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Magnefix MD4

991.184 G01 03

3.5.5

Cable boxes for plastic-insulated

cables (XLPE)

A dry cable box is available for connecting plastic-insulated

cables. This cable box consists of a plastic sleeve for each

phase. This cable box is also used for:



single-core cables up to 240 mm



three-core cables up to 3 x 240 mm



single-core Eaton transformer cable.

A cable box for plastic-insulated cable consists of:



3 insulating conduits (a).



1 bag containing 3 rubber sleeves treated with silicone

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.

OTE

Terminate the cable cores and the splice in
accordance with the cable manufacturer’s

instructions.

3.5.6

Cable boxes to non-standard

specification

It is possible to use a different make of cable box or a

combination of an Eaton cable box with a non-standard

cable termination material.

In this case terminate the cable and/or cable box in

accordance with the instructions of the relevant

manufacturer. If in doubt, please contact Eaton Service for

advice.

Cable box for XLPE cables.

Содержание Magnefix MD4

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

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