Reclosers Cooper Power Systems Service Information Types RV and WV Maintenance Instructions S280-30-9 34.5 Kv • 400 Amp (Type RV) (Serial No. 4111 and after) 34.5 Kv • 560 Amp (Type WV) (Serial No. 901 and after) NOTICE: This document is also applicable to Cooper Power Systems product serial numbers beginning with the characters CP57. CAUTION Do not energize this equipment out of oil. Figure 1. Type RV oil -interrupting, hydraulically controlled, automatic circuit recloser. CONTENTS Introduction .......................................................................2 Description and Operation .............................................2 General ............................................................................2 Manual Operating Handle ..............................................2 Non-Reclosing Lever ......................................................2 Contact Position Indicator ..............................................2 Interrupters ......................................................................2 Closing Solenoid .............................................................3 Closing Solenoid Contactor ...........................................3 Hydraulic Pump and Lockout Piston .............................3 Series Trip Solenoids ......................................................3 Time Delay Unit ...............................................................3 Mechanism Operation .....................................................4 Hydraulic Control System Operation ...........................4 Maintenance.......................................................................5 Frequency of Maintenance ............................................5 Periodic Maintenance Inspection ..................................5 Manual Operation of the Recloser ................................6 Insulation Level Withstand Tests ...................................7 Oil Condition ....................................................................7 84601KMA Shop Maintenance Procedures .................................8 Control Lever Overtravel Adjustments ......................8 Bushings ...................................................................8 Interrupters Assembly ...............................................9 Closing Solenoid Contactor ......................................9 Closing Solenoid .......................................................9 Series Trip Solenoid ..................................................10 Solenoid Disassembly .............................................10 Solenoid Replacement ............................................10 Time Delay Unit ..........................................................11 Maintenance .............................................................11 Replacement ............................................................11 Removing Mechanism from Head ............................11 Reinstalling Mechanism into Head ..........................12 Testing .........................................................................12 Service Parts List .......................................................12 Bushing Part (Figure 24) ..........................................13 Head and Tank Assembly (Figure 25) ......................14 Trip Coil and Interrupter Mechanisms (Figure 26) ...16 Closing Solenoid and Hydraulic Control Parts (Figure 27) ...............................................................18 These instructions do not claim to cover all details or variations in the equipment, procedure, or process described, nor to provide direction for meeting every possible contingency during installation, operation, or maintenance. When additional information is desired to satisfy a problem not covered sufficiently for the user’s purpose, please contact your Cooper Power Systems sales engineer. January 1987 ● New Issue 1 Types RV and WV Maintenance Instructions INTRODUCTION Service Information S280-30-9 provides the maintenance instructions for Type RV and WV three-phase, hydraulically controlled, oil reclosers. Included is a general description of the recloser and its operation, instructions for periodic inspection and routine maintenance, testing procedures, and instructions for shop repairs. A service parts list, keyed to exploded-view drawings of the recloser is included at the back of the manual. DESCRIPTION AND OPERATION General The Type RV and WV reclosers are self-controlled devices that sense and interrupt distribution system fault currents. They automatically reclose to restore service if the fault is temporary and then reset for another programmed sequence of operations. If the fault is permanent the recloser locks open after one, two, three or four operations, depending upon its operating settings. All three phases open, close, and lock out simultaneously. Opening sequences of these reclosers can be all fast, all delayed, or any combination of fast followed by delayed operations; up to the maximum of four operations. On coordinated systems, fast operations clear temporary faults before branchline fuses can be damaged. Delayed openings allow time for fuses or other downline protective devices to clear so that permanent faults can be confined to smaller sections of line. Closing energy, as well as energy to charge the opening springs, is supplied by a high-voltage closing solenoid which is momentarily connected phase-to-phase through a high-voltage contactor. A “trip-free” yellow operating handle, located under the sleet hood, will manually lock open the recloser. It cannot manually close the recloser, but must be in the CLOSED position for the closing solenoid contactor to operate. A red contact position indicator, linked to the recloser mechanism but independent of the yellow operating handle, is also located under the sleet hood. Figure 2. Untanked Type RV recloser. 