ABB SafeLink RMU Mechanism and Interlock Replacement

Work Practice WP1061
ABB SafeLink RMU Mechanism and Interlock Replacement
Table of Contents
SCOPE
This work practice sets out the steps to be followed when replacing isolator and switch fuse mechanisms and the fuse
door interlock assembly in ABB SafeLink Ring Main Units.
There have been design alterations made by the manufacture to the SafeLink units over the years. This means that
the methods of removing / refitting the fuse access door and face plate may differ slightly, i.e. the positions and
number of fixing screws. However, the procedure for replacing the mechanisms and fuse door interlock remains the
same.
There are several SafeLink RMU configurations. This document has been constructed for the most common
configuration “CFC” (Isolator – Switch fuse – Isolator).
Risk assessment RSK-100363 identified that incorrect reassembly of the ring main unit could result in incorrect or
unsafe operation was the cause for greatest concern.
DEFINITIONS
Nil
TOOLS, EQUIPMENT AND MATERIALS

 Operating handle
 4 mm Allen key
 2 mm extended handle T-bar Allen key (250 mm long)
 #2 point Phillips head screwdriver
 #3 point Phillips head screwdriver
 2 x 8 mm open ended spanners
 3/8 drive socket set with extension bar and at least a 13 mm and a 16 mm socket.
 Torque wrench capable of accurately exerting 22 N m force (where 22 N m is in the mid-range of the wrench).
 KOPR-KOTE, Anti-seize lubricant (SC16390) or similar
 Cable ties, medium to small in size
 Permanent marking pen
PRELIMINARY
Risk assess, check HV phasing on voltage indicator test points, permits, check operation.
Step 1 Check RMU has not already been upgraded to “C” variant or above standard ( see Section 6).
Step 2 Carry out appropriate site specific hazard assessment.
Step 3 Check HV phasing on RMU voltage indicator test points (this will be done as part of the forward switching).
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Owner: EGM Operations Release: 9, 29 Jun 2023 | Doc ID: 2955885

