Mcset 4 Installation Guide

Installation instruction

Medium Voltage switchgear

MCset 4 - 24 kVWithdrawable SF6 circuit breaker

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General 4Glossary 4Symbols 4Recommendations 5Standard tightening torques 6List of bags and accessories 6

Approximate dimensions and weights 7Gas exhaust version 7Gas exhaust version with IPX� protection unit 8Internal arc version with protection on 3 sides 9Internal arc version with protection on 4 sides �0Internal arc version with protection on 4 sides with IPX� protection unit ��Cubicle AD4 (for unit entry from above) �2Cubicles CL4-GL4 (for unit entry from above) �2

Handling instructions 13Packaging �3Handling �4Storing �5

Installation and operation recommendations 16The switchgear’s resistance to ageing in an MV substation �6 Operation and maintenance �6 Unpacking 17Unpacking �7Tools �7

Floor finishingand cubicle fastening 18Surface condition �8Floor quality �8 Description of the fixing rails and accessories �8Placing and adjusting on standard civil engineering works �8Placing and adjusting on earthquake resistant civil engineering works 20

Mobile part extraction 22Safety rules for use 22 Extraction and lowering tool 22Without lowering (extraction table) 22Mobile part extraction 23 Procedure to draw-out the mobile part 23 Procedure to draw-in the mobile part 26 Procedure to extract the VT’s 29 Procedure to insert the VT’s and to close the MV cable compartment 3�

Contents

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Access to the interior of the cubicle 33AD4 - RD4 cubicle 33CL4 cubicle (bus-section) 34CL4 cubicle (bus-section) with upstream CT’s 35GL4 cubicle (bus-riser) 36TT4 cubicle 37DI4 cubicle 38AD4 cubicle incoming from the top (RHC) 39

Installation instructions 40Preparation of the cubicle to the positioning 40Adjusting cubicles on standard civil engineering works 4� Fastening to the floor on standard civil engineering works 4�Fastening to the floor on earthquake resistant civilengineering works 42 Verify correct positioning 42Assembly tunnel 43Cubicle coupling 47 Connection of earthing busbar 54End panels assembling 55Fitting the main busbars 60�250A main busbars 6�2000 / 2500A main busbars 62Fitting joint covers 63Positioning the joint covers 65

Connection of the LV cables 66LV cable connections 66Closing the top entry LV cable steel sheet. 67

Earthing circuit equipotential connection and MV cable earthing 68Starting conditions 68 Equipotential connection of the switchboard’s earth to the substation earth 68Connection of MV cables 69One single core or three-core cable per phase 69� to 4 single core cables per phase 70 Three-core cable per phase 70Anchoring supports for MV cables 7�Earthing of MV cable shields 72Earthing of MV cable shields (DI4) 72Final operations 73

Fitting fuses in DI4 cubicle 74

Contents

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Tests on site 75Checking and cocking the internal arcing detector 75Voltage test on the main circuits 76How to prepare the units 76Operations to be carried out on the unit to be connected to the testing equipment 77 Withdraw the VT fuses 77Close the earthing switch 78Prevent the insertion of the circuit-breaker 79Open the earthing switch 80Restore the possibility of circuit-breaker insertion 8�After performing the test 8�

Contents

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Nota: this document is available for all the units ordered from the �st of March 2008.

General

SMALT operation

Symbols

Glossary UF Functionnal Unit (cubicle + mobile part + Sepam)gas exhaust basic version, without internal arc withstand

AD4 incomming / outgoing cubicle

RD4 incomming / outgoing cubicle (without circuit-breaker)

CL4 - GL4 withdrawable line coupling cubicle

TT4 mesurement and busbar earthing cubicle

AD4 RHB - RHC bus riser cubicle trough the top

DI4 fuse switch outgoing cubicle

TT voltage transformer

TC current transformer or current sensor

VPIS Voltage Presence Indicating System

LV low voltage

MV voltage class 24 kV

SMALT earthing switch

BB busbar

mobile partSF withdrawable circuit-breaker with SF6 breaking which is used in

AD4 and CL4 cubicles

ERT rack-in or rack-out and removal tool of the mobile parts on the ground

extraction table extraction or insertion table without the removal tool of the mobile parts on the ground

Operation position.

Open earthing switch mechanical indicator.

Close earthing switch mechanical.

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It is compulsory forbidden to remove the parts bearing this marking when the equipment is energised.

It is compulsory forbidden to walk on the parts bearing this marking.

Marking

All type of equipment installation such as lamp or light are forbidden.Installation above the switchboard

of ceiling H u 2.80m to install a tunnel (even 2.90m for internal arc performance 31.5kA - 0.15s).installationI

It is necessary to have a height

Height (H) of ceiling for tunnel

Mobile part operationOperating position.

Plug-in position.

Withdrawn position.Insertion / extraction position.

Recommendations

General

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List of bags and accessories

The elastic washers placed on the external sides of the pads and busbars ensure better distribution of stress regarding bolts tightened to the recommended torques.

Application methods:(non greased screws and bolts)

Standard tightening torques

screw torque in NmØ 6 �3

Ø 8 28

Ø �0 50

Ø �2 75

Ø �4 �20

package contentswitchboard end and fixing parts

- switchboard end sheets- tunnels- cubicle fixing rails (lengh: 2m) - bag of screws and expansion pins

cubicle component* (bag located inside of each cubicle)

- busbar- bag of screws

standards accessories (bag located inside of the 1st cubicle of the switchboard)

- operating crank- identification front plates- civil engineering guide- installation instruction- using instruction

mobile part tools - ERT or extraction table

package (may be supplied)

content

spare parts (bag located inside of the 1st cubicle of the switchboard)

- fuses, cranks, etc.

optional accessories

- earthing truck (independant box)

- phase balance testing device

- mobile part tools: ERT or extraction table (independant box)

* the VT’s fuses are already fitted inside their compartment in the cubicle.

