Eaton VSR Series User manual

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IB01301027E
Instructions for VSR-Series Breaker To Vacuum Starter Replacement For Type 5HK Breakers
(5HK-VSR Vacuum Starter Replacement Unit)

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 1Page 1
Page 1Page 1
Page 1
Effective: May 2008Effective: May 2008
Effective: May 2008Effective: May 2008
Effective: May 2008
IB01301027E
IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS
CAN RESULT IN DEATH, SERIOUS PERSONAL INJURY OR
PROPERTY DAMAGE.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE
ATTEMPTING ANY UNPACKING, ASSEMBLY, OPERATION OR
MAINTENANCE OFTHE VACUUM MOTOR STARTER.
INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED
ONLY BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK
SHOULD NOT BE CONSIDERED ALL INCLUSIVE REGARDING
INSTALLATION OR MAINTENANCE PROCEDURES. IF FURTHER
INFORMATION IS REQUIRED, YOU SHOULD CONSULT
EATON’S ELECTRICAL SERVICES & SYSTEMS.
THEVACUUM STARTER REPLACEMENTS DESCRIBED INTHIS BOOK
ARE DESIGNEDANDTESTEDTO OPERATEWITHINTHEIR NAMEPLATE
RATINGS. OPERATION OUTSIDE OFTHESE RATINGS MAY CAUSETHE
EQUIPMENTTO FAIL, RESULTING IN DEATH, BODILY INJURYAND
PROPERTY DAMAGE.
ALL SAFETY CODES, SAFETY STANDARDSAND/OR REGULATIONSAS
THEY MAY BEAPPLIEDTOTHISTYPE OF EQUIPMENT MUST BE
STRICTLYADHEREDTO.
THESEVACUUM MOTOR STARTER REPLACEMENTSARE DESIGNEDTO
BE INSTALLED PURSUANTTOTHE NATIONAL ELECTRICAL CODE
(NEC). SERIOUS INJURY, INCLUDING DEATH, CAN RESULT FROM
FAILURE TO FOLLOW THE PROCEDURES OUTLINED IN THIS MANUAL.
THESEVACUUM MOTOR STARTER REPLACEMENTSARE SOLD
PURSUANTTOA NON-STANDARD PURCHASINGAGREEMENTWHICH
LIMITS THE LIABILITY OF THE MANUFACTURER.
All possible contingencies which may arise during installation, operation or maintenance, and all details
and variations of this equipment do not purport to be covered by these instructions. If further information
is desired by purchaser regarding his particular installation, operation or maintenance of particular equip-
ment, contact a Cutler-Hammer representative at Eaton Corporation.
EE
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WARNING
WARNING

