Capacitor Vacuum Switch Installation, Operation and ... · Installation, Operation and Maintenance Manual. ... jack/trolley. HANDLE WITH CARE. ... 1” bolts in the surge arrester

Product manual

PS36 Capacitor Vacuum SwitchInstallation, Operation and Maintenance Manual

2 ABB | PS36 Capacitor Vacuum Switch

1.0 About this manual ......................................................................................................................................................3

2.0 Safety information ......................................................................................................................................................3

3.0 Packaging and transport.............................................................................................................................................3

4.0 Acceptance ...............................................................................................................................................................4

5.0 Quality standards .......................................................................................................................................................4

6.0 Storage and handling .................................................................................................................................................4

7.0 Lifting the PS36 .........................................................................................................................................................5

8.0 Description of operation .............................................................................................................................................6

8.1 Standards .....................................................................................................................................................6

8.2 Capacitor bank application ............................................................................................................................7

8.3 Anti-condensation heater operation................................................................................................................7

9.0 Technical data ............................................................................................................................................................8

10.0 Dimensions ................................................................................................................................................................9

11.0 Installation ................................................................................................................................................................ 10

11.1 Initial set-up ................................................................................................................................................ 10

Rating plate, Terminal types ......................................................................................................................... 10

11.2 Mounting .................................................................................................................................................... 11

11.3 High voltage connections ............................................................................................................................ 12

Live and/or capacitor connections, Grounding .......................................................................................12 - 13

12.0 Control wiring and connections ................................................................................................................................. 14

12.1 Connection plug part numbers .................................................................................................................... 15

12.2 Controlling / operating the switch ................................................................................................................ 16

DC control operation, Electrically held operation, Auxiliary limit switch operation .....................................16 - 17

12.3 Manual trip operation .................................................................................................................................. 18

Manual trip lever with vertically/horizontally mounted switches ...................................................................... 19

13.0 Operation testing and initial checks ........................................................................................................................... 20

13.1 Pre-installation ............................................................................................................................................ 20

13.2 Pre-energization .......................................................................................................................................... 20

13.3 Service Operation ....................................................................................................................................... 21

14.0 Maintenance ........................................................................................................................................................... 21

Appendix A: Crate dimensions (sea / air) ............................................................................................................... 22

Appendix B: Control wiring – DC control, AC heater ............................................................................................... 23

IndexPS36 Capacitor Vacuum Switch

PS36 Capacitor Vacuum Switch | ABB 3

1.0 About this manualThis manual relates specifically to the 3-phase PS36 vacuum switch range manufactured by ABB. For specific information relating to ABB’s range of single phase vacuum switches - including variants of the PS15, PS17 and PS25, please contact your ABB representative.

Manual revision: 1.3 Revision date: July 2013

3.0 Packing and transportEach PS36 switch comes packaged individually in a timber crate suitable for either sea or air transportation. All timbers used in packaging are heat treated to ISPM 15 and are suitable for international shipping. See Appendix A for typical crate dimensions

2.0 Safety informationEnsure the installation, operation and maintenance of the PS36 switch is carried out by qualified personnel authorised to handle high voltage equipment.

Strictly follow the information in this instruction manual.

Check the rated performance of the apparatus is not exceeded during service.

Ensure the personnel operating the vacuum switch have access to and have read this instruction manual.

Incorrect operation, handling or maintenance can result in death, severe personal injury and equipment damage.

Read and understand the contents of this instruction manual and follow all locally approved procedures and safety practices before installing, operating and maintaining this equipment.

Pay special attention to the safety issues represented by the following symbol

Pay special attention to the important notes represented by the following symbol

The switch should always be transported in the

upright position.

The switches should be stacked no more than

2 units high.

The switch is packed in the CLOSED position; however

the switch may be shipped and transported in the open

or closed position with no detrimental effect to switch

operation.


5.0 Quality standardsABB’s switch manufacturing facility is certified to the following quality and environmental standards:

− ISO 9001:2000 (Quality) − ISO 14001:2004 (Environmental)

6.0 Storage and handlingUpon receipt, the vacuum switch should be carefully unpacked and checked as described above. The original packaging material should be used for subsequent shipping and storage.

Store the vacuum switch in a dry, dust-free, non-corrosive area. Ensure the vacuum switch is positioned to minimise the risk of mechanical damage – particularly the insulator sheds.

