01 4ib 60305

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Instruction Bulletin - 01.4IB.60305

PowlVac® CDR & GCB Series 4
Vacuum Circuit Breakers
5kV & 15kV - 1200A, 2000A, & 3000A - 25kA, 36kA, 50kA, & 63kA
PowlVac® CDR & GCB Series 4 Vacuum Circuit Breakers 01.4IB.60305
Contact Information
Powell Electrical Systems, Inc.

powellind.com
info@powellind.com
Service Division
PO Box 12818
Houston, Texas 77217-2818
Tel: 713.944.6900
Fax: 713.948.4569
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01.4IB.60305
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
NOTICE is used to address practices not related
to personal injury.
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01.4IB.60305
Contents
Ch 1 General Information..................................................................................................1
A. Scope.................................................................................................................................................................2
B. Purpose..............................................................................................................................................................2
C. Instruction Bulletins Available Electronically. ....................................................................................................3
D. Associated Bulletins...........................................................................................................................................3
Ch 2 Safety.........................................................................................................................4
A. Safe Work Condition..........................................................................................................................................4
B. Safety Guidelines................................................................................................................................................4
C. General. ............................................................................................................................................................5
D. Specific...............................................................................................................................................................5
E. X-Rays...............................................................................................................................................................6
F. Safety Labels......................................................................................................................................................6
Ch 3 Equipment Description..............................................................................................7
A. General. ............................................................................................................................................................7
B. The Stored Energy Mechanism.............................................................................................................................7
1) Mechanical Description........................................................................................................................................................... 7
2) Electrical Description..............................................................................................................................................................19
C. Racking Mechanism.......................................................................................................................................... 20
1) Breaker Position Indicator.....................................................................................................................................................20
2). Interlocking...............................................................................................................................................................................20
D. Circuit Breaker Compartment Interfaces............................................................................................................ 22
1) Primary Disconnecting Devices...........................................................................................................................................22
2) Secondary Disconnecting Devices......................................................................................................................................22
3) MOC (Mechanism Operated Cell Switch) Actuator.........................................................................................................22
4) TOC (Truck Operated Cell Switch) Actuator......................................................................................................................22
5) Ground Connection................................................................................................................................................................22
6) Shutter Rollers..........................................................................................................................................................................23
7) Anti-Rollout Latch...................................................................................................................................................................23
E. Vacuum Interrupters........................................................................................................................................ 23
F. Vacuum Interrupter Connection........................................................................................................................ 23
1) 25kA, 36kA, & 50kA Rated Circuit Breakers.......................................................................................................................23
2) 63kA Rated Circuit Breakers..................................................................................................................................................23
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Contents
Ch 4 Installation..............................................................................................................24
A. Receiving......................................................................................................................................................... 24
B. Handling......................................................................................................................................................... 24
C. Storage. ......................................................................................................................................................... 25
D. Placing the Circuit Breaker Into Service. ........................................................................................................... 26
1) High Voltage Insulation Integrity........................................................................................................................................26
2) Vacuum Integrity.....................................................................................................................................................................27
3) Control Voltage Insulation Integrity...................................................................................................................................28
4) Mechanical Operation Check...............................................................................................................................................29
5) Electrical Operation Check....................................................................................................................................................30
E. Inserting the Circuit Breaker Into the Circuit Breaker Compartment. ................................................................... 30
1) Prior to Inserting the Circuit Breaker into the Circuit Breaker Compartment...........................................................31
2) Inserting the Circuit Breaker to the Test/Disconnected Position..................................................................................32
3) Inserting the Circuit Breaker to the Connected Position................................................................................................33
F. Removing the Circuit Breaker From the Circuit Breaker Compartment.................................................................. 35
1) Removing the Circuit Breaker from the Connected to the Test/Disconnected Position.........................................35
2) Removing the Circuit Breaker from the Test/Disconnected Position out of the
Circuit Breaker Compartment..............................................................................................................................................36
G. Electric Remote Racking................................................................................................................................... 36
Ch 5 Maintenance............................................................................................................37
A. General Description......................................................................................................................................... 37
1) Introduction..............................................................................................................................................................................37
2) Inspection and Cleaning.......................................................................................................................................................38
B. Mechanism Area.............................................................................................................................................. 38
1) Mechanical Operation...........................................................................................................................................................38
2) Lubrication................................................................................................................................................................................39
3) Closing Spring Removal.........................................................................................................................................................43
4) Slow Closing of Mechanism..................................................................................................................................................44
5) Mechanism Adjustments.......................................................................................................................................................44
6) Electrical Operation................................................................................................................................................................49
C. Vacuum Interrupter and Contact Area.............................................................................................................. 49
1) Vacuum Interrupter and Contact Erosion.........................................................................................................................49
2) Vacuum Integrity.....................................................................................................................................................................49
3) Mechanical Adjustment of Vacuum Interrupters............................................................................................................50
D. Optional Maintenance Procedures.................................................................................................................... 50
1) High Potential Tests................................................................................................................................................................50
2) Timing........................................................................................................................................................................................50
3) Primary Resistance Check.....................................................................................................................................................51
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01.4IB.60305
Contents
Ch 6 Recommended Renewal Parts and Replacement Procedures................................52
A. Ordering Instructions...................................................................................................................................... 52
B. Recommended Renewal Parts............................................................................................................................ 52
C. Replacement Procedures. ................................................................................................................................. 52
1) Vacuum Interrupter Assembly..............................................................................................................................................53
2) Sliding Contact Finger Assembly (for circuit breaker rated up to 50kA only)...........................................................53
3) Closing Coil Assembly............................................................................................................................................................53
4) Primary Shunt Trip Coil Assembly.......................................................................................................................................53
5) Secondary Shunt Trip Coil Assembly..................................................................................................................................53
6) Undervoltage Device Assembly (UV)..................................................................................................................................53
7) Charging Motor Assembly....................................................................................................................................................53
8) Anti-Pump Relay Assembly...................................................................................................................................................54
9) Latch Check Switch.................................................................................................................................................................54
10) Motor Cutoff Switch Assembly.............................................................................................................................................54
11) Auxiliary Switch.......................................................................................................................................................................54
12) Ground Connection Assembly.............................................................................................................................................54
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Figures
Figure 1 PowlVac® CDR & GCB Series 4 Circuit Breaker Front View with Cover............8
Figure 2 PowlVac® CDR Series 4 Circuit Breaker Front View without Cover
(up to 50kA)......................................................................................................9
Figure 3 PowlVac® CDR & GCB Series 4 Circuit Breaker Front View without Cover
(63kA).............................................................................................................10
Figure 4 PowlVac CDR Series 4 Circuit Breaker Rear View (up to 50kA shown)..........11
Figure 5 Primary Current Close-Ups............................................................................12
Figure 6 Cam and Fundamental Linkage Positions....................................................14
Figure 7 Mechanism and Trip Linkages.......................................................................15
Figure 8 Operation Sequence......................................................................................17
Figure 9 Typical Control Scheme.................................................................................18
Figure 10 Closed Door Racking Mechanism and Interlock...........................................21
Figure 11 Circuit Breaker in Shipping Carton................................................................24
Figure 12 Circuit Breaker with Shipping Bracket..........................................................24
Figure 13 Circuit Breaker on Crane................................................................................25
Figure 14 Secondary Disconnect Override Device........................................................29
Figure 15 Secondary Disconnecting Device..................................................................33
Figure 16 Racking Mechanism Retainer Assembly.......................................................33
Figure 17 Circuit Breaker in Test Position......................................................................33
Figure 18 Accessing the Racking Drive Shaft Extension...............................................34
Figure 19 Racking the Circuit Breaker...........................................................................35
Figure 20 Anti-Rollout Latch..........................................................................................36
Figure 21 Lubrication.....................................................................................................41
Figure 22 Lubrication (cont)..........................................................................................42
Figure 23 Main Closing Spring Assembly Compressed for Removal............................43
Figure 24 Main Closing Spring Assembly Installed......................................................43
Figure 25 Primary Trip Prop Adjustment.......................................................................45
Figure 26 Feeler Gauge..................................................................................................46
Figure 27 Latch Check Switch Adjustment....................................................................48
Figure 28 Primary Current Path.....................................................................................56
Figure 29 Control Devices..............................................................................................58
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01.4IB.60305
Tables
Table A Field Dielectric Test Values...................................................................................26

Table B Lubrication...........................................................................................................40
Table C Timing...................................................................................................................50
Table D Primary Resistance..............................................................................................51
Table E Primary Current Path...........................................................................................55
Table F Control Devices.....................................................................................................57
Table G Miscellaneous Parts.............................................................................................59
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01.4IB.60305
Ch 1 General Information
! WARNING
The equipment described in this document may contain high voltages and currents which can
cause death or serious injury.
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
Prior to adjustments, servicing, maintenance, or any act requiring the operator to make physical
contact with the equipment, the power source must be disconnected and the equipment grounded.
Failure to do so may result in death or serious injury.
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

A. Scope The illustrations contained in this document

may not represent the exact construction
The information in this instruction bulletin details of the PowlVac CDR or GCB Series 4
describes the following PowlVac® CDR (Closed vacuum circuit breakers. The illustrations
Door Racking) and GCB (Generator Circuit in this document are provided as general
Breaker) Series 4 vacuum circuit breakers: information to aid in showing component
locations.
• 05PV36CDR 1200, 2000, & 3000A
• 05PV50CDR 1200, 2000, & 3000A All illustrations and photos are shown using
deenergized equipment.
• 05PV63CDR 1200, 2000, & 3000A
• 05PV63GCB 1200, 2000, & 3000A
• 15PV25CDR 1200, 2000, & 3000A ! WARNING
• 15PV36CDR 1200, 2000, & 3000A
Follow the appropriate safety precautions
• 15PV50CDR 1200, 2000, & 3000A
while handling any of the equipment. Failure
• 15PV63CDR 1200, 2000, & 3000A to do so may result in death or serious injury.
• 15PV63GCB 1200, 2000, & 3000A
B. Purpose To the extent required, the products described

herein meet the applicable ANSI, IEEE, and
The information in this instruction bulletin NEMA Standards; however, no such assurance
is intended to provide details required to is given with respect to local codes and
properly install, operate, and maintain the ordinances which may vary greatly.
PowlVac CDR and GCB Series 4 vacuum circuit
breakers described in Ch 1 General Information,
A. Scope.
This instruction bulletin provides:
1. Safety guidelines
2. General descriptions of the operation and
maintenance of the PowlVac CDR and GCB
Series 4 vacuum circuit breakers
3. Instructions for installation and placing the
circuit breaker into service
4. Instructions for part replacement
5. Information for ordering renewal parts
6. Procedure for critical adjustments
7. Illustrations, photographs, and description
of the circuit breakers
2 Powered by Safety® General Information

01.4IB.60305
C. Instruction Bulletins Available Electronically D. Associated Bulletins
• 01.4IB.51000C PowlVac® Metal-Clad

NOTICE Switchgear 5kV & 15kV
• 01.4IB.51200C PowlVac-AR® Arc Resistant
Changes to the instruction bulletin may be Switchgear 5kV & 15kV
implemented at any time and without notice. • 01.4IB.51808A Vacuum Type Remote
Go to powellind.com to ensure use of the current Racking Device (51897G29)
instruction bulletin for Powell equipment. • 01.4IB.65220 Lifting Devices
For more information visit powellind.com.

To contact the Powell Service Division call
1.800.480.7273 or 713.944.6900, or email
info@powellservice.com.
For specific questions or comments pertaining

to this instruction bulletin email
documents@powellind.com with the IB number
in the subject line.
General Information Powered by Safety® 3

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 instruction bulletin and all other
and identification tags. associated documentation before uncrating
the circuit breakers.
2. After properly interrupting the load current,
OPEN the disconnecting device(s) for each Each user has the responsibility to instruct and
source. supervise all personnel associated with usage,
installation, operation, and maintenance of this
3. Wherever possible, visually verify that all equipment on all safety procedures.
blades of the disconnecting devices are
fully OPEN or that drawout type circuit Furthermore, each user has the responsibility
breakers are withdrawn to the fully of establishing a safety program for each type
disconnected position. of equipment encountered.
4. Apply lockout/tagout devices in accordance The circuit breaker described in this instruction
with a documented and established policy. bulletin is operated by a high-energy,
high-speed mechanism that is interlocked
5. Use an adequately rated voltage detector to provide specific operating sequences. It
to test each phase conductor or circuit part is mandatory that the following rules be
to verify they are deenergized. Test each observed to ensure the safety of personnel
phase conductor or circuit part both associated with usage, installation, operation,
phase-to-phase, and phase-to-ground. and maintenance of this circuit breaker.
Before and after each test, determine
that the voltage detector is operating The safety rules in this instruction bulletin are
satisfactorily. not intended to be a complete safety program.
The rules are intended to cover only some of the
Informational Note: See ANSI/ISA-61010-1 important aspects of personnel safety related
(82.02.01)/UL 61010-1, Safety Requirements to PowlVac® CDR & GCB Series 4 vacuum circuit
for Electrical Equipment for Measurement, breakers.
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.
4 Powered by Safety® Safety

