BCS Switchgear Inc.

Switchgear | Circuit Breakers | Parts | Tech Support

INSTRUCTIONS IB-69000

Series PV-26 POWL-VAC®

VACUUM CIRCUIT BREAKERS
4.16kV 1200A and 2000A

INSTALLATION

III
mm
r SI
OPERATION

MAINTENANCE

POWELL
)
INDUSTRIES,INC .
POWELL ELECTRICAL MANUFACTURING COMPANY
•
8550 MOSLEY DRIVE HOUSTON, TEXAS 77075 USA
•
PHONE (713) 944-6900 FAX (713) 947-4453
bcsswitchgear.com | 888.599.0486 Need Help? 888.599.0486

Courtesy of NationalSwitchgear.com
 BCS Switchgear Inc. Switchgear | Circuit Breakers | Parts | Tech Support
P-69000 PV-26 Vacuum Circuit Breakers IB-69000

CONTENTS

I. INTRODUCTION

II. SAFETY 1
A. X-RAYS 1
B. SAFETY LABELS 1

III. DESCRIPTION 2
A. GENERAL 2
B. THE STORED ENERGY MECHANISM . . 2
C. INTERLOCKING 7
D. VACUUM INTERRUPTER CONNECTIONS
E. OPERATING SOLENOIDS 8
F. THE ANTI-PUMP RELAY 9
G. MOTOR CUTOFF SWITCH 9
H. VACUUM INTERRUPTERS 9
J. SECONDARY DISCONNECT PLUG 9

IV. INSTALLATION 9
A. RECEIVING c
n
B. HANDLING O
'
C. STORAGE 9
D. PUTTING INTO SERVICE 10
(1) High Voltage Insulation Integrity 10
(2) Vacuum Integrity 11
(3) Control Voltage Insulation Integrity 11
(4) Mechanical Operation Check 11
(5) Electrical Operation 12
E. INSERTING BREAKER INTO SWITCHGEAR EQUIPMENT 12
F. POWER RACKING DEVICE 13

V. MAINTENANCE 13
A. GENERAL 13
Introduction
(1) 13
Inspection and Cleaning
(2) 13
B. MECHANISM AREA 14
(1) Mechanical Operation 14
(2) Lubrication 14
(3) Closing Spring Removal and Slow Closing of Mechanism
(4) Mechanism Adjustments
(a) Adjustment of Ratchet Wheel Holding Pawl

i POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

bcsswitchgear.com | 888.599.0486 Need Help? 888.599.0486

Courtesy of NationalSwitchgear.com
 BCS Switchgear Inc. Switchgear | Circuit Breakers | Parts | Tech Support

P-69000 PV-26 Vacuum Circuit Breakers IB-69000

Adjustment of Primary and Secondary Trip Latches and Latch

(b)
Check Switch 16
(c) Adjustment of Close Latch 16
(5) Electrical Operation 16
C. INTERRUPTER AND CONTACT AREA 16
(1) Vacuum Interrupter Contact Erosion
(2) Sliding Contact Wear 16
(3) Mechanical Adjustment of Interrupters 17
(4) Vacuum Integrity 17
D. OPTIONAL MAINTENANCE PROCEDURES 17
(1) High Potential Tests 17
(2) Primary Resistance Check 17

VI . RECOMMENDED RENEWAL PARTS AND REPAIR PROCEDURES 17

A. ORDERING INSTRUCTIONS 17
B. RECOMMENDED RENEWAL PARTS 18
C. REPLACEMENT PROCEDURES 18
(1) Vacuum Interrupter 18
(2) Closing Coil Assembly 19
(3) Shunt Trip Coil Assembly, Left 19
(4) Shunt Trip Coil Assembly, Right 19
) (5) Undervoltage Device Assembly 20
(6) Charging Motor Assembly 21
(7) Anti- Pump Relay 21
(8) Latch Check Switch 22
(9) Motor Cutoff Switch Assembly 22
(10) Ground Shoe Finger Assembly 22
(11) Auxiliary Switch 22
(12) Pin Retaining Rings 23

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA n

bcsswitchgear.com | 888.599.0486 Need Help? 888.599.0486

Courtesy of NationalSwitchgear.com
 P- 69000 PV-26 Vacuum Circuit Breakers IB-69000

ILLUSTRATIONS
Figure 1. Side view of PV-26 Circuit Breaker 2
Figure 2. Front View of PV-26 Circuit Breaker with Cover In Place . 3
Figure 3. Front View of PV-26 Circuit Breaker with Cover Removed 3
Figure 4. Charging Motor and Motor Cutoff Switch 4
Figure 5. Main Operating Mechanism - Right Oblique View 4
Figure 6. Main Operating Mechanism - Left Oblique View 4
Figure 7. Close Latch Arm Engaging Close Latch Shaft 5
Figure 8. Cam and Fundamental Linkage Positions 6
Figure 9. Interrupter and Operating Rod Mechanism 7
Figure 10. Mechanism and Trip Linkages 7
Figure 11. Shunt Trip Coil, right 8
Figure 12. Circuit Breaker in Shipping Carton 9
Figure 13. Circuit Breaker with Secondary Test Connector in Place . 10
Figure 14. Circuit Breaker Being Lifted on Crane 10
Figure 15. Main Closing Spring Assembly Installed 15
Figure 16. Main Closing Spring Assembly Compressed For Removal 15
Figure 17. Primary Trip Latch Adjusting Screw 16
Figure 18. Contact Erosion Measurements 17
Figure 19. Trip Lever Gap Adjustment 20
Figure 20. Undervoltage Device Mounted on Circuit Breaker 20
Figure 21. Undervoitage Device 21
Figure 22. Anti-Pump Relay 21
Figure 23. Ground Shoe 22
Figure 24. Auxiliary Switch 23
Figure 25. Pin Retaining Rings 23

TABLES
Table I. Circuit Breaker Lubrication 15
Table II. Interrupter and Sliding Contact Finger Assemblies 18
Table III. Control Devices 18
Table IV. Miscellaneous Parts 18

m POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

)
CAUTION
Before any adjustment, sen/ icing, parts 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.

6. Do not attempt to close the breaker by hand on a

INTRODUCTION
live circuit.
7. Do not use an open circuit breaker by itself as the
Before uncrating the breakers, study this manual.
Follow the recommended procedure for putting into service.
.
sole means of isolating a high voltage circuit For
complete isolation, the circuit breaker should be in
the disconnected position, or should be withdrawn
This manual contains:
completely.
1. Safety Rules.
8. For the safety of personnel performing mainte-
2. A general description of the operation of the
nance operations on the breaker or connected
circuit breakers.
equipment, all components should be discon-
3. Instructions for putting into service.
nected by means of a visible break and securely
4. Instructions for maintenance and replacement
grounded.
of parts with critical adjustments.
5. List of renewal parts.
A. X-RAYS
These instructions do not purport to cover all detaiis or When voltage is applied across the contacts of a
variations of the circuit breakers nor to provide for every vacuum interrupter, there is the possibility of generation of
possible contingency or hazard to be met in connection X-rays. The intensity of this radiation is dependent on the
with installation, testing, operation and maintenance. \ peak voltage and the contact gap. At the normal operating
Should further information be desired or should particular voltage of this class of equipment, the radiation levels are
problems arise which are not covered sufficiently for the negligible. At the voltages specified for testing, it is recom-
user' s purposes, the matter should be referred to the mended that the test operator be not less than one meter
Powell Electrical Manufacturing Company. in front of the circuit breaker and separated from the
vacuum interrupters under test by the one thicknesses of
steel used in the construction of the circuit breaker frame.
The circuit breaker must be either fully open or fully closed
II. SAFETY when making high potential tests. Do not test with contacts
partially open.
The circuit breakers described in this manual are
operated by high energy, high speed mechanisms inter-
locked to provide safe operating sequences. To insure the
B. SAFETY LABELS
safety of personnel associated with installation, operation
The circuit breaker has these warning and caution
and maintenance of these breakers, the following rules
labels attached at the indicated locations. Whenever the
should be observed:
circuit breaker is handled or maintained, these warnings
and cautions must be observed.
1. Only qualified personnel trained in the installation,
operation and maintenance of power circuit break-
ers should be allowed to work on these breakers.
2. Do not work on an energized breaker.
3. Do not work on a breaker with the secondary test
coupler connected (See Figure 13).
4. Do not work on a closed breaker.
5. Do not work on a breaker with closing springs
charged.
)

