RX-RC REV 7.pdf

D600087 REV 7

Installation, Operation & Maintenance Manual For Rapier RX-RC Air Break Switch

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DIMS.This drawing has copyright and may not be copied in whole or in part or used for any purpose other than that for whichit is supplied without express written consent.

DRAWING NO.

COPYRIGHTCREV DATE UNIT 14, THORPE LANE,

THORPE INDUSTRIAL ESTATE,BANBURY, OXON. OX16 8UT.Tele:- 01295 270448Fax:- 01295 270446

ISOLATORSPOWER

LIMITED

DRWN1234

ECR No.

ECR

REVD600087 7ERECTION INSTRUCTIONS FOR RX-RC AIR BREAK SWITCHDISCONNECTOR04/12/2002

JCW

2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792


Page 01

RX-RCServo Controlled Rocking Isolator

Installation, Operation & Maintenance ScheduleIntroductionThe Rapier RX-RC is a servo controlled operating mechanism designed to operate switch disconnectors at voltages up to 36kV and current carrying capability of up to 630A.The integral Gemini-RTU and actuator allows the disconnector to be either locally or remotely controlled.

The Gemini RTU consists of control electronics and battery charger allowing the switchgear to be monitored and controlled for up to 24 hours under power failure conditions. The control electronics includes DNP3 and IEC 60870-5-101 communication protocols as standard (others on request) and can communicate via a range of media including low Power Radio, Paknet, GSM, Optical fibre, PSTN, RS 232 and RS485

This manual sets out the requirements for the installation of the equipment to a suitable structure, setting of the switch mechanism for correct operation. The operation of the equipment once installed and set and the recommended maintenance for the equipment.

The manual should be used in conjunction with the contract drawings supplied by Power Isolators Ltd. for the equipment.

Contents: Page No.1.0 Mounting Steel Work To Pole...............................................................2

1.1 Mounting Crossarms..............................................................2

2.0 Mounting 12-24kV Phase Assemblies.................................................32.1 Fitting Load Break Heads........................................................ 32.2 Mounting 36kV Phase............................................................. 42.3 Fitting Phase Coupling............................................................ 4

3.0 Drive Lever Position............................................................................6

4.0 Mounting Spring Mechanism............................................................... 6

5.0 Fitting Top Drive Rod & Setting Double Acting Spring Mechanism..... 75.1 Fitting Middle & Bottom Drive Rod........................................... 8

6.0 Mounting & Operating Gemini RTU..................................................... 96.1 Alternative Mounting............................................................... 9

7.0 Connecting Drive Rod To Gemini RTU.................................................107.1 Cutting Middle Drive Rod To Length.........................................10

8.0 Lock Off Brackets................................................................................10

9.0 Typical Arrangement Drawing............................................................. 12

10.0 Options Fault Passage Indicator........................................................ 1310.1 Animal Guard........................................................................1410.2 Surge Arrestor...................................................................... 15

11.0 Maintenance......................................................................................16

12.0 Product Data Health and Safety Requirements................................... 17

13.0 Contact Details................................................................................... 20

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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Crossarms

M16X45mmBolts

M20 Bolts(See Contract Drg.)

Drill 2off22mm

Holes

Page 02

1.0 Mounting steelwork to pole. Fit to pole as shown on contract drawing

Fig. 1

1.1 Mounting crossarmsNote - For correct operation of the switch it is important that the crossarms are horizontal and parallel. This will provide a flat platform for the switch disconnector and once this is achieved tighten all bolts.

Fig. 2


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Single PhaseAssembly

Crossarms

Support Steelwork

Bearing ClampingU Bolt

Slide Base FixingBolts downChannel Base

Folded ChannelBase

Base Fixing(M12X30mm Bolts)

Load Break Head

Striker Plate

ClampingBolt

Page 03

2.0 Mounting 12-24kv Single Phase Assemblies

Place the single phase units on the support steelwork at the phase centres specified on the contract drawing. (Fit phase unit fixing bolts, only finger tight at this stage). Refer to item 2.1 for fitting 36kV Load Break Heads.

