MEDIUM VOLTAGE SWITCHGEAR

HWX
Single/Duplicate Busbar
The complete solution for process
plants, power stations, other
industries

Installation, Operation &

Maintenance Manual

AREVA T&D

HWX

MEDIUM VOLTAGE SWITCHGEAR

Single/Duplicate Busbar

12KV HORIZONTAL ISOLATION HORIZONTAL DRAWOUT VACUUM

SWITCHGEAR TYPE HWX
RATING AND SPECIFICATION
Type

Unit

HWX

Rated Voltage

kV

7.2/12

Rated Continuous Current

630/1250/2000/2500/2800/3150

Rated Frequency

Hz

50

Rated Interrupting Current

kA

26.2/31.5/40/44

Rated Making Current

kA

65.5/80/100/110

Rated Short Time (3 sec) Current

kA

26.2/31.5/40/44

Operating Duty

IEC :62271-200-100

Power Frequency withstand voltage

kV

28/35

Impulse Withstand Voltage

kVp

60/75

Auxiliary Contacts

kVp

60/75

Auxiliary Contacts

Approximate Dimension

mm

4 NO + 4 NC
2430/2600x660/860x1800 (H x W x D)
2118 x 660x1625(HxWxD

INTRODUCTION
The entire range of HWX type
equipment has been designed, for
indoor use and every care has been
taken in the design to ensure its
suitability for this purpose.
The equipment requires minimum
maintenance. By following the
routines recommended in this
manual, the user can easily ensure
good condition throughout the life
of the quipment.
SAFETY
Before working on the equipment, it
is necessary for the operator to
ensure that it has been safely
disconnected from electrical
supplies and that the necessary
safety earths have been fitted and a
suitable permit to work issued. In
the event of any doubt in this
respect, the operator shall seek the
advice of his local supply authority
to ensure that he has taken the
necessary actions to comply with
local safety requirements.
The circuit breaker closing
mechanism is capable of storing a
considerable amount of energy and
therefore, before commencing
work, steps must be taken to
discharge this energy and leave the

springs in a discharged state

(SPRINGS FREE).
To assist in its safe operation the
equipment can be fitted with
padlocking facilities which shall be
applied as appropriate.
Before commencing and after
completion of work, all control
switches shall be left in the
appropriate positions.
Should the operator require any
guidance or advice regarding the
equipment, he is free to contact the
manufacturer.
The Company policy is continuous
development and improvement of
its product. Therefore it reserves the
right to supply products which may
vary slightly from those described
and illustrated in this publication.
1.0 DESCRIPTION
1.1 General
HWX metalclad indoor single
busbar air insulated vaccum
switchgear is for use on distribution
networks having a highest system
voltage up to 12 kV, a short circuit
current rating up to 40kA, a
maximum full load current of 2000A/
2500A/ 2800A and a lightning

impulse level up to 75 kVp (BIL.)

Typical sectional views are shown in
Fig. 1&2.
1.2 Construction
Standard incomer and feeder units
comprise of two main parts: the
fixed housing and the truck
mounted horizontally isolated circuit
breaker.
The housing is of fabricated sheet
steel with separate compartments
for the circuit breaker, busbars,
current transformers and multicore
cable glands.
A panel at the front of the housing
above the circuit breaker
compartment accommodates the
terminal blocks, fuses and links for
the secondary circuits and the
multicore termination. The panel
may also be used to mount
electrical instruments like relays,
meters etc.
The primary connection spouts in
the circuit breaker compartment are
equipped with earthed metal safety
shutters, which are controlled by
arms mounted on the sides of the
circuit breaker compartment and
operated automatically by
movement of the circuit breaker.
With the circuit breakr withdrawn
from the housing, each shutter can
be independently padlocked.
The three phase assembly of the
truck mounted horizontally isolated
circuit breaker is contained within a
moulded phase separated
insulation structure. The truck also
incorporates the simple low energy
hand or motor charged spring
operated mechanism, the three
phase drive assembly and the
circuit breaker plugging in isolating
mechanism.
Insertion of the circuit breaker is
pushed into the housing is in 3
stages.
The secondary plug from the panel
is to be first plugged into the
breakers secondary socket and the
interlock rod is pushed towards the
mechanism. This will allow the truck
to take further into the panel. Then
the circuit breaker is pushed as far
as possile into the housing and it is
finally plugged in by means of a
detachable winding handle which
locates on the racking drive shaft
situated below the circuit breaker
mechanism facia. Reversal of the
above isolates and withdraws the
circuit breaker primary terminals
make with contacts in the housing

primary connection spouts.

Access to the busbar compartment
for making the busbar joints is via
removable covers on top of the
housing and at the rear of the
busbar compartment.
Earth bars associated with the cicuit
breaker is within the housing, and
brought out externally as a single
connection at the rear of the
housing. This connection are
connected the main inter-unit earth
bars.
2.0 INSTALLATION

of units is not distorted in any way.

