10 operating instruction 247.pdf

Operating Instructions No. 247 (EN)

Device: Hybrid Integrated Compact ModuleHYpact 123 F1/4025

HYpact 145 F1/4025

Manufacturer: AREVA Energietechnik GmbH High Voltage Products Lilienthalstr. 150 34123 Kassel Germany

AGK/CSCBA 247 (EN) REV0 ID No. 2 032 651 2007 10 04

BG . () 22200.

LT Sudtyje yra Kioto protokole nurodyt fluorint iltnamio efekt sukeliani duj. Globalinio iltjimo potencialas(GWP) 22200.

ES Contiene gases fluorados de efecto inver-nadero regulados por el Protocolo de Kioto. Potencial de calentamiento atmos-frico (PCA) 22200.

HU A Kioti Jegyzknyv hatlya al tartoz fluortartalm veghzhats gzokat tar-talmaz. Globlis felmelegedsi potencil 22200.

CS Obsahuje fluorovan sklenkov plyny zahrnut v Kjtskm protokolu. Potencil globlnho oteplovn (GWP) 22200.

MT Fih gassijiet serra fluworinati koperti bil-Protokoll ta Kjoto. Potenzjal ta' Tisin Globali (GWP) 22200.

DA Indeholder fluorholdige drivhusgasser omfattet af Kyoto-protokollen.GWP 22200.

NL Bevat onder het Protocol van Kyoto val-lende gefluoreerde broeikasgassen. Aar-dopwarmingsvermogen (GWP) 22200.

DE Enthlt vom Kyoto-Protokoll erfasste fluo-rierte Treibhausgase. Treibhauspotenzial (GWP): 22200.

PL Zawiera fluorowane gazy cieplarniane objte Protokoem z Kioto. Wspczynnik ocieplenia globalnego (GWP) 22200.

ET Sisaldab Kyoto protokolliga hlmatud flu-oritud kasvuhoonegaase. Globaalset soo-jenemist phjustav potentsiaal(GWP) 22200.

PT Contm gases fluorados com efeito de estufa abrangidos pelo Protocolo de Quioto. Potencial de aquecimento global (PAG) 22200.

EL . (GWP) 22200.

RO Conine gaze fluorurate cu efect de ser reglementate de protocolul de la Kyoto. Potenial de nclzire global(GWP) 22200.

EN Contains fluorinated greenhouse gases covered by the Kyoto Protocol. Global warming potential (GWP) 22200.

SK Obsahuje flurovan sklenkov plyny zahrnut v Kjtskom protokole. Potencil globlneho otepovania (GWP) 22200.

FR Contient des gaz effet de serre fluors relevant du protocole de Kyoto. Potentiel de rchauffement plantaire(PRP) 22200.

SL Vsebuje fluorirane toplogredne pline, ki jih zajema Kjotski protokol. Potencial global-nega segrevanja (GWP) 22200.

GA ---- FI Sislt Kioton pytkirjan soveltamisa-laan kuuluvia fluorattuja kasvihuonekaa-suja. Lmmitysvaikutus (GWP) 22200.

IT Contiene gas fluorurati ad effetto serra disciplinati dal protocollo di Kyoto. Poten-ziale di riscaldamento globale(GWP) 22200.

SV Innehller sdana fluorerade vxthusgas-er som omfattas av Kyotoprotokollet. Fak-tor fr global uppvrmningspotential (GWP-faktor) 22200.

LV Satur Kioto protokol noteikts fluortas siltumncefekta gzes. Globls sasilanas potencils (GSP) 22200.

Table of Contents

1 Introduction 1.1 General Information 1.2 Special Instructions 2 Safety 2.1 General Safety Instructions 2.2 Special Safety Instructions 2.3 Handling SF6 Gas 2.4 Transport and Handling at the Erection Site 3 Technical Description 3.1 Technical Data: HYpact 3.2 Technical Data: Spring Operating Mechanism 3.3 Technical Data: Motor-Operated Mechanism of Disconnector-Earthing Switch 3.4 Design and Operation 3.4.1 Spring Operating Mechanism 3.4.2 Type ME1-3 Motor-Operated Mechanism for Disconnector-Earthing Switch 3.4.3 Combined Mechanical Position Indicator 4 Transport and Storage 4.1 Transport 4.2 Storage 5 Preparation for Erection 5.1 Required Documents 5.2 Using the Checklist 5.3 Checklist for Erection and Commissioning 5.4 Materials and Equipment to be Provided by Station 5.4.1 Materials 5.4.2 Hoisting Equipment 5.4.3 Tools 5.4.4 Other Tools and Equipment 5.4.5 Testing and Measuring Equipment 5.4.6 Auxiliary Materials and Supplies 5.5 Unloading and Unpacking the Transport Units 5.6 Checking the Shipment 5.6.1 Completeness and Lack of Damage 6 Erection 6.1 General Instructions 6.2 Supports on Foundation 6.3 Mounting the Module

AGK/CSCBA 247 (EN) REV0 ID No. 2 032 651 3 / 56

6.4 Mounting the Circuit Breaker Drive Rod 6.5 Attaching the Mimic Diagram Mounting Plate 6.6 Mounting the Drive Rod of the Combination Disconnector-Earthing Switch 6.7 Spring Operating Mechanism 6.8 High Voltage Terminal Pads 6.9 Earthing (Grounding) the Circuit Breaker 7 Commissioning 7.1 Connecting the Density Monitor 7.2 Checking the Contacts of the SF6 Density Monitor 7.3 Checking the Anti-Condensation Heaters of the Circuit Breaker and the Combination

Disconnector-Earthing Switch 7.4 Supply Voltages 7.5 Electrical Operation Test of Type ME1-3 Motor-Operated Mechanism for

Disconnector-Earthing Switch 7.6 Electrical Connection 7.7 SF6 System 7.7.1 Filling the Breaker with SF67.8 Functional Testing 7.8.1 Test Operations 7.8.2 Motor Charging Time of the Closing Spring 7.8.3 Operating Times 7.8.4 Manual Operation 7.8.5 Anti-Pumping System 7.8.6 Functional Lockout 7.8.7 Final Tasks 7.9 Handling and On-Site Testing of Current Transformers 7.9.1 Handling 7.9.2 On-Site Testing 7.10 Mounting the Ice Guard 8 Instructions for Troubleshooting the Control System 9 Inspection, Maintenance and Reconditioning


List of Figures Fig. A 3.4: HYpact hybrid integrated compact module Fig. A 3.4.1 a: FK 3-.. spring operating mechanism (schematic diagram) Fig. A 3.4.1 b: FK 3-.. spring operating mechanism (auxiliary equipment) Fig. A 3.4.3: Position indicator (sequence of earthing process) Fig. A 4.1: Transport unit (module) Fig. A 6.2: Erection of lower supports on foundation Fig. A 6.3 a: Mounting the module Fig. A 6.3 b: Removal of ice guard Fig. A 6.3 c: Lifting the module with a fork-lift truck Fig. A 6.3 d: Lifting the module with a crane Fig. A 6.4: Circuit breaker drive rod Fig. A 6.5: Mimic diagram Fig. A 6.6 Drive rod and adjustment of combination disconnector-earthing switch Fig. A 6.7 a: Removing the covers from the operating mechanism Fig. A 6.7 b: Transport lock on opening latch mechanism Fig. A 6.8: Mounting the high voltage terminal pads Fig. A 7.2: Connecting the SF6 piping Fig. A 7.7.1.: SF6 pressure curve for pe = 0.64 MPa , UW1 = 0.54 MPa Fig. A 9: Permissible number of CO operations (n) before replacement of arcing

contacts as a function of the breaking current (I/kA)


1 Introduction

These operating instructions, also referred to below as the manual, apply only to the HYpact hybrid integrated compact modules listed on the first page.

