FXT11 SF6 CIRCUIT BREAKER WITH BLR-XE SPRING OPERATING MECHANISM MANUAL A.D1014 v, GEC ALSTHOM __— e TaDCONTENTS TECHNICAL CHARACTERISTICS GENERAL DESCRIPTION OF THE CIRCUIT BREAKER DESCRIPTION OF THE CIRCUIT BREAKER SUB-ASSEMBLIES POLE OPERATION OPERATING MECHANISM SF6 MONITORING PACKING - TRANSPORT STORAGE, INSTALLATION FILLING WITH SF6 GAS INSPECTION BEFORE COMMISSIONING. MAINTENANCE MAINTANCE OPERATION DETAILS TOOLS AND ACCESSORIES TAGE EDA Wat A_07/94 A.DI011*) TECHNICAL CHARACTERISTICS Short time minimal temperature .. up to -25 «C Rated voltage up to 123 kV Rated normal current up to 2500 A Rated frequency .. 50 or 60 Hz Short time current (for 3 seconds) up to 25 kA. Rated dielectric withstand (at sea level) power frequency withstand voltage lightning impulse withstand voltage up to 230 kV up to 550 kV peak up to 25 kA Rated breaking capacity (symmetrical short-circuit) Rated short-circuit making current .. up to 62.5 kA peak Rated opening time 37 ms Total breaking time 60 ms Rated closing time 90 ms Rated operating sequence © - 0.3s - CO - 3min - CO or CO - 15s - CO Resistance of main contacts (new contact). < 40 po SF6 density rated eso 53.29 kg/m? first threshold ..... 48.86 kg/m? second threshold... 47.40 kg/m? Wie. effective pressure at rated... first threshold (P1) .. second threshold (P2) . SF6 mass for one three-pole circuit breaker .. - 6.4 bar (P2 +0.2 + 0.05 bar) on Auxiliary voltages (usual) opening and closing circui heating (and lighting) circuits motor 48 - 110 - 125 - 220 - 250 v= 220 V 48 - 110 - 125 - 220 - 250 v= or 220 V 50-60 Hz Consumption closing and opening i permanent heating oa ” thermostat heating (if temperature < motor “SC) THE ABOVE CHARACTERISTICS ARE GENERALLY VALID. ONLY THOSE VALUES GIVEN ON THE RATING PLATE OF THE CIRCUIT BREAKER ARE CONTRACTUALLY BINDING. TOE REV OTE TaNTAL al A_07/94 A.D1011GENERAL DESCRIPTION OF CIRCUIT BREAKER (fig 1) The circuit breaker is made up of three poles operated by means of a spring- operating mechanism. © The pole comprises : - An interrupting chamber (1) in a ce- ramic envelope, placed vertically. - A_ hollow insulating ceramic support column (2), through which passes an sulated operating rod, fixed to the mo- ving contact of the interrupting chamber. ~ At the base of the column, a housing (4) which encloses the rod/erank device for operating the moving contact. <=> —_ = [= B es @—. 2 =) => oc a> Ss BE BATE A 07/94 A.D10112.4 - Built-in safety devices (fig 15) © Opening always has priority over clo- CLOSED _ position, the latching disk (2) from turning, prevents the closing spring from being slackened again. sing. When the circuit breaker is already in a bolt (5) prevents which @ At the end of the closing operation, a bolt (44) correctly positions the disk (2) by the action of the cam (31). Proper cam (25) latching at the end of the closing spring reloading operation and correct positioning of the bolt (5) depend on this position. elf the latching disk (20) is not cor- rectly in place, the tie-tod (28) is bloc- Ked vertically ‘by its lower notch, pre- venting the disk (2) from tuming, and hence the circuit breaker from closing. a 15/41 Rev DATE TaeRT A 07/94 A.D1011fig 16 : Shown circuit breaker open, closing spring loaded. Tia TONE Naa 16/41 | A_07/94 A.D1011BEV DATE A_07/94 A.D1011SF6 MONITORING 1- DENSIMETER The density of SF6 gas is monitored using a densimeter fitted with 2 contacts (Pl) and (P2). This is placed inside the support beam. These contacts close one after the other if the volume of gas decreases, and they define two distinct thresholds. The contacts are cabled to the terminal block inside the cabinet and are usually left available to the utility for the follo- wing use : = the first threshold (PI) acts as a war ig (top-up necessary). 