Eaton Cutler-Hammer DSII Series Programming manual

ltcml Cutler-Hammer
I. B. 694C694-02
Instructions for Installation, Operation and Maintenance of
Low Voltage Power Circuit Breakers Types DSll and DSLll
Effective 07/97, Supersedes l.B. 694C694-01 dated July, 1995
Courtesy of NationalSwitchgear.com

Courtesy of NationalSwitchgear.com

I. B. 694C694-02
PURPOSE
This instruction manual is expressly intended to cover
the installation, operation and maintenance of Types
DSll and DSLll Power Circuit Breakers and Type DSll
Drawout Fuse Trucks. These breakers are usually sup-
plied as part of low voltage metal enclosed drawout
switchgear. This manual applies only to the circuit
breakers and their details. Type DSll breakers, not Type
DSLll, may also be supplied as fixed mounted units. In
the case of fixed versions of the Type DSll breaker, cer-
tain sections of this manual referring to such items as
position interlocks and the drawout mechanism will not
apply.
Trip units associated with Type DSll and DSLll Power
Circuit Breakers will be addressed in a general manner
in this manual. Specific trip unit details and time-current
characteristic curves are covered in a separate docu-
ment specific to the trip unit itself.
For information concerning Types DSll and DSLll Power
Circuit Breakers, Type DSll Drawout Fuse Trucks and
their accessories consult the applicable Instruction Book
or other descriptive publications.
Page iii
For application information, consult Cutler-Hammer Inc.,
see applicable Descriptive Bulletins, Application
Publications and/or Industry Standards.
SAFETY
All safety codes, safety standards and/or regulations
must be strictly observed in the installation, operation
and maintenance of this equipment.
A WARNING
THE WARNINGS AND CAUTIONS INCLUDED AS
PART OF THE PROCEDURAL STEPS IN THIS MAN-
UAL ARE FOR PERSONNEL SAFETY AND PROTEC-
TION OF EQUIPMENT FROM DAMAGE. AN EXAM-
PLE OF A TYPICAL WARNING LABEL HEADING IS
SHOWN ABOVE TO FAMILIARIZE PERSONNEL
WITH THE STYLE OF PRESENTATION. THIS WILL
HELP
TO INSURE THAT PERSONNEL ARE ALERT
TO WARNINGS. IN ADDITION, CAUTIONS ARE ALL
UPPER CASE AND BOLDFACE.
All possible contingencies which may arise during installation operation or maintenance, and all details and variations
of this equipment do not purportto be covered by these instructions. If further information is desired by purchaser
regarding hisparticularinstallation, operation or maintenance of particularequipment, contactthe local Cutler-
HammerInc. representative.
Effective 07 /97
Courtesy of NationalSwitchgear.com

Page iv
l.B. 694C694-02
TABLE OF CONTENTS
SECTION 1: INTRODUCTION PAGE
1-1 General lnformation.............................................................................................................................................1
1-2 Safety Features...................................................................................................................................................2
1-3 Safety Practices ..................................................................................................................................................2
1-4 Qualified Personnel .............................................................................................................................................3
1-5 Other Publications
and Documentation...............................................................................................................3
SECTION 2: RECEIVING, HANDLING AND INSTALLATION
2-1 General lnformation.............................................................................................................................................5
2-2 Unpacking Circuit Breaker...................................................................................................................................5
2-2.1 Storing Circuit Breaker ...........................................................................................................................5
2-3 Lifting Circuit Breaker..........................................................................................................................................5
2-4 Breaker Inspection ..............................................................................................................................................6
2-5 Levering Circuit Breaker......................................................................................................................................7
2-6 Drawout Dummy Element ...................................................................................................................................8
2-7 Fixed Circuit Breaker...........................................................................................................................................8
SECTION 3: EQUIPMENT DESCRIPTION
3-1 Type DSll Circuit Breaker....................................................................................................................................9
3-2 Type
DSLI I (Limiter) Circuit Breaker .................................................................................................................1O
3-3 Basic Breaker Assembly ................................................................................................................................... 11
3-4 Pole Units.......................................................................................................................................................... 11
3-4.1 Primary Moving Contact Assembly ...................................................................................................... 11
3-4.2 Primary Stationary Contact Assembly.................................................................................................. 12
3-5 lnterphase Barriers............................................................................................................................................ 12
3-6 DE-ION Arc Chutes (Interrupter Assemblies)....................................................................................................14
3-7 Electronic Tripping System................................................................................................................................14
3-7.1 Electronic Trip Unit............................................................................................................................... 16
3-7.2 Sensors ................................................................................................................................................ 16
3-7.3 Trip Actuator......................................................................................................................................... 16
3-8 Operating Mechanism .......................................................................................................................................17
3-8.1 Manually Operated Circuit Breaker ......................................................................................................17
3-8.2 Power Operated Circuit Breaker ..........................................................................................................
