Installation and service manual NSO80/NRO80 Motor / manual operating mechanism DTR.05.07.03.EN Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl INTRODUCTION. Dear customer! Thank sincerly for purchasing our product. We are glad to deliver you an operating mechanism type NSO80 / NRO80 which has been designed in order to meet your usable needs. We are deeply convinced that advantages of the mechanisms would be confirmed during exploitation. The purpose of this instruction is to provide information on operating mechanism type NSO80 / NRO80 for high voltage disconnectors and earthing switches 72,5; 123; 245; 420 kV. The instruction includes technical data, design description and also recommendation for adjustment and service. The instruction has been issued with an intention to help in proper installation, servicing and operation of the operating mechanisms. Follow carefully requirements specifed in this instruction ensures troublefree service of operating mechanisms and is a condition of validity of manufacturer's guarantee. Carefully read and understand this instruction sheet before installation, operation and maintenance of operating mechanism. Would you have any questions please contact ZWAE sp. z o.o. We kindly remind basic principles of exploitation both mechanisms: • follow strictly the principles included in this instruction, • perform periodic inspections of mechanisms, consistent with principles included in this instruction, • use only recommended operational materials, • all inspections and services perform consistent with health and safety at work rules. Observance of recommendations included in this instruction ensures permanent operating mechanism’s efficiency. Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdanska Str; 84-300 Lebork, Poland phone / fax: +48 59 86-336-15 / 86-333-86 Web site: www.zwae.com.pl e-mail: zwae@zwae.com.pl 1. APPLICATION. NSO80 motor operating mechanisms are intended for HV outdoor disconnectors and earthing switches which angular displacement is up to 192° and both closing and opening operations anti-torque is up to 800 Nm. The operating mechanisms are compatible with disconnectors and earthing switches produced by ZWAR, operating at 110, 220 and 400 kV voltage (e.g. ONIII110..., ONI220, ONS..., UNIII110...). They replace manual or pneumatic operating mechanisms as an upgrade of existing HV disconnectors. 2. ADAVANTAGES. • simple design using standard elements; • high torque, enabling operation of single- and three- pole sets of disconnectors in extreme weather conditions (heavy icing); • variuos auxiliary and control equipment (including 15 circuit auxiliary connector); • possibility of remote control, electrical locking of operating mechanism's main circuit and earthing blade and current paths difference protection; • corrosion – resistant materials (housing made of aluminium and painted); • high reliability; • easy service and maintenance. 3. SERVICE CONDITIONS Operating mechanisms are dedicated to outdoor switchgears in following ambient conditions: a) temperature ..................................................................................................from 233 (-40 °C) up to 313 K (+40°C) b) air humidity ...........................................................................................up to 100% with temperature 293 K (20° C) c) altitude above the sea level ..................................................................................................................up to 1000 m d) wind speed.............................................................................................................................................up to 30 m/s Page 2/12 Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 4. CONSTRUCTION AND OPERATING RULE. 13 10 1 5 2 3 4 6 7 11 8 9 12 The motor operating mechanism includes: 1 – Housing; 2 – Mechanism with multi-stage worm-gearing, driven by an electric motor; 3 – Control panel; 4 – Control mode switch; 5 – Control buttons; 6 – Electromagnetic locking; 7 – Secondary circuit switch: 7 NC + 8 NO contacts (free regulation and configuration) and a switch for differential protection of contact rails; 8 – Heater to evaporate water condensate from the interior; 9 – Terminal strip for connecting control and power circuits; 10 – Limit switches, disconnecting motor power supply at specific angular displacement of the main shaft; 11 – Motor supply control system; 12 – Cable gland unit; 13 – Drive shaft; 4.1. Housing. The housing is made from aluminium metal sheet, species PA4, covered by powder painting epoxy color. Doors are stuffed with silicone seal. The construction of housing is on protection level IP54 with simultaneous interior air. It has been achieved thanks by labyrinth seal of drive shaft's output on the top of housing and using net-protected gland hole in the bottom of housing. 