—

DISTRIBUTION SOLUTIONS

1YEPTSR0019S001 REV A
R-MEC Spring dead tank
outdoor vacuum circuit breaker
Instruction, operation and maintenance manual
15.5kV 1250A
DISTRIBUTION SOLUTIONS R-MEC instruction manual

Contents
1 Safety Notices 4
2 Introduction 5
3 Receiving, handling and storage 5
3.1 Receiving Inspection 5
3.2 Handling 6
3.3 Storage 6
4 General product description 7
4.1 High Voltage Assembly 7
4.2 Housing 7
4.3 Phase assembly 7
4.4 Spring based mechanism 7
4.5 Trip and Close coils 7
4.6 2nd Tripping Coil (backup trip coil) 8
4.7 Trip Coil Monitor 8
4.8 Undervoltage Trip Coil (UV) 8
4.9 Vacuum interrupters life expectancy chart 9
4.10 Auxiliary switches – current specifications 9
4.11 Current transformer connections 10
4.12 Typical R-MEC ratings nameplate 10
4.13 HV components, typical schematic and general dimensions 11
5 Electrical specifications 14
6 Standard production tests 15
7 Operation 16
7.1 Manual spring charging operation 16
7.2 Electrical Spring Charging Operation 16
7.3 Circuit breaker closing 17
7.4 Circuit breaker opening 17
7.5 External manual trip push button 17
8 Operational check prior installation 19
8.1 Functional tests 19
8.2 Vacuum integrity test 19

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9 Installation 21
9.1 Mounting 21
9.2 Grounding 21
9.3 Arrester Protection 21
9.4 Control Power 21
9.5 Final Inspection 22
10 Inspection, maintenance and adjustment 23
10.1 Maintenance periodicity 24
10.2 Control wiring and main components inspection 24
10.3 Torque verification in HV compartment components and mechanism 25
10.3.1 HV compartment components torque verification: 25
10.3.2 Mechanism torque verification: 25
10.4 Measurement and readjustment of contacts travel & overtravel gap (wipe) 27
10.5 Insulation evaluation (Hi-Pot) and contact resistance measurement 30
10.5.1 Insulation evaluation High Pot Test 30
10.5.2 Contact resistance measurement 30
10.6 Mechanism and HV components cleaning and relubrication 31
10.6.1 Shafts and hooks cleaning 31
10.6.2 Rollers cleaning 32
10.6.3 Check Cleaning effectiveness 32
10.7 Mechanism re-greasing 34
10.7.1 Shafts greasing 34
10.7.2 Closing hook pin greasing 35
10.7.3 Hooks greasing 35
10.7.4 Anti-reclosing lever greasing 36
10.7.5 Rollers greasing 36
10.8 Other parts to be lubricated 37
10.9 Final functional tests 37
11 R-MEC troubleshooting 38
12 End of life recycle/disposal 39

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Figure 1 - Hazardous voltage warning

1 Safety Notices
Install the R-MEC circuit breaker within the design limitations as described on its nameplate
and in these instructions.

Follow your company’s safety procedures.

This breaker should not be used by itself as the sole means of isolating a high voltage circuit.
For the safety of personnel performing maintenance operations on the breaker or connecting
equipment, all components should be electrically disconnected by means of a visible break and
should be securely grounded.

This product is intended to be operated and maintained by qualified persons, thoroughly

trained and knowledgeable 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 this document contains some warnings and
cautions against some specific service methods that could cause personal injury to service
personnel, damage equipment, or render it unsafe. These warnings do not cover all conceivable
ways in which service, whether or not recommended by ABB, might be performed or the
possible hazardous consequences of each conceivable way, nor could ABB investigate all such
ways. 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 is based on the latest product information available
at the time of printing. The right is reserved to make changes at any time without notice.

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2 Introduction
These instructions do not attempt to provide the user of this equipment with every possible
difficulty that may occur in the application, operation and maintenance of the product. Also, as
improvement in parts and assemblies are made, some parts may differ in appearance as
depicted in the illustrations; however, functionality will be equivalent.

The Type R-MEC vacuum circuit breaker is a high-voltage, three-phase device incorporating
three vacuum interrupters, gang operated by a spring charged mechanism. Together with the
optional relaying and current transformers, the breaker will sense an overload and automatically
open.

Satisfactory performance of the breaker is contingent upon the correct installation, and
adequate maintenance and service of the product. Careful study of these instructions will
permit the user to obtain maximum benefit from this device.

3 Receiving, handling and storage

Each breaker is assembled and tested at the factory prior to shipment following strict
procedures.

