Download New vacuum interrupters for contactors and switches

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New vacuum
interrupters
for contactors
and switches
Requirements to be met by
vacuum interrupters
Contactors
The pertinent standard for contactors
with rated voltages of more than 1 kV is IEC
60470 [3]. This standard defines the requirements the contactor has to satisfy as
well as the so-called ‘utilization categories’,
AC-1, AC-2, AC-3 and AC-4. The higher
the AC number, the higher the required
switching capacity of the contactor.
The advantages of vacuum technology, as demonstrated for example by
Since all of the VS vacuum interrupters
vacuum circuit-breakers, persuaded ABB Calor Emag Mittelspannung
for contactors satisfy the maximum re-
GmbH of Germany to develop a range of vacuum interrupters for contac-
quirements, only the highest utilization
tors and switches rated up to 12 kV and 36 kV, respectively. Switching
category, AC-4, is looked at here. This
devices equipped with the new interrupters are extremely compact and
describes a cage induction motor ap-
robust, and easily satisfy all the electrical and mechanical requirements
plication involving starting, plugging, re-
specified in the pertinent IEC standards.
versing and inching. Table 1 gives the
applicable values for the rated making
A
capacity and rated breaking capacity, both
BB Calor Emag Mittelspannung
range of applications. No other kind of cir-
of which depend on the specified rated cur-
GmbH, Germany, has been developing and
cuit-breaker is as versatile or reliable, re-
rent.
manufacturing vacuum interrupters for
quires less maintenance or is environmen-
The values in Table 1 take account of the
circuit-breakers since the early 1980s 1 .
tally kinder. All of these advantages of vac-
fact that contactors are often used to
At the company’s R&D center in Ratingen,
uum technology can be made available to
switch motors on and off. Since the switch-
engineers use state-of-the-art tools and
contactors and switches by modifying it
ing frequency is therefore much higher than
powerful computer software, eg for the
accordingly. ABB Calor Emag Mittelspan-
with circuit-breakers, contactors and their
electrical and magnetic field calculations, to
nung has therefore developed a new
vacuum interrupters have to exhibit much
optimize the design and functionality of the
family of vacuum interrupters, designated
longer mechanical and electrical lifetimes.
interrupters.
VS, for use in contactors and switches.
As rule, the minimum required number of
Among the most recent results of
Although these two applications do not
switching cycles over the lifetime of the
this work are new contact materials and
make the same high demands on the rated
contactor is 1 million. For special applica-
contact systems based on both radial
short-circuit breaking current as circuit-
tions, the same number of switching cycles
magnetic field (RMF) and axial magnetic
breakers, several special requirements
is required at rated current.
field (AMF) principles [1,2]. These new sys-
have to be satisfied, eg in the case of vac-
Contactors are also used to switch small
tems and materials easily satisfy the re-
uum contactors a lifetime of at least 1 mil-
capacitor banks in accordance with IEC
quirements that have to be met by medi-
lion mechanical switching cycles.
60056 [4]. For this application, the vacuum
um-voltage circuit-breakers:
interrupter must be capable of interrupting
•
•
Rated voltages up to 52 kV
without restriking, since restriking causes
Rated short-circuit breaking currents up
overvoltages that could destroy the con-
to 63 kA/80 kA
•
Rated currents up to 5000 A
Circuit-breakers equipped with vacuum in-
nected apparatus.
Dr. Harald Fink
Dietmar Gentsch
Dr. Markus Heimbach
Switch-disconnectors
terrupters have been commercially avail-
ABB Calor Emag Mittelspannung
IEC also defines the main requirements
able for almost two decades, during which
GmbH
for switches and switch-disconnectors:
time they have proved their worth in a wide
32
ABB Review 3/1999
IEC 60265-1 [5] deals with the switchgear
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1
Some of the vacuum interrupters manufactured by ABB Calor Emag Mittelspannung GmbH
and IEC 60420 [6] with the interactions
switching cycles, a figure which is not usu-
cable-charging breaking current has to be
taking place in switch-fuse combinations.
ally a problem for a vacuum interrupter.
interrupted under earth-fault conditions
Unlike the interrupters used in contactors,
Switches must also be capable of dis-
(IEC 60265-1). In this case, the peak tran-
an interrupter in a switch-disconnector only
connecting capacitor banks without restrik-
sient recovery voltage (eg, 68.8 kV for a
has to be able to interrupt currents of the
ing. Capacitive interruption, for which high
rated voltage of 24 kV) is higher than for an
order of magnitude of the rated current
dielectric strength is essential, is also re-
interruption without earth fault by a factor of
(IEC 60265-1). During testing of the so-
quired for frequent disconnections of over-
about 1.4. This makes enormous demands
called transfer current (IEC 60420) a some-
head lines and cables under no-load or
on the dielectric strength of vacuum inter-
what higher current could flow, depending
low-load conditions.
rupters.
on the current rating of the fuse. However,
The highest demands are made on
Summing up, it can be said that while
as a rule all the switching operations are
the dielectric strength when the rated
contactors and switches make similar de-
handled reliably by the vacuum interrupter
and make no special demands on its
design.
