August 2015
Instruction Book IB02707112E
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
50VCPW-VSR 350 390A Shown
Supersedes May 2014
Effective
2
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITY
The information, recommendations, descriptions and safety notations in this document are based on Eaton Corporation’s (“Eaton”)
experience and judgment and may not cover all contingencies. If further information is required, an Eaton sales office should be consulted.
Sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other
contractual agreement between Eaton and the purchaser.
THERE ARE NO UNDERSTANDINGS, AGREEMENTS, WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS
FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OTHER THAN THOSE SPECIFICALLY SET OUT IN ANY EXISTING CONTRACT
BETWEEN THE PARTIES. ANY SUCH CONTRACT STATES THE ENTIRE OBLIGATION OF EATON. THE CONTENTS OF THIS DOCUMENT
SHALL NOT BECOME PART OF OR MODIFY ANY CONTRACT BETWEEN THE PARTIES.
In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or other-wise for any
special, indirect, incidental or consequential damage or loss whatsoever, including but not limited to damage or loss of use of equipment,
plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the
purchaser or user by its customers resulting from the use of the information, recommendations and descriptions contained herein. The
information contained in this manual is subject to change without notice.
3
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
WARNING
IMPROPERLY INSTALLING OR MAINTAINING THESE PRODUCTS CAN
RESULT IN DEATH, SERIOUS PERSONAL INJURY OR PROPERTY DAMAGE.
READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING
ANY UNPACKING, ASSEMBLY, OPERATION OR MAINTENANCE OF THE
DEVICE.
INSTALLATION OR MAINTENANCE SHOULD BE ATTEMPTED ONLY
BY QUALIFIED PERSONNEL. THIS INSTRUCTION BOOK SHOULD NOT
BE CONSIDERED ALL INCLUSIVE REGARDING INSTALLATION OR
MAINTENANCE PROCEDURES. IF FURTHER INFORMATION IS REQUIRED,
YOU SHOULD CONSULT EATON’S ELECTRICAL SERVICES & SYSTEMS.
THE UNITS DESCRIBED IN THIS BOOK ARE DESIGNED AND TESTED TO
OPERATE WITHIN THEIR NAMEPLATE RATINGS. OPERATION OUTSIDE OF
THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL, RESULTING IN
DEATH, BODILY INJURY AND PROPERTY DAMAGE.
ALL SAFETY CODES, SAFETY STANDARDS AND/OR REGULATIONS AS
THEY MAY BE APPLIED TO THIS TYPE OF EQUIPMENT MUST BE STRICTLY
ADHERED TO.
THESE VACUUM STARTER REPLACEMENT UNITS ARE DESIGNED TO
BE INSTALLED PURSUANT TO THE AMERICAN NATIONAL STANDARDS
INSTITUTE (ANSI). SERIOUS INJURY, INCLUDING DEATH, CAN RESULT
FROM FAILURE TO FOLLOW THE PROCEDURES OUTLINED IN THIS
MANUAL.
This product was manufactured by Eaton Corporation at the
Power Breaker Center (PBC): 310 Maxwell Avenue, Greenwood, SC
29646.
All possible contingencies which may arise during installation,
operation or maintenance, and all details and variations of this
equipment do not purport to be covered by these instructions. If
further information is desired by purchaser regarding his particular
installation, operation or maintenance of particular equipment,
contact a Eaton representative.
Contents
Sections
INTRODUCTION .................................. 4
SAFE PRACTICES ................................. 6
RECEIVING, HANDLING, AND STORAGE .............. 7
DESCRIPTION AND OPERATION .....................11
INSPECTION, MAINTENANCE, AND INSTALLATION .....16
REPLACEMENT OF COMPONENTS ................. 20
REMOVAL OF PHASE BARRIERS AND FUSE .......... 25
REPLACEMENT PARTS ........................... 26
4
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
SECTION 1: INTRODUCTION
The purpose of this book is to provide instructions for receiving
and handling, storage, installation, operation and maintenance of
the Westinghouse
*
type VCP-W Medium Voltage Vacuum Starter
Replacement (also referred to as VSR-Series). The Vacuum Starter
Replacement units are designed to be used in existing type VCP-W
metalclad switchgear and provide equal of superior electrical and
mechanical performance as compared to the design ratings of the
original power circuit breakers when switching motors. VSR-Series
Units provide reliable control, protection and performance, with ease
of handling and maintenance. Like ratings are interchangeable with
each other.
This book is intended to be used in conjunction with the technical
information provided with the original equipment order which
includes, but is not limited to electrical control schematics and wiring
diagrams, outline diagrams, installation plans, and procedures for
installation and maintenance of accessory items.
Satisfactory performance is dependant upon proper application,
correct installation, and adequate maintenance. It is strongly
recommended that this instruction book be carefully read and
followed in order to realize optimum performance and long useful life
of the unit.
ote:N * Westinghouse may also be designated as Cutler-Hammer and/or
Eaton.
WARNING
SATISFACTORY PERFORMANCE OF THESE UNITS ARE CONTINGENT
UPON PROPER APPLICATION, CORRECT INSTALLATION AND ADEQUATE
MAINTENANCE. THIS INSTRUCTION BOOK MUST BE CAREFULLY READ
AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE FOR
LONG USEFUL LIFE OF THE UNITS. IT IS FURTHER RECOMMENDED THAT
THE INSTALLATION BE PERFORMED BY A EATON CORPORATION TRAINED
ENGINEER OR TECHNICIAN.
VSR-SERIES UNITS ARE PROTECTIVE DEVICES, AS SUCH, THEY ARE
MAXIMUM RATED DEVICES. THEREFORE, THEY SHOULD NOT UNDER ANY
CIRCUMSTANCE BE APPLIED OUTSIDE THEIR NAMEPLATE RATINGS.
ALL POSSIBLE CONTINGENCIES WHICH MIGHT ARISE DURING
INSTALLATION, OPERATION, OR MAINTENANCE, AND ALL DETAILS
AND VARIATIONS OF THIS EQUIPMENT ARE NOT COVERED BY THESE
INSTRUCTIONS. IF FURTHER INFORMATION IS DESIRED BY THE
PURCHASER REGARDING A PARTICULAR INSTALLATION, OPERATION, OR
MAINTENANCE OF THIS EQUIPMENT, THE LOCAL EATON’S ELECTRICAL
SERVICES & SYSTEMS REPRESENTATIVE SHOULD BE CONTACTED.