Fig. 3

Note- If load break heads are not required go to 2.2.! Fit the load break heads to the single phase units before fitting the phase units to the support

steelwork as shown in (Fig.4).

! Fit the load break heads into the appropriate sleeves, rotate the LBH until it is aligned with the lugs on the striker plate, then lightly tighten the clamping bolt.Check the alignment by operating each single phase manually, ensure the LBH is operated during Opening and reset during closing. When alignment is correct fully tighten the clamp bolt

Fig.4

2.1 Fitting Load Break Heads (if required).


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Single PhaseAssembly

Load Break Head

Crossarms

Support Steelwork

Bearing ClampingU Bolt (M10)

Base Fixing(M20X110mm Bolts)

Page 04

Phase Coupling

Bearing ClampingU Bolt

2.2 Mounting 36kV Single Phase Assemblies! Place the single phase units on the support steelwork at the phase centres specified on the contract

drawing.(See Fig. 5)

! Fit phase unit fixing bolts, only finger tight at this stage.

Fig.5

2.3 Phase Coupling Tube ! Place the square coupling tube through all three phase units, thus aligning the three main bearings.

Fully tighten the M10 nuts on the bearing clamp U bolts on each phase to a minimum of 19Nm Torque (Fig.6).

! Manually push the switch to the Closed position to line up the phase units.

! Fully tighten the phase unit fixing bolts to a minimum of 32Nm(M12) / 160Nm(M20) Torque.

! At this stage, close the switch by hand until fully home, i.e. On to factory set stops. In this position the male contacts should protrude through the female contacts by a minimum of the chamfer length on the male contact and the flicker blades should be latched in, if fitted (Fig.7 & 8).

! If any of the phases are significantly lagging, undo the phase unit fixing bolt and shim the phase unit until the phase is no longer lagging.

Fig.6


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Fig. 7 Fig. 8

Drawing of RX Contact Shown Fully Home

Flicker Blade Shown Latched in Position

Arc-Chute

Flicker Blade

Ensure Flicker is AlignedCentrally With Arc-Chute

View A

View A

Arc-Chute

Latch

Flicker Blade

Male Contact

Chamfer

Female Contact

Page 05


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

HolesNot Used

Page 06

Double ActingSpring MechanismMounting Plate

Double ActingSpring Mechanism

On Rear Of DASM Remove M10 Nut, Washer & Spring Washer From Mounting Bolts. Align Studs On DASMWith Holes On Mounting

Plate & Refit M10 Nut,Washer & Spring Washer.

3.0 Drive Lever Position! The universal drive lever has been designed so that it can be used with the majority of mounting

arrangements. The switch position is shown as Closed.

! See the contract drawing for the specific mounting arrangement. The drive lever is then fixed to the phase coupling with the U bolts.

! The drive rods are not added at this time.

Fig.9 Fig.10

4.0 Mounting Spring Mechanism.Fig.11


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

2Rotate ClockwiseTo Shorten, Anti-Clockwise toLengthenMech / SwitchDrive Rod

Eye-Bolt& LockNut

This End ToEye-Bolt onDrive Lever

DASM

5.0)Fitting Top Drive Rod & Setting DASM (Drive Lever to Double Acting Spring Mech)

Fig.12

! Ensure that when the switch is closed the profiled latch on the D.A.S.M is fully latched in. This is achieved by fully closing the switch i.e. on to factory set stops, and rotating the top drive rod to lengthen it. When the latch drops in, the rod should be rotated a further 1/2 turn and then locked off.

Fig.13

Page 07


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Top Drive Rod

InsulatingInsert

Mech / SwitchDrive Rod

Bottom Drive Rod

InsulatingInsert

Top DriveRod

Coupling

Bottom DriveRod

Middle Drive Rod

Middle DriveRod

Page 08

5.1 Fitting Middle & Bottom Drive Rod.(Double Acting Spring Mech To Rapier RTU)The middle drive rod & insulating insert, (as specified on the contract drawing) is connected to the Double Acting Spring Mech.