Ensure that any lifting slings are of
adequate strength and in good
condition.
Approximate weight are:
Current Weight of Weight of
Rating
Circuit
Housing
(Amps) Breaker (kg)
(kg)
800

130/170

350/370

1250

130/180

370/410

2000

210

500

2500

215

530

2800

225

555

3150

235

560

2.1 Despatch and Packing

2.3 Storage
The equipment is designed and
despatched so as to involve
minimum of erection work. The
circuit breaker is located and
secured in the housing during
transit.
2.2 Unloading and
inspection
IMPORTANT :
THE EQUIPMENT SHOULD BE
EXAMINED IMMEDIATELY
AFTER THE RECEIPT. IF THE
EQUIPMENT HAS BEEN
DAMAGED, BOTH THE
TRANSPORT CONTRACTOR
AND AREVA LIMITED
SWITCHGEAR DIVISION OR
THE LOCAL REPRESENTATIVE
SHALL BE ADVISED AS SOON
AS POSSIBLE.
Where the equipment is supplied in
packing cases these shall be placed
TOP uppermost and the top
removed first. All necessary
erection details are supplied in
plastic bags or packing cases which
are tagged and numbered. The tage
number, together with a description
of a contents are listed on the
packing list supplied.
Reference to this list will enable
easy location of the required
components. The equipment
should be transferred to the switchhouse immediately after unloading;
under no circumstances shall it be
exposed to direct and excessive
moisture. Where heaters are fitted
they should be energised as soon
as possible. The equipment is
provided with lifting points which
must be used.
Care must be taken to ensure that
no undue stresses are placed on
any part of the equipment,
especially that the projecting base

If the equipment is not required for

immediate use it should be stored in
a clean, dry, well ventilated place
and covered. Should storage be
prolonged, routine inspections
should be carried out as if the
equipment were in service.
Temperature and humidity
conditions shall be such that
condensation of moisture does not
occur. Where fitted, unit heaters
should be energised as soon as
possible.
The equipment must not be
exposed to direct moisture as it is
for indoor use only.
2.4 Site
The site should, as far as possible,
be free from damp, excessive
vibration and high and widely
varying temperatures. Relative
humidity must be such that
condensation in or on the
equipment will not occur. Special
precautions must be taken where
the relative humidity exceeds 80%.
These may include operating the
unit heaters and also preferably
equipping the substation with
dehumidification equipment.
There should be ample room for
painting and maintenance work to
be carried out. Recommended and
minimum distances are shown on
the switchboard drawing supplied
with each contract.
2.5 Foundations and Unit
Erection
It is important that the finished floor
area is flat, and not sloping by more
than 3 mm over any 2500 mm. The
area shall extend a minimum of 600
mm to the rear of the panel, 1000
mm to the front of he front
foundation fixings and 200 mm

FIG. 1. Sectional side view of HWX Panel up to 12 kV 1250A, 40kA

2430/2600

ACCESS FOR RACK IN/OUT

AFTER OPENING THE DOOR

FRONT VIEW

660

50X6 CU EARTH
BUS

960/1130
1470

RACKING SCREW

DRIVE BEAM

902

Y
B

Y
B

BUSBAR

SECTIONAL SIDE VIEW OF HWX PANEL UP TO 12kV 1250A, 40kA

MAIN CABLE ENTRY

50X6 CU. EARTH BUS

175

SURGE
DIVERTERS
(FOR MOTOR FDRS)

PVC SHROUD

BUS-BAR COMPARTMENT

REMOVABLE COVER
FOR CT ACCESS
FROM FRONT

895

BLOW-OFF COVERS

CT-CABLE COMPARTMENT

BREAKER COMPARTMENT

INSTRUMEN
T CHAMBER

CHANCE OVER
DRIVE

INTERPANEL
ACCESS
FOR CONT. WIRING

MULTICORE CABLE ENTRY

RACKING
SCREW

SEC. PLUG
SOCKET

352

OPTIONAL DUPLICATE BUS-BAR

ARRANGEMENT
CAN BE MOUNTED ON TOP OF PANEL IF
REQUIRED

690

BLOW-OFF

545
565

3
NTS

BLOW-OFF COVERS

660
352

Y1

Y2

545

OPTIONAL DUPLICATE BUS-BAR ARRANGEMENT

CAN BE MOUNTED ON TOP OF PANEL IF
REQUIRED

BUSBAR COMPARTMENT

690

INTERPANEL ACCESS
FOR CONT. WRING
565

CHANGE OVER
DRIVE
960/1130

INSTRUMEN
T CHAMBER
EXTENSION CHAMBER FOR ADD. CABLES
BREAKER COMPARTMENT BLOW-OFF COVERS BUS-BAR COMPARTMENT
902
500
895

