ABB IS-limiter User manual

— 36kV Is-limiterTM panel Installation, operation and maintenance manual
—
DISTRIBUTION SOLUTIONS
36kV IS-limiterTM panel
Installation, operation and
maintenance manual

—
ABB’s 36kV Is-limiterTM panel is a
three-phase, metal enclosed,
air-insulated switchgear and
all units are factory-assembled,
type tested and suitable for indoor
applications up to 36 kV.
The panels are fitted with
Is-limiterTM switch inserts as fixed
installation along with CTs &
busbars.

—
Your safety first - always!
That's why our instruction manual begins with these
recommendations.
• Keep this installation, operation and maintenance manual accessible to
all personnel involved in installation, operation and maintenance
• Ensure that the switchgear and accessories are stored in a closed room
free of dust and moisture till erection
• Ensure installation of switchgear and/or switchboard in closed rooms
suitable for electrical equipment
• Ensure that installation, operation and maintenance are carried out by
only trained, qualified and authorized personnel
• Fully comply with the legally recognized standards (IEC or local), regulations of the local electrical
authority and stipulated safety requirements
• Ensure that activities related to switchgear are carried out as per relevant instructions and
guidelines given in this manual, and applicable local safety standards and work practices
•Ensure that operating conditions are within the specified operating limits
• Pay special attention to the hazard notes in the instruction manual marked with this warning
symbol
Danger!
• Do not exceed the loads quoted in the technical data of the specification in normal operation of the
switchgear or switchboard
• Keep the instruction manual accessible to all persons concerned with installation, operation and
maintenance
• Always follow this installation, operation and maintenance manual and respect the rules of good
engineering practice
• Hazardous voltage can cause electrical shocks and burns
• Disconnect power, then earth and short circuit connection before proceeding to work on the
switchgear
• Do not override safety interlocks, either electrical or mechanical, during operation and/or
maintenance
• The user’s personnel are to act responsibly in all matters affecting safety at work and the correct
handling of the switchgear
If you have any further questions on this instruction manual, the members of our field organization will
be pleased to provide the required information.

436KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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Table of contents
05 1. Summary
1.1 General
1.2 Standards and specifications
1.3 Operating conditions
1.3.1 Normal operating conditions
1.3.2 Special operating conditions
06-7 2. Technical data
2.1 IS-limiterTM panel
2.2 IS-limiterTM switch
2.3 Tripping device and auxiliary circuits
08-18 3. Panel structure and components
3.1 Basic structure
3.2 Enclosure
3.3 Construction of the panels
3.4 Interlocks / protection
against maloperation
3.5 Functions of the IS-limiterTM components
3.5.1 IS-limiterTM insert holder
3.5.2 IS-limiterTM insert
3.5.3 Tripping current transformers
3.5.4 Tripping device
19-20 4. Dispatch and storage
4.1 Condition on delivery
4.2 Packaging
4.3 Transport
4.4 Delivery
4.5 Unloading & unpacking
4.6 Intermediate storage
21-23 5. Erection of the switchgear on site
5.1 General site requirements
5.2 Foundation
5.2.1 Checking of foundation
5.2.2 Mounting of cubicle on
foundation frame
5.3 Erection of the panels
5.4 Fixing IS-limiterTM inside the panel
5.5 Connection of the power and
control cable
5.6 Earthing the switchgear
5.7 Concluding installation work
24-27 6. Commissioning/operation
6.1 Commissioning
6.1.1 Preparatory work
6.1.2 Start-up
6.2 Switching the tripping device ON
6.3 Switching operation
6.4 Electrical displays and monitoring
6.5 Earthing and short-circuiting with
earthing cable set
6.6 Test procedures
6.6.1 Testing the off-circuit condition
6.6.2 Testing for in-phase condition
6.6.3 Tests on the pulse transformer
28-31 7 Maintenance
7.1 General
7.2 Inspection
7.3 Servicing
7.3.1 IS-limiterTM device
7.4 Repair
7.4.1 Switchgear surfaces
7.4.2 Replacement of components
7.5 Tests on interlocks
7.5.1 Testing of interlock conditions
7.6 Spare parts and auxiliary materials
7.6.1 Spare parts
7.6.2 Auxiliary materials
32 8. Disposal