4.2. Driving mechanism. Driving mechanism consist: – electric motor; – multistage gearing; – worm gear; – gearing. Electric motor drives the screw through the two-stage gearing. As a result of screw rotations, a nut placed on the screw moves along the screw, causing rotation of a cooperating fork. On a fork shaft is settled down a gear, which cooperates with gear fastened on a drive shaft. As a result of application worm gear, drive shaft angular displacement is limited to 192°. Avarage gear ratio amounts to 375 and maximum torque amounts to 800 Nm. Page 3/12 Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 4.3. Control board. The control board is made in the form of bar with installed control devices. Set of control devices consist: – control type switch (remote – local – manual); – close button; – open button; – electromagnetic locking button; – electromagnetic locking unit (which prevents possibility put in a crank). At the rear side of control board has been placed electromagnetic locking, which permits put in a crank in drive socket only in manual steering mode (after switching on voltage at stopping electromagnet). After pulling back electromagnetic locking (black knob) microswitch cuts off steering voltage and prevents starting motor with inserted crank. In case of control board disassembly it is necessary to take care of electromagnet coil’s location (together with dedicated microswitch) in relation to mechanical locking’s surface. Correct coil’s location prevents pulling off electromagnetic locking without switching on voltage at electromagnetic locking’s coil. On the other hand, in pulled off position, microswitch cuts off steering circuit voltage and as a result the motor’s start is impossible. 4.4. Secondary circuit switch. Applicated auxiliary connector includes package of 15 contacts and additional microswitch with one opening and one closing contact dedicated to differential protection of current paths. Package of contacts are controlled by cams, which are settled on the shaft. Direct connection between auxiliary connector and drive shaft provides perfect representation disconnector's position. In typical performance auxiliary connector has been configurated for 8 NO contacts, 7 NC contacts and one pair of contacts dedicated to differential protection of current paths. Switch's configuration, especially mounting steering cams, allows for smooth regulation of enclosing angle and reconfigurate switch at target destination. 4.5. Drive performance. ATTENTION! During connecting supply voltage please pay special attention maintaining supply phases sequence. Otherwise limit switch would not switch off an impulse, which holds steering circuit (what bring to stoppers breaking down – rubber sleeve and starting motor's termal protection). During first run, control mode switch should be in 'local' position. Then put on operating mechanism starting impulse (green button) – with the restriction that supply phases order is correct, the nut at worm gear will move to the left side. Otherwise you should immediately change control mode switch position into 'manual' mode (cutting off steering voltage and stopping operating mechanism) and then exchange two motor's supply phases, changing thus rotating direction. Page 4/12 Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl Switching on impulse by using green button, located in front side of control panel or remote control, causes connecting voltage on one motor's contactor. Torque from motor shaft is transered through gearing to the drive shaft. After reaching drive shaft angle 192°, NC contacts of limit switches are opened and motor's supply voltage is cut off. With the restriction circumstances described above, operating mechanism is ready to work by given an impulse using second button, enabling realisation reverse manoeuvre. During whole operating mechanism’s moving phase exists direct movement transfer on auxiliary switch, causing its NC and NO contacts opening operation, consistent with connection diagram. Cross locking realised with auxiliary contacts of supply voltage connectors prevents mistakenly put on voltage at motor in opening and closing direction in the same time. In case of necessity changing operate mode into manual mode (control mode switch in position 'manual'), pushing electromagnetic locking’s button allows stepping back the locking with simultaneous exposing hole prepared for inserting manual crank. 