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Powell PowlVac IB-65020A CDR 27kV Manual

Vacuum, 1200a & 2000a
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IB-65020A PowlVac® CDR 27kV & 38kV
Vacuum Circuit Breaker
27kV & 38kV
1200A & 2000A
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Summary of Contents for Powell PowlVac IB-65020A CDR 27kV

  • Page 1 IB-65020A PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker 27kV & 38kV 1200A & 2000A Powered by Safety ®...
  • Page 2 IB-65020A 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: 713.948.4569 Powered by Safety ®...
  • Page 3 “IMPORTANT”. This is defined as: IMPORTANT IMPORTANT IMPORTANT indicates a section of the manual covering a non hazardous situation, but one where Powell feels proper attention is warranted. Powered by Safety ®...

  • Page 4: Table Of Contents

    IB-65020A Contents Ch 1 General Information ....................1 A. S ................................2 cope B. p ................................2 urpoSe c. I .....................2 nStructIon ulletInS vAIlABle lectronIcAlly Ch 2 Safety ........................3 A. S ............................3 ondItIon B. S ...............................3 Afety uIdelIneS c. G ................................4 enerAl d. S ................................4 pecIfIc e.
  • Page 5 PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Contents f. r ................32 eMovInG the IrcuIt reAker roM the WItchGeAr quIpMent 1) Removing the Circuit Breaker from the Connected to the Test/Disconnect Position ..........32 2) Removing the Circuit Breaker from the Test/Disconnect Position out of the Circuit Breaker Compartment ...32 Ch 5 Maintenance ......................33 A.
  • Page 6 IB-65020A Figures Figure 1 Front View of PowlVac® CDR Circuit Breaker with Cover .......7 Figure 2 Rear View of PowlVac® CDR Circuit Breaker ...........8 Figure 3 PowlVac® CDR Circuit Breaker Compartment ..........9 Figure 4 Operating Pushrod Assembly of PowlVac® CDR Circuit Breaker ....10 Figure 5 Ground Connection of PowlVac®...
  • Page 7 PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A This page is intentionally left blank. Powered by Safety ®...

  • Page 8: Ch 1 General Information

    This document and all other documentation shall be fully read, understood, and all warnings and cautions shall be abided by. If there are any discrepancies or questions, the user shall contact Powell immediately at 1.800.480.7273.

  • Page 9: S Cope

    Ch 1 General Information, A. S cope For more information visit www.powellind.com. To contact the Powell This instruction bulletin provides: Service Division call 1.800.480.7273 or 713.944.6900, or email 1. Safety guidelines info@powellservice.com. 2. General descriptions of the operation and maintenance of the PowlVac CDR 27kV &...

  • Page 10: Ch 2 Safety

    IB-65020A Ch 2 Safety B. S Afety uIdelIneS Study this instruction bulletin and all other A. S ondItIon associated documentation before uncrating the circuit breakers. The information in Section A is quoted from NFPA 70E 2004 - Article 120, 120.1 Establishing an Each user has the responsibility to instruct Electrically Safe Work Condition.

  • Page 11: G Eneral

    DO pecIfIc NOT FORCE THE PARTS INTO POSITION. 1. DO NOT WORK ON AN ENERGIZED CONTACT POWELL FOR INSTRUCTIONS. CIRCUIT BREAKER. If work must be performed on a circuit breaker, remove it from service and remove it from the metal-clad switchgear.

  • Page 12: X-R Ays

    IB-65020A e. X-r f. S Afety ABelS When high voltage is applied across the The equipment described in this document has DANGER, WARNING, CAUTION, and contacts of a vacuum interrupter, there is the possibility of generation of X-rays. The intensity instruction labels attached to various locations.

  • Page 13: Ch 3 Equipment Description

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Ch 3 Equipment Description CAUTION CAUTION A. G enerAl Prior to removing the front cover, the user must make sure the circuit breaker is in the The PowlVac® CDR 27kV & 38kV vacuum circuit OPEN position and the main closing spring is breakers (Figure 1) are closed door racking fully discharged.

  • Page 14: Figure 1 Front View Of Powlvac® Cdr Circuit Breaker With Cover

    IB-65020A Figure 1 Front View of PowlVac® CDR Circuit Breaker with Cover Mechanism Operated Cell Switch (MOC) Actuator a. Push to Trip Roller k. Truck Operated Cell Switch (TOC) Actuator b. Handle c. Secondary Disconnect Blocking Pin Manual Trip Paddle m.