The switch is delivered affixed to the crate / pallet base with M12 hex head screws. It is strongly recommended that the switch is left on the pallet base during any movements, and that all movements be performed with a forklift or pallet jack/trolley.

HANDLE WITH CARE.

Do not attempt to move the switch unassisted –

The PS36 weighs approximately 105kg (230lb).

Do not lift the switch using the insulators –

always move using the switch body.

Ensure correct lifting technique is used at all times.

Failure to follow correct handling procedures could

result in personal injury and equipment damage.

4.0 AcceptanceEvery PS36 vacuum switch comes fully assembled, tested and packaged at the ABB factory. It is in good condition when accepted by the carrier for shipment.

On receipt, inspect the switch thoroughly for any damage and loss of parts incurred during shipping. Should any damage or loss be discovered, notify the shipping carrier and ABB immediately. Take photos of supplied condition as required.

The contents inside of a shipped box include:

− 1 x 3-phase vacuum switch with nameplate

corresponding to the unit ordered

− 1 x PS36 installation, operation and maintenance

manual

− 6 x protective bird caps for the exposed HV terminals

− NO external HV or LV connection or control cables

are supplied with the switch units unless separately

ordered

PS36 Capacitor Vacuum Switch


Figure 3: Lifting the switch horizontally using the lifting brackets

7.0 Lifting the PS36 When lifting the switch, avoid any stress to the functional insulating parts (poles) and the terminal connections of the unit. When lifting the switch off the base pallet the integrated housing lifting holes should be used (Figure 2). This ensures the centre of gravity of the unit is maintained and prevents the switch from swinging around when off the ground.

It is recommended that a jib or crane should be used when lifting the switch as shown in figure 2. Care should be taken to ensure that any ropes or slings used do not interfere with the switch insulator poles.

If the switch requires mounting either horizontally or vertically (ie base not on ground), purpose designed lifting brackets and associated fasteners can be supplied by ABB (figure 3 and 4).

The brackets are to be bolted to the body of the switch using 1” bolts in the surge arrester mounting holes.

Once the switch is firmly in place using the base mounting holes/ brackets, the lifting brackets should be removed before energising the switch or putting into service. Further information on installation can be found in section 11.

When lifting the switch using the supplied brackets, the centre of gravity is maintained through the axis lines shown.

Figure 4: Lifting the switch vertically using the lifting brackets

Figure 2: Lifting the switch using the integrated lifting points

Care should be taken when lifting up the switch using

the side lifting brackets. Lifting the switch too quickly

could result in the switch tipping over and damaging the

insulators.

Centre of gravity line

Centre of gravity line


8.0 Description of operation The PS36 vacuum switch is a solid dielectric, gang operated 3-phase vacuum switch suitable for use in a wide range of industrial and distribution system applications.

The switch utilizes ABB’s proven vacuum technology that is specifically designed for switching capacitor loads. Its design incorporates a fast acting solenoid mechanism, which provides force-travel characteristics ideal for vacuum switching. The solenoid mechanism also reduces the number of parts in the design and reduces the need for routine maintenance.

The PS36 differs to the single interrupter design of lower voltage ABB PS switches in that each phase is switched using a pair of vacuum interrupters connected in series. This is achieved by connecting together two switching poles with heavy duty bus connections. The current flow path for a particular phase is shown in figure 5.

A unique characteristic of the PS36 switch is the two-stage closing operation. When a close signal is sent to the switch, the first interrupter of each phase will simultaneously close, followed 100ms later by the second interrupter of each phase simultaneously.

Further information on the switch operation can be found in section 12.

Each vacuum switch has insulators made of advanced ‘hydrophobic cycloalaphatic epoxy’ (HCEP) resin. This is highly chip and crack resistant with insulating properties similar to silicone. The hydrophobic property lead to less surface wetting, provides better reliability and improves life expectancy. It is resistant to ultraviolet light while its high creepage characteristics ensure suitability in highly contaminated environments.

Each vacuum switch consists of:

− Six single pole vacuum switches with mechanical latching (separate open and close signals required for operation), depending on model ordered.

− A mechanical position indicator signalling OPEN / CLOSED position state, while doubling as a lever to manually trip the switch. See figure 5.

− Various control voltage options. − Auxiliary limit switch contact outputs for switch position

indication. Both heavy duty contacts and signal duty volt free contacts which monitor each pole are provided.

− Standard 10-pin panel mounted mil-spec connection plug − Highly durable, corrosion resistant, grade 304 stainless

steel tank housing − Optional ABB CQ900R Smart controller for manual

or automatic switch / capacitor bank operation.

