Cutler-Hammer 50 VCP-T25, 50 VCP-TR25, 75 VCP-T16, 75 VCP-TR16, 75 VCP-TR20 Instructions For The Use, Operation And Maintenance

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I.B. 69C3067H06

Effective February 2003 Supersedes I.B. 69C3067H05 dated March 2002

Cutler-Hammer

Instructions for the Use, Operation and Maintenance of Types VCP-T and VCP-TR Vacuum Circuit Breakers

VCP-T Drawout

(with or without trip unit - shown with Digitrip Trip Unit)

VCP-TR Fixed

(with or without trip unit - non-automatic shown)

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I.B. 69C3067H06

Page iii

Effective 2/03

All possible contingencies which may arise during installation, operation or maintenance, and all details and variations of this equipment do no purport to be covered by these instructions. If further information is desired by purchaser regarding his particular installation, operation or maintenance of particular equipment, contact a Cutler-Hammer representative.

IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS CAN RESULT IN DEATH, SERI- OUS PERSONAL INJURY, OR PROPERTY DAMAGE.

READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING ANY UNPACKING, ASSEM- BLY, OPERATION OR MAINTENANCE OF THE CIR- CUIT BREAKERS.

INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT BE CON- SIDERED ALL INCLUSIVE REGARDING INSTALLA- TION OR MAINTENANCE PROCEDURES. IF FUR- THER INFORMATION IS REQUIRED, YOU SHOULD CONTACT CUTLER-HAMMER

WARNING

THE CIRCUIT BREAKER ELEMENTS 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.

SERIOUS INJURY, INCLUDING DEATH, CAN RESULT FROM FAILURE TO FOLLOW THE PROCE- DURES OUTLINED IN THIS MANUAL. THESE CIR- CUIT BREAKER ELEMENTS ARE SOLD PURSUANT TO A NON-STANDARD PURCHASING AGREEMENT WHICH LIMITS THE LIABILITY OF THE MANUFAC- TURER.

WARNING

Cutler-Hammer

Pittsburgh, PA 15220

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TABLE OF CONTENTS

Page

SECTION 1: INTRODUCTION

1-1 VCP-T and VCP-TR Vacuum Circuit Breaker Ratings....................................................................................................................................1

1-2 Types VCP-T and VCP-TR Outlines and Dimensions....................................................................................................................................2

SECTION 2: SAFE PRACTICES

SECTION 3: RECEIVING, HANDLING AND STORAGE

3-1 Receiving.......................................................................................................................................................................................................11

3-2 Handling ........................................................................................................................................................................................................11

3-2.1 Unpacking ....................................................................................................................................................................................11

3-2.2 Lifting ...........................................................................................................................................................................................11

3-3 Storage .........................................................................................................................................................................................................12

3-4 Typical Breaker and Cassette Weights.........................................................................................................................................................12

SECTION 4: INSTALLATION AND WIRING

4-1 Initial Inspection ...........................................................................................................................................................................................20

4-2 Electrical Clearances ...................................................................................................................................................................................20

4-3 Interphase Barriers........................................................................................................................................................................................20

4-4 Front Cover ..................................................................................................................................................................................................20

4-5 Installing Fixed Circuit Breaker .....................................................................................................................................................................20

4-5.1 Fixed Mechanical Interfaces ........................................................................................................................................................20

4-5.2 Fixed Electrical Interfaces ............................................................................................................................................................20

4-6 Installing Drawout Circuit Breaker.................................................................................................................................................................21

4-6.1 Drawout Mechanical Interfaces ....................................................................................................................................................21

4-6.2 Circuit Breaker Positioning ...........................................................................................................................................................22

4-6.3 Drawout Electrical Interfaces .......................................................................................................................................................24

4-6.4 Levering Circuit Breaker ...............................................................................................................................................................26

SECTION 5: DESCRIPTION AND OPERATION

5-1 Introduction ...................................................................................................................................................................................................29

5-2 Vacuum Interrupter Assembly ......................................................................................................................................................................29

5-2.1 Contact Erosion Indicator..............................................................................................................................................................32

5-2.2 Contact Wipe and Stroke..............................................................................................................................................................32

5-3 Stored Energy Mechanism ...........................................................................................................................................................................33

5-3.1 Manual Operation ........................................................................................................................................................................33

5-3.2 Electrical Operation ......................................................................................................................................................................34

5-3.3 Trip Free Operation ......................................................................................................................................................................34

5-3.4 Anti-Pump Feature .......................................................................................................................................................................34

5-3.5 Latch Check Switch ......................................................................................................................................................................34

5-3.6 Mechanical Interlocks ...................................................................................................................................................................34

5-4 Connection Diagrams....................................................................................................................................................................................35

5-4.1 Timing...........................................................................................................................................................................................35

5-4.2 Secondary Connections................................................................................................................................................................35

5-5 Electronic Tripping System ...........................................................................................................................................................................41

5-5.1 Microprocessor-Based Trip Unit ...................................................................................................................................................41

5-5.2 Rating Plug ...................................................................................................................................................................................42

5-5.3 Current Sensors............................................................................................................................................................................42

5-5.4 Trip Actuator .................................................................................................................................................................................42

5-6 Accessory Devices........................................................................................................................................................................................43

5-6.1 Plug-in Electrical Accessories.......................................................................................................................................................43

5-6.2 Internal Electrical Accessories......................................................................................................................................................44

5-6.3 Mechanical Accessories ..............................................................................................................................................................46

SECTION 6: INSPECTION AND MAINTENANCE

6-1 Introduction ...................................................................................................................................................................................................47

6-2 Frequency of Inspection and Maintenance...................................................................................................................................................47

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6-3 Vacuum Interrupter Integrity Test..................................................................................................................................................................47

6-4 Contact Erosion.............................................................................................................................................................................................49

6-5 Contact Wipe.................................................................................................................................................................................................49

6-6 Insulation ......................................................................................................................................................................................................51

6-7 Insulation Integrity Check..............................................................................................................................................................................51

6-8 Primary Circuit Resistance Check ................................................................................................................................................................51

6-9 Mechanism Check ........................................................................................................................................................................................51

6-10 Lubrication ....................................................................................................................................................................................................51

6-11 Troubleshooting ............................................................................................................................................................................................51

SECTION 7: RENEWAL PARTS

7-1 General ......................................................................................................................................................................................................56

7-2 Ordering Instructions.....................................................................................................................................................................................56

7-3 Mechanism and Related Parts......................................................................................................................................................................57

7-4 Current Path..................................................................................................................................................................................................58

7-5 Electrical Attachments...................................................................................................................................................................................59

7-6 Other Breaker Related Parts.........................................................................................................................................................................62

7-7 Trip Unit and Related Parts...........................................................................................................................................................................63

LIST OF FIGURES

Figure Title Page

1-1 VCP-TR Fixed Breaker 4.76/8.25kV, 600A/800A, 16kA, 60kV BIL Only Outlines..............................................................................2

1-2 All VCP-TR Fixed (except 4.76/8.25kV, 600/800A, 16kA, 60kV BIL see Figure 1-1) Outlines ................................................................3

1-3 VCP-T Drawout Breaker 4.76/8.25kV Outlines Outlines ....................................................................................................................4

1-4 VCP-T Drawout Breaker 4.76/8.25kV Outlines ..................................................................................................................................5

1-5 VCP-T Drawout Breaker 8.25/15kV Outlines .....................................................................................................................................6

1-6 VCP-T Breaker Cassette Up to 95kV BIL Outlines ............................................................................................................................7

1-7 VCP-T Breaker Cassette 60kV BIL Outlines ......................................................................................................................................8

1-8 VCP-T Breaker Cassette 60 & 95kV BIL Outlines .............................................................................................................................9

3-1 Fixed Breaker Shown Mounted on Pallet..........................................................................................................................................11

3-2 Keyed Shipping Clamp Being Removed from Fixed Breaker...........................................................................................................12

3-3 Front and Rear Views VCP-TR Fixed (4.76 and 8.25kV, 600/800A, 16kA, 60kV BIL).....................................................................13

3-4 Front and Rear Views All VCP-TR Fixed (except 4.76 and 8.25kV, 600/800A, 16kA, see Figure 3-3)............................................14

3-5 Front and Rear Views VCP-T Drawout (4.76 and 8.25kV, 600/800A, 16kA, 60kV BIL)...................................................................15

3-6 Front and Rear Views All VCP-T Drawout (except 4.76/8.25kV, 630/800A, 16kA, 60kV BIL see Figure 3-5) .................................16

3-7 Front and Rear Views Drawout Cassette (For use with 60kV BIL Drawout Breakers Only).............................................................17

3-8 Front and Rear Views Drawout Cassette (For use with all 95kV BIL Drawout Breakers).................................................................18

3-9 Typical VCP-T Front Cover...............................................................................................................................................................19

4-1 Typical Fixed Non-Automatic VCP-TR 15KV Circuit Breaker...........................................................................................................21

4-2 Bottom View of VCP-TR Circuit Breaker showing Mounting Holes ..................................................................................................21

4-3 Cassette Rejection Interlock Pin Positioning ....................................................................................................................................22

4-4 Positioning Circuit Breaker with Lifter...............................................................................................................................................23

4-5 Breaker Shoot Bolts Against Cassette..............................................................................................................................................23

4-6 Shoot Bolt Handle in Up (Locked) Position.......................................................................................................................................23

4-7 Shoot Bolt Handle Shown in Position “C” - Shoot Bolts Protrude Fully from Cradle.........................................................................24

4-8 Shoot Bolt Handle Shown in Position “B” - Shoot Bolts Protrude Partially from Cradle....................................................................24

4-9 Shoot Bolt Handle Shown in Position “A” - Shoot Bolts Retracted Fully Inside Cradle.....................................................................24

4-10 Circuit Breaker Umbilical Cord Shown Connected to Breaker Prior to Breaker Insertion.................................................................25

4-11 Secondary Connector Viewed from Rear of Breaker........................................................................................................................25

4-12 Cassette Secondary Connector and Interlock Lever ........................................................................................................................25

4-13 Drawout Cassette with Primary Safety Shutters Open Showing Fixed Primary Stabs.....................................................................26

4-14 Circuit Breaker Shown in Levered Out (DISCONNECT) Position - Correct for Breaker Positioning................................................26

4-15 Circuit Breaker Shown in Levered In (CONNECT) Position - Incorrect for Breaker Positioning.......................................................26

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4-16 Cradle Mounted Levering Mechanism..............................................................................................................................................27

4-17 Levering Circuit Breaker ...................................................................................................................................................................27

4-18 Circuit Breaker Connected as Indicated by Fully Connected Position Label....................................................................................27

4-19 Circuit Breaker Shown in CONNECT Position with Secondary Connections Made.........................................................................28

4-20 Primary Safety Shutters Shown in Open Position with Fixed Primary Stabs Exposed.....................................................................28

4-21 Padlocking Device on Side of Cassette............................................................................................................................................28

5-1 Rigid Frame Construction ................................................................................................................................................................29

5-2 VCP-TR Fixed Non-automatic Circuit Breaker (Front Cover Removed)...........................................................................................30

5-3 VCP-T Drawout Circuit Breaker (Front Cover Removed).................................................................................................................31

5-4 Fixed 50 VCP-TR Interrupter Assembly (600/800A, 16kA shown)...................................................................................................32

5-5 Drawout 150 VCP-T Interrupter Assemblies (1200A, 25kA shown) .................................................................................................32

5-6 Breaker Closing Springs Being Manually Charged...........................................................................................................................33

5-7 Motor Operator Shown Installed ......................................................................................................................................................34

5-8 Typical Cover Mounted Key Interlock ..............................................................................................................................................34

5-9 Typical Mechanical Cable Interlock ..................................................................................................................................................35

5-10 VCP-T and VCP-TR Non Trip Unit Connection Diagram..................................................................................................................36

5-11 VCP-T and VCP-TR with 520V Trip Unit Connection Diagram.........................................................................................................37

5-12 VCP-T and VCP-TR with 1150V Trip Unit Connection Diagram.......................................................................................................38

5-13 VCP-T Drawout Umbilical Cord and Connector Wiring Diagram......................................................................................................39

5-14 Secondary Protective Hood..............................................................................................................................................................35

5-15 Top View Secondary Connectors ....................................................................................................................................................40

5-16 Secondary Male Connector with Female Pins..................................................................................................................................40

5-17 Optional Terminal Block ...................................................................................................................................................................40

5-18 AMP Secondary Wiring Removal Tool (AMP#305183) (C-H#MAMPSEC) ......................................................................................40

5-19 Digitrip RMS 1150Vi Programmable Trip Unit Installed in T-VAC Circuit Breaker............................................................................41

5-20 Hand Held Tester..............................................................................................................................................................................41

5-21 Through-The-Window Electrical Accessories...................................................................................................................................43

5-22 Shunt Trip Device .............................................................................................................................................................................43

5-23 Spring Release Device .....................................................................................................................................................................43

5-24 Undervoltage Release Device ..........................................................................................................................................................44

5-25 Rugged Motor Operator....................................................................................................................................................................45

5-26 Auxiliary Switch ................................................................................................................................................................................45

5-27 Pushbutton Cover Mounted .............................................................................................................................................................46

5-28 Door Escutcheon and Gasket...........................................................................................................................................................46

6-1 Contact Erosion Mark Visible on Stem ............................................................................................................................................50

6-2 Contact Wipe Inspection Area .........................................................................................................................................................50

6-3 Satisfactory Contact Wipe Condition with Breaker Closed .............................................................................................................50

6-4 Unsatisfactory Contact Wipe Condition with Breaker Closed .........................................................................................................50

6-5 Circuit Breaker Lubrication ...............................................................................................................................................................54

6-6 Drawout Cassette Lubrication ..........................................................................................................................................................55

LIST OF TABLES

Table Title Page

1.1 VCP-T and VCP-TR Ratings ..............................................................................................................................................................1

3.1 Circuit Breaker and Cassette Weights..............................................................................................................................................12

4.1 Cassette Rejection Interlock Pin Locations.......................................................................................................................................21

5.1 Digitrip Trip Units .............................................................................................................................................................................41

5.2 Current Sensors and Matching Rating Plugs ...................................................................................................................................42

5.3 Shunt Trip Ratings ...........................................................................................................................................................................44

5.4 Spring Release Ratings ....................................................................................................................................................................44

5.5 Undervoltage Release Ratings .........................................................................................................................................................44

5.6 Motor Operator Ratings ....................................................................................................................................................................45

5.7 Auxiliary Switch Contacts Interrupting Capacities.............................................................................................................................45

6.1 Inspection and Maintenance Procedures .........................................................................................................................................48

6.2 Test Voltage......................................................................................................................................................................................49

6.3 Typical Resistance Measurements...................................................................................................................................................51

6.4 Troubleshooting Guide......................................................................................................................................................................52

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SECTION 1: INTRODUCTION

The purpose of this book is to provide instructions for unpacking, storage, use, operation and maintenance of VCP-T drawout type and VCP-TR fixed type Vacuum Circuit Breakers. VCP-T and VCP-TR are compact vac- uum interrupting elements designed for applications such as: mine power centers, portable power substa- tions, fixed breaker or drawout switchgear and portable generators, all without compromising metal clad expec- tations. VCP-T and VCP-TR breakers were specifically designed to provide proven reliable performance in a small package. The circuit breakers are available in volt- age classes of 4.76, 8.25 and 15.0 kV. They are tested in accordance with ANSI C37.04 and C37.09 (Table

1.1).

