Eaton Power Xpert XGIS Instruction Booklet
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Eaton Power Xpert XGIS Instruction Booklet

Gas insulated switchgear
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Instruction Booklet IB022018EN
Effective July 2020
Instructions for the installation and
commissioning of Power Xpert
TM
XGIS gas insulated switchgear

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Summary of Contents for Eaton Power Xpert XGIS

  • Page 1 Instruction Booklet IB022018EN Effective July 2020 Instructions for the installation and commissioning of Power Xpert XGIS gas insulated switchgear...
  • Page 2 Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear EATON www.eaton.com...
  • Page 3 THE COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect,incidental or consequential damage or loss...

  • Page 4: Table Of Contents

    1.3 Power Xpert XGIS elements ........
  • Page 5 Table 13. Top VT installation tool components ..........64 EATON www.eaton.com...
  • Page 6 BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT BE CONSIDERED ALL INCLUSIVE REGARDING INSTALLATION OR MAINTENANCE PROCEDURES. IF FURTHER INFORMATION IS REQUIRED, YOU SHOULD CONTACT EATON. m WARNING DO NOT ATTEMPT ANY WORK ON THIS EQUIPMENT SUCH AS INSTALLING COMPONENTS, PERFORMING ANY EXAMINATIONS, PERFORMING ANY ADJUSTMENTS, PERFORMING ANY SERVICING, OR PERFORMING ANY MAINTENANCE WHILE IT IS ENERGIZED.

  • Page 7: Section 1: Introduction

    This information should be given to the Eaton sales office if a question should arise concerning the switchgear or if renewal parts are required. This information is sufficient for Eaton to find the manufacturing information for the switchgear.

  • Page 8: General Information

    Figure 3 and Figure 4 show XGIS system power components for a 1250 A standard section and a 1250 A bus tie section. Figure 5 shows an XGIS vertical section with front and interior control components. Figure 2. XGIS interior and control elements. EATON www.eaton.com...
  • Page 9 Switch Operator Vacuum Vacuum Rear Circuit Breaker Circuit Breaker Arc Relief Mechanism Compartment Cable Cable Tank Compartment Cable Connectors Cable Clamp Braces 3PDS = Three Position Disconnect Switch Figure 3. XGIS 1250 A cable connection section, side view EATON www.eaton.com...
  • Page 10 VT Earthing Relief Switch Operator Rear Vacuum Arc Relief Circuit Breaker Compartment Vacuum Mechanism Circuit Breaker Tank Bus Tie Compartment Bus Joints 3PDS = Three Position Disconnect Switch Figure 4. XGIS 1250 A bus tie section, side view EATON www.eaton.com...

  • Page 11: Power Xpert Xgis Elements

    Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear 1.3 Power Xpert XGIS elements Low-voltage compartment Voltage Detection System Low-voltage panel Meters and relays Three position disconnect switch Tank pressure...

  • Page 12: Standard Features

    Low-voltage control wiring is routed from the internal vertical must be heated to more than 500º Celsius (932º F) before it will section terminal boards to an Eaton blue colored top hat, above the decompose. The symmetry of the atoms in its molecular structure low-voltage compartment.
  • Page 13 Behind the low-voltage panel and above the output cable compartment, the gas tank is the heart of the XGIS switchgear. The tank is pressurized to slightly over atmospheric pressure with SF gas, to insulate the MV components inside the tank. EATON www.eaton.com...
  • Page 14 This linear travel device is mechanically tank. If repairs inside the tank are required, an Eaton service repre- coupled to its operating mechanism through the tank wall. In the sentative should be contacted.
  • Page 15 This cam limit switch has four contacts. The contacts are used in the electric control system to signal 3PDS status: closed, opened and grounded. The 3PDS and circuit breaker are mechanically and electrically interlocked to prevent inappropriate operation. EATON www.eaton.com...

  • Page 16: Table 1. 3Pds Status Display Table

    The “PUSH TO OPEN” button is protected by a padlock-able cover. The cover status is indicated by an electrical interlock block mounted on the breaker frame top. Figure 19. 3PDS locking features - standard. EATON www.eaton.com...

  • Page 17: Ground Bus

    Interlocking Circuit breaker trip-free features The XGIS 3PDS and circuit breaker are extensively mechanically and The Eaton XGIS Vacuum Circuit Breaker incorporates electrical electrically interlocked to prevent inappropriate operation. trip-free characteristics. That is, the contacts of the circuit breaker must return to the open position and remain there when an opening 1.3.2 Ground bus...

