Ormazabal cgmcosmos-l Instruction manual

LIB
cgmcosmos
Medium voltage cubicles with full insulation
in SF
6
gas up to 24 kV for Belgium
Synergrid AA10
General instructions
IG-296-EN, version 01, 12/03/2020

In view of the constant evolution in standards and design, the characteristics of the elements contained in this manual are subject
to change without prior notice. These characteristics, as well as the availability of components, are subject to confirmation by
Ormazabal.
CAUTION!
When medium-voltage equipment is operating, certain components are live, other parts may be in movement and some may
reach high temperatures. Therefore, the use of this equipment poses electrical, mechanical and thermal risks.
In order to ensure an acceptable level of protection for people and property, and in compliance with applicable environmental
recommendations, Ormazabal designs and manufactures its products according to the principle of integrated safety, based on
the following criteria:
• Elimination of hazards wherever possible.
• Where elimination of hazards is neither technically nor economically feasible, appropriate protection functions are
incorporated in the equipment.
• Communication about remaining risks to facilitate the design of operating procedures which prevent such risks,
training for the personnel in charge of the equipment, and the use of suitable personal protective equipment.
• Use of recyclable materials and establishment of procedures for the disposal of equipment and components so
that once the end of their service lives is reached, they are duly processed in accordance, as far as possible, with the
environmental restrictions established by the competent authorities.
Consequently, the equipment to which the present manual refers complies with the requirements of section 11.2 of Standard
IEC 62271-1. It must therefore only be operated by appropriately qualified and supervised personnel, in accordance with the
requirements of standard EN 50110-1 on the safety of electrical installations and standard EN 50110-2 on activities in or near
electrical installations. Personnel must be fully familiar with the instructions and warnings contained in this manual and in other
recommendations of a more general nature which are applicable to the situation according to current legislation[1].
The above must be carefully observed, as the correct and safe operation of this equipment depends not only on its design but also
on general circumstances which are in general beyond the control and responsibility of the manufacturer. More specifically:
• The equipment must be handled and transported appropriately from the factory to the place of installation.
• All intermediate storage should occur in conditions which do not alter or damage the characteristics of the equipment
or its essential components.
• Service conditions must be compatible with the equipment rating.
• The equipment must be operated strictly in accordance with the instructions given in the manual, and the applicable
operating and safety principles must be clearly understood.
• Maintenance should be performed properly, taking into account the actual service and environmental conditions in
the place of installation.
The manufacturer declines all liability for any significant indirect damages resulting from violation of the guarantee, under any
jurisdiction, including loss of income, stoppages and costs resulting from repair or replacement of parts.
Warranty
The manufacturer guarantees this product against any defect in materials and operation during the contractual period. In the
event that defects are detected, the manufacturer may opt either to repair or replace the equipment. Improper handling of this
equipment and its repair by the user shall constitute a violation of the guarantee.
Registered Trademarks and Copyrights
All registered trademarks cited in this document are the property of their respective owners. The intellectual property of this manual
belongs to Ormazabal.
[1] For example, in Spain the “Regulation on technical conditions and guarantees for safety in high-voltage electrical installations” – Royal Decree
337/2014 is obligatory.