1-1 T-VAC and T-VACR Vacuum Breaker Ratings

Refer to Table 1.1

The circuit breaker's nameplate provides complete rat- ing information. Reliable control and protection for medi- um voltage equipment and circuits are achieved through the use of VCP-T and VCP-TR Vacuum Breakers.

SATISFACTORY PERFORMANCE OF THESE BREAKERS IS CONTINGENT UPON PROPER APPLI- CATION, CORRECT INSTALLATION AND ADE- QUATE MAINTENANCE. THIS INSTRUCTION BOOK MUST BE CAREFULLY READ AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE FOR LONG USEFUL LIFE OF THE CIRCUIT BREAKERS.

VCP-T and VCP-TR CIRCUIT BREAKERS ARE PRO- TECTIVE DEVICES, AS SUCH, THEY ARE MAXIMUM RATED DEVICES. THEREFORE, THEY SHOULD NOT UNDER ANY CIRCUMSTANCES BE APPLIED OUT- SIDE THEIR NAMEPLATE RATINGS.

WARNING

Table 1.1 VCP-T and VCP-TR Ratings (ANSI C37.04 and C37.09)

Identification Rated Values

Circuit

Breaker

Type

50 VCP-T16

and

50 VCP-TR16

50 VCP-T20

and

50 VCP-TR20

50 VCP-T25

and

50 VCP-TR25

75 VCP-T16

and

75 VCP-TR16

75 VCP-T20

and

75 VCP-TR20

75 VCP-T25

and

75 VCP-TR25

150 VCP-T16

and

150 VCP-TR16

150 VCP-T20

and

150 VCP-TR20

150 VCP-T25

and

150 VCP-TR25

Voltage

Class

kV rms

4.76

8.25

Short Circuit

➂

Breaking

Current

kA rms

Short Circuit

Making Current

kA Peak

Mechanical

Endurance

C - O

Operations

20000 20000 10000 10000

10000 10000 10000 10000

20000 20000 10000 10000

10000 10000 10000 10000

Continuous

Current

Amperes

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

600

800 1200 1600

➁

Power

Frequency

kV rms

Impulse

Withstand

kV Peak

➀

Insulation Level

➀

Use 15kV Breaker and Cassette when 95kV Impulse Withstand required ➁1600A VCP-T Breaker not available

➂

Also 2 Second Short Time Current Rating

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Figure 1-1 VCP-TR Fixed Breaker 4.76/8.25kV, 600A/800A, 16kA, 60kV BIL Only Outlines in inches [mm]

1-2 Types VCP-T and VCP-TR Outlines and Dimensions (Circuit Breakers and Drawout Cassettes)

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Figure 1-2 All VCP-TR Fixed (except 4.76/8.25kV, 600/800A, 16kA, 60kV BIL see Figure 1-1) Outlines in inches [mm]

Vertical

Barriers (2)

95kV BIL Only

Horizontal

Barriers (3)

95kV BIL

Only

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Figure 1-3 VCP-T Drawout Breaker 4.76/8.25kV Outlines in inches [mm] (Refer to above Applicable Ratings Table)

Applicable Ratings

kV 16kA

4.76/8.25kV 600A

60kV BIL 800A

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Figure 1-4 VCP-T Drawout Breaker 4.76/8.25kV Outlines in inches [mm] (Refer to above Applicable Ratings Table)

Applicable Ratings

kV 16kA 20kA 25kA

4.76/8.25kV NA 600A 600A

60kV BIL NA 800A 800A

1200A 1200A 1200A

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Figure 1-5 VCP-T Drawout Breaker 8.25/15kV Outlines in inches [mm] (Refer to above Applicable Ratings Table)

Applicable Ratings

kV 16kA 20kA 25kA

8.25/15kV 600A 600A 600A

All 95kV BIL 800A 800A 800A

1200A 1200A 1200A

1200A

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Figure 1-6 VCP-T Breaker Cassette Up to 95kV BIL Outlines in inches [mm] (Additional Details Figures 1-7 &1-8)

Breaker Shown in Fully

Connected Position

Breaker Shown in

Disconnected Position

Barrier Shown not

Applicable to 60kV BIL

Breaker

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Figure 1-7 VCP-T Breaker Cassette 60kV BIL Outlines in inches [mm] (Additional Details Figure 1-6)

Cell/Breaker Rejection

Pin Locations

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Figure 1-8 VCP-T Breaker Cassette 95kV BIL Outlines in inches [mm] (Additional Details Figure 1-6)

75 & 95kV BIL

95kV BIL

Only

Multi-Layer

Glass Polyester

insulating

B-Plane Insert

Dimensional View

Cell/Breaker

Rejection Pin

Locations

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SECTION 2: SAFE PRACTICES

The circuit breakers are equipped with high speed, high energy operating mechanisms. They are designed with built-in safety interlocks to provide for safe operation. In addition, other optional interlocks are available depend- ing upon the application. Refer to Section 5 for addition- al interlock information. It is the customers’ responsibility to insure that appropriate interfaces with the breakers are provided and tests conducted to adequately prove proper installation and functioning.

TO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLATION, OPERATION, AND MAINTENANCE OF THESE BREAKERS, THE FOLLOWING PRAC- TICES MUST BE FOLLOWED:

• Only qualified persons, as defined in the Local Electrical Codes, who are familiar with the installation and maintenance of medium voltage circuits and equipment, should be permitted to work on these breakers.

• Read these instructions carefully before attempting any installation, operation or maintenance of these breakers.

• Always remove drawout type breakers from their enclosure before performing any maintenance. Failure to do so could result in electrical shock lead-

ing to death, severe personal injury and/or property damage.

• Always make sure that primary and secondary power are disconnected from a fixed breaker before performing any maintenance. Failure to do so could result in electrical shock leading to death, severe personal injury and/or property damage.

• Do not work on a closed breaker or a breaker with closing springs charged. The closing springs should be discharged and the main contacts open before working on the breaker. Failure to do so could result in cutting or crushing injuries.

• Do not use a circuit breaker by itself as the sole means of isolating a high voltage circuit. As appropriate, use an isolation means and follow all lock-out and tagging rules of the Local Electrical Codes and any and all applicable codes, regulations and work rules.

• Always ensure that drawout circuit breakers are in one of their designed cell positions, such as Connect, Test/Disconnect or Remove. A circuit breaker permitted to remain in an intermediate posi- tion could result in control circuits being improperly connected resulting in electrical failures.

• Breakers are equipped with safety interlocks. Do Not defeat them. This may result in death, bodi- ly injury and/or equipment damage.

• Do not work on a circuit breaker while suspended from a lifting means. Maintenance work should be performed on a properly supported cart or table.

WARNING

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and understand the directions. Unpacking a fixed circuit breaker is described in the next paragragh in detail. Upacking a drawout circuit breaker is also simple to accomplish and is not described here in detail. Just pro- ceed by carefully removing all packing material used for protection during shipment and the fasteners used to secure the drawout circuit breaker to its shipping pallet.

When ready to inspect and install the circuit breaker, carefully remove any banding straps and lift off the card- board box. Remove any additional packing material and internally packed documentation. The circuit breaker is mounted to a wooden shipping pallet. A keyed metal clamp is used on each side of the circuit breaker to hold it to the wooden pallet (Figure 3-1). Remove the screws from the wooden pallet on each side and lift up and out on the keyed metal clamps for removal (Figure 3-2). The circuit breaker is now ready to be removed from its ship- ping pallet. Save all shipping hardware and packaging material for any future shipments of the circuit breaker.

3-2.2 LIFTING

To closely examine, install or just become familiar with the circuit breaker, carefully lift and place the circuit breaker on a solid work surface capable of handling the circuit breaker's weight (Table 3.1). The circuit breaker is provided with two integrally mounted lifting hooks for use with a standard sling (Figure 3-1). Once the sling is properly placed, the breaker can be carefully lifted and moved using an overhead lifter or portable floor lifter. Every effort should be made to minimize circuit breaker swing or tilt.

Figure 3-1 Fixed Breaker Shown Mounted on Pallet

SECTION 3: RECEIVING, HANDLING AND STORAGE

VCP-T and VCP-TR circuit breakers are subjected to complete factory production tests and inspection before being packed. They are shipped in packages designed to provide maximum protection to the equipment during shipment and storage and at the same time to provide convenient handling.

3-1 RECEIVING

Until the breaker is ready for use, it is best NOT to remove it from its container. If the breaker is to be placed in storage, maximum protection can be obtained by keeping it packed as shipped.

Upon receipt of the equipment, inspect the containers for any signs of damage from rough handling and/or external damage incurred during the transportation phase. Record any observed damage for reporting to the transportation carrier and Cutler-Hammer. All reports should be as specific as possible and include the order number and other applicable nameplate infor- mation.

Every effort is made to ensure that circuit breakers arrive at their destination undamaged and ready for installation. Care should be exercised, however, to pro- tect the breakers from impact at all times. Do not remove protective packaging until the circuit breakers are ready for inspection, testing and/or installation.

3-2 HANDLING

DO NOT USE ANY LIFTING DEVICE AS A PLAT- FORM FOR PERFORMING MAINTENANCE, REPAIR OR ADJUSTMENT OF THE BREAKER, FOR OPEN- ING OR CLOSING THE CONTACTS OR CHARGING THE SPRINGS. THE BREAKER MAY SLIP OR FALL CAUSING SEVERE PERSONAL INJURY. ALWAYS PERFORM MAINTENANCE, REPAIR AND ADJUST- MENTS ON A WORKBENCH CAPABLE OF SUP- PORTING THE BREAKER.

Shipping containers are designed to be handled either by use of a sufficiently strong rope sling and overhead lifting device or by a fork lift truck. If containers must be skidded for any distance, it is preferable to use roller conveyors or individual pipe rollers.

3-2.1 UNPACKING

Before beginning to unpack new circuit breakers, read

WARNING

Lifting Hooks

Keyed Shipping Clamp

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THE CUSTOMER SHOULD READ AND UNDER- STAND THE MATERIAL PRESENTED AND ANY WARNINGS OR CAUTIONS OFFERED IN THE INSTRUCTION BOOK BEFORE ANY ATTEMPT IS MADE TO INTERFACE WITH THIS CIRCUIT BREAK- ER.

IT IS IMPERATIVE THAT ALL APPLICABLE ANSI STANDARDS BE COMPLIED WITH IN EVERY RESPECT AND THAT NO COMPROMISES ARE MADE WITH RESPECT TO THE ANSI GUIDELINES OR INTENT.

UNDER NO CIRCUMSTANCES SHOULD ALTER- ATIONS BE MADE TO CUTLER-HAMMER SUPPLIED VCP-T VCP-TR CIRCUIT BREAKERS UNLESS THE ALTERATION IS SPECIFICALLY ADDRESSED IN AND PERMITTED BY THIS INSTRUCTION BOOK.

3-3 STORAGE

If the circuit breaker is to be placed in storage, maxi- mum protection can be obtained by keeping it packed as shipped. Before placing it in storage, checks should be made to make sure that the breaker is free from ship-

ping damage and is in satisfactory operating condition. Outdoor storage is NOT recommended. If unavoidable,

the outdoor location must be well drained and a tempo- rary 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 recommend- ed 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.

WARNING

Figure 3-2 Keyed Shipping Clamp Being Removed From Fixed Breaker

3-4 TYPICAL BREAKER AND CASSETTE WEIGHTS

Table 3.1 Circuit Breaker and Cassette Weights

Circuit Current Approximate Weight Breaker Rating (kg) Type (Amps) Fixed Drawout Cassette

50 VCP-TR16

and

50 VCP-T16

50 VCP-TR20

and

50 VCP-T20

50 VCP-TR25

and

50 VCP-T25

75 VCP-TR16

and

75 VCP-T16

75 VCP-TR20

and

75 VCP-T20

75 VCP-TR25

and

75 VCP-T25

150 VCP-TR16

and

150 VCP-T16

150 VCP-TR20

and

150 VCP-T20

150 VCP-TR25

and

150 VCP-T25

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

600

800 1200 1600

153 153 155 157

159 159 161 163

166 166 168 170

155 155 157 159

161 161 161 163

166 166 168 170

155 155 157 159

161 161 163 166

168 168 170 172

232 232 234

237 237 239

243 243 245

232 232 234

239 239 241

245 245 247

234 234 237

239 239 241

245 245 247

157 157 157 NA

161 161 161 NA

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Figure 3-3 Front and Rear Views VCP-TR Fixed (4.76 and 8.25kV, 600/800A, 16kA, 60kV BIL)

Integral Lifting Hook Pole Unit Molding 11 Gauge Grounded (Earth) Steel Barrier Front Cover (Figure 3-9 for details) Trip Unit Location (Non-Automatic Breaker Shown)

Secondary Disconnect with Protective Hood Vacuum Interrupter Primary Conductor Interface Drive Insulator with Internal Contact Loading Spring (Wipe Spring) Vacuum Interrupter Movable Stem Rear Customer Mounting Holes Customer Ground (Earth) Connection

2 3 4

7 8

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Figure 3-4 Front and Rear Views All VCP-TR Fixed (except 4.76 and 8.25kV, 600/800A, 16kA, see Figure 3-3)

Horizontal Phase Barrier (95kV BIL Only) Vertical Phase Barrier (95kV BILOnly) Integral Lifting Hook Front Cover (Figure 3-9 for details) 11 Gauge Grounded (Earth) Steel Barrier Pole Unit Molding Trip Unit Location (Non-Automatic Breaker Shown)

4 5

10 11

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Figure 3-5 Front and Rear Views VCP-T Drawout (4.76 and 8.25kV, 600/800A, 16kA, 60kV BIL)

