Professional Documents
Culture Documents
A INTRODUCTION 01
4.0 INSTALLATION 18
4.1 Foundation Preparation 18
4.2 Order of Installation 19
4.3 Horizontal movement of Panels 19
4.4 Erection of Cubicle 20
4.5 Connection of Main Busbar 21
4.6 Connection of Earth Busbar 27
4.7 Connection of Control Wires 28
4.8 Power cable termination 28
4.8.1 Preparation of Cable Gland Plate 28
4.8.2 Power cable termination 28
4.9 Inspection after Installation 29
7.0 MAINTENANCE 42
7.1 GENERAL 42
7.2 Daily Inspection 42
7.2.1 Visual Inspection 42
7.2.2 Variants 43
7.2.3 Check on metal parts 43
7.2.4 Noise Identification 43
7.3 Annual Maintenance 43
7.4 Safety Precautions 43
7.5 Maintenance Procedures 43
7.6 VCB Maintenance & Inspection 45
7.6.1 Maintenance & Inspection Schedule 45
7.6.2 Check on Vacuum 45
8.0 TROUBLESHOOTING 50
10 MANDATORY SPARES 59
NOTE 60
INTRODUCTION
A - INTRODUCTION
IMPORTANT NOTE -
Only the Speci c written Technical Instructions supplied by E&A manufacturer. Non Compliance with this instruction may result
must be used. Our products must only be commissioned, in serious damage to the product and its associated items, as
operated, serviced, repaired or decommissioned in accounts well as health hazard or mortal danger.
with Technical Instructions which have been supplied by the
WARRANTY
Our products are subjected to factory inspection and testing which refer to international regulations.
according to the applicable standards and provisions.
Non-compliance with the instructions of the suppliers of
The correct function and the service life of the switchgear are cables and connecting accessories as regards application and
in uenced greatly by compliance with the installation, installation.
commissioning and operating conditions stipulated in this
Any aggressive climate conditions (humidity, pollution etc.)
manual.
prevailing in the immediate environment of switchgear not
Non-compliance with these provisions may compromise suitable to this effect or not protected accordingly.
warranty claims.
This manual does not contain any instructions regarding the
Any local provision which does not contradict the speci cations mechanical lock-outs to be performed. The work described is
of this document, especially as regards safety for personnel and performed on de-energized (on installation) or mechanically
buildings, must be complied with. locked out (decommissioned) switchgear.
E&A cannot be held liable for the possible consequences of:
Non-compliance with the provisions contained in this manual,
25 / 26.3 kA
Short Time Withstand Current (3s)
Current ratings 40 / 50 kA
62.5 / 65.75 kAp
Short Circuit Making current
100 / 125 kAp
Width# 600 mm 800 mm 1000 mm
Dimension Depth # 1570 / 1970 / 2170 / 2270 mm
Height 2495 mm
Partition Class PM
Loss of Service continuity LSC-2B
Construction
Degree of protection IP42 (Higher IP on request)
Internal Arc Classification A (F, L,R), up to 40 / 50kA, up to 1s
IEC Standard IEC 62271-100
Type Designation VK series
Operating Sequence O-0.3sec-CO-3min-CO
Opening time < 35 ms
VCB Break time < 3 cycles
Mechanical Operations 10,000
Closing /Tripping Coil 24 / 48 / 110 / 220 V DC
1.1.2 - Normal service conditions for indoor - Admissible 1.1.5 - Admissible air humidity
ambient temperature
The average air humidity measured over a period of 24 hours,
The ambient temperature must be in the range of 5°C to must not exceed 95%.
+40°C.
The average vapour pressure, measured over a period of
For Higher ambient, please contact E&A Sales Department. 24 hours, must not exceed 22 mbar.
The average air humidity measured over a period of one
month, must not exceed 90%.
1.1.3 - Installation altitude
High-voltage switchgear has been designed according to the
appropriate international standards and can be installed up to an The average vapour pressure, measured over a period of one
altitude of 1000m. month, must not exceed 18 mbar. Condensate may form in case
of sudden temperature uctuations due to excessive ventilation,
At higher installation altitudes, the reduced voltage endurance
increased air humidity or hot air. Such condensate formation can
must be taken into account.
be avoided by a suitable arrangement of the room or the
In special cases, please contact the E&A Sales Department. building (suitable ventilation, air dehumidi er, heating etc.).
If the average air humidity exceeds 95%, we recommend that
appropriate remedies are adopted. Support or any advice, please
contact the E&A Service.
