ABB

SD SERIES 2B
SWITCHGEAR MANUAL

ABB Ltd
Switchgear Division
Auckland
New Zealand Document #: SD2BMANUAL
Phone: +64 9 837 1234 Revision 13
Fax: +64 9 837 2950 30/03/2000
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TABLE OF CONTENTS

1 GENERAL DESCRIPTION ...............................................................................1

1.1 APPLICATION 1
1.1.1 ACCESSORIES ...........................................................................................................................1
1.2 SD RATINGS 1
1.3 FUNCTIONAL DESIGN FEATURES 1

2 INSTALLATION ................................................................................................3
2.1 GENERAL 3
2.2 TRANSPORT 3
2.3 MOUNTING 3
2.4 INTERCONNECTED UNITS 4
2.5 BUSBAR END COVER 4
2.6 CABLE BOXES 5
2.7 OIL FILLING 5
2.8 EARTH CONNECTION 5
2.9 GENERAL ARRANGEMENTS 6

3 CABLE KITS .....................................................................................................8

3.1 RAYCHEM KIT LIST 8

4 OPERATION .....................................................................................................9
4.1 BASIC SWITCH 9
4.1.1 OFF TO ON .................................................................................................................................9
4.1.2 ON TO OFF .................................................................................................................................9
4.1.3 OFF TO EARTH..........................................................................................................................9
4.1.4 EARTH TO OFF..........................................................................................................................9
4.2 SWITCH FUSE 10
4.3 REPLACING FUSES 10
4.4 CABLE TESTING 11
4.5 INTERLOCKS 11
4.5.1 ON/OFF/EARTH .......................................................................................................................12
4.5.2 TEST ACCESS COVERS..........................................................................................................12
4.5.3 USING TEST DEVICE .............................................................................................................12
4.5.4 FUSE ACCESS COVER............................................................................................................12

5 MAINTENANCE ..............................................................................................13
5.1 GENERAL 13
5.2 CORROSION PROTECTION 13
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1 GENERAL DESCRIPTION
1.1 APPLICATION
The SD Series 2 switch range is designed for use on distribution systems to switch 3-phase
currents up to 400-600A (depending on voltage) at voltages up to 12kV. SD switches are
available in a variety of configurations made up from a switch and an automatic tripping
switch fuse (activated by a fuse striker). These include an RMU (a ring main unit
comprising 2 switches & 1 switch fuse), single, double and triple switches and a single
switch fuse. Each switch and switch fuse has an associated cable earthing switch as part of
the module.
All these configurations can be supplied with extensibility to allow bus-interconnection to
build up a switchboard arrangement.
General arrangement and foundation details are shown in Figures 3 and 4 (pp 6 & 7).

1.1.1 ACCESSORIES
A wide range of accessories including earth fault indicators, voltage indicators and flush
front covers are available. Full details of these are contained in ABB document
SD2BACCESSORY.

1.2 SD RATINGS

Busbar Load Load Break Maximum Fuse

Current (A) Current (A) Rating (A)
Ring Switch
7.2 kV 630 630 —
12 kV 630 400 —
Switch Fuse with 10" Fuses
7.2 kV 630 — 112
12 kV 630 — 80
Switch Fuse with 14" Fuses
7.2 kV 630 — 150
12 kV 630 — 125

Impulse Withstand Level: 95/110 kV peak.

Short Circuit Rating:
Standard Unit High Rated Unit
Making Capacity: 50 kA peak @ 12kV 50 kA peak @ 12 kV
54.8 kA peak @ 7.2 kV 54.8 kA peak @ 7.2 kV
Withstand Capacity: 20 kA for 3 sec @ 12 kV 20 kA for 3 sec @ 12 kV
21.9 kA for 2 sec @ 7.2 kV 21.9 kA for 3 sec @ 7.2 kV
1.3 FUNCTIONAL DESIGN FEATURES