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 1

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

In front of this casting in an accessible position is the

CAUTION operating mechanism assembly which provides motion to
READ INSTRUCTIONS BEFORE Attached to outside each of the vacuum interrupter moving contacts through
ENERGIZING . THIS DEVICE MAY face of mechanism top cast epoxy operating rods.
PRODUCE HARMFUL X-RAYS cover plate.

iq

CAUTION /
REMOVAL OF SECONDARY DIS-
CONNECT PLUG WILL TRIP A
CLOSED BREAKER AND DISCHA- Attached to front cover
0 0
RGE THE MAIN CLOSING to left of secondary h
disconnect aperture.
SPRING

(b>
DANGER
BE SURE CIRCUIT BREAKER
CONTACTS ARE OPEN AND Attached to front cover
SPRINGS DISCHARGED BEFORE; at top right hand cor-

Figure 1. Side View of PV-26 Circuit Breaker

ner and also in mecha-
DOING MAINTENANCE WORK; nism compartment on
dashpot bracket.

a. Anti rollout Release Lever

CAUTION b. Operating rod
DO NOT MANUALLY CHARGE c. Secondary Disconnect Guide
UNLESS THE SECONDARY DIS-
Attached to front cover
to left of manual charg-
d. Mechanism Housing
CONNECT PLUG OR THE INTER - ing handle socket. e. Cast Epoxy Insulator
LOCK OVERRIDE DEVICE IS f. Upper Primary Disconnect
FIRMLY SEATED IN THE DISCON- g- Vacuum Interrupter
NECT RECEPTACLE h. Lower Primary Disconnect
J- Anti Bellows Spring
k. Contact Pressure Spring
Bell Crank
III. DESCRIPTION
B. THE STORED ENERGY MECHANISM
A. GENERAL (Figure 1)
The front cover (Figure 2) has cutouts and apertures
The PV26 Circuit Breaker uses sealed vacuum interrup- giving access to various operating functions and access to
.
ters to control the primary circuit Primary connections to the secondary disconnect terminal block.
the associated metal clad switchgear are made by tubular
copper busbars. Cast epoxy insulation provides support for Removal often (10) holding screws enables the front cover
the primary bars and the vacuum interrupter assemblies. to be removed giving access to the stored energy mecha-
nism and its interlocks, auxiliary switches, operating motor
All the current carrying components are located behind and motor cutoff switch (Figure 3) .
an epoxy casting which supports the vacuum interrupter.

2 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV- 26 Vacuum Circuit Breakers IB-69000

mechanism shelf (Figure 4). Its output shaft is screwed to a

coupler which inserts into the eccentric drive shaft. This
shaft is supported in bearings in the charging mechanism
frame and transmits the motor torque from the right to the
left side of the breaker.

When the motor is energized, the eccentric shaft rotates

and causes the driving arm links to pivot about the cam
shaft (Figure 6). The drive pawl located on the links
engages with the ratchet wheel and rotates it, one tooth at
a time. The ratchet wheel is prevented from rotating
backward by a holding pawl, which is supported on links
that project upward from the cam shaft.

cl
Figure 2. Front View of PV-26 Circuit
Breaker with Cover In Place

a. Cover Attachment Bolts

b
b. Handle C
c. Operations Counter
d. Manual Charging Crank e
e. Nameplate
f. Spring Charge Indicator
g- Manual Close Paddle
h. Breaker Open/Closed Indicator f
j-
Figure 3. Front View of PV-26 Circuit
Manual Trip Paddle
k. Secondary Disconnect Guide
Secondary Disconnect Receptacle Breaker with Cover Removed
m. Padlock Provision - Movable Arm
n. Padlock Provision - Stationary Clip
a. Anti-Pump Relay
b. MOC Operating Arm
c. Auxiliary Switch
The mechanism is of the stored energy type in which a d. Shunt Trip Coil
gear motor is used to compress a closing spring. During a e. Closing Coil
closing operation, the energy stored in the closing spring is f. Charging Motor
used to close the vacuum interrupter contacts, compress g- Main Closing Spring
the contact pressure springs, and overcome friction forces. h. Connecting Rods
When the breaker is tripped, the energy stored in the
opening and overtravel springs will open the contacts at the
correct speed. The motor, located under the breaker
mechanism shelf is supported by a bracket bolted to the

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 3

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

To insure correct synchronization of the drive and hold As the ratchet wheel is rotated, projections from its side
pawls, the hold pawl links are located by an adjustable faces will engage drive plates attached to the cam shaft and
eccentric stop located at the left front of the mechanism. the cam shaft will rotate. Attached to the ends of the cam
When the mechanism is operated manually, the top pawl shaft are crank arms and pointing outward from these are
becomes the driving pawl and the bottom pawl becomes crank pins. These engage with the bottom ends of the
the holding pawl. connecting rods (Figure 6) , the top ends of which engage
pins projecting from the spring compression plate which
straddles the main closing spring. As the cam shaft rotates,
the connecting rods pull the spring compression plate
downward,compressing the closing spring.

Figure 4. Charging Motor and Motor Cutoff

Switch

a. Motor Cutoff Switch Assembly

b. Charging Motor

A
Figure 6. Main Operating Mechanism - Left
Oblique View
©
a. Drive Pawl

<3) b.
C.
Ratchet Wheel
Holding Pawl
d. Holding Pawl Adjusting Eccentric
e. Drive Plate
Figure 5. Main Operating Mechanism - f. Crank Arm
Right Oblique View g- Crank Pin
h. Secondary Trip Latch Adjusting Screw
j - Latch Check Switch
k. Connecting Rod
a. Mechanism Reset Spring
b. Close Bar Adjusting Screw
c. Motor Cutoff Cam
d. Motor Cutoff Switch Operating Arm

4 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

When the close latch is released either under the

action of the closing solenoid or the manual close plate, the
closing spring pulls the cam shaft around, and the main
closing cam moves the main linkage into the closed
position. The main linkage rotates the center lever of the
jack shaft. The jack shaft has 3 pairs of levers to which are
attached the operating rods. The operating rods,which are
approximately horizontal, are moved away from the vacuum
interrupter by the rotation of the jack shaft (Figure 1, Page
2) .

At the end of the operating rods remote from the jack

shaft levers is a stud and yoke which connects with the bell
crank levers (Figure 9) . Also connected to the bell crank
levers, the spring yoke is restrained by a lock nut on a stud
which passes through the contact pressure spring. The
contact pressure spring has initial compression such that as
soon as the vacuum interrupter contacts touch, they are
loaded by a force sufficient to resist their separation under
the highest electromagnetic forces exerted by the rated
short circuit current.

Further movement of the operating rods compresses

the contact pressure spring even more and produces a gap
between the face of the spring yoke and the lock nut. This
gap will reduce as the vacuum interrupter contacts erode.
Figure 7. Close Latch Arm Engaging Close
Latch Shaft The bell crank levers, which are located on the epoxy
casting, are supported on a hinge pin bridging the epoxy
support casting.
a. Close Latch Arm
b. Close Latch Shaft In the linkage positions shown in Figures 8b and 8d,
the contact pressure springs are acting to compress the
three (3) main mechanism links (Figure 9) .

The ratchet wheel will drive the cam shaft so that the
connecting rods go down to their lowest position and then
start to move upward. At a certain point, the spring force
will overcome friction and resistance and start to rotate the
cam shaft. At the same time, the pawls are uncoupled from
the ratchet wheel and the motor cutoff switch is operated.
The motor cutoff switch located on the right of the mecha-
nism is operated by the spring charge flag falling into the
spring charge cam (Figure 5) . The spring charge flag will
now show that the mechanism is charged. The cam shaft
would continue to rotate, except that it is restrained by the
close latch arm engaging against the close latch shaft
(Figure 7) . The main operating cam located between the
mechanism side sheets is now in a position where the main
drive linkage can move to the reset position (Figure 8a) .

