CHANGING PLASTIC TYPE CUT-OUTS AND UPGRADING THE …

Module 55C

Mod55C.docx Issue 2 14/06/19 DMT CP411LV Page 1 of 13 © 2019 Electricity North West Limited.

CHANGING PLASTIC TYPE CUT-OUTS AND UPGRADING THE SERVICE TERMINATION POSITION WITH THE INCOMING SERVICE LIVE (PVC CABLE)

1. PURPOSE

When there is any need to carry out any work at a single phase termination position it is now a requirement to carry out sufficient work at the same time to bring all the equipment and connection arrangements up to modern standards, generally as set out in Drawing I 411P1-M55-001-2 below, such that the service termination is left, fitted with:

A modern 100amp cut-out.

A meter security block.

A satisfactory earth terminal connected to the distribution network earth.

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Note: The double pole isolator is only required if the consumer's installation is unsafe to reconnect.

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2. CHANGING THE CUT-OUT

WARNINGS: THIS MODULE IS ONLY TO BE USED FOR LIVE CUT-OUT CHANGES ON CUT-OUTS WHICH HAVE BEEN ASSESSED USING THE GUIDANCE SET OUT IN CP606, PROCEDURE B07, AND HAVE BEEN JUDGED TO BE SUITABLE BY THE COMPETENT PERSON ON SITE. IN GENERAL, THEY ARE THOSE CUT-OUTS WHICH HAVE A REMOVABLE SEALING CHAMBER AND REMOVABLE FUSE CHAMBER. CUT-OUTS MUST HAVE SEPARATE, BUT INTERLOCKING PARTS, FOR THE FUSE CHAMBER AND THE SEALING CHAMBER. DESIGNS WHERE IT IS NECESSARY TO THREAD THE CORES THROUGH APERTURES IN A CASTING SHALL NOT BE ATTEMPTED LIVE.

ANY CUT-OUT INDENTIFIED IN CP606 PROCEDURE B07, APPENDICES A OR B CANNOT BE CHANGED WHILST LIVE. IF ANY DOUBT EXISTS IN IDENTIFYING THE TYPE OR THE MANUFACTURER OF THE CUT-OUT TO BE WORK ON, THEN IT MUST BE COMPLETED DEAD.

ON NO ACCOUNT MUST FORCE BE USED TO REMOVE ANY METALWORK WHICH IS PART OF A CUT-OUT.

Notes: Approved protective equipment shall be worn (See CPLV411 Section 2.)

Refer to the drawings and photographs in Appendix A as required, throughout the following procedures.

Associated Drawings: I 411P1-M55-001-2 I 411P1-M55-002-2 I 411P1-M55-003-1

2.1 General

Because of the large number of differing designs of old type cut-outs which are in use throughout Electricity North West, it is impracticable to write an instruction which deals specifically with the breaking down of each individual type.

In this Jointing Module, the instructions covering the breaking down of cut-outs are of a general nature. Reliance is placed upon the competence and experience of the jointing staff engaged in this activity to recognise any potential hazards.

If the design, condition or physical location of a particular cut-out prevents it from being safely changed with the service live, then arrangements shall be made for the service to be made dead.

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2.2 Safety

The work shall be carried out in accordance with Electricity North West Distribution Safety Rules.

Only approved Insulated Tools shall be used.

Only approved Shrouding shall be used.

Approved PPE shall be worn. Face visor, coveralls, insulated gloves and protective footwear must be worn during this procedure.

Use the approved fire extinguisher (2kG Powder) as per CPLV411 Section 2. This is the standard fire extinguisher kitted with the van.

2.3 Preliminary Work

Arrange adequate and secure lighting. A range of lighting will usually be required due to the need to wear face visors and other PPE for certain activities. Examples of lighting include head torches and free standing lights. Hand-held torches shall not be used.

Visually examine the service termination to ensure that the cut-out can be safely changed with the service cable live.

Determine the cut-out can be changed to the constructional dimensions in the construction drawings in this module.

Determine whether the cut-out is high enough off the floor to permit a safe working position.

Determine whether the service cable is supported sufficiently to prevent excessive vertical or horizontal movement whilst the cable is being worked on.

Shroud all exposed metalwork within the working zone, except any metalwork on which work is actually to be done. Use approved shrouding only.

Take adequate precautions to avoid fire or scorching in the vicinity of the service termination by removing loose flammable materials and by suitable use of heat resisting materials.

Where any of the equipment being worked on is found to contain asbestos containing materials or similar suspicious materials, all live working shall stop and the procedures in CP670, Working Safely with Asbestos Containing Materials (Asbestos Task Book), shall be used to remove that equipment safely before any further work can proceed.

2.4 Removal of the Old Cut-out

Cleat the cable securely to the wall at floorboard level (see Drawings I 411P1-M55-002 & I 411P1-M55-003).

