GENERAL OFFICE TECHNICAL SPECIFICATION 37-2 ISSUE3 FEBRUARY 1990 cents) TATRA eca a LV DISTRIBUTION FUSE-BOARDS WA, ce CONTENTS: Page ‘Summary of appicabilty of “Type and design” ‘and “Construction” clauses fo each type of equipment. 6 Foreword 7 Scope 7 References 8 Type and design to Construction 21 Shon circuit rating : 24 Clearances 24 Fuses and fuse-carrers 25 Neutral and earth connections .. 26 Gurrent transformers 27 Instrument panels and auxiliary supply circuits 27 ‘Small wiring wove Circuit labels. 29 Type tests 30 Routine nigh voltage tests 35 APPENDIXES ‘A. Alternative types of distributor unit......t B - Summary of options and type designations of each type of equipment. 44 ILLUSTRATIONS, Figures 1 -6. : 30-40 Prise cides \ ‘Ts Spectcaton ese by the Elccly Supply Indy in conjunction wih the Trae Assbeatians 0: ober bodoe ‘cxnonloagod the document Est TechnealSpecicabons are ewses whan necessary by the isue omer of evsd pages or compete new eaters. t Istmponant at users ES Tectia! Specseatone Sas ‘econ at they aren postesson ol he aos sue© Copyright 1990 Electricity Council All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written consent of the Electricity Council Specific enquiries concerning this document should be addressed to: Head of Distribution Engineering The Electricity Council 30 Millbank London SW1P 4RD Indemnity The Electricity Council disclaim all liability for any loss, damage, injury or other consequence whatsoever arising from any unauthorised use however caused, including any such resulting from error, omission or negligence in its application.ESI Technical Specification 37-2 Page 3 Issue 3 February 1990 INDEX Page ‘Summary of applicability of “Type and design” and “Construction” clauses to each type of equipment ...c..nnmnn eo Foreword....... seseneneenee . 5) 1 ‘Scope seensereeenen vena sesennensesenenesan sesenenel 2 Reterences... : . 8 3 ‘Type and design u leon oO 3A Goneral sevenntnnnnninnnn 10 3.1.1 All types of equipment eg 3.1.2 All shielded patterns of equipment. ceed 3.1.3. Indoor fuseboards and fuse-pillars only a 3.1.4 Fuse - cabinets only a 3.1.5 Transformer mounted fuseboxes ... 13, 3.2 Incoming transformer units coed 3.2.1. Units for indoor fuseboards and fuse - pillars ...... 14 3.2.2. Units for fuse-cabinets 3.2.3 Units incorporating disconnectOtS.....:::nnnnn 14 3.2.4 Units incorporating link-carriers.. 15 3.2.5 Units for indoor fuseboards with connections for other wall-mounted equipment : 16 3.2.6 Units for fuse-cabinets with fuses in the transformer connection .. 16 3.3 Busbars (excep! fuseboxes) oo 17 3.4 Outgoing distributor units AT 3.5 Fuseboxes only. x 17 3.5.1. 400A Transtormeridistributor unit eee) 3.5.2. 315A Transtormeridistributor unit 20 4 Construction sense 24 4.1 Requirements applicable to indoor fuseboards only ar} 4.2. Requirements applicable to fuse-pillars Only ....c sneered 4.3. Requirements applicable to fuse-cabinets only 21Page 4 Issue 3 February 1990 INDEX (continued) Page 4.4 Requirements for outdoor use applicable to fuse-pillars and fuse-cabinets ......22 4.5 Requirements for tuseboxes. 22 4.6 General requirements applicable to all equipments. 23 5 Short-circuit rating ..nccceee . 24 6 Clearances on 7 Fuses and fuse-carriers. 25 7.1. Fuses for distributor circuits. ee) 7.4.4 Fuse-tinks 25, 7.1.2. Fuse-carriers. 7.2. Fuses for transformer connection connie RS 7.3. Fuses for auxiliary supply 26 8 Neutral and earth connections eee 8.1 Alltypes of equipment except fuseboxes 26 82 Fuseboxes see sone BT 9 Current transtormers 27 10 Instrument panels and auxiliary supply circuits. sees BT 1 Small wiring co nnn 29 12 Circuit labels. a 29 13 Typetests. ear seen 18.1 Short-circuit withstand test. “ so 30 1.2 Temperature rise test seinen BO 13.2.1 General : 30 13.2.2 Additional requirements for fuse-cabinets and fuseboxes.... =) 13.2.3. Additional requirements for fuse-cabinets with fuses in the transformer connection sen G2 18.3 High voltage tests, 32 42.3.1 Complete equipments.....snsennee 32 13.3.2 Additional tests on fuse-carriers sees 18.3.3. Test on disconnector operating poles even 8BESI Technical Specification 37-2 INDEX (continued) 13.4 Torque test on thumbscrews. 13.5 Environmental tests 13.5.1 Test for first numeral 3 of IP33 13.5.2 Test for second numeral 3 of IP33 13.6 Test for effectiveness of shielding of live connections .. 13.7 Flame tests 13.7.1 Form of test specification 13.7.2 Procedure 13.8 Mechanical operation test 14 Routine high voltage tests 14.1 Routine tests for complete equipments 14.2 Routine tests on disconnector operating poles: 14.3 Routine tests on wedge-operating mechanisms 14.4 Sampling procedure for routine tests. ILLUSTRATIONS Figs. 1-6. Appendix A Alternative types of distributor unit. Appendix B Summary of options and type designations of each equipment Page 5 Issue 3 February 1990 Page 33 33 33 34 35 35 35 35 35 36-40 AtESI Technical Specification 37-2 Page 6 Issue 3 February 1990 Summary of applicability of “type and design” and “construction” clauses to each type of equipment. x indicates a clause applicable to that equipment, Clause fae! i as ae Fuseboxes ee » | « a2 x x x x 313 x x 314 x 315 x 32 x x x a24 x x 322 x 323 x x x 324 x x x 325 x 326 | x | 33 _ x | 34 x x x a5 x | 354 x 352 x 44 x 42 x 43 j x | 4a x x 48 x | 48 x x x x {ESI Technical Specification 37-2 Page 7 Issue 3 February 1990 L.V. DISTRIBUTION FUSEBOARDS. FOREWORD. ‘The purpose of this Specification is to define a range of low voltage distribution fuseboards for use in indoor and outdoor substations. It updates and supersedes Issue 2 dated November 1984. It covers fuseboards of two alternative patterns (Shielded patern with insulation to shield operators and others working on the equipment against inadvertent contact with live components. (ii) Non-shielded pattern of traditional design, ie without any specific requirement for the shielding of busbars and other live components against contact by operators. Italso includes some types of fuseboard with electrical protective equipment between the transformer LV terminals and the busbars. ‘The existence of ESI Technical Specifications is not intended to restrict or inhibit the introduction of new forms of equipment provided that such designs comply with those requirements in respect of safety, security and operation which are generally understood by manufacturers and users L SCOPE This Specification covers distribution fuseboards of the following types for use in electricity substations which supply low voltage combined neutral and earth (CNE) or separate neutral and earth (SNE) networks (®)_Fuseboards for use in indoor substations only (subsequently referred to as indoor fuseboards and designated Type IFB). Gi)_ Pillar mounted fuseboards (subsequently referred to as Fuse-pillars and designated Type FP), (ii) Transformer mounted fuseboards in cabinets (subsequently referred to as fuse-cabinets and designated Type TMC). (iv) Transformer mounted single way fuseboxes (subsequently referred t0 as fuseboxes and designated Type TFX), ‘These equipments are for use on 3-phase. 4-wire AC systems at a frequency of 50 Hz. The rated operational voltage of the equipments shall be 415 V and the rated insulation voltage shall be 440 V, Certain single way fuseboxes may also be used on 240-0-240 V 3-wire or 0-240 V 2-wire single-phase systems; these will have a rated operational voltage of 480 V and rated insulation voltage of 510 V,ESI Technical Specification 37-2 Page 8 Issue 3 February 1990 2 REFERENCES This Specification makes reference to the following documents: BS 88. “Cartridge fuses for voltages up to and including 1000 V AC and 1500 V DC’ Part 1: “Specification of general requirements’ Section 2.2: “Additional requirements for fuses with fuse-links for bolted connections" Part 5 “Specification of supplementary requirements for fuse - links for use in AC electricity supply networks’ Part 6: ‘Specification of supplementary requirements for fuses of compact dimensions for use in 240/415V AC industrial and commercial electrical installations’. BS 381C, “Specification for colours for identification, coding and special purposes" BS 410, ‘Specification for test sieves’ BS 1363, “Specification for 13 A plugs, switched and unswitched socket - outlets and boxes BS 2562, "Specification for cable boxes for transformers and reactors’ BS 2569, xecification for sprayed metal coutings” Part Protection of iron and steel by aluminium and zine atmospheric corrosion BS 2989, “Specification for continuously hot-dip zine coated and iron-zine alloy coate BS 8382. ‘Specification for electroplated coatings on threaded components’ BS 3692, “Specification for ISO metric precision hexagon bolts, serews and nuts BS 3938, ‘Specification for current transformers’. BS 4579, “Specification for performance of mechanical and compression joints in electric cable and wire connectors’ Pan 3 “Mechanical and compression joints in aluminium conductors’. BS 5419, “Specification for air-break switches. air-break disconnectors, air-break switch disconnectors and fuse-combination units for voltages up to and including 1000V AC and 1200V DCESI Technical Specification 37-2 Page 9 Issue 3 February 1990 BS 5486, “Low voltage switchgeur and controlgear assemblies Part 1 “Specitication for type-tested and partially type-tested assemblies" (general requirements). BS 5490, +S cification lor classification of degrees of protection provided by enclosures’, BS 5783, “Codes of practice for handling of electrostatic sensitive devices’ BS 6001, “Sampling procedures and tables for inspection by attributes” BS 6231, “Specification for PVC-insulated cables for switchgear and control gear wiring” BS 6346, ‘PVC- insulated cables for electricity supply ESI Technical Speci distribution networks" ation 12-8. “The application of fuse-links to 11 kV and 6.6 KV/415 V ESI Technical Specification 35-1, “Distribution transformers from 16 kVA to 1000 kVA’ ESI Technical Specification 50-2, "Bimetallic ammeters’. S1 Technical Specification 98-1, “Surface preparation and paint finishing of new plant and equipment BEB Specification $.12. “Standard numbering for small wiring for switchgear and transformers” Engineering Recommendation M15/4, “Fused flexible leads for use with portable voltage ‘measuring instruments at voltages up 0 600 volts AC/DCESI Technical Specification 37-2 Page 10 Issue 3 February 1990 3 ‘TYPE AND DESIGN 34 General $4.1 All equipments (both shielded and non-shielded patterns) This Specitication