2.2. - APp, correction according to atmospheric pressure APp (bat) = 1.013 - Pay (bar) 2.3 - Calculation : an example Determining the filling pressure of the circuit breaker, rated pressure 7 bars, ambient temperature S°C, local atmo- spheric pressure 932 mbar. On the curve, fig 18, APt for SC = -0.51 bar APp = 1.013 - 0.932 = 0.081 bar = the second threshold (P2) is an alarm Pring 7 - 0.51 + 0.081 which must be used either to lock the = 6571 bar circuit breaker in position, or to cause an automatic opening. The option is chosen by the client according to ope- rating needs. ‘All rated performances are guaranteed up to the minimum specified ambient temperature and up to the second ‘threshold (P2). 2- MEASURING THE DENSITY When direct measurement of the density is not possible, this is inspected using an industrial pressure gauge which mea- sures effective pressure. A rated effective pressure, defined for normal atmospheric pressure (1013 hPa) and an ambient temperature of 20°C corresponds to the rated density. For each pressure measurement (filling, densimeter threshold —_inspection...), the effective rated pressure must be correc- ted according to the ambient temperatu- re at the time of measuring and the atmospheric pressure of the site. The real pressure is therefore : Pr * Pree + APt + APP 2.1 - APt, correction according to temperature The value for the correction is read di- rectly from the curve in fig 18. TRE TDA aR 18/41 | A_07/94 A.D1011fig 18 PRESSURE CORRECTION ACCORDING TO TEMPERATURE ke =, At -20 -10 Oe, +10) +20 61] 0,5 +15 0,31 FS 16,4 1,0 ‘I +10 16,4] i AS +05 BB 1 > oe +20 +30 +40 ‘+50 +60 apt ¥ FE TT BAF aA ig9/at_ | A_07/94 A.D1011PACKING - TRANSPORT During transport, the circuit breaker is uncoupled from’ the operating —mecha- nism. The spring control mechanism is vacuum packed in a reinforced plastic envelope containing dessicants. The effective SF6 filling pressure for transport and handling is 0.3 bar in the poles (20C - 1013 hPa). In all cases, the elements belonging to any one circuit breaker are packed in the same case, which prevents transit mistakes during transport. STORAGE Storage procedures defined below corres- pond to storage times not exceeding two years. For longer periods, special packing and procedures have to be stu- died. 1 SHORT STORAGE (AROUND 6 MONTHS) The equipment must be stored in its transport packaging, this being placed on beams in a place out of the reach of flooding. 2- MID-TERM STORAGE (LESS must be stored on transport packing ope- aired room out of ‘Number of breaker Packing case characteristics pa (fig 19) a ; "THAN 2 YEARS) 21 - Gireuit breaker Lenghth Lom | 390 | 390 ‘Width W cm | 100 | 190 The _ equipment Height HH om__| 310 | 310 beams with its Volume m 12 | 23 ned, in a closed, Gross weight G ke __|1300 |3250 the reach of flooding. ‘Special packaging is used for double- pole circuit breaker. 2.2- Operating mechanism The operating mechanism is stored in the same place as the circuit breaker, as it is not possible to separate these two sub-assemblies. Gastightness must be checked in vacuum. If the vacuum is deteriorated, proceed as follows : = The operating mechanism must be placed so as to ensure air intake through the ventilators laid out in the rear and side panels. = In order to prevent corrosion damage through formation of condensation water, the _anticondensation__cireuit__must plugged in To this end, 2 provisional cable shall be inserted" through the compression gland on the bottom panel and linked to the corresponding terminals. pressure of ith lifting tool Gig 2a TABE TT BE waa 20/41 | A_07/94 A.D1011INSTALLATIO) = Check that the concrete _ structures ‘conform to the circuit breaker drawings. = Open the packing case. Take out the operating mechanism being careful _not to damage the poles (lift the operating mechanism slightly to one side). = Put the interface and support frame- work packages aside if these are sup- plied by GEC ALSTHOM. * Check that the sub-assemblies are in good condition, and that the order num- bers for the operating mechanism and the poles correspond. 