FC MCC User Manual V0
FC MCC User Manual V0
FC MCC User Manual V0
3kV-12kV
Air Insulation Switchgear
User Manual
SecoGear MCC
Page 1 of 73
Safety f irst!
Important recommendations:
Switchgear and/or switchboards should be installed in closed rooms suitable for elect rical equipment.
Installation, operation and maintenance should be carried out by licensed electricians.
Fully comply with the applicable standards (e.g. IEC), the utility connection requirements and the
applicable safety regulations.
Observe the relevant instructions in the instruction manual for all actions in relation to switchgear and
switchboards.
Pay attention to the hazard notes in the instruction manual marked with this warning symbol.
Make sure that the specified data are not exceeded under switchgear or switchboard operating
conditions.
Keep the instruction manual accessible to all personnel involved in installation, operation and
maintenance.
The users must act responsibly in all matters affecting safety at work and correct handling of the
switchgear.
WARNING
Always follow the instruction manual and respect the rules for good engineering practice!
Disconnect power, then earth and short-circuit before proceeding with any work on the
equipment.
If you have any further questions about this instruction manual, our field team will be pleased to provide the
required information.
We reserve all rights to this publication. We do not accept any responsibility for the information provided,
which is subject to alternation.
Page 2 of 73
INDEX
1. General 4
1.1 Summary 4
1.2 Standard and specification 4
1.3 Operating conditions 5
1.4 Safety and environment protection requirement 6
2. Technical Specification 7
2.1 Technical specification for SecoGear MCC 7
2.2 Technical specification for Fuse - Contactor 7
2.3 Technical specification for Fuse 8
2.4 Main circuit resistance of Contactor 8
2.5 Technical specification for Earthing switch 8
3. Panel design and equipment 9
3.1 Basic structure and variants 9
3.2 Interlock/protection against erroneous operation 15
3.3 Mechanical Position Indicator(Optional) 24
3.4 Fortress / Castell keylock(Optional) 25
3.5 Panel to Panel Coupling 29
3.6 Arc release system 30
3.7 Motorized operation mechanism(Optional) 36
4. Dispatch and storage 42
4.1 Condition on delivery 42
4.2 Packing 42
4.3 Transport 42
4.4 Upon Receipt 44
4.5 Intermediate storage 44
5. Assembly of the switchgear on site 46
5.1 Panel layout for switchgear arrangement 46
5.2 Installation method 49
6. Operation of the switchgear 51
6.1 Preparations 51
6.2 Use of hand tools 51
6.3 Rack F-C truck out from service position to test / disconnected position 52
6.4 Earthing switch operation 56
7. Inspection and maintenance 58
7.1 Summary 58
7.2 Inspection and maintenance interval 58
7.3 Diagnosis and trouble shooting for malfunctioning during operations 59
7.4 Maintenance item and cycle 60
7.5 Routine Inspection 60
7.6 Service 61
7.7 Repairs 61
7.8 Inspection Items 61
7.9 Performance test 62
7.10 Major Repairs and examples 62
7.11 Spare parts 72
7.12 Accessories / operating tools 72
8. Appendix 73
Page 3 of 73
1. General
1.1 Summary
This publication contains the information required for installation, commissioning, operation and maintenance of
SecoGear MCC.
SecoGear MCC is three-phase, metal enclosed, air-insulated factory assembled switchgear. SecoGear MCC is
type-tested and suitable for indoor applications up to 12 kV. The panel is designed with withdrawable modules
and is fitted with a single busbar system. The withdrawable parts are equipped with fuse-contactor.
Details of the technical design and configuration of individual switchgear, such as the technical data, detailed
part lists for the individual panels and comprehensive circuit documentation etc., can be found in the relevant
order documents.
For correct usage of the switchgear, please read this manual carefully. It is always advisable to use the
manual for all operations regarding installation, commissioning, operation and maintenance of SecoGear
MCC air-insulated switchgear.
This instruction is also used as references for personnel to carry on regularly maintenance for switchgear.
SecoGear MCC complies with the standards and specifications for factory-assembled, metal enclosed and type
tested high voltage switchgears to IEC publications as given below.
Page 4 of 73
1.3 Operating conditions
1.3.1 Normal operating conditions
The switchgear is fundamentally designed for the normal service conditions for indoor switchgear to IEC Publication
IEC62271-1ed 1.1 (2011). The following limit values, among others, apply.
Ambient temperature
- - Maximum + 40°C
- - 24h-Medium +35°C
- - Minimum -15°C
Humidity
- Highest average value measured over 24 hours
o Relative humidity 95 %
- Highest average value measured over 1 month
o Relative humidity 90 %
Page 5 of 73
1.4 Safety and environment protection requirement
1.4.1 Safety Procedure
Wear the safety uniform according to electric safety regulations before entering the site
Comply with industry work procedure. Power supply shall be operated by authorized staff.
Page 6 of 73
2. Technical Specif ication
2.1 Technical specification for SecoGear MCC
Table 2.1
ITEM Unit Specification
Function F-C
Rated voltage: kV 3.6/7.2/12
Rated frequency: Hz 50/60
Rated power freq Phase to phase and to earth 28
kV
withstand voltage (1 min): Between isolating distance 32
Rated lightning impulse Phase to phase and to earth 75
kV
withstand voltage: Between isolating distance 85
Main busbar rated current A 1250/2000/2500/3150
Rated current, max. A 400
4/6(without current limitation through
Rated short time withstand current KA
HRC fuse)
Rated duration time for short-circuit s. 3/1
F-C circuit
kA 50
Prospective breaking current, max
Main circuit resistance µΩ ≤400
Class A FLR for 40 kA, 1s for all HV
Internal arc degree with arc safety channel
compartment
Loss of service continuity classification LSC-2B
Partition CLASS PM
Table 2.2
Item Unit Specification
Rated Voltage Kv 3.6/7.2/12
Rated Frequency Hz 50/60
Rated power freq withstand voltage (1 min) kV 38
Rated lightning impulse withstand voltage: kV 75
Rated Currents for contactor: A Decided by Rating of fuse
Rated short-time withstand current (3s\1s): kA 4\6
Rated making current: kA 4
Rated short-circuit breaking current (expected value) kA 50
Rated peak withstand current kA 10.4
Maximum rated breaking current A 3200
Minimum rated breaking current A 80
Utilization category AC3/AC4
Damage Classification Type C
Latch type both latched & non latched reqd Mechanical/ Electrical
Mechanical life (Electrical latch) Times 300k
Mechanical life (Mechanical latch) Times 300k
Page 7 of 73
Number of auxiliary contacts 5a/5b check customer requirement
Minimum Auxiliary contacts rating AC 110V/5A, AC220V/2A AC 0r DC
24/30/36/48/60/110/125/220 V DC
Control voltage:
110/125/220 V AC
Under voltage and tripping coil for Mechanical Latched
Required
type contactor
Anti-pumping relay Required
The drop-out voltage of contactor(Electric latch-in) 10%~75%
Max take –over current A 3200
Table 2.5
S/N Specification Unit Data
2 Rated Work frequency withstand voltage (1min) in open condition of switch kV 20/28
3 Rated Lighting impulse withstand voltage (peak value) in open condition of switch kVp 60/75
Page 8 of 73
3. Panel design and equipment
All compartments except Busbar compartment are accessible from the front with their own independent doors.
