Installation BCS Switchgear Inc. Switchgear Circuit Breakers Parts .

.comGEI-86150-ACONNECTED-This is the breaker's "In-Service" position.It is fully inserted in its compartment; the primary andsecondary disconnect contacts are fully engaged. The breakermust be tripped before it can be racked into or out of thisposition.TEST-In this positior; the primary contacts are discon nected but secondary contacts remain engaged. This allowscomplete breaker operation without energizing the primarycircuit.DISCONNECTED-Both primary and secondary contactsare disengaged.' . . .J b. Verify that the breaker is the correct type for thatcompartment.c. Insure that the breaker is OPEN.d. Apply a thin, fresh coat of D80HD38 lubricant to the·breaker's primary disconnects.www.Eo''.a. Check the compartment to insure that it is free offoreign objects.lec.S·.'. · .·*-· '%'\ 1. Prior to lifting a breaker to its intended compartmentlocation, observe the following precautions:tricalPartMBreakers can be racked belween the above positions withthe compartment door closed. Each of the three positions isclearly shown by a rotatry indicator visible through an openingin the door.Breaker InsertionualsThe drawout operation features four discrete positions:·WITHDRAWN-With the compartment door open, thebreaker can be manually pulled out to the WITHDRAWNposition. At this point the tracks are fully extended and thebreaker is completely out of its compartment, ready forremoval. Note that the racking mechanism is not employed formovement of the breaker between the DISCONNECTED andWITHDRAWN positions.anThe jackscrew drives the crankshaft via an internallythreaded trunnion supported in a crank centrally located onthe crankshaft. The jackscrew is rotated by a removable,externally-operated crank handle (Part No. 193A 1990P1) in serted thru an opening in the breaker's escutcheon. Access tothis opening is via a sliding cover marked RACKING SCREW:Fig. 2Fig. 35

GEI-86150-A2. AKD-6 switchgear breaker compartments are factoryshipped less breakers and with the inner housing stowed in theCONNECTED position by a shipping bolt painted yellow. As thefirst step in preparing for breaker insertion, remove and discardthis bolt and its shipping tag.Breaker Removal (Code A)1 . Trip the breaker.com· -'2. Insert the racking handle and rotate it counterclockwiseuntil it stops. The indicator should read DISC.Toward the end Of the above racking movement, thebreaker's "clOsing spring interlock" is activated; this automati cally discharges the closing spring (if in a charged state) butdoes not close the breaker.3. Pull the inner housing out until it stops. It will then be inthe.DISCONNECTED position.uals4. Rotate the two track lock links and pull the right track allthe way out.3. Remove the racking handle, open the compartment door.5. Using a suitable lifting device, hoist the breaker until itsmounting pins are approximately one inch above the tracks.4. Rotate the two track lock links and pull the breaker all theway out.NOTE: To avoid damaging the arc quenchers, aspreader bar must be used for hoisting thesebreakers. Two hoisting slots are provided in eachside frame-see Fig. 2. The spreader bar's hooksshould be placed in the forward slots for non-fusedbreakers and in the rear slots for fused breakers.an5. Attach the lifting device and raise the breaker until itsmounting pins clear the track.6. Push the tracks into the compartment, then lower thebreaker to a flat surface; avoid protrusions that could damage\the internal parts of the breaker.6. Pull the left track out to the limit of its travel; lower thebreaker onto the track so that its mounting pins drop into thetrack slots.tricalPartMNOTE: After a breaker is removed from its com partment, the inner house cannot be manuallypushed all the way back into the compartment. Thelatches that rest on the drawout mechanism pinsprevent this.CAUTION: Breakers and tracks are equipped withrejection hardware which acts to prevent the tracksfrom accepting a breaker whose rating does notmatch that of the compartment. This rejection systemis separately described under the heading INTER CHANGEABILITY starting on Page 1 4.CODE B (AKR S UBSTRUCTURE) (Fig. 4)7. Attach the racking handle to the racking screw thru theopening at the lower left corner of the breaker escutcheon.Access to the racking screw is obtained by depressing the TRIPbutton and sliding the racking screw cover to the right; releasingthe TRIP button locks the cover open.8. Rotate the racking handle counterclockwise (if possible)until it stops, then remove it. The purpose of this step is toposition the slotted crank arms at the proper angle necessary toengage the fixed racking pins in the compartment.9. Push the breaker in against the track stops. Rotate thetwo track lock links to lock the breaker in place. Close the door.lec10. Again insert the racking handle (as in Step 7) and rotateit clockwise until it stops. A few turns before the stop is reached,turning torque will noticeably increase as the breaker's discon nect fingers engage the stationary studs. The breaker is now inthe CONNECTED position and the position indicator will showCONN.EThe complete racking cycle requires approximately 24 turnsof the racking handle.www11. Remove the racking handle and depress the TRIPbutton to close the racking screw cover.6·The AKA substructure is a self-contained, open-type frame work serving as the stationary receptacle for a drawout breaker.Featuring closed-door type drawout operation, it is designedfor convenient mounting in individual breaker compartments ofdrawout switchgear equipments. It provides means for makingthe primary and secondary connections to the removablebreaker element and is factory aligned.All AKA 8-type breakers for use in substructures areequipped with a "deep" escutcheon instead of the standardescutcheon employed on the A-type models. This configurationallows the breaker to be racked between the CONNECTEDand DISCONNECTED positions with the door closed. The dooris hung on the compartment (not on the slide rails) and does notmove with the breaker as it does in the A-type AKD-6 models.The racking mechanism is breaker-mounted and is identicalto that of the Code A breaker; the same support method (pinsengaging slots in slide rails) is also used. In operation, thesubstructure traverses the same four drawout positions as theA-types: CONNECTED-TEST-DISCONNECTED WITHDRAWN. Breaker position is registered directly bymarkings on the left side of the escutcheon, these becomingvisible as it emerges throught the door cutout.