CRANE CRANE
LIFTING
HOOKS
1 2
LIFTING
CRANE FIXTURE
ROPE/CHAIN
LIFTING
FIXTURE
LIFTING
FIXTURE
HOOKS
Definition Level
Operations requiring training and which can be performed by an approved third party 2
10-12 times manoeuvres should be carried out in order to check the mechanical
- X X
operation of the equipment
The minimum threshold (85% of Un) of the coil for electrical operation should be tested - X X
10-12 times manoeuvres should be carried out in order to check the mechanical
- X X
operation of the equipment
The minimum threshold (85% of Un) of the coil for electrical operation should be tested - X X
Wrapped under heat sealing cloth with inspection doors to change the
1 2 3
desiccant bags
The minimum threshold (85% of Un) of the coil for electrical operation should be tested - - X
ARC DEFLECTOR
METERING METERING
COMPARTMENT COMPARTMENT
EMERGENCY
BUSBAR
DOOR BYPASS
COMPARTMENT
VCB
POSITION
HANDLE INDICATOR
VCB INSULATOR
MANUAL VCB
OPERATING
TRIP COMPARMENT
INSTRUCTION
VIEWING MANUAL HANDLE
WINDOW CLOSE
CABLE VIEWING
COMPARMENT WINDOW
VCB RACKING
SOCKET SURGE CABLE
ARRESTOR COMPARMENT
EARTHBAR
3.1.1 - Circuit breaker Compartment Disconnected positions, separates the contact arms and their
xed contacts. These shutters prevent access to the xed
The Circuit breaker compartment contains a withdrawable
contacts, while in isolated position.
vacuum circuit breaker.
The withdrawable VCB moves on two in-built rails. It can be
transferred between the Connected and Test positions using a 3.1.2 - Busbar Compartment
Racking Handle with front door closed.
The Busbar compartment holds the busbar for connectivity
In the Connected /service position, the moving upper and the between the switchgear and epoxy coated connection (Busbar
lower contact arms of the VCB engages with the xed contacts Bushing) that is connected to breaker. The busbar extends from
connected to the bus bars and the outgoing circuit respectively. one switchgear cubicle to the adjacent and so on. All the busbar
joints are covered with PVC Boots.
Shutters operated by the VCB movement In the Test/
3.1.3 - Cable and CT compartment lamps/meters, push buttons, relays and control switches etc are
mounted on LV compartment door and inside LV Compartment.
The Cable compartment contains:
Insulating bushings with Cable connecting terminals.
3.1.5 - VT Compartment ( 2-Tier VT Panel)
A section of the main earth busbar.
A 2-Tier arrangement for the Bus VT Trolley and the Line VT
Current transformers.
trolley in the same panel is as shown above.
The Gland Plate is tted at rear bottom of cable compartment.
Both the VT trolley can be Racked-in and Racked-out
The cable is accessible from rear of the cubicle by opening the
individually.
cable compartment covers.
Exclusive Panel for Bus VT can also be provided with same
arrangement excluding Line VT trolley and its xed contacts.
3.1.4 - Low Voltage Compartment
Line VT can also be mounted below breaker and even in Riser
This compartment consists of all the low voltage equipments viz. Panel as per customer requirement.
Fuses MCBs, control terminals, protective relays, Indicating
GAS DUCT
METERING
METERING COMPARTMENT
COMPARTMENT
BUS VT
POSITION
INDICATOR BUSBAR
VIEWING COMPARTMENT
HANDLE
WINDOW BUS
PADLOCK
VT
VT TROLLY
RACKING
SOCKET LINE VT
POSITION
INDICATOR R
Y
PADLOCK
HANDLE LINE
VT B
VT TROLLY
RACKING
SOCKET
EARTHBAR
Metering
Compartment
Arc Deflector
Earth Switch
Arrangement
VT VT VT VT
E E E E E
Socket for
Charging Handle
Trip Button
Closing Button
Indicators
Operation
Counter
Control Plug
Locking Handle
Socket for
Racking handle
Earthing
VCB wheels
Contact Arms
VCB Mechanism
Vacuum
Interrupters
Control Plug
VCB Racking
Wheel
Socket for
Charging Handle Trip Button
Closing Button
Indicators
Operation
Counter
Control Plug
Locking Handle
Socket for
Racking handle
Vacuum
Interrupters
Trip / Close Button
Control Plug
VCB Racking
Wheel
a) Charging Operation
Con rm that the VCB is in the DISCHARGED state.
When a control supply of the VCB is connected, the motor starts
The CHARGED condition indicated by YELLOW colour. While running, and the indicator changes to CHARGED status after the
DISCHARGED condition indicated by WHITE colour. closing springs are charged. The motor will then stop. The
charging operation is now complete.
Manual charging can be performed in the event of motor
malfunctions.
