Sabre VRN-FS SEC SmART

Installation, Operation and Maintenance Manual

 TABLE OF CONTENTS
1 GENERAL DESCRIPTION ..................... 4 6.8 Auxiliary Wiring Switch testing .......................... 21
2 TECHNICAL DATA ................................ 4 7 SABRE ‘MANUAL’ OPERATION ..........22
2.1 Sabre VRN-FS Dimensions (Including Cabling 7.1 Opening the Main Door ....................................... 22
Boxes) .................................................................. 5 7.2 Obtaining the Operating Handle ........................ 22
2.2 Sabre VRN-FS Schematic Line Diagram ........... 6 7.3 Circuit Breaker Operation ................................... 23
2.3 Foundation Details .............................................. 6 7.3.1 Padlocking to prevent operation............................. 23
3 FRONT PANEL LAYOUT ...................... 7 7.3.2 Circuit Breaker from ‘MOTORISED’ to ‘MANUAL’
operation ................................................................ 23
4 DESIGN .................................................. 8 7.3.3 Operate CB/T-Off from ‘ON’ to ‘OFF’ .................... 23
4.1 General ................................................................. 8 7.3.4 CB/T-Off from ‘SERVICE’ to ‘ISOLATED’ ............. 24
4.2 Stainless Steel Gas Enclosure ........................... 8 7.3.5 To Earth CB/T-Off at ‘ISOLATE’ position ............... 25
4.3 Housing ................................................................ 8 7.3.6 To remove Earth from CB/T-OFF........................... 26
4.4 Tee-Off Circuit Breaker ....................................... 8 7.3.7 Operate CB/T-Off from ‘ISOLATE’ to ‘SERVICE’... 26
7.3.8 To Close CB/T-Off to ‘SERVICE’ ........................... 27
4.5 Ring Switches ...................................................... 8 7.4 ‘Pull To Trip’ ......................................................... 28
4.6 Operation ............................................................. 8 7.5 Circuit Breaker From ‘Tripped’ to ‘Reset’ .......... 29
4.7 Test Facilities ...................................................... 8 7.6 Circuit Switch Operation .................................... 30
4.8 Interlocks ............................................................. 8 7.6.1 Circuit Switch from ‘MOTORISED’ to ‘MANUAL’
4.9 Padlocks .............................................................. 9 operation ............................................................... 30
5 SABRE UNIT INSTALLATION .............. 9 7.6.2 Padlocking to prevent operation ............................ 30
5.1 Receipt and Storage of Unit ............................... 9 7.6.3 Circuit Switch from ‘MAIN ON’ to ‘OFF’ ................. 30
7.6.4 Circuit Switch from ‘OFF’ to ‘EARTH ON’ ............. 31
5.2 Slinging Details ................................................... 10 7.6.5 Circuit Switch from ‘EARTH ON’ to ‘OFF’ .............. 32
5.2.1 Sabre VRN-FS Unit ............................................... 10 7.6.6 Circuit Switch from ‘OFF’ to ‘MAIN ON’ ................. 32
5.3 Sabre VRN-FS Unit Floor Mounting 7.7 Testing Circuit Switch Cables ............................ 33
Dimensions ......................................................... 11 7.7.1 Circuit Switch Cable Test Padlock Facility ............ 34
5.3.1 Unit Location ......................................................... 11 8 CABLE BOX ACCESS ...........................35
5.4 Cable Terminations ............................................. 12 8.1 Release T-Off Interlock & Remove Cable Box .. 35
5.4.1 Torque Settings On Cable Bushings ..................... 13 8.2 Refit Cable Box & Reset T-Off Interlock ............ 36
5.5 Earthing ................................................................ 13
8.3 Release Ring Switch Cable Box Interlock ......... 37
5.6 Marshalling Box .................................................. 13
8.4 Refit Cable Box & Reset Ring Switch Interlock 38
6 COMMISSIONING TESTS ..................... 14
6.1 Main Circuit Resistance Tests ........................... 14
9 EARTH FAULT INDICATION .................39
9.1 Overview .............................................................. 39
6.2 Secondary Wiring Insulation Resistance
9.2 Operation ............................................................. 39
Testing ................................................................. 15
9.3 Installation ........................................................... 40
6.2.1 1 kV test. ............................................................... 15
6.3 HV Tests Before Cabling or Connection To 9.3.1 Multi Core Cable System ....................................... 40
Transformer ........................................................ 15 9.3.2 Single Core Cable System .................................... 40
9.3.3 EFI Testing ............................................................ 41
6.3.1 HV Insulation Resistance Testing ......................... 16
6.3.2 Power Frequency Testing ..................................... 17 10 SABRE UNIT MAINTENANCE ..............42
6.4 Electrical Tests After Cabling or Connection 10.1 Operating Conditions .......................................... 42
To Transformer ................................................... 17 10.2 Maintenance Intervals ......................................... 42
6.5 Relay Type Protection Tests .............................. 18 10.3 Maintenance Schedule ........................................ 42
6.5.1 Relay Primary Injection Test - Overcurrent Test ... 18 10.4 SF6 Issues ............................................................ 43
6.5.2 Relay Primary Injection Test - Earth Fault Test ..... 19 10.4.1 SF6 Gas Leakage ................................................. 43
6.5.3 Relay Secondary Injection Tests - Overcurrent and 10.4.2 SF6 Gas Topping Up ............................................. 43
Earth Fault Test ..................................................... 19 11 CIRCUIT BREAKER REMOTE ACTUATOR
6.6 VPIS & NEON Indication (if fitted) ...................... 20 OPTION ..................................................44
6.6.1 Pickup voltage ....................................................... 20 11.1 Remote Operation Conditions ........................... 44
6.6.2 Crossover voltage ................................................. 20
11.2 Manual Operation ................................................ 44
6.6.3 Phase comparator ................................................. 20
6.7 Shunt Trip (if fitted) ............................................. 21 11.3 Circuit Breaker Trip Reset .................................. 44
11.4 Remote Actuator Disengage .............................. 45

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 Validity

This manual was produced in January 2021 and applies to the Sabre VRN-FS - SEC smART unit only.

Due to Lucy Electric’s policy of continuous research and development, Lucy Electric reserves the right to
change the design and specification of it’s products without prior notice.

Safety

Operators of this equipment must have experience and

expertise with switchgear. To prevent personal injury or
equipment damage this manual must be read carefully.

This manual MUST be readily available whenever the unit is

handled or operated.

If this equipment suffers from any fault or damage, contact the

manufacturer and/or supplier immediately.

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 1. GENERAL DESCRIPTION
The Sabre VRN-FS is compact SF6 insulated Vacuum Ring Main Unit (RMU). The unit can be mounted
to the smallest distribution transformer, or be sited in a free standing format. Designed to be used both
indoors and outdoors, the unit has a long service life and requires virtually zero maintenance.

2. TECHNICAL DATA
Sabre VRN-FS SmART
Rated Voltage 17.5kV
Impulse Withstand Voltage 95kV
Normal Current Ring Switches 400A
Tee-Off Circuit Breaker 250A
Short Circuit Peak Making Current Ring Switches 52.5kA
Tee-Off Circuit Breaker 52.5kA
Short Circuit Breaking Current Tee-Off Circuit Breaker 21kA RMS
1 Second Short Time Current Ring Switches 21kA
Tee-Off Circuit Breaker 21kA
Earth Switch Peak Making Current Ring Switches 52.5kA
Tee-Off Circuit Breaker 52.5kA
Internal Arc Rating Freestanding 21kA 1 sec
Gas pressure Min Operating Pressure 0 Bar G
IP Rating Up to IP54W
Weight 465kg
Testing standards BS EN 60265-1 / BS EN 62271-103
BS EN 60129 / BS EN 62271-102
BS EN 60694 / BS EN 62271-1
BS EN 60298 / BS EN 62271-200
IEC 60056 / BS EN 62271-100
ENA TS 41-36
IEC 62271-102
IEC 62271-100
IEC 62271-103

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 2.1 Sabre VRN-FS Dimensions (Including Cabling Boxes)

Dimensions in millimetres.

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 2.2 Sabre VRN-FS Schematic Line Diagram

2.3 Foundation Details

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 3. FRONT PANEL LAYOUT

1 : Fascia / Front Panel 14: Ring Switch 1 Selector

2 : Pull To Trip' knob 15: Ring Switch 1 Cable Box Interlock

3 : Circuit Breaker / T-Off Operation Slot 16: Ring Switch 1 Indicator

4 : Circuit Breaker / T-Off Indicator 17: Ring Switch 1 Operation Aperture

5 : Circuit Breaker / T-Off Selector 18: Circuit Label - Customer customization

6 : Disconnector Operation Slot 19: Optional VPIS Plates for LH/RH Ring
Switches & CB/T-Off
7 : Disconnector indicator (Service/Earth) 20: SF6 Top up Valve - Hansen Coupling

8 : Disconnector Padlock Flap 21: Pressure Indicator

9 : Ring Switch 2 Indicator 22: T-Off Cable Box Interlock

10: Ring Switch 2 Selector 23: Operating Handle (operating Handle Stowed
on the Inside of the Door)
11 : Ring Switch 2 Operation Aperture 24: Protection Relay

12: Ring Switch 2 Cable Box Interlock 25: Ring Switch 1

13: Cable Test Access Cover 26: Ring Switch 2

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 4. DESIGN
4.1 General
The Sabre VRN-FS is a non extensible RMU comprising of a tee-off vacuum circuit breaker and two fault-
make load break ring switches contained within a common SF6 gas insulated stainless steel enclosure.
The unit is suitable for both indoor and outdoor applications and can be used either as a freestanding unit,
or for mounting to a transformer complying with ENATS 35-1.

4.2 Stainless Steel Gas Enclosure

The gas enclosure is manufactured from stainless steel and fabricated utilising automatic 'robot welding'
techniques to produce consistent leak- free equipment.

4.3 Housing
The housing of the Sabre VRN-FS is fully treated; using zinc coated steel and electrostatically applied
oven cured paint, to resist weather and pollution attacks. All units are provided with a hinged,
weatherproof and lockable door.

4.4 Tee-Off Circuit Breaker

The tee-off circuit breaker comprises of three vacuum interrupters, which have a fault-make, fault-break rating.
Opening of the circuit breaker is achieved by manually operating the handle as standard.
Earthing of the outgoing cable, from the tee-off circuit breaker, is achieved by the use of the circuit breaker in series
with the off-load disconnector/selector switch.

4.5 Ring Switches

The two ring switches are of the single break, fault-make / load- break 3 position types, 'ON', 'OFF' and
'EARTH'.

4.6 Operation
All operating positions and instructions are indicated on the main panel at the front of the unit. Operation
is by means of manually independent mechanisms, which are mounted externally to the gas enclosure.
The tee-off vacuum circuit breaker has two operating positions, 'ON' or 'OFF', with an off-load, interlocked
selector allowing isolation & earthing of the tee-off circuit.
A single, “Y”-bar type operating handle is stored at the front door. Symbols located on the end of the
operating handle indicate direction of operation.

4.7 Test Facilities

The Sabre VRN-FS has fully interlocked integrated ring switch cable test facilities in accordance with
ENATS 41-36 requirements. Access to the test terminals is achieved by pulling a lever located on the front
fascia inside the front door. This will allow the cover underneath the unit to drop down. Where cable test
facilities are required on the T-off, an alternative interlocked system, using plug-in connectors, is
available.

4.8 Interlocks
Positive safety interlocks are incorporated on all switch positions.

4.9 Padlocks
The door has cam action lever locking with padlockable protection cover. The padlock
hasp hole size 8mm.
All switch and selector positions can be padlocked. The padlock hasp hole size is
8.5mm diameter.

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 4.10 Transformer Protection
The circuit breaker enables the VRN to protect transformers with ratings well in excess of those of a
comparable HV fused unit. Protection is achieved by the use of ring core current transformers in
combination with a protection relay. The ring core current transformers are mounted around the rear tee-
off bushings, external to the SF6 chamber, but within the cladding of the unit. The protection relay, is
mounted behind a cover at the front of the unit.

5. SABRE UNIT INSTALLATION

Electrical testing done during the commissioning phase of

installation is to be completed by competent and responsible
electrical personnel only.

5.1 Receipt and Storage of Unit

Units are shipped with covers closed and bolted, (all switches are in the closed position), with temporary
protective covers over Tee-Off bushings if transformer mounted. If the units are to be stored for long
periods, a dry well ventilated area should be provided. Covers should be left closed to minimise breathing
– especially in situations with wide daily temperature variations.

The Sabre VRN-FS unit undergoes strict quality checks during manufacturing and despatch at the Lucy
production facility, prior to it being delivered to the customer. Ensure that during transit the unit has not
sustained any damage, if so then contact the manufacturer and/or supplier immediately.

DO NOT OPERATE the unit if it is damaged.

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 5.2 Slinging Details

5.2.1 Sabre VRN-FS Unit

The unit should always be lifted by using all four of the 'eye' hooks. These are located on top of the
unit as shown:

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 5.3 Sabre VRN-FS Unit Floor Mounting Dimensions

The units are designed for bolting down onto a concrete plinth using 4 - M16 bolts.

View From Above Unit

5.3.1 Unit Location

Authorities will have their preferred instructions for the installation of electrical equipment and these must
be adhered to. If none are available, however, the following sequence is recommended.

1 : Prepare the plinth, casting in floor chases in accordance with the Company's contract or arrangement
drawings.
2 : Locate the unit, loosely assemble the floor fixings and grout in the rag bolts.
3 : When the cement has hardened, tighten the fixings - shimming under the unit base as required to level the unit
and ensure that it rests equally at each fixing.

