Instruction, operation, and maintenance manual. Page 2. 2 | Page. Instruction Manual for HV Unit of OVR-15, 27 & 38. Copy Right.
OVR-15, 27 & 38 outdoor vacuum recloser High voltage unit Instruction, operation, and maintenance manual
-- DISTRIBUTION SOLUTIONS OVR-15, 27 & 38 outdoor vacuum recloser High voltage unit Instruction, operation, and maintenance manual Copy Right This manual and parts thereof must not be reproduced or copied without written permission from ABB, and the contents thereof must not be imparted to a third party, nor used for any unauthorized purpose. Disclaimer The data, examples and diagrams in this manual are included solely for the concept or product description and are not to be deemed as a statement of guaranteed properties. All persons responsible for using the equipment addressed in this manual must satisfy themselves that each intended application is suitable and acceptable, including that any applicable safety or other operational requirements are compiled with. In particular, any risk in applications where a system failure and/or product failure would create a risk for harm to property or persons (including but not limited to personal injuries or death) shall be the sole responsibility of the person or entity applying the equipment and those so responsible are hereby requested to ensure that all measures are taken to exclude or mitigate such risks. This product has been designed to be connected to medium voltage distribution networks. It is the sole responsibility of the person or entity responsible for the network administration to ensure a secure connection to the network and take necessary measures to protect the product and the network, its system and interface included against any kind of security breaches, unauthorized access, interference, intrusion, leakage and /or thefts. ABB is not liable for any such damages and/or losses. This product is intended to be operated and maintained by qualified personnel, thoroughly trained and knowledgeable with regards to the associated hazards involved. This publication is written only for such qualified personnel and is not intended to be a substitute for adequate training and experience in the safety procedures for this device. This document has been carefully checked by ABB, but deviations cannot be completely ruled out. In case any errors are detected, the reader is kindly requested to notify the manufacturer. Other than under explicit contractual commitments, in no event shall ABB be responsible or liable for any loss or damage resulting from the use if this manual or the application of the equipment. 2|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 1 CONTENTS A. Introduction .......................................................................................................................................... 6 B. Environmental protection program ................................................................................................ 6 C. X-ray emission standards .................................................................................................................. 6 D. End of life recycle/disposal............................................................................................................... 7 E. Product related safety notices ......................................................................................................... 7 F. Working on HV cabinets and mandatory safety procedures. ................................................... 8 G. Warning Texts and Symbols..............................................................................................................9 2 Packing and transport ...................................................................................................................... 10 3 Receipt and Storage prior to installation .....................................................................................11 4 Technical details ................................................................................................................................ 14 5 General Description of ovr-15, 27 & 38 recloser .......................................................................... 16 5.1.1 Housing........................................................................................................................................................................ 16 5.1.2 Recloser Pole and current & voltage sensor ........................................................................................................ 17 5.1.3 Current & voltage sensor ......................................................................................................................................... 17 5.1.4 Single Coil Magnetic Actuator ................................................................................................................................ 18 5.1.5 Emergency Manual Trip (k69) Handle ................................................................................................................... 18 5.1.6 Mechanical ON/OFF position Indicator................................................................................................................ 18 5.1.7 Status Auxiliary limit switches................................................................................................................................ 18 6 Standard production tests.............................................................................................................. 19 7 Installation .......................................................................................................................................... 19 7.1.1 7.1.2 Vacuum test procedure............................................................................................................................................20 Contact Resistance ...................................................................................................................................................20 7.2.1 Pole mounting ............................................................................................................................................................ 