covers arrangements of indoor fuseboards, fuse-pillars and fuse-cabinets as described below, suitable for use with 200, 315, 500, 800 and 1000 kVA transformers to ESI Technical Specification 35-1. The equipment shall be complete with supporting members as, required, on which shall be mounted an incoming transformer unit and outgoing distributor units ‘with busbars, and an instrument panel, as appropriate. ‘This Specification also covers outdoor single-way fuscboxes for use with 50 and 100 kVA cable connected rural transformers and 200 kVA cable connected transformers all to EST Technical Specification 35-1. All fuscboxes shall be of the shielded pattern only. All parts of the distribution equipment shall, as fur as practicable, be readily accessible and replaceable without excessive dismantling. The design shall be such that the cables can be readily jointed from the front. Insulating materials shall be as nearly non-hygroscopic mat ind resistant to tracking as present good turing technique permits. All such materials, including those used as shields and barriers, shall be subjected to a flammability test as shown in Clause 13.7. All parts of equal size and rating shall be interchangeable, The general design shall be such that the number of joints shall be kept to a minimum. All main current carrying components (other than those made of aluminium or aluminium alloy) shall be electro tin plated. Al bolted clectrical joints shall be secured by corrosion-proof high tensile steel bolts to BS 3692, Grade 8.8. All bolts shall be plated to BS 3382 and shall have corrosion-proof locking features. On equipments without their full complement of distributor units, fixings shall be provided for the future installation of distributor units up to the maximum capacity of the fuseboard, All equipments shall comply with the general requirements of BS 5486 Part 1, with service conditions for temperate climates according to Clause 6.1 of that Standard. 312 All shielded patterns of equipment For indoor fuseboards and for fuse-pillars, fuse-cabinets and fuseboxes with the door(s) open the « degree of protection against people and foreign bodies shall be IP 2X according to BS 5490. On 9 ¢ ‘equipments not equipped with their full complement of distributor units (or fuses in the case of Tuseboxes) this degree of protection shall be maintained for the unequipped positions. tis preferable. though not essential, for the same degree of protection to be maintained while installing additional distributor units. Protection of units with fuses withdrawn is dealt with in Clause 3.4.ESI ‘Technical Specification 37-2 Page 11 Issue 3 February 1990 3.1.3 Indoor fuseboards and fse-pillars only ‘The indoor fuseboards and fuse-pillars shall be designed to take the following arrangement: Busbars rated at cither 1600 A or 800 A. Incoming transformer unit with the same rating as the busbar. Five outgoing distributor units S00A distributor units shall normally be provided: however 400A units may be provided as an alternative where the purchaser requests such units ‘The framework shall normally be arranged to accommodate the equipment in the following order reading from the front, left to right: Distributor units. Transformer unit Instrument panel. By agreement between the purchaser and the manufacturer the sequence of the equipme be varied, s may At least two distributor units shail be provided. Where only two are provided they shall be positioned so as to ensure adequate support for the busbars during short-circuit tests and also during transport. It shall be possible to install and conne spare positions whilst the remainder of the equipment is in normal service. The design shall be such that whilst this work is in progress, exposed “live” and, where necessary, “earthed” ‘metalwork in the vicinity can be guarded by simple portable insulating screens. additional distributor units in the The arrangement of the incoming and outgoing units shal be suitable for cables approaching from below. In the case of indoor fuseboards, however. the design shall be such that at the option of the purchaser the transformer connections and/or distributor cables may approach from above and an extra cable support bar supplied on reques ‘The distributor units shall be mounted side by side with the red, yellow and blue phase fuses mounted in sequence vertically, the red phase being at the top. 3.14 Fuse-cabinets only ‘The fuse-cabinets shall be designed to take any of the alternative arrangements detailed in Table |. Equipments bearing a type designation suffixed "S” are of the shielded pattern, while those suffixed “NS” are of the non-shielded pattern, Types TMC10S and TMCIS are fitted with fuses in the incoming transformer connections - further details are given in Clause 3.2.6. The distributor units shall be mounted side by side with the red, yellow and blue phase fuses ‘mounted in sequence vertically, the red phase being at the top.ESI Technical Specification 37-2 Page 12 Issue 3 February 1990 ‘Table 1 - Alternative arrangements of fuse-cabinets | ypedesionations | Twcis | Twcas ) meas | woes | Tucss ] i ted | ang | Vand” | "ang | ang | Twcxes | TMCS _Twcins | racans | micsns | racens | TwCsNs | arsomersze man) | 0008 | 1oo0Kva | sooava | soonva | soonva | ecowa | s0oKvA | cunning orbustars | 600 | 6008 | 00a | on | oa | 12508 | aoa Srdinconing ‘rnsormer nt | | Prete saugmentir | nore | sone | rane | nae | nono | eas) ts framing vaste! No sie of gang i Barn | Nemo soon | ausooa | soo, | sxsoon | 21600A asta | 4500 (0 Atamatvedeson saan | saaoon | sx4008 | oooa | atooa | aadooa | extooa [atprchasrsreques) | Taster ype en | unt) unt | at | ae | at) at foestae sutstnion | sabrnton | subetaion | sittaton | subraion | suitaton | autsaion ‘reac’ | ‘reat. | “ereavo” | “oreabe’ | “oreave. | “orcabe commaces | comeced | corrected | cornices | connacied | comncted Trans‘omer tangs | F F F F . F F fac tore 25 ; sb sea) \ i oTRato | seooons | sone00s esowo0s | eoosoos | soacos | szoaeons | aooanns Demand nex onseon | ose | oon, | oss0n | oscoa | oron | oso sea 5208 | ‘05608 | oaeoA | caeda | caeoA | ‘Ova | GaadA 5 Maximum dimensions \ tena wn zeomm | sr0nm | si0mm | 610mm — stom | siomm | 610mm ‘tenn Sy \ Hegrtrom ante ine | atria 1) Wraps canine asomm | scomm | ssomm | esomm | 460mm | som | ss0mn" rere ates — | 270mm | 1270am | 270mm | 1270mM | 1270mM | 1270 | 270mm + PravonalESI Technical Specification 37-2 Page 13 Issue 3 February 1990 ALS Transformer mounted fuseboxes ‘Two designs of fusebox are detailed in Table 2 below: ‘Table 2 - Alternative designs of fusebox ‘Type designations TFX1 TFX2 Transformer size (max) 200 kVA 100 kVA, | ‘Current rating 400A 315A No. of fuses 3 1.20r Transformer type cable cable (to ESI35-1) connected connected rural ‘Transformer flange facing F BE $20 fooy 8 (to fig. 25 of BS 2562) ( mye] In these single-way equipments the incoming transformer units also form the outgoing distributor units. Transformer disconnecting links and busbars are not required, However an. instrument panel and associated current transformers shall only be provided if specified by the purchaser, Both equipments are to be of the shielded pattern only, ‘The fuses shall be mounted side by side with phase markings blue-yellow-red in sequence from left to right viewed from the front. ‘Type TEX2 fuseboxes will be used with transformers connected to provide 240 V 2 wire or 240- 0-240 V 3 wire single phase supplies or 240/415 V 3 phase 4 wire supplies: hence either one, two or three fuses may be required. Where only one or two fuses are provided the phase marking may be omitted ‘Type TFX2 fuscboxes will have a rated operational voltage of 480 V and a rated insulation voltage of 510 V. By agreement between the transformer manufacturer and the purchaser the cases of type TFX2 fuseboxes may be manufactured integrally with the transformer tank. Such equipments shall not have the transformer and the fusebox in a common chamber: in all other respects the appropriate parts of this Specification shall apply to such integral fuseboxes. 32 Incoming transformer units (All types of equipment except fuseboxes) Incoming transformer units rated at 1600A (or 1250A for the type TMC10S fused transformer- mounted cabinets) shall be provided with pole operated disconnectors (isolators); whilst those rated at 800 A may be provided with either pole operated disconnectors or carriers fitted with solid copper links. Provision shall be made on each phase for one current transformer as specified in Clause 9, “Current transformers”. It shall be possible to change current transformers if necessary.$1 Technical Specification 37-2 Page 14 Issue 3 February 1990 A bolted link rated at not less than half that of the phase connections shall be provided for disconnection of the neutral Each phase and the neutral of the transformer unit shall be colour marked to correspond with the busbars to which they relate. 3.2.1 Units for indoor fuseboards and fuse-pillars The transformer unit shall have the phases arranged vertically. For indoor fuseboards the design shall permit the use of either bare or insulated bars (see also Clause 3.2.5) or single core incoming cable as follows: 1600 A units to be suitable for 7 cables, 800 A units to be suitable for 4 cables. ‘The incoming cables will be single core 600/100 V solid aluminium PVC insulated of either armoured or un-armoured construction, with a PVC sheath, to BS 6346, up to and including 740 mm? nominal cross-section, Cable termination arrangements shall be suitable for either compression lugs or bolted clamps ws required by the purchaser. Cable cleats shall be provided to give adequate support to the cables in normal service and when subjected to the short circuit duty specified in Clause 5, “Short-circuit rating” For fuse-pillars only cable connections are likely to be use not required he facility for bar connections is, 3.2.2 Units for fuse-cabinets ‘The transformer unit may be arranged with the phases mounted either horizontally or vertically. Hard-drawn, high conductivity copper connections or other material as approved by the purchaser, with provision for adjustment, shall be provided between the transformer LV terminal stems and the terminals of the disconnectors or linked fuse-cartiers and neutral link ‘These connections shall be suitable for connecting to the appropriate terminals shown on Figs C2 and C5 of ESI Technical Specification 35-1 and for 1600 A and 1250 A equipments the phase connections shall either connect to both fixing positions of transformer bushing. assemblies designed for two cables per phase, or connect to both faces of the fixing position adjacent to the transformer. 