GE PowerVac 5kV VL User manual

1
GE PowerVac®5kV VL
for PowerVac®Vacuum Circuit Breakers
Type PV VL 4.16-250-0
with ML-19 Mechanism
Instructions
DEH 40012
g
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2
DEH-40012
WARNINGS, CAUTIONS AND NOTES
AS USED IN THIS PUBLICATION
This document is based on information available at the time of this publication. While efforts have
been made to ensure accuracy, the information contained herein does not cover all details or varia-
tions in hardware and software, nor does it provide for every possible contingency in connection
with installation, operation, and maintenance. Features may be described herein that are not
present in all hardware and software systems. GE Industrial Systems assumes no obligation of
notice to holders of this document with respect to changes subsequently made.
WARNINGS Warningnoticesareusedin this publicationtoemphasize that hazardousvoltages,
currents, or other conditions that could cause personal injury or death are present
in this equipment or may be associated with its use.
Warning notices are also used for situations in which inattention or lack of equip-
mentknowledgecould cause either personal injuryor damage to equipment.
CAUTIONS Caution notices are used for situations in which equipment might be damaged if
care is not taken.
NOTES Notes call attention to information that is especially significant to understanding
andoperatingthe equipment.
GEIndustrialSystemsmakesno representation or warranty, expressed,implied,or statutory, with
respect to, and assumes no responsibility for the accuracy completeness, sufficiency, or useful-
ness of the information contained herein. No warranties of merchantability or fitness for purpose
shall apply.
The following is a trademark of GE Company: PowerVac®
©2000GE Company
AllRightsReserved
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PowerVac®5kV Vertical Lift
Table of Contents
3
Chapter 1. Introduction
1-1 Safety ...................................................................................................................... 6
1-2 Maintenance ........................................................................................................... 6
Chapter 2. Description....................................................................................................................7
Chapter 3. Receiving, Handling & Storage
3-1 Receiving................................................................................................................ 8
3-2 Handling ..................................................................................................................8
3-3 Storage ....................................................................................................................8
3-4 SafetyPrecautions ..................................................................................................8
3-5 UnpackingtheBreaker ............................................................................................8
3-6 SafetyInterlocks ......................................................................................................9
PositiveInterlockSystem .......................................................................................9
Interference Bolts .................................................................................................. 10
Chapter 4. Installation
4-1 Breaker Preparation............................................................................................... 11
4-2 EquipmentTest Position ....................................................................................... 11
4-3 PositiveInterlock System .................................................................................... 11
4-4 Checkingfor Proper Interlock ...............................................................................12
4-5 PrimaryContact Penetration ................................................................................. 14
4-6 Stationary Auxiliary Switch (MOC) ....................................................................... 16
4-7 Stops......................................................................................................................16
4-8 Ground...................................................................................................................16
4-9 SecondaryCoupler................................................................................................ 17
4-10 Position Switch ..................................................................................................... 17
Chapter 5. Operation
5-1 Description ............................................................................................................ 18
5-2 Close Spring Charging ....................................................................................... 19
5-3 Trip-FreeOperation .............................................................................................. 20
5-4 ClosingOperation .................................................................................................20
5-5 OpeningOperation................................................................................................ 21
Chapter 6. Control Circuit
6-1 Typical Wiring Controls ........................................................................................22
Chapter 7. Mechanical Check and Slow Close
7-1 Visual Inspection .................................................................................................. 25
7-2 Closing Spring Charging ...................................................................................... 25
7-3 Closing Spring Gag ..............................................................................................25
7-4 Slow Closing......................................................................................................... 25
7-5 GagTool Removal .................................................................................................25
Chapter 8. Dimensional Checks
8-1 PrimaryContact Erosion ....................................................................................... 26
8-2 Spring Wipe Indicator ..........................................................................................26
8-3 ContactGap ........................................................................................................... 27
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PowerVac®5kV Vertical Lift
Table of Contents
4
Chapter 9. Electrical Checks
9-1 ElectricalOperation............................................................................................... 28
9-2 HighPotential Test ................................................................................................ 28
Primary Circuit....................................................................................................... 28
SecondaryCircuit.................................................................................................. 28
9-3 Primary Circuit Resistance.................................................................................... 28
9-4 Vacuum IntegrityTest............................................................................................ 28
9-5 Insulation Tests ..................................................................................................... 29
Chapter 10. Maintenance
10-1 General .................................................................................................................. 30
10-2 Service Conditions................................................................................................ 31
10-3 Fault Interruptions ................................................................................................. 31
10-4 Contact Erosion ..................................................................................................... 31
10-5 Transfer FingerWear............................................................................................. 31
10-6 Mechanism ............................................................................................................ 31
10-7 PrimaryInsulation Parts ........................................................................................ 31
10-8 Lubrication ............................................................................................................ 32
10-9 RecommendedMaintenance ................................................................................ 32
10-10 BreakerTiming andSpeed Check ........................................................................ 32
Chapter 11. Mechanical Adjustments
11-1 General .................................................................................................................. 35
11-2 WipeAdjustment................................................................................................... 35
11-3 ContactGapAdjustment....................................................................................... 36
11-4 Trip Coil Plunger ................................................................................................... 37
11-5 Close Coil Plunger ................................................................................................ 38
11-6 Control Switch Adjustment .................................................................................. 39
11-7 Adjustment of MOC Switch .................................................................................. 39
11-8 PositiveInterlock................................................................................................... 40
Chapter 12. Repair and Replacement
12-1 General .................................................................................................................. 44
12-2 Replacing Interrupters ........................................................................................... 44
12-3 Primary Bushing.................................................................................................... 45
12-4 Mechanism ............................................................................................................ 45
