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PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 This page is intentionally left blank. Powered by Safety ®...
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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: 713.948.4569 Powered by Safety ®...
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“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 ®...
IB-65100 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 ................................3 ENERAL D. S ................................4 PECIFIC E.
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PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 Contents Ch 4 Installation......................23 A. R ................................ 23 ECEIVING B. H ................................ 23 ANDLING C. S ................................23 TORAGE D. P ......................24 LACING THE IRCUIT REAKER ERVICE 1) High-Voltage Insulation Integrity ............................24 2) Vacuum Integrity ..................................25 3) Control Voltage Insulation Integrity ..........................26 4) Mechanical Operation Check ..............................26...
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IB-65100 Contents Ch 6 Recommended Renewal Parts and Replacement Procedures .......47 A. O ............................. 47 RDERING NSTRUCTIONS B. R ........................... 47 ECOMMENDED ENEWAL ARTS C. R ..........................47 EPLACEMENT ROCEDURES 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 Device Assembly (UV) ..........................57...
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PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 Figures Figure 1 Front View of PowlVac® ASD Circuit Breaker with Cover ............7 Figure 2 Rear View of PowlVac® ASD Circuit Breaker ................8 Figure 3 PowlVac® ASD Circuit Breaker Compartment ..............9 Figure 4 Operating Pushrod Assembly of PowlVac®...
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.
IB-65100 A. S All illustrations are shown using deenergized COPE equipment. The information in this instruction bulletin describes the following PowlVac ASD 38kV WARNING WARNING vacuum circuit breakers: Be sure to follow the appropriate safety • 38PV40ASD - 1200A & 2000A precaution while handling any of the •...
IB-65100 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.
DO and any adverse local conditions including NOT FORCE THE PARTS INTO POSITION. excessive dust, ash, corrosive atmosphere, CONTACT POWELL FOR INSTRUCTIONS. vermin and insect infestations. E. X-R D. S PECIFIC...
IB-65100 F. S AFETY ABELS The equipment described in this document has DANGER, WARNING, CAUTION, and instruction labels attached to various locations. All equipment DANGER, WARNING, CAUTION, and instruction labels shall be observed when the circuit breaker is handled, operated, or maintained.
1) Mechanical Description A. G ENERAL a) General The PowlVac ASD 38kV vacuum circuit breaker (Figure 1) is a version of the PowlVac 38kV The stored energy mechanism is located CDR (IB-65020) vacuum circuit breaker. It in the front of the circuit breaker behind eliminates the need for an umbilical cord in the front cover.
IB-65100 Figure 1 Front View of PowlVac® ASD Circuit Breaker with Cover a. Push to Trip Roller Manual Charging Crank b. Handle k. Manual Trip Paddle c. Test Plug Interlocking Device Breaker Open/Closed Indicator d. Test Receptacle Guide m. Manual Close Paddle e.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 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 g. Secondary Disconnect Plug h.
IB-65100 Figure 3 PowlVac® ASD Circuit Breaker Compartment a. Push to Trip Knob 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 Compartment Interference Plate Circuit Breaker Base Pan k.
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IB-65100 b) Main Spring Charging System are assembled to the crank arms, which point outward. The crank arms engage The charging motor (Figure 6, i), located the bottom ends of the connecting on the bottom right of the base pan, is rods (Figure 6, e).
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 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 Spring g.
IB-65100 Figure 7 Close-Up Front View of PowlVac® ASD 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 p. Camshaft d. Holding Pawl Support Arm q.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 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 ®...
IB-65100 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.
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PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 The close latch shaft, when released d) Tripping System either by the closing coil or the manual close operator, allows the main closing In the closing cam and fundamental spring to pull the crank arms upward. linkage positions shown in Figures 8b As the crank arm moves upward it and 8d, the contact loading springs...
IB-65100 With the standard electrical control c) Anti-Pump Relay scheme, as soon as the main closing spring is discharged on a closing The anti-pump relay (Figure 6, b) operation, the charging motor is provides a logic function for the control switched on to recharge the springs.
The main racking mechanism is located in the switchgear. The main levering in device components for the PowlVac ASD circuit breakers are described in the following sections: a) Interlocks PowlVac ASD circuit breakers are...
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 Figure 11 Test Plug Jumper Interlock While in the TEST/DISCONNECTED the test plug interlock device ensures that the circuit breaker cannot be moved to the CONNECTED position or removed from the compartment while the test plug jumper in place.