3.2.3 Units incorporating disconnectors (1000 A, 1250 A and 800 A equipments) “The rated normal current of the incoming unit shall be 1600 A, 1250 A or 800 A. The neutral connection shall be rated at not less than half that of the phase connections (ie 800 A, 625 A or 400 A minimum, respectively). A pole-operated disconnector shall be provided in each phase of the incoming transformer circuit. ‘The disconnector contacts shall include means of contact tightening designed to obviate slackening when subject to vibration; good contact shall not depend on the natural spring of the contacts. Either a single device operating on both top and bottom contacts, or separate devicesESI Technical Specification 37-2 Page 15 Issue 3 February 1990 be used. Sufficiently good contact shall be made on closing the disconnector $0 urrent can be safely carried prior to tightening the contacts. ‘The contact-tightening device shalt be operated by an insulated tool, which may be incorporated in the operating pole. In the case of non-shielded pattem equipments the tool shall remain in the device during tightening or slackening the contacts. Where crank action is used, the total movement from full slackness to full lightness of the device shall be confined to an angular rotation of not more than 140° in one movement {It shall be possible to retain the disconnectors in the open position by a suitable insulated device, which shall incorporate provision for padlocking the disconnectors in this position. Details of the safety padlock to be used for this purpose are given in Clause 4.6. For shielded pattern equipments the required degree of protection shall be obtained whether the disconnectors are in the closed or open position. When in the open position this may be by fitting one inyulated cover over all phases, and this cover may be the same device required to retain the disconnectors in the open position. If so, it must be transparent or otherwise permit clear observation of the disconnector position, When the disconnectors are in the transitional stage between open and closed, maintenance of the full degree of protection is not mandatory but the possibility of inadvertent touching of live metal by the operator must be minimised, On equipments incorporating pole operated disconnectors facili framework of an indoor fuseboard ori cs shall be provided on the dle a pillar or cabinet to store the operating pole when not in use. A pole made entirely trom insulating material is preferred. However, if metal has to be incorporated. the design shall include a shield on either the pole or the equipment to keep the operator's hands clear of the metalwork. In the case of shielded pattern equipments it is ‘mandatory that no exposed metal on the operating pole can become live. Where a separate tool is provided for operating the contact tightening device similar storage facilities shall be provided. Similar facilities shall be provided for storing the locking - off device, if this cannot be left in position irrespective of wh ther the disconnectory are open or closed, Insulated dividing barriers shall be provided between phase contact assemblies and between phase and neutral contact assemblies, so as 10 prevent accidental bridging across phases, or between phase and neutral 3.24 Units incorporating link-carviers (800 A equipments only) A through grip shrouded carrier of suitable insulating material fitted with a solid copper link rated at 800 A shall be provided on each phase. This shall be clearly labelled “800 A Link". Each carrier shall be suitable for inserting in a phase of the unit by hinge action pivoted on the lower contact and for withdrawing by snatch action. Each carrier shall be complete with two insulated contact-tightening thumbscrews. Sulficienily good contact shall be made on inserting the castier so that current can be safely carried prior to tightening the contact-tightening thumbscrews. Where this unit is mounted vertically, provision shall be made for an insulated locking-off device that can be padlocked in position. If non-transparent, it shall be such that it can only beESI Technical Speci Page 16 Issue 3 February 1990 fitted over the unit when the carriers have been removed, and facilities shall be provided for storing the locking-off device on the framework of an indoor fuseboard or inside a cabinet when not in position on the transformer unit Where this unit is mounted horizontally in a cabinet of the non-shielded pattern it shall be fully Shrouded with insulating material on the sides and at the front. The front shall be hinged and be of transparent material. Facilities shall be provided for locking the cover in position, For shielded pattern equipments, the requirements for shrouding shall be the same as that for the outgoing distributor ways, as detailed in Clause 3.4. Details of the safety padlock to be used for locking-off are given in Clause 4.6. Invulated dividing barriers shall be provided between phase contact assemblies and between phase and neutral contact assemblies unless itis impossible to bridge them with an 800 A Tink 3.2.8 Units for indoor fuseboards with provision for busbar connections from other wall- mounted equipment In certain circumstances it may be necessary to supply an indoor fuseboard through such equipment as an air eircuit-breaker or heavy-current fuses mounted on a framework covered by aa separate document In this case the unit covered by Clause 3.2.1 will be required as detailed there, but provision for incoming transformer e: tead of les, horizontal connections of the same current rating as the busbars shall be extended from the incoming contacts of the disconnector in each phase as fr as the right-hand extremity of the support framework. The neutral/earth bar shall be extended similarly. Suitable support insulators shall be provided for these extensions, which shall be on the same vertical centres as the disconnectors. Details of any holes required for bolted ‘connections to the equipment on the adjacent framework will be specified by the purchaser. 3.2.6 Units for fuse-cabinets types TMCIOS and transformer connection CHS with provision for fuses in the ‘Type TMC10S fuse-cabinets shall be provided with incoming transformer units incorporating, disconnectors and rated at 1250 A, but otherwise complying with Clause 3.2.3. ‘Type TMCIIS fuse-cabinets shall be provided with 800 A incoming transformer units complying with either Clause 3.2.3 (for disconnectors) or Clause 3.2.4 (carriers with solid links). With both types of cabinet, provision shall be made for mounting in the top of the cabinet bolted fuse-Link in each phase of the incoming connections between the transformer terminals and the disconnectors, or carriers with solid links. ‘The fuse-links to be used in the transformer conn transformer connection” jon are specified in Clause 7.2, “Fuses for Access to the bolted fuse-links shall be by removal of the cabinet roof or other approved means. Although both of these equipments are to be of the shielded pattem only, the required degree of ‘operittor protection for such equipments need not apply when access is obtained 0 these fuse: links.ESI Technical Specification 37-2 Page 17 Issue 3 February 1990 (ote: These types of fuse-cabinet are intended for use in situations where overall system design considerations require the fitting of main LV electrical protection close to the transformer terminals, 1600 A equipments have been omitted because of the excessive heat loss from fuse- links of that rating, 3.3. Busbars (All types of equipment except fuseboxes) Busbars shall be of hard-drawn high conductivity copper or other material as approved by the purchaser. The rated normal current of the phase busbars shall be the same as that of the incoming transformer unit, ‘The neutral/earth busbar shall be rated in accordance with Clause 8.1 Busbars shall be situated at the rear of the equipment Phase busbars shall be colour indicated in sequence from top to bottom, red, yellow, blue and the neutral/earth busbar, mounted at the bottom shall be colour indicated black. If the colour indication is on the busbars it shall not be continuous and shall be such that it cannot be istaken for an insulating covering, 34 Outgoing distributor units (AI types of equipment except for fuseboxes) ‘See Appendix A for alternative types of distributor ‘The rated current of an outgoing circuit shall normally be 500 A; 400 A units may be provided a the purchaser's request Cable termination arangements shall be suitable for accommodating up to and including 300 mm? conductor cable with either cable lugs or mechanical clamps. Cable lugs, which may bbe sweated type or compression type, will be supplied by the purchaser. ‘The phase cable side contacts shall be to one of the following designs (see Fig 2): (i) Where cable lugs are to be used they shall be designed with long and short reach and shall be fitted with forward projecting M12 corrosion proof captive steel studs, one per contact, complete with a full nut, The contacts shall be so designed that they provide adequate spacing and are fully interchangeable to facilitate terminating the phase conductors of a cable whatever their lay. (ii) An altemative design for use with cable lugs has fixed contacts which shall be provided with two holes rear and forward positioned to facilitate terminating the phase conductors of a cable whatever their lay, using a solid spacer of adequate thickness to give clearance and an M12 steel bolt and full nut (iii) Mechanical clamps suitable for use with solid aluminium conductors and complying with BS 4579: Part 3 to type 2 classification shall be provided by the ‘manufacturer. They shall be located so as to provide adequate spacing and shall have fixing arrangements to facilitate terminating the phase conductors of a cable ‘whatever their lay. Relocatable or alternative components shall make them suitable for cable conductors of sizes between 70 mm? and 300 mm?.ESI Technical Specification 37-2 Page 18 Issue 3 February 1990 In the case of designs (i) and (ii) adequate means, such as a focknut or lockwasher, shall be provided for locking the nut securing the lug. Flat washers or other means shall be incorporated to avoid distorting the lug, which may be made from a relatively soft material. ‘There shall be no