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MEDIUM VOLTAGE SWITCHGEAR

HWX
Single/Duplicate Busbar
The complete solution for process
plants, power stations, other
industries

Installation, Operation &


Maintenance Manual

AREVA T&D
HWX
Single/Duplicate Busbar
MEDIUM VOLTAGE SWITCHGEAR

12KV HORIZONTAL ISOLATION HORIZONTAL DRAWOUT VACUUM


SWITCHGEAR TYPE HWX

RATING AND SPECIFICATION

Type Unit HWX

Rated Voltage kV 7.2/12

Rated Continuous Current A 630/1250/2000/2500/2800/3150

Rated Frequency Hz 50

Rated Interrupting Current kA 26.2/31.5/40/44

Rated Making Current kA 65.5/80/100/110

Rated Short Time (3 sec) Current kA 26.2/31.5/40/44

Operating Duty – IEC :62271-200-100

Power Frequency withstand voltage kV 28/35

Impulse Withstand Voltage kVp 60/75

Auxiliary Contacts kVp 60/75

Auxiliary Contacts – 4 NO + 4 NC

Approximate Dimension mm 2430/2600x660/860x1800 (H x W x D)


2118 x 660x1625(HxWxD

INTRODUCTION springs in a discharged state


(SPRINGS FREE).
The entire range of HWX type
equipment has been designed, for To assist in its safe operation the
indoor use and every care has been equipment can be fitted with
taken in the design to ensure its padlocking facilities which shall be
suitability for this purpose. applied as appropriate.

The equipment requires minimum Before commencing and after


maintenance. By following the completion of work, all control
routines recommended in this switches shall be left in the
manual, the user can easily ensure appropriate positions.
good condition throughout the life
of the quipment. Should the operator require any
guidance or advice regarding the
SAFETY equipment, he is free to contact the
manufacturer.
Before working on the equipment, it
is necessary for the operator to The Company policy is continuous
ensure that it has been safely development and improvement of
disconnected from electrical its product. Therefore it reserves the
supplies and that the necessary right to supply products which may
safety earth’s have been fitted and a vary slightly from those described
suitable permit to work issued. In and illustrated in this publication.
the event of any doubt in this
respect, the operator shall seek the 1.0 DESCRIPTION
advice of his local supply authority
to ensure that he has taken the 1.1 General
necessary actions to comply with
local safety requirements. HWX metalclad indoor single
busbar air insulated vaccum
The circuit breaker closing switchgear is for use on distribution
mechanism is capable of storing a networks having a highest system
considerable amount of energy and voltage up to 12 kV, a short circuit
therefore, before commencing current rating up to 40kA, a
work, steps must be taken to maximum full load current of 2000A/
discharge this energy and leave the 2500A/ 2800A and a lightning

1
impulse level up to 75 kVp (BIL.) primary connection spouts. of units is not distorted in any way.
Typical sectional views are shown in Ensure that any lifting slings are of
Fig. 1&2. Access to the busbar compartment adequate strength and in good
for making the busbar joints is via condition.
1.2 Construction removable covers on top of the
housing and at the rear of the Approximate weight are:
Standard incomer and feeder units busbar compartment.
comprise of two main parts: the Current Weight of Weight of
fixed housing and the truck Earth bars associated with the cicuit Rating Circuit Housing
mounted horizontally isolated circuit breaker is within the housing, and (Amps) Breaker (kg) (kg)
breaker. brought out externally as a single 800 130/170 350/370
connection at the rear of the
The housing is of fabricated sheet housing. This connection are 1250 130/180 370/410
steel with separate compartments connected the main inter-unit earth 2000 210 500
for the circuit breaker, busbars, bars. 2500 215 530
current transformers and multicore
2800 225 555
cable glands. 2.0 INSTALLATION
3150 235 560
A panel at the front of the housing 2.1 Despatch and Packing
above the circuit breaker 2.3 Storage
compartment accommodates the The equipment is designed and
terminal blocks, fuses and links for despatched so as to involve If the equipment is not required for
the secondary circuits and the minimum of erection work. The immediate use it should be stored in
multicore termination. The panel circuit breaker is located and a clean, dry, well ventilated place
may also be used to mount secured in the housing during and covered. Should storage be
electrical instruments like relays, transit. prolonged, routine inspections
meters etc. should be carried out as if the
2.2 Unloading and equipment were in service.
The primary connection spouts in inspection Temperature and humidity
the circuit breaker compartment are conditions shall be such that
equipped with earthed metal safety IMPORTANT : condensation of moisture does not
shutters, which are controlled by occur. Where fitted, unit heaters
arms mounted on the sides of the THE EQUIPMENT SHOULD BE should be energised as soon as
circuit breaker compartment and EXAMINED IMMEDIATELY possible.
operated automatically by AFTER THE RECEIPT. IF THE
movement of the circuit breaker. EQUIPMENT HAS BEEN The equipment must not be
With the circuit breakr withdrawn DAMAGED, BOTH THE exposed to direct moisture as it is
from the housing, each shutter can TRANSPORT CONTRACTOR for indoor use only.
be independently padlocked. AND AREVA LIMITED
SWITCHGEAR DIVISION OR 2.4 Site
The three phase assembly of the THE LOCAL REPRESENTATIVE
truck mounted horizontally isolated SHALL BE ADVISED AS SOON The site should, as far as possible,
circuit breaker is contained within a AS POSSIBLE. be free from damp, excessive
moulded phase separated vibration and high and widely
insulation structure. The truck also Where the equipment is supplied in varying temperatures. Relative
incorporates the simple low energy packing cases these shall be placed humidity must be such that
hand or motor charged spring TOP uppermost and the top condensation in or on the
operated mechanism, the three removed first. All necessary equipment will not occur. Special
phase drive assembly and the erection details are supplied in precautions must be taken where
circuit breaker plugging in isolating plastic bags or packing cases which the relative humidity exceeds 80%.
mechanism. are tagged and numbered. The tage These may include operating the
number, together with a description unit heaters and also preferably
Insertion of the circuit breaker is of a contents are listed on the equipping the substation with
pushed into the housing is in 3 packing list supplied. dehumidification equipment.
stages.
Reference to this list will enable There should be ample room for
The secondary plug from the panel easy location of the required painting and maintenance work to
is to be first plugged into the components. The equipment be carried out. Recommended and
breakers secondary socket and the should be transferred to the switch- minimum distances are shown on
interlock rod is pushed towards the house immediately after unloading; the switchboard drawing supplied
mechanism. This will allow the truck under no circumstances shall it be with each contract.
to take further into the panel. Then exposed to direct and excessive
the circuit breaker is pushed as far moisture. Where heaters are fitted 2.5 Foundations and Unit
as possile into the housing and it is they should be energised as soon Erection
finally plugged in by means of a as possible. The equipment is
detachable winding handle which provided with lifting points which It is important that the finished floor
locates on the racking drive shaft must be used. area is flat, and not sloping by more
situated below the circuit breaker than 3 mm over any 2500 mm. The
mechanism facia. Reversal of the Care must be taken to ensure that area shall extend a minimum of 600
above isolates and withdraws the no undue stresses are placed on mm to the rear of the panel, 1000
circuit breaker primary terminals any part of the equipment, mm to the front of he front
make with contacts in the housing especially that the projecting base foundation fixings and 200 mm