21 8 Recloser operation ............................................................................................................................ 27 3|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 9 Inspection and maintenance ..........................................................................................................28 10 Typical rating plate details..............................................................................................................30 11 GA of HV cabinet drawings ............................................................................................................. 31 11.1.1 OVR-15 HV Cabinet General Arrangement: .......................................................................................................... 31 11.1.2 OVR-27 HV Cabinet with Single Voltage Sensing General Arrangement: ...................................................... 32 11.1.3 OVR-27 HV Cabinet with Double Voltage Sensing General Arrangement: .................................................... 33 11.1.4 OVR-38 HV Cabinet General Arrangement: ..........................................................................................................34 12 Recommended spare parts.............................................................................................................35 4|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 For your safety! - Make sure that the installation place & environment is suitable for the electrical apparatus. - Check that all the installation, putting into service and maintenance operations are carried out by qualified personnel having relevant knowledge of the apparatus. - Make sure that the standard and legal prescriptions are complied with during installation, putting into service and maintenance, so that installations according to the rules of good working practice and safety in the workplace are constructed. - Strictly follow the information given in this instruction manual. - Ensure that the rated performance of the apparatus is not exceeded during service. - Ensure that the personnel operating the apparatus have this instruction manual to hand as well as the necessary information for correct intervention. 5|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 A. INTRODUCTION This manual contains the information needed to install HV unit of OVR-15, 27 & 38 Auto-recloser and put them into service. For correct use of the product, please read this manual carefully along with instruction, operation, and maintenance manual for low voltage unit. OVR-15, 27 & 38 reclosers are designed for different installation configurations. However, the mounting structure for this apparatus allows further technical-construction modifications (at the customer's request) to adapt to special installation requirements. Consequently, the information given below may sometimes not contain instructions concerning special configurations. Apart from this manual, it is therefore always necessary to consult the latest technical documentation (electric circuit and wiring diagrams, assembly and installation drawings, any protection coordination studies, etc.), especially regarding any variants requested in relation to the standardized configurations. Only use original spare parts for maintenance operations. For further information, please refer recommended spare part list mentioned in this manual. All the installation, putting into service, running and maintenance operations must be carried out by skilled personnel with in-depth knowledge of the apparatus. B. ENVIRONMENTAL PROTECTION PROGRAM The OVR-15, 27 & 38 reclosers are manufactured in accordance with the ISO 14000 Standards (Guidelines for environmental management). The production processes are carried out in compliance with the Standards for environmental protection in terms of reduction in energy consumption as well as in raw materials and production of waste materials. All this is thanks to the medium voltage apparatus manufacturing facility environmental management system. C. X-RAY EMISSION STANDARDS One of the physical properties of vacuum is the possibility of X-ray emission when the interrupter contacts are open & subjected to high voltage. Specific tests carried out shows that local emission at a distance of 10 cm from the Interrupter or pole surface does not exceed 1mSv/h. It follows that: At the rated service voltage, use of vacuum interrupter is absolutely safe. Application of the withstand voltage at industrial frequency, according to the IEC 62271 - 111 standard, is safe. Application of a voltage higher than the power frequency withstand voltage at the industrial frequency or direct current specified in the IEC standard, may cause permanent damage to the unit and it is out of the guaranteed operating limits. Limitation of the above-mentioned local phenomena, with interrupters with open contacts, depends on keeping the specified distance between the contacts. This condition is intrinsically guaranteed by correct operation of the operating mechanism and adjustments of the transmission system. 