2430/2600

PVC SHROUD

1470

SEC. PLUG
SOCKET

RACK IN
SCREW

DRIVE BEAM

CIRCUIT
RING TYPE CT SPOUT

CT-CABLE
COMPARTMENT

REMOVABLE COVER FOR CT

ACCESS :
FROM FRONT
ACCESS FOR RACK IN/OUT
AFTER OPENING THE DOOR

MAIN CABLE ENTRY

MULTICORE CABLE ENTRY

50X6 CU. EARTH BUS

FRONT VIEW

SECTIONAL SIDE VIEW OF 12kV 2000A/2500A, 40kA HWX PANEL

FIG. 2. Sectional side view of 12 kV 2000A/2500A, 40kA HWX PANEL

INTERPANEL ACCESS
FOR CONTROL WIRING

INSTRUMENT CHAMBER
VACUUM CIRCUIT BREAKER
SAFETY SHUTTER ARRANGEMENT
DRAW-OUT PT

BUSBAR CHAMBER

SEC. PLUG SOCKET

SPOUTS
VACUUM INTERRUPTER

BREAKER CHAMBER

CT & CABLE CHAMBER

RACKING ARRNG.
MULTICORE CABLE ENTRY

MAIN EARTHING

MAIN POWER CABLE ENTRY

ACCESS FOR RACK IN/OUT

AFTER OPENING THE DOOR

FRONT VIEW

SECTIONAL SIDE VIEW OF HWX PANEL UP TO 12KV, 1250A, 25KA

FIG. 2A Sectional side view of 12 kV 1250A, 25kA HWX PANEL

beyond the extreme right-hand and

left-hand foundation fixings.
Correct operation of the equipment
is dependent on it being level. It is
essential, therefore, that care is
taken at all stages of erection, in
particular the lining up and leveling
of the first unit, which will be the
datum for all other units. Failure to
erec the first unit correctly will result
in mal-alignment throughout the
switchboard & this will cause rack
in/rack out problem of breakers
within the housing. Foundation
channels must be checked for
curvature. Any found to be distorted
must be straightened if possible or
replaced. Under no circumstances
shall distorted channels be used.
Foundation fixings may be one of
two types :
Foundation Channels or Foundation
Bolts.
2.5.1. Foundation
Channels
Prepare the floor and foundations &
then proceed as follows :
i) Determine the highest point on
the channels. This point then
becomes the datum for all units,
it is useful to use this point for
erection of the first unit.
ii)

With reference to general

arrangement drawing of the

switchboard, check to unit

serial numbers and remove the
circuit breaker from the housing
to be erected first. Position the
housing on the channels.
iii) Locate the foundation bolts and
associated washers through the
holes in the base of the housing
into the spring loaded nuts
within the channels. DO NOT
TIGHTEN.
iv) Using 2 plumb lines level the
housing front to back and
across the width. Levelling is
carried out using shim plates.
These shims shall be located
adjacent to and on the outside
of the foundation bolts such
that they will also support the
adjacent housing when that is
erected. Refer to Figure 3.
Shims must also be placed
under the base sheet in the
apron area to make up any gap
between the floor. Once the
housing has been levelled the
foundation may be nipped-up
but not tightened.
v)

Position the next housing to be

erected close up to the first, fit
the foundation bolts and level
up as before. Remove the
housin top and rear covers and
fit the inter-housing fixing
screws, nip-up only at this
stage. Refer to Figure 4.

Remove lifting plate before

mounting panel.
vi) Repeat the above for the
remaining housings
remembering to check the unit
serial numbers with the general
arrangement drawing of the
switchboard. Finally, tighten all
foundation bolts and inter
housing fixings.
vii) Check the alignment of the
instrument panels for squares
and equality of spacing
between panels.
viii) Rubber gasket should be
provided between the panels.
2.5.2 Foundation Bolts
(Expanding type)
Preparing the floor as stated in
Section 2.5 then proceed as
follows :
a) Determine the highest point on
the floor. This point then
becomes the datum for all units.
It is useful to use this point for
erection of the first unit.
b) With reference to the general
arrangement drawing of the
swithboard check the unit serial
numbers and remove the circuit
breaker from the housing the
housing on the floor.
c) Carry out operations iii, iv, v vi,
1.5mm
1.5mm

Max variation
from verticle

Top of unit frame

Use plumb line down
sideframe to measure
alignment. Variation
must be within 1.5mm

Use plum line down rear

of frame for vertical

Floor

50mm Sq. shims

50mm Sq. shims fitted

as appropriate under
unit to level

NOTE :
Do not make adjustments
to moving portion

Foundation bolt
Positions

FIG. 4. Unit Leveling Instruction

2 - M8 x 16mm long
Hex. HD screws with
washer

1.

6 - M 10x22mm long
Hex. HD screws wih
nuts & washers

M8x20mm long Hex.

HD screw with nut &
washer

FIG. 5. Inter Unit Fixing

& vii Section 2.5.1 except fit the

foundation bolts as follows :
Using the holes in the base of
the housing as a template drill
the floor for accepting M12 x 75
mm long expanding bolts.
2.6 BUSBAR ASSEMBLY
2.6.1

General

The cross-section of busbars is

given on the general arrangement
drawing of the swithboard.
Before assembly, all contact
surfaces of the busbars and
housing connections must be
cleaned to ensure a good contact
surface. Unplated contact surfaces
shall be cleaned using a branded
liquid silver polish. After cleaning, all
surfaces shall be wiped wth a clean
cloth to remove any metal dust, etc.
Joints shall be assembled as soon
as possible after preparation.

Where multiple busbars are used,

and units require spacers (supplied)
fitting between the busbars at the
spout connections, also, where
busbars on end units are in the front
(Red and Blue phases) and upper
(yellow phase) positions on
additional spacer (supplied) will be
required between the spout
connections and the busbar in order
to keep the busbar run straight.
When an extension unit is being
erected these spacers must be
removed to accommodate the
extension busbars and refitted in
the same positions in the extension
unit. The busbar joints shall be
encapsulated with compound &
tapping.
2.7 Unit Earthing

The same treatment of contact

surfaces shall be carried out on all
other joints, such as the tee off to
voltage transformers and main
cable connections.

The main earth bars associated with

the circuit breaker truck and the
circuit earthing switch are
connected within the housing &
brought out externally at the rear of
the housing. The only assembly
required on site is to connect the
earth bars of adjacent units together
using the main external earth bars
supplied.

2.6.2

2.8 Main Cables

Assembly

The busbars shall be assembled

such as to be parallel to the line of
the switchboard and suitable for
extension if necessary.

The main cables shall be made off

in acordance with the cabling
schedule.

Red and Blue phases (the two outer

phases) shall be assembled on the
front face of the spout connection
only, Yellow phase (the centre
phase) shall shall be assembled on
the front face of the spout
connection only. Assemble Blue
phase first, then Red phase and
finally Yellow phase Ref.
figure 5.

2.9 Multicore Cables and

Inter-Unit Wiring (Bus
Wires)
The only secondary wiring required
on site is to run and terminate the
multicore cables and connect the
inter-unit bus-wires in accordance
with the wiring diagram
supplied.