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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
Contents
Contents
1. General description ...................................................4
1.1. Models ......................................4
1.2. Standards applied............................4
1.3. Main components ...........................5
1.3.1. Gas tank .....................................6
1.3.2. Driving mechanism compartment ............6
1.3.3. Base .........................................7
1.3.4. Name plate ..................................8
1.4. Electrical specifications......................10
1.5. Dimensions and weights ....................11
1.6. Operating conditions .......................12
2. Handling and transport...........................................13
2.1. Lifting means ...............................13
3. Storage......................................................................16
4. Installation ...............................................................17
4.1. Unpacking the equipment ..................17
4.2. Location of accessories during transport .....17
4.3. Minimum installation distances..............19
4.4. Recommended cable connection trenches...19
4.4.1. Cubicles with classification of internal arc
IAC up to 20 KA - 1 s.........................20
4.5. Fastening to the floor .......................23
4.5.1. Fastening to the floor on profile .............23
4.5.2. Fastening to the floor by anchoring..........23
4.6. Connecting the cubicles.....................27
4.7. Earthing the switchgear .....................28
4.8. Cable connections ..........................29
4.8.1. Horizontal front connection .................31
4.9. Vertical front connection ....................33
5. Recommended sequence of operations.................35
5.1. Gas pressure check..........................35
5.2. Feeder function .............................36
5.2.1. Mimic diagram..............................36
5.2.2. Actuating levers ............................36
5.2.3. Opening operation from
the earthing position........................37
5.2.4. Switch closing operation from
isolating position ...........................38
5.2.5. Opening operation from closed position.....39
5.2.6. Earthing operation from isolating position ...40
5.2.7. Cable test...................................41
5.3. Fuse protection function with
AR driving mechanism ......................42
5.3.1. Mimic diagram..............................42
5.3.2. Actuating levers ............................43
5.3.3. Opening operation from earthing position...43
5.3.4. Spring charge operation and closing
of the switch from isolating position.........44
5.3.5. Opening operation from closed position.....44
5.3.6. Earthing operation from isolating position ...45
5.4. Fuse replacement sequence .................46
5.4.1. Selecting recommended fuses ..............50
5.5. Circuit-breaker function with
RAV driving mechanism .....................51
5.5.1. Mimic diagram..............................51
5.5.2. Spring charge and actuating levers ..........52
5.5.3. Opening operation from earthing position...52
5.5.4. Closing operation from isolating position ....54
5.5.5. Opening operation from closed position.....57
5.5.6. Earthing operation from isolating position ...59
6. Safety elements........................................................61
6.1. Interlocks ...................................61
6.1.1. Locking with a padlock......................61
6.1.2. Locking with a lock..........................62
7. Maintenance.............................................................64
7.1. Preventive maintenance of
the cgmcosmos-v cubicle with
RAV driving mechanism .....................64
8. Spares and accessories ............................................65
9. Environmental information ....................................67

1. General description
[2] Further information at www.ormazabal.com
Ormazabal's cgmcosmos system, designed in accordance
with the requirements set out in regulations of the
International Electrotechnical Committee (IEC), is formed
by dierent unifunctional and multifunctional switchgear
models, with full insulation in SF6gas, thus allowing
dierent secondary electrical distribution schematics to be
congured in medium voltage up to 24 kV[2].
1.1. Models
Unifunctional switchgear Function
cgmcosmos-l Feeder (K)
cgmcosmos-p Fuse protection (T)
cgmcosmos-v Vacuum circuit-breaker (D)
Table 1.1. Unifunctional switchgear
Unifunctional switchgear Function
cgmcosmos-2lP 2 feeders and 1 fuse protection function (KTK)
Table 1.2. Multifunctional switchgear
1.2. Standards applied
Standard Description
IEC 62271-1 Common specications for high voltage switchgear standards
IEC 62271-100 High voltage alternating current circuit-breakers
IEC 62271-102 Alternating current earthing switches and disconnectors
IEC 62271-103 High voltage switches for rated voltages above 1 kV and below 52 kV
IEC 62271-105 Alternating current switch-fuse combinations
IEC 62271-200 A.C. metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV
IEC 62271-206/IEC 61243-5 Voltage presence indicating systems
IEC 60529 Degrees of protection provided by enclosures (IP Code)
IEC 60282-1 Current-limiting fuses
Table 1.3. Standards
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General description General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

1.3. Main components
1Gas tank
1.1 Side connection female bushings
2Driving mechanism area
2.1 Actuating shafts (see mimic diagram of each model)
2.2 LRM-VDS system according to NBN EN 61243-5
3Base
3.1 Cable compartment access cover
3.2 Medium voltage cable xing support
3.3 Gas relief compartment
3.4 Earth collector
3.5 Front cable connection bushings
* Optional elements.
Figure 1.1. Main components of the cgmcosmos cubicles
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
General description

