Medium-voltage switchgear units WS Gas-Insulated Switchgear up to 36 kV Installation instructions Technical manual AGS 531 596-01 05/2017 Legal notices The Schneider Electric brand and all registered trademarks of Schneider Electric Industries SAS to which this guide refers are the general property of Schneider Electric SA and its subsidiaries. They are not allowed to be used for any other purpose without the written approval of the copyright owner. These guidelines and their contents and protected in accordance with the French law on the protection of intellectual property ("Code de la propriété intellectuelle français", hereinafter referred to as "the law"), the laws on the copyright of texts, sketches and models as well as trademark law. By reading these guidelines, you automatically consent to refrain from reproducing these guidelines either in whole or in part without the written approval of Schneider Electric. Reproduction for non-commercial, personal use as stipulated in the law constitutes an exception here. In addition you also consent to refraining from creating hypertext links to this manual or its contents. No rights or licenses shall be granted by Schneider Electric for personal and non-commercial use of this manual or its contents except for a non-exclusive licence for consultation in its present form and at the reader's own risk. All other rights are reserved. Electrical equipment should only be operated, maintained and repaired by suitably qualified persons. Schneider Electric assumes no liability for any consequences resulting from the use of this equipment. Since standards, specifications and models may change from time to time, all information provided in this publication is subject to confirmation. Manufacturer: Schneider Electric Sachsenwerk GmbH Rathenaustraße 2 93055 Regensburg Germany +49 (0) 9 41 46 20-0 +49 (0) 9 41 46 20-418 Service: Schneider Electric GmbH MS GIS Rathenaustraße 2 93055 Regensburg Germany +49 (0) 9 41 46 20-777 +49 (0) 9 41 46 20-776 WS Contents Contents Remarks on this manual ................................................................... 6 Purpose and target group................................................................................. 6 Reference documents ...................................................................................... 6 Terms and symbols used.................................................................................. 7 Please note ...................................................................................................... 7 Verwendete Abkürzungen ................................................................................ 8 Any questions or suggestions? ........................................................................ 8 1 Safety provisions........................................................................ 9 2 Technical Data ......................................................................... 11 3 4 2.1 Intended use ........................................................................................ 11 2.2 Applicable standards ............................................................................ 11 2.3 Environmental and operating conditions .............................................. 12 2.4 Recycling the switchgear at the end of the service life ...................... 13 Variants overview ..................................................................... 14 3.1 Single busbar panel WSA .................................................................... 14 3.2 Double busbar panel WSB ................................................................... 17 Packaging, transport, storage .................................................. 20 4.1 Shipping units....................................................................................... 20 4.2 Packaging ............................................................................................ 20 4.3 Transport .............................................................................................. 21 4.3.1 4.3.2 4.3.3 4.4 AGS 531 596-01 | 05/2017 Transport with a forklift ............................................................... 21 Transport by means of a crane .................................................. 22 Delivery ...................................................................................... 24 Storage................................................................................................. 24 3 Contents WS 5 Switchgear set up .................................................................... 25 5.1 Installation of the first switchgear panel ............................................... 25 5.1.1 5.2 Lining up additional panels................................................................... 27 5.2.1 Screw-fastening the switchgear panels................................................ 29 5.4 Installation of intermediate frame ......................................................... 32 5.4.2 5.4.3 Installation of side panel....................................................................... 38 5.6 Fastening the panels to the foundation bar .......................................... 40 5.7 Installation of busbar sections .............................................................. 41 5.7.2 4 Installation of intermediate frame for one or two current transformer modules in line with the busbar .............................. 32 Installation of the intermediate frame on the busbar end for busbar earthing switch and single or double cable connection.................................................................................. 34 Installation of intermediate frame on busbar end for one or two functional units with fully insulated busbar connection.... 36 5.5 5.7.1 7 Insert adjustable bridge elements .............................................. 27 5.3 5.4.1 6 Installation of a switchgear panel with transport device ............. 25 Standard panel (Busbar rated (service) current up to 2500 A) ............................ 41 Supplementary panel ................................................................. 43 Gas compartment and gas line concept .................................. 44 6.1 Gas compartments of WSA (Single busbar) ........................................ 44 6.2 Gas compartments of WSB (Double busbar) ....................................... 45 6.3 Gas compartment connections concept ............................................... 45 6.4 Activating the desiccant (molecular sieve), screw- fastening the mounting cover..................................................................................... 47 6.5 Evacuation of the busbar gas compartments ....................................... 49 6.6 Filling the busbar gas compartments to the rated filling pressure ........ 50 6.7 Pressure transmitter ............................................................................. 51 6.8 Attachment of the IGIS gas compartment monitoring system ............. 52 6.9 Gas pressure monitoring via pressure gauge ...................................... 53 Installation work on the switchgear .......................................... 55 7.1 Screw on the earth cable ..................................................................... 55 7.2 Screw-fasten the cover plates (Rear side of panel) ............................. 56 AGS 531 596-01 | 05/2017 WS Contents 8 9 Commissioning ........................................................................ 57 8.1 Concluding tasks .................................................................................. 57 8.2 Commissioning..................................................................................... 58 8.3 Optional high-voltage test on commissioning....................................... 59 8.4 Cable check after installation ............................................................... 62 High-voltage connection .......................................................... 64 9.1 Screw-fastening the cable iron ............................................................. 64 9.2 Cable connectors for inner cone-type connection bushings ................ 65 9.3 Cable connectors for outer cone-type connection bushings ................ 66 9.4 Fully insulated conductor bar connection ............................................. 68 9.5 Handling the Cu shields on high-voltage cables with ring core current transformers ..................................................................... 69 9.6 Current transformer in line with busbar (current measurement on the busbar).................................................. 69 9.7 Screw-fastening the dummy plug ......................................................... 70 10 Replacement of components and switchgear panels .............. 71 11 Annex ....................................................................................... 72 11.1 Auxiliary equipment .............................................................................. 72 11.2 Coating of sealing surfaces and seals ................................................. 72 11.3 Coating the contact surfaces................................................................ 73 11.4 Screw locking compound ..................................................................... 74 11.5 Specifications for screw connections ................................................... 