A Summary of Major Improvements to the ABB Recloser and Type R Breaker

A Summary of Major Improvements to the ABB Recloser and Type R Breaker

Table of Contents Introduction....................................................................3 Center Bumper..................................................................4 Trip Shaft Adjustment and Stop Bracket...............................................5 Close and Trip Solenoids..........................................................6 Trip Latch Return Spring..........................................................7 Lubrication.....................................................................7 Closing Springs..................................................................8 Transfer Link...................................................................8 Crank Arms....................................................................10 Center Mechanism Repositioning...................................................10 Pull Rods.....................................................................11 Summary of Available Modernization Kits............................................12 List of Figures Figure 1 - Mechanism and Other Design Improvement Identification.........................3 Figure 2 - Center Bumper Location...................................................4 Figure 3 - Trip Shaft Adjustment Components...........................................5 Figure 4 - Old Trip Solenoid........................................................6 Figure 5 - Old Close Solenoid.......................................................6 Figure 6 - New Trip Solenoid.......................................................6 Figure 7 - New Close Solenoid......................................................6 Figure 8 - Old Trip Latch Return Spring...............................................7 Figure 9 - New Trip Latch Return Spring..............................................7 Figure 10 - R-Breaker Mechanism Trip Latch Return Spring Location........................7 Figure 11 - Short Mechanism.......................................................7 Figure 12 - Old R-Breaker and ESVA Recloser Transfer Link...............................9 Figure 13 - Old ES, ESM and ESV Recloser Transfer Link.................................9 Figure 14 - New R-Breaker and ESVA Recloser Transfer Link..............................9 Figure 15 - Replacement Transfer Link for Original R-Breaker..............................9 Figure 16 - Type R-Breaker Mechanism Crank Arm Location..............................10 Figure 17 - Pull Rods............................................................11 Figure 18 - Pull Rod Replacement Assembly Kit Style Numbers............................11 Figure 19 - Operating System Design Improvements.....................................12 Figure 20 - Standard Control Device Replacement Kits...................................13 Figure 21 - ABB Operating System Enhancement Kit Descriptions..........................14 Figure 22 - Recloser Bushings......................................................14 Figure 23 - Replacement Vacuum Breaker Bushings.....................................15 2

Introduction The basic design of the mechanism used in the ABB (formerly Westinghouse) Type R vacuum breaker, ES oil recloser, ESM oil recloser, ESV vacuum recloser, and ESVA vacuum recloser has been constant from its introduction in 1969 until today. During this period there were a few component design changes. These changes, aimed at increasing mechanism reliability, were made as a result of manufacturing and engineering improvements, and/or field experience. It is the purpose of this bulletin to describe these changes, identify the old and new designs, make recommendations relative to these changes, and specify enhancement kits to add to breakers and reclosers in the field. To aid in determining which breakers and reclosers should include these changes, a table (Figure 1) showing the effective dates or serial numbers of each change and the appropriate sections of this paper is included below. Figure 1 - Mechanism and Other Design Improvement Identification Serial # or Mfg Date of Unit Center Bumper Trip Shaft Adj.* Close & Trip Solenoids* Trip Latch Return Spring* Lubrication* Closing Springs* Transfer Link Crank Arms Center Mech. Pull Rods Page # 4 5 6 7 7 8 8 10 10 11 69A---VB- 75E100VB 75E101VB- 76A100VB 76A101VB- 76E---VB 76E---VB- 79H100VB 79H101VB- 1979 1979-1981 1981-1983 1983-90H-- -VB Post-90H--- VB *Recommended field enhancements 3

Center Bumper The center bumper design change is not a direct mechanism change, and it only affects Type R breaker designs. The center bumper was added to all R-breaker designs in 1975, starting with serial number 75E101VB. The center bumper was added to minimize primary contact rebound and reduce strain on the auxiliary switch linkage. The drawing below shows the location of the center bumper in relation to the main operating shaft. A center bumper can be added to R-breakers manufactured prior to May 1975 through the purchase of kit style number 316D804G69. This kit also includes two new closing spring assemblies, an adjustable trip shaft kit, field installation instructions, and a new field adjustment drawing. The center bumper can be added to enhance the operation of older R-breakers to reduce rebound and strain on auxiliary switches. Figure 2 - Center Bumper Location 4

