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

12KV HORIZONTAL ISOLATION HORIZONTAL DRAWOUT VACUUM

MEDIUM VOLTAGE SWITCHGEAR

SWITCHGEAR TYPE HWX

RATING AND SPECIFICATION

Type Unit HWX

Rated Voltage kV 7.2/12

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

Rated Frequency Hz 50

Rated Interrupting Current kA 26.2/31.5/40

Rated Making Current kA 65.5/80/100

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

Operating Duty – IEC 56 (1987)/IS 13118(1991)

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)

INTRODUCTION springs in a discharged state

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

The equipment requires minimum Before commencing and after

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

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

OPTIONAL DUPLICATE BUS-BAR 690

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

Y Y

545
B B
INTERPANEL
660 352 ACCESS
FOR CONT. WIRING

CHANCE OVER
565

DRIVE

INSTRUMEN
T CHAMBER

960/1130
BREAKER COMPARTMENT
BLOW-OFF COVERS
902 BUS-BAR COMPARTMENT
895

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

50X6 CU EARTH
BUS
PVC SHROUD

2430/2600
SURGE
DIVERTERS
SEC. PLUG
(FOR MOTOR FDRS)
SOCKET

RACKING
SCREW DRIVE BEAM
1470
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
Y Y

545
660 B B

352 INTERPANEL ACCESS

FOR CONT. WRING

CHANGE OVER
DRIVE

565
INSTRUMEN
T CHAMBER

960/1130
EXTENSION CHAMBER FOR ADD. CABLES

BREAKER COMPARTMENT BLOW-OFF COVERS BUS-BAR COMPARTMENT

902 500
895

PVC SHROUD

SEC. PLUG

2430/2600

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

SOCKET

RACK IN

1470
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
MAIN CABLE ENTRY
MULTICORE CABLE ENTRY
50X6 CU. EARTH BUS
FRONT VIEW
SECTIONAL SIDE VIEW OF 12kV 2000A/2500A, 40kA HWX PANEL

4
 left-hand foundation fixings.
Correct operation of the equipment
is dependent on it being level. It is
essential, therefore, that care is
taken at all stages of erection, in
particular the lining up and leveling
of the first unit, which will be the
datum for all other units. Failure to
erec the first unit correctly will result
in mal-alignment throughout the
switchboard & this will cause rack
in/rack out problem of breakers
within the housing. Foundation
channels must be checked for
curvature. Any found to be distorted
must be straightened if possible or
replaced. Under no circumstances
shall distorted channels be used.
Foundation fixings may be one of
two types :
Foundation Channels or Foundation
Bolts.
2.5.1. Foundation
Channels
Prepare the floor and foundations &
then proceed as follows :
i) Determine the highest point on
the channels. This point then
becomes the datum for all units,
it is useful to use this point for
erection of the first unit.
ii) With reference to general
arrangement drawing of the
switchboard, check to unit
Top of unit frame
Use plumb line down
sideframe to measure
alignment. Variation
must be within ± 1.5mm
NOTE :
Do not make adjustments
to moving portion
FIG. 4. Unit Leveling Instruction
5
serial numbers and remove the
circuit breaker from the housing
to be erected first. Position the
housing on the channels.
iii) Locate the foundation bolts and
associated washers through the
holes in the base of the housing
into the spring loaded nuts
within the channels. DO NOT
TIGHTEN.
iv) Using 2 plumb lines level the
housing front to back and
across the width. Levelling is
carried out using shim plates.
These shims shall be located
adjacent to and on the outside
of the foundation bolts such
that they will also support the
adjacent housing when that is
erected. Refer to Figure 3.
Shims must also be placed
under the base sheet in the
apron area to make up any gap
between the floor. Once the
housing has been levelled the
foundation may be ‘nipped-up’
but not tightened.
v) Position the next housing to be
erected close up to the first, fit
the foundation bolts and level
up as before. Remove the
housin top and rear covers and
fit the inter-housing fixing
screws, ‘nip-up’ only at this
stage. Refer to Figure 4.
Remove lifting plate before
50mm Sq. shims
Foundation bolt
Positions
mounting panel.
vi) Repeat the above for the
remaining housings
remembering to check the unit
serial numbers with the general
arrangement drawing of the
switchboard. Finally, tighten all
foundation bolts and inter
housing fixings.
vii) Check the alignment of the
instrument panels for squares
and equality of spacing
between panels.
viii) Rubber gasket should be
provided between the panels.
2.5.2 Foundation Bolts
(Expanding type)
Preparing the floor as stated in
Section 2.5 then proceed as
follows :
a) Determine the highest point on
the floor. This point then
becomes the datum for all units.
It is useful to use this point for
erection of the first unit.
b) With reference to the general
arrangement drawing of the
swithboard check the unit serial
numbers and remove the circuit
breaker from the housing the
housing on the floor.
c) Carry out operations iii, iv, v vi,
1.5mm
Max variation
1.5mm from verticle
Use plum line down rear
of frame for vertical
Floor
50mm Sq. shims fitted
as appropriate under
unit to level