74 AGS 531 596-01 | 05/2017 5 Remarks on this manual WS Remarks on this manual Purpose and target group This Technical Manual describes operation and maintenance of gas-insulated medium-voltage switchgear units of the WS series. Read through the manual carefully before working on the switchgear. The work described in this manual may only be performed by specialist electricians with proven experience in conjunction with the WS series (training certificate) This technical manual is a part of the product and must therefore be stored so that it is always available to people who will work on the switchgear. If the switchgear is moved to another location, this technical manual must be provided with it. This technical manual cannot describe all individual cases conceivable for the product or every customised version. For this reason only the basic assembly procedure is described. The assembly work for the relevant switchgear version is shown in detail for each required step in the enclosed assembling drawings. If information is required that is not described in this manual and the enclosed assembling drawings, please contact the manufacturing plant. As our products are subject to continuous development; we reserve the right to make changes regarding the standards, illustrations and technical data. All dimensional data in this manual are in millimetres. Reference documents Es sind die folgenden zusätzlichen Dokumente zu beachten: 6 ● Purchase agreement with the stipulations regarding the switchgear-specific equipment and the legal details ● Operating Manual WS AGS 531 591-01 ● The appropriate switchgear-specific circuit diagrams / documentation. ● the Operating Manuals of the low-voltage devices installed in the switchgear (e.g. voltage presence detecting systems, devices in low-voltage cabinet) ● The manufacturer's installation instructions for the cable connection systems connected to the switchgear ● The Switchgear Configuration „WS” ● The enclosed assembling drawings. AGS 531 596-01 | 05/2017 WS Remarks on this manual Terms and symbols used The following special messages may appear throughout this manual or on the equipment to warn of potential hazards or to call attention to information that clarifies or simplifies a procedure. This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. The addition of this symbol to a "Danger" or "Warning" safety label indicates that an electrical hazard exists which will result in personal injury if the instructions not followed. DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE NOTICE is used to address practices not related to physical injury. Please note Electrical equipment should only be operated, maintained and repaired by suitably qualified persons. Schneider Electric assumes no liability for any consequences resulting from the use of this equipment. Persons who are in possession of the skills and relevant know-how required for assembly and operation of electrical equipment and who have undergone safety training so as to be able to recognise and avoid the dangers involved shall be regarded as qualified persons here. AGS 531 596-01 | 05/2017 7 Remarks on this manual WS Verwendete Abkürzungen Ur rated voltage Ir rated operating current Any questions or suggestions? Do you have any questions or suggestions regarding this manual, or do you require further information? We always strive to provide you with the best-possible information for optimum, safe use of our products. Thus, do not hesitate to contact us if you have any recommendations, amendments or proposals for improvement. 8 AGS 531 596-01 | 05/2017 WS 1 Safety provisions Safety provisions Prior to work on the switchgear panel, always note: DANGER RISK OF FATAL INJURIES FROM ELECTRICAL VOLTAGE! ● Always disconnect and earth high voltage and supply voltage prior to removing covers and prior to assembly or maintenance work. ● Comply with the five safety rules: 1. Disconnect, 2. Safeguard against unintentional restarting, 3. Establish zero voltage, 4. Earth and short circuit, 5. Cover or shield any adjacent energised parts. Failure to heed this warning will result in fatal or serious injuries. WARNING DANGER DUE TO MOVING PARTS IN MECHANICAL DRIVES. Prior to assembly and maintenance work: ● Disconnect supply voltage. ● Relieve the energy storing device of the circuit-breaker by pressing OFFON-OFF. ● Switch on the earth-proof earthing switch. ● Do not remove the mechanisms during maintenance work. Failure to heed this warning could result in fatal or serious injuries. WARNING RISK OF INJURY DUE TO SHARP-EDGED SHEET METAL AND METAL PARTS! During assembly and maintenance work: ● Always wear the approved protective clothing in accordance with the valid accident prevention and work regulations. ● Always cover sharp edges. Failure to heed this warning could result in serious injuries. AGS 531 596-01 | 05/2017 9 Safety provisions WS Applicable standards and regulations: ● AC metal enclosed switchgear for rated voltages over 1 kV up to and including 52 kV: IEC 62271-200 ● Use and handling of sulphur hexafluoride (SF6) in high-voltage switchgear units: IEC 62271-4 ● Observe the valid accident prevention, operating and work regulations for the site. ● Erection: IEC 61936-1 / EN 505221 ● Operation of electrical switchgear: EN 50110-11 1 The relevant national standards in the country of installation must be observed. Behaviour in case of incidents or accidents: The switchgear of the WS-Series is equipped with pressure relief ports in case of an interior fault, which prevent the switchgear panels and the switchgear unit exploding. Details of building safety in case of interior faults (compressive stress of switchgear room and the necessary pressure relief openings) are not described in this technical manual. On request, pressure calculations can be drawn up for switchgear rooms with recommendations on pressure relief openings. This service is subject to a fee. Contact the manufacturing plant for further details. In case of a fire or internal faults, toxic and corrosive decomposition products may be released. Follow the accident and safety specifications at the site. In case of injuries to persons, First Aid measures must be taken. 10 AGS 531 596-01 | 05/2017 WS Technical Data 2 Technical Data 2.1 Intended use Gas-insulated WS medium-voltage switchgear units are exclusively intended for switching and distributing electrical energies. They may only be used in the scope of the specified standards and the switchgear-specific technical data. Any other utilization constitutes improper use and may result in dangers and damage. Liability Disclaimers The manufacturer shall not be held responsible for damage which occurs if ● instructions in this Technical Manual are not complied with; ● the switchgear is not operated according to its intended use (see above); ● the switchgear is assembled, connected or operated improperly; ● accessories or spare parts are used which have not been approved by the manufacturer; ● the switchgear is converted without the manufacturer’s approval, or if inadmissible parts are added. No liability is accepted for parts provided by customers, e.g. voltage transformers. 2.2 Applicable standards Series WS switchgear units are: ● metal-enclosed ● SF6-insulated ● type-tested and prefabricated ● tested for internal faults (qualification IAC) ● dimensioned for indoor installation WS switchgear units meet the following standards and regulations: AGS 531 596-01 | 05/2017 Designation Standards Switchgear IEC 62271-200 IEC 62271-1 Circuit-breaker IEC 62271-100 Earthing switch IEC 62271-102 Disconnector IEC 62271-102 Current transformer IEC 61869-2 Voltage transformer IEC 61869-3 Voltage detection systems IEC 61243-5 Protection against accidental contact, foreign bodies and water IEC 60529 Installation IEC 61936-1 Operation of electrical equipment EN 50110-1 11 Technical Data WS Degrees of protection against accidental contact and foreign objects according to IEC 60529 1 2 Main electric circuits IP65 Drives IP2X1 Low-voltage cabinet IP3X1 Cable compartment IP3X2 optional IP 52 optional Insulating gas Insulating gas acc. to IEC 60376 Type Rated pressure pre at 20 °C Sulphurhexafluorid (SF6) MPa 0,03–0,075 relativ3 refer to Chapter 6.6 "Filling the busbar gas compartments to the rated filling pressure" on page 50: 3 2.3 Environmental and operating conditions Switchgears of the WS series may not be operated except under normal operating conditions in accordance with the stipulations contained in IEC 62271-200. Operation under conditions other than these is not permitted without prior consultation with and the approval of the manufacturer. Ambient conditions (in accordance with IEC 62271-200) Temperature class 4 12 „minus 5 indoors“4 Min./max. ambient temperature °C (– 5/+40)4 Average value over 24 hours °C ≤ 354 mean rel. air humidity: 24 hour/ 1 month % (≤ 95 / ≤ 90)4 Installation altitude above sea-level m ≤ 10004 other values available on request AGS 531 596-01 | 05/2017 WS 2.4 Technical Data Recycling the switchgear at the end of the service life The switchgear contains SF6 gas. SF6 is a greenhouse gas with a greenhouse potential of 22 800 compared to CO2. ● Do not dismantle anything without prior permission. ● Do not handle SF6 gas if you are not certified for this. ● Do not allow SF6 gas to escape into the atmosphere. This is punishable under local regulations and directives (EU Directive 517/2014 for all European countries). Schneider Electric provides a complete service for the dismantling and recycling of medium voltage switchgear and SF6 gas at the end of the service life. This service complies with IEC 62271-4 and local regulations. Please contact Schneider Electric for details. AGS 531 596-01 | 05/2017 13 Variants overview WS 3 Variants overview 3.1 Single busbar panel WSA A B C D G E F Fig. 1 Single busbar panel WSA A Drive with front control panel B Circuit-breaker compartment C Busbar tank with disconnector and earthing switch D Cable test sockets 14 E Supporting structure with cable connection area F Low-voltage cabinet G IVIS voltage information system AGS 531 596-01 | 05/2017 WS Variants overview Basic modules of a WSA single busbar switchgear Circuit-breaker panel Circuit-breaker panel Circuit-breaker panel ● Circuit-breaker ● Circuit-breaker ● Circuit-breaker ● Disconnector / earthing switch ● Disconnector / earthing switch ● Disconnector / earthing switch ● Toroidal-current transformer ● Toroidal-current transformer ● Toroidal-current transformer ● Single cable connection ● Multiple cable connection ● Multiple cable connection ● flange-mounted, disconnectable voltage transformers ● disconnectable, flange-mounted voltage transformers with primary fuse protection (on request in case of 36 kV) Circuit-breaker