1 HDU 05004-YN Rev. C
Motor Operated Mechanisms Types MT50 and MT100
Instruction Manual
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For High-Voltage Disconnectors and Earthing Switches for Outdoor Installation
Table of Contents
Sr. Description No.
Page No.
1
General Remarks
3
2
Design
3
3
Optional Extras
5
4
Method of Operation
5
5
Technical Data
8
6
Transportation and Storage
9
7
Installation
9
8
Commissioning
9
9
Maintenance
10
10
Spare Parts
11
11
List of Components
12
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General remarks Practical experience has shown that strict adherence to the recommendation of this instruction manual will ensure the best possible safe performance of the equipment. In an instruction manual it is not possible to cover every possible eventuality that might occur when using technical apparatus. It is therefore requested that all incidences, in particular those for which the instruction manual provides no plausible explanation, be reported to us directly or through our local representatives. These instructions are based on the present technical design. We reserve the right to make any technical changes without prior notice. We cannot accept any responsibility for damage resulting directly from incorrect handling or operation, irrespective of whether specific reference is to be found in the instructions for erection and operation or not. With respect to this document we reserve all rights also in the event of a patent being issued and registration being made under other commercial rights. Misuse, in particular copying and handing over to third parties is prohibited and offenders can be prosecuted under civil and criminal law.
2
Design The motor-operated mechanisms type MT50 and MT100 are designed for outdoor installation and used for the electrical remote operation of disconnectors and earthing switches. All components of the operating mechanism are installed in a polyurethane painted aluminium housing (12) with a door (12a) at the front. Power transmission from the motor (1) to the operating spindle (2) is via a gear train. The control components are attached to a mounting plate (4) and wired to the terminal strip (5). The length of the terminal strip support is designed to accommodate the maximum equipment configuration. The terminal designations are consistently structured, i.e. the same terminal designations are used for the same function in all possible versions . A clearance of approx. 10 cm is provided for connecting the control cables to the terminal strip. The connections to motor (1), limit switches (17), (if included) blocking magnet (19) are routed via a set of terminals (27). The basic version includes the fallowing: -
a contactor control with self holding interlock scheme
-
an 8-pole Auxiliary switch with 4NC + 4NO contacts, Switching capacity of each contact is 2 A at 220 V DC, at T=20 ms. 2
2
Cross sectional area for all internal connections is 1.5 mm (except for motor which is 0.56 mm ) flexible, grey for DC & Auxiliary switch wiring and black for AC wiring. All Auxiliary switch contacts are wired upto terminals. In the case of AC operation, a rectifier (37) is installed upstream of the DC motor. The door and the housing are connected with cable (26) to earth connection and angle. The incoming and outgoing cables are passed from below through a 3 mm thick removable cable entr y plate (9) made of aluminium. Cable glands are not included in the standard scope of delivery, and must be provided by the customer. An anticondensation heater (11) permanently connected to the voltage supply is mounted on the mounting plate.
2.1
Manual Emergency Operation Crank (18), which can be inserted into the auxiliary pin (8) for emergency operation, serves for adjusting the unit and performing emergency operations. It is not permitted to use a drilling machine instead of the emergency crank. The corresponding opening provided on the housing is closed by cover (15). When the manual emergency crank is inserted into the auxiliary pin a safety contact (14) interrupts the control circuit for the motor to ensure that actuation is possible only by using the emergency crank. The opening for manual emergency operation is loc ated approx. 250 mm below the top edge of the box on the right-hand side. It is sealed with a cover (15) incorporating bayonet lock.
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Unauthorised manual operation is restricted by providing a cover (15) alongwith a padlock arrangement on the door. For manual operation first the front door to be opened after removing the padlock and then cover (15) can be removed for insertion of the manual handle. Ensure blocking magnet (19) (if provided) is energised or pulled up manually. For safety ensure Local-Remote selector switch is in Local mode.
2.2
Blocking Magnet Optionally a blocking magnet (19) can be installed. The blocking magnet de-energised prevents the motor-operated mechanism from being operated manually. In this case it is not possible to insert the hand crank (18) into the auxiliary pin (8) for emergency operation. In the case of AC operation, a rectifier (37) is installed upstream of the blocking magnet. An additionally interlock switch (51), directly attached and actuated by the blocking magnet (19) allows electrical operation only when the blocking magnet is energised.
