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Service Manual Power Xpert® FMX

Power Xpert® FMX

Exchanging the circuit-breaker

Table of contents

Power Xpert® FMX 606.3768-02 8 April 2013 www.eaton.com 2

Table of contents


Table of contents

1 General 4 1.1 Introduction 4 1.2 Explanation of used warnings 4 1.3 Safety relating to medium-voltage installations 4 1.4 Tools, aids and protection equipment 5 1.5 Product standards and guidelines used 5 1.6 Product information 6

2 FMX SYSTEM DESCRIPTION 8 2.1 FMX System description 8 2.2 Cross-section, single line diagram and list of functions 8 2.3 Technical specifications, general 10

3 EXCHANGING THE CIRCUIT-BREAKER 11

Appendix 1 – Contact values 21

Appendix 2 - Materials and tools 22

General

4 Power Xpert® FMX 606.3768-02 8 April 2013 www.eaton.com

1 General

1.1 Introduction

The user must have authority to perform switching operations, which means being qualified in accordance with locally applicable guidelines, government legislation and in-house company regulations with respect to the operation of medium-voltage installations.

Legal and other regulations and documents pertaining to accident prevention, personal safety and environmental protection must be observed.

"The service activities described in this Service Manual are the full responsibility of the user and/or the third party who perform these activities.

Eaton assumes no responsibility with respect to these activities and shall not be liable for any costs, damages or losses whatsoever arising from or attributable to the service activities or to the use of this Service Manual by user and/or third party, including but not limited to loss of production, loss of profit or revenue, loss of use, claims of customers of user or for any other indirect or consequential damage or loss."

Operations involving the repair of the switchgear unit are to be carried out by personnel of Eaton Industries (Netherlands) B.V. or by Eaton trained and certified personnel.

Information with respect to these operations is, therefore, not included in this manual.

1.2 Explanation of used warnings

The manual uses the following names and signs to highlight important (safety) information:

WARNING

This warning indicates that non-observance of the specified (safety) instructions COULD result in serious bodily injury or even death.

NOTE

This note provides the user with additional information. The user's attention is drawn to possible problems.

TIP

Tips provide the user with suggestions and advice on how to make certain tasks easier or more convenient.

1.3 Safety relating to medium-voltage installations

LIFE HAZARD

Operations on medium-voltage installations can be life threatening if the necessary procedures are not observed.

Always take suitable precautions before working on a medium-voltage installation..

All personnel involved in operations carried out on, with or near electrical installations require to have been instructed on the safety requirements, safety rules and instructions applicable to the operation of the installation. Personnel must wear suitable clothing which fits the body closely. The person in charge of the operations must ensure that all requirements, regulations and instructions are complied with. The FMX unit has been designed to ensure that it exceeds applicable regulations. Furthermore, primary component enclosures are arc-resistant and interlocks have been fitted to prevent dangerous operations.

Operations when the unit has been isolated

Switching off prior to carrying out operations on an isolated system is subject to a number of essential requirements.

1. Switching off;

2. Complete isolation;

3. Protection from reactivation;

4. Checking whether the unit is dead;

5. Provide short-circuit proof protective earthing and a visible work-in-progress earth when needed.

6. Provide protection with respect to active components in the vicinity.

Safe layout of the work area

Ensure that access and escape routes are free at all times.

Do not leave flammable materials in or near access and escape routes. Flammable materials must not be stored in areas which could be affected by arcs.

In the event of a fire

Never attempt to extinguish a fire on the switchgear unit before it is completely dead, this applies to both primary and secondary switchgear. Even if non-conducting extinguishing materials are used, electricity may pass through the extinguishing equipment. Never extinguish a fire on the unit with water. Prevent water from flowing into the unit. Keep well clear of the unit while the fire is being extinguished in the area around the unit.

General


1.4 Tools, aids and protection equipment

Tools, aids and protection equipment must meet the requirements of national and international standards insofar as they are applicable.

Drawings and documents

Recent documents of the electrical installation must be available in order to gain sufficient understanding of the schematic layout of the switchgear unit.