1. M8x20mm long Hex.
HD screw with nut &
washer
FIG. 4. Inter Unit Fixing
& vii Section 2.5.1 except fit the
foundation bolts as follows :
Using the holes in the base of
the housing as a template drill
the floor for accepting M12 x 75
mm long expanding bolts.
2.6 BUSBAR ASSEMBLY
2.6.1 General
The cross-section of busbars is
given on the general arrangement
drawing of the swithboard.
Before assembly, all contact
surfaces of the busbars and
housing connections must be
cleaned to ensure a good contact
surface. Unplated contact surfaces
shall be cleaned using a branded
liquid silver polish. After cleaning, all
surfaces shall be wiped wth a clean
cloth to remove any metal dust, etc.
Joints shall be assembled as soon
as possible after preparation.
The same treatment of contact
surfaces shall be carried out on all
other joints, such as the tee off to
voltage transformers and main
cable connections.
2.6.2 Assembly
The busbars shall be assembled
such as to be parallel to the line of
the switchboard and suitable for
extension if necessary.
Red and Blue phases (the two outer
phases) shall be assembled on the
front face of the spout connection
only, Yellow phase (the centre
phase) shall shall be assembled on
the front face of the spout
connection only. Assemble Blue
phase first, then Red phase and
finally Yellow phase Ref.
figure 5.
2 - M8 x 16mm long
Hex. HD screws with
washer
Where multiple busbars are used,
and units require spacers (supplied)
fitting between the busbars at the
spout connections, also, where
busbars on end units are in the front
(Red and Blue phases) and upper
(yellow phase) positions on
additional spacer (supplied) will be
required between the spout
connections and the busbar in order
to keep the busbar run straight.
When an extension unit is being
erected these spacers must be
removed to accommodate the
extension busbars and refitted in
the same positions in the extension
unit. The busbar joints shall be
encapsulated with compound &
tapping.
2.7 Unit Earthing
The main earth bars associated with
the circuit breaker truck and the
circuit earthing switch are
connected within the housing &
brought out externally at the rear of
the housing. The only assembly
required on site is to connect the
earth bars of adjacent units together
using the main external earth bars
supplied.
2.8 Main Cables
The main cables shall be made off
in acordance with the cabling
schedule.
2.9 Multicore Cables and
Inter-Unit Wiring (Bus
Wires)
The only secondary wiring required
on site is to run and terminate the
multicore cables and connect the
inter-unit bus-wires in accordance
with the wiring diagram supplied.
6 - M 10x22mm long
Hex. HD screws wih
nuts & washers
2.9.1 Multicore Cables
The multicore cables enter at the
front of the housing from the base of
the housing right-hand and/or left-
hand frame, from where they run
vertically via a removable wiring
through to the multicore cable gland
compartment situated at the top of
the housing frame. In this
compartment the outer insulation
on the cable is cut back to allow the
multicores to be taken via the main
wiring through to the termination in
the housing front panel.
2.9.2 Inter-unit Wiring
(Bus Wires)
For ease of location, each wire is
fitted with an idenification ferrule
which corresponds with that on the
wiring diagram. Where wires pass
through to adjacent panels the
holes shall be fitted with a
protective grommet.
3.0 COMMISSIONING
TESTS AND INSPECTION
The test outlined in this section are
those to be made after the
equipment has been erected, but
before energisation.
3.1 Precautions
The policy to be adopted in making
the equipment available for
commissioning or maintenance
shall be that, it is isolated, proved
dead and earthed.
Precautions shall be taken to ensure
that the isolated equipment cannot
be re-energised from any high or
low voltage sources of supply.
The circuit breaker operating
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 REMAINS SAME FOR ALL THE PANELS IRRESPECTIVE OF INDIVIDUAL PANEL CURRENT RATING

