OPERATION & MAINTENANCE MANUAL FOR 400kV CIRCUIT BREAKER

JINDAL INDIA THERMAL POWER LIMITED (2 x 600MW THERMAL POWER PROJECT)

OPERATION & MAINTENANCE MANUAL FOR 400kV CIRCUIT BREAKER

Owner

JINDAL INDIA THERMAL POWER LIMITED

Project

2 x 600 MW THERMAL POWER PROJECT

Consultant

TATA CONSULTING ENGINEERS

Document O & M Manual Document Number Siemens Limited, Type (Information Only) Document 400kV Circuit Aurangabad. SIEM-JITPL.5404A-EL-3-2112 Name Breaker - Manual Copyright Siemens Ltd 2007. The reproduction, transmission or use of this document or its contents is not permitted without express written authority. Offenders will be liable for damages. All rights, including rights created by patent grant or registration of a utility model or design, are reserved.

DOC. No. - SIEM-JITPL.5404A-EL-3-2112 400kV Circuit Breaker Date 23.06.2011 Page 1 of 109 JINDAL INDIA THERMAL POWER LIMITED Project O&M TATA CONSULTING ENGINEERS Consultant
(2 x 600 MW THERMAL POWER PROJECT)

Operating Instructions
Circuit-Breaker 3AP2 Fl for rated voltage 420 kV

1003006a

Siemens Ltd.
Siemens Ltd 2007

The Siemens Ltd, Power Transmission and Distribution Group, High Voltage Division has introduced and appiies a quality system in accordance with EN ISO 9001. If you require further copies of the operating instructions, please order them from the appropriate Siemens office, indicating the title and order number:

Published by: Siemens Ltd. Power Transmission and Distribution High Voltage E-76. Waluj MIDC Aurangabad 431136 Tel.: +91 240-2554008 Fax: +91 240-2554701 Subject to change. All rights, including rights of translation, reproduction by printing, copying or similar methods, even of parts are reserved. Offenders will be liable for damages.

1 Contents 1 2 2.1 2.1.1 2.1.2 2.2 3 3.1 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.2 3.3 3.4 3.5 3.6 3.6.1 3.6.2 3.6.3 3.6.4 3.7 3.7.1 3.7.2 3.7.3 3.8 3.8.1 3.8.2 3.8.3 3.8.4 3.8.5 3.8.6 3.8.7 3.8.8 3.9 3.9.1 Contents General Introduction Arrangement of the Operating Instructions Communication by Means of the Operating Instructions Safety Instructions Description Technical Data Standards, Regulations Operating Temperatures Insulation Rating Electrical Data Operating Times Arc Quenching Medium SF6 Auxiliary Switch Anti-Condensation Heaters Reference Contact IK-3 Further Technical Data Circuit-Breaker Pole Column Interrupter Unit Arc Quenching Spring Drive Mechanism of the Circuit- Breaker Charging the Closing Spring Closing Opening Operating Sequence Function of the Spring Drive Mechanism Charging the Closing Spring Closing Tripping Control Spring Winding Mechanism Gas Monitoring Lockouts Motor Control Anti-Condensation Heaters Signals Free Auxiliary Switch Contacts Operating Cycle Counter Reference Contact IK-3 Introduction 7 7 7 7 8 11 11 11 11 12 12 13 14 14 15 15 15 16 18 20 22 24 24 24 25 25 26 26 29 34 35 36 36 39 39 39 39 40 40 41 41

1 Contents

4 4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.3.1 4.3.2 4.4 4.5 4.5.1 4.5.2 4.5.3 4.5.4 4.5.5 4.5.6 4.5.7 4.5.8 4.5.9 4.5.10 4.5.11 4.6 4.6.1 4.6.2 4.6.3 4.7 4.7.1 4.7.2 4.7.3 4.8 4.9 4.9.1 4.9.2 4.9.3 5 5.1 5.1.1 5.1.2 5.1.3

Installation Safety Rules for Installation Delivery and Storage Packing Checking on Arrival Storage Cleaning Liquids, Lubricants and Corrosion Protection Agents Cleaning Liquids Lubricants and Corrosion Protection Agents General Instructions for Installation Installation of the Circuit-Breaker Requirements for Assembly Assembly on Supporting Pillars at the Place of Installation Assembly Overview Disassembling the Insulator Column Kit Assembly of the Control Cubicle Assembly of the Operating Mechanism Cubicles Assembling the Insulator Column Erecting the Double-Break Assembly Lifting Plate Coupling the Operating Mechanism Connecting the Gas Pipes Earthing and Connecting the Leads Earthing Work on High-Voltage Terminals Connecting the Leads Filling the Circuit-Breaker with Gas Evacuating Filling the Breaker from the Gas Cylinder Leakage Test after Installation Carrying Out Test Operations Checks before Commissioning Anti-Condensation Heaters Test of Wiring between Substation and Circuit-Breaker Commissioning Report Operation Instructions for Operation Closing and Opening SF6 Pressure General Lockout

43 43 46 46 46 46 48 48 49 50 51 51 51 52 52 55 56 57 62 68 69 70 72 72 72 73 74 74 74 76 77 79 79 79 79 81 81 81 81 82

1211

1 Contents

5.1.4 5.1.5 5.1.6

Mechanical Reclosing Lockout Max. Permissible Number of Interruptions Recommended Procedure in the Event of Irregularities on the Circuit-Breaker 3AP2 Fl Disposing of High-Voltage Switching Devices and Systems Maintenance Inspection and Maintenance - General Maintenance Services (Schedule) Assignment of Personnel Maintenance Kits Initial Date for Inspection and Maintenance Service Disturbances Points to be Noted Safety Rules for Inspection and Maintenance Service - General Maintenance Schedule Work to be Carried Out in Accordance with the Maintenance Schedule General Inspection Drawing Off the SF6 Gas Check of Contact System Evacuating and Filling the Circuit-Breaker with Gas Check Gas Pressure Gauge Testing the Density Monitor Check for Leaks on Operational Circuit- Breaker Checks at Drive Mechanism Terminal Strip Anti-Condensation Heaters Function Checks Check of Motor Control Measuring the SF6 Gas Humidity Content Measuring the SF6 Air Content Anti-Corrosion Protection Special Occurrences Commissioning Report for the Circuit-Breaker 3AP

82 82 85

5.2 6 6.1 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 6.1.6 6.2 6.3 6.4 6.4.1 6.4.2 6.4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11 6.4.12 6.4.13 6.4.14 6.4.15 6.4.16

87 89 89 89 90 90 90 91 91 92 96 98 98 98 99 100 103 103 104 105 107 107 107 108 108 108 109 109 111

Function Diagram of Spring Drive

Mechanism

119

1 Contents 5

2 General

2
2.1

General
Introduction

These operating instructions apply to high-voltage circuit-breakers with the serial numbers given on the title page. They are intended to familiarize operating personnel with the design and functioning of the circuitbreaker. They also supply details of operation and provide information on installation and maintenance. All values of pressure given are gauge values unless absolute pressure is expressly stated. It is advisable for the operating personnel to familiarize themselves as early as possible with the instructions, and with the aid of other documents supplied to gather any relevant further information on the circuit-breaker and its features.

Note
The operating instructions contain information on proper operation and maintenance of the circuit-breaker, together with certain supplementary warning notices. They are intended to point out impermissible actions and to show the potential danger associated with operation of the circuit-breaker. Should further information be desired or should particular problems arise which are not covered sufficiently in the operating instructions, the matter should be referred to the local Siemens sales office. 2.1.1 Arrangement of the Operating Instructions These operating instructions are divided into chapters 1- Contents, 2- General, 3- Description, 4- Installation, 5- Operation and 6- Maintenance. 2.1.2 Communication by Means of the Operating Instructions In verbal or written communication, as well as when ordering any spare parts required, please use the designations and part numbers used in the operating instructions, giving details of the order number of the operating instructions 927 00966 174 A, the page number and specifying the number of the illustration (Fig.). In this way, misunderstandings can be prevented.

2 General

2.2

Safety Instructions

During operation, certain parts of the circuit-breaker are live and hazardous voltages therefore present. Certain parts are also under gas pressure (SF6). In its pure state, sulphur hexafluoride (SF6) is a colourless, odourless, tasteless, non-toxic and non-flammable gas, inactive like nitrogen. SF6 is safe if there is adequate oxygen present in inhaled air. SF6 constitutes no danger to the ecosystem. Personnel must be thoroughly familiar with all warnings and procedures for installation, operation, maintenance and repair contained in these operating instructions.

WARNING
Non-observance of warnings can result in death, severe personal injury and substantial property and environmental damage. The user of the circuit-breaker must ensure that the installation, maintenance and relevant operating directives to the appropriate activity, local safety regulations and information on what to do in the event of an accident are available or displayed, e.g. on a notice board so that they can be referred to at any time. Additionally to the safety rules valid in the country in question a few precautionary measures and points to be noted are listed below: The accessory items required for installation, operation and maintenance of the circuit-breaker and for reasons of safety (protecting clothes, devices for manual operation, warning signs, hand lamps, fire extinguishers etc.) must be stored neatly at a certain point and be checked regularly for completeness and proper functioning. This also includes the complete operating instructions. The specified maintenance intervals and the instructions for repair and replacement must be adhered to. Detailed warning references describing the secure execution of dangerous work are included in the particular sections of the operating instructions. They are highlighted by frames, bold lettering and/or other means.

WARNING
in the sense of these operating instructions means that death, severe personal injury or substantial property and environmental damage may occur if appropriate safety measures are not taken.

Attention
in the sense of these operating instructions means that light personal injury or property/environmental damage may occur if appropriate safety measures are not taken.

Note
Note in the sense of these operating instructions means information to simplify and improve the handling of the circuit-breaker. They are based on the experiences of Siemens staff.

3 Description

3
3.1

Description
Technical Data

The 3AP2 Fl circuit-breaker is of the self-compression type and uses SF6-gas for insulation and arc-quenching purposes. It is of triple-pole outdoor design. The circuit-breaker is equipped with one operating mechanism per pole and therefore suitable for single and triple pole auto reclosing.

3.1.1

Standards, Regulations

The circuit-breaker, together with the equipment and special tools supplied, is in conformity with the statutory laws, rules and standards applying at the time of delivery. - The specifications in IEC Publications 62271-100. - The specifications in lEC-Publications 60694.

3.1.2

Operating Temperatures

The circuit-breakers are designed for operation in an ambient temperature range from -25C to 45C.

3 Description

3.1.3

Insulation Rating
420 kV

Rated voltage Rated short-duration power-frequency withstand voltage to earth across the open circuit-breaker between phases Rated lightning impulse withstand voltage to earth across the open circuit-breaker between phases Impulse against power frequency voltage Rated switching impulse withstand voltage to earth across the open circuit-breaker between phases Impulse against power frequency voltage Flashover distance in air to earth across the open circuit-breaker between phases

520 kV 610 kV 520 kV

1425 kV 1425 kV 1425 kV 1425 kV +240 kV

1050 kV 1050 kV 1575 kV 900 kV + 345 kV

3180 mm 3200 mm see dimension drawing

Minimum creepage distance over the insulators' surfaces to earth across the open circuit-breaker Table 1 Insulation rating

10050 mm 10500 mm

3.1.4

Electrical Data
420 kV 50 Hz 3150 A 50 kA 600 A 400 A ace. to IEC 135kA 3s O-0,3s-CO-3min-CO

Rated voltage Rated frequency Rated normal current Rated short-circuit breaking current Rated line-charging breaking current (1.4 p.u.) Rated cable-charging breaking current (1.4 p.u.) Transient recovery voltage under terminal fault conditions Rated short-circuit making current Rated short-circuit duration Rated operating sequence Table 2 Electrical data

3 Description

3.1.5

Operating Times

Minimum command duration (Closing com- 80 ms mand) Minimum command duration (Opening command) Closing time Opening time Rated break time Close-open-time Dead time Table 3 Operating times 80 ms 65 ms + 6 ms 23 ms + 3 ms <40 ms 60 ms + 10 ms 300 ms

10

3 Description 3.1.6 Arc Quenching Medium SF6

a b c e Fig. 1

SF6-filling gauge pressure (nominal density line) Signal Loss of SF6 General lockout SF6 Liquefaction curve SF6-filling and operating values of density monitor (gauge pressure)
44.6 kg 966 dm3 6.0 bar

Filling weight (complete circuit-breaker) Volume (complete circuit-breaker) SF6 nominal filling gauge pressure at +20C Monitoring of the SF6 Signal Loss ofSF6 at 20C General lockout SF6 at 20C Filter material (complete circuit-breaker) Table 4 Arc quenching medium SF6

5.2 bar 5.0 bar

7.5 kg

3.1.7.