Warning signs

If necessary, suitable warning signs shall be placed on the switchgear unit during operations to highlight possible hazards. The warning signs must comply with the applicable standards, insofar as they apply.

Performing measurements safely on the unit

Suitable and safe measuring equipment must be used for measuring safely on the unit. These instruments must be checked before and after use. The instruments must also be inspected periodically in accordance with the applicable regulations.

1.5 Product standards and guidelines used

Table 1: Current product standards used

Switchgear IEC Standard Title

General 62271-1 Common specifications for high-voltage switchgear and controlgear

62271-200 A.C. metal-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 52 kV

62271-201 A.C. insulation-enclosed switchgear and controlgear for rated voltages above 1 kV and up to and including 38 kV

Devices 62271-100 High-voltage alternating-current circuit-breakers

62271-102 Alternating current disconnectors and earthing switches

50181 Plug-in type bushings above 1kV up to 36kV and from 250A to 1.25kA for equipment other than liquid filled transformers

Degrees of protection 60529 Degrees of protection provided by enclosures (IP Code)

Voltage detection 61243-5 Live working - Voltage detectors - Part 5: Voltage detecting systems (VDS)

Transformers 60044-1 Instrument transformers - Part 1: Current transformers

60044-2 Instrument transformers - Part 2 : Inductive voltage transformers

Communication 60870-5 Telecontrol equipment and systems. Part 5: Transmission protocols

61850 Communications networks and systems in substations

ISO ISO 9001-2000 Quality

ISO 14001 Environmental management

General


1.6 Product information

The unit is equipped with type plates on the inside walls of the secondary compartment

The system nameplate includes:

technical specifications;

serial number and year of manufacture.

Each panel is uniquely identifiable by its panel nameplates.

They are located on the left inside wall in the cable connection compartment of each panel.

The panel type plate includes:

the switch type;

technical specifications.

Application outside the 'Normal Service Conditions' set out in IEC

Please contact Eaton if the unit is used in an environment not in accordance with the 'Normal Service Conditions' in IEC 62271-1.

Eaton Industries (Netherlands) B.V. P.O. box 23, 7550 AA Hengelo, The Netherlands

Powering Business worldwide

M.V. SWITCHGEAR IEC 62271-200

system: FMX r1.0 Metal enclosed w.o. no.:xxxxxxx

Serialno: xxxFMXxxxxxxxx Year of man.: 2010

Ur 24 kV Up 125 kV Ud 50 kV fr 50/60 Hz

Ir 2000 A Ik 16 kA Ip 63 kA tk 3 s

IAC AFL Ua xxx VDC

Main switching device: 25kA-1s

Cable compartments: 25kA-1s

Fig. 1-1: Example of system nameplate

CIRCUIT-BREAKER IEC 62271-100

type: NVF18CA-2416 r1.0

Ur 24 kV Up 125 kV Ir 1600 A

Ik 25 kA tk 3 s Ic 31.5 A

Isc 25 kA DCcomponent 35% Ima 63 kA

Ua xxx VDC

Operating sequence O - 0.3s – CO - 15s - CO

Classification M2 E2 C2

For system information refer to nameplate

Fig. 1-2: Example of panel type plate for circuit-breaker

CURRENT TRANSFORMER IEC 60044-1

type: CTS 90 Make: EATON

S1 – S2 75/5 A

5 VA Cl 10P10 ext. 120%

Ip 63 kA Ik 25 kA tk 1 s

Fig. 1-3: Current transformer information plate

VOLTAGE TRANSFORMER IEC 60044-2

type: YH0-3 Make: Sadtem

A-N 10000/√3

a1-n 100/√3 7,5 VA Cl. 0,2 Sth. 400VA

da-dn 100/3 30 VA Cl. 3P Sth. 100VA

12-28-75 kV 1,9 Ur - 8h

Fig. 1-4: Voltage transformer Information plate

General


Table 2: Explanation of type plate data in accordance with IEC

Variable Description Unit

system System -

r. Release -

IEC IEC reference -

type Type of switching device -

serial no. Serial number -

year of man. Year of manufacturing -

w.o.no. Works order number -

fr Rated frequency Hz

Ik Rated short-time withstand current kA

Ima Rated short-circuit making current kA

Ip Rated peak withstand current kA

Ir Rated normal current A

Isc Rated short-circuit breaking current kA kA

tk Rated duration of short-circuit s

Ua Rated supply voltage of auxiliary circuits V

Ud Rated short-duration power-frequency withstand voltage (1 minute) kV r.m.s.