neutral link. The neutral conductor shall be terminated directly on to the neutral/earth busbar as detailed in Clause 8.1 Cable support shall be provided by a suitable cleat, or other method specified by the purchaser. The centte line of this support shall be not fess than 450 mm below the centre line of the neutral/earth busbar, except in the case of indoor fuseboards where the purchaser has specified that the cables should approach from above. Where only CNE type cables are to be used this dimension may be reduced to 240 mm by agreement between the manufacturer and the purchaser. The cable supports shall be adequate to support the outgoing cable in normal service ‘and when subjected to the short circuit duty specified in Clause 5, “Short circuit ratings”, Each phase shall be provided with a fixed contact assembly of one-piece construction which shall be suitable for accommodating a fuse-cartier in accordance with Table 4 (Clause 7.1.2). Each fuse-carrier shall be suitable for inserting in a phase of the unit by hinge action pivoted on the lower contact and for withdrawing by snatch action, The contacts shall be arranged to permit contact tightening and the contact surfaces shall be flat and accurately aligned in pairs. Sufficiently good contact shall be made on inserting the fuse-carrier so that current can be safely carried prior to tightening the contact-tightening thumbscrews. IFit is necessary to dismantle the contact assemblies in order to select the correct phase sequence, or for any other purpose during assembly on site, then the design shall be such that a correct alignment of the contaets is obtained without the need for special jigs. Contact assemblies shall be supported from the steel framework by insulating material. The arrangement of the supports shall be such that mechanical stresses produced in service by the temperature rise of connections shall not adversely affect the alignment of the contacts. It shall be possible with ease and safety when both busbar and outgoing circuits are live to fit a current transformer ratio 00/5, 5 VA output Class 5 accuracy, of the design as supplied by the ‘manufacturer over the red phase fuse contact of any outgoing distributor unit, and, on non- shielded equipments, to use a clip-on ammeter over any fuse assembly when a current transformer is not fitted, (On non-shielded equipments insulated dividing barriers shall be provided between phase contact assemblies and phase and neutral/earth contact assemblies which shall be make it impossible to insert a fuse-carrier between contacts of different phases. On shielded-pattern equipments the required degree of protection shall be obtained with all fuses in position and also with suitable insulated shields fitted on any units that have the fuses, withdrawn. With neither fuses nor shields in position maintenance of the full degree of protection is not mandatory but the design shall be such as to minimise the possibility of inadvertent touching of live metal by the operator. Each shielded-pattern equipment shall be supplied with a sufficient number of shields for one distributor unit, By use of separate shields for busbar and cable-side contacts or other means shall be possible to gain access to any one cable-side contact for testing, with all busbar-side contacts and the other two cable side contacts still shielded. It shall also be possible to connect the leads of a fault re-energising device or other test equipment on to both contacts of any one itI Technical Specification 37-2 Page 19 Issue 3 February 1990 phase with the other phases still shielded or their fuses in position. A typical wedge-type clamp for these terminals is shown in Fig 4 The design of shielded-pattem equipments shall make it impossible for a fuse-link to make contact across the terminals of different phases or different units, 35 ‘useboxes only The rated normal current of these equipments shall be as detailed in Table 2 and the neutral connections shall be rated at 315 A. Copper connections, with provision for adjustments, shall be provided between the transformer LV terminal stems and the incoming terminals of the fuses and neutral link In these equipments the incoming transformer unit also forms the outgoing distributor unit. Each phase shall be provided with a fixed contact assembly of one-piece construction which shall be suitable for accommodating a fuse-cartier in accordance with Table 4 (Clause 7.1.2). Each fuse ‘carrier shall be suitable for insertion in a phave of the unit by hinge action pivoted on the lower contact and for withdrawal by snatch action. Sufticiently good contact shall be made on inserting the fuse-cartier so that current can be safely carried prior to tightening the contact- tightening thumbycrews, The contacts shall be arranged to permit contact tightening and the ccomtact surfaces shall be flat and accurately aligned in pairs, Contact assemblies shall be supported from the steel framework by insulating material. ‘The arrangement of the supports shall be such that mechanical stresses produced in service by the temperature rise of connections shall not adversely affect the alignment of the contacts. It shall also be possible to connect the leads of a fault re-energising device or other test equipment on to both contacts of any phase with the other phases still shielded or their fuses in position. A. typical wedge-type clamp for these terminals is shown in Fig 4. It shall be impossible to accidentally bridge across live phase contact assemblies and phase and neutral/earth contact assemblies with a fuse-carrier, A bolted link rated at 315 A shall be provided for disconnection of the neutral. No special provision within the fusebox is required for locking-off isolated transformer connections, It shall be possible for the user to insulate the transformer connections, after installation, by taping or Sleeving, so as to reduce the risk of faults and/or injury to personnel, 3.5.1 400A Incoming transformerioutgoing distributor unit (Fusebox type designation TFX1) ‘The rated normal current of this equipment shall be 400 A and the neutral connections shall be rated at 315A ‘Cable termination arrangements shal! be suitable for accommodating up to and including, 185 mm? conductor cable with either sweated lugs or compression lugs which will normally be supplied by the pusESI Technical Specification 37-2 Page 20 Issue 3 February 1990 Alternatively mechanical clamps to BS 4579 Part 3 to type 2 classification and suitable for solid aluminium conductors between 70 mm? and 185 mm? may be used. Provision is required for only one cable and a support cleat should be provided. 35.2 315A Incoming transformerioutgoing distributor unit (Fusebox type designation TEX2) The rated normal current of this equipment shall be 315 A and the neutral connections shall have the same rating as the phase connections, Cable termination arrangements shall be suitable for use with cables ranging from 25 mn single-phase service cables, with concentric neutral, up to and including 120 mm three-phase cables. Connections may be made with mechanical clamps or cable lugs. Any cable lugs required, which may be compression type or sweated, will normally be supplied by the purchaser. Pinch-screw or tunnel type terminals shall not be used. Provision will normally be required for up to two outgoing cables either single or three-phase Appropriate cleats shall be provided to support the outgoing cables.ESI Technical Specification 37-2 Page 21 Issue 1 February 1990 4 CONS TRUCTION 4.1 Requirements applicable to indoor fuseboards only Supporting structures shall comprise frameworks constructed from rolled or pressed steel ‘members. The structures shall be arranged either for wall mounting or floor mounting with horizontal support from a wall in accordance with the purchaser's requirements. All fixing holes shall give a suitable clearance for M16 bolts, The centre line of any fuse shall be not more than 1680 mm above floor level, The cable supports shalll be above floor level The ferrous surfaces shall be prepared and painted to meet the test requirements of ESL ‘Technical Specification 98-1 with quality for serviee Class 5 4.2 Requirements applicable to fuse-pillars only The design of pillar shall be such that itis suitable for mounting on a flat base or piers (at or slightly above ground level) and provision shall be made for fixing the pillar to the formation by the inclusion of four clearance holes for M16 Foundation bolts. These bolts vill be supplied by the purchaser. Rear access to the pillar is not required. An unswitched metal-enclosed heater rated at between 60 watts and 120 watts shall be provided to prevent condensation, 4.3. Requirements applicable to fuse-cabinets only ‘The rear of the cabinet shall incorporate a short trunking piece of not less than 100 mm in length which may be detachable, On all cabinets except type TMC] this shall be centrally positioned in relation to the side wally of the cabinet. On type TMC cabinets the trunking shall be so positioned that the vertical centre line of the mounting flange shall be not greater than 305 mm trom the extremity of any part of the cabinet body on the right hand side when viewed from the front. The thickness of the flange(s) of this trunking shall be strong enough to support the ‘weight of the cabinet and cables and be adequate to ensure a waterproof seal when finally mounted onto the transformer and cabinet, The flange as shown in Fig 3a shall be suitable for mounting on the transformer flange securing the low voltage bushing mounting plate on transformer types (ESI Technical Specification 35-1) shown in Table | for each type of ca A suitable gasket shall be provided for insertion between each flange of the cabins transformer. ibinet ‘and the Access shall be provided for the neutral/earth busbar earthing connection to be brought through the base of the cabinet ‘The cabinet bodies shall be of the maximum dimensions shown in Table 1. Provision shall be made for supporting the lower half of the cabinet by means of two adjustable Supports which shall hear against the tank of the transformer when the cabinet is in position. ‘These supports shall be adjustable in length from inside the cabinet and shall have end c prevent damage to the transformer tank paint finish, 8 t0ESI Technical Specification 37-2 Page 22 Issue 1 February 1990 44° Requirements for outdoor use applicable to fuse-pillars and fuse-cabinets Construction shall be such that the possibility of damage