RESUBSTRUCTUREFigure 4. AKR-50 breaker, B-type drawout substructure mounting, manually operated7

Breaker Insertion (Code B)Breaker Removal (Code B)foreign objects.b. Verify that the breaker Is the correct type for thatcompartment.c. Insure that the breaker is OPEN.d. Apply a thin, fresh coat of 050HD38 lubricant to thebreaker's primary disconnects.e. Insure that the racking cams on the breaker arecorrectly positioned for initial engagement with thepins in the compartment. To do this, insert the rackinghandle and rotate it fully counterclockwise.2. Using a suitable lifting mechanism and spreader rig, raisethe breaker above the elevation of the tracks. (Use the forwardslots for non-fused breakers, the rear slots for fused models.)3. Open the compartment door. Rotate the two track locklinks and pull the breaker out to the track travel limit-this is theWITHDRAWN position.4. Before proceeding with subsequent operations to re move the breaker from the compartment, visually check thebreaker's spring charge and close indicators to verify thatbreaker is open and the springs are discharged.5. Attach the lifting device and hoist the breaker until itsmounting pins clear the track slots.,6. Swing the breaker forward until the primary disconnectsclear the compartment; lower the breaker onto a flat surfacefree of protrusions that could damage the breaker's internalparts.calPartM3. Rotate the two track lock links and pull the tracks out to thelimit of their travel.2. Insert the racking handle and rotate it counterclockwiseuntil the breaker travels from CONNECTED through TEST tothe DISCONNECTED position, as indicated by the jackscrewcoming to a solid stop. This operation should be performed withthe door closed. If the breaker closing spring is fully charged, itwill be automatically discharged a few turns before the end ofthe racking action.ualsa. Check the compartment to insure that it is free of1. With the door closed and latch, trip the breaker.an1. Prior to lifting a breaker to its intended compartmentlocation, observe the following precautions:4. Slowly lower and guide the breaker so that the breakermounting pins drop into the slots in the tracks. Remove thelifting device.5. Push the breaker into the compartment until it reaches thetrack stops. This is the DISCONNECT position. At this point theracking arms are positioned to engage the fixed racking pins inthe compartment, ready to begin the racking motion.www.Electri6. Close the compartment door. Insert the racking handleinto the racking screw opening in the breaker escutcheon. Byclockwise rotation of the handle, move the breaker through theTEST posi!ion into the CONNECTED position; the latter isindicated when the jackscrew comes to a solid stop.8.comGEI-86150-Ai!III·l

