Related Manuals for ABB R-MAG 38kV 1250/2000A
Summary of Contents for ABB R-MAG 38kV 1250/2000A
- Page 1 1VAL255104-MB Rev C R-MAG Medium Voltage Outdoor Dead ® Tank Vacuum Magnetic Circuit Breaker Instruction Manual 38kV 1250/2000A...
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Page 2: Table Of Contents
Table of Contents SAFETY NOTICES ......................4 INTRODUCTION ......................5 RECEIVING, HANDLING AND STORAGE ..............5 Receiving Inspection ..................... 5 Handling ........................5 Storage.......................... 6 GENERAL DESCRIPTION ....................6 High-Voltage Assembly ....................6 Housing ......................... 7 Magnetic Actuator ......................7 Actuator Controller ...................... - Page 3 Figure 5 Interrupter Assembly 38 kV, 2000 A ................16 Figure 6 Trip Handle ........................17 Figure 7 ABB R-MAG - Vacuum Interrupter Electrical Switching Life Curves (31.5 kA) .... 18 Figure 8 ABB R-MAG - Vacuum Interrupter Electrical Switching Life Curves (40 kA) ....19 Figure 9 High Voltage Cabinet Layout ..................
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Page 4: Safety Notices
These warnings do not cover all conceivable ways in which serv- ice, whether or not recommended by ABB, might be performed or the possible hazardous consequences of each conceivable way, nor could ABB investigate all such ways. Anyone using... -
Page 5: Introduction
File a formal claim with the carri- er, supported with paid freight bill, inspection report and invoice. The local ABB Sales Office must be notified. This must be done within 10 days of receipt or receiver assumes all responsibility for damage. -
Page 6: Storage
Breaker has high center of gravity. If the breaker becomes unbalanced during lifting, there is a risk of death or serious bodily injury. Figure 2 Lifting Detail 3.3 Storage For prolonged storage, indoor storage is recommended. If stored outdoors, the cabinet heaters must be energized to maintain the warranty. -
Page 7: Housing
The magnetic actuator has no user serviceable parts and therefore no lubrication or mainte- nance is required. Should an actuator fail to operate, please immediately contact ABB for service. The permanent magnets inside the actuator are extremely powerful, with the potential to trap fingers. -
Page 8: Operation
6. OPERATION 6.1 Closing In the open position, the magnetic actuator’s armature rests against the bottom plate in the actuator assembly. The armature is held there by the force developed by the magnet. When the top coil is energized, the magnetic flux generated is in the same direction as the magnet assembly. -
Page 9: Operational Check Prior To Installation (Electrical Close/Open)
7. OPERATIONAL CHECK PRIOR TO INSTALLATION (ELECTRICAL CLOSE/OPEN) The breaker should be tested for mechanical and electrical operation before delivery to the installation site. Make the necessary control power connections. Open the door of the low voltage compartment to observe the mechanical operations. A manual trip handle is provided on the outside of the cabinet. -
Page 10: Arrester Protection
8.3 Arrester Protection ABB recommends that surge arresters be properly applied in the substation. 8.4 Control Power Supply the control power as indicated on the wiring diagram. Verify connections for the heaters before applying power. -
Page 11: Inspection, Maintenance And Adjustment
11. Ensure that all tools are removed. 12. Confirm that all high voltage test connections have been removed. 9. INSPECTION, MAINTENANCE AND ADJUSTMENT The R-MAG breaker is an extremely simple device and requires minimal maintenance, depending on the frequency of operation and local environmental conditions. The safety and successful functioning of any apparatus or system connected with the breaker largely depends on the proper and reliable operation of the unit. -
Page 12: High-Pot Test
9.2 High-Pot Test High voltage applied across an open gap in a vacuum can produce X-radiation. No radiation is emitted when the breaker is closed, since no gap exists. Also, when the breaker is open to the specified contact spacing in service or tested within the voltages specified, X-radiation at one meter is below the level of concern. - Page 13 2. Connect the transducer to the rod’s end as shown below: 3. Connect the transducer to the motion analyzer. ABB utilizes a Kocos – ACTAS P14: 4. Connect the AMP meter to the actuator coil cables:...
- Page 14 5. Connect the Kocos to the breaker contacts/bus: 5. If the result is different from the suggested range of 0.157 in – 0.177 in (4.0 mm – 4.5 mm), turn the pushrod’s end clockwise to increase wipe, or counter-clockwise to decrease wipe, depending on the adjustment needed to achieve a measurement within the specified range.