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

Figure 8. Cam and Fundamental Linkage Positions

The linkage is restrained from movement by the With the standard electrical control scheme, as soon as
secondary trip prop acting on the primary trip prop roller. the closing spring is discharged on a closing operation, the
The component of force tends to make the primary trip prop motor is switched on to recharge the spring. This leaves
move upward, but it is restrained by the secondary trip prop the main closing cam in a position where the tripped
face acting on the primary trip prop roller. The clearance linkage can reset under the action of the reset spring
between the primary trip prop roller and the secondary trip (Figure 8d), and the primary and secondary trip props can
prop is controlled by the primary trip prop adjusting screw. fall into the reset position. The reset spring stretches
When the trip shaft is rotated by the action of the manual between an extension of the main cam roller pin and a
trip plate or the electric trip solenoid, the secondary trip spring support pin located on the left mechanism side
prop moves down and permits the primary trip prop to sheet. The trip latch check switch operated by a lever on
move upward, thus permitting the main linkage to move the trip shaft will now close (Figure 6) .
upward and the jack shaft to rotate, opening the breaker.
The jack shaft extends from the left to the right side of the
breaker frame and is supported at the main breaker frame
side sheets and by the mechanism side sheets. An exten-
sion of the jack shaft projects through the left breaker side
sheet and operates the MOC switch drive.

6 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

)
The second purpose is to insure that the control circuits
cannot be broken when the breaker is in the connected
a position and the breaker cannot be moved from the con-
nected position unless its main contacts are first opened.

The circuit breaker interlock system is accomplished

© through the functions of both the external levering-in device
© and the circuit breaker itself.

o
f

> 9
h

Figure 9. Interrupter and Operating Rod

Mechanism Figure 10. Mechanism and Trip Linkages

a. Cast Epoxy Insulator

b. Upper Primary Disconnect a. Secondary Trip Prop Adjusting Screw
c. Vacuum Interrupter b. Trip Bar
c.

*-
'
Lower Primary Disconnect Secondary Trip Latch
e. Anti Bellows Spring d. Secondary Linkage Roller
f. Contact Pressure Spring e. Reset Spring
g Bell Crank f. Cam Shaft
h. Operating Rod g- Main Drive Cam
h. Center Phase Operating Lever
j - Main Cam Roller
k. Primary Trip Prop Adjusting Screw
C. INTERLOCKING Primary Trip Prop
m Primary Trip Prop Roller
The first purpose of the interlocks is to insure that a
breaker cannot be moved from the disconnected to the The circuit breaker can not be moved into the test
connected position unless the main breaker contacts are position ( from outside the ceil ) unless the the access door
open and the secondary control circuitry from the compart- to the levering-in shaft is closed. If the circuit breaker is in
ment to the circuit breaker is completed. the connected position, the "PUSH TO CLEAR" button will
J

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 7

Courtesy of NationalSwitchgear.com
 P- 69000 PV-26 Vacuum Circuit Breakers IB-69000

trip the unit, hold it trip-free, and discharge the closing D. VACUUM INTERRUPTER CONNECTIONS
spring. When the "PUSH TO CLEAR" button is depressed,
the access door will open, exposing the levering-in shaft. Connection to the vacuum interrupter stems is made by
One- half turn of the shaft in either direction (racking the unit means of cast copper. The top stem of the interrupter is
in or out) will lock the door open and hold the push to clear threaded, and a copper casting is screwed onto this stem.
function in an engaged condition. The upper primary disconnect is threaded onto the copper
casting. A similar casting and primary disconnect assembly
With the levering- in device in the fully racked out is mounted to the bottom of the vacuum interrupter. The
position, the access door must be closed to insert the moving stem of the vacuum interrupter passes through the
breaker into the "TEST" position from the outside. The casting where multiple parallel sliding contacts make
breaker may be removed from the "TEST" position without contact with the casting and the moving stem of the
closing the access door, however, it cannot be reinserted vacuum interrupter. The multiple parallel paths of the
until the door is closed. There is an anti-rollout latch sliding contacts keep the current density low.
located at the bottom of the circuit breaker that will lock the
unit in the "TEST" position, preventing accidental removal.
E. OPERATING SOLENOIDS
The secondary disconnect plug may be inserted before
or after reaching the "TEST" position, however, it must be The closing solenoid located under the middle of the
inserted and locked in place, using the locking bar, prior to mechanism is attached to the breaker mechanism shelf by
any attempt to move the circuit breaker into the "CONNECT- two screws accessible from beneath the mechanism.(Figure
ED" position. Insertion of the secondary disconnect plug 3) .
will cause the charging motor to operate and charge the
closing spring. Note that operation of the "PUSH TO
CLEAR " button will discharge the spring, as described
above, prior to allowing access to the levering-in shaft.
Removal of the secondary disconnect plug in the "TEST"
position will cause all springs in the operating mechanism
to discharge.

The sequence for moving the circuit breaker from the

"TEST" position to the "CONNECTED" position is as follows:

1. Engage the "PUSH TO CLEAR " button and open

the access door.
2. One- half turn of the levering- in shaft will lock the
door and hold the clear functions.
3. Four full turns of the shaft will open the shutters
in front of the primary bushings.
4. Four and one- half turns begins the movement of
Figure 11. Shunt Trip Coil, right
the breaker.
5. Approximately eighteen turns of the shaft moves
the breaker to the fully "CONNECTED" position. The shunt trip solenoid is to the left of the mechanism
6. At this point the access door may be manually and is supported from the mechanism mounting angle.
closed and the circuit breaker will become (Figure 3) .
functional.
Either a second shunt trip solenoid or an undervoltage
Note: The circuit breaker cannot be moved to or from trip device may be furnished as an option. When furnished,
the connected position unless it is opened manual either of these devices is to the right of the mechanism and
ly or electrically. The secondary disconnect plug is supported from the mechanism mounting angle (Figure
cannot be removed in the connected position. 11). Only one of these two auxiliary trip devices may be
furnished on any one circuit breaker, as both types are
located in the same space.

8 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

F. THE ANTI- PUMP RELAY

The anti-pump relay is located on the upper left side of
the rear mechanism mounting bracket (Figure 3).

G. MOTOR CUTOFF SWITCH

The motor cutoff switch, which is located at the right of
the mechanism, is attached to a bracket which is bolted to
the breaker mechanism shelf (Figure 4) .
H. VACUUM INTERRUPTERS
All vacuum interrupters used in the circuit breakers S
covered by this instruction book are the same size and
appearance, but different ratings differ in their internal con-
struction. Each vacuum interrupter bears a label to indicate
its part number. Vacuum interrupters must be replaced Figure 12. Circuit Breaker in Shipping Car-
only with new interrupters of the same part number. ton
J. SECONDARY DISCONNECT PLUG
Control power is transferred from the switchgear to the B. HANDLING
circuit breaker by means of the secondary disconnect plug
and umbilical cord attached to the switchgear , This The breaker can be lifted by an overhead crane using
arrangement makes the secondary connection visible in all holes which have been provided for hooks at the top of the
positions of the circuit breaker. breaker frame side sheets (Figure 14) . Do not attempt to
move the circuit breaker using a fork lift.

IV. INSTALLATION C. STORAGE

A. RECEIVING It is recommended that the breaker be put into service
immediately in its permanent location. If this is not possi-
Figure 12 shows the breaker enclosed in the carton ble, the following precautions must be taken to assure the
used for shipment. Check for signs of damage. If damage proper storage of the breaker:
is found or suspected, file claims as soon as possible with (1) The breaker should be carefully protected against
the transportation company, and notify the nearest repre- condensation, preferably by storing it in a warm dry
sentative of Powell Electrical Manufacturing Co. room of moderate temperature, such as 40°-100°F,
The carton is attached to the shipping skid by two since dampness has an adverse effect on the
bands. Remove these bands and lift the carton off the insulating parts. Circuit breakers for outdoor metal-
circuit breaker. The breaker is attached to the skid by two clad switchgear should be stored in the equipment
more bands. When these are removed, the breaker may be only when power is available and the heaters are in
removed from the shipping skid. operation to prevent condensation.
(2) The breaker should be stored in a clean location, free
from corrosive gases or fumes. Particular care should
be taken to protect the equipment from moisture and
cement dust, as this combination has a very corrosive
effect on many parts.
(3) Unplated surfaces of rollers, latches, etc., of the

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB- 69008

operating mechanism should be coated with

grease to prevent rusting.