Up, Uw Rated lightning impulse withstand voltage (peak) kV

Ur Rated voltage kV

Ur.t Rated voltage factor and corresponding rated time Vs

Isolation level Rated insulation level kV

Class M, E, C Classification according to IEC -

Operating sequence Rated operating sequence -

VA Rated output VA

CL Accuracy Class -

IAC Internal Arc Classification -

AFLR A= Authorized personnel only

F = Front side

L = Lateral sides

R = Rear side

-

FMX SYSTEM DESCRIPTION


2 FMX SYSTEM DESCRIPTION

2.1 FMX System description

The FMX switchgear system is a system with circuit-breakers which can be available for applications up to 24kV.

The system is fully metal-enclosed. A very compact and safe implementation is achieved using high-quality epoxy resin insulation.

Electric field strengths are kept at low levels by using specially shaped single-pole insulation components, as a result of which the risk of an internal fault is kept to an absolute minimum.

All live primary components of the unit and the main components of the drive mechanisms are housed in a closed enclosure. This prevents any dust, moisture and other environmental factors from affecting the proper operation of the system.

The enclosure is also arc resistant and thus provides conditions of optimum safety for the operator. The cable compartments are also available in arc-proof configuration.

Two basic panel versions are available:

a vacuum circuit-breaker of 630, 800, 1250, 1600, 2000 A.

a sectionaliser panel with vacuum circuit-breakers of 1250, 1600, 2000 A.

Both versions can be supplied in any combination and sequence in a system.

The system has two compartments: one main Busbar/Change-over switch compartment and a Circuit-breaker/Cable connection compartment.

The main busbar system is on top of the panel and is completely closed. In the cable compartment are the current transformers and in the cable compartment voltage transformers can also be installed. The voltage transformers in the cable compartment are fully electrically operated from the front of the panel where the cable must be tested. Busbar voltage transformers are on the top of the system and also on top of the sectionalisers. Cables with a diameter up to 800 mm2 can be connected with T-connectors and cables for more than 1200 mm2, a flag connection is available. An interlocked cable connection point to test the cables is in the front of the panel.

Earthing of the busbar is possible with the sectionaliser. It is also possible to make a circuit-breaker applicable for earthing the busbar. The circuit-breaker is equipped with vacuum interrupters and an electromagnetic mechanism, suitable for 30,000 operations. The circuit-breaker can be exchanged within 30 minutes from the front side of the panel. The change-over switch has two positions, connected to the busbar or connected to earth. The cable is earthed via the circuit-breaker. The interlock between the circuit-breaker and the door of the cable compartment is mechanical. The interlock between the circuit-breaker and the change-over switch is electric.

The insulation of the busbar system is based on air insulation. All other insulation is obtained by an insulating epoxy resin in which all single phase components are embedded and where the field strength between the conductors is controlled by the thickness and shape of the epoxy resin.

2.2 Cross-section, single line diagram and list of functions

Functions circuit-breaker

Connect cable to busbar.

Disconnect cable.

Connect cable to earth.

Protect outgoing feeder from overcurrents.

Testing of the cable.

Functions sectionaliser

Connection of sections.

Disconnection of sections.

Earthing of sections.



