Professional Documents
Culture Documents
WARNING
IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS CAN
RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING
ANY UNPACKING, ASSEMBLY, OPERATION OR MAINTENANCE OF THE
CIRCUIT BREAKERS.
INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY
BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT
BE CONSIDERED ALL INCLUSIVE REGARDING INSTALLATION OR
MAINTENANCE PROCEDURES. IF FURTHER INFORMATION IS REQUIRED,
YOU SHOULD CONSULT EATONS ELECTRICAL SERVICES & SYSTEMS.
THE CIRCUIT BREAKERS DESCRIBED IN THIS BOOK ARE DESIGNED AND
TESTED TO OPERATE WITHIN THEIR NAMEPLATE RATINGS. OPERATION
OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL,
RESULTING IN DEATH, BODILY INJURY AND PROPERTY DAMAGE.
ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS
THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY
ADHERED TO.
THESE VACUUM REPLACEMENT CIRCUIT BREAKERS ARE DESIGNED TO
BE INSTALLED PURSUANT TO THE AMERICAN NATIONAL STANDARDS
INSTITUTE (ANSI). SERIOUS INJURY, INCLUDING DEATH, CAN RESULT
FROM FAILURE TO FOLLOW THE PROCEDURES OUTLINED IN THIS
MANUAL.
ii
www.eaton.com
Table of Contents
SECTION 1: INTRODUCTION
1.1 VISUAL INSTRUCTION BOOKLET ESSENTIALS
1.2 QUICK RESPONSE CODE
1.3 AVAILABLE DHP-VR CIRCUIT BREAKERS
4
4
4
4
10
11
11
11
12
12
19
19
19
19
20
20
20
20
21
21
21
21
21
23
23
23
24
24
24
30
30
30
30
31
31
32
32
32
32
32
32
33
33
34
34
34
35
35
36
36
37
37
37
40
42
42
42
24
24
24
24
25
25
25
iii
SECTION 1: INTRODUCTION
The purpose of this book is to provide instructions for receiving and
handling, storage, installation, operation and maintenance of the
DHP VR-Series circuit breaker. The Vacuum Replacement Circuit
Breakers (also referred to as VR-Series) are designed to be used in
existing Westinghouse type DHP metal-enclosed switchgear and
provide equal of superior electrical and mechanical performance
as compared to the design ratings of the original circuit breaker.
VR-Series Circuit Breakers provide reliable control, protection and
performance, with ease of handling and maintenance. Like ratings
are interchangeable with each other.
This book is intended to be used in conjunction with the technical
information provided with the original equipment order which
includes, but is not limited to electrical control schematics and wiring
diagrams, outline diagrams, installation plans, and procedures for
installation and maintenance of accessory items.
Satisfactory performance is dependant upon proper application,
correct installation, and adequate maintenance. It is strongly
recommended that this instruction book be carefully read and
followed in order to realize optimum performance and long useful life
of the circuit breaker.
WARNING
SATISFACTORY PERFORMANCE OF THESE BREAKERS IS CONTINGENT
UPON PROPER APPLICATION, CORRECT INSTALLATION AND ADEQUATE
MAINTENANCE. THIS INSTRUCTION BOOK MUST BE CAREFULLY READ
AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE
FOR LONG USEFUL LIFE OF THE CIRCUIT BREAKERS. IT IS FURTHER
RECOMMENDED THAT THE INSTALLATION BE PERFORMED BY AN EATON
TRAINED ENGINEER OR TECHNICIAN.
VR-SERIES BREAKERS ARE PROTECTIVE DEVICES, AS SUCH, THEY ARE
MAXIMUM RATED DEVICES. THEREFORE, THEY SHOULD NOT UNDER ANY
CIRCUMSTANCE BE APPLIED OUTSIDE THEIR NAMEPLATE RATINGS.
ALL POSSIBLE CONTINGENCIES WHICH MIGHT ARISE DURING
INSTALLATION, OPERATION, OR MAINTENANCE, AND ALL DETAILS
AND VARIATIONS OF THIS EQUIPMENT ARE NOT COVERED BY THESE
INSTRUCTIONS. IF FURTHER INFORMATION IS DESIRED BY THE
PURCHASER REGARDING A PARTICULAR INSTALLATION, OPERATION, OR
MAINTENANCE OF THIS EQUIPMENT, THE LOCAL EATON REPRESENTATIVE
SHOULD BE CONTACTED.
Existing
Breaker
Rating
Existing Breaker
Rated Continuous
Current at 60 Hz
VR-Series
Breaker
Rating
Rated
Voltage
Factor
Rated Withstand
ANSI Test Voltage
Rated
ShortCircuit
Maximum Sym.