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The SD switch is an oil-filled switch using rose and poker contacts for main and earth
switches. The switches are operated by a manually charged spring bank. The spring bank
drives the poker contacts to the ON or OFF position.
Cable connection is made to the bushing stems projecting from the lower front of the tank.
(Section 2 deals with installation and cable connection).
The main switch moving contact operates horizontally across the bottom of the tank while
the earth contacts move vertically at the front. Three busbars run laterally across the width
of the tank interconnecting switch modules and, when required, extension bushings in the
tank sides.
In the case of a fused switch, the fuses are positioned between the sliding contact housing
and the busbar system by means of self-aligning contacts. This arrangement allows the fuse
carrier to be lifted clear of the oil (and out of the circuit) for fuse changing. The fused
switches use a fuse incorporating a fuse striker pin. This ensures that all phases are opened
when any fuse operates.
Mechanisms are charged by horizontal operating shafts that pass out through the front of the
tank where the drive dogs are attached. Shaft seals are provided to prevent ingress of
moisture and dust.
The switch status is shown by indicator flags, swivelling on the shaft bosses, which are
visible through the window located between each pair of shafts. The ON indicator is
connected to the main switch contact driving shaft at the lower rear by means of a flexible
cable. The EARTH indicator has a rod connecting it to the earth contact bridge at the lower
front. When both ON and EARTH flags are withdrawn, ie both contact sets are open, the
fixed OFF indicator is shown.

The top of the tank is closed by a lid assembly incorporating access covers for cable testing
and, in the case of a fused switch, fuse access. When the fuse access cover is raised the fuse
carrier assembly is lifted clear of the oil. A special test device can be inserted at the access
opening to test the cable.
Various interlocks are provided to prevent inadvertent unsafe operation and these are further
described in Section 4.5. Circuit mimic diagrams and operating directions are clearly
displayed adjacent to the operating dogs at the front of the tank. A rating label showing load,
fault current and voltage levels for the switch, with its serial numbering, is attached to the
lower front.

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2 INSTALLATION
2.1 GENERAL
The weight of each unit is:
Without Oil Filled with Oil Oil Volume
(kg) (kg) (litre)
SD 115 160 50
SD2 190 275 95
SD3 250 375 140
SDAF3 250 370 135
SDAF 170 250 90
SDAF14 180 275 110
SDAF14-3 262 410 170
SDM 250 460 210

The switch and mechanism are factory set and require no attention before commissioning.
Switches are shipped, bolted to a pallet and protected with a packing cover. On receipt,
check each unit for transit damage, paying particular attention to insulation, and make good
any damaged paintwork.
The unit should be stored under cover in dry conditions. Units in storage should be filled
with clean dry oil.
Before putting the units into service, remove any storage oil and refill with clean dry oil.

2.2 TRANSPORT
The units are shipped from the factory without oil. When units are transported with oil, it is
possible that there will be seepage through the vent plug. The seepage volume will be only a
small volume and need cause no concern. The level of oil in the unit must be checked before
use.

2.3 MOUNTING
The equipment should be mounted on a concrete base designed to support the equipment
weight as detailed in the table above. The concrete base should be mounted on a suitably
prepared and compacted base. The concrete base should be smooth and must be installed
such that it is level. The maximum deviation in the height of the mounting pad must be less
than 5mm in any direction.
The units are fastened by four M12 bolts. Ensure the galvanised base piece is installed in the
service position as illustrated in Figure 1. The galvanised base piece is needed to separate
the stand from the ground to prevent corrosion of the stand. Ensure that there is free air
movement around the stand and prevent build up of material around the base of the stand.

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(a) (b)
Figure 1: Base Piece Location. (a) For Transport. (b) For Service.

2.4 INTERCONNECTED UNITS

Units can be interconnected using the extensible busbar option. The coupling kit is part
number N0095A and includes all links, covers and Raychem insulation.
Carefully check the plinth to find the highest point (in the setting area), and position the first
unit so that its base is no lower than this point, using shims if necessary. This will facilitate
the installation of extension units. Ensure that the unit is vertical, and then secure in
position.
Extension units must be placed so that the dimension between the side faces of adjacent
units is 221mm. The stems of the opposing busbar bushings must be in line.
For the interconnection procedure refer to the detailed instructions supplied with each
coupling kit or to the detailed instruction manual available from ABB (Document #
SD2BCOUPLING).

2.5 BUSBAR END COVER

Busbar end covers MUST BE USED when an extensible switch has been installed but the
busbar bushings have not been connected to another unit. Refer to instructions supplied with
busbar end cap kit N0096A. A detailed instruction manual (Document # SD2BENDCAP) is
available from ABB.

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2.6 CABLE BOXES
The cable box will accommodate cables up to 300mm². The
centre of the bushing hole is approximately 687mm above
ground level. The width of the cable box varies with the type of
switch used, but has a minimum width of greater than 230mm.
Suitable Raychem kits that can be used with the SD range of
switchgear are detailed in Section 3.

