Instruction Booklet IB02101001E Effective October 2009 ...

ContentsDescription Page

1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22: Receiving, Handling, and Storage . . . . . . . . . . . 43: Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54: Inspection Before Start-up . . . . . . . . . . . . . . . . 95: Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106: Maintenance and Troubleshooting . . . . . . . . . . 107: Bolt Torque Values . . . . . . . . . . . . . . . . . . . . . . 158: Renewal Parts Information . . . . . . . . . . . . . . . 16

Effective October 2009Instruction Booklet IB02101001E

Instructions for Installation, Operation, and Maintenance of the Eaton 15 kV Single Phase Enclosed Generator Breaker

2

Instruction Booklet IB02101001EEffective October 2009


EatOn COrPOratIOn www.eaton.com

Section 1: IntroductionRead and understand these instructions before attempting any instal-lation, operation, or maintenance of this switchgear .

1.1 Purpose

This instruction book is expressly intended to cover the installa-tion, operation, and maintenance of the 15 kV 5000 A Single Phase Enclosed Generator Breaker . It does not purport to cover all possible contingencies, variations, and details that may arise during installa-tion, operation, or maintenance of this equipment .

If further information is desired by the purchaser regarding this par-ticular installation or application information, contact the local Eaton Corporation sales office and review the appropriate industry stan-dards .

1.2 Application and Description

The 15 kV Single Phase Enclosed Generator Breaker assembly is specially designed to function properly when placed electrically between two large inductive pieces of equipment such as a genera-tor and a step up transformer . If needed, optional surge capacitors can be added to the assembly to adjust the Transient Recovery Voltage (TRV) response of the system . This assembly can be used to protect 20 to 100 MW, 5/15 kV single phase generating systems . It provides clean, green protection eliminating the use of potentially environmentally harmful substances like SF6 gas and oil . It provides a much greater mechanical endurance life of 5,000 operations when compared to traditional oil circuit breakers that only had 10% to 25% of this capability .

The 15 kV, 5000 A, Single Phase Enclosed Generator Breaker con-sists of metal enclosed switchgear as defined in industry standard Institute of Electrical and Electronic Engineers (IEEE) C37 .20 .3 . The system contains a fixed mounted breaker installed in an enclosure with a bus system connecting the breaker to roof bushings . When current transformers are required, they are mounted on the internal side of the roof bushings . The enclosure is a ventilated enclosure . An internal control box is mounted in the left side of the enclosure for customer secondary connections .

The 15 kV Single Phase Enclosed Generator Breaker bus system is assembled using maintenance free hardware that does not require re-torquing during the life of the equipment . The through hardware used in the bus system utilizes the patented SpiralockT thread lock-ing technology .

The only exception is where the bus system bolts to the rear of the breaker . Presently, the copper castings still use a standard thread . This connection should be checked on a yearly basis to verify tight-ness .

1.3 Revision Level

Revision level is 1 . This is a new document .

1.4 Documentation References

For further information on application, refer to the applicable descrip-tive bulletins, publications, and/or industry standards .

Download Eaton Corporation’s information from www .eaton .com . Also download IB 68C5043-latest version “Instructions for the Use, Operation and Maintenance of VCP-WG / VCP-WRG 75 kA Vacuum Circuit Breakers” .

1.5 Eaton Corporation Contact Information

To reach an EatonCare representative for customer and sales sup-port, please contact us: 877-ETN-CARE (877-386-2273) or log onto www .eaton .com .

Eaton’s Electrical Services and Systems (EESS) team can be reached at 1-800-498-2678, 24 hours/day and 7 days a week .

Prior to contacting Eaton, have the following information available:

1 . General order number (G .O .) or shop order number (S .O .);

2 . Location of the installation; and

3 . Date of manufacture .

1.6 Safety Precautions

WARNINGONly quAlIfIed electRIcAl WORkeRs WIth tRAINING ANd expeRI-eNce ON hIGh vOltAGe cIRcuIts shOuld be peRmItted tO WORk ON thIs equIpmeNt. they shOuld be fAmIlIAR WIth the WORk tO be peRfORmed, the sAfety equIpmeNt RequIRed, ANd hAzARds INvOlved.

1 . Read and understand these instructions before attempting any installation, operation, or maintenance of the 15 kV Single Phase Enclosed Generator Breaker .

2 . Disconnect all low voltage and medium voltage power sources before working on the equipment per Occupational Safety and Health Act (OSHA) and local lockout and tag out procedures . Verify voltages have been removed, ground both load and line side connections . Observe the National Fire Protection Association’s (NFPA) Publication #70 that is commonly known as the National Electrical Code (NEC), #70E that is commonly known as the standard for Electrical safety in the workplace, OSHA, and local procedures and standards . This includes visual inspec-tions while the equipment door is open, making any adjustments inside or outside the switchgear, performing maintenance, or installing replacement parts .

dANGeRAll ApplIcAble sAfety cOdes, sAfety stANdARds, ANd sAfety ReGulAtIONs must be stRIctly AdheRed tO WheN INstAllING, OpeRAtING, OR mAINtAINING thIs equIpmeNt. fAIluRe tO fOllOW these INstRuctIONs cAN Result IN deAth OR seveRe INjuRy. WhIle eNeRGIzed, AN ARc flAsh ANd shOck hAzARd exIsts. cONsult NfpA 70e ANd OshA GuIdelINes fOR OpeRAtOR sAfety pRIOR tO seRvIcING, INspectING, OR OpeRAtING equIpmeNt.

