Installation, Operation and

Maintenance Instructions

Metal–Clad Cassette type 12kV Vacuum Circuit Breakers

DIYA Series

IMPROVEMENTS IN PRODUCT DESIGN ARE A CONTINUOUS PROCESS AT MEGAWIN SWITCHGEAR-P-LTD.

CONTENTS OF THIS MANUAL ARE LIKELY TO VARY SLIGHTLY WITH ACTUAL PRODUCT SUPPLIED. PLEASE REFER
CONTRACTUAL DRAWINGS FOR AUTHENTIC INFORMATION ON ACTUAL PRODUCT SUPPLIED.

Cat.No. DIYA-1212 Rev.0

Megawin 1
Thank you for choosing this MEGAWIN product, which is a user friendly Vacuum Circuit Breaker –
Model DIYA-1212. It is suitable for use in your Electricity Distribution Networks up to and
including 12kV, 1250A, 25kA, 50Hz. Solidly / Effectively Earthed / Un-Earthed system. Before
getting to know more details about the product please go through carefully the following
important terms and their meanings.

Safety Instructions:

1. General instructions:

To ensure personnel & product safety, always remember that this equipment contains very high voltage and hazardous to life with high
speed operating mechanical parts. The equipment is designed for operation and control from remote as well.

Non-observance of the safety instructions can result in severe personal injury and/or property damage.

Only qualified personnel should work on or around this equipment, after becoming thoroughly familiar with all warnings, safety notices
and maintenance procedures contained herein.

The successful and safe operation of this equipment is dependent on proper storage, handling, installation, operation and
maintenance.

Qualified person:
For the purpose of this instruction manual / product labels, a “qualified person” is one who is familiar with the construction, operating
instructions of this Vacuum Circuit Breaker, including its control equipment and is aware of the Danger & Caution requirements.

In addition, he has the following qualifications:

a) Is trained, knowledgeable about the specific purpose, functioning of the Circuit Breaker in its given location, has the
necessary authorization to energize / de-energize the circuit, grounding / earthing it, to clear line / load faults, connect
circuits using equipments in accordance with the established procedures of the Distribution Company and their safety
practices.
b) Is trained in working on high voltage equipments and in following the safety norms, use of protective devices / equipment in
accordance with the established safety practices.
c) Is trained in rendering first aid to an electrically / mechanically injured person.

Independent of the safety instructions given in this manual, prevailing local laws, ordinates, guidelines, statutory requirements
and pre-qualification standards for operation of electrical equipment including labor health / safety / insurance and
environment protection norms apply.

2. Important terms and definitions

Danger ! Caution !
Where ever this word “CAUTION” is used in these
Where ever this word “DANGER” is used in these instructions, instructions, it means that damage to the panel,
it means that injuries can occur to person(s) if the relevant surrounding property or environment can occur if the
safety measures and care are not taken. Strictly follow the relevant precautionary measures are not taken. Adopt
safety instructions. strictly the precautions given here in.

Megawin 2
 PREFACE
This Installation, Operation and Maintenance Manual for Indoor Metal Clad
Cassette Type Vacuum Circuit Breakers conforms to relevant IEC/BIS standards
and practices applicable and prevailing in the Country of Origin, at the time of
delivery. If correctly used, the inherent features built-in provide a high degree
of safety to man and product, by way of mechanical inter-locks to prevent
faulty operation and shock-proof metal encapsulation of live parts, provided it
is properly earthed.

The perfect and safe operation of the switchgear is however conditional and
depend on:
 Proper transportation, un-loading, storage, un-packing and shifting to the
point of installation
 Observance of correct installation, establishing and maintaining low
resistance earth connections
 Qualified operating personnel with high degree presence of mind
 Correct installation and commissioning
 Diligent operation and maintenance without tampering / defeating of
inter-locks
 Following the instructions applicable at site for installation, operation
and safety.
 Adhering to schemes and instructions contained in Contractual Drawings

IMPROVEMENTS IN PRODUCT DESIGN ARE A CONTINUOUS PROCESS AT MEGAWIN SWITCHGEAR-P-LTD.

CONTENTS OF THIS MANUAL ARE LIKELY TO VARY SLIGHTLY WITH ACTUAL PRODUCT SUPPLIED. PLEASE REFER
CONTRACTUAL DRAWINGS FOR AUTHENTIC INFORMATION ON ACTUAL PRODUCT SUPPLIED.

Megawin 3
 CONTENTS
Page Page
1. Receiving the consignment 5 26.1 Breaker Truck 38
1.1 Plan unloading and storage 5 26.2 Voltage Transformer 40
1.2 Packing details 7 26.3 Earth Switch operation checks 40
1.3 Packing method 7 26.3.1 Incomer earth switch operation 40
1.4 Unloading 8 26.3.2 Outgoing Feeder earth switch opn. 41
1.5 Examining for damage – Insurance 9 27. Pre-commissioning (Electrical Tests) 41
1.6 Storing at site 9 27.1 Electrical operations - Breaker 41
1.7 Shifting Switchgear Cubicles to 27.2 Electrical operations - Relays & Meters 42
their point of installation 9 27.3 High Voltage Test on main circuit 43
1.8 Handling of VCB truck 13 28. Checking and storing accessories 43
29. Revising the Circuit Diagrams 44
2. Technical illustration of equipment 14 30. Settings for Space Heaters, lamps 44
2.1 General introduction 14 31. Operating Instructions 45
2.2 Design Features 15 31.1 Breaker truck positions 45
2.3 Understanding panel construction 15 31.2 Opening/closing compartment doors 47
2.4 Special tools and accessories 21 32. Engaging breaker to Service manually 48
33. Dis-engaging the breaker truck to
3. Functional classification of panels 22 Test / Removed position manually 49
4. Safety interlocks 23 34. Castell Key Operation (Optional) 49
5. Technical Data 26 35. Disconnecting the LV Plug 49
6. Rating Plate 27 36. Connecting the LV Plug 50
7. Ambient Temperature and Humidity 27 37. Circuit Breaker Operating Mechanism 50
8. Site altitude matters 27 38. Circuit Breaker Operation 50
9. Installation 29 39. Emergency manual tripping Breaker 51
9.1 Preparing the switchgear room 29 40. Main Circuit earthing 51
9.2 Foundation 29 41. Maintenance Instructions 55
9.2.1 False floor 30 41.1 Preventive maintenance schedule 55
9.2.2 Concrete floor 30 41.2 Cleaning 57
9.3 Room size and clearances 31 41.3 Lubrication 57
10. Tools / tackles for installation 31 42. Replacement Parts 57
11. Assembling the switchboard 32 43. Break-down maintenance 58
12. Removal of breaker truck 32 43.1 Defeating the door Interlock of breaker
13. Bolting the Panels together 33 chamber 58
14. Grouting Switchboard to Foundation 33 43.2 Restoration of door interlock 59
15. Connecting the Main bus-bars 34 44. Disposal of Product 60
16. Coupling through Earth Bars 34 45. Summary of Important Instructions 57
17. Making the HV & LV Connections 34
18. Earthing the Switchboard 35
19. Checking the bolted joints 36
20. Cleaning the Switchboard 36
21. Inserting the breaker truck 36
22. Protecting the panels
against environmental effects 37
23. Inter panel Wiring 37
24. Putting the Switchgear into Service 37
25. Pre-commissioning checks & tests 38
26. Mechanical checks on active devices 38

Megawin 4
 1. RECEIVING THE CONSIGNMENT

1.1 Plan unloading and storage arrangements well in advance.

a) The Metal Clad Vacuum Circuit Breakers are shipped in open top trucks (Fig.1) for inland
transportation and in standard closed top hi-cube containers for export consignments (Fig.2)

14 feet

Fig.1

15 feet

Fig.2

b) Roadways, pathways, gate ways leading to the installation site / storage godown should,
therefore, be wide and tall enough to permit entry of trucks & containers
c) Maximum weight of a package will be 1.8 Tons ( 1,800kgs ) and dimensions will be Width
1400 x Length 1900 x Height 2400mm ( Approximately 4’6” x 6’4” x 8’ )
d) For open Truck load, a 10 Ton boom crane / hydra crane will be needed.

Fig.3

Megawin 5
 e) For Container load, a high raise Fork Lift Truck with 1.5 meter fork length is mandatory.

Fig.4 1.5mtr

f) Being a product designed for installation indoors, covered storage with essential leak proof
roofing and all sides preferably covered by walls, with tall & wide doorways is strictly
recommended (Fig.5)

Fig.5

g) Indoor movement of consignment can be done ideally by a 5 Ton Fork Lift Truck. If it is not
possible to manovure indoor movement using a Fork Lift Truck, it will be essential to use
minimum 2 Ton x 2 Pallet Trucks and 4 men to control and manage the cargo movement.

2 Ton Capacity Hydraulic Pallet Truck x 2 Nos.

Fig.6

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 1.2 PACKING DETAILS

Each wooden Case contains 2 Nos. fully assembled Circuit Breaker Panels. The draw-out
Vacuum Circuit Breaker (VCB) truck is supplied duly fitted inside its cubicle. The cubicle should
not be lifted from the top while the circuit breaker is inside. Also refer Packing List supplied
with Invoice & other Dispatch documents for specific Gross Weight and dimension details.

1.3 PACKING METHOD

The Circuit Breaker cubicles are packed in one of the following methods:-

 For domestic supplies, 2 Nos. Cubicles are fixed on a sturdy wooden pallet and covered by
plastic sheet for surface protection and packed in normal wooden case / ply box / tarpaulin
wrap.

Fig.7
 For export supplies, single cubicles are packed individually, in sea-worthy wooden cases,
with durable poly-urethane bags enclosing the vinyl wrapped panels. De-hydrant pouches
are kept inside the cubicles to absorb moisture resulting from condensation.

Fig.8
Smaller accessories required to operate and maintain the panels like ramp, handles etc. are
either packed separately or kept in one of the cubicles having free space ( please see packing list
for details ).

Megawin 7
 1.4 UNLOADING

CAUTION !
1) While unloading, care must be taken to see that cubicles are not dropped. They should not
be tilted more than 5 degrees from the vertical plane. Never handle or put to rest the
cubicle on its sides. They must be kept in upright condition always.

2) Do not un-pack before unloading the wooden cases containing VCB Cubicles. Take care not
to damage the plastic sheet because it protects the switchgear against environmental
effects.

OPEN PACKING INDOORS

Fig.9 Fig.10

3) Lift the Cubicle from the bottom. Send the wire rope through the wooden pallet and ensure
the 2 rope slings do not slip inwards. Use adequate length of wire ropes to avoid exertion of
pressure on the cubicle sides / top corners.

6” Maximum

Ground level
Fig.11

Megawin 8
 4) Lift slightly (2 – 3 inches) to check for proper balance of load. Shift sling position if necessary
only after keeping the cubicle down.
5) Once satisfied about proper balance of load, move the packed cubicle away from the truck
after lowering it to about 6 inches from ground / floor level (Fig.11) and move to storage
area. Take care not to hit the suspended cargo to any obstruction like tree / fence / wall or
any other strewn item lying on the ground.
6) Avoid unpacking if storage of the cubicles is expected to last long. However, this is subject
to the condition that no apparent damage in transit is visible while unloading.