Note: The number of times the handle must be operated b) Closing Operation
depends on the angle of handle during operations.
When a closing signal is given, the closing coil is energized, the
Insert the charging handle into the charging socket and move it indicator changes to CLOSE, con rming that the VCB is close. As
up and down several times (usually 7 counts) until a click sound soon as the closing is complete, the motor starts to run, and the
is heard. closing spring is recharged.
If the VCB is in OPENED conditioned, it is ready to be CLOSED.
c) Tripping Operation
b) Closing Operation When a tripping signal is given, the tripping coil is energized,
the indicator changes to OPEN con rming that the VCB is open.
Push the CLOSE button to initiate the close operation. The
indicators on the VCB will now read CLOSED and DISCHARGED.
Operating Pin
for Test Service
Indicator
VCU Jaw
Fuse Blown Contact
up Flap
HT Fuse HT Fuse Inside
Housing Housing
L&T Electrical & Automation
On Off
Operation Indication
Counter Trip Push
Button
Control
Plug
Locking Socket for VCU racking
Handle Racking Handle Wheel
VCU racking
Wheel
Figure 3.3.1 A VCU Front View Figure 3.3.1 B VCU Side View
3.3.2 Construction
As shown in gure: 1, the vacuum contactor consists of three switch as well as hold the vacuum contactor in ON condition.
Epoxy cast Poles, each individual epoxy cast Pole forms a The durable opening springs open the contacts very fast so as to
switching pole. These epoxy cast consist of main current caring open the circuit effectively to improve the response time of your
components with vacuum tubes are mounted on rigid epoxy control circuit. The number of auxiliary contacts are 3 NO + 3
base plate to further improve insulation properties. This is part is NC.
the further attached to a very simple, compact, durable and
In case of latch type arrangement, there is a sub assembly which
maintenance free solenoid type mechanism. The compact
hold the VC on closed condition till opening command is not
vacuum contactor unit featured with minimum no. of
activated. For latch type external and shunt release arrangement
components which enhance the mechanical life of the contactor.
is carried out the opening operation.
There are two operating coils in the contactor, both are used to
R Y B
E1 E3 E5 P1 P3 P2 HT B2 A2 A3 B3 FB1
1 2 3 31 14 41 21 13 17 16 15 34
FUSE 10A D
PF
PANEL OVERVIEW
C IL IL
D
1-1 2-1 3-1
61 13 52a 41 23 33 51
52b 52b 52a 52a 52b
52 AX
A1
B 14 42 24 34 52 A
62
A2 A B
220µF
430V
CC B
B1
TC
220µF
B2
430V
B
32 24 D 42 23 27 26 25 35
N1 N3 N2 B02 A02 A03 B03 FB2
LEGEND DESCRIPTION
E5 E3 E1
CC CLOSING COIL 7 6 5 4 3 2 1
TC TRIPPING COIL P3 B2
14 13 12 11 10 9 8
a VC AX CONTACT N/O
HT A2 A3 B3
b VC AX CONTACT N/C 21 20 19 18 17 16 15
52 VACUUM CONTACTOR V/C A02 A03 B03 N3 B02
28 27 26 25 24 23 22
IL INTERLOCK SWITCH
FB2 FB1 N1 P1
LS1-3 FUSE BLOW LIMIT SWITCH 35 34 33 32 31 30 29
AX AUXILIARY SWITCH N2 P2
B 42 41 40 39 38 37 36
FBR FUSE BLOW RELAY
SECONDARY DISCONNECTING SWITCH (SDS) ARRANGEMENT
D VDR VOLTAGE DEPENDANT RESISTOR (FRONT VIEW)
16
+ VE
R Y B
E1 E3 E5 P1 P3 P2 B2 A2 A3 B3 FB1
1 2 3 31 14 41 13 17 16 15 34
FUSE 6A
PF
PANEL OVERVIEW
COMMON
52b
61 62
Schematic control wiring diagram for VCU (Non-Latch type)
32 24 42 23 27 26 25 35
N1 N3 N2 B02 A02 A03 B03 FB2
E5 E3 E1
LEGEND DESCRIPTION 7 6 5 4 3 2 1
CC CLOSING COIL P3 B2
14 13 12 11 10 9 8
a VC AX CONTACT N/O
A2 A3 B3
b VC AX CONTACT N/C 21 20 19 18 17 16 15
52 VACUUM CONTACTOR V/C A02 A03 B03 N3 B02
28 27 26 25 24 23 22
IL INTERLOCK SWITCH
FB2 FB1 N1 P1
LS1-3 FUSE BLOW LIMIT SWITCH 35 34 33 32 31 30 29
AX AUXILIARY SWITCH N2 P2
42 41 40 39 38 37 36
FBR FUSE BLOW RELAY
SECONDARY DISCONNECTING SWITCH (SDS) ARRANGEMENT
A VDR VOLTAGE DEPENDANT RESISTOR (FRONT VIEW)
17
INSTALLATION
4.0 INSTALLATION
4.1 - Foundation Preparation Mark the allocated positions of the panels on the cement
surface for easy positioning. Ensure that minimum working
It is important that the nished oor area is at, and not sloping.
space is available on Front, rear, Top and on side of rst and
If the oor is not level, the switchgear may be deformed during
last panel once the panels are coupled.
installation, resulting in eventual malfunction of the equipment.