3 Never try to disconnect or open the secondary circuit of a current transformer that is carrying load current . In this situation, the transformer develops a dangerous high voltage .

3




Before energizing the 15 kV Single Phase Enclosed Generator Breaker:

4 . Make sure the 15 kV Single Phase Enclosed Generator Breaker is securely fastened to a surface that is level within ± 0 .125 in . in 36 in . (3 .2 mm in 914 .4 mm) front to rear, left to right, and diagonally .

5 . Always be sure that all hardware is in place and torqued per Section 7 before putting the 15 kV Single Phase Enclosed Generator Breaker into operation (see Section 3) .

6 . Confirm that all insulating barriers are installed .

7 . Confirm that no tools or other objects are left inside the equip-ment .

8 . Confirm that all devices, doors, and covers are in place .

1.7 Switchgear Identification

A nameplate is located on the outside the main front access door of the 15 kV Single Phase Enclosed Generator Breaker (see Figure 1) . Contained on this nameplate are the Eaton Corporation product ratings . This information should be given to the Eaton Corporation sales office if a question should arise concerning the switchgear or if renewal parts are required . This information is sufficient for Eaton Corporation to find the manufacturing information for the switchgear .

Figure 1. Typical Nameplate.

WARNINGexceedING NAmeplAte RAtINGs Of the 15 kv sINGle phAse eNclOsed GeNeRAtOR bReAkeR cOuld cAuse pROpeRty dAmAGe, seveRe INjuRy, OR deAth.

the system must be OpeRAted WIthIN Its NAmeplAte RAtINGs.

1.8 Safety Features

The 15 kV Single Phase Enclosed Generator Breaker has several built-in features to reduce hazards and to provide proper operating sequences .

1 . Facilities are provided for padlocking the doors closed .

2 . Mechanical indicators show whether the switch mechanism is OPEN or CLOSED .

1.9 Ratings and Standards

Table 1. 15 kV Single Phase Enclosed Generator Breaker Voltage and Frequency Ratings, RMS Values.

description 15 kv

Rated Maximum Design Voltage 15 kV

Impulse Withstand Voltage, BIL* 95 kV

Low Frequency Withstand Voltage 36 kV

Rated Frequency 25 Hz

* Basic Impulse Level (BIL)

Table 2. 15 kV Single Phase Enclosed Generator Breaker Main Bus Current Rating.

for the main bus continuous current Rating 5000 A

Related Capability Rating

Momentary Current Rating, 210 kA Peak 210

Rating (10 Cycles), 120 kA RMS Asym. 128

Short Time Current Rating, 1 s, 80 kA RMS 80

Table 3. 15 kV Single Phase Enclosed Generator Breaker Standards.

standards document

Underwriters Laboratory (UL) or Canadian Standards Association (CSA) Listing to:

ANSI/IEEE C37.20.3ANSI C37.57

Additional Applicable Standards: IEEE C37.04IEEE C37.09IEEE C37.013IEEE C37.013aNEMA SG-4

4




Section 2: Receiving, Handling, and Storage2.1 Receiving

A visual inspection - inside and out - should be performed immedi-ately upon receipt of the 15 kV Single Phase Enclosed Generator Breaker before removing it from the truck . Shipping papers should be checked to be sure all boxes or other accompanying pieces have been received . If any damage or shortages are evident, a claim should be filed at once with the carrier and the nearest Eaton Corporation office notified .

The data nameplate for each 15 kV Single Phase Enclosed Generator Breaker is located on the main front access door . The General Order (G .O .) number from the nameplate should be given to the Eaton Corporation representative whenever identification of the equipment is required .

2.2 Handling

The base of the 15 kV Single Phase Enclosed Generator Breaker is designed to accept the forks of a fork truck . This is the recommend-ed method for moving the equipment (see Figure 2) .

otee:N If a fork truck will be used to move the equipment, all of the front or rear louver covers, depending on whether the forks will be inserted from the front or the rear of the equipment, will have to be removed to prevent dam-age to the louver covers .

Figure 2. Location of the Fork Pockets, Lifting Lugs, and Jacking Pads (Rear View Shown).

Four lifting lugs are provided on the bottom of the 15 kV Single Phase Enclosed Generator Breaker for location of hooks to lift the complete structure (see Figure 2) .

otee:N If vertical lifting is required, the lifting should be as close to vertical as possible . An angle of no more than 10-15 degrees should be maintained away from obstructions such as a conduit and control cabinet .

The 15 kV Single Phase Enclosed Generator Breaker will be provided with four jacking pads to aid in lifting or leveling the equipment (see Figure 2) . Also, these will allow someone to jack and roll the unit into place for low overhead clearance installations .

These are the only recommended methods of moving the equip-ment . Extreme care should be used not to damage or deform the equipment if other moving methods are employed .

The typical weight for the 15 kV Single Phase Enclosed Generator Breaker assembly is approximately 11,500 lbs . (5216 kg); however, this can change depending on which optional features have been purchased . Consult the specific project drawings for exact weights .

2.3 Storage

If it is necessary to store the equipment before installation, keep it in a clean, dry location with ample air circulation and heat to prevent condensation . Like all electrical apparatus, these units contain insu-lation that must be protected against dirt and moisture .

Outdoor assemblies may be stored outside only if the space heaters are energized and any openings are closed . See the supplied wiring diagrams for details concerning energizing the heaters .

Fork Pockets

Lifting Lugs and

Jacking Pads

5




Section 3: Installation3.1 Preparing for Installation

3.1.1 access to the 15 kV Single Phase Enclosed Generator Breaker

Each 15 kV Single Phase Enclosed Generator Breaker is shipped from the factory with the circuit breaker contacts OPEN and the closing springs DISCHARGED .