1.5 EXAMINING FOR DAMAGE – INSURANCE

As soon as material is un-loaded, survey the consignment for any transit damage. Report to
MEGAWIN immediately in case damage noticed. Unpack to examine extent of damage and exact
portion affected. If reason for damage is Transport, record the damage on Delivery Note / Bill of
Lading / Lorry Receipt, in the presence of delivery agency and take an endorsement from them. This
report is essential for lodging insurance claims.

1.6 STORING AT SITE

 Store the units in upright position only.
 Do not remove them from their pallets.
 Ensure the units are stored in adequately covered location such that they are protected from
sun, rain, flood, flowing water, water splash during floor cleaning, garden sprinklers and other
such possibilities. Also ensure safety to material in terms of pilferage / theft / acts of enemy,
including fire.

1.7 SHIFTING SWITCHGEAR CUBICLES TO POINT OF INSTALLATION:

 Move the cubicles on their pallets to the nearest point of installation using a fork-lift truck or
mobile crane or hydraulic pallet trucks.
 Open the wooden box containing breaker handling accessories. You will need the racking
handle and spring charging handle.

Racking handle Spring charging handle

Fig. 12
Earth Switch operating handle (optional)

Megawin 9
  Further, a service trolley is always supplied as a separate item along with the consignment.
Please refer the following figures to understand the service trolley:
Breaker platform
Height adjustment wheel
Engaging guide rod
Automatic Breaker lock-stud
Service Trolley anchor

Breaker lock-stud actuator

Engaging guide rod

Service Trolley Panel mating end of Service Trolley

Fig. 13

 Remove the packing material wrapping the breaker cubicle. Take care not to damage any
protruding component like selector switch handles, interlock key / rotary switch position lock,
panel lock / key etc.
 Remove the draw-out breaker by doing the following steps (See explanation on next page)

Step-1 Step-2 Step-3

Step-4 Step-5 Step-6

Fig. 14

Megawin 10
 Step-1: The breakers are supplied in OFF condition, duly engaged to service position. Because
of door interlock, it is not possible to open the breaker chamber door unless and until the
breaker is brought to test position. After checking the status of breaker through viewing
window on the breaker chamber door and ensuring breaker is in OFF condition, ( see Fig. 16
below ), insert the breaker racking handle through the racking port provided for rack in / rack
out. In case the breaker is in ON condition (see Fig. 17 below), please insert the Trip tool in the
tripping port and push hard with open palm. The breaker will make a thud noise and open. You
can now see the OFF status as in Fig. 16.

Viewing window for

breaker status
Fig. 15 Tripping rod

Step-2: On reaching the test position, un-screw the thumb grip bolts holding the door in closed
condition. The door will now open.

Step-3: Position and align the service trolley with the open breaker chamber. Push the service
trolley until it mates with the panel front and gets locked in. It may be necessary to adjust the
platform height on service trolley to match the level of breaker truck.

Step-4: Un-plug the LV multi-pin plug and keep it on the open door (see inset on picture in this
step). Gently pull the breaker truck on to the service trolley.

Step-5: Sling the lifting hook in the handle provided on the breaker truck and gently raise the
breaker truck. It will tilt backwards as shown in the picture. Do not panic. It normally tilts. Just
beware and ensure nobody is hurt.

Step-6: Lift away and store separately in a clean dust free place, indoors, until the panel is
installed and ready for pre-commissioning checks.

Megawin 11
  Generally the breaker truck is kept in OFF condition, during transit. However, check the status
by observing the mechanical status indication on breaker front. See Fig. 14 and Fig.15

Breaker OFF Breaker ON

Indication Indication

Fig. 16 Fig. 17

 With breaker in OFF, rotate anti-clockwise to disengage the breaker truck from its SERVICE
position to TEST & ISOLATE position.
 By design, it is not possible to insert and engage the racking handle as long as the Breaker is in
ON condition.

CAUTION !
DO NOT attempt to take out the breaker truck without using the service trolley provided. It is very
heavy and can cause injury to personnel handling it.

 Open the PT chamber door. You will find 2 Nos. M16 bolts holding down the frame to the pallet.
Remove these bolts.
 Remove the rear bottom cover and wire mesh behind it, to access the cable chamber by un-
screwing the holding bolts.
 Now remove the bolts holding the cubicle to the pallet on rear side (cable chamber).
 Now with the breaker truck removed, move the cubicle manually, with care, on to the lowered
hydraulic pallet truck arms using crow bars. You will need 1 No. hydraulic pallet truck of 2 ton
capacity. Raise the Pallet Truck slightly and move Panel to the point of installation.
 At least 2 persons on each side of the cubicle should be available while moving the cubicle. This
is over and above the hydraulic pallet truck driver. That is, at least 5 persons required while
moving the cubicle.
 Keep pieces of wooden blocks at hand. They should be taller than the hydraulic pallet truck arms
(in lowered condition). Lower the cubicle in the desirable position on the wooden blocks.
Release the hydraulic pallet trucks.

Megawin 12
  Tilt the Cubicle slightly so as to release the wooden blocks.
 Use a crow-bar at the cubicle’s lower vertical corners to position the cubicle into its pre-
determined place and secure it to the floor with foundation anchor bolts.
 Take care to ensure the diagonals of the cubicle are not disturbed.

1.8 HANDLING OF VCB TRUCK

The VCB Truck can be lifted by means of the two eye bolts provided (Fig.17), using suitable hoisting
gear. Lift slowly and carefully as you can expect a 30 degree tilt backwards (Fig.18)

Lifting & pulling

handle

5 degree tilt back-wards.

Fig.18

The vacuum circuit breakers are supplied in their OFF condition. Their springs are in discharged
condition. These conditions can be seen on the VCB Truck front. See Fig.19 below.

Spring status indication

Breaker status indication

Breaker Operation counter

Fig.19

Megawin 13
 2. TECHNICAL ILLUSTRATION OF EQUIPMENT

Low Voltage
Metering Chamber Bus-Bar Chamber

Breaker Chamber

Cable Chamber

CT & Cable Chamber

Draw-out PT Assy.
Fig.20 (For Incomer only)

2.1 GENERAL INTRODUCTION

The Vacuum Circuit Breaker Panels – DIYA-12 Series, are air-insulated, factory assembled, type-
tested, metal-clad, single bus-bar switchgear suitable for indoor installation conforming to
International Electrotechnical Commission (IEC) specifications IEC 62271-200.

 All switching operations can be performed with high voltage door closed.
 Standard degree of ingress protection IP4x in accordance to IEC 60529
 Panels tested for internal arc as per IEC 62271-200
 Partition class : PM (All partitions are metallic)
 Positively driven shutters, with padlocking in closed condition to protect against
accidental contact with live parts.
 Logical interlocks between the circuit breaker operations and the racking mechanism of
the truck prevent mal-operation.
 Cable side of breaker cubicles can be supplied with integral earth switch duly
interlocked with circuit breaker as an optional feature.
 Incoming Feeder also can be fitted with integral earth switch with suitable interlocks to
achieve interlocking with up-stream breaker as an optional feature.
 Optionally, Bus-side/Cable Side Earthing trolleys are also available and can be given

Megawin 14
  Operation of all switching, disconnecting and earthing functions are from panel front.
 High flexibility due to various configurations of the basic panel types.
 The Panels are free floor standing arrangement.
 Power Cable connection from rear. Control cable termination from front (bottom or
top)
 Breaker truck provided is of draw-out Cassette type having service, test and isolated
positions behind closed door.
 All internal control wiring routed through metallic ducts including incoming LV Cables
 All partitions, doors and metallic shutters are solidly earthed to sub-station earth point

2.2 DESIGN FEATURES

The circuit breaker cubicle is divided into 5 chambers ( see Fig. 20 ):

 Low voltage (or Metering) chamber
 Breaker chamber
 PT ( potential transformer ) Chamber
 Cable chamber with CTs and optional earth switch
 Bus-bar chamber
These chambers are firmly bolted together. The high voltage chambers are provided with
safety fly-open flaps on top to relieve un-due pressure developing under internal arc fault
conditions without affecting personnel manning the sub-station. It is ensured by design,
that fault in one chamber will not extend to the other chambers. The enclosures are made
of powder coated sheet steel.

2.3 UNDERSTANDING PANEL CONSTRUCTION

2.3.1 Low Voltage ( or Metering) Chamber This chamber houses the total electrical
control on the switchgear ( Fig.21 )

Numerical protection relay

Fig.16 Low Voltage chamber
Indication Lamps

Energy Meter
Window Annunciator

Test terminal block for Energy Meter

Ammeter, Frequency Meter

Breaker control switch ( T/N/C switch )

Local / Remote selector switch

Fig. 21

Megawin 15
 Terminal Blocks
LV chamber door
(inside view)
PT LT Fuse, 3-Pin Socket
Heater & Lamp Switches

AC / DC control MCBs

Fig.22 Low Voltage Chamber ( with Door open)

2.3.2 Breaker Chamber

It contains the draw-out truck fitted with vacuum circuit breaker. It moves on 4 stepped wheels
two parallel channels fitted firmly on the side frames of the cubicle. The movement itself is
achieved by means of a heavy lead screw rod held between bush bearings. The act of
threading / un-threading this lead screw rod in a square nut held firmly in a fixed position in the
cubicle lends motion to the draw-out truck. It moves between two positions – SERVICE
(engaged position) and TEST (disengaged, drawn to front) position. These operations are
possible behind closed door of the breaker chamber ( see Fig. 23, 24).

Breaker
Chamber

Breaker in Service position PT Draw-out lever Breaker in Test position

(dismannntled condition)
Fig. 23 Fig. 24

Megawin 16
 2
6

8
3

Fig-25 Breaker truck in breaker chamber ( with door open )

1. Breaker truck 5. Service trolley auto-locking slot

2. Multi-pin plug interlock lever 6. Viewing window for VCB position
3. Door interlock catch piece 7. Manual Trip Push Button
4. Racking interlock channel 8. Manual Close Push Button

Megawin 17
 7

6
8
3 5

4
1

Fig-26 Breaker in breaker chamber ( with door closed )

1. View window for breaker status 5. Door Interlock piece fixing hardware
2. Racking port (used for trip-tool bracket fixing also)
3. Spring charging port 6. Viewing window for breaker location
4. Manual Breaker trip port 7. Thumb-grip door fixing bolts
8. Manual Breaker Close port

Megawin 18
 2.3.3 Breaker truck

LV Multi-pin Plug interlock lever

Manual Spring charging port

Manual close push button

Manual trip push button

Breaker Rating Plate

Breaker status display area

Interlock Lever

Breaker Rack-in / Rack-out port

Fig.27 Breaker truck front

HT Plug in Contact-Bus-Bar side

Interrupter Housing
Interrupter

Copper Flexibles
HT Plug in Contact-Cable side

Shutter actuators

Breaker Earth contact fingers

Lead Screw for Rack-in / Rack-out

Fig.28 Breaker truck ( rear view )

Megawin 19
 2.3.4 Bus-bar Chamber :

Composite Bus-Spout &

Bus Support

Fig.29 Busbar Compartment

The busbar compartment contains:

 The main R-Y-B Phase sleeved bus-bars

 Breaker busbar spout bushings with mating contacts for the upper contact arms of breaker
truck.
 The main busbars are extended from one switchgear cubicle to its adjacent cubicle. The
ends of these sections are bolted at site, after the Switchboard is formed using multiple
cubicles.