5
1.1 General
ABB’s 36kV Is-limiterTM panel is a three-phase, metal
enclosed, air-insulated switchgear and all units are factory-
assembled, type tested and suitable for indoor applications
up to 36 kV. The panels are fitted with Is-limiterTM switch
inserts as fixed installation along with CTs & Busbars.
This Manual does not contain any instruction relevant to
customer specific documents. Details of the technical
design and equipment of individual switchgear, such as
technical data, detailed component lists for the individual
panels, detailed wiring diagrams etc. can be found in the
relevant order documents.
1.2 Standards and
specifications
The Is-limiterTM switchgear complies with standard and
specifications prescribed on IEC publications 62271-200 and
62271-1 for factory-assembled, metal enclosed, and type
tested high voltage switchgears.
Additionally, the switchgear offers IP4X degrees of
protection for the enclosure as prescribed by the IEC
publication 60529.
All other corresponding IEC publications, national and local
safety at work regulations and safety regulations for
production materials must be followed during erection and
operation of these systems. The order related details
provided by ABB are also to be taken into account.
1.3 Operating conditions
1.3.1 Normal operating conditions
The switchgear installations are fundamentally designed
for the normal operating conditions for indoor switchgear
and switchboards in accordance with IEC Publication
IEC62271-200. The following limit values, among others,
apply:
Ambient temperature:
• Maximum:+ 40°C
• Maximum: 24-hour average+ 35°C
• Minimum: (according to "minus 5 indoor" class) - 5°C
With indoor installation, it is assumed that the humidity
within the enclosure can reach high values, but that there is
normally no condensation on the equipment installed.
Condensation can be prevented by appropriate design of
the station building or switch room.
The maximum altitude at which the unit may be installed is
1000 m above sea level.
1.3.2 Special operating conditions
The manufacturer must be consulted in advance for special
operating condition.
For example:
• At site altitudes over 1000 m, the insulation level must
allow for the reduction in the dielectric strength of
the air
• Any increased ambient temperatures must be taken into
account in the design of the busbars or their current
carrying capacity will be limited
Notes on special climatic operating conditions:
When operating switchgear in climates with high humidity
and/or major rapid temperature fluctuations, there is a risk
of dew deposits, which has to remain an exceptional
condition for indoor switchgear under normal operating
conditions. Preventive measures (e.g. suitable ventilation
and proper air conditioning of the building or housing,
use of dehumidifying equipment, etc.) must be taken into
consideration in consultation with ABB to avoid this
condensation phenomenon and any resulting corrosion or
other adverse effects.
—
1. Summary

636KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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2. Technical data
2.1 Is-limiterTM panel
Electrical data
Rated voltage kV 36
Rated power frequency withstand
voltage
kV 70
Rated lightning impulse withstand
voltage
kVp 170
Rated frequency Hz 50
Rated current of busbars A 1250, 2000, 25001)
Peak withstand current kAp 100
Rated short-time current 3s kA 40
Rated control supply voltage V DC 110, 220;
AC 110, 220
1) With cooling fan
Dimensions and weight
Dimensions
Height mm 28451)
Width mm 13002)
Depth mm 2345
Weight including Is-limiterTM switch kg 2200
1) Including absorber assembly. Without absorber assembly 2610
2) Including end covers
1300
2610
2345
23451300
2845
—
Overall dimension of panel with absorber assembly
—
Overall dimension of panel without absorber assembly

