S Reclosers. Types RX, and W Maintenance Instructions CONTENTS

Transcription

1 Reclosers Types RX, and W Maintenance Instructions 14.4 Kv 400 Amp (Type RX) (Serial No. 679 and after) 14.4 Kv 560 Amp (Type W) (Serial No and after) S Service Information 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 RX oil -interrupting, hydraulically controlled, automatic circuit recloser KMA CONTENTS Introduction...2 Description and Operation...2 General...2 Manual Operating Handle...2 Non-Reclosing Lever...2 Contact Position Indicator...2 Interrupters...3 Closing Solenoid...3 Closing Solenoid Contactor...3 Hydraulic Pump and Lockout Piston...3 Series Trip Solenoids...3 Time Delay Unit...3 Mechanism Operation...3 Hydraulic Control System Operation...5 Maintenance...5 Frequency of Maintenance...5 Periodic Maintenance Inspection...5 Manual Operation of the Recloser...6 Mechanism In Oil...7 Mechanism Out of Oil...7 Insulation Level Withstand Tests...8 Oil Condition...8 Shop Maintenance Procedures...8 Control Lever Overtravel Adjustments...8 Bushings...9 Interrupters Assembly...9 Closing Solenoid Contactor...10 Closing Solenoid...10 Series Trip Solenoid...11 Solenoid Disassembly...11 Solenoid Replacement...11 Time Delay Unit...11 Maintenance...12 Replacement...13 Reinstalling Mechanism into Head...13 Testing...13 Service Parts List...13 Bushing Part (Figure 24)...14 Head and Tank Assembly (Figure 25)...16 Trip Coil and Interrupter Mechanisms (Figure 26)...18 Closing Solenoid and Hydraulic Control Parts (Figure 27)...20 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

2 Types RX and W Maintenance Instructions INTRODUCTION Service Information S provides the maintenance instructions for Type RX, and W three-phase, hydraulically controlled, vacuum 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 explodedview drawings of the recloser is included at the back of the manual. DESCRIPTION AND OPERATION General The Type RX, and W 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 momentariiy 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. The location of the major components of a RX recloser are shown in Figure 2. They are similar for the W 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 vacuum interrupter contacts are open; when the flag is up, the contacts are closed. Figure 2. Untanked Type RX recloser KMA 2

3 S Interrupters Circuit opening and fault interruption is achieved by bridgetype 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 self-cleaned 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. 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 snapaction 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 quick reset 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). Series Trip Solenoids 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, by approximately 200 percent, 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. Time Delay Unit When the mechanism is sequenced to a delayed operation 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 3. Series Trip coil KMA 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 ready for another opening operation. 3

4 Types RX and W Maintenance Instructions Figure 4a. Time delay unit (old) KMA Figure 4b. Time delay unit (new) KMA Figure 5. Head mechanism lever arrangement 4

5 S 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 number of operations. The hydraulic pump (Figure 6) is linked to the closing-solenoid plunger and is pushed downward with each operation of 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. 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. Figure 7. Hydraulic pump cross section KMA Ratings ELECTRICAL RATINGS Type RX Type W Nominal system voltage, kv Maximum rated voltage, kv Rated impulse withstand voltage (BIL) kv crest Hertz withstand voltage, kv Dry, one minute Wet, ten seconds Rated maximum continuous current, amps DUTY CYCLE % of Maximum Number of Unit Operations Interrupting Circuit Rating X/R Value Type RX Type W Total 62 Total 58 Figure 6. Hydraulic pump KMA MAINTENANCE Frequency of Maintenance 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 5

6 Types RX and W Maintenance Instructions 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 RX and W 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 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 9 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 and the vacuum integrity of the interrupters. (See page 8 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. 14. Remove the moving contact assembly from the bottom of the contact lift rod and inspect 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, if one half or more of the contact load surface is worn away the interrupter assembly must be replaced. C. Figure 8 shows a new contact and a contact that has experienced severe interrupting duty. The used contacts have reached the conditon where the interrupter assembly should be replaced. 15. Reinstall bushings, use new gaskets, (See page 9 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 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 while raising the tank. B. Replace the head bolts and tighten to 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: If 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 8 ) 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. 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 and disassemble bushings, discard old gaskets. Inspect bushing porcelain, rod and hardware for damage. Replace as required. 9. Replace all external seals and gaskets. 10. Inspect mechanism for cracks, carbon traking, flashovers or other damage. Repair or replace as required. 11. Check the condition of the closing solenoid contractor contact tips. If the contact tips are eroded replace entire contactor assembly. (See page 10 for replacement procedure.) 12. Inspect closing coil cracks or other damage. 13. Inspect series trip solenoid KMA Figure 8. Left: new moving contact; right: contact after one full duty cycle. 6