18
3-9 Movable Primary and Secondary Contacts....................................................................................................... 18
3-1 O Standard and Optional Devices......................................................................................................................... 19
3-10.1 Motor Cut-Off Switch (LS) .................................................................................................................... 19
3-10.2 Spring Release Device (SRO) .............................................................................................................. 19
3-10.3 Anti-Pump Relay (Y) ............................................................................................................................. 19
3-10.4 Shunt Trip Attachment (ST A) ............................................................................................................... 19
3-10.5 Latch Check Switch.............................................................................................................................. 20
3-10.6 Auxiliary Switch .................................................................................................................................... 20
3-10.7 Undervoltage Trip Attachment (UVT A) ................................................................................................. 20
3-10.8 Overcurrent Trip Switch........................................................................................................................ 21
3-11 Miscellaneous Details........................................................................................................................................ 21
3-11.1 Interference lnterlock............................................................................................................................ 21
3-11.2 Ground Contact.................................................................................................................................... 22
3-11.3 Close Bar Guard................................................................................................................................... 22
3-11.4 Operation Counter................................................................................................................................ 22
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I. B. 694C694-02
Pagev
SECTION 4: BASIC OPERATING INSTRUCTIONS PAGE
4-1 Manual Circuit Breaker Operation .....................................................................................................................23
4-1.1 Spring Charge Mechanism for Manually Operated Breakers...............................................................23
4-2 Power Circuit Breaker Operation.......................................................................................................................24
4-2.1 Spring Charge Mechanism for Power Operated Breakers...................................................................25
4-2.2 Power Operation ..................................................................................................................................29
4-3 Closing Mechanism ...........................................................................................................................................29
4-4 Opening (Tripping) Mechanism .........................................................................................................................
31
4-5 Mechanical Interlocking System Description..................................................................................................... 34
4-5.1 Remove Position .................................................................................................................................. 34
4-5.2 Disconnect Position .............................................................................................................................. 34
4-5.3 Test Position......................................................................................................................................... 34
4-5.4 Connect Position .................................................................................................................................. 36
4-5.5 Mechanical Interlocking System Operation .......................................................................................... 36
4-5.6 Spring Discharge Interlock ................................................................................................................... 38
4-5.7 Connected Breaker Manual Close lnterlock......................................................................................... 38
4-5.8 Electric Lockout Equipped Breaker ...................................................................................................... 38
4-5.9 Closed Breaker Interlock...................................................................................................................... 38
4-5.10 Padlocking Provision ............................................................................................................................40
4-6 DSLll Circuit Breaker
and Fuse Truck............................................................................................................... 41
4-6.1 DSLll Current Limiters..........................................................................................................................42
4-6.2 Blown Limiter Indicator.........................................................................................................................42
4-6.3 Fuse Truck ...........................................................................................................................................42
4-6.4 Fuse Truck Installation and Use...........................................................................................................43
4-6.5 Fuse Replacement ...............................................................................................................................43
4-6.6 Blown Fuse Indicator............................................................................................................................43
SECTION 5: INSPECTION AND MAINTENANCE
5-1 General .............................................................................................................................................................45
5-2 General Cleaning Recommendations ...............................................................................................................45
5-3 When to Inspect ................................................................................................................................................45
5-4 What to Inspect .................................................................................................................................................45
5-4.1 DSll-308 Through DSll-620 Inspection ................................................................................................46
5-4.2 DSll-632
and DSll-840/850 lnspection.................................................................................................46
5-4.3 DSll-308 Contact Replacement............................................................................................................46
5-4.4 DSll-516 Through DSll-840/850 Contact Replacement .......................................................................46
5-4.5 Arc Chutes............................................................................................................................................47
5-4.6 Power Operated Mechanism................................................................................................................48
5-5 Factory Adjustments..........................................................................................................................................48
5-5.1 Trip Latch Overlap Adjustment.............................................................................................................50
5-5.2 Breaker Open Position Stop Adjustment (DSll-632 Only) ....................................................................50
5-5.3 Moving Contact Adjustment .................................................................................................................52
5-5.4 Levering Mechanism Adjustment .........................................................................................................52
5-6 Lubrication.........................................................................................................................................................53
5-6.1 Lubrication Frequency..........................................................................................................................53
5-6.2 Lubrication Location .............................................................................................................................53
SECTION 6: RENEWAL PARTS
6-1 General .............................................................................................................................................................56
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Page vi
Figure
1-1
1-2
1-3
1-4
2-1
2-2
2-3
2-4
2-5
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
3-17
3-18
3-19
3-20
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
l.B. 694C694-02
FIGURES
Title Page
Type DSll Circuit Breaker Family..............................................................................................................1
Typical DSll Nameplate ............................................................................................................................3
