Page 2
IB-60202 Contact Information Powell Electrical Systems, Inc. www.powellind.com info@powellind.com Service Division PO Box 12818 Houston, Texas 77217-2818 Tel: 713.944.6900 Fax: 713.948.4569 Powered by Safety ® Courtesy of store.ips.us...
Page 3
“IMPORTANT”. This is defined as: IMPORTANT IMPORTANT IMPORTANT indicates a section of the manual covering a non hazardous situation, but one where Powell feels proper attention is warranted. Powered by Safety ® Courtesy of store.ips.us...
IB-60202 Contents Ch 1 General Information ....................1 A. S ................................2 cope B. p ................................2 urpoSe c. I .....................2 nStructIon ulletInS vAIlABle lectronIcAlly Ch 2 Safety ........................3 A. S ............................3 ondItIon B. S ...............................3 Afety uIdelIneS c. G ................................4 enerAl d. S ................................4 pecIfIc e.
Page 5
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Contents e. I ..............29 nSertInG the IrcuIt reAker nto the IrcuIt reAker oMpArtMent 1) Prior to Inserting the Circuit Breaker into the Circuit Breaker Compartment ............30 2) Inserting the Circuit Breaker to the Test/Disconnected Position .................31 3) Inserting the Circuit Breaker to the Connected Position ....................32 f.
Page 6
IB-60202 Figures Figure 1 PowlVac® CDR Vacuum Circuit Breaker Front View with Cover .....7 Figure 2 PowlVac® CDR Vacuum Circuit Breaker with Front Cover Removed ....8 Figure 3 PowlVac® CDR Vacuum Circuit Breaker Rear View ........9 Figure 4 Cam and Fundamental Linkage Positions ...........11 Figure 5 Mechanism and Trip Linkages ..............12 Figure 6...
Page 7
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Tables Table A Field Dielectric Test Values ..................24 Table B Lubrication ......................37 Table C Timing ........................49 Table D Primary Resistance .....................49 Table E Primary Current Path ..................60 Table F Control Devices ....................61 Table G Miscellaneous Parts ....................63 Powered by Safety ®...
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.
For more information visit www.powellind. PowlVac CDR vacuum circuit breakers com. To contact the Powell Service Division call described in Ch 1 General Information, A. 1.800.480.7273 or 713.944.6900, or email cope info@powellservice.com.
IB-60202 Ch 2 Safety B. S Afety uIdelIneS Study this instruction bulletin and all other A. S ondItIon associated documentation before uncrating the circuit breakers. The information in Section A is quoted from NFPA 70E 2004 - Article 120, 120.1 Establishing an Each user has the responsibility to instruct and Electrically Safe Work Condition.
DO excessive dust, ash, corrosive atmosphere, NOT FORCE THE PARTS INTO POSITION. vermin and insect infestations. CONTACT POWELL FOR INSTRUCTIONS. d. S pecIfIc 1. DO NOT WORK ON AN ENERGIZED CIRCUIT BREAKER. If work must be...
IB-60202 e. X-r f. S Afety ABelS When high voltage is applied across the The equipment described in this document has DANGER, WARNING, CAUTION, and contacts of a vacuum interrupter, there is the possibility of generation of X-rays. The intensity instruction labels attached to various locations.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Ch 3 Equipment Description B. t tored nerGy echAnISM 1) Mechanical Description A. G enerAl The stored energy mechanism is located PowlVac® circuit breakers use sealed vacuum in the front of the circuit breaker behind interrupters (Figure 3, f ) to control the the front cover.
IB-60202 Figure 1 PowlVac® CDR Vacuum Circuit Breaker Front View with Cover a. Cover Bolts Manual Charging Crank b. Front Cover MOC Actuator c. Breaker Position Indicator k. Circuit Breaker Open/Closed Indicator d. Nameplate Secondary Disconnect Receptacle e. Racking Drive Shaft Extension m.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 2 PowlVac® CDR Vacuum Circuit Breaker with Front Cover Removed a. Anti-Pump Relay v. Crank Arm Camshaft b. Opening Spring w. Ratchet Wheel m. Main Closing Cam c. Main Closing Spring x. Pawl Lift Drive Plate n.
IB-60202 Figure 3 PowlVac® CDR Vacuum Circuit Breaker Rear View a. TOC Actuator n. Worm Gear b. Main Insulator (Wishbone) o. Racking Drive Shaft c. Upper Primary Disconnecting Device p. Ground Connection d. Support Strut q. Serial Number Plate e. Insulating Pole Support r.
