ABB SafePlus XT, Installation And Operating Instructions Manual

Page 1: ...L SafeRing XT SafePlus XT Installation and operating instructions Compact and Smarter No live parts exposed High reliability and safety Safe and easy for operators in both maintenance and operating conditions ...

Page 2: ...ng XT SafePlus XT can be supplied in a number of different configurations suitable for most switching applications in 12kV distribution networks Digital solutions like smart automation control and monitoring diagnostics features make it a reliable solution for smart networks and substations ...

Page 3: ...ransport and handling 12 13 3 1 Packing 3 1 2 Transport 3 1 3 By receiving inspection 3 2 Storage 3 2 1 Intent 3 2 2 Codes and standards 3 2 3 Storage condition 4 Technical data 14 4 1 Electrical data SafeRing XT SafePlus XT 5 Installation 15 17 5 1 Standard 3 Way Ring Main Unit 5 2 3 way Ring Main Unit 3 way Ring Main Unit Coupling 5 3 Standard 3 Way Ring Main Unit Metering Module 6 Dimensions 18...

Page 4: ... 9 1 External busbar 10 Current and voltage transformers 30 31 11 Motor operation 32 12 Protection 33 13 Pressure indicator 34 35 13 1 Gas pressure 13 2 Altitude 13 2 1 Adjustment of gas pressure in higher ltitudes 14 Operation of the switchgear 36 37 14 1 Operating conditions 14 2 General warnings and precautions 14 3 Putting into service 14 4 Start up 15 Operation 38 41 15 1 Operation of C modul...

Page 5: ...5 19 1 Procedure for switchgear with test points 19 2 Procedure for testing directly on the cable connector with the cable connected to the switchgear 20 Service and maintenance 46 49 20 1 General warnings and cautions 20 2 Maintenance intervals 20 3 Inspection general aspects 20 4 Servicing instructions 20 5 Repairs 20 6 Tool list SafeRing XT SafePlus XT 21 Environmental certification 50 21 1 Lif...

Page 6: ...er s personnel are responsible for all matters regarding safety in the workplace and correct use of the switchgear 1 3 Crucial information Pay special attention to the information shown in the manual by the following attention symbol After this symbol there are four different explanations indicating what types of injuries or damages can be caused should the recommended precautions not be followed ...

Page 7: ...ods and Initiate the Permit To Work PTW process STEP 2 Clearly identify the work location and equipment Use your senses to identify problem areas Define the work area via barriers and barricading and label equipment Avoid distractions such as talking or texting on phone STEP 3 Disconnect all sources and Secure against reconnection Perform switching when required and only while wearing the proper P...

Page 8: ...hnicians engineers and approved channel partners Certification to perform installation and commissioning maintenance and repairs extension upgrade and retrofit end of life services and replacements at site 1 6 Disclaimer When carrying out the installation work you and your company agree s that the installation is performed solely at your own risk and that ABB shall not be liable for any damage or ...

Page 9: ...ty due to its extendibility and the possible combination of fully modular and semi modular configurations with a maximum of 5 modules in one SF6 tank The units are delivered from the factory ready for installation Routine tests are carried out on all units modules before dispatch No special tools are required for installing the equipment Available modules are C Cable switch D Direct cable connecti...

Page 10: ...onnector Operation handle access 10 Switch Disconnector Operation selector knob 11 Fault passage indicator 12 VCB Push button Open Close 13 Spring Charging Indicator 14 VCB Open Close Indicator 15 Voltage presence indicator 16 Disconnector On Off Earth Indication 17 Disconnector operation handle access 18 Protection relay 19 Disconnector operation selector knob 20 VCB V Module Mimic 21 Switch Disc...

Page 11: ...ng Module 1 Lightning arrester jumpers 2 Lightening arrester 3 Insulating boots 4 R Y B jumpers assembly 5 Extension bushing assembly 6 Lifting angle lugs 7 Auxiliary PT 8 12 kV PT 9 Low voltage and battery compartment 10 FRTU compartment Figure 2 4 Metering Module outer assembly ...