by vandals and removal of fastenings from the outside shall be minimised, Fusi pillars and fuse-cabinets shall be weatherproof and of robust construction and shall be provided with watershed tops, which in the case of cabinets shall be removable. They shall be ‘manufactured from sheet steel and the design shall prevent the accumulation of water, which may initiate corrosion, Adequate ventilation shall be provided to permit natural circulation of air. The ventilation apertures shall be suitably screened to prevent the entry of snow, vermin and other foreign bodies. The degree of protection against persons, foreign bodies and ingress of water shall be IP 33 in accordance with BS 5490. ‘Access to the front of a pillar shall be by means of two hinged doors, and to the front of a cabinet by one door normally hinged on the left-hand side when viewed from the front. Locking. arrangements shall be provided to secure the door(s) top and bottom and operated by a central handle with provision for a security padlock, as detailed in Clause 4.6. One of the following alternative weather-resistant treatments shall be used: (i) For pillars and cabinets manufactured from uncoated sheet steel, all ferrous, surfaces and edges shall be cleaned of scale and rust by shot-blasting and shall be treated on the same day, without outdoor exposure, with a zine spray. The zine shall be applied by a flame gun process of a thickness Znd in accordance with Clause 5 of BS 2569, Part |. However, where powder coating is also to be applied, the zine coating may be of thickness Zn3. Gi) The pillar or cabinet may be fabricated from hot-dip zin BS 2989, of a high-quality heavy duty grade steel and a coating type to be approved by the Purchaser. In either case both external and internal painting finishes shall be carried out in accordance with ESI Technical Specification 98-1. Bither a process including a zinc chromatic based priming paint and a final coat of durable oil and weather resisting paint, or, with the approval of the purchaser, an electrostatically applied powder coating process may be used. All painting processes must be suitable for “on-site” repair of damage sustained during transport and installation, ws (Wyte) The final coat shall be Dark Admiral Grey, colour 634 in BS 381C. ‘The finish shall comply With the test requirements for service Class 3 of ESI Technical Specification 98-1. All labels used shall be made from weather-resistant material. 4.5 Requirements for fuseboxes The requirements of Clause 4.4 (above) are also generally applicable to fuseboxes.ESI Technical Specification 37-2 Page 23 Issue 1 February 1990 4.6 General requirements applicable to all equipments All equipments (other than fuseboxes) shall be fitted with removable devices to facilitate handling during transport, mounted one at each end and as near as possible to the balance line. The specified degree of environmental protection shall be maintained after removal of these devices (Clause 4.4 above), Any equipment which is not stable on its own supports shall be fitted for transit and storage with removable extension feet to provide stability, these feet being returnable to the manufacturer, A nameplate shall be fixed to the equipment detailing the following information: (i). Serial number, which shall be unique. ii) Year of manufacture (iii) Normal current rating of busbar. iv) Normal current rating of incoming unit (v)_ Reference to this Specification, (vi) Gross weight. when fully equipped (kg). (vii) Manufacturer's name and reference number. The gross weight shall be stencilled externally of on the frame of indoor fuseboards, ‘The facilities required for padlocking differ accordingly to the function of the padlock: (i) Safety padlocks are required to lock disconnectors ete in the open position, to ensure safety of personnel working on the system. Provision shall be made for these locks to have a body up to 38 mm square with a 7 mm diameter shackle having a clear inside width of 20 mm and an inside length of between 16 mm and 30 mm. The holes provided for the shackle to pass through shall be not less than 8 mm diameter, Gi). Seeutr padlocks are for locking outdoor equipment to prevent access by the public and to give security against vandal attack. Provision shall be made for these padlocks to have a body up 0 63. mm square and with a 10 mm diameter shackle having a clear inside width of 35 mm and an inside length of between 25 mm and 45 mm. The holes provided for the shackle shall not be less than 12 mm diameter,ESI Technical Speci Page 24 Issue 1 February 1990 5 SHORT-CIRCUIT RATING ‘The distribution equipment contained in the fuseboard shall be proven by test to be capable of carrying without undue distortion or deterioration the following 3-phase or I-phase currents in accordance with BS 5486 Part 1 rable 3 Incoming | RMS short Factor for transformer circuit Duration initial i stort factor unit rating current peak 315A) | | \ 400A ) 18.0kA 08 sec 20 0.30 BOA ) | | | 12508 ) 10004 ) 35.5 kA 05 sec 2a 0.25 By agreement between manufacturer and purchaser where two 800 A fuseboards are to be coupled together, the short-circuit rating of the busbars shall be as for 1600 A equipments. For all equipments other than fuseboxes, the short-circuit withstand test on the neutral/earth busbar system shall be carried out at test currents of 60% of the values in Table 3. For fuseboxes, this test shall be done at the full test current (18 kA). If the largest sizes of fuse-links limit the peak current and the clearance time to lower values than these, such lower values may be substituted in respect of the portions of the fuseboard which are protected by the fuses. (This exemption does not apply to the transformer units and busbars of ‘equipments with fuses in the transformer connection), Evidence shall be submitted that a complete equipment of each basic design offered has been tested for compliance with this clause. 6 CLEARANCES All equipments shall be designed to ensure that adequate clearances are provided to permit the incoming transformer circuit to be left in an open or closed position and alive with the locking device in position, and the door(s) closed in the case of a pillar, cabinet or fusebox. For all connections in air the clearance and creepage distances shall be not less than 25 mm between conductors and 19 mm from conductors to earth. The 19 mm minimum clearance shall also apply between opposite contacts of a fuseway and also of a fully-open disconnector. When these clearances cannot be obtained, or where special risks exist extinguishing solid insulation shall be provided.ical Specification 37-2 Page 25 Issue 1 February 1990 7 FUSE AND FUSE-CARRIERS 1 Fuses for distributor circuits 71.1 Fuse-tinks Fuse-links shall be in accordance with ESI Technical Specification 12-8 and BS 88 Parts 1 and 5, For indoor fuseboards, tuse-pillars and fuse-cabinets the fuse-links shall normally have 92 mm fixing centres, However, at the purchaser's request. fuse-links having 82 mm fixing centres may be used as an alternative. The two sizes of fuse-Hink may not be mixed in any one equipment. For fuseboxes the fuse-Links shall have 82 mm fixing centres. 712 Fuse-carriers A through grip shrouded fuse-carrier of porcelain or other approved insulating material shall be provided for cach phase. The fuse-carrier shall provide a secure connection for the fuse-link by means of wedge connections and insulated contact-tightening thumbscrews. Sutficiently good ‘contact shall be made on inserting the fuse-carrier so that current can safely be carried in the interval prior to the tightening of the contact tightening thumbscrews. The sizes and applications of fuse-carriers are given in Table 4, Tabled Terminal centres ESI Technical Specification FU%2"=tNG Application 92mm 12-8 500A | Indoor fuseboards, | | tuse pillars, | tuse-cabinets “82mm 12-8 400A | ‘Indoor fuseboards, “Fuse-pillars, *Fuse-cabinets 82 mm 12-8 315A fuseboxes * Where specitied by purchaser. In any one equipment only one size of fuse-carrier may be used. 7.2 Fuses for transformer connection Fuse-cabinets having fuses in the transformer connection shall use the following fuse-Links: Table 5 Fuse-cabinet_ Fuse rating British Fuse-link type (max) Standard reference T™MC10S 1250A BS 88: Section 2.2 Ref 01 TMs11S, 800 A BS 88: Section 2.2 Ref C3ESI Technical Speci Page 26 Issue 1 February 1990 tion 37-2 7.3. Fuses for auxiliary supply Fuses for auxiliary circuits shall be of 32A maximum rating, back-connected and suitable for use with fuse-tinks to BS 88: Part 6, Ref Fl. 8 NEUTRAL AND EARTH CONNECTIONS, 8.1 All types of equipment except fuseboxes A. common neutral/earth busbar shall be provided, having a rating of not less than half that of the phase busbars. This busbar shall be insulated from the metal framework andior shell of the equipment; the insulation shall be capable of withstanding a test voltage of 7 kV RMS according to Clause 13.3.1. ‘The following captive fasteni with adequate locking facilities shall be provided:~ (i) One on the neutral/earth busbar, projecting forwards, for each distributor cable. Gi) Qne connected to the neutral/earth busbar, projecting forwards, with a label reading “LV neutral earth” in close proximity. (iii) One on the framework of indoor fuseboards only, with a label reading “HV steelwork earth” in close proximity, Fuse-pillars and fuse-cabinets shall be provided with an earth marshalling busbar instead of the HY steelwork earth terminal, (it) above. The earth marshalling busbar shall have a rating of not tess than half that of the phase busbars. It shall be mounted inside and electrically in eontact with the shell ofthe pillar or cabinet. The earth marshalling busbar shall be provided with three captive fastenings with adequate locking facilities, with a label reading “HV steelwork earths” in close proximity. All types of equipment shall be provided with a removable bolted link between the neutral/earth busbar and the earth marshalling busbar (or the framework of indoor fuseboards). It shall be accessible when all distributor units are in position and cabled. A label reading “Disconnect, ‘when overall resistance to earth is greater than one ohm” shall be mounted in close proximity. This link must be capable of carrying fault current as detailed in Clause 5, The fastenings for all the above neutral and earth connections shall be M12 x 50 mm and of high tensile steel to BS 3692, minimum grade 8.8, ‘Terminal blocks shall be provided as