Eaton Magnefix MD4 User Manual Download Page 31

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Magnefix MD4

991.184 G01 03

3.5 Connecting the cables, general

OTE

Cables may only be connected:

•

by authorised and qualified personnel;

•

in accordance with the instructions in this

manual;

•

in accordance with the instructions of the cable

manufacturer.

IFE HAZARD

•

Always earth the installation.

•

Never work on a live or partly live installation.

A steel cable clamp.

3.5.1

Cable connection points

All Magnefix cable, busbar connection and fuse panels

have 12 mm cable connection pins.

3.5.2

Fixing the cables

The cables can be fixed using plastic or steel cable clamps.

Triple plastic cable clamp for single-core cables 20-

43 mm in diameter.

Summary of Contents for Magnefix MD4

Page 1: ...e Netherlands tel 31 74 246 91 11 fax 31 74 246 44 44 e mail info electric eaton com Internet www eaton eu in the event of a malfunction Eaton Electrical Solutions Services tel 31 74 246 68 88 Install...

Page 2: ...2 991 184 G01 03 Administrative data Version number G01 03 Date of issue 30 10 2013...

Page 3: ...he 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 op...

Page 4: ...tion 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 cabl...

Page 5: ...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 8...

Page 6: ...pping 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...

Page 7: ...ecessary 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 act...

Page 8: ...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 IE...

Page 9: ...ipment 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 sw...

Page 10: ...rk order number Ur rated voltage kV fr rated frequency Hz Ir rated normal current A Ir T off rated normal current A switch circuitbreaker Ik rated short time withstand voltage kA tk rated duration of...

Page 11: ...onnection facilities for incoming and outgoing cables The assembled modules are mounted in an upright or wall mounted frame The modules can be assembled in any sequence a set of screw rods holds them...

Page 12: ...ave arcing contacts and internal tripping and contact force springs A ferromagnetic steel plate to which the permanent magnet can attach is also fitted between the mobile contacts Fitted to the outsid...

Page 13: ...ps or pins are connected to the earthing point of the switchgear using a bolted connection and special earthing cables Earthing of the protected panel The earthing system for the protected panel consi...

Page 14: ...s carried out in good time in accordance with the instructions in this manual Replace worn and or damaged parts only with genuine Eaton spare parts or spare parts approved by Eaton Take the following...

Page 15: ...load break switches Normal current A 400 400 400 Breaking current cos 0 7 A 400 400 400 Short circuit making current kA 31 31 31 Short time withstand current 1s kA 14 4 14 4 14 4 Capacitive earth faul...

Page 16: ...h circuit panel including switch caps and fuse holders excluding fuses 230 mm 37 5 kg Busbar connecting panel with SVS or HC switchgear 91 mm 9 kg Height 1517 mm Depth with fuse panel 517 mm Depth wit...

Page 17: ...luding switch caps and fuse holders excluding fuses 230 mm 37 5 kg Busbar connecting panel with SVS or HC switchgear 91 mm 9 kg Height overall height 1487 mm Depth with fuse panel 517 mm Depth without...

Page 18: ...trip indicator 2 3 4 Heat radiation noise and gases Heat In general it can be said that the heat generated in full load service will lead to a maximum temperature rise of the outer surface not exceedi...

Page 19: ...area before installing the system Temperature maximum 40 C measured over a period of 24 hours average not more than 35 C minimum not less than 25 C The room must be free from dust corrosive or flammab...

Page 20: ...nsformer Position the ventilation slots such that the air flow intended for transformer ventilation does not pass over the switchgear If ventilation air flow over the switchgear cannot be avoided inst...

Page 21: ...ion Left Unsealed floor risk of contamination Right The cable trench is filled with sand and the floor of the switchroom is covered Cable cellar Thoroughly seal the opening between the switchroom and...

Page 22: ...el cable clamp m e Adjustable distance plate for plastic cable clamp n f 1 Earth bar g 1 Branch earth bar h 2 Slotted tube for fixing the earth bar k 1 Cross coupling l 1 Earth strip m Steel cable cla...

Page 23: ...plates d and or e to the C sections c 2 Fit the triple plastic cable clamp b to the C section c 3 For switchgear with protected panels Fit the cable support section r to the C section c 1 3 3 3 5 Fit...