Interrupting Capability
Breaker Type a
kV
MVA
Amps
MVA
Low Freq.
kV RMS
Impulse
kV Peak
I
kA RMS
KI
kA RMS
kA RMS / Peak
50DHP-VR
4.16
75
1200
50DHP75
1.36
19
60
8.8
12
19 / 32
4.16
75
1200
50DHP75U
1.24
19
60
29
36
58 / 97
50DHEP-VR
4.16
250
1200 / 2000
50DHEP250
1.24
19
60
29
36
58 / 97
50DHP-VR
4.16
250
1200 / 2000
50DHP250
1.24
19
60
29
36
58 / 97
4.16
250
1200 / 2000
H50DHP250
1.24
19
60
29
36
78 / 132
4.16
250
1200 / 2000
50DHP250U
1.19
19
60
41
49
78 / 132
4.16
350
50DHP350
1.19
19
60
41
49
78 / 132
75DHP-VR
7.2
500
75DHP500
1.25
36
95
33
41
66 / 111
75DVP-VR
7.2
500
1200 / 2000
75DVP500
1.25
36
95
33
41
66 / 111
150DHP-VR
13.8
500
150DHP500
1.30
36
95
18
23
37 / 62
13.8
500
1200 / 2000
H150DHP500
1.30
36
95
18
23
58 / 97
13.8
750
1200 / 2000
150DHP500U
1.30
36
95
28
36
58 / 97
13.8
1000
1200 / 2000
150DHP500XU
1.30
36
95
37
48
77 / 130
13.8
750
1200 / 2000
150DHP750
1.30
36
95
28
36
58 / 97
13.8
1000
1200 / 2000
150DHP750U
1.30
36
95
37
48
77 / 130
13.8
750
150DHP750C
1.30
36
95
28
36
58 / 97
13.8
1000
1200 / 2000
150DHP750CU
1.30
36
95
37
48
77 / 130
13.8
750
1200 / 2000
H150DHP750
1.30
36
95
28
36
77 / 130
13.8
750
H150DHP750C
1.30
36
95
28
36
77 / 130
13.8
1000
150DHP1000
1.30
36
95
37
48
77 / 130
13.8
500
1200 / 2000
150DVP500
1.30
36
95
18
23
37 / 62
13.8
750
1200 / 2000
150DVP750
1.30
36
95
28
36
58 / 97
15.0
N/A
1200 / 3000
150DHP50G
1.00
36
95
50
50
82 / 137
150DVP-VR
150DHP-VR-50G
B
C
G
H
Breaker Type
Existing Breaker
Rated Continuous
Current at 60 Hz
(Amps)
50DHP-VR 250/250U
1200 / 2000
48.76
22.40
21.88
7.00
24.03
8.50
16.50
12.69
15.12
B
C
D
E
D
G
H
Breaker Type
Existing Breaker
Rated Continuous
Current at 60 Hz
(Amps)
50DHP-VR 350
1200 / 2000
57.16
22.65
22.38
7.00
29.38
8.50
16.50
12.69
15.12
F
Made in the U.S.A.
94C9523H49
G
Table 4. DHP-VR (7.5kV and 15kV Ratings) Dimensions
Breaker Type
Existing Breaker
Rated Continuous
Current at 60 Hz
(Amps)
75DHP-VR 500
60.75
31.25
10.00
34.81
10.00
19.75
20.69
150DHP-VR 500
60.75
31.25
10.00
34.81
10.00
19.75
20.69
150DHP-VR 750
60.75
31.25
10.00
34.81
10.00
19.75
20.69
150DHP-VR 750C
73.75
31.00
10.00
38.35
10.00
19.75
20.69
150DHP-VR 1000
73.75
31.00
10.00
38.35
10.00
19.75
20.69
F
Made in the U.S.A.
94C9523H49
Breaker Type
Existing Breaker
Rated Continuous
Current at 60 Hz
(Amps)
150DHP-VR-50G
73.72
31.00
10.00
38.44
10.00
19.72
WARNING
TO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLATION,
OPERATION, AND MAINTENANCE OF THESE BREAKERS, THE FOLLOWING
PRACTICES MUST BE FOLLOWED:
10
3.2 HANDLING
WARNING
DO NOT USE ANY LIFTING DEVICE AS A PLATFORM FOR PERFORMING
MAINTENANCE, REPAIR OR ADJUSTMENT OF THE BREAKER OR FOR
OPENING, CLOSING THE CONTACTS OR CHARGING THE SPRINGS. THE
BREAKER MAY SLIP OR FALL CAUSING SEVERE PERSONAL INJURY.
ALWAYS PERFORM MAINTENANCE, REPAIR AND ADJUSTMENTS ON A
WORKBENCH CAPABLE OF SUPPORTING THE BREAKER TYPE.
3.1 RECEIVING
Until the breaker is ready to be delivered to the switchgear site
for installation, DO NOT remove it from the shipping crate. If the
breaker is to be placed in storage, maximum protection can be
obtained by keeping it in its crate.
Upon receipt of the equipment, inspect the crates for any signs of
damage or rough handling. Open the crates carefully to avoid any
damage to the contents. Use a nail puller rather than a crow bar
when required.
11
3.3 STORAGE
The breaker is shipped with its contacts open and closing springs
discharged. The indicators on the front panel should confirm this.
Insert the end of the maintenance tool into the manual charge
socket opening and charge the closing springs by moving the
handle up and down the full range of motion. When charging is
complete the ratchet will no longer advance and the spring charged /
discharged indicator displays charged. (Figure Set 3.3). Remove the
maintenance tool. Push the manual close button. The breaker will
close as shown by the breaker contacts closed indicator. Push the
manual trip button. The breaker will trip as shown by the breaker
contacts open indicator. After completing this initial check, leave
the closing springs discharged and breaker contacts open.