2 The location of the major components of a RV recloser are shown in Figure 2. They are similar for the WV recloser. Being aware of the location of these components and their operation will provide a quicker and clearer understanding of the recloser maintenance and repair procedures that follow. Manual Operating Handle When the recloser operates to lockout, the (yellow) manual operation handle drops down (“trips-free”) from under the sleet hood, to give a visual indication of recloser lockout. The handle must be reset manually before the recloser can be closed. Lifting the handle up mechanically closes the closing solenoid contactor, and if power is available to the closing coil circuit, the closing solenoid will energize, resetting the recloser. A closed recloser can be manually opened and locked out by pulling down the yellow handle. Non-Reclosing Lever The non-reclosing lever provides the capability for locking out the recloser on the first trip operation regardless of the programmed number of operations to lockout. Contact Position Indicator The red arrow-like contact position indicator flag is coupled to the recloser mechanism to show the position of the main contacts. When the flag is down, the interrupter contacts are open; when the flag is up, the contacts are closed. Interrupters Circuit opening and fault interruption is achieved by bridge-type contacts that provide two current breaks in series per phase. The bayonet-type moving contacts are silverplated tungsten alloy for erosion resistance and good conductance. The stationary contact assemblies are tulip-type clusters of silverplated contact fingers held together by garter springs. The contacts are selfcleaned by the opening and closing wiping action. Each current break is provided with a self-generating-type arc interrupter structure which includes a series of vented chambers. 86821KMA S280-30-9 As the contacts open, the arc generates gas pressure in the upper chamber which blasts oil across the arc and out through the vents. As a result, arc extinction is fast and arc energy levels do not increase as fast at higher fault-current levels. Closing Solenoid The moving contacts of the interrupters are closed by the closing solenoid, which also extends the opening springs in the head mechanism. This solenoid is energized for only a few cycles during each closing operation when it is momentarily connected across phases B and C. Closing Solenoid Contactor Mechanically operated by the head mechanism, the snap-action contacts of the closing coil contactor complete the high-voltage circuit to the closing solenoid for each closing operation. Hydraulic Pump and Lockout Piston The hydraulic pump counts the number of times the recloser trips. With each trip the pump piston is pushed into the pump cylinder, oil is forced through the lockout cylinder check valve into the lockout cylinder. This causes the lockout piston to be raised one step. When the recloser resets the pump piston is pulled back to the top of the pump cylinder and oil is drawn in through the intake check valve. If the recloser trips again the pump piston will actuate causing the lockout piston to be pushed up another step. This cycle will repeat until the recloser locks out. Once locked out the quickreset rod is mechanically raised allowing the lockout piston to quickly resettle. If the recloser does not lockout, the lockout piston will resettle gradually (at a rate of approximately 90 seconds per accumulated operation at 25° C). Figure 3. Series Trip coil. 86825KMA Series Trip Solenoids Time Delay Unit The series trip solenoids (Figure 3) are connected in series with the interrupters, each carries full line current. When line current exceeds the minimum trip rating of a coil the plunger is drawn into the solenoid. Near the end of the plunger stroke the recloser mechanism trips. When the recloser mechanism is sequenced to the delayed operation phase, the speed of plunger movement is restrained by a time-delay unit. The restrained plunger movement provides a fixed time delay before the recloser mechanism trips. When the mechanism is sequenced to the delayed operation phase, the latch assemblies of the trip solenoid plunger linkages are engaged with the arms on the sealed time-delay units, Figure 4a and 4b. Trip solenoid plunger movement is then restrained by the time-delay unit, which provides a consistent delay action by forcing hydraulic fluid through a calibrated orifice within the unit. Figure 4a. Time delay unit (old). Figure 4b. Time delay unit (new). 82020KMA 86780KMA 3 Types RV and WV Maintenance Instructions MECHANISM OPERATION The operating mechanism, mounted in the head, opens and closes the interrupter contacts. Contact opening is initiated by a series trip solenoid which triggers the trip mechanism to release the loaded opening springs. Contact closing is performed by the closing solenoid which also charges the opening springs and resets the mechanism for the next trip operation. The basic operation of the mechanism is shown in Figure 5. With the interrupter contacts closed (a), the opening springs are fully extended and the mechanism is in the reset state. When excessive current levels are passing through the series trip coil the solenoid plunger is actuated. The trip solenoid plunger operates the toggle latch, releasing the toggle. This action releases the opening springs (b) which starts the contact bar assembly in motion. The spring-biased reset lever rotates to snap the toggle closed. This action of the reset lever also pulls the plunger out of the closing solenoid. At this point the interrupter contacts are fully open (c) and the mechanism is in the open state. When the closing solenoid plunger reaches the top of its stroke it mechanically closes the closing coil contactor which energizes the closing solenoid. As the plunger is drawn down into the coil the reset lever is pulled back and latched in its original position. The interrupter contacts are closed (d) and the opening springs are extended.The mechanism is now readyfor another opening operation. HYDRAULIC CONTROL SYSTEM OPERATION The hydraulic pump, associated cam, and linkages regulate the number of fast and delayed operations, count the operations to lockout, and initiate lockout after a preset numberof operations. The hydraulic pump (Figure 6) is linked to the closing-solenoid plunger and is pushed downward with each return operation of Figure 5. Head mechanism lever arrangement 4 Figure 6. Hydraulic pump. 86827KMA S280-30-9 the plunger. With its downward stroke, the pump forces a measured amount of oil under the lockout piston (Figure7), causing it to rise one step. When the closing coil is energized, the recloser contacts close and the pump returns to its normal position. Ratings ELECTRICAL RATINGS Nominal system voltage, kv Maximum rated voltage, kv Rated impulse withstand voltage (BIL) kv crest 60-Hertz withstand voltage, kv Dry, one minute Wet, ten seconds Rated maximum continuous current, amps Type RV Type WV 34.5 38 34.5 38 150 150 70 60 70 60 400 560 DUTY CYCLE % of Interruping Rating Maximum Circuit X/R Value 15-20 45-55 90-100 4 8 15 Number of Unit Operations Type RV Type WV 28 24 10 Total 62 28 20 10 Total 58 MAINTENANCE Frequency of Maintenance Figure 7. Hydraulic pump cross section. 