Page 24: ...ng k to the rear of frame leg a using the fasteners 1 2 3 3 9 Fitting the second frame leg 1 Fix the second frame leg a 2 Fit cross coupling k using the fasteners 3 Fit earth bar f using another slott...

Page 25: ...ar NOTE Make sure no dust or dirt can penetrate into the switch and fuse caps 4 Place the switchgear in the frame a 5 Fit the switchgear to the frame using the shafts 1 and safety rings 2 NOTE Fit the...

Page 26: ...section r to the underside of the C section p 3 Fit the cable clamps s to the cable support section 4 Secure the cables in the clamps and tighten the clamps firmly 1 4 3 3 14 Checks 1 Check the connec...

Page 27: ...Earth bar g 1 Branch earth bar h 5 Braces j 8 Distance piece k 2 Horizontal suspension beam l 1 Earth strip m Steel cable clamp n Plastic cable clamp o Fasteners to secure the switchgear to the vertic...

Page 28: ...the C sections c 2 Fit the triple plastic cable clamp b to the C section c 3 For systems with Protected panels Fit the cable support section r to the C section c 1 3 3 4 5 Fixing the C sections and e...

Page 29: ...3 Fit the braces h using the fasteners 2 3 3 4 8 Fitting the frame 1 Lay the frame on the braces and attach it to the fixed section using the fasteners 1 2 Fit the other suspension beam k to the vert...

Page 30: ...ng the cables Chapter 9 fit C section p to the wall or floor of the substation at the same height as the wall frame C section c 2 Fit the cable support section r to the underside of the C section p 3...

Page 31: ...uctions of the cable manufacturer LIFE HAZARD Always earth the installation Never work on a live or partly live installation A steel cable clamp 3 5 1 Cable connection points All Magnefix cable busbar...

Page 32: ...copper cores ranging from 3 x 95 mm2 up to 3 x 240 mm2 Concentric cable core clamps comprise 1 connecting piece 1 2 clamping rings with hexagon socket head screws 2 1 gland 3 Concentric cable core cl...

Page 33: ...pe e Small and medium sized cable boxes for PILC cable boxes up to 3 x 70 mm2 and up to 150 mm2 1 universal cable box for PILC Cu and Al up to 3 x 240 mm2 C 2 protection covers c 1 hose clip d 1 O rin...

Page 34: ...ne grease b 3 tapered sealing plugs c 2 protection covers d 1 extension protection cover optional e The protection covers protect the cable cores against touching This provides double insulation NOTE...

Page 35: ...ore clamps universal 2 steel cable clamps Cable box for PILC with copper core up to 3 x 70 mm2 REMARK It is also possible to use a cable box with gland or entry bushing Procedure 1 Incise the cable at...

Page 36: ...diameter of the cable box Ensure that the upper side of the tape is flush with that of the lead sheath see arrow Smooth out any wrinkles 5 6 REMARK The filling opening is located at the front Make sur...

Page 37: ...30 mm 16 Check that the O rings c are fitted across the cast resin insulation 17 Apply cable grease lightly to the cast resin insulation 13 17 18 Connect the cable cores to the connection points using...

Page 38: ...box completely on to the cast resin insulation 24 Fit the protection covers c at the rear side and secure them 22 24 REMARK Make sure that the clamping edge of the cable box adequately rests on the be...

Page 39: ...socket head screws 2 1 gland 3 2 steel cable clamps 1A Concentric cable core clamps Cu 95 to 240 mm2 REMARK It is also possible to use a cable box with gland or entry bushing For cables with an alumin...

Page 40: ...diameter d measured across the lead sheath Take into account that several layers of polyethylene tape are to be applied over the lead sheath 4 Deburr sharp edges 3 4 5 Degrease the upper side of the...

Page 41: ...n to the cable as far as possible 7 10 12 Fix the cable in the cable clamp c at position M previously marked Move the distance piece b until the centre of the cable is exactly in line with the centre...

Page 42: ...the cable box to prevent intrusion of dirt 22 Shorten the cable cores so that all three of them fit into the recesses in the connecting pieces 18 20 23 Position the cable cores in the recesses in the...

Page 43: ...de the cable box completely on to the cast resin insulation 27 Fit the protection covers c at the rear side and secure them 25 26 REMARK Make sure that the clamping edge of the cable box adequately re...

Page 44: ...socket head screws 2 1 gland 3 2 steel cable clamps For cables with an aluminium core Eaton cable core clamps are only suitable for connecting cables with a copper core Aluminium cables are to be conn...

