PCC (TS)

Thank you for choosing L&T as your supplier of Low Voltage

Switchgear and giving us the opportunity to serve you.

Please read this manual carefully for proper installation,

safe, easy and efficient operation.

Only authorized and qualified personnel should be allowed

to work on the switchgear. An authorized and qualified

operator is a person having detailed information about

installation and commissioning of switchgear or specially

trained for the maintenance of the switchgear and fully

aware of the hazards caused by unsafe operation. An

operator should also have basic knowledge of First Aid.

The information herein is general for all specifications, part

of which may not be applicable for specific applications or

variants. Refer the following 'as built' documents for any

particular installation:

• Reference list of drawings (RLD)

• Single line drawings

• General Arrangement (GA)drawings

• Master bill of materials (MBOM)

• Scheme drawings

In case of any conflict between this manual and drawings

available with you, the drawings shall take precedence.

For additional information or clarification please send

your queries to AtYourService@Lntebg.com for quick

resolution.

All our switchgear undergo rigorous testing and qualitychecks at our factory. However, we recommend verificationand testing at site, especially after storage.

Following symbols have been used in this manual to indicate varying levels of danger:

Warning-Highly dangerous- can cause death or serious injury

Caution-Dangerous- cancause injuries or damage the switchgear.

Type TS PCC

CONTENTS

1 INTRODUCTION 1

20

2 CONSTRUCTION 2

• TECHNICAL DATA 4

• PANEL CONFIGURATIONS 6

• BUSBARS AND DROPPERS 10

• AUXILIARY BUSBARS 11

3 HANDLING & TRANSPORTATION 12

• RECEIVING 13

• HANDLING 13

4 STORAGE 16

5 GENERAL SAFETY 18

6 INSTALLATION

• TYPICAL ARRANGEMENTS 21

• TOOLS 22

• SITE PREPARATION 22

• ERECTION 22

• FLOOR PREPARATION & PANEL MOUNTING 22

• CONNECTION OF TRANSPORTUNITS & BUSBARS 24

• CONNECTION OF EARTHBARS 25

- PCC (TS) - PCC (TS) 25

- PCC (TS) - MCC (TX) 25

• POWER CABLE 26

• CONTROL CABLES 28

• INTERPANEL WIRING 28

Type TS PCC

CONTENTS

• INSTALLATION OF LOOSE MATERIAL 29

- METERING AND CONTROL DEVICES 29

- ACB 29

- CONTROL TRANSFORMERS 31

• INSTALLING AN EXTENSION PANEL 32

7SITE TESTING 34

• TESTING SWITCHBOARDS 35

• TESTING CURRENTTRANSFORMERS 35

• TESTING POTENTIAL TRANSFORMERS 35

• TESTING METERS AND TRANSDUCERS 35

• TESTING RELAYS 36

• TESTING CONTROL CIRCUITS 36

8 PRE-ENERGIZING CHECKS 38

• COMMISSIONING 40

• OPERATION 42

• MAINTENANCE 46

- PRECAUTIONS 47

- ROUTINE CHECKS 47

- ACB MAINTENANCE 48

- REMOVAL OF ACB 49

- REMOVAL OF DOORS 49

9TROUBLE SHOOTING 50

10 RECOMMENDATIONS 53

11 LIST OF FIGURES 54

12 LIST OF TABLES 54

Type TS PCC

INTRODUCTION

IMPORTANTNOTE

Only the Specific written Technical Instructions supplied by L&T must be used. Our products must only be commissioned,

operated, serviced, repaired or decommissioned in accounts with Technical Instructions which have been supplied by the

manufacturer. Non Compliance with this instruction may result in serious damage to the product and its associated items, as

well as health hazard ormortal danger.

WARRANTY

Ourproducts are subjected to factory inspection and testing according to the applicable standards and provisions.

The correct function and the service life of the switchgear are influenced greatly by compliance with the installation,

commissioning and operating conditions stipulated in this manual.

Non-compliance with these provisions may compromise warranty claims.

Any local provision which does not contradict the specifications of this document, especially as regards safety for personnel

and buildings, must be complied with.

L&T cannot be held liable for the possible consequences of:

• Non-compliance with the provisions contained in this manual, which refer to international regulations.

• Non-compliance with the instructions of the suppliers of cables and connecting accessories as regards application and

installation.

• Any aggressive climate conditions (humidity, pollution etc.) prevailing in the immediate environment of switchgear not

suitable to this effect ornot protected accordingly.

• This manual does not contain any instructions regarding the mechanical lock-outs to be performed. The work described is

performed on de-energized (on installation) ormechanically locked - out (decommissioned) switchgear.

Type TS PCC 1

CONSTRUCTION

Type TS PCC 2

CONSTRUCTION

1. Power Control Centre type TS is a free-standing and

floor mounting switchboard suitable for indoor

installation.

2. The frames are of bolted construction with welded base

and top.

3. Each vertical panel is divided into distinct zones for

busbars, droppers, auxiliary busbars, unit compartment,

power cabling and control terminals Figure 2.

4. The unit compartments houses main equipment like Air

Circuit Breakers, Fuse Switches, Moulded Case Circuit

Breakers and associated auxiliary equipment.

5. For optimum utilization of panel space, compartment

have variable heights with a minimum of 220 mm.

6. Up to two tiers of ACB can be mounted in TSpanel.

7. Compartment doors are provided with twin-action

door fasteners (Cam Lock). While closing, the fastener

engages with the frame in the first quarter turn, and in

the second quarter turn, it pulls the door towards the

frame. This ensures compression of gasket between door

and frame. The fasteners are operated by special key.

8. The rear doors are hinged and provided with twin action

door –fasteners.

Figure 2 - Door Open view

Auxiliary Busbars

Horizontal Wireway

Unit Compartment

Aux. Compartment

Terminal Chamber

Figure 1 - Typical PCC panel

Type TS PCC 3

L&T´s TS range of Low Voltage Power Control Centers comply with IEC 61439-Part1 & 2. TS is designed to enhance safety of the users. Its modular construction facilitates logistics, installation, commissioning and maintenance.

CONSTRUCTION

TECHNICAL DATA

Table No. 1

To increase cabling area, add-on-chambers (AOCs) with a depth of 300 mm are provided on the rear side.

Designation Power Control Centre (PCC) Type TS

Standards and specifications

Power Switchgear and Controlgear (PSC) Assemblies

IEC 61439 - 2, BS EN 61439 - 2

Testing under conditions of arcing due internal faults

to IEC 61641

Insulation characteristics

Clearance > 20 mm

Creepage distances > 20 mm

Overvoltage category II / III / IV

Pollution degree 3

Field condition Inhomogeneous (non-uniform)

Electricalcharacte-ristics

Voltage ratings

Rated operational voltage (Ue) up to 690 V

Rated insulation voltage (Ui) 1000 V

Rated impulse withstand voltage (Uimp) 6 / 8 / 12 kV

Rated frquency (fn) 50 / 60 Hz

Type TS PCC 4

CONSTRUCTION

Table No. 1

Electricalcharacte-ristics

Main Horizontal busbars:

Rated current (InA) up to 6300 A

Rated peak withstand current (Ipk) up to 220 kA

Rated short-time withstand current (Icw) up to 100 kA, 1s

up to 50 kA, 3s

Current ratings Vertical Distribution busbars for PCC:

Rated current (InA) up to 2000 A

Rated peak withstand current (Ipk) up to 220 kA

Rated short-time withstand current (Icw) up to 100 kA, 1s

up to 50 kA, 3s

Rated conditional short-circuit current (Icc) up to 80 kA

Permissible conditional short-circuit current up to 100 kA

Internal Arc fault conditions

Duration 500 ms

Acceptance Criteria as per IEC 61641 1 to 7

In accrodance with IEC 60529:

Mechanical characte-ristics

Degree of Protection

External IP 30 / IP 40 / IP 42 / IP 54

Internal IP 2X / IP XXB / IP 4X / IP XXD

Mechanical Impact as per IEC 62262 IK 08 / IK 09 / IK 10

Forms of as per IEC 61439 - 2 Form 1 to Form 4

Separationas per BS EN 61439 - 2 upto Form 4, Type 6

Height (mm) 2200, 2400

Dimensions Width (mm) 700, 900, 1000 (PCC)

Depth (mm) 600, 1000, 1100 (PCC)

Surface Treatment

Structure Alu-zinc / powder coated / painted

Internal Components Alu-zinc / powder coated / painted

External Components powder coated / painted

Resitance toDamp heat cycling test IEC 60068-2-30

CorrosionSalt mist test IEC 60068-2-11

Plastic components

Flame retardant, self-extinguishing, Halogen-free

IEC 60695-2-10, IEC 60695-2-11

Type TS PCC 5

CONSTRUCTION

PANEL CONFIGURATION

(Depth = 600mm)

Power cable area

Control cable area

*F Front Side

(All dimensions are in mm)

440 600 800

*F *F *F

215

295

*F

800

554.75155.25

215

295

*F

600

215

295

*F

440

30

300

*F

295

*F

300

30

215

*Dimensions do not includedoors

2200 / 2

400

Type TS PCC 6

CONSTRUCTION

PANEL CONFIGURATION

(Depth = 1000mm)

300 440 600 800 1000

*F *F *F *F *F

754.75155.25

*F295

615

615

295

*F

554.75155.25

615

295

*F

615

295

*F

615

295

*F

Power cable area

Control cable area

*F Front Side

(All dimensions are in mm)*Dimensions do not includedoors

2200 / 2

400

300 440 600 800 1000

Type TS PCC 7

CONSTRUCTION

PANEL CONFIGURATION

(Depth = 1100mm)

300 440 600 800 1000

*F *F *F *F *F

1000

754.75155.25

295

715

715

295

*F

800

554.75155.25

715

295

*F

600

715

295

*F

440

715

295

*F

300

Power cable area

Control cable area

*F Front Side

(All dimensions are in mm)

30

*Dimensions do not includedoors

2200 / 2

400

Type TS PCC 8

CONSTRUCTION

PANEL CONFIGURATION

(Depth = 1260mm)

300 440 600 800 1000

*F *F *F *F *F

754.75155.25

*F295

875

875

295

*F

554.75155.25

875

295

*F

875

295

*F

875

295

*F

Power cable area

Control cable area

*F Front Side

(All dimensions are in mm)*Dimensions do not includedoors

2200 / 2

400

300 440 600 800 1000

Type TS PCC 9

CONSTRUCTION

BUSBARS AND DROPPERS

1. Bus-bars are arranged in a Double deck Figure 3. They

are available in two variations depending on the rating /

busbar material (Aluminum or Copper), - Double deck

non-interleaved (DDNIL) arrangement – with phase

sequence of B-Y R-N -Double deck interleaved (DDIL)

arrangement with phase sequence of B-Y-R-B-Y-R-N with

5 0 % neutral (B-Y-R-B-Y-R-N-Nin 100% neutral).

N N R YR BY B

DDIL system

N BR Y

DDNIL system

Figure 3 - Double Deck arrangement of busbars Figure 4 - Busbar Supports

2. In case of DDIL arrangement the busbars are interleaved.

The links connecting ACB to busbars or droppers are

connected to both packets of busbars and droppers. To

facilitate cable / duct termination, cable / duct links are

not interleaved. They are stacked together for each

phase.

Figure 6 - Two links supportFigure 5 - Four links support

Type TS PCC 10

CONSTRUCTION

AUXILIARY BUSBARS

Auxiliary busbars are located in the top front chamber of the

panel and segregated from main busbars by a metallic

partition.

Horizontal wirewayShipping section terminals

A horizontal wireway is provided immediately below the

auxiliary busbar for interpanel wiring. Shipping section

terminals if required are mounted in the horizontal wireway

Figure 7.

Table No. 2

* The above table is indicative and can be configured based on actual requirements.

Wire Way

Block Sr. No. Description

1 Space Heater - Ph

2 Space Heater - N

1 st 3 240 / 110 AC V Aux supply - Ph / Clean Earth Bus

block 4 240 / 110 AC V Aux supply - N

5 110 V DC Aux Bus supply - +ve

6 110 V DC Aux Bus supply - -ve

7 Annunciation Test Bus

8 Annunciation Accept Bus

2 nd 9 Annunciation Reset Bus

block 10 Annunciation Alarm Bus

11 Clean Earth Bus

12 Configurable

Figure 7 - Aux bus chamber

Up to 12 Auxiliary busbars of 63 A rating can be provided. The Auxiliary busbars are mounted in Nylon Housing to provide

segregation and prevent accidental contact.

Type TS PCC 11

HANDLING AND

TRANSPORTATION

Type TS PCC 12

HANDLING AND TRANSPORTATION

Figure 8 - Packing case Details

Receiving:

Onreceipt of the PCCs at site:

• Verify the following details on packing case Figure 8 :

• Item no.:

• Description of material:

• Package No.:

• Gross weight:

• Netweight:

• Dimensions:

• Volumes:

• Storage of goods:

• Special instruction:

• Verify the quantity of TUs & loose material as per the

packing list.

• If the packing case is damaged, open the cases and

inspect the PCCs. Report any damage or loss of

components to the transport/carrier and lodge a claim

with the insurance agency or inform your nearest L&T

office.

Handling:

TUs can be handled either by fork-lift or overhead cranes

in an upright position depending on where they have to

be placed. Care should be taken to see that the TUs don’t

topple during transportation.

• Avoid tilting of TUs(Panels).

• While transporting the panel using a forklift, ensure that

the distance between the legs of the forklift and ground

is at least 12 cm.

• Limit the speed of the forklift to 10 kmph.

• Use both legs of the forklift.

If switchgear are to be installed at higher elevations, shift

them from the unloading spot through the opening

planned in the building for this purpose. This should be one

with all safety precations and strict supervision by trained

personnel.

Figure 9 - Positioning of TU on truck

Type TS PCC 13

HANDLING AND TRANSPORTATION

We recommend handling and shifting panels in packed condition only.

DO NOT MOVE THE PANEL BY INSERTING A CROWBAR BELOW THE BASE FRAME. Thismay cause damage to the base frame.

• In case the TU is unpacked before reaching the site, use

the lifting channel provided at the top of the panel for

easy transportation Figure 9 & Figure 10 .

Figure 11 - Chain marks on packed TUs

If rollers are used for placing the sections on the foundation,

retain the base plank to avoid damage to the baseframe.

Ensure that:

• The load of the TU is equally distributed by using all

the lifting angle holes.

• The sling of the crane is in good condition.

• The TUdoes not tilt or topple during transit.

In case of handling by lifting crane,

• Suspend ropes from the hook and pass them under the

wooden pallet at the bottom of the TU.

• Center of gravity indicators and chain marks are

provided on the TUas shown in Figure11.

• Use PP (Poly-propylene) ropes of minimum 1" diameter

for this purpose. Choose the diameter of the rope

according to the weight of the TU which is mentioned

inGA your drawing.

• Verify that the route from the unloading spot to the

erection spot has free access.

