ABB R-MAG Series User manual

Instructions for
Vacuum Circuit Breaker
Type ABB R-MAG
(OVB-DCM)
15.5 kV 1250/2000/3000 A
38-929M-15A

38-929M-15A 10/15/02 1:11 PM Page 2

TABLE OF CONTENTS
Description Section Number
Safety Notices.................................................................................................. 1
Introduction...................................................................................................... 2
Receiving, Handling and Storage.................................................................... 2
General Description......................................................................................... 3
Standard Production Tests............................................................................... 4
Operation......................................................................................................... 4
Operational Checks Prior to Installation .......................................................... 5
Installation........................................................................................................ 6
Inspection, Maintenance and Adjustment........................................................ 8
R-Mag Electrical Specifications....................................................................... 22
Renewal Parts.................................................................................................. 25
Appendix A - Installation/Maintenance Instructions......................................... 27
LIST OF ILLUSTRATIONS
Description Page
Figure 1. Hazardous Voltage Nameplate......................................................... 1
Figure 2. Lifting Detail...................................................................................... 3
Figure 3. Interrupter Assembly, 1200 A........................................................... 11
Figure 4. Interrupter Assembly, 2000 A........................................................... 12
Figure 5. Interrupter Assembly, 3000 A........................................................... 13
Figure 6. Contact Erosion Graph, 15 kV.......................................................... 14
Figure 7. Contact Travel and Over-Travel Adjustment...................................... 15
Figure 8.Trip Handle........................................................................................ 16
Figure 9. High Voltage Cabinet Layout ............................................................ 17
Figure 10.Typical Schematic Diagram ............................................................ 18
Figure 11.Typical Connecting Diagram........................................................... 19
Figure 12.Typical Outline 1200 A.................................................................... 20
Figure 13.Typical Outline 2000, 3000 A.......................................................... 21
Figure 14. Breaker Nameplate......................................................................... 25
38-929M-15A 10/15/02 1:11 PM Page 3

38-929M-15A 10/15/02 1:11 PM Page 4

Figure 1. Hazardous Voltage Nameplate
1.0 SAFETY NOTICES
This circuit breaker should be installed within the design limitations as described on its
nameplate and in these instructions.
Follow your company’s safety procedures.
This breaker should not be used by itself as the sole means of isolating a high voltage circuit.
For the safety of personnel performing maintenance operations on the breaker or connecting
equipment, all components should be electrically disconnected by means of a visible break
and should be securely grounded.
This product is intended to be operated and maintained by qualified persons, thoroughly
trained and knowledgeable of the hazards involved.This publication is written only for such
qualified persons and is not intended to be a substitute for adequate training and experience
in the safety procedures for this device.
WARNING
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 which could cause personal injury to service
personnel or could damage equipment or render it unsafe. Please understand that these
warnings could not cover all conceivable ways in which service, whether or not recommended
by ABB, might be done or of the possible hazardous consequences of each conceivable way,
nor could ABB investigate all such ways. Anyone using service procedures or tools, whether
or not recommended by ABB, must satisfy himself thoroughly that neither personal safety nor
equipment safety will 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.
Page 1
HAZARDOUS VOLTAGE
CAN SHOCK, BURN
OR CAUSE DEATH.
Do not attempt to handle, install, use or service
this product before reading instruction book.
234P05IH0IA
WARNING
38-929M-15A 10/15/02 1:11 PM Page 5