Page 12: ...ny such damage has occurred a claim must be submitted to the carrier immediately After unpacking the following must be checked 1 Operating handle A one piece is included normally fixed on inside of main door 2 Check that the pointer on the pressure indicator B is in the green area 3 Carry out a function test on the mechanical parts 4 Visual check of the switchgear Any faults or omissions must be r...

Page 13: ...o store the unit under covered area in a dry and well ventilated area until it is installed and put into operation Although product is outdoor it is recommended to avoid storage of the packed unit under open to sky area for longer period of time not more than 3 4 months The ground surface level where the unit is stored should be fairly flat and free from all type of debris The wooden pallet base s...

Page 14: ...isconnector kVp 110 110 110 Rated normal current A 630 630 Rated frequency Hz 50 50 50 50 Breaking capacities Active load breaking current A 630 Closed loop breaking current A 630 Cable charging breaking current A 63 31 5 Line charging breaking current A 1 10 Earth fault breaking current A 190 Cable and line charging breaking current under earth fault conditions A 110 Short circuit breaking curren...

Page 15: ... NOTE The tools required for installation and maintenance of the switchgear are specified in the tool list in chapter 20 6 Unit A B C D E 1 way 340 190 290 170 85 2 way 665 515 615 325 170 3 way 990 840 940 650 170 4 way 1315 1165 1265 975 170 5 way 1640 1490 1590 1300 170 5 1 Standard 3 Way Ring Main Unit Figure 5 1 Foundation details Standard 3 Way RMU ...

Page 16: ... 3 Way Ring Main Unit Metering Module Ring Main Unit 1 Refer Chapter 5 1 NOTE The unit must be fixed using the bolts shown in the position in red Use M10 or M12 screws NOTE The tools required for installation and maintenance of the switchgear are specified in the tool list in chapter 20 6 Ring Main Unit 1 Ring Main Unit 2 Figure 5 2 Foundation View coupled RMU Figure 5 3 Foundation View Standard 3...

Page 17: ... Hex Nut Foundation Bracket of RMU M10 Hot Dip Galvanized Cup Washer Hot Dip Galvanized M10x100 Anchor Bolt Maximum limit is 60mm 40mm Hot Dip Galvanized M10x100 Anchor Bolt Foundation Bracket of RMU 40mm Wherever it is not possible to have proper leveling use channel ISMC 75 as per IS 2062 1999 Alternatively unit can be directly bolted to the concrete foundation with suitable M10 Fischer bolts Fi...

Page 18: ...are preliminary and may change after final design preparation based on final scope of supply and installation details of the switchgear As a consequence provided values of dimensions and weights are NOT to be considered as final but only for standard reference purposes ACCORDINGLY YOU EXPRESSLY ACKNOWLEDGE AND AGREE THAT VALUES OF DIMENSIONS AND WEIGHTS PROVIDED HEREIN ARE NEITHER FINAL NOR BINDIN...

Page 19: ...re Melting decomposing and evaporation of materials Tested according to IEC standard 62271 200 The capability of SafeRing XT SafePlus XT switchgear to withstand internal arc is proven by type tests performed according to internal arc classification IAC as described in the standard IEC 62271 200 as follows Accessibility A and B switchgear A Accessible to authorized personnel only 300 mm safety dist...

Page 20: ... the basic parameters below Basic parameters of set up IAC AFLR up to 10 kA 0 1s 21kA 1s Minimum height of ceiling 3000 mm Recommended distance to Rear Lateral wall 800 mm with accessible Rear Lateral side 100 mm recommended for non accessible Rear Lateral side 700mm Minimum height of the cable trench 700mm Minimum depth of the cable trench Distance from ground level 7 2 Non arc proof version The ...

Page 21: ... be open when Disconnector or Switch disconnector is in Off or On condition 2 Cable door Can be opened only when particular module earth switch is in On position 3 Once the door is open Disconnector or Switch disconnector operation access is blocked Refer Chapter 19 Cable testing and Chapter 8 1 3 Defeat interlock for more information 2 Ensure the Switch Disconnector Disconnector of respective mod...