1. Busbar 2. Secondary compartment 3. Arc absorber 4. Operating panel 5. 2-position change-over switch 6. EM-Mechanism 7. Vacuum interrupter 8. Cable test opening 9. Cable connection 10. Voltage transformer

Fig. 2-1: Cross section circuit-breaker 630 / 800 A

1. Busbar 2. Secondary compartment 3. Arc absorber 4. Operating panel 5. 2-position change-over switch 6. EM-Mechanism 7. Vacuum interrupter 8. Cable test opening 9. Cable connection

Fig. 2-2: Cross section circuit-breaker 1250 / 1600 / 2000 A

1. Busbar 2. Secondary compartment 3. Arc absorber 4. Operating panel 5. 2-position change-over switch 6. EM-Mechanism 7. Vacuum interrupter

Fig. 2-3:Cross section sectionaliser 1600 / 2000 A



2.3 Technical specifications, general

Table 3: Technical specifications

Item Explanation Specification

Sound emission A-weighted equivalent noise pressure level at the work area.

Less than 70 dB(A) In accordance with EN292-2

Radiation emission

This emission is measured by the Physikalisch-Technische Bundesanstalt at a distance of 100 mm from the surface of the vacuum switch.

A Certificate of Conformity has been issued to this effect.

Less than 2x10-7 Sv/hour at operating voltage

Weight of the heaviest transport unit Nett (kg) Gross (kg)

See delivery note for the exact value.

1 circuit-breaker 630, 800 A 625 675

1 circuit-breaker 1250 A 750 800



1 sectionaliser 1600 A 1400 1500

1 sectionaliser 2000 A 1550 1650

Unit dimensions Width (mm)

Depth (mm)

Height (mm)

1 circuit-breaker 630, 800, 1250 A 500 1440 2100* Refer to the floor plan

1 circuit-breaker 1600, 2000 A 1000 1440 2100*

1 sectionaliser 1600 A 1200 1440 2250*

1 sectionaliser 2000 A 1325 1440 2250*

Unit dimensions including

Width (mm)

Depth (mm)

Height (mm)

Packing 1 circuit-breaker 630, 800,1250 A 800 1600 2220 Refer to the floor plan

1 circuit-breaker 1600, 2000 A 1100 1600 2220

1 sectionaliser 1600 A 1300 1600 2220

1 sectionaliser 2000 A 1425 1600 2220

Lifting and transport Facilities

The unit is fitted with special lifting fixtures. The unit may only be lifted by these fixtures.

Connection of power cables

In accordance with cable and plug manufacturer specifications.

Degree of protection Protection degree in accordance with IEC 60529 IP31D

* Per section one arc absorber box of 150 mm should be installed. With busbar voltage transformers the height is 500 mm more.

EXCHANGING THE CIRCUIT-BREAKER


3 EXCHANGING THE CIRCUIT-BREAKER

Exchanging a vacuum circuit-breaker within the FMX switchgear may only be done by certified persons. Certified persons will only receive a certificate if they pass a special Eaton training. The certificate is valid for one year and only applicable for the trained person and organisation. Extension of the certificate can only be given by Eaton.

Exchanging a circuit-breaker is only necessary in a very few occasions. Please consult the Eaton Service Organisation.

Cables connected to the panel that needs an exchange of the circuit-breaker should be earthed on the opposite side!

In case of a defect the circuit-breaker has to be exchanged and the complete system should be de-energized for a short period.

Starting position of the Circuit-breaker see Fig. 3-1:

Circuit-breaker ON.

2-position change-over switch in Busbar position.

Procedure:

Switch OFF the circuit-breaker.

Use the built-in voltage detector to check that the cable is dead in the outgoing panel. Arrows and dots are visible:

Detector is functioning correctly and the cable is live.

Arrows and dots not visible: cable is dead.

NOTE

The visible dot shows that the detector is functioning correctly in accordance with the demands for voltage detecting systems as described in VDE 0682 art. 415.

This is a continuous internal function check.

When the arrows and dots are not visible then check the operation of the voltage detection using the voltage detection tester see Fig. 3-2:

Insert the tester plugs in the contact sockets “earth” and L1. Test the detector by pressing the tester button. The tested phase arrow and dot should now be present;

Repeat the test for L2 and L3.