Auxiliary Switch
250 VDC 10A 2.5 A 220 VDC 10A 2.5 A 2A 125VDC 10A 4A 2.5 A 110VDC 10A 5A 4A 60VDC 10A 9A 7A 48VDC 10A 10A 9A

Rated voltage Rated normal current Switching capacity Resistive load

Resistive-inductive load 1,2 A (time constant x = 20 ms) Table 5 Auxiliary switch

Auxiliary switch contact class 1

11

3 Description 3.1.8 Anti-Condensation Heaters

90 W 210 W

Control cubicle Operating mechanism Table 6 Anti-condensation heaters

The anti-condensation heaters must always be switched on. 3.1.9 Reference Contact IK-3
Principle Hall sensor Magnet Supply voltage Operating temperature Output Resolution Transmission Fixed Hall sensor and moving magnet HE-6103 HE-6104 24VDC -40C ... +85C 4...20 mA, CLOSE: >18 mA, OPEN: <6 mA <0,2 ms Current loop, max. 500 m

Table 7 Technical Data IK-3

3.1.10

Further Technical Data

Note
Technical Data for Trip voltage Control voltage Heater voltage Pressure monitoring for SF6 Charging motor of the spring drive mechanism

are indicated in the circuit diagram.

Note
Technical Data for Circuit-breaker weights the permitted cable pull F

are indicated in the dimension drawing.

12

3 Description

3.2

Circuit-Breaker

The pole columns of the circuit-breaker are each mounted on a base 11, to the side of each of which an operating mechanism cubicle 15.1 is fitted. The insulator columns are assembled from several multished insulators and each of them supports an double break interrupter assembly consisting of two interrupter units 22 with grading capacitors 23 connected in parallel and a bell-crank mechanism 21. Control cabinet 12 is also located at pole B.
21

15.1

12

11 12 15.1 16 21 22 Fig. 2

Base Control cubicle Operating mechanism cubicle Post insulator Bell-crank mechanism Interrupter unit Design of the circuit-breaker 3AP2 Fl
1003000a

13

3 Description

The two interrupter units provide a double-break feature per pole, the grading capacitors ensuring uniform voltage distribution. The double break assembly and the insulator column are filled with SF6 for arc-quenching and insulating purposes. The density of the SF6 gas for each circuit-breaker pole is monitored by a density monitor and the gas pressure indicated by a manometer. The energy required for switching is stored in one closing spring and one opening spring. The closing and opening springs are located in the operating mechanism unit. Control cabinet 12, which is attached to circuit-breaker pole B, contains the equipment for controlling and monitoring the circuit-breaker and the terminal blocks required for the electrical connection. SF6 gas is monitored single-poled in the operating mechanism cabinet. There are cables for electrical coupling of the control with the three operating mechanism.

14

3 Description

3.3

Pole Column

The circuit-breaker's three pole columns are of identical design. Fig. 3 shows a cross-section of a pole column. The double break assembly unit is mounted on post insulators which provide insulation against earth.

15.16.3

22.22

15.11

15.9 15.8.3
15 15.11 15.16.3 15.8.3 15.9 16 16.9 18.27.1 21 22 22.1 22.22 Fig. 3 Corner gear Filter cowl Filter bag Shaft Lever Post insulator Operating rod Driving rod Bell-crank mechanism Interrupter unit Jacket High-voltage terminal Sectional view of pole column

15

15

3 Description The switching operation is transmitted to the interrupter units 22 (high-voltage potential) by the spring drive mechanism (ground potential) via an operating mechanism rod 18.27.1, the shaft 15.8.3, the operating rod 16.9 and the bell-crenk mechanism 21. The filter cowls 15.11 contains the filter material 15.16.3 which collects SF6 decompositon products and moisture residue.
23.1
23.2

22
1001360a

22 23 23.1 23.2 Fig. 4

Interrupter unit Grading capacitor Inner bracket Outer bracket Arrangement of grading capacitor

16

3 Description

3.4 Interrupter Unit Fig. 5 shows a sectional view of an interrupter unit. The breaker contacts are accommodated in the gas-tight porcelain jacket 22.1.

15.11 16.9 21.1 22.1 22.11 22.11.1 22.11.17 22.11.18 22.11.19 22.11.2 22.17.1 22.17.2 22.22 22.23 22.29 22.3 22.31 22.32 22.35 22.4 22.41 22.45 22.5 22.52 22.9 Fig. 5

Filter cowl Operating rod Gear unit housing Jacket Tube contact Nozzle Piston Valve plate Valve group Auxiliary nozzle Pull rod Coupling rod High-voltage terminal Inner socket Sealing ring Contact laminations Contact carrier Base Cover Tandem gear Heat cylinder Electrode Guide rail Pin Pin Interrupter unit

The main circuit of an interrupter unit consists of the high-voltage terminal 22.22, the socket 22.32, the contact carrier 22.31, the contact laminations 22.3 arranged in rings in the contact carrier, the heat cylinder 22.41, the inner socket 22.23 and the gearbox 21.1. The contact laminations 22.3 support themselves centrically from the contact carrier 22.31 inwards to the heating cylinder 22.41. The internal stress of the contact laminations 22.3 generates the necessary contact pressure from the contact carrier 22.31 onto the heating cylinder 22.41.

17

3 Description

Parallel to the main circuit is the arcing circuit, which is made up of the movable pin 22.9 in the contact carrier 22.31 and the moving tube contact 22.11 situated in the heating cylinder 22.41. The pin 22.9 and the tube contact 22.11 are made of materials which produce only minimal contact erosion. The tube contact 22.11, the piston 22.11.17 and the heat cylinder 22.41 are mechanically interconnected and coupled with the pull rod 22.17.1. They form the moving part of the interrupter unit. A guide rail 22.5 is mounted at the nozzle 22.11.1. This engages with the control lever 22.46 via the pin 22.52. As a result, the control lever is subjected to rotary movement, causing linear movement of the pin against the direction of movement of the nozzle. The electrode 22.45 is connected to the nozzle via the gears using two connecting rods and provides the pin with dielectric shielding. The rear side of the piston 22.11.17 is equipped with a valve plate 22.11.18 which together with the valve group 22.11.19 makes up the compression unit for arc quenching. The breaking process in the interrupter unit is described in a schematic diagram in the section 3.5 Arc Quenching.

18

3 Description

3.5

Arc Quenching

In an opening operation, the main contact that exists between the contact laminations 22.3 and the heat cylinder 22.41 is opened (Fig. 6, position b). The arcing contact, consisting of the pin 22.9 and the tube contact 22.11 remains closed, with the result that the current commutates onto the arcing contact.
22.11.19 KV 22.11.18 22.41 22.11 22.5 22.52

a)

22.11.17

HV

22.11.2 22.3

22.11.1 22.9 22.51 22.46 22.56

b)

C)

d)

a) b) c) d) HV KV 22.11 22.11.1 22.11.17 22.11.18 22.11.19 22.11.2 22.3 22.41 22.46 22.5 22.51 22.52 22.56 22.9 Fig. 6

CLOSED position Opening: main contact in OPEN position Opening: arcing contact in OPEN position OPEN position Heating volume Compression volume Tube contact Nozzle Piston Valve plate Valve group Auxiliary nozzle Contact lamination Heat cylinder Cam lever Guide rail Coupler Pin Lever Pin (moving) Schematics of opening operation

19

3 Description

The pin (moving) 22.9 is moved against the direction of movement of the tube contact 22.11 by the connected components of heating cylinder 22.41, nozzle 22.11.1, connecting rod 22.51, pin 22.52, control lever 22.46 (circuit-breaker opening movement). The moved electrode 22.45 is also pushed in the direction of the heating cylinder 22.41. During the continued course of the opening operation, the arcing contact opens, creating an arc (Fig. 6c). At the same time, the heat cylinder 22.41 moves to the left and compresses the quenching gas between piston 22.11.17 and valve group 22.11.19. This causes the quenching gas to be forced in the direction opposite to the movement of the moving contact components through the non-return valve, consisting of piston 22.11.17 and valve plate 22.11.18, into the heat cylinder and through the gap between the tube contact 22.11 and the arc quenching nozzle, thus quenching the arc. With large short-circuit currents the quenching gas surrounding pin 22.9 in the arcing chamber is heated by the arc's energy and driven into the heat cylinder 22.41 at high pressure. When the current passes through zero, the gas flows back from the heat cylinder into the nozzle and quenches the arc. When this happens, the valve plate 22.11.18 in the heat cylinder 22.41 prevents the high pressure from entering the compression chamber between piston 22.11.17 and the valve group 22.11.19.

20

3 Description

3.6

Spring Drive Mechanism of the Circuit-Breaker

This section contains a general presentation of the spring drive mechanism; see the 3D illustration on the foldout page at the end of these operating instructions. Its function is described in section 3.7 Function of the Spring Drive Mechanism.

3.6.1

Charging the Closing Spring

Circuit-breaker in OPEN position The closing spring 18.4 (see 3D illustration at the end of these operating instructions) is charged by the charging gears 18.2 using the motor 18.1 byway of the charging shaft 18.14 and connecting rod 18.10. At the end of the charging operation, the charging shaft is separated from the gears by the free-wheel 18.3 and secured with the CLOSE latch 18.17. The closing spring 18.4 is now charged for the closing operation and the circuit-breaker is therefore ready for closing.

3.6.2

Closing

The closing latch 18.17 is released by actuation of the trip coil 18.16. The energy of the discharging closing spring 18.4 is transmitted via the cam plate 18.6 to the lever 18.7 and the operating shaft 18.22 connected to it. In the process, the opening spring 18.11 is charged by means of the rotation of the operating shaft 18.22, the operating lever 18.24 and the connecting rod 18.27. The movement of the connecting rod 18.27 along the operating mechanism rod 15.9.1, the torque shaft 15.8 and the operating rod 16.9 is transmitted to the centre interrupter unit 22. At the same time, the contacts of the interrupter units 22 are closed. On completion of the closing operation, the residual kinetic energy is absorbed by closing damper 18.41. Cam 18.19 and roller 18.41.1 prevent backward swinging of charging shaft 18.14. Lever 18.7 is simultaneously engaged with OPEN latch 18.9. The pole is now in a CLOSED position and can thus be switched off. The closing spring 18.4 is then completely recharged in less than 15 s. A mechanical lockout prevents switching back on of the operating mechanism before the opening operation.

21

3 Description

3.6.3

Opening

Actuating tripping coil 18.8 releases OPEN latch 18.9. The contacts of interrupter unit 22 are separated by opening spring 18.11 via connecting rod 18.27, operating lever 18.24, operating mechanism rod 18.27.1, lever 15.9, torque shaft 15.8.3 and operating rod 16.9. The kinetic energy at the end of the opening cycle will thereby be absorbed by opening damper 18.15. Opening damper 18.15 simultaneously serves as an end stop for the opening cycle.

3.6.4

Operating Sequence

In the closed position of the circuit-breaker, the opening and closing spring are in charged state. This means the circuit-breaker is in a position to perform O-C-0 switching sequences.

22

3 Description

3.7

Function of the Spring Drive Mechanism

The function of the spring drive mechanism is described below in conjunction with the major modular assemblies. It is advisable first to read the section 3.6 Spring Drive Mechanism of the Circuit-Breaker.

3.7.1

Charging the Closing Spring

Starting position: the circuit-breaker is in the OPEN position. The closing and opening spring are relaxed, i.e. a switching operation is not possible. The cam disc 18.6 and the connecting rod 18.10 are near the lower dead centre point. The guide lever 18.7 and operating lever 18.24 are rigidly connected and are in the OPEN position (Fig. 7). To charge the closing spring, the charging shaft 18.14 is rotated by means of the charging motor 18.1 and gears 18.2. The free-wheel 18.3 engages in the cam of the charging shaft 18.14 (Fig. 8) and rotates it as far as the upper dead centre point. The charging shaft 18.14 is then turned as far as the closing latch 18.17 more quickly by the effect of the partly relaxed closing spring 18.4 than by the freewheel, i.e. the form-fit between the free-wheel of the charging gear and the charging shaft is cancelled and the charging shaft outpaces the charging gear. Before the cam plate 18.6 is stopped in the position 10 beyond the upper dead centre by means of the roller 18.23 and the closing latch 18.17 (Fig. 9), the cam 18.19 fixed to the mechanism housing disengages the free-wheel 18.3 from the charging shaft 18.14 (Fig. 10). Charging shaft 18.14 and gear 18.2 are thereby separated. The motor is shut down automatically and runs down with the gearing. The closing spring is charged and the operating mechanism ready for the closing process.