Integral Lifting Hook Front Cover (Figure 3-9 for details) 11 Gauge Grounded (Earth) Steel Barrier Pole Unit Molding Trip Unit Secondary Disconnect Protective Hood (Umbilical Cord not shown)

4 5

Vacuum Interrupter Primary Disconnect Finger Cluster Drive Insulator with Internal Contact Loading Spring (Wipe Spring) Vacuum Interrupter Movable Stem Cradle with Levering Mechanism Shoot Bolt Handle Shoot Bolt Push/Pull Handle Racking Screw Lock Plate Levering Drive Nut Integral Wheel Shutter Operator

11 12

15 16

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Figure 3-6 Front and Rear Views All VCP-T Drawout (except 4.76/8.25kV, 600/800A, 16kA, 60kV BIL see Figure 3-5)

Secondary Disconnect Protective Hood (Umbilical Cord not shown) Vacuum Interrupter Primary Disconnect Finger Cluster (1200A Cluster Shown) Drive Insulator with Internal Contact Loading Spring (Wipe Spring) Vacuum Interrupter Movable Stem Cradle with Levering Mechanism Shoot Bolt Handle Shoot Bolt Push/Pull Handle Racking Screw Lock Plate Levering Drive Nut Integral Wheel Shutter Operator Primary Disconnect Cup (95kV BIL Only)

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Figure 3-7 Front and Rear Views Drawout Cassette (For use with 60kV BIL Drawout Breakers Only )

Automatic Primary Safety Shutters (Closed Position) Cradle Stop/Hook Stop Mounting Holes Rejection Interlock Pins Interlock Lever (Secondary Contact) Grounding (Earthing) Bar Position Switches

5 6

Breaker Position and Safety Shutter Padlocking Mechanism Primary Connection Pad Primary Insulating Tube (Spout) Safety Shutter Operating Arm Secondary Umbilical Cord Connector Anti-tilt Channel Customer Earth (Ground) Connection

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Figure 3-8 Front and Rear Views Drawout Cassette (For use with all 95kV BIL Drawout Breakers)

Automatic Primary Safety Shutters (Closed Position) Cradle Stop/Hook Stop Mounting Holes Rejection Interlock Pins Interlock Lever (Secondary Contact) Grounding (Earthing) Bar Position Switches

Anti-tilt Channel Breaker Position and Safety Shutter Padlocking Mechanism Primary Connection Pad Primary Insulating Tube (Spout) Safety Shutter Operating Arm Secondary Umbilical Cord Connector Customer Earth (Ground) Connection

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Figure 3-9 Typical VCP-T Front Cover

Accessory Window (3) Contact Status (Open-Close) Spring Status (Charged-Discharged) Manual “OFF” Button Manual “ON” Button Manual Charging Handle Operations Counter Nameplate

OPEN

PUSH OFF

DISCHARGED

PUSH ON

CLOSED

CHARGED

(Red)

(Green)

(Yellow)

(White)

(Green)

(Red)

Trip Unit (Optional) Rating Plug Trip Unit Test Port Trip Unit Cover with Two Mounting Screws (Screws Accept Customer Supplied Lead Security Seals) Front Cover Mounting Hardware Drawout Cradle (Drawout Circuit Breaker Only - See Figures (3-5 & 3-6)

4 5

7 8

10 11 12

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the barriers used with specific breakers. Any other barriers required to meet ANSI requirements must be supplied by the customer. They must be constructed of an appropriate insulating material, such as thick high strength, track resis- tant glassmat polyester or polycarbonate of appropriate thickness.

4-4 FRONT COVER

The front cover of VCP-T and VCP-TR circuit breakers is designed such that the customer can choose to have a closed door or open door design. If a closed door design is selected, an appropriately sized door cutout can be provid- ed by the customer to permit access to all front mounted circuit breaker controls and devices (Figure 3-9).

4-5 INSTALLING FIXED CIRCUIT BREAKER

The VCP-TR fixed type circuit breaker differs from the VCP-T drawout circuit breaker in that it has no levering device, primary disconnects and secondary umbilical dis- connect (Figure 4-1). In addition, a VCP-TR fixed circuit breaker does not have a standard feature to hold the breaker in a trip free position. To ensure the proper sequence of operation between two or more circuit break- ers, an optional key interlock and/or optional cable interlock can be used.

4-5.1 FIXED MECHANICAL INTERFACES

The customer is responsible for providing all required mechanical interfaces to insure that the VCP-TR fixed cir- cuit breaker is properly installed and applied in a fixed con- figuration. This responsibility includes but is not limited to the following:

1. The circuit breaker must be securely mounted in an installation capable of supporting the circuit breaker’s weight. Mounting holes are provided in the bottom pan of the circuit breaker for use with appropriate mounting hard- ware (Figures 1-1, 1-2, 1-3, and 4-2).

2. Appropriately sized, secured, and braced primary con- nections must be provided, whether the connections take the form of cable or bus bar. Circuit breaker primary termi- nals have holes for making bolted horizontal primary bus connections. Refer to Figures 1-1 through 1-3 for primary connection details, such as primary spacing and hole pat- terns.

4-5.2 FIXED ELECTRICAL INTERFACES

Secondary electrical connections can be made through a standard secondary disconnect block or an optional screw type terminal block. Both secondary connection devices are mounted at the top, front of the circuit breaker. Secondary contacts are dedicated and identified. Refer to Figures 5-10 to 5-13 for secondary connection details.

SECTION 4: INST ALLATION AND WIRING

Refer to the circuit breaker weights in Table 3.1 to ensure that any table used for inspections is capable of supporting the circuit breaker.

4-1 INITIAL INSPECTION

Before attempting to use or put a circuit breaker into ser- vice, examine it for loose or obviously damaged parts. In addition, compare the circuit breaker nameplate with asso- ciated drawings, shipping papers and ordering information for compatibility. A circuit breaker should also be operated manually. To check the manual operation of a circuit break- er, follow the operational procedures outlined in Section 5.

For fixed breaker applications, an electrical operations check should be performed after the breaker is appropri- ately mounted, secondary wiring completed, and any appropriate interphase barriers installed. To check the electrical operation of a circuit breaker, follow the opera- tional procedures outlined in Section 5.

For drawout breaker applications, an electrical operations check should be made with the breaker in the TEST posi- tion or by using a “Test Cable” with the breaker out of its cell. Refer to paragraphs later in this section covering “Circuit Breaker Positioning” and “Drawout Electrical Interfaces”. Once familiar with this information, refer to Section 5 for electrical operation procedures.

4-2 ELECTRICAL CLEARANCES

It is the responsibility of the customer to insure that the proper electrical clearances are maintained on the circuit breaker, in the assembly structure, and between the circuit breaker and its assembly structure. These required electri- cal clearances must be in keeping with the appropriate ANSI standards and the specific BIL application level. The BIL rating associated with a particular circuit breaker is clearly indicated on its nameplate located on the front cover. Also refer to Table 1.1 for circuit breaker rating details.

4-3 INTERPHASE BARRIERS

ANSI requires specific dielectric performance. It is the cus- tomer's responsibility to insure that all required interphase barriers are in place on the circuit breaker before the circuit breaker is placed in service. Appropriately sized and con- structed barriers are supplied with the circuit breaker. The number and types (vertical or horizontal) of barriers used with fixed and drawout circuit breakers depends primarily on the circuit breaker rating. Refer to Figures 1-1 to 1-9 for

NOTICE

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A 5a, 5b auxiliary switch with double break, wipe type con- tacts is provided as standard for customer use.

4-6 INSTALLING DRAWOUT CIRCUIT BREAKER

VCP-T circuit breakers are installed in structures equipped for drawout circuit breakers. A bolted-in drawout cassette supports the circuit breaker (Figures 3-7 and 3-8).

4-6.1 DRAWOUT MECHANICAL INTERFACES

Each drawout circuit breaker is supplied with the following interlocks to insure safe and proper operation.

Rejection Interlocks

Rejection interlocks are steel pins mounted at the bottom of the drawout circuit breaker and in the base tray (floor) of the cassette to prevent the insertion of a circuit breaker into a structure with a higher power rating. The pins are factory mounted in the circuit breaker. It is the customer’s

responsibility to correctly mount the pins in the dra- wout cassette.

DO NOT DISABLE REJECTION INTERLOCKS. DOING SO AND USING A CIRCUIT BREAKER IN A STRUC- TURE WITH A HIGHER POWER RATING COULD RESULT IN AN ELECTRICAL FAULT WHICH COULD RESULT IN DEATH, BODILY INJURY AND/OR EQUIP- MENT DAMAGE.

As the circuit breaker is pushed into the structure, the mat- ing pins on the bottom of the circuit breaker move past a set of corresponding pins in the cassette, if the circuit breaker and cassette are compatible. If there is a mis- match between the circuit breaker and the cassette, the rejection pins prevent the circuit breaker from being fully inserted into the cassette.

Before attempting to position the circuit breaker for inser- tion into its cassette, compare the positioning of the rejec- tion interlock pins in the cassette in keeping with Table 4.1 and Figure 4-3 and ratings information supplied on the cir- cuit breaker’s nameplate. Proceed if the circuit breaker and cassette are compatible. If they are not compatible, do not attempt to insert the circuit breaker into the cassette. Contact Cutler-Hammer for assistance if required.

Figure 4-1 Typical Fixed Non-Automatic VCP-TR 15KV Circuit Breaker

Figure 4-2 Bottom View of VCP-TR Circuit Breaker showing Mounting Holes

WARNING

Table 4.1 Cassette Rejection Interlock Pin Locations

Pin Locations

①

Cassette Used For

1 2 3 4 5 6 7 8 9

Short Circuit Rating (kA)

16 20 25

Current Rating (A)

600 800

1200

Rated Voltage (kV)

4.76

8.25

15.0

Type

Dummy Element

Circuit Breaker

0 0 0 0 0 1 0 1 1

0 0 0 0 1 0 1 1 0

0 0 0 1 1 1

0 1

①

0 = no pin required, 1 = pin required

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NEVER DISABLE OR DEFEAT ANY INTERLOCKS. HAZARDOUS VOLTAGES WILL CAUSE DEATH, SEVERE PERSONAL INJURY OR PROPERTY DAM- AGE.

Secondary Control Interlock

This interlock insures that the breaker cannot be levered into the CONNECTED position if the cassette end connec- tor of the secondary umbilical cord is not properly engaged with its cassette mounted connector. This interlock inter- faces with the cradle mounted shoot bolt interlock which will prevent secondary disconnection with the breaker con- nected .

Levering Interlock

The levering crank can only be engaged when the breaker is open and the horizontal shoot bolts located in the break- er cradle are properly engaged (fully extended). The break- er contacts will not close manually or electrically while the levering crank is engaged. However, the closing spring may discharge. Shoot bolt details are provided later.

Anti-Close Interlock

This interlock prevents releasing the closing springs electri- cally or manually if the breaker is already closed.

Anti-Latch Interlock

This interlock prevents the breaker contacts from being closed between the CONNECTED and TEST positions. However, the closing spring may discharge.

Shutter Drive Interlock

The metallic primary safety shutters are independently

operated permitting them to be locked in the closed posi- tion for safety when the breaker is disconnected or removed.or the open position for servicing the fixed primary disconnects. The locking system is not automatically dis- abled when the breaker is being connected. Consequently, the lock must be removed prior to racking or damage to the shutter drive will result.

Handle Interlock

Prevents racking in or removing a circuit breaker which is closed.

Hook Interlock

Prevents a circuit breaker which is “racked in” from being inserted into a cassette. Refer to the CAUTION below.

4-6.2 CIRCUIT BREAKER POSITIONING

The T-VAC drawout circuit breaker has three normal posi- tions within the cassette:

• DISCONNECT

• TEST

• CONNECT In the DISCONNECT position, the circuit breaker

is completely inside the cassette in the forward most position. The breaker end of the connector of the secondary umbilical cord is made but the cassette end of the connector of the umbilical cord is not made. The shoot bolts cannot be fully engaged. Primary connect- ions are not made.

In the TEST position, the circuit breaker is also com- pletely inside the cassette in the forward most position. In this position, however, the secondary connections are made on both the breaker end and the cassette end. The shoot bolts are fully engaged and the interlock lever must be locked. The Primary connections are not made.

In the CONNECT position, the circuit breaker is in the cas- sette as far as possible. The primary connections are fully made and secondary connections remain made and locked in position.

MAKE SURE THE CIRCUIT BREAKER ELEMENT IS IN THE FULLY RACKED OUT POSITION IN THE CRADLE BEFORE ANY ATTEMPT IS MADE TO PUT THE CIR- CUIT BREAKER INTO THE CASSETTE. FAILURE TO DO SO COULD RESULT IN EQUIPMENT DAMAGE OR BODILY INJURY DURING LIFTING AND HANDLING. REFER TO PARAGRAPH 4-6.4 FOR CIRCUIT BREAK- ER LEVERING DETAILS (FIGURES 4-14 AND 4-15).

Figure 4-3 Cassette Rejection Interlock Pin Positioning

Cassette Base Tray Front

NOTE: Rejection pin nuts located on bottom side of the tray should be torqued to 8-10 foot-pounds

WARNING

CAUTION

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A number of labels have been applied to the circuit breaker and its cassette to facilitate the connection and disconnection of the secondary umbilical cord, inserting the circuit breaker, levering the circuit break- er to the CONNECT position and removal of the circuit breaker. These operations are also described in detail in this instruction book. Become familiar with the labels as they not only provide assistance initially, but provide a good quick reference at a later date when the instruction book may not be readily available.

With secondary connections to the circuit breaker only made as supplied from the factory, carfully position the cir-

cuit breaker directly in front of its cassette using appropri- ate slings and an overhead lifter as described earlier in paragragraph 3-2.2 (Figure 4-4). The cradle portion (bot- tom portion) of the drawout circuit breaker is provided with integrally mounted wheels for rolling on the floor of the cas- sette in a guided manner.

Position the circuit breaker so that the two rear wheels begin to roll on the cassette’s floor and then firmly push the circuit breaker into the cassette until the horizontal shoot bolts on either side of the breaker cradle contact the front of the cassette (Figure 4-5). Care should be taken not to

bind the secondary umbilical cord between the circuit breaker and cassette as the circuit breaker is pushed into its cassette. At this point the breaker cannot be

inserted any further until the shoot bolts are retracted using the spring loaded shoot bolt handle on the lower left side of the cradle (Figure 4-6) . The lifting slings can now be removed from the circuit breaker.

The shoot bolt handle as shown in Figure 4-6 has three labeled positions

Position “A” - Full down position causing the shoot bolts to retract fully inside the breaker cradle (not engaged)

Position “B” - Partially up position causing the shoot bolts to only protrude partially (partially engaged).

