OPERATION & MAINTENANCE

INSTRUCTION MANUAL
Medium Voltage Switchgear up to 17.5 kV
alfa-12

www.alfanar.com
Contents
1.0 GENERAL 6
1.1 Information concerning this manual 7
1.2 Symbols 8
1.3 Limitation of liability 9
1.4 Copyright 9
1.5 Service department 9

2.0 SAFETY 10
2.1 Customer’s responsibility 11
2.2 Service personnel 13
2.2.1 Qualifications 13
2.2.2 Coaching / training 13
2.3 Intended purpose and proper use 14
2.4 Standards and regulations 14
2.5 Personal protective equipment 14
2.6 Preventive measures to avoid accidents 15
2.7 Specific dangers 15
2.8 Signs 17

3.0 TECHNICAL DATA 18

3.1 Rating plate 19
3.2 Data sheets 20
3.2.1 Dimensions and weight 20
3.2.2 Connected loads 20
3.3 Service conditions 20

4.0 STRUCTURE AND FUNCTION 21

4.1 Modes 22
4.2 Overview of features 22
4.3 Compartments 23
4.3.1 Busbar compartment 23
4.3.2 Circuit breaker compartment 23
4.3.3 Cable connection compartment 24
4.3.4 Low voltage compartment 25
4.4 Pressure reduction system 25
4.5 Door lock systems 26
4.5.1 Plug interlock 26
4.5.2 Locking matrix 27
4.6 Circuit breaker 28
4.6.1 Vacuum interrupter (LV6/LV8A) LSIS 28
4.6.2 Embedded poles 29
4.7 alfa-12 IF (Incoming Feeder) overview 30
4.8 alfa-12 OF (Outgoing Feeder) overview 30
4.9 alfa-12 BC (Bus Coupler) overview 31
4.10 alfa-12 BR (Bus Riser) overview 31
4.11 Exploded view representation 32
4.12 Accessories 32

5.0 TRANSPORT PACKING & STORAGE 33

5.1 Safety notes for transport 34
5.2 Symbols on the packing 35
5.3 Transport inspection 36
5.4 Packing 36
5.5 Transport 36

6.0 INSTALLATION 38
6.1 General site requirements 39
6.2 Foundations 39
6.2.1 Method of installation B – Fixing with anchoring bolts to concrete floor 41
6.3 Main busbars installation 42
6.4 Installation of the main busbars 43
6.4.1 Busbar compartment access 43
6.4.2 Busbars installation 43
6.5 Cable connection 44
6.5.1 Power cables 44
6.5.2 Control cables 45
6.6 Installation of the earthing 46
6.7 Final erection work 46
7.0 OPERATION 47
7.1 Health, safety and security during operation 48
7.2 Removing plug-in modules 49
7.3 Installing plug-in modules 50
7.4 Rack-in/out 51
7.4.1 Rack-in to service mode 51
7.4.2 Rack-out to test mode 51
7.5 Switching earth switch on and off 52
7.5.1 Closing the earth switch 52
7.5.2 Earthing switch opening 53
7.6 Voltage transformer 54
7.6.1 Installation 54
7.6.2 Switching voltage transformer 54

8.0 MAINTENANCE 56
8.1 Safety 57
8.2 General 58
8.2.1 Maintenance jobs 58
8.2.2 Intervals for inspection, servicing, and repairs 59
8.3 Inspection and overhauling 60
8.4 Preventive maintenance & servicing 60
8.4.1 Maintenance in busbar compartment 60
8.4.2 Maintenance in cable compartment 61
8.4.3 Maintenance in voltage transformers compartment 63
8.4.4 Maintenance in circuit breaker compartment 64
8.4.5 Maintenance in the low voltage compartment 66
8.5 Corrective maintenance and repairs 67
8.5.1 Switchgear in general 67
8.5.2 The circuit breaker 68
8.5.3 The earthing switches 69
8.5.4 Replacing parts 70
8.6 Tightening torques 71
1 GENERAL
1.1 Information concerning this manual
This manual contains important information related to operation, maintenance and handling of air insulated, alfa-12
Medium Voltage Switchgear. Full compliance with all safety and service instructions given herein is the most
important condition for smooth and safe operation. Also, in addition to this manual, you should follow all local
safety and accident-prevention instructions and regulations.

All persons involved must carefully read this manual and become familiar with the equipment before starting any
installation, operation, servicing or maintenance works.

This manual is an integral element of the product. It must be stored close at hand and must always be available to
all personnel.

To make things clearer and easier to understand, the pictures contained in this manual may have been magnified, or
may not show exactly what you see on your specific equipment.

The documentation accompanying this equipment may contain further instructions, manuals etc. by OEMs of
components integrated with this equipment. Be sure to comply with any such such information (especially safety
and security) in addition to all information contained herein.

The documentation accompanying this equipment comprises of:

• This operating manual

• Layout diagram
• Suppliers' documentations
• Bill of materials
• Electric flow / wiring / connection diagrams
• For manufacturer's certificate of conformity
please contact alfanar customer service
• electric flow / wiring / connection diagrams
1.2 Symbols
Safety information
This manual uses symbols to highlight information concerning health, safety and security. Such information always
starts with an eye-catching title like "Danger", "Warning", or "Caution", indicating the degree to which life, limb or
property are at risk.

Such information must be absolutely complied with. Use common sense and caution to avoid accidents and damage
to persons and property.

DANGER
Indicates an imminently hazardous situation, which, if not avoided, will result in death,
serious injury or property damage.

WARNING!
Indicates an imminently hazardous situation, which, if not avoided, could result in
death, serious injury or property damage.

CAUTION!
Indicates a potentially hazardous situation, which, if not avoided, could result in minor
or moderate injury or property damage.

Recommendations

NOTE
Highlights tips, tricks and useful information to help you operate your equipment
trouble-free and efficiently.

Danger to life caused by electric voltage!

Indicates life-threatening situations caused by hazardous voltages. There is a danger of
serious injury or death if the safety notes are not complied with.
The work to be performed must only be carried out by qualified electricians.

CAUTION!
Important information. Failure to comply may lead to material damage due to incorrect
current and/or voltage.

8
1.3 Limitation of liability
All information and notes in this manual were compiled under due consideration of valid standards and regulations,
the present status of technology and our years of knowledge and experience. The manufacturer cannot be made
liable for damage resulting from:

• Disregarding these instructions

• Unintended use
• Employment of untrained personnel
• Unauthorized conversions
• Technical modifications
• Use of unapproved spare parts

In case of customized versions, the actual scope of delivery can vary from the explanations and representations in
these instructions, because of the utilization of additional options or due to latest technical changes.

Apart from this, the obligations agreed upon in the delivery contract, the General Terms of Business, the delivery
conditions of the manufacturer and the legal regulations valid at the time of contract apply.

1.4 Copyright
Treat these instructions confidentially. They are intended only for persons working with the system. Passing these
instructions on to third parties without the written consent of the manufacturer is not permitted.

NOTE
The contents of these instructions, texts, drawings, pictures and other representations
are protected by copyright law subject to industrial property rights. Any misuse is
punishable.

Reproduction of any kind – even in the form of excerpts – as well as the use and/or disclosure of the contents without
the written consent of the manufacturer is not permitted. Violations require compensation. The right to further
claims remains reserved.

1.5 Service department

If you have any technical questions, please contact the alfanar customer service department. For more information
concerning individual contacts and persons, please contact alfanar customer service for assistance.

Our staff are always happy to receive feedback, to hear about customer experiences and new information, and to
learn of issues that may arise during the operation of our equipment. We use this information to help improve our
products.
2 SAFETY
This section provides you with an overview of all-important safety aspects for optimal protection of personnel as
well as safe and trouble-free operation.

Disregarding the service instructions and safety regulations specified in this manual may result in considerable
danger.

2.1 Customer’s responsibility

This equipment is usually operated in commercial environments. That means the owner/operator is bound by legal
obligations concerning health and safety at work etc.

All persons concerned must comply with all safety instructions in this manual and with all local standards, rules and
regulations concerning health, safety, accident prevention and environmental protection that may apply at the place
of installation and operation of this equipment. In particular, the following principles apply:

It is incumbent upon the owner/operator to obtain all pertinent information concerning applicable law and to
conduct a risk evaluation to determine specific hazards arising out of specific work conditions at this workplace.
Such risk analysis must then result in specific instructions for the operation of this specific equipment.

During the entire period this equipment is in operation, the owner/operator must keep track of changing work
conditions and/or legal stipulations and update instructions, as necessary.

The owner/operator must unambiguously stipulate and communicate responsibilities concerning installation,
operation, servicing, maintenance, cleaning etc. to all responsible personnel involved in carrying out those duties.

The owner/operator must make sure that all employees and other persons who work at, on, near, or with this
equipment have read and understood this manual. The owner/operator must conduct, on a regular schedule,
coaching and training sessions, instructing employees on the possible hazards associated with the use of this
equipment.

The owner/operator must make sure that combustible goods and matter are not stored in the vicinity of this
equipment.

Protective and safety equipment.