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Page 15: Figure 4 Interrupter Assembly 38 Kv, 1250 A
Figure 4 Interrupter Assembly 38 kV, 1250 A... -
Page 16: Figure 5 Interrupter Assembly 38 Kv, 2000 A
Figure 5 Interrupter Assembly 38 kV, 2000 A... -
Page 17: Figure 6 Trip Handle
Figure 6 Trip Handle... -
Page 18: Figure 7 Abb R-Mag - Vacuum Interrupter Electrical Switching Life Curves (31.5 Ka)
100000 10000 1000 Current (kA, rms) Type R-MAG, 38kV, 2000A, 31.5kA, 200kV BIL 100000 10000 1000 Current (kA, rms) Type R-MAG, 38kV, 1250A, 31.5kA, 200kV BIL Figure 7 ABB R-MAG - Vacuum Interrupter Electrical Switching Life Curves (31.5 kA) -
Page 19: Figure 8 Abb R-Mag - Vacuum Interrupter Electrical Switching Life Curves (40 Ka)
Type R-MAG, 38kV, 40 kA Figure 8 ABB R-MAG - Vacuum Interrupter Electrical Switching Life Curves (40 kA) -
Page 20: Figure 9 High Voltage Cabinet Layout
Figure 9 High Voltage Cabinet Layout... -
Page 21: Figure 10 Typical Schematic Diagram
Figure 10 Typical Schematic Diagram... -
Page 22: Figure 11 Typical Outline, 1250 A
Figure 11 Typical Outline, 1250 A... -
Page 23: Figure 12 Typical Outline, 2000 A
Figure 12 Typical Outline, 2000 A... -
Page 24: Kv R-Mag Electrical Specifications
10. 38 kV R-MAG ELECTRICAL SPECIFICATIONS 38 kV, 31.5 kA R-MAG IB Rating Structure Parameter Rating Rated Maximum Voltage 38kV Voltage Range Factor, K Rated Continuous Current 1250A/2000A* Temperature Range -40C to +40C Dielectric Strength Dry 60Hz 1 minute 80kV Wet 60Hz 10 sec 75kV Full Wave Withstand... -
Page 25: Table 2 R-Mag 38 Kv, 40 Ka Ratings
38 kV, 40kA R-MAG IB Rating Structure Parameter Rating Rated Maximum Voltage 38kV Voltage Range Factor, K Rated Continuous Current 1250A/2000A Temperature Range -40C to +40C* Dielectric Strength Dry 60Hz 1 minute 80kV Wet 60Hz 10 sec 75kV Full Wave Withstand 200kV Minimum Creep to Ground 33"... -
Page 26: Typical Current Transformer Connections
10.1 Typical Current Transformer Connections 600:5 MULTI-RATIO 1200:5 MULTI-RATIO CURRENT TRANSFORMER CURRENT TRANSFORMER TERMINAL RATIO TERMINAL RATIO X2-X3 50-5 X2-X3 100-5 X1-X2 100-5 X1-X1 200-5 X1-X3 150-5 X1-X3 300-5 X4-X5 200-5 X4-X5 400-5 X3-X4 250-5 X3-X4 500-5 X2-X4 300-5 X2-X4 600-5 X1-X4 400-5... -
Page 27: Auxiliary Switch Current Specifications
10.2 Auxiliary Switch Current Specifications • Tested per UL Document 1054. AC tests specs with one set of contacts. DC tests specs with two sets of contacts in series. • Contacts will carry 140 A for 3 seconds. • Overload test – 50 operations at 90 A and 120 VAC. VOLTS NON INDUCTIVE CIRCUITS INDUCTIVE CIRCUITS MAKE... -
Page 28: Breaker Nameplate
10.4 Breaker Nameplate Figure 13 Breaker Nameplate 11. RENEWAL PARTS Renewal parts are available exclusively from ABB. Contact your local ABB field sales office for the latest R-MAG Spare Parts List. 12. PRODUCT RECYCLING Definitions and regulations of hazardous materials are country-specific and change when knowledge of materials increases. - Page 29 APPENDIX A INSTALLATION / MAINTENANCE INSTRUCTIONS R-MAG Medium Voltage Vacuum Power Circuit Breaker...
- Page 30 Table of Contents OVERVIEW ........................32 CONTROL BOARDS AVAILABLE/MAGNETIC ACTUATOR COIL ENERGIZING CAPACITOR ..........................33 BINARY INPUTS ......................33 Remote Close (KM1005, CH 1, Pins 1 and 2) ............. 33 Remote Open (KM1005, CH 2, Pins 3 and 4) ............. 33 Auxiliary Open / Safe Open (KM1005, CH 3, Pins 5 and 6) ........