6|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 D. END OF LIFE RECYCLE/DISPOSAL ABB is committed for complying with relevant legal and other statutory requirements for environment protection according to the ISO 14001 standard. The duty of the end user is to facilitate end of life recycling & disposal according to the applicable regulations. During disposal of product, it is necessary to act in according with local legal requirements in force. Disposal can either be carried out thermally in an incineration plant or by storing on a waste site. Following are the methods of recycle/disposal: Table 1 : Recycle/disposal methods Raw Material Iron Stainless steel Copper Brass Aluminum Zinc Thermoplastic Epoxy incl. 60% quartz Rubber Porcelain Packing foil Wooden pallet Recycle Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Environmental effects & reuse processes Separate, utilize in favor of new source (ore) Separate, utilize in favor of new source (ore) Separate, utilize in favor of new source (ore) Separate, utilize in favor of new source (ore) Separate, utilize in favor of new source (ore) Separate, utilize in favor of new source (ore) Make granulate, re-use or apply as energy superior additive in refuse incineration Cut into pieces & use as high-grade energy additive in cement mill Cut into pieces & used for landfills High grade energy additive in refuse incineration E. PRODUCT RELATED SAFETY NOTICES The OVR-15, 27 & 38® recloser should be installed within the design limitations as described on its nameplate and in these instructions. In addition, always follow your company's safety procedures. This recloser should not be used by itself as the sole means of isolating a medium voltage circuit. For the safety of the personnel performing maintenance operations on the recloser or connecting equipment, all components should be electrically disconnected by means of a visible break and securely grounded. This manual uses terms "ground" & "grounding" as per IEEE. These are equivalent to IEC terms "earth" and "earthing". This manual contains terms and expressions commonly used to describe this kind of equipment. These instructions do not attempt to provide the user of this equipment every possible answer to questions which may appear in the application, operation, and maintenance of the product. 7|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 Detailed descriptions of standard repair procedures, safety principles, and service operations are not included. It is important to note that this document contains some warnings and cautions against some specific service methods that could cause personal injury to service personnel or could damage equipment or render it unsafe. These warnings do not cover every conceivable method in which service (whether or not recommended by ABB) may be performed. Secondly, ABB cannot predict or investigate all potential hazards resulting from all conceivable service methods. Anyone using service procedures or tools, whether or not recommended by ABB, must be completely certain that both their personal safety and the safety of the equipment will not be jeopardized by the service method or tools selected. All information contained in this manual is based on the latest product information available at the time of printing. The right is reserved to make changes at any time without notice. Also, as improvements in assemblies and parts are made, some parts may differ in appearance that depicted in illustrations; however, functionality will be equivalent. F. WORKING ON HV CABINETS AND MANDATORY SAFETY PROCEDURES. Whenever it is required to work on HV &/or LV units, it is mandatory to follow following minimum procedures: a. Isolate the recloser from power system on its both sides. Put recloser in OPEN condition by operating the emergency manual trip handle (yellow handle). Once recloser is opened, the handle gets locked & blocks close operation both electrically & mechanically till the handle is reset to its original (not operated) position. b. Confirm the OPEN status of the recloser from the mechanical ON/OFF indicator, from SLD on LCD display & the indication LEDs on RER615 HMI. c. Always put the SERVICE /DISCHARGE selector switch in the LV cabinet to DISCHARGE position. d. Follow the safety warning instructions on various warning labels provided on the LV & HV units e. Remove the control cable from both HV & LV cabinets & cover the 24 pin male connectors by plastic caps provided. Although warning hazards are related to personal injury, it is necessary to understand that under certain operational conditions, operation of damaged equipment may result in degraded process performance leading to personal injury or death. Therefore, comply fully with all warning and caution notices. 8|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 G. WARNING TEXTS AND SYMBOLS Warning texts mentioned are stated based on different degrees of urgency, which should be carefully observed. These are described below. Danger Danger Indicates an immediate risk situation that can lead to death or serious personnel injury if not avoided Warning Warning Indicates an immediate risk situation that can lead to death or serious personnel injury if not avoided Caution Note Caution Indicates a risk situation that can lead to small or moderate damage Note is used when there is a danger that can lead to equipment damage only. Important Important indicates an operation or a suggestion for handling. Warning Symbols Following warning symbols may appear on warning sticker as a part of the product. 9|Page Instruction Manual for HV Unit of OVR-15, 27 & 38 2 PACKING AND TRANSPORT GOODS MARKING The recloser is transported in "Contact OPEN" position. The factory assembled recloser may be transported in different packing cases for HV unit, LV unit and mounting brackets. Each case is marked with case markings on two sides with indelible black ink. The case markings include information of case number, gross weight, etc. Optional accessories like auxiliary power voltage transformer, terminal connectors, etc. might be transported in a separate case. In addition to the above, the cases are marked with the following symbols. These should be observed when choosing lifting equipment. Figure-1 : General symbols on packing case DOCUMENTS Documents provided with the recloser during dispatch. - Instruction manual - Routine test certificate - Drawings - Packing list - Other documents as mutually agreed in contract with ABB TRANSPORT AND LIFTING The recloser shall be transported in packed condition only. Before