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TERASAKI TemPower2 Instruction Manual

Air circuit breaker
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Innovators in Protection Technology
Air Circuit Breaker
Instruction Manual
AGR-22 Overcurrent Protective Device
03-M55EC

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  • Page 1 Innovators in Protection Technology Air Circuit Breaker Instruction Manual AGR-22 Overcurrent Protective Device 03-M55EC...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. SAFETY NOTICES 5. OVERCURRENT RELEASE (OCR) 2. RECEIVING AND HANDLING 5-1. Specifications 2-1. Transportation Precautions 5-2. Display Navigation and Characteristic Setting Procedures 2-1-1. Transporting the ACB 5-3. Characteristic Setting 2-1-2. Transporting the breaker body 5-3-1. L characteristic for general feeder 2-1-3.

  • Page 3: Safety Notices

    1. SAFETY NOTICES Thank you for purchasing the TERASAKI AR-series Air Circuit Breaker (TemPower2). This chapter contains important safety information. 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 4 Operation Precautions (continued) CAUTION Repeated open/close operation by the motor charging mechanism without pause should not exceed 15 times. If repeated continuous open/close operation is inevitable, a pause of at least 20 minutes should be provided after the repetitions of 15 times.

  • Page 5: 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. Check that the ACB is not damaged during shipment.

  • Page 6: 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. Take care not to exert forces on the front cover and the control circuit contacts shown in Fig. 2 . Otherwise, a deformation or damage may result.

  • Page 7: Installation Precautions

    2-3. Installation Precautions CAUTION Electrical work must be done by competent persons. Do not place the ACB in such an area that is subject to high temperatures, high humidity, dusty air, corrosive gases, strong vibration and shock, or other unusual conditions. Mounting the ACB in such an area could cause a fire or malfunction. Be careful to prevent foreign objects (such as debris, concrete powder, dust, chippings, and iron powder) and oil or rainwater from entering the ACB.
  • Page 8 Use the receptacles shown in Table 2 to make connections with plug-in tab terminals (#187) of position switches, control circuit terminals, and auxiliary switches. Table 2 Receptacles for #187 tab terminals Wire thickness (mm Recommended terminals Applicable crimp tool Manufacturer 0.75 - 1.25 18 - 16 TMEDN480509-FA...

  • Page 9: General

    3. GENERAL 3-1. Types and Descriptions is available in types shown in Tables 3 and 4. Table 3 Standard types Frame size (A) 1250 1600 2000 2500 3200 4000 Type AR208S AR212S AR216S AR220S AR325S AR332S AR440S IEC, EN, AS 4000 Max.
  • Page 10 Table 4 High-performance types Frame size (A) 1250 1600 2000 1600 2000 2500 3200 Type AR212H AR216HS AR220H AR316H AR320HS AR325H AR332H IEC, EN, AS Max. rated current [I ] (A) 1250 1600 2000 1600 2000 2500 3200 *1, *2 Marine use N-phase rated current (A) 1250...
  • Page 11 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 Impulse withstand Insulation resistance Circuit...

  • Page 12: Parts And Functions

    3-2. Parts and Functions Fig. 7 provides a general views of the ACB. ON-OFF indicator Front cover Spring charge indicator ON-OFF cycle counter OFF button Spring charging handle ON-OFF button cover Lock-in-OFF plate ON button ON-OFF button cover Overcurrent release (OCR) OCR cover Rating nameplate Position indicator...
  • Page 13 1 ACB Consists of breaker body and draw-out cradle Draw-out cradle Comes with main circuit terminals , control circuit terminals , auxiliary switches , and position switches Breaker body Contains the ON-OFF mechanism, the closing coil the tripping device, and overcurrent release OFF button Push to open the ACB.
  • Page 14 Position switches (optional) Indicate the present breaker body position: CONN., TEST, ISOLATED or INSERTED. The position switches are available in 2C or 4C configuration. Connections to the position switches are made through #187 plug- in tab terminals (standard) or M4 screws. Control circuit terminals Allow connections of external control wire to the control circuits.