General

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Approximate dimensions and weights

Gas exhaust version

Dimensions AD4 CL4 + GL4 TT4 RD4 DI4width (mm) 900 900 + 900 900

height (mm) internal arc withstand 25kA - 1s 2325

internal arc withstand 31.5kA - 0.15s 2377 2377

depth (mm) �750 + 40

Approximate weights (without LV cables or accessories) AD4* CL4 + GL4 TT4 RD4 DI4weight (kg) �300 900 + 500 650 750 550

* with 2 CT’s per phase, circuit breaker and withdrawable VT compartment.

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Gas exhaust version with IPX1 protection unit




depth (mm) �84�




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Internal arc version with protection on 3 sides (wall installation)

Dimensions AD4 CL4 + GL4 TT4 RD4 DI4

width (mm) 900 900 + 900 900



depth (mm) �900 + 40




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Internal arc version with protection on 4 sides, in substations with a ceiling height between 2.8** and 4m



internal arc withstand 31.5kA - 0.15s 2784** 2784**

depth (mm) �900 + 40

Approximate weights (without LV cables or accessories) AD4* CL4 + GL4 TT4 RD4 DI4weight (kg) �350 �025 + 625 800 950 700

* with 2 CT’s per phase, circuit breaker and withdrawable VT compartment.** for internal arc performance 3�.5kA – 0.�5s, the minimum ceiling height will be 2.9m.


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Internal arc version with protection on 4 sides in a substation with a ceiling height of 2.8** to 4m with IPX1 protection unit



internal arc withstand 31.5kA - 0.15s 2784** 2784**

depth (mm) �99�

Approximate weights (without LV cables or accessories) AD4* CL4 + GL4 TT4 RD4 DI4weight (kg) �350 �025 + 625 800 950 700

* with 2 CT’s per phase, circuit breaker and withdrawable VT compartment.** for internal arc performance 3�.5kA – 0.�5s, the minimum ceiling height will be 2.9m.


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Cubicle AD4(for unit entry from above)

Dimensions AD4 CL4-GL4width (mm) 900 900 + 900

height (mm) internal arc withstand 25kA - 1s 2325 2325


depth (mm) 2250 + 40 2250 + 40

Approximate weights (without LV cables or accessories) AD4* CL4-GL4weight (kg) �400 ��00 + 500


Cubicles CL4-GL4 (for unit entry from above)


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Warning

Do not walk on the top of packaged units.

- The units may include or not the circuit-breaker.

- The units are shipped on a pallet, in a closed crate.

Marine packaging

- the units may include or not their circuit-breaker.

- The units are shipped simply placed on a pallet and wrapped in a polyethylene bag.

Standard packaging

Packaging

Handling instructions

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Cubicle AD4 (for unit entry from above)

Cubicle CL4 with upstream CTs

Use a 900mm minimum width crosspiece between rings.

- Attach the four slings to the relevant lifting devices.- As soon as the unit is lifted, the pallet can be removed.

Handling using a sling

Handling


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Handling on rollers

Warning

Before putting the unit on the rollers, remove the pallet.

After prolonged storage, thoroughly clean insulating parts before operation.Prolonged storage

Store the devices in their original packaging, placed on dry ground or on a material insulating it from moisture.

Storing


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After 6 to �2 month operations, we recommend you to check the busbars and MV cable connection tightening.It should be done with a calibrated torque spanner, adjust to lower torque compare to values indicated in page 6.If no problems are detected and if the busbars and cable connections haven’t been modified, it will not necessary to do again this check. In case of dismantling, the elastic washers must be change and replace by new ones supplied by Schneider Electric.

It is strongly advised to periodically carry out (minimum every 2 years approximately) a few operation cycles on operating devices.Outside normal conditions of use (between -5°C and 40°C , absence of dust, corrosive gas, etc.), it is recommended to examine with our Schneider Electric services centre the steps to be taken, in order to ensure correct functioning of the installation.

Our service centre is at your disposal at any time: - to undergo an installation diagnostic,- to offer you, if need be, suitable maintenance operations,- to offer you maintenance contracts,- to offer you adaptations.

Operation and maintenance

The necessity of correct implementation of connectionsNew cold retractable or slip-on technology offers ease of installation that favours resistance over time.Their design allows them to used in polluted environments with harsh climatic conditions.

Impact of the relative humidity factorInstalling a heating device is essential in climates with high relative humidity levels and major temperature differences.Ensure that draughts and / or thermal shocks are avoided in all cubicle compartments in order to avoid the creation of dew points (sources of partial discharges).The equipment must be installed in conformity with the relevant IEC standard. Outside of these normal usage conditions, we recommend contacting Schneider Electric to determine the operations to be carried out as well as their frequency according to the actual service conditions.

Ventilation control:Grid size must be suited to the power dissipated in the substation. These grids must be placed exclusively in the vicinity of the transformer, in order to avoid air circulation on the MV switchboard.

The switchgear’s resistance to ageing in an MV substation depends on 3 main factors

Installation and operation recommendations

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Units shall be unpacked in close proximity to the erection site.

Don’t dismantle any parts from the unit.

- Fork or ring spanner n.�9 (A� ou A2).Tools

see pages 7 and 8). - Remove the pallet and lay the unit on the floor.- Then remove the four anchoring devices and the relevant cage nuts. - In the case of units provided with end panels, after having removed the anchoring devices, put back the bolts on the end panels. The circuit breakers are delivered in cubicles in a withdrawn position. Warning

Unpacking

Unpacking

Standard cubicle

AD4, RHC – RHB cubicles, CL4 cubicle with upstream CT’s- Remove the plastic wrapping and lifting the unit by the four anchoring devices (for handling

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Description of the fixing rails and accessories

For the rolling of mobile part extraction tools without degrading the floor, it must have a compression withstand u 33 Mpa.

Floor quality

The floor surface must be level (no bumps) and such that a 2 meters rule placed on all surfaces and in every direction shows a clearance of no more than 5mm.

Surface condition

Placing and adjusting on standard civil engineering works

Earthquake resistant civil engineering:- 2 fixing rails A (length 2 m), - 8 expansion pins B, - 4 fastening shims C.

Standard civil engineering:- � fixing rail A (length 2 m),- 4 expansion pins B, - 2 fastening shims C.

Take the equipment from the civil engineering package of the switchboard packaging.

