TERASAKI TemPower AR650S Instruction Manual
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TERASAKI TemPower AR650S Instruction Manual

Air circuit breakers
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INSTRUCTION MANUAL FOR AIR CIRCUIT BREAKERS
(With Draw-out Cradle and Type AGR-11B Overcurrent Protective Device)
AR650S,AR663S,AR663H
Types:
Notice
 Be sure to read this manual before installing, operating, servicing, or inspecting the ACB.
 Please retain this manual for future reference.
 Electrical work must be done by competent persons.
 ACB maintenance, inspection, parts replacement, OCR field tests and setting changes must be
performed by competent persons.
KRB-5331g

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  • Page 1 INSTRUCTION MANUAL FOR AIR CIRCUIT BREAKERS (With Draw-out Cradle and Type AGR-11B Overcurrent Protective Device) AR650S,AR663S,AR663H Types: Notice  Be sure to read this manual before installing, operating, servicing, or inspecting the ACB.  Please retain this manual for future reference. ...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY NOTICES 6-2-1. Preparation 2. RECEIVING AND HANDLING 6-2-2. Arc chambers 2-1. Transportation Precautions 6-2-3. Stationary arc contact and moving arc contact 2-1-1. Transporting the ACB 6-2-4 Latch release coil (LRC) 2-1-2. Transporting the breaker body 6-2-5.
  • Page 4 KRB-5331g...

  • Page 5: Safety Notices

    1. SAFETY NOTICES Thank you for purchasing the TERASAKI AR-series Air Circuit Breaker (TemPower2). This chapter contains important safety information.7 Be sure to carefully read these safety notices, instruction in this manual, and other documents accompanying the Air Circuit Breaker (hereinafter referred to as the ACB) to familiarize yourself with safe and correct procedures or practices before installing, operating, or servicing the ACB.
  • Page 6  Operation Precautions (continued) CAUTION  Do not force down the charging handle after completion of manual charging operation. Doing so may cause a malfunction.  The permissible operating voltage of the spring charging motor is 85 to 110% of the rated ac voltage or 75 to 110% of the rated dc voltage.

  • Page 7: Receiving And Handling

    2. RECEIVING AND HANDLING Upon receipt of your ACB, check the following. If you have any question or problem, contact us at the indicated on the back cover of this manual.  Check that the ACB received is as ordered and that the accessories are as specified. ...

  • Page 8: Transporting The Breaker Body

    2-1-2. Transporting the breaker body  Use an optional lifter or lifting plate to transfer the breaker body.  When transporting the breaker body on a lifter, move the lifter with the lifter fork held at the lowest possible position. ...

  • Page 9: Transporting The Draw-Out Cradle

    2-1-3. Transporting the draw-out cradle  When transporting the draw-out cradle, hold it using lifting attachments or wire ropes through the lifting holes or carry it by the portions (4 points) marked with the arrows shown in Fig 3. When carrying the draw-out cradle, take care not to exert forces on the arc gas barrier, the draw-out arm, the auxiliary switches, the control circuit terminals, the control terminal block cover, and the control circuit contacts.

  • Page 10: Storage Precautions

    2-2. Storage Precautions It is recommended that the ACB be used as soon as you have received it. If it is necessary to store the ACB, note the following:  Store the ACB in a dry indoor location to prevent condensation due to sudden changes in ambient temperature. Condensation has a harmful effect on the ACB insulation.
  • Page 11  Use the following screws with appropriate length for the main circuit terminals. Main circuit terminal screws: Hex head M10, with flat washers (2), spring washer (1) and nut (1) per screw Tightening torque: 22.5 - 37.2 N·m Table 1 Number of main circuit terminal screws required ACB type AR650S, AR663S, AR663H Number of main circuit...
  • Page 12  Use a support to hold conductors securely at distance L as shown in Fig. 6 and Table 2. Such a support will help preventing the conductors and main circuit terminals from being deformed or damaged due to a large electromagnetic force caused by any fault current.
  • Page 13 (5) Tilt the terminal block down as shown in Fig. 9. After connecting wires, tilt the terminal block up again and fix it with the terminal block fixing screws. Auxiliary switch terminal screw (Control terminal screw) (Position switch terminal screw) Pan head M4 x 8, with spring washer and terminal washer...

