Eaton Cutler-Hammer DS Series, Instructions Manual

Page 1: ...RUCTIONS BEFORE ATTEMPTING ANY ASSEMBLY OPERATION OR MAINTENANCE OF THE SWITCH Cutler Hammer Distribution and Control Business Unit Electrical Components Division Pittsburgh PA 15220 1 8 33 790 11 Eff...

Page 2: ...eral 4 1 Levering Device 4 2 Charge The Closing Springs 4 3 Close The Breaker 4 4 Open The Breaker 4 5 Place The Breaker In The Test Position 4 6 Place The Breaker In The Connect Position 4 7 Remove T...

Page 3: ...g System 8 0 8 1 8 2 8 2 1 8 3 8 4 8 5 8 6 8 7 8 7 1 8 7 2 8 7 3 8 7 4 8 7 5 8 7 6 8 7 6 1 8 7 6 2 8 7 6 3 General The Amptector II A Trip Unit The Amptector I A Trip Unit Ground Fault Protection Maki...

Page 4: ...er Operated Mechanisms Factory Adjustments Trip Latch Overlap Breaker Open Position Stop DS 632 Only Moving Contact Adjustment Levering Mechanism LUBRICATION Frequency Location and Lubricant Section 1...

Page 5: ...chematic and Connection Diagrams for Power Operated Breakers Principal Parts in a Manually Charged Spring Operated Mechanism Spring Charging Mechanism on Manual Operated Breakers These Sketches Show t...

Page 6: ...Illustration of Tripping System Standard Amptector II A Solid State Trip Unit Amptector II A Trip Unit with Front Cover Removed Optional Amptector I A Solid State Trip Unit Amptector I A Trip Unit wit...

Page 7: ...er Contacts and their Adjustment DS 840 Breaker Open Position Stop and Anti Rebound Latch Levering Mechanism Lubrication Points on Left Side of Mechanism Lubrication Points on Right Side of Mechanism...

Page 8: ...Codes Safety Standards and or Regulations as they may be applied to this type of equipment must be strictly adhered to Allpossible contingencies which may arise during installation operation or maint...

Page 9: ...ribed in this book were designed and tested to operate within their nameplate ratings Operation outside of these ratings may cause the equipment to fail resulting in bodily injury and property damage...

Page 10: ...TED DEVICES THEREFORE THEY SHOULD NOT UNDER ANY CIRCUMSTANCES BE APPLIED OUTSIDE THEIR NAMEPLATE RATINGS OPERATION OUTSIDE OF THESE RATINGS MAY CAUSE THE EQUIPMENT TO FAIL RESULTING IN BODILY INJURY A...

Page 11: ...y includes a chassis a control panel an operating mechanism a levering in device var ious interlocks and three insulated pole unit assemblies mounted on a base OSL 416 OSL 632 OSL 840 1600 3200 4000 2...

Page 12: ...ave 50 more fingers than the 08 206 Effective October 1998 Page3 4 D8 206S has twice as many main contacts and arms as the D8 206 5 The pole unit hinge joint of D8 2068 is a forked con struction or a...

Page 13: ...cation between the TEST and the CONNECT positions or the DISCONNECT position 5 Provisions for Padlocking Breakers can be pad locked open to prevent electrical or manual closing This padlocking can als...

Page 14: ...ropes chains etc to avoid possible damage to parts or dropping the unit Use breaker lifting adapter Effective October 1998 7 Use handle on front panel of circuit breaker to move it into or out of cell...

Page 15: ...STORING If it is necessary to store the equipment before installa tion keep it in a clean dry place protected from dirt and water and with ample air circulation and heat if neces sary to prevent cond...

Page 16: ...ker element can be withdrawn from its compartment for the first time two shipping braces must be removed from the lower part of the breaker front panel These braces are small steel angles bolted to th...

Page 17: ...With the breaker pulled completely to the end of the rails remove the two 2 six inch long pieces of split plastic tubing that are on the rear of the stationary rails immediately below the hold down ho...

Page 18: ...ping sys tem ORAWOOT Ullt T PmltTIOl I ll lf Jc ATO S lUNca Cffi itQE tNDt ATOR Fig 5 View Showing Controls on the Panel 391066 Effective October 1998 The remainder of the drawout element includes the...