- Page 31 List of Illustrations Apx Figure 1 Electrical System Block Diagram ................32 Apx Figure 2 Electrical Load Curves ..................37 Apx Figure 3 Standard Actuator Circuit Board and Connection Diagram ........41 Apx Figure 4 Standard Actuator Circuit Board and DIP Switch Settings ........43 Apx Figure 5 Ready LED Continually Flashing ................
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Page 32: Overview
1. OVERVIEW The actuator control board is comprised of a Power Supply Recharge Unit, Control Unit, and FET Switching circuit which connects the Storage Unit Capacitors to the Magnetic Actuator coils. The power supply recharge circuitry adapts whatever input voltage, within the specified range (see CONTROL BOARDS AVAILABLE/MAGNETIC ACTUATOR COIL ENERGIZING CAPACITOR), is supplied to maintain an 80 V charge voltage across the capacitors. -
Page 33: Control Boards Available/Magnetic Actuator Coil Energizing Capacitor
2. CONTROL BOARDS AVAILABLE/MAGNETIC ACTUATOR COIL ENERGIZING CAPACITOR 1. Low voltage full optional board (17 – 75 VDC or 20 – 52 VAC). 2. High voltage full optional board (77 – 280 VDC or 85 – 264 VAC). 3. 0.1 farad aluminum electrolytic capacitors. 3. -
Page 34: Protection Trip / Second Trip (Km1005, Ch 4, Pins 7 And 8)
ignored. In order for the breaker to open correctly, there must be sufficient energy in the capacitors. 3.4 Protection Trip / Second Trip (KM1005, CH 4, Pins 7 and 8) This input can be configured as either a Protection Trip or Second Trip function. It is programmed via Jumper JP1001 pins 1 and 2 or as a normal input by jumpering JP1001 pins 2 and 3. -
Page 35: Binary Outputs
4. BINARY OUTPUTS Binary outputs are simply pairs of mechanical wipe relay contacts. They can be employed to switch in other circuitry or to an alarm indicator. See Apx Table 2 Output Contact Specifications and Apx Figure 2 Electrical Load Curves for the power limitations of the contacts. Notice the flat curve for AC voltage in Apx. -
Page 36: Apx Table 2 Output Contact Specifications
CHARACTERISTIC WIPE CONTACTS RELAY SWITCHING CHARACTERISTICS Maximum Switching Power 1500 VA on Resistive load Maximum Switching Voltage 400 VAC, 300 VDC Maximum Switching Current Maximum Rated Current CONTACTS CHARACTERISTICS 100 mΩ (measured by voltage drop 6 Maximum On Resistance (Ron) VDC 1 A) Maximum Capacitance 1.5 pF... -
Page 37: Features
Apx Figure 2 Electrical Load Curves 5. FEATURES 5.1 Temperature Protection The Temperature Protection circuit monitors the average temperature of a critical area on the CONTROL BOARD power supply. The output power will be linearly reduced to zero as the component temperature increases from 78 degrees C to 95 degrees C. -
Page 38: Reduced Power Consumption
Jumper JP1019. (see Apx. Figure 4 Standard Actuator Circuit Board and DIP Switch Settings). 5.6 RS-232 Port / JTAG Communication Port Used by ABB factory only. 6. POWER CONSIDERATIONS The control board power supply recharge unit adapts any voltage within the specified range of the board to maintain 80 V across the capacitors. -
Page 39: Discharging Storage Unit Capacitors
6.1 Discharging Storage Unit Capacitors Make sure ED2.0 Control Power is removed before attempting to discharge the capacitors. See paragraph below. The actuator control board provides access through KM1003 for discharging the Storage Unit capacitors. Make sure the control board power is removed before attempting to discharge the capacitors. -
Page 40: Breaker Ready / Not Ready Binary Output Contacts And Ready Light Status
Breaker Ready / Not Ready Binary Output Contacts and Ready Light Status CIRCUIT BREAKER POSITION CLOSE OPEN CONDITION Ready LED: on Ready LED: on Capacitor Energy sufficient For O- Ready contact: closed Ready contact: closed CO operations Not ready contact: opened Not ready contact: opened Ready LED: blinking Ready LED: blinking... -
Page 41: Standard Actuator Circuit Board And Connection Diagram
7. STANDARD ACTUATOR CIRCUIT BOARD AND CONNECTION DIAGRAM Apx Figure 3 Standard Actuator Circuit Board and Connection Diagram... -
Page 42: Control Board Connectors
8. CONTROL BOARD CONNECTORS KM1001-1 ELECTRONIC GRD (0 VDC) KM1001-2 ELECTRONIC GRD (0 VDC) KM1001-3 +18 VDC KM1001-4 +18 VDC KM1001-5 ON SIGNAL (0 VDC) KM1001-6 OFF SIGNAL (0 VDC) Apx Table 5 KM1001 - Breaker Position (CB Position) KM1002-1 CAPACITOR PLUS (+80 VDC) KM1002-2 CAPACITOR PLUS (+80 VDC) -
