CGMCOSMOS-2LV MEDIUM-VOLTAGE SF GAS ... version 01 05.07.2011 GENERAL INSTRUCTIONS FOR CGMCOSMOS-2LV MEDIUM VOLTAGE SF6 GAS-INSULATED RING MAIN UNIT UP TO 12 kV Page 3 of 53 CONTENTS

IG-179-GB version 01

05.07.2011

GENERAL INSTRUCTIONS FOR CGMCOSMOS-2LV

MEDIUM VOLTAGE SF6 GAS-INSULATED RING MAIN UNIT UP TO 12 kV

Page 1 of 53

IG-179-GB

version 01

General Instructions

CGMCOSMOS-2LV

MEDIUM-VOLTAGE SF6 GAS-INSULATED RING MAIN UNIT

UP TO 12 kV

05.07.2011

Secondary Distribution Switchgear

Primary Distribution Switchgear

Protection and Automation

Distribution Transformers

Transformer Substations

Low Voltage Boards

LIB

Legal Deposit: 1983/2011

CAUTION!

When MV equipment is operating, certain components are live, other parts may be in movement and some may reach high temperatures. Therefore, the use of this equipment poses electrical, mechanical and thermal risks. In order to ensure an acceptable level of protection for people and property, and in compliance with applicable environmental recommendations, Ormazabal designs and manufactures its products according to the principle of integrated safety, based on the following criteria:

Elimination of hazards wherever possible.

Where elimination of hazards is neither technically nor economically feasible, appropriate protection functions are incorporated in the equipment.

Communication about remaining risks to facilitate the design of operating procedures which prevent such risks, training for the personnel in charge of the equipment, and the use of suitable personal protection equipment.

Use of recyclable materials and establishment of procedures for the disposal of equipment and components so that once the end of their useful lives is reached, they are duly processed in accordance, as far as possible, with the environmental restrictions established by the competent authorities.

Consequently, the equipment to which the present manual refers complies with the requirements of section 11.2 of the forthcoming IEC standard 62271-1. It must therefore only be operated by appropriately qualified and supervised personnel, in accordance with the requirements of standard EN 50110-1 on the safety of electrical installations and standard EN 50110-2 on activities in or near electrical installations. Personnel must be fully familiar with the instructions and warnings contained in this manual and in other recommendations of a more general nature which are applicable to the situation according to current legislation. The above must be carefully observed, as the correct and safe operation of this equipment depends not only on its design but also on general circumstances which are in general beyond the control and responsibility of the manufacturer. More specifically: The equipment must be handled and transported appropriately from the factory to the place of installation.

All intermediate storage should occur in conditions which do not alter or damage the characteristics of the equipment or its essential components.

Service conditions must be compatible with the equipment rating.

The equipment must be operated strictly in accordance with the instructions given in the manual, and the applicable operating and safety principles must be clearly understood.

Maintenance should be performed properly, taking into account the actual service and environmental conditions in the place of installation.

The manufacturer declines all liability for any significant indirect damages resulting from violation of the guarantee, under any jurisdiction, including loss of income, stoppages and costs resulting from repair or replacement of parts. Guarantee

The manufacturer guarantees this product against any defect in materials and operation during the contractual period. In the event that defects are detected, the manufacturer may opt either to repair or replace the equipment. Improper handling of this equipment and its repair by the user shall constitute a violation of the guarantee. Registered Trademarks and Copyrights

All registered trademarks cited in this document are the property of their respective owners. The intellectual property of this manual belongs to the manufacturer. In view of the constant evolution in standards and design, the characteristics of the elements contained in this manual are subject to change without prior notification. These characteristics, as well as the availability of components, are subject to confirmation by Ormazabal’s Technical - Commercial Department.


05.07.2011



Page 3 of 53

CONTENTS

1 MAIN DESCRIPTION....................................................................................................... 4

1.1 CGMCOSMOS-2LV .................................................................................................. 4 1.2 APPLIED STANDARDS............................................................................................ 4

2 COMPONENTS OF CGMCOSMOS-2LV......................................................................... 5

3 TECHNICAL CHARACTERISTICS ............................................................................... 11

3.1 MECHANICAL CHARACTERISTICS: DIMENSIONS AND WEIGHTS................... 11

4 TRANSPORTATION...................................................................................................... 13

4.1 LIFTING METHODS................................................................................................ 13 4.2 LOCATION OF ACCESSORIES DURING TRANSPORT....................................... 14

5 STORAGE...................................................................................................................... 15

6 INSTALLATION ............................................................................................................. 16

6.1 CIVIL ENGINEERING WORKS FOR INDOOR INSTALLATIONS.......................... 16 6.2 UNPACKING THE EQUIPMENT ............................................................................ 17 6.3 FASTENING TO THE FLOOR ................................................................................ 18 6.4 EARTHING THE EQUIPMENT ............................................................................... 23 6.5 CABLE CONNECTION ........................................................................................... 23

