Powell POWLVAC 15PV63SASD User manual

IB-60030
Instructions
Installation Maintenance Renewal Parts
Powell Electrical Systems, Inc. •www.powellind.com
PowellApparatus Service Division (PASD) •http://www.powellservice.com
PO Box 12818, Houston, Texas 77217
•Tel: [phone] •Fax: [phone]
©2001 Powell Electrical Systems, Inc. All rights reserved. 02/2005
POWLVAC®63kA
AUTOMATIC SECONDARY DISCONNECT (ASD)
CIRCUIT BREAKER
Model Number: 15PV63SASD

2
IB-60030
PowlVac®63kAASD Circuit Breaker
Contents
Section Page
I. INTRODUCTION .......................................................................................................................7
A. SCOPE ............................................................................................................................................... 7
B. PURPOSE .......................................................................................................................................... 7
C. INSTRUCTIONBULLETINSAVAILABLE ELECTRONICALLY............................................................ 7
II. SAFETY.......................................................................................................................................7
A. GENERAL ........................................................................................................................................... 8
B. SPECIFIC............................................................................................................................................ 8
C. X-RAYS ............................................................................................................................................... 8
D. SAFETY LABELS ............................................................................................................................... 8
III. EQUIPMENT DESCRIPTION...................................................................................................9
A. GENERALDESCRIPTION.................................................................................................................. 9
B. THE STORED-ENERGY MECHANISM ............................................................................................ 13
1) Mechanical Description................................................................................................................ 13
2) Electrical Description................................................................................................................... 14
C. RACKING MECHANISM ................................................................................................................... 19
1) GeneralDescription ..................................................................................................................... 19
2) StandardCircuitBreakerInterlocking ........................................................................................... 19
D. CIRCUIT BREAKER COMPARTMENTINTERFACES...................................................................... 20
1) PrimaryDisconnectingDevices ................................................................................................... 20
2) Secondary Disconnecting Device................................................................................................. 20
3) MOC (Mechanism-Operated Contact)Actuator............................................................................ 20
4) TOC(Truck-OperatedContact)Actuator ...................................................................................... 20
5) GroundConnection ...................................................................................................................... 20
6) Shutter Rollers............................................................................................................................. 20
7) Anti-Rollout Latch ........................................................................................................................ 20
E. VACUUM INTERRUPTERS .............................................................................................................. 20
F. VACUUM INTERRUPTER CONNECTION ........................................................................................ 20
IV. INSTALLATION ........................................................................................................................21
A. RECEIVING....................................................................................................................................... 21
B. HANDLING ........................................................................................................................................ 21
C. STORAGE......................................................................................................................................... 22
D. PLACING THE CIRCUIT BREAKER INTO SERVICE ...................................................................... 22
1) High VoltageInsulationIntegrity................................................................................................... 22
2) VacuumIntegrity.......................................................................................................................... 23
3) Control VoltageInsulation Integrity............................................................................................... 24
4) Mechanical Operation Check....................................................................................................... 25
5) Electrical Operation Check25
6) Racking Mechanism Check ......................................................................................................... 25
E. INSERTINGTHE CIRCUIT BREAKER INTOTHE METAL-CLAD SWITCHGEAR ........................... 26