Position “C” - Full up position which causes the shoot bolts to protrude completely (fully engaged).

These three handle positions are important and play a critical role while connecting and disconnecting the secondary umbilical cord to and from the drawout cas- sette as well as during insertion and removal of the cir- cuit breaker from the cassette.

Figure 4-4 Positioning Circuit Breaker With Lifter

Figure 4-5 Breaker Shoot Bolts Against Cassette

Shoot Bolt

Figure 4-6 Shoot Bolt Handle in Up (Locked) Position

Shoot Bolt

Handle in

Position “C”

Protruding

Left Side

Shoot Bolt

NOTICE

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The circuit breaker and cassette are designed such that the lower portion of the circuit breaker (the cradle) is held in the DISCONNECT/TEST position by two shoot bolts which fit into the rectangular slots of interlock plates located on each side of the cassette’s frame. The shoot bolt handle can be in either Position “B” (partially engaged) or Position “A” (not engaged) for the breaker to be in the DISCON-

NECT position. The shoot bolt handle must, however, be in Position “C” (fully engaged) to be the TEST position and before the circuit breaker can be levered to the CONNECT- ED position as dictated by the design’s mechanical inter- locking system. Levering of the circuit breaker is discussed in paragraph 4-6.4. The three shoot bolt handle positions (A, B and C) are shown Figures 4-7, 4-8 and 4-9).

Retract the shoot bolts by pushing the shoot bolt handle down to Position “A” (Figure 4-9) and push the circuit breaker the rest of the way into the cassette against the stop. At this point, the front of the cradle will be flush with the front of the cassette. Rotate the shoot bolt handle up to Position “B” (Figure 4-8) permitting the shoot bolts to pro- trude partially into the rectangular slots of the interlock plates on each side of the cassette. The circuit breaker is now held in the DISCONNECT position.

For the circuit breaker to be in the TEST position, the sec- ondary connection must be made between the breaker and the cassette. Refer to paragraph 4-6.3 for details on mak- ing secondary connections to the cassette .

Once the secondary connection is made and the shoot bolt handle is in Position “C” (fully engaged), the circuit breaker can be levered from the TEST position to the CONNECT- ED position. For the circuit breaker to reach its CON- NECTED position, it must be manually levered to that posi- tion as described in paragraph 4-6.4. When the circuit breaker is levered to the CONNECTED position, the lower cradle portion remains locked in the position dictated by the shoot bolts. The upper portion of the circuit breaker moves into the structure to the CONNECTED position.

4-6.3 DRAWOUT ELECTRICAL INTERFACES

Circuit Breaker Secondary Connections

Secondary connections are made through the use of an umbilical cord (Figure 4-10). The secondary connector on the breaker end of the cord is connected to its compatible secondary connector located under a protective hood on the upper front portion of the circuit breaker (Figure 4-11).

This connection is already made when the breaker is shipped from the factory. If there is a need to make this

connection in the field, it can be simply accomplished as follows: Connect the breaker side connector of the umbili- cal cord to the circuit breaker’s connector. Once the push-in connection is made, the breaker end of the umbili- cal cord is secured in place with two self threading screws that screw into two mounting holes in the top of the break- er’s secondary mounting hardware. With the breaker end of the umbilical cord securely in place, take the cassette end of the umbilical cord and carefully lay it over the front of the circuit breaker in preparation for movement of the breaker into the cassette (Figure 4-10). At this point, the circuit breaker is ready to be inserted into its cassette. Refer to paragraph 4-6.2 for details on positioning of the circuit breaker for insertion into its cassette.

Figure 4-9 Shoot Bolt Handle Shown in Position “A” - Shoot Bolts Retracted Fully Inside Cradle

Figure 4-8 Shoot Bolt Handle Shown in Position “B” - Shoot Bolts Protrude Partially From Cradle

Figure 4-7 Shoot Bolt Handle Shown in Position “C” - Shoot Bolts Protrude Fully From Cradle

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Cassette Secondary Connections

Once the circuit breaker is in position in the cassette as described in paragraph 4-6.2 with the breaker end of the umbilical cord properly connected to the breaker, the cas- sette end connector of the umbilical cord can be connect- ed. Once this connection is made, the circuit breaker will be in its operable TEST position.

To make the cassette’s secondary connection, make sure the shoot bolt handle is in Position “B” (Figure 4-8). With the interlock lever in Location “2” (back and to left) (Figure 4-12), take the unconnected cassette end connector of the umbilical cord (making certain that the connector is orient- ed correctly before insertion) and firmly insert it into its compatible

Figure 4-11 Secondary Connector Viewed From Rear of Breaker

Mounting Screw

Protective Hood

Figure 4-10 Secondary Umbilical Cord Shown Connected to Breaker Prior to Breaker Insertion

secondary connector at Location “1” on the top front underside of the cassette (Figure 4-12). Make certain

that the connector on the umbilical cord is completely inserted into the cassette’s connector. Hold the con-

nector firmly in place and flush against the underside of the cassette on all sides with one hand while pulling the inter- lock lever from Location “2” to Location “3” (right and for- ward in keyed slot) (Figure 4-12). This will lock the sec- ondary connector of the umbilical cord and the cassette’s secondary connector together.

The shoot bolt handle can now be rotated to its full up posi- tion, Position “C” (Figure 4-7). In this position the shoot bolts engage the cassette’s interlock plates completely and the interlock lever cannot be moved back to Location “2”. Since the interlock lever cannot be moved, the umbilical cord cannot be disconnected from the cas- sette. The circuit breaker is now in the TEST position and ready to be tested mechanically or with secondary control voltage or ready to be levered to the CONNECTED posi- tion. Refer to paragragraph 4-6.4 for levering details.

To disconnect the umbilical cord from the cassette, the breaker must be levered to the TEST position and the shoot bolt handle must be rotated down to Position “A” (Figure 4-9). The interlock lever is once again moved to Location “2” which unlocks the secondary connector (Figure 4-12) . The cassette end of the umbilical cord can now be removed from the cassette’s connector in Location “1” (Figure 4-12). Since the shoot bolt handle is in Position “A” (shoot bolts fully retracted) and the umbilical cord is disconnected from the cassette, the circuit breaker is in the DISCONNECT position and can be removed from the cassette.

PrimaryConnections

Primary connections are made when the spring loaded fin- ger clusters (disconnects) mounted on the rear of the cir- cuit breaker automatically engage the horizontal stabs rigidly mounted inside the insulating spouts) at the

Figure 4-12 Cassette Secondary Connector and Interlock Lever

Interlock Lever in

Location “2”

Cassette

Umbilical Connector

Location “1”

Location “3”

for Interlock Lever

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back of the cassette (Figures 3-5, 3-6 and 4-13). Proper engagement (fully engaged) of the finger clusters (discon- nects) and the cassette stabs takes place as the circuit breaker is levered into the fully CONNECTED position, as described next in paragraph 4-6.4. The primary safety shutters automatically move out of the way as the circuit breaker is levered toward the CONNECT position exposing the fixed primary stabs in the cassette. The primary safety shutters also close automatically as the circuit breaker is levered toward the TEST position. Refer to the next para- graph 4-6.4 levering details and additional safety shutter information.

4-6.4 LEVERING CIRCUIT BREAKER

MAKE SURE THE CIRCUIT BREAKER ELEMENT IS IN THE FULLY RACKED OUT POSITION IN THE CRADLE BEFORE ANY ATTEMPT IS MADE TO PUT THE CIR- CUIT BREAKER INTO THE CASSETTE. FAILURE TO DO SO COULD RESULT IN EQUIPMENT DAMAGE OR BODILY INJURY DURING LIFTING AND HANDLING. REFER TO PARAGRAPH 4-6.2 FOR CIRCUIT BREAK- ER POSITIONING DETAILS AND SEE FIGURES 4-14 AND 4-15.

The purpose of the levering device is to move the circuit breaker from the TEST position to the CONNECT position and from the CONNECT position to the TEST position. The mechanism is comprised of a drive screw and nut, and is part of the lower cradle assembly (Figure 4-16) .

Figure 4-13 Drawout Cassette with Primary Safety Shutters Open Showing Fixed Primary Stabs

6 Fixed Primary Stabs

Inside Insulating Spouts

CAUTION

Figure 4-14 Circuit Breaker Shown in Levered Out DIS- CONNECT Position - Correct for Breaker Positioning

Figure 4-15 Circuit Breaker Shown in Levered In CON- NECT Position - Incorrect for Breaker Positioning

Incorrect For Circuit Breaker Positioning

Correct For Circuit Breaker Positioning

Racking Screw Lock Plate

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Once the VCP-T circuit breaker is in the TEST position with the secondary umbilical cord properly connected, it is ready to be levered into the CONNECTED position. Using a deep (1 inch/25 mm) socket and levering crank, engage the large drive nut on the front of the breaker cradle. Note that a racking screw lock plate surrounds the drive nut and must be pushed back before the drive nut can be engaged (Figures 4-14 and 4-16).

If the shoot bolt handle is not in its proper full up Position “C” with the shoot bolts protruding fully into the cassette’s side interlock plates or if the circuit breaker is closed while the breaker is in the CONNECT position, the racking screw lock plate cannot be recessed to begin the levering process. If the breaker is closed and in the TEST position, it will trip when the screw lock plate is pushed. In addition, the circuit breaker will not close with the locking plate recessed.

To connect the circuit breaker, lever it in a clockwise direc- tion (Figure 4-17). The upper circuit breaker portion moves into the cassette, while the lower cradle portion remains stationary in the front portion of the cassette. Continue lev- ering the circuit breaker until it comes to a definite stop position where the primary connections will have been automatically made. This fully connected position range is also indicated when the circuit breaker front wheel well edge lines up with the fully connected position label on the lower center portion of the cassette floor (Figure 4-18). The circuit breaker is shown in the CONNECTED position in Figure 4-19.

Figure 4-16 Cradle Mounted Levering Mechanism

Drive Nut

Racking Screw

Lock Plate

Figure 4-17 Levering Circuit Breaker

Figure 4-18 Circuit Breaker Connected as Indicated by Fully Connected Position Label

NOTICE

RANGE

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Figure 4-19 Circuit Breaker Shown in CONNECT Position with Secondary Connections Made

Figure 4-20 Primary Safety Shutters Shown in Open Position with Fixed Primary Stabs Exposed

Figure 4-21 Padlocking Device on Side of Cassette

Padlocking Mechanism

cuit breaker out of the CONNECT position by turning the crank in a counterclockwise direction. As the breaker approaches the TEST position, the primary safety shutters automatically cover the fixed stabs. Continue levering the breaker to the TEST position where it will once again mate with the front of its cradle. Refer to paragraph 4-6.3 for instructions on how to dis- connect the secondary umbilical cord from the cassette if the breaker is to be removed from its cassette. Disconnecting the umbilical cord will put the breaker in the DISCONNECT position which is necessary before removing it from the cassette.

During the levering process, the metallic primary safety shutters in the cassette automatically move out of the way exposing the fixed cassette stabs, thus permitting the cir- cuit breaker to make its primary connection (Figure 4-20). When the circuit breaker is levered from the CONNECT position to the TEST position, the safety shutters automati- cally close over the fixed primary stabs. A padlocking device is provided on the side of the cassette to permit padlocking the primary safety shutters in an open position for inspection or in the closed position to prevent inadver- tant contact with the fixed primary stabs. Padlocks must be removed before the circuit breaker is levered in either direction to prevent shutter system damage (Figures 3-7, 3-8 and 4-21).

To lever the circuit breaker out of the CONNECT position, reverse the process just described for levering the circuit breaker to the CONNECT position. Remember that the

circuit breaker must be open before the racking screw lock plate can be recessed to gain access to the large drive nut (Figure 4-16). Once the drive nut is accessible, engage it with the socket and levering crank. Begin levering the cir-

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SECTION 5: DESCRIPTION AND OPERATION

5-1 INTRODUCTION

The VCP-T vacuum circuit breaker is a drawout device while the VCP-TR circuit breaker is a fixed mounted device. The VCP-T drawout circuit breaker is comprised of two parts. The upper circuit breaker element, much like the fixed VCP-TR circuit breaker element and a lower portion called the cradle. The cradle primarily provides the lever- ing mechanism for moving the circuit breaker into and out of the CONNECTED position. They are designed, tested and in accordance with ANSI Standards C37.04, C37.09 abd C37.20.2. The ratings are shown in Table 1.1.

The circuit breakers utilize a proven two step stored energy mechanism, which is available as standard with manually charged closing springs or optionally with electrically charged closing springs. A high degree of service continu- ity is provided by the open-close open (O-CO) circuit breaker duty cycle. A wide range of AC and DC control voltages are available: 24, 48, 110, 125, 220 and 250 Vdc, and 110, 120, 220 and 240 Vac.

VCP-T and VCP-TR circuit breakers are true metal-clad circuit breakers encompassing all the features normally associated with a true metal-clad design, such as:

● Insulation and isolation of compartments

● 11 gauge grounded steel safety barrier between primary

and mechanism compartments

Figure 5-1 Rigid Frame Construction

The circuit breakers utilize a rigid frame construction of engineered thermoset composite resins with a patented pole unit molding. In addition to high strength structural properties, the material used has excellent dielectric char- acteristics and resists tracking (Figure 5-1).

The fixed type VCP-TR circuit breaker element uses cop- per primary conductors with silver plated joints. Upper and lower conductors have two holes for making bolted hori- zontal bus or cable connections. Secondary connections can be made through a standard secondary disconnect block or an optional screw type terminal block supplied in kit form.

The drawout VCP-T circuit breakers utilize spring loaded finger disconnects to make its primary connection. The number of individual silver plated fingers that make up a finger cluster depends upon the current rating of the circuit breaker. The circuit breaker finger disconnects mate with rigidly mounted, silver plated stabs mounted in the rear portion of the cassette.

Controls and indicators, common to all ratings, are func- tionally grouped on the front of the circuit breaker. The front escutcheon (faceplate) is also common for all voltage and current ratings. A mechanical operations counter is provid- ed as standard on all circuit breakers.

VCP-T drawout type and VCP-TR fixed type circuit break- ers are supplied as standard with a front mounted 5a, 5b auxiliary switch for customer use. The switch is a heavy duty, double break type switch with wipe type contacts (Figures 5-2 and 5-3).

5-2 VACUUM INTERRUPTER ASSEMBLY

All VCP-T and VCP-TR circuit breakers utilize vacuum interrupters for interruption and switching functions (Figures 5-4 and 5-5). Vacuum interruption offers the advantages of enclosed interrupters, reduced size and weight, short inter- rupting time, long life, reduced maintenance, and environ- mental compatibility.