23

3 Description

18.10 18.11 18.14 18.15 18.16 18.17 18.17.1 18.19 18.22 18.23 18.24 18.27 18.27.1 18.31 18.4 18.4.1 18.41 18.41.1 18.6 18.7 18.7.1 18.8 18.9 18.9.1 18.9.2 22 Fig. 7

Connecting rod (for closing spring) Opening spring Charging shaft Damper for opening Release CLOSE Closing latch Support lever Cam Operating shaft Roller Operating lever Connecting rod (for opening spring) Driving rod Mechanical closing interlock Closing spring Spring washer Damper for closing Roller Cam disc Lever Roller Release OPEN Opening latch Supporting latch Support lever Interrupter unit Function diagram of closing and opening latching: OPEN position, closing and opening spring relaxed

24

3 Description

18.20

18.14
18.2

18.3
18.1

1000661a

18.1 18.14 18.2 18.20 18.3 Fig. 8

Motor Charging shaft Charging gear Cam Free-wheel Function of the free-wheel: Charging of the closing spring

18.4

1000810a

18.14 18.17 18.23 18.31 18.4 18.6 Fig. 9

Charging shaft Closing latch Roller Mechanical closing interlock Closing spring Cam disc Function diagram of closing and opening latching: OPEN position, closing spring charged

25

3 Description

18.14 18.2 18.20 18.3 Fig. 10

Charging shaft Charging gear Cam Free-wheel Function of the free-wheel: Uncoupling the charging gear

3.7.2

Closing

Actuating CLOSE tripping coil 18.16 releases cam disk 18.6 via CLOSE latch 18.17 and supporting lever 18.17.1 (Fig. 11).

18.16

18.17.1 18.23 18.17

18.6

1000813a

18.16 18.17 18.17.1 18.23 18.6 Fig. 11

Release CLOSE Closing latch Support lever Roller Cam disc Function diagram of closing and opening latching: Disenagement of the closing latch

26

3 Description

The effect of the closing spring turns the charging shaft 18.14 (Fig. 12). The roller 18.7.1 of the lever 18.7 moves along the cam 18.6 and transmits the movement to the operating shaft 18.22. The movement is then transmitted by the lever 18.24 (fixed to the operating shaft 18.22) and the operating mechanism rod 18.27.1 to the interrupter unit 22. The contacts of the interrupter unit 22 are closed.

18.11 18.14 18.22 18.24 18.27 18.27.1 18.6 18.7 18.7.1 18.9 18.9.1 22 Fig. 12

Opening spring Charging shaft Operating shaft Operating lever Connecting rod (for opening spring) Driving rod Cam disc Lever Roller Opening latch Supporting latch Interrupter unit Function diagram of closing and opening latching: Closing

27

3 Description At the same time the opening spring 18.11 is charged by way of the operating lever 18.24 and the connecting rod 18.27. The opening latch 18.9 moves along the roller of the latch lever 18.9.1 (Fig. 12). At the end of the curve, the lever 18.7 overtravels, with the result that the opening latch 18.9 can drop behind the roller of the latch lever 18.9.1 (Fig. 13).

18.19 18.41 18.41.1 18.6 18.7 18.7.1 18.9 18.9.1 Fig. 13

Cam Damper for closing Roller Cam disc Lever Roller Opening latch Supporting latch Function diagram of closing and opening latching: Overtravel of the lever

28

3 Description

On completion of the closing cycle, cam 18.19 will run on roller 18.141.1 and transfer its residual kinetic energy to damper for closing 18.41 (Fig. 13). Following this, roller 18.41.1 will jump behind cam 18.19 to prevent backward swinging of charging shaft 18.14 (Fig. 15). After leaving the cam disc 18.6, the lever 18.7 turns back a little towards OPEN, until the opening latch 18.9 is resting on the roller of the supporting latch 18.9.1 (Fig. 14). The circuit-breaker is now latched in the CLOSED position.

18.19 18.41.1 18.6 18.7 18.9 18.9.1 Fig. 14

Cam Roller Cam disc Lever Opening latch Supporting latch Function diagram of closing and opening latching: Latching in the closed position

29

3 Description

18.14 18.15 18.17 18.17.1 18.31 18.4 Fig. 15

Charging shaft Damper for opening Closing latch Support lever Mechanical closing interlock Closing spring Function diagram of closing and opening latching: Latching of the charged closing spring

As the closing process takes place, the charging motor is switched on. The charging of the closing spring is repeated according to paragraph 3.7.1 Charging the Closing Spring. Subsequently the charging shaft must be latched to top dead centre with the charged closing spring (Fig. 15). Mechanical closing lock-out 18.31 prevents unintentional starting of the operating mechanism before the opening cycle by blocking supporting lever 18.17.1 (see Fig. 15). The closing and opening springs are charged and the circuit-breaker is consequently ready for an O-C-0 switching sequence.

30

3 Description

3.7.3

Tripping

Actuating OPEN trip coil 18.8 releases OPEN latch 18.9 via supporting latch 18.9.1 and supporting lever 18.9.2. Operating lever 18.24 and lever 18.7 are withdrawn by opening spring 18.11 over connecting rod 18.27 to the OPEN position (Fig. 16). The contacts of interrupter unit 22 are simultaneously shifted to the OPEN position over operating mechanism rod 18.27.1. At the end of the opening movement the kinetic energy is absorbed by the damper (for opening) 18.15. The damper serves also as end stop.

18.11 18.15 18.24 18.27 18.27.1 18.7 18.8 18.9 18.9.1 18.9.2 22 Fig. 16

Opening spring Damper for opening Operating lever Connecting rod (for opening spring) Driving rod Lever Release OPEN Opening latch Supporting latch Support lever Interrupter unit Function diagram of closing and opening latching: Disengagement of the opening latch

31

3 Description 3.8 Control

The control system includes all secondary technical components necessary for the operation of the circuitbreaker, which are for the main part located inside the control cubicle and the housing of the operating mechanism. The documentation for the circuit-breaker includes the circuit diagram of the control system. This diagram contains the following documents: Location diagram Schematic diagram Extended equipment diagram with technical data and list of equipment Terminal diagram Connector diagram

Fig. 17 shows the inside of the control cubicle.

R..

1001369a

K... P... R... S4 X1 12.1.1 18

Contactors, time relays Operating cycle counter Heating (preventing condensation formation) Confirmation Terminal blocks Equipment mounting plate Climate-proof, ventilated and heated outdoor cubicle, degree of protection IP 55 Inside of the control cubicle.

Fig. 17

32

3 Description

Note
The operator is responsible for the fuse protection for the auxiliary circuits, unless otherwise agreed with the manufacturer. 3.8.1 Spring Winding Mechanism

The spring winding mechanism consists of the motor and the charging gear. The spring state indicators (symbols) are on the spring cups and will be shown by intelligible symbols. See chapter 3.6 Spring Drive Mechanism of the Circuit-Breaker.

a) b) 18.1 18.11 18.16 18.20 18.4 18.8 Fig. 18

Spring is charged Spring is not charged Motor Opening spring Release CLOSE Motor limit switch Closing spring Release OPEN Spring drive mechanism

3.8.2

Gas Monitoring

Each pole column is a closed gas compartment (Fig. 19) and is gas-monitored individually. The gas compartment of a pole column to be monitored contains a non-return valve, a density monitor B4 and pressure gauge, the filling connection W1, the test connection W2 and piping for connecting the components.

33

3 Description

B4 MA W1 W2 Fig. 19

SF6 density monitor Pressure gauge Filling flange Test connection Diagram of SF6 monitoring in a pole column

The density of the SF6 arc quenching material in the gas compartment is monitored by a density monitor B4 (Fig. 21). The SF6 filling and response values for the density monitor can be found in section 3.1.6 Arc Quenching Medium SF6. The connection W1 (Fig. 20) for filling the pole column with SF6 gas is in the relevant operating mechanism unit next to the pressure gauge. The test connection W2 is located in the base (at the side of the operating mechanism cubicle) (Fig. 21).

1001304a

W1 flange

Filling

Fig. 20 Filling flange W1

34

3 Description

B4

1001305a

B4 W2 Fig. 21

Density monitor Test connection Test connection W2 (view with cover of the contact position indicator removed)

3.8.2.1

Function of the Density Monitor

The density monitor compares the density of the SF6 gas in the compartment to be monitored with the density of reference gas enclosed inside the monitor. Both gases are exposed to the same ambient temperature. The density comparison is replaced by a pressure comparison in both systems (gas compartment - reference compartment). The density monitor responds to a change in pressure as a result of a leak between circuit-breaker gas compartment and atmosphere. Pressure changes as a result of temperature changes are not taken into account. The density monitor is set at the works to the limit density required. Resetting is neither necessary nor possible.

35

3 Description

5.00 5.10 5.20 5.30 5.40 Fig. 22

Bellows Microswitch Housing Circuit-breaker gas compartment Reference gas compartment Schematic diagram of the density monitor (under working pressure)

3.8.3

Lockouts

The individual functions are explained in the order of their appearance in the circuit diagram. A General lockout SF6 prevents any switching of the circuit-breaker if the SF6 pressure is too low. The closing lockout prevents the circuit-breaker from being switched on while the closing spring is being charged. The anti-pumping device of the circuit-breaker pole ensures that it is not repeatedly opened and closed in the event of simultaneous CLOSE and OPEN commands. The swich S4 is for acknowledgement of enforced triple-pole operation. 3.8.4 Motor Control

The motor charges the closing spring and is controlled by a limit switch. 3.8.5 Anti-Condensation Heaters

To protect sensitive components in the operating mechanism cubicles and in the control cubicle from condensed water during rapid temperature changes, the units are always fitted with heating resistors. As condensation can occur at any ambient temperature, these resistors must always be in continuous operation. 3.8.6 Signals

Signals are information on the condition of the circuit-breaker.

36

3 Description

3.8.7

Free Auxiliary Switch Contacts

Additional free auxiliary switch contacts at the terminal fixture X1 are available for customer's purposes.

3.8.8

Operating Cycle Counter

The circuit-breaker is equipped with one counter per pole (Fig. 17). It counts the number of switching operations performed.

37

3 Description

3.9

Reference Contact IK-3

3.9.1

Introduction

Attention
The warnings in the operating instructions for high-voltage circuit-breakers must be observed! Work may only be performed at the reference contact in the OPEN position with the closing and opening springs relaxed. Discharge the closing and opening springs: Disconnect motor power supply, Open circuit-breaker (from closed position), Close the circuit-breaker, Re-open the circuit-breaker.

The reference contact is connected mechanically to the interrupter unit of a high-voltage circuit-breaker and serves for indirect determination of the switching time/ inherent switching time. The reference contact is tripped by the operating mechanism of the circuit-breaker. The difference in time between switching the interrupter unit and the output signal of the reference contact is recorded in the test document. There is no direct mechanical connection with the circuit-breaker's contact system.

FA RK UE Fig. 23

Operating mechanism Reference contact Interrupter unit Function diagram of the IK-3

The IK-3 is a non-contact contact system consisting of a Hall Effect sensor with actuating magnets. The Hall sensor is the fixed part and the magnet the moving part of the contact system.

38

3 Description

A B Fig. 24

Edge to be evaluated at CLOSE Edge to be evaluated at OPEN Output signal of the IK-3

The IK-3 is designed as a two-wire system in which the output signal is transmitted by a current loop.

1 2 3 4 Fig. 25

Sensor electronics Sensor HE-6103 Magnet HE-6104 Fastening plate Reference contact

The reference contact is set at the factory. The air gap between the sensor and the magnet must be 2 ... 4 mm.