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 5.4 Cable Terminations

The bushings for each switch and circuit breaker are located at the front of the unit. All sets of the bushing
are type ‘C’ with in-line bolted connections M12 threaded in accordance with EN50181.
The bushings are accessible by removing the interlocked cable box covers at the front of the unit.
The maximum cable size that can be used are:
• 300mm² single core cable
• 500mm² three core cable

The following type of termination is to be used with the Sabre VRN-FS SmART:

Ring Switch & T-Off Bushings

Plug-In Type

Contact Lucy Electric for further cable termination details

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 5.4.1 Torque Settings On Cable Bushings

Refer to the plug-in sockets manufactures installation guide for torque settings.
Cables can be routed via trenches, passages or ducts, depending on the type of gland plates fitted
All the cable boxes have removable covers for accessibility.

To install the plug-in type sockets onto the end of each cable, comply with the socket manufacturer’s
instructions
If plug-in termination is being used, lubricate the bushing and inside of
the socket before fitting. Contact termination supplier for details of
correct lubricates to be used.

Both T-Off and ring cable boxes have removable

panels for increase in accessibility.

5.5 Earthing 5.6 Marshalling Box

The Sabre VRN-FS unit should be earthed at either The marshalling box located on the left hand side of
of the primary earth points. These earth points are the unit and houses the terminals for all customer
located at the rear of the unit, either side of the options including ring switch actuators, pressure
Cable Test Access Cover as shown. switch, G3 RTU and EFI CT’s.

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 6. COMMISSIONING TESTS
It is recommended that Electrical Circuit Resistance readings are taken.
This is to ensure good working order of all moving parts inside the unit,
and to make sure the unit is safe to operate for testing.

6.1 Main Circuit Resistance Tests

Resistance readings should be taken for the following circuit path for each phase:
• Ring switch 1 to ring switch 2
• Ring switch 1 to T-Off
• Ring switch 2 to T-Off

These readings taken are to be compared with the following maximum values.

Circuit Resistance Value (microhms)

Ring Switch To Ring Switch 260
Ring Switch To T-Off 265

Any readings which are above these maximum values should be reported to appropriate supervising
personal for review.

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 6.2 Secondary Wiring Insulation Resistance Testing

Insulation resistance testing is conducted at 1kV in accordance with international standards.

In addition to this, the Sabre VRN-FS unit is also tested at 2kV during the manufacturing process and is
not required to be re-tested at this voltage level.

It is recommended that sensitive electronics devices, motors and actuators, be detached from the unit
prior to testing (this includes any case earths found on relays etc). 1kV testing across auxiliary indication
wiring and contacts across EFI’s/FPI’s is not recommended, unless approved by the manufacturer.

If testing is conducted across such contacts, the applied test voltage must not exceed 1kV.

6.2.1 1 kV test.
• Remove the earth link (see below).
• Where units are not fitted with a removable earth link, ensure all earths
are removed from the unit, both internally and externally.
• If protection relays are fitted remove the relay from its housing on the
front of the unit before commencing test.
• Attach the black (negative) lead of the test set to the unit at any point
where a bolted connection is present (nut etc.).
• Using the red (positive) lead as a probe, test each of the connections
located on the terminal block in the Marshalling box for approx 2
seconds.
• Any indication of continuity should be investigated and rectified.

Removal of the Earth link

1. Position of earth link 2. Lift link with finger. 3. Rotate the link completely
away from the terminal.

6.3 HV Tests Before Cabling or Connection To Transformer

The following tests are to be undertaken AFTER ensuring the Main Circuit Resistance’ readings are within
specification (Section ’6.1 Main Circuit Resistance Tests’).
For HV tests, the circuit breaker must be in the ‘ON’ position, and the following tests be taken through the
cable terminals.

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 6.3.1 HV Insulation Resistance Testing
Using a suitable insulation resistance test device (1kV or 5kV dc megger), measure the insulation
resistance to earth of each of the three terminals in turn, with the other two earthed. The readings should
not be less than 100 megohms, lower values may indicate damaged or dirty insulation.

WARNING: THE FOLLOWING TESTS SHOULD NOT BE UNDERTAKEN IF THESE READINGS ARE LESS
THAN 100 MEGOHMS.

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 6.3.2 Power Frequency Testing

These test values are to IEC 60694.

Conduct these tests as follows:
• Ensure unit has correct gas pressure.
• Ensure the tripper is shorted out before testing.
• Ensure the VPIS (if fitted) is shorted to earth.
• Follow the test schedule below (see diagram for
labelling).
• Apply test voltages as per table below.
• The test is considered acceptable when neither
breakdown or flashover has occurred (where
necessary, fit additional insulation onto the
bushings).

Test Schedule

Test RH Ring LH Ring Disconnector CB Switch Apply Test Earth

Switch Switch Voltage To:
Test Phase To Phase And Phase To Earth.
1 Closed Closed Service Closed U1, W1 Frame, V3
2 Closed Closed Service Closed V1 Frame, U3, W3
3 Closed Closed Service Open U1, V1, W1 U3, V3, W3
4 Open Open Service Closed U1, V1, W1, U3, V3, W3
U2, V2, W2

Test 17.5kV Duration Fit Insulation Caps

(Mins) And Adaptors
1 30.4kV 1 Yes
2 30.4kV 1 Yes
3 36kV 1 Yes
4 36kV 1 Yes

Test Voltages (Represent 80% of the routine factory test voltage)

6.4 Electrical Tests After Cabling or Connection To Transformer

Switch one of the ring switches into the ‘EARTH ON’ position, slide the ‘Ring Switch Selector’ into the
centre position, then open the cable test access cover (For this operation, please ensure the relevant ring
switch is in the 'EARTH ON' position and the 'Ring Switch Selector' is in the centre position, padlocked if
applicable).
Apply a test voltage of 25kV dc (or as specified by network owner) to earth for 15 minutes. Repeat tests
on the other ring switch.

It should be noted that for transformer connected units, the circuit breaker or selector should be in the
isolating position before proceeding to ensure the transformer does not suffer any damage.

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 6.5 Relay Type Protection Tests

Please Note: The following test diagrams in this section are generic and only for explanation purposes
for relay type systems.

6.5.1 Relay Primary Injection Test - Overcurrent Test

• Ensure the ring switch and circuit breaker are closed.

• Setup test as shown, ensuring the removable earth link & test link are fitted and closed.
• Ensure the 3 phase shorting link (100A rating) is fitted as shown.
• Setup relay for overcurrent test, including settings.
• Apply the appropriate test current to the relay setting and CT ratio.
• Repeat for each phase.
• Repeat for each ratio - values to be recorded if necessary.

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 6.5.2 Relay Primary Injection Test - Earth Fault Test

• Ensure the ring switch and circuit breaker are closed.

• Setup test as shown, ensuring the removable earth link & test link are fitted and closed.
• Setup relay for earth fault test, including settings.
• Apply the appropriate test current to the relay setting and CT ratio.
• Repeat for each phase.
• Repeat for each ratio - values to be recorded if necessary.

6.5.3 Relay Secondary Injection Tests - Overcurrent and Earth Fault Test
Consult the appropriate relay technical documentation for recommended secondary injection procedure,
commissioning checks and any necessary equipment required.

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 6.6 VPIS & NEON Indication (if fitted)

Both VPIS (voltage presence indication system) & neon indication systems are available as an option.

The VPIS system is generally in accordance with IEC 61958 and is complete with voltage limiting devices
to ensure safety in the event of an insulation failure.

VPIS can be used to test both for correct phase orientation of cables and for the presence of voltage. The
VPIS system can be the Pfisterer type (4mm sockets HR system using relevant HR adapters) which
comply with IEC 61243-5 either with or without push button neons.

Push Button Neons

The following checks should be made during commissioning where applicable.

6.6.1 Pickup voltage

For a 17.5kV unit this value will be below 5kV.
• Using a high voltage test set, apply the appropriate voltage to the unit between the selected phase (left or right side)
and earth.
• Insert the appropriate neon test device into the relevant socket and check that voltage presence is indicated by the
flashing neon (in some cases the flashing may be very rapid and appear as continuous).

6.6.2 Crossover voltage

Once it is determined that the Neon indicators are functional and correct pickup values determined,
proceed to completing a crossover check. Test as follows:
• Using a high voltage test set, apply the appropriate voltage to the unit between the selected phase (left or right side)
and earth. For 17.5kV units this is normally 6.9kV.
• Insert a neon indicator into the appropriate phase and check operation.
• With power maintained on the unit, check each of the other phase neon's (both left and right) for any indication of
voltage. There should be no indication on the other phases.

6.6.3 Phase comparator

The Pfisterer phase comparator can be used to determine correct phase connection of a cabled unit. Test
as follows:
• Ensure both ring switches are open if the HV cables are going to be used to carry out the test.
• For 17.5kV and higher system voltages, ensure the HR - LRM adapter is inserted into the sockets (or the Pfisterer
converter).
• Connect the comparator according to the manufacturer's instructions and check the unit for correct connection of
phase cables according to the coloured lights.
• The comparator can also be used as a neon voltage presence indicator.

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 6.7 Shunt Trip (if fitted)

Where shunt trip terminals have been fitted in the marshalling box, the following procedure is to be
followed to ensure effective operation of the shunt trip device.
• Locate the shunt trip terminals on the marshalling box using the supplied wiring diagram to confirm the terminal
numbering.
• Using appropriate test set, apply voltage to the two previously identified terminals.

Note:
• If the unit is fitted with a DC shunt coil then tests should be done at 70% & 110% rated voltage.
• If the unit has an AC coil fitted, then testing should be done at 85% & 110% of rated voltage.
• The unit should trip.
• The operation of the shunt trip device is thereby confirmed. Any unexpected tripping operation during testing
should be investigated and reported to the appropriate responsible person/supervisor.

6.8 Auxiliary Wiring Switch testing

Auxiliary wiring should be checked for continuity as well as various auxiliary switches and contacts.
Please refer to the supplied marshalling box wiring diagram.
The following are to be checked on the unit, to ensure correct operation, before completing installation:
• Ring switch auxiliary contacts.
• CB/T-Off auxiliary contacts.
• Motorization indication circuits - operation of motor actuation should be checked if fitted/supplied with the unit.

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 7. SABRE ‘MANUAL’ OPERATION

Check the pressure indicator on the front panel, behind main

door. Ensure the pointer is in the green zone before any
switching operations are carried out.

After all manual operations are complete, ensure the

Local/Remote switch in the RTU is switched back to
the ‘REMOTE’ position.
7.1 Opening the Main Door
1 : Remove Padlock and swing the protection cover 2 : Release both door catches as shown and open the
away to reveal two door catches. door.

7.2 Obtaining the Operating Handle

1 : Operating handle in stowed position inside main 2 : Lift handle and remove as shown.
door.

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 7.3 Circuit Breaker Operation
7.3.1 Padlocking to prevent operation Remove padlock for operation
1 : Slide the 'Disconnector Padlock Flap' to the right to 2 : Remove padlock from the 'Disconnector Padlock
lock all CB/Tee-Off operations and lock flap using a Flap', then slide the selector left to the 'CB AND
padlock as shown. DISCONNECTOR FREE' position.

7.3.2 Circuit Breaker from ‘MOTORISED’ to ‘MANUAL’ operation

1 : Locate the Local/Remote switch in the marshalling box and Switch from ‘REMOTE to ‘OFF’.

7.3.3 Operate CB/T-Off from ‘ON’ to ‘OFF’

1 : Insert the operating handle into the 'Circuit 2 : Move the operating handle upwards to the ‘OFF’ &
Breaker Operation Slot' as shown. ‘Reset’ direction, during which the first step it
switches OFF the CB and when the operating
handle is moved further upwards, it resets the
mechanism so that it is ready for next switching ON
operation or movement of the shutters for switching
to EARTH. This upward movement to switch OFF
and Reset does not require much force/speed of
operation.

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 3 : The circuit breaker indicator will now show 'off' as 4 : Remove operating handle.
shown:

! Note: Ensure the 'Disconnector Padlock Flap' is in the 'CB AND DISCONNECTOR FREE' position
before operation (Section ’7.3.1 Padlocking to prevent operation).

7.3.4 CB/T-Off from ‘SERVICE’ to ‘ISOLATED’

1 : With the circuit breaker in the 'OFF & RESET' 2 : Insert the operating handle into the 'Disconnector
position (Section ’7.3.3Operate CB/T-Off from Operation Slot' as shown.
‘ON’ to ‘OFF’), slide the 'Circuit Breaker/T-Off
Selector' to the 'DISCONNECTOR' (centre)
position as shown.

3 : Firmly lift the operating handle up from the 4 : The CB/T-Off Disconnector indicator will now show
'SERVICE' to the 'ISOLATE' position. 'Isolated' and 'Earth Selected' as shown:

5 : 4. Remove operating handle.

! Note: Ensure the 'Disconnector Padlock Flap' is in the 'CB AND DISCONNECTOR FREE' position
before operation (Section ’7.3.1 Padlocking to prevent operation).

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 7.3.5 To Earth CB/T-Off at ‘ISOLATE’ position

1 : With the circuit breaker 'OFF' and the 2 : Insert the operating handle into the 'Circuit Breaker
Disconnector in 'ISOLATE', slide the 'Circuit Operation Slot' as shown.
Breaker/T-Off Selector' left to the 'CB EARTH'
position as shown.

3 : Firmly pull the operating handle down from the 4 : The circuit breaker indicator will now show 'earth
'OFF’ & ‘RESET' to 'ON' position. on' as shown:

5 : Remove operating handle.

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 7.3.6 To remove Earth from CB/T-OFF

1 : Insert the operating handle into the 'Circuit Breaker 2 : Move the operating handle upwards to the ‘OFF’ &
Operation Slot' as shown. ‘Reset’ direction, during which the first step it
switches OFF the CB and when the operating
handle is moved further upwards, it resets the
mechanism so that it is ready for next switching ON
operation or movement of the shutters for switching
to EARTH. This upward movement to switch ‘OFF
& RESET’ does not require much force/speed of
operation.

3 : The circuit breaker indicator will now show 'off' as 4 : Remove operating handle.
shown:

7.3.7 Operate CB/T-Off from ‘ISOLATE’ to ‘SERVICE’

1 : With the circuit breaker in the 'OFF & RESET' 2 : Insert the operating handle into the 'Disconnector
position, slide the 'Circuit Breaker/T-Off Selector' to Operation Slot' as shown.
the 'DISCONNECTOR' (centre) position as shown.

