01.4SM.

1800B Undervoltage Assembly

for PowlVac® Circuit Breakers

48VDC & 125 VDC

(For PowlVac® Circuit Breakers manufactured
prior to September 2014)

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Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

Contact Information

Powell Electrical Systems, Inc.

www.powellind.com
[email protected]

Service Division
PO Box 12818
Houston, Texas 77217-2818

Tel: 713.944.6900
Fax: 713.948.4569

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 01.4SM.1800B

Signal Words Qualified Person

As stated in ANSI Z535.4-2007, the signal word is For the purposes of this manual, a qualified
a word that calls attention to the safety sign and person, as stated in NFPA 70E®, is one who has
designates a degree or level of hazard seriousness. skills and knowledge related to the construction
The signal words for product safety signs are and operation of the electrical equipment and
“Danger”, “Warning”, “Caution” and “Notice”. installations and has received safety training to
These words are defined as: recognize and avoid the hazards involved. In
addition to the above qualifications, one must also
be:
! DANGER
1. trained and authorized to energize,
DANGER indicates an imminently hazardous deenergize, clear, ground, and tag circuits
situation which, if not avoided, will result in and equipment in accordance with
death or serious injury. established safety practices.
2. trained in the proper care and use of
personal protective equipment (PPE)
! WARNING such as rubber gloves, hard hat, safety
glasses or face shields, flash clothing, etc.,
WARNING indicates a potentially hazardous
in accordance with established safety
situation which, if not avoided, could result in
practices.
death or serious injury.
3. trained in rendering first aid if necessary.

! CAUTION
CAUTION used with the safety alert symbol,
indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.

CAUTION
CAUTION, used without the safety alert
symbol, is used to address practices not
related to personal injury.

NOTICE
IMPORTANT indicates a section of the manual
covering a non hazardous situation, but
one where Powell feels proper attention is
warranted.

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Contents
Ch 1 General Information .................................................................................................1
A. Scope ................................................................................................................................................................2
B. Purpose .............................................................................................................................................................2
C. Service Manuals Available Electronically ...........................................................................................................2

Ch 2 Safety ........................................................................................................................3
A. Safe Work Condition . ........................................................................................................................................3
B. Safety Guidelines ...............................................................................................................................................3
C. General .............................................................................................................................................................4
D. Specific ..............................................................................................................................................................4
E. X-Rays ..............................................................................................................................................................5
F. Safety Labels .....................................................................................................................................................5

Ch 3 Equipment Description .............................................................................................6

A. General .............................................................................................................................................................6

Ch 4 Installation ................................................................................................................7
A. Calibrating the Replacement/Add-On 48VDC Undervoltage Assembly . ................................................................7
B. Removing the Old 48VDC Undervoltage Assembly and Installing the Replacement
48VDC Undervoltage Assembly .........................................................................................................................8
1) Removing the Old UV Assembly ........................................................................................................................................... 8
2) Installing the Replacement UV Assembly ........................................................................................................................... 8
C. Calibrating the Replacement/Add-On 125VDC Undervoltage Assembly ...............................................................9
D. Removing the Old 125VDC Undervoltage Assembly and Installing the Replacement
125VDC Undervoltage Assembly .................................................................................................................... 10
1) Removing the Old UV Assembly .........................................................................................................................................10
2) Installing the Replacement UV Assembly .........................................................................................................................10
E. Testing the Replacement Undervoltage Assembly ..............................................................................................12v
F. Installing an Add-On Undervoltage Assembly .................................................................................................. 13
G. Testing an Add-On Undervoltage Assembly ...................................................................................................... 14

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

Figures
Figure 1 Replacement 48VDC Undervoltage Device Assembly
with Tools Required .........................................................................................7
Figure 2 Relay Time Delay .............................................................................................7
Figure 3 Trip Arm ...........................................................................................................7
Figure 4 Wishbone Support Channel ............................................................................8
Figure 5 Jackshaft Collar ..............................................................................................8
Figure 6 Replacement 125VDC Undervoltage Device Assembly
with Tools Required .........................................................................................9
Figure 7 Relay Time Delay ...........................................................................................10
Figure 8 Trip Arm .........................................................................................................10
Figure 9 Wishbone Support Channel ..........................................................................11
Figure 10 Jackshaft Collar ............................................................................................11
Figure 11 Test Cabinet with Umbilical Cord ..................................................................12
Figure 12 Compressing Solenoid Plunger & Tightening Jackshaft Collar ...................13
Figure 13 Solenoid Plunger in Place with Jackshaft Collar Tightened ........................13
Figure 14 Auxiliary Switch to UV Jumper Illustration ..................................................14

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Ch 1 General Information

! WARNING
The equipment described in this document may contain high voltages and currents which can
cause serious injury or death.