8.1 StandardsAll ABB PS36 vacuum switches comply with the following standards:

− IEEE (ANSI) C37.66:2005 − Class 2 restrike rating (in accordance with IEEE 37.66)

All ABB PS36 vacuType test certificates from independent laboratories are available upon request.

Figure 5: Representative current flow path, phase 1.

Mechanical trip / position indicator lever



8.2 Capacitor bank application

The switch is suitable for a variety of applications including pole mounted capacitor banks and metal-enclosed capacitor banks. It is an outdoor device, which can also be applied to indoor solutions.

It is highly recommended that the vacuum switch is protected under short-circuit conditions. Fuses and circuit breakers are typically used. For example, in pole mounted capacitor banks, expulsion ‘drop-out’ fuses are typically connected upstream as means of protection. Figure 6 shows a typical connection diagram for a polemount capacitor bank. For specific installation recommendations or advice, please contact ABB.

The vacuum switches can be switched using a variety of controls. Manual control (ie. push buttons) is the most basic form. Automatic controls using time, temperature, voltage, current, VAR, power factor or a combination of the above (ie CQ900 Smart controller) can also be used.

ABB can provide the complete polemount solution through integration of its range of outdoor products. ABB’s product range also includes, but is not limited to power capacitors, controllers, control voltage transformers, surge arrestors and fuse cut-outs. Please contact ABB for further information on related products and solutions.

8.3 Anti-condensation heater operationThe PS36 contains an integrated thermostat and heating device to prevent the occurrence and build up of condensation inside the switch housing.

If the PS36 is installed outdoors it is a requirement that the anti-condensation heater power supply be connected. For indoor and metal enclosed applications, the heater connection is generally not required.

The wiring configuration options of the PS36 allows for the heater to be run from an AC power source regardless of whether the switch is being operated from an AC or DC source. This prevents the potential to drain a DC power source when continual low temperature operation is called for.

It is also common to connect the VT to its own drop out fuse so that control power is not lost in the case of a failed capacitor causing a fuse to blow. This is useful for troubleshooting purposes, and allows the control circuit (including the switch) to be tested without connecting the capacitor bank to the network.

More information on control wiring can be found in section 12.

DANGER HIGH VOLTAGE!

The application engineering of the PS36 vacuum

switch should only be performed by authorised

personnel.

CT

CONTROLLER

VT

FUSES

SURGE ARRESTERS

VACUUM SWITCHES

CAPACITOR BANK

LOAD SIDESUPPLY SIDE

CONNECTION DIAGRAM

Figure 6: Typical pole mount capacitor bank connection diagram

The switches need a control signal (pulse) lasting a

minimum of 1 second to fully operate the switch

(open / close).

The VT in the above diagram is shown with the HV

terminals connected phase-phase. It is also common

to connect the VT phase-neutral with no detrimental

effects to switch or controller operation.


9.0 Technical data

Electrical

Rated Maximum Voltage

Ungrounded capacitor banks, line-to-line kV rms

Grounded capacitor banks, line-to-line kV rms

38

66

Lightning impulse withstand voltage

Line to ground kV BIL

Open contact kV BIL

200

200

Power frequency withstand voltage, 60Hz

Dry, 1.0 minutes kV

Wet, 10 seconds kV

70

60

Continuous current (50/60Hz) A 300

Capacitive switching current A 300

Symmetrical fault making current A 5000

Short time withstand current

1.0 second (symmetrical) A 12500

High frequency making current

Transient peak A

Transient in-rush frequency Hz

15000

6,000

Control voltage range

120V AC (50/60Hz) VAC

120V DC VDC

240V AC (50 / 60 Hz) VAC

90….130

90….130

205.…265

Nominal current draw

during close A

during trip/open A

30

10

Signal pulse length required S 1.0

Nominal open time msec

Nominal close time msec

100

250

Creepage distance

Terminal to terminal mm / inch

Terminal to ground mm / inch

1600 / 63

1350 / 53

Manual trip opening force kg / lb 10 / 22

General

Weight kg

lb

105

230

Operating temperature range °C

°F

−40 to +65

−40 to +149

Mechanical endurance

close-open operations 30,000+

Control wiring requirements

Number of pins

Wire size mm2

AWG

10

1.5 to 2.5

16 - 13

Accessories / options

Junction box

Wildlife protective covers (additional if required)

Capacitor bank controller

– ABB CQ900L (local) and CQ900R (remote)

Connection cables (including connectors)

Remote / Low power pack supplies

Side lifting brackets


Type test certificates from independent testing facilities

are available upon request.