7 SEQUENCE OF OPERATIONS..................................................................................... 35

7.1 CHECKING VOLTAGE PRESENCE AND PHASE BALANCE ............................... 35 7.2 OPERATING LEVERS............................................................................................ 36 7.3 FEEDER FUNCTIONAL UNIT ................................................................................ 37 7.4 CIRCUIT-BREAKER ............................................................................................... 41 7.5 CABLE TEST .......................................................................................................... 45 7.6 FITTING THE CABLE COMPARTMENT ACCESS COVER................................... 45 7.7 INTERLOCKS ......................................................................................................... 46

8 MAINTENANCE............................................................................................................. 47

8.1 VOLTAGE PRESENCE / ABSENCE DETECTOR.................................................. 47 8.2 SPARES AND ACCESSORIES .............................................................................. 48 8.3 ENVIRONMENTAL INFORMATION ....................................................................... 48

9 ANNEX 1: ANCHORING DIAGRAM ............................................................................. 50

10 ANNEX 2: AUXILIARY CIRCUITS ................................................................................ 51

10.1 COILS...................................................................................................................... 51 10.2 MOTORIZED UNITS ............................................................................................... 51

11 ANNEX 3: RECOMMENDED CABLE CONNECTION TERMINALS ............................ 52



IG-179-GBversion 01

05.07.2011

Page 4 of 53

1 MAIN DESCRIPTION

1.1 CGMCOSMOS-2LV

CGMCOSMOS-2LV consists of a fully insulated SF6 multifunctional cubicle, which can be used in secondary electrical distribution diagrams up to 12 kV.

It is made up of 3 fully SF6 insulated functional units:

Two feeder functional units

One circuit-breaker protection functional unit.

Figure 1.1: CGMCOSMOS-2LV single-wire diagram

1.2 APPLIED STANDARDS

This cubicle system has been designed to meet the requirements of the following standards:

Standard Description

IEC 62271-1 High-voltage switchgear and control gear Part 1: Common specifications standards.

SANS 1874 / NRS 006

Switchgear – metal-enclosed ring main units for rated A.C. voltages above 1 kV and up to and including 36 kV.

SANS 62271-200 / IEC 62271-200

Alternating current metal-enclosed switchgear and control gear for rated voltages above 1 kV and up to and including 52 kV.

SANS 62271-100 / IEC 62271-100

High-voltage switchgear. Part 100: High voltage alternating current circuit-breakers.

SANS 62271-102 / IEC 62271-102

Alternating current disconnectors and earthing switches.

SANS 60265-1 / IEC 60265-1

High Voltage switches for rated voltages above 1 kV up to and including 52 kV.

SANS 60529 / IEC 60529

Degrees of protection provided by enclosures.

SANS 61243-5 / IEC 61243-5

Voltage detectors - Voltage detecting systems (VDS).

SANS 62271-202 / IEC 62271-202

High-voltage switchgear and control gear – Part 202: High-voltage/low-voltage prefabricated substation.


05.07.2011



Page 5 of 53

2 COMPONENTS OF CGMCOSMOS-2LV CGMCOSMOS-2LV is made up of a series of independent compartments, as shown in the next figure.

1 Pressure relief duct (for outdoor installations) 3c Gas relief compartment

2 Tank 4 Name plate 3 Base 5 Driving mechanism compartment 3a Cable test facilities 6 ekorIVDS 3b Cable compartment

Figure 2.1: Main components of CGMCOSMOS-2LV

1

2

3

4

3a

3b

5

3c

6



IG-179-GBversion 01

05.07.2011

Page 6 of 53

Tank:

CGMCOSMOS-2LV keeps the switching and breaking elements, as well as busbars inside a unique stainless steel SF6-filled tank which is permanently sealed, thus building a fully insulated unit.

Figure 2.2: Tank

The tank has a manometer for checking the gas pressure, which can easily be seen from outside the cubicle. The manometer scale is divided into different colors: red, grey and green. For safe operation, the needle must be in the green zone of the corresponding temperature band.

A membrane at the bottom of the tank allows gases to escape in the event of an internal arc.

Figure 2.3: Manometer

Inside the tank we find:

The Switch-Disconnector and Earthing Switch. This component has three positions: closed, open and earthing.

The operation is carried out using the actuating lever on 2 different shafts in the same driving mechanism: one for the switch (switching between the closed and open positions) and another for the earthing switch (which switches between the open and earthing positions).

These elements are manually operated in an independent way, i.e., their actuation speed does not depend on the speed of the lever during the manual operation.

The protection circuit-breaker and earthing switch: The CGMCOSMOS-2LV protection circuit-breaker uses vacuum switching technology.

The operation is carried out using 2 different actuating levers on 2 different shafts in the same driving mechanism: one for the circuit-breaker (switching from open to closed position)


05.07.2011



Page 7 of 53

and another for the earthing switch (which switches between the open and earthing positions).