01.4IB.60305
C. General These circuit breakers utilize stored energy

mechanisms. These mechanisms must be
1. Only supervised and qualified personnel serviced only by skilled and knowledgeable
trained in the usage, installation, operation, personnel capable of releasing each spring
and maintenance of a circuit breaker shall load in a controlled manner. Detailed
be allowed to work on this equipment. It is information regarding these mechanisms is
mandatory that the appropriate instruction found in this instruction bulletin.
bulletins, supplements, and service
advisories be studied, understood, and 4. DO NOT ATTEMPT TO CLOSE THE CIRCUIT
followed. BREAKER MANUALLY ON AN ENERGIZED
CIRCUIT.
2. Maintenance programs must be consistent
with both customer experience and 5. DO NOT USE AN OPEN CIRCUIT BREAKER
manufacturer’s recommendations, AS THE SOLE MEANS OF ISOLATING A
including service advisories and instruction HIGH VOLTAGE CIRCUIT. For complete
bulletin(s). A well planned and executed isolation, the circuit breaker shall be in
routine maintenance program is essential the disconnected position or shall be
for circuit breaker’s reliability and safety. withdrawn completely.
3. Service conditions and circuit breaker 6. ALL COMPONENTS SHALL BE

applications shall also be considered in the DISCONNECTED BY MEANS OF A VISIBLE
development of safety programs. Variables BREAK AND SECURELY GROUNDED FOR
include ambient temperature; humidity; SAFETY OF PERSONNEL PERFORMING
actual continuous current; thermal cycling; MAINTENANCE OPERATIONS ON THE
number of operations; interrupting duty; CIRCUIT BREAKERS.
and any adverse local conditions including
excessive dust, ash, corrosive atmosphere, 7. Interlocks are provided to ensure the
vermin and insect infestations. proper operating sequences of the circuit
breakers and for the safety of the user. If for
D. Specific any reason an interlock does not function
as described, do not make any adjustments,
1. DO NOT WORK ON AN ENERGIZED modification, or deform the parts. DO
CIRCUIT BREAKER. If work must be NOT FORCE THE PARTS INTO POSITION.
performed on a circuit breaker, remove it CONTACT POWELL FOR INSTRUCTIONS.
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.
Safety Powered by Safety® 5

E. X-Rays F. Safety Labels
When high voltage is applied across the The equipment described in this document
contacts of a vacuum interrupter, there is the has DANGER, WARNING, CAUTION, and
possibility of generation of X-rays. The intensity instruction labels attached to various locations.
of the X-radiation is dependent on the peak All equipment DANGER, WARNING, CAUTION,
voltage and the contact gap. At the normal and instruction labels shall be observed when
operating voltage for this type of equipment, the circuit breaker is handled, operated, or
the radiation levels are negligible. At the maintained.
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 NOTICE
front cover construction are between the test
personnel and the vacuum interrupters, and Warning and Caution labels are located in
that the test personnel be no closer than one various places. Do not remove or deface any
meter (3’) from the front of the circuit breaker. of these warning/caution labels.
THE CIRCUIT BREAKER SHALL BE EITHER
FULLY OPEN, OR FULLY CLOSED WHEN
MAKING HIGH POTENTIAL TESTS. DO NOT
TEST WITH CONTACTS PARTIALLY OPEN.
6 Powered by Safety® Safety

01.4IB.60305
Ch 3 Equipment Description circuit breaker between the test/disconnected

and connected positions. The racking
A. General mechanism provides the motion to
engage/disengage the primary disconnecting
devices and to open/close the shutters in
NOTICE metal-clad switchgear.
Powell is committed to continuous product B. The Stored Energy Mechanism

improvement.
1) Mechanical Description
It is possible that improvements occurred
between revisions to this document and The stored energy mechanism is located in
therefore, may not be described in these the front of the circuit breaker behind the
instructions. If the equipment does not front cover. The front cover is held in place
resemble the photographs and descriptions by ten (10) cover bolts (Figure 1, a) that
contained herein, contact Powell before may be removed, allowing access to the
attempting to perform any actions. stored energy mechanism and its interlocks,
auxiliary switches, racking mechanism, and
PowlVac® circuit breakers use sealed vacuum other control devices.
interrupters (Figure 4, f) to control the primary
circuit. The primary connections to the
associated metal-clad switchgear are made ! CAUTION
by parallel copper busbars terminating Prior to removing the front cover, ensure the
in multiple contact fingers of the primary circuit breaker is in the OPEN position and
disconnecting devices (Figure 4, c & g). The the main closing spring is fully discharged.
primary disconnecting devices, busbars, and Failure to do so may result in injury.
vacuum interrupter assemblies are supported
by insulators specifically designed for the
application. On the escutcheon of the stored energy
mechanism, there are two (2) indicators
The primary current path side of the circuit that show the various states of operation
breaker is considered the rear of the circuit of the mechanism and two (2) manual
breaker, while the side with the cover operators that will open/close the stored
containing the various indicators and manual energy mechanism. The circuit breaker
operators is considered the front of the nameplate (Figure 1, e) is also located on
circuit breaker. By removing the front cover, the mechanism escutcheon. If for any
the operating mechanisms of the circuit reason the escutcheon is removed from the
breaker are exposed. The stored energy circuit breaker, it shall be verified that the
mechanism assembly provides motion to each serial number contained on the nameplate
of the vacuum interrupters, moving contact matches the engraved serial number plate
assemblies through operating pushrods (Figure 4, q) permanently affixed to the
(Figure 5, h & p). In the same metal enclosed rear of the circuit breaker frame prior to
compartment as the stored energy mechanism installing the escutcheon.
is the circuit breaker racking mechanism and
interlocks which control the movement of the
Equipment Description Powered by Safety® 7

Figure 1 PowlVac® CDR & GCB Series 4 Circuit Breaker Front View with Cover
e f
g
h
i
j
k
m
l
n
o
p
q
a. Cover Bolts j. Handle

b. Circuit Breaker Monitor IR Window k. MOC Actuator
c. Front Cover l. Circuit Breaker Open/Closed Indicator
d. Breaker Position Indicator m. Secondary Disconnect Receptacle
e. Nameplate n. Secondary Disconnect Latch
f. Padlock Provision - Movable Arm o. Manual Close Operator
g. Racking Drive Shaft Extension p. Operations Counter
h. Manual Trip Operator q. Spring Charge Indicator
i. Manual Charging Crank
8 Powered by Safety® Equipment Description

01.4IB.60305
Figure 2 PowlVac® CDR Series 4 Circuit Breaker Front View without Cover (up to 50kA)
a
b
c
d
g f
i
j k
l
m
n
o
p
q
r
s
t
u v
w ae
x
y af
z
ab ag
aa
ah
ac
ad
a. Anti-Pump Relay l. Reset Spring w. Crank Arm

b. Circuit Breaker Monitor™ m. Camshaft x. Ratchet Wheel
(Optional) n. Main Closing Cam y. Pawl Lift Drive Plate
c. Opening Spring o. Auxiliary Switch z. Close Latch Arm
d. Main Closing Spring p. Charging Motor aa. Close Latch Shaft
e. Connecting Rod q. Latch Check Switch ab. Drive Pawl
f. Racking Drive Shaft Extension r. Secondary Trip Prop Adjusting Screw ac. Closing Coil
g. Shock Absorber (Dashpot) s. Jackshaft ad. Pawl Support Arm
h. Primary Shunt Trip Coil t. Holding Pawl Support Arm ae. Motor Cutoff Cam
i. Secondary Trip Prop u. Crank Pin af. Close Bar Adjusting Screw
j. MOC Actuator v. Holding Pawl Adjusting Eccentric ag. Charging Motor Drive Shaft
k. Main Cam Roller ah. Motor Cutoff Switch

Figure 3 PowlVac® CDR & GCB Series 4 Circuit Breaker Front View without Cover (63kA)
a
b
c
d
e
f
g h
i
j
k
l
m
n
o
p
q
r
s
t
u
v w
x af
y
z ag
aa
ac ah
ab
ai
ad
ae
a. Anti-Pump Relay l. Main Cam Roller x. Crank Arm

b. Circuit Breaker Monitor™ m. Reset Spring y. Ratchet Wheel
(Optional) n. Camshaft z. Pawl Lift Drive Plate
c. Anti-Bellows Spring o. Main Closing Cam aa. Close Latch Arm
d. Main Closing Spring p. Auxiliary Switch ab. Close Latch Shaft
e. Connecting Rod q. Charging Motor ac. Drive Pawl
f. Shock Absorber (Dashpot) r. Latch Check Switch ad. Closing Coil
g. Anti-Bellows Spring s. Secondary Trip Prop Adjusting Screw ae. Pawl Support Arm
h. Racking Drive Shaft Extension t. Jackshaft af. Motor Cutoff Cam
i. Primary Shunt Trip Coil u. Holding Pawl Support Arm ag. Close Bar Adjusting Screw
j. Secondary Trip Prop v. Crank Pin ah. Charging Motor Drive Shaft
k. MOC Actuator w. Holding Pawl Adjusting Eccentric ai. Motor Cutoff Switch

01.4IB.60305
Figure 4 PowlVac CDR Series 4 Circuit Breaker Rear View (up to 50kA shown)
a
b
c
d
e
h
i
j
k
l
p
m
n
q
o
a. TOC Actuator J. Wheel

b. Main Insulator (Wishbone) k. Crank Arm Roller
c. Upper Primary Disconnecting Device l. Racking Crank Arm
d. Support Strut m. Racking Shaft
e. Insulating Pole Support n. Worm Gear
f. Vacuum Interrupter o. Racking Drive Shaft
g. Lower Primary Disconnecting Device p. Ground Connection
h. Anti-Rollout Latch q. Serial Number Plate
i. Frame

Figure 5 Primary Current Close-Ups
a
i
b j
c
d k l
e o m
f
g p n
h
Up to 50kA 63kA Only
a. Lower Vacuum Interrupter Casting i. Lower Vacuum Interrupter Casting

b. Operating Pin j. Operating Pin
c. Bell Crank k. Bell Crank
d. Lock Nut l. Lock Nut
e. Spring Yoke m. Spring Yoke
f. Jackshaft Pin n. Contact Loading Spring
g. Contact Loading Spring o. Jackshaft Pin
h. Operating Pushrod p. Operating Pushrod

01.4IB.60305
The mechanism employed in the circuit breaker is a stored energy system which uses a charging
motor to compress the main closing spring. During the closing operation the energy stored in
the main closing spring is released. This allows the mechanism to close the vacuum interrupter
contacts, compress the contact loading springs, charge the opening springs, extend the
anti-bellows springs (63kA only) (Figure 3, c), and overcome frictional forces. When the circuit
breaker is opened, the energy stored in the opening and contact loading springs is released, and
the vacuum interrupter contacts are opened.
The charging motor (Figure 2, p), located on the bottom right of the base pan, is assembled to
the circuit breaker by a bracket that is bolted to the base pan. The charging motor drive shaft
inserts into the eccentric drive shaft. The eccentric drive shaft is supported by needle roller
bearings in the mechanism frame side sheets and transmits the motor torque to the left side of
the mechanism.
When the charging motor is energized, the eccentric drive shaft rotates and causes the pawl
support arms to pivot about the camshaft (Figure 2, m). The drive pawl, which is supported by
the arms, engages with the ratchet wheel and drives the ratchet wheel one tooth at a time. To
prevent backwards motion of the ratchet, a spring-loaded holding pawl is used to latch the
ratchet wheel after each advance from the drive pawl.
To ensure correct synchronization of the drive and holding pawl, the position of the holding pawl
support arms are adjustable by the holding pawl adjusting eccentric (Figure 2, v) located to the
left front of the mechanism. When the mechanism is operated manually, the top pawl becomes
the drive pawl and the bottom pawl becomes the holding pawl.
The ratchet wheel (Figure 2, x) has projections from its side faces which engage the drive plates as
it rotates. These drive plates are attached to the camshaft, thus causing the camshaft to rotate.
Attached to the ends of the camshaft are crank arms (Figure 2, w). The crank pins
(Figure 2, u) on the crank arms point outward. The crank arms engage the bottom ends of the
connecting rods (Figure 2, e). The pins that project from the spring yoke, which straddles the
main closing spring, engage the top ends of the connecting rods. As the camshaft rotates the
connecting rods will pull the spring yoke downward, compressing the main closing spring.
The ratchet wheel drives the camshaft 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 camshaft. At the same time, the pawls are
uncoupled from the ratchet wheel by the pawl lift drive plate (Figure 2, y) and the motor cutoff
switch is operated. The motor cutoff switch (Figure 2, ah), located to the right of the mechanism,
is operated by the spring charge indicator and motor cutoff cam (Figure 2, ae). The spring charge
indicator (Figure 1, q) will display that the mechanism is charged. The camshaft would continue
to rotate, except that it is restrained by the close latch arm (Figure 2, z) engaging against the close
latch shaft (Figure 2, aa). The main closing cam, located between the mechanism side sheets, is
now in a position where the fundamental linkage can move to the reset position.