Page 17
PowlVac® CDR Vacuum Circuit Breaker IB-60202 The mechanism employed in the circuit operated manually, the top pawl becomes breaker is a stored energy system which the drive pawl and the bottom pawl uses a charging motor to compress the becomes the holding pawl. main closing spring.
IB-60202 Figure 4 Cam and Fundamental Linkage Positions b) Breaker Closed - Spring Discharged a) Breaker Open - Spring Charged - Links Reset c) Breaker Open - Spring Discharged d) Breaker Closed - Spring Charged Powered by Safety ® Equipment Description Courtesy of store.ips.us...
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 5 Mechanism and Trip Linkages a. Secondary Trip Prop Adjusting Screw b. Secondary Trip Prop Shaft c. Secondary Trip Prop d. Secondary Linkage Roller e. Main Cam Roller f. Reset Spring g. Camshaft h.
Page 20
IB-60202 The close latch, when released either by the of the contact loading spring force, closing coil or the manual close operator, enabling a lower spring rate to be used. allows the main closing spring to pull the It also multiplies the contact movement crank arms upward thus rotating the main by a factor of approximately 3, so that the closing cam and driving the fundamental...
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 6 Operation Sequence Secondary Disconnect Makes Motor “M” Green Light Energized Energized Close Spring Charged Makes Breaks Breaks Makes Makes White Light Motor “M” “Y” Circuit Energized Deenergized Disabled Close Control “CS/C” Makes Close Coil “CC”...
PowlVac® CDR Vacuum Circuit Breaker IB-60202 With the standard electrical control c. Anti-Pump Relay scheme, as soon as the main closing spring The anti-pump relay (Figure 2, a) is discharged on a closing operation, the provides a logic function for the control charging motor is switched on to recharge circuit which prevents a continuous the springs.
IB-60202 e. Control Circuit the breaker position indicator displays “BREAKER CONNECTED”, and this The typical AC & DC electrical control is fully visible in the aperture, the schemes are shown in Figures 7 & 8. The circuit breaker is in the connected control scheme of any particular circuit position.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 • The control circuits cannot be Figure 9 Closed Door Racking Mechanism and Interlock broken when the circuit breaker is in the connected position. • The circuit breaker cannot be removed from the circuit breaker compartment with the circuit breaker closed or with the main closing spring charged.
IB-60202 roller under the breaker frame d. c IrcuIt reAker oMpArtMent nterfAceS follow a cam mounted in the circuit 1) Primary Disconnecting Devices breaker compartment. The cam, in all intermediate positions between There are six primary disconnecting the test/disconnected and connected devices on the circuit breaker.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 3) MOC (Mechanism-Operated Contact) 6) Shutter Rollers Actuator The circuit breaker travels between the The MOC, located in the switchgear, is test/disconnected and connected positions operated by a lever which extends from as the crank arm rollers (Figure 3, k) the circuit breaker operating mechanism.
IB-60202 f. v AcuuM nterrupter onnectIon Connection to the vacuum interrupter stems are made by means of copper contact blocks. The top stem of the vacuum interrupter is threaded and a copper contact block is screwed onto this stem. The contact block and the vertical connector bars are bolted together and the vertical connector bars in turn are assembled to the upper primary disconnecting...
When the circuit breaker is received check for any sign of damage. If damage is found or suspected, file all claims immediately with the transportation company and notify the nearest Powell representative. Estimated size and weight for shipping a PowlVac® on a pallet: • Size: 42” width x 42” depth x 47” height • Weight: 675 lbs.
IB-60202 If necessary, the circuit breaker can be moved warm dry room of moderate temperature, by a fork lift truck or an overhead crane. such as 40°-100°F. Circuit breakers used in When using a fork lift truck take care to avoid outdoor metal-clad switchgear should be components located under the circuit breaker stored in the equipment only when power...
DC testing is not the breaker functions are thoroughly checked. The preferred method, however, values are user must verify functions after receipt. Powell provided due to the availability of DC test recommends that the tests be performed in the sets.
The tests described above are the only tests Powell recommends AC testing for reliable required to ascertain insulation integrity. verification of vacuum integrity. All Because of the design of the PowlVac®...
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Powell recognizes the widespread use CAUTION CAUTION of DC hipot equipment in the field and the desire to use this equipment to verify If DC high potential testing (hipot) is required, vacuum integrity. However, the capacitive...
IB-60202 Figure 13 Secondary Disconnect Override CAUTION CAUTION Device Remove all grounding conductors applied for this test before placing the circuit breaker back into service. 4) Mechanical Operation Check The contacts of the vacuum interrupter during normal operation cannot be closed unless the secondary disconnect plug is inserted into the secondary disconnect receptacle.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 5) Electrical Operation Check First, remove the control fuses in the compartment. Connect the jumper To check the basic electrical operation cable to the secondary disconnect plug of the circuit breaker, a circuit breaker in the compartment and to the circuit test cabinet should be used.