1.1 AVAILABLE VCPW-VSR UNITS
Refer to Table 1.1
Table 1. VCPW-VSR Availability and Interchangeability
Original Breaker Type MV-VSR Breaker
To Vacuum Starter
Replacement Unit
BIL
kV
Rated Maximum
kV
Contactor Amps Maximum Fuse
Rating Amps
Fused Short
Circuit Rating
kA
Maximum
Continuous
Amps
50VCP-W 250-1200A 50VCPW-VSR-250-290A 60 4.76 400 230 50 230
50VCP-W 250-1200A 50VCPW-VSR-250-390A 60 4.76 400 390 50 390
50VCP-W 350-1200A 50VCPW-VSR-350-290A 60 4.76 400 230 50 230
50VCP-W 350-1200A 50VCPW-VSR-350-390A 60 4.76 400 390 50 390
75VCP-W 500-1200A 75VCPW-VSR-500-290A 60 7.2 400 230 50 230
75VCP-W 500-1200A 75VCPW-VSR-500-390A 60 7.2 400 390 50 390
5
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Table 2. VCPW-VSR Dimensions
Device Type
Existing Breaker
Rated Continuous
Current at 60 Hz
(Amps) A B C D E F G H I J K
50VCPW-VSR 250 230A / 390A 29.44 29.12 10.00 29.81 12.00 13.63 27.80 29.56 2.25 20.88 24.63
50VCPW-VSR 350 230A / 390A 31.44 29.12 10.00 29.94 12.00 13.63 27.80 29.56 2.25 20.88 24.63
75VCPW-VSR 500 230A / 390A 29.44 29.12 10.00 29.81 12.00 13.63 27.80 29.56 2.25 20.88 24.63
D
F
E
B
C C
A
H
G
K
JI
6
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
SECTION 2: SAFE PRACTICES
VSR-Series units are equipped with high speed, high energy
operating mechanisms. They are designed with several built-in
interlocks and safety features to provide safe and proper operating
sequences.
WARNING
TO PROTECT THE PERSONNEL ASSOCIATED WITH INSTALLATION,
OPERATION, AND MAINTENANCE OF THESE UNITS, THE FOLLOWING
PRACTICES MUST BE FOLLOWED:
•
Only qualified persons, as defined in the National Electrical
Safety Code, who are familiar with the installation and
maintenance of medium voltage circuits and equipment,
should be permitted to work on these units.
•
Read these instructions carefully before attempting any
installation, operation or maintenance of these units.
•
Always remove the unit from the enclosure before
performing any maintenance. Failure to do so could result in
electrical shock leading to death, severe personnel injury or
property damage.
•
Do not work on a unit with the secondary test coupler
engaged. Failure to disconnect the test coupler could result
in an electrical shock leading to death, personnel injury or
property damage.
•
Do not work on a closed unit. The main contacts should be
open before working on the unit. Failure to do so could result
in cutting or crushing injuries.
•
Do not use a MV-VSR by itself as the sole means of isolating
a high voltage circuit. Remove the unit to the Disconnect
position and follow all lockout and tagging rules of the
National Electrical Code and any and all applicable codes,
regulations and work rules.
•
Do not leave the unit in an intermediate position in the
cell. Always have the unit either in the Test or Connected
position. Failure to do so could result in a flash over and
possible death, personnel injury or property damage.
•
These units are equipped with safety interlocks. Do not
defeat them. This may result in death, bodily injury or
equipment damage.
7
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
SECTION 3: RECEIVING, HANDLING, AND
STORAGE
Type VCP-W VSR-series breaker to vacuum starter replacement units
are subjected to complete factory production tests and inspection
before being packed. They are shipped in packages designed to
provide maximum protection to the equipment during shipment
and storage and at the same time to provide convenient handling.
Accessories such as the cell code plate, etc. are shipped with the
unit (Figure 3.1).
3.1 RECEIVING
Until the unit is ready to be delivered to the switchgear site for
installation, DO NOT remove it from the shipping crate. If the unit
is to be placed in storage, maximum protection can be obtained by
keeping it in its crate.
Upon receipt of the equipment, inspect the crates for any signs of
damage or rough handling. Open the crates carefully to avoid any
damage to the contents. Use a nail puller rather than a crow bar
when required.
When opening the crates, be careful that any loose items or
hardware are not discarded with the packing material. Check the
contents of each package against the packing list.
Examine the unit for any signs of shipping damage such as broken,
missing or loose hardware, damaged or deformed insulation and
other components. File claims immediately with the carrier if
damaged or loss is detected and notify the nearest Eaton’s Electrical
Services & Systems office.
Tools and Accessories
Contact Wear Gauge: Optional item used to check contact wear.
(Style 5259C11H01) (See Section 5)
Racking Handle: The original VCP-W racking handle is used to assist
in moving the MV-VSR into and out of the cell.
Lifting Yoke: Optional lifting device that can be used to install a VSR
into upper compartment of VCP-W switchgear. (Style 94M7103G99)
3.2 HANDLING
WARNING
DO NOT USE ANY LIFTING DEVICE AS A PLATFORM FOR PERFORMING
MAINTENANCE, REPAIR OR ADJUSTMENT OF THE UNIT OR FOR OPENING,
CLOSING THE CONTACTS OR CHARGING THE SPRINGS. THE UNIT MAY
SLIP OR FALL CAUSING SEVERE PERSONAL INJURY. ALWAYS PERFORM
MAINTENANCE, REPAIR AND ADJUSTMENTS ON A WORKBENCH
CAPABLE OF SUPPORTING THE UNIT.
VCPW-VSR unit shipping containers are designed to be handled
either by use of a rope sling and overhead lifting device or by a
fork lift truck. If containers must be skidded for any distance, it is
preferable to use roller conveyors or individual pipe rollers.
Once the unit has been inspected for shipping damage, it is best to
return it to its original shipping crate until it is ready to be installed in
the Metal-Clad Switchgear.
