ZWAE ONIII User manual

Installation and service manual
Zakład Wytwórczy Aparatów Elektrycznych Sp. z o.o.
ONIII
Outdoor disconnector 40kA
Manual No DTR.01.11.01.EN

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zwae.com.pl
WARNING
During the operation of electrical equipment, certain parts of
these devices are normally under dangerous voltage, and me-
chanical parts, also remotely controlled, can move quickly.
Failure to follow the warning instructions can result in serious
personal injury or material damage.
Only suitably qualied personnel can work on or near the de-
vice. This personnel must know exactly all safety rules and
rules for maintaining the device in accordance with these
instructions.
The problem-free and safe operation of this device requires
proper transport, proper storage, construction and assembly
as well as careful service and maintenance.

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Table of Contents
1. TRANSPORT ........................................ 4
1.1 Unpacking and inspection.............................. 4
1.2. Storage and transport................................. 4
2. DESCRIPTION ...................................... 6
2.1. Construction and principle of operation.................. 6
2.2. Climatic conditions................................... 6
2.3. Nameplate .......................................... 7
2.4. Basic technical parameters ............................ 7
3. INSTALLATION AND ADJUSTMENT .................... 8
3.1. Preparing contact surfaces ............................ 8
3.2. Poles adjustment .................................... 8
3.3. Disassembly of the transport lock ...................... 9
3.4. Operating mechanism assembly. . . . . . . . . . . . . . . . . . . . . . . . 10
3.5. Pole coupling and adjustment.......................... 10
3.6. Earthing switches coupling ............................ 13
3.7. Earthing switches operating regulation .................. 14
3.8. Grounding of the base frames.......................... 15
4. OPERATING MANUAL ................................ 15
4.1. Notes about connecting activities ...................... 15
5. INSPECTIONS AND MAINTENANCE .................... 16
5.1. Visual inspections.................................... 16
5.2.Periodical check-ups .................................. 16
5.3. Spare parts and recommended service materials ......... 17
6. UTILIZATION ........................................ 18

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1. TRANSPORT
1.1 Unpacking and inspection
Immediately after receiving the disconnector it should checked the delivery compliance with the shipping spec-
ication. Then should be checked whether the disconnector has not been mechanically damaged during trans-
port and the data on the nameplate match the order.
1.2. Storage and transport
Disconnector poles are transported in assembled condition. During the unloading and assembly process, the
disconnector poles should be lifted using transport belts, placed in the manner shown in the following graphic.
During transport, disconnector poles are placed on wooden beams, which should be removed immediately
before placing the pole on the supporting structure, unscrewing the four screws with a wrench size 13.

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During transport poles must be secured against tipping over and the central contact should be open. The dis-
connector can be transported by means of transport with open cargo area. On at, hard surfaces it is allowed
to move the disconnector’s poles with a pallet truck in the manner shown below, with particular care to prevent
the pole from tipping over.
Disconnector poles can be stored in an open space but poles should be put so that the base does not stand
directly on the ground.
psc

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2. DESCRIPTION
2.1. Construction and principle of operation
Outdoor disconnector type ONIII- ... is an insulating, two-column switch, with horizontal contacts movement.
It is designed to work in networks with voltage corresponding to the rated voltage, at frequencies up to 60 Hz
inclusive. The disconnector can be used as a single-pole switch with an individual operating mechanism or in
three-pole set with one common operating mechanism. Disconnector poles can be set in parallel or in serial
connection. Disconnector visual drawing in parallel conguration is shown below.
2.2. Climatic conditions
The disconnector is designed for outdoor operation, at ambient temperature from -50 to +40° C and relative
humidity up to 100%.
Current path
Base frame
Rotating base
Poles coupling mechanism
Left-sided earthing switch
Operating mechanism
Operating mechanism's supporting structure
Right-sided earthing switch
Earthing switches coupling mechanism

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2.3. Nameplate
2.4. Basic technical parameters
No. Parameter Value
1. Rated operating voltage 72,5 [kV] 123 [kV]
2. Rated current 1600 [A] 1600 [A]
3. Peak current 100 [kA] 100 [kA]
4. Short-circuit current, 1-sec. 40 [kA] 40 [kA]
5. Short-circuit current, 3-sec. 31,5 [kA] 31,5 [kA]
6.
Test voltage (50 Hz) for insulation:
- to earth and between phases,
- between contacts of one pole.
140 [kV]
160 [kV]
230 [kV]
265 [kV]
7.
Surge test voltage for insulation:
- to earth and between phases,
- between contacts of one pole.
325 [kV]
375 [kV]
550 [kV]
630 [kV]
8. Radio interference voltage <1000 [µV] <1000 [µV]
9. Rated mechanical operating life: 2000 cycles 2000 cycles
10.
Dedicated operating mechanism:
- motor,
- manual.
NSO80
NR-5
NSO80
NR-5