Remove the fuse carrier and check polarity. (Procedure G16 CP606/610)

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Note: Where the polarity is confirmed as being reversed (cross polarity), this cannot be safely rectified by crossing connections in the cut-out. In all such cases this cross polarity shall only be corrected by cutting the service cable external to the property and making a transposition joint to reverse the error, or by using a cut-out specifically designed to permit the transposition of the Live fuse carrier with the Neutral block.

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If fuse carriers are to be used for shrouding purposes, then the fuse must be removed.

Check Earth Loop Impedance. (Procedure G20 CP606/610)

Remove meter tails and any earth connections from the cut-out. Where the meter has been connected using cabled meter tails, apply phase marker tapes to the meter tails for identification. Disconnect the meter tails from the meter. Remove all cables from the meter. Secure consumer tails and any other apparatus clear of the working zone and shroud with suitable insulating material. Shroud any exposed earthing. Remove the meter from the meter board.

Remove the fuse carriers from the service cut-out (acting as shrouding).

Offer the cut-out terminal block and cable entry cover against the end of the service cable. (For side entry cable arrangement, offer up cut-out terminal block and rear portion of sealing chamber.)

Check that the phase and neutral cores are of sufficient length to enter the terminal block correctly.

If insufficient length exists strip back the service cable as detailed in Section 2.5 of this instruction, otherwise proceed directly to Section 2.6 or 2.7 dependent upon the cable type.

2.5 Cable Preparation for Plain and Split Concentric Cables

Support the cut-out in the upright position allowing room to work around the cable.

Position and fix the new meter board (if required).

Prepare the new cut-out (fit the PME link if appropriate).

Mark the base position of the new cut-out cable crutch cover on the meter board.

Shroud the existing cut-out and all exposed metal work.

Remove the PVC sheath to 10mm above the mark made during this procedure.

2.6 PME Cable Procedure

Remove N/E wires from cut-out.

Straighten out N/E Wires. (Check for trapped wires and insulation damage around the crutch area. Form birdcage arrangement.)

Apply layers of vinyl neutral (N) tape 20mm up from PVC cut.

Re- shroud N/E wires and position out of way.

Remove the cut-out retaining screws, supporting the cut-out, from the meter board.

Whilst supporting the cut-out, undo the phase terminal block phase retaining screws.

Remove the existing cut-out, then immediately shroud the phase conductor with approved insulating finger.

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2.7 Non PME Procedure

Remove earth wires from cut-out.

Straighten out earth wires. (Check for trapped wires and insulation damage around the crutch area. Form birdcage arrangement.)

Apply layers of green & yellow PVC tape 20mm up from PVC cut.

Re- shroud earth wires & position out of way.

Remove neutral wires from cut-out.

Straighten out neutral wires. (Check for trapped wires and insulation damage around the crutch area. Form birdcage arrangement.)

Apply layers of vinyl neutral (N) tape 20mm up from PVC cut.

Re-shroud neutral wires & position out of way.

Remove the cut-out retaining screws, supporting the cut-out, from the meter board.

Whilst supporting the cut-out, undo the phase terminal block phase retaining screws.

Remove the existing cut-out.

Remove the existing cut-out, then immediately shroud the phase conductor with approved insulating finger.

2.8 Fitting the New Cut-out

Offer up the cut-out terminal block and cable entry cover against the cable termination.

Use a china graph pencil to mark where the phase cores require cutting.

Check that when the cores are finally connected into the terminal block, the PVC sheath will extend 10mm into the cable entry cover.

Establish how many tails are to be taken from the cut-out and remove the knockouts.

Shroud the cores and cut to length using approved insulated cutters. Remove the insulation to the depth of the terminal barrel plus 5mm of insulation using the approved insulated core knife. Shroud using a temporary insulating finger. For split concentric cable repeat same procedure for the neutral and shroud using a temporary insulating finger.

When connecting the phase, neutral and earth to the terminal block as per the following instructions, it is important: To make sure that each conductor is properly gripped by BOTH screws. Not to disturb the cores once the screw have been tightened. To tightly screw down all unused terminal screws.

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Remove the temporary insulating finger and carefully insert the phase conductor. Tighten the top screw first. Once this has been done tighten the bottom screw. Insert empty fuse carrier / shroud.

Remove the temporary insulating finger and carefully insert the neutral conductor. Tighten the top screw first. Once this has been done tighten the bottom screw.

Remove the temporary insulating finger and carefully insert the earth conductor. Tighten the top screw first. Once this has been done tighten the bottom screw.

Fit the cut-out shroud to the live terminal block.

Replace any cut-out fillers.

Tighten the cut-out onto the service termination board.

Confirm polarity / Impedance. (Procedure G16 and G20 CP606/610)

Carry out test procedures as per Electricity North West requirements.

Fix all remaining items (stickers / labels) onto the cut-out.

