Eaton DST-2-7.5-500, DST-2-15-VR+500, DST-2-7.5-VR+500, DST-2-15-VR+500U, DST-2-15-500 Instruction Book

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Instruction Book IB182942EN
Supersedes March 2018 Effective
DST-2-VR
+
VR-Series+ Replacement Circuit Breaker
DST-2-VR+ 250 2000A Shown
DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton’s experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted. Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise 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 facilities, or claims against the purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The information contained in this manual is subject to change without notice.
DANGER
IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS MAY CAUSE THE EQUIPMENT TO FAIL, RESULTING IN DEATH, SEVERE PERSONAL INJURY, EQUIPMENT DAMAGE AND/OR IMPROPER OPERATION.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING ANY UNPACKING, ASSEMBLY, OPERATION OR MAINTENANCE OF THE CIRCUIT BREAKERS.
INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOKLET SHOULD NOT BE CONSIDERED ALL INCLUSIVE REGARDING INSTALLATION OR MAINTENANCE PROCEDURES. IF FURTHER INFORMATION IS REQUIRED, YOU SHOULD CONSULT EATON’S ELECTRICAL SERVICES & SYSTEMS.
THE CIRCUIT BREAKERS DESCRIBED IN THIS BOOK ARE DESIGNED AND TESTED TO OPERATE WITHIN THEIR NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL, RESULTING IN DEATH, SEVERE PERSONAL INJURY, EQUIPMENT DAMAGE AND/OR IMPROPER OPERATION.
ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY ADHERED TO.
THESE VACUUM REPLACEMENT CIRCUIT BREAKERS ARE DESIGNED TO BE INSTALLED PURSUANT TO THE AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI). SERIOUS INJURY, INCLUDING DEATH, SEVERE PERSONAL INJURY, EQUIPMENT DAMAGE AND/OR IMPROPER OPERATION.
This product was manufactured by Eaton at the Power Breaker Center (PBC): 310 Maxwell Avenue, Greenwood, SC 29646.
All possible contingencies which may arise during installation, operation or maintenance, and all details and variations of this equipment do not 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 an Eaton representative.
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Instruction Book IB182942EN July 2018 www.eaton.com
Table of Contents
SECTION 1: INTRODUCTION 4
1.1 VISUAL INSTRUCTION BOOKLET ESSENTIALS 4
1.2 QUICK RESPONSE CODE 4
1.3 AVAILABLE DST-2-VR+ CIRCUIT BREAKERS 4
SECTION 2 : SAFE PRAC TICES 7
SECTION 3 : RECEIVING, HANDLING, AND STORAGE 8
3.1 RECEIVING 8
3.2 HANDLING 9
3.3 STORAGE 9
3.4 APPROXIMATE WEIGHT BY TYPE 9
SECTION 4: DESCRIPTION AND OPERATION 12
4.1 VACUUM INTERRUPTER 12
4.1.1 VACUUM INTERRUPTER ASSEMBLY 12
4.1.2 CONTACT EROSION INDICATOR 12
4.1.3 CONTACT WIPE AND STROKE 13
4.2 LINE AND LOAD CONDUCTOR ASSEMBLIES 13
4.3 STORED ENERGY MECHANISM 13
4.3.1 CLOSING SPRING CHARGING 13
4.3.2 CLOSING OPERATION 13
4.3.3 TRIPPING OPERATION 14
4.3.4 TRIP-FREE OPERATION 14
4.4 CONTROL SCHEMES 14
4.4.1 TIMING 14
4.5 SECONDARY CONNECTION BLOCK 14
4.6 INTERLOCKS 14
4.6.1 ANTI-CLOSE INTERLOCK 14
4.6.2 SHUTTER OPERATING MECHANISM 14
4.6.3 RACKING SYSTEM TRIP AND SPRING RELEASE INTERLOCKS 16
4.7 RACKING MECHANISM 16
4.7.1 LE VERING SYSTEM TRIP A ND SPRING RELEASE INTERLOCKS 16
4.8 GROUNDING CONTACT 16
4.9 MISCELLANEOUS ITEMS 16
4.9.1 OPERATIONS COUNTER 16
SECTION 5: INSPECTION & INSTALLATION 20
5.1 EXAMINATION FOR DAMAGE 20
5.1.1 NAMEPL ATE VERIFICATION 20
5.2 SURE CLO SE MECHANISM ADJUSTMENT 20
DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
5.3 MANUAL OPERATION CHECK 21
5.4 VACUUM INTERRUPTER INTEGRIT Y 21
5.5 LOW FREQUENCY WITHSTAND TEST ( INSULATION CHECK ) 21
5.6 CONTACT EROSION AND WIPE 21