1- MOUNTING THE SUPPORT FRAMEWORK = If the support framework is supplied by GECALSTHOM, proceed as fol- ows : = Assemble each frame to the ground (Gig 20), fix the upper brackets (12) to the uprights (11), then the lower brac- kets (13). - Fix each support framework to the ground. Always allow at least one shim (18) at each fixing point, between the concrete and the lower bracket ( support framework must never rest di- rectly on the concrete). Use the was- hers (17) for tightening the support fra- mework (fixing kit N55010201). = Check that the top surfaces of the support framework are horizontal (max. allowable deviation : Smm/m). = Fit the cross-piece (19) on to the ‘Support framework on the operating me- chanism side only (for fixing the L.V. cables) (kit N5S010501). a 14 = SCREW H M10-30 15 = FLAT WASHER M10 16 = NUT H MIO 4 = SCREW H M10-30 15 = FLAT WASHER M10 16 = NUT H M10 TAGE 2/41 TARA A.D1011 TEV ORE A 07/942- ASSEMBLING THE CIRCUIT BREAKER ON THE SUPPORT FRAMEWORK - Fit the lifting tool on to the upper terminals as shown in fig 21. (This tool may be fitted in factory) fig 21 SCREW H M12-45 WASHER M12 = Put the sling on the circuit breaker, lift it up and place it on the support framework. Check the orientation of the revolving shaft, which determines the po- sition of the operating mechanism (never lift the circuit breaker without taking off the operating mechanism). - Fix the beam on to the support fra- mework (assembly kit N55010201). ~ Remove the lifting tool. > Check that there is gas in the poles (these are filled with gas for transport at the effective pressure of 0.3 bar at 20°C 1013 hPa) : Take off the valve protection (11) (fig 22). : Unscrew the plug (12). | Fit the filling tool (13), tightening the nut by hand. Unscrew the cap on the tool val- ve (13). Press the valve briefly: gas should escape. If no gas escapes, contact our after- sales service. - Leave filling tool in place for fur- ther filling (the cap (14) may be repla- ced). PGE 22/41 BEY DATE A_07/94 A.D10113- MOUNTING AND COUPLING THE OPERATING MECHANISM (fig 23) - Take off the packing protection from the operating mechanism. = Put a flexible sling on the operating ‘mechanism under the roof edge. = Lift the operating mechanism, offering up the fixing brackets (11) on the beam (12). During this operation, fit the rod (17) on to the lever (18). Do not put any grease on this joint. = Fit provisionally 2 screws (13) on each side of the beam (assembly kit NSS010101). - Fit the pins (16) to determine the fi- nal position of the operating mechanism. = Add the other two fixing screws and ighten up the assembly. = Block the retaining clip (20) with help from the thin washers (24), placing the- se between the rod (17) and was- her (19), in such a way that X amount of play is obtained - from 0.20 mm to.0.50 mm - between the retaining clip (20) and the washer (19). ‘SURE IS LOWER COND THRESHOLD. fig 23 13 = SCREW H M10-30 14 = WASHER Mio isenurMio | FACE EV ONE TAROT 23/41 A_07/94 A.D10114- CONNECTING THE SF6 DENSIMETER Connect up the cable wires of the SF6 densimeter to the operating mechanism terminal, as per the specific electrical diagram. 5- HIGH VOLTAGE CONNECTION Before coupling the H.V. connectors, prepare the contact surfaces as follows : = Dry rub with fine emery cloth. = Clean carefully to remove the resultant dust. = Spread thinly with electrical contact grease (see below). = Rub over the grease with A400 water- proof abrasive paper. = Assemble immediately. CONTACT GREASE The electrical contact grease must be made up of a mixture of : = 50% neutral vaseline (01835106), = 50% contact grease (-01835118). To ensure that the mixture is clean, it should preferably be prepared and kept in tubes. A. small quantity of the mixture must be placed on the surface to be grea- sed, spread out and finally wiped with a clean cloth, in order to leave a thin film of grease on the surface. PAGE 24/41 A 07/94 WAROAL A.D1011 aFILLING WITH SE6 GAS ig 24) OWING TO THE DANGER INVOL- YED WHEN TRANSPORTING POR- CELAINS, ALL PERSONS PRESENT. DURING GAS FILLING MUST BE UNDER SHELTER OR RESPECT A