In order to gain access to the interior, be sure the equipment is on a true and level surface (defined as ± 0 .125 in . in 36 in . [3 .2 mm in 914 .4 mm]) front to rear, left to right, and diagonally .

When handling the 15 kV Single Phase Enclosed Generator Breaker, be sure the circuit breaker contacts are OPEN and the closing springs are DISCHARGED . Do not operate the equipment unless it is setting on a true and level surface .

3.2 Installing the 15 kV Single Phase Enclosed Generator Breaker

3.2.1 Preparing the Installation Site

Eaton recommends the preparation of a true and level concrete pad at the installation site that is of sufficient size and strength to accommodate the 15 kV Single Phase Enclosed Generator Breaker . True and level is defined as level within ± 0 .125 in . in 36 in . (3 .2 mm in 914 .4 mm) front to rear, left to right, and diagonally, measured at any point beneath the supporting framework of the equipment .

NOtIceAll INstAllAtION sIte pRepARAtIONs must fOllOW ANd cONfORm tO All ApplIcAble stAte, ReGIONAl, ANd lOcAl cOdes.

The base of the 15 kV Single Phase Enclosed Generator Breaker provides two hold-down points on each side of the enclosure . The diameter of the hold-down points are 0 .75 in . (19 .05 mm) . Refer to the supplied drawings for specific hold-down clamp locations when preparing the installation site .

otee:N It is the responsibility of the customer and/or installer to insure that the installation site is prepared following and conforming to all state, regional, and local codes .

The installation site must provide sufficient clearance to allow proper air follow through the louvers of the equipment . The installation site should be clear of any vegetation or debris that could clog or restrict airflow .

otee:N Reduced airflow could cause heat build-up within the equipment result-ing in decreased performance and capacity of the equipment .

Figure 3. Typical Location of the Intake and Exhaust Louver Covers.

Front View

Exhaust Louver Cover

Intake Louver Covers

Rear View

Exhaust Louver Cover

Intake Louver Cover

6




3.2.2 Moving the Equipment to the Installation Site

1 . Move the 15 kV Single Phase Enclosed Generator Breaker to the installation site using one of the handling methods detailed in Section 2 .2 - Handling .

2 . If a fork truck will be used to move the equipment, depending on whether the forks will be inserted from the front or the rear of the equipment, all of the front or rear louver covers will have to be removed to prevent damage to the louvers (see Figure 3) .

A . Determine if the fork truck will lift the equipment from the front or rear .

B . Remove and save the hardware securing the intake (lower) and/or exhaust (upper) louver covers and remove the covers .

C . Move the equipment to the installation site . Care should be taken not to damage the door handle if the equipment is moved from the front .

D . After the equipment has been set in its final installation posi-tion (see Section 3 .2 .3), use the original hardware to reinstall the intake and/or exhaust louver covers .

3.2.3 Securing the Equipment at the Installation Site

1 . If provisions have been made to utilize the hold-down points provided with the equipment (see Figure 4), align the equipment with the hold-down bolts in the installation pad .

2 . Carefully lower the equipment onto the hold-down bolts and Installation pad . Secure the equipment to the installation pad using the appropriate hardware . The diameter of the hold-down holes is 0 .75 in . (19 .05 mm) .

otee:N It is the responsibility of the customer and/or installer to insure that the method/hardware used to secure the equipment at the installation site con-forms to all state, regional, and local codes .

Figure 4. Location of the Hold-down Points in the Base of the Equipment.

Hold-down Clamp/Bolt Hole

3.3 Grounding the 15 kV Single Phase Enclosed Generator Breaker

WARNINGONly quAlIfIed electRIcAl WORkeRs WIth tRAINING ANd expeRIeNce ON hIGh-vOltAGe cIRcuIts shOuld be peRmItted tO WORk ON thIs equIpmeNt. peRsONNel shOuld be fAmIlIAR WIth the WORk tO be peRfORmed, the sAfety equIpmeNt RequIRed, ANd hAzARds INvOlved.

The customer-supplied ground cables are to be connected to the 15 kV Single Phase Enclosed Generator Breaker via the stainless steel, NEMA, 4-hole ground pads . The ground pads are located on oppo-site sides of the equipment base (see Figure 5) .

Figure 5. Typical Location of the Ground Pads in the Base of the Equipment.

WARNINGAll GROuNd cAble cONNectIONs tO thIs equIpmeNt must be mAde fOllOWING All INdustRy stANdARds. fAIluRe tO dO sO mAy Result IN dAmAGe tO the equIpmeNt ANd cAuse seveRe peRsONAl INjuRy OR deAth.

Ground connections to the ground pads MUST be made using cus-tomer-supplied ground cables and appropriate connectors .

1 . Following all applicable industry codes and standards, connect the customer-supplied ground cable to both of the ground pads provided in the base of the equipment .

Ground Pad

7




3.4 Vacuum Interrupter Integrity

Conduct a vacuum interrupter integrity check as described in Section 6 .4 .

3.5 Connecting the High-voltage Primary Power Cables

WARNINGONly quAlIfIed electRIcAl WORkeRs WIth tRAINING ANd expeRIeNce ON hIGh-vOltAGe cIRcuIts shOuld be peRmItted tO WORk ON thIs equIpmeNt. peRsONNel shOuld be fAmIlIAR WIth the WORk tO be peRfORmed, the sAfety equIpmeNt RequIRed, ANd hAzARds INvOlved.