  • Page 14: General

    3. GENERAL 3-1. Types and Descriptions TemPower2 is available in types shown in Tables 3 and 4. Table 3 Standard types Frame size (A) 5000 6300 Type AR650S AR663S IEC, EN, AS 6300 Max. rated current [I ] (A) *1 5000 Marine use 6300...
  • Page 15 Table 4 High-performance types Frame size (A) 6300 Type AR663H IEC, EN, AS 6300 Max. rated current [I ] (A) *1 Marine use 6300 N-phase rated current (A) 6300 Number of poles *2, *3 Dielectric withstand voltage [U ] (50/60Hz) 1000 Operating voltage [U ] (50/60Hz)
  • Page 16 Table 6 shows the dielectric withstand voltage and the insulation resistance of the ACBs. CAUTION  Do not perform dielectric withstand/insulation resistance tests under other conditions than specified. Doing so may cause a malfunction. Table 6 Dielectric withstand voltage and insulation resistance Insulation Impulse withstand resistance...

  • Page 17: Parts And Functions

    3-2. Parts and Functions Fig. 10 provides a general views of the ACB. Control terminal block cover ◯ Front cover ◯ ON-OFF indicator ◯ ON-OFF cycle counter ◯ Charge indicator ◯ Specification nameplate ◯ Cover fixing ◯ OFF button ◯ screw ON-OFF button cover ◯...
  • Page 18 Arc chamber ◯ Control circuit contact ◯ Main circuit contact ◯ Mold cover ◯ Mold base ◯ Breaker body roller ◯ Grip ◯ Transport roller ◯ Breaker body (rear view) ◯ Gas exhaust port ◯ Arc gas barrier ◯ Main circuit terminal ◯ Breaker draw-out arm ◯...
  • Page 19 Consists of breaker body ◯ and draw-out cradle ◯ ◯ Draw-out cradle Comes with main circuit terminals ◯ , control circuit terminals ◯ , auxiliary switches ◯ ◯ Contains the ON-OFF mechanism, the closing coil，the tripping device, and overcurrent Breaker body ◯...
  • Page 20 Control circuit Allow connections of external control wire to the control circuits. Wire connections are ◯ terminals made through M4 screw terminals. Fig. 11 shows the control circuit terminals. Fig. 11 Control circuit terminals Control terminal Protects the position switches, the control circuit terminals and the auxiliary switches from ◯...

  • Page 21: Circuits And Ratings

    3-3. Circuits and Ratings Fig. 12 shows an ACB circuit diagram and Table 9 and Fig. 13 show the function of each terminal and the meaning of each sign in the diagram. Fig. 12-1 Breaker circuits 1 Table 9-1 Terminal functions and circuit symbols 1 (Applicable to both 50 and 60Hz for AC. mean the polarity for DC) Terminal No.
  • Page 22 *8: For motor split circuit, terminals ‚ 02 , 22 and 03 ‚ 07 are used for charging and closing operation respectively. *9: Do not use these terminals for other circuits when both instantaneously rated shunt trip and UVT are fitted. These terminals are used by Terasaki as the anti-burnout SW for the instantaneously rated shunt trip.
  • Page 23 Fig. 14 provides the terminal arrangement of the ACB. Position switches Main/control circuit Auxiliary switches Upper stage Middle stage Lower stage (When standard 4C + optional 6C are used) Upper stage Middle stage Lower stage (When standard 4C is used) Fig.
  • Page 24 Table 12 Ratings of undervoltage trip device (UVT) Rated voltage Opening voltage Attraction voltage Coil exciting Power consumption (VA) Coil resistance (ohm) * range (V) current (A) Normal Attraction AC100 35 - 70 AC110 38.5 - 77 93.5 AC120 42 - 84 AC200 70 - 140 AC220...

  • Page 25: Operation

    4. OPERATION 4-1. Charging and Opening operation DANGER  Never touch live terminal parts. Otherwise, electric shock may result. CAUTION  Do not force down the charging handle after completion of manual charging operation. Doing so may cause a malfunction. ...