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 2Page 2
Page 2Page 2
Page 2 Effective: May 2008Effective: May 2008
Effective: May 2008Effective: May 2008
Effective: May 2008
Table of Contents
SECTION1:INTRODUCTION ......................................................................................................................................... 5
1.1 AVAILABLE 5HK-VSR MOTOR STARTER REPLACEMENTS ................................................................................................................................... 5
SECTION 2: SAFE PRACTICES ..................................................................................................................................... 7
SECTION3:RECEIVING, HANDLINGANDSTORAGE ......................................................................................................... 8
3.1 RECEIVING .......................................................................................................................................................................................................... 8
3.2 HANDLING .......................................................................................................................................................................................................... 8
3.3 STORAGE ............................................................................................................................................................................................................. 8
3.4 5HK-VSRAPPROXIMATEWEIGHTS ...................................................................................................................................................................... 9
SECTION 4: INSTALLATIONAND INSPECTION .............................................................................................................. 12
4.1 EXAMINATION FOR DAMAGE ............................................................................................................................................................................. 12
4.1.1 NAMEPLATEVERIFICATION ............................................................................................................................................................................. 12
4.2 INITIAL INSPECTIONAND OPERATION ............................................................................................................................................................... 12
4.3 VACUUM INTERRUPTER INTEGRITY ................................................................................................................................................................... 12
4.4 INSULATION INTEGRITY ..................................................................................................................................................................................... 13
4.5 INTERRUPTER WEAR CHECK ............................................................................................................................................................................. 13
4.6 PRIMARY CIRCUIT RESISTANCE ........................................................................................................................................................................ 13
4.7 ELECTRICAL OPERATIONS CHECK .................................................................................................................................................................... 13
4.8 INSERTION PROCEDURE .................................................................................................................................................................................... 13
4.9 REMOVAL PROCEDURE ..................................................................................................................................................................................... 15
SECTION 5: DESCRIPTIONAND OPERATION ................................................................................................................. 16
5.1 CONTACTOR OPERATION ................................................................................................................................................................................... 16
5.2 PHASE BARRIERS .............................................................................................................................................................................................. 18
5.3 SECONDARY DISCONNECTS .............................................................................................................................................................................. 18
5.4 INTERLOCKS ...................................................................................................................................................................................................... 18
5.5 LEVERING-IN INTERLOCK .................................................................................................................................................................................. 18
5-6 MISCELLANEOUS ITEMS .................................................................................................................................................................................... 19
5-6.1 GROUND CONTACT ......................................................................................................................................................................................... 19
5-6.2 OPERATIONS COUNTER ................................................................................................................................................................................... 19
5-7 LEVERING DEVICE ............................................................................................................................................................................................. 19
SECTION6: INSPECTIONANDMAINTENANCE ............................................................................................................... 20
6.1 GENERAL ........................................................................................................................................................................................................... 20
6.2 VACUUM INTEGRITY CHECK .............................................................................................................................................................................. 20
6.3 INTERRUPTING WEAR CHECK ........................................................................................................................................................................... 20
6.4 INSULATION INTEGRITY CHECK ......................................................................................................................................................................... 21
6.5 CONTACT RESISTANCE CHECK .......................................................................................................................................................................... 21
SECTION7: REPLACEMENTOFCOMPONENTS .............................................................................................................. 22
7.1 REPLACEMENT OFVACUUM INTERRUPTERS .................................................................................................................................................... 22
7.1.1 ADJUSTINGVACUUM INTERRUPTERS ............................................................................................................................................................. 22
7.2 Coil Replacement ............................................................................................................................................................................................... 23
7.3 Control Board Check and Replacement .............................................................................................................................................................. 23
7.4 STOPASSEMBLY REPLACEMENT ....................................................................................................................................................................... 23
7.5 AUXILIARY CONTACT MAINTENANCEAND REPLACEMENT .............................................................................................................................. 24
7.6 MECHANICAL LATCH ......................................................................................................................................................................................... 25
7.6.1 LATCH REMOVAL ............................................................................................................................................................................................. 25
7.6.2 LATCH INSTALLATION ..................................................................................................................................................................................... 26
SECTION8: REPLACEMENTPARTS .............................................................................................................................. 27

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
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IB01301027E
Tables
Table 1.1 - 5HK-VSRVacuum Motor Starter Replacement UnitAvailability and Interchangeability ................................................................. 5
Table 1.2 - 5HK-VSRVacuum Motor Starter Replacement Unit Dimensions in Inches .................................................................................. 6
Table 3.1 - MaximumWeight by StarterType ........................................................................................................................................ 9
Table 4.1 - Dip Switch Setting-ControlVoltage ..................................................................................................................................... 12
Table 4.2 - Control Board Dropout Settings ......................................................................................................................................... 12
Table 5.1 - SL Contactor Ratings ........................................................................................................................................................ 16
Table 6.1 - RecommendedTorqueValues* ........................................................................................................................................... 20
Table 7.1 - Unlatch Coil Impedance .................................................................................................................................................... 25