4.6. Coupling shaft. Coupling shaft enables connection between disconnector or earthing switch shaft and drive shaft. Typical coupling shaft length is 700 or 1700 mm, and maximum deflection angle from vertically axis is 18°. The coupling shaft construction enables easy shortening and adaptation to switchgear's assembly circumstances. 4.7. Supporting structure. On customer's request operating mechanism could be delivered with supporting structure. Depending on performance it enables operating mechanism to high voltage disconnector assembly. Producer does not exclude using customer supporting structures, under circumstance their proper stiffness. 5. INSTALLATION. 5.1. Inspection the operating mechanism before installation. Before installation make sure that the contents of motor drive plate and its equipment are under switchgear's project. 5.2. Operating mechanism to supporting structure assembly. Before mounting operating mechanism to supporting structure one attachment bolts should be covered with TECTYL506 oil or protection lubricant TDM. Then is permitted to mount operating mechanism to supporting structure. 5.3. Coupling with disconnectors ONIII 123 and 245 kV. For coupling operating mechanism with disconnectors is used coupling shaft. Where driving 3-poles set with one operating mechanism, shaft from disconnector's side ends with a 'fork' screwed on coupling mechanism by 4 screws M12x30. While in case of 1-pole disconnector or earthing switch or coupled with existing upper coupling, the shaft ends with socket mounted directly to crank-gear. In case of different types of high voltage switches, coupling shaft's ending is adjusted to specific apparatus type (vertical or pantographed disconnectors). 5.4. Operating mechanism’s control and regulation. After finishing coupling operating mechanism with disconnector, check the operation corretctness of the auxiliary switches, reproducing HV's switch state. In particular if: • disconnector's closing state is signalised not earlier than after reaching by its moving mechanisms dead position (position in which extrnal forces effect on moving contacts do not cause their opening); • disconnector's opening state is signalised not earlier than disconnector's or earthing switch's moving contacts reach way equal or greater than 80% insulation space. Furthermore, you should also check whether the switch's contacts, dedicated to protect current paths, change when the disconnector's contacts are in proper intermediate position. If switchgear's designer does not define in different way, switching over should perform in accordance with operating mechanism's schematic diagram. Moreover, electromagnetic locking's functioning should be tested. In non-voltage state, electromagnetic locking unit successfully blocks possibility of disclosure hole to put into the manual crank. Voltage for electromagnetic locking’s coil can be switched on only in manual control mode. Using control type switch ('manual control mode') and pressing electromagnetic locking's button put on voltage for triggering coil and only after put off mechanical locking (black knob) is enabled to install manual crank. 5.5. Protective earthing connection. For earth connection is used a terminal shown on dimensions drawing. The terminal consist M12 screw and a washer. The rail's cross section between operating mechanism and switchgear's earth connections ought to be chosen in accordance with legal regulation in force. Prior to the protecting earth connection to the operating mechanism’s housing carefully clean the earthing terminal's Page 5/12 Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl surface. At the end of earthing rail R13 hole for fastening screw ougth to be drilled. After smoothing surface and lubricating the hole, using petroleum jelly, is allowed to assembly the rail to earthing terminal, with paying attention for carefully screw's bolting on. 5.6. Connection of control and auxiliary circuits. Control cable should be entered into housing through the gland in operating mechanism's duct plate. Connection between control cable's wires and operating mechanism's terminal strip should be performed in accordance with proper switchgear's project. When connecting the motor supply voltage, pay special attention to maintain correct phase sequence. 5.7. Tests before first run. Before putting the operating mechanism into service, workmanship quality and proper interaction with the HV switch should be checked. For that purpose, please make 10-20 electrically controlled closing and opening operations, simultaneously watching carefully cooperation of elements. In case of finding any irregularity in the work of operating mechanism or cooperating HV switch, the regulation of respective subassemblies and appropriate tests should be repeated. 6. OPERATING MANUAL. 