When the unit is ready for installation, a lifting harness in conjunction
with an overhead lift or portable floor lift can be used to move the
unit, if this is preferable to rolling the unit on the floor using self
contained wheels. If the unit is to be lifted, position the lifting device
(lifting straps should have at least a 1600 pound capacity) over the
unit and insert the lifting harness hooks into the unit side openings
and secure. Be sure the hooks are firmly attached before lifting
the unit. Stand a safe distance away from the unit while lifting and
moving.
Figure 3.1. Contact Wear Gauge
8
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
3.3 STORAGE
If the MV-VSR is to be placed in storage, maximum protection
can be obtained by keeping it in the original shipping crate. Before
placing it in storage, checks should be made to make sure that the
unit is free from shipping damage and is in satisfactory operating
condition.
The unit is shipped with its contacts open, the indicators on
the front panel should confirm this. Outdoor storage is NOT
recommended. If unavoidable, the outdoor location must be well
drained and a temporary shelter from sun, rain, snow, corrosive
fumes, dust, dirt, falling objects, excessive moisture, etc. must be
provided. Containers should be arranged to permit free circulation of
air on all sides and temporary heaters should be used to minimize
condensation. Moisture can cause rusting of metal parts and
deterioration of high voltage insulation. A heat level of approximately
400 watts for each 100 cubic feet of volume is recommended with
the heaters distributed uniformly throughout the structure near the
floor.
Indoor storage should be in a building with sufficient heat and
circulation to prevent condensation. If the building is not heated, the
same general rule for heat as for outdoor storage should be applied.
3.4 VCPW-VSR APPROXIMATE WEIGHTS
Refer to Table 3.
Table 3. Maximum Weight by Type
Type Amperes LBs
50VCPW-VSR 250 230 290
390 310
50VCPW-VSR 350 230 290
390 310
75VCPW-VSR 500 230 290
390 310
Figure 3.2. Lifting VCPW-VSR
9
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Figure 3.3. Front External View of 50VCPW-VSR
Front External View
1 Lifting Point 4 Push To Open Button 7 Lift / Pull Handle
2 Extension Rail Interlock 5 Main Contact Status 8 Code Plate
3 Ground Contact 6 Starter Operations Counter
2
3
1
4
5
6
7
8
10
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Figure 3.4. Rear External View of 50VCPW-VSR
Rear External View
1 Fuse 3 Phase Barrier 5 Primary Disconnects
2 Lifting Point 4 Extension Rail Interlock
2
1
3
4
5
5
11
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
SECTION 4: DESCRIPTION AND OPERATION
The VCPW-VSR Vacuum Motor Starter Replacement is a medium
voltage (4.76 / 7.2kV maximum) vacuum starter used for the control
of three phase motors. The SL Contactor has a current rating of
400A.
The SL Contactor utilizes Eaton’s vacuum interrupters that exhibit
both a long electrical life and a high interruption capability. Ratings
for the contactor are shown in Table 4.1. The 400 amp contactor
has three Axial Magnetic (A-M) coils at the fixed end of the vacuum
interrupters. The A-M coils establish a magnetic field within the
interrupter during fault conditions. The field disperses the arc during
fault current interruption, allowing the contactor to interrupt a very
high fault current. See Figure 4.2.
WARNING
SATISFACTORY PERFORMANCE OF THESE CONTACTORS IS CONTINGENT
UPON PROPER APPLICATION, CORRECT INSTALLATION AND ADEQUATE
MAINTENANCE. THIS INSTRUCTION BOOK MUST BE CAREFULLY READ
AND FOLLOWED IN ORDER TO OBTAIN OPTIMUM PERFORMANCE FOR THE
LONG, USEFUL LIFE OF THE CONTACTOR.
4.1 CONTACTOR OPERATION
Mechanically Latched Starter
The mechanically latched starter is closed by energizing the starter
control board with the appropriate control voltage at terminals 1 and
2. The control board rectifies the input voltage and applies pulse
width modulated DC output voltage to the coils. The output voltage
is approximately full voltage for the first 200 milliseconds after
energization, during which time the starter closes and seals. After
the starter is electrically closed, a mechanical latch is engaged that
holds the moving armature plate in the closed position. Power is
then removed from the control board. Refer to Figure 4.1, for typical
schematic for latched contactor.
To open the starter, the unlatch coil is energized with the appropriate
control voltage. The coil engages a release lever on the latch
mechanism. The starter is then forced opened by the return spring.
Mechanical opening is also provided.
Control Scheme
A position switch contact is in the contactor closing circuit, which
remains made while the contactor is being racked between the Test
and Connected positions. Consequently, it prevents the starter from
closing automatically, even though the control switch close may have
been made while the starter is racked to the connected position.
When the close contact is made, the MX closes the starter. If the
close contact is maintained after the starter closes, the Y-relay
is picked up. The Y/a contact seals in Y until the close contact is
opened. The Y/b contact opens the MX circuit, so that even though
the starter would subsequently open, it could not be reclosed before
the close contact was released and remade. This is the antipump
function.
Auxiliary Contacts
An operating lever attached to the rotating shaft operates a set of
auxiliary contacts located on each side of the starter (Figure 4.2).
The standard configuration is 3NO-3NC contact on each side of the
starter. The auxiliary contacts are rated 600V, 10 amps continuous.
Minimum ratings are 5 volts, 100 milliamps. Refer to Table 5.1 for
make/break ratings.
Control Voltages
AC
DC
Control Circuit Burden
Closing (200 Milliseconds)
110/120 AC, 125 DC
20/240 Ac
Holding
110/120 AC, 120 DC
220/240 AC
Auxiliary Contact Rating
Voltage (Max)
Continuous Current
Making Capacity
Breaking Capacity
Min. Voltage/Current
Latch
Mechanical Life
Trip Voltage
Min. Trip Voltage
Trip Burden
(24 vDC)
(125 vDC)
(110 vAC & 120 vAC)
Trip Time
Maximum Interrupting Current (3 OPS.)