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 4Page 4
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Effective: May 2008
Figures
Figure 1-1 Outline and Dimensions in inches ofType 5HK-VSR Vacuum Motor Starter Replacement Unit ............. 6
Figure 3-1 Typical 5HK-VSR Levering Crank .......................................................................................................... 8
Figure 3-2 Overhead Lifting of 5HK-VSR ............................................................................................................... 8
Figure 3-3 Front External View of 5HK-VSR Vacuum Starter Replacement Unit .................................................. 10
Figure 3-4 Rear External View of 5HK-VSR Vacuum Starter Replacement Unit ................................................... 11
Figure 4-1 Coil Control Board with Dip Switch .................................................................................................... 12
Figure 4-2 Coil Control Board Removal ............................................................................................................... 12
Figure 4-3 Alignment of 5HK-VSR ....................................................................................................................... 13
Figure 4-4 Insertion of HK-VSR (5HK-VSR-250 shown) ........................................................................................ 14
Figure 4-5 5HK-VSR in Disconnect Position ........................................................................................................ 14
Figure 4-6 5HK-VSR in Connect Position ............................................................................................................. 15
Figure 4-7 5HK-VSR Position Indicator ................................................................................................................ 15
Figure 5-1 SL Front and Rear View Major Components ........................................................................................ 17
Figure 5-2 SL Rear View Major Components ....................................................................................................... 17
Figure 5-3 SL Contactors Assembly ..................................................................................................................... 18
Figure 5-4 Secondary Contact Block of 5HK-VSR ................................................................................................ 19
Figure 5-5 5HK-VSR Code Plate .......................................................................................................................... 19
Figure 5-6 5HK-VSR Cell Code Plate Installed .................................................................................................... 19
Figure 5-7 5HK-VSR Ground Contact ................................................................................................................... 19
Figure 6-1 Interrupter Wear Check ...................................................................................................................... 20
Figure 7-1 Loosening Locknut .............................................................................................................................. 22
Figure 7-2 Removing Clamp Securing LowerTerminal ......................................................................................... 22
Figure 7-3 Removing Bolt and Shunt Supports ..................................................................................................... 22
Figure 7-4 Removing Bolt Securing UpperTerminal ............................................................................................. 22
Figure 7-5 Removal of Vacuum Interrupter .......................................................................................................... 23
Figure 7-6 Installation of Bolt and Shunt Supports .............................................................................................. 23
Figure 7-7 Remove the Coil Mounting Angle ....................................................................................................... 24
Figure 7-8 Remove the Lockout Securing the Return Spring Bolt ........................................................................ 24
Figure 7-9 Unscrew the Return Spring Assembly ................................................................................................. 24
Figure 7-10 Install New Coils on Cores ................................................................................................................ 24
Figure 7-11 Stop Assembly Adjustment Block ...................................................................................................... 24
Figure 7-12 Remove theTwo Mounting Screws Securing the Contact AssemblyTo Bearing Retainer ................... 25
Figure 7-13 Adjust the Gap Between Plunger and Operating Arm to .110 Inches .................................................. 25
Figure 7-14 Coil Core Retaining Bolt ................................................................................................................... 25
Figure 7-15 Alignment of Latch Components ....................................................................................................... 25
Figure 7-16 Location of Latch Assembly on Conductor Base Plate ...................................................................... 26
Figure 7-17 Set Gap Between Roller Bearing and Cam to .5mm (.020”) ............................................................... 26

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 5Page 5
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IB01301027E
SECTION1:INTRODUCTION
The purpose of this book is to provide instructions for receiving,
handling, storage, installation, operation and maintenance of Type
5HK-VSR Vacuum Motor Starter Replacement Units. They are
horizontal drawout type removable interrupting elements for use in
existing 5HK Metal-Clad Switchgear. 5HK-VSR Motor Starter
Replacements provide reliable control, protection and performance,
with ease of handling and maintenance. Like ratings are inter-
changeable with each other.
1.1 AVAILABLE 5HK-VSR MOTOR STARTER REPLACEMENTS
Refer to Table 1.1
SATISFACTORY PERFORMANCE OFTHESEVACUUM MOTOR STARTER
REPLACEMENT UNITS IS CONTIGENT UPON PROPERAPPLICATION,
CORRECT INSTALLATIONANDADEQUATE MAINTENANCE. THIS
INSTRUCTION BOOK MUST BE CAREFULLY READAND FOLLOWED IN
ORDERTO OBTAIN OPTIMUM PERFORMANCE FOR LONG USEFUL
LIFE OFTHEVACUUM MOTOR STARTER.
TYPE 5HK-VSRVACUUM MOTOR STARTER REPLACEMENT UNITSARE
PROTECTIVE DEVICES,AS SUCH,THEYARE MAXIMUM RATED
DEVICES. THEREFORE, THEY SHOULD NOT UNDER ANY CIRCUM-
STANCE BEAPPLIED OUTSIDETHEIR NAMEPLATE RATINGS.
Table 1.1 - 5HK-VSRVacuum Motor Starter Replacement UnitAvailability and Interchangeability
WARNING
Original Breaker Type
(Does Not Include MOC
Operator or Blown Fuse
Protection)
MV-VSR Breaker
to Motor Starter
Replacement Unit
Rated Max.
Volts kV
Contactor
Amps
Max.
Fuse
Rating
Amps
Short
Circuit
Rating
kA
5HK-250-1200A 5HK-VSR-250 4.76 400 230 / 390 50
5HK-350-1200A 5HK-VSR-350 4.76 400 230 / 390 50

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 6Page 6
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Table 1.2 - 5HK-VSRVacuum Motor Starter Replacement Unit Dimensions in Inches
Figure 1-1 Outline and Dimensions in inches of Type 5HK-VSR Vacuum Motor Starter Replacement Unit
Rating A B C D E F
5HK-VSR-230/390 48.25 20.25 7.00 25.40 8.00 15.58
$
%
&&
'
(
)