3
PowlVac®63kAASD Circuit Breaker IB-60030
Contents
Section Page
1) Inserting theASD Circuit Breaker ............................................................................................... 26
2) Racking theASD Circuit Breaker ................................................................................................. 27
3) Through Door Racking Optionfor the ASD Circuit Breaker ......................................................... 30
4) Power Racking ............................................................................................................................ 31
V. MAINTENANCE........................................................................................................................32
A. GENERALDESCRIPTION................................................................................................................ 32
1) Introduction .................................................................................................................................. 32
2) Inspection and Cleaning............................................................................................................... 33
B. MECHANISMAREA ......................................................................................................................... 33
1) MechanicalOperation .................................................................................................................. 33
2) Lubrication ................................................................................................................................... 33
3) Main Closing Spring Removal, Slow Closing ofMechanism, and
Latch Check SwitchAdjustment.................................................................................................. 34
4) MechanismAdjustments ............................................................................................................. 36
5) Electrical Operation ..................................................................................................................... 37
C. VACUUM INTERRUPTERAND CONTACTAREA ............................................................................ 37
1) Vacuum Interrupter and ContactErosion...................................................................................... 37
2) VacuumIntegrity.......................................................................................................................... 37
3) MechanicalAdjustmentofVacuumInterrupters ........................................................................... 37
D. OPTIONAL MAINTENANCE PROCEDURES................................................................................... 38
1) High Potential Tests..................................................................................................................... 38
2) Timing .......................................................................................................................................... 38
3) Primary Resistance Check .......................................................................................................... 38
VI. RECOMMENDED RENEWAL PARTS AND REPAIR PROCEDURES ...............................42
A. ORDERINGINSTRUCTIONS ............................................................................................................ 42
B. RECOMMENDED RENEWAL PARTS ............................................................................................. 42
C. REPLACEMENT PROCEDURES..................................................................................................... 46
1) Vacuum InterrupterAssembly ...................................................................................................... 46
2) Closing CoilAssembly ................................................................................................................. 46
3) Primary ShuntTrip CoilAssembly ............................................................................................... 46
4) Secondary Shunt Trip CoilAssembly........................................................................................... 47
5) UndervoltageDeviceAssembly .................................................................................................... 47
6) Ground ConnectionAssembly ..................................................................................................... 47
7) Charging MotorAssembly............................................................................................................ 48
8) Anti-Pump RelayAssembly ......................................................................................................... 48
9) Latch Check Switch..................................................................................................................... 49
10) Motor Cutoff SwitchAssembly ..................................................................................................... 49
11) Auxiliary Switch........................................................................................................................... 50
12) Primary Disconnecting Device SpringAssembly.......................................................................... 50

4
IB-60030
PowlVac®63kAASD Circuit Breaker
Figures
Figure Page
Figure 1. PowlVac® 63kAASD Circuit Breaker ................................................................................................9
Figure 2. PowlVac® 63kAASD Circuit Breaker (Top and Side View) ..............................................................10
Figure3. PowlVac® 63kAASD Circuit Breaker (Rear View) .......................................................................... 11
Figure4. ASDCircuitBreaker-InteriorView(FrontCoverRemoved) .............................................................12
Figure5. CamandFundamental Linkage Positions........................................................................................16
Figure6. Mechanismand Trip Linkages .........................................................................................................16
Figure7. OperationSequence(StandardControl)...........................................................................................17
Figure8. TypicalControlScheme ...................................................................................................................18
Figure9. Circuit Breaker in ShippingCarton...................................................................................................21
Figure10. Circuit Breaker Shipping Bracket.....................................................................................................21
Figure11. Circuit Breaker and Fork Lift ............................................................................................................21
Figure12. Circuit Breaker and Crane ...............................................................................................................22
Figure13. ASD Circuit Breaker - Test Position.................................................................................................28
Figure 14. ASD Circuit Breaker - Racking HandleInsertion ..............................................................................28
Figure 15. Racking theASD Circuit Breaker.....................................................................................................28
Figure16. ASD Circuit Breaker Removal -Applying theAnti-RolloutLatch.......................................................29
Figure17. Through Door Racking Option for Circuit Breaker.............................................................................30
Figure18. MainClosing SpringAssembly Compressed for Removal ................................................................34
Figure19. MainClosingSpringAssembly Installed ..........................................................................................34
Figure20. Latch Check SwitchAdjustment.....................................................................................................35
Figure21. Primaryand SecondaryTrip PropAdjustment .................................................................................36
Figure22. PrimaryTripPropAdjusting Screw ..................................................................................................37
Figure23. Lubrication (1 of 2) ..........................................................................................................................40
Figure24. Lubrication (2 of 2) ..........................................................................................................................41
Figure25. Primary CurrentPath .......................................................................................................................43
Figure26. ControlDevices ...............................................................................................................................44
Figure27. Closing CoilAssembly.....................................................................................................................46
Figure28. Primary Shunt Trip CoilAssembly ...................................................................................................46
Figure29. Trip Lever GapAdjustment...............................................................................................................46
Figure30. UndervoltageDeviceAssembly ........................................................................................................47
Figure 31. Ground Connection ..........................................................................................................................47
Figure32. ChargingMotorAssembly................................................................................................................48
Figure33. Anti-PumpRelay .............................................................................................................................48
Figure34. Latch Check Switch.........................................................................................................................49
Figure35. Motor Cutoff SwitchAssembly.........................................................................................................49
Figure36. Auxiliary Switch...............................................................................................................................50
Figure37. PrimaryDisconnectingDeviceSpringAssembly..............................................................................50