Outdoor storage is NOT recommended. If unavoidable, the outdoor
location must be well drained and a temporary shelter from sun,
rain, snow, corrosive fumes, dust, dirt, falling objects, excessive
moisture, etc. must be provided. Containers should be arranged
to permit free circulation of air on all sides and temporary heaters
should be used to minimize condensation. Moisture can cause
rusting of metal parts and deterioration of high voltage insulation.
A heat level of approximately 400 watts for each 100 cubic feet of
volume is recommended with the heaters distributed uniformly
throughout the structure near the floor.
Indoor storage should be in a building with sufficient heat and
circulation to prevent condensation. If the building is not heated, the
same general rule for heat as for outdoor storage should be applied.
12
Type
Amperes
LBs
50DHP-VR 250
1200
435
2000
510
1200
480
2000
510
1200
495
2000
525
1200
510
2000
565
1200
480
2000
565
1200
485
2000
565
1200
485
2000
565
1200
575
2000
600
3000
600
1200
680
3000
760
50DHP-VR 250U
50DHP-VR 350
75DHP-VR 500
150DHP-VR 500
H150DHP-VR 500
150DHP-VR 750
150DHP-VR 1000
150DHP-VR 50G
Figure 3.3.a. Front External View of 5kV DHP-VR (50DHP-VR 250 1200A Shown)
9
2
10
11
12
5
6
13
14
Code Plate
11
Operations Counter
12
Removable Faceplate
13
Rail Latch
14
10
13
Figure 3.3.b. Rear External View of 5kV DHP-VR (350 MVA Rating)(Outer Phase Barrier Removed For Demonstration Purposes)
6
7
2
8
9
3
10
11
12
4
Rear External View
1
Lifting Point
Phase Barrier
Vacuum Interrupter
10
11
Ground Contact
Guide Channel
Snubber Bolt
12
Breaker Wheel
14
Figure 3.3.c. Front External View of 7.5 and 15kV DHP-VR (150DHP-VR 500 2000A Shown)
8
9
2
3
10
11
4
5
6
12
Code Plate
Operations Counter
10
Removable Faceplate
11
12
15
Figure 3.3.d. Rear External View of 7.5 and 15kV DHP-VR (150DHP-VR 500 2000A Shown)
5
1
7
2
3
8
9
4
Rear External View
1
Lifting Point
Guide Channel
Snubber Bolt
Phase Barrier
Ground Contact
16
8
9
1
2
10
3
4
11
12
Operations Counter
Removable Faceplate
10
11
Code Plate
12
17
8
9
3
Rear External View
1
Lifting Point
Phase Barrier
Guide Channel
Snubber Bolt
Ground Contact
18
APPROXIMATE MECHANISM
CHASSIS WIDTH (INCH)
18WR
20WR
29WR
18
20
27
19
WARNING
FAILURE TO REPLACE THE INTERRUPTER ASSEMBLY WHEN INDICATED BY
THE CONTACT EROSION INDICATOR COULD CAUSE THE BREAKER TO FAIL,
LEADING TO DEATH, PERSONAL INJURY OR PROPERTY DAMAGE.
WARNING
THERE IS NO PROVISION FOR IN-SERVICE ADJUSTMENTS OF CONTACT
WIPE AND STROKE. ALL SUCH ADJUSTMENTS ARE FACTORY SET AND
SHOULD NOT BE ATTEMPTED IN THE FIELD.
WARNING
ALL PHASE BARRIERS MUST BE IN PLACE BEFORE PLACING THE
CIRCUIT BREAKER INTO SERVICE. FAILURE TO HAVE THEM IN POSITION
CAN CAUSE DEATH, SERIOUS PERSONNEL INJURY AND/OR PROPERTY
DAMAGE.
20
WARNING
KEEP HANDS AND FINGERS AWAY FROM BREAKERS INTERNAL PARTS
WHILE THE BREAKER CONTACTS ARE CLOSED OR THE CLOSING SPRINGS
ARE CHARGED. THE BREAKER CONTACTS MAY OPEN OR THE CLOSING
SPRINGS DISCHARGE CAUSING CRUSHING INJURY. DISCHARGE
THE SPRINGS AND OPEN THE BREAKER BEFORE PERFORMING ANY
MAINTENANCE, INSPECTION OR REPAIR ON THE BREAKER.
THE DESIGN OF THIS CIRCUIT BREAKER ALLOWS MECHANICAL CLOSING
AND TRIPPING OF THE BREAKER WHILE IT IS IN THE CONNECT
POSITION. HOWEVER, THE BREAKER SHOULD BE CLOSED MECHANICALLY
ONLY IF THERE IS POSITIVE VERIFICATION THAT LOAD SIDE CONDITIONS
PERMIT. IT IS RECOMMENDED THAT CLOSING THE BREAKER IN THE
CONNECT POSITION ALWAYS BE DONE WITH THE CUBICLE DOOR
CLOSED. FAILURE TO FOLLOW THESE DIRECTIONS MAY CAUSE DEATH,
PERSONAL INJURY, OR PROPERTY DAMAGE.