The owner/operator must evaluate if, and what kind of protective and/or safety equipment is required and have it
installed.

The owner/operator must make sure there is an upstream feeder panel capable of shutting down this equipment in
case the standard shutdown procedure is out of order.

The owner/operator must have safety and protective equipment installed that detects short circuits and separates all
phases connected.
Safety signs.
The owner/operator must have a safety sign installed, close to the equipment and easily visible, denying access to
unauthorized persons.

The owner/operator must provide employees with personal protection equipment (PPE) and have safety signs
installed close to the equipment that are easily visible, requiring appropriate use and wearing of PPE when working
with the equipment.

Risk evaluation.
The owner/operator must conduct a risk evaluation and establish:
Whether the installation of wrong plug-in modules might cause hazards in downstream plant segments.

Whether the reestablishment of the power supply after a power failure might cause hazards in downstream plant
segments.

Whether failure or problems with a control system might cause hazards.

Technically sound condition.

The owner/operator must make sure that the equipment is always in a technically sound condition. Therefore, the
following principles apply:

The owner/operator must make sure that service and maintenance jobs are carried out as laid out in this manual and
the other OEM manuals provided together with this documentation.

The owner/operator must have all safety and protective equipment checked for integrity and functionality on a
regular schedule.

The owner/operator must make sure that this equipment is operated only within the framework of conditions as set
out above.

The owner/operator must make sure that this switchgear is operated only when any and all protective and safety
equipment is installed and any and all doors, flaps etc. are closed.

12
2.2 Service personnel
2.2.1 Qualifications

WARNING!
Danger of injury if personnel are insufficiently qualified! Improper operation can lead to
serious personal injuries or property damage. Therefore, have all activities performed
only by qualified personnel.

The following qualifications are specified for different areas of activity listed in the manual.

▪ A professional electrician
Based on their professional training, know-how and experience as well as knowledge of the applicable standards and
regulations the professional electrician can perform work on electrical systems, detect, and avoid possible dangers
on their own. The professional electrician has been trained for the special location where they work and knows the
relevant standards and regulations.

2.2.2 Coaching / training

The owner/operator of this equipment must make sure that operators undergo coaching / training on a regular
schedule. Coaching / training sessions must be logged and recorded.

Date Name Type of coaching / training Coach / trainer / instructor Signature

Table 1 Sample Record Form

Only persons of whom it may be expected to perform their work reliably are permitted as personnel. Persons whose
reaction capability is impaired, e.g. through drugs, alcohol or medication are not permitted to perform any work on
the equipment.

When selecting the personnel, the stipulations regarding age and occupation applying at the location must be
observed.
2.3 Intended purpose and proper use
alfa-12 Medium Voltage Switchgear has been designed and built for the sole purpose and use as described herein.
This equipment is a metal-clad, plug-in medium voltage switchgear for indoor installation - type-tested,
factory-built, and ready to use. This equipment has been designed and built for the intended purpose and service
conditions as described in the service manual. For precise purpose and use, please refer to order documents.

WARNING!
Danger due to wrong operation and/or misuse, use or operation of this equipment not
described herein or going beyond what is described herein may lead to dangerous situations.
Therefore:
▪ Be sure to use equipment as described herein.
▪ Be sure to comply with all information contained herein.

The manufacturer shall not be held liable for any damage whatsoever resulting from wrong operation and/or misuse.
The owner/operator shall be held liable for any damage whatsoever resulting from wrong operation and/or misuse.

2.4 Standards and regulations

alfa-12 Switchgear is designed and built according to IEC 62271-200 / IEC 62271-1; internal arc class according to
IEC 62271-200, and internal arc class IAC AFLR.

2.5 Personal protective equipment

Wearing of personal protective equipment is required when working to minimize the risk of injury and health
hazards.
▪ Always wear the appropriate protective equipment for the respective task being performed.
▪ Follow the instructions on personal protective equipment that are posted in the work area.

Safety Clothing Safety Boots Hardhat

Proper safety clothing should be well-fitting,
no cuffs, to prevent entanglement or getting
caught; easily tears away to divert strain
from body; fire retardant; and provide
worker comfort. Do not wear jewelry (rings,
watches, necklaces etc.).
Foot protection from falling
or rolling objects; punctures
from sharp objects; electrical
hazards; slippery or uneven
surfaces.
Protects the head from the
impact of falling or
fast-moving objects and
hot gases.

14
REQUIRED FOR CERTAIN JOBS.
Special personal protection equipment (PPE) may be required to carry out certain jobs, e.g. under voltage. They are
mentioned explicitly in the various chapters of this manual. For further details concerning the various types of PPE,
see below:

Face protection Protective gloves

To protect eyes and face against flames, sparks To protect the hands against friction, grazes,
or glowing material, hot particles, or exhaust punctures or deep cuts as well as contact with
gases. hot surfaces.

2.6 Preventive measures to avoid accidents

It is incumbent upon the owner/operator to explicitly stipulate and communicate accident prevention measures and
rules of behavior for dangerous situations and accidents at the place of installation of this equipment. On principle,
however, the following standards always apply:

▪ Be prepared to deal with fires and accidents.

▪ First aid kits, blankets, safety equipment and fire extinguishers should be located throughout the workplace and
readily accessible.
▪ Make sure all persons (operators and other personnel) are trained in first aid, alarm, and evacuation procedures etc.
▪ Keep access ways clear for emergency vehicles and personnel.

2.7 Specific dangers

The following section lists the residual risks that have been determined by the risk assessment.

▪ Heed the safety instructions listed here, and the warnings in subsequent chapters of this manual, to reduce health
hazards and to avoid dangerous situations.

Internal arc fault

DANGER!
Internal arc faults may constitute a hazard to life and limb.
Internal arc faults generate high pressures and temperatures inside the switchgear.
Doors not properly closed and locked may pop open and injure people. Even more
dangerous are hot gases blasting out of the switchgear.
Incidents of that sort may cause the most severe injuries and kill people. Therefore, be
sure that all doors are properly locked during operation.
Electricity

DANGER!
Electricity may constitute a danger to life and limb.
Touching live components may constitute a hazard to life and limb. Damaged
components and/or insulation may constitute a hazard to life and limb. Therefore:
As soon as you notice damage to components or insulation, cut off power supply and
repair components or insulation.
All works on electrical equipment must be carried out by skilled electricians,
exclusively.
There are Five Safety Rules that must be complied with during all works on electrical
equipment:
1. Switch off.
2. Secure against re-start.
3. Make sure there is no more electricity flowing to the equipment.
4. Earth and short circuit.
5. Cover and protect adjacent live components.
Protect live components against humidity. Humidity may cause short circuits.
Equipment should only be operated if all doors, flaps, lids, covers, screens etc. are in
place, closed and shut etc.

Fast-moving objects

WARNING!
Fast-moving objects projected from different sources may constitute an injury hazard.

This switchgear may be equipped with (optional) relief flaps that pop open in the event
of an internal arc fault. Objects on top of those flaps may be projected into the air and
constitute a severe injury hazard.

Therefore, do not place objects on the roof (relief flaps) of a board.

Falling hazard

WARNING!
When climbing a ladder to carry out jobs at high places, there is a danger that if the
ladder topples over, persons can get hurt.

Therefore, make sure the ladder is safely secured.

16
Sharp edges, pointed corners

CAUTION!
Edges and corners may constitute an injury hazard.
Sharp edges and pointed corners may cause multiple wounds to the skin (cuts, grazes
etc.). Therefore:
Use common sense and caution when working near edges and corners, especially inside
the switchgear.
Be sure to wear your PPE (personal protection equipment).

2.8 Signs

WARNING!
Illegible signs constitute an injury hazard.
In the course of time, signs, labels etc. may get dirty, disappear or become illegible in
some way or other. Therefore:
Make sure any and all signs, labels etc. concerning health, safety, security and proper
operation are visible and easy to read at all times.
Replace missing and damaged signs, labels etc. immediately.

You will see the following symbol somewhere on the inside or outside of the switchgear. It applies to its immediate
surroundings.

Electricity!
Areas marked with this sign may be accessed by skilled electricians only. These signs
are mounted to doors, covers, screens etc. that are not locked and where live parts are
accessible when such doors, covers etc. are opened or removed.
3 TECHNICAL
DATA
The most important specifications of this equipment are contained in the rating plate. The following section contains
tables with the specifications of the various types of boards. For complete specifications, please consult the alfa-12
Switchgear documentation.

3.1 Rating plate

The rating plate is located on the outside of the door of the circuit breaker compartment.

1
alfanar Electrical Systems 13
2

3 Manufacturer's Name Rated Voltage (Ur) 14

4 Country of Origin Rated Frequency ( Fr) 15
5 Type Designation Rated Power Frequency Withstand Voltage (Ud) 16
6 Vendor's Name
Rated Lighting Impulse Withstand Voltage (Up) 17
7 Reference of Specification
8 Manufacturer's Serial No. Rated Normal Current ( Ir) 18
9 Contract Number Rated Short-time Withstand Current 19
(for main and earthing circuits)
10 Instruction Book Reference
Rated Duration of short Circuit (Tk) 20
11 Year of Manufacture (for main and earthing circuits)
12 Applicable Standard Rated Peak Withstand Current (Ip) 21
(for main and earthing circuits)
22
IAC: AFLR.