2.7 OIL FILLING

Before the equipment is put into service check the interior of

687
the switch tank for cleanliness, loose packing etc, and then fill
with transformer oil that meets standards BS 148 and IEC 296.
The oil level mark corresponds to the correct level with covers
closed (fuse carriage lowered). If filling a fused unit with the
carriage raised, stop when oil is visible at the lower edge of
window, close cover and check level. Add oil as necessary to
reach correct level. Approximate oil capacities are shown in the >230
table in Section 2.1
Figure 2: Dimensions
within Cable Box.

2.8 EARTH CONNECTION

Each SD unit has an earth point on the lower front side, marked with the IEC earth symbol.
Earthing connectors to continue the earth between SD units are supplied in the coupling kit
N0095A. This will provide a continuous earth run along the length of the switchboard. A
bolted earth connection is provided to each cable gland when glands are fitted.

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2.9 GENERAL ARRANGEMENTS

440mm clearance required to 515mm clearance required to

raise fuse access cover. raise fuse access cover.
630mm clearance required for 630mm clearance required for
test device access. test device access. 630mm clearance required for
VT fuse replacement.

630
630
630

515
815

440
646 751

1574
1574

1324
1282
1282

260 386 260 491 217 598

SIDE VIEW SIDE VIEW SIDE VIEW

SD, SD2, SDX, SDAF, SDAF3 SDAF14, SDAF14-3 SDM

(a) (b) (c)

Figure 3: Side Views of SD Equipment. (a) 10" Fuse. (b) 14" Fuse. (c) SDM.

384 384

811
160 245.5 245.5 160
944 to centre line of bushings
(690 for short height stands)

31 692 31
208
60

754 131.5 245.5 245.5 131.5

Figure 4: Detailed front view (showing sweep of operating handle) and foundation plan for SDAF3.

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320 566 811 524 811

FRONT VIEW

263 221 509 221 754 221 468 221 754 221

201 283 447 283 692 283 406 283 692 283

M12 RAGBOLT FIXINGS

60
FOUNDATION PLAN 208

EDGE OF CONCRETE

131 132 132 246 132 131 246 246 132 234 234 131 246 246 132

SD2 SD3 SDAF SDAF3

SINGLE LINE DIAGRAM

811 566 524 524 811

221 754 221 509 221 464 221 468 221 754

283 692 283 447 283 402 283 406 283 692

131 246 246 132

234 234 131 246 246 132

SDAF3 SDX SDM SDAF14 SDAF14-3

Figure 5: Front View, Mounting Layout and Single Line Diagrams for
a Combination of 10" and 14" SD Equipment.

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3 CABLE KITS
3.1 RAYCHEM KIT LIST

Conductor Size Range (mm²)

Cable Type 16-35 50-95 -120 -150 -185 -240 -300

Screened 3 Core MIND PILC with Armour

EPKT EPKT EPKT EPKT EPKT EPKT EPKT
Kit Number
3637 3643 3649 3649 3649 3655 3655
Inline Boot Suffix -05 -06 -07 -07 -07 -07 -07
Angle Boot Suffix -08 -09 -10 -10 -10 -10 -10

Belted 3 Core MIND PILC with Armour

EPKT EPKT EPKT EPKT EPKT EPKT EPKT
Kit Number
3667-PT 3673-PT 3679-PT 3679-PT 3679-PT 3685-PT 3685-PT
Inline Boot Suffix -05 -06 -07 -07 -07 -07 -07
Angle Boot Suffix -08 -09 -10 -10 -10 -10 -10

Single Core MIND PILC

EPKT EPKT EPKT EPKT EPKT EPKT EPKT
Kit Number
3578-PT 3578-PT 3583-PT 3588-PT 3588-PT 3588-PT 3593-PT
Inline Boot Suffix -05 -06 -07 -07 -07 -07 -07
Angle Boot Suffix -08 -09 -10 -10 -10 -10 -10

3 Core XLPE Insulated

IXSU IXSU IXSU IXSU IXSU IXSU IXSU
Kit Number
F3321 F3321 F3331 F3331 F3331 F3331 F3331
Inline Boot Suffix -06 -06 -07 -07 -07 -07 -07
Angle Boot Suffix -09 -09 -10 -10 -10 -10 -10

Single Core XLPE Insulated

IXSU IXSU IXSU IXSU IXSU IXSU
Kit Number
F3121 F3121 F3131 F3131 F3131 F3141
Inline Boot Suffix -06 -06 -07 -07 -07 -07
Angle Boot Suffix -09 -09 -10 -10 -10 -10

NOTE:
1. Raychem jointing instructions should be adhered to.
2. Use only sealed type cable lugs.
3. It is desirable that air circulation be allowed around raychem joints, sealed boxes are not
recommended.
4. A quick release inline boot is available which rolls over the cable termination
5. Tail length 450mm.