If the breaker is stored for any length of time, it should

be inspected periodicaiiy to see that rusting has not started
and to insure good mechanical condition, Should the
breaker be stored under unfavorable atmospheric condi-
tions, it should be cleaned and dried before being placed
in service.

D. PUTTING INTO SERVICE

Before shipment from our factory, all breaker functions
will have been thoroughly checked. If the user wishes to
recheck the operation, we recommend that the check be
performed in the sequence listed below: 1
>

(1) High voltage insulation integrity.

(2) Vacuum integrity in the interrupters.
(3) Control voltage insulation integrity.
(4) Mechanical operation of the mechanism. Figure 14. Circuit Breaker Being Lifted by
(5) Electrical operation of the mechanism. Crane

CAUTION
High voltage across the open gaps of the
interrupter can produce radiation. Personnel should
stand at least 1 meter (39 inches) away from the break-
er, in front of the front cover, when conducting high
voltage tests. Test voltage should not exceed 36kV, 50
or 60 Hz, or 50kV dc.

(1) High Voltage Insulation Integrity

To check insulation integrity, the AC high potential test
described below is strongly recommended, DC high
potential testing is not recommended except for the Vacu-
um Interrupter Integrity Test.

Caution: If DC high potential testing is required, the DC

high potential test machine must not produce instantaneous
peak voltages exceeding 50kV.

The circuit breaker insulation should be tested with the

Figure 13. Circuit Breaker with Secondary circuit breaker in the "CLOSED" position. Test each pole of
the breaker separately, with the other 2 poles grounded.
Test Connector in place
Perform the one minute normal frequency withstand test
described in ANSI Standard C37.20.2-1987, 5.2.1 and
5.2.1.1, at the voltage level appropriate for the equipment .

10 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P- 69000 PV-26 Vacuum Circuit Breakers IB-69000

This test will have checked all of the support insulation, breakdown occurs the interrupter should be replaced.
and also the primary phase-to-phase insulation.

. .y
Caution: Remove all grounding conductors applied for this v
CAUTION
test before placing the breaker back into service. WHEN TESTING WITH DC, USE A DC HIGH POTEN-
TIAL TEST SET WITH FULL WAVE RECTIFICATION

^
MANY : DC' filG POTENTIALITEST : SETS USE HALF
'

WAVE RECTIFICATION. DO NOT USE THESE HALF- |

-
(2) Vacuum Integrity
WAVE RECTIFIERS, THE CAPACITANCE OF THE
VACUUM INTERRUPTER IN COMBINATION WITH THE
Vacuum interrupters used in Powl- Vac circuit breakers
are highly reliable interrupting elements ,
LEAKAGE : CURRENTS IN THE RECTIFIER AND ITS: DC
Satisfactory
VOLTAGE MEASURING EQUIPMENT MAY RESULT IN

^ ^
performance of these devices is primarily dependent upon
the integrity of the vacuum in the chamber and internal
APPLYING PEAK OLTAGEG :V S MUCH AS : TPME::
dielectric strength. Both these parameters can be readily
TIMES THE; MEASURED ; VOLfKGEL : ;; P
: THESE| |- : : I
checked by a high potential test.
MALLY HIGH VOLTAGES MAY GIVE A FALSE INDICA-
TION OF A DEFECTIVE INTERRUPTER , AND MAY
PRODUCE ABNORMAL X-RADIATION.
CAUTION
APPLYING ABNORMALLY HIGH VOLTAGE ACROSS A
No attempt should be made to try to compare the
PAIR OF CONTACTS IN VACUUM MAY PRODUCE X -
condition of one vacuum interrupter with another nor to
RADIATION. THE RADIATION MAY INCREASE WITH
correlate the condition of any interrupter with low values of
THE INCREASE IN VOLTAGE AND/ OR DECREASE IN
dc leakage current. There is no significant correlation.
CONTACT SPACING.
After the test potential is removed, discharge any
X-RADIATION PRODUCED DURING THIS TEST WITH
electrical charge that may be retained.
RECOMMENDED VOLTAGE AND NORMAL CONTACT
SPACING IS EXTREMELY LOW AND WELL BELOW
MAXIMUM PERMITTED BY STANDARDS. HOWEVER,
AS A PRECAUTIONARY MEASURE AGAINST POSSI - (3) Control Voltage Insulation Integrity
BILITY OF APPLICATION OF HIGHER THAN RECOM-
MENDED VOLTAGE AND/OR BELOW NORMAL . CON- If the user wishes to check the insulation integrity of the
TACT SPACING, IT IS RECOMMENDED THAT ALL control circuit, it may be done with a 500 volt or 1000 volt
OPERATING PERSONNEL STAND AT LEAST ONE insulation tester or with an ac high potential tester. The ac
METER AWAY : IN FRONT OF THE BREAKER. high potential test should be made at 1125 volts, 60 Hz, for
one minute. The charging motor must be disconnected at
DO NOT APPLY VOLTAGE THAT IS HIGHER THAN its connection plug prior to testing the control circuit. The
THE RECOMMENDED VALUE . DO NOT USE CON- motor itself may be similarly tested at a voltage not to
TACT SEPARATION THAT IS LESS THAN THE NOR - exceed 675 volts, 60 Hz. Be sure to remove any test
MAL OPEN POSITION SEPARATION OF THE BREAK
-

- jumpers and reconnect the charging motor when the tests

ER CONTACTS . are complete.

(4) Mechanical Operation Check

The test of the vacuum interrupter will determine its
internal dielectric condition and vacuum integrity. With the In normal operation, the contacts of the vacuum
breaker open and removed from the cell, apply the high interrupters cannot be closed unless the secondary discon-
potential across each interrupter separately. Connect the nect plug is in position, To check the breaker outside
" hot" lead of the test source to the upper stud of the pole of the compartment, it is necessary to simulate the connec-
under test and the ground lead to the lower stud . If the test tion of secondaries by inserting the secondary test connec-
supply is center-point grounded, the connections may be tor in the slot below the fixed secondary contacts (Figure
.
made either way Apply 36kV rms 60 Hz or 50kV dc and 13) . This device must be removed after testing and before
hold for a minimum of five (5) seconds. If no breakdown the breaker is inserted into the cell. An interference plate
) occurs the interrupter is in acceptable condition. If a will deter insertion of the circuit breaker into the cell with the

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 11

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

test connector in place. The manual charge lever should and the access door must be closed prior to any attempt to
now be inserted into the manual charge crank and pushed engage the breaker. Refer to the section on interlocking for
down until a metallic click is heard. This indicates that the details. The rollout latch will engage at this point.
holding pawl has dropped into place on the ratchet wheel.
Lift the lever until it is horizontal and then depress. The To insert a breaker into an upper compartment, a lift
procedure is repeated until the spring charge flag indicates truck is required. Refer to the detailed procedure in the
.
that the close spring is now charged This requires about instruction book for metal- clad switchgear equipment, IB-
60 operations of the handle. Remove the handle. Push the 68000. The levering-in device and interlocking works as
round blue "PUSH TO CLOSE" plate and the breaker will described for insertion into a lower compartment.
close. The flag located above the "PUSH TO CLOSE" plate
will now read "CLOSED". Push the round red trip plate To move the circuit breaker into the "CONNECTED"
located at the top of the escutcheon and the breaker will position, in an upper or lower compartment, the secondary
open as indicated by the breaker condition flag. disconnect must be inserted and locked in place by the
locking bar. To engage the levering-in device, press the
(5) Electrical Operation "PUSH TO CLEAR " button and the access door will open
simultaneously. Note that insertion of the secondary
disconnect will charge the closing springs and depressing
To check the electrical operation of the breaker, a
the "PUSH TO CLEAR " button will discharge the closing
jumper cable must be used. First, remove the control fuses
spring. Refer to the section on interlocking for details.
in the compartment. Connect the jumper cable to the
umbilical cord in the compartment and to the breaker.
The levering-in crank may now be inserted into the
Insert the fuses. The motor mechanism will automatically
access window to engage the hex shaft. Rotate the crank
charge the stored energy closing springs. Operation of the
clockwise to move the breaker into the "CONNECTED"
closing switch on the front door of the compartment will
position. The force required to rotate the crank will be low
cause the breaker to close. The circuitry is arranged to
at the beginning of the motion when the movement of the
cause the motor to operate again and charge the closing
crank serves only to open the shutters; however, as the
spring. Operating the electrical trip switch on the front door
breaker moves toward the "CONNECTED" position the force
will cause the breaker to open. Alternately, the breaker may
required will increase due to engagement of the ground
be connected to a test cabinet to perform these functions.
contact and the primary disconnects, Once the initial
engagement is made the force will decrease, Continued
rotation will move the breaker further into the cell to ensure
E. INSERTING BREAKER INTO that contact wipe or overlap of the primary contacts is
SWITCHGEAR EQUIPMENT correct.

