault make technology,
within the CB.
When a device attempts to close, thyristors energise the LV network with short pulses of
current of increasing magnitude, and duration, these pulses check the network impedance,
before activating the mechanical switch.
If a fault is present, preventing the CB from operating, the FPI LED on the CB control panel
will light.
Out of Phase
When the CB is open, the phase difference between busbar and cable voltage is monitored.
If the phase difference is greater than 15 degrees, then the out of phase indicator will light.
The CB cannot be closed when a phase error is present.
The fault indications are on the CB control panel, and also relayed to LV control.
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The FPI is illuminated in the
following circumstances:
Out of phase indicator
- When the CB trips on fault or
overcurrent
- CB is installed across 2 out of
phase sources
- When the CB sees transient
fault current (does not
necessarily trip)
- In the case of a ph-ph fault the
FPI and out of phase indicators
may be illuminated
- When an attempt to close is
aborted due to excess current
(fault on make)
Figure 52: Circuit Breaker fault indications
8.3.4
Link Box Switch Operation (Fault Conditions)
Fault Break
When a fault occurs on the network, the switches will not operate. They are not rated to
break fault current. The switches pass fault current so that the substation CB (or series fuse
depending on the magnitude of the fault current) can operate to clear the fault. Once the
fault has been cleared by the CB, the LBSs can be operated while the faulted cable is deenergised to isolate the faulted section of network. After the faulted part of the network is
isolated, the CB can then attempt to close, restoring supplies to the remaining healthy
sections of the network.
Fault Make
The LBS will not close if there is a fault on the network. This is prevented by the intelligent
fault make technology within the LBS. For the device to close, thyristors energise the LV
network with short pulses of current of increasing magnitude and duration, to check the
network impedance, before activating the mechanical switch. In the LBS, if a fault is present
the FPI LED will light, and the Link Box mechanical switch will be prevented from closing.
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FPI – Indication, illuminated when:
1.
Switch sees overcurrent / fault current.
2.
Close operation is aborted due to
persistent network fault (Fault on
Make)
Figure 53: Circuit Breaker Fault Make
Out of Phase
When a Link Box Switch is open, the phase difference between the cable voltage and Link
Box busbar voltage is monitored. If the phase difference is greater than 15 degrees, then the
out of phase indicator will light. A link box switch cannot be closed when a phase error is
present.
Out of phase –
Switch current
direction
indicators flash
Figure 54: Circuit Breaker Out of Phase
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Three Phase Fault
If there is a three phase fault, all CBs will trip at the substation, the SCADA communication
from the substation to the link boxes will be lost, (PLC comms use the LV cable to transmit
data) and therefore remote control of the LB switches will be lost.
With no power at the link boxes, it will not be possible to locally or remotely open switches
on the faulted section of network.
Isolation of the faulted section of network can only be achieved by removing the switches
from the LB quadrant, leading to the faulted section of network.
As the network will be dead in this scenario, the switches looking into the fault can be
removed from the link box in the closed position. This will allow the substation CBs to be
closed, and supplies to be restored to the remaining sections of network.
Once the fault is repaired the switches can be reinstalled, but must be installed in the open
position.
NOTE: A mains powered device to enable the operation of the Link Box Switches
while they are not connected to the network will be available at the closest substation
to the link box.
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8.4
Device Removal and Replacement
CB removal should not necessitate the interruption of supplies (unless for a planned
shutdown or during a fault).
Prior to CB removal, ensure that the LV way or ways, where the CBs are to be removed from
are back-fed.
Under normal operating conditions, the removal of equipment should not necessary.
If for any reason the equipment needs to be removed or replaced, the following procedures
shall be followed.
8.4.1
CB Removal
When CB is fully operational, remove as follows:
1. Open CB switch as described earlier.
Press and hold open
button for 5 seconds.
The flashing frequency of
the open LED will increase
and the open button can
be released.
A loud audible click from
the CB solenoid will be
heard when the CB
completes the open
operation and the open
LED will be illuminated.
Figure 55: CB Removal
2. Remove series fuse
Figure 56: Remove series fuse
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3. Fit Fuse Stalk Covers.
Data & CB Power
Connector
PLC Connector
Figure 57: Circuit Breaker Data and Power Connector
4. Unplug Modbus power and data connectors, and PLC connectors if connected.
CB Fuse Stalk
Covers fitted
NOTE: The CBs are supplied with insulating fuse stalk
covers. These are designed to prevent any accidental
contact with exposed and potentially live CB fuse stalks
while installing or removing the CBs. They will be located in
the secondary substation where the CBs are installed, in a
suitable container next to the RTU.
Under no circumstances shall the CB fuse stalk covers
be removed from the substation.
Figure 58: Circuit Breaker insulating fuse stalks
5. Loosen CB retaining thumb screws while supporting CB weight.
Figure 59: Procedure - loosen Circuit Breaker thumb screws
6. Withdraw CB from LV distribution board.
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8.4.2
CB Replacement
CB installation/replacement should not necessitate the interruption of supplies (unless for a
planned shutdown or during a fault).
Prior to CB installation, ensure that the LV way or ways to be installed to are back-fed.
Always contact LV control before undertaking any work on the system.
NOTE: If re-installing CBs after previous removal, CBs shall be replaced in the same location
on the LV Board from where they were removed.
1. Set Gateway (RTU) to local mode, before undertaking any work in the substation.
2. If necessary, remove the LV fuses from the LV distribution board, where the CBs are to be
installed, and then check state of LV Network, with an approved testing device (e.g. test
lamp).
3. On the CB to be installed, ensure CB series fuse is removed and CB fuse stalk insulated
covers are in place.
CB Fuse Stalk
Covers fitted
Figure 60: CB fuse stalk insulated covers
4. Loosen CB thumbscrews, install CB to LV board, and tighten CB thumbscrews, while
supporting CB weight to secure CB to LV board.
Note: the CB will not power up at this stage as solenoid and logic power is provided from the
power & data cable.
Figure 61: Circuit Breaker thumb screws
5. Connect the CB Power & Data (MODBUS) connector – this will power up the CB and the LED
indicators on the CB will illuminate.
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6. Ensure that the Port and Phase indications on the CB are correct, as indicated by the CB
Address information card by the RTU.
An example of a CB Address information card is shown below.
Taking way 84 as an example:


All CBs in this way should be set to Port 4
The phase LED should reflect the phase that the CB is installed to.
The CB installed to Way 84, on the L1 (Brown) phase, is addressed Port 4, L1 as shown.
Port 4
Phase = L1
CB Address
button (A)
Figure 62: Circuit Breaker port and phase configuration
The CB address can be changed by pressing the address (A) button – each press of the
button scrolls through the available CB addresses (Port 1, L1 to Port 5, L3).
Press the button repeatedly until the CB shows the correct address. For new CBs the
address flashes ‘0’ on power up, this will keep flashing until button A is pressed, (providing
the address isn’t ‘0’)
NOTE: the CB address can only be changed within the first 30 seconds following CB power
up, after this period the port number goes out and the address is locked. Pressing button A
within 30 seconds of the Circuit Breaker power up’ will give the user an additional 30
seconds per button press, before the address is locked.
To change the address of a CB that has a locked address (i.e. has been powered on for
more than 30 seconds without the address button being pressed):



Reset the CB by removing the power data cable, and then reconnecting it.
Set the CB address by pressing the address button within 30 seconds (repeatedly press
the address button until the required CB Port and Phase is displayed)
To check the address of the CB, if the address is locked and not being displayed, press
address button (A)
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NOTE: Setting the CB address should only be required if a CB is being replaced with a
new unit, or if there is a valid reason for moving a CB from its original location to a
new location on the LV board.
If a CB is replaced in the location from where it was removed it will not be necessary
to change the CB address.
If a CB is to be removed and reinstalled it shall be installed in the same location on
the LV board from where it was removed.
7. Repeat steps 3 – 6 for any remaining CBs to be installed on the LV way being worked on.
8. Set the Gateway (RTU) to remote mode, Contact LV Control, confirm that CB can be seen
from PowerOn, and ask LV Control to perform connectivity checks. Confirm remote operation
of the CBs by performing close and open commands on each CB while the series fuse is
removed.
Verify operation of remotely controlled CB with LV control engineer, confirming LV Way and
Phase.
9. Set the Gateway (RTU) to local mode.
10. Ensure CB is open, (if it is closed perform a local Open operation by pressing and holding the
CB open button).
Press and hold open
button for 5 seconds.
The flashing frequency of
the open LED will increase
and the open button can
be released.
A loud audible click from
the CB solenoid will be
heard when the CB
completes the open
operation and the open
LED will be illuminated.
Figure 63: Circuit Breaker open operation
11. Remove CB insulated fuse stalk covers.
12. Check using an approved testing device that there is no voltage between neutral and the
cable CB fuse stalk.
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No light between cable fuse
stalks and neutral confirms
switch is open in scenario
where circuit is back-fed.
Cable voltage LED will be lit to
indicate the circuit is back-fed
Figure 64: Circuit Breaker confirm switch is open
13. Check using an approved testing device that there is no voltage the busbar CB fuse stalk and
the cable CB fuse stalk.
No light confirms
Switch is open in
scenario where circuit
is not back-fed.
Cable voltage LED will be lit to
indicate the circuit is back-fed.
Figure 65: Circuit Breaker check voltage - busbar CB fuse stalk and the cable CB fuse stalk
14. Insert CB series fuse and tighten thumbscrews.
15. Ensure fuse selection on CB reflects size of fuse installed, (press fuse selection toggle button
to switch between 315A and 400A settings). 500A fuse is not currently supported.
Figure 66: Circuit Breaker fuse selection toggle button
16. Close the CB locally by pressing and holding the close button on the CB, and stand clear
while the CB is performing the close operation.
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Press and hold Close
button for 5 seconds.
When close LED flashes
quickly release button
and stand clear of
device.
17. Repeat steps 10 – 16 for any remaining CBs on the LV way being worked on.
18. Set Gateway (RTU) to remote
19. Contact LV control and confirm CB states and load readings.
20. Repeat steps 1 - 19 for any remaining LV ways to be installed to.
8.4.3
LB Control Panel Removal
Contact LV Control and inform them of the removal of the Link Box control panel.
The following steps describe how to disconnect and remove the Link Box Control Panel.
All operations undertaken within the link box shall be treated as linking and fusing,
and appropriate PPE shall be worn at all times.
1. Lift link box pavement cover.
2. Remove LB Bell cover retaining strap, and lift modified LB bell cover.
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Loosen
LB
retaining
strap wing nuts (do not
fully undo), and remove
LB bell cover retaining
strap.
Figure 67: Link Box Control Panel Removal
3. Put LB Control Panel in local mode, by pressing the Local/Remote button. NOTE: When LB
Controller is in local mode a buzzer will sound, this is normal behaviour, and is a feature to
prevent the LB being left in local mode.
Local / Remote
toggle push
button.
Local LED –
illuminated when LB
is in local mode.
Remote LED –
illuminated when LB
is in remote mode.
Figure 68: Control Panel Local/Remote button
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4. Unplug all Link Box switch plugs from the sides of the control panel. To remove a plug:
a. Tilt the control panel so that the plug to be removed is angled upwards to make
access to the plug easier.
b. Use an insulated screwdriver to gently lift and release the plug retaining clip
Figure 69: release the plug retaining clip
c.
Whilst the plug retaining is released pull the plug sideways, away from the LB control
panel.
Pull
Figure 70 Link Box switch plug removal
d. Repeat for all Link Box Switch plugs connected to LB Control Panel.
