Eaton Cutler-Hammer DS Series User manual

Instructions for
Low-Voltage
Power Circuit Breakers
Types DS and DSL
READ AND UNDERSTAND THESE INSTRUCTIONS
BEFORE ATTEMPTING
ANY ASSEMBLY, OPERATION, OR
MAINTENANCE OF THE SWITCH
Cutler-Hammer
Distribution and Control Business Unit
Electrical Components Division
Pittsburgh, PA 15220
1.8. 33-790-11 Effective October, 1998Supersedes1.8. 33-790-1H dated September, 1996
Courtesy of NationalSwitchgear.com

Table of Contents
Description
Introduction ......................................................................... .
General Description
.................................................................. .
Basic Breaker Assembly
......................................................... .
Arc Chutes
................................................................... .
Optional Components
........................................................... .
Accessories
................................................................... .
Special Circuit Breakers: DS-206S and DS-416S
...................................... .
Safety Features
...................................................................... .
Recommended Safety Practices
......................................................... .
Section 1 -Receiving, Handling
and Storing ................................................ .
1.0 Receiving And Handling
...................................................... .
1.1 Storing ................................................................... .
1.2 Weights: Circuit Breakers And Fuse Trucks
....................................... .
Section 2 -First Removal of Breaker from Compartment
....................................... .
2.0 General
................................................................... .
2.1 Setting The Rails In Front Of The Compartment ................................... .
2.2 Removing Shipping Brace
.................................................... .
2.3 Lifting The Breaker
.......................................................... .
Section 3 -Preliminary Examination of Circuit Breaker
........................................ .
3.0 General
................................................................... .
3.1 Independent Manual And Power-operated Breakers ................................ .
3.1.1 Closing Facilities ........................................................... .
3.1.2 Tripping Facilities
........................................................... .
3.2 Levering Device
..................................... · ....................... .
Section 4 -Basic Operating Instructions
.................................................... .
4.0 General
................................................................... .
4.1 Levering Device ............................................................ .
4.2 Charge The Closing Springs
.................................................. .
4.3 Close The Breaker
.......................................................... .
4.4 Open The Breaker
.......................................................... .
4.5 Place The Breaker
In The Test Position ........................................... .
4.6 Place The Breaker
In The Connect Position ...................................... .
4.7 Remove The Breaker For Final Inspection
........................................ .
4.8 Final Inspection
............................................................ .
4.9 Amptector Trip Settings
...................................................... .
4.10 Place The Breaker
In Service .................................................. .
Section 5 -Description and Explanation of Operation
......................................... .
5.0 General
................................................................... .
5.1 The Operating Mechanism And How It Works ..................................... .
5.1.1 Power-Operated Mechanism .................................................. .
5.1.2 Explanation of Spring-Charging Mechanism for Power-Operated Breakers
.............. .
5.1 .2.1 Power Operation ........................................................... .
5.1.3 Manual-Operated Mechanisms
................................................ .
5.1.4 Explanation of Spring-Charging Mechanism for Manually-Operated Breakers
............ .
5.1.5 Circuit Breaker Closing Mechanism
............................................ .
5.1.6 Circuit Breaker Tripping or Opening Mechanism
................................... .
Effective October 1998
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Page ii
Description
5.1.6.1
5.1.7
5.1.7.1
5.1.7.2
5.1.7.3
5.1.7.4
5.1.8
5.1.8.1
5.1.8.2
5.1.8.3
5.1.8.4
5.1.8.5
Miscellaneous Details
....................................................... .
Mechanical Interlocking, Description and Explanation of Operation
.................... .
The REMOVE Position
....................................................... .
The DISCONNECT Position
.................................................. .
The TEST Position
.......................................................... .
The CONNECT Position
..................................................... .
Detailed Explanation of Mechanical Interlock System
............................... .
Spring Discharge Interlock
.................................................... .
Connected Breaker Manual Close Interlock
....................................... .
Breaker Equipped for Electric Lockout
........................................... .
Closed Breaker Interlock
..................................................... .
Padlocking Provision
........................................................ .
Section 6 -Circuit Breaker Pole Units, Description and Operation
................................ .
6.0 General
................................................................... .
6.1 Moving Contact Sub-assemblies ................................................ .
6.2 Stationary Contact Sub-assemblies
............................................. .
Section 7 -Arc Chute
.................................................................. .
7.0 General
................................................................... .
Section 8 -Circuit Breaker Automatic Tripping System
......................................... .
8.0
8.1
8.2
8.2.1
8.3
8.4
8.5
8.6
8.7
8.7.1
8.7.2
8.7.3
8.7.4
8.7.5
8.7.6
8.7.6.1
8.7.6.2
8.7.6.3
General
................................................................... .
The Amptector II-A Trip Unit
................................................... .
The Amptector I-A Trip Unit
................................................... .
Ground Fault Protection
...................................................... .
Making Current Release (Discriminator)
........................ · .................. .
Servicing Of Amptector Trip Unit.
............................................... .
Actuator
................................................................... .
Sensors
................................................................... .
Optional Accessories
........................................................ .
Undervoltage Trip Attachment
................................................. .