AUTIHEE

Stamp

autihee

Rectangle

autihee

Typewritten Text

30

autihee

Typewritten Text

autihee

Typewritten Text

autihee

Typewritten Text


Figure 7: PS36 dimensions

Note: All dimensions are shown in mm (inches).

10.0 Dimensions

918(36.2")

874(34.4")

307(12.1")

818(32.2")

807(31.8")

812(32”)

911(35.9")

400(15.8")

688(28.1")


11.0 Installation

11.1 Initial set-upRating plate

Check the rating plate to ensure the vacuum switch is the correct unit for the installation being carried out.

The name plate contains the following information:

− Part number − Rated voltage − Rated switching current − Control voltage − Lightning impulse withstand level − Short time current level

− High freq transient current level − Re-strike classification − Applicable test standard − Manufacture date − Serial number

Terminal types

The PS36 is manufactured with heavy duty terminals fitted for the high voltage connections.

There are two terminal types available – single hole palms (Figure 8) and double hole (NEMA type) palms (Figure 9). Due to the continuous current rating of 300A it is not recommended that stripped / bare cable terminals (Figure 10) be fitted to the PS36 due to their maximum design rating of 200A.


Only personnel trained to handle high voltage

equipment should be authorised to carry out

installation of PS switches.

The orientation of the terminal palms is fixed during

manufacture and cannot be altered once it leaves

the factory.

Figure 8:

Single hole palm

terminal

(400A max rating)

Figure 9:

Double hole NEMA

type terminal

(400A max rating)

Figure 10:

Standard 200A bare

cable terminal. NOT

AVAILABLE



11.2 MountingThe standard mounting of the PS36 is with the base fixed to a floor panel or bracket (insulators pointing up). Alternatively the PS36 can also be mounted vertically or horizontally with the base against a wall or upright channel bracket. Figure 11 outlines the position of the fixing points on the mounting channels.

Pre-assembled brackets for mounting the switch to

a pole with the switch in either vertical or horizontal

orientation are available from ABB.

Please contact ABB for details.

It is strongly recommended if the switch is being

mounted horizontally or vertically, that fixing bolts

be fitted in all available holes in the mounting

bracket channels. Mounting fasteners are not

included.

Ensure the mounting arrangement does not reduce

the required insulation level of the switch or

adjacent equipment.

When lifting the switch ensure the correct lifting

methods described in section 7 are followed.

Figure 11: Position of mounting channel holes –

switch in horizontal orientation

450mm (18”)

225mm (9”)

125mm(5”)

55.5mm(2.2”)

700mm (28”)

811.5mm (32.5”)

Ø 12mm

655mm(26.2”)


11.3 High voltage connections

Line and/or capacitor connections

The dual vacuum interrupter design of the PS36 means that there is no fixed orientation for which side of the switch must be connected to the source or load side of the switch (Figure 12). The most important consideration is that each phase is connected across the appropriate terminals.

ENSURE ALL POWER IS DISCONNECTED AND ISOLATED BEFORE PERFORMING ANY CONNECTIONS TO THE HV SWITCH TERMINALS

Figure 12: Correct conductor connections.

Lado da Linha / Fonte

Lado da Carga / Capacitor


Ensure the correct size conductors, lugs and/or terminal

connection palms appropriate for the terminal type and

switching application are used. The holes in both the

single and double hole PS36 terminals can accommodate

cable fitted with lugs up to M12 (1/2”).

If a single insulated conductor is to be used for terminal

connections, it is recommended that no less than

75mm2 (AWG 2/0) conductors are used. Please refer to

local standards and cable manufacturer data for more

information on recommended conductor capacities.

Tighten all terminal bolts using a torque wrench to 20

Nm (15 lb-ft). When tightening the connections take care

not to place undue stress on the terminals which may

compromise their integrity.

The arrangement of high voltage cables should not reduce

the required insulation level of the switch or adjacent

equipment.

Line /

Source side

Load /

Capacitor side


Grounding

The PS36 is fitted with a multi-directional cable clamp to solidly ground the switch housing (figure 13). The grounding clamp can accept wire sizes up to 75mm2 (2/0 AWG).Alternatively, a 1” bolt can be used if the ground conductor is lugged.