Figure 71: Link Box Controller Plugs
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5. Turn link box control panel face down, and remove the LB Controller neutral connector from
the rear of the panel.
Figure 72: Link Box Controller Neutral Connection
6. Withdraw LB Control Panel from link box, and place somewhere safe.
8.4.4
LB Control Panel Replacement
Link Box Control Panel Orientation
The control panel can be rotated 180o in the link box, but once commissioned, the control
panel orientation in the link box cannot be changed. The location of Quadrant (Pocket) Q1
will be clearly marked with a traffolyte label on the inside of the Prysmian box.
IMPORTANT: The Q1 label on the control must always line up with the Q1 label on the
inside of the link box.
Ensure that the control panel is correctly orientated in the link box before making any
connections.
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Quadrant 1
label on LB
LB controller Q1
must line up
with LB Q1 label
NOTE:
Link Box Switches in
Q1, must be connected
to the Link Box
Controller, to enable
PLC communication to
take place.
Figure 73: Link Box Control Panel Orientation
To reconnect the LB Controller, follow these steps:
1. Connect the neutral cable to the reverse of the link box control panel.
Neutral
connector on
control panel.
Brass wedge
clamp to
provide neutral
connection to
link box neutral
stalk.
2. Place the control panel on top of the switches face up, and reconnect the switches to the
control panel. Ensure that all switch leads and connectors are accessible, and not trapped
under the controller.
IMPORTANT: Ensure Q1 on LB Control Panel lines up with the Q1 label on the inside of the
Link Box.
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Figure 74: Positioning Link Box Controller
3. Connect each switch plug to the relevant socket on the control panel.
NOTE: Each switch has a corresponding socket on the controller which matches the
switch position in the Link Box; this is shown in the below diagram.
Figure 75: Socket positioning on the controller
Each switch plug must be connected to the correct socket on the controller to avoid
potential switching errors or an internal fault in the Link Box Controller.
Ensure when connecting switches to the controller that the switch leads do not cross
over each other.
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To correctly connect each switch to the control panel:
a. Locate the plug into the controller socket with the clip facing upwards.
b. Gently push the plug/connector into the socket until it is heard clicking into place.
Figure 76: Connecting switches to the control panel
4. Repeat for each switch in the Link box.
5. Verify that the Link Box Control Panel has power and is correctly displaying the state of the
switches.
In the below example switches in Q1, Q2, Q3 are open, switches in Q4 closed.
Figure 77: Control Panel displaying the state of the switches
On initial power-up the SYS-FAIL indicator will remain on for about 1 minute while the
controller initialises.
6. Press the LED TEST button to ensure that all LEDs are working (the LED Test button
illuminates all control board LEDs).
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Figure 78: Control Panel LED TEST button
7. After the control panel has been powered up for a period of about 1 minute the SYS-Fail LED
will go out, and shortly afterwards the COMMS LED should start flashing, indicating that the
LB controller is communicating with the control system. (Note: requires one switch to be
closed towards a distribution substation).
8. Contact LV Control and verify link box SCADA connectivity as follows.
a. Confirm that LV control can connect to the link box and read analogues / switchstates.
b. Place the Link Box Controller in Remote mode by pressing local/remote button until
the remote LED is illuminated. Confirm with LV control.
Local / Remote
toggle push
button.
Local LED –
illuminated when LB
is in local mode.
Remote LED –
illuminated when LB
is in remote mode.
Figure 79: Controller in Remote mode
c.
Trigger an FPI from a switch and confirm that LV Control receive a corresponding FPI
alarm.
NOTE: To verify that the control board is orientated correctly and LV Control are
receiving the correct readings for each switch, an FPI can be triggered locally from
any of the switches; the FPI is then verified and acknowledged by LV Control.
To trigger an FPI on a switch, press the select button until the required switch is selected
for control.
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Q2, L2 Selected for control
Select button cycles
through available
switches for
control.
Pressing select,
selects next
connected switch
(indicated by
orange LED)
Figure 80: Select button cycles through available switches for control
Hold select button for at least 5 seconds, and then release, an FPI will be generated
locally and at LV Control. (IMPORTANT: this only works when the controller is in remote
mode).
NOTE: When communicating with the LV control engineer, the LB number,
destination, and phase shall be used to identify the switch.
e.g. “triggering FPI on L2, at link box 421080 towards TC 40185”
d. Confirm with LV Control that the FPI alarm received was for the correct switch, and
then repeat the process for one switch in each Quadrant.
9. Once connectivity is verified, and all switches are in the required open/close positions, ensure
LB Controller is in remote mode, and replace the LB bell cover and lid.
8.4.5
LB Switch Removal
Link Box Switch removal should not necessitate the interruption of supplies (unless for a
planned shutdown or during a fault).
Prior to Link Box Switch removal, ensure that the circuits supplied via the switches to be
removed are back-fed.
NOTE: Switches should ONLY be removed in the open position. If switches are
inoperable and closed the link box should be made dead prior to switch removal.
Switches shall be removed one at a time.
Removal instructions:
1. Contact LV Control to inform them of switch removal.
2. Remove link box lid and modified bell cover.
3. Set LB Control panel to local mode.
4. Open switches to be removed. (Ensure opening switches does not interrupt supplies).
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5. Disconnect the switches to be removed from the Link Box control panel.
Pull
Figure 81: Disconnecting the switches plugs
6. If not all switches are to be removed, the LB Control panel can be left connected to the
remaining switches; manoeuvre the LB Control panel in the Link Box, to allow unrestricted
access to the top of the switches to be removed. Fit dummy switches into all pockets where
switches have been removed.
7. Insert the 5mm Long reach insulated Allen key tool (Material code: 32103B), modified for use
with LBS only, into the switch retaining wedge clamp screws and loosen clamps.
LB Switch
retaining
screws.
Figure 82: Removing link Box Switches
8. Withdraw switch from link box.
9. Repeat steps 4 – 8 for all switches to be removed.
10. When all work has been completed:
a. If LB Controller has been removed to facilitate switch removal, connect the controller
back up to the relevant switches (be sure to put the correct switch to the
corresponding connection on the Controller
b. Put the LB Controller into remote mode, then contact LV Control to verify remote
connectivity to the link box, and to confirm that switch-states & analogues are
reporting correctly.
c. Replace the modified bell cover and LB pavement cover.
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NOTE: If switch is being removed to create a point of isolation, or for an extended
period of time, inform LV Control.
8.4.6
LB Switch Replacement
Link Box Switch replacement/installation, should not necessitate the interruption of supplies
(unless for a planned shutdown or during a fault).
Prior to Link Box Switch replacement/installation, ensure that the circuits supplied via the
switches to be installed are back-fed.
NOTE: Switches can be installed to any position in a link box; they are generic and
not quadrant/pocket or phase specific.
Switches shall be installed one at a time.
The following steps should be followed, to install or replace link box switches in a link box
that has existing LV automation devices installed, that is when removing a point of isolation
or replacing a faulty switch.
1. Contact LV Control to inform them of switch replacement/installation.
2. Set LB Control panel to local mode by pressing the local/remote button, and manoeuvre LB
Control panel to provide access to the quadrant/pocket that switches are to be installed.
3. Check that the switches to be installed are in the open position with an approved testing
device
Figure 83: Checking that the switches to be installed are in the open position
IMPORTANT: A Switch shall not be installed to a link box if it is closed.
If a switch is closed it shall be opened prior to installation.
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A mains powered device to enable the operation of the Link Box Switches while they are not
connected to the network will be available at the closest substation to the link box (the
device will also work when powered from an inverter).
4. Prior to installing any switches, using test lamp, ensure that the LV network is configured as
expected, and no faults are present.
5. Install the OPEN switch into the link box, and tighten the LB wedge clamp retaining screws
with a 5mm long reach insulated Allen key tool (Material code: 32103B), modified for use with
LBS only.
LBS
retaining
screws.
Figure 84: Installing switches using 5mm Allen Key
6. Repeat steps 3 – 5 for all switches to be installed.
7. If LB Controller has been removed to facilitate switch installation, connect the controller back
up to the relevant switches. Be sure to put the correct switch to the corresponding connection
on the Controller.
8. When the LB Control Panel is installed, connect newly installed switch plugs to the
corresponding Link Box Control Panel sockets.
For each switch gently push the plug/connector into the socket until it is heard clicking into
place.
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NOTE: Each switch has a corresponding socket on the controller which matches the
switch position in the Link Box; this is shown in the below diagram.
Figure 85: Showing correct socket on the controller to avoid potential switching errors
Each switch plug must be connected to the correct socket on the controller to avoid
potential switching errors or internal damage to the link box controller.
Ensure when connecting switches to the controller that the switch leads do not cross
over each other.
NOTE: Newly installed switches should show as open on the LB Control Panel.
9. Contact LV Control to ensure the connected switches can be seen remotely.
10. Run through relevant connectivity checks with LV Control. i.e:


If LB Control Panel has been removed and replaced follow Step 8 in section 8.4.4.
If LB Control Panel has remained connected verify switch states with LV Control.
11. Place the LB Control Panel in remote mode and ask LV Control to operate any switches
required to return the network to its normal running arrangement.
12. Replace the modified bell cover and LB pavement cover.
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8.5
Abnormal Operation
If any part of the system fails or does not behave as expected, it shall be necessary to
remove the failed device from the network, for return to the manufacturer.
NOTE – There are no user serviceable parts in the system.
8.5.1
CB Removal (Inoperable)
If possible when removing a CB it shall first be opened.
If the CB has malfunctioned and Local or Remote operation of the CB is not possible, the
series fuse shall be removed from the CB housing.
This will allow safe removal of the CB in the open or closed position.
Steps for removal:
1. Remove series fuse
Loosen thumb screws
and remove fuse.
Always wear protective
LV gloves.
Figure 86: Remove Series Fuse
2. Fit CB fuse stalk covers
CB Fuse Stalk
Covers fitted
NOTE: The CBs are supplied with insulating fuse stalk
covers.
These are designed to prevent any accidental contact with
exposed and potentially live CB fuse stalks while installing or
removing the CBs.
They will be located in the secondary substation where the
CBs are installed, in a suitable container next to the
Gateway (RTU).
Under no circumstances shall the CB fuse stalk covers be
removed from the substation.
Figure 87: insulated fuse stalk
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3. Loosen CB retaining thumb screws while supporting CB weight.
Figure 88: Circuit Breaker retaining thumb screws
4. Withdraw CB from LV distribution board.
8.5.2
LB Switch Removal (Inoperable)
When the network is energised, a link box switch must be OPEN before it is removed.
Any load breaking should be achieved by the switch performing an open operation (from a
local or remote open command). Load current should not be broken when a switch is
removed.
If the network is dead then the switch can be removed in any state, but it must be reinstalled
in the open position.
IMPORTANT: If switch cannot be operated and opened, the link box shall be made
dead before switch removal is commenced.
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9
Commissioning and Installation Procedure
9.1
Onsite installation and commissioning procedure for substation Gateway
(RTU) and Circuit Breakers
This section provides guidelines on how to install the LV Remote Control and Automation
substation equipment, including:




Guidelines on how and where the equipment should be installed in the substation;
Instructions for the physical installation of equipment;
The electrical connections to be made to the equipment;
Operational commissioning checks and interaction with commissioning engineers and LV
Control.
Fitting of the equipment requires the following to be work undertaken:





Visual inspection of LV board and wall fixings;
Drilling into walls (4 x small holes to accept small fibre raw plugs);
Small wiring (mounting single phase fused spur, connecting power and data leads to
Gateway (RTU);
Attaching Power & Data bus near or to LV board (via zip ties or similar);
Routing of cabling between RTU & LV board.