12-5 Control Switches................................................................................................... 45
12-6 Trip Coil Replacement .......................................................................................... 45
12-7 Closing Coil Replacement .................................................................................... 47
12-8 Auxiliary SwitchReplacement.............................................................................. 47
12-9 MotorReplacement ............................................................................................... 49
12-10 “Y” Relay Replacement ........................................................................................ 49
Chapter 13. Renewal Parts
13-1 Ordering Instructions ............................................................................................ 51
Chapter 14. Stationary Cubicle Subassembly
14-1 Introduction ........................................................................................................... 53
14-2 MajorComponents ............................................................................................... 53
14-3 Testing and Inspection.......................................................................................... 54
14-4 CompartmentMaintenance................................................................................... 58
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PowerVac®5kV Vertical Lift
Table of Contents
5
List of Figures
1. View of the 5kV ‘VL’ Breaker with Front Cover ............................................................................... 7
2. Hookinglifting eyes ........................................................................................................................... 8
3. ManualTrip & Close .......................................................................................................................... 9
4. PositiveInterlock ............................................................................................................................... 9
5. Rating Interference Bolt .................................................................................................................. 10
6. Positive Interlock system ................................................................................................................ 12
7. Manual charge handle ..................................................................................................................... 13
8. Primary Contact Insertion ............................................................................................................... 14
9. Primary contact penetration and wipe ........................................................................................... 15
10. MOCswitch ...................................................................................................................................... 16
11. Secondarydisconnect coupler........................................................................................................ 17
12. Front View of ML-19 Mechanism with Front Cover Removed ..................................................... 18
13. Charging & Trip system left side view ............................................................................................ 19
14. Manual Charging system right side view .......................................................................................19
15. Electrical Charging system right side view .................................................................................... 20
16. Closing linkageleft side view.......................................................................................................... 20
17. Opening spring & auxiliary switch left side view ........................................................................... 21
18. Wipe Spring assembly left side view ............................................................................................. 21
19. Typical ML-19mechanisminternalwiring connections ................................................................ 22
20. Typical breaker wiring diagram (Replacement for breakers with MS mechanisms................... 23
21. Typical breaker wiring diagram (Replacement for breakers with ML mechanisms ................... 24
22. Closing spring withgagtool inserted ............................................................................................. 25
23. Contact ErosionIndicator ................................................................................................................ 26
24. Primary contact erosion measurement-rear view ........................................................................ 26
25. Wipe indicator check and wipe measurement-rear view ............................................................. 27
26. Sample Operating Speed Graphs .................................................................................................. 33
27. Opening SpeedAdjustment............................................................................................................ 33
28. Travel Transducer Installation (Part#0144D1235G00X)............................................................... 34
29. Wipe Insulator.................................................................................................................................. 35
30. Contact GapAdjustment—OpeningBuffer.................................................................................... 36
31. Contact Gap measurement, wipe indicator check and wipe measurement ................................ 36
32. Trip coil gapadjustment .................................................................................................................. 37
33. Tripcoil buttonwithgage ................................................................................................................ 37
34. Tripcoilassembly ............................................................................................................................ 37
35. Close coilassembly-frontview ....................................................................................................... 38
36. Close coil gapadjustment-front view ............................................................................................. 38
37. SM/LS & CHG switch adjustment-left side view............................................................................ 39
38. CL/MS andpositiveInterlock switchadjustment-right sideview ................................................. 39
39. Positive Interlock ............................................................................................................................. 40
40. Adjustment of MOCSwitch/PlungerInterlock................................................................................ 41
41. Toggle Linkage Positions ................................................................................................................. 42
41A ToggleLinkagePositions (ViewfromRight Side) .......................................................................... 42
42. Toggle Linkage Positions(Viewfrom Right Side) .......................................................................... 42
42A ToggleLinkagePositions (ViewfromRight Side) .......................................................................... 42
43. Pole Assembly ................................................................................................................................. 44
44. TripCoiland Linkage(ClosingSpring Removed) .......................................................................... 46
45. Front View of ML-19 Breaker Mechanism (Lower)....................................................................... 48
46. Front View of ML-19 Breaker Mechanism (Upper) ....................................................................... 49
47. Motor Cutoff Switch ........................................................................................................................ 50
48. ClosingSpringGag .......................................................................................................................... 50
49. Front View of ML-19 Mechanism with Front Cover Removed ..................................................... 51
50. Schematic of ML-19 Mechanism .................................................................................................... 52
51. Typical stationary structure wiring ................................................................................................. 56
52. Electrical schematic diagram for vertical lift elevating mechanism ............................................ 57
53. Positive interlock M-26 units ........................................................................................................... 59
Appendix A .............................................................................................................................................. 63
List of Tables
1. Measurements .................................................................................................... 43
2. Adjustments........................................................................................................ 43
3. ML-19 Control Devices and Voltages................................................................ 47
4. Elevating Motor Troubleshooting...................................................................... 57
Trouble Reporting Form.......................................................................................... 66-67
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6
PowerVac®5kV Vertical Lift
Chapter 1. Introduction
1-1 Safety
IT IS IMPERATIVE THAT ALL PERSONNEL
ASSOCIATEDWITHTHISEQUIPMENTREAD
AND COMPLETELY UNDERSTAND THE
WARNINGS LOCATEDTHROUGHOUTTHIS
INSTRUCTION BOOK. FAILURE TO DO SO
CANRESULTINDAMAGETOPROPERTYOR
PERSONALINJURY.
Each user must maintain a safety program for
the protection of personnel, as well as other
equipment, from the potential hazards associ-
atedwithelectricalequipment.