panel Bus section coupler ● Circuit-breaker ● Circuit-breaker ● Disconnector / earthing switch ● Disconnector / earthing switch ● Toroidal-current transformer ● Toroidal-current transformer ● Single cable connection ● ● flange-mounted, disconnectable voltage transformers on the busbar lower busbar tie connection in gas-filled compartment AGS 531 596-01 | 05/2017 Bus sectionalizer ● with disconnector in the busbar run 15 Variants overview End panel Cable connection in downward direction for inner cone-type bushings size 1 – 3, or fully insulated conductor bar terminal WS End panel Cable connection in upward direction for inner cone-type bushings size 1 – 3, or fully insulated conductor bar terminal Busbar metering panel with current transformers in the busbar run A Busbar metering panel with current transformers in the busbar run and metal-enclosed voltage transformers in outgoing feeder area, connected via cable Busbar earthing with earthing switch in the busbar run A B 16 B Cable connection and earthing for work purposes on the busbar, e. g. for metal-enclosed busbar voltage transformers or cable connections. Inner conetype bushings size 1 or 2 Fully insulated conductor bar terminal forward, to busbar ends AGS 531 596-01 | 05/2017 WS 3.2 Variants overview Double busbar panel WSB H A G B F C E D Fig. 2 Double busbar panel WSB A Drive B Tank with circuit-breaker C Busbar tank 1 with disconnector and earthing switch D Busbar tank 2 with disconnector AGS 531 596-01 | 05/2017 E F G H Supporting structure and cable connection Low-voltage cabinet Cable test sockets IVIS voltage information system 17 Variants overview WS Basic modules of a WSB single busbar switchgear Circuit-breaker panel Circuit-breaker panel ● Circuit-breaker ● Circuit-breaker ● Disconnector / earthing switch ● Disconnector / earthing switch ● Toroidal-current transformer ● Toroidal-current transformer ● Single cable connection ● Multiple cable connection ● flange-mounted, disconnectable voltage transformersr Bus coupler ● Circuit-breaker ● Disconnector / earthing switch ● Toroidal-current transformer ● lower busbar tie connection in gas-filled compartment 18 Bus coupler in single-panel width with Circuit-breaker panel ● Circuit-breaker ● Disconnector / earthing switch ● Toroidal-current transformer ● Multiple cable connection ● flange-mounted, disconnectable voltage transformers ● with primary fuse protection (in case of 36 kV available on request) Bus section coupler lower busbar (busbar 1 analogous) ● Circuit-breaker ● Circuit-breaker ● Disconnector / earthing switch ● Disconnector / earthing switch ● Toroidal-current transformer ● Toroidal-current transformer ● up to max. 1250 A AGS 531 596-01 | 05/2017 WS Variants overview Circuit-breaker panel ● Circuit-breaker ● Disconnector / earthing switch ● Toroidal-current transformer ● Single cable connection ● flange-mounted, disconnectable voltage transformers on the busbar Bus sectionalizer with disconnector in the busbar run Busbar earthing with earthing switch in the busbar run A Busbar metering panel with current transformers in the busbar run and metal-enclosed voltage transformers in outgoing feeder area, connected via cable AGS 531 596-01 | 05/2017 End panel Cable connection in downward and upward arrangement, depending on the busbar position, for inner cone-type bushings size 1-3 or fully insulated conductor bar terminal A B B Cable connection and earthing for work purposes on the busbar, e. g. for metal-enclosed busbar voltage transformers or cable connections. Inner conetype bushings size 1 or 2 Fully insulated conductor bar terminal forward, on busbar ends 19 Packaging, transport, storage WS 4 Packaging, transport, storage 4.1 Shipping units ● Delivery is effected in terms of prefabricated single switchgear panels. One transport unit consists of max. 2 individual switchgear panels which are fastened to the pallet. ● The busbar compartment with three-position switch, the circuit-breaker compartment, the drive mechanisms and the supporting structures are mounted ready for connection and routine-tested. The individual busbar links are mounted on site. ● The WS series switchgear panels are delivered with the circuit-breaker set to “OFF”, the energy storing device released and the disconnector and earthing switch set to “OFF”. ● The make-proof busbar earthing switch (see Chapter 3, page 13) is supplied in position “ON”. ● The standard accessories are included. The weight of the complete transport units is specified on the packaging. 4.2 Packaging ● In case of HGV transport only, the switchgear panels are delivered on pallets with PE-protective sheeting (Fig. 3). ● For transport by sea, they are packaged in sealed aluminium film with desiccant and in a closed wooden create with a tightly sealed wooden base (including in container transport), Fig. 4. ● As air freight, the switchgear panels are packaged in wooden crates and with a protective hood (dust protection) made from PE-sheeting or in wooden crates likewise with a sealed wooden bases but without protective hoods (Fig. 4). When transporting the switchgear panels, ensure that the transport units do not shift or tilt over (nail the transport pallet to the loading bed if necessary). Observe the centre of gravity label (see Fig. 4) to help ensure safe transport. You can find the label on the packaging or on the switchgear panel. Fig. 3 Packaging in PE protective film on pallet 20 Fig. 4 Centre of gravity information on the transport unit (wooden crate for export packaging) AGS 531 596-01 | 05/2017 WS 4.3 Packaging, transport, storage Transport WARNING RISK OF SEVERE INJURIES FROM TILTED LOADING! ● The transport unit's centre of gravity is marked (see Fig. 4, page 20) and must be observed: ● Secure transport units from shifting and tilting over during transport. Failure to heed this warning could result in death, serious injuries or material damage. 4.3.1 Transport with a forklift Only transport the switchgear panel on the pallet. The forks must be located fully under the transport unit (Fig. 6). Fig. 5 Transport units must not tip over AGS 531 596-01 | 05/2017 Fig. 6 Transport with a forklift 21 Packaging, transport, storage 4.3.2 WS Transport by means of a crane WARNING RISK OF INJURY DUE TO INSUFFICIENTLY SECURED LOAD! ● Make sure the rope is strong enough to bear the weight of the panels and complies with the appropriate regulations for hoisting equipment. Failure to heed this warning could result in death, serious injuries or material damage. Crane transport of individual panels 1. Remove transport packaging (protective films). 2. Attach rope/chains to the jack rings located on the busbar tank (Fig. 7). ≥1000 NOTICE The ropes must have the following minimum lengths:: L ≥ 1,000 mm. 3. Release transport fastening device of the panel from the transport pallet 4. Lift the panel carefully with the crane. If necessary, mount transport rolling device (refer Chapter 5.1.1 as of page 25). 5. Lower the panel slowly to the floor at its place of destination. Fig. 7 Crane transport of individual panels 22 AGS 531 596-01 | 05/2017 WS Packaging, transport, storage Crane transport with coupling panels bolted togethe The use of special transport technology may be required when transporting coupling panels. Special crane traverses (Fig. 8, 1x) with adjustable wire rope tackle (Fig. 9, 2x), may be required for this purpose. These transportation aids are not included in scope of delivery NOTICE Use only lifting devices with valid CE marking! Observe in this connection the instruction sign affixed to the panel (Fig. 10). ● Requirements for the traverse: ○ Carrying capacity: min. 2000 kg ○ Length: min. 1000 mm Fig. 8 Crane traverse with adjustable safety load hook, 360° rotation Fig. 9 Adjustable wire rope tackle A Fig. 10 A Instruction sign for the necessity of crane traverses with adjustable wire rope tackle with WS coupling panels AGS 531 596-01 | 05/2017 23 Packaging, transport, storage 4.3.3 4.4 WS Delivery ● Handle shipping units carefully when unloading and unpacking them. ● Shipping units must be checked upon receipt. Any damage which may have occurred in transit must be recorded and reported to the manufacturer immediately. ● The consignment must be checked for completeness based on the shipping documents. The supplier must be notified in writing without delay about any possible deviations. Storage WARNING RISK OF SEVERE INJURIES FROM TILTED LOADING! ● Ensure sufficient load capacity and evenness of the substrate. ● Only store switchgear panels vertically and do not stack. Failure to heed this warning could result in death, serious injuries or material damage. If the panels are not set up immediately after delivery they can be stored, providing the following conditions are adhered to: ● Only store switchgear panels vertically and do not stack. ● Storage in interior rooms only. ● Switchgear panels and accessories must be sealed in an aluminium film with desiccant and packed in a wooden crate (maximum storage time of ten year from packaging date). + 40 ºC – 5 ºC Fig. 11 Schematic diagram of storage conditions 24 AGS 531 596-01 | 05/2017 WS Switchgear set up 5 Switchgear set up 5.1 Installation of the first switchgear panel 5.1.1 Installation of a switchgear panel with transport device WARNING RISK OF INJURY DUE TO TIPPING PANELS! ● Move panel by rolling it towards the installation area over the foundation bar structure parallel using the transport device. ● Pay attention to flooring ducts - risk of accidents! ● To reduce the accident hazard, have the panel rolled to the installation area over the foundation bar structure by two fitters. Failure to heed this warning could result in fatal or serious injuries. 1. Insert transport device (included under "transport aids" in Accessories) in panel supporting structure, and screw-fasten. A B Fig. 12 Insert and screw-fasten transport device in panel supporting structure A Lifting transport device B Supporting structure 2. Lower panel using the transport device. Release transport device from the panel supporting structure. 