During the closing operation of the circuit-breaker, with its actuating lever, the springs are charged and the unit gets prepared for opening.

The circuit-breaker is opened by means of the button on the front of the unit.

The CGMCOSMOS-2LV protection circuit-breaker is also capable to ensure the isolating distance by means of its associated disconnector, and has earthing switching capacity.

These elements are manually operated in an independent way, i.e., their actuation speed does not depend on the speed of the lever during the manual operation.

Driving Mechanism Compartment:

This is the compartment in which the switch-disconnector or the circuit-breaker is actuated, depending on the type of functional unit.

The mimic diagram for the MV main circuit is displayed on the cover of this compartment, and includes all the position indicators for the actuators.

1 Protection unit 5 Status indicators

2 Operation area:

GREY for circuit-breaker YELLOW for earthing switch

6 Voltage presence/absence detector ekorIVDS

3 Spring charge indicator 7 Locking with a padlock

4 Operation counter 8 Manometer window

Figure 2.4: Mimic diagram of circuit breaker function

4

3

1

7

2

8

5 6



IG-179-GBversion 01

05.07.2011

Page 8 of 53

1 Operation area:

GREY for switch disconnector

YELLOW for earthing switch 3 Status indicators

2 Voltage presence/absence detector ekorIVDS 4 Locking with a padlock

Figure 2.5: Mimic diagram of feeder function

NOTE

The B and BM driving mechanisms can be replaced (due to improved characteristics) in any of the three switch-disconnector positions. These positions can be blockedon the B and BM mechanisms by means of a padlockable fixing device, whether or not the function is operating. The BR-AV and BR-AMV driving mechanisms can be replaced in either open or earthing positions (never when the circuit-breaker is closed).

Figure 2.6: Fixing device

DANGER

Only personnel specially trained and approved by Ormazabal can replace the driving mechanisms.

Base:

Made up of the cable test facilities, cable compartment and the gas relief compartment:

Cable test facilities: located in the intermediate front section of the cubicle, it has a cover interlocked with the earthing switch, thus allowing front access to the cable test female bushings.

Cable compartment: located in the lower front section of the cubicle, it has a cover interlocked with the earthing switch and with the cable test facilities. The function has to be in its earthing position and it’s needed to remove the cable test facilities’ cover before you have front access to the Medium Voltage cables.

Figure 2.7: Cable compartment

1

2

4

3


05.07.2011



Page 9 of 53

The cable compartment is designed to contain up to:

1 shielded screw-in terminal per phase with space for the corresponding incoming power cables (three-core or single-core cables for feeders and single-core cables for circuit-breaker).

Cable ties for the power cables.

Earthing bars

Gas relief compartment: This is located in the lower bottom section of the unit. In the event of an internal arc, the gases produced are deflected downwards, to the rear and upside, and in no way affecting any persons, cables, or the rest of the Transformer Substation switchgear.

ekorIVDS

The ekorIVDS unit displays three signals which correspond to each of the phases. The presence of voltage is indicated in each phase by means of flashing indicators.

The ekorIVDS unit indicates presence of voltage within the operating range specified in standard SANS 61243-5 / IEC 61243-5.

Figure 2.8: Voltage presence / absence detector

The ekorIVDS unit displays the following indications:

L1, L2, L3

Display each of the indicator phases The numbering corresponds to the order of the phases, from left to right, seen from the front of the cubicle. Each phase has a test point for checking the phase balance between cubicles.

Test point connected to earth This is only used for comparing the phases.

Voltage presence indicator A flashing light indicates the presence of voltage in that phase.

The purpose of the test points for the three phases and earth is to make it easier to check the phase balance between functional units. Ormazabal’s specific phase comparator ekorSPC can be used to do this.

NOTE

If the indicators do not light up, use other means to check that there is no voltage.



IG-179-GBversion 01

05.07.2011

Page 10 of 53

Name plate

CGMCOSMOS-2LV has a name plate indicating some of the following values:

Figure 2.9: Name plate on CGMCOSMOS-2LV

(*) In the event of a problem or non-conformity, note down this number and send it to Ormazabal's Technical - Commercial Department.

No. Cubicle serial number(*)

Designation Ormazabal cubicle model

General instru. Manual of General Instructions (IG-179)

Standards Regulations applied to the equipment

Ur Rated voltage (kV)

Up Lightning impulse withstand voltage (kV)

Ud Power frequency withstand voltage (kV)

fr Rated frequency (Hz)

Ir Rated current (A)

Class Breaking element classification according to IEC

n Number of mainly active load breaking operations

Ik / Ip Short-time withstand current/Short-time withstand peak value

tk Short-time withstand current time

IAC Internal Arc Classification

SF6 Weight of insulating fluid (g)

Pme Minimum operating gas pressure (MPa)

Pre Gas pressure inside the tank (MPa)

Sequence Circuit-breaker rated sequence

ISC Rated short-circuit switching current in circuit-breaker function (kA)