Thefollowingrequirementsareintendedtoaug-
ment the user’s safety program but NOT sup-
plant the user’s responsibility for devising a
complete safety program. The following basic
industry practiced safety requirements are ap-
plicable to all major electrical equipment such
asswitchgearor switchboards. GEneithercon-
donesnorassumesany responsibility for prac-
tices which deviate from the following:
1. ALL CONDUCTORS MUST BE ASSUMED
TOBEENERGIZEDUNLESSTHEIRPOTEN-
TIAL HAS BEEN MEASURED AS TO
GROUND.
Many accidents have been caused by
powersystemback feedsfrom awidevari-
ety of sources.
2. It is strongly recommended that all equip-
mentbecompletelyde-energized,verified
tobe“dead”,thengroundedwithadequate
capacitygroundingassembliespriortoany
maintenance. Thegroundingcableassem-
bliesmustbeable to withstand energizing
fault levels so that protective equipment
mayclearthe circuitsafely. Additional dis-
cussionon thisconceptiscoveredin Chap-
ter20ofANSI/NFPA70B,Electrical Equip-
mentMaintenance.
3. Althoughinterlockstoreduce some of the
risksareprovided, the individual’sactions
while performing service or maintenance
are essential to prevent accidents. Each
person’sknowledge;hismentalawareness;
and his planned and executed actions of-
ten determine if an accident will occur.
The most important method ofavoiding
accidents is for all associated personnel
to carefully apply a thorough understand-
ingofthespecificequipmentfromtheview-
points of its purpose, its construction, its
operation and the situations which could
behazardous.
1-2 Maintenance
All personnel associated with installation, op-
eration and maintenance of electrical equip-
ment,suchaspower circuit breakers and other
powerhandlingequipment,mustbethoroughly
instructed, with periodic retraining, regarding
powerequipmentingeneralaswellasthe par-
ticular model of equipment on which they are
working. Instruction books, actual devices and
appropriate safety and maintenance practices
such as OSHA publications, National Electric
Safety Code (ANSI C2), and National Fire Pro-
tectionAssociation (NFPA)70BElectricalEquip-
mentMaintenancemust becloselystudiedand
followed. During actual work, supervision
should audit practices to assure conformance.
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2-1 Description
The PowerVac®5kV VL vacuum circuit breaker
isaverticallift,removableand interchangeable
interrupting element, for use in metal-clad
switchgeartoprovide protectionand control of
electrical apparatus and power systems. The
PowerVac 5kV VL Type PV-VL1 circuit breaker
with ML-19 mechanism is available in continu-
ous current ratings of 1200 and 2000 amperes
in accordance with industry standards.
PowerVac®5kV Vertical Lift
Chapter 2. Description
Referto thebreaker nameplatefor completerat-
ing information of any particular breaker. The
nameplatealsodescribesthe control power re-
quirements for that breaker. The application of
a breaker must be such that its voltage, current
and interrupting ratings are never exceeded.
Since this book is written to include all ratings
of the breaker, as well as several design varia-
tions, the instructions will be of a general char-
acter and all illustrations will be typical unless
otherwisespecified.
1 Nameplate 5 Charge/DischargeIndicator 9 ManualChargeLever
2 CoverMountingBolts 6 Counter 10 SecondaryCoupler
3 FrontRemovableCover 7 ManualTripButton 11 PositiveInterlockRoller
4 Open/CloseIndicator 8 ManualCloseButton 12 PlungerInterlock(MOC)
13 PrimaryBushings (1200Ampshown)
3
Figure 1. View of 5kV ‘VL’ Breaker with Front Cover
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PowerVac®5kV Vertical Lift
Chapter 3. Receiving, Handling & Storage
3-1. Receiving
Eachbreakeris carefully inspected beforeship-
ment. Immediately upon receipt of the circuit
breaker, anexaminationshouldbemade forany
damage sustained in transit. If injury or rough
handling is evident, a claim should be filed im-
mediatelywith thetransportationcompany,and
the nearest GE Sales Office should be notified.
CAUTION: THE BREAKER HAS BEEN
SHIPPED IN THE CLOSED POSITION.
3-2. Handling
It is expected that care will be exercised during
the unpacking and installation of breakers so
that no damage will occur from careless or
rough handling, or from exposure to moisture
or dirt. Loose parts associated with the breaker
aresometimesincludedinthesamecrate.Check
all parts against the packing list to be sure that
noparts have been overlooked.
3-3. Storage
It is recommended that the breaker be put into
service immediately in its permanent location.
Ifthisisnot possible, the followingprecautions
must be taken to assure the proper storage of
thebreaker.
The breaker should be stored in a clean loca-
tion, free from corrosive gases or fumes. Par-
ticularcareshouldbetaken toprotecttheequip-
ment from moisture and cement dust, as this
combinationhas averycorrosiveeffecton many
parts.
Breakers should be carefully protected against
condensation, preferably by storing in a warm,
dryroomofmoderate temperaturesuchas 40to
100° F. High humidity may have an adverse ef-
fect on the insulating parts and should be
avoided. Circuit breakers for outdoor metal-
clad switchgear should be stored in the equip-
mentonlywhenpowerisavailableandtheheat-
ers are in operation to prevent condensation.
Rollers,latches,etc.oftheoperatingmechanism
should be coated with GE part No.
0282A2048P009(Mobil28red)greasetoprevent
rusting.
If the breaker is stored for any length of time, it
should be inspected periodically to see that
corrosion has not started. Should the breaker
be stored under unfavorable atmospheric con-
ditions,itshouldbeservicedbeforebeingplaced
on line.