3. For the distance dimension between wall and panel, please refer to the installation plan (Fig. 14, page 26, item A). Align the rear of the panel supporting structure to the outer edge of the foundation bar structure (Fig. 14, page 26, item B). Do not yet screw-fasten the panel to the foundation bar structure. This would rule out subsequent alignment or readjustment of the panel. 4. Remove transport covers and mounting covers (Fig. 15, page 26, Pos. A and B). AGS 531 596-01 | 05/2017 25 Switchgear set up WS A B Fig. 13 Transport of panel to installation surface Fig. 14 Installation of first panel A Refer to installation B Rear of panel flush with foundation bar A B Fig. 15 A Remove transport cover B Remove mounting cover 26 AGS 531 596-01 | 05/2017 WS Switchgear set up 5.2 Lining up additional panels 5.2.1 Insert adjustable bridge elements WARNING RISK OF INJURY DUE TO TIPPING PANELS! ● Roll the individual panels to the installation area using the transport device, over the bridge elements and parallel over the foundation bar structure. ● Pay attention to flooring ducts! Risk of accidents. Failure to heed this warning could result in fatal or serious injuries. Adjustable bridge elements under "transport aids" in accessories. 1. Place bridge elements over the foundation bar design, adjust and clamp one side of the bridge elements with the foundation bar (wing nut screw coupling). 2. Move panel by rolling it towards the panel already installed leaving a distance of approx. 500 mm. A D B C Fig. 16 Lining up additional panels A Transport device B Foundation bar C Adjustable bridge elements D Transport trolley AGS 531 596-01 | 05/2017 27 Switchgear set up WS 3. Coat sealing surfaces (see Chapter 11.2, page 72). 4. Lower panel using the transport device. Release transport device from the panel supporting structure. 5. Lift panel via the four setscrews in the panel supporting structure. A B Fig. 17 „Lifting“ the panel via the four setscrews A Setscrew B Panel supporting structure 6. Insert transport trolley (included under "transport aids" in accessories) in panel supporting structure. Engage four connecting pins on the transport trolley in the left and right angular brackets of the panel supporting structure. A Fig. 18 Insert transport trolley in panel supporting structure A Panel supporting structure 28 AGS 531 596-01 | 05/2017 WS 5.3 Switchgear set up Screw-fastening the switchgear panels Assembly drawing AGSC91098-01 1. Before screw-fastening the panel to the adjacent panels or the appropriate end plate, fasten the lateral rubber profiles to the panel as shown in the assembly drawing. 2. Screw-fasten panel to the front cover and in the low-voltage cabinet to the adjacent panel or the end plate. Fig. 19 Screw-fastening of the panels on the front side AGS 531 596-01 | 05/2017 29 Switchgear set up WS 1. Coat the sealing surfaces between the busbar compartments (Fig. 20, item A) and the toroidal sealing ring (Fig. 20, item B) with SF6 multipurpose lubricant MS (see Chapter 11.2, page 72). Insert toroidal sealing ring. A B Fig. 20 Panel screw-fastening A Sealing surfaces B Sealing ring 2. Push panel to the panel already installed. 3. Lift panel via the four setscrews in the panel supporting structure (Fig. 17, page 28). 4. Release transport trolley from the panel supporting structure. 5. Align panel via the four setscrews in the panel supporting structure (see Fig. 17, page 28) with the busbar sealing surfaces. 6. Align panels with the panel front (front cover / circuit-breaker area) using a rule. 7. Screw-fasten panels to each other along the busbar sealing surfaces: a. without busbar cladding: Tighten screw couplings M8 with a torque of 36 ± 4 Nm (Fig. 21, page 31). b. with busbar cladding: Tighten screw coupling M8 (not greased) with a torque of 20 ± 4 Nm (Fig. 22, page 31). 30 AGS 531 596-01 | 05/2017 WS Switchgear set up A C B M8 x 25 36 ± 4 Nm Fig. 21 Panel screw-fastening (without busbar compartment cladding) A Panel 1 B Panel 2 C Sealing surfaces D C A B M8 x 30 20 ± 4 Nm Fig. 22 Panel screw-fastening (with busbar compartment cladding) A Panel 1 B Panel 2 C Sealing surfaces D Sealing ring AGS 531 596-01 | 05/2017 31 Switchgear set up WS 5.4 Installation of intermediate frame 5.4.1 Installation of intermediate frame for one or two current transformer modules in line with the busbar Individual components of intermediate frame in switchgear accessories. 1. Screw-fasten current transformer module with left and right adjacent panel. 2. Screw-fasten individual components of intermediate frame to each other. Tighten screw couplings M8 x 16 with a torque of 36 ± 4 Nm. A A B M8 x 16 M8 x 16 M10 x 20 Fig. 23 Top mounting, front jack ring A Jack ring B Washers A10 M10 x 20 Fig. 24 Top mounting, rear jack ring A Washers A10 3. "Draw in" setting nuts M8 to the front longitudinal sections (Fig. 25, page 33, item A and B). Screw-fasten front covers. Tighten screw couplings M8 x 16 with a torque of 36 ± 4 Nm. Insert magnetic shims. 4. Drill bore-holes Ø 10 H11 in panel supporting structure of the left and right adjacent panel. "Draw in" setting nuts M8 to the "inside" of the adjacent panels. 5. Slip completely screw-fastened intermediate frame between the two panels. Align intermediate frame with front covers along the lined-up switchgear units 6. Insert spacers (12 mm) and washers (1 mm) (Fig. 26, page 33, item A and B) between the lower longitudinal sections (Fig. 25, page 33, item D and E) and the panel supporting structure. Tighten screw couplings M8 with a torque of 36 ± 4 Nm. 7. Screw-fasten upper longitudinal sections (Fig. 25, page 33, item F and G) via two angular brackets each to the left and right adjacent panel. Tighten screw couplings M8 on front and rear jack rings with a torque of 36 ± 4 Nm. Tighten screw couplings M10 on the upper longitudinal section with a torque of 72 ± 7 Nm. 32 AGS 531 596-01 | 05/2017 WS Switchgear set up H G F A I B C D E Fig. 25 Intermediate frame A, B Front longit. sections C Lower transv. section D, E Lower longit. section J F, G H, I J Upper longit. section Upper transv. section Drilling Ø10 H11 A B M8 x 25 C Fig. 26 Bottom mounting, panel supporting structure A Space B Washer C Panel supporting structure AGS 531 596-01 | 05/2017 33 Switchgear set up 5.4.2 WS Installation of the intermediate frame on the busbar end for busbar earthing switch and single or double cable connection Individual components of intermediate frame in switchgear accessories. 1. Screw-fasten individual components of intermediate frame to each other. Tighten screw couplings M8 x 16 with a torque of 36 ± 4 Nm. A A B M8 x 16 M8 x 16 M10 x 20 Fig. 27 Top mounting, front jack ring A Jack ring B Washer A10 M10 x 20 Fig. 28 Top mounting, rear jack ring A Washer A10 2. "Draw in" setting nuts M8 to the front longitudinal sections. Screwfasten front covers. Tighten screw couplings M8 x 16 with a torque of 36 ± 4 Nm. Insert magnetic shims 3. Drill bore-holes Ø 10 H11 in panel supporting structure of the adjacent panel. "Draw in" setting nuts M8 to the "inside" of the adjacent panel. Insert spacers (12 mm) and washers (1 mm) between the lower longitudinal section and the panel supporting structure. Set in screws M 8 x 25. 4. Align intermediate frame with front covers along the lined-up switchgear units. Tighten screw couplings M8 on the lower longitudinal section with a torque of 36 ± 4 Nm 5. Screw-fasten the upper longitudinal section (Fig. 29, page 35, Pos. H) via two angular brackets to the adjacent panel. Tighten screw couplings M8 on front and rear jack ring with a torque of 36 ± 4 Nm. Tighten screw couplings M10 on the upper longitudinal section (8) with a torque of 72 ± 7 Nm. 34 AGS 531 596-01 | 05/2017 WS Switchgear set up G H F B D I A E C J Fig. 29 Intermediate frame A Side frame B Longitudinal section C, D Lower transv. sections E Lower longit. section F, G H I J Upper transv. sections Upper longit. section Drilling Ø10 H11 see Chapter 5.5, page 38. A B M8 x 25 C Fig. 30 Bottom mounting, panel supporting structure A Spacer B Washer C Panel supporting structure AGS 531 596-01 | 05/2017 35 Switchgear set up 5.4.3 WS Installation of intermediate frame on busbar end for one or two functional units with fully insulated busbar connection Individual components of intermediate frame in switchgear accessories. A B M8 x 16 M10 x 20 Fig. 31 Top mounting, front jack ring A Jack ring B Washer A10 1. Screw-fasten functional unit for fully insulated busbar connection. 2. Fasten side frames (Fig. 32, page 37, item A and B) and lower transverse sections (item C and D), upper transverse sections (item E and F) and the intermediate bar (item G) together. Tighten screw couplings M8 x 16 with a torque of 36 ± 4 Nm. 3. "Draw in " setting nuts M8 to the front longitudinal sections. Screwfasten front covers. Tighten screw couplings M8 x 16 with a torque of 36 ± 4 Nm. Insert magnetic shims. 4. Drill boreholes Ø 11 in panel supporting structure. Insert screw couplings M8 x 50. 5. Align intermediate frame with front covers along the lined-up switchgear units. Tighten screw couplings M8 on the lower longitudinal section and the intermediate bar (item G) with a torque of 36 ± 4 Nm. 6. Screw-fasten the upper longitudinal section (item H) via an angular bracket to the adjacent panel. Tighten screw couplings M8 on front jack ring with a torque of 36 ± 4 Nm. Tighten screw couplings M10 on the upper longitudinal section « with a torque of 72 ± 7 Nm. 7. Screw-fasten transverse bracket (item I). Tighten screw couplings M8 x 16 for connection to the functional unit with a torque of 36 ± 4 Nm. 8. Insert intermediate bar (item J) in side frame (item A and B) and screw-fasten it. 36 AGS 531 596-01 | 05/2017 WS Switchgear set up H E M F I K G J L C A D B Fig. 32 Intermediate frame A, B Side frame C, D Lower transv. sections E, F Upper transv. sections G Intermediate bar H Upper longit. sectionl I Transverse bracket J K L M Intermediate bar Screws M8 x 16 + Washer A10 Drilling Ø10 H11 U section for installation of side panel A B M8 x 25 C Fig. 33 Bottom mounting A Spacer B Washer C Panel supporting structure AGS 531 596-01 | 05/2017 37 Switchgear set up 5.5 WS Installation of side panel Side wall, cover, angle, U-profile and small parts are to be found in the switchgear accessories. A A M8 x 16 M10 x 20 Fig. 34 Top mounting, front jack ring A Jack ring M10 x 20 Fig. 35 Top mounting, rear jack ring A Washer A10 1. Drill holes Ø 10 H11 with the dimensions specified in the control panel support (Fig. 36, page 39, item A). Setzmuttern M8 (Fig. 37, page 39, Pos. C) "Draw in" setting nuts M8 to the "inside" of the adjacent panel. 