Trip Shaft Adjustment and Stop Bracket One of the major advantages of vacuum interrupters is reduced maintenance. For users to take advantage of this, it is important that the operating mechanism also exhibits the same feature. Therefore, the ABB design objective is to minimize the number of mechanism adjustments required. Operating experience has shown that this general concept is sound, but some adjustments are required to ensure positive operation. Units shipped prior to 1976 do not have a method to adjust the trip latch wipe. The trip shaft was redesigned to allow adjustment and include a stop bracket. The stop bracket provides a consistent positive trip stop. Figure 3 below shows the new trip shaft adjustment components. We recommend that the new trip shaft adjustment system be added to standard units that were built before January 1, 1976 (before serial number 76A 101 VB). Style number 316D804G70 is a trip latch adjustment kit, which includes an instruction leaflet. The adjustment kit is also part of the modernization kit style number 316D804G69. This kit also includes the center bumper, two new closing spring assemblies, instructions for field installation, and the field adjustment drawing. Figure 3 - Trip Shaft Adjustment Components 1. With mechanism open and closing springs charged, apply downward force on the back of trip latch. Slowly rotate tripshaft adjusting screw clockwise until the trip shaft releases. This is no overlap position. To obtain recommended trip latch wipe, rotate adjusting screw 8 1/2 turns in a counter clockwise direction. 2. Trip coil lever should be adjusted to clear the trip lever.25 with a 0.1 minimum overlap by adjusting the trip coil mounting position. 3. Set the latch check switch adjustment screw to operate the micro-switch after the trip latch is latched. 5

Close and Trip Solenoids In June of 1976, the trip and close solenoids were converted from purchased components to self-manufactured components. This increased control of manufactured quality and overall design. This redesign also substantially lowered the ohmic rating, thereby increasing the current draw for more positive operation. The original solenoid designs were industrial type solenoids, while the new are a clapper type design. Figures 4 through 7 below show the old and the new solenoids for easy identification. The old (moving armature) type solenoids are blue or yellow in color. It is necessary that if a coil needs to be replaced, the entire solenoid assembly must be replaced. Figure 20 shows the assembly style numbers for the appropriate trip and close solenoids. NOTE: The new 125 volt DC and 230 volt AC closing coils have a resistance of 8 ohms versus 50 ohms for the old. Therefore, the operating current is higher with the new coil. In many cases, the old design control schemes relied on the 52 relay contacts to interrupt the current on the closing coil. The 52 contacts may not be able to interrupt the higher coil current. For coil changeouts, there must be two 52b contact in series with the 52 contacts. 125 volt DC trip coils should have two 52a contacts wired in series ahead of the trip coil. Figure 4 - Old Trip Solenoid Figure 5 - Old Close Solenoid Figure 6 - New Trip Solenoid Figure 7 - New Close Solenoid 6

Trip Latch Return Spring The trip latch return spring was changed in mid-1976 to provide a more positive return of the trip latch. Figures 8 through 10 below show the location of the trip latch return spring in the mechanism, as well as old and new springs for identification. The spring style number 628A316H06 can be ordered as part of the small spring replacement kit style number 316D804G66, which includes all small springs used in the mechanism. Pre-1976 trip latch return springs should be replaced at the next major maintenance. Figure 8 - Old Trip Latch Return Spring Figure 9 - New Trip Latch Return Spring Figure 10 - R-Breaker Mechanism Trip Latch Return Spring Location Lubrication In August of 1979 (prior to serial #79H---VB), the mechanism grease was changed from a conventional oil-based lubricant to Dow Corning #33M Grease Medium. The Dow Corning #33M grease has a greater operating range for improved low temperature operation and exhibits greater life in outdoor operation. A grease kit, style #316DBO4G71 (which includes new washers and grease), is available. Some users have found it more efficient to purchase one or more "short mechanisms" and use these assemblies to replace the mechanism in the breaker, reducing breaker down time, while allowing the old mechanism to be stripped down and lubricated in a maintenance facility. It is recommended that the mechanism be re-greased at the next major maintenance, if it has not been previously re-greased. Alternatively, a factory authorized rebuild of the short mechanism (pictured in Figure 11) is available. Figure 11 - Short Mechanism Style # 4990C92G05 < 3/83 Style # 4990C92G03 3/83 7