Figure 1: Rating Plate

1 Manufacturer's Logo 12 Standard Applied

2 Manufacturer's Group Name 13 Manufacturer's Name
3 Manufacturer's Name 14 Rated Voltage
4 Country of Origin 15 Rated Frequency
5 Type 16 Rated Power Frequency Withstand Voltage
6 Vendor’s Name 17 Rated Lightning Impulse Withstand Voltage
7 Reference of Customer Specification 18 Rated Normal Current
8 Serial No. 19 Rated Short - time Withstand Current
9 Contract No. 20 Rated Short-circuit Duration
10 Instruction Book Reference 21 Rated Peak Withstand Current
11 Year of Manufacture 22 Internal Arc Class
3.2 Data sheets
3.2.1 Dimensions and weight
Width of board Value Unit
1000 mm
alfa-12
650 mm
Standard height of board Value Unit
All types 2500 mm
Depth of board without doors and back wall Value Unit
All types 1750 mm
Weight of board Value Unit
All types 1400 -1700 KG
Table 2: Dimensions and Weight

3.2.2 Technical data

Value Unit
Rated Voltage 12 17.5 KV
Rated power frequency withstand voltage 38 KV
Rated lightning impulse withstand voltage 95 KV
1250 A
Rated current of busbars
3150 A
Rated short time withstand current 31.5 3 25 3 KA s
Frequency 50 60 Hz
Protection class IP 41
125 VDC
Rated auxiliary voltage supply
220 VAC / 3ph
O-0.3 s-CO-15 s-CO
Operating sequence
O-0.3 s-CO-3 min-CO
Table 3: alfa-12 Technical Data

3.3 Service conditions

Conditions Value Unit
Ambient temperature
Max 50 °C
Min -5 °C
Mean Value over 24 h Max. 40 °C
Relative Humidity
Mean Value over 24 h Max. 95 %
Mean Value over one month Max. 90 %
Altitude at location of installation Max. 1000 Meters above sea level
Table 4: alfa-12 Service Conditions

NOTE
Use of the equipment in conditions different than mentioned is subject to receiving prior
approval from the manufacturer.

20
4 STRUCTURE
& FUNCTION
Depending on the actual purchase order placed by the customer, this equipment consists of a combination of the
following types of switchboard sections:

▪ IF (Incoming Feeder) Fig. 13

▪ OF (Outgoing Feeder) Fig. 14
▪ BC (Bus Coupler) Fig. 15
▪ BR (Bus Riser) Fig. 16

The alfa-12 board is available in a number of different configurations. Their differences (apart from general features
common to all boards) will be described in the following sections.

4.1 Modes
Service mode
'Service mode' means the plug-in module is in the position where it is fully connected for operation. That means the
contacts are engaged, the control plug has been plugged in, and the main power circuit and auxiliary circuit have
been connected.

Test mode
'Test mode' means the plug-in module is in the position where the auxiliary circuit is connected, but the main circuit
is not. That means the main power circuit contacts are not engaged, but the control plug has been plugged in. The
effect is the switchgear can be switched OFF for test purposes.

Idle mode
'Idle mode' means, neither the auxiliary circuit nor the main power circuit are connected. That means the plug-in has
been placed in its rack in the board, but the main power circuit contacts are not engaged, and the control plug has
not been plugged in.

4.2 Overview of features

All types of boards are comprised of the following:
▪ Metallic barriers between boards.
▪ Internal metallic barriers between busbar compartment and cable connection compartment.
▪ Internal metallic barriers between circuit breaker compartment and busbar compartment; and between circuit
breaker compartment and cable connection compartment.
▪ When plug-ins are pulled out, shutters cover counter-contacts in the rack.
▪ Plug-ins with identical features and properties are interchangeable. There is a mechanical encoding system to
prevent inadmissible combinations of plug-ins and boards.

22
4.3 Compartments
Compartments:

A. Busbar compartment B
B. Low voltage compartment A
E
C. Circuit breaker compartment
D. Cable connection compartment
E. VT compartment

C
D

Figure 2: Compartment Overview

4.3.1 Busbar compartment

The busbar compartment contains horizontal
busbars L1, L2 and L3. Busbars are made of
copper. They are subdivided into sections within
the board. Upon request, if multiple boards are
placed side by side, busbars are pushed through
cast-resin bushings into adjacent boards and
bolted up with the busbars there.

Figure 3: Busbar Compartment

4.3.2 Circuit breaker compartment

The circuit breaker compartment is mainly equipped with the circuit
breaker, spout bushings and a shutter system. The live fixed contacts of
spout bushings are automatically covered by metallic shutters as soon
as the breaker has reached the Test position.

Figure 4: Circuit Breaker Compartment

Control plug
The control plug connects the circuit breaker to the low voltage compartment.
Circuit breakers with identical features and properties are interchangeable.
There is a mechanical encoding system to prevent inadmissible combinations of circuit breaker and boards.

The socket of the control plug has a locking arrangement.

1. Control plug can be plugged in or pulled only if the circuit breaker is in test mode.
2. Circuit breaker cannot be switched to service mode if the control plug is not in place.

Figure 5: Control Plug Socket Figure 6: Padlock on the Shutter

Shutters can be secured by means of a locking device or by placing a padlock. When secured, they cannot be opened.

4.3.3 Cable connection compartment

The cable connection compartment contains the earth
switch.
The earth switch can be switched on only if the circuit
breaker is in test mode or completely removed, and any
blocking magnets that might exist are in release mode.
The earth switch is operated from the front side of the
board.
There is a display in the front of the earth switch operating
mechanism (see Fig. 7). It shows the current position of
the earth switch.
Figure 7: Cable Connection Compartment

A padlock on the shutter of the earth switch makes sure that the earth
switch cannot be operated by unauthorized personnel.

Figure 8: Padlock on Earth Switch ON

24
4.3.4 Low voltage compartment
The low-voltage compartment contains the control, protection devices, measuring instruments and malfunction
indicators of the board. The low-voltage compartment is mounted on top of the circuit breaker compartment and
protected by means of a flash barrier.
If multiple boards are placed side by side, cross connections with the adjacent low-voltage compartment is
established by pushing the looped circuits through round openings in the lateral walls.
Cable glands in those round openings prevent damage to cables.

Figure 9: Low Voltage Compartment

4.4 Pressure reduction system

The busbar compartment (A), circuit breaker compartment (C) and cable connection compartment (D) are equipped
with pressure relief flaps, which open to the top in the event of an internal arc fault. (refer to Figure 2 for
compartments)

NOTE
For precise information on actual devices provided on your equipment, see layout in
switchgear documentation.

Figure 10: Pressure Reduction System

4.5 Door lock systems
• The door of the circuit breaker compartment can be opened only if the circuit breaker is in test mode or in idle
mode.
• The circuit breaker can be moved from Test position to Service position only if the circuit breaker compartment
door is closed.

Internal locking systems of boards

- Switchgear can be actuated only if the circuit breaker is clearly either in test mode or in-service mode.
- Circuit breaker can move from Test to Service position only if the door of the circuit breaker compartment is
closed.
- It is not possible to rack-in the circuit breaker from Test to Service position unless the control plug is connected to
the circuit breaker.
- It is not possible to rack-in the circuit breaker to Service position unless associated earthing switch is in Earth Off
condition.
- It is not possible to close the earthing switch unless the circuit breaker is in Test position, idle mode, or has been
removed from the panel.

Locking systems between boards

Locking systems between boards are usually project-specific, e.g.:
- The busbar earth switch can be actuated only if all circuit breakers of the busbar section concerned are either in test
mode or in idle mode.
- Circuit breaker can be switched to service mode only if the busbar earth switch of the concerned busbar section is
off.

Door locking devices

Padlocks can be placed at the following points:
- On the doors of the circuit breaker compartment, cable connection compartment and low voltage compartment.
- On the shutters of the circuit breaker compartment.
- On the operating shutter of the earth switch.

4.5.1 Plug interlock

In accordance with IEC 62271-200, the plug interlock has interlocking function which prevents the following
operations.
• Racking-in of the circuit breaker when the LV plug is not connected.
• Disconnection of the LV plug when the circuit breaker is in the racked-in position.

Figure 11: Plug Interlock

26
4.5.2 Locking matrix
The vertical column of Table 5 contains actions, the horizontal row contains conditions.
In order to carry out the actions, the conditions ticked must be fulfilled.

Circuit breaker in idle or test mode or removed

Door of circuit breaker compartment closed

Circuit breaker in test or service mode

Blocking magnet unlocked (optional)

Circuit breaker in idle or test mode

Control plug in place

Circuit breaker off

Earth switch off

Conditions

Actions
Plug or pull control plug
Switch circuit breaker from test to service mode
Switch circuit breaker from service to test mode
Switch on circuit breaker
Switch on earth switch
Open door of circuit breaker compartment

Table 5: Locking Matrix

4.6 Circuit breaker
4.6.1 Vacuum Interrupter (LV6/LV8A) LSIS
LS Vacuum Interrupter consists of a ceramic insulator, two end plates, arc shield, bellows, a movable and fixed
electrode, and contact set. The ambient gas pressure within the evacuated tube is approximately 10-6 torr.