Cubicle fixing

the supplied expansion pins, screws and washers.Cut the last rail to the required length.

Placing the fixing railsPlace and fix the rails to the floor using

Drill holes in the floor and the fixing rails.

Preparation

Floor finishing and cubicle fastening

Tools

Drill. Socket spanner n.�3.

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For the correct installation of cubicles, it is advised to comply with a tolerance of ± 0.1 cm / m and a max gap of ± 0.3 cm on the length of the switchboard.

Longitudinal adjustment Using a water level and using shims before tightening the screws.

Tightening the fixing rails


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Tools

Place and fix the rails to the floor using the supplied expansion pins, screws and washers.Cut the last rail the required length.

Placing the fixing rails

Preparation Drill holes in the floor and the fixing rails.

Placing and adjusting on earthquake resistant civil engineering works

Tools

Socket spanners n.�3.


Drill.

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The rails must be very smooth, because adjustment-using actuators is not possible.

Longitudinal adjustment Using a water level and using shims before tightening the screws.

For the correct installation of cubicles, it is advised to comply with a tolerance of ± 0.1 cm / m and a max gap of ± 0.3 cm on the length of the switchboard.

Transversal adjustment.Using a spirit level and using shims before tightening the screws.


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For more details:refer to the device attached manual.

Overall dimensions and weights

Without lowering (extraction table)

The support C rails might be adjusted independently by an action the lever A one side only.

A: crankB: connecting device to the unitsC: circuit-breaker supporting railD: locating pins for matching to the unitsE: wheel brake

Overall dimensions and weights

Extraction and lowering tool

These tools allow to extract the mobile parts (circuit-breaker, contactor, sectionning truck). The ERT allow to leave the mobile part on the floor.These tools are intended to be used only as an accessory of MCset switchboards.They shall be used when the units have been laid on the floor.They shall not be modified.

Safety rules for use

weight86 kg

weight60 kg

Mobile part extraction

A: connecting device to the unitsB: circuit-breaker supporting railC: locating pins for matching to the unitsD: wheel brakeE: crank for width adjustmentF: screw for height fixingG: screws for compensation of floor

unevenness

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- Turn the selector 2 to the position marked

with .Then remove the circuit-breaker;

pull it out until it comes against the stops of trolley.

WarningDuring this operation the circuit-breaker springs can be tripped automatically.

- Lock the trolley in position by pushing and turning the two latching handles in the indicated way. - After the operation, make sure that the trolley is locked.

- Move the extraction tool into position in front of the unit (take care that the locating pins engage with the holes provided on the unit).

- Lock the wheels by pressing the brake.

Extraction of the mobile part (procedure is the same with an ERT or an extraction table)

- Open the access door to the circuit-breaker compartment.At the �st extraction:- Remove the strap part (1). - Remove the block which hold the rod in upper position (2).

Unit with circuit-breaker in disconnected / test position.

Starting condition

Procedure to draw-out the mobile part

Warning

The mobile part shall be move with the extraction tools only.Do note apply effort on the connection arms.The extraction of the mobile part shall be done when the units have been laid on the floor.


- Unplug the connector of LV circuits.

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- Release the brakes on the trolley wheels.- Take away the trolley (1).

- Return selector to the position .- Unlock the trolley from the unit by turning the two handles in the indicated way.

- Lower the shutter. To close the door without the circuit-breaker inside: - push the hook A to the top, - push the locking part B in the indicated position, then let A free.

The locking system will reset automatically when the circuit-breaker is inserted.

Closing the MV door


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- Take away the trolley.

- Set the selector 2 to position .

Leaving the mobile part on the floor (only with ERT)

- Put the circuit-breaker on the ground by turning the crank (2).


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- Set selector 2 to position .

ERT- Move the trolley under the circuit-breaker until it comes against the stop.

Insertion with the ERT or with extraction table

- Cubicle: the circuit-breaker compartment door is open.- ERT: the rails of trolley are in the lowered position.- Circuit-breaker: it is on the floor with the

selector 2 in the position marked .

Starting conditions

Procedure to draw-in the mobile part

- Move the trolley into position in front of the unit; take care that the locating pins engage with the holes provided on the unit.

- By turning the crank (1), lift the circuit-breaker up to the insertion level.

- Approach the trolley with the circuit-breaker in front of the unit.


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the two handles and then pulling them out. - Release the brakes on the trolley wheels.- Remove the trolley.

- Unlock the trolley from the unit by turning

circuit-breaker compartment until it stops.- Set selector 2 to position .

- Set the selector 2 to position .- Push the circuit-breaker into the

- Lock the wheels by pressing the brakes.- Lock the trolley in position by pushing and turning the two latching handles (after the operation, make sure that the trolley is locked).


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- Lift the black shutter located on the back of the door before closing the door.

- Push and hold the locking device (A - B).- Plugging-in the connector of LV circuits. (C). If the connector is not properly inserted, the locking device will prevent the door from being closed.


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- Draw-out the VT truck.- Remove the 2 bolts.- Remove the 5 nuts fixing and the crosspiece.

- Disconnect the LV connector of the VT secondaries.

- Close the earthing switch (see page 78).- Draw-out the fuses of the VT’s (see page 77).- Remove the 2 fixing bolts by using the operating crank.- Open the access door.

Tools Operating crank (provided).

Tools - Fork or ring spanner n.�0 (A)- Fork or ring spanner n.�3 (B)- Ratched spanner n.�0 (C1)

Cubicles equiped with draw-out VT’s

Procedure to extract the VT’s


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- Disconnect the LV connector of the VT secondaries.

Units equipped with fixed VTs

- Open the circuit-breaker compartment door.- Remove the bottom plate of the circuit-breaker compartment by unscrewing the 4 fixing bolts.

- Close the earthing switch (see page 78).- Remove the 2 fixing bolts by using the operating crank.- Open the access door.

- Remove the 2 bolts.- Remove the 5 nuts fixing and the crosspiece.- Remove the VT assembly, by running it on its wheels.

- Disconnect the connection bar of each VT by unscrewing the nut.

To have an easier access inside the cubicle, remove the bottom sheet of the circuit-breaker compartment and the barriers between phases.