When the manual trip button is held depressed, any attempt to close
the breaker results in the closing springs discharging without any
movement of the pole shaft or vacuum interrupter stem.
There are two basic control schemes for each series of Type VCP-WR
breakers, one for DC control and one for AC control voltages (Figure
4.5). Specific wiring schematics and diagrams are included with each
breaker.
21
OPERATION
SWITCH TERMINAL
LS1
bb
C and NO
CS
T
Y
SR
M
ST
PR
O
PS1
PS2
LS2
aa
C and NC
LS2
bb
LC
PS1
PS2
22
Brown Switch
Black Switch
C and NO
C and NO
C and NC
Black Switch
C and NO
Brown Switch
4.7 INTERLOCKS
Milliseconds / Maximum
Closing Time
(From Initiation of Close Signal to Contact Make)
75
Opening Time
(Initiation of Trip Signal to Contact Break)
45
Reclosing Time
(Initiation of Trip Signal to Contact Make)
190
WARNING
INTERLOCKS ARE PROTECTIVE DEVICES FOR PERSONNEL AND
EQUIPMENT. DO NOT BYPASS, MODIFY, OR MAKE INOPERATIVE ANY
INTERLOCKS. DOING SO COULD CAUSE DEATH, SERIOUS PERSONAL
INJURY, AND/OR PROPERTY DAMAGE.
There are several interlocks built into the VR-Series vacuum
replacement breakers. Each of these interlocks, though different
in form, duplicate or exceed the function of the original breakers
interlocks. These interlocks exist to safeguard personnel and
equipment. The basic premise behind the interlocking arrangement
on the vacuum replacement breaker is that the breaker must not be
inserted into or removed from a live circuit while the main contacts
are closed. Also considered in the interlocking is that the breaker
should pose no greater risk than necessary to the operator in or out
of the cell.
Figure 4.7. Code Plate (5kV DHP-VR)
23
WARNING
DO NOT FORCE THE BREAKER INTO THE CELL. DOING SO MAY DAMAGE
PARTS THEREBY RISKING DEATH, PERSONAL INJURY, AND/OR PROPERTY
DAMAGE.
24
NOTICE
ALL TYPE DHP-VR BREAKERS UTILIZE THE DHP-VR SURE CLOSE
MECHANISM TO CONTROL MOC VELOCITY AND CLOSELY MIMIC THE
DYNAMICS AND VELOCITIES OF OLDER BREAKERS. IT IS IMPERATIVE
THAT THIS MECHANISM BE ADJUSTED TO MATCH THE NUMBER OF MOC
SWITCHES (FROM 0 TO 3) MOUNTED IN THE CELL. ALWAYS MAKE SURE
THE MECHANISM IS PROPERLY ADJUSTED BEFORE ANY ATTEMPT IS
MADE TO INSERT THE BREAKER INTO THE CELL.
IN ADDITION, THE MOC PANTOGRAPH MUST BE CHECKED BEFORE ANY
ATTEMPT IS MADE TO INSERT THE BREAKER INTO THE CELL. DETAILED
PROCEDURES FOR EACH TEST ARE OUTLINED IN SECTION 5 OF THIS
MANUAL.
The cell mounted Truck Operated Cell Switch (TOC) is operated
by movement of the breaker truck into or out of the Connected
position.
25
8
1
10
3
4
5
11
12
6
7
LH Closing Spring
Closing Cam
10
11
Ratchet wheel
Operations Counter
RH Closing Spring
12
Charging Motor
26
1
8
9
10
3
4
5
11
12
6
7
LH Closing Spring
Closing Cam
10
11
Ratchet wheel
Operations Counter
RH Closing Spring
12
Charging Motor
27
3
4
5
6
7
8
9
10
11
12
2
13
14
Ratchet Wheel
11
Anti-Close Interlock
Pole Shaft
Spring Crank
12
Cam Shaft
13
Closing Spring
14
10
28
5
1
2
3
7
8
10
11
12
Charging Schematic
1
Closing Cam
Main Link
Cam Shaft
10
Operating Rod
Banana Link
11
Pole Shaft
Trip latch
12
29
WARNING
BEFORE PLACING THE BREAKER IN SERVICE, CAREFULLY FOLLOW THE
INSTALLATION PROCEDURE BELOW AND THE SAFE PRACTICES SET
FORTH IN SECTION 2. NOT FOLLOWING THE PROCEDURE MAY RESULT IN
INCORRECT BREAKER OPERATION LEADING TO DEATH, BODILY INJURY,
AND PROPERTY DAMAGE.
When the breaker is first commissioned into service and each time
the breaker is returned to service, it should be carefully examined
and checked to make sure it is operating correctly.
