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PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker

IB-65100

Recommended Renewal Parts and Replacement Procedures

Figure 26

Vacuum Interrupter Assembly
Drawing (38kV, 1200A)

WL35616BP

(2X) 23

(2X) 41

(4X) 20

(2X) 39

(2X) 24

(2X) 46

(2X) 32

(3X) 36

ETAIL

0.150” - 0.188”

Summary of Contents for 27PV25ASD

Page 1: ...IB 65100 PowlVac ASD 27kV 38kV Vacuum Circuit Breaker 27kV 38kV Circuit Breaker with Automatic Secondary Disconnect Powered by Safety...

Page 2: ...Powered by Safety PowlVac ASD 27kV 38kV Vacuum Circuit Breaker IB 65100 This page is intentionally left blank...

Page 3: ...owered by Safety IB 65100 Contact Information Powell Electrical Systems Inc www powellind com info powellind com Service Division PO Box 12818 Houston Texas 77217 2818 Tel 713 944 6900 Fax 713 948 456...

Page 4: ...oderate injury Not stated in ANSI Z535 4 2002 4 13 4 13 3 as a signal word but used in this manual is IMPORTANT This is defined as IMPORTANT indicates a section of the manual covering a non hazardous...

Page 5: ...CHANISM 6 1 Mechanical Description 6 2 Electrical Description 17 C RACKING MECHANISM 19 1 General Description 19 2 Circuit Breaker Racking Mechanism 20 D CIRCUIT BREAKER COMPARTMENT INTERFACES 20 1 Pr...

Page 6: ...AR EQUIPMENT 29 1 Removing the Circuit Breaker from the Connected to the Test Disconnected Position 29 2 Removing the Circuit Breaker from the Test Disconnect Position out of the Circuit Breaker Compa...

Page 7: ...RENEWAL PARTS 47 C REPLACEMENT PROCEDURES 47 1 Vacuum Interrupter Assembly 48 2 Closing Coil Assembly 56 3 Primary Shunt Trip Coil Assembly 56 4 Secondary Shunt Trip Coil Assembly 57 5 Undervoltage De...

Page 8: ...8 Cam and Fundamental Linkage Positions 14 Figure 9 Mechanical and Trip Linkages 15 Figure 10 Typical Control Scheme 18 Figure 11 Test Plug Jumper Interlock 20 Figure 12 Secondary Disconnect Receptacl...

Page 9: ...WARNING WARNING Before any adjustment servicing part replacement or any other act is performed requiring physical contact with the electrical working components or wiring of this equipment the power s...

Page 10: ...ts 6 Procedure for critical adjustments 7 Illustrations photographs and description of the circuit breaker The illustrations contained in this document may not represent the exact construction details...

Page 11: ...for the available fault duty B SAFETY GUIDELINES Study this instruction bulletin and all other associated documentation before uncrating the circuit breakers Each user has the responsibility to instr...

Page 12: ...THE SOLE MEANS OF ISOLATING A HIGH VOLTAGE CIRCUIT For complete isolation the circuit breaker shall be in the disconnected position or shall be withdrawn completely 6 ALL COMPONENTS SHALL BE DISCONNEC...

Page 13: ...ent DANGER WARNING CAUTION and instruction labels shall be observed when the circuit breaker is handled operated or maintained Warning and Caution labels are located in various places in and on the sw...

Page 14: ...locks which control the movement of the circuit breaker between the test disconnected and connected positions B THE STORED ENERGY MECHANISM 1 Mechanical Description a General The stored energy mechani...

Page 15: ...d Test Receptacle Guide e Test Plug Receptacle with Boot f Test Plug Disconnect Latch g Front Cover Bolts 12 h Nameplate i Mechanism Operated Cell Switch MOC Actuator j Manual Charging Crank k Manual...

Page 16: ...B 65100 Equipment Description Figure 2 Rear View of PowlVac ASD Circuit Breaker a Primary Disconnect b Vacuum Interrupter c Lifting Point d High Voltage Pushrod e Shutter Operator f Interference Plate...