Page 19: ...rm in TEST Position 391068 RATCHET WHEEL TRIP ACTUATOR CLO i CAM l B 33 790 11 EMERGENCY CHARGING HANDLE HOLD PAWL Fig 6b DS 416 Breaker with Front Panel Removed 391070 SENSORS SECONDARY DISCONl ll CT...

Page 20: ...only on power operated breakers can be supplied on manually operated breakers Effective October 1998 Page 11 On power operated breakers the springs are normally charged by an electric motor Closing m...

Page 21: ...ent with both main and secondary contacts disengaged If the crank is withdrawn the shut ter will close completely and the breaker may be locked in this position as later described in Section 5 1 8 5 o...

Page 22: ...g condi tions are met Effective October 1998 Page 13 1 The closing springs are charged 2 The levering arms are in either the TEST position as in Figure 7 or in the CONNECT position Figure 8 3 The leve...

Page 23: ...sudden increase in load on the crank as previously described in paragraph 4 1 Note however that before the stop is reached an increase in load on the crank will be felt after the breaker has moved ab...

Page 24: ...parts of these are combined into one sub assembly illustrated in Figures 10 11 12 and 13 There are two varieties of mechanisms for the complete line of DS and DSL breakers Power Operated Manually Ope...

Page 25: ...e device 26 do not have internal flats but are mounted on separate bushings and are free to rotate on the crank shaft Figure 17 is an exploded view of the crankshaft parts Figure 16a is a view looking...

Page 26: ...rgency charge pawl 33 is used to advance the ratchet wheel 17 several teeth on each stroke of the charge handle 34 This device 26 also pivots on the crank shaft 5 1 2 1 Power Operation The electrical...

Page 27: ...Switch Lever 25 Drive Plates 2 14 Draw Out Unit Base 26 Emergency Charge Device 15 Motor Cut Off Switch 27 Pawl Lifter 16 Ratchet Bushing 28 Oscillator Pawl 17 Ratchet Wheel 30 Oscillator 18 Hold Pawl...

Page 28: ...Spring 10 Spring End 11 Crank Arm Fig 16 Power Operated Spring Charge Details Effective October 1998 b SpringDischarged 17 Ratchet Wheel 18 Hold Pawl 19 Oscillator Bushing 20 Oscillator Spring 21 Rat...

Page 29: ...rn Spring 4 Drive Plata 9 Bearing Race 14 Spring Retainer 5 Precision Spacer 1O Thrust Be iring 15 Crank Arm Fig 17 Crank Shaft Assembly of Power Operated Mechanism 385304 Fig 18 Emergency Spring Char...

Page 30: ...66 0 b Connecting Diagram MOUNTING SRACKET COJL SPRING RELEASE TRI SHAFT LEVER COMPARTMENT TRIP LINK c Trip Details 391088 MOTOR CUT OFF SWITCH MANUAL CHARGE MfCWA lt5 t d Spring Release Details e Spr...

Page 31: ...oil and will open its Y contact in the SR circuit This allows only one close operation until the close contact CS C has been reset The Y coil has a very low drop out voltage On some circuit breakers a...

Page 32: ...ame as the main close cam and crank arms The other parts are the front crank assembly which is piv oted to a bracket fastened to the main frame base and has a socket for the manual charge handle The r...

Page 33: ...ole Lever Pin 11 Moving Contact Arm 12 Stationary Arcing Contact 13 Moving Contact Pivot Pin 14 Main Drive Link 15 Main Roller 16 Spring Release Latch 17 Insulating Link Adjusting Stud and Locknut 18...

Page 34: ...spring charging stroke The closing springs are charged by counterclockwise rotation of the ratchet and drive plates until the close cam stop roller meets the spring release latch as shown in Figure 2...

Page 35: ...aft 1 8 33 790 11 on the roller constraining link This force tends to rotate the trip latch counterclockwise but the trip latch is kept from rotating by overlap of the latch surface of the trip shaft...

Page 36: ...Figure 26 shows a bottom view of the breaker drawout unit Visible in this picture are details as follows 1 The Interference Interlocks These are Z shaped brackets which prevent circuit breakers with i...

Page 37: ...View of Breaker Unit Showing Interfer ence Interlock Motor Cut off Switch and Other Details not Visible from Above 1 8 33 790 11 Fig 26c Front View Showing Close Bar Guard 391071 Fig 26b Rear View Sho...