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Step 4 Issue and or receive an access permit in accordance with SAHV procedures.
WARNING: The RMU must be remotely isolated from all possible sources of supply.
Step 5 Operator earths must be applied at adjacent / remote sites.
Step 6 Check operation of RMU - check operation of isolators and switch fuses, make sure interlocks and
indicators function correctly. (Refer to Energy Queensland Switchgear Operations Manual).
Step 7 Check condition of RMU – The RMU must be in very good condition. It must be clean, free from corrosion
and have no signs of insect infestation. If the RMU is considered to be in poor condition replace the entire
RMU.
PROCEDURE
Energex own SafeLink RMUs with a manufacture date from 2002 onwards. Figure 5—1 shows an early model and
Figure 5—2 shows a late model (late 2007 model).
Figure 5—1 - Early model Figure 5—2 - Late model
NOTE: It is highly recommended that anti-seize lubricant (SC16390) or similar is applied to all
threaded components that are removed and replaced as part of this work practice.
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Accessing Mechanisms and Fuse Door Interlock Assembly
Figure 5—3 - Early model RMU
Step 1 Test to prove de-energised and place the switch fuse and all isolators in the “EARTH” position.
Step 2 Remove HV fuse access door. (Open door to approximately 30o and pull door out at that angle).
Step 3 Remove all cable box covers.
CAUTION: At this stage do not operate the switchfuse, leave it in the “EARTH” position. Failure to
observe this will break the “fuse door interlock latch” or the plastic indicating disc.
Step 4 Place both isolators in the “OPEN” position.
Step 5 Fit a cable tie around each selector assembly (see Figure 5—4).
Figure 5—4 - Cable tie fitted around each selector assembly
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Step 6 Remove all rotary selectors: - Use a 2 mm hex drive (“T” bar Allen key, 250 mm long ideally). Loosen the
grub screw approx. six turns only. Remove Allen key then remove the rotary selector from its shaft
(see Figure 5—5).
Figure 5—5 - Removing rotary selectors
Step 7 Remove the “Perforated Division Panel” by removing the six screws (see Figure 5—6).
Figure 5—6 - Removing perforated division panel
Step 8 Remove the “HV Fuse Access Door Interlock Assembly” screws - cut the sticker away to gain access to the
left hand side screw then remove both screws (see Figure 5—7 & Figure 5—18).
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Figure 5—7 - Removing “HV Fuse Door Interlock Assembly” screws
NOTE: The interlock will now not be attached and will fall away when the face plate is removed.
Step 9 Remove the face plate screws (3 screws in each side).
Figure 5—8 - Remove face plate screws
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Step 10 To remove the face plate, work the face plate forward over the rotary selector shafts and allow it to pivot
down. Hang the face plate with cable ties out of the way. Leave all of the voltage indicator test point wiring
in place (see Figure 7-9).
NOTE: The HV fuse access door interlock assembly (if still in place) is loose. Remove this as the face
plate is worked forward.
Figure 5—9 - Face plate pivoted down
NOTE: If required reconnect the voltage indicator test points wiring as shown in Figure 5—10.
TOP
TOP
SCREENS –0 Red – L1 White – L2 Blue – L3
Figure 5—10 - Voltage indicator test point wiring connections
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Remove Isolator Mechanism
Step 1 With the mechanism in the “OPEN” position remove it by removing the 4 bolts (see Figure 5—11)
Step 2 Take note of any earth wires that may be secured under one of these bolts.
Step 3 Tilt the mechanism forward and unhook / slide the spring from the standoff (see Figure 5—12).
Figure 5—11 - Unbolting mechanism Figure 5—12 - Removing mechanism
Step 4 For a FAILED mechanism using a permanent marker record the following information on the backing plate
of each old mechanism and return to Geebung depot.
Serial number
Year of manufacture
Site ID (e.g. SC123456, RM 2)
Left or right isolator
Any replaced mechanism that HAS NOT FAILED may be disposed of appropriately.
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Remove Switchfuse Mechanism
Step 1 With the mechanism in the “EARTH” position remove it by removing the 4 bolts and round spacers
(see Figure 5—13).
Step 2 Take note of any earth wires that may be secured under one of these bolts.
Step 3 Tilt the mechanism forward and unhook/slide the spring from the standoff (see Figure 5—14).
Figure 5—13 - Unbolting mechanism Figure 5—14 - Removing mechanism
Step 4 For a FAILED mechanism using a permanent marker record the following information on the backing plate
of each old mechanism and return to Geebung depot.
Serial number
Year of manufacture
Site ID (e.g. SC123456, RM 2)
If more than one switchfuse mechanism exists (CFCF) record left or right.
Any replaced mechanism that HAS NOT FAILED may be disposed of appropriately.
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Fit New Switchfuse Mechanism
Step 1 Figure 5—15 shows the “cable box cover interlock drive plates” fitted correctly to the “contact drive shafts”
which are all in the “OPEN” position.
NOTE: The “switchfuse contact drive shaft” position is different relative to the “Isolator contact drive
shaft” position as shown in Figure 7-15. However the “cable box cover interlock drive plates”
always face the same way.
NOTE: The old switchfuse mechanism should have been removed while it was in the “EARTH”
position. When this mechanism was removed the contact drive shaft will have moved slightly
in a clockwise direction almost to the “OPEN” position driven by the s light tension of the
earthing contacts.
The point is the “switchfuse contact drive shaft” will not remain in the true “EARTH” position
once the mechanism is removed.
Step 2 For ease of installation the new switchfuse mechanism should be fitted while it is in the “OPEN” position.
Rotate (by hand) the “switchfuse contact drive shaft” to the approximate “OPEN” position as shown in
Figure 5—15.
Figure 5—15 - Cable box cover interlock drive plates correctly fitted (“OPEN” position)
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Step 3 The new mechanism must be in the “OPEN” position. (See Figure 5—16). The output shaft and the
position indicator shaft must be in the position shown in relation to the mechanism back cover. The cable
box door interlock components are also shown in the correct position.
Figure 5—16 - Switchfuse mechanism shown in the “OPEN” position