Figure 12: Vacuum Interrupter Schematic

28
4.6.2 Embedded poles
The vertical column of the table 5 contains actions, the horizontal row contains conditions.
In order to carry out the actions, the conditions ticked must be fulfilled.

Front Side Top

VL-12H32A13

Front Side Top

VL-12H320D32
4.7 alfa12- IF (Incoming Feeder) overview
The alfa-12 board is available in two different widths.
Depending on the width of the board, the precise dimension is either alfa-12 650 or alfa-12 1000. The layout,
however, is always the same, see Fig. 13.

Components:
A. Busbar compartment
B. Low voltage compartment 1
A
C. Circuit breaker compartment B
2
D. Cable connection compartment
E. VT compartment 5

Main Components: 10 4

1. Busbars
12
2. Cast-resin support
3. VT bushing
4. VCB bushing 5
7
5. Current transformer
8
6. Earth switch actuation linkage 6
3
7. Earth switch 10

8. Earth connection auxiliary switch 13 E D 9

9. Earthing bar
10. Wire duct
Figure 13: alfa-12 IF (Incoming Feeder) Overview
11. Power cable termination
12. Circuit breaker
13. Voltage transformer

4.8 alfa-12 OF (Outgoing Feeder) overview

Components:
A. Busbar compartment
B. Low voltage compartment A
1
C. Circuit breaker compartment B
2
D. Cable connection compartment
3

Main Components: C
10
1. Busbars
2. Cast-resin support 4
7
3. Busbar dropper 12

4. VCB bushing 8
5. Current transformer
11
6. Earth switch actuation linkage
7. Earth switch 6

8. Earth connection auxiliary switch 5

9. Earthing bar D 9
10. Wire duct
11. Power cable
12. Circuit breaker Figure 14: alfa-12 OF (Outgoing Feeder) Overview

30
4.9 alfa-12 BC (Bus Coupler) overview
Components:
A. Busbar compartment
1
B. Low voltage compartment A

C. Circuit breaker compartment B

2
3
D. Lower busbar compartment
C
Main Components:
5
1. Busbars 10

2. Cast-resin support 11

3. Busbar dropper
4. VCB bushing 4
D

5. Current transformer
1
6. Earth switch actuation linkage
7. Earth switch
8. Earth connection auxiliary switch 5
9
9. Earthing bar
10. Wire duct
11. Circuit breaker Figure 15: alfa-12 BS (Bus Coupler) Overview

4.10 alfa-12 BR (Bus Riser) overview

Components:
A. Busbar compartment 1
A
B. Low voltage compartment B 2

C. Voltage transformer compartment

Main Components:
1. Busbars
2. Cast-resin support 5

3. Cast-resin bushing
4. Voltage transformer
5. Wire duct

4
C

Figure 16: alfa-12 BR (Bus Riser) Overview

4.11 Exploded view representation

Figure 17: alfa-12 Exploded View Representation

4.12 Accessories
• Moving crank
Crank for moving the circuit breaker from test mode to service mode and back.

Figure18: Moving Handle

• Switching crank
Switching earth switch ON and OFF.

Figure 19: Switching Handle

• Circuit breaker stand

Stand for moving the circuit breaker from the panel and back (as applicable).

Figure 20: Circuit Breaker Stand (For cassette type design)

32
5 TRANSPORT
PACKING & STORAGE
Depending on circumstances and requirements, equipment may come packed for motor or ocean transport (i.e.
seaworthy crates). For transport, equipment may be subdivided into packing units usually comprised of up to three
boards. Packing units may be moved by means of a crane or pallet truck. Be sure to comply with all information in
this section. Accessory parts for connecting boards and busbars will be stored inside the packing units. Spare parts
and switchgear accessories will come in separate packing units - see docket (packing list).

5.1 Safety notes for transport

Suspended Loads

WARNING!
Life-threatening hazard due to suspended loads!
When lifting loads a life-threatening hazard is posed by falling loads or swinging parts.
Consequently:
▪ Never position yourself under a suspended load!
▪ Heed the instructions concerning the intended lifting points.
▪ Do not attach to projecting machine components or to the eyes of attached
components; ensure that the sling gear is securely seated.
▪ Only use approved lifting gear and slings with sufficient load-bearing capacity.
▪ Do not use frayed or scored rope or belts.
▪ Do not lay ropes and belts on sharp edges and corners, do not knot or twist ropes and
belts.
▪ Do not place objects on the roof (relief flaps) of a board.

Improper transport

CAUTION!
Improper transport can result in damage!
Improper transport can cause extensive material damage.
Therefore:
When unloading the packing units upon delivery and during in-house transport, exercise
caution and observe the symbols on the package.
Use only the provided attachment points.
Do not remove packaging material until units are ready for assembly.

34
 5.2 Symbols on the packing
Fragile
Identifies packages with fragile
or sensitive content.
Handle package with care, do
not drop and do not subject to
shock loads.
Protect against heat
Protect packages against heat
and direct insulation.
Place pallets correctly on fork
lift trucks
Make sure the truck's lifting
forks are not under, but between
the pallet's crossbeams.
Top
The arrows in this sign
symbolize the top side of the
package. They must always
point up, otherwise, the
contents may get damaged.
Load is top-heavy
The packing unit is heavier at
the top and is not stable. Secure
the unit against tipping over.
Place lifting forks in the center
of the pallet
Make sure the forks are in the
center of the pallet and
between the crossbeams.
Protect against wetness
Protect packages against water
and keep dry.
Do not tilt packing units
Do not tilt packing units during
transport. Equipment might get
damaged.
MAX
30°
Max. admissible angle of crane
ropes / chains etc.
When moving packing units by
crane, the angle of ropes,
chains etc. must not exceed 30
degrees.
5.3 Transport inspection
Check the delivery immediately on receipt for completeness and transport damage.
If externally detectable transport damage is found, proceed as follows:
▪ Do not accept the delivery, or, accept only with reservation.
▪ Record the extent of transport damage in the transport documents or on the delivery note of the forwarding agent.
▪ Start complaints procedure.

NOTE
Claim any damage as soon as it is detected.
Compensation claims can only be submitted within the applicable complaints periods.

5.4 Packing
Concerning packaging
The individual packages have been packed to match the transport conditions that can be expected. Only
environmentally friendly materials were used for packing.
The packaging has the function of protecting the individual components against damage, corrosion, etc., until they
are finally assembled. The packaging material must therefore not be damaged and should only be removed just
before assembly is to take place.

5.5 Transport
Using a crane to move packing units
Cranes may be used for packing units that are equipped with crane lugs. Conditions:
• Cranes, lifting gear, slings etc. must be suitable for the weight of the packing unit.
• The operator must be trained and authorized to use a crane.
• Loads must be evenly distributed for lifting.
• All doors, covers, flaps etc. must be properly closed and locked.

Attaching hoisting gear to packing units that contain only one board: Figure 21: Crane Lugs
• Ropes, slings, belts etc. (Fig. 21) must be attached to at least four crane lugs.
• Make sure the packing unit is suspended properly. Compensate, if the center of gravity is off-center.
• Move the load.

36
Using a forklift truck to move packing units
Packing units on pallets may be moved using a forklift truck, provided the following conditions are fulfilled:
• The forklift truck must be suitable for the weight to be lifted.
• The operator must be trained and authorized to use a forklift truck.
• The forks must be long enough to protrude on the opposite side.

Slinging loads
• Drive the forks of the forklift truck under the packing units.
• Retract the forks until they protrude on the opposite side. alfanar Alfanar Electrical Systems
alfanar Alfanar Electrical Systems

• Make sure the packing unit cannot tilt if the center of gravity is off-center.
• Lift the packing unit up and start moving it.

Storing packing units

Figure 22: Forklift

Conditions for storing packing units:

• Indoor storage only.
• Storage must be dry and dust-free.
• Avoid contact with aggressive gases, liquids etc.
• Protect against direct sun exposure.
• Protect against mechanical shocks, shaking etc.
• Temperature: 5 to 40 °C.
• Relative humidity: 95 % max. during 24 h and 90 % max. during a month.
• When storing for longer than 3 months, check the state of parts and packing units at regular intervals. If necessary
repeat conservation measures.

NOTE
Packing units may display instructions and information for storage going beyond details
mentioned above. Be sure to take good note and comply.
6 INSTALLATION
To obtain an optimum installation sequence and ensure high quality standards, site installation of the switchgear
should only be carried out by specially trained and skilled personnel, or at least by personnel supervised and
monitored by responsible persons.

6.1 General site requirements

On commencement of installation on site, the switchgear room must be:
▪ Completely finished.
▪ Provided with lighting and electricity supply.
▪ Lockable, dry, and with facilities for ventilation.
▪ All the necessary preparations such as wall openings, ducts, etc. for laying the power and control cables up to the
switchgear must already be completed.
▪ Compliance with the conditions for indoor switchgear according to IEC 62271-200 / IEC 62271-1.