Figure 2. Hooking lifting eyes
3-4 Safety Precautions
This circuit breaker uses powerful springs for
energystorage.DONOT WORKON THEINTER-
RUPTERS OR THE MECHANISM UNLESS THE
CIRCUIT BREAKER IS IN THE “OPEN” POSI-
TIONAND BOTHTHECLOSING ANDOPENING
SPRINGS ARE EITHER DISCHARGED OR
GAGGEDAND ALLELECTRICALPOWERIS RE-
MOVED.
The precautions are required to prevent acci-
dental operation. Anyone working on the cir-
cuit breaker should be familiar with the con-
tents of this instruction book.
3-5 Unpacking the Breaker
The circuit breaker has been supplied with a
box of maintenance items. After removing the
protective cardboard, locate this package and
removetwoeachbreakerlifting eyes. After re-
movingthecleats thatattachthebreaker to the
skid, hook the lifting eyes on both sides of the
breaker in line with the front edge of the pri-
mary bushing plate at the point of the lifting
arrows (see Figure2). Connect a 1,000 lb.mini-
mum rated chain fall or sling (not provided) to
theselifting hooksandremovethebreakerfrom
the skid.
Packing List
Withyour breaker, you should have received:
1. Manual charging handle. (Part No.
0282A7227P001)
2. Gagtool. (PartNo. 0209B8043G003)
3. Breaker Instruction BookDEH40012
4. Elemenatary Wiring Diagram per breaker
summary.
5. (1)Tube of GE red grease. (Part No.
0282A2048P010)
6. (2) Breaker lifting hooks . (Part No.
0348A3356P001)
7. (6) MOC adjustment washers. (Part No.
0348A3185P001
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CAUTION: THE CIRCUIT BREAKER HAS
BEEN SHIPPED IN THE CLOSED POSITION.
After removing packing material, open the
breakerby pushing in firmlyon the manualtrip
button (Figure2, Item8),whilekeepinghands
awayfrommovingparts. A safe way to do this
istopush on thetripbuttonwith the round side
of the maintenaince handle. Verify that the op-
eration counter advances one count.
Closing and opening springs are now in their
discharged positions. Check this by first press-
ing the manual close button, then the manual
trip button. The indicator flags on the front of
the breaker should show “OPEN” and
“DISCHGD”.
All mechanical and electrical checks listed in
Chapter 4 should be completed before putting
breakers in service.
3-6 Safety Interlocks
Each PowerVac®VL vacuum circuit breaker is
provided with the following interlocks:
Positive Interlock System
The purpose of the positive interlock is to pre-
ventmovingthebreakertoorfromtheconnected
positionwhile themain contactsare closed,and
to prevent closing the contacts unless the
breakerisinthefullyconnectedposition. These
importantsafetyfeaturesareachievedbymeans
of the positive interlock roller on the right side
of the breaker and positive interlock cam and
stationary “flag” in the switchgear cell.
PowerVac®5kV Vertical Lift
Chapter 3. Receiving, Handling & Storage
A major goal in the design of switchgear has
alwaysbeenthe interchangeabililty of break-
ers.GESwitchgear has been verysuccessful
inachievingthatgoalformany years. Analy-
sisofinstructionbook adjustments, shop tol-
erances, and service advice letters issued in
recentyears,however,has demonstratedthat
tolerancesinswitchgear equipment installed
and presently operating can change, result-
inginsituationswhereitisimpossibletomeet
all adjustments. Also, when an adjustment
is brought into specification it can cause a
problemwithanotherinterfaceoradjustment.
Although GE has made every effort to assure
interchangabilityand satisfactoryinterface with
existingequipment. Olderequipment andfield
modifications that may have been made over
the years, may require additional procedures
beforethe newvacuumbreakercanbeinstalled
in the cubicle. At a minimum, all breaker-to-
switchgear interfaces as explained in this sec-
tionshouldbeverifiedforproperoperationprior
to energizing. The interfacing parts on all rat-
ings of type AM breakers are functionally the
same.
The following section defines the essen-
tial dimensions relating to the interfacing
elements of the breaker and switchgear,
to assure reliable performance. Some of
these elements also affect the other im-
portant interfaces required for reliable op-
eration of the equipment, such as:
1. Positive interlock safety feature.
2. Mechanism operation.
3. Primary disconnect penetration.
4. Secondary coupler penetration.
Figure 4.
Positive
Interlock
Figure 3. Manual Trip & Close
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PowerVac®5kV Vertical Lift
Chapter 3. Receiving, Handling & Storage
Interference Bolts
This interlock permits only a breaker with a
matching continuous current rating to be in-
sertedinto ametal-cladcompartmentofidenti-
calrating.The rating interferencebolthas been
assembled to match the current rating of the
compartment.This assemblyisdone byfasten-
ing a bolt on the lower left side of the breaker
truck to align with the proper cubicle interfer-
ence plate. This bolt should not be removed.
Figure5.
Figure 5. Rating Interference Bolt
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11
PowerVac®5kV Vertical Lift
Chapter 4. Installation
4-1 Breaker Preparation
Prior to interfacing the breaker into the
switchgear cell, rub a small amount of
0282A2048P009 red grease, provided with the
breaker, on the silvered portion of the breaker
studs, ground shoe, and 16 secondary coupler
pins, to form a thin coating for contact pur-
poses.
4-2 Equipment Test Position
In most AM breaker Metal-Clad Switchgear
units, there is a breaker “Test Position” which
allowsyouto functionallytestthe breakerwith-
outconnectingtothebus.Thispositionislow-
eredfullydownfrom thebreakerbeingfullycon-
nectedinto the cubicle. When in the “test posi-
tion”,a secondary coupler cable must be used
to connect the secondary control circuits for
electricalbreakeroperation.