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 3 : Firmly pull the operating handle down from the 4 : The CB/T-Off Disconnector indicator will now show
'ISOLATE' to 'SERVICE' position. 'Service' as shown:

4. Remove operating handle.

7.3.8 To Close CB/T-Off to ‘SERVICE’

1 : Slide the 'Circuit Breaker/T-Off Selector' to the 'CB 2 : Insert the operating handle into the 'Circuit Breaker
SERVICE' position as shown. Operation Slot' as shown.

3 : Firmly pull the operating handle down from the 4 : The circuit breaker indicator will now show 'ON' as
'OFF & RESET' to 'ON' position. shown:

5 : Remove operating handle.

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 7.4 ‘Pull To Trip’
The ‘Pull To Trip’ facility enables the ‘Circuit Breaker’ to be switched from ‘ON’ to ‘OFF’ simply by pulling out the
knob on the fascia.
1 : With the ‘Circuit Breaker’ in the ‘ON’ position. 2 : Pull out the knob as shown.

3 : The ‘Circuit Breaker’ will now be in the ‘OFF’

position.

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 7.5 Circuit Breaker From ‘Tripped’ to ‘Reset’
When the ‘Circuit Breaker’ has been tripped on fault or through pull to trip (if available) then a manual
‘Reset’ operation is required.
1 : Remove padlock from the ‘Disconnector Padlock 2 : Insert the operating handle into the ‘Circuit Breaker
Flap’, then slide the selector left to the ‘CB AND Operation Slot’ as shown.
DISCONNECTOR FREE’ position.

3 : Move the operating handle upwards to the ‘OFF &

RESET’ direction to reset the mechanism so that it
is ready for the next operation which is either
switching ‘ON’ or movement of the shutters for
switching to ‘EARTH’. This upward reset
movement does not require much force/speed of
operation.

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 7.6 Circuit Switch Operation
The movement of the ‘Circuit Switch Selector’ can be restricted depending on the position of the ‘Circuit
Switch’. Full ‘Circuit Switch Selector’ movement is only with the ‘Circuit Switch’ in the ‘Off’ position.
7.6.1 Circuit Switch from ‘MOTORISED’ to ‘MANUAL’ operation
1 : Locate the Local/Remote switch in the marshalling 2 : Locate the Local/Remote operation switch on the
box and Switch from ‘REMOTE to ‘OFF’. unit’s front panel. Switch from ‘REMOTE’ to the
‘LOCAL’ position by lifting and holding.

Note: If any problems with the Circuit Switch resetting

1 : If the Circuit Switch has any problems with
resetting, by inserting the ‘Disengagement Boss’
and pushing in should reset the motor mechanism.

7.6.2 Padlocking to prevent operation

1 : With either of the ‘Circuit Switches’ in any position, the corresponding ‘Circuit
Switch Selector’ can be slid into the centre position and padlocked, preventing
any operation of the circuit switch.

7.6.3 Circuit Switch from ‘MAIN ON’ to ‘OFF’

1 : Slide the ‘Circuit Switch Selector’ to the ‘Main 2 : Insert the operating handle into the ‘Circuit Switch’.
Switch’ position as shown.

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 3 : Rotate the operating handle from the ‘MAIN ON’ to the ‘OFF’ position as shown.
Note the arrow directions on the handle.
The ‘Circuit Switch’ indicator will now show ‘OFF’ as shown.

! Note: Ensure the 'Disconnector Padlock Flap' is in the 'CB AND DISCONNECTOR FREE' position
before operation (Section ’ Note: If any problems with the Circuit Switch resetting).

7.6.4 Circuit Switch from ‘OFF’ to ‘EARTH ON’

1 : Slide the ‘Circuit Switch Selector’ to the ‘Earthing 2 : Insert the operating handle into the ‘Circuit Switch’.
Switch’ position as shown.

3 : Rotate the operating handle from the ‘OFF’ to the ‘EARTH ON’ position as shown.
Note the arrow directions on the handle.
The ‘Circuit Switch’ indicator will now show ‘EARTH ON’ as shown.

! Note: Ensure the 'Disconnector Padlock Flap' is in the 'CB AND DISCONNECTOR FREE' position
before operation (Section ’ Note: If any problems with the Circuit Switch resetting).

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 7.6.5 Circuit Switch from ‘EARTH ON’ to ‘OFF’
1 : Slide the ‘Circuit Switch Selector’ to the ‘Earthing 2 : Insert the operating handle into the ‘Circuit Switch’.
Switch’ position as shown.

3 : Rotate the operating handle from the ‘EARTH ON’ to the ‘OFF’ position as shown.
Note the arrow directions on the handle.
The ‘Circuit Switch’ indicator will now show ‘OFF’ as shown.

! Note: Ensure the 'Disconnector Padlock Flap' is in the 'CB AND DISCONNECTOR FREE' position
before operation (Section ’ Note: If any problems with the Circuit Switch resetting).
7.6.6 Circuit Switch from ‘OFF’ to ‘MAIN ON’
1 : Slide the ‘Circuit Switch Selector’ to the ‘Main 2 : Insert the operating handle into the ‘Circuit Switch’.
Switch’ position as shown.

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 3 : Rotate the operating handle from the ‘OFF’ to the ‘MAIN ON’ position as shown.
Note the arrow directions on the handle.
The ‘Circuit Switch’ indicator will now show ‘MAIN ON’ as shown.

! Note: Ensure the 'Disconnector Padlock Flap' is in the 'CB AND DISCONNECTOR FREE' position
before operation (Section ’ Note: If any problems with the Circuit Switch resetting).

7.7 Testing Circuit Switch Cables

For this operation, please ensure the relevant circuit switch is

in the 'EARTH ON' position and the 'Circuit Switch Selector' is
in the centre position, padlocked if applicable (as shown)

1 : Open cable test access cover by holding the test 2 : Move the interlock flap out of the way of the
box, pulling the access knob forward, and then required ring switch test bushings.
lower the test access cover.

3 : Insert the operating handle into the star point earth 4 : Pull down away from the bushings
bar.

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 5 : When the star point earth bar is clear from all the bushings, remove the operating handle and allow to pivot
down into the access cover as shown.
Test connections can be now made onto the bushings marked with the relevant phase (red, yellow, blue or L1,
L2, L3).

Note: With the star point earth bar removed access to operate the circuit switch is prevented.

Returning star point earth bar to its closed position.

6 : Close the star point earth bar by pivoting it towards 7 : Close the 'Test Access Cover' by lifting and
the bushings by hand. Move the padlock flap clear, ensuring catch lock is located fully. Ensure the
then insert the handle into the socket and drive the access knob is fully back locked in it’s original
earth bar firmly onto the bushings. Ensure full position.
contact of the earth bar onto the 3 bushing
contacts.

The circuit switch can now be operated 'EARTH ON' to 'OFF'.

7.7.1 Circuit Switch Cable Test Padlock Facility

Access to the star point earth bars can be prevented by using a
padlock for each circuit switch as shown.

To allow access to a star point earth bar, remove the padlock on the
side of the required earth bar, then slide the padlock flap clear.

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 8. CABLE BOX ACCESS
The Sabre VRNFS has cable box interlock facilities on both the ring switch and T-off cable boxes. The
interlock ensures that the cable boxes can only be removed or fitted when the relevant ring switch
or T-off is in the ‘Earth On’ position therefore ensuring the unit cannot be operated. The unit can
only be operated out of the ‘Earth On’ when a cable box is securely fitted.

8.1 Release T-Off Interlock & Remove Cable Box

For this operation please ensure the following:
• Switch Local/Remote switch to ‘OFF’ Section 7.3.2 Circuit Breaker from ‘MOTORISED’ to ‘MANUAL’ operation on
page 23
• CB/T-Off Disconnector is selected to ‘ISOLATED’ Section ’7.3.4 CB/T-Off from ‘SERVICE’ to ‘ISOLATED’’
• CB is closed to ‘EARTH’ Section ’7.3.7 Operate CB/T-Off from ‘ISOLATE’ to ‘SERVICE’’
After all manual operations are complete, ensure
the Local/Remote switch is switched back to the
‘REMOTE’ position.
1. Slide the ‘Disconnector Padlock Flap’ to the right. 2. Push the CB cable test access cover knob in and
rotate clockwise 45°.

3. Remove all the screws around the T-off cable 4. Carefully lift and pull away the cable box from the
box (including 2 underneath). unit.

Note: With the T-Off cable box removed, the unit cannot be operated.

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 8.2 Refit Cable Box & Reset T-Off Interlock

The operation for refitting the T-Off cable box is the exact reversal of the previous removal procedure
paying particular attention to the following:

1. Ensure that the two location pins on the 2. Once the cable box has been completely refitted,
backsheet locate with the two holes at the rotate the CB cable test access cover knob in the
bottom of the cable box and also that the anitclockwise direction until it ejects out.
interlock lug of the cable box is inserted fully into
the slot in the back of the unit as shown below.

The unit will now be fully operational.

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 8.3 Release Ring Switch Cable Box Interlock

For this operation please ensure the relevant ring switch is closed to ‘EARTH’ Section ’7.6.4 Circuit Switch
from ‘OFF’ to ‘EARTH ON’’

1. Slide the relevant ‘Ring Switch Selector’ to the ‘CABLE TEST ACCESS’ central position and padlock
if applicable as shown.

2. Push in the relevant ‘Cable Box Interlock Lever’.

3. Remove all the screws around the ring switch 4. Carefully lift and pull away the cable box from the
cable box (including underneath). unit.

Note: With the Ring Switch cable box removed, the unit cannot be operated.

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 8.4 Refit Cable Box & Reset Ring Switch Interlock

The operation for refitting the Ring Switch cable box is the exact reversal of the previous removal
procedure paying particular attention to the following

1. Ensure that the interlock lugs either side of the

cable box are inserted fully into the slots in the
side of the unit as shown below.

2. Once the cable box has been completely refitted, pull out the relevant ‘Cable Box Interlock Lever’.

The unit will now be fully operational.

:

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 9. EARTH FAULT INDICATION
The Sabre VRNFS is fitted with a mains powered Earth Fault Indicator (EFI) with auto reset functionality.
The EFI is housed to the left hand side within a steel enclosure to prevent the device being tampered with.

All safety, installation and testing documentation supplied

within the EFI technical manual must be adhered to and
information supplied in this document.

9.1 Overview

The EFI has a flexible split core Current Transformer (CT) fixed around the three phases of the cable
system that detects a current imbalance due to an earth fault. An earth fault trip is indicated by an LED
(Light Emitting Diode) indicator fitted to the unit, with a second LED Remote Indication (optional) and an
auxiliary relay contact for connection to other systems (optional). In an open ring network the path of the
fault current from the feeding point to the fault location is marked by the triggered EFI’s. The defective
conductor segment is located between the last EFI that has been triggered and the first EFI, which is still
inactive.
When a mains supply is first applied to the EFI or when it returns after the fault is cleared, the unit will first
require up to 7 minutes to charge the on-board backup power supply before it can fully function. This
backup power supply is used to retain power to the unit on fault detection for a typical period of 10 hours
for the purpose of driving the primary LED indicator as well as the remote LED indicator and Aux Relay,
if fitted.

9.2 Operation
The EFI is programmed to trip at a nominal earth fault current of 50A and resets automatically from a fault
state on detecting the presence of healthy mains for more than 10 seconds. It can also be reset manually,
prior to mains being restored by pressing the Test/Reset button for a period of more than 3 seconds. This
will reset activate the Aux Relay contacts (closed), if connected, and both the primary LED indicator and
remote LED indicator (if connected) will flash at a rate of approximately 1 Hz. This test state will continue
for a period of 60 seconds or until the test button is pressed again to terminate test mode. To terminate a
test, the Test/Reset button is pressed again. This will reset the Aux. Relay to the reset (opened) position
and stop flashing of both the primary LED indicator and remote indicator, if fitted.

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 9.3 Installation

9.3.1 Multi Core Cable System

For multi-core cable systems the CT sensor is mounted on
the screened part of the cable below the stripped back
point of the cable as shown in diagram below.

The centre cable-tie of the CT sensor is used to secure the sensor firmly on the cable.

The flexible iron core of the sensor must be wrapped in a closed circle and pulled tight with the second
cable tie, as far as possible.

Care should be taken to ensure that the sensor is mounted on the screened part of the cable. The screen
of the cable should be turned back underneath the core and terminated to earth as shown. The third cable
tie (if fitted) must be closed, to ensure the end of the CT is properly aligned.

The end of the bands should be fitted neatly under itself. Care must be taken during this process to ensure
the CT is closed properly, otherwise the accuracy of the trip level will be affected.

9.3.2 Single Core Cable System

For single core cable systems the CT sensor is mounted

on the screened part of the cable below the stripped
back point of the cable as shown in diagram below.

The centre cable-tie of the CT is first used to secure the sensor on one of the cables.

The flexible iron core of the sensor is then wrapped in a closed circle around all three cables and pulled
tightly with the second cable-tie as far as is possible.

Care should be taken to ensure that the sensor is mounted on the screened part of the cable. The screen
of all three conductors should be turned back underneath the core and terminated to earth as shown.

The third cable tie (if fitted) must be closed, to ensure the end of the CT is properly aligned.

The end of the bands should be fitted neatly under itself. Care must be taken during this process, to
ensure the CT is closed properly, otherwise the accuracy of the trip level will be affected.

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 9.3.3 EFI Testing

To check the trip current level of the EFI, the following test should be conducted:
1 : Ensure that mains voltage is supplied to the unit for a period of greater than 7 minutes.
2 : Generate a fault current less than 45A in the current carrying conductor running through the CT sensor. This
should not trip the unit.
3 : Generate a fault current greater than 55A for a period of 1 second. This should trip the unit.
4 : Should the mains voltage still be connected the unit will reset after a period of 10 seconds.