Pay particular attention to the following requirements for correct The area of the sub-station oor in front of the switchgears
erection: must be at and level so that the VCB can be easily racked in
and out of the panel. Special cement with hardener should
The panel must be placed on a at and level foundation
be used in these areas to prevent the cement from cracking
without any foreign materials over the openings. Foundation
under the weight of the VCB.
channels or uni-struts may be used to ensure this condition.
However, ensure that the space in between is cement lled. Note - CARE SHOULD BE TAKEN WHEN TIGHTENING THE
The level of the oor should be within +/- 0.5mm/m and FOUNDATION BOLTS AS EXCESSIVE TIGHTENING WILL DISTORT
+/- 2mm across the entire width of the switchboard. THE BOTTOM PLATE.
SIDE VIEW
TOP VIEW
Coupling Hole
marked in
red colour
Panel Coupling
Figure 4.4.1 Panel showing Coupling Hole Location (After xing Top
Interpanel Bracket)
After Placing One panel to other, Panel shall be coupled on
the holes as shown in gure 4.4.2.
Generally M8 Bolts are required for Panel coupling.
Similarly all the panels shall be coupled together.
P
D
S BUSBAR
SPACER
MAIN BUSBAR
1 10 35
Table 4.5.3 Bolt size v/s Required Torque wrench for Busbar
HIGH TENSION
STEEL BOLT
PLAIN WASHER
PLAIN WASHER
SPRING WASHER
HIGH TENSION
STEEL NUT
Top
Perforated
Cover
Middle
Channel
Bottom
Perforated
Cover
Busbar
Compartment
Cover
At the end of this step, all obstructions on the rear side of the panel are removed. The busbar compartment can now be accessed as
shown in the following images.
Busbar
Compartment
Cover
Busbar Shrouds
The busbar joints are then covered with busbar shrouds. A fully
The following sequence must be followed while installing the mounted busbar looks as shown in the image below.
horizontal busbar
M10 x 40 Hardware
M10 x 40 Hardware
R
Y
Tightening Torque - 35 Nm
Last step is to mount the rear top and bottom covers followed by
tightening of all bolts.
Repeat Steps 1 to 10 above for adjacent set of panels till the last
panel.
4.5.3 - Typical Insulation Boot (Optional) For non-standard design, HV insulation tape must insulate
any other exposed live parts that are not covered with the
insulation boots.
Ensure that all joint surfaces are clean and securely bolted
before wrapping with the sealant.
Connection
of Earth bar
Earth Bar between
2 panels
Rear Side of
Panel 1
Rear Side of
Panel 2
Figure 4.5.3 B Insulating Boots on Main Busbar End Figure 4.6 B Earth Bar View before Connection
As shown in Figure 4.6 B, Panels have been coupled and earth bar connection is to be done. After Coupling Earth bar links shall be
passed from one panel to another through earth bar coupling hole. As shown in Figure 4.6 C, Panels have been coupled and earth bar
connection is done. The connection to the station earthing system should have a cross section of not less than that of the earth bar
mounted on the switchboard.
Metering
Compartment
VCB Compartment
For control wiring connection, remove the Aux Cable side plate and Aux Cable Bottom entry plate (Figure 4.7). Control cable entry
is given at front and rear bottom side of the panel. After Control cable connection, re x the Aux Cable side plate & bottom plate.
4.8 - Power Cable Termination match the cable diameter as shown in below Figure.
The power cable entry point is provided with a removable gland
plate and is located at the base of the cable compartments. CUT CIRCLE ON GLAND PLATE
Standard cable entry is from the bottom. Top entry is available if WHILE CABLE TERMINATION
speci ed at the time of placing the order.
Adjust the position of the power cable and mount the cable
HOLE FOR CABLE LUG
gland plates onto the welded studs at the base plate. Tighten CABLING LINK
TERMINATION
the nuts securely.