If an ungrounded capacitor bank is specified, special

consideration must be given to the connection of

the switches. ABB recommends that the switches be

mounted on suitable insulators (and subsequently

grounded) to prevent damage due to voltage

differential of the potentially energized rack. Please

consult ABB if using ungrounded capacitor banks.

The customer is responsible for grounding the

switch in a safe manner and in accordance with all

applicable standards. Failure to adequately ground

the switch housing can cause damage to the

electronic components inside the switch, and

result in switch failure.

Solidly ground all equipment. Failure to achieve an

effective ground connection can result in death or

severe personal injury.

Figure 13: Position of grounding point on tank housing.

(Insulators removed for clarity).

1” threaded grounding point


Control of the PS switch is made through a standard Mil-spec 10 pin male connection plug located on the lower tank (Figure 14). Identification of the pins in the cable plug is shown in figure 15.

Several pin-out combinations are available depending on whether the switch control is AC or DC, whether the heater supply is AC or DC and what configuration the actuator limit switches are – see Appendix B for further options. Special care should be taken to ensure the correct connections are made for the switch ordered / supplied.

The below table (refer Figure 16) identifies the standard signal configuration for an AC controlled (and heated) switch.

For special connection types not shown in this manual,

please contact ABB

BA

CD E

F

GH

I

J

Figure 14: Pin orientation of 10-

pin panel mount plug.

Figure 15: Pin identification of

cable socket

Wire ID Pin Label Signal Description

1 A Active / heater

2 B Neutral / Common

3 C Close

4 D Trip / Open

5 E Limit Switch “A” N/O Com

6 F Limit Switch “A” N/O Signal

7 G Limit Switch “B” N/C Signal

8 H Limit Switch “B” N/C Com

9 I Limit Switch “C” (Actuator) Com

10 J Limit Switch “C” (Actuator) N/O

It is recommended that control cables containing

cores no smaller than 1.5mm2 (15 AWG) are used.

Complete wiring loom and plug assemblies of various

lengths are available from ABB upon request.

12.0 Control wiring and connections



POLE GROUP 1

POLE GROUP 2

A

B

C

H

I

J

G

F

DE

NOTE:1. Contacts show switch in open state2. LS “A” and LS “B” contacts rated for 15A, 125/250VAC. 0.5A, 125DVC3. LS “C” contacts rated for 5A. 125/250VAC. 0.1A, 125DVC

ACT1A

THERMOSTAT15°C ON

HEATER100-260VAC

40W

TRIPCURRENT

SIGNAL

ACT1B ACT2A ACT2B ACT3A ACT3B

LS “B” N/C COM

COMMON

CLOSECLOSE

TRIP

CLOSECURRENT

SIGNAL

DCCOIL

1A

DCCOIL2A

DCCOIL3A1

2

3

4

5

POLE GROUP 1

CONTROL PCB

DCCOIL1B

DCCOIL2B

DCCOIL3B1

2

3

4

5

POLE GROUP 2

CONTROL PCB

TRIP

LS “A” N/O COM

LS “C” ACT COM

LS “C” ACT N/O

LS “B” N/C

LS “A” N/O

COM

HEATER

POLE GROUP 1

POLE GROUP 2

A

B

C

H

I

J

G

F

DE

NOTE:1. Contacts show switch in open state2. LS “A” and LS “B” contacts rated for 15A, 125/250VAC. 0.5A, 125DVC3. LS “C” contacts rated for 5A. 125/250VAC. 0.1A, 125DVC

ACT1A

THERMOSTAT15°C ON

HEATER100-260VAC

40W

TRIPCURRENT

SIGNAL


LS “B” N/C COM

COMMON

CLOSECLOSE

TRIP

CLOSECURRENT

SIGNAL

DCCOIL

1A

DCCOIL2A

DCCOIL3A1

2

3

4

5

POLE GROUP 1

CONTROL PCB

DCCOIL1B

DCCOIL2B

DCCOIL3B1

2

3

4

5

POLE GROUP 2

CONTROL PCB

TRIP

LS “A” N/O COM

LS “C” ACT COM

LS “C” ACT N/O

LS “B” N/C

LS “A” N/O

COM

HEATER

12.1 Connection plug part numbers Part Number (Standard Mil-Spec)

10 pin male plug on switch MS 3102R 18S-10P

10 pin female cable socket MS 3106F 18-1S+EBL44+10C

Figure 16: Control block diagram

Pole group 1

Pole group 2


12.2 Controlling / operating the switchOperation of the PS36 switch requires a control signal of at least 1 second be applied for each TRIP (OPEN) and CLOSE operation. Signals are to be supplied between the active pin (open or close) and the neutral pin.