5.7 PRIMARY CIRCUIT RESISTANCE 21
5.8 ELECTRICAL OPERATIONS CHECK 21
5.9 MECHANICAL INTERLOCK (FLOOR TRIP) OPERATIONAL CHECKS 21
5.10 OPERATION, INSERTION AND REMOVAL ( LEVERING-IN VERSION) 22
5.10.1 OPERATIONAL POSITIONS ( LEVERING-IN VERSION) 22
5.10.2 INSERTION PROCEDURE ( LEVERING- IN VERSION ) 22
5.10.3 REMOVAL PROCEDURE (LE VERING- IN VERSION ) 23
5.11 OPERATION, INSERTION, AND REMOVAL FOR 5kV AND 15kV MODELS WITH ROTARY RACKING PROVISIONS 24
5.11.1 Operational Positions ( Domestic and some Canadian Rotary Racking Versions) 24
5.11.2 5kV Insertion Procedure (DST-2-5-VR+ 250, Domestic and Canadian Rotary Racking Version) 24
5.11.3 5kV Removal Procedure (DST-2- 5-VR+ 250, Domestic and Canadian Rotary Racking Version) 25
5.11.4 15kV Insertion Procedure ( DST-2-15-VR+ 500/750 Domestic and Canadian Rotary Racking Version) 25
5.11.5 15kV Removal Procedure (DST-2-15-VR+ 500/750 Domestic and Canadian Rotary Racking Version) 26
SECTION 6: INSPECTION & MAINTENANCE 27
6.1 INSPECTION FREQUENCY 27
6.2 INSPECTION AND MAINTENANCE PROCEDURES 27
6.3 VACUUM INTERRUPTER INTEGRIT Y TEST 28
6.4 CONTACT EROSION AND WIPE 28
6.5 INSULATION 29
6.6 INSULATION INTEGRIT Y CHECK 29
6.7 PRIMARY CIRCUIT RESISTANCE CHECK 29
6.8 VR-SERIES+ CIRCUIT BREAKER ELEMENT MECHA NISM CHECK 29
6.8.1 CLOSURE™ TEST 29
6.9 MAINTENANCE RECOMMENDATION 33
SECTION 7: REPLACEMENT PARTS 35
7.1 GENERAL 35
7.2 ORDERING INSTRUCTIONS 35
Instruction Book IB182942EN July 2018 www.eaton.com
iii
DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
SECTION 1: INTRODUCTION
This instruction booklet provides information on receiving and handling, storage, installation, operation and maintenance of the DST-2 VR-Series+ vacuum replacement circuit breaker. The Vacuum Replacement circuit breakers (also referred to as VR-Series+) are designed to be used in existing Federal Pacific type DST-2 metal-clad switchgear. The VR-Series+ circuit breakers provide superior electrical and mechanical performance as compared to the design ratings of the original circuit breaker. VR-Series+ circuit breakers provide reliable control, protection and performance, with ease of handling and maintenance. Like ratings of the VR-Series+ circuit breakers are interchangeable with each other.
The VR-Series+ circuit breaker element offers:
10-year or 10,000 operation scheduled maintenance intervals.
When applied in “usual service conditions” as defined by IEEE C37.04-1999, the VR-Series+ circuit breaker element requires maintenance only once every ten years or ten thousand operations, which ever comes first.
ote:N See Inspection & Maintenance section in this booklet for details.
Increased mechanical endurance. Circuit breakers in repetitive
duty applications offer 50% more operations over conventional vacuum circuit breaker elements before parts replacement may be needed.
Increased short circuit capability. The VR-Series+ circuit breaker
short circuit capability can be increased to 41 kA, provided a bus bracing study is performed and the switchgear is adequately braced to meet the requirements per IEEE C37.59.
Use this instruction bulletin in conjunction with the technical information provided with the original equipment order which includes electrical control schematic and wiring diagrams, outline diagrams, installations plans, and procedures for installation and maintenance of accessory items.
Satisfactory performance is dependent on proper application, correct installation, and adequate maintenance. It is very important that this installation and maintenance instruction booklet be read and followed closely to achieve optimum performance and a long useful circuit breaker life in its application.
