Powell PowlVac IB-65020A CDR 27kV User manual

IB-65020A PowlVac®CDR 27kV & 38kV
Vacuum Circuit Breaker
27kV & 38kV
1200A & 2000A
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IB-65020A
Contact Information
Powell Electrical Systems, Inc.
www.powellind.com
[e-mail]
Service Division
PO Box 12818
Houston, Texas 77217-2818
Tel: [phone]
Fax: [phone]

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PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker
IB-65020A
Signal Words
As stated in ANSI Z535.4-2002, § 4.13-4.13.3 the
signal word is a word that calls attention to the
safety sign and designates a degree or level of
hazard seriousness. The signal words for product
safety signs are “Danger”, “Warning”, and
“Caution”. These words are defined as:
DANGER indicates an imminently hazardous
situation which, if not avoided, will result in
death or serious injury.
DANGERDANGER
!
WARNING indicates a potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
WARNINGWARNING
!
CAUTIONCAUTION
!
CAUTION indicates a potentially hazardous
situation which, if not avoided, may result in
minor or moderate injury.
Not stated in ANSI Z535.4-2002, § 4.13-4.13.3
as a signal word but used in this manual is
“IMPORTANT”. This is defined as:
IMPORTANT indicates a section of the manual
covering a non hazardous situation, but
one where Powell feels proper attention is
warranted.
IMPORTANTIMPORTANT
!
Qualified Person
For the purposes of this manual, a qualified person,
as stated in NFPA 70®, is one familiar with the
construction and operation of the equipment and
the hazards involved.
In addition to the above qualifications, one must
also be:
1. trained and authorized to energize,
deenergize, clear, ground, and tag circuits
and equipment in accordance with
established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
in accordance with established safety
practices.
3. trained in rendering first aid if necessary.

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IB-65020A
Contents
Ch 1 General Information.................................................................................................1
A. Sc o p e ................................................................................................................................................................2
B. pu r p o S e .............................................................................................................................................................2
c. In S t r u c t I o n Bu l l e t I n S Av A I l A B l e el e c t r o n I c A l l y .....................................................................................................2
Ch 2 Safety ........................................................................................................................3
A. SA f e Wo r k co n d I t I o n .........................................................................................................................................3
B. SA f e t y Gu I d e l I n e S ...............................................................................................................................................3
c. Ge n e r A l .............................................................................................................................................................4
d. Sp e c I f I c ..............................................................................................................................................................4
e. X-rA y S ..............................................................................................................................................................5
f. SA f e t y lA B e l S .....................................................................................................................................................5
Ch 3 Equipment Description.............................................................................................6
A. Ge n e r A l .............................................................................................................................................................6
B. th e St o r e d en e r G y Me c h A n I S M ............................................................................................................................6
1) Mechanical Description.......................................................................................................................................................... 6
2) Electrical Description.............................................................................................................................................................17
c. rA c k I n G Me c h A n I S M ......................................................................................................................................... 20
d. cI r c u I t Br e A k e r co M p A r t M e n t In t e r f A c e S ........................................................................................................... 20
1) Primary Disconnecting Devices..........................................................................................................................................20
2) Secondary Disconnecting Devices.....................................................................................................................................20
3) MOC (Mechanism Operated Cell Switch) Actuator........................................................................................................21
4) TOC (Truck Operated Cell Switch) Actuator.....................................................................................................................21
5) Ground Connection ...............................................................................................................................................................21
6) Shutter Operator ....................................................................................................................................................................21
7) Test Position Interlock ...........................................................................................................................................................21
e. vA c u u M In t e r r u p t e r S ....................................................................................................................................... 21
f. vA c u u M In t e r r u p t e r co n n e c t I o n S ..................................................................................................................... 21
Ch 4 Installation..............................................................................................................22
A. re c e I v I n G ........................................................................................................................................................ 22
B. hA n d l I n G ........................................................................................................................................................ 22
c. St o r A G e .......................................................................................................................................................... 23
d. pl A c I n G t h e cI r c u I t Br e A k e r In t o Se r v I c e ............................................................................................................ 23
1) High Voltage Insulation Integrity .......................................................................................................................................24
2) Vacuum Integrity....................................................................................................................................................................25
3) Control Voltage Insulation Integrity..................................................................................................................................26
4) Mechanical Operation Check..............................................................................................................................................27
5) Electrical Operation Check...................................................................................................................................................27
e. In S e r t I n G t h e cI r c u I t Br e A k e r In t o t h e SW I t c h G e A r eq u I p M e n t .............................................................................. 28
1) Prior to Inserting the Circuit Breaker into the Circuit Breaker Compartment..........................................................29
2) Inserting the Circuit Breaker to the Test/Disconnect Position .....................................................................................30
3) Inserting the Circuit Breaker to the Connected Position...............................................................................................30