• Unload the TUsafter reaching the unloading spot.

o o

oo

o o

oo

Figure 10 - Lifting angles

While unloading a TU, ensure that the remainingTUs are placed securely on the truck and are not indanger of toppling over.

Type TS PCC 14

RECEIPT AND HANDLING

To facilitate transportation and handling, the Power Control

Centre (PCC) TS is split into multiple sections/ transport units

(TUs). Each section is wrapped with a HDPE (High Density

Polyethylene) cover and packed in a wooden case. To arrive

at the approximate overall dimensions of the

packing cases, add 300 mm to the dimensions of the

respective section.

List of equipments and special tools for site erectionand assembly

• Crane and truck for equipment shifting.

• Slings and ropes - As per requirement.

• Rolling pipes - 10 Nos.

• Channels - 10 m.

• Crowbars - 4 Nos.

• Welding machines - 1 No.

• Spanner sets - 1 Set.

(Ring & Open spanner size 13mm, 17mm, 19mm, and

24mm. Box orpipe spanner 13mm.)

For safe handling lifting angle (θ) should be greater than 45° Figure 9 & Figure 10.

Type TS PCC 15

STORAGE

Type TS PCC 16

STORAGE

If the PCC is to be commissioned at a later date, the

following precautions should be taken.

• OUTDOOR STORAGE SHOULD BE AVOIDED. Store all

cases indoors, in a clean, dry and well ventilated place

where seepage of water and condensation does not

occur.

• Maintain a minimum temperature of - 5 C and humidit y

of less than 50%.

• If civil construction is being carried out in the vicinity,

ensure that the PCC is completely protected from

debrisand dust.

• Keep proper tags / markings on the panels for easy

traceability.

• Unpacking of the TUs at site is preferable. In case it

becomes necessary to unpack the TUs during storage,

make sure that packing of all the internal components

e.g. covers on the relays and meters mounted on the

door etc remain intact (Highlighted in the figure

below). Also inspect the PCC for scratches, if any.

Please use paint supplied with the loose materials to

touch up scratch marks.

The switchboard should be stored indoors withproper ventilation. Moist / corrosiveenvironments may affect the metallic parts andcause their insulation to deteriorate.

Type TS PCC 17

GENERAL SAFETY

Type TS PCC 18

GENERAL SAFETY

While shifting the panel from storage point to erection site:

• Use a lifting crane to load the panel on to the truck.

Ensure that TUs are placed in a vertical position on the

truck.

• Tie the TUsproperly to prevent unwanted movement.

• Refer the previous section for TU handling instructions.

(Page No.12).

• Personnel handling the equipment must be skilled and

authorised to handle the intended voltage level.

• All working personnel must be aware of safety

practices.

• Safety shoes should be worn so as to avoid the risk of

any electric shock while at work.

• Gloves and goggles should be used while working in the

proximity of hot and hazardous materials to avoid bodily

injury.

• Appropriate tools and instruments should be used as

stated on page no. 16 for precise workmanship.

• Suitable Caution labels and sign boards should be

erected at the time of installation and testing of boards

as a mark of caution.

Type TS PCC 19

INSTALLATION

Type TS PCC 20

INSTALLATION

1000 mm

Type TS PCC 21

22

00

mm

Typical arrangements

Power Control Centre

Figure 12 - Typical arrangements

INSTALLATION

TOOLS

• Torquewrench

• BushRatchet

• Hydraulic jack

• Rubber mallet

• Clamps

SITE PREPARATION

1. The installation site must be clean and the surface even.

Use shims if the floor is uneven. An uneven foundation

may cause misalignment of sections, bus-bars and

hinged doors of the unit.

2. Walls and ceilings must be plastered with painting

completed.

3. Doorsand windows must be installed.

4. Openings in the floor, wall and ceiling for cables,

conductor pipes, bars and ventilation must be in

accordance with the construction drawings provided.

5. Supporting brackets, beams, enclosures and foundation

frames must be assembled and painted.

6. lf necessary, braces appropriate to the basic

dimensions of the switchgear installation with cross

struts corresponding to the panels must be assembled.

Figure13 - Tools

Suitable indoor conditions must be maintainedand necessary emergency exits must be providedin the switchgear room.

Excessive temperature fluctuations and highhumidity should be prevented.

Condensation should be prevented.

If the plant´s atmosphere is likely to containexcessive steam or reactive gases comprisingsulphur or chlorine, ensure that the Switchboardis placed in a separate pressurized room.

Panel 1

5. Place the first TU over the base channel frames erected

in the floor concrete by the civil contractor. Check

correctness of leveling (± 1 mm tolerance per meter is

allowed) and alignment of panels & proceed as per

General Arrangement (GA) Drawings.

6. Maintain clearances as mentioned in GA drawings.

Provide sufficient space on all sides of the panel for

personnel to work conveniently.

FLOOR PREPARATION AND PANEL MOUNTING

Panel can be mounted on the floor either by bolting or tack-

welding with the ISMC Base Channel / Base Frame.

The panel is provided with integral 50 mm base Frame made

of 3mm sheet metal.

Follow the steps listed below to mount the panel.

• Grout / weld the ISMC Base Channel / Base Frame on the

inserts in the floor. Make sure that it is perfectly leveled.

• Place the panel on to the ISMC Base Channel / Base

Frame.

• Refer Figure 14 for placing the panel on to the ISMC Base

channel / Base frame

• Tack-weld or bolt the panel with the ISMC Base

Channel / Base Frame.

• When bolting the panel, drill the required holes in the

ISMC Base Channel/Base Frame, so that it matches with

the holes provided in the integral base Frame.

ERECTION

1. After TUs have reached the installation site, unpack the

TUs and move the packing material to its allocated

area.

2. Check if all components are in place as per your

drawings (MBOM) and the packing list.

3. Vertical sections should be shifted sequentially into the

installation site for ease of installation.

4. The TUs must be carried in an upright position to avoid

the risk of toppling. Refer the section Floor preparation &panel mounting.

Figure 14 - Panel Mounting on ISMC Base Channel / Base Frame

Panel 2 Panel 3

ISMC Base Channel/Base

Type TS PCC 22

INSTALLATION

A typical drawing is shown below for reference:

FRONT

Foundation holes

Figure15 - Integral Base Frame

A typical drawing for the ISMC base Frame with the holes

punched is shown below along with the coupling of the

integral base frame to the ISMC Frame: Figure 15.

• To access the foundation holes given on the integral

base Frame, open the front & rear doors and remove

the gland plate.

• Bolt or tack-weld the panel to the ISMC Base Channel/

Base Frame.

Figure16 - ISMC Base Frame

Ensure that the board is properly aligned while

bolting / tack-welding.

Please ask for project specific drawings if you arebolting the panel to an ISMC base channel/frame. Ifyou decide tp tack-weld the panels to the basechannels/frames, such drawings are not requiredFigure 14.

Coupling of ISMC Frame to the integral

Integral Base Frame

ISMC Base Frame

Type TS PCC 23

INSTALLATION

CONNECTION OF TRANSPORT UNITS AND BUSBARS

1. For access to the horizontal busbars, remove top plates

and hoods (if provided) by removing all the bolts

provided on the top Figure 16.

2. Remove the fish plates provided on the right side of the

busbar to connect it with subsequent TUs placed

sequentially.

3. Clean the fishplates with a wire brush. Wipe them with a

soft, dry cloth and then immediately apply contact

grease on them. Hindustan Petroleum, MPL (EXXON) /

Petroleum Jelly J. P. grade contact grease or equivalent

is recommended.

4. Bolt adjacent TUs together - holes are provided in the

gasketted side pillar. This should be done before joining

the busbars.

5. Join horizontal bus bars using the fishplates as shown in

Figure17.

Figure 18 - Busbar joining

Figure 17 - Top plate

Ensure bus bars are properly aligned so that there

is no strain on any of the support insulators.

6. Tighten all electrical connections with a torque wrench

to the torque values as mentioned in table no. 3

Figure18.

Figure 19 - Tightning of Busbar joints

Size of bolt Torque in m.kg

Table No. 3

Thread

(Boltsize)

Kgf

m

Nm

Socke

t No.

(mm)

Normal Bolt

(Grade:4.8)

High Tensile

Norm

al Bolt Bolt

(Grade: 8.8) (Grade: 4.8)

HighTensile

Bolt

(Grade:8.8)

M6 0.38 1.05 3.7 10.29 11/10

M8 0.85 2.5 8.3 24.51 13/12

M10 1.88 4.7 18.8 46.09 17/16

M12 3.2 6.5 31.38 63.74 19/18

For aluminum bus bar system normal torque to be applied even if the bolt is HT. HT torque values are applicable

only for hole less bus bar joints.

Type TS PCC 24

Figure 21 - PCC - PCC Earthbar Coupling

INSTALLATION

7. Join the auxiliary busbars by joining the auxbus fish plate

provided for the same in the left side TU Figure 19.

CONNECTION OF EARTHBARS

PCC (TS) - PCC (TS)

1. For single front panels, open the rear door of the panel to

access the horizontal earthbar.

2. In case of a back to back arrangement, open the cable

alley to access horizontal earthbar.

3. Remove the fishplate provided on left hand side TU to

connect it with subsequent TUsplaced sequentially.

4. Join the earth bars using the fishplate provided and check

correctness.

5. Tighten the connection with a torque wrench to the

torque values as mentioned in Table no. 3.

EARTHBAR FISHPLATE

PCC (TS)-MCC (TX)

1. Open the rear door of the PCC.

2. Remove the fishplate provided at the end of horizontal

earthbar at the bottom.

3. Connect the fishplate with the already extended MCC

earthbar.

4. Tighten the connection with a torque wrench to the

torque values as mentioned in Table No.3.

MCC HORIZONTAL EARTHBAR

PCC HORIZONTAL EARTHBAR

Figure 22 - PCC - MCC Earthbar Coupling

Figure 20 - Auxbus joining

Type TS PCC 25

INSTALLATION

POWER CABLE:

TOP CABLE ENTRY

1. Remove the top plate Figure 24.

2. Punch the required holes on the top plate depending on

cable size and gland type.

3. Follow the instruction given under cable termination.

Figure 24 - Power Cable terminals

Power cable terminals

Gland Plate

Cable termination:

1. Remove insulation from cable ends without damaging

the conductor strands.

2. In case sector shape conductors are used, form the

conductor using a circular forming die.

3. Refer following section for terminating power cables.

4. Clean the conductor and coat immediately with

inhibiting compound like petroleum jelly.

5. Crimp the lug terminals properly as improper crimping

may result in higher temperature rise at the joints.

6. Coat the lug barrel with an inhibiting compound from

inside.

12*R

Forming should be done prior to cleaning and

applying inhibiting compound.

Figure 23 - Top plate

BOTTOM CABLE ENTRY

Remove the gland plate-provided at the rear bottom side of

the panel in two sections Figure 25.

Figure 25 - Power cable terminals

Punch the required holes on the gland plate depending on

cable size and gland type Figure 27.

Power cable terminal

Figure 26 - Power cable terminals bottom cable entry

Type TS PCC 26

INSTALLATION

6. Use lugs with serrated barrels for crimping aluminium

conductors (Serration increases the pull strength after

crimping. It also cuts through the oxide film, if any,

formed on the conductor).

7. Use proper crimping dies, as recommended by the lug

manufacturer. For aluminium conductors, use ring or

hexagonal dies. Ensure that the die surfaces meet

during crimping. Incomplete crimping will result in

higher temperature rise at the joints.

8. Ensure proper clamping of cables on the glands and

cableclamps to avoid weight of cables acting directly on

the termination.

9. Block all the unused holes Figure 27.10. Ensure no free hanging of cable wire.

11. All cable wires should be supported appropriately &

rigidly at required no. of locations. Ensure cables are at a

safe distance (min 50 mm) from live parts.

BUSDUCT TERMINATION:

TOP BUSDUCT ENTRY

• Remove the top plate of the incomer or outgoing

feeder.

• Connect the flats of the busduct with the links at the

end of the busduct riser using the flexibles Figure28.

BOTTOM BUSDUCT ENTRY

• Remove the gland plate provided at rear bottom side of

the feeder.

• Connect the flats of the busduct with the links at the

end of the busduct link using the flexibles Figure 29.

Figure 27 - Top Busduct termination

Bus duct termination

Bus duct termination

Duct link

Figure 28 - Bottom Busduct termination

In case Busduct flats and links are of differentmaterial, use bimettalic flexibles to joint thebusduct flats and links.

Type TS PCC 27

Terminal Block Base plate/ gland plate

Figure 29 - Control Cable terminals

INSTALLATION

CONTROL CABLES:

1. Remove the gland plate / base plate.

2. Punch the required holes on the gland plate / base plate

depending on cable size and gland type.

3. Route the wires through the holes punched in to the

base plate and terminate the cables in the terminal

block provided at the bottom of the panel as per the

schemes.

Use of copper wire is recommended.

Ensure that the connection of the wire is as per

the scheme drawing provided.

Interpanel wiring

1. Wiring is through the horizontal wire-way at the top

along the auxiliary bus.

2. For wiring, separate terminals are provided in the left

hand side of the right most TU which are named XS-YY

(X - terminal no. and YY - panel no. (01, 02, 03 etc.)). The

wire bunch to be connected to these terminals is in the

left-hand side transport unit. The wires have ferrules with

the terminal no. and should be connected their respective

terminals. The no. of terminals and no. of wires to be

to be connected are equal.

For example, consider the panels and transport units shown

in the sketch. The transport unit (TU) consists of panel 1F

and 2F, while TU-2 consists of panel 3F and 4F. The

terminals named 1,2,3... -XS03 are mounted in panel 3F

as shown in the figure. The mounted terminals are

connected to their respective equipment in panels 3F and

4F. The wires going from TU-1 to TU-2 are bunched and kept

with panel 2F. The wire which is to be connected to terminal

1 of panel 3F will have a ferrule marked 1XS03 at the end of

it and will be kept in 2F.

Figure 30 - Interpanel Wiring

T.U.-1 T.U.-2

1F 2F 3F

Terminals names 1,2,3...XS03

Wire bunch to be connected having corresponding ferrules marked 1,2,3...XS03

4F

Horizontal wirewayShipping section terminals

Type TS PCC 28

INSTALLATION

Figure 32 - ACB lifting truck

ACB

• Unpack the ACB properly to avoid damaging it using

crowbar Figure 32.

• Open the ACB compartment door using the camlock

key provided.

• Rack out the cradle using the racking handle.

• If cradle movement is not smooth, apply contact grease.

Also check for the free movement of safety shutters.

• Put the ACB on the cradle with the help of ACB lifting

truck Figure 33.

Note that ACB lifting truck will be supplied only if asked bythe customers.

In case if you dont have ACB lifting truck please contact thesales team for ordering the same or email toAtYourService@Intebg.com

Installation of loose material:

Metering and control devices:

• Unpack the metering and control devices (like meters

and relays) if they were sent as separate packages.

• Position the device in the apt cut-out or base plate

provided.

• Wirethem as per the scheme drawing provided.

• Refer to the device leaflet for further details about the

device.