FIG. 5. Busbar Assembly and Torque Settings.

7
mechanism is capable of retaining a
stored closing spring charge.
Before attempting any work, the
stored charge must be released by
operating the circuit breaker
manually from OFF to ON to OFF.
Where motor spring charged
operating mechanisms are fitted the
supply to the motor must be
disconnected.
3.2 Mechanical Testing
Manual operational checks should
be carried out on the circuit breaker
to ensure correct operation of
interlocks, primary connection
safety shutter, operating
mechanism, trips, auxiliary switches
and the circuit breaker racking
mechanism.
3.3 Electrical Tests –
Secondary Insulation
WARNING :
Before commencing the tests
described in sections 3.3.1 and
3.3.2 on the secondary insulation
take the following precautions :
Disconnect the wiring to circuit
breaker mechanism spring
charging motor and rectifier.
Disconnect the wiring to /
withdraw any relying devices.
Short circuit current transformer
secondary windings.
Disconect secondary wiring on
voltage transformers.
Isolate any isolatable voltage
transformers.
After completion of testing all
conductors shall be discharged
to earth, temporary connections
recomved and components
reconnected.
3.3.1 Megger Test
The secondary insulation includes
the insulation associated with the
secondary wiring. For this test the
ends of the secondary wiring should
be looped together, at some
convenient point such as terminal
board and jsing a 500V megger
measure the resistance, which
should not be less than 2
megaohms between the loops and
earth.
3.3.2 High Voltage Test
For this test the ends of the
secondary wiring should be looped
together at some convenient point
such as a terminal board and a
voltage of 2 kV A.C. applied for 1
minute between the loops and
earth.
3.4 Electrical Test –
Primary Insulation
● Warning : Before
commencing tests 3.4.1 and
3.4.2 on the primary insulation
take the following
precautions :
● Short circuit and earth current
transformer secondary
windings. Under no
circumstances shall current
transformer secondaries be
open circuited with the
primary on load.
● On fixed voltage transformers
remove the connection
between the primary terminal,
by removing primary fuse.
● Isolate isolatable voltage
transormers.
● After testing, all conductors
shall be discharged to earth.
Temporary connections
should be removed.
Components should be
reconnected.
3.4.1 Megger Test
The primary insulation includes the
insulation associated with the high
voltage circuit. While carrying out
this test it should be noted that,
insulation varies considerably with
atmospheric conditions, dryness
and cleanliness of the equipment;
low readings may occur as a result
of surface leakage over the
insulation. Using a 500V megger
measure the resistance to earth of
each phase in turn. If the resistance
falls below an obsolute minimum of
1000 megohms after careful
cleaning and drying of all exposed
surfaces a check of the equipment
should be made for insulation
damage.
3.4.2 High Voltage Test
IS : 13118 & IEC 56 gives full
information regarding high voltage
testing after erection on site.
With the circuit breaker CLOSED a
power frequency voltage should be
applied to each phase in turn
between the phase conductor and
earth for 1 minute.
12 kV highest system voltage – 28
kV rms power frequency for 6.6 kV
system apply 20 kV ac rms for 1
minute power frequency.
After high voltage tests have been
completed, a further megger test
should be made to check that the
initial resistance has not altered
significantly.
3.5 High Voltage Test –
Voltage Transformers
Where high voltage tests on voltage
transformers have been agreed they
should be in accordance with the IS
: 2071, IS : 3156, to which reference
should be made.
3.6 High Voltage Tests-
Integrity of Vacuum
Interrupers
IMPORTANT : X-ray radiation from
Vacuum Interrupers.
Any electrical gap in a hard vacuum
when stressed electrically may
generate X-rays.
In the case of HWX equipment tests
have shown that X-ray emission at
the voltage stated is less than the
permited level. It is pointed out that
the permitted level is for continuous
exposure, whereas the test voltage
is applied for a short time on each
occasion. The vacuum circuit
breaker does not emit X-ray
radiation at working voltage.
The integrity of the vacuum
interrupters can be checked on site
by applying a test voltage of 20 kV
ac rms or 30 kV dc for 2 or 3
seconds across the open contacts
of each phase in turn with the other
side earthed. No evidence of
breakdown indicates that the
interrupter is in a satisfactory
condition.
Should a breakdown occur, the
circuit breaker should be kept out of
service and the matter reported
without delay to the AREVA
LIMITED, SWGR DIVISION AT
AEI/Salt Lake Works.
3.7 Final Inspection
The equipment should be given a
final inspection before it is put into
service.
Check that all covers are in place
and fully secured.
Check earth bars for continuity.
Check that all fuses and links are
inserted.
8