7 S 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. 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. 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 Oil). 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. CAUTION The mechanism may be damaged if it is "quick-tripped" with the yellow operating handle while out of oil. 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. Figure 10. Resetting trip reset KMA 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. Figure 9. Manually closing recloser KMA 7

8 Types RX and W Maintenance Instructions one or more of the interrupters is most likely the cause. Retest each interrupter individually to determine the failed phase or phases, and replace the interrupter(s). Retest to confirm the repair. B. If the recloser faiis 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. Figure KMA Trip lever releases mechanism when opening recloser out of oil. Insolation Level Withstand Tests High-potential withstand tests provide information on the dielectric condition of the recloser and the vacuum integrity of the interrupters. Testing is performed at 75% of the rated low-frequency withstand voltage (37.5 kv). TEST 1: Proceed as follows: 1. Manually close main contacts of recloser (see page 7 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 7 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 7 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 seconds. 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 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. 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. Filtering 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 R , 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 leverclockwise 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 12. Overtravel adjustment of control lever. 8

9 S Bushings Bushing maintenance generally 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. Refer to Figure 13 and proceed as follows: 1. Disconnect the bushing lead from the bottom end of the bushing rod. 2. Remove the three hex head capscrews and clamps that secure the bushing to the head and lift out the complete bushing assembly. 3. Remove and discard the lower bushing gasket. Figure 14. Bushing parts. 6. Install the bushing assembly (new or reworked) into the head using a new lower bushing gasket. Position the bushing with the stud end of the terminal pointing outward. 7. Position the clamping ring with the split centered between two clamping bolts. 8. Reassemble the bushing to the head casting. Tighten the bolts evenly, a little at a time, to a torque of ft-lbs. Figure 13. Replacing bushing with recloser tanked. 4. Depending upon the extent of damage, the complete bush ing assembly can be replaced or new ceramic only can be installed. If new ceramic only is to be installed, refer to Figure 14 and proceed as follows: A. Unscrew the bushing terminal and withdraw the rod from the bottom of the bushing ceramic; discard the terminal gasket. B. Insert the rod assembly all the way into the new ceramic, making sure the roll pin is seated in the locking groove in the top of the bushing. C. Assemble the terminal to the bushing rod using a new terminal gasket; tighten to 35 ft-lbs. of torque. NOTE: Apply a very small amount of petroleum jelly to the knurled surface of the inside face of the terminal before assembly to the bushing rod. 5. Twist off the split aluminum clamping ring from the old bushing and install on the new bushing if it is in good condi tion; replace the ring if damaged. NOTE: The clamping ring cushions and distributes the pressure between the ceramic and the clamps. DO NOT OMIT. NOTE: Clamping forces must be applied gradually and equally in rotation to each bolt. This results in an evenly distributed gasket sealing pressure. 9. 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. 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. 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. 9

10 Types RX and W Maintenance Instructions 2. Remove the C-type retaining rings and withdraw 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 clear ance to grounded parts KMA Figure 15. Assembled interrupter and stationary contacts, type RX. 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. Closing Solenoid 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. 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. Figure 16. Replacing closing coil contactor 86824KMA Figure 17 Replacing closing solenoid KMA 10

11 S 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 contactor 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. SERIES TRIP SOLENOID The continuous current rating and the trip current rating of the recloser can be changed 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. 3. Remove 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 solenoid frame. 7. Replace any damaged parts at this time. 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 upper washer requires a larger center slot. The same lower 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. 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. Solenoid Disassembly 1. Remove cotter pin; slide out groove pin that connects the insulated operating links to the solenoid plunger (Figure 18). 2. Remove bolt that fastens outer coil terminal and bushing lead. Figure 19. Assembling solenoid series trip coil KMA Figure 18. Replacing series trip coil KMA TIME DELAY UNIT The recloser is equipped with hydraulically-operated time delay units on each phase. These provide the different time-current characteristic (TCC) curves, as shown in Reference Data R Each unit can provide either of two-time delay characteristic curves, but not all four (KA1 194R1 provides B and C curves and KA1194R2 provides D and E curves). 11

12 Types RX and W Maintenance Instructions 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. 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: 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 Disconnect any accessories, such as a ground trip solenoid, at their terminals. 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. Replacement Replacement time-delay kits include a factory calibrated timedelay, 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 time-delay unit is installed. Figure 21. Disconnect couplers KMA 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. Figure 20. Series trip solenoid removal KMA Removing Mechanism from Head To gain access to components located in or on the main frame, the following procedure may be used to remove the mechanism from the head. 12 Figure 22. Remove E-ring to disconnect auxiliary operating lever KMA