2
3

FIG. 1. Sectional side view of HWX Panel up to 12 kV 1250A, 40kA

BLOW-OFF
BUSBAR

OPTIONAL DUPLICATE BUS-BAR 690


ARRANGEMENT
CAN BE MOUNTED ON TOP OF PANEL IF
REQUIRED R R

545
Y Y
B B
INTERPANEL
660 352 ACCESS
FOR CONT. WIRING

CHANCE OVER

565
DRIVE

INSTRUMEN

960/1130
T CHAMBER

BREAKER COMPARTMENT
BLOW-OFF COVERS
902 BUS-BAR COMPARTMENT
895
2430/2600

50X6 CU EARTH
BUS
PVC SHROUD
SURGE
DIVERTERS
SEC. PLUG
(FOR MOTOR FDRS)
SOCKET

RACKING
1470

SCREW DRIVE BEAM

RACKING SCREW
REMOVABLE COVER
FOR CT ACCESS 175
FROM FRONT
ACCESS FOR RACK IN/OUT
AFTER OPENING THE DOOR

MULTICORE CABLE ENTRY CT-CABLE COMPARTMENT MAIN CABLE ENTRY


50X6 CU. EARTH BUS

FRONT VIEW SECTIONAL SIDE VIEW OF HWX PANEL UP TO 12kV 1250A, 40kA NTS
BLOW-OFF COVERS BUSBAR COMPARTMENT
690
OPTIONAL DUPLICATE BUS-BAR ARRANGEMENT
CAN BE MOUNTED ON TOP OF PANEL IF
REQUIRED R R

545
Y1 Y2

660 B B

352 INTERPANEL ACCESS


FOR CONT. WRING

CHANGE OVER

565
DRIVE

INSTRUMEN

960/1130
T CHAMBER
EXTENSION CHAMBER FOR ADD. CABLES

BREAKER COMPARTMENT BLOW-OFF COVERS BUS-BAR COMPARTMENT


902 500
895

PVC SHROUD
2430/2600

SEC. PLUG
SOCKET
1470

RACK IN
CIRCUIT
SCREW DRIVE BEAM
RING TYPE CT SPOUT CT-CABLE
COMPARTMENT
REMOVABLE COVER FOR CT
ACCESS :
FROM FRONT
ACCESS FOR RACK IN/OUT
AFTER OPENING THE DOOR
MULTICORE CABLE ENTRY MAIN CABLE ENTRY
50X6 CU. EARTH BUS
FRONT VIEW
SECTIONAL SIDE VIEW OF 12kV 2000A/2500A, 40kA HWX PANEL

FIG. 2. Sectional side view of 12 kV 2000A/2500A, 40kA HWX PANEL

INTERPANEL ACCESS
FOR CONTROL WIRING

INSTRUMENT CHAMBER

VACUUM CIRCUIT BREAKER


SAFETY SHUTTER ARRANGEMENT

DRAW-OUT PT

BUSBAR CHAMBER

SEC. PLUG SOCKET

BREAKER CHAMBER SPOUTS


VACUUM INTERRUPTER

CT & CABLE CHAMBER

RACKING ARRNG.