Check that padlocks are fitted
(where applicable).
Check all moving parts of the safety
shutters, the circuit breaker racking
mechanism, circuit and busbar
earthing switch operating
mechanisms, isolatable voltage
transformer operating mechanisms
and all interlocks.
Operate the Truck electrically and
manually to ensure it is functional.
Ensure all insulation surfaces are
clean and dry.
Touch up paint work where
necessary.
3.8 Recordings
Records are of value in establishing
the frequency of maintenance,
therefore careful note should be
taken of relevant items each time
maintenance is carried out.
In order that a complete history is
available, records should be started
immediately after commissioning
and should include –
Date of completion
Circuit breaker operations counter
reading
Interrupter contact wear reading
Number of short circuit operations
Details of any work carried out
4.0 OPERATION
4.1 General
The circuit breaker operating
mechanism may be one of 2 types :
Hand charged spring with shunt
trips, manual push button closing
and tripping, optional local/remtote
electrical spring release.
Motor charged spring with shunt
trips, manual push bottom closing
and tripping, optional local/remote
electrical spring release.
4.2 Closing the Circuit
Breaker
4.2.1 Motor Charged
Spring Mechanism
Manually : Press the CLOSE button
to release the pre-charged springs,
operating the mechanism to ON
thus closing the circuit breaker.
Electrically : Turn the
9
LOCAL/REMOTE selector switch to
the required position and operate
trhe appropriate OPEN/CLOSE
switch to CLOSE the circuit breaker.
Note : The motor will automatically
recharge the mechanism springs
after a closing operation enabling
an instanceous close after trip to be
carried out.
4.2.2 Hand Charged
Spring Mechanism
Insert the spring charge handle into
the ‘MANUAL CHARGE’ orifice in
the mechanism facia, locating the
slot in the handle on the drive pin in
the charging shaft. Push the handle
fully into the shaft and rotate the
handle anticlockwise in the clean
movement to charge the springs.
Remove the handle.
Operate the spring release manually
or electrically as described in
Section 4.2.1
Note : The mechanism springs can
be recharged after a closing
operation enabling an
instantaneous close after trip to be
carried out.
4.3 Opening the Circuit
Breaker
4.3.1 Motor Charged
Spring Mechanism
Manually : Press the TRIP button,
operating the mechanism to OFF
thus opening the circuit breaker.
Electrically : Turn the
LOCAL/REMOTE selector switch to
the required position and operate
the appropriate OPEN/CLOSE
SWITCH to open the circuit braker.
4.3.2 Hand Charged
Spring Mechanism
4.4 Withdrawal of the
circuit breaker from the
SERVICE position
i. Trip the circuit breaker (Section
4.3)
ii. Press the circuit breaker TRIP
botton and hold depressed
while operating the isolating
mechanism to the free position.
This operation also holds the
mechanism tripped and makes
accessible the circuit breaker
racking drive shaft.
iii. Insert the racking handle into
the racking orifice below the
mechanism facia, locating the
slot in the handle on the drive
pin the racking shaft. Push the
handle fully on to the shaft and
rotate the handle anti clockwise
untill the circuit breaker stops
withdrawing from the housing.
Remove the handle.
iv. Using the handles on the circuit
breaker truck pull the circuit
breaker from the housing. This
operation also automatically
closes the safety shutters over
the busbar and circuit primary
connection spouts.
4.5 Operation of the
Circuit Breaker in the TEST
Position
a. Withdraw the circuit breaker
from the housing as described
in Section 4.4 till the TEST
position.
b. The secondary socket/plug
umbelical cable between the
circuit breaker and the housing
front panel will remain
connected.
c. Operate the isolating
mechanism from the FREE to
the LOCKED position. The
circuit breaker may now be
operated.
4.6 Insertion of the Circuit
Breaker into the Service
Position
i. Wite the circuit breaker isolating
mechanism in the FREE
position [Section 4.4(ii)] push
the circuit breaker as far as