  • Page 26: Closing Operation

    circuit terminals □ and □ , the charging motor is activated to start charging the closing springs. Upon completion of the charging operation, the charge indicator shows “CHARGED” and the charging motor is automatically deactivated. The time required for the motor charging operation depends on the operation voltage or the ACB types, but does not exceed 10 seconds.

  • Page 27: Motion Of Operation Mechanisms

    4-1-5. Motion of operation mechanisms Figs. 16 - 19 illustrate the motion of the charging and ON-OFF mechanisms. For manual closing operation, ON button ◯ rotates counterclockwise. For electrical closing operation, push rod ◯ ' protrudes downward from the latch release coil (LRC) and charge latch trigger ◯...
  • Page 28 The charging handle or the charging motor provides a counterclockwise rotation to charging cam ◯ . This rotates closing release lever ◯ and closing tripper lever counterclockwise and a semicircular pawl engages ◯ with closing release lever ◯ . And charging lever ◯ rotates clockwise so that closing spring ◯...

  • Page 29: Draw-Out And Insertion Operation

    4-2. Draw-out and Insertion Operation 4-2-1. General The draw-out type ACB consists of the breaker body and the draw-out cradle. The main and control circuit terminals are installed on the draw-out cradle, which permits you to draw out and inspect or service the breaker body without the need for removing wiring from the terminals.

  • Page 30: Draw-Out Operation

    4-2-2. Draw-out operation DANGER  Never touch live terminal parts. Otherwise, electric shock may result.  Do not leave the ACB body in the removed position. The weight of the ACB may cause serious injury. CAUTION  If the ACB has the breaker fixing bolts, be sure to loosen the bolts on both sides before draw-out operation. Otherwise, damage to the ACB may result.

  • Page 31: Putting The Breaker Body Back Into The Draw-Out

    4-2-2-2. Moving the breaker body from the TEST position to the ISOLATED position 1) Open the ACB. (If the ACB remains closed, the draw-out handle (Fig. 21 ◯ ) cannot be inserted). 2) Press the release button (Fig. 21 ◯ ).
  • Page 32 4) If the ACB has the breaker fixing bolts (Fig. 21 ◯ ), make sure the bolts are loosened and, holding both the grips (Fig. 21 ◯ firmly push the breaker body into the draw-out cradle.  If the ACB body is pushed out of position, it may not be inserted smoothly. Push the rail stoppers (Fig.

  • Page 33: Contact Status Of Auxiliary And Position Switches

    4-2-4. Contact status of auxiliary and position switches Tables 17 and 18 show the contact status of auxiliary switches and position switches respectively. Table 17 Contact statues of auxiliary switches ACB state Status of Status of Breaker a-contact b-contact body position CONN.

  • Page 34: Lock In Off Procedure

    4-4. Lock in OFF Procedure 1) Open the OFF button cover shown in Fig. 24. 2) Raise the OFF-lock tab and close the button cover. 3) Lock the button cover using a padlock with ø6 shackle (up to 3 padlocks can be used) as shown in Fig. 25. The OFF button is locked depressed, which disables the ON button.

  • Page 35: Breaker Fixing Bolt Securing Procedure

    4-6. Breaker Fixing Bolt Securing Procedure 1) Move the breaker body to the CONN. position. 2) Tighten the breaker fixing bolt (Fig. 27) using the draw-out handle. This procedure is required for both the sides of the ACB. Breaker fixing bolt (red) Spring washer Flat washer Grip Fig.

  • Page 36: Overcurrent Release (Ocr)

    5. OVERCURRENT RELEASE (OCR) Options available for the type AR ACBs include a highly reliable, multi-functional overcurrent release (OCR) with a built-in 16-bit microprocessor. This OCR is supplied with power through a CT and main circuit current signals from current sensors. When the OCR detects a fault, it sends a trip signal to the magnet hold trigger (MHT) or provides a trip indication or an alarm depending on the type of the fault.