lifting the case, observe the information on it (such as symbol, weight, etc.). Following precautions are to be taken while lifting: 10 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 - Ensure that packing cases are not placed on wet surfaces / waterlogged areas. - Reclosers should not be stacked one over the other. - Reclosers should be lifted by a lifting device equipped with forks or slings. If a crane is used, slings shall be used. The units must not be rolled or dropped. Figure-2 : Packing case lifting arrangement 3 RECEIPT AND STORAGE PRIOR TO INSTALLATION RECEIPT OF RECLOSER Each recloser is assembled and tested at the factory. Prior to shipment, the equipment is thoroughly inspected to ensure a quality product free from defects. If damage is noticed, call the carrier at once for inspection, and request an inspection report. Afterwards, file a formal claim with the carrier, supported with the Airway/Roadway Bill. Each delivery, on receipt, should be checked for, - Shortages and discrepancies. (Check against order and delivery documents). - Any transit damage and material losses. - Abnormality, if any, must be notified immediately to ABB, forwarding agents and the insurance company. Instructions and literature packed with the recloser should be kept with the unit. Additional copies may be obtained upon request from the local ABB sales office. Following are the typical parts in which recloser are generally shipped from factory. 11 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 Default Shipment Optional items (only if ordered separately) High voltage (HV) cabinet Control cable (length as per order specific drawings) Mounting brackets Auxiliary power cable (2x1.5 sq.mm) Terminal connectors for main power cable connections Insulating boots for main power connections Auxiliary power voltage transformers Any additional spares STORAGE OF RECLOSER The recloser with complete packing should always be stored indoor to protect from direct sunlight & rain or snow. The recloser should be stored in its original transport units, where they are well protected from damage. Reclosers can be stored up to 3 months from date of shipment from the factory. For longer storage, the packing needs to be removed and the recloser to be kept under controlled environmental conditions. We define storage in controlled conditions as a place with: - Leak proof roof - Solid, flat ground - Relative humidity less than 50% - Temperature 20 0C (+10oC) - The heating elements must be connected to the electric supply to protect the control equipment from corrosion or freezing damage. Structures may be stored outdoors with proper care by avoiding any water accumulation or soil deposition. Spare parts should be stored indoors in their original packing. Important The HV cabinets must be stored in the upright position to avoid moisture accumulation. Recommended storage temperature range is -20 oC to + 40 oC. Note If the recloser is not placed in service immediately, it is essential that proper care be exercised in handling and storage to ensure good operating condition in the future. Please consult ABB if the recloser will be in storage for an extended period of time before installation. 12 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 HANDLING Each HV cabinet come with lifting brackets on the sides of these cabinets for lifting. A four-point lift is strongly recommended using the loops in these brackets. The approximate mass in Kg is separately mentioned on rating plates on HV cabinets. Figure-3 : HV cabinet lifting details Caution Caution Caution Caution Exercise care during lifting to avoid damage to the poles Do not place the recloser HV unit on an uneven surface. Placing the HV unit on an uneven surface may cause tilting / galling of the HV unit causing damage to the equipment and injuries to the person nearby Spreader bar should be used if necessary, to ensure lifting straps do not press against and damage the poles, & mechanical ON/OFF indicator. Do not use forklift to move recloser as it may damage the mechanical ON/OFF position indicator, Yellow Trip handle and associated interlock Caution Exercise care during lifting to avoid damage to the poles 13 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 4 TECHNICAL DETAILS This operating instruction is applicable for medium voltage, three phase mechanically ganged operated vacuum reclosers OVR-15, 27 & 38 HV Unit. Each OVR-15, 27 & 38 Recloser has three vacuum interrupters, each assembled in pole casted with an advanced Hydrophobic Cycloaliphatic Epoxy (HCEP). Together with the specialized control functions, the recloser will sense a pickup current (or other pre-configured condition) and automatically open, or "trip". After a pre-configured Open Interval Time, the recloser will close again. If the tripping condition still exists, the recloser will trip again and reclose. OVR-15, 27 & 38 can be reclosed up to three times in one operating cycle. The standard OVR-15, 27 & 38 recloser control, RER615, will allow up to three closing operations before the recloser will "lock out" in the open position. 14 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 TABLE 1 : TECHNICAL DATA SHEET FOR OVR-15, 27 & 38 Sr. Technical Characteristic No. 1 Installation OVR-15 OVR-27 OVR-38 Outdoor, Pole / substation mounting 2 Suitable as standard IEC 62271-100 / IEEE C37.60 3 Rated system voltage 15 kV 27 kV 38 kV 4 Rated frequency 50 / 60 Hz 5 Nominal current at 40 OC ambient 630 Amps 1000 Amps 1200 Amps 6 Short time current withstand capability 12.5 kArms for 3 sec 12.5 kArms for 3 sec 16 kArms for 3 sec 7 Fault current breaking capability 12.5 kArms 12.5 kArms 16 kArms 8 Making current capability 32.5 kAp One minute power frequency withstand 9 capability (Dry / Wet ) 50 kVrms / 45 kVrms Lightning Impulse voltage withstand 10 capability 110kVp 11 Switching of line charging current 2 A 32.5 kAp 60 kVrms / 50 kVrms 125kVp 5 A 41.6 kAp 70 kVrms / 60 kVrms 170kVp 5 A 12 Switching of Cable charging current Operating sequence (Reclosing 13 Sequence) 14 Closing time 10 A 25 A 40 A O 0.2 s CO 2 s CO 2 s CO - Lockout 65 ms 15 Opening time 16 Number of operations at rated current 17 Insulating Material of Poles 40 ms 10000 CO (With proper periodic maintenance the unit can perform up to 25000 CO operations) Hydrophobic cycloaliphatic epoxy insulator 18 Type of operating mechanism Magnetic actuator 19 Minimum Creepage distance Center to center distance between 20 phases Mass of the Auto Recloser Excluding 21 Mounting Frame (Approx.) 