  • Page 18: Bracing

    An auxiliary section side wall is bolted to the end sheet of lineup end vertical sections. In addition, an angle is attached to the auxiliary section rear panel and to the side of the vertical section end sheet. See Figure 27. Multiple auxiliary sections can be attached to a lineup. EATON www.eaton.com...
  • Page 19 Lebensgefahr! Thermische Überlastung durch kurzgeschlossene Sekundärwicklung Disconnect the device and system before Nie Sekundärwicklung kurzschließen beginning any work and protect it against Gefahr! Hochspannung! cable vault). beeing energized unintentionally Danger! High Voltage! Connection Plug Figure 28. Fused voltage transformer. EATON www.eaton.com...
  • Page 20 SSIS conductors passing through connected to the switch. the CTs before terminating at the tank bushings. Main bus CT and bracket dimensions will differ depending upon the CT rating and applicable standards. EATON www.eaton.com...
  • Page 21 Figure 35 shows main bus CT mounting brackets. Figure 36. Example 1250 A main bus CT. Figure 35. Example main bus CT mounting brackets. Figure 37. Example 2000 A / 2500 A main bus CT. Figure 38 shows the CT brackets for main bus CTs. EATON www.eaton.com...
  • Page 22 Figure 40 and Figure 41 show examples of cable side current Figure 42 shows 1250 A cable connection CTs mounted to the front transformers. The 1250 A CT fits over one bushing per phase while of the tank. the 2500 A CT fits over two bushings per phase. EATON www.eaton.com...
  • Page 23 SSIS bus. In that case, a different SF tank is used, the output bushings are mounted vertically in the tank bottom and connected to bus joints connecting SSIS bus sections. EATON www.eaton.com...
  • Page 24 When surge arresters are included, they replace one of the power cable connectors, allowing a maximum of two power cable connections per phase. Figure 48 shows an example surge arrester designed for connection using tee type connectors. EATON www.eaton.com...

  • Page 25: Xgis Vertical Section Configurations

    Power Xpert Effective July 2020 XGIS gas insulated switchgear NOTE: TEE CONNECTORS NOT INCLUDED NOTE: TEE CONNECTORS NOT INCLUDED POWER XPERT XGIS CABLE GROUNDING KIT 1250 A, ONE CABLE POWER XPERT XGIS CABLE GROUNDING KIT 1250 A, THREE CABLES Figure 49.
  • Page 26 This section can be furnished with fused VTs with be furnished with a set of VTs with the VT earthing switch and bus a disconnect switch, cable CTs, remote-mounted fused VTs or surge CTs. arresters. Figure 53. Bus tie one-line. Figure 52. Feeder/incoming one-line. EATON www.eaton.com...
  • Page 27 This section can be furnished with fused VTs with a disconnect with the VT earthing switch and bus CTs. switch, cable CTs, remote-mounted fused VTs or surge arresters. Figure 55. Disconnector one-line. Figure 54. Bus sectionalizer one-line. EATON www.eaton.com...
  • Page 28 Figure 56. Cable connector one-line. Table 2, Table 3 and Table 4 list the vertical section dimensions, electrical data and relevant standards for Power XPert XGIS switchgear. Table 5 lists the Power XPert XGIS switchgear rated operating conditions. EATON www.eaton.com...

  • Page 29: Type Xgis Gas Insulated Switchgear Ratings (Tables 2, And 3)

    Number of operations - No-load or full load > 10,000 / > 2,000 Three-position disconnect switch Number of operations > 2000 Heat Loss for representative sections 1250 A 683 W 2000 A 905 W 2500 A 1554 W EATON www.eaton.com...

  • Page 30: Table 4. Relevant Standards

    ≤ 35° C on average over 24 hours ≥ -5° C ≤ 1000 m Altitude Contact Eaton for applications above 1000 m. Atmosphere No dust, smoke or corrosive or inflammable gas or vapor, or salt (clean industrial air) Storage conditions To retain all of the functional qualities when stored for prolonged periods, we recommend that the equipment be stored in its original packaging, in well-ventilated, clean, and dry conditions, sheltered from the sun and rain, at a temperature >...