Refer to the metal- clad switchgear instruction book for Once the breaker has reached the fully "CONNECTED"
general information and cautions before attempting to insert position, the levering-in mechanism will stop rotating and a
a circuit breaker into the switchgear equipment. flag indicating that the breaker is fully "CONNECTED" will
appear. DO NOT attempt to force the levering-in device
Each circuit breaker and each cell is provided with a further or damage will occur. The levering-in crank may
coding plate designed to insure that no breaker with less now be removed and the access door can be closed. The
than the required voltage, continuous current or interrupting circuit breaker is now ready for service.
current rating is placed in any cell. If you attempt to insert
an improperly rated breaker into a cell, these coding plates The maximum force required on the levering-in crank
will interfere with each other and deter the insertion. The for normal insertion of a circuit breaker will not exceed 35
interference will occur before the breaker can engage the Ibs-ft. Excessive force may damage the levering-in device,
levering- in mechanism. DO NOT attempt to force a breaker circuit breaker or switchgear equipment.
past this interference or remove the coding plate from either
the cell or the breaker. To move a circuit breaker from the "CONNECTED"
position to the "DISCONNECTED" position (or "TEST'
To insert a breaker into a lower compartment, first align position), first the circuit breaker must be tripped, This
the wheels with the housing floor pan channels. Then roll may be accomplished manually or electrically. To engage
the breaker into the housing until it stops. Note that the the levering-in crank the "PUSH TO CLEAR " button must be
levering- in device must be in the fully racked out position depressed and the access door opened. (Remember that

12 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

the "PUSH TO CLEAR " button will discharge all springs in inspected and necessary maintenance be performed as
the circuit breaker) . Engage the levering-in crank and rotate soon as is practical. Some atmospheric conditions such as
counter - clockwise until the indicator flag reads extremes of dust and moisture or corrosive gases might
"TEST / DISCONNECTED " and the levering - in device stops . indicate inspection and maintenance at more frequent
DO NOT attempt to rotate the crank further in the counter- intervals than 2000 operations. Very clean and dry condi-
clockwise direction or damage to the device may occur. tions combined with low switching duty will justify longer
times between inspection and maintenance operations.
The circuit breaker is now disconnected from the With experience, each user can set an inspection and
primary contacts and may be tested electrically or mechani- maintenance schedule which is best suited for the particular
cally. use.

To remove the circuit breaker from the compartment, A permanent record of all maintenance work should be
release the secondary disconnect plug by rotating the kept, the degree of detail depending on the operating
locking bar left and down. The secondary disconnect plug conditions. In any event, it will be a valuable reference for
may now be pulled out of the circuit breaker . If the circuit subsequent maintenance work and for station operation. It
breaker is in a lower compartment it may be removed by is recommended that the record include reports of tests
releasing the rollout latch on the breaker and rolling the made, the condition of breakers and repairs and adjust-
breaker out. If the circuit breaker is in an upper compart- ments that were made. This record should begin with any
ment a lift truck is required. Refer to the Metal-Clad checks done at the time of installation and energization.
Switchgear instruction book IB-68000 for a detailed proce-
dure on removal. Because of extensive quality control checks made at
the factory, the operations counter on a new circuit breaker
F. POWER RACKING DEVICE will normally register over a hundred operations. The actual
reading of the operations counter should be recorded when
the circuit breaker is put into service and whenever any
A motor- driven racking device is available as an maintenance is performed.
optional accessory refer to IB68030 for details on operation.
Before attempting any maintenance work, take note of
V. MAINTENANCE safety practices outlined in Section II of this book.

-
MAKE CERTAIN THAT THE CONTROL CIRCUITS ARE
Contact Powell ApparatusService Division for assis DE-ENERGIZED AND THE BREAKER IS RESTING SECURE-
tance in performing maintenance or setting up a main- LY OUTSIDE THE SWITCHGEAR HOUSING. DO NOT
tenance program. WORK ON A CLOSED BREAKER OR A BREAKER WITH
THE CLOSING SPRINGS CHARGED.

A. GENERAL (2) Inspection and Cleaning

Give the breaker a visual check for loose or damaged
(1 ) Introduction parts. Tighten or replace loose or missing hardware. Any
part damaged so as to interfere with normal operation of the
A regular maintenance schedule should be established circuit breaker should be replaced. This inspection will be
to obtain the best service and reliability from the circuit much easier if the front cover is removed.
breaker. Powl-Vac circuit breakers are designed to comply
with industry standards requiring maintenance every 2000 Clean the breaker, removing loose dust and dirt. Do
operations or once a year, whichever comes first. not use an air hose to blow the breaker out; this may result
in loose dirt or grit being blown into bearings or other
Actual inspection and maintenance will depend upon critical parts and causing excessive wear. Either use a
individual application conditions such as number of opera- vacuum cleaner or wipe with a dry lint-free cloth or an
tions, magnitude of currents switched, desired overall industrial-type wiper.
system reliability and operating environment. Any time the
breaker is known to have interrupted a fault current at or Primary insulation, including the operating rods, should
near its rating it is recommended that the breaker be be cleaned also. Wipe clean with a dry lint-free cloth or an

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 13

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

industrial type wiper. If dirt adheres and will not come off open, remove the screw at the top of the spring rod
by wiping, remove it with distilled water or a mild solvent together with the lock washer. Remove the top cover by
such as denatured alcohol. Be sure that the breaker is dry unfastening the nine attachment screws, Remove the
before returning it to service. Do not use any type of spacer from below the top cover. Utilizing a .5-13 x 1.25
detergent to wash the surface of the insulators, as detergent inch screw in place of the original, insert screw and screw
may leave an electrical conducting residue on the surface down until tension is taken off the connecting rods (Figure
as it dries. 15) . The connecting rods can now be unhooked from the
spring yoke pins and the spring assembly removed. Care
should be taken on reassembly to insure correct location of
B. MECHANISM AREA
the spacer. See Figure 16.

(1) Mechanical Operation With the main spring assembly removed, rotate the cam
shaft so that the crank arms are pointing downward. The
Remove the circuit breaker front cover, exposing the main linkage will now move into the reset position. Push
mechanism. Make a careful visual inspection of the mech- the "PUSH TO CLOSE" plate and hold in while operating the
anism for loose, damaged or excessively worn parts. Oper- hand charge lever to rotate the cam shaft. Once the close
ate the breaker several times manually. release latch arm is past the close shaft latch plate, the
"PUSH TO CLOSE" plate may be released. As the main
See the sections headed "Mechanical Operation cam engages the main linkage roller, the jackshaft will com -
Checks " under the heading PUTTING INTO SERVICE for mence to rotate. Continue to operate the hand charge lever
further information. until the crank arms point upward. The breaker will now be
closed and there will be a gap between the contact overtra -
(2) Lubrication vel nuts and the contact spring yokes. See Figure 9.