  • Page 15: Figure 2 Rear View Of Powlvac® Cdr Circuit Breaker

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 2 Rear View of PowlVac® CDR Circuit Breaker a. Upper Primary Disconnect (3) b. Lifting Points (2) c. Vacuum Interrupter (3) d. Lower Primary Disconnect (3) e. High Voltage Insulator (3) f.

  • Page 16: Figure 3 Powlvac® Cdr Circuit Breaker Compartment

    IB-65020A Figure 3 PowlVac® CDR Circuit Breaker Compartment a. Racking Indicator Flag b. Push to Trip Knob c. Racking Access Window d. Primary Disconnect Bushing e. Shutter f. Shutter Lift Arm g. Center Alignment Block h. Ground Bus Compartment Interference Plate Circuit Breaker Pan Weldment Powered by Safety ®...

  • Page 17: Figure 4 Operating Pushrod Assembly Of Powlvac® Cdr Circuit Breaker

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 4 Operating Pushrod Assembly of PowlVac® CDR Circuit Breaker Figure 5 Ground Connection of PowlVac® CDR Circuit Breaker Powered by Safety ® Equipment Description...
  • Page 18 IB-65020A The charging motor (Figure 6, i), located the top ends of the connecting rods. As the on the bottom right of the base pan, is camshaft rotates the connecting rods pull assembled to the circuit breaker by a the spring yoke downward, compressing bracket that is bolted to the base pan.

  • Page 19: Figure 6 Front View Of Powlvac® Cdr Circuit Breaker Without Cover

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 6 Front View of PowlVac® CDR Circuit Breaker without Cover a. Opening Spring b. Anti-Pump Relay c. Trip Tube d. Main Closing Spring e. Connecting Rod f. Opening Anti-Bellows Spring g.

  • Page 20: Figure 7 Close-Up Front View Of Powlvac® Cdr Circuit Breaker Mechanism

    IB-65020A Figure 7 Close-Up Front View of PowlVac® CDR Circuit Breaker Mechanism a. Primary Shunt Trip Coil m. Drive Pawl b. Secondary Trip Prop Adjusting n. Pawl Support Arm Screw o. Closing Coil c. Latch Check Switch Operator p. Camshaft d.

  • Page 21: Figure 8 Cam And Fundamental Linkage Positions

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 8 Cam and Fundamental Linkage Positions b) Breaker Closed - Spring Discharged a) Breaker Open - Spring Charged - Links Reset c) Breaker Open - Spring Discharged d) Breaker Closed - Spring Charged Powered by Safety ®...

  • Page 22: Figure 9 Mechanical And Trip Linkages

    IB-65020A Figure 9 Mechanical and Trip Linkages a. Secondary Trip Prop Adjusting Screw b. Secondary Trip Prop Shaft c. Secondary Trip Prop d. Secondary Linkage Roller e. Main Cam Roller f. Reset Spring g. Camshaft h. Main Closing Cam Center Phase Operating Lever Jackshaft k.
  • Page 23 PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Each operating pushrod assembly The fundamental linkage is restrained from (Figure 2, g) encloses a contact loading movement by the secondary trip prop spring. At the end of this spring is a (Figure 9, c) acting on the primary trip pivot block.

  • Page 24: Electrical Description

    IB-65020A 2) Electrical Description d. Operating Solenoids a. Charging Motor Electrical operation of the circuit breaker is accomplished using The function of charging motor operating solenoids. (Figure 6, i) is to compress the main closing spring of the stored energy The closing coil (Figure 7, o) is an mechanism, thus providing the operating solenoid located at the...

  • Page 25: Figure 10 Operation Sequence

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 10 Operation Sequence Secondary Disconnect Makes Motor “M” Green Light Energized Energized Close Spring Charged Makes Breaks Breaks Makes Makes White Light Motor “M” “Y” Circuit Energized Deenergized Disabled Close Control “CS/C”...

  • Page 26: Figure 11 Typical Control Scheme

    IB-65020A Figure 11 Typical Control Scheme Close Trip To Rated To Rated To Rated Control Power Control Power Control Power 125VDC/120VAC 125VDC 125VDC 125VDC Device Cross Reference Tables Device IDs LS = Spring Charge Limit Switch (Shown w/ Spring Discharged) LCS = Latch Check Switch (Shown w/ Spring Discharged) Y = Anti-Pump Relay 12 K...

  • Page 27: Acking M Echanism

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A d. c e. Control Circuit IrcuIt reAker oMpArtMent nterfAceS The typical AC & DC electrical control 1) Primary Disconnecting Devices schemes are shown in Figure 11. There are six primary disconnecting The control scheme of any particular devices on the circuit breaker.