MINIMUM SAFETY DISTANCE, (ABOUT 50m). ~ Prepare the filling equipment : + Fit the pressure reducing valve (3) to the gas bottle (1). . Briefly open the bottle tap (2) and the handle (8) of the pressure re- ducing valve to get rid of the air contained inside the pipe (about 20s at ow flow rate). + Close the tap (2) and connect the ipe (4) to the filling tool (5), already fitted during inspection for SF6. > Calculate the filling pressure according to the temperature and the local atmo- spheric pressure (see page 19). Filling will be to the calculated pressure, plus 0.1 bar. = Open the gas bottle tap (2) and use the pressure relief valve (3) to obtain a low flow rate. + Close the gas bottle tap (2) from time to time in order to read the pres- sure on the gauge (9). Continue filling up to the required pressure, then close valves (2) and (8) in that order. - Confirm the reading by fitting the 0.16 bar pressure gauge (10) to the tool (5) in place of the pipe (4). Keep the open end of the pipe (4) high up so that the SF6 gas does not escape and to prevent damp air from entering. - When the desired pressure is confir- med, remove the pressure relief valve and the pipe and store them in a dry place. ~ Remove the filling tool (5) and put back on the plug (12 - fig 22). NOTE: The quantity of gas necessary for filling is given in the technical cha- acteristics. (CHECKING THE PRESSURE After allowing the temperature to stabili- ze for at least 12 hours following filling, it is necessary to check and adjust. the Pressure to its corrected value, as defi. ned according to the ambient tempera. ture and the atmospheric pressure, + Fit the filling tool (5) and connect the 0...16 bar pressure gauge (10). + If the measured pressure is too high, adjust the pressure with the _ pressure gauge valve to reach the required cor. rected pressure. If, on the other hand, the pressure is too low, topping up is necessary. Pressure adjustment must not exceed 0.5 bar; otherwise it would be necessary to cary out a further inspec- tion after a stabilizing time of 2 to 3 hours ~ Remove the filling tool (5) and put back on the plug (12 - fig 22), using a tightening torque of 4 daN.m (flat 50 spanner). Tightness is guaranteed only if, this condition is observed. PROE 25/41 EE A_ 07/94 A.D1011 26INSPECTIONS BEFORE CO! SIONNING The circuit breaker is assembled and tested entirely in-factory. In situ inspection after installation is therefore minimal = Check that assembly conforms to the instructions in the manual. = Check the gastightness of the SF6 fil- ling cap, using a leak detector. - Check the power supply of the LV. circuits of the operating mechanism. = Connect up the motor, allow it to re- load the closing spring and carry out 5 CO cycles. OWING TO THE DANGER INVOL- VED WHEN TRANSPORTING _POR- CELAINS, ALL PERSONS PRESENT DURING THE FIRST OPERATIONS MUST BE UNDER SHELTER OR RESPECT A MINIMUM SAFETY DISTANCE (ABOUT 50m). - Check that the permanent heating in the operating mechanism. = Note the number on the operation counter. 26/41 BEV DaTE A_07/94 A.D1011MAINTENANCE FXT circuit breakers use SF6 as an are extinguishing medium and require only very little maintenance. 1- MAINTENANCE PLAN In normal operating conditions, the maintenance plan may be defined as follows : L.1- Periodic visual checking At least once a year. It is not necessa- ry to shut down the circuit breaker. 1.2 - Inspections Every five years, Inspection necessitates the shutdown of the circuit breaker. It is not necessary to take apart the inter- rupting chambers and the other sub- assemblies. 