While in the test position, the breaker interlock
is not activated. The interlock roller will not
rest in the lower “Vee” notch in the equipment
interlock cam plate allowing the operator to
closeand openthe breakerelectricallyormanu-
ally (see Figure 6).
The breaker positive interlock system should
be checked while in the test position prior to
elevatingthebreaker.
WARNING: FAILURETO PROPERLYVERIFY
ALL BREAKER SWITCHGEAR INTERFACES
ANDPROPERPOSITIVEINTERLOCKOPERA-
TION COULD RESULT IN A BREAKER OP-
ERATIONALFAILURE.
4-3 Positive Interlock
Thepositive interlocksystemprevents connect-
ingordisconnectingthebreakerin the cubicle,
when the breaker is in the closed position and
the vacuum contacts are closed.
Thisinterlock featureisaccomplishedbyaroller
and lever located on the interlock shaft, on the
right side of the breaker. (Figures 1, 4 and 6)
The positive interlock lever (roller) provides a
trip-free and discharged condition when rack-
ing the breaker in the connected or disconnect
position.When thebreakerisraisedorlowered,
thepositiveinterlockroller and lever areforced
forward by the postitive interlock cam on the
right side of the switchgear cell. The interlock
rollerandlever areheldin this forwardposition
duringraisingandloweringoperations,prevent-
ing the breaker from being closed in any inter-
mediate position between the connect and the
fully lowered position. Any attempt to charge
thebreakerwillcausethe storedenergysprings
toautomaticallydischarge without the breaker
contacts closing or moving. The breaker must
befullyconnected(raised)andtheclutch handle
must be released before the breaker can be
closed. Releasing the clutch handle allows the
interlock cam plate in the cell to move down-
ward allowing the interlock roller and lever to
return to their normal vertical positions. The
breakermaythenbeclosed.
Thefollowingpositiveinterlockadjustmentsare
made at the factory and verified for proper op-
eration per Figure 6. The distance from the top
ofthestationaryflagtothetopoftheswitchgear
guide rails is set. This maintains the surface
upon which the breaker wheels rest when the
breaker is lowered. The upper elevating motor
limit switch is then adjusted to achieve a roller
to flag clearance of 1/16" to 1/8" as shown in
Figure 6. The limit switch de-energizes the el-
evating motor circuit and should be activated
when the primary disconnects and secondary
couplerreach theirnominalcontact penetration
position. If the timing of this sequence is off,
the cell must be adjusted back to factory speci-
fications.
Typical instructions for making adjustments to
thecellpositiveinterlockcam as provided with
the original equipment are outlined in Figure 6
andFigure53.
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12
4-4 Check for Proper Interlock
and Trip-free Functions Before
Energizing the Breaker
WARNING: THE PRIMARY EQUIPMENT
SHOULDBECOMPLETELY DE-ENERGIZED
WHILE THE TESTS ARE IN PROGRESS.
DO NOT INSTALL OR REMOVE THE
BREAKER OR MAKE ADJUSTMENTS UN-
LESS THE BREAKER IS OPEN.
To testthefunction of thepositiveinterlock sys-
temandtrip free function, thefollowingchecks
should be made:
1. Verify that red grease has been rubbed on
the silvered portion of the breaker studs,
ground shoe, and 16 secondary coupler
pins, forming a thin coating for contact
purposes.
2. Before inserting the New VL vacuum
breaker into the cubicle, verify the cubicle
interlock position by measuring the dis-
tancebetween(Figure6)themovableposi-
tive interlock cam to the back of the lifting
saddleof theracking mechansim. Thisdis-
tance should be 10 7/8” minus 0, plus
1/16”.
Figure 6. Positive Interlock system
PowerVac®5kV Vertical Lift
Chapter 4. Installation
3. Lower the elevating mechanism lifting
bracketsuntilthe lifting bracketsareinthe
fullyloweredposition. Thebreakershould
then enter the housing freely. After first
assuring that the breaker is in the open
position,pushthebreakerinto theunituntil
it rests against the rear of the front lifting
saddle of the elevating mechanism.The
clearance between the interference block
on the breaker and the interference block
ontheinterlockmechanismshould befrom
.063"to.125".
4. With the breaker in the lowered position,
thepositiveinterlockrollerengagesin the
lowerVee notch,intheinterlockcamplate.
The breaker should be in the opened posi-
tion and the closing springs discharged
asindicatedby the flagindicators. (Figure
1, items 4 and 6) Using the manual charg-
inghandle,chargethebreaker. Thenclose
the breaker and recharge. (Figure 7, Item
1). With the elevating motor switch in a
neutralposition engagetheclutchtoverify
theoperationof the positiveinterlock.The
springswilldischargeandthe breakerwill
open.
NOTE: TABLE 3, FIGURES 6, 52, 53, AND
54 HAVE BEEN PROVIDED TO FAMILIAR-
IZE THE OPERATOR WITH THE EQUIP-
MENTRACKING SYSTEMANDTROUBLE-
SHOOTING.
(-0, + 1/16”)
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WARNING: AGAIN, BEFORE PROCEEDING
WITHTHISCHECK, IT IS NECESSARYTHAT
THEPRIMARYCIRCUITSBEDE-ENERGIZED.
5. Raise the breaker to the connect position.
Thiscanbedone manually with anelevat-
ing wrench or electrically with an elevat-
ingmotor providedwiththeoriginalequip-
ment.
To elevate the breaker, first–verify the
breakerisintheopenpositionandtheclos-
ing springs are discharged. Place the el-
evating control selector switch on the el-
evatingmotorto “RAISE”.Aclutch handle
under the elevating motor is then pulled
forwarduntilalimitswitchengagestoraise
thebreaker intothe unit.Carefullyraisethe
breaker and while elevating, note that the
shutter slides open and the breaker studs
center with respect to the openings in the
stationary disconnecting devices or dam-
age to the contacts may result.