MULTICORE CABLE ENTRY MAIN EARTHING MAIN POWER CABLE ENTRY

ACCESS FOR RACK IN/OUT


AFTER OPENING THE DOOR

FRONT VIEW SECTIONAL SIDE VIEW OF HWX PANEL UP TO 12KV, 1250A, 25KA

FIG. 2A Sectional side view of 12 kV 1250A, 25kA HWX PANEL

4
beyond the extreme right-hand and switchboard, check to unit mounting panel.
left-hand foundation fixings. serial numbers and remove the
circuit breaker from the housing vi) Repeat the above for the
Correct operation of the equipment to be erected first. Position the remaining housings
is dependent on it being level. It is housing on the channels. remembering to check the unit
essential, therefore, that care is serial numbers with the general
taken at all stages of erection, in iii) Locate the foundation bolts and arrangement drawing of the
particular the lining up and leveling associated washers through the switchboard. Finally, tighten all
of the first unit, which will be the holes in the base of the housing foundation bolts and inter
datum for all other units. Failure to into the spring loaded nuts housing fixings.
erec the first unit correctly will result within the channels. DO NOT
in mal-alignment throughout the TIGHTEN. vii) Check the alignment of the
switchboard & this will cause rack instrument panels for squares
iv) Using 2 plumb lines level the
in/rack out problem of breakers and equality of spacing
housing front to back and
within the housing. Foundation between panels.
across the width. Levelling is
channels must be checked for carried out using shim plates.
curvature. Any found to be distorted These shims shall be located viii) Rubber gasket should be
must be straightened if possible or adjacent to and on the outside provided between the panels.
replaced. Under no circumstances of the foundation bolts such
shall distorted channels be used. that they will also support the 2.5.2 Foundation Bolts
adjacent housing when that is (Expanding type)
Foundation fixings may be one of erected. Refer to Figure 3.
two types : Shims must also be placed Preparing the floor as stated in
under the base sheet in the Section 2.5 then proceed as
Foundation Channels or Foundation apron area to make up any gap follows :
Bolts. between the floor. Once the
housing has been levelled the a) Determine the highest point on
2.5.1. Foundation foundation may be ‘nipped-up’ the floor. This point then
Channels but not tightened. becomes the datum for all units.
It is useful to use this point for
Prepare the floor and foundations & v) Position the next housing to be erection of the first unit.
then proceed as follows : erected close up to the first, fit
i) Determine the highest point on the foundation bolts and level b) With reference to the general
the channels. This point then up as before. Remove the arrangement drawing of the
becomes the datum for all units, housin top and rear covers and swithboard check the unit serial
it is useful to use this point for fit the inter-housing fixing numbers and remove the circuit
erection of the first unit. screws, ‘nip-up’ only at this breaker from the housing the
stage. Refer to Figure 4. housing on the floor.
ii) With reference to general
arrangement drawing of the Remove lifting plate before c) Carry out operations iii, iv, v vi,

1.5mm
Max variation
1.5mm from verticle

Top of unit frame

Use plumb line down


sideframe to measure
alignment. Variation Use plum line down rear
must be within ± 1.5mm of frame for vertical

Floor

50mm Sq. shims

50mm Sq. shims fitted


NOTE : as appropriate under
Do not make adjustments unit to level
to moving portion

Foundation bolt
Positions

FIG. 4. Unit Leveling Instruction

5
2 - M8 x 16mm long
Hex. HD screws with
washer
6 - M 10x22mm long
Hex. HD screws wih
nuts & washers

1. M8x20mm long Hex.


HD screw with nut &
washer

FIG. 5. Inter Unit Fixing

& vii Section 2.5.1 except fit the Where multiple busbars are used, 2.9.1 Multicore Cables
foundation bolts as follows : and units require spacers (supplied)
Using the holes in the base of fitting between the busbars at the The multicore cables enter at the
the housing as a template drill spout connections, also, where front of the housing from the base of
the floor for accepting M12 x 75 busbars on end units are in the front the housing right-hand and/or left-
mm long expanding bolts. (Red and Blue phases) and upper hand frame, from where they run
(yellow phase) positions on vertically via a removable wiring
2.6 BUSBAR ASSEMBLY additional spacer (supplied) will be through to the multicore cable gland
required between the spout compartment situated at the top of
2.6.1 General connections and the busbar in order the housing frame. In this
to keep the busbar run straight. compartment the outer insulation
The cross-section of busbars is When an extension unit is being on the cable is cut back to allow the
given on the general arrangement erected these spacers must be multicores to be taken via the main
drawing of the swithboard. removed to accommodate the wiring through to the termination in
extension busbars and refitted in the housing front panel.
Before assembly, all contact the same positions in the extension
surfaces of the busbars and unit. The busbar joints shall be 2.9.2 Inter-unit Wiring
housing connections must be encapsulated with compound & (Bus Wires)
cleaned to ensure a good contact tapping.
surface. Unplated contact surfaces For ease of location, each wire is
shall be cleaned using a branded 2.7 Unit Earthing fitted with an idenification ferrule
liquid silver polish. After cleaning, all which corresponds with that on the
surfaces shall be wiped wth a clean The main earth bars associated with wiring diagram. Where wires pass
cloth to remove any metal dust, etc. the circuit breaker truck and the through to adjacent panels the
Joints shall be assembled as soon circuit earthing switch are holes shall be fitted with a
as possible after preparation. connected within the housing & protective grommet.
brought out externally at the rear of
The same treatment of contact the housing. The only assembly 3.0 COMMISSIONING
surfaces shall be carried out on all required on site is to connect the TESTS AND INSPECTION
other joints, such as the tee off to earth bars of adjacent units together
voltage transformers and main using the main external earth bars The test outlined in this section are
cable connections. supplied. those to be made after the
equipment has been erected, but
2.6.2 Assembly 2.8 Main Cables before energisation.