  • Page 28: Moc (Mechanism Operated Cell Switch) Actuator

    IB-65020A 3) MOC (Mechanism Operated Cell Switch) 6) Shutter Operator Actuator The shutter operator (Figure 2, h) is located The mechanism operated cell switch on each side of the circuit breaker frame. (MOC), located in the switchgear, is an As the circuit breaker travels between the auxiliary switch operated by a lever which test/disconnected and connected positions extends from the circuit breaker operating...

  • Page 29: Ch 4 Installation

    If damage is found or suspected, file claims as soon as possible with the transportation company and notify the nearest Powell representative. Estimated size and weight for shipping a PowlVac® CDR 27kV or 38kV circuit breaker on a pallet: • Size: 42” width x 42” depth x 47” height...

  • Page 30: S Torage

    Before shipment from our factory, all circuit c. S torAGe breaker functions are thoroughly checked. The user must verify functions after receipt. Powell It is recommended that the circuit breaker be recommends that the tests be performed in the put into service immediately in its permanent...

  • Page 31: High Voltage Insulation Integrity

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A 1) High Voltage Insulation Integrity CAUTION CAUTION CAUTION CAUTION If DC high potential testing is performed, the DC high potential test machine must High voltages across the open gaps of the not produce instantaneous peak voltages vacuum interrupter can produce x-radiation.

  • Page 32: Vacuum Integrity

    Powell recommends AC testing for reliable verification of vacuum integrity. All The tests described in this section are the PowlVac CDR 27kV and 38kV circuit...

  • Page 33: Control Voltage Insulation Integrity

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Powell recognizes the widespread use of DC hipot equipment in the field and CAUTION CAUTION the desire to use this equipment to verify If DC high potential testing is performed, vacuum integrity. However, the capacitive...

  • Page 34: Mechanical Operation Check

    IB-65020A 5) Electrical Operation Check CAUTION CAUTION To check the basic electrical operation Remove all grounding conductors applied for of the circuit breaker, a circuit breaker field dielectric test before placing the circuit test cabinet should be used. Connect breaker back into service. the secondary disconnect from the test cabinet to the circuit breaker to be tested.

  • Page 35: I Nserting The C Ircuit B Reaker I Nto The Switchgear E Quipment

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A e. I An alternate method for the electrical nSertInG the IrcuIt reAker nto the WItchGeAr operation check is to use a test jumper quIpMent cable to electrically operate the circuit breaker using the control circuitry of CAUTION CAUTION the circuit breaker compartment.

  • Page 36: Prior To Inserting The Circuit Breaker Into The Circuit Breaker Compartment

    Contact CAUTION CAUTION Powell for further information. Before inserting a circuit breaker into the Examine the circuit breaker circuit breaker compartment, be sure that compartment to see that it is clean and...

  • Page 37: Inserting The Circuit Breaker To The Test/Disconnect Position

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 14 Top View L-Shaped Slot 2) Inserting the Circuit Breaker to the Test/Disconnect Position CAUTION CAUTION Prior to inserting the circuit breaker into the circuit breaker compartment, make sure that the control circuits are deenergized.

  • Page 38: Figure 15 Push To Trip Knob & Racking Access Window

    IB-65020A Figure 15 Push to Trip Knob & Racking Access Figure 16 Racking Indicator Flags & Racking Window Handle a. Push to Trip Knob b. Racking Access Window a. Insert racking handle (Figure 16, b) into the racking access window and turn the racking handle clockwise until the circuit breaker is fully racked into the circuit breaker compartment.

  • Page 39: Emoving The

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A f. r racking out of the circuit breaker eMovInG the IrcuIt reAker roM the WItchGeAr towards test/disconnect position. quIpMent d. Continue racking the circuit breaker out Refer to the metal-clad switchgear instruction until the indicator flag (Figure 16, a) bulletin and drawings produced specifically displays “TEST/DISCONNECT”.

  • Page 40: Ch 5 Maintenance

    Powell the metal-clad switchgear for reasons other immediately. than scheduled circuit breaker maintenance if it has been more than one year since the last vacuum integrity test.

  • Page 41: Inspection And Cleaning

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A Because of extensive quality control tests Primary insulation, including the vacuum made at the factory, the operations counter interrupter supports and the operating on a new circuit breaker will normally pushrods, should be cleaned. Wipe clean register over a hundred operations.

  • Page 42: Lubrication

    Furthermore, removal of the main closing spring permits Powell offers a complete lubrication kit slow closing of the mechanism and the (Powlube-102) which contains all the vacuum interrupter contacts. For details, lubricants required for maintaining the see Ch 5 Maintenance, B.

