Eaton Magnefix MD4 User manual

MV switchgear

Magnefix MD4

User manual 991.184 G01 03

User manual

Medium-voltage switchgear

Magnefix MD4

991.184 G01 03

Eaton Industries (Netherlands) B.V.

P.O. Box 23, 7550 AA Hengelo, The Netherlands

tel: +31 74 246 91 11

fax: +31 74 246 44 44

e-mail: [email protected]

Internet: www.eaton.eu

in the event of a malfunction

Eaton Electrical Solutions & Services: tel: +31 74 246 68 88

Installation, connection, operation, checking, commissioning, decommissioning and maintenance of

Magnefix MD4 medium-voltage switchgear should only be carried out by suitably qualified personnel.

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991.184 G01 03

Administrative data

Version number: G01 03

Date of issue: 30-10-2013

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CONTENTS

1. INTRODUCTION ..................................................................................... 7

1.1 General system description .................................................................................. 7

1.2 Using the user manual .......................................................................................... 7

1.2.1 Target group ........................................................................................................... 7

1.2.2 Structure of the user manual ................................................................................... 7

1.3 Safety regulations ................................................................................................. 8

1.3.1 General instructions ................................................................................................ 8

1.3.2 Switch room safety .................................................................................................. 8

1.3.3 Notation guide ......................................................................................................... 9

1.3.4 What to do in the event of a fire............................................................................... 9

1.4 Product information .............................................................................................. 9

1.4.1 The type plate ......................................................................................................... 9

2. SYSTEM DESCRIPTION ....................................................................... 11

2.1 The switchgear .................................................................................................... 11

2.1.1 Type of switchgear ................................................................................................ 11

2.1.2 Configuration of switchgear ................................................................................... 11

2.1.3 The cable panel .................................................................................................... 11

2.1.4 The branch-circuit panel ........................................................................................ 11

2.1.5 The fuse panel ...................................................................................................... 12

2.1.6 The protected panel .............................................................................................. 12

2.1.7 The busbar connecting panel ................................................................................ 12

2.1.8 Switching on and off .............................................................................................. 12

2.1.9 The indicators ....................................................................................................... 13

2.1.10 Earthing ................................................................................................................ 13

2.2 Switchgear safety ................................................................................................ 13

2.2.1 Switchgear operation ............................................................................................ 13

2.2.2 Safety features ...................................................................................................... 14

2.2.3 Use of safety features ........................................................................................... 14

2.2.4 Carrying out work .................................................................................................. 14

2.2.5 Safety markings .................................................................................................... 14

2.3 General technical data ........................................................................................ 15

2.3.1 Electrical data ....................................................................................................... 15

2.3.2 Dimensions and weights ....................................................................................... 16

2.3.3 SEG protection relay ............................................................................................. 18

2.3.4 Heat, radiation, noise and gases ........................................................................... 18

3. SETTING UP THE SYSTEM .................................................................. 19

3.1 Introduction ......................................................................................................... 19

3.1.1 Transport .............................................................................................................. 19

3.1.2 Environmental requirements .................................................................................. 19

3.2 General ................................................................................................................ 19

3.2.1 During operation ................................................................................................... 19

3.2.2 Ventilation ............................................................................................................. 20

3.2.3 During transport and storage ................................................................................. 20

3.2.4 Floor ..................................................................................................................... 21

3.2.5 Ceiling .................................................................................................................. 21

3.3 Assembling the upright frame ............................................................................ 22

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3.3.1 Parts list of upright frame ...................................................................................... 22

3.3.2 Additional parts for upright frame for systems with Protected panel ....................... 22

3.3.3 Assembling the frame legs .................................................................................... 23

3.3.4 Fixing the front C-sections..................................................................................... 23

3.3.5 Fit the C-sectionsto the frame ............................................................................... 23

3.3.6 Fitting the earth bar to the frame ........................................................................... 23

3.3.7 Fitting the branch earth bar ................................................................................... 24

3.3.8 Fitting the cross coupling ...................................................................................... 24

3.3.9 Fitting the second frame leg .................................................................................. 24

3.3.10 Fitting the earth strip ............................................................................................. 24

3.3.11 Position the switchgear on the frame ..................................................................... 25

3.3.12 Fitting the dust cap ................................................................................................ 25

3.3.13 Fit the C-section to the front of the frame (systems with Protected panel only) ...... 26

3.3.14 Checks.................................................................................................................. 26

3.3.15 Spare panels ......................................................................................................... 26

3.4 Assembling the wall frame ................................................................................. 27

3.4.1 Parts list for the wall frame .................................................................................... 27

3.4.2 Additional parts for upright frame for systems with Protected panel ....................... 27

3.4.3 Assembling the wall frame .................................................................................... 28

3.4.4 Fixing the front C sections ..................................................................................... 28