Closing Springs In 1981, the closing springs were changed to increase the closing force and provide long term stability. The new material is more resistant to losing tension over time. It is possible to determine if the mechanism has the latest type closing springs by their color. The latest closing springs are grey in color; previous assemblies were silver, gold, or black. Kit style #316D804G65 consists of two new closing spring assemblies and four washers. Alternately, kit style #316D804G69 consists of two new closing spring assemblies, a new center bumper, an adjustable trip shaft, field installation instructions, and a new field adjustment drawing. It is recommended that the closing springs be replaced during the next major maintenance if any of the earlier type are still in use. When changing springs, the front end of the spring coil end should be in approximately the 2 o clock position so the last spring coil does not the hit the bottom of the trip coil clapper when the springs discharge. Transfer Link In March 1983, the transfer link was redesigned to combine the recloser link and breaker link into one piece to reduce inventory. The link is now made as a stainless steel casting, a more consistent manufacturing operation, instead of a brazed assembly. The new R-breaker and ESVA recloser transfer link overall size is different from the old and is not directly interchangeable on earlier Type R breakers. The earlier ES, ESM and ESV recloser link dimensions are the same as the new and are interchangeable. Therefore, when changing a complete mechanism assembly, it is important to determine which transfer link is present. Figures 12 through 15 show the old and new links. The following kits are available to accommodate different scenarios: Style #4990C92G05 - This is a complete short mechanism which includes the updated crank arm assembly. It can be used on the new or the old design by using the existing transfer link. Style #316D804G24 - This is a complete mechanism; it is the new mechanism with the new transfer link modified for use on all Type R-breakers and all ESVA recloser designs. Style #279C693G06 - This is a complete mechanism; it is the new mechanism with the new transfer link, usable on all ES, ESM and ESV reclosers, as well as newer design Type R-breakers and ESVA reclosers manufactured after March of 1983. Style #4831B99H01 - This is the new cast transfer link modified for use on all Type R-breakers and Type ESVA reclosers. Style #3911B99H01 - This is the new cast transfer link which fits all ES, ESM and ESV reclosers, as well as all Type R-breakers and ESVA reclosers manufactured after March of 1983. 8

Figure 12 - Old R-Breaker and ESVA Recloser Transfer Link Figure 13 - Old ES, ESM and ESV Recloser Transfer Link Figure 14 - New R-Breaker and ESVA Recloser Transfer Link Figure 15 - Replacement Transfer Link for Original R-Breaker Style # 4831B99H01 Style # 3911B99A01 9

Crank Arms In 1983, the crank arm pin location was moved downward an additional five degrees to increase the starting force of the mechanism. This also increased the operating speed of the mechanism. Figure 16 below shows the position of the right crank arm. The left crank arm is behind the spring charged semaphore. Kit style #316D804G68 includes two crank arm assemblies and an instruction drawing. The crank arms should not be changed in any reclosers. It is suggested that they may be changed in Type R-breakers, but should only be used with the modern solenoid and closing spring assemblies. Caution: The two crank arms must be the same on any mechanism, old and new may not be mixed. Figure 16 -Type R-Breaker Mechanism Crank Arm Location Center Mechanism Repositioning The overall design of the Type R vacuum breaker remained basically unchanged from its introduction in 1969 until 1983. In March of 1983, the overall R-breaker and ESVA recloser design was modified by relocating the operating mechanism from the left hand side adjacent to the relay panel to the rear of the low voltage housing with a separate access door. The operating mechanism was also moved to the center phase for more even distribution of forces. The terminal blocks were also moved to accommodate the new arrangement. The new mechanism housing is smaller and can be used in all units. The old design is easy to identify because the mechanism is not in the center of the low voltage housing. The position change from side to center cannot be made to any existing R-breakers or ESVA reclosers. 10