  • Page 43: Slow Closing Of Mechanism

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A Figure 18 Main Closing Spring Assembly The procedure for spring removal is as follows: Installed 1. With the main closing spring discharged and the circuit breaker contacts open, remove the bolt at the top of the spring rod together with the flat washer and lock washer.
  • Page 44 IB-65020A Table B Lubrication Location Reference Figure Lubricant Method Electrical Parts Wipe clean. Apply lubricant only Primary Disconnecting Device Figure 19, c Mobilgrease 28 to actual contact surface. Wipe clean. Apply lubricant only Test Plug Receptacle Figure 19, b Mobilegrease 28 to actual contact surface.

  • Page 45: Figure 19 Lubrication

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A Figure 19 Lubrication Spring Yoke b.. Test Plug Receptacle Primary d. Primary Trip Disconnecting Prop Bearing Device Primary Trip Trip Shaft g. Fundamental h. Jackshaft Pawl Support Prop Roller Bearing Linkage Pin Support Crank Pin Ratchet Wheel...

  • Page 46: Figure 20 Lubrication (Cont)

    IB-65020A Figure 20 Lubrication (cont) Main Closing p. Secondary Spring Guide Linkage Roller q. Primary Trip Fundamental Prop Linkage Open-Closed Flag Support Jackshaft Camshaft w. Motor Drive Flag Drive Outer Bearings Needle Shaft Support Lever Pin at Support Bearings Bearings Jackshaft Close Shaft Motor Cutoff...

  • Page 47: Mechanism Adjustments

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A 4. Continue to operate the charging a. Adjustment of Ratchet Wheel Holding handle until the crank arms point Pawl downward. The circuit breaker will The holding pawl support arm now be closed and there will be a gap (Figure 7, d) is adjusted by the holding between the operating pushrod lock pawl adjusting eccentric (Figure7, f ).

  • Page 48: Figure 21 Primary & Secondary Trip Prop Adjustment

    IB-65020A is also attached to the circuit breaker is 0.005” to 0.015”. The primary trip frame near the ground connection on prop adjusting screw is accessible an engraved metal plate. The serial from the rear of the stored energy number found on the nameplate must mechanism and is located inside match the number affixed to the frame.

  • Page 49: Figure 22 Feeler Gauge

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A Figure 22 Feeler Gauge CAUTION CAUTION Do NOT allow the secondary trip prop adjusting screw to turn while loosening the locking nut. Failure to observe this caution will severely damage the mechanism. 4.

  • Page 50: Figure 23 Trip Armature Assembly Left View

    IB-65020A Figure 23 Trip Armature Assembly Left View crescent wrench. Repeat steps 9 through 12. Note: Bend the latch check operator in very small increments. This process may take several attempts. ii. If the circuit breaker did NOT TRIP during the test performed in step 12, proceed to step 14.

  • Page 51: Figure 24 Trip Armature Assembly Right View

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A Figure 24 Trip Armature Assembly Right View 19. If there is an air gap of 0.040” (Figure 23, c) between the trip armature actuator (Figure 23, b) and the latch check operator (Figure 23, d) of 0.040”, then proceed to step 21. If there isn’t an air gap, loosen the 10-32 pan head kep nut (Figure 23, a).

  • Page 52: Figure 26 Latch Check Switch Adjustment

    IB-65020A 21. Perform the latch check switch 3. Loosen the two screws which secure adjustment per the procedure found the latch check switch and rotate in Ch 5 Maintenance, B. M the latch check switch about the echAnISM , 4) Slow Closing of Mechanism, pivot screw downward to the lowest d.

  • Page 53: Electrical Operation

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A e. Adjustment of Close Latch Shaft 6) Electrical Operation The close latch shaft (Figure 7, l) passes After performing any necessary mechanical through the side sheets of the stored and lubrication maintenance, operate the energy mechanism frame at the front of circuit breaker electrically several times to and below the cam shaft.

  • Page 54: Mechanical Adjustment Of Vacuum Interrupters

    OPEN position. When the , 1) Vacuum Interrupter Assembly rocedureS circuit breaker opens, record the tripping or contact the Powell Service Division. time. Operate the test source to the OPEN position to open the circuit breaker and d. o...

  • Page 55: Primary Resistance Check

    PowlVac® CDR 27kV &38kV Vacuum Circuit Breaker IB-65020A 3) Primary Resistance Check The micro-ohm values of resistance must not exceed the limits in Table D, Primary This check is not required for routine Resistance. maintenance but it is recommended after any major maintenance that requires Table D Primary Resistance disassembly of any part of the primary...