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 7Page 7
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IB01301027E
SECTION 2: SAFE PRACTICES
Type 5HK-VSR Vacuum Motor Starter Replacements are designed
with several built-in interlocks and safety features to provide safe
and proper operating sequences.
TO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLA-
TION, OPERATION,AND MAINTENANCE OFTHESEVACUUM
MOTOR STARTER REPLACEMENTS, THE FOLLOWING PRAC-
TICES MUST BE FOLLOWED:
yy
yy
yOnly qualified persons, as defined in the National Electrical
Safety Code, who are familiar with the installation and
maintenance of medium voltage circuits and equipment,
should be permitted to work on these starters.
yy
yy
yRead these instructions carefully before attempting any
installation, operation or maintenance of these starters.
yy
yy
yAlways remove the starter from the enclosure before
performing any maintenance. Failure to do so could result
in electrical shock leading to death, severe personnel injury
or property damage.
yy
yy
yProper personal protective equipment must be worn at all
times.
yy
yy
yDo not work on a starter with the secondary test coupler
engaged. Failure to disconnect the test coupler could
result in an electrical shock leading to death, personnel
injury or property damage.
yy
yy
yDo not work on a closed starter. The main contacts must be
open before working on the starter. Failure to do so could
result in injury.
yy
yy
yDo not use a starter by itself as the sole means of isolating a
high voltage circuit. Remove the starter to the Disconnect
position and follow all lockout and tagging rules of the
National Electrical Code and any and all applicable codes,
regulations and work rules.
yy
yy
yDo not leave the starter in an intermediate position in the
cell. Always have the starter either in theTest or Connected
position. Failure to do so could result in a flash over and
possible death, personnel injury or property damage.
yy
yy
yStarters are equipped with safety interlocks. Do not defeat
them. This may result in death, bodily injury or equipment
damage.
WARNING

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 8Page 8
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SECTION3:RECEIVING, HANDLINGANDSTORAGE
Type 5HK-VSR motor starter replacements are subjected to
complete factory production tests and inspection before being
packed. They are shipped in packages designed to provide
maximum protection to the equipment during shipment and storage
and at the same time to provide convenient handling. The original
HK levering crank can be used to lever the starter (Figure 3-1).
3.1 RECEIVING
Until the starter is ready to be delivered to the switchgear site for
installation, DO NOT remove it from the shipping crate. If the starter
is to be placed in storage, maximum protection can be obtained by
keeping it in its crate.
Upon receipt of the equipment, inspect the crates for any signs of
damage or rough handling. Open the crates carefully to avoid any
damage to the contents. Use a nail puller rather than a crow bar
when required.
When opening the crates, be careful that any loose items or
hardware are not discarded with the packing material. Check the
contents of each package against the packing list.
Examine the starter for any signs of shipping damage such as
broken, missing or loose hardware, damaged or deformed
insulation and other components. File claims immediately with the
carrier if damage or loss is detected and notify the nearest Eaton’s
Electrical Services & System office.
Tools and Accessories
Levering Crank: Used to crank the starter between Disconnect
and Connect positions.
Turning Dolly: Optional item used to help maneuver starter when
out of structure.
Contact Wear Gauge: Optional item used to check contact wear.
(Style 5259C11H01)
Lifting Sling: Optional item used to lift the starter.
(Style 94B1194G01)
3.2 HANDLING
DO NOT USE ANY LIFTING DEVICE AS A PLATFORM FOR
PERFORMING MAINTENANCE, REPAIR OR ADJUSTMENT OF
THE STARTER OR FOR OPENING, CLOSING THE CONTACTS.
THE STARTER MAY SLIP OR FALL CAUSING SEVERE PERSONAL
INJURY. ALWAYS PERFORM MAINTENANCE, REPAIR AND
ADJUSTMENTS ON AWORKBENCH CAPABLE OF SUPPORTING
THE STARTERTYPE.
HK-VSR starter shipping containers are designed to be handled
either by use of a lifting sling and overhead lifting device or by a
fork lift truck. If containers must be skidded for any distance, it is
preferable to use roller conveyors or individual pipe rollers.
Once a starter has been inspected for shipping damage, it is best to
return it to its original shipping crate until it is ready to be installed in
the Metal-Clad Switchgear.
When a starter is ready for installation, a lifting sling in conjunction
with an overhead lift or portable floor lift can be used to move a
starter, if this is preferable to rolling the starter on the floor using
self contained wheels. If the starter is to be lifted, position the
lifting device over the starter and insert the lifting harness hooks
into the starter side openings and secure. Once the lifting sling is
securely seated in the lifting holes, the starter can be carefully lifted
and moved. (Figure 3-2) Stand a safe distance away from the
starter while lifting and moving.
3.3 STORAGE
If the motor starter is to be placed in storage, maximum protection
can be obtained by keeping it in the original shipping crate. Before
placing it in storage, checks should be made to make sure that the
starter is free from shipping damage and is in satisfactory operating
condition.
Figure 3-1 Typical 5HK-VSR Levering Crank
WARNING
Figure 3-2 Overhead Lifting of 5HK-VSR