The equipment is designed for use, installation, and maintenance by knowledgeable users of such
equipment having experience and training in the field of high voltage electricity. This document
and all other documentation shall be fully read, understood, and all warnings and cautions
shall be abided by. If there are any discrepancies or questions, the user shall contact Powell
immediately at 1.800.480.7273.

! WARNING
Before any adjustment, servicing, part replacement, or any other act is performed requiring
physical contact with the electrical working components or wiring of this equipment, the power
supply must be disconnected. Failure to follow this warning may result in injury or death.

NOTICE
The information in this instruction bulletin is not intended to explain all details or variations of the
Powell equipment, nor to provide for every possible contingency or hazard to be met in connection
with installation, testing, operation, and maintenance of the equipment. For additional
information and instructions for particular problems, which are not presented sufficiently for the
user’s purposes, contact Powell at 1.800.480.7273.

NOTICE
Powell reserves the right to discontinue and to change specifications at any time without incurring
any obligation to incorporate new features in products previously sold.

General Information Powered by Safety® 1

 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

A. Scope 3. Illustrations, photographs, and description

of the undervoltage device
The information in this service manual
describes the following Undervoltage Device: The illustrations contained in this document
may not represent the exact construction
• 50028G11P 48VDC details of each particular type of undervoltage
• 50028G10P 125VDC device. The illustrations in this document
are provided as general information to aid in
This device can be used in the following showing component locations only.
circuit breakers manufactured prior to
September 2014: All illustrations and photos are shown using
deenergized equipment.
• PowlVac® STD
• PowlVac® CDR
• PowlVac® ASD ! WARNING
• PV System 27® CDR
Be sure to follow the appropriate safety
• PV System 38® CDR
precaution while handling any of the
• PowlVac® 38kV CDS
equipment. Failure to do so may result in
serious injury or death.
Note: This undervoltage device will not fit
in any PowlVac-ND® circuit breaker
configurations. To the extent required, the products described
herein meet the applicable ANSI, IEEE, and
This device can be used in the following NEMA Standards; however, no such assurance
replacement circuit breakers: is given with respect to local codes and
ordinances which may vary greatly.
• PowlVac® AM 15kV
• PowlVac® DH 15kV C. Service Manuals Available Electronically
• PowlVac® DHP 15kV
• PowlVac® DST 15kV For more information visit
• PowlVac® HK 15kV www.powellind.com. To contact the Powell
• PowlVac® PSD 15kV Service Division call 1.800.480.7273 or
• PowlVac® WSA 15kV 713.944.6900, or email
[email protected].
B. Purpose

The information in this service manual is

intended to provide information required
to properly install the undervoltage device
described in Ch 1 General Information,
A. Scope.

This service manual provides:

1. Safety guidelines
2. Instructions for installation and placing the
undervoltage device into service
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 01.4SM.1800B

Ch 2 Safety 6. Where the possibility of induced voltages

or stored electrical energy exists, ground
A. Safe Work Condition the phase conductors or circuit parts
before touching them. Where it could be
The information in Section A is quoted from reasonably anticipated that the conductors
NFPA 70E 2012 - Article 120, 120.1 Establishing an or circuit parts being deenergized
Electrically Safe Work Condition. could contact other exposed energized
conductors or circuit parts, apply ground
120.1 Process of Achieving an Electrically Safe connecting devices rated for the available
Work Condition fault duty.