3.4.5 Fixing the C-sections and earth bar to the frame ................................................... 28

3.4.6 Fixing the branch earth bar ................................................................................... 28

3.4.7 Preparing fixed section .......................................................................................... 29

3.4.8 Fitting the frame .................................................................................................... 29

3.4.9 Fitting the installation to the wall ........................................................................... 29

3.4.10 Fixing the earth strip ............................................................................................. 30

3.4.11 Fitting the dust cap ................................................................................................ 30

3.4.12 Fitting the C-section in lower station (systems with Protected panel only) .............. 30

3.4.13 Checks.................................................................................................................. 30

3.4.14 Spare panels ......................................................................................................... 30

3.5 Connecting the cables, general .......................................................................... 31

3.5.1 Cable connection points ........................................................................................ 31

3.5.2 Fixing the cables ................................................................................................... 31

3.5.3 Fixing the cable cores ........................................................................................... 32

3.5.4 Cable boxes for paper-insulated lead-covered cables (PILC) ................................. 33

3.5.5 Cable boxes for plastic-insulated cables (XLPE).................................................... 34

3.5.6 Cable boxes to non-standard specification ............................................................ 34

3.6 Connecting the paper-insulated lead-covered cables (GPLK) .......................... 35

3.6.1 PILC with copper core up to 3 x 70 mm

2

, universal clamps ................................... 35

3.6.2 PILC with copper cores, 3 x 95 mm

2

up to 3 x 150 mm

2

, concentric clamps .......... 39

3.6.3 PILC with copper or aluminium cores up to 3 x 240 mm

2

, gland entry .................... 44

3.6.4 PILC with copper or aluminium cores up to 3 x 240 mm

2

, with plastic entry bushing47

3.7 Filling the cable box for paper-insulated, lead-covered cables ........................ 51

3.7.1 Materials required ................................................................................................. 51

3.7.2 Procedure ............................................................................................................. 51

3.8 Connection of plastic-insulated cables to C(able) and T(ransformer) panels .. 55

3.8.1 Plastic-insulated cable with copper core up to 3 X 70 mm

2

, universal clamps ........ 55

3.8.2 Connection of plastic-insulated cables with copper cores, 3 x 95 mm

2

up to 3 x

240 mm

2

, concentric clamps .................................................................................. 58

3.8.3 Plastic-insulated cable in a top connection ............................................................ 62

3.8.4 Connecting cables 95 mm

2

and over using alternative materials ............................ 63

3.8.5 Connecting Eaton 16 mm

2

transformer cable to the protected branch of the universal

clamps .................................................................................................................. 64

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3.9 Connection of plastic-insulated cables to Protected panels ............................ 67

3.9.1 Plastic-insulated cable with copper core up to 3 x 70 mm

2

..................................... 67

3.9.2 Connection of plastic-insulated cables with copper cores, 3 x 95 mm

2

up to 3 x

240 mm

2

............................................................................................................... 71

4. SYSTEM OPERATION .......................................................................... 75

4.1 Safe switching ..................................................................................................... 75

4.1.1 Switching on safely ............................................................................................... 75

4.1.2 Switching off safely ............................................................................................... 75

4.1.3 Safe earthing ........................................................................................................ 75

4.2 Switching ............................................................................................................. 76

4.2.1 Switching on ......................................................................................................... 76

4.2.2 Switching off ......................................................................................................... 79

4.3 Changing a fuse .................................................................................................. 80

4.4 Resetting an overcurrent indicator .................................................................... 81

4.4.1 Electromechanical overcurrent indicator ................................................................ 81

4.4.2 Electronic overcurrent indicator ............................................................................. 81

4.5 Protective relay operation .................................................................................. 81

4.6 Voltage indication ............................................................................................... 82

4.6.1 Voltage indication.................................................................................................. 83

4.6.2 System ‘dead’ indication ....................................................................................... 83

4.6.3 Phase sequence indicator ..................................................................................... 84

4.6.4 Demonstrate phases are in line ............................................................................. 85

4.7 Earthing ............................................................................................................... 86

4.7.1 Equipment............................................................................................................. 86

4.7.2 Earthing a cable using single-pole slow earthing ................................................... 87

4.7.3 Earthing a cable using three-pole high-speed earthing .......................................... 88

4.7.4 Removing three-pole high-speed earthing ............................................................. 90

4.7.5 Earthing a transformer .......................................................................................... 91

4.7.6 Earthing a protected panel .................................................................................... 92

4.8 Measuring, testing and phase sequence testing ............................................... 94

4.8.1 Measuring ............................................................................................................. 94

4.8.2 Testing .................................................................................................................. 94

4.8.3 Phase sequence testing ........................................................................................ 95

5. SYSTEM COMMISSIONING AND DECOMMISSIONING ..................... 96

5.1 Commissioning ................................................................................................... 96

5.1.1 Acceptance testing ................................................................................................ 96