6.1. Remote manoeuvring. Set control mode switch in 'remote' position. In that switch's position, buttons are unavailable and manual drive locking's supply voltage is inactive. 6.2. Local manoeuvring. Set control mode switch in 'local' position. In that switch's position, remote control is disconnected and manual drive's locking is not power supplied. Local control's buttons are working. Pushing 'on' button causes apparatus closing. Pushing 'off' button causes apparatus opening. Improper buttons using does not cause apparatus damage or improper functioning. 6.3. Manual manoeuvring. Set control mode switch in 'manual' position. In that switch's position, remote and local control is disconnected. Manual drive's electromagnetic locking is ready to work. In order to start manual drive one should: • unbolt manual crank's socket cap (nut on the right side of operating mechanism); • push 'blockade' button; • pull mechanical lock (black knob); • release 'blockade’ button; • insert the crank; • move crank in left or right direction, up to a nut on the screw reach location, where it switches microswitch; • pull out the crank; • bolt manual crank's socket cap. 7. INSPECTIONS AND MAINTENANCE. 7.1. Visual inspections. It is recommended to carry out visual inspections once a year and after each failure or short circuit in the switchgear. Check in particular: a) condition of earthing clamp, b) condition of external mechanisms, c) condition of external parts. 7.2. Periodical check-ups. Periodical and maintenance check-ups one should perform once in five years. During check-up and maintenance the using of energetic devices rules and health and safety at work rules should be respected. Check in particular: a) condition of earthing clamp and earthing instalation; b) condition of mechanisms, bearings and connection components; c) correction of reaching limit positions; d) condition of auxiliary switches clamps; e) condition of anti-corrosion protective coatings; f) adhesion of door cover's sealing to housing border; g) heater unit. Page 6/12 Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 7.3. Spare parts and recommended service materials. The use of high quality components and exploitation experience indicate long liveness of operating mechanisms (even 30 years). However in case of damages, the manufacturer provides spare parts in accordance to Customer's order. Ordered spare parts could be assembled only with te producer's knowledge and agreement. • WHITE PHARMACEUTICAL PETROLEUM JELLY (acid-free) used for lubrication electric contacts (earthings, contacts of HV switches); • PROTECTIVE LUBRICANT TDM, in accordance with PN-64/C-96146 used for maintenance metal surfaces, ex. in deep-sea transport (shaft's and coupling elements). 8. STORAGE AND TRANSPORT. 8.1. Shipment packing and transport. Operating mechanisms type NSO80 are transported in cardboard packing. Operating mechanisms should be transported in despatching packages using closed means of transport. Packages should be protected againts crashing together and vehicle's parts and also against sudden shocks. 8.2. Storage. After receiving the operating mechanisms, the recipient should check if: • the contents of data plate, version and equipment of the operating mechanism is consistent with the order and with the usage; • operating mechanism has not been damaged in transport. It is recommended to keep the operating mechanisms in closed rooms, in the atmosphere free from aggressive chemical factors, in surrounding temperature from -25° C up to +40° C and the relative moisture not over 70%. Additional protection for long-time transport or storage is sack with moisture-absorbing substance. It should be removed from operating mechanism directly before switching on the heater. 9. TECHNICAL DATA. No. 1. Parameter Rated voltage / rated current: - squirrel cage motor - series motor - contactor’s coil of motor’s supply voltage control (depending on motor rated voltage) 2. 3x 400 VAC / 4,5 A 220 VDC / 4 A 110 VDC / 10 A 400 VAC 220 VDC 110 VDC - contactor’s coil 220 VDC 220 VAC 110 VDC 110 VAC - heater 230 VAC 220 VDC - electromagnetic locking 220 VDC 110 VDC Rated power: - squirrel cage motor - series motor - contactor’s coil - heater - locking electromagnet’s coil 3. Value Shaft torque: - rated - maximum 750 W 500 W 7W 25 W 7W 500 Nm 800 Nm 4. HV switch’s operating time: ~8s 5. Quantity of manual drive crank’s turns: ~ 100 6. Main shaft’s angular displacement: 192o ± 2o 7. Rated switching capability of control switch: 8. Maximum wires cross section: 4 mm2 9. Housing’s protection level: IP 54 10. Operating mechanism’s weight: 11. Rated mechanical operating life: AC-15; 230 V; 2,5 A DC-13; 220 V; 0,25 A ~ 56 kg ~ 2000 cycles Note: The manufacturer reserves the