1.3.1. Gas tank
Sealed compartment which houses the busbar and the
switching and breaking elements, where the insulating
medium is SF6.
Each gas tank has a pressure relief device to allow gases to
escape in the event of an internal arc.
Thanks to the hermetically-sealed nature of the gas
tank containing all the medium voltage elements, the
equipment is expected to have a minimum service life of 30
years, without replenishing the gas according to Standard
IEC 62272-1.
Figure 1.2. Gas tank for cgmcosmos-l
1.3.2. Driving mechanism compartment
This is the compartment in which the switch-disconnector
or the circuit-breaker is actuated, depending on the type of
function.
The mimic diagram for the main medium voltage circuit
is displayed on the cover of this compartment. The mimic
diagram includes all the position indicators for the driving
elements.
The cgmcosmos system has, in line with the cubicle model,
the following types of driving mechanism:
BTilting l
BM Motorised tilting l
AR Accumulation of energy with latch p
ARM Accumulation of energy with motorised latch p
RAV Circuit-breaker with reclosing option v
RAMV Circuit-breaker with motorised reclosing option v
Figure 1.1. Types of driving mechanisms
These elements are operated independently, i.e., their
actuation speed does not depend on the speed of the
manual operation.
The B, BM, AR and ARM driving mechanisms can be replaced
by upgrading in any of the three positions (closed - open -
earth). Whilst the driving mechanism is withdrawn, these
positions of the switch can be blocked using a coupling
device, whether in service or not.
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General description General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

1.3.3. Base
Made up of the cable compartment and the gas relief
compartment:
Cable compartment
Located in the lower front section of the cubicle and has
a cover interlocked with the earthing switch, thus allowing
front access to the medium voltage cables.
As standard, designed to contain up to:
1. Two shielded screw-in terminals (reduced) per phase
or one terminal (reduced) plus surge arrester (reduced)
with space for the corresponding incoming power
cables.
2. Cable ties for the power cables.
3. Earthing bars.
As an option:
1. Two symmetric terminals or symmetric terminal plus
symmetric surge arrester.
2. Metallic voltage transformers.
Figure 1.3. Cable compartment
Gas relief compartment
Ormazabal's cgmcosmos system is designed and
constructed to withstand at least the thermal and dynamic
eects of an arc of 16 kA for 1 seconds should a defect
result in an internal arc in the gas compartment. The system
conducts the gases generated in a fully controlled manner
to avoid any possible injury to people in the equipment
operation area.
Optionally, a gas expansion relief duct can be
positioned in the rear of the cubicle to redirect the
gases to the top section. Please check with Ormazabal.
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
General description

1.3.4. Name plate
Every unit includes a name plate, with some of the following
data:
Figure 1.4. Name plate detail
Name plate
N° Cubicle serial number*
Type Ormazabal switchgear system.
Designation Cubicle model
Standard Standards applied to the equipment
Name Equipment name
UrEquipment rated voltage (kV)
UpLightning impulse withstand voltage (kV)
UdPower frequency withstand voltage (kV)
frEquipment rated frequency (Hz)
IrEquipment rated current (A)
Instructions Manual General Instructions Manual (IG) for the system
Class Driving mechanism class according to IEC 62271-103
NNumber of mainly active load breaking operations
Ik/IpShort-time withstand current/Short-time withstand peak value
tkShort-time withstand current time
Pre Gas pressure inside the gas tank (MPa)
Pme Minimum operating gas pressure (MPa)
SF6Weight of insulating uid (g)
CO2eEquivalent CO2uid mass (t)
Year Year of manufacture
TC Minimum working temperature
IAC Internal arc classication
* In the event of incident, this number should be reported to Ormazabal.
Table 2.4. Name plate
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General description General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