• Carry out the settings of magnitude and time delay (if

any) for the installed protective and control devices as

shown in scheme drawing and MBOM (Master Bill of

Materials).

• Place the terminal covers properly to adhere to stated

ingress protection (IP) level.

• Check alignment of operating handles for all switches.

• While dispatching the switchboard, secondaries of all

current transformers are shorted. Remove these shorting

while connecting relays/meters and store them

separately.

• Ensure again that all doors are closed and no connection

is left loose.

Figure 31 - Unpacked ACB

Type TS PCC 29

INSTALLATION

Loading in panel:

1. Pull-out the Cradle Rails & ensure that position indication

shows ‘DISCONNECTED’

2. Load the ACB using crane. Even bottom trolley can be

used.

Improper loading of ACB may lead to personal

injury and damage to product.

4. Gently push the ACB to DISCONNECTED position and

close the Panel door.

If equipped with Rating Error Preventor, Cradle will not

accept ACB of different rating.

5. Keeping the OFF button pressed, open the Racking

Shutter. In case panel door is open, also gently defeat

Racking Interlock.

3. Ensure that ACB rests correctly in 2 slots on either side

of cradle rail.6. Rack-in the ACB to Service position. Two almost

-simultaneous ‘Click’ sounds confirm ‘CONNECTED’

position.

Excessive forceful racking-in beyond Connected

position lead to product damage.

Type TS PCC 30

INSTALLATION

Figure 33 - Installation of Control Transformer

Control Transformers

1. Unpack the Control Transformer.

2. Open the compartment door in which the Control

Transformer is to be installed.

3. Bolt the Control Transformer to the base plate.

4. Terminate the primary and secondary wires of the

transformer on the respective terminals.

5. The primary wire has a ferrule with capital letters while

that of the secondary is with unicase Figure 32.

6. Check the connections and tighten the bolt.

Type TS PCC 31

INSTALLATION

INSTALLING AN EXTENSION PANEL

Tojoin an extension panel to existing TS,

1. Remove the end cover of existing TS at the joining end 3. Necessary busbars / fishplates are supplied with the

Figure 35. extension panel.

2. Follow instructions listed in ‘Connection of TUs’ under 4.Place the end cover on the newly added panel.

Installation on page no. 19.

Ensure that both power and control circuits are switched off before taking the end cover off the TU.

Type TS PCC 32

End Cover

Figure 34 - Extension of Panel

Type TS PCC 33

SITE TESTING

Type TS PCC 34

SITE TESTING

TESTING YOUR SWITCHBOARD

1. Keep all power circuit switches ON.

2. Isolate all parallel paths.

3. Ensure all power circuits are connected.

4. Measure all insulation resistance (IR) values between

phases with respect to earth, phases with respect to

neutral and between phase and earth with respect to

neutral with a 500 V megger and compare with the table

below.

In case megger trips while testing, go on isolating one

panel fromthe switchboard till the fault isfound.

B)Dielectric Strength Testat 2.5KV for 1 Sec.

Check (phase)

a) R/Y/B/N

b) R/Y/B

c) R/Y

d) R

With respect to

…….E

…….N

…….B

…….Y

5. Carry out HV test at 2 KV for control circuits and at 2.5 KV

for power circuit for one second and limit the voltage to

8 5 % of the preceding value for every consecutive test.

TESTING OF AIR CIRCUIT BREAKER(ACB)

1. Check rating & type of the ACB are as per MBOM

drawing.

2. Check the door interlocks of the ACB. Door should not

open when the ACB is in SERVICE or TEST position. In

these positions, it should be possible to open the door

only with door interlock defeat facility.

3. Carry out electrical function checks on the ACB with

respect to control schematics. (Simulating each logic

condition).

4. Check anti pumping operation of the ACB. (Press the

closePB (Push Button) and keep it pressed, the ACB

closes). Now reset the trip command and then press the

close PB, ACB closes now. Hence the anti pumping

feature of ACB is checked.

5. If the ACB has in-built protection release, it should be

tested with the respective testing kit.

6. Carry out functional tests on the ACB as per control

wiring scheme of the respective feeder.

TESTING POTENTIAL TRANSFORMERS (VoltageTransformer and Control Transformer)

A) Insulation Resistance Test with 500V Megger before andafter H.V.Test (All values in M.ohms).

1. Check nameplates and ensure they are as per drawings.

2. Check PT Secondary is wired correctly with proper gauge

of conductor.

3. Check PT mounting and ensure they are adequately

supported.

4. Check PTcircuit's earth link.

5. Check the polarity of PT. Using a battery operated polarity

tester, check that positive EMF is induced between

terminals S1 and S2 when a positive current pulse is

applied between P1 to P2.

6. Check ratio of all cores. Conduct ratio test by applying

1 phase 240V across the primary. Note voltage at

secondary. Calculate the ratio tabulate and compare the

value with the nameplate values.

7. Measure winding resistance.

8. Check tightness of all connecting terminals.

TESTING OF METERS AND TRANSDUCERS:

1. Inspect all meters and transducers for proper

mounting and for any damage.

2. Testwith calibrated meters.

3. Check CT and VT connections with particular reference

to their polarities for power type meters wherever they

are provided.

R Y B N

E 0.5 0.5 0.5 0.5

N 0.5 0.5 0.5 ~

B 0.5 0.5 ~ ~

Y 0.5 ~ ~ ~

Type TS PCC 35

SITE TESTING

4. Check for the earthing of meters and transducers as

per the drawing.

Type TS PCC 36

TESTING OF RELAYS:

1. Inspect for propermounting and for any breakage.

2. Ensure all gagging of moving parts are removed.

3. Check nameplate details as per specification.

4. Set the relay as per setting sheet, (protection co-

ordination) and check for its operation at set values.

TESTING CURRENT TRANSFORMERS (Cts):

3. Check CT secondary links are properly connected as per

the scheme drawing.

4. Check CT mountings and ensure they are adequately

supported and clamped.

5. Check polarity of CT. Use a battery operated polarity

tester. Depending upon the type of CT apply a positive

pulse at P1 and a negative pulse at P2 (where P1 and

P2 are two ends of the coil). Connect a null

deflection galvanometer and observe the direction. It

should be towards the right hand side.

6. Measure winding resistance of CT secondary using a

multi meter in ohmmeter mode in case of protective CT

core to ensure that the CTsecondary is not open.

7. Check tightness of all bolts, clamps connecting terminals.

8. Check for earthing connections of CTis as per drawing.

1. Check nameplates and ensure CTs they are as per

drawings and specifications.

2. Check wether the CT secondary is wired correctly with

propergauge of conductor.

CHECK POTENTIAL PROBLEMS

Verification of vendor documents Incomplete documentation

Verification of General Arrangement &

Mechanical check

Cleaning

Wobbling of doors

Misalignment of pillars

Alignment of handle

• Appearance (Visual)

• Dimension

• Verticality & Waviness

Powder Coating:

• Surface Finish Glossy or Matt

• Paint Shade

• Dry Film Thickness

Orange peel effect, Bubbles, Dent Marks, Pinholes

Paint shade difference, low gloss

DFT low /high

Busbar Arrangement Busbar coupling not ok

Fishplate & harwdware missing

Busbar& Power Joints Tightness Loose joints, No red marking, Wrong H / Wsize

Pull test for crimping and termination and

visual inspection of wiring

Loose crimping

Wrong lug used

Loose termination

Poor wire bunching & dressing

Clearance Low clearance

Partition Provision (Form of Separation) Shroud not provided at Live terminal, Cover / Barrier missing

Degree of Protection (IP) Pinholes at door corners, control plate gasket not proper,

extra holes on pillars / end cover / doors

CT Polarity Wrong CT wiring, mixing of protection & metering CT wires,

neutral CT connection wrong

Current Injection (Primary / Secondary) Wrong wiring of trip circuit / protection circuit, wrong termination

at relays

Insulation Resistance (Megger) Low IR value

Dielectric Test (High Voltage) for Power &

Control Circuit

Presence of foreign material in Busbar zone, insulation puncture

Type TS PCC 37

SITE TESTING

PRE-ENERGISING

CHECKS

Type TS PCC 38

PRE-ENERGISING CHECKS:

Ensure the following checks are carried out before energizing:

Sr.No. Check Point OK

1 Overall Appearance & surface finish

2 Verticality of Panels

3 Room ventilation

4 Fire Extinguisher

5 Rubber mats of grade 1100 V

6 Loose supplied item fitted

7 Verification of BOM as per GA drawing

8 T ightness of busbar Joints

9 Wiring check as per scheme drawings

10 Phase sequence / Polarity check

11 CT & PT ratio check (on Sampling)

12 Insulation Resistance

13 High Voltage Test (Power Circuit)

14 High Voltage Test (Control Circuit)

15 All doors closed

Type TS PCC 39

COMMISSIONING

OFF ON

Type TS PCC 40

COMMISSIONING

be checked beforeGeneral parameters which must

commissioning the switchboard are :

• Control andIndication

• Remote Operation (if any)

• Electrical Interlocks (if any)

Congratulations!

Your switchboard has now been commissioned.

Type TS PCC 41

OPERATION

Type TS PCC 42

OPERATION

3. Pull the ACB out using pull-out handles.

ACB Interlocks:

• ON-OFF Button padlocking:

To prevent unauthorized access, ON / OFF buttons can be

padlocked orsealed, together or individually.

• Sealing the Release cover:

Protection setting for Release can be secured using a

standard lead seal.

• Safetyshutter padlocking:

Users can padlock top or bottom part of the Safety shutter

to secure access to Line and/or load side.

Padlocking both buttons

Seal ing Either/Both buttons

Lock ing any one button

Racking-out

1. For D/O ACB remove the Transportation Cushion (2

Nos.) & it’s instruction label, before doing racking

operation of the ACB.

2. Keeping OFF button pressed, open the Racking Shutter.

In case ACB is out of the panel or the panel door is

open, gently press Racking Interlock to defeat it. Rack-

out the ACB to Disconnected position.

Note: Once racking shutter is opened, the ACB can

not be closed, even by an electrical closing command.

Note: After removing the racking handle, the racking

shutter automatically recloses only in distinct

‘Connected’ / ‘Test’ and ‘Disconnected’ positions. Hence,

ACB cannot be closed in any Intermediate positions to

ensureUser safety.

Excessive, forceful Racking-out beyond Disconnected

position may lead to Product damage.

Remove Transportation Cushion

Remove Caution Flap

Take out the handle

Type TS PCC 43

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OPERATION

Racking Interlock defeat:

Tools required: None

Racking interlock prevents opening of racking shutter and

thus, racking in / out of the ACB when panel door is open.

If it is necessary to rack-out the ACB with panel door open,

racking interlock can be defeated. For opening racking

shutter with panel door open, gently push the racking

interlock lever in addition to keeping 'OFF' button pressed.

It is recommended to carry-out racking operation only

with panel door closed.

ACB Panel Indications

ACB panel has following indications on it –

• Green indicating lamp - Breaker ‘OFF’

• Red indicating lamp - Breaker ‘ON’

• Amber indicating lamp - ‘AUTOTRIP’

• Blue indicating lamp - ‘SPRING CHARGED’

• R, Y, B Phase indications.

ACB front facia indication –

• OFF /ON Indication.

• ‘Spring Charged’ indication with Yellow color and

discharge indication with black color.

• Racking shutter padlocking:

Tools required: Screw Driver (Tip width 3 mm)

To prevent inadvertent racking operation, racking shutter

can be padlocked, when ACB is in distinct Service, Test or

Isolated positions and racking shutter is closed. Upto 3

padlocks can be used at a time.

• Locking OFF button:

ACB can be locked in ‘OFF’ condition to prevent

unauthorized ‘ON’ operation. This feature is mainly used for

interlocking with other ACBs or electrical devices in an

electrical scheme.

Press the ‘OFF’ button and turn the key. When key is

removed, the ACB remains locked in OFF position. For

switching the ACB ‘ON’, reinsert the key & turn to release

OFFbutton.

• Door Interlock defeat:

Tools required: Philips Head Screw driver (Tip number 2) or

Screw driver (Tip width 6 mm)

If the ACB is equipped with Door interlock, panel door

cannot be opened when ACB is in Service condition.

If it is necessary to open the panel door with ACB in Service

condition, Door Interlock can be defeated as illustrated

herewith.

Opening panel door when ACB terminals are live,

may lead to electric shock and personal injury.

Figure 35 - Front facia of A C B

Type TS PCC 44

Type TS PCC 45

MAINTENANCE

Type TS PCC 46

MAINTENANCE

Figure 36 - Tightening of Busbar & Dropper Joint

PRECAUTIONS

1. Switch off the incoming power supply before removing

top plates and side covers. Isolate incoming power

supply.

2. For safety of personnel, while working on bus bars,

provide temporary earthing using a metallic chain/strip

near the work place. Remove this earthing only after the

job is completed.

3. Switch off the control supply. Isolate remote control

voltage sources.

4. Measure busbar voltage to ensure that bus bars are

de-energized.

5. Ensure that only qualified personnel are permitted to

use the defeat mechanism to gain access to an

energised compartment.

6. Do not attempt to withdraw the unit or disconnect any

terminations when the defeat mechanism has been

used to open a compartment door.

7. Current transformer primaries must not be energised

when secondaries are open circuited.

8. Short all CTsecondaries.

9. In case of shutdown on only one feeder, padlock the

power switch in OFFposition.

10. After maintenance, if TS is going to be de-energised for

a longer period, switch on the panel space heaters to

prevent moisture condensation on the cables/

insulators.

ROUTINE CHECKS

Carry out the following checks regularly:

1. Inspect all devices every two months to ensure that the

equipment is in properworking order.

2. Check tightness of bolted joints (mainly Busbar) Figure

36.

- prior toenergisation

- six months after load is connected

- one year after the second check and then once a year

Type TS PCC 47

MAINTENANCE

3. Inspect all wiring for wear and cuts every two months.

4. Clean and lubricate the stab-in contacts once a year

with HPMPL (EXXON)grease.

5. Remove burnt out fuses if any.

6. Check terminal block contacts for loose connections.

7. Examine indicating lamps and replace if required.

8. Ensure all safety interlocks are functional and in proper

working order every two months.

9. Look for indications of overheating, sparking or

insulation breakdown on the busbars.

10. Inspect all auxiliary and control circuits every two

months for desired functioning.

11. Grease racking screw and telescopic rails at least once a

year. Use grease 'HP-LETHON-2' or 'SYNTHOLUBE-20 of

HJ Leach & Co.

12. Ensure that the earth wires are connected to the main

earth bar (except electronic device earthing).

13. Ensure no tools or loose materials are left inside the TS

as these can cause faults.

14. Keep the switchboard free of dust. Use a vacuum

cleaner to remove the dust.

Do not operate equipment whose arc chutes are removed.

Overheating at terminals and joints can result in serious accidents including flashovers. Regulartemperature checks at termination using an 'Infrared Temperature scanner' will help to detect anyoverheating for timely preventive action.

If ACB is not being racked-out in a year, it is recommended to carry-out racking operation of the ACB as apart of routine maintenance.