  • Page 56: Ch 6 Recommended Renewal Parts And Replacement Procedures

    The recommended quantity is not specified. This must be determined 1. Order Renewal Parts from Powell at by the user based on the application. As a www.powellind.com or call 1.800.480.7273. minimum, it is recommended that one set of parts be stocked per ten circuit breakers or less.

  • Page 57: Vacuum Interrupter Assembly

    (24). The vacuum interrupter should only be ix. Carefully loosen and remove 3 of 4 replaced by a qualified person or a Powell button head cap screws (20). Notice Service technician. Contact Powell for further that shims (approximately ⁵/₈” OD,...
  • Page 58 IB-65020A document the distance that the (3) should be pointed in the same front terminal clamp (10) is screwed direction as the shunt (6), as well onto the threads of the vacuum as in the same direction as the two interrupter (3).
  • Page 59 PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A ae. Replace the temporary bolt with WARNING WARNING the original hardware when the vacuum interrupter (3) is pulled When any maintenance procedure requires far enough to align the bolt the opening or closing of the circuit breaker holes.

  • Page 60: Figure 27 Vacuum Interrupter Assembly Drawing (38Kv, 1200A)

    IB-65020A Figure 27 Vacuum Interrupter Assembly Drawing (38kV, 1200A) etail (2X) 41 (2X) 23 (2X) 24 0.150” - 0.188” (4X) 20 (2X) 39 (2X) 32 (2X) 39 (3X) 36 (2X) 46 Powered by Safety ® Recommended Renewal Parts and Replacement Procedures...

  • Page 61: Closing Coil Assembly

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A iv. If the gap needs to be decreased, e. Trip the circuit breaker electrically hold the high voltage regulator (13) several times to ensure that the primary with channel lock pliers, loosen the shunt trip coil assembly is functioning hex head nut (46) and turn the high properly.

  • Page 62: Undervoltage Device Assembly (Uv)

    IB-65020A d. Bolt the new assembly in place and 10) Auxiliary Switch reconnect it to the wiring harness. No Refer to SM-1100 Auxiliary Switch Assembly adjustment is required. for replacement and installation e. Reassemble the connecting rod and procedures. main closing spring, if previously removed.

  • Page 63: Figure 28 Primary Current Path

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Table E Primary Current Path Rated Vacuum Primary Breaker Rated Shunt Continuous Interrupter Disconnecting Type (kV) Contact Current (Amps) Assembly Device 38PV40CDR 1200 43649G02P 40723P01 43315P01 (6) Upper 43651G01P 38PV40CDR 2000 43650G02P 43667P01 Lower...

  • Page 64: Table F Control Devices

    IB-65020A Table F Control Devices Primary Shunt Trip Coil Secondary Undervoltage Charging Control Assembly (2) Shunt Trip Anti-Pump Closing Coil Device Motor Voltage Coil Assembly Relay (5) Assembly Assembly (4) Assembly 3-Cycle 5-Cycle 24VDC 50027G05P 50041G08P 50042G06P 50028G04P RR2BA-US- 48VDC 50027G01P 50041G01P 50042G01P...

  • Page 65: Figure 29 Control Devices

    PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A Figure 29 Control Devices a. Primary Shunt Trip Coil (3 cycle) b. Primary Shunt Trip Coil (5 cycle) c. Charging Motor Assembly d. Closing Coil Assembly e. Anti-Pump Relay f. Undervoltage Device Assembly Powered by Safety ®...

  • Page 66: Table G Miscellaneous Parts

    IB-65020A Table 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 BA-2RV2-A2 Motor Cutoff Switch Assembly 50756G03P Image Not Available PowlVac® Lubrication Kit Powlube-102 Operating Pushrod 43645P01 Primary Disconnect Removal Tool 43397H01P...
  • Page 67 PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker IB-65020A This page is intentionally left blank. Powered by Safety ® Recommended Renewal Parts and Replacement Procedures...
  • Page 68 IB-65020A PowlVac® CDR 27kV & 38kV Vacuum Circuit Breakers 27kV & 38kV 1200A & 2000A January 2009 Powered by Safety ® Powell Electrical Systems, Inc. Tel: 713.944.6900 • Fax: 713.948.4569 Service Division - Houston www.powellind.com PO Box 12818 • Houston, TX • 77217 info@powellind.com ©2006 Powell Industries, Inc. • All rights reserved.

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