2.9.1

Multicore Cables

The multicore cables enter at the

front of the housing from the base of
the housing right-hand and/or lefthand frame, from where they run
vertically via a removable wiring
through to the multicore cable gland
compartment situated at the top of
the housing frame. In this
compartment the outer insulation
on the cable is cut back to allow the
multicores to be taken via the main
wiring through to the termination in
the housing front panel.
2.9.2 Inter-unit Wiring
(Bus Wires)
For ease of location, each wire is
fitted with an idenification ferrule
which corresponds with that on the
wiring diagram. Where wires pass
through to adjacent panels the
holes shall be fitted with a
protective grommet.
3.0 COMMISSIONING
TESTS AND INSPECTION
The test outlined in this section are
those to be made after the
equipment has been erected, but
before energisation.
3.1 Precautions
The policy to be adopted in making
the equipment available for
commissioning or maintenance
shall be that, it is isolated, proved
dead and earthed.
Precautions shall be taken to ensure
that the isolated equipment cannot
be re-energised from any high or
low voltage sources of supply.
The circuit breaker operating
mechanism is capable of retaining a

TORQUE SETTING 60NM

BUSBAR
RATING
AND
SIZES
END
UNITS

INTERMEDIATE
UNITS

END
UNITS

END
UNITS

INTERMEDIATE
UNITS

END
UNITS

BUSBAR
RATING
AND
SIZES

1250A
1
BUSBAR
16X60 SQ. MM.
= 960 SQ. MM.

1600/2000A
2
BUSBAR
16X60 SQ. MM.
= 1920 SQ. MM.

M12 X 70MM HEX HEAD BOLT, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER

133MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER

165MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
2500A
3
BUSBAR
16X60 SQ. MM.
= 2880 SQ. MM.

197MM LONG STAINLESS STEEL STUD, PLAIN WASHER, SPRING WASHER, NUT & 16MM SPACER
3000A
4
BUSBAR
16X60 SQ. MM.
= 3840 SQ. MM.

NOTE :
1) Busbar configuration may vary depending upon switchgear rating and specifications. Please refer seperate contract related dowings for detailed arrangements.

FIG. 5. Busbar Assembly and Torque Settings.

stored closing spring charge.

Before attempting any work, the
stored charge must be released by
operating the circuit breaker
manually from OFF to ON to OFF.
Where motor spring charged
operating mechanisms are fitted the
supply to the motor must be
disconnected.
3.2 Mechanical Testing
Manual operational checks should
be carried out on the circuit breaker
to ensure correct operation of
interlocks, primary connection
safety shutter, operating
mechanism, trips, auxiliary switches
and the circuit breaker racking
mechanism.
3.3 Electrical Tests
Secondary Insulation
WARNING :
Before commencing the tests
described in sections 3.3.1 and
3.3.2 on the secondary insulation
take the following precautions :
Disconnect the wiring to circuit
breaker mechanism spring
charging motor and rectifier.
Disconnect the wiring to /
withdraw any relying devices.
Short circuit current transformer
secondary windings.
Disconect secondary wiring on
voltage transformers.
Isolate any isolatable voltage
transformers.
After completion of testing all
conductors shall be discharged
to earth, temporary connections
recomved and components
reconnected.
3.3.1

Megger Test

The secondary insulation includes

the insulation associated with the
secondary wiring. For this test the
ends of the secondary wiring should
be looped together, at some
convenient point such as terminal
board and jsing a 500V megger
measure the resistance, which
should not be less than 2
megaohms between the loops and
earth.
3.3.2

High Voltage Test

For this test the ends of the

secondary wiring should be looped
together at some convenient point

such as a terminal board and a

voltage of 2 kV A.C. applied for 1
minute between the loops and
earth.
3.4 Electrical Test
Primary Insulation
Warning : Before
commencing tests 3.4.1 and
3.4.2 on the primary insulation
take the following
precautions :
Short circuit and earth current
transformer secondary
windings. Under no
circumstances shall current
transformer secondaries be
open circuited with the
primary on load.
On fixed voltage transformers
remove the connection
between the primary terminal,
by removing primary fuse.
Isolate isolatable voltage
transormers.
After testing, all conductors
shall be discharged to earth.
Temporary connections
should be removed.
Components should be
reconnected.
3.4.1

Megger Test

The primary insulation includes the

insulation associated with the high
voltage circuit. While carrying out
this test it should be noted that,
insulation varies considerably with
atmospheric conditions, dryness
and cleanliness of the equipment;
low readings may occur as a result
of surface leakage over the
insulation. Using a 500V megger
measure the resistance to earth of
each phase in turn. If the resistance
falls below an obsolute minimum of
1000 megohms after careful
cleaning and drying of all exposed
surfaces a check of the equipment
should be made for insulation
damage.
3.4.2

system apply 20 kV ac rms for 1

minute power frequency.
After high voltage tests have been
completed, a further megger test
should be made to check that the
initial resistance has not altered
significantly.
3.5 High Voltage Test
Voltage Transformers
Where high voltage tests on voltage
transformers have been agreed they
should be in accordance with the IS
: 2071, IS : 3156, to which reference
should be made.
3.6 High Voltage TestsIntegrity of Vacuum
Interrupers
IMPORTANT : X-ray radiation from
Vacuum Interrupers.
Any electrical gap in a hard vacuum
when stressed electrically may
generate X-rays.
In the case of HWX equipment tests
have shown that X-ray emission at
the voltage stated is less than the
permited level. It is pointed out that
the permitted level is for continuous
exposure, whereas the test voltage
is applied for a short time on each
occasion. The vacuum circuit
breaker does not emit X-ray
radiation at working
voltage.
The integrity of the vacuum
interrupters can be checked on site
by applying a test voltage of 20 kV
ac rms or 30 kV dc for 2 or 3
seconds across the open contacts
of each phase in turn with the other
side earthed. No evidence of
breakdown indicates that the
interrupter is in a satisfactory
condition.
Should a breakdown occur, the
circuit breaker should be kept out of
service and the matter reported
without delay to the AREVA
LIMITED, SWGR DIVISION AT
AEI/Salt Lake Works.