2.3.5 Cable Chamber – CTs and Earth Switch assembly( Outgoing Feeders )

Power Cable Terminals

Current Transformers (CTs)

Earth Switch (optional)

Fig.30 Cable chamber

Megawin 20
 2.3.6 PT Chamber ( Incoming Feeders ) – Situated on the front below Incomer breaker chamber

PT Fuses

Potential Transformers ( PTs )

Fig.31
PT Chamber door ( with
automatic PT draw-out feature )

2.4 SPECIAL TOOLS AND ACCESSORIES:

Following tools and accessories are supplied with the switchgear cubicle. Exact quantity
depends on the number of cubicles that make a Switchboard line-up.

Spring charge handle

Racking handle

Tools and tackles Service Trolley

Tripping rod ( used when breaker
chamber door is closed )

Earth Switch operating handle (optional)

Fig-32

Megawin 21
 3. FUNCTIONAL CLASSIFICATION OF PANELS :

Depending on how the Panel cubicles are employed in a Distribution Network scheme, they are
called as Incomer Feeder Panel or Outgoing Feeder Panel or Bus-Coupler Panel or Bus-Tie Panel.
However, all these panels are constructed by using identical parts to the extent possible. The
following single line diagrams would help understand these varieties of Panels:

Incoming Feeder panels

They receive the power cables from another Sub-Station and

therefore act like incoming power supplier to the Multi-Feeder
Switchboard at a given location.

Typically, they have Voltage Transformers connected to the

Incoming Cable Terminals, Energy Meter to help record power
flowing in, besides other Protection & Control devices.

Fig.33
Outgoing Feeder Panels:

These are used to deliver electrical energy to the Load Centres.

Typically they have Energy Meters, Cable Side Earthing Switches
besides the Protection and Control devices. Generally, Voltage
Transformers are not provided in these Outgoing Feeders as they
deliver power at Voltage available on a common Bus-Bar, fed by the
Incoming Feeders. Incoming & Outgoing Feeder panels contain
current transformers to sense abnormalities in the network and
also measure the high currents flowing by stepping it down to a
Fig.34 measureable level.

Bus-Coupler Panels:

Whenever a Switchboard is having 2 or more Incoming Feeders,

it is essential to have a Breaker between them for efficient
distribution of power. Often they ensure parallel operation of
the Incoming feeders which deliver power through a set of
Outgoing Feeders. In the event of an interruption of incoming
power, it becomes necessary to take Power from the adjacent
Bus-Bar system. On such occasions, the Bus-Coupler helps in
rendering power from the other Incoming Feeder. Definite
inter-locks are provided in Bus-Couplers to ensure non-
paralleling of Incoming Feeders.
Fig.35

Megawin 22
 In Bus-Coupler panels, one panel is used to house the Breaker truck and another adjacent panel
for raising ( crossing over ) of the Bus-Bar connections from lower HT Spout Terminals to the
upper HT Spout Terminals of adjacent Breaker Panel line-up bus bars ( upper spouts ).
Therefore, the dummy chamber is known as either Bus-Riser Panel or Bus-Bar Cross-over
chamber. Generally, both the panels are supplied as one complete unit.

Stand alone Panel with Incoming & Outgoing cable box ( ICOG Panel )

Sometimes, it may not be necessary to have a

multi-panel Switchboard line-up for a simple Load
Centre. Often in case of medium sized Industries it
would be necessary to only connect High Voltage
side of a Transformer to the Incoming Power
supply point of supply Company. In such
applications it is enough to have one Single
Breaker Panel with facility to connect Power
Cables on both Incoming side and Outgoing side.
For such requirements, ICOG Panels are supplied
with either a rear or side additional chamber
suitable to terminate both incoming and outgoing
power
1.3. Cables
Interlocks Fig.36

4. SAFETY INTERLOCKS

The following are the built-in safety interlocks in our VCB Cubicles:

Name of interlock feature Why and how it works

1) Racking interlock 1. To prevent engaging the VCB Truck to High

Voltage contacts in ON condition.
2. The access point for engaging the Racking
handle is blocked by a built-in steel flag.
3. To gain access, the interlock lever needs to
be lifted vertically. This is possible only
when VCB is OFF and subject to the
DANGER ! condition that the multi-pin LV Plug is fitted
Disengaging the VCB Truck when it is ON, in its socket
live and carrying Power will result in a huge 4. VCB cannot be switched ON in any
arc and cause serious injury to operator. intermediate position between Test &
Such accidents are often FATAL, beware! Service

Megawin 23
 Name of interlock feature Why and how it works
2) LV Plug interlock 1 To ensure LV Auxiliary Power supply (both
AC & DC) is available to the VCB Truck before
engaging to Service position. Auxiliary
Power is required for the VCB to Trip under
an emergency condition.
2 A lever near the LV Socket needs to be
rotated 90 Degrees (approximately) to allow
the LV Plug engage in its socket on VCB
Truck.
3 Once the LV Plug is in place, the interlock
lever can be lifted, thus permitting insertion
of the Racking handle.
3) Door interlock – Breaker Chamber 1. To prevent opening of the Breaker Chamber
door when VCB is in service position.
2. When Breaker is in Service Position, the
door interlock lever on right hand side of the
Breaker Chamber prevents the door from
opening
3. To open the door, with VCB in OFF condition,
the VCB Truck needs to be racked out, until
it reaches the Test Position.
4. Only then the door interlock lever releases
its hold on the door
4) Earth Switch interlock – Outgoing 1. To prevent switching ON the Earth Switch as
Feeders ( when integral Earth Switch long as VCB is in Service Position.
is provided) 2. Only when the VCB is in Test Position, it is
possible to operate the Earth Switch to ON
condition. As long as Earth Switch is ON, it is
DANGER ! not possible to engage the VCB Truck to
Earthing a live line causes grievous injury to Service position.
the operator and equipment. More so, 3. When Earth Switch is OFF, only then VCB
because the Earth Switch is a manually Truck can be engaged to Service Position.
operated device. NEVER attempt to Close Once VCB is in Service position, Earth Switch
the Earth Switch onto Live Cable terminals. cannot be switched ON.
5) Earth Switch Electrical Interlock - 1. To prevent up-stream Breaker from closing
Incomers (switching ON) when the integral Earth Switch is
ON. The Earth Switch is fitted near incoming
Power Cable Terminals in Incomer Cubicle
2. A limit switch is fitted near the integral Earth
Switch so as to actuate when ever Earth Switch is
ON.
3. NO contact of this limit switch should be
wired in the Trip circuit of upstream Breaker
and NC contact should be wired in the
closing circuit of upstream Breaker.

Megawin 24
 Earth Switch electrical interlock – 4. When Incomer Earth Switch is ON, limit
Incomers ( continued…) switch actuates and upstream Breaker
cannot close electrically.

Name of interlock feature Why and how it works

6) Earth Switch Mechanical interlock 1. To prevent in-advertent closing of Earth Switch

with up-stream Breaker for fitted on Incoming Feeder Cable side when up-
Incoming VCB Cubicle stream Breaker is ON
2. Two Castle Locks (lock bases) with One Key
provided. One Castel Lock base is fitted on the
Cubicle front, near to the Earth Switch Operating
lever and the second lock base is supplied loose.
This loose lock base is meant for fitting in the
upstream Breaker such that the Castle Key
remains trapped in the upstream Breaker as long
as it is ON.
3. When up-stream Breaker is OFF, only then the
Castle Key can be removed and brought to the
Earth Switch provided in the corresponding
Incomer Feeder. This key when inserted and
used in the lock base on VCB Cubicle to release
the Earth Switch operating lever. Now it can be
rotated using the operating handle and Earth
Switch can be closed.
4. The Castle Key remains trapped in the Earth
Switch lock base until the Earth Switch is ON.
Upstream Breaker cannot be closed (switched
ON) without this Key. To release the Key, operate
Earth Switch to OFF condition.

7) Castle Key Interlock for up-stream 1. To prevent VCB from Switching ON without
Breaker / Isolator / any other device satisfying system requirements with respect
to up-stream Breaker / Isolator /any other
device.
2. Two Castle Locks (lock bases) are provided
with One Key. One Lock base is fitted on the
VCB Mechanism and the other is supplied
loose. The lock base supplied loose needs to
be fitted appropriately on the up-stream
VCB / Isolator
3. The Key therefore remains stuck in the up-
stream Breaker / Isolator until the same is
OFF condition. Only after upstream Isolator
is switched OFF, the Key is released.
4. This key is then inserted in the VCB Panel’s
thus permitting it to operate

Megawin 25
 Name of interlock feature Why and how it works

8) Electrical Closing Interlock (for 1. To incorporate any other interlock logic

future) 2. Please refer the schematic drawings, DC
Circuit Diagram. Generally the Terminal
Block Nos. X2-16 and X2-17 connected to
wires K7 and K9 are for any additional
Interlocks to be provided in the VCB closing
circuit. Generally these terminal blocks are
supplied with a piece of loop wire, shorting
the terminals for achieving continuity in
closing circuit. Remove this loop wire if
additional interlocks between other
Switchgear / Gadget is to be achieved.

5. TECHNICAL DATA

Rated Voltage (U) kV 12

Rated short-duration power-frequency with stand kV / 28
voltage (U) per minute minute
Rated lightning impulse withstand voltage (U) kVp 75
Rated frequency (f) Hz 50
Rated short circuit breaking current kA rms 25
Rated short circuit making current kAp 62.5
Rated peak withstand current (Ip) kAp 62.5
Rated short-time withstand current (Ik) kA rms 25
Rated short circuit duration (tk) Sec 3
Rated normal current of the Busbar A 1250
Rated normal current for incoming and outgoing A Incoming Feeders 1250A &
feeders Outgoing Feeders 630A, 800A
Ambient temperature ⁰C -5 to +50
Loss of service continuity LSC2B
Partition class PM
Degree of protection IP4X, IP2X
Internal Arc classification IAC AFLR 12kV, 25kA

Megawin 26
 6 RATING PLATE

A rating plate containing specific data is fixed

inside each panel. The draw-out vacuum circuit
breaker truck has its own rating plate which is
applicable to only that specific Feeder in which
it is housed. It is not to be interpreted as the
Bus-Bar rating of the entire Switchboard.

Fig.37

7. AMBIENT TEMPERATURE AND HUMIDITY

Ambient temperature is understood as the temperature of the air in the switchboard room.

At ambient temperature below -5° C prevailing for a longer period the switchboard room needs
to be heated.