5.1.2 Inspections ........................................................................................................... 96

5.1.3 Handover .............................................................................................................. 96

5.2 Decommissioning ............................................................................................... 96

5.2.1 Dismantling ........................................................................................................... 96

5.2.2 Procedure ............................................................................................................. 97

5.2.3 Disposal ................................................................................................................ 97

6. INSPECTION, MAINTENANCE AND REPAIR OF THE SYSTEM ........ 98

6.1 Logbook............................................................................................................... 98

6.2 Inspection and maintenance, general ................................................................ 98

6.2.1 Types of maintenance ........................................................................................... 98

6.2.2 Frequency ............................................................................................................. 98

6.2.3 Tools ..................................................................................................................... 99

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6.3 Cleaning .............................................................................................................. 99

6.3.1 Switchgear has been isolated ................................................................................ 99

6.4 Inspection and maintenance schedule............................................................. 100

6.4.1 Periodic checks ................................................................................................... 100

6.4.2 Periodic check of protected panel ........................................................................ 100

6.4.3 Maintenance ....................................................................................................... 100

6.5 Topping up grease-filled cable boxes for paper-insulated lead-covered cables101

6.6 Fault diagnosis .................................................................................................. 102

6.6.1 What to do in the event of a fault ......................................................................... 102

7. ACCESSORIES ................................................................................... 103

7.1 Spare parts ........................................................................................................ 103

7.2 Accessories ....................................................................................................... 105

8. GLOSSARY ......................................................................................... 106

8.1 Safety and personnel qualification................................................................... 106

8.2 Abnormal Operating conditions ....................................................................... 107

8.3 Equipment and the area surrounding it ........................................................... 107

9. APPENDIX ........................................................................................... 108

9.1 Appendix - Electrical Diagram .......................................................................... 108

9.2 Appendix - Floor plan ....................................................................................... 109

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1. INTRODUCTION

1.1 General system description

Magnefix switchgear is intended for building compact

switchgear and distribution systems in a medium-voltage

system. This switchgear can be used:

 in compact transformer substations in a ring cable

system, decentralised transformer arrangements,

customer connections;

 for feeding large buildings;

 on the storeys of buildings;

 in railway signalling and protection systems.

In distribution panels, Magnefix switchgear is used as cable

disconnector, busbar disconnector and tie circuit breaker.

Magnefix switchgear with a protected panel is used for

protected connections of additional ring cable connectors in

distributions networks and for protected connections of

distribution transformers having powers exceeding

1000 kVA.

1.2 Using the user manual

1.2.1 Target group

The switchgear is designed for use by personnel who are

expert or adequately trained in using switchgear and/or

carrying out electrical operations.

For definitions of these terms, see Chapter 8 – Glossary.

1.2.2 Structure of the user manual

The manual contains 9 chapters.

Chapters 1 and 2 contain general information on the

system (design and construction) and the manual, and

general safety aspects. The information is presented in the

form of descriptive texts, supported by illustrations as

necessary. Illustrations are numbered consecutively for

each chapter, and are captioned if necessary.

Chapters 3 to 7 consist mainly of procedures. These

procedures contain step-by-step descriptions of actions in

the order in which they should be carried out. Illustrations

are on the same page as the relevant step and have the

same number.

WARNING

Never take any action without knowing what effect

it will have.

REMARK

Read through all actions first, using the relevant

figures. Contact Eaton if you do not understand

what you have to do.

Further information regarding chapters 3 to 7 is given

below.

Chapter 3 – Switchgear set-up

The manual assumes that the switchgear is being

assembled and connected by the user . It also describes

the requirements for the switchroom. This chapter also

includes the procedures for connecting cables.

Chapter 4 – Switchgear set-up

This chapter is aimed at the operator who is expected to

operate and monitor the system independently. For that

reason, these activities are described in detail.

Switchgear commissioning and decommissioning

Chapter 5.1 sets out the actions required before the system

can be commissioned.

Chapter 5.2 deals with decommissioning the system. It also

includes recommendations for the safe disposal of the

system or parts of the system.

Chapter 6 - Inspection, maintenance and repair of

the switchgear

This chapter describes only those operations that may be

carried out by the user.

NOTE

Operations not included in the manual must be

carried out by or under the supervision of Eaton.

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Chapter 7 - Accessories

This chapter gives a summary of available accessories and

spare parts.

Chapters 8 and 9 are explanatory chapters of a general

nature.

Chapter 8 - Glossary

This chapter contains clarifications of specific terms used in

the manual but not explained further.

Chapter 9 – Appendix

This chapter contains the appendices.

1.3 Safety regulations

NOTE

Read this user manual carefully before

commissioning the switchgear. Make sure that you

have read and understood all safety instructions

and warnings.

1.3.1 General instructions

Read this user manual carefully before commissioning the

switchgear. Make sure that you have read and understood

all safety instructions and warnings.