Doors are of pressure resistant. Inspection window made of security glass is provided on F-C Combination
compartment door and cable compartment door. The panel design provides air gap between two adjacent panels as
cushion after panels are joined together.
At the bottom of the cable compartment Gland plate is fitted. The rear wall of the Busbar compartment, intermediate
wall, mounting plate with shutters and horizontal partition form part of the internal partitioning.
The earthed internal partitioning ensures safe access to the F-C Combination and cable compartment even when the
busbars are energized.
The low voltage compartment is fully protected from the high voltage area with the earthed steel-sheet casing.
On the end sides of the switchboard, end cover plates are provided for consistent appearance, as well as mechanical
and thermal strength in case of internal arc fault in the end panel.
Doors, rear walls and cover plates are treated against corrosion and then coated with high quality paint. The finishing
coat is in the standard RAL 7035 colour (special colours by agreement). The doors for F-C Combination and cable
compartment are pressure resistant and can be fitted with central locking system with handles.
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3.1.3 Switchgear structure:
Page 10 of 73
3.1.4 Layout of Auto-transformer motor starting configuration
SecoGear MCC panel has various configurations based on the components inside the switchgear etc.,
2. Mechanical Interlock between ES with all FC/ Contactor truck for reverse/ star-delta and auto-transformer
Figure 3.2-01
Dimension in mm
Description Item
(12kV)
Height A 2200
Rated current of branch
Width B 650
400A 4kA
Depth C 1400
Page 11 of 73
Figure 3.5: Typical dimensions of SecoGear
(including withdrawable FC )
Figure 3.6: Bus bar compartment Figure 3.7: panel to panel Busbar connection
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3.1.6 F-C Combination compartment
The F-C Combination compartment contains all the necessary interfaces for all the operations of the withdrawable
part & the Panel. Compartment is metallically partitioned from all the sides.
The metallic shutters inside the panel opened by means of actuating bracket mounted on withdrawable part (2 in
Figure 3.9) while inserting to service position, and are closed when FC truck is removed from the panel.
In the disconnected/test position, F-C Combination is completely inside the panel with Door closed condition.
From the Inspection window on the door, Mechanical indicators for ON/OFF and emergency OFF Push buttons
located on the F-C Combination can be observed.
The under carriage assembly establishes the mechanical connection between the panel and the
F-C Combination. The moving part with the F-C Combination is moved manually or by a motor by means of a Racking
handle, between the service or test/disconnected positions with the front doors closed. Auxiliary Switches are
provided in undercarriage for Service and test/disconnected position.
Page 13 of 73
Figure 3.9: Withdrawable type FC
The Earthing switch can be operated with either a manual or motorized mechanism, with position indicated by
mechanical indicator on driveshaft and the auxiliary switch. Three surge arrestor can be mounted in the space
available.
Rated voltage Panel width Max. number of parallel cables Max. cross section of cables
12 650 2 630
Page 14 of 73
Figure 3.14: Cable compartment
1. Power cable connection Bar 2. Cable clamp 3. Gland plate 4. Main Earthing Bar
For the cable connection, only bottom entry is possible. Standard design offers 2-630mm2 cables per. Different
number of cables per phase & size can be provided based on requirement.
Page 15 of 73
Additional safety interlocks
High Voltage compartment door Truck in service or
can’t be opened undefined position M O
Open high voltage
F-C truck can’t be racked-in compartment door M O
Cable compartment door can’t be
opened Open earthing switch M S
Cable compartment door can be
opened Close earthing switch M S
Cable compartment door can’t be
opened Available voltage E O
Padlocks
Contactor can not be opened Contactor closed M O
High voltage compartment door
opening M O
Insertion of the FC racking-in/out
crank lever M O
Insertion of the earthing switch
operating lever M O
Shutters opening or closing M O
3.2.1 Interlock for the front cable compartment door and earthing switch (Optional)
Make sure the earthing switch is in close status before closing the front cable
compartment door.
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1 12
1. Support plate 16. Fixed Pin
2
2. Spacer 17. Torsional spring
3 13 3. Plate
4. Auxiliary switch
4
5. Compressed Spring
14 6. Pin
5 7. Guide Plate
6 8. Rectifier bridge
7 9. Triangular plate
10. Pin
11. Block rod
8 15
12. Trigger plate
9 16 13. Block plate
10 17 14. Electromagnet
15. Pin
11 Figure 3.15: Exploded view for interlock structure
During opening the front cable compartment door, the triangular plate will rotate anti-clockwise by torsional spring,
then the block plate will slide upward to block the ES handled from inserting, so that the ES can’t be operated. (See
Figure 3.16 and Figure 3.17).
Triangular plate
Torsional spring
Block plate
Figure 3.16: Triangular plate position Figure 3.17: Block plate position
If the ES is open before closing the front cable compartment door, then rotate the triangular plate clockwise by hand.
Make sure the block plate will not block the ES operation handle, then insert the ES handle, turn the handle 180°
clockwise to close the earthing switch.
The trigger Plate which fixed on the door will push the triangular Plate rotating clockwise during closing front cable
compartment door, then the block plate will be Slided downward, so that the earthing switch operating handle can be
inserted(See Figure 3.18).