In addition, another plate into the operation area of each
mechanism is also included with some of the following
data:
Figure 1.5. Mimic diagram plate
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
General description

1.4. Electrical specifications
Rated voltage [kV] 12 24
Frequency [Hz] 50
Rated current [A]
Busbars and cubicle interconnection 400/630
Feeder 400/630
Transformer output 200
Rated short-time withstand current [kA]
Con tk= (x) s 16/20** (1/3 s)/25 (1 s) 16/20** (1/3 s)/25 (1 s)
Peak value 40/50**/62.5 41.6/52**/65 40/50**/62.5 41.6/52**/65
Rated insulation level [kV]
Power frequency rated withstand voltage (1 min) 28/32 50/60
Lightning impulse rated withstand voltage 75/85 125/145
Internal arc in tank
Front and side accessibility 16/20**/25 kA (1 s) 16/20**/25 kA (1 s)
Front, side and rear accessibility*** 20** kA (1 s) 20** kA (1 s)
Internal arc classication in accordance with IEC 62271-200
IAC AF/AFL IAC AFL 20 kA 1 s IAC AFL 20 kA 1 s
IP rating: gas tank IP X8 IP X8
IP rating: external enclosure IP 2XD IP 2XD
Standard unit colour (RAL) grey 7035 / blue 5005 grey 7035 / blue 5005
Category of loss of service continuity [LSC] LSC2 LSC2
Compartmentalisation class PM PM
** Tests conducted at current 21 kA/52.5 kA (50 Hz) – 54.6 kA (60 Hz).
Table 2.5. Electrical specications
The values set out in this table are general for the
cgmcosmos system and are only valid when conrmed
by Ormazabal. Some cubicle models can withstand
partial values. For more detailed information, contact
Ormazabal.
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General description General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

1.5. Dimensions and weights
Figure 1.6. cgmcosmos dimensions
Module Height (h)
[mm]
Width (a)
[mm]
Depth (f)
[mm]
Bushings height (g)
[mm]
Weight
[kg]
-l[2] [3] [4] 1300 365 735 725 90
1740 1165 100
-p 1300 470 735 410 140
1740 850 150
-v (RAV) 1740 480 845 695 240
-2lp[2] [3] 1300 1190 735
Feeder Fuse protection 290
725 410
1740 1165 850 310
The weight refers to the enclosure, with no metering transformer inside.
[2] In the case of dual symmetric terminal, the depth of the switchgear increases by 200 mm and the weight by 5 kg, per feeder function.
[3] In the case of symmetric terminal plus symmetric surge arrester, the depth of the switchgear increases by 200 mm and the weight by 5 kg, per feeder
function.
[4] For exterior cable test device, please check with Ormazabal.
Table 1.1. Dimensions and weights
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
General description

1.6. Operating conditions
Installation Indoor
Maximum ambient temperature + 40°C
Minimum ambient temperature - 5°C/- 30°C(a)
Maximum mean ambient temperature, measured over a 24-hour period + 35°C
Maximum mean relative humidity, measured over a 24-hour period < 95%
Maximum mean relative humidity, measured over a 1-month period < 90%
Maximum mean vapour pressure, measured over a 24-hour period 2.2 kPa
Maximum mean vapour pressure, measured over a 1-month period 1.8 kPa
Maximum height above sea level 2000 m
Solar radiation Negligible
Pollution due to corrosive and/or ammable gases Insignicant
Vibrations due to systemic movements or caused by causes external to the switchgear Negligible
(a) Storage: - 40°C
Table 2.6. Operating conditions
The specications refer to the section "Normal service
conditions for indoor cubicles" in the IEC 62271-1
standard "Common specications for high-voltage
cubicles".
For special service conditions: ambient temperature
above +40°C, installation between 2000 and 4000 m
above sea level, signicant pollution level, or others
dierent to those described, check with Ormazabal.
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General description General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