39

4 Installation

4
4.1

Installation
Safety Rules for Installation

WARNING
Danger to installation personnel can result from - hazardous voltage - SF6-gas - falling and/or toppling parts and/or moving parts. Non-observance of warnings can result in death, severe personal injury and substantial property and environmental damage. In order to avoid accidents, fire and impermissible burdens on the environment and in order to assure the functional reliability of the switchgear, the user must ensure that: a responsible person, if necessary authorized to supervise, is put in charge of performance of commissioning, only qualified and instructed personnel are assigned, the regulations and instructions for work safety (e.g. in the use of equipment), together with instructions on action to be taken in the event of accidents and fire, are available at all times and if necessary displayed in the place of work, the tools, equipment and apparatus required for work safety and the personal protective equipment required for certain tasks are available, only those materials, lubricants and auxiliary equipment approved by the manufacturer are used.

40

4 Installation

The safety regulations in these operating instructions are minimum requirements. They do not affect statutory laws, standards, specifications or internal regulations of the company concerned with the work. They do not claim to cover all eventualities and must be expressed concretely by the responsible persons at the latest before work actually starts. In addition to company internal rules and the specific work conditions, the product descriptions and instructions for use of tools, devices, apparatus, materials, lubricants and auxiliary equipment must be taken into account. The following safety regulations provide an overview of the dangers existing and their sources, and describe the possible consequences if the rules specified are not complied with. They are expressed more exactly in the operating instructions.

WARNING
Hazardous voltage - Electric shock and burning as a result of arcing are possible if live parts are approached.

If high voltage is present in the vicinity at the place-where work is to be done, a responsible person from the power supply utility must, before work starts:

Switch off and isolate Prevent unintentional switch-on Test that equipment is dead Ground and short-circuit the equipment Cover or fence off nearby live parts

It must be confirmed that these safety measures have been taken.

WARNING
The pole columns are under pressure (see section 3.1.6 Arc Quenching Medium SF6) - Damage to the porcelain parts can result in severe personal injury. Do not allow any tools or hoisting gear to knock against the porcelain parts. Do not lean any ladders against the pole columns; use step ladders.

41

4 Installation

WARNING
SF6 is heavier than air. In closed areas it may displace the air - Danger of suffocation! Use a service unit for all work with SF6 gas. Extract the SF6 filling; do not let it escape into the air.

WARNING
Improperly performed installation and maintenance can result in danger and malfunctions.

In the context of installation and commissioning, the commissioning report must be filled out.

42

4 Installation

4.2

Delivery and Storage

Attention
Avoid damaging the porcelain bodies.

4.2.1

Packing

The circuit-breaker is supplied as pretested modular assembly. If transported by land, the components are delivered in crates. If transported by container (by sea), some are supplied on pallets and some in crates. All components and parts required for commissioning and operation are included in the shipment in a separate package. The parts comprised in the transport unit are indicated in the checklist provided with every circuit-breaker. SF6 gas is supplied in cylinders. The electrical circuit-breaker control is wired to the terminal strip in the control cubicle.

4.2.2

Checking on Arrival

When a shipment arrives it should be checked immediately against the dispatch notes and check list. If it shows signs of damage determine the extent of the damage and its probable cause without delay. Should the damage have been caused in transport, call in a representative of the forwarding agent in order to record the facts. This is an essential requirement if a claim for damages is to be submitted.

4.2.3

Storage

If a circuit-breaker is not to be assembled immediately after delivery, the crates can be stored outdoors. For better ventilation and as a protection against ground dampness, the crates should then be placed on wooden planks and covered with tarpaulins.

Note
In case of storing the circuit-breaker longer then 3 months the anti-condensation heater in the control cubicle and on the operating mechanism cubicles must be switched on.

43

4 Installation

After one year's storage, the external surfaces treated with Tectyl 506 should be given a thick second coating. Before storing the accessory items, check their plastic wrapping for signs of damage. If the plastic foil has sustained damage, unpack the parts and store them in a dry, ventilated room.

44

4 Installation

4.3

Cleaning Liquids, Lubricants and Corrosion Protection Agents

4.3.1

Cleaning Liquids

For cleaning and degreasing metal parts and sealing rings use any of the following (not included in the scope of supply).

Attention
Improper handling can result in personal injury, fire and environmental damage.

In the interest of safety, follow instructions for use of cleaning liquids carefully. Outer surfaces/minor dirt
Cleaning liquids Instructions Warm water solution with a mild household cleaning liquid Wipe off with a damp lint-free paper or cloth. Avoid drips. Do not let solution get into openings and gaps.

Outer surfaces, parts/greasy surfaces, surfaces coated with anticorrosion agent (Tectyl 506), sealing rings
Cleaning liquids Cold-application cleaning agent, hydrocarbonbasis (free from halogenated hydrocarbons) flash point >55C, e.g. Shellsol D60 (Shell), Essovarsol 60 (Esso), Aral 4005 (Aral), Haku 1025/920 (Kluthe) Wipe off with a damp lint-free paper or cloth. Avoid drips. Wipe clean with a dry, lint-free paper or cloth. Immerse small parts if necessary. Do not immerse sealing rings in agent.

Instructions

Safety instructions Fire hazard! No smoking! Read product descriptions and follow relevant safety instructions.

Insulating parts in SF6-compartments

Cleaning liquids Instructions Ethyl alcohol, isopropyl alcohol, Haku 3294 (Kluthe) Wipe off with a damp lint-free paper or cloth. Avoid drips.

Safety instructions Flammable! No smoking! Explosion protection necessary! Read product descriptions and follow relevant safety instructions.

45

4 Installation

4.3.2

Lubricants and Corrosion Protection Agents

The following lubricants and corrosion protecting agents are required for installation and maintenance of the circuit-breakers: Kliiber grease Centoplex 24 DL

for all lubricating points and non-hot-galvanized screws, unless another brand of lubricant is specified.

Isoflex Topas L32 for radial sealing rings and rolling contact bearings of the SF6 shaft seal on the corner gear and on the operating mechanism. Shell Vaseline 8420 for sealing rings and terminal faces for high-voltage cables. WD40 or Trost Multifunction Fluid for flange faces inside the sealing rings, including the slots.

Tectyl 506
for flange faces outside the sealing rings and for clamping sleeves. Molykote Longterm 2 plus for the threads of all hot-galvanized screws.

46

4 Installation

4.4

General Instructions for Installation

For assembling the circuit-breaker use only the bolts supplied. Spare bolts are included in the accessories pack, in case any are lost during assembly work.

WARNING
If unsuitable bolts are used, they can malfunction and cause severe personal injury. If the number of bolts supplied for the pressure vessels is insufficient, spare bolts must be ordered from the factory only. Grease the threads of all hot-galvanized bolts with Molykote Longterm 2 plus.

Attention
Unchecked tightening can result in damage to or loosening of bolt joints. Use torque wrench for assembly. Tightening torque see Table 11.

Bolts are of 8.8 grade or higher.

i.e. Minimum tensile strength 800 N/mm2 Minimum yield strength ReH = 640 N/mm2
Screwed joint M6 M8 M10 M12 M16 M20 M24 Table 11 Tightening torque 8 + 1 Nm 20 + 2 Nm 40 + 4 Nm 70 + 7 Nm 170 + 20 Nm 340 + 30 Nm 600 + 60Nm Tightening torques required for screw joints

Screw on all union nuts with a tightening torque of 40 4 Nm. Differing torques are indicated in the text. Any locking washers and gaskets loosened or exposed during assembly must be replaced.

47

4 Installation

4.5

Installation of the Circuit-Breaker

WARNING
The control leads must not be connected to the terminal block of the operating mechanism until the circuit-breaker has been erected complete with the pole columns.

4.5.1

Requirements for Assembly

You will require the following equipment and tools for next work steps in the assembly of the circuit-breaker: A crane with suitable suspension tackle Evacuating equipment P= 20 mbar SF6 filling device W423 SF6-leak detector A conventional standard toolbox.

4.5.2

Assembly on Supporting Pillars at the Place of Installation

The circuit-breaker must be assembled at the point of installation. The following sequence of steps must thereby be observed.

WARNING
Failure to observe the specified screw lengths for assembly of the circuit-breaker can lead to severe damage or even destruction of the circuit-breaker.

48

4 Installation

4.5.3

Assembly Overview

Fig. 26

Assembly overview

Note
Discard all screws and nuts marked red! 4.5.4 Disassembling the Insulator Column Kit

Loosen the M16 nuts at the fixing point between the bracket 1.3 and the wooden beams 1.6. Lift the three insulator columns in the kit with the crane and put them down onto the brackets 1.3 on a solid base but do not disconnect the suspension tackle fom the insulator column kit.

49

4 Installation

VD 1.3 1.4 1.5 1.6 1.8 Fig. 27

Packaging cap for insulator column Bracket Connecting plate Lifting eye plate Wooden beam Lifting eye-bolt Insulator column kit

Disassemble the insulator column kit as shown in Fig. 27 starting at the bottom and put the individual columns down on a solid base. Put the insulator columns down on the connecting plates or a wooden base (rest on the metal flange, not on the porcelain parts).

Fig. 28

Separating the insulator columns

4.5.4.1

Fixing the Reinforcing Sheets

To fit the reinforcing sheets 1 and 2 in the breaker base, replace the four M 16x80 screws shown in Fig. 29 and the three M16x55 screws on all three pole columns with the seven M16x10 screws supplied in the accessory pack.

Note
When replacing the screws to fit the reinforcing sheets 1 and 2, make sure that the screws are individually loosened, replaced and tightened again.

50

4 Installation

BM 16x55 BM 16x55

BM 16x55

B Fig. 29

The M16x55 screw is not replaced. Screw distribution for insulator column assembly.

The screws are then tightened to 170 Nm.

51

4 Installation 4.5.5 Assembly of the Control Cubicle

12
15.1 Fig. 30

Control cubicle Operating mechanism Control cubicle/operating mechanism transport unit

Insert the crane hook into the lifting eye-bolts of the control cubicle and undo screw joints to the other components of the transport unit. Move control cubicle with a crane and bolt in front to the centre pillar (pole B) (4 bolts M 16x60, 4 nuts, 8 washers from the accessories pack). The length of the bolts from the accessories pack is suitable for a pillar wall thickness of up to 35 mm (Fig. 31).

52

4 Installation

11.13 12 Fig. 31

Pillar Control cubicle Assemble control cubicle at pillar

4.5.6

Assembly of the Operating Mechanism Cubicles

The doors of the operating mechanism cubicles are labelled LA, LB and LC. The operating mechanism cubicles are assembled on the pillars for poles A, B and C according to this labelling. This allocation of operating mechanism to poles must be strictly observed because of the coded pole connecting cables. To assemble the drive cabinet, insert the crane hooks into the lifting eye-bolts of the drive cabinet and undo the screwed connections to the other components of the transport unit. Place the operating mechanism cabinet with base 11 onto flange plate F of the corresponding pillar and secure with screws (4 screws M 16x80, 4 nuts, 8 washers from the accessory pack). The length of the bolts from the accessories pack is suitable for a pillar wall thickness of up to 45 mm (Fig. 32).

4 4 Installation

53

F 11 Fig. 32

Pillar Flange Plate Breaker base Operating mechanism cabinet with base mounted on pillar

4.5.7

Assembling the Insulator Column

The circuit-breaker poles are labelled LA, LB and LC on the double interrupter heads, the insulator columns and the lower part of the circuit-breaker. Make sure the double interrupter heads and insulator columns are assigned correctly to the circuit-breaker poles and check the last four digits in the serial number on the lower part of the circuit-breaker when you install the circuit-breaker. The insulator columns consisting of corner gears, insulators and operating rods are fully assembled at the factory. The top openings on the insulator columns are sealed with a packaging cap for protection and to prevent contamination during transport (Fig. 33).

54

4 Installation

VD 1.8 Fig. 33

Packaging cap Lifting eye-bolt Packaging cap for insulator column

Attention
The time between removing the transport cover and evacuation of the circuit-breaker pole must not exceed one hour.

Attention
During assembly work, the open insulator column should be protected against atmospheric influences using suitable covers. Remove the bolt 10.9 (Fig. 49) from the corner gear 15 and the lever 15.9 and keep them ready for linking the operating rod. Remove the transport fastenings (cable ties) for the operating rod 18.27.1 (Fig. 49). Installing the insulator columns The insulator columns for the circuit-breaker are identical. Use the pole labels on the corner gear to assign the poles.