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Block plate
Trigger plate
Slide cover
Blocking coil
Cam
Block rod
Plate
Page 18 of 73
The block rod will move uptoward by compressed spring after closing the ES, so that it will not block the plate on the
door, so the the front cable compartment door can be open. (See Figure 3.21).
Block rod
Compressed spring
Plate
Figure 3.21: Block rod can’t block the plate on the door
Notes: The electrical interlock (Blocking coil C4) and trigger plate can be released under emergency cases by
unscrewing the special bolts with special wrench on the front cable compartment door . (See Figure 3.22).
3.2.2 Interlock for F-C compartment door and F-C truck (Optional)
When F-C compartment door is open:
Slide plates block the handle guide bushing from moving inward, so that the undercarriage rack in handle can’t be
inserted, F-C track can’t be racked in(See Figure 3.23).
Slide plates
Figure 3.23: Undercarriage for FC panel
Page 19 of 73
When F-C compartment door is close:
For FC panel, the trigger plate on the FC compartment door will push the connecting lever moving inward, leading the
slide plates move toward two sides, so that the handle can be inserted into the handle guide bushing,then rack in or
rack out the FC truck(See Figure 3.24).
Trigger plate
Hook
Figure 3.26: Release the interlock under emergency cases for FC panel
Page 20 of 73
Figure 3.27: Shutter interlock (Optional)
3.2.4 Door lock (Optional)
Door lock with Handle:
For locking the door press the door against panel, rotate the handle clock wise by 90 degrees.
For unlocking, rotate the handle counter clock wise direction by 90 degrees as shown in the below picture.
Key lock for door Handle:
For Locking, rotate the key by 180 degrees counter clock wise direction.
For unlocking, rotate the key by 180 degrees clock wise direction.
Accessories include:
1 1. 8PV1060168 1 pcs
2 2. M8x20_GB70 2 pcs
3 3. D8_GB97_1 4 pcs
4 4. 8PV1064172 1 pcs
5 6 7 8 9
5. D8_GB93 2 pcs
6. M8_GB6170 2 pcs
7. D10_GB97_1 1 pcs
8. D10_GB93 1 pcs
9. M10_GB6170 1 pcs
10. 8PV1064176 1 pcs
11. 8PV1064173 1 pcs
12. 8PV1064174 1 pcs
13. 8PV1064175 1 pcs
10 11 12 13
When trolley is locked to panel, F-C switchgear can be pulled out or pushed into switchgear compartment. If trolley is
not be locked to panel, F-C switchgear cannot be pulled out or pushed into switchgear compartment.
Page 22 of 73
3.2.6 Racking handle Interlock for F-C truck Undercarriage (Optional)
Make sure the F-C compartment is clear and without any unexpected object.
Make sure the F-C compartment door is closed completely.
The main requirement for this interlock is that the racking handle can’t be released unless the F-C truck is in work or
test position, the main structure is shown in Figure 3.32
Accessories include:
1 1. D2X8 1 pcs
5
2 2. 8PV1060115 1 pcs
3 3. 8PV1060119 1 pcs
6
4. 8PV1060141 1 pcs
4
7 5. 8PV1060112 1 pcs
8 6. 8PV1060114 1 pcs
7. 8PV1060113 1 pcs
8. 8PV1060116 1 pcs
9 9. 8PV1060117 1 pcs
Figure 3.32: Interlock between trolley and panel
Rotate the cover plate clockwise to open the undercarriage handle hole. (See Figure 3.33).
Lift the small cylindrical handle upward, then insert the undercarriage handle into the handle hole (See Figure 3.34).
Release the small cylindrical handle, then the block plate which assembled with small cylindrical handle will slide into
the groove which on the handle, so the undercarriage handle can’t be pulled out during racking in or racking out
process. (See Figure 3.35).
Page 23 of 73
Block plate
Undercarriage handle
Lift the small cylindrical handle upward again for pulling out the undercarriage handle.
Notes: Racking handle Interlock for the F-C truck Undercarriage can be released under emergency cases by
unscrewing the bolts with wrench on F-C compartment door (See Figure 3.36).
Fixed Bolts
Page 24 of 73
Support Plate
Locating Pin
Rotation Plate
Guide Rod
Torsion Spring
Bolt pin
Label
Figure 3.38: Structure of the Indicator
Through the small window on FC door, the indicator label can be saw. When FC is at TEST Position, it shows like Figure
3.39.a), when FC is at SERVICE Position, it shows like Figure 3.39.b), when FC is at Middle Position, it shows like Figure
3.39.c).
Key locks are provided to interlock between the swithgear & other componentes in the Switchger.
Secogear panel has 4 keylocks for the applications mentioned in the Table 3.1 & as shown in Figure 3.46. Key lock
used is of Fortress make. Part Number: clin-x025 (shown in Figure 3.40)
Page 25 of 73
Figure 3.40: Keylocks on Secogear Panel & single line diagram for FC truck & ESW operation
Page 26 of 73
Interlock arrangement & operation :
2 key locks are provided for Rack in & Rackout operation of the FC truck& 2 key lock are provided for ESW close &
open operations, Figure 3.42 shows the Interlock arrangement inside the panel partition sheet.
FC truck Rack in key lock will be trapped into the lock when FC truck will be in service position, locking pin as shown in
Figure 3.43 will not allow FC truck to rack in till key lock is unlocked. In the similar way rackout key lock will function as
shown in Figure 3.44.
Figure 3.43: Functional truck racking- Out key lock in locked position
Page 27 of 73
Figure 3.44: Functional truck racking-In key lock in locked position
Earth switch closing key lock will be trapped into the lock when ESW is in closed position, locking pin as shown in
Figure 3.45 will not allow ESW to open till key lock is unlocked. In the similar way earth switch opening key lock will
work as shown in Figure 3.46.
Figure 3.45: ES closing key lock in locked position Figure 3.46: ES opening key lock in locked position
Page 28 of 73
3.5 Panel to Panel Coupling
Figure 3.47 shows typical 2 panel line up of Seco gear, Seco gear panels are coupled together side by side in front
middle & rear. Figure 3.48 shows the internal connection between the Secogears.
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Same fixing arrangement is provided between the End Panel & End covers. In the similar ways panels can coupled for
any number of Panel line up depending on customer order. Bus bar panel to panel coupling already explained under
section 3.1 & figure 3.7.