Page 45: ...underside of the gland bush so that a hole is created whose inside diameter equals the diameter measured across the lead sheath 5 Slide the gland bush along the lead sheath 6 Solder the gland bush b...

Page 46: ...amp c at position M previously marked Move the distance plates b until the centre of the cable is exactly in line with the centre of the cable box Firmly tighten the cable clamp 14 For copper cored ca...

Page 47: ...of 1 connecting piece 1 2 washers with hexagon socket head screws 2 1 gland 3 2 steel cable clamps For cables with an aluminium core Eaton cable core clamps are only suitable for connecting cables wit...

Page 48: ...gths 1 2 3 Saw off the entry bushing in accordance with the diameter d measured across the lead sheath Take into account that several layers of polyethylene tape are to be applied over the lead sheath...

Page 49: ...and fit the two fixing shells k in the lower recess of the entry bushing 10 Clamp it using the hose clip d 7 9 1 Slot for O ring 2 Slot for fixation 11 Slide the cable box on to the cast resin insula...

Page 50: ...pper cored cables depending on the core diameter refer to the procedure described in 3 x 70 mm2 Chapter 3 6 1 13 to 23 3 x 95 mm2 Chapter 3 6 2 13 to 27 19 For cables with an aluminium core Once the c...

Page 51: ...insulated lead covered cable 3 7 2 Procedure Proceed as follows 1 Remove the transport storage cover from the can of grease a and place the filling cover e using the fixing ring With each can of grea...

Page 52: ...completely filled 10 When the grease in the cable box touches the cast resin insulation continue pumping steadily until the cable box has expanded by approximately 2 cm NOTE Maximum working pressure...

Page 53: ...ble box has cooled down and immediately put your thumb on the opening This is necessary as the grease in the cable box is under pressure Pinch the filling hose to remove grease residues 20 Fit the rub...

Page 54: ...Earthing should be done right above the outer cable sheath so that the cable box can be lowered if necessary This earth connector has to be attached to the horizontal earth bar REMARK Make sure that...

Page 55: ...insulating conduits a 1 bag containing 3 greased rubber sleeves b 3 sealing plugs c 2 protection covers d 1 extension protection cover e optional 3 cable core clamps universal 2 steel cable clamps or...

Page 56: ...ce with the instructions of the cable supplier 1 3 Cut off the cable cores 2 to 3 mm below the cast resin insulation a 4 Remove the insulation from the cable cores over a distance of 30 mm 3 4 5 Inser...

Page 57: ...cable cores are correctly positioned in the clamps This is where the associated cross sectional area is stated see detail 11 13 13 Tighten the hexagon socket head screws torque 15 Nm 11 lbf 14 Ensure...

Page 58: ...core clamps are only suitable for connecting copper cable cores Terminate the cable cores and the splice in accordance with the cable manufacturer s instructions 1A Concentric cable core clamps Cu 95...

Page 59: ...dance with the instructions of the cable supplier 1 3 Cut off the cable cores 2 to 3 mm below the cast resin insulation 4 Remove the insulation from the cable cores over a distance of 30 mm 3 5 5 Inse...

Page 60: ...rews torque 15 Nm 11 lbf Ensure that the screws are fitted in the same direction angled forward for all three phases 13 Slide the other washers 2B as far as possible on to the connecting pieces and fi...

Page 61: ...nsulated members Check that the flattened sides of the washers around the insulating conduits abut 18 Fit both protective covers d and secure them Make sure that the conduits adequately rest on the be...

Page 62: ...g plug to half the diameter of the cable or panel pilot cone 3 Slide the sealing plug up the cable 4 Connect the cables refer to one of the preceding paragraphs according to the type of cable used 5 H...

Page 63: ...the crimp hose sealing the insulating conduit up the cable 4 Slide the insulating conduit with the sleeve up the cable 5 Fix the cable core clamp to the connection pin of the Magnefix using an approve...

Page 64: ...lows 1 Insert the greased rubber sleeves b into the feed apertures of the insulating conduits a at the top 2 Slide the insulating conduit up the cable 3 Connect the cable cores to the connection point...

Page 65: ...rminal block NOTE The flattened sides of the washers around the insulating conduits must abut 7 8 Fix the cable and the rubber rings on the cable in the cable clamps Firmly tighten the clamps 9 Fit bo...