The air temperature in the panels should always be about 5°C above the ambient temperature
to avoid condensation. (Switch on the built-in heaters if necessary )

Occasional humidity up to 95% is permissible.

If the truck-type switchboard is exposed to humid climate and rapid temperature changes occur,
the switchboard room itself needs to be heated / de-humified.

8. SITE ALTITUDE EFFECTS

The rated insulation level B.I.L. (rated system voltage, rated power frequency withstand voltage
and impulse withstand voltage) specified for the equipment is in accordance with the provisions
of IEC Publication 62271, based on standard atmospheric conditions (1013 h Pa, 20°C and 11
g/m³ water content) i.e sea level. The insulating capacity of an insulation in air decreases with
increasing altitude as result of changes in air density.

Megawin 27
 Standards promulgated by IEC and others disregard this decrease in insulating capacity, for
altitude upto 1000m i.e the decrease of approximately 9% insulation level at sea level, at this
altitude is still permissible.

Our own recommendation is as follows:

Since this method is used for rating insulation up to altitudes of 1000m has proved satisfactory,
it should be applied to higher altitudes. The altitude correction factor should therefore be
based on the insulating capacity at 1000m, which is lower by 9% (Corresponding to 0.91 or
1/1.1) than the capacity at sea level.

The following expression thus applies for the selection of the equipment.
Rated withstand voltage to be selected > = Rated withstand voltage/1.1*a

Example :
Site altitude above mean sea level ....................................3000m
Required impulse withstand voltage ..................................75kVp
Correction factor .....................................0.78 ( Fig 31)
Rated impulse withstand voltage to be selected 75/(1.1X0.78) = 87.4kVp
( This product is designed to withstand impulse voltage up to 95kVp )

Fig.38

Megawin 28
 9. INSTALLATION

The installation sequence should be planned and prepared with care. Ensure that the erectors
and the operating personnel read this installation, operating & maintenance instructions.

9.1 PREPARING THE SWITCHGEAR ROOM

Study the following points carefully:

 Foundation – recommended foundation detailed below

 Room size and accessibility – recommendations detailed below
 Construction and load bearing capacity of the floor – Observe local statutory requirements
 Illumination, heating, power supply, water supply and disposal – Observe local statutory
requirements
 Routing of low-voltage and high voltage cables – Follow local statutory procedures
 Earthing systems – Follow local statutory procedures

9.2 FOUNDATION

CAUTION ! Following figure is a typical foundation plan for 3 Panel Switchboard.

Please refer Contractual Drawings for foundation details applicable to the specific
supply.

Fig.39

Megawin 29
 Two options prevail in general practice.

(A) False floor

Place a girder frame flush with finished floor, common to several or all of the Switchgear panels
so that it is parallel to operating front. The girder is meant to support the bottom rails. All the
edges of the panel should rest on this frame. Refer Fig.40

Details of girder frame:

Fig.40
GIRDER FRAME
(B) Concrete Floor

This should be provided with foundation rails across the cable trenches on which the panels are
to rest. For floor cut-outs (refer to Fig. 41) the foundation should be prepared before the
panels arrive. Level differences between the mounting surfaces of the individual panels should
be determined and compensated for by using shims. The level difference beyond permissible
tolerance has to be suitably compensated.

Foundation rails
Cable trench

Fig.41

Megawin 30
 9.3 ROOM SIZE AND CLEARANCES

Minimum clearance to the ceiling above At least 600mm

the top (ref figure12)
Width of control aisle in front of the At least 2000mm
panel for single row
Clearance between the wall and the At least 800mm
cubicle rear

*In case of LV chamber with extra height: it should be ascertained that a min clearance of
600mm is available above the LV chamber.

600mm

800mm 2000mm
800mm

PANEL FRONT

Fig.42 Fig.43

10 TOOLS AND TACKLES FOR INSTALLATION:

Equipments required are:

 Mobile crane/chain pulley block of 3 ton capacity
 Lifting tackles
 Fork lift truck with a fork length of about 1.5m
 Hydraulic jacks or winches and roller pads or pallet trucks
 Crowbars
 Heavy gauge Pipes ( OD 120mm approx. x 1500mm long ) – 3 Nos.
 Torque wrench (8 to 10Nm; 20 to 70Nm)
 Shim plates
 Wire brush, copper sponge
 Soft, lint-free cloth
 Cleaning agent
 Several strong boards

Megawin 31
 TOOLS & TACKLES….Equipments required ( continued ):

 Rope or chain with transport shackles

 Grease
 Plumbline-bob, nylon thread

11 ASSEMBLING THE SWITCHBOARD

Carry out the work described under clause 12 below. While bolting the panels/bus bars, keep the
bolts loose (not fully tightened) till all the bolts followed by foundation bolts.

12. REMOVAL OF BREAKER TRUCK: (refer clause 1.7 page 9)

 Bring the draw-out Breaker truck to test / isolate position.

 Open the door of the circuit breaker compartment
 Mark the draw-out truck and it’s fixed cubicle for their Feeder identification.
 Disconnect multi-pin plug from its socket and place it on the open door or inside breaker
chamber if door needs to be closed ( take care it does not touch any other live / metallic
part ).
 Position the service trolley ( supplied loose ) in front of the Breaker chamber, raise the
platform to match the breaker truck, engage and push firmly to automatically lock it.
 Ensure the breaker lock stud on the service trolley is almost fully sucked down and flush to
allow the breaker truck to move out without hinderance.
 Hold the Breaker Truck by its fixed handle provided on front top and pull gently but firmly
towards you (forward). Tow it away from the panel on its handling trolley, to safe custody.
 Unload the breaker truck using hoist / crane / chain pulley etc. from atop the service trolley
to make the service trolley free for subsequent use.
 Once the service trolley is gone, close the CB chamber door firmly not to allow rodent entry.
 Remove the remaining draw-out breaker trucks in the same manner as detailed above.

CAUTION !
NEVER handle a Breaker Truck by holding it’s contact arms

Bus-Bar side High Voltage contacts

Always live in Service conditions.

Cable side High Voltage Terminals will

be live in Incoming Feeder cubicles.

Breaker chamber with breaker withdrawn

and shutters held open
Fig.44 Fig.45

Megawin 32
13 BOLTING THE PANELS TOGETHER:

It is always preferable to install the centrally located cubicle first (refer Contractual Drawings).
This practice should be invariably adopted for board with 20 or more panels. After installing the
centre cubicle, the other units can be installed on either sides of it in proper sequence, with help
of the General Arrangment Drawing.

13.1 Procedure

 Firstly ensure the perfect alignment / diagonals checks of the central cubicle in its place on
the foundation. Ensure switchgear cubicle is correctly leveled and absolutely vertical. Use
level guage & plumb line. If necessary place shims, washers / plates to correct and
compensate any misalignment.
 Place shims under the upright and rigid frame and
 Under the bottom rails near the 30mmX30mm cutouts for foundation bolts.
 Remove and re-use later the panel coupling blots fitted at the left hand side walls of each
cubicle (as viewed from front).
 Move up the second cubicle.
 Align this on foundation, similar to the first cubicle. Also adjust it to achieve the correct
level and make sure both cubicles stand vertically in perfection.
 Use shims if necessary, in the same manner as for the first transport unit.
 Using the coupling hardware (bolts & nuts) removed earlier join the adjoining cubicles.
 Check whether the panels are truly vertical. If necessary slacken and seal gaps with shims,
rubber gaskets etc.
 Move the remaining cubicles one by one as per their sequence of location, one on either
side, one at a time, aligning and checking them at every stage and bolt them together.

CAUTION ! Do not tighten the coupling bolts at this stage.

14. GROUTING SWITCHBOARD TO FOUNDATION

The Dia 20mm x 4 holes on panel base plate / frame, where 4 Nos. M16 bolts were used to
secure the panel to the pallet are also meant for grouting purpose. Refer to Fig. 39.

Embed anchor bolts in the foundation (during casting of floor) using the details given in the
foundation drawing or drill the concrete suitably for fixing M16 anchor bolts. In case
foundation rails are being used, drill 18mm diameter holes in them.

Insert shims between the foundation and panel bottom to ensure alignment. Place a M16 flat
washer, followed by a M16 spring washer and then the the M16 hexagonal nuts. Tighten the
M16 nuts without distorting the panel alignment.

Megawin 33
 15 CONNECTING THE MAIN BUSBARS

Start working on the bus-bars only after the panel cubicles have been aligned / adjusted
correctly, fully coupled and grouted.
Access to the bus-bar chamber is from the rear and / or top side. When need to access from top
side, opening the explosion vents is essential. Make sure to fix the explosion vents back in place
after completing the Bus-Bar connections. All necessary hardware is supplied for fixing the main
bus-bars. Generally the hardware are fitted in their respective coupling holes.

 For Aluminum Bus-Bars, use the wire brush to brush the contact surfaces criss-cross until
bright metal shines. Wipe using a clean cloth. (Do not do this for copper bus-bars)
 HT Hexagonal Bolts of size M12 of length appropriate for the number of Bus-Bars to couple
are used along with 2 plain washers and a spring washer and M12 Nuts are generally used
for bus bars joints. Use the plain washers one on either side of the bolt while the spring
washer needs to be placed on the Nut side after the flat washer. Do not over-tighten. Use a
Torque Wrench for final tightening. Recommended torque is 70Nm.
 Use spacers / links supplied with bus bars.
 Allow the joint to settle down in 24hrs & check the value of the torque with the torque
wrench.
 The busbars of adjacent units may be joined together using the bus bars and hardware
supplied.
 Re-fix the Bus-Bar chamber rear covers and top explosion vent covers carefully after the bus
bars are bolted.

16 COUPLING THROUGH RUNNING EARTH BUS-BAR

The earth bars of the cubicles must be linked together to form a continuous Earth Bus-Bar.
Smaller of the two pieces (called a fishplate ) is to be un-bolted and taken out through side
opening, into the adjacent panel. The cover on the side wall of the extreme end panels should
be properly adjusted after joining the earth bars to prevent entry of vermin, rodents, reptiles
etc. All bolts used in the fitting of this earth bus is also to be tightened adequately.
Recommended torque is 70Nm. Refer figure 47.

17 MAKING THE HIGH VOLTAGE (HV) AND LOW VOLTAGE (LV) CABLE CONNECTIONS

The cable connection points of each switchgear cubicle are fitted with appropriate sized bolts
for cable lugs. However, they may need to be discarded if found inadequate (when number of
cables & therefore cable lugs are more.

Megawin 34
 The removable Gland Plates / Trays provided must be taken out for making suitable cutouts to
suit the power cable chosen. These gland plates must be re-fitted in their place in the cable
compartment. For approach to cable terminations, remove the lower rear cover which should
be refitted after the termination is done.

Check the control power and auxiliary circuit connections of switching devices at random, but
examine all terminal block connections, making sure that the blocks are correctly labeled and
replace any missing labels to the circuit diagram. Seal all the LV Cable entry points to prevent
entry of vermin / rodents / reptiles. If cable glands used, ensure they are firmly fitted to ensure
LV Cables are firmly held in place without causing un-due loading on Terminal Blocks.