55

4 Installation

H 1.4 1.5 15 15.9.01 1.8 Fig. 34

Wood Connecting plate Lower lifting eye plate Comer gear Lever Upper lifting eye plate Installing insulator columns (diagram shows the top insulator column in the kit)

Loosen and remove the 2 lifting eye plates 1.5. Before you raise the insulator column place a wooden base under the corner gear. This will prevent damage when turning. Now lift the insulator column carefully by the 2 angled lifting eye bolts 1.8. Make sure that the crane hook and the insulator column head are always vertical to prevent the insulating columns slipping when lifted. The connecting plate 1.4 can then be loosened and removed. You can remove the lower connecting plate once the insulator column has been lifted far enough. Now insert the insulator column carefully into the carrier opening.

Fig. 37

Breaker pole mounted

56

Then align the insulator column so that pegging out with the bolt 10.9 (Fig. 49) is possible. Now tighten the four M 16x65 screws to a torque of 170 Nm. Tighten the four M8x40 screws and nuts with a torque of20Nm.
15.16.3

16.7

1002226a

Fl N VD 1 15.16.3 16 16.7 16.9 1.8 2 Fig. 38

Humidity indicator Groove for teflon strip 16.6.1 Packaging cap Transport protection device Desiccant agent Post insulator Sealing ring Operating rod Lifting eye-bolt Cable fastener Packaging cap for insulator column

57

4 Installation

4.5.8

Erecting the Double-Break Assembly

The coupling bolt 10.9 on the corner gear should be removed and laid out ready for later use. Remove the 90 offset jack rings 1.8 and laid out ready for the next insulator column.

Attention
During assembly work, the open insulator column should be protected against atmospheric influences using suitable covers.

Remove the packaging cover from the insulator column and read the moisture indicator on the inside of the cover immediately. Handling the humidity indicator The effectiveness of the drying agent can be determined using the humidity indicator. In its initial state (dry) the indicator display is blue. If the relative humidity increases, the indicator display changes from blue to pink. When taking the reading, check which semicircle is the most pink or is already lighter than the area around all the semicircles. (Fig. 39). The relative humidity in % is above this figure, but still below the next higher figure.

Note
The humidity value reading may not exceed 40 %. If the humidity value is above this, inform the nearest Siemens representative!

58

4 Installation

Fig. 39

Humidity indicator

The old desiccant agent is removed and disposed of. Treatment of the sealing flanges and the guide

The sealing faces of the flanges and the guide must be treated carefully since even minor damage may lead to leaking joints.

A B C Fig. 40

Grease with corrosion protection agent WD 40 or Trost multifunction oil Grease with Tectyl 506 Grease sealing rings with Vaseline 8420 Treatment of the sealing flanges and the guide

The flange for the insulator column should also be cleaned and treated with Tectyl. Take two new O-rings from the accessory kit, clean with lint-free cloth, lubricate with Vaseline and lay out ready for use.

59

4 Installation

Move the lever to CLOSED position (the drive rod moves upwards) and lock it to the base using the rubber retaining ring supplied so that ir remains in CLOSED position. Position a lubricated O-ring on the upper flange of the post insulator column. Remove the transport protection 1, which is used only during transport (Fig. 38) from the guide tube 16.6. The prepared sliding ring 16.6.1 from the accessory pack is positioned around the groove with one hand. At the same time, the guide 16.6 can be pushed over the slide ring with the other hand (see Fig. 46).

Note
When inserting the guide, ensure that the longer section of the guide is at the bottom. By turning it slightly in all directions, ensure that the lower O-ring is positioned centrically in the groove.

16.9.1

16.3

1002573a
16.3 16.6 16.6.1
16.7 16.9 16.9.1 Fig. 41 Post insulator Centering guide Teflon strip Sealing ring Operating rod Yoke head Teflon strip

Insert the upper O-ring in the upper groove on the guide. Install spacer Insert three spacers W350 in the post insulator flange so that the slit in the threaded bolt is pointing to the flange and fasten M16 nuts (Fig. 46).

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4 Installation

W350 16.6 16.7 16.9.1 Fig. 42

Spacer Centering guide Sealing ring Yoke head Install spacer

Lift double interrupter head to eye level with crane on the lifting plates (Fig. 47).

1 Fig. 43

Lifting plate Lifting plate arrangement

Attention
The double interupter head must be suspended horizontally for assembly.

61

4 Installation

Remove the transport cover 21.9.9 (Fig. 45) from the double interrupter head and take out the desiccant bags. Prepare the sealing flanges as described above. Remove the cable binder used as transport protection. Bring the interrupter unit into OPEN position by pulling the two coupling levers jerkily as far as they will go. The coupling bolt 21.7.3 supplied can be used for this purpose. The double interrupter head is placed on the spacer in such a way that the grading capacitors are situated on the side of the operating mechanism cabinet. The holes in the fork head of the drive rod and in the two coupling levers should be aligned, to enable the coupling bolt to be inserted. To do this, the two coupling levers are held in a V-shape with one hand, while the coupling bolt is inserted into the aligned holes with the other hand after positioning the drive rod. Protect coupling bolt 21.7.3 with PE fuse 21.11.

1002230a

VD 15.16.3 1.8 21.9.9 Fig. 44

Packaging cap Desiccant agent Lifting eye-bolt Packaging cap for double interrupter head Packaging cap for double interrupter head and insulator column

62

4 Installation

W350 16.6 16.7 21.11 21.7 21.7.3 Fig. 45

Spacer Centering guide Sealing ring SL-Safety clip Coupling lever Coupling bolt Erecting the double-break assembly

63

4 Installation

W350 16.3 16.6 16.6.1 16.7 16.9 16.9.1 21.1 21.7 21.7.3 Fig. 46

Spacer Post insulator Centering guide Teflon strip Sealing ring Operating rod Yoke head Housing Coupling lever Bolt Centering guide and coupters fitted

Attention
Hold the double-break assembly by means of the crane; do not lift it! Remove the three spacers. To do this, unscrew the nuts and unscrew the threaded bolt downwards out of the hexagonal socket. Remove the hexagonal socket to the side. Before the double interrupter head is lowered, release the reversing lever 15.9 from its locked position -remove the rubber retaining ring and bolt 10.9. Carefully lower the double interrupter head onto the insulator and screw it onto the insulator column to 170 Nm with 8 screws M 16x75.

4.5.9

Lifting Plate

The lifting plates used for hoisting the double interrupter head are removed. The screws are re-used.

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4 Installation

1 22 Fig. 47

Lifting plate Interrupter unit Lifting plate arrangement

4.5.10

Coupling the Operating Mechanism

Using the manual actuator supplied, the lever 15.9 is moved in such a way that it can be connected to the bolt 10.9. The bolt remains in operating position.

W387 15.9 18.27.1 Fig. 48

Manual operating device W387 Lever Driving rod Manual operating device W387

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4 Installation

15.9

10.1

10.9

18.27.1

10.1

10.9

1 2 10.1 10.9 15.9 18.27.1 Fig. 49

Marking position Operation position Bolt with lock washer Bolt Lever Driving rod Coupling the operating mechanism

Set up the two other poles in the same way replacing the original screws after removal of the lifting eye-bolts. Next pull the bolt 10.9 out at all three poles (Fig. 49) so that it can be secured in the ring groove with the locking plate 10.1 and two M6 screws. Bend the locking plate after tightening the two M6 screws. 4.5.11 Connecting the Gas Pipes

During assembly of the tube connections, ensure that the sealing surfaces are clean and the O-ring gasket is in perfect condition. An gas line must be connected for each pole column.

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4 Installation

To connect the gas pipes 51.1 to the flanges 15.40 of the pole columns, remove the union nuts 15.40.1 with sealing cap (Fig. 50) from the flanges 15.40 and make the connections as shown in Fig. 51. First of all align the gas tube flange 51.1 parallel to the surface of the flange 15.40 on the corner gear and insert a new O-ring 15.40.3 which has been lubricated with Vaseline. Then quickly screw on locking nuts 51.1.1 by hand and tighten with a wrench. Screw on the locking nuts 15.40.4 to a tightening torque of 40 Nm. Vaseline and a new O-ring are to be found in the accessory pack. Keep the locking screws of the gas pipes and the union nuts with sealing caps of the flanges on the pole columns in a safe place for future transportation and repairs.

15 15.40 15.40.1 15.40.2 15.40.3 15.40.4 Fig. 50

Corner gear Flange Union nut Cap plug O-ring gasket Valve plunger Gas connection with non-return valve

15
15.40 15.40.3 51.1 51.1.1 Fig. 51

Corner gear Flange O-ring gasket Gas pipe Union nut Mounting the gas pipe

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4 Installation

4.6

Earthing and Connecting the Leads

4.6.1

Earthing

Connect the breaker base to the high-voltage station earth by means of earth terminals provided.

a) Fig. 52

Earthing bolts Earthing bolts in base (viewed from outside/inside)

4.6.2

Work on High-Voltage Terminals

WARNING
For safety reasons, work on high-voltage terminals should be carried out before the circuitbreaker is filled with SF6-gas up to nominal pressure. The connection of the high-voltage conductors is allowed at nominal SF6 pressure provided that the warnings are followed.

WARNING
High gas pressure - Danger of bursting! The porcelain insulators should not be exposed to any stress (e.g. from vibration, etc.). Great care should be taken to avoid damaging the porcelain body and fins with tools or handling aids.

68

4 Installation Connecting the high-voltage conductors Brush the contact surfaces of the high-voltage terminals with a steel wire brush, which has only been used for aluminium, until they are bright and slightly roughened. Wipe the contact surfaces off with lint-free paper or cloth and lightly coat them with acid-free Vaseline, e.g. Shell Vaseline 8420. Make the connections and tighten the screws. Before commissioning, retighten once again. In the case of connecting parts made of copper, copper-aluminium spacers must be used. 4.6.3 Connecting the Leads

WARNING To avoid damaging the circuit-breaker by inadvertent operation, switch on the power to the motor only when the circuit-breaker has been filled with SF6 gas. Pressure must at least be at the level of general lockout SF6, see Table 4. When the power to the motor is switched on, the closing springs are charged automatically.

Note
Connecting cables must be fitted in dead state.

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4 Installation

4.7

Filling the Circuit-Breaker with Gas

4.7.1

Evacuating

WARNING
Evacuate the circuit-breaker not later than one hour after removing the transport cover from the double interrupter head. If serving equipment is not available, you must have a vacuum pump to evacuate the poles before filling with SF6 gas. Connect the service unit at the filling connection W1 (Fig. 1). Evacuate the circuit-breaker down to a pressure of < 0.02 bar; then switch the service unit for "fill". The required filling pressure and response values are temperaturedependent and must be taken from the diagram, SF6 filling curve and response values of the density monitor, see 3.1.6 Arc Quenching Medium SF6.

4.7.2

Filling the Breaker from the Gas Cylinder

Siemens offers a complete filling device of type W423 for filling the circuit-breaker with SF6 gas from a gas cylinder (Fig. 53).

Attention
The circuit-breaker may be filled only by or under the supervision of qualified personnel, and in accordance with the SF6 filling curve (see under 3.1.6 Arc Quenching Medium SF6).

Attention
For filling the breaker with gas only use as good as new SF6-gas which corresponds the demands ace. IEC 60376.

70

4 Installation

WARNING
High gas pressure - Danger of bursting! Exceeding the permissible filling pressure can cause the pole columns to burst, resulting in severe personal injury and damage to property. The filling device must include a safety valve (operating pressure 8.0 bar). The safety valve prevents the pressure compartments from being overstressed due to an impermissibly high pressure.

Fig. 53

Gas filling device W423

To pour in gas, connect the hose of the filling device to the filling flange W1 of the pole (Fig. 54 and Fig. 55). Using the handwheel on the control valve, regulate the gas flow to prevent possible freezing of the cylinder. Monitor the filling process on the precision pressure gauge. Care must be taken that the filling pressure, which depends on the ambient temperature (see rating plate with information about the filling pressure at 20C), is correct.

W1 Fig. 54

Filling flange Filling flange W1

4 Installation

71

W 1 1 2 3 4 Fig. 55 Filling flange Gas cylinder Pressure reducer regulating valve Precision pressure gauge (-1.0 bar up to 9.0 bar) Safety valve Gas filling device connected

At an ambient temperature other than +20C, the SF6 filling pressure must be taken from the diagram (Fig. 1). The filling pressure may be up to 0.30 bar over the nominal pressure curve (temperature-independent). When filling is completed, unscrew the hose of the filling device and close the filling flange. Screw on the union nut by hand (4 Nm). Ensure that all parts are clean.