1.1 VISUAL INSTRUCTION BOOKLET ESSENTIALS
Eaton provides additional documentation designed to enhance the technical information provided in this instruction booklet for the VR-Series+ circuit breakers. The Visual Instruction Booklet Essentials (VIBE) is a digital supplemental booklet featuring user interactive content and informative videos intended to assist with the maintenance of the VR-Series+ circuit breaker. The VIBE document is available for immediate download at www.eaton.com/VR-Series.
Figure 1.1. Quick Response Code
VR-Series+ QR Code
1.2 QUICK RESPONSE CODE
VR-Series+ circuit breakers have a quick response code (QR Code) on the escutcheon of the circuit breaker front cover. This QR Code is a matrix barcode that provides direct access to download VR-Series+ specific documentation, such as product instruction booklets and the VIBE documentation. See Figure 1.1 for the featured VR-Series+ QR Code.
ote:N A smart phone with an adequate QR Code Scanner application must be
used. Downloading content may incur data charges from the mobile service provider.
WARNING
SATISFACTORY PERFORMANCE OF THESE CIRCUIT BREAKERS IS CONTINGENT UPON PROPER APPLICATION, CORRECT INSTALLATION AND ADEQUATE MAINTENANCE. THIS INSTRUCTION BOOKLET MUST BE CAREFULLY READ AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE FOR LONG USEFUL LIFE OF THE CIRCUIT BREAKERS. IT IS FURTHER RECOMMENDED THAT THE INSTALLATION BE PERFORMED BY AN EATON TRAINED ENGINEER OR TECHNICIAN.
+
VR-SERIES THEY ARE MAXIMUM RATED DEVICES. THEREFORE, THEY SHOULD NOT UNDER ANY CIRCUMSTANCE BE APPLIED OUTSIDE THEIR NAMEPLATE RATINGS.
ALL POSSIBLE CONTINGENCIES WHICH MIGHT ARISE DURING INSTALLATION, OPERATION, OR MAINTENANCE, AND ALL DETAILS AND VARIATIONS OF THIS EQUIPMENT ARE NOT COVERED BY THESE INSTRUCTIONS. IF FURTHER INFORMATION IS DESIRED BY THE PURCHASER REGARDING A PARTICULAR INSTALLATION, OPERATION, OR MAINTENANCE OF THIS EQUIPMENT, THE LOCAL EATON REPRESENTATIVE SHOULD BE CONTACTED.
1.3 AVAILABLE DST-2-VR+ CIRCUIT BREAKERS
Refer to Table 1.
CIRCUIT BREAKERS ARE PROTECTIVE DEVICES, AS SUCH,
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Instruction Book IB182942EN July 2018 www.eaton.com
Table 1. DST-2-VR+ Availability and Interchangeability
Nominal 3-Phase
Existing DST-2
Circuit Breaker Type
DST-2-7.5-500
DST-2-15-500
DST-2-15-500U
DST-2-15-750
DST-2-15-500/750
a
All circuit breakers have a 3 second short-time and 3-cycle interrupting ratings.
b
Non-standard rating.
c
Requires bus bracing study and additional switchgear bracing.
+
DST-2-VR Circuit Breaker
a
Type
DST-2-7.5-VR+500
DST-2-15-VR+500
DST-2-15-VR+500U
DST-2-15-VR+750
DST-2-15-VR+41
Maximum Voltage
kV MVA Amps K
8.25 500 1200 / 2000 1.25 36 95 33 41 66 / 111
15.0 500 1200 / 2000 1.30 36 95 18 23 37 / 62
c
15.0 500 1200 / 2000 1.30 36 95 28 36 58 / 97
15.0 750 1200 / 2000 1.30 36 95 28 36 58 / 97
b c
15.0 N/A 1200 / 2000 1.0 36 95 41 41 77 / 130
MVA Class
Existing Circuit Breaker Rated Continuous Current at 60 Hz
Rated Voltage Factor
Rated Withstand ANSI Test Voltage
Low Freq. kV RMS
Impulse kV PeakIkA RMS
DST-2-VR
VR-Ser ies+ Replacement Circuit Breaker
Closing and
Rated Short-Circuit
Maximum Sym. Interrupting Capability
KI kA RMS kA RMS / Peak
Latching / Momentary Capabilities
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Instruction Book IB182942EN July 2018 www.eaton.com
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DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
B
C C
A
D
E
Table 2. DST-2-VR+ Dimensions
Existing Circuit Breaker Rated Continuous Current at 60 Hz
Circuit Breaker Type
DST-2-VR+
6
(Amps) A B C D E F
1200 / 2000 65.38 25.75 7.88 34.18 11.00 19.81
Instruction Book IB182942EN July 2018 www.eaton.com
F
SECTION 2: SAFE PRACTICES
VR-Series+ circuit breakers are equipped with high speed, high energy operating mechanisms. They are designed with several built­in interlocks and safety features to provide safe and proper operating sequences.