Step 4 Align the “position indicator shaft” and the “output shaft” as shown in (Figure 5—16).
Step 5 Hook / slide the spring of the new mechanism over the standoff and position the mechanism
Step 6 Bolt the new mechanism in place – 22 N m. Ensure the earth wire connection, is replaced under the head
of the upper right bolt or the lower left bolt.
Step 7 Check by hand the “cable box door interlock component” is free to move and returns to its normal position
under the spring tension.
Step 8 Place the switchfuse in the “EARTH” position.
Step 9 IMPORTANT: Shorten the trip plunger as far as possible (see Figure 5—26)
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Fit New Isolator Mechanism
Step 1 Fit new “Isolator Mechanism”. The new mechanism must be in the “OPEN” position. (See Figure 5—17).
The output shaft and the position indicator shaft must be in the position shown in relation to the mechanism
backing plate. The cable box door interlock components are also shown in the correct position.
Figure 5—17 - Isolator mechanism shown in the “OPEN” position
Step 2 Hook / slide the spring of the new mechanism over the standoff and position the mechanism
Step 3 Bolt the new mechanism in place – 22 N m. Ensure the earth wire connection is replaced under the head of
a bolt.
Step 4 Check by hand the “cable box door interlock component” is free to move and returns to its normal position
under the spring tension.
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Fit New Type Fuse Door Interlock Assembly
There have been changes to the fuse door interlock since 2000 (Figure 5—18). Method of removing the existing
interlock will differ slightly depending on the type of interlock encountered.
Figure 5—18
NOTE: Regardless of the type of interlock discovered the replacement interlock CA2513 (Figure 7.22)
is the correct / approved substitute.
NOTE: The new fuse door interlock assembly mounts to the switchfuse mechanism. Refer to Figure
5—20, Figure 5—21 and Figure 5—22 to assist with the following steps.
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Step 1 Remove the upper left hand side mounting screw of the switch-fuse mechanism. The round spacer behind
the mechanism plate is now loose and can fall out of position.
Step 2 Fit the short extension standoff to where the upper left hand side mechanism mounting screw was, torque
to 22 N m.
Step 3 If the voltage indication loom earth wire was fitted to the lower right hand side mechanism mounting screw,
move it to the upper right hand side mechanism mounting screw, torque to 22 N m.
Step 4 Remove the lower right hand side mechanism mounting screw. The round spacer behind the mechanism
plate is now loose and can fall out of position.
Step 5 Fit the long extension standoff to where the mechanism mounting screw was, torque to 22 N m.
Step 6 Fit the interlock assembly to the two extension standoffs using M8 x 20 set screws with flat and bevel
washers, torque to 22 N m.
Step 7 With the switchfuse in the “EARTH” position the bottom of the sliding plate should be in contact with the
plastic “T” so that the plastic “T” can push the sliding plate up when turned. See Figure 5—21.
CAUTION: There should be no requirement to change the position of the switchfuse mechanism. However
if this is required do not switch the switchfuse mechanism from the “EARTH” position to the
“OPEN” position without pushing the “red fuse door interlock latch” to the left
(see Figure 5—21). This latch will be broken by the sliding steel plate being pushed up if it is
not held to the left.
Step 8 Fit and close the fuse access door. Check that the fuse access door catch moves the latch of the fuse door
interlock assembly and that the latch returns fully when the fuse access door catch is opened (Refer to
Figure 5—19). Remove the fuse access door.
Figure 5—19 - Checking correct position of interlock assembly
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Figure 5—20 - Switchfuse Mechanism and New Fuse Door Interlock Assembly
Figure 5—21 - New Fuse Door Interlock Assembly Workings
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Figure 5—22 - New Fuse Door Interlock Assembly with all Components and ABB part numbers
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“E” mechanism from April 2017
Table 5-1
Mechanism New stock code Type “E”
Isolator / ring switch mechanism 24748
Switch fuse mechanism 24747
The “E” type mechanism does not change the operation method or rating of the switchgear, and there are no external
changes. The "E" type mechanism is externally identical to previous mechanism versions. The method of replacing
the mechanism (both isolator and switch fuse) remains the same as detailed in 7.4 & 7.5 of this work practice.
ABB has performed endurance and functional testing to ensure that it provides the required functionality beyond the
required service life.
When performing the operational reset task on the switch fuse isolator the “E” type mechanism makes a notable
“spring discharge” type noise not experienced with previous model mechanisms.
Internally, the method of interlocking has changed, and operators may note a difference in sensitivity of the interlock.
Assemble RMU
Step 1 Fit new isolator and switch fuse mechanisms (see Clauses 5.4 & 5.5).
Step 2 Fit new fuse door interlock assembly (see Clause 5.6).
Step 3 Ensure all of the voltage indicator test point wiring is in place and correct (see Figure 5—10).
Step 4 Fit the face plate (see Figure 5—8) and at the same time:
Step 5 Fit brass trip plunger (with a flat washer) into the face plate (see Figure 5—7).
Step 6 Fit perforated division panel (see Figure 5—6).
Step 7 Fit all rotary selectors (see Figure 5—4 & Figure 5—5).
Step 8 Place the isolators in the “EARTH” position.
Step 9 Fit HV fuse access door — slide door in at approximately 30o, close and latch.
Step 10 Fit all cable box covers.
Step 11 Check complete operation of RMU including all interlocks.
Step 12 Check switch fuse trip function, (see Clause 5.9)
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Switchfuse Trip Function – Checking and Adjusting
Step 1 Check the RMU is completely assembled with the HV fuse access door closed and latched.
Step 2 Place the switch fuse in the “ON” position.
Step 3 Use a small screw driver or similar tool to check the trip mechanism play and to trip the switch fuse. The trip
mechanism should have approximately 1mm of play with slight spring tension returning the plunger (see
Figure 5—23).
Figure 5—23 - Switch Fuse Checking and Tripping Figure 5—24 - Switch Fuse in the Trip Position
Step 4 To adjust the trip mechanism:
Place the switch fuse in the “EARTH” position.