1.1 General Information

These instructions contain a description of the HYpact hybrid integrated compact module. When writing a manual of this type, it is not impossible to include every pos-sible eventuality that might occur when using technical equipment. In the event of questions, orders for replacement parts, or equipment malfunction, please contact the nearest AREVA representative, citing all the information listed on the nameplates. HYpact hybrid integrated compact modules are specifically designed to allow for long maintenance intervals. Experience has shown that the operational reliability of the equipment is guaranteed by proper servicing and by following the instructions given in this manual. This document and the equipment described herein are subject to change without no-tice in the interest of further development. No claims may be derived from the specifications, figures, or descriptions. AREVA Energietechnik GmbH shall not be liable for any errors contained in this document. This document may not be duplicated in any way or passed on to a third party without the written consent of AREVA Energietechnik GmbH.

1.2 Special Instructions

Special instructions (labeled Note or Important) and safety instructions (labeled Caution or Danger) are included in this manual. Special instructions contain the following types of information:

Note

Instructions containing practical tips.

Important

Instructions for avoiding product damage.

Safety instructions are explained in Section 2.


2 Safety

2.1 General Safety Instructions

The operator of the hybrid integrated compact module described in this manual must make sure

that erection, commissioning, and maintenance are carried out only by a qualified electrical technician trained for this purpose or under the direction and supervision of such a technician; that erection, commissioning, and maintenance are carried out in compliance with electrical codes and regulations; that the switchgear unit and all adjacent live parts are de-energized before any work is begun and remain de-energized while work is carried out; that all erection, commissioning, operating, and maintenance personnel are famil-iar with the contents of this manual (including all safety instructions), with all safety regulations applicable locally, and with instructions regarding action to be taken in the event of accidents, and that they can consult these documents at any time; and that the specified maintenance intervals and instructions for reconditioning and part replacement are followed.

The assigned personnel must keep in mind that certain parts of the compact module will carry hazardous voltage levels during operation, and that linkages and levers may move suddenly and unpredictably as the result of external control operations.

2.2 Special Safety Instructions

The text of this manual includes special safety instructions that are specifically marked. There are two categories of special safety instructions in this manual:

! Caution

Warnings about hazardous situations that could potentially lead to minor injuries or damage to the product or to nearby objects.

! Danger

Warnings about imminent danger that could potentially lead to death or serious injury.


2.3 Handling SF6 Gas

Sulfur hexafluoride (SF6) is a colorless, odorless gas. Pure SF6, as specified in IEC 60376, is not toxic. It is not a hazardous substance and is therefore not subject to regulations governing hazardous materials. The applicable international toxicity standard is IEC 61634.

! Caution

When SF6 is used in high voltage switchgear, decomposition products of varying toxicity are formed as the result of electrical discharge and arcs.

These products can irritate mucous membranes, the respiratory tract, and other unprotected skin surfaces.

Personnel must therefore always observe the following safety rules when working on open switchgear:

Do not eat, drink, smoke, or store food in rooms containing SF6 systems. This is especially important during maintenance operations when gas compartments are open.

Do not touch parts in the vicinity of the insulating gas without proper protective clothing and/or equipment.

Do not stir up the powdery decomposition products. Make sure the room is well ventilated when working on indoor breakers.

Use only the minimum number of personnel absolutely neces-sary for performing the work.

Wash the entire body thoroughly after work. Personnel must be equipped with the following items when doing any work involving used or contaminated SF6 gas:

Appropriate protective respiratory equipment such as full-face respirator (gas mask) or respirator plus gas-tight safety gog-gles per DIN EN 175

Dust-tight protective suit made of nonwoven material (dispos-able coveralls)

Rubber gloves or disposable gloves Rubber boots or disposable boots

After work is completed, wash the respirator, safety goggles, rub-ber boots and rubber gloves with water. Collect the water. Dispose of the water and the protective coveralls separately.


2.4 Transport and Handling at the Erection Site

Important

All pressure specifications are given in relative values.

! Caution

The HYpact hybrid integrated compact module is shipped at a gas gauge pressure of approximately 0.03 MPa (0.3 bar).

If the equipment is not handled properly, the composite insulators may burst and cause damage to persons or property.

To minimize the consequences of insulator breakage, never move the compact module if the pressure exceeds the ship-ping pressure.

Applicable safety regulations and requirements and the safety instructions given in Section 2 of this manual must be followed during any transport or handling operation. The operator of the hybrid integrated compact module shall be responsible for com-pliance with safety requirements.


3 Technical Description

3.1 Technical Data: HYpact

Type HYpact 123 HYpact 145

Rated voltage kV 123 145Rated frequency Hz 50/60 50/60Rated normal current A 2500 2500Rated short-circuit breaking current kA 40 40Rated short-circuit making current kA 100/104 100/104

Rated peak withstand current kA 100/104 100/104

Rated short-time withstand current kA 40 40

Rated duration of short circuit s 3 3

Rated power frequency withstand voltage, 1min

Static

To ground kV 230 275

Across open switching device kV 265 315

Rated lightning impulse withstand voltage

To ground kV 550 650

Across open switching device kV 630 750

Rated mechanical terminal load N 1000-1250 1000-1250

Static plus dynamic N 3000-5000 3000-5000Temperature range C -30 / +40 -30 / +40

Minimum creepage path of composite insulators

mm 4505 4505

Maximum dimensions L-W-H *) mm 2513-3520-4432 2513-3520-4432

Maximum weight with supports *) kg 2800 2800 *) Specifications correspond to associated dimension drawing


3.2 Technical Data: Spring Operating Mechanism

Type (see nameplate) FK 3-..Motor for charging the closing spring: Rated voltage (preferred values)

Direct voltage V 60/110/125/220/250 *)

Alternating voltage V 120/230 *)

Allowable rated voltage deviation 85 to 110 % VnPower input W

3.3 Technical Data: Motor-Operated Mechanism of Disconnector-Earthing Switch

Type ME1-3Rated torque Nm 140Motor voltage V dc 48/60/110/220/240 *)Control voltage V dc 48/60/110/220/240 *)Heater rating W 8

Heater voltage V ac 110/127/220 *)

Frequency with alternating current Hz 50

Auxiliary switch Non-adjustable

Rated contact current A 2

Contact rating per IEC 60694 A / ms 100A / 30ms

Degree of protection (optional) IP54Weight kg ca. 25*) Specify when ordering.


3.4 Design and Operation

The HYpact hybrid integrated compact module is modular in design. It has been pre-assembled and tested at the factory. The module consists of three separate gas compartments that are all monitored by the SF6 system. Each of these gas compart-ments houses the circuit breaker and the combination disconnector and earthing switch for one phase. The design of the circuit breaker is based on the successful field-proven AREVA T&D air-insulated circuit breakers with spring operating mechanisms. When the current is interrupted, a transition from the conductive to the insulating state occurs within a few milliseconds. During the opening operation, an arc is formed that is quenched by gas flow within the interrupter unit. In third-generation SF6 circuit breakers, the required quenching pressure is generated in a pressure chamber by the energy of the arc itself as a function of current. The operating mechanism supplies only the energy for the contact movement and an auxiliary piston. The circuit breakers are connected with one another by a torsion linkage and with the operating mechanism by a connecting linkage. The combination disconnector and earthing switch is effectively protected from inter-ference by being located along with the circuit breaker in a housing that forms a gas compartment. The housing contains a mushroom-shaped movable contact that can be moved into the fixed contact of either the disconnector or the earthing switch by means of a lever mechanism on a contact pin. In the intermediate position, both the disconnector and the earthing switch are in open position. The contact pin is con-nected to the circuit breaker, and the fixed contact of the disconnector is connected to the insulator bushing. The ring-shaped fixed contact of the earthing switch is inte-grated in the housing. A tension-compression linkage connects the combination dis-connector-earthing switch with the mechanism. The HYpact hybrid integrated compact module operates on the principle of integral earthing (or grounding). This means that the earthing switch portion of the combina-tion disconnector-earthing switch is used only to prepare for earthing (grounding). The interrupter unit of the circuit breaker not only interrupts the current but also handles the final earthing or grounding. This permits a simpler earthing switch design as far as electrical requirements are concerned since the circuit breaker meets the stringent requirements for short-circuit making capacity. A mechanical indicating device located in the operating area of the HYpact compact module shows the various breaker posi-tions clearly in a comprehensive mimic diagram. Measuring devices (current transformers) can be mounted on the bushings of each phase. A terminal box serves as the customer interface. The transport unit (referred to below as the module) is mounted on two supports to which the operating mechanisms and the transformer terminal box are also mounted.