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3. INSTALLATION AND ADJUSTMENT
The delivered disconnector is completely regulated and ready to work. Assembly is reduced to:
a) installation poles on a supporting structure,
b) attaching supporting construction for the operating mechanisms,
c) installation of operating mechanisms,
d) poles coupling and regulation,
e) earthing switches coupling,
f) earthing switches regulation,
g) grounding the base frame and operating mechanisms.
3.1. Preparing contact surfaces
Contacts resistance depends primarily on the quality and cleanliness of the contact surface. These surfaces
should be very precisely prepared. The method of preparing aluminum and silver contacts surfaces is de-
scribed below:
• aluminum – aluminum connection
Remove the oxide layer from the contact surface with a wire brush. After this treatment, the surface should be
matt gray, devoid of shiny areas. Clearly remove shavings and aluminum dust from the surface, for example by
lubricating with acid-free grease and then removing it. After this treatment, the surface should be greased with
acid-free grease to protect it from oxidation of aluminum. The prepared surface should not be exposed to the
atmosphere longer than the time needed to prepare the cooperating surface.
• copper – silver connection
The copper surfaces should be cleaned of oxides with a brass wire brush and then proceed as for the aluminum
surface. Silver surfaces do not need to be cleaned with a brush, but they can be cleaned with a mild abrasive,
for example steel wool. After cleaning, cover the surface with a thin layer of acid-free grease.
3.2. Poles adjustment
The disconnector poles should be placed on the supporting structure, which has mounting holes in accordance
with the drawing below.

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3.3. Disassembly of the transport lock
Remove the transport blockade from the poles attached to the supporting structure.
To remove the blockage, unscrew the M10 screw in the disconnector base frame and the M12 screw in the drive
lever has to be unscrewed. After removing the blockade, the M12 screw must be crewed back in the same place.

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3.4. Operating mechanism assembly
The operating mechanism should be mounted on the supporting structure, under driving crank located in dis-
connector base. After the operating mechanism is assembled, the coupling shaft must be attached to connect
the operating mechanism to the crank. The assembly method is shown in the gure below.
Tightening torque: M12 - 80 Nm, M16 - 100 Nm.
3.5. Pole coupling and adjustment
After setting the poles on the supporting structure, check the end positions of the current paths and, if neces-
sary, correct the position of the bumpers and the lengths of the shafts of the disconnector kinematic system.
After checking the correctness of operation of the poles the coupling rods can be assembled.
Operating mechanism's
supporting structure
Operating mechanism
Crank gear
Coupling shaft
Current path position adjustment screws
Current path rotation angle limit bumper

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Tightening torque of M16 screws - 100 Nm.
Poles coupling regulation consists of such a setting of the length of the tie rod and coupling lever location ad-
justment so that the current paths at each pole reach the limit positions according to the following requirements.
Coupling tie rod

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Regulation process should be performed in following way:
a) Initially coupling tie rods should be installed in such a way that one pole would not be connected (tie rod
ending hang on a line below coupling lever);
b) Coupling tie rod should be extended or shortened in such a way that current path in driving pole would
be achieve require limit positions. If tie rod length change forecloses achievement of the limit positions
driving lever position should be changed on driving pole. The next gure presents the behavior of the
disconnector’s poles when changing the position of the dive lever while maintaining the same length of
tie rod. After changing the position of the lever it is necessary to correct the of the tie rod and check limit
positions of the current path.
c) After nishing one pole coupling regulation it is permitted to tighten up tie rod to the last pole and repeat
steps from subpoint b.
Regulation lever
– left position.
Regulation lever
– right position. Regulation lever
– neutral position.

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3.6. Earthing switches coupling
Earthing switches have to be coupled using coupling shafts, which length is presented in the table below.
Right earthing switch shaft
Left earthing switch shaft
Type
Application
Coupling shaft
– left earthing
switch
Coupling shaft
– right earthing
switch
ONIII-72 A = 735 A = 795
ONIII-123 A = 1335 A = 1395

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3.7. Earthing switches operating regulation
Earthing regulation consists of coupling shaft adjustment, in order to earthing blades on each pole should
achieve end positions in accordance with requirements presented in the drawing below and earthing circuit
closing occur simultaneously.
On one of earthing switches coupling rods there should be placed earthing switch blockade, in order to enable
earthing work only with open disconnector. Figure blow shows the way of tting the blockade.
Contacts points of
contacts location
In lower end position, the earthing
blade's ending cannot be located
over insulators coupling tie rod
6

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3.8. Grounding of the base frames
After regulation of the disconnector and earthing knives the base frame should be grounded. Earthing connec-
tion points are marked on the disconnector base. In the case of earthing the disconnector with built-in earthing
switch, the earthing line should be connected as close as possible to the cable connecting the earthing switch
knife with the base. The arrangement of connections is shown in the next gure.
4. OPERATING MANUAL
Disconnector’s switching is achieved by using an appropriate motor or manual operating mechanisms.
4.1. Notes about connecting activities
a) While disconnector’s or its earthing switch’s manueovering all safety at work rules applicable in installa-
tion’s location should be respected.
b) Energized disconnector can be manueovered only when capacity of intermittent current will have negligi-
ble value or any signicant voltage change between any pole’s contact elements would appear.