6. Holdtheclutch handle in theforwardposi-
tion until a limit switch on the structure
opens to stop the motor at the end of the
upward travel of the breaker. The springs
will charge when the clutch handle is re-
leased.
CAUTION: THEMOTORRAISE/LOWERSE-
LECTOR SWITCH MUST NOT BE USED TO
ENERGIZEOR INTERRUPTMOTORCIRCUIT
AT ANY TIME.
1 Manual charging handle
2 Positive interlock
Figure 7. Manual charge handle
WARNING: DONOTATTEMPTTOMANUALLY
CHARGE A CHARGED BREAKER. TO DO
SO COULD DAMAGE THE CHARGING
CLUTCH AND MAKE THE MANUAL CHARG-
INGFEATUREINOPERABLE.
2
PowerVac®5kV Vertical Lift
Chapter 4. Installation
7. Whenthebreakerisfullyelevated,theclear-
ance between the breaker lifting rail and
the upper stop bolts should not be more
than .125" and not less than .094".
8. Thepositiveinterlock roller shouldbecen-
teredintheupper “VEE” and the interlock
roller should have 1/16" clearance to the
stationary plate directly under it.
9. Inordertolower the breakerfrom the con-
nected position, the breaker should be
open. The closing springs will be dis-
charged when the clutch handle is en-
gaged.
To lower the breaker, place the elevating
control selector switch on the elevating
motorto“lower”. Aclutch handle in back
of the elevating motor is then pulled for-
warduntila limit switchengages,to lower
the breaker to the bottom of the cubicle.
10.To raise or lower the breaker, the clutch
mustbeheld in theengagedposition,oth-
erwise a spring will return it to its disen-
gagedpositionandopentheelectricalcir-
cuit to the motor.
CAUTION: THE POSITIVE INTERLOCK LE-
VERROLLERWILLDISCHARGETHEOPEN-
ING AND CLOSING SPRINGS AS THE EL-
EVATING MOTOR CLUTCHISENGAGED.
11. The breaker may be raised or lowered by
an emergency hand crank which can be
insertedafterremovingthemotor.Themo-
tor is removed by unlatching the motor
assemblyfromitssupportanddisconnect-
ing the motor lead plug. After removing
themotor,insertthe manualcrankandpull
the clutch forward. Rotate the crank until
the coupling engages the clutch. The
clutch handle will be held in the down
positionbyalatch on the crankassembly.
Thebreakermustbeopenbeforethecrank
canbeinsertedandheldin the clutchcou-
pling.
Courtesy of NationalSwitchgear.com

14
Whenthebreakerisinthe fully elevated and in
the connected position, releasing the motor
operating handle will return the positive inter-
lockrollerintothe upper Vee notch in theinter-
lock cam plate. The breaker positive interlock
switchwillcloseand energize the motor charg-
ing circuit allowing the closing spring to
charge. The breaker may now be closed.
Inordertolowerthebreakerfromtheconnected
position, the breaker should be opened. If the
breaker has not been opened, operating the
motor elevating clutch will open the contacts
and discharge the springs.
4-5 Primary Contact Penetration
AftercompletingthePositiveInterlockandtrip
freefunctionalchecks,lowerthebreakandwith-
draw it from the cell. Inspect the contact sur-
facesofboththe breaker studs and the station-
ary disconnecting devices.Theprimary discon-
nect devices utilize silver to silver contacts to
insure against reduction of current carrying ca-
pacityduetooxidationofthecontactsurfaces.
These contacts are of the high pressure line
contact tube and socket design, the tube being
backedupbyheavygartersprings.
1. Each segment of the stationary discon-
nectingdeviceshouldmake a heavy im-
pression in the contact lubricant on the
breakerstuds asshowninFigure9. Con-
tactwipeshould startnotless than .125"
from thetopof thecontactball, although
each contact need not start at the same
location.
2. The penetration of the breaker stud in-
sidethe stationary disconnectingdevice,
as indicated by the contact lubricant,
should be 3/4” to 7/8” as shown in Fig-
ure9.Thisindicatesthatthebreakerstuds
contacted at the full pressure center of
thesilverbandon the stationarydiscon-
necting device correctly.
3. Should the inspection of the contacts
showthatthe breakerisnot beingraised
to the proper position, readjust the up-
perstopbolts and limitswitchestoraise
or lower the breaker to the proper loca-
tion (See Figure 6 and 53). Lock the stop
bolts in the new position.
4. If proper contacting cannot be attained
bythe abovemethods, additionaladjust-
mentsmaybenecessary.
ContactthelocalGE Sales Office for factory
assistance.
Figure 8. Primary Contact Insertion
PowerVac®5kV Vertical Lift
Chapter 4. Installation
Courtesy of NationalSwitchgear.com

15
Figure 9. Primary contact penetration and wipe
PowerVac®5kV Vertical Lift
Chapter 4. Installation
Final
Position
1/2” to 5/8”
Electrical
Wipe
Initial
Electrical
Contact
3/4” to 7/8”
Travel
3000A Contact
Wipe area should
be a minimum of
60% contact width
1200A & 2000A
Contact Wipe
should be a line
1/16” to 1/8”
wide.