Personnel

The user must make sure that personnel are qualified to

carry out the task.

Safety of bystanders

Access to the equipment is to be limited to those directly

involved in operating or maintaining it.

Safety plan

It may be necessary to draw up a safety plan.

Comprehensive advice on this should be obtained from the

relevant authorities (fire brigade, local authorities,

occupational health & safety, company safety department,

first aid service etc.).

Safety standards

Magnefix switchgear without protected panel complies with

the following standards:

IEC 62271-103:

High voltage switches for rated voltages

above 1 kV and less than 52 kV;

IEC 60282:

High voltage fuses;

IEC 62271-105:

High voltage switch-fuse combinations for

rated voltages above 1 kV up to and

including 52 kV.

IEC 62271-1:

Common specifications for high voltage

switchgear and controlgear standard.

IEC 60529:

Degrees of protection provided by

enclosures (IP Code);

IEC 62271-201:

A.C. insulation-enclosed switchgear and

controlgear for rated voltages above 1 kV

and up to and including 52 kV, protection

grade PB1;

Magnefix switchgear with protected panel additionally

complies with the following standards:

IEC 62271-100:

High-voltage alternating-current circuit-

breakers (relevante delen);

IEC 61000:

Electromagnetic compatibility (EMC).

Magnefix switchgear can be used in areas under normal

conditions as described in IEC 62271-1, Chapter 2.1.

1.3.2 Switch room safety

The installation and the switchroom must comply with all

local safety regulations in force.

The switchroom is the room in which the switchgear has

been set up and must meet at least the following

requirements:

Clear space

To the front and rear of the switchgear, and between two

installations sited opposite each other, enough space must

be allowed over the entire length of the installation to allow

operations to be carried out.

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Escape routes

To the front and rear of the installation and between two

installations sited opposite each other, an escape route at

least 0.5 m wide and 2 m high must be present over the

entire length. The width of the escape route is measured

from the part of the installation which projects furthest. The

escape route must be completely clear and as far as

possible in a straight line.

REMARK

The installation may be set up with the back against a

wall. In that case there will be no clear area or escape

route at the rear.

Entrances

Entrances to the switchroom and escape routes must be

kept clear at all times.

Storage of materials

Items not connected with the installation must not be stored

in the switchroom. Flammable materials, combustible

gases and hazardous chemicals must not be stored.

Availability of extinguishers

Suitable extinguishers must be present in and around the

switchroom. Obtain expert advice (fire brigade) on the best

choice and location of the extinguishers.

1.3.3 Notation guide

This manual uses warning boxes to alert the user to

possible dangers while operating or maintaining the

equipment:

WARNING

Personal (fatal) danger to personnel and

bystanders.

CAUTION

Danger of damage to equipment.

NOTE

Important note for clarification.

REMARK

Useful advice.

1.3.4 What to do in the event of a fire

In the event of a fire in the switchroom, proceed as follows:

 Evacuate all personnel from the switchroom.

 Call the fire brigade.

 Notify specialists who can switch off the installation

completely, i.e. including:

 incoming cables;

 low-voltage cables;

 feedback from the low-voltage side;

 any other power sources.

 Follow local fire instructions.

WARNING

• NEVER ATTEMPT TO EXTINGUISH THE

INSTALLATION BEFORE IT IS COMPLETELY

DEAD.

• NEVER extinguish with a water jet.

• Make sure that no water flows into the

installation.

• Keep well clear of the switchgear while the fire

is being extinguished in the area around

it.

Even when using non-conducting extinguishing

materials, a voltage may pass through the

extinguishing equipment.

Extinguishing:

 If possible, leave extinguishing the fire to the fire

brigade.

 Use non-conducting extinguishing materials.

 If necessary, use extinguishers in the area around the

installation. Never attempt to extinguish the installation

itself, even if it appears to be dead.

1.4 Product information

The main system specifications are indicated on the type

plates. Further information is available from the information

pack which includes this manual.

1.4.1 The type plate

A complete type plate is made up of a main type plate with

supplementary type plates as required. The main type plate

is headed with the Eaton logo and address.

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type plate (main section) of the fixed part (example)

supplementary type plate (most commonly used) on vacuum circuit-breaker (example)

Variable

Description

unit

(English)

system

-

rel.

release

-

IEC

-

serial.no.

Serial number

-

year of constr.

year of construction

-

w.o.no.

work order number

-

U

r

rated voltage

kV

f

r

rated frequency

Hz

I

r

rated normal current

A

I

r

T-off

rated normal current

A

switch/circuitbreaker

I

k

rated short time withstand voltage

kA

t

k

rated duration of short-circuit

s

I

p

rated peak withstand current

kA

U

p

rated lightning impulse withstand voltage (peak value)

kV

peak

U

d

rated power frequency withstand voltage

kV

peak

I

ma

rated short-circuit making current

kA

I

sc

rated short-circuit breaking current

kA

I

c

rated cable charging breaking current

A

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2. SYSTEM DESCRIPTION

2.1 The switchgear

2.1.1 Type of switchgear

Magnefix is a fully enclosed type of switchgear.. The use of

quartz-powder-filled epoxy resin allows a very compact

configuration.