22 Protection class for cabinet (HV & LV) Maximum load on foundations 23 (inclusive of the mass of the recloser) 24 Suitable for wind Speed up to 25 Ambient Temperature range 481 mm 394 mm 960 mm 394 mm 1178 mm 394 mm 140 kg 145 Kg 180 Kg IP55 11600 N Compression (open operation) 7000 N Tension (close operation) 200 km/Hr. -40 0C to +55 0C For other technical details, please refer the order specific drawings. 15 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 5 GENERAL DESCRIPTION OF OVR-15, 27 & 38 RECLOSER HIGH VOLTAGE ASSEMBLY The high-voltage assembly of the OVR-15, 27 & 38 consists of three poles mounted onto a common housing. Each of the poles is a separate assembly comprised of a vacuum interrupter assembled in a HCEP molded pole. All the three poles are gang operated by a single coil magnetic actuator through a common operating shaft. 5.1.1 Housing The housing comprises of a stainless steel enclosure. The bottom cover of the housing is removable. Housing is provided with legs for safe transportation and storage. These legs are not meant to be used for mounting the recloser on its structure. The HV unit has its dedicated name plate showing important rating information, serial number of HV unit and manufacturing year is mounted on the front side of the HV cabinet. The ON/OFF position indicator is also provided in the front side and is visible from ground. A 50 W heater is provided in the high voltage cabinet, to prevent condensation and must be energized at all times. Fig-5.1: OVR-15 HV cabinet overview Figure-5.2 : OVR-27/38 HV cabinet overview 16 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 5.1.2 Recloser Pole and current & voltage sensor Each of the three recloser poles consists of vacuum interrupter inside a pole cast with an advanced Hydrophobic Cycloaliphatic Epoxy (HCEP). The upper and lower terminals for connecting medium voltage power conductors are made of ETP copper. 5.1.3 Current & voltage sensor The current (I) sensing is by current transformer (CT) and voltage (U) sensing is by a voltage divider. The sensor secondary connections are bought out of the pole via shielded cables. In OVR-15 & 27, option is available for single OR dual voltage sensing per pole. Figure-6.1: OVR-15 Pole with single voltage sensor Figure-6.2: OVR-15 Pole with dual voltage sensor Figure-6.3: OVR-27/38 Pole with single voltage sensor Figure-6.4: OVR-27 Pole with dual voltage sensor 17 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 5.1.4 Single Coil Magnetic Actuator The recloser is operated by a single coil magnetic actuator. One actuator gang operates all the three poles through a common shaft mechanism. The magnetic actuator is bi-stable and does not require any continuous power to hold it in ON or OFF position. Note - Disassembly of the magnetic actuator is not allowed. Lubrication or maintenance is not required and will void the warranty. - Should an actuator fail to operate, contact ABB Customer Service Group. 5.1.5 Emergency Manual Trip (k69) Handle A yellow colored handle is provided on the side of HV cabinet housing for mechanically opening the recloser during emergency situations. When viewed from front of the cabinet (with rating plate visible), this handle can be seen on the right hand side of the housing. Recloser can be mechanically opened (not manual close possible) by pulling this handle from ground level with a standard hook stick (not in ABB's scope). Please refer the clause "mechanical opening" under the "operation" section for more information. 5.1.6 Mechanical ON/OFF position Indicator The HV cabinet includes a mechanical ON/OFF position indicator which can be easily viewed from the ground level. The general color convention is: Default Color coding Option available on request* Close Red Green Open Green Open * Please check the order specific documents for confirming the color coding 5.1.7 Status Auxiliary limit switches The status limit switches are mounted inside the HV cabinet housing. They are wired to provide the recloser status information to the protection & control in LV control cabinet. 18 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 6 STANDARD PRODUCTION TESTS Routine tests are carried out on OVR-15, 27 & 38 with HV units connected with its dedicated LV units . The standard factory production tests include: 1. Verification of wiring as per approved wiring diagram. 2. Electrical operation: a. Close and Open in Local/Remote modes b. Overcurrent response and automatic reclosing through primary injection. 3. Functional checks of manual controls (K69) & associated electrical & mechanical close block 4. Contact resistance measurements on poles. 5. One minute power frequency voltage withstand test on primary circuit of HV unit. 6. Partial discharge test 7. Minimum Trip and Time-Current Test 8. No load mechanical operation test. The routine test report with a summary of results is shipped as a part of documentation package. 