Arc proof version of Secogear consist of arc duct for collecting & exhausting the hot gases;This duct is mounted on
top of the Switchgear and it is extended on both right & left extremities. This solution is capable to guarantee the
safety of the personnel standing in front of the switchgear, according to the IEC 62271- 200.
This arc duct solution is in orrded to avoid the exhausting of the gases and the overpressure inside of the switchgear
installation room is to prolong the exhaust duct outside of the substation. In this case take care of the accessibility of
the persons in the gas exhausting zone and protect the gas exhaust cahnnel extremity in order to avoid entrance of
water, dust, small animals and any forien object.
Arc duct design is divided into diffent modules for ease of assembly at customer Site. Two types of arcducts based on
shape of the arc exhaust system, 1.Dome type & 2. Flat type Below Figure 3.49 shows the Typical Dome type arcduct
with Right side arc exhaust system for Secogear panels with 650mm width for 2 panels switchboard& Figure 3.50
Shows Flat type arcduct.
25 mm of bending
1. Arc duct Module – for 650mm width SecoGear 2. Extension for Arc exhaust
3. Arc Exhaust
Figure 3.49: Secogear Switchgear with Arc duct –Dome type Side exhaust (Right)
Page 30 of 73
25 mm of bending
1. Arc duct Module – for 650mm width SecoGear 2. Extension for Arc exhaust
3 Arc Exhaust
Figure 3.50: Secogear Switchgear with Arc duct –Flat type Side exhaust (Right)
The number of arc duct modules (1 in Figure 3.50) depends on the switchgear panels in the lineup. Arc duct is
assembled with the panel using screw M8X25 & washer. Below Figures shows fixing locations on the panel & final
assembly of arc duct with SecoGear respectively.
Figure 3.51: Front & side fixing holes for Arc duct module on SecoGear panel
Figure 3.52: Rear fixing holes for Arc duct module SecoGear panel
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The modules are assembled Panel by Panel and bolted together at overlaps at the panel joints.
Figure 3.53: Arc tunnel Assembly Figure 3.54: Connecting Chamber Assembly
Arc tunnel is mounted on top of the switchgear, to secure the connection of the arc tunnel on side, it is connected to
the panel at two 2 places at rear side of the panel shown in Figure 3.55. Front side connection done as shown in
Figure 3.56.
Page 32 of 73
Figure 3.56: Arc tunnel Front side fixing
Side cover is mounted on the side of arc tunnel. Gap cover plate 1, 2, 3 in (Figure 3.58) is used to connect arc tunnel
and side cover. The connection between Side cover& Panel are shown in Figure 3.59.
Connection6- is between arc tunnel & gapcovers1, 2 & 3 in Figure 3.58. Connection-7 between Gap covers1, 2, 3 and
side cover. Connection-8 is between side cover to arc tunnel. Connection-9 is between side cover &cover plate.
Connection -10 is between cover plate & to the switchgear.
Page 33 of 73
Figure 3.58: Arc tunnel to side plate fixing Figure 3.59: Arc tunnel to side plate fixing
Before connecting the connection chamber, the gap cover plate and support should be assembled.
First, then install the connection tunnel (Figure 3.60). The cover plate bottom should be installed inside the switchgear
end-cover. Figure 3.61 shows the connection between Arc tunnel & connection chamber.
Figure 3.60: Arc tunnel to connection tunnel fixing Figure 3.61: Arc tunnel to connection tunnel fixing
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Arc Exhaust Assembly:
Figure 3.62 Shows the Exhaust assembly for the Flat type of Arc duct & Figure 3.63 shows the Exhaust assembly for
Dome type of arc duct.
Figure 3.64: Over all assembly of Dome type Arc duct to the Secogear panel
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Figure 3.65: Over all assembly of Flat type Arc duct to the Secogear panel
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3.7.1.1 Electromotion Control System of Power Operation for FC truck
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Figure 3.68 is the “EOD-C1-M” Main control unite of power rank in/out
operation. It is assembled inside the LV compartment. The Power lamp
will be lighted when the Power is on.
Parameter of Main Control Unite: EOD-C1-M
1. Rated Voltage: VC/DC 220V
2. Capacity: 5A, 250VAC or 30VDC
3. Power Frequency Withstand Voltage: 2000VAC/1min
4. Operation condition: -20℃~+50℃
5. Standby power: <15W
Figure 3.69 is the Principal of wiring diagram for Electro motion Control system. When the power is on, the
Electro motion Control system will be standby after self-checking. The power lamp of the “EOD-C1-M” and
“EOD-C1” will be lighted; the other lamp will not be lighted. In the same time, the Fault output pin #9 & #10 is
switched off, the running interlock output pin #11 & #12 is switched on, and the motor power output pin #14 &
#15 has no power output. When power operation order is input from EOD-C1 or remote operation, power
operation system will be:
1. Unready lamp of EOD-C1 will be lighted, if conditions of rank-in or rank-out do not reached;
2. Will drive the motor to do power rank in/out operation though the Motor pin #14 & #15. In the same time,
lamp of Running will be lighted; the running interlock output pin #11 & #12 is switched off. And control system
will scan the position of truck, interlock signals and current of motor. When control sy stem receive a stop
signal, for example: FC truck reach the right work or trial position, manual operation handle inserted into
Page 38 of 73
operation hole, front middle door opened, or motor overloaded (current bigger than 2.0A), the system will stop
the power operation.
3. If the stop is caused by the overload of motor, the error lamp of EOD-C1 will be lighted. In the same time, the
Fault output pin #9 & #10 will be switched on. In this case, control system couldn’t receive any operation order
except to push the reset button of EOD-C1 over 3 seconds to recovery the system into standby status.
Motor
Page 39 of 73
1. Switch of Power Operation
2. Reset Button
4 1
3. Open Operation Button
5 4. Lamp of Power
5. Lamp of Running
6
6. Lamp of Error
7 7. Lamp of Unready
2
8. Close Operation Button
8
3
Figure 3.72 is the Operation interface “EOD-C2” of Power Operation for Earthing Switch. This device is assembled on
the door of LV compartment. Item 1 is the switch of power operation. Turn on this switch will allow the power of
Earthing switch. Turn off this switch will forbid the power operation. Item 8 is the Power close operation button. Push
this button will close the earthing switch by power operation. Item 3 is the Power open operation button. Push this
button will open earthing switch by power operation. Item 4 is the Lamp of Power, it will be lighted when the control
has power. Item 5 is the Lamp of Running. It will be lighted during power open or close operation. Item 6 is lamp of
Error. Error lamp will be lighted when power operation stopped abnormally, means power operation stopped but
earthing switch not reach the right open-position or closeposition, for example, motor is overloaded in the process of
power operation. Item 7 is Lamp of Unready. It will be lighted when trying to do power operation but the system is not
ready.