High Voltage Test

3.7 Final Inspection

IS : 13118 & IEC 56 gives full

information regarding high voltage
testing after erection on site.
With the circuit breaker CLOSED a
power frequency voltage should be
applied to each phase in turn
between the phase conductor and
earth for 1 minute.
12 kV highest system voltage 28
kV rms power frequency for 6.6 kV

The equipment should be given a

final inspection before it is put into
service.
Check that all covers are in place
and fully secured.
Check earth bars for continuity.
Check that all fuses and links are
inserted.

Check that padlocks are fitted

(where applicable).
Check all moving parts of the safety
shutters, the circuit breaker racking
mechanism, circuit and busbar
earthing switch operating
mechanisms, isolatable voltage
transformer operating mechanisms
and all interlocks.
Operate the Truck electrically and
manually to ensure it is
functional.
Ensure all insulation surfaces are
clean and dry.
Touch up paint work where
necessary.
3.8 Recordings
Records are of value in establishing
the frequency of maintenance,
therefore careful note should be
taken of relevant items each time
maintenance is carried out.
In order that a complete history is
available, records should be started
immediately after commissioning
and should include

LOCAL/REMOTE selector switch to

the required position and operate
trhe appropriate OPEN/CLOSE
switch to CLOSE the circuit breaker.
Note : The motor will automatically
recharge the mechanism springs
after a closing operation enabling
an instanceous close after trip to be
carried out.
4.2.2 Hand Charged
Spring Mechanism
Insert the spring charge handle into
the MANUAL CHARGE orifice in
the mechanism facia, locating the
slot in the handle on the drive pin in
the charging shaft. Push the handle
fully into the shaft and rotate the
handle anticlockwise in the clean
movement to charge the springs.
Remove the handle.
Operate the spring release manually
or electrically as described in
Section 4.2.1
Note : The mechanism springs can
be recharged after a closing
operation enabling an
instantaneous close after trip to be
carried out.

Date of completion
Circuit breaker operations counter
reading
Interrupter contact wear reading
Number of short circuit operations
Details of any work carried out
4.0 OPERATION
4.1 General
The circuit breaker operating
mechanism may be one of 2 types :
Hand charged spring with shunt
trips, manual push button closing
and tripping, optional local/remtote
electrical spring release.
Motor charged spring with shunt
trips, manual push bottom closing
and tripping, optional local/remote
electrical spring release.
4.2 Closing the Circuit
Breaker
4.2.1 Motor Charged
Spring Mechanism
Manually : Press the CLOSE button
to release the pre-charged springs,
operating the mechanism to ON
thus closing the circuit breaker.
Electrically : Turn the

4.3 Opening the Circuit

Breaker
4.3.1 Motor Charged
Spring Mechanism
Manually : Press the TRIP button,
operating the mechanism to OFF
thus opening the circuit breaker.
Electrically : Turn the
LOCAL/REMOTE selector switch to
the required position and operate
the appropriate OPEN/CLOSE
SWITCH to open the circuit braker.
4.3.2 Hand Charged
Spring Mechanism
4.4 Withdrawal of the
circuit breaker from the
SERVICE position
i.

Trip the circuit breaker (Section

4.3)

ii.

Press the circuit breaker TRIP

botton and hold depressed
while operating the isolating
mechanism to the free position.
This operation also holds the
mechanism tripped and makes
accessible the circuit breaker
racking drive shaft.

iii. Insert the racking handle into

the racking orifice below the
mechanism facia, locating the

slot in the handle on the drive

pin the racking shaft. Push the
handle fully on to the shaft and
rotate the handle anti clockwise
untill the circuit breaker stops
withdrawing from the housing.
Remove the handle.
iv. Using the handles on the circuit
breaker truck pull the circuit
breaker from the housing. This
operation also automatically
closes the safety shutters over
the busbar and circuit primary
connection spouts.
4.5 Operation of the
Circuit Breaker in the TEST
Position
a. Withdraw the circuit breaker
from the housing as described
in Section 4.4 till the TEST
position.
b. The secondary socket/plug
umbelical cable between the
circuit breaker and the housing
front panel will remain
connected.
c. Operate the isolating
mechanism from the FREE to
the LOCKED position. The
circuit breaker may now be
operated.
4.6 Insertion of the Circuit
Breaker into the Service
Position
i.

Wite the circuit breaker isolating

mechanism in the FREE
position [Section 4.4(ii)] push
the circuit breaker as far as
possible into the housing.

ii.

Locate the racking handle as

described in Section 4.4 (ii) and
rotate the handle clockwise until
the circuit breaker stops
moving. (It may be necessary to
push on the circuit breaker
truck in order to start the
racking in operation). Remove
the handle.

iii. Operate the circuit breaker

isolating mechanism to the
LOCKED position. The circuit
breaker can now be switched
ON as described in Section 4.2
to put the circuit breaker into
service.
4.7 Busbar and Circuit
Earthing
4.7.1

General

Earthing trucks are usually provided

with each switchboard as a

standard for discharging the

residual charged voltage remaining
in the busbar and in the circuit.

ii.

