EuroMax

Specification and description of substation EuroMax

New design for more security and longer operating life time

Dipl. Ing.
20/7/2014 Page : 1 /13
André Meuleman
 EuroMax

Advantage :
 Factory assembled substation, ready for connection on the distribution network.
 Low weight and small dimensions.
 The upper part of the housing is substantially not welded. The choice of the constructive design don’t need
welding. By welding the hot dip galvanizing corrosion-protection dissolves and the following weld grinding
causes more losses of the galvanizing layer as permitted.
 All part have an 100% non-porous power coating
 Double doors with a visible, mechanically pressure-resistant closing plane by means of an internal door
combination with covered hinges.
 Complete oil-tight welded, hot dip galvanized and additionally coated steel foundation, with removable lifting
bolts.
 The bottom of the steel foundation oil pan is distanced of the earth level and bearing surface of the complete
substation, so cable and pipe can pass between earth and bottom
 The steel foundation has a weight of approximately 800 kg.
 Oil-tightness checked oil pan
 The cable entry in the compartments is above the earth level and do not need a shrinking process.
 All compartments are separated accessible.
 The MV- and LV- switchgear are attached on a base frame, witch are screwed on earthed hot dip galvanized
side frames on both long sides of the substation. This side frames connect and earth simultaneously the steel
foundation, the outside frames and the housing
 To lead, in case of and internal arcing, do to an internal fault in the MV-switchgear, the hot gases at an harmless
outside of the substation, the gases are collected in a cooling compartment downside of the MV-switchgear, in
direction of the transformer compartment. So the gases can’t arrive on the operator side of the MV-switchgear.

Dipl. Ing.
20/7/2014 Page : 2 /13
André Meuleman
 EuroMax

Normative references for the substation EuroMax

EN 50464 series, Three-phase oil-immersed distribution transformer 50 Hz, from 50 kVA to 2500 kVA
With highest voltage for equipment not exceeding 36 kV
EN 60076 series, Power transformer (IEC 60076 series)
EN 60243-1 Electrical strength of insulating materials – Test methods – Part 1:Test at power frequencies
(IEC 60243-1)
EN 60439 series, Low-voltage switchgear and controlgear assemblies (IEC 60439 series)
EN 60439-1:1999, Low-voltage switchgear and controlgear assemblies Part 1:Type-tested and partially
type-tested assemblies (IEC 60439-1:1999)
EN 60529:1991, Degree of protection provided by enclosures (IP Code) (IEC 60529:1989)
EN 60721-1, Classification of environmental condition – Part 1:Environment parameters and their
severities (IEC 60721-1)
EN 60947-1, Low-voltage switchgear and controlgear – Part 1:General rules (IEC 60947-1)
EN 60947-2, Low-voltage switchgear and controlgear – Part 2:General rules (IEC 60947-2)
EN 61936-1, Power installation exceeding kV a.c. – Part 1:Common rules (IEC 61936-1)
EN 62262, Degree of protection provided by enclosures for electrical equipment asainst external
mechanical impacts (IP code) (IEC 62262)
EN 62271-1:2008, High-voltage switchgear and controllgear – Part1:Common specifications
(IEC 62271-1:2007)
EN 62271-200:2004, High-voltage switchgear and controllgear – Part 200:AC metal-enclosed
switchgear and controllgear for rated voltage above 1 kV and up to and including 52 kV
(IEC 62271-200:2003)
EN 62271-201:2006, High-voltage switchgear and controllgear – Part 201:AC insulation-enclosed
switchgear and controllgear for rated voltage above 1 kV and up to and including 52 kV
(IEC 62271-201:2006)
EN 62271-202, High-voltage switchgear and controlgear – Part 202:High voltage/low voltage
Prefabricated substation (IEC 62271-202 : 2006)
IEC 60721-2-2, Classification of environmental conditions – Part 2:Enviraomental conditions appearing in
nature. Precipitation and wind
IEC 60721-2-4, Classification of environmental conditions – Part 2:Enviraomental conditions appearing in
nature – Solar radiation and temperature.
IEC/TR 62271-300, High-voltage switchgear and controlgear – Part 300:Seismic qualification of
alternating current circuit-breakers

Dipl. Ing.
20/7/2014 Page : 3 /13
André Meuleman
 EuroMax

Conditions of use :
Mounting, set-up and operation of substation are to be executed by trained personal only, trained in the use of MV-
switchgear, transformer, LV-switchgear. The appropriate IEC – regulations are to be payed attention.
The technical lifetime of the substation is at least 40 years.