Note: The middle drive rod requires cutting to the correct length, this must not be done until the RTU has been fitted to the pole see stage 7.0.

Fig.14

Fig.15

Switch Shown inON Position


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Clamps

ActuatorMountingPole

MountingBrackets

Lock OffBracket

M20 Bolts(See Contract Drg.)

Locking Pin& Chain

Drill 2off22mm

Holes

MountingPole

MountingBracket

Lifting Eyes

6.0 M o u n t i n g O f G e m i n i R T U

6.1 Optional Mounting Of Gemini RTU(For use with round steel poles and where drilling of mounting holes is not possible)

Refer to Gemini RTU manual (Section 4) & Contract Drawing for exact mounting details.

Fig.16

Attach the mounting brackets onto the M10 studs on the rear of the RTU. Refer to Gemini RTU manual (Section 4) & Contract Drawing for exact mounting details.

Fig.17


Page 09

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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

1View Of RTUCoupling.(Switch In OffPosition)

2Unlock PadlockAnd Remove.

Fit CouplingTo RTU

Fit LockingPin

Fit Pad-Lock

Coupling

BottomDriveRod

TopDriveRod

MiddleDriveRod

Page 10


8.0 Locking Off Instructions.The Locking Off Procedure Is Identical For Locking The Switch In The ON Or OFF Position, Instructions Show Locking Off The Switch In The OFF Position.

7.0 Connecting Drive Rod RTUConnect Bottom Drive Rod To RTU As Shown In Fig. 18 (Note: RTU Should Be In The On Position)

Fig.18

7.1 Cutting Middle Drive Rod To Length

Note: The Switch & RTU Must Be In The Closed Position i.e ON.

Fig.19

Lock OffPosition OFF

Lock OffPosition ON

Cut Line, CentralWith Coupling

Cut Off Hatched Area,Insert Rod Into Coupling& Tighten Grub Screw.

(Note: Fine AdjustmentOf The Length Of The Drive Rod Is Done ByTurning The Drive Rod,The Limits On The RTUMust Not Be AdjustedFor This Purpose)

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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

8View With SwitchLocked In TheON Position.

7Fit PadlockThroughLocking Pin.

3Remove LockingPin From Drive Rod.

4DisconnectDrive Rod.

5Move DriveRod To OtherSide Of BracketAnd Fit LockingPin.

6Fit Pin ThroughBracket.

Page 11


Note:- Unlocking is a reversal of the above procedure.

Note:- When replacing locking pin into drive rod ensure chain is free from snagging.

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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Servo controller

Secondary Automation scheme for control of Automated air break switches

Primary substationSCADAControl system

Communication viaLow power radio, GSM etc

Protocol - DNP V3.0

Double actingspring mechanism

Hook stickmanual overideNote: Actuatordrive to be disconnected & locked offbefore use.

Remote controlled RX-RCswitch at normally open point VT option for

voltage sensingand power supply.(Not included instandard offer)

Antenna InsulatingInsert

Locking points for use whenmanual override is required

yi

rng

me

Dw

n

Tp

cal A

rae

nt

rai

gFig. 209.0 Typical Arrangement Drawing


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JCW

2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

GROUND LEVEL

FPI Sensor Unit

GeminiRTU

UmbilicalCable

Page 13

10.0Options Fault Passage Indicator (FPI)! A fault passage indicator is available for use with the RX-RC. This is a retrofitable unit which will

detect fault currents and has adjustable threshold sensitivity. It consists of a sensor unit and umbilical cable which is connected to the Gemini RTU mains terminal block. The general arrangement is a shown below.

! For detailed installation and performance details refer to the FPI installation and user guide.

Fig.21


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2330N/A

19/03/2003 JCW 2475

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02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Animal Guard

Remove Two ScrewsFrom Gland Plate &Fit Animal-Guard, RefitThe Two Screws

Using Suitable CoachScrew (Not Supplied)Fasten Guard To Pole

Run The Cable InsideThe RTU MountingBracket

Page 14


10.1RX-RC Options- Animal Guard! An optional animal guard is available to protect the exposed cables e.g. power or aerial leads, if

live stock is likely to be in the vicinity of the control cabinet.

