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: [phone]
fax: [phone]
e-mail: [email protected]
Internet: www.eaton.eu
in the event of a malfunction
Eaton Electrical Solutions & Services: tel: [phone]
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
2.3.4Heat, 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
3.4.6Fixing 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 mm2, universal clamps...................................35
3.6.2 PILC with copper cores, 3 x 95 mm2up to 3 x 150 mm2, concentric clamps..........39
3.6.3 PILC with copper or aluminium cores up to 3 x 240 mm2, gland entry....................44
3.6.4 PILC with copper or aluminium cores up to 3 x 240 mm2, 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 mm2, universal clamps ........55
3.8.2 Connection of plastic-insulated cables with copper cores, 3 x 95 mm2up to 3 x
240 mm2, concentric clamps..................................................................................58
3.8.3 Plastic-insulated cable in a top connection ............................................................62
3.8.4 Connecting cables 95 mm2and over using alternative materials............................63
3.8.5 Connecting Eaton 16 mm2transformer 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 mm2.....................................67
3.9.2 Connection of plastic-insulated cables with copper cores, 3 x 95 mm2up to 3 x
240 mm2...............................................................................................................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)
(English)
system
-
-
rel.
release
-
IEC
-
-
serial.no.
Serial number
-
year of constr.
year of construction
-
w.o.no.
work order number
-
Ur
rated voltage
kV
fr
rated frequency
Hz
Ir
rated normal current
A
IrT-off
rated normal current
A
switch/circuitbreaker
Ik
rated short time withstand voltage
kA
tk
rated duration of short-circuit
s
Ip
rated peak withstand current
kA
Up
rated lightning impulse withstand voltage (peak value)
kVpeak
Ud
rated power frequency withstand voltage
kVpeak
Ima
rated short-circuit making current
kA
Isc
rated short-circuit breaking current
kA
Ic
rated cable charging breaking current
A