5
PowlVac®63kAASD Circuit Breaker IB-60030
Tables
Figure Page
TableA. Field Dielectric Test Values ................................................................................................................ 23
TableB. Timing ................................................................................................................................................. 38
TableC. PrimaryResistance ............................................................................................................................ 38
TableD. Lubrication .......................................................................................................................................... 39
TableE. PrimaryCurrentPath .......................................................................................................................... 43
TableF. ControlDevices(1).............................................................................................................................. 44
TableG. Miscellaneous Parts ........................................................................................................................... 45

6
IB-60030
PowlVac®63kAASD Circuit Breaker
BEFORE ANY ADJUSTMENT, SERVICING, PARTS REPLACEMENT,
OR ANY OTHER ACT IS PERFORMED REQUIRING PHYSICAL
CONTACT WITH THE ELECTRICAL WORKING COMPONENTS OR
WIRING OF THIS EQUIPMENT, THE POWER SUPPLY MUST BE
DISCONNECTED. FAILURE TO FOLLOW THIS WARNING MAY
RESULT IN INJURY OR DEATH.
WARNING
!
THE EQUIPMENT DESCRIBED IN THIS DOCUMENT MAY CONTAIN
HIGH VOLTAGES AND CURRENTS WHICH CAN CAUSE SERIOUS
INJURY OR DEATH.
THE EQUIPMENT IS DESIGNED FOR USE, INSTALLATION, AND
MAINTENANCE BY KNOWLEDGEABLE USERS OF SUCH
EQUIPMENT HAVING EXPERIENCE AND TRAINING IN THE FIELD
OF HIGH VOLTAGE ELECTRICITY. THIS DOCUMENT, AND ALL
OTHER DOCUMENTATION SHALL BE FULLY READ,
UNDERSTOOD, AND ALL WARNINGS AND CAUTIONS SHALL BE
ABIDED BY. IF THERE ARE ANY DISCREPANCIES OR
QUESTIONS, THE USER SHALL CONTACT POWELL ELECTRICAL
MANUFACTURING COMPANY IMMEDIATELY AT 1-800-480-7273.
WARNING
!