2.0 INTRODUCTION
These instructions do not attempt to provide the user of this equipment with every possible
difficulty which may occur in the application, operation and maintenance of the product. Also,
as improvement in parts and assemblies are made, some parts may differ in appearance as
depicted in the illustrations; however, functionality will be equivalent.
The Type R-MAG Vacuum breaker is a high-voltage, three-phase device incorporating three
vacuum interrupters gang operated by a magnetic actuator.Together with the optional relaying
and current transformers, the breaker will sense an overload and automatically open.
Satisfactory performance of the breaker is contingent upon the correct installation, adequate
maintenance and service of the product. Careful study of these instructions will permit the
user to obtain maximum benefit from this device.
3.0 RECEIVING, HANDLING AND STORAGE
Each breaker is assembled and tested at the factory prior to being prepared for shipment.
This equipment was packed and shipped in factory new condition. If damage is noted, call the
carrier at once for inspection, and request an inspection report. File a formal claim with the
carrier, supported with paid freight bill, inspection report, and invoice.The local ABB Sales
Office must be notified. Normally this must be done within 10 days of receipt or receiver
assumes all responsibility for damage.
3.1 Receiving Inspection
Upon receipt, it is important to inspect promptly to be certain that the correct material has
been received. In case of shortage, immediately notify the local ABB Sales Office.
Check all parts against the shipping list as they are unpacked. Instructions and literature packed
with the breaker should be kept with the unit.The cabinet provides a convenient place to keep
this instruction book, a copy of the schematic diagram, and the card carrying the service record
of the unit. Additional copies may be obtained upon request from the local ABB Sales Office.
If the breaker is not to be placed in service immediately, it is essential that proper care be
exercised in the handling and storage to ensure good operating conditions in the future.
(See 3.3 - Storage)
3.2 Handling
The R-MAG solid dielectric breaker comes with two brackets that attach to the sides of the
cabinet and provide provisions for lifting the breaker. A two-point lift is recommended using
the loops in these brackets. (See Figure 2)
Page 2
38-929M-15A 10/15/02 1:11 PM Page 6

Caution - Exercise care
during lifting to avoid
damage to the bushings.
Breaker has high center
of gravity.
3.3 Storage
For prolonged storage, indoor storage is recommended. If stored outdoors, the cabinet
heaters must be energized to maintain warranty. The mechanism and control compartment is
equipped with heaters to reduce condensation.
4.0 GENERAL DESCRIPTION
4.1 High-Voltage Assembly
The high-voltage section of the R-MAG consists of three individual phase assemblies
mounted on insulating standoffs. Each phase of the R-MAG consists of a single vacuum
interrupter, flexible shunt and operating rod.
4.2 Housing
The doors of the breaker housing are removable and are retained by four pins.The position
indicator is visible through the front door.The breaker nameplate showing rating information,
serial number, and shop order number are mounted on the right-hand side of the housing.
4.3 Phase Assembly
Figure 3 shows the details of the phase assembly.The back bus work is attached directly to
the fixed contact stud on the back end of the vacuum interrupter.The current transfer
assembly housing is fastened to the opposite end of the vacuum interrupter. In the current
transfer assembly, a contact block/flexible shunt transfers current from the moving contact of
the vacuum interrupter directly through the bus to the bushing.
Page 3
Figure 2. Lifting Detail
38-929M-15A 10/15/02 1:11 PM Page 7

4.4 Magnetic Actuator
The magnetic actuator incorporates a very powerful permanent magnet assembly. When the
armature is in contact with the upper plate, the magnet produces a holding force in excess of
1500 lbs. Attached to the armature are two stainless steel guide rods.The upper guide rod
attaches to the lower end of the main operating rod, which connects directly to the moving
contacts of the vacuum interrupters.The lower guide rod mounts to the manual trip assembly.
Disassembly of the magnetic actuator is not necessary nor recommended. Lubrication or
maintenance is not required. Should an actuator fail to operate, contact ABB for service.The
permanent magnet inside the actuator is extremely powerful with the potential to trap fingers.
4.5 Standard Control (ED2.0)
The standard control package of the R-MAG is the ED2.0.The ED2.0 consists of a power
supply, position indication and capacitor charging/discharging system. Refer to Appendix A for
an extensive overview of the ED2.0.
5.0 STANDARD PRODUCTION TESTS
Standard production tests include:
1. Verification of all wiring per connection diagrams.
2. Electrical operation: Close and trip. Overcurrent response and automatic closing, with
relaying control option.
3. Check on functioning of all manual controls: Local/remote, non-reclosing, ground fault
bypass, etc.
4. Three readings are made on each phase of the breaker using a Biddle “Ductor.”Typical
values do not exceed 150 micro ohms.
5. Voltage Withstand:The complete breaker is tested (a) between live parts and tank, (b)
across open contacts, and (c) between phases. In compliance with ANSI C37.09 & IEC
an AC dielectric withstand test at 50 kV is performed.Test duration is one minute.
6. Wiring Insulation: The terminal block connections are given an over-potential test of 1500
volts AC to ground.
6.0 OPERATION
6.1 Closing
In the open position, the magnetic actuator’s armature rests against the bottom plate in the
actuator assembly.The armature is held there by the force developed by the magnet.When
the top coil is energized, the magnetic flux generated is in the same direction as the magnet
assembly.The armature is drawn into the coil and brought into contact with the upper plate. In
this position, the coil is de-energized and the armature is held in position by the magnet
alone. As the armature is drawn into the coil, the operating rod, which is attached to the top
guide rod, moves the moving contact of the vacuum interrupter towards the closed position.
The actuator has more stroke than the vacuum interrupter and the interrupter contacts make
contact before the actuator has completed the stroke.The additional movement of the
operating rod after the contact closing causes the contact pressure spring to compress at the
top of the operating rod.This “over-travel” allows for contact wear in service.
Page 4
38-929M-15A 10/15/02 1:11 PM Page 8