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21
20
2, 2a
10
37
13
1
14
12
27 29
39 15
3 19
11
39
12a
26
23
16
9
5
4
6
Figure 1 : Inside view of motor-operated mechanisms type MT 50 and MT 100
1 2 3 4 5 6 9 10 12 13 14 15 16 19 20 21 23 26 27 29 37 39
Motor (with cover 1a) Operating spindle (with cover 2a) and gear-train Auxiliary switch Mounting plate Terminal strip Control contractor Supply lead plate Operating shaft Housing (with door 12a) Control disc Safety contract Cover for emergency operation Venting hole with filter insert for ventilation Blocking magnet Push button (open & close) Gasket Earthing connection angle Flexible earthing connection Terminals Changeover switch Rectifier Varistor
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Optional Extras (depending on customer’s order)
3.1
Additional Auxiliary switch contacts upto max. 16 contacts in any combination can be provided. Please refer to schematic drawing submitted against order for details.
Caution :-
Ensure Auxiliary switch elements positions are not altered if removed for any maintenance. When they are to be replaced, ensure that any two elements of the same colour are not placed next to each other. It is necessary to place elements of blue and black colours alternatively.
Blue Blue Wrong
Black Black Wrong
Blue Black Right
3.2
Local control system, consisting of:
3.2.1
One changeover switch (29) (local - remote) and two push buttons (20) (ON, OFF) or,
3.2.2
One changeover switch (29) (local - OFF - remote) and two push buttons (20) (ON, OFF)
3.3
Blocking magnet (19) for preventing maloperation during manual emergency operation.
3.4
Adjustable thermostat for Heater (11 )
3.5
Interior lighting (48), with ON/OFF switch
3.6
Handle (35).
4
Method of Operation
4.1
Method of Mechanical Operation The motor-operated mechanism is fitted with a spindle, mounted on bearings in a housing closed at the sides. The motor (1 ) is below the spindle (2) and arranged parallel to it, with a two-step gear train (for MT50) or three-step gear train (for MT100) between them. Power is transmitted to the output shaft (10) from the spindle via a slide with two transmission bolts onto an operating cross, which in each of its end positions is arrested by one of these bolts. When the end position has been reached, t he slide is halted by a cup-spring stop, without the operating position altering any further. On request, the manual emergency operation feature can be protected against maloperation by means of a blocking magnet (19). When the blocking magnet is de-energised, the manual emergency crank (18) cannot be inserted. Unauthorised removing of cover (15) for manual emergency operation is prevented by built-on padlock on the door.
4.2
Method of Electrical Operation The motor-operated mechanism is normally controlled from a control room or a local control cubicle, using an ON or OFF command (minimum pulse duration 25 ms). The control contactor picks up and remains in hold on position through self holding contact. The operating angle of the output shaft (10) is 190 degrees. When either of the end positions is reached, a limit switch (17) cancels the hold on and terminates the switching operation. The limit switches are tripped by the operating cross on the output shaft. In the case of AC operation, a rectifier (37) is installed upstream of the DC motor. Release of the contactors via Auxiliary switch contacts is not permissible! Auxiliary switches (3) are actuated by the control disc (13) fitted to the operating shaft (10). The position signal meets the requirements of IEC Publication IEC62271- 102, third edition and VDE standard 0670,
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part 2. A “CLOSED” position signal is given after closing near the top dead center (i.e. after closing of the current path of the disconnector and near top dead center interlock ing by the operating linkage) and is cancelled upon opening even before the top dead center is reached (i.e. before interlocking is cancelled). The signal for the “OPEN” position is given analogously. The safety contact (14) interrupts the control circuit for the motor when the manual emergency crank (18) is inserted, so that the unit can now be operated only with the manual emergen cy crank. The optional blocking magnet (19) when de-energised, prevents the motor-operated mechanism from being operated manually, as it is not possible to insert the hand crank (18) into auxiliary pin (8) for emergency operation. In the case of AC operation, a rectifier (37) is installed upstream of the blocking magnet. An additional interlock switch (51), directly attached and actuated by the blocking magnet (19) allows electrical operation only when the blocking magnet is energised.
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C A V 0 4 2 z H 0 5
Figure 2a Example of internal wiring diagram (MT50 standard design), for motor operation with DC supply.
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Figure 2b Example of internal wiring diagram (MT50 standard design), for motor operation with single phase AC supply
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5
Technical Data
5.1
Technical data of the motor-operated mechanisms Rated motor voltage
48,110,125,220, 250VDC, 3 415 VAC
Admissible deviation from the rated motor voltage Rated motor output, short time duty
+10% / -15% type MT 50
470 W
&MT100 Switching time (depending on load)
type MT 50
between 3 to 7 sec
type MT 100
or 6 to 12 sec depending on system
Number of switching cycles permissible per hour
10
(we recommend to wait 3 minutes after every switching operation to allow the motor to cool down) Rated torque on the operating shaft at rated voltage
type MT 50
500 Nm
type MT 100
1000 Nm
type MT 50
5 Nm
type MT 1 00
8 Nm
Torque required at the operating shaft for emergency operation Revolution of the emergency crank for a 1 90 degree switching angle of the operating shaft
at least 70
Heating capacity
approx. 25 W
Heating voltage
220V AC
Degree of protection against contact with live or moving parts ingress of foreign bodies and water
IP 54
Cross-section of internal wiring
1.5 mm2
(except motor)
(0.56 mm2)
Max. cross-section of supply leads
5.2
solid
4 mm2
stranded (with end sleeve)
2.5 mm2
Weight
44 kg approx.