  • Page 15: Circuits And Ratings

    3-3. Circuits and Ratings Fig. 10 shows an ACB circuit diagram and Table 9 and Fig. 11 show the function of each terminal and the meaning of each sign in the diagram. Fig. 10 Breaker circuits Table 9 Terminal functions and circuit symbols (Applicable to both 50 and 60Hz for AC. mean the polarity for DC) –...
  • Page 16 1 1 1 3rd character: Type of contact 1: Common, 2: b-contact, 4: a-contact 2nd character: Type of switch 1: Auxiliary switch, 2: Position switch (CONN.), 3: Position switch (TEST), 4: Position switch (ISOLATED), 5: Position switch (INSERTED) 1st character: Number of contact 1 - 0: Number of auxiliary and position switch, A –...
  • Page 17 Table 12 Ratings of auxiliary and position switches Auxiliary switches Position switches For general feeder For microload Voltage (V) Resistive load Inductive load Resistive load Inductive load Resistive load Inductive load (A) *1 (A) *2 (A) *2 AC100 - 250 AC251 - 500 DC30 DC125...

  • Page 18: 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 spring 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 19: Closing Operation

    Motor charging When the charge indicator (Fig. 13 ) changes to “DISCHARGED” while both the specified operation and control voltages are applied, 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 20: Motion Of Operation Mechanisms

    4-1-4. Motion of operation mechanisms Figs. 14 - 17 illustrate the motion of the charging and ON-OFF mechanisms. For manual closing operation, ON button rotates counterclockwise. For electrical closing operation, push ' protrudes downward from the latch release coil (LRC) and charge latch trigger rotates clockwise.
  • Page 21 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 that closing spring...

  • Page 22: 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 23: 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 24: Putting The Breaker Body Back Into The Draw-Out Cradle

    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. 19 ) cannot be inserted). 2) Press the release button (Fig. 19 ). The release button will be locked depressed. 3) Unlock the position lock lever (Fig.
  • Page 25 5) Push the rail stoppers (Fig. 19 8 ) outward on both sides of the draw-out cradle (Fig. 19 ) to unlock the draw-out rail, and then push the rail ends to insert the rail until it stops. The draw-out rail will be locked again by the stoppers. Breaker body Draw-out cradle Breaker body rollers...

  • Page 26: Contact Status Of Auxiliary And Position Switches

    4-2-4. Contact status of auxiliary and position switches Tables 15 and 16 show the contact status of auxiliary switches and position switches respectively. Table 15 Contact statues of auxiliary switches ACB state Status of Status of Breaker a-contact b-contact body position CONN.

  • Page 27: Off Button Locking Procedure

    4-4. OFF Button Locking Procedure 1) Open the OFF button cover shown in Fig. 23. 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. 23. The OFF button is locked depressed, which disables the ON button.

  • Page 28: Breaker Fixing Bolt Securing Procedure

    4-6. Breaker Fixing Bolt Securing Procedure 1) Move the breaker body to the CONN. position. 2) Loosen the breaker fixing bolt shown in Fig. 25, move the spring and flat washers close to the bolt head and push the bolt into the U-notch of the grip.

  • Page 29: 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 8- 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 tripping coil (TC) or provides a trip indication or an alarm depending on the type of the fault.

  • Page 30: Display Navigation And Characteristic Setting Procedures

    5-2. Display Navigation and Characteristic Setting Procedures CAUTION OCR setting changes must be performed by competent persons. The following describes how to navigate through displayed items on the LCD and set the OCR characteristic. 1) Push the right end of the OCR cover to the left at the recess on the front cover to unlatch and open the OCR cover. See Fig. 28.
  • Page 31 3) The LCD navigation procedure is as shown in Fig. 30 below. Initial display *1 Monitor mode Phase current R phase, actual *3 MONI MODE PHASE CURRENT PHASE CURRENT I1 1200 A Set mode R phase, max *3 MODE PHASE CURRENT I1 1600 A Test mode S phase, actual *3...
  • Page 32 4) Before changing OCR settings, open the ACB and then draw the ACB body to the TEST position or lock the OFF button to prevent the ACB from being closed inadvertently. 5) The OCR setting procedure is as shown in Figs. 31 and 32 below. Initial display *1 Monitor mode Phase current...
  • Page 33 Initial display *1 Monitor mode Phase current R phase, actual MONI MODE PHASE CURRENT PHASE CURRENT I1 1200 A Set mode Numbers – represent buttons on the OCR front panel. MODE Buttons on the OCR front panel *1: The LCD returns to the initial display if no button is pressed for 30 Test mode seconds.