6.2 Opening
When the bottom coil is energized, the magnetic flux generated opposes the force generated
by the magnet assembly.This reduces the holding force, the armature is released and the coil
attracts the armature to the bottom plate. Once there, it is held open by the magnet.
7.0 OPERATIONAL CHECK PRIOR TO INSTALLATION
The breaker should be tested for mechanical and electrical operation before delivery to the
installation site. Make the necessary control power connections. Open the door of the low
voltage (LV) compartment to observe the mechanical operations. A manual trip handle is
provided on the outside of the cabinet. (See Figure 8)
7.1 Electrical Close and Open
Observe the position-indicator located on the front of the actuator cover plate. If the panel is
green, the breaker is open, and if the panel is red, the breaker is closed.To perform a close
or open, ensure the “Ready” light is illuminated above the Close (1), and Open (0), buttons.
Press the appropriate button firmly, keeping hands and loose clothing clear of operating
linkages. Nothing will happen if the open button is pressed if the breaker is already open and
conversely for close.
Note: In the event of a malfunction or loss of source voltage, the “Ready” light will not be
illuminated.
7.2 Vacuum Test
Make an over-voltage test on each phase assembly to verify that there has been no loss of
vacuum in transportation or handling. Experience has indicated that while a vacuum
interrupter with the vacuum seal intact will withstand 37.5 kVAC across the open contacts for
one minute, the same interrupter open to normal atmosphere will flashover at the gap at a
much lower voltage.
Page 5
38-929M-15A 10/15/02 1:11 PM Page 9

TEST PROCEDURE
RADIATION WARNING: High voltage applied across an open gap in a vacuum can produce
X-radiation. No radiation is emitted when the interrupter is closed since no gap exists. Also,
when the breaker is open to the specified contact spacing in service or tested within the
voltages specified, X-radiation at one meter is below the level of concern. A danger could
exist at voltages above or contact spacing below that specified on the nameplate.
1. With the breaker in the open position, jumper both sets of three top terminals together.
Ground one set of terminals and the housing. Connect the high voltage to the other set of
terminals.
2. Stand clear more than one meter before energizing the high voltage source.
3. Apply a test voltage of 37.5 kVAC for one minute. Do not exceed 37.5 kVAC.
4. If internal flashover occurs, isolate the phases and test each one independently to
identify the defective interrupter. Any defective interrupter must be replaced prior to the
breaker being placed in service.
8.0 INSTALLATION
It is required that the breaker be vertical and level, and securely fastened. Follow your
company guidelines and various codes for setting the height of the breaker, securing the
frame to the pole or foundation, and for making connections.
8.1 Mounting
The breaker is normally shipped suitable for substation mounting.The following is the
recommended installation procedure:
Substation Mounting
1. With the lifting brackets mounted to the breaker roof, lift the breaker off the pallet and
move into position.
2. Bolt the legs to the pad, and raise the upper portion to the desired height.
3. Bolt legs to the sides of the breaker.
4. Make sure all hardware is tight.
Page 6
38-929M-15A 10/15/02 1:11 PM Page 10