7
PowlVac®63kAASD Circuit Breaker IB-60030
I. INTRODUCTION
A. SCOPE
Thisinstruction bulletin describes the following:
PowlVac®63kAAutomatic Secondary Discon-
nect Circuit Breaker (ASD) Model 15PV63kASD
B. PURPOSE
Thisinstruction bulletin is intended to provide the
informationrequiredtoproperlyoperateandmaintain
the PowlVac®63kA ASD Circuit Breaker described in
Section A. Scope.
Thisinstructionbulletinprovides:
1. Guidelinesforsafety
2. Generaldescriptionsoftheoperation and mainte-
nance of theAutomatic Secondary Disconnect
3. Instructions for installation and placing the circuit
breakersintoservice
4. Instructionsforpartreplacement
5. Renewal parts lists
It should be noticed that some of the illustrations
contained herein may not represent the exact con-
struction details of each particular type. These
illustrationsareprovided as general information to aid
inshowing component locations.
To the extent required, the productsdescribed herein
meet the applicableANSI, IEEE, and NEMAStan-
dards;however, no such assuranceis given with
respect to local codes and ordinances since the
specificationsvary greatly.
C. INSTRUCTION BULLETINSAVAILABLE
ELECTRONICALLY
Many Powell Electrical Manufacturing Company
Instruction Bulletins are posted on the company
Web site at www.powellind.com. For more informa-
tion contact PowellApparatus Service Division
(PASD) by phone at 1-800-480-7273, 713-944-6900,
or send an e-mail to [email protected].
II. SAFETY
Study this instruction bulletin and all other associated
documentationbeforeuncratingthePowlVac®63kA
ASDCircuit Breaker.
Each user has the responsibility to instruct and
superviseall personnel associated with usage, installa-
tion,operation, and maintenance of thisequipment on
allsafety procedures which must be observed. Fur-
thermore, each user has the responsibility of devising a
completesafety program for each type of equipment
encountered.
The circuit breaker described in this instruction bulletin
is operated by high energy, high speed mechanisms
interlockedtoprovide specific operating sequences.
To ensure the safety of personnel associated with
usage,installation,operation, and maintenance of
these circuit breaker, it is mandatory that the following
safetyrulesbeobserved. THESE RULES ARE NOT
INTENDED TO BE A COMPLETE SAFETY PRO-
GRAM, BUT ARE INTENDED TO COVER ONLYTHE
IMPORTANTASPECTS OF PERSONNEL SAFETY
RELATED TO POWLVAC®63kA ASD CIRCUIT
BREAKER.
THE INFORMATION IN THIS INSTRUCTION BULLETIN IS NOT INTENDED TO EXPLAINALL
DETAILS OR VARIATIONS OF THE POWLVAC 63kAASD CIRCUIT BREAKER, NOR TO PROVIDE
FOR EVERY POSSIBLE CONTINGENCY OR HAZARD TO BE MET IN CONNECTION WITH
INSTALLATION, TESTING, OPERATION, AND MAINTENANCE OF THE EQUIPMENT. FOR
ADDITIONALINFORMATION AND INSTRUCTIONS FOR PARTICULAR PROBLEMS, WHICH ARE NOT
PRESENTED SUFFICIENTLY FOR THE USER’S PURPOSES, CONTACT POWELLELECTRICAL
MANUFACTURING COMPANYAT 1-800-480-7273.
IMPORTANT
!

8
IB-60030
PowlVac®63kAASD Circuit Breaker
A. GENERAL
1. Onlysupervisedandqualifiedpersonneltrainedin
theusage, installation, operation, and maintenance
of the circuit breaker shall be allowed to work on
this equipment. It is mandatory that this instruc-
tionbulletin, any supplements, and service adviso-
riesbe studied, understood, and followed.
2. Maintenance programs must be consistent with
bothcustomerexperienceand manufacturer’s
recommendations,includingserviceadvisoriesand
theinstruction bulletin(s). Awell-planned and
executedroutine maintenance program is essential
for circuit breaker reliability and safety.
3. Serviceconditionsandcircuit breaker applications
shallalso be considered in the development of
suchprograms, including such variables as
ambienttemperature and humidity, actual continu-
ouscurrent, thermal cycling, number of operations,
interrupting duty, and any unusual local conditions
such as excessive dust, ash, corrosive atmo-
sphere,vermin,and insect problems.
B. SPECIFIC
1. DO NOT WORK ON AN ENERGIZED CIRCUIT
BREAKER. Ifwork must be performed on a circuit
breaker,removeitfromserviceandremoveitfrom
themetal-cladswitchgear.
2. DO NOT WORK ON A CIRCUIT BREAKER WITH
THECONTROLCIRCUIT ENERGIZED.
3. EXTREME CARE MUST BE EXERCISED TO
KEEP ALL PERSONNEL, TOOLS, AND OTHER
OBJECTS CLEAR OF MECHANISMS WHICH
ARE TO BE OPERATED, DISCHARGED, OR
RELEASED. Thecircuitbreaker utilize stored-
energy mechanisms. These mechanisms must be
servicedonly by skilled and knowledgeable
personnelcapable of releasing each spring load in
acontrolledmanner. Detailedinformationregard-
ing these mechanisms is found in this instruction
bulletin.
4. DO NOTATTEMPT TO CLOSE THE CIRCUIT
BREAKER MANUALLY ONAN ENERGIZED
CIRCUIT.
5. DO NOT USE AN OPEN CIRCUIT BREAKER
AS THE SOLE MEANS OF ISOLATINGA HIGH
VOLTAGE CIRCUIT. For complete isolation, the
circuit breaker shall be in the disconnected
position or shall be withdrawn completely.
6. ALL COMPONENTS SHALL BE DISCON-
NECTED BY MEANS OF A VISIBLE BREAK
AND SECURELY GROUNDED FOR THE
SAFETY OF PERSONNEL PERFORMING
MAINTENANCE OPERATIONS ON THE CIR-
CUITBREAKER.
7. Interlocksareprovidedtoensurethe proper
operatingsequences of the circuit breaker andfor
the safety of the user. If for any reason an inter-
lock does not function as described, do not make
any adjustments, modification, or deform the parts.
DO NOT FORCE THE PARTS INTO POSITION.
CONTACT POWELL ELECTRICALMANUFAC-
TURING COMPANY FOR INSTRUCTIONS.
C. X-RAYS
When high voltage is applied across the contacts of a
vacuuminterrupter, there isthe possibility of generation
of X-rays. The intensity of this radiation is dependent
on the peak voltage and the contact gap. At the
normaloperating voltage for this type of equipment, the
radiationlevels are negligible. At the voltagesspecified
for testing, test personnel shall be in front of the circuit
breaker such that the two layers of steel used in the
frameand front cover construction arebetween the test
personneland the vacuum interrupters, and that the
test personnel be no closer than one meter from the
frontofthecircuit breaker. THE CIRCUIT BREAKER
SHALL BE EITHER FULLY OPEN, OR FULLY
CLOSED WHEN MAKING HIGH POTENTIAL
TESTS. DO NOT TEST WITH THE CONTACTS
PARTIALLY OPEN.
D. SAFETY LABELS
ThecircuitbreakerhasDANGER, WARNING, CAU-
TION, and instruction labels attached to various
locations. Allequipment DANGER, WARNING,
CAUTION,and instruction labelsshall beobserved
when the automatic secondary disconnect is handled,
operated,ormaintained.

