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Product manual

GW56 - 252—300
Double break disconnectors
2 GW56 - 252—300 Double break disconnectors

The information contained in this document may be subject to change without prior warning and should not be considered as binding on ABB High Voltage Switchgear Co., Ltd.,
Beijing (abbr. ABB Beijing) 's behalf. ABB Beijing accepts no liability for any errors that may appear in this document. ABB Beijing is not liable for any damage resulting from the
incorrect interpretation of this document. This document, or parts thereof, may not be reproduced or copied without ABB Beijing's consent. It must not be distributed to others, or
used by unauthorized parties. Any breaches to the above will be penalized with the support of applicable laws.

© Copyright 2018 ABB All rights reserved.

www.abb.com.cn
GW56 - 252—300 Double break disconnectors 3

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Table of contents

Packing, transport and storage 4

Product and application 6
Installation 8
Maintenance 18
4 GW56 - 252—300 Double break disconnectors

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Packing, transport and storage

Packing Ambient condition:

ABB will prepare, pack and load disconnectors The surrounding air must be free from dust,
according to requirement of customer inspection, smoke, corrosive or inflammable gas, steam or salt
guaranteeing that equipment and packing medium. The temperature is not less than -30.
material are qualified for international freight by Outdoor storage time should be less than 12
sea or by air. months. For long term storage, products must be
packed. Please clean the outer insulation before
Main blade and insulator of disconnector will be assembling.
packed in wood crate; the packing crate will be
treated by steam to guarantee that it will be free Storage in a humid climate, without proper
of insect eggs, plant seeds or animalcule. The ventilation, can lead to discoloring of zinc coated
crate is strong enough for transport under normal surfaces. This discoloring is known as white rust,
conditions by sea and road freight. The drive and consists mainly zinc oxide and zinc hydroxide
mechanism will be packed in a polywood box. and is a result of a chemical reaction between pure
zinc on the surface and moisture. The long term
All parts of the product shall be carefully packed rust protection is not affected because the steel-
and marked to ensure quick identification and zinc layer under the surface remains unaffected.
erection on site. All packing will be seaworthy for
on-deck/under-deck transport. Stacking of cases:
Stacked layers should be confirmed with the
Transport packing requirements (please refer to the
For extreme bad freight condition, purchaser markings on the packing cases). Cases of different
should provide information before award of order widths shall normally not be stacked. If cases of
and special packing can be applied accordingly different widths need to be stacked, a framework
with agreement of the customer. must be used between the cases in order to
distribute the pressure evenly. Stacking of more
When products are transported by trucks, the than two cases is not allowed. It must be noted
speed of trucks shall be steady to avoid that stacking causes instability sidewise and
mechanical damage. therefore the cases must be secured, i.e.,
prevented from tumbling down or rolling over.
Storage
Upon arrival each unit should be checked An approved store is defined as:
according to the shipping documents and the Stored in indoor or under the roof to avoid the
order. If damage is discovered or suspected, the exposure to sunshine and rain. The equipment can
case should be opened and photos should be be stored outdoors. If this happens they should be
taken. The package should be opened carefully to protected by at least a tarpaulin. The tarpaulin
avoid the damage on the outer insulation. shouldn't be so tight so that air circulation to zinc
coated surfaces is still prevented.
Upon arrival it is important that the plastic cover
will be removed in order to prevent corrosion due Drive mechanism:
to condensation. If intermediate storage cannot The drive mechanism should be unpacked on
be avoided, please recover the package for safety arrival. If it is not kept in an approved store, the
storage. heating element must be connected and
permanently switched on to prevent the control
Storage site: equipment from corrosion or damage due to
The products shall be stored indoors or under a freezing.
rain-proof cover. The ground should be strong
enough to stand the pressure of packing case. The
product shall be stored horizontally above ground
level to avoid cracking or water damage.
GW56 - 252—300 Double break disconnectors 5

Disconnectors and insulators: Marking

The disconnectors and insulators should be stored Each package will contain one main crate for
in their original cases where they are properly disconnector and one for mechanism. Accessory
protected from damage. The units shall not stand will be packed inside the main crate for
in water. The disconnectors can be stored disconnectors, with optional frame and pole beam,
outdoors. If this happens they should be one set of package can consist up to several boxes,
protected by at least a tarpaulin. The tarpaulin ie disconnector box, mechanism box, insulator box,
shouldn't be so tight so that air circulation to zinc Box and crate will be marked with serial numbers. If
coated surfaces is still prevented. Any condense desired by the customer the necessary information
should easily drip off. The lowest permitted will be marked onto the boxes by our factory
ambient temperature for storage is -30℃. according to the existing specifications.