Overcurrent Trip Switch
...................................................... .
High Load Switch (available with Amptector I-A only)
............................... .
Latch Check Switch
......................................................... .
Auxiliary Switches
.......................................................... .
Amptector Trip Unit Test Kit
................................................... .
General
.................................................................. .
Description
................................................................ .
Operation
................................................................. .
Section 9 -DSL Circuit Breakers and Fuse Trucks
............................................ .
9.0 General
................................................................... .
9.1 DSL Current Limiters ......................................................... .
9.2 Blown Limiter Indicator
....................................................... .
9.3 Fuse Trucks
............................................................... .
9.3.1 Installing Fuse Trucks ....................................................... .
9.3.2 Replacing Fuses
........................................................... .
9.3.3 Blown Fuse Indicator
........................................................ .
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Effective October 1998
Courtesy of NationalSwitchgear.com

Description
Section 10 -Fixed Breakers ............................................................. .
10.0 General
................................................................... .
Section
11 -Drawout Dummy Elements .................................................... .
11.0 General
................................................................... .
Section 12 -Inspection and Maintenance
................................................... .
12.0
12.1.1
12.1.2
12.1.2.1
12.1.2.2
12.1.3
12.1.3.1
12.1.3.2
12.1.4
12.1.5
12.1.5.1
12.2
12.2.1
12.2.2
12.2.3
12.2.4
12.3
12.3.1
12.3.2
General
................................................................... .
When to Inspect
............................................................ .
What to Inspect
............................................................ .
DS-206, DS-206S, DS-416, DS-416S and DS-420
................................. .
DS-632 and DS-840
........................................................ .
Replacement of Contacts
.................................................... .
DS-206
.................................................................. .
DS-416, DS-416S, DS-420, DS-632 and DS-840
.................................. .
Arc Chutes
................................................................ .
General Inspection
......................................................... .
Power Operated Mechanisms
................................................. .
Factory Adjustments
......................................................... .
Trip Latch Overlap
.......................................................... .
Breaker Open Position Stop (DS-632 Only)
...................................... .
Moving Contact Adjustment
................................................... .
Levering Mechanism
........................................................ .
LUBRICATION
............................................................. .
Frequency
................................................................ .
Location and Lubricant
...................................................... .
Section 13 -Renewal Parts
............................................................. .
13.0 General
................................................................... .
13.1 Identifying Parts For DS-416S And DS-206S ...................................... .
13.1 .1 DS-416S Parts ............................................................. .
13.1 .2 DS-206S Parts ............................................................. .
List of Tables
1.
2.
3.
4.
5.
Type DS Breaker Ratings ........................................................ .
DSL Breakers -Current Limiting Type Breakers and Combinations
........................ .
Approximate Weights
........................................................... .
Frame Size and Sensor Ratings
................................................... .
Sensor and Limiter Ratings
....................................................... .
Effective October 1998
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List of Illustrations
Figure
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6b
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Title
The Type DS Low Voltage Power Circuit Breaker is Shipped Inside Its Own Compartment
Rails are Stowed away
in the Compartment .................................... .
Levering Device Crank Handle Installed
....................................... .
Use
of Breaker Lifting Adapter ............................................... .
View Showing Controls on the Panel
.......................................... .
Left Side
of Breakerwith Levering Device Arm in REMOVE Position ................. .
DS 416 Breakerwith Front Panel Removed
.................................... .
Right Side Showing Levering Device Arm
in TEST Position ........................ .
Rear View Showing Levering Device Arm
in CONNECT Position .................... .
Method Used to Press Trip Plate and Lower Shutter with One Hand,
Preparatory to Inserting Crank
........................................... .
Front View
of Mechanism (Manual Spring Charge Except for DS-632/840) ............ .
Front View
of Mechanism (Power-Operated Spring Charge) ........................ .
Rear
of Power-Operated Mechanism ......................................... .
Rear View
of Mechanism (Left Close Spring Removed) ........................... .
Arrangement
of the Principal Parts of a Power Operated Mechanism
The Close Spring is Shown
in the Charged Position ........................... .
Front
View Showing Major Parts of the Crank Shaft Assembly
Some Parts are Omitted for Clarity
........................................ .
Power-Operated Spring-Charge Details
........................................ .
Crank Shaft Assembly
of Power-Operated Mechanism ........................... .
Emergency Spring-Charge on Power Operated Mechanism
........................ .
Standard Schematic and Connection Diagrams for Power-Operated Breakers
.......... .
Principal Parts
in a Manually Charged Spring Operated Mechanism ................. .
Spring-Charging Mechanism on Manual Operated Breakers
........................ .
These Sketches Show the Four Basic Positions
of Breaker and Linkage
with Enlarged View
of Trip Shaft and Latch .................................. .
Shunt Trip Details Showing Trip Shaft Adjustment
............................... .
Actuator
................................................................ .
DS-632 Breakerwith Front Panel Removed
.................................... .
Bottom View
of Breaker Unit Showing Interference Interlock,
MotorCut-off Switch and Other Details not Visible from Above
.................. .
Front
View Showing Close Bar Guard ......................................... .
Rear View Showing the Seismic Positioner
..................................... .