2. Screw-down U section (Fig. 36, page 39, item B). Tighten screw couplings M8 with a torque of 36 ± 4 Nm (Fig. 37, page 39, item B). "Draw in" setting nuts M8 to U section (Fig. 37, page 39, item D. 3. Screw-fasten clip to rear and front jack ring. Tighten screw couplings M8 with a torque of 36 ± 4 Nm. 4. Screw-fasten angular bracket (Fig. 36, page 39, item C) to the two clips. Tighten screw couplings M10 with a tightening torque of 72 ± 7 Nm. "Draw in" setting nuts M8 to angular bracket. 5. Screw-fasten side panel (Fig. 36, page 39, item D). Tighten screw couplings M8 with a tightening torque of 36 ± 4 Nm. 6. Screw-fasten cover (Fig. 36, page 39, item E). Tighten screw couplings M8 with a tightening torque of 36 ± 4 Nm. 7. If the side panel is being installed with IGIS module, the cover (Fig. 36, page 39, item E) is screwed down after laying the transmitter signal lines. 8. Close boreholes in side panel and cover using caps Ø 32 mm. 38 AGS 531 596-01 | 05/2017 WS Switchgear set up C E D A B Fig. 36 Installation of side panel A Panel supporting structure B U section C Angular bracket D Side wall E Cover C D A B E Fig. 37 Bottom mounting, panel supporting structure A Panel supporting structure B Screw M8 x 12 C Adjusting nut in the adjacent panel D Adjusting nut in the U-profilel E Side panel AGS 531 596-01 | 05/2017 39 Switchgear set up 5.6 WS Fastening the panels to the foundation bar 1. Before fastening the panel, make sure that all the previous steps have been accomplished. 2. Drill four fastening points Ø 8.5 mm through the panel supporting structure in the foundation bar. Tap a thread M10. 3. Slip any required shims in directly besides the fastening points. Relieve setscrews (turn back). 4. Screw-fasten panel supporting structure with foundation bar. Tighten screw couplings M10 with a minimum torque of 40 Nm (applies only to ratchet bolts with a sufficient thread depth of 8 mm). D B C A Fig. 38 Fastening the panels to the foundation bar A Panel supporting structure B Fastening point C Set screws D Screw M10 x L (Length L is dependent on the strength of the straightening tool profile) 40 AGS 531 596-01 | 05/2017 WS Switchgear set up 5.7 Installation of busbar sections 5.7.1 Standard panel (Busbar rated (service) current up to 2500 A) Bushings, busbar sections and hardware in switchgear accessories. In case of busbar compartment cladding, coat grooves in bushing, in flange, and toroidal sealing rings with SF6 multi-purpose lubricant MS (refer to Chapter 11 from page 72). The individual cladded compartments are sealed optimally against each other by means of toroidal sealing rings and coating with SF6 multi-purpose lubricant MS. 1. Insert toroidal sealing rings. Screw down bushings and flanges. Tighten screw couplings M6 with a torque of 8 ± 1 Nm 2. Coat contact surfaces with contact lubricant KL (refer to Chapter 11 from page 72). Contact surfaces must not get into contact with screw locking compound LOCTITE®. If the two agents are mixed, contact will be impaired. 3. Wet threads with screw locking compound LOCTITE® (refer to Chapter 11 from page 72) 4. Insert busbar sections, taking account of the installation position of the two disc springs located on either side, "center" between the bushings and screw down. Tighten screw couplings M10 with a torque of 10 Nm. 5. The busbar is screw-fastened to a post insulator on the left and right end panels, and in the case of bus coupler panels. 6. Check disconnector blades for "hitting" the fixed contact on the busbar (for switching on the disconnector, refer to the operating instructions AGS 531 591-01). Due to the jerky movements of the disconnector blades, it may not be possible to adhere to the dimension 5 +2/-4 . The following setting is admissible in these cases: If the distance at 9.5 revolutions of the actuating crank amounts to ≤ 10 mm, then the disconnector blade may touch the stop of the contact during the last 0.5 revolution of the actuating crank. AGS 531 596-01 | 05/2017 41 Switchgear set up WS 2000/2500 A ▲ 1250/1600 A 1) B 2/-4 5+ ▲ ■ A 1250 A ● C Fig. 39 Installation of busbar sections; drawing shows central panel, viewed from the mounting cover A Scew M6 x 25; tightening torque of 8 ± 1 Nm B Scew M8 x 25; tightening torque of 20 ± 2 Nm C Disc spring 1) only with bus bar comp. dadding ▲ Contact lubricant KL ■ SF6- Multi-purpose lubticant MS ● 42 Screw locking compound LOCTITE® AGS 531 596-01 | 05/2017 WS 5.7.2 Switchgear set up Supplementary panel (Current transformer module in line with the busbar) Bushings, busbar sections and hardware in switchgear accessories. 1. Remove mounting cover from the chamber. 2. Screw down bushings and flanges. 3. Coat contact surfaces with contact lubricant K (refer to Chapter 11 from page 72). Contact surfaces must not get into contact with screw locking compound LOCTITE®. 4. Wet threads with screw locking compound LOCTITE® (refer to Chapter 11 from page 72). 5. Insert busbar sections, "center" between the bushings and screw down. Transition resistance measurement of busbar screw fastening Comply with the manufacturer’s specifications regarding the contact resistance measuring unit. 1. Measure transition resistance R between the individual busbar sections with 100 A DC. Busbar rated (service) current [A] Approximate values Resistance R [μΩ] 1250 25 1250/1600 17 2000/2500 9 2. The measured resistance values should be comparable. If one value exceeds the average of the other measured values by max. 20 % or more, undo busbar screw fastening; clean contact surfaces carefully and repeat the mounting procedure. AGS 531 596-01 | 05/2017 43 Gas compartment and gas line concept WS 6 Gas compartment and gas line concept 6.1 Gas compartments of WSA (Single busbar) 1. The gas compartments of circuitbreakers and busbars are separated. The cladded compartments of the individual panels are interconnected by piping and, if necessary, can be disconnected from the gas compartment of the switchgear in question. Non-cladded gas compartments, e.g. busbar gas compartment of the WSA type and circuit-breaker gas compartment of the WSA without cladding, form a common gas compartment. 2. At the left end panel, or - in case of switchgear equipped with bus coupler - on the left and right end panel, pressure transmitters are installed which transmit the measured values to IGIS via signal lines. 3. A gas compartment diagram is available in the switchgear's "info" tray. P2 A P1 Fig. 40 Gas compartments of WSA Busbar compartments not cladded P1 Busbar gas compartment P2 Circuit-breaker gas compartment A Pressure transmitter 44 AGS 531 596-01 | 05/2017 WS 6.2 Gas compartment and gas line concept Gas compartments of WSB (Double busbar) The gas compartments of the switchgear panels are connected by piping and can be disconnected from the switchgear's gas compartments, if necessary. P2 A P3 P1 Fig. 41 Gas compartments of WSB: P1 Busbar gas compartment P2 Busbar gas compartment P3 Circuit-breaker gas compartment A Pressure transmitter 6.3 Gas compartment connections concept Connecting busbar gas lines (only in case of busbar compartment cladding) Refer to gas compartment diagram! 1. Remove yellow protective caps. Screw-fasten "bus lines" of the individual busbar gas compartments to one another taking account of the gas compartment diagram. Minimum tightening torque for gas line screw coupling: 20 Nm. 2. To prepare for evacuation of the busbar gas compartments, disconnect all gas lines connecting the switchgear's busbar chambers to the "bus line". Connecting circuit-breaker gas lines 1. Remove yellow protective caps. Screw-fasten "bus lines" of the individual circuit-breaker gas compartments to one another taking account of the gas compartment diagram. 2. Connect circuit-breaker gas lines of the individual circuit-breaker chambers with the "bus line". Minimum tightening torque for gas line screw coupling: 20 Nm. AGS 531 596-01 | 05/2017 45 Gas compartment and gas line concept WS B A B A Fig. 42 Gas line, panel WSA with busbar compartment cladding A Busbar B Circuit-breaker A A Fig. 43 Gas line, panel WSA without busbar compartment cladding A Circuit-breaker C B C B A A Fig. 44 Gas line, panel WSB A Busbar 1 B Busbar 2 C Circuit-breaker 46 AGS 531 596-01 | 05/2017 WS 6.4 Gas compartment and gas line concept Activating the desiccant (molecular sieve), screwfastening the mounting cover Activate desiccant Clean busbar gas compartments including mounting parts, removing loose particles such as abrasion, paint, dust or precipitated moisture by means of a dry, non-fibrous cloth. 1. The desiccant bag is located below the mounting orifice underneath a cover. 2. Tear open polybag by piercing several holes in the cover using a chisel or a similar tool. NOTICE Screw-fasten the mounting cover immediately after activating the desiccant (see Fig. 45). A B Fig. 45 Activating the desiccant A Desiccant bag B Cover Screw-fasten mounting cover The welding bolts on the busbar chamber must not get into contact with SF6 multi-purpose lubricant MS. 1. Coat the sealing surfaces on the busbar chamber, the mounting cover and the toroidal sealing ring with SF6 multi-purpose lubricant MS (refer to Annex, Chapter 11 from page 72). Insert toroidal sealing ring. NOTICE Screw-fasten the mounting cover immediately after activating the desiccant (see Fig. 45). 