Pull Rods In 1974, the pull rod material was changed from phenolic to high-strength alumina porcelain. In 1983, the geometry of the pull rod was changed to align with the new center mechanism breaker design. Later, in August of 1990 (serial numbers after 90H---VB), the material was changed to polymeric concrete. The change to polymeric concrete allowed the metallic connections to be molded in during the manufacturing process to improve strength and dimensional consistency. The phenolic pull rods are brown in color, while the porcelain insulators used in the pull rod assembly are ASA/ANSI 70 gray. This change is not considered a required field change and is recommended only for those installations where problems have occurred. Minor modification of the mounting assembly is required from the old phenolic designs. Pull rod assembly style numbers are shown in Figure 18. Figure 17 - Pull Rods Figure 18 - Pull Rod Replacement Assembly Kit Style Numbers Rating 15 kv, 600 A, R-1 15 kv 600/1200 A R-2, R-3 15 kv, 600/1200 A, R-4 15 kv, 2000/3000 A R-3, R-4 27 kv, 1200/2000 A, R-1, R-2, R-3 38 kv 1200 A, Type V 150 kv BIL 38 kv, 1200 A, 200 kv BIL Style Number Prior to March 1983 316D804G47 316D804G47 316D804G47 ----- ----- ----- ----- Style Number March 1983 to date 5636B86G01 5636B86G02 5636B86G03 5636B86G06 5636B85G01 5634B55H01 5639B52H01 11

Summary of Available Modernization Kits Figures 19 and 20 summarize the available kits for each of the described improvements. They also highlight which kits are recommended for purchase to improve performance of field units. Additional information is provided in Figures 21 and 23. Figure 21 is an accurate description of each field enhancement kit while Figure 23 shows style numbers for some replacement bushing assemblies. Figure 19 - Operating System Design Improvements Serial # or Mfg Date of Unit Center Bumper Trip Shaft Adj.* Close & Trip Solenoids* Trip Latch Return Spring* Lubrication* Motor Closing Springs* Transfer Link Crank Arms Center Mech. Pull Rods Rec. Kit Style #s 316D804G 69A---VB- 75E100VB 69, 66 & 71 75E101VB 76A100VB 69, 66 & 71 76A101VB -76E---VB 71, 66 & 65 76E---VB- 79H100VB 65 & 71 79H101VB -1979 65 1979-1981 65 1981-1983 None 1983-90H- --VB None Post-90H-- -VB None Related Kit Style Numbers G69 G69 or G70 See Figure 20 G66 G71 See Figure 20 G65 or G69 See Page 8 G68 N/A See Figure 18 *Recommended field enhancements 12

Figure 20 - Standard Control Device Replacement Kits Voltage Standard Motor* Low Temp. Trip Close Coil Resistance (incl. crank & Motor* Solenoid Solenoid (Ohms) roller) (motor only) Assembly Assembly 24 VDC N/A N/A 316D804G25 N/A L915167G01 3.10 48 VDC 316D804G85 N/A 316D804G60 316D804G31 L915167G01 3.10 125 VDC 316D804G23 608B144H04 316D804G61 316D804G30 L915166G01 8.00 Special 125 VDC 316D804G23 608B144H04 1879B10G10 1879B09G07 L992147G01 12.40 120 VAC 316D804G23 608B144H04 N/A 316D804G31 L915167G01 3.10 240 VAC 316D804G23 608B144H05 N/A 316D804G32 L915166G01 8.00 Capacitor Trip N/A 608B144H05 316D804G27 1879B09G06 L915165G01 52.00 Dual Trip Solenoid Assemblies 48/125 VDC 316D804G26 1 - L915166G01 8.00 1 - L915167G01 3.10 48 VDC/AC Cap Trip 1882B73G03 1 - L915167G01 3.10 1 - L915165G01 52.00 48 VDC/Battery Trip 1882B73G04 2 - L915167G01 3.10 125 VDC/Cap Trip 1882B73G05 1 - L915166G01 8.00 1 - L915165G01 52.00 *Standard motor for ambient temperature to -30 0 C; low temperature motor for ambient temperature to -40 0 C 13