Spare parts: Nameplate:

Spare parts shall be kept indoors in an approved All permanent equipment of the works shall be
storage and in their original packing. This is provided with a securely fixed nameplate maker's
especially important for rubber components (seals name, model, serial number, year of manufacturing,
etc.), which must also be protected from sunlight main characteristic data of the respective
to avoid drying. Frames can be stored outdoors. equipment and further relevant information. All
main equipment should have the nameplates in
English or language upon request.

Packing crate illustration

Product packing and markings (Figure 1)

Figure 1-1 Drive mechanism plywood packing Figure 1-2 Insulator packing
6 GW56 - 252—300 Double break disconnectors

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Product and application

Application Electrical schematic diagram

ABB double break disconnectors GW56 series Electrical schematic diagram will be delivered
applies highest voltage of equipment 72.5 - 300 KV along with drive mechanism.
and rated frequency of 50 Hz or 60 Hz. It is
appropriate for outdoor installations and it can General
ensure isolation and connection directly across the The three-pole disconnector is a double break (or
horizontal gap. It is especially suitable for three-column rotary) disconnector. The design
substations with small installation area. consists of three separate poles, interconnected
by coupling rods for transmission of the drive
Type designation moment. The arms on top of the insulators carry
GW56-XXX(D) the high voltage contacts. When actuated both
GW56: double break disconnectors. arms of the main blade rotate ~ 85 degrees. The
XXX: maximum equipment voltage, ie 145. rotating insulators are mounted on a steel base
D: one earthing switch applied. and linked with a coupling rod. In open position
DII: two earthing switch applied. the disconnector creates a horizontal isolating
Without D: earthing switch not applied. distance. The contact pins in the terminals can
rotate ~85 degrees.
Main technical parameters
Technical parameters comply with latest IEC
standard or upon request. Please refer to technical
datasheet approved by contract and nameplate.

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Operation conditions
Application Outdoor or indoor
Ambient temperature Maximum temperature +50℃
Minimum temperature -30℃
Altitude Less than 1000 m*
Atmosphere conditions There shall be no dust, corrosive or explosive mediums in the
ambient air that may significantly influence disconnectors
Maximum daily average relative humidity 95% ℃
Maximum wind velocity 35 m/s*

Note: * or upon request.

GW56 - 252—300 Double break disconnectors 7

Figure 1 GW56 structure

Disconnector have separate operating mechanisms. The main units are:

1 Main Fixed contacts 8 U shape bolt

2 Insulator 9 Operating mechanism
3 Base 10 Coupling rod
4 Base (Operation) 11 Operating mechanism
5 Main blade 12 Connection plate
6 Vertical rod 13 Coupling rod
7 L shapes steel 14 Fixed contacts of earthing switch
8 GW56 - 252—300 Double break disconnectors

— Delivery
Check the disconnectors for any transport

Installation damages immediately upon delivery. Damage to

packaging may be a sign of rough handling. Note
any damage (it is advisable to take pictures).

Products are provided with this product manual,

quality certificate, packing list. Please check the

CAUTION software and accessories along with the product

according to the packing list. Be careful not to
damage the product.
FOR YOUR SAFETY
DO NOT ATTEMPT TO HANDLE, INSTALL, USE
OR SERVICE THIS PRODUCT BEFORE READING
Check the products as below after unpacking.
THE INSTRUCTION MANUAL.
Note!
Failure to read the instruction manual prior to
performing these actions can lead to serious Check the product appearance for damage.
injury and/or damage.
Note!
Check the accessories according to the
packing list to ensure they are complete.
Safety notice
This disconnectors should be installed within the design limitations as
Note!
described on its rating plate and in these instructions. Follow your
Check if the product marking are clear and
company's safety procedures.
correct.

This product is intended to be operated and maintained by qualified

Note!
persons who are thoroughly trained and who understand the hazards
When unpack, attention that some
involved. This publication is written only for such qualified persons and
components are fragile and may be
is not intended to be a substitute for adequate training and experience
damaged by sudden shocks or careless
in safety procedures for this device.
handling. Be careful to avoid damages or
deformations of components which may
— cause inconvenient assembly.