Rated Current
Maximum Rated Voltage
Making/Breaking Capacity
Short Time Current
30 Sec.
1 Sec.
8.7 MS (0.5 Cycle)
Mechanical Life
Electrical Life
BIL
Dielectric Strength (60 Hz)
Closing Time
(Energized To Contact Touch)
Opening Times
Arcing Time
Pickup Voltages
Dropout Voltage
8500 Amps (SL-400)
400 A Enclosed
7.2kV
4000 Amps
2400 A
6000 A
63kA Peak
(l
2
t = 5.89mega-joles)
2,500,000 Operations
300,000 Operations
60 kV (1.2 x 50 Milliseconds)
20 kV (1 Minute)
80 Milliseconds
30 to 330 Milliseconds
Dip Switch Selectable
Refer to Table 5.2
12 ms (0.75 Cycle) or less
80% Rated Coil Voltage
60% Rated Coil Voltage
Selectable: Refer to Table 5.1
110/120, 220/240, 50/60 Hz
1 kVA
1.8 kVA
40 VA
50 VA
600 V
10 A
7200 VA
125 VA
720 VA
125 VA
5V/100mA
250,000 operations
24 Volts
125 Volts
110/120 Volts
80% Rated Coil Voltage
400 VA
400 VA
400 VA
30 M sec (2 cycles)
(AC)
(DC)
(AC)
(DC)
(DC)
(DC)
(AC)
Table 4.1. SL Contactor Ratings
12
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Figure 4.1. Typical Control Schematic
Figure 4.2. SL Front and Rear View Major Components
SL Front View Major Components
1 Frame 8 Vacuum Interrupter
2 Front Mounting Holes (4) 9 Standoff Insulator (3)
3 Operating Plate 10 Main Shaft
4 Auxiliary Contact Operating Lever 11 Moving Armature Plate
5 Standard Auxiliary Contacts 12 Optional Auxiliary Contacts
6 Coil Control Board & Terminal Block 13 Stop Assembly
7 Axial Magnetic Coil (3) SL400 Only 14 Base Plate
SL Back View Major Components
1 Rear Mounting Holes (2) 5 Upper Terminals (3)
2 Shunt Supports (6) 6 Lower Terminals (3)
3 Coils (2) 7 Locknut For Return Spring Bolt
4 Coil Mounting Angle
1
2
4
3
5
6
7
8
9
10
11
12
13
14
1
2
4
3
5
6
7
13
b
22
8
b
17
10
b
15
7
PR
CS
T
CS
C
695
ab
124
1
CC
1
CC
2
2
CB
MX
TF
Y
21 24 20 16
PS
PS
FU
FU
SPRING CHARGE INDICATING
LIGHT NOT AVAILABLE
WITH VSR-SERIES UNITS
(+)
(-)
Ya
INT
MX
Y
VAC CONTROL
W G R
7 8
TC
AC
CAP TRIP
DEVICE
AC
-
+
a
a
19
a
18
AUXILIARY CONTACTS
13
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Figure 4.3. SL Contactors Assembly
4.2 ELECTRO-MOC
Installation / Operation / Ratings
Overview
MV-VSR vacuum starter replacements are designed for thousands of
mechanical operations. The mechanisms utilize solenoids for closing
and have limited excess kinetic energy and travel to operate auxiliary
devices. Mechanism Operated Contact (MOC) switch operation
requires more kinetic energy than the MV-VSR can deliver, so an
alternative must be utilized when MOC operation is required. Eaton
offers an electrical state-changing relay for this function. It does not
require an electrical latch. Eaton calls this an “Electro-MOC”. The
Electro-MOC can be installed in place of or used in conjunction with
the exiting MOC and has sufficient “a” and “b” contacts for most
applications. (Figure 4.4)
Figure 4.4. Electro-MOC
Contactor Closed
1 Armature Shaft 4 Operating Plate
2 Moving Armature 5 Overtravel
3 Stop
Contactor Open
1 Armature Shaft 4 Operating Plate
2 Moving Armature 5 Return Spring
3 Stop
1
2
3
4
5
1
2
3
4
5
Installation
Installation is simple. The Electro-MOC may be mounted to either
a horizontal or vertical surface, but horizontal is preferred. The
mounting location should also have sufficient room and access for
control power and a/b contact wiring. (Figure 4.6)
An “order-specific” wiring diagram and schematic is furnished with
each MV-VSR for field connections. The information also provides
details for interfacing to an existing MOC switch. The original “a”
contacts must be wired in parallel with the “a” contacts on the
Electro-MOC. The original “b” contacts must be wired in series with
the “b” contacts on the Electro-MOC. It is suggested that polarized
voltages should not be used on adjacent contacts. This is because
of the remote possibility of flashover during transition between
adjacent contacts, especially at higher DC ratings or in highly
inductive circuits.
Further clarification is provided in the “order-specific” information.
(Figure 4.8)
Operation
The operation of the Electro-MOC requires an available (free)
“a” and “b” contact in the existing breaker and/or MV-VSR. An
interposing relay may also be used when “a” and “b” contacts are
unavailable. These contacts are used to operate the Electro-MOC.
The diagrams provided with the order include this information.
When the VSR, air circuit breaker, or vacuum replacement (described
as a switching device) is opened or closed, the Electro-MOC coil is
energized through the external breaker/interposing relay contacts,
changes state and is mechanically latched in the new configuration
until the coil is reenergized. The contacts selected to control the
Electro-MOC coil require ratings for “making only”. The Electro-MOC
has internal contacts to break the circuit.
Ratings
The Electro-MOC relay has been tested to many different circuit
conditions. The interrupting ratings are based on 10,000 life-
operations, using suddenly applied and removed rated voltage, with
no extensive burning of contacts. The interrupting rating column
headed “double contacts” means two contacts in series. Short-time
and continuous ratings are based on temperature rise in contact
members and supporting parts not exceeding 50°C above ambient.
WARNING
THIS VACUUM STARTER REPLACEMENT IS NOT DESIGNED TO OPERATE A
SEPARATE EXTERNAL AUXILIARY SWITCH (MOC SWITCH).
14
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Drill 3X .234 Holes
For Mounting Electro-MOC
Mounting Centers
1.875
3.750
No. of Decks
3
5
8
10
Mtg Ctr
4.719
5.969
7.844
9.094
Figure 4.4. Electro-MOC
Figure 4.5. Electro-MOC Contacts
4.2 PHASE BARRIERS
WARNING
DO NOT PLACE THE STARTER IN ITS COMPARTMENT WITHOUT THE
PHASE BARRIERS IN PLACE. THE ABSENCE OF BARRIERS CAN CAUSE
A CATASTROPHIC FAILURE DURING AN INTERRUPTION OR OPERATION,
CAUSING DEATH, SEVERE PERSONAL INJURY OR PROPERTY DAMAGE.