Drawout Unit Position Indicator
.............................................. .
Relation
of Shutter, Trip Plate, and Trip Shaft ................................... .
Relation
of Shutter, Interlock Cam and Levering Device Arms ...................... .
Close-Release Interlock to Discharge Springs on Levering Out
of Compartment and
Conn. Position no Manual Close Interlock
................................... .
Close Interlock to Prevent Efforts to Close a Breaker that is Already Closed
........... .
Padlock Device -Locked Trip Free and Shutter Raised
........................... .
Three-Pole Assembly
of DS-206 Pole Units on Frame ............................ .
Three-Pole Assembly
of DS-416 and DS-420 Pole Units on Frame .................. .
Three-Pole Assembly
of DS-632 Pole Units on Frame ............................ .
Three Pole Assembly
of DS-840 Pole Units on Frame ............................ .
Type DS-206 Pole Unit Assembly -Front View
.................................. .
Type DS-206 Pole Unit Assembly -Rear
View .................................. .
Effective October 1998
Page iv
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Figure
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Title
Type DS-416 Pole Unit Assembly- Front View .................................. .
Type DS-416 Pole Unit
Assembly- RearView .................................. .
Type DS-420 Pole Unit Assembly -Front
View .................................. .
Type DS-420 Pole Unit Assembly -Rear
View .................................. .
Type DS-632 Pole Unit Assembly -Front
View .................................. .
Type DS-632 Pole Unit Assembly -Rear
View .................................. .
Type DS-840 Pole Unit Assembly -Front
View .................................. .
Type DS-840 Pole Unit Assembly -Rear
View .................................. .
Moving and Stationary Contact Details DS-206
................................. .
Moving and Stationary Contact Details DS-416
................................. .
Moving and Stationary Contact Details DS-420
................................. .
Moving Contact Details DS-632
............................................. .
Stationary Contact Details DS-632
........................................... .
Moving Contact Details DS-840
............................................. .
Stationary Contact Details DS-840
........................................... .
Breakerwith Barrier Removed to Show Mounting
of Arc Chutes .................... .
DS-206
Arc Chute with Details .............................................. .
DS-416/420 Arc Chute with Details
........................................... .
DS-632
Arc Chute with Details .............................................. .
DS-840
Arc Chute with Details .............................................. .
Schematic Illustration
of Tripping System ...................................... .
Standard Amptector II-A Solid-State Trip Unit
................................... .
Amptector II-A Trip Unitwith Front Cover Removed
.............................. .
Optional Amptector I-A Solid-State Trip Unit
.................................... .
Amptector I-A Trip Unit with Front Cover Removed
.............................. .
Trip Actuator
............................................................ .
DS-840 Breakerwith Front Panel Removed
.................................... .
DS-840 Breaker Rear View Showing Sensors
.................................. .
Undervoltage Trip Device
.................................................. .
Undervoltage Trip Device Operation
.......................................... .
Overcurrent Trip Switch
.................................................... .
Overcurrent Trip Switch Operation
............................................ .
High Load Switch
........................................................ .
Latch Check Switch
....................................................... .
Latch Check Switch Operation
............................................... .
Auxiliary Switch Construction Details
.......................................... .
Amptector Trip Unit Test Kit (ForAmptector
1-A and 11-A) .......................... .
Test Kit in Operation
...................................................... .
DSL-206 Breaker Side View
................................................ .
DSL-206 Breaker Front View (DSL-416 Similar)
................................. .
DSL-416 Breaker Side View
................................................ .
Blown Limiter Indicator
..................................................... .
DS-3200 Fuse Truck FrontView
............................................. .
DS-3200 Fuse Truckwith Front Cover Removed
................................ .
DS-4000 Fuse Truck Side View
............................................. .
Contacts and their Adjustment, DS-206 Breaker
................................. .
Contacts and their Adjustment, DS-416/420 Breaker
............................. .
Effective October 1998
Page v
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Page vi
Figure
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87
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91
Title
Contacts and their Adjustment, DS-632 Breaker ................................. .
Contacts and their Adjustment, DS-840 Breaker
................................. .
Open Position Stop and Anti-Rebound Latch .................................... .
Levering Mechanism
...................................................... .
Lubrication Points on Left Side of Mechanism ................................... .
Lubrication Points
on Right Side of Mechanism ................................. .
Page
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Effective October 1998
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1.8. 33-790-11
Page vii
PURPOSE
This instruction book is expressly intended to cover the installation, operation and maintenance
of Low Voltage Power Circuit Breakers, Types DS and DSL.
For application information, consult your nearest Cutler-Hammer sales office, see Cutler-Hammer
Descriptive Bulletin 32-850, or appropriate ANSI Standards.
SAFETY
All Safety Codes, Safety Standards and/or Regulations as they may be applied to this type of
equipment must be strictly adhered to.
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 furtherinformation is desired by purchaserregarding hisparticularinstallation, operation or
maintenance of his equipment, the localCutler-Hammer representative should be contacted.
Effective October 1998
Courtesy of NationalSwitchgear.com

Page viii
1.8. 33-790-11
CAUTION
The
circuit breakers described in this book were
designed and tested
to operate within their nameplate
ratings. Operation
outside of these ratings may cause
the equipment to fail, resulting in bodily injury and
property damage.