13 S 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. 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) the mechanism and secure with the washer and E-ring (Figure 22). 6. Reconnect the bushing leads to the end of the bushings. TESTING Procedures for testing the Type RX and W reclosers are included in the Installation Manual S Figure 23. Lifting mechansim in and out of the head KMA 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. 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 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 Systems' 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. All 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. 13

14 Types RX and W Maintenance Instructions Figure 24. Bushing Parts. 14

15 S Bushing Parts (Figure 24) Oty. Item Catalog per No. Description Number Assy. 1 Bushing Assembly Type RX (consists of items 9 through 12) 11-5/8-inch standard creepage KA717R /8-inch standard creepage with BCT accy. KA717R inch extra-creepage KA717R inch extra-creepage with BCT accy. KA717R4 6 Bushing Assembly Type W (consists of items 9 through 12) 11-5/8-inch standard creepage KA717R /8-inch standard creepage with BCT accy. KA717R inch extra-creepage KA717R inch extra-creepage with BCT accy. KA717R Hex jam nut, 1/2-20, brass K H 12 3 Flat washer KP2028A Split lockwasher, med. 1/2 bronze K A 6 5 Capscrew, hex hd, 3/8-16 x 2-1 /4, stl. K Q 18 6 Bushing clamp KP1109R 18 7 Clamping ring KP1111R 6 8 Lower bushing gasket KP2090A Terminal Assembly Type RX KA143L900 1 Type W KA17W Upper bushing gasket KP2090A Bushing ceramic Type RX Standard creepage KP1110R 1 Standard creepage with BCT accy. KP171W 1 17-inch extra-creepage KP1578R 1 17-inch extra-creepage with BCT accy. KP186W 1 Bushing ceramic Type W Standard creepage KP1110R 1 Standard creepage with BCT accy. KP171 W 1 17-inch extra-creepage KP1578R 1 17-inch extra-creepage with BCT accy. KP186W 1 Qty. Item Catalog per No. Description Number Assy. 12 Bushing rod assembly Type RX Standard and 17-inch creepage KA716R7 1 Standard and 17-inch creepage with BCT accy. KA716R11 1 Bushing rod assembly Type W Standard and 17-inch creepage KA716R20 1 Standard and 17-inch creepage with BCT accy. KA716R21 1 The following parts are applicable to the bushing current transformer accessory. Quantities shown for one current transformer. 13 Capscrew, hex hd, 3/8-16 x 1-7/8, stl. K Q 3 14 Transformer clamping flange KP170W Flange gasket KP2090A Replacement current transformer 600:5 multi-ratio KA159W1S :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. K Q 3 19 Transformer clamping sleeve KP169W O-ring gasket, used with transformer clamping sleeve that has machined groove. Old style clamping sleeve, without groove, use KP2090A66. KP2000A Hex nut, 3/8-16, stl K Q 3 22 Stud K P3149A Bushing spacer KP275W 1 15