The busbar earthing and circuit

earthing trucks are similar to
standard breaker trucks in
appearance but will not consist of
any mechanism or interrupter.

iii. Insert the earthing truck into the

housing as described in section
4.6. the circuit/busbar is/are
now earthed through the
earthing truck.

Busbar earthing truch consist of top

stems whereas circuit earthing truck
consist of bottom stems, the other
end of the stems are shorted and
connected to the earth. When it is
required to earth the busbars or
circuits and earthing truck should
be inserted as appropriate.
For earthing of circuit side, an
earthing switch is provided on rear
side of the outgoing panels.
Operating instructions for the same
are provided on rear cover of the
panel. The interlocking arrangement
ensures that the switch shall always
be operating when the breaker is
NOT in service position & the
metallic safety shutters are closed.
Special care to be taken for
insertion of EARTH TRUCK into
panel.
Warning :
Before carrying out any earthing
operations it is recommended
that the section(s) of busbars
and/or the circuit(s) required to
be earthed be disconnected.
Precautions should also be taken
to ensure that the alternative
source of supply is also
disconnected. It is preferred that
equipment should be proved
dead before earthing.
4.7.2 Application of a
Circuit/Busbar Earth
i.

Fully withdraw the circuit

breaker from the housing as
described in Section 4.4

Carry out the precautions

referred to in Section 4.7.1

Manual Spring
Charge Acess

Truck
Interlock

Operations
counter
FIG. 7. Mechanism Facia

4.7.3 Removing of
Busbar/Circuit Earthing
Truck
Reverse the procedure described in
Section 4.7.2. Note that no manual
Trip Push Button is available in
earthing truck.
4.8 Electrical Testing of
Busbars and Circuits
4.8.1

General

4.8.2 Procedure for

Preparing the Circuit for
Testing
i.

4.8.3 Procedure for

Preparing the Busbars for
Testing
i.

Electrical testing of the busbars and

circuit may be carried out an every
unit be means of portable test
bushings which are inserted into the
primary spout connections.
Warning :
On the unit(s) under test it is
essential that precautions, to
ensure that the equipment cannot
be reenergised, are taken both in
the preparing the unit(s) and
during the time that tests are
being carried out.

Earth the circuit with the help of

circuit earthing truck.

Withdraw the circuit breaker

from its housing as described in
Section 4.4 and earth the
section of busbar, to be tested
by Busbar Earthing Truck.

5.0 EMERGENCY
MANUAL OPERATION
MOTOR CHARGED
SPRING MECHANISM
5.1 General

Before inserting or removing test

bushings it is essential that the fixed
conductor within the spout is
proved dead.

Should the electrical supply be

disrupted to the circuit breaker
mechanism spring charge motor or
for mechanical test on the circuit
breaker, the closing springs can be
recharged by means of a removable
handle which locates in the circuit
breaker mechanism facia.

Isolate all transformers during

test

5.2 Closing the Circuit

Breaker

While disconnected/ reconnection

is being carried out it is
recommended that earths are
applied.

Refer to figure 7 and ascertain the

mechanism spring state.

Spring charge pawls

If supply to
motor is lost
during
charging
operation, the
charging
operation can
be completed
manually.
If the supply is restored the mechanism will rest. It may be necessary
to reset the mechanism manually. This is achieved by lifting the spring
charge pawls. The wheel will turn release pawls onto the wheel.
FIG. 6. Resetting Motor Mechanism after Loss of supply

If SPRINGS CHARGED : Refer to

MANUALLY, Section 4.2.1.
If Springs Free : Remove the
motor supply fuses. Inser the spring
charge handle into the Manual
Charge orifice in the mechanism
facia, locating the slot in the handle
on the drive pin in the charging
shaft. Push the handle fully on to the
shaft and rotate the handle
anticlockwise in one clean
movement to charge the springs.
Remove the handle. Press the close
button operating the mechanism to
ON thus closing the circuit breaker.
Note : The mechanism springs can
be recharged after a closing
operation enabling an

10

instantaneous close after trip to be

carried out.
If Springs partially charged
(indicated by the lable being part
way between Springs charged
and Springs Free) complete the
charging and closing of the circuit
breaker as described under
Springs Free.

release coils is their replacment.

The assembly procedure of trip &
closing coil pot is described in this
manual.
6.1 Precautions
Refer to the notes inside the front
cover and Section 3.1
6.2 Inspection

Note : In order to make the

mechanism capable of further
charging operations after closing
the circuit breaker from a Springs
Partially Charged position during
the time that the motor supply may
be disrupted, it is necessary to
remove the circuit breaker from the
housing, remove the mechanism
cover and rotate the ratchet wheel
anti-clockwise until the link pin on
the ratchet is at the lowest point.
However, restoration of the motor
supply will complete the travel of
the ratchet wheel, thus making the
above procedure unnecessary.
Refer to Figure 6.
5.3 Opening the Circuit
Breaker
Refer to Manually Section 4.3.1.
6.0 MAINTENANCE

Refer to figures 7 & 8 and for

location of circuit breaker
operations counter and interrupter
wear indicator.

It is recommended that an
examination to be carried out
whichever occurs first :
i.

8 years

ii.

2000 normal operations

iii. 100 fault operations. Where the

fault current is less than the
rating of the circuit breaker this
number may be increased.
Further advice can be obtained
from the manufacturer.

In particular the maintenance policy

is based on the concept of
Inspection, Examination/ Service
and Overhaul is defined in the
standard.

