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.
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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
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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
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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
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Effective: May 2008Effective: May 2008
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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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Effective: May 2008
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