This equipment was packed and shipped in factory new condition. If damage is noted, call
the carrier at once for inspection and request an inspection report. File a formal claim with the
carrier, supported with paid freight bill, inspection report and invoice. The local ABB Sales Office
must be notified. This must be done within 10 days of receipt or receiver assumes all
responsibility for damage.

3.1 Receiving Inspection

Upon receipt, it is important to inspect promptly to be certain that the correct material has
been received. In case of shortage, immediately notify the local ABB Sales Office.

Check all parts against the shipping list as they are unpacked. Instructions and literature
packed with the breaker should be kept with the unit. The cabinet provides a convenient place
to keep this instruction book, a copy of the schematic diagram and the card with the service
record of the unit. Additional copies may be obtained upon request from the local ABB Sales
Office.
If the breaker is not to be placed in service immediately, it is essential that proper care be
exercised in the handling and storage to ensure good operating conditions in the future. (See
3.3 storage).

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3.2 Handling

The R-MEC circuit breaker comes with two brackets that attach to the sides of the cabinet
and provide provisions for lifting the breaker. A two-point lift is recommended using the loops
in these brackets. (See Figure 2 - Lifting detail)

CAUTION
Exercise care during lifting to avoid damage to the bushings. Breaker has high center of
gravity.

Figure 2 - Lifting detail

3.3 Storage

For prolonged storage, indoor storage is recommended. If stored outdoors, the cabinet
heaters must be energized to maintain the warranty. The mechanism and control compartment
is equipped with heaters to reduce condensation. This recommendation is also shown in
following nameplate located low voltage compartment door.

Figure 3 - Indoor storing recommended notice nameplate

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4 General product description

4.1 High Voltage Assembly

The high-voltage section of the R-MEC consists of three individual phase assemblies
mounted on insulating standoffs. Each phase of the R-MEC consists of a single vacuum
interrupter, flexible shunt and operating rod.

4.2 Housing

The doors of the breaker housing are removable and retained by hinge pins. The position
indicator is visible through the front door. The breaker nameplate showing rating information,
serial number and customer order number is mounted on the right-hand side of the housing.

4.3 Phase assembly

Figure 16 shows the details of the phase assembly. The back bus work is attached directly
to the fixed contact stud on the back end of the vacuum interrupter. The current transfer
assembly housing is fastened to the opposite end of the vacuum interrupter. In the current
transfer assembly, a contact block/flexible shunt transfers current from the moving contact of
the vacuum interrupter directly through the bus to the bushing.

4.4 Spring based mechanism

The EL-mechanism is the core of the R-MEC mechanism, it´s well proven modular design
which allows the user to provide easy and quick maintenance. This mechanism was derived from
other ABB medium voltage circuit breakers, installed in thousands of substations worldwide,
therefore its reliability and robustness is ensured.

By utilizing a modular design, the R-MEC breaker has a quick-change trip/close coil and
charging motor design that makes repair of these commonly repaired parts easy. Additionally,
the R-MEC mechanism features a mechanical anti-pump device to eliminate reliance on
electrical anti-pump devices. For breaker rebuilds or repairs, the entire EL-mechanism can be
removed and replaced in under an hour. Replacement of coils and motor can be done within
minutes by removing a single screw.

4.5 Trip and Close coils

R-MEC breaker features a set of smart coils for remote trip and close operations, with on-
board microprocessors that monitor for coil continuity, over-current and over temperature
scenarios and provide a more efficient response than standard coils. These coils are installed in
right side of mechanism.

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4.6 2nd Tripping Coil (backup trip coil)

A second tripping coil can be added as per customer requirements to provide a backup
tripping coil in case the primary one is failed or simply because the control scheme requires it.
This 2nd tripping coil will mechanically trip the mechanism with exactly the same functionality of
the main standard tripping coil.

4.7 Trip Coil Monitor

Smart Coils can be monitored by means of a device known as STU (Shunt Trip Unit) that is
wired in parallel with the trip coil to continuously monitor the health of the coil. This device will
be shown an alarm through the simplicity of a NO/NC contact where a protection relay input
can be connected.
It might be the case that when an ABB Relion relay is used as the main protection relay of
the R-MEC circuit breaker, the STU device is replaced by the internal trip coil monitor available
in one of the ABB Relion inputs. Consult schematics to confirm.

4.8 Undervoltage Trip Coil (UV)

Under voltage coil can be found in the coil support (right side of the EL mechanism) next to
trip coil 1 and close coil. Function of Undervoltage trip coil is to automatically trip the R-MEC
circuit breaker as soon as the control power is removed. Therefore, special care is needed when
commissioning or during maintenance before control power is provided, as this UV coil will keep
the R-MEC breaker in open position. Only after power is applied the UV coil will allow the breaker
to close.
Whenever control voltage decays below rated value for UV coil (70 % of nominal control
voltage) BREAKER WILL AUTOMATICALLY TRIP WITHOUT ANY DELAY. Keep this above
consideration in mind for safety during maintenance or testing procedure of R-MEC breaker.
This coil is added into R-MEC mechanism as per customer request, therefore not all R-MEC
in field will be featured with this undervoltage trip coil, consult Bill of Materials and schematics
for reference.