- Remove the barriers between phases following the sequence indicated in the figure.- Close again the circuit-breaker’s and VTs’ compartment doors.


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- Check that the earthing switch is close (see at page 78).- Replace the VT truck into position.

- Assemble the barriers between phases following the sequence indicated in the figure.

Operating crank (provided).

Tools - Fork or ring spanner n.�0 (A)- Fork or ring spanner n.�3 (B)- Ratched spanner n.�0 (C1)

For unit equipped with draw-out VTs

Procedure to insert the VT’s and to close the MV cable compartment

If the MV and LV cable connection are not immediately done, proceed with the following instructions.

Close the door and secure it by means of the 2 bolts to be tightened with the operating crank.

- Remount the sheet steel bottom plate of the circuit-breaker compartment and fasten it by means of the 4 bolts provided.

- Remount the crosspiece across the front bottom by means of the 5 nuts and 2 bolts provided.

- Plug-in the connector of the VT secondaries.


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- Remount the crosspiece across the front bottom by means of the 5 nuts and 2 bolts provided.

- Plug-in the LV connector of the VT.

- Chek that the earthing switch is close (see at page 78).- Replace the VTs. - Connect the connection bar of each VT by screwing the nut.

- Assemble the barriers between phases following the sequence indicated in the figure.

Operating crank (provided)

Tools - Fork or ring spanner n.�0 (A)- Fork or ring spanner n.�3 (B)- Screwdriver n.�0 (C)- Ratched spanner n.�0 (D)

For unit equipped with fixed VTs

- Close the door and secure it by means of the 2 bolts to be tightened with the operating crank.

- Remount the sheet steel bottom plate of the circuit-breaker compartment and fasten it by means of the 4 bolts provided.


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Access to the LV terminal and to the internal arcing detector.

Access to the LV compartment

Access to the circuit-breaker (AD4).

Access to MV cables, VT’s, earthing switch, CT’s secondaries and toroidal CT’s. Access to the rear adjustment bolts.

Access to the main busbars.

Additional cables access from the front.

Access to the rear adjustment bolts through the cable basement or trench.

AD4 - RD4 cubicle

No access from the rear

Access to the interior of the cubicle

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Access to the LV compartment

Access to the circuit-breaker.

Access to VT’s and lower main busbar. Access to the rear adjustment bolts.


Additional access to the lower main busbar from the front.

CL4 cubicle (bus-section)



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Access to the LV compartment.


Access to VT’s and lower main busbar. Access to the rear adjustment bolts.

Access to the main bubars.


CL4 cubicle (bus-section) with upstream CT’s

Access from the rear is imperative for

this version

Access to the CT’s and to the voltage cable measurment.


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Access to the CT’s secondaries and lower main busbar. Access to the rear adjustment bolts.




GL4 cubicle (bus-riser)


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Access to VT’s, earthing switch and lower connection. Access to the rear adjustment bolts.



TT4 cubicle



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Access to MV cables, earthing switch, fuses and switch. Access to the rear adjustment bolts.

Access to the main busbar (if a single DI4 cubicle is placed side-by-side to other units, it is easier to get access from the busbar compartments of the adjacent cubicle).


DI4 cubicle



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Access to VT’s, earthing switch and CT’s secondaries. Access to the rear adjustment bolts.


Additional cables access from the front.


AD4 RHC cubicle (for unit entry from above)


Access to MV cables.

Access from the rear is imperative for this version.

Access to MV cables.

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Preparation of the cubicle to the positioning

Cubicle shall be prepared in the erection site. Operations Cubicle page

Racking-out of the mobile part AD4, CL4-GL4 23

Racking-out of the VT’s AD4, CL4-GL4, RD4, TT4 29

Removal of the bottom plate of the MV compartment AD4, CL4-GL4, RD4, TT4 30

Removal of the barriers between phases AD4, CL4-GL4, RD4, TT4 30

Note: the positioning can be done by rolling or lifting.

Positioning on the cable basement

Place the crossing tools across the cable basement.

If the cable basement consists of one uninterrupted opening on the floor, the use of special crossing tools is required.

Place the crossing tools across the cable basement, in the location where the unit is to be placed.

Move the cubicle by means of rollers and position it in front of the crossing tools.

Then push the unit in position.

Important For cubicles equipped with a tunnel, it must be installed before placing the cubicle in position (see page 39).

Insert the roller (A) under the cubicle by using a lever.

A: rollersB: crossing tools.

Installation instructions

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Lift the rear of the cubicle by screwing the 2 actuators to level the cubicle.

Screw the lock nut A on each actuator D, place washer C, then screw the actuators in the quick cage nuts.

Place the 2 quick cage nuts B at the rear of the cubicle, by gaining access underneath the cubicle.

Position the support plate E at the rear of the cubicle by gaining access through the maintenance space.

The operations described here after must only be carried out once the cubicle is positioned on civil engineering works.

Adjusting cubicles on standard civil engineering works

Place the fastening screws at the front of the cubicle and tighten them.

To be retrieved from the bag of screws and bolts.

Note: Remove the front panel (if the cubicle is fitted with VT, it is first necessary to remove them, see the chapter “Access to the interior of a cubicle”).

Fastening to the floor on standard civil engineering works

Tool- 2 open end spanners n. �8.


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- Fork or ring spanner n.�0 (A). - Ratchet spanner n.�0 (B1).- Spirit level.

Tools

- Remount the sheet steel bottom plate of the circuit-breaker compartment.- Fasten the 4 fixing bolts.

Starting situationCircuit breaker and VT truck removed from the unit. Bottom plate of the circuit-breaker compartment removed from the unit.

Verify correct positioning

- Check that the unit is level by means of a spirit level.- Check that the doors could open and close correctly.- Insert the circuit breaker.

Place the fastening screws at the front of the cubicle and tighten them.


Place the fastening screws at the rear of the cubicle and tighten them.


Note: Remove the front panel (if the cubicle is fitted with VT, it is first necessary to remove them, see the chapter “Access to the interior of a cubicle”).