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c) The disconnector cannot be closed until its earthing switch has been opened.
d) Disconnector earthing switch can be manueovered from open to close position only:
• If the disconnector is in open position,
• After ensuring that earthing switch will be working under discharging current of the bushings, rails, in-
coming supplies, short cables and power lines capacities, with current and voltage parameters specied
in technical data.
5. INSPECTIONS AND MAINTENANCE
5.1. Visual inspections
It is recommended to carry out visual inspections in accordance with rules being in force in switchgear or after
each failure or short circuit. Check in particular:
a) condition of current path’s central contacts,
b) condition of earthing switch’s contacts.
5.2. Periodical check-ups
In order to ensure continuous and failure-free operation of disconnectors, it is necessary to perform periodic
check-ups. While the internal regulations in force in the distribution centre do not oblige to more frequent main-
tenance, inspections are required in accordance with the following schedule:
• Periodic inspection- after 5 years of operation or after 1000 operation cycles;
• General inspection of earthing switch’s contacts.
During inspection and maintenance, the applicable regulations for the operation of energy devices and the re-
quirements determining the safety work of the inspectors must be obeyed.
The scope of activities to be performed during each maintenance is as follows:
a) Periodical inspection:
• Check condition of current paths central contacts;
• Check condition of earthing switch contacts;
• Check the correctness of taking the end positions;
• Check the condition of mechanisms and bearings
• Check tightness of screw connections and fasteners;
• Clean the outer surfaces of insulators;
• Check the condition of protective coating and parts protecting against corrosion;
• Lubricate the current path contacts and the earthing switch contacts (not required for disconnectors
equipped with graphite AgC contacts) 1);
•Perform thermal inspection of the disconnector at rated current 2);

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b) General inspection:
• Perform the complete set of activities disrobed at ‘Periodic inspection’;
• Clean all moving parts;
• Measure the voltage drop of the disconnector main circuits at current I=100A DC 3);
• Check dimensional compliance of the disconnector with the dimensional drawing, in particular insula-
tion gaps and spaces between live parts;
• Check the condition of anti-interference screens (if installed);
• Check technical condition of insulators 4);
• Check the operation and condition of arcing contacts (if installed) 5);
• Check earthing of the disconnector bases.
1) When assessing condition of the disconnector contacts, check if the silver coating surfaces have not been
damaged permanently.. If necessary, replace damaged contacts with new ones.
2) In case of thermal tests, the permissible temperature values are given in Table 14 of the PN-EN 62271-1:
2018-02 standard should be adopted as a criterion for assessing the correct operation of the disconnector.
3) In case of measuring the voltage drop of the main circuit of a disconnector not connected to the busbar sys-
tem, the acceptable values indicated in the factory test report of the nished product should be taken as the
criterion for assessing the correct operation of the disconnector. In the case the disconnector is connected to
the busbar system, the voltage drop should not be exceeded 250 µΩ.
4) When assessing the condition of insulators, it is necessary to check if there are no losses or damage to the insula-
tors, with particular emphasis on the surface of the shade. If necessary, replace damaged insulators with new ones.
5) When assessing the condition of the arcing contacts, it is necessary to check whether there are no cavities or
pits on the contact surfaces. If necessary, replace damaged contacts with new ones.
5.3. Spare parts and recommended service materials
The use of high quality components and exploitation experience indicate long liveness of disconnectors (about
40 years). If the disconnector is damaged due to improper assembly or operation, it is possible for the manu-
facturer to repair it for a fee. Disconnector type ONIII does not possess parts, which should be replaced during
normal operation in service life.
For disconnectors maintenance, materials listed below have to be used:
a) WHITE PHARMACEUTICAL PETROLEUM JELLY (acid-free) used for lubrication electric contacts (earth-
ings, contacts of HV switches),
b) LUBRICANT for bearings, for example LT4 or similar, used for lubricating ball joints.

Zakład Wytwórczy
Aparatów Elektrycznych Sp. z o.o.
Gdańska 60, 84-300 Lębork
POLAND
Address of correspondence:
Kębłowo Nowowiejskie, ul. Łąkowa 2
84-351 Nowa Wieś Lęborska
POLAND
[email protected]
tel.: [phone]
www.zwae.com.pl
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6. UTILIZATION
The ONIII disconnectors are made of materials that are recyclable.
The main materials from which the disconnectors are built are:
• steel (hot-dip galvanized);
• aluminum;
• copper.
The disconnectors do not contain any dangerous substances. In accordance with applicable regulations, it is
possible to return a worn out, complete disconnector to the manufacturer.