It is considerably more difficult to verify
fault throwing (ie, making on a short-circuit).
Table 1:
Rated making capacity and maximum breaking capacity given in
IEC 60470 (utilization category AC-4)
IEC requires the switch, and therefore usu-
U/Ue
cos ϕ
No of tests
8
1.1
0.35
100
10
1.1
0.35
25
I/Ie
ally the vacuum interrupter, to be capable of
making on a full short-circuit current up to
five times without the contacts welding
together. The maximum mechanical and
electrical lifetimes lie in the region of 10,000
Rated making capacity
Max rated breaking capacity
Ie
Rated current
Ue Rated voltage
ABB Review 3/1999
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13
Ø16
W
3
Ø55
96 ( VS1) 116 ( VS2 )
80 ( VS1) 100 ( VS2 )
Ø51
2
1
Ø51
Vacuum interrupter VS1/VS2
for use in contactors
2
VS1 interrupter rated 7.2 kV, 400 A
VS2 interrupter rated 12 kV, 400 A
Sectional view of the VS vacuum
interrupter
3
Vacuum (≤10E-7 mbar)
Al2O3 ceramic
OFHC copper
All VS vacuum interrupters
feature a guide flange
for the movable stem and an
anti-torsion device to
prevent the bellows from
twisting.
4
Dimensions in mm
1
2
3
mands on the vacuum interrupters, con-
creased rated lightning impulse withstand
considerably to reduce possible overvolt-
siderable differences exist between them.
voltage and rated short-duration power-fre-
ages caused by the current in the induct-
The challenge for the development engi-
quency withstand voltage that result from
ance before chopping being re-directed
neers was therefore to design an inter-
the higher rated voltage.
into the parallel capacitance.
rupter that was economically priced and
3 shows a sectional view of the VS1
A new bellows has also been developed
compact and which, in spite of the dissim-
(7.2 kV, 400 A). As with all vacuum inter-
with a mechanical lifetime of at least 1 mil-
ilarities, could be used for both applica-
rupters from ABB Calor Emag Mittel-
lion switching cycles. VS interrupters have
tions.
spannung, the insulator material is high-
a guide flange through which the movable
purity Al2O3 ceramic. With the exception of
stem passes and which gives it a certain
the contacts, the metallic parts are made
axial freedom in relation to the cover, plus
of oxygen-free high conductivity (OFHC)
an anti-torsion device to protect the bel-
copper. The parts with complex shapes
lows from twisting 4 . A special feature is
VS1/VS2 interrupters for
are produced by means of hot press forg-
the use of copper for both the cover and
contactors
ing.
the conductor. To stop these two parts
The new VS series of interrupters
a
The contacts of the VS1 and VS2
from being cold-welded together during
rated voltage of 7.2 kV and rated current of
interrupters for contactors are made of
switching or the insertion of the interrupter,
400 A satisfy most of the demands made
WCAg instead of the more commonly used
the latter is hard-plated with chromium.
on medium-voltage contactors. The small-
CuCr. The hard-metal component, tung-
Wear on parts is therefore only minimal,
est of the new interrupters, the VS1 2 ,
sten carbide (WC), makes the contacts re-
allowing up to 2 million switching opera-
was therefore dimensioned with these rat-
sistent to erosion caused by arcing. As a
tions. The wing-like protrusions on the con-
ings. For the 12-kV market, ABB Calor
result, contacts have an electrical lifetime of
ductor engage in the cover to prevent the
Emag Mittelspannung developed the VS2,
several hundred thousand switching cycles
bellows from twisting during assembly, etc.
which also has a rated current of 400 A.
at rated current. Also, with WCAg the
The successful development of new,
The VS2 has a longer ceramic body 2
chopping current is in the region of 0.5 A,
compact vacuum interrupters depends
than the VS1 to increase the insulation in
compared with 3 to 5 A for CuCr, which is
to a large extent on correct calculation
air. This is necessary because of the in-
used widely in circuit-breakers. This helps
of the electrical field.