Ic Cable charging switching current in circuit-breaker function (A)

Year Year of manufacture

TC Thermal class (ºC)


05.07.2011



Page 11 of 53

3 TECHNICAL CHARACTERISTICS

3.1 MECHANICAL CHARACTERISTICS: DIMENSIONS AND WEIGHTS

a Width h Cubicle height f Depth i Bushings height (protection position) g Bushings height (feeder position) k Pressure relief duct height

Figure 3.1: CGMCOSMOS-2LV dimensions (with pressure relief duct - Outdoor installations)

Pressure relief duct height (k)

[mm]

Cubicle height (h)

[mm]

Width (a) [mm]

Depth (f) [mm]

Bushings Height [mm]

Weight [kg]

Feeder Position (g)

Protection Position (i) 1700 1500 1095 940

800 485 440



IG-179-GBversion 01

05.07.2011

Page 12 of 53

a Width h Height

f Depth i Bushings height (protection position) g Bushings height (feeder position)

Figure 3.2: CGMCOSMOS-2LV dimensions (without pressure relief duct - Indoor installations)

Height (h)

[mm] Width

(a) [mm] Depth (f)

[mm] Bushings Height

[mm] Weight

[kg] Feeder Position

(g) Protection Position (i) 1500 1095 823

800 485 420


05.07.2011



Page 13 of 53

4 TRANSPORTATION

4.1 LIFTING METHODS

For indoor installations, the cubicles must always be kept upright, directly on the ground or on a pallet depending on the type of handling involved.

To handle CGMCOSMOS-2LV, one of the following methods must be used:

1. Using a forklift truck or hand-operated pallet truck[1]

Figure 4.1: Lifting CGMCOSMOS-2LV using a fork-lift truck

2. Raising it using slings fixed to the lifting supports on the sides of the top of the

cubicle. The angle of pull should be as vertical as possible (with an angle greater than 60º from the horizontal).

Figure 4.2: Lifting CGMCOSMOS-2LV with slings

ATTENTION

The use of lifting beams is required for cubicle assemblies with control boxes. As the sole exception, slings may be used if the cubicles of the assembly have identical height control boxes installed.

[1] Position the rear of the cubicle facing the driver, to avoid damaging the front.



IG-179-GBversion 01

05.07.2011

Page 14 of 53

3. If it is not possible to use the aforementioned methods, rollers may be used underneath the cubicles. Another option is to slid the cubicles over rods (these same rods can be used to help get over the trench).

4.2 LOCATION OF ACCESSORIES DURING TRANSPORT

During transport, the cubicle must be perfectly seated and fixed so that it cannot move about and possibly damage the equipment.

A number of accessories are supplied with the cubicles, located on the roof of the tank, as indicated in the following figure:

1 Accessory Box

Figure 4.3: Location of accessories during transport

The accessory box contains the following items:

Ormazabal’ s IG-179 General Instructions Document

Actuating levers

Floor fastening assembly

1


05.07.2011



Page 15 of 53

5 STORAGE If it needs to be stored, the equipment must be placed on dry ground or on top of damp-proof insulating material, still in its original packaging.

After prolonged storage, clean all the insulating parts carefully before commissioning the equipment. The enclosure should be cleaned with a clean dry lint-free cloth.

Figure 5.1: Storage

Maximum height above sea level 2000 m

Store in non-corrosive environments

The equipment must be adjusted to the atmospheric pressure of the installation site; otherwise, the manometer needle may indicate an incorrect value (red scale) even if the internal pressure is correct.

55ºC max

- 5ºC min



IG-179-GBversion 01

05.07.2011

Page 16 of 53

6 INSTALLATION

6.1 CIVIL ENGINEERING WORKS FOR INDOOR INSTALLATIONS

The minimum distances to the walls and roof, and from the trench for the MV cables are as follows:

Figure 6.1: Distances for civil engineering works (without pressure relief duct - Indoor installations)

Minimum Distances [mm]

Cubicle Side wall (a) 100 Ceiling (b) 600

Clearance (c) 800 Rear wall (d) > 100

These measurements have been obtained in accordance with the internal arc tests which have been carried out, according to Annex A of standard IEC 62271-200.

a

b

c

d


05.07.2011



Page 17 of 53

6.2 UNPACKING THE EQUIPMENT

CGMCOSMOS-2LV comes wrapped in protective plastic.

On receiving the equipment, check that the goods supplied correspond to the order and associated documentation.

The procedure for unpacking the equipment is as follows:

1. Using a blade, cutter or similar tool, cut the cellophane wrapped around the cubicle[2].

2. Remove the cellophane.

3. Detach the white polystyrene corner pieces.

4. Unscrew the fixings between the base and the pallet.

5. Remove the pallet, handling the cubicle as indicated in section 2.1.

6. Unpack the accessory box located at the top of the cubicle.

7. Remove the self-adhesive protective plastic from the cable compartment cover. Remove the cover.

8. Dispose of any waste in an environmentally-friendly manner.

It is advisable to make a visual inspection of the equipment to check whether it has suffered any damage in transit. If so, contact Ormazabal’s Technical - Commercial Department immediately.