DO NOT PLACE ANY CIRCUIT BREAKER IN SERVICE WITHOUT ITS SUPPLIED HORIZONTAL AND VERTI- CAL BARRIERS, IF SO SUPPLIED, BEING PROPERLY IN PLACE. FAILURE TO COMPLY WITH THIS WARN- ING CAN CAUSE A CATASTROPHIC FAILURE RESULTING IN DEATH, SEVERE PERSONAL INJURY AND PROPERTY/EQUIPMENT DAMAGE.

The vacuum interrupters are mounted vertically and sup- ported from the fixed stem connected to the top conductor. A patented pole unit molding encloses each of the vacuum interrupter assemblies on three sides and provides the

WARNING

Pole Unit Molding

Front Cover

Steel Barrier

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Figure 5-2 VCP-TR Fixed Non-Automatic Circuit Breaker (Front Cover Removed)

Secondary Wiring Through-The-Window Accessories Electric Charging Motor Manual Charging Handle Contact Status (Open-Close) Spring Status (Charged-Discharged)

Manual “OFF” Pushbutton Manual “ON” Pushbutton Operations Counter 5A/5B Auxiliary Switch Opening Spring OFF Key Lock Location Motor Cutoff Switch Trip Unit Location

1 2 3 4 5

7 8 9

10 11 12 13

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Figure 5-3 VCP-T Drawout Circuit Breaker (Front Cover Removed)

Secondary Wiring Through-The-Window Accessories Electric Charging Motor Manual Charging Handle Contact Status (Open-Close) Spring Status (Charged-Discharged) Manual “OFF” Pushbutton Manual “ON” Pushbutton Operations Counter 5A/5B Auxiliary Switch

Opening Spring OFF Key Lock Location Motor Cutoff Switch Trip Unit (Optional) Cradle with Levering Mechanism Shoot Bolt Handle Shoot Bolt Racking Screw Lock Plate Levering Drive Nut Push/Pull Handle

1 2 3 4 5

11 12 13

7 8

17 18

19 20

5 6

7 8

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required mounting means, insulation, isolation, strength and rigidity. Certain VCP-T and VCP-TR circuit breakers are supplied with vertical and horizontal barriers already in place and are required to be in place before the circuit breaker is put into service (Figures 3-4 and 3-6). Other barriers may also be required in keeping with paragraph 4-3.

The current transfer system consists of a unique flexible connector attached to the movable stem of the vacuum interrupter. The flexible connector consists of a large

number of flexible leaf conductors that are pressure welded on both ends. One end of the flexible connector is attached to the movable vacuum interrupter stem and the other end to the circuit breaker's lower conductor. As the vacuum interrupter stem moves and the flexible con- nector flexes, current is safely and efficiently transferred between the stem and lower conductor.

5-2.1 CONTACT EROSION INDICATOR

The purpose of the contact erosion indicator is to monitor any erosion of the vacuum interrupter contacts. Contact erosion is, however, very minimal over time with Cutler-Hammer vacuum interrupters. A contact erosion indicator mark is located on the moving stem of the interrupter (Figure 6-1). The erosion mark can be observed from the rear of the circuit breaker, and should be done with the circuit breaker closed. If the erosion mark is no longer visible with the circuit breaker closed, the entire vacuum interrupter assembly must be replaced.

5-2.2 CONTACT WIPE AND STROKE

Contact wipe is the indication of (1) the force holding the vacuum interrupter contacts closed and (2) the energy available to hammer the contacts open with sufficient speed for interruption.

Stroke is the gap between fixed and moving contacts of a vacuum interrupter with the breaker open.

The circuit breaker mechanism provides a fixed amount of motion to the drive insulators. The first portion of the motion is used to close the contacts (i.e. stroke) and the remainder is used to further compress the preloaded contact spring. This additional compression is called wipe.

Wipe and stroke are thus related to each other. As the stroke increases due to the erosion of contacts, the wipe decreases. A great deal of effort has been spent in the design of all Cutler-Hammer vacuum circuit breakers, in order to eliminate the need for field adjustments of wipe or stroke. Refer to paragraph 6-7 for details on visually inspecting contact wipe.

THERE IS NO PROVISION FOR IN SERVICE ADJUST- MENTS OF CONTACT WIPE AND STROKE. ALL SUCH ADJUSTMENTS ARE FACTORY SET AND SHOULD NOT BE ATTEMPTED IN THE FIELD.

Figure 5-4 Fixed 50 VCP-TR Interrupter Assembly (600/800A, 16kA shown)

Figure 5-5 Drawout 150 VCP-T Interrupter Assemblies ( 1200A, 25kA shown)

CAUTION

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5-3 STORED ENERGY MECHANISM

KEEP HANDS AND FINGERS AWAY FROM THE BREAKER'S INTERNAL PARTS WHILE THE BREAK- ER CONTACTS ARE CLOSED OR THE CLOSING SPRINGS ARE CHARGED. THE BREAKER CON- TACTS MAY OPEN OR THE CLOSING SPRINGS DIS- CHARGE CAUSING INJURY. DISCHARGE THE SPRINGS AND OPEN THE BREAKER BEFORE PER- FORMING ANY MAINTENANCE, INSPECTION OR REPAIR.

The two step stored energy mechanism is arranged verti- cally in front of the circuit breakers. It is easily accessed by removing four cover screws and the front cover (Figures 3-9, 5-2 and 5-3). The mechanism is based on a proven cam and spring design.

The stored energy mechanism uses stored potential energy to close the circuit breaker. Sufficient energy to open the circuit breaker becomes available after a closing operation. After closing, springs can be recharged permit- ting the following operating sequence: open - close - open (O-CO). This feature provides a high degree of ser- vice continuity.

Manual controls are front accessible. Motion to close and open the interrupter contacts is provided through operat- ing rods connecting the mechanism to the interrupter assemblies.

5-3.1 MANUAL OPERATION

A standard circuit breaker is a manually operated breaker with one shunt trip. The closing springs can only be charged manually. To manually charge the springs, insert one finger in the recess behind the charging handle and pull out. This permits a hand to grasp the handle and

begin charging (Figure 5-6). It takes a number of down- ward strokes on the charging handle to complete the manual charging process. Keep in mind that it is possible to manually recharge the springs immediately after clos- ing the circuit breaker and before it has been tripped open.

Manually operated circuit breakers are normally closed and opened by hand using the manual "ON" and manual "OFF" buttons respectively. These buttons are conve- niently located on the front of the circuit breaker (Figure 3-9). Performing either operation is accomplished by pressing and releasing the appropriate button. Access to these pushbuttons can be limited by the use of an option- al, padlockable cover. In addition, complete access to the "ON" pushbutton can be prevented with an optional pre- vent close cover. The status of the springs and the prima- ry contacts is always indicated in an indicator window just above the pushbuttons. In addition, the standard shunt trip can also be used to electrically trip (open) the circuit breaker.

Other optional electrically operated devices are available to automatically close or trip manually operated circuit breakers. An electrical spring release is available to close a manually operated circuit breaker. Two other optional devices, a second shunt trip or an undervoltage release, can be used to automatically trip (open) a manually oper- ated circuit breaker. All of these optional devices can be installed in the field. For more details, refer to paragraph 5-5.1 later in this section.

Manually operated circuit breakers are pre-wired to accept the addition of an electrical motor operator. An electrical operator is used to automatically charge the closing springs. Refer to paragraph 5-3.2 for more details.

Figure 5-6 Breaker Closing Springs Being Manually Charged

WARNING

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5-3.2 ELECTRICAL OPERATION

For electrically operated circuit breakers, the springs are normally charged through the use of a rugged electrical motor operator (Figure 5-7). The springs can, however, be manually charged as just described in the previous section.

Like the manually operated circuit breaker discussed in the previous section, electrically operated circuit breakers can also be manually closed and opened through the use of the front mounted manual "ON" and manual "OFF" pushbuttons. A factory supplied electrically operated cir- cuit breaker is equipped as standard with a spring release to close the circuit breaker electrically and a shunt trip to trip (open) the circuit breaker electrically. A second shunt trip or an undervoltage release are available optional devices. Refer to paragraph 5-5.1 for more details.

5-3.3 TRIP FREE OPERATION

When the manual trip button is held depressed, any attempt to close the circuit breaker will be prevented.

5-3.4 ANTI-PUMP FEATURE

All circuit breakers have a standard mechanical anti- pump feature. If the circuit breaker is open, it only accepts one attempt to reclose when the close com- mand continues uninterrupted.

5-3.5 LATCH CHECK SWITCH

Any circuit breaker capable of being electrically closed is provided with a latch check switch. The latch check switch insures that all closing conditions are met before the circuit breaker can be electrically closed. If a spring release device is supplied for installation in the field, a latch check switch must also be purchased and used.

5-3.6 MECHANICAL INTERLOCKS

The mechanical interlock function can be provided in two ways:

(1) One is an optional fixed breaker key interlock located on the circuit breaker's front cover (Figure 5-8). The key interlock can utilize Ronis, Castell or Kirk devices. This mechanical interlock feature prevents the circuit breaker from closing.

(2) The other means is a family of optional mechanical interlocks (Figure 5-9). They are used to prevent the closing of two or three circuit breakers. The mechanical interlock holds one or more circuit breakers tripped (pre- vents closure) when others are closed. The circuit breakers are interconnected with either cables or rods, depending upon the relative orientation of the breakers.

Figure 5-7 Motor Operator Shown Installed

Figure 5-8 Typical Cover Mounted Key Interlock

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5-4 CONNECTION DIAGRAMS

Connection Diagrams for all circuit breakers are shown in Figure 5-10, 5-11, 5-12 and 5-13.

5-4.1 TIMING

The opening and closing times for the circuit breakers vary depending upon the control voltage and the power rating. Typical values for VCP-T and VCP-TR breakers are given below:

Closing Time (from initiation of close signal to contact make) - 60 milliseconds

Opening Time (from initiation of trip signal to contact break) - 25 to 38 milliseconds

Reclosing Time (from initiation of trip signal to contact make) - 250 milliseconds

5-4.2 SECONDARY CONNECTIONS

Each secondary wiring point is identified and dedicated to a specific function. The wiring points are finger safe

with no more than two wires per terminal. Two male

type secondary plug-in connectors are mounted on the

top rear portion of the circuit breaker. The plug-in con-

nectors are protected by a molded hood (Figure 5-14).

When the front cover of the circuit breaker is removed,

the top of each plug-in connector is exposed. A label on

each connector identifies the wiring points (Figure 5-15).

There are two secondary connection options for fixed

type VCP-TR circuit breakers:

(1) Standard Secondary Disconnect Block - The sec-

ondary disconnect block is a female connector with

male pins compatible with a male connector with female

pins mounted under the protective hood (Figure 5-16).

The customer plugs secondary wiring with crimp-on

connectors into the back of the female plug-in connec-

tor.

(2) Optional Screw Type Terminal Block - For those cus-

tomers preferring to wire to a terminal block, an optional

screw type terminal block is available for terminating the

secondary wiring leaving the female secondary discon-

nect block. The terminal block is available in kit form

(Figure 5-17).

Drawout type VCP-T circuit breakers utilize an umbilical

cord utilizing a male connector with female pins on the

breaker end and a female connector with male pins on

the cassette end. One end plugs into its matching con-

nector mounted under a protective hood on the front top

portion of the circuit breaker. The other end plugs into

its matching connector mounted under the front top por-

tion of the drawout cassette.

A standard tool is available from the plug-in connector

manufacturer (AMP) to facilitate the removal of sec-

ondary wiring from the plug-in connector (Figure 5-18).

The connector halves must be separated to use this

tool.

Figure 5-9 Typical Mechanical Cable Interlock

Figure 5-14 Secondary Protective Hood

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Figure 5-10 VCP-T and VCP-TR Non Trip Unit Connection Diagram

NOTES

1. THE “SR” DEVICE HAS ADDITIONAL CIRCUITRY THAT PROVIDES A 0.2 SECOND SIGNAL PULSE FOR CLOSING OPERATION POWER MUST BE REMOVED AND THEN REAPPLIED FOR A SUBSEQUENT OPERATION.

2. THE “LCS” ACTS AS A “LOGIC” INPUT TO THE “SR” DEVICE. THE CLOSE SIGNAL PULSE WILL NOT BE SENT UNTIL THE BREAKER IS RESET.

3. MOTOR OPERATOR SWITCH SHOWN WITH CLOSING SPRING DISCHARGED.

4. EITHER AN OPTIONAL UVR OR OPTIONAL SECOND SHUNT TRIP CAN BE USED IN THIS POSITION (BUT NOT BOTH).

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Figure 5-11 VCP-T and VCP-TR with 520V Trip Unit Connection Diagram

NOTES

1. ALL AUX. SWITCHES SHOWN WITH BREAKER IN OPEN POSITION AND WITH SPRING NOT CHARGED AND WITH TRIP UNIT IN “NON-TRIPPED” STATE (OTS SWITCHES).

2. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIL AND A P.C. BOARD. THE PRINTED CIRCUIT PROVIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR SUBSEQUENT OPERATION.

A LATCH CHECK SWITCH (LCS) ACCESSORY MAY BE CONNECTED TO THE SPRING RELEASE. THE (CLOSED) LCS DELAYS THE SPRING RELEASE PULSE UNTIL THE BREAKER MECHANISM IS READY TO CLOSE (CHARGED AND RESET). (THIS WILL INSURE THAT THE LATCH WILL ALWAYS BE IN THE PROPER STATE BEFORE THE SPRING

RELEASE PULSE IS INITIATED). IF VOLTAGE IS MAINTAINED TO THE SPRING RELEASE, THE CLOSING PULSE WILL OCCUR WHEN THE MECHANISM IS CHARGED AND RESET (LCS OPEN). VOLTAGE MUST BE REMOVED AND RE-APPLIED TO THE SPRING RELEASE FOR SUBSEQUENT OPERATION.

3. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NONE-ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.

4. ON THREE POLE BREAKERS HAVING GROUND FAULT FUNCTIONALITY, A JUMPER INSTALLED FROM B-6 TO B-7 WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL GROUND FAULT SENSING. INPUTS B-4 AND B-5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS.

5. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.

6. SECOND SHUNT TRIP MAY BE INSTALLED ( USING A-7, A-8 CONTACTS) IN PLACE OF UVR. THIRD AUX SWITCH NOT AVAILABLE WITH SECOND SHUNT TRIP.

