Genie range SF6 indoor switchgearinstallation, operation and maintenance instructions version 002 / August 2000 Genie range contents page general general description introduction weights and dimensions storage installation floor preparation connection of panels connection of busbars installation of pilot cables connection main cable connection busend cable box connection operation operation of switch - main operation of switch - earth operation of circuit breaker - main operation of circuit breaker - earth operation of busbar earthing switch cable testing main cable phase live indication operation of pocket terminal accessing VT’s disconnection of V.T.s commissioning introduction physical checks HV. withstand test test voltages test connection maintenance SF6 gas endurance characteristics product support 2 2 2 3 4 4 5 8 9 10 10 11 12 12 12 13 14 14 15 16 16 17 18 19 19 19 19 20 20 21 22 23 23 MERLIN GERIN 1 the range comprises:s CB2 200A circuit breaker s CB6 630A circuit breaker s CB12 1250A circuit breaker s BS6 630A bus section s BS12 1250A bus section s SW6 630A switch s SWE busbar earthing switch The equipment is suitable for indoor use only. weight (kg) (packed) h w d 2380 530 1300 450 2380 770 1300 500 2380 770 1300 500 2380 1010 1300 550 2380 600 1300 550 2380 840 1300 600 2380 770 1300 500 2 MERLIN GERIN . operation and maintenance of the Genie range of equipment.Genie range general description introduction These instructions cover all operations concerning handling. installation. Should the busbar chamber or cable box become exposed to the elements. It is therefore necessary to protect the equipment from the environment before and during erection/commissioning. they should be thoroughly cleaned prior to energising. weights and dimensions unit(s) circuit breaker/switch extended circuit breaker circuit breaker/switch (with bus end cable box) extended circuit breaker (with bus end cable box) circuit extended bus-section breaker/switch circuit breaker (with busbar VT) (with busbar VT) average dimensions (mm) (packed) approx. tighten to a torque value of 5. dry switchroom and protected against dust and debris.Genie range storage note: lifting chains/ropes should be positioned @1800mm and 1650mm from lifting points. dyscon boots. tighten to a torque value of 5. new fixings and seals must be used to re-secure the facia after lifting. lifting bars are fixed to unit using existing fixings (marked'F') tightened to a torque value of 10Nm(7. 180 165 0mm 'F' 'F' 'F' m 0m 165 LIFTING POINTS LIFTING POINTS LIFTING POINTS LIFTING POINTS maximum mass = 300kg maximum mass = 350kg offloading All units are delivered on pallets (secured by 2 x M8 screws and nuts). screws etc. glands. They should be stored in a warm. note: lifting chains/ropes should be positioned @1800mm and 1650mm from lifting points. ancillary kits Ancillary kits containing busbars. MERLIN GERIN 3 .4Nm(4lb/ft). important during lifting of the unit all four lifting points must be used. as shown.4Ib/ft). are supplied loose with each unit or fastened to the panel or secured in the cable box. The units can be off loaded by forklift truck or by using a lifting kit consisting of 2 lifting bars and can be off loaded using an overhead crane (see above diagrams). new fixings and seals must be used to re-secure the facia after lifting.4Nm(4Ib/ft). storage These units are designed for indoor use and must not be left outdoors.4lb/ft). m 0m 0m m 180 'F' important during lifting of the unit all four lifting points must be used. as shown. lifting bars are fixed to unit using existing fixings (marked'F') tightened to a torque value of 10Nm(7. e. Drill front and back fixing positions through access holes. switch. busbar earthing panel Line up the first panel in position(see Unistrut diagram above).Genie range installation floor preparation Please refer to the arrangement drawing for foundation details. The recommended drill size is 16mm Ø. M10 CHANNEL FIXING FOOT OF UNIT 698 NOTE: FLOOR LEVEL FLUSH TO + . we strongly recommend the use of foundation channels. Install rawlbolts. i.1mm WITH FOUNDATION CHANNEL 41 SPRING LOADED CHANNEL NUT 70 CHANNELS GROUTED IN POSITION USING SETTING JIGS SUPPLIED CHANNELS MADE IN SUBFLOOR The units can be directly bolted to the concrete floor by use of 2 x 10mm rawlbolts for single width panels or 4 x 10mm rawlbolts for bus-section and extended circuit breaker panels. (shown above). Unistrut P3270 or similar. Insert 2 channel nuts into the Unistrut as shown and slide into position. note: the floor must be 1mm below the top of the Unistrut erection/connection circuit breaker. access holes 4 MERLIN GERIN . Finger connect the M10 nuts and washers. line up the first panel in position and remove the lower panel front plate. Manoeuvre next panel into position and repeat. Manoeuvre next panel into position and repeat. Finger connect the M10 screws at the front and rear of the unit (do not tighten). The floor tolerance is ±1mm over 1 metre. If the panel is being bolted directly to the floor. Where it is