Fastening to the floor on earthquake resistant civil engineering works


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Tools - Ratchet spanner n.�0 (A).- Fork or ring spanner n.�0 (B).

Take out from bolts and screws bag: - nuts F,- bolts G,- washers E.

For the following versions, see drawing ref. 038334��N0:- internal arc version on 4 sides, incoming from the top,- internal arc version on 4 sides (3�.5kA / 0.�5s), incoming from the top, - internal arc version on 4 sides (3�.5kA / 0.�5s), incoming from the bottom: the assembly is the same as the previous version. See guide «Installation drawing files - AAA�3028EN - REV B0».

Cubicle configuration:- internal arc version on 4 sides

Assembly tunnel

- Take out from the wood crate the panels and the roof.- Fix the panels at the rear, then at the front of the cubicle.- Fix the roof.- Respect the assembly as shown on the diagram.


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Take out from bolts and screws bag:- nuts F,- bolts G,- washers E.

Assembly tunnel

For the following versions, see drawing ref. 03837230N0:- internal arc version on 4 sides, IPX�, incoming from the top,- internal arc version on 3 sides, IPX�, incoming from the bottom. - internal arc version on 4 sides (3�.5kA / 0.�5s), IPX�, incoming from the top. - internal arc version on 4 sides (3�.5kA / 0.�5s), IPX�, incoming from the bottom: the assembly is the same as the previous version.

- Take out from the wood crate the panels and the roof.- Fix the panels at the rear, then at the front of the cubicle.- Fix the roof.- Respect the assembly as shown on the diagram.


Cubicle configuration: - internal arc version on 4 sides,- IPX1 protection degree.

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Take out from bolts and screws bag: - nuts F,- bolts G,- washers E.

For the following versions, see drawing ref. 038334��N0:- internal arc version on 4 sides, incoming from the top,- internal arc version on 4 sides (3�.5kA / 0.�5s), incoming from the top, - internal arc version on 4 sides (3�.5kA / 0.�5s), incoming from the bottom: the assembly is the same as the previous version.See guide «Installation drawing files - AAA�3028EN - REV B0».

Cubicle configuration:- internal arc version on a wall

Assembly tunnel

- Take out from the wood crate the panels and the roof.- Fix the panel at the front and the plate at the rear of the cubicle.- Fix the roof on the front panel and on the wall.- Respect the assembly as shown on the diagram.


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- Fork or ring spanner n.�0 (B).- Take out from the wood crate the panels and the roof.- Fix the panels at the rear, then at the front of the cubicle.- Fix the roof.- Respect the assembly as shown on the diagram.

- washers E.Tools - Ratchet spanner n.�0 (A).

top.Take out from bolts and screws bag:- bolts G,

For the following versions, see drawing ref. 03833229N0:- gas exhaust, IPX�, incoming from the

Cubicle configuration: - gas exhaust,- IPX1 protection degree.

Assembly tunnel


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Tools - 2 ratchet spanners n.�3 (A) with the relevant extension.

Cubicle coupling

Cubicle configuration:- gas exhaust,- AD4, CL4-GL4, TT4, DI4, RD4.

For more details, see drawing ref. 03833�04N0.

Take out from bolts and screws bag:- nuts F and I,- bolts G and H,- washers L.

- In order to put in place the 2nd cubicle, operate as for the �st cubicle.- Fasten the two units together (9 fixing points).- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.


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Tools - 2 ratchet spanners n.�3 (A) with the relevant extension.- 2 ratchet spanners n.�0 (B).

Take out from bolts and screws bag:- nuts F and I,- bolts G and H,

Cubicle coupling

Cubicle configuration:- gas exhaust,- incoming from the top,- AD4.


- In order to put in place the 2nd cubicle, operate as for the �st cubicle.- Fasten the two units together (�2 fixing points).- For access to the fixing points,see the chapter “Access to the interior of the cubicles”.


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operate as for the �st cubicle.- Fasten the two units together (�2 fixing points).- Join the top panels with the crosspiece C as show in the picture.- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.

- 2 ratchet spanners n.�3 (A) with the relevant extension.- 2 ratchet spanners n.�0 (B).- In order to put in place the 2nd cubicle,

- nuts F and I,- bolts G and H,- washers L.Tools

Cubicle coupling

Cubicle configuration:- gas exhaust,- IPX1,- AD4, CL4-GL4, TT4, DI4, RD4.

For more details, see drawing ref. 03833�04N0.Take out from bolts and screws bag:


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- In order to put in place the 2nd cubicle, operate as for the �st cubicle.- Fasten the two units together (9 fixing points).- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.


Take out from bolts and screws bag:- nuts F ,- bolts G .

Cubicle coupling

Cubicle configuration:- internal arc protection on 3 sides,- AD4, CL4-GL4, TT4, DI4, RD4.



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- In order to put in place the 2nd cubicle, operate as for the �st cubicle.- Fasten the two units together (�5 fixing points).- Join the top panels with the crosspiece C as show in the picture.- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.



Cubicle coupling

Cubicle configuration:- internal arc protection on 4 sides,- AD4, CL4-GL4, TT4, DI4, RD4,- tunnel.



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- In order to put in place the 2nd cubicle, operate as for the �st cubicle.- Fasten the two units together (�2 fixing points).- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.


Take out from bolts and screws bag:- nuts F and I,- bolts G and H.

Cubicle coupling

Cubicle configuration:- internal arc protection on 4 sides,- incoming from the top,- AD4.



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- In order to put in place the 2nd cubicle, operate as for the �st cubicle.- Fasten the two units together (�5 fixing points).- Join the top panels with the crosspiece C as show in the picture.- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.



Cubicle coupling

Cubicle configuration:- internal arc protection on 4 sides,- IPX1 protection degree,- AD4, CL4-GL4, TT4, DI4, RD4.

For more details and for the following version, see drawing ref. 03833�05N0:- internal arc protection 3 sides, tunnel,- internal arc protection 4 sides,- internal arc protection 4 sides, tunnel, incoming from the top.


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- Tightening torques 30 Nm.

- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.

Take out from bolts and screws bag:- nuts I,- bolts H,- washers E.