The 15 kV Single Phase Enclosed Generator Breaker is furnished with four (4) roof bushings (two input and two output terminals [see Figure 6]), that have a NEMA six hole pad on top .

Figure 6. Location of the Input and Output Terminals Located on the Roof of the Equipment.

The pole and bushing location information is shown in Figure 7 .

Front

Load Side Terminals of Circuit Breaker

(To Bottom of Breaker)

Line Side Terminals of Circuit Breaker

To Top of Breaker) Figure 7. 15 kV Single Phase Enclosed Generator Breaker Phase Orientation.

WARNINGAll hIGh-vOltAGe cAble cONNectIONs tO thIs equIpmeNt must be mAde fOllOWING All INdustRy stANdARds. fAIluRe tO dO sO mAy Result IN dAmAGe tO the equIpmeNt ANd cAuse seveRe peRsONAl INjuRy OR deAth.

1 . Route the high-voltage input cables to the 6 hole NEMA Pads on the two load terminals on the roof of the equipment . Connect the high-voltage load cables to the load terminals .

2 . Route the high-voltage line cables to the 6 hole NEMA Pads on the two line terminals on the roof of the equipment . Connect the high-voltage line cables to the line terminals .

Front

Pole 2 Bushing No . 3




8




3.6 Connecting the Customer-supplied Secondary Control wiring

Each 15 kV Single Phase Enclosed Generator Breaker is custom built to customer specifications for the secondary control wiring . All customer secondary control wiring connections will be made in the secondary control box located on the internal left side of the equip-ment (see Figure 8) .

Figure 8. Secondary Control Box Supplied with the Equipment.

WARNINGAll secONdARy cONtROl WIRING cONNectIONs tO thIs equIpmeNt must be mAde fOllOWING All INdustRy stANdARds. fAIluRe tO dO sO mAy Result IN dAmAGe tO the equIpmeNt ANd cAuse seveRe peRsONAl INjuRy OR deAth.

1 . Insure that all power to the 15 kV Single Phase Enclosed Generator Breaker (both primary and secondary) has been turned off and locked out following facility approved procedures .

2 . Open the secondary control box door .

3 . Route and secure all customer-supplied secondary control wiring to the secondary control box .

WARNINGAll secONdARy cONtROl WIRe ROutING ANd cONNectIONs must be mAde fOllOWING All INdustRy stANdARds. fAIluRe tO dO sO mAy Result IN dAmAGe tO the equIpmeNt ANd cAuse seveRe peRsONAl INjuRy OR deAth.

4 . Follow the detailed wiring diagrams supplied with the equipment to connect the customer-supplied secondary control wiring to the terminal blocks within the secondary control box .

3.6.1 Connecting Control and auxiliary Power

The 15 kV Single Phase Enclosed Generator Breaker assembly is designed to utilize 125 Vdc for the control circuits and 120 Vac for the auxiliary circuits that is to be provided by the customer . The aux-iliary circuit elements would encompass the heaters used to control condensation . Fused circuit protection is standard in both ac and dc circuits .

1 . Insure that all primary power to the 15 kV Single Phase Enclosed Generator Breaker has been turned off and locked out following facility approved procedures .


3 . Route and secure the required ac voltage to the pertinent termi-nal blocks based on the project specific wiring diagrams .

4 . Route and secure the required dc voltage to the pertinent termi-nal blocks based on the project specific wiring diagrams .

5 . These connections should be doubled checked to ensure that the ac and dc circuits are terminated correctly . If not, control compo-nent damage could occur in the system when energized .

3.6.2 Connecting the Customer Ordered Current transformers (Cts)

The customer ordered current transformers (CTs) with the 15 kV Single Phase Enclosed Generator Breaker have been factory installed on the internal side of the roof bushings . The roof bushings have an internal shield that controls the voltage gradient on the CTs (see Figures 9 and 10) . The CT wiring for customer connection has been routed to the secondary control box .

Figure 9. Possible Locations for the Optional CTs.

Secondary Control

Box

CT Locations

9




Figure 10. CT Installed in the Equipment.

WARNINGAll secONdARy WIRING cONNectIONs tO thIs equIpmeNt must be mAde fOllOWING All INdustRy stANdARds. fAIluRe tO dO sO mAy Result IN dAmAGe tO the equIpmeNt ANd cAuse seveRe peRsONAl INjuRy OR deAth.

The customer-ordered current transformers (CTs) that were supplied with the 15 kV Single Phase Enclosed Generator Breaker, require the following steps to be completed .



3 . Route and secure customer-supplied CT wiring to the secondary control box .

WARNINGAll secONdARy cONtROl WIRe ROutING ANd cONNectIONs must be mAde fOllOWING All INdustRy stANdARds. fAIluRe tO dO sO mAy Result IN dAmAGe tO the equIpmeNt ANd cAuse seveRe peRsONAl INjuRy OR deAth.

4 . Refer to the detailed wiring diagrams supplied with the equip-ment to connect the customer CT wiring to the appropriate ter-minal blocks within the secondary control box .

Section 4: Inspection Before StartupEach 15 kV Single Phase Enclosed Generator Breaker is properly assembled at the factory before shipment . However, vibration and mechanical stresses imposed by transit and installation can adverse-ly affect non-maintenance free hardware . Therefore, a final inspec-tion is essential before energizing .

1 . Check all non-maintenance free hardware bolted bus connections for proper tightness, referring to Section 6 for the procedures to access the bolted bus to breaker connections and Section 7 for torque values .

2 . Check to see if the space heaters are energized .