Phase barriers on all VCPW-VSR starters are made of glass polyester.
They are all easily removed for access to the fuses.
Table 4.2. Electro-MOC Contact Ratings
Contact
Circuit
Volts
Short
Time
Rating
(Amps)
Continuous
Rating
(Amps)
Interruptive Rating (Amps)
Resistive Inductive
125Vdc 60 30 Single Contact 5 2
Double Contact 10 5
250Vdc 60 30 Single Contact 3 1
Double Contact 5 2
120Vac 60 30 Single Contact 20 20
Double Contact 30 30
240Vac 60 30 Single Contact 15 15
Double Contact 20 20
480Vac 60 30 Single Contact 7.5 10
Double Contact 15 10
600Vac 60 30 Single Contact 7.5 10
Double Contact 7.5 10
Original MOC Switch
a a
Electro-MOC Switch
**Wire the Electro-MOC “a” contacts in
parrallel with the original MOC “a” contacts.
Original MOC Switch
b
b
Electro-MOC Switch
**Wire the Electro-MOC “a” contacts in
series with the original MOC “a” contacts.
15
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
4.3 SECONDARY DISCONNECTS
The VSR control circuit is connected to the switchgear control
through a multi-contact block (See Section 3 for component
location). The movable secondary control contacts mounted on the
unit are self-aligning, line-contact, slip-type connectors. The multiple
finger arrangement on the unit makes contact with a stationary
mounted element. The contact surfaces on the stationary element
are recessed to prevent accidental short-circuiting of the control
circuits.
These secondary disconnects mate in both the operating and test
positions. No special jumper is required.
Mechanical stops prevent over-travel and avoid damage to the
disconnecting devices when the unit is racked into operating
position.
WARNING
INTERLOCKS ARE PROTECTIVE DEVICES FOR PERSONNEL AND
EQUIPMENT. DO NOT BYPASS, MODIFY, OR MAKE INOPERATIVE ANY
INTERLOCKS. DOING SO COULD CAUSE DEATH, SERIOUS PERSONNEL
INJURY, AND/OR PROPERTY DAMAGE.
4.4 INTERLOCKS
There are several interlocks built into the VSR-Series vacuum
starter replacements. Each of these interlocks, though different in
form, duplicate or exceed in function that of the original breaker.
These interlocks exist to safeguard personnel and equipment. The
basic premise behind the interlocking arrangement on the vacuum
replacement starter is that the starter must not be inserted into or
remove from the live circuit while the main contacts are closed.
Also considered in the interlocking is that the starter should pose no
greater risk than necessary to the operator in or out of the cell.
4.5 RACKING-IN INTERLOCK
The racking-in interlock is designed to prevent moving the starter
into or out of the Connect position, if the starter contacts are closed.
VCPW-VSR interlocks are completely compatible with the existing
racking system located in the existing VCP-W assembly structure.
VCPW-VSR starters utilize a interlock design that is very similar to
the design used on VCP-W breakers.
4.6 RACKING MECHANISM
The purpose of the racking device is to move the VSR between the
TEST and CONNECTED positions. For the VCPW-VSR, the device
is a drive screw and drive nut. Although the device is mounted
in the switchgear compartment, a brief description here will help
understand the operation. For additional information on the insertion
and removal of a VSR from its compartment refer to the insertion
and removal sections in this manual.
The racking device consists of a drive screw, a drive nut, two side
rails and a sliding cage. In the TEST position, the nut is all the way
to the front. As the VSR is pushed in, the racking latch snaps on the
nut. Turning the crank clockwise while pushing forward advances the
VSR toward the CONNECTED position. During this travel, the floor
tripper TRIP roller is lifted up holding the VSR trip free. When the
VSR reaches the CONNECTED position, the crank cannot be turned
any further. A red flag indicates that the VCPW-VSR is fully engaged.
If the VSR is closed in the CONNECTED position, engagement of
the slider will open the contactor and permit use of the racking
crank. After tripping the VSR, the racking crank can be engaged and
the VSR withdrawn to the TEST position by turning the racking crank
counterclockwise. This position is indicated by no further motion of
the crank.
The VCPW-VSR racking latch can be disengaged only when the VSR
is in the TEST position by lifting the latch release. As the VSR is
withdrawn, it comes out with the contacts open.
4.7 GROUND CONTACT
The ground contact is an assembly of spring loaded fingers for all
VCPW-VSR Vacuum Motor Starter Replacement designs providing a
disconnectable means for grounding the starter chassis, after it has
been inserted into a switchgear cell (Figure 4.6). The ground contact
is located on the underside of the chassis next to the secondary
contact block. An extension of the switchgear ground bus is secured
to the cell floor in such a position to engage the ground contact
automatically, when the starter is pushed into the Test position. It
remains engaged in all positions from Test to and including Connect.
4.8 OPERATIONS COUNTER
All VCPW-VSR Vacuum Motor Starter Replacement Units are
equipped with a mechanical operations counter (Figures 3.3). As the
starter opens, the counter advances the reading by one.
Figure 4.6. Ground Contact
16
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
SECTION 5: INSPECTION, MAINTENANCE,
AND INSTALLATION
WARNING
ALL WORK PERFORMED ON THIS STARTER SHOULD BE DONE WITH THE
MAIN DISCONNECT DEVICE OPEN AND LOCKED OUT. AS WITH ANY
STARTER OF THIS VOLTAGE, THERE IS DANGER OF ELECTROCUTION AND/
OR SEVERE BURNS. MAKE CERTAIN THAT POWER IS OFF. CHECK FOR
VOLTAGE WITH VOLTAGE SENSOR OR A METER OF THE APPROPRIATE
RANGE. MAKE CERTAIN THAT ALL TRANSFORMERS ARE ISOLATED
TO PREVENT FEEDBACK AND THE RESULTANT GENERATION OF HIGH
VOLTAGE.