1. Determine all possible sources of electrical B. Safety Guidelines

supply to the specific equipment. Check
applicable up-to-date drawings, diagrams, Study this maintenance procedure and all other
and identification tags. associated documentation before installing the
undervoltage device.
2. After properly interrupting the load current,
OPEN the disconnecting device(s) for each Each user had the responsibility to instruct
source. and supervise all personnel associated with
usage, installation, operation, and maintenance
3. Wherever possible, visually verify that all of this equipment on all safety procedures.
blades of the disconnecting devices are Furthermore, each user has the responsibility
fully OPEN or that drawout type circuit of establishing a safety program for each type
breakers are withdrawn to the fully of equipment encountered.
disconnected position.
It is mandatory that the following rules be
4. Apply lockout/tagout devices in accordance observed to ensure the safety of personnel
with a documented and established policy. associated with usage, installation, operation,
and maintenance of these circuit breakers.
5. Use an adequately rated voltage detector
to test each phase conductor or circuit part The safety rules in this service manual are not
to verify they are deenergized. Test each intended to be a complete safety program. The
phase conductor or circuit part both rules are intended to cover only some of the
phase-to-phase, and phase-to-ground. important aspects of personnel safety related to
Before and after each test, determine the undervoltage device.
that the voltage detector is operating
satisfactorily.

Informational Note: See ANSI/ISA-61010-1

(82.02.01)/UL 61010-1, Safety Requirements
for Electrical Equipment for Measurement,
Control, and Laboratory Use - Part 1: General
Requirements, for rating and design
requirements for voltage measurement
and test instruments intended for use on
electrical systems 1000 V and below.

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

C. General 4. DO NOT ATTEMPT TO CLOSE THE CIRCUIT

BREAKER MANUALLY ON AN ENERGIZED
1. Only supervised and qualified personnel CIRCUIT.
trained in the usage, installation, operation, 5. DO NOT USE AN OPEN CIRCUIT BREAKER
and maintenance of the circuit breaker shall AS THE SOLE MEANS OF ISOLATING A
be allowed to work on this equipment. It is HIGH VOLTAGE CIRCUIT. For complete
mandatory that this service manual and any isolation, the circuit breaker shall be in
supplements be studied, understood, and the disconnected position or shall be
followed. withdrawn completely.
2. Maintenance programs must be consistent 6. ALL COMPONENTS SHALL BE
with both customer experience and DISCONNECTED BY MEANS OF A
manufacturer’s recommendations, VISIBLE BREAKER AND SECURELY
including service advisories and instruction GROUNDED FOR SAFETY OR PERSONNEL
bulletin(s). A well planned and executed PERFORMING MAINTENANCE
routine maintenance program is essential OPERATIONS ON THE CIRCUIT BREAKERS.
for circuit breaker’s reliability and safety. 7. Interlocks are provided to ensure the
3. Service conditions and circuit breaker proper operating sequences of the circuit
applications shall also be considered in the breakers and for the safety of the user. If for
development of safety programs. Variables any reason an interlock does not function
include ambient temperature; humidity; as described, do not make any adjustments,
actual continuous current; thermal cycling; modifications, or deform the parts. DO
number of operations; interrupting duty; NOT FORCE THE PARTS INTO POSITION.
and any adverse local conditions including CONTACT POWELL FOR INSTRUCTIONS.
excessive dust, ash, corrosive atmosphere,
vermin and insect infestations.
D. Specific

1. DO NOT WORK ON AN ENERGIZED

CIRCUIT BREAKER. If work must be
performed on a circuit breaker, remove it
from service and remove it from the metal-
clad switchgear.
2. DO NOT WORK ON A CIRCUIT BREAKER
WITH THE CONTROL CIRCUIT ENERGIZED.
3. EXTREME CARE MUST BE EXERCISED
TO KEEP ALL PERSONNEL, TOOLS, AND
OTHER OBJECTS CLEAR OF MECHANISMS
WHICH ARE TO BE OPERATED,
DISCHARGED, OR RELEASED. These
circuit breakers utilize stored energy
mechanisms. These mechanisms must be
serviced only by skilled and knowledgeable
personnel capable of releasing each spring
load in a controlled manner. Detailed
information regarding these mechanisms is
found in this service manual.
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 01.4SM.1800B

E. X-Rays

When high voltage is applied across the

contacts of a vacuum interrupter, there is
the possibility of generation of X-rays. The
intensity of the X-radiation is dependent on
the peak voltage and the contact gap. At
the normal operating voltage for this type of
equipment, the radiation levels are negligible.
At the voltages specified for testing, test
personnel shall be in front of the circuit
breaker such that the two layers of steel used
in the frame and front cover construction are
between the test personnel and the vacuum
interrupters, and that the test personnel be no
closer than one meter (3’) from the front of the
circuit breaker. THE CIRCUIT BREAKER SHALL
BE EITHER FULLY OPEN OR FULLY CLOSED
WHEN MAKING HIGH POTENTIAL TESTS.
DO NOT TEST WITH CONTACTS PARTIALLY
OPEN.