Figure 6 Cam and Fundamental Linkage Positions
a) Breaker Open - Spring Charged - Links Reset b) Breaker Closed - Spring Discharged
c) Breaker Open - Spring Discharged d) Breaker Closed - Spring Charged

01.4IB.60305
Figure 7 Mechanism and Trip Linkages
a
m
k
b
c l
e j
f d
g
n
i
h
a. Secondary Trip Prop Adjusting Screw
b. Secondary Trip Prop Shaft
c. Secondary Trip Prop
d. Secondary Linkage Roller
e. Main Cam Roller
f. Reset Spring
g. Camshaft
h. Main Closing Cam
i. Center Phase Operating Lever
j. Jackshaft
k. Primary Trip Prop Roller
l. Primary Trip Prop Adjusting Screw
m. Primary Trip Prop

The close latch, when released either by the an approximate 3 to 1 multiplication of

closing coil or the manual close operator, the contact loading spring force, enabling
allows the main closing spring to pull the a lower spring rate to be used. It also
crank arms upward thus rotating the main multiplies the contact movement by a
closing cam and driving the fundamental factor of approximately 3, so that the
linkage into the closed position. This mechanism linkages have relatively large
causes the main linkage to rotate the movements and are less critical.
jackshaft such that the operating pushrods
(Figure 5, h & p) are driven toward the In the cam and fundamental linkage
current carrying side of the circuit breaker. positions (Figure 4, b & d), the contact
loading springs and the main opening
Each operating pushrod assembly has a springs are both acting to compress the
recess at each end which encloses a contact three (3) main mechanism links. The
loading spring (Figure 5, g & n). At the end jackshaft extends from the left to the right
of this spring is a spring yoke side of the circuit breaker frame and is
(Figure 5, e & m), which connects with supported at the main circuit breaker frame
bell cranks. The spring yoke is restrained side sheets and by the mechanism side
by a lock nut on a stud which passes sheets. The outer operating levers on the
through the contact loading spring and jackshaft have connections to the circuit
is attached to the operating pushrod breaker opening springs (Figure 2, c).
assembly. The contact loading spring has
initial compression such that as soon as The fundamental linkage is restrained from
the vacuum interrupter contacts touch, movement by the secondary trip prop
the springs are preloaded to a value acting on the primary trip prop roller.
sufficient to resist vacuum interrupter A component of force tends to make the
contact separation under the highest primary trip prop rotate upward, but it
electromagnetic forces exerted by the rated is restrained by the secondary trip prop
short circuit current. Further movement face acting on the primary trip prop roller.
of the operating pushrod assembly The clearance between the primary trip
compresses the contact loading spring prop roller and the secondary trip prop
even more and produces a gap between is controlled by the primary trip prop
the face of the spring yoke and the lock adjusting screw. When the trip shaft is
nut. This “nut gap” is used to evaluate the rotated by the action of the manual trip
erosion of the vacuum interrupter contacts. operator or the primary shunt trip coil, the
secondary trip prop face moves downward
For each phase, bell cranks (Figure 5, c & k) and permits the primary trip prop to rotate
are located on the outside of the lower upward, thus permitting the main linkage
primary disconnecting devices and are to move upward and the jackshaft to
supported by bearings. Each bell crank rotate, opening the circuit breaker. The left
is connected to an operating pin, which jackshaft levers engage a shock absorber
passes through a slot in the lower primary (Figure 2, g), which controls the rebound
disconnecting devices and engage an of the vacuum interrupter contacts on an
extension to the vacuum interrupter opening operation. An extension of the
assembly thus moving the vacuum jackshaft projects through the left circuit
interrupter contact. The bell cranks give breaker side sheet and operates the MOC
actuator (Figure 2, j).

01.4IB.60305
Figure 8 Operation Sequence
Secondary
Disconnect
Makes
Motor “M” Green Light

Energized Energized
Close Spring
Charged
LS LS LS LS LCS
Makes Breaks Breaks Makes Makes
White Light Motor “M” “Y” Circuit

Energized Deenergized Disabled
Close Control
“CS/C” Makes
Close Coil “CC”

Energized
Close Spring
Discharged
LS LS LS LS 52/b
Breaks Makes Breaks Makes Breaks VCB Closed
White Light Motor “M” Prevents “Y” Coil Close Coil “CC”
Deenergized Energized Close Coil Energized Deenergized
Energization 52/b 52/a
Before Breaks Makes
Spring is “Y” Contact
Close Spring Fully Charged Makes
Charged Green Light
Deenergized
“Y” Coil Trip Circuit Red Light
“Seals In” Set Up Energized
LS LS LS LS
Release Close
Makes Breaks Breaks Makes Control Switch
“CS/C” Breaks
White Light Motor “M”
Energized Deenergized
“Y” Coil
Deenergized
“Y” Contact
Breaks
Prevents
Pumping
if VCB Trips
Before Control
Switch is
Released

Figure 9 Typical Control Scheme
(optional, but no UV) (optional, but no TC2) (ARM/G only)
CLOSE TRIP1 TRIP2
1 3 5 7
9 11 28 12 18 13 25 21 26 23
ARM/G ONLY NON-ARM/G

11
11
7
23
ER
11
R
19
21
52
R
9 3 21 11
13
b 52 52 52 52
11 20 a b a b
7 CBM 10 4 22 12
LS
M2
9
J Y CBM 1 13 M2
4 1 52 52
TO RATED CONTROL POWER
8
4
6
7 a CBM a ER
2 14 RM1
10
Y1
RM1
(TYPICAL)
18
9
1 2 4 6 8
T1
T2
C RM 125VDC
28
26
12
2
LCS
NO NC 5 17
52 52 15 19 29 31
CBM a a
E
8 6 18
E
J
LS
15
19
F
COMM (FUTURE)
COMM (FUTURE)
CBM 15 23
52
F
1 52
9 7 b a
16 24
LS
24
b
25
20
M1
16
CBM
M1
5
1 A 1 12 1 1 1
M Y CC LS TC1 TC2 UV 16 20 30 32
CBM CBM CBM
2 B 2 K 2 2 2
2 3 6
Secondary Disconnect
22
27
17
14
10
HE SENSOR TO CBM HE
17 10 14 22 27 24
1 24
10 17
2 25
DEVICE IDs 3
11 18
26
LS = SPRING CHARGE LIMIT SWITCH (SHOWN W/SPRING DISCHARGED) 4 12 19 27

LCS = LATCH CHECK SWITCH (SHOWN W/SPRING DISCHARGED)
Y = ANTI-PUMP RELAY 5
13 20
28
TC = BREAKER TRIP COIL
CC = BREAKER CLOSE COIL 6 29
14 21
M = CHARGING MOTOR
7 30
52/a = BREAKER AUXILIARY CONTACT (NORMALLY OPEN)
52/b = BREAKER AUXILIARY CONTACT (NORMALLY CLOSED) 8
15 22
31
SD = BREAKER SECONDARY DISCONNECT ( )
TB = TERMINAL BLOCK 9 16 23 32
RM = RACKING MOTOR
UV = UNDERVOLTAGE TRIP COIL
ER = EMERGENCY RACKING ISOLATION SWITCH
CBM = CIRCUIT BREAKER MONITORING
(FRONT VIEW)

01.4IB.60305
With the standard electrical control c. Anti-Pump Relay

scheme, as soon as the main closing spring
is discharged on a closing operation, the The anti-pump relay (Figure 2, a)
charging motor is switched on to recharge provides a logic function for the control
the springs. This leaves the main closing circuit which prevents a continuous
cam in a position where a tripped linkage electrical close signal from causing the
can reset under the action of the reset circuit breaker to continuously
spring (Figure 2, l) and the primary and re-close after a trip signal. The
secondary trip props can fall into the anti-pump relay is located on the circuit
reset position. The reset spring stretches breaker frame, inside the circuit breaker
between an extension of the main cam to the right of the left opening spring
roller pin and a spring support pin located and is supported by two screws.
on the left mechanism side sheet. The
latch check switch (Figure 2, q), operated d. Operating Solenoids
by a lever on the trip shaft, will close as the
secondary trip prop reaches the fully reset Electrical operation of the circuit
position. breaker is accomplished using
operating solenoids.
2) Electrical Description
The closing coil (Figure 2, ac) is an
a. Charging Motor operating solenoid that is located at
the bottom center of the mechanism,
The function of the charging motor and is assembled to the circuit breaker
(Figure 2, p) is to compress the main base pan by bolts accessible from
closing spring of the stored energy underneath the circuit breaker.
mechanism, thus providing the
necessary energy to close the circuit The primary shunt trip coil
breaker. The charging motor, located is located at the top left side of the
at the bottom right of the base pan, mechanism, and is assembled to the
is assembled to the circuit breaker by lower frame channel by two bolts.
a bracket that is bolted to the circuit
breaker base pan. Either a secondary trip coil or an
undervoltage device may be furnished
b. Motor Cutoff Switch as an option. When furnished, either of
these devices will be located at the top
The motor cutoff switch right side of the mechanism, installed
(Figure 2, ah) provides an electrical on the lower frame channel. Only one
break in the control circuit supplying of these two operating solenoids may
the charging motor when the main be furnished on any one circuit breaker,
closing spring is fully charged and the as both devices are located in the same
stored energy mechanism is ready for space.
a closing operation. It is located at the
bottom right of the mechanism, and is
supported by a bracket which is bolted
to the circuit breaker base pan.

e. Control Circuit 1) Breaker Position Indicator
The typical electrical control scheme is The breaker position indicator

shown in Figure 9. (Figure 1, d) is visible through an opening
in the circuit breaker front cover. The
The sequence of operation for all indicator displays whether the circuit
control schemes is shown in breaker is in the connected or the
Figure 8. Circuit breaker mounted test/disconnected positions. When
auxiliary contacts not used in the the breaker position indicator displays
control circuit are brought out for “BREAKER CONNECTED”, and this is fully
control and indication functions. The visible in the aperture, the circuit breaker
metal-clad switchgear equipment is in the connected position. When the
may provide a circuit breaker MOC breaker position indicator displays
(Mechanism Operated Cell Switch) for “BREAKER TEST/DISCONNECTED”, and
additional contacts. this is fully visible in the aperture, the circuit
breaker is in the test/disconnected position.
C. Racking Mechanism In positions other than the connected and
test/disconnected positions, the breaker
The closed door racking mechanism consists position indicator does not display an
of a racking shaft (Figure 10, c) with racking indication.
crank arms (Figure 4, l) at each end, which
are supported by the frame side sheets. The Refer to Ch 4 Installation, E. Inserting the
racking shaft also supports a worm gear Circuit Breaker into the Circuit Breaker
assembly (Figure 10, b) at the right end just Compartment for more information.
inside the right side sheet. In addition, the
racking crank arms have rollers on the end, 2). Interlocking
which engage the vertical slots of the racking
hooks in the circuit breaker compartment. PowlVac circuit breakers are provided
Rotation of the racking crank arms will drive with several interlocks that operate in
the circuit breaker into or out of the connected conjunction with the circuit breaker
position. This action also operates the compartment to ensure the proper
compartment shutters. Bolts on the side sheets operation of the circuit breaker. Do
are the means of positive stop for the racking not attempt to modify or bypass these
crank arms rotation. interlocks, as they are necessary for the safe
operation of the circuit breaker.
The racking mechanism is the mechanical
assembly that facilitates moving the circuit The purpose of the interlocks is to ensure:
breaker between the breaker
test/disconnected and the connected positions • The circuit breaker cannot be moved
in the circuit breaker compartment. The from the test/disconnected to the
main racking mechanism components for the connected position unless the main
PowlVac® CDR & GCB Series 4 circuit breakers circuit breaker contacts are opened and
are shown and described in the following the secondary control circuitry from
sections: the compartment to the circuit breaker
is completed, and the circuit breaker

01.4IB.60305
cannot be removed from the connected Figure 10 Closed Door Racking Mechanism and
to the test/disconnected position unless Interlock
the main contacts are opened.
• The control circuits cannot be broken

when the circuit breaker is in the
connected position. a
b
c
• The circuit breaker cannot be removed
from the circuit breaker compartment
with the circuit breaker closed or with
the main closing spring charged. d
Closed door racking circuit breaker

interlocking is primarily achieved by means
of an interlock bar acting upon the racking
drive shaft, an interlock bar attached to the
secondary disconnect receptacle, and a
tripping linkage and roller under the frame
of the circuit breaker that interfaces with a. Interlock Cam
the circuit breaker compartment. b. Worm Gear
c. Racking Shaft
An interlock bar prevents the rotation of the d. Racking Drive Shaft Extension
racking drive shaft extension
(Figure 10, d) whenever the circuit breaker
Racking the circuit breaker in from the
is closed or the secondary disconnect plug
test/disconnected position to the
is removed. This prevents movement of
connected position also rotates the
the circuit breaker when the circuit breaker
interlock cam (Figure 10, a) attached to the
is closed, or when the control circuits are
racking shaft. A cam follower, attached to a
disconnected.
lever pivoted on the circuit breaker frame,
drives a secondary disconnect locking
bar downward. The locking bar engages
a slot in the interlock bar attached to the
secondary disconnect plug. The cam profile
is arranged so that the lever can only be in
its upward position when the racking crank
arms are fully in the test/disconnected
position.
This ensures that the control circuits cannot

be disconnected in any position except the
test/disconnected position. The tripping
linkage and roller under the breaker frame
follow a cam mounted in the circuit breaker
compartment. The cam, in all intermediate
positions between the test/disconnected
and connected position, lifts the tripping 2) Secondary Disconnecting Devices

roller. Lifting the tripping roller actuates
the manual trip operator which holds the Control power is transferred from the
breaker in a trip free condition. The manual metal-clad switchgear to the circuit breaker
trip operator also actuates the latch check by means of the secondary disconnect
switch, thus blocking any electrical closing device. The secondary disconnect
signal. receptacle (Figure 1, m) is located on the
bottom right side of the circuit breaker.
The interlock bar attached to the secondary The secondary disconnect plug is attached
disconnect also actuates the secondary to the switchgear and is located on the
trip prop shaft and the close latch upon right side wall of the circuit breaker
removal from the circuit breaker. This final compartment. This arrangement allows the
interlock ensures that the circuit breaker is secondary connection to be visible in all
in the open position and the main spring positions of the circuit breaker.
is discharged prior to removal from the
compartment. 3) MOC (Mechanism Operated Cell Switch)
Actuator
D. Circuit Breaker Compartment Interfaces
The MOC, located in the switchgear, is
1) Primary Disconnecting Devices operated by a lever which extends from
the circuit breaker operating mechanism.
There are six primary disconnecting Movement of the MOC actuator
devices on the circuit breaker. They are (Figure 2, j) is directly related to the
arranged, two per phase, with the upper movement of the circuit breaker
device connected to the stationary end mechanism and contacts.
of the vacuum interrupter, and the lower
device connected to the moving end of the 4) TOC (Truck Operated Cell Switch) Actuator
vacuum interrupter assembly. Each primary
disconnecting device (Figure 4, c & g) has The TOC, located in the switchgear, is
multiple contact fingers which will mate operated by circuit breaker truck position.
with the stationary primary disconnecting To accomplish this, a TOC actuator
devices in the circuit breaker compartment. (Figure 4, a) is located on the right top of the
circuit breaker frame and it is designed to
strike the TOC as the circuit breaker travels
! CAUTION to the connected position.
Do not handle or move the circuit breaker by 5) Ground Connection

the primary disconnecting devices, as damage
may occur. The ground connection is an assembly
of spring-loaded fingers that effectively
grounds the circuit breaker frame as
it is inserted into the circuit breaker
compartment. The ground connection
(Figure 4, p) is located at the rear edge of the
floor pan of the circuit breaker between the