not possible to guarantee that the floor is within the specified tolerance. Genie range installation connection of panels Remove pilot cable box (if fitted) . To remove undo the 10 x M6 captive screws along the top and rear of the busbar chamber cover. or factory installed via a busbar trunking. With the busbar chamber cover removed. Place the pilot cable box on the top of the low voltage cabinet. An additional pilot cable tray can be supplied for fitting to the LV compartment to allow the multicores to travel to the relevant panel. To remove undo the 9 x M6 screws and nuts along the top and rear of the busbar chamber. Full assembly instructions are provided with the appropriate kits.bolt the panel busbar chamber flanges together using 10 x m6 screws and nuts via the flange holes along the lower and front edges. multicore pilot cable riser kit (bottom entry cables) A multicore pilot riser kit is available for switchboards which require bottom entry multicore pilot cables. Repeat until all panels within the switchboard have been installed and bolted together.) Remove the busbar chamber top and rear cover plate. It can be supplied loose for installation onto an existing switchboard. MERLIN GERIN 5 . (Approximate weight of pilot cable box is 10kg. This allows easy fixing and support for all multicore cables associated with the switchboard. note: standard LV cabinet door not shown for clarity wide Genie LV cabinet Genie housing 1. Using a hoist or similar offer the LV Cabinet up to the unit as shown. 3. Fix the cabinet in place using 6 off M6 x 16 Screws with 1 off M6 Form ‘A’ Washer under the head of each screw. Using a hoist or similar offer the LV Cabinet up to the unit as shown. 3. note: wide LV cabinet door not shown for clarity 6 MERLIN GERIN . 2. Locate the LV Cabinet onto the Genie Mecho Cover Plate. 2.Genie range installation standard Genie LV cabinet Genie housing 1. Fix the cabinet in place using 6 off M6 x 16 Screws with 1 off M6 Form ‘A’ Washer under the head of each screw. Locate the LV Cabinet onto the Genie Mecho Cover Plate. The method of connection remains the same as for standard panels. With the lower front and rear access panels removed.Genie range installation connection of front earth conductors and remaining panel fixings Remove the housing lower front plate by removing 8 x M6 screws.panel main earth conductor as illustrated and secure using 1 x M10 screw. secure the panels using 2 x M6 screws. Connect front panel . With the busbar system assembled. Secure the low voltage instrument cabinets together using 1 x M5 screw. note: for inverted MV cable boxes the assembly illustrated dashed should be used. note: access is required via the busbar chamber top access plates. nuts and washers. replace all covers. nuts and washers should be fitted to the busbar chamber flanges to ensure a tight seal. nut and washers at the front and rear fixing points. With the busbar fixing studs removed. M10 HEX HEAD BOLT M10 WASHERS M10 LOCK NUT completing the installation Ensure all insulation and chambers are clean and free from debris. M10 HEX HEAD BOLT M10 WASHERS M10 LOCK NUT REAR EARTH BAR CONNECTOR PANEL TO PANEL LOWER FIXING MAIN EARTH BAR REAR EARTH BAR SIDE SHEET MERLIN GERIN 7 . To complete the installation.panel fixings as illustrated. washers and nuts at the lower panel . nuts and washers per panel. Bolt these together using 2 x M10 screws. connection of end panel earth conductor Connect end panel earth conductor as illustrated using 1 x M10 screw. assemble the busbar system as illustrated opposite. washers and nut. studs inserted and nuts tightened to the torque advised replace the busbar chamber covers and pilot cable boxes (if fitted) for the complete switchboard. washers and nut at the fixing point adjacent to the bus-wiring aperture. tighten all floor fixings. note: all 20 x M6 screws. and components removed REAR EARTH BAR END PANEL EARTH BAR connection of rear earth conductor and busbar assemblies Each panel has an earth conductor fitted at the rear. Remove the rear access plates. REAR EARTH BAR BUSBAR CHAMBER INVERTED CABLE BOX REAR EARTH BAR CONNECTOR PANEL TO PANEL LOWER FIXING STANDARD CABLE BOX END PANEL EARTH BAR Fit the busbar chamber end covers using 20 x M6 fixing screws. SIDE SHEET MAIN EARTH BAR FACIA UPRIGHT bus-section earth conductors Short front and rear earth conductors for use on bus-sections are provided. refer to accessory kit instructions for full details note: it is recommended prior to refitting busbar chamber covers that the busbars are tested . Please consult us regarding additional tests which may be required for this busbar system. Clean dyscon boots and bushings. Dow Corning silicon grease to boots. Dow Corning silicon grease to boots.see page 20 for typical tests connection of busbars totally encapsulated and earth screened MOULDED CONDUCTIVE SCREEN (EARTHED) INSULATION EPOXY END PLUG WITH MOULDED METAL INSERT INSULATED BUSBAR WITH METALISED COATING INTERNAL SCREEN (LIVE) Busbar torque 54Nm Ensure that the environment is clean and dry. Fit busbars into boots as shown above.see page 20 for typical tests. Clean dyscon boots and bushings. note: it is recommended prior to refitting busbar chamber covers that the busbars are tested . 