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4.9 Vacuum interrupters life expectancy chart

Following picture represents the relation between the current interrupted by the vacuum
interrupters and the maximum number of operations at given current.

Figure 4 - R-MEC vacuum interrupter model VG4S-U

4.10 Auxiliary switches – current specifications

Following specifications define the main auxiliary switches capabilities. The quantity of
available contacts will depend on the specific control, refer to schematics to confirm.

• Max operational voltage: 220 VDC/CVA

• Nominal switching current: 2.0 A
• Switching capability: Inductive loads with L/R ratio (time constant) of 20ms
• Max dielectric strength: 2.0kV for 1 minute
• Insulation resistance: ≥500Mohm
• Max mechanical durability: ≥1,00,000 operations
• Max electrical durability: ≥50,000 operations

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4.11 Current transformer connections

R-MEC circuit breaker can be featured with a maximum of 2 window type current
transformers per bushing. These current transformers are usually manufactured by ABB
following either IEEE or IEC standards, therefore secondary connections will follow standards
regulations. Following table shows the secondary connections for most popular current
transformers despite its application (relaying or metering). Refer to schematics to confirm ratio
and secondary taps.

600:5 Multi-ratio 1200:5 Multi-ratio

Terminal Ratio Terminal Ratio
X2-X3 50-5 X2-X3 100-5
X1-X2 100-5 X1-X1 200-5
X1-X3 150-5 X1-X3 300-5
X4-X5 200-5 X4-X5 400-5
X3-X4 250-5 X3-X4 500-5
X2-X4 300-5 X2-X4 600-5
X1-X4 400-5 X1-X4 800-5
X3-X5 450-5 X3-X5 900-5
X2-X5 500-5 X2-X5 1000-5
X1-X5 600-5 X1-X5 1200-5

4.12 Typical R-MEC ratings nameplate

Following picture shows the standard R-MEC ratings nameplate, final ratings and details
may vary from order to order depending on specific requirements of each job.

Figure 5 - Breaker nameplate

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4.13 HV components, typical schematic and general dimensions

Figure 6 - High voltage compartment layout

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Figure 7 - Typical schematic diagram

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Figure 8 - R-MEC general dimensions 15.5kV, 1250A

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5 Electrical specifications

Rated maximum voltage (rms): 15.5 kV

Rated lightning impulse withstand voltage (BIL) 110 kV
Rated power-frequency withstand voltage-Dry 50 kV (1 min)
Rated power-frequency withstand voltage-Wet 40 kV (10sec)
Rated frequency 50/60 Hz
Number of poles 3 – simultaneously operated
Rated continuous current (rms) @ 50/60Hz 1250 A
Rated symmetrical interrupting rms current 31.5 kA (E2)
Rated peak withstand 82 kA
Rated short time current 31.5 kA
Rated short time current duration 3 Sec
D.C. time constant 45ms
Minimum opening time 35ms
D.C. component 38%
TRV first pole to clear factor 29.2 kV
Operating duty sequence O-0.3sec-CO-15sec-CO
Rated operating endurance 10,000 Operations (M2)
Short line fault surge impedance 450 Ω
Out of phase making and breaking current 7.875 kA
Out of phase voltage factor 2.5
Line charging current 100 A (C1)
Cable charging current 25 A (C1)
Back to back capacitor bank inrush making current 20 kA-peak
Back to back capacitor bank switching current 630 A (C1)
Capacitor bank frequency of inrush current 4250 Hz
Operating temperature -30°C to +40°C (-22°F to 104°F)

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6 Standard production tests

Standard production tests are carried out before each R-MEC breaker is shipped out according
to IEEE C37.09 requirements, including the following tests:

• Verification of all wiring per connection diagrams

• Electrical operation: close and trip. overcurrent response and automatic closing,
with relaying control option
• Check functioning of all manual controls: close/trip, local/remote, non-reclosing,
ground fault bypass, etc.
• Three readings are made on each phase of the breaker using a Biddle “Ducter.”
Typical values do not exceed 100 micro ohms.
• Voltage Withstand: the complete breaker is tested between live parts and tank,
across open contacts and between phases. In compliance with IEEE C37.09 and
IEC 62271-100, an AC dielectric withstand test at 50 kV is performed. Test duration
is one minute.
• Wiring Insulation: The terminal block connections are given an over-potential test
of 1800 volts AC to ground (for 1 sec).
• Verification of CTs functionality: each current transformer is verified to confirm
ratio and polarity as per order specifications
• Manual trip validation: manual tripping functionality is verified; ANSI 69 function
is tested (mechanical close blocking)
• Vacuum interrupters travel and operation synchronization: after settling of
vacuum interrupters, travel displacement, penetration, bounce and timing is
confirmed