7
2.2 Is-limiterTM switch
Electrical data
Rated voltage Rated current Rated power frequency
withstand voltage
Rated lightning impulse
withstand voltage
Weight
Is-limiterTM insert holder Is-limiterTM insert
kV A kV kVp Kg Kg
36 1250,2000,25001) 70 170 60 42
1) With cooling fan installed in panel
2.3 Tripping device and auxiliary circuits
Electrical data
Device
Power consumption1) Rated supply voltages
AC
VA
DC
W
AC (f=50/60 Hz)
V
DC
V
Tripping device 80 - 110, 220 -
Auxiliary circuits
(blocking magnet, auxiliary relay) - 60 110, 220 110, 220
1) approximate values

836KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
3.1 Basic structure
(Figures 3.1 to 3.4)
The basic design of the panels comprises the
stationary enclosure structure parts made from
Aluzinc sheet.
The Is-limiterTM holder assembly is fixed inside
panel enclosure on steel frame which is
supported with structure. At the bottom of the
Is-limiterTM holder assembly copper contacts are
provided for incoming cable connections which
are supported by support insulator on steel
channel which in turn is fixed with panel
structure. At the top side (i.e. outgoing side)
T contact is provided which on one side is fixed
with Is-limiterTM top contacts & other side of it, the
jumpers are connected.
The outgoing cable connections are provided at
rear side below CT.
Panels with Is-limiterTM are designed for the
following applications amongst others:
• feeding into existing systems
(transformer or generator feeders)
• coupling between power systems
• bridging of short-circuit current
limiting reactors in transformer or
generator feeders
The Is-limiterTM panels can be supplemented
by additional panels (circuit-breakers,
disconnectors, cable terminal and surge
arrestor panel)
Further details on the structure of and equipment
in the switchgear can be found in the relevant
order documents.
3.2 Enclosure
The panel enclosure consists of Aluzinc steel
sheets which are rivetted to each other. The roof
of the high voltage compartment is fitted with
integrated pressure relief devices. These devices
open when overpressure occurs as a result of
an internal arc fault. The front is sealed off by
flame- proof doors with hinges at the left and an
opening angle of approx. 1800. At rear side, there
are rear covers provided to have access to the
CTs & other components which are mounted at
rear side of the panel. LV compartment containing
the tripping device can be assembled separately
as a self-supporting sheet-steel enclosure.
It is separated and protected from the high
voltage area.
If an internal arc fault occurs, the auxiliary
switches 3, controlling the pressure relief devices
(figure 5.3) achieve Ith-limitation
by un-delayed release.
The panel doors are made of high quality steel
sheets, which undergo thorough cleaning through
7 tank process before powder coating. The
finishing coat is of standard RAL 7035 color
shade. (Special color shades on request and by
mutual agreement).
3.3 Construction of panels
Is-limiterTM fixing
(Figures 3.2)
The Is-limiterTM holders are fixed on the steel
frames with hex. socket cap screws. These two
steel frames are firmly connected with the panel
structure with L type frames at both left & right
side of the panel side walls.
The Is-limiterTM inserts are inserted in the jaw type
contacts of the insert holder & then clamped
securely with rotating locking levers at top &
bottom of the insert holder.
—
3. Panel structure and components