Page 38: ...four breaker positions Figure 27 Page 29 A WARNING DO NOT TAMPER WITH INTERLOCKING AND IF IS NOT FUNCTIONING HAVE IT CORRECTED INTER LOCKING THAT IS FUNCTIONING IMPROPERLY CAN RESULT IN MECHANICAL AN...

Page 39: ...the position indicator 1 8 33 790 11 In this position the following conditions exist A The breaker will be held in its compartment as the levering rollers have lowered into the slots in the cradle arm...

Page 40: ...orm shaft will not be cleared So it is necessary to push the trip plate in which moves the hook back out of the way of the shutter lower projection This permits the shutter to be pushed down ward to c...

Page 41: ...er lock cam stops with the shutter interlock pin blocked Thus the shutter stays down and the breaker stays tripped when the crank handle is removed The breaker is held trip free so it cannot be closed...

Page 42: ...otates the close bar cam has been rotated counter clockwise by Pin B to the CLOSE position This releases the spring release latch through the linkage shown in Figure 30 which results in a trip free op...

Page 43: ...terlock 5 1 8 2 Connected Breaker Manual Close Interlock The purpose of this Interlock is to make possible a choice between being able to close the breaker by hand push on the Close bar and not being...

Page 44: ...This may be the main circuit or any other desired circuit This is accomplished by making it impos sible to release the spring release latch by the spring release device unless the monitored circuit is...

Page 45: ...e three major parts involved which are interleaved and assembled on the left hand side of the levering device assembly 1 The Shutter 2 The Trip Plate 3 The Padlock Interlock Lever The Padlock Interloc...

Page 46: ...0 6 1 MOVING CONTACT SUB ASSEMBLIES The moving contact members of all ratings consist of blades hinged at the bottom to the lower main terminal through controlled pressure rotating contacts and with m...

Page 47: ...top of the main moving contact blade assembly This has the arcing contact tips of arc resist ing metallic composition permanently fastened near the upper end of the assembly The moving contact blade...

Page 48: ...current pushes the lower end of the finger toward the moving contact Hinging the finger at the top thus results in what is sometimes called blow on action This greatly increases the capability of the...

Page 49: ...W inmne r tiiiofcitidl 01el rase 4 4Sii6aosor 5 Lower Main Terminal 6 BJ ileTarimihai J t 111 I I I I 1 1 i i I I Jl 1 8 33 790 11 currents This results in a blow on action on the arcing contacts Figu...

Page 50: ...G PIVOT BLOCK HINGE SPRING STATIONARY ARCING CONTACTS Fig 37 Type DS 206 Pole Unit Assembly Front View 384502 Effective October 1998 INSULATING LINK INSULATING l 11111 AO JUSTING NUT LOWER Page 41 Cou...

Page 51: ...Page 42 1 8 33 790 11 Fig 38 Type DS 206 Pole Unit Assembly Rear View 384499 Effective October 1998 Courtesy of NationalSwitchgear com...

Page 52: ...T ARCING CONTACT SPRING STATIONARY MAIN CONTACT FINGERS MOLDED SASE MOVING CONTACT ASSEMBLY Fig 41 Type DS 420 Pole Unit Assembly Front View 391101 Effective October 1998 MOVING MAIN CONTACT Page 43 F...

Page 53: ...TOP PINS MOLDED SASE STATIONARY ARCING CONTACTS ADJUSTMENT LOCKNUT Fig 45 Type DS 840 Pole Unit Assembly Front View 391094 l B 33 790 11 Fig 44 Type DS 632 Pole Unit Assembly Rear View 391095 Fig 46 T...

Page 54: ...ontact Right Hand 9 Stationary Arcing Contact Left Hand 10 Stationary Arcing Contact Spring 11 Contact Spacer 12 Stationary Arcing Contact Spring Fig 47 Moving and Stationary Contact Details DS 206 38...

Page 55: ...15 Rod End 16 Stationary Arcing Contact Right Hand 17 Stationary Arcing Contact Left Hand 1S Stationary Arcing Contact Spring HI Arcing Contact Retaining Pin 20 Bearing Tube Fig 48 Moving and Stationa...

Page 56: ...g Main Contact 8 Moving Arcing Contact 9 Clevis 15 Rod End 16 Stationary Arcing Contact Right Hahd 17 Stationary Arcing Contact Left Hand 18 Stationary Arcing Contact Spring 19 Arcing Contact Retainin...