86717KMA Because reclosers are applied under widely varying operating and climatic conditions, maintenance intervals are best determined by the user, based on actual operating experience. To assure proper operation, reclosers must be maintained when they have operated the equivalent of a complete duty cycle and before the dielectric strength has deteriorated below prescribed levels. In the absence of specific operating experience, the following procedures are recommended. • When Type RV and WV reclosers are operated under usual service conditions as defined in ANSI (American National Standards Institute) C37.60, “Standard Requirements for Automatic Circuit Reclosers for Alternating Current Systems,” it is recommended that the following maintenance procedures be performed at the completion of an equivalent duty cycle. • However, if the recloser has not completed an equivalent duty cycle within three years, it is recommended that a Periodic Maintenance Inspection be performed at that time. Periodic Maintenance Inspection The lockout piston is linked to the sequence selector cam and the lockout bar. Upward movement of the lockout piston causes the cam to rotate counterclockwise and the lockout bar to advance one step. The number of fast operations is preset on the cam. After these operations, the cam engages the roller and pushes it to the right. A mechanism arm attached to the roller engages the time-delay mechanism on each phase. Subsequent operations are then delayed. When the lockout bar completes its travel, it trips the lockout latch. Another set of linkages and springs then lock the recloser contacts open. The quick reset rod is raised, allowing the hydraulic pump and lockout piston assembly to reset quickly. The entire pump and sequencing mechanism is now ready for the next full sequence of operations. For temporary faults that are cleared before the recloser mechanism reaches lockout, the hydraulic pump and lockout piston assembly resettles gradually (at a rate of approximately 90 seconds per operation at 25° C) to reset the recloser mechanism. Each periodic maintenance inspection at the completion of an equivalent duty cycle should include at least the following: 1. Bypass and remove the recloser from service. 2. Thoroughly clean exterior of unit. 3. Inspect external components. A. Check for broken or cracked bushings. Replace as necessary. (See page 8 for procedure.) B. Check for paint scratches and other mechanical damage; paint to inhibit corrosion. C. Note counter reading and enter in the record log. 4. Perform a dielectric withstand test to check the insulation level of the recloser. (See page 7 for procedure.) 5. Manually operate mechanism; operation should match configuration noted on the data plate. A. Partially untank unit and support head and mechanism assembly with clean wooden blocks. B. Use manual closing tool to close interrupters. C. Pull down on strip solenoid trip links until mechanism trips. NOTE: The force required to pull down the trip-links will be increased when the time delay units are engaged. D. Repeat steps B and C until lockout has been reached (yellow handle will drop). 6. Untank the recloser to expose the internal components. 5 Types RV and WV Maintenance Instructions CAUTION Be sure the recloser is open (yellow operating handle under the sleet hood is down) before untanking, so that the mechanism can not be accidently tripped while out of oil. 7. Clean all internal components. A. Remove all traces of carbon by wiping with a clean, lintfree cloth. B. Flush the mechanism with clean transformer oil. CAUTION Never use volatile solutions, detergents, or water-soluble cleaners. 8. Remove bushings, clean and inspect. NOTE: DO NOT dismantle oil filled bushings. 9. Replace all external seals and gaskets. 10. Inspect mechanism for cracks, carbon tracking, flashovers or other damage. Repair or replace as required. 11. Check the condition of the closing solenoid contactor contact tips. If the contact tips are eroded replace entire contactor assembly. (See page 9 for replacement procedure.) 12. Inspect closing coil for cracks or other damage. 13. Inspect series trip solenoid. 14. Remove the moving contact assemblies from the bottom of the contact lift rod, and check the erosion of the contact load surfaces. A. Arcing tips of the moving contacts can experience considerable erosion before replacement is necessary. Slight pitting and discoloration can be dressed with a piece of crocus cloth. B. However, erosion of the contact load current surfaces necessitates replacement of the entire interrupter assembly. C. Figure 8 shows a moving contact after it has experienced severe interrupting duty and a new contact for comparison. The used contact has reached the condition where interrupter replacement is necessary. 15. Reinstall bushings, use new gaskets. (See page 8 for installation procedures.) 16. Drain the tank, and clean out all sludge and carbon deposits. If oil is to be reused it must be filtered and the dielectric strength checked. 17. Fill with new, clean insulating oil up to 2-1/4 inches below the top of the tank flange. Tank capacity is approximately 41 U.S. gallons. See Oil Condition on page 7. 18. Clean the head gasket seat and retank the recloser. A. Move the yellow operating handle under the sleet hood to the up position to avoid any possible binding during tanking. B. Replace the head bolts and tighten to 35-55 ft-lbs. torque. Apply clamping force gradually and equally, in rotation, to each bolt to achieve an evenly distributed gasket sealing pressure. 19. Check the oil level with the dipstick in the head and adjust the level to the upper line on the dipstick. NOTE: lf the recloser is equipped with an oil-sight gage, the oil level should be above the sight gage. If the oil surface line is visible in the window, add oil to raise the level to the upper line on the dipstick. 