9
The copper contacts for incoming cable
connections are connected to bottom of the
Is-limiterTM assembly which are supported by
insulator support. At the out-going side of the
Is-limiterTM assembly, the jumpers are connected
through T shaped copper connection.
The jumpers at other end are connected to
CT incoming side. These jumpers are having
insulator support at top of the panel & at front
of the panel above Is-limiterTM Inserts. The
outgoing cables are connected to the copper
contacts which are connected to the jumpers
coming from CT outgoing side.
Between each Is-limiterTM, insulating phase
barriers are provided which are fixed with steel
frame with bracket. At bottom side, phase
barriers are supported on barrier support.
LV or tripping cabinet
(Figures 3.1a, 3.5 and 3.6)
LV compartment contains the tripping device for
the Is-limiterTM and the secondary equipment in
the panel required for the particular application.
The control wiring is led through generously
dimensioned metal covered ducts in the panel
area. The left-hand duct is reserved for the
incoming and outgoing control wiring.
The internal panel wiring is located on the
right-side duct.
Warning!
In order not to alter the electromagnetic
compatibility (EMC) of the tripping device,
no additional wiring may be installed parallel to
the following connections or laid in the conduits
later date:
• connection between the movable hinged
frame (where the tripping device is located)
and the anti-interference unit
• connections between tripping current
transformers and clamps
• connections between pulse transformers and
clamps
3.4 Interlocks/protection
against maloperation
In order to avoid hazardous situations and
maloperation, a series of interlocks are provided
to protect personnel and the switchgear.
The normally effective interlocks are as follows:
• The front door of the Is-limiterTM panel can only
be opened when series connected circuit
breaker or disconnector is in open condition.
(electromechanical interlock)
• The rear covers (3 Nos.) can only be opened
when series connected circuit breaker or
disconnector is in open condition
(electromechanical interlock)
• The series connected circuit breaker can only
be closed when the Is-limiterTM switch is ready
for operation & has not tripped
(electromechanical interlock).
• If the Is-limiterTM trips, the series connected
circuit-breaker or disconnector must also be
opened.
• Details of any further interlocks can be found
in the relevant order documents for the
individual installation.

10 36KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
3.5 Functions of the
Is-limiterTM components
The Is-limiterTM is a high-speed switching device
with a current-limiting effect. The Is-limiterTM is
tripped and the short-circuit current limited at
the first rise in short-circuit current. The
maximum asymmetric short-circuit current
flowing through the Is-limiterTM is thus limited.
Please consult the detailed special publications or
the ABB Is-limiterTM brochure for the technical
processes involved in short-circuit limiting and
for examples of the Is-limiterTM use.
Is-limiters basically comprise the following:
• Is-limiterTM insert holder
• Is-limiterTM insert
• Tripping current transformer
• Tripping device
3.5.1 Is-limiterTM insert holder
(Figure 3.7)
Two insulators 5.1 and 5.2 for each phase are
located on holder metal bracket 9. The insulators
support the pole heads 4.1 & 4.2 with clamping
device into which the Is-limiterTM insert assembly 2
is inserted. Insulators (for 36 kV) are fitted with a
pulse transformer. This transmits the tripping
pulse from the tripping device to the charge 3 in
the Is-limiterTM insert tube and at the same time
serves to isolate the tripping device electrically
from the charge at system potential.
The telescope contacts 7 are located on the
insulators fitted with pulse transformers.
The clamping device is activated by a lever on pole
head. The Is-limiterTM insert is held in the jaw
contacts of the insert holder with the help of lever.
For testing of the pulse transformer, see the notes
in section 6.6.3.
3.5.2 Is-limiterTM insert
(Figure 3.7)
The Is-limiterTM insert is the switching element.
The insert contains the main conductor 6 in a
sturdy insulating tube 10 in the form of triple
bursting bridge 1 each containing one charge 3.
When tripping occurs, the charge is activated,
and the main conductor is broken at the rupture
joint of bursting bridge.
The current commutates to the parallel high
voltage high rupturing capacity fuse (HV fuse) 11.
The fuse element of the HV fuse blows and limits
any further current rise. The current is zero at the
next voltage zero.
—
3. Panel structure and components

11
1 Enclosure assembly
2 LV box door
3 Glass window
4 Main panel door
5 Handle
6 Door hinges
7 Side sheets
8 Vertical L support
9 IslimiterTM fixing steel frame
10 Top channel for support insulator
11 QR6 tripping device
3.5.3 Tripping current transformers
(Figure 3.5)
The tripping transformers 9 are current
transformers which are installed in series with
the Is-limiterTM and serve to measure the current
flowing through the Is-limiterTM.
From the outside, the Is-limiterTM current
transformers cannot be distinguished from
conventional transformers. The particularly
notable characteristics of the special transformer
are:
• an extremely high overcurrent factor
• an iron core with air gap to keep remnant
induction low
• a low resistance shield between the primary
and secondary sides
3.5.4 Tripping device
(Figure 3.1)
The tripping device is installed in the separate
low voltage compartment above the Is-limiterTM
compartment.
For details of the tripping unit type QR6 & Test
Procedure please refer separate manual
GCEA670650 P0102 Rev 01 .
Note: In some cases tripping unit is supplied in
separate floor mounted steel cabinet, depending
on customer requirement & floor space
availability.
—
Fig 3.1a – Panel structure assembly
1
6
11
2
3
4
5
—
Fig 3.1b – Panel enclosure - inside view
10
9
8
7