The busbars shall be assembled The main cables shall be made off 3.1 Precautions
such as to be parallel to the line of in acordance with the cabling
the switchboard and suitable for schedule. The policy to be adopted in making
extension if necessary. the equipment available for
commissioning or maintenance
Red and Blue phases (the two outer 2.9 Multicore Cables and shall be that, it is isolated, proved
phases) shall be assembled on the Inter-Unit Wiring (Bus dead and earthed.
front face of the spout connection Wires)
only, Yellow phase (the centre Precautions shall be taken to ensure
phase) shall shall be assembled on The only secondary wiring required that the isolated equipment cannot
the front face of the spout on site is to run and terminate the be re-energised from any high or
connection only. Assemble Blue multicore cables and connect the low voltage sources of supply.
phase first, then Red phase and inter-unit bus-wires in accordance
finally Yellow phase Ref. with the wiring diagram The circuit breaker operating
figure 5. supplied. mechanism is capable of retaining a

6
TORQUE SETTING 60NM

BUSBAR
RATING
AND
SIZES

END INTERMEDIATE END


UNITS UNITS UNITS

BUSBAR
RATING
AND
SIZES

END INTERMEDIATE END


UNITS UNITS UNITS

1250A M12 X 70MM HEX HEAD BOLT, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
1
BUSBAR
16X60 SQ. MM.
= 960 SQ. MM.

133MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
1600/2000A
2
BUSBAR
16X60 SQ. MM.
= 1920 SQ. MM.

165MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
2500A
3
BUSBAR
16X60 SQ. MM.
= 2880 SQ. MM.

197MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER

3000A
4
BUSBAR
16X60 SQ. MM.
= 3840 SQ. MM.

NOTE :
1) Busbar configuration may vary depending upon switchgear rating and specifications. Please refer seperate contract related dowings for detailed arrangements.

FIG. 5. Busbar Assembly and Torque Settings.

7
stored closing spring charge. such as a terminal board and a system apply 20 kV ac rms for 1
Before attempting any work, the voltage of 2 kV A.C. applied for 1 minute power frequency.
stored charge must be released by minute between the loops and
operating the circuit breaker earth. After high voltage tests have been
manually from OFF to ON to OFF. completed, a further megger test
Where motor spring charged 3.4 Electrical Test – should be made to check that the
operating mechanisms are fitted the Primary Insulation initial resistance has not altered
supply to the motor must be significantly.
disconnected. ● Warning : Before
commencing tests 3.4.1 and 3.5 High Voltage Test –
3.2 Mechanical Testing 3.4.2 on the primary insulation Voltage Transformers
take the following Where high voltage tests on voltage
Manual operational checks should precautions : transformers have been agreed they
be carried out on the circuit breaker should be in accordance with the IS
to ensure correct operation of ● Short circuit and earth current : 2071, IS : 3156, to which reference
interlocks, primary connection transformer secondary should be made.
safety shutter, operating windings. Under no
mechanism, trips, auxiliary switches circumstances shall current 3.6 High Voltage Tests-
and the circuit breaker racking transformer secondaries be Integrity of Vacuum
mechanism. open circuited with the Interrupers
primary on load.
3.3 Electrical Tests – IMPORTANT : X-ray radiation from
Secondary Insulation ● On fixed voltage transformers Vacuum Interrupers.
remove the connection
WARNING : between the primary terminal, Any electrical gap in a hard vacuum
by removing primary fuse. when stressed electrically may
Before commencing the tests generate X-rays.
described in sections 3.3.1 and ● Isolate isolatable voltage
3.3.2 on the secondary insulation transormers. In the case of HWX equipment tests
take the following precautions : have shown that X-ray emission at
● After testing, all conductors the voltage stated is less than the
Disconnect the wiring to circuit shall be discharged to earth. permited level. It is pointed out that
breaker mechanism spring Temporary connections the permitted level is for continuous
charging motor and rectifier. should be removed. exposure, whereas the test voltage
Components should be is applied for a short time on each
Disconnect the wiring to / reconnected. occasion. The vacuum circuit
withdraw any relying devices. breaker does not emit X-ray
3.4.1 Megger Test radiation at working
Short circuit current transformer voltage.
secondary windings. The primary insulation includes the
insulation associated with the high The integrity of the vacuum
Disconect secondary wiring on voltage circuit. While carrying out interrupters can be checked on site
voltage transformers. this test it should be noted that, by applying a test voltage of 20 kV
insulation varies considerably with ac rms or 30 kV dc for 2 or 3
Isolate any isolatable voltage atmospheric conditions, dryness seconds across the open contacts
transformers. and cleanliness of the equipment; of each phase in turn with the other
low readings may occur as a result side earthed. No evidence of
After completion of testing all of surface leakage over the breakdown indicates that the
conductors shall be discharged insulation. Using a 500V megger interrupter is in a satisfactory
to earth, temporary connections measure the resistance to earth of condition.
recomved and components each phase in turn. If the resistance
reconnected. falls below an obsolute minimum of Should a breakdown occur, the
1000 megohms after careful circuit breaker should be kept out of
3.3.1 Megger Test cleaning and drying of all exposed service and the matter reported
surfaces a check of the equipment without delay to the AREVA
The secondary insulation includes should be made for insulation LIMITED, SWGR DIVISION AT
the insulation associated with the damage. AEI/Salt Lake Works.
secondary wiring. For this test the
ends of the secondary wiring should 3.4.2 High Voltage Test
be looped together, at some 3.7 Final Inspection
convenient point such as terminal IS : 13118 & IEC 56 gives full
board and jsing a 500V megger information regarding high voltage The equipment should be given a
measure the resistance, which testing after erection on site. final inspection before it is put into
should not be less than 2 service.
megaohms between the loops and With the circuit breaker CLOSED a
earth. power frequency voltage should be Check that all covers are in place
applied to each phase in turn and fully secured.
3.3.2 High Voltage Test between the phase conductor and
earth for 1 minute. Check earth bars for continuity.
For this test the ends of the
secondary wiring should be looped 12 kV highest system voltage – 28 Check that all fuses and links are
together at some convenient point kV rms power frequency for 6.6 kV inserted.