3 . Wipe away any dust or dirt that may have accumulated in compartment(s), paying particular attention to insulators and insu-lating material .

4 . A final thorough inspection should be made to ensure that no tools or other objects are accidentally left on or inside the enclo-sure .

10




Section 5: Operation5.1 Alarms

The alarms described in the following section are designed to alert the facility of problems within the 15 kV Single Phase Enclosed Generator Breaker .

5.1.1 Local/remote Switch Position Indication

The 15 kV Single Phase Enclosed Generator Breaker is supplied with a dry contact that monitors the position of the local/remote switch (see job specific wiring diagrams) .

5.2 Operating the 15 kV Single Phase Enclosed Generator Breaker

After physical installation is complete, the high-voltage and second-ary control connections are made, and final inspection has been per-formed, the 15 kV Single Phase Enclosed Generator Breaker is ready to put into service . To put the equipment into service, proceed with the following steps .

1 . Open the front door of the equipment .

2 . Set the “Local/Remote” switch to the “Local” position (see Figure 11) .

3 . Move the Breaker Control switch to the “Closed” position . When the breaker closes, the red Breaker Closed indicator light will illu-minate (see Figure 11) .

4 . Open the breaker .

Figure 11. Breaker Controls and Indicator Lights.

6 . Set the “Local/Remote” switch to the “Remote” position (see Figure 11) .

7 . Try to close breaker remotely . When the breaker closes, the red Breaker Closed indicator light will illuminate (see Figure 11) .

Section 6: Maintenance

WARNINGONly quAlIfIed electRIcAl WORkeRs WIth tRAINING ANd expeRI-eNce ON hIGh vOltAGe cIRcuIts shOuld be peRmItted tO WORk ON thIs equIpmeNt. they shOuld be fAmIlIAR WIth the WORk tO be peRfORmed, the sAfety equIpmeNt RequIRed, ANd hAzARds INvOlved.

6.1 Inspection and Maintenance Schedule

The 15 kV Single Phase Enclosed Generator Breaker has been con-structed with maintenance free hardware insuring long, dependable service . However, as with all high voltage equipment, the breaker should be inspected on a regular periodic basis to ensure all com-ponents are functioning correctly and the insulation system integrity is being maintained . See the appropriate instruction documents for the component devices .

To assure high quality service, a definite maintenance schedule, systematically followed, is essential . Plant, operating, and local con-ditions vary to such an extent that the schedule must be prepared to suit the conditions . However, the following general requirements should be helpful in setting up the program .

6.1.1 Individual Devices

The maintenance schedule for individual devices, such as circuit breakers, relays, etc ., should be based upon recommendations con-tained in the individual instruction book for the device . These opera-tions should be coordinated with the overall program to result in the least operating inconvenience and circuit shutdown .

6.1.2 Overall Installations

The 15 kV Single Phase Enclosed Generator Breaker installation should be given a thorough overall maintenance check at the end of the first year in service because it provides an opportunity to evalu-ate conditions at an early point in the life of the equipment . Where conditions are abnormal, more frequent inspection and maintenance is necessary . Where conditions warrant, a longer period of time between maintenance periods may be used . The following require attention:

Buses and Connectionse:

De-energize the primary circuits and remove the cover plates from the primary compartments . Before cleaning, take “MEGGER” read-ings between phases and each phase to ground . Inspect for signs of overheating or weakened insulation . Remove dust from buses, connections, supports, and enclosure surfaces . A vacuum cleaner with a long nozzle will be of assistance . Wipe clean with warm water and wipe dry.

After the buses have been dusted and wiped clean, take “MEGGER” readings again between each phase and ground and between phases . Keep a record of these readings for future refer-ence in determining when trends occur that would indicate a lower-ing of the insulation resistance .

Periodic high potential tests are not required . They are recom-mended only after repair of high-voltage buses or installation, or when the trend of “MEGGER” readings indicates it to be advisable . This field test should be made before the main cables are connected and should not exceed 27 kV, 60 Hz, 1 minute for 8 .25 kV and 15 kV switchgear . Surge protective devices such as capacitors and arrest-ers must be disconnected during high-potential tests .

Breaker Closed Indicator

Breaker Open Indicator

Breaker Control Switch

Remote / Local Switch

Control Power Switch

11




6.2 General Routine Maintenance

6.2.1 Cooling air Flow

Proper airflow through the 15 kV Single Phase Enclosed Generator Breaker is critical to equipment functioning . If airflow is restricted, the equipment could overheat causing improper operation and a drop in its performance rating .

To maintain proper air flow:• Insure that the areas around the intake and exhaust louvers are

open and clear of debris or vegetation that could reduce airflow .• Inspect the wire mesh screens installed in each louver . Remove

any dust or debris that may be clogging the screen .

6.3 Bus Connection Inspection Procedure

The 15 kV Single Phase Enclosed Generator Breaker bus system has been assembled using maintenance free hardware that DOES NOT require re-torquing during the life of the equipment . The hard-ware used in the bus system utilizes the patented Spiralock thread technology . The Spiralock hardware can be identified by the “pink” hew produced by the coating .

However, the hardware used in the bolted connections where the bus system connects to the rear of the breaker DOES need to be checked and re-torqued if necessary . To check and re-torque this hardware, refer to the procedures that follow .