Technical data of the built-in control contactors Operating voltage
110, 125 or 220V DC, 110 or 220 VAC, 50/60 Hz
Admissible deviation from the operating voltage
+10% / -15%
Rated power consumption of magnet coils
when operated with DC
Pick-up/holding 7W/7W
when operated with AC
Pick-up/holding 60 VA / 9 VA (50 W/2.2 W)
Minimum signal duration for self-holding 5.3
25 ms
Technical data of the blocking magnets Operating voltage
110, 125 or 220V DC
Admissible deviation from the operating voltage
+10% / -15%
Rated power consumption of magnet coil
approx. 6 W
Duration factor
100 %
Note: Due
to continuous efforts to improve our products, the details given in this publication may be changed without notice.
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Technical Data of the Auxiliary Switches -
Switching capacity of each contact = 2 A at 220 V DC, T = 20 ms
-
Current carrying capacity = 10 A 0
0
9.5 ...17.5
0
9.5 ...17.5
0
NC contact NO contact 0
0 Off
0
190 On
Main contact of disconnector
Auxiliary switch, functional diagram
6
Transportation and Storage Each operating mechanism is specially packed before shipment. As soon as the equipment arrives at the place of destination an inspection for damage in transit should be carried out to find out the extent of damage, the cause of damage and, if necessary, its originator. The damage report, if any, should immediately be sent to the appropriate forwarding agency to be passed on to the transportation insurance company. The operating mechanisms should be stored indoor. In dry climate the duration for transportation and storage of the operating mechanisms must not exceed 6 month without heating. For longer times of storage or if there is danger of moisture condensation the heater has to be connected unless precautions were taken by appropriate packing or storage to prevent moisture condensation.
7
Installation Every operating mechanism should be mounted in accordance with the mounting instructions for the unit for which it is intended and relevant order bound drawings. For direct attachment of the operating mechanisms to disconnectors or earthing switches designed for wall mounting, special instructions if supplied alongwith the unit have to be observed. If the customer decides at a later date to mount the equipment in this way, he should contact our sales depar tment for these instructions. The interior parts of the operating mechanisms (e.g. Auxiliary switches, contactors, etc.) are not resistant to the atmospheric conditions prevailing outdoors ; therefore, care must be taken to ensure that parts are not exposed to humidity during installation. Connection of the motor control components is made at terminal strip (5), and that of Auxiliary switch (3) directly at the Auxiliary switch contacts or at the terminal strip (5), depending on customer’s order. To avoid condensation it is absolutely necessary to connect the heater (11) . After installation the heater is to be commissioned immediately even if the associated disconnectors and earthing switches have not yet been commissioned.
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Commissioning After connecting all cables, first operate the motor operated mechanism with the emergency crank. It is not permitted to use a boring machine instead of the emergency crank. If the disconnector or earthing switch engages properly according to the corresponding operating instructions, the operating mechanism can be actuated electrically. Make sure that safety contact (14) is functioning properly, i.e. the circuit must be interrupted when the emergency hand crank (18) is inserted. Also check the Auxiliary switch(es) (3) for proper contact make in the two end positions. Adjustments of the Auxiliary switches are to be made by specialised personnel only. Check blocking magnet (19) to make sure that its blocking pin is properly located before interlocking disc when the magnet is de-energised and prevents insertion of the hand crank (18). If the units are painted, keep the venting hole with filter free from paint.
9
Maintenance The motor-operated mechanism hardly needs any maintenance. It is recommended to have an inspection carried out together with the inspection of the corresponding disconnector or earthing switch after the first 5 years of operation, at the latest, however, after 1,000 make and break operations. The inspection intervals mentioned above apply to normal ambient conditions. For extraordinary conditions (e.g. use in tropical climate or at excessively low temperatures or heavy pollution) these intervals should be reduced by 50%. The following details should be observed during the inspection or random test: a)
Stop electrical supply to disconnector and earthing switch. Care should be taken that heating circuit and control voltage of the blocking magnet are disconnected.
b)
Observe IEC and national safety regulations.
c)
Carry out several test operations by hand.
d)
Check safety contact (14) (for details see section 8), limit switch (17) and heating resistor (11) for proper functioning.
e)
Check Auxiliary switch(es) (3) for proper contact make in both switching positions. Adjustments of the Auxiliary switch, if required, should only be made by specialists.
f)
Check proper functioning of blocking magnet (19) and interlock switch (51), for details see section 8.
g)
Check whether the control and signalling cable are properly fitted to all terminals.
h)
Check whether the movement is properly transmitted from the operating shaft (10) to Auxiliary switch (3) via control disc (13). If necessary, clean and grease the guides and running surfaces.
i)
Check for inadmissible ingress of foreign bodies and moisture.
k)
Clean filter insert of cable gland (16) in supply lead plate (9).