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7 Operation
Circuit breaker operation can be either manual or electrical (Figure 9 - Circuit breaker
operation)

Figure 9 - Circuit breaker operation

7.1 Manual spring charging operation

To manually charge the closing spring, it is necessary to repeatedly activate the charging
lever (2) (maximum rotation of the lever: about 90°) until the yellow signaling device (8) appears;
indicating completion of charging. The maximum force which can normally be applied to the
lever is <250N.

7.2 Electrical Spring Charging Operation

The R-MEC is equipped with an electric charging motor (3). When the control power is
supplied to the charging motor circuit (see electrical diagram Figure 7), the charging motor will
charge the closing spring until the yellow signal device appears. The circuit is designed such
that the charging motor will turn on whenever the closing spring is discharged.
If the power circuit is cut off during charging, the geared motor stops and will automatically
start recharging spring when the power returns. In any case, it is always possible to complete
the recharging operation manually.

For remote signaling, spring charge status indicator is available as a “C Contact” in the BS2
module (see electrical diagram in Figure 7).

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7.3 Circuit breaker closing

- In the open position, this operation can only be carried out with the closing spring
completely charged
- The circuit breaker must be in open position and with the manual trip push button
(located in the right-side panel from the exterior of the breaker) released.
- For manual closing, press the pushbutton (6).
- The operation can also be carried out remotely by means of control circuit delivering
power to the close coil.
- The closing operation is signaled by the OPEN/CLOSE indicator (9).

7.4 Circuit breaker opening

- This operation can be carried out with the closing spring charged or discharged.
- For manual opening, press the pushbutton (5).
- The operation can also be carried out remotely by means of control circuit delivering power
to trip coil (10) or optional second trip coil (4).
- The opening operation is signaled by the OPEN/CLOSE indicator (9).

7.5 External manual trip push button

The breaker has additionally a mechanical way available from the exterior for opening the
breaker which is a red push button located in the right-side wall of the breaker. To use it
following procedure must be followed:
1. If breaker is in closed position, release the lock pin from the side of the pushbutton
and press the red button until it locks again with the lockpin.
2. After above step, breaker will automatically trip and remain locked in the trip position
until push button is released again from the lock pin and returned to its original
position (push button completely out of its bracket).
3. Push button has additionally a hole to keep manual trip mechanism in both
conditions (tripped or free) with a LOTO device.
See Figure 10 for more detail.

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Figure 10 - External push button manual trip

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8 Operational check prior installation

Figure 11 - Mechanical parts warning

The R-MEC breaker should be tested for mechanical and electrical operation before delivery
to the installation site. Make the necessary control power connections (coils and motor). Open
the door of the low voltage compartment to observe the mechanical operations.

8.1 Functional tests

1. Verify correct function of coils, motor, pushbuttons, signaling (breaker position

“Green for open and red for close”), spring charging condition (white for discharged,
yellow for charged spring) and operation counter.

2. Also verify manual trip operation as described and verify that auxiliary switches
(52a/52b) change of position depending on the operation (close/open).

3. Perform a few operations with manual spring charging and the front pushbuttons
and a few operations with the motor for spring charging and coils.

4. If the spring is not charged or if the external manual trip is pressed, the breaker
should not close. Also verify antipumping function by holding open button and trying
to close the breaker, breaker should not close.

8.2 Vacuum integrity test

Perform an over-voltage test on each phase assembly to verify that there has been no loss
of vacuum in transportation or handling. Experience has shown that a vacuum interrupter with
the vacuum seal intact will withstand 37.5 kVAC across the open contacts for one minute, and
the same vacuum interrupter open to normal atmosphere will flashover at the gap at a much
lower voltage.

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RADIATION WARNING
High voltage applied across an open gap in a vacuum can produce X- radiation. No radiation is
emitted when the interrupter is closed, since no gap exists. Also, when the breaker is open to
the specified contact spacing in service or tested within the voltages specified.
X- radiation at one meter is below the level of concern. A danger could exist at voltages above
or contact spacing below that specified on the nameplate.