(grease wipe)
8 3/16 M 26
9 3/4 M 36
12 3/4 M 36HH
Courtesy of NationalSwitchgear.com

16
4-6 Stationary Auxiliary Switch
(MOC)
TheStationaryAuxiliary Switchisa Mechanism
Operated Contact (MOC) which is an optional
switch mounted in the switchgear cell. When
the breaker has been elevated to the fully con-
nected position, the MOC switch will be actu-
ated whenever the breaker is closed. The MOC
switch is actuated by the plunger mounted on
the top of the breaker mechanism. (Figure 10
Item 1). The MOC switch has a number of “a”
contacts(closed whenthebreaker isclosedand
open when the breaker is open) and “b” con-
tacts (open when the breaker is closed and
closed when the breaker is open).
The following paragraph defines the essential
dimensionsrelatingto theinterfacingelements
ofthebeakerandswitchgear, to assurereliable
performance.
The following elements are important factors
whichcommonly affecttheoperationofthe sta-
tionaryauxiliaryswitch.
PowerVac®5kV Vertical Lift
Chapter 4. Installation
1. Plungertravel on the breaker.
2. The gap between the top of the plunger
on the breaker and the bottom of the rod
on the stationary auxiliary switch mecha-
nism.
3. Variationsbetweenbreakersinthedistance
from the underside of the lift rail and the
top of the plunger.
4. Variations in the rotation requirements to
“make” and “break” the stationary auxil-
iary switch contacts.
5. Conditionof theplungerinterlock compo-
nents on the breaker.
6. Elevatingmechanism limit switchconsis-
tency.
7. Breakelevatingmechanismpositivestops.
8. Seismic events.
Some of these elements also affect the other
importantinterfacesrequired forreliableopera-
tion of the equipment, such as:
1. Primary disconnectpenetration.
2. Secondary couplerpenetration.
3. Thepositive interlock mechanism.
A major goal in the design of switchgear has
alwaysbeenthe interchangeabilityofbreakers.
GE Switchgear has been very successful in
achievingthatgoal formanyyears. Analysisof
instructionbookadjustments,shop tolerances,
andserviceadvicelettersissuedinrecentyears,
however,havedemonstrated that tolerances in
switchgear equipment installed and presently
operating can result in situations where it is
impossible to meet all adjustments or that an
adjustment is brought into specification and it
causes a problem with another interface.
4-7 Stops
The stop pins and stop bolts on the elevating
mechanism are emergency mechanical stops
which would come into use only if the upper
elevatingmotorswitch is completely outofad-
justment or has failed. Elevating against these
stops may be quite audible and the operator
should release the clutch handle immediately,
de-energizing the elevating motorcircuitor the
elevatingmotor circuitprotectivefusewillopen
to protect the motor. The stop bolts should be
set to 3/32" to 1/8" clearance and only changed
orreset afterallotherelevatingadjustmentsare
made and verified. Figure 6 and 53.
4-8 Ground
A visual check should be made to observe the
ground connection. The ground shoe on the
moveable breaker is designed to have a nomi-
nal engagement of 1-1/2" +1/4" vertically with
thesteeland copper springloadeddisconnects
of the ground device in the switchgear.
Figure 10. MOC switch
1. Adjustment
washer
2. Operating
switchrod
3. Plunger
interlock
Courtesy of NationalSwitchgear.com

17
4-9 Secondary Coupler
On the top left front of the breaker, there is a
plastic block which holds the male secondary
coupler pins. This block should make contact
with, and slightly raise a spring loaded plastic
block which holds female secondary coupler
sockets on the switchgear. The contact depres-
sion should be 1/8". It is not always possible
to have the plastic blocks in contact over their
entire flat surface. Often, the rear of the blocks
are engaged while a gap exists along the front
edge.Thisisanacceptable condition. The con-
tacting block surfaces should touch and the fe-
maleblock edgemoveupward between1/32"to
1/8". See Figure 11.
Figure 11. Secondary disconnect coupler
1
2
3
1 Secondary disconnect block shims
2 16 Secondary disconnect pins
3 Ground pin for use with a test cabinet
PowerVac®5kV Vertical Lift
Chapter 4. Installation
4-10 Position Switch (TOC)
The position switch is an optional device
mounted in the rear left side of the switchgear
cubicle. The switch contacts operate when the
liftingmechanismisin either the fullyraisedor
fullylowered position.Switchoperation should
be checked with the breaker withdrawn manu-
allyandthe equipmentde-energized,and again
electrically, with the breaker in the cubicle.
Courtesy of NationalSwitchgear.com

18
5-1 Description
The PowerVac®5kV VL vacuum circuit breaker
uses a sealed vacuum power interrupter to es-
tablish and interrupt a primary circuit. Primary
connections to the associated metal-clad
switchgeararemadebypole assemblies, elec-
trically and mechanically connected to the
vacuuminterrupters.The operatingmechanism
provides vertical motion at each pole location
in order to move the lower contact of the
vacuuminterruptersfroman open position to a
spring-loadedclosedpositionand then back to
the open position on command.
The ML-19 mechanism (Figure 12) is a stored-
energytypemechanismand uses a gearmotor
tochargeaclosingspring. During a closing op-
eration, the energy stored in the closing spring
isused toclose thevacuum interruptercontacts,
charge the wipe springs which load the con-
tacts,chargetheopeningsprings,andovercome
bearing and other frictional forces.
PowerVac®5kV Vertical Lift
Chapter 5. Operation
The energy then stored in the wipe and open-
ing springs will open the contacts during an
openingoperation.
Closing and opening operations are controlled
electrically by the control switch on the metal-
clad door or remote relaying.
Mechanicalcontrolformaintenanceoremergen-
cies is provided by manual close and trip but-
tons on the circuit breaker.
Also, the closing spring may be manually
charged (Figure 7) for de-energized checks and
maintenance.
