Genie range SF6 indoor switchgear

installation, operation and maintenance instructions version 002 / August 2000

Genie range contents

page
general general description introduction weights and dimensions storage installation floor preparation connection of panels connection of busbars installation of pilot cables connection main cable connection busend cable box connection operation operation of switch - main operation of switch - earth operation of circuit breaker - main operation of circuit breaker - earth operation of busbar earthing switch cable testing main cable phase live indication operation of pocket terminal accessing VTs disconnection of V.T.s commissioning introduction physical checks HV. withstand test test voltages test connection maintenance SF6 gas endurance characteristics product support 2 2 2 3 4 4 5 8 9 10 10 11 12 12 12 13 14 14 15 16 16 17 18 19 19 19 19 20 20 21 22 23 23

MERLIN GERIN

Genie range general description

introduction These instructions cover all operations concerning handling, installation, operation and maintenance of the Genie range of equipment.

the range comprises:s CB2 200A circuit breaker s CB6 630A circuit breaker s CB12 1250A circuit breaker s BS6 630A bus section s BS12 1250A bus section s SW6 630A switch s SWE busbar earthing switch The equipment is suitable for indoor use only. It is therefore necessary to protect the equipment from the environment before and during erection/commissioning. Should the busbar chamber or cable box become exposed to the elements, they should be thoroughly cleaned prior to energising. weights and dimensions
unit(s)

circuit breaker/switch

extended circuit breaker

circuit breaker/switch (with bus end cable box)

extended circuit breaker (with bus end cable box)

circuit extended bus-section breaker/switch circuit breaker (with busbar VT) (with busbar VT)

average dimensions (mm) (packed) approx. weight (kg) (packed)

h w d

2380 530 1300 450

2380 770 1300 500

2380 770 1300 500

2380 1010 1300 550

2380 600 1300 550

2380 840 1300 600

2380 770 1300 500

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Genie range storage

note:
lifting chains/ropes should be positioned @1800mm and 1650mm from lifting points, as shown.

note:
lifting chains/ropes should be positioned @1800mm and 1650mm from lifting points, as shown.

0m

0m

180

'F'

important
during lifting of the unit all four lifting points must be used. lifting bars are fixed to unit using existing fixings (marked'F') tightened to a torque value of 10Nm(7.4Ib/ft). new fixings and seals must be used to re-secure the facia after lifting, tighten to a torque value of 5.4Nm(4Ib/ft).

important
during lifting of the unit all four lifting points must be used. lifting bars are fixed to unit using existing fixings (marked'F') tightened to a torque value of 10Nm(7.4lb/ft). new fixings and seals must be used to re-secure the facia after lifting, tighten to a torque value of 5.4Nm(4lb/ft).

180

165 0mm

'F'

'F' 'F'

m 0m 165

LIFTING POINTS

LIFTING POINTS

LIFTING POINTS

LIFTING POINTS

maximum mass = 300kg

maximum mass = 350kg

offloading

All units are delivered on pallets (secured by 2 x M8 screws and nuts). The units can be off loaded by forklift truck or by using a lifting kit consisting of 2 lifting bars and can be off loaded using an overhead crane (see above diagrams).

storage

These units are designed for indoor use and must not be left outdoors. They should be stored in a warm, dry switchroom and protected against dust and debris.

ancillary kits

Ancillary kits containing busbars, dyscon boots, glands, screws etc. are supplied loose with each unit or fastened to the panel or secured in the cable box.

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Genie range installation

floor preparation

Please refer to the arrangement drawing for foundation details.

M10 CHANNEL FIXING FOOT OF UNIT

698

NOTE: FLOOR LEVEL FLUSH TO + - 1mm WITH FOUNDATION CHANNEL

41

SPRING LOADED CHANNEL NUT

70

CHANNELS GROUTED IN POSITION USING SETTING JIGS SUPPLIED

CHANNELS MADE IN SUBFLOOR

The units can be directly bolted to the concrete floor by use of 2 x 10mm rawlbolts for single width panels or 4 x 10mm rawlbolts for bus-section and extended circuit breaker panels. The floor tolerance is 1mm over 1 metre.