If there is any gap between the power cable and the gland
cover, apply sealing compound around the Cables to ll the
gap as shown in Figure 4.8.1 B. TERMINATION LUG
POWER CABLE
Figure 4.8.1 B - Assembly of Cable Gland Plate Upon completion of cabling, plug the opening of the cable entry
to prevent small animals from entering the switchgear.
The cable earth screen should be properly connected to the
panel earth.
4.9 - Inspection After Installation
For Single core cables, there should be a gap between the
Check the door to ensure that it can be opened and closed
split plates and the former sealed with the compound. This is
smoothly.
to prevent eddy current circulation.
Check that all bolts and nuts are securely bolted.
Note: Bolts and nuts are marked by manufacturer to enable
4.8.2 - Power Cable Termination
detection of loose connections.
Figure 4.8.2 C the cables should be terminated vertically and
exposed live parts at cable terminations are to be insulated with
tape. Cable supports are provided to prevent undue stress on the If these markings are shifted, re-tighten nuts.
bushing caused by the weight of an unsupported cable. Ensure that all interpanel gaps are sealed.
For top cable entry design, cable supports is an optional item. If Ensure that all exposed busbar connecting joints are tted
not provided, ensure no undue stress at the cable connection by with insulation boots or taped properly.
positioning the cable lug opening to the same level as the bar
hole. Ensure that no tools or loose parts are left inside any
compartment.
Refer to the instruction manuals supplied by the manufacturer of
the termination kits for preparing the cable termination. Clean any debris and dust inside and outside of the panels.
Check the system voltage and ensure that the voltage is
within speci ed limits for which the unit is designed.
Check the frequency and ensure that the frequency is as per
the speci cation.
Ensure that recommended ratings of fuses are used and there
are no loose connections.
VCB Racking
Mechanism Interlock
Handle & latch
Figure 5.1 A - VCB in Disconnected Figure 5.1 B - VCB in Test Figure 5.1 C - VCB in Service
Figure 5.1.1 A - Door Locked Figure 5.1.1 B - Door latch Open Figure 5.1.1 C - Door Opening
Earth Switch
Earth switch
Operating Rod
CABLE EARTH SWITCH OPERATING SEQUENCE EARTH SWITCH OPERATING SEQUENCE WITH MIL
Hooter
Control Plug
Arrangement
Earthing Truck
Racking handle Hole
Racking Wheel
Arrangement
Control Plug
Latch for Handle
It may be necessary to perform primary or secondary injection Engage all VCBs into the CONNECTED position and ensure
tests on site to establish that no CTs, relays and wirings are they are in OPEN position.
damaged during transportation. Ensure all VCB & metering doors are tightly bolted down.
Check that all CT shorting links are at their original positions. Ensure earthing switches are disconnected from live (if inbuilt
Perform primary/secondary current injection tests on all relays with panel).
wherever possible to establish that the tripping time
corresponds to that shown on the relay manufacturer s
tripping characteristic curve. The switchgears are now ready for energization.
7.0 MAINTENANCE
7.1 - General 7.2 - Daily Inspection
Routine inspection should be conducted at regular intervals. Although daily inspection is speci ed, it is possible for the
Inspection of the switchgears should be made as soon as maintenance staff to conduct weekly checks to anticipate any
possible after the occurrence of a fault on the circuit. The deviations from norms after ascertaining that the switchgear is
switchgears should not be put into operation without a stable over a period of service.
complete check and test after the clearance of a fault.
Monitor the meter readings. If the readings taken are
A maintenance program should be planned for the equipment. abnormal, check the loads to ascertain the status.
The frequency of the inspection and maintenance should be
No covers are to be opened. The switchgears are checked
adjusted to take into account the environmental and operating
externally for any anomalies.
conditions, and fault history. A recommended maintenance
schedule is shown in below Table. When an abnormal is detected, identify the location and
degree of severity by opening the panel door as necessary.
FREQUENCY DESCRIPTION WHAT TO DO Necessary safety precautions are to be taken if doors are
opened.
Daily Physical appearance Visual inspection
Doors and covers to Monitor meter When the abnormality is not expected to lead to an
be bolted. reading immediate malfunction of the switchgear, the problem is
Check for noise, smell recorded as a reference data for the next periodic inspection.
or damage
If the abnormality is expected to lead to switchgear failure,
Yearly Complete switchgear Routine de-energize the switchgear affected after establishing that it
maintenance
is safe to do so and rectify the fault.
Table No 7.1 Maintenance Schedule Table
Record the results of the inspection and action taken to remedy a defect on the checklist.