7 INSTALLATION The OVR-15, 27 & 38 recloser can be installed in a substation frame, pole-mounting frame, or can be mounted into a customer supplied structure. However, it is required that in all of the mounting methods the recloser be vertical, levelled and securely fastened. Follow your company guidelines and various codes for setting the height of the recloser, securing the frame to the pole or foundation, and making connections. Before shipping from factory, the OVR-15, 27 & 38 recloser HV unit is tested as a system in factory with a LV control. It is mandatory that during installation, the HV unit and LV control cabinet are properly matched by serial number mentioned on rating plates provided on each of them. Note - All metal mounting frames and structures must be commonly grounded to the grounding grid at site. For proper operation of the electronic components, it is mandatory that the total impedance of the grounding grid at site should be less than one Ohm (1 ) - It is also mandatory to ensure that all the grounding connections to the welded star grounding pad inside the LV cabinet are always intact and secured. - Be careful not to bend the cable below a radius of 12 inches to avoid damage to itself. 19 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 TESTS BEFORE INSTALLATION 7.1.1 Vacuum test procedure It is recommended to conduct one minute power frequency voltage withstand test on each interrupter to verify that there has been no loss of vacuum during transportation or handling. Experience has indicated that while a vacuum interrupter with the vacuum seal intact will withstand 40 kV AC (80% of 50kV) for OVR-15, 45 kV AC (80% of 60kV) for OVR-27 and 56 kV AC (80% of 70kV) for OVR-38 across the open contacts. The same interrupter with leaked vacuum (open to normal atmosphere) will flashover at the gap at a much lower voltage. High voltage applied across an open gap in a vacuum can produce X-ray radiation. However, no radiation is emitted when the recloser is closed since no gap exists. Also, X-ray radiations at one meter is below the concern level when the recloser is open to the specified contact spacing during testing (within specified voltages) or in normal service conditions. Danger could exist at voltages above rating plate specified voltages. For testing, with recloser in open position, connect all the three upper terminals together with jumpers. Connect all three lower terminals together with separate jumper and ground them to cabinet housing. Connect the high voltage to the top terminals. During testing, it is mandatory that. - HV & LV cabinets are connected properly by the control cable - Both HV and LV cabinets are securely grounded. - LV cabinet is placed at least three meters away from HV cabinet - Stand clear more than three meters before energizing the high voltage source. - Do not apply voltage for more than 60 seconds. If internal flashover occurs, isolate the phases, and test each one independently to identify the defective interrupter. Any defective pole assembly must be replaced prior to the recloser is installed & placed in service. 7.1.2 Contact Resistance Close the recloser with the help of LV unit and connecting cable associated with that. Measure contact resistance with suitable equipment rated not less than 100 A DC. The value of the contact resistance for each phase should not exceed 40 micro-ohms. Make sure that the current injection leads of contact resistance measurement kit are connected across the incoming & outgoing terminals of the pole only. Note If the vacuum interrupter / complete pole needs to be replaced, please contact ABB MOUNTING The HV Cabinet is shipped with mounting frame as per agreed type of mounting during ordering stage. For details, refer the recloser mounting documents supplied with the order bound drawings for details. Caution Do not use forklift to move recloser as it may damage the mechanical ON/OFF position indicator, Yellow Handle and associated interlock. 20 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 7.2.1 Pole mounting For pole mounting frames, perform the following; 1. Attach the lifting hooks on the sides of the recloser as indicated in section 3 "Handling" 2. Complete the HV cabinet mounting on pole, as per detailed procedure in this manual 3. If Voltage Transformers (VTs) are used, it is recommended to install the frame without the transformers and then install the VT's once the recloser and VT mounting brackets are on the pole. 4. Make sure all hardware is fastened tightly. Caution Note Do not exceed 750N cantilever force on any of the bushing terminals in any direction. Failure to comply will result in permanent damage Follow your company's instructions for electrical products/assemblies. This operation should be done once it is secured that; there is no hazard or unsafe condition to the operator, such as energized OR live conductors. 21 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 Figure-12: General arrangement for OVR-15,27,38 Pole Mounting Note - The heights of pole structure and recloser location shown are for reference purpose only. These depend on user's installation. - XXX: To be decided by the user. - Supply of pole is not in ABB's scope. 22 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 GROUNDING Important Always follow international, national and company specific regulations when grounding the equipment. All metal mounting frames and structures must be commonly grounded to the grounding grid at site. Grounding is important to ensure proper operation of all electronic components, as well as to prevent penetration of EMC noise and other transients into the sensitive electronic circuits (RER615 relay, ACM, radios, etc.). Each HV cabinet includes two stainless steel welded grounding pads for grounding. Each pad will have internal threaded hole (M8 for HV unit) as shown in below figure. 