6.3.1 removing the Glass Poly Insulation Panel


WARNINGfAIluRe tO cOmpletely dIscONNect the 15 kv sINGle phAse eNclOsed GeNeRAtOR bReAkeR fROm All pOWeR sOuRces pRIOR tO INspectION ANd mAINteNANce mAy Result IN seveRe INjuRy OR deAth the equIpmeNt must be cOmpletely dIscONNected fROm All pOWeR sOuRces befORe peRfORmING ANy INspectION Of the equIpmeNt. WhIle eNeRGIzed, AN ARc flAsh ANd shOck hAzARd exIsts. cONsult NfpA 70e ANd OshA GuIdelINes fOR OpeRAtOR sAfety pRIOR tO seRvIcING, INspectING, OR OpeRAtING equIpmeNt.

2 . Working from the rear of the equipment, turn 1/2 turn latches until the door is released (see Figure 12) .

Figure 12. Rear Wall Door to Be Opened.

3 . Remove and save the hardware securing the eight (8) red glass plates holding the rear red glass panel in place .

Figure 13. Hardware to Be Removed from the Red Glass Panels.

4 . The glass poly insulation panels can be reinstalled following these steps in reverse order .

1/2 Turn Latches

12




6.3.2 Checking the “Weep” Holes


WARNINGfAIluRe tO cOmpletely dIscONNect the 15 kv sINGle phAse eNclOsed GeNeRAtOR bReAkeR fROm All pOWeR sOuRces pRIOR tO INspectION ANd mAINteNANce mAy Result IN seveRe INjuRy OR deAth.

the equIpmeNt must be cOmpletely dIscONNected fROm All pOWeR sOuRces befORe peRfORmING ANy INspectION Of the equIpmeNt. WhIle eNeRGIzed, AN ARc flAsh ANd shOck hAzARd exIsts. cONsult NfpA 70e ANd OshA GuIdelINes fOR OpeRAtOR sAfety pRIOR tO seRvIcING, INspectING, OR OpeRAtING equIpmeNt.

2 . Inspect the “Weep” holes located in the base of the equipment to insure they are clear of any debris (see Figure 14) . If any debris is found, remove it to allow any condensation to drain from the equipment .

Figure 14. Location of the “Weep” Holes (Painted Yellow).

3 . Close the rear door .

6.3.3 Cleaning and Checking the torque of the Bus System to Breaker Bolted Connections


WARNINGfAIluRe tO cOmpletely dIscONNect the 15 kv sINGle phAse eNclOsed GeNeRAtOR bReAkeR fROm All pOWeR sOuRces pRIOR tO INspectION ANd mAINteNANce mAy Result IN seveRe INjuRy OR deAth. the equIpmeNt must be cOmpletely dIscONNected fROm All pOWeR sOuRces befORe peRfORmING ANy INspectION Of the equIpmeNt. WhIle eNeRGIzed, AN ARc flAsh ANd shOck hAzARd exIsts. cONsult NfpA 70e ANd OshA GuIdelINes fOR OpeRAtOR sAfety pRIOR tO seRvIcING, INspectING, OR OpeRAtING equIpmeNt.

2 . Follow the steps in Section 6 .3 .1 - Removing the Glass Poly Insulation Panel - after opening the rear door to remove the insu-lation panel . This will provide access to the bus connections on the rear of the breaker (see Figure 15) .

Figure 15. Location of the Bus Connections.

3 . Before cleaning the bus system to breaker bolted connections, take and record the “MEGGER” readings between the connec-tions and to ground .

4 . Inspect the bus system to breaker bolted connections for signs of overheating or corrosion . Remove any dust or debris from the connections and surrounding area . An industrial grade vacuum cleaner would assist this procedure . Wipe clean with isopropyl alcohol or distilled water only, then wipe dry .

WARNINGdO NOt use sOlveNts, OIls, OR GReAses ON OR NeAR thIs equIp-meNt. WAteR ANd IsOpROpyl ARe the ONly AppROved cleANeRs fOR thIs equIpmeNt.

Weep Hole

Location

13




cAutIONIsOpROpyl AlcOhOl Is flAmmAble. pROvIde AdequAte veNtIlAtION ANd keep AWAy fROm flAmes ANd OtheR IGNItION sOuRces. cONsult yOuR sAfety depARtmeNt befORe usING.

5 . Using the torque values given in Section 7, check the torque of the hardware at the bus system to breaker bolted connections .

6 . After the bus system to breaker bolted connections have been cleaned and the torque checked, take “MEGGER” readings again between the phases and ground . Keep a record of these read-ings for future reference in determining when trends occur that would indicate a lowering of the insulation resistance .

7 . Periodic high-potential tests are not required and are recom-mended only after repair of high-voltage live parts or when the trend of “MEGGER” readings indicates it to be advisable . This field test should be made before the main cables are connected and should not exceed the values in the Table 4 .

Table 4. Field Dielectric Test Values.

kv class test voltage, 60 hz Ac, Applied for One (1) Minute

15 27

8 . Prior to reinstalling the rear insulation and wall panels, perform a vacuum integrity test (see Section 6 .4) . If additional breaker ele-ment testing is required after the vacuum integrity test, reference IB 68C5043-latest version for additional procedures .

9 . Reinstall the rear insulation panel and close the rear door .

The intent of the cleaning procedure is to remove as much dirt, dust, and other foreign material as possible from the insulation with mini-mum exposure to any solvents . The recommended cleaning proce-dure is to use a lint-free cloth . In most cases this will be sufficient .

For accumulations that cannot be removed by the above procedure, a lint-free cloth, slightly dampened with water, can be used . Allow the apparatus to dry for at least four hours at room temperature before energizing or testing . If a lint-free, water dampened cloth does not produce satisfactory results, use a lint-free cloth damp-ened with isopropyl alcohol . Dry the same as when using a water-dampened cloth .