NOTE: Fitting of LV equipment shall only be undertaken by suitably trained staff.
Prior to any work being undertaken, an onsite risk assessment shall be undertaken, and any
risk mitigation measures put in place.
9.1.1
Substation Equipment Overview
Figure 89 shows the substation equipment, and all required connections.
Figure 89: Substation Equipment Overview
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Figure 90 shows the substation devices to be installed.
Gateway (RTU)
LV Circuit Breaker
Power & Data Bus
Figure 90: Substation devices to be installed
1. The Gateway (RTU) is fitted to a meter board and then wall mounted, with suitably sized
screws.
It should be supplied from a permanently connected fused spur, and mounted as close to the
LV board as possible to minimise PLC signal loss, through the small section wires
connecting to the Circuit Breakers.
The Gateway should be in an area with adequate mobile phone coverage, as data
connectivity to the LV Control Centre is via GPRS or 3G; if the signal is weak the aerial must
be positioned in a location to improve reception (alternatively a high gain antenna should be
fitted).
2. The Power & Data Bus is a small unit that connects the devices on the LV distribution
board to the Gateway (RTU), and provides the following connections:



3 x PLC connectors, pre-wired and terminated with 4mm shrouded plugs (one per
phase);
15 x CB power & data connectors to accept power & data cables from the installed CBs
(one per CB);
2 x 3m leads for connection to the RTU MODBUS and PLC terminal blocks.
It is a small lightweight unit with loops attached at the rear to facilitate mounting via cable
ties, and should be mounted near to or under the LV board as shown in the picture.
3. The single phase CB installed to the LV board in place of a standard LV fuse requires
connection to the power data bus via a pre-terminated 7-core cable (three cables of
appropriate lengths provided for L1, L2 & L3).
The CB also provides sockets for the PLC connectors, which provide a direct connection
onto the LV board busbars.
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9.1.2
Gateway (RTU) Installation / Mounting
The RTU should be mounted to the substation wall as close to the LV board as possible.
NOTE: The maximum length of cable available (as standard) between the Gateway
(RTU) and the Power Data Bus is 3m.
9.1.3
Power & Data Bus Installation
The Power & Data Bus (PDB) is a lightweight, compact unit that provides the interface
between the RTU and CBs / LV Board.
Figure 91: Power & Data Bus Installation
Connections to the PDB are as follows:



Two 3m leads provide connection to the RTU comms terminal blocks (PLC & CB Power,
Data);
One 1.2m lead, terminated with 4mm shrouded plugs (one per phase) provides PLC
connection to the LV bus-bars via the CB PLC sockets;
15 sockets enable 15 CBs to be connected via pre-terminated power & data leads.
3m PLC lead to
Gateway (RTU)
3m Power and data
lead to Gateway
(RTU)
1.2m PLC lead and
connectors to LV
board.
Figure 92: Connections to the PDB
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The Power & Data Bus is simple to install, and should be located at the bottom of the LV
distribution board. See below example.
Figure 93: LV Board with Power & Data Bus installed
The PDB is attached to the LV board with cable ties, or similar through fixings on the back of
the unit.
Attach PDB with cable ties or
similar looped through fixings on
reverse of unit.
Figure 94: PDB fixings - Cable Ties
9.1.4
Gateway (RTU) Installation Connections
After mounting the Gateway (RTU) to the wall in a suitable position, and securing the Power
data bus below the LV board, all necessary connections should be made to the Gateway
(RTU) terminal blocks.
The GPRS antenna should also be installed.
The Gateway (RTU) terminal blocks and GPRS connection can be accessed by removing
the lower front panel of the Gateway (RTU).
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Remove lower
Gateway (RTU) cover
to reveal RTU
terminal blocks, and
connectors. To
remove cover undo 2
x cover screws.
Removing cover reveals RTU connections
Figure 95: Gateway (RTU) with cover removed
The RTU connectors and terminal blocks with their designations are shown below:
Cable 5
Cable 2
Cable 4
Cable 3
Cable 1
PH 3
N
L
PH 2
PH 1
+24V (Battery)
0V (Battery)
3.15A Fuse
DC Supply+ (RED)
MODBUS D+ (YELLOW)
MODBUS D- (BLACK)
DC Supply- (GREEN)
No Connection
Neutral (BROWN plus DRAIN
wire combined)
3.15A Fuse
SE
U
E
R
RE
V
ER
ED
R
FO
U
UT
F
S
Solenoid Power (ORANGE)
Figure 96: Gateway (RTU) Connection Diagram
There are a total of six cables which must enter the Gateway enclosure, through cable
glands on its bottom surface. The following is a brief description of each one.
Cable 1 – This cable supplies mains voltage to the Gateway (RTU) unit and is its primary
source of power. The Live connection, L, is made to a fused spur, connected directly to one
of the phases, on the busbar within the substation. It is important that the Neutral
connection, N, is connected to the Neutral from which L is referenced.
Cable 2 – This cable provides the Power Line Communications interface connection to the
Gateway (RTU). This cable must be cut to length and terminated as per the diagram. The
cable itself has four cores, one of the cores is green and yellow. This wire is unused and
should be trimmed neatly during installation. It is important to follow the colour coding exactly
in order to ensure correct phase alignment, failure to do so will result in degraded
communication performance. (Phase 1 - Brown, Phase 2 – Black, Phase 3 – Grey).
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Cable 3 – This cable provides the Power & MODBUS communications interface between the
Gateway (RTU), and the PDB, and subsequently the Circuit Breaker. This cable consists of
eight individual cores, arranged in four twisted pairs. Each pin shown on Figure 96 has a
corresponding core identified by its colour, and again must be followed exactly to ensure
proper operation of the system, and to prevent any damage. ( 1 – Red, 2 – Yellow, 3 –
Black, 4 – Green, 5 – No Connection, 6 – Brown plus the Drain wire combined, 7 – Orange ).
Cable 4 – This is the connection from the auxiliary battery backup within the substation. This
must be a nominal 24V supply. Power is only taken from this supply when the supply present
on Cable 1 is absent for any reason.
Cable 5 – This cable provides the GPRS antenna connection, the SMA connector on the
cable must be passed through the largest cable gland and connected to the SMA jack inside
the enclosure. The point at which this connection is made, is then to be securely attached to
the CB, using the cable tie fixing point provided.
Cable 6 – A second neutral cable is connected to the neutral bar on the LV panel and
provides a neutral connection for the PLC communication and for the solenoid power supply,
it is connected to the RTU (Gateway) at the terminal where the brown wire and drain wire
from cable 3 are terminated.
Cable entry locations via cable glands at the bottom of the Gateway (RTU) are shown below:
Figure 97: Cable entry locations Gateway (RTU)
Important Note – When making connections to Gateway (RTU) terminal blocks:



Ensure all cables are neatly and securely terminated.
No un-insulated conductor should be left exposed.
All attempts must be made to minimise length of cable inside enclosure to ease routing
within the enclosure.
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Steps to correctly make connections to Gateway (RTU) are as follows:
1. Cut PDB Power & Data (MODBUS) cable to suitable length and feed through Gateway (RTU)
cable gland 3. Strip back individual cables and connect to RTU terminal block as shown in
Figure 98:
POWER &
DATA RTU
Connections
DC Supply+ (RED)
MODBUS D+ (YELLOW)
MODBUS D- (BLACK)
DC Supply- (GREEN)
No Connection
Cable 3 - POWER &
DATA Cable to RTU (7
core cable)
Neutral (BROWN plus DRAIN
wire combined)
Solenoid Power (ORANGE)
POWER &
DATA BUSBAR
Figure 98: PDB Power & Data (MODBUS) Connections
2. Cut PLC (4-core cable, green and yellow core not used) cable to suitable length and feed
through Gateway (RTU) cable gland 2. Strip back individual cables and connect to Gateway
(RTU) terminal block as shown in Figure 99:
Cable 2 - Power
Line Carrier (PLC)
Cable to RTU
PH 3
PH 2
PH 1
POWER &
DATA BUSBAR
Figure 99: Power and Data Busbar connections




Grey wire to PH 3.
Black wire to PH 2.
Brown wire to PH 1.
Green and Yellow wire unused.
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3. Feed the GPRS Antenna cable through cable gland 5 and connect to the SMA connector
inside the Gateway
GATEWAY
Cable 5
CABLE 5 – GSM/GPRS ANTENNA
Figure 100: GPRS Antenna cable
4. Feed the mains voltage lead through cable gland 1 and connect to an un-switched FCU fed
directly from one of the phases on the busbar within the substation. It is important that the
Neutral connection, N, is connected to the Neutral from which L is referenced.
Figure 101: Gateway (RTU) Mains Power Connection
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5. The gateway accepts a 24V supply, which is used as a backup power source, in the event
that the primary 240V power source is lost. This will enable the Gateway (RTU) to remain
powered up, in the event of a loss of supply to the substation.
A 24V RTU battery backup power source, is to be used and connected via a suitable 2-core
cable through cable gland 4 of the Gateway, connect it to the 24V battery terminal, and wire
the other end to the 24V supply.
Figure 102: Gateway (RTU) Battery Backup Connection
Once all connections have been made to the Gateway (RTU), power-up the Gateway (RTU)
and verify that power LEDs illuminate and that after a period of approximately two minutes
the SYS-Fail LEDs are not illuminated.
9.1.5
RTU and CB Installation & Commissioning Process
The Gateway (RTU) will be pre-commissioned by the onsite Commissioning Engineer prior
to them being installed. All GPRS and SCADA settings will be set up. Therefore no on-site
Gateway (RTU) configuration shall be required.
A Gateway (RTU) build sheet, with site details and Gateway (RTU) SCADA setup details will
be sent to the RTU desk prior to the Gateway (RTU) installation.
This document is limited to the On-site process for commissioning the system, and does not
cover the Gateway (RTU) setup and configuration.
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Installation and commissioning steps follow:
1. Prior to undertaking any work, Contact LV Control and the Gateway (RTU) desk to confirm
that they have received the relevant commissioning documentation, and are available to
support the installation.
2. Complete on-site risk assessment and put into place any identified risk mitigation measures.
3. Install Gateway and Power & Data bus.
4. Put the Gateway in Local Mode, by rotating the Local/Remote selector until the Local LED is
illuminated
Power LEDs
Indicates there is Power on the Gateway
module. (Should always be illuminated)
Local / Remote Selector
Rotating the selector
button, will alternate
between local and
remote settings.
Set to Local to enable
local control of CBs.
Figure 103: Gateway (RTU) Installation & Commissioning Process
5. Install Circuit Breakers to one way of the LV board as follows:
NOTE: CBs shall be installed one LV way at a time.
a. Apply back-feed to LV way where the CBs are to be installed.
b. If necessary, remove the LV fuses from the LV distribution board where the CBs are to be
installed, and then check state of LV Network with an approved testing device (e.g. test
lamp).
c.
On the CB to be installed, ensure CB series fuse is removed and CB fuse stalk insulated
covers are in place.
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CB Fuse Stalk
Covers fitted
Figure 104: Circuit Breaker - Fuse Stalk Covers Fitted
d. Loosen CB thumbscrews, install CB to LV board, and tighten CB thumbscrews while
supporting CB weight to secure CB to LV board.
Figure 105: Circuit Breaker thumb screw fixings
e. Repeat for remaining two CBs to be installed to the LV way.
6. When all CBs are installed to the first LV way make the following connections to the Power
Data Bus:
a. Connect PLC connectors from PDB to Circuit breakers:
These are on a three-core, pre-wired connector with brown, black and grey leads terminated with
4mm shrouded banana plugs.