6.2 Foundations
The following two basic installation methods of switchgear in the switch room are distinguished:
Method A – Installation on the base irons of “C” profile shape
As standard, it is recommended to install the switchgear on the base irons of “C” profile shape set into the concrete
floor of switch room. In this case, the units are fastened using the special bolt blocks.

Method B – Installation on a leveled concrete floor

Installation directly on a leveled concrete floor makes much higher demands on the floor leveling, which must, in
this case, fulfill the same tolerances as the base irons during installation method A. In this case, fastening is carried
out by means of anchoring bolts in the concrete floor.

Generally, it is possible to recommend the following procedure of switchgear anchoring, namely for any of
the cited methods of installation:
• The switchgear panels are bolted together in the front and rear part into one unit.

• If seismic resistance is not required, it is not necessary to attach each switchgear panel to the floor or frame, but it
suffices to only fix outside panels in each row of switchgear.

• If seismic resistance is required, it is necessary to attach each switchgear panel to the floor or frame. To achieve
seismic resistance the special fixing system is used. This system preferably makes use of a steel floor frame with "C"
profile shape, but moreover, with an additional special fixing element.

• Please contact the manufacturer for further details.

Further structural data guidelines given can provide a rough calculation of the space required and planning of the
room design for a switchgear project. The general foundation drawing is given in Figure (23 and 24) according to
parameters of units.
 2000
318 668

85

85
150
450 800

75 75
225

318 668
58

58
103

650 1000 1000 1000

FRONT
2500

OUTGOING INCOMER BUS BUS RISER

COUPLER
OF IF BC BR

Figure 23: Foundation Drawing

2000 2500
ROOM ENTRANCE

4000
2600

MV CABLE ENTRY CONTROL CABLE ENTRY

THE FOUNDATION FRAME MUST BE EXACTLY FLUSH TO THE FINISHED FLOOR. IT MUST BE
ADJUSTED EXACTLY TO A MAX. TOLERANCE OF +/-1MM / M. WEIGHT OF THE PANEL 1400KG
APPROXIMATELY.
Figure 24: Foundation of Frame Dimensions

40
6.2.1 Method of installation B – Fixing with anchoring bolts to concrete floor
The general foundation drawing is given in Figures 23 and 24 according to parameters of units.
The procedures:

• Carefully clean the area where the switchgear will be installed.

• On the slab, visibly trace the perimeter of all the units making up the switchgear according to the relevant drawing
taking the minimum wall and obstacle clearances into account.
• Level the floor both longitudinally and transversally evenness tolerance is ± 1mm within a measuring length of 1m.
• Drill the floor at the foreseen fixing points, referring to the general arrangement drawing to make the holes, use a
hammer drill with the bit size according to the steel plugs used.
• Insert the plugs in the holes and put the individual panels on the traced perimeters of the units creating the
switchgear.
• Level the units and then bolt them together in the front and rear part.
• Fix the units with bolts with special washers (the coupling material is supplied by request).
• In the case of a metal floor, use the attachment according to Figure 25 to make the holes, use a drill
with a suitable bit size for the type of fixing to be made (through or threaded hole).

M12
M12

Figure 25: Fixing with Metal Structures

6.3 Main busbars installation
Use bolts of tensile class 8.8. The tightening torques for the busbar screw connections with dished washer are as
follows:

Component Thread Torque

M8 20 Nm
Rail / Bar connections M10 40 Nm
M12 65 Nm

The individual installation stages are as follows:

• Transport the switchgear panels to the prepared installation point following the sequence shown on the switchgear
plan.
• Align the switchgear panels on the floor frame for correct positioning and vertical alignment (deviations of the
panel edges from the vertical must not exceed 2 mm, especially at the front).
• When assembling switchgear with more than eight panels it is advisable to start from the center.
• Bolt the panels together. Insert a M8X20 bolt with a space washer in all “A” holes (as shown in Figure 26 below)
to couple the panels.

LV
COMPARTMENT

BUSBAR
COMPARTMENT

VCB
COMPARTMENT

CABLE
COMPARTMENT

Figure 26: Panel Frame Side Holes Locations

42
6.4 Installation of the main busbars
6.4.1 Busbar compartment access
• Before fixing the panels side by side, be sure that the bushings are fixed.
• Clean the insulation on the busbar sections with a soft, dry cloth, and check for insulation damage. Remove greasy
or adhesive dirt as described:
• Busbar connections:
o The silver-plated surfaces of the connections must be cleaned with a metal-free nonwoven cleaning cloth and
apply a thin layer of mechanical grease.
o The non-silver-plated surfaces of the connections can be either brushed with a wire brush, preserving the grease
film, or cleaned with a metal-free non-woven cleaning cloth and evenly greased with a thin layer of mechanical
grease.
• Install insulation boots on busbar joints.

Figure 27: Busbars Connection

6.4.2 Busbars installation

• Install the busbars, panel by panel, according to the ratings of the switchgear. Bolt on the individual busbar
elements one above the other (depending on the system layout) and in line with the flat branch conductor.
• For the tightening torque, please refer to the tightening table. Use two dished washers for each screw. Use bolt of
tensile class 8.8.
• Install insulation shroud on each busbar joint (as applicable).

NOTE
• Quality of the copper busbar connections does not change according to the operating
time and therefore it is not necessary to inspect tightness of busbar connections
regularly. However, this is based on the condition that correct assembly is carried out as
described above and especially that all connections are tightened with the prescribed
torque according to the above table.
• We recommend only inspecting tightness of busbar connections during inspections.
• Busbars are insulated and busbar joints are fitted with insulation shrouds for the
all-current range.
 Figure 28: Tee-off 1250A, Busbars 1250A Connection Details

6.5 Cable connection

6.5.1 Power cables
• The standard method for entry of power cables in the switchgear is shown in Fig 29.
• The cables are conveyed from below, through floor covering, which is divided at the cable entry point.
• The cables go through a rubber grommet, which can be adapted to the required cable diameter.
• Cables are fastened in the panel by means of cable clamps mounted on cable strips, which are part of the panel floor
covering. The clamps make it possible to fasten cables.

Figure 29: Power Cable Entry Point

44
Cable sealing ends are mounted on the cable cores according to the manufacturer’s instructions. It is possible to use
cable sealing ends from different manufacturers (e.g. Pirelli, Raychem etc.), but it is necessary to keep the length of
the cable ends, including cable sealing ends, which is given by the distance of cable connecting bars from the panel
floor covering.
These bars have different versions, which differ in their number of parallel cables and the values of rated and
short-circuit currents.
The bars are equipped with holes for M16 bolts. If M12 bolts are used for cable connections, special washers with
the diameter for M12 screws must be used. In all cases, the earthing of cable screens is carried out on the
strip-holding cable clamps. The cable strip is connected to the earth potential.
The cable connections bars are equipped with holes for M16 screws, but they are supplied without screws, washer
and nuts. The supply of this material, according to the cable termination, is at customer expense.

Important note
Connection with single-core plastic insulated cables is presumed in the typical panels. In the case of any atypical
cable connections or of special cables (e.g. three-core cables, cables with paper or special insulation etc.), an
agreement must be reached between the customer and manufacturer.

Mounting procedure for power cables

• Power cables must be inserted, cut to length and stripped.
• Grommet must be adapted to the cable diameter and fitted onto the cable.
• Cable sealing ends must be prepared and mounted on cable cores according to manufacturer’s instructions.
• Cable lugs must be connected to the prepared connections bars with strain relief.
• Earthing of cables must be connected.
• Individual parts of the floor covering must be mounted.
• Cables must be fastened in the prepared cable clamps.

6.5.2 Control cables

The control cables are conveyed into the panel through the control-wiring duct on the left-hand side of the panel.
Mounting procedure
• Insert the cables into the control-wiring duct on the left-hand side. The duct is covered.
• Fasten the control cables at the top end of the duct, strip the insulation and convey cable control cores into the low
voltage compartment.
• Connect control cables to the terminal strip according to the circuit diagram.
6.6 Installation of the earthing
• Connect main earthing bar with connections provided in every panel.
• Connect the earthing conductor coming from the earth electrode, preferably via a removable bolted connection for
testing purposes, to the main earthing bar of the switchgear as shown below:

EARTHING
CONNECTION
POINT

Figure 30: Earthing Connection with Panel

6.7 Final erection work

• Check painted areas of the switchgear for possible damage, touching up with paint where required.
• Check bolt connections, that were carried out during onsite erection of the busbars and earthing system, and tighten
where required.
• Clean the switchgear thoroughly.
• Remove all foreign objects from the panels.
• Correctly replace all coverings, etc. removed during erection and connection.
• In the enclosure, any remaining openings must be closed if they are no longer needed.
• Check the isolating contacts and interlocking mechanisms for smooth motion, and grease again with mechanical
grease where necessary.
• Withdrawable circuit breaker parts must be inserted, and the control wirings connected.
• Panel doors must be properly closed.