Basic data of substation (depending on specification) :

- Outdoor under direct sunlight and still air.
- Ambient temperature : -30 up to +50 °C.
- Average ambient temperature in any one year : 30 °C.
- Average relative humidity in any one year : 79%
- Average maximum relative humidity in any one year : 94%
- Maximum ambient temperature inside the enclosure : 45 °C.
- Operational altitude : up to 1000m (higher altitude possible after technical modification of used equipment)
- Rated voltage : 12 kV to 24 kV.
- Rated power : up to 500 kVA for EMP 500 and EMP 500.2
up to 1000 kVA for EMP 500.1
up to 1600 kVA for EMP 1000-1600
- Frequencies : 50 Hz and 60 Hz, also special frequency 16 2/3 Hz on request.
- Rated withstand voltage : 28/75 kV and 50/125 kV.
- Rated short-time current 20 kA 1 sec.
- Rated peak current : 50 kA.
- Star point treatment : fixed – or low resistance.
- Type of used component : SF6 insulated switchgear (12 kV,24 kV), oil filled insulated transformer up to 1600
kVA.
- Contained type : 20K (up to 1600 kVA)
- Degree of protection MV-/LV-room : IP 54.
- Degree of protection transformer room : IP 43 stoke safe.
- Erection : generally 500-550 mm in the ground.
- Operation : from outside ; walk in not possible.
- Roof load : 2500 N/m2 (during installation or snow)
- Wind force acc. IEC 694 (700 N/m2)
- Out forces by impact stress on casing, doors, rock lever handles and ventilation openings according to EN
62271-202
- Noise level : reduction of transformer, noise level within station by 3 dB (A)
- EMV-test : on all test points with 200 mm distance to the station levels always below < 100 µT.

The unit substation is suitable for use in tropical climatic area and is capable of operating according IEC EN DIN 62271-
202 Annex D.

Dipl. Ing.
20/7/2014 Page : 4 /13
André Meuleman
 EuroMax

Casing Construction
The substations type EuroMax are, factory assembled and type tested units.
They have a MV-, Transformer- and LV-room. The compartments are separated and the equipment is enclosed in the
weatherproof enclosure.
After connecting the MV- and LV-cables, the substation is ready for operation.

The substation is manufactured as a complete metal-sheet bended construction and consist of:
- Oil-tight welded, hot dip galvanized and additionally coated steel foundation, with removable lifting bolts. The
oil collect pan is made of 4 mm thick steel sheets. It constitutes the mechanical base frame for the other
structures and can be embedded in the earth.
- Casing, incl. doors and cover sheets for the MV- and LV-rooms as one unit removable from the base, made of
2 mm cold rolled galvanized sheet steels. The double doors to the MV- and LV-rooms have a visible,
mechanically pressure-resistant closing plane by means of an internal door combination with 3 covered hinges.
The metal-swing lever locks, are prepared for fitting standard profile cylinder with 45° or 90° lock-in angle.
The profile cylinders are protected with weather hoods. The opening angle of the doors is 120°.
- Carriers to keep the MV- and LV-equipment, connected with the steel base foundation, strip galvanized.
- Simply removable roof.

The Substation can, completely equipped, lifted by crane.

The lifting gear has to fasten on the four removable lifting bolts of the basic unit.
At truck forwarding, please note the load regulations.

Dipl. Ing.
20/7/2014 Page : 5 /13
André Meuleman
 EuroMax

Material and surface treatment:

1) Steel foundation
Material: sheet steel 4 mm according EN 10029 No. S235JRG2, complete oil-tight welded,
Surface treatment: completely welded hot dip galvanized > 750 gr/sqm => 70 µm.
Corrosion protection with powder coated and bituminize ; Color: black.
The oil – tightness is checked by the penetration method according DIN 54152 Part 1.
Oil pan capacity for 100% of oil coolant transformer.

2) Casing, incl. doors and cover sheets for the MV- and LV-rooms and roof
Material: The part above oil pan are made from first class cold rolled galvanized sheet steel and coated by electrostatic
plastic powder coating , thickness 2 mm. The complete with all needed holes, punched and bended parts are 100%
nonporous powder coated, thickness of coating > 70 µm., baked at >200 degrees.The used varnish powders are free of
heavy metal and are nontoxic. So the highest corrosion protection is guaranteed.
Standard colour : light gray (RAL 7032- S). Other colors, also combinations, are possible. The standard power coating
can be changed into another colour by the end user. It is to use a special liquid paint, Surface grinding is not necessary.
The former corrosion protection is maintained.