possible into the housing.
ii. Locate the racking handle as
described in Section 4.4 (ii) and
rotate the handle clockwise until
the circuit breaker stops
moving. (It may be necessary to
push on the circuit breaker
truck in order to start the
racking in operation). Remove
the handle.
iii. Operate the circuit breaker
isolating mechanism to the
LOCKED position. The circuit
breaker can now be switched
ON as described in Section 4.2
to put the circuit breaker into
service.
4.7 Busbar and Circuit
Earthing
4.7.1 General
Earthing trucks are usually provided
with each switchboard as a
standard for discharging the
residual charged voltage remaining
in the busbar and in the circuit.
The busbar earthing and circuit
earthing trucks are similar to
standard breaker trucks in
appearance but will not consist of
any mechanism or interrupter.
Busbar earthing truch consist of top
stems whereas circuit earthing truck
consist of bottom stems, the other
end of the stems are shorted and
connected to the earth. When it is
required to earth the busbars or
circuits and earthing truck should
be inserted as appropriate.
For earthing of circuit side, an
earthing switch is provided on rear
side of the outgoing panels.
Operating instructions for the same
are provided on rear cover of the
panel. The interlocking arrangement
ensures that the switch shall always
be operating when the breaker is
NOT in service position & the
metallic safety shutters are closed.
Special care to be taken for
insertion of EARTH TRUCK into
panel.
Warning :
Before carrying out any earthing
operations it is recommended
that the section(s) of busbars
and/or the circuit(s) required to
be earthed be disconnected.
Precautions should also be taken
to ensure that the alternative
source of supply is also
disconnected. It is preferred that
equipment should be proved
dead before earthing.
4.7.2 Application of a
Circuit/Busbar Earth
i. Fully withdraw the circuit
breaker from the housing as
described in Section 4.4
Spring charge pawls
If supply to
motor is lost
during
charging
operation, the
charging
operation can
be completed
manually.
If the supply is restored the mechanism will rest. It may be necessary
to reset the mechanism manually. This is achieved by lifting the spring
charge pawls. The wheel will turn release pawls onto the wheel.
FIG. 6. Resetting Motor Mechanism after Loss of supply
ii. Carry out the precautions
referred to in Section 4.7.1
iii. Insert the earthing truck into the
housing as described in section
4.6. the circuit/busbar is/are
now earthed through the
earthing truck.
4.7.3 Removing of
Busbar/Circuit Earthing
Truck
Reverse the procedure described in
Section 4.7.2. Note that no manual
Trip Push Button is available in
earthing truck.
4.8 Electrical Testing of
Busbars and Circuits
4.8.1 General
Electrical testing of the busbars and
circuit may be carried out an every
unit be means of portable test
bushings which are inserted into the
primary spout connections.
Warning :
On the unit(s) under test it is
essential that precautions, to
ensure that the equipment cannot
be reenergised, are taken both in
the preparing the unit(s) and
during the time that tests are
being carried out.
Before inserting or removing test
bushings it is essential that the fixed
conductor within the spout is
proved dead.
Isolate all transformers during
test
While disconnected/ reconnection
is being carried out it is
recommended that earths are
applied.
Manual Spring
Charge Acess Truck
Interlock
Operations
counter
FIG. 7. Mechanism Facia
4.8.2 Procedure for
Preparing the Circuit for
Testing
i. Earth the circuit with the help of
circuit earthing truck.
4.8.3 Procedure for
Preparing the Busbars for
Testing
i. Withdraw the circuit breaker
from its housing as described in
Section 4.4 and earth the
section of busbar, to be tested
by Busbar Earthing Truck.
5.0 EMERGENCY
MANUAL OPERATION
MOTOR CHARGED
SPRING MECHANISM
5.1 General
Should the electrical supply be
disrupted to the circuit breaker
mechanism spring charge motor or
for mechanical test on the circuit
breaker, the closing springs can be