The design of the operating

mechanism is such that no
adjustments are required
throughout its lifetime, subsequent
examinations will consist of visual
inspection for wear, corrosion, loose
components and unless there is
reason to believe that there is
deterioration, no dismanting is
allowed.

These intervals may vary greatly

depending on the duty the
equipment is called upon to perform
and the environment in which it is
situated. The time intervals are
therefore best determined by user
experience based on the behaviour
of the equipment on the particular
installation.
Vacuum switchgear is low
maintenance equipment, the
vacuum interrupter being a sealed
unit which does not require
maintenance during its lifetime. The
only readjustment which may be
required in case of trip and spring

Care must be taken to ensure that

no lubricant is applied to the
operating mechanism electrical
release coil plunger or electrical trip
coil plunger.
Should there be any doubts about
the condition of any components a
more detailed examination must be
made.
6.3.2 Circuit Earthing
Truck

6.3 Examination/Service

The maintenance policy for HWX

switchgear is based on IS
10118:(1982) reference to which
should be made for a general
background to this subject.

Because of the widely varying

condition of operation of individual
installations it is not possible to law
down precise recommendations for
the intervals between maintenance
required under all circumstances.

11

A careful routine scrutiny of the

equipment is required for any signs
of deterioration or abnormality.
Inspections should include
operational checks.

The mechanism is supplied with the

lubrication for life and normally
further lubrication should not be
required. In the event that
components are replaced they
should be lubricated with aeroshell
17 grease or an equivalent silicon
base grease containing
Molybdenum Disulphide.

6.3.1 Circuit Breaker and

Operating Mechanism

Manual closing and opening

operations should be made to
check the closing and tripping
mechanisms. The electrical closing
and tripping circuits should also be
checked.
The duty imposed on spring charge
motor is very light, consequently
maintenance is unlikely to be
necessary. However, the assembly
procedure of motor is given in this
manual.

Under normal service conditions

earthing truck is virtually
maintenance free.
Inspection, cleaning and
relubrication is recommended after
2-3 years under unfavourable
ambient conditions such as
excessive dust collection,
aggressive atmospheres,
continuous high relative humidity in
excess of 70%. Aseol molitea or
Molydag 47 is to be used for the relubrication of contacts and bearing
joints.
6.3.3 Primary
Conductors and
Connections
Remove the appropriate covers and
check that all electrical joints and
connections are sound.
Remove any deposits of dust etc.
6.3.4

Auxiliary Switches

Ensures that all connections are

tight at the terminals and the
change over of contacts are
checked periodically with a
continuity meter.
6.3.5

Insulators

All insulators should be cleaned

with a non-sheeding cloth.
6.3.6 Vacuum
Interrupters
Refer to Section 3.6

Examination is confined to the

inspection of the commutator for
scoring, the brushes for excessive
wear and free movement in the
brush retainers.

6.3.7 Primary Isolating

Contacts
Check the condition of the plug and

finger contacts. Any furnished

surfaces should be cleaned using a
branded liquid silver polish and a
non-shedding cloth.
6.3.8 Secondary
Isolating Contacts
Ensure that all connections are tight
at the terminals. Contact surfaces
should be treated in a similar
manner to the primary contacts.
6.3.9 Primary Connection
Spounts Safety Shutters
Clean and examine all parts of the
shutters and operating mechanism
for wear and loose components. If
required parts should be sparingly
lubricated with a good quality
mineral oil.

An overhaul will be necessary

when :
a. An examination has identified a
component(s) as being less
than satisfactory.
b. The limit of contact wear of a
vacuum interrupter has been
reached. Refer to fig. 8

Spring Release Coil Refer to

Figure-12 for fitting instructions Trip
Coil Refer to Figure 13 for Fitting
instructions.
LT Fuses
Voltage Transformer Fuses
Auxiliary Switch
Limit Switch
Isolating Contacts

c. The vacuum interrupter and the

circuit breaker operating
mechanism have performed the
number of operations indicated
in the following table.

All spares should be stored in such

a manner as to protect against
corrosion, humidity, adverse
atmospheric conditions mechanical
damage and vermin.

7.0 SPARES

When ordering spares of

replacements a complete
description should be given,
together with relevant nameplate,
data and serial numbers. For further
details regarding spares the Spares
Manual can be referred.

The following spares should be kept

in stock, actual quantities will
depend on the number of circuit
breaker in service and operating
conditions.

Spout safety shutters shall not be

opened without first earthing the
busbars and/or circuit cables.
Prove dead after opening.

With VCB Closed Insert Contact

Wear Gauge into Gap Between
the Drive Insulator and the
Spring Guide Rod. This is a GO
/ NO - GO Gauge.

6.3.10 Recommissioning
Inspection
Refer to Section 3.7

The Gap when New is 5mm,

which, when the interrupter is
Worn Out, will reduce to 3 mm.

6.4 Overhaul
Overhaul comprises work carried
out to restore the equipment to a
satisfactory condition including the
replacement of components.

FIG. 8. Contact Wear Gauging

12

MOTOR ASSEMBLY
Reference Figure No. 9
Opn. No.

Checkpoint/Remarks

Operation Description

01.

Unscrew the 4 Nos. M4 slotted head screw from the Motor

Gear Box Unit.

02.

Fit 1 No. MB 2010 DU Bush to the Motor Bracket Casting

(110) with loctite 638.

03.

PUT2 Nos. M12 Brass Washer (117) and 1 No. Eccentric

Drive (111) over the Motor Shaft (As shown in the drawing)
such that their keyways are matching.

04.