The starter should be serviced on a regular basis. The time interval
between maintenance checks is variable and dependant on factors
such as environment, duty cycle, etc. Unless the experience of the
maintenance personnel suggests a different service interval, the
contactor should go through a checkout after each 50,000 operations
or annually, which ever occurs first.
5.1 GENERAL
The starter should be kept clean and free from dust and other
accumulated deposits. Dust can be removed from the starter by
wiping with a lint free cloth.
Inspect for loose joints that produce excess heat and discolor
conductors. Verify that insulation has not been damaged by high
temperatures. Do not over-torque bolts while verifying tightness.
Hardware is both Metric and US standard sizes. Refer to Table 5.3
for recommended torque values.
WARNING
BEFORE PLACING THE STARTER IN SERVICE, CAREFULLY FOLLOW THE
INSTALLATION PROCEDURE IN THIS MANUAL AND THE SAFE PRACTICES
SET FORTH IN SECTION 2. NOT FOLLOWING THE PROCEDURE MAY RESULT
IN INCORRECT STARTER OPERATION LEADING TO DEATH, BODILY INJURY,
AND PROPERTY DAMAGE.
When the starter is first commissioned into service and each time
the starter is returned to service, it should be carefully examined and
checked to make sure it is clean and operating correctly.
5.2 EXAMINATION FOR DAMAGE
Examine the starter for loose or obviously damaged parts. Never
attempt to install nor operate a damaged starter.
5.2.1 NAMEPLATE VERIFICATION
Compare the starter nameplate information with switchgear
drawings for compatibility. Starter and compartment code plates do
match power ratings, but do not match control voltages.
5.3 INITIAL INSPECTION AND OPERATION
Inspect the starter for any damage that occurred during shipment,
storage, and installation.
Set the dip switches in the coil control board for the proper control
voltage and dropout time (Figures 4.1 and 4.2 and Tables 5.1 and
5.2). When control information is supplied, dip switches will be
factory set.
Sequence the control circuit, including closing the starter with the
main power circuits de-energized and locked out.
Verify that the starter will be connected to an incoming power
supply and outgoing load with characteristics agreeing with the
starter rating and coil burden requirements.
1 2 3 4 5 6
ON
OFF
Dip Switch
Figure 5.1. Coil Control Board with Dip Switch
Figure 5.2. Coil Control Board Removal
Table 5.1. Dip Switch Setting-Control Voltage
Setting SW1 SW2 SW3
110 vAC 50 Hz Off Off Off
120 vAC 60 Hz On Off Off
220 vAC 50 Hz Off On Off
240 vAC 60 Hz Off On Off
125 vDC Off Off On
Table 5.2. Control Board Dropout Settings
Delay Setting SW4 SW5 SW6
30 ms Off Off Off
50 ms On Off Off
130 ms Off On Off
250 ms On On Off
330 ms Off Off On
17
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Table 5.3. Recommended Torque Values
Diameter (mm) Torque N-m Bolt Size lb-in.
4 2.8 - 3.1 8 - 32 24
5 5.6 - 6.2 10 - 32 36
6 9.4 - 10.4 .25 - 20 72
8 22.9 - 25.4 .31 - 18 144
10 45.5 - 50.6 .38 - 16 300
12 79.2 - 88.0 .50 - 13 540
ote:N Recommended Torque Values unless otherwise specified.
5.4 VACUUM INTEGRITY CHECK
WARNING
THIS PROCEDURE REQUIRES THE USE OF A HIGH POTENTIAL TEST UNIT
WHICH PRODUCES HAZARDOUS VOLTAGES.
APPLYING HIGH VOLTAGES ACROSS THE OPEN CONTACTS OF A
VACUUM INTERRUPTER MAY PRODUCE X-RAYS. THE RADIATION MAY
INCREASE WITH AN INCREASE IN THE VOLTAGE OR A DECREASE IN THE
DISTANCE BETWEEN THE OPEN CONTACTS. THE LEVELS OF RADIATION
GENERATED AT THE RECOMMENDED TEST VOLTAGES AND NORMAL
CONTACTOR OPEN GAP SPACING ARE EXTREMELY LOW. HOWEVER, AS A
PRECAUTIONARY MEASURE IT IS RECOMMENDED THAT ALL OPERATING
PERSONNEL STAND AT LEAST THREE FEET AWAY FROM THE CONTACTOR
WHILE PERFORMING THIS TEST.
Vacuum starters depend on the vacuum in each interrupter to
successfully stop current flow to the connected load when the
starter opens.
Starters are thoroughly tested at the factory prior to shipment. They
can, however, be damaged by improper handling during shipment
and storage. The integrity of the vacuum interrupters should
therefore be verified before the contactor is energized for the first
time. The check should also be made each time the contactor is
serviced or repaired, otherwise the test should be performed each
50,000 operations or annually, whichever occurs first.
To verify the integrity of the vacuum interrupters a voltage of
19kV-ac should be applied across the open contacts of the
interrupters. The voltage should be applied for 60 seconds without
breakdown. Breakdown is defined as a current of 5mA or more
flowing across the open contacts. Note that approximately 1mA of
current will flow through each interrupter during the AC test due to
the capacitance of the vacuum interrupter.
If a DC high potential test unit is used, make certain that the peak
voltage does not exceed 28kV, the peak of the corresponding AC
RMS test voltage. A megger cannot be used to verify vacuum
integrity due to its limited output voltage.
5.5 INSULATION INTEGRITY CHECK
PRIMARY CIRCUIT:
The integrity of primary insulation may be checked by the AC high
potential test. The test voltage is 15kV, RMS, 60Hz. Conduct the test
as follows:
Close the starter. Connect the high potential lead of the test
machine to one of the phases of the starter. Connect the remaining
two phases and starter frame to ground. Start the machine with
output potential at zero and increase to the test voltage. Maintain
the test voltage for one minute. Repeat for the remaining phases.
Successful withstand indicates satisfactory insulation strength of the
primary circuit.
Open the starter. Connect the high potential lead of the test
machine to one of the poles of the starter. Connect the remaining
poles and starter frame to ground. Start the machine with output
potential at zero and increase to the test voltage. Maintain the
test voltage for one minute. Repeat for the remaining five poles.
Successful withstand indicates satisfactory insulation strength of the
primary circuit.