ATTENTION

The self-adhesive plastic must be removed from the cable compartment cover so that the equipment enclosure’s earth connection may have the proper electrical continuity.

[2] It is advisable to cut the cellophane at the rear of the cubicle or at the corner to avoid scratching the surface.



IG-179-GBversion 01

05.07.2011

Page 18 of 53

6.3 FASTENING TO THE FLOOR

Before assembling CGMCOSMOS-2LV, the floor must be carefully leveled to prevent any deformation.

The unit can be fastened to the floor in two ways:

6.3.1 Floor Fastening on a Profile

If the floor of the Transformer Substation is not sufficiently uniform, it is advisable to install the MV cubicle assembly on an auxiliary profile. This profile must be anchored to the floor using expansion screws.

1 M10 x 25 screw 3 Anchoring support

2 66 x 65 x 4 mm profile

Figure 6.2: Location of CGMCOSMOS-2LV on profile

6.3.2 Fastening to the Floor by Anchoring

If the floor of the Transformer Substation is even enough, it is advisable to install CGMCOSMOS-2LV directly anchored to the floor.

The sequence for anchoring the cubicles to the floor is as follows:

NOTE

By default, CGMCOSMOS-2LV is supplied with the switches in earthing position.

1

2

3


05.07.2011



Page 19 of 53

1. The unit's switches must be in the earthing position[3].

2. Remove the two covers of the cable test facilities, using its central handle to pull it up and forward as indicated in the figure.

Figure 6.3: Removing the cable test facilities cover

3. Unscrew the screws and remove the cable compartment cover, using the central handle on the cover to pull it up and forward as indicated in the figure.

Figure 6.4: Removing the cable compartment cover

[3] See section 7. Sequence of Operations



IG-179-GBversion 01

05.07.2011

Page 20 of 53

4. Anchor the cubicle to the floor of the Transformer Substation using screws through the holes made in the base for this purpose. This will prevent vibrations or movements due to short-circuits, possible flooding of the Transformer Substation, etc. Anchoring dimensions are shown in annex 1.

To have access to the front fastening points, the cable support clamp, the rubber grommet and gland plates have to be removed as shown in the figures.

1 Cable support clamp 2 Rubber grommet 3 Gland plates

Figure 6.5: Cable support clamp, rubber grommet and gland plates

Figure 6.6: Cable support clamp removed Figure 6.7: Rubber grommet and gland plates removed

1

3

2


05.07.2011



Page 21 of 53

1 Front fastening points Figure 6.8: Access to the front fastening points

If there is enough free space to access the back of the cubicle, rear fastening points can be anchored through the rear holes of the base.

Figure 6.9: Rear accessibility

1



IG-179-GBversion 01

05.07.2011

Page 22 of 53

In an installation with the cubicle near the rear wall, the intermediate division plate can be dismounted to gain accessibility to the rear anchoring points.

Figure 6.10: Intermediate division plate to be

dismounted Figure 6.11: Access to rear anchoring point

CAUTION

After anchoring the unit to the floor, do not forget to fix the intermediate division plate again. Take special care with the lower flange.

Another possibility for rear anchoring points is to fasten the cubicle to the floor

via the two anchorage holes on the side.

Figure 6.12: Fixing the cubicle with a side “L” piece via holes on the side


05.07.2011



Page 23 of 53

6.4 EARTHING THE EQUIPMENT

DANGER

Earthing the equipment is an essential condition for safety.

At each side of CGMCOSMOS-2LV, connect the end earthing bar to the transformer substation’s general earth connection.

Figure 6.13: earth connector

6.5 CABLE CONNECTION

DANGER

Never touch live connectors, not even screened connectors. Screening does not constitute a protection against direct contact.

When the equipment is in service and a reserve cubicle is left with voltage in the upper busbar and without the cables in the lower bushings, insulating plugs must be placed in the bushings (EUROMOLD type) or close the earthing switch and lock that position with a padlock.

The MV feeder inputs, as well as outputs to the transformer or other cubicles are via cables. These cables and the corresponding bushings on CGMCOSMOS-2LV can be connected with reinforced (screw-in) connecting points, IEC type.

The recommended terminals are described in annex 3.



IG-179-GBversion 01

05.07.2011

Page 24 of 53

6.5.1 Front Connection

1. Close the earthing switch.

2. Remove the cover to access the cable test facilities, using its central handle to pull it up and forward.

Figure 6.14: Remove cable test facilities cover

3. Unscrew the screws and remove the cable compartment cover, using the central handle on the cover to pull it up and forward

Figure 6.15: Remove cable compartment cable cover


05.07.2011



Page 25 of 53

4. The next step varies depending on the type of cable and functional unit. You can thus find two cases:

4a. three-core-cable in feeder position 4b. single-core cable in feeder or protection position

4a. Case of three-core cable (feeder position)

a) Dismount the front angular sheet.