If one or more arrows and dots do not appear, this might be the result of a faulty voltage detector. Should this be the case contact Eaton. Ensure by other means that the cable is dead before carrying out any further switching operations.

Fig. 3-1

Fig. 3-2

Fig. 3-3



When the arrows and dots are visible then the functionality of the voltage detector can be tested as follows:

Connect a wire from the tester between the contact sockets “earth” and L1. The arrow and dot indication from this phase must disappear.

Repeat this test with the phases L2 and L3.

NOTE

The detector also has a piezo test button on the front for testing the LCD screen only.

If the VDS system is functioning well but shows a “life” cable, switch off all incoming cables and earth these cables higher in the system.

Push OFF button for moving the 2-position change-over switch to the Earth position (Fig. 3-4).

Push ON button for Circuit-breaker ON. The cable is now connected to earth.

Fig. 3-4

Open the top-unit and turn off the auxiliary voltage by switching the MCB's off (Fig. 3-5).

Fig. 3-5

Remove the strip, filoform covering plate and disconnect the low voltage terminals on clamps 1 up to 68 (X1) (Fig. 3-6).

Fig. 3-6



Pull the Earth Lock and remove the cable door.

Fig. 3-7

Manually switch off the circuit-breaker.

Fig. 3-8

Move the change-over selector switch to the left (Manual) position.

Fig. 3-9

Remove the 4 screws of the manual operation panel. Remove the Earth Lock and Manual Switch Off Handle.

Fig. 3-10

Push the Earth Lock support to the right.

Fig. 3-11



Prove that all connection points (cable and change-over switch side) are dead. Do this by inserting a HV test probe into the holes and test the voltage to earth.

Fig. 3-12

Remove the interlock of the cable compartment door (Fig. 3-13).

Unscrew 5 captive bolts of the circuit-breaker. Leave the upper mid bolt connected. For unscrewing the upper 2 bolts, turn the cover to open the openings (Fig. 3-14& Fig. 3-15).

Fig. 3-13

Fig. 3-14

Fig. 3-15

Place the truck. Make sure that the truck is placed in the right position (height) and that the brakes are activated (Fig. 3-16).

Fig. 3-16



Unscrew the bolt on the backside of the Circuit-breaker (Fig. 3-17).

Fig. 3-17

Unscrew the last captive bolt (upper mid position) of the circuit-breaker (Fig. 3-18).

Fig. 3-18

Withdraw the circuit-breaker out of the panel. During withdraw make sure it is kept in a horizontal position. (Fig. 3-19)

Fig. 3-19

Remove the truck with circuit-breaker and change it by a second truck with a new circuit-breaker (Fig. 3-20).

Place the second truck with the new circuit-breaker. Make sure it is placed in the right position (height) and that the brakes are activated (Fig. 3-21).

Then move the circuit-breaker into the panel.

Fig. 3-20

Fig. 3-21



Tighten the first bolt (upper mid position) before removing the truck! Tighten with a torque of 40 Nm (Fig. 3-22).

Fig. 3-22

Release the brake of the empty second truck and remove the truck (Fig. 3-23).

Fig. 3-23

Tighten the remaining 5 captive bolts. Tighten with 40 Nm. Check if the gray back plate of the mechanism hits the white plate of the housing (Fig. 3-24).

Fig. 3-24

Bring the secondary wiring with plugs back to the top-unit (Fig. 3-25).

Fig. 3-25

Tighten the bolt on the back side of the Circuit-breaker with a long tool (Fig. 3-26).

Fig. 3-26



Install the interlock of the cable compartment door (Fig. 3-27).

Install the complete Manual Operation Panel. Make sure that the Change-over selector slide is in the manual position (left) (Fig. 3-28).

Fig. 3-27

Fig. 3-28

Install the 4 screws of the manual operation panel. Install the Earth Lock and Manual Switch Off Handle (Fig. 3-29& Fig. 3-30).