Where it is not possible to guarantee that the floor is within the specified tolerance, we strongly recommend the use of foundation channels, i.e. Unistrut P3270 or similar.
note: the floor must be 1mm below the top of the Unistrut

erection/connection circuit breaker, switch, busbar earthing panel

Line up the first panel in position(see Unistrut diagram above). Insert 2 channel nuts into the Unistrut as shown and slide into position. Finger connect the M10 screws at the front and rear of the unit (do not tighten). Manoeuvre next panel into position and repeat. If the panel is being bolted directly to the floor, line up the first panel in position and remove the lower panel front plate. Drill front and back fixing positions through access holes. The recommended drill size is 16mm . Install rawlbolts, (shown above). Finger connect the M10 nuts and washers. Manoeuvre next panel into position and repeat.

access holes
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Genie range installation

connection of panels

Remove pilot cable box (if fitted) . To remove undo the 9 x M6 screws and nuts along the top and rear of the busbar chamber. Place the pilot cable box on the top of the low voltage cabinet. (Approximate weight of pilot cable box is 10kg.)

Remove the busbar chamber top and rear cover plate. To remove undo the 10 x M6 captive screws along the top and rear of the busbar chamber cover.

With the busbar chamber cover removed,bolt the panel busbar chamber flanges together using 10 x m6 screws and nuts via the flange holes along the lower and front edges. Repeat until all panels within the switchboard have been installed and bolted together.

multicore pilot cable riser kit (bottom entry cables)

A multicore pilot riser kit is available for switchboards which require bottom entry multicore pilot cables. This allows easy fixing and support for all multicore cables associated with the switchboard. It can be supplied loose for installation onto an existing switchboard, or factory installed via a busbar trunking. An additional pilot cable tray can be supplied for fitting to the LV compartment to allow the multicores to travel to the relevant panel. Full assembly instructions are provided with the appropriate kits.

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Genie range installation

standard Genie LV cabinet Genie housing

1. Using a hoist or similar offer the LV Cabinet up to the unit as shown. 2. Locate the LV Cabinet onto the Genie Mecho Cover Plate. 3. Fix the cabinet in place using 6 off M6 x 16 Screws with 1 off M6 Form A Washer under the head of each screw.
note: standard LV cabinet door not shown for clarity

wide Genie LV cabinet Genie housing

1. Using a hoist or similar offer the LV Cabinet up to the unit as shown. 2. Locate the LV Cabinet onto the Genie Mecho Cover Plate. 3. Fix the cabinet in place using 6 off M6 x 16 Screws with 1 off M6 Form A Washer under the head of each screw.
note: wide LV cabinet door not shown for clarity

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Genie range installation

connection of front earth conductors and remaining panel fixings

Remove the housing lower front plate by removing 8 x M6 screws. Remove the rear access plates. With the lower front and rear access panels removed, secure the panels using 2 x M6 screws, washers and nuts at the lower panel - panel fixings as illustrated. Connect front panel - panel main earth conductor as illustrated and secure using 1 x M10 screw, washers and nut. Secure the low voltage instrument cabinets together using 1 x M5 screw, washers and nut at the fixing point adjacent to the bus-wiring aperture.

connection of end panel earth conductor

Connect end panel earth conductor as illustrated using 1 x M10 screw, nut and washers at the front and rear fixing points.
note: for inverted MV cable boxes the assembly illustrated dashed should be used.
M10 HEX HEAD BOLT M10 WASHERS M10 LOCK NUT

completing the installation

Ensure all insulation and chambers are clean and free from debris. To complete the installation, tighten all floor fixings, replace all covers, and components removed

REAR EARTH BAR

END PANEL EARTH BAR

connection of rear earth conductor and busbar assemblies

Each panel has an earth conductor fitted at the rear. Bolt these together using 2 x M10 screws, nuts and washers per panel.

SIDE SHEET MAIN EARTH BAR

FACIA

UPRIGHT

bus-section earth conductors

Short front and rear earth conductors for use on bus-sections are provided. The method of connection remains the same as for standard panels. With the busbar fixing studs removed, assemble the busbar system as illustrated opposite. With the busbar system assembled, studs inserted and nuts tightened to the torque advised replace the busbar chamber covers and pilot cable boxes (if fitted) for the complete switchboard.
note: all 20 x M6 screws, nuts and washers should be fitted to the busbar chamber flanges to ensure a tight seal.

REAR EARTH BAR

BUSBAR CHAMBER

INVERTED CABLE BOX

REAR EARTH BAR CONNECTOR PANEL TO PANEL LOWER FIXING

STANDARD CABLE BOX

END PANEL EARTH BAR

Fit the busbar chamber end covers using 20 x M6 fixing screws, nuts and washers.
note: access is required via the busbar chamber top access plates.
M10 HEX HEAD BOLT M10 WASHERS M10 LOCK NUT REAR EARTH BAR CONNECTOR

PANEL TO PANEL LOWER FIXING MAIN EARTH BAR

REAR EARTH BAR SIDE SHEET

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Genie range installation

connection of busbars totally encapsulated

Busbar torque 54Nm Ensure that the environment is clean and dry.