Magnefix MD4 switchgear is easy to install on site.

Magnefix switchgear offers high operational reliability, even

under adverse operating conditions. Magnefix switchgear is

shock-resistant, tropicalised and safe to touch because of

its double insulation.

2.1.2 Configuration of switchgear

Magnefix switchgear is a modular system built up of

standard panels. The basic modules (basic panels) are:

 The cable panel, with bottom or top connection for

feeder cables;

 The branch-circuit panel (usually combined with a fuse

or protected panel)

 The fuse panel;

 The protected panel;

 The busbar connecting panel.

The switch panels (cable panel and branch-circuit panel)

are provided with single-pole switch caps; each phase

having one switch cap. A switch cap may be fitted with an

indicator for continuous overcurrents.

An outgoing cable can be connected to the fuse panel (for

example, for connection to a transformer).

Three single core plastic cables having a maximum 240

mm

2

cross section may be connected to the protected

panel.

There are also modules for special uses, such as:

 The busbar connecting panel;

 The busbar connection for a cable;

 The connecting panel (for example, for connection to

an Eaton high-voltage Capitole or SVS busbar

system);

 The separate fuse panel (not connected to the

busbars, but having connection facilities for incoming

and outgoing cables).

The assembled modules are mounted in an upright or wall-

mounted frame. The modules can be assembled in any

sequence; a set of screw rods holds them together. Rubber

sleeves are used to ensure that no spark voltages can

develop at the connections between the panels.

The sides are provided with plastic plates, the top being

fitted with a dust cover. These facilities protect the

switchgear against dust, dirt and water drops.

Silver-plated tubular conductors act as busbars; they

create the electrically conductive connections between the

panels. The busbars are situated completely inside the

epoxy resin insulation.

Configuration

Magnefix switchgear comes in two configurations:

 Switchgear built up of conventionally cast epoxy resin

insulated modules. These modules have a flat well-

finished outside surface.

 Switchgear featuring pressure gelated epoxy resin

insulated modules. The outside of these modules has

a glossy appearance. From a functional point of view

there is no difference between the two configurations.

2.1.3 The cable panel

The cable panel has a three-phase connection point for the

cable (three round pins each measuring 12 mm). Fitted on

the cable panel are three switch caps on which the

connection between the cable and busbar can be seen to

be made or broken.

2.1.4 The branch-circuit panel

The branch-circuit panel is similar to the cable panel, but it

has no three-phase connection point for the cable. The

branch-circuit panel links the fuse or protected panel to the

busbar system. Fitted on the branch-circuit panel are three

switch caps on which the connection between the fuse or

protected panel and busbar can be seen to be made or

broken.

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2.1.5 The fuse panel

The fuse panel has a three-phase cable-connection point

and three fuse holders with removable caps. A mechanical

interlock ensures that the fuses cannot be replaced until

the switch caps of the branch-circuit panel have been

removed.

The connection contacts on the transformer side of the

fuse holder are deep in the holder so they cannot be

accidentally touched.

2.1.6 The protected panel

The protected panel has a three-phase cable-connection

point, a three-phase vacuum circuit-breaker with

autonomous switch-off function and a mimic diagram.

Using a vacuum circuit-breaker combined with the

protection relay enables overloads, short-circuits and

earthing fault currents to be switched off.

A mechanical lock ensures that the vacuum circuit-breaker

can only be switched on manually when the circuit is dead,

after the switch caps of the branch-circuit panel have been

removed

2.1.7 The busbar connecting panel

The purpose of the busbar connecting panel is to enable

two busbar systems to be connected. The connecting

panel is generally supplied without switch caps.

A connecting panel is used in redundant switchgear.

2.1.8 Switching on and off

REMARK

The following is a description of the switchgear.

For the procedures refer to Chapter 4.

Switching is achieved by fitting or removing switch caps. Be

sure to use a springing handle when performing this

operation. The switch caps ensure a double interruption of

each phase.

The fixed switch contacts are fitted to the busbar and the

cable connection point. They have replaceable arcing

chambers and arcing contacts. The 'on' switch cap is

secured by a strong permanent magnet (hence the name:

Magnefix).

The mobile switch contacts are housed in the switch caps.

They have arcing contacts and internal tripping and contact

force springs.

A ferromagnetic steel plate, to which the permanent

magnet can attach, is also fitted between the mobile

contacts. Fitted to the outside of the cast-resin insulated

member of the switch is a spring-mounted cam.