Tools - 2 ratchet spanners n.�7 (A) with the relevant extension.- Ring spanner n.�7 (B).- Torque spanner (C).

Connection of earthing busbar


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Operating instructions:- Position the profile C and fix them as show.- Position the panel D and fix them in the upper locations.- Position the panel E and fix them in the upper locations.- Finish the fixing of the 2 panels as show.- Apply the adhesive plate B on panel D.

- Repeat the operation for the right side.- For access to the fixing points, see the chapter “Access to the interior of the cubicles”.


Take out from bolts and screws bag:- bolts F-G-H,- nuts I,- washers L-M-N.

Important

End panels are fixed to the cubicles with bolts and nuts. Assembling must be carried out on the erection site.

End panels assembling

: G + I + L

: H + I + L

: F + I + L

: G + L

: H + I + M + N

: H + L

Cubicle configuration:- gas exaust.

For more details, see drawing ref. 03835598N0.


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Take out from bolts and screws bag:- bolts F-G-H,- nuts I,- washers L-M-N.

: G + I + L

: H + I + L

: F + I + L

: G + L

: H + I + M + N

: H + L


Cubicle configuration:- gas exhaust,- incoming from the top,- AD4.


Operating instructions:- Position the profile C and fix them as show.- Position the panel D and fix them in the upper locations.- Position the panel E and fix them in the upper locations.- Finish the fixing of the 2 panels as show.- Position the panel O and fix them as show.- Apply the adhesive plate B on panel D.

- Repeat the operation for the right side.

- For access to the fixing points, see various possibilities of access to the interior of the cubicles.


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Take out from bolts and screws bag:- bolts H,- nuts G and I,- washers L-M-N.

: H + L

: H + I + L + N

: G + H + M

: H + I + L


Cubicle configuration:- Internal arc protection on 3 sides.

For more details, see drawing ref. 03837�0�N0.

Operating instructions:- Position and fix the uprights D and E and the traverse C.- Position and fix the traverse A and F. - Position and fix the panel O. - Position and fix the panels P and Q. - Position and fix the panel S, the plate R and the supporting T.

- Repeat the operation for the right side.



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Take out from bolts and screws bag:- bolts H,- nuts G and I,- washers L-M-N.

: H + L

: H + I + L + N

: G + H + M

: H + I + L


Cubicle configuration:- Internal arc protection on 4 sides.


Operating instructions:- Position and fix the uprights D and E and the traverse C.- Position and fix the traverse A and F. - Position and fix the panel O. - Position and fix the panels P and Q. - Position and fix the panel S, the plate R and the supporting T.- Position and fix the panel U. - Repeat the operation for the right side.



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- 2 ratchet spanners n.�0 (B) with the relevant extension for one.Operating instructions:

Take out from bolts and screws bag:- bolts H,- nuts G and I,- washers L-M-N.: H + L

: H + I + L

: H + I + L + N

: G + H + M

Tools


Cubicle configuration:- internal arc protection on 4 sides.- incoming from the top,


- Position and fix the uprights D and E and the traverse C.- Position and fix the traverse A and F. - Position and fix the panel O. - Position and fix the panels P and Q. - Position and fix the panel S, the plate R and the supporting T.

- Repeat the operation for the right side.- For access to the fixing points, see various

possibilities of access to the interior of the cubicles.


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This procedure shall be repeated for any unit added to the switchboard.

- Fit the main busbars between the 2 units. - Insert the bolts and tighten them (to be recommended tightening value).

Cubicle type CL4 and GL4Cubicle type AD4-CL4-GL4-TT4-RD4 and DI4.

Tools- Fork or ring spanner n. �9 (A). - 2 ring spanners n.�9 (B1) or as alternative.- 2 ratchet spanners n.�9 (B2). - torque spanner (C).

For access to busbars, see various possibilities of access to the interior of the cubicles.

For more details, see drawing ref. 0383566�N0.

Fitting the main busbars


1 : self-locking nut2 : nut3 : washer4 : screw

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630 and 1250A tee-connections

1250A main busbars

Main busbars – top view

Lower main busbars – top view (CL4-GL4)


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2000 / 2500 A tee-connections

2000 / 2500A tee-connections

630 / 1250A tee-connections

2000 / 2500A main busbars

Main busbars – top view

Lower main busbars – top view (CL4-GL4)

Lower main busbars – top view


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Cut the joint covers as shown in the drawings in this page and in the following one.

Cutting joint covers

Choose the proper joint cover type according to the needs of each unit of the switchboard as shown in the following drawing.Tools

Choosing proper joint covers

For more details, see drawing ref. 0383566�N0.

Fitting joint covers

right

sid

e en

dor cu

bicl

e A

D4

right

sid

e en

d ou

tgoi

ng y

630

A

cubi

cle

DI4

rig

ht s

ide

end

outg

oing

y 6

30A

cubi

cle

TT4

right

sid

e en

d y

630A

cubi

cle

TT4

in a

ny m

iddl

e po

sitio

n y

630A

cubi

cle

AD

4 in

any

mid

dle

posi

tion

cubi

cle

CL4

cubi

cle

AD

4 in

any

mid

dle

posi

tion

outg

oing

y 6

30A

cubi

cle

DI4

in

any

mid

dle

posi

tion

outg

oing

y 6

30A

cubi

cle

TT4

left

end

pane

l y

630A

cubi

cle

DI4

le

ft si

de e

nd

outg

oing

y 6

30A

cubi

cle

AD

4 le

ft si

de e

nd

cubi

cle

AD

4 le

ft si

de e

nd

outg

oing

y 6

30A

right side end panel left side end panel

or or

or or or

03833376N0

�st cut

2nd cut3rd cut

4th cut�st cut 2nd cut 3rd cut

4th cut �st + 4th cut 2nd + 3rd cut

right end

right end

right end left end

intermediate intermediate

- Stanley knife.cubicle AD4


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4th cut �st cut

3rd cut 2nd cut

5th cut

�st cut

right end

2nd cut

right end

3rd cut

left end

4th cut

right end

�st + 4th cut

intermediate

2nd + 3rd cut

intermediate

2nd + 5th cut

right end left end

2nd + 3rd + 5th cut

intermediate

�st cut 2nd cut

�st cut

right end

2nd cut

right end

�st + 2nd cut

intermediate

without cut �st + 3rd cut 2nd + 4th cut

�st cut 2nd cut

3rd cut 4th cut

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- Open the joint cover and put it into position on the busbar joint.