Page 43: Default Jumper And Dip Switch Settings
9. DEFAULT JUMPER AND DIP SWITCH SETTINGS Unless specified by the customer, the Low Energy and Under Voltage trip functions are disabled. Input three is set for Auxiliary trip mode as opposed to the Protection Relay trip mode. The Protection Relay mode has a lower switching threshold (7 VDC). See section BINARY INPUTS for the switch and jumper locations. -
Page 44: Troubleshooting Flowcharts
<30 SEC SINCE CLOSE POWER UP OPERATION CHECK CLOSE COIL CONNECTIONS & CONTINUITY POSSIBLE ISSUES: 1) ED2.0 BOARD BAD* 2) AUX SUPPLY LOW 3) FAULTY CAPACITORS* *Please contact an ABB sales representative for a replacement Apx Figure 5 Ready LED Continually Flashing... -
Page 45: Apx Figure 6 Ready Led Off
*Please contact an ABB sales representative for a replacement Apx Figure 6 Ready LED Off... -
Page 46: Apx Figure 7 Conditions For Cb Not Opening/Closing
AUX SUPPLY CLOSE COIL BAD MISSING OR CLOSE SIGNAL ED2.0 Board Bad* CONNECTED CAPACITOR VOLTAGE LOW AUX SUPPLY MISSING OR ED2.0 Board Bad* *Please contact an ABB sales representative for a replacement Apx Figure 7 Conditions for CB Not Opening/Closing... -
Page 47: Instructions For Troubleshooting A Control Board
11. INSTRUCTIONS FOR TROUBLESHOOTING A CONTROL BOARD The Power Supply recharge circuitry either reduces (high voltage board) or increases (low volt- age board) input voltage within the specified range supplied to maintain an 80 V charge voltage across the capacitors. The Control Unit monitors binary inputs and outputs, hardware and software configurations, position sensors, capacitor charge, and switches the FET circuit to connect the capacitor voltage to the magnetic actuator coils following an open or close command. -
Page 48: Ready Light Is Off
1. Use diagram on the previous page for references to troubleshooting the actuator control board. 2. Disconnect source power to outdoor breaker. 3. Warning: removing cover exposes live voltage. 4. Remove the two #4 screws holding on the Push button plate and let it hang down. 5. -
Page 49: Specific Line Item Check Is Shown Below
11.2 SPECIFIC LINE ITEM CHECK IS SHOWN BELOW POSSIBLE PROBLEMS POSSIBLE SOLUTIONS CAUSES The auxiliary supply Check pins 2 and 3 on KM1003 to confirm proper voltage is absent. input voltage is applied. Check the magnetic actuator circuit. Unplug the magnetic actuator from the plug to the left of the mechanism (MA). - Page 50 PROBLEMS POSSIBLE POSSIBLE SOLUTIONS CAUSES In this case, only the opening operation is avail- able; open the circuit breaker (the ready LED will be turned off) and check the closing coil circuit. The circuit breaker is Unplug the magnetic actuator from the plug to the closed and the close left of the mechanism (MA).
- Page 51 If it happens immediately when the supply Capacitor bank is not voltage is switched off and the ready LED is connected. immediately turned off, check the capacitor bank circuit. POSSIBLE PROBLEMS POSSIBLE SOLUTIONS CAUSES Check the closing coil circuit. Disconnect the magnetic actuator from the plug to the left of the mechanism.
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Page 52: Instructions For Changing Out A Control Board
The UV function is active and the Either disable the UV function or connect to a dif- The circuit breaker auxiliary supply is ferent voltage source. opens if the parallel to this input. auxiliary supply is The energy failure switched off If possible, disable the function via I1004-1. - Page 53 (in particular during service operation). Proper ESD protection must always be applied when handling this card. ABB can supply a document regarding to ESD protection.
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Page 54: Apx Figure 9 Control Board With Terminal Numbering
9. Perform this process in reverse order to reinstall the board. Apx Figure 9 Control Board with Terminal Numbering Apx Figure 10 Control Board, Simplified... -
Page 55: Apx Figure 11 Ed2.0 Control Board Parts And Mounting
Apx Figure 11 ED2.0 Control Board Parts and Mounting... - Page 56 For more information, please contact: ABB Inc. 655 Century Point Lake Mary, FL 32746 All sales are subject to ABB Inc. General Terms and Phone: +1 407-732-2000 ext. 2510 Conditions of Sale. While every effort has been made +1 800-929-7947 ext. 5 to assure accuracy, the information in this document Customer.service.group@us.abb.com...