20. Perform high-potential insulation withstand test (page ) to make sure the dielectric clearances within the tank have not been compromised. Also, use a suitable tester to verify that the recloser is operating per data plate specifications. Manual Operation of the Recloser The recloser may be closed and opened manually while the mechanism is either in or out of oil. MECHANISM IN OIL For a tanked recloser (mechanism immersed in oil) use the following manual operating procedure. 1. To close the recloser. A. Remove the closing tool port cover and gasket from the side of the head casting. B. Insert the KA90R T-handle closing tool (furnished as an accessory) into the closing tool port (Figure 9) and engage the pin on the closing shaft. Figure 9. Manually closing recloser. 85693KMA Figure 8. Left: new moving conact; right: contact after one full duty cycle. 6 82008KMA C. Lift up the yellow operating handle under the sleet hood to reset the mechanism. D. Turn the closing tool one-quarter turn clockwise to close the main contacts. S280-30-9 CAUTION Never use the KA90R closing tool to close an energized recloser. Forcing the tool beyond the mechanism stop may shear the pin on the closing shaft. 2. To open the recloser. A. Pull down the yellow operating handle to trip open the recloser. NOTE: If the mechanism is partially untanked, and properly supported, the recloser can be tripped open by pulling down on the series trip solenoid linkage. MECHANISM OUT OF OIL To operate the mechanism out of oil, proceed as follows: 1. To close the recloser. A. If the mechanism is still mounted in the head use the procedure for a tanked recloser above (Mechanism in 0il). B. If the mechanism is removed from the head turn the trip reset shaft (Figure 10) with a pair of needlenose pliers to reset the mechanism, then turn the closing shaft clockwise with the closing tool to close the main contacts. 86793KMA Figure 11. Trip lever releases mechanism when opening recloser out of oil. Figure 10. Resetting trip reset. 82016KMA CAUTION The mechanism may be damaged if it is "quick-tripped" with the yellow operating handle while out of oil. 2. To open the recloser contacts while the mechanism is out of oil, proceed as follows: A. Using the T-handle closing tool turn the closing shaft clockwise and hold against the stop. B. Release the trip lever (Figure 11 ) by moving it to the right. C. Then slowly allow the closing tool to rotate counterclockwise to open the main contacts. NOTE: This procedure requires two people; one to operate the closing tool, the other to operate the trip lever. Insulation Level Withstand Tests High-potential withstand tests provide information on the dielectric condition of the recloser. Testing is performed at 75% of the rated low-frequency withstand voltage (52.5 kv). TEST 1: Proceed as follows: 1. Manually close main contacts of recloser (see page 6 for procedure). 2. Ground recloser tank and head. 3. Connect all three source-side bushings (1, 3, 5) together. 4. Apply proper test voltage to source-side bushings. 5. The recloser should withstand the test voltage for 60 seconds. TEST 2: Proceed as follows: 1. Manually close main contacts of the recloser (see page 6 for procedure). 2. Ground recloser tank and head. 3. Ground Phase A (bushing 2) and Phase C (bushing 6). 4. Apply proper test voltage to Phase B (bushing 3). 5. The recloser should withstand the test voltage for 60 seconds. TEST 3: Proceed as follows: 1. Open main contacts of recloser (see page 6 for procedure). 2. Ground recloser tank and head. 3. Connect and ground all three load-side bushings (2, 4, 6). 4. Connect all three source-side bushings (1, 3, 5). 5. Apply proper test voltage to source-side bushings. 6. The recloser should withstand the test voltage for 60 seconds. 7. Reverse the connections: ground source-side bushings (1, 3, 5); apply test voltage to load-side bushings (2, 4, 6) for 60 sec onds. 8. The recloser should withstand the test voltage for 60 seconds. TEST RESULTS: These high potential withstand tests provide information on the dielectric condition of the recloser and the integrity of the interrupters. A. If the recloser passes the closed-contacts tests (Tests 1 and 2) but fails the open-contacts test (Test 3) a deterioration of one or more of the interrupters is likely to be the cause. Check each interrupter individually to determine the failed phase or phases, and replace the interrupter(s). Retest to confirm the repair. B. If the recloser fails the closed-contacts tests (Test 1 and 2) the cause is likely to be a diminished electrical clearance or a failed insulation. After correcting the problem, retest to confirm the repair. Oil Condition Oil provides the internal insulation barrier between phases and from phase to ground, and must be replaced before it deteriorates below a safe dielectric level. Replace the oil if its dielectric strength falls below 22 kv. 7 Types RV and WV Maintenance Instructions New oil should always be filtered before use, even though it is obtained from an approved source. Passing the oil through a blotter press will remove free water and solid contaminants such as rust, dirt, and lint. Keep aeration to a minimum during filtering to prevent moisture in the air from condensing in the oil and lowering its dielectric strength. Used oil must be treated before reusing. FiItering may remove absorbed and free water and other contaminants to raise the dielectric strength to acceptable levels. However, filtering does not always remove water-absorbing contaminants and the dielectric strength may fall rapidly after being returned to service. Therefore the recloser should be filled with new oil, or oil that has been restored to like-new condition. Oil used in these reclosers conforms to ASTM Standard D3487, Type l; its property limits are shown in Reference Data R280-90-1, “Oil Specifications and Tests.” SHOP MAINTENANCE PROCEDURES The operations described in this section should be performed under the cleanest conditions possible. The repair work, except for bushing replacement, will be simplified if the work bench is arranged so the mechanism/head assembly can be inverted (bushings down). No special tools are required for any of the repair procedures. Control Lever Overtravel Adjustment Check for proper adjustment of the control lever by first removing the sleet hood cover to expose the control lever. From the OPEN position, slowly push the control lever toward the CLOSED position. As the lever is pushed up, latching of the recloser will be felt. At this point the dimension between the top of the control lever and the underside of the sleet hood should be 1/4 inch (Figure 12). If the control lever is not adjusted properly, remove the C-ring and slide the control lever from the shaft. Rotate the control lever clockwise to reduce the dimension or counterclockwise to increase the dimension. Slide the control lever back onto the shaft and recheck the dimension. When the proper dimension has been obtained replace the C-ring. Figure 13. Bushing replacement. 