ACB Maintenance:

Type TS PCC 48

Nature of

MaintenanceSchedule/Frequency Actions

Routine

Quarterly Temperature check at termination

Yearly

Open & Re-close the ACB

Rack-out & Rack-in the ACB

Inspect Arc Chutes for erosion

Inspect Contacts for erosion

1 Year or 500 operations (whichever

is earlier)Greasing of Operating Mechanism

Specific

When any Electrical accessory

needs replacementReplace the specific accessory

When ACB clears a major fault

Inspect Arc Chutes for erosion & replace,

if required

Inspect contacts for erosion & replace

Main Contacts, if required

In case of an abnormal external

event, such as flashover in panel

Inspect Jaw Contacts & replace, if required

Inspect Cradle Terminals and replace, if

required

On completion of Electrical life Replace all Arc Chutes

Replace all Main Contacts

MAINTENANCE

Figure 37 - ACB lifting truck

Figure 38 - Consealed hinge door

Removal of ACB:

1. Trip the ACB. Isolate all remote voltage sources.

Ensure that control circuit is de-energised.

2. Rack out the ACB to ISOLATED POSITION. Open the

compartment door. Pull out the ACB to maintenance

position page no. 33.

3. Position the ACB lifting truck in front of the ACB. Put the

lifting sling around the ACB lifting lugs figure 32.

4. Remove the nuts anchoring the ACB to the telescopic

rails and lift the ACB carefully by raising the lifting arm

of the ACB lifting truck.

5. Push the rails inside and close the compartment door.

6. After removal, the ACB should be stored properly. Keep

it covered with a polythene bag, free from dust.

7. While re-inserting the ACB, ensure that the ACB as well

as all downstream feeder switches/isolators are open.

Removal of doors

Type TS PCC 49

1. Isolate the feeder.

2. In fixed type module disconnect all wires terminating at

the equipment on the door.

3. Remove the bolts provided at the hinge figure 37 and

slideout the door.

TROUBLE

SHOOTING

Type TS PCC 50

TROUBLE SHOOTING

• Switch on control MCB / control fuse, ensure interlocks

are active and turn on the feeder.

• If control MCB / control fuse trips verify the field

terminations on the SIC.

• If the control MCB has not tripped but the breaker still

fails to operate, then check the helth of the control circuit

using a line tester.

• If the problem persists, check for component failure.

• After trouble-shooting ensure that the ACB is racked in to

serviceposition.

If the problem persist,contact your nearestsalesoffice

oremail your query to AtYourService@Intebg.com

On a live switchboard :

• Identify fault location using indicating lamps or

monitoring system.

• Reset the relay orMCB after the fault has been cleared.

• Check if breaker has been properly racked in to service

position.

• Check if respective MCBs are in ‘ON’ position.

• Check for availability of supply at the control MCB

connected to the auxiliary bus.

• If control fuse is used, check the health of the fuse.

Replace if necessary.

• Check the termination at shipping section terminals.

(These are terminals for terminating wires running

between panels)

• Check whether terminations from field connections are :

1. Correctly terminated

2. Tight

• Rack out the ACB to test position.

Periodical tightening of terminations as prescribed

in commissioning manual of the ACB should be

followed.

Type TS PCC 51

TROUBLE SHOOTING

Problem Probable Causes Our Suggestion

ACB does not close

on pressing "ON"

button

One or more arc-chute(s)

not secured properly

U / V release is present but

not energized

Mechanism spring is not

charged. Indicator is in

black background

Trip Reset link is

projecting out

Racking Shutter is open

"OFF" button is locked

Mechanical Interlock

disables closing

Press each arc chute

firmly by hand

Energize U / V release

Charge the mechanism

spring manually till a

distinct sound is heard

& indicator turns yellow

Press trip reset link to

reset position

Close Racking Shutter (Insert

Racking Handle once & pull back)

Unlock "OFF" button

Re - check before attempting

to close the ACB

Racking shutter does not

re-close automatically afterracking handle is pulled out

ACB is in-between

Service / Test / lsolated

position. Position

Indicator is not aligned

with any of the positions

Rack in or out the ACB to

any of the distinct positions

ACB cannot be pushed in to

Isolated position

ACB & Cradle ratings

do not match

Put correct ACB

Racking Shutter does not open "OFF" button not kept

pressed fully

Door open / missing; hence

Racking interlock is active

Position lock(s) active

Keep OFF button pressed

Close / provide door;

else press Racking interlock

lever (on extreme lower left side)

manually

Unlock

ACB does not close electrically Electrical antipumping

is active

Interrupt 'Close' command once

Difficulty in racking the ACB

in or out

ACB may not be properly

mounted on telescopic

rails

Withdraw ACB and check

mounting.

Type TS PCC 52

RECOMMENDATIONS

Problem Probable Causes Our Suggestion

Excessive pitting in the main

contacts

Arcing contacts may not

be fitted properly

Check adjustment of arcing

contacts with filler gauge

(>0.9 mm and <1mm).

Overheating of main contacts Arcing contacts may be

touching each other

Check adjustment of arcing

contacts with filler gauge

(>0.9 mm and <1mm).

Overheating of jaws and

terminals

Terminals may be

terminated loosely

Tighten terminations and

terminals periodically

ACB trips soon after closing The setting of overcurrent

release or relay may be

lower than the current

drawn by feeder.

Check the setting of overcurrent

release or relay

Type TS PCC 53

1. Provide a small cabinet in every switchgear room to store.

• Tools like screw drivers, fuse pulling handle, chassis

racking handles.

• All reference drawings like General Arrangement

Drawing, Scheme drawing.

• Consumable spares like bulbs, fuses.

2. Do not use rewired HRC fuses. It may cause an explosion

orarc, leading to a fire.

LIST OF FIGURES

Figure 1 - PCC panel 03

Figure 2 - Door Openview 03

Figure 3 - Double Deck arrangement of busbars 10

Figure 4 - Busbar Support 10

Figure 5 - Four linkssupport 10

Figure 6 - Two links support 10

Figure 7 - Auxbus Chamber 11

Figure 8 - Packing caseDetails 13

Figure 9 - Positioning of TUon truck 13

Figure 10 - Lifting angles 14

Figure 11 - Chain marks on packed TUs 14

Figure 12 - Typical arrangements 21

Figure 13 - Tools 22

Figure 14 - Panel Mounting on ISMC Base Channel / Base Frame 22

Figure 15 - Integral Base Frame 23

Figure 16 - ISMC BaseFrame 23

Figure 17 - Topplate 24

Figure 18 - Busbar joining 24

Figure 19 - Tightning of Busbar joints 24

Figure 20 - Auxbus joining 25

Figure 21 - PCC - PCC Earthbar Coupling 25

Figure 22 - PCC - MCC Earthbar Coupling 25

Figure 23 - Topplate 26

Figure 24 - Power Cable terminals 26

Figure 25 - Power cable terminals 26

Figure 26 - Power cable terminals bottom cable entry 26

Figure 27 - Top Busduct termination 27

Figure 28 - Bottom Busduct termination 27

Figure 29 - Control Cable terminals 28

Figure 30 - Interpanel Wiring 28

Figure 31 - Unpacked ACB 29

Figure 32 - ACB lifting truck 29

Figure 33 - Installation of Control Transformer 31

Figure 34 - Extension of Panel 32

Figure 35 - Front facia of ACB 44

Figure 36 - Tightening of Busbar & Dropper Joint 47

Figure 37 - ACB lifting truck 49

Figure 38 - Consealed hingedoor 49

Type TS PCC 54

LIST OF TABLES

Table1

Table2

Table3

- Technical Data 04

- Size of bolt Torquein m.kg 11

- Size of bolt Torque 24

NOTE

Type TS PCC 55

NOTE

Type TS PCC 56

NOTE

Type TS PCC 57

EM

I24

08

15

S

PT TAMCO INDONESIA (A LARSEN & TOUBRO Group Company)

F-36 , Jalan Jababeka Raya Jababeka Industrial Estate , Cikarang Utara Bekasi , 17530 , West Java , IndonesiaT +62 21 8935070 F +62 21 8935071

Email: SalesDept@Lntebg.com Website: www.LNTEBG.com© Electrical Systems & Equipment

Registered Office:L&T House, N. M. Marg Ballard EstateMumbai - 400 001, INDIA

Air Circuit Breaker Maintenance:

• Thorough cleaning of the ACB and its cradle

• Mechanical checks such as arcing contact gap, tightness

check, greasing all moving parts

Annual Maintenance Contracts (AMC):

• Electrical substation Maintenance (periodic maintenance

of entire low voltage range of switchgear)

Switchboard Maintenance:

• Erection, Testing and Commissioning

• Commissioning assistance

• Totalvisual check

• Checks- Closing coil, trip coil and auxiliary contacts etc

• Vacuum cleaning

• Tightness check for busbar joints and droppers

• Greasing of all moving parts

• IR(Insulation resistance) and high voltage test• Switchboard maintenance (periodic maintenance of Low

voltage switchboard)• Maintenance workshop

• Retrofitting of the necessary products

Services we offer:

MCC (TX)

Thank you for choosing L&T as your supplier of Low Voltage

Switchgear and giving us the opportunity to serve you.

Please read this manual carefully for proper installation,

safe, easy and efficient operation.

Only authorized and qualified personnel should be allowed

to work on the switchgear. An authorized and qualified

operator is a person having detailed information about

installation and commissioning of switchgear or specially

trained for the maintenance of the switchgear and fully

aware of the hazards caused by unsafe operation. An

operator should also have basic knowledge of First Aid.

The information herein is general for all specifications, part

of which may not be applicable for specific applications or

variants. Refer the following 'as built' documents for any

particular installation:

• Reference list of drawings (RLD)

• Single line drawings

• General Arrangement (GA)drawings

• Master bill of materials (MBOM)

• Scheme drawings

In case of any conflict between this manual and drawings

available with you, the drawings shall take precedence.

For additional information or clarification please send

your queries to AtYourService@Lntebg.com for quick

resolution.

All our switchgear undergo rigorous testing and qualitychecks at our factory. However, we recommend verificationand testing at site, especially after storage.

Following symbols have been used in this manual to indicate varying levels of danger:

Warning-Highly dangerous- can cause death or serious injury

Caution-Dangerous- cancause injuries or damage the switchgear.

Type TX MCC

CONTENTS

1 INTRODUCTION 1

2 CONSTRUCTION 2

• TECHNICAL DATA 5

• PANEL CONFIGURATIONS 8

• BUSBARS AND DROPPERS 10

• AUXILIARY BUSBARS 11

• TX COMPARTMENTS 12

• FEEDER DETAILS 13

• LOCATION OF POWER AND CONTROL CONTACTS IN VARIOUS POSITIONS 15

• Closed door operations 16

3 HANDLING & TRANSPORTATION 18

• RECEIVING 19

• HANDLING 19

4 STORAGE 22

5 GENERAL SAFETY 24

28

6 INSTALLATION 26

• TYPICAL ARRANGEMENTS 27

• TOOLS 28

• SITE PREPARATION

• ERECTION 28

• FLOOR PREPARATION & PANEL MOUNTING 28

• CONNECTION OF TRANSPORTUNITS & BUSBARS 30

• CONNECTION OF EARTHBARS 31

- MCC-MCC 31

- PCC-MCC 31

• POWER CABLE TERMINATION 32

Type TX MCC

CONTENTS

• TERMINATIONS OF POWER CABLES 33

• Interpanel wiring 39

• INSTALLATION OF LOOSE MATERIAL 39

- Metering and control devices 39

- Modules 40

- Control Transformers 40

• INSTALLING AN EXTENSION PANEL 41

7SITE TESTING 43

• TESTING SWITCHBOARDS 44

• TESTING CURRENTTRANSFORMERS 44

• TESTING POTENTIAL TRANSFORMERS 44

• TESTING METERS AND TRANSDUCERS 45

• TESTING RELAYS 45

• TESTING CONTROL CIRCUITS 45

8 PRE-ENERGIZING CHECKS 47

• COMMISSIONING 49

• OPERATION 51

• MAINTENANCE 55

- PRECAUTIONS 56

- ROUTINE CHECKS 56

- REMOVAL OF POWER CONTACTS 57

- REMOVAL OF DOORS 57

9TROUBLE SHOOTING 59

10 RECOMMENDATIONS 61

11 LIST OF FIGURES 62

12 LIST OF TABLES 63

Type TX MCC

Type TX MCC

INTRODUCTION

IMPORTANTNOTE

Only the Specific written Technical Instructions supplied by L&T must be used. Our products must only be commissioned,

operated, serviced, repaired or decommissioned in accounts with Technical Instructions which have been supplied by the

manufacturer. Non Compliance with this instruction may result in serious damage to the product and its associated items, as

well as health hazard ormortal danger.

WARRANTY

Ourproducts are subjected to factory inspection and testing according to the applicable standards and provisions.

The correct function and the service life of the switchgear are influenced greatly by compliance with the installation,

commissioning and operating conditions stipulated in this manual.

Non-compliance with these provisions may compromise warranty claims.

Any local provision which does not contradict the specifications of this document, especially as regards safety for personnel

and buildings, must be complied with.

L&T cannot be held liable for the possible consequences of:

• Non-compliance with the provisions contained in this manual, which refer to international regulations.

• Non-compliance with the instructions of the suppliers of cables and connecting accessories as regards application and

installation.

• Any aggressive climate conditions (humidity, pollution etc.) prevailing in the immediate environment of switchgear not

suitable to this effect ornot protected accordingly.

• This manual does not contain any instructions regarding the mechanical lock-outs to be performed. The work described is

performed on de-energized (on installation) ormechanically locked - out (decommissioned) switchgear.

Type TX MCC 1

CONSTRUCTION

Type TX MCC 2

CONSTRUCTION

Figure 1 - Floor mounted panel

• Motor Control Centre type TXis a free-standing and floor

mounting switchboard available in single front and back

to back versions. Suitable for indoor installation.

• Each vertical panel is divided into distinct zones for

busbars, feeders, power cabling and auxiliary busbars

Figure 2.

• The compartment houses modules for individual feeders

comprising equipment such as fuse switches, MCCB,

contactors, relays, timers and associated auxiliary

equipments.

• For optimum utilization of panel space, modules have

variable width and variable heights which is further

explained on Page No. 9.

• The structural members of the panel are closed profiled

providing higher strength against mechanical forces

generated.

Type TX MCC 3

CONSTRUCTION

Figure 2 - Different Compartments

160mm Quarter Width Module

160mm Half Width Module

320mm Half Width Module

320mm Full Width Module

Fractional width modules

Cam-Lock

Auxiliary busbar zone

Power Cabling Area

Type TX MCC 4

TECHNICAL DATA

L&T´s TX range of Low Voltage Motor Control Centers comply with IEC 61439-Part 1 & 2. It is designed to enhance safety of the users. Its modular construction facilitates logistics, installation, commissioning and maintenance.