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PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker
IB-65020A
Contents
f. re M o v I n G t h e cI r c u I t Br e A k e r fr o M t h e SW I t c h G e A r eq u I p M e n t ............................................................................ 32
1) Removing the Circuit Breaker from the Connected to the Test/Disconnect Position.............................................32
2) Removing the Circuit Breaker from the Test/Disconnect Position out of the Circuit Breaker Compartment...32
Ch 5 Maintenance...........................................................................................................33
A. Ge n e r A l de S c r I p t I o n ........................................................................................................................................ 33
1) Introduction.............................................................................................................................................................................33
2) Inspection and Cleaning ......................................................................................................................................................34
B. Me c h A n I S M Ar e A ............................................................................................................................................. 34
1) Mechanical Operation ..........................................................................................................................................................34
2) Lubrication...............................................................................................................................................................................35
3) Closing Spring Removal........................................................................................................................................................35
4) Slow Closing of Mechanism.................................................................................................................................................36
5) Mechanism Adjustments......................................................................................................................................................40
6) Electrical Operation...............................................................................................................................................................46
c. vA c u u M In t e r r u p t e r A n d co n t A c t Ar e A ............................................................................................................. 46
1) Vacuum Interrupter and Contact Erosion........................................................................................................................46
2) Vacuum Integrity....................................................................................................................................................................46
3) Mechanical Adjustment of Vacuum Interrupters .................................................................................................................47
d. op t I o n A l MA I n t e n A n c e pr o c e d u r e S ................................................................................................................... 47
1) High Potential Tests ...............................................................................................................................................................47
2) Timing ......................................................................................................................................................................................47
3) Primary Resistance Check ....................................................................................................................................................48
Ch 6 Recommended Renewal Parts and Replacement Procedures ...............................49
A. or d e r I n G In S t r u c t I o n S ..................................................................................................................................... 49
B. re c o M M e n d e d re n e W A l pA r t S ........................................................................................................................... 49
c. re p l A c e M e n t pr o c e d u r e S .................................................................................................................................. 49
1) Vacuum Interrupter Assembly.............................................................................................................................................50
2) Closing Coil Assembly ...........................................................................................................................................................54
3) Primary Shunt Trip Coil Assembly ......................................................................................................................................54
4) Secondary Shunt Trip Coil Assembly .................................................................................................................................54
5) Undervoltage Device Assembly (UV).................................................................................................................................55
6) Charging Motor Assembly ...................................................................................................................................................55
7) Anti-Pump Relay Assembly..................................................................................................................................................55
8) Latch Check Switch................................................................................................................................................................55
9) Motor Cutoff Switch Assembly............................................................................................................................................55
10) Auxiliary Switch ......................................................................................................................................................................55

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IB-65020A
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Figures
Tables
Figure 1 Front View of PowlVac® CDR Circuit Breaker with Cover ...............................7
Figure 2 Rear View of PowlVac® CDR Circuit Breaker...................................................8
Figure 3 PowlVac® CDR Circuit Breaker Compartment ................................................9
Figure 4 Operating Pushrod Assembly of PowlVac® CDR Circuit Breaker .................10
Figure 5 Ground Connection of PowlVac® CDR Circuit Breaker.................................10
Figure 6 Front View of PowlVac® CDR Circuit Breaker without Cover .......................12
Figure 7 Close-Up Front View of PowlVac® CDR Circuit Breaker Mechanism ............13
Figure 8 Cam and Fundamental Linkage Positions ...................................................14
Figure 9 Mechanical and Trip Linkages......................................................................15
Figure 10 Operation Sequence .....................................................................................18
Figure 11 Typical Control Scheme ................................................................................19
Figure 12 Circuit Breaker in Shipping Carton...............................................................22
Figure 13 Lifting the Circuit Breaker by Crane .............................................................23
Figure 14 Top View L-Shaped Slot.................................................................................30
Figure 15 Push to Trip Knob & Racking Access Window...............................................31
Figure 16 Racking Indicator Flags & Racking Handle ..................................................31
Figure 17 Main Closing Spring AssemblyCompressed for Removal ............................35
Figure 18 Main Closing Spring AssemblyInstalled.......................................................36
Figure 19 Lubrication....................................................................................................38
Figure 20 Lubrication (cont) .........................................................................................39
Figure 21 Primary & Secondary Trip Prop Adjustment ................................................41
Figure 22 Feeler Gauge .................................................................................................42
Figure 23 Trip Armature Assembly Left View ...............................................................43
Figure 24 Trip Armature Assembly Right View.............................................................44
Figure 25 Circuit Breaker Trip Roller.............................................................................44
Figure 26 Latch Check Switch Adjustment ...................................................................45
Figure 27 Vacuum Interrupter Assembly Drawing (38kV, 1200A)...............................53
Figure 28 Primary Current Path....................................................................................56
Figure 29 Control Devices.............................................................................................58
Table A Field Dielectric Test Values..................................................................................24
Table B Lubrication ..........................................................................................................37
Table C Timing..................................................................................................................47
Table D Primary Resistance .............................................................................................48
Table E Primary Current Path ..........................................................................................56
Table F Control Devices....................................................................................................57
Table G Miscellaneous Parts............................................................................................59