Positioning the joint covers

clip

- Close it and fix by using the proper pins.- Closing the MV cable compartment.- Replace the VT truck into position (see page 3� for the description of this operation).


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Entry from the top.

Maximum entry section available for LV cables.

Entry from the bottom.

- Entry from the bottom in every single cubicle. LV cables shall be run to the LV compartment inside the vertical duct on the right end side provided for every single unit.- To install the LV cables in the vertical duct, you should extract the circuit breaker and the VT’s (see page 28 and 34).

LV cable connections

Connection of the LV cables

- Remove the 2 fixing bolts (1) of the LV entry steel sheet.- Make a hole in the sheet according to the number and type of cables.- Install the grommets (not supply) on the sheet and insert the cables.- Remount the metal sheet (2 screws).

- Socket spanners n.�0.

Tools

- Drill.

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- To reach the terminal blocks of the LV cables, take off the top front sheet metal (remove the 6 fixing bolts). - Connect the cables to the terminal blocks according to the schematic diagrams.

LV cable connections

Closing the top entry LV cable steel sheet.

To keep the panel protection degree between 2 cubicles, the top entry LV cable sheet must be install:- on the right for all cubicles,- on the left on the cubicle positioned at the right side end of the switchboard.

To make an easier installation, the fixing holes are oblong.

- Socket spanners n.�0.Tools

Connection of the LV cables

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- Ratchet spanner n.�7 (A1).- Fork or ring spanner n.�7 (B).

Tools

After connecting the earth links between units, the earth circuit shall be bonded to the substation earth. To that purpose, the earth conductor is provided with holes suitable for M�0 bolted connections. The link to the substation earth can be ran through an unused cable grommet.

Equipotential connection of the switchboard’s earth to the substation earth

If the MV cables have not been connected at the erection of the switchboard, in order to get access to the connecting terminals, it is necessary to carry out the following operations:- remove circuit-breakers and VTs (both fixed and withdrawable versions) (see pages 23),- remove barriers between phases and the bottom plates of the circuit-breaker compartment (see pages 29).

Starting conditions

Earthing circuit equipotential connection and MV cable earthing

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- Cut the cable grommets according to the number and diameter of cables.

- Remove the bottom metal plates in the cable compartment.

General

Connection of MV cables

- 2 fork or ring spanners n.�9 (A).- Torque spanner (B).

Tools

The instructions refer to one phase; repeat the procedure for the other two.

One single core or three-core cable per phase

In order to terminate the MV cables, see the relevant manufacturer’s instructions.

- Fit them to the cables.

- Bolt the cable lugs to the proper connecting terminal, using the grommets the closest to the rear (tightening torque 50 Nm).


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- Run the three-core cable through the toroidal CT (if requested).

- Cut the cable grommets according to the number and diameter of cables.

In order to terminate the cables, see the relevant manufacturer’s instructions.

Three-core cable per phase

Example of terminals (suggested by Schneider Electric) compatible for cable 630 mm²: -Raychem - type TMPP, -Pirelli - type STI-GT, -F&G - type Typ AV 20 E. Cable-terminals: -Cembre - series A-M.

Tighten to 50 Nm.

- Bolt the cable lug to the proper connecting terminal. - Insert the cable one by one starting from the one closest to the rear.

Tools- Fork or ring spanner n.�3 (A).- 2 fork or ring spanners n.�9 (B).- Torque spanner (C).

The instructions refer to one phase; repeat the procedure for the others.

1 to 4 single core cables per phase


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- Fit the crosspiece on the bottom plate (1 bolt – nuts assembling).- Fit the anchoring supports on the cable according the picture above for 3 single core cables.

- Fit the metal bottom plates.- Unused holes shall be closed with cable grommets (not cut).1: fixing point for the crosspiece.

Tools- Fork or ring spanner n.�3.

Anchoring supports for MV cables

For access to the cable compartment, see “Access to the interior of the cubicles”.

Take off from the cubicle components package: the metal bottom plates, the cable anchoring supports, the crosspiece to fix the anchoring supports, the screws bag.

The operation is the same for all types of cables.

- Fit the anchoring supports on the cable according the picture above for � three-core cables.

- Take care to not hurt the cable isolating when you clamp the anchoring support.


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The earth braid shall be connected to the earth bar on the rear of the switchboard.

Earthing of MV cable shields (DI4)

Example: one cable per phase, 3 braids or wires to connect.

In the presence of toroidal CTs, take care to run the earthing connection through the CT before fixing it.Example: one cable per phase, 3 braids or wires to connect.

The earth braids or wires shall be connected to the left hand side earth conductor provided in each cable compartment.

Earthing of MV cable shields rear rear

front


front

Two cables per phase, 6 braids or wires to connect.

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For a description of insertion of circuit-breaker, see page 26.

Insertion of circuit-breaker

For a description of VT truck replacing, see page 3�.

VT truck replacing

Final operations


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- The fuse characteristics and direction of mounting are printed on the fuse. - Turn the fuse so that the label is in front (striker at the top end).

- The striker end of the fuse is marked.For different types of fuse, please contact Schneider Electric.

Install FUSARC type fuses with medium type strikes according to IEC 32 - 3IEC 282-1 and DIN 43-625.

- Fuses shall never be held in the middle.

- Then fit the top end of the fuse in the upper contact and check that the field control screen is properly closed.- Turn the fuse so that the label is in front.

- Insert the bottom end of the fuse all the way into the lower ring contact.

- Open the upper field control screen by means of the top end of the fuse.

- Open the MV compartment.- Insert in first the fuse of the farthest phase.

Fitting fuses in DI4 cubicle

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Checking and cocking the internal arcing detector(1)

The internal arcing detector is located on the roof of the cubicle.To be operational, it must be in cocking position.