recharged by means of a removable
handle which locates in the circuit
breaker mechanism facia.
5.2 Closing the Circuit
Breaker
Refer to figure 7 and ascertain the
mechanism spring state.
If “SPRINGS CHARGED” : Refer to
“MANUALLY”, Section 4.2.1.
If “Springs Free” : Remove the
motor supply fuses. Inser the spring
charge handle into the “Manual
Charge” orifice in the mechanism
facia, locating the slot in the handle
on the drive pin in the charging
shaft. Push the handle fully on to the
shaft and rotate the handle
anticlockwise in one clean
movement to charge the springs.
Remove the handle. Press the close
button operating the mechanism to
ON thus closing the circuit breaker.
Note : The mechanism springs can
be recharged after a closing
operation enabling an
10
 instantaneous close after trip to be
carried out.
If “Springs partially charged”
(indicated by the lable being part
way between “Springs charged”
and “Springs Free”) complete the
charging and closing of the circuit
breaker as described under
“Springs Free”.
Note : In order to make the
mechanism capable of further
charging operations after closing
the circuit breaker from a “Springs
Partially Charged” position during
the time that the motor supply may
be disrupted, it is necessary to
remove the circuit breaker from the
housing, remove the mechanism
cover and rotate the ratchet wheel
anti-clockwise until the link pin on
the ratchet is at the lowest point.
However, restoration of the motor
supply will complete the travel of
the ratchet wheel, thus making the
above procedure unnecessary.
Refer to Figure 6.
5.3 Opening the Circuit
Breaker
Refer to “Manually” Section 4.3.1.
6.0 MAINTENANCE
The maintenance policy for HWX
switchgear is based on IS
10118:(1982) reference to which
should be made for a general
background to this subject.
In particular the maintenance policy
is based on the concept of
Inspection, Examination/ Service
and Overhaul is defined in the
standard.
Because of the widely varying
condition of operation of individual
installations it is not possible to law
down precise recommendations for
the intervals between maintenance
required under all circumstances.
These intervals may vary greatly
depending on the duty the
equipment is called upon to perform
and the environment in which it is
situated. The time intervals are
therefore best determined by user
experience based on the behaviour
of the equipment on the particular
installation.
Vacuum switchgear is low
maintenance equipment, the
vacuum interrupter being a sealed
unit which does not require
maintenance during its lifetime. The
only readjustment which may be
required in case of trip and spring
11
release coils is their replacment.
The assembly procedure of trip &
closing coil pot is described in this
manual.
6.1 Precautions
Refer to the notes inside the front
cover and Section 3.1
6.2 Inspection
A careful routine scrutiny of the
equipment is required for any signs
of deterioration or abnormality.
Inspections should include
operational checks.
Refer to figures 7 & 8 and for
location of circuit breaker
operations counter and interrupter
wear indicator.
6.3 Examination/Service
It is recommended that an
examination to be carried out
whichever occurs first :
i. 8 years
ii. 2000 normal operations
iii. 100 fault operations. Where the
fault current is less than the
rating of the circuit breaker this
number may be increased.
Further advice can be obtained
from the manufacturer.
6.3.1 Circuit Breaker and
Operating Mechanism
The design of the operating
mechanism is such that no
adjustments are required
throughout its lifetime, subsequent
examinations will consist of visual
inspection for wear, corrosion, loose
components and unless there is
reason to believe that there is
deterioration, no dismanting is
allowed.
Manual closing and opening
operations should be made to
check the closing and tripping
mechanisms. The electrical closing
and tripping circuits should also be
checked.
The duty imposed on spring charge
motor is very light, consequently
maintenance is unlikely to be
necessary. However, the assembly