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PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker
IB-65020A
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IB-65020A
General Information
WARNINGWARNING
!
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
immediately at 1.800.480.7273.
WARNINGWARNING
!
Before any adjustment, servicing, part 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.
IMPORTANTIMPORTANT
!
The information in this instruction bulletin is not intended to explain all details or variations of the
equipment, nor to provide for every possible contingency or hazard to be met in connection with
installation, testing, operation, and maintenance of the equipment. For additional information
and instructions for particular problems, which are not presented sufficiently for the user’s
purposes, contact Powell at 1.800.480.7273.
Ch 1 General Information
Powell reserves the right to discontinue and to change specifications at any time without incurring
any obligation to incorporate new features in products previously sold.
IMPORTANTIMPORTANT
!

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2
PowlVac® CDR 27kV & 38kV Vacuum Circuit Breaker
IB-65020A
General Information
A. Sc o p e
The information in this instruction bulletin
describes the following PowlVac® CDR
27kV & 38kV vacuum circuit breakers:
• 27PV25CDR-1200A&2000A
• 38PV40CDR-1200A&2000A
B. pu r p o S e
The information in this instruction bulletin is
intended to provide information required to
properly operate and maintain the
PowlVac CDR 27kV & 38kV vacuum circuit
breakers described in Ch 1 General
Information, A. Sc o p e .
This instruction bulletin provides:
1. Safety guidelines
2. General descriptions of the operation and
maintenance of the PowlVac CDR
27kV & 38kV vacuum circuit breaker
3. Instructions for installation and placing the
circuit breaker into service
4. Instructions for part replacement
5. Information for ordering renewal parts
6. Procedure for critical adjustments
7. Illustrations, photographs, and description
of the circuit breaker
The illustrations contained in this document
may not represent the exact construction
details of each particular type of circuit breaker.
The illustrations in this document are provided
as general information to aid in showing
component locations only.
All illustrations and photos are shown using
deenergized equipment.
Be sure to follow the appropriate safety
precaution while handling any of the
equipment. Failure to do so may result in
serious injury or death.
WARNINGWARNING
!
To the extent required, the products described
herein meet the applicable ANSI, IEEE, and
NEMA Standards; however, no such assurance
is given with respect to local codes and
ordinances which may vary greatly.
c. In S t r u c t I o n Bu l l e t I n S Av A I l A B l e el e c t r o n I c A l l y
For more information visit
www.powellind.com. To contact the Powell
Service Division call 1.800.480.7273 or
713.944.6900, or email
[e-mail].

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IB-65020A
Safety
Ch 2 Safety
A. SA f e Wo r k co n d I t I o n
The information in Section A is quoted from
NFPA 70E 2004 - Article 120, 120.1 Establishing an
Electrically Safe Work Condition.
120.1 Process of Achieving an Electrically Safe
Work Condition
1. Determine all possible sources of electrical
supply to the specific equipment. Check
applicable up-to-date drawings, diagrams,
and identification tags.
2. After properly interrupting the load current,
OPEN the disconnecting device(s) for each
source.
3. Wherever possible, visually verify that all
blades of the disconnecting devices are
fully OPEN or that drawout type circuit
breakers are withdrawn to the fully
disconnected position.
4. Apply lockout/tagout devices in accordance
with a documented and established policy.
5. Use an adequately rated voltage detector
to test each phase conductor or circuit part
to verify they are deenergized. Test each
phase conductor or circuit part both
phase-to-phase, and phase-to-ground.
Before and after each test, determine
that the voltage detector is operating
satisfactorily.
6. Where the possibility of induced voltages
or stored electrical energy exists, ground
the phase conductors or circuit parts
before touching them. Where it could be
reasonably anticipated that the conductors
or circuit parts being deenergized
could contact other exposed energized
conductors or circuit parts, apply ground
connecting devices rated for the available
fault duty.
B. SA f e t y Gu I d e l I n e S
Study this instruction bulletin and all other
associated documentation before uncrating
the circuit breakers.
Each user has the responsibility to instruct
and supervise all personnel associated with
usage, installation, operation, and maintenance
of this equipment on all safety procedures.
Furthermore, each user has the responsibility of
establishing a safety program for each type of
equipment encountered.
The circuit breakers described in this
instruction bulletin are operated by a
high-energy, high-speed mechanism that
is interlocked to provide specific operating
sequences. It is mandatory that the following
rules be observed to ensure the safety of
personnel associated with usage, installation,
operation, and maintenance of these circuit
breakers.
The safety rules in this instruction bulletin are
not intended to be a complete safety program.
The rules are intended to cover only some of the
important aspects of personnel safety related to
PowlVac® CDR 27kV & 38kV vacuum circuit
breakers.