Switching on the switch caps

To switch on, put a switch cap on the springing handle.

Next, push the switch cap against the cam using the

switching handle. Push the springing handle to compress

its closing spring.

As soon as the force on the switch is more than the

resistance of the cam, the cap is pushed over the cam by

the action of the closing spring in the handle. Now the

switch contacts close: the main contacts first, followed by

the arcing contacts.

When switched on, the magnet and ferromagnetic plate

keep the switch caps in position. Next, remove the

springing handle from the switch cap.

Switching on a protected panel

To enable the panel to be switched on, first remove the

corresponding switch caps by pulling them out using the

springing handle. Next, manually switch on the three

phases of the vacuum circuit-breaker. Now the switch caps

are replaced one at a time.

The protected panel has a position indicator for checking

purposes

Incorrect switching operations are avoided thanks to the

use of mechanical interlocks.

Switching off the switch caps

To switch off, put the springing handle on the switch cap.

Next, pull off the cap. The main contacts are released first.

Simultaneously, the opening springs are tensioned, but the

magnet holds the arcing contacts closed. Pull with more

force to release the ferromagnetic plate. The opening

springs pull the arcing contacts out of the arcing chambers

at high speed.

Switching off a protected panel

A protected panel can be switched off as follows:

 automatically by the autonomous switching off

mechanism;

 manually by activating the switch-off push button.

Incorrect switching operations are avoided thanks to the

presence of a key interlock.

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13

2.1.9 The indicators

The overcurrent indicator.

The switch caps may have an overcurrent indicator at the

front.

Working either electromechanically or electronically, the

overcurrent indicator is fitted under the protection cap of

the switch cap.

REMARK

Fitted with an electronic overcurrent indicator, the

switch cap is 21 mm higher than a switch cap with

an electromechanical overcurrent indicator.

There is a small window in the protection cap.

If the current passing the switch cap exceeds a preset

value, a red flag is displayed in the window. As soon as the

overcurrent situation ceases to exist, the electromechanical

overcurrent indicator can be reset using a magnet.

The electronic version has a self-resetting function.

The position indicator

The protected panel has a position indicator at the front (in

the panel diagram). This position indicator operates

mechanically.

If the position indicator is black, the vacuum circuit-breaker

is switched on.

If the position indicator is white, the vacuum circuit-breaker

is switched off.

2.1.10 Earthing

General

Magnefix switchgear can be earthed via the cable and the

transformer. It is not possible to earth the busbar system.

Cable earthing

The earthing system for the cable consists of a set of three

earthing caps fitted where the switch caps are located, in

the cable panel to be earthed.

Transformer earthing

The earthing system for the transformer consists of a set of

three earthing pins fitted in the corresponding fuse panel.

The earthing caps or pins are connected to the earthing

point of the switchgear using a bolted connection and

special earthing cables.

Earthing of the protected panel

The earthing system for the protected panel consists of a

set of three earthing caps fitted where the switch caps are

located, in the corresponding branch-circuit panel. In order

to start with the standard earthing procedure, the vacuum

circuit-breaker must be switched on and interlocked using a

key.

2.2 Switchgear safety

This paragraph contains a description of the safety

provisions on the Magnefix switchgear and directions on

how to deal with them.

2.2.1 Switchgear operation

Competence

The equipment must only be operated by skilled personnel

and specialist operators.

Actions not described in this manual.

Operating or maintenance actions not described in this

manual may be required:

 Actions which are specific to your installation are

described in the operating instructions supplied with it.

See information pack which includes this manual.

 Actions which are not described at all may only be

carried out in consultation with an Eaton specialist.

The instructions of this specialist must be followed

exactly.

Special safety measures

In general it will not be necessary to take special safety

precautions when operating the switchgear. It is advisable,

however, to wear suitable ear protection for repeated

switching.

When carrying out work, please observe the following:

 Cover open switches (on panels completely or partly

switched off) with protective covers. A protective cover

must be fitted immediately after switching off and it

must not be removed again until just before switching

on.

 Always protect cable connection points that are not

used with a dummy cable box.

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2.2.2 Safety features

The switchgear is provided with the following safety

features:

 All-round insulation protecting against touching live

parts.

 Mechanical interlocks prohibiting faulty switching

operations.

 Visible isolation between busbar and cable (the switch

caps have been visibly removed).

 Facilities for earthing cables and transformers.

2.2.3 Use of safety features

 Keep the insulation (i.e. the outside of the switchgear)

in a perfectly clean and dry condition.

 Replace mechanical interlocks as quickly as possible

if they do not perform optimally.

 Cover switched-off cast-resin insulated members that

may still be live, and put-up a warning notice.

 Keep earthing caps and earthing cables in perfect

condition. Make sure that the earthing points on the

upright or wall-mounted frame are free from corrosion

and oxidation, and that they are conductively

connected to earth.