The PLC plugs, plug into the CB PLC socket, located in-between the CB thumb screws.
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L1 PLC plug connected to CB
Figure 106: L1 PLC plug connected to Circuit Breaker
The diagram below shows all PLC connections from the PDB to the CBs.
NOTE: There are only 3 PLC connections per Gateway, and they can be
connected to any three Circuit Breakers on the same LV way, providing that the
correct phasing is maintained, as shown below.
The Circuit Breaker PLC connectors provide a direct connection onto the LV board
busbars.
L1 PLC
Connector
(Brown)
L2 PLC
Connector
(Black)
CB Power &
Data to RTU
(MODBUS)
L3 PLC
Connector
(Grey)
PLC to Gateway
POWER &
DATA BUSBAR
Figure 107: PLC connections from the PDB to the CBs
b. Connect the Power & Data (MODBUS) cables to each CB from the PDB (any socket
on the PDB can be used).
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CB Power &
Data to RTU
(MODBUS)
CB Power &
Data Cables
(MODBUS)
PLC to Gateway
Figure 108: Circuit Breaker power and data
Connecting the CB power & data cables will power up the CBs.
Data & CB Power
Connector
Figure 109: CB power & data cables
7. Set the Circuit Breaker address to match the settings provided by the on-site commissioning
engineer by pressing the Address (A) button on the CB until it displays the required port and
phase.
The CB address can be changed during a 30 second period after the CB is powered up, after which
time it is locked. The address is changed by pressing the address (A) button, which cycles through all
available CB addresses (Port 1, L1 -> Port 5, L3)
The CB address is made up of a Port Number (1-5), displayed on an 8 segment display on the front of
the CB, and a phase designation LED (L1, L2, L3) which should match the phase that the CB is
installed to.
Combining CB port number and phase designation provides a CB with a unique address (on the LV
board).
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Figure 110: Circuit Breaker port number and phase designation
Pressing the address button scrolls through the available CB addresses see below for
sequence:
etc…
Port 1 Line 1
Port 1 Line 2
Port 1 Line 3
Port 2 Line 2
Port 2 Line 2
Port 2 Line 3
The maximum address is Port 5, L3. When this address is reached, further presses of the
address button will cycle back through the address range from the start (Port 1, L1).
The Port number set on the CB locally, corresponds to the way that the CB is associated with
on PowerOn, therefore it must be set correctly to ensure that commands from LV control
reach the correct CB.
NOTE: No two CBs installed to the same LV board should have the same phase
designation and port number.
If the CBs on an LV board are addressed correctly, the following will be true:



All CBs on the same way should have the same port number
The phase indicator LED (L1, L2, L3) must match the phase that the CB is installed to.
The addresses on the CBs will match the CB address info card by the Gateway.
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LB 421312
LB 421311
LB 421318
LB 421313
8. Affix the CB address information card onto the substation wall next to the Gateway. This info
card will be provided by the on-site commissioning engineer, see below for an example.
9. Contact the RTU desk and run through RTU & CB connectivity checks as per the substation
commissioning flowchart and the EOS 09-0080c ‘LV commissioning checklist’. A copy of the
commissioning flowchart Figure 115.
10. If commissioning checks are successful, put RTU in remote mode, contact LV Control and
request that a Close and Open command is performed on each CB.
NOTE: Verify the operation of each CB for the open and close operations, ensuring that
the expected CB is operating.
If CB operation checks are successful, the CB series fuse can be inserted, and the CB closed
and put into service.
11. Remove CB insulated fuse stalk covers.
12. Check using an approved testing device that there is no voltage between neutral and the
cable CB fuse stalk.
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No light between
cable fuse stalk and
neutral confirms
Switch is open in
scenario where circuit
is back-fed.
Figure 111: Test Circuit Breaker in open scenario
13. Check using an approved testing device that there is no voltage between the busbar CB fuse
stalk and the cable CB fuse stalk.
No light confirms
Switch is open in
scenario where circuit
is not back-fed.
Figure 112: Circuit Breaker in open scenario – CB not back-fed
14. Insert CB series fuse and tighten thumbscrews.
15. Ensure fuse selection on CB reflects size of fuse installed (press fuse selection toggle button
to switch between 315A and 400A settings).
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Figure 113: Circuit Breaker Fuse Selector
16. Put the Gateway in Local Mode
17. Close the CB locally by pressing and holding the close button on the CB, and stand clear
while the CB is performing the close operation.
Press and hold Close
button for 5 seconds.
When close LED flashes
quickly release button
and stand clear of
device.
Figure 114: Circuit Breaker closing procedure
18. Repeat steps 12 to 17 for any remaining CBs on the LV way being worked on.
19. For any further LV ways to be populated with CBs, repeat steps:



4&5
7&8
11 to 19
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9.1.6
Substation Commissioning Flowchart
The Substation commissioning process is summarised in the below flowchart:
Substation commissioning
Field Engineer
LV control
RTU desk
Site preanble
Site identified
Risk assesment
Equipment inventory
HV RTU to Local
No
Site ready
Rectify missing elements
Yes
Contact LV control
Install LV back feed
Check site credentials
against PowerON
Install RTU
(gateway)
Commicatio to FEP
working
Yes
All site data
correct
No
Rectify missing elements
Yes
Operate
Dummy
breakers
Check 3G/ GPRS
link
No
Yes
Check commuincation
between RTU and
breakers
Check analouges
Install Circuit breakers
Fuses out breakers open
Check breaker visibility
in PowerON and
analogue values being
returned
Fuse rating
changed on
Breakers by
operational staff
Rectify
communication
Issyes
No
Fuse Value in
PowerON
changes
Yes
Fault find
No
Breakers visible
from RTU
Yes
Operate circuit breakers
No
Fault find
Check connection
between breaker and
Switch
No
Breakers operate
remotley
Check RTU
configuation and
PowerON
configuration
Yes
Install fuses
Close breakers from
PowerON
Remove Back feed
Figure 115: Substation Commissioning Diagram
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9.2
Onsite installation and commissioning procedure for Link Box Devices
This section provides guidelines on how to install the LV Remote Control and Automation
link box equipment, including:



Instructions for the physical installation of equipment;
The electrical connections to be made to the equipment;
Operational commissioning checks and interaction with commissioning engineers and LV
Control.
Fitting of the equipment requires the following to be work undertaken:


Visual inspection of link box;
Reconfiguration of LV network to provide back-feed to link box.
NOTE: Fitting of LV equipment shall only be undertaken by suitably trained staff.
Prior to any work being undertaken, an onsite risk assessment shall be undertaken, and any
risk mitigation measures put in place.
Specific tools required to install the LV Automation link box equipment are shown in the table
below.
All tools required to work on the system are approved for use and available from the UKPN
materials e-catalogue.
ALLEN KEY
INSUL T-BAR
LONG REACH
5MM
Material code:
32103B
SPINNER NUT
INS 10MM
Material code:
33706F
This tool is required to
loosen/tighten the Link Box
Switch retaining clamps. Tool
modified for use with link box
switches only.
NOTE: Link box switches
cannot be installed or
removed without this tool.
This tool is required to
loosen/tighten the Link Box
neutral
connector
which
clamps on to the link box
neutral stalk.
Figure 116: Specific tools required to install the LV Automation link box equipment
This document is limited to the On-site process for commissioning the system, and does not
cover the system setup and configuration.
NOTE: The installation of link box equipment should not necessitate the interruption
of supplies; if it is not possible to install switches to a pocket without taking
customers off supply DO NOT install the switches.
IMPORTANT: All operations undertaken within the link box while installing the link
box equipment shall be treated as linking and fusing, and appropriate PPE shall be
worn at all times.
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9.2.1
LB Equipment Overview
Link Box switches
Link Box Switches are a single phase Load Break/Fault Make device that can be retrofitted
to existing Prysmian Link Boxes currently used on the LV network. The Link Box Switch
replaces standard links; therefore to fully populate a four-way link box requires the
installation of 12 switches.
Figure 117: Link Box Installation
Where not all quadrants (pockets) in a link box are to be fitted with switches, the remaining
links or empty ways are covered by a dummy blanking switch body, of the same dimensions
as the switches.
Figure 118: Link Box Switch Dummy
Fitment of the dummy switches provide a stable flat base for the LB control panel to sit on,
and ensures that the volume of air under the diving bell cover, remains consistent.
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Link Box Switch Control Panel
The control panel sits above the switches and provides remote comms to the link box, and
local control of the switches.
The status of each switch is provided by an LED mimic panel, which also provides FPI
indication for each device, and the comms status of the controller.
The control panel is connected directly to the switches via flexible cables (one per switch),
plus a neutral cable, which is connected to the neutral stalk in the link box. It utilises Power
Line Carrier (PLC) to communicate over the LV network to a Gateway unit located at the
distribution substation.
Figure 119: Link Box Switch Control Panel
A new modified plastic bell cover
The LB switches and control panel sit significantly higher than the original cast iron LB lid,
and a new Diving Bell lid is supplied to accommodate this additional height.
Figure 120: Diving Bell Lid Installed
The diving bell lid is made from lightweight plastic, therefore to prevent the lid from floating
up, in the event that a link box floods, a metal retaining strap is provided which hooks under
the second tier of the link box.
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9.2.2
LB Commissioning Information
The substation RTUs will be pre-commissioned with the link box details by the onsite
commissioning engineer prior to them being installed. When a link box is commissioned, the
Substation Gateway (RTU) holds all commissioning information for the link box controllers
that communicate via it (i.e. all LBs fed from the substation); there are no settings to be
changed locally on the LB Controller.
Specific commissioning details requiring careful attention when installing are:


Q1 must be connected to switches (IMPORTANT, Q1 must be connected to enable PLC
connection);
The orientation of the link box with respect to the commissioning sheets; e.g. Q1
destination from LB controller must match Q1 destination on PowerOn diagram.
An example of how the link box is
represented in PowerOn is shown in the
centre of the picture to the left.
Note the quadrant (pocket) designations
Q1, Q2, Q3, Q4.
The controller orientation when it is
installed must be such that Q1
destination on the controller matches
the Q1 destination on the LV diagram.
In some cases the physical orientation
of the link box in the ground with respect
to the LV network will not allow correct
orientation of the LB controller (the
controller can only be orientated two
ways in a LB).
If this scenario occurs the Gateway
(RTU) desk shall be notified, and the LV
diagram will be amended to reflect a
change in the Q1 connection.
Figure 121: PowerOn representation
A LB controller build sheet with link box details, including the destination of each quadrant,
will be sent to the RTU desk prior to the Link Box installation.
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9.2.3
LB Switch and Controller Commissioning Process
1. Prior to undertaking any work, Contact LV Control, and the RTU desk, to confirm that they
have received the relevant commissioning documentation, and are available to support the
installation.
2. Complete on-site risk assessment, and put into place any identified risk mitigation measures.
3. Set any substation Gateway (RTU) that is supplying the LBs, where equipment is being
installed to local mode.
Power LEDs
Local / Remote Selector
Indicates there is Power on the Gateway
module. (Should always be illuminated)
Rotating the selector
button, will alternate
between local and
remote settings.
Set to Local to enable
local control of CBs.
Figure 122: Gateway (RTU) power and local/remote indicators
4. Remove link box pavement cover and standard diving bell cover, then verify quadrant
destinations:
a. If LB controller can be installed so that Q1 destination matches the commissioning
sheet Q1destination details (and therefore the LV diagram) go to step 5.
b. If it is not possible to install LB controller so that its Q1 destination matches the
commissioning sheet, contact the RTU desk and:
i. Provide details of the link box orientation.
ii. Agree a new destination for the LB controller Q1, and note details on
commissioning sheet.