12 36KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
1 Phase barriers
2 Earthing strip
3 IslimiterTM holder assembly
4 Handle for locking
5 Hardware for insert holder
6 Jaw type fixed contact
—
Fig 3.2 - Insert holder mounting
4
3
2
4
1
5
6
—
Fig 3.3 – Insert mounting
1 Contacts for cable connection
2 Support insulators
3 Steel channel
4 Locking handle
5 Fuse assembly
6 Is-limiter insert
6
5
4
1
2
3
1 T contact
2 IslimiterTM top side
3 Hardware
4 Jumpers
5 Earthing bolt
6 Insulator support
—
Fig 3.4 - Top side connection. Is-limiterTM assembly
1
6
5
4
3
2

13
—
Fig 3.5 - Cross section view
—
Fig 3.6 - Front view with door open
1 Is-limiterTM insert
2 Contacts for incoming cable connection
3 Phase barrier front
4 LV compartment
5 Support insulators
6 Absorber assembly
7 Explosion vents
8 Shrouds
9 Current transformer
10 Contacts for O/G cable connection
11 Rear phase barrier
12 Rear cover
13 Is-limiterTM insert holder
14 Phase barrier supports
15 Earthing bolt
16 Earthing bar
17 Cooling fan
1 Is-limiterTM insert R Y B phase
2 Lever for clamping
3 Insulator support
4 Right side cover
5 LV compartment door
6 Dummy door
7 Absorber assembly
8 Left side cover
9 Structure assembly
10 Phase barrier
11 Phase barrier support
12 Earthing bar
6
17
5
4
15
13
1
3
2
15
14
7
8
9
10
11
12
16
7
8
9
10
11
12
5
6
1
2
3
4

14 36KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
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Fig 3.7 - Is-limiter assembly
1 Bursting bridge
2 Is-limiterTM insert assembly
3 Charge
4.1 Top pole head
4.2 Bottom pole head
5.1 Top insulator
5.2 Bottom insulator
6 Main conductor
7 Tripping contact
8 Mounting hardware
9 Mounting bracket
10 Insulating tube
11 Fuse
9
5.1
4.1
7
2
1
6
3
11
10
7
4.2
5.2
8

15
—
Fig 4.1 - Handling with forklit
—
Fig 4.2 - Handling with forklit

16 36KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
—
Fig 4.3 - Mounting of lifting hooks
Lifting hooks
mounted on side sheet
Side
sheet
Lifting hook
—
Fig 4.4 - Lifting with crane
Lifting hook

17
—
Fig 5.1 - Incoming cable connection
—
Fig 5.2 - Outgoing cable connection
1 Cable lug
2 Hardware
3 Insulator support
4 Cable gland
5 Is-limiterTM assembly
6 Cable connection piece
7 Single core power cable
1 Cable lug
2 Hardware
3 Insulator support
4 Cable gland
5 Cable connection piece
6 Single core power cable
3
2
1
4
6
5
7
4
3
5
2
1
6
4

18 36KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
3
21
3
1
3
2
1 Bracket for switch
2 Explosion vent
3 Aux. switch for flap
1 Cable support channels
2 Earthing bars
3 Earthing support
—
Fig 5.3 - Auxiliary switches for flap
—
Fig 5.4 - Earthing bars & connections