16 Types RXand W Maintenance Instructions Figure 25. Head and tank assemblies. 16

17 S Head and Tank Assemblies (Figure 25) Item Catalog Ouan. No. Description Number Req d. 1 Cover plate KP609R 2 2 Gasket KP611R 2 3 Capscrew hex hd,1/4-20 x 3/4, stl K Q 8 4 Split lockwasher, med, 1/4, stl K Z 8 5 Dipstick KA363R 1 6 O-ring gasket KP2000A9 1 7 Closing coil instruction plate KP2312R 1 8 Self-tapping screw, Type F, #2 x 3/16, sst K A 2 9 Capscrew, hex hd,1/4-20 x 5/8, stl K Q 2 10 Manual closing tool access cover plate KP246R Cover plate gasket KP2000A Capscrew, hex hd, 5/8-11 x 1-1/2, stl K Q 2 13 Split lockwasher, med,5/8, stl K Z 2 14 Lifting lug KP456H Ground connector KA392R 1 16 Head casting includes control shaft bushings KA840R 1 17 Head gasket KP2103A Nameplate Type RX KP1RX 1 Type W KP228W 1 19 Voltage data plate KP567R 1 20 Coil data plate KP2119A Operating data plate KP1371R 1 22 Self-tapping screw, Type Z, #4 x 3/16, sst K A 8 23 Sleet hood cover plate K283R 1 24 Thread cutting screw, Type T #12 x 1/2. sst K A 5 25 Contact indicator plate KP1067R 1 26 Handle designation plate KP390R 1 27 Self-tapping screw, Type F, 2-56 x 3/16, sst K A 4 28 Manual operating handle assembly KA477R 1 29 Spacer KP3009A Lever and split shaft assembly KA313R 1 31 Spacer KP3011 A Spacer KP3011 A7 1 Item Catalog Quan. No. Description Number Req d. 33 Lever and split shaft assembly KA312R 1 34 Retaining ring, Type C,5/16. sti, WA516 K M 1 35 Roll pin 1/8 x 3/4 K C 1 36 Retaining ring, Type C,1/4, stl, WA514 K M 2 37 One shot link and pin assembly KA505R 1 38 Retaining ring, Type C,3/8, stl, WA518 K M 2 39 Spacer KP3013A Groove pin KP3126A One shot handle assembly KA504R 1 42 Spacer KP3010A Spacer KP3013A Indicator and support assembly KA317R 1 45 Retaining ring, Type C,3/16 stl, WA510 K A 3 46 Groove Pin KP3123A Spacer K3006A Link KP1059R 1 49 Shaft and lever assembly KA319R 1 50 Pin KP3190A Spacer KP3007A Flatwasher, #14S, brass K A 1 53 Cotter pin,3/32 x1/2, stl K A 1 54 Roll pin,3/32 X 1/2, stl K C 1 55 Counter KA28C0A Self-tapping screw, Type F 6-32 x 3/8, sst K A 2 57 Bracket KP1598R 1 58 Self-tapping screw, Type Z, #10 x 3/8, sst K A 2 59 Capscrew, hex hd,1/2-13 x 3-1/4, stl K Q Flatwasher KP2028A Pipe plug, 1, sq hd KP2007A Tank KA88W 1 63 Pipe plug, 1/2, sq hd KP2007A Oil sampling and drain valve assy. KA809R 1 65 Tank liner kit KA867R 1 66 Tank data plate KP200W 1 17

18 Types RX and W Maintenance Instructions Figure 26. Trip coil and interrupter mechanisms. 18

19 S Trip Coil and Interrrupter Mechanisms(Figure 26) Item Catalog Quan No. Description Number Req d 1 Time-delay unit replacement kit, complete (includes attaching screws) For B and C curves KA1194R1 3 For D and E curves KA1194R2 3 2 Trip link assembly, complete KA161R 3 3 Torsion spring KP576R 3 4 Roll pin, 1/8 X 3/4, stl K M 3 5 Trip lever stop KP577R 3 6 Retaining ring Type C, 5/16. stl, WA516 K M 6 7 Flat washer, 5/16, AN, stl K Z 6 8 Groove pin KP3125A2 3 9 Capscrew with lockwasher, 1/4-20 x 1/2. stl K A 6 10 Contact rod guide Type RX KP346W1 3 Type W KP346W Moving contact rod assembly Type RX, phases A & B KA44RV2 2 Type RX, phase C KA44RV1 1 Type W, phases A & B Below Serial No KA29WV1 2 Serial No and above KA165W2 2 Type WV, phase C Below Serial No KA29WV1 1 Serial No and above KA165W Pin KP517RV 3 13 Retaining ring, Type C,1/4, stl, WA514 K A Contactor toggle spring KP141R Groove pin KP1306R 1 16 Closing solenoid contactor KA430R Capscrew, hex hd, with lock washer, 1/4-20 x 1/2, stl K A 3 18 Machine screw, rd hd 1/4-20 x 1/2, brass K A 7 19 Hex nut, 1/4-20 brass K A 6 20 Split lockwasher, med, 1/4, brz K A 7 21 Closing coil fuse assembly (also included in closing coil replacement kit, item 36, Figure 27) kv (2 red color bands) KA259R kv (black color band) KA259R kv (yellow color band) KA259R kv (red color band) KA259R Clamp KP2006A Wire lead KA28W Lead RX KP3250A1 12 W KP3250A Hex bolt, 3/8-24 X 7/8, silicon brz K A 3 26 Washer, 3/8. brass K H 3 27 Lockwasher, 3/8. brz K A 9 28 Hex nut, 3/8-24, brass K H 3 29 Cotter pin, 1/46 X 1/2. stl K A 3 30 Pin KP3114A Bracket KP Coil gap (used only on coils below 100 amp) Phases A & B KP13RV2 2 Phase C KP13RV1 1 Item Catalog Quan. No. Description Number Req d. 33 Capscrew, hex hd, 1/4-20 x 7/8. stl K A 6 34 Self-tapping screw, rd hd, Type F, #2 x 5/16. stl K A 6 35 Eyelet KP1351R 6 36 Plunger guide KP622R 6 37 Plunger guide KP312R 6 38 Plunger assembly KA604R 3 39 Solenoid frame assembly KA603R 3 40 Coil washer (see item 43) KP318R 6 or 3 41 Barrier KP1684R 3 42 Series coil replacement kit (includes item 20 Figure 25) (Add coil rating as suffix to catalog number) Type RX Phases A & B KA869R2 2 Phase C KA869R1 1 Type W Phases A & B KA835W2 2 Phase C KA835W Coil washer (used instead of KP318P on top of 400 and 560 amp coils only) KP1075R 3 44 Interrupter assembly Type RX Phases A & B KA49RV2 2 Phase C KA49RV1 1 Type W Phases A & B below serial no KA28WV2 2 Phase C below serial no KA28WV1 1 Phases A & B serial no and above KA168W2 2 Phase C serial no and above KA168W Roll pin, 1/8 X 5/8. stl K M 3 46 Moving contact assembly Type RX KA46RV1 3 Type W KA105DV Spacer KP1505R 3 48 Flat washer, 5/16. stl K Z 3 49 Stop nut, 5/16 KP2020A Flat washer, 1/4, stl K A 6 51 Stopnut 1/4-20 KP2020A Flat washer, 3/8. stl K A 9 53 Lockwasher, med, 3/8,, stl K Z 9 54 Hex nut,3/8-16, stl K A 9 55 Stringer assembly KA62R 9 56 Insulator KP3230A Flat washer, #24S, brass K H 3 58 Lead Type RX (4 per phase) KP3250A1 12 Type W (6 per phase) KP3250A Insulator KP2104A Insulator sleeve KP2104A Toggle assembly Type RX Serial no and above KA166W 1 Below serial no KA450R3 1 Type W Serial no and above KA166W 1 Serial nos KA450R Bracket KP257L 2 19