Page 66: ...Magnefix MD4 66 991 184 G01 03 9 NOTE The bending radius of the cable must be at least 30 cm 10 Connect the cable to the transformer 10 11 Protect the connections using the plastic guard 11 a b...

Page 67: ...ed materials 3 insulating conduits a 1 bag containing greased rubber sleeves b 3 sealing plugs c 3 protection tubes d 18 plastic screws e 3 cable core clamps universal plastic cable clamps j Cable box...

Page 68: ...ance with the instructions of the cable supplier 1 3 Cut off the cable cores 2 to 3 mm below the cast resin insulation 4 Remove the insulation from the cable cores over a distance of 30 mm 3 5 5 Inser...

Page 69: ...conduits 6 8 10 Lightly grease the cast resin insulation using silicone grease or acid free Vaseline 11 Connect the cable cores to the connection points using the cable core clamps 12 Make sure that t...

Page 70: ...the rubber sleeves on to the cast resin insulated members 15 16 Place the protection tubes d and hand tighten the screws e Make sure that the insulating conduits adequately rest on the bottom most loc...

Page 71: ...cable cores Terminate the cable cores and the splice in accordance with the cable manufacturer s instructions For cables with an aluminium core Eaton cable core clamps are only suitable for connectin...

Page 72: ...ructions of the cable supplier 1 3 Cut off the cable cores 2 to 3 mm below the cast resin insulation 4 Remove the insulation from the cable cores over a distance of 30 mm 3 5 5 Insert the greased rubb...

Page 73: ...Ensure that the screws are fitted in the same direction angled forward for all three phases 13 Slide the other washers 2B as far as possible on to the connecting pieces and fit the hexagon socket head...

Page 74: ...ting conduits and the rubber sleeves on to the cast resin insulated members 17 18 Place the protection tubes d and hand tighten the screws e Make sure that the insulating conduits adequately rest on t...

Page 75: ...the protected panel The vacuum circuit breaker of the protected panel can only be switched on if the adjacent switch caps have been pulled out When switching on for maintenance purposes the vacuum cir...

Page 76: ...re for switch caps WARNING Never fit a switch cap if the current indicator window shows a red flag 1 Check that the overcurrent indicator a has been reset no red flag is shown 2 Put a switch cap on th...

Page 77: ...elease knob 1 upwards and satisfy yourself that the guard 2 opens 4 Place the switch on lever 3 in the lip 4 5 Move the switch on lever 3 upwards 6 Satisfy yourself that the position indicator 5 chang...

Page 78: ...the release knob 1 upwards and satisfy yourself that the guard 2 opens 3 Place the switch on lever 3 in the lip 4 4 Move the switch on lever 3 upwards 5 Satisfy yourself that the position indicator 5...

Page 79: ...itch Procedure for protected panel 1 If the relay has switched off the protected panel the electronic trip indicator 9 will show a red field the mechanical position indicator 5 will show a white field...

Page 80: ...it seems that just one fuse has blown Procedure 1 Switch off the adjacent phases of the branch circuit panels in accordance with procedure 4 2 2 2 Turn the interlock cam counter clockwise 3 Remove the...

Page 81: ...rent indicator a magnet has been supplied Procedure 1 Eliminate the overcurrent condition 2 Slide the magnet through the slot at the front of the switch cap The red flag disappears The overcurrent ind...

Page 82: ...ights up when a voltage is present at the test point of the probe The push button is used to test the probe The rated voltage of the probe must match the operating voltage of the switchgear being test...

Page 83: ...tester 4 6 2 System dead indication WARNING NEVER work on unearthed switchgear even if the voltage tester indicates no voltage Always put protection caps on all open cast resin insulated members that...

Page 84: ...as a scale on which the rated operating voltage is indicated Different voltmeters are available for different operating voltages Phase sequence indicator Testing the phase sequence indicator Proceed a...

Page 85: ...D E F For busbars points G H K 4 Check that the phase sequence indicator displays a voltage each time 5 Repeat this procedure for all phases to be tested 6 Test the phase sequence indicator once again...

Page 86: ...g MUCO The standard earthing cap may have screw or ball head type contacts A bag containing high speed earthing equipment and a corresponding switch on lever is available for three pole high speed ea...