Item 2 is the Reset Button, when Item 6 lamp of Error or Item 7 Lamp of Unready be lighted, please press this button
over 3 seconds to reset the electromotion control.
The conditions for power close operation:
1. Earthing switch is in the right open-position.
2. FC truck is in test-position.
3. Earthing switch manual operation handle is not inserted into operation hole.
4. Front cable compartment door is close.
The conditions for power open operation:
1. Earthing switch is in the right close-position
2. FC truck is in test-position
3. Earthing switch manual operation handle is not inserted into operation hole.
4. Front cable compartment door is close.
If trying to do power operation but the conditions not reached, the item 7 lamp of Unready will be lighted.
Page 40 of 73
3.7.2.2 Principal of wiring diagram
Figure 3.73 is the Principal of wiring diagram for Electro motion Control system. When the power is on, the Electro
motion Control system will be standby after self-checking. The power lamp of the “EOD-C2-M” and “EOD-C2” will be
lighted, other lamps will not be lighted. In the same time, the Fault output pin #9 & #10 is switched off, the running
interlock output pin #11 & #12 is switched on, and the motor power output pin #14 & #15 has no power output.
When power operation order is input from EOD-C2 or remote operation, power operation system will be:
1. Unready lamp of EOD-C2 will be lighted, if conditions of power open or close do not reached;
2. Will drive the motor to do power open or close operation though the Motor pin #14 & #15. In the same time,
lamp of Running will be lighted, the running interlock output pin #11 & #12 is switched off. And control
system will scan the position of earthing switch, interlock signals and current of motor. When control
system receive a stop signal, for example: earthing switch reach the right close or open position, manual
operation handle inserted into operation hole, or motor overloaded (current bigger than 1.2A), the system
will stop the power operation.
If the stop is caused by the overload of motor, the error lamp of EOD-C2 will be lighted. In the same time, the Fault
output pin #9 & #10 will be switched on. In this case, control system couldn’t receive any operatio n order except to
push the reset button of EOD-C2 over 3 seconds to recovery the system into standby status.
Page 41 of 73
4. Dispatch and storage
At the time of dispatch, the factory assembled SecoGear will have withdrawable parts either securely locked in the
service position or packed separately, depending on the rating of the equipment, transport mode and destination.
The SecoGear panels are verified in the factory for completeness as per order requirement, and also passed routine
testing as per IEC 62271-200: 2011.
The busbars are not assembled; they are packed separately with fasteners and accessories.
4.2 Packing
Based on the kind of transportation and country of destination, the packing may vary. To protect against moisture a
drying agent bag is provided. IEC62271-1ed 1.1 (2011) guidelines are followed.
Panels with basic or no packing
Panels with seaworthy or similar packing (including packing for containerized shipments)
o Sealed in polyethylene sheeting
o Transport drying agent bags included
o Moisture indicator included
Observe the directions for use of the drying agent bags. Note the following
o Drying agent color observed blue indicates the packaged equipment is dry condition
o Drying agent color observed pink indicates the packaging contains moisture (relative humidity
above 40%). Please contact the manufacturer in this case before installation
4.3 Transport
The transport units normally comprise of individual panels and, in exceptional cases, small groups of panels.
The panels are equipped with four (4) lifting eyebolts.
Only carry out loading operations when all precautionary measures to protect personnel and materials have
been taken, with the following equipment:
Crane of suitable capacity: the minimum capacity shall be 2 tons for lifting single panel
Maintain an angle of at least 60° from the front for the ropes leading to the crane hook (Figure 4.1~4.2)
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HANG THE UNITS USING ALL 4 EYEBOLTS!
Lifting hook
Spreader
Hook
Base frame
a) Overall View
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≥60°
≥60°
The responsibilities of the consignee when the switchgear arrives at the site include, but are not limited to, the
following:
Check the consignment is complete and without damage (e.g. look for any adverse effect caused by moisture). In
case of doubt, the packing must be opened and then properly resealed with new drying agent bags (when
intermediate storage is necessary).
If any quantities are short, or defects or transport damage are noted, these must be;
Documented on the respective shipping document
Notified to the relevant carrier or forwarding agent immediately in accordance with the relative liability
regulations
Note: Always take photographs to document any major damage.
Intermediate storage should follow the following practices to avoid any negative consequences:
4.5.1 Panels with basic packing or without packing
A dry well-ventilated storeroom with a climate in accordance with IEC62271-1ed 1.1 (2011)
Store the panels upright
Do not stack panels
Panels with basic packing;
Open the packing, at least partially
Panels without packing;
Loosely covered with polythene
Ensure that there is sufficient air circulation
Check regularly for any condensation during storage.
4.5.2 Panels with seaworthy or similar packing with internal protective covers
Store the transport units;
o Protected from the weather
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o In a dry place
o Safe from any damage
Check the packing for damage
Check the drying agent;
o On arrival of the consignment
o Subsequently at regular intervals
4.5.3 When the maximum storage period (starting from the date of packing) has been exceeded
The protective function of the packing can no longer be guaranteed
Take suitable action if intermediate storage needs to be continued
Warning:
Do not walk on the top of the panels (due to rupture points in pressure
relief devices) ! The pressure relief devices can be damaged!
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5. Assembly of the switchgear on site
In order to obtain an optimum installation sequence and ensure high quality standards, site installation of the
switchgear should only be carried out by specially trained, or at least by supervised personnel and monitored by
responsible persons.
On commencement of installation on site, the switch-room must be fundamentally finished, provided with lighting
and the electricity supply, lockable, dry and with facilities for ventilation. It is also required that the basic frame and
indoor ground for the switchgear should be checked and accepted before the construction. It must be ensure that the
ceiling height is sufficient for the opening travel of the pressure relief plates.
Tolerances for laying the floor frame are:
Evenness tolerance: ± 1mm within a measuring length of 1m.