If a DC high potential machine is used, make certain that the peak
voltage does not exceed the peak of the corresponding AC RMS test
voltage.
SECONDARY CIRCUIT:
Connect all points of the secondary disconnect pins with a shorting
wire. Connect this wire to the high potential lead of the test
machine. Ground the starter frame. Starting with zero, increase the
voltage to 1125 RMS, 60 Hz. Maintain the voltage for one minute.
Successful withstand indicates satisfactory insulation strength of the
secondary control circuit. Remove the shorting wire.
5.6 INTERRUPTING WEAR CHECK
The interrupters used in the starter are designed for long electrical
life. Replacement should be at 300,000 operations except in
cases of plugging or jogging which may require more frequent
replacement. Verification of contact wear can be made by following
the procedure below.
The overtravel gap for a new starter is .080” and is set at the
factory. As the contacts wear the overtravel is reduced. The SL
interrupter design allows for .080” wear before replacement is
required. To verify that the contacts are not worn beyond their
allowable limits, close the contactor with rated control power. Insert
the .020” contactor wear gauge, p/n 5259C11H01, between the
operating plate and the washer on the lower insulator stem of each
pole. Refer to Figure 5.3. If the gauge cannot be freely inserted
on each pole, all three interrupters must be replaced. Refer to the
section 6 for instructions on replacing the interrupters.
Figure 5.3. Interrupter Wear Check
5.7 CONTACT RESISTANCE CHECK
Testing that measures the contact resistance of the vacuum
interrupters is not recommended since the results can vary widely
on good contacts. If a resistance check is performed, the best
results will be with a test module that will force 10 amps through
the contacts while measuring resistance. The resistance should not
exceed the factory test levels by more than 15%.
ote:N Do not use a 100 Amp source. Test sets with output exceeding 10
Amps can damage the fuse elements
5.8 ELECTRICAL OPERATIONS CHECK
After going through the above steps, the starter is now ready to be
operated electrically. It is preferred that this check be made with the
starter in the Test position in the switchgear compartment.
Since the Type VCPW-VSR Vacuum Motor Starter Replacement
Unit is for use in existing VCP-W Metal-Clad Switchgear, installation
18
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
procedures are similar. If it is necessary to reference anything in the
unit compartment, refer to the original instruction books supplied
with the assembly.
Refer to Figures 3.3 and 3.4, for any parts identification required
during these installation procedures.
a. The starters faceplate and barriers must be positioned properly
and securely bolted in position, as shown in Figures 3.3 and 3.4,
before inserting the starter into the cell.
b. Carefully follow the insertion procedure in section 5 to get
the VSR unit into the test position inside the compartment and
to engage the secondary contacts to proceed with the electrical
operations check.
WARNING
AS SOON AS THE SECONDARY CONTACTS MATE UP, THE STARTER IS
READY FOR OPERATION IF THE CONTROL CIRCUIT IS ENERGIZED.
c. Once the starter is in the test position, it may be electrically
closed and tripped by using a control switch on the cell door, or it
may be manually tripped by means of the trip button, located on the
faceplate of the starter.
5.9 CELL CODE / REJECTION PLATE INSTALLATION
Cell code plates and circuit breaker rejection plates are required to
reject circuit breakers and breaker to vacuum starter replacement
units that do not match the electrical rating structure of the existing
cell. If the momentary rating of a unit is increased, a code plate and
a cell rejection plate must be installed to accept the new unit and
reject all others of lesser ratings. If momentary ratings of the new
unit is the same as the original breaker, then the original cell code
plate may be retained.
A unit code plate is factory installed on VSR-series units. Cell code
plates are automatically furnished with each unit. (Rejection plates
have stamped orientation as “LH” and “RH” for clarity.) (Figure 5.5)
NOTICE
REJECTION PLATES MUST BE INSTALLED INTO THE PROPER INTENDED
SWITCHGEAR PER THE NAMEPLATE RATING. IF THE REJECTION PLATE IS
NOT INSTALLED CORRECTLY THE VSR CAN NOT BE INSERTED INTO THE
INTENDED STRUCTURE.
WARNING
ARC FLASH INCIDENCES WITH MV SWITCHGEAR CAN OCCUR DURING THE
PROCESS OF INSERTING AND REMOVING VSR UNITS IN SWITCHGEAR
CUBICLES. IT IS STRONGLY RECOMMENDED THAT PROPER PPE
(PERSONAL PROTECTIVE EQUIPMENT) BE WORN BY PERSONNEL WHO
RACK UNITS USING THE MANUAL RACKING HANDLE OR THE ROTARY
RACKING HANDLE. EATON CORPORATION PROVIDES A UNIVERSAL
REMOTE POWER RACKING SYSTEM (RPR-2) WHICH IS COMPATIBLE WITH
THE INTERNAL ROTARY RACKING UNITS. THIS SYSTEM MAY ALLOW
PERSONNEL TO WEAR A LOWER LEVEL OF PPE DURING THE INSERTION
OR REMOVAL PROCESS AS LONG AS RACKING CAN BE PERFORMED FROM
OUTSIDE THE FLASH PROTECTION BOUNDARY.
5.10 INSERTION PROCEDURE
WARNING
EXAMINE THE INSIDE OF THE CELL BEFORE INSERTING THE STARTER
FOR EXCESSIVE DIRT OR ANYTHING THAT MIGHT INTERFERE WITH THE
STARTER TRAVEL.
KEEP HANDS OFF THE TOP EDGE OF THE FRONT BARRIER WHEN PUSHING
A STARTER INTO A CELL. FAILURE TO DO SO COULD RESULT IN BODILY
INJURY, IF FINGERS BECOME WEDGED BETWEEN THE STARTER AND
THE CELL. USE BOTH FULLY OPENED HANDS FLAT ON THE FRONT OF THE
STARTER TO ADVANCE INO THE STRUCTURE.
If the VCPW-VSR is being inserted into an upper compartment or
will be positioned in a lower compartment without the use of a
drawout ramp or dockable dolly, the extension rails must first be
put in position. Carefully engage the left and right extension rails to
the fixed structure rails and ensure they are properly seated in place
(Figure 5.6). Once the extension rails are properly in place, the VSR
can be carefully loaded on the extension rails using an overhead lifter
and lifting yoke. Remove the lifting yoke when the VSR is securely
seated on the extension rails.