  • Page 34: Characteristic Setting

    5-3. Characteristic Setting 5-3-1. L characteristic for general feeder Characteristic settings and characteristic curves of the type AGR-22L OCR (with L characteristic) are shown in Table 18 and Fig. 33 respectively. Table 18 Settings of type AGR-22L OCR (with L characteristic) Setting item Symbol Setting range...
  • Page 35 Long time delay trip Short time delay trip, instantaneous trip and pretrip alarm Note 1: The operating time ( ) at a long time delay (or N-phase protection) trip pickup current setting is given by (1.125 I t = -27.94 t 0.15 [sec] = Long time delay (or N-phase protection) trip...

  • Page 36: R Characteristic For General Feeder

    5-3-2. R characteristic for general feeder Characteristic settings and characteristic curves of the type AGR-22R OCR (with R characteristic) are shown in Table 19 and Figs. 34 – 36 respectively. Table 19 Settings of type AGR-22R OCR (with R characteristic) Setting item Symbol Setting range...
  • Page 37 Long time delay trip Short time delay trip, instantaneous trip and pretrip alarm Note 1: The operating time ( ) at a long time delay (or N-phase protection) trip pickup current setting is given by Type of protection characteristic: It 0.02 0.15 1.981 10...
  • Page 38 Long time delay trip Short time delay trip, instantaneous trip and pretrip alarm Note 1: The operating time ( ) at a long time delay (or N-phase protection) trip pickup current setting is given by 0.02 Type of protection characteristic: I 1.667 t 0.15 [sec]...
  • Page 39 Long time delay trip Short time delay trip, instantaneous trip and pretrip alarm Note 1: The operating time ( ) at a long time delay (or N-phase protection) trip pickup current setting is given by 6.111 t 0.15 [sec] 1.125I = Long time delay (or N-phase protection) trip pickup current setting i = Overcurrent...

  • Page 40: S Characteristic For Generator Protection

    5-3-3. S characteristic for generator protection Characteristic settings and characteristic curves of the type AGR-22S OCR (with S characteristic) are shown in Table 20, and Fig. 37 respectively. Table 20 Settings of type AGR-22S OCR (with S characteristic) Setting item Symbol Setting range Rated current *1...

  • Page 41: Operation Indication And Indication Resetting Procedure

    5-4. Operation Indication and Indication Resetting Procedure The OCR has LEDs on the front panel to provide operation indications as shown in Fig. 38 and Tables 21 - 23. It also outputs operation signals to contacts. To reset LEDs, contact output and LCD display, press the reset button (Fig. 38 ) or isolate the control power (Fig.
  • Page 42 Table 22 Operation indication 2 Control power State Type of OCR Operation supply Remarks When activated When reset Long tome TRIP I 6.40 kA delay trip 24.0sec (LT) LCD displays trip pickup current, trip cause and operating time. Short time TRIP I 9.60 kA delay trip...

  • Page 43: Ocr Function Check

    5-5. OCR Function Check CAUTION OCR function check and setting changes must be performed by competent persons. 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 44: Ocr Characteristic Check

    5-6. OCR Characteristic Check CAUTION OCR check must be performed by competent persons. The following describes how to check the OCR characteristic. To check other items of OCR than described in this section, use type ANU-1 OCR checker (optional). 5-6-1. Characteristic of adjustable undervoltage trip device (UVT) The following describes how to check the characteristic of the adjustable undervoltage trip device (UVT).

  • Page 45: Maintenance, Inspection And Parts Replacement

    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 by aging or the like when abnormality is found during normal inspection.

  • Page 46: 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. Prior to commencing any work on the ACB, open an upstream circuit breaker or the like to isolate all sources of power/voltage from the main and control circuits.
  • Page 47 Table 26 Normal inspection procedure Check point Check item Description Discoloration Check connection conductors, main circuit terminals, and current carrying parts for heat discoloration. of conductors 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 48 Table 27 Detailed inspection procedure Check Check item Description point Parting With ACB open, remove arc chamber and, using feeler gauge, make sure distance between moving distance and stationary contact tips is 20 1mm. If not so, replace both moving and stationary contacts. If it is useless to replace contacts, contact us.

  • Page 49: 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. Remaining heat may cause a burn. Prior to commencing any work on the ACB, open an upstream circuit breaker or the like to isolate all sources of power/voltage from the main and control circuits.
  • Page 50 (2) Pull out the front cover 3 or 4 cm as shown in Fig. 42. Front cover 3-4 cm Fig.42 Pulling out the front cover (3) Use a flatblade screwdriver to raise the moving core of the UVT until the core no longer returns. To do this, insert the blade of the screwdriver between the core and metal plate top end and pry the core up.
  • Page 51 Lock pin Fig. 45 Location of the lock pin Fig. 46 Pressing down the lock pin (7) Push the front cover in place and secure with the front cover mounting screws. If the ACB has side covers, install them with the side cover mounting screws. When installing the front cover, first install and torque a cover mounting screw at the upper left corner of the cover while aligning the screw with the corresponding mounting hole.