Lubricate the mechanism and other specified parts in (4) Mechanism Adjustments
accordance with the lubrication chart, Table I, Page 16.
Several factory adjustments in the mechanism are
The chart shows the location of all surfaces which described below. No adjustment of these settings is
should be lubricated together with the type of lubricant and required for routine maintenance, but they may need to be
method of application. The guiding rule in lubrication adjusted after major overhaul or removal of the mechanism.
should be to lubricate regularly, use lubricant sparingly and DO NOT ADJUST THESE SETTINGS UNNECESSARILY.
remove all excess lubricant.
(a) Adjustment of Ratchet Wheel Holding Pawl
Anderol 757 Grease should be lightly applied to those The ratchet wheel holding pawl (c, Figure 6, Page
bearing surfaces which are accessible and a light synthetic 4) is adjusted by an eccentric cam (d, Figure 6, Page
machine oil such as Anderol A456 should be used to 4) . If the pawl is not properly adjusted, there will be a
penetrate through to surfaces which are inaccessible. The "knocking" noise when the ratcheting mechanism is
mechanism should be in the open, spring discharged operating, or the mechanism will not ratchet at all. To
position for lubrication. There is no necessity to disassem- adjust the pawl, remove the escutcheon to gain access
ble the mechanism for lubrication. Tilting the breaker will to the head of the bolt holding the eccentric cam.
facilitate the entry of the lubricant to the bearing surfaces. Loosen the bolt slightly. While charging the spring
using the charging motor to drive the mechanism, grip
(3) Closing Spring Removal and the eccentric cam with a pair of slip- joint pliers or a
similar tool and rotate the cam slightly until the ratchet-
Slow Closing of Mechanism ing operation is smooth. This may require several
charging cycles, as each charging cycle lasts only a
Disassembly of the mechanism is not required for
few seconds. When the eccentric cam is properly set,
routine lubrication; however, for major overhaul, removal of
re-tighten the mounting bolt and replace the escutch-
the closing spring is necessary. Removal of the spring
eon. Be sure that the escutcheon is reinstalled on the
permits slow closing of the vacuum interrupter contacts .
proper circuit breaker, since the escutcheon contains
The procedure for spring removal is as follows:
the nameplate with all the breaker 's rating and serial
number information.
With closing spring discharged and breaker contacts

14 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

Figure 15. Main Closing Spring Assembly Figure 16. Main Closing Spring Assembly
Installed Compressed for Removal
\

Table I. Circuit Breaker Lubrication

locotion lubricant Method location lubricant Method

Electrical Ports Main Spring Guide Rod Anderol A757
Main Primary Mobilgrease 28 Wipe clean. Apply lubricant Motor Drive Shaft Anderol A 456
Disconnect Tubes only to actual contact surface . Support Bearing
Motor Drive Shoft
Sliding Contact Mobilgrease 28 With breaker closed, wipe clean and Anderol A757
apply thin smear of lube above sliding Coupler Recess
.
contact fingers Bell Crank Do Not Lubricate
Mechanical Parts
Trip .Shaft Support Anderol A 456
Motor Cutoff Switch Anderol 757 Grease Apply to peripheral surface only. Bearings
Cam
Clos? Shaft Support Anderol A 456
Close Shaft Latch Face Anderol 757 Grease Apply light coating of grease Bearings
and remove all excess . Primary Trip Prop Anderol A 456
Wheels Anderol A 456 Tilt dummy breaker sideways Shaft Support Bearings
and rotate wheels while lubricating.
Primary Trip Prop Anderol A 456
Camshaft Shaft Roller
Camshaft Needle Anderol A 456
Bearings Main Linkage Anderol A456 Apply to penetrate where pins pass
through links.
Crank Pins Anderol A 456
Fixed link Pin Anderol A 456 Apply to penetrate where pin passes
Spring Yoke Pins Anderol A 456 through end link.
Rochet Wheel Anderol A757 Open -Closed Flag Drive Anderol A456
Powls Anderol A757 Lever at Jackshaft
Oscillator Arms at Anderol A 456 Jackshaft Outer Anderol A 456
Camshaft Bearing Supports
Jackshaft Lever Pins Anderol A 456 Avoid lubricant on push rods. Jackshaft Supports Anderol A 456
Passing Through Push at Mechanism
Rods
Flag Support Pins Anderol A 456

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 15

Courtesy of NationalSwitchgear.com
 P- 69000 PV-26 Vacuum Circuit Breakers IB-69000

(b) Adjustment of Primary and Secondary

Trip Latches and Latch Check Switch
Q
Adjust the secondary trip latch adjusting screw (a,
Figure 10, Page 7) so that the overlap of the secondary
TJ1
trip prop on the primary trip prop roller is approximately
.125 inch. Adjust the primary trip latch adjusting screw
so that with the main linkage in the reset position the
clearance between the primary trip latch roller and the
secondary trip prop is 0.030 inch. The primary trip
Adjustnerrt
screw
latch adjusting screw is accessible from the rear of the
mechanism, through an access hole in the support
housing of the center phase (Figure 17) . With an 0.030
inch wire gauge between the trip bar lever and the
secondary trip latch adjusting screw, the latch check 'u
switch should be open. With no gap between the lever
and the screw, the latch check switch should be
closed . Z]

(c) Adjustment of Close Latch

The close shaft passes through the side sheets of Figure 17. Primary Trip Latch Adjusting
the mechanism frame at the front of and below the cam Screw
shaft. The left end of the shaft is shaped to make a
latch face interference with the latch arm which is fixed
to the cam shaft (Figure 7, Page 5). The other end of
the close shaft is on the right side of the mechanism
and a small lever attached to it is positioned by an
adjusting screw (b, Figure 5, Page 4) . With the main closing the breaker and measuring the gap between the
closing spring charged, turn the latch adjusting screw nut and yoke for the contact pressure spring assembly
inward toward the rear of the breaker until the latch is .
(refer to Figure 18 for location) The gap is preset at the
released and the breaker closes. Unscrew the adjust- factory to approximately .469 inches. When the vacuum
ment screw 21/2 full turns and lock in position with the .
interrupter contacts have eroded 125 inches the unit should
locking nut. .
be replaced The overtravel gap (or nut gap) will measure
.344 inches at this point (there is a 1:1 ratio between
contact wear and the overtravel gap) .
(5) Electrical Operation
After any necessary mechanical maintenance and
lubrication are done, operate the circuit breaker electrically (2) Sliding Contact Wear
several times to ensure that the electrical control system
works properly. See section headed "Electrical Operation" To examine the movable contact rod of the vacuum
under the "Putting into Service" heading in this instruction interrupter the breaker must be in the open position. Wipe
book. away the lubrication on the lower stem of the vacuum inter-
rupter ( this is located under the anti-bellows spring, refer to
.
Figure 9) Check for indications of abnormal wear identified
by exposed copper on the silver plated surface, erosion or
C. INTERRUPTER AND CONTACT AREA pitting in the surface, or excessive discoloration due to heat.
If any of these conditions are present in more that one
(1) Vacuum Interrupter Contact Erosion location on the lower stem, the assembly should be re-
placed .
At each inspection, the vacuum interrupters should be
checked for contact erosion. This is accomplished by

16 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

be performed. See the section of this instruction bulletin

headed “PUTTING INTO SERVICE" for details of these
procedures.

--
4 04
(2) Primary Resistance Check
f
This check is not required for routine maintenance, but
it is suggested after any major maintenance that requires
.
disassembly of any part of the primary circuit This check
o should be done after interrupter replacement.

CLDSED POSITION To check the resistance, pass a minimum of 100A DC

through the circuit breaker pole with the breaker closed.
Measure the voltage drop across the primary contacts and
o i
| Wit calculate the resistance. This resistance should not exceed
55 micro-ohms for 1200A and 2000A breakers rated 5kV,
250 MVA Class.
VERTRAVEL GAP
When making this test, connect to the ends of both
Figure 18. Contact Erosion Measurements primary disconnects to ensure that the full current path is
included in the measurement.

To return an undamaged unit back to service, the stem VI. RECOMMENDED RENEWAL
must be relubricated with a light coat of Mobilegrease 28 PARTS AND REPAIR
contact lubricant.
) PROCEDURES
(3) Mechanical Adjustment of Interrupters
A. ORDERING INSTRUCTIONS
There are no adjustments required for routine mainte-
nance. (1) Order Renewal Parts from Powell Apparatus Service
Refer to the section on vacuum interrupter replacement Division (PASD) .
for details on how to install and adjust the interrupter (2) Always specify complete nameplate information,
assembly. Settings should not be adjusted unnecessarily. including:

a. Type
(4) Vacuum Integrity b. Serial Number
c. Rated Voltage
Refer to Page 11 for information on vacuum integrity d. Rated Amps
and testing of interrupters. e. Impulse Withstand
f. Control Voltage (for control devices and coils)
D. OPTIONAL MAINTENANCE
PROCEDURES (3) Specify the quantity and description of the part, and IB-
69000. If the part is in the tables of recommended
renewal parts, give its catalog number. If the part is not
(1) High Potential Tests in the tables, the description should be accompanied
by a marked illustration from this bulletin, a photo or a
These tests are not ordinarily required for routine sketch showing the part needed.
maintenance, but should be performed after a heavy fault
interruption or after the breaker has been in storage for an (4) Standard hardware, such as screws, bolts, nuts, wash-
extended time, especially in a damp location or other ers, etc., should be purchased locally. Hardware used
adverse environment. Both the High Voltage Insulation in bolted joints of conductors must be SAE Grade 5 or
Integrity and Control Voltage Insulation Integrity tests should better in order to insure proper clamping torque and