(h) Isolating contacts (l) Current transformers (CT) and voltage transformers (VT)
The isolating contacts should be examined for discoloration and Steps should be taken to ensure that voltage transformers are
deformation due to overheating or environmental isolated and discharged to earth before commencing
examination. Care should be taken to ensure that the main circuits isolated. Check the operation of the relays/
transformers are not made live inadvertently due to feedback contactors by energising the control circuit.
from the secondary windings.
In the case of the CT, attention is drawn to the dangerous
(n) Final veri cation before re-energization
voltages that may result if the secondaries are open-circuited
while the primaries are on load. A nal check is to be carried out to ensure that the switchgears
are restored to the original conditions and no tools are left inside
Any connections removed for checking/testing must be correctly
the switchgears. Cancel the permit-to-work and warn all the
replaced and securely tightened. Insulation resistance and
workers of the re-energization.
continuity tests of the secondary windings should be carried out
where possible.
Generally, check CT's and VT's for physical appearance and that (o) Records
all related connections are tight. The insulation material should Record actions taken and details of the corrective action on
be cleaned and closely examined for any signs of damage such defect for future references.
as cracks, tracking marks or peeling.
In case of withdrawable VT's, the isolating contacts should be
checked, cleaned and lubricated sparingly. The correct operation 7.6 - VCB Maintenance And Inspection
of safety shutters for the VT truck should also be veri ed. Primary Check Points for Periodical Inspection.
and secondary fuses should be tested for continuity.
General checks should be done one year after installation and
once every 2 years thereafter, depending on severity of usage &
(m) Control relays or contactors environmental conditions. This should be done against a well
documented schedule of requirements.
Inspect mechanical parts for free movement with the control and
CHECK
CHECK ITEM CHECK METHOD CRITERIA WHAT TO DO FREQUENCY
POINT
Tightness of By tightening them No loose Re-tighten
with screw driver loose
bolts andnuts and wrench connections connections
Clean with a
vacuum
The VCB cleaner. Wipe
Dust and should be with a clean,
Visual check
foreign matter clear of dust dry cloth and
and stains recommended
cleaning agent Once in 3
Entire years
VCB / VCU (As66)
Deformation, No
deformation,
excessive Replace parts,
Visual check excessive
wear and wear or if necessary
damage damage
Lost or
No missing Replace
missing Visual check
parts parts missing parts
CHECK
CHECK ITEM CHECK METHOD CRITERIA WHAT TO DO FREQUENCY
POINT
Check circuits
The closing and the closing
and tripping and tripping
operations can devices.
Electrical Check at the be done
Control When the Once in 3
closing and DISCONNECTED smoothly
Circuit tripping motor cannot years
position
Motor can spring charge,
spring charge check if line
automatically fuse is blown.
Replace if
blown.
Tighten with screw No loose Re-tighten
Terminal
Auxilary driver screws Once in 3
switch Moulding and No damage or Replace with years
Visual check damaged
contacts deformation
Remove
There should
Dust and foreign matter
Visual check be no dust and
foreign matter with
foreign matter
pressurized air
Smooth
Manual operation Operation
Operating operation Clean off old Once in 3
should be lubricant and
mechanism Lubricant of Check by sight and years
smooth
bearing pins touch apply a small
Shaft of amount of
closing and Must rotate fresh lubricant,
tripping Visual check smoothy if necessary.
portion
There should Clean the
Main circuit be a thin film contact surface
disconnects/ Dis- of old grease Once in 3
of contact
contact colouration of Visual check and apply a years
grease on the
finger contacts thin film of new
contact
surface grease
Clean with
There should
pressured air
be no foreign
and then wipe
Contamination matter
with clean cloth Once in 3
Main barrier and dis- Visual check
colouration There should years
be no tracking Replace when
marks, cracks damaged
or damages
CHECK
CHECK ITEM CHECK METHOD CRITERIA WHAT TO DO FREQUENCY
POINT
Measuring Resistance Tester When the
location insulation
Main resistance
conductor- between the
Ground/Main 500M Ω or more 2000V
main circuit
conductors terminals is
Measurement low, clean the
of insulation Once in 3
surface of the years
resistance
vacuum
Control circuit interrupter with
2M Ω or more 500V a dry cloth and
Ground
then take the
measurements
again
Carried out
Across each set of contacts Trip time & Close time when speed
Timing Test As per specs
of operation
is critical
CHECK
CHECK ITEM CHECK METHOD WHAT TO DO FREQUENCY
POINT
Cleaning of Once in 3
Cleaning Visual Clean the complete VCU with dry cloth
complete VCU months
Breakdown will occur in the vacuum interrupter with vacuum less than 0.1mmHg when applied with a voltage of about
17 21kVAC. Therefore, the vacuum interrupter internal vacuum pressure can be checked by applying the voltage of 25 kV AC in this
voltage withstand test.