Table No. 1

Designation Motor Control Center (MCC) Type TX

Standards and specifications

Power Switchgear and Controlgear (PSC) Assemblies

IEC 61439 - 2, BS EN 61439 - 2

Testing under conditions of arcing due internal faults

to IEC 61641

Insulation characteristics

Clearance > 20 mm

Creepage distances > 20 mm

Overvoltage category II / III / IV

Pollution degree 3

Field condition Inhomogeneous (non-uniform)

Electricalcharacte-ristics

Voltage ratings

Rated operational voltage (Ue) up to 690 V

Rated insulation voltage (Ui) 1000 V

Rated impulse withstand voltage (Uimp) 6 / 8 / 12 kV

Rated frquency (fn) 50 / 60 Hz

Type TX MCC 5

TECHNICAL DATA

Table No. 1

Electricalcharacte-ristics

Main Horizontal busbars:

Rated current (InA) up to 6300 A

Rated peak withstand current (Ipk) up to 220 kA

Rated short-time withstand current (Icw) up to 100 kA, 1s

up to 50 kA, 3s

Current ratings Vertical Distribution busbars for MCC:

Rated current (InA) up to 2000 A

Rated peak withstand current (Ipk) up to 220 kA

Rated short-time withstand current (Icw) up to 100 kA, 1s

up to 50 kA, 3s

Rated conditional short-circuit current (Icc) up to 80 kA

Permissible conditional short-circuit current up to 100 kA

Internal Arc fault conditions

Duration 500 ms

Acceptance Criteria as per IEC 61641 1 to 7

In accrodance with IEC 60529:

Mechanical characte-ristics

Degree of Protection

External IP 30 / IP 40 / IP 42 / IP 54

Internal IP 2X / IP XXB / IP 4X / IP XXD

Mechanical Impact as per IEC 62262 IK 08 / IK 09 / IK 10

Forms of as per IEC 61439 - 2 Form 1 to Form 4

Separationas per BS EN 61439 - 2 upto Form 4, Type 6

Height (mm) 2200, 2400

Dimensions Width (mm) 700, 900, 1000 (MCC)

Depth (mm) 600, 1000, 1100 (MCC)

Surface Treatment

Structure Alu-zinc / powder coated / painted

Internal Components Alu-zinc / powder coated / painted

External Components powder coated / painted

Resitance toDamp heat cycling test IEC 60068-2-30

CorrosionSalt mist test IEC 60068-2-11

Plastic components

Flame retardant, self-extinguishing, Halogen-free

IEC 60695-2-10, IEC 60695-2-11

Type TX MCC 6

TECHNICAL DATA

Table No. 2

Material

Aluminium

Panel

Version

Single Front (Side cable entry)

Single front (Rear cable entry)

Back to back

configuratio

n

Height (mm)

2400

s

Width (mm)

900 / 1000

700

900

Depth

(mm)

600 / 1000

1000

1100

Depth

including

doors (mm)

644 / 1044

1044

1144

Back to back 1000 1000 1044

Copper

Single Front (Side cable entry)

Single front (Rear cable entry)

Back to back

Back to back

2200 / 2400

900 / 1000

700

900

1000

600/ 1000

1000

1100

1000

644

1044

1144

1044

Type TX MCC 7

CONSTRUCTION

PANEL CONFIGURATIONS

*Dimensions do not includedoors

Cabling Area

*F Front Side

*R Rear Side

(All dimensions are in mm)

SINGLE FRONT SINGLE FRONT

900 1000

2200/2

400

*F

A

B C

D E

F

G

*F

A

B C

D E

F

G

SINGLE FRONT

900

*F

A

B C

D E

F

G

2200/2

400

2200/2

400

30

260

540

600

*F

30360

540

30

600

*F

1000

540

*F

260

SINGLE FRONT

10002200/2

400

*F

A

B C

D E

F

G

1000

540

*F

365 30

Type TX MCC 8

CONSTRUCTION

PANEL CONFIGURATIONS

Cabling Area

*F Front Side

*R Rear Side

640

305

30

1000

*F

1000

360

30

314

314

360

*F

*R

265

30

314

314

265

1100

*F

*R

BACK TO BACKSINGLE FRONT

1000700

*F

A

B C

D E

F

G

2200/2

400

*F

A

B

D E

F

G

2200/2

400

B A C K TO B A C K

900

*F

A

B C

D E

F

G

2200/2

400

(All dimensions are in mm)

*Dimensions do not include doors

Type TX MCC 9

CONSTRUCTION

Figure 5 - Dropper supports

Figure 5.1 - Fully enclosed droppers Figure 5.2 - Fully enclosed droppers (top view)

Figure 4 - Busbar Supports

BUSBARS AND DROPPERS

1. Bus-bars are arranged in a Double deck configuration

Figure 3. They are available in two different arrangements

depending on the rating / busbar material (Aluminum

or Copper), - Double deck non-interleaved (DDNIL)

arrangement – with phase sequence of B-Y-R-N-Double

deck interleaved (DDIL) arrangement with phase

sequence of B-Y-R-B-Y-R-N with 5 0 % neutral ( B-Y-R-B-Y-

R-N-Nin 100% neutral) Figure3.

2. Aluminum and Copper droppers are fixed by supports

and covered to form a fault free zone Figure 5, 5.1 & 5.2.

Figure 3 - Double Deck Arrangement of busbars

Type TX MCC10

Horizontal wireway

CONSTRUCTION

Shipping section terminals

Figure 6 - Aux bus chamber

Up to 12 Auxiliary busbars of 63 A rating can be provided. The Auxiliary busbars are mounted in Nylon Housing to provide

segregation and prevent accidental contact.

Table No. 3

* The above table is indicative and can be configured based on actual requirements.

Wire Way

Block Sr. No. Description

1 Space Heater - Ph

2 Space Heater - N

1 st 3 240 / 110 AC V Aux supply - Ph / Clean Earth Bus

block 4 240 / 110 AC V Aux supply - N

5 110 V DC Aux Bus supply - +ve

6 110 V DC Aux Bus supply - -ve

7 Annunciation Test Bus

8 Annunciation Accept Bus

2 nd 9 Annunciation Reset Bus

block 10 Annunciation Alarm Bus

11 Clean Earth Bus

12 Configurable

AUXILIARY BUSBARS

Type TX MCC11

Auxiliary busbars are located in the top front chamber of the

panel and segregated from main busbars by a metallic

partition.

In back-to-back TX’s, auxiliary busbars are placed in one of

the fronts and tap-offs are taken for the units in both the

fronts.

A horizontal wireway is provided immediately below the

auxiliary busbar for interpanel wiring. Shipping section

terminals are mounted in the horizontal wireway if required.

Figure 6.

TX COMPARTMENTS

The modules are fully interchangeable with optional rating

error preventers. Modules can be replaced quickly, reducing

maintenance downtime.

The modules in TXcome in two broad categories.

a. Fractional Width

b. Full width

Q Q Q Q

H H

F

2Q 2 Q 2Q 2Q

2H 2H

2F

Flexibility of MCC Modules

CONSTRUCTION

1H

Figure 9 - 1 Half(160 mm height)

2H

Figure 10 - 2 Half320 mm height)

2F

Figure 12 - 2 Full (320 mm height)

3F

Figure 13 - 3 Full (480 mm height)

1Q

Figure 7 - 1 Quater(160 mm height)

2Q

Figure 8 - 2 Quater(320 mm height)

1F

Figure 11 - 1 Full (160 mm height)

Type TX MCC12

CONSTRUCTION

Figure 14 - Full width power switch padlocking

Figure 16 - Fractional module padlocking

Figure 15 - Full width module padlocking

FEEDER DETAILS

1. All operations of the Feeder (Module) are possible in

closed door condition. The module can be drawn out

from Service to Isolated position without opening the

compartment door.

2. The feeders are mounted on guiding rails which are

specially designed to provide positive guidance and

smooth movement of the unit.

3. Padlocking facility for power switches is available in

'ON' and 'OFF' positions Figure 14.

4. Module padlocking facility is available in Service, Test and

Isolated position Figure 15 & 16.

Figure 18 - Safety shutter

Figure 17 - Door defeat interlock

Figure 19 - Earthing for full width module

5. Interlocks are provided for safe operation. Module

cannot be racked IN / OUT if the power switch is in ON

condition. Module door cannot be opened in Service

and Test position. However, interlock defeat facility is

available which should be used judiciously Figure 17.

Type TX MCC13

6. Safety shutters are provided for total separation from

live busbar when Module is not inserted in the panel

Figure 18.

7. The 'make first, break last' type scraping earth system is

provided on all draw out units. For full width module,

scrapping earth contact is provided on left side of the

module. Counter part of the scrapping earth is mounted

on vertical connection of the main earthbar Figure 19.

CONSTRUCTION

Figure 20 - Earthing for fractional module module

8. For the Fractional Modules, earthing is achieved through

the fixed contact as highlighted in Figure 20 which is

connected to the copper strip running at the bottom of

the tray connecting to vertical earthbar.

9. Incoming, outgoing contacts have ratings of 63A, 135A,

250A, 400A, 630A. The incoming power contacts are

located on the LHS while the outgoing power contacts

are located on RHS in the Full width module and bottom

and top respectively in Fractional width module Figure 21

Figure 21 - Power contacts (Full Module)

Power contacts

Figure 21 - Power contacts (Quarter Module)

PowerContacts

10. Ammeters, indicating lamps, control switches and push

buttons are mounted on a control plate, fitted on the

unit.This can be hinged out for access to their rear

terminals and to the equipment behind it by re mo v i ng

screw shown in Figure 22.

Figure 22 - Control plate

Position

indicator

11. The starter unit in the fully draw-out version has

following positions:

a) Service (connected) position.

b) Testposition

c) Isolatedposition

Position indicator visible from the outside is provided at

the bottom of the module.

12. The control contacts, i.e. the Secondary Isolating

Contacts (SICs) are mounted in 2 columns in the full

width module. Both columns can have the following

varieties of SICs Figure 23.

• Service + Test SICs (which make contact in Service

and Test positions)

• TestSICs (which make contact in Test position only)

• Service SICs (which make contact in Service position

only).

Figure 23 - SICs in a full width module

Type TX MCC14

POSITION OF THE MODULE

POWER CONTACTS

CONTROL CONTACTS

SERVICE CONNECTED CONNECTED

TEST DISCONNECTED CONNECTED

ISOLATED DISCONNECTED DISCONNECTED

Figure 24 - SICs in a fractional module

State of SICs in various positions:

13. SIC Mounting in Fractional modules Figure 24.

a. Test SICs are not provided in Quarter width modules.

b. All SICs are mounted on the rear Side of the module.

c. Only one SIC block is provided in a quarter width

module and two blocks in a half width module.

SIC's in Fractional Module

CONSTRUCTION

Table No. 4

LOCATION OF POWER AND CONTROL CONTACTS IN VARIOUS POSITIONS

Figure 27 - Isolated position

Figure 26 - Test position

Control contacts

Power contacts

Figure 25 - Service position

Type TX MCC15

CONSTRUCTION

Comparison of TERA with IEC

Method of ConnectionService Position

Withdrawable Contacts

Closed door operations

Removed Position

Isolated Position

Test Position

Position

Incoming Main Circuit

Circuit

Withdrawable Contacts

Incoming Main Circuit

Withdrawable Contacts

Auxiliary Circuit

Condition of circuits within withdrawable parts Live Live

Dead if no backfeed is present

Condition of outgoing Assembly terminals of Main terminals

Live Dead

Dead if no Dead if no backfeed backfeed is present is present

IEC

61439

oror

Method of ConnectionService Position

Withdrawable Contacts

Removed Position

Isolated Position

Test Position

Position

Incoming Main Circuit

Circuit

Withdrawable Contacts

Incoming Main Circuit

Withdrawable Contacts

Auxiliary Circuit

Condition of circuits within withdrawable parts Live Live

Dead if no backfeed is present

Condition of outgoing Assembly terminals of Main terminals

Live Dead

Dead if no Dead if no backfeed backfeed is present is present

T-

ER

A

Connected Open but not necessarily disconnected (isolated)

Isolated

Type TX MCC16

17

HANDLING AND

TRANSPORTATION

Type TX MCC18

RECEIPT AND HANDLING

Figure 28 - Packing case Details

Receiving:

Onreceipt of the MCCs at site:

• Verify the following details on packing case (Fig. 28) :

• Item no.:

• Description of material:

• Package No.:

• Gross weight:

• Netweight:

• Dimensions:

• Volumes:

• Storage of goods:

• Special instruction:

• Verify the quantity of TUs & loose material as per the

packing list.

• If the packing case is damaged, open the case and

inspect the MCCs. Report any damage or loss of

components to the transport/carrier and lodge a claim

with the insurance agency or inform your nearest L&T

office.

Handling:

TUs can be hadled either either by fork-lift or overhead

cranes in an upright position depending on where they have

to be placed. Care should be taken to see that the TUs don’t

topple during transportation.

• Avoid tilting of TUs(Panels).

• While transporting the panel using a forklift, ensure that

the distance between the legs of the forklift and ground

is at least 12 cm.

• Limit the speed of the forklift to 10 kmph.

• Use both legs of the forklift.

If switchgear are to be installed at higher elevations, shift

them from the unloading spot through the opening

planned in the building for this purpose. This should be

done with all safety precautions and strict supervision by

trained personnel.

Figure 29 - Positioning of TU on truck

Type TX MCC19

RECEIPT AND HANDLING

o o

oo

o o

oo

In case of handling by lifting crane,

• Suspend ropes from the hook and pass them under the

wooden pallet at the bottom of the TU.

• Centre of gravity indicators and chain marks are provided

on the TUas shown in Figure 31.

• Use PP (Poly-propylene) ropes of minimum 1" diameter

for this purpose. Choose the diameter of the rope

according to the weight of the TU which is mentioned in

your GA drawing.

• Verify that the route from the unloading spot to the

erection spot has free access.

• Unload the TUsafter reaching the unloading spot.

Figure 30 - Lifting Angle

While unloading a TU, ensure that the remainingTUs are placed securely on the truck and are notin danger of toppling over.

If rollers are used for placing the sections on the foundation,

retain the base plank to avoid damage to the base frame.

Ensure that:

• The load of the TU is equally distributed by using all the

lifting angle holes.

• The sling of the crane is in good condition.

• The TU does not tilt or topple during transit.

Figure 31 - Chain marks on packed Tus

We recommend handling and shifting panels in packed conditiononly.

DO NOT MOVE THE PANEL BY INSERTING A CROWBAR BELOW THE BASE FRAME. This maycause damage to the base frame.

• In case the TU is unpacked before reaching the site, use

the lifting channel provided at the top of the panel for

easy transportation Figure 29 & Figure 30.

Type TX MCC20

RECEIPT AND HANDLING

Tofacilitate transportation and handling, the Motor Control

Centre (MCC) TX is split into multiple sections/

transport units (TUs).Each section is wrapped with a HDPE

(High Density Polyethylene) cover and packed in a wooden

case. To arrive at the approximate overall dimensions of the

packing cases, add 300 mm to the dimensions of the

respective section.