  • Page 31: Xgis Vertical Section Outlines And Dimensions

    Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear 1.5 XGIS vertical section outlines and dimensions 1.5.1 1250 A vertical section Figure 57. 1250 A vertical section dimensions. EATON www.eaton.com...

  • Page 32: 2000 A / 2500 A Vertical Section

    Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear 1.5.2 2000 A / 2500 A vertical section Figure 58. 2000 A/ 2500 A vertical section dimensions. EATON www.eaton.com...

  • Page 33: Ssis Conductor System

    2500 A bus, and also provides connections in either cross or end Main busbars are installed and coupled to the bus connection configurations. bushings fitted on top of the sealed tank. Main horizontal busbars are enclosed in a separate compartment above the sealed tank. EATON www.eaton.com...

  • Page 34: Power Cable Conductors In Xgis Switchgear

    The maximum number of cable connectors possible depends on the XGIS rating. Multiple connectors per phase are configured using tee or elbow type separable connectors (Figure 65). A surge arrester can be connected as the last connected device. EATON www.eaton.com...
  • Page 35 The separable connectors include a shield layer that is used to ground the exterior of the connectors. The ground wires must be fastened to the compartment ground bus. This will ensure the outer surface of the separable connectors are at ground potential. EATON www.eaton.com...

  • Page 36: Voltage Detection System

    XGIS front panel face and operates in accordance with IEC 61243-5 (integrated voltage detection systems). This system looks for the presence of voltage in each of the three phases and indicates the line status using LED display symbols on the device display. EATON www.eaton.com...

  • Page 37: Section 2: Safe Practices

    • hands, faces and exposed skin immediately. Tools and PPE must also be cleaned. MUST NOT be discharged into the atmosphere. It should be • collected and may be reused only after treatment and testing by qualified experts. EATON www.eaton.com...

  • Page 38: Section 3: Receiving, Handling And Storage

    File claims immediately with the carrier if damage or loss is detected and notify the nearest Eaton office. 3.3 Handling The XGIS vertical section may be top heavy and subject to tipping danger.

  • Page 39: Lifting

    The weights in Table 8 below are for vertical sections including in conjunction with the Eaton top lifting bracket. three-position disconnect switches and circuit breakers (as appropriate), incoming bus bar, bus fused VTs and cable CTs but When a vertical section is to be lifted, position the lifter over the excluding control and protection relays, and other custom features.

  • Page 40: Section 4: Initial Inspection

    The breaker will close as shown by the breaker contacts “closed” (red) indicator. Operate the push-to-open button. The breaker will open as shown by the breaker contacts “open” (green) indicator. After completing this initial check, leave the closing springs “discharged” and breaker contacts “open” . EATON www.eaton.com...

  • Page 41: Section 5: Installation

    The XGIS switchgear is designed for installation in the electrical room over cable vaults. It is very important that the installed lineup be level and mounted on the same plane. Eaton recommends that the electrical room design include steel rails embedded in the vault concrete, for mounting the XGIS switchgear.
  • Page 42 Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear 2.76 2.76 [70.00 mm] [70.00 mm] Figure 72. Example XGIS switchgear cable vault foundation diagram. EATON www.eaton.com...
  • Page 43 Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear Figure 73. Typical vertical section clearance dimensions in control room. EATON www.eaton.com...
  • Page 44 Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear Figure 74. XGIS vertical section minimum ceiling height requirements EATON www.eaton.com...

  • Page 45: Field Installation Precautions

    XGIS seismic rating. See 5.7.2 for detailed assembly instructions. 5.7.1 Drawings XGIS switchgear are furnished with project drawings specific to the project and client. Refer to the project drawings for details of the equipment and its installation. EATON www.eaton.com...
  • Page 46 9 - Splice Plate Splice Plate Splice Plate 7 - Splice Plate 6 - Splice Plate 2 & 3 - Main Bus Compartment Vertical Joins Figure 75. XGIS vertical section attachment guide for AFLR (Access Front Lateral Rear) sections. EATON www.eaton.com...
  • Page 47 Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear Splice Plate Splice Plate Splice Plate Lorem ipsum Splice Plate Splice Plate Figure 76. XGIS vertical section attachment guide for AFL (Access Front Lateral) sections. EATON www.eaton.com...
  • Page 48 Attach using four sets of M10-1.5 x 30 lg SHCS, M10 wide flat washer, M10 split lock washer, and M10 nut to attach the sections horizontally below the tank. See Figure 82 and Figure 83. Figure 77. Front edge attachments. EATON www.eaton.com...
  • Page 49 2 sets of M8 wide washer, M8 split lock washer, M8 nut. Attach the remaining two sets of two holes using through hardware: Qty 4 sets of M8-1.25 lg SHCS, M8 wide washer, M8 split lock washer, M8 nut. Figure 81. Rear vertical splice plate. EATON www.eaton.com...