18 EARTHING THE SWITCHBOARD

The earth busbar running through out

the length of the multi-panel
switchboard actually protrudes out of
the end panel sides. They carry a 12mm
diameter hole meant for connecting the
station earth points.

Connect the protruded earth terminals

on either ends of the Switchboard to the
station earth pits. Ensure the earth pits
are properly designed and maintained
for the purpose. ( Two or more earth
pits may be required as prescribed by
statutory guidelines prevailing locally).
Termination facility for earth connection
is provided on earth bus-bar mounted in
the cable chamber.

Ensure the cover plate at the earth bus is fitted back in place
Fig.46
to block excess gap and prevent entry of rodents, reptiles etc.

Megawin 35
 19 CHECKING THE BOLTED JOINTS

Check all bolted joints with a torque wrench. Ensure following prescribed values are maintained.

Size of Bolt M8 M10 M12 M16

Property class 6.6 8.8 8.8 8.8

For A T A T A T A T

Type of joint Torque (Nm)

Steel to Steel 32 22 65 45 115 80 -- --

Steel with insulator 16 12 32 25 60 48 110 88

Bus-bar to Bus-Bar 20 17 40 35 70 60 155 130

joints
Busbar with steel 20 17 40 35 70 60 -- --

A — Assembly T – Testing
Fig.47

20 CLEANING THE SWITCHBOARD

Clean all insulators, insulating bushings and bus bars in all compartments using a soft dry lentil
free cloth. Do not use any abrasive chemicals or detergents to clean insulated parts. Use only
distilled water if necessary. Openings to the switching-device compartment must be free of
grease and other deposits.

21 INSERTING THE BREAKER TRUCK

 Open the front door of breaker chamber on the cubicle
 Position the service trolley with breaker truck on it and align with the channel rails on
side frames in breaker chamber. Adjust the platform height if necessary.
 Ensure the service trolley gets locked properly.
 Push the breaker truck into the panel, as far as it can go without experiencing any
resistance.
 Remove the service trolley by moving the un-locking lever to the right. See pictures
below

Move lever right-

wards to un-lock
Fig. 48

Megawin 36
  Fit the LV multi-pin plug into position.
 Ensure breaker status is OFF. Close the breaker chamber door. Insert racking handle in
the racking port. Turn clock-wise to engage the breaker truck.
 Follow the above sequence and insert remaining draw-out Breaker trucks in the same
manner

22 PROTECTING THE PANELS AGAINST ENVIRONMENTAL EFFECTS

 Small damage to paint finish during the process of installation may need touch up
painting. Ensure the necessary touch up is done by an experienced person.
 Tighten all the inter-panel coupling bolts
 Fit all the removable covers / parts that were removed during the process of
installation, in their respective positions. This is essential to prevent entry of rodents
and reptiles.
 Close all doors and covers firmly and properly
 All openings that were used to facilitate installation should be closed and sealed to
make the cubicle totally vermin-proof. Plug any excess holes / openings with
permanent setting M-Seal putty / equivalent substance.

23 INTER-PANEL WIRING

 The Inter-Panel connecting wires have been connected at one end on their
respective terminal blocks while the other end have been left loose, in a loop,
inside the LV compartment of certain panels. These loose ends of the wires must
be connected, referring to contractual drawings furnished.

24. PUTTING THE SWITCHGEAR INTO SERVICE

CAUTION ! - ENSURE THE FOLLOWING PRE-CONDITIONS PREVAIL BEFORE PROCEEDING:

 The Incoming Power Cable is dead (up-stream Breaker is OFF)

 Integral Earth Switch is OFF
 The external Interlock terminals X2-16 and X2-17 are either wired up to external inter-
lock circuits or shorted by means of a piece of shorting wire.
 External Inter-lock conditions stand fulfilled to permit Breaker operations
 Auxiliary DC & AC supplies are healthy – use a Multi-meter and check availability of the
same, at their designated terminal blocks
 MCBs / Toggle Switch provided for connecting Auxiliary supply are in OFF condition.

Megawin 37
 25 PRE-COMMISSIONING CHECKS:

a) Visual checks for any damage to protection, control and indication elements fitted on the
Cubicle – rectify if any damage noticed

b) Visual checks for any loose wiring / un-terminated wire. Tighten / terminate the wire(s)
firmly in their position.

c) Mechanical check for all moving parts – breaker truck, earth switch, voltage transformer

26 MECHANICAL CHECK FOR ALL MOVING PARTS

26.1 BREAKER TRUCK

Check Breaker spring status: They are

supplied in spring discharged
condition and therefore the
mechanical status indicator should
show discharged condition. If found
in spring charged / partially charged
condition, Close the Breaker by
pushing the manual close Button (
Green Push Button on Breaker truck
front ). You will hear a thud sound
denoting the Breaker has closed (also
observe the Breaker status indication
as described above). Soon after
follow by pushing the Red Push
Button to Trip the Breaker and thus
discharge the spring fully.
Fig. 49

 Check Breaker status: The mechanical flag with a white circle on green background
indicates the Breaker is OFF. This is the condition in which the Breaker is supplied. In
case you see a vertical white line on red background, the Breaker is ON. Press the
manual TRIP red button (red push button on breaker truck front ). You will hear a loud
thud sound denoting the Breaker is OFF. Also the Green label with white circle appears
in its corresponding window.

 Charge the Spring manually using the Spring Charging handle ( Z-shaped rod ). Rotate
clock-wise (in the direction) to charge the spring. It will start rotating effortlessly and
stiffen towards the end. Carefully listen and expect a distinct click sound at the end of

Megawin 38
 the rotation denoting that the spring is charged ( also see the spring status ). Further
clock-wise rotation will be effortless and un-purposeful.

 CAUTION ! Do not attempt to rotate the spring charging handle anti-clockwise. It is

likely to deform vital components and impair proper function of the spring charging
mechanism, besides disturbing the limit switch settings ( essential for electrical spring
charging)

 With Spring in charged condition, press the manual close button ( green button ) to
close the Breaker. Observe the breaker close (by the thud sound) and also the indicator
change its indication to ON. Press the manual TRIP button ( red button ) to trip the
breaker. Observe the breaker open (by the thud sound) and also the indicator change
its indication to OFF. Also observe / record the reading on the operation counter.

 The above operations can be done a few times to make sure every aspect is functioning
properly.

 Should you find any difficulty, CONTACT MEGAWIN while standing in front of the
Breaker.

ENGAGING & DIS-ENGAGING THE BREAKER TRUCK:

 With the Breaker chamber door opened, Breaker Truck in OFF condition, Multi-pin Plug
in position, insert the racking handle in its port and rotate clockwise to move the
breaker truck to SERVICE position.

CAUTION ! You may not be able to insert the handle if LV plug is not connected.
Therefore, first connect the LV multi-pin plug. This will ensure automatic lifting of the
interlock lever while racking handle is inserted. This is an in-built safety feature.

 In case there exists and integral Earth switch, ensure the Earth Switch is in OFF condition
 Observe the Bus-Bar shutter and Cable spout shutter move away smoothly to make way
for the Breaker HT Contact Arms engage their fingers firmly onto the fixed contacts in
their respective spouts.
 Should you find resistance at any point of time, halt and observe. Check for likely mis-
alignment of rolling and engaging parts. Align them & retry.
 Rotate the racking handle clock-wise until the Breaker Truck reaches the SERVICE
position, indicated by a label on the base plate ( breaker chamber floor ).
 Rotate the racking anti-clockwise to disengage the breaker truck and move to TEST
POSITION.
 Do this a few times to satisfy the breaker truck is engaging & dis-engaging smoothly.

REPEAT THE ABOVE WITH BREAKER CHAMBER DOOR CLOSED. This time, switch ON the
auxiliary power supplies (AC & DC) so that the TEST / SERVICE Indication lamps glow. One of
them alone will glow depending on the location of breaker truck. To ascertain the position of
Breaker Truck ( with breaker chamber door being closed ), observe these indication lamps.

Megawin 39
 26.2 VOLTAGE TRANSFORMER ( or ) POTENTIAL TRANSFORMER (PT) - INCOMERS

 In this model, the Voltage Transformers when provided, are fitted below the Breaker
chamber with access from front (usually on Incomer Feeder cubicles). They serve the purpose
of sensing & measuring incoming line parameters and protect the load from un-due voltage
fluctuations.

 A swing door held by thumb grip bolts on RHS and hinges on the left, is designed such that
opening the door actually disengages the Voltage Transformer simultaneously from its contact
with the incoming HT Live parts.

CAUTION !

 Removal / Fitment of a PT Fuse is possible only by an experienced operator under close

supervision. Adopt all safety measures including HT gloves, rubber gum boots and rubber foot
mat suitable for rated high voltage withstand up to 15kV.

 IT IS STRONGLY RECOMMENDED THAT SUCH PT FUSE REPLACEMENT IS DONE WITH THE

UP-STREAM BREAKER IN SWITCHED “OFF” CONDITION.

 A Multi-pin Plug & Socket arrangement is used to connect the LV side of the Voltage
Transformer to the LV Chamber where the measurement and protection devices are mounted.

 A set of MCBs (or) LV Fuses are used between these terminals to isolate the PT secondary from
their designated Terminal Blocks

 Engage the PT and disengage it, several times to ensure smooth movement and engagement
with HT contacts.

26.3 EARTH SWITCH OPERATION CHECKS:

The Cubicle for Incomer and Outgoing Feeders are provided with integral Earth Switch. The
operating shaft is mechanically interlocked with the breaker truck such that Earth Switch will
operate only when the Breaker Truck is drawn out and kept at TEST position OR in isolated
position outside the Cubicle.
This projection hinders entry of breaker truck
when Earth Switch ON

Fig.41
26.3.1 INCOMER-EARTH SWITCH OPERATION:

Fig. 50

Megawin 40
 DANGER ! Attempting to earth live cables can cause serious injury/death to the operator!

 With the Breaker Chamber door open, fit the Castle Key brought from upstream Breaker
/ Isolator in the Earth Switch Castle Interlock Base and rotate key clock-wise (in the free
to rotate direction). Only in this condition it will be possible to operate the Earth Switch
 Ensure the Breaker Truck is totally withdrawn and kept in Test Position.
 Engage the Earth Switch operating handle and rotate `Clock-wise’ to Switch ON the
Earth Switch
 Once Earth Switch is ON, remove the operating handle and close the Breaker Chamber
door.
 Lock the Breaker Chamber door and remove the door handle key. Hand over key to
Authorized Sub-Station In-charge.
 Hang a CAUTION placard on the Breaker Chamber door handle reading “CABLE UNDER
MAINTENANCE”

26.3.2 OUTGOING FEEDER – EARTH SWITCH OPERATION

 With the Breaker Chamber door open and Breaker Truck in TEST position, engage the
Earth Switch operating handle on the Earth Switch operating shaft.
 Rotate Clock-wise to Switch ON the Earth Switch and Anti-Clockwise to Switch OFF.
 With Earth Switch in ON Condition, remove the operating handle and lock the Breaker
Chamber door.
 Remove the door handle key and hand over to Authorized Sub-Station In-charge.
 Hang a CAUTION placard on the Breaker Chamber door handle reading “CABLE UNDER
MAINTENANCE”.