1.3 - Servicing Service when one of the following crite- ria is reached : - operating time > 20 years ~ number of mechanical cycles > 3000 ~ electric wear : see 1.4 or 1.5 For circuit breakers which are used only very rarely, it is advised to cary out in addition at least 2 CO cycles per year to check that the circuit breaker and its related control circuits are operating cor rectly. kA) 25) 16 10 120-39 30100 1.4 - Limit of electrical _wear (see 1.5) Electrical wear can be determined by means of the curve below. The curve corresponds with the formula : ENF = 12500 kA? (constant) (N = number of interruptions made at the value 1). Example: it is possible to ensure 48 interruptions at the current 16 kA. 300 1000 3060 "Number of interruptions 27/41 REY BATE A_ 07/94 A.D1011 ww1.5 - Interrupting contact wear ‘measurement When limit of electrical wear can not be determined as described in para- graph 1.4, it is possible to estimate the interrupting contact wear by comparison of the X dimension, as described _abo- ve, with the X value measured in facto. ry on the circuit breaker in new condi. tion. Proceed as follows = Disconnect the C.B. from the net. work, and release springs in the control ‘mechanism. = Disconnect the rod, removing the split pin (20), washer (19), see figure 23. = Fit the tooling ‘lever (11) onto the C.B. lever (12), fig 25. = Fit the tool (21) as per figure 25, using 3. screws (22). Screw (23) must be unscrewed. = Put an indicating lamp on pole 1 = Close the pole, using lever (11) damp switches on). Screw the screw (23) until lamp switches off. + Measure and note dimension X1. - Proceed identically, connecting lamp on pole 2 then 3. Measure and note dimensions X2 and X3. As contacts wear increases, dimension Xl, X2, X3_ decreases. Compare the measured dimensions X with those mea- sured during factory tests of circuit breaker. The initial value is engraved on housing at each pole base. variation _(Xinitial_- _ Xmeasured) ‘must not exceed 29 mm. 2B 2 fig 25 > i TE DATE A_07/94 A.D1011 »2- MAINTENANCE OPERATIONS . PERIODIC VISUAL CHECKING : INSPECTION : SERVICE (OPERATING TIME) : SERVICE (MECHANICAL OPERATIONS) SERVICE (ELECTRICAL WEAR) 1 Operation counter reading. + Overall check : appearance (corrosion, paintwork, signs of heating). I Check operation of permanent heating. Check ventilators. If the circuit breaker is fitted with a permanent SF6 pressure gauge, : 1 1 check that the needle is in the green area (crossing of the needle and temperature circle). Check SF6 densimeter thresholds. Then adjust pressure to its rated value. Check arcing contact wear (if necessary, see 1.5). MH: Check tightening of parts not subject to pressure (framework - ’ + deck - cabinet). ‘Check tightening of low voltage terminals (* 6 months after ‘commissionning).. . Check relay operation. ' Check latch operation. . Lubricate gear wheels, chains, operating axles, runners, springs. . Check motor drive belt, change it if necessary. Change opening stop. Change door seals, side pannel seals and roof seals. Measure operating times for poles and auxiliary contacts. Carry out operations at recommended cycles and at rated voltage. e Replace (or repair) interrupting chambers. PAGE TE DATE ARUAT 29/41 | A 07/94 D1011VASELINE OIL SAE 90 OIL © 8 View F fig 31 A.D1011 REY DATE A_ 07/94 PAGE 34/414.2 - Motor removal and replacement (fig 32) - Open the C.B. and release springs. = Remove fuses or open the CB. in motor circuit. - Remove the left-hand side panel (20) of the operating mechanism. - Disconnect the wiring. ~ Remove nuts (12) and washers (13). - Take out the motor (11). = Replace the motor by one with the same reference, motor is normally sup- plied with its notched wheel (14) and plate (16). - Put back and fix the assembly on to the operating mechanism using the nuts (12) and washers (13). Take care to place the belt (15) on the small notched wheel (14). 