Straightness tolerance: 1mm per 1m, but not more than 3mm over entire length of frame.
a) Back to back
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b) Back to wall
Figure 5.1: Cross Section View
H: Maintain space, should make sure at least 300mm.
**: 1900mm are required for panel replacement.
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Figure 5.2: Top view of the layout and sectional view of false floor
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5.2 Installation method
The following 3 basic installation methods of switchgear in the switchroom are distinguished:
Method A: Install on floor without base frame
In this case the panels fixed on the floor directly using bolts. This method is applicable for concrete floor and metal
structure floor (E-Room). Figure 5.3 shows the installation interface.
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Figure 5.4: Method B installation interface
Generally it is possible to recommend the following procedure of switchgear anchoring and namely for any of the
cited methods of installation:
1. The switchgear panels are bolted together in the front and rear part into one unit;
2. Fix the switchgear panels or the base frame on the floor.
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6. Operation of the switchgear
6.1 Preparations
Warning:
a. Comply with all relevant safety regulations.
b. Maintain F-C in disconnection position.
c. Remove earth wires and short wires of the hazardous areas.
d Pay attention to any abnormal situations.
LV compartment door lock’s key Rack handle for truck Earthing switch operation handle
drawing no: 5GD.253.008 FC truck: 5PV1.064.046 drawing No.: 5GD.253.144
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6.3 Rack F-C truck out from service position to test / disconnected position
6.3.1 Move F-C Combination truck from transfer truck into the switchgear
a. Check the FC truck, then spread with an adequate amount of conductive paste. Check the interlocking
mechanism and spread lubricant on the moving parts to ensure flexible operation.
b. Place the FC truck on transfer truck and put in lock position. (See Figure 6.1).
FC locked on the
transfer truck
Adjusting nut
c. Move the transfer truck to the front of the switchgear, turn the adjusting nuts to adjust the height of the
transfer truck platform, (See Figure 6.1). Aim the guiding pin at the guiding jack in front of the switchgear,
push and make the transfer truck engage with the switchgear by lock plate. At the same time, Insert the
front guide rail of the transfer truck into the bottom guide rail groove of the switchgear truck. (See Figure
6.2).
Warning:
The trolley has 4 nuts for adjusting the platform, to the same level of the FC
compartment.
d.Make sure the transfer truck interlock block plate(Optional) have been pulled downtoward by the lock plate
on the truck, also make sure the rack in and rack out keylocks are in unlock position before pushing the FC
into the compartment. (See Figure 6.3).
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Block plate
(Optional)
e. Push the two sliding cranks inward under the truck to remove the locked position with the transfer truck,
and then push the truck forward to make it enter the switchgear compartment and lock it in the disconnect
/ test position. (See Figure 6.4).
f. Operate the lock plate releasing lever of the transfer truck to remove the locked relation between the
transfer truck and the switchgear, and then remove the transfer truck. The transfer truck interlock block
plate will be moved uptoward by torsional spring to blocked the FC truck from pulling out. (See Figure 6.5).
Block plate
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6.3.2 Move the truck from disconnect / test position to service position.
a. Make sure the front cable compartment door and the back door of the switchgear are closed, make sure
the earthing switch is in the open position, the FC compartment is clear and without any unexpected object.
b. Insert the secondary plug of the truck into the socket on the upside of the switchgear truck compartment
and lock it. (See Figure 6.6 & Figure 6.7).
6.3.3
Figure 6.6: Take off secondary plug from truck Figure 6.7: Put the secondary plug
into switchgear socket
c. Make sure the FC is in open position (if it doesn’t in open position, make FC open).
d. Close the circuit FC compartment door.Make sure the rack in keylock is in unlock position. (Optional)
f. Lift the small cylindrical handle upward, Insert the rocking crank of the truck into the rectangular cranking
hole of the screw mechanism of the truck through the operation hole under the door of the FC
compartment. (See Figure 6.8). (Optional)
e. Turn the crank clockwise (approximately 20 turns) until it can’t be moved any more, at the same time a
voice of “KA” will be heard, then the FC truck is in the service position. The FC position indicator (Optional) will
be changed the status from “TEST” to “SERVICE”. (See Figure 6.9).
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Position indicator
f. The position indicator on the door of the low voltage compartment (if it is installed) shows the FC truck is in
service position.
g. Lift the small cylindrical handle upward again, then take off the rocking crank, the racking operation is
finished.
h. Rotate the rack out keylock in order to lock the FC in the service position if required.
Warning:
The truck is not allowed to be placed in any intermediate position between
disconnect/test position and operating position.
Warning:
The truck is not allowed to be placed in any intermediate position between
disconnect / testing location and operation position.
6.3.6 FC
The operation instructions refer FC truck instruction manual and FC instruction manual.
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6.4 Earthing switch operation
The earthing switch has a rapid close-open mechanism which is irrelevant with the rotation speed of the driven shaft.
The function of closing brake quickly can be realized through the rapid close-brake mechanism.
The earthing switch, FC truck and front cable compartment door have a mechanical interlock to prevent incorrect
operation.
The earthing switch can be operated only when the truck is in the disconnect / test position and the front cable
compartment door of the switchgear is in the closed position.
The earthing switch have two keylocks to lock the earthing switch with open or close position as required.
The operating hole of the earthing switch located in the lower position of the right side in front of the panel.
b. Check other electrical interlock , make sure it will allow to pull down the slide cover on earthing switch
operation hole.
c. Make sure the earthing switch close keylock is in unlock position before closing the earthing switch.
d.Open the operating hole slide and insert the operating handle, and turn the handle 180° clockwise to close
the earthing switch(See Figure 6.11).
Close
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e. Ensure the earthing switch is fully closed.
f. Rotate the earthing switch open keylock in order to lock the earthing switch in the close position if required.
Warning:
Check the position indicator on low voltage compartment door.
Check the flag adjacent to the earthing switch operating hole.
Warning:
Make sure the cable compartment is clear and without any unexpected
object.
Make sure the front cable compartment door is closed completely.
a. Check that the voltage presence indication on the drawer plate is off. (Optional) (Figure 6.6).
b. Check other electrical interlock , make sure it will allow to pull down the slide cover on earthing switch
operation hole.
c. Make sure the earthing switch open keylock is in unlock position before opening the earthing switch.
d. Insert the earthing switch operating handle, and turn the handle 180° conterclockwise to open the switch
(See Figure 6.12).