2. Screw-fasten mounting cover. The following tightening torques apply to screw couplings M8: a. Steel cover, hex. nut with ratchet 14 +2/-1 Nm. b. Aluminium cooler cover, hex. nut without ratchet 8 +2/-1 Nm. AGS 531 596-01 | 05/2017 47 Gas compartment and gas line concept WS ■ A ■ ■ Fig. 46 Screw-fastening the mounting cover A Mounting cover ■ ■ 48 SF6 - Multi-purpose lubricant MS not lubricated AGS 531 596-01 | 05/2017 WS 6.5 Gas compartment and gas line concept Evacuation of the busbar gas compartments Refer to gas compartment diagram. Normally, the filling and extraction valves for the busbar gas compartments and the circuit-breaker gas compartments are located on the last but one panel. DANGER RISK OF FATAL INJURIES FROM ELECTRICAL VOLTAGE! ● The switchgear must not yet be energized! Failure to heed this warning will result in fatal or serious injuries. Evacuate the busbar gas compartments of the entire switchgear to ≤ 1 kPa abs.. C B C D A B A Fig. 47 Filling and extraction valve for the circuit-breaker compartment A Cap B Filling and extraction valve C Circuit-breaker gas compartment AGS 531 596-01 | 05/2017 Fig. 48 Filling and extraction valve for busbar gas compartment A Rear wall of switchgear panel B Cap C Filling and extraction valve D Busbar gas compartment 49 Gas compartment and gas line concept 6.6 WS Filling the busbar gas compartments to the rated filling pressure The pressure data are referred to +20 °C and an absolute atmospheric pressure of 0.1013 MPa. Rated filling pressure, refer to name plate: pre 0,03 MPa rel. pre 0,05 MPa rel. pre 0,075 MPa rel. 1. Switch service instrument over to "filling" mode. Connect gas filling device. 2. Insert insulating gas until the rated filling pressure is reached. Watch rated filling pressure on secondary pressure gauge of the gas refilling device 3. Disconnect gas refilling device. After approx. 24 hours: Leakage test by means of leakage detector A test for leakage is required whenever gas-tight flange couplings have been made. 1. Use a leakage detector. Observe the instructions of the leakage detector's manufacturer. 2. Check the flange couplings mounted during installation by holding the leakage detector close to them. The flange coupling's tightness is ensured if the leakage detector does not react. Dew point measurement of the insulating gas 1. Use a dew point measuring device. Observe the instructions of the manufacturer of the dew point measuring device. 2. Connect dew point measuring device to a filling valve. The measuring procedure is described in the operating instructions for the dew point measuring device. The dew point temperature must not be higher than –15 °C. 3. Disconnect dew point measuring device. Screw-fasten cap on filling valve. 50 AGS 531 596-01 | 05/2017 WS 6.7 Gas compartment and gas line concept Pressure transmitter The pressure transmitters are included in separate packaging in the switchgear accessories. 1. Remove the caps from the filling and extraction valves taking account of the gas compartment diagram, and fasten the pre-assembled pressure transmitters. Coat sealing rings with SF6 multi-purpose lubricant MS (refer to "Annex", Chapter 11 from page 72). 2. Lay signal line in cable duct of the side panel. 3. Non-used cable lengths must be wound up and fastened to the side panel using cable clips. 4. Connect signal lines to IGIS. Fig. 49 Pressure transmitter A B Fig. 50 Mounting of pressure transmitter Example: WSA with busbar compartment cladding A Pressure transmitter for circuit-breaker gas compartment B Pressure transmitter for busbar gas compartment AGS 531 596-01 | 05/2017 51 Gas compartment and gas line concept 6.8 WS Attachment of the IGIS gas compartment monitoring system The gas compartment monitoring system IGIS and hardware are included in separate packaging in the switchgear accessories. 1. Open flap for IGIS (magnetic plate). 2. Insert IGIS and attach the clips on the left and right rear sides; tighten by means of a screw driver. 3. Wiring to Phoenix plug-and-socket connections according to the switchgear's circuit diagrams. 4. Connectors of the signal cables to the pressure measuring points in question on the IGIS (P1 - P3). 5. Close non-used inputs using a cover. A C B Fig. 51 Installation and connection of IGIS A Side panel B Fastening clamps, left and right C Signal lines to the pressure transmitters 52 AGS 531 596-01 | 05/2017 WS 6.9 Gas compartment and gas line concept Gas pressure monitoring via pressure gauge As an alternative to the IGIS gas compartment monitoring system, there are switchgear models with ambient-temperature compensated pressure gauges. Each circuit-breaker compartment and the combined busbar gas compartments are connected to a pressure gauge each. The pressure data are referred to +20°C and indicated as absolute values. B A C D Fig. 52 Pressure monitoring A Pressure gauge (pressure measuring device) for circuit-breaker gas compartment B Filling and extraction valve with cap (circuit-breaker gas compartment) C Pressure gauge for busbar section, right-hand D Filling and extraction valve with cap (busbar section, right-hand) A B D C Fig. 53 Pressure monitoring A Front shutter B Gas line, circuit-breaker gas compartment C Gas line, busbar gas compartment D Feeder, low-voltage cubicle AGS 531 596-01 | 05/2017 53 Gas compartment and gas line concept WS Pressure indication on pressure gauge The pressure indication on the pressure gauge is ambienttemperature compensated, i.e. the pressure indicated corresponds to a temperature of 20 °C in the switchgear room. The pressure indication remains constant if the operating mode remains unchanged, even if the temperature in the switchgear room changes. Signalling contact Switching functions 1 closes if pre-alarm is reached during pressure drop 2 closes if main alarm is reached during pressure drop 3 (optional) closes, if the warning level is reached on pressure increase Setting according to customer’s specification. B C D A Fig. 54 Pressure monitoring A Pressure gauge (pressure measuring device) for circuit-breaker gas compartment B Pressure gauge (pressure measuring device) for circuit-breaker gas compartment C Pressure gauge for busbar section, right-hand D Filling and extraction valve with cap (busbar section, right-hand) A B Fig. 55 Pressure monitoring A Front shutter B Gas line, circuit-breaker gas compartment 54 C C Gas line, busbar gas compartment AGS 531 596-01 | 05/2017 WS Installation work on the switchgear 7 Installation work on the switchgear 7.1 Screw on the earth cable Sections of the earth conductor, plates and hardware included in switchgear accessories. 1. Coat contact surfaces on earth connector (underside of busbar chamber), plate and section of earth conductor with contact lubricant KL (refer to "Annex", Chapter 11 from page 72). 2. Screw-down plate. Tighten screw couplings M8 with a torque of 20 ± 2 Nm. 3. Screw-down section of earth conductor. Tighten screw couplings M10 with a torque of 40 ± 4 Nm. 4. Connect earth conductor of switchgear to earth conductor of the switchgear building (this connecting line is not included in the scope of supplies). Fig. 56 Mounting the earthing bus to the busbar compartment busbar 1 A Fig. 57 Attachment of earthing bus line to busbar compartment busbar 1 A Fold out swing frame AGS 531 596-01 | 05/2017 Fig. 58 Connecting external control lines 55 Installation work on the switchgear WS External control lines Cable clips, screws, spring washers etc. are not included in the scope of supplies 1. Remove transport securing device (screw coupling M6) from the swing frame. 2. Fold swing frame out. Introduce external control lines to the cable irons through the opening in the base plate. Fix external control lines to cable iron using cable clips. 3. Connect wires to terminals according to diagram. 7.2 Screw-fasten the cover plates (Rear side of panel) Screw-fasten cover plates to the rear of the panel supporting structure (cover plate and hardware are included in the switchgear accessories). Fig. 59 Screw-fastening the cover plate 56 AGS 531 596-01 | 05/2017 WS Commissioning 8 Commissioning 8.1 Concluding tasks DANGER RISK OF FATAL INJURIES FROM ELECTRICAL VOLTAGE! ● Ensure the high-voltage is not connected. ● All live parts must be earthed Failure to heed this warning will result in fatal or serious injuries. NOTICE If you discover irregularities, errors or malfunctions, do not put the switchgear into operation, but notify the manufacturer's works instead. Clean and check assembly work 1. Clean the switchgear to eliminate soiling due to assembly work. 2. Remove all the attached information tags, cards, brochures and instructions no longer needed. 3. Check whether all parts have been reattached which were unbolted while work was being performed at the construction site: a. High voltage connection b. Earth cable c. Panel screw fastenings d. Busbar links. Damaged paint The components are powder-coated. Minor paint damage can be retouched with commercially available lacquer, in accordance with the customer-specific version. Checking AGS 531 596-01 | 05/2017 ● Check the switchgear for damage which might be due to transport or assembly work. ● Comparea data on the nameplate to the required ratings. ● Check supply voltage of the control and operating devices. ● Check wiring laid on the site. ● Check insulation gas monitoring and rated filling pressure indication on the IGIS/pressure gauge. 57 Commissioning 8.2 WS Commissioning DANGER RISK OF FATAL INJURIES FROM HIGH VOLTAGE! ● Ensure the high-voltage is not connected. ● All live parts must be earthed Failure to heed this warning will result in fatal or serious injuries. NOTICE ● Refer to the operating manual of the WS series (AGS 531 591-01). ● While the power supply is not available, blocking coils (locking the interrogation lever and circuit-breaker push-button, depending on design), are in “locked” position. An undervoltage release (optional) has dropped out. In this case, first perform items 3 to 5. ● The energy storing device of the circuit-breaker drive mechanism is charged automatically, as soon as the power supply is available. 1. Perform manual switching trials on the individual switching devices. 2. Check position indicators. 3. Apply supply voltage. 