WARNING Note!
DETAILED DESCRIPTIONS OF STANDARD REPAIR PROCEDURES, SAFETY Use box cover or plate as a temporary
PRINCIPLES AND SERVICE OPERATIONS ARE NOT INCLUDED. IT IS storage platform to prevent equipment
IMPORTANT TO NOTE THAT THIS DOCUMENT CONTAINS CERTAIN damaged or contaminated by sand,
WARNINGS AND CAUTIONS REGARDING CERTAIN SPECIFIC SERVICE prevent sand entering lubricant nozzle and
METHODS THAT COULD CAUSE PERSONAL INJURY TO SERVICE screw holes and prevent damaging the zinc
PERSONAL OR COULD DAMAGE EQUIPMENT OR RENDER IT UNSAFE. coating and the main contact.
PLEASE UNDERSTAND THAT THESE WARNINGS CANNOT COVER ALL
CONCEIVABLE WAYS IN WHICH SERVICE, WHETHER OR NOT Note!
RECOMMENDED BY ABB, MIGHT BE PERFORMED OR POSSIBLE Bolts should be fastened with below table
HAZARDOUS CONSEQUENCES OF EACH CONCEIVABLE WAY, NOR except special instructions in the manual.
COULD ABB INVESTIGATE ALL SUCH WAYS. ANYONE USING SERVICE
PROCEDURES OR TOOLS, WHETHER OR NOT RECOMMENDED BY ABB,
MUST THOROUGHLY ENSURE ONESELF THAT NEITHER PERSONAL NOR Steel to other
EQUIPMENT SAFETY WILL BE JEOPARDIZED BY THE SERVICE METHOD Steel to Steel
Diameter materials
OR TOOLS SELECTED. of bolts Galvanized Stainless Galvanized or
bolt steel bolt stainless steel bolts
All information contained in this manual is based on the latest product M8 23 N.m 22 N.m 22 N.m
information available at the time of printing. The right is reserved to
M10 46 N.m 33 N.m 33 N.m
make changes at any time without notice.
M12 79 N.m 56 N.m 56 N.m
M16* 195 N.m 136 N.m 120 N.m
M20 390 N.m 274 N.m 206 N.m

* Max torque of M 16 bolt for a pivot is 120 N.m.

** Molykote BR2 or equivalent lubricant applied.
GW56 - 252—300 Double break disconnectors 9

Note!
Main components list of gang
Correct components selection is the pre-
operation product. condition for correct installation. Below
quantities is only applied for one unit
product with three phase. Attention to
key components designation below which
will be used in installation procedure.
Wrong components installation will
damage equipment.

Scope may adjust according to contract

scope. DIS-Disconnecting switch; ES-
Earthing switch.

2 Connect the insulator and main blade (120 N.m).

Installation procedure
1 Install steel frame and plate

1.1 Check foundation dimension.

1.2 Install Base A, B, C on structure with M16 bolts

(195 N.m).

The bolts between Base and structure is not in

ABB scope if ABB no supply the structures.

3 Connect the insulator and fixing contact of Disc

and ES(if need): (120 N.m)

Without earthing switch(ES)

With earthing switch(ES)

10 GW56 - 252—300 Double break disconnectors

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Installation

4 Install the main blade and fixing contact with

insulator above the base (M16 bolts 195 N.m).

4.1 Make sure the base be in the closing position. 4.2 Install the main blade with insulator to the base.
(M16 bolts 195 N.m).
Attention to the hole are in correct position as
flowing figure.

4.3 Install the fixing contact with insulator to the

base. (M16 bolts 195 N.m).
GW56 - 252—300 Double break disconnectors 11

5 Adjustment for driving main blade

5.1 Daub appropriate amount grease on the 5.2 If the moving contact vertically symmetrical or
contacts to protect surface. operate main blade the insertion depth can’t satisfy the requirement
to closing position. Check the moving contact of 63±6mm, you may adjust the support insulator
vertically symmetrical refers to fixed contact, and with long M16 bolts between insulator and base
refers to the left and right sides and a fixed and between terminal and insulator .
contact insertion depth is appropriate. Fully
closed position as shown in Figure below, the
distance between main blade arm to fixed contact
is 63±6mm.