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Figure 5-12 VCP-T and VCP-TR with 1150V Trip Unit Connection Diagram

NOTES

1. ALL AUX. SWITCH CONTACTS SHOWN WITH BREAKER IN OPEN POSITION AND WITH TRIP UNIT IN “NON-TRIPPED” STATE (OTS SWITCHES).

2. THE SPRING RELEASE ACCESSORY CONSISTS OF A “SR” COIIL AND A P.C. BOARD. THE PRINTED CIRCUIT PROVIDES A .20 SECOND PULSE FOR THE CLOSING OPERATION. VOLTAGE MUST BE REMOVED AND THEN REAPPLIED FOR SUBSEQUENT OPERATION.

THE LATCH CHECK SWITCH (LCS) ACTS AS A “LOGIC” INPUT TO THE “SR” DEVICE. THE CLOSE SIGNAL PULSE WILL NOT BE SENT UNTIL THE BREAKER IS RESET.

3. TO PROVIDE SELECTED TIME DELAYS FOR SHORT TIME AND/OR GROUND TIME FUNCTIONS FOR TESTING OR NONE-ZONE INTERLOCKING APPLICATIONS, A JUMPER FROM B-8 TO B-9 IS REQUIRED.

4. ON BREAKERS HAVING GROUND FAULT FUNCTION ACTIVE, A JUMPER INSTALLED FROM B-6 TO B-7 WILL ENABLE SOURCE GROUND FAULT SENSING AND DISABLE RESIDUAL GROUND FAULT SENSING. INPUTS B-4 AND B-5 WILL BE REASSIGNED FOR SOURCE GROUND SENSOR INPUTS.

5. NORMALLY OPEN CONTACT PROGRAMMED AS RELAY A, VIA DIGITRIP FRONT PANEL (ALARM CONTACT).

6. NORMALLY CLOSED CONTACT PROGRAMMED AS RELAY B, VIA DIGITRIP FRONT PANEL (BLOCK CLOSE CONTACT).

7. NORMALLY OPEN CONTACT PROGRAMMED AS RELAY C, VIA DIGITRIP FRONT PANEL (LATCHING CONTACT).

8. MOTOR OPERATOR SWITCH SHOWN WITH BREAKER CLOSING SPRING DISCHARGED.

9. SECOND SHUNT TRIP MAY BE INSTALLED ( USING A-7, A-8 CONTACTS) IN PLACE OF UVR.

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Figure 5-13 VCP-T Drawout Umbilical Cord and Connector Wiring Diagram

‘A’ BLOCK

BREAKER SIDE

‘B’ BLOCK

BREAKER SIDE

‘A’ BLOCK

UMBILICAL CASSETTE SIDE

CUSTOMER CONNECTION

‘B’ BLOCK

UMBILICAL CASSETTE SIDE

CUSTOMER CONNECTION

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Figure 5-15 Top View Secondary Connectors

Legend

AS Auxiliary Switch

MOTOR Charging Motor

SC Spring Charge Indicator SR Spring Release

S/T Shunt Trip S/T2 Shunt Trip 2 UVR Undervoltage Release

Secondary Connectors

Figure 5-16 Secondary Male Connector with Female Pins

Figure 5-17 Optional Terminal Block

Figure 5-18 AMP Secondary Wiring Removal Tool (AMP#305183) (C-H#MAMPSEC)

Hinged Covers

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A functional local test can be performed through the trip unit’s test receptacle (Figure 5-19). A small hand held functional Test Kit is used to check circuitry and mechanical tripping functions (Figure 5-20).

When the circuit breaker is shipped from the factory, the trip unit’s protective functions are normally set at mini- mum values. For specific overload tripping characteris- tics and time/current curves to coordinate with a load or system, refer to the trip unit instruction book.

Functions 520V 1150V

➁

LSIG Protection Yes Yes Disable (I) Yes Yes GF Protection Yes Yes GF Alarm No Yes Display No Yes

①

Programmable No Yes Metering No Yes Power and

Energy Values No Yes Power Quality No Yes Communication No Yes

5-5 ELECTRONIC TRIPPING SYSTEM

VCP-T and VCP-TR circuit breakers utilize a three part tripping system:

• Microprocessor-based trip unit

• Current Sensors

• Trip Actuator All three parts of the tripping system are discussed here,

except that the trip unit itself is not discussed in detail. For detailed information pertaining to the different trip unit models available with these circuit breakers, refer to the specific instruction leaflet dedicated to the trip units.

5-5.1 MICROPROCESSOR-BASED TRIP UNIT

VCP-T and VCP-TR circuit breakers can use either of two Digitrip RMS trip units whose main features are summarized in Table 5.1. The two models (Model 520V and Model 1150V) are not interchangeable in the field. Contact Cutler-Hammer for upgrading to Model 520V or Model 1150V.

The electronic trip units are self-powered. When the cir- cuit breaker is closed, no external power is required to operate their protective systems. Current signal levels and the control power are derived from the current sen- sors mounted behind the cassette.

Table 5.1 Digitrip Trip Units

Figure 5-19 Digitrip RMS 1150V Programmable Trip Unit Installed in VCP-T Circuit Breaker

① Three-line, (eight characters per line) LED display. ➁ Available control voltages are 24/48Vdc, 120Vac and 240Vac

Figure 5-20 Hand Held Tester

Test Receptacle

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5-5.2 RATING PLUG

All trip units use a fixed type rating plug. The current rating of the rating plug must match the current rating of the current sensors (Figure 5-19 and Table 5.2). The rating plug performs several functions:

1) It tells the trip unit what the rating is of the current sensors. A label on the front of the rating plug clearly indicates that the rating plug and sensors must have the same rating.

2) It determines the maximum instantaneous setting which is a function of the current sensor rating.

If the rating plug is removed from the trip unit, the circuit breaker will trip if it is carrying current. Make certain the rating plug is secured in position with its retaining screw.

Do not torque the retaining screw beyond 15 In-Oz.

Refer to Table 5.2 for a tabulation of the available rating plugs.

5-5.3 CURRENT SENSORS

Three current sensors are installed at the rear of the cassette on the lower terminals (Figure 3-19). The sen- sors produce an output current proportional to the load current. Under preselected conditions of current magni- tude and time, the sensors furnish the trip unit with a signal and the energy required to trip the circuit breaker.

Table 5.2 Current Sensors and Matching Rating Plugs

Neutral current sensors are available for customer installation. The additional sensor is not supplied with the circuit breaker and must be ordered separately. They are wired to the trip unit through the secondary contacts of the circuit breaker.

Zero sequence transformers (vectorial summation) are available with a 100:1 and 200:1 tap ratio.

Refer to Table 5.2 for a tabulation of the available cur- rent sensor ratings.

5-5.4 TRIP ACTUATOR

The trip actuator is a small cylindrically shaped electro- magnetic device which acts mechanically to trip the cir- cuit breaker. In general, it is comprised of a permanent magnet, a coil and a spring loaded rod to produce the mechanical tripping, and a lever for resetting the actua- tor after tripping occurs. The electronic trip unit provides a pulse which counteracts the effect of the permanent magnet, allowing the spring loaded rod to act mechani- cally. The device is reset when the circuit breaker opens.

Current Rating in Amperes

100 200 250

300 400 600

630 800 1000

1200 1250 1600

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5-6 ACCESSORY DEVICES

A variety of accessory devices are available for use with VCP-T and VCP-TR circuit breakers. Unless otherwise stated, they should be considered optional devices in the sense that they are not provided as standard on a manually operated circuit breaker.

Circuit breaker accessories are common to all circuit breaker ratings. The accessories fall into one of three categories:

• Plug-in electrical

• Internal electrical

• Mechanical

5-6.1 PLUG-IN ELECTRICAL ACCESSORIES

There are three plug-in electrical accessories. All three can be viewed for identification by name and rating through viewing windows located in the right front of the circuit breaker (Figure 5-21). These accessories can be factory installed or field installed using a kit. A maximum of three plug-in accessories can be mounted. Two trip devices and one close device can be used. The three plug-in accessories are:

• Shunt Trip (ST)

• Spring Release (SR)

• Undervoltage Release (UVR) Shunt Trip - The shunt trip opens the circuit breaker

instantaneously when its coil is energized by a voltage input (Figure 5-22 and Table 5.3). One shunt trip is sup- plied as standard with all manually operated and electri- cally operated circuit breakers. An optional second shunt trip can be supplied for customer use.

Spring Release - The spring release remotely closes the circuit breaker when the coil is energized by a voltage input (Figure 5-23 and Table 5.4). A spring release is supplied as standard with all electrically operated circuit breakers. In every other situation, the spring release is an optional device.

Undervoltage Release - The undervoltage release opens the circuit breaker when the supply voltage falls below 70% (Figure 5-24 and Table 5.5). If the release is not energized to 85% of its supply voltage, the circuit breaker cannot be reclosed electrically or manually. The undervoltage release device is always optional.

Figure 5-21 Through-The-Window Electrical Accessories

Figure 5-22 Shunt Trip Device

Figure 5-23 Spring Release Device

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Control Operational Dropout Inrush Continuous Voltages Voltage Voltage Power Power

Range

35-60%

Consumption Consumption

24 Vdc 20 - 26 8 - 14 250 VA 18 VA 48 Vdc 41 - 53 17 - 29 275 VA 18 VA 110 Vdc 94 - 121 39 - 66 450 VA 10 VA 125 Vdc 106 - 138 44 - 75 450 VA 10 VA 220 Vdc 187 - 242 77 - 132 450 VA 10 VA 250 Vdc 213 - 275 88 - 150 450 VA 10 VA 110 Vac 94 - 121 39 - 66 450 VA 10 VA 120 Vac 102 - 132 42 - 72 450 VA 10 VA 220 Vac 187 - 242 77 - 132 400 VA 10 VA 240 Vac 204 - 264 84 - 144 400 VA 10 VA

Control Operational Inrush Power Typical

Voltages Voltage Range Consumption Closing Time

24 Vdc 20-27 250 VA 60 ms 48 Vdc 41-53 250 VA 60 ms 110 Vdc 94 - 121 450 VA 60 ms 125 Vdc 106-138 450 VA 60 ms 220 Vdc 187 - 242 450 VA 60 ms 250 Vdc 213 - 275 450 VA 60 ms 110 Vac 94 - 121 450 VA 60 ms 120 Vac 102 - 132 450 VA 60 ms 220 Vac 187 - 242 450 VA 60 ms 240 Vac 204 - 264 450 VA 60 ms

5-6.2 INTERNAL ELECTRICAL ACCESSORIES

Other electrical accessories are mounted inside the cir- cuit breaker behind the front cover. Access to these devices is gained by simply removing the front cover.

There are two internally mounted electrical accessories.

• Motor Operator

• Auxiliary Switch Motor Operator - A motor operator is a rugged electric

motor assembly internally mounted in the circuit breaker (Figure 5-25 and Table 5.6). It charges the closing springs electrically for remote or local operation. The motor operator can be factory or field installed.

Manually operated circuit breakers are pre-wired to accept the addition of an electrical motor operator in the field. A UL listed motor operator kit is available for this conversion.

Auxiliary Switch - A 5a, 5b auxiliary switch is supplied as standard on all circuit breakers for customer use (Figure 5-26 and Table 5.7). The switch is a heavy duty, double break type switch with wipe type contacts.

Table 5.3 Shunt Trip Ratings

Table 5.4 Spring Release Ratings

Control Operational Inrush Power Typical

Voltages Voltage Range Consumption OpeningTime

24 Vdc 17-26 250 VA 25 - 38 ms 48 Vdc 34-53 250 VA 25 - 38 ms 110 Vdc 77 - 121 450 VA 25 - 38 ms 125 Vdc 88-138 450 VA 25 - 38 ms 220 Vdc 154-242 450 VA 25 - 38 ms 250 Vdc 175-275 450 VA 25 - 38 ms 110 Vac 77 - 121 Cap. Trip 25 - 38 ms 120 Vac 84-132 Cap. Trip 25 - 38 ms 220 Vac 154 - 242 Cap. Trip 25 - 38 ms 240 Vac 168 - 264 Cap. Trip 25 - 38 ms

Figure 5-24 Undervoltage Release Device

Table 5.5 Undervoltage Release Ratings

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Figure 5-25 Rugged Motor Operator Kit

Figure 5-26 Auxiliary Switch

Table 5.6 Motor Operator Ratings

Control Operational Running Inrush Power Charging Voltages Voltage Range Current Current Consumption Time

24 Vdc 20-27 8 Amperes 400% of Running 250 VA 5 sec 48 Vdc 41-53 4 Amperes 400% of Running 250 VA 5 sec 110 Vdc 94 - 121 3 Amperes 400% of Running 250 VA 5 sec 125 Vdc 106 - 138 3 Amperes 400% of Running 250 VA 5 sec 220 Vdc 187 - 242 2 Amperes 400% of Running 250 VA 5 sec 250 Vdc 213 - 275 2 Amperes 400% of Running 250 VA 5 sec 110 Vac 94 - 121 3 Amperes 400% of Running 250 VA 5 sec 120 Vac 102- 132 3 Amperes 400% of Running 250 VA 5 sec 220 Vac 187 - 242 2 Amperes 400% of Running 250 VA 5 sec 240 Vac 204 - 264 2 Amperes 400% of Running 250 VA 5 sec

Table 5.7 Auxiliary Switch Contacts Interrupting Capacities

Continuous Current (amperes)

Control Circuit Voltage

Non-inductive Circuit Interrupting Capacity in Amperes

Inductive Circuit Interrupting Capacity in Amperes

120 Vac

240 Vac

24 Vdc

48 Vdc

125 Vdc

250 Vdc

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5-6.3 MECHANICAL ACCESSORIES

There are six mechanical type accessories:

• Operations Counter

• Key Interlock

• Mechanical Interlock

• Pushbutton Cover

• Prevent Close Cover

• Door Escutcheon Operations Counter - The operations counter is a

standard mechanical device used to provide a record of the number of circuit breaker operations. It is mounted on the right side of the circuit breaker and can be viewed through the front cover (Figure 3-9).

OFF Key Lock - The key lock secures the circuit breaker in the "OFF" (open) position. It is an optional device mounted in the lower right portion of the circuit breaker and can be viewed through the front cover (Figure 5-8). The customer supplies the key lock. The lock choices are Ronis, Castell or Kirk.

Mechanical Interlock - A family of mechanical inter- locks are available to interlock the closing of two or three circuit breakers. The mechanical interlock holds one or more circuit breakers tripped (prevents closure) when others are closed. An assembly on each breaker

is interconnected with either cables or rods, depending upon the relative orientation of the breakers. Rods can be used only when the circuit breakers to be interlocked are vertically stacked. Cables can be used for any ori- entation of the breakers. Mechanical interlocks are available for both fixed and drawout circuit breakers and in both 2-way and 3-way versions. An illustration of a 2- way cable interlock mounted on two drawout circuit breakers is shown in Figure 5-9.

