Medium Voltage Products
NPS modular outdoor switch disconnectors
Operating, maintenance and recycling
This common document is applicable to all versions
of NPS modular outdoor switch disconnectors. Detailed
mounting instructions for each type are included
in the delivery.
Designation: The basic NPS pole element
is a disconnector. It can be upgraded to limited purpose
switch disconnector (according to IEC standard)
by adding optional breaking elements. Breaking chambers
(630A breaking capacity) fulfill all requirements of general
purpose switch disconnector except short-circuit making
capacity, which is less than the rated peak withstand
current of the disconnector element, but more than
necessary in most rural overhead line applications.
In some cases designation switch or load-break switch
is adopted from spoken language.
WARNING
HAZARDUS VOLTAGE CAN SHOCK, BURN,
OR CAUSE DEATH.
Do not attempt to handle, install, use or service this product
before reading instruction this document.
Safety Notices
Must always follow the directions in the manual and good
engineering practice.
Dangerous voltage can cause electric shock and burns.
– Do not perform any activity described in this document with the
switch energized.
– ALWAYS follow your company’s or country’s Safety procedures
before performing any work on this equipment.
– NPS outdoor switch disconnector should be installed only within
the design limitation.
– All the activities listed on this document it must be performed with
the switch completely de-energized, isolated, grounded and out
of service.
– Must be observed appropriate guidance given in the manuals for
all operations performed on the apparatus.
– This product is intended to be installed, operated and maintained
by qualified personel, thoroughly trained and knowledgeable with
the regards of the hazards involved. This publication is written only
for such qualified persons and is not intended to be a substitute
for adequate training and experience in the safety procedures for
this device.
Warning
Detailed descriptions of standard repair procedures, safety
principles, and service operations are not included. It is important
to note that this document contains some warnings and cautions
against some specific service methods that could cause personal
injury to service personnel, or could damage equipment or render
it unsafe. These warnings do not cover every conceivable method
in which service (whether or not recommended by ABB) may
be performed. Secondly, ABB cannot predict or investigate
all potential hazards resulting from all conceivable service
methods. Anyone using service procedures or tools, whether
or not recommended by ABB, must satisfy himself thoroughly that
neither personal safety nor equipment safety will be jeopardized
by the service method or tools selected.
All information contained in this manual ris based on the latest
product information available at the time of printing. The right is
reserved to make changes at any time without notice.
NPS modular outdoor switch disconnectors
Operating, maintenance and recycling
Operation
Application
NPS switch disconnectors are intended for medium voltage
overhead lines.
Typical functions are:
– To make a safe isolating distance between live parts and
the working object. All criteria of IEC publication 62271‑102
(2001) are fulfilled: increased withstand voltage, visible isolating
distance, eventual leakage current is led away to earth, and
locking options. All safety procedures shall be followed: ensure
the load current does not exceed the breaking capacity, open
disconnector, use voltage detector, connect earthing device, lock
the disconnector, and use the warning shield. The risk of eventual
back feed shall be eliminated.
– To isolate faulty network portions and restore other portions.
– Fault localizing by closing against fault. The maximum fault current
at the location shall be known and specified fault making capacity
of the switch shall not be exceeded.
See more details in chapter: Application limitations.
– Isolating distribution transformers.
Transformer voltage
Breaking current
Max. transformer
of the whips
power
[kV]
[A]
[kVA]
10
40
690
15
32
830
20
25
866
Other applications are possible, if the specified switch ratings are
not exceeded.
Application limitations
– The rated load breaking current and number of breaking
operations, together with the rated short-circuit making current
and number of making operations, is given for each type in the
NPS brochure. NPS is not suitable for fault breaking and frequent
load control.
– Ambient conditions
– The ice-breaking class is 5 mm for motor operated switches
and 10…20 mm for manually operated switches. A heavier ice
layer may prevent normal operation.