detailed in Clause 10, Of these, one for the auxiliary circuit neutral shall be connected to the neutral/earth busbar by a cable of not fess than 10 mm cross- section; another for the auxiliary circuit earth shall be connected to the earth marshalling busbar, again by a cable of not less than 10 mnication 37-2 Page 27 Issue 1 February 1990 82 Fuseboxes Common neutral/earth connection facilities are required, which shall have a minimum current rating of 315A. They shall be insulated from the shell of the fusebox: the insulation shall be Capable of withstanding a test voltage of 7 kV RMS avcording to Clause 13.3.1 Provision shall be made inside the shell of the fusebox for the following conneetions: (i) Transformer neutral ii) Distributor cable neutral(s); (type TEX? fuseboxes take two cables), (ii) LV neutral earthing cable. (iv) Bolted link to shell, ( be accessible alter all cables have been connected. To be labelled Disconnect when the overall resistance to earth is greater than one ohm.” (¥) Two earth terminals for the shell 9 CURRENT TRANSFORMERS Except for fuseboxes or unless otherwise required by the purchaser, three dual-ratio current transformers shall be provided on the incoming circuit. suitable for the operation of bi-metallic ammeters. They shall comply with BS 3938, with SVA output and accuracy Class 5. ‘The ratios shall be: Incoming cireuit rating Current transformer ratio 1600.4 L600/800/5 1250.4 1200/6015 800A 800/400/5 The three secondary connections of dual-ratio current transformers shall be brought out to the instrument panel or otherwise made accessible to facilitate reselection of the ratio safely with the busbars and incoming transformer connection alive. On shielded pattern equipments the required degree of personnel protection shall be maintained when carrying out this operation, Alternative tapping connections shall be clearly marked to indicate the ratio. 10 INSTRUMENT PANELS AND AUXILIARY SUPPLY CIRCUITS Except for fuseboxes, an instrument pane! suitably wired shall be provided to accommodate three bi-metallic ammeters in accordance with ESI Technical S tion 50-2 and having a thirty ‘minute time lag and with direct reading scales according to the current transformer ratio and. minimum scale as follows:ESI Technical Speci Page 28 Issue 1 February 1990 ion 37-2 Current transformer ratio Seale range Minimum scale marking (in use) {in use) 1600/5 0- 1920 320A 1200/5 0- 1400 A 240.4 00/5 0- 9604 160A 6005 0- 720A 120.4 40015 0- 480A 80.4 ‘The bi-metallic ammeters shall have either reversible scale plates or alternative scale plates, only one scale being visible at any one time. The cable connections shall be of sufficient length to allow for the removal of the ammeters from the front of the panel. ‘The instrument panel shall preferably be mounted in such a position that neither cable installation nor jointing are impeded. If it is mounted in front of the cables it shall be removable As an alternative to the three bi-metallic ammeters the purchaser may specify the provision of aan electronic maximum demand indicator. The following equipment shall also be mounted on the instrument panel: - Upto three auxiliary supply fuses (see Clause 7.3), = One 13 A switched socket outlet to BS 1363. All fuses shall be clearly labelled, ‘The phase connection to the fuse-carriers shall be made onto the nearest phase busbar, using a hard-drawn high conductivity insulated or fully-shrouded copper strap of not fess than 75 mu ross - section. “The following terminal blocks shall be mounted on the instrument panel, or in an altemnative location where small wiring cables can be connected without risk of contact with any primary ‘connections: - Two for phase connections to auxiliary equipment installed by the user and supplied from two of the three auxiliary supply fuses. (For fuse-pillars only, the heater is to be supplied from one of these), = One for neutral connections of all auxiliary supply ci method of connection to neutral/earth busbar). its (see Clause 8.1 for = One for earth connections of all auxiliary supply circuits (see Clause 8.1 for method of connection to the earth marshalling busbar). In addition to the 13A switched socket outlet and the fuse-pillar heater the auxiliary supply circuits may feed: = A voltage transformer to be used in conjunction with an earth fault indicator; accommodation, mounting provision and wiring are required if requested.ESI Technical Specification 37-2 Page 29 Issue 1 February 1990 A supply for substation lighting or any other auxiliary, which will be connected as required by the user. See Fig 5 for the wiring diagram for auxiliary supply circuits. Note for users:- Hazard of potential rise of auxiliary supplies: ‘When it is necessary to leave the neutral/earth to frame/earth link open and the transformer LV neutral earthed remotely, because of earth resistance greater than one ‘ohm, and the substation lighting and heating installation is supplied from the auxiliary supply connections on the equipment it is recommended that a 1:1 isolating transformer, insulated for 7 kV, should be inserted between the auxiliary supply terminals and the building installation. ‘The 13 A switch-socket is then best removed from the instrument panel and its wi disconnected at the fuse and terminal blocks. un SMALL WIRING ‘The secondary wiring of the current transformers shall be carried out in 2.5 mm? PVC-insulated cable to BS 6231 type BR. coloured black or an equivalent cross-linked polyethylene insulated le. Current transformer secondary connections shall have ferrules marked in accordance with BEB Specification S.12. ‘The secondary wiring of the group of current transformers shall be connected separately to earth, at the earth terminal block. The earth connections shall be accessible from the front of the equipment. The wiring of the auxiliary supply circuits shall be carried out in PVC-insulated cable to BS 6231 type BR. or an equivalent cross-linked polyethylene cable, with the cores fervuled and coloured as follows: Phase - RE Neutral - Light blue “Earth” = Green/Yellow Each individual neutral lead shall be brought back separately as far as the neutral terminal block ‘and each individual earth lead shall be connected separately to the earth terminal block. The individual circuits shall be wired in 4 mm? cable, while terminal blocks shall be wired back to their respective sources in 10 mm? cable (also see Clause 8.1). Wiring shall be fixed and preferably housed as far as practicable in PVC conduit or channelling: if wiring cleats are used they shall be of the insulated limited compression type. 2 CIRCUIT LABELS. Blank circuit labels 75 x 50 mm made of insulating material shall be mounted in suitable positions to identify each outgoing circuit. These labels shall be securely held without the use ‘of screws and it shall be possible to locate them in position and remove them from the front without danger when the equipment is “alive”. These labels shall be suitable for engraving with black letters on a white background.ESI Technical Speci Page 30 Issue 1 February 1990 B TYPE TESTS The following type tests, based on BS 5486 and BS 5490 (where applicable) shall be carried out on each basic design of low voltage fuseboard: (i) Short-circuit withstand test (ii) ‘Temperature rise test. Git) High voltage tests (iv) Torque test on thumbscrews. (¥) Environmental test (outdoor equipments) (vi) Shielding test (shielded-pattern equipments). (vii) Flame tests. (vili) Mechanical operation test ‘The type tests needed for each variation of any basic design of equipment shall be agreed with the purchaser - however the short-circuit test shall be mandatory. 13.1 Short-cireuit withstand test Each individual design and size of complete d accordance with the parameters set out evidence of compliance with that Clause. ribution fuseboard shall be short-circuit tested in Clause 5. A certificate shall be submitted by way of 13.2 Temperature rise test 13.2.1 General Distribution fuseboards shall be so designed as to ensure that thermal interaction does not unduly affect the performance of any of the components, Evidence shall be submitted that temperature rise tests have been carried out on complete distribution fuseboards of each type to demonstrate that they will comply with this clause. Tests, of temperature rise shall be made with alternating current at the design frequency ‘Tests shall be made with the incoming circuit carrying its rated current and with the minimum number of outgoing circuits connected to balance this. For arrangements where exact balance is, ‘not possible, the outgoing circuit most remote from the incoming circuit shall be arranged to carry only sufficient current to obtain current balance, The distributor units connected shall be jointed with aluminium conductor cable approximately 3.m in length. In order to determine the temperature rise of terminals when fuse-links are fitted, fuse-Links in accordance with ESI Technical Specification 12-8 shall be inserted. For all equipments with 500 A distributor units, the conductor size of the cable shall be 300 mm? and the fuse-link current rating 630 A. Each feeder shall carry 555 A unless only partly loaded to obtain current balance.ESI Technical Specification 37-2 Page 31 Issue 1 February 1990 For equipments with 400 A distributor units two of these units shall be jointed with cable of 185 mm: conductor size which shall both be loaded to 400 A. The rating of the fuse - Ii them shall be 400A. ks in ‘Type TFX1 fuseboxes shall be jointed with one cable of 185 mm? conductor size, fitted with 400 A fuse-links and loaded to 400 A, In the case of type TFX2 fuseboxes, the outgoing way shall be jointed with cable of 120 mm? conductor size which shall be loaded to 315 A. The rating of the fuse-finks in it shall be 315 A. ‘The tests shall be carried out with the base of the fuse-pillar, fuse-cabinet or fusebox closed and its door(s) shut as in normal service. Temporary connections used for the tests shall be such that their temperature rise, measured at a distance of 300 mm from the point of connection, is not less than 40°C or not less than the actual temperature rise of the adjacent current carrying parts under test if this should be below 40°C. ‘Temperatures shall be regularly monitored by means of thermocouples attached to the following points: (1) The top contact of each phase of the transformer units. (2) The top fuse contact of each phase of each distributor unit (3) All cable sockets (4)_ Air temperatures at the top and 300 mm from the bottom of the distribution fuseboard, inside the casing of fuse-pillars and fuse-cabinets and within SO mm measured horizontally from the busbars of indoor fusebourds, (5) Fuse-carrier handles of the uppermost phase. (6) Door-handle(s) of the fuse-pillar or fuse-cabinet. The test shall be made for atime sufficient for the temperature rise to reach a constant value (normally not exceeding 8 hours), In practice. this condition is reached when the variation does not exceed 1°C per hour ‘The temperature rise at any point shall not exceed 65°C relative to the ambient temperature ‘outside the fuseboards, except that the temperature rise of any fuse-carrier handle must not exceed 25°C and that of any door handle must not exceed 30°C 132.2 Additional requirements for fuse-cubinets and fuseboxes The incoming temporary connections shall be of an appropriate size to achieve a temperature rive of 40°C when carrying the rated current of the cabinet under test, They shall be bolted to the transformer unit connections as in normal service ‘The mouth of the throat piece through which the incon ing connections pass shall be effectively blanked off.ication 37-2 Page 32 Issue t February 1990 In addition to the points mentioned above, temperatures shall be regularly monitored by means Of thermocouples attached to the following points: (7) The incoming temporary connections at a distance of 300 mm from the point of connection. (8) ‘The interconnecting point where the fuse-cabinet is normally connected to the transformer. 