Pushbutton Cover - An optional padlockable cover is available to limit access to the "ON" and "OFF" pushbut- tons (Figure 5-27).

Prevent Close Cover - The optional prevent close cover completely prevents access to the "ON" pushbut- ton. It must be used in conjunction with the pushbutton cover.

Door Escutcheon - The door escutcheon is an optional molded frame used to seal space between the circuit breaker and a compartment door cutout, should the customer choose to have a through the door type mounting configuration. It is supplied with a mounting gasket (Figure 5-28).

Figure 5-28 Door Escutcheon and Gasket

Figure 5-27 Pushbutton Cover Mounted

One Access Door Open

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SECTION 6: INSPECTION AND MAINTENANCE

6-1 INTRODUCTION

FAILURE TO INSPECT, CLEAN AND MAINTAIN CIR- CUIT BREAKERS CAN REDUCE EQUIPMENT LIFE OR CAUSE THE EQUIPMENT NOT TO OPERATE PROPERLY UNDER FAULT CONDITIONS. THIS COULD RESULT IN EQUIPMENT DAMAGE, BODILY INJURY OR EVEN DEATH.

ONLY PERSONNEL FAMILIAR WITH THE HAZARDS ASSOCIATED WITH WORKING ON POWER CIRCUIT BREAKERS SHOULD CARRY OUT INSPECTION AND MAINTENANCE PROCEDURES.

• INSPECTION AND MAINTENANCE PERSONNEL SHOULD BE FAMILIAR WITH THE SPECIFICS ASSOCIATED WITH THE CIRCUIT BREAKERS AS PRESENTED IN THIS INSTRUCTION BOOK.

• DO NOT WORK ON A CIRCUIT BREAKER IN THE CONNECTED POSITION.

• DO NOT WORK ON A CIRCUIT BREAKER WITH SECONDARY DISCONNECTS ENGAGED

• DO NOT WORK ON A CIRCUIT BREAKER WITH SPRINGS CHARGED OR CONTACTS CLOSED.

• DO NOT DEFEAT ANY SAFETY INTERLOCKS.

• DO NOT STAND LESS THAN ONE METER AWAY FROM THE CIRCUIT BREAKER WHEN TESTING FOR VACUUM INTEGRITY.

FAILURE TO FOLLOW ANY OF THESE INSTRUC- TIONS MAY CAUSE DEATH, SERIOUS BODILY INJURY, OR PROPERTY DAMAGE.

6-2 FREQUENCY OF INSPECTION AND MAINTE- NANCE

Periodic inspections and associated maintenance are essential for the safe and reliable operation of VCP-T and VCP-TR circuit breakers. The inspection frequency and associated maintenance recommmended are intended to insure the best possible ongoing service. It

is imperative that an establised schedule be followed. To establish an exact schedule for a specific installation, use the following guidelines:

1. In a clean, non-corrosive environment, inspect and maintain each breaker every 2000 operations or 3 years, whichever comes first.

2. For special conditions such as frequent breaker oper- ation, contaminated environments, and/or high tempera- ture/humidity conditions, the inspection frequency should be more frequent.

3. Inspect a breaker every time it interrupts fault current.

4. Follow the steps outlined in Table 6.1 entitled “Inspection and Maintenance Procedures”.

5. Create and maintain a dated permanent record of all inspections, maintenance performed, actions taken, observations made, and measurements taken. Not only will this provide valuable historical information, it can help to establish whether or not the present schedule needs to be adjusted.

6. Perform ongoing visual inspections, when possible, of all equipment on a regular basis. Be alert for an accu- mulation of dirt in and around the breaker, loose hard- ware or discolored insulation.

6-3 VACUUM INTERRUPTER INTEGRITY TEST

Vacuum interrupters used in these circuit breakers are highly reliable interrupting elements. Satisfactory perfor- mance of these devices is dependent upon the integrity of the vacuum in the interrupter and the internal dielec- tric strength. Both of these parameters can be readily checked by a one minute ac high potential test. (See Table 6.2 for appropriate test voltage.) During this test, the following warning must be observed:

WARNING

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Table 6.1 Inspection and Maintenance Procedures

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shall be as shown in Table 6.2.

Table 6.2 Test Voltage

The current delivery capability of 25 ma ac and 5 ma dc apply when all three VIs are tested in parallel. If individual VIs are tested, current capability may be one third of these values.

SOME DC HIGH POTENTIAL UNITS, OPERATING AS UNFILTERED HALF-WAVE RECTIFIERS, ARE NOT SUITABLE FOR USE TO TEST VACUUM INTER- RUPTERS BECAUSE THE PEAK VOLTAGE APPEAR- ING ACROSS THE INTERRUPTERS CAN BE SUB- STANTIALLY GREATER THAN THE VALUE READ ON THE METER.

6-4 CONTACT EROSION

Since the contacts are contained inside the interrupter, they remain clean and require no maintenance. However, during high current interruptions there may be a minimum amount of erosion from the contact surfaces. Maximum permitted erosion is 3 mm. 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 pole unit assem- bly must be replaced (Figure 6-1).

6-5 CONTACT WIPE

To check contact wipe, close the breaker and observe the drive insulators from the rear of the breaker (Figure 6-2). Since the indicator to be observed is in the lower rear portion of each pole unit assembly, a flashlight should be used. Refer to Figures 6-3 and 6-4 for graphical represen- tations of satisfactory and unsatisfactory contact wipe con- ditions. If the identified wipe indicator is observed to be below the top surface of the drive insulator as shown in Figure 6-3, the contact wipe is satisfactory. If the wipe indi- cator is observed to be flush with or protruding out past the top surface of the drive insulator as shown in Figure 6-4, the contact wipe is unsatisfactory. The pole unit assembly must be replaced when an unsatisfactory wipe condition is observed.

Vacuum Interrupter Integrity Test Voltage

at 60 Hz dc

Breaker Rated

Maximum Voltage

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APPLYING ABNORMALLY HIGH VOLTAGE ACROSS A PAIR OF OPEN CONTACTS IN VACUUM MAY PRO- DUCE X-RADIATION. THE RADIATION MAY INCREASE WITH THE INCREASE IN VOLTAGE AND/OR DECREASE IN CONTACT SPACING. X-RADI- ATION PRODUCED DURING THIS TEST WITH REC- OMMENDED VOLTAGE AND NORMAL CONTACT SPACING IS EXTREMELY LOW AND WELL BELOW MAXIMUM PERMITTED BY STANDARDS. HOWEVER, AS A PRECAUTIONARY MEASURE AGAINST POSSI- BILITY OF APPLICATION OF HIGHER THAN RECOM- MENDED VOLTAGE AND/OR BELOW NORMAL CON- TACT SPACING, IT IS RECOMMENDED THAT ALL OPERATING PERSONNEL STAND AT LEAST ONE METER AWAY IN FRONT OF THE BREAKER.

With the circuit breaker open and securely sitting on the floor or secured in a fixed position, connect all top primary studs (bars) together and to the high potential machine lead. Connect all bottom studs together and ground them along with the breaker frame. Start the machine at zero potential, increase to appropriate test voltage and main- tain 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 circuit breaker in service.

AFTER THE HIGH POTENTIAL IS REMOVED, AN ELECTRICAL CHARGE MAY BE RETAINED BY THE VACUUM INTERRUPTERS. FAILURE TO DISCHARGE THIS RESIDUAL ELECTROSTATIC CHARGE COULD RESULT IN AN ELECTRICAL SHOCK. ALL SIX PRI- MARY TERMINALS AND THE CENTER RING OF EACH VACUUM INTERRUPTER OF THE CIRCUIT BREAKER SHOULD BE GROUNDED TO REDUCE THIS ELECTRICAL CHARGE BEFORE COMING IN CONTACT WITH THE PRIMARY CIRCUIT.

To avoid any ambiguity in the ac high potential test due to leakage or displacement (capacitive) current, the test unit should have sufficient volt-ampere capacity. It is recom- mended that the equipment be capable of delivering 25 milliamperes for one minute.

Although an ac high potential test is recommended, a dc test may be performed if only a dc test unit is available. In this case the equipment must be capable of delivering 5 milliamperes for one minute to avoid ambiguity due to field emission or leakage currents and the test voltage

WARNING

20 kV 28 kV 20 kV 28 kV 27 kV 40 kV

4.76 kV

8.25 kV

15.0 kV

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Top Inspection Area

Figure 6-1 Contact Erosion Mark Visible on Stem

Figure 6-4 Unsatisfactory Contact Wipe Condition with Breaker Closed

Figure 6-3 Satisfactory Contact Wipe Condition with Breaker Closed

Figure 6-2 Contact Wipe Inspection Area

Drive Insulator

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Top Surface Drive Insulator

Wipe Indicator Below Top Surface

Top Surface Drive Insulator

Wipe Indicator Flush with Top Surface

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across the studs on the breaker side of the disconnect for each pole. The resistance should not exceed the val- ues shown in Table 6.3.

6-9 MECHANISM CHECK

Make a careful visual inspection of the mechanism for any loose parts such as bolts, nuts, pins and rings. Check for excessive wear or damage to the breaker components. Operate the breaker several times manu- ally and electrically. Check the closing and opening times to verify that they are in accordance with the limits in paragraph 5-4.1.

6-10 LUBRICATION

Maintenance of these circuit breakers and cassettes consists mainly of keeping them clean with a minimal amount of lubrication recommended. VCP-T and VCP- TR circuit breakers should be lubricated every 3 years or 2000 operations with a high quality 10W30 motor oil and/or magna-lube G teflon grease C-H #53701AI as indicated in Figure 6-5. As required for smooth opera- tion, lubricate the drawout cassette also with a high quality 10W30 motor oil and/or magna-lube G teflon grease C-H #53701AI as indicated in Figure 6-6.

Table 6.3 Typical Resistance Measurements

6-11 TROUBLESHOOTING

Refer to Table 6.4 for troubleshooting suggestions. It will help to determine the probable causes of simple circuit breaker problems and possible corrective actions. If the problem cannot be resolved with the aid of this guide, contact the Cutler-Hammer service center for more in- depth assistance.

Rated Continuous Resistance

Current (amperes) (microohms)

600 46

800 44 1200 39 1600 36

6-6 INSULATION

In VCP-T and VCP-TR circuit breakers, insulation mainte- nance primarily consists of keeping all insulating surfaces clean. This can be done by wiping off all insulating sur- faces 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. Be sure that the surfaces are dry before placing the breaker in service. If a solvent is required to cut dirt, use Stoddard's Solvent (Cutler-Hammer 55812CA) or commercial equivalent. Secondary control wiring requires inspection for tightness of all connections and damage to insulation.

6-7 INSULATION INTEGRITY CHECK

Primary Circuit: The integrity of primary insulation may be checked by the AC high potential test. The test volt- age depends upon the maximum rated voltage of the breaker. For the breakers rated 5.0kV, 12kV and 15.0 kV, the test voltages are 15kV, 21 kV and 27 kV rms respectively. Conduct the test as follows:

Close the breaker. Connect the high potential lead of the test machine to one of the poles of the breaker. Connect the remaining poles and breaker frame to ground. Start the machine with output potential at zero and increase to the test voltage. Maintain the test volt- age for one minute. Repeat for the remaining poles. Successful withstand indicates satisfactory insulation strength of the primary circuit.

If a DC high potential machine is used, make certain that the peak voltage does not exceed the peak of the corresponding AC RMS test voltage.

Secondary Circuit: Isolate the motor by pulling apart the two insulated quick disconnecting terminals in the two motor leads provided for this purpose. 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 1500 volts rms. Maintain the voltage for one minute. Successful withstand indi- cates satisfactory insulation strength of the secondary control circuit. Remove the shooting wire and reconnect the motor leads.

6-8 PRIMARY CIRCUIT RESISTANCE CHECK

Since the main contacts are inside the vacuum cham- ber, they remain clean and require no maintenance at any time. If desired, the DC resistance of the primary circuit may be measured as follows: close the breaker, pass at least 100 amps DC current through the breaker. With the low resistance instrument, measure resistance

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Symptom Probable Cause Corrective Actions

Table 6.4 Troubleshooting Guide (continued on next page)

Circuit breaker undesirably opens

Circuit breaker cannot be opened remotely, but can be opened locally

Circuit breaker cannot be opened locally

Circuit breaker makes no attempt to close with either local (manual) or remote controls; springs do not discharge

Undervoltage release operates; volt- age too low or zero.

Shunt Trip operates

Trip latch is defective

Shunt trip control signal absent or too low

Shunt trip is faulty or improperly installed.

Secondary contact wiring problem

OPEN pushbutton locked Faulty mechanism or one or more

vacuum interrupter contacts welded Closing spring not fully charged

(check SPRING CHARGED indica- tor)

If equipped with undervoltage release, undervoltage release is not energized or is faulty

Circuit breaker locked in OPEN position

Circuit breaker interlocked with another circuit breaker or device

Check and correct the UVR supply voltage (85-110% rated voltage)

Check control signal(s) to shunt trip; correct if necessary

Inspect latch condition and engagement before closing; con- sult Cutler-Hammer service center

Check supply voltage exceeds minimum of voltage range when signal is applied to shunt trip

Remove front cover; check voltage supplied to shunt trip; make sure shunt trip is seated and retainer snapped into place. Check for shunt trip motion; replace shunt trip if faulty

Make sure electrical pin and socket connectors are properly seated in molded plug. Verify proper wiring

Remove lock Contact Cutler-Hammer service

center Charge spring manually; check

voltage to electrical operator; replace electrical operator if faulty

Unplug undervoltage release from mounting deck and retry closing operation; if OK, check voltage supply to undervoltage release (>85%); replace undervoltage release if faulty

Check reason for lock

Check for presence of an interlock- ing scheme (cable interlock or key interlock); check to see if inter- locked circuit breaker is CLOSED

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Symptom Probable Cause Corrective Actions

Table 6.4 Troubleshooting Guide (continued from previous page)

Circuit breaker cannot be closed remotely (can be closed locally)

Circuit breaker cannot be closed locally (but can be closed remotely)

Circuit breaker does not recharge electrically but will recharge manually

Spring release (closing) coil supply voltage low or spring release faulty

Secondary contact wiring problem

Latch check switch open

Opening and/or closing pushbuttons locked

Charging motor supply voltage absent or too low (< minimum of range )

Charging motor faulty

Check power supply voltage; replace spring release if faulty

Make sure electrical pin and sock- et connectors are properly seated in molded plug. Verify proper wiring

Bad switch or not reset

Check reason for lock

Check charging motor electrical circuit voltage (check under load)

Replace charging motor assembly

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Figure 6-5 Circuit Breaker Lubrication

USE 10W30 OIL ON MAIN PIVOT OF POLE SHAFT (BEAR- ING SURFACES) INDICATED HERE ON BOTH SIDES

USE 10W30 OIL ON BOTH MOLDED SURFACES AND STEEL BEARING SURFACES ALONG BREAKER LAYSHAFT (8 LOCATIONS TOTAL)

USE 10W30 OIL ON BEARINGS AND MAGNA-LUBE ON THREADS OF JACK SCREW (ENTIRE LENGTH OF JACK SCREW

MAGNA-LUBE

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Figure 6-6 Drawout Cassette Lubrication

MAGNA-LUBE TOP UNDERSIDE OF ANTI- TILT CHANNELS SHOWN HERE ALONG ENTIRE SURFACE

MAGNA-LUBE FULL LENGTH OF GROUNDING (EARTHING) BAR SPAR- INGLY BOTH SIDES AS SHOWN SHOWN

USE 10W30 OIL INSIDE FLANGE OF DRIVE PLATE BEARING BOTH SIDES OF CASSETTE

USE 10W30 OIL INSIDE OF ROLLER AND MAGNA-LUBE OUTSIDE OF ROLLER

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SECTION 7: RENEWAL PARTS

7-1 GENERAL

In order to minimize production downtime, it is recom- mended that an adequate quantity of spare parts be car- ried in stock. The quantity will vary from customer to customer, depending upon the service severity and con- tinuity requirements. Each customer should develop his own stock level based on operating experience.

