THIS IS AN UNCONTROLLED DOCUMENT, THE READER MUST CONFIRM ITS VALIDITY BEFORE USE ENGINEERING CONSTRUCTION STANDARD ECS 02-0037 INSTALLATION OF SERVICE WAYS AND CABLES (SCHNEIDER ELECTRIC) Network(s): EPN, LPN, SPN Summary: This standard details the termination kits and Service Ways to be used for the installation of Service cables into UK Power Network's LV Distribution Cabinets supplied by Schneider Electric. Owner: Paul Williams Approved By: Steve Mockford Approved Date: 31/03/2014 Review Date: 31/03/2017 This document forms part of the Company s Integrated Business System and its requirements are mandatory throughout UK Power Networks. Departure from these requirements may only be taken with the written approval of UK Power Networks Director of Asset Management. If you have any queries about this document please contact the author or owner of the current issue. Document History (The document history notes below are intended as a guide only and may not cover all of the changes. If you wish to make use of this document it should be read in full.) Version Date Details Author 3.0 20/03/2014 Document reviewed no changes required Paul Williams 2.4 10/07/2012 Document reviewed for publishing on G81 website Lee Strachan 2.3 22/08/2011 Document reclassified from EI to ECS Don Fossett 2.2 14/03/2011 Document rebranded Peter Rix 2.1 13/08/2010 Reviewed and review date extended Jesse Garcia 2.0 14/06/2010 Review of original Jesse Garcia 1.0 28/06/2007 Original D J Collis
Contents 1 Introduction... 3 2 Scope... 3 3 Glossary and Abbreviations... 3 4 Distribution Way Removal... 4 4.1 Removing LV Distribution Ways... 4 5 Installing a 600A Service Way... 6 6 Installing an 800A Service Way... 7 7 Top Entry 800A Service Way (LV Distribution Boards)... 9 8 Cable Installation Options... 12 9 Dependent Documents... 12 UK Power Networks 2014 All rights reserved 2 of 12
1 Introduction This engineering standard details cable installation methods to be used when installing a 600A or 800A service way into the new range of Schneider Electric (Merlin Gerin) LV distribution equipment. This engineering standard also provides details of the different cabling options and cable installation methods. The previous practice of purchasing bespoke cabinets to provide 800A services will be phased out as stocks are run down and the Schneider Electric LV distribution equipment, with the kits outlined in this engineering standard, will replace them. Individual cabling instructions are contained in this document and the associated drawings are available as appendices on Alfresco. 2 Scope This standard applies to the common range of UK Power Network s LV distribution equipment and includes: 13975S LV cabinet 4 x 500A ways 800A busbars. 13976C LV cabinet 5 x 500A ways 1600A busbars. 13977M LV cabinet 7 x 500A ways 1600A busbars. 13985B LV pillar 6 way 1600A. 13986L LV pillar 8 way 1600A. 13970T 1600A indoor LV board. 13971D 1600A indoor extension board. 3 Glossary and Abbreviations Term UK Power Networks Definition UK Power Networks (Operations) Ltd consists of three electricity distribution networks: Eastern Power Networks plc (EPN). London Power Network plc (LPN). South Eastern Power Networks plc (SPN). UK Power Networks 2014 All rights reserved 3 of 12
4 Distribution Way Removal 4.1 Removing LV Distribution Ways UK Power Networks now buys LV distribution cabinets and pillars preloaded with 630A distribution ways. To allow the installation of a 600A service way, one distribution way must be removed. When installing an 800A service way, two distribution ways must be removed. Follow the instructions below to remove either one or two distribution ways to allow installation of the service ways. For LV cabinets the 800A service ways have been designed to go on the left hand end of the cabinets away from the transformer disconnector. On LV boards the position of the service way may be chosen to suit site requirements. 1. Undo and remove the phase screen retaining screw. This allows the phase screen to be removed. 2. The screening may now be removed. Lift each phase screen slightly and remove to expose the stalks and mounting bolts. 3. Remove the black plastic plug to expose the 17mm nuts that secure the distribution way to the busbars and remove the nut. There is one nut per phase. UK Power Networks 2014 All rights reserved 4 of 12
4. Remove the fixing bolts at the bottom and top of the distribution way. 5. The distribution way may now be removed. These components may be retained for spares or returned to the plant store for re-use. For an 800A service repeat the process and remove a second way adjacent to the first way removed. UK Power Networks 2014 All rights reserved 5 of 12
5 Installing a 600A Service Way The 600A service way takes up the same space as one distribution way. Follow the removal process in Section 3.1 to remove the distribution way. 600A service ways have been designed to accommodate only un-armoured single core cables up to 400mm 2 and UK Power Networks uses a UT/9I connector to terminate these cables. 1. Install the 600A service way into one way on the LV cabinet, board or pillar. 2. Install the spacer washer provided behind the service way as shown. Install the top mounting bolt and clear plastic screen. 3. Install the bottom mounting bolt. Note: The screen provided should be mounted on the bottom fixing bolt for top entry cables. 4. Install the busbar connecting nut on each phase and tighten all three phases and the unit mounting bolts. 5. Install the four-way cable cleat to replace original. 6. Install the neutral connection. This is either a double bolt unit (shown) or has a single bolt connection to the LV cabinet and pillar neutral bars. Check that all electrical and support nuts and bolts have been tightened before cabling. UK Power Networks 2014 All rights reserved 6 of 12