4. Check electrical functions of control and operating devices: a. Motor drives of disconnectors and earthing switches (optional) b. Perform manual switching trials on the individual switching devices 5. Check position indicators and interlocks. 6. Before connecting, check the connected feeder cables for phase coincidence (see Operating Manual AGS 531 591-01). 58 AGS 531 596-01 | 05/2017 WS 8.3 Commissioning Optional high-voltage test on commissioning General Optionally, the busbar can be subjected to a power frequency withstand test. The test voltage is supplied via the high-voltage terminal of a panel. To this effect, a test unit and test cables are required, which are not included in the scope of supplies. DANGER RISK OF FATAL INJURIES FROM HIGH VOLTAGE! Im zur Spannungsprüfung genutzten Feld sowie an der Sammelschiene dürfen keine Hochspannungskabel angeschlossen sein. ● No high-voltage cables must be connected in the incoming feeder panel for the voltage test and to the busbar. ● All high-voltage terminals must be closed surge-proof during the test phase. ● Earth the residual phases using commercially available earthing devices. Failure to heed this warning will result in fatal or serious injuries. Also observe the operating and installation instructions of the testing device manufacturer while doing so. AGS 531 596-01 | 05/2017 59 Commissioning WS Preparations 1. All panels must be isolated from the power supply, and earthed. 2. Incoming feeder panel for voltage test: a. Remove the cable compartment cover. Mount test cable to a phase of the high-voltage terminal. Open high-voltage terminals must be closed surgeproof during the test phase. Earth the residual phases using commercially available earthing devices. b. Earth the voltage transformers and capacitive measuring connectors. Disconnect the surge arrester. D 7 G B A C F E Fig. 60 A Outgoing feeder panels B Incoming feeder panel for voltage test C Voltage transformer D Busbar E Test unit (e g. high-voltage source, test transformer) F Test cable(s) G Busbar voltage transformer 3. Busbar: a. Earth voltage transformer / surge arrester. b. Earth capacitive measuring connectors. c. Close open high-voltage terminals in a surge-proof fashion. 60 AGS 531 596-01 | 05/2017 WS Commissioning Power frequency withstand test: 4. Power frequency withstand test of the busbar: a. Connect test unit to the test cable. b. Switch earthing switch in the incoming feeder panel OFF. c. Switch disconnector and circuit-breaker in the incoming feeder panel ON. d. Perform power frequency withtstand tests successively for all phases (L1, L2, L3) according to the specifications of the test unit manufacturer. NOTICE Observe admissible test values for the switchgear and the admissible test values for power frequency withstand tests after installation of the switchgear in accordance with IEC 62271-200. 5. Once the power frequency withstand test has been completed, earth all the tested high voltage lines again. Comply with the applicable safety provisions! Once the power frequency withstand test has been completed: 6. Once the power frequency withstand test has been completed a. remove the test unit and the test cable, b. reconnect earthed or removed voltage transformers, capacitive measuring connectors or surge arresters, c. mount high-voltage cables or surge-proof covers on the incoming feeder panel and reinsert cable compartment cover. AGS 531 596-01 | 05/2017 61 Commissioning 8.4 WS Cable check after installation Perform cable tests on the rear test connectors (see Fig. 61). Fig. 61 Perform high-voltage cable test via rear-side test adapters DANGER RISK OF FATAL INJURY FROM ARC FAULT! Protection against arc fault is limited due to the arrangement of the test sockets on the rear side. Switchgear panels with operating voltage at the busbar are therefore to be found under maintenance conditions during the cable inspection ● Define and cordon off safety distances prior to the cable inspection. ● Maintain safety distances during the cable inspection. ● The system operator is under obligation to provide a professional cable inspection. Failure to heed this warning will result in fatal or serious injuries. A test unit and a test adapter are required for the cable inspection which are not included in the scope of delivery. NOTICE ● The busbar can be operated with rated voltage during cable tests in the outgoing feeder (see nameplate). ● Observe the assembly and test instructions for the cable fittings and the terminating connectors! 1. Isolate the outgoing feeder cable of the appropriate switchgear panel from the power supply. 2. Isolate outgoing feeder cable in the remote station. 3. Earth the outgoing feeder cable. 4. Disconnect the following devices or earth them if this is envisaged: a. Pluggable voltage transformers b. Pluggable surge arresters c. Measuring amplifiers for capacitive voltage measurement. 62 AGS 531 596-01 | 05/2017 WS Commissioning If non-detachable voltage transformers (connected via cable) are used, these must be disconnected on the switchgear end and the sockets must be closed “surge-proof” using dummy plugs. 5. Remove the test connector's dummy plugs. 6. Connect the test adapter/test cable to test sockets and test unit (observe the manufacturer’s instructions). Panel in test position: NOTICE Make sure that the distance between the metallic components of the test setup and the earthed switchgear supporting structure is sufficiently dimensioned. 7. Panel in test position: In case of the intertripping circuit, the circuit-breaker is switched off by actuation of the earthing switch towards “OFF”: a. Turn interrogating lever "earthing switch" and insert crank. b. Turn crank counter-clockwise by 1 turn, until the circuit-breaker has switched OFF. Thus, the test position has been reached. 8. Perform cable test according to the specifications of the manufacturer of the cable or the cable connector. Once the cable test has been completed 9. Re-earth outgoing feeder cable: a. Switch earthing switch completely OFF b. Charge energy storing device c. Switch earthing switch ON again 10. Re-connect the disconnected devices. 11. Remove test set and close test socket “surge-proof” using the dummy plug. Cable test from the opposite side with the cables connected, on the WS switchgear: For test set-up and implementation, refer to the instructions of the cable manufacturer. Refer to items 1-4 and 7-10 of this section! Admissible limits for the switchgear panels in case of cable tests 1 AGS 531 596-01 | 05/2017 UO/U (Um)1 [kv] DC test voltage for initial / repeat test [kV] max. 15 min 0.1 Hz AC test voltage [kV] max. 60 min 40–65 Hz AC test voltage [kV] max. 60 min 6/10 (12) 34 18 12 12/20 (24) 67 36 24 18/30 (36) 76 54 36 Description U0/U (Um): HD 620/621 S1 or IEC 60502-2 63 High-voltage connection WS 9 High-voltage connection 9.1 Screw-fastening the cable iron Cable irons, angular brackets and hardware are included in switchgear accessories. ● Insert cable irons and angular brackets in panel supporting structure, and screw them down Connector bushings Outer cone-type or inner cone-type sockets acc. to EN 50181 are standard equipment of the panels. Available connection types: see Switchgear Configuration. NOTICE ● Cable connectors, tools, accessories (cable clips, screws, spring washers etc.) are not included in the scope of supplies. ● Mount cable connectors according to the mounting instructions of the cable connector's manufacturer. While mounting the cable connectors, observe the specified tightening torques. ● When shrink-fitting cable boxes, make sure that the cable connection area of the panel is not heated beyond the admissible service temperature. ● We cannot accept any liability for consequential damage (charred cables of the capacitive indicator) which might result from shrinkfitting components in the cable connection compartment using an open flame. DANGER RISK OF FATALITIES DUE TO HIGH VOLTAGE! he transport protection caps located on the high-voltage terminals by the factory are not surge-proof. ● Prior to commissioning, the transport protection caps must be replaced by surge-proof caps. Failure to heed this warning will result in fatal or serious injuries. 64 AGS 531 596-01 | 05/2017 WS 9.2 High-voltage connection Cable connectors for inner cone-type connection bushings 1. Remove grease and silicone from appliance couplers using a cleaning agent (refer to "Annex", Chapter 11 as of page 72). 2. Mount cable connector according to the instructions of the cable connector manufacturer. Insert cable connector in inner cone-type connection bushing (press down) and screw-fasten safely. Tighten screw couplings M8 with a torque of 15 ± 3 Nm. A B NOTICE After the cable connector has been inserted and screwed down, no cantilever loads and torsional forces must act on the inner conetype connection bushing (risk of damage to the inner cone-type connection bushing). 3. If necessary, re-adjust cable iron, align cables and fasten them to the cable iron using cable clips. C Abb. 62 Example of cable connector for inner cone-type coupler, make Pfisterer, system CONNEX A Cable clip B Adjustable cable iron C Earth conductor Connector shell with conductive contact surface with reference to switchgear's metal enclosure: If the metallic connector shell features a conductive surface in contact with the metal cladding of the switchgear (this applies for the Pfisterer brand, system CONNEX), the cable's Cu shield must not be connected to the connector shell (contacting). If for operational reasons it is not possible to provide an insulation between the cable's Cu shield and the connector shell, consult the manufacturer. 1. Coat contact surfaces of earth connection (cable's Cu shield) withcontact lubricant KL (refer to "Annex", Chapter 11 as of page 72). 