IB-60202 further force should not be exerted. Once e. I nSertInG the IrcuIt reAker nto the IrcuIt factory torque limits are reached a torque reAker oMpArtMent limiting clutch on the racking handle will 1) Prior to Inserting the Circuit Breaker into engage and disallow any further racking.
Contact detailed information. Powell for further information. CAUTION CAUTION Examine the circuit breaker compartment to see that it is clean and Before inserting any circuit breaker into a...
IB-60202 Figure 14 Inserting Circuit Breaker into IMPORTANT IMPORTANT Compartment The illustrations shown for all racking procedures are provided to show device locations and are intended only as a guideline. These illustrations may not be representative of site specific safety practices for performing the procedure.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 15 Secondary Disconnecting Devices Figure 16 Racking Mechanism Retainer Assembly a. Handle 3) Inserting the Circuit Breaker to the Connected b. Secondary Disconnect Receptacle Position c. Secondary Disconnect Plug d. Secondary Disconnect Latch a.
IB-60202 c. Turning the racking handle clockwise d. Once the circuit breaker has reached will begin to rack the circuit breaker the connected position, remove the into the compartment. When the circuit racking handle, close the teardrop cover breaker is racked into the compartment, on compartment door, and operate the the force needed to rotate the racking circuit breaker as required.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 f. r 2) Removing the Circuit Breaker from the eMovInG the IrcuIt reAker roM the IrcuIt Test/Disconnected Position out of the Circuit reAker oMpArtMent Breaker Compartment 1) Removing the Circuit Breaker from the Connected to the Test/Disconnected CAUTION CAUTION Position...
IB-60202 Figure 19 Anti-Rollout Latch 3) Power Racking This is an alternative to the manual racking procedures described above utilizing a motor driven mechanism and electric control, allowing the user to perform the racking function without being located in front of the circuit breaker compartment. The Power Racking Device mounts onto the compartment door when the closed door racking circuit breaker is used.
A permanent record of all maintenance and/or not fully understood, contact Powell work should be kept, the degree of detail immediately. depending upon the operating conditions.
IB-60202 Table B Lubrication Reference Location Lubricant Method Figure Electrical Parts Primary Disconnecting Device Figure 20, a Mobilgrease 28 Wipe clean. Apply lubricant only to actual contact surface. Ground Connection Figure 21, z Mobilgrease 28 Wipe clean. Apply lubricant only to actual contact surface. Secondary Disconnect Receptacle Figure 20, k Mobilgrease 28...
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 20 Lubrication Primary b. Main Closing Disconnecting Spring Guide Device Spring Yoke d. Primary Trip Prop Roller g. Fundamental Primary Trip Trip Shaft h. Pawl Support Jackshaft Crank Pin Linkage Pin Prop Bearing Bearing Support Secondary...
IB-60202 Figure 21 Lubrication (cont) q. Racking Contact Block Mechanism Secondary Racking Linkage Roller Drive Shaft Extension w. Fundamental u. Primary Trip Open-Closed Flag Support Jackshaft Ground Linkage Prop Flag Drive Outer Bearings Connection Lever Pin at Support Jackshaft aa. Camshaft ab.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Because of extensive quality control tests Primary insulation, including the vacuum made at the factory, the operations counter interrupter supports and the operating on a new circuit breaker will normally pushrods, should be cleaned. Wipe clean register over one hundred operations.
Before applying any type of lubrication to the circuit breaker, the stored energy mechanism should be in the open position, and all springs should be discharged. Powell offers a complete lubrication kit (Powlube-102) which contains all the lubricants required for maintaining the circuit breakers. Powlube-102 contains Rheolube 368A grease, Anderol 456 oil, and Mobilgrease 28.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 23 Main Closing Spring Assembly 4) Slow Closing of Mechanism Installed The slow closing of mechanism described is not required for routine maintenance; however, it may be a useful procedure for troubleshooting circuit breaker misoperation.
IB-60202 5) Mechanism Adjustments To adjust the pawl perform the following steps: WARNING WARNING 1. Remove the escutcheon to gain access to the head of the bolt When any maintenance procedure requires holding the adjusting eccentric. the opening or closing of the circuit breaker 2.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 b. Adjustment of Primary Trip Prop c. Tripping System Adjustment Figure 24 Primary Trip Prop Adjustment WARNING WARNING Prior to performing any adjustment or maintenance procedure, all high voltage components shall be deenergized, disconnected by means of a visible break, and securely grounded.