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 17

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers

prevent overheating of the joints. Hardware should be Table IV. Control Devices (1)
plated to deter corrosion.
Control Closing Shunt Charging -
Anti Pump
Voltage Coil Trip Motor Relay
B. RECOMMENDED RENEWAL PARTS Left(2)

24 VDC N/A 50027G05 N/A N/A

It is recommended that sufficient renewal parts be 48 VDC 50026G01 50027G01 69335G03 PVKUP11D55-48
carried in stock to enable the prompt replacement of any 125 VDC 50026G03 50027G02 69335G01 -
PVKUP11D55 110

.
worn, broken or damaged part A stock of such parts
250 VDC 50026G04 50027G03 69335G02 -
PVKUP11D55 110(5)
120 VAC 50026G01 50027G01 69335G01 PVKUP11A55-120
minimizes service interruptions caused by breakdowns and 240 VAC 50026G02 50027G06 69335G02 PVKUP11A55-240

saves time and expense. When continuous operation is a

Capacitor
Trip(6) N/A 50027G04 N/A N/A
primary consideration, more renewal parts should be
carried, the amount depending on the severity of the service
and the time required to secure replacements.

Spare or replacement parts which are furnished may

Control Shunt Under -
Voltage Trip Voltage
not be identical to the original parts, since improvements Right(3) Device(4)
are made from time to time. The parts which are furnished, 24VDC 50025G06 69346G04
however, will be interchangeable. Tables II, III and IV list 48 VDC 50025G01 69346G03
125 VDC 50025G03 69346G01
the recommended spare parts to be carried in stock by the 250VDC 50025G04 69346G02
user. The recommended quantity is not specified. This 120VAC 50025G01 N/A
must be determined by the user based on the application. 240VAC 50025G02 N/A
Capacitor
As a minimum, it is recommended that one set of parts be Trip (6) 50025G05 N/A
stocked per ten breakers or fraction thereof.

Table II. Interrupter and NOTES FOR TABLE IV /

1. One each required per breaker if breaker was originally
Sliding Contact Assemblies equipped with this item. All breakers have closing coil, left
shunt trip, charging motor, and anti-pump relay Right shunt .
Breaker type Rated kV Rated Rated Interrupter
.
trip and undervoltage device are optional See notes 2, 3 and
Continuous
Current
Momentary
kA
Assembly
(3 per Brkr) .
4
2. Standard shunt trip.
05PV26250-0 4.76 1200 58 69336G01 3. Secondary shunt trip, where furnished. Cannot be present with
05PV26250-Q 4.76 2000 58 69336G02 undervoltage device.
4. Where furnished. Cannot be present with right-hand shunt trip.
5. For 250VDC applications, a dropping resistor, 50747-G2, is
required in series with this relay’s coil .
6. For use with capacitor trip units with 240VAC input. Consult
Table III. Miscelaneous Parts factory for other ratings.

Qty/Brkr Description Catalog No.

PVBA-2RV2-A2
1
1
Latch Check Switch
Motor Cutoff Switch Assembly 50756G03
C. REPLACEMENT PROCEDURES
Ground Shope Finger Assembly
05PV26250-0 1200A & 2000A
1 Contact 69058P 01
This section includes instructions for replacing all the
2 Spring 50703P24 parts recommended as renewal parts. Before attempting
any repair work, take note of safety practices outlined in
Auxiliary Switch Assembly 50933G05
Section II of this book.
1

MAKE CERTAIN THAT THE CONTROL CIRCUITS ARE

DE-ENERGIZED AND THE BREAKER IS RESTING SECURE-
LY OUTSIDE THE SWITCHGEAR HOUSING. DO NOT
WORK ON A CLOSED BREAKER OR A BREAKER WITH
THE CLOSING SPRINGS CHARGED.

18 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

(1) Vacuum Interrupter erosion) . The measurement should be in excess of the

factory setting of .469 inches.
The vacuum interrupter assembly is not field serviceable
and must be replaced as an assembly. This assembly
7. Operate the breaker (close/open) approximately 50
times. This will seat the interrupter contacts.
includes the primary disconnects, interrupter tube, and
moving contact assembly.
8. Re- check the nut gap. If the nut gap measures .469 ±
(a) Removal of the Vacuum Interrupter Assembly
.015 inches it is ready for installation. If the nut
gap measures outside of this range it may be adjusted
by the following method:
1. Verify that all springs are discharged and that the a). Disconnect the yoke from the moving
unit is in the open position. contact stem of the vacuum interrupter.
2. Disconnect the contact pressure spring yoke from b). Remove the 3/8 inch hardware that
the moving contact stem of the vacuum interrupter attaches the operating rod to the bellcrank.
by removing the pair of 3/8 inch bolts. c) . Rotate the bell crank and yoke forward
3. Rotate the yoke forward to clear it from the area. away from the operating rod.
4. Remove the (4) four mounting bolts that hold the d) . Loosen the locking nut on the operating
assembly in the cast epoxy insulator. These are rod.
located on each primary disconnect clamp. The e) . To increase nut gap lengthen the
upper hardware is 3/8 inch hex head and the lower operating rod (turn counter clockwise), To de-
hardware is 5/16 inch hex head. crease nut gap shorten the operating
5. The assembly may be lifted out of the casting. rod (turn clockwise) . The nut
gap changes approximately .06 inches per
full turn of the operating rod.
(b) Installation of the Vacuum Interrupter Assembly f). Re-assemble, close the breaker, and re-check the
nut gap.
)JOTE: Prior to installation, inspect the assembly for
adequate lubrication on the moving stem and for handling (2) Closing Coil Assembly
damage.
The closing coil is located in the lower front center of
1. Verify that ail springs are discharged and that the the circuit breaker. See Figure 3, Page 3. To replace it:
.
unit is in the open position
a. Remove front cover of the breaker.
2. Install the vacuum interrupter assembly into the cast b. Unplug the closing coil from the wire harness.
epoxy insulator using the four (4) mounting bolts. c. Remove two bolts holding closing coil assembly to
Do not tighten the bolts ( 3/8 inch at top and 5/16 the mechanism shelf and drop the closing coil out
inch on bottom) . of the breaker.
d. Insert new closing coil assembly into the breaker
3. Check for primary disconnect alignment. The vertical from below, bolt it in place and plug it into the
height is preset. The horizontal dimension is 7.00 wiring harness. No adjustment is required.
inches center-to- center. This must be set with-in e. Close breaker several times electrically to insure
± .031 inches. that coil is functioning properly.
f. Replace front cover.
4. Tighten the mounting bolts. The upper pair of 3/8 inch
bolts should be torqued at 28 to 33 ft-lbs, the lower
5/16 inch bolts should be torqued at 15 to 20 ft-lbs. Re- (3) Shunt Trip Coil Assembly, Left
check the position of the primary after tightening.
This assembly is located in the center part of the
5. Attach the yoke assembly to the moving contact mechanism area, just to the left of the main closing spring.
stem of the interrupter using a pair of 3/8 inch bolts. See Figure 3, Page 3. To replace it:

6. Close the breaker and measure the nut gap. (Refer to a. Remove front cover of breaker.
the previous section on vacuum interrupter contact b. Unplug the trip coil from the wiring harness.

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 19

Courtesy of NationalSwitchgear.com
 P- 69000 PV-26 Vacuum Circuit Breakers IB-69000

c. Remove the two bolts holding the trip coil assem- f. Trip the breaker electrically several times to insure
bly to the breaker frame and remove the assembly. that the coil is functioning properly,
d. Bolt new assembly in place and plug it into the g. Replace front cover.
wiring harness .
e. With the breaker mechanism in the reset position, (5) Undervoltage Device Assembly
check the gap between the trip coil armature and
the trip lever extending from the trip shaft. This This assembly is located in the center part of the
gap should be between 1/4 inch and 5/16 inch. If mechanism area, just to the right of the main closing spring.
necessary, bend the trip lever slightly to achieve See Figure 20. To replace it:
.
this setting See Figure 19.
f . Trip the breaker electrically several times to insure a. Remove front cover of breaker.
that coil is functioning properly. b. Remove right hand main operating spring connect-
9- Replace front cover. ing rod. See section headed "Closing Spring
Removal and Slow Closing of Mechanism" under
Maintenance in this instruction book for procedures
for removing this rod.
c. Unplug the undervoltage device from the wiring
harness.
d. Remove the two bolts holding the undervoltage
device assembly to the breaker frame and remove
the assembly.