2. Screw-down Cu shield of cable to cable iron. 3. Close unused inner cone-type connection bushings with surgeproof dummy plugs. AGS 531 596-01 | 05/2017 65 High-voltage connection 9.3 WS Cable connectors for outer cone-type connection bushings 1. Mount cable connector according to the instructions of the cable connector manufacturer. Torque for tightening the cable connection (flat termination) to the outer cone-type connection bushing (thread M16): max. 50 Nm. NOTICE If the cable connector's manufacturer specifies a different tightening torque, the latter must be used. Do not use tightening torques exceeding 50 Nm. 2. Slip cable connector onto outer cone-type connection bushing, and screw it down. Tighten screw couplings M8 with a torque of 10 ± 2 Nm. NOTICE After the cable connector has been slipped on and screwed down, no cantilever loads and torsional forces must act on the outer conetype connection bushing (risk of damage to the outer cone-type connection bushing). 3. If necessary, re-adjust cable iron, align cables and fasten them to the cable iron using cable clips. 4. Coat contact surfaces of earth connection (cable connector shell and cable Cu shield) with contact lubricant KL (refer to "Annex", Chapter 11 as of page 72). 5. Screw-down earth connection of cable connector shell and Cu shield of cable to cable iron. 6. Close non-used outer cone-type connection bushings with surgeproof caps. 66 AGS 531 596-01 | 05/2017 WS High-voltage connection Connector for belted cable (only up to 24 kV) for outer cone-type connection bushing Mount hose-type cable box and connecting adapter according to manufacturer's mounting instructions. A B A B C C Fig. 63 Example of cable connector for outer cone-type coupler, make KABELRHEYDT, type AGG 20/400 (plug-in contact) A Cable clip B Adjustable cable iron C Earth conductor AGS 531 596-01 | 05/2017 Fig. 64 Example of belted cable for outer cone-type coupler, make F&G, type SKV 10D A Connecting pin B Connecting adapter C Adjustable cable iron 67 High-voltage connection 9.4 WS Fully insulated conductor bar connection To verify precise contacting of the fully insulated conductor bar, remove circuit-breaker module (refer to operating instructions AGS 531 591-01). Fully insulated conductor bars, rings and hardware included in switch-gear accessories. 1. Remove cover (blanking cover). 2. Mount fully insulated conductor bar according to mounting instructions of the manufacturer. 3. Check precise contacting between round conductor and fully insulated conductor bar. 4. Insert desiccant. 5. Screw-fasten circuit breaker module and fill it to rated filling pressure (refer Chapter 6.6, page 50). A Fig. 65 Example of fully insulated conductor bar connection, make Meßwandlerbau, system DURESCA A Screw M8 x 40; Tightning torque 20 ± 2 Nm 68 AGS 531 596-01 | 05/2017 WS 9.5 High-voltage connection Handling the Cu shields on high-voltage cables with ring core current transformers 1. Coat contact surfaces of earth connection (Cu shield) with contact lubricant KL refer to "Annex", Chapter 11 as of page 72). A B C 2. Route earth connection (Cu shield) of the conductor in question (L1, L2 and L3) directly on the high-voltage cable to the cable current transformer on the insulated earth return bar, and screw-fasten it. 3. Route return line of earth connection bus line (in terms of PE conductor SL, marked in yellow/green) from the opposite earth return bar of the cable current transformer to the cable iron over the shortest distance, and screw it down. Fasten Cu shield to the conductor using an insulating tape or a cable clip. 9.6 D E F G Fig. 66 Fundamental drawing: handling the Cu shields on the high-voltage cables with ring core current transformers A Cabel connector B Cu shield C Cable clip (insulating tape) D Earth return bar E Ring core CT F Earth shield bus cable (SL) G Cable iron Current transformer in line with busbar (current measurement on the busbar) Trailing cables ready for installation included in switchgear accessories. 1. Take account of obligatory assembly drawing. 2. Remove transport protective caps from the connection bushings (socket-contacts). 3. Mount cable connector according to the instructions of the cable connector manufacturer. Insert cable-con-nector in inner cone-type connection bushing (press down) and screw-fasten safely. Tighten screw couplings M8 with a torque of 15 ± 3 Nm. NOTICE After the cable connector has been inserted and screwed down, no cantilever loads or torsional forces must act on the inner conetype connection bushing (risk of damage to the inner cone-type connection bushing). 4. If necessary, re-adjust cable iron, align cables and fasten them to the cable iron using cable clips. AGS 531 596-01 | 05/2017 69 High-voltage connection 9.7 WS Screw-fastening the dummy plug NOTICE Close unused outer or inner cone-type connection bushings with surge-proof dummy plugs (surgeproof dummy plugs are not included in the scope of supplies). Surge-proof dummy plugs are available from the manufacturer of the cable connection system. 1. Remove transport protection cap (made of plastic). 2. Screw-fasten the dummy plug. A B Fig. 67 Example of dummy plug for inner conetype connection bushing A Transport protection cap B Dummy plug 70 AGS 531 596-01 | 05/2017 WS 10 Replacement of components and switchgear panels Replacement of components and switchgear panels Drives, transformers, voltage transformers, testing and monitoring systems and entire switchgear panels can be exchanged if necessary. Should you have any queries regarding replacement of components or panels, please contact the manufacturer’s Service Centre. In order for your queries to be processed correctly, the following information is required from the rating plate of the switchgear concerned (see "Rating plate" chapter in operating instructions AGS 531 591-01). AGS 531 596-01 | 05/2017 ● Type designation ● Serial number ● Year of construction 71 Annex WS 11 Annex 11.1 Auxiliary equipment CAUTION DANGER OF INJURY FROM INCORRECT HANDLING OF AUXILIARY EQUIPMENT! ● Observe the safety data sheets for the auxiliary equipment. Failure to heed this warning could result in injuries and material damage. Auxiliary products Ref. no. Cleaning product: Surfaces in gas tanks (white spirit, 0.5 l) Surfaces outside of gas tanks (bottle 1 l) S009002 S008152 Synthetic lubricant (KL), 0.5 kg can ST312-111-835 SF6 multi-purpose lubricant MS, 0.75 kg can ST312-109-847 Screw locking compound LOCTITE ® S008329 Touch-up pen (specify colour shade) S009562 The auxiliary products are available from the manufacturer. The use of other auxiliary products is not admissible. 11.2 Coating of sealing surfaces and seals NOTICE Sealing surfaces, once coated with SF6 multi-purpose lubricant, should not be touched, if possible. Any contamination may impair function (leakage). 1. Sealing surfaces, seals (cord sealing rings) and grooves for cord sealing rings must be cleaned with particular care using cleaning agent for insulating gas compartments and a lint-free cloth. 2. Check visually for cleanness. 3. Immediately afterwards, apply SF6 multi-purpose lubricant MS using a nylon brush or a leather cloth. 4. Use the nylon brush or the leather cloth only for this work and store them in a place where they are protected against soiling. 72 AGS 531 596-01 | 05/2017 WS 11.3 Annex Coating the contact surfaces NOTICE Contact areas, once coated with synthetic lubricant (KL), must not be touched. 1. Contact surfaces must be subjected to preliminary treatment before screw-fastening (see Table below). 2. Immediately after the pre-treatment, coat both contact surfaces sparingly with a thin and uniform film of synthetic lubricant (KL) so that the space between the contact surfaces is completely filled once the screws have been fastened 1 2 3 4 AGS 531 596-01 | 05/2017 Material of contact surfaces Pretreatment silver-plated Clean1 nickel-plated Remove passivation layer4 Copper or copper alloy Clean1 expose bare metal2 Aluminium alloy Clean1 expose bare metal2 Steel Clean1 expose bare metal2 Galvanized zinc-plated steel Remove passivation layer but not the zinc coating3 Hot-dip galvanized sheet Clean1, passivation need not be removed Clean with a non-fluffing cloth, use detergent in case of more severe dirt Clean expose bare metal - treat full surface with an abrasive cloth or a rotating grinder (grain 100 or 80) or - with a steel wire brush clearly marked for use with copper only using a brass brush, steel brush rub briefly by hand, using Scotchbrite abrasive (ensure Ni layer is not reduced) 73 Annex 11.4 WS Screw locking compound NOTICE ● Observe the specifications of the manufacturer of the screw locking compound. ● In case the thread reach exceeds 1.2 x the screw diameter and in case of blind hole threads, only wet the nut's thread. 1. Preparing the thread surfaces: clean and degrease thread surfaces using cleaning agent and a lint-free cloth. 2. Application of adhesive: Coat the entire circumference of 2 or 3 threads in the area to be glued with liquid screw locking compound. Max. time for positioning: 60 sec. 11.5 Specifications for screw connections NOTICE ● Generally speaking, the threads of the screws should not be pre-treated. ● Max. tolerance for the effective tightening torque: ±15% ● The strength of the nuts must match the strength class of the screw used or be higher. General screw connections Strength class or material Screw Plastic Thread Ø Self-locking screw ≥ 8.8 ≤ 10.9 ≥ 8.8 Tightening torque [Nm] M4 0.25 2.6 M5 0.5 5.0 7.0 M6 0.8 8,8 6.5* 12.3 M8 1.8 21,0 17.0* 30.0 M 10 3.5 42.0 59.0 M 12 6.0 70.0 97 M 16 12 170 M 20 330 * for self-tapping screws 74 AGS 531 596-01 | 05/2017 WS Annex Screw connection for current transfer Screw connection for terminal strips Screws: Strength class ≥ 8.8 Copper conductor material Thread Ø AGS 531 596-01 | 05/2017 Tightening torque [Nm] Thread Ø Tightening torque [Nm] M 2.5 (M 2.6) 0.5 M6 6.5 M3 0.7 M8 17 M 3.5 1.0 M 10 35 M4 1.5 M 12 68 M5 2.5 M 16 135 75 Schneider Electric 35 rue Joseph Monier 92500 Rueil Malmaison - France Phone: +33 (0) 1 41 29 70 00 www.schneider-electric.com As standards, specifications, and designs change from time to time, please ask for confirmation of the information given in this publication. © 2017 Schneider Electric. All Rights Reserved. AGS 531 596-01 – 05/2017