8.2 Grounding
The breaker cabinet includes a standard NEMA 2 hole drilled stainless steel pad on the rear
for grounding. Any voltage transformers used should be grounded to the main ground wire
leading from the breaker to ground.
To ground the control cabinet, use the connector provided which accepts a #6 - 2/0 AWG
conductor. Ground the control cabinet to the main ground wire from this external connector.
All ground wire used must be #6 AWG minimum.
8.3 Arrester Protection
ABB recommends that surge arresters be properly applied in the substation.
8.4 Control Power
Supply the control power as indicated on the wiring diagram. If 240 VAC is used, verify the
connections for the heaters before applying power.
For breakers not equipped with DIN-Rail style connectors, check all terminal block
connections for proper tightness.
For details of the overall control circuit refer to the specific wiring diagrams supplied with the
breaker.
8.5 Final Inspection
When the breaker has been installed and all mechanical and electrical connections
completed, EXCEPT ENERGIZING THE POWER LINE, the following points of inspection are
recommended:
1. Ensure the breaker is properly leveled and securely anchored.
2. Make a final check of tightness of all hardware.
3. Check that the heaters work.
4. Securely tighten terminal and ground connections.
5. Check control cable entrance fittings for tightness.
6. Operate the breaker from the control box to verify normal operation.
7. Secure all doors and ensure proper gasketing for weather.
8. Ensure that all tools are removed.
Page 7
38-929M-15A 10/15/02 1:11 PM Page 11

9.0 INSPECTION, MAINTENANCE AND ADJUSTMENT
The R-MAG is an extremely simple device and will require minimal maintenance depending
on the frequency of operation and local environmental conditions.
The safety and successful functioning of any apparatus or system connected with the breaker
depends to a large extent on the proper and reliable operation of the unit.
To provide long reliable service, the breaker must have systematic inspection at regular intervals.
Operating experience based on environmental conditions, the number of operations, magnitude
of current and any unusual operation which occurs, will soon establish a maintenance schedule
which will give assurance of proper breaker reliability.The following check list is a minimum guide.
1. Check the phase assemblies for external damage and clean if contamination is evident.
2. Lubricate wear points and all pins in linkage assemblies with grease.
3. Check contact wear. As a vacuum interrupter continues to perform, material from the butt
contacts is gradually eroded away, and the moving contact is driven deeper into the
interrupter by the operating mechanism.The over-travel spring at the upper end of the
operating rods ensures that proper contact pressure is maintained in the closed position.
Contact erosion reduces the compression of the over-travel spring, which in turn
increases the contact travel. (Total travel of the actuator is fixed.) See 9.2 steps 9-11 for
minor adjustments.
Contact wear can be visually inspected. A line is scribed on the moving contact stem
0.08” from VI end guide.When the line reaches the VI end guide, replace vacuum
interrupters. Figures 3-7 and Procedures 9.1 and 9.2.
Contact wear can also be monitored by interruption magnitudes and quantity.
4. Verify that the breaker operates correctly using the electrical controls.
5. A Hi-Pot test can be made to verify the vacuum integrity.
RADIATION WARNING: High voltage applied across an open gap in a vacuum can produce
X-radiation. No radiation is emitted when the breaker is closed since no gap exists. Also,
when the breaker is open to the specified contact spacing in service or tested within the
voltages specified, X-radiation at one meter is below the level of concern. A danger could
exist at voltages above or contact spacing below that specified on the nameplate.
A. With the breaker in the open position, jumper both sets of three top terminals.Ground one
set of terminals and the housing. Connect the high voltage to the other set of terminals.
B. Stand clear more than one meter before energizing the high voltage source.
C. Do not exceed 37.5 kV. Page 8
38-929M-15A 10/15/02 1:11 PM Page 12