27 PRE-COMMISSIONING ( ELECTRICAL TESTS):

A) Electrical operations – Breaker, Relays, Meters
B) High Voltage Tests on Main Circuit

27.1 ELECTRICAL OPERATIONS – Breaker:

ENSURE INCOMING POWER CABLES ARE NOT LIVE DURING THESE TESTS

 Keep the Breaker Truck in its TEST position inside the Cubicle
 Ensure availability of proper auxiliary power supplies ( AC & DC ) at their designated
terminal blocks in the newly installed Switchboard. Use a multi-meter to verify
these.
 Plug-in the multi-pin plug into its socket.
 Switch ON the AC & DC control MCBs provided inside the LV chamber
 The spring charging motor starts charging the spring. A distinct sound prevails
indicating the process is on

Megawin 41
  Observe the mechanical spring status on the breaker truck after the charging stops.
It will indicate spring charged. Also observe the blue LED which will be glowing to
indicate spring is charged.
 The breaker status being OFF, the green LED will also be glowing. Also check the
mechanical indication for breaker status. The white circle on green back ground will
be there.
 Push the trip circuit healthy electrical push button. White lamp glows to indicate
healthy trip circuit.
 Hold the pistol grip breaker control switch provided on the LV (Metering) Chamber
and rotate in the direction of Breaker ON/Close. You can hear the thud sound
indicating the breaker is ON. Red indication lamp will glow and green indication
lamp will go off.
 With the spring charged, the Breaker will now function a Trip-Close-Trip action ( O-C-
O ) sequence based on the stored energy in the Spring Mechanism.
 Blue indication lamp will be glowing to show spring charge available.
 Now, rotate the breaker control switch in the direction of OFF/ Open. The Breaker
will open. Observe the indication lamps.
 Blue lamp will still be glowing, indicating spring is having necessary charge.
 Again rotate the breaker control switch. Rotate in the direction of ON / Close.
Immediately after the closing attempt, the spring will charge again.

REPEAT THESE ELECTRICAL OPERATIONS WITH BREAKER TRUCK IN SERVICE POSITION.

27.2 ELECTRICAL OPERATIONS - RELAYS & METERS

 Refer separate instruction manuals for Relay & Meter setting procedures
 Engage an experienced Field Testing team and conduct Secondary and Primary
Current Injection Tests to check the behavior of the Relays and Instruments. Also
actuate the Breaker through simulated fault conditions through Protection &
Auxiliary Relays, with line dead.
 Set values corresponding to the initial load conditions or as desired by Engineer
concerned, for efficient protection and metering.
 Ensure the right CT tap setting is selected during this test.
 Energy measurement checks will need the Voltage Transformer (Potential
Transformer) to be connected in the circuit. To get the PT connected, ensure the HT
PT Fuses & LT PT Fuses are fitted in place. Generally HT PT Fuses are supplied loose
to avoid damage to them while in transit.

Megawin 42
 27.3 HIGH VOLTAGE TESTS ON MAIN CIRCUIT

 Firstly, Isolate the Voltage Transformer

 Clean all insulation parts, busbar, Interrupter surfaces thoroughly
 Using a 2.5kV motorized Megger check for Insulation resistance of Bus-Bars, Cable
end-terminations in fixed housing, Breaker Truck & Earth Switch. One of the leads of
the Megger should be connected to Earth and the other to each Phase at a time.
Repeat tests with leads connected between Phases as well. The Megger value
should be more than 100 MegOhms.
 Then apply AC High Voltage of 24kV (rms) for 1 minute across the Breaker
Interrupters (in open condition) and Earth. You may short the 3 phases to reduce
testing time, but remember to remove the shorting conductor soon after the test. In
absence of AC High Voltage Test Kit, a DC Test kit would also do.
 Repeat the Megger Tests once again after the High Voltage test. You can expect a
marginally reduced reading, which is normal.
 Withdraw the Breaker from SERVICE position and Test the High Voltage Cables and
Cable Terminations by applying 24kV(rms) AC Voltage for 1 minute or DC High
Voltage as per prevailing procedures and acceptable norms at the point of
installation.
 For Voltage Transformer, perform Megger Test using a 500V Megger, between
secondary winding and earth point. Perform HV Test at 24kV (rms) for 1 minute
between HV & LV windings.
 With the Breaker Truck engaged in SERVICE and in ON condition, measure Contact
Resistance of main circuit using a direct reading Micro Ohm-meter. The results are
to be compared to the values furnished in the Routine Test Reports.

28 CHECKING AND STORING ACCESSORIES

The items listed below, which are required for regular operation and maintenance of
the Switchgear must be readily available in the switchgear room or an adjacent room.
Subject them to periodic checks in pre-determined frequency.

1) Racking handle for moving the truck from TEST to SERVICE position – 1 No.
Check: The condition of the engaging part, elbow joint, ball-socket joint tightness
2) Spring charging handle for emergency manual spring charging – 1 No.
Check: The dowel pin fitted is secure in its place at the point of engagement
3) Cam Switch (Breaker Control & Local / Remote Switch) keys if provided – 1 No. each
Check: Ensure it is not deformed / bent or broken
4) Earth Switch operating handle – 1 No. ( if applicable )
Check: The point of engagement is not deformed / broken
5) Set of Installation, Operating & Maintenance instruction Manual – 1 No.
Check: Ensure they are the updated and latest version applicable. Add additional
Notes / pages for any location specific interlocks, pre-cautions, pre-conditions etc.

Megawin 43
 6) Set of As-Built Drawing containing essentially the total Switchboard circuit diagrams,
operating instructions for Relays, Meters and other important devices, spare castell
lock key (optional – if used),
7) Service Trolley for removal / insertion of breaker truck from panel cubicle
8) Trip Tool for mechanical ON / OFF operation (if not desirable to be kept on panel for
reasons of control on authorized operators)

FOLLOWING SAFETY DEVICES MANDATORY IN MOST STATES (not in MEGAWIN scope of supply )

a) Rubber Mat of suitable voltage grade for Panel front

b) HT Gloves (up to 15kV) – 2 pairs
c) Rubber Gum Boots – 2 pairs
d) Discharge Rods – Hotline hook stick
e) Fire Extinguishers – CO2 (for Electrical fires)
f) Fire Buckets with sand alone ( CAUTION : Do not store water )
g) Electric shock treatment chart
h) First Aid kit for cuts / burns
i) Additional DANGER / CAUTION boards ( if necessary )
j) Any other mandatory / statutory devices prescribed by local statutory authorities

29 REVISING CIRCUIT DIAGRAMS:

If circuits have been modified during installation, they are to be marked up on the
existing circuit diagrams. When work has been completed, ensure the original diagrams
are revised. Soft copies of Drawings are generally provided with the Panels. However, if
not found, please ask MEGAWIN for the same.

IMPORTANT: Discard old / obsolete Drawings

30 SETTINGS FOR SPACE HEATERS, LAMPS:

For panels installed in a humid environment, space heaters are fitted in the circuit
breaker and cable compartments. The thermostatically controlled heaters should be
switched ON before taking the panels into service. The thermostat shall be set to cut off
supply to heaters at about 5°C higher than the maximum ambient temperature
prevailing. Example: If Ambient temperature is 35°C, the Thermostat should be set to
40°C. Heaters must be kept “ON” under all the conditions (even during maintenance).

Illumination Lamps are provided with auto-cut off door switch. They illuminate the LV
Metering Chamber only when the LV chamber door is opened. The door switch could
need adjustment at the time of actual installation. Observe and adjust if the setting is
disturbed in transit.

Megawin 44
 OPERATING INSTRUCTIONS

31.1 BREAKER TRUCK POSITIONS:

A) SERVICE position

In this position, the draw-out breaker truck is fully racked-in and connected to high
voltage spouts, for its intended function. In this position, the contact arms of the circuit
breaker gets connected to the bus-bars on upper side and incoming / outgoing cables on
the lower side via the fixed spout bushings fitted in the cubicle and Isolating contacts
fingers on Breaker Truck arms.

The truck gets locked against with-drawal, in this SERVICE position as long as it is ON.

The low voltage circuit remains connected through the low voltage multi-pin plug and
socket connection. The indication lamp meant for service position indication glows on
the panel front. A viewing window for viewing breaker location ( See No. 6 on Fig.26
page 18 ) will also help see the physical location of the breaker truck when the breaker
chamber door is closed. During maintenance (breaker chamber in open condition),
SERVICE label is seen on the breaker chamber floor, once the breaker truck reaches the
service position.

SERVICE POSITION label

Fig. 51

Megawin 45
 B) TEST Position

In this position, the Breaker Truck is at a pre-determined isolating distance from the
main circuit contact spouts, in accordance to VDE 0670, Part 2 / 2.65. The contact
spouts themselves are concealed under automatic shutters, which close as the Breaker
Truck is being drawn-out from SERVICE position. In TEST position, the LV control circuits
remain connected through the multi-pin plug-socket arrangement. The truck gets locked
in TEST position automatically on reaching the position, which is distinctly indicated by a
label “TEST” fitted on the Breaker Chamber floor.

TEST POSITION label

Fig.52

Megawin 46
 As the LV multi-pin plug and socket are connected, following tests can be carried out:

 The breaker can be switched ON / OFF, from both local & remote control room.
 The breaker compartment door can be opened to observe the behavior of breaker.
 Tests by simulation of faults through protection Relays.
 Proper functioning of indication lamps and electrical interlocks can be tested.
 Since breaker is isolated from main bus-bar contacts, HT Cables can be tested for
location of cable faults, safely.

Compartment Segregation of the entire cubicle, as specified in IEC 62271-200, is

maintained, making it absolutely safe for operator to work in any compartment.

C) DISCONNECTED / ISOLATED Position

This is the position attained by totally withdrawing the Breaker Truck from its racking
arrangement. Also the Breaker is said to be disconnected fully after the LV multi-pin
plug & socket connection is removed as well. The Breaker truck can remain idle inside
the cubicle in this position, while all other gadgets like space heater and thermostat etc.
operate and keep the Breaker truck free from damage under moisture / rusting & dust.

D) WITHDRAWN / REMOVED Position

In this position, the truck is outside the panel cubicle and isolated both electrically and
mechanically from it. Only mechanical operation checks can be performed on the
Breaker Truck in this condition. Service trolley provided, is used at the cubicle front to
withdraw the truck out of the panel smoothly.

31.2 OPENING / CLOSING OF COMPARTMENT DOORS

A) Breaker Chamber Door

This door can be opened and closed only when the truck is in the TEST position and the
multi-pin plug and socket connection for LV cables are connected. The door interlock
should not be defeated unless and until it becomes absolutely necessary.

Defeating the Breaker Chamber door interlock

 Unscrew the two small hexagonal bolts used for fixing the Trip tool bracket. They
actually hold the door interlock piece behind them (inside breaker chamber).
 Un-screw fully, until the interlock piece inside drops off.
 Remove all the door holding thum-bolts and open the door.