Clean dyscon boots and bushings. Apply DC4, Dow Corning silicon grease to boots. Fit busbars into boots as shown above.

refer to accessory kit instructions for full details note: it is recommended prior to refitting busbar chamber covers that the busbars are tested - see page 20 for typical tests

connection of busbars totally encapsulated and earth screened

MOULDED CONDUCTIVE SCREEN (EARTHED)

INSULATION

EPOXY END PLUG WITH MOULDED METAL INSERT

INSULATED BUSBAR WITH METALISED COATING

INTERNAL SCREEN (LIVE)

Busbar torque 54Nm Ensure that the environment is clean and dry.

Clean dyscon boots and bushings. Apply DC4, Dow Corning silicon grease to boots. Fit busbars into boots as shown above.

note: it is recommended prior to refitting busbar chamber covers that the busbars are tested - see page 20 for typical tests. Please consult us regarding additional tests which may be required for this busbar system.

MERLIN GERIN

Genie range installation

arrangement of bus-section busbars connection of busbars totally encapsulated/earth screened

Busbar torque 54Nm Ensure that the environment is clean and dry. Remove dyscon boots and clean bushings. Apply DC4, Dow Corning silicon grease to boots. Fit busbars into boots as shown.

refer to accessory kit instructions for full details

installation of pilot cables through pilot cable box standard arrangement optional

Remove the pilot cable box cover by unscrewing the 4 x M6 screws. Pilot cables can be installed from above or below using pre-punched gland plates with various sized electrical knock-outs.

Remove the pilot cable box cover by unscrewing the 2 x M6 screws. Pilot cables can be installed from above or below using individual sliding gland plates or by drilling the single sliding plate, as shown.

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Genie range connection

main cable connection

All units are fitted with dry type cable boxes suitable for accepting heat shrink or cold fit termination kits. Accessory kits containing gland plates etc are available. Cable termination torque = 54NM

note: red phase bushing is on rear left of unit. note: ensure that cable is supported by gland plate before placing on bushings.

standard cable entry

inverted cable entry

10

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Genie range connection

bus end cable box connection

standard cable entry

inverted cable entry

Dyscon elbow adaptors

Dyscon dry - type cable terminations are standard on 1250A panels and optional on 200A/630A panels.
note: the hole size in the dyscon palm for connecting the main cable is 14mm for M12 fixing.

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Genie range operation

operation of switch main

Check that the gas indicator is in the green healthy condition. Check the facia diagram for the service condition. Remove padlocks if fitted. Move select to main switch position.

Insert handle as shown and pull down firmly until the switch closes. The selector lever will be locked into the main switch position.

Fit padlock into the handle socket padlock bracket if required. To open, rotate the handle through 180 and reverse the procedure.

operation of switch earth

Check that the gas indicator is in the green healthy condition. Check the facia diagram for the service condition. Remove padlocks if fitted. With the switch in the open position, move the selector lever to earth switch position.

Insert handle as shown and pull down firmly until the switch closes. The selector will be locked in the earth switch position.

Fit padlock into the handle socket padlock bracket if required. To open, rotate the handle through 180 and reverse the procedure.

12

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Genie range operation

operation of circuit breaker main

Check that the gas indicator is in the green healthy condition. Check the facia diagram for the service condition. Remove padlocks if fitted. Move select to main circuit breaker position. Insert handle as shown and pull down firmly to charge springs.

Pull down on lever firmly.The selector will be locked into the main circuit breaker position. Fit padlock into the circuit breaker closed in service position if required.

To store an additional charge on the springs, rotate the handle through 180 and insert as shown. Move handle up to reset and earth off position.

The handle can then be reversed once more and pulled down to store an additional charge. See indicator flag on top of unit.

To open the circuit breaker press the push circuit breaker off button. Fit padlock into the circuit breaker open position if required.

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Genie range operation

operation of circuit breaker earth

Check that the gas indicator is in the green healthy condition. Check the facia diagram for the service condition. Remove padlocks if fitted. With the circuit breaker in the open position, move the selector lever to earth switch position. Insert handle as shown and pull down firmly to charge springs.

Pull down on lever firmly to close to the earth on position. The selector will be locked in the earth position.