Cocking the internal arcing detector:- push the metal rod (1) in direction of the bottom of the cubicle,- hang up the rod (1) on the support (2).

1: metal rod,

This operation has to be made during assembly of the tunnels (option) or during operation on the roof of the cubicle.

2: support.(�) The internal arcing detector is mounted

according to the internal arcing withstand characteristics of the cubicle.

Tests on site

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- Circuit-breaker in disconnected position and the compartment door open. - Lift the locking rod A located on the top of the circuit-breaker mechanism.- Insert spacer U to keep the rod in raised position.- Push the circuit-breaker to the service position and remove spacer U.- Charge the closing spring of the circuit-breaker and close it by pressing pushbutton “ I ”.

For a complete description of the following operations, please consult the SF circuit-breaker instruction for use handbook.

Operations to be carried out on units not directly connected to the testing equipment

How to prepare the units

During the voltage tests, all the unit shall be fitted with the relevant circuit-breakers. The circuit-breakers shall be plugged in service position and closed. Since hand closing is not permitted with closed doors, a special procedure is required (see below) when auxiliary power supply is not available.Obviously, the MV cables shall be disconnected and the earthing switch shall be opened.

The leads from the testing equipment shall be connected to the MV cable lugs of a unit. This requires the opening of a lower door during the test for passing the above-mentioned leads.

This preparation entails the bypass of some interlock. Only appropriately trained staff shall be allowed to operate.The procedures described in the following shall be strictly applied. Voltage transformers and lightening arresters, if any, shall be disconnected during the voltage tests at power frequency in order to avoid severe damages. NB: In units equipped with VTs withdrawable fuse version, disconnect the fuses. In units equipped with fixed VTs, disconnect the VTs power supply primary circuit.CTs secondaries shall be short-circuited at the LV terminal boards (if the auxiliary circuits are open).

WarningThe power-frequency test voltage shall be 80% of the rated test value (40kV rms), because the units have already been tested in Schneider Electric factory at �00% of the voltage rated value) and shall be applied to each phase conductor of the main circuit for � minute earthing the other two phase conductors.

After erection, the equipment shall be tested in order to check the correct installation.

Voltage test on the main circuits

Tests on site

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The symbols marked on the blue front cover of the circuit-breaker summarise the above-mentioned procedure.

- Set selector 6 to withdrawn position .- Insert the crank into hole 7 and turn counter clockwise until further rotation becomes impossible.

Starting conditions- Selector 6 in position

Withdraw the VT fuses

Starting conditionsThe circuit-breaker is in disconnected position, or in test / disconnected position or removed from the unit.

Operations to be carried out on the unit to be connected to the testing equipment

- Set selector 6 to . This operation requires first to pull outward the selector and then to turn it.This operation turns off the CT’s secondaries.

Tests on site

Remove the possible keys or padlocks preventing the operation of the earthing switch.

Verify that the voltage indicating lamps are off.

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The symbols marked on the yellow front cover summarise the above-mentioned procedure. For more protection, it is possible to prevent the insertion of the circuit-breaker by setting the selector P as shown in the following drawing.

The earthing switch is in closed position. The MV cables are short-circuited and earthed. The selector in this position prevents the insertion of the circuit-breaker.

Turn selector 4 clockwise to position I. Insert the crank into hole 5 and turn it clockwise until the earthing switch position indicator reads “on”.

Set selector 4 to . This operation requires first to pull outward the selector and then to turn it.

Push the pushbutton of the earthing switch electromechanical lock. If the cubicle is not equipped with this option, go directly to the following sequence.

Close the earthing switch

Tests on site

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Warning

The operation described is allowed only for testing configuration; this operation, performed when the switchboard is in service, is extremely dangerous because it makes the operator reach the live parts.

Make ineffective the interlock preventing the opening of the earthing switch with open door by entering the slot indicated with a screwdriver and pushing it downwards. This operation allows the access to the earthing switch operating shaft.

Remove the 2 screws indicated in the figure and open the lower door.

Set selector P to .

Open the VT compartment door

Prevent the insertion of the circuit-breaker

Tests on site

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The symbols marked on the yellow front cover summarise the above-mentioned procedure.

The earthing switch is in open position.

Set selector 4 to position “O”. Insert the crank into hole 5 and turn its counter clockwise until the earthing switch position indicator reads “off”.

Tests on site

Set selector 4 to . This operation requires first to pull outward the selector and then to turn it.

Push the pushbutton of the earthing switch electromechanical lock. If the cubicle is not equipped with this option, go directly to the following sequence.

Open the earthing switch

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Set selector P in horizontal position

Restore the possibility of circuit-breaker insertion

- Move the circuit-breaker to the disconnected position.- Close the earthing switch.- Remove the test leads. If provided, reinstall the VT truck.- Close the door and secure it by fixing the 2 bolts.- Open the earthing switch.- Plug-in the VT fuses.

After performing the test

Connect the leads from the testing equipment to the MV cable lugs.

Charge the closing spring of the circuit-breaker and close it by pressing pushbutton “ I ”.

Push the circuit-breaker to the service position and remove spacer U.

With the circuit-breaker in disconnected position and the compartment door open, lift the locking rod A located on the top of the circuit-breaker mechanism. Insert spacer U to keep the rod in raised position.

Tests on site

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82 - 07897542EN indice: D0 Schneider Electric

Schneider Electric Industries SAS89, boulevard Franklin RooseveltF-92505 Rueil-Malmaison CedexTel: +33 (0)� 4� 29 85 00www.schneider-electric.comwww.merlin-gerin.com

07897542EN - REV. D0 03/2008

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As standards, specifications and designs change from time to time, please ask for confirmation of the information given in this publication. This document has been printed on ecological paper.

Publishing: Schneider Electric Industries SAS.Design: Profil.Printing:

Schneider Electric group service centers are there to provide: - engineering and technical assistance,- commissioning,- training,- preventive and corrective maintenance,- adaptation work,- spare parts.

Call your sales representative who will put you in touch with your nearest Schneider Electric group service center or directly call the following telephone number: +33 (0)4 76 57 60 60 Grenoble France.

Mcset 4 Installation Guide

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