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 9Page 9
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IB01301027E
Outdoor storage is NOT recommended. If unavoidable, the outdoor
location must be well drained and a temporary shelter from sun,
rain, snow, corrosive fumes, dust, dirt, falling objects, excessive
moisture, etc. must be provided. Containers should be arranged to
permit free circulation of air on all sides and temporary heaters
should be used to minimize condensation. Moisture can cause
rusting of metal parts and deterioration of high voltage insulation. A
heat level of approximately 400 watts for each 100 cubic feet of
volume is recommended with the heaters distributed uniformly
throughout the structure near the floor.
Indoor storage should be in a building with sufficient heat and
circulation to prevent condensation. If the building is not heated, the
same general rule for heat as for outdoor storage should be applied.
Table 3.1 - MaximumWeight by StarterType
Circuit Breaker Type Max. Amperes LBs.
5HK-VSR
390
405
230
390
3.4 5HK-VSRAPPROXIMATEWEIGHTS
Refer to Table 3.1

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 10Page 10
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Figure 3-3 Front External View of 5HK-VSR Vacuum Starter Replacement Unit
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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 11Page 11
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IB01301027E
Figure 3-4 Rear External View of 5HK-VSR Vacuum Starter Replacement Unit
3ECONDARY"LOCK
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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 12Page 12
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Page 12 Effective: May 2008Effective: May 2008
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Effective: May 2008
SECTION 4: INSTALLATIONAND INSPECTION
BEFORE PLACINGTHE STARTER IN SERVICE, CAREFULLY FOLLOW
THE INSTALLATION PROCEDURE BELOWANDTHE SAFE PRACTICES
SET FORTH IN SECTION 2. NOT FOLLOWINGTHE PROCEDURE MAY
RESULT IN INCORRECT STARTER OPERATION LEADINGTO DEATH,
BODILY INJURY,AND PROPERTY DAMAGE.
When the starter is first commissioned into service and each time
the starter is returned to service, it should be carefully examined
and checked to make sure it is clean and operating correctly.
4.1 EXAMINATION FOR DAMAGE
Examine the starter for loose or obviously damaged parts. Never
attempt to install nor operate a damaged starter.
4.1.1 NAMEPLATEVERIFICATION
Compare the starter nameplate information with switchgear
drawings for compatibility. Starter and compartment code plates do
match power ratings, but do not match control voltages.
4.2 INITIAL INSPECTIONAND OPERATION
Inspect the starter for any damage that occurred during shipment,
storage, and installation.
Set the dip switches in the coil control board for the proper control
voltage and dropout time (Figures 4-1 and 4-2 and Tables 4.1 and
4.2). When control information is supplied, dip switches will be
factory set.
Sequence the control circuit, including closing the starter with the
main power circuits de-energized and locked out.
Verify that the starter will be connected to an incoming power
supply and outgoing load with characteristics agreeing with the
starter rating and coil burden requirements.
WARNING
Figure 4-1 Coil Control Board with Dip Switch
Figure 4-2 Coil Control Board Removal
1 2 3 4 5 6
ON
OFF
Dip Switch
Table 4.1 - Dip Switch Setting-ControlVoltage
gnitteS1WS2WS3WS
zH05caV011ffOffOffO
zH06caV021nOffOffO
zH05caV022ffOnOffO
zH06caV042ffOnOffO
CDV521ffOffOnO
gnitteSyaleD4WS5WS6WS
sm03ffOffOffO
sm05nOffOffO
sm031ffOnOffO
sm052nOnOffO
sm033ffOffOnO
Table 4.2 - Control Board Dropout Settings
4.3 VACUUM INTERRUPTER INTEGRITY
Using a dry lint free cloth or a paper towel, clean all the insulating
surfaces of the pole units. Conduct a vacuum interrupting integrity
check as described in Section 6.2.