01.4IB.60305
center and right poles of the circuit breaker. F. Vacuum Interrupter Connection
An extension of the metal-clad switchgear
ground bus is secured to the circuit breaker 1) 25kA, 36kA, & 50kA Rated Circuit Breakers
compartment floor and engages the
ground connection as the circuit breaker Connection to the vacuum interrupter
is placed into the disconnected position. stems is made by means of copper contact
The ground connection system remains blocks. The top of the vacuum interrupter
engaged in all subsequent positions of the is threaded and a copper contact block is
circuit breaker until the circuit breaker is screwed onto this stem. The contact block
removed from the compartment. and the vertical connector bars are bolted
together and the vertical connector bars in
6) Shutter Rollers turn are assembled to the upper primary
disconnecting devices of the circuit breaker.
The circuit breaker travels between the Another copper contact block is clamped to
test/disconnected and connected positions the bottom or moving stem of the vacuum
as the crank arm rollers (Figure 4, k) interrupter. For circuit breakers rated up
engage the vertical slots of the racking to and including 50kA, the sliding contact
cams attached in the circuit breaker finger assembly makes contact with this
compartment. This action also drives block on the lower primary disconnecting
the compartment shutters to open/close devices. The multiple parallel paths of the
which allows the primary disconnecting sliding contact finger assembly keeps the
devices to connect/disconnect. Downward current density low.
movement of the crank arms rollers in the
slots will move the shutters to the fully 2) 63kA Rated Circuit Breakers
open position before the circuit breaker
travels towards the connected position. Connection to the vacuum interrupter
stems are made by means of copper
7) Anti-Rollout Latch vacuum interrupter castings. The top of the
vacuum interrupter is fixed and a copper
The circuit breaker is equipped with an vacuum interrupter casting is fastened to
anti-rollout latch (Figure 4, h) which the stem. The upper primary disconnecting
prevents inadvertent removal from the devices are then assembled to the vacuum
circuit breaker compartment by engaging a interrupter casting. Another copper
block in the circuit breaker compartment. vacuum interrupter casting with primary
disconnecting device is mounted to the
E. Vacuum Interrupters bottom or moving stem of the vacuum
interrupter. The multi-contact bands inside
PowlVac® circuit breakers utilize sealed vacuum the lower vacuum interrupter casting make
interrupters to control the primary circuit. contact with this block and the moving
Some vacuum interrupters appear to be stem of the vacuum interrupter. The
identical in size and shape externally, but types multiple parallel paths of the multi-contact
vary in rating due to the differences in their bands keep the current density low.
internal construction. Refer to Table E, Primary
Current Path for a listing of vacuum interrupters
used in PowlVac CDR and GCB Series 4 circuit
breakers.

Ch 4 Installation When a metal-clad switchgear assembly is

installed in a Power Control Room, a circuit
A. Receiving breaker housed in the lower circuit breaker
compartment may be shipped installed in the
When the circuit breaker is received check for equipment. In these cases, the circuit breaker
any sign of damage. If damage is found or will be in the test/disconnected position and
suspected, file all claims immediately with the it will be bolted to the compartment floor by
transportation company and notify the nearest use of a shipping bracket (Figure 12, a). The
Powell representative. horizontal leg of the bracket is bolted to the
compartment floor and the vertical leg is
Approximate size and weight for shipping a bolted to the front of the circuit breaker using
PowlVac® CDR & GCB Series 4 vacuum circuit the lower cover bolts. Remove these bolts,
breakers on a pallet: discard the shipping angle, and then replace
the cover bolts.
• Size: 42” width x 42” depth x 47” height
• Weight: 675 lbs Figure 12 Circuit Breaker with Shipping Bracket
Figure 11 shows the circuit breaker enclosed

in the carton used for shipment. The carton is
attached to the shipping pallet by metal bands.
Remove these bands and lift the carton from
the pallet so that the circuit breaker is visible.
The circuit breaker is attached to the pallet
by metal shipping brackets. When these are
removed the circuit breaker may be removed
a
from the shipping pallet. Refer to
Ch 4 Installation, B. Handling for more
information.
a. Shipping Bracket
Figure 11 Circuit Breaker in Shipping Carton
B. Handling
After the circuit breaker has been removed

from its shipping pallet it may be rolled on
its own wheels on a level surface. This is the
preferred way of handling the circuit breaker.
When rolling the circuit breaker it should be
pushed and steered by the steel frame or the
front cover.
! CAUTION
Do not handle or move the circuit breaker by
the primary disconnecting devices, as damage
may occur.
24 Powered by Safety® Installation

01.4IB.60305
If necessary, the circuit breaker can be moved the equipment is in transit and storage, these
by a fork lift truck or an overhead crane. design considerations are not fully functional.
When using a fork lift truck take care to avoid In general, the following measures must be
components located under the circuit breaker considered.
floor pan. The forks on the truck should be set
for a dimension over the forks of 28 inches. 1. Equipment designed for indoor installation
The forks should then ride under the wheel must be stored indoors in a climate
axles. The circuit breaker can also be lifted by controlled environment to prevent
an overhead crane using the two lifting points condensation of moisture. Exposure to rain
which have been provided for hooks at the top and the elements, even for a short period,
of the circuit breaker frame side sheets can permanently damage the equipment.
(Figure 13). Space heaters within the equipment should
be energized, if so equipped. Humidity
Figure 13 Circuit Breaker on Crane controlling desiccant materials should
be utilized when space heaters are not
provided or cannot be energized. The
temperature should be kept above 33°F/1°C
and below 140°F/60°C. The relative
humidity should be kept below 60% or a
dew point of 15°C/59°F. The equipment
should be stored in such a manner as
to leave all doors and panels accessible
for inspection. The equipment must be
inspected on a routine basis to assure
operational integrity.
2. Equipment designed for outdoor exposure
may be stored either in indoor or outdoor
storage locations. The equipment must
be protected from airborne external
contaminates if stored outdoors. Outdoor
storage will also require additional care
to maintain temporary covers over
the openings and shipping splits. The
equipment must be provided with control
power to facilitate the energization of
space heaters, as well as other temperature
and humidity controlling equipment. The
C. Storage temperature should be kept above freezing
(>33°F/1°C) and below (<140°F/60°C). The
Shipping and storage of electrical equipment relative humidity should be kept below
requires measures to prevent the deterioration 60% or a dew point of 15°C/59°F. The
of the apparatus over a long unused period. equipment should be stored in such a
The mechanical and dielectric integrity must manner as to leave all doors and panels
be protected. Electrical equipment is designed accessible for inspection. The equipment
for use in a variety of environments. When must be inspected on a routine basis to
assure its integrity.
Installation Powered by Safety® 25

3. The auxiliary control devices, ship loose be used to detect any weakening of the
material and protective relays must also insulation system from one check period to
be protected. This includes items such as the next.
battery chargers, UPS systems, lighting,
installation hardware and air conditioning. To check insulation integrity, the AC high
If prolonged storage is anticipated, potential test described below is strongly
humidity controlling desiccant materials recommended. DC testing is not the
should be utilized. Desiccant packets preferred method, however, values are
should be installed in all compartments and provided due to the availability of DC test
packing containers. sets.
D. Placing the Circuit Breaker Into Service
Before shipment from the factory, all circuit

! CAUTION
breaker functions are thoroughly checked. The If DC high potential testing is performed, the DC
user must verify functions after receipt. Powell high potential test machine must not produce
recommends that the tests be performed in the instantaneous peak voltages exceeding 50kV.
sequence listed below:
1) High Voltage Insulation Integrity The circuit breaker insulation should be

tested with the circuit breaker vacuum
interrupter contacts in the closed position.
! CAUTION
Test each pole of the circuit breaker
High voltages across the open gaps of the separately, with the other 2 poles and
vacuum interrupter can produce radiation. the frame grounded. Perform the field
Personnel should stand at least one meter dielectric test described in ANSI Standard
away from the circuit breaker with the covers in C37.20.2, at the voltage level appropriate
place when conducting high voltage test. Test for the equipment.
voltages should not exceed 14.25kVAC
(20.1kVDC) for circuit breaker with a rated Table A Field Dielectric Test Values
maximum voltage of 4.76kV, and 27kVAC Rated Maximum Voltage Power Frequency
(38kVDC) for circuit breaker with a rated (kV rms) Withstand (kV rms)
maximum voltage of 15kV. 4.76 14.25
8.25 27
The primary circuit insulation on the circuit 15 27
breaker may be checked phase-to-phase
and phase-to-ground using a 2500V This test will have checked all of the
insulation resistance tester. Since definite primary phase-to-ground and
limits cannot be given for satisfactory phase-to-phase insulation.
insulation values when testing with an
insulation resistance tester, a record should
be kept of the insulation resistance tester
readings as well as the temperature and
humidity readings. This record should

01.4IB.60305
2) Vacuum Integrity
! CAUTION
After the high potential is removed, an ! CAUTION
electrical charge may be retained by the
vacuum interrupters. Failure to discharge this Applying abnormally high voltage across
residual electrostatic charge could result in an a pair of contacts in vacuum may produce
electrical shock. All six primary disconnecting x-radiation. The radiation may increase with
devices of the circuit breaker and the metallic increased voltage and/or decreased contact
mid band ring if present should be grounded spacing.
and remain grounded for at least one minute
to reduce this electrical charge before coming X-radiation produced during this test with
in to contact with the primary circuit. the voltage specified in Table A and normal
contact spacing is extremely low and well
below the maximum permitted by standards.
CAUTION Do not apply voltage that is higher than the

recommended value. Do not use contact
Remove all grounding conductors applied for
separation that is less than the normal open
this test before placing the circuit breaker back
position separation of the circuit breaker
into service.
contacts.
The tests described in this section are the

Powell recommends AC testing for reliable
only tests required to ascertain insulation
verification of vacuum integrity. All
integrity. Because of the design of the
PowlVac® 5kV and 15kV circuit breakers
PowlVac® insulation system, no valid data
shall be tested with a minimum of 25kVAC
can be obtained utilizing other types of
applied across fully open contacts for 10
high voltage insulation tests.
seconds. No dielectric breakdown during
the test period constitutes a successful test.
Note: This test does not replace the AC

high potential testing (Hipot) used to
determine “High voltage insulation
integrity.” See Ch 4 Installation,
D. Placing the Circuit Breaker into
Service, 1) High Voltage Insulation
Integrity.
Powell offers a compact and lightweight

PowlVac Vacuum Integrity Tester
designed specifically for PowlVac circuit
breakers. If this device is used, refer to
the instruction bulletin provided with the
vacuum integrity tester.

Powell recognizes the widespread use

of DC hipot equipment in the field and ! CAUTION
the desire to use this equipment to verify
vacuum integrity. However, the capacitive If DC high potential testing (hipot) is required,
component of the vacuum interrupter the DC high potential test machine must
during DC testing may yield false negative not produce instantaneous peak voltages
test results, which are often misinterpreted exceeding 50kV.
as vacuum interrupter failure. When DC
testing is performed, a test set providing No attempt should be made to try to
a full wave rectified 50kVDC hipot voltage compare the condition of one vacuum
can be applied for 5 seconds as a interrupter with another, nor to correlate
“go - no go” test. the condition of any vacuum interrupter
with low values of DC leakage current.
Recording the leakage readings is not There is no significant correlation.
necessary, as a dielectric breakdown will
trip all portable DC hipot test sets. If a
DC test breakdown occurs, the test must
be repeated after reversing the DC high
! CAUTION
voltage test supply connection across the After the high potential is removed, an
vacuum interrupter. A vacuum interrupter electrical charge may be retained by the
should be questioned only if it has failed vacuum interrupters. Failure to discharge this
both tests. residual electrostatic charge could result in an
electrical shock. All six primary disconnecting
devices of the circuit breaker and the metallic
! CAUTION mid band ring if present should be grounded
and remain grounded for at least one minute to
When testing with DC, use a DC high potential
reduce this electrical charge before coming in
test (hipot) set with full wave rectification.
to contact with the primary circuit.
Many DC high potential test sets use
half-wave rectification. Do not use these
half-wave rectifiers. The capacitance of the 3) Control Voltage Insulation Integrity
vacuum interrupter in combination with
the leakage currents in the rectifiers and If the user wishes to check the insulation
its DC voltage measuring equipment may integrity of the control circuit, it may be
result in applying peak voltages as much as done with a 500V or 1000V insulation
three times the measured voltage. These resistance tester or with an AC high
abnormally high voltages may give a false potential tester. The AC high potential test
indication of a defective vacuum interrupter, should be made at 1125V, 50 or 60 Hz for
and may produce abnormal x-radiation. one minute. The charging motor must be
disconnected prior to testing the control
circuit. The charging motor itself may be
similarly tested at a voltage not to exceed
675V, 50 or 60 Hz. Be sure to remove any
test jumpers and reconnect the charging
motor when the tests are complete.

01.4IB.60305
Figure 14 Secondary Disconnect Override

CAUTION Device
Remove all grounding conductors applied

for this test before placing the circuit breaker
back into service.
4) Mechanical Operation Check
! CAUTION
Keep personnel, tools, and other objects
clear of mechanisms that are to be operated
or released. Failure to do so may result in
equipment damage and/or minor or moderate
injury.
The contacts of the vacuum interrupter

during normal operation cannot be closed
! CAUTION
unless the secondary disconnect plug is The MOC actuator is exposed when the circuit
inserted into the secondary disconnect breaker is outside the metal-clad switchgear
receptacle. To check the circuit breaker and can cause serious injury if the test
outside of the circuit breaker compartment, personnel or any object is in the travel path
it is necessary to simulate the connection during operation. Care should be taken to
of secondary disconnecting device by isolate the MOC side of the circuit breaker for
inserting the secondary disconnect these tests.
override device (Figure 14) in the secondary
disconnect receptacle. This device must be
removed after testing and before the circuit Push the manual close operator
breaker is inserted into the compartment. (Figure 1, o) inward and the circuit breaker
The mechanical operation of the circuit will close. The circuit breaker open/closed
breaker is checked by inserting the manual indicator located above the manual close
charging handle into the manual charging operator will now display
crank and pushing down until a metallic “BREAKER CLOSED”. Push the manual
click is heard. (This indicates that the trip operator (Figure 1, h) inward, which is
holding pawl has dropped into place on located at the top of the escutcheon and
the ratchet wheel). Lift the handle until the circuit breaker open/closed indicator
it is horizontal and then depress. The will now display “BREAKER OPEN”.
procedure is repeated until the spring
charge indicator indicates
“CLOSING SPRING CHARGED”. This
requires about 60 operations of the handle.
Remove the handle.