IB-65100 device connected to the stationary end breaker, check the assembly to assure it has of the vacuum interrupter, and the lower not been damaged during shipment and is device connected to the moving end of the tight. Check the linkage to make sure it has vacuum interrupter assembly.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 F. O I. V PERATING OLENOIDS ACUUM NTERRUPTERS The closing coil solenoid (Figure 7, o), located For a listing of the vacuum interrupters used under the mechanism, is attached to the in Type ASD circuit breakers, see Table C, breaker bottom pan by two screws accessible Primary Current Path.
When the circuit breaker is received, check for signs of damage. If damage is found or suspected, file claims as soon as possible with the transportation company and notify the nearest Powell representative. B. H ANDLING The circuit breaker is equipped with four wheels so that it may be rolled easily on level floors.
The insulation system from one check period to user must verify functions after receipt. Powell the next. recommends that the tests be performed in the sequence listed below:...
Test each pole of the circuit verification of vacuum integrity. All breaker separately, with the other 2 poles PowlVac ASD 38kV circuit breakers shall be and the frame grounded. Perform the field tested with a minimum of 40kVAC applied dielectric test described in ANSI Standard across fully open contacts for 10 seconds.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 Recording the leakage readings is not 3) Control Voltage Insulation Integrity necessary, as a dielectric breakdown will trip all portable DC hipot test sets. If a If the user wishes to check the insulation DC test breakdown occurs, the test must integrity of the control circuit, it may be be repeated after reversing the DC high...
IB-65100 Push the manual close paddle (Figure 1, m) 1) Inserting the Circuit Breaker to the Connected inward and the circuit breaker will close. Position The circuit breaker open/closed indicator (Figure 1, l), located above the manual close Follow the steps below to prepare the breaker paddle will now display, “Breaker Closed”.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 Figure 14 Push to Trip Knob & Racking Access Figure 15 Racking Indicator Flags & Racking Door Handle a. Push to Trip Knob b. Racking Access Door Note: The compartment door is removed for clarity.
IB-65100 2) Inserting the Circuit Breaker to the F. R EMOVING THE IRCUIT REAKER FROM THE WITCHGEAR Test/Disconnect Position QUIPMENT 1) Removing the Circuit Breaker from the CAUTION CAUTION Connected to the Test/Disconnected Position Prior to inserting the circuit breaker into the circuit breaker compartment, make sure that CAUTION CAUTION...
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 2) Removing the Circuit Breaker from the 3) Removing the Circuit Breaker with Test Plug Test/Disconnect Position out of the Circuit Interlock Engaged Breaker Compartment CAUTION CAUTION CAUTION CAUTION Prior to removing the circuit breaker from the Prior to removing the circuit breaker from the circuit breaker compartment, make sure that circuit breaker compartment, make sure that...
Ch 5 Maintenance A. G ENERAL ESCRIPTION 1) Introduction Note: Contact Powell Service Division for assistance in performing maintenance or setting up A regular maintenance schedule must be a maintenance program either by phone established to obtain the best service and (1.800.480.7273), by email...
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 A permanent record of all maintenance 2) Inspection and Cleaning work should be kept, the degree of detail depends upon the operating conditions. Visually check the circuit breaker for loose The record will be a valuable reference for or damaged parts.
Before applying any type of lubrication to the circuit breaker, the stored-energy mechanism should be in the open position, and all springs should be discharged. Powell offers 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.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 Figure 16 Lubrication Spring Yoke b. Test Plug Receptacle Primary Primary d. Trip Shaft Disconnecting Disconnecting Bearing Device Fundamental Jackshaft g. Pawl Support h. Crank Pin Ratchet Wheel Linkage Pin Support Pawls Motor Drive Close Latch...
IB-65100 Figure 17 Lubrication (cont) m. Main Closing Spring Guide n. Primary Trip Fundamental Prop Linkage p. Open-Closed q. Flag Support Jackshaft Camshaft Motor Cutoff Flag Drive Outer Bearings Needle Lever Pin at Support Bearings Jackshaft u. Close Shaft Motor Drive w.
IB-65100 Figure 18 Main Closing Spring Assembly Figure 19 Main Closing Spring Assembly Compressed for Removal Installed a. Spacer a. Connecting Rod b. Flat Washer b. Flat Washer c. Lock Washer c. Bracket d. Bolt d. Bolt e. Bracket 3) Closing Spring Removal spring rod together with the flat washer, and lock washer.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 4) Slow Closing of Mechanism 5) Mechanism Adjustments The slow closing of mechanism described WARNING WARNING is not required for routine maintenance; however, it may be a useful procedure When any maintenance procedure requires for troubleshooting circuit breaker the opening or closing of the circuit breaker misoperation.
IB-65100 To adjust the pawl perform the following b. Adjustment of Primary Trip Prop steps: Figure 20 Primary & Secondary Trip Prop 1. Remove the escutcheon to gain access Adjustment to the head of the bolt holding the adjusting eccentric. 2.