Page 57: ...oving Arm Inner Links Straight 8 Moving Arm Inner Links Offset 9 Hinge Springs Outer 10 Hinge Spring Center 11 Spring 12 Locking Nut 13 Hinge Assembly 14 Hinge Bearing Tube 15 Adjustment Locking Clip...

Page 58: ...fl 13 6 Main Contact Fingers 7 locking Nut 8 Bearing Tube 10 Arcing Contact left Hand 11 Arcing Contact Riqht Hand Fig 51 Stationary Contact Details DS 632 383414 Effective October 1998 Page 49 1 t 12...

Page 59: ...ing Nut 5 Fl Od End 13 Assembly 6 Adjusting Nut 14 Hinge Bearing Tube 7 Moving Arm 15 Adjustment Locking Clip Inner Links Straight 16 Insulating Link 8 Moving Arm Inner Unks Offset NOTE 1 Raised beari...

Page 60: ...Tube 4 Contact Spring Inner 9 Arcing Contact Spring 5 Spring Button 10 Arcing Contact Right Hand Fig 53 Stationary Contact Details DS 840 391271 Effective October 1998 0 0 0 0 CD 3 ___ ____ ______ 6 i...

Page 61: ...hutes 391072 Fig 55 DS 206 Arc Chute with Details 383973 ll lSULATING INSULATING lll ACER PLATE TOP STRIPS STEEL PLATES Fig 56 DS 4161420 Arc Chute with Details 391270 INSULATING INSULATING SPACER PLA...

Page 62: ...ass polyester plates These plates produce turbulence in the exhaust gases above the steel plates and prevent electrical breakdown over the top of the arc chute or to ground WARNING ALL ARC CHUTES AND...

Page 63: ...ail able over a wide range of current ratings The automatic overload and short circuit tripping charac teristics for a specific breaker rating as determined by the sensor rating are determined by the...

Page 64: ...Both trip units have the same reliability and repeatability inherent in solid state design As shown in Figure 5 the Amptector trip unit is at the top front of the breaker Figure 60 shows a close up o...

Page 65: ...panel Figure 59 shows a typical standard wiring diagram which includes the Amptector II A trip unit terminal block The following table explains the markings of the terminals A Sensor phase A ON Output...

Page 66: ...are cali brated as shown on the curve 5 Instantaneous pick up 4 to 12 X sensor rating scREW mnVER CALIBRATION SLOTS LONG DELAY CURRENT Y CKUP _ TO L 5X SENSOR RATING INSTANTl N 0US P CKUP 4 TO 12X SEN...

Page 67: ...at 4 IA 1 1 6 8and10TimesSensorRatinQ1 l 4 1 1 1 il 14___ __ _ __ 1 1 1 1 1 ii ii StKJrt 0e1ay rime ii Calibraledat0 5 0 33 11 11 and0 18Seconds At2 5 t 1 t t1 t t t l t 1 t t1 t t t t t 1 t lt tl t t...

Page 68: ...d rma Cotibra19cl at 0 5 0 35a1 d 0 22 s cands V v7 I 7 I j l 1 I v V I I V I A YV I L v _ V lnstontanews Pickup V V Colibrared ot4 6 8 10 1 1 v and 12Times Sensor RatlnQ v 11 1 1 1 N CURRENT IN MULTI...

Page 69: ...nally developed ground current Such an exter nal source could be a ring type transformer through which all the load current conductors would have to pass In the case of a three phase four wire circuit...

Page 70: ...erforming Amptector trip unit check Special handling and test equipment are required to ser vice solid state devices If use of the tester shows that an Amptector trip unit is not operating correctly i...

Page 71: ...e Sensor Ratings Amperes Type Amperes DS 206 or 800 50 1 00 150 200 300 400 DSL 206 400 600 800 DS 206S 800 100 150 200 300 400 600 800 DS 416 DSL 416 1600 100 150 200 300 400 600 or 800 1200 1600 DS...

Page 72: ...ober 1998 Page 63 SHAFT W POLE BKR IONII SEO POSITION 11 I r Ji 17 it BKR CLOSED U V ENERGIZED Fig 68 Undervoltage Trip Device Operation As the breaker opens a pin on the left pole unit shaft strikes...