2

1

5

3

4

3

6

Fig. A 3.4: HYpact hybrid integrated compact module

1 Combination disconnector-earthing switch

2 Current transformer 3 Support

4 Circuit breaker operating mecha-nism

5 Transformer terminal box 6 Ice guard


3.4.1 Spring Operating Mechanism

The operating mechanism consists of a steel structure that is self-supporting and pro-tected against corrosion. The door, floor, rear panel, removable side panels, and roof are made of aluminum sheet. For storing the required operating energy, helical compression springs are charged by an electric motor via a gear unit (Figure A 3.4.1 a). Electrical actuation of the closing and opening coils causes latches to be unlatched, which releases the energy of the springs for operating purposes. The spring energy is transmitted to the pole columns by the lever on the rear of the mechanism and by the drive rod and the connecting rods. Charging the Closing Energy Storage Mechanism After control voltage has been applied, the motor (70.01) immediately starts up and charges the closing spring (70.25) via the gear unit (70.04), crank wheel (70.30), and chain (70.26). This operation is terminated once the crankpin (70.29) with linked chain (70.26) has gone beyond top dead center and supports the roller (70.28) of the crank wheel (70.30) on the closing latch (70.05). At the conclusion of the charging process, the tooth space (70.27) of the crank wheel (70.30) has reached the driving pinion. This allows the gear unit (70.04) and the mo-tor (70.01), which has been turned off by the control cam (70.22) and the motor limit switch (70.24), to run down and stop unimpeded without loading the closing latch (70.05). The repositioned motor limit switch (70.24) has closed the closing circuit, and the spring position indicator (70.31) has been switched to "closing spring charged." Closing Operation The closing latch (70.05) is released by the electrical command to the closing coil (70.06) or by operation of the manual release mechanism (70.07). The closing shaft (70.09) is accelerated by action of the closing spring (70.25) linked to the crank wheel (70.30). The cam disc (70.10) turns the adjacent roller follower (70.11) in the closing direction. The circuit breaker is closed by means of the main shaft (70.12), the drive lever (70.18), and a coupled linkage. At the completion of the closing motion, after rotating 60, the main shaft (70.12) is lowered onto the opening latch (70.16) safely and with low impact by a lever arm of the roller follower (70.11), thanks to the specially de-signed cam disc (70.10). At the same time, the cam disc (70.10) has left the roller fol-lower (70.11), and the circuit breaker is locked in the closed position and can now be opened. In the course of the closing motion, the opening springs (70.20) and (1.806) are charged. The excess residual energy is stored again in the closing spring. Control, indicating, and latching functions at the end of the closing motion:

The auxiliary switch (70.21) that is coupled to the main shaft (70.12) has closed the opening coil circuit and interrupted the closing circuit. The circuit breaker can be opened electrically, but another closing operation or a pulse applied to the clos-ing coil is prevented. A lever (not shown) that is controlled by the main shaft (70.12) has blocked the closing latch (70.05) and thus also mechanically prevents another closing opera-tion. The position indicator (70.52) has been turned by the main shaft (70.12) to the closed position. The motor limit switch (70.24), which is actuated by the control cam, has closed the motor circuit.


The closing coil circuit has been interrupted by a contact of the motor limit switch (70.24). This prevents another electrical closing operation. At the same time, the spring position indicator (70.31) has been set to "closing spring discharged."

Recharging the Closing Energy Storage Mechanism When the motor limit switch (70.24) is moved by the control cam (70.22) at the end of the closing motion, the motor circuit is closed, and the closing spring (70.25) is auto-matically re-charged. Opening Operation The opening latch (70.16) is released by the electrical command to the opening coil (70.99) or by operation of the manual release mechanism (70.13). The action of the charged opening springs (70.20 and 1.8.06) causes the main shaft (70.12) and the circuit breaker that is connected to it to be accelerated in the open direction. Towards the end of the opening operation, the opening brake (70.17) becomes active and brakes the moving parts of the circuit breaker and operating mechanism until they come to a complete stop. Control, indicating, and latching functions at the end of the opening motion:

The auxiliary switch (70.21) that is coupled to the main shaft (70.12) has inter-rupted the opening coil circuit and closed the closing circuit. This prevents another electrical opening operation. An electrical closing operation is again possible. A lever (not shown) that is controlled by the main shaft (70.12) has again released the closing latch (70.05) for a subsequent closing operation. The circuit breaker can be closed mechanically. The position indicator (70.52) has been turned to the open position by the main shaft.


1.8

1.8.06

1.8.07

2.3

70.53

70.30 70.29 70.28 70.27

70.52

70.31

70.26

70.25 70.2070.2270.24

70.23 70.21

70.19

70.13

70.14

70.99

70.16

70.18

70.17

70.1070.01

70.0870.0670.04 70.02 70.1170.0970.0770.0570.03

70.12

Mechanism in open position with closing spring discharged

Fig. A 3.4.1 a: FK 3-.. spring operating mechanism (schematic diagram)

1.8 Crankcase 1.8.06 Opening spring 1.8.07 Insulating rod 2.3 Drive rod 70.01 Motor 70.02 Backstop 70.03 Free-wheeling mechanism 70.04 Gear unit 70.05 Closing latch 70.06 Closing coil 70.07 Manual closing lever 70.08 Close button 70.09 Closing shaft 70.10 Cam 70.11 Roller follower 70.12 Main shaft 70.13 Manual opening lever 70.14 Open button 70.16 Opening latch

70.17 Opening brake 70.18 Operating lever 70.19 Chain 70.20 Opening spring 70.21 Auxiliary Switch 70.22 Control cam 70.23 Lever 70.24 Motor limit switch 70.25 Closing spring 70.26 Chain 70.27 Tooth space 70.28 Roller 70.29 Crankpin 70.30 Crank wheel 70.31 Spring position indicator 70.52 Position indicator 70.53 Hand crank 70.99 Opening coil


2

1

3 4 5 6

20

7

8

9 10 11 12

13

17

16

18 19

21 22 23 24

25 26

14

15

Fig. A 3.4.1 b: FK 3-.. spring operating mechanism (auxiliary equipment)

1 Circuit breaker terminal strip 2 Disconnector closed 3 Disconnector open 4 Earthing switch closed 5 Earthing switch closed 6 Anti-pumping system, circuit

breaker 7 SF6 monitor 8 Lighting 9 Door contact for lighting 10 Earthing switch control, closed 11 Earthing switch control, open 12 Earthing switch control, general 13 Terminal strip, disconnector-

earthing switch

14 Locking plate 15 Locking screws 16 Heating unit 17 Heating protection (fuse) 18 Motor protection, circuit breaker 19 Motor protection, disconnector-

earthing switch 20 Remote-local switch (optional) 21 Circuit breaker closed (local) 22 Circuit breaker open (local) 23 Disconnector closed (local) 24 Disconnector open (local) 25 Earthing switch closed (local) 26 Earthing switch open (local)


3.4.2 Type ME1-3 Motor-Operated Mechanism for Disconnector-Earthing Switch

Manual Operation

The ME1-3 motor-operated mechanism can be operated with the hand crank in the event of a control voltage failure or during maintenance operations. To do so, turn the mode selector lever (70.15) to the Disconnector manual or Earthing switch manual position. Insert the hand crank into the crank hole so that it engages with the manual opera-tion shaft. The position selected for the mode selector lever (70.15) defines the position of the locking lever so that the locking disk only permits the pre-selected operation sequence (Disconnector closed Disconnector open or Earthing switch closed Earthing switch open). In order to carry out both operations, the hand crank must be removed and the mode selector lever (70.15) reset.