IB-60202 breaker operates. Do NOT turn the Note: Do NOT tilt the armature. Tilting the screw any further clockwise after the armature by applying a load to the breaker operates. right of the feeler gauges will produce incorrect results. 7. Turn the secondary trip prop adjusting screw counter-clockwise 13.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 15. If the circuit breaker did not TRIP Figure 26 Latch Check Switch Adjustment during the test performed in step 14, remove the feeler gauges and trip the breaker. Decrease the gap between the trip coil armature and the trip lever by bending the trip lever upwards slightly using channel lock pliers or a small crescent...
IB-60202 5. To confirm that the latch check To adjust the close latch shaft perform switch is properly set, slowly depress the following procedures: and release the manual trip operator 1. Remove the escutcheon. to verify that the latch check switch 2.
As the vacuum interrupter it should only be the contacts erode with use, this gap will done by a qualified technician or a Powell decrease. Because the factory setting of service technician. Contact Powell for the lock nut gap varies for each vacuum further assistance at 1-800-480-7273.
IB-60202 2) Timing When making this test, be sure that the test current passes through both main At normal control voltage, operate the horizontal primary disconnecting devices test source to the “close” position to close of each pair, or the resistance measurement the circuit breaker and record the closing will be affected.
The recommended quantity is not specified. This must be determined 1. Order Renewal Parts from Powell at by the user based on the application. As a www.powellind.com or call 1.800.480.7273. minimum, it is recommended that one set of parts be stocked per ten circuit breakers or less.
Figure 27 Tension Relieved on Opening Springs CAUTION CAUTION The vacuum interrupter should only be replaced by a qualified person or a Powell Service technician. Contact Powell for further assistance at 1.800.480.7273. CAUTION CAUTION e. If present, loosen the set screw holding Ensure all operating springs are discharged the operating yoke to the operating pin.
Page 59
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Loosen, but do not remove the four and lower blocks are approximately bolts connecting the vertical connector parallel. The recommended method of bars above the vacuum interrupter installing the upper contact block is to to the upper primary disconnecting restrain the block in a vise or a similar devices.
IB-60202 Figure 29 Lower Contact Block Setting u. Remove the pin and reassemble the bell cranks. Figure 31 Operating Yoke Setting q. Remove the nut from the bell crank mounting bolt and remove the bell cranks (Figure 30). v. Lubricate the pin with a liberal coat of r.
Page 61
PowlVac® CDR Vacuum Circuit Breaker IB-60202 w. Apply a light coat of Mobilgrease 28 to the left and right sides of the lower CAUTION CAUTION contact block and reassemble the sliding contact finger assembly. Tighten If adjustment of the operating yoke is with a torque wrench to 8-12 lb-ft.
IB-60202 f. Repeat the above steps as required to The sliding contact finger assemblies on obtain the specified stroke. the PowlVac® circuit breakers are reversible. With the circuit breaker closed, Since only the upper ends of the fingers measure the gap between the experience any wiping action, the wear is contact loading spring yoke and the normally confined to that end.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 4) Primary Shunt Trip Coil Assembly 5) Secondary Shunt Trip Coil Assembly This assembly (Figure 2, g) is located in the This assembly is located in the center part center part of the mechanism area, just left of the mechanism area, just to the right of of the main closing spring.
IB-60202 f. Trip the circuit breaker several times d. Prior to installing new relay, reconnect electrically to ensure that secondary all wires to the proper terminals. shunt trip coil assembly is functioning e. Place the new anti-pump relay over properly. the lower screw and reinstall the upper g.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 d. Connect the wires to the new switch e. Operate the circuit breaker electrically and fasten switch in place with screws several times to ensure the switch and nut plate previously removed. functions properly. e.
IB-60202 g. Reconnect the wiring. Make sure the wires are connected to the same terminals from which they were removed. h. Verify the auxiliary spare contacts are wired in accordance with the original circuit breaker diagram. Operate the circuit breaker electrically several times to ensure the switch functions properly.
PowlVac® CDR Vacuum Circuit Breaker IB-60202 Figure 33 Control Devices a. Primary Shunt Trip Coil (3 cycle) b. Primary Shunt Trip Coil (5 cycle) c. Charging Motor Assembly d. Closing Coil Assembly e. Anti-Pump Relay f. Undervoltage Device As sembly Powered by Safety ®...
Need help?
Do you have a question about the IPS PowlVac IB-60202 CDR and is the answer not in the manual?
Questions and answers