6 Installing an 800A Service Way The 800A service way takes up the same space as two distribution ways. Follow the removal process in Section 3.1 to remove the distribution ways. 800A service way kits have been designed to work with un-armoured and armoured single core cables. These cabling options will remain available and include: 185mm 2 bunched waveform. 300mm 2 stranded copper (double insulated un-armoured). 740mm 2 sectorial aluminium (armoured). 630mm 2 stranded copper (armoured). 300mm 2 parallel waveform cables. A range of cabling solutions are available to cope with these different existing and new cabling options. These are provided in the attached drawings listed in Section 7, which detail cable installation, SAP codes and phasing of the cable connections. Where UK Power Networks provides and owns the service cables, our preferred cabling solution is to use bunched 185mm 2 waveform cables and a UT/9I connector to terminate these cables. The instructions in this section apply to all 800A service way kits as the installation process is common to all cable solutions. 1. Install the 800A service way into two ways on the LV cabinet, board or pillar. Install the busbar screen in the left hand position. 2. Install the spacer washer provided. Install top mounting bolt and clear plastic screen. 3. Install the bottom mounting bolt. Note: The screen provided should be mounted on the bottom fixing bolt for top entry cables. UK Power Networks 2014 All rights reserved 7 of 12
4. Install the busbar connecting nut on each phase and tighten all three phases and the unit mounting bolts. 5. The 800A service way is now secure in position. 5. Install the cable cleat, to replace the two original cleats. Note: EPN/SPN 630/740mm cabling solution shown. 6. Install the neutral connection. Both busbar bolts must be installed and tightened. Check that all electrical and support nuts and bolts have been tightened before cabling. You are now ready to start cabling. UK Power Networks 2014 All rights reserved 8 of 12
7 Top Entry 800A Service Way (LV Distribution Boards) When installing an 800A service way onto a LV distribution board it may be reversed to cope with top entry cables where the cables enter the substation at high level. Top entry cable access requirements are more common on the LPN network, therefore the LPN cabling solution was used to demonstrate the process. To allow the 800A service way to accept top entry cables the copper work must be reversed. This may be done more easily before the service way is mounted on the LV distribution board. The pictures below illustrate the process to be followed. 800A service ways, supplied by Schneider Electric, are ready for bottom entry cables. 1. The clear plastic screening and the white phase covers must be removed in one piece. The screen is secured by the bolt at the top of the distribution Way and a bolt on the busbar screen. 2. This will expose the busbar stalks and cable connection plates. 3. You may now reverse the busbar screen so that the steel bracket is at the bottom. UK Power Networks 2014 All rights reserved 9 of 12
4. Remove the cable connection plates and reverse their position. The copper-work from L3 moves to L1 Note: A packing washer must be placed between the connector plate and the mounting stalk. The copper work from L2 is reversed The copper work from L1 moves to L3 UK Power Networks 2014 All rights reserved 10 of 12
5. Move the neutral connection to the top neutral bar. 6. Install the cable cleat at the top of the LV board as shown. 7. The clear plastic screening must now be removed from the white phase barriers and moved up so that the bottom of the screening is level with the bottom of the L3 phase shield. 8. The cut-out on the clear plastic screen must be removed. This will allow the screen to be refitted. 9. To maintain the IP rating of the board, insert the small angled clear plastic piece shown and mount with bracket supplied behind the circuit designation label. UK Power Networks 2014 All rights reserved 11 of 12
8 Cable Installation Options New service cables owned by UK Power Networks will use 185mm² bunched cables. The new 800A service ways have been designed to handle this cabling solution. Current cabling options are still supported. 600A service way currently used in LPN will remain unchanged apart from changes to allow installation into the Schneider Electric LV distribution equipment. Kits are also available to deal with the current cabling and termination solutions being used on LPN, SPN and EPN. The drawings associated with this engineering standard provide cabling information, Stores codes and phasing information. Wherever possible, common components have been used. The current SPN and EPN solutions will be phased out. The LPN solution will use the same service way with an alternative cable cleat. The current practice on the LPN network, which requires the customer to supply the service cables, will remain in force. There are six cabling options available. These are shown in the attached drawings: ECS 02-0037.1 600A Service 300/400mm Stranded Copper Cables (UK Power Networks). ECS 02-0037.2 800A Service 185mm 2 Bunched Cables (UK Power Networks). ECS 02-0037.3 800A Service 2 x 300mm 2 cables (LPN). ECS 02-0037.4 800A Service 740mm 2 Armoured Cables (SPN). ECS 02-0037.5 800A Service 630mm 2 Armoured cables (EPN). ECS 02-0037.6 800A Service Parallel 300mm 2 Waveform Cables (EPN). 9 Dependent Documents The documents below are dependent on the content of this document and may be affected by any changes. ECS 02-0037.1 ECS 02-0037.2 ECS 02-0037.3 ECS 02-0037.4 ECS 02-0037.5 ECS 02-0037.6 600A Service 300/400mm Stranded Copper Cables (UK Power Networks) 800A Service 185mm 2 Bunched Cables (UK Power Networks) 800A Service 2 x 300mm 2 cables (LPN) 800A Service 740mm 2 Armoured Cables (SPN) 800A Service 630mm 2 Armoured cables (EPN) 800A Service Parallel 300mm 2 Waveform Cables (EPN) UK Power Networks 2014 All rights reserved 12 of 12