Vacuum integrity test procedure:

1. With the breaker in the open position, jumper both sets of three top terminals
together. Ground one set of terminals and the housing. Connect the high voltage to
the other set of terminals.
2. Stand clear more than one meter before energizing the high voltage source.
3. Apply a test voltage of 37.5 kVAC for one minute. Do not exceed 37.5 kVAC.

If internal flashover occurs, isolate the phases and test each one independently to identify
the defective interrupter. Any defective interrupter must be replaced prior to the breaker being
placed in service.

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9 Installation
The breaker must be vertical, level and securely fastened. Follow your company guidelines
and codes for setting the height of the breaker, securing the frame to the foundation, and
making power connections.

9.1 Mounting

The breaker is normally shipped suitable for substation mounting. The following is the
recommended installation procedure:

1. With the lifting brackets mounted in each side of breaker´s roof, lift the breaker off
the pallet and move into position
2. Bolt the legs to the pad and raise the cabinet upper portion to the desired height
3. Bolt the legs to the sides of the breaker
4. Make sure all hardware is tight

9.2 Grounding

The breaker cabinet has two ground parts, one on each side wall. It is important that both
of these be connected to the ground grid with #6AWG or larger wire. If the ground pad is
provided on the roof, it should be connected to the ground pad on the side sheet.

9.3 Arrester protection

ABB recommends that surge arresters be properly applied in the substation.

9.4 Control power

Supply the control power as indicated on the schematic diagram. Verify the heaters
connections before applying power. Check all terminal block connections for proper tightness.
For details of the overall control circuit, refer to the specific schematic diagrams supplied with
the breaker.

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9.5 Final Inspection

When the breaker has been installed and all mechanical and electrical connections
completed, EXCEPT ENERGIZING THE POWER LINE, the following points of inspection are
recommended:
1. Ensure the breaker is properly leveled and securely anchored.
2. Make a final check of tightness of all hardware.
3. Check that the heaters work properly
4. Securely tighten terminal and ground connections.
5. Check control cable entrance fittings for tightness.
6. Operate the breaker from the pushbuttons to verify normal operation.
7. Secure all doors and ensure proper gasketing for weather.
8. Ensure that all tools are removed.

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10 Inspection, maintenance and adjustment

The R-MEC circuit breaker is an extremely simple device and requires minimal inspections
and maintenance, depending on the frequency of operation and local environmental conditions.
The safety and successful functioning of any apparatus or system connected with the
breaker largely depends on the proper and reliable operation of the unit.
To provide long reliable service, the breaker must have systematic inspections at regular
intervals. Operating experience based on environmental conditions, the number of operations,
magnitude of interrupted current and any unusual operation, will establish a maintenance
schedule that gives assurance of proper breaker reliability.

The maintenance activities are intended to only be carried out by qualified persons,
thoroughly trained and knowledgeable of the hazards involved. Furthermore, it is advisable to
call on ABB personnel, for checking the performance in service and for repairs.

Cut off the power supply to the medium voltage circuit and follow proper lock-out tag-out
procedures as specified by the facility and applicable safety regulations. Ensure that, the
apparatus is under safe conditions during the maintenance operations. Before carrying out any
operations, check that the circuit breaker is open, with the spring discharged.

• DO NOT work on an energized circuit breaker

• DO NOT work on a closed breaker
• DO NOT work on a breaker unless all components are disconnected by means of a visible
break and securely grounded
• DO NOT work on a breaker with power supplied to the secondary control circuit
• DO NOT defeat safety interlocks. This may result in bodily injury, death and/or
equipment damage
• DO NOT work on a breaker with a charged closing spring
• DO NOT use a circuit breaker by itself as the sole means of isolating a high voltage circuit

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10.1 Maintenance periodicity

Given the R-MEC expectancy life of 10,000 operations, the maintenance plan is given in
terms of these operations. A summary is provided in table below showing the different
activities needed for each scenario.

Activity Every 2000 operations1 Every 4000 operations2

Control wiring and main components
inspection
Chapter 10.2
Torque verification in HV compartment
components and mechanism
Chapter 10.3
Measurement and readjustment of
contacts travel & overtravel gap (wipe)
Chapter 10.4
Insulation evaluation (Hi-Pot) and
contact resistance measurement
Chapter 10.5
Mechanism and HV components
cleaning and relubrication
Chapter 10.6
1
Activities to be performed after reaching operation number: 2000, 4000, 6000 and 8000
2
Activities to be performed after reaching operation number 4000 and 8000

NOTE
Maintenance periodicity is based on a “normally polluted” environment. If the breaker is
installed in environments with a higher pollution level (mining or similar), consider periodicity
of maintenance to be reduced to half or as required to ensure proper working of the circuit
breaker.