Push the VSR into the compartment until the TEST position is
reached as confirmed by a metallic sound of the racking latch
engaging the racking nut (Figures 5.7). Once the VSR is in the TEST
position, the extension rails can be removed.
To engage the secondary contacts, raise the handle to the
secondary disconnect cage and pull the cage forward as far as
possible (Figure 5.8). As soon as control power is available, the
motor will start charging the closing springs.
Figure 5.5. VCPW-VSR Rejection Plate (230A VSR Shown)
Figure 5.4. VCPW-VSR Code Plate (250MVA VSR Shown)
19
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
Figure 5.6. Inserting Guide Rails
WARNING
DO NOT USE ANY TOOL OTHER THAN THE RACKING-IN CRANK PROVIDED
TO RACK THE VSR FROM TEST OR CONNECTED POSITIONS. CORRECT
OPERATION OF SOME OF THE INTERLOCKS IS DEPENDENT ON USE OF THE
PROVIDED RACKING CRANK. PERSONAL INJURY OR EQUIPMENT DAMAGE
COULD RESULT FROM THE USE A TOOL OTHER THAN THE PROPER
RACKING-IN CRANK.
NOTICE
THE VSR AND INTEGRAL RACKING MECHANISM INCLUDES ALL
NECESSARY INTERLOCKS THAT WHEN INTER-FACED WITH A COMPATIBLE
STRUCTURE WILL RENDER THE VSR MECHANISM MECHANICALLY AND
ELECTRICALLY TRIP-FREE DURING THE RACKING PROCESS.
To move the VCPW-VSR to the CONNECTED position, engage the
racking-in crank with the structure mounted racking shaft (Figure
5.9). Turn the racking-in crank in a clockwise direction and the VSR
will move slowly toward the rear of the structure. When the VSR
reaches the CONNECTED position, it will become impossible to
continue turning the racking-in crank. The CONNECTED position
will also be indicated by a red flag indicator just below the racking
device. If a spin-free racking-in crank is being used, it will spin free
once the CONNECTED position is reached. Secondary contacts will
automatically engage if not already engaged manually in the TEST
position.
To remove the VCPW-VSR from the structure, reverse the procedure
just described by turning the racking-in crank in a counterclockwise
direction. Keep in mind that safety interlocks may cause the VSR to
open during the removal process. It depends on what condition the
VSR was in as removal began.
Figure 5.8. Engaging Secondary Contacts
Figure 5.7. Insertion of the VCPW-VSR
Figure 5.9. Engaging Secondary Contacts
20
Instruction Book IB02707112E
August 2015
50/75VCPW-VSR
Breaker To Vacuum Starter Replacement Unit
EATON CORPORATION www.eaton.com
SECTION 6: REPLACEMENT OF
COMPONENTS
6.1 REPLACEMENT OF VACUUM INTERRUPTERS
If the vacuum interrupters fail the vacuum integrity or wear check, or
if they have more than 300,000 operations, they must be replaced.
The three interrupters must be replaced as a set.
WARNING
THERE ARE BELLOWS IN EACH INTERRUPTER THAT SEAL THE MOVING
CONTACT FROM THE ATMOSPHERE. THESE BELLOWS ARE FRAGILE
AND MUST BE PROTECTED FROM ANY TORSIONAL LOADING. AN
APPROPRIATE TOOL MUST SUPPORT THE MACHINED FLATS ON EACH
END OF THE INTERRUPTER WHEN TIGHTENING ANY HARDWARE ON
THE INTERRUPTER. BOTTLE WRENCH, CUTLER-HAMMER PART NUMBER
4A36081H01, IS PROVIDED WITH EACH SET OF REPLACEMENT VACUUM
INTERRUPTERS AND SHOULD BE USED IN THIS APPLICATION.
Remove each vacuum interrupter using the steps listed below:
1. Loosen locknut securing threaded rod to top of standoff insulator
(Figure 6.1). Note the number of threads between the two 10mm
nuts.
2. Rotate insulator clockwise to screw insulator off threaded rod.
3. Remove clamp securing lower end of the vacuum interrupter to
the housing (Figure 6.2).
4. Remove bolt and shunt supports securing end of the lower
terminal to the housing (Figure 6.3).
5. Remove the bolt securing the vacuum interrupter to the upper
terminal (Figure 6.4).
6. Hold insulator down and rotate lower portion of the vacuum
interrupter assembly forward to remove (Figure 6.5).
7. Insert new the vacuum interrupter assembly (reverse of step 6).
8. Install the bolt securing the vacuum interrupter to the upper
terminal, do not tighten.
9. Install bolt and shunt supports securing lower terminal to housing
(Figure 6.6). When tightening insure laminated shunt is straight and
shunt supports are in the correct position.
10. Tighten bolt securing vacuum interrupter to upper terminal while
holding bottle wrench on upper vacuum interrupter stem. Torque to
200 lb-in (22.6 Nm). Insure the laminated shunt is not twisted.
11. Install clamp securing lower end of vacuum interrupter to
housing.
12. Rotate insulator counter-clockwise until the number of threads
noted in step 1 is obtained.
6.1.1 ADJUSTING VACUUM INTERRUPTERS
After 3 new vacuum interrupter’s have been installed, set the proper
open gap using the steps listed below. Three battery operated test
lights or continuity testers are needed for the proper setting of the
open gap.
1. Attach test lights across the upper and lower terminals of each
interrupter.
2. Rotate insulator on middle phase bottle until light flickers. Rotate
clockwise if light is not on, counterclockwise if light is on.
3. From the point the light flickers, rotate insulator on middle phase
bottle counter-clockwise three and twothirds turns to establish
a 5.5mm open gap. Use markings on insulator to verify correct
rotation. (Two thirds turn is equal to 8 divisions that are molded on
the surface of the insulator.)
4. Slowly rotate the main shaft, closing the vacuum interrupter’s,
until the middle phase light is on. Adjust the insulators on the two
outside phases so that the lights on all three phases come on
Figure 6.1. Loosening Locknut
Figure 6.2. Removing Clamp Securing Lower Terminal
Figure 6.3. Removing Bolt and Shunt Supports
Figure 6.4. Removing Bolt Securing Upper Terminal
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