  • Page 52: Arc Chambers

    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) Carefully lay the breaker body on spacers with the backside down as shown in Fig. 47. The spacers must be at least 7-cm high to prevent deformation of protrusions on the breaker body backside, and have the size and strength that allow the breaker body to be safely laid on them.

  • Page 53: Stationary Contact

    6-2-3. Stationary contact The following describes how to replace the stationary contact. Fig. 50 shows the general view around the stationary contact. Main circuit contact Stationary contact Mold base Stationary contact tip Moving contact tip Engagement measuring hole Moving contact mounting screw, Moving contact Hex.
  • Page 54 4) Tilt and remove the stationary contact as shown in Fig. 52. Current sensor Control wire Stationary contact (tilted) Power supply CT Stationary contact (removed) Fig. 52 Removing the stationary contact • • x 5) Reinstall each part or component in reverse order of removal after inspection. As to the moving contact-related parts, however, install the insulated operation rod, insulation plate, spacer, moving contact, upper separator, lower separator, flat washer, spring washer, and moving contact mounting screw in this order.

  • Page 55: Moving Contact

    6-2-4. Moving contact The following describes how to replace the moving contact. 1) Make preparations for parts replacement. Refer to section 6-2-1. 2) Remove the arc chambers and stationary contact. Refer to sections 6-2-2 and 6-2-3. 3) Insert an Allen wrench of a nominal diameter of 5 into each of the Allen wrench holes shown in Fig. 51, turn each moving contact mounting screw two or three turns to loosen, and raise and remove the upper separator shown in Fig.

  • Page 56: Latch Release Coil (Lrc)

    6-2-5 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 adjustable undervoltage trip device, turn the cover mounting screws five or six turns to loosen as shown in Fig.
  • Page 57 7) Reinstall each part or component in reverse order of removal after inspection. When installing the LRC, make sure the nameplate on the LRC can be viewed from the front of the ACB. Fig. 59 provides the general view of the LRC. Plunger Hand connector (green) LRC mounting screw...

  • Page 58: Shunt Trip Device (Sht)

    6-2-6. 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) If the ACB is not equipped with the adjustable undervoltage trip device, turn the cover mounting screws five or six turns to loosen as shown in Fig.

  • Page 59: Tripping Coil (Tc) Or Adjustable Undervoltage Trip Device

    6-2-7. Tripping coil (TC) or adjustable undervoltage trip device (UVT) The tripping coil (TC) and the adjustable undervoltage trip device (UVT) are the same in installation position and replacement procedure. The TC allows overcurrent release only and the UVT allows both overcurrent release and undervoltage trip operation. The TC/UVT replacement procedure is as follows: 1) Make preparations for parts replacement.

  • Page 60: Uvt

    6) Unscrew the TC mounting screws shown in Fig. 64, disconnect the hand connector (red, 1 for TC or 2 for UVT)}, and remove the TC or UVT. Hand connector (red) TC mounting screw TC mounting screw Pan head M4 x 8 (2) with spring and flat washers Tightening torque: 1.3 - 1.7 N·m Fig.

  • Page 61: Auxiliary Switches

    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 62 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. Operation lever Shaft lever Fig. 69 Removing the auxiliary switches • • x 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 63: Troubleshooting Flowcharts

    12 in Table 26 and Nos. 21-25 in Table Is “ERROR 07 Press the reset Check the tripping Contact Terasaki. SETTING VALUE” Button to turn off the LED operation. See No. 29 in displayed on the LED? and check OCR settings.
  • Page 64 Move the body to the “CONN.”, Repair intermediate position? mechanism. See No. 11 in “TEST” or “ISOLATED” position. Table 26. Is manual closing Contact Terasaki. Is the OFF button locked Unlock Possible? or any other OFF-lock active? Set correctly Is the REMOTE/...
  • Page 65 The ACB cannot be opened. circuit and terminals. See Repair Nos. 5 and 12 in Table 26. Check SHT, TC Is manual opening Contact Terasaki. Repair/replace and UVT. See Nos. 11 - 25 possible? in Table 27. Set correctly Is the REMOTE/...

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