Figure 6.16

b) Dismount the cable support clamp.

Figure 6.17



IG-179-GBversion 01

05.07.2011

Page 26 of 53

c) Dismount the rubber grommet and gland plates.

Figure 6.18

d) Mount the cable support clamp as shown in the figure below. Next, fit the rear gland plate. Then, loosen the cable clamp.

Figure 6.19


05.07.2011



Page 27 of 53

e) Connect the terminals on the front bushings.

Figure 6.20

f) Secure the cables using the rubber grommet, as well as the cable clamp.

Figure 6.21



IG-179-GBversion 01

05.07.2011

Page 28 of 53

g) Mount the front gland plate.

Figure 6.22

h) Mount the front angular sheet.

Figure 6.23


05.07.2011



Page 29 of 53

4b. Case of single-core cable (feeder position and protection position)

a) Dismount the front angular sheet.

Figure 6.24

b) Dismount the cable support clamp

Figure 6.25



IG-179-GBversion 01

05.07.2011

Page 30 of 53

c) Dismount the rubber grommets and gland plates.

Figure 6.26

d) Mount the cable support clamp as shown in the figure below. Next, fit the rear gland plate. Then, loosen the cable clamps.

Figure 6.27


05.07.2011



Page 31 of 53

e) Connect the terminals on the front bushings.

Figure 6.28

f) Secure the cables using the rubber grommets, as well as the cable clamps.

Figure 6.29



IG-179-GBversion 01

05.07.2011

Page 32 of 53

g) Mount the front gland plate.

Figure 6.30

h) In the case of a protection position, mount the current transformers

Figure 6.31


05.07.2011



Page 33 of 53

i) Mount the front angular sheet.

FEEDER POSITION PROTECTION POSITION

Figure 6.32

5. Connect the terminal earth connectors and the cable screen earth connectors if

applicable.

Figure 6.33: Terminal earth connection



IG-179-GBversion 01

05.07.2011

Page 34 of 53

Figure 6.34: View of all the cables connected

6. Put the cable compartment cover back in place. 7. Put the cable test facilities cover back in place.


05.07.2011



Page 35 of 53

7 SEQUENCE OF OPERATIONS

ATTENTION

Before carrying out any operation when voltage is present, check the SF6 gas pressure with the manometer.

ATTENTION

For safety reasons, maintenance operations performed directly on the driving mechanism must be performed WITHOUT any actuating lever inserted.

7.1 CHECKING VOLTAGE PRESENCE AND PHASE BALANCE

Ormazabal’s ekorSPC[4]phase comparator should be used for checking that the MV cables are correctly connected to the Transformer Substation feeder cubicles.

Firstly, connect the red cables of the ekorSPC unit to the corresponding phase test points on the ekorIVDS[5] units, and the black cable to the earth test point. This operation must be repeated for all the phases L1, L2 and L3.

Figure 7.1: ekorSPC unit

Balanced phases Unbalanced phases

Figure 7.2: Comparison of phases

[4] Optionally, other comparison devices which comply with the IEC 61958 standard may be used. [5] See section 1.1.1. ekorVPIS- Voltage Presence Indicator Unit.



IG-179-GBversion 01

05.07.2011

Page 36 of 53

7.2 OPERATING LEVERS

7.2.1 Lever for feeder This lever is used for operating the feeder

functional units of CGMCOSMOS-2LV with driving mechanisms B and BM. It is an anti-reflex lever that is used for closing and opening operations in both the switch-disconnector and the earthing switch.

Figure 7.3: Feeder lever

7.2.2 Lever for circuit-breaker

Two levers are used for operating the BR-AV and BR-AMV mechanisms of the circuit-breaker position of CGMCOSMOS-2LV. One is used for the closing operations of the circuit-breaker. The other is used for closing and opening operations of the earthing switch(this is the same lever as the one used in the feeder functional units).

Figure 7.4: Circuit-breaker levers


05.07.2011



Page 37 of 53

7.3 FEEDER FUNCTIONAL UNIT

7.3.1 Opening Operation from the Earthing Position

1. Move the actuation shaft access handle in the yellow zone to its lower position.

Figure 7.5: Move actuation shaft access handle

2. Insert the lever in the earthing switch

actuation shaft.

3. Turn the lever anticlockwise.

Figure 7.6: Turn lever anticlockwise

4. Remove the lever. The handle returns to its original position.

5. Verify that the feeder is in disconnected

position.

Figure 7.7: Verify feeder disconnection



IG-179-GBversion 01

05.07.2011

Page 38 of 53

7.3.2 Switch Closing Operation from the Open Position

1. Move the actuation shaft access handle in the grey zone to its lower position.


2. Insert the lever in the switch-

disconnector actuation shaft.