LACING THE IRCUIT REAKER ERVICE 4) Mechanical Operation Check. To adjust the PowlVac ASD Tripping System 10. Manually CLOSE the circuit breaker. perform the following steps: 11. Using leaf type feeler gauges with a total of .090” thickness selected, 1. Prior to performing this adjustment...
IB-65100 13. Choose one of the following steps Figure 22 Trip Armature Assembly Left View according to the TRIP status: If the circuit breaker TRIPPED during the test performed in step 12, increase the gap between the trip coil armature and the latch check operator by bending the latch check operator downwards slightly using channel lock pliers or a small...
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 18. If there is an air gap of 0.040” between Figure 23 Trip Armature Assembly Right View the trip armature actuator (Figure 22, b) and the latch check operator (Figure 22, d) of 0.040”, then proceed to step 20.
IB-65100 20. Perform the latch check switch 3. Loosen the two screws which secure adjustment per the procedure found in the latch check switch and rotate the Ch 5 Maintenance, B. M latch check switch about the pivot ECHANISM 4) Slow Closing of Mechanism, d. Latch screw downward to the lowest position Check Switch Adjustment.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 e. Adjustment of Close Latch Shaft f. Open and Close Spring Release Lever Adjustment The close latch shaft (Figure 7, l) passes through the side sheets of the stored If the circuit breaker has rolled over an energy mechanism frame at the front of obstruction on the floor which caused and below the cam shaft.
RESULT. When it is necessary to remove or replace the vacuum interrupter, refer to Ch 6 Recommended Renewal Parts and Replacement Procedures, C. R EPLACEMENT , 1) Vacuum Interrupter Assembly ROCEDURES or contact the Powell Service Division. Powered by Safety ® Maintenance...
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 2) Timing To check the primary resistance, pass a minimum of 100A DC through the circuit Perform CLOSE and OPEN timing tests at breaker pole, with the circuit breaker the nominal control voltage. The voltage is closed.
NSTRUCTIONS Powell recommends that only qualified persons perform maintenance on these units. Refer 1. To order Renewal Parts from Powell, visit to the Qualified Person Section in the front the website at www.powellind.com or call of this instruction bulletin. If these circuit 1.800.480.7273.
The vacuum interrupter should only be Note: It is important to document the replaced by a qualified person or a Powell location and size of the bottom bus Service technician. Contact Powell for further support and the high voltage housing assistance at 1.800.480.7273.
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IB-65100 frame. The pushrod will break if it Prior to assembly, clean all parts, hits the frame with sufficient force. including the high voltage housing xii. Place the vacuum interrupter (3) (11) with denatured alcohol. and the front terminal clamp (10) ii.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 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®...
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IB-65100 ab. Align the hex head cap screws ix. Apply Lock-Tite 243 to the hex head (32) to the threads of the screws (39 & 23) and install and vacuum interrupter (3). torque the screws to 30 ft.-lbs. ac. Insert an 1½” temporary bolt x.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 iv. If the gap needs to be decreased, 3) Primary Shunt Trip Coil Assembly hold the high voltage regulator (13) with channel lock pliers, loosen the This assembly (Figure 7, a) is located in the hex head nut (46) and turn the high center part of the mechanism area, just left voltage regulator disc (13) to the...
IB-65100 4) Secondary Shunt Trip Coil Assembly f. Trip the circuit breaker several times electrically to ensure that secondary This assembly is located in the center part shunt trip coil assembly is functioning of the mechanism area, just to the right of properly.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 f. Install the UV assembly device ensuring 6) Charging Motor Assembly that it is in full contact with the mounting surface. Attach the UV using This assembly is located lower right hand the two 5/16-18 x 3/4 HEX head bolt, flat side of the mechanism (Figure 6, i).
IB-65100 7) Anti-Pump Relay Assembly g. Relays in 250VDC closing circuits are provided with dropping resistors to This assembly is located near the top of the apply the proper voltage to the relay mechanism, to the right of the opening coil.
PowlVac® ASD 27kV & 38kV Vacuum Circuit Breaker IB-65100 8) Latch Check Switch 9) Motor Cutoff Switch Assembly The latch check switch is located on the left The motor cutoff switch assembly is located side of the main mechanism frame, near the on the floor pan of the mechanism area just bottom of the main closing spring right of the main mechanism (Figure 7, t).
IB-65100 10) Auxiliary Switch h. Operate the circuit breaker electrically several times to ensure the switch The auxiliary switch is located on the lower functions properly. left front of the mechanism area Replace the front cover (Figure 6, h). CAUTION CAUTION Ensure that the control circuits are deenergized and the circuit breaker is...
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