Type DSLll Breaker with Integral Current Limiters....................................................................................4
DSll Breaker Shown on Compartment's Captive Extension Rails ............................................................4
DSll Breaker with Lifting Yoke Installed....................................................................................................6
DSll Breaker with One lnterphase Barrier Removed ................................................................................6
DSll Breaker with One Arc Chute Removed ............................................................................................7
DSll Levering Device Arm Shown in REMOVE Position ..........................................................................7
Typical Fixed Type DSll Circuit Breaker ..................................................................................................8
Type DSll Circuit Breaker (Front and Rear Views) ..................................................................................9
Type DSLll Circuit Breaker (Front and Rear Views) ..............................................................................10
Typical OSI I Faceplate............................................................................................................................12
Type DSll-308 Pole Unit Assembly (Front View) ....................................................................................13
Type DSll-308 Pole Unit Assembly (Rear View) ....................................................................................13
Type DSll-516 Pole Unit Assembly (Front View) ....................................................................................14
Type DSll-516 Pole Unit Assembly (Rear View) ....................................................................................14
DSll lnterphase Barriers Being Removed ..............................................................................................15
DSll Arc Chute Being Removed..............................................................................................................15
Typical Type DSll Tripping System Diagram ..........................................................................................15
Type DSll Trip Actuator ..........................................................................................................................16
Typical FronVRear View of Manual Spring Charge Mechanism ............................................................17
Typical FronVRear Views of Power Operated Spring Charge Mechanism ............................................18
Type DSll Circuit Breaker (Bottom View)................................................................................................19
Anti-Pump Relay Shown Unmounted......................................................................................................19
Power Operated DSll Breaker (Front Cover Removed)..........................................................................20
Latch Check Switch Operation................................................................................................................ 21
Undervoltage Trip Attachment Operation................................................................................................ 21
Overcurrent Trip Switch Operation..........................................................................................................22
Close Bar Guard Shown Installed ..........................................................................................................22
Manual Charging of Breaker Closing Springs ........................................................................................23
Principal Parts in Manually Charged Spring Operated Mechanism ........................................................24
Manually Operated Spring-Charging Mechanism Details ......................................................................25
Principal Parts
in Power Operated Mechanism (Close Spring Shown in Charged Position) ..................26
Crank Shaft Assembly Front View (Some Parts Omitted for Clarity) ......................................................27
Power Operated Spring-Charge Details..................................................................................................28
Four Basic Positions of Breaker and Linkage (Enlarged View of Trip Shaft) ..........................................30
Emergency Spring-Charge on Power Operated Mechanism.................................................................. 31
Basic Schematic and Connection Diagrams for Power Operated Breaker ............................................32
Drawout Unit Position Indicator ..............................................................................................................33
Shutter, Trip Plate and Trip Shaft Relationship ......................................................................................35
Shutter, Interlock Cam and Levering Device Arms Relationship ............................................................37
Close-Release Interlock to Discharge Springs on Levering Out ............................................................39
Close Interlock Preventing Efforts to Close Already Closed Breaker......................................................40
Padlock Device (Locked Trip-Free with Shutter Raised) ........................................................................
41
DSLll-516 Circuit Breaker (Side View) ....................................................................................................42
Blown Limiter lndicator............................................................................................................................44
DSll-FT32 Fuse Truck (Front View) ........................................................................................................44
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I. B. 694C694-02
Page vii
Figure Title Page
4-19 DSll-FT32 Fuse Truck (Rear View) .........................................................................................................44
4-20 DSll-FT32 Truck (Front Cover Removed)................................................................................................44
5-1 DSll-308 Contacts and Adjustments........................................................................................................47
5-2 DSll-516/620 Contacts and Adjustments.................................................................................................48
5-3 DSll-632 Contacts and Adjustments........................................................................................................49
5-4 DSll-840/850 Contacts and Adjustments.................................................................................................50
5-5 Shunt Trip Details Showing Trip Shaft Adjustment..................................................................................
51
5-6 Open Position Stop and Anti-Rebound Latch .......................................................................................... 51
5-7 Levering Mechanism................................................................................................................................52
5-8 Left Side of Mechanism Lubrication Points..............................................................................................54
5-9 Right Side of Mechanism Lubrication Points ..........................................................................................54
5-1 O Shunt Trip Device Lubrication..................................................................................................................54
5-11 Spring Release Device Lubrication..........................................................................................................54
5-12 Trip Shaft Lubrication...............................................................................................................................55
Table
1.1
1.2
2.1
3.1
4.1
5.1
Effective 07 /97
TABLES
Title Page
Type DSll Breaker Ratings ........................................................................................................................2
Type DSLll Breaker
and Combination Ratings ..........................................................................................3
Circuit Breaker and Fuse Truck Weights ...................................................................................................5
Compatible Circuit Breakers and Compartments.....................................................................................22
Sensor
and Limiter Ratings......................................................................................................................42
Lubrication Frequency .............................................................................................................................53
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I. B. 694C694-02
SECTION 1: INTRODUCTION
1-1 GENERAL INFORMATION
Type DSll and DSLll Power Circuit Breakers are hori-
zontal drawout magnetic air circuit breakers utilizing an
electronic tripping system. They are designed for use in
metal enclosed switchgear assemblies having maximum
voltages of 635 volts AC for Type DSll breakers and
600 volts AC for Type DSLll breakers. Depending on
the specific breaker being considered, DSll and DSLll
breakers are available in frame sizes from 800 through
5000 amperes with interrupting ratings as high as
85,000 amperes rms symmetrical for Type DSll and
200,000 amperes rms symmetrical for Type DSLll
breakers. (Figure 1-1, Tables 1.1 and 1.2). The breaker
nameplate provides complete rating information and all
DSll breakers conform to applicable NEMA, ANSI and
IEEE standards (Figure 1-2).