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 10. SABRE UNIT MAINTENANCE
10.1 Operating Conditions
Ideal' in-service conditions Standard' in-service conditions
• Unit is to be installed and commissioned in • Unit is to be installed and commissioned in
accordance with manufacturers instructions. accordance with manufacturers instructions.
• Humidity below 40% with no dripping water. • Humidity below 60%.
• Indoors completely protected from the weather. • Unit used indoors or outdoors, but not subjected to
extreme weather conditions eg: ice, snow, dust
• Minimal dust and adequate air circulation.
storms, heavy rain etc.
• Ambient temperature between -5 ºC and 40ºC.
• Ambient temperature between -25 ºC and 40ºC.
• No contact with chemical agents.
• No regular or thick covering of leaves or debris.
• No infestation of any animals.
• No contact with chemical agents.
• No contact with any plant life.
• No infestation of any animals.
• No foundation movements.
• No contact with any plant life.
No damage to the unit of any kind.
• No foundation movements.
• No damage to the unit of any kind.

'Aggressive Conditions' are any other conditions not covered in the description of IDEAL and
STANDARD conditions.

10.2 Maintenance Intervals

The following maintenance intervals should be adhered to for optimal operation of the unit.

Conditions
'Ideal' 'Standard' 'Aggressive'
Gas Enclosure No Attention No Attention No Attention
Housing Interior No Attention No Attention Every 5 Years
Housing Exterior No Attention Every 5 Years Every 2 Years

10.3 Maintenance Schedule

The following is the recommended maintenance schedule for the Sabre VRN-FS:
Gas Enclosure: No routine maintenance required.
Housing Interior: Performed with the main door open if the unit is an outdoor unit.

Outdoor Unit: Indoor and Outdoor Units: Housing Exterior:

• Check the condition of the • Check that the protector cap is fitted over Indoor and Outdoor Units:
main door seal the SF6 filler valve
• Check that all external fixings
• Check the inside of the door • Check the operation of the unit (including are present and tight
for: interlocks with the unit isolated)
• Check that all labels are
- Heavy dust deposits • Clean the unit thoroughly present
- Water ingress • Touch up paint-work as necessary • Check that all earth
- Contamination by animal, connections are present
• Check that the SF6 gas indicator is in the
insect or plant life
Green Zone • Clean the unit thoroughly
- If the indicator is in the Red Zone, refer • Touch up paint-work as
to Section ’10.4.2 SF6 Gas Topping necessary
Up’
If a unit has not been operated for a considerable time, and if it is practicable to do so, operate it a few
times to ensure that switch is functioning correctly.

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 10.4 SF6 Issues

10.4.1 SF6 Gas Leakage

1 : If the unit suffers a loss of gas pressure the pointer will be in the Red Zone. In this extremely unlikely event the
following procedure should be followed.
2 : If the gas pressure indicator is showing no pressure then do not operate any part of the switchgear and contact
you local Lucy Switchgear office immediately.
3 : If the gas pressure indicator is in the red zone, but still registering some pressure, proceed to Section ’10.4.2
SF6 Gas Topping Up’. It is safe to operate the switchgear in this condition. If this is not possible contact your
local Lucy Switchgear office as soon as possible.
4 : If, after topping up, the gas pressure indicator continues to show a drop in pressure contact your local Lucy
Switchgear office.

10.4.2 SF6 Gas Topping Up

The SF6 top up valve is located under the pressure

gauge on the front panel as shown:

Hansen coupling
behind protective cap

The unit should be filled to the recommended pressure using either a temperature compensated gauge
on the regulator head of the SF6 supply or, where such a gauge is unavailable, compensating for
temperature using a graph.

Before filling the switchgear, all pipes and fittings must be purged using SF6 to avoid any impurities
inadvertently entering the unit or contaminating the filling valve (Hansen valve B2H16-BS) on the unit.
SF6 gas to IEC 60376 must always be used.

Note: Ensure all SF6 gas handling equipment is in good condition and moisture free.

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 11. CIRCUIT BREAKER REMOTE ACTUATOR OPTION
The circuit breaker remote actuator is located (if fitted) on the right hand side of the unit as shown.

11.1 Remote Operation Conditions

The operation of the circuit breaker remote actuator can only be permitted when:-
i) the disconnector is in the ‘SERVICE’ position.
ii) the circuit breaker and disconnector operation shutters are closed.
iii) Local/Remote switch on the marshalling box to be switched to 'Remote'.

11.2 Manual Operation

With the remote actuator fitted, the circuit breaker can be operated manually by first
switching the Local/Remote switch on the marshalling box to 'OFF', then opening the
circuit breaker shutter and inserting the operating handle.

After manual operation, the remote actuator unit will automatically reset when remote
operation is again required.

11.3 Circuit Breaker Trip Reset

When the circuit breaker fitted with actuator trips, CB will automatically reset via a built-
in auto reset spring within the mechanism.

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 11.4 Remote Actuator Disengage

If a power failure occurs during a circuit breaker ‘OFF & RESET’ to ‘ON’ remote operation, it can be continued
manually by opening the circuit breaker shutter and inserting the operating handle (Section ’7.3.8 To Close CB/T-
Off to ‘SERVICE’’).
If a power failure occurs during a circuit breaker ON’ to ‘OFF & RESET’ remote operation, it can be continued
manually by:

1 : Open the remote actuator unit cover by undoing 2 : Firmly push in the actuator boss to disengage the
the captive screw. actuator gearbox.

3 : The circuit breaker operation can now continue manually by opening the circuit breaker shutter and inserting
the operating handle(Section ’7.3.8 To Close CB/T-Off to ‘SERVICE’’).

When power is re-applied the remote actuator will automatically re-engage when remote operation is again required.

Remote Actuator Unit Cover Padlock

Access to the circuit breaker remote actuator unit can be prevented by using a padlock
on the cover as shown.

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Gemini 3
Installation, Operation and Maintenance Manual
 TABLE OF CONTENTS
12. Safety Symbols ...........................48 20.1 Replace a fuse ....................................... 71
13. Safety Information ......................49 21. RTU and Module Returns ...............72
14. Introduction .................................50 Appendix A. Technical specification ........ 73
14.1 What’s in this manual? ......................... 50 Appendix B. Module LED states ............... 75
14.2 Who should read this manual? ............ 50 B.1 MCM (Master Control Module) LEDs ............. 75
15. Gemini 3 RTU overview ..............51 B.2 PSM (Power Supply Module) LEDs ............... 76
15.1 Upgradeability ....................................... 51 B.3 DSM (Dual Switch Module) LEDs .................. 77
15.2 Backplane .............................................. 52 Appendix C. Module connector details .... 78
15.3 Enclosure ............................................... 52 C.1 MCM (Master Control Module) connector
15.4 Gemini 3 RTU modules ......................... 52 details .......................................................78
15.5 General module features ...................... 52 C.2 PSM (Power Supply Module) connector details 81
15.6 Firmware and configuration updates .. 53 C.3 DSM (Dual Switch Module) connector details 83
15.7 Gland Plate ............................................. 53
Appendix D. EMC and environmental
16. Gemini 3 components ................54 tests ............................................................. 85
16.1 Door and battery switches ................... 55 E.1 Overall ........................................................... 85
16.2 Batteries ................................................. 55 E.2 Electromagnetic compatibility (EMC) tests .... 85
16.2.1 Optimal battery charging ...........................55 E.3 Electrical tests ................................................ 85
16.2.2 Battery deep-discharge protection ............55 E.4 Environmental tests ....................................... 86
16.2.3 Spare fuses ...............................................55 E.5 Mechanical tests ............................................ 86
16.3 Modules ................................................. 56
16.3.1 MCM (Master Control Module) overview .....56
16.3.2 PSM (Power Supply Module) overview .......56
16.3.3 DSM (Dual Switch Module) overview ..........56
16.3.4 HMI (Human Machine Interface) overview ..56
16.3.5 Comms Device ..........................................56
16.4 Local/Remote Switch ...............................56
17. Initial Power Up ............................ 57
18. Commissioning ...........................58
18.1 Programming the RTU .......................... 58
18.1.1 About the Configuration Tool ...................... 58
18.1.2 Obtain an automatic IP address .................. 58
18.1.3 Download the Configuration Tool ............... 59
18.1.4 Log in to the RTU .......................................... 59
18.1.5 View the RTU’s firmware version ................ 59
18.1.6 Upgrade the RTU’s firmware ........................ 60
18.1.7 Change the RTU IP address settings .......... 60
18.1.8 Write the configuration to the RTU ............. 60
18.1.9 Run the Commissioning wizard .................. 61
18.2 Running commissioning checks ......... 61
18.2.1 Configuration Tool ........................................ 61
18.2.2 HMI ................................................................. 62
18.2.3 Lucy RMU Switchgear Simulator ................. 62
18.2.3.1About the HMI panel layout and controls 63
18.2.3.2Test basic operations using the HMI 64
18.2.3.3Test switch controls using the HMI 65
19. Maintenance ................................66
19.1 Maintenance guidelines ....................... 66
19.2 Maintaining the RTU ............................. 67
19.2.1 Check the enclosure integrity ...................... 67
19.2.2 Check the battery .......................................... 67
19.2.3 Check the backplane and modules ............. 67
19.3 Battery care, installation and
replacement ........................................... 68
19.3.1 Nickel Metal Hydride Battery ....................... 69
19.4 Module replacement guidelines .......... 70
20. Troubleshooting .........................71

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 12. Safety Symbols
The symbols in the following table may be used on the Gemini 3 RTU equipment or in its documentation.
For safety reasons, they should be understood before the Gemini 3 is installed or commissioned.

Symbol Description

Caution, risk of electric shock

Caution, hot surface

Caution, refer to documentation

Caution, electrostatic sensitive device

Caution, heavy

Protective conductor terminal

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 13. Safety Information

DEATH OR SEVERE PERSONAL INJURY WILL RESULT

IF THE FOLLOWING PROPER PRECAUTIONS ARE NOT TAKEN

• Isolate or disconnect the equipment from hazardous live voltages before opening the unit for any reason. There
are live parts inside. Only suitably trained personnel are permitted to remove covers on the equipment.
• This unit contains internal protection fuses. For continued protection against risk of fire or electric shock, replace
fuses with the same type and rating. Follow guidelines in “Section 20. Troubleshooting” before replacement of
these devices.
• The Gemini 3 must always be earthed when connected to a mains supply.
• The Gemini 3 power supply unit contains large capacitors. Wait approximately two minutes for them to fully to fully
discharge before changing modules or power supplies.
• The Gemini 3 contains high capacity batteries which can present a risk of electrical shock and high circuit current.
Do not allow them to become shorted together. To install or replace the batteries, follow the procedure in
“Section 19.3 Battery care, installation and replacement”.
• If the RTU is connected to one, two or three current transformers (CT), and the connector in the RTU is not
plugged into the control unit, there could be dangerous voltages on the connector block. In this case, the CT
connections must always be shorted in the switchgear marshalling box before disconnecting the connector from
the control unit.

Note Lucy Electric ring-main units (RMUs) can be fitted with a full-way diode protection circuit, which can prevent high
voltages occurring on the CT terminals. Check with Lucy Electric on the particular configuration of your switchgear.

• In order for the RTU to function correctly and in compliance with the specifications detailed in “Section Appendix
E EMC and environmental tests”, the RTU must be installed and maintained to the instructions detailed in
“Section 19. Maintenance” and electricity network industry best practice.
• The Gemini 3 enclosure with batteries weighs over 40 kg. Standard health and safety procedures should be
followed when lifting or moving it. Two people are recommended when lifting the unit.
• If the RTU is used in a manner not specified by the manufacturer, the RTU protection may be impaired.
• The RTU should be operated within the specified electrical and environmental limits.

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 14. Introduction
14.1 What’s in this manual?
This manual contains information about installing, commissioning, and maintaining the Gemini 3 RTU hardware.
For information about using the Gemini 3 Configuration Tool, refer to the Gemini 3 Administration Manual.

14.2 Who should read this manual?

This manual is intended for planners, operators, commissioning engineers, and service and maintenance personnel.
A general knowledge of electrical engineering is required to understand this manual.

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 15. Gemini 3 RTU overview
The Gemini 3 is a general-purpose Remote Terminal Unit (RTU) designed to remotely monitor and control medium/
high voltage switchgear. It will normally be used in conjunction with a SCADA system to control a number of
switchgear units covering a wide area, as shown in the figure below:

15.1 Upgradeability
The Gemini 3 RTU has a modular design allowing a wide range of systems to be configured, ranging from a very
simple monitoring device through to a sophisticated multi-switch control unit with high input count of analogue and
digital signals as well as secure switchgear control outputs. A wide range of modules is available which can monitor
and safely control the switchgear in the very difficult electrical and environmental conditions experienced by the
switchgear.
The Gemini 3 is a highly versatile RTU which can be upgraded by adding extra modules. For example, a two-module
device can be upgraded from a purely monitoring RTU to a fully-monitored one, two, three or four-switch control
RTU.
This is a major advantage in areas where monitoring is required at all sites but the location of the switching sites is
unknown, uncertain or variable. This represents a considerable cost saving in the planning and implementation of
networks while preserving the ultimate in flexibility.

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 15.2 Backplane
The backplane supports five modules, allowing a range of RTU configurations to be assembled. The backplane
contains the following signals:

• Logic supply
• Switch supply
• CAN bus
• Local/remote status

15.3 Enclosure
The Gemini 3 is housed in a suitable IP rated enclosure. The Gemini 3 enclosure has the following:

• Constructed from painted mild steel

• Gland plate for easy fitting of umbilical cables

15.4 Gemini 3 RTU modules

The Gemini 3 Remote Terminal Unit is a very flexible device due to its modular design. It is supplied as standard in
a 5-slot cubicle. (Other cubicle versions are available on request.)
This allows various RTU configurations to be built up from a range of modules. These have been specially designed
for the safe control and monitoring of electrical switchgear in the secondary distribution sector.
At its simplest, a basic monitoring-only RTU may consist of a Master Control Module (MCM) fitted to a backplane
assembly for direct mounting in an existing enclosure.
Typically, to allow expansion to a controlling RTU a Power Supply Module (PSM) would also be fitted. (The PSM
module is required in order to use the Dual Switch Module (DSM).) To simplify installation, the whole device is
supplied in a suitable cubicle.
Additional modules can then be fitted according to evolving control and monitoring requirements. These additional
modules give the following features:
• Digital input points (single and double points)
• Analogue input points
• Control outputs
• Fault detection functions
• Power meter functions

15.5 General module features

All modules have the following general features:
• Built-in diagnostics
• Status indicators
• Continuous-status monitoring
• Each module registered by serial number/type
• Defined responsibilities
• Factory-calibrated measurements
• Module replacement does not affect calibration
• Safety checks and interlocks

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 15.6 Firmware and configuration updates
With a suitable TCP/IP based comms device fitted, RTU firmware and configuration updates can be installed
remotely. Network configuration changes can also be performed preventing unnecessary journeys to remote or
inaccessible sites.