Place the key (115) through the keyway thus locking the
eccentric drive with the motor shaft.

05.

Fit the two charging pawls (113) with DU bushes (116)

through gradual, application of pressure on a bench vice.

06.

Insert the pawls (113) into the motor shaft such that the
stepped positions are in opposite direction and the plane
faces fall upon one another.

07.

Insert the other eccentric drive into the motor shaft and
key it.

08.

File M12 shim washers to have slots for the key and place
these above the second eccentric drive.

09.

Key the end bearing (112) to the shaft. The top end of the
Aluminium Bracket and the top of the end bearing meshes

10.

Fit the Aluminium Bracket (110) after proper adjustment

to the motor shaft housing by M4X30 long (161) round
head screws and M4 spring washers (180) at the four
ends. Tighten the screws with a screw driver.

Check tightening of the motor

bracket to the gear box housing by
double nuts and loctite.

11.

Keep the assembly in the bin free on the motor shaft.

Check that the pawls are absolutely.

COL P ONLY

Alignment of keyaways should be

checked.

COLs F. G. H. M. & N.

MOTOR SHAFT

Exploded Assembly of type HWX

Charging Pawls & Eccentrics
Note : This DU Bush used only on Cols F. G. H. M. & N.

FIG. 9. HWX SPMX from a Mechanism Motor Assembly

13

Spring Release Coil Pot Sssembly

Reference Figure No. 10
Opn. No.

Operation Description

Checkpoints/Remarks

01.

Assembly Release Spindle (97) with release plunger

(106) and Lock with M6 Hex Nut, so that 15 mm
(approx) of Spindle comes out of Plunger.

Check the Locking

02.

Put the Release Coil within the Release Coil Pot

(91)

Check the tightness between

them

03.

Place the Pole Piece (96) inside the Release Coil

and lock with the Coil Pot (91) with the help of a
fastener (99)

04.

Put the Assembled Release Spindle of Operation

No. 1 with Spring (98) on it. Press the Plunger so
that the other end of the Spindle comes out through
the Pole Piece. Lock the Spindle with 1 No. M6 HEX
NYLOC Nut to restrict the Spring back action of the
Plunger.

Check easy movement of

Spindle

05.

Fix up Release Lever (92) on the Coil Pot with the

help of M6x30 HEX HD Screw and Lock it to ensure
easy movement of Release Lever around the Pivot.

Check Easy movement of the

Release Lever Pivoting about
the Screw after locking.
The Screw Head should be
downward.

FIG. 10. HWX SPMX from a Mechanical Realease Coil Pot Assembly

TRIP BOX ASSEMBLY

Reference Figure No. 11
Opn. No.

Operation Description

Checkpoints/Remarks

01.

Assemble the Trip Plunger (251) and Brass Stud (250)

and lock them with Two Nos. M5HEX Head Nut si tgat
25 mm (approx) of Brass Stud comes of the Trip Plunger.

02.

Put the above Assembly and Pole Piece with the locked
side of the Trip Plunger downward into the Trip Coil

Check easy movement of the Trip

Plunger in the Trip Coil.

03.

Fit the Buffer pin (109) in the M5 thread hold of the Trip
Box through the 7.8 mm dia hole of the Trip Box top
face and lock with M5 Hex But (167).

14

TRIP BOX ASSEMBLY

Reference Figure No. 11 (Contd.)
Opn. No.

Operation Description

04.

Put the Neoprene Buffer (104) on Buffer Pin (109)

05.

Put the Assembled Trip Coil within the Trip Box (101)
and lock the Pole Piece with the Trip Box with A Fastener
(99)

06.

Apply grease (ROCOL) on Trip Bar (102). Assemble Trip

Bar and Trip Box with Pivot Pin (103) with E-Clips on
both sides.

Check easy pivoting of Trip Bar

on Trip Box.

Fixing the Fastener

Check easy movement of the
Plunger inside the Coil

104
103 189
250

102

252

253
101

254

109

(A)

Unbolt Drive Spring From

ON/OFF Indicator.

(B)
251

Spring Charge Indicator Using

Good Long Nosed Pliers
Remove Spring Charge Reset
Spring from Facia.

FIG. 11. Tip Box Assebly for HWX Mechanism

Remove Facia (# Screws) Disconnect

coil, Using Long Nosed Pliers
Remove Spring Clip, Slide Out
Plunger, Coil can now be Removed
from the Coil Box.

167

167

Disconnet coil and remove coil assembly (2

bolts from rear)
Using long nosed pliers remove the spring clip.
Remove plunger, coil can now be removed from
the coil box.
To refit the coil, reverse the sequence and check
electrical operation.
FIG. 12. Replacing Spring Release Coil

AREVA T&D Worldwide Contact Centre:

http://www.areva-td.com/contactcentre/
Tel.: +44 (0) 1785 250 070

www.areva-td.com

Reverse Sequence to Refit Coil.

Check Electrical Operation.
FIG. 13. Replacing Shunt Trip Coil

SWITCHGEAR- L4- FACTS - EN- 2 - - AREVA - 2005. AREVA, the AREVA logo and thereof are trademarks and service marks of AREVA.
All trade names or trademarks mentioned herein whether registered or not, are the property of their owners. - Switchgear Kolkata.
Our policy is one of continuous development. Accordingly the design of our products may change at any time. Whilst every effort is made to produce up to date literature, this brochure should only be regarded as a guide and is intended for information
purposes only. Its contents do not constitute an offer for sale or advise on the application of any product referred to in it. We cannot be held responsible for any reliance on any decisions taken on its contents without specific advice.

Checkpoints/Remarks