Vacuum
34
interrupters
designed
ABB Review 3/1999
for
5
shows the
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electrical potential distribution and the elec-
offset by two important advantages: due to
made more compact and the design more
trical field strength in the VS1 for an applied
the outstanding insulation properties of the
cost-effective. If the ceramic body of a
voltage of 60 kV. This value is specified in
vacuum, the internal structures can be
vacuum interrupter had to be shaped to
IEC 60694 [7] as the peak value of the rated
lightning impulse withstand voltage under
more severe conditions. In spite of being
Electrical potential distribution (a) and electrical field strength (b)
in the VS1 interrupter for an applied voltage of 60 kV
5
extremely compact, the VS1 and VS2 interrupters easily satisfy the dielectric requirements imposed by the rated short-duration
power-frequency withstand voltage and
rated lightning impulse withstand voltage.
It goes without saying that this also applies
to the VS vacuum interrupters designed for
use in switches, for which the test voltages
are even higher due to the higher rated voltage.
The impressive way in which the VS1
handles a three-phase interruption as per
IEC 60470 (utilization category AC-4) can
be seen in 6 . The oscillograms show
the interruption of a short-circuit current of
4 kA (recovery voltage 7.9 kV). Whereas
IEC 60470, AC-4, only requires 3.2 kA, the
rated interruption current of the VS1 and
VS2 is 4 kA. Both VS1 (7.2 kV) and VS2
(12 kV) easily satisfy the requirements given
in the standards for the different switching
operations.
VS3/VS4 interrupters for switches
Two vacuum interrupters have been developed by ABB Calor Emag Mittelspannung
for use in switches: VS3 with a rated
voltage of 12 kV, and VS4 with 24/36 kV.
Both classes have the same outside
dimensions as the VS2 interrupter 2 .
Since, due to its extremely compact
design, the external insulating distance of
the VS4 does not satisfy the dielectric
requirements specified in IEC 60694,
either the switch compartment in which
the interrupter is mounted has to be filled
with an insulating compound that forms
a mould around it, or an insulating gas
with a higher dielectric strength has to be
used.
The additional cost of this is, however,
ABB Review 3/1999
35
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Phase 1
8
kA
4
T
C
8
kV
4
0
0
-4
-4
-8
-8
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Oscillogram of a three-phase interruption of a
4-kA short-circuit current (recovery voltage: 7.9 kV),
performed with a VS1 interrupter
6
Oscillogram of a single-phase interruption of a rated
cable-charging breaking current under
earth-fault conditions, performed by a VS4 interrupter
(rated voltage: 24 kV)
7
U
Phase 2
8
kA
4
I
0
0
-4
-4
-8
-8
U
Phase 3
8
kA
4
I
8
kV
4
8
kV
4
0
0
-4
-4
-8
-8
0
50
150
100
U
80
80
A
kV
40
40
0
0
U
I
-40
-80
0
ms
t
-40
50
100
ms
150
-80
t
achieve the same dielectric strength,
References
[7] IEC 60694: Common clauses for high-
the overall cost would be considerably
[1] H. Fink, D. Gentsch, G. Pilsinger,
voltage switchgear and controlgear stan-
higher.
W. Shang: Vakuumschaltkammern für
dards, 1996.
For many of the applications with
zuverlässige Mittelspannungsschaltgeräte.
such switch interrupters the use of addi-
Elektrizitätswirtschaft 96 (97) 14, 749–752.
tional
anyway
[2] H. Fink, D. Gentsch, M. Heimbach, G.
planned. The bellows used with VS3 and
Pilsinger, W. Shang: New developments in
VS4 are the same as those used with the
vacuum interrupters based on RMF and
interrupters for contactors. Also the same
AMF technologies. 18th International Sym-
Authors
are the guideways and anti-torsion devices.
posium on Discharges and Electrical Insu-
Dr. Harald Fink
An oscillogram of a cable-charging break-
lation
Dietmar Gentsch
ing current being interrupted by a VS4
Netherlands.
Dr. Markus Heimbach
(rated voltage 24 kV) under earth-fault con-
[3] IEC 60470: High-voltage alternating
ABB Calor Emag Mittelspannung GmbH
ditions (53 A) is shown in 7 . Vacuum inter-
current contactors, 1974.
P.O. box 1220
rupters handle even interruptions of this
[4] IEC 60056: High-voltage alternating
D-40832 Ratingen
kind without restriking.
current circuit-breakers, 1987.
Germany
[5] IEC 60265: High-voltage switches –
Telefax: +49 2102 121713
Part 1: Switches for rated voltages above
E-mail:
IEC standards with ease and also meet
1 kV and less than 52 kV, 1998.
[email protected]
demand for a uniform, compact and cost-
[6] IEC 60420: High-voltage alternating
[email protected]
effective design.
current switch-fuse combinations, 1990.
[email protected]
insulating
moulding
is
With its VS family, ABB offers a series of
vacuum
36
interrupters
that
ABB Review 3/1999
satisfy
the
in
Vacuum,
1998,
Eindhoven,