2. Handling and transport
[3] Position the rear of the cubicle facing the driver, to avoid damaging the front.
Important: During transport, the switchgear must
be perfectly seated and xed so that it cannot move
about and possibly damage the equipment.
2.1. Lifting means
The switchgear must always be kept upright, directly on the
ground or on a pallet depending on the type of handling
involved.
One of the following methods must be used for assemblies
of up to 4 cgmcosmos functional units:
1. Using a forklift truck or pallet jack.[3]
Figure 2.1. Lifting a cgmcosmos cubicle with a fork-lift truck
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
Handling and transport

2. Lifting using slings or chains xed to the lifting supports
on the sides of the top of the cubicle. The angle of pull
should be as vertical as possible (with an angle greater
than 60° from the horizontal).
Figure 2.2. Lifting cgmcosmos cubicles with chains
3. If it is not possible to lift using the aforementioned
methods, rollers may be used underneath the
switchgear. Another option is to slide the cubicles over
rods (these same rods can be used to help get over the
cable trench).
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Handling and transport General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

4. To handle 5 functional unit assemblies (consisting
of either coupled modules or compact assemblies
associated with modules), use lifting systems (slings,
lifting beam, etc.) with a pull angle greater than 65° and
less than 115° in order to prevent possible damage to
the cubicles during hoisting.
The use of lifting beams is required for cubicle
assemblies with control boxes. As the sole exception,
slings or chains may be used if the cubicles of the
assembly have identical height control boxes installed.
Figure 2.3. Lifting a set of 5 cgmcosmos functional units with lifting
beam and chains
Figure 2.4. Lifting a set of 5 cgmcosmos functional units with a forklift
truck
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
Handling and transport

3. Storage
If it needs to be stored, the equipment must be placed on
dry ground or on top of damp-proof insulating material, still
in its original packaging.
After prolonged storage, clean all the insulating parts
carefully before commissioning the equipment. The
enclosure should be cleaned with a clean, dry lint-free cloth.
Figure 3.1. Storage
Storage must always be INDOORS, with the following
conditions recommended:
1. Ambient air temperature should not exceed 40°C
and its mean value, measured in a period of 24 hours,
should not exceed 35°C.
2. The ambient air temperature should not drop below
- 5°C. There are also cubicles with storage temperature
up to -40°C.
3. The switchgear must be protected from direct solar
radiation.
4. Altitude, both in transport and in storage, must not
exceed 2000 m.
5. The environmental air must not have any signicant
contamination from dust, smoke, corrosive and/or
inammable gases, vapours or salt.
6. The switchgear must be protected from the rain, and
the humidity conditions should be as follows:
a. The mean relative humidity value, measured over a
period of 24 hours, must not exceed 95%.
b. The mean water vapour pressure value, measured in
a period of 24 hours, must not exceed 2.2 kPa.
c. The mean relative humidity value, measured over a
period of one month, must not exceed 90%.
d. The mean water vapour pressure value, measured
in a period of one month, must not exceed 1.8 kPa.
7. During transport, vibrations caused by external factors
or seismic movements must be insignicant.
Any other conditions must be notied beforehand,
since the equipment must be factory-adjusted to
the environmental pressure at the nal destination
or during transport. Otherwise, the pressure gauge
needle may indicate an incorrect value, even if the
equipment's internal gas pressure is correct.
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Storage General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