Fig. 3-29

Fig. 3-30

Lock the 2-position change-over switch by padlocking the selector in the mid position (Fig. 3-31).

Fig. 3-31



Turn on the auxiliary voltage by switching the MCB’s. Next close the top-unit door (Fig. 3-32).

Switch on the circuit-breaker by pushing the push button on the top-unit door. The cable is now earthed via the circuit-breaker (Fig. 3-33).

Insert the test pins in the cable test facility holes (Fig. 3-34).

Connect the test apparatus (Fig. 3-35):

Connect the current injection cables to the earth bar and the backside of the test pin.

Connect the voltage measurement cables to the earth bar and the backside of the test pin.

Switch off the circuit-breaker by pushing the push button on the top-unit door (Fig. 3-36).

Fig. 3-32

Fig. 3-33

Fig. 3-34

Fig. 3-35

Fig. 3-36



Inject 100A DC (I0) through the created circuit and measure the voltage U2 (mV) (Fig. 3-37).

Calculate the resistance of the created circuit with following formula R2 = (U2/ I0) * 1000 (Fig. 3-38).

Switch on the circuit-breaker by pushing the push button on the top-unit door (Fig. 3-39).

Inject again 100A DC (I0) through the created circuits (in this case two circuits) and measure the voltage U2 (mV) (Fig. 3-40).

Now calculate the current I2 (ADC) that runs through the cable plug with following formula: I2 = (U2 / R2) * 1000.

Also calculate the current (I1) that runs through the circuit-breaker. This current can be calculated with following formula: I1 = I0 - I2 (Fig. 3-41).

Fig. 3-37

Fig. 3-38

Fig. 3-39

Fig. 3-40

Fig. 3-41



Connect the voltage measurement cable to the earth bar of the 2-position change-over switch

(Fig. 3-42).

Inject again 100A DC (I0) through the created circuits (in this case two circuits) and measure the voltage U1 (mV) (Fig. 3-43).

Now calculate the resistance R1 of this circuit. This can be done with following formula: R1 = (U1 / I1) * 1000.

Check if the calculated value is according the required value (see appendix for values per circuit-breaker type) (Fig. 3-44).

If the values are ok, the breaker is built in correctly.

Remove the test apparatus (Fig. 3-45).

Install the filoform covering plate and strip.

Remove the padlock on the 2-position selector switch.

Remove the take-over earthing on the backside of the plugs.

Install the cable door

The panel is now ready for use again (Fig. 3-46).

Fig. 3-42

Fig. 3-43

Fig. 3-44

Fig. 3-45

Fig. 3-46


Appendix 1 – Contact values

630 A max. 160 mV 630 A max. 90 mV

800 A max. 160 mV 800 A max. 90 mV

1250 A * 1250 A *

1600 A * 1600 A *

2000 A * 2000 A *

* Please contact Eaton for more information.


Appendix 2 - Materials and tools

Materials:

Scotch-Brite pads

Silicon grease

Acid free Vaseline

Breaker

Tools:

Special long tool (green piece)

Truck for replacing breaker

Voltage test pin


Eaton’s Electrical Sector is a global leader in power distribution, power quality, control and automation, and monitoring products. When combined with Eaton’s full-scale engineering services, these products provide customer-driven PowerChain™ solutions to serve the power system needs of the data center, industrial, institutional, public sector, utility, commercial, residential, IT, mission critical, alternative energy and OEM markets worldwide.

PowerChain solutions help enterprises achieve sustainable and competitive advantages through proactive management of the power system as a strategic, integrated asset throughout its life cycle, resulting in enhanced safety, greater reliability and energy efficiency. For more information, visit www.eaton.com/electrical.

Eaton Industries (The Netherlands) B.V.

P.O. Box 23

7550 AA Hengelo

The Netherlands

Tel.: +31 74 246 91 11

Fax: +31 74 246 44 44

[email protected]

www.eaton.eu/electrical

© 2013 Eaton Corporation

All rights reserved

Art.no.: 606.3768-02

http://www.eaton.com/electrical

mailto:[email protected]

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