WARNING
FOR ALL TYPE DHP-VR HOUSINGS EQUIPPED WITH MECHANISM
OPERATED CELL (MOC) SWITCHES, THE STEPS OUTLINED IN
THIS PARAGRAPH MUST BE PERFORMED BEFORE INSTALLING A
REPLACEMENT DHP-VR CIRCUIT BREAKER. FAILURE TO COMPLY COULD
CAUSE SEVERE PERSONAL INJURY, DEATH, EQUIPMENT DAMAGE AND/
OR IMPROPER OPERATION
All Type DHP-VR breakers utilize the DHP-VR SURE CLOSE
mechanism to control MOC velocity and closely mimic the dynamics
and velocities of older breakers. It is imperative that this mechanism
be adjusted to match the maximum number of MOC switches
(from 0 to 3) mounted in the cell. If the adjustment is made on the
DHP-VR breaker to be compatible with one housing with a given
number of MOC switches, make sure the adjustment is checked
and compatible if the breaker is moved to a different housing of the
same rating.
The breaker has been factory adjusted to operate one mechanism
operated cell (MOC) switch in the cell. This means that for
applications with either no MOC switch or one MOC switch, no
field adjustments are required. It is only for the cases of 2 or 3
MOC switches that the drive spring adjustment is required. The
adjustment is done with the breaker out of the cell, open and all
springs discharged. Refer to Figures 5.1 through 5.6 for reference
assistance.
Finally, the SURE CLOSE mechanism provides an effective way to
evaluate the condition of the MOC in the cell. If the SURE CLOSE
drive spring is properly adjusted, but the MOC does not fully open
or close, it is time to maintain the MOC in the cell. Maintenance
usually means cleaning and lubricating the MOC mechanism.
If the MOC has seen a large number of cycles, however, worn
components may have to be replaced.
To adjust the SURE CLOSE drive spring for a specific number of
MOC switches, proceed with the following steps:
Step 1: Remove the right hand phase barrier from the breaker
(Figure 3.4, 3.6, & 3.8).
Step 2: Locate the MOC drive spring (Figure 5.1). It is located in
the left lower portion of the breaker as viewed from the top rear
of the breaker with the phase barriers removed.
30
GAUGE
2MOC
1MOC
ALIGN THIS
SURFACE WITH
THE STEP ON
THE GAUGE
RELATIVE TO
THE NUMBER
OF MOC
SWITCHES TO
BE OPERATED
Step 3: From the factory, the drive spring comes set for 0 or 1
MOC switch. Refer to Figure 5.2 to see how that adjustment
would look. Notice that there is a nut and a jam nut on the
threaded rod to make the adjustment easy. Also notice that a
step gauge is provided and bolted next to the spring to further
simplify the adjustment (Figures 5.2 and 5.3).
WARNING
Figure 5.5. Drive Spring Shown Adjusted for Two MOC Switches
31
NOTICE
IF THE SPRINGS ARE TO BE CHARGED ON A CLOSED BREAKER, NO
CLICK IS HEARD AT THE END OF CHARGING OPERATION. DISCONTINUE
CHARGING AND REMOVE THE MAINTENANCE TOOL AS SOON AS
CHARGED FLAG IS FULLY VISIBLE. CONTINUE ATTEMPTS TO FURTHER
CHARGE MAY RESULT IN DAMAGE TO THE MECHANISM.
WARNING
ALWAYS REMOVE THE MAINTENANCE TOOL AFTER CHARGING THE
SPRING. FAILURE TO REMOVE THE MAINTENANCE TOOL FROM THE
BREAKER COULD CAUSE INJURY TO PERSONNEL AND/OR EQUIPMENT
DAMAGE IF THE BREAKER WAS TO CLOSE.
Close and trip the breaker by pushing the close lever then the trip
lever (Figure Set 3.3).
WARNING
EXAMINE THE INSIDE OF THE CELL BEFORE INSERTING THE BREAKER
FOR EXCESSIVE DIRT OR ANYTHING THAT MIGHT INTERFERE WITH THE
BREAKER TRAVEL.
WARNING
5.6 INSULATION
Check breaker primary and secondary insulation per Section 6.
WARNING
FOR ALL TYPE DHP HOUSINGS, THE ADJUSTMENT STEPS OUTLINED
IN THIS PARAGRAPH MUST BE PERFORMED BEFORE INSTALLING A
REPLACEMENT DHP-VR CIRCUIT BREAKER. FAILURE TO COMPLETE THESE
STEPS COULD RESULT IN EQUIPMENT DAMAGE AND/OR IMPROPER
OPERATION.
Before racking a breaker into any and all housings, the snubber bolts
must be adjusted as outlined in steps 1 and 2. Refer to Figures 3.4,
3.6, 3.8, and 5.8 for reference purposes. If a breaker is moved from
one housing to another, the procedure must be repeated for the
new housing.
Step 1: Measure the distance from the floor plate to the underside
of the current transformer shelf on both sides of the housing in
line with the location of the snubber bolts on each side of the
breaker (Figure 5.8).
Step 2: Adjust the height of the top of the snubber bolt to be
between 0.0 and 0.031 (0.0 and 1/32) inches below the measured
height of the current transformer shelf and tighten the locking
nut.
Figure 5.8. Snubber Bolt Adjustment
0.00 to 0.031
NNote: Reference Section 3 for the
specific location of the Snubber
Bolt for each DHP-VR Rating.