F. Safety Labels

The equipment described in this document

has DANGER, WARNING, CAUTION, and
instruction labels attached to various locations.
All equipment DANGER, WARNING, CAUTION,
and instruction labels shall be observed when
the circuit breaker is handled, operated or
maintained.

NOTICE
Warning and Caution labels are located in
various places in and on the switchgear and
on the circuit breaker removable element.
Always observe these warnings and caution
labels. Do NOT remove or deface any of these
warning/caution labels.

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

Ch 3 Equipment Description
A. General

The undervoltage assembly (UV) is located in

the center part of the mechanism area just to
the right of the main closing spring.

! CAUTION
Ensure that the control circuits are
deenergized and the circuit breaker is
deenergized, disconnected by means of a
visible break, and securely grounded. Do NOT
start to work on a closed circuit breaker or a
circuit breaker with the main closing spring
charged.

The undervoltage device assembly consists of

the following:

• Undervoltage Device
• Jackshaft Collar
• 8/32” x 5/8” socket head screw (4)
• 5/16”-18 x ¾” HEX head bolt (2)
• 5/16” Flat Washers (2)
• 5/16” Lock Washers (2)
• Trip Arm
• Auxiliary Switch to Undervoltage (UV)
Jumper

Tools required (furnished by customer):

• Flat Head Screwdriver

• Socket Wrench
• 5/32” Allen Wrench
• 9/64” Allen Wrench
• ¾” Socket
• ½” Socket
• 7/16” Socket

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 01.4SM.1800B

Ch 4 Installation 7. When replacing an old style UV assembly

(manufactured prior to May 2007), remove
A. Calibrating the Replacement/Add-On 48VDC the old trip arm, 50358P01 and replace it
Undervoltage Assembly with the new trip arm, 50183P01 (Figure 3).

Figure 1 Replacement 48VDC Undervoltage Figure 2 Relay Time Delay

Device Assembly with Tools Required

a. Under/Over Dial
Perform the following steps prior to installation b. “U” Voltage Dial
of the replacement/add-on undervoltage c. “H” Hysteresis Dial
device assembly. d. “Tt” Time Delay Dial

1. Ensure the circuit breaker is in the OPEN

position and all springs are DISCHARGED. Figure 3 Trip Arm
2. On the UV assembly, locate the
“Under/Over” dial (Figure 2, a) at the top of
the device. Adjust the dial until the arrow
points to NO MEMORY on the “Under” side.
3. Adjust the relay voltage, top blue dial “U”
(Figure 2, b) to 30 volts. Adjust the relay
hysteresis, middle blue dial “H” (Figure 2, c) a
to 20%. Adjust the relay time delay, bottom
blue dial “Tt” (Figure 2, d) to 0.1.
4. Remove the front cover of the circuit
breaker.
5. Remove the escutcheon plate.
6. Refer to the “Maintenance” chapter of the a. Trip Arm
circuit breaker instruction bulletin and
follow the instructions to remove the main
closing spring.

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

B. Removing the Old 48VDC Undervoltage Figure 4 Wishbone Support Channel

Assembly and Installing the Replacement 48VDC
Undervoltage Assembly

1) Removing the Old UV Assembly

Perform the following to remove the old

UV assembly: a

a. Using a 5/32” Allen wrench, unscrew the

trip arm from the secondary trip prop
shaft.
b. Remove the secondary trip prop reset
spring from the trip arm but leave the a. Wishbone Support Channel
spring connected to the mechanism. It
will be reattached to the new trip arm.
c. Disconnect the UV wires from the circuit b. Connect the wire lead on the UV
breaker harness. assembly to the wire lead on the circuit
d. Remove the UV assembly from the breaker harness by matching the wire
wishbone support channel by using a tag numbers.
½” socket. c. Using 9/64” Allen wrench, install the
jackshaft collar to the jackshaft with the
2) Installing the Replacement UV Assembly hardware supplied (4 - 8/32 x 5/8 socket
cap screw). Tighten all four screws
Note: When replacing all hardware, use equally, allowing the collar to slide
LOCTITE 243 on the threads. When along the jackshaft (Figure 5).
adding/replacing a new style UV
assembly (manufactured on or after Figure 5 Jackshaft Collar
May 2007) the existing trip arm should
NOT be replaced.