List of equipments and special tools for site erectionand assembly

• Crane and truck for equipment shifting.

• Slings and ropes - As per requirement.

• Rolling pipes - 10 Nos.

• Channels - 10 m.

• Crowbars - 4 Nos.

• Welding machines - 1 No.

• Spanner sets - 1 Set.

(Ring & Open spanner size 13mm, 17mm, 19mm, and

24mm. Box orpipe spanner 13mm.)

For safe handling lifting angle (θ) should be greater than 45° Figure 29 & Figure 30.

Type TX MCC21

STORAGE

Type TX MCC22

STORAGE

If the MCC is to be commissioned at a later date, the

following precautions should be taken.

• OUTDOOR STORAGE SHOULD BE AVOIDED. Store all

cases indoors, in a clean, dry and well ventilated place

where seepage of water and condensation does not

occur.

• Maintain a minimum temperature of - 5 C and humidit y

of less than 50%.

• If civil construction is being carried out in the vicinity,

ensure that the MCC is completely protected from debris

and dust.

• Keep proper tags/markings on the panels for easy

traceability.

• Unpacking of the TUs at site is preferable. In case it

becomes necessary to unpack the TUs during storage,

make sure that packing of all the internal components

e.g. covers on the relays and meters mounted on the door

etc. remain intact (Highlighted in the figure below). Also

inspect the MCC for scratches, if any. Please use paint

supplied with the loose materials to touch up scratch

marks, if any.

The switchboard should be stored indoors withproper ventilation. Moist/ corrosiveenvironments may affect the metallic parts andcause their insulation to deteriorate.

Type TX MCC23

GENERAL SAFETY

Type TX MCC24

GENERAL SAFETY

While shifting the panel from storage point to erection site:

• Use a lifting crane to load the panel on to the truck.

Ensure that TUs are placed in a vertical position on the

truck.

• Tie the TUsproperly to prevent unwanted movement.

• Refer the previous section for TU handling instructions.

Page No.1.

• Personnel handling the equipment must be skilled and

authorised to handle the intended voltage level.

• All working personnel must be aware of safety

practices.

• Safety shoes should be worn so as to avoid the risk of

any electric shock while at work.

• Gloves and goggles should be used while working in the

proximity of hot and hazardous materials to avoid bodily

injury.

• Appropriate tools and instruments should be used as

stated on page no. 21 for precise workmanship.

• Suitable Caution labels and sign boards should be

erected at the time of installation and testing of boards

as a mark of caution.

Type TX MCC25

INSTALLATION

Type TX MCC26

INSTALLATION

Typical arrangements

644 mm

Type TX MCC27

22

00

mm

Motor Control Centre

Figure 32 - Typical arrangements

INSTALLATION

TOOLS

• Torquewrench

• BushRatchet

• Hydraulic jack

• Rubber mallet

• Clamps

SITE PREPARATION

1. The installation site must be clean and the surface even.

Use shims if the floor is uneven. An uneven foundation

may cause misalignment of sections, bus-bars and

hinged doors of the unit.

2. Walls and ceilings must be plastered with painting

completed.

3. Doorsand windows must be installed.

4. Openings in the floor, wall and ceiling for cables,

conductor pipes, bars and ventilation must be in

accordance with the construction drawings provided.

5. Supporting brackets, beams, enclosures and foundation

frames must be assembled and painted.

6. lf necessary, braces appropriate to the basic

dimensions of the switchgear installation with cross

struts corresponding to the panels must be assembled.

Figure 33 - Tools

Suitable indoor conditions must be maintainedand necessary emergency exits must be providedin the switchgear room.

Excessive temperature fluctuations and highhumidity should be prevented.

Condensation should be prevented.

If the plant´s atmosphere is likely to containexcessive steam or reactive gases comprisingsulphur or chlorine, ensure that the Switchboardis placed in a separate pressurized room.

ERECTION

1. After TUs have reached the installation site, unpack the

TUs and move the packing material to its allocated

area.

2. Check if all components are in place as per your

drawings (MBOM) and the packing list.

3. Vertical sections should be shifted sequentially into the

installation site for ease of installation.

4. The TUs must be carried in an upright position to avoid

the risk of toppling. Refer the section Floor preparation &panel mounting.

5. Place the first TU over the base channel frames erected in

the floor concrete by the civil contractor. Check

correctness of leveling (± 1 mm tolerance per meter is

allowed) and alignment of panels & proceed as per

General Arrangement (GA) Drawings.

6. Maintain clearances as mentioned in GA drawings.

Provide sufficient space on all sides of the panel for

personnel to work conveniently.

FLOOR PREPARATION AND PANEL MOUNTING

Panel can be mounted on the floor either by bolting or tack-

welding with the ISMC Base Channel / Base Frame.

The panel is provided with integral 50 mm base Frame made

of 3mm sheet metal.

Follow the steps listed below to mount the panel.

• Grout / weld the ISMC Base Channel / Base Frame on the

inserts in the floor. Make sure that it is perfectly leveled.

• Place the panel on to the ISMC Base Channel / Base

Frame.

• Refer Figure 34 for placing the panel on to the ISMC Base

channel / Base frame

• Tack-weld or bolt the panel with the ISMC Base

Channel / Base Frame.

• When bolting the panel, drill the required holes in the

ISMC Base Channel / Base Frame, so that it matches with

the holes provided in the integral base Frame.

Panel 1

Figure - 34

Panel 2 Panel 3

ISMC Base Channel/Base

Type TX MCC28

INSTALLATION

FRONT

Foundation holes

Figure 35

• To access the foundation holes given on the integral

base Frame, open the front & rear doors and remove

the gland plate.

• Bolt or tack-weld the panel to the ISMC Base Channel /

Base Frame.

Figure 36 - ISMC Base Frame

Ensure that the board is properly aligned while

bolting / tack-welding.

Please ask for project specific drawings if you arebolting the panel to an ISMC base channel/frame. Ifyou decide tp tack-weld the panels to the basechannels/frames, such drawings are not requiredFigure 35.

A typical drawing for the ISMC base Frame with the holes

punched is shown below along with the coupling of the

integral base frame to the ISMC Frame: Figure 36.

Coupling of ISMC Frame to the integral

Integral Base Frame

ISMC Base Frame

Type TX MCC29

INSTALLATION

CONNECTION OF TRANSPORT UNITS AND BUSBARS

1. For access to the horizontal busbars, remove top plates

and hoods (if provided) by removing all the bolts

provided on the top Figure 37.

2. Remove the fish plates provided on the right side of the

busbar to connect it with subsequent TUs placed

sequentially.

3. Clean the fishplates with a wire brush. Wipe them with

a soft, dry cloth and then immediately apply contact

grease on them. Hindustan Petroleum, MPL (EXXON)/

Petroleum Jelly J. P. grade contact grease or equivalent

is recommended.

4. Bolt adjacent TUs together - holes are provided in the

gasketted side pillar. This should be done before joining

the busbars.

5. Join horizontal bus bars using the fishplates as shown in

Figure 38.

Figure 38 - Top plate

Figure 37 - Top plate

Ensure bus bars are properly aligned so that there

is no strain on any of the support insulators.

6. Tighten all electrical connections with a torque wrench

to the torque values as mentioned in table no. 5 Figure

39.

Figure 39 - Tightening of Busbar joints

Size of bolt Torque in m.kg

Table No. 5

Thread

(Boltsize)

Kgf

m

Nm

Socke

t No.

(mm)

Normal Bolt

(Grade:4.8)

High Tensile

Norm

al Bolt Bolt

(Grade: 8.8) (Grade: 4.8)

HighTensile

Bolt

(Grade:8.8)

M6 0.38 1.05 3.7 10.29 11/10

M8 0.85 2.5 8.3 24.51 13/12

M10 1.88 4.7 18.8 46.09 17/16

M12 3.2 6.5 31.38 63.74 19/18

For aluminum bus bar system normal torque to be applied even if the bolt is HT. HT torque values are applicable

only for hole less bus bar joints.

Type TX MCC30

INSTALLATION

Figure 41 - MCC - MCC Earthbar Coupling

7. Join the auxiliary busbars by joining the auxbus fish plate

provided for the same in the left side TU Figure 40.

CONNECTION OF EARTHBARS

MCC-MCC

1. For single front panels, open the rear door of the panel to

access the horizontal earthbar.

2. In case of a back to back arrangement, open the cable

alley to access horizontal earthbar.

3. Remove the fishplate provided on left hand side TU to

connect it with subsequent TUsplaced sequentially.

4. Join the earth bars using the fishplate provided and check

correctness.

5. Tighten the connection with a torque wrench to the

torque values as mentioned in Table no. 5.

PCC-MCC

1. Open the rear door of the PCC.

2. Remove the fishplate provided at the end of horizontal

earthbar at the bottom.

3. Join the earthbar of PCC with the already extended MCC

earthbar using the fishplate.

4. Tighten the connection with a torque wrench to the

torque values as mentioned in Table No.5.

Figure 42 - PCC - MCC Earthbar Coupling

PCC HORIZONTAL EARTHBAR

MCC HORIZONTAL EARTHBAR

Figure 40 - Auxbus joining

Type TX MCC31

INSTALLATION

POWER CABLE TERMINATION

Power cable routing & dressing in cable alley chamber:

• Step 1: Branch out the cables (in case of multicore cables)

just after the gland plate at the bottom (in case of bottom

cable entry)

This will ease the flexibility required for fool-proof

termination

• Step 2 : By approximation, estimate the length of the

cable required to terminate the cable with required

bending radius (approx. 12 times the outer radius of the

cable as shown in Detail B, C, D)

• Step 3 : Take the branched out cables to the respective

feeder through the side walls of the cable alley as shown

in figure 44.

• Step 4 : Make the required curvature depending on the

type adaptor used for the feeder. Refer Termination of

Power Cables section.

• Step 5 : Adequately tie the cables with cable ties in the

cable bracket provided on the sides of the cable alley

Lug termination at the power terminal to be done only

after cable routing & dressing.

• Step 6 : *Using appropriate hardware and lug & with the

required torque value, tighten the cables to the respective

terminals, Refer table no. 6 (ensure the cable's stress /

weight is not transferred to the terminals).

*Hardware selection should be according to the

specification of Lug manufacturer/ supplier.

Figure 43 - Rear Cable Entry (Side View). Cables branching out though the side walls of cable alley.

Datail F

Datail G

Datail H

Cables to be tied to the cable bracket on the side walls of cable alley

Figure 44 - Side Cable Entry (Front View) Cables tied to cable bracket present on the sides of cable alley

All cables to be tied to cable bracket present on the sides of cable alley

Detail A

Detail B

Detail C

Detail D

Detail E

Ensure no cables are free hanging.

All cable wires should be supported appropriately and rigidly on the cable brackets.

Ensure cables are at a safe distance (min 50 mm)from liveparts.

Ensure bus bars are properly aligned so that thereis no strain on any of the support insulators.

Use of copper wires/cables is recommended forcontrol circuitspurposes.

Oblong holes are provided for Aluminiumfishplate joints. Extra drilling on the bus-bars/fishplates should be avoided.

Type TX MCC32

INSTALLATION

TERMINATIONS OF POWER CABLES

Power cables routed from cable chamber are connected to

feeder’s power contacts through lugs. Below instruction are

for all types of cable entries and terminations.

• Cable routing method to be followed in all the cases

• Cable clamp brackets are fixed at the same level as their

respective feeder so as to hold the cables rigidly.

• According to side and top cable entry and link

arrangement, chose one from below options and follow

the steps.

There are 2 types of lug termination in TX .This is based of

the rating of the feeder and cable size (No of runs of

cable/phase and Sq.mm of cable). The following are the

types

1. Direct termination - Lug is directly terminated on the

outgoing power contacts of the feeder.

2. Adaptor Termiantion - Adaptors are provided on the

power terminals and lug termination is done on the

adaptors

1. Direct Termination

There 4 types of direct cable termination SCE and 1 in RCE.

Side Cable Entry (Top/Bottom)

1. 400A contact direct termination -Refer Detail C

No. of runs of power cable possible per phase :2 (front &

back)

*M12 bolt to be used for lug termination

## The contacts encircled must not be tilted / misaligned /

stressed due to cable weight after termination.

2. 250A contact direct termination -Refer Detail C No. of

runs of power cable possible per phase :1 (front only)

*M12 bolt to be used for lug termination

3. 135A contact direct termination -Refer Detail D

No. of runs of power cable possible per phase: 2 (front &

back)

*M6 bolt- lug termination -without extension link

*M8 bolt- lug termination -with extension link

4. 135A contact direct termination - Refer Detail E & ETop

View

No. of runs of power cable possible per phase: 2 (front &

back)

*M8 bolt to be used for lug termination

Detail C

Phase Barrier

LUG Termination in front and back ofPower terminal (2/Phase)- only for 400A

LUG Termination infront only (1/Phase)for 250A

## CONTACT ALIGNMENT

Detail D

Contact alignment#

LUG Termination without extension link

Phase Barrier

LUG Termination with extension link

Detail E

Phase Barrier

Contact alignment#

Detail E - Top View

LUGTermination

Type TX MCC33

INSTALLATION

2. Adaptor Termination

Side Cable Entry (Top/Bottom)

1. Refer Detail A

No. of runs of power cable possible per phase: 3

*M12 bolt to be used for lug termination

2. Refer Detail B

No. of runs of power cable possible per phase: 2

*M12 bolt to be used for lug termination

Detail H

Rear Cable Entry

5. Refer detail H

No. of runs of power cable possible per phase: 2

*M12 bolt to be used for lug termination

LUG Termination

Phase Barrier

Detail A

LUGTermination

LUG Termination in front and back

Detail B

Rear Cable Entry (Top/ Bottom)

3. No. of runs of power cable possible per Phase: 3

*M12 bolt to be used for lug termination

Refer Detail F

Detail F

LUGTermination

Phase Barrier

Detail G

4. No. of runs of power cable possible per phase:2

M12 bolt to be used for lug termination

Refer Detail G

LUG Termination

Phase Barrier

Type TX MCC34

INSTALLATION

SIC CABLE TERMINATION

1. All cables to be unprepared (lugless) -strip length 12mm±

1mm (Caution: termination with lug will either cause

damage to terminals or loose terminations)

2. Cable termination capacity: 1:1.5 sq.mm / 1:2.5 sq.mm

only per terminal

3. For operating the SIC terminal for termination only L&T

supplied tool to be used (Caution: any other tool will

cause damage to the SIC contacts)

4. Ensure the cable is dressed with cable ties and the stress

of the cable doesn't affect the SICs free movement

Pictorial Representation of procedure to be followed for termination of control wires on SIC. The same sticker is applied inside your switchgear assembly as well.