5) Electrical Operation Check First, remove the control fuses in the

compartment. Connect the jumper
To check the basic electrical operation cable to the secondary disconnect plug
of the circuit breaker, a circuit breaker in the compartment and to the circuit
test cabinet should be used. Connect breaker. Insert the fuses. The charging
the secondary disconnect from the motor will automatically charge the stored
test cabinet to the circuit breaker to be energy mechanism’s main closing springs.
tested. The test cabinet provides control Operation of the breaker control switch
voltage via a secondary disconnect plug on the front door of the compartment
to the circuit breaker and the appropriate will cause the circuit breaker to close. The
control switches to verify the close and circuitry is arranged to cause the charging
open functions of the circuit breaker. motor to operate again and charge the
Specialized versions of the test cabinet main closing spring. Operating the breaker
may also contain circuits for circuit control switch on the front door will cause
breakers equipped with dual shunt trip the circuit breaker to open.
coils, undervoltage devices, or other
options. With the secondary disconnect
plug installed in the circuit breaker under ! CAUTION
test, operate the power switch on the
test cabinet. The charging motor will Pole unit parts are energized at full circuit
automatically charge the stored energy voltage when the circuit breaker is in the
mechanism’s main closing springs. connected position. Prior to moving the
Operation of the control switch on the test circuit breaker into the connected position,
cabinet to the “close” position will cause the make sure that the main barrier assembly has
circuit breaker to close. been properly fastened in place. Failure to
do so may cause equipment damage and/or
The circuitry is arranged to cause the minor or moderate injury.
charging motor to operate again and
charge the main closing spring. Operating E. Inserting the Circuit Breaker Into the Circuit
the control switch on the test cabinet to Breaker Compartment
the “open” position will cause the circuit
breaker to open. Refer to the metal-clad switchgear instruction
bulletin and drawings produced specifically
Alternatively, a test jumper cable may be for the installed equipment for additional
used to electrically operate the circuit information and cautions before attempting
breaker using the control circuitry of the to insert the circuit breaker into the metal-clad
circuit breaker compartment. Caution switchgear equipment.
must be exercised if this option is chosen
to ensure that operation of the control
circuitry of the compartment used for NOTICE
test does not cause undesirable effects
or unintended operation of other To insert the circuit breaker into the upper
interconnected equipment such as compartment a lifting device must be used.
supervisory controls, SCADA, or automatic Refer to the Lifting Device instruction bulletin
transfer schemes. for details on how to insert a circuit breaker
into the upper compartment.

01.4IB.60305
lubrication procedures. If the primary

NOTICE disconnecting devices are damaged
make no attempt to repair. Contact
Be sure that the racking crank arms at the Powell for further information.
sides of the circuit breaker point in the
direction of the primary disconnecting devices Examine the circuit breaker
and the circuit breaker position indicator compartment to see that it is clean and
displays breaker test/disconnected. clear of debris that might interfere with
circuit breaker travel.
Each circuit breaker and circuit breaker
compartment is provided with interference
plates which are designed to ensure that no CAUTION
circuit breaker with less than the required Before inserting any circuit breaker into a
voltage, continuous current, or interrupting compartment, verify that the circuit breaker
current rating is placed in the incorrect circuit rating meets or exceeds the metal-clad
breaker compartment. If you attempt to insert switchgear rating.
an improperly rated circuit breaker into the
circuit breaker compartment, these plates will
interfere with each other and deter further
insertion. The interference will occur before CAUTION
the circuit breaker reaches the disconnected Before inserting a circuit breaker into
position. Do not attempt to force the circuit the circuit breaker compartment, be
breaker past the compartment interference sure that the indicator flag on the front
plate or remove the interference plates from cover of the circuit breaker displays
either the compartment or the circuit breaker. “BREAKER TEST/DISCONNECTED”.
Remove the incorrectly rated circuit breaker
and insert a properly rated circuit breaker into
the circuit breaker compartment.
NOTICE
1) Prior to Inserting the Circuit Breaker into the
The illustrations shown for all racking
Circuit Breaker Compartment
procedures are provided to show device
locations and are intended only as a guideline.
a. Check the Primary Disconnecting
These illustrations may not be representative
Devices and Circuit Breaker
of site specific safety practices for performing
Compartment
the procedure. Before attempting any racking
Examine the primary disconnecting procedure, review Chapter 2.
devices for any signs of damage and
contamination. Check to see that
none are bent out of alignment. If
contamination is found refer to
Ch 5 Maintenance, A. General
Description, 2) Inspection and Cleaning
and Ch 5 Maintenance, B. Mechanism
Area, 2) Lubrication for cleaning and

2) Inserting the Circuit Breaker to the

Test/Disconnected Position ! CAUTION
Before racking a circuit breaker in or out of the
NOTICE compartment, make sure that any position
interlocks are unlocked and in the position to
To insert the circuit breaker into the upper allow racking. If not, the racking mechanism
compartment a lifting device must be used. may be damaged.
Refer to the Lifting Device instruction bulletin
for details on how to insert a circuit breaker
into the upper compartment. a. Verify that the circuit breaker
open/closed indicator displays
“BREAKER OPEN” and if not, press the
manual trip operator to open the circuit
! CAUTION breaker.
b. To insert the circuit breaker into the
Prior to inserting the circuit breaker into the lower circuit breaker compartment,
circuit breaker compartment, make sure that open the compartment door and align
the control circuits are deenergized. the wheels with the floor pan channels
of the compartment. Verify that the
floor pan channels are free of debris
! CAUTION prior to inserting the circuit breaker.
c. Roll the circuit breaker into the
Use only the racking tools provided by Powell compartment until the racking crank
for inserting and removing the circuit breaker. arms make contact with the vertical
The use of other tools such as electric drills, slots in the compartment. The
impact drill, etc., may damage the racking anti-rollout latch on the lower right side
mechanism and render it inoperative. of the circuit breaker will engage the
block in the compartment, preventing
accidental removal of the circuit breaker
! CAUTION from the compartment.
Before inserting the circuit breaker into the Note: This is the Disconnected Position.
compartment, be sure that the racking crank
arms of the circuit breaker are in the fully d. Insert the circuit breaker compartment’s
withdrawn position, pointing towards the secondary disconnect plug
movable primary disconnects. Otherwise, the (Figure 15, c) into the circuit breaker
primary disconnects, shutters, or the racking secondary disconnect receptacle
mechanisms may be damaged. (Figure 15, b). While holding the plug
in the inserted position, move the
secondary disconnect latch
(Figure 15, a), from left to right until
it has engaged the housing of the
secondary disconnect plug.
e. For non-Arc Resistant switchgear only,
assemble the racking mechanism
retainer assembly (Figure 16) to the
01.4IB.60305
circuit breaker compartment and secure Figure 17 Circuit Breaker in Test Position
the racking drive shaft extension in
place by placing the shaft retainer
holder into the shaft retainer anchor,
then lock the racking drive shaft
extension in place using the wing nut.
Close and latch the circuit breaker
compartment door.
Note: This is the Test Position.
Figure 15 Secondary Disconnecting Device
a
b
3) Inserting the Circuit Breaker to the Connected
Position
c
d
NOTICE
To insert the circuit breaker into the upper
a. Secondary Disconnect Latch compartment a lifting device must be used.
b. Secondary Disconnect Receptacle Refer to the Lifting Device instruction bulletin
c. Secondary Disconnect Plug for details on how to insert a circuit breaker
d. Interlock Bar into the upper compartment.
Figure 16 Racking Mechanism Retainer

Assembly ! CAUTION
Prior to inserting the circuit breaker into the
circuit breaker compartment, make sure that
the control circuits are deenergized.

Figure 18 Accessing the Racking Drive Shaft

! CAUTION Extension
Use only the racking tools provided by Powell

for inserting and removing the circuit breaker.
The use of other tools such as electric drills,
impact drill, etc., may damage the racking
mechanism and render it inoperative.
! CAUTION
Before inserting the circuit breaker into the
compartment, be sure that the racking crank
arms of the circuit breaker are in the fully
withdrawn position, pointing towards the
movable primary disconnects. Otherwise, the
primary disconnects, shutters, or the racking
mechanisms may be damaged.
! CAUTION c. Turning the racking handle clockwise

will begin to rack the circuit breaker
Before racking a circuit breaker in or out of the into the compartment. When the circuit
compartment, make sure that any position breaker is racked into the compartment,
interlocks are unlocked and in the position the force needed to rotate the racking
to allow racking. Otherwise, the racking handle will be low at the beginning of
mechanism may be damaged. motion as the movement of the racking
crank arms is only opening the shutters.
a. Rotate the levering access (teardrop) Once the shutters are open, the circuit
flap (Figure 18) on the compartment breaker begins to move toward the
door 180° to gain access to the racking stationary primary disconnecting
drive shaft extension. devices. When the movable primary
b. Insert the racking handle onto the disconnecting devices of the circuit
racking drive shaft extension. breaker engage with the stationary
primary disconnecting devices of the
compartment, the force required to
rotate the racking handle will increase
appreciably. This force will decrease
as the primary disconnecting devices
spread and engage fully. Continuing
rotation of the racking handle will cause
the circuit breaker to travel further into
the compartment ensuring wipe or
overlap of the primary disconnecting

01.4IB.60305
devices. Continue racking until the F. Removing the Circuit Breaker From the Circuit
breaker position indicator Breaker Compartment
(Figure 1, d) displays “BREAKER
CONNECTED”. This will be
approximately 22 rotations from ! CAUTION
the starting point. When the circuit
breaker reaches the end of the racking Prior to removing the circuit breaker from the
travel, the operator will notice an circuit breaker compartment, make sure that
increased amount of force. If the the control circuits are deenergized.
operator continues to apply force, a
torque limiter on the racking handle
will produce a sharp clicking sound ! CAUTION
indicating the torque limit is reached at
35-ft-lb. Should the operator continue Prior to removing the circuit breaker from the
to apply force, the torque limiter will circuit breaker compartment, make sure the
continue to operate with no further circuit breaker is in the open position and all
buildup of torque on the circuit breaker springs are discharged.
racking mechanism.
d. Once the circuit breaker has reached the 1) Removing the Circuit Breaker from the
connected position, remove the racking Connected to the Test/Disconnected Position
handle, close the teardrop cover on the
compartment door, and operate the a. Verify that the circuit breaker
circuit breaker as required. open/closed indicator displays
“BREAKER OPEN”. If “CLOSED”, operate
Note: This is the Connected Position. the circuit breaker control switch to
open the circuit breaker.
Figure 19 Racking the Circuit Breaker b. Rotate the levering access (teardrop)
flap (Figure 18) on the compartment
door and place the racking handle
socket onto the racking drive shaft
extension.
c. Turn the racking handle
counterclockwise until the breaker
position indicator displays
“BREAKER TEST/DISCONNECTED”.
d. Remove the racking handle.
Note: This is the Test Position.

2) Removing the Circuit Breaker from the Figure 20 Anti-Rollout Latch

Test/Disconnected Position out of the Circuit
Breaker Compartment
! CAUTION
Prior to removing the circuit breaker from the
circuit breaker compartment, make sure that
the control circuits are deenergized.
! CAUTION
Prior to removing the circuit breaker from the
circuit breaker compartment, make sure the
circuit breaker is in the open position and all
springs are discharged.
G. Electric Remote Racking
a. Open the circuit breaker compartment
door. There is an alternative to the manual racking
b. Disassemble the racking mechanism procedures described above utilizing a motor
retainer assembly (Figure 16) from the driven mechanism and electric control,
racking drive shaft extension. allowing the user to perform the racking
c. Move the secondary disconnect latch function without being located in front of the
(Figure 15, a) to the left. This will circuit breaker compartment. The electric
unlock the secondary disconnect plug, remote racking device mounts onto the
allowing it to be removed. Remove the compartment door. Refer to the instruction
secondary disconnect plug. bulletin provided with the electric remote
racking device for the proper operational
instructions.
! CAUTION
Removal of the secondary disconnect plug will
trip a closed breaker and discharge the main
closing spring.
d. Press the anti-rollout latch (Figure 20) to

release the circuit breaker and pull the
circuit breaker out of the circuit breaker
compartment using the handles.