15.7 Gland Plate

A split gland plate is provided that removes the need for multiple plugs and sockets. Releasing the two fixing bolts
allows the gland plate to be split and cables passed through the gland plate.

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 16. Gemini 3 components

Modules
Enclosure
Local/Remote
HMI Switch
Power Supply
Unit

Comms
Device

Battery Remote I/O

Pack Units

Switches
Spare Fuses

Switches The door and battery switches

For more information, see “Door and battery switches” on page 55.
Battery pack The rechargeable sealed nickel–metal hydride battery pack
For more information, see “Batteries” on page 55.
Modules The backplane housing the Master Control Module (MCM) and its slave modules
For more information, see “Modules” on page 56.
Enclosure The outer enclosure of the RTU
For more information, see “Enclosure” on page 53.
Comms Device A modem or other device communicates with the SCADA system via a communications
channel
For more information, see “Comms Device” on page 56.
Power supply The manually-switchable AC power supply unit
unit For more information, see Power Supply I/P (from LV) in “Technical specification” on
page 73
HMI An optional module for controlling and monitoring the RTU locally
For more information, see “HMI (Human Machine Interface) overview” on page 56.
Spare fuses A set of spare fuses is attached to the inner door of the RTU
For more information, see “Spare fuses” on page 55.
Local/Remote A switch for setting the RMU operation mode.
Switch For more information, see “Local/Remote Switch” on page 56

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 16.1 Door and battery switches

Door switch Puts the RTU in power-saving mode when door closed.
In power-saving mode, the LEDs on the modules and the HMI are powered off.
Battery fuse For more information, see “Spare fuses” on page 55
Battery switch Isolates the battery so that you can change the battery or test its voltage off-load.
Isolating the battery also assists when powering down the RTU, as without the switch you
have to remove the battery fuse.
Note: This item is an optional extra.

16.2 Batteries
The RTU can be supplied with either sealed lead-acid (SLA) or nickel–metal hydride (NiMH high temperature)
batteries. These are for operating the ring switch or CB actuators and for providing backup power for the RTU.

16.2.1 Optimal battery charging

The temperature sensor contains intelligence which identifies the battery type and applies the appropriate charging
routines ensuring that they are optimally charged and cannot be overheated. For sealed lead-acid (SLA) batteries,
this sensor is mounted close to the batteries, and for nickel–metal hydride (NiMH high temperature) batteries, it is
embedded within the battery pack. The temperature sensor plugs into the PSM.

16.2.2 Battery deep-discharge protection

The RTU prevents the batteries from becoming fully discharged if the terminal voltage reaches a programmable
minimum set point. Fully discharged batteries (particularly sealed lead acid) can be permanently damaged and
should be avoided.

Battery test

The RTU can perform a periodic battery test by disconnecting the charger from the battery and
applying an internal load to the batteries. The RTU then measures the battery terminal voltage and
current throughout the test to determine its condition.
During this test, the lid of the cubicle may become hot. Care should be taken not to touch or place any
objects on this lid at any time.
Note The battery test can also be started from the SCADA control centre.
16.2.3 Spare fuses

The fuses on the Gemini 3 RTU are user replaceable. The spare fuses are attached to the bottom of the inner door
of the RTU.
For information about replacing the RTU fuses, see “Replace a fuse” on page 72.

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 16.3 Modules

16.3.1 MCM (Master Control Module) overview

The MCM contains the main processor for the RTU. It supervises all modules and manages the protocol
communications.
Note All configurations of the RTU must have an MCM fitted.

16.3.2 PSM (Power Supply Module) overview

The PSM works with the DSM (Dual Switch Module) to provide secure switching operations. It generates regulated
power for the other modules and external communication equipment. It also provides intelligent battery charging to
maintain a secure supply.
Note Model AUT0000678 is suitable for Sealed Lead Acid (SLA) and Nickel Metal Hydride (NiMH) batteries,
AUT0000554 is suitable for Sealed Lead Acid batteries only.

16.3.3 DSM (Dual Switch Module) overview

The DSM provides the inputs and outputs to perform secure interlocked control via a selected protocol. It has a
combination of digital and analogue inputs and relay outputs for control and monitoring. It can be used to trigger
actuator (servomotor) control outputs. One DSM can control up to two ring switch actuators.

16.3.4 HMI (Human Machine Interface) overview

The HMI (Human Machine Interface) is an optional module that allows local control and monitoring of the Gemini 3
RTU without the need for a computer.
It has the following features:
• It can be used to issue local commands (with appropriate security access enabled) or to view data only.
The customisable 4 x 20-character LCD screen displays site information such as currents, voltages, and digital input
status.

16.3.5 Comms Device

4G M2M gateway unit

16.4 Local/Remote Switch

The Local/Remote switch is used to inform the RTU of
which mode the RMU is being operated in.

REMOTE - Operation via SCADA

LOCAL - Operation via HMI hand held unit
OFF - Manual operation using operating handle

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 17. Initial Power Up
Before energising this equipment, ensure that it is correctly earthed using the external M8 earth stud. Also check
that the PSU voltage selector switch is set to the correct voltage.
Ensure that the batteries are connected, the battery switch (if fitted) is on and the PSU RTU power supply is OFF.
Check that the PSM AC supply LED is red and the CAN LED’s on all modules are flashing green. Check battery
voltage at the PSM using either a suitable meter or the Gemini 3 RTU Configuration Tool. It should be a nominal
24VDC and the correct polarity, the actual value being dependent on the charge state. If different from expected,
then check voltage at the battery terminals (for Lead Acid) and the battery leads for connection errors.
Turn the PSU RTU power switch to on, the PSM AC supply LED should change to green.
The ‘batt health’ LED on the PSM (Power Supply Module) may not illuminate green until the battery is fully charged.
Refer to “Section 19.3 Battery care, installation and replacement”.

Important; No other connections other than those supplied with the RTU or approved by Lucy
Electric should be made to the battery/batteries.

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 18. Commissioning
This section of the manual is intended for commissioning engineers.
There are two stages to the process of commissioning the Gemini 3:

Program the RTU

You upgrade and configure the RTU.
Once this stage has been completed, the RTU is connected to your network and goes live.

Check the RTU

You run and approve your organisation’s commissioning checks.
Once this stage has been completed, the RTU commences active service.

18.1 Programming the RTU

To program the RTU, you complete the following steps:
1: Check your PC meets the minimum requirements.
2: Configure your laptop to receive an automatic IP address from the RTU.
3: Connect your laptop to the RTU using the ETH-1 port.
4: Download the Gemini 3 Configuration Tool from the RTU, see “Download the Configuration Tool” on page 60
and have Java Run Time Environment installed.
5 : Start the Configuration Tool and log in to the RTU, see “Log in to the RTU” on page 60.
6 : Identify the RTU’s firmware version, see “View the RTU’s firmware version” on page 60.
7 : If necessary, upgrade the bootloader firmware, see “Upgrade the RTU’s firmware” on page 61.
8 : If necessary, upgrade the application firmware, see “Upgrade the RTU’s firmware” on page 61.
9 : Verify the RTU’s firmware version.
10 : Load the configuration file from your laptop into the Configuration Tool.
11 : Change the RTU IP address settings if required, see “Change the RTU IP address settings” on page 61.
12 : Write the configuration file to the RTU, see “Write the configuration to the RTU” on page 61.
13 : Activate the configuration file, and then restart the RTU.

18.1.1 About the Configuration Tool

The Configuration Tool is used during commissioning to upgrade, configure, and check the RTU:
• Upgrade the RTU’s module firmware
• Set the RTU’s site-specific DNP3 address and IP addresses to allow it to communicate with the SCADA system
• Write the configuration file containing the “hardwired” I/O points to the RTU
• Check that the RTU is operating normally by running commissioning checks.
• For full information on how to use the Configuration Tool, see the Administration Manual.

18.1.2 Obtain an automatic IP address

Before commissioning the RTU, you should configure your laptop to obtain an automatic IP address from the DHCP
server on the RTU.

The following instructions are for modifying the IPv4 address settings on Windows 7.

1 : Open Network Connections by clicking the Start button, and then clicking Control Panel. In the search box,
type adapter, and then, under Network and Sharing Center, click View network connections.
2 : Right-click the connection that you want to change, and then click Properties. If you're prompted for an
administrator password or confirmation, type the password or provide confirmation.
3 : On the Networking tab, under This connection uses the following items, click Internet Protocol Version
4 (TCP/IPv4), and then click Properties.
4 : Click Obtain an IP address automatically.

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 18.1.3 Download the Configuration Tool

1 : Configure your laptop to receive an automatic IP address from the MCM (which has an embedded DHCP
server).
For more information, see “Obtain an automatic IP address” on page 59.
2 : Connect an Ethernet patch cable from your laptop to the ETH-1 port on the MCM.
If your laptop has an auto-crossover Ethernet port, you can use a standard RJ45 Ethernet cable to connect to
the MCM. If not, you will need to use a crossover Ethernet cable.

The RTU allocates an IP address to your laptop (usually 192.168.1.10).

3 : Once you have been allocated an IP address, use a web browser to go to https://192.168.1.1.
• This is the address of the website hosted on the Gemini 3 RTU.
• You can safely ignore any warnings about the website’s security certificate.
When you are asked for authentication, type either the Gemini 3 credentials that your organisation has given you or
the following default credentials:

Option Description
User Name gemini3
Password password

4 : Click Download the Configuration Tool.

5 : Save G3ConfigTool.jar to a suitable location on your laptop’s hard disk.

18.1.4 Log in to the RTU

1 : Using Windows Explorer, locate G3ConfigTool.jar, and then double-click it.

2 : In the Login dialog box, type the following, and then click Login:

Option Description
User Name Admin
Password blank
RTU Address 192.168.1.1

18.1.5 View the RTU’s firmware version

You can check which version of the module firmware is installed on the RTU.

1 : On the Help menu, click About RTU.

2 : Open Site Information.
3 : Inspect the value for the Software Package Version property.
If the firmware version is incorrect, upgrade the firmware. For more information, see “Upgrade the RTU’s
firmware” on page 61.

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 18.1.6 Upgrade the RTU’s firmware

You can upgrade the firmware on all of the modules in the RTU using Software Distribution Packages contained in
ZIP files.
Before you begin, make sure that you have the correct version of the following firmware Software Distribution
Package files in a suitable location on your laptop:

• SDP_Bootloader.zip (This file upgrades the bootloader

firmware.)
• SDP.zip (This file upgrades the application firmware.)
1: In the navigation pane, click the Utilities tab.
2: Click Upgrade.
3: Under Select Software Distribution Package file, click Load, and then browse to SDP_Bootloader.zip.
4: In the Select software version for MCM drop-down list, select Do Not Upgrade MCM.
5: Selecting this option means that the MCM is not upgraded at this point.
6: Leave the Auto select the latest version check box selected to automatically select a compatible firmware
version to upgrade each module.
7 : Click Start Upgrade.
8 : Follow the instructions on screen.
9 : When the bootloader firmware upgrade has completed, click OK to close the Done dialog.
10 : Under Select Software Distribution Package file, click Load, and then browse to SDP.zip.
11 : In the Select software version for MCM drop-down list, select the version with the highest number. If the
version numbers are the same, select the current version.
12 : Selecting this option means that the MCM is upgraded at this point.
13 : Leave the Auto select the latest version check box selected to automatically select a compatible firmware
version to upgrade each module.
14 : Click Start Upgrade.
15 : Follow the instructions on screen.
16 : When the application firmware upgrade has completed, click OK to close the Done dialog.

When the firmware upgrade has completed, check that the RTU now has the correct version of the firmware
installed. For more information, see “View the RTU’s firmware version” on page 60.

18.1.7 Change the RTU IP address settings

By default, the ETH-0 (Ethernet 0) port on the Gemini 3 RTU is used to communicate with the SCADA system. You
use the Configuration Tool to change the default IP address settings for the ETH-0 port so that the RTU is connected
to the same network as the SCADA system.
1: On the File menu, click New, and then click Load from a file.
2: Browse to the configuration file on your laptop, and then click Open.
3: Go to Configuration > Ports > ETH-0.
4: Select the Configure check box.
5: Click Static IP.
6: In the IP Address, Submask, and Gateway boxes, type the IP address settings for the RTU.

18.1.8 Write the configuration to the RTU

1 : On the Control menu, click RTU Configuration, and then click Write Configuration.
2 : On the Done dialog, click Activate Now.
3 : On the Success dialog, click Restart Now.
The RTU is warm restarted.
Now connect the RTU to your network using the ETH-0 connector.

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 18.1.9 Run the Commissioning wizard

The Commissioning wizard helps commissioning engineers to quickly create site-specific configuration settings
that allow the RTU to communicate with the SCADA system.
1 : Start the Configuration Tool.
2 : Click Commissioning > Wizard > Start Commissioning.
3 : On the Site Information page, follow the instructions on screen, and then click Next.
• Fields shaded white are optional.
• Fields shaded blue are required.
• Fields shaded red are incomplete.

You will find extra information about some of the settings in the table below.

Setting Description
IEC 104 Type an address in the range 0–65535.