DANGER
TO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLATION, OPERATION, AND MAINTENANCE OF THESE CIRCUIT BREAKERS, THE FOLLOWING PRACTICES MUST BE FOLLOWED:
Only qualified persons, as defined in the National Electrical Safety Code, who are familiar with the installation and maintenance of medium voltage circuits and equipment, should be permitted to work on these circuit breakers.
Read these instructions carefully before attempting any installation, operation or maintenance of these circuit breakers.
Always remove the circuit breaker from the enclosure before performing any maintenance. Failure to do so could result in electrical shock leading equipment failure, resulting in death, severe personal injury, equipment damage and/or improper operation.
Do not work on a circuit breaker with the secondary test coupler engaged. Failure to disconnect the test coupler could result in an electrical shock leading to death, severe personal injury, equipment damage and/or improper operation.
Do not work on a closed circuit breaker or a circuit breaker with closing springs charged. The closing spring should be discharged and the main contacts open before working on the circuit 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. Remove the circuit breaker to the ‘Disconnect’ position and follow all lockout and tagging rules of the National Electrical Code and any and all applicable codes, regulations and work rules.
Do not leave the circuit breaker in an intermediate position in the circuit breaker compartment. Always have the circuit breaker either in the ‘Test’ or ‘Connect’ position. Failure to do so could result in a flash over causing the equipment to fail, resulting in death, severe personal injury, equipment damage and/or improper operation.
Always remove the maintenance tool from the circuit breaker after charging the closing springs.
Circuit breakers are equipped with safety interlocks. Do not defeat them. This may result in equipment failure, resulting in death, severe personal injury, equipment damage and/or improper operation.
DST-2-VR
VR-Ser ies+ Replacement Circuit Breaker
+
Instruction Book IB182942EN July 2018 www.eaton.com
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DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
SECTION 3: RECEIVING, HANDLING, AND STORAGE
VR-Series+ 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. Accessories such as the maintenance tool, code plate, (if applicable) etc. are shipped with the circuit breaker.
3.1 RECEIVING
Until the circuit breaker is ready to be delivered to the switchgear site for installation, DO NOT remove it from the shipping crate. If the circuit breaker is to be placed in storage, maximum protection can be obtained by keeping it in its crate.
Upon receipt of the equipment, inspect the crates for any signs of damage or rough handling. Open the crates carefully to avoid any damage to the contents. Use a nail puller rather than a crow bar when required.
When opening the crates, be careful that any loose items or hardware are not discarded with the packing material. Check the contents of each package against the packing list.
Examine the circuit breaker for any signs of shipping damage such as broken, missing or loose hardware, damaged or deformed insulation and other components. If damaged or loss is detected, file claims immediately with the carrier and notify an Eaton representative.
Figure 3.1.a. Typical Tools and Accessories
Figure 3.1.b. Rotary Racking Handle
Tools and Accessories
Maintenance Tool (Style# 94C9506G01): This tool is used to manually charge the closing springs. One maintenance tool is provided with each vacuum replacement circuit breaker.
Rotary Racking Handle (Style# 94B4102G21): Rotary racking is possible utilizing a speed-handle, suitable extensions and a standard 3/4” socket. One rotary racking handle is provided per order. If necessary, additional racking handles may be purchased directly from Eaton. This handle is used with the rotary racking system for insertion and removal.
Levering Handle: The original DST-2 levering handle is used to assist in moving the circuit breaker into and out of the cell. However, it cannot be used with the rotary racking system. Its use is illustrated in section 5 of this manual.
Secondary Connection Block Extension Cable: The extension
cable can be used to connect the circuit breaker to a “test cabinet” or to the switchgear cell’s secondary receptacle block so that the breaker can be electrically operated while not installed in the switchgear cell. This extension cable is the same one provided with the original Federal Pacific breaker and is therefore not included as part of the vacuum replacement breaker
Lifting Strap (Style# 94B1194G01): Optional item recommended for lifting the DST-2-VR+ circuit breaker.
.