  • Page 50: Low Voltage Control Connections

    Figure 83. Bus tie lower compartment attachments. EATON www.eaton.com...

  • Page 51: Ssis Bus Installation In Xgis Gas Insulated Switchgear

    Type C Type C End Bus Joint Cross Bus Joint 1250 A Busbar End Bus Joint End Bus Joint Disk Disk Clamshell Type C Double Threaded Rod Type C Tank Bushing Cone Figure 86. SSIS components and assemblies. EATON www.eaton.com...

  • Page 52: Field Installation Precautions

    A - 650 mm phase B - 700 mm phase C - 750 mm One 800 mm and one 600 mm (left to right) phase A - 750 mm phase B - 700 mm; phase C - 650 mm EATON www.eaton.com...
  • Page 53 C (rated 1250 A) and Type F (Rated 2500 A) receptacles. Power comes into the bus joint through the bus connection and passes into the tank through a Type C cone. The unused bus joint receptacle is plugged and capped. Figure 89. Feeder section main bus connections. EATON www.eaton.com...
  • Page 54 Torque the nut to 45 Nm (33.2 ft-lb) with a calibrated torque wires to each joint, in a daisy chain fashion, with provided fasteners. wrench. Tighten them to finger tightness. The assembled joint should look like the image below for intermediate joints. EATON www.eaton.com...

  • Page 55: Low-Voltage Control Cables

    5.11 Low-voltage control cables The low-voltage control wiring brought in from outside (through the Eaton blue top hat wire channels), or routed up through cutouts in the low-voltage compartment base, will require glands and caulking to completely fill any wireway apertures.
  • Page 56 (protection of insulation), then the conductors must be bundled together and conduit hub filled with caulk as described for the internal wiring in paragraphs f) and g) above . Figure 100. Adjustable - low-voltage side, fixed opening EATON www.eaton.com...

  • Page 57: Installing Cable Adapters

    CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, AND EQUIPMENT Eaton DTS1242 and DTB1242 cable adapters can be used on XGIS DAMAGE. switchgear. Other cable adapters are also applicable, and can be applied once their suitability has been determined.

  • Page 58: Installing Current Transformers

    Detailed installation instructions for cable cleats In every case, the CTs will be installed on the tank top before the can be found in Eaton Cooper installation manual CTCC-10. SSIS bus and bus joints are installed. See Figure 24 for an example of cable cleats.
  • Page 59 See Figure 47 for an example of a bus tie tank with its connection cones projecting down from the tank bottom. Figure 102 shows a bus sectionalizer tank bottom CT in its bracket. Figure 103. Illustration showing bus tie CT mounted in its bracket below the tank. EATON www.eaton.com...

  • Page 60: Installing Cts On Main Bus Or Cable Side Applications

    Attach tie mounts to the tank studs and the CTs against the rear mounting bracket. and wire tie the wires to them. Route the wires into the vertical LV wire way through a grommet and up into the LV compartment. EATON www.eaton.com...

  • Page 61: Un-Installing Cts On Main Bus Or Cable Side Applications

    Taking care not to scrape the connection bushings, slide each Figure 107. 2000 A / 2500 A cable CT bracket with rear bracket, CT away from the tank rear face and off of the connection spacers, and front bracket. bushings. EATON www.eaton.com...

  • Page 62: Voltage Transformer Installation And Removal

    The default configuration, the “High Lift” truck, used on installations where the control room ceiling is high enough above the gear to accommodate the truck height above the vertical section top (see Figure 108 and Figure 109). Figure 109. Top fused VT high lift truck on rails. EATON www.eaton.com...
  • Page 63 CARE MUST BE TAKEN TO MOVE THE TRUCK SLOWLY ON ITS RAILS, TO AVOID LOAD SWINGS DURING LIFTING, TRANSPORT OR LOWERING, AND TO PROPERLY STOP THE TRUCK AT THE RAIL END STOPS. Figure 112. VT front lift initial position. EATON www.eaton.com...