Each DSll and DSLll breaker consists of a basic break-
er assembly, three interrupter assemblies (arc chutes),
barriers and an electronic trip unit. DSLll breakers have
integrally mounted, series connected current limiters.
The purpose of the current limiters is to extend the inter-
rupting rating of the standard DSll breaker (Figure 1-3).
Page 1
The Type DSll breaker is a four position drawout
(Connect, Test, Disconnect and Remove) design sup-
plied with either a manually or electrically operated, two-
step stored energy mechanism. This type of mechanism
assures positive control at the instant of closing the
main contacts.
Controls and indicators are functionally grouped on the
front of the breaker. The faceplate,
in conjunction with a
closed breaker compartment door, provides a double
steel safety barrier.
DSll breakers can be withdrawn on extension rails for
inspection, minor maintenance
or a visual inspection of
the inside of the breaker compartment. The captive
extension rails are a permanent part of the breaker com-
partment (Figure 1-4).
NOTICE
Please read and understand these instructions
before attempting
to unpack, operate or maintain
this equipment. Study the breaker and its mecha-
nism carefully before attempting to operate it on an
energized circuit.
DSll-632 DSll-840 DSll-308
Figure 1-1 Type OSI/Circuit BreakerFamily
Effective 07 /97
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Page 2
A WARNING
TYPE DSll AND DSLll BREAKERS ARE PROTEC-
TIVE DEVICES.
AS SUCH, THEY ARE MAXIMUM
CURRENT RATED DEVICES. THEREFORE, THEY
SHOULD NOT UNDER
ANY CIRCUMSTANCES BE
APPLIED OUTSIDE THEIR NAMEPLATE RATINGS.
OPERATION OUTSIDE OF THESE RATINGS COULD
RESULT IN DEATH, BODILY INJURY OR PROPERTY
DAMAGE.
1-2 SAFETY FEATURES
Types DSll and DSLll Circuit Breakers and associated
drawout equipment are manufactured with built-in inter-
locks and safety related features. They are provided to
reduce hazards to operating personnel and provide
proper operating sequences.
A WARNING
TYPES DSll AND DSLll CIRCUIT BREAKERS ARE
STRONGLY BUil T AND PROVIDED WITH SAFETY
FEATURES. NEVERTHELESS, THE VOLTAGES,
Table 1.1 Type OSI/ BreakerRatings
. . .,
I: 'I
J :1
DSll-308 800 42,000 30,000
DSll-508 800 65,000 50,000
DSll-608 800 65,000 65,000
DSll-516 1600 65,000 50,000
DSll-616 1600 65,000 65,000
DSll-620 2000 65,000 65,000
DSll-632 3200 85,000 65,000
DSll-840 4000 130,000 85,000
DSll-850 5000 130,000 85,000
© MBXlmum voltages at which the interrupting ratings apply are:
System Voltage Maximum Voltage
208 or 240 254
480 508
600 635
® Also short-time ratings.
l.B. 694C694-02
CURRENTS AND POWER LEVELS AVAILABLE IN
AND AROUND THIS EQUIPMENT WHEN
IT IS IN
OPERATION ARE EXTREMELY DANGEROUS AND
COULD
BE FATAL UNDER NO CIRCUMSTANCES
SHOULD INTERLOCKS AND OTHER SAFETY FEA-
TURES BE MADE INOPERATIVE, AS THIS MAY
RESULT IN DEATH, BODILY INJURY OR PROPERTY
DAMAGE.
1-3 SAFETY PRACTICES
To pro~ect personnel associated with the installation,
operation and maintenance of this equipment, the fol-
lowing practices must be followed:
1. Only qualified electrical personnel familiar with the
equipment, its operation and the associated hazards
should be permitted to work on the equipment.
Additionally, only qualified personnel should be per-
mitted to install or operate the equipment.
2. Always be certain that the primary and secondary cir-
cuits are de-energized or the circuit breaker is
removed to a safe work location before attempting
any maintenance.
3. For maximum safety, only insert a completely assem-
bled breaker into an energized cell.
I I • • I • j 1 • •
I I·'
.11
I: JI
:. : I
600 v
30,000 30,000 30,000 30,000
42,000 50,000 50,000 42,000
50,000 65,000 65,000 50,000
42,000 50,000 50,000 42,000
50,000 65,000 65,000 50,000
50,000 65,000 65,000 50,000
65,000 65,000 65,000 65,000
85,000 85,000 85,000 85,000
85,000 85,000 85,000 85,000
@ Short circuit ratings of non-automatic breakers except the DSll-840/850 which is 65,000.