46
7 OPERATION
7.1 Health, safety and security during operation

DANGER!
Electricity and internal arc faults constitute a severe hazard to life and limb.
Contact with live components may cause death or severe injuries.
Dirt inside the equipment may cause faulty operation and generate internal arc faults.
Internal arc faults inside the switchgear may cause death or severe injuries.
Therefore, make sure all doors remain locked during operation:
▪ To prevent contact with live components
▪ To prevent dirt from penetrating the equipment and to protect people in the event of an
internal arc fault.

CAUTION!
The locking device of the handling trolley may constitute a pinching / crushing
hazard.
The mechanism moves when a plug-in is brought in place. Hands and fingers may get
pinched and crushed.
Therefore, when handling plug-ins on the cart, keep your hands away from the locking
mechanism.

WARNING!
The use of unsuitable tools may constitute a safety hazard.
Always use the special tools supplied by the manufacturer when handling and servicing
the switchgear. Using other tools may compromise the safety and security of the
switchgear and result in damage to the switchgear, or cause severe injuries or death.

48
7.2 Removing plug-in modules
1. Switch off the circuit breaker. Use electrical method, or in case of emergency, the mechanical method.
Mechanical method (Fig. 31):
- Rotate emergency actuating rod and center with circuit breaker OFF button.
- Press emergency OFF button; display will show the symbol "0".

Figure 31: Emergency OFF

2. Open door of circuit breaker compartment.

3. Disconnect control plug from circuit breaker and place it in holding bracket in panel.
4. Unfold ramp located in front bottom of the panel.
5. Push unlatching device (Fig. 32) of the circuit breaker to the right (4) and to the left (3).
6. Grab the plug-in by the handles (3, 4) and pull the circuit breaker slightly to keep the latching device In the
Unlock position. Now grab handles (5, 6) and pull the circuit breaker out from the circuit breaker compartment.
7. Close circuit breaker compartment door.

5 6

3 4

Figure 32: Removing of Plug-in Module

7.3 Installing plug-in modules
1. Open circuit breaker compartment.
2. Make sure there are no tools or other objects on the plug-in module.
3. Place the circuit breaker in front of the open compartment.
4. Align circuit breaker trolley wheels with the guide rails available on compartment floor.
5. Insert circuit breaker in breaker compartment.
6. Make sure the circuit breaker snaps properly in place on both sides of the compartment.
7. Connect control plug with socket.
8. Close compartment door.

Figure 33: Withdrawable Circuit Breaker

WARNING!
Foreign objects may cause internal arc faults in the switchgear. Arc faults
constitute a severe injury hazard.
Foreign objects (tools etc.) left lying in the switchgear, especially on the circuit breaker
may cause arc faults.
Therefore, before you install the plug-in, make sure there are no objects lingering in the
switchgear or on the circuit breaker.

50
7.4 Rack-in/out
7.4.1 Rack-in to service mode
1. Ensure control plug is connected.
2. Ensure circuit breaker is in ‘OFF’ position.
3. Close corresponding door.
4. Ensure concerned earthing switches are in ‘OFF’ position.
5. Rotate knob to access the handle orifice.
6. Insert the handle into handle orifice and turn the handle in a clockwise direction (CW) until rotation of the handle
become idle.
7. Check Test/Service indication points toward ‘Service’.
8. Remove handle and make sure the opening for the crank is completely covered.

7.4.2 Rack-out to test mode

Switching circuit breaker from service to test mode:
1. Ensure circuit breaker is in ‘OFF’ position.
2. Rotate knob to access the handle orifice.
3. Insert the handle into handle orifice and turn the handle in a counterclockwise direction (CCW) until rotation of
the handle become idle.
4. Check Test/Service indication points toward ‘Test’.
5. Remove handle and make sure the opening for the crank is completely covered.

Figure 34: Racking-In / Out Circuit Breaker

7.5 Switching earth switch on and off
Be sure to switch on the earth switch before you carry out any works in the cable connection compartment.

WARNING!
Internal arc faults may constitute a hazard to life and limb.
Malfunctioning earth switches may generate arc faults. Arc faults may constitute a
hazard to life and limb if protective doors are left open. Therefore:
▪ Be sure that switchgear doors are closed before you actuate the earth switch.
▪ To actuate the earth switch, be sure to use only the actuating key provided for that
purpose.

7.5.1 Closing the earth switch

Proceed as follows:
1. Ensure circuit breaker is open and kept in Test / Isolated position.
2. Ensure cables are not energized by checking “CVI”.
3. Rotate earth switch (ES) knob to open access for ES operating shaft.
4. Engage the ES operating handle; rotate it to the left until handle rotation stops, to close the earth switch (ES).
5. Check earth switch indication.

Figure 35: Earthing Switch Operation

NOTE
Earthing switch handle orifice remains open if the earthing switch is in the CLOSED
position.

52
7.5.2 Earthing switch opening
Proceed as follows:
1. Engage the ES operating handle and turn it to the right until handle rotation stops, to open the earth switch (ES).
2. Check earth switch indication.
3. Rotate earth switch (ES) knob to close the access for ES operating shaft.

NOTE
Access for ES operating shaft remains OPEN if the Earth switch (ES) is in CLOSED
position.

Figure 36: Earth Switch

7.6 Voltage transformer
7.6.1 Installation
The alfa-12 Switchgear units are equipped with a withdrawable voltage transformer for monitoring cables or
busbars with high-voltage fuses. The voltage transformer is located in the front or rear side of the switchgear
(as required). The primary voltage for the transformer is tapped by means of the spring borne primary contacts on
the cable-connection or busbar system. The primary contact is connected to the transformer via a high-voltage fuse
(2 A rated current). The secondary voltage of the transformer is conducted to the low voltage top housing via a
secondary plug. For layout of VT board, refer to the general arrangement drawing.

Figure 37: Voltage Transformer

7.6.2 Switching voltage transformer

To Rack-in voltage transformer, proceed as follows:
1. Ensure VT control plug is connected.
2. Ensure VT compartment door is closed.
3. Slide the front shutter to access the handle orifice.
4. Insert the racking handle in handle orifice and rotate the handle in a clockwise (CW) direction until it stops and
further rotation is not possible.
5. Check the status indication points to ‘Connected’.
6. Remove the handle.

To Rack-out voltage transformer, proceed as follows:

1. Ensure VT compartment door is closed.
2. Slide the front shutter to access the handle orifice.
3. Insert the racking handle in handle orifice and rotate the handle in a counterclockwise (CCW) direction until it
stops and further rotation is not possible.
4. Check the status indication points to ‘Isolated’.
5. Remove the handle.

54
Figure 38: Voltage Transformer-Door Open Figure 39: Voltage Transformer-Door Closed

Figure 40: Voltage Transformer-Racking Operation

8 MAINTENANCE
8.1 Safety

WARNING!
Injury hazard posed by improperly executed maintenance work!
Improper maintenance can cause severe injury or property damage. Consequently:
- Prior to starting work, ensure that there is sufficient assembly space.
- Ensure order and cleanliness at the assembly site. Loose parts and tools, or parts and
tools placed on top of each other are a hazard.
- If components have been removed, ensure that they are properly mounted; re-install all
mounting elements and comply with all screw tightening torque specifications.

DANGER!
Electricity may constitute a danger to life and limb.
Contact with live components constitutes a hazard to life and limb.
Therefore, comply with the Five Safety Rules. Before starting any works, carry out the
following:
1. Switch off.
2. Secure against re-start.
3. Make sure there is no more electricity in the equipment.
4. Earth and short circuit.
5. Cover and protect adjacent live components.

WARNING!
Pressure springs constitute a hazard of injuries.
Plug-in modules and the actuating mechanism of earth switches contain pressure
springs. When dismantling such components, pressure springs may shoot out
unexpectedly and cause severe injuries. Therefore:
- Do not dismantle. In the event of problems with plug-ins and earth switch actuating
devices replace the entire unit.
- Leave repair to skilled personnel.
- Comply with OEMs' manual.

WARNING!
The use of unsuitable tools may constitute a safety hazard.
Always use the special tools supplied by the manufacturer when handling and servicing
the switchgear. Using other tools may compromise the safety and security of the
switchgear and result in damage to the switchgear or cause severe injuries or death.
 CAUTION!
Unsuitable fuses may constitute a hazard of material damage.
Installation of unsuitable fuses may cause damage to property, e.g. voltage transformer
etc. Therefore, when installing new fuses, make sure they are of the same specifications
as the old fuses.

NOTE
All maintenance on this equipment must be carried out by skilled electricians,
exclusively.

8.2 General
Maintenance serves to preserve trouble-free operation and achieve the longest possible working life of the
switchgear. The owner/operator must adapt service and maintenance intervals to actual service conditions at the
workplace.