80 Sq.mm cross-section, solid copper strip/equivalent is recommended for grounding. If auxiliary power voltage transformers is used, it should be grounded to the main ground conductor leading from the recloser HV Cabinet to ground. It is mandatory that both the HV cabinet is firmly grounded as shown in figure in this section, when installed. For the proper operation of electronic components, it is mandatory that the total impedance of grounding grid at site should be less than one Ohm (1 ). Grounding Pad Figure -13 : Provisions for Grounding Connections on HV cabinet 23 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 Figure-14 : Grounding connections proposed for OVR-15,27,38 Pole Mounted arrangement Note The grounding cables used shall be same for all components ARRESTER PROTECTION Surge arresters can be connected on both HV (source and load) sides of the recloser. It is recommended that the arrester grounds are connected to the recloser ground and continued to the pole ground. The leads connecting the arresters to recloser pole terminals should be as short as feasible to limit stray inductance and to maximize the arresters' effectiveness. 24 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 LINE CONNECTIONS The recloser is connected in series with the line. The medium voltage line conductors are to be connected to the OVR terminal H1 & H2 via suitable terminal connector/clamp. Both these terminals are silver plated copper. The fasteners use for connectors must be torqued between 50 to 60 NM (442 to 531 inch lbf). Respective H1 and H2 terminals Line connections for OVR-15 and OVR-27/38 are shown in the below pictures General convention proposed for power connection is H1 terminal should be on the source side and H2 on load side. However, based on site requirements, these terminals can be connected in reverse order as well. Plain terminal Dia. 25.4mm Plain terminal Dia. 25.4mm Fig-17: Line connections for OVR-15 Pole 25 | P a g e Fig-17.1: Line connections for OVR-27 SVS Pole Instruction Manual for HV Unit of OVR-15, 27 & 38 Fig-17.1: Line connections for OVR- 27 SVS Pole If a voltage transformer (PT) is used for providing external AC auxiliary power to the LV cabinet, then it is recommended to connect this PT on the source side of the recloser so that auxiliary power is available even if the recloser is in open condition during service. This will avoid unnecessary draining of recloser battery back-up power. FINAL INSPECTIONS BEFORE ENERGIZING The recloser should be tested for mechanical and electrical operation before it is energized in the power system. It is to be noted that the recloser is shipped in OPEN (OFF) condition from the factory. Caution Do not ground either side of the battery or attach ground to the terminals of the actuator operating coils. This will result in permanent damage to the unit. When the recloser has been installed completely with all mechanical and electrical connections completed, conduct following mandatory inspection before energizing the recloser on the main lines; 1. Ensure the recloser is properly levelled and securely anchored. 2. Make a final check of tightness of all hardware. 3. Securely tighten terminals and ground connections. 4. Check control cable is properly connected, routed and secured. 5. Ensure both the HV & LV cabinets are grounded as mentioned in this manual. 26 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 8 RECLOSER OPERATION Following are the descriptions about major operations for the recloser. Please refer Table of operation procedure in this section for further information. CLOSING OVR-15, 27 & 38 recloser can be closed only electrically. With RER615 in LOCAL mode, the recloser can be closed from the "I" pushbutton on the RER615 front HMI. If proper remote connection is established, the recloser can also be closed from remote SCADA via communication, with RER615 relay in REMOTE mode. Due to safety concerns, OVR-15, 27 & 38 is not allowed to manually be closed and does not have any separate provision to close the recloser manually using any hook stick. OPENING OVR-15, 27 & 38 recloser can be opened mechanically as well as electrically. With RER615 is in LOCAL mode, the recloser can be opened from the "O" pushbutton on the RER615 front HMI. If proper remote connection is established, the recloser can also be opened from remote SCADA via communication, with RER615 relay in REMOTE mode. MECHANICAL (MANUAL) OPENING If due to some reason it is not possible to electrically open (LV cabinet door is locked or electrical opening is disabled/de-energized) the recloser main contacts, the high voltage unit may be safely opened mechanically with the help of a standard insulated hook stick from ground level (the hook stick is not in ABB's scope of supply). Manual opening can be performed by quickly and firmly pulling down the emergency manual trip handle (yellow handle) located on the side of the HV unit. This will mechanically open all three poles simultaneously. OVR-15, 27 & 38 has a safe and secured manual trip arrangement. When the recloser is opened manually, the yellow handle remains locked in and blocks any further close operation of the recloser (CLOSED BLOCKED). Such a situation for manual opening the recloser can most likely be an emergency situation, it is to be ensured that the recloser should not be closed back if it is manually opened. To ensure recloser stays open, a provision is made inside the recloser that no electrical close command can be initiated from the LV cabinet locally or remotely. Further, to ensure additional safety, OVR-15, 27 & 38 HV unit gets mechanically locked even if electrical command is forced from the LV unit. After the emergency situation is taken care of, to enable closing operation, it is mandatory to reset the yellow handle manually to its normal position. This can be done by pulling down the interlock reset handle with the help of hook stick. 