13.2.3 Additional requirements for fuse-cabinets types TMC 108 and TMC 11S (with fuses in the transformer connection) The test shall be carried out with the specified type and rating of transformer fuses in position. Also, temperatures shall be regularly monitored by means of thermocouples attached to the following additional points (9) The fuse contacts on the incoming side of the transformer fuses. (10) The fuse contacts on the busbar side of the transformer fuses, 133 igh voltage tests 13.3.1 Complete equipment A complete equipment, with neutral links in position, shall be high voltage tested in accordance with BS 5486 Part 1, Clause 8.2.2, using a test voltage of 2.5 kV (RMS). applied for one minute. A further test on a complete equipment, but with the link between the neutral/earth busbar and the frame or shell removed, shall be carried out. The auxiliary circuits shall be disconnected at the auxiliary fuses and the neutral/earth busbar. The three phase busbars and the neutral/earth busbar shall be bonded together and a test voltage of 7 KV (RMS) applied between these busbars and the frame or shell of the equipment for ten seconds 133.2 Additional tests on fuse-carviers ‘Type tests on fuse-carriers specified in Clause 7.1.2, including their associated wedge-operating thumbscrews, shall be carried out as set out below. Type tests shall be carried out for each new design of fuse-carrier or thumbscrew and for any change in material of either component. ‘The tests shall be made at an ambient temperature between 15°C and 25°C with alternating current of approximately sinusoidal waveform at a frequency of between 45 Hz to 62 Hz inclusive. The test voltage of 3.75 kV (RMS), shall be applied for one minute between: (i) Both of the fuse-carrier terminals without a fuse-link being fitted. ii). One of the fuse-carrier terminals and metal foil which shall be wrapped around such surfaces of the insulating material of the fuse-carrier, including the thumbserews, which can be touched during live replacement or withdrawal of fuse-carriers. For this test, a fuse-link of the largest dimensions intended for the fuse-carrier shall be fitted. (One pole of the with the metal fol {ng transformer shall be earthed during parts (i) and (ji) of the test, together in part (ii).Technical Specification 37-2 Page 33 Issue 1 February 1990 ‘The voltage shall be applied at a low value and shall be brought up to the full value as rapidly as is consistent with its value being indicated by the measuring instrument. The test voltage shall be maintained at the steady value for one minute and may then be rapidly reduced before switching off, If the voltage cannot be maintained at the specified value or if there is visible evidence of sparking or tracking, this shall be regarded as failure of the test. Following the high voltage test, the fuse-carrier shall be placed in a humidity cabinet for 48 hours in which the humidity is maintained between 91 % and 95 % and the temperature ‘maintained within 2°C of any convenient value between 20°C and 30°C. Prior fo being placed in a cabinet, the fuse-carvier shall be brought to a temperature within +4°C, -0°C of the cabinet temperature. Immediately after removal from the cabinet. and after wiping off any drops of. water resulting from condensation, the insulation resistance shall be measured by the application of a voltage of 500 V DC between the points specified above. The insulation resistance shall be not less than 5 megohms, L 3 Test on disconnector operating poles ‘The operating poles for transformer disconnectors shall be tested in accordance with Clause 8.2.2.3 of BS 5486 Part 1, but the test voltage shall be 5 kV applied for two minutes water bath may be used with the purchaser's consent. The same test shall be used for the operating tools of contact tightening devices, where applicable 134 Torque test on thumbscrews Type tests shall be carried out on six random samples of the insulated thumbscrews, each complete with the wedge operating screw, 1o confirm the mechanical strength of the thumbscrew, Each wedge operating screw shall in turn be placed in a vice and a torque applied in a clockwise direction to the insulated thumbscrew using a torque spanner adapted as. necessary, Each insulated thumbscrew shall withstand a torque of [2 Nm, without fracturing or turning on the shank of the wedge operating screw. This type test shall be carried out for each new design of thumbscrew or wedge operating screw and for any change in material 13.5 Environmental tests Evidence shall be submitted that for each design of fuse-pillar, fuse-cabinet, or fusebox the degree of protection is IP 33 according to BS 5490 with the following tests 135.1 Test for first numeral 3 of P33 Section 7.3 of BS 5490 applies. It is permissible for the test wire or rod to pass through any gauze or grille covering ventilation openings but if it docs so, internal baffles must prevent any size wire passing to any point in the vicinity of the electrical equipment. 135.2 Test for second numeral 3 of 1P33 Section 8.3 of BS 5490 applies. The test shall be made with equipment as shown in figure 4 of BS 5490 provided the stated conditions are complied with and that the equipment tested will within the radius of the oscillating tube as shown. Where this condition cannot be fulfilled the test shall be with a hand-held spray according to figure 5 of BS 5490.fechnical Specification 37-2 Page 34 Issue 1 February 1990 For transformer-mounted equipment a temporary blanking plate shall be attached to the mounting flange The design shall be considered satisfactory if inspection after the test shows that there is no evidence of water on any internal surface, where it could have harmful effects on insulation or cause corrosion. 13.6 Tests for effectiveness of shielding of live connections (Shielded pattern equipments) Evidence shall be submitted that for each design of shielded-pattern fuseboard, and with the doris) open in the case of fuse-pillars, fuse-cabinets and fuseboxes, the degree of protection of persons against contact with live parts is IP 2X. Tests shall be made in accordance with BS 5490, Section 7.2 using the Standard test finger shown in Figure I of that Specification. The tests shall include sections of busbars crossing unequipped distributor unit positions, transformer isolators in both open and closed positions. and distributor units with fuses withdrawn but with cable-side and busbar-side contacts covered by the type of shield provided. 13.7 Flame tests ‘A specimen of each type of material used for the non-metallic parts of the fuseboards shall be tested in accordance with the following conditions: 13.7.1 Form of test specimen The specimen of insulating material under test shall be 127 mm long, 25 mm wide and 3 mm thick. A line shall be drawn across the specimen at 38 mm from one end. 13.7.2 Procedure The specimen shall be tested in a draught-free atmosphere. It shall be clamped in a rigid support at one end so that its longitudinal axis is horizontal and its transverse axis is 45° to the horizontal, so that the marked line on the specimen is clearly visible. The mark shall be 38 mm from the free end, A piece of clean wire gauze (aperture 850 microns), mesh number 18 (refer to BS 410), 100 mm square shall be clamped in a horizontal position 6 mm below the specimen with 6 mm of the unsupported end of the specimen projecting beyond the edge of the gauze as shown in Fig.6 of this Specification. A bunsen burner of 10 mm diameter bore with a non-luminous flame 12 mm to 19 mm in height shall be placed under the centre of the free end of the specimen so that the top of the flame just touches it ‘The flame shall he removed after 10 seconds and the specimen shall not burn back or scorch ‘more than 38 mm, ie not beyond the line marked on the sample. This test is to be repeated on two further samples, in which conformity with the same requirements shall be established. If compliance with the requirements as laid down above is obtained on all three samples, the ‘material shall be deemed to be satisfactory.ESI Technical Specification 37-2 Page 35 Issue 1 February 1990 13.8 Mechanical operation test Satisfactory mechanical operation of the disconnectors shall be verified after their the equipment. The number of operating cycles shall be 50. 4 ROUTINE HIGH VOLTAGE TESTS 14.1 Routine tests for complete equipments Each complete fuseboard shall e tested in a manner similar to that outlined in Clause 13.3.1 above. 