32
KEEP HANDS OFF THE TOP EDGE OF THE FRONT BARRIER WHEN PUSHING
A BREAKER INTO A CELL. FAILURE TO DO SO COULD RESULT IN BODILY
INJURY, IF FINGERS BECOME WEDGED BETWEEN THE BREAKER AND
THE CELL. USE THE HANDLES PROVIDED ON THE FRONT OF THE BREAKER
FACEPLATE, OR USE BOTH FULLY OPENED HANDS FLAT ON THE FRONT OF
THE FACEPLATE.
b. Position the breaker in front of the cell, and line up the guide
channel on the rear right hand side of the breaker near the
floor with the guide rail on the right hand side of the cell floor.
Once the breaker is aligned with the cell floor guide, push the
breaker into the cell until the rail latch at the front of the guide
channel catches in a notch in the guide rail, and prevents further
movement of the breaker toward the rear of the cell (Figures 5.9).
The breaker is now in the Test position, and secondary contacts
can be engaged.
Figure 5.9. Insertion of 15kV DHP-VR
WARNING
EXCESSIVE FORCE, APPLIED TO THE RACKING MECHANISM WHILE THE
BREAKER IS CLOSED, COULD SHEAR OFF THE PIN THAT THE RACKING
CRANK ENGAGES DURING OPERATION.
WARNING
WHILE RACKING THE BREAKER, NOTE ANY SUDDEN RESISTANCE
TO RACKING OR SIGNS OF BINDING. DETERMINE THE CAUSE OF
INTERFERENCE AND CORRECT, AS APPROPRIATE, BEFORE PROCEEDING.
Press down on the rail latch on the front right side of the breaker
with your foot, and push the breaker toward the rear of the cell as
far as it will go. Be sure the breaker is pushed in until it stops. This
will bring the racking nut on the breaker up to the screw in the cell.
Engage the racking crank on the racking shaft, push moderately
toward rear of the cell, and turn crank clockwise. (Figure 5.12)
The breaker will move slowly toward the rear of the cell. After
the breaker starts to move, it is not necessary to push. Continue
cranking until the crank turns freely, and the breaker stops moving.
When the breaker is fully engaged, the faceplate will almost touch
the cell frame angles. The breaker is now in the OPERATING or
ENGAGED position, and may be operated electrically using the
control switch on the cell door.
NOTICE
handle with the other hand. The secondary engaging handle is
located to the right of the operating rod, just inside a rectangular
hole. By pulling firmly on the engaging handle, complete
secondary engagement will be insured.
e. The breaker may now be electrically closed and tripped by using a
control switch on the cell door, or it may be manually operated by
means of the close and trip buttons, located on the faceplate of
the breaker.
THE BREAKER MAY BE OPEN AND ITS CLOSING SPRING MAY DISCHARGE
AS IT IS WITHDRAWN FROM THE CELL. IT DEPENDS ON WHETHER THE
BREAKER WAS LEFT CLOSED OR OPEN, OR WHETHER THE SPRING WAS
LEFT CHARGED OR DISCHARGED.
To remove the breaker from the operating position, trip the breaker
open, and engage the racking crank on the racking device shaft. Turn
the crank counterclockwise until the crank rotates freely. Pull the
breaker toward the front of the cell until the rail latch engages the
slot in the rail. The breaker is now secured in the TEST position.
To remove the breaker from the cell, press down on the rail latch to
free the breaker from the rail. Pull the breaker out of the cell.
33
WARNING
STAND AT LEAST ONE METER AWAY FROM THE BREAKER WHEN TESTING
FOR VACUUM INTEGRITY.
WARNING
DO NOT WORK ON A BREAKER IN THE CONNECTED POSITION.
INSPECTION ITEM
CRITERIA
INSPECTION METHOD
1.
No Dirt
Visual Check
No Cracking
Visual Check
Vacuum Integrity
Withstand
27k 60Hz For 1 Minute
Hipot Tester
Insulation Integrity
Withstand
15kV, 60Hz For 1 Minute
(5kV Rating)
27kV, 60Hz For 1 Minute
(15kV Ratings)
Hipot Tester
Withstand
1125V, 60Hz For 1 Minute
Hipot Tester
Vacuum Interrupters
Replace VI Assembly
Adequate Vacuum
2.
3.
4.
Insulation
Power Element
Operating Mechanism
Visual Check
Primary Disconnects
No Burning Or Damage
Visual Check
Wiring
Visual Check
Terminals
Tight
Visual Check
Motor
Tightness Of Hardware
Visual Check
Clean As Necessary
Lubrication
Manual Operation
Smooth Operation
CloSure Test
BOLT SIZE
8 - 32
10 - 32
.25 - 20
.31 - 18
.38 - 16
.50 - 13
24
36
72
144
300
540
34
Since the contacts are contained inside the interrupter, they remain
clean and require no maintenance. However, during high current
interruptions there may be a minimal amount of erosion from the
contact surfaces. To determine contact erosion, close the breaker
and observe the vacuum interrupter moving stem from the rear of
the breaker. If the mark on each stem is visible, erosion has not
reached maximum value thus indicating satisfactory contact surface
of the interrupter. If the mark is not visible, the vacuum interrupter
assembly must be replaced (Figure 6.1 and 6.2).