right to introduce some modifications owing to technological progress. Page 7/12 Page 8/12 50 62 63 K3 S7 60 11 12 97 98 61 S3 K4 Y 4 3 14 13 12 1 13 2 K1 Crank-handle Blocking Work mode mapping Voltage decay mapping Heater 6 + 5 + 8 9 L2 4 2 L1 3 1 7 4 3 2 1 + K1 M L3 6 5 10 5 6 K4 A1 A2 3 4 1 2 manual control local control (motor) remote control Switch position 1-2 Notes: 1. Shown: K3 in no voltage position S7 in position 'manual control' S7 - linking program 3 2 Control 4 7 8 5 6 1 S2 9 14 S1 2 95 12 12 13 11 11 14 13 close 10 2 1 4 K2 K1 S5 open A - HV switch 1 3 96 A2 K2 44 43 Control circuit power supply Y - Crank-handle interlocking coil MP K3 A2 A1 A1 22 21 22 2 1 21 K4 2 1 44 43 Motor circuit power supply K1 - Closing contactor K2 - Opening contactor K3 - Supply voltage control contactor K4 - Thermal relay S1 - Closing pushbutton S2 - Opening pushbutton S3 - Crank-handle releasing pushbutton S4 - Closing limit switch S5 - Opening limit switch MP - Crank-handle blocking switch S6 - Current paths difference protection contact S7 - Control mode switch (remote-local-manual) S8 - Auxiliary switch E - Heater M - Asynchronous motor (3-phase) 51 E 22 21 K2 S4 K1 3-4 K3 5 6 14 15 16 7-8 4 2 5-6 K2 3 1 17 18 9 - 10 6 5 19 20 21 11 - 12 8 7 10 9 22 23 24 12 11 25 26 14 13 27 S6 S6 S8 S8 A 28 16 15 30 HV switch CLOSED 29 18 17 S8 31 20 19 34 35 Loss contact of main circuit 33 24 23 36 37 38 39 28 27 40 Reaching required Insulating Gap "C" 26 25 Auxiliary contact diagram 32 22 21 41 30 29 42 44 45 HV switch OPEN 43 4 3 S6 46 2 1 47 A Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 10. SCHEMATIC DIAGRAM OF OPERATING MECHANISM NSO80 (WITH 3-PHASE MOTOR). 50 51 E 63 K3 S7 60 11 12 97 98 61 Y S3 K4 4 3 12 14 13 1 13 2 K1 K2 A2 A1 Crank-handle blocking Work mode mapping Voltage decay mapping A - HV switch P - Rectifier 6 + 5 + K2 6 5 8 - + + 9 1 K1 2 4 3 A2 A1 - K4 3 K2 4 A1 A2 K1 K1 K2 ~ K2 K1 K3 2 2 D2 D1 1 22sp 21sp 21sp 22sp 32sp 31sp 1 P 32sp 31sp K2 2 14 1 manual control local control (motor) remote contol Connector position S7 - linking program 1-2 S7 in position 'manual control'. 3-4 5-6 1. Shown: K3 in no voltage position on L1, L2, L3; Notes: 4 7 3 5 M 6 5 K1 6 Motor supply Y - Crank handle interlocking coil Control 4 8 3 6 2 S2 7 14 5 12 S1 1 1 K2 K1 12 13 11 11 14 13 9 95 96 A2 A1 21st 22st S5 Close 2 2 1 4 3 21st 22st 2 Open 10 MP K3 K4 2 1 44 K2 Control system supply K1 - Closing contactor K2 - Opening contactor K3 - Supply voltage control contactor K4 - Thermal relay S1 - Closing pushbutton S2 - Opening pushbutton S3 - Crank-handel blocking release pushbutton S4 - Closing limit switch S5 - Opening limit switch MP - Crank-handle blocking switch S6 - Busbar difference protection contacts S7 - Control type switch (remote - local - manual) S8 - Auxiliary switch E - Heater M - DC electric motor 62 22 21 S4 1 44 43 ~ 43 + K1 15 16 7-8 4 3 17 18 9 - 10 6 5 19 20 21 11 - 12 8 7 10 9 22 23 24 12 11 25 26 14 13 27 S6 S6 S8 S8 A 28 16 15 30 CLOSED HV switch 29 18 17 S8 31 20 19 32 34 35 24 23 36 37 38 39 28 27 40 41 30 29 42 Reaching required insulating gap "C" 26 25 Auxiliary contact diagram Loss of contact of main circuit 33 22 21 43 45 OPEN 46 2 1 HV switch 44 4 3 S6 47 A Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 11. SCHEMATIC DIAGRAM OF OPERATING MECHANISM NSO80 (WITH DC MOTOR). Heater Page 9/12 Page 10/12 A - HV switch 37 36 35 38 MP 50 51 2 1 E Crossed field defines microswitch's closed contact Side socket covered (mechanical locking) The crank inserted in side socket MP - Interlocking coil's microswitch (linking program) Manual operating blocking MP - Interlocking coil's microswitch 34 Work mode mapping Y - Interlocking coil 33 14 Y 4 2 Heater S8 - Auxiliary switch E - Heater S3 - Crank-handle releasing pushbutton S3 13 1 2 3 1 1-2 2 3 4 6 4 2 3-4 1 5 3 1 5 6 8 7 7 S8 S8 A 8 S8 9 10 11 12 11 12 13 14 13 15 Loss contact of main circuit 14 16 15 16 Auxiliary contact diagram Disconnector CLOSED 10 9 Reaching required Insulating distance "C" A Disconnector OPEN Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 12. SCHEMATIC DIAGRAM OF MANUAL OPERATING MECHANISM NRO80. Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 224 168 184 204 13. DIMENSIONS DRAWING. 18° 18° Max. 2000 18° 126 18° 787 Gland DP29 176 226 186 435 612 674 189 2 x M16 35 490 16 516 210 163 625 337 120 M12 1. Deviation of dimensions - 1,5% 2. The manufacturer reserves the right to introduce some modifications owing to technological progress. Page 11/12 Zak³ad Wytwórczy Aparatów Elektrycznych Sp. z o.o. 60 Gdañska Str; 84-300 Lêbork, Poland Phone / Fax: +48 59 86-336-15 / + 48 59 86-333-86 www.zwae.com.pl; e-mail: zwae@zwae.com.pl 14. NOTES. 14. NOTES. Page 12/12