4.7.3

Leakage Test after Installation

After successful assembly of the circuit-breaker and filling with SF6 gas, the tube connections should be checked for leakages. A leak detector must be used. If a leak is detected:

WARNING
Release the SF6-pressure before working on the screw connections of the gas chamber. If a leak is discovered, undo the leaking connection and check the sealing surface for damage or foreign bodies. Then fit a new seal, remake the connection and repeat the leak test.

72

4 Installation

4.8

Carrying Out Test Operations

When installation work is finished, the circuit-breaker is in the OPEN position. The closing spring of the operating mechanism is not charged. See section 3.7 Function of the Spring Drive Mechanism When the motor control power supplies are switched on, the charging motors automatically start up and stop again when the closing spring has been charged and latched. The operating mechanism is now ready for a closing operation.

WARNING
Blocking of the circuit-breaker is possible. Before the start of a test run it is essential to check that the bolts 10.9 are inserted in the breaker position 2 and secured (Fig. 56)

A B 10.9 15.9 Fig. 56

Operation position Marking position Bolt Lever Coupling point on corner gear

WARNING
Danger of bursting if porcelain bodies are damaged. Severe personal injury can result. For safety reasons no persons may remain within 60 m of the circuit-breaker while the first 5 test operations are being carried out.

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4 Installation

WARNING
Danger of serious mechanical damage! Mechanical test operations must only be performed with sufficient SF6 gas filling: Pressure must at least be at the level of general lockout SF6, see Table 4.

When installation work is finished, 5 test switching operations should be carried out per circuit-breaker pole. With regard to the possibility of the porcelain components having suffered transport damage, these mechanical switching operations must be performed by remote control as safety switching operations.

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4 Installation

4.9

Checks before Commissioning

Attention
The items listed below should be strictly followed during commissioning.

4.9.1

Anti-Condensation Heaters

Check that heating resistors in the three operating mechanism cubicles and in the control cubicle are working, and also the function of any monitoring equipment fitted.

4.9.2

Test of Wiring between Substation and Circuit-Breaker

Check all command and signalling paths.

4.9.3

Commissioning Report

It should be checked that the commissioning report enclosed with the circuit-breaker has been completed in full and signed. Please return it to the manufacturer at the following address: Siemens Ltd. PTD-Division E-76. Waluj MIDC Aurangabad 431136

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5 Operation

5
5.1

Operation
Instructions for Operation

5.1.1

Closing and Opening

WARNING
Danger of serious mechanical damage! An SF6-minimum gas pressure (SF6-blocking pressure) must be available for test operations (without current and voltage).

WARNING
Danger! - High voltage! A circuit-breaker connected to high voltage may only be operated conforming with the safety regulations of the facility. In this case, the general lockouts of the circuit-breaker may not be bypassed. Switching operations triggered directly at the tripping coil will bypass both the switchgear interlock and general lockouts of the circuit-breaker.

5.1.2

SF6 Pressure

The pressure of the SF6 gas in the pole columns is monitored by a density monitor and shown on the respective pressure gauge. The response values of the density monitor are shown, see 3.1.6 Arc Quenching Medium SF6. If the SF6 pressure drops unduly low, a signal Loss of SF6 is initiated. The circuit-breaker must then be topped up as soon as possible with SF6 from a gas cylinder or using the filling device connected to the flange W1 on the gas monitoring unit until nominal pressure is restored. The circuit-breaker must be isolated for this. When filling has been completed, the circuit-breaker can be put back into operations.

WARNING
The circuit-breaker must be switched off and earthed for SF6 filling work. The circuit-breaker can be switched back on when filling is complete and the earthing has been disconnected.

76

5 Operation

The filling flange W1 for filling the circuit-breaker with SF6 gas is located inside the drive mechanism housing (connecting thread M26x1.5 or M45x2). The operational gas pressure can be read on the pressure gauge MA (see section 3.8 Control).

WARNING
Release the SF6-pressure before working on the screw connections of the gas chamber. If the above signal is initiated again after some time, the leak must be located and, if possible, sealed. If the leak cannot be sealed, the nearest Siemens representative should be notified. 5.1.3 General Lockout

If the SF6 pressure in the circuit-breaker drops so low that perfect arc-quenching can no longer be ensured, a general lockout becomes effective and blocks all further operation. 5.1.4 Mechanical Reclosing Lockout

If the circuit-breaker pole is in the CLOSED position, a mechanical reclosing lock-out in the operating mechanism comes into effect. It prevents the operating mechanism from being switched back on. 5.1.5 Max. Permissible Number of Interruptions

The relationship between breaking current I, max. permissible number of interruptions is shown in Fig. 57. If the interruptions take place with higher current, the number of possible interruptions decreases as shown in Fig. 57.

77

5 Operation

I k n X

Breaking current in kA Weighting factor Max. permissible number of interruptions During the type tests 10000 mechanical operation cycles were carried out. Max. permissible number of interruptions as a function of the breaking current.

Fig. 57

The chart (Fig. 57) relates to one pole of a triple-pole circuit-breaker. Three times the number of the permissible single-pole opening operations may thus result in a triple-pole circuit-breaker (e.g. 18 single-pole opening operations with 50 kA). Weighting factor k simplifies calculation of the max. permissible number of interruptions at different breaking currents.

78

5 Operation
m

6000 - (ni ki)

nx =
ki kx n. nx Weighting factor for breaking current I Weighting factor for breaking current lx Number of carried out interruptions at breaking current I Number of remaining permissible interruptions at breaking current lx. Formula for calculating the max. number of permissible interruptions i=1

kx

1000037b

Fig. 58

The maximum number of interruptions still permissible with a given number of operations (with consequent wear) already carried out can be calculated using the above equation. For example: The circuit-breaker with a rated short-circuit breaking current of 50 kA has performed 250 interruptions with breaking currents of 3.15 kA, and 2 interruptions 20 kA. How many interruptions at 40 kA are still permissible?

6000 - (n3.15 k3.15 + n20 k20)

n40 = =

6000 - (250 1 + 2 100)

=

6000 - (250 + 200)

= 10,7

k40
Fig. 59 Number of remaining permissible interruptions at breaking current lx.

520

520

A total of 10 interruptions at 40 kA are still permissible.

79

5 Operation 5.1.6 Recommended Procedure in the Event of Irregularities on the Circuit-Breaker 3AP2 Fl

Note
The following table is an aid in recognition and assessment of any irregularities occuring in operation of the circuit-breaker. It also enables specific details to be given if Siemens service Berlin personnel have to be summoned. In such a case, please telephone during business hours

Tel.: +91 240 2565 142

or by fax

+91 240 2554 701

WARNING
To avoid any hazard, only qualified personnel may do the work described below.

WARNING
Work may only be done on the operating mechanism when the opening and closing spring are relaxed.

WARNING
The circuit-breaker must be switched off and earthed for SF6 filling work. The circuit-breaker can be switched back on when filling is complete and the earthing has been disconnected. Release the SF6-pressure before working on the screw connections of the gas chamber.

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5 Operation

Signal/Lock-out

Effect

Possible cause(s)

Remedial measure(s)

Loss of SF6

Signal only (Leak generally slow) SF6 leak

Locate fault and seal leak. Top up SF6 to nominal pressure

General SF6 lock-out

No switching possible

SF6 leak

See Loss of SF6 Provide motor supply/replace motor

Reclosing lockout longer than 15s

Closing spring not charged, no closing possible

No motor power supply/Motor defective

Table 12 Disturbances

81

5 Operation

5.2

Disposing of High-Voltage Switching Devices and Systems

The circuit-breaker 3AP2 Fl is an environmentally compatible product. In disposal, priority must be given to reuse of the materials. Environmentally acceptable disposal of the device is possible in line with current legislation.

The device can be recycled as mixed scrap, or, if it is dismantled as far as possible, in a more environmentally acceptable way as sorted scrap with a mixed-scrap residual portion. The following materials have been used to make up the device: Steel, copper, aluminium, PTFE, cast resin or cast-resin-impregnated fabric, glass-fibre-reinforced plastics, rubbers for sealing, ceramics, greases. Before disposal, it should be ensured that the Shell Aero Fluid hydraulic fluid present in the drive mechanism dampers is drained. This should be done in accordance with current official regulations at the time of disposal. No oils used in the circuit breaker contain PCB.

In as-supplied-by-Siemens state, the device incorporates no hazardous substances in the sense of the pertinent regulations in Germany. If the device ist to be operated outside Germany, the locally applicable laws and regulations must be followed.

The insulating and quenching media SF6 can be removed by suction using suitable equipment and, after reconditioning, can be made available for reuse. In the opened gas compartments, there may be solid decomposition products resulting from switching operations. The gaseous products are absorbed by the built-in filters. When switching devices incorporating SF6 as insulating and quenching medium are disposed of (with particular regard to filter material and solid decomposition products), the necessary safety measures must be complied with. Local customer support offices will be able to answer any questions concerning disposal.

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6 Maintenance

6
6.1

Maintenance
Inspection and Maintenance - General

The circuit-breaker can only function reliably if it is correctly maintained. The purpose of inspection and maintenance therefore is: to determine to what extent certain parts have worn and to assess their state, to ensure that parts still in good condition are kept in this state, to replace certain parts in good time, to ensure corrosion protection.

Inspection and maintenance services are categorized in line with the work involved and designated accordingly.

WARNING
Non-observance of warnings can result in death, severe personal injury and substantial property and environmental damage.

6.1.1

Maintenance Services (Schedule)

The inspection and maintenance services scheduled in the Table 13 are each offered separately by Siemens Ltd.. Circuit-breakers which are operated frequently obviously suffer greater wear than circuit-breakers operated only seldom. The following distinction must be made: Mechanical wear caused by friction (mechanical operating cycles) and Arc erosion due to the switching of load currents or fault currents.

The wear reserve is calculated so that in most cases the various inspection and maintenance services can be performed at fixed intervals. Only if the circuit-breakers are operated particularly frequently might it be necessary to bring forward the corresponding service, because the permissible number of mechanical operations and/or load or fault switching operations have already been exceeded (see section 5.1.5 Max. Permissible Number of Interruptions). 6.1.2 Assignment of Personnel

The inspection and maintenance service may only be carried out by or under the supervision of qualified personnel. This personnel can be assigned by the customer or the next Siemens office. Tel.: +91 240 2565 142 Fax: +91 240 2554 701 If requested, the customer's personnel can be trained at the manufacturer's works. The advantage of calling in Siemens personnel is that the work is carried out in accordance with the latest information and experience gained with a large number of circuit-breakers. This is then reflected in the circuitbreaker having a higher reliability standard. Moreover, the fact that they are familiar with the circuit-breaker also enables Siemens personnel to do the job in less time. In this way service interruptions are kept to a minimum. Assignment of Siemens personnel also means that tools and measuring instruments etc. that are usually not worth buying are provided on a hire basis. "Maintenance kits" required as part of maintenance, as well as consumables (cleaning liquids, lubricants etc., see section 4.3 Cleaning Liquids, Lubricants and Corrosion Protection Agents) are also supplied.

6.1.3

Maintenance Kits

Maintenance kits contain various spare parts in the appropriate quantities for the particular service. 83

6 Maintenance

Maintenance kits are supplied and charged for by Siemens Ltd. as part of the inspection and maintenance service. It is not advisable for the customer to hold stocks of maintenance kits, as some parts, e.g. O-ring seals, are subject to aging.

6.1.4

Initial Date for Inspection and Maintenance Service

The starting date for the inspection and maintenance schedule is that at which the filter material is placed in the circuit-breaker, which is then evacuated and filled with gas. This is normally the year of production. The starting date is only related to the insertion of the filter material, not to the date of energization. The starting date should be recorded in writing and the number of mechanical operations and fault current operations etc. monitored in order to see whether inspection and maintenance should be carried out as a function of time or of wear.

6.1.5

Disturbances

In the event of a disturbance, please request appropriate Siemens representation of qualified personnel. We ask you to state the type and extent of the disturbance as accurately as possible. Please name any that are showing signs of damage. To simplify identification, state the designations given in the operating instructions (designations and part numbers together with the order number of the operating instructions 927 00966 174 A, page number, number of the illustration) and state the serial number of the circuit-breaker concerned.