Page 22: ...d then Push inside 3 Slide down 10 12mm the door completely till it locks and engage properly with cable compartment slots 4 Cable door can t be refix when Disconnector or Switch disconnector is in Off or On condition 5 Cable door Can be refix only when particular module earth switch is in On position 3 Lift the door upward direction then tilt outward and open door completely Figure 8 2 Removal of...

Page 23: ...nector operation selector knob 3 Defeat Interlock Plate 4 Handle for defeat Interlock 5 Clockwise rotation blocking pin for V module selector knob Blocks the clockwise rotation for V module selector knob to restrict the ON operation of Disconnector 6 Anti Clockwise rotation blocking pin for V module selector knob Allows anti clockwise rotation of selector knob only when Defeat interlock is perfect...

Page 24: ...w in reverse direction Ensure the Switch Disconnector Disconnector of respective module is in Earth position iii Dis engage the defeat interlock from flange C ii Lift the Defeat interlock 10 12mm i Pullout defeat interlock from Pin i Once all the work is done refix the cable door For more details refer chapter 8 1 1 8 1 2 DANGER Defeat interlock will allow the operation from Earth to Off Or Off to...

Page 25: ... phase positions sequence 3 Cables correctly clamped and gland area sealed properly to avoid dust verm entry All 3 cables in 3 core terminations cut and adjusted properly so that cable lug hole and M16 copper hole of cable bushing is concentric In case of a cable length mismatch no tool or crooked method employed by which cable bushing are stressed Dust or other particles accumulated because of im...

Page 26: ...an integrated earthing wire Delivered in 3 phase kits complete with cable lugs bolt connection and stress grading adapter designed to ensure a reliable installation Screened touchproof separable connectors for cable size upto 300 sq mm 400Sq mm contact ABB can be used in SafeRing XT Available options Types SafeRing XT SafePlus XT can be supplied with the bushings as shown below Following pictures ...

Page 27: ...e following manufacturers of cable terminations are recommended SafeRing XT screened termination kit suitability Single Cable Double cable 1 Cable Surge arrester Sr No Make Company Model Model Model 1 NKT CB 24 630 CC 24 630 CSA M16 630 2 Nexan Euromold 480TB G 3 Tyco Raychem RSTI 58 RSTI CC 58 RSTI 58SA 4 3M 93 EE 705 6 5 Prysmian MSCEA 630 6 Sudkabel SET 24 7 BBC Cellpack CTS 630 24kV CTKS 630 2...

Page 28: ... termination remove the bottom cover of the RMU for easy routing pulling of cables Ensure once termination is completed bottom cover is refixed with proper hardware as per table WASH N_ISO7089_8x16x1 6 PA6 NC WASH SP_DIN6796_8 4 18 X39CRM017 1 PL HEX HD SCR_ISO4017_M8X20 A4 70 PL Figure 8 18 Bottom cover details 8 6 Earthing Of RMU Rear side earthing connections are provided on both end of RMU for...

Page 29: ...D OPER ATING INSTRUCTIONS 9 Extension of switchgear Figure 9 1 Coupled SafePlus XT 3 way unit CCV CCV 9 1 External busbar SafePlus XT can be equipped with a side extension See separate document 2REA063298 for more details ...

Page 30: ...the easy termination of cables adjustable arrangements are given for current transformers A Up Down Front Rear adjustments are possible NOTE Make and size of the CT s shown for representative purpose only As per requirement it will vary A Figure 10 1 CT Mounting details Figure 10 3 CT Fixing Step 02 Figure 10 4 CT Fixing Step 03 SafeRing XT SafePlus XT can be equipped with current transformers Fig...

Page 31: ... the hardware 6 Then fix the upper CT Engage the teeth of the CT plate with the slot and then tightened the hardware Figure 10 5 CT Fixing Step 04 Figure 10 6 CT Fixing Step 05 Each current transformer must be mounted onto its high voltage cable before the cable termination is fitted Once cable termination job completed ensure M8 hardware mounted Left Right side A on highlighted area to restrict t...