PROCEDURE TO BE FOLLOWED FOR FIELD CONTROL WIRES TERMINATION ON SIC

Ter No: 10 Ter No: 20 • The SIC which is mounted on the cable alley is suitable forLUG LESS TERMINATION

• SPECIAL TOOL to be used for SIC TERMINATION• The tool will be supplied as a loose item in a separate box

CAUTION along with each switchboard

SPECIAL TOOL

Ter No: 11

Ter No: 1

STEP 1

a)Wire to be stripped using wire stripper up to 12+1 mm

12+1 mm

b)The wire must be multi

stranded

c)Do not use wire cutter for stripping the wires

STEP 2

All wires strands to be twisted together

STEP 3

a)Special tool to be inserted in the respective SIC terminal (as shown in photo) cavity

and press it.

b)Wire to be inserted on therespective SIC terminal as per

scheme

STEP 4

a)Remove the SIC special tool from SIC

b)Following self check to

be performed after the termination.

(i) Termination strength

(ii) No strands out

Type TX MCC35

INSTALLATION

Figure 45 - Control Cable terminals

Tightening torque values have been provided in Table No.5

on page No. 30.

Follow the following steps for removal of SICs for re-wiring / replacement:

1. Female SIC

Step 1 : Take the corresponding feeder to isolate position.

When the feeder is in isolated position, male SICs

gets disengaged from female SIC.

Step 2 : Open the cable alley door, without disturbing any

other feeder or Power cable termination follow

the below steps

Step 3 : Remove the SIC covers (1).

Step 4 : Unscrew the bottom SIC screws (7 & 8)

Step 5 : Unscrew the bottom SIC bracket's (2) hardwares

(4, 5, & 6)

Step 6 : Unscrew the female SICs (3) top screws

Step 7 : Plug out all the terminals &Remove the female SICs

(3)

2. MALE SIC

Step 1 : Takethe feeder out of the boards

Step 2 : Place it on a table

Step 3 : With the mechanism racking handle, take the

feeder to serviceposition (Ref fig 2.2)

Step 4 : Unscrew (10) the male SIC (9) (Ref fig 2.3)

Step 5 : Plug out all the terminals and take the SIC out

Follow the following steps for fixing SICs:

Detail A - Female SIC Removal

1

45

6

7

3

2

8

Type TX MCC36

INSTALLATION

Male SIC Fixing in Module

10

9

MALE SIC FIXING

Step 1 : Takethe feeder out of the boards.

Step 2 : Place it on a table.

Step 3 : With the mechanism racking handle, take the

feeder to serviceposition (Ref fig 2.2).

Step 4 : Mount the male SIC (ensure terminal numbering

(1- 20) matches with female SIC) outside the slot of

SIC holder as shown in detail f.

Step 5 : Fix the SIC using hardwares (9)& (10).

FEMALE SIC FIXING

Step 1 : Fix the top SIC bracket (8) alone using hardwares

(4), (5)& (6).

Step 2 : Take the female SIC (3), (ensure terminal

numbering (1-20) matches with male SIC) and fix

the bracket between the slot as shown in detail g.

Step 4 : Fix female SIC using harwares (7) & (8).

Step 3 : Fix the bottom SIC bracket (8).

Step 4 : Terminate all the cables on the SIC as per scheme.

Step 5 : Carry out SIC alignment (refer SIC alignment sop).

Step 6 : Replace the SIC covers (1).

Follow the following steps for SIC Alignment:

Step 1 : Remove the SIC covers and loosen the bracket

hardwares - 4 nos of screws.

(caution :do not remove the hardware)

Step 2 : Take the corresponding feeder to test state slowly.

(caution : operate the racking handle slowly & do

not damage the SIC pins)

Step 3 : Lift up the bottom SIC bracket and align both male

and female SIC. (caution : continue to hold the

bracket from bottom)

Step 4 : Tigheten the hardware by continuing to hold the

SIC bracket from bottom.

Step 5 : The SICs are aligned. Operate the module from

isolate to test & then to service.

Step 6 : For any issues, refer SIC trouble shooting page 38.

Detail C - Female SIC Removal

Detail D

See detail D

SIC tool supplied by L&T

Cable termination circular slots

Tool insertion square slots

Lift up the botom bracket along with SIC

Type TX MCC37

INSTALLATION

SIC TROUBLE SHOOTING

Type TX MCC38

S.No. PROBLEM POSSIBLE CAUSE ACTION

1 FEEDER is not racking from ISOLATE (I) position to TEST (T) position in door closed condition

The handle is not inserted properly

The Racking mechanism is not working

The female SIC holding bracket in cable aley is bent / deformed

Cable stress on the female SIC / or on SIC Cover due to routing near sides of female SIC

The SIC alignment is not correct

The Male SIC is damaged

Insert the handle, press it and Turn the handle Clock-wise. Refer Page 53 for details

Racking mechanism need to be fixed

Replace the bracket if they are deformed, Repeat SIC alignment

Re-route the cabling near the Female SIC.

Ensure cable ties don't obstruct SIC free movement

Repeat SIC Alignment procedure

Replace Male SIC. Do SIC alignment

2 FEEDER is not racking from TEST (T) position to SERVICE(S) position

The Racking mechanism is not working

The O/G contact fixing support is loose

The O/G Contacts are misaligned / damaged

Racking mechanism need to be fixed

Check the tightness of the O/G Contact fixing support

Check Power cable termination instruction

3 FEEDER status indication Lamp not working

No control supply available

The male SIC is damaged

Loose termination

Indication lamp burn-out

Check control supply

Replace Male SIC. Repeat SIC aliment

Re-check termination. Refer SIC termination procedure

Replace indication lamp

4 Loose termination of SIC SIC termination tool not used

Lugs on cables are used for termination

SIC block damaged

Use the SIC special tool for termination

Use only bare condctor stripped to 12mm length for termination

Replace damaged SIC. Repeat SIC alignment

Table No. 6

INSTALLATION

Interpanel wiring

1. Wiring is through the horizontal wire-way at the top

along the auxiliary bus.

2. For wiring, separate terminals are provided in the left

hand side of the right most TU which are named XS-YY

(X - terminal no. and YY - panel no. (01,02,03 etc.)). The

wire bunch to be connected to these terminals is in the

left-hand side transport unit. The wires have ferrules with

the terminal no. and should be connected their respective

terminals. The no. of terminals and no. of wires to be

connected are equal.

For example, consider the panels and transport units shown

in the sketch. The transport unit (TU) consists of panel 1F

and 2F, while TU-2 consists of panel 3F and 4F. The terminals

named 1,2,3... -XS03 are mounted in panel 3F as shown in

the figure. The mounted terminals are connected to their

respective equipment in panels 3F and 4F. The wires going

from TU-1 to TU-2 are bunched and kept with panel 2F. The

wire which is to be connected to terminal 1 of panel 3F will

have a ferrule marked 1XS03 at the end of it and will be kept

in 2F.

Figure 46 - Interpanel Wiring

T.U.-1 T.U.-2

1F 2F 3F

Terminals names 1,2,3...XS03

Wire bunch to be connected having corresponding ferrules marked 1,2,3...XS03

4F

Horizontal wirewayShipping section terminals

INSTALLATION OF LOOSE MATERIAL

Metering and control devices:

1. Unpack the metering and control devices (like meters and

relays) if they were sent as separate packages.

2. Position the device in the apt cut-out or base plate

provided.

3. Wire them as per the scheme drawing provided.

4. Refer product inserts for further details about thedevice.

5. Carry out the settings of magnitude and time delay (if

any) for the installed protective and control devices as

shown in scheme drawing and MBOM (Master Bill of

Materials).

6. Place the terminal covers properly to adhere to stated

ingressprotection (IP) level.

7. Check alignment of operating handles for all switches.

8. While dispatching the switchboard, secondaries of all

current transformers are shorted. Remove these shorting

cables while connecting relays/meters and store them

separately Figure 48.

Figure 47 - Relay Mounting on Panel

9. Ensure again that all doors are closed and no connection

is left loose.

Type TX MCC39

Modules

1. Modules are not bolted inside the panel.

2. Open the compartment door.

3. Takethe module out. Refer Page No.38 & 39

4. Remove the padding provided (for transit) at the sides of

the module.

5. Insert the module inside the panel and bring it to

service position.

Control Transformers

1. Unpack the Control Transformer.

2. Open the compartment door in which the Control

Transformer is to be installed.

3. Bolt the Control Transformer to the base plate Figure 49.

4. Terminate the primary and secondary wires of the

transformer on the respective terminals.

INSTALLATION

Figure 48 - Control Transformer Mounting on Panel

Figure 49 - Installation of Control Transformer

5. The primary wire has a ferrule with capital letters while

that of the secondary is with unicase Figure 50.

Type TX MCC40

6. Check the connections and tighten the bolt.

INSTALLATION

End Cover

Figure 50 - Extension of Panel

INSTALLING AN EXTENSION PANEL

Tojoin an extension panel to your existing TX,

1. Remove the end cover of existing TX at the joining end

Figure 51.

2. Follow instructions listed in ‘Connection of TUs’ under

Installation on Page No. 24.

Ensure that both power and control circuits are switched off before taking the end cover off the TU.

3. Necessary busbars / fishplates are supplied with the

extension panel.

4. Place the end cover on the newly added panel.

Type TX MCC41

Type TX MCC42

SITE TESTING

Type TX MCC43

SITE TESTING

TESTING SWITCHBOARDS

1. Keep all power circuit switches ON.

2. Isolate all parallel paths.

3. Ensure all power circuits are connected.

4. Measure all insulation resistance (IR) values between

phases with respect to earth, phases with respect to

neutral and between phase and earth with respect to

neutral with a 500 V megger and compare with the table

below.

A) Insulation Resistance Test with 500V Megger before and

after H.V.Test (All values in M.ohms).

In case megger trips while testing, go on isolating one

panel fromthe switchboard till the fault isfound.

B)Dielectric Strength Testat 2.5KV for 1 Sec.

Check (phase)

a) R/Y/B/N

b) R/Y/B

c) R/Y

d) R

With respect to

…….E

…….N

…….B

…….Y

5. Carry out HV test at 2 KV for control circuits and at 2.5 KV

for power circuit for one second and limit the voltage to

8 5 % of the preceding value for every consecutive test.

TESTING CURRENT TRANSFORMERS (CTs):

1. Check nameplates and ensure CTs they are as per

drawings and specifications.

2. Check wether the CT secondary is wired correctly with

propergauge of conductor.

3. Check CT secondary links are properly connected as per

the scheme drawing.

4. Check CT mountings and ensure they are adequately

supported and clamped..

5. Check CT polarity. Use a battery operated polarity

tester. Depending upon the type of CT apply a positive

pulse at P1 and a negative pulse at P2 (where P1 and

P2 are two ends of the coil). Connect a null

deflection galvanometer and observe the direction. It

should be towards the right hand side.

6. Measure winding resistance of CT secondary using a

multi meter in ohmmeter mode in case of protective CT

core to ensure that the CTsecondary is not open.

7. Check for any physical damage.

8. Check tightness of all bolts, clamps connecting terminals.

9. Check for earthing connections of CTis as per drawing.

TESTING POTENTIAL TRANSFORMERS (VoltageTransformer and Control Transformer)

1. Check nameplates and ensure they are as per drawings.

2. Check PT Secondary is wired correctly with proper gauge

of conductor.

3. Check PT mounting and ensure they are adequately

supported.

4. Check PTcircuit’s earth link.

5. Check polarity of PT. Using a battery operated polarity

tester, check that positive EMF is induced between

terminals S1 and S2 when a positive current pulse is

applied between P1 TOP2.

HV test kit

Type TX MCC44

R Y B N

E 0.5 0.5 0.5 0.5

N 0.5 0.5 0.5 ~

B 0.5 0.5 ~ ~

Y 0.5 ~ ~ ~

SITE TESTING

6. Check ratio of all cores. Conduct ratio test by applying

1 phase 240V across the primary. Note voltage at

secondary. Calculate the ratio, tabulate and compare the

value with the nameplate values.

7. Measure winding resistance.

8. Check for any physical damage.

9. Check tightness of all connecting terminals.

10. Check for the earthing of PTas per the drawing.

TESTING METERS AND TRANSDUCERS:

1. Inspect all meters and transducers for proper mounting

and for any damage.

2. Testwith calibrated meters.

3. Check CT and VT connections with particular reference to

their polarities for power type meters wherever they are

provided.

4. Check for the earthing of meters and transducers as per

the drawing.

TESTING RELAYS:

1. Inspect for propermounting and for any breakage.

2. Ensure gagging on all the moving parts is removed.

3. Check nameplate details as per specification.

4. Set the relay as per setting sheet, (protection co-

ordination) and check for its operation at set values.

TESTING CONTROL CIRCUITS

1. Check the insulation of the auxiliary circuit before testing

the control circuitry using megger.

2. Check that fuses are fitted in the main and auxiliary circuit

and that ratings are appropriate for the circuit.

3. Perform the electrical continuity test on the control circuit

for any lapse in connection.

4. Check for the phase sequence of the incoming supply.

5. Repeat the test as stated in the FAT (Factory Acceptance

Test) for all the feeders existing.

6. Check the settings of overload relays and other

protection relays. During commissioning checks, set the

overload relay to the minimum value. Setting of the relay

should be as per setting chart supplied by L&T.

CLOSING,TRIPANDEMERGENCYCIRCUITS

1. Close the incomer and check the functionality of the

closing feeder as per scheme drawing provided.

2. Check the indication corresponding to the feeder.

3. Carry out the test for tripping as per FAT (Factory

Acceptance Test)that is unique for every switchboard.

4. Check the Emergency push buttons and other trip

mechanisms using scheme drawing provided.

Perform the test as per SAT (Site Acceptance Test) if

provided. (Note that SAT is provided on request.)

Type TX MCC45

CHECK POTENTIAL PROBLEMS

Verification of vendor documents Incomplete documentation

Verification of General Arrangement &

Mechanical check

Cleaning

Wobbling of doors

Misalignment of pillars

Alignment of handle

• Appearance (Visual)

• Dimension

• Verticality & Waviness

Powder Coating:

• Surface Finish Glossy or Matt

• Paint Shade

• Dry Film Thickness

Orange peel effect, Bubbles, Dent Marks, Pinholes

Paint shade difference, low gloss

DFT low /high

Busbar Arrangement Busbar coupling not ok

Fishplate & harwdware missing

Busbar& Power Joints Tightness Loose joints, No red marking, Wrong H / Wsize

Pull test for crimping and termination and

visual inspection of wiring

Loose crimping

Wrong lug used

Loose termination

Poor wire bunching & dressing

Clearance Low clearance

Partition Provision (Form of Separation) Shroud not provided at Live terminal, Cover / Barrier missing

Degree of Protection (IP) Pinholes at door corners, control plate gasket not proper,

extra holes on pillars / end cover / doors

CT Polarity Wrong CT wiring, mixing of protection & metering CT wires,

neutral CT connection wrong

Current Injection (Primary / Secondary) Wrong wiring of trip circuit / protection circuit, wrong termination

at relays

Insulation Resistance (Megger) Low IR value

Dielectric Test (High Voltage) for Power &

Control Circuit

Presence of foreign material in Busbar zone, insulation puncture

SITE TESTING

Type TX MCC46

PRE-ENERGISING

CHECKS

Type TX MCC47

PRE-ENERGISING CHECKS:

Ensure the following checks are carried out before energizing:

Sr.No. Check Point OK

1 Overall Appearance & surface finish

2 Panel is on a level surface

3 Room ventilation

4 Fire Extinguisher

5 Rubber mats of grade 1100 V

6 Loose items fitted

7 Verification as per BOM and GA

8 T ightness of busbar Joints

9 Wiring check as per scheme drawings

10 Phase sequence / Polarity check

11 CT & PT ratio check (on Sampling)

12 Insulation Resistance

13 High Voltage Test (Power Circuit)

14 High Voltage Test (Control Circuit)

15 All doors closed

Type TX MCC48

COMMISSIONING

OFF ON

Type TX MCC49

COMMISSIONING

be checked beforeGeneral parameters which must

commissioning the switchboard are :

• Control andIndication

• Remote Operation (if any)

• Electrical Interlocks (if any)

Figure 51 - Energised Panel

Congratulations!