• On the Configure Switchgear page, select which RTU switch is connected to which RMU manufacturer’s switch
or circuit breaker. If an RTU switch is not connected, select Disabled.
• On the Configure FPI page, follow the instructions on screen.
• On the Configure SCADA page, select the distribution network that the RTU will be installed in.
• On the Configure Field Device page, select the appropriate Modbus device for the power meter or protection
relay. If a Modbus device is not connected, select Disabled.
• On the Configure PLTU page, follow the instructions on screen.
• To modify the existing commissioning settings, click Commissioning > Wizard > Re-run Commissioning.

18.2 Running commissioning checks

Commissioning checks consist of functional checks and communications checks. There are several Lucy Electric
tools that you can use to run commissioning checks.

18.2.1 Configuration Tool

You can use the Configuration Tool to run local commissioning checks such as the following:

• Test output controls

• Verify input states
• Check communications
• View alarms

Real-time Monitor Allows commissioning engineers to verify input states and view alarms on
the RTU.
Commissioning Mimic Provides an overview of the points, values, and channels that have been
defined in the HMI menu structure.

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 18.2.2 HMI

You can use the HMI (Human Machine Interface) to run commissioning checks.
The HMI is an optional module that allows local control and monitoring of the Gemini 3 RTU without the need for a
laptop.

18.2.3 Lucy RMU Switchgear Simulator

In order to perform functional checks, the RTU must be powered up and connected to the switchgear via its umbilical
cable. If the switchgear is live, this might not be possible unless permission is given from the control centre.
In this situation, you can use the RMU Switchgear Simulator to fully exercise the Gemini 3 RTU without operating
the switchgear:
• Simulate alarms
• Simulate analogue inputs
• Simulate controls
Note This Lucy Electric tool is an optional extra. It is supplied with full user documentation.

About communications checks

SCADA communications check

The SCADA communications check is required to perform the following tasks:

• Make sure that events occurring in the RTU are successfully reported to the SCADA system.
• Make sure that controls issued by the SCADA system are successfully carried out on the switchgear.

If the switchgear is live, these checks can be performed using the optional Lucy RMU Switchgear Simulator.
Events such as switch open/close, insulation low (i.e. SF6 leakage) etc. can be initiated on the simulator and
confirmed by the control engineer in the SCADA control centre.
Controls can also be issued from the SCADA control centre and confirmed by the local installation engineer. There
is a special control indication (dummy control) on the MCM which illuminates an LED to prove that the
communication system is working. It is also possible to perform automatic controls using the Lucy RMU Switchgear
Simulator.

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 18.2.3.1 About the HMI panel layout and controls

Test the HMI controls

Basic HMI controls

• Use the navigation buttons to scroll through the menus and the displayed text.
• Press the MENU button at any time to return to the top of the Main menu.
• Press the ESC button to go back one step in the menu structure.

Note This set of tests uses an example module configuration for a basic controlling RTU (MCM - PSM – DSM). Your
configuration may be different.

Action Result
If not already fitted, connect the HMI to the The PWR LED on the HMI lights.
MCM using cable AUT0000177. The LCD screen becomes active and the
backlight switches on.
On the Main menu, use the  button to select The Info menu is displayed.
Info. The Software page is displayed.
Press the OK button. The visible text scrolls to the right.
Press the  button to select Software. The visible text scrolls to the left.
Press the OK button. The visible text scrolls up.
Press the  button. The visible text scrolls down.
Press the  button. The Info menu is displayed.
Press the  button.
Press the  button.
Press the ESC button.
Press the MENU button.
On the Main menu, use the $ button to select The Control menu is displayed.
Control. The Dummy Switch page is displayed.
Press the OK button. The message Pos: Open is displayed.
Press the  button to select Dummy Switch. Check that the DUMMY LED on the MCM is
Press the OK button. either fixed green or fixed red.

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 Operating mode

The MODE button allows the Off-Local-Remote operating mode to be selected.

Note The press times specified below are default values and may be configured differently in the configuration file.

Action Result
Press and hold the MODE button for 5 The OFF mode LED on the HMI lights.
seconds. Check that the OFF LED on the MCM is fixed green.
Press the MODE button for 3 seconds, and The LOCAL mode LED on the HMI lights.
then release it. Check that the LOCAL LED on the MCM is fixed
green.
Press the MODE button for 3 seconds, and The REMOTE mode LED on the HMI lights.
then release it. Check that the REMOTE LED on the MCM is fixed
green.

18.2.3.2 Test basic operations using the HMI

Note This set of tests uses an example module configuration for a basic controlling RTU (MCM - PSM – DSM). Your
configuration may be different.

Action Result
Login as 'Engineer' user and set the operating The LOCAL mode LED on the HMI lights.
mode to Local. Check that the LOCAL LED on the MCM
displays fixed green.
On the Main menu, use the  button to select The Control menu is displayed.
Control. The Battery Test page is displayed.
Press the OK button.
Select PSM - Battery Test.
Press the OK button.
Press and hold the ACT button together with The message Command accepted is briefly
the CLOSE button for ~2 seconds. displayed.
The BATT HEALTH LED on the PSM displays
fast-blinking green to show that the battery test
is in progress.
Press and hold the ACT button together with The message Command accepted is briefly
the OPEN button for ~2 seconds. displayed.
The BATT HEALTH LED on the PSM displays
fixed green to show that the battery test has
stopped.

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 18.2.3.3 Test switch controls using the HMI

Action Result
Set the operating mode to Local. The LOCAL mode LED on the HMI lights.
Check that the LOCAL LED on the MCM
displays fixed green.
On the Main menu, use the  button to select The Control menu is displayed.
Control. The DSM 1 - A page is displayed.
Press the OK button.
Select DSM 1 - A.
Press the OK button.
Press and hold the ACT button together with A spinning | character is displayed, and then
the CLOSE button for ~5 seconds. the message Operating... is displayed.
Release the buttons. The switch/circuit breaker contacts close.
The message Pos: Close is displayed.
The message Operation finished is displayed.
Check that the IPA LED on the DSM is either
fixed green or fixed red.
Press and hold the ACT button together with A spinning | character is displayed, and then
the OPEN button for ~5 seconds. the message Operating... is displayed.
Release the buttons. The switch/circuit breaker contacts open.
The message Pos: Open is displayed.
The message Operation finished is displayed.
Check that the IPA LED on the DSM is either
fixed green or fixed red.

Note To preserve the HMI display, it must not be left powered for longer than eight hours. Closing the RTU door
switches off the HMI.

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 19. Maintenance
This section of the manual is intended for service and maintenance personnel, who should be aware of the correct
working procedures to ensure safety.

19.1 Maintenance guidelines

Before servicing the RTU

De-commission the RTU, so that the SCADA control room is aware.

Note: if the RTU is put in out-of-service mode using the Configuration Tool, all SCADA communications are stopped.
Set the correct RTU state. Set it to LOCAL to allow local operations, or to OFF to inhibit all switchgear operations.
To set the correct mode, use the Local Remote Module (if fitted), otherwise use the MODE button on the HMI or
MCM.

Servicing the RTU

Any disassembly of the RTU may expose hazardous voltages. In addition, electronic parts may be damaged if
suitable electrostatic voltage discharge (ESD) precautions are not taken.

After servicing the RTU

After servicing the RTU, check the following items:
• All of the connectors are in their correct places, and firmly connected.
• The battery switch is on (if fitted).
• All of the modules have their LEDs working as expected, such as slow-blinking green OK LEDs, fixed green PWR
LEDs, and blinking green CAN LEDs. Problems will be shown in the alarm section in the Configuration Tool as
active alarms. If they are still active after acknowledging them, the problem is still present and must be solved.
• All of the RTU functionality is working as expected. A checklist and test procedure should be followed, checking
also in cooperation with the SCADA control room if possible.
• The RTU is left in an operable state, usually setting the RTU in REMOTE mode.
Note: If not left in this state, remote control is not possible.
• The RTU box is locked properly (if applicable).

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 19.2 Maintaining the RTU
Routine maintenance of the Gemini 3 RTU covers three areas:
• Enclosure integrity
• Battery condition
• Backplane and modules
Tip Restock any missing spare fuses during routine maintenance. For information, see “Spare fuses” on page 55.
If you are unsure about any of the items in the checklists below, consult Lucy Electric for advice using the details on
the back cover of this manual.

19.2.1 Check the enclosure integrity

The Gemini 3 is designed for long term use in an outdoor environment, so it is important to make sure that the control
electronics are properly protected from the elements. Carry out the following hardware checks to make sure that the
case is fully weatherproof:

• Check the outer door seal for security and no signs of water entry.
• Check that the door latches function correctly.
• Check that the door hinges are functioning correctly and are securely attached.
• Remove any debris which may have collected in the lip of the case.
• Clean the enclosure using a lint free cloth damped with water whilst the contacts are not energised.

19.2.2 Check the battery

The Gemini 3 has a built-in battery test that applies a load to the battery to make sure that it can supply current to
the load. This test can be activated remotely from the SCADA control centre or locally using the HMI. For
information, see “Test basic operations using the HMI” on page 65.
• Check that the battery connections are free of corrosion.
• For sealed lead-acid batteries, apply a smear of silicone grease to the connections and check they are tight to
prevent corrosion.
• Clean battery using a lint free cloth, damped with water only (avoiding the contacts).

19.2.3 Check the backplane and modules

• Inspect the internal wiring for damage or any loose connections.

• Check the tightness of all cable-to-module connections.
• Check that the module retaining screws are tight.
• Check the tightness of the LV power input connections.

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 19.3 Battery care, installation and replacement
Risk of fire if batteries are replaced with incorrect type or polarity. Dispose of used batteries
according to local regulations.

Sealed lead acid batteries are not fully charged on delivery and should be fully charged as soon as possible. They
will deteriorate if allowed to become fully discharged. The date of manufacture is located on the battery top in the
format mm/yy or wk/yy.
If the batteries are being stored for an extended period of time, it is recommended that they are stored at 20°C in a
dry frost free area. The open circuit voltage should be measured after six months, then every three months. They
should be recharged if the voltage is 12.57V or below. For storage temperatures of 30°C, the open circuit voltage
should be measured after four months, then every two months.
Nickel Metal Hydride batteries can be stored safely between +10 and +30 °C in low humidity for up to twelve months
without charging. However, since they will naturally discharge it is recommended that they are charged annually
otherwise the capacity may suffer slightly. This can be recovered by two or three successive charge & discharge
cycles. The date of manufacture is located on the battery top in the format dd/mm/yyyy.

• Do not dismantle, open or shred batteries.

• Do not expose batteries to heat or fire. Avoid storage in direct sunlight.
• Do not short-circuit batteries.
• Do not subject batteries to mechanical shock.
• In the event of battery leaking, do not allow the liquid to come in contact with the skin or eyes. If contact has been
• made, wash the affected area with copious amounts of water and seek medical advice.
• Do not use any charger other than that specifically provided for use with the equipment.
• Do not use battery which is not designed for use with the equipment.

Replacement batteries can be obtained from Lucy Electric.

Part Numbers Description

AUT0000520 24V/11Ah NiMH Battery Pack

The BATT HEALTH LED on the PSM (Power Supply Module) may not light green until the battery is fully charged.

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 19.3.1 Nickel Metal Hydride Battery

Procedure for installing or replacing a nickel metal hydride battery.

1 : Disconnect the battery.

a) Remove the three M6 bolts securing the battery clamp.

b) Remove the F3 BATTERY fuse or set battery switch to

'OFF' (if fitted) to isolate the battery.

c) Disconnect the battery lead connector from the top of

the battery fuse/door switch unit, as shown.

2: Remove the battery.

3: Fit new battery to RTU, observing the correct orientation for the battery leads.
4: Connect the battery lead connector into the top of the battery fuse/door switch unit.
5: Fit the battery clamp using the three M6 bolts and washers, ensuring that the leads are not fitted under the
clamp.
6 : Refit the F3 battery fuse or set battery switch to 'ON' (if fitted).

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 19.4 Module replacement guidlines

Modules must not be installed or removed whilst the RTU is powered, otherwise damage may
occur.

General guidelines
• The PSM must be fitted on the left hand side. All other modules may be fitted in any position and order.
• Accidentally fitting a module upside-down is possible, although it will not work since it will not be physically
connected.
• If you are installing a module into the backplane, take care to fit it evenly on to the location pegs.
• Tighten the module retention screws evenly. This will ensure that the module connector at the back mates
correctly with the backplane connector.
• Don’t over-tighten the module retention screws – hand tight is sufficient.

Module ID guidelines

• Modules that have the rotary ID selector must be set to a different ID for each module of a particular type. For
example, in order to fit two DSMs, one must have one ID (for example, 1) and the other must have a different ID
(for example, 2). They will subsequently be referred to as DSM1 and DSM2 respectively. A small flatblade
screwdriver or preset tool (blade width 3mm maximum) is needed to set the ID selector switch.
• Valid module IDs are 1–7. ID 0 is reserved for factory test, 8 and 9 are not available. As a result, seven is the
maximum number of modules of the same type that can be fitted into the same backplane.
• Modules can be assigned any valid ID, but it will simplify fault finding to number modules from 1, running from left
to right. The ID switches must be set before fitting the modules into the backplane.
• The RTU cannot be fitted with more than one module of the types that do not have a rotary ID selector, such as
the PSM and the MCM.
• Replacement modules must have their software updated to match the software loaded on the RTU and be
registered in the internal RTU module database. Re-power the RTU and connect the configuration tool.

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 20. Troubleshooting
Symptom Possible cause/remedy
No power from Auxiliary connector (IEC outlet) Check fuse F1 (Auxiliary Output), T3.15AH/250V~.
PSM AC Supply LED is red Check fuse F2 (RTU Power), T3.15AH/250V~.
PSM Batt Health LED is red Check: Battery switch (if fitted) is on fuse F3
(Battery), 15A/32Vdc ATO battery voltage.
Check: PWR (power) LED's are green on all
modules.
Check: OK LED's are green on all modules.
MCM does not detect a module Ensure that ID switch positions are different for similar
modules. Refer to “Module replacement guidlines” on
page 71 for more information.