14.2 Routine tests on disconnector operating poles Routine tests on insulated poles for operating the transformer disconnectors shall be carried out on a representative sample of poles; where applicable, these tests shall be carried out on a representative sample of operating tools for contact tightening devices. These tests shall be carried out in a manner similar to that outlined in Clause 13.3.3 above. Ifa water bath is used. each pote tested shall be immersed to within 10 mmm of the base metal 14.3 Routine tests on wedge-operating mechanisms Routine tests on wedge-operating thumbscrew’ shall be carried out on representative samples by subjecting them to a high voltage test at the manufacturer's works. Each thumbscrew under test shall have the major accessible portion of the insulated section encased in conducting foam, and atest voltage of 3.75 kV, 45Hz to 62 Hz AC. applied for one second between the metal insert of the thumbscrew and the conducting foam. The conducting, foam shall be carbon loaded and have a surface resistivity, measured on a square sample, of 10,000 ohms per square, in accordance with BS 5783: 1987: Clause 2.3.1. All traces of carbon must be removed after the test. 144 Sampling procedure for routine tests ‘Sampling for routine tests shall be in accordance with BS 6001, using the maximum acceptable quality tevel (normal inspection). In the event of electrical breakdown of any component an test it shall be examined for the cause of failure. In accordance with the maximum AQL in BS 6001, 100% of that production batch shall be subjected to the routine testsFig.1 Pole operated isolator - simple typical drawing {a} : 2 ay y eit 8 Soe oi at Fig.2 Typical distributor unit arrangements S| Drawing No.970202°2 a zESI Technical Specification 37-2 Page 37 Issue 1 February 1990 6 MOLES 16 O14: se | 10 wiotes 32 ota XY us | 25 FLANGE THICKNESS Tam BiKLHU smn KAXIKUM fa? pig 89 pty 8? Qt _ 610 De faxieuR Fig.3(a) +F° flange for all types of fuse-cabinet and fusebox except 370 6 MOLES 16 01A— 8 Motes 32 01a: ma ie ig aD D oO Le. 8 2s. FLANGE THICKNESS y 7 Tam MINIMUS oe Adam MAXIHUM 3(b) “E? flange for fusebox type SI Drawing No 370203ESI Technical Specification 37-2 Page 38 Issue 1 February 1990 29 Gi 12 Figd Typical clamp for connecting fault re-energising device on to distributor unit ESI Drawing No:370204PHASE @ SUBSTATION LIGHTING (CONNECTED BY USER) cr. AS ALTERNATIVE TO HEATER ( iTEM@) SECONDARIES NEUTRAL/EARTH STEELWORK EARTH key. @ fuses @ PHASE CONNECTION BLOCKS 3 @ 134 switcHen socket ouTLET Z @ EARTH FAULT INDICATOR VOLTAGE TRANSFORMER (WHEN CALLED FOR) 2 @© HEATER (FUSEPILLAR ONLY} g © EARTH CONNECTION BLOCK re © NEUTRAL CONNECTION BLOCK ge 325 gte Fig.5 Schematic diagram of auxili ESI Drawing No. 370205, supplies. (Not applicable to fuseboxes)I Specification 37-2 Page 40 Issue 1 February 1990 Centre of free end oF Specimen ~ under — test Fig.6 Flame test apparatus ESI Drawing No:370208ESI Technical Specification 37-2 Page 41 Issue 1 February 1990 APPENDIX A Alternative types of distributor unit AL GENERAL For shielded patterns of equipment only. alternative designs of distributor units 10 that outlined in Clause 3.4 are permitted. Such units shall comply with Clause 3.1.2 and with as many of the requirements of Clauses 3.4 and 7.1.2 as are consistent with the design of the altemative distributor unit, The number of departures from the requirements of these two Clauses shall be Kept to a minimum, however compliance with Table 4 is mandatory: whilst the requirements of all other clauses of this Specification shall be met. (It is not intended to restrict the application of such distributor units to any particular types of equipment. although it is recognised that their application to fuseboxes could be limited), Altemative designs of distributor unit shall comply with, and be tested to, the requirements of BS 5419. The rated enclosed thermal current of the distributor unit shall normally be SOOA; 400A units may be provided at the purchaser's request. Such distributor units sall be equally suitable, without modification, for use in 1600A equipments with a short-circuit rating of 35.5 kA or 800 A equipments with a short circuit rating of 18 kA. Where such distributor units take the form of triple pole fuse-switches or fuse-disconnectors either single pole or triple pole operation may be provided. However where triple pole operation is provided, Facilities shall also be provided for the separate operation of each pole. Al ‘operating mechanisms shall be of either the stored energy operation or the independent manual operation type, Its not necessary for the operating mechanism to remain in position on the distributor unit when not in use ‘The utilisation category of switching devices for distributor units shall be AC22 and the fused short cireuit current 35.5 KA, Each fuse-link shall occupy a separate fuse-carrier (ee Table 4, Clause 7.1.2). Fuse-carriers shall be readily removeable to facilitate the replacement of fuse-links, All switching clements shall be of the double-break type and have definite ON and OFF positions. It shall be impossible for any switch to move independently of the operating mechanism. The switching state of each phase (ON of OFF, CLOSED or OPEN) shall be readily visible by inspection and simple, clear indication provided. Where switching is effected by movement of the fuse-carrier, the indication shall be int Demountable operating mechanisms shall engage with both the distributor unit body and the appropriate switching element(s) in one single operation, Interlocks shall be provided to ensure that the mechanism is correctly Hitted and locked into position before it can be operated. It shall not be necessary to reset an operating mechanism between successive operations regardless of the previous or intended operation, Minimum isolation distances in the OFF position shall be [2 mm for each break, ON and OFF states shall be clearly identified.-al Specification 37-2 uel February 1990 Access shall be available for the use of test probes complying with Engineering Recommendation M15/4. They shall be able to make contact with top and bottom fuse link terminals when fuse carriers are installed and top and bottom fused contacts when fuse carriers are removed, It shall also be possible to connect the leads of a fault re-energising device or other test equipment onto both fixed contacts of any one phase with other phases still shielded or thei fuses in position, The manufacturer shall supply a design of terminal for use with his distributor ‘nit and the fault re-energising device, to be used in lieu of that shown in figure 4, Equipments using demountable operating mechanisms shall have storage facilities for a ‘complete mechanism. Space shall be provided inside pillars and cabinets for the secure stowage of the operating mechanism; whilst for indoor fuseboards a bracket (which may be separate from the fuseboard) shall be provided. A2 TYPE TEST! All type tests listed in Clause 13 shall be carried out on each basic design of low volta fuseboard incorporating an altemative type of distributor unit. However, the design of the distributor unit may call for the following vari (i) Temperature rise test In addition to monitoring the temperature rise at the locations listed in clauses 13.2.1 and 13.2.2, the temperatures shall be monitored regularly at all points of contact between the fuse-link and the fixed contacts of the top terminals of each phase. (ii) High voltage test Generally as clause 13.3.1, but the 2.5 kV test to be repeated with earthed demountable operating mechanisms in place on the phase under test on at least half of the distributor way ‘The tests on fuse-carriers set out in clause 13.3.2 shall be carried out, but it shall be recognised that some minor variations will arise according to the design of fuse-cartiers used in the alternative types of distributor unit (iti) Torque test on thumb-screws This test is not applicable (unless the fuse-carrier of the alternative type of distributor unit incorporates thumb-serews for contact-tightening). The following additional type tests, in accordance with BS 5419, shall be carried out on the distributor units: (iv) Rated making and breaking capacity tests As clause 8.2.4 of BS 5419. Utilisation category AC22. Rated operational voltage 415 V single phase (also three phase for three pole ganged equipments).ESI Technical Specification 37-2 Page 43 Issue 1 February 1990 (v) Rated fused short circuit current test As clause 8.2.7 of BS 5419. 35.5 kA prospective short circuit current and rated operational voltage of 415V. 500 A equipments to be fitted with 630 A fuse-links, 400 A equipments to be fitted with 400 A fuse-links. (vi) Mechanical endurance test As clause 8.2.9 of BS 5419 to 1000 operating cycles. (vii) Electrical endurance test As clause 8.2.10 of BS 5419 to a minimum of 50 operating cycles. Utilisation category AC22, Rated operational voltage of 415V single phase (or three phase for three pole ganged equipments),ESI Technical Specific Page 44 Issue 1 February 1990 APPENDIX B Summary of options and type designation for each equipment Indoor Current fuseboards rating IEB 1600S 1600) 1FB 1600 Ns aoa} IFB 8008 800A) 1FB 800 NS 80a) Fuse-pillars FP 1600S 1600A FP 1600 NS. 1600 A. } FP 8008 800A) F800 NS sa) Fuse-cabinets (Table | gives more details) TMC2NS 1600 A TMCIS 1600) ) TMC1NS 16004) > TMC2s 160A) ) ) Options (a) Distributor cables from above (b) Busbar connections from separately ‘mounted protection equipment (c) 400 A distributor units with 82 mm fuse terminal centres (a), (b) and (c) as above, also (d) Disconnectors or link-carriers (c) as above (c) and (d) as above (c) as above, also (e) transformer unit with horizontal or vertical phasesESI Technical Specification 37-2 Page 45 Issue 1 February 1990 Fuse Current Options rating TMC3S 800A) TMC3NS. 800A } (c) and (4) as above aces soa) TMCANS eon) TMCSS sa) TMCSNS. A TMC10S 1250 A (as TMC2S) TMCHIS 800A (as TMC3S) Fuseboxes (Table 2 gives more details) TEXI 400 A TFX2 BISA (a) One, two or three fuses (b) Constructed integral with transformer tank~zA ©1993 ELECTRICITY ASSOCIATION SERVICES LIMITED Engineering Publications AMENDMENT 1, 1993 Technical Specification 37-2 Issue 3, 1990 LV distribution fuse-boards Page 7 Foreword Page 8 Page 9 In indent (ii), delete: of traditional design Insert new paragraph at end of Foreword: This Technical Specification has been amended to introduce the changes necessary to ensure that it ‘meets the requirements of Clause 11 of the Utilities Supply and Works Contracts Regulations 1992 (SI 1992 No 3279). References After BS 88, insert: (Associated Standards: EN 60 269, IEC 269) After BS 410, insert: (Associated Standards: ISO 565, ISO 2194, ISO 3310) After BS 2569, insert: (Associated Standard: ISO 2063) After BS 2989, insert: (Associated Standards: EN 10 142, EN 10 147)

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