Maintenance comprises the following closely related activities:

▪ Inspection and overhauling Determination of the actual condition
▪ Preventive maintenance & servicing Measures to preserve the specified condition
▪ Corrective maintenance &repair Measures to restore the specified condition

8.2.1 Maintenance jobs

The following jobs must be carried out:
• Visual inspections
▪ After cleaning, check the equipment for cracked insulation, defects in paint work etc.
• Screwed and bolted connections
▪ Check for tightness.
• Functional checks
▪ Check all doors, flaps, locking mechanisms as well as actuating and drive devices for proper functioning.
• Lubrication
▪ Grease and oil movable parts, when and where necessary.
▪ Clean and lubricate plug-in contacts, counter-contacts, and earthing bars.
▪ Lubricate earth switch.

58
 NOTE
• When carrying out all maintenance work, the regulations in the country of installation
must be strictly complied with.
• Maintenance work may only be performed in a careful manner by trained personnel
familiar with the characteristics of the individual switchgear, in accordance with all
relevant IEC safety regulations and those of other technical authorities, and with other
overriding instructions. It is recommended that alfanar service personnel be called in to
perform the servicing and repair work detailed below.
• The inspection and servicing intervals for some of the equipment/components (e.g.
parts subjects to wear) are determined by fixed criteria, such as switching frequency,
length of service and number of short-circuit breaking operations. On the other hand, for
other parts the length of the intervals may depend, for example, on the different modes
of operation in individual cases, the degree of loading, and environmental influences
(including pollution and aggressive air).
• If necessary, further details can be taken from the technical documentation for the
switchgear installation (including, for example, any special operating conditions agreed
on).

8.2.2 Intervals for inspection, servicing, and repairs

Time intervals for maintenance work to be carried out always depend on:
▪ The operating conditions of the switchgear
▪ The mode of operation
▪ The number of rated and short-circuit current switching operations
▪ Ambient temperature, pollution etc.
We recommend carrying out the maintenance work at the following intervals:

Activity performed Time interval in year According to number of switching operations

Inspection 41
Servicing 42 10 0003
Repair As required As required
1. In more demanding service conditions, we recommend reducing this interval suitably.
2. According to the results of the inspection.
3. See the circuit breaker instruction manuals.
8.3 Inspection and overhauling
▪ Where necessary, the working area must be isolated and secured against reconnection in accordance with the safety
regulations specified by IEC and appropriate national standards before inspection.
▪ Correct condition of the switchgear should be monitored by regular inspections.
▪ Under normal operating conditions, inspection should be carried out once every four years by specially trained
professional electricians.
▪ Under abnormal operating conditions (including adverse climatic conditions) and/or special environmental
stresses (heavy pollution and aggressive atmosphere, among others), inspection may be necessary at shorter
intervals.
▪ Inspection is primarily to carry out a visual check for grime, corrosion, and moisture:
o Effects of high temperature on the main circuits
o Traces of partial discharge on the insulating material parts
o Traces of leakage current on the insulating material parts
o Surfaces of the contact systems
▪ However, inspection must also include correct mechanical/electrical operation of the following parts:
o Switching devices
o Actuating
o Interlocking
o Protection
o Signaling devices

8.4 Preventive maintenance & servicing

When, during an inspection as per paragraph 8.3, the need to carry out cleaning operations is noted,
proceed as follows:
▪ Where necessary, the work area must be disconnected from the power supply and locked against reconnection in
conformity with the safety standards specified in the IEC directive and in the relative national regulations.
▪ Clean the surfaces:
o Remove any dry dust deposits which are not very adherent using a soft dry cloth.
o Remove any more adhering dirt with a low alkaline detergent or with ETHANOL F 25 M.
▪ Clean the insulating surfaces and the conductive components with ETHANOL F 25 M.
▪ After cleaning, rinse with clean water and dry carefully.
▪ Should any partial discharges occur as a consequence of the condensation phenomenon, a temporary remedy which
is often effective is application of a thin layer of silicone over the surface involved.

8.4.1 Maintenance in busbar compartment

8.4.1.1 Preparations of busbar compartment for maintenance
▪ Make the plant you want to work on safe (follow the plant safety regulations).
▪ Rack-out all the circuit breakers from Service position to Test position.
▪ Close the earth switch relative to the main busbars.
▪ By accessing through the circuit breaker compartment, remove the busbar compartment covers.
▪ After removal of busbar compartment covers, busbar compartment components are visible.

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 Figure 41: Busbar Compartment Top View

8.4.1.2 Procedure for busbar compartment maintenance

• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths) for the following busbar compartment components:
• Main busbars
• Busbars bushing
• VCB upper bushing
• Busbar joining cover
• Insulator support
• Earthing switch
• Current transformers
• Visually check the connections of the current transformers.
• Visually check that the insulating covering of the main busbars and the insulating joining cover of the busbars to
ensure their integrity and do not show any breakages.
• Using a dynamometric spanner, check tightness of all the screws and bolts, refer to the table of tightening torques.

8.4.2 Maintenance in cable compartment

8.4.2.1 Preparations of cable compartment for maintenance
• Make the plant you want to work on safe (follow the plant safety regulations).
• Make sure that the circuit-breaker is in the Open position.
• Rack the circuit breaker out from the Service position to the Test / Isolated position.
• Manually close the earthing switch.
• Open the cable compartment door; the cable compartment components are visible.
8.4.2.2 Procedure for cable compartment maintenance
• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths) for the following cable compartment components:
- Power cables and barriers
- Cable busbar connections
- Insulator support
- Earthing switch
- Current transformer
- CB lower bushing
- Space heater
- Earthing busbar
• Visually check the connections of the current transformers and space heater.
• Visually check that the insulating covering of the main busbars and power cables to ensure their integrity and do
not show any breakages.
• Using a dynamometric spanner, check tightness of all the screws and bolts, refer to the table of tightening torques.

Figure 42: Cable Compartment View

8.4.2.3 Procedure for earthing switch maintenance

• Carry out a visual inspection of the mechanical connections and check for any presence of dirt, humidity, and signs
of corrosion on the main operating shaft and on the contact parts of the blades.
• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths).
• If necessary, grease the moving mechanical parts by applying a thin layer of mechanical grease for moving parts.
• Manually carry out the five closing/opening operations of the earthing switch.
• Manually check correct changeover of the earthing switch signaling contacts.

Figure 43: Earth Switch

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8.4.3 Maintenance in voltage transformers compartment
8.4.3.1 Preparations of VT compartment for maintenance
• Make the plant you want to work on safe (follow the plant safety regulations).
• Make sure that the circuit breaker is in the Open position.
• Rack the circuit breaker out from the Service position to the Test / Isolated position.
• Manually close the earthing switch.
• Rack the voltage transformer out from the Service position to the Test position.
• Open the VT compartment door; and align the VT handling trolley with the wheel guide rails.
• Remove secondary plug.
• Manually withdraw the VT truck and lock VT with VT handling trolley.
8.4.3.2 Procedure for VT compartment maintenance
• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths) for the following cable compartment components:
• VT busbars connection
• Insulator support
• Voltage transformers
• VT truck
• Visually check the connections of the voltage transformers and secondary plug.
• Visually check that the insulating covering of the VT busbars to ensure their integrity and do not show any
breakages.
• Using a dynamometric spanner, check tightness of all the screws and bolts, refer to the table of tightening torques.

8.4.3.3 Procedure for VT maintenance

Cleaning and checking of the fuses
• Manually connect the fuses contained in the resin tube of the voltage transformers.
• Carry out a visual inspection on the fuses and check for any presence of dirt.
• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths).

Figure 44: Voltage Transformer Fuse Replacement

Mechanical operation check
• Carry out a visual inspection of the mechanical connections and check for any presence of dirt, humidity, and signs
of corrosion on the main operating shaft and on the contact parts of the primary side.
• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths).
• If necessary, grease the moving mechanical parts by applying a thin layer of mechanical grease for moving parts.
• Manually carry out the five rack-in/out operations and check primary side touch, shutters, and interlocks operation.

Figure 45: Voltage Transformers Truck

8.4.4 Maintenance in circuit breaker compartment

8.4.4.1 Preparations of CB compartment for maintenance
• Make the plant you want to work on safe (follow the plant safety regulations).
• Make sure that the circuit breaker is in the Open position.
• Rack-out all the circuit breakers from Service position to Test position.
• Manually close the earthing switch.
• Close the earth switch relative to the main busbars.
• Open the CB compartment door.
• Remove CB secondary plug.
• Manually withdraw the CB truck, the CB compartment components are visible.

Figure 46: CB Compartment with CB Truck

Figure 47: Isolation Contacts

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8.4.4.2 Procedure for CB compartment maintenance
• Remove any dust deposits using a dry cloth that does not leave any deposits on the treated surfaces (do not use
woolen cloths) for the following CB compartment components:
o Busbar and cable isolating contacts
o Busbar and cable shutters and its mechanism
o CB earthing busbar
• Carry out a visual inspection on the top and bottom isolating contacts and shutters, the mechanical parts of the
interlocks, door interlocks in the circuit breaker compartment and check for any presence of dirt, humidity, and
signs of corrosion on the moving parts.
• Check that the moving parts can slide evenly. If necessary, grease the mechanical moving parts by applying a thin
layer of mechanical grease for moving parts.