Blocking Mechanical blocking is provided for the following positions:

Disconnector closed / Earthing switch open Disconnector open / Earthing switch open Earthing switch closed / Disconnector open

To block the mechanism, move the mode selector lever (70.15) to the desired po-sition and insert the crank hole bolt (70.21) into the crank hole so that it engages with the manual operating shaft (70.22) and lock it with the padlock (70.23). When the ME1-3 motor-operated mechanism is blocked, the control and motor cir-cuits are interrupted by the mode selector limit switch.

Operation Types of use Remote-controlled, electrical or manual operation of the combination disconnector-earthing switch Mechanical blocking is provided for the following positions:

Disconnector closed / Earthing switch open Disconnector open / Earthing switch open Earthing switch closed / Disconnector open


Operation Remote control as standard operation

The mode selector lever (70.15) is in the remote control position. The locking pin (70.30) is engaged. The crank hole bolt (70.21) is locked with the padlock (70.23).

70.30

70.23

70.21

70.15

70.15 Mode selector lever 70.21 Crank hole bolt

70.23 Padlock 70.30 Locking pin

When the mode selector lever (70.15) is in this position, electrical remote control is activated, and mechanical blocking and manual operation are not possible.

Manual operation of the disconnector

The disconnector position indicator is in the Disconnector open position, the Disconnector closed position or in an intermediate position. The latter is only possible when there is an incomplete electrical operation and is normally displayed as a fault by the control system (watchdog timer). The mode selector lever (70.15) is in the remote control position.

70.30

70.23

70.21

70.15



Remove the padlock (70.23) and the crank hole bolt (70.21). Lift and turn the locking pin (70.30), move the mode selector lever (70.15) counter-clockwise until it hits the stop, turn and release the locking pin (70.30), and then move the mode selector lever (70.15) back until the locking pin (70.30) engages. The mode selector lever (70.15) is now in the Disconnector manual position.


crank hole

rotation symbol

Insert the hand crank into the crank hole in the housing and switch the combina-tion disconnector-earthing switch to the desired position as shown by the rotation symbol. The final position is reached as soon as the hand crank (with torque control) is stopped by the position limiter (14 to 18 revolutions). To take pressure off the posi-tion limiter, turn the hand crank back 1 revolution maximum. Remove the hand crank. Lift and turn the locking pin (70.30), move the mode se-lector lever (70.15) clockwise to the remote control position, turn and release the locking pin (70.30), and move the mode selector lever (70.15) until the locking pin (70.30) engages. Insert the crank hole bolt (70.21) and lock it with the padlock (70.23). The ME1-3 motor-operated mechanism can now be operated again by remote control.

Manual operation of the earthing switch

The earthing switch position indicator is in the Earthing switch open position, the Earthing switch closed position or in an intermediate position. The latter is only possible when there is an incomplete electrical operation and is normally displayed as a fault by the control system (watchdog timer). The mode selector lever (70.15) is in the remote control position.

70.30

70.23

70.21

70.15



Remove the padlock (70.23) and the crank hole bolt (70.21). Lift and turn the locking pin (70.30), move the mode selector lever (70.15) clock-wise until it hits the stop, turn and release the locking pin (70.30), and then move the mode selector lever (70.15) back until the locking pin (70.30) engages. The mode selector lever (70.15) is now in the Earthing switch manual position.


crank hole

rotation symbol

Insert the hand crank into the crank hole and switch the combination disconnector-earthing switch to the desired position as shown by the rotation symbol. The final position is reached as soon as the hand crank (with torque control) is stopped by the position limiter (14 to 18 revolutions). To take pressure off the posi-tion limiter, turn the hand crank back 1 revolution maximum. Remove the hand crank. Lift and turn the locking pin (70.30), move the mode se-lector lever (70.15) counterclockwise to the remote control position, turn and re-lease the locking pin (70.30), and move the mode selector lever (70.15) until the locking pin (70.30) engages. Insert the crank hole bolt (70.21) and lock it with the padlock (70.23). The ME1-3 motor-operated mechanism can now be operated again by remote control.

Blocking in the Disconnector manual position

crank hole

70.30

70.23

70.21

70.15

70.21

70.22

70.15 Mode selector lever 70.21 Crank hole bolt 70.22 Manual operation shaft



Lift and turn the locking pin (70.30), move the mode selector lever (70.15) counter-clockwise until it hits the stop, turn and release the locking pin (70.30), and then move the mode selector lever (70.15) back until the locking pin (70.30) engages. Insert the crank hole bolt (70.21) in the crank hole and engage it by turning the manual operation shaft (70.22). Lock the crank hole bolt (70.21) and mode selector lever (70.15) with the padlock (70.23). To do so, turn the crank hole bolt (70.21) with the connected manual operation shaft (70.22) so that the padlock (70.23) can be inserted.

Blocking in the Earthing switch manual position

70.30

70.23

70.21

70.15

crank hole

70.21

70.22

70.15 Mode selector lever 70.21 Crank hole bolt 70.22 Manual operation shaft


Lift and turn the locking pin (70.30), move the mode selector lever (70.15) clock-wise until it hits the stop, turn and release the locking pin (70.30), and then move the mode selector lever (70.15) back until the locking pin (70.30) engages. Insert the crank hole bolt (70.21) in the crank hole and engage it by turning the manual operation shaft (70.22). Lock the crank hole bolt (70.21) and the mode se-lector lever (70.15) with the padlock (70.23). To do so, turn the crank hole bolt (70.21) with the connected manual operation shaft (70.22) so that the padlock (70.23) can be inserted.


3.4.3 Combined Mechanical Position Indicator

In switchgear where earthing is based on the principle of integral earthing, the exist-ing making capacity of the circuit breaker is used to reduce the electrical load on the earthing switch. This is achieved when the earthing switch, which is located between the circuit breaker and the disconnector, is closed while the other two devices are in the open position. The circuit breaker is then closed again immediately after that via a forced follow-up operation and thus the earthing process is completed. In contrast to conventional earthing, the earthing switch in integral earthing is used solely to pre-pare for earthing. This difference is made clear to the user by a combined mechani-cal position indicator. CB = circuit breaker D = disconnector ES = earthing switch

D closed D closed D open D open D open ES open ES open ES open ES closed ES closed

CB closed CB open CB open CB open CB closed

temporary earthing preparation

earthing completed

Fig. A 3.4.3: Position indicator (sequence of earthing process)


4 Transport and Storage 4.1 Transport

The standard module is shipped as a three-pole unit. The two supports with mounted operating mechanisms (Fig. A 3.4) and the acces-sories are shipped in separate units. The dimensions of the transport unit are as follows: width approx. 3.6 m, height approx. 2.4 m, length 2.3 m. Weight of the transport unit: approx. 2.5 t.