27 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 Figure-18 : Manual Opening 9 INSPECTION AND MAINTENANCE The OVR-15, 27 & 38 will require minimal maintenance if handled properly. Frequency of operation and local environmental conditions should be considered when determining maintenance schedule. To a large extent, the safety and successful functioning of any apparatus or system connected with the recloser depends on the proper installation, commissioning, programming and configuration of the unit. To provide long, reliable service, the recloser should be inspected at regular intervals. Operating experience, environmental conditions, the number of operations, the magnitude of current interrupted and any unusual service conditions will guide you in establishing a maintenance schedule. The maintenance work can only be carried out by trained personnel who knows & respect all safety regulations, furthermore, it is recommended that ABB service personnel should be called in, to check the service performance and for repair work. ACTIVITIES BEFORE DOING ANY MAINTENANCE OF THE RECLOSER HV UNIT 1. Follow all activities mentioned in previous clause 2. Disconnect the power supply from both sides of the HV unit 3. Ensure that the isolators on both sides of the feeder are open properly and securely locked out 4. Ensure that the main circuit is properly earthed 5. Ensure that all the safety norms are followed as per your country and company's policy 28 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 TABLE 3 : RECOMMENDED INSPECTION AND MAINTENANCE PLAN Sr. Tests/ Work to be performed no. Inspections 1 Visual Pole terminals for cleanliness, damage inspections (bents/breaks) and tightness of connections The poles can be cleaned with a mild detergent. Check for visible corrosion or damage to metal parts and cables Check all connections of metal parts (nuts, bolts, Hardware) Check all the Ground (earth) connections to be secured and undamaged All nameplates/rating plates, labels clearly legible & secured Any loose wire connections 2 Function tests Battery general condition and terminals Fault-free operation of communication modules ( if applicable) Protection test using secondary injection equipment, in conjunction with recloser function test (see the Installation and commissioning section of the control and protection relay instruction manual) Measure the insulation resistance (Value should be more than 100 mega ohm) Proper/smooth operation of Emergency Manual Trip (K69) handle Recommended Interval for installations in normal environment 18 months (adjust interval according to experience) Recommended Interval for installations in extreme environment 12 months (adjust interval according to experience) 6 months 6 months 6 months 6 months 4 years (adjust interval according to experience) 2 years (adjust interval according to experience) 12 months 12 months 3 Replacements Battery Replacement 3 to 5 Years (Please refer to the battery product documentation by the manufacturer for instructions on optimal utilization of battery life; based on frequency/duration of external auxiliary supply failures and extent of battery discharge during such conditions) 3 to 5 years It may be required to remove the RER615 relay & Batteries for replacements. On the basis of the result obtained during the periodic inspection, it is possible to set the optimal time interval for carrying out maintenance work. 29 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 10 TYPICAL RATING PLATE DETAILS RATING PLATE ON OVR-15 HV CABINET Description Product Name Rated Voltage Rated Current Insulation Level Short Circuit Breaking Current Short circuit withstand current and duration Short Circuit Making Current (Peak) Mass (Approx.) LV HV Instruction Manual OVR-15 OVR-15 15.5kV 630 A 50/110 kV pk 12.5 kA 3sec 12.5 kA 3sec 31.25 kA pk 70 140 1VYN401790-021 Product OVR-27 OVR-27 27kV 1000 A 60/125 kV pk 12.5 kA 3sec 12.5 kA 3sec 31.25 kA pk 70 140 1VYN401790-049 OVR-38 OVR-38 38kV 1200 A 70/170 kV pk 16 kA 3sec 16 kA 3sec 41.6 kA pk 70 175 1VYN401390-078 30 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 11 GA OF HV CABINET DRAWINGS 11.1.1 OVR-15 HV Cabinet General Arrangement: 31 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 11.1.2 OVR-27 HV Cabinet with Single Voltage Sensing General Arrangement: 32 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 11.1.3 OVR-27 HV Cabinet with Double Voltage Sensing General Arrangement: 33 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 11.1.4 OVR-38 HV Cabinet General Arrangement: 34 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 12 RECOMMENDED SPARE PARTS The following spares shall be kept in stock to take care of any contingency TABLE 7 : LIST OF RECOMMENDED SPARE PARTS FOR OVR-15, 27 & 38 RECLOSER Sr. No. Description Part No Displayed as 1. Aux limit switch for position indication, 1NO+1NC LXW22A-11MB Composite cable with counter Phoenix connectors, gland plate and cable gland 2. a) 6 meter length b) 9 meter length c) 12 meter length d) 15 meter length a) 2REA033941A0001 b) 2REA037869A0001 c) 2REA033932A0001 d) 2REA033933A0001 3. Heater 230V AC, 50W GCE0990162P0101 4. Oil damper 2REA026181P0001 5. Indicator assembly & ON indicator cap 2REA028893A0001 2REA028553P0001 6. CT protection resistor 25W, 25Ohm resistor 2REA029829A0001 7. ACM with counterpart connectors 2REA033084A0002 8. Intelligent Battery Charger IVYN401701-BV Apart from above we recommend to regularly monitor battery health (since, batteries have limited lifetime depending on environmental conditions), and procure them in advance whenever, they are nearing their end of life. 35 | P a g e Instruction Manual for HV Unit of OVR-15, 27 & 38 2REA060274/ REV-A- L/ 29.06.2021 For more information, please contact: ABB India Limited Plot No.34, Street No.1 MIDC Industrial Area, Satpur Nashik 422007 Maharashtra India Customer support: 18004200707 Customer support: ppmvsupport@in.abb.com customer.service.group@in.abb.com ABB US 680 Century Point Suite 1050 Lake Mary, Florida 32746, USA Customer Service 1-800-929-7947 Customer.Service.Group@us.abb.com ABB de México S.A. de C.V. Av. Central 310 Parque Logístico CP. 78395 San Luis Potosí, SLP, México Tel: +52 444 870 8000 ABB Argentina S.A.U. Norberto López 3600 B1805ABT, El Jagüel, Buenos Aires Aftersales Support: ar-epdsgarantia@abb.com Revision Table: Rev. A Description New Releases Date 29.06.2021 RemarksMicrosoft Word for Microsoft 365