Open
e. Check the mechanically interlocked label and indication light to ensure the earthing switch is fully open.
f. Rotate the earthing switch close keylock in order to lock the earthing switch in the open position if required.
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7. Inspection and maintenance
7.1 Summary
After the process of installation and testing, the switchgear is available to use. Timely and proper maintenance can
keep the switchgear trouble-free and can prolong the life of the switchgear as long as possible.
The maintenance work must be carried out by certified persons who are familiar with the related operations of the
switchgear and understand relevant GB standards and other safety rules and important guides established by other
technical department. Let the worker of GE Company assist in when the switchgear and its components need to be
repaired. Users should think about the operating environment and the operation frequency when developing
maintenance rules. Usually the inspection of some equipment / components (such as wearing parts) and the
maintenance intervals (maintenance period) depend on the running time, operating frequency and the number of
short circuit. The maintenance period of other parts depends on the working situation, the degree of the load and
environmental impact (including pollution and corrosive gasses).
The maintenance interval determined by operating conditions of the switchgear depends on the operating mode, the
operating number of rated current and short circuit current, environment temperature and pollution.
The recommending maintenance interval is showed in the following table:
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7.3 Diagnosis and trouble shooting for malfunctioning during operations
The cable compartment door The Earthing switch is not completely opened
Open the Earthing switch
can ‘t be closed / opened
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7.4 Maintenance item and cycle
Maintenance of the switchgear should be carried out by the trained personnel, who are
familiar with the switchgear characteristics, according to the manufacturer’s
instruction, IEC and local safety standards.
It is recommended any major repairing (if required) shall be assisted by the manufacturers or representative.
The purpose for routine inspection is to find issues in advance so they can be resolved immediately.
Routine inspection includes:
Check compartment doors are closed properly
Verify the control voltage, auxiliary voltage and battery voltage are in normal condition
The status indication and position indication for the FC and earthing switch etc are normal
Check ammeter and voltmeter on the display
Check relay indications. (The power indication should be on and fault indication should be off.)
Check alarm and pre alarm indications
Partial discharge should not occur on the surfaces of equipment at operating voltage. This can, for example,
be detected by characteristic noises, a clearly perceptible smell of ozone, or visible glowing in the dark;
Check the heater condition, if installed. The relay monitoring the heater current is in the low voltage
compartment. Check the heater circuit if the red current indication turn off due to the heater losing power
supply. ( see Figure 7.1)
If any abnormal condition is found, then the cause must be identified in order to restore normal condition.
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7.6 Service
Safety measure: The power must be shut down before scheduled switchgear service, and
the work area must be isolated. Measures must be taken to disallow the power being
switched on. Ensure proper earthing and padlocks in place. Specially trained personnel are
required to supervise.
The purpose for the service is to guarantee the operation quality of the switchgear and avoid any possible
malfunctions. This increases the life of the switchgear. The scope of work is as follows:
Inspection: Determination of the actual condition
Servicing: Measures to preserve the specified condition
Repair: Measures to restore the specified condition
The service interval for the switchgear is depending on external factors including the operating environment, the
operation frequency and service age etc.
It is recommended to have switchgear serviced every 2-3 years, if installed in good environment and not
frequently operated.
It is recommended to have switchgear serviced every year, if operated more than 10 times a month.
It is recommended to have switchgear serviced every half year, if installed in adverse environment and
frequently operated.
It is recommended to have the FC replaced, if reached its mechanicall operating cycles or rated short circuit
breaking times.
7.7 Repairs
Check all the compartments and internal components for dampness, rust and dirt.
Check the tightening torques for the busbar bolted connections on selected samples.
Remove the pressure flaps on the busbar compartment and remove the insulation shield (See Figure
7.2). Check if the torque is 86 Nm with the torque wrench.
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Insulation shield (for side panel) Insulation shield(Middle panel)
Performance test is to validate the electrical performance of the switchgear. It is recommended to be carried out
together with the scheduled service.
Be sure to comply with the applicable safety regulations when carrying out repairs.
Open the main busbar compartment and check the tightening torques for the busbar bolted connections
Check the main busbar and branch busbar for any dampness or rust.
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Check all the sidewalls for any dampness or rust.
Check the main busbar compartment for any unexpected object.
Restore the insulation shield and the pressure flap on the top of the panel.
Check the fitness of the fixed contact and the surface condition.
Open the cable compartment and check the cable connection as wells as the connectors for color distortion.
Check the sealing condition of through holes for the primary and secondary cables.
Check the heater condition.
Check the FC and cable compartment for unexpected objects.
Check the secondary connections of the CTs.
Check the current terminals in the low voltage compartment for the close loop of the secondary current
circuit. Check the protection relay, ammeter and energy meter etc. on the CT secondary are in service.
Unexpected objects in the busbar compartment , or the loose bolted connection, may result heated joint or even
phase fault.
Verify the switchgear is de-energized and the safety measures are in place.
Method 1:
Remove the Arc duct assembly
Remove the pressure flaps on the busbar compartment , as well as the same on the adjacent panels. Now
the busbar is visible.( see Figure 7.3)
Remove the pressure flap on the busbar compartment
Remove the busbar insulation shield
Remove the connection bolt on the main bar and branch busbar
Remove the busbar from the busbar compartment
Install the new main busbar and fasten the joints
Cover the busbar joints with insulation shield
Reassemble the pressure flaps for the busbar compartment
Pay attention to the direction of the taper washers and the bolted connection torque should
reach 86 N-m.
Figure 7.3: Busbar after opening the pressure flaps on the busbar compartment
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Method 2:
Withdraw the FC
Open the cable compartment door
Remove the secondary wiring terminal strip of electric component on the partition plate assembly
Remove the obstruction part of key lock ( see Figure 7.4) (Optional)
Withdraw the partition plate assembly ( see Figure 7.5)
Operator step in to the cable and FC compartment
Remove the middle partition plate(upper) ( see Figure 7.6)
Remove the busbar insulation shield
Remove the connection bolt on the main bar and branch busbar
Remove the busbar from the busbar compartment
Install the new main busbar and fasten the joints
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Figure 7.6: Middle partition plate (upper)
7.10.2 Inspection and replacement of the fixed contact and spout bushing
It is normal to find the fix contact surface oxidized due to current flow and the environmental factors during period of
service. However if the surface is become rusty due to wet or corrosive joins conditions, the fixed contact must be
replaced. The spout bushing may be replaced depending of its condition.