4. Installation
4.1. Unpacking the equipment
[4] It is advisable to cut the cellophane at the rear of the cubicle or at the corner to avoid scratching the surface.
The cgmcosmos system switchgear is supplied as standard
protected by plastic packaging.
On receiving the equipment, check that the goods supplied
correspond to the order and associated documentation. If
this is not the case, contact Ormazabal immediately.
The disassembly process for the equipment is as follows:
1. Using a blade, cutter or similar tool, cut the cellophane
the cubicle is wrapped in.[4]
2. Completely remove the cellophane.
3. Detach the white polystyrene corner pieces.
4. Unscrew the xings between the base and the pallet.
5. Remove the pallet, handling the cubicle as indicated in
section 2.1.
6. Unpack the accessories box in the front section or on
the top of the cubicle.
7. Remove the self-adhesive protective plastic from the
cable compartment cover.
The self-adhesive plastic must be removed from the
cable compartment cover so that the equipment
enclosure's earth connection may have the proper
electrical continuity.
8. Dispose of any waste in an environmentally-friendly
manner.
It is advisable to make a visual inspection of the equipment
to check whether it has suered any damage in transit. If
damaged, contact Ormazabal immediately.
4.2. Location of accessories during transport
A number of accessories are supplied with the cubicles,
located as indicated in the gures below:
Figure 4.1. Location of accessories in transport in unifunctional
cgmcosmos cubicles
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
Installation

Figure 4.2. Location of accessories in transport in multifunctional
cgmcosmos cubicles
Depending on the cubicle model, the accessory box
contains some of the following items:
1. Ormazabal's IG-296 General Instructions document
2. Actuating lever
3. Spring charge lever
4. Cubicle connecting kit:
a. Springs
b. Grease
c. Earthing strip
5. End plug kit:
a. Cubicle end assembly
b. Nylon thread
c. Plastic plugs
d. Side cover
6. Side cover
7. Floor fastening assembly
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Installation General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard

4.3. Minimum installation distances
[5] For any doubts, please ask Ormazabal.
[6] In each case, bear in mind which cable is to be used in the particular installation.
The minimum distances to the walls and ceiling which must
be maintained in the installation are as follows:
Figure 4.3. Minimum installation distances
Minimum distances [mm]
Side wall (a) 100
Roof (b) 1740 mm high 560
1300 mm high 700
Front clearance (c) 800
Rear wall (d) cgmcosmos-v 50
Other functions 100
Table 4.1. Minimum installation distances
The measurements indicated in the table have been
obtained in accordance with the dimensions of the
test room for the gas insulated modules, in accordance
with Annex AA of Standard IEC 62271-200.
The space required to extend the assembly with an
additional cubicle is 150 mm plus the width of the new
cubicle.[5]
4.4. Recommended cable connection trenches
Minimum recommended dimensions based on the trench
dimensions used in the tests in accordance with Standard
IEC 62271-200. These dimensions may vary, in accordance
with the radius of curvature of the cables.[6]
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General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard
Installation

4.4.1. Cubicles with classification of internal arc IAC up to 20 KA[7] - 1 s
[7] Tests carried out with a test current of 21 kA.
Feeder function
Dimensions in mm.
Front and rear cable input or output (D1/D2).
Side cable input or output (D3/D4).
Figure 4.4. Dimensions [mm] of the cable trench for cgmcosmos-l
Trench necessary for the feeder ["L" or "T" Terminal 400/630 A]
Cable data Approximate
radius of
curvature*
[mm]
Minimum depth
Cable insulation Cable type
Cable
section
[mm2]
Cable
diameter
[mm]
D1 D3
Height 1300 mm Dry insulation
Single-core
150 38 500 350 400
185 42 600 400 500
240 42
300 48
750 600
650
400 48
Three-core 150 85 600
185 85
D2 D4
Height 1740 mm Dry insulation
Single-core
150 38 500 (R) 370*
(F) 370 400
185 42 600 (T) 370
(F) 370 500
240 42
300 48
750
(T) 370
(F) 450 650
400 48
Three-core 150 85 (T) 370
(F) 550 500
185 85
* Check against the data of the manufacturer of the cable used.
(T) Rear cable input or output.
(F) Cable front input or output.
Table 4.2. Trench necessary for the feeder
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Installation General instructions
cgmcosmos: Medium voltage cubicles with full insulation
in SF6gas up to 24 kV in accordance with IEC Standard