5.3 Keeping well contacted between every finger 5.4 Double check every finger should be contacted
of moving contact and fixing contact. If no, you fixing contact well.
need adjust the bolts of fixing contacts.
12 GW56 - 252—300 Double break disconnectors

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Installation

6 Install Eathing switch

6.1 Install the coupling rods

Cut coupling rods according to phase to phase distance P
Left ES Phase A to B and Right Phase B to C : L1=P=450±5
Left ES Phase B to C and Right Phase A to B : L1=P=480±5

6.2 Install A,B,C phase Earthing Switch (90 N.m)

GW56 - 252—300 Double break disconnectors 13

7 Install mechanism on the structure

7.1 Measure the distance (L) between mechanism 7.3 Connect vertical Rod after keep both of
and drive axis as following figure. disconnector and mechanism in closing position.
M12 (79 N.m) M16 (195 N.m)

Notes:
ŸBefore linking the vertical rod and driving
mechanism, keep main blade is in closing
7.2 Cut vertical Rod according to the following position and rotate the drive in the close
figure. position by manual handle;
ŸTighten the U bolts.
14 GW56 - 252—300 Double break disconnectors

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Installation

8 Adjustment only for “B” phase

8.1 Put main blade is on closed position. The perfect position is fixing contact center line is same as
main blade center line. Every type disconnector have a stopper on fixing contact, the distance between
moving finger contact and stopper is 0~15 mm It is acceptable.

2000(2500) A 3150A

Open operation with manual handle, make sure the angle of opened to closed position should be 85±5
degree. If necessary, can adjust the length of couple rod.
GW56 - 252—300 Double break disconnectors 15

8.2 Couple rod and driver axis must be on correct closing position as following figure.

8.3 Couple rod and driver axis is on opening position as following figure.
16 GW56 - 252—300 Double break disconnectors

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Installation

9 Connect the other two phase (applied to the

gang operation product)

9.1 Three-pole main blade is in the close position. 9.3 Open operation with manual handle, make
sure the main blade of opening and closing should
9.2 Connect the coupling rod as follow. be same position. If necessary, can adjust the
length of coupling rod.

10 Adjustment for Earthing switch

10.1 Appropriate amount of grease on the fixed 10.3 The first manual and electric operation
contact to protect the surface. earthing switch, make sure that the three-phase
basic synchronization to fully open and fully closed
10.2 Manual three-phase earthing switch are position.
pushed to the closing position, closing two
contacts to touch that symmetrical to the fixed 10.4 If the three-phase synchronization does not
contact. If need, Loosening the bolts at the bottom meet the requirements, you need to loosen the U
of ES arm(1) or adjust fixing contact of ES position bolt, earthing switch adjustment will lead or lag to
(2). other consistent, then tighten the U type bolt.

(1) (2)
GW56 - 252—300 Double break disconnectors 17

11 Bolts should be fastened with torque tools. 13 Final inspection

( torque value see page 7 ).
It is necessary to inspect and verify the equipment
carefully after its installation and before its
12 Commissioning operation.
Ÿ Inspect all the insulators to see if any of them
1) Inspect the power of motor for mechanism; are broken or defective.
Ÿ Inspect the positioning conditions of all the
2) Rotate the mechanism to the middle position contacts.
between open and close position by manual Ÿ Inspect the tightness of all the bolts.
handle; Ÿ Inspect the isolation distance, the net safety
distances of live parts of the equipment, and the
3) Check whether the direction of mechanism stroke of the equipment.
match the main blade with motor drive; Ÿ Inspect the installation and operation condition
of the earthing switch (if any).
4) Measure the circuit resistance of the entire loop Ÿ Inspect whether or not the operations,
of disconnector following the table below in the lubrication and strokes of all the drive
close position. mechanisms are correct. Check their idle
strokes, mechanical connection, and the
5) Connect the feeder line to the terminal of main excessive clearance during their control or
blade. installation.
Ÿ The position must be in open position, or the Ÿ Inspect the safety, proper functions and
flexible conductor will be twisted; operation convenience of all the switch locking
Ÿ Before connection, the surface of terminal must drive mechanisms (if any).
be furnished by steel wire brush, and greased Ÿ Inspect whether or not the insulators and the
with thin layer. moving parts are clean.

6) It is necessary to make open-close cycle for 15

times by motor-drive mechanism to inspect
whether or not the adjustment is proper. After the
test operations, the connections between the
vertical connecting rods and L plate must be
locked.
18 GW56 - 252—300 Double break disconnectors

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Maintenance

Note! General inspections

Abide by all the safety precautions and Ÿ Inspect the equipment and its drive mechanisms
the local or general regulations before to make them under good operation statuses.
maintenance. Make sure all of its power Ÿ Inspect the bolts, nuts and gaskets and make
supplies are disconnected and all drive sure they are in their original positions and in
mechanisms are locked. The both sides of good condition. Replace the seriously worn or
the equipment should be respectively corroded parts.
connected with an earth wire or an Ÿ Inspect all the safety interlocking devices and
equivalent body. test them to ensure their normal operations.
Ÿ Inspect whether or not the insulators are in
good condition and whether or not their
Contacts surfaces are clean.
Clean the contacts. Paste a piece of even Molykote Ÿ Inspect the connecting terminals according to
BR2 film on the surface of each contact and get rid the instructions given by the manufacturer.
of the surplus part. Inspect whether or not the
contact is on the proper making position. If a
contact is damaged or seriously abraded due to
mechanical loads, electric arcs and/or other
factors, it should be replaced.