  • Page 37: Characteristics

    5-2. Characteristics 5-2-1. L characteristic for general feeder A general view, characteristic settings, and characteristic curves of the type AGR-11BL OCR (with L characteristic) are shown in Fig. 29, Table 20, and Fig. 30 respectively. ◯ ◯ ◯ ◯ ◯ ◯...
  • Page 38 Long time delay trip, Short time delay trip and Instantaneous trip N-phase protection trip Note 1: The operating time (t) at a long time delay (or N-phase protection) trip pickup current setting is given by t = -27.94×t { 1 - ( 1.125I } ±15% +0.15 –0 [sec] ×log = Long time delay (or N-phase protection) trip pickup current setting,...

  • Page 39: Ocr Setting Procedure

    5-3. OCR Setting Procedure CAUTION  OCR setting changes must be performed by competent persons.  After setting changes are made, the settings be checked with e.g., a type ANU-1 OCR checker (optional).  After completion of OCR tests, be sure to return the settings to the original values. Failure to do so may cause a fire or burnout.

  • Page 40: Operation Indication

    5-4. Operation Indication The OCR has LEDs on the front panel to provide operation indications as shown in Fig. 33 and Table 21. It also outputs operation signals to contacts. (Red) ◯ Fig. 33 LEDs Table 21 Operation indication Contact output Control Type of OCR power...

  • Page 41: Maintenance, Inspection And Parts

    Normal inspection includes inspection and actions that can be done only with removing the arc chamber, contacts, front cover and  the like. Normal inspection can be performed by the user. Terasaki also provides normal inspection service. Detailed inspection includes inspection, actions, and parts replacement that will be done to prevent functional degradation caused ...

  • Page 42: Inspection Procedures

    6-1. Inspection Procedures CAUTION  ACB maintenance, inspection and parts replacement must be performed by competent persons.  Do not touch ACB current carrying parts and ACB structural parts close to a current carrying part immediately after the ACB trips open. Remaining heat may cause a burn. ...
  • Page 43 Table 24 Normal inspection procedure Check point Check item Description Discoloration Check connection conductors, main circuit terminals, and current carrying parts for heat of conductors discoloration. If such a symptom is found, contact us. Check that screws, bolts, nuts, washers, springs, retainers and the like are not missing. If any parts 2 Parts missing are missing, contact us.
  • Page 44 Table 25 Detailed inspection procedure Check point Check item Description Disconnect hand connector (red) and, using tester, measure coil resistance between terminals and 1 Coil resistance make sure holding coil is rated at 410 - 510 Ω and attraction coil at 5.6 - 6.8Ω. (*) If not so, replace UVT.