Fig. A 4.1: Transport unit (module)

SF6 gas cylinders, if ordered, are shipped in separate transport units.

! Caution

Improper handling of the transport units can result in seri-ous accidents.

Follow the directional markings on the packaging.

4.2 Storage

Modules may be stored indefinitely indoors in dry spaces. If the components are stored outdoors or under a protective roof, the anticonden-sation heaters of the operating mechanisms for circuit breakers, disconnectors, and earthing switches and also any terminal boxes or control cabinets must be electrically connected to prevent condensation and corrosion.


5 Preparation for Erection

5.1 Required Documents

The following documents must be available at the erection site for in order to carry out erection and commissioning:

Shipping documents Operating instructions including checklists for erection and commissioning Dimension drawing Schematic diagram Routine test certificates

5.2 Using the Checklist

If used properly, the enclosed checklist will ensure that all the important procedures that guarantee the operating safety and reliability of the HYpact modules will be car-ried out. It is enclosed with these operating instructions as a colored sheet and can also be found in Section 5.3. When using the checklist, follow these instructions:

Use the checklist for only one module.

Additional checklists may be provided for specific components of the module. Enter the module serial number on each sheet.

Perform all procedures listed on the checklist. After work is completed, the checklist must be dated, stamped with the company name, and signed by the individual in charge of commissioning. Send a copy of the checklist to the manufacturer (see checklist):

Important

If this checklist is not on file when warranty claims are submitted, the extent of the warranty claim may be reduced.


5.3 Checklist for Erection and Commissioning

HYpact Data:

Serial No.

Customer:

Station:

Erection

No. Operation to Be Performed Section 1 Safety instructions have been carefully read and are under-

stood 2

2 Nameplates and labeling have been checked 3.2

3 Materials provided by station checked for completeness 5.4

4 Shipment checked for completeness and lack of damage 5.6.1

5 Torques for bolted joints checked 6

6 Supports mounted on foundation and leveled 6.2

7 Module bolted to supports 6.3

8 Circuit breaker drive rod attached 6.4

9 Mimic diagram mounting plate attached 6.5

10 Drive rod for combination disconnector-earthing switch mounted and adjusted; test operations performed manually

6.6

11 Transport lock removed from operating mechanism 6.7

12 High voltage terminals installed 6.8

13 Supports grounded 6.9

14 Density monitor cable connected 7.1


Commissioning Serial No.:

No. Operation to Be Performed Section or Value

HYpact Hybrid Integrated Compact Module

1 SF6 gas in circuit breaker poles topped up to rated pressure as shown on nameplate

7.7.1

2 SF6 connection checked 7.7.1

3 Operation of anticondensation heater(s) of the operating mechanism(s) checked

7.3

4 Five (5) closing and 5 opening operations executed by remote control

7.8.1

5 Motor charging time [sec.] of operating mechanism closing spring checked

7.8.2

6 Closing time [ms] checked 7.8.3 A

B

C

7 Opening time [ms] checked 7.8.3 A

B

C

8 Manual closing & opening operations checked 7.8.4

9 Anti-pumping system checked 7.8.5

10 Functional lockout checked 7.8.6

11 Testing and measuring equipment removed 7.8.7

Combination Disconnector-Earthing Switch

12 Nameplate checked

13 Operation of mechanisms anti-condensation heater checked 7.3

14 Operation of alarm contacts in closed and open positions checked

7.5

15 Five (5) closing and 5 opening operations executed by remote control

7.8.1


Check of Overall Operation

16 Resistance of main circuit measured Pole A

Pole B

Pole C

17 Interlocks between high voltage devices checked

18 Wiring of control cabinet and/or individual devices checked

19 Testing and measuring equipment removed

Please send one completed and signed copy of the checklist to:

AREVA Energietechnik GmbH, High Voltage Products, Dept. TDS-DHK/CS, Lilienthalstr. 150, 34123 Kassel, Germany, Fax: +49(0)561 502-2774

City Date Stamp Signature


5.4 Materials and Equipment to be Provided by Station

5.4.1 Materials

Foundation, anchor bolts, nuts, and washers Earthing (grounding) connections and fasteners

If not included with order:

Supports in accordance with AREVA Energietechnik GmbH drawing High voltage terminals and fasteners

5.4.2 Hoisting Equipment

Crane or forklift truck of sufficient height and load-carrying capacity Round slings and lifting tackle (shackles, eyebolts, etc.) of appropriate load-bearing capacity for weight specifications given above

Important

The minimum crane height required is 8 m.

For different insulation heights, please refer to the di-mension drawing.

5.4.3 Tools

Torque Wrenches and Accessories

Tool No. Description Illustration Order No.T003 Torque wrench 80-400 Nm;

14x18 mm drive

2008996

T006 Drive adapter For use with 14x18 mm sockets in connection with 9x12 mm torque wrench drive

2009000

T099 Hex key or Allen wrench 4 mm

1054565


Heads for Torque Wrenches

Tool No. Description Illustration Order No.T008 Open-ring wrench 19 mm,

head for torque wrench, 9x12 mm seat

2009001

T009 Open-ring wrench 24 mm, head for torque wrench, 9x12 mm seat

2009002

T098 Open-end wrench 22m, head for torque wrench, 14x18 mm seat

2033297

T011 Open-end wrench 36 mm, head for torque wrench, 14x18 mm seat

2009004

Double open-ended wrenches

Tool No. Order No.

T013 10x11 mm 1053523

T014 12x13 mm 1053560

T016 18x19 mm 1053638

T017 22x24 mm 1053687

T019 32x36 mm 1053742

T020 36x41 mm 1053766

5.4.4 Other Tools and Equipment

Crowbar

Rubber mallet Stainless steel wire brush Gas-filling device with pressure-reducing valve and DILO supply connection (DN8 for circuit breaker)


5.4.5 Testing and Measuring Equipment

Multimeter SF6 leak detector Timer for operating times and motor charging time

5.4.6 Auxiliary Materials and Supplies

Molykote BR2 Plus (grease) For lubricating screws and bolts SF 1377 silicone grease For lubricating bolted contact surfaces and also gaskets and sealing surfaces, if needed Loctite, Type 243 (blue) For locking bolts and screws

If not included with order:

SF6 gas, grade as specified in IEC 60376

5.5 Unloading and Unpacking the Transport Units

After the transport units have been received, check them against the accompany-ing documents for completeness and for possible shipping damage.

Note

Report any shipping damage to the freight forwarder and the nearest AREVA representative immediately.

! Danger

Improper handling may result in serious damage or injury caused by falling loads.

Use a crane and rope of sufficient load-bearing capacity. Make sure the ropes only come in contact with the specified contact points of the three-pole transport unit.

5.6 Checking the Shipment

5.6.1 Completeness and Lack of Damage

Before beginning assembly and installation, check the shipment for completeness and potential damage as follows:

Inspect components visually for damage, particularly porcelain components. Compare the labeling on the module with the serial number on the shipping docu-ments.


6 Erection

6.1 General Instructions

All settings and adjustments have already been made at the factory. The drive rod of the operating mechanism has been adjusted and locked with a locking com-pound. Circuit breaker and operating mechanism are shipped in the open position. Both springs of the operating mechanism are discharged. Disconnector and operating mechanism are shipped in the closed position. In the spring operating mechanism, the opening latch assembly has been secured for shipping with a cable tie. Note: The main shaft of the spring mechanism is fixed in the open position by the opening spring located in the mechanism. The breaker poles have been evacuated at the factory and filled with SF6 at ship-ping pressure (gauge pressure 0.03 MPa = 0.3 bar). Whenever the instructions call for bolt (or screw) coated with locking adhesive," always use the liquid locking adhesive Loctite (blue). Time required for installation: approximately 6 man-hours.