10.2 Control wiring and main components inspection

With the circuit-breaker completely disconnected from power system, perform the
following maintenance activities:
1. Cut the power supply to the spring charging motor, refer to schematics to identify
power control disconnect switch. Verify that the breaker operates correctly using
the electrical controls.
1. Discharge the spring by closing and opening the circuit-breaker by means of the
closing and opening pushbuttons in front of the mechanism (See Figure 9)
2. Confirm space heaters are working properly, and thermostat is functioning well
3. Verify standoff insulators and pull-rods from external damages (Figure 16)

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4. Clean silicon surface of vacuum interrupter from dust/dirt with cleaning agents &
dry cotton-cloth. Ensure that no cotton-threads are left on the surface (Figure 16)
5. Check for any abnormal contamination, traces of corrosion in housing and any trace
of partial discharge phenomena on insulators
6. Check for all the retainers are in place and not missing or broken/cracked

10.3 Torque verification in HV compartment components and mechanism

Correct operation of components in HV compartment and mechanism are dependent on

proper torque application in joint and fixing points, follow next steps to verify torque.

10.3.1 HV compartment components torque verification:

1. Torque on current carrying parts must be within following tolerances:

a) .250-20 flex connectors 7-10 ft-lbs (Figure 16)
b) .375-16 bus connections 27-35 ft-lbs (Figure 16 - M)
c) .500-13 contact block* 65-80 ft-lbs (Figure 17 - C)

2. Verify torque in vacuum interrupter rear fixing point

3. Verify torque in standoff insulators and front support (Figure 16)
4. Verify torque in support bars (front and rear) (Figure 16)
5. Verify torque in main shaft side bearing supports (Figure 6)
6. Verify torque between tray-system and main structure (Figure 6)

10.3.2 Mechanism torque verification:

Remove mechanism cover by unscrewing the four corner bolts, see Figure 6 for
reference, continue with following activities once mechanism is exposed as in Figure 9:

1. Verify screws and links of auxiliary switch system (Figure 9)

2. Remove coil-bracket by unscrewing the coils-bracket-assembly screw (Figure 12), verify
the screws used to fix the different coils are tight, re-assemble the coil-bracket-assembly
on mechanism.
3. Spring-charging motor to be inspected for any abnormal noise. Absence of lubrication
can cause noise. Re-tight spring charging motor as shown in picture Figure 13.
4. Check the counter increment after one CO cycle, and if it does not then replace the
counter. Ensure the new counter reading is set to the previous counter reading. In order
to remove counter, coil mounting-bracket needs to be removed as well.
5. Damper to be checked for the proper functioning and check that the oil/lubrication on
top has not come out. If no lubrication is present, lubricate. Damper nut to be checked
for tightness.

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Figure 12 - Coils-bracket-assembly removal Figure 13 - Spring-charging motor screw

6. Check the plastic tube (passing thru pushbuttons) is not deformed (see Figure 14)
7. Apply grease Molykote 111 or similar on the pull-rod pin-surface as shown in Figure 15

Figure 14 - Lubrication on pull-rod pin Figure 15 - Plastic tube

8. Verify torque in all mechanism frame hardware and mechanism fixing hardware, see
Figure 18 and Figure 19 for reference. Torque on hardware to be applied as per below:

Tightening torque value

Bolt dimension Remarks
Property class 8.8
M5 7 Nm
M6 10 Nm Check calibration date of the
M8 25 Nm torque tool before the
M10 48 Nm application
M12 68 Nm

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10.4 Measurement and readjustment of contacts travel & overtravel gap (wipe)

1. For each phase assembly, measure contacts travel by measuring (K) in both conditions
(open/close) with a Vernier caliper, measure the difference in measurements between
contact block in open and closed position, ensure the travel limits are within 0.433" to
0.492" (11mm - 12.5mm).
If travel needs to be increased/decreased, this can be done by doing small adjustments
in over-travel gap (wipe), follow next steps.
2. Measure over-travel gap (L) with the breaker in the close position. Confirm this
measurement is within these limits: 0.177” to 0.204" (.196” std) [4.5 – 5.2mm (5mm std)]
Breakers in field can be found with lower values, it is mandatory to adjust back to
described limits.
3. If needed, minor adjustments can be made to over-travel gap (L) by loosening the nut (D)
and rotating the pullrod (A).
a. To increase overtravel, rotate pullrod counterclockwise
b. To decrease overtravel, rotate pullrod clockwise
c. One turn of pullrod, changes overtravel aprox 0.076” (1.95 mm)

Caution:
• Over-travel gap to be measured only in CLOSE position; for that purpose, springs need
to be charged with help of manual-lever
• Over-travel gap adjustment, by means of rotating pullrod, needs to be done when
breaker is in OPEN position in small steps.