8
Check that padlocks are fitted LOCAL/REMOTE selector switch to slot in the handle on the drive
(where applicable). the required position and operate pin the racking shaft. Push the
trhe appropriate OPEN/CLOSE handle fully on to the shaft and
Check all moving parts of the safety switch to CLOSE the circuit breaker. rotate the handle anti clockwise
shutters, the circuit breaker racking untill the circuit breaker stops
mechanism, circuit and busbar Note : The motor will automatically withdrawing from the housing.
earthing switch operating recharge the mechanism springs Remove the handle.
mechanisms, isolatable voltage after a closing operation enabling
transformer operating mechanisms an instanceous close after trip to be iv. Using the handles on the circuit
and all interlocks. carried out. breaker truck pull the circuit
Operate the Truck electrically and breaker from the housing. This
manually to ensure it is 4.2.2 Hand Charged operation also automatically
functional. Spring Mechanism closes the safety shutters over
the busbar and circuit primary
Ensure all insulation surfaces are Insert the spring charge handle into connection spouts.
clean and dry. the ‘MANUAL CHARGE’ orifice in
the mechanism facia, locating the 4.5 Operation of the
Touch up paint work where slot in the handle on the drive pin in Circuit Breaker in the TEST
necessary. the charging shaft. Push the handle Position
fully into the shaft and rotate the
3.8 Recordings handle anticlockwise in the clean a. Withdraw the circuit breaker
movement to charge the springs. from the housing as described
Records are of value in establishing Remove the handle. in Section 4.4 till the TEST
the frequency of maintenance, position.
therefore careful note should be Operate the spring release manually
taken of relevant items each time or electrically as described in b. The secondary socket/plug
maintenance is carried out. Section 4.2.1 umbelical cable between the
circuit breaker and the housing
In order that a complete history is Note : The mechanism springs can front panel will remain
available, records should be started be recharged after a closing connected.
immediately after commissioning operation enabling an
and should include – instantaneous close after trip to be c. Operate the isolating
carried out. mechanism from the FREE to
Date of completion the LOCKED position. The
4.3 Opening the Circuit circuit breaker may now be
Circuit breaker operations counter Breaker operated.
reading
4.3.1 Motor Charged 4.6 Insertion of the Circuit
Interrupter contact wear reading Spring Mechanism Breaker into the Service
Position
Number of short circuit operations Manually : Press the TRIP button,
operating the mechanism to OFF i. Wite the circuit breaker isolating
Details of any work carried out thus opening the circuit breaker. mechanism in the FREE
position [Section 4.4(ii)] push
4.0 OPERATION Electrically : Turn the the circuit breaker as far as
LOCAL/REMOTE selector switch to possible into the housing.
4.1 General the required position and operate
the appropriate OPEN/CLOSE ii. Locate the racking handle as
The circuit breaker operating SWITCH to open the circuit braker. described in Section 4.4 (ii) and
mechanism may be one of 2 types : rotate the handle clockwise until
Hand charged spring with shunt 4.3.2 Hand Charged the circuit breaker stops
trips, manual push button closing Spring Mechanism moving. (It may be necessary to
and tripping, optional local/remtote push on the circuit breaker
electrical spring release. 4.4 Withdrawal of the truck in order to start the
circuit breaker from the racking in operation). Remove
Motor charged spring with shunt SERVICE position the handle.
trips, manual push bottom closing
and tripping, optional local/remote i. Trip the circuit breaker (Section iii. Operate the circuit breaker
electrical spring release. 4.3) isolating mechanism to the
LOCKED position. The circuit
4.2 Closing the Circuit ii. Press the circuit breaker TRIP breaker can now be switched
Breaker botton and hold depressed ON as described in Section 4.2
while operating the isolating to put the circuit breaker into
4.2.1 Motor Charged mechanism to the free position. service.
Spring Mechanism This operation also holds the
mechanism tripped and makes 4.7 Busbar and Circuit
Manually : Press the CLOSE button accessible the circuit breaker Earthing
to release the pre-charged springs, racking drive shaft.
operating the mechanism to ON 4.7.1 General
thus closing the circuit breaker. iii. Insert the racking handle into
the racking orifice below the Earthing trucks are usually provided
Electrically : Turn the mechanism facia, locating the with each switchboard as a