8 MERLIN GERIN .Genie range installation connection of busbars totally encapsulated Busbar torque 54Nm Ensure that the environment is clean and dry. Apply DC4. Fit busbars into boots as shown above. Apply DC4. Pilot cables can be installed from above or below using individual sliding gland plates or by drilling the single sliding plate. Dow Corning silicon grease to boots. Remove the pilot cable box cover by unscrewing the 2 x M6 screws. MERLIN GERIN 9 . refer to accessory kit instructions for full details installation of pilot cables through pilot cable box standard arrangement optional Remove the pilot cable box cover by unscrewing the 4 x M6 screws.Genie range installation arrangement of bus-section busbars connection of busbars totally encapsulated/earth screened Busbar torque 54Nm Ensure that the environment is clean and dry. Remove dyscon boots and clean bushings. Apply DC4. Pilot cables can be installed from above or below using pre-punched gland plates with various sized electrical knock-outs. as shown. Fit busbars into boots as shown. Cable termination torque = 54NM note: red phase bushing is on rear left of unit. standard cable entry inverted cable entry 10 MERLIN GERIN .Genie range connection main cable connection All units are fitted with dry type cable boxes suitable for accepting heat shrink or cold fit termination kits. note: ensure that cable is supported by gland plate before placing on bushings. Accessory kits containing gland plates etc are available. Genie range connection bus end cable box connection standard cable entry inverted cable entry Dyscon elbow adaptors Dyscon dry .type cable terminations are standard on 1250A panels and optional on 200A/630A panels. note: the hole size in the dyscon palm for connecting the main cable is 14mmø for M12 fixing. MERLIN GERIN 11 . Move select to main switch position. operation of switch earth Check that the gas indicator is in the green healthy condition. To open. Insert handle as shown and pull down firmly until the switch closes. 12 MERLIN GERIN . The selector will be locked in the earth switch position. Remove padlocks if fitted.Genie range operation operation of switch main Check that the gas indicator is in the green healthy condition. rotate the handle through 180° and reverse the procedure. To open. Remove padlocks if fitted. The selector lever will be locked into the main switch position. Fit padlock into the handle socket padlock bracket if required. Fit padlock into the handle socket padlock bracket if required. Check the facia diagram for the service condition. With the switch in the open position. move the selector lever to earth switch position. rotate the handle through 180° and reverse the procedure. Check the facia diagram for the service condition. Insert handle as shown and pull down firmly until the switch closes. Fit padlock into the circuit breaker closed in service position if required. Remove padlocks if fitted. Pull down on lever firmly. See indicator flag on top of unit.Genie range operation operation of circuit breaker main Check that the gas indicator is in the green healthy condition. Move handle up to reset and earth off position. Move select to main circuit breaker position. Check the facia diagram for the service condition.The selector will be locked into the main circuit breaker position. To store an additional charge on the springs. MERLIN GERIN 13 . rotate the handle through 180° and insert as shown. To open the circuit breaker press the push circuit breaker off button. Fit padlock into the circuit breaker open position if required. Insert handle as shown and pull down firmly to charge springs. The handle can then be reversed once more and pulled down to store an additional charge. With the circuit breaker in the open position. important note: the busbar earthing switch should only be operated when the busbars are de-energised. Check the facia diagram for the service condition. 14 MERLIN GERIN . Remove padlocks if fitted. Fit padlock into the handle socket padlock bracket position if required. To open rotate the handle through 180° and reverse the procedure. To open rotate the handle through 180° and insert and move handle up to reset and earth off position. The selector will be locked in the earth position. Pull down on lever firmly to close to the earth on position. Fit padlock into the handle socket padlock bracket position if required. Insert handle as shown and pull down firmly to charge springs. operation of busbar earthing switch Check that the gas indicator is in the green healthy condition. note: the circuit breaker off button will not operate. move the selector lever to earth switch position. Insert handle as shown and pull down firmly until the switch closes.Genie range operation operation of circuit breaker earth Check that the gas indicator is in the green healthy