procedure of motor is given in this
manual.
Examination is confined to the
inspection of the commutator for
scoring, the brushes for excessive
wear and free movement in the
brush retainers.
The mechanism is supplied with the
lubrication for life and normally
further lubrication should not be
required. In the event that
components are replaced they
should be lubricated with aeroshell
17 grease or an equivalent silicon
base grease containing
Molybdenum Disulphide.
Care must be taken to ensure that
no lubricant is applied to the
operating mechanism electrical
release coil plunger or electrical trip
coil plunger.
Should there be any doubts about
the condition of any components a
more detailed examination must be
made.
6.3.2 Circuit Earthing
Truck
Under normal service conditions
earthing truck is virtually
maintenance free.
Inspection, cleaning and
relubrication is recommended after
2-3 years under unfavourable
ambient conditions such as
excessive dust collection,
aggressive atmospheres,
continuous high relative humidity in
excess of 70%. Aseol molitea or
Molydag 47 is to be used for the re-
lubrication of contacts and bearing
joints.
6.3.3 Primary
Conductors and
Connections
Remove the appropriate covers and
check that all electrical joints and
connections are sound.
Remove any deposits of dust etc.
6.3.4 Auxiliary Switches
Ensures that all connections are
tight at the terminals and the
change over of contacts are
checked periodically with a
continuity meter.
6.3.5 Insulators
All insulators should be cleaned
with a non-sheeding cloth.
6.3.6 Vacuum
Interrupters
Refer to Section 3.6
6.3.7 Primary Isolating
Contacts
Check the condition of the plug and
finger contacts. Any furnished
surfaces should be cleaned using a
branded liquid silver polish and a
non-shedding cloth.
6.3.8 Secondary
Isolating Contacts
Ensure that all connections are tight
at the terminals. Contact surfaces
should be treated in a similar
manner to the primary contacts.
6.3.9 Primary Connection
Spounts Safety Shutters
Clean and examine all parts of the
shutters and operating mechanism
for wear and loose components. If
required parts should be sparingly
lubricated with a good quality
mineral oil.
Spout safety shutters shall not be
opened without first earthing the
busbars and/or circuit cables.
Prove dead after opening.
6.3.10 Recommissioning
Inspection
Refer to Section 3.7
6.4 Overhaul
Overhaul comprises work carried
out to restore the equipment to a
satisfactory condition including the
replacement of components.
An overhaul will be necessary
when :
a. An examination has identified a
component(s) as being less
than satisfactory.
b. The limit of contact wear of a
vacuum interrupter has been
reached. Refer to fig. 8
c. The vacuum interrupter and the
circuit breaker operating
mechanism have performed the
number of operations indicated
in the following table.
7.0 SPARES
The following spares should be kept
in stock, actual quantities will
depend on the number of circuit
breaker in service and operating
conditions.
FIG. 8. Contact Wear Gauging
Spring Release Coil – Refer to
Figure-12 for fitting instructions Trip
Coil – Refer to Figure 13 for Fitting
instructions.
LT Fuses
Voltage Transformer Fuses
Auxiliary Switch
Limit Switch
Isolating Contacts
All spares should be stored in such
a manner as to protect against
corrosion, humidity, adverse
atmospheric conditions mechanical
damage and vermin.
When ordering spares of
replacements a complete
description should be given,
together with relevant nameplate,
data and serial numbers. For further
details regarding spares the Spares
Manual can be referred.
With VCB Closed Insert Contact
Wear Gauge into Gap Between
the Drive Insulator and the
Spring Guide Rod. This is a GO
/ NO - GO Gauge.
The Gap when New is 5mm,
which, when the interrupter is
Worn Out, will reduce to 3 mm.
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.
both sides.

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.
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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