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 13Page 13
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IB01301027E
4.4 INSULATION INTEGRITY
Check the starter primary and secondary insulation integrity per
Section 6.4.
4.5 INTERRUPTER WEAR CHECK
The interrupters used in the starter are designed for long electrical
life. Replacement should be at 300,000 operations except in cases
of plugging or jogging which may require more frequent replace-
ment. Contact wear can be made verified by following the
procedure in Section 6.3.
4.6 PRIMARY CIRCUIT RESISTANCE
Testing that measures the primary circuit resistance is not recom-
mended since the results can vary widely on good contacts. If a
resistance check is required, check primary resistance per section
6-5.
4.7 ELECTRICAL OPERATIONS CHECK
After going through the above steps, the starter is now ready to be
operated electrically. It is preferred that this check be made with
the starter in the Test position in the switchgear compartment.
Since the Type 5HK-VSR Vacuum Motor Starter Replacement Unit is
for use in existing 5HK Metal-Clad Switchgear, installation proce-
dures are similar. If it is necessary to reference anything in the
breaker compartment, refer to the original instruction books supplied
with the assembly.
Refer to Figures 3-3 and 3-4, for any parts identification required
during these installation procedures.
a. The starters faceplate and barriers must be positioned properly
and securely bolted in position, as shown in Figures 3-3 and 3-4,
before inserting the starter into the cell.
EXAMINE THE INSIDE OF THE CELL BEFORE INSERTING THE
STARTER FOR EXCESSIVE DIRT OR ANYTHING THAT MIGHT
INTERFERE WITH THE STARTER TRAVEL.
KEEP HANDS OFF THE TOP EDGE OF THE FRONT BARRIER WHEN
PUSHING A STARTER INTO A CELL. FAILURE TO DO SO COULD
RESULT IN BODILY INJURY, IF FINGERS BECOMEWEDGED
BETWEENTHE STARTER ANDTHE CELL. USETHE HANDLES
PROVIDED ON THE FRONT OF THE STARTER FACEPLATE, OR
USE BOTH FULLY OPENED HANDS FLAT ONTHE FRONT OFTHE
FACEPLATE.
b. Position the starter in front of the cell, and line up the wheel
guides. Once the starter is aligned with the cell floor guide, push
the starter into the cell, until the racking arms prevent further
movement of the starter toward the rear of the cell (Figures 4-3).
Using the original air circuit breaker racking handle, turn clockwise
until the position indicator is in the test position. (Figure 4-4).
AS SOONASTHE SECONDARY CONTACTS MATE UP,THE STARTER IS
READY FOR OPERATION IFTHE CONTROL CIRCUIT IS ENERGIZED.
c. once the starter is in the test position, it may be electrically
closed and tripped by using a control switch on the cell door, or it
may be manually tripped by means of the trip button, located on the
faceplate of the starter.
4.8 INSERTION PROCEDURE
a. With the starter outside the cell, using the racking handle
advance the starter racking mechanism counterclockwise to the
“TRIP FREE” position as shown by the position decal on the front of
the starter. In this position the racking “arms” should be facing the
rear as shown in Figure 4-3. Move the starter to the withdrawn
position (hard stop) in the cell. Note the starter will not go into the
withdrawn position and the cell door cannot be closed unless the
starter and enclosure have proper matching code plates.
WARNING
WARNING
NOTICE
Figure 4-3 Alignment of 5HK-VSR

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 14Page 14
Page 14Page 14
Page 14 Effective: May 2008Effective: May 2008
Effective: May 2008Effective: May 2008
Effective: May 2008
b. From the withdrawn position, insure the starter is open. Close
the compartment door and open the sliding panel. Using the racking
handle advance the starter racking mechanism clockwise for
approximately two turns. The starter should be held captive in the
cell. This is the disconnect position (Figure 4-5) and the position
indictor will show “TRIP-FREE”. The starter secondary will not mate
with the cell secondary therefore the starter should not be
operated in this position.
c. 5HK-VSR - Further advancing the starter racking mechanism
clockwise will rack the starter into the test position (Figure 4-3).
The position indicator on the front of the starter will show “TEST/
CONNECT”. The starter secondary contacts will be made in this
position, the starter will also engage the cell ground stab. In this
position the starter can be operated either electrically or mechani-
cally.
d. Engage the racking handle and rotate clockwise to further
advance the starter, advancing will cause the cell shutter to open
and the starter to fully engage the primary stabs as evidence by the
levering arms resting completely against the positive stops located
on the starter truck. This is the fully connected position (Figure 4-
6). The position indicator on the starter will show “TEST/CON-
NECT”.
Once the secondary disconnect block is engaged in the
“test” position, it will remain connected throughout further
inward movement as the starter advances from the “test”
to the “connect” position.
DO NOTATTEMPTTO REMOVEA CLOSED STARTER. VERIFYTHE
STARTER IS INTHE OPEN POSITION PRIORTO PROCEEDING.
4.9 REMOVAL PROCEDURE
To remove the starter from the cell, insure the starter is open.
Close the main starter door and open the sliding access panel, if not
already open. Engage the racking handle. Rotate the racking lead
screw counterclockwise (using the racking handle) to move the
starter out. Once movement has started, the starter will be trip free
if any attempt to close it is made before reaching the test position.
The shutter will close after the main stabs have cleared, isolating
the starter from its source. Continue racking until the starter
reaches the “TEST” position, the position indicator will indicate
“TEST/CONNECT”.
5HK-VR - To remove the starter from the “TEST” position to the
“DISCONNECT” position, the starter must be tripped if closed.
Rotate the levering lead screw counterclockwise until the starter
reaches hard stops. This is the “WITHDRAWN” position. The
racking arm rollers will clear the cell guide slots and the starter can
be rolled out of the cell, if desired.
NOTICE
WARNING
Figure 4-4 Insertion of HK-VSR (5HK-VSR-250 shown)
Figure 4-5 5HK-VSR in Disconnect Position