1. Disconnect bushing lead from bottom end of bushing rod. 2. Loosen the clamp securing the corona shield (Figure 14). Push shield up bushing to expose O-ring, remove O-ring. Figure 12. Overtravel adjustment of control lever. Bushings Bushing maintenance generalIy consists of a thorough cleaning and a careful examination for chips, cracks, or other mechanical damage during the periodic maintenance inspection. Bushings must be replaced whenever damage is discovered. The bushings used on Type RV and WV reclosers are oil-filled. The special fixtures and procedures required to assemble these bushings is beyond the scope of normal shop maintenance repair. Therefore if an oil bushing is in any way damaged, the complete bushing assembly must be replaced. Refer to Figure 13 and proceed as follows: 8 Figure 14. Corona shield. 86823KMA S280-30-9 3. Remove the three hex head capscrews and clamps that secure the bushing to the head and pull corona shield and clamp off bottom of bushing as it is lifted out. 4. Remove and discard the lower bushing gasket. 5. Twist off the split aluminum clamping ring from the old bushing and install on the new bushing, if it is in good condition—replace if damaged. NOTE: The clamping ring cushions and distributes the pressure between the ceramic and the clamps. DO NOT OMIT. 6. Install the new bushing through the head and slide corona shield and clamp over bushing. 7. Position bushing with the stud end of the terminal pointing outward. 8. Position the clamping ring with the split centered between two clamping bolts. 9. Reassemble the bushing to the head casting. Tighten the bolts evenly, a little at a time, to a torque of 10-15 ft-lbs. NOTE: Clamping forces must be applied gradually and equally in rotation to each bolt. This results in an evenly distributed gasket sealing pressure. 10. Install corona shield O-ring into groove on bushing. 11. Slide corona shield down so inside edge is flush with mechanism frame. Position clamp approximately 1/4” above edge of the shield and secure tightly. 12. Reconnect the lead to the bushing rod. Interrupter Assembly 1. Using a 1/2-inch thin wall socket, remove the vibration-proof hex nut that secures the contact yoke to the lift rod. Gently tap contact arm to remove contacts from the lift rod. 2. Remove the terminal bolt from the top of each stationary contact assembly. 3. Remove hex nuts, flat washers, and lock washers that secure the interrupter assembly to the stringers. 4. Slide the arc interrupter assembly (Figure 15) off. 5. Place the replacement interrupter assembly into position and secure it with original hardware. 6. InstalI the terminal bolts into each stationary contact assembly. 7. Place the movable contact assembly onto the lift rod and install a new vibration-proof hex nut. NOTE: It is recommended that vibration-proof nuts not be reused. Closing Solenoid Contactor If the contacts are badly burned or eroded, the entire contactor must be replaced. See Figure 16 and proceed as follows: 1. Unhook the two toggle springs from the pin that connects the operating shaft of the contactor to the toggle arm. 2. Remove the C-type retaining rings and withdraw the pin. 3. Disconnect the two coil leads from the contactor. NOTE: Reattach the lockwasher and hex nut to the contactor terminal immediately after disconnecting the coil lead to prevent loss of moving contact parts which are attached to the support plate with the same hardware. 4. Disconnect the two fuse leads from the contactor. 5. Remove three hex head capscrews and lockwasher that attach the contactor to the underside of the recloser mechanism frame and remove contactor. 6. Install new contactor by reversing the disassembly procedure. Use new C-rings to secure the toggle-link pin. 7. Connect solenoid coil leads to lower terminals. 8. Connect fuse leads to upper terminals. NOTE: Be sure coil and fuse leads are positioned for maximum clearance to grounded parts. NOTE: The arc interrupter and contact assembly and the moving contact assembly are both replaced as assemblies. They should both be replaced at the same time. Figure 16. Replacing closing coil contactor 86824KMA Closing Solenoid Figure 15. Interrupter assembly. 85695KMA The closing solenoid coil is connected phase-to-phase and is rated to operate at full system voltage. It is protected with two fuses, one on either side. A data plate attached to the recloser head between source side bushings 3 and 5 provides the coil connection information. 9 Types RV and WV Maintenance Instructions If the solenoid coil must be replaced, due to damage or change in operating voltage, refer to Figure 17 and proceed as follows: 1. Disconnect the two coil leads from closing solenoid contactor. NOTE: Reattach the lockwashers and nut to the contactor terminal immediately after disconnecting the coil lead to prevent loss of parts of the moving contact arm assembly which is attached to the support plate with the same hardware. SERIES TRIP SOLENOID The continuous current rating and the trip current rating of the recloser can tee charged by installing new coils in the series trip solenoids. Tripping occurs at about 200% of the continuous current rating of the standard coil and at about 140% when the alternate (400X or 560X) coils are used. The maximum interrupting rating of the recloser is dependent upon the continuous current rating of the series trip coil. Two different coil replacement kits are required. One for Phase A and Phase B solenoids and another for Phase C (the interrupter furthest away from the sleet hood) which has an opposite wind because it mounts differently on the interrupter. The same basic replacement procedure is used for either type coil. Solenoid Disassembly 1. Remove cotter pin; slide out the groove pin and spacer that connects the insulated operating links to the solenoid plunger (Figure 18). 