4. Travel can also be adjusted with the breaker in closed position by losing damper nut
(Figure 6) and rotating damper clockwise (increase travel) and counterclockwise (reduce
travel). DO NOT ADJUST MORE THAN 2 TURNS OF THE DAMPER (Figure 6) AS
CLOSING/OPENING SPEEDS CAN BE MODIFIED AFTER RECOMMENDED NUMBER OF
TURNS.
5. After any adjustment in damper or contacts travel, recheck over-travel gap (L). Adjust (L)
again if required. If over-travel gap (L) is confirmed tighten again the nut (D).
6. Excess overtravel can cause faulty operation; if it happens, reduce overtravel to normal
values and check that mechanism latches in closed condition.

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Figure 16 - R-MEC interrupter assembly 15.5kV, 1250A

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Figure 17 - Contact travel and over-travel adjustment 15.5kV 1250A

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10.5 Insulation evaluation (Hi-Pot) and contact resistance measurement

10.5.1 Insulation evaluation High Pot Test

RADIATION WARNING
High voltage applied across an open gap in a vacuum can produce X- radiation. No radiation is
emitted when the interrupter is closed, since no gap exists. Also, when the breaker is open to
the specified contact spacing in service or tested within the voltages specified.
X- radiation at one meter is below the level of concern. A danger could exist at voltages above
or contact spacing below that specified on the nameplate.

Vacuum integrity test procedure:

1. With the breaker in the open position, jumper both sets of three top terminals
together. Ground one set of terminals and the housing. Connect the high voltage to
the other set of terminals.
2. Stand clear more than one meter before energizing the high voltage source.
3. Apply a test voltage of 37.5 kVAC for one minute. Do not exceed 37.5 kVAC.

If internal flashover occurs, isolate the phases and test each one independently to identify
the defective interrupter. Any defective interrupter must be replaced prior to the breaker being
placed in service.

10.5.2 Contact resistance measurement

Measure contact resistance with suitable equipment rated not less than 100 A. The value
should not exceed 100 micro ohms. If measured resistance is above this value, check again
torque in main components as per 10.3.

Figure 19 - Mechanism hardware 2

Figure 18 - Mechanism hardware 1

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10.6 Mechanism and HV components cleaning and relubrication

10.6.1 Shafts and hooks cleaning

For cleaning purposes use diluent such as Rivolta B.W.R 210 or Tecno Europa C18 FAST.
Clean the seats of the two shafts shown in the picture. Use a brush to help to remove old
grease and dirt. Identify these components in followings in Figure 20, Figure 21 and Figure 22.

Figure 20 - Closing shaft and opening hook

Figure 21 - Closing shaft and opening hook 2

Figure 22 - Antireclosing lever and closing hook

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10.6.2 Rollers cleaning

For cleaning purposes use diluent such as Rivolta B.W.R 210 or Tecno Europa C18 FAST.
Clean the two rollers shown in Figure 23. Use a brush to help to remove old grease and dirt.
Verify that both rollers can rotate free.

Figure 23 - Rollers cleaning

10.6.3 Check Cleaning effectiveness

a) Closing function
With closing spring discharged and the R-MEC breaker in open position, turn the
closing shaft and then push the hook as in the picture.
Release the shaft and then release the hook. The cleaning is effective if the hook returns
behind the shaft instantaneously without slow moving of either the shaft or the hook.

Figure 24 - Closing function verification

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b) Anti-reclosing function
With closing spring discharged and the R-MEC breaker in open position push down the
anti-reclosing lever and check that it restores its position.

Figure 25 - Anti-reclosing function verification

c) Opening function
With the closing spring charged and the R-MEC breaker in open position, turn the shaft
and then push the hook as in the picture.
Release the Shaft and then release the hook.
The cleaning is effective if the hook returns behind the shaft instantaneously without
slow moving of either the shaft or the hook.

Figure 26 - Opening function verification

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10.7 Mechanism re-greasing

10.7.1 Shafts greasing

Before greasing remove the cleaner by means of pressurized air. Lubricate the seats of
the three shafts shown in the Figure 28 on the inside of the sidewalls with Kluber Isoflex Topas
NB 52 grease or similar (see Figure 27), preferable spray version.

Figure 27 - Isoflex topas NB52

Figure 28 - Greasing of shafts

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10.7.2 Closing hook pin greasing

Lubricate the pin shown in Figure 29 with Kluber Isoflex Topas NB 52 or similar grease
lube, preferable spray version.

Figure 29 - Closing hook pin greasing

10.7.3 Hooks greasing

Grease the hooks as shown below in Figure 30 with Kluber Isoflex Topas NB 52 grease
or similar, preferable spray version.