Page 87: ...ting the earthing caps never put your hand between the red ring on the mounting rod and the earthing caps 1 Check that the cable to be earthed is dead 2 Connect the earthing caps to the earthing point...

Page 88: ...1 on switching the switch caps on and off Procedure 1 Check that the cable to be earthed is dead 2 Connect the high speed earthing equipment to the earth bar of the Magnefix switchgear using the eart...

Page 89: ...e protruding part of the switch on equipment A is at the left 5 6 Push in the interlock pins on the switch grip to release them and then push the switch on equipment forcefully in the direction of the...

Page 90: ...Magnefix MD4 90 991 184 G01 03 4 7 4 Removing three pole high speed earthing Proceed as follows 1 Turn the grip to the opening position 2 Pull the earthing cap forcefully from the fixed component 2 3...

Page 91: ...s Make sure the switchgear is dead and pay attention to any feedback from the low voltage side 2 Connect the earthing pins to the earthing point of the Magnefix switchgear using the earthing spider or...

Page 92: ...earthing It is assumed that the switch caps of the corresponding branch circuit panel have been removed If the electric trip indicator 10 shows a red field the fault requires to be repaired first bef...

Page 93: ...NING When fitting the earthing caps never put your hand between the red ring on the mounting rod and the earthing caps 12 Use the installation rod to switch on the three earthing caps firmly on the ca...

Page 94: ...cessary repeat the procedure for the other phases 8 Remove the measurement connections 4 4 8 2 Testing Measuring rods are available for testing they can be fitted directly to the fixed contact in the...

Page 95: ...pins are used Procedure 1 Isolate the installation 2 Provide earthing using the earthing caps with extended connection pins and the earthing spider REMARK Do not remove the short circuit strip nor the...

Page 96: ...order to establish whether the configuration of materials is consistent with the order 5 1 2 Inspections After the switchgear has been set up the inspections to be carried out include the following on...

Page 97: ...r complete to Eaton for further processing Clean the switchgear thoroughly and store it for re use Make an appointment with Eaton to have the switchgearoverhauled NOTE Do not dismantle the switchgear...

Page 98: ...lar intervals 6 2 1 Types of maintenance There are two types of maintenance for Magnefix 1 Maintenance the user can do Cleaning Inspection for visible deficiencies corrosion discharge phenomena 2 Main...

Page 99: ...r of the switch caps are to be cleaned in accordance with the procedures set out below 6 3 1 Switchgear has been isolated Remove dust and dirt using a soft hand brush or by blowing Persistent dirt can...

Page 100: ...on of the switch caps 4 If necessary clean with a dry cloth 5 Remove any black deposits from silver plated contacts by mild scouring with a scouring pad and slightly grease contacts using acid free Va...

Page 101: ...ngress of air 2 Undo the hose clip and slide the cable box far enough down for the nylon vent threads to be fitted If the sliding action is difficult due to the grease having become too viscous you ca...

Page 102: ...ecautions to keep such hazards to a minimum You will need to contact Eaton Service if work on the primary part of the installation is required All operations must be carried out by or under the superv...

Page 103: ...3x1 683 098 12 Cap for busbar screw rod MD4 MF 685 010 20 O ring for cast resin insulated member 027 428 21 Sleeves 3 off 682 958 22 Insulating conduit for dry cable box 682 335 23 Sealing plug for dr...

Page 104: ...460 T unit 32 MD4 fuse holder complete 683 274 33 MD4 operating handle 681 074 34 Cover for MD4 fuse panel 681 316 35 Reset magnet 683 625 37 Half frame leg 4 off required for 1 frame 682 214 39 Cabl...

Page 105: ...685 005 683 766 earthing cap ball head bolt terminal 685 006 684 412 earthing cap ball head bolt terminal with column 685 008 685 003 Earthing equipment for fuse panel 685 102 N A Earthing equipment...

Page 106: ...AGER must be appointed in accordance with EN 50110 1 the INSTALLATION MANAGER is directly responsible for operation of the installation If two or more installations are in close proximity to each othe...

Page 107: ...it switchgear A unit to protect or switch on or off in one place two or more parts of an electrical installation Switchroom The location in which the switchgear is set up Working area A clearly design...

Page 108: ...Magnefix MD4 108 991 184 G01 03 9 APPENDIX 9 1 Appendix Electrical Diagram...

Page 109: ...Magnefix MD4 991 184 G01 03 109 9 2 Appendix Floor plan...

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