2. Remove bolt that fastens the outer coil terminal and the bushing lead. 3. Remove the capscrew that connects the inner coil terminal strap to the interrupter current interchange. 4. Remove elastic stop nut and flat washer that secure solenoid frame to the upper current exchange mounting board. Lift entire solenoid assembly off board. 5. Remove solenoid plunger, guide clips, guide channels and upper coil washer. 6. Lift coil slightly and pull out of the solenoid frame. 7. Replace any damaged parts at this time. Figure 17 Parts involved in solenoid coil replacement. 86828KMA 2. Remove four capscrews and lockwashers which attach base plate to bottom of solenoid frame posts and lower coil and base plate. 3. Remove coil from the base plate and discard coil gasket. 4. Using a new coil gasket, install new closing coil on the base plate. NOTE: A new coil gasket is included in the closing coil replacement kit. 5. Reassemble base plate to solenoid frame posts and connect coil leads to the contact or terminals. Make sure the coil leads clear the solenoid frame by at least 1/2-inch. 6. The closing coil replacement kit includes two new coil fuses which should be installed with the new coil. 7. The closing coil replacement kit also includes a new voltage date plate. Replace the plate on the sleet hood of the recloser head if the operating voltage of the recloser is being changed. NOTE: RV reclosers, with 34.5 kv closing coil, between serial number 4110 have a rigid tube insulator on the long coil lead. Replacement coils for units below serial number 4110 include additional parts to modify the solenoid assembly to accommodate the rigid insulating tube. Installation instructions are included with the kit. 10 Figure 18. Series trip solenoid removal. 85662KMA Solenoid Replacement Check lower coil washer before installing new coils. For coils rated 280 amperes and below the upper and lower coil washers are identical. For 400 and 560 ampere rated coils, the lower washer requires a larger center slot. The same upper washer is used with all coil sizes. 1. Pass upper insulating washer over terminal strap and align its slot with the coil slot (Figure 19). 2. Insert coil into the frame and slide the upper coil washer into position. 3. Replace in order the guide channels, guide clips and plunger. 4. Place the solenoid assembly back on the mounting board and secure it with the flat washers and elastic stop nuts. S280-30-9 Figure 19. Assembling solenoid series trip coil. 82023KMA 5. Connect operating links to the solenoid plunger with the groove pin, spacer and cotter pin. 6. Connect the coiI terminals to the current interchange and the bushing lead to complete the assembly. TIME DELAY UNIT The recloser is equipped with hydraulically-operated time delay units on each phase. These provide the different timecurrent characteristic (TCC) curves, as shown in Reference Data R28091-6. Each unit can provide either of two-time delay characteristic curves, but not all four (KA1194R1 provides B and C curves and KA1194R2 provides D and E curves). When the mechanism is sequenced to the delayed operation phase, the latch assembly of the trip-coil plunger linkage is engaged with the arm of the time-delay unit, this provides consistent delay action by forcing hydraulic fluid through an orifice in the unit. Special aircraft-type fluid is used to minimize temperature effects. Figure 20. Series trip solenoid removal. 86780KMA Removing Mechanism from Head To gain access to components located in or on the main frame, thefollowing procedure maybe used to remove the mechanism from the head. NOTE: These procedures will be simplified if the untanked head and mechanism assembly can be inverted (bushings down). The unit can be supported on its bushings. 1. Disconnect all six bushing leads from the ends of the bushings. 2. Disconnect the lockout lever and contact position indicator shafts by disengaging the spring loaded couplers and locking them in the disengaged position, Figure 21. Maintenance Maintenance to the time delay units is limited to checking the fluid level in the units. Some loss of fluid is normal, therefore this inspection should be made each time periodic maintenance is performed. To check the fluid level, remove the socket-head filler plug located on the side of the unit. Add enough fluid to bring the level up to the filler plug hole. Avoid introducing dirt, lint or any other foreign material when filling the unit as this can plug the orifice and cause erratic time-delay action. NOTE: A special fluid replacement kit, catalog number KA806R2, is available. The kit consists of approximately 60 cc (2 US fl oz.) of the special hydraulic fluid in an eye-dropper bottle. Replacment Replacement time-delay kits include a factory calibrated time delay, four flat head screws and a minimum-trip calibration spring. Remove the malfunctioning unit and install the replacement in its place (see Figure 20). The minimum trip setting of the recloser must be recalibrated by adjusting the spring tension whenever a new timedelay unit is installed. Figure 21. Disconnect couplers. 86830KMA 11 Types RV and WV Maintenance Instructions 3. Disconnect any accessories, such as a ground trip solenoid, at their terminals. 4. If the recloser is equipped with the auxiliary switch accessory, remove the C or E-ring and washer, Figure 22, and disconnect the operating lever of the switch from the recloser mechanism. Reinstalling Mechanism into Head To reinstall the recloser mechanism assembly into the head, the following procedure may be used. 1. Install the couplers on the lockout lever and contact position indicator shafts. Lock them in the disengaged position. 2. Carefully lower the mechanism assembly onto the six pipe spacers which have been positioned over the mounting holes in the casting. 3. Install the six socket head bolts and tighten evenly to avoid any binding of the mechanism. NOTE: Replace the hex head bolts in the bottom of the closing solenoid frame if eye-bolts were used for handling the recloser mechanism (Figure 23) 4. Re-engage the lockout lever and contact position indicator shaft by releasing the shaft couplers. 5. Reconnect the operating lever of the auxiliary switch (if used) to the mechanism and secure with the washer and E-ring (Figure 23). 6. Reconnect the bushing leads to the end of the bushings. TESTING Procedures for testing the Type RV and WV reclosers are included in the Installation Manual S280-30-1. Figure 22. Remove E-ring to disconnect auxiliary operating lever. 