Megawin 47
 CAUTION:
1) Do not enter the Breaker Chamber when door interlock is defeated. First switch-OFF
HT power supply to the specific Feeder. It might warrant taking Bus-Bar shut down
as well.
2) Soon after opening the door, fit the door holding interlock piece back in its place.

B) Door to LV compartment

To open the LV compartment door

 Rotate anti-clockwise the thumb bolts until the door opens free.
 Open the door

CAUTION: Take care not to get into contact with any terminal of door mounted
equipment. Both AC & DC auxiliary power supplies are available on these door mounted
equipment. DC supply available could cause burn injury and AC supply can cause severe
electric shock.

To Close the LV compartment door

 Close the door and push firmly to hold it in place

 Rotate the thumb-bolts in clock-wise direction, little by little of each bolt at a time to
ensure even pressure on the gaskets.

CAUTION: Ensure adequate pressure prevails to actuate the door switch to depress and
cut off supply to the panel illumination lamp.

32 ENGAGING BREAKER TRUCK TO SERVICE, MANUALLY

To Insert the VCB inside the panel :

 Ensure the VCB is OFF. Operate mechanically to attain the OFF condition.
 Open the front door of the Breaker Chamber
 Position the service trolley with breaker truck on it in front of the breaker chamber such
that the stepped wheels on breaker truck align to the channel rails in breaker chamber
 Gently push the breaker truck into the breaker chamber of the cubicle as much as it enters
 You can see the TEST POSITION label
 Connect the LV multi-pin plug & socket
 Insert the racking handle and observe the interlock rod moves up and make way for the
racking handle
 This is the TEST position.

Megawin 48
 To engage the Breaker Truck to SERVICE position :

 Ensure the VCB is OFF

 Ensure plug & socket is connected & front door closed
 Insert the Racking handle into the racking port & rotate in clockwise direction till it stops
 Remove the Racking handle,
 Now the Breaker truck is in SERVICE position and ready for operation

33. DIS-ENGAGING BREAKER TRUCK TO TEST / REMOVED POSITION MANUALLY

To Rack out the VCB from SERVICE position to TEST position

 Ensure the VCB is OFF

 Insert the Racking handle & rotate in anti clockwise direction till it comes outwards.
 It will stop at TEST position.
 Open the Breaker Chamber door and position the service trolley.
 Remove the LV multi-pin plug from its socket. Stow the cable & plug assembly in its position
on the door
 Pull Breaker truck forwards onto the service trolley

CAUTION: The Breaker Truck weighs 180kgs approx. Make sure the service trolley ios
locked and standing firmly on all four rollers. Never attempt to unload the breaker truck
using manpower in absence of a service trolley.

 Remove the service trolley

 Close the front door and lock it
 Tow away the breaker truck for carrying out maintenance work.

34. CASTELL KEY INTERLOCK OPERATIONS (optional)

 Make sure that the circuit breaker is open.

 Castell key can be engaged and rotated only in this condition
 Insert the castle key and turn clock wise to enable breaker operation
 When Breaker is ON, the key gets trapped in the castell lock base.

35. DISCONNECTING THE LV PLUG

 Firstly switch-OFF the AC / DC MCBs provided in the LV Metering chamber.

 With the breaker truck locked in TEST position, open the breaker chamber door.
 Unlock the LV plug and dis-engage by turning down the holding clip.
 Pull off the plug vertically and stow it in its holder provided on the door.

Megawin 49
 36. CONNECTING THE LV PLUG

 Ensure the AC / DC supply MCBs provided in the LV Metering chamber is in OFF

condition.
 Place the LV plug, duly aligned over the LV socket and push down firmly to engage.

CAUTION: Ensure proper alignment before pushing down into socket, as otherwise
the plug contacts can get deformed beyond repair due to mis-match.

 Simultaneously pull the retaining clip over the plug to hold it down firmly.
 Close the breaker compartment door.

37. CIRCUIT BREAKER OPERATING MECHANISM

Operating mechanism is of the spring stored energy type. For electrically operated
breakers, motor automatically charges the closing spring after each switching ON
operation. If the auxiliary supply to motor fails, the closing spring can also be charged
manually by using the spring charging handle. The tripping spring is charged each time
the breaker is closed.

38 CIRCUIT BREAKER OPERATION

a) MANUAL SPRING CHARGING UNDER EMERGENCY ( FAILURE OF AUXILIARY POWER SUPPLY

TO SPRING CHARGING MOTOR )

NOTE:
For this particular Product, manual charging of the closing spring is possible only
with the Breaker Chamber door closed and Breaker Truck is in TEST position.

 Ensure Breaker is in OFF condition and spring is fully discharged,

 Insert spring charging handle in the designated port on Breaker chamber door
 Turn the crank until the symbol “spring charged” appears in viewing window on
indicator.
 Remove the spring charging handle.
 If auxiliary power supply is restored to the spring charging Motor, while manual
spring charging is in progress, allow the Motor to complete the spring charging
operation.

NOTE:
Do not panic if Auxiliary Power supply is restored to spring charging Motor. The
operator is not at risk as the hand crank arrangement frees and detaches itself
automatically in the anti-clockwise direction, by design. Simply pull the handle out
and relax.

Megawin 50
 9. EMERGENCY MANUAL TRIPPING OF BREAKER

 Use the Tripping Tool (rod) supplied with each and every Breaker Cubicle. This Trip
Rod has to remain in its holding bracket at all times (Fig. 53)

TRIPPING TOOL TRIPPING TOOL INSERTED

Fig.53

 Slide away the yellow plastic disc covering the port provided on the breaker
chamber door for tripping
 Insert the trip tool in this trip port (hole) and push firmly to trip the breaker (switch
OFF the breaker). This tool is long enough to trip the breaker irrespective of its
position (whether in TEST or in SERVICE).
 Check the breaker status indications – mechanical OFF is visible through the viewing
window and electrically the green indication lamp glows to signal Breaker is OFF

NOTE:
There is a likelihood that the green indication lamp may not glow ( no DC power supply or
indication lamp defunct or NO/NC contact not okay etc.). The Mechanical OFF condition
indicator is more reliable and correct.

40 MAIN CIRCUIT EARTHING

40.1 Direct earthing of busbars with conductors

 Switch off all breakers feeding the bus-bars

 Open upper rear bolted cover and wire mesh cover inside ( busbar chamber).

Megawin 51
  Use a hook stick / hotline operating rod of at least 2 meter length.

Bus-bar chamber rear access

openingloves

Hook stick ( minimum

2 meters long ) Station
earth point

Use hand gloves

glovesloves Fig.54

 Connect a thick flexible cable to a cleaned station earth point firmly. The other end
of the cable is to be sleeved off to expose the cable conductor. Tie / secure by PVC
tape, this free end of cable to the tip of hook stick.
 Holding the hook stick at the free end, with high voltage withstand hand gloves, gum
boots on, touch the earthed cable end on the hook stick to all the bus-bar joining /
connection points. Do this on all 3 phases.
 Once satisfied, short all phases with a thick flexible conductor and bolt it firmly to
the nearest earth point in the cubicle.
 Essentially place WARNING & CAUTION plates near the open bus-bar chamber and
switchboard front, besides all other noticeable locations in the working area.
 DO-NOT ALLOW ANY UNAUTHORIZED PERSONNEL near the switchboard.

Megawin 52
 40.2 Earthing of outgoing cables through integral Earth Switch ( Outgoing Feeders )

 Switch OFF the breaker in the panel where Power cable is to be earthed
 With-draw the Breaker Truck to TEST position.
 Open the Breaker Chamber door
 Ensure that no back feed exists on the cables from any other Power source
 Engage the Earth Switch operating handle to the Earth Switch operating rod
available on the right hand side (RHS) panel front (Fig. 50)
 Rotate handle clock-wise (also see the green label showing direction of rotation to
close Earth Switch)
 Remove the handle after the operation.
 Close the Breaker Chamber door and lock it. Keep the key with authorized S/S in-
charge.
 Essentially place WARNING & CAUTION plates near the Cable Box of the specific
Outgoing Feeder and specific Feeder’s Panel Front, besides all other noticeable
locations in the working area.
 DO-NOT ALLOW ANY UNAUTHORIZED PERSONNEL near the Switch-board.

40.3 Earthing of incoming cables through integral Earth Switch ( Incoming Feeders )

 All the interlock conditions as narrated above (under Clause 40.2) is applicable here
as well, to achieve safety to operating personnel by ensuring that attempt to earth is
made only after the VCB is drawn-out to Test / Isolated position
 The incoming feeder cubicles are fitted with Castel Key interlocked integral Earth
Switch suitable to earth the incoming Power Cables.
 The second Castel lock base is fitted on the corresponding up-stream Breaker and
holds the Key in it ( key trapped condition ) as long as it is ON condition. The Castell
Key is released in OFF condition alone.
 This Castell Key is needed to permit operation of the integral Earth Switch provided
in the Incoming Feeder cubicle.
 Given the castell key is made available ( up-stream Breaker is OFF), insert the Castel
Key in the Castel Lock base fitted near the Earth Switch operating rod (RHS side of
Incomer cubicle)
 Rotate key to free Earth Switch operating rod.
 Withdraw the Breaker to TEST position

 Engage the Earth Switch operating handle to the Earth Switch operating rod and
rotate clock-wise to earth the incoming cable (also see the green label for direction
of rotation to switch ON earth switch)
 Remove operating handle, close breaker chamber door and lock it. Keep the key
with authorized S/S in-charge.

Megawin 53
  Essentially place WARNING & CAUTION plates near the Cable Box of the specific
Outgoing Feeder and specific Feeder’s Panel Front, besides all other noticeable
locations in the working area.
 DO-NOT ALLOW ANY UNAUTHORIZED PERSONNEL near the Switch-board.

Removing Earth connections - MANDATORY

 In all above cases, irrespective of direct earth or earthing through Earth Switch, it is
essential to remove the Earth Connection to enable restore Power supply to load /
Switch ON the Breaker.
 Disconnect and remove the shorting and earth conductors from Bus-Bars
 Close the rear cover of Bus-Bar chamber and bolt it firmly
 Switch OFF the integral Earth Switch of incoming /outgoing feeders in order to
enable Breaker Truck move in and engage to SERVICE position.
 Remove the temporary warning plates

NOTES:

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Megawin 54
 41. MAINTENANCE INSTRUCTIONS

STATUTORY WARNING !

1) Maintenance, repair and modification work shall be carried out only by

specially trained personnel in accordance with the operating instructions
and specially made written instructions. Training and information
sessions for personnel will be provided by the competent MEGAWIN
department / authority.
2) Before starting any work on any of the panel cubicles, reference must be
made to prevailing local regulations and permissions MANDATORY for
working on High Voltage switchgear.

3) MEGAWIN must not be held responsible for any accident, injury,

impairment or death caused due to non-adherence of above.