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 15Page 15
Page 15Page 15
Page 15
Effective: May 2008Effective: May 2008
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Effective: May 2008
IB01301027E
Figure 4-6 5HK-VSR in Connect Position
Figure 4-7 5HK-VSR Position Indicator

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
IB01301027E
Page 16Page 16
Page 16Page 16
Page 16 Effective: May 2008Effective: May 2008
Effective: May 2008Effective: May 2008
Effective: May 2008
Table 5.1 - SL Contactor Ratings
control board with the appropriate control voltage at terminals 1 and
2. The control board rectifies the input voltage and applies pulse
width modulated DC output voltage to the coils. The output voltage
is approximately full voltage for the first 200 milliseconds after
energization, during which time the starter closes and seals. After
the starter is electrically closed, a mechanical latch is engaged that
holds the moving armature plate in the closed position. Power is
then removed from the control board. Refer to Figure 5-1, for
typical schematic for latched contactor.
To open the starter, the unlatch coil is energized with the appropri-
ate control voltage. The coil engages a release lever on the latch
mechanism. The starter is then forced opened by the return spring.
Mechanical opening is also provided.
Control Scheme
A position switch contact is in the contactor closing circuit, which
remains made while the contactor is being levered between the
Test and Connected positions. Consequently, it prevents the starter
from closing automatically, even though the control switch close
may have been made while the starter is levered to the connected
position.
When the close contact is made, the MX closes the starter. If the
close contact is maintained after the starter closes, the Y-relay is
picked up. The Y/a contact seals in Y until the close contact is
opened. The Y/b contact opens the MX circuit, so that even though
the starter would subsequently open, it could not be reclosed
before the close contact was released and remade. This is the
antipump function.
SECTION 5: DESCRIPTIONAND OPERATION
The 5HK-VSR Vacuum Motor Starter Replacement is a medium
voltage (4.76kV maximum) vacuum starter used for the control of
three phase motors. The SL Contactor has a current rating of 400
amps.
The SL Contactor utilizes Eaton’s Cutler-Hammer vacuum interrupt-
ers that exhibit both a long electrical life and a high interruption
capability. Ratings for the contactor are shown in Table 5.1. The
400 amp contactor has three Axial Magnetic (A-M) coils at the fixed
end of the vacuum interrupters. The A-M coils establish a magnetic
field within the interrupter during fault conditions. The field
disperses the arc during fault current interruption, allowing the
contactor to interrupt a very high fault current. See Figure 5-2.
SATISFACTORY PERFORMANCE OF THESE CONTACTORS IS
CONTINGENT UPON PROPER APPLICATION, CORRECT INSTAL-
LATION AND ADEQUATE MAINTENANCE.THIS INSTRUCTION
BOOK MUST BE CAREFULLY READ AND FOLLOWED IN ORDER
TO OBTAIN OPTIMUM PERFORMANCE FORTHE LONG, USEFUL
LIFE OF THE CONTACTOR.
5.1 CONTACTOR OPERATION
Mechanically Latched Starter
The mechanically latched starter is closed by energizing the starter
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WARNING