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Instruction Book IB182942EN July 2018 www.eaton.com
DST-2-VR
VR-Ser ies+ Replacement Circuit Breaker
+
3.2 HANDLING
WARNING
DO NOT USE ANY LIFTING DEVICE AS A PLATFORM FOR PERFORMING MAINTENANCE, REPAIR OR ADJUSTMENT OF THE CIRCUIT BREAKER OR FOR OPENING, CLOSING THE CONTACTS OR CHARGING THE SPRINGS. THE CIRCUIT BREAKER MAY SLIP OR FALL CAUSING SEVERE PERSONAL INJURY. ALWAYS PERFORM MAINTENANCE, REPAIR AND ADJUSTMENTS ON A WORKBENCH CAPABLE OF SUPPORTING THE CIRCUIT BREAKER TYPE.
VR-Series+ circuit breaker shipping containers are designed to be handled either by use of an 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.
Once a circuit breaker has been inspected for shipping damage, it is best to return it to its original shipping crate until it is ready to be installed in the metal-clad switchgear.
When the circuit breaker is ready for installation, a lifting harness in conjunction with an overhead lift or portable floor lift can be used to move the circuit breaker. If the circuit breaker is to be lifted, position the lifting device over the circuit breaker and insert the lifting harness hooks into the circuit breaker side lifting points and secure (lifting straps should have at least a 1000lbs lift capacity). Be sure the hooks are firmly attached before lifting the circuit breaker. Stand a safe distance away from the circuit breaker while lifting and moving.
Figure 3.2. Lifting DST-2-VR
+
3.3 STORAGE
If the circuit breaker is to be placed in storage, maximum protection can be obtained by keeping it in the original shipping crate. Confirm that the circuit breaker is free from shipping damage and is in satisfactory operating condition before placing it in to storage.
The circuit breaker is shipped with its contacts open and closing springs discharged. The indicators on the front cover should confirm this. Insert the end of the maintenance tool into the manual charge socket opening and charge the closing springs by moving the handle up and down the full range of motion. When charging is complete the ratchet will no longer advance and the spring charged / discharged indicator displays ‘Charged’. (Figure Set 3.3). Remove the maintenance tool. Push the “manual close” operator. The circuit breaker will close as shown by the circuit breaker contacts ‘Closed’ indicator. Push the “manual trip” operator. The circuit breaker will trip as shown by the circuit breaker contacts ‘Open’ indicator. After completing this initial check, leave the closing springs ‘Discharged’ and circuit breaker contacts ‘Open’.
Outdoor storage is NOT recommended. If unavoidable, the outdoor location must be well drained and a temporary shelter from sun, rain, snow, corrosive fumes, dust, dirt, falling objects, excessive moisture, etc. must be provided. Containers should be arranged to permit free circulation of air on all sides and temporary heaters should be used to minimize condensation. Moisture can cause rusting of metal parts and deterioration of high voltage insulation. A heat level of approximately 400 watts for each 100 cubic feet of volume is recommended with the heaters distributed uniformly throughout the structure near the floor.
Indoor storage should be in a building with sufficient heat and circulation to prevent condensation. If the building is not heated, the same general rule for heat as for outdoor storage should be applied.
3.4 APPROXIMATE WEIGHT BY TYPE
Table 3. Approximate Weight by Type
Type Amperes LBs
DST-2-VR+ 500
DST-2-VR+ 750
ote:N * = An additional 75# is added with the optional internal Rotary Racking
system.
1200 650*
2000 750*
1200 630*
2000 750*
Instruction Book IB182942EN July 2018 www.eaton.com
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DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
Figure 3.3.a. Front External View of DST-2-VR
+
3
3
4 5
6 7
8 9
1 2
10 11
12
Front External View
1 Lock Out / Tag Out 5 Manual Charging Socket 9 Push To Close Button
2 Levering In Access 6 Spring Charged / Discharged Indicator 10 Interlock Pedal
3 Handle 7 Operations Counter 11 Manual Motor Cut-Off Switch
4 Breaker Position Indicator 8 Push To Open Button 12 Tow Hitch
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Instruction Book IB182942EN July 2018 www.eaton.com
Figure 3.3.b. Rear External View of DST-2-VR
DST-2-VR
+
VR-Ser ies+ Replacement Circuit Breaker
+
1 1
3
4
2
5 6
Rear External View
1 Lifting Points 4 Anti Rotation Self Adjuster (Optional)
2 Secondary Disconnects 5 Ground Contact
3 Primary Disconnects 6 Shutter Roller
Instruction Book IB182942EN July 2018 www.eaton.com
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