– Ambient temperature
–40 … +40 °C versions with porcelain and silicone insulators
–50 … +40 °C versions with epoxy resin insulators
Contact the manufacturer for higher ambient temperatures.
Higher ambient temperatures are possible for lower rated
currents.
– Pollution
– The creepage distance of standard insulators is sufficient
to cover the requirements of IEC 60815 for pollution classes II-IV
depending on the rated voltage and insulator type.
Detailed information about available creepage distance is given
in NPS brochure.
2 NPS modular outdoor switch disconnectors
– Altitude
– The type tested ratings are valid up to 1000m altitude.
Correction factors for higher altitudes are given in IEC publication
60694 (1996) Fig.1. Sometimes it is necessary to select a switch
for a higher rated voltage, but in many cases it is possible
to accept a minor reduction of withstand voltages. In that case
the risks can be minimized by using lightning arresters.
Operation under different fault conditions
– The fault (short-circuit or earth fault) shall be cleared by a circuit
breaker before opening the disconnectors or switch disconnectors.
– NPS_ switches can be closed against fault if the specified shortcircuit making current is not exceeded. The making capacity
depends on the closing speed in case of a disconnector with
breaking whips or breaking chambers NPAK4 (250A). Manual
closing shall be fast and determined (operating time 1,2 s). The
control cabinet should be equipped with fast operating motor drive
(operating time 1,2 s). The operator shall be protected against
eventual sparking.
Breaking chambers NPAK5 have an internal spring device and
the making capacity is independent of the operating speed.
Manual operation
The disconnector shall be operated in one continuous determined
movement. Speed is important when closing against a fault.
The required operating force is higher under ice conditions.
The manual operating device shall be always locked to prevent
unauthorized operation.
After opening ensure complete opening of breaking elements.
After closing ensure fully closed position and that the hook
of the breaking whips is caught behind the whips.
During manual operation it is easy to detect the eventual need
of adjustment and maintenance. See chapter „maintenance”.
Control cabinets
The motor is operated by push-buttons behind the door or
by remote control system. Manual operation is possible by a hand
crank, which is stored behind the door. Detailed instructions in 34
UEMC 35_ manual.
Also the motor operating device shall be padlocked in open
position if safe isolation is required.
Remote control and local automation applications
The main purpose of remote control and local automation systems
is to reduce outage times by fast isolating and restoring
operations.
Normal safety procedures shall not be forgotten, if a safe isolating
distance is needed for maintenance or repair actions.
Earthing and application of the operating rod insulator
For safety reasons, the mounting crossarm (beam) of the switch
disconnector must always be earthed. Concerning earthing
practices and application of the eventual operating rod insulator,
the local safety regulations and IEC publication 61936‑1 shall
be followed.
Line connections
the line conductor direct also to the moving terminal. The following
issues shall be observed:
– The cable and connector may be mechanically stressed by the
operation movement. A loose connection or broken conductor
strand may result from frequent operations in the worst cases.
– A thick cable or inflexible cable routing may increase the required
operating force.
These risks can be reduced by the following application guide:
Line
Recommended connection
< 50 mm2 overhead line
Direct connection possible
< 100 mm 2 overhead line
Hinged terminal recommended on the
> 100 mm2 overhead line
Third insulator set recommended
rocking side
Earth cable
Flexible dropper recommended
Transformer connection
Flexible extension bar
The mm2 limits above are informative only. The function is strongly
affected by the flexibility, length and routing of the jumper cable.
The clearances may be changed during operation. This risk can be
reduced by sufficient tolerances or by using insulated jumper
cables.
Minimum clearances basing to IEC publication 61936‑1:
– 12 kV 150 mm,
– 24 kV 220 mm,
– 36 kV 360 mm (200 kV).
The minimum clearance across open contacts is based on type
tests and is given for each type in the mounting instructions.
The line connector shall be selected based on conductor material
and size. See Enclosure 1. for details.