Page 73: ...cks up on an overload condition at a lower pick up value than the breaker overload trip setting of the Amptector trip unit Its function is to give advance notice of an overload condition before the br...

Page 74: ...ed con tact of the switch is closed See Figures 72 and 73 When this switch is supplied the contact is usually connected in the closing circuit of the circuit breaker to insure that the tripping system...

Page 75: ...e it reads 0 8 amps CIRCUIT SEl t4 TOR SW TCH CURilENT AOJUST CONTROi PO NE l IJllD CATING UGHT RED POWER SWITCH NSTANTANEOus TESTSMTI H 1 8 33 790 11 while the high range covers 0 80 amps The timer r...

Page 76: ...1 8 33 790 11 Page 67 Fig 76 Test Kit in Operation 384826 Effective October 1998 Courtesy of NationalSwitchgear com...

Page 77: ...rrent limiting fuses of any other design The current limiters are held in place in an extension pro vided on the back of the circuit breaker This extension makes the DSL circuit breakers eight inches...

Page 78: ...ering mechanism as provided on the DS circuit breakers See Figures 81 and 82 9 3 1 Installing Fuse Trucks The fuse truck is normally installed in series with a circuit breaker of the same current rati...

Page 79: ...uck See Figure 83 After replacing fuses be sure that all connection bolts are tight and that any truck parts removed in the process have been replaced 1 8 33 790 11 Fig 81 DS 3200 Fuse Truck Front Vie...

Page 80: ...HASING THE CONTROL POWER FOR TRIPPING THE CIRCUIT BREAKER MUST BE FROM A RELIABLE SOURCE Fig 82 DS 3200 Fuse Truck with Front Cover Removed 391078 Effective October 1998 Fig 83 DS 4000 Fuse Truck Side...

Page 81: ...ummy Elements 11 0 GENERAL A dummy element consists of a drawout frame or truck with disconnecting contacts and with connecting links between the upper and lower terminals on each pole When inserted i...

Page 82: ...tion and the assurance of service con tinuity inspection and maintenance checks on them should be made on regular schedules Since maintenance of these breakers will consist mainly in keeping them clea...

Page 83: ...e extended to a more DIMENSION A ltJOMl IM M BOTH SIDES 1 BREAKER CLOSED 1 8 33 790 11 economical point Conversely if the recommended inspection shows for instance heavy accumulations of dirt or other...

Page 84: ...tacts and their Adjustment DS 632 Breaker Effective October 1998 Page 75 Note Switching and fault interruptions and the mak ing of motor inrush currents will cause some pitting of the breaker contact...

Page 85: ...heir Adjustment DS 840 Breaker 1 8 33 790 11 Close the breaker and check the contact engagement according to Figures 84 and 85 The main stationary con tact fingers should be parallel B to the fixed co...

Page 86: ...contacts are secured to the moving contact assembly by two bolts Removal of these bolts permits the replacement of the moving contacts To change the fixed arcing and main contacts the fixed contact a...

Page 87: ...ected to the minimum by repeated 1 8 33 790 11 operations and normally encountered atmospheric tem perature and dirt conditions There are a few adjustments made at the factory and subjected to quality...

Page 88: ...206 this is obtained by the adjusting nuts located on the insulating link stud above and below the pivot block Refer to Figures 37 and 38 These nuts are self locking and must be tight when the adjust...

Page 89: ...RCUIT BREAKER AT RECOMMENDED FREQUENCIES COULD RESULT IN FAILURE OF EQUIPMENT TO OPERATE PROPERLY UNDER FAULT CONDITION WHICH COULD CAUSE EQUIP MENT DAMAGE AND OR BODILY INJURY 12 3 2 Location and Lub...

Page 90: ...y When inquiring about or ordering parts refer to the fig ures in this book and the renewal parts data for identifica tion of the part or sub assembly in question Effective October 1998 13 1 IDENTIFYI...

Page 91: ...Page 82 1 8 33 790 11 Memorandum Effective October 1998 Courtesy of NationalSwitchgear com...

Page 92: ...1 8 33 790 11 Page 83 Memorandum Effective October 1998 Courtesy of NationalSwitchgear com...

Page 93: ...ler Hammer Distribution and Control Business Unit Electrical Components Division Pittsburgh Pennsylvania U S A Effective October 1998 Printed in U S A CCI 1 8 33 790 11 Courtesy of NationalSwitchgear...