6.1.6

Points to be Noted

The locking elements of any screwed joints opened for inspection must be replaced. The same applies to all seals and gaskets exposed in the process. All open circuit-breaker parts should be covered to prevent the ingress of dirt. During normal operation no switching dust should result from switching. If dust is found after repeated interruption of high short-circuit currents, proceed as follows: Any switching dust should be removed immediately when the circuit-breaker is opened and any subassemblies have been removed. When this dust is exposed to air for some time it will absorb moisture and can then only be removed with difficulty. Gloves should be worn! Remove the dust with a piece of cloth or use a vacuum cleaner. Do not stir it up unnecessarily. Cloths and switching dust should be disposed of in keeping with environmental regulations.

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6 Maintenance

6.2

Safety Rules for Inspection and Maintenance Service - General

WARNING
Danger to maintenance personnel can result from hazardous voltage operating mechanisms under spring pressure gas pressure in the pole columns SF6-gas and its decomposition products falling and/or toppling parts and/or moving parts.

Non-observance of warnings can result in death, severe personal injury and substantial property and environmental damage.

In order to avoid accidents, fire and impermissible burdens on the environment and in order to assure the functional reliability of the switchgear, the user must ensure that: a responsible person, if necessary authorized to supervise, is put in charge of performance of maintenance only qualified and instructed personnel are assigned, the regulations and instructions for work safety (e.g. in the use of equipment), together with instructions on action to be taken in the event of accidents and fire, are available at all times and if necessary displayed in the place of work, the tools, equipment and apparatus required for work safety and the personal protective equipment required for certain tasks are available, only those materials, lubricants and auxiliary equipment approved by the manufacturer are used.

The safety regulations in these operating instructions are minimum requirements. They do not affect statutory laws, standards, specifications or internal regulations of the company concerned with the work. They do not claim to cover all eventualities and must be expressed concretely by the responsible persons at the latest before work actually starts. In addition to company internal rules and the specific work conditions, the product descriptions and instructions for use of tools, devices, apparatus, materials, lubricants and auxiliary equipment must be taken into account.

85

6 Maintenance The following safety regulations provide an overview of the dangers existing and their sources, and describe the possible consequences if the rules specified are not complied with. They are expressed more exactly in the operating instructions. Hazardous voltage - Electric shock and burning as a result of arcing are possible if live parts are approached. Before maintenance is to be done, a responsible person from the power supply utility must, before work starts: Switch off and isolate Prevent unintentional switch-on Test that equipment is dead Ground and short-circuit the equipment Cover or fence off nearby live parts

It must be confirmed that these safety measures have been taken. The closing and opening springs may be charged. If the control and motor power supply are not switched off, the closing spring will be automatically recharged after a closing operation. The spring state indicator shows only the position of the closing spring - unintentional switching operations can lead to severe personal injury. Before beginning maintenance work, relax the opening and closing springs as follows: Disconnect motor power supply, open the circuit-breaker, if the circuit-breaker is in the CLOSED position. close the circuit-breaker and re-open the circuit-breaker. disconnect the control voltage.

The pole columns are under pressure (see section 3.1.6 Arc Quenching Medium SF6) - Damage to the porcelain parts can result in severe personal injury. Before opening interrupter units, ensure pressure relief by means of the facility provided. After relieving the pressure, gradually and uniformly undo the screw joints. Do not allow any tools or hoisting gear to knock against the porcelain parts. Do not lean any ladders against the pole columns;use step ladders.

SF6 is heavier than air and can displace the air required for breathing - Danger of suffocation!

86

6 Maintenance

SF6 is odourless, non-toxic and about five times heavier than air. SF6 leads to displacement of oxy gen. SF6 concentrations of more than 19 % vol. call for special protective measures. Such concentrations can occur in opened and unventilated SF6 compartments, in confined spaces on the floor of switchgear installations and in lower-level rooms (e.g. basements, cable ducts). Sulphur hexafluoride (SF6) must not be let off to the atmosphere. For maintenance work gas servicing equipment should be used.

Specifications for the use of SF6 gas IEC 60376 IEC 60480

For Germany, the following also applies: Accident prevention sheet (relating to SF6 installations) issued by the statutory industrial accident insurance institution for precision mechanics and electrical engineering. Under effects of arcs, gaseous decomposition products and switching dust occur. Decomposition products of SF6 are toxic - Coming into physical contact with them or inhaling them can cause irritation to the skin, eyes and mucous membranes. Nausea, dizzines and lung oedema can result. These substances vary in toxicity. In combination with moisture, switching dust is caustic and forms a coating that sticks fast. Small quantities of gaseous decomposition products already initiate alarm signals, e.g. pungent disagreeable smell similar to rotten eggs (hydrogen sulphide), before there is danger of suffocation. If emptied housings are opened after correct pressure relief, there is the possibility of contact with switching dust. Do not inhale or swallow switching dust (use dust masks), avoid contact with the eyes (wear gas-tight goggles) and the skin (use special working clothes). If switching dust has got onto the skin nevertheless, use plenty of water to rinse it off. Handle filters, rags and other material so that the dust extracted does not come off again. Do not open filter bags. Work clothes, filter bags, rags etc. which have come into contact with such dust, dispose of according to local regulations. Local environmental protection regulations must always be taken into account when SF6 is disposed of. In special cases regarding SF6 disposal, the nearest Siemens office should be contacted. Thoroughly clean face, neck, arms and hands with soap and plenty of water before breaks and at the end of work. Do not eat, drink or smoke in rooms containing opened gas compartments with switching dust, and do not keep any foodstuffs in them.

87

6 Maintenance

6.3

Maintenance Schedule

The maintenance schedule provides an overview of work to be done in the individual checks/inspections. A detailed description of the work steps is given in section 6.4 Work to be Carried Out in Accordance with the Maintenance Schedule. In both sections, the work steps are referred to by the same numbers.

WARNING
Danger to maintenance personnel can result from - hazardous voltage - operating mechanisms under spring pressure - gas pressure in the pole columns - SF6-gas and its decomposition products - falling and/or toppling parts and/or moving parts.

The Safety rules listed in section 6.2 should be followed.

Check and maintenance service Checks Due to time interval After 12 years Due to wear after 3000 operating cycles I < Inom Remarks Circuit-breaker must be taken out of service and must be isolated. Gas compartments need not be opened. Circuit-breaker must be taken out of service and must be isolated. Gas compartments are opened. Circuit-breaker must be taken out of service and must be isolated. Gas compartments are opened.

Maintenance

After 25 years

after 6000 operating cycles I < Inom

Check of contact system

Permitted conductor pull F

Table 13 Maintenance services

88

6 Maintenance

6.3.1
A X B X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

Maintenance Schedule
Subsection 6.4.1 6.4.2 6.4.3 6.4.3.1 6.4.3.2 6.4.4 6.4.5 6.4.6.1 6.4.6.2 6.4.7 6.4.8 6.4.9 6.4.10 6.4.11.1 6.4.11.2.1 6.4.11.2.2 6.4.11.3 6.4.11.4 6.4.12 6.4.13 6.4.14 6.4.15 Maintenance service General Inspection Drawing Off the SF6 Gas Check of Contact System Dimensional Check on the Contact System Replace Filter Evacuating and Filling the Circuit-Breaker with Gas Check Gas Pressure Gauge Check Function of Gas Density Monitor Check of the Operating Values of the Gas Density Monitor Check for Leaks on Operational CircuitBreaker Checks at Drive Mechanism Terminal Strip Anti-Condensation Heaters Functional Check, Trip Circuits Functional Check, Reclosing Lock-Out Functional Check SF6 Lockout Functional Check, Anti-Pumping Feature Function Check of Enforced Triple-Pole Operation Feature Check of Motor Control Measuring the SF6 Gas Humidity Content Measuring the SF6 Air Content Anti-Corrosion Protection

Table 14 Maintenance Schedule

A = Checks B = Maintenance 6 Maintenance

6.4

Work to be Carried Out in Accordance with the Maintenance Schedule

The measures compiled in the section 6.3 Maintenance Schedule are described in detail below.

6.4.1

General Inspection

The general inspection covers a visual check of the circuit-breaker without it having to be dismantled. The visual check contents the following checks: Check the SF6 filling with the circuit-breaker pressure gauge, see 6.4.1.1. contamination of insulating parts damage to the porcelain body Earth terminal Number of operating cycles Check the SF6 Filling with the Circuit-Breaker Pressure Gauge 89

6.4.1.1

When measuring, the temperature dependence of the pressure as shown in the diagram SF6 filling curve and operating values of density monitor (see 3.1.6 Arc Quenching Medium SF6) should be taken into account. This means that, if possible, the mean temperature of the SF6 gas in the circuit-breaker should be determined (Measurements should be avoided in times of strong fluctuations of the ambient temperature and immediately after high-current loads). If the measured value falls below the specified SF6 filling curve, correct the SF6 gas filling (using a gas cylinder or service unit). Check humidity and the air content of the SF6-gas that may be left in the service unit (see 6.4.13 Measuring the SF6 Gas Humidity Content). If the measured SF6 pressure lies below the filling curve by not more than 0.30 bar (permissible gas loss), refill with SF6. If the measured value is more than 0.30 bar below the filling curve specified, a leak test must be carried out and the leak must be repaired. Then the filling must be corrected. 6.4.2 Drawing Off the SF6 Gas

It is recommended to draw off the SF6-gas with a service unit so that it can again be used almost completely for the subsequent filling. The service unit has all the facilities for drawing off and filling the SF6-gas. The condition of the SF6-gas in the service unit should be checked in advance. 6.4.3 Check of Contact System

The interrupter unit is described in section 3.4 Interrupter Unit.

Note
For the contact system check it is necessary to call in Siemens personal.

6.4.3.1

Dimensional Check on the Contact System

The inspection of the contact system has to be made by a dimensional and a visual check. The permissible contact erosion will be given by the dimension a.

22.11.17 22.17.1 22.17.2 22.23 22.9 Fig. 60

Piston Pull rod Coupling rod Base Pin Inspection of contact carrier

90

6.4.3.2

Replace Filter

It is absolutely necessary to protect the filter material against atmospheric humidity. The material must therefore not be directly exposed to the open air for a longer period than 1 hour. It is supplied in closed tins. Check the closed tins for damage. Filter material from leaky tins must not be used. The filter material is accommodated in the filter cowl (see 3.4 Interrupter Unit). Remove cover 15.16.11 with Oseal ring (Fig. 61) (4xM10 screws). Remove the old filter bags from the filter cowls. Lay the new filter bags in the filter cowls. Grease cover 15.16.11 (Fig. 62) with seal ring at the sealing surfaces and reinstall (4xM10 screws).

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6 Maintenance

Note
Dispose of old filter bags 15.16.3 in accordance with local regulations.

Note
Do not fit new filter bags until shortly before evacuation (max. one hour).

A B 1 15 15.16.11 Fig. 61

Grease with corrosion protection agent WD 40 or Trost multifunction oil Grease with Tectyl 506 Grease sealing rings with Vaseline 8420 Corner gear Cover with O-seal ring Treatment of the sealing flanges

15.11 15.16.1 15.16.11 15.16.3 Fig. 62

Filter cowl Sealing ring Cover with O-seal ring Filter bag Inserting the filter

6.4.4

Evacuating and Filling the Circuit-Breaker with Gas

The circuit-breaker may be filled only by or under the supervision of qualified personnel, and in accordance with the SF6 filling curve (see under 3.1.6 Arc Quenching Medium SF6).

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6 Maintenance

WARNING
A safety valve with a nominal opening pressure of 8.0 bar must be part of the filling device. The safety valve prevents the pressure compartments from being overstressed due to an impermissibly high pressure.

To fill the breaker with gas, a service unit may be used since this contains all the necessary facilities. If a service unit is not available, a vacuum pump must then be available for evacuating the circuit-breaker prior to the SF6 being filled in. The SF6-gas is then taken directly from a gas cylinder via the SF6 filling device W423. Filling by using a service unit Connect the service unit at the filling connection W1 (Fig. 63). Evacuate the circuit-breaker down to a pressure of < 0.02 bar; then switch the service unit for "fill". The required filling pressure and response values are temperature-dependent and must be taken from the diagram, SF6 filling curve and response values of the density monitor, see 3.1 Technical Data.