19
4.1 Condition on delivery
The factory assembled panels are dispatched
without Is-limiterTM inserts (Inserts are packed
separately in separate special packing).
The panels are checked at the works for:
- completeness of the equipment installed
- with reference to the terms on customer order
- Prior to dispatch, panels are subjected to
routine tests
4.2 Packaging
The Is-limiterTM panels are packed for transport in
following types:
• Panels with seaworthy packaging or similar
(including packaging for containerized
shipments):
- Sealed in polythene sheeting
- Transport drying agent bags included
- Moisture indicator included
- When aluminum composite sheeting is
used, a sight window is fitted for checking
• Observe the directions for use of the drying
agent bags
The following applies:
- Colored indicator blue: contents dry
- Colored indicator pink: contents moist
(relative humidity above 40%)
4.3 Transport
Figure 4.1-4.4
Normally, each individual panel is a separate
transport unit. The panels are fixed on wooden
pallet with bolts. The foundation frame for
installation at site is packed separately during
dispatch of panel for transport to customer site.
Following precautions must be taken during
transport of the panels:
- Transport switchgears upright
- Take the high center of gravity into account
- Carry out loading operations only after
ensuring that all precautionary measures to
protect personnel and materials are taken
- Use crane, fork-lift truck and / or manual
trolley jack
When performing loading work, take all necessary
precautions to avoid injury and damage to the
materials.
Loading must only be carried out with
• crane
• forklift and/or
• Trolley jack
Handling by crane:
• Use lifting ropes of appropriate load capacity
with spring catches with eyebolt diameter of
30 mm
• Maintain a rope angle of 60° from the
horizontal between the shackles and crane
hook
• Hang the switchgear using all lifting hooks!
—
4. Dispatch and storage

20 36KV ISLIMITER PANEL INSTALLATION, OPERATION AND MAINTENANCE MANUAL
4.4 Delivery
The responsibilities of the consignee when the
switchgear arrives at site include, but are not limited to, the
following:
• Checking the consignment for completeness and
freedom from damage (e.g. also for moisture and its
detrimental effects). in cases of doubt, the packaging
must be opened and then properly resealed, fitting new
drying agent bags, when intermediate storage is
necessary
• If any short quantities, defects or transport damages are
noted:
- To be documented on the respective shipping
document
- Notify the relevant carrier or forwarding agent
immediately in accordance with the relevant liability
regulations
• Note:
Always take photographs to document any major
damage
4.5 Unloading & unpacking
Unloading the switchgear from truck must be carried out by
appropriate handling methods described in section 4.3.
Unpacking:
- Remove wrapping / plastic bag covers, cardboard
pads etc.
- Open the compartment door and loosen the bolts fixing
the switchgear to pallet
- Lift the switchgear by crane following instructions
given below:
remove the pallet
position unloading shims
put the switchgear on loading shims using crane
The packing is intended for transport and not for storing
purpose. Upon receipt, the switchgear must be unpacked
and installed under clean, dry, dust-free, indoor conditions
and anti-condensation heaters shall be switched ON.
4.6 Intermediate storage
Optimum intermediate storage where it is necessary –
without detrimental consequences depends on compliance
with a number of minimum conditions for the panels and
assembly materials
1. Panels with seaworthy or similar packaging with internal
protective sheeting:
• Store the transport units:
- protected from the weather
- in a dry place
- safe from damage
• Check the packaging for damage
• Check the drying agent (see also section 4.2):
- on arrival of the consignment
- later at regular intervals
• When the maximum storage period, starting from the
date of packaging, has been exceeded:
- the protective function of the packaging can no
longer be guaranteed
- take suitable action if intermediate storage is to
continue
Note
Do not walk on the roof of the panel
(rupture points in pressure relief device)!
Note
For the panels which are stored for intermediate periods
after unpacking, where panel is subjected to direct
ambient / environmental conditions it is recommended to
arrange auxiliary supply near panel & to keep heaters
inside the panel ON to avoid condensation / dew deposits
inside the panel.