2.2.4 Carrying out work

WARNING

• ALWAYS check that the equipment is dead.

• Fit suitable earthing.

• NEVER approach an unearthed installation.

• Always work on dead installations.

Ensure maintenance work is carried out in good time, in

accordance with the instructions in this manual.

Replace worn and/or damaged parts only with genuine

Eaton spare parts, or spare parts approved by Eaton.

Take the following minimum precautions when carrying out

work:

Working on live or partly live installation:

 Eaton advises, for the necessary safety, never to work

on live or partly live installations. This is described in

NEN 3840 Operation of electrical installations - High

Voltage, Chapter 6.2.

Working on a dead installation:

 After switching off a panel, IMMEDIATELY fit a set of

covers to the open switches or fuse holders.

 ALWAYS check that the equipment is dead.

 Fit earthing; work on earthed panels only.

 When performing measurements check that the

vacuum circuit-breaker is switched on and interlocked.

When re-commissioning

 Check that all work in the immediate area has been

completed.

 Check (if appropriate) that all related work in other

areas has been completed.

 Verify the safety of all persons involved.

 Remove safety earthing and other safety features.

2.2.5 Safety markings

Fitted to the front of the dust hood placed over the

switchgear is a sign displaying:

PLACE CAP SLOWLY AGAINST STOP

THEN PUSH ON ENERGETICALLY

The following signs indicate possible dangers:

Dangerous electrical voltage.

Electrical safety earth.

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15

2.3 General technical data

This section contains general technical data only. For details concerning your own system, please refer to the information pack

supplied with it, which includes this manual.

2.3.1 Electrical data

Rated values:

Voltage

kV

3.6

7.2

12

Impulse withstand voltage

kV

40/46

60/70

75/85

Power frequency withstand voltage

kV

10/12

20/23

28/32

Frequency

Hz

50/60

Busbar system

Normal current

A

400

Short-time withstand current (1s)

kA

14.4

Peak withstand current

kA

31

Single-pole load-break switches

Normal current

A

400

Breaking current (cos  = 0.7)

A

400

Short-circuit making current

kA

31

Short-time withstand current (1s)

kA

14.4

Capacitive earth fault current

A

240

Cable charging current

A

25

No-load transformer breaking current

kVA

1250

Fuses

Normal current

A

57.7

Voltage

kV

10/12

Dimensions according to DIN43625

Vacuum circuit-breaker

Type

NVX124A-1204

Normal current

A

400

Short-time withstand current (1s)

kA

14.4

Short-circuit breaking current

kA

14.4

Direct current component

%

20

Making current

1)

A

*

1)

There is no making current when switching on. The vacuum circuit-breaker can only be switched on

when the circuit is dead.

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991.184 G01 03

2.3.2 Dimensions and weights

Dimensions – upright version

Panel name width weight

Cable panel (including switch caps) 91 mm 15 kg

Busbar connection 91 mm 7.5 kg

Connecting panel 91 mm 4.5 kg

Busbar connecting panel (sectional panel including switch caps) 182 mm 19.5 kg

Protected panel with current transformers (including branch-circuit panel and switch caps) 230 mm 61.5 kg

Fuse panel with branch-circuit panel (including switch caps and fuse holders, excluding fuses)

230 mm 37.5 kg

Busbar connecting panel with SVS or HC switchgear 91 mm 9 kg

Height 1517 mm

Depth with fuse panel 517 mm

Depth without fuse panel

(measured with a switch cap having an electromechanical indicator) 423 mm

Depth with protected panel (including earthing interlock) 570 mm (+ 27)

Calculation of width (example):

B= (K x 91) + (T x 230) + 72 where: K: number of cable panels

T: number of protected branches

Total switchgear width (B): number of panels (panel width) + 2 side plates.

Maximum switchgear width (B): 1404 mm (including 3

rd

support point) or maximum weight: 240 kg.

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Dimensions – wall-mounted version

Panel name widths weight

Cable panel (including switch caps) 91 mm 15 kg

Busbar connection 91 mm 7.5 kg

Connecting panel 91 mm 4.5 kg

Busbar connecting panel (sectional panel including switch caps) 182 mm 19.5 kg

Protected panel with current transformers (including branch-circuit panel and switch caps) 230 mm 61.5 kg

Fuse panel with branch-circuit panel (including switch caps and fuse holders, excluding fuses)

230 mm 37.5 kg

Busbar connecting panel with SVS or HC switchgear 91 mm 9 kg

Height (overall height) 1487 mm

Depth with fuse panel 517 mm

Depth without fuse panel

(measured with a switch cap having an electromechanical indicator) 465 mm

Depth with protected panel (including earthing interlock) 605 mm (+ 27)

Calculation of width (example):

B= (K x 91) + (T x 230) + 72 where: K: number of cable panels

T: number of protected branches

Total switchgear width (B): number of panels (panel width) + 2 side plates.