Figure 19. Trip Lever Gap Adjustment

(4) Shunt Trip Coil Assembly, Right

This assembly is located in the center part of the
mechanism area, just to the right of the main closing spring.
See Figure 11, Page 8. To replace it:
Figure 20. Undervoltage Device Mounted
a. Remove front cover of breaker . on Circuit Breaker
b. Unplug the trip coil from the wiring harness.
c. Remove the two bolts holding the trip coil assem-
bly to the breaker frame and remove the assembly. e. Bolt new assembly in place.
NOTE : It will be easier to remove the trip coil assembly if f. Re- assemble the main operating spring connecting
the right hand main operating spring connecting rod.
rod is removed. See section headed "Closing
While the undervoltage device has been tested at
9-
Spring Removal and Slow Closing of Mechanism " the factory, it is necessary to check and possibly
under Maintenance in this instruction book for adjust its settings once it has been assembled to
procedures for removing this connecting rod . the circuit breaker. This will require a variable
d. Bolt new assembly in place and plug it into the voltage DC source capable of output of from 40%
wiring harness. No adjustment is required. to 100% of the DC rating of the undervoltage
e. Re-assemble spring connecting rod and main device. Connect this source to the terminals of the
spring, if previously removed.

20 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers

undervoltage device coil. b. Unplug the motor from the wiring harness.
Apply a DC voltage of 80% of the undervoltage c. Remove the two bolts holding the motor mounting
coil rating. The undervoltage device should pick bracket to the mechanism shelf and slide the motor
up and allow the breaker to close. Close and trip to the right, disconnecting the motor shaft from the
the breaker several times, using manual or shunt mechanism, and lift the motor out.
trip, to be sure that the vibration of breaker opera- d. Lubricate the end of the shaft of the new motor
tion does not cause the undervoitage device to liberally with Anderol 757 grease.
drop out improperly. If the device does drop out e. Position the new motor assembly in the circuit
during this test, rotate the knob at the bottom of breaker, being sure that the pin on the end of the
the device to the right in 1/8 turn steps until the drive shaft engages the slot in the mechanism
proper operation is obtained. This adjustment may shaft.
be fine turned by bending the tab at the base of f. Bolt the motor to the mechanism shelf and plug it
the beam spring up in 1/16 inch steps. See Figure into the wire harness.
21. g- Operate the circuit breaker several times to insure
that the motor operates smoothly.
h. Replace front cover.

(7) Anti-Pump Relay

This relay is located near the top of the mechanism, to
the left of the main operating springs. See Figure 22. To
replace it:

Figure 21. Undervoitage Device nHBB

a. Beam Spring Tab
Check dropout of undervoitage device by
reducing test voltage to 52-56%. The undervoitage
device should drop out and cause the breaker to
trip in this voltage range. If dropout voltage is too
low, bend the tab at the base of the beam spring
down slightly to raise the voltage. Figure 22. Anti-Pump Relay
h. Disconnect the test source and plug the undervoit-
age device into the wiring harness. a. Remove front cover of breaker.
i. Replace front cover. b. Disconnect leads from anti-pump relay, being
careful to note which wires go to which terminal.
(6) Charging Motor Assembly C. Loosen lower mounting screw of relay.
d. Remove upper mounting screw and lift relay off
The charging motor assembly is located under the lower screw.
mechanism shelf at the right-hand side of the mechanism e. Place new relay over lower screw, reinstall upper
(See Figure 4, Page 4). To replace it: screw, and tighten both screws.
f. Reconnect all wires to the proper terminals of the
a. Remove front cover of the breaker. relay.

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 21

Courtesy of NationalSwitchgear.com
 P- 69000 PV- 26 Vacuum Circuit Breakers

9- Relays in 250VDC closing circuits are provided with (10) Ground Shoe Finger Assembly
dropping resistors to apply the proper voltage to
the relay coil. The resistor is mounted adjacent to The ground shoe assembly is located at the rear edge
the relay. It may be replaced by unplugging it from of the breaker floor pan under the center pole of the
the relay and unscrewing the mounting feet from breaker. See Figure 23. To replace it:
the breaker frame, replacing the resistor and
reassembling. a. Remove bolts holding the ground shoe to the bot-
h. Operate the breaker several times to insure that the tom pan.
relay functions properly. b. Insert new assembly from below the breaker floor
i. Replace front cover. pan.
c. Reinstall the two mounting bolts.

(8) Latch Check Switch

The latch check switch is located on the left-hand side
of the main mechanism frame, near the bottom of the main
closing spring. See Figure 6, Page 4. To replace it:

a. Remove the front cover of breaker.

b. Remove two screws holding switch to mechanism.
Do not lose nut plate into which these screws are
threaded.
c. Disconnect wires from switch.
d. Connect wires to new switch and fasten switch in
place with screws and nut plate previously re-
moved .
e. Adjust switch per instructions in section headed
"Adjustment of Primary and Secondary Trip Latches
and Latch Check Switch" under MAINTENANCE in
this instruction book.
f. Operate breaker electrically several times to insure
that it is working.
g- Replace front cover. Figure 23. Ground Shoe
(9) Motor Cutoff Switch Assembly
(11) Auxiliary Switch
The motor cutoff switch assembly is located on the
mechanism shelf , just to the right of the main mechanism.
The auxiliary switch is located in the lower left front of
See Figure 4, Page 4. To replace it:
the mechanism area. See Figure 24. To replace an
auxiliary switch:
a. Remove the front cover of breaker.
a. Remove the front cover of breaker.
b. Disconnect wires from switch, being careful to
b. Disconnect wires from switch, being careful to
identify each wire by the terminal number from
identify each wire by the terminal number from
which it was removed.
which it was removed.
c. Remove the two bolts holding the assembly to the
c. Remove the "E" ring securing the switch operating
breaker floor pan and remove the assembly.
arm to the operations counter linkage.
d. Install new cutoff switch assembly, bolt it to the
d. Remove the two screws holding the auxiliary switch
mechanism shelf. Reconnect the wiring. No
to its mounting bracket, and remove the switch.
adjustment is needed.
e. Insert the new switch and attach it to the mounting
e. Operate breaker electrically several times to insure
bracket with the two screws removed in step d.
that it is working.
f. Replace front cover.

22 POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA

Courtesy of NationalSwitchgear.com
 P-69000 PV-26 Vacuum Circuit Breakers IB-69000

f. Insert the operating arm of the switch into the hole

in the end of the operations counter linkage and
secure with the "E" ring removed in step c.
g- Reconnect the wiring. Be sure wires are connected
INSTALLATION EARS
to the same terminals from which they were re- I
REMOVAL EARS

moved. 062'
h. Operate breaker electrically several times to insure
that it is working.
.
I Replace front cover. Figure 25. Pin Retaining Ring

NOTES:

Figure 24. Auxiliary Switch

(12) Pin Retaining Rings

Pin retaining rings, such as those shown in Figure 25,
are used in a number of places throughout the circuit
breaker to retain pins and shafts.
REUSE OF THIS TYPE RETAINING RING IS NOT REC-
OMMENDED. The retaining rings are removed by squeez-
ing the removal ears together using standard pliers. To
install a new retaining ring, insert it into the groove and
squeeze the installation ears to within 1/16" of each other.
See Figure 25.

POWELL ELECTRICAL MANUFACTURING COMPANY, HOUSTON, TEXAS, USA 23

Courtesy of NationalSwitchgear.com
 POWELL ELECTRICAL MANUFACTURING COMPANY
•
8550 MOSLEY DRIVE HOUSTON, TEXAS 77075 USA
PHONE (713) 944-6900 • FAX (713) 947-4453

COPYRIGHT ® 1- 93 Printed in U.S.A.

Courtesy of NationalSwitchgear.com