Clean the contact with the cotton-free paper, and apply some pure alcohol if necessary. Brush a small amount of
contact lubrication grease (DE-G51 of BRITAIN) on the surface after wiping. It is important to check any abnormal
condition such as the burning marks on the spout bushing, which may be caused by the epoxy.
Verify the switchgear is de-energized and the safety measures are in place.
Withdraw the FC
Push the wheel forward to unlock the interlock of shutter (See Figure 7.7) (Optional)
Open the shutter mechanism, and insert two M8 bolts into the overlapping holes on the shafts (See Figure
7.8). Then the fixed contacts along with the spout bushing are visible.
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Figure 7.8: Insert bolts into the overlap holes to disable the shutter mechanism
Inspect the contacts. Replace the contact if the silver coating on copper is worn, or the surface is corroded,
damaged or over heated.
Remove the centre bolt of the fixed contact, and replace the fixed contact.(see Figure 7.9)
Replace the spout bushing
Remove the bolt at the joint of the upper branch and main busbar
Remove the center bolt of the fixed contact and bolt of copper subplate then remove the vertical
connections and copper subplate.
Remove four fixing screws of the spout bushing and then the spout bushing can be removed (see Figure 7.9)
Replace the new spout bushing and fasten the fixing screws (M8). Inject glass glue in the clearance between
the spout bushing and the mounting metal frame
Insert the upper branch busbar and copper subplate into the spout bushing, and fix the fixed contact
Don’t fasten the bolt initially when locking the fixed contact, Please fasten by applying torque
when the upper branch and main busbar are fixed;
Attention: The torque will be different based on different sizes of the bolt and with/without lubrication. Corresponding
torques of different bolts identified below:
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Recommend torque (N-m)
Bolt size Without lubrication (oil) With lubrication (oil)
M8 26 10
M10 50 20
M12 86 40
M16 200 80
M20 300 120
Tighten the bolt on the upper branch and main busbar. Ensure that applied torque is 86 N-m.
Remove the inserted bolts on the driving mechanism of the shutter, and then put down the shutters.
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Figure 7.11: Installing surge arrester
Remove the cable between the arrester and copper connection (See Figure 7.13)
Remove the fixed bolts on both sides of the mounting bracket of the arrester
Push the three arresters and the bracket
Remove the fixed bolts on the mounting bracket of the arrester(See Figure 7.14)
Install the new arrester and fasten the bolts with the mounting bracket
Screw the both sides bolts on the brackets
Fix the connection between the arrester and copper connection
Confirm the equipment be powered off and make sure to follow proper safety measure.
Confirm the Earthing Switch is in OPEN position.
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Figure 7.13: Mounting plate of the current transformer
Pull out the mounting plate of the current transformer and then put on the ground
Remove the four bolts which are used to fix the current transformer, and remove the current transformer
Replace the current transformer with new one now and screw on the four bolts
Ensure the marking on the mounting plate for the installing position of the current transformer
before removing the four bolts to avoid the wrong position with the hole of the copper
connections after installing the new current transformer.
Assemble the current transformer in its place on mounting plate and tighten the mounting plate by
tightening the 4 pcs of M12 bolts
Screw on the bolts on the current transformer and the both side copper connections
Fix the bolt of the branch busbar on current transformer ,but do not fully tighten
Adjust the position of current transformer and then fasten
Fasten the bolts on the copper connections and the current transformer mounting with a torque wrench with
torque of 86 N-m
Connect the secondary connection of the CT and cover it according to the requirements
Reassemble the cable clamp and cable, the arrester according the above instructions following up in reverse
Way
Ensure switchgear is in Power OFF position and consider the safety measures
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Figure 7.14: Screw of the fixed ring on drive rod Figure 7.15: Fixed bracket for the drive mechanism
Loosen and the grub screws of the fixed ring (see Figure 7.14), but do not screw it off. The parts of the drive
rod in the switchgear can be pushed backwards now.
Both the screws can be access only when the Earthing Switch is in OPEN position
Attention: Don’t fully remove the drive rod, otherwise all the parts will fall out.
Completely draw out the drive rod from another side at a slight angle
Loosen both of the bolts on the fixing bracket (see Figure 7.15), and then remove the fixing bracket and
plastic indication plate
Attention: Replace the bevel gear assembly and Earthing Switch in the same way. Use care to
avoid the damage as the main body is much heavier.
Unscrew the flexible connections between the Earthing Switch and common earthing busbar. (See Figure
7.17)
Remove the fixing screw of the Earthing Switch, and then push the bevel gear and the main body of the
Earthing Switch .
Now replacement can be done with the above instructions following the previous instructions in reverse
order.
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There are two types potential indicator. One is with latching contact, and another is without the latching contact. The
replacement for the two types is the same. (See Figure 7.22)
Cut off the auxiliary power of potential indicator (if any)
Disconnect all the connection from the back of the indicator
Remove the lock of the potential indicator, and then push it out (See Figure 7.23)
Replace with the new one, and fix the lock
Reconnect the wires at back
Recover the auxiliary power
Please refer to recommended spare parts list below. Other spare parts are also available based on customer’s
requirement.
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8. Appendix
Before start working, please check and make sure all item listed in “list of onsite service safety checking”. For some
reasons if the work is interrupted, please make sure site safety procedure is integral when restarting the work.
1. Before work, please check site layout, with and without electric area, earthing line layout, ON or OFF of the
control power, state of the temporary power, if supervisor is on his/her position and safety exits.
2. Ensure if safety procedures on working sheet are well implemented, recheck if safety procedures comply with
requirements, if isolation procedure between live equipment and test equipment is established, if there is a clear
instructions on labels.
3. Once equipment is in power off phase, it is strictly forbidden to operate the FC or switch. Please switch OFF FC
and move FC to test or withdrawn position. Instrument and power transformer to power of the equipment shall
be switched off in order to avoid any charging of the equipment by mistake.
4. Please ensure the switchgear reference and number to avoid working on the wrong equipment.
5. All current transformer and voltage transformer secondary winding shall only have one permanent and reliable
protective earthing.
6. If there is a necessary that person has to get into switchgear to give proper service, must make sure this person’s
safety.
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