Perform the following to install the

replacement UV assembly:
a
a. Install the replacement UV assembly
device ensuring that it is in full contact
with the mounting surface of the
wishbone support channel
(Figure 4, a). Attach the UV using the
two 5/16”-18 x ¾” HEX head bolts, flat
washers, and lock washers. Tighten the a. Jackshaft Collar
bolts to 13-14 ft-lbs.

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 01.4SM.1800B

d. Slide the collar assembly along the C. Calibrating the Replacement/Add-On 125VDC
jackshaft until the operating link Undervoltage Assembly
(Figure 12, b) slot is aligned and
engages with the rivet (Figure 12, c) on Figure 6 Replacement 125VDC Undervoltage
the rocker arm. Secure the collar to the Device Assembly with Tools Required
jackshaft just enough that it will not
spin when depressing the rocker arm.
e. Press the rocker arm (Figure 12, a)
causing it to pivot and compress the
spring on the solenoid plunger. While
holding this position, rotate the collar
up until the slot on the operating link of
the collar engages with the rocker arm
rivet. Securely tighten the four screws
holding the jackshaft collar halves
together. Once the collar is secure,
the solenoid plunger should remain
completely depressed (Figure 13). If it is
not, redo step e until complete. Perform the following steps prior to installation
f. Refer to the Maintenance chapter of the of the replacement/add-on undervoltage
circuit breaker instruction bulletin and device assembly.
reverse the instructions for removing
the main closing spring and reinstall the 1. Ensure the circuit breaker is in the OPEN
main closing spring. position and all springs are DISCHARGED.
g. Test the UV assembly per 2. On the UV assembly, locate the
Ch 4 Installation, E. Testing the “Under/Over” dial (Figure 7, a) at the top of
Undervoltage Assembly. the device. Adjust the dial until the arrow
points to NO MEMORY on the “Under” side.
Note: The large voltage dropping resistor 3. Adjust the relay voltage, top blue dial “U”
used with the 48VDC Undervoltage (Figure 7, b) to 70 volts. Adjust the relay
Assembly generates significant heat hysteresis, middle blue dial “H” (Figure 7, c)
during normal operation. Ensure to 20%. Adjust the relay time delay, bottom
there is a minimum air gap of blue dial “Tt” (Figure 7, d) to 0.1.
1/2 inch between the resistor and any 4. Remove the front cover of the circuit
non-metallic component, such as breaker.
control wiring, cable ties, etc., after 5. Remove the escutcheon plate.
installation of the device. 6. Refer to the “Maintenance” chapter of the
circuit breaker instruction bulletin and
follow the instructions to remove the main
closing spring.
7. When replacing an old style UV assembly
(manufactured prior to May 2007), remove
the old trip arm, 50358P01 and replace it
with the new trip arm, 50183P01 (Figure 8).

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

Figure 7 Relay Time Delay D. Removing the Old 125VDC Undervoltage

Assembly and Installing the Replacement 125VDC
Undervoltage Assembly

1) Removing the Old UV Assembly

a
Perform the following to remove the old UV
assembly:
b
a. Using a 5/32” Allen wrench, unscrew the
c trip arm from the secondary trip prop
shaft.
b. Remove the secondary trip prop reset
d
spring from the trip arm but leave the
spring connected to the mechanism.
It will be reattached to the new trip arm.
c. Disconnect the UV wires from the circuit
breaker harness.
d. Remove the UV assembly from the
wishbone support channel by using a
a. Under/Over Dial ½” socket.
b. “U” Voltage Dial
c. “H” Hysteresis Dial 2) Installing the Replacement UV Assembly
d. “Tt” Time Delay Dial
Note: When replacing all hardware, use
Figure 8 Trip Arm LOCTITE 243 on the threads. When
adding/replacing a new style UV
assembly (manufactured on or after
May 2007) the existing trip arm should
NOT be replaced.