Remove HV fuse access door. (Open door to approximately 30o and pull door out at that angle).
Using two 8 mm open ended spanners adjust the length of the trip plunger. (Work through the
perforated division panel). Undo the lock nut, adjust the length by turning the brass component in the
desired direction then tighten the lock nut (see Figure 5—25 and Figure 5—26).
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Figure 5—25 - Adjusting the length of the trip plunger Figure 5—26 - Open view of trip plunger
NOTE: If for example there was 3 mm of play, lengthen the trip plunger by 2 mm. If on the other hand
there was no play, shorten the trip plunger by 1 mm.
NOTE: With the incorrect play the switch fuse will still trip manually however a blown HV fuse striker
may not initiate a trip.
Step 5 Re-assemble the RMU and check switch fuse mechanism play and trip function.
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LABELLING AND DATA RECORDING

When the mechanisms and the fuse door interlock assembly have been replaced and all final checks prove the RMU
is fit for service, thoroughly clean the appropriate area of the face plate and fit the Gravoply “E” mechanism sticker
(SC25073).
The Mechanism E (paper) sticker will be supplied as part of the mechanism kit, and should be attached to the
mechanism itself.
Figure 6—1 - Mechanism E Label identifier fitted to RMU
The ABB SafeLink Mechanism Upgrade Form, either 1040 (Paper) or FFA Generic data capture (update 27) is to be
completed and sent back to Network Data.
FINAL CHECKS
Step 1 Check operation of RMU - check operation of isolators and switch fuse, make sure interlocks (fuse door
interlock and cable box cover interlocks) and indicators function correctly. (Refer to Energy Queensland
Switchgear Operations Manual).
Step 2 Place all isolators and the switchfuse in the “OPEN” position prior to surrendering of any permit.
Step 3 Return all old mechanisms, interlocks and the standard operating handle to the bins or cages provided at
the hubs for the eventual return to the Eagle Farm Distribution Centre.
Step 4 Check HV phasing on RMU voltage indicator test points after re-energisation.
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SUPPORTING DOCUMENTATION
HazChat - On-Site Hazard Assessment
EQL SWMS - Safe Work Method Statements
Energy Queensland Switchgear Operations Manual
Environmental Management System - Environmental Standard - 2947192
Procedures for Safe Access to High Voltage Electrical Apparatus (SAHV) - 2904212
Electrical Safety Rules 2022 - 6503074
Risk Assessment RSK – 100363 ABB SafeLink RMU - Isolator Mechanism Replacement
Risk Assessment RSK – 100553 ABB SafeLink RMU - Installation of Standard Vent Chute Indoor Substation Site
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Table of Contents
Scope ...................................................................................................................................................................... 1
Definitions ............................................................................................................................................................... 1
Tools, Equipment and Materials ............................................................................................................................. 1
Preliminary .............................................................................................................................................................. 1
Procedure ............................................................................................................................................................... 2
Accessing Mechanisms and Fuse Door Interlock Assembly........................................................................ 3
Remove Isolator Mechanism ........................................................................................................................ 7
Remove Switchfuse Mechanism .................................................................................................................. 8
Fit New Switchfuse Mechanism.................................................................................................................... 9
Fit New Isolator Mechanism ....................................................................................................................... 11
Fit New Type Fuse Door Interlock Assembly ............................................................................................. 12
“E” mechanism from April 2017 .................................................................................................................. 16

Assemble RMU ........................................................................................................................................... 16
Switchfuse Trip Function – Checking and Adjusting .................................................................................. 17

Labelling and Data Recording .............................................................................................................................. 19
Final Checks ......................................................................................................................................................... 19
Supporting Documentation ................................................................................................................................... 20
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Work Practice WP1061

TOOLS, EQUIPMENT AND MATERIALS

 2 mm extended handle T-bar Allen key (250 mm long)

 #2 point Phillips head screwdriver

 #3 point Phillips head screwdriver

 2 x 8 mm open ended spanners

 KOPR-KOTE, Anti-seize lubricant (SC16390) or similar

 Cable ties, medium to small in size

 Permanent marking pen

Step 2 Carry out appropriate site specific hazard assessment.

Owner: EGM Operations Release: 9, 29 Jun 2023 | Doc ID: 2955885