condition. Remove padlocks if fitted. Check the facia diagram for the service condition. MERLIN GERIN 15 . The test access key will be locked in position until the earth star point is firmly replaced. Push in and rotate test access key cover lever 90° clockwise and remove cover.Genie range operation cable testing main cable Ensure that the main earth switch is “earth on”. Unit shown with earth star point connected. note : ensure cables are discharged before touching bushings. Push lever in and rotate 90° anti-clockwise. Remove the earth star points as shown to provide access for cable testing. The test access key can be padlocked in position if required. Insert test access key into the key way (as shown). Reverse the procedure to return to service condition. This will open the key way. Refer to Sepam 2000 commissioning manual for further details. insert neon indicator lamp into the relevant phase socket as shown. note : the neon indicator lamp can be proved before and after insertion using a neon verification box (Kit Ref. operation of TSM2001 pocket terminal Open the facia of the Sepam 2000 and connect the TSM20001 pocket terminal as shown. The indicator lamp will illuminate if the phase is live.Genie range operation phase live indication To test for phase live condition. RMR-A24). 16 MERLIN GERIN . The handle can now be replaced in the VT cover flap and this can be closed and the panel can be returned to service condition. To re-connect the VT’s. Insert the racking handle into the top position of the slot. in service isolated MERLIN GERIN 17 . See page 12 for operation instructions.Genie range operation accessing VT’s important note: before accessing VT’s (during commissioning or replacing fuses) ensure that the main earth switch is padlocked in the earth on position. The VT’s are now disconnected. If the unit is a bus-section ensure that the bars are earthed or completely isolated. Turn in an anti-clockwise direction as far as it will go and remove handle. isolation of VT’s Ensure that the main switch is in the Earth On position Open VT cover on lower front of unit and remove racking handle from its storage position. Remove the lower circuit breaker front cover access panel for access to solid link and fused type connection. the above procedure should be reversed remembering to ensure that the main switch is in the Earth ON position. Remove the fuse completely from the unit to disconnect the VT. Reverse the procedure to connect the VT’s disconnection of VT’s . Reverse the procedure to connect the VT’s 18 MERLIN GERIN .solid link note: ensure the circuit is earthed Pull back the VT insulating boot and loosen the VT connection using a 6mm allen key as shown. Disconnect the VT as shown.fused link note: ensure the circuit is earthed Grasp the grey fuse tube and push up until the bottom is clear of the black insulation boot.Genie range operation disconnection of VT’s . note: all voltages should be applied instantaneously unless otherwise specified protection and control system Refer to Sepam commissioning guide or relay manufacturer’s data. note: ensure VT’s are disconnected prior to carrying out any HV pressure tests R1 MERLIN GERIN Y1 B1 19 . Confirm the phase relationship of the neon indicator sockets.Genie range commissioning commissioning All equipment is subject to stringent quality and operational checks prior to despatch. B2 Y2 R2 high voltage withstand test to BS/IEC Connect the H. however it is the owners responsibility to ensure that commissioning tests have been completed to IEC60694. Closing coils should operate between 85% and 110% of the rated voltage. test access and various interlocks. V. physical checks Remove all packaging and transit labels from the equipment. Check the operation of the switches/circuit breaker. Check the data plate details against the specification. test set and carry out the withstand tests in accordance with the following tables. functional checks Check operation of auxiliary switch contacts and remote indication in accordance with the schematic diagram. Check the pick up voltage of auxiliary coils if fitted. Opening coils should operate between 70% and 110% of the rated voltage. The following is a resume of these tests. Y2. Y1.CT spill test .relay timing and functionality tests 20 MERLIN GERIN . frame R2. . Y.6 7. frame R. Y Y.2 12 13.5 15 25 32 test connection . frame The following tests should also be carried out. B1. B R. Y2. test voltage current practice) 7. frame R1.primary injection . If additional information and/or assistance is required please consult us.secondary injection . B2 earthed terminals frame B.circuit breaker / switch test number 1 2 3 4 5 6 CB / switch closed closed closed closed open open live terminals R.c. frame Y. R R1. B2.relay secondary injection . B1 R2.8 AC test voltage (kV) 8 16 23 32 frequency (Hz) 50 50 50 50 duration (minutes) 1 (AC) 15 (DC) 1 (AC) 15 (DC) 1 (AC) 15 (DC) 1 (AC) 15 (DC) (d. B B.Genie range commissioning test voltages rated voltage (kV) 3.CT polarity test . Y1. Humidity below 