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
Effective 07 /97
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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
Effective 07 /97
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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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