Maintenance
In most cases manual switches are operated so seldom that
scheduled maintenance is not economically feasible. Operating
staff should observe the function during operation and report
to maintenance staff if necessary. Adjustment can also be made
when the switch is operated.
Reliable operation is a primary requirement for remote controllable
switches and regular maintenance should be arranged.
Preventive maintenance
Manual switches with breaking whips
Action
Lubrication of main contacts
Visual inspections:
Frequency
Notes
5 years or if special need observed
Only if the line is dead for other reasons
3-5 years during normal operation
Adjustment of closed position
Some overtravel in closed direction needed
Breaking whip function
The hook is caught behind the whip in closed position
Breaking whip condition
Replace, if broken or badly deformed
Condition of the operating rod insulator (if any)
Replace, if damaged
Condition of the insulators
Clean if excessive pollution layer observed
Crossarm fixing
Tighten, if moving during operation
Earthing cable
Measurement of the earthing resistance
Repair mechanical damages, loose or corroded connections
(6 years)
According to local safety codes
NPS modular outdoor switch disconnectors 3
NPS modular outdoor switch disconnectors
Operating, maintenance and recycling
Motor operated switches and switches with breaking chambers
Action
Lubrication of the main contacts and operating arm/lever
of the breaking chamber
Inspection of the mechanical operation of the breaking
Frequency
Notes
3-5 years
3-5 years
Operating arm and lever are in line, the switch reaches normal end positions
chamber
5 years
Eventual signs of oil leakage
Inspection of control rod adjustment
Visual inspection oil the oil chamber NPAK2
3-5 years
Some overtravel in closed position needed, see mounting instructions
Breaking whips function and condition
3-5 years
The hook is caught behind the whip in closed position. Replace broken or
Crossarm fixing
5 years
Tighten, if moving during operation
Condition of the operating rod insulator (if any)
5 years
Replace, if damaged. Composite type NPSZJ 30 recommended for this
5-10 years
3 years
Clean if excessive pollution layer observed
badly deformed whips.
application.
Condition of the insulators
Earthing cables
Measurement of the earthing resistance
Lubrication of the mechanism
Inspection and replacement of batteries
(6 years)
According to local safety codes
5 years
See control cabinet manual 34 UEMC 35
As needed
See control cabinet manual 34 UEMC 35
Electrical and mechanical endurance
– The mechanical endurance of NPS disconnectors and load break
switches with chambers is at least 2000 no-load operations.
There is no need to replace parts due to mechanical wear in
normal applications.
– Electrical endurance
– Breaking whips:
– 100 breaking operations specified max. breaking current
(25 A/24 kV, 40 A/12 kV)
– Breaking chamber NPAK 4:
– 100 breaking operations 250 A mainly active load
– Breaking chamber NPAK 5:
– 100 breaking operations 400 A mainly active load
– 10 breaking operations 630 A
– 50 making operations 8 kA (peak) or 2 making operations
10 kA (peak)
– 10 making operations 12,5 kA (12 kV)
Repair
All disconnector components can be replaced using standard hand
tools. A damaged breaking chamber should be replaced or sent
to ABB for repair.
4 NPS modular outdoor switch disconnectors
Repair mechanical damages, loose or corroded connections
Spare parts
Switch type
Part
Current path, complete with
24 kV
24 kV
36 kV
epoxy insulators
silicone or porcelain insulators
silicone insulators
NPSZC 2
NPSZC 1
NPSZC 1
NPSZJ 21 (replaces NPSZJ 20)
NPSZJ31 – silicon insulator
silicon insulators NPSZJ32
NPSZJ 1 standard
– normal creepage and NPSZJ33
contacts
Insulator
Operating rod insulator
NPSZJ 2 long
increased creepage
NPTOE3 „black”
NPTOE 3 „black”
NPSZJ 30
NPSZJ30 composite
NPSZJ 30 composite
Breaking whips (3 pcs)
NPAB 1/3
NPAB 1/3
Breaking chambers (complete
NPAK 4/3
NPAK 41/3
3 pcs set with brackets))
NPAK 5/3
NPAK 5/3
Oil for NPAK 2 breaking
NPAB 4/3
Transformer oil, for example Neste Trafo10X
chamber
Contact grease
Spark gap
Hinged terminal
MOBILUX EP2
MOBILUX EP2
NPAP 4/3 for epoxy insulators only
NPAP 3/3 for porcelain insulators only
OJUPZL 9/3
OJUPZL 9/3
Grease for motor operating
MOBILUX EP2
Isoflex Topas NCA52 (Klueber)
device
Instructions for recycling the product
Introduction
Environmental regulations vary from country to country and develop fast. These instructions are informative only. The appropriate
current local regulations shall be followed at the time of recycling.