! Caution

Fasteners (screws or bolts, nuts, coupling pins, etc.) that are not strong enough may fail during installation, commissioning, or op-eration and cause serious damage or injury.

Use only the fasteners supplied with the equipment. Always use the correct fastener grade and type (check the text and strength specifications).

Always tighten fasteners to the specified torques (lubricate threads per instructions).

! Danger

Improper handling may result in serious damage or injury caused by falling loads.

Standing under suspended loads is prohibited. All personnel involved in the installation operation must wear protective headgear (hard hats).


6.2 Supports on Foundation

1

3 2 4

5

Fig. A 6.2: Erection of lower supports on foundation

1 Support 2 Anchor bolt, M24 3 Nut, N24 TZN

4 Washer, 24 5 Foundation

Important

The foundation ends of the supports have 30 holes that permit horizontal tolerance adjustment with respect to the foundations. The anchor bolts must therefore be equipped with washers of sufficient size (e.g. 50, t=8).

Screw the bottom nuts (3) and washers (4) on the anchor bolts (2). Place lower supports (1) on anchor bolts, and use the nut (3) to adjust the vertical tolerance. After the supports have been adjusted, tighten the top nuts (3) and washers (4) on the anchor bolts (2) to a torque of 333 Nm (with strength class 5.6 for M24). For anchor bolts of a different strength class, apply the torques appropriate for the strength class.


6.3 Mounting the Module

X

X

6a

3

2

4

6b

1

5

7

Fig. A 6.3 a: Mounting the module

1 Hexagon bolt, M16x40 A2-70 2 Washer, 16 200 - HV - A2 3 Hexagon nut, M16 A2-70 4 Module

5 Fastening screw 6a Support with pre-mounted

mechanism 6b Support 7 Transport profile


Removal of ice guard The ice guard has been pre-mounted at the factory. To remove the ice guard, proceed as follows: Loosen the eight mounting bolts four on the front and four on the back

(Fig. 6.3 b) and lift up the front of the ice guard to remove.

a

b

Fig. A 6.3 b: Removal of ice guard

a Nut b Riveted nut


The module can be moved using a fork-lift truck or a crane.

Important

To prevent damage to the tank when lifting the module using a fork-lift truck, transport profiles (7) have been attached to the module (see Fig. 6.3 a, lower right). These transport profiles must be installed if the module is to be lifted using a fork-lift truck.

Cast-on eyelets or lugs are located on the tank, but they must not be used for lifting the module. To lift the module using a crane, proceed as shown in Fig. A 6.3 d.

Lifting the module using a fork-lift truck:

Lift the module using a fork-lift truck (fork length 2.30m, cross section 150x60mm) as shown in Fig. 6.3 c and position it above the pre-mounted supports.

For safety reasons, do not retract the fork and back up the fork-lift truck until the module has been bolted to the supports.

Mount the module on the supports using the 12 mounting screws (5), tightening to a torque of 202 Nm. Using a level, align the module horizontally in both planes by adjusting the lock nuts on the anchor bolts so that the module is level. Tighten the nuts on the anchor bolts to a final torque of 333 Nm and lock them. Remove the hoisting gear. Remove the transport profiles (7).

Fig. A 6.3 c: Lifting the module with a fork-lift truck


Lifting the module using a crane:

Remove the transport profiles (7). Secure the hoisting gear to the outer poles as shown in Fig. 6.3 d. Lift the module using a crane and position it above the pre-mounted supports. Slowly lower the module. Lower the crane a few centimeters more in order to remove the tension from the hoisting gear. Mount the module on the supports using the 12 mounting screws (5), tightening to a torque of 202 Nm. Using a level, align the module horizontally in both planes by adjusting the lock nuts on the anchor bolts so that the module is level. Tighten the nuts on the anchor bolts to a final torque of 333 Nm and lock them. Remove the hoisting gear.

Fig. A 6.3 d: Lifting the module with a crane


6.4 Mounting the Circuit Breaker Drive Rod

Lubricate the studs (3, 9) with Molykote BR2 plus (see figure). Insert the drive rod (7) into the drive lever (8) and insert the stud (9). Lock the stud (9) with the screw (12), sleeve (10) and washer (11), and tighten to a torque of 10 Nm. Insert the drive rod (7) into the circuit breaker lever (1) and insert the stud (9). Lock the stud (3) with the bolt (6), sleeve (4) and washer (5), and tighten to a torque of 10 Nm.

If the holes in the drive rod and the lever of the circuit breaker do not align, proceed as follows:

By twisting the coupling shaft (2) with the open-end wrench (T020), position the circuit breaker lever (1) so that the holes in the drive rod (7) and the lever are aligned.

3

9 10 11 12

7

4 5 6

8

1

2

Fig. A 6.4: Circuit breaker drive rod

1 Circuit breaker lever 2 Coupling shaft 3 Stud, 16x54 4 Sleeve (stud lock) 5 Washer, 6.4 200 - HV - A2 6 Hexagon bolt, M6 x 16 A2-70

7 Drive rod 8 Drive lever 9 Stud, 16x68 10 Sleeve (stud lock) 11 Washer, 6.4 200 - HV - A2 12 Hexagon screw, M6 x 16 A2-70


6.5 Attaching the Mimic Diagram Mounting Plate

The mimic diagram mounting plate is used for visual display of the operating positions and is shipped in the crate containing the accessories. Attach the mounting plate using the four preassembled hexagon socket head

screws and the hex key or Allen wrench (T099).

Fig. A 6.5: Mimic diagram


6.6 Mounting the Drive Rod of the Combination Disconnector-Earthing Switch

Lubricate the stud (6) and ball journal of the drive rod with Molykote BR2 plus (see figure). Insert the drive rod (4) into the drive lever (5) and insert the stud (6). Lock the stud (6) with the screw (12), sleeve (7) and washer (8), and tighten to a torque of 10 Nm. Fit the washer (2) on the ball journal of the drive rod. Insert the drive rod (4) into the lever of the combination disconnector-earthing switch (1). Slide on the washer (2) and tighten the nut (3) to a torque of 140 Nm.

If the holes in the drive rod and the lever of the circuit breaker do not align, proceed as follows:

Twist the lever of the combination disconnector-earthing switch (1) and position it so that the holes of the drive rod (4) and the lever are aligned.

2 3

6 7

8 9

4

5

position: disconnector closed

1

Fig. A 6.6 Drive rod and adjustment of combination disconnector-earthing switch

1 Lever of combination disconnector-earthing switch

2 Washer, 16 A2 3 Nut, M14 4 Drive rod 5 Drive lever

6 Stud, 16x52 7 Sleeve (stud lock) 8 Washer, 6.4 200 - HV - A2 9 Hexagon screw, M6 x 16 A2-70


Factory-set adjustment devices are located on the combination disconnector-earthing switches of the poles. Fig. A 6.6 shows the device for the disconnector closed position (as-delivered condi-tion). After connecting the drive rod, check to see whether the indicators are within the re-spective scale graduation or division in all positions of the combination disconnector-earthing switch. To do so, proceed as follows:

Carry out a test operation manually (disconnector closed > disconnector open) and check the position. If necessary, the drive rod length must be adjusted until the correct position is reached. Carry out a test operation manually (disconnector open > earthing switch closed) and check the earthing switch closed position. Carry out a test operation manually (earthing switch closed > disconnector open > disconnector closed ) and check the position. The respective positions can be read on the position indicator (Fig. A 3.4.3).