7-2 ORDERING INSTRUCTIONS

a. Always specify the breaker rating information and

shop order number.

b. Describe the item, give the style number, and specify the quantity required.

c. Specify the voltage for electrical components. d. Specify the method of shipping desired. e. Send all orders or correspondence to the nearest

Cutler-Hammer sales office.

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7-3 MECHANISM AND RELATED PARTS (1) Charging Handle with Stop Pawl Assembly

Requires C-HESS (Cutler-Hammer Engineering Services and Systems) Installation

(2) Accessories Tray

Customer Field Installable

(3) Breaker Key Interlock Provision

Customer Field Installable

* Cutler-Hammer does not supply Lock or Key, only the provision

(4) Mechanism*

Requires C-HESS (Cutler-Hammer Engineering Services and Systems) Installation

* Includes charging handle

(5) Operations Counter

Customer Field Installable

Description

Handle Includes Stop Pawl Assembly

Style#

2A10892G01

Description

Style#

Tray where UVR, Shunt Trip, Spring

Release, Latch Check Switch and

Shunt Trip Switch Mount

2A10891G01

Lock Type

Lock Required* Key Required* Style#

Ronis

Castell

Kirk

1104A

CL1019

CN22-104-1B92890

Protec

CL1062

67A3140G01 67A3140G02 67A3140G03

Style#Voltage Class (kV rms)Circuit Breaker Type

50 VCP-T16 and VCP-TR16 50 VCP-T20 and VCP-TR20 50 VCP-T25 and VCP-TR25 75 VCP-T16 and VCP-TR16 75 VCP-T20 and VCP-TR20

75 VCP-T25 and VCP-TR25 150 VCP-T16 and VCP-TR16 150 VCP-T20 and VCP-TR20 150 VCP-T25 and VCP-TR25

4.76

8.25

15.0

67A3141G01 67A3141G02 67A3141G03 67A3141G04 67A3141G05 67A3141G06 67A3141G07 67A3141G08 67A3141G09

Cat#Description

Mechanical Counter

MCOUNT

HARDWARE INCLUDED

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(6) Opening Spring and Guide

Customer Field Installable

(7) Faceplate, Buttons and Flags

Requires C-HESS (Cutler-Hammer Engineering Services and Systems) Installation

7-4 CURRENT PATH (1) Pole Unit Assembly (VCP-T and VCP-TR)

Requires C-HESS (Cutler-Hammer Engineering Services and Systems) Installation

(8) Shock Absorber

Customer Field Installable

67A3158G22 67A3158G32 67A3158G42 67A3159G22 67A3159G32 67A3159G42 67A3160G22 67A3160G32 67A3160G42

HARDWARE INCLUDED

Description

Style#

Description

Style#

Faceplate, Buttons and Flags

2A10895G01

5kV/16kA 5kV/20kA 5kV/25kA

7.5kV/16kA

7.5kV/20kA

7.5kV/25kA 15kV/16kA 15kV/20kA 15kV/25kA

67A3158G21 67A3158G31 67A3158G41 67A3159G21 67A3159G31 67A3159G41 67A3160G21 67A3160G31 67A3160G41

600

800

1200

Style# Style#

Circuit

Breaker

Type

Description

Shock Absorber All Breakers

Style#

67A3143G01

Shock Absorber Installed

Black Opening Spring (Low Energy) Blue Opening Spring (High Energy)

67A3142G01 67A3142G02

67A3158G25 67A3158G35 67A3158G45 67A3159G25 67A3159G35 67A3159G45 67A3160G25 67A3160G35 67A3160G45

1600

Style# Style#

67A3158G24 67A3158G34 67A3158G44 67A3159G24 67A3159G34 67A3159G44 67A3160G24 67A3160G34 67A3160G44

Normal Current (Amperes)

(Includes VI, Flex Connector and Drive Rod Assembly)

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7-5 ELECTRICAL ATTACHMENTS (1) Shunt Trip (Opening Coil)

Customer Field Installable

(2) Spring Release (Closing Coil)

Customer Field Installable

(3) Undervoltage Release

Customer Field Installable

(4) Shunt Trip Switch

Customer Field Installable

(5) Latch Check Switch

Customer Field Installable

Control Voltage

24 Vdc

48 Vdc 110 Vdc 125 Vdc 220 Vdc 250 Vdc 110 Vac 120 Vac 220 Vac 240 Vac

Style#

67A3145G11 67A3145G12 67A3145G13 67A3145G13 67A3145G14 67A3145G14 67A3145G15 67A3145G15 67A3145G16 67A3145G16

Control Voltage

24 Vdc

48 Vdc 110 Vdc 125 Vdc 220 Vdc 250 Vdc 110 Vac 120 Vac 220 Vac 240 Vac

Cat#

MSRC MSRH MSRA MSRA MSRR MSRR MSRA MSRA MSRR MSRR

Control Voltage

24 Vdc

48 Vdc 110 Vdc 125 Vdc 220 Vdc 250 Vdc 110 Vac 120 Vac 220 Vac 240 Vac

Cat#

MUVRC MUVRH MUVRE MUVRE

MUVRF

MUVRF MUVRA MUVRA MUVRR MUVRR

Description

2a/2b Contacts

Description

Single Pole, Single Throw Contact Switch

Style#

67A3146G01

Style#

67A3150G01

NOTE: For an optional shunt trip capability, both a shunt trip and a shunt trip switch must be ordered and used.

NOTE: For conver- sion from manual to electrical closing, both a spring release and a latch check switch must be ordered and used.

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6) Auxiliary Switch

Customer Field Installable

7) Motor Operator

Customer Field Installable

8) Motor Brush Kit

Customer Field Installable

9) Breaker Secondary Disconnect Block

Customer Field Installable

10) Breaker Terminal Block Bracket

Customer Field Installable

11) Screw Type Terminal Block

Customer Field Installable

Style#

67A3147G01

Description

5a/5b Double Break Type

Stylet#

69C3193G11 69C3193G01 69C3193G12 69C3193G13 69C3193G14 69C3193G15

HARDWARE INCLUDED

Description

2 - 30 Position Connectors Labeled

and assembled to

Mounting Tray

Style#

67A3148G01

HARDWARE INCLUDED

Description

2 - 30 Position Connectors labeled for External Wiring

Style#

67A3149G01

HARDWARE INCLUDED

Description

Screw Type Terminal Block

with Hinged Covers

Style#

67A3151G01

HARDWARE INCLUDED

Description

One Kit All Motors

Style#

8063A77G01

HARDWARE INCLUDED

Additional items available from manufacturer:

Socket for 14-18 AWG. wire (AMP #66598-2)

Socket for 18-26 AWG. wire (AMP #641300-2)

Socket Crimper Tool (AMP #90067-4)

Removal Tool (AMP #305183)

Additional items available from manufacturer:

Pin for 14-18 AWG. wire (AMP #66597-2)

Pin for 18-26 AWG. wire (AMP #640545-2)

Pin Crimper Tool (AMP #90067-4)

Removal Tool (AMP #305183)

Control Voltage

24 Vdc

48 Vdc 125 Vdc 250 Vdc 120 Vac 240 Vac

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14) Secondary Umbilical Cord

Customer Field Installable

15) Simple Ground and Test Device

Customer Field Installable

16) Dummy Element

Customer Field Installable

12) Secondary Terminal Block Kit

Customer Field Installable

13) Secondary Terminal Wire Kit

Customer Field Installable

Style#

1B93092G01

Description

15 (6 point) Terminal Blocks and Labels

Style#

1B93093G01

Description

90 Wires with Terminal Connectors

(AMP and FastOn on opposite ends)

Additional items available from manufacturer:

Pin for 14-18 AWG. wire (AMP #66597-2)

Pin for 18-26 AWG. wire (AMP #640545-2)

Pin Crimper Tool (AMP #90067-4)

Style#

69C3323G01

Description

Secondary Umbilical Cord

(Drawout Circuit Breakers Only)

Style#

67A3056G01

Description

Simple Ground and Test Device

Style#

67A3055G01

Description

Dummy Element

HARDWARE INCLUDED

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7-6 OTHER BREAKER RELATED PARTS (1) Phase Barriers

Customer Field Installable

(2) Pushbutton External Lock Cover

Customer Field Installable

(3) Door Escutcheon and Gasket

Customer Field Installable

(4) Blank Cover for Fixed Breaker

Customer Field Installable

(5) Non-Automatic Trip Unit Cover

Customer Field Installable

Description

Horizontal Barriers (All 95kV BIL)

Inside Vertical Barriers (All 95 kV BIL)

Outside Vertical Barriers (All 95kV BIL dra-

wout only)

Style#

67A3152G01 67A3152G02 67A3152G03

Description

Metal Frame (includes hinged plastic windows)

Plastic Frame (includes hinged plastic windows)

Metal Frame with Blocked Close Button Cover

Pastic Frame with Blocked Close Button Cover

Cat#

MCOVM MCOVP MCOVC MCOVH

“CLOSED Button Cover

Plastic Frame shown without hinged plastic windows

Metal Frame shown with hinged plastic windows

HARDWARE INCLUDED

Gasket

Escutcheon (door frame)

HARDWARE INCLUDED

Description

Protects Against Dust and Dripping Water by

Sealing Space Between Breaker and

and Compartment Door Cutout

Cat#

MDES

Description

VCP-TR

Style#

2C12815H03

Description

VCP-T & VCP-TR

Style#

2C12812H06

HARDWARE INCLUDED

Inside Vertical

Barriers

(One Set)

Horizontal Barriers

(One Set)

Outside Vertical

Barriers

(One Set)

Left Barrier

Right Barrier

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I.B. 69C3067H06

Page 63

Effective 2/03

(7) Spout Boot

Customer Field Installable

(3) Trip Unit Current Sensors and Rating Plug

Customer Field Installable

(4) Zero Sequence Current Transformer

Customer Field Installable

Style#

69C3016G01 69C3016G02

(6) IP54 Cover Kit (Transparent)

Customer Field Installable

(2) 520V Trip Unit Kit

Requires C-HESS (Cutler-Hammer Engineering Services and Systems) Installation

Description

Provides protection against dust and

dripping water (IP54)

Style#

2C14892G01

HARDWARE INCLUDED

Style#Trip Unit Model

520V Trip Unit 67A3154G01

HARDWARE INCLUDED

Description

Spout Boot Kit includes required boots, fins and wire

ties sufficient for 6 spouts (6 boots, 6 fins and 18

wire ties)

Style#

69C3320G01

Wire Tie

Boot

Fin

Style#Power Supply VoltageTrip Unit Model

1150V Trip Unit 1150V Trip Unit 1150V Trip Unit

24 to 48 Vdc

120 Vac 240 Vac

67A3153G01 67A3153G02 67A3153G03

HARDWARE INCLUDED

7-7 TRIP UNIT AND RELATED PARTS (1) 1150V Trip Unit Kit (Trip Unit and Power Supply)

Requires C-HESS (Cutler-Hammer Engineering Services and Systems) Installation

Description

Zero Sequence Current Transformer

(100:1 and 200:1 tap ratio)

(50:1 tap ratio)

Sensor (Amps)

100 200 250 300 400 600 630

800 1000 1200 1250 1600

Style#

69C3011H01 69C3011H02 69C3011H25 69C3011H03 69C3011H04 69C3011H06 69C3011H63 69C3011H08 69C3011H10 69C3011H12 69C3011H13 69C3011H16

Rating Plug (Amps)

100 200 250 300 400 600 630

800 1000 1200 1250 1600

Style#

5720B93G01 5720B93G02 5720B93G03 5720B93G04 5720B93G05 5720B93G06 5720B93G07 5720B93G08 5720B93G09 5720B93G10 5720B93G11 5720B93G12

Rating

Plug

Current

Sensors

Rating Plug and

Sensors Must

Have Matching

Ratings

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I.B. 69C3067H06

Cutler-Hammer

Pittsburgh, Pennsylvania U.S.A.

Effective 2/03 (ISI) Style 69C3067H06 Printed in U.S.A.

This instruction booklet is published solely for informa- tion purposes and should not be considered all inclu- sive. If further information is required, you should con- sult Cutler-Hammer.

Sale of product shown in this literature is subject to terms and conditions outlined in appropriate Cutler- Hammer selling policies or other contractual agreement between the parties. This literature is not intended to and does not enlarge or add to any such contract. The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Cutler-Hammer.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PAR- TICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEAL- ING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CONTAINED HEREIN. In no event will Cutler-Hammer be responsible to the purchaser or user in contract, in tort (including negligence), strict lia- bility or otherwise for any special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facili- ties, or claims against the purchaser or user by its cus- tomers resulting from the use of the information, recom- mendations and description contained herein.

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Cutler-Hammer 50 VCP-T25, 50 VCP-TR25, 75 VCP-T16, 75 VCP-TR16, 75 VCP-TR20 Instructions For The Use, Operation And Maintenance

Specifications and Main Features

Frequently Asked Questions

User Manual