Effective 07 /97
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I. B. 694C694-02
4. Always insure that drawout breakers are in one of
their designed cell positions, such as Connected,
Test, Disconnected or Withdrawn. A breaker permit-
ted to remain
in an intermediate position could result
in control circuits being improperly connected result-
ing
in electrical failures.
1-4 QUALIFIED PERSONNEL
For the purpose of operating and maintaining low volt-
age circuit breakers, a person should not be considered
qualified if the individual is not thoroughly trained
in the
operation of the circuit breaker and how it interfaces
with a switchboard. In addition, the individual should
have knowledge of the connected loads.
For the purpose of installing and inspecting circuit
breakers and their associated switchboard, a Qualified
Person should also be trained with respect to the haz-
ards inherent to working with electricity and the proper
way to perform such work. The individual should be able
to de-energize, clear and tag circuits
in accordance with
established safety practices.
1-5 OTHER PUBLICATIONS AND
DOCUMENTATION
In addition to this instruction manual, other printed infor-
mation and documentation is available and supplied as
appropriate. This additional information can include, but
not necessarily be limited to,
an instruction manual for
the specific electronic trip unit being used with the circuit
breaker, a Renewal Parts Data Book, and necessary
dimensional drawings.
Effective 07 /97
Figure 1-2 Typical OSI/ Nameplate
Table 1.2 Type DSLllBreakerandCombination
Ratings
Page 3
Type Frame Max Interrupting Rating,
DSLll-308©
DSLll-516©
DSLll-620©
DSLll-632®
DSLll-840®
Size, Amp.
RMS Sym. Amp., System
Voltage
600 or Below
800 200,000
1600 200,000
2000 200,000
3200® 200,000
4000 200,000
ID Limiter Integral with drawout breaker element.
® DSll-632 breaker and DSll-FT32 drawout fuse truck in separate interlocked
compartments.
® DSll-840 breaker and DSll-FT40 drawout fuse truck in separate interlocked
compartments.
© Maximum continuous rating limited to 3000A when fuse truck compartment
is above breaker compartment.
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Page 4
Figure 1-3 Type DSLI/ Breaker with Integral Current
Limiters
l.B. 694C694-02
Figure 1-4 DSll BreakerShown on Compartment's
Captive Extension Rails
Effective 07 /97
Courtesy of NationalSwitchgear.com

I. B. 694C694-02
SECTION 2: RECEIVING, HANDLING AND
INSTALLATION
2-1 GENERAL INFORMATION
Types DSll and DSLll Circuit Breakers, when supplied
as part of a metal-enclosed switchgear assembly may
~e sh~pped cof'!lpletely assembled and already in~talled
in their respective breaker compartments. Receiving
and handling of this equipment is addressed
in an
assembly instruction manual supplied with the assem-
bled equipment. This instruction manual still applies,
however, to all other aspects of the circuit breakers.
Before beginning to unpack new DSll breakers, read
and understand these directions. Following the direc-
tions will ensure that you have caused no damage.
Every effort is made to insure that DSll breakers arrive
~t their destination undamaged and ready for installa-
tion. Care should be exercised, however, to protect the
~reakers fr~m imp~ct at all times. Do not remove protec-
t~ve pac~aging until the breakers are ready for inspec-
tion, testing and/or installation. Shipping containers
should
be inspected for obvious signs of rough handling
~nd/or external damage incurred during the transporta-
tion phase. Record any observed damage for reporting
to the transportation carrier and Cutler-Hammer, once
the inspection is completed. All reports and claims
should
be as specific as possible and include shop
order and general order information.
2-2 UNPACKING CIRCUIT BREAKER
When ready to inspect and install the DSll breaker
carefully open the shipping container and remove
~ny
packing material and any internally packed documenta-
tion. The circuit breaker is designed and balanced to be
easily lifted from the shipping container using the appro-
priate lifting yoke and
an overhead or portable lifting
device.
A CAUTION
DO NOT ATTEMPT TO LIFT BREAKERS WITH ORDI-
NARY CRANE HOOKS, ROPES, CHAINS OR OTHER
SUCH DEVICES. FAILURE TO FOLLOW THIS CAU-
TION COULD RESULT IN DAMAGE TO VITAL
PARTS SUCH
AS ARC CHUTES, BARRIERS AND
WIRING.
Effective 07 /97
Page 5
2-2.1 STORING CIRCUIT BREAKER
If it is necessary to store a circuit breaker before instal-
lation, do so
in its original shipping container. Keep the
circuit breaker
in a clean dry place. Ensure there is
ample air circulation and heat, if necessary, to prevent
condensation. It is very important that the insulation
used
in the breaker not be exposed to dirt or moisture.
NOTICE
A c~rcuit breaker that has been stored for any length
of time should be operated a minimum of five times
before it is placed in service.