3. Turn the lever clockwise.

Figure 7.9: Turn lever clockwise


5. Verify that the feeder is in connected

position.

Figure 7.10: Verify feeder connection


05.07.2011



Page 39 of 53

7.3.3 Opening Operation from the Closed Position



2. Insert the lever in the switch-

disconnector actuation shaft.




5. Verify that the feeder is in disconnected

position.

Figure 7.13: Verify feeder disconnection



IG-179-GBversion 01

05.07.2011

Page 40 of 53

7.3.4 Earthing Operation from the Open Position



2. Insert the lever in the earthing switch-

actuation shaft.




7. Verify that the feeder is in earthing

position.

Figure 7.16: Verify earthing position


05.07.2011



Page 41 of 53

7.4 CIRCUIT-BREAKER

7.4.1 Opening Operation from the Earthing Position




actuation shaft.




5. Verify that the circuit-breaker is in

disconnected position.

Figure 7.19: Verify circuit-breaker disconnection



IG-179-GBversion 01

05.07.2011

Page 42 of 53

7.4.2 Switch Closing Operation from the Open Position



2. Insert the lever in the circuit-breaker

actuation shaft.

3. Move the lever up and down until the status indicator changes.




connected position.

Figure 7.22: Verify circuit-breaker connection


05.07.2011



Page 43 of 53

7.4.3 Opening Operation from the Closed Position

1. Press the red button.

Figure 7.23: Location of red button


disconnected position.

Figure 7.24: Verify circuit-breaker connection



IG-179-GBversion 01

05.07.2011

Page 44 of 53

7.4.4 Earthing Operation from the Open Position




actuation shaft.





earthing position.

Figure 7.27: Verify earthing position


05.07.2011



Page 45 of 53

7.5 CABLE TEST

CGMCOSMOS-2LV is equipped with cable test facilities. For more information on how to perform the cable test, please refer to Ormazabal's Spare parts and accessories instruction document RA-235.

7.6 FITTING THE CABLE COMPARTMENT ACCESS COVER

1. Rest the cover on the lower profile of the base

Figure 7.28: Rest the cover on the lower profile

2. Lift the cover slightly until it engages in the side slots on the base

Figure 7.29: Lift the cover until it engages

3. Push the cover down until the top engages in place

Figure 7.30: Push the cover down Figure 7.31: Tops engaged in place

4. Screw the cover with two M8 bolts.

ATTENTION

Before carrying out any operation it’s mandatory to screw the cover with the two M8 bolts with a 25 Nm torque.

NOTE

To unlock the cable compartment access cover, reverse the sequence of operation.



IG-179-GBversion 01

05.07.2011

Page 46 of 53

7.7 INTERLOCKS

7.7.1 Locking with a padlock

The cubicles are supplied with an independent padlock interlock for both the switch-disconnector, in its closed or open positions, and the earthing switch, in its closed or open positions. Padlocks with ring diameters of between 8 and 12 mm can be used.

Figure 7.32: Feeder Unit with padlock interlock

NOTE

In the case of the circuit-breaker unit, it is also possible to lock it by padlock.


05.07.2011



Page 47 of 53

8 MAINTENANCE

ATTENTION

For safety reasons, maintenance operations performed directly on the driving mechanism must be performed WITHOUT any actuating lever inserted.

The live parts of CGMCOSMOS-2LV´s main circuit and switching equipment do not require inspection or maintenance, as they are completely insulated in SF6 and therefore unaffected by the external environment. Class E2 electrical endurance tests mean there is no restriction on maintenance of the breaking components.

The operating mechanism for CGMCOSMOS-2LV switching equipment does not require lubrication for correct operation, according to the service conditions specified in IEC 62271-1, throughout its estimated lifetime.

These mechanisms must be inspected when used under extreme conditions (dust, salt, pollution). It is advisable to carry out at least one operation during the inspections.

Components manufactured from galvanized sheet steel have been painted to ensure their resistance to corrosion. Any scratches, dents or similar on them must be repaired to prevent corrosion.

8.1 VOLTAGE PRESENCE / ABSENCE DETECTOR

To test the ekorIVDS voltage presence/absence detector, connect it to a 230 Vac power supply. To do this, disconnect it from the cubicle and, using 4 mm terminals, apply voltage between the test point for the phase to be checked and the earth test point. Polarity does not apply to the 230 Vac connection, so the phase and neutral can be connected either way. If an intermittent light signal is observed, the indicator is working correctly. To correctly test the indicator, this check should be carried out for all three phases.

The ekorIVDS indicator can be replaced if necessary. To do so, remove the two screws on the top right and bottom left of the indicator. The indicator can then be disconnected from the base without needing to power down the feeder.

Figure 8.1: ekorIVDS connection



IG-179-GBversion 01

05.07.2011

Page 48 of 53

8.2 SPARES AND ACCESSORIES

Although the unit has been designed for a service life in accordance with IEC 62271-200, certain components can be replaced and installed for various reasons.