I)
Check gasket (21) of the door (12a) and replace, if necessary.
m)
After inspection, carry out a number of electrical test operations and reconnect the heating circuit and the blocking magnet to the power supply.
CAUTION :-
-
Ensure that Auxiliary switch elements position or orientation is not altered if it is removed for any maintenance work. This is because it has built-in blow out magnet.
-
Ensure blocking magnet (if provided) is in disengaged position.
-
Cleaning of any plastic parts must be done with dry cloth only.
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Spare Parts It is recommeded to keep the following parts in stock so that, in case of disturbances, prolonged periods of interruption are avoided by rapidly replacing the individual parts. When ordering spare parts, indicate the following details : a)
Type and serial number according to the rating plate of the specific unit.
b)
Designation of spare part, item no. and order no. in accordance with these instructions.
c)
Motor, control, heating and blocking magnet voltage.
Designation
Motor (with pinion) for MT 50/MT 100 operating voltage 110...125 V DC 220...250 V DC Cabon brush for motor Rectifier 15 A Peak block voltage 500 V AC Control contactor operating voltage 220 V AC, 50 Hz 110 V DC 125 V DC 220 V DC Additional : auxiliary contact 1 NC + 1 NO 1 NC + 3 NO Miniature Circuit Breaker 6 A AC for Motor and Control circuit 6 A AC for Heating and Lighting circuit 3 A AC Auxiliary switch elements with roller BLUE BLACK Auxiliary switch elements without roller (required for double decker arrangement) BLUE BLACK Limit switch Safety contact Blocking magnet 110 V DC 125 V DC 220 V DC Inter-locking switch (at blocking magnet) Anticondensation heater operating voltage 220...250 V AC Thermostat Door sealing gasket Sealing ring Molycote longterm 2 plus Dowty seal Retaining ring Cylindrical pin 12 Roll pin 3.5x16 Split pin 3.5x22
Identification Item Fig. letter Sr. No.
M
1
1
Quantity per operating mechanism
Order No.
1
G1
37
1
2 1
K1E, K2A
6
1
2
1HYN050001R601 1HYN050001R602 1HYN350028P98 1HYN450040P1
1HYN450102P1 1HYN450102P2 1HYN450102P3 1HYN450102P4 1HYN450102P5 1HYN450102P23 1HYN450102P6 1HYN450102P8 1HYN450102P20 As per specific 1HYN450103R2 scheme and order
108 90
1HYN450103R3 S1E, S2A S3 Y1
17 14 19
1 1 1
2 1 1
1HYN450013P1 1HYN450017P1 1HYN350027P15 1HYN350027P13 1HYN350027P11
Y1-S3V
51
R1 23T -
11 11 21
-
1 1 1
1
1HYN450039R1
1 1 1 piece approx. 2 m 2 1 can 250 gm 2 2 1 1 1
MT430162P20 1HYN450182P1 1HYN450193P1 1HYN450038P1 GON598000P521 1HYN450042P111 1HYN450107P1 1HYN450095P1 MT430189P262 MT430405P2312
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List of Components Item No.
Designation
1 2 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 21 23 24 25 26 27 29 30 31 35 37 39 42 43 51
Motor (with cover 1a) Operating spindle (with cover 2a) and gear-train Auxiliary switch Mounting plate Terminal strip Control contractor Auxiliary pin for emergengy operation Supply lead plate (with earthing connection angle 23 and ventilating hole 16) Operating shaft Anticondensation heater Housing (with door 12a) Control disc Safety contract Cover for emergency operation (undertachable by chain) Cable gland with filter insert Limit switch Swivelling emergency crank Blocking magnet Push button Door sealing gasket Earthing connection angle Mounting holes of operating mechanism (thread M16) Miniature Circuit Breaker Flexible earthing connection Power block terminal strip Changeover swith (Local-OFF-Remote) Push button (Close-Open) Operating lever Handle Rectifier Varistor Compartment for instructoin and wiring and diagrams Rating plate Interlock switch blocking magnet 19
Fig. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 -
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"ABB is woking continuously to improve the products. We therefore reserve the right to change designs, dimensions data without prior notice."
3 0 8 0 0 2 C . v e R N Y 4 0 0 5 0 U D H 1
ABB Limited Business Area : Disconnectors Maneja, Vadodara 390 013 India India Tel. :
+91-265-2604080 +91-265-2604082/2604261 Fax : +91-265-2638927
www.abb.co.in