Packaging
The switch elements are packed in corrugated cardboard boxes.
The cardboard can be recycled. Sometimes the boxes are wrapped in transparent polyethylene foil, which may be recycled, or
disposed of together with normal waste.
The operating rods and mounting crossarms are normally not
packed.
To avoid pollution due to unnecessary transportation, the manufacturer will not accept used packaging. Recycling has to be
arranged locally according to local instructions.
NPS modular outdoor switch disconnectors 5
NPS modular outdoor switch disconnectors
Operating, maintenance and recycling
Materials of the product
Part
Material
Weight kg/pc
Phase element NPS 24kV, epoxy resin insulators and silicon insulators normal creepage
Base
Insulator
Current path
Breaking whip
Whip support + hook
Hot dip galv. steel
2.4
Epoxy resin, silica filler
1.6
Copper, tin and silver plating
0.76
Stainless steel
0.05
Hot dip galv. steel
1.1 /phase
Hot dip galv. steel
4; 5 – for silicon insulators
Porcelain
3.9;
Phase element NPS 24kV, porcelain insulators and silicon
Base
Insulator
Insulator caps
Current path
Breaking whip
Whip support + hook
silicon rubber
6
Aluminium alloy
2 x 0.2
Copper, tin and silver plating
1.2
Stainless steel
0.05
Hot dip galv. steel
1.1
Hot dip galv. steel
4; 5 – for silicon insulators
Phase element NPS 36kV, porcelain and silicon insulators
Base
Insulator
Porcelain
8
silicon rubber
9 for normal creepage distance version and
8 for increased creepage disnatce version
Insulator caps
Current path
Aluminium alloy
2 x 0.2
Copper, tin and silver plating
1.2
Stainless steel
0.05
Hot dip galv. steel
1
Housing
Epoxy resin, silica filler
2.05
Arc extinguishing sheets
Polyacetal resin (POM)
0.15
Operating lever
Stainless steel
0.05
Shaft + bushing
Aluminium alloy
0.26
Moving contact
Stainless steel
0.15
Breaking whip
Whip support + hook
Breaking chamber NPAK 4 (dry)
Fixed contact
Contact tips
Springs
Copper, silver plating
0.2
Tungsten copper
0.01
Stainless steel
0.1
Copper
0.23
Hot dip galv. steel
1
Housing
Epoxy resin, silica filler
2.05
Arc extinguishing sheets
Polyacetal resin (POM)
0.15
External arc control
Brackets + operating arm
Breaking chamber NPAK 5 (dry)
Operating lever
Stainless steel
0.3
Shaft+bushing
Aluminium alloy
0.26
Moving contact
Copper, silver plating
0.18
Fixed contact
Copper, silver plating
0.2
Tungsten copper
0.01
Contact tips
Springs
Operating arm
Brackets
6 NPS modular outdoor switch disconnectors
Stainless steel
0.1
Copper and Hot dip galv. steel
1.1; 2.2
Hot dip galv. steel
0.5
Part
Material
Weight kg/pc
Mounting accessories and manual operating device
Crossarm
Hot dip galv. steel
20
Operating shaft+lever
Hot dip galv. steel
6.9/11.9
Angular supports
Hot dip galv. steel
8.5
Operating rods
Hot dip galv. steel
12
Rod supports
Hot dip galv. steel
1.0
Polyacetal resin (POM)
0.25
Silicon rubber, glasfiber composite, aluminium
0.65
Hot dip galv. steel
4
Operating rod insulator
NPTOE3
NPSZJ30
Handle
Recycling
The product can be dismantled by hand or crushed mechanically.