Perform the following to install the

replacement UV assembly:
a
a. Install the replacement UV assembly
device ensuring that it is in full contact
with the mounting surface of the
wishbone support channel
(Figure 9, a). Attach the UV using the
a. Trip Arm two 5/16”-18 x ¾” HEX head bolts, flat
washers, and lock washers. Tighten the
bolts to 13-14 ft-lbs.

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 01.4SM.1800B

Figure 9 Wishbone Support Channel d. Slide the collar assembly along the
jackshaft until the operating link
(Figure 12, b) slot is aligned and
engages with the rivet (Figure 12, c) on
the rocker arm. Secure the collar to the
jackshaft just enough that it will not
spin when depressing the rocker arm.
a e. Press the rocker arm (Figure 12, a)
causing it to pivot and compress the
spring on the solenoid plunger. While
holding this position, rotate the collar
up until the slot on the operating link of
the collar engages with the rocker arm
a. Wishbone Support Channel rivet. Securely tighten the four screws
holding the jackshaft collar halves
together. Once the collar is secure,
b. Connect the wire lead on the UV the solenoid plunger should remain
assembly to the wire lead on the circuit completely depressed (Figure 13). If it is
breaker harness by matching the wire not, redo step e until complete.
tag numbers. f. Refer to the Maintenance chapter of the
c. Using 9/64” Allen wrench, install the circuit breaker instruction bulletin and
jackshaft collar to the jackshaft with the reverse the instructions for removing
hardware supplied (4 - 8/32 x 5/8 socket the main closing spring and reinstall the
cap screw). Tighten all four screws main closing spring.
equally, allowing the collar to slide g. Test the UV assembly per
along the jackshaft (Figure 10). Ch 4 Installation, E. Testing the
Undervoltage Assembly.
Figure 10 Jackshaft Collar

a. Jackshaft Collar

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

E. Testing the Replacement Undervoltage Assembly Figure 11 Test Cabinet with Umbilical Cord

Perform the following to test the UV assembly:

a
Note: This test must be done electrically.
b
CLOSE TRIP
c
! CAUTION ON
UV
OFF

UV TRIP
d
POWER

Prior to connecting the test cabinet make sure ON OFF

e
the power switch and the UV power switch are
in the OFF position. Failure to do so may result
in personal injury.
f

1. Connect the test cabinet umbilical cord to

the circuit breaker secondary disconnect
receptacle.
2. Turn the UV power switch (Figure 11, e) on
the test cabinet to the ON position.
3. Turn the test cabinet power switch
(Figure 11, c) to the ON position. This will
charge the circuit breaker.
4. After the circuit breaker is fully charged, g
push the close push button (Figure 11, a)
on the test cabinet and ensure the circuit
breaker is in the closed position by viewing
CLOSED in the circuit breaker position a. Close Push Button
indicator located on the front cover of the b. Trip Push Button
circuit breaker. c. Test Cabinet Power Switch
5. Push the UV trip push button d. UV Trip Push Button
(Figure 11, d) on the test cabinet. At this e. UV Power Switch
time the UV device will trip the circuit f. Test Cabinet Umbilical Cord
breaker. g. Test Cabinet Umbilical Plug

Note: If the circuit breaker does not trip refer

to the Adjustment of Primary and
Secondary Trip Prop section of the
circuit breaker instruction bulletin.
Once these adjustments have been
made repeat steps 1-5 of this section.

6. Reinstall the escutcheon plate and front

cover of the circuit breaker.