9
standard for discharging the
residual charged voltage remaining ii. Carry out the precautions Manual Spring
in the busbar and in the circuit. referred to in Section 4.7.1 Charge Acess Truck
Interlock
The busbar earthing and circuit iii. Insert the earthing truck into the
earthing trucks are similar to housing as described in section
standard breaker trucks in 4.6. the circuit/busbar is/are
appearance but will not consist of now earthed through the Operations
any mechanism or interrupter. earthing truck. counter

Busbar earthing truch consist of top FIG. 7. Mechanism Facia


stems whereas circuit earthing truck 4.7.3 Removing of
consist of bottom stems, the other Busbar/Circuit Earthing
end of the stems are shorted and Truck 4.8.2 Procedure for
connected to the earth. When it is Preparing the Circuit for
required to earth the busbars or Reverse the procedure described in Testing
circuits and earthing truck should Section 4.7.2. Note that no manual
be inserted as appropriate. Trip Push Button is available in i. Earth the circuit with the help of
earthing truck. circuit earthing truck.
For earthing of circuit side, an
earthing switch is provided on rear 4.8 Electrical Testing of 4.8.3 Procedure for
side of the outgoing panels. Busbars and Circuits Preparing the Busbars for
Operating instructions for the same Testing
are provided on rear cover of the 4.8.1 General
panel. The interlocking arrangement i. Withdraw the circuit breaker
ensures that the switch shall always Electrical testing of the busbars and from its housing as described in
be operating when the breaker is circuit may be carried out an every Section 4.4 and earth the
NOT in service position & the unit be means of portable test section of busbar, to be tested
metallic safety shutters are closed. bushings which are inserted into the by Busbar Earthing Truck.
Special care to be taken for primary spout connections.
insertion of EARTH TRUCK into
panel. Warning : 5.0 EMERGENCY
MANUAL OPERATION
Warning : On the unit(s) under test it is MOTOR CHARGED
essential that precautions, to SPRING MECHANISM
Before carrying out any earthing ensure that the equipment cannot 5.1 General
operations it is recommended be reenergised, are taken both in
that the section(s) of busbars the preparing the unit(s) and Should the electrical supply be
and/or the circuit(s) required to during the time that tests are disrupted to the circuit breaker
be earthed be disconnected. being carried out. mechanism spring charge motor or
Precautions should also be taken for mechanical test on the circuit
to ensure that the alternative Before inserting or removing test breaker, the closing springs can be
source of supply is also bushings it is essential that the fixed recharged by means of a removable
disconnected. It is preferred that conductor within the spout is handle which locates in the circuit
equipment should be proved proved dead. breaker mechanism facia.
dead before earthing.
Isolate all transformers during 5.2 Closing the Circuit
4.7.2 Application of a test Breaker
Circuit/Busbar Earth
While disconnected/ reconnection Refer to figure 7 and ascertain the
i. Fully withdraw the circuit is being carried out it is mechanism spring state.
breaker from the housing as recommended that earths are
described in Section 4.4 applied. If “SPRINGS CHARGED” : Refer to
“MANUALLY”, Section 4.2.1.
Spring charge pawls If “Springs Free” : Remove the
motor supply fuses. Inser the spring
If supply to charge handle into the “Manual
motor is lost Charge” orifice in the mechanism
during facia, locating the slot in the handle
charging on the drive pin in the charging
operation, the shaft. Push the handle fully on to the
charging shaft and rotate the handle
operation can anticlockwise in one clean
be completed movement to charge the springs.
manually. Remove the handle. Press the close
button operating the mechanism to
If the supply is restored the mechanism will rest. It may be necessary ON thus closing the circuit breaker.
to reset the mechanism manually. This is achieved by lifting the spring
charge pawls. The wheel will turn release pawls onto the wheel. Note : The mechanism springs can
be recharged after a closing
FIG. 6. Resetting Motor Mechanism after Loss of supply operation enabling an