  • Page 64: Voltage Transformer Installation

    VT Installation/Removal tool, Eaton catalog number 87A1060G01. Eaton will furnish one tool per XGIS lineup. This tool is Prepare the vertical section for VT installation composed of three elements, and additional tools can be purchased from Eaton or purchased from McMaster-Carr using the following Remove the top sheet from the VT compartment.
  • Page 65 Remove the VT port cover plate from the top of the XGIS tank. • Figure 116 shows the VT connection ports. Figure 118. Lower VT bracket into place in VT compartment. Lower the VT into place (see Figure 119). • Figure 116. VT connection ports. EATON www.eaton.com...

  • Page 66: Voltage Transformer Removal

    Fuse replacement is the same for both main bus and external fused VTs. The main bus VT will be installed in its mounting bracket with the VT body vertical (see Figure 112). The external VT will be mounted horizontally. EATON www.eaton.com...
  • Page 67 Figure 122. Fused VTs at start of procedure. Figure 124. Remove threaded cap. Using a suction cup or other attachment device, draw the fuse out • of its insulating cylinder container. EATON www.eaton.com...

  • Page 68: Auxiliary Cabinet Installation

    1/2 inch (M12) eye bolts placed in the corners of the auxiliary panel top surface (see Figure 127). To prepare the auxiliary panel for lifting, remove its top low voltage wireway top plate to access the lifting eyes holes (Figure 127). EATON www.eaton.com...
  • Page 69 These end sheets have bolt holes that are used to attach the end sheet to the vertical section. The bolt holes that usually attach an end sheet to the vertical section can also be used to attach an auxiliary cabinet. EATON www.eaton.com...
  • Page 70 Use seven (7) M8x30 bolts to attach the L bracket to the auxil- iary panel rear wall. Use four (4) M8x75 bolts to attach the L bracket to the vertical section end sheet. See Figure 131. EATON www.eaton.com...

  • Page 71: Section 6: Commissioning

    • regulations. of the cabinet for damage; if there is any, use the right paint to touch up. Contact your Eaton Engineering Systems and Services professional to provide testing services. Replace parts removed during installation. • Take out all tools and other devices that do not belong to the •...

  • Page 72: Section 7: Testing

    Below is a list of common tests that may be performed on the energizing the switchgear for normal service, remove the three XGIS switchgear. Consult Eaton engineering services for more wires from the front of the voltage detecting device. information.

  • Page 73: Performing Switchgear Voltage Test

    3. Disconnect the fused VT signal cable plug from its VT receptacle. 4. Remove the VT from the VT port area (see Figure 116). 5. Install an insulating dummy plug, Eaton Catalog Number 87A1025H01. 6. Secure the dummy plug to the VT port by tightening the bolts to 13 Nm (115 in.-lb.) See Figure 133, below.

  • Page 74: Appendices

    Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear Appendices EATON www.eaton.com...

  • Page 75: Appendix A - Xgis Switchgear Commissioning Checklist

    3PDS Status flags on the operator front panel; Confirm the detent stop at each position. The T-handle will require removal and re-insertion after arriving at each position. Return the 3PDS to Open position; close the Manual Access Door EATON www.eaton.com...
  • Page 76 System devices Check gas pressure Test for leaks Clean area around sample/ access port Remove protective cap Install adapter Take sample Check gas quality (optional) Prepare sample for proper shipment per DOT requirements Monitor gas pressure over two-week period EATON www.eaton.com...
  • Page 77 3PDS manual operation T-handle Earthing set (optional) Plug-in indicator unit for capacitive indication – if necessary Phase comparator in the case of more than one incoming feeder (optional) Provide Operator instruction in the switchgear operation (theory and practice) EATON www.eaton.com...
  • Page 78 Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear Notes: EATON www.eaton.com...
  • Page 79 Instruction Booklet IB022018EN Instructions for the installation and commissioning of Power Xpert Effective July 2020 XGIS gas insulated switchgear Notes: EATON www.eaton.com...
  • Page 80 1000 Eaton Boulevard Cleveland, OH 44122 United States Eaton.com © 2020 Eaton All Rights Reserved Eaton is a registered trademark. Printed in USA All other trademarks are property Publication No. IB022018EN / TBG 001430 July 2020 of their respective owners.

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