Effective October 1998
Courtesy of NationalSwitchgear.com

1.8. 33-790-11 Page 1
Introduction
These instructions cover the description, operation and
maintenance of Cutler-Hammer Type DS and Type DSL
Low Voltage AC Power Circuit Breakers and Type DS
Drawout Fuse Trucks. These breakers are usually sup-
plied as part of low voltage metal enclosed switchgear of
the four-position drawout type. These instructions apply
only to the circuit breakerand its auxiliary drawout details
which have been designed as a completely integrated
drawout unit. Type DS Breakers (not DSL) may also be
supplied in a fixed mounted version. In this case the sec-
tions of this book referring to the levering device, position
interlocks, and spring discharge interlock will not apply.
The DS and DSL Circuit Breakers operate on the mag-
netic De-ion principle
of interruption. In these breakers
the arc rises into a series of insulated steel plates. The
plates break the rising arc into a series
of smaller arcs to
cool and extinguish them and funnel the heat to ambient
air.
DS and DSL Breakers are available for application at
voltages from 208 to 600Vac; with continuous currents of
50 to 4000 amps; and with interrupting capabilities up to
200,000 amps. Refer to the breaker nameplate for the
complete rating information for any given breaker. Break-
ers conform to NEMA, ANSI and IEEE standards.
TYPE OS AND DSL BREAKERS ARE PROTECTIVE
DEVICES. AS SUCH, THEY ARE MAXIMUM CUR-
RENT RATED DEVICES. THEREFORE, THEY
SHOULD NOT UNDER ANY CIRCUMSTANCES BE
APPLIED OUTSIDE THEIR NAMEPLATE RATINGS.
OPERATION OUTSIDE OF THESE RATINGS MAY
CAUSE THE EQUIPMENT TO FAIL, RESULTING IN
BODILY INJURY AND PROPERTY DAMAGE.
The available DS and DSL Breakers and their rated per-
formance capabilities are given in Tables 1 and 2.
Table 1 - Type DS Breaker Ratings
Interrupting Ratings, RMS Symmetrical Amperes
Breaker Frame Size, With Instantaneous Trip
Type Amp. 208-240V 480V 600V
DS-206 800 42,000 30,000 30,000
DS-206S 800 50,000 42,000 42,000
DS-416 1600 65,000 50,000 42,000
DS-416S 1600 65,000 65,000 50,000
DS-420 2000 65,000 65,000 50,000
DS-632 3200 85,000 65,000 65,000
DS-840 4000 130,000 85,000 85,000
l Also short-time ratings.
i Short circuit ratings
of non-automatic breakers except the DS-840 which is 65,000.
Maximum voltages at which the interrupting ratings apply are:
System Voltage Maximum Voltage
208 or 240 254
480 508
600 635
Interrupting ratings are based
on the standard duty cycle con-
sisting
of an opening operation, a 15 second interval and a
close-open operation,
in succession, with delayed tripping in
case of short-delay devices.
The standard duty cycle for short-time ratings consists
of main-
taining the rated current for two periods
of 1/2 second each,
with a 15-second interval ofzero current between the two periods.
Effective October 1998
With Short Delay TriPli
208-240V 480V 600V
30,000 30,000 30,000
42,000 42,000 42,000
50,000 50,000 42,000
65,000 65,000 50,000
65,000 65,000 50,000
65,000 65,000 65,000
85,000 85,000 85,000
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Page2
l.B. 33· 790-11
Table 2 - DSL Breakers -Current Limiting Type Breakers and Combinations
Type OSL-206
Frame Size, Amperes 800
Max. Interrupting Rating,
RMS Symm. Amp., System
Voltage 600 or Below 200,000
Notes: DSL-206 and DSL-416 include limiters integral
with drawout breaker elements. DSL-632 includes
DS-632 breaker and DS-3200 drawout fuse truck, in
separate interlocked compartments. Maximum con-
tinuous rating limited to 3000A when fuse compart-
ment is above breaker compartment in same unit.
DSL-840 includes DS-840 breaker and DS-4000 draw-
out fuse truck, in separate interlocked compart-
ments. Maximum interrupting rating limited to
150,000 amperes when 6000A fuses are used.
GENERAL DESCRIPTION
Cutler-Hammer OS and OSL Circuit Breakers are hori-
zontal drawout magnetic air circuit breakers. They are
designed for use in Metal-Clad Switchgear assemblies
having maximum voltages of 635 volts AC for
OS Circuit
Breakers and 600 volts for OSL. They are equipped with
spring-stored, energy-closing mechanisms. All primary
insulation to ground is glass polyester. These breakers
have many common features, but they will vary in size
and detail depending on the specific breakertype number
and ratings. Figure 1 shows Type
OS Low Voltage Power
Circuit Breaker shipped inside its own compartment. Fig-
ures 78 and 79 show Types OSL-206 and OSL-416 Cir-
cuit Breakers.
Each
OS and OSL Circuit Breaker consists of a basic
breaker assembly, three interrupter assemblies (arc
chutes), barriers, and an Amptector solid-state trip unit.