NOTE: When communicating with the RTU desk, the LB number, and destination shall be used
to identify a quadrant/pocket.
e.g. “Q1 destination at link box 421080 is TC 40185”
c.
The RTU desk will amend the LV diagram with the agreed updated LB orientation
details.
5. Reconfigure LV network so that the LB links where switches are to be installed can be
removed (e.g. apply backfeed).
6. Attach link box neutral connector to the link box neutral stalk, and then tighten the neutral
wedge clamping mechanism with the 10mm insulated nut spinner.
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Figure 123: Link Box Switch Neutral Connector
7. Working on one quadrant/pocket at a time install the link box switches as follows:
a. Using test lamp, ensure that LV network is configured as expected, and no faults are
present.
Figure 124: Link Box - test configuration
b. Remove all links from quadrant where switches are to be installed.
c.
Check that the switches to be installed are in the open position, with an approved
testing device
Figure 125: Check Link Box Switches are installed are in the open position
IMPORTANT: A Switch shall not be installed to a link box if it is closed.
If a switch is closed it shall be opened prior to installation.
A mains powered device to enable the operation of the Link Box Switches, while they
are not connected to the network will be available, at the closest substation to the link
box (the device will also work when powered from an inverter).
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d. Install the OPEN switch into the link box, and tighten the LB wedge clamp retaining
screws, with a 5mm long reach insulated allen key tool (Material code: 32103B). Tool
modified for use with link box switches only.
LBS
retaining
screws.
Figure 126: Installing OPEN switch into the link box,
e. Repeat steps a – d for all switches in the quadrant.
8. Repeat step 7 for all quadrants/pockets to be installed to.
NOTE: In some cases is will not be possible to install all switches without first closing the
switches in one quadrant. See below example:
Switches to be installed
in Q1, Q2 & Q3.
Q3
OPEN
Backfed
OPEN
OPEN
OPEN
Backfed
Q1
OPEN
Q4
Q2
Backfed
To Customers & Pot End
OPEN
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Open switches installed
to Q1 & Q2
Removing links in Q3
will make box dead and
interrupt supply to
customers fed from Q4
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Open
Backfed
Open
Open
To Customers & Pot End
Q1
Open
Q2
Backfed
Open
OPEN
OPEN
OPEN
OPEN
OPEN
OPEN
CLOSED
Backfed
Q1
CLOSED
Instructions to connect the
controller are available in section
8.4.4, and instructions to locally
operate the switches are
available in section 7.5
Q3
Backfed
Then Close the switches in Q1
manually.
Q4
Open
Backfed
Q4
Q3
Backfed
SOLUTION – Temporarily
connect the control panel to:
a) The LB neutral
connector
b) The switches in Q1
To Customers & Pot End
Controller can now be
disconnected to allow
installation of remaining
switches in Q3 with LB fed
through closed switches in Q1.
Alternatively the controller can
be left connected, and moved
out of the way to allow switch
installation if space permits.
CLOSED
Figure 127: Operating switches to aid installation
9. Install switch blanks to Quadrants/Pockets where switches are not to be installed.
10. Connect the neutral cable to the reverse of the link box control panel.
Neutral
connector on
control panel.
Brass wedge
clamp to
provide neutral
connection to
link box neutral
stalk.
Figure 128: Neutral connection to Link Box Panel
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11. Place the control panel on top of the switches face up and reconnect the switches to the
control panel. Ensure that all switch leads and connectors are accessible, and not trapped
under the controller.
IMPORTANT: Ensure Q1 on LB Control Panel matches Q1 on commissioning forms
Figure 129: LB Control Panel matches Q1 on Prysmian Box
12. Connect each switch plug to the relevant socket on the control panel.
NOTE: Each switch has a corresponding socket on the controller, which matches the
switch position in the Link Box; this is shown in the below diagram.
Figure 130: Correct Link Box connection procedure
Each switch plug must be connected to the correct socket on the controller, to avoid potential
switching errors.
Ensure when connecting switches to the controller, that the switch leads do not cross over each
other.
IMPORTANT: Q1 MUST BE CONNECTED TO SWITCHES TO PROVIDE THE SCADA
COMMS (PLC) CONNECTION ONTO THE LINK BOX BUSBAR
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To correctly connect each switch to the control panel:
a. Locate the plug into the controller socket with the clip facing upwards
b. Gently push the plug/connector into the socket until it is heard clicking into place.
Figure 131: Link Box Switch plug/connector installation
c.
Repeat for each switch in the Link box.
13. Attach supplied traffolyte label to the inside of the link box to mark the Quadrant 1 location.
The label should be attached with a suitable adhesive.
Quadrant 1
label on LB
LB controller Q1
must line up
with LB Q1 label
Figure 132: Traffolyte label positioned inside link box to mark the Quadrant 1 location
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14. Verify that the Link Box Control Panel has power and is correctly displaying the state of the
switches.
In the below example switches in Q1, Q2, Q3 are open, switches in Q4 closed.
Figure 133: Verify Link Box Control Panel has power and is correctly displaying state of switches
On initial power-up the SYS-FAIL indicator will remain on for about 2 minutes while the
controller initialises.
15. Press the LED TEST button to ensure that all LEDs are working (the LED Test button
illuminates all control board LEDs)
Figure 134: Control board LED diagram
16. After the control panel has been powered up for a period of about 2 minutes the SYS-Fail
LED will go out, and shortly afterwards the COMMS LED should start flashing, indicating that
the LB controller is communicating with the control system (note requires one switch to be
closed towards a substation).
17. Contact the RTU desk and verify link box SCADA connectivity as follows.
a. Confirm that RTU desk can connect to the link box and read analogues / switchstates. Follow the link box flowchart Figure 138 and EOS 09-0080c ‘LV
Commissioning Sheet.
b. Place the Link Box Controller in Remote mode by pressing local/remote button until
the remote LED is illuminated. Confirm with RTU desk.
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Local / Remote
toggle push
button.
Local LED –
illuminated when LB
is in local mode.
Remote LED –
illuminated when LB
is in remote mode.
Figure 135: Link Box Control Panel Local – Remote, toggle push button
c.
Trigger an FPI from a switch and confirm that the Gateway (RTU) Desk receives a
corresponding FPI alarm.
NOTE: To verify that the control board is orientated correctly and PowerOn is
receiving the correct readings for each switch, an FPI can be triggered locally from
any of the switches; the FPI is then verified and acknowledged by LV Control or in
this case the RTU Desk.
To trigger an FPI on a switch, press the select button until the required switch is selected
for control.
Q2, L2 Selected for control
Select button
cycles through
available switches
for control.
Pressing select,
selects next
connected switch
(indicated by
orange LED)
Figure 136: Link Box Controller Switch Selector
Hold select button for at least 5 seconds, and then release, an FPI will be generated
locally and relayed to PowerOn (IMPORTANT: this only works when the controller is in
remote mode).
NOTE: When communicating with the LV control engineer or RTU Desk, the LB
number, destination, and phase shall be used to identify the switch.
e.g. “triggering FPI on L2, at link box 421080 towards TC 40185”
d. Confirm with RTU desk that the FPI alarm received was for the correct switch, and
then repeat the process for one switch in each Quadrant.
e. Ask RTU desk to confirm that the dummy switch is operating as expected.
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18. Contact LV Control to verify correct operation of switches, by asking LV Control engineer to
perform an operation on each switch (ensuring backfeed is in place, and operation of
switches does not interrupt supplies)
19. Ask LV Control to put link box back to normal running arrangement, by remotely operating the
switches and verify that the switches have operated as expected
20. Install modified diving bell cover, and bell cover retaining strap, and then replace LB
pavement cover.
Figure 137: Modified Bell Cover and Retaining Strap
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9.2.4
Link Box Commissioning Flowchart
The Link Box commissioning process is summarised in the below flowchart:
Link Box commissioning
Field Engineer
Site preamble
Link Box identified
Risk assessment
Equipment
inventory
RTU desk
LV Contol
Breakers must be open this
to be checked before work
commences. If in closed
state they must be opened
locally before installation
No
LB ready
Rectify missing
elements
Yes
Check site
credentials against
PowerON This must
include quadrant
alignment
Contact RTU desk
Install Link Box
controller and
open switches in
Q1
Commication
to RTU
working
All site data
correct
Yes
Yes
Fault find
Check connection
between LB
controller and
Switch
Rectify missing
elements
Check PLC to
RTU
No
Check LB switch
visibility and
analogue values
being returned
Check
communication
between RTU and
LB
Check analogues
Install remaining
open switches
Fault find
No
No
No
Switch visible
Send EFPI
Switch visible
Yes
Check in
PowerON against
documentation
This process is to be repeated
for each quadrant. Using the
test button on the LB control
panel to select each
connected quadrant in
sequence and then to send a
indication to PowerON
Yes
Close switch from
PowerON
Contact LV control
Make good LB
chamber
Figure 138: Link Box Switch Commissioning Flowchart Diagram
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9.2.5
Link Box Switch Installation Flowchart
The Link Box Switch installation process is summarised in the below flowchart:
Link Box Switch installation Checks
Does LB already have switches
installed in one or more
quadrants?
No
Switches can only be installed
Prysmian link boxes. Arrange
Replacement of Link Box with
Prysmian Link Box
No
Yes
Set LV Remote control RTU to
manual at substation connected
to link box, and inform LV
control
Is Link Box of the current
Prysmian type?
No
Yes
Does outgoing cable from
LB quadrant lead directly to
a pot-end?
Can LV network be
reconfigured to enable an
open point to be created at
quadrant where switches are
to be installed?
No
Is switch to be installed at
existing open point?
Yes
Yes
Yes
No
Installation of switches should not
cause interruption to customers’
supplies. Inform LV control that
switch cannot be installed and
consider planned shutdown
Switches should not be installed to
link box quadrants leading to a potend. Inform LV control that switch
cannot be installed.
No
Is switch installation high
priority or driven by
requirement for QOS
improvement?
Yes
Refer to EDS 00 0004,
MANAGEMENT OF
PLANNED SHUTDOWNS, and
arrange shutdown accordingly.
Move open point to / remove
links from quadrant where
switches are to be installed.
Switch not installed at this time
Switch can be installed
Figure 139: Link Box Switch Installation checks Flowchart Diagram
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9.3
System Alteration Notice and Asset Registration
All assets connected to distribution networks must be registered in the Asset Management
System (previously Ellipse) in accordance with EOP 12-0215 ‘Asset Registration - Recording
New or Amended Asset Information in Ellipse’. A template has been prepared to register
each CB and Link box switch installation as contained in Appendix A.
10
References
EOP 12-0215
Asset Registration - Recording New or Amended Asset Information in
Ellipse
HSS 01 069
Personal Protective Equipment (PPE).
HSS 40 017
Low Voltage Re-Energising Devices
HSS 40 023
Energisation of Networks following faults and emergencies
HSS 40 045
Basic Requirements for Live Working on Low Voltage Apparatus
UKPN DSR
Distribution Safety Rules Summer 2012 Edition
11
Dependent Documents
The documents below are dependent on the content of this document and may be affected
by any changes.
Manual
LV Remote Control Manual Autumn 2013
EOS 09-0080A
Substation commissioning flowchart copy of Figure 115
EOS 09-0080B
Link box commissioning flowchart copy of Figure 138
EOS 09-0080C
LV Commissioning Sheet
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Appendix A - Asset Registration
LB 421312
LB 421311
LB 421318
LB 421313
Asset Registration will be carried out in accordance with EOP 12-0215.