2-3 LIFTING CIRCUIT BREAKER
To closely examine, install orjust to become more famil-
iar with the circuit breaker, carefully lift and place the
breaker,on a.solid work surface capable of handling the
breakers weight (Table 2.1) or on the captive drawout
e~e~sion rails ~f the breaker compartment (Figure 1-4).
This
1s accomplished by using the appropriate lifting
yoke and lifter. The lifting yoke consists of two sheet
steel hooks specially shaped to hook under the top
edges of the large openings on each circuit breaker side
sheet (Figure 2-1).
Table 2. 1 CircuitBreaker and Fuse Truck Weights
Type Pounds
DSll-308 150
DSll-508 195
DSll-608 200
DSll-516 195
DSll-616 200
DSll-620 200
DSll-632 300
DSll-840 400
DSll-850 400
DSLll-308 200
DSLll-516 260
DSLll-620 275
DSll-FT32 Fuse Truck 325
DSll-FT40 Fuse Truck 430
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Page 6
If the breaker is to be lifted onto the compartment's
extension rails, be certain the rails are fully extended
before the breaker is lifted. Be certain that the four
rollers, two on either side of the circuit breaker, are seat-
ed properly on the extension rails before removing the
lifting device.
2-4 BREAKER INSPECTION
All breakers, once removed from their shipping containers,
should be visually inspected for any obvious damage.
Remove the glass polyester interphase barriers. Note
any cautions or instructions printed directly on the barri-
ers. These instructions will insure proper positioning of
the barriers in the circuit breaker once the barriers are
replaced (Figure 2-2).
A WARNING
INTERPHASE BARRIERS ASSIST IN MAINTAINING
PROPER CLEARANCES AND MUST BE IN PLACE
Figure 2-1 OSI/ Breaker with Lifting Yoke Installed
l.B. 694C694-02
AT ALL TIMES DURING CIRCUIT BREAKER OPERA-
TION WITHIN A BREAKER COMPARTMENT.
Remove the three arc chutes which are mounted on top
of the pole units. Each arc chute is held in place by one
top inserted screw (Figure 2-3).
A WARNING
ARC CHUTES MUST ALWAYS BE SECURED PROP-
ERLY IN PLACE BEFORE A CIRCUIT BREAKER IS
INSTALLED IN A CIRCUIT BREAKER COMPART-
MENT.
Inspect the primary contact structure to be sure no dam-
age has occurred during shipment. Replace all inter-
phase barriers and arc chutes.
Checking the electrical and/or manual operation of each
breaker can be done later following the instructions out-
lined in Section 4.
Figure 2-2 OSI/ Breaker with One lnterphase Barrier
Removed
Effective 07 /97
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I. B. 694C694-02
2-5 LEVERING CIRCUIT BREAKER
A WARNING
EXCESSIVE LEVERING TORQUE CAN DAMAGE
THE BREAKER, THE SWITCHGEAR AND CAUSE
SEVERE PERSONAL INJURY. DO
NOT APPLY
TORQUE IN EXCESS OF 25 FOOT-POUNDS.
The breaker drawout element has four normal positions
in its compartment as determined by the levering
device:
• REMOVE Position (Figure 2-4)
• DISCONNECT Position
• TEST Position
• CONNECT Position
The REMOVE position is the first position
in the compart-
ment as the breaker element is pushed directly by hand
as far as it will go. The DISCONNECT, TEST and CON-
NECT positions are reached only by means of the lever-
ing device. The levering device is hand operated with a
removable crank handle. The handle is placed on the
levering device worm shaft, which is exposed by pushing
Figure 2-3 OSI/Breaker with One Arc Chute Removed
Effective 07 /97
Page 7
and holding the Push-To-Trip button on the front of the
breaker and depressing the shutter (Figure 3-3).
With the breaker sitting on the extension rails, make cer-
tain that the breaker levering mechanism arms are
in
the REMOVE position (Figure 2-4). If they are not, turn
the levering crank
in the direction required to get the lev-
ering arms in the REMOVE position. Carefully push the
circuit breaker into the breaker compartment until it
physically stops. Begin turning the levering crank in a
clockwise direction. Initially, it helps to push a bit on the
front of the breaker while turning the levering crank to
get the mechanism engaged and started. A continued
clockwise rotation of the levering crank will move the
breaker to the DISCONNECT, TEST and the CON-
NECT positions. When the CONNECT position is
reached, the crank suddenly becomes hard to turn. At
this point, stop turning the crank. Note that as the break-
er is cranked and the different positions are reached, a
position indication is given in the position indicator win-
dow on the front of the breaker (Figure 3-3).
Rotation of the levering crank counterclockwise will turn
the levering device arms so as to withdraw the breaker
from the compartment. The procedure is basically the
same as just described except
in the opposite direction.
Figure 2-4 DSll Levering Device Arm Shown in
REMOVEPosition
Courtesy of NationalSwitchgear.com

Page 8
NOTICE
If the breaker is levered out from the TEST position
to the REMOVE position with the closing springs
charged, a trip free closing operation automatically
takes place, but the breaker contacts do not close.