D. 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 breaker being in service.
5. Contact Resistance: Measure contact resistance with suitable equipment rated not less
than 100 A.The value should not exceed 150 micro ohms.
9.1 Replacement of Vacuum Interrupter (See Figures 3-7)
With R-MAG breaker in the open position:
1. Remove 1/2 x 12 bolt (H) through the Contact Block (C) on moving end of the Vacuum
Interrupter (VI).
2. Loosen Hex (F) nut one turn on Bolt stem (E) attached on moving end of the VI.
3. Remove X-washers and pins on Triangle Bell crank at Pivot Bracket and Bolt Stem.
4. Swing Pull Rod (A) away and remove Bolt Stem ensuring Hex nut remains in position.
5. Wedge large screwdriver tip to spread gap on the Contact Block. (This will allow the
threaded moving end of the VI to easily spin out of the Contact Block in step 7.)
6. Remove bus at fixed end of the VI.
7. Rotate VI counterclockwise (CCW) until it is completely free of the Contact Block.
8. Install new VI, carefully ensuring the VI spins in to the Contact Block without any
resistance.The bellows portion of the VI is very sensitive to torsion forces. Ensure VI is
completely against the bus at the moving end of the VI and the VI stem is flush with
Contact Block. Remove screwdriver used to spread Contact Block.
9. Replace the bus on fixed end of the VI.
10. Replace Bolt Stem to location one turn from tight, with pin hole horizontal.
11. Replace Pin and X-washer at Pivot Bracket.
12. Refer to 9.2 for adjustment instructions prior to replacing the pin through Bell Cranks and
Bolt Stem.
Page 9
38-929M-15A 10/15/02 1:11 PM Page 13

9.2 Contact Travel and Over-Travel Adjustment (See Figure 7)
With the breaker in the open position:
1. Loosen Locknut (F) on Bolt Stem (E).
2. Remove Pin (B) while applying pressure from the back of the Contact Block. Allow
Contact Block to move slowly to closed position. Caution: finger pinch point.
3. Loosen Pullrod Locknut (D).
4. Turn Pullrod until center of hole for Pin (B) is 1.687” from Contact Block (C). (This step
sets a reference point for the Bell Cranks.)
5. Spin Bolt Stem (E) until Pin (B) can be inserted and then remove Pin (B). (This step
establishes a reference from VI Contact to the bell cranks.)
6. Spin Bolt Stem (E) 6-6.5 full turns (6.5 turns is preferred final travel, but 6 acceptable
prior to contact conditioning) CW. (This step sets the Contact Travel.)
7. Pull from back of Contact Block (C) until Pin (B) can be inserted.
8. Install new X-washer and tighten all hardware. Do not reuse washers.
9. Measure Travel and Over-Travel by opening and closing breaker. Confirm breaker is
within limits. Minor adjustments can be made by turning pushrod (A).
10. Over-Travel Limits (Gap produced at top of Pullrod while closed) are MIN 0.17”, MAX
0.260”.
11. Travel Limits (Difference in measurements between Contact Block in open and closed
position) are 10.5 mm - 12.5 mm (0.413”-0.492”).
Operate breaker a minimum of 200 times to season new contacts, readjust breaker (Step 9).
Page 10
38-929M-15A 10/15/02 1:11 PM Page 14

Page 11
Figure 3. Interrupter Assembly
1200 A
38-929M-15A 10/15/02 1:11 PM Page 15

Page 12
Figure 4. Interrupter Assembly
2000 A
38-929M-15A 10/15/02 1:11 PM Page 16

Page 13
Figure 5. Interrupter Assembly
3000 A
38-929M-15A 10/15/02 1:11 PM Page 17

Page 14
Figure 6. Contact Erosion Graph
Permissible number of vacuum interrupter operating
cycles n as a function of the breaking current lafor
15 kV R-MAG Vacuum Interrupter.
38-929M-15A 10/15/02 1:11 PM Page 18

Figure 7. Contact Travel and Over-Travel Adjustment
Page 15
1.687”
38-929M-15A 10/15/02 1:11 PM Page 19

Figure 8.Trip Handle
Page 16
38-929M-15A 10/15/02 1:11 PM Page 20