1S ge ee eae = Before blocking, check the correct fle tension in the belt (15). a FASE Teo TROT 35/41_ | A 07/94 A.D1011 a24.3 ~ Motor drive belt replacement (fig 33) ) = Open the C.B. and release springs. - Remove fuses or open the C.B. in motor circuit. - Remove the lefthand side panel of the operating mechanism. - Remove the motor, —_unscrewing nuts (12) and washers (13). - If applicable, remove the voltage re- Tease electromagnet. - Tum the cam (22) in top neutral point position (PMH), using the crank if necessary. ~ Fit the tool (17) : + Insert the rod (17) under the le- ver (21), Put the strap (17a) onthe part (26) and screw the mut (I7b) to position the rod (17) and maintain the lever (21). - Put the cam (22) in low neutral point position (PMB) turning the wheel (24). - Remove screw (27) and spacer (16) ~ Remove the worn belt. - Insert a new belt (15) between the plate and the pin, in point (A). - Position the belt (15) on the notched wheel (24). - Put back the spacer (16) and screw (14) (Stick the screw using LOC- TITE 262) + check the good position of the belt (15) on the noched wheel (24) and through columns (25). - Put back motor (11) using nuts (12) and washers (13). Take care to place the belt (15) on the small notched wheel (14). Before blocking, check the correct tension in the belt. 9 - Tum the cam (22) in top neutral point position (PMH). - Unscrew the nut (17b) and remove the tool (17). = Put back parts which were removed before (voltage release electromagnet...) - Put back the side panel of the ope- rating mechanism. 36/41 | A 07/94 A.D1011 334.4 - Closing oF o et fig 34 replacement > (oltage release electromagnet) CLOSING |] | (Gig 34) gap 2 mm "oy The electromagnets are accessible by re~ moving the left-hand side panel. The electromagnet support brackets (I) are factory fixed with pins (12) so as to ensure the correct stroke of the elec- tromagnets. rea = To replace an electromagnet : = Disconnect the wiring. ue - Remove the 2 fixing screws (13). - Replace the electromagnet with one of | -—————___, the same type. Stick the screws (13) | [TRIPPING | te with LOCTITE 262. Sy sap 2 mms __, = Connect the wiring. 1B NOTE: The support bracket (Il) is 9 pinned after adjusting to a gap of 2 mm. u The screw (14) is adjusted so. that the stroke of the core of the electromagnet is limited to 1lmm. srokes 4 1 coil 2 coils race aaa Ta 37/41_| A 07/94 A.D1011 34.5 - Replacing an opening electromagnet (voltage loss electromagnet) (fig 35). The electromagnet support brackets (11) are fixed and pinned (12) in factory so as to ensure correct electromagnet tra- vel To replace an electromagnet : Disconnect the wiring - Remove the two nuts (13) and the - Replace using an electromagnet with the same part number. Screw the rod (15) tightly into the core (16), pu- ting back the nuts and washers as shown in the diagram (fig 35). = Refit the coil (18) on to the support bracket (11), fit the core (16), taking care that the washer (19) is in place. Screw the assembly together with the screws (13). = Compress the spring (20) to keep the split pins (12). core against the stop. Check the 2mm ~ Remove the two screws (14) to free gap between the screw head and the the coil (18) (NOTA: These two srews bracket (22). When this gap is obtai- are stuck with “Loctite” during assem- ned, tighten and pin the bracket (11) bly.) once more. - Unscrew the core (16) rod (15). fig 35 is 2 16 ¥ i iu 19 g | ae & 2 14 2 2 if Fo ia 38/41 WEY BATE A_07/94 A.D10114.6 - Opening stop replacement (ig 36-37) The stop is accessible by removing the right-hand side panel, and the roof. To remove the stop, it is first neces- sary to remove the opening spring res- traint (fig 36) = = Make a mark A on the head of the screw (11) and on the fixed part (12). = measure and note down the dimension @. ~ Cut the metal wire (13), = Unscrew the screw (11) until the spring (14) is free. © Change the stop (fig 37): fig 37 2 = Remove the 2 CHC M6 screws (Il) and the nylstop nuts (12). = Replace the rubber plate (13), the plate (14) and the 2 plates (15). + Put back 2 new screws (Il) and 2 nuts (12). The screws (Il), once tighte- ned, must Ieave a gap of about 0.5mm between the plate (14) and the body of the stop. @ Put back the spring restraint (fig 36): «Screw in the serew to obtain the inti tial dimension (Z). Adjust. the rotation of the screw (11) bby making the marks (A) coincide. + Stop the screw (11) from turing with a galvanized wire (13). 13, 14 gap 0.5 mm 15 u TAGE REV DaTE 39/41_| A_07/94 A.DI011