Page 17: ...b Racking Access Door c Primary Disconnect Bushing d Shutter e Shutter Lift Arm f Ground Bus g Secondary Disconnect Receptacle h Center Alignment Block i Compartment Interference Plate j Circuit Brea...

Page 18: ...y 10 PowlVac ASD 27kV 38kV Vacuum Circuit Breaker IB 65100 Equipment Description Figure 4 Operating Pushrod Assembly of PowlVac 38kV ASD Circuit Breaker Figure 5 Ground Connection of PowlVac ASD 38kV...

Page 19: ...atchet wheel Figure 7 i rotates projections from its side faces engage the drive plates The drive plates are attached to the camshaft and cause the camshaft to rotate Crank arms Figure 7 h are attache...

Page 20: ...0 Equipment Description Figure 6 Front View of PowlVac ASD Circuit Breaker without Cover a Opening Spring b Anti Pump Relay c Trip Tube d Main Closing Spring e Connecting Rod f Opening Anti Below Spri...

Page 21: ...rt Arm e Jackshaft f Holding Pawl Adjusting Eccentric g Crank Pin h Crank Arm i Ratchet Wheel j Pawl Lift Plate k Close Latch Arm l Close Latch Shaft m Drive Pawl n Pawl Support Arm o Closing Coil p C...

Page 22: ...Vacuum Circuit Breaker IB 65100 Equipment Description Figure 8 Cam and Fundamental Linkage Positions a Breaker Open Spring Charged Links Reset c Breaker Open Spring Discharged b Breaker Closed Spring...

Page 23: ...p Shaft c Secondary Trip Prop d Secondary Linkage Roller e Main Cam Roller f Reset Spring g Camshaft h Main Closing Cam i Center Phase Operating Lever j Jackshaft k Primary Trip Prop Roller l Primary...

Page 24: ...is nut gap is used to evaluate the erosion of the vacuum interrupter contactors d Tripping System In the closing cam and fundamental linkage positions shown in Figures 8b and 8d the contact loading sp...

Page 25: ...sing spring is fully charged and the stored energy mechanism is ready for a closing operation The motor cutoff switch is located at the bottom right side of the mechanism and is supported by a bracket...

Page 26: ...16 20 17 M1 F E C1 14 Y1 J 11 10 9 12 9 9 11 11 12 12 Close Trip 18 18 13 13 TB 1 3 TB 4 TB 1 1 3 3 5 5 7 7 LS LCS 52 a 52 b 52 a 52 b 52 a 52 a 1 2 9 10 3 4 13 14 11 12 1 7 4 11 J Y LS C LCS NO NC L...

Page 27: ...akers are described in the following sections a Interlocks PowlVac ASD circuit breakers are provided with several interlocks that operate in conjunction with the circuit breaker cell to ensure the pro...

Page 28: ...and the shutters are closed The secondary devices may be connected so the breaker may be electrically or manually operated While in the TEST DISCONNECTED the test plug interlock device ensures that th...

Page 29: ...kshaft using linkages The MOC switch actuator is located at the lower right side of the circuit breaker Before installing the circuit breaker check the assembly to assure it has not been damaged durin...

Page 30: ...f the spring channel and is held by two screws Figure 6 b H MOTOR CUTOFF SWITCH The motor cutoff switch which is located at the right of the mechanism is attached to a bracket which is bolted to the c...

Page 31: ...o lifting holes which have been provided for hooks at the top of the circuit breaker frame Figure 2 c Figure 13 Lifting the Circuit Breaker by Crane C STORAGE It is recommended that the circuit breake...

Page 32: ...C high potential test machine must not produce instantaneous peak voltages exceeding 85kV for the 38kV rated circuit breaker or 64kV for the 27kV rated circuit breaker CAUTION CAUTION The primary circ...

Page 33: ...standards Do NOT apply voltage that is higher than the recommended value Do NOT use contact separation that is less than the normal open position separation of the circuit breaker contacts 2 Vacuum In...