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Instructions for
VSR-Series Type 5HK
Vacuum Motor Starter
IB01301027E
Page 17Page 17
Page 17Page 17
Page 17
Effective: May 2008Effective: May 2008
Effective: May 2008Effective: May 2008
Effective: May 2008
IB01301027E
Figure 5-1 SL Front and Rear View Major Components
Axial Magnetic Coil (3) SL400 only
Vacuum Interrupter
Standoff Insulator (3)
Moving Armature Plate
Optional Aux Contacts
Stop Assembly
Baseplate
8
9
10
11
12
13
14
Frame
Front Mounting Holes (4)
Operating Plate
Main Shaft
Aux Contact Operating Lever
Standard Aux Contacts
Coil Control Board &
Terminal Block
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
2
6
5
4
3
7
Upper Terminals (3)
Lower Terminals (3)
Locknut for Return Spring Bolt
5
6
7
Rear Mounting Holes (2)
Shunt Supports (6)
Coils (2)
Coil Mounting Angle
1
2
3
4
5
6
7
1
2
3
4
Figure 5-2 SL Rear View Major Components
MX
M
AC AC
M6 34
8
6A
2
(WHT)
(BLK)
(BLK)
(WHT)
COIL CONTROLLER
M
M
M
5
1
7
6
DC
COIL
1
DC
COIL
2
CLOSE
LATCH
UNLATCH
COIL
MX
CONTROL VOLTAGE
OPEN
OL
CLOSE
DC
COIL
+
+
-
-
-
+

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Instructions for
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Vacuum Motor Starter
IB01301027E
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Page 18Page 18
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Page 18 Effective: May 2008Effective: May 2008
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Effective: May 2008
Auxiliary Contacts
An operating lever attached to the rotating shaft operates a set of
auxiliary contacts located on each side of the starter (Figure 5-2).
The standard configuration is 3NO-3NC contact on each side of the
starter. The auxiliary contacts are rated 600V, 10 amps continuous.
Minimum ratings are 5 volts, 100 milliamps. Refer to Table 5.1 for
make/break ratings.
5.2 PHASE BARRIERS
DO NOT PLACE THE STARTER IN ITS COMPARTMENT WITHOUT
THE PHASE BARRIERS IN PLACE. THE ABSENCE OF BARRIERS
CAN CAUSE A CATASTROPHIC FAILURE DURING AN INTERRUP-
TION OR OPERATION, CAUSING DEATH, SEVERE PERSONAL
INJURY OR PROPERTY DAMAGE.
Phase barriers on all 5HK-VSR starters are made of glass polyester
or Lexan. They are all easily removed for easy access to fuses.
5.3 SECONDARY DISCONNECTS
The VSR control circuit is connected to the switchgear control
through a multi-contact block (See Section 3 for component
location). The movable secondary control contacts mounted on the
breaker are self-aligning, line-contact, slip-type connectors. The
multiple finger arrangement on the breaker makes contact with a
stationary mounted element. The contact surfaces on the station-
ary element are recessed to prevent accidental short-circuiting of
the control circuits.
These secondary disconnects mate in both the operating and test
positions. No special jumper is required.
Mechanical stops prevent over-travel and avoid damage to the
disconnecting devices when the circuit breaker is levered into
operating position.
5.4 INTERLOCKS
There are several interlocks built into the VSR-Series vacuum
starter replacements. Each of these interlocks, though different in
form, duplicate or exceed in function that of the original breaker.
These interlocks exist to safeguard personnel and equipment. The
basic premise behind the interlocking arrangement on the vacuum
replacement starter is that the starter must not be inserted into or
remove from the live circuit while the main contacts are closed.
Also considered in the interlocking is that the starter should pose no
greater risk than necessary to the operator in or out of the cell. In
addition to the original interlocks, VSR-Series starters provide an
anti-close interlock.
INTERLOCKS ARE PROTECTIVE DEVICES FOR PERSONNEL AND
EQUIPMENT. DO NOT BYPASS, MODIFY, OR MAKE INOPERATIVEANY
INTERLOCKS. DOING SO COULD CAUSE DEATH, SERIOUS PERSON-
NEL INJURY,AND/OR PROPERTY DAMAGE.
5.5 LEVERING-IN INTERLOCK
The levering-in interlock is designed to prevent moving the starter
into or out of the Connect position, if the starter contacts are
closed. 5HK-VSR interlocks are completely compatible with the
Figure 5-3 SL Contactors Assembly
Operating Plate
Overtravel
4
5
Armature Shaft
Moving Armature
Stop
Contactor Closed Contactor Open
1
2
3
Operating Plate
Return Spring
4
5
Armature Shaft
Moving Armature
Stop
1
2
3
4
5
1
2
3
4
5
1
2
3
WARNING
WARNING