01.4IB.60305
Ch 5 Maintenance is known to have interrupted a fault current

at or near its rating, it is recommended
A. General Description that the circuit breaker be inspected and
the necessary maintenance be performed
as soon as practical. Some atmospheric
! CAUTION conditions such as extremes of dust,
moisture, or corrosive gases might indicate
Prior to beginning any maintenance inspection and maintenance at more
procedures, make certain that the control frequent intervals. Very clean and dry
circuits are deenergized and the circuit breaker conditions combined with low switching
is resting securely outside the circuit breaker duty will justify longer times between
compartment. Do not work on a closed circuit inspection and maintenance operations.
breaker or a circuit breaker with the main With experience, each user can set an
closing spring charged. inspection and maintenance schedule that
is best suited for use.
NOTICE If maintenance is performed at longer

time intervals than one year, the vacuum
Before attempting any maintenance work, integrity test should be performed each
it is important to study and fully understand time the circuit breaker is removed from
the safety practices outlined in Chapter 2 of the metal-clad switchgear for reasons other
this instruction bulletin. If there is any reason than scheduled circuit breaker maintenance
to believe there are any discrepancies in the if it has been more than one year since the
descriptions contained in this instruction last vacuum integrity test.
bulletin, or if they are deemed to be confusing
A permanent record of all maintenance
and/or not fully understood, contact Powell
work should be kept, the degree of detail
immediately.
depending upon the operating conditions.
The record will be a valuable reference for
1) Introduction subsequent maintenance work and for
station operation. It is also recommended
A regular maintenance schedule must that the record include reports of tests
be established to obtain the best service performed, the condition of circuit
and reliability from the circuit breaker. breakers, and any repairs or adjustments
PowlVac® circuit breakers are designed to that were performed. This record should
comply with industry standards requiring begin with tests performed at the time of
maintenance every 1000 or 2000 operations installation and energization, and all data
depending upon the rating of the circuit should be graphed as a function of time to
breaker, or once a year. ensure a proper maintenance cycle is being
scheduled.
Actual inspection and maintenance will
depend upon individual application Because of extensive quality control tests
conditions such as number of operations, made at the factory, the operations counter
magnitude of currents switched, desired on a new circuit breaker will normally
overall system reliability, and operating
environment. Any time the circuit breaker
Maintenance Powered by Safety® 37

register over one hundred operations. The water or a mild solvent such as denatured
reading of the operations counter should alcohol. Be sure that the circuit breaker
be recorded when the circuit breaker is dry before returning it to service. Do
is placed into service and when any not use any type of detergent to wash the
maintenance work is performed. surface of the insulators as detergent may
leave an electrically conducting residue on
2) Inspection and Cleaning the surface as it dries.
B. Mechanism Area
! CAUTION
When cleaning the circuit breaker insulating ! WARNING
supports and bus insulation, use only
denatured alcohol or isopropyl alcohol to When any maintenance procedure requires
remove foreign material. Failure to do so may the opening or closing of the circuit breaker
damage the dielectric and/or the mechanical or the charging of any of the stored energy
properties of the insulation. mechanism springs, exercise extreme caution
to make sure that all personnel, tools, and
other miscellaneous objects are kept well
Visually check the circuit breaker for loose
clear of the moving parts or the charged
or damaged parts. Tighten or replace
springs. Failure to do this may cause damage
loose or missing hardware. Any damaged
to the equipment or moderate/minor injury to
parts that will interfere with the normal
personnel.
operation of the circuit breaker should be
replaced. This inspection will be much
easier if the front cover and interphase 1) Mechanical Operation
barrier assembly are removed.
Remove the circuit breaker front cover
Clean the circuit breaker by removing any to expose the stored energy mechanism.
loose dust and dirt. Do not use compressed Make a careful visual inspection of the
air to clean the circuit breaker. This may mechanism for loose, damaged, or
result in loose dirt or grit being blown excessively worn parts.
into bearings or other critical parts, thus
causing excessive wear. Use a vacuum Note: If timing tests are performed as
cleaner, or wipe with a dry lint-free cloth or in, Ch 5 Maintenance, D. Optional
an industrial-type wiper to clean the circuit Maintenance Procedures, do not
breaker. Do not use solvents, de-greasers, operate the circuit breaker until these
or any aerosol products to clean in the area tests are completed. Operation of the
of any mechanisms. mechanism may alter the “As found”
operating condition of the circuit
Primary insulation, including the vacuum breaker stored energy mechanism.
interrupter supports and the operating
pushrods, should be cleaned. Wipe clean For further details, see
with a dry lint-free cloth or an industrial Ch 4 Installation, D. Placing the Circuit
type wiper. If dirt adheres and cannot be Breaker Into Service,
removed by wiping, remove it with distilled 4) Mechanical Operation Check.
38 Powered by Safety® Maintenance

01.4IB.60305
2) Lubrication
! CAUTION
Before applying any type of lubrication to the
circuit breaker, the stored energy mechanism
should be in the open position, and all springs
should be discharged.
Powell offers a complete lubrication kit

(Powlube-104) which contains all the
lubricants required for maintaining the
circuit breakers. Powlube-104 consists
of (1) A-grease, (1) B-grease, and (1) C-oil.
Prior to March 2014, Powell provided
Powlube-101 and Powlube-102 which
contained (1) tube of Anderol 757 or
Rheolube 368A, (1) tube of Mobilgrease 28
and (1) bottle of Anderol A456 oil.
A – Grease should be lightly applied to

those bearing surfaces that are accessible.
Inaccessible surfaces, such as bearings, may
be lubricated with a light synthetic machine
oil such as C - Oil. B – Grease should be
applied to the electrical contact surfaces.
Lubricate the stored energy mechanism

and other specified parts in accordance
with Table B, Lubrication. See
Figures 21 & 22 for labeled lubrication
photographs.
Table B, Lubrication lists the location of all

surfaces that should be lubricated, the type
of lubricant to be used, and the method of
applying the lubricant. The guiding rule
in lubrication is to lubricate regularly, use
lubricant sparingly and remove all excess
lubricant. Tilting the circuit breaker will
enable the lubricant to cover the bearing
surfaces.

Table B Lubrication
Reference
Location Lubricant Method
Figure
Electrical Parts
Contact Block (up to 50kA only) Figure 22, r B - Grease Wipe clean. Apply lubricant only to actual contact surface.
Ground Connection Figure 22, z B - Grease Wipe clean. Apply lubricant only to actual contact surface.
Primary Disconnecting Device Figure 21, a B - Grease Wipe clean. Apply lubricant only to actual contact surface.
Secondary Disconnect
Figure 21, k B - Grease Wipe clean. Apply lubricant only to actual contact surface.
Receptacle
Mechanical Parts
Camshaft Needle Bearings Figure 22, aa C - Oil
Close Latch Shaft Face Figure 20, n A - Grease Apply a light coating of grease and remove all excess.
Close Shaft Support Bearing Figure 22, ab C - Oil
Flag Support Pin Figure 22, x C - Oil
Fundamental Linkage Figure 22, w C - Oil Apply to penetrate where pins pass through lines.
Fundamental Linkage Pin Figure 20, g C - Oil Apply to penetrate where pin passes through end link.
Jackshaft Lever Pins passing
Figure 20, j C - Oil Avoid lubricating on operating pushrods.
through Operating Pushrods
Jackshaft Outer Bearing Support Figure 22, y C - Oil
Jackshaft Support Figure 20, i C - Oil
Main Closing Spring Guide Rod Figure 20, b C - Oil
Motor Cutoff Cam Figure 22, ae A - Grease Apply to peripheral surface only.
Motor Drive Shaft Coupling Figure 22, ad C - Oil
Motor Drive Shaft Roller Needle
Figure 20, o C - Oil
Bearings
Motor Drive Shaft Support
Figure 22, ac C - Oil
Bearings
Open-Close Flag Drive Lever Pin
Figure 220, v C - Oil
at Jackshaft
Pawl Support Arm Figure 20, h C - Oil
Pawls Figure 20, p C - Oil
Primary Trip Prop Figure 22, u C - Oil
Primary Trip Prop Bearing Figure 20, e C - Oil Remove main closing spring.
Primary Trip Prop Roller Figure 20, d C - Oil Remove main closing spring.
C - Oil Apply C - Oil to the crank arm rollers and racking crank arms.
Racking Mechanism Figure 22, q
A - Grease Wipe clean. Apply A - Grease to worn gear.
Ratchet Wheel Figure 20, l A - Grease
Secondary Linkage Roller Figure 22, t C - Oil Remove main closing spring.
Spring Yoke Pin Figure 20, c C - Oil
Trip Shaft Bearing Figure 20, f C - Oil
Wheel Figure 22, af C - Oil
Note: For all previous lubrication requirements Powlube-104 A-Grease replaces Anderol 757 and
Rheolube 368A, B-Grease replaces Mobilgrease 28 and C-Oil replaces Mobil 1 and Anderol 456.
See Ch 5 Maintenance, B. Mechanism Area, 2) Lubrication for more details.

01.4IB.60305
Figure 21 Lubrication
a
b
c
a. Primary b. Main Closing

Disconnecting Spring Guide
Device Rod
d
e
f g
h i
j k
l
m n
c. Spring Yoke d. Primary Trip o p
Pin Prop Roller
e. Primary Trip f. Trip Shaft g. Fundamental h. Pawl Support i. Jackshaft j. Jackshaft

Prop Bearing Bearing Linkage Pin Arm Support Lever Pin
k. Secondary l. Ratchet Wheel m. Jackshaft n. Close Latch o. Motor Drive p. Pawls

Disconnect Lever Pin Shaft Face Shaft Roller
Receptacle Needle
Bearing
Note: 50kA circuit breaker shown.

Figure 22 Lubrication (cont)
q q. Racking r. Contact Block

Mechanism
r
t s
u v
w
x
y
aa
ab z
af
s. Racking t. Secondary
Drive Shaft Linkage Roller
ac ad ae Extension
u. Primary Trip v. Open-Closed w. Fundamental x. Flag Support y. Jackshaft z. Ground

Prop Flag Drive Linkage Pin Outer Bearings Connection
Lever Pin at Support
Jackshaft
aa. Camshaft ab. Close Shaft ac. Motor Drive ad. Motor Drive ae. Motor Cutoff af. Wheel
Needle Support Shaft Support Shaft Coupling Cam
Bearings Bearing Bearings
Note: 50kA circuit breaker shown

01.4IB.60305
3) Closing Spring Removal Figure 24 Main Closing Spring Assembly

Installed
Figure 23 Main Closing Spring Assembly
Compressed for Removal
a
b c
a d e
b c
d e
a. Bracket
b. Bolt
c. Lock Washer
d. Flat Washer
a. Bracket e. Spacer
b. Bolt
c. Flat Washer The procedure for spring removal is as
d. Spacer follows:
e. Connecting Rod
a. With the main closing spring discharged
The closing spring must be removed and the circuit breaker contacts open,
in order to perform slow closing of remove the bolt (Figure 24, b) at the top
mechanism. of the spring rod together with the flat
washer, and lock washer.
Although main closing spring removal is b. Remove the horizontal bracket
usually not necessary for lubrication, it may (Figure 24, a) at the top of the main
be necessary for performing adjustments closing spring by unfastening the two
or major overhaul tasks. Furthermore, attachment bolts.
removal of the main closing spring permits c. Remove the spacer (Figure 24, e) from
slow closing of the mechanism and the below the bracket.
vacuum interrupter contacts. For details, d. Turn the bracket 90˚, and replace it on
see Ch 5 Maintenance, B. Mechanism Area, the top of the spring yoke.
4) Slow Closing of Mechanism. e. Place the spacer above the bracket with
the flat washer above the spacer.
f. Insert bolt and tighten until the tension
is taken off the connecting rods.
g. With a slight rocking motion of the main
closing spring assembly, the connecting
rods (Figure 23, e) can now be unhooked
from the spring yoke pins and the
main closing spring assembly can be
removed.
Note: Care should be taken on reassembly

to ensure correct location of the flat
washer, lock washer and spacer.

4) Slow Closing of Mechanism 5) Mechanism Adjustments
The slow closing of mechanism described Several factory adjustments in the stored
is not required for routine maintenance; energy mechanism are described in this
however, it may be a useful procedure section. NO ADJUSTMENT OF THESE
for troubleshooting circuit breaker SETTINGS IS REQUIRED FOR ROUTINE
misoperation. MAINTENANCE, but they may need to be
adjusted after a major overhaul or removal
a. With the main closing spring assembly of the mechanism.
removed, rotate the camshaft so that
the crank arms are pointing downward.
The fundamental linkage will now move CAUTION
into the reset position.
b. Push the manual close operator inward Do NOT adjust these settings unnecessarily as
and hold it in while operating the damage to the circuit breaker may occur.
charging handle to rotate the camshaft.
c. When the close release latch arm has a. Adjustment of Ratchet Wheel Holding
passed the close shaft latch plate, the Pawl
manual close operator may be released.
As the main closing cam engages The holding pawl support arm
the main cam roller, the jackshaft will (Figure 2, t) is adjusted by the holding
commence to rotate. pawl adjusting eccentric (Figure 2, v).
d. Continue to operate the charging
handle until the crank arms point If the pawl is not properly adjusted,
upward. The circuit breaker will now be there will be a “knocking” noise when
closed and there will be a gap between the ratchet mechanism is operating or
the operating pushrod lock nuts and the stored energy mechanism will not
the pivot blocks. ratchet at all.
e. Return the circuit breaker to the open
position by depressing the manual trip To adjust the pawl perform the
operator. following steps:
f. To install the main closing spring
assembly reverse the preceding removal 1. Remove the escutcheon to gain
procedure. access to the head of the bolt
holding the adjusting eccentric.
2. Loosen the bolt slightly.
3. Grip the eccentric with a pair of
slip-joint pliers or a similar tool and
rotate the stop slightly.
4. Tighten the holding bolt with the
eccentric in the new position.
5. While charging the main closing
springs, using the charging motor
to drive the mechanism, observe
the ratcheting operation for
improvement.