10
instantaneous close after trip to be release coils is their replacment. The mechanism is supplied with the
carried out. The assembly procedure of trip & lubrication for life and normally
closing coil pot is described in this further lubrication should not be
If “Springs partially charged” manual. required. In the event that
(indicated by the lable being part components are replaced they
way between “Springs charged” 6.1 Precautions should be lubricated with aeroshell
and “Springs Free”) complete the 17 grease or an equivalent silicon
charging and closing of the circuit Refer to the notes inside the front base grease containing
breaker as described under cover and Section 3.1 Molybdenum Disulphide.
“Springs Free”.
6.2 Inspection Care must be taken to ensure that
Note : In order to make the no lubricant is applied to the
mechanism capable of further A careful routine scrutiny of the operating mechanism electrical
charging operations after closing equipment is required for any signs release coil plunger or electrical trip
the circuit breaker from a “Springs of deterioration or abnormality. coil plunger.
Partially Charged” position during Inspections should include
the time that the motor supply may operational checks. Should there be any doubts about
be disrupted, it is necessary to the condition of any components a
remove the circuit breaker from the Refer to figures 7 & 8 and for more detailed examination must be
housing, remove the mechanism location of circuit breaker made.
cover and rotate the ratchet wheel operations counter and interrupter
anti-clockwise until the link pin on wear indicator. 6.3.2 Circuit Earthing
the ratchet is at the lowest point. Truck
However, restoration of the motor 6.3 Examination/Service
supply will complete the travel of Under normal service conditions
the ratchet wheel, thus making the It is recommended that an earthing truck is virtually
above procedure unnecessary. examination to be carried out maintenance free.
Refer to Figure 6. whichever occurs first :
i. 8 years Inspection, cleaning and
5.3 Opening the Circuit relubrication is recommended after
Breaker ii. 2000 normal operations 2-3 years under unfavourable
iii. 100 fault operations. Where the ambient conditions such as
Refer to “Manually” Section 4.3.1. fault current is less than the excessive dust collection,
rating of the circuit breaker this aggressive atmospheres,
6.0 MAINTENANCE number may be increased. continuous high relative humidity in
excess of 70%. Aseol molitea or
The maintenance policy for HWX Further advice can be obtained Molydag 47 is to be used for the re-
switchgear is based on IS from the manufacturer. lubrication of contacts and bearing
10118:(1982) reference to which joints.
should be made for a general 6.3.1 Circuit Breaker and
background to this subject. Operating Mechanism 6.3.3 Primary
Conductors and
In particular the maintenance policy The design of the operating Connections
is based on the concept of mechanism is such that no
Inspection, Examination/ Service adjustments are required Remove the appropriate covers and
and Overhaul is defined in the throughout its lifetime, subsequent check that all electrical joints and
standard. examinations will consist of visual connections are sound.
inspection for wear, corrosion, loose
Because of the widely varying components and unless there is Remove any deposits of dust etc.
condition of operation of individual reason to believe that there is
installations it is not possible to law deterioration, no dismanting is 6.3.4 Auxiliary Switches
down precise recommendations for allowed.
the intervals between maintenance Ensures that all connections are
required under all circumstances. Manual closing and opening tight at the terminals and the
operations should be made to change over of contacts are
These intervals may vary greatly check the closing and tripping checked periodically with a
depending on the duty the mechanisms. The electrical closing continuity meter.
equipment is called upon to perform and tripping circuits should also be
and the environment in which it is checked. 6.3.5 Insulators
situated. The time intervals are
therefore best determined by user The duty imposed on spring charge All insulators should be cleaned
experience based on the behaviour motor is very light, consequently with a non-sheeding cloth.
of the equipment on the particular maintenance is unlikely to be
installation. necessary. However, the assembly 6.3.6 Vacuum
procedure of motor is given in this Interrupters
Vacuum switchgear is low manual.
maintenance equipment, the Refer to Section 3.6
vacuum interrupter being a sealed Examination is confined to the
unit which does not require inspection of the commutator for 6.3.7 Primary Isolating
maintenance during its lifetime. The scoring, the brushes for excessive Contacts
only readjustment which may be wear and free movement in the
required in case of trip and spring brush retainers. Check the condition of the plug and

11
finger contacts. Any furnished An overhaul will be necessary Spring Release Coil – Refer to
surfaces should be cleaned using a when : Figure-12 for fitting instructions Trip
branded liquid silver polish and a a. An examination has identified a Coil – Refer to Figure 13 for Fitting
non-shedding cloth. component(s) as being less instructions.
than satisfactory. LT Fuses
6.3.8 Secondary Voltage Transformer Fuses
Isolating Contacts b. The limit of contact wear of a Auxiliary Switch
vacuum interrupter has been Limit Switch
Ensure that all connections are tight reached. Refer to fig. 8 Isolating Contacts
at the terminals. Contact surfaces
should be treated in a similar c. The vacuum interrupter and the All spares should be stored in such
manner to the primary contacts. circuit breaker operating a manner as to protect against
mechanism have performed the corrosion, humidity, adverse
6.3.9 Primary Connection number of operations indicated atmospheric conditions mechanical
Spounts Safety Shutters in the following table. damage and vermin.

Clean and examine all parts of the 7.0 SPARES When ordering spares of
shutters and operating mechanism replacements a complete
for wear and loose components. If The following spares should be kept description should be given,
required parts should be sparingly in stock, actual quantities will together with relevant nameplate,
lubricated with a good quality depend on the number of circuit data and serial numbers. For further
mineral oil. breaker in service and operating details regarding spares the Spares
conditions. Manual can be referred.
Spout safety shutters shall not be
opened without first earthing the
busbars and/or circuit cables. With VCB Closed Insert Contact
Prove dead after opening.
Wear Gauge into Gap Between
the Drive Insulator and the
6.3.10 Recommissioning
Inspection Spring Guide Rod. This is a GO
/ NO - GO Gauge.
Refer to Section 3.7
The Gap when New is 5mm,
6.4 Overhaul which, when the interrupter is
Worn Out, will reduce to 3 mm.
Overhaul comprises work carried
out to restore the equipment to a
satisfactory condition including the
replacement of components. FIG. 8. Contact Wear Gauging

12
MOTOR ASSEMBLY
Reference Figure No. 9

Opn. No. Operation Description Checkpoint/Remarks


01. Unscrew the 4 Nos. M4 slotted head screw from the Motor
Gear Box Unit.

02. Fit 1 No. MB 2010 DU Bush to the Motor Bracket Casting


(110) with loctite 638.

03. PUT’2 Nos. M12 Brass Washer (117) and 1 No. Eccentric Alignment of keyaways should be
Drive (111) over the Motor Shaft (As shown in the drawing) checked.
such that their keyways are matching.