Figure 21 - ABB Operating System Enhancement Kit Descriptions Style 316D804G64 316D804G65 316D804G66 316D804G67 316D804G68 316D804G69 316D804G70 316D804G71 Description Spring Release Latch Replacement Kit Consists of close prop, spacer, needle bearing spring and hardware Closing Spring Replacement Kit Consists of 2 closing spring assemblies and 4 -washers Small Spring Replacement Kit Consists of all small springs used in mechanism for one unit Roller & Link Assembly Consists of trip latch constraining link, mechanism link and main roller Crank Arm Assembly Consists of right and left crank arm Modernization Kit Consists of two closing spring assemblies, trip shaft adjustment kit, bumpers, mounting hardware and instructions Trip Shaft Adjustment Kit Consists of clip, lever and adjustment drawing -Washer Replacement and Lubrication Kit Consists of 6 of each of the 6 -washer sizes used in the mechanism plus tube of Dow Corning #33 grease Figure 22 - Recloser Bushings Style Description Outline 5860C85G01 15 kv 110 kv BIL ES/ESM w/clamp terminal 5563A10 5860C85G02 15 kv 110 kv BIL ES/ESM w/4-hole pad terminal 5563A09 5860C85G03 27 kv 125 kv BIL ESV w/clamp terminal 6483A96 5860C85G04 27 kv 125 kv BIL ESV w/4-hole pad terminal 6483A97 5860C85G05 27 kv 150 kv BIL ESV w/clamp terminal 6483A98 5860C85G06 27 kv 150 kv BIL ESV w/4-hole pad terminal 6483A99 5860C85G07 38 kv 150 kv BIL ESV w/clamp terminal 6483A98 5860C85G08 38 kv 150 kv BIL ESV w/4-hole pad terminal 6483A99 14

Figure 23 - Replacement Vacuum Breaker Bushings Style Description Outline 3160804G01 R1, 15 kv, 600 Amp with Clamp Terminal 3A31848 3160804G02 R1, 15 kv, 600 Amp with 4-Hole Pad Terminal 6463A83 3160804G03 R1, 15 kv, 600 Amp with Stud Terminal 8015A80 3160804G75 R2, R3, R4, 15 kv, 600/800 Amp with 4-Hole Pad 9232A41 Terminal 3160804G79 3160804G04 316D804G05 R2, R3, R4, 15 kv, 600/800 Amp with Stud Terminal R2, R3, R4, 15 kv, 1200 Amp with 4-Hole Pad Terminal for Pre-1983 Breakers R2, R3, R4, 15 kv, 1200 Amp with Stud Terminal for Pre-1983 Breakers 316D804G72 R2, R3, R4, 15 kv, 1200 Amp with Stud Terminal 9232A41 316D804G82 R2, R3, R4, 15 kv, 1200 Amp with Extra Creep 9232A42 Porcelain and Stud Terminal 316D804G84 R2, R3, R4, 15 kv, 1200 Amp with Extra Creep 8025A74 Porcelain and Stud Terminal 316D804G77 316D804G16 R1, R2, 27 kv, 600/800 Amp, 125/150 kv BIL with 4-Hole Pad Terminal R1, R2, 27 kv, 1200 Amp, 125/150 kv BIL with 4-Hole Pad Terminal for Pre-1983 Breakers 316D804G78 R1, R2, 27 kv, 1200 Amp, 125/150 kv BIL with 9232A45 Stud Terminal for Post-1983 Breakers 316D804G14 Type V 38 kv, 1200 Amp, 150 kv BIL with 4-Hole Pad Terminal 316D804G80 Type V 38 kv, 1200 Amp, 150 kv BIL with 9232A46 Stud Terminal 316D804G83 Type V 38 kv, 1200 Amp, 150 kv BIL with Extra 9232A48 Creep Porcelain and Stud Terminal For sales and information, contact your local sales representative. For technical support call +1-407-732-2000 or 1-800-929-7947. 15

ABB Inc. 655 Century Point Lake Mary, FL 32746 U.S.A. For sales & marketing contact your local representative or: Tel: +1-407-732-2000 1-800-929-7947 Fax: +1-407-732-2161 www.abb.com/mediumvoltage WP-CCRVB-04.02-01-B April 2002 Replaces MECH1A