2.9 Completing the Termination

Split the cable entry bush and trim to fit around the service cable.

Fit the cable entry cover and split grommet into position.

Note that the service termination board on which the termination is mounted (formerly known as the Meter Board) is the property of Electricity North West and the consumer is not entitled to mount any of their own equipment on this board.

In some cases there may be sufficient room to re-align the various pieces of equipment so that correct use can be made of the meter security block, and to ensure there is enough room to mount the 100amp double pole isolator if required.

Remove any redundant equipment that is mounted on the board, but is clearly disconnected and no longer in use (eg bell transformer). Return this equipment to the consumer for disposal.

2.9.1 If the Consumer's Tails from their Consumer Unit/Main Switch are in Poor or Unsafe Condition

When the consumer’s tails from their consumer unit/main switch are in poor or unsafe condition, such that they should not be reconnected, proceed as follows:

Install a 100amp double pole isolator / disconnector (connected to the customer's side of the meter with a set of 25mm2 meter tails).

To the incoming supply, complete the termination up to the installation of the 100amp double pole disconnector and its connection to the meter.

Leave the customer tails unconnected.

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Following successful testing, re-energise the service termination up to the outgoing terminals of the 100amp double pole disconnector (which should be left in the OFF position with a temporary seal).

Leave the consumer’s tails unconnected and advise the consumer to call a qualified electrician to make the necessary repairs to their installation. Complete form in Appendix A of Mod 64 and issue to the consumer.

2.10 Fit Meter Security Block and Meter Tails and Re-Fit Meter

Secure the meter security block into the meter.

Only in situations where it is physically impossible to position the meter above the cut-out and fit a meter security block, because of the space available, is it permitted to connect between the cut-out and meter, using double insulated single core cable tails.

Cut the following:

Length as required of brown (live) 25mm² cable.

Length as required of blue (neutral) 25mm² cable.

Strip 25mm of the conductor insulation and secure the tails in the consumer's side live and neutral terminals of the meter.

Note: Ensure that there is no gap between the interconnector block and the cut-out.

Temporarily place the meter and interconnector block in position with the cut-out and mark the top centre of the meter. Remove the meter and interconnector block and secure a screw at the mark.

Position the meter and interconnector block on the cut-out so that the meter hangs off the screw. Check that there is no gap between the interconnector block and cut-out and secure the meter to the meter board.

Secure the tails of the interconnector block to the cut-out.

2.11 Fitting an Earth block (where required)

(Fitting an earth block may not be required for certain types of cut-out.)

Position the earth block with the base 65mm from the bottom of the meter board and the left side of the earth block approximately 150mm from the left side of the meter board, so that it is positioned to the right of the cut-out (generally as shown in drawing: I 411P1-M55-001-2).

Set, mark and cut the 16mm2 earth cable to fit between the cut-out and the earth block.

Slide the warning label down the earth cable, and position so that it is fully visible.

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Strip 20mm of insulation from the end of the consumer’s earth cable, but leave disconnected at this time.

Check that the grub screws of all the terminals are secure.

2.12 Reconnection and Testing

Re-test for correct polarity.

Re-connect the earth leads from the consumer's equipment (which had been removed earlier) into the earth terminal block.

In the case of PME earthing system: Fix the PME Link inside the cut-out. Fix a PME label to the neutral/earth block cover.

Fit the neutral/earth block cover and insert the fuse carrier fitted with the correct size of main fuse.

Seal the fuse carrier to the cut-out using approved sealing wire and seal both top and bottom sections.

Re-seal the meter terminal cover using sealing wire and seal.

Check that the service cable is securely attached with cleats. Replace with new cleats as necessary.

2.13 The Domestic Outside Viewing Cabinet

Secure the cabinet door to prevent interference whilst working.

Use adequate weather protection to shield the working area from inclement weather.

Use PPE as required to comply with the safety rules.

It may be impractical to replace the new cut-out using above methods in Sections 2.1 to 2.8 due to working constraints. The conductors may not be flexible enough to remove and insert in to a fixed cut-out. If insufficient cable length is not available, it may be necessary to dig at the base. The alternative method is to undo all the fixing screws of the cut-out and remove the cable cover.

Proceed as follows:

Undo the conductor screws and carefully lift off the main assembly.

Shroud all the conductors immediately.

Re-align the conductors to suit the replacement cut-out.

Remove the conductor shrouds and fit the cut-out.

Tighten conductor screws.

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Insert and tighten fixing screws, cable cover and grommet (Section 2.9) .

Continue with installation of meter tails (Section 2.10), Earth Block if required (Section 2.11) and Reconnection and Testing (Section 2.12) as detailed above.

Some existing cut-outs may require a joint and a new cable length if insufficient cable length is not obtained for the modern type cut-out.

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CHANGING PLASTIC TYPE CUT-OUTS AND UPGRADING THE …