2-6 DRAWOUT DUMMY ELEMENT
A dummy element consists of a drawout frame or truck
with disconnecting contacts and connecting links
between the upperand lower terminal on each pole.
When inserted into a compartment, it bridges the upper
and lower stationary disconnecting contacts
in each
phase. This makes it the equivalent to an isolating dis-
connecting switch.
IT MUST BE EMPHASIZED THAT A DUMMY ELE-
MENT IS NOT A BREAKER. IT HAS NO CURRENT
BREAKING ABILITY WHATSOEVER. The dummy ele-
ment is almost always key interlocked with a breaker or
other load interrupting device to insure that it will be iso-
lated or carrying NO current before it can be levered to
the DISCONNECT position.
Dummy elements require the same size compartment
as an equivalent Type DSll breaker of the same frame
size.
2-7 FIXED CIRCUIT BREAKER
The Type DSll Fixed Circuit Breaker differs from the
drawout version in that it has no levering device, primary
disconnects and secondary disconnects. A fixed circuit
breaker does not have a padlock feature to hold the
breaker in a ''trip-free" position. To insure the proper
sequence of operation between two or more breakers, a
key interlock is mounted in the levering device location.
The breaker stabs have holes for bolting to primary bus
connections. Rear mounted terminal blocks serve as
secondary contacts. The basic breaker frame is modi-
fied to permit the fixed breaker to be mounted on a
panel (Figure 2-5).
l.B. 694C694-02
Figure 2-5 Typical Fixed Type OSI/ Circuit Breaker
Effective 07 /97
Courtesy of NationalSwitchgear.com

I. B. 694C694-02
SECTION 3: EQUIPMENT DESCRIPTION
3-1 TYPE DSll CIRCUIT BREAKER
Type OSI I Circuit Breakers are designed specifically for
use
in metal enclosed low voltage switchgear assem-
blies (Figure 3-1).
The controls and indicators are functionally grouped on
the front of the circuit breaker. Easy access to the
stored energy mechanism and control devices is gained
by removing the circuit breaker faceplate. Inspection,
minor maintenance, and many replacement functions
II lnterphase Barrier
fl Arc Chutes
El Secondary Disconnects
11 Main Disconnect
El Levering Device Arm
11 Metal Faceplate
lfl Trip Unit
El Emergency Charge Handle
II Trip Unit Sensors
involving the mechanism, control, and/or accessory
devices can be easily accomplished.
Page 9
DSll Circuit Breakers are available with either a manual-
ly operated or electrically operated two-step stored
energy mechanism. It provides positive control of the
closing instant.
Six continuous current frame sizes, 800 through 5000
amps, are covered by just three physically different cir-
cuit breaker sizes. A variety of optional accessories are
available and common to all circuit breaker frames.
Figure 3-1 Type OSI/ Circuit Breaker (Front and Rear Views)
Effective 07 /97
Courtesy of NationalSwitchgear.com

Page 10
The frame width and height are the same for the DSll-
308 through the DSll-620 circuit breakers. They could be
placed into compartments having the same dimensions.
However, interference interlocks are provided to prevent
insertion of circuit breakers with mismatching discon-
nects or insufficient interruption ratings into compart-
ments carrying higher current.
Circuit Protection is supplied by an electronic, micro-
processor based tripping system. True RMS sensing is
provided for proper correlation with thermal characteris-
tics of conductors and equipment.
II Blown Limiter Indicators
El Current Limiter
II Secondary Disconnects
II Main Disconnect
El Isolating Transformer
II Trip Unit Sensor
II Arc Chute
l.B. 694C694-02
3-2 TYPE DSLll (LIMITER) CIRCUIT BREAKER
Type DSLll Circuit Breakers are coordinated combina-
tions of standard DSll Circuit Breakers and series con-
nected current limiters. The primary purpose of the cur-
rent limiters is to extend the interrupting rating of the
DSll Circuit Breaker up to 200,000 amps (Figure 3-2).
DSLll Circuit Breakers are intended for applications
requiring the overload protection and switching functions
of air circuit breakers on systems whose available fault
currents (1) exceed the interrupting ratings of the circuit
breakers alone and/or (2) exceed the withstand and
interrupting ratings of downstream circuit components.
Figure 3-2 Type DSLI/Circuit Breaker(Front and Rear Views)
Effective 07 /97
Courtesy of NationalSwitchgear.com

I. B. 694C694-02
The 800 through 2000 amp frame DSLll Circuit
Breakers have the limiters integrally mounted on the
drawout breaker elements. On 3,200 and 4,000 amp
frame combinations, the limiters are mounted on sepa-
rate drawout trucks. They fit into compartments of equal
size to their compatible circuit breakers and are normal-
ly positioned adjacent to one another.
On overloads and faults within the circuit breaker interrupt-
ing rating, the circuit breaker protects the limiters. On high-
er fault currents exceeding the circuit breaker rating, the
limiters protect the circuit breaker.