  • Page 45: Parts Replacement Procedure

    6-2. Parts Replacement Procedure CAUTION  ACB maintenance, inspection and parts replacement must be performed by competent persons.  Do not touch ACB current carrying parts and ACB structural parts close to a current carrying part immediately after the ACB trips open.
  • Page 46 (2) Remove the contact block fixing screws as shown in Fig. 35. Contact block Contact block fixing screw Pan head M5 x 10 (2) with spring and flat washers Tightening torque: 2.6 - 3.5 N·m Fig. 35 Contact block fixing screws (3) Slide the front cover to the left and flip the contact block up as shown in Fig.
  • Page 47 (5) Flip the contact block down and slide the front cover to the original position as shown in Fig. 38. Front cover Contact block Fig. 38 Sliding the front cover to the original position (6) Perform manual closing/opening operation of the ACB. Refer to sections 4-1-2 and 4-1-3. (7) Reinstall each part or component in reverse order of removal after inspection.
  • Page 48 6-2-2. Arc chambers The following describes how to replace arc chambers. 1) Make preparations for parts replacement. Refer to section 6-2-1. 2) Turn the arc chamber mounting screw eight or ten turns to loosen as shown in Fig. 40. (The arc chamber mounting screws are of captive type and cannot be removed from the arc chamber.) Arc chamber mounting screw (captive)
  • Page 49 6-2-3. Stationary arc contact and moving arc contact The following describes how to replace the stationary arc contact and moving arc contact. Fig. 43 shows the general view around the stationary arc contact and moving arc contact. Mold base Stationary arc contact Moving arc contact tip Main circuit contact Stationary arc contact tip...
  • Page 50 4) Remove the stationary arc contact and moving arc contact shown in Fig 45. Stationary arc contact Moving arc contact Fig. 45 Stationary arc contact and moving arc contact 5) Reinstall moving arc contact according to the following procedures.  Put an moving arc contact mounting screw through the installation hole after having put masks between A and B together .
  • Page 51 6-2-4 Latch release coil (LRC) The following describes how to replace the latch release coil (LRC). 1) Make preparations for parts replacement. Refer to section 6-2-1. 2) If the ACB is not equipped with the fixed type undervoltage trip device, remove the side covers and then loosen the front cover mounting screws and turn the front cover mounting screws five or six turns to loosen as shown in Fig.
  • Page 52 6-2-5. Shunt trip device (SHT) The following describes how to replace the shunt trip device(SHT). 1) Make preparations for parts replacement. Refer to section 6-2-1. 2) Remove the side covers and then loosen the front cover mounting screws and turn the front cover mounting screws five or six turns to loosen as shown in Fig.
  • Page 53 6-2-6. Control relay The following describes how to replace the control relay. 1) Make preparations for parts replacement. Refer to section 6-2-1. 2) If the ACB is not equipped with the fixed type undervoltage trip device, remove the side covers and then loosen the front cover mounting screws and turn the front cover mounting screws five or six turns to loosen as shown in Fig.
  • Page 54 6) Pull out the OCR as shown in Fig. 54, remove the hand connector(s) above the OCR and place it on the floor. The hand connector(s) below the OCR does not require to be removed. The type and quantity of the hand connectors vary depending on the specification of the ACB.
  • Page 55 9) Remove the relay retainer shown in Fig. 56 and remove the control relay from the relay base. Control relay Relay retainer Relay seat Fig. 56 Control relay and related parts 10) Reinstall each part or component in reverse order of removal after inspection. Do not forget to install the OCR ground terminal and the relay base ground terminal.
  • Page 56 6-2-7. Magnet hold trigger (MHT) The following describes how to replace the magnet hold trigger (MHT). 1) Make preparations for parts replacement. Refer to section 6-2-1. 2) Remove the OCR and the relay base. Refer to items 2 - 8, section 6-2-7. 3) Unscrew the MHT mounting screws shown in Fig.
  • Page 57 6-2-8. Auxiliary switches The following describes how to replace auxiliary switches. 1) Make preparations for parts replacement. Refer to section 6-2-1, 1) and 2). 2) If the ACB is equipped with the control terminal block cover, loosen both the cover fixing screws and remove the cover. 3) Remove the auxiliary switch mounting screws shown in Fig.
  • Page 58 5) With the operation lever raised, uplift the auxiliary switch unit, pull the shaft lever through the U-notch, and remove the auxiliary switch unit. See Fig. 61. Auxiliary switches Operation lever Shaft lever Fig. 61 Removing the auxiliary switches 6) Reinstall each part or component in reverse order of removal after inspection. When installing the auxiliary switch unit, apply molybdenum grease to the engagement of the operation lever and the shaft lever.
  • Page 59 7. TROUBLESHOOTING FLOWCHARTS Figs. 63 - 66 are troubleshooting flowcharts where typical troubles and remedial actions are shown. Closing springs Contact Terasaki. Contact Terasaki. cannot be charged Check the charging Is manual charging Is manual charging mechanism. See No. 12...
  • Page 60 “TEST” or “ISOLATED” position. in Table 24. Is the OFF button Is manual closing locked or any other OFF- Unlock Contact Terasaki. Possible? lock active? Is the SHT trip Deactivate Check the operation voltage. Supply correct voltage. command active?
  • Page 61 Correct/adjust Repair See No. 11 in Table 24. as specified? Check the tripping Is the load current as operation. See No. 25 Contact Terasaki. specified? in Table 25. Check Are main circuit contacts. See Nos. terminal screws loose? See Retighten Repair/replace 9 - 10 in Table 24.
  • Page 62 Circuit Breaker Division 6-13-47 Kamihigashi, Hiranoku, Osaka 547-0002, Japan TEL +81-6-6791-2763 FAX +81-6-6791-2732 www.terasaki.co.jp kiki-info@terasaki.co.jp Published in December 2008 Revised in April 2011, Revised in July 2015 Revised in February 2017 The contents of this manual may be subject to change without notice.

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