Figure 30 - Hooks greasing

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10.7.4 Anti-reclosing lever greasing

Grease the anti-reclosing lever as shown below in Figure 31 with Kluber Isoflex Topas
NB52 grease or similar, preferable spray version.

Figure 31 - Anti-reclosing lever greasing

10.7.5 Rollers greasing

Grease the two rollers with Isoflex Topas NB 52 grease or similar, preferable spray
version, keeping hook under the shaft. See Figure 32.

Figure 32 - Rollers greasing

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10.8 Other parts to be lubricated

Grease other parts of the mechanism in the shown areas using Kluber Isoflex Topas NB 52
grease or similar, preferable spray version. Some parts are accessible by de-installing the motor.

Figure 33 - Greasing other mechanism parts

10.9 Final functional tests

After re-greasing, repeat 10 times the checks listed in sub-clause 7 (closing function,
anti-reclosing function, opening function).
Finally, perform 30 complete operations: charge - close - recharge -open - close - open,
15 operations shall be carried out manually (closing/opening by pushbuttons, spring
charging by lever) and 15 electrically (closing/opening by coils, spring charging by motor),
checking the correct functionality of the breaker.

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11 R-MEC troubleshooting
Fault Cause Remedy
Spring does not get • Motor has wrong or no • Check voltage at the motor
charged operating voltage leads and related terminal
• Motor gear damaged, motor blocks
burnt, gear-train damaged • Replace burnt motor by
• Disconnection in motor removing frontal screw
wires • Check if there is any loose
connection
Closing of breaker does • Close coil does not operate • Tighten the frontal coil fixing
not take place although after powering screw if found loose
there is an indication • Wrong wiring of the auxiliary • Check the wiring as per
that the spring is circuit schematic drawing
charged • Check voltage at the close coil
connection and control circuitry
• Replace coil by removing frontal
fixing screw
Breaker fails to open • Opening coil does not • Tighten the frontal coil fixing
operate after powering screw if found loose
• Wrong wiring of the auxiliary • Check the wiring as per
circuit schematic drawing
• Check voltage at the close coil
connection and control circuitry
• Replace coil by removing frontal
fixing screw
Operations counter not • Foreign body blocking • Replace operations counter,
operating operation ensure the new operations
• Failure in counter arm counter reflects the same
number as the previous one
Improper damping or • Foreign body blocking • Replacement of damper
damper fluid leaking operation • Measure the total height of
• Failure in damper original damper before removal
and set the new one at same
height
Breaker not correctly • Blocked auxiliary switch • Replace links
showing the position • Auxiliary switch links • Replace of complete auxiliary
disconnected or broken switches block

Caution: Replacement should be done under supervision of qualified personnel.

In case of major replacements (i.e. complete mechanism) contact ABB service team.

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12 End of life recycle/disposal

ABB is committed for complying with relevant legal and other statutory requirements for
environment protection according to the ISO 140001 standard. The duty of the end user is to
facilitate end of life recycling & disposal according to the applicable regulations.
During disposal of product, it is necessary to act in according with local legal requirements
in force. Disposal can either be carried out thermally in an incineration plant or by storing on a
waste site.

Following are the methods of recycle/disposal:

Raw Material Recycle Environment effects and reuse processes

Iron Yes Separate, utilize in favor of new source (ore)
Stainless steel Yes Separate, utilize in favor of new source (ore)
Copper Yes Separate, utilize in favor of new source (ore)
Brass Yes Separate, utilize in favor of new source (ore)
Aluminum Yes Separate, utilize in favor of new source (ore)
Zinc Yes Separate, utilize in favor of new source (ore)
Thermoplastic Yes Make granulate, re-use, or apply as energy superior
Epoxy incl. 60% quartz Yes Additive in refuse incineration
Rubber Yes Cut into pieces and use as high grade energy
Porcelain Yes Additive in cement mill
Packing foil Yes Cut into pieces and used for landfills
Wooden pallet Yes High grade energy additive in refuse incineration

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For more information please contact:

ABB México SA de CV
Av. Central 310
San Luis Potosí, SLP, 78395
Phone: + 52 444-870-8000
01 800-5222-365
[email protected]

ABB Inc.
Lake Mary, FL 32746
Phone: +1 407-732-2000 ext. 2510
+1 800-929-7947 ext. 5
[email protected]

http://www.abb.com/mediumvoltage

1YEPTSR0019S001 Rev. A – January 2020

All sales are subject to ABB General Terms and
Conditions of Sale. While every effort has been made
to assure accuracy, the information in this document
is subject to change without notice

© Copyright 2020 ABB. All rights reserved

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