Attribute Description
Attribute Value
Description
Manufacturers Name
EAT
EA Technology Ltd
Manufacturers Type/Model
Suggested value format
Single phase CB
Serial number
Year Manufactured
2015
Short time Fault Rating
53/
53kA/Unknown
Operating Mechanism Energy
SOL
Solenoid
Remote Close available
Y
Arc Extinction Method
OTH
Other
CMR or Feeder Ref
TC 40094 Way 81
Continuous Rated Current (A)
400
Insulation Medium
Air
Circuit Name
Port 1_L3
Operating Voltage (kV)
0.240
240V single phase
Plant position
FRE
Free Standing
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The following template needs to be completed for each LBS installed.
Attribute Description
Attribute Value
Description
Manufacturers Name
EAT
EA Technology Ltd
Suggested value format
Manufacturers Type/Model
Serial number
Year Manufactured
2015
Short time Fault Rating
0
0
Operating Mechanism Energy
SOL
Solenoid
Remote Close available
Y
Arc Extinction Method
OTH
Other
CMR or Feeder Ref
link box 421080
Continuous Rated Current (A)
400
Insulation Medium
Air
Circuit Name
Q1_L3 towards TC 40185
Operating Voltage (kV)
0.240
240V single phase
Plant position
FRE
Free Standing
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The following template needs to be completed for each link box control panel installed.
Attribute Description
Attribute Value
Description
Manufacturers Name
EAT
EA Technology Ltd
Suggested value format
Manufacturers Type/Model
Serial number
Year Manufactured
2015
CMR or Feeder Ref
link box 421080
Plant position
IntegralFPI (Y/N)
Y
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The following template needs to be completed for each Gateway (RTU) installed.
Attribute Description
Attribute Value
Description
Manufacturers Name
EAT
EA Technology Ltd
Suggested value format
Manufacturers Type/Model
Serial number
Year Manufactured
2015
CMR or Feeder Ref
TC 40094
Plant position
Wall mounted
RTUNAME
RTU Software/Config Version
IntegralFPI (Y/N)
Y
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This LV distribution board has FUN-LV single phase CBs
installed
on an
feeder to board
allow capacity
with single
another substation.
This
LVoutgoing
distribution
has sharing
FUN-LV
Main equipment comprises: three single phase circuit breakers, a Gateway (RTU), a
battery pack and a Power Data Bus – Energy Store (PDB-ES). Neither the batteries
nor the PDB-ES should need to be touched.
CB close-up
A Gateway (RTU)
The CB has a series connected 82mm fuse-link which will operate if the fault current
is greater than the CB break rating. Following a fault the CB will attempt a reclose,
but before the CB closes it tests the feeder to determine whether a fault is still
present. If a fault is detected the CB will not close nor re-energise the feeder.
To operate the CB locally
Check each CB is in the expected state. Two voltage LEDs (top and bottom) are
illuminated indicating both the busbar and the feeder are LIVE and when the CB is
closed the two green LEDs (midway up) are illuminated.
Turn the knob on the Gateway anticlockwise into the Local position. The Remote
LED will go out and the Local LED will illuminate.
To open a CB, one at a time, press the open button for five seconds then release.
The CB will open ten seconds later giving you time to move away from in front of the
CB. Check the two LEDs midway have gone out. Repeat for the other two CBs.
To close a CB, again one at a time, press the close button for five seconds then
release. The CB will close (assuming no fault is present) ten seconds later giving you
time to move away. Check the two LEDs midway are illuminated. Repeat for the
other two CBs.
Return the Gateway to Remote by turning the knob on the gateway clockwise.
To form a point of isolation (POI)
Open the CB as above.
Remove the black control cable and the phase coloured PLC cable.
Slacken the two wedge tightening wingnuts and remove the whole CB from the
distribution board stalks. Just removing the series fuse-link does not form a POI.
Note which CB was connected to each phase. There is a L1, L2 and L3 indicator.
Insert a caution cover over each exposed set of distribution board stalks.
To return to service
With test lamps check the phases are LIVE and in phase.
Check the CB is open by measuring the resistance between the two CB contacts.
Insert the CB on the stalks and tighten the wedge tightening wingnuts making sure
the correct CB is returned to the phase from where it came.
Insert the black control cable and the phase coloured PLC cable. It does not matter
which black cable is used, but the phase coloured PLC cables must be in the right
order. They do only go around one way.
Wait for the CB to initialise and LEDs to light up. The Port 1 and correct phase
indication should match the CB’s position. Two voltage LEDs (top and bottom) are
illuminated indicating both the busbar and the feeder are still LIVE.
Close the CB, one at a time, as described above.
For further information consult EOS 09-0080 LV Remote Control Equipment that can
be found in the Asset Management section of Alfresco.
Alternatively contact Peter Lang 07875 111863.
Milestone 3.42
Advanced Use Cases
Milestone 3.42 Advanced Use Cases
Contents
1.
2.
Introduction............................................................................................. 3
Asset Guarding....................................................................................... 4
Background ............................................................................................ 4
SOPs for asset guarding ........................................................................ 4
Advanced Use Case .............................................................................. 8
Advanced Use Case Annex – For discussion with Imperial College ..... 9
3.
Connection to teed circuits ................................................................... 10
Sharing capacity and support across boundaries during HV faults ..... 10
Operational considerations .................................................................. 17
Conclusions .......................................................................................... 18
Advanced Use Case ............................................................................ 19
4.
Loading to Dynamic Limits ................................................................... 20
Background .......................................................................................... 20
FUN-LV Loading to Dynamic Cable Limits .......................................... 20
Basic Principles .................................................................................... 20
Identifying Dynamic Limits ................................................................... 21
Loading to Dynamic Cable Limits: FUN-LV Summary ......................... 21
Advanced Use Case ............................................................................ 23
5.
Reverse Power Flows .......................................................................... 25
Background .......................................................................................... 25
Link Box Switches and Reverse Power Protection for FUN-LV ........... 25
LV interconnection in networks normally designed to be operated in radial modes
Proposed Solution ................................................................................ 27
Radial Embedded Substations (RES) .................................................. 28
Appendix 1 – Description of Reverse Power ................................................ 29
27
UK Power Networks (Operations) Limited. Registered in England and Wales. Registered No. 3870728. Registered Office: Newington House, 237 Southwark Bridge Road, London, SE1 6NP
Page 2 of 2
Milestone 3.42 Advanced Use Cases
1. Introduction
This document details the evidence for the PPA Energy milestone, on Advanced Use Cases, for Work Stream 3 of
FUN-LV. The key deliverable is:
•
Documentation of three agreed Advanced Use Cases for the Soft Open Points for use by Imperial.
The Advanced Use Case titles have been agreed with UK Power Networks, and Imperial College as a relevant project
partner:
• Asset Guarding
• Connection to teed circuits
• Loading to dynamic limits
In addition, the following issue was considered and documented, which is not considered to be an Advanced Use Case
(as it does not relate to the SOP control algorithm), but is recorded here as it is considered to be in the interest of the
project:
• Reverse Power Flows
For each Advanced Use Case, the background information is presented, followed by the Advanced Use Case:
• Section 2 relates to Asset Guarding
• Section 3 relates to Connection to teed circuits
• Section 4 relates to Loading to Dynamic Limits
• Section 5 relates to reverse power flows
UK Power Networks (Operations) Limited. Registered in England and Wales. Registered No. 3870728. Registered Office: Newington House, 237 Southwark Bridge Road, London, SE1 6NP
Page 3 of 3
Milestone 3.42 Advanced Use Cases
2. Asset Guarding
Background
When a network asset, such as transformers, cables, switchgear and other network items, is heavily loaded, damage
can occur shortening the operational lifetime of that asset and meaning that they require replacement sooner. Asset
Guarding aims to protect network assets from this damage.
Historically assets have been protected against overload damage by
• System architecture and design
• Predictable loads and patterns
• Slow and notified load growth
• Annual site inspections/ MDI (Maximum Demand Indicator) readings
• Very coarse overcurrent protection
But the increase in low carbon technologies means much of this has or is about to change in unknown ways and
timescales.
SOPs for asset guarding
SOPs have the potential to support in Asset Guarding by:
• Measuring power flows and directions
• Calculating “Virtual Measurements”
• Alarming “at risk” conditions
• Visibility of system and asset performance
• Equalising asset utilisation and capacity
• Controlling to Dynamic Ratings* (or Ultimate Emergency Rating as appropriate)
• Controlling Fault Levels*
• Shortening extreme support mode periods*
• Monitoring Rate of Use of life
• Reducing number of faults and fault durations
*All the benefits except those asterisked can also be delivered in whole or part by the monitoring systems associated
with Method 1.
These can be categorised as steps sequentially undertaken by the SOP, and significant expected benefits, illustrated
below.
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Milestone 3.42 Advanced Use Cases
Figure 1. Steps taken by SOP relating to Asset Guarding
Expected benefits
Equalising asset utilisation and capacity
Controlling to dynamic ratings (or Ultimate Emergency Rating as
appropriate)
Controlling fault levels
Shortening extreme support mode periods
Reducing number of faults and fault durations
Figure 2. Benefits relating to Asset Guarding expected from SOP
Each of these is explored in more detail in the table below.
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Milestone 3.42 Advanced Use Cases
SOP support function
Measuring power flows and
directions
Calculating “Virtual
Measurements”
Implication
Already the requirement for (i) certain inputs
to SOP (transformer and circuit information
measured at each substation, and at SOP)
and (ii) SOP output reporting to PowerOn
Fusion (POF) (status and alarms – see Use
Case 5 Visualise PE status).
Application: All network types.
SOP current will be monitored at each end
of each line. This will provide details of both
the transfer through the line and consumed
by load/losses on the line. This data can be
used, with metering data and network
connectivity, to provide real time virtual time
series measurements of loads (see also
dynamic line rating).
Equalising asset utilisation
and capacity
Core SOP function – see Use Case 8
Equalise Load.
Controlling to Dynamic
Ratings (or Ultimate
Emergency Rating as
appropriate)
Dynamic ratings are being explored under
activity WS3.14.
Application: SOPs operating on
interconnected LV networks.
Controlling Fault Levels
UER will be automatically accounted for in
rate of use of life calculations, and because
of the SOP current limiting and thermal
protection features are unlikely to be an
issue unless cables less than 95mm 2 are
used as interconnectors; for larger cables,
the SOP rating will be the limiting factor.
Enhanced SOP function – see Use Case 10
Control Fault Level. There are two levels of
fault level control: (1) allow connections
across boundaries through installation of PE
Next step / notes
There is a task on Imperial College
(Nathaniel) to expand / detail the
requirements in TPS document 31
(pages 6-8) – to be reviewed by PPA
Energy.
Specification of required data being
reviewed by Imperial (Nathaniel) (as
above). Will need to be reviewed for
suitability for dynamic line rating and
network modelling by CGI.
No implications for SOP control
algorithm. Calculate virtual
measurements offline (CGI) and
pass relevant information back to
SOP. This relates to the FUN-LV
activity on LV 3-phase modelling and
load allocation.
Will be implemented as part of the
SOP control algorithm. No explicit /
additional activity required under this
activity.
Include UER tests related to small
cable sizes in dynamic ratings work.
The former is the deployment of
SOPs across boundaries – this is
covered under site selection.
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Milestone 3.42 Advanced Use Cases
SOP support function
Reducing number of faults
and fault durations
Implication
without increasing fault level and (2)
advanced features, including estimating fault
level, reporting measurements outside target
range, determine and report how fault level
changes with SOP operation.
Application: All LV network types.
SOP circuits will be monitored at each end.