OSL breakers have added current limiters to extend their
interrupting range to 200,000 amps. Various accessories
are also provided.
Basic Breaker Assembly
The basic breakerassembly includes a chassis, a control
panel, an operating mechanism, a levering-in device, var-
ious interlocks, and three insulated pole unit assemblies
mounted on a base.
OSL-416 OSL-632 OSL-840
1600 3200 4000
200,000 200,000 200,000
On the front of the breaker are the control items needed
for proper operation of the circuit breaker. They are:
breaker position indicator, breaker open/closed indicator,
levering device shutter and shaft, breakertrip plate, clos-
ing spring charged/discharged indicator, Amptector trip
test terminal access, Amptector trip controls, closing
spring charge handle, close
bar and padlock plate.
Arc Chutes
Each arc chute contains vertical steel splitter plates, insu-
lating spacers and plates. These are all assembled in an
insulating arc chute jacket. The arc chutes mount on top
of the pole units and are vented to atmosphere.
Optional Components
Optional components provided upon order are: under-
voltage trip attachment, overcurrent trip switch, high-load
trip switch, latch check switch, auxiliary switches.
Accessories
Levering crank and Amptector Test Kit are supplied as
required.
Since the major components and the accessories
depend on the particular type and rating of circuit
breaker, packing lists provided with each shipment and
more detailed sections of this instruction book should be
referred to for special information. Any questions about
the circuit breakers may be referred to the nearest Cutler-
Hammer Sales Office. When making inquiries about type
OS (OSL) circuit breakers always provide the specific
type number, continuous current rating, mechanism type,
applicable order numbers, breaker shop orders or style
numbers, date of manufacture and other pertinent infor-
mation as shown on the circuit breaker nameplate. Inquir-
ies can be handled faster when complete information is
provided with the initial inquiry.
Effective October 1998
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l.B. 33-790-11
Special Circuit Breakers: DS-206S and DS-416S
Table 1 gives the interrupting rating of DS-2068 as
42,000 amperes at 600 volts
AC. It is an improved model
of DS-206, which has an interrupting capacity of 30,000
amperes at 600 volts
AC. Yet, the maximum continuous
current rating of 800 amperes is the same for both types.
Also, their parts are similar except for these differences:
1. D8-2068 uses the three piece base of the 08-416
type, instead of the one piece molded base of the
DS-206.
2. D8-2068 uses the D8-416 arc chute.
3. D8-2068 main disconnects have 50% more fingers
than the 08-206.
Effective October 1998
Page3
4. D8-206S has twice as many main contacts and arms
as the D8-206.
5. The pole unit hinge joint of D8-2068 is a forked con-
struction or a miniature version of the
08-416 hinge.
6. Fifty ampere sensors cannot be installed on
D8-206S; but they can be put on DS-206.
Similarly, the parts of D8-4168 are almost identical to
those of D8-420. Their interrupting ratings are the same:
65,000 amperes at 480 volts AC and 50,000 amperes
at
600 volts AC. But, the maximum continuous current rat-
ing of
08-420 is 2,000 amperes and for D8-416S it is
1600 amperes.
Compared to Type D8-416, D8-4168 has higher inter-
rupting ratings, giving it improved operating flexibility. See
Table 1.
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Page4 1.8. 33-790-11
Safety Features
Type DS (DSL) Breakers are manufactured with several
built-in interlocks and safety features to reduce hazards
and provide proper operating sequences. UNDER NO
CIRCUMSTANCES SHOULD THEY BE MADE INOP-
ERATIVE AS THIS MAY RESULT
IN BODILY INJURY
OR PROPERTY DAMAGE.
1. Positive mechanical indicators on front panel show
whether the breaker is open or closed, and whether
the closing spring is charged or discharged.
2. Closing Spring Automatic Discharge -Mechanical
interlocking automatically discharges the closing
springs when the breaker is removed from its com-
partment.
3. Mechanical interlocking prevents levering of breaker
unless its contacts are open. Contacts cannot be
closed until the breaker is levered into TEST or CON-
NECT positions.
4. Mechanical interlocking prevents closing of breaker
contacts while it is being levered into or out of its cell,
or while it is standing in any intermediate location
between the TEST and the CONNECT positions or
the DISCONNECT position.
5. Provisions for Padlocking-Breakers can be pad-
locked open to prevent electrical or manual closing.
This padlocking can also secure the breaker in the
connected, test, or disconnected position by prevent-
ing levering.
6. In the CONNECT position automatic mechanical
interlocking prevents the disconnecting or withdrawal
of a closed breaker. This avoids drawing dangerous,
destructive arcs on the disconnecting contacts when
the circuit is energized.
7. In the REMOVE position mechanical interlock sys-
tem prevents the closing springs from being charged
or remaining charged.
8. The integral fuses on Types DSL-206 and DSL-416
breakers are inaccessible until the breaker is com-
pletely withdrawn from its compartment, thereby
assuring complete isolation.
Likewise, the Type DSL-632 and DSL-840 fuses are
inaccessible until the separate fuse truck is completely
withdrawn and the fuses isolated. The fuse truck is key
interlocked with the breaker to prevent withdrawing or
insertion unless the breaker is open.