Dipl. Ing.
20/7/2014 Page : 6 /13
André Meuleman
 EuroMax

Equipment possibilities
MV-Switchgear:
The substation is designed for SF6-gas-insulated, complete metal enclosed switchgear manufactured an tested according
EN 62271-200:2004.

Possible supplier :
- ABB Safering/Safeplus 12/24kV; CCF or CCV
- Siemens Type 8DJH 12/24kV; RRT or RRL
- Schneider RM6
The switchgears are integrated in the casing so, that no hot gases, caused by internal error, attain the operation side of the
switchgear, but do release over the transformer room to the outside.

LV Module:
The LV Compartment is, according to the specification of the client, prefabricated installed and tested.
To standard equipment belongs:
- Main switch: Circuit breaker 2500 A by rated power of the transformer 1600 kVA
- 10 Outgoings: LV HRC strip-fuse-switch-disconnector-ACB-MCCB; DIN-Standard or IEC-Standard
- 3 pieces Current Transformers; class 1 ; 2500/5A ; IP20
- 3 pieces Ammeters in bi-metal design with drag pointer (15min); class 1 ; 1000-2500/5A
- 1 piece Voltage meter with selector switch, measuring line to line and lines to bus voltage; 500V
- 1 piece Socket with fuse
- 1 piece Terminal board
Displaying instruments, socket, fuses and terminal board are installed in an instrument panel.
An N- and PE busbar are installed in the low area of the LV compartment.
Outgoing cables can be fixed on an iron track in the area of the cable connecting room in the foundation base.
The compartment, will be equipped basically, with a hydrostatic heating. The electrical power is 300W. The Hygrostat
keeps the relative humidity less than 70%. This avoids, as experience shows, any dew on spare parts.

Dipl. Ing.
20/7/2014 Page : 7 /13
André Meuleman
 EuroMax

Transformer compartment:
The transformer-compartment is equipped with movable transformer attachment profiles.
It can be installed transformers up to 1600 kVA, depending of the substation.
Prefabricated and tested MV-cables connect the transformer with the MV-switchgear.
The transformer has to be strongly attached to the base frame, before transporting the substation with the transformer

Mounting or changing the transformer on the site:

Please take attention that no tension is on the transformer.
The MV-feeders of the switchgear and the LV-distribution are without voltage and earthed.
Please make following steps:
Remove the roof by loosing the attachment screws. There are accessible after opening the doors.
Open also the doors to the transformer compartment.
Take of the roof. The transformer is now free accessible.
1. Loosen the attachment of the transformer and remove the transformer by lifting.
2. Align the U-tracks in the oil –collecting pan according. The new transformer.
3. Drive in the transformer, attach and connect
4. Install the roof again and screw it.

Earth System:
The earthing busbar is mounted in the low area of the LV-compartment. Complete with three earthing point MV-,
Transformer, LV-part. Connect on this busbar the deep earth system iron earthband, to install by the customer, around the
entire substation, in an approximate distance of 1m.

Dipl. Ing.
20/7/2014 Page : 8 /13
André Meuleman
 EuroMax

Forwarding, Erection and Mounting:

If a compact station ordered with transformer, the station is ready for connection.
Erection at the destination site according dimension plan site excavation drawing.
At ascertainment of the excavating deep, please consider the later terrain level and the expecting surface water.
The building pit must have a capable of bearing ground.
Roughness has to balance by an horizontal sand bed.
At difficult ground conditions is a support of lean concreate or sleepers necessary.
The erection of the complete equipped substation in the building pit happens with a suitable crane. For this purpose, the
lifting gear is to fasten on the four movable lifting bolts.

Connecting the cables

a) On the MV side: remove the covers from the steel base foundation and the medium voltage switchgear.
b) On the LV side: remove the cover from the steel base foundation.
After this, the whole connecting sector is frontward free for placing and connecting the cables.
Behind connection, the previous removed parts have to install in reverse order.

Dipl. Ing.
20/7/2014 Page : 9 /13
André Meuleman
 EuroMax

Dimension Drawing Substation EuroMax EMP 500

Dipl. Ing.
20/7/2014 Page : 10 /13
André Meuleman
 EuroMax

Dimension Drawing Substation EuroMax EMP 500.1

Dipl. Ing.
20/7/2014 Page : 11 /13
André Meuleman
 EuroMax

Dimension Drawing Substation EuroMax EMP 500.2

Dipl. Ing.
20/7/2014 Page : 12 /13
André Meuleman
 EuroMax

Dimension Drawing Substation EuroMax EMP 1000-1600

Dipl. Ing.
20/7/2014 Page : 13 /13
André Meuleman