20 Types RX and W Maintenance Instructions Figure 27. Closing solenoid and hydraulic control parts. 20

21 S Closing Solenoid and Hydraulic Contol Parts (Figure 27) Item Catalog Quan. No. Description Number Req d. 1 Capscrew, hex socket hd 1/2-13 x 4-1/2 stl KP2036A3 6 2 Split lockwasher, med, 1/2, stl K Z 6 3 Spacer KP3182A1 6 4 Counter shaft coupler KP2448R 1 5 Operating lever coupler KP2447R 1 6 Pivot pin KP418H 1 7 Retaining ring Type C, 1/4, stl K M 1 8 Lockout piston link KP122R 1 9 Pin KP3055A Lockout piston KP112R 1 11 Spring clip KP2018A Pump link KA97R 1 13 Pump piston KP1733R 1 14 Pin KP3055A Pump piston shell KP1732R 1 16 Retaining ring, Type E, 1/8, stl K A 1 17 Quick reset valve assembly KA423R 1 18 Pump and lockout piston block KP1300R 1 19 Capscrew, hex hd,1/4-20 x 1-3/4, stl K A 2 20 Split lockwasher, med, 1/4, stl K A 2 21 O-ring gasket KP2000A Ball KP2025A Ball seat KP155H Ball retainer pin KP3051A Ball retainer pin KP3051A Gasket KP116R 1 27 Retaining ring, Type C, 3/8, stl K M 2 28 Groove pin KP3126A2 1 Item Catalog Quan. No. Description Number Req d. 29 Flat washer, SAE, 3/8, stl K A 2 30 Plunger and link assembly KA50R 1 31 Stringer assembly KA62R 4 32 Split lockwasher, med, 3/8. stl K Z Hex nut, 3/8-16, stl K A 4 34 Solenoid frame KP100R Capscrew, 3/8-16 x 1-1/2. stl K A 8 36 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 KA834R1 3.3 kv KA834R kv KA834R2 6.0 kv KA834R kv KA834R kv KA834R kv KA834R kv KA834R5 Rec!osers with low voltage closing 48 vdc KA834R16* 125 vdc KA834R7* 250 vdc KA834R8* 37 Solenoid gasket KP389R 1 38 Solenoid frame post KP1669R 4 39 Solenoid bridge plate assembly KA644R3 * No fuses required with low-voltage dc coils, when converting a recloser to low-voltage operation use the low-voltage contactor and coil kit, P/N KA887R: specify desired operating voltage (Vdc or Vac). 21

22 1991 Cooper Power Systems, Inc. Kyle is a registered trademark of Cooper Industries, Inc Hickory Street Pewaukee, WI Printed on Recycled Paper KTM 7/91