04. Place the key (115) through the keyway thus locking the
eccentric drive with the motor shaft.

05. Fit the two charging pawls (113) with DU bushes (116)
through gradual, application of pressure on a bench vice.

06. Insert the pawls (113) into the motor shaft such that the
stepped positions are in opposite direction and the plane
faces fall upon one another.

07. Insert the other eccentric drive into the motor shaft and
key it.

08. File M12 shim washers to have slots for the key and place
these above the second eccentric drive.

09. Key the end bearing (112) to the shaft. The top end of the
Aluminium Bracket and the top of the end bearing meshes

10. Fit the Aluminium Bracket (110) after proper adjustment Check tightening of the motor
to the motor shaft housing by M4X30 long (161) round bracket to the gear box housing by
head screws and M4 spring washers (180) at the four double nuts and loctite.
ends. Tighten the screws with a screw driver.

11. Keep the assembly in the bin free on the motor shaft. Check that the pawls are absolutely.

COL P ONLY COLs F. G. H. M. & N.

MOTOR SHAFT

Exploded Assembly of type HWX


Charging Pawls & Eccentrics

Note : This DU Bush used only on Cols F. G. H. M. & N.

FIG. 9. HWX SPMX from a Mechanism Motor Assembly

13
Spring Release Coil Pot Sssembly
Reference Figure No. 10
Opn. No. Operation Description Checkpoints/Remarks

01. Assembly Release Spindle (97) with release plunger • Check the Locking
(106) and Lock with M6 Hex Nut, so that 15 mm
(approx) of Spindle comes out of Plunger.

02. Put the Release Coil within the Release Coil Pot • Check the tightness between
(91) them

03. Place the Pole Piece (96) inside the Release Coil
and lock with the Coil Pot (91) with the help of a
fastener (99)

04. Put the Assembled Release Spindle of Operation • Check easy movement of
No. 1 with Spring (98) on it. Press the Plunger so Spindle
that the other end of the Spindle comes out through
the Pole Piece. Lock the Spindle with 1 No. M6 HEX
NYLOC Nut to restrict the Spring back action of the
Plunger.

05. Fix up Release Lever (92) on the Coil Pot with the • Check Easy movement of the
help of M6x30 HEX HD Screw and Lock it to ensure Release Lever Pivoting about
easy movement of Release Lever around the Pivot. the Screw after locking.
• The Screw Head should be
downward.

FIG. 10. HWX SPMX from a Mechanical Realease Coil Pot Assembly

TRIP BOX ASSEMBLY


Reference Figure No. 11
Opn. No. Operation Description Checkpoints/Remarks

01. Assemble the Trip Plunger (251) and Brass Stud (250) —
and lock them with Two Nos. M5HEX Head Nut si tgat
25 mm (approx) of Brass Stud comes of the Trip Plunger.

02. Put the above Assembly and Pole Piece with the locked Check easy movement of the Trip
side of the Trip Plunger downward into the Trip Coil Plunger in the Trip Coil.

03. Fit the Buffer pin (109) in the M5 thread hold of the Trip
Box through the 7.8 mm dia hole of the Trip Box top
face and lock with M5 Hex But (167).

14
TRIP BOX ASSEMBLY
Reference Figure No. 11 (Contd.)

Opn. No. Operation Description Checkpoints/Remarks

04. Put the Neoprene Buffer (104) on Buffer Pin (109)

05. Put the Assembled Trip Coil within the Trip Box (101) • Fixing the Fastener
and lock the Pole Piece with the Trip Box with A Fastener • Check easy movement of the

Our policy is one of continuous development. Accordingly the design of our products may change at any time. Whilst every effort is made to produce up to date literature, this brochure should only be regarded as a guide and is intended for information
(99) Plunger inside the Coil

06. Apply grease (ROCOL) on Trip Bar (102). Assemble Trip Check easy pivoting of Trip Bar
Bar and Trip Box with Pivot Pin (103) with E-Clips on on Trip Box.

purposes only. Its contents do not constitute an offer for sale or advise on the application of any product referred to in it. We cannot be held responsible for any reliance on any decisions taken on its contents without specific advice.
both sides.

104

103 189

250
102
252

253

101
254
109

(A) Unbolt Drive Spring From


ON/OFF Indicator.
167
(B) Spring Charge Indicator Using
Good Long Nosed Pliers
251
Remove Spring Charge Reset
167 Spring from Facia.

SWITCHGEAR- L4- FACTS - EN- 2 - © - AREVA - 2005. AREVA, the AREVA logo and thereof are trademarks and service marks of AREVA.
Remove Facia (# Screws) Disconnect

All trade names or trademarks mentioned herein whether registered or not, are the property of their owners. - Switchgear Kolkata.
coil, Using Long Nosed Pliers
FIG. 11. Tip Box Assebly for HWX Mechanism Remove Spring Clip, Slide Out
Plunger, Coil can now be Removed
Disconnet coil and remove coil assembly (2 from the Coil Box.
bolts from rear)
Reverse Sequence to Refit Coil.
Using long nosed pliers remove the spring clip. Check Electrical Operation.

Remove plunger, coil can now be removed from FIG. 13. Replacing Shunt Trip Coil
the coil box.

To refit the coil, reverse the sequence and check


electrical operation.

FIG. 12. Replacing Spring Release Coil

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