When the internal vacuum pressure is not suf ciently high, breakdown will occur immediately. Hence 10 seconds of voltage
application is suf cient.
0.3kVA
100V/30kV
5A 0-150V
Supply
V
Source
A
0.5A VCB
Figure 7.6.2 B Set-up for High Voltage Withstand Test for Vacuum Interrupter
Voltage
(kVAC)
25 25kV
10 Seconds Time
If the ammeter indicates current ow in the process of increasing voltage, then the voltage must be reduced to zero and gradually
increased again. Repeat this process 2 or 3 times. Interrupter is defective if the current increases with the voltage. The leakage current
is almost zero for good interrupters.
8.0 TROUBLESHOOTING
The switchgears are manufactured under strict quality control and has undergone routine factory tests before dispatching from the
factory. However, should any defects be found during daily or periodical inspections, investigate the cause of trouble and take the
necessary action according to recommendations in Table 5 below:
overheated 2. Overload
2. Limit current to the rated value
1. Replace insulators
1. Insulators cracked
Ground fault or 2. Clean and dry insulators with
2. Insulators stained with foreign matters and
failed dielectric suitable cleaning agent
moisture
tests
3. Plug gaps and openings and remove
3. Instrusion of rodents
rodents
1. Replace bulb
1. Bulb filament broken
CONTROL CIRCUIT
prolonged period)
Replacement Procedure for VCU - Trip Coil (Applicable for Latch type only)
Due to frequent switching applications may cause the coil to please follow the following procedure to replace the trip coil of
carry high current for more instances. Thus coil may over heat the vacuum contactor. To identify the trip coil assembly refer
and shortens its life. May high current ow during operation can stage:5 of assembly. Refer below images and instruction for
damaged the trip coil. In such cases replacement is essential then replacement of trip coil.
The coil is designed for very long life, eventualities such as (solenoid) becomes essential. Please follow the following
operations of vacuum contactor without economy resistor may procedure to replace the closing coil of the vacuum contactor.
cause overheating and consequent damage of closing coil. In
To start with please isolate the vacuum contactor from the high
certain chemically polluted atmosphere application, the coil
Voltage High Power supply. Keep the Vacuum Contactor outside
insulation, deteriorated over the time, starts getting overheated.
on the panel for convenience and follow the pictorial
In addition, in-frequent switching applications cause the coil to
instructions given on the next page below:
carry high current for more instances. This over heats the coil
and shortens its life. In such cases replacement of closing coil
a. Unfasten the hardware and remove the front and back cover of the fabrication structure & isolate all the electrical connections to
the closing coil.
b. Unfasten the bolts on the L shaped plate holding the coil axially
c. Lift the closing coil side-wards and remove it from the front door of the fabrication structure.
d. Replace the closing coil and repeat the above procedure in reverse order to assemble the vacuum contactor.
1.0 Introduction
Blown HRC fuses can be identi ed by observing striker visibility (Expelled striker can be seen on Blown HRC Fuse) on the fuse front cap
(as shown in gurw 01& 02). In the event of fuse blown off, striker pin will come out of the front cap of fuse & actuate the push cord
assembly tted on the housing front cap. Push cord assembly will actuate the limit switch & provide indication of fuse blown
off&simultaneously trip the VCU.
Porcelain Moisture
End cap barrel Star core tight seal
Front Cap
Figure 1 Figure 2
HRC fuses shall be mounted in VCU housing in such way that, front cap of fuse (imbedded with striker mechanism) shall be directed
towards VCU front side as shown in gure 02 & 03.
STEP - 01
Picture 04 shows VCU assembly, whose HRC fuse is to be replaced. Open 2Nos Screw Rivets highlighted in (Blue Circle & Arrow)
picture 05 with the help of star head screw driver.
Figure 4 Figure 5
STEP - 02
After opening PP Rivet, Top cover of VCU can be taken out by pulling it vertically upward as shown in picture 06. VCU Top cover
(Sheet metal cap with PC sheet) will smoothly open in upward direction only; do not apply force in other directions. VCU Top cover
shall be preserve in neat & clean location.
Figure 6 Figure 7
STEP - 03
Picture 07 shows VCU after opening Top Cover. Take out the red Epoxy front cover by opening 4Nos white Nylon Boltsper phase
(Housing) as shown in picture 07 and 08. This step is applicable for housing/phase, whose HRC fuse is to be replaced. Epoxy front
cover& Nylon bolts shall be preserve in neat & clean location.
Front
Cover
Figure 8 Figure 9
STEP - 04
Loose M5 Allen bolt highlighted in picture 09. M5 Allen Bolts shall not be attempted to taken out from assembly. Bolts shall be loose
to release the fuse from clamp only. This step is applicable for housing/phase, whose HRC fuse is to be replaced.