Figure 12. Front View of ML-19 Mechanism with Front Cover Removed
1 OpeningSpring
2 ChargingMotor
3 CloseSpring
4 ManualClose Button
5 Charge/Discharge Indicator
6 ManualTripButton
7 Open/CloseIndicator
8 Counter
9 Manual Charge Lever
10 Positive InterlockSwitch
11 Close Relay
12 Cam shaft
13 Close coil
14 Close coiladjustmentcollar
15 Close latch check switch
16 Opening dashpot
17 Auzilaryswitch
18 MOC Plungerlinkage
19 Positive interlock bar
Courtesy of NationalSwitchgear.com

19
PowerVac®5kV Vertical Lift
Chapter 5. Operation
5-2 Close Spring Charging
Figure 13 shows a left side view of the closing
spring.Theclosing spring ischarged and ready
to close. The closing spring charging system
consists of a closing spring mounted on the
left side of the breaker and the electrical charg-
ing system mounted on the right side of the
breaker. Both components are fastened to the
cam shaft (Figure 13, Item 2).
Figure 14. Manual Charging system
right side view
1 Manual charging crank
2 One way clutch
Amanual chargingsystem isprovidedtomanu-
ally charge the breaker, or while under mainte-
nance so that the mechanism can be slow
closed and the closing spring can be charged.
(Figure14,Item1)
WARNING: DONOTATTEMPT TO MANU-
ALLYCHARGEACHARGEDBREAKER. TO
DOSOCOULD DAMAGETHECHARGING
CLUTCHAND MAKETHEMANUAL CHARG-
INGFEATUREINOPERABLE.
Themanualchargingsystem(Figure14)works
directly on the cam shaft where a one-way
clutch(Figure14, Item 2), drivenbyamanual
handle,providesrotationoftheratchetwheel.
Manualpumpingofthehandle advances the
ratchetwheelandtheholdingpawl prevents
counter-rotationwhilethe handle isreturning
foranotherstroke.Approximately eightcom-
pletestrokesofthemanualhandlearerequired
foronecompletespring-chargingoperation.
When the spring charge indicator (Figure 1,
Item5)shows“CHARGED”,MANUALCHARG-
ING MUST BE DISCONTINUED TO AVOID
MECHANISMDAMAGE.
Figure 13. Charging & Trip system left side view
1 Closingspring 4 Trip return spring
2 Cam shaft 5 Trip linkage
3 Trip Solenoid 6 52 Chg & SM/LS switch
Courtesy of NationalSwitchgear.com

20
Theclosing coilcannotbeelectrically energized
unlessthe closingspringiscompletelycharged.
This action is prevented by the 52/CHG switch
in the closing circuit. (Figure 13, Item 6)
5-3 Trip Free Operation
The linkage is mechanically trip-free in any lo-
cation on the closing stroke. Electrically ener-
gizing the trip coil while closing will, after the
auxiliary switch contacts change position, ro-
tate the trip latch and permit the circuit breaker
to open fully. The linkage will reset as in a nor-
mal open operation and the closing spring will
recharge as described under “CLOSE SPRING
CHARGING”.
5-4 Closing Operation
By either energizing the close solenoid or de-
pressingthemanualclosebutton(Figure1,Item
8) the close latch (Figure 15, Item 5) is rotated,
releasingtheclosingspring (Figure 13, Item 1).
This action releases the energy in the closing
spring and transmits it to the closing cam (Fig-
ure16,Item 1)andclosing roller(Figure16,Item
2)causing thelinkageto riseuntil thecloseprop
(Figure16,Item3) canslipunder thecloseroller
(Figure16,Item 2)andhold thelinkagein place.
As the linkage moves, the primary drive crank
(Figure16,Item5)rotatestheprimarycrossshaft
(Figures 16 & 17, Item 4) which in turn rotates
the outer phase bell cranks. (Figure 17, item 2)
Figure 15. Electrical Charging system
right side view
1 Charging arms 5 Close latch
2 Ratchet wheel 6 Chargingmotor
3 Drivingpawl 7 52 LCS switch
4 Holdingpawl 8 Triplatch
Springcharging isaccomplishedelectrically by
a rotating eccentric on the output shaft of a
gear motor (Figure 15, Item 6) which in turn
drives pivoted charging arms (Figure 15, Item
1). The charging arms oscillate about the
centerlineofa ratchetwheel(Figure 15, Item2).
A driving pawl (Figure 15, item 3), mounted
within the charging arms, oscillates with the
chargingarms.Startingfrom itsrear-mostposi-
tion, the charging arms rotate forward, while
spring forces engage the driving pawl with a
toothonthe ratchetwheel.The ratchetwheelis
advancedbytherotatingchargingarmsandpawl
assembly. Advancement of one tooth spacing
is provided for each oscillation of the system.
The ratchet motion is restricted to one direc-
tion by a spring-loaded holding pawl (Figure
15,Item4) that preventsthe ratchet wheelfrom
going backwards as the charging arm oscil-
lates back to pick up the next tooth. Thirteen
completecyclesofthechargingarmsareneeded
for a full charge of the closing spring. The effi-
cient, compact gear motor accomplishes this
action in about two seconds. When the charg-
ingcycleiscomplete, the ratchet wheelisposi-
tionedsothat a missing toothisadjacentto the
driving pawl and any motor overspin will not
drive the ratchet wheel, thus preventing dam-
agetothesystem.
PowerVac®5kV Vertical Lift
Chapter 5. Operation
1 Closing cam 4 Primary cross shaft
2 Closing roller 5 Primary drive crank
3 Close proplatch 6 Trip latch
Figure 16. Closing linkage left side view
View rotated
90 degrees
Courtesy of NationalSwitchgear.com