Effective October 1998
Courtesy of NationalSwitchgear.com

1.8. 33-790-11 Page 5
Recommended Safety Practices
Type OS circuit breakers are complex electrical devices
containing high speed, high energy, operating mecha-
nisms. They are designed to operate within the current
and voltage limitations on the breaker nameplate. Do not
apply these breakers to systems with currents and/or
voltages exceeding these limits.
1. To perform work on Type OS Circuit Breakers
requires personnel with training and experience in
high voltage circuits. Only qualified electrical work-
ers, familiar with the construction and operation of
such equipment and the hazards involved, should be
permitted to work on these circuit breakers.
2. Only Qualified Persons as defined in the National
Electric Safety Code should be permitted to assem-
ble, operate or maintain these breakers.
3. The breakers are equipped with various interlocks.
DO NOT MAKE ANY OF THE INTERLOCKS INOP-
ERATIVE AS THIS MAY RESULT
IN BODILY
INJURY OR PROPERTY DAMAGE.
4. Never put a breaker into a cell without barriers and
arc chutes.
5. Always be sure that all switch hardware is in place
and bolted tightly before inserting breaker into cell.
6. Do not lift breaker with ordinary crane hooks, ropes,
chains, etc., to avoid possible damage to parts
or
dropping the unit. Use breaker lifting adapter.
Effective October 1998
7. Use handle on front panel of circuit breaker to move
it into or out of cell. Keep fingers and hands off top,
bottom or sides of breaker when moving it into or out
of cell to prevent bodily injury.
8. When operating breaker without arc chutes and bar-
riers, keep hands, arms, head and tools out of area
where contacts travel. Severe bodily injury could
result from being struck by the moving contacts
either as they open or close.
9. Be sure circuit breakercontacts are open and closing
springs are discharged before doing maintenance
work.
10.
Be sure circuit breakercontacts are open and closing
springs are discharged aftercompleting maintenance
work.
11. Never leave breaker
in an intermediate position in a
cell. Always have the breaker either in the discon-
nect, test or connected position because control cir-
cuits may be either improperly connected (or
disconnected) and may cause electrical failures.
12. Avoid trip-free type operation because it causes
more shock on some parts
of breakerthan normal
closing operations. Refer to last paragraph
in Item 4.1.
13. Before operating breaker
in test position, be sure that
closing the breakerwill not cause another electrically
interlocked breaker to inadvertently trip.
Courtesy of NationalSwitchgear.com

Page 6 1.8. 33-790-11
Section 1 - Receiving, Handling and Storing
1.0 RECEIVING AND HANDLING
The circuit breakers may be shipped completely assem-
bled and inside their respective compartments.
Receiving and handling of this equipment is covered in
Cutler-Hammer Instruction Book 32-690 for Low-Voltage
Metal-Enclosed Switchgear, Types DS and DSO.
If the circuit breakers are not shipped in the switchgear
assembly, they will be packed separately in individual
cartons or crates. These packages must be handled with
care to avoid hidden damage to the circuit breakers.
If the circuit breakers have been shipped in the switch-
gear assembly, proceed as described in Section 2. If the
breakers have been shipped in separate packages, re-
move them from the crate
or carton carefully so as not to
cause damage. Place the breakers
on the switchgear
extension rails. (See Section 2.3 before attempting to lift
breakers.) Remove the insulating barriers and arcchutes.
Inspect the contact structures to be sure no damage has
occurred during shipment. Replace the arc chutes and
insulating barriers and proceed as described in Section 3.
1.1 STORING
If it is necessary to store the equipment before installa-
tion, keep it in a clean dry place, protected from dirt and
water and with ample air circulation and heat, if neces-
sary, to prevent condensation. Like all electrical appara-
tus, these units contain insulation. Although it is of
highest quality, it, like all other insulation, must be pro-
tected against dirt and moisture. Refer to Instruction
Book 32-690-C for details.
Note: Breakers that have been stored or have infre-
quentoperations shall be operated a minimum of five
times before being placed in service.
1.2 WEIGHTS: CIRCUIT BREAKERS AND FUSE
TRUCKS
Table 3 gives the approximate weights of DS and DSL
circuit breakers. They will vary slightly due to the differ-
ences in functional components of the individual DS
Breaker, and the size of the current limiters supplied on
DSL Breakers. Fuse truck weights will vary due to differ-
ences of fuse sizes.
Table 3 - Approximate Weights
Drawout Elements Pounds
DS-206 Circuit Breaker .............. 150
DS-206S Circuit Breaker ............. 160
DS-416 Circuit Breaker
.............. 195
DS-416S Circuit Breaker
............. 200
DS-420 Circuit Breaker .............. 200
DS-632 Circuit Breaker
..............
300
DS-840 Circuit Breaker .............. 400
DSL-206 Circuit Breaker ............. 200
DSL-416 Circuit Breaker ............. 260
DS-3200 Fuse Truck ................ 325
DS-4000 Fuse Truck ................ 430
Effective October 1998
Courtesy of NationalSwitchgear.com

1.8. 33-790-11
Page?