41.1 PREVENTIVE MAINTENANCE SCHEDULE:

A) Routine Inspection Schedule:

Depending upon the environment in which this type of Switchgear Panels are going to
be installed and used, the end user is urged to prepare a Routine Inspection Schedule.
The frequency could vary from once a year in the initial period to several times a year as
the installation grows older.

We recommend the following as a bare minimum to start with:

1) Twice each year make the following checks ( peak winter and peak summer ). For
Tropical areas, it can be before monsoon rains and after monsoon rains.

a) Make a general visual check and keep records – No. of operations made by the
Breaker, condition of all digital instruments – display satisfactory, all indication
lamps in order (simulate an auto-trip and observe).
b) Check whether the loose accessories are complete and in proper shape.
c) Clean and lubricate the wheels as well as moving parts of the truck and
interlocking plate.
d) Relays to be tested for their functionality.
e) Clean the panels, essentially with a vacuum cleaner only. Never use water.
f) If total shut-down possible, observe insulator surface for dust accumulation /
moisture etc.

Megawin 55
 g) Check condition of space heaters, their thermostat settings
h) Check for ingress of vermin / reptiles / rodents (if any) before the Switchboard is
restored into service.

Every fifth year (or) 1000 operations, which ever is earlier

a) Remove the Breaker truck out of the cubicle

b) Test operate the circuit breakers – using a Breaker analyzer check the closing,
opening speeds, travel and compare with Routine Test Reports provided
during the supply. Preserve the records on findings.
c) Carry out all maintenance work which involve cleaning, lubrication of moving
parts and electrical contact parts
d) Clean the panels and check the connections.
e) Lubricate all the bearing surfaces, bearings and articulated joints (refer
Clause 41.3 for lubricants to be used)
f) Re-insert the draw-out Breaker
g) Check the switchgear panel and put the Breaker back into service.

If work has to be carried out inside the cubicles, isolate the switchboard from all HT
Connections and LT Auxiliary supplies. Make sure that it cannot be charged without prior
clearance from operating / maintenance in-charge. Check it is electrically isolated and
earthed adequately, short-circuit the feeders and bus-bars if necessary. Adhere to all
regulations and safety measures, maintain and service the built-in equipment, e.g. circuit
breakers, voltage transformers, current transformers, relays, meters, protective devices
etc. in accordance with their operating instructions.

Before removing the front cover plate of the breaker truck (operating mechanism)
discharge the closing and tripping springs. Follow the instructions given on the
mechanism housing. Only standard tools are required.

Put the switchgear back into service as described under Clause 32 of this manual.

Service the switchgear at shorter intervals if the air is very humid or dust laden or is
otherwise polluted. The cause of any disturbance or short-circuit must be determined
immediately and damaged parts replaced, irrespective of whether an inspection is due
or not.

Megawin 56
 41.2 CLEANING:

CAUTION !

For safety reasons, cleaning of panels shall be taken up only when total shutdown of
main & auxiliary power supply is taken, the breaker is in the open state, closing spring
of the breaker is discharged & the breaker truck is removed out of the panel.

Cleaning agents & accessories required:

Perchloroethylene, DC2-26, small brushes, dusters and vacuum cleaner for sheet metal
parts.

Note:
a) Trichloroethylene, perchloroethylene and tetrachloroethylene have a harmful effect
on cast resin parts and must not come into contact with them.

b) Cast resin parts should be cleaned with distilled water only

c) Silver plated and other contact surfaces are to be cleaned with a clean cloth. Never
use abrasive paper / cloth / files.

41.3 LUBRICATION:

Soon after cleaning:

a) Lubricate the isolating contacts and their mating contacts with neutral grease /
refined white petroleum jelly.
b) Apply a thin film of neutral grease to the bearings and articulated joints of operating
mechanisms, draw-out parts and shutters, door hinges and locks.
c) Recommended neutral greases are
 SERVOGEM 2(multipurpose) of Indian Oil Corporation make / Equivalent
 Multipurpose grease 'H' of Hindustan Petroleum Ltd. make / Equivalent
 Any other chemically neutral grease which can withstand temperature up to 150°C

42 REPLACEMENT PARTS:
Items such as post insulators, bushing with mating contacts, measuring instruments,
current transformers etc. can be replaced. If replacement is likely to prove difficult ask
the nearest MEGAWIN representative in good time for deputation of trained personnel.
The representative will assist you in deciding what spare parts need to be kept in stock.

Megawin 57
 When ordering spare parts and units give the following details:

a) Type and Serial No. of the switchboard (see Rating plate)

b) Exact description of the unit or part, referring to this operating instructions manual
c) Drawing No., sketch or diagram
d) Use names / terminology used in this Manual
e) Send photograph of the component needed ( when no description exists herein )

43. BREAK-DOWN MAINTENANCE

43.1 Defeating of door interlock of Breaker Chamber:

CAUTION: Defeating any interlock is resorted to as a last option. The interlock defeat
operation can lead to dangerous consequences as access is allowed to the areas / parts
which are likely to be live.

The breaker compartment door interlock should only be defeated if the Breaker
Truck cannot be moved to the DISCONNECTED position from SERVICE position and the
situation cannot be cleared in any other way

a) Switch off the circuit breaker

b) Make sure that the bus-bars are not live – Earth them to ensure total safety
c) Also ensure the Cable side is not energized. Switch OFF up-stream Breaker if
necessary. Earth the cable side through the integral earth switch ( if fitted ) or by
using flexible conductors of adequate thickness.
d) Unscrew all the locking thumb grip bolts on the Breaker chamber door
e) Un-screw the two M6 bolts used for fixing trip tool bracket and also the interlock
piece within the breaker chamber
f) The retaining door catch drops off inside the Breaker chamber, at the end of
loosening the M6 bolts, allowing the door to open.
g) Insert the racking handle in the port and rotate anti-clock-wise.
h) Observe where the obstruction is and rectify the same
i) Rack-out the Breaker truck and check the various features provided on it are
working satisfactorily. Repair / rectify if any deformation observed.

43.2 Restoration of Door Interlock:

After rectifying the problem, the door of the HV compartment can be closed and
interlocks can be restored by following the procedures as listed above, in the reverse
sequence.

Megawin 58
 44. DISPOSAL OF PRODUCT:
This product is environment friendly.

The following materials have been used to make the device: Steel, Copper, Aluminum,
Cast-resin, glass reinforced thermoplastics, rubber, porcelain, grease & similar lubrication
materials. PVC is used as an insulation material for control wires.

In disposal, priority must be given to re-use the materials by recycling.

In “as-supplied” condition, the product does not emit any hazardous rays, material or
harmful gases.

During disposal of the product, care must be taken to dismantle as far as possible in a
manner more accepted as environment friendly. Re-cycle-able & Non-recyclable scraps,
are to be segregated properly.

The recyclable materials like steel, copper, aluminum to be reused by sending them back
to smelters.

Non-recyclable materials like Cast-Resin parts, fiber-glass reinforced insulation etc. can
be broken into pieces and used as secured land filling materials.

Rubber being bio-degradable material must be recycled through authorized contractors.

PVC material should not be burnt as they release halogenated hydrocarbons which can
affect the ozone layer. Therefore, PVC must be recycled through experts in the field.

Contact MEGAWIN for any other questions concerning disposal.

Megawin 59
 45. SUMMARY OF IMPORTANT INSTRUCTIONS
No. LIST OF Dos No. LIST OF DON'Ts
1 Clean the contact surfaces of the bus- 1 Do not use emery paper, abrasives, files
bars contact area before fitting them or solvents to clean bus-bars
2 Check for rated auxiliary voltages 2 Do not use Resistors / Capacitors to
available at site with compatibility of alter the Auxiliary supply voltage
component's fitted
3 Ensure all bolts are adequately 3 Do not over-tighten Bolts / Nuts as they
tightened as per torque recommended - are injurious to the components and
refer table furnished in this manual. can impair their performance.
4 Seal all un-used holes, openings to 4 Do-not leave any door, cover or louvre
prevent entry of vermin, rodents, open after routine maintenance.
reptiles or any un-wanted matter
5 Stow operating tools, handles and 5 Do not leave any tools, handles and
tackles in close proximity of the tackles in their operating condition /
Switchboard and visible to operator positions to prevent mis-use.
6 Ensure all interlocks are in position and 6 Do not defeat any interlock. It can be
functional hazardous to people and property.
7 Remove Breaker Truck from cubicle fully 7 Do not keep the LV multi-pin plug
for maintenance and ensure the spring connected in the Breaker Truck during
is in discharged codition. Disconnect the cleaning / maintenance, to prevent
LV multi-pin plug as well to prevent inadvertent remote operation
electrocution.
8 Make sure the Bus-Bar and Cable side 8 Do not go near the shutters with Bus-
shutters are fully closed and padlocked Bars live / Incoming cable live. Clean
in closed condition while cleaning. the area from a distance using vacuum
cleaner.
9 Use lubricants as specified herein. 9 Do not use readily available auto-
Ensure equivalents are verified for their mobile / heavy machinery grease / lube
composition and properties oil. Do not smear grease / lubricants on
insulation material / wiring etc. Do not
apply excessive grease.
10 Check space heaters and thermostats 10 Do not ignore a defunct Heater /
periodically for their operating health Thermostat. Replace them immediately

11 Periodically check DC supply system for 11 Do not depend upon a poor DC supply
its healthy condition. Ensure system. Replace / rectify it.
rectification if found un-healthy.
12 Check insulation value on HV Circuit 12 Do not use Megger of smaller capacity.
insulation with a 2.5kV motorized Results are not likely to reflect actual
Megger and record the values in a condition of insulation
history card

Megawin 60
 No. LIST OF Dos No. LIST OF DON'Ts
13 Maintain a log book and keep it readily 13 Do not ignore any minor discrepancy
accessible to evaluate performance of noticed. Record them and look for
the Breaker remedies.
14 Ensure only trained & experienced 14 Un-authorized personnel must not be
personnel attend to the Switchgear. allowed near the Switchgear
15 Breaker settings to be analyzed once in 15 Do not rely on external appearance of
every 5 years or after 20 short circuit the Switchgear alone. Efficiency can be
operations, whichever is earlier. deterriorated internally.
16 Periodically operate the Breaker 16 When spring is electrically charging do
manually to keep their manual not indulge in settings / manual
mechanisms in good working condition adjustments.

17 Clean and lubricate with Breaker in 17 Do not lubricate or clean when breaker
stationary condition. is in spring charging / engaging / dis-
engaging motion.
18 Re-fix the defeated interlocks after the 18 Never discard any of the interlocks
purpose of defeating is achieved. provided as they are fitted with so
much thoughtfulness towards safety.

For any clarification related to the contents here in, contact:

The Manager – Servicing,

MEGAWIN SWITCHGEAR –P- LTD.,
Unit-II, 2/18 & 2/19, Narasothipatty,
Perumal Malai Adivaram, P.O. Alagapuram,
Salem – 636 004, Tamil Nadu
Tel: 0427 2330288 / 2330498 Mobile: 097900 34429
Email: service@megawinswitchgear.com

For Spares, please Email to: spares@megawinswitchgear.com

Megawin 61