Page 32: ...ted behind the front mimic The mechanisms for all the switches and breakers are operated manually with the operating lever standard or are fitted with motor operation additional equipment For upgradation retrofitting of motorized operation refer separate document number 2REA064412 Figure 11 1 Motor ring switch Figure 11 2 Motor VCB ...

Page 33: ...have been delivered and that they are all of the same type Check that the current transformers are of the correct type with the correctly rated transformer ratio for the distribution transformer s rated current and for the adjustment range on the protection relay see protection relay manual Relays with auxiliary voltage SafeRing XT SafePlus XT with vacuum circuit breakers are delivered with self p...

Page 34: ...s with a nominal pressure of 1 3 bar absolute at 20o C SafeRing XT SafePlus XT are sealed for life and fitted with a temperature compensated pressure indicator WARNING Operation when pressure is too low pointer in red area If pointer is in red area the operation of the switchgear can not be done under live conditions voltage on SF6 gas needs to be topped up according to instruction and the filling...

Page 35: ...he sealing between the pressure indicator and the valve is smooth and clean and screw the pressure indicator to the RMU switchgear with tightening torque max 45 Nm as shown below Figure 13 4 Unscrewing of Manometer NOTE Screw unscrew on thiS C hexagonal nut only The pressure indicator can be dismounted from the switchgear without SF6 leakage from the SF6 tank 13 2 Altitude Height above sea level f...

Page 36: ...s follows Testing of the switching device or the vacuum interupter to VDE 0671 part 100 or IEC 62271 100 at the relevant rated power frequency withstand voltage may only be performed by trained personnel observing the stipulations of the EU basic standard Stipulation 96 29 Euratom of the senate from 13 May 1996 ABI L 159 from 29 June 1996 Application of the rated power frequency withstand voltage ...

Page 37: ...e SF6 gas pressure of the tank It needs to be at green level before operating the switchgear Instruct local operators regarding the basic features for correct use of the switchgear Other checkpoints Depending on the allocation of responsibilities it may also be necessary to check the following equipment in the vicinity of the switchgear Power cables Auxiliary cables Auxiliary power source Remote c...

Page 38: ...or OFF ON Earth Figure 15 1 ON OFF EARTH indications Figure 15 2 C Module switch disconnector in OFF position Figure 15 3 C Module selector knob Figure 15 4 Operation of C Module switch disconnector Figure 15 5 C Module switch disconnector in ON position Earthing switch Selector Knob Rotate anti clockwise then insert operating handle To Close Turn the operating handle anti clockwise To Open Turn t...

Page 39: ...system The Switch disconnector is only switched after pressing these buttons Red A push button for switch Off the Switch disconnector Green B push button to switch On the Switch disconnector A Green push button closes the switch B Red push button opens the switch C Spring Charge Discharge mechanical indication for circuit breaker D Mechanical Counter for Number of operations of Vacuum Circuit Brea...

Page 40: ...indicator will indicate discharged 6 If the vacuum circuit breaker is equipped with motor operation optional it is not necessary to charge the spring by hand The motor starts charging the spring automatically as soon as the auxiliary voltage is switched on 7 Push red button to Open the VCB 8 Once VCB Opened Indicator will change to 0 Figure 15 18 VCB operation step 5 Figure 15 19 VCB operation ste...

Page 41: ...g handle To Close Turn the operating handle clockwise To Open Turn the operating handle anti clockwise Earthing switch Operation Selector Knob Rotate clockwise then insert operating handle To Close Turn the operating handle clockwise To Open Turn the operating handle anti clockwise Figure 15 22 Disconnector in Off Position step 1 Figure 15 23 Disconnector selector knob step 2 Figure 15 24 Disconne...

Page 42: ... remove the front mesh C DANGER Make sure there is no voltage in the busbars and cable terminals and that the risk of reconnection is eliminated in all units Any remote control must also be prevented DANGER Always check voltage presence before start of any work inside M module NOTE Ensure that HV fuse dummy fuse is inserted properly into both upper and lower fuse holder A C B Figure 16 1 RMU Meter...