Your switchboard has now been commissioned.

Type TX MCC50

OPERATION

Type TX MCC51

OPERATION

FRACTIONAL MODULES:

Racking-in:

1. Prior to insertion of the module, ensure that the position

indicator of the module is showing ‘isolated’ position. If

not, bring it to ‘isolated’ position using the camlock key

Figure 53.

2. Insert the module by racking it and moving it in, while

keeping the key turned. Bring it to service position by

pushing the racking handle twice Figure 54.

Racking-out:

1. Turn the key anticlockwise until the position indicator

indicates isolated (I)position.

2. Bring the module to draw out position using the camlock

key and pull the module out.

Refer Table No. 7 for position / condition of Knob, ROM

(Rotary Operating Mechanism) and Handle, power

contacts and SICs of fractional width modules during the

Rack-in and Rack-out process.

Figure 53 - Service-Test-Isoalted-Withdrawable Position of the Fractional Module

Figure 52 - Camlock key

Table No. 7

SERVICETEST

ISOLATEDDRAWOUT

KNOB POSITION

ROM POSITION

HANDLE POSITION

POWER CONTACTS

SIC

SERVICE (S)- OFF OR- O

N

CONNECTED CONNECTED

TEST (T) - OFF DISCONNECTED CONNECTED

ISOLATION (I) - OFF DISCONNECTED DISCONNECTED

DRAWOUT - OFFSAME AS IN ISOLATION

DISCONNECTED DISCONNECTED

Type TX MCC52

Figure 55 - Full width module in Test position

OPERATION

Figure 56 - Full width module in Isolated position

FULL WIDTH MODULES

1. Prior to insertion of the module, ensure that the position

indicator of the module is showing ‘isolated’ position

Figure 22. If not, bring it to ‘isolated’ position using the

racking handle.

2. To rack in, Insert the handle in the slot provided on the

front of the module Figure 58.

• Press and rotate clockwise to move forward (I->T->S)

Figure 55.

• Rotate the handle through 90 degree in clockwise

direction to bring it to Isolated position Figure 57.

3. To rack out, follow the sequence mentioned above in

an anti-clockwise direction from service to isolated.

The handle cannot be taken out in any

intermediate position.

KEEPING THE HANDLE PRESSED IN, ENSURE THIS GAP IS ZERO AND THEN ROTATE.

Figure 58 - Lifting of Full width module

Figure 57 - Position for handle insertion

4. Towithdraw the module, lift the strip and use the lifting

rod provided to take it out Figure 59.

Lifting Rod

Figure 54 - Full width module in Service position

• After a 90 degree turn from service position, the module

will come to the test position and the handle can be taken

out. Figure 56.

Type TX MCC53

Type TX MCC54

MAINTENANCE

Type TX MCC55

MAINTENANCE

PRECAUTIONS

1. Switch off the incoming power supply before removing

top plates and side covers. Isolate incoming power

supply.

2. For safety of personnel, while working on bus bars,

provide temporary earthing using a metallic chain/strip

near the work place. Remove this earthing only after the

job is completed.

3. Switch off the control supply. Isolate remote control

voltage sources.

4. Measure busbars voltage to ensure that bus bars are

de-energized.

5. Ensure that only qualified personnel are permitted to

use the defeat mechanism to gain access to an

energised compartment.

6. Do not attempt to withdraw the unit or disconnect any

terminations when the defeat mechanism has been

used to open a compartment door.

7. Current transformer primaries must not be energised

when secondaries are open circuited.

8. Short all CTsecondaries.

9. In case of shutdown on only one feeder, padlock the

power switch in OFFposition.10. After maintenance, if TX is going to be de-energised for

a longer period, switch on the panel space heaters to

prevent moisture condensation on the cables/

insulators.

ROUTINE CHECKS

Carry out the following checks regularly:

1. Inspect all devices every two months to ensure that the

equipment is in properworking order.

2. Check tightness of bolted joints (mainly Busbar)

Figure 60.

- prior toenergisation

- six months after load is connected

- one year after the second check and then once a year

Figure 59 - Tightening of Busbar & Dropper Joint

3. Inspect all wiring for wear and cuts every two months.

4. Look for signs of wear of the silver plating on the stab-in

contacts and on the contacts fixed to the dropper at the

point where the stab-in contacts engage with the fixed

contacts. The plating is part of the protection against

corrosion when module is outside the panel.

5. Clean and lubricate the stab-in contacts once a year

with HPMPL (EXXON)grease.

6. Remove burnt out fuses if any.

7. Check terminal block contacts for loose connections.

8. Examine indicating lamps and replace if required.

9. Ensure all safety interlocks are functional and in proper

working order every two months.

10. Look for indications of overheating, sparking or

insulation breakdown on the busbars.

11. Inspect power and control contacts. Replace worn out

contacts (refer the section replacement of power

contacts on Page No. 28)

12. Inspect all auxiliary and control circuits every two

months for desired functioning.

13. Grease racking screw and telescopic rails at least once a

year. Use grease 'HP-LETHON-2' or 'SYNTHOLUBE-20 of

HJ Leach & Co.

14. Ensure that the earth wires are connected to the main

earth bar (except electronic device earthing).

15. Ensure no tools or loose materials are left inside the TX

as these can cause faults.

16. Keep the switchboard free of dust. Use a vacuum

cleaner to remove the dust.

Figure 60 - Tightening of Busbar Joints

Do not operate equipment whose arc chutes are removed.

Type TX MCC56

MAINTENANCE

UNIT REMOVAL AND REPLACEMENT

• Make sure that the power switch in the unit is in the

'OFF’ position before withdrawal (Refer section

operation of the module for withdrawal of the module

on Page No. 38 & 39).

• Remove the module.

• Reverse the process for unit replacement.

REMOVAL OF DRAWOUT POWER CONTACTS AND DOORS

Although extremely unlikely, if sparking occurs at the power

contacts due to pitting (corrosion), then adopt the following

procedure to remove the unit from TXand replace the stab-

in contacts.

Keep the unit free from dust. (Specially for power and controlcontacts)

REMOVAL OF POWER CONTACTS

For fractional modules

• Bring the power switch to OFFposition.

• Bring the module to isolated position using the key

provided as explained in operation of fractional width

module on Page No. 38.

• Withdraw the module.

• The power contacts are visible on the back side of the

module.

• Remove the SIC block mounted on the upper side of the

power contacts Figure 59.

• Remove the grub screw which joins power contact and

housing.

• Gently push the power contact out from the back.

Figure 62.

Figure 61 - Power Contacts in Fractional module

Power Contact

For full width modules:

• To rack the module out, refer to the procedure mention

on Page 39.

• Remove the connection of links and power contacts by

removing the bolts shown in Figure 63 (1).

• Remove the power contact from it's arm by unscrewing it

with the help of a screw driver through provided access

as show in Figure 63 (2).

Figure 62 - Power Contacts in Full width module

1 23

Type TX MCC57

MAINTENANCE

• Toremove the fixed power contact, slide them up in the

direction indicated in Figure 63 (3)

• The power contacts are housed in a click-fit cap

arrangement. A screw driver may be used as a lever to

open the cap replace with new contact.

• Reverse this procedure to fix power contact back on the

module.

If only the capneeds to be replaced,do not removethe

connection between the link and the power contact.

Cap

Figure 63 - Power contacts in a contact housing

REMOVAL OF DOORS

• Isolate the feeder.

• In fixed type module disconnect all wires terminating at

equipment located on the door.

• Remove the bolts provided at the hinge Figure 65 and

slide out the door.

Figure 64 - Concealed hinge door

Type TX MCC58

TROUBLE

SHOOTING

Type TX MCC59

On a live switchboard :

• Identify fault location using indicating lamps or

monitoring system.

• Check for availability of supply at SIC’s (Secondary

Isolating Contact or Draw-out terminals) connected to

auxiliary bus.

• Check if power switch/MCCB is in ‘ON’ position.

• Reset the relay orMCB after the fault has been cleared.

• Check if control MCB is ‘ON ‘after opening the

compartment door.

• If control fuse is used, check the health of the fuse.

Replace if necessary.

• Check whether terminations from field connections are :

1. Correctly terminated

2. Tight

TROUBLE SHOOTING

• Check whether inputs coming from the field are

functioningor not.

• Switch on control MCB/ control fuse, ensure interlocks

are active and turn on the feeder.

• If control MCB/ control fuse trips verify the field

terminations on the SIC.

• If control MCB/ control fuse has not tripped but the

module still fails to operate, then check the health of the

control circuit using a line tester.

• If the problem persists, check for component failure.

• After trouble-shooting ensure that the module is racked

in to service position.

If the problem persist,contact your nearest salesoffice

oremail your query to AtYourService@lntebg.com

Type TX MCC60

RECOMMENDATIONS

1. Provide a small storage cabinet in every switchgear room

for:

• Tools like screw drivers, fuse pulling handle, chassis

racking handles.

• All reference drawings like General Arrangement

Drawing, Scheme drawing.

• Consumable spares like bulbs, fuses etc.

2. Do not use rewired HRC fuses. They may cause arcing or

explosions, leading to a fire.

Type TX MCC61

LIST OF FIGURES

Figure 1 - Floor mounted panel 03

Figure 2 - Different Compartments 04

Figure 3 - Double Deck arrangement of busbars 10

Figure 4 - Busbar Support 10

Figure 5 - Dropper Support 10

Figure 5.1 - Fully EnclosedDroppers 10

Figure 5.2 - Fully Enclosed Droppers(Topview) 10

Figure 6 - Auxbus Chamber 11

Figure 7 - 1 Quater (160 mm height) 12

Figure 8 - 2 Quater (320 mm height) 12

Figure 9 - 1 Half (160 mm height) 12

Figure 10 - 2 Half (320 mm height) 12

Figure 11 - 1 Full (160 mm height) 12

Figure 12 - 2 Full (320 mm height) 12

Figure 13 - 3 Full (480 mm height) 12

Figure 14 - Full width power switch padlocking 13

Figure 15 - Full width module padlocking 13

Figure 16 - Fractional module padlocking 13

Figure 17 - Door defeat interlock 13

Figure 18 - Safety shutter 13

Figure 19 - Earthing for full width module 13

Figure 20 - Earthing for fractional module module 14

Figure 21 - Power contacts 14

Figure 22 - Control plate 14

Figure 23 - SIC in full width module 14

Figure 24 - SICs in fractional module 15

Figure 25 - Module in Service position 15

Figure 26 - Module in Testposition 15

Figure 27 - Module in Isolated position 15

Figure 28 - Packing case Details 19

Figure 29 - Positioning of TUon truck 19

Figure 30 - Lifting Channel 20

Figure 31 - Chain marks on packed Tus 20

Figure 32 - Typical arrangements 27

Figure 33 - Tools 28

Figure 34 - Panel mounting on ISMC Base Channel/Base Frame 28

Figure 35 - Integral Base Frame 29

Figure 36 - ISMC BaseFrame 29

Figure 37 - Topplate 30

Figure 38 - Busbar joining 30

Figure 39 - Tightening of Busbar joints 30

Figure 40 - Auxbus joining 31

Figure 41 - MCC - MCC Earthbar Coupling 31

Figure 42 - PCC - MCC Earthbar Coupling 31

Figure 43 - Rear Cable Entry 32

Figure 44 - Side CableEntry 32

Figure 45 - Control Cable terminals 36

Figure 46 InterpanelWiring 39

Figure 47 - Relay Mounting on Panel 39

Figure 48 - Control Transformer Mounting on Panel 40

Figure 49 - Installation of Control Transformer 40

Type TX MCC62

LIST OF FIGURES

LIST OF TABLE

Type TX MCC63

Figure 50 - Extension of Panel 41

Figure 51 - Energised Panel 50

Figure 52 - Camlock key 52

Figure 53 - Service-Test-Isoalted-Withdrawable Position of the Fractional Module 52

Figure 54 - Full width module in Service position 53

Figure 55 - Full width module in Testposition 53

Figure 56 - Full width module in Isolated position 53

Figure 57 - Position for handle insertion 53

Figure 58 - Lifting of Full width module 53

Figure 59 - Tightening of Busbar & Dropper Joint 56

Figure 60 - Tightening of Busbar Joints 56

Figure 61 - Power Contacts in Fractional module 57

Figure 62 - Power Contacts in Full width module 57

Figure 63 - Power contacts in a contact housing 58

Figure 64 - Concealed hinge door 58

Table1 - Technical Data 05

Table2 - Panel Configuration 07

Table3 - Typical Auxiliary busbararrangement 11

Table4 - State of Power & Control Contacts in Various positions 15

Table5 - Size of bolt Torquein m.kg 30

Table6 - SIC TroubleShooting 38

Table7 - State of Power & Control Contacts in Various positions - Fractional width module 52

NOTE

Type TX MCC64

NOTE

Type TX MCC65

PT TAMCO INDONESIA (A LARSEN & TOUBRO Group Company)

F-36 , Jalan Jababeka Raya Jababeka Industrial Estate , Cikarang Utara Bekasi , 17530 , West Java , IndonesiaT +62 21 8935070 F +62 21 8935071

Email: SalesDept@Lntebg.com Website: www.LNTEBG.com© Electrical Systems & Equipment

Registered Office:L&T House, N. M. Marg Ballard EstateMumbai - 400 001, INDIA

ACB Maintenace:

• Thorough cleaning of the ACB and its cradle

• Mechanical checks such as arcing contact gap, tightness

check, greasing all moving parts

Annual Maintenance Contracts (AMC):

• Electrical substation Maintenance (periodic maintenance

of entire low voltage range of switchgear)

Switchboard Maintenance:

• Erection, Testing and Commissioning

• Commissioning assistance

• Totalvisual check

• Checks- Closing coil, trip coil and auxiliary contacts etc

• Vacuum cleaning

• Tightness check for busbar joints and droppers

• Greasing of all moving parts

• IR(Insulation resistance) and high voltage test• Switchboard maintenance (periodic maintenance of Low

voltage switchboard)• Maintenance workshop

• Modification (change or addition in the rating of motor

feeder)

• Retrofitting of the necessary products

Services we offer:

EM

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