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 01.4SM.1800B

Figure 12 Compressing Solenoid Plunger & F. Installing an Add-On Undervoltage Assembly

Tightening Jackshaft Collar
Perform steps 1 through 6 of Ch 4 Installation,
A. Calibrating the Replacement/Add-On
Undervoltage Assembly.
a
Once the steps above have been completed
b perform the following to install the add-on
undervoltage assembly:
c
1. Remove wire #1 found on pin #9 and wire
#2 found on pin #10 (Figure 14) from the
auxiliary switch located to the left of the
mechanism.
2. Connect wires #1 and #2 to their
a. UV Rocker Arm
corresponding number on the auxiliary
b. Operating Link
switch to UV jumper (Figure 14, a).
c. Rivet
3. Route the unconnected ends of the UV
jumper to the UV wiring harness
Figure 13 Solenoid Plunger in Place with (Figure 14, b) and connect them to the
Jackshaft Collar Tightened corresponding wire tags #1 and #2.
4. Using a 9/64” Allen wrench, install the
jackshaft collar to the jackshaft with the
hardware supplied (4 - 8/32 x 5/8 socket cap
screw). Tighten all four screws equally,
allowing the collar to slide along the
jackshaft (Figure 5).
5. Slide the collar assembly along the
jackshaft until the operating link
(Figure 12, b) slot is aligned and engages
with the rivet (Figure 12, c) on the rocker
arm. Secure the collar to the jackshaft
just enough that it will not spin when
depressing the rocker arm.
6. Press the rocker arm (Figure 12, a) causing
it to pivot and compress the spring on
the solenoid plunger. While holding this
position, rotate the collar up until the
rivet is fully engaged to the bottom of the
operating link (Figure 12). Securely tighten
the four screws holding the jackshaft
collar halves together. Once the collar is
secure, the solenoid plunger should remain
completely depressed (Figure 13). If it is
not, redo step 6 until complete.

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 Undervoltage Device for 48VDC & 125VDC 01.4SM.1800B

7. Refer to the Maintenance chapter of the breaker is in the closed position by viewing
appropriate circuit breaker instruction CLOSED in the circuit breaker position
bulletin and reverse the instructions for indicator located on the front cover of the
removing the main closing spring and circuit breaker.
reinstall the main closing spring. 5. Push the UV trip push button
8. Test the UV assembly per Ch 4 Installation, (Figure 11, d) on the test cabinet. At this
G. Testing an Add-On Undervoltage Assembly. time the UV device will trip the circuit
breaker.
Note: When adding-on a 48VDC
Undervoltage Assembly the large Note: If the circuit breaker does not trip refer
voltage dropping resistor used to the Adjustment of Primary and
generates significant heat during Secondary Trip Prop section of the
normal operation. Ensure there is a circuit breaker instruction bulletin.
minimum air gap of 1/2 inch between Once these adjustments have been
the resistor and any non-metallic made repeat steps 1-5 of this section.
component, such as control wiring,
cable ties, etc., after installation of the 6. Reinstall the escutcheon plate and front
device. cover of the circuit breaker.

G. Testing an Add-On Undervoltage Assembly Figure 14 Auxiliary Switch to UV Jumper

Illustration
Perform the following to test the Add-On UV
assembly:
a
Note: This test must be done electrically. 1 1

2 2
CAUTION
1
2

!
b
Prior to connecting the test cabinet make sure
the power switch and the UV power switch c
are in the OFF position. Failure to do so may
2
1

result in personal injury.

TCP2

TCP1
11

14

13
16
15

6
5

7
3

1. Connect the test cabinet umbilical cord to

8
4

11

the circuit breaker secondary disconnect

receptacle.
2. Turn the UV power switch (Figure 11, e) on
the test cabinet to the ON position. 15 13 11 9 7 5 3 1 d
3. Turn the test cabinet power switch 17 14 12 10 8 6 4 2

(Figure 11, c) to the ON position. This will

charge the circuit breaker. a. Auxiliary Switch to
4. After the circuit breaker is fully charged, Undervoltage (UV) Jumper
push the close push button (Figure 11, a) b. UV Wiring Harness
on the test cabinet and ensure the circuit c. Undervoltage Device
d. Auxiliary Switch

14 Powered by Safety® Installation

 01.4SM.1800B
Undervoltage Assembly
for PowlVac® Circuit Breakers

48VDC & 125VDC

(For PowlVac® Circuit Breakers manufactured
prior to September 2014)
October 2014

Powell Electrical Systems, Inc.

Service Division - Houston
Powered by Safety® Tel: 713.944.6900 • Fax: 713.948.4569
www.powellind.com
PO Box 12818 • Houston, TX • 77217 ©2006 Powell Industries, Inc. • All rights reserved. [email protected]