WARNING
APPLYING ABNORMALLY HIGH VOLTAGE ACROSS A PAIR OF CONTACTS
IN VACUUM MAY PRODUCE X-RADIATION. THE RADIATION MAY
INCREASE WITH THE INCREASE IN VOLTAGE AND/OR DECREASE IN
CONTACT SPACING. X-RADIATION PRODUCED DURING THIS TEST
WITH RECOMMENDED VOLTAGE AND NORMAL CONTACT SPACING
IS EXTREMELY LOW AND WELL BELOW MAXIMUM PERMITTED BY
STANDARDS. HOWEVER, AS A PRECAUTIONARY MEASURE AGAINST
POSSIBILITY OF APPLICATION OF HIGHER THAN RECOMMENDED VOLTAGE
AND/OR BELOW NORMAL CONTACT SPACING, IT IS RECOMMENDED THAT
ALL OPERATING PERSONNEL STAND AT LEAST ONE METER AWAY IN
FRONT OF THE BREAKER.
With the breaker open and securely sitting on the floor, connect
all top/front primary studs (bars) together and the high potential
machine lead. Connect all bottom/rear studs together and the high
potential return lead. Do not ground them to the breaker frame. Start
the machine at zero potential, increase to appropriate test voltage
and maintain for one minute.
Successful withstand indicates that all interrupters have satisfactory
vacuum level. If there is a breakdown, the defective interrupter or
interrupters should be identified by an individual test and replaced
before placing the breaker in service.
WARNING
FAILURE TO REPLACE A VACUUM INTERRUPTER ASSEMBLY WHEN
CONTACT EROSION MARK IS NOT VISIBLE OR WIPE IS UNSATISFACTORY,
WILL CAUSE THE BREAKER TO FAIL TO INTERRUPT AND THEREBY CAUSE
PROPERTY DAMAGE OR PERSONNEL INJURY.
WARNING
SOME DC HIGH POTENTIAL UNITS, OPERATING AS UNFILTERED HALFWAVE RECTIFIERS, ARE NOT SUITABLE FOR USE TO TEST VACUUM
INTERRUPTERS BECAUSE THE PEAK VOLTAGE APPEARING ACROSS THE
INTERRUPTERS CAN BE SUBSTANTIALLY GREATER THAN THE VALUE
READ ON THE METER.
Vacuum Interrupter Integrity Test Voltage
Breaker Rated Maximum Voltage
AC 60Hz
DC
27 kV
40 kV
35
Figure 6.3. The Arrow Shows The T Contact Wipe Indicator Example with Blue Spring (If the T or any portion of its visible
as shown with the breaker closed, the wipe is satisfactory)
(See Next Figure for Graphic of All Possibilities)
6.5 INSULATION
In VR-Series breakers, insulation maintenance primarily consists of
keeping all insulating surfaces clean. This can be done by wiping off
all insulating surfaces with a dry lint free cloth or dry paper towel.
In case there is any tightly adhering dirt that will not come off by
wiping, it can be removed with a mild solvent or distilled water.
But be sure that the surfaces are dry before placing the breaker in
service. If a solvent is required to cut dirt, use Isopropyl Alcohol or
commercial equivalent. Secondary control wiring requires inspection
for tightness of all connections and damage to insulation.
SECONDARY CIRCUIT:
Isolate the motor by disconnecting the two motor leads from the
terminal block. Connect all points of the secondary disconnect pins
with a shooting wire. Connect this wire to the high potential lead
of the test machine. Ground the breaker frame. Starting with zero,
increase the voltage to 1125 RMS, 60 Hz. Maintain the voltage for
one minute. Successful withstand indicates satisfactory insulation
strength of the secondary control circuit. Remove the shooting wire
and reconnect the motor leads.
36
Figure 6.5. Status Indicators (A shows the contact status indication and B shows the spring indication.)
The resistance should not exceed the factory levels more than 15%.
Factory test levels are recorded on the circuit breaker test form,
which is included with the breaker. If measurements exceeds 15%,
contact the manufacturer.
Discharged
Open
WARNING
37
Step 5 - Clean the far left cam with a mild solvent such as alcohol.
Place the tape around the cam starting from the bottom up. Make
certain that the tape adheres well to the cam surface. (Figure 6.6).
Step 6 - Mount the transparent CloSure Test Tool (Figure 6.7b)
with two bolts and washers. Refer to Figure 6.7a and Table 6.1 for
approximate mounting holes. Hand tighten the bolts.
Step 7 - Using a red Sanford Sharpie fine point permanent marker
(or equivalent), place the marker tip in the proper hole (C)
located over the cam and make a heavy mark on the tape by
moving the marker as described in Figures 6.9, 6.11, and 6.12.
Remove the marker from the hole.
A-1
A-2
A-3
A-4
C-2
C-1
C-4 C-5
C-6
C-3
Step 9 - Place the marker back in the hole. While holding the marker
tip against the tape, close the breaker (Figure 6.10). Remove the
marker from the hole.