86831KMA 5. Remove the six socket head bolts and lockwashers that secure the frame to the head casting and carefully lift the mechanism from the head. Six long pipe spacers will be released when the mechanism is lifted. NOTE: By temporarily substituting eye-bolts for two of the hex head bolts in the bottom of the closing solenoid frame, the mechanism can be easily lifted and handled with a hoist (Figure 23). 6. Remove couplers from contact position indicator and lockout lever shafts. Figure 23. Lifting mechansim in and out of the head. 12 86831KMA SERVICE PARTS LIST The service parts and hardware listed and illustrated include only those parts and assemblies usually furnished for repair or involved in the maintenance procedures described in this manual. Further breakdown of listed assemblies is not recommended. Dimensions of all common hardware parts have been carefully checked so that they may be locally acquired. The suffix letter of the 14 character catalog number for common hardware parts codes the plating of the part: A - No plating; raw material H - Silver M- Black oxide Q- Cadmium + zinc + chromate Y - Zinc + chromate Z - Electro zinc + bronze irridite A hardware kit, Catalog No. KA849R1, contains an assortment of roll pins, cotter pins, retaining rings, stop nuts, etc.—common hardware parts used in Cooper Power System's reclosers that may not be readily locally available. To assure correct receipt of any parts order, always include recloser type and serial number. Because of Cooper Power System's continuous improvement policy, there may be instances where the parts furnished may not look exactly the same as the parts ordered. However, they will be completely interchangeable without any rework of the recloser. AlI parts carry the same warranty as any whole item of switchgear, i.e. against defects in material or workmanship within a period of one year from date of shipment. S280-30-9 Figure 24. Bushing Parts. Bushing Parts (Figure 24) Item No. 1 2 3 4 5 Description Bushing Assembly Type RV Below Serial No. 9000 (includes: bushing corona shield (10), shield clamp (9), O-ring (11) and conductive gasket (8). Standard bushing Standard bushing with BCT accy. Above Serial No. 8999 Standard bushing Standard bushing with BCT accy. Type WV Below Serial No. 1700 (includes: bushing corona shield (10), shield clamp (9), O-ring (11) and conductive gasket (8). Standard bushing Standard bushing with BCT accy. Above Serial No. 1699 Standard bushing Standard bushing with BCT accy. Hex jam nut, 1/2-20, brass Flat washer Split lockwasher, med. 1/2 bronze Capscrew, hex hd, 3/8-16 x 2-1/4, stl. Catalog Number Qty. Assy. KA899R1 6 KA899R1 6 KA56RV1 6 KA56RV2 6 KA841W1 6 KA841W2 6 KA56RV3 6 KA56RV4 K880725320050H KP2028A903 6 12 12 K900830050000A 6 K730101127225Q 18 Item No. Description Catalog Number Qty. Assy. 6 Bushing clamp KP1109R 18 7 Clamping ring KP1111R 6 8 Lower bushing gasket KA1193R 6 9 Clamp KP109WV 6 10 Corona shield KP582RV900 6 11 O-ring KP2000A19 6 The following parts are applicable to the bushing current transformer accessory. 12 Bushing spacer KP275W1 1 13 Capscrew, hex hd, 3/8-16 x 1-7/8, stl. K730101157187Q 3 14 Transformer clamping flange KP170W1 1 15 Flange gasket KP2090A73 2 16 Replacement current transformer 600:5 multi-ratio KA159W1S 1 1200:5 multi-ratio KA132W 1 17 CT washer, used with plastic housing CT’s KP312W 1 18 Capscrew, hex hd, 3/8-16 x 1 stl. K730101137100Q 3 19 Transformer clamping sleeve K P169W1 1 20 O-ring gasket, used with transformer clamping sleeve that has machined groove. Old style clamping sleeve, without groove, use KP2090A66. KP2000A64 1 21 Hex nut, 3/8-16, stl. K880201116037Q 3 22 Stud KP3149A40 1 13 Types RV and WV Maintenance Instructions Figure 25. Head and tank assemblies. 14 S280-30-9 Head and Tank Assemblies (Figure 25) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Description Cover plate Gasket Capscrew hex hd, 1/4-20 X 3/4, stl Split lockwasher, med, 1/4, stl Dipstick O-ring gasket Closing coil instruction plate Self-tapping screw, Type F, #2 x 3/16. sst Capscrew hex hd, 1/4-20 x 5/8. stl Manual closing tool access cover plate Cover plate gasket Capscrew, hex hd, 5/8-11 x 1-1/2, stl Split lockwasher, med, 5/8’ stl Lifting lug Ground connector Head casting, includes control shaft bushings Head gasket Nameplate Type RV Type WV Type VWV38 Voltage data plate Coil data plate Operating data plate Self-tapping screw, Type Z, #4 x 3/16 sst Sleet hood cover plate Thread cutting screw, Type T, #12 x 1/2, sst Contact indicator plate Handle designation plate Self-tapping screw, Type F, 2-56 x 3/16, sst Manual operating handle assembly Spacer Lever and split shaft assembly Spacer Spacer Item No. Catalog Number Quan. Req’d KP609R KP611R 2 2 33 34 K730101125075Q K900801025000Z KA363R KP2000A9 KP2312R 8 8 1 1 1 35 36 K751515102018A 2 K730101125062Q 2 KP246R1 KP2000A12 1 1 39 40 41 42 43 44 45 K730101162150Q K900801062000Z KP456H2 KA392R 2 2 2 1 KA840R KP2103A8 1 1 KP564RV KP113WV KRW173F KP567R KP2119A9 KP1371R 1 1 1 1 1 1 K801515004018A K283R 8 1 K781515112050A KP1067R KP390R 5 1 1 K751515102018A 4 KA477R KP3009A39 KA313R KP3011A5 KP3011A7 1 1 1 1 1 37 38 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Description Lever and split shaft assembly Retaining ring, Type C, 5/16. stl, WA516 Roll pin,1/8x3/4 Retaining ring, Type C,1/4 stl WA514 One shot link and pin assembly Retaining ring, Type C, 3/8. stl, WA518 Spacer Groove pin One shot handle assembly Spacer Spacer Indicator and support assembly Retaining ring, Type C, 3/16, stl, WA510 Groove Pin Spacer Link Shaft and lever assembly Pin Spacer Flatwasher, #14S brass Cotter pin, 3/32 X 1/2 stl Roll pin, 3/32 X 1/2, stl Counter Self-tapping screw, Type F, 6-32 x 3/8. sst Bracket Self-tapping screw, Type Z #10 x 3/8. sst Capscrew, hex hd, 1/2-13 x 3-1/4, stl Flatwasher Pipe plug, 1”, sq hd Tank Pipe plug 1/2”, sq hd Oil sampling and drain valve assy. Tank liner kit Tank data plate Catalog Number Ouan. Req’d. KA312R 1 K970901312000M K970801125075C 1 1 K970801250000M KA505R 2 1 K970801375000M KP3013A91 KP3126A4 KA504R KP3010A5 KP3013A38 KA317R 2 1 1 1 1 2 1 K970915188000A KP3123A12 K3006A9 KP1059R KA319R KP3190A11 KP3007A8 K900525026056A K970801093050A K970801093050C KA28C0A2 3 1 1 1 1 1 1 1 1 1 1 K751515106037A KP1598R 2 1 K801515010037A 2 K730101150325Q KP2028A23 KP2007A4 KA88W KP2007A3 10 10 1 1 1 KA809R KA867R KP200W 1 1 1 15 Types RV and WV Maintenance Instructions Figure 26. Trip coil and interrupter mechanisms. 