1001304a

W1 Fig. 63

Filling flange Filling flange W1

Filling the breaker from the gas cylinder Siemens offers a complete filling device of type W423 for filling the circuit-breaker with SF6 gas from a gas cylinder (Fig. 64).

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6 Maintenance

W1 1 2 3 4 Fig. 65

Filling flange Gas cylinder Pressure reducer regulating valve Precision pressure gauge (-1.0 bar up to 9.0 bar) Safety valve Gas filling device connected

To fill, couple the service connection of the filling device with the filling connection W1 (Fig. 63). Slowly open the regulating valve (Fig. 65) at the pressure reducer with the vent valve closed, to avoid any ice formation at the fitting. Monitor the filling process at the precision pressure gauge 3. Care must be taken that the filling pressure, which depends on the ambient temperature, is correct. For nominal filling pressure see diagram in section 3.1 Technical Data. At an ambient temperature other than +20C, the SF6 filling pressure must be taken from the diagram (Fig.1).

94

6 Maintenance The filling pressure may be up to 0.30 bar over the nominal pressure curve (temperature-independent). When filling is completed, unscrew the filling device and close maintenance flange W1 (from Dilo). Tighten the union nut by hand (4 Nm).

6.4.5

Check Gas Pressure Gauge

The difference between the measured values on the test pressure gauge class 0.6 and the operating pressure class 1.0 must not be greater than the sum of the permissible divergence between the two pressure gauges. This means that with a test pressure gauge of class 0.6 having a range from 15.0 bar the divergence from the circuitbreaker pressure gauge of class 1.0 must not be greater than 0.30 bar. A divergence greater than 0.30 bar must be noted at the circuit-breaker pressure gauge (handwritten on adhesive tape).

6.4.6 6.4.6.1

Testing the Density Monitor Check Function of Gas Density Monitor

Undo sealing cap on test connection W2 (the gas compartment and density monitor are separated by a nonreturn valve) and check whether the density monitor contacts respond.

6.4.6.2

Check of the Operating Values of the Gas Density Monitor

Note
The adjustments of the density monitor for the SF6 signals and the SF6 general lockout cannot be monitored by the filling device W423. For this the filling device W424 is required instead. For testing the density monitor B4, a connection W2 is provided in the rear wall of the operating mechanism unit 18. (3/4" thread, Fig. 66). The hose of SF6 filling unit W424 can be connected here without any SF6 having to be extracted from the circuit-breaker.

95

6 Maintenance

B4

1001305a

B4 W2 Fig. 66

Density monitor Test connection Test connection W2 (view with cover of the contact position indicator removed)

To check the density monitors, remove nut with insert. Gas cannot escape from the breaker with the service connection open. The service connection W2 is now directly connected with the density monitor, so that after connection of the filling device W424 the switching points of the density monitor can be checked by regulation of the SF6 pressure at the pressure reducer (section 3.1.6 Arc Quenching Medium SF6).

6.4.7

Check for Leaks on Operational Circuit-Breaker

The rated pressure of the SF6-gas can be found in the table in the section 3.1.6 Arc Quenching Medium SF6. When the filling of the circuit-breaker is completed, all new connections must be checked for leaks. This can occur with a leak-detector or leak-detecting spray e.g. from Wobst. If neither is available, leaks can also be checked using soap solution. If a leak is detected:

WARNING
Release the SF6-pressure before working on the screw connections of the gas chamber.

If a leak is discovered, undo the leaking connection and check the sealing surface for damage or foreign bodies. Then fit a new seal, remake the connection and repeat the leak test.

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6 Maintenance 6.4.8 Checks at Drive Mechanism

6.4.8.1

Auxiliary Switch

The bearings of the auxiliary switch are maintenance-free. The coupling gear must be checked for wear and damage (Fig. 67).

18.10

18.22

18.10 18.22 Fig. 67

Coupling rod for auxiliary switch Auxiliary switch Auxiliary switch

Should leads be disconnected from the auxiliary switch contact, press the spring shackle at the AMP connector to release. With AMP connectors with insulation casing, release is automatic when the sleeves are pulled (Fig. 68).

1 2 3 Fig. 68

Insulation sleeve Spring shackle Direction of pull AMP connector

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6 Maintenance

6.4.8.2

Visual Inspection of the Spring Drive Mechanism

Visually inspect dampers for closing and opening for any leaks. Look out for reddish oil traces in the vicinity of the lower damper fastener (Fig. 69).

Note
If you find any reddish oil traces at the specified positions (Fig. 69), inform the Siemens representative responsible and ask for expert assistence.

18.15 18.41 Fig. 69

Damper for opening Damper for closing Check the dampers

6.4.8.3

Check Trip Coil and Latching Blocks

Check firm connection of the trip plate (cheese head screws M6x40, tightening torque 81 Nm) and the latching blocks (cheese head screws M 10x70, tightening torque 404 Nm) (Fig. 70).

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6 Maintenance

A 18.16 18.21.1 18.21.2 18.21.4 18.8 Fig. 70

Cheese-head screw M 10x70 Release CLOSE Support lever Reversing lever Hex. screw 4x (M6x40) Release OPEN Latching block

6.4.9

Terminal Strip

Check the terminal connections for firm seating and the terminals for damage. 6.4.10 Anti-Condensation Heaters

Check the effectiveness of the anti-condensation heating and the function of the existing monitoring device if applicable. 6.4.11 Function Checks

6.4.11.1 Functional Check, Trip Circuits Check the tripping action of the circuit-breaker via all the existing tripping paths. 6.4.11.2 Functional Check Lock-Out 6.4.11.2.1 Functional Check, Reclosing Lock-Out

During the process of charging the closing spring, the effectiveness of the reclosing lock-out must be checked by means of an electrical CLOSE command. The tripping coil must not operate. Perform this check at all poles. 6.4.11.2.2 Functional Check SF6 Lockout At a level below the operating pressure, check the signal and the effectiveness of the function lockout SF6 lockout by means of electrical CLOSE and OPEN commands in all tripping paths. The circuit-breaker must not operate.

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6 Maintenance

6.4.11.3 Functional Check, Anti-Pumping Feature Circuit-breaker in closed position: (closing spring tensioned) Give electrical CLOSE command and keep button pressed in (maintained command)

The circuit-breaker must only switch off. 6.4.11.4 Function Check of Enforced Triple-Pole Operation Feature Close all three poles of the circuit-breaker and open one of them by actuating the operating trip 18.8 (Fig. 70). After the time set on the enforced triple-pole operation relay on the plant side has elapsed, the other two circuitbreaker poles must also be tripped by the enforced triple-pole operation contactor. Carry out this test in a similar manner on the other two circuit-breaker poles. 6.4.12 Check of Motor Control

Check whether after a closing operation the motor is activated by a limit switch, and, whether after the charging process of the closing spring the motor is deactivated via a limit switch. Perform this check at all poles. 6.4.13 Measuring the SF6 Gas Humidity Content

Before putting the breaker into operation, the humidity of the SF6-gas must be checked. For this a commercially available dew point measuring instrument with C scale can be used. The maximum permissible dew point temperatures at operating pressure corresponding to the permissible humidity are stated below.
Critical humidity limit Maximum permissible humidity during commissioning/in operation -5C (+23F) -10C(+14F)

Table 15 Dew point

If the measured dew point temperature lies above -10C/+14F, then the SF6 gas must dried using a service unit. 6.4.14 Measuring the SF6 Air Content

When the breaker has been filled with new gas and following maintenance work, the air content should not be more than 5 % as measured with the SF6 percentage instrument 3-027 from DILO (D-87727 Babenhausen, Federal Republic of Germany). This instrument measures the SF6 volumetric portion (at least 95 %).

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6 Maintenance

6.4.15

Anti-Corrosion Protection

Check the paintwork of the circuit-breaker for damage. Defective parts must be derusted, provided with a priming coat and varnished.

6.4.16

Special Occurrences

Check whether, since the last instance of maintenance, any special occurrences, e.g. incorrect opening and closing of the circuit-breaker, loss of SF6-gas etc. have been documented.

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SIEMENS
Commissioning Report for the Circuit-Breaker 3AP
General
Customer Substation Feeder Circuit-breaker type Name of inspector Signature Countersignature Date

Technical data
Serial number: SF6 - filling pressure at + 20C, ace. to rating plate Rated voltage Rated normal current Rated short-circuit breaking current Rated control voltage Rated signalling voltage Rated voltage (circuit-breaker charging motor) Rated current (Charging motor of the circuit-breaker) Circuit diagram no./lndex (Circuit-breaker) Order number of the operating instruction/index Bar KV A KA V V V A

Switching duty
Overhead line Generator Coupling Shunt reactor Other Transformer Cable Capacitor

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Attention
Mechanical test operations must only be performed with sufficient SF6 gas filling: Pressure must at least be at the level of general lockout SF6.

Transport damage
Pole A Delivery complete ace. to check list Visual check for damages (post insulator/bushing and interrupter unit) Operating mechanism Control Transport damage notified Check SF6 transport filling (only 3AP1) Pole B Pole C OK

Installation
OK In accordance with operating instructions in chapter Installation

If commissioning is not performed immediately the items listed below must be checked:
Pole A Electrical circuit for charging motor is interrupted at a suitable point Anti-condensation heaters connected Evacuation (.... min, .... mbar) (3AP2, 3AP1 DT) Date of charging the filters (3AP1 DT) Protective gas filling (SF6 filling to approx. 0.30 bar) bar Pole B Pole C OK

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Commissioning
Pole A Motor circuit-breaker setting checked (see circuit diagram) MCBs (if included in scope of supply): tripping current in accordance with circuit diagram > ln [A] Check of the anti-condensation heaters (all phases) [A] SF6 -system filled up to rated pressure [bar/C] 5 CLOSED-OPEN safety switching operations (by remote control, 60 m safety distance) Pole B Pole C OK

Attention
On three phase A.C. motors, the rotary field direction must be taken into account when connecting the motor voltage.

Function tests ace. to breaker circuit diagrams

OPEN-CLOSE switching operations, lockouts, signals, anti-pumping etc. All details checked against circuit-breaker circuit diagram and system circuit diagram, in particular: Closing 1 Closing 2 Opening 1 Opening 2 Opening 3 OK

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Monitoring SF6
Pole A Density monitor serial number Loss of SF6 1. General lockout SF6 2. General lockout SF6 Pole B Pole C Unit bar/C bar/C bar/C bar/C bar/C bar/C Control

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Signals (1)
OK Charging motor: Charging time (< 15 s) K9 picked up (motor starting) Closing spring discharged 1. Auto-reclose lockout Signal Time delay of signal s s

Auto-reclose interlocking I Auto-reclose interlocking II 2. Auto-reclose lockout Signal Time delay of signal s

Auto-reclose interlocking 1

Auto-reclose interlocking II

Enforced triple-pole operation feature 1

Signal Time delay of signal s

Closing lockout 1

Enforced triple-pole operation feature 2

Signal Time delay of signal s

Closing lockout 2

Anti-pumping device 1

Anti-pumping device 2

Circuit-breaker tripping

Indication of circuit-breaker position

Relays, contactors in local control panel (for testing see system circuit diagram)

Operating cycles counter

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Signals (2)
OK Anti-condensation heaters (MCB trip signal F3) Heating current monitoring functional Charging motor (MCB trip signal F1) Limit switch Damping Automatic TRIP Synchronization of the circuit-breaker poles Motor run time monitoring Signal Time delay of signal min

Operating hours counter Socket and lighting Switch (remote/local control) The stated functional tests were performed up to the control panel in the circuit-breaker control cabinet/local control cabinet or control room

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Final checks
Pole A SF6 leaktightness testing of newly made joints SF6 humidity (dew point)1)2) SF6 content2) Final SF6 filling Date of taking measurements Leads firmly connected to main terminal Operations counter reading after completion of work Damage to paintwork repaired and newly fitted screws painted C % bar/C Date Pole B Pole C Unit

1) Maximum permissible dew point during commissioning = -10 C (+14 F) 2) Measurements not required if gas filled from a new cylinder Remarks Remarks

Please complete and return to: Siemens Ltd. PTD H 3 Circuit Breaker E-76, Waluj MIDC Aurangabad - 431136 India Fax: +91 240 2554 701

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