Step 10 - While closely observing the pole shaft at the right side of
the circuit breaker (Figure 6.11), recharge the closing springs with
the maintenance tool. As the circuit breaker is recharged, there
should be no movement of the pole shaft. If there is movement of
the pole shaft while recharging, this indicates a problem with the
circuit breker - stop the test and consult the factory.
Step 11 - Open the circuit breaker, then close it, then reopen it.
Verify that the mark made in Step 7 is aligned with the pen
opening. If it is not aligned, this indicates a problem with the
circuit breaker - stop the test and consult the factory.
Step 12 - Inspect the circuit breaker to assure it is in the open
position and the closing springs are discharged. Alternately
depress the Open and Close clappers a few times to ensure the
circuit breaker is completely discharged. Remove the transparent
CloSure Tool.
Step 13 - Remove the tape from the cam and place it on a sheet of
paper that can be kept as a record of the test. Record the date of
the test, person conducting the test, circuit breaker serial number,
and the operations counter on the tape or paper (Figures 6.14 and
6.15).
Step 14 - Evaluate the CloSure performance by comparing the
test tape with the illustration in Figure 6.16. Measure the over
travel X. If X is greater than or equal to 0.6, the circuit breaker
performance is satisfactory. If X is less than 0.6, this indicates
a problem with the circuit breaker - consult the Power Breaker
Center for technical support.
Step 15 - Reassemble the front cover onto the circuit breaker.
Return the circuit breaker to its original configuration and setup.
Figure 6.7. Attaching CloSure Test Tool at Hole A & B
38
B-1
B-2
ELEMENT
DESIGNATION
APPROXIMATE
MECHANISM
CHASSIS WIDTH
(INCH)
UPPER
MOUNTING
HOLE
LOWER
MOUNTING
HOLE
MARKER
PLACEMENT
HOLE
18WR
20WR
29WR
18
20
27
A1
A1
A1
B2
B2
B2
C1
C2
C5
Width
Cam
CloSureTM Tool
Marker
15 O
15 O
39
6.9 LUBRICATION
All parts that require lubrication have been lubricated during the
assembly with molybdenum disulphide grease. Eaton No. 53701QB.
Over a period of time, this lubricant may be pushed out of the way
or degrade. Proper lubrication at regular intervals is essential for
maintaining the reliable performance of the mechanism. The breaker
should be relubricated once a year or per the operations table (Table
6.2), which ever comes first. The locations shown in Figure 6.17
should be lubricated with a drop of light machine oil.
After lubrication, operate the breaker several times manually and
electrically.
Roller bearings are used on the pole shaft, the cam shaft, the
main link and the motor eccentric. These bearings are packed at
the factory with a top grade slow oxidizing grease which normally
should be effective for many years. They should not be disturbed
unless there is definite evidence of sluggishness, dirt or parts are
dismantled for some reason.
If it becomes necessary to disassemble the mechanism, the
bearings and related parts should be thoroughly cleaned, remove old
grease in a good grease solvent. Do not use carbon tetrachloride.
They should then be washed in light machine oil until the cleaner is
removed. After the oil has been drawn off, the bearings should be
packed with Eaton Grease 53701 QB or equivalent.
OPERATIONS
750
400
400
5 3/16" Approx
"X" Inches
CloSureTM Distance
40
8.0 to 10
Inches
INSPECTION AREA
PROBABLE DEFECTS
Control Circuit
FAILS TO CLOSE
Closing Springs Not Charged
Secondary Disconnects
Motor Cut-off Switch (Poor Or Burned Contacts. Lever Not Operational.)
Terminals And Connectors (Poor Or Burned Contacts)
Motor (Brushes Worn Or Commutator Segment Open)
Mechanism
Control Circuit
(Close Coil Does Not Pick Up)
UNDESIRABLY CLOSES
Control Circuit
Mechanism
FAILS TO CLOSE
No Trip Sound
Control Circuit
Trip Mechanism
Trip Mechanism
UNDESIRABLY TRIPS
Control Circuit
Mechanism
41
7.1 GENERAL
(48vDC)
(125vDC)
(250vDC)
(120vAC)
(240vAC)
94C9525H01
94C9525H02
94C9525H03
94C9525H04
94C9525H05
6.
2.
RECTIFIER
Rectifier
94C9525G09
7.
3.
(48vDC)
(125vDC)
(250vDC / 240vAC)
94C9525G10
94C9525G11
94C9525G12
8.
94C9525G13
9.
94C9525H06
10.
4.
5.
42
94C9525H07
94C9525H08
(LS) (20WR/29WR)
(LS) (18WR)
94C9525G14
94C9525G15
24vDC
48vDC
125vDC / 120vAC
250vDC / 240vAC
94C9525G16
94C9525G17
94C9525G18
94C9525G19
48vDC
125vDC
250vDC
120vAC-C/M 48vDC-T
240vAC-C/M 48vDC-T
120vAC-C/M 120vAC-CT
240vAC-C/M 240vAC-CT
94C9525G01
94C9525G02
94C9525G03
94C9525G04
94C9525G05
94C9525G06
94C9525G07
43
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Eaton.com
2015 Eaton
All Rights Reserved
Printed in USA
Publication No. IB182017EN
July 2015