16 S280-30-9 Trip Coil and Interrrupter Mechanisms (Figure 26) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Description Time-delay unit replacement kit complete (includes attaching screws) For B and C curves For D and E curves Trip link assembly, complete Torsion spring Roll pin, 1/8 X 3/4, stl Trip lever stop Retaining ring, Type C, 5/16, stl, WA516 Flat washer, 5/16, AN, stl Groove pin Capscrew with lockwasher 1/4-20 x 1/2, stl Contact rod guide Type RV Type WV Moving contact rod assembly Type RV, phases A & B Type RV, phase C Type WV, phases A & B Below Serial No. 1300 Serial No. 1300 and above Type WV, phase C Below Serial No. 1300 Serial No. 1300 and above Pin Retaining ring, Type C,1/4, stl, WA514 Contactor toggle spring Groove pin Closing solenoid contactor Capscrew, hex hd, with lock washer,1/4-20 x 1/2, stl Machine screw, rd hd,1/4-20 x 1/2, brass Hex nut, 1/4-20, brass Split lockwasher, med 1/4 brz Closing coil fuse assembly (also included in closing coil replacement kit, item 36, Figure 27) 2.4-3.3 kv (2 red color bands) 4.15-6 kv (black color band) 7.2-11 kv (yellow color band) 12-14.4 kv, 17.0 kv, 34.5 kv (red color band) Spacer Capscrew, hex hd,1/4-20 x 1, brass Lead Phase A & B Phase C Hex bolt, 3/8-24 X 7/8, silicon brz Washer, 3/8, brass Lockwasher, 3/8, brz Hex nut 3/8-24, brass Cotter pin, 1/16 X 1/2, stl Pin Capscrew, hex hd, 3/8-24 X 7/8, silver brz Coil gap (used only on coils below 100 amp) Phases A & B Phase C Catalog Number Quan. Req’d. Item No. 33 34 KA1194R1 KA1194R2 KA161R KP576R K970801125075M KP577R 3 3 3 3 3 3 K970901312000M K900201032056Z KP3125A2 6 6 3 K830101125050A 6 KP346W1 KP346W2 3 3 KA44RV2 KA44RV1 2 1 KA29WV1 KA165W2 2 2 35 36 37 38 39 40 41 42 43 44 KA29WV1 KA165W1 KP517RV 1 1 3 K970901250000A KP141R1 KP1306R KA430R3 13 2 1 1 K8830101125050A 3 K721525125050A K881025120025A K900830025000A 3 9 7 2 KA259R904 KA259R901 KA259R902 KA259R903 KP3009A13 2 K730115125100A 2 KP148WE KP149WE K700133337087A K900525039087H K900830037000A K880725324037H K970501062050A KP3114A1 2 1 3 3 9 3 3 3 K700122227087A 6 KP13RV2 KP13RV1 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Description Capscrew, hex hd,1/4-20 x 7/8, stl Self-tapping screw, rd hd, Type F, #2 x 5/16, stl Eyelet Plunger guide Plunger guide Plunger assembly Solenoid frame assembly Coil washer (see item 43) Barrier Series coil replacement kit (includes item 20, Figure 25) (Add coil rating as suffix to catalog number) Type RV Phases A & B Phase C Type WV Phases A & B Phase C Coil washer (used instead of KP318P on top of 400 and 560 amp coils only) Interrupter assembly Type RV Phases A & B Phase C Type WV Phases A & B below serial no. 1300 Phase C below serial no. 1300 Phases A & B serial no. 1300 and above Phase C serial no. 1300 and above Roll pin, 1/8 X 5/8, stl Moving contact assembly Type RV Type WV Spacer Flat washer, 5/16, stl Stop nut, 5/16 Flat washer, 1/4, stl Stopnut, 1/4-20 Flat washer, 3/8, stl Lockwasher, med, 3/8,, stl Hex nut,3/8-16, stl Stringer assembly Insulator Flat washer, #24S, brass Lead Type RV (4 per phase) Type WV (6 per phase) Spacer Insulator Toggle assembly Type RV S/N 7399 and below S/N 7400 and above Type WV S/N 1300 and below S/N 1301 and above Catalog Number Quan. Req’d. K730101125087A 6 K751501102031A KP1351 R KP622R KP312R KA604R KA603R KP318R KP1684R 6 6 6 6 3 3 6 or 3 3 KA869R2___ KA869R1___ 2 1 KA835W2 ___ KA835W1___ 2 1 KP1075R 3 KA49RV2 KA49RV1 2 1 KA28WV2 2 KA28WV1 1 KA168W2 2 KA168W1 K970801125062M 1 3 KA46RV1 KA105DV1 KP1505R K900201031000Z KP2020A4 K900201025000A KP2020A3 K900201037000A K90801037000Z K880201116037A KA62R KP3230A14 K900525039087H 3 3 3 3 3 6 6 9 9 9 9 9 3 KP3250A1 KP3250A1 K P3011A39 KP2104A9 12 18 3 3 1 KA450R3 KA166W 1 1 KA450R3 KA166W 1 1 2 1 17 Types RV and WV Maintenance Instructions Figure 27. Closing solenoid and hydraulic control parts. 18 S280-30-9 Closing Solenoid and Hydraulic Contol Parts(Figure 27) Item No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Description Capscrew, hex socket hd, 1/2-13 x 4-1/2, stl Split lockwasher, med,1/2, stl Spacer Counter shaft coupler Operating lever coupler Pivot pin Retaining ring, Type C, 1/4, stl Lockout piston link Pin Lockout piston Spring clip Pump link Pump piston Pin Pump piston shell Retaining ring, Type E,1/8”, stl Quick reset valve assembly Pump and lockout piston block Capscrew, hex hd,1/4-20 x 1-3/4, stl Split lockwasher, med,1/4, stl O-ring gasket Ball Ball seat Ball retainer pin Ball retainer pin Gasket Retaining ring, Type C, 3/8”, stl Groove pin Flat washer, SAE,3/8, stl Plunger and link assembly Catalog Number Quan. Req’d. KP2036A3 K900801050000Z KP3182A1 KP2448R KP2447R KP418H K970901250000M KP122R KP3055A3 KP112R KP2018A1 KA97R KP1733R KP3055A1 KP1732R K971001125000A KA423R KP1300R 6 6 6 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 K730101125175A K970801025000A KP2000A3 KP2025A2 KP155H2 KP3051A3 KP3051A1 KP116R K970901312000M KP3126A2 K900201037000A KA50R 2 2 2 2 2 1 1 1 2 1 2 1 Item No. 31 32 33 34 35 36 Description Stringer assembly Split lockwasher, med, 3/8. stl Hex nut, 3/8-16, stl Solenoid frame Capscrew, 3/8-16 x 11/2, stl Closing coil replacement kit (includes closing coil, lower coil gasket 37 (Figure 27) two fuse assemblies 57 (Figure 26), and voltage data plate, 19 Figure 25). 2.4 kv 3.3 kv 4.16-4.8 kv 6.0 kv 7.2-8.32 kv 11.0 kv 12.2-13.2 kv 14.4 kv 17.0 kv 20.0 kv 23.0-24.9 kv 34.5 kv Reclosers with low voltage closing 48 vdc 125 vdc 250 vdc 37 Solenoid gasket 38 Solenoid frame post 39 Solenoid bridge plate assembly Catalog Number KA62R K900801037000Z K880201116037A KP100R2 K730101137125A Quan. Req’d. 4 12 4 1 8 KA834R1 KA834R10 KA834R2 KA834R6 KA834R3 KA834R9 KA834R4 KA834R5 KA834R12 KA834R11 KA834R13 KA834R14 KA834R16* KA834R7* KA834R8* KP389R KP1669R KA644R3 1 4 fuses required with low-voltage dc coils, when converting a recloser to * No low-voltage operation use the low-voltage contactor and coil kit, P/N KA887R: specify desired operating voltage (Vdc or Vac). 19 Cooper Power Systems Quality from Cooper Industries ©1997 Cooper Power Systems, Inc. Kyle® is a registered trademark of Cooper industries, Inc P.O. Box 1640, Waukesha, WI 53187 http://www.cooperpower.com/ KDL 7/05