20.1 Replace a fuse

To replace fuses F1 and F2:
1: Switch off the RTU power and disconnect the LV input cable.
2: Turn the fuse holder cap anti-clockwise and remove to gain access to the fuse.
3: Replace the fuse with similar type and rating.
4: Replace the fuse holder cap and LV input cable.
5: Switch on the RTU power.

To replace fuse F3:

1 : Set the battery switch (if fitted) to OFF or disconnect the battery cable.
2 : Replace the fuse with similar type and rating.
3 : Set the battery switch (if fitted) to ON or reconnect the battery cable.

Replacement fuses can be obtained from Lucy Electric

Name Description Location Part Number

F1 AUXILIARY OUTPUT T3.15AH/250V~ (5 X 20mm) PSU side panel EF0000149
F2 RTU INPUT T3.15AH/250V~ (5 X 20mm) PSU side panel EF0000149
F3 BATTERY 15 A/32Vdc (ATO) Door switch housing EF0000146

Front panel LED’s may also aid troubleshooting, refer to Appendix B “Module LED states” on page 75 for more
information.

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 25. RTU and Module Returns
In the unlikely event that the RTU or a module needs to be returned for repair or modification, please follow the steps
below to return a faulty RTU to Lucy Electric:

1 : Obtain a Repair and Modification Authorization Form (RMA) from your local Lucy Electric representative.
2 : Complete the form with the information below:
Equipment model
Model and serial number
Description of failure (please provide as much information as possible)
Value for customs (if applicable)
Delivery and invoice addresses
Contact details
3 : Send RMA form to your Lucy Electric representative.
4 : Your Lucy Electric representative will provide you with the information below:
Price for repair & shipping
RMA number
Repair centre address

5 : Pack the unit and address the shipment to the repair centre.
Ensure all items are protected by appropriate packaging, ie: anti-static bags and foam protection.
Ensure a copy of the import invoice (if applicable) and RMA is enclosed with the RTU.
E-mail or fax a copy of the import invoice and air way-bill to your Lucy Electric representative (if applicable).

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 Appendix ATechnical specification

Outer Enclosure Optional – painted/coated mild steel

Dimensions 5 slot cubicle (for up to 5 modules)

• Height = 678 mm
• Width = 560 mm
• Depth = 228 mm

Weight - 465kg nett (including the RMU)

Method of Mounting Unit mounted
Ventilation Natural
Degree of Protection IP55 Category 2 (IP65 Category 1 available on request)
Operating Temperature Cabinet - 25° C to 55° C ambient

Electronics -25° C to 70° C ambient

Relative Humidity Up to 95%
Operating Altitude 2000 m above sea level (maximum)
Pollution Level Degree 2 (EN61010-1:2010)
Equipment Protection Class 1 (EN6010-1:2010)
Overvoltage Category III (EN61010-1:2010)
Power Supply I/P (from Note This option is user selectable on the power supply unit.
LV)
Switch-selectable 115 or 230V~ 50-60 Hz (via internal PSU)

Due to the PSU, 5kV transformer and switched mode PSU combination, voltages of
between 90 - 150V~ (115V~ setting) or 180 - 365V~ (230V~ setting) can be
accommodated without damage to the RTU

Source power required – 150 VA depending on configuration of RTU

350 VA maximum for 5-slot RTU (with maximum load connected to auxiliary output)
LV Supply I/P Connector 2 terminals - push fit, wire size 0.5 - 4mm²
Auxiliary Output Power 115/230V~, 50-60Hz, Maximum power 100VA (dependent upon LV input) - IEC 320
(C13) socket
Peripheral Equipment The Gemini 3 RTU provides a number of DC outputs to power peripheral equipment:
Power
• PSM 24Vdc (non-isolated). Maximum current 1A.
• PSM – Either one or two isolated 12/24Vdc supplies (depending on unit
specification). 12Vdc output(s) maximum current 2.5A, 24Vdc output(s) maximum
current 1A.
The total RMS power consumption on all outputs should not exceed 25W for reliable
long term operation.

Total peak power consumption should not exceed 50W.

Battery Type 24V 11 Ah NiMH options
Battery Charger Internal, intelligent , temperature-compensated
Battery Runtime RTU only (no comms) - typically 24 hrs after which a min of 5 switch operations can be
completed
Control Electronics Modular - aluminium extrusion
Processor Modules MCM: ARM

Other modules: ARM Cortex-M

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 Communication RS-232, Ethernet, RS-485
Interfaces
Communication Media Radio, GSM, GPRS, Fibre
Protocols DNP3.0 serial, DNP3.0 TCP/IP, IEC 60870-5-104, IEC 60870-5-101

Note The RTU currently uses these protocols in the slave role when communicating
with the SCADA control centre.

Modbus RTU (RS-485) or TCP Master

Controls Local control via optional HMI or laptop computer

Remote control from SCADA

Switchgear Interface Plug-in multi-core cables to switchgear, directly to DSM module or RTU mounted
sockets (cost option)
Configuration On computer, Java-based Configuration Tool application

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 Appendix B Module LED states
B.1 MCM (Master Control Module) LEDs
LED Description Healthy state Alarm states
OK RTU health Slow-blinking green Fast-blinking green - warning alarm
Slow-blinking red - error alarm
Fast-blinking red - critical alarm
Fast-blinking red/green bootloader
mode
Solid red - watchdog alarm
PWR Module's internal 3.3V power rail Fixed green Fixed red - internal fault
CAN CANbus traffic Fast-blinking green - CAN Off - no traffic received
heartbeat message Fixed red or orange - CANbus error
or address ID clash

LED Description On state

LOCAL Operating mode that allows local operations Fixed green
This is the operating mode for upgrading the RTU.
REMOTE Operating mode that allows remote operation by the SCADA system Fixed green
This is the normal operating mode for the RTU.
OFF Operating mode that inhibits all switchgear operations Fixed green
This is the operating mode for servicing the RTU.

LED Description Healthy state Indication

DUMMY Dummy switch control Fixed green or red The DUMMY switch is in the
Used for RTU testing and You can use the Configuration Open position, which shows that
SCADA feedback purposes. Tool to set this LED to display the the dummy relay is working.
Open colour as either green or
red in use.
AUTO AUTO mode indication used to Off or Red The AUTO LED is red when the
indicate whether the RTU is RTU is in automatic mode.
running automatic sequence.

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 B.2 PSM (Power Supply Module) LEDs
LED Description Healthy state Alarm states
OK RTU health Slow-blinking green Fast-blinking green - warning alarm
Slow-blinking red - error alarm
Fast-blinking red - critical alarm
Fast-blinking red/green bootloader
mode
Solid red - watchdog alarm
PWR Module's internal 3.3V power rail Fixed green Fixed red - internal fault
CAN CANbus traffic Fast-blinking green - CAN Off - no traffic received
heartbeat message Fixed red or orange - CANbus error or
address ID clash

LED Description Healthy state Alarm states

AC SUPPLY AC supply status Fixed green Fixed red - AC supply off
LOGIC SUPPLY Logic supply status Fixed green Fixed red - logic supply off
MOTOR SUPPLY Motor supply status Green/off
BATT CHARGER Battery charger status Green/off Fixed red - battery charger or battery
fault

Off - battery charger off

BATT HEALTH Battery status Fixed green Fixed red - battery low or disconnected
Fast-blinking red - RTU about to
shutdown low battery
Fast-blinking green - battery test in
progress
FAN Fan on Fixed green Fixed red - fan supply fault
DC 1 Power supply status Fixed green Fixed red - power supply fail or fault
DC 2 Off - power supply module not fitted
24V AUX

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 B.3 DSM (Dual Switch Module) LEDs

LED Description Healthy state Alarm states

OK RTU health Slow-blinking green Fast-blinking green - warning alarm

Slow-blinking red - error alarm

Fast-blinking red - critical alarm

Fast-blinking red/green bootloader

mode

Solid red - watchdog alarm

PWR Module's internal 3.3V power rail Fixed green Fixed red - internal fault
CAN CANbus traffic Fast-blinking green - CAN Off - no traffic received
heartbeat message
Fixed red or orange - CANbus error or
address ID clash

LED Description Healthy state

Inputs
IP Switch contacts open Fixed green or red
IP Switch contacts closed
You can use the Configuration Tool to
set this LED to display the Switch Open
colour as either green or red in use.

• If Switch Open is configured to display

as red, then Switch Closed will display
as green.
• If Switch Open is configured to display
as green, then Switch Closed will
display as red.
Only one of the Switch Open and
Switch Closed LEDs will be lit at any
one time.
IN number Inputs 1-10 LEDs will be on or off according to input
state.
Shows the associated input state.
Outputs
OP M+ Motor +ve On when switchgear operation in
progress, otherwise off.
Power is switched on to switchgear actuator
OP Switchgear open operation in progress Off

When on, shows that a switchgear open operation is in You can use the Configuration Tool to
progress set this LED to display the Switch Open
OP Switchgear close operation in progress colour as either green or red in use.

When on, shows that a switchgear close operation is in • If Switch Open is configured to display
progress as red, then Switch Closed will display
as green.
• If Switch Open is configured to display
as green, then Switch Closed will
display as red.
OP 1 Output 1 Off
When on, shows that output 1 is active

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 Appendix C Module connector details
This appendix contains connector details of the digital inputs, digital outputs, and analogue inputs for each module.

Note The connectors in the following tables are displayed viewed from the front.

C.1 MCM (Master Control Module) connector details

J905 J803
USB RS-232 B
Connection Type - USB Type A Connection Type - 9wD Male
Layout Pin Signal Layout Pin Signal
1 +5Vdc 1 DCD
2 USB Data + 2 RX
3 USB Data - 3 TX
4 0V 4 DTR
Notes 5 ISO 0V
• For factory use only 6 DSR
7 RTS
8 CTS
9 RI

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 J901 J801
DEBUG ETH-1
Connection Type - Molex Micro-Fit 3.0 Connection Type - RJ45 (8W)
Layout Pin Signal Layout Pin Signal
1 0V 1 TX+
2 RX 2 TX-
3 TX 3 TPN+
4 Boot Mode Select 4 RX+ (no user
connection)
Notes 5 No connection
6 TPN-
• For factory use only
7 No connection
8 Earth (no user
connection)
Notes
• ETH-1 is typically used for configuration.

J904
DOOR SWITCH
Connection Type - Molex 5569
Layout Pin Signal
1 Door Switch Input*
2 0V

* Link to 0V when door is OPEN

J902 J802
RS485 RS-232 A
Connection Type - 3.5 mm Pluggable Terminal Block Connection Type - 9wD Male
Layout Pin Signal Layout Pin Signal
1 Termination* 1 DCD
2 Termination* 2 RX
3 RS485 A+ 3 TX
4 RS485 B- 4 DTR
5 ISO 0V 5 ISO 0V
*Link pins 1 and 2 to terminate with 120 Ω 6 DSR
7 RTS
8 CTS
9 RI
Notes
• RS-232 A is typically used for control/SCADA.

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 J903 J800
HMI ETH-0
Connection Type - RJ45 (6 way) Connection Type - RJ45 (8 way)
Layout Pin Signal Layout Pin Signal
1 HMI Power Output 1 TX+
(+35Vdc)
2 HMI Detect 2 TX-
3 CAN-L 3 TPN+
4 CAN-H 4 RX+
5 0V 5 RX+
6 0V 6 TPN-
7 No connection
8 Earth (No user
connection)
Notes
• ETH-0 is typically used for control/SCADA.

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 C.2 PSM (Power Supply Module) connector details

J804
DC OUTPUTS
Connection Type - 3.5 mm Screw Terminal Block
Layout Pin Signal
1 DC 1 + Isolated +12V positive output. Maximum 2.5A
2 DC 1 - Isolated +12V negative output.
3 DC 2 + Normally non isolated +24Vdc positive output
(dependent on model number)
4 DC 2 - Normally non isolated +24Vdc negative output
(dependent on model number)
5 24V AUX Non isolated +24Vdc positive output
6 24V AUX Non isolated +24Vdc negative output
7 24V AUX Non isolated +24Vdc positive output
8 24V AUX Non isolated +24Vdc negative output
Notes
+24Vdc\1A Non isolated is common to DC2 and 24V AUX.
DC 2 and 24V AUX maximum combined current = 1A average, 3A peak
For providing DC power to a communications or auxiliary device ensure an adequately rated cable is used.
The DC outputs are intended to be the sole DC supply for communication or auxiliary devices. Care must be taken
to ensure no external voltage can be applied to these terminals as damage to the equipment may occur.
If the device to be powered is located outside of the RTU cabinet/panel please consult Lucy Electric for advice.

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 J800 J802
SENSOR BATTERY
Connection Type - Molex Micro-Fit 3.0 Connection Type - JST VL Plug
Layout Pin Signal Layout Pin Signal
1 APP Flash Write Enable 2 Battery Positive Input
2 Clock
+28Vdc maximum
3 Data 1 Battery Negative Input
4 0V 0V

5 +3.3Vdc Output
6 ID Flash Write Enable

J803 J801
24V AUX FAN DC SUPPLY
Connection Type - Molex 5569 (4 way) Connection Type - Molex 5569 (8 way)
Layout Pin Signal Layout Pin Signal
1 Fan Speed Input* 1 Battery Test Load O\P +
2 Fan DC (+24V switched) 2 Battery Test Load O\P -
on AUT0000678
revision 3 and above
3 +24V Aux non isolated 3 Battery Load Control
positive output.
4 +24V Aux non isolated 4 PSU Not used
negative output
* Open collector output from fan 5 PSU Not used
6 PSU status not used
Notes
+24Vdc\1A Non isolated is common to DC2 and 24V Aux. 7 DC In -
DC2 and 24V Aux maximum combined current = 1A 8 DC In +
average, 3A peak.

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 C.3 DSM (Dual Switch Module) connector details

SW901
Module ID Switch
The Module ID Switch is used to set the address of multiple modules of the same type. Each module of the same
type must have a unique ID (between 1 - 7) set by this switch.