Section 2- First Removal of Breaker from Compartment
2.0 GENERAL
To examine and become familiar with the construction
and operation of the breaker, it first must be withdrawn
from the compartment. There are rails provided which
permitthe breakerto be rolled out ofthe compartment so
that it can be examined on all sides and operated. First
unlatch and open the compartment door.
2.1 SETTING THE RAILS IN FRONT OF THE COM·
PARTMENT
Refer to Figures 1 and 2. There are two rails for each
breaker compartment which, when not in use, are stored
on the inside of the compartment in a back-sloping posi-
tion. Withdraw each rail completely and let it down into a
horizontal position, as shown in Figure 2.
The first movement of the breaker toward the front of the
compartment must be done with the levering device.
Fig. 1 The Type DS Low Voltage PowerCircuitBreakeris
ShippedInside Its Own Compartment (388880*)
*PHOTO NUMBER
Effective October 1998
Fig. 2 Rails are Stowedawayin the Compartment.
Withdraw as Shown (383027)
2.2 REMOVING SHIPPING BRACE
Before the circuit breakerelementcan be withdrawn from
its compartment for the first time, two shipping braces
must be removed from the lower part of the breaker front
panel. These braces are small steel angles bolted
to the
front ofthe circuit breaker and to the bottom cradle of the
circuit breaker compartment.
During shipment, the front wheels ofthe breakerare lifted
approximately 1/16 inch above the compartment rails,
and the unit is held part way between DISCONNECT and
TEST positions by means of its levering device and the
shipping angle.
1. With a screwdriver, remove the two (2) outside .25-20
panhead screws with captive washers from the bot-
tom leg of the two angles. Do not discard, as later
they will be returned to theirtapped holes. Do not
remove the center screw from the bottom cradle.
2. The levering device is now used to release the
breakerfrom the shipping position. When the breaker
is part way between DISCONNECT and TEST posi-
tions as described above the breaker levering device
interlock will hold the shutter down and the trip plate
depressed. The hex shaft of the levering device will
be exposed and ready to receive the levering crank
handle. See Figure 3. Insert the crank and turn in a
counter-clockwise direction and observe the action of
Courtesy of NationalSwitchgear.com

Pages
the drawoutposition indicator. The indicatorwill move
down to the REMOVE position at which time the load
on the crank handle increases because a stop has
been reached.
Fig. 3 Levering Device CrankHandle Installed. Read
Section
2.2 on this Operation (391177)
Note: Do not apply force on the crank handle after
the stop has been reached as the breaker is now free.
3. When the position indicator shows the levering
device to be
in the REMOVE position, remove the
hand crank. Pull the breaker out onto the extended
rails. This will require more effort than normal as the
rear wheels are jammed into the cradle hold-down
hooks by two lengths of plastic tubing. Refer to illus-
trations in the stationary structure Instruction Book
32-690 covering shipping braces.
4. Remove the two (2) .25-20 panhead screws holding
the two shipping angles to the front panel of the
breaker. Care must be exercised to prevent marring
the front panel.
Two or more flat washers are used
between the angle and front panel for shipping. Dis-
card the angles.
5. Immediately replace the two panhead screws dis-
carding all washers.
l.B. 33-790-11
ARC CHUTES
3 ~EOlHRf.O
POL YE.STEP
BARRIERS
t REOUfREO
LEVF.J::llNG
OE VICE A AM ·~
OISCONNECTf.D
POSITION
Fig. 4 Use of BreakerLifting Adapter(391187)
6. With the breaker pulled completely to the end of the
rails, remove the two (2) six inch long pieces of split
plastic tubing that are on the rear of the stationary
rails immediately below the hold-down hooks. This
tubing is for shipping purposes only and is to be dis-
carded.
7. The stationary secondary disconnecting contacts are
covered by a sheet of insulating material during ship-
ment. This must be removed and discarded before
the breaker is moved to the TEST or CONNECTED
position.
8. Push the breaker back into its compartment, and
replace the two (2) panhead .25-20 screws at the
front edge of the cradle.
2.3 LIFTING THE BREAKER
When it is necessary to lift the breaker off the rails, all lift-
ing should be done only with the accessory lifting
adapter. DO NOT ATTEMPT TO LIFT BREAKER WITH
ORDINARY CRANE HOOKS, ROPES, CHAINS ETC.,
AS VITAL PARTS SUCH AS WIRING, BARRIERS AND
ARC CHUTE PARTS MIGHT BE DAMAGED. Figure 4
shows a view of the breaker with the lifting adapter in
place. The lifter consists essentially of two sheet steel
hooks specially shaped to hook under the top edges of
the large openings on each circuit breaker side sheet,
or
in the specially provided lifting lugs on some breakers,
and a spreader. Actual lifting may be with a crane, chain
block or with the optional lifting mechanism which can be
supplied for the switchgear. The breaker must be pulled
completely to the end of the rails.
Effective October 1998
Courtesy of NationalSwitchgear.com

1.8. 33-790-11 Page 9
Section 3 - Preliminary Examination of Circuit Breaker
3.0 GENERAL
Read these instructions carefully and look at the breaker
as it stands out
of the compartment before trying to oper-
ate
it. Refer to Figures 5, 6, 7 and 8.