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4 OPERATION

The following sections give a brief overview of the operation of the switches.
Comprehensive switching details are given in the detailed operating manual (Document #
SD2BOPERATION) available from ABB.

4.1 BASIC SWITCH

Reference to the circuit mimic diagram shows the arrangement of the switch and the switch
status will be displayed in the indicator window immediately above. The sliding interlock
bar above the window prevents closure of the main or earth switch while the other is closed.

4.1.1 OFF TO ON
To operate from OFF to ON, first ensure the interlock bar is slid to the extreme right; the
tag will virtually touch the yellow earth dog. Attach the black socket of the operating handle
to the black (left-hand) dog so that the hinge does not collapse when down force is applied
(if it does, reverse it to use the other side of the black socket). To turn ON, press the handle
with a firm positive motion (clockwise with a standard handle) through the full 90° of
movement. The padlocking lug on the dog should now be close to the top bar and aligned
with the hole to allow a padlock to be passed through both. The mechanism will discharge
after approximately 600 of handle movement and the status indicator will show ON (white
letters against a red background).

4.1.2 ON TO OFF
If turning OFF immediately after turning ON, the handle must be removed and reversed
using the other socket to ensure the hinge is locked. This breakaway feature of the handle
ensures there is a minimum 3 second delay between OFF to ON and ON to OFF, avoiding
instinctive attempts to open the switch if closing onto a fault condition. To switch OFF,
raise the handle with a firm positive motion (anti-clockwise) through the 900 to bring the
padlocking lug to the lower padlocking bar. The status indicator will show OFF (white
letters against a green background).

4.1.3 OFF TO EARTH

The interlock bar must be slid to the extreme left (as indicated on the tag stamped "MOVE
BEFORE EARTHING").
The appropriate yellow socket on the handle is fitted to the yellow dog. To EARTH, press
the handle down (anti-clockwise), firmly through 900 to the padlocking position. Status will
now show EARTH ON (black against a yellow background).

4.1.4 EARTH TO OFF

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Handle is raised (clockwise) in a reversal of 4.1.3 after changing drive sockets. OFF will
show in the window.

4.2 SWITCH FUSE

A switch fuse is operated in exactly the same way as a basic switch. However, as the handle
is rotated anti-clockwise to switch from ON to OFF the switch is actually tripped in the first
part of the movement and then the mechanism reset in the remaining movement. The
indicator will immediately show OFF. If a fuse blows, the striker pin will initiate tripping of
the switch. The switch will be off and the display will show OFF, however, the switch dog
will still be in the ON position. The handle must be used after a fuse fails to reset the
mechanism to the OFF position.
The fuse access cover cannot be opened unless the switch is reset to OFF.

4.3 REPLACING FUSES

Before the fuses can be accessed, the switch fuse section must be turned OFF.
The fuse access cover can be released by undoing the two M10 stainless hex head set screws
at the centre front of the cover. Grasp the handle on the front edge of the cover and raise to
the limit of movement. This will bring the fuse carrier flush with the top of the tank and
earth the rear end of each fuse. The lid prop at the left rear will lock the raised cover in the
uppermost position automatically. To release the cover, the lid prop must be pressed back.
TRAINED SERVICE PERSONNEL ONLY SHOULD WORK ON THE
EQUIPMENT. EXTREME CARE MUST BE TAKEN AT ALL TIMES WHILST
REPLACING FUSES. IF THE FUSE HOUSING HAS BEEN DAMAGED IN ANY
WAY THE UNIT MUST BE THOROUGHLY FLUSHED. ENSURE SWITCH IS
COMPLETELY ISOLATED BEFORE ATTEMPTING TO FLUSH THE UNIT.
Fuses can be released by pulling the stirrups off the clips gripping the end caps. Ensure fuses
are replaced with the striker pin end to the rear of the tank, and stirrups pressed completely
home and locked into both notches on each clip. IF A STIRRUP IS NOT PRESSED
COMPLETELY HOME THERE IS THE POSSIBILITY IT MAY FALL OFF THE
CLIP AFTER THE FUSE CARRIER IS LOWERED. If this happens, it may interfere
with the mechanism operation.
If the stirrups are not replaced on the fuses, a fuse is left out, or there is a blown fuse with a
striker pin ejected, the stirrups will be caught by the fuse earth fingers and prevent the
closing of the cover. If resistance is felt in the initial closing movement DO NOT FORCE
THE COVER DOWN, raise the cover again and inspect the carrier for the items mentioned
above.