6.7 Spring Operating Mechanism

! Danger

Off-load operations can result in damage to the mechanism due to excess energy and may cause personal injury.

Never charge or operate the operating mechanism unless it is mechanically connected to the pole columns.

Remove the right side cover from the mechanism (Figure A 6.7 a): To do so, remove the two M5 screws, and pull the bottom of the side covers out and then down and remove them.

Remove the transport lock (cable tie) from the opening latch mechanism (Fig-ure A 6.7 b).

Fig. A 6.7 a: Removing the covers from the operating mechanism

Fig. A 6.7 b: Transport lock on opening latch mechanism


6.8 High Voltage Terminal Pads

Before bolting the terminal pad (a) and terminal face (b) together, brush them with a stainless steel wire brush until they are bright. Then wipe them with a clean rag and immediately apply a light coat of SF 1377 silicone grease or acid-free Vaseline. Fasten the high voltage terminal pads with the accompanying bolts (M16 x 70 A2-70) and tighten them to a torque of 202 Nm. Place one washer each under the bolt and the nut.

(a)

(b)

Fig. A 6.8: Mounting the high voltage terminal pads

6.9 Earthing (Grounding) the Circuit Breaker

Earth (or ground) the supports.


7 Commissioning

7.1 Connecting the Density Monitor

Remove the filler plug by unscrewing and removing the union nut from the cable gland on the rear of the circuit breaker operating mechanism. Then screw on the union nut loosely.

Insert the density monitor cable through the cable gland and cable conduit and connect it according to the schematic diagram.

Secure the cable to the roof of the operating mechanism using the preassembled cable tie and tighten the union nut.

Important

To prevent damage to the cable, make sure it is free of kinks and is not pulled too tight.


7.2 Checking the Contacts of the SF6 Density Monitor

For functional testing of the contacts or operating points, fill the SF6 piping with gas.

Note

Since the ends of the SF6 piping system are equipped with check valves, uncontrolled leaks of SF6 are prevented. A leak is simu-lated by pressing a poppet valve on the piping.

Disconnect the SF6 piping from all three pole columns. Fill the SF6 piping to rated density (black dot in the green field of the density moni-tor dial). Check the UW 1 contact:

Lower the SF6 pressure until the "UW1 (SF6 alarm)" value is reached. Check operating point UW1 at contacts 1 and 2 using a multimeter.

Check the UW 2 contacts: Lower the SF6 pressure further until the "UW2 (SF6 lockout)" value is reached. Check operating point UW2 at contacts 3 and 4 using a multimeter.

Check the SF6 piping joints for tightness, and if necessary retighten to a torque of 30 Nm (10%). Use two wrenches for tightening.

Important

The SF6 density monitor is temperature-compensated, i.e., the ambient temperature does not affect either the indica-tion or the alarm contacts.

2

1

Fig. A 7.2: Connecting the SF6 piping


7.3 Checking the Anti-Condensation Heaters of the Circuit Breaker and the Combination Disconnector-Earthing Switch

Measure the resistance of the anti-condensation heater at the terminals in the cir-cuit breaker operating mechanism. Check the measured value against the reference value on the routine test certifi-cate and enter it on the checklist.

7.4 Supply Voltages

! Danger

Before connecting the supply and control cables, make sure the unit is not energized.

! Caution

As soon as the supply voltage has been applied and the motor protection switch is turned on, the motor will charge the closing spring.

Before applying voltage or turning on the motor protec-tion switch, make sure that there are no objects or parts of the body in the charging system area.

When supply voltage has been applied, the anti-condensation heater will be hot. It can burn skin or clothing.

Do not touch the heater.

Insert all supply and control cables through cable glands and connect them to the terminals in accordance with the schematic diagram.

7.5 Electrical Operation Test of Type ME1-3 Motor-Operated Mechanism for Disconnector-Earthing Switch

Operate using local control (optional feature) in both closed and open positions. Check the alarm contacts in closed and open positions. Check heater operation.

Important

Manual operation of the control contactors in motor-operated mechanisms is not permitted.


7.6 Electrical Connection

! Danger

Follow the safety instructions given in Section 2.

Before connecting the supply and control cables, make sure the unit is not energized.

! Caution

Current transformers are short-circuited by means of earthing (or grounding) jumpers until commissioning be-gins. These jumpers may need to be removed.

Make sure that all earthing jumpers are installed in ac-cordance with the applicable schematic diagram.

As soon as the supply voltage has been applied and the motor protection switch is turned on, the circuit breaker mo-tor will charge the closing spring.

Before applying voltage or turning on the motor protec-tion switch, make sure that there are no objects or parts of the body in the charging system area.

When supply voltage has been applied, the anti-condensation heaters of the mechanisms will be hot. They can burn skin or clothing.

Do not touch the heaters.

The two control and supply lines from the circuit breaker operating mechanism to the operating mechanism of the combination disconnector-earthing switch have been connected at the factory by a plug-and-socket connector. The supports must be earthed (grounded) at the earthing (grounding) holes. Connections to the high voltage terminals must correspond to the respective di-mension diagram. Brush the terminal faces and lubricate them with SF 1377 silicone grease.


7.7 SF6 System

7.7.1 Filling the Breaker with SF6

! Danger

Improper transport or handling can result in damage to the composite insulators. If this is the case, bursting may occur when equipment is filled to rated pressure.

To avoid serious accidents, inspect the equipment visu-ally for damage before filling it with SF6. While the breaker is being filled with SF6, all personnel must be in a protected location or at a safe distance from the equipment (at least 40 m).

! Caution

During the filling operation, the pressure-reducing valve of the gas-filling device must not be set any higher than 1.1 times the rated SF6 pressure. If this pressure is exceeded, it may lead to actuation of the breaker's pressure-relief de-vice. The filling pressure is set manually by adjusting the pressure-reducing valve.

Important

The rated pressure pe is given on the respective name-plate.

If there is no nameplate, the rated pressure can be read on the density meter dial.

If there is any doubt about SF6 quality (when using un-sealed SF6 cylinders, for example), check the dewpoint of the SF6 gas after the filling operation. Purge the hose of the gas-filling device with SF6 before the filling operation. The density monitor can be checked against the pres-sure curve shown below by using a test manometer and a thermometer.

Connect the supply hose of the gas-filling device (SF6 cylinder with pressure-reducing valve or gas cart) to the supply connection (DILO type, DN 8). Fill the HYpact circuit breaker to rated pressure. The rated pressure is indicated by the black dot at the end of the green field on the density monitor dial. After a temperature equalization period of approximately 1 hour, check the SF6 pressure again and correct it, if necessary. Check all SF6 piping sealing points for leaktightness using an SF6 leak detector.


Fig. A 7.7.1.: SF6 pressure curve for pe = 0.64 MPa , UW1 = 0.54 MPa

1 Rated pressure curve 2 Alarm pressure curve 3 Lockout pressure curve 4 SF6 liquefaction curve


7.8 Functional Testing

! Danger

Follow the safety instructions given in Section 2. Never operate the circuit breaker when the SF6 pressure is below the lockout value (red area of the density moni-tor scale). During test operations, all personnel must be in a pro-tected location or at a safe distance (at least 40 m) from the equipment.

! Caution

Long-lasting voltage loading may destroy the shunt release coils. The internal protective circuit only prevents excessive voltage loading when the breaker has been properly con-nected.

Never connect coils directly to the control voltage. Connect coils only via the terminals provided.

7.8.1 Test Operations

Carry out five closing and five opening operations by remote control. Operate using local control (optional feature) in both closed and open positions.

7.8.2 Motor Charging Time of the Closing Spring

After each closing operation, the motor will charge the closing spring. Once the spring is charged, the motor circuit is automatically interrupted by the motor limit switch. The position indicator for the closing spring will then show "spring charged."