Lubrication
It is suggestive to use the lubricants of the
following types to lubricate the main bearings and
pivots of the connecting rods.

Castrol - Spheerol Shell - Alvania R2

AP3/LMX
EXXON (ESSO) - Beacon P290 Chevron - Dura-Lith
grease EP

The lubricants of the special types below are

needed under extreme temperatures (from -20℃
to -50℃) and special atmospheric conditions.

EXXON (ESSO) -Beacon 325 Neste -Rasva 606

Other lithium base lubricants meeting the

following requirements might be used.
Ÿ High hydrophobicity Strong oxidation stability.
Ÿ Very low start-up and operation torques under
any temperatures.
Ÿ Containing an anticorrosion additive.
Ÿ Being adaptive to the local temperature
condition.
GW56 - 252—300 Double break disconnectors 19

Maintenance plan

Minimal maintenance is required. However, routine Preventive maintenance schedule is made below.It
checks and necessary maintenance are is recommended to follow below procedures on
recommended to ensure good performance. schedule.

Items Action to perform in compliance with the instructions Frequency of actions

MINOR INSPECTION
A1) Verify the mechanical parts of the equipment and of the protection surfaces
are not damaged.
A2) Verify the shell of the low voltage cables and the earthing cables are not damaged.
A3) Verify the insulators are not damaged and there is no filth deposition
A on the surfaces. A4) Verify equipment and drive mechanisms in good status.
During site routine
Disconnector A5) Verify the bolts, nuts and gaskets in their original positions and good condition.
inspection or, in any
in service Replace the seriously worn or corrosion parts.
case, every 4 years
A6) Verify all interlock components and test to ensure them in good condition.
A7) Verify terminals connecting according to this manual.
A8) Verify the sealing of gear box if aging. Keep gear box clean.
A9) Verify the drive mechanism is not damaged.

OPTIONAL:
Check the heater with thermal detector.

INSPECTION ON DISCONNECTOR
B1) Carry out checks A1-A9 described in section A.
B2) Verify and clean all live parts.
B3) Measure resistance of live parts.
B4) Verify bolt tightening.
B5) Verify operation of local controls.
B6) Verify manual operation.
B B7) Verify correct coupling of main contact.
Every 8 years or every
Disconnector B8) Verify surface condition of contacts.
5000 operations
out of service
INSPECTION OF THE DRIVE MECHANISM
B9) Verify that all mechanical and electrical components, cables and earthing
connections are not damaged.
B10) Verify lubrication of gears.
B11) Verify the correct operation of the following electrical components:
Heating and anti-condensation resistance;
Motor protection automatic switch;
Electromechanical interlock.

MAJOR INSPECTION
C1) Full check of the disconnector as per section B;
C2) Check the condition and the wear of the main components, the conditions
C
of the insulators and the mechanical adjustments performed during installation
Disconnector Every 15 years or every
(see installation manual). If you find any deviation, restore the required conditions.
out of service 10.000 operations
In case replacement of units or components is required, comply with procedures
in the installation manual. In case of troubles or doubts on how to restore
correctly the required conditions, please contact ABB
—
ABB High Voltage Switchgear
Co., Ltd., Beijing
Add.: No.12 Jingyuan Street,
Beijing Economic-Technological
Development Area Beijing, 100176,
P.R.China
Tel: +86 10 6781 8000
Fax: +86 10 6781 8001

ABB Jiangsu Jingke Instrument

Transformer Co., Ltd.
Add.:No.9 Gucheng Road Su-Su Industriial
Park, Suqian,Jiangsu, 223800
P.R China
Tel: +86 527 8288 0810
Fax: +86 527 8288 0868

www.abb.com.cn

© Copyright 2018 ABB. All rights reserved.

Note: We reserve the right to make technical changes or
modify the contents of this document without prior notice.
With regard to purchase orders, the agreed particulars shall
prevail. ABB does not accept any responsibility whatsoever
for potential errors or possible lack of information in this
document
3211-5879CNTHB

We reserve all rights in this document and in the subject

matter and illustrations contained therein. Any reproduction,
disclosure to third parties or utilization of its content - in
whole or in parts - is forbidden without ABB's prior written
consent.