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IF FOR SOME REASON A FUSE CARRIAGE HAS TO BE LOWERED WITHOUT
FUSES, ENSURE STIRRUPS ARE IN THE POSITION SHOWN BELOW.

STIRRUP

FUSE CARRIAGE

Figure 6: Stirrup Position Required to Lower Fuse Carriage without Fuses.

Note: The SD range of switch fuses is designed to operate with fuse links manufactured to
standards IEC 282:1985 and BS 2692:1986, heavy range (table 12) which calls for a striker
energy of 2 joules plus or minus 1 joule.

4.4 CABLE TESTING

TRAINED SERVICE PERSONNEL ONLY SHOULD WORK ON THE
EQUIPMENT. EXTREME CARE MUST BE TAKEN AT ALL TIMES DURING
CABLE TESTING.

1. Ensure that the circuit is not energised.

2. Operate the switch to EARTH ON thus earthing the cable.
3. Raise the test access cover. This is only possible when the switch is in the EARTH ON
position.
4. Insert test device and connect test leads.
5. Operate switch to OFF position. This locks the test device in position and an interlock
prevents the main switch being operated into the ON position.
6. Testing can now be carried out. The ABB test device suitable for use with this
equipment has the following ratings:
• 24 kV AC for 1 minute.
• 36 kV DC between phases with mid point earthed for 15 minutes.
• 25 kV DC to earth for 15 minutes.
• 200 A continuously.
• NOTE: For test levels to be applied after erection of switchgear refer to
appropriate standards.
7. After testing, switch back to EARTH ON and remove test device.

It is necessary to secure the test access cover before the earth can be removed. The switch is
now ready for putting back into service.

4.5 INTERLOCKS

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Interlocked functions are referred to in each relevant section but a summary is made here for
quick reference.

4.5.1 ON/OFF/EARTH
It is not possible to switch both Main and Earth switches ON together. The sliding bar
mounted between the operating dogs must be positioned to select the operation required.

4.5.2 TEST ACCESS COVERS

The switch must be in EARTH ON before the test access cover can be opened. Once the
cover is opened, the switch CANNOT BE SWITCHED TO OFF OR ON until the cover
is closed again.

4.5.3 USING TEST DEVICE

With a cover open (the switch in EARTH ON) the Test Device can be inserted. Once fully
inserted, the EARTH switch can be switched to OFF, which will lock the test device in
position. The presence of the test device prevents switching the main switch to ON. To
remove the test device the earth switch must be returned to EARTH ON

4.5.4 FUSE ACCESS COVER

The switch fuse must be OFF (and the dog in the OFF position) before the cover will open.
Fuses can be replaced and the switch cannot be turned ON while the cover is open.
The switch fuse must be switched to EARTH ON before the test device can be inserted.
Once in place, switching EARTH to OFF will lock it in place.

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5 MAINTENANCE
5.1 GENERAL
This switchgear should be maintained in accordance with: the recommendations of British
Standard Code of Practice C.P. 1009 for the maintenance of insulating oil; British Standard
Code of Practice BS 5405:1976; the maintenance of electrical switchgear; the user's own
maintenance regulations; and the following instructions.
If the SD switchgear suffers problems, please contact your ABB supplier or Switchgear
Division at the following address for advice:

ABB Ltd
Switchgear Division
133 Central Park Drive
PO Box 83-203
Auckland 8
New Zealand

Ph: +64 9 837 1234

Fax: +64 9 837 2950

5.2 CORROSION PROTECTION

All external surfaces of this switchgear are zinc sprayed or electroplated and painted to
prevent corrosion. All nuts, bolts etc that are disturbed during erection should be repainted
immediately to consolidate the electroplating and thereafter painting will only be required at
very infrequent intervals. Stainless steel fastenings are not painted during production and do
not need to be painted on site.
The stand must be mounted on the galvanised mounting plate supplied, or suitable
substitute, to prevent corrosion of the stand base.

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