The complete drawout element includes the circuit
breaker itself and its auxiliaries. The circuit breaker con-
sists
of four major components:
1. The operating mechanism.
2. The contacts, operated by the mechanism.
3. The arc chutes, which interrupt the arc which always
results from opening the breaker under load or short
circuit conditions.
4. The Amptector® solid-state overcurrent tripping sys-
tem.
ORAWOOT Ullt!T
PmltTIOl\I ll\lf>Jc.ATO~·--
S?lUNca Cffi\itQE----
tNDt<:ATOR
Fig. 5 View Showing Controls on the Panel (391066)
Effective October 1998
The remainder of the drawout element includes the fol-
lowing auxiliary components:
1. lnterphase insulating barriers which isolate the arc
chutes from each other and from ground.
2. Drawout element frame and rollers.
3. The levering device, for placing the element into its
various positions inside the compartment.
4. The main disconnecting contacts, for connecting the
breaker to power source and load.
5. The secondary contacts, for connecting the control
circuits to the electrical operating parts
of the ele-
ment.
6. The interlocks, which increase the safety of opera-
tion.
7. Drawout element position indicator.
EMERGlKl\ICV
------1DHAm:nNG
HANDLE
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Page 10
LEVERING DttVICE ARM
(REMOVE POSITION) ROLLER
ARC CHUTE
STEEL
FRONT PANEL
Fig. 6a Left Side of Breaker with Levering Device Arm in
REMOVE Position (391065)
ARC
CHUTE
LEVERING DEVICE ARM
(TEST POSITIONI
Fig. 7 Right Side Showing Levering Device Arm in TEST
Position (391068)
RATCHET
WHEEL
TRIP
ACTUATOR
CLO!i!:
CAM
l.B. 33-790-11
EMERGENCY
CHARGING
HANDLE
HOLD
PAWL
Fig. 6b DS 416 Breaker with Front Panel Removed
(391070)
SENSORS
SECONDARY
DISCONl\ll':CTING
CONTACT COVER
SECONDARY
DISCONNECTING
CONTACTS
MAIN
DISCONNECTING
CONTACTS
LEVERING
DEVICE ARM
(CONNECTED
POSITION)
Fig. 8 Rear View Showing Levering Device Arm in
CONNECT Position (391067)
Effective October 1998
Courtesy of NationalSwitchgear.com

1.8. 33-790-11
8. Open-Close indicator.
9. Spring charge indicator.
10. The close bar and trip plate.
11. Steel front cover.
12. Nameplate with complete rating information.
The Type DSL-206 and DSL-416 drawout elements also
include the following components:
1. Current limiters.
2. Isolating transformers, connected in parallel with the
limiters.
3. Combination "Blown Limiter Indicator'' and anti-single
phase device, connected to the isolating transform-
ers, actuated by blowing of one or more of the cur-
rent limiters. This device has individual phase
indicators and a common "RESET" button extending
through the front cover.
Each breaker is equipped with a spring-type stored
energy closing mechanism. This mechanism closes the
circuit breaker contacts with the necessary speed and
force, independently
of the operator. Basically, the clos-
ing springs must first be charged or cocked before the
breaker can be closed. The springs are then released by
releasing the spring release latch. The breaker is opened
by releasing the tripping latch.
3.1 INDEPENDENT MANUAL AND POWER-
OPERATED BREAKERS
3.1.1 Closing Facilities
On manually operated breakers, the closing springs can
be charged only by hand, by means
of the spring-charge
handle. The actual closing of the breaker is done only by
hand-push
on the close bar. As optional equipment, the
electrical spring release attachment normally supplied
only on power-operated breakers can be supplied on
manually operated breakers.
Effective October 1998
Page
11
On power-operated breakers, the springs are normally
charged by an electric motor. Closing may be done elec-
trically by
an electro-magnetwhich lifts the closing spring
release latch. Both
of these operations can be done by
hand ifthe control power source fails.
3.1.2 Tripping Facilities
The breaker can be tripped open by hand by pushing
with the finger on the trip plate on the breaker panel or
the trip plate on the breaker compartment door (the latter
is operative only when the breaker is in the connected
position).
The breaker can also be tripped electrically by the follow-
ing devices:
1. Shunt trip device, optional equipment on manually
operated breakers.
2. Trip Actuator, energized from the Amptector trip unit.
3. Undervoltage Trip Device (Optional on all breakers)
4. Blown Limiter Indicator (for DSL breakers)
3.2 LEVERING DEVICE
The drawoutelement has four normal positions in its
compartment, determined by the levering device:
1. The REMOVE position, Figure 6.
2. The DISCONNECT position.
3. The TEST position, Figure 7.
4. The CONNECT position, Figure 8.
The REMOVE position is the first position in the compart-
ment as the element is pushed directly
by hand as far as
it will go. The DISCONNECT, TEST, and the CONNECT
positions are reached only
by means of the levering
device. This is hand operated with a removable crank
handle. This handle is placed
on the levering device
worm shaft, which is exposed by depressing the shutter.
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