Notes
• Any position other than 1 - 7 will disable the card and will not be detected by the Configuration Tool.
• If a module ID is changed, the RTU must be restarted and the modules re-registered.

J900 J901
SWITCH A INPUT INDICATORS 8 to 10 SWITCH B INPUT INDICATORS 8 to 10
Connection Type Connection Type
3.5 mm Pluggable Terminal Block 3.5 mm Pluggable Terminal Block
Layout Pin Signal Layout Pin Signal
6 SW A Indicator IN8 6 SW B Indicator IN8
5 Isolated 0V 5 Isolated 0V
4 SW A Indicator IN9 4 SW B Indicator IN9
3 Isolated 0V 3 Isolated 0V
2 SW A Indicator IN10 2 SW B Indicator IN10
1 Isolated 0V 1 Isolated 0V

Notes
• Connect Isolated 0V to Indicator inputs to activate, typical loop “wetting” current <2 mA at +12 Vdc. Ensure loop
resistance is below 300 ohms, including wire, connectors and contacts.

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 J4 J3
CT A Connection Type - Molex 5569 CT B Connection Type - Molex 5569
Layout Pin Signal Layout Pin Signal
1 Connected to J4 pin 4 1 Connected to J3 pin 4
2 Phase A 2 Phase B
3 Connected to J4 pin 6 3 Connected to J3 pin 6
4 Connected to J4 pin 1 4 Connected to J3 pin 1
5 Common 5 Common
6 Connected to J4 pin 3 6 Connected to J3 pin 3
Notes Notes
• Phase current from switch A CT input: • Phase current from switch B CT input:
1A Nominal 1A Nominal
2A Maximum 2A Maximum
Frequency range 40 - 70Hz Frequency range 40 - 70Hz

J702 J700
SW A Connection Type - Molex 5569 SW B Connection Type - Molex 5569
Layout Pin Signal Layout Pin Signal
1 Motor +VE (+24 Vdc switched) 1 Motor +VE (+24 Vdc switched)
2 No connection 2 No connection
3 SW A Spare output relay COM 3 SW B Spare output relay COM
4 SW A Close relay N/O 4 SW B Close relay N/O
5 SW A Open relay N/O 5 SW B Open relay N/O
6 Isolated GND 6 Isolated GND
7 SW A Indicator 2 7 SW B Indicator 2
8 Isolated GND 8 Isolated GND
9 SW A Indicator 3 9 SW B Indicator 3
10 Isolated GND 10 Isolated GND
11 SW A Indicator 5 11 SW B Indicator 5
12 SW A Indicator 6 12 SW A Indicator 6
13 Motor -VE 13 Motor -VE
14 No connection 14 No connection
15 SW A Spare output relay N/O 15 SW B Spare output relay N/O
16 SW A Close relay COM 16 SW B Close relay COM
17 SW A Open relay COM 17 SW B Open relay COM
18 SW A Indicator 4 18 SW A Indicator 4
19 Isolated GND 19 Isolated GND
20 SW A Open status Indicator 20 SW B Open status Indicator
21 SW A Close status Indicator 21 SW B Close status Indicator
22 SW A Indicator 1 22 SW B Indicator 1
23 SW A Indicator 7 23 SW B Indicator 7
24 Isolated GND 24 Isolated GND
Notes
• Motor +VE switched, relative to Motor -VE, peak current 16A
• Switch Close and Open are software configurable to switch A contacts to Motor +VE (pull up), Motor -VE (pull
down) or B contacts (Link). Maximum current 1A.
• Connect Isolated GND to Indicator inputs to activate, typical loop “wetting” current <2 mA at +12 Vdc. Ensure loop
resistance is below 300 ohms, including wire, connectors and contacts.

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 Appendix D EMC and environmental tests
The Gemini 3 is fully tested for both electromagnetic compatibility (EMC) and the environmental conditions that it is
designed to work in.

Note The type tests only apply to the Gemini 3 RTU in its enclosure. For OEM variants, consult Lucy Electric for
advice using the details on the back cover of this manual. Any customer-specified third-party equipment to be
included in the RTU (such as a communication device) must be agreed as being suitable for the application.

D.1 Overall
Test Standard Description
Environmental Test Requirements ENA EATS 48-5 Issue 4 2015 + UK Energy Networks Association
For Protection and Control Amendment 1 2016 overall standard
Equipment and Systems

D.2 Electromagnetic compatibility (EMC) tests

Test Standard Level/Class
Radiated Disturbance EN55011:2009 + A1:2010 + Class A
EN55022:2010
Conducted Disturbance EN55016-1-2:2014 + A1:2005 + Class A
A2:2006
Radiated radio frequency EN61000-4-3:2006 + A1:2008 + Level 3
electromagnetic field immunity A2:2010
Electrostatic discharge immunity EN61000-4-2:2009 Level 3
Power frequency magnetic field EN61000-4-8:2010 Level 4
immunity
Power frequency immunity EN60255-26:2013 -
Conducted disturbance induced by rf EN61000-4-6:2009 Level 3
fields immunity
Fast transient immunity EN61000-4-4:2014 Level 4
Damped oscillatory wave immunity EN61000-4-18:2007 Level 3
Surge immunity EN61000-4-5:2006 Level 4
AC and DC voltage dips & EN61000-4-11:2004 -
interruption immunity
Conducted, common mode EN61000-4-16:1998 + A1:2004 + Level 4
disturbance A2:2011
Pulse magnetic field immunity EN61000-4-9:1994 +A1:2001 Level 5
Damped oscillatory magnetic field EN61000-4-10:1994 + A1:2001 Level 5
immunity
Burst immunity EN60255-22-1:2005 -
Damped oscillatory wave EN61000-4-18:2007 + A1:2010 -

D.3 Electrical tests

Test Standard Description
Dielectric Voltage Strength EN60255-27:2014 Section 10.6.4.3 Power Port 1 minute @2kV

CT Input 1 minute @2.5kV

Impulse Voltage Strength EN60255-27:2014 Section 10.6.4.2 1 second @5kV
Electrical Safety EN61010-1:2010 -

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 D.4 Environmental tests
Test Standard Description
Temperature Cold Heat Storage EN60068-2-1:2007 -25°C, 96 hours
Temperature Cold Heat Operating EN60068-2-1:2007 -25°C, 96 hours
Temperature Dry Heat Storage EN60068-2-2:2007 +70°C, 96 hours
Temperature Dry Heat Operating EN60068-2-2:2007 +55°C, 96 hours
Damp heat, steady state EN60068-2-78:2002 +40°C, 93%, 56 days
Damp Heat, Cyclic EN60068-2-30:2005 +55°C, 95%, six 12 hour cycles
Change of temperature EN60068-2-14:2009 +70°C, -25°C, seven 2 hour cycles
Composite Temperature/Humidity EN60068-2-38:2009 +65°C, -10°C, 93%, ten 24 hour cycles
Cyclic Test
Degree of protection provided by EN60529:1992 + A2:2013 IP55 Category 2
enclosure (IP code)
IP65 Category 1 (available)
Solar Radiation EN60068-2-5:2011 Five 24 hour cycles

D.5 Mechanical tests

Test Standard Level/Class
Vibration EN60255-21-1:1996 Response Class 2, Endurance Class 1
Shock EN60255-21-2:1996 Response Class 2,Endurance Class 2
Bump EN60255-21-2:1996 Class 1
Seismic EN60255-21-3:1995 Class 1

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 Glossary

Ah ampere-hour
A unit of electric charge used to measure battery capacity.

APN Access Point Name

CT current transformer

CTS Clear To Send (RS-232)

DCD Data Carrier Detect (RS-232)

DHCP Dynamic Host Configuration Protocol

Network client devices use DHCP to request Internet Protocol parameters such
as an IP address from a network server.

DNP3 Distributed Network Protocol, version 3

A telecommunications standard that defines communications between master
stations, remote terminal units (RTUs), and other intelligent electronic devices
(IEDs).

DSR Data Set Ready (RS-232)

DTR Data Terminal Ready (RS-232)

dynamic IP An IP address that is automatically assigned by a DHCP server. Opposite of static

IP.

EMC electromagnetic compatibility

Devices that meet EMC requirements can operate within a system’s expected
electromagnetic limits.

ENA Energy Network Association

FPI Fault Passage Indicator

Gemini Lucy Electric’s range of automation components.

Gemini 3 The third generation of Lucy Electric’s general-purpose RTU.

GND ground potential

GPRS General Packet Radio Service

GSM Global System for Mobile Communications (originally Groupe Spécial Mobile)
The default global standard for mobile communications.

HMI Human Machine Interface

IEC 60870-5-101 Also known as IEC 101.

A protocol for the monitoring, control, and associated communications of electrical
power systems.
It is primarily used with relatively slow transmission media on the serial port.

IEC 60870-5-104 Also known as IEC 104.

A protocol that enables communication between control stations and substations
using a standard TCP/IP network.
It is primarily used over a standard Ethernet network.

IP55 Ingress Protection rating (for water and solid objects)

LED light-emitting diode

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 LV low voltage
0–415 VAC

NUA Each serial port (NTP1 and NTP2) on a Paknet Radio-Pad has a unique 14-digit
Network User Address (NUA). The NUA of each port is printed on a label on the
Radio-Pad packaging box.

OEM original equipment manufacturer

Paknet Vodafone’s Packet Radio Service

The Vodafone core network is known as the Packet Radio Network (PRN) and the
Radio-Pad utilisation of this is called the Packet Radio Service (PRS) or Paknet.

PSTN public switched telephone network

PSU power supply unit

RI Ring Indicator (RS-232)

RMU ring main unit

RS-232, RS-485 Standards for transmission of data using serial communication.

RTS Request To Send (RS-232)

RTU remote terminal unit

RX Receive Data (RS-232)

SCADA Supervisory Control And Data Acquisition

static IP An IP address that is configured manually. Opposite of dynamic IP.

SWA steel wire armoured

TX Transmit Data (RS-232)

V~ voltage (alternating current)

Vdc voltage (direct current)

VT voltage transformer

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 Copyright
© 2021 Lucy Electric. All rights reserved.

This document contains confidential information that shall not be transmitted to any third party without
written consent of Lucy Electric. The same applies to file copying (including but not limited to electronic
copies), wholly or partially.

It is prohibited to change any and all versions of this document in any manner whatsoever, including but
not limited to dividing it into parts. In case of a conflict between an electronic version (e.g. PDF file) and
the original paper version provided by Lucy Electric, the latter will prevail.

Lucy Electric and/or its associated companies disclaim liability for any direct, indirect, consequential or
incidental damages that may result from the use of the information or data, or from the inability to use the
information or data contained in this document.
Gemini 3 is a registered trademark of Lucy Electric. All other product and company names mentioned are
trademarks or registered trademarks of their respective owners.

Marking with the CE symbol indicates compliance of this device to the following European Commission
product directives:

2014/35/EU Low Voltage Directive

2014/30/EU Electromagnetic Compatibility Directive
2012/19/EU Waste Electrical Equipment Directive
2011/65/EU Restriction of Hazardous Substance Directive

This device is to be installed and operated as described.

Any modifications not approved by Lucy Electric could nullify the CE marking of this product and lead to
prosecution. A declaration of conformity has been made and is located at Lucy Electric, Howland Road,
Thame, Oxfordshire, OX9 3UJ, United Kingdom.

WEEE Statement

Instructions for Disposal: Please dispose of Waste Electrical and Electronic Equipment (WEEE) at
designated collection points for the recycling of such equipment.

LIOM01-069 - Issue 1 Sabre VRN-FS - SEC smART January 2021 91

Lucy Electric worldwide offices

Lucy Electric UK Limited Lucy Electric Arabia Co. Ltd Lucy Asia Pacific Sdn. Bhd
Howland road, Thame, Oxfordshire, OX9 3UJ, Novotel Business Centre, PO Box 35340 Unit 17-05-06, Level 17
United Kingdom. Dammam 31488, Saudi Arabia. PJX-HM Shah Tower,
Tel: +44 (0) 1844 267 267 Tel:+96 6138 147 910 No16A Jalan Persiaran Barat, 46050
Fax: +44 (0) 1844 267 223 Fax: +96 6138 147 914 Petaling Jaya, Selangor, Malaysia
E-mail: salesuk@lucyelectric.com E-mail: salesksa@lucyelectric.com Tel: +603 74910700
Aftersales: Fax: +603 79316923
contractmanagement@lucyelectric.com E-mail: salesmy@lucyelectric.com
Lucy Middle East F.Z.E. Lucy Electric South Africa (Proprietary) Lucy Electric (Beijing) Co. Ltd
Limited
PO Box 17335, Jebel Ali, Dubai, Unit 12 & 13,Block C, Honeydew Bussiness Park, 1503 Room 1122, Tower A, Gateway
United Arab Emirates. Citrus Street, Laser Park, Honeydew, 2170, South Square, No. 18 Xiaguangli, North
Tel: +9714 812 9999 Africa. Road East Third Ring, Chaoyang
Fax: +9714 812 9900 Postal Address: P.O. Box 1078, Honeydew. Distric, Beijing, China. 100027
E-mail: salesme@lucyelectric.com Tel: +27 11 0257490 Tel: +86-(0)10 59231176
Aftersales: customer.service@lucyelectric.com Fax: +27 11 7943277 Fax: +86-(0)10 59231177
E-mail: salesza@lucyelectric.com E-mail: salescn@lucyelectric.com
Lucy Electric Thailand Limited Lucy Electric India Private Ltd
388 Exchange Tower, 37th Flr Unit 3702 F-10, MIDC
Sukhumvit Road, Klongtoey Sub district Ambad
Klongtoey District, Bangkok, 10110 Nasik 422010, India.
Thailand Tel: +91 253 2381603
Tel: +66 (02) 663 4290 Fax: +91 253 2381247
Fax: +66 (02) 663 4293 E-mail:leindia@lucyelectric.com
E-mail: salesth@lucyelectric.com

www.lucyelectric.com