Maximum switchgear width (B): 1404 mm (including 3

rd

support point) or maximum weight: 240 kg

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991.184 G01 03

2.3.3 SEG protection relay

The protection relay is fitted in a separate secondary

compartment under the switching mechanism for the

protected panel. This protection relay comes with a

separate manual. This manual is part of the information

pack.

Refer to Chapter 9 for electrical diagram.

The secondary compartment consists of the following:

 metal cover (11);

 protection relay (10);

 electric trip indicator (9).

Protection relay and trip indicator.

2.3.4 Heat, radiation, noise and gases

Heat

In general, it can be said that the heat generated in full-

load service will lead to a maximum temperature rise of the

outer surface not exceeding the body temperature.

Radiation

Radiation is well below the safety standard level.

Noise

In general it can be stated that the switchgear does not

generate any noise under operating conditions apart from

switching operations. The noise during switching

operations is less than 70 dB(A), such that noise protection

measures are not required.

Gases

Before service, in service and after service no gases will be

released (except when an electric arc develops).

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3. SETTING UP THE SYSTEM

3.1 Introduction

3.1.1 Transport

Transport for the Magnefix switchgear can be arranged by

Eaton. Detailed instructions are beyond the scope of this

manual. Please contact Eaton Service if necessary. You

will find the address and telephone number on the title

page of this manual.

CAUTION

Transport the fuses in appropriate (original)

packing only.

The switchgear can be installed by the user's authorised

personnel.

This chapter contains general information on transporting

and setting up Magnefix MD4 switchgear and on

connecting the cables.

3.1.2 Environmental requirements

The switchroom in which the switchgear is set up must

comply with the following:

 all safety regulations in force locally;

 the requirements set out in the chapter on safety;

 the requirements in this paragraph.

3.2 General

3.2.1 During operation

Climate

In accordance with IEC 62271-1 par. 2.1.1 the climate in

the switchroom must comply with the following

requirements:

 Humidity:

maximum 90% relative over a period of 1 month. In

new buildings it is essential to dry out the area before

installing the system.

 Temperature:

 maximum +40°C, measured over a period of 24

hours.

 average not more than +35°C.

 minimum not less than - 25°C.

 The room must be free from dust, corrosive or

flammable gases and salts.

The minimum temperature for Magnefix switchgear with P

panel must not be lower than -5° C.

If the Magnefix switchgear is installed in a switchroom

where unfavourable environmental conditions prevail,

special precautions must be taken to counteract discharges

and the attendant accelerated ageing of the switchgear.

Factors adversely affecting switchgear service life are:

 A combination of dust and moisture: installation in

areas of high relative humidity, high groundwater level

or in areas abounding in water;

 Temperature variations within the switchroom (which

are liable to cause condensation);

 Presence of corrosive substances, for example in the

proximity of chemical plants, farms or alongside large

motorways;

 A salty atmosphere; for example, in a coastal region.

 Air currents, for instance caused by draughts or

transformer ventilation air, carrying dust liable to

deposit on the switchgear.

The sections that follow describe the main steps that are

required to be taken in order to keep the Magnefix

switchgear in a proper (and therefore reliable) condition for

as long as possible.

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991.184 G01 03

3.2.2 Ventilation

Magnefix MD4 switchgear does not require ventilation.

However, air circulation around the switchgear may carry

dust liable to deposit on the installation.

Take the following precautions in order to prevent

undesirable air circulation:

General

 Ensure that the switchroom doors provide a good seal

in order to prevent draughts.

 If located alongside a busy motorway or in the vicinity

of a farm or chemical plant, take action to minimise the

quantity of polluted air entering through the ventilation

slots.

Room without a transformer

 Avoid air circulation inside the room; the switchgear

does not need any cooling.

 If you decide on having a ventilation slot, position it

low in the room.

Room with a transformer

 Position the ventilation slots such that the air flow

intended for transformer ventilation does not pass over

the switchgear.

 If ventilation air flow over the switchgear cannot be

avoided, install an adequate dust guard.

 Keep the switchgear thoroughly clean.

3.2.3 During transport and storage

If the switch panels are stored temporarily prior to

installation, or during transport:

 Do not unpack the switch panels;

 Store the switch panels vertically in a dry and dust-

free area;

 Ensure that the transportand storage environment

complies as far as possible with the requirements of

IEC 62271-1, par. 2.1.1;

 Avoid condensation caused by rapid temperature

changes.

NOTE

Keeping the installation under adverse conditions in

the open air may cause corrosion and deterioration of

the insulation level.

Ventilation:

Left: correct set-up.

Right: air currents deposit dust and dirt.

Ventilation:

Top: correct set-up.

Bottom: air currents deposit dust and dirt.

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Eaton Magnefix MD4 User manual

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