Measure the motor charging time after a closing operation. Check the measured charging time against the reference values in the routine test certificate and enter it on the checklist.

7.8.3 Operating Times

The closing time is the time from the start of the tripping pulse to the point when the contacts touch. The opening time is the time from the start of the tripping pulse to the point when the contacts separate.

Attach test leads for measuring operating times to the pole columns of the circuit breaker and connect them to the measuring device. Carry out one closing operation and one opening operation while measuring the operating times. Check the measured operating times against the reference values in the routine test certificate and enter them on the checklist.


7.8.4 Manual Operation

To prevent accidental operation, the manual operating levers are locked by the lock-ing plate (14) and locking screws (15) (see Figure A 3.4.1 b).

Loosen the locking screws approximately one full turn and move the locking plate downward and to the left. Carry out one closing operation and one opening operation using the manual op-erating mechanism. Close the locking plate and secure it again with the locking screws. If the circuit breaker is operating properly, it will immediately carry out the opera-tions.

! Caution

When the manual operating mechanism is being used, one operation will be carried out by circumventing all electrical interlocks.

Always check the SF6 pressure before any manual op-eration.

7.8.5 Anti-Pumping System

The anti-pumping system guarantees that the circuit breaker will always reach the open position in situations in which both a closing and an opening command have been issued.

To check operation of the anti-pumping system, move the breaker first to the open position. While continuously applying an opening command, also give a closing command. If the circuit breaker is operating properly, it will execute only one closing operation and one opening operation.

For the next testing step, move the breaker to the closed position. While continuously applying a closing command, give also an opening command. If the circuit breaker is operating properly, it will execute only one opening opera-tion.

The anti-pumping system is automatically reset when there are no more operating commands.

7.8.6 Functional Lockout

Jumper the density monitor contacts at the terminal strip. Give one closing command and one opening command. If the circuit breaker is operating properly, it will not execute an operation.

Remove the jumpers from the terminal strip.

7.8.7 Final Tasks

Remove all testing and measuring equipment from the breaker. Clean up the erection site.

The breaker is ready to be connected to the high voltage system.


7.9 Handling and On-Site Testing of Current Transformers

7.9.1 Handling Current transformers (CTs) are designed as low-power transformers and are provided for the connection of electrical protective and measuring equipment under field condi-tions.

! Danger

To prevent hazards caused by high voltages, current trans-formers must never be operated with an open circuit or with fuse protection at the electrical terminals on the secondary side. One terminal on the secondary side must be securely earthed or grounded so that the earth potential (potential to ground) will be clearly defined.

Use extreme caution when handling current transformers in order to ensure that the insulation is not damaged and also that no additional electrical and mechanical loads are applied to the magnetic core material; such loads could have a negative effect on the magnetic properties of the core material over the long term. After these devices have been received, inspect them visually to make sure that they do not show any sign of external damage, including moisture.

7.9.2 On-Site Testing

The current transformers that are used have already undergone routine testing at the factory in compliance with applicable standards so that on-site testing can be reduced to a minimum. Check the devices for damage and make sure that the current transformers have been properly connected electrically on the secondary side and properly earthed (grounded). Further inspection and testing of current transformers in compliance with special cus-tomer specifications may include the following procedures:

Checking the terminal markings Testing the insulation property (dielectric strength) of the secondary winding Testing the current transformation ratio and the connected load Polarity testing Measuring the magnetizing current for protection cores

Such procedures are not included in our on-site inspection and testing program and may only be performed by experienced and trained technicians. Performance of these additional tests for current transformers also requires the avail-ability of special testing and measuring instruments on site.

! Danger

Current transformers must never be operated with open, un-earthed (ungrounded) secondary circuits.

Current in the primary circuit with an open secondary circuit gen-erates hazardous high voltages that will destroy the current trans-former and endanger the lives and health of personnel.

If it should become necessary to perform any of the tests listed above, then both the appropriate technical personnel and the proper testing and measuring equipment are available at our Product Service Center on request.


7.10 Mounting the Ice Guard

To mount the ice guard, proceed as follows: Attach the ice guard using the eight mounting screws four on the front and four

on the back.


8 Instructions for Troubleshooting the Control System

If operating commands are delayed or are not executed, proceed as follows:

Check the spring charging state. Measure the control voltage. Interrupt the control circuits. Check the SF6 pressure. Check the terminal connections to make sure they are tight and properly con-nected. Check the wiring against the schematic diagrams and correct, if necessary. Check the shunt releases and replace any defective coils after determining and eliminating the cause of any overload. Check any contactors located in the path of the faulty control circuit and replace them, if necessary.

If any defect is found in the SF6 density monitor, replace the monitor.


9 Inspection, Maintenance and Reconditioning

Inspection On an occasional basis during routine inspections, after 6 years at the latest. Maintenance After 12 and 24 years. Reconditioning After 2500 operations at rated normal current or after a total current as shown in Figure A 9.

! Caution

Under certain operating conditions, such as operation of reactors, capacitor banks (especially back-to-back condi-tions), and series gaps, reconditioning will be necessary af-ter fewer operations.

Circuit breaker maintenance may only be performed by qualified personnel, as described in Section 2.1.

Important

The time intervals given above are based on empirical values determined over many years of field experience. Regionally applicable standards and regulations may specify shorter intervals.

Training seminars are held on a regular basis at the manufacturer's plant. If neces-sary, technical personnel can also be requested at any time. Replacement of the arcing contacts is necessary if a total current (effective value of the short-circuit breaking current) is reached. Figure A 9 shows the relationship be-tween the number of operations under normal operating conditions and the breaking current.

Fig. A 9: Permissible number of CO operations (n) before replacement of arcing contacts as a function of the breaking current (I/kA)


Table of ContentsList of FiguresIntroductionGeneral InformationSpecial InstructionsSafetyGeneral Safety InstructionsSpecial Safety InstructionsHandling SF6 GasTransport and Handling at the Erection SiteTechnical DescriptionTechnical Data: HYpactTechnical Data: Spring Operating MechanismTechnical Data: Motor-Operated Mechanism of Disconnector-EarDesign and OperationSpring Operating MechanismType ME1-3 Motor-Operated Mechanism for Disconnector-EarthinCombined Mechanical Position IndicatorTransport and StorageTransportStoragePreparation for ErectionRequired DocumentsUsing the ChecklistChecklist for Erection and CommissioningMaterials and Equipment to be Provided by StationMaterialsHoisting EquipmentToolsOther Tools and EquipmentTesting and Measuring EquipmentAuxiliary Materials and SuppliesUnloading and Unpacking the Transport UnitsChecking the ShipmentCompleteness and Lack of DamageErectionGeneral InstructionsSupports on FoundationMounting the ModuleMounting the Circuit Breaker Drive RodAttaching the Mimic Diagram Mounting PlateMounting the Drive Rod of the Combination Disconnector-EarthSpring Operating MechanismHigh Voltage Terminal PadsEarthing (Grounding) the Circuit BreakerCommissioningConnecting the Density MonitorChecking the Contacts of the SF6 Density MonitorChecking the Anti-Condensation Heaters of the Circuit BreakeSupply VoltagesElectrical Operation Test of Type ME1-3 Motor-Operated MechaElectrical ConnectionSF6 SystemFilling the Breaker with SF6Functional TestingTest OperationsMotor Charging Time of the Closing SpringOperating TimesManual OperationAnti-Pumping SystemFunctional LockoutFinal TasksHandling and On-Site Testing of Current TransformersHandlingOn-Site TestingMounting the Ice GuardInstructions for Troubleshooting the Control SystemInspection, Maintenance and Reconditioning