Page 34: ...he condition of one vacuum interrupter with another nor to correlate the condition of any vacuum interrupter with low values of DC leakage current There is no significant correlation 3 Control Voltage...

Page 35: ...verify that the circuit breaker rating meets the metal clad switchgear rating 1 Inserting the Circuit Breaker to the Connected Position Follow the steps below to prepare the breaker for inserting into...

Page 36: ...king handle Figure 15 b into the racking access door and rack the circuit breaker in Once the circuit breaker is fully connected the racking indicator flag Figure 15 a will display CONNECTED Figure 15...

Page 37: ...Figure 1 e g Lock the test plug disconnect latch Figure 11 e to the left Once you have completed steps a through g the circuit breaker is ready to be tested F REMOVING THE CIRCUIT BREAKER FROM THE SWI...

Page 38: ...ith Test Plug Interlock Engaged CAUTION CAUTION Prior to removing the circuit breaker from the circuit breaker compartment make sure that the control circuits are deenergized CAUTION CAUTION Prior to...

Page 39: ...t breaker PowlVac ASD circuit breakers are designed to comply with industry standards requiring maintenance every 500 operations depending upon the rating of the circuit breaker or once a year The nee...

Page 40: ...material Failure to do so may damage the dielectric and or the mechanism properties of the insulation 2 Inspection and Cleaning Visually check the circuit breaker for loose or damaged parts Tighten o...

Page 41: ...a complete lubrication kit Powlube 102 which contains all the lubricants required for maintaining the circuit breakers Powlube 102 contains Rheolube 368A grease Anderol 456 oil and Mobilgrease 28 Rheo...

Page 42: ...a Spring Yoke Pin d Trip Shaft Bearing f Jackshaft Support g Pawl Support Arm h Crank Pin k Motor Drive Shaft Roller Needle Bearings l Close Latch Shaft Face j Pawls e Fundamental Linkage Pin b Test...

Page 43: ...ever Pin at Jackshaft q Flag Support Pin r Jackshaft Outer Bearings Support y Wheel w Motor Drive Shaft Coupling o Fundamental Linkage t Motor Cutoff Cam u Close Shaft Support Bearing s Camshaft Needl...

Page 44: ...gure 16 j Anderol 456 Oil Close Latch Shaft Face Figure 16 l Rheolube 368A Grease Apply a light coating of grease and remove all excess Ratchet Wheel Figure 16 i Rheolube 368A Grease Fundamental Linka...

Page 45: ...he main closing spring discharged and the circuit breaker contacts open remove the screw at the top of the spring rod together with the flat washer and lock washer 2 Remove the horizontal bracket at t...

Page 46: ...en position by depressing the manual trip operator 6 To install the main closing spring assembly reverse the preceding removal procedure 5 Mechanism Adjustments When any maintenance procedure requires...

Page 47: ...ing and serial number information The serial number of the circuit breaker is also attached to the circuit breaker frame near the ground connection on a stamped metal plate The serial number found on...

Page 48: ...rew Figure 22 c clockwise in 1 8 turn 45 increments until the breaker trips OPENS Carefully note the rotational position of the too used to turn the adjusting screw at the moment the breaker operates...

Page 49: ...e and the trip lever by bending the trip lever upwards slightly using channel lock pliers or a small crescent wrench Note Bend the trip lever in very small increments This process may take several att...

Page 50: ...push to trip support bracket and let it suspend from the top of the circuit breaker v Rotate the trip armature actuator to achieve the desired height of 1 676 0 06 Figure 24 b from the top of the tri...

Page 51: ...The latch switch contacts are now OPEN 4 Insert a 0 045 gauge between the secondary trip prop adjusting screw Figure 25 c and latch check operator Rotate the latch check switch upwards until the conta...

Page 52: ...etighten the locking nut holding the screw 7 Repeat step 5 Then CLOSE and OPEN the circuit breaker to ensure proper operation 8 Replace the escutcheon f Open and Close Spring Release Lever Adjustment...

Page 53: ...y There are several factory adjustments which will vary over the operating life of the vacuum interrupter ADJUSTMENTS OF THESE SETTINGS ARE ONLY NECESSARY WHEN REPAIR REQUIRES THE REMOVAL OR REPLACEME...