01.4IB.60305
6. If the ratcheting operation has not Perform the following procedures to

improved, repeat the preceding adjust the primary trip prop:
sequence until the ratcheting
operation is smooth. This may 1. Remove the main closing spring.
require several charging cycles. Refer to Ch 5 Maintenance,
7. When the eccentric is properly set B. Mechanism Area, 3) Closing Spring
replace the escutcheon. Removal.
2. Adjust the primary trip prop
Be sure that the escutcheon is adjusting screw (Figure 25, d) so
reinstalled on the proper circuit breaker, that with the fundamental linkage
since the escutcheon contains the in the reset position, the clearance
nameplate with the circuit breaker between the primary trip prop
rating and serial number information. roller and the secondary trip prop
The serial number of the circuit breaker is 0.005” to 0.015”. The primary trip
is also attached to the circuit breaker prop adjusting screw is accessible
frame near the ground connection from the rear of the stored energy
on an engraved serial number metal mechanism and is located inside
plate. The serial number found on the the hole beside the lower middle
nameplate must match the number insulator supporting the live part
affixed to the frame. assembly.
3. Adjust the secondary trip prop
b. Adjustment of Primary Trip Prop adjusting screw (Figure 27, c) so the
secondary trip prop top edge is in
Figure 25 Primary Trip Prop Adjustment the line of sight with the top of the
rivet of the primary trip prop roller
a b c as shown in Figure 25.
0.005-0.015" 4. Replace the main closing spring.
d
a. Secondary Trip Prop

b. Primary Trip Prop Roller
c. Primary Trip Prop
d. Primary Trip Prop Adjusting Screw
e. Rivet
f. Trip Bar

c. Tripping System Adjustment increments until the breaker trips

OPEN. Carefully note the rotational
position of the tool used to turn the
! WARNING adjusting screw at the moment the
breaker operates. Do NOT turn the
Prior to adjustments, servicing, maintenance,
screw any further clockwise after the
or any act requiring the operator to make
breaker operates.
physical contact with the equipment, the
7. Turn the secondary trip prop
power source must be disconnected and the
adjusting screw counterclockwise
equipment grounded. Failure to do so may
1½ full turns from the position
result in death or serious injury.
noted in step 6.
8. While holding the secondary trip
To adjust the Tripping System perform prop adjusting screw from turning,
the following steps: securely tighten the secondary trip
prop adjusting screw locking nut.
1. Prior to performing this adjustment 9. Manually charge the main closing
procedure, all high voltage spring using the manual charge
components shall be deenergized, handle per Ch 4 Installation,
disconnected by means of visible D. Placing the Circuit Breaker Into
break and securely grounded, and Service, 4) Mechanical Operation
ensure that the control circuits are Check.
deenergized. 10. Manually CLOSE the circuit breaker.
2. Remove the circuit breaker front 11. Using leaf type feeler gauges with
cover. a total of 0.090” thickness selected,
3. Loosen the secondary trip prop position the feeler gauge as shown
adjusting screw locking nut several in Figure 26.
full turns (Figure 27, d).
Figure 26 Feeler Gauge
CAUTION
Do NOT allow the secondary trip prop
adjusting screw to turn while loosening the
locking nut. Failure to observe this caution
will severely damage the mechanism.
4. With the secondary disconnect

plug (Figure 15, c) or secondary
disconnect override device inserted
(Figure 14), manually charge the
circuit breaker main spring.
5. Manually CLOSE the circuit breaker.
6. Slowly turn the secondary trip prop
adjusting screw (Figure 27, c)
clockwise in 1/8 turn (45˚)

01.4IB.60305
12. Slowly depress the trip coil armature Note: Do NOT tilt the armature. Tilting the
using the manual charge handle. armature by applying a load to the
Position the handle as shown in right of the feeler gauges will produce
Figure 26. Depress the handle until incorrect results.
the armature contacts the feeler
gauges. The circuit breaker should 15. If the circuit breaker did not TRIP
not trip. during the test performed in
step 14, remove the feeler gauges
Note: Do NOT tilt the armature. Tilting the and trip the breaker. Decrease the
armature by applying a load to the gap between the trip coil armature
right of the feeler gauges will produce and the trip lever by bending the
incorrect results. trip lever upwards slightly using
channel lock pliers or a small
13. Choose one of the following steps crescent wrench. Repeat steps 9, 10,
according to the TRIP status: and 14.
i. If the circuit breaker TRIPPED
during the test performed in Note: Bend the trip lever in very small
step 12, increase the gap increments. This process may take
between the trip coil armature several attempts.
and the trip lever by bending
the trip lever downwards slightly 16. Repeat steps 9 through 15 until
using channel lock pliers or a the breaker does not trip with the
small crescent wrench. Repeat 0.090” gauge inserted in the trip coil
steps 9 through 12. armature gap and does trip with the
0.030” gauge inserted into the trip
Note: Bend the trip lever in very small coil armature gap.
increments. This process may take 17. Manually CLOSE and TRIP the circuit
several attempts. breaker so that all springs are
discharged.
ii. If the circuit breaker did NOT 18. Perform the latch check switch
TRIP during the test performed adjustment per the procedure found
in step 12, reset the feeler gauges in Ch 5 Maintenance, B. Mechanism
with 0.030” selected and position Area, 4) Slow Closing of Mechanism,
the feeler gauge as shown in d. Latch Check Switch Adjustment.
Figure 26. 19. Replace circuit breaker front cover.
14. Slowly depress the trip coil armature

using the manual charge handle.
Position the handle as shown in
Figure 26. Depress the handle until
the armature contacts the feeler
gauges. The circuit breaker should
trip.

d. Latch Check Switch Adjustment the secondary trip prop adjusting

screw (Figure 27, c) and latch check
The latch check switch adjustment operator. Rotate the latch check
(Figure 27) described is not required switch upwards until the contacts
for routine maintenance; however, are closed. (An audible click of
the latch check switch may need to be the contacts will be heard). At the
adjusted after major overhaul, removal position where the click is heard
of the mechanism, or tripping system hold the switch and retighten the
adjustment. two screws which secure the latch
check switch. Remove the gauge.
Figure 27 Latch Check Switch Adjustment 5. To confirm that the latch check
switch is properly set, slowly depress
a 0.045" and release the manual trip operator
b d
to verify that the latch check switch
OPENS and CLOSES properly. (An
audible click of the contacts will
be heard). The latch check switch
contacts will OPEN as the latch
check operator is moved by the
manual trip operator away from
c the secondary trip prop adjusting
Pivot Screw screw. Slowly withdraw the manual
trip operator and the latch check
a. Latch Check Switch switch contacts should close when
b. Latch Check Operator the latch check operator is between
c. Secondary Trip Prop Adjusting Screw 0.045” to 0.015” away from the
d. Secondary Trip Prop Adjusting Screw Nut
secondary trip prop adjusting screw.
6. Depress the manual close operator
To adjust the latch check switch perform and rotate the crank arm until
the following steps: resistance is felt.
7. Depress and hold the manual trip
1. Remove the main closing spring.
operator inward and rotate the
Refer to Ch 5 Maintenance,
crank arms until the spring charge
B. Mechanism Area, 3) Closing Spring
indicator displays, CLOSING SPRING
Removal.
DISCHARGED.
2. Rotate the crank arms until the
8. Reinstall the circuit breaker main
spring charge indicator displays,
closing spring.
CLOSING SPRING CHARGED.
3. Loosen the two screws which secure
the latch check switch and rotate
the latch check switch about the
pivot screw downward to the lowest
position allowed. The latch switch
contacts are now OPEN.
4. Insert a 0.045” gauge between

01.4IB.60305
e. Adjustment of Close Latch Shaft 6) Electrical Operation
The close latch shaft (Figure 2, aa) passes After performing any necessary mechanical
through the side sheets of the stored and lubrication maintenance, operate the
energy mechanism frame at the front of circuit breaker electrically several times to
and below the cam shaft. One end of ensure that the electrical control system
the shaft is shaped to make a latch face works properly. See Ch 4 Installation,
and interferes with the close latch arm D. Placing the Circuit Breaker Into Service,
(Figure 2, z), which is fixed to the cam 5) Electrical Operation Check.
shaft. The other end of the close latch
shaft is attached to a lever positioned C. Vacuum Interrupter and Contact Area
by a close bar adjusting screw
(Figure 2, af). 1) Vacuum Interrupter and Contact Erosion
To adjust the close latch shaft perform At each inspection the vacuum interrupters
the following procedures: should be checked for contact erosion.
The circuit breaker must be closed for this
1. Remove the escutcheon. check. Each new vacuum interrupter is set
2. Loosen the locking nut from the with a gap of about 1/4” to 5/8” between
close bar adjusting screw while the contact loading spring yoke and the
holding the position of the close bar lock nut on the operating pushrod stud. As
adjusting screw with a screw driver. the contacts erode with use, this gap will
3. Back out the close bar adjusting decrease. Because the factory setting of
screw by turning the screw the lock nut gap varies for each vacuum
counterclockwise 2 full turns. interrupter, a label is provided on the
4. With the secondary disconnect lower part of each vacuum interrupter.
plug (Figure 15, c) or secondary The original factory setting of the gap and
disconnect override device inserted the end-of-life measurement of this gap
(Figure 14), manually charge the is recorded on the label. When the gap
circuit breaker main closing spring measurement reaches the end-of-life value
with a manual charging handle until given on the label, the vacuum interrupter
the spring charge indicator displays should be replaced.
CLOSING SPRING CHARGED.
5. Turn the close bar adjusting screw 2) Vacuum Integrity
clockwise until the main closing
spring discharges, then depress the Refer to Ch 4 Installation, D. Placing
manual trip operator to OPEN the the Circuit Breaker Into Service,
circuit breaker. 2) Vacuum Integrity for information on
6. Turn the close bar adjusting screw vacuum integrity and testing of vacuum
3 to 3½ full turns counterclockwise. interrupters.
Retighten the locking nut holding
the screw.
7. Repeat step 5. Then CLOSE and
OPEN the circuit breaker to ensure
proper operation.
8. Replace the escutcheon.

3) Mechanical Adjustment of Vacuum 2) Timing

Interrupters
At normal control voltage, operate the
There are no adjustments required test source to the “close” position to close
for routine maintenance of a vacuum the circuit breaker and record the closing
interrupter assembly. There are several time. The closing time from energizing the
factory adjustments which will vary over closing coil to vacuum interrupter contact
the operating life of the vacuum interrupter. touch should not exceed the values in
the timing table. Again, at normal control
voltage, operate the test source to the
! CAUTION “open” position to open the circuit breaker
Adjustments of these settings are only and record the opening time. The opening
necessary when repair requires the removal time from energizing the shunt trip coil to
or replacement of the vacuum interrupter. vacuum interrupter contact part should not
Do not adjust these settings unnecessarily as exceed the values in Table C, Timing.
damage to the circuit breaker may result.
Table C Timing
Closing Time Tripping Time
When it is necessary to remove or replace
3 Cycle ≤80 ms <35 ms
the vacuum interrupter of a 63kA rated
circuit breaker, it should only be done by 5 Cycle ≤80 ms <55 ms
a qualified technician or a Powell service
technician. Contact Powell for further
assistance at 1.800.480.7273.
D. Optional Maintenance Procedures
1) High Potential Tests
High potential tests are not required for

routine maintenance but are recommended
after a heavy fault interruption, any major
circuit breaker repair that involves the
primary current path or when the circuit
breaker has been in storage for an extended
time, especially in a damp location or other
adverse environment. In these cases, both
the High Voltage Insulation Integrity and
Control Voltage Insulation Integrity tests
should be performed. Refer to
Ch 4 Installation, D. Placing the Circuit
Breaker Into Service for details of these
procedures.

01.4IB.60305
3) Primary Resistance Check Table D Primary Resistance

Rated
This check is not required for routine Breaker Rated Resistance
Continuous
maintenance but it is recommended after Type (kV) Micro-Ohms
Current (A)
any major maintenance that requires 05PV36CDR 4.76 1200 60
disassembly of any part of the primary 05PV36CDR 4.76 2000 50
current path. 05PV36CDR 4.76 3000 40
05PV50CDR 4.76 1200 60
To check the resistance, pass a minimum of 05PV50CDR 4.76 2000 45
100A DC through the circuit breaker pole, 05PV50CDR 4.76 3000 40
with the circuit breaker closed. Measure 05PV63CDR 4.76 1200 60
the voltage drop across the primary 05PV63CDR 4.76 2000 40
contacts and calculate the resistance. The 05PV63CDR 4.76 3000 40
resistance should not exceed the values
05PV63GCB 4.76 1200 60
provided in this instruction bulletin for
05PV63GCB 4.76 2000 40
the specific type and rating of the circuit
05PV63GCB 4.76 3000 40
breaker being measured.
15PV25CDR 15 1200 70
15PV25CDR 15 2000 50
When making this test, be sure that the
15PV25CDR 15 3000 40
test current passes through both main
15PV36CDR 15 1200 60
horizontal primary disconnecting devices
15PV36CDR 15 2000 50
of each pair, or the resistance measurement
15PV36CDR 15 3000 40
will be affected. This may be done by
connecting the current source leads to two 15PV50CDR 15 1200 60
blocks of full round edge copper 1” thick 15PV50CDR 15 2000 45
by 3” or 4” wide by 4” long, and pressing 15PV50CDR 15 3000 40

these blocks into the upper and lower 15PV63CDR 15 1200 40
primary disconnecting devices of the circuit 15PV63CDR 15 2000 40
breaker compartment. The voltage drop 15PV63CDR 15 3000 40
measurement may be made between these 15PV63GCB 15 1200 40
two blocks. 15PV63GCB 15 2000 40
15PV63GCB 15 3000 40
The micro-ohm values of resistance must
not exceed the following limits:

Ch 6 Recommended Renewal Parts and recommended spare parts to be carried in

Replacement Procedures stock by the user. The recommended quantity
is not specified. This must be determined
A. Ordering Instructions by the user based on the application. As a
minimum, it is recommended that one set of
1. Order Renewal Parts from Powell at parts be stocked per ten circuit breakers or less.
powellind.com or call 1.800.480.7273.
Powell recommends that only qualified
2. Always specify complete nameplate technicians perform maintenance on these
information, including: units. Refer to the Qualified Person section in
the front of this instruction bulletin. If these
• Circuit Breaker Type circuit breakers are installed in a location
• Serial Number where they are not maintained by a qualified
• Rated Voltage technician, a spare circuit breaker should be on
• Rated Amps site ready for circuit breaker replacement. The
• Impulse Withstand malfunctioning unit can then be returned to
• Control Voltage (for control devices and the factory for reconditioning.
coils)
C. Replacement Procedures
3. Specify the quantity and description
of the part and the instruction bulletin This section includes instructions for replacing
number. If the part is in any of the the parts recommended as renewal parts.
recommended renewal parts tables, specify Before attempting any maintenance repair
the catalog number. If the part is not in work, take note of the safety practices outlined
any of the tables, a description should be in Ch 2 Safety of this instruction bulletin.
accompanied by a marked illustration from
this instruction bulletin, a photo or simply
submit a sketch showing the part needed. ! CAUTION
Ensure that the control circuits are
B. Recommended Renewal Parts
deenergized and the circuit breaker is
deenergized, disconnected by means of a
A sufficient amount of renewal parts should be
visible break, and securely grounded. Do NOT
stored to enable the prompt replacement of
start to work on a closed circuit breaker or a
any worn, broken or damaged part. A sufficient
circuit breaker with the main closing spring
amount of stocked parts minimizes service
charged. When any maintenance procedure
interruptions caused by breakdowns and saves
requires the opening or closing of the circuit
time and expense. When continuous operation
breaker or the charging of any of the stored
is a primary consideration, a larger quantity of
energy mechanism springs, exercise extreme
renewal parts should be stocked depending
caution to ensure that all personnel, tools, and
on the severity of the service and the time
other miscellaneous objects are kept clear of
required to secure replacement parts.
the moving parts of the charged springs.
Since parts may be improved periodically,
renewal parts may not be identical to the
original parts. Tables E, F, and G list the
52 Powered by Safety® Recommended Renewal Parts and Replacement Procedures

01.4IB.60305
1) Vacuum Interrupter Assembly rear mounting clip and remove the finger
assembly. Invert the assembly and place
Refer to service manual 01.4SM.1900 it in the mounting clips. Tighten the bolt
Vacuum Interrupter Assembly for holding the rear mounting clip. If copper
replacement and installation procedures on is visible at more than one contact location
circuit breakers rated up to and including on a finger assembly, that assembly
50kA. should be replaced. Apply a light coat of
B - Grease contact lubricant to both sides
of the contact blocks and to the contact
NOTICE areas of the lower primary disconnecting
devices. Reassemble the sliding contact
For all 63kA rated circuit breakers, the
finger assemblies by replacing the four
vacuum interrupter should only be replaced
sockethead screws and tighten to a torque
by a qualified person or a Powell Service
value of 8-12 ft-lb.
technician. Contact Powell for further
assistance at 1.800.480.7273.
3) Closing Coil Assembly
2) Sliding Contact Finger Assembly (for circuit Refer to service manual 01.4SM.1300
breaker rated up to 50kA only) Closing Coil Assembly for replacement and
installation procedures.
To clean, inspect, and lubricate the sliding
contact finger assemblies (Figure 28) 4) Primary Shunt Trip Coil Assembly
remove the four sockethead screws holding
the sliding contact finger assemblies and Refer to service manual 01.4SM.1600
pivot the assemblies down. Wipe the Primary Shunt Trip Coil Assembly for
lubrication from the surfaces of the lower replacement and installation procedures.
contact block, sliding contact fingers, and
the lower primary disconnecting devices 5) Secondary Shunt Trip Coil Assembly
and examine the surfaces. The sliding
contact finger locations should present a Refer to service manual 01.4SM.1700
burnished silver contact without copper Secondary Shunt Trip Coil Assembly for
appearance at more than one location. replacement and installation procedures.
If the copper si visible at more than one
location per pole or silver is torn on the 6) Undervoltage Device Assembly (UV)
lower contact block the vacuum interrupter
assembly should be replaced. Refer to service manual 01.4SM.1800C
Undervoltage Assembly for replacement and
The sliding contact finger assemblies installation procedures.
on the PowlVac® circuit breakers are
reversible. Since only the upper ends of 7) Charging Motor Assembly
the fingers experience any wiping action,
the wear is normally confined to that Refer to service manual 01.4SM.1200
end. If the upper ends of the fingers show Charging Motor Assembly
noticeable wear, the finger assemblies can for replacement and installation procedures.
be reversed. Loosen the bolt holding the
Recommended Renewal Parts and Replacement Procedures Powered by Safety® 53

8) Anti-Pump Relay Assembly 12) Ground Connection Assembly
Refer to service manual 01.4SM.1000 This assembly is located at the rear edge
Anti-Pump Relay Assembly for replacement of the floor pan of the circuit breaker,
and installation procedures. between the center and right poles of the
circuit breaker (Figure 4, p).
9) Latch Check Switch
a. Elevate and secure the circuit breaker so
Refer to service manual 01.4SM.1400 Latch there is at least 6 inches of clear space
Check Switch Assembly for replacement and under the circuit breaker base pan.
installation procedures. b. Remove the bolt holding the retaining
clip to the ground connection mounting
10) Motor Cutoff Switch Assembly bracket, and remove the retaining clip.
c. Slide the assembly slightly forward,
Refer to service manual 01.4SM.1500 Motor so that the ends of the mounting rods
Cutoff Switch Assembly for replacement and on each side of the assembly is clear
installation procedures. of the holes in the ground connection
mounting bracket. Press down on the
11) Auxiliary Switch assembly and remove it from bottom of
circuit breaker.
Refer to service manual 01.4SM.1100 d. Remove the two red spacer tubes from
Auxiliary Switch Assembly for replacement the socket head screws which holds the
and installation procedures. assembly together.
e. Assemble the new assembly with the
red spacer tubes and torque to
8-12 ft-lb.
f. Wipe the old lubricant off the ground
connection mounting bracket on the
circuit breaker, and apply a thin coat
contact lubricant Mobilgrease 28 to
the mounting bracket. Insert the new
assembly from below the circuit breaker
floor pan and press up and slide back
until the mounting rods can be inserted
into the holes in the ground connection
mounting bracket.
g. Reinstall the retaining clip.

01.4IB.60305
Table E Primary Current Path

Breaker Rated Rated Sliding Contact Finger Primary Disconnect Vacuum
Type kV Continuous Assembly Finger Cluster Interrupter
Current (Up to 50kA only) Assembly
(Amperes)
05PV36CDR 4.76 1200 50952G01 0282A2700G002
60501G02
05PV36CDR 4.76 2000 50952G01 0209B4272G002
05PV36CDR 4.76 3000 50956G02 0209B4272G002 60500G03
05PV50CDR 4.76 1200 50956G01 0282A2700G002
60501G03
05PV50CDR 4.76 2000 50956G01 0209B4272G002
05PV50CDR 4.76 3000 50956G02 0209B4272G002 60500G03
05PV63CDR 4.76 1200 N/A 0209B4272G002
05PV63CDR 4.76 2000 N/A 0209B4272G002 Contact Powell
05PV63CDR 4.76 3000 N/A 0209B4272G002
05PV63GCB 4.76 1200 N/A 0209B4272G002
05PV63GCB 4.76 2000 N/A 0209B4272G002 Contact Powell
05PV63GCB 4.76 3000 N/A 0209B4272G002
15PV25CDR 15 1200 50952G01 0282A2700G002

60501G01
15PV25CDR 15 2000 50952G01 0209B4272G002
15PV25CDR 15 3000 50956G02 0209B4272G002 60500G03
15PV36CDR 15 1200 50952G01 0282A2700G002
60500G01
15PV36CDR 15 2000 50952G01 0209B4272G002
15PV36CDR 15 3000 50956G02 0209B4272G002 60500G03
15PV50CDR 15 1200 50956G01 0209B4272G002
60500G03
15PV50CDR 15 2000 50956G01 0209B4272G002
15PV50CDR 15 3000 50956G02 0209B4272G002 60500G03
15PV63CDR 15 1200 N/A 0209B4272G002
15PV63CDR 15 2000 N/A 0209B4272G002 Contact Powell
15PV63CDR 15 3000 N/A 0209B4272G002
15PV63GCB 15 1200 N/A 0209B4272G002
15PV63GCB 15 2000 N/A 0209B4272G002 Contact Powell
15PV63GCB 15 3000 N/A 0209B4272G002

Figure 28 Primary Current Path
Primary Disconnect Finger Cluster Sliding Contact Finger Assembly

Up to and Including 63kA (Up to and Including 50kA)
Vacuum Interrupter Assembly Vacuum Interrupter Assembly

Up to and Including 50kA 63kA Only

01.4IB.60305
Table F Control Devices

Primary Shunt Trip Coil Secondary Undervoltage
Charging
Control Assembly (2) Shunt Trip Device Anti-Pump Relay Closing Coil
Motor
Voltage Coil Assembly Assembly (5) Assembly
3-Cycle 5-Cycle Assembly
(3) (4)
24VDC 50027G05 50041G08 50042G06 n/a n/a n/a n/a
48VDC 50027G01 50041G01 50042G01 50028G11 50960G06 RR2BA-US-DC48V 50026G01
125VDC 50027G02 50041G02 50042G03 50028G10 50960G04 RR2BA-US-DC110V 50026G03
250VDC 50027G03 50041G03 50042G04 n/a 50960G05 RR2BA-US-DC110V 50026G04
120VAC 50027G01 50041G05 50042G01 n/a 50960G04 RR2BA-US-AC120V 50026G01
240VAC 50027G06 50041G06 50042G02 n/a 50960G05 RR2BA-US-AC240V 50026G02
Capacitor Trip (6) 50027G04 50041G04 50042G05 n/a n/a n/a n/a
Notes:
1) One required per circuit breaker if the circuit breaker was originally equipped with this item. All
circuit breakers have a closing coil, primary shunt trip coil, charging motor, and an anti-pump
relay assembly. Secondary shunt trip coils and undervoltage device assemblies are optional
(see notes 2-7).
2) Primary shunt trip coil is available as a 3 cycle and 5 cycle control device. Trip coil assemblies
must only be replaced with the same type as originally supplied.
3) Secondary shunt trip coil cannot be furnished with an undervoltage device assembly.
4) Where furnished, cannot be present with secondary shunt trip coil assembly.
5) For 250VDC applications, a dropping resistor 50747G02P is required in series with the
anti-pump relay assembly.
6) For use with capacitor trip units with 240VAC input. Consult factory for other circuit breaker
ratings.
7) All control devices are available with push-on terminals. Consult factory for control devices
with screw terminals.

Figure 29 Control Devices
a b c
d e f
a. Primary Shunt Trip Coil (3 cycle)

b. Primary Shunt Trip Coil (5 cycle)
c. Charging Motor Assembly
d. Closing Coil Assembly
e. Anti-Pump Relay
f. Undervoltage Device Assembly

01.4IB.60305
Table G Miscellaneous Parts

Description Catalog Number Illustration
Auxiliary Switch
102112PB
Ground Connection
25kA 50951G02
36kA 50952G03
50kA
50952G02P
63kA
Latch Check Switch
BA-2RV2-A2
Motor Cutoff Switch Assembly
50756G03P
PowlVac® Hardware Kit
6050G24
PowlVac® Lubrication Kit
Powlube-104
Operating Pushrod Assembly
25kA 50934G22
36kA 50934G23
50kA 50934G24
63kA 50934G25

01.4IB.60305
PowlVac® CDR & GCB Series 4
Vacuum Circuit Breakers
October 2017
Powell Electrical Systems, Inc.

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

01 4ib 60305

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Powered by Safety®

Instruction Bulletin - 01.4IB.60305

Powell Electrical Systems, Inc.

Signal Words Qualified Person

This page is left blank intentionally.

Powered by Safety® iii

Table A Field Dielectric Test Values...................................................................................26

This page is left blank intentionally.

General Information Powered by Safety® 1

A. Scope The illustrations contained in this document

B. Purpose To the extent required, the products described

This instruction bulletin provides:

2 Powered by Safety® General Information

C. Instruction Bulletins Available Electronically D. Associated Bulletins

• 01.4IB.51000C PowlVac® Metal-Clad

For more information visit powellind.com.

For specific questions or comments pertaining

General Information Powered by Safety® 3

Ch 2 Safety 6. Where the possibility of induced voltages

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

4 Powered by Safety® Safety

C. General These circuit breakers utilize stored energy

3. Service conditions and circuit breaker 6. ALL COMPONENTS SHALL BE

2. DO NOT WORK ON A CIRCUIT BREAKER

3. EXTREME CARE MUST BE EXERCISED

Safety Powered by Safety® 5

E. X-Rays F. Safety Labels

6 Powered by Safety® Safety

Ch 3 Equipment Description circuit breaker between the test/disconnected

Powell is committed to continuous product B. The Stored Energy Mechanism

Equipment Description Powered by Safety® 7

a. Cover Bolts j. Handle

8 Powered by Safety® Equipment Description

a. Anti-Pump Relay l. Reset Spring w. Crank Arm

Equipment Description Powered by Safety® 9

a. Anti-Pump Relay l. Main Cam Roller x. Crank Arm

10 Powered by Safety® Equipment Description

a. TOC Actuator J. Wheel

Equipment Description Powered by Safety® 11

Figure 5 Primary Current Close-Ups

Up to 50kA 63kA Only

a. Lower Vacuum Interrupter Casting i. Lower Vacuum Interrupter Casting

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Figure 6 Cam and Fundamental Linkage Positions

c) Breaker Open - Spring Discharged d) Breaker Closed - Spring Charged

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Figure 7 Mechanism and Trip Linkages

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The close latch, when released either by the an approximate 3 to 1 multiplication of

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Figure 8 Operation Sequence

Motor “M” Green Light

White Light Motor “M” “Y” Circuit

Close Coil “CC”

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Figure 9 Typical Control Scheme

(optional, but no UV) (optional, but no TC2) (ARM/G only)

CLOSE TRIP1 TRIP2

ARM/G ONLY NON-ARM/G

LS = SPRING CHARGE LIMIT SWITCH (SHOWN W/SPRING DISCHARGED) 4 12 19 27

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With the standard electrical control c. Anti-Pump Relay