40% and no dripping water. salt). Ambient temperature between -5oC and +40oC. mould).Genie range maintenance routine maintenance recommendations to BS6626:1985 Routine maintenance will depend on the conditions to which the unit is subjected and to the relevant codes and practice. temperature cycles greater than 40oC or less than -5oC. MERLIN GERIN 21 . Unit may be indoors or outdoors within enclosures. No over-voltage or over-current (above rating). No abnormally high number of operations . No abnormally high number of faults . dust storms. flooding. No earth movements. operational conditions No mal-operation of any kind. heavy rain storms. irrespective of site conditions.refer to the graph.refer to the graph. No over-voltage or over-current (above rating). Periodic inspection of the substation and equipment will be necessary to establish the conditions to which the units are subjected to.refer to the graph. standard conditions environmental conditions Unit installed and commissioned in accordance with the manufacturer’s conditions. No contact with any chemical agents (eg. note: local legislation may dictate maintenance be carried out with greater frequency. No infestation of any animal life (eg. dense coastal fog or acid rain. No damage to the unit of any kind. No regular or thick covering of debris. Please contact your local Merlin Gerin representative for further details. Humidity below 60%. Minimal dust and air circulation. No abnormally high number of operations . No contact with any chemical agents (eg. completely protected from the weather. No earth movements. No infestation of animal or plant life. but must not be subjected to regular extremes of weather eg. ideal conditions gas enclosure no attention standard conditions no attention aggressive conditions no attention mechanism housing no attention no attention no attention every 10 years every 10 years every 5 years ideal conditions environmental conditions Unit installed and commissioned in accordance with the manufacturers instructions Indoors. No contact with any plant life (eg. salt). heavy snow and ice.refer to the graph. No damage to the unit of any kind. No abnormally high number of faults . aggressive conditions Any environmental or operational conditions which do not satisfy either of the above two descriptions must be deemed aggressive. operational conditions No mal-operation of any kind. insects). Check inside the MV cable box. labels and earth connections are present and tight. ingress of water or contamination by animal or plant life.Genie range maintenance maintenance general operation Check that the gas indicator is in the green zone. mechanism In the unlikely event of a mechanism failure. Check the operation of the unit and all mechanical interlocks. busbar system LV cabinet and pilot cable box for heavy deposits of dust. please contact Schneider Services. housing Check all external fixings. leakage of SF6 If the gas pressure indicator needle is within the red zone or in the extremely unlikely event of a gas leak contact your local Merlin Gerin office immediately. For circuit breaker panels check the electrical protection system. 22 MERLIN GERIN . Clean the units thoroughly and touch up paint work as necessary. full spare parts service .Genie range endurance characteristic Endurance Characteristics NUMBER OF OPERATIONS CURRENT INTERRUPTED (A) product support s after sales s for products within warranty (12 months from date of commissioning or 18 months from date of dispatch .whichever is the sooner).erection and commissioning of new equipment .training MERLIN GERIN 23 .maintenance contracts including protection and testing . please contact our customer service department on Tel: 0113 290 3500 Fax: 0113 290 3710 s for products outside the warranty please contact our Services division on Tel: 0113 284 8900 Fax: 0113 284 8910 s Services division are also able to offer .system design . contractors. Schneider Electric operates from 16 industrial and commercial sites. Schneider offers a full range of products and services for panel builders. will develop the most effective and economical solution. control and automation Schneider Electric is the leading UK and world expert in the development and manufacture of products for the distribution and industrial applications of electricity. OEMs. specifiers and the electrical supply industry for commercial and industrial applications.500 people. with 2. Sales engineers are skilled at assessing individual requirements and combined with the expert support of it’s product specialists. . Schneider Electric is committed to supporting its customers at every stage of a project. is the largest dedicated sales force in the UK electrical industry. Our 180 sales engineers.Expertise Schneider Electric in electrical distribution. In the UK. and achieves an annual turnover in excess of £270 million. uk Publication No.MV082000 2000 O/S-BP .Merlin Gerin Medium Voltage.co.schneider. 123 Jack Lane. Leeds LS10 1BS Tel: 0113 290 3500 Fax: 0113 290 3710 Internet address: http://www.