This provides opportunities to monitor:
(a) Bursts of incipient fault current that
indicate an emergency defect and
allow other fault detection, location
and management techniques.
To report data that can be used to estimate
location and characteristics of events.
Shortening extreme support
mode periods
Application: Applies to SOPs operating
across network boundaries on
interconnected LV networks.
Next step / notes
The latter is an Imperial College
activity, which will not form part of
the SOP field trials.
No explicit activity required for PPA,
other than to manage and review
Imperial’s activities.
Specification and reporting of event
detection and classification to be
prepared (John). (Imperial already
have samples of indicative event
data)
There is a requirement for the SOP
to ride through such events, but to
“stop” (protect itself) before
exceeding thermal limits of the PE
device. The decision making for this
needs to be designed.
Inherent feature of SOP operation.
No additional work required.
By enabling additional load transfers across
boundaries (without exceeding fault current
limits) additional support during HV faults
can be provided, by proving an additional
infeed to an interconnected area. This will
share load to be supported by LV circuits
more evenly and reduce the probability of LV
cascades and their onset should they occur,
as it will take longer for fuses to blow.
Hence the duration of cascade faults is
reduced, as the SOP allows network
operators to “buy time”, during which field
staff can be sent to the event.
Table 1. Elements of Asset Guarding
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Milestone 3.42 Advanced Use Cases
Advanced Use Case
Use Case
Element
Advanced Use
Case #
Application
Use Case Name
Use Case
Description
Primary Actor
Precondition
Trigger
Basic Flow
Description
1
SOP
Asset guarding
The aim of asset guarding is to protect network assets from damage caused by:
• being heavily overloaded for periods of time,
• sustaining excessive voltage, unbalance or harmonics,
• sequences of faults or incipient current bursts, or
• excess rate of use of life.
The above can lead to shortening the asset’s operational life. This Use Case
covers the use of the SOP in assisting in Asset Guarding.
SOP
The SOP is on and either operating in idle mode (monitoring) or “on” (i.e.
transferring load or making quality of supply adjustments).
This is an ongoing activity – in idle mode and when operating (load transfer or
other QoS improvements). In idle mode, the SOP will re-activate upon detecting
an event including abrupt surges, and dips of loss of voltage that are sustained
on incoming circuits.
The SOP measures power flow data and reports status to control. In order to
“asset guard”, the SOP:
1. Controls any transfers to dynamic limits (demonstration in scope, but not
for Version 1 of the SOP control algorithm).
2. As part of loading to dynamic limits algorithm, SOP calculates and stores
(and reports) rate of use of life according to algorithm concepts being
developed by PPA Energy.
If the SOP detects an asset overload (connected circuit or transformer) which
exceeds either (1) a capacity limit (e.g. 160% loaded) or (2) a capacity and time
limit (e.g. 120% loaded for 6 hours), this is reported as an alarm to control.
These decision making process to be defined. Emergency ratings will vary
depending on asset specification and environment so all SOP parameters,
including overload ratings, can be set on a site by site basis at commissioning.
Alternate Flow
In the event of / in order to support the restoration following a network fault, SOP:
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Milestone 3.42 Advanced Use Cases
1. Monitors and records bursts of incipient fault current, and makes this
information available to Users; and
2. Reports data that can be used to estimate location and characteristics of
events.
Table 2. Advanced Use Case for Asset Guarding
Advanced Use Case Annex – For discussion with Imperial College
Incipient faults – for discussion
a) Where the SOP operates on fault current and on retry the current is still live on all phases, and
operations restart.
b) Where there is a voltage dip and a current rise on one phase (in excess of normal rating but less than
needed to cause trip).
c) Where there is a voltage dip and current rise on two phases in excess of normal rating but less than
needed to cause trip
Table of limits
The limits discussed in Stage 3 of the basic flow could include:
• Loading
• Voltage
• Voltage unbalance
• Current unbalance
• Harmonics (V)
• Harmonics (I)
• Power factor
• Loading to dynamic limits
• Incipient current bursts
• Circuit breakers operations and currents
• Temperature of SOP
• Air temperature
And are subject to detailed ongoing discussions with Imperial College
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Milestone 3.42 Advanced Use Cases
3. Connection to teed circuits
Background
So far in the FUN-LV project, considerations for potential sites for Soft Open Points (SOPs) have been based on the
assumption that there is a single circuit connecting each SOP port and substation. However, this may not be the case;
it is possible that the SOP port is connected to a teed circuit, and hence to two substations. The implications of such a
SOP connection need to be considered. This note summarises initial thoughts on this scenario.
Sharing capacity and support across boundaries during HV faults
Figure 3. Weakly interconnected blocks of LV substations
In the example case we have three “blocks” of substations that are interconnected with each other, but only weakly
interconnected, or isolated across boundaries and breaks. In such cases, often the connection is not direct from the
substation to the SOP, but to another circuit via a Tee joint or a link box, which already interconnects two substations.
In such a block as illustrated above the substations are usually well interconnected and consequently:
• There are well balanced voltages across the networks; and
• The substations are already sharing loads well, dynamically.
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Any imbalance of transformer utilisation will usually be due to large point loads, which in turn will usually cause a voltage
depression (or conversely a lightly loaded area will experience a voltage rise).
The figure below expands a section of the network.
Figure 4. Expanded diagram of network
And the figure below expands the network further.
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Milestone 3.42 Advanced Use Cases
Figure 5. Diagram of network expanded further
In the above diagram, “m” represents some form of monitoring for complex loads (kW / kVA).
With each SOP port monitored, and if each substation has its LV boards monitored1, then we know:
• The total load on the circuit m1-m2-SOP
• The transformer loads at TB1 and TB2
With DPlan load allocation, we also know the location of the loads and can estimate the power through, and voltage on,
each line section at each time.
1
A principal has been agreed that, where the SOP port is connected to two or more substations, they will be grouped into two
“clusters” and the closest substation of each cluster will be monitored to be representative. This should not require any additional
monitoring beyond that required for a basic teed circuit.
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Milestone 3.42 Advanced Use Cases
Figure 6. DPlan load allocation
The standard SOP autonomous Use Case accounts for three independent ports, directly connected to individual
substations. The Advanced Use Case needs to handle the above situations and produce appropriate, if not perfect, local
transfers.
From the:
• Transformer loads and voltages we know where the spare capacity and overloads are; and
• LV circuit monitoring we will know what dynamic transfer capacity is available.
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Scenario 1
Figure 7. Scenario 1 – Highly loaded TB1, lightly loaded TA1 and TC1
In the above scenario, the substations in block B are highly loaded, and the substations at A and C are lightly loaded.
TA1 and TC1 are connected to block B via the SOP. Support from the SOP will reduce transformer loads at TB1 and
TB2, and circuit loads at TB1 and TB2, by transfers from TA1 and TC1 via SOP.
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Milestone 3.42 Advanced Use Cases
Scenario 2
Figure 8. Scenario 2 – Low volts at TB2, medium volts at TB1 and TB3
In the above scenario, the power from the SOP will automatically flow to the area where volts are lower, easing TB2
whilst leaving TB3 much the same.
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Milestone 3.42 Advanced Use Cases
Scenario 3
Figure 9. Scenario 3 – Low volts at TB1
In the above scenario, we see that there is capacity at TB2 and TA1. On the SOP circuit TB1/TB2 the current will tend
to be drawn from TB2 because the voltage there will be higher.
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Milestone 3.42 Advanced Use Cases
Operational considerations
Scenario 4
Figure 10. Scenario 4 – Operational considerations
In the above scenario:
• The SOP is to receive and summate LV feeder loads.
• The load at TA1, TB1 and TB2 is summed to produce the load on the Spine Circuit.
• Transformer loads are monitored at TB1 and TB2 to determine the utilisation of each, and their average utilisation is
calculated to determine the potential for transfers to and from Block B via cable A-tee.
• The capacity available on cable A-tee is determined in relation to its dynamic rating.
Operation
• The SOP will consider potential transfers initially as though TB1 and TB2 have a single combined utilisation.
• The SOP will increase the load transfer in steps.
• The SOP receives status updates from TB1 and TB2 (TF and LV cables) and reviews utilisation and dynamic rating
before enacting the next step.
• There will need to be an anti-hunting mechanism to prevent frequent bistable operation and create smooth
transfers.
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Milestone 3.42 Advanced Use Cases
Conclusions
•
•
•
•
•
It appears that we can summate the transformer capacities at the remote ends of the circuit to determine the
potential for transfer.
The voltages are likely to both indicate and control the transformers’ relative capacity to accept or release capacity
transferred.
In most cases the cables will be the limiting condition for transfers.
Once a power transfer has been identified, and the potential of the cables to transfer has been confirmed, the
transfer can be initiated.
It is assumed that the transferred power will automatically find its way to relieve overloading and low voltages with
teed circuits. At the set one-minute intervals there is the opportunity to re-evaluate the transfer against the circuit
ends and the dynamic circuit limits, and to adjust by increasing or decreasing to suit (the thermal time constant
being such that any additional thermal rise that occurs in one minute is very unlikely to be significant under normal
loading conditions).
Under HV fault support conditions the same is true, but care needs to be taken that a step change in current does not
provoke a fuse to fail, which has been well overloaded before or after the HV event. This can be achieved by the SOP
taking account of the dynamic rating of fuses before committing step changes in support.
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Milestone 3.42 Advanced Use Cases
Advanced Use Case
Use Case
Element
Advanced Use
Case #
Application
Use Case Name
Use Case
Description
Primary Actor
Precondition
Trigger
Basic Flow
Description
2
SOP
Connection to teed circuits
So far in the FUN-LV project, considerations for sites for Soft Open Points (SOPs)
have been based on the assumption that there is a single circuit connecting each
SOP port and substation. However, this may not be the case, especially in
interconnected areas; it is possible that the SOP port is connected to a teed circuit,
and hence to two substations.
SOP
A site is selected whereby one or more SOP ports are connected to a teed circuit
and hence to two or more substations (unlikely to be more than three).
As above.
The SOP takes information from all connected substations, and manages
transformer and cable loads on all connected assets. For cables, the SOP
should:
1. Sum loads from all connected feeders and SOP output to identify the
load on the connected circuit;
2. Ensure that each feeder is not exceeding its rating; and
3. Monitor feeder ends to ensure that limits are not exceeded.
For transformers:
1. Sum transformer loads together to check whether there is available
capacity overall;
2. If required, make incremental changes to SOP export and monitor the
outcome on connected transformers;
3. Do not exceed maximum utilisation for transformers.
Alternate Flow
Table 3. Advanced Use Case for Connection to teed circuits
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Milestone 3.42 Advanced Use Cases
4.Loading to Dynamic Limits
Background
The true rating of an asset is not constant over time, but changes significantly with type, age, position, temperature and
load profile. Dynamic Rating involves determining the rating of an asset in real-time, in order to utilise the capacity of that
asset efficiently. Loading to LV cable dynamic limits takes advantage of the control over the load that is provided by
Power Electronics to release thermal capacity conventionally reserved to allow for normally uncontrollable fluctuations in
load currents. This use case is not applicable to Method 1.
FUN-LV Loading to Dynamic Cable Limits
The key functionalities of the FUN-LV Power Electronics (PE) solution include:
• The ability to finely control power flow;
• To provide capacity equalisation between distribution substations irrespective of their network impedances or
sources of supply; and
• To release LV circuit capacity by control of circuit loading and unbalance to dynamic limits.
To be able to transfer power between substations it is necessary to make the maximum use of both transformation and
existing cables, without unduly compromising their integrity or life.