6.4 Vacuum Integrity Test

Vacuum interrupters used in these Vacuum Circuit Breaker Elements are highly reliable interrupting elements . Satisfactory performance of these devices is dependent upon the integrity of the vacuum in the interrupter and the internal dielectric strength . Both of these parameters can be readily checked by a one minute ac high poten-tial test . Refer to Table 5 for the appropriate test voltage . During this test, the following warning must be observed:

WARNINGApplyING AbNORmAlly hIGh vOltAGe AcROss A pAIR Of cON-tActs IN vAcuum mAy pROduce x-RAdIAtION. the RAdIAtION mAy INcReAse WIth the INcReAse IN vOltAGe ANd/OR decReAse IN cONtAct spAcING. x-RAdIAtION pROduced duRING thIs test WIth RecOmmeNded vOltAGe ANd NORmAl cONtAct spAcING Is extRemely lOW ANd Well belOW mAxImum peRmItted by stAN-dARds. hOWeveR As A pRecAutIONARy meAsuRe AGAINst pOssIbIl-Ity Of ApplIcAtION Of hIGheR thAN RecOmmeNded vOltAGe ANd/OR belOW NORmAl cONtAct spAcING, It Is RecOmmeNded thAt All OpeRAtING peRsONNel stANd At leAst fOuR meteRs AWAy IN fRONt Of the bReAkeR elemeNt.

With the breaker element open, connect all output roof bushings together and to the high potential machine lead . Connect all input roof bushings together and ground them along with the breaker frame . Start the machine at zero potential, increase to appropriate test voltage and maintain for on minute .

A successful withstand indicates that all interrupters have a satisfac-tory vacuum level . If there is a breakdown, the defective interrupter or interrupters should be identified by an individual test and replaced before placing the breaker in service .

WARNINGAfteR the hIGh pOteNtIAl Is RemOved AN electRIcAl chARGe mAy be RetAINed by the vAcuum INteRRupteRs. fAIluRe tO dIs-chARGe thIs ResIduAl electROstAtIc chARGe cOuld Result IN AN electRIcAl shOck. All sIx ROOf bushINGs Of the eNclOsed GeNeRAtOR bReAkeR shOuld be GROuNded tO Reduce thIs electRI-cAl chARGe befORe cOmING IN cONtAct WIth the pRImARy cIRcuIt. If ANy AddItIONAl testING OR checks WIll be peRfORmed ON the bReAkeR elemeNt, theN the ceNteR RING Of eAch vAcuum INteR-RupteR shOuld be GROuNded pRIOR tO cONtActING the bReAkeR elemeNt.

14




6.5 Heater Troubleshooting and Replacement

During scheduled periodic maintenance shutdowns when access to the interior of the 15 kV Single Phase Enclosed Generator Breaker is planned, the functionality of the heaters should be verified .

WARNINGfAIluRe tO cOmpletely dIscONNect the 15 kv sINGle phAse eNclOsed GeNeRAtOR bReAkeR fROm All pOWeR sOuRces pRIOR tO INspectION ANd mAINteNANce mAy Result IN seveRe INjuRy OR deAth. the equIpmeNt must be cOmpletely dIscONNected fROm All pOWeR sOuRces befORe peRfORmING ANy INspectION Of the equIpmeNt. WhIle eNeRGIzed, AN ARc flAsh ANd shOck hAzARd exIsts. cONsult NfpA 70e ANd OshA GuIdelINes fOR OpeRAtOR sAfety pRIOR tO seRvIcING, INspectING, OR OpeRAtING equIpmeNt.

1 . Locate all heaters in the main bus area under the breaker and control components .

otee:N There are two (2) heaters in the main bus area, one(1) under the break-er, and one (1) in the Secondary Control Box .

2 . Examine the detailed wiring diagrams to determine how to ener-gize ONLY the heater circuit .

3 . Place a hand close enough to the heater to determine that heat is being produced after a reasonable time of being energized .

4 . If no heat is being produced, first remove the power from the heater then proceed with the following steps to replace the faulty heater .

5 . Remove and save the hardware securing the heater cover over the heater (see Figure 16) . Remove the heater cover .

Figure 16. Typical 15 kV Single Phase Enclosed Generator Breaker Heater.

To avoid any ambiguity in the ac high potential test due to leakage or displacement (capacitive) current, the test unit should have sufficient volt-ampere capacity . It is recommended that the equipment be capable of delivering 25 milliamperes for one minute .

Although an ac high potential test is recommended, a dc test may be performed if only a dc test unit is available . In this case, the equipment must be capable of delivering 5 milliamperes for one minute . When a DC test voltage is used, a high field emission cur-rent from a microscopic sharp spot on one contact can be misin-terpreted as a sign of a vacuum interrupter filled with air . To avoid a misinterpreted test result, the open interrupter should always be subjected to both voltage polarities . That is, apply the DC Voltage:

• first, so that one contact of the interrupter is the cathode; and • second, so that the other contact of the interrupter is the cath-

ode .

A bad interrupter filled with air will have a similarly high leakage cur-rent in both polarities . A good interrupter with a good vacuum level may still have a high leakage current, but this will generally be in only one polarity . Such an interrupter usually has a tiny sharp spot on one contact that produces a high field emission current when the sharp spot is a cathode, but not on an anode . In addition, such an interrupter would also normally withstand the required AC voltage which is the definitive test of its vacuum integirty .