Page 54: ...m interrupter contact part should not exceed the values listed in Table C Timing 3 Primary Resistance Check The primary resistance check is not required for routine maintenance but it is recommended a...

Page 55: ...aution to ensure that all personnel tools and other miscellaneous objects are kept clear of the moving parts of the charged springs Ch 6 Recommended Renewal Parts and Replacement Procedures A ORDERING...

Page 56: ...errupter 3 to move to the CLOSED position vii With a pencil trace an outline of the bottom bus support 7 on the high voltage housing 11 During reassembly the outline will enable proper alignment of th...

Page 57: ...1 Vacuum Interrupter Assembly a Disassembly steps vii through ix The documentation should include part location and conditions i Prior to assembly clean all parts including the high voltage housing 1...

Page 58: ...r IB 65100 Recommended Renewal Parts and Replacement Procedures Figure 26 Vacuum Interrupter Assembly Drawing 38kV 1200A W L 3 5 6 1 6 B P 1 2X 23 2X 41 16 2 4X 20 2X 39 7 35 10 11 2X 39 6 3 18 2X 24...

Page 59: ...evice Assembly 38PV40ASD 38 1200 43649G02P 40723P01 43315P01 6 38PV40ASD 38 2000 43650G02P 43667P01 Upper 43651G01P Lower 43316P01 27PV25ASD 27 1200 43642G03P 40723P01 43315P01 6 27PV25ASD 27 2000 436...

Page 60: ...d per circuit breaker if the circuit breaker was originally equipped with this item All circuit breakers have a closing coil primary shunt trip coil charging motor and an anti pump relay assembly Seco...

Page 61: ...ewal Parts and Replacement Procedures Figure 28 Control Devices a b c d e a Primary Shunt Trip Coil 3 cycle b Primary Shunt Trip Coil 5 cycle c Charging Motor Assembly d Closing Coil Assembly e Anti P...

Page 62: ...G Miscellaneous Parts Description Catalog Number Illustration Auxiliary Switch Push On Terminals 102109LN Screw On Terminals 102109LP Ground Connection 25kA 40767G01 40kA 40767G01 Latch Check Switch...

Page 63: ...e 243 to the button head cap screws 20 and install them ix Apply Lock Tite 243 to the hex head screws 39 23 and install and torque the screws to 30 ft lbs x Torque the hex nuts 39 and the hex head cap...

Page 64: ...breaker e Insert the new assembly into the circuit breaker from below and bolt it in place Reconnect the assembly to the wiring harness No adjustment is required f Close the circuit breaker several ti...

Page 65: ...onnect it to the wiring harness No adjustment is required e Reassemble the connecting rod and main closing spring if previously removed f Trip the circuit breaker several times electrically to ensure...

Page 66: ...Removal and reinstall the main closing spring m Test the UV assembly to ensure that it is set properly and that the relay drops out at 70V If further adjustments are needed refer to the middle dial U...

Page 67: ...note which wires go to which terminal c Remove the mounting screws of the mounting bracket of the assembly and remove the assembly from the circuit breaker d Remove the anti pump relay from the mount...

Page 68: ...EA 5 Mechanism Adjustments d Latch Check Switch Adjustment f Operate circuit breaker electrically several times to ensure the switch functions properly g Replace the front cover 9 Motor Cutoff Switch...

Page 69: ...r b Disconnect the wires from the auxiliary switch being careful to note which wires go to which terminal c Remove the E ring securing the switch operating arm to the operations counter linkage d Remo...

Page 70: ...Powered by Safety PowlVac ASD 27kV 38kV Vacuum Circuit Breaker IB 65100 This page is intentionally left blank...

Page 71: ...Houston PO Box 12818 Houston TX 77217 Tel 713 944 6900 Fax 713 948 4569 www powellind com info powellind com 2006 Powell Industries Inc All rights reserved 27kV for 1200A 2000A 38kV for 1200A 2000A IB...

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