The essential difference between Loading to Dynamic Limits and Dynamic Rating is the control over the load that is
provided by Power Electronics that prevents dynamic ratings being exceeded. Dynamic line rating schemes, by contrast,
are usually confined to assessing the rating of overhead lines under loading, ambient temperature and wind conditions,
but without the ability to control flow other than reserving a capacity margin to account for normal fluctuation in load
currents or in the extreme switching off. This means that, with the capability to load to dynamic limits, the thermal capacity
conventionally reserved to allow for normally uncontrollable fluctuations in load currents can be released for use.
Basic Principles
The loading profiles of equalisation circuits will be a combination of the difference between the connected substations
and the load on the circuit itself and may therefore be quite different in nature to that of distribution circuits, potentially
having higher peak loads but for shorter periods than conventionally loaded circuits.
Controlled loading to dynamic limits should also enable increases in the maximum sustainable short transfers to be
obtained under LV support mode transfers on interconnected networks under HV fault conditions, reducing the risk of LV
cascades.
The information being collected should allow the conductor temperature for the next 24 hours to be calculated based on
the historical and predicted load. Thus, emergency rating can be obtained forward from any point within the next 24
hours.
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Milestone 3.42 Advanced Use Cases
Identifying Dynamic Limits
The diagram below shows the FUN-LV approach to cable dynamic rating. It is based on the predicted load profile after
planned management with the SOP. It is assumed that SOP dynamic limits for the next 24 hours will be based on the
equivalent periods the previous week. This will require access to the previous week’s load and weather data and ideally
current and forecast weather data, and then refined in real time, with load being limited to the dynamic rating. PPA
Energy has a separate workstream activity to develop dynamic loading concepts and ratings.
Figure 11. Dynamic Rating Flow Chart
Loading to Dynamic Cable Limits: FUN-LV Summary
Key points about the FUN-LV approach to loading to dynamic cable limits:
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Milestone 3.42 Advanced Use Cases
•
•
•
•
During FUN-LV, the power flows within the network will be managed through the use of Soft Open Points (SOPs).
Existing cable profiles are not so important to the dynamic cable limits work; it is the transfer load profiles which are
important.
Load transfer planning will be established one day ahead then refined in real-time.
Appropriate dynamic ratings will be selected with reference to established look-up tables.
o PPA Energy has an activity to develop the methodology to produce such tables.
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Milestone 3.42 Advanced Use Cases
Advanced Use Case
Use Case
Element
Advanced Use
Case #
Application
Use Case Name
Use Case
Description
Primary Actor
Precondition
Trigger
Basic Flow
Alternate Flow
Description
3
SOP
Loading to dynamic limits
The SOP is capable of finely controlling power flow on connected feeders. This
capability can be used to ensure that the cable limit, which may be a dynamic
limit, is not exceeded, in order to release thermal capacity on the cable that is
normally reserved for contingency.
Where there is an option for a 3-port SOP to choose one feeder over another,
e.g. if one cable has a higher rate of use of life than another, then this will be
based on a weighted system using Rate of Use of Life and System Losses.
SOP
The SOP is on, i.e. transferring load or making quality of supply adjustments.
The SOP is making a transfer, or an emergency situation has been identified.
For more on emergency situations, refer to notes below the table.
The SOP has access to a lookup table on dynamic ratings – how and where the
analysis takes place is work in progress (PPA activity WS3.14)
The SOP ensures that the transfer does not result in the cable (and transformer)
load exceeding the dynamic limit.
The SOP control algorithm may determine a level of transfer required, which, if
made, would cause the cable to exceed its dynamic limit. The SOP makes the
maximum transfer possible whilst staying within the dynamic limit, and logs the
condition and duration of the constraint for performance analysis (i.e. “optimal
SOP transfer limited by dynamic cable rating”, Date and time, for xx minutes).
In emergency situations, the SOP would load the cable to a higher level for a
relatively short time to Ultimate Emergency Ratings (UER), report an alert and log
the condition and duration of the constraint (as above). Dynamic limits table to
cover normal conditions and emergency situations.
The impact of dynamic rating on rate of use of life on Teed circuits will need to be
taken account for each section of line. PPA Energy will need to think this through
in WS3.14 – but not for implementation in Version 1.
Table 4. Advanced Use Case for Loading to dynamic limits
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Milestone 3.42 Advanced Use Cases
Emergency situations
How does SOP know there is an emergency?
1. Instructed by control – There needs to be a control option to set and reset.
2. LV volts at one or more SOP ends experience abrupt and sustained significant voltage, surge or dip (driven by
the loss of other associated HV or LV circuits)
3. It sees load in excess of the normal dynamic rating and below that of its UER (Ultimate Emergency Rating)
4. It sends an alarm and continues to operate unless:
a. Instructed to stop by control
b. UER exceeded
c. ROUOL (Rate of Use of Life) exceeded for emergency rating
d. An LV fault occurs
5. Sends alarms when approach to the end of its UER time i.e. 60 mins, 30 mins, 5 mins
6. Reset after UER and records max load, period, ROUOL
7. Takes account of previous history i.e. needs to have a period to cool before more UER, but ROUOL can start
from where it left off but accounting for loading and cooling time.
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Milestone 3.42 Advanced Use Cases
5. Reverse Power Flows
Background
Radial distribution networks are usually designed on the basis of power flowing in one direction. Traditionally, power has
flowed from large generators to the transmission system, and through the distribution system to loads.
The introduction of generation and meshed systems at the distribution level can result in electricity flows in both directions
under both normal and fault conditions. Protection for such systems has been designed accordingly, e.g. with the use of
directional overcurrent relays to ensure that not only are fault currents interrupted but also to minimise the sections of
network disconnected and the number of customers interrupted by the fault (see Appendix 1 for more on Reverse Power).
Reverse power flows can be problematic if they are not considered at the design stage.
Problems can include:
• Voltages (e.g. high volts caused by Distributed Generation);
• Currents flowing in opposite direction to normal e.g. from LV to HV through transformers under both normal and
fault conditions, if their direction is unrecognised can cause sub–optimal performance or mal-operation if not
explicitly accounted for.
• Protection failures including: malfunctioning (failing to clear the fault), slow operation (due to fault current sharing
between several protection devices reducing the current available in any one protection device), and mal-grading
(causing incorrect sequence of protection device operation or tripping).
These are not problems for meshes created by LV SOPs, or for existing meshes where LV SOPs are introduced. This
is because SOPs inherently limit fault current (to their rated or dynamic load current) and should therefore not unduly
change fault current flow paths, and consequently not significantly change the speed of operation of fuses, transformer
Air Circuit Breakers (ACBs) or LV Way Circuit Breakers (CB) of the type used in Method 1.
Link Box Switches and Reverse Power Protection for FUN-LV
Reverse power flow under HV fault conditions potentially becomes an issue for Method 1 installations if:
• A substation is paralleled with two or more other substations; and
• The LV parallel is across an HV Normally Open Point (NOP).
An example HV fault scenario is shown below.
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Milestone 3.42 Advanced Use Cases
MSS
CB1
LV SS
C
CB2
LV SS
A
LV SS
B
Link box
Figure 12. Scenario for reverse power flow issues
The sequence of events is as follows:
1. A ph-ph fault occurs on the HV part of the network, between the Main Sub Station (MSS) and secondary
substation (SS) A. Note that reverse power fault currents do not arise for Phase-E HV faults2
2. The Circuit Breaker (CB2) at the MSS feeding the fault trips due to overcurrent – so if the Link Box (LB) is
configured as normally open, there is no issue (i.e. no part of the network is feeding the fault).
3. If the link box is closed, i.e. with the use of a LB switch, then the fault remains fed from MSS CB1 via LV
SS B and C, via the link box and LV SS A, with the power flowing in the reverse direction to normal through
transformer A to the HV fault.
4. In an established fully interconnected HV/LV system a transformer LV ACB has been provided with a reverse
power relay that is set to operate at twice full load current after the MSS circuit breaker has tripped and so
to disconnect the HV fault.
2
Note that for a pure phase to earth HV fault there is no zero sequence path through a DY11 transformer so the HV system will
remain energised from a live LV system but no fault current will flow. This is normal for fully interconnected HV/LV systems.
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Milestone 3.42 Advanced Use Cases
LV interconnection in networks normally designed to be operated in radial modes
LV interconnection can occur across HV normal open point breaks in systems that are normally designed to be operated
in radial modes due to temporary fusing, construction and maintenance activities and occasionally due to errors in
operation and circuit connectivity or labelling
Depending on the system design, there are two different outcomes:
1. There is a single secondary substation (SS B) in parallel with SS A, with a single set of LV fuses forming the
interconnection: The LV fuses / CB (feeding SS B) operate quickly, and disconnect the HV fault. The LV
cables and transformers are protected against thermal damage. The LV fuses at SS B are likely to operate
before the fuses at SS A due to additional load current.
2. There are two or more secondary substations in parallel with SS A (or more than one set of fuses or LV CBs
forming the parallel): The LV fuses / CBs may take up to 10 minutes to be activated, 3 in which time significant
damage could be caused to network equipment. This is because of the impedance of the LV network, and
fault and load currents are shared through the parallel paths, resulting in lower currents through protection
devices and hence much longer tripping times.
This suggests that if Method 1 (or variations thereof) is implemented in this type of network (parallel secondary
substations on different HV feeders), reverse power flows may arise during HV faults, and steps need to be taken to
protect network equipment from damage that could arise due to thermal overload.
Proposed Solution
Provision of Reverse Power Protection is being separately considered during the design stage of Method 1
demonstrations and in the specifications for associated monitoring and control equipment.
Where substations are not already provided with transformer ACBs and commissioned Reverse Power Relays, it is
proposed that:
• All the network LV ways are monitored (for all substations connected to LB switch), and the sum of the reverse
power calculated (for this purpose it is not essential that LV service ways are monitored).
• If the reverse power sum of the LV ways exceeds the full rated transformer load for more than a specified time i.e.
0.25 seconds (radial HV networks) or 0.35 seconds (meshed HV network) then:
o The LV CB(s) at that substation should be tripped on reverse power flow; and
o The status is alarmed back to control.
3
Appendix 3 of LE System Review report; 1991
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Milestone 3.42 Advanced Use Cases
•
•
Radial networks: Need to provide time for MSS HV CB protection to operate and CB to trip. This normally takes
less than 0.5 second, but allow 1 second for long circuits with slow CBs.
Meshed HV network: Similar to above, but for ring CBs and MSS HV CBs to trip normally takes less than 1 second,
but can be up to 2 seconds with slow CBs.
Radial Embedded Substations (RES)
For Radial Embedded Substations within otherwise fully interconnected areas that have with a single, presently open,
LV cable to the network that it is proposed to close with Remote Control Circuit Breakers (RCCBs), an alternative
approach to Reverse Power Protection is proposed that uses the power calculation faculties within individual Remote
Control Circuit Breakers (RCCBs).
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Milestone 3.42 Advanced Use Cases
Appendix 1 – Description of Reverse Power
Under normal operating conditions, Reverse Power Flows are those in the opposite direction to those that would be
expected to flow for a radial system operating normally. Reverse Power flows usually occur when systems are meshed
and/or when there is an excess of distributed generation over the load demanded from the circuit. At the extreme, reverse
power flows can cause substations to be “exporting”, i.e. power is being transferred from the low voltage side to the high
voltage side, rather than vice versa.
Under HV fault operating conditions:
• Reverse Power Flows are, on meshed HV systems, those that flow in the direction that a reverse power relay is
set to operate for.
• On HV/LV interconnected systems, reverse power may flow though transformers from LV to HV during either (1)
the clearance of an HV Phase to Phase fault or (2) the LV support mode for an HV Phase to Earth HV Fault.
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