No special tools are required for dismantling manually.
In case of dismantling, the parts can be sorted, for example, in the
following way:
– steel,
– stainless steel,
– aluminium,
– copper,
– insulators and breaking chamber housings,
– transformer oil,
– others.
The aluminium caps of porcelain insulators can be separated
by melting the sulphur cement at 110…150 °C or by crushing.
In case of mechanical crushing the parts may be sorted by special
machines.
Parts including hazardous materials (e.g. transformer oil) shall be
removed manually before crushing.
Enclosure
Line connections
Copper connectors:
– Check that the conductor area fits the connector being used
and tighten to the correct torque.
Aluminium connectors:
– Ensure that the conductor area and material fits the connector
type being used. The solid aluminium bar shall be left in the
empty slot, if a double slot connector (type KG_) is used for
a single conductor. The oxidized surface of the conductor end
and the grooved bottom of the connector shall be removed
by a steel brush and the surfaces greased immediately with
a special grease formulated for aluminium connections
to prevent reoxidation. The slots of KG_ connectors are greased
by the manufacturer.
– Tighten to the correct torque.
– Recommended greases: ENSTO type SR1, ABB DSAX-RK,
PENETROX-A.
Directory of potentially hazardous material and problem waste
Note!
The aluminium oxide layer increases contact resistance and may
cause dangerous overheating.
Part
Oil breaking chamber
Damaging material
Note
Transformer oil*)
Problem waste
Eventual residues of
Problem waste
contact grease**)
(grease only))
(NPAK2)
Copper parts
*) oil chambers never are never more in ABB offer however can still be exploited,
**) contact grease MOBILEX EP2.
NPS modular outdoor switch disconnectors 7
Conductor material and area
Bolt size/torque
OJUZLL1/3
Cu 16…63 mm2
M8 20 Nm
NPTL 24/3
Al 62…90 mm2
M8 20 Nm
2 x Al 16…70 mm2
M8 20 Nm
2 x Al 50…240 mm2
M10 40 Nm
Cu 10…95 mm2
M10 40 Nm
max.
20
max. 42
Connector type
preceding instructions depending on the conductor type. Leave
the solid aluminium bar in the aluminium slot, if only copper
conductor is connected.
(42)
(36)
(45)
(50)
max.
20
(45)
max. 42
(42)
OJUZLL 3/3 (KG6.1)
(36)
max. 42
(50)
OJUZLL 4/3 (KG43)
max.
20
max. 42
Cu
(50)
(36)
(50)
(36)
KG 36
Al 50…240 mm2
Al
Al
For more information please contact:
ABB Sp. z o.o.
Branch in Przasnysz
59 Leszno St
06-300 Przasnysz, Poland
Phone: +48 29 75 33 000
Fax: +48 29 75 33 327
www.abb.pl
(42)
Cu
(45)
Al
(42)
(45)
max.
20
Al
Cu
Cu
We reserve the right to make technical changes or modify the contents of this
document without prior notice. With regard to purchase orders, the agreed
particulars shall prevail. ABB does not accept any responsibility whatsoever
for potential errors or possible lack of information in this document. We reserve
all rights in this document and in the subject matter and illustrations contained
therein.
Any reproduction, disclosure to third parties or utilization of its contents
– in whole or in parts – is forbidden without prior written consent of ABB.
© Copyright 2012 ABB
All rights reserved
3405PL518-W1-en. Edition 02.2012
Combined connector for aluminium and copper (KG36)
Note which slot is for copper (a force-fit tin plated copper bar will
be found inserted into the slot for copper conductors). Follow the