Fig.22

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2330N/A

19/03/2003 JCW 2475

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02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

Surge Arrestor

Bolt Surge ArrestorMounting Bracket Using SuppliedM12 Bolts

Fit Surge ArrestorTo Mounting Bracket

Single ConnectorMounting Hole

10.2RX-RC Options- Surge Arrestor! Surge arrestor mounting plates are available to allow the fitting of Surge Arrestors to Rapier RX

switches.

Fig.23

Page 15


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19/03/2003 JCW 2475

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02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

11.0 Maintenance

Note: all maintenance should be carried out by suitably qualified personnel.

Preventative Maintenance

Biannual Check

We recommend a visual inspection of the equipment biannually (every 2 years) including the workings of the mechanisms.

As a general requirement, all fixings should be secure and free from any corrosion that may weaken them, and all moving parts should be clean and free to move without excessive friction or obstruction.

Worn parts should be noted and Power Isolators Ltd contacted for further advice on whether replacement is necessary.

A close inspection of the Insulators is advisable in areas of vandalism, to check for cracks or chips from impact. Insulators may be cleaned and wiped down using a non-abrasive detergent to remove heavy build-up of deposits on the sheds. Necessity and frequency of cleaning will depend upon climatic and environmental conditions.

Where possible all parts (both the disconnector and the earth switch, interlocks etc) should be operated to confirm they are working correctly

Ten Year Check

Power Isolators equipment has a design life of 25 years. However, on a ten year periodic basis the following additional checks should be made, particularly in cases of high pollution or salt spray environment, or high current loading and frequent operational conditions.

Contacts

A visual inspection should be made to look for signs of electrical erosion and physical wear.

Mechanism

Any auxiliary wiring should be checked for signs of deterioration of insulation, loose contacts etc. Wiring integrity can ne checked using a multi-meter connected each end.


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

12.0 Product Data Health and Safety Requirements

High Voltage Isolators and Disconnectors

1. RANGE OF MANUFACTURE Power Isolators Ltd manufacture a wide range of high voltage Isolating Switches and Disconnectors using various metals and porcelain insulators.

2. TESTING OF PRODUCTSAll products are type tested in accordance with relevant British or International Standards and are routine tested during, or on completion of manufacture. The tests are made in accordance with the purchaser's standard or the relevant British or International Standard.

3. RATING OF PRODUCTSAll products are assigned a rating - which forms the basis of testing.

4. SPECIFIED REQUIREMENTSThe customer is always made aware of the assigned rating and usually specifies requirements in relation to the eventual duty. All isolating switches and disconnectors are fitted with a Rating Label.

5. UTILISATION OF ISOLATING SWITCHES & DISCONNECTORSThe customer or ultimate user is fully responsible for the utilisation of isolating switches and disconnectors taking into account the assigned rating, the service conditions and the required factor of safety; the manufacturers responsibility is to provide isolating switches and disconnectors which when tested in accordance with the relevant specification achieves the specified rating.

During the construction of overhead lines or substations incorporating isolating switches or disconnectors, care must be taken to avoid excessive force on the equipment especially on the porcelain insulators. In particular reliance should not be placed on the insulators as a means of support for personnel or erection equipment during erection or construction operation.

6. HEALTH HAZARDSThere are no significant health or fire hazards associated with isolating switches or disconnectors as supplied by the manufacturer.

7. MATERIALS7.1 The metal components, iron, steel, aluminium, copper and copper alloy, present no significant health or fire hazards.

7.2 The porcelain insulators incorporated into the product are made from materials listed in the European Care Inventory 06-402-64-4. All the constituent materials are banded into a simple vitreous mass.

7.3 Some Metal Components are electro plated or galvanised. Insulators are cleaned in a manner which may leave a fine film of Refined Mineral Oil on the surface. The manufacturer's Health & Safety data on this substance is available on application to Power Isolators Limited.