Figure 48: CB Compartment without CB Truck

8.4.5 Maintenance in the low voltage compartment
8.4.5.1 Preparations of LV compartment for maintenance
• Make the plant you want to work on safe (follow the plant safety regulations).
• Make sure that the circuit breaker is in the Open position.
• Rack the circuit breaker out from the Service position to the Test/Isolated position.
• Manually close the earthing switch.
• Open the miniature circuit breakers positioned inside the low voltage compartment to remove the auxiliary power
supply to the panel.
• Carry out a visual inspection on all the cabling and terminal boxes, and check for any presence of dirt.
• Manually check correct insertion of the cabling in the terminal box.

Figure 49: LV Compartment Internal View

8.4.5.2 Procedure for LV compartment maintenance

• Carry out a visual inspection on all the wiring and terminal blocks, and check for any presence of dirt and remove
any dust deposits.
• Manually check correct insertion of the wiring in the terminal blocks.
Checking of correct operation of the protection release
• Withdraw the protection release from the fixed part fixed onto the door of the low voltage compartment.
• Using current and volumetric test boxes, carry out inspections to check perfect operation of the protections
themselves.

Figure 50:
LV Compartment External View

NOTE
To check operation of the protection releases, refer to the operating manual of the
protection provided by the manufacturer.

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Measuring the insulation resistance of the auxiliary circuits
Using the Megger instrument, measure the resistance between the phase involved and the conductive electric part
(switchgear structure). The value must not be less than 1Mohm and remain constant over time.

8.5 Corrective maintenance and repairs

8.5.1 Switchgear in general
Repair of surface damage
• Carry out repair work immediately after a defect has been discovered.
• Completely remove all rust from damaged painted areas on steel sheet and other steel parts by mechanical means
e.g., with a wire brush.
• Lightly grind the surrounding paint coat and carefully degrease the entire area. Then immediately apply an
anti-rust primer, and, after an appropriate hardening time, apply the topcoat. Only use suitable and compatible
paint products.
• Apply the topcoat in standard RAL 7038 color, or the relevant special color.
Carefully remove any white rust on aluminum/zinc surfaces with a wire brush or cleaning pad, and clean loosely
adhering particles with a dry, non-fraying cloth. Next, treat the cleaned parts with zinc spray or zinc powder paint
and, finally, treat with aluminum spray for color matching.
• Carefully remove any white rust from passivated operating parts and rust formation on phosphatized parts with a
wire brush or metal-free cleaning pad, and clean with a dry cloth. Then grease evenly (with mechanical grease for
moving parts).

Apparatus in general
• Follow the maintenance instructions in the manuals for individual equipment components.
• Check that the bolt connections at the contact points in the busbar system and the earth connections are tight, and
that the contact system functions correctly.
• Where necessary, grease slide plates and bearings in the panel again or thoroughly clean them. Then grease them
again with mechanical grease for moving parts lubricant.
• Top up grease on contact areas in the contact system when corroded or otherwise as necessary, or, when lubrication
is inadequate or missing, thoroughly clean the areas concerned and grease them again with mechanical grease for
moving parts lubricant.
• Remove the contact system for thorough cleaning.
• Check that all contact fingers and ring tension springs have a perfect fit.

Replacement of the contact pins when the surface is damaged

After any required replacement of contact pins, the latter should be retightened using the socket head bolts.

Replacement of complex functional groups

Precise matching of functions for control, interlocking and signaling only permits replacement of individual
components to a limited extent. The following assemblies are prefabricated and tested at the works, maintaining
high quality standards. In the case of faults, they must therefore be completely replaced.
8.5.2 The circuit breaker
Identification of causes, upon circuit breaker tripping
Upon circuit breaker tripping, the circuit must never be re-closed, before having identified and eliminated the
tripping cause. There may be multiple causes:
• Depending on the type of control unit, refer to the appropriate manuals.
• In function of the type of fault and the priority of installation re-starting, certain precautions should be taken. In
particular, insulation and dielectric tests on parts or on the entire installation must be performed. These checks and
tests must be piloted and conducted by qualified personnel.

Circuit breaker maintenance

Symptoms Incriminated unit Probable causes and remedies
Voltage too low at motor terminals
Electrical control unit motor • restore voltage
Impossible to arm • possibly change the motor
Cabling Check connections of auxiliary circuits
The release is not connected properly
• check the circuit
Impossible to close the Closing release • the coil is cut off
circuit breaker, the indicator • change the release
remains in the Open position.
Arming device The control unit is not armed.
• arm the unit
There is a fault on the main HV circuit
The circuit breaker All opening releases or poor setting of protection circuits.
closes and immediately opens. (direct or indirect) • eliminate this fault
• adjust the protection circuits
The release is not connected properly.
• check the circuit
The circuit breaker cannot The coil is cut off.
Opening release
be remotely opened. • change the release
• check the protection circuit
Table 6: Circuit Breaker Maintenance

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 Draw-out circuit breaker and cradle maintenance
Symptoms
The circuit breaker on its
truck was just inserted into
its cradle.
The circuit breaker cannot
rack-in.
The shutters are not locked
when the circuit breaker is
on its truck and extracted
from the cradle.
Table 7: Table for Draw-out Circuit Breaker and Cradle
8.5.3 The earthing switches
In function of the type of fault and the priority of installation re-starting, certain precautions should be taken. In
particular, insulation and dielectric tests must be performed on parts or on the entire installation. These checks and
tests must be piloted and conducted by qualified personnel.
Symptoms
An indicator light does not
light up
Impossible to close the
earthing switch, the
indicator remains in the
Open position
Impossible to open the
earthing switch, the
indicator remains in the
Close position
Incriminated unit Probable causes and remedies
Check that the low voltage plug was
The low voltage plug connected, and that the interlock arm
interlock arm angle is sufficient.
Make sure that any possible interlocks
An interlock on the panel on the panel do not act against the
circuit breaker rack-in.
Adjust the shutter lock and the raising
The sliding shutters roller located on the side of circuit
breaker’s truck.
Adjust the shutter lock and the raising
Shutter lock roller located on the side of circuit
breaker's truck
(see cradle installation manual).
Re-adjust the motor roller setting for
shutter raising on the side of the
circuit breaker truck
Shutter raising system
(see installation manual).
If the shutters are bent,
Contact alfanar service center.
Incriminated unit Probable causes and remedies
Test the contact.
• change if faulty
Electrical control • otherwise, readjust its position
relative to the contact angle
Cabling Check connections of auxiliary circuits
Make sure that any possible interlocks
on the panel do not act against the
An interlock on the panel earthing switch close.
Check that the electrical interlocking
is not in place
The control unit is not armed.
Arming device • arm the unit
• check that the crank is not in place
Make sure that any possible interlocks
An interlock on the panel on the panel do not act against the
earthing switch open.
The control unit is not armed.
• arm the unit
Arming device
• check that the crank is not in place
Table 8: Table for earthing switch
8.5.4 Replacing parts
The operations listed in the table below can be conducted by the customer or by alfanar.
After each operation, conduct electric tests according to the standards in force.
Caution: when conducting replacements, it is imperative that all the following accessories must be replaced with
new parts.
• Nylstop (self-stopping nut)
• Contact washer
• Stop ring
• Mechanical pin

COMPARTMENT DESCRIPTION
- Main busbars
- Busbars bushing
- Busbar joining cover
Busbar compartment
- Insulator support
- Current transformers
- Condenser busbar
- Earthing switch
- Insulator support
- Current transformers
Cable compartment
- Space heater
- Cable busbars connection
- Power cables and barriers
- Earthing busbar
- VCB bushing
- Isolating contacts
- Complete circuit breaker
- Shutters with operating mechanism
- Earthing busbar
CB compartment
- Door holding arm
- CB interlock rod
- Spouts
- Complete circuit breaker
- Earthing busbar

- Earthing busbar
- VT complete set
VT compartment
- Supporting insulator
- VT busbar droppers

- Protection relays
LV compartment - Control equipment
- Indication lamps

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 COMPARTMENT DESCRIPTION
- Low voltage plug
- Switching shaft
- Closing spring
- Opening spring
- Motor
- Manual charging shaft
- Driving shaft
- Closing coil
- Trip coil
Circuit breaker
- Tulip contactor
- Auxiliary switch
- Insulation rod
- Upper and lower terminals
- Vacuum interrupter
- Heat sink
- Withdrawal screw
- Handle
- Wheels

- Solenoid coil
- Control housing
Earth switch - Indication contact
- Power unit
- Rod

Voltage transformer - HV fuses

Table 9: Replacing Parts

8.6 Tightening torques

Torques in the table apply to screwed and bolted connections that have not been greased.

Component Thread Torque

M8 20 Nm
Rail / bar connections M10 40 Nm
M12 65 Nm

Current transformer M8 20 Nm max.

M12 40 Nm max.

Voltage transformer 20 Nm max.

M8 12 Nm
M10 26 Nm
Cast-resin insulators
M12 36 Nm
M16 88 Nm

Table 10: Tightening Torques

Notes
For catalogue soft copy scan QR code MKT-129973- LV INST-AUG01-20

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