Fit padlock into the handle socket padlock bracket position if required. To open rotate the handle through 180 and insert and move handle up to reset and earth off position.
note: the circuit breaker off button will not operate.

operation of busbar earthing switch

Check that the gas indicator is in the green healthy condition. Check the facia diagram for the service condition. Remove padlocks if fitted.

Insert handle as shown and pull down firmly until the switch closes.

Fit padlock into the handle socket padlock bracket position if required. To open rotate the handle through 180 and reverse the procedure.

important note: the busbar earthing switch should only be operated when the busbars are de-energised.

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Genie range operation

cable testing main cable

Ensure that the main earth switch is earth on. This will open the key way. Push in and rotate test access key cover lever 90 clockwise and remove cover.

Insert test access key into the key way (as shown). Push lever in and rotate 90 anti-clockwise. The test access key can be padlocked in position if required.

Unit shown with earth star point connected.

Remove the earth star points as shown to provide access for cable testing. The test access key will be locked in position until the earth star point is firmly replaced. Reverse the procedure to return to service condition.
note : ensure cables are discharged before touching bushings.

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Genie range operation

phase live indication

To test for phase live condition, insert neon indicator lamp into the relevant phase socket as shown. The indicator lamp will illuminate if the phase is live.
note : the neon indicator lamp can be proved before and after insertion using a neon verification box (Kit Ref. RMR-A24).

operation of TSM2001 pocket terminal

Open the facia of the Sepam 2000 and connect the TSM20001 pocket terminal as shown. Refer to Sepam 2000 commissioning manual for further details.

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MERLIN GERIN

Genie range operation

accessing VTs
important note: before accessing VTs (during commissioning or replacing fuses) ensure that the main earth switch is padlocked in the earth on position. If the unit is a bus-section ensure that the bars are earthed or completely isolated. See page 12 for operation instructions.

Remove the lower circuit breaker front cover access panel for access to solid link and fused type connection.

isolation of VTs
Ensure that the main switch is in the Earth On position

Open VT cover on lower front of unit and remove racking handle from its storage position. Insert the racking handle into the top position of the slot. Turn in an anti-clockwise direction as far as it will go and remove handle. The VTs are now disconnected. The handle can now be replaced in the VT cover flap and this can be closed and the panel can be returned to service condition. To re-connect the VTs, the above procedure should be reversed remembering to ensure that the main switch is in the Earth ON position.
in service isolated

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Genie range operation

disconnection of VTs - solid link

note: ensure the circuit is earthed

Pull back the VT insulating boot and loosen the VT connection using a 6mm allen key as shown.

Disconnect the VT as shown.

Reverse the procedure to connect the VTs

disconnection of VTs - fused link

note: ensure the circuit is earthed

Grasp the grey fuse tube and push up until the bottom is clear of the black insulation boot.

Remove the fuse completely from the unit to disconnect the VT.

Reverse the procedure to connect the VTs

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MERLIN GERIN

Genie range commissioning

commissioning
All equipment is subject to stringent quality and operational checks prior to despatch, however it is the owners responsibility to ensure that commissioning tests have been completed to IEC60694. The following is a resume of these tests.

physical checks
Remove all packaging and transit labels from the equipment. Check the data plate details against the specification. Check the operation of the switches/circuit breaker, test access and various interlocks.

functional checks
Check operation of auxiliary switch contacts and remote indication in accordance with the schematic diagram. Confirm the phase relationship of the neon indicator sockets. Check the pick up voltage of auxiliary coils if fitted. Closing coils should operate between 85% and 110% of the rated voltage. Opening coils should operate between 70% and 110% of the rated voltage.
note: all voltages should be applied instantaneously unless otherwise specified

protection and control system

Refer to Sepam commissioning guide or relay manufacturers data.

B2 Y2 R2

high voltage withstand test to BS/IEC

Connect the H. V. test set and carry out the withstand tests in accordance with the following tables.
note: ensure VTs are disconnected prior to carrying out any HV pressure tests

R1
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Y1

B1
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Genie range commissioning

test voltages

rated voltage (kV) 3.6 7.2 12 13.8

AC test voltage (kV) 8 16 23 32

frequency (Hz) 50 50 50 50

duration (minutes) 1 (AC) 15 (DC) 1 (AC) 15 (DC) 1 (AC) 15 (DC) 1 (AC) 15 (DC)

(d.c. test voltage current practice) 7.5 15 25 32

test connection - circuit breaker / switch

test number 1 2 3 4 5 6

CB / switch closed closed closed closed open open

live terminals R, Y, B R, Y Y, B B, R R1, Y1, B1 R2, Y2, B2

earthed terminals frame B, frame R, frame Y, frame R2, Y2, B2, frame R1, Y1, B1, frame