NOTE

Certain spares and accessories must be installed in the cubicle by specializedpersonnel. Please contact Ormazabal's Technical - Commercial Department.

Enclosure Switch Disconnector

Position Circuit-Breaker

Position Cable compartment access cover X X Cable test facility cover X X MV cable fixing support X X

Others Switch Disconnector


Position Control box X X Auxiliary profiles for fastening to the floor

X X

If any of the stated auxiliary components need to be changed, the corresponding spare parts kit must be ordered, and the instructions given in the corresponding documentation must be followed.

8.3 ENVIRONMENTAL INFORMATION

CGMCOSMOS-2LV is defined as a sealed, pressurized system, according to IEC 62271-1, which contains sulphur hexafluoride (SF6).

SF6 is included in the Kyoto Protocol list of greenhouse gases. SF6 has a GWP (Global Warming Potential) of 22,200 units. (TAR, IPCC 2001).

[6] Components which can only be replaced by specially qualified Ormazabal personnel. [7] Components which can only be replaced by specially qualified Ormazabal personnel.

Driving mechanism[6] Switch Disconnector


Position B X - BM X - BR-AV - X BR-AMV X Opening coil X X Bistable X X Actuating lever X X

Protection, Metering and Control

Switch Disconnector Position

Circuit-Breaker Position

ekorIVDS[7] X X

ekorVPIS X X ekorSPC X X


05.07.2011



Page 49 of 53

At the end of the product's life, the SF6 contained in it must be recovered for processing and recycling, to prevent it being released into the atmosphere. Extracting and handling of SF6 must be carried out by qualified personnel, using a sealed piercing system. For the usage and handling of the SF6, the indications listed in IEC 62271-303 must be followed.



IG-179-GBversion 01

05.07.2011

Page 50 of 53

9 ANNEX 1: ANCHORING DIAGRAM

Figure 9.1: : Anchoring diagram CGMCOSMOS-2LV


05.07.2011



Page 51 of 53

10 ANNEX 2: AUXILIARY CIRCUITS

10.1 COILS

The electrical characteristics of the coil and contact indicating the switch position are as follows:

Electrical Characteristics

Driving Mechanism BR-AV

Rated Voltage 24 Vdc

Maximum consumption 130 W

Internal Insulation 2 kV

Opening Time 55 ms

Break Time 65 ms

Tripping Coil

Closing Time 55 ms

Switch position indicating contacts

2 NO + 2 NC

Rated Voltage 250 Vac Indicating Contact

Rated Current 16 A

10.2 MOTORIZED UNITS

The electrical characteristics are as follows:

Electrical Characteristics Driving

Mechanism BM

Driving Mechanism

BR-AMV

Rated Voltage 24 Vdc 24 Vdc

Peak current <5 A <15 A

Motor operation time 3 s <20 s

Motorized units

Motor Consumption 50 W 50 W Switch indication contacts 2 NO + 2 NC 2 NO + 2 NC

Earthing indication contacts 1 NO + 1 NC 1 NO + 1 NC Rated Voltage 250 Vac 250 Vac

Indicating Contact

Rated Current 16 A 16 A

NOTE

The electrical diagrams are supplied with the order documents.



IG-179-GBversion 01

05.07.2011

Page 52 of 53

11 ANNEX 3: RECOMMENDED CABLE CONNECTION TERMINALS

Cable connections

12 kV Type Cable

Connector Manufacturer Current rating

[A] Connector type Section [mm2]

630 450SR 70-300

630 400LB 50-300

630 400TB 70-300 EUROMOLD(*)

630 440TB 185-630

KABEL-DRAHT 630 SEHDT13 185-240

SCREENED

NKT 630 AST 10/630 25-240

EUROMOLD(*) 630 15TS 35-630

KABEL-DRAHT 630 SEHDG12 35-185

630 UHGK+RICS 120-300

Dry insulation

NOT SCREENED

RAYCHEM 630 IXSU+RICS 16-800

SCREENED EUROMOLD(*) 630 K-400TB-MIND 25-240

630 UHGK+RICS 120-300 Impregnated

cable NOT SCREENED RAYCHEM

630 IXSU+RICS 16-800 (*) Connectors tested in CGMCOSMOS cubicles.


05.07.2011



Page 53 of 53

NOTES



IG-179-GBversion 01

05.07.2011

Page 54 of 53

NOTES


05.07.2011



Page 55 of 53

NOTES

TECHNICAL – COMMERCIAL DEPARTMENT:

www.ormazabal.com

Documents

CGMCOSMOS-2LV MEDIUM-VOLTAGE SF GAS ... version 01 05.07.2011 GENERAL INSTRUCTIONS FOR CGMCOSMOS-2LV MEDIUM VOLTAGE SF6 GAS-INSULATED RING MAIN UNIT UP TO 12 kV Page 3 of 53 CONTENTS