.comAKR- 6 0-50www.ElectricalPartManualsGEI-86150-AFig. 59

CODE D (AK D-8 SWITCHGEAR) (Fig. 5)The drawout operation features four discrete positions:TEST-In this position the primary contacts are discon nected but secondary contacts remain engaged. This allowscomplete breaker operation without energizing the primarycircuit. DISCONNECTED-Both primary and secondary contactsare disengaged.·WITHDRAWN-With the compartment door open, thebreaker tan be manually pulled out to the W ITHDRAWNposition. At this point the tracks are fully extended and thebreaker is completely out of its compartment, ready for re moval. Note that the racking mechanism is not employed formovement of the breaker between the DISCONNECTED andWITHDRAWN positions.triBreaker Insertion (Code D)1. Prior to lifting a breaker to its intended compartmentlocation, observe the following precautions:.Eleca. Check the compartment to insure that it ts free offoreign objects.b. Verify that the breaker is the correct type for thatcompartment.c. Insure that the breaker is OPEN.d. Apply a thin, fresh coat of D50HD38 lubricant to thebreaker's primary disconnects.e. Insure that the racking cams on the breaker are cor rectly positioned for initial engagement with the pinsin the compartment. To do this, insert the rackinghandle and rotate it fully counterclockwise.www2. Using a suitable lifting mechanism and spreader rig,raise the breaker above the elevation of the tracks. (Use theforward slots for non-fused breakers, the rear slots for fusedmodels.)103. Slowly iower and guide the breaker so that the breakermounting pins drop into the slots in the tracks. Remove thelifting device.\4. Push the breaker into the compartment until it reachesthe track stops. This is the DISCONNECT position. At thispoint the racking arms are positioned to engage the fixedracking pins in the compartment, ready to begin the rackingmotion.calPartMCONNECTED-This is the breaker's " In-Service" position.It is fully inserted in its compartment; the primary and secon dary disconnect contacts are fully.engaged. The breaker mustbe tripped before it can be racked into or out of this position.ualsAll AKA D-type breakers for use in AKD-8 are equipped witha deep escutcheon instead of the standard escutcheon emp loyed on the A-type models.The in and out movement of the breaker betweenCONNECTED-TEST-DI SCONNECTED positions is identicalto "A" type AKD-6 models with the exception of breaker posi tioning indication. AKR-"D" type breaker position is registereddirectly by markings on the left and right side of the escutch eon, these becoming visible as it emerges through the doorcutout.anThis type drawout breaker is supported by two protrudingpins on each side of its frame; these engage slots in telescop ing slide rails (tracks) mounted to each sidewall of the switch gear. Unlike AKD-6 Switchgear the door on AKD-8 switchgearremains stationary and closed while the breaker is racked outfrom the connected, thru test to disconnected position.comGEI-86150-A5. Close the compartment door. Insert the racking handleinto the racking screw opening in the breaker escutcheon. Byclockwise rotation of the handle, move the breaker through theTEST position into the CONNECTED position; the latter isindicated when the jackscrew comes to a solid stop.Breaker Removal (Code D)1.With the door closed and latch, trip the breaker.2. Insert the racking handle and rotate it counterclockwiseuntil the breaker travels from CONNECTED through TEST tothe DISCONNECTED position, as indicated by the jackscrewcoming to a solid stop. This operation should be performedwith the door closed. If the breaker closing spring is fullycharged, it will be automatically discharged a few turns beforethe end of the racking action.3. Open the compartment door. Pull the breaker out to thetrack travel limit-this is the WITHDRAWN position.4. Before proceeding with subsequent operations to re move the breaker from the compartment, visually check thebreaker's spring charge and close indicators to verify thatbreaker is open and the springs are discharged.5. Attach the lifting device and hoist the breaker until itsmounting pins clear the track slots.6. Swing the breaker forward until the primary disconnectsclear the compartment; lower the breaker onto a flat surfacefree of protrusions that could damage the breaker's internalparts.

. , "-"J' ECTIONSTERMINAL BOARDMOUNTED ON LEFTSIDE OF BREAKERIn all electrical connections good joint conductivity is a must.When making power connections to stationary breakers, themating joint surfaces must be clean and have a smooth finish.They should be parallel and firmly bolted or clamped together.In addition, the bus or cable conductors must have amplear:npacity to prevent overheating.Control ConnectionsThe outgoing connections to a breaker's accessories andcontrol devices must be in accordance with the specific wiringdiagram applicable to that breaker.CLOSINGSOURCEControl connections to stationary breakers are made to aterminal board mounted on the breaker. Figure 6 shows typicalclosing and tripping connections. If equipped with an overcur rent trip device which includes a ground fault element for use on4-wire circuits, an additional terminal board is provided on thebreaker for connecting to the equipment-mounted neutralsensor (physically located in the neutral OURCEtricalPartMOn drawout breakers the col)trol circuits terminate in thebreaker compartment on the stationary portion of separablesecondary disconnects - see fig. ){6 07 0.---- - 809010 0(- )( )0-rr-n.-u u--TO AUX. SW.CONTACT"a"lec .EwuvTRIPSOURCE5Fig. 6 Control connections to stationary breakers-front view.(X)wwCLOSE7 Y SECONDARY DISCONNECT BLOCKSLOCATED AT TOP OF COMPARTMENT POSITIONS 11 AND FURNISHEDl[ --------------------0 N l Y W H E N R E Q U IR E D llFig.7 Control connections to drawout breakers-front view of breaker compartment.11

.comGEI-86150-AOPERAT IONELECTRICAL CLOSINGA breaker may be equipped to operate either manually orelectrically. Both types of operation result in the same fast cl : sing movement as far as the contact action is concerned.The variation is