Interlock arrangements trip the circuit breaker whenever
any limiter blows. The circuit breaker cannot be reclosed
on a live source unless there are three unblown limiters
on the circuit. The blown indicator provides a visual indi-
cation when a current limiter in any phase has interrupt-
ed a short circuit. In addition, it is the device that insures
a circuit breaker will be tripped when any current limiter
has blown, preventing single phasing.
DSLll-308 through DSLll-620 Circuit Breakers must be
completely withdrawn from the compartment, thus
assuring complete isolation, before the integral fuses
are accessible.
Fuses for Types DSLll-632 and DSLll-840 Circuit
Breakers are mounted on a separate fuse truck. The
fuse truck is key interlocked with the circuit breaker to
prevent withdrawing or insertion unless the circuit break-
er is disconnected.
NOTICE
Refer to Section 4 for additional information con-
cerning limiter ratings, limiter replacement, blown
fuse indicator operation, and fuse truck installation.
A WARNING
THE CIRCUIT BREAKER'S FACEPLATE, INTER-
PHASE BARRIERS AND ARC CHUTES MUST BE IN
PLACE BEFORE INSTALLING A CIRCUIT BREAKER
IN A CIRCUIT BREAKER COMPARTMENT. IF A CIR-
CUIT BREAKER IS ENERGIZED WITHOUT THESE
ITEMS PROPERLY INSTALLED, A DISASTROUS
SHORT CIRCUIT FAULT WITHIN THE SYSTEM
COULD OCCUR, RESULTING IN EQUIPMENT DAM-
AGE, BODILY INJURY AND/OR DEATH.
Effective 07 /97
Page 11
3-3 BASIC BREAKER ASSEMBLY
The basic breaker assembly includes a chassis, a con-
trol panel, an operating mechanism, a tripping system, a
levering-in device (drawout breakers only), various
required interlocks, and three insulated pole unit assem-
blies.
The control items needed for proper operation of the
breaker are located on the front panel. Controls are
functionally grouped for convenience. All operating per-
sonnel should be familiar with their locations and func-
tions (Figure 3-3).
Access to the operating mechanism and internally
mounted auxiliary devices is gained
by removing the
breaker faceplate. The faceplate is held in place by front
accessible bolts.
3-4 POLE UNITS
The pole unit assembly is a molded base of high
strength insulating material in which is mounted one to
three sets of primary contact assemblies. The exact
design configuration depends upon the frame size of the
circuit breaker.
A DSll-308 pole unit assembly consists of a single mold-
ed base and three sets of primary contact assemblies.
The primary contact assembly is made up of two parts,
the stationary contact assembly and the movable contact
assembly, each mounted individually in the insulating
base (Figures 3-4 and 3-5).
Pole unit assemblies for other DSll circuit breaker frame
sizes are similar to the DSll-308 in design configuration,
except each of the three poles are mounted on individ-
ual insulating bases (Figures 3-6 and 3-7).
3-4.1 PRIMARY MOVING CONTACT ASSEMBLY
The primary moving contact assembly for all ratings
consists of moving arms hinged at the bottom to the
lower main terminal through controlled pressure rotating
contacts. At the upper end of the primary moving
assembly are the main and arcing contacts. The arcing
contacts of all frame sizes are essentially the same
design. The number of moving arms, the number of
main contacts, and the number of main disconnect con-
tact fingers vary with the frame size. A strong and rigid
insulating link operates the moving contact blade
assembly.
Courtesy of NationalSwitchgear.com

Page 12
l.B. 694C694-02
11 Digitrip Trip Unit
El Nameplate
El Shutter (Levering Shaft Access)
11 Open-Close Indicator
Ill Push to Close Button
IE Spring Charge Indicator
mRemove Assist Handle Ill Padlock Plate
Ill Emergency Charge Handle
II Drawout Position Indicator
El Push to Trip Button
Figure 3-3 Typical OSI/ Faceplate
3-4.2 PRIMARY STATIONARY CONTACT
ASSEMBLY
The stationary contact assembly consists of butt type
main contacts which carry the main continuous load cur-
rent. It is comprised of a multiplicity of individual fingers.
Each finger is hinged at the upper end under controlled
pressure. The stationary arcing contacts are similar for
all frame sizes and consist of two parallel fingers, one on
each side of the upper main terminal. They are spring
loaded toward each other by compression springs and
have arc resisting tips. The previously described moving
arcing contact wedges the stationary contact fingers
apart as the breaker closes.
In addition, the parallel
action of the magnetic fields of the currents in each arc-
ing contact finger causes the fingers to be attracted
toward each other when closing against fault currents.
This results
in a "blow-on" action on the arcing contacts.
3-5 INTERPHASE BARRIERS
Glass polyester interphase barriers assist in maintaining
proper clearances and must be in place at all times dur-
Effective 07 /97
Courtesy of NationalSwitchgear.com