The following tests should also be carried out. If additional information and/or assistance is required please consult us. - primary injection - secondary injection - CT spill test - CT polarity test - relay secondary injection - relay timing and functionality tests

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Genie range maintenance

routine maintenance recommendations to BS6626:1985

Routine maintenance will depend on the conditions to which the unit is subjected and to the relevant codes and practice. Periodic inspection of the

substation and equipment will be necessary to establish the conditions to which the units are subjected to.

ideal conditions gas enclosure no attention

standard conditions no attention

aggressive conditions no attention

mechanism housing

no attention no attention

no attention every 10 years

every 10 years every 5 years

ideal conditions

environmental conditions
Unit installed and commissioned in accordance with the manufacturers instructions Indoors, completely protected from the weather. Humidity below 40% and no dripping water. Minimal dust and air circulation. Ambient temperature between -5oC and +40oC. No contact with any chemical agents (eg. salt). No infestation of any animal life (eg. insects). No contact with any plant life (eg. mould). No earth movements. No damage to the unit of any kind.

operational conditions
No mal-operation of any kind. No abnormally high number of operations - refer to the graph. No abnormally high number of faults - refer to the graph. No over-voltage or over-current (above rating).

standard conditions

environmental conditions
Unit installed and commissioned in accordance with the manufacturers conditions. Humidity below 60%. Unit may be indoors or outdoors within enclosures, but must not be subjected to regular extremes of weather eg. heavy rain storms, dust storms, heavy snow and ice, flooding, temperature cycles greater than 40oC or less than -5oC, dense coastal fog or acid rain. No regular or thick covering of debris. No contact with any chemical agents (eg. salt). No infestation of animal or plant life. No earth movements. No damage to the unit of any kind.

operational conditions
No mal-operation of any kind. No abnormally high number of operations - refer to the graph. No abnormally high number of faults - refer to the graph. No over-voltage or over-current (above rating).

aggressive conditions

Any environmental or operational conditions which do not satisfy either of the above two descriptions must be deemed aggressive.

note: local legislation may dictate maintenance be carried out with greater frequency, irrespective of site conditions. Please contact your local Merlin Gerin representative for further details.

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Genie range maintenance

maintenance

general operation Check that the gas indicator is in the green zone. For circuit breaker panels check the electrical protection system. Check the operation of the unit and all mechanical interlocks.

housing Check all external fixings, labels and earth connections are present and tight. Check inside the MV cable box, busbar system LV cabinet and pilot cable box for heavy deposits of dust, ingress of water or contamination by animal or plant life. Clean the units thoroughly and touch up paint work as necessary.

leakage of SF6
If the gas pressure indicator needle is within the red zone or in the extremely unlikely event of a gas leak contact your local Merlin Gerin office immediately.

mechanism
In the unlikely event of a mechanism failure, please contact Schneider Services.

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MERLIN GERIN

Genie range endurance characteristic

Endurance Characteristics

NUMBER OF OPERATIONS

CURRENT INTERRUPTED (A)

product support s after sales

s for products within warranty (12 months from date of commissioning or 18 months from date of dispatch - whichever is the sooner), please contact our customer service department on Tel: 0113 290 3500 Fax: 0113 290 3710 s for products outside the warranty please contact our Services division on Tel: 0113 284 8900 Fax: 0113 284 8910 s Services division are also able to offer - full spare parts service - maintenance contracts including protection and testing - erection and commissioning of new equipment - system design - training

MERLIN GERIN

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Expertise

Schneider Electric

in electrical distribution, control and automation

Schneider Electric is the leading UK and world expert in the development and manufacture of products for the distribution and industrial applications of electricity. In the UK, Schneider Electric operates from 16 industrial and commercial sites, with 2,500 people, and achieves an annual turnover in excess of 270 million. Schneider offers a full range of products and services for panel builders, OEMs, contractors, specifiers and the electrical supply industry for commercial and industrial applications. Schneider Electric is committed to supporting its customers at every stage of a project. Our 180 sales engineers, is the largest dedicated sales force in the UK electrical industry. Sales engineers are skilled at assessing individual requirements and combined with the expert support of its product specialists, will develop the most effective and economical solution.

Merlin Gerin Medium Voltage, 123 Jack Lane, Leeds LS10 1BS Tel: 0113 290 3500 Fax: 0113 290 3710 Internet address: http://www.schneider.co.uk

Publication No.MV082000 2000 O/S-BP