The electronics inside the switch ensure power is only drawn for the time required to actuate the switch (approx 100ms). Leaving the control signal permanently on to the switch (latched signal) has no detrimental effect on switch operation. The pin assignment for the neutral (B), close (C) and open (D) remains the same for each variant of the PS36 (Figure 16).

An electronic manual or automatic controller is recommended for operating PS vacuum switches. The controller contacts should have a transient inrush rating of greater than 10A per switch (30A total). It is recommended that a controller operating a PS36 switch should contain a “Slow Blow” 10 to 12 amp switch fuse.

The ABB CQ900 series capacitor controller is ideal for control of the entire range of PS series vacuum switches. The CQ900L is a standalone automatic smart controller while the CQ900R is a fully featured remote controllable device utilizing DNP3.0 as the communications protocol. Other features include a 4-line LCD screen, user friendly interface, neutral current sensing, ABB CapLink short range wireless communications, and intuitive programming software. Please contact your ABB representative for more information.

DC Control Operation

The rapid current draw that takes place when the switch operates requires that the DC power source be chosen carefully to match.

If 48V DC control operation is required, please contact ABB for application advice specific to 48V DC operation. It is recommended that a capacitor discharge power supply be utilised for 48VDC control applications.

The dual pole design of the PS36 switch requires

a two-stage closing operation. This results in the

highest restrike classification being achieved and

excellent withstand capabilities. When a close

signal is sent to the switch, the first interrupters

of each phase will close simultaneously, followed

100ms later by the second interrupter of each phase

simultaneously. The resultant “clunk clunk” noise

heard during a PS36 closing operation is a unique

operating characteristic of the switch and is no cause

for concern.

Due to the current draw from the switch during the

OPEN / CLOSE operation (up to 30A), it is recommended

that no more than one PS36 switch be actuated

simultaneously on the same supply.

It is recommended that a VT no smaller than 1.5KVA be

used for controlling the PS36 (particularly for polemount

operation).

Using an undersized power supply can cause an

instantaneous voltage drop during switching and

prevent the switch from completing its operation.

Continued operation under this condition can damage

the switch’s control circuit board leading to switch

failure. Please contact ABB for more information if

unsure.

It is common that many UPS / inverter style power

supplies will not be able to handle the high inrush

currents required to drive the switch. Continued

attempts to operate the switch with an underpowered

supply can damage the switch controls.

It is recommended that a high capacity battery pack

be used if DC is the preferred operating voltage type.



Electrically held operation

Electrically held / contactor type operation is NOT available with the PS36. Please contact ABB if electrically held operation is a requirement for your application.

Auxiliary limit switch operation

Each PS36 switch is fitted with internal limit switches to indicate the position of the switch HV contacts. The output from the volt-free contacts can be connected to a relay or control system to monitor the operation of the switch remotely.

There are two types of limit switches in the PS36 – a N/O and N/C (changeover) heavy duty contact, and lighter duty contacts which measure the position of each actuator pole individually with the outputs being connected in series. The following table outlines the ratings of each type:

An example of the connections of each of these is shown in figure 16.

N/O or N/C is based on whether the switch

is in the open position.

Rated current –

AC 125/250VAC)

Rated current –

DC (125VDC)

Limit switch output “A”

– Heavy duty

15 A 0.5 A

Limit switch output “B”

– Heavy duty

15 A 0.5 A

Limit switch output “C”

- Actuator

5 A 0.1 A

Given the internal limit switch is controlled by the

movement of the DC solenoid within the switch, if

the switch is damaged (due to excess wear, external

physical force, welding of the HV contacts etc.)

the limit switch may not give a true indication of

the position of the HV contacts inside the vacuum

interrupter.

The limit switch output should not be used as the

sole indication of the status of the switch especially

where live voltages and personnel are involved.

Proper isolation and earthing procedures should

always be used where live equipment is concerned

to ensure a true visual break.


12.3 Manual trip operationAs with all models in the PS switch range, the PS36 has a combined manual trip lever / switch position indicator.

The switch can be manually opened by pulling down on the manual trip lever, typically with a hook-stick. The manual trip lever requires approx 10kg (22lb) of force to open.