Table 5. Test Voltage

breaker Rated maximum voltage

vacuum Interrupter Integrity test voltage

ac 60 hz dc

Up to and including 17.5 kV 27 kV 40 kV

The current delivery capability of 25 ma ac and 5 ma dc apply when all three VIs are tested in parallel . If individual VIs are tested, current capability may be one third of these values .

cAutIONsOme dc hIGh pOteNtIAl uNIts , OpeRAtING As uNfIlteRed hAlf-WAve RectIfIeRs, ARe NOt suItAble fOR use tO test vAcuum INteR-RupteRs becAuse the peAk vOltAGe AppeARING AcROss the INteR-RupteRs cAN be substANtIAlly GReAteR thAN the vAlue ReAd ON the meteR.

15




6 . Note their orientation then remove the heater power wires from the stud-type terminal block located at the end of the heater and mark them for installation purposes .

7 . Remove and save the hardware securing the heater to its mount-ing surface . Remove the heater .

8 . Align the new heater in the original mounting position . Secure the new heater to the mounting surface using the original mount-ing hardware .

9 . Connect the original wiring to the stud-type terminal block on the end of the heater .

10 . Align the heater cover in its original position . Secure the heater cover using the original mounting hardware .

11 . Once the new heater has been installed, re-energize only the heater circuit and verify the operation of the new heater .

6.6 Lubrication

The 15 kV Single Phase Enclosed Generator Breaker switchgear is designed so that lubrication is not required under normal conditions . However, abnormal local conditions such as high humidity, salt-laden atmosphere, corrosive gases, or severe circuit operating conditions may demand the use of lubricants . All mechanical parts have been lubricated during assembly with molybdenum disulphide grease (Eaton Corporation Material No . 53701QB) .

The application of the lubricants should be held to a minimum to reduce the accumulation of dust and dirt .

Section 7: Bolt Torque ValuesUse the following torque values for tightening bus joints .

Table 6. Bolt Torque Values for Bus Connection.

Recommended spiralock Applied torque

dry

bolt size minimum torque maximum torque

Bus Through Hardware 1/2-13

83 lb-ft (112 .5 N-m)

90 lb-ft (122 .0 N-m)

Hardware in Rear Breaker Connection 1/2-13

83 lb-ft (112 .5 N-m)

90 lb-ft (122 .0 N-m

16




Section 8: Renewal Parts

Table 7. Common Renewal Parts

Item No. part Name/description

“quantity used on the Assembly” unit of meas. component supplier-Oem

component supplier (Oem) part No.

1 120 V 1000 W Strip Heater 3 EA Caloritech SS1531

2 125 V 300 W Heater 1 EA Heatrex 276-7

3 600 V, 30 A, Single Pole FuseBlock 7 EA Ferraz shawmut USM1

4 600 V 35 A Terminal Block 93 EA Weidmuller WDU4

5 LV Fuse, 600 V, 30 A 4 EA Bussmann ATM-30

6 LV Fuse, 600 V, 2 A 3 EA Bussmann ATM-2

7 High Voltage Bushing, Air to Air w/ Gasket 4 EA H-J International 20-210-000E07T

8 3500 A Copper Flex Shunt 16 EA H-J International FLEX-0003-00

9 120 V AC Green LED Indicating Light 1 EA Eaton 10250T197LGP2A

10 120 V AC Red LED Indicating Light 1 EA Eaton 10250T197LRP2A

11 Breaker Control Switch 1 EA Electroswitch 2438D

12 Local/Remote Control Switch 1 EA Electroswitch 24203B

13 Station Class Lighting Arrestor 4 EA Copper Power Systems

14 15 kV Single Pole ZORC 2 EA Strike P1-13.8kV

15 600 V, C600 5000:5 A Multi-Ratio Current Transformer 4 EA Polycast 131-Q16356-A1R

16 Copper Breaker Connector 8 EA Customer Industries Inc. 68C5210

17 ANSI Station Class Lighting Arrestor 8.9 kJ/kV 4 EA Cooper Power Systems UX0180151445A11

18 Aux. Control Relay 2 EA Eaton D15CR22AB

19 CT Shorting Block 6 EA GE 1KU-6SC

20 Current Monitoring Relay 7 EA Eaton ECSNCFCS

17




Notes:

18




Notes:

19




Notes:



Eaton CorporationElectrical Group1000 Cherrington ParkwayMoon Township, PA 15108United States877-ETN-CARE (877-386-2273)Eaton .com

© 2009 Eaton CorporationAll Rights ReservedPrinted in USAPublication No . IB02101001E / TBG000255October 2009

PowerChain Management is a registered trademark of Eaton Corporation .

All other trademarks are property of their respective owners .

The instructions for installation, testing, maintenance, or repair herein are provided for the use of the product in general commercial applications and may not be appropriate for use in nuclear applica-tions . Additional instructions may be available upon specific request to replace, amend, or supplement these instructions to qualify them for use with the product in safety-related applications in a nuclear facility .

The information, recommendations, descriptions, and safety nota-tions in this document are based on Eaton’s experience and judg-ment with respect to Retrofitting of Power Breakers . This instruction-al literature is published solely for information purposes and should not be considered all-inclusive . If further information is required, you should consult an authorized Eaton sales representative .

The sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties . This literature is not intended to and does not enlarge or add to any such contract . The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Eaton .

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or conse-quential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its cus-tomers resulting from the use of the information, recommendations and description contained herein .

Date post:	20-Mar-2022
Category:	Documents
Upload:	others
View:	2 times
Download:	0 times

Instruction Booklet IB02101001E Effective October 2009 ...

Documents