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19/03/2003 JCW 2475

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02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

12.0 Product Data Health and Safety Requirements Continued.

7.3 Continued: These do not constitute a significant health hazard. However, personal hygiene could be important and it is recommended that hands are washed after handling isolating switches or disconnectors. Prolonged skin contact should be avoided.

8. PACKAGINGIsolating Switches & Disconnectors are normally packed in wooden cases, with internal separation being achieved by interlays of wood. Hence there is a fire hazard.

All packing cases must be stored away from sources of heat or other means of ignition.

9. FIRE9.1 In the event of fire occurring there are no health hazards arising from metal or porcelain components (other than from zinc coating). The fumes from burning packaging and from the small amount of grease require the use of H.S.E. normal approved protective equipment in such circumstances to avoid health hazard. If high temperatures are reached there may also be fumes from the zinc protective coating applied to ferrous components and H.S.E. approved respiratory protection should be worn when involved in fires of this nature.

9.2 After a fire porcelain insulators incorporated into isolating switches and disconnectors will probably be broken and will require the exercise of the same precautions as covered in Section 12 below.

10 . WEIGHTThe weight of individual isolating switches varies from 20Kg to over 2000Kg. Isolating switches and disconnectors are delivered in packages ranging from 30Kg to in excess of 2000Kg in weight. The weights of isolating switches and corresponding packages may be obtained from despatch/shipping documentation, or by case markings, or by application to the Commercial Department, Power Isolators Limited.

11. HANDLING OF ISOLATING SWITCHES & DISCONNECTORSIn lifting and moving of isolating switches and disconnectors, whether in transportation storage or for erection at the ultimate site due regard must be given to several relevant factors i.e.

11.1 Mechanical aids e.g. fork lift trucks or cranage must always be used to lift/move isolating switches, phase units or packages in excess of the weight assessed as safe for manual handling. When lifting individual heavy phase units, isolating switches or disconnectors special attention must be given to the method of attachment of lifting gear or slings in order that correct distribution of load is obtained. Lifting methods which create excessive bending loads, in relation to the loads applied during normal duty, should be avoided.

11.2 The porcelain of the insulators is a brittle material, despite the possession of inherent strength in all normal loading conditions. Impact damage or dropping will usually cause fracture of the porcelain into numerous pieces of various sizes. These have extremely sharp edges, capable of causing dangerous incised wounds.


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

12.0 Product Data Health and Safety Requirements Continued.

12. DISPOSAL OF BROKEN INSULATORS12.1 Loading of broken insulators into skips, etc., by whatever means requires use of the heaviest protective gloves and footwear and possibly gaiters to protect the operator from the risk of injury. Face protection should also be worn since badly handled pieces may shatter further with a risk of flying shards. It is recommended that visors are of the extra length variety with brow guards.

12.2 Ultimate disposal of damaged metalwork and broken insulators may only be made in authorised landfill sites. There is now environmental hazard associated with such disposal.

13. PROVISION OF INSTRUCTIONThe contents of this document should be brought to the attention of all personnel concerned with the handling, storage and use of isolating switches and disconnectors.

14. INFORMATIONThe information on this Product Data Sheet is in accordance with the latest knowledge. The use of this information by the customer or ultimate user and the use to which the isolating switches and disconnectors are put are beyond the control of Power Isolators Limited. This information is provided without any representation or warranty expressed or implied.


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2330N/A

19/03/2003 JCW 2475

CHECKED

02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

13.0 CONTACT DETAILS

Power Isolators Ltd.Unit 14, Thorpe Lane, Thorpe Way Industrial Estate, Banbury, Oxon OX16 4UT

Tel: +44(0)1295 270448 Fax: +44(0)1295 270446Email: [email protected]

Power Isolators Ltd is a wholly owned subsidiary of the Lucy Group of companies.


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2330N/A

19/03/2003 JCW 2475

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02/07/2003 JCW 264428/07/2003 JCW 267406/08/2003 JCW 2696

5 20/08/2003 JCW 27126 10/09/2003 JCW 27466 10/09/2003 JCW 2792

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