Rear
Cover
Figure 10 Figure 11
STEP - 05
Take out the Red Epoxy rear cover by opening 4Nos white Nylon
Bolts per phase (Housing) as shown in picture 10 and 11. This
step is applicable for housing/phase, whose HRC fuse is to be
replaced. Epoxy rear cap & Nylon bolts shall be preserve in neat &
clean location.
For VCU with CVT, Red Epoxy rear cover can be open by
keeping HV cable connected inside housing.
Figure 12
STEP - 06
Loose M5 Allen bolt highlighted in picture 12. M5 Allen Bolts shall not be attempted to taken out from assembly. Bolts shall be loose
to release the fuse from clamp only. This step is applicable for housing/phase, whose HRC fuse is to be replaced.
STEP - 07
Take out the blown fuse from front side only, as shown in picture 13. If required, fuse can be pushed from back side as shown in
picture 14 for easy access.
Figure 13 Figure 14
STEP - 08
After taking out blown fuse, fresh HRC fuse can be assembled in housing by referring reverse procedure given in STEP 07 to STEP 01.
During & after assembly, follow checklist to ensure accuracy & trouble free operations.
3.0 - Checklist:
Fuse Make & Rating shall be as per speci cations& similar to the fuse to be replaced.
Dimensions of New HRC fuse shall be same as the fuse to be replaced.
Use 4mm Allen key & apply 6 N-m torque for tightening Front and rear clamp Allen bolts as shown in picture 09 & 12.
M5 Allen bolt shall be xed after placing New HRC fuse at equidistance (Outer face of Fuse & Fuse clamp shall match with each
other).
Apply 0.5 N-m torque for tightening Nylon bolts (White Color) shown in picture 07 & 10. Nylon bolt tightening torque shall be
0.5N-m only. Excessive tightening torque will damage the bolts permanently.
Contact Resistance shall be checked after fuse replacement & to be compared with healthy phase to ensure accuracy in assembly
joints.
Measurement of contact resistance for comparison shall be done at similar points.
All components shall be clean & damage free before assembly.
DO s DON Ts
Perform all the operations in CLOSE door condition only. Do not apply any ammable lubrication on the busbar joints
(Rack in, Rack out, Open and Close) or VCB nger contacts.
Ensure following before racking the VCB from TEST to Do not perform any operations in OPEN door condition. (Rack
SERVICE position. in, Rack out, Open and Close).
1. VCB is in TEST position. Do not operate the interlocking lever on VCB.
2. VCB is in OPEN condition. Do not try to rack in VCB when control plug is not engaged.
By operating the VCB forcefully it may damage the control
3. Earth switch is in OFF condition if provided.
plug mechanism.
4. Control circuit plug is fully engaged. Red lever on control
Do not try to rack in VCB when VCB is in CLOSED condition.
plug mechanism should come upward direction when
CONTROL PLUG is fully engaged. Do not try to operate Earth switch when VCB is in
CONNECTED position if provided.
Ensure VCB compartment door is fully closed and all the bolts
on VCB compartment door are fully Tightened. Do not operate the VCB when castle lock is in LOCKED
condition.
Earth switch should be operated when VCB is in
DISCONNECTED position. Do not operate the padlock handles if door bolts are not
tightened fully by Allen key.
Always cross check rating of the VCB before insertion inside
the panel. Do not try to insert wrong rating VCB inside the panel.
Ensure complete switchboard is free from dust and any other Do not insert VCB without unlatching the shutter assemblies.
foreign particles.
Do not try to by pass VCB compartment door interlock when
Ensure all openings including hole provided for earthing the feeder is in Live condition.
connection are properly closed with seal to avoid any
vermin/ reptile entry.
Ensure that the shutter assembly is unlatched before inserting
the VCB into the panel.
Please keep the heater "ON" in all Panels including Dummy
panel.
Note - While Ordering Spares please mention "Board Drawing Number" as given in Switchboard Name Plate.
(Other spares available on request)
L&T Electrical & Automation, Electrical Systems & Equipment - Head Office
L&T gate no. 5, L&T Business Park TC II, Tower B 7th floor, Saki-Vihar Road,
Powai, Mumbai 400 072 Tel.: +91 22 6705 1748 Fax: +91 22 6705 1556
Email: ese-cmt@Lntebg.com Website: www.Lntebg.com
The information contained herein is correct at time of printing, but as the products and its manufacturing processes are being developed continuously,
this information is subject to change without notice and the company cannot be held liable for any alleged misinterpretation howsoever arising.