9
PowlVac®63kAASD Circuit Breaker IB-60030
III. EQUIPMENT DESCRIPTION
A. GENERAL DESCRIPTION
PowlVac®circuitbreakers use sealed vacuum interrupt-
ers (Figure 3, f) to control the primary circuit. The
primary connections to the associated metal-clad
switchgearare made by parallel copper busbars
terminating in multiple contact fingers of the primary
disconnecting devices (Figure 3, d and g). The primary
disconnectingdevices,busbars,andvacuum inter-
rupterassemblies are supported by insulators (Figure
3, e) specifically designed for the application.
The primary current path side of the circuit breaker is
considered the rear of the circuit breaker, while the
sidewith the cover containing the variousindicators
andmanual operators is considered the front of the
circuitbreaker. Byremoving the front cover, the
operatingmechanisms of the circuit breaker are
exposed. Thestored-energy mechanism assembly
providesmotiontoeachofthe vacuum interrupter
movingcontactassembliesthroughoperatingpushrods
(Figure 3, r). In the same metal enclosed compartment
as the stored-energy mechanism is the circuit breaker
racking mechanism and interlocks which control the
movement of the circuit breaker between the test/
disconnected and connected positions. The racking
mechanismprovidesthemotiontoengage/disengage
theprimary disconnecting devices and to open/close
the shutters in metal-clad switchgear.
Figure 1. PowlVac®63kA ASD Circuit Breaker
a. Cover Bolts
b. Front Cover
c. Name Plate
d. MOC Actuator
e. Handle
f. Operations Counter
g. Manual Charging Crank
h. Spring Charge Indicator
i. Manual Close Operator
j. Open/Close Indicator
k. Manual Trip Operator
l. Padlock Provision - Latch for Movable Arm
m. Padlock Provision - Movable Arm
n. Racking Drive Shaft Shutter
o. Position Indicator
p. TOC Actuator
f
a
p
d
b
e
l
jg
q
c
ik
s
h
t
n
o
uv
m
q. Secondary Disconnect Plug
r. Secondary Disconnect
Handle
s. Pin Guide
t. Slider
u. Pivotal Lock
v. Wiring Bundle
r

10
IB-60030
PowlVac®63kAASD Circuit Breaker
a
Figure 2. PowlVac®63kA ASD Circuit Breaker (Top and Side View)
a. Secondary Disconnect - Pins
b. Serial Number Plate
c. Ground Connection
b
c