Page 43: ...necessary to improve visibility by additional means Operating temperature The VPIS will operate reliably over a temperature range of 25 C to 50 C Phase comparison and testing of VPIS Each phase of the integrated voltage presence indicating system has a connection point on the front panel which can be used to perform phase comparison and to test the voltage presence indicator Threshold values for v...

Page 44: ... is obtained by opening the top front LV door panel A A shunt trip coil and Close coil AC or DC can be fitted on V Module Circuit breaker 18 2 Remote control and monitoring unit SafeRing XT SafePlus XT can be equipped with an integrated remote control and monitoring unit B This unit is pre engineered and can be delivered and installed as a retrofit solution or complete from factory B A Figure 18 1...

Page 45: ...e for testing directly on the cable connector with the cable connected to the switchgear 1 Open switch disconnector disconnector 2 Check voltage status 3 If voltage is not present close the earthing switch 4 Open cable compartment cover 5 Connect test rod or test lead to cable connector keeping the cable connected to the switchgear 6 Insert defeat interlock Refer Chapter 8 1 3 to open the earthing...

Page 46: ... out always depend on the operating conditions of the switchgear and above all on the mode of operation the number of rated and short circuit current switching operations ambient temperature pollution etc The maintenance intervals and measures to be taken that are given in table below are recommended for SafeRing XT SafePlus XT under normal service conditions Three year intervals are recommended f...

Page 47: ...scharges occur as a result of condensation application of a thin silicone film over the surface concerned is often effective as a temporary remedy It is advisable to ask the ABB after sales service department for advice regarding permanent solutions to this uncommon type of problem Repair measures If any irregular conditions are detected appropriate servicing or repair measures must be taken 20 4 ...

Page 48: ...g plier ergo X Strippling plier X Universal plier Bits set with screwdriver handle X 3 8 Long ratchet L 50 cm X 3 8 Pipe set Content 3 8 ratchet L 24 cm 3 8 extender L 3 7 5 cm 3 8 Bits holder 8 mm 3 8 pipe 10 mm 3 8 pipe 11 mm 3 8 pipe 12 mm 3 8 pipe 13 mm 3 8 pipe 14 mm 3 8 pipe 15 mm 3 8 pipe 17 mm 3 8 pipe 19 mm 3 8 pipe Bits PH 1 X Bits PH 2 X Bits FT 4 Bits FT 5 5 x Bits PZ 1 Bits PZ 2 X Bit...

Page 49: ... key set 1 5 10 mm Tools Required Extra tools Head lamp LED Flashlight LED Multi purpose service spray 5 56 Permanent Marker Small cable ties L 203 x 2 5mm Large cable ties L 375 x 7 6mm Multimeter UT58B Insulation tape Tesaflex 53948 Working Gloves Specialist Cloth Scotch Brite Silicon handling glove Nitrile powder free Hammer 12 oz Clamp 300 x 100 mm Bow saw nr 10 12 300 mm Extra bow saw blades ...

Page 50: ...on quartz 15 3 6 Yes Grind to powder and use as high grade energy additive in cement mill Rubber 2 2 2 Yes High grade energy additive in refuse incineration SF6 gas 2 7 0 6 Yes ABB India Ltd reclaims used SF6 gas recyclables 401 97 32 Unspecified 9 00 No Total weight 410 100 Packing foil 0 20 Yes High grade energy additive in refuse incineration Wooden pallet 21 50 Yes Re use or use as energy addi...

Page 51: ...t discharge SF6 into the atmosphere Use an SF6 servicing unit with filler system Check the connections for gas tightness Work which generates strong heat e g welding is prohibited Do not smoke eat drink or store foodstufs in the switchgear room Protect your hands Wear protective gloves to avoid physical injury and contact with liquid gas PROTECTIVE ACTION AND RULES OF BEHAVIOUR Leakage Turn of the...

Page 52: ...system room Opening of and working on or in opened SF6 gas compartments additional measures please complete and delete where not applicable Only open SF6 gas compartments after complete empyting and equilization with atmospheric pressure Use personal protective equipment Protective gloves acid resistent Disposable goggles Protective overalls with hood Skin protection Breathing mask fiber or closed...

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