When the switch is in the closed position, the indicator lever arm will be sitting in the horizontal position (parallel to the base) (Figure 17). When tripped or open the lever will hang down approx 45deg from its closed position (Figure 18).

Excessive force used to manually trip the switch can pull the indicator lever out of its locating mechanism resulting in non-indication of switch operations. It can also stress or damage the lever, reducing its operational life.

Where possible, it is better to use electrical control signals to operate the switch.

The trip lever can only be used to open the switch.

The switches internal mechanisms will not allow the

switch to be closed manually using the indicator/trip

lever. Trying to force the switch to close this way can

result in damage to the switch.

Figure 17: Indicator lever arm in switch closed position. Figure 18: Indicator lever arm in switch open position.

(Label removed for clarity)



Manual trip lever with vertically / horizontally mounted switches

When the switch is in its standard (upright) configuration the manual trip function is performed by pulling down on the manual trip lever. If the switch is mounted vertically or horizontally (as per figures 3 and 4) the manual trip lever can be mounted in a way that still allows manual tripping by pulling down on the lever. See figures 19 and 20.

To modify the position of the indicator lever:

− Remove the housing indicator lever label − Loosen the lever fixing screw using a 5mm hex

wrench / Allen key, until the lever is able to move freely from its locating slot.

− Rotate the lever arm 90 degrees so that the lever is horizontal in the closed position. Take care to ensure the lever sits back in the locating slot.

− Place some loctite on the thread and re-tighten the M5 hex head screw

− Replace the housing indicator label.

Figure 19: Indicator lever arm in closed position. Figure 20: Indicator lever arm in open position.


13.2 Pre-energization

Once installed (before HV is turned on) the following operation checks / tests should be performed:

− The switch mounting points are mechanically secure and the switch is solidly in place.

− The earth cable has been installed in the switches earth point.

− The control cable has been firmly screwed into place using the correct Mil-Spec mating connector.

− Electrical clearances between the switch and other apparatus is maintained.

− All terminal connections are tight and fit for purpose. − Operate the switch using the electrical control signals.

This can either be from an automatic capacitor controller or manual test box. If available at this point it is best to use the control device (and power source) that will be controlling the switch when in general operation.

− Ensure that the position indicator lever transitions from the open to closed position with the appropriate signal.

− Ensure that when the close signal is sent that the double clunk noise characteristic of the dual interrupter operation is noted.

− If being monitored, check that the state of the limit switch contacts transitions with each operation as expected.

The switch is now ready for service operation.

Before operation, the following inspections / tests should be performed:

− Insulators are free from damage and chips − Tank housing is free from dents and obvious damage

− HV terminals are solidly fixed. Terminals do not twist with hand force

− Position indicator / manual trip lever is not jammed − If in the closed position, pull down on the manual

trip lever to open the switch manually.

13.0 Operation testing and initial checks

Before connection of the HV conductors the following

operation tests should be performed (test bench or

workshop operation):

− Operate the switch using the electrical control

signals. This can either be from an automatic

capacitor controller, manual test box or custom

source.

− Ensure that the position indicator lever transitions from the

open to closed position with the appropriate signal.

− Ensure that when the close signal is sent that the double clunk

noise characteristic of the dual interrupter operation is noted.

− It is recommended that a meter be used to confirm the

continuity or open state across the terminals of each phase.

− If being monitored, check that the state of the limit switch

contacts transitions with each operation as expected.


Ensure authorised personnel perform the installation

and operation of high voltage equipment. Failure

to execute safe work practices can result in death,

severe personal injury and equipment damage.

It is recommended that the fuse links (or similar) be removed

before the below steps to ensure a physical barrier between the

switch and the system.

13.1 Pre-installation

The PS36 can only be closed using an electrical

control signal. There is no manual close function.




Ensure authorised personnel perform the

maintenance of high voltage equipment in

accordance with standard operating procedures.

Failure to execute safe work practices can result

in death, severe personal injury and equipment

damage.

14.0 Maintenance

13.3 Service operation

− Ensure switch is in the OPEN position

before replacing fuse links (upstream protection)

back into service. Failure to do so can damage

the capacitors, blow the fuses and trip upstream

protection devices.

− If not already done so, energise the high voltage

lines as per your company’s standard operating

procedures.

The capacitor bank requires several minutes

to discharge prior to, and between successive

operations. If the waiting time is not specified

on the capacitor unit rating plate, contact the

manufacturer. Standard discharge levels are 50V in

5 minutes (AS and IEEE) or 75V in 10 minutes (IEC):

− Assuming the minimum reclose block period has

been satisfied, the switch can be operated with

the capacitor bank online.

− The switch can now be left to operate as required

via manual, automatic or remote means and in

accordance with your company’s procedures for

safe capacitor bank control.

The PS36 vacuum switch has been designed with a mechanical life of over 30,000 close-open operations without the need for routine maintenance. The switches do however require routine inspection to check for physical damage and to verify their operation.

The frequency of inspection depends on the service conditions. The switches are designed for widely varying applications and climatic conditions and thus service intervals are best determined by the operator based on site conditions and operating experience.


Appendix A: Crate dimensions (sea / air)

1100mm(43.3”)

1042mm(41”)

1200mm(47.2”)

800mm(31.5”)

858mm(33.8”)

29mm29mm

29mm

1100mm(43.3”)

1042mm(41”)

1200mm(47.2”)

800mm(31.5”)

858mm(33.8”)

29mm29mm

29mm

1100mm(43.3”)

1042mm(41”)

1200mm(47.2”)

800mm(31.5”)

858mm(33.8”)

29mm29mm

29mm


Appendix B: Control wiring – DC control, AC heater

Wire ID Pin Label Signal

v A AC Active (for heater)

2 B Neutral / Common

3 C Close

4 D Trip

5 E Limit Switch “A” N/C

6 F Limit Switch A/B COM

7 G Limit Switch “B” N/O

8 H AC Heater COM

9 I Limit switch “C” Actuator Common

10 J Limit switch “C” Actuator N/O

ACT1A

THERMOSTAT15°C ON

HEATER100-260VAC

40W

TRIPCURRENT

SIGNAL


AC HEATER COM

COMMON

AC HEATER

CLOSECLOSE

COM

TRIP

CLOSECURRENT

SIGNAL

DCCOIL

1A

DCCOIL2A

DCCOIL3A1

2

3

4

5

POLE GROUP 1

CONTROL PCB

POLE GROUP 1

POLE GROUP 2

DCCOIL1B

DCCOIL2B

DCCOIL3B1

2

3

4

5

POLE GROUP 2

CONTROL PCB

TRIP

LS “A” N/O

LS “C” ACT COM

NOTE:1. Contacts show switch in open state2. LS “A” and LS “B” contacts rated for 15A, 125/250VAC. 0.5A, 125VDC3. LS “C” contacts rated for 5A. 125/250VAC. 0.1A, 125VDC

A

B

C

H

I

J

G

F

DE

LS “C” ACT N/O

LS “B” N/C

LS A/B COM

ACT1A

THERMOSTAT15°C ON

HEATER100-260VAC

40W

TRIPCURRENT

SIGNAL


AC HEATER COM

COMMON

AC HEATER

CLOSECLOSE

COM

TRIP

CLOSECURRENT

SIGNAL

DCCOIL

1A

DCCOIL2A

DCCOIL3A1

2

3

4

5

POLE GROUP 1

CONTROL PCB

POLE GROUP 1

POLE GROUP 2

DCCOIL1B

DCCOIL2B

DCCOIL3B1

2

3

4

5

POLE GROUP 2

CONTROL PCB

TRIP

LS “A” N/O

LS “C” ACT COM

NOTE:1. Contacts show switch in open state2. LS “A” and LS “B” contacts rated for 15A, 125/250VAC. 0.5A, 125VDC3. LS “C” contacts rated for 5A. 125/250VAC. 0.1A, 125VDC

A

B

C

H

I

J

G

F

DE

LS “C” ACT N/O

LS “B” N/C

LS A/B COM

Pole

group 1

Pole

group 2

AB

B A

ustr

alia

_DP

D 3

000

JULY

201

3

Contact us

For further information please contact:

ABB Australia Pty Limited 88 Beresford Road Lilydale Vic 3140 Australia Phone +61 (0) 3 9735 7333 Fax +61 (0) 3 9735 3863

www.abbaustralia.com

Note

While care has been taken to ensure that the information contained in this document is correct, no responsibility can be accepted for any inaccuracy. We reserve the right to alter or modify the information contained herein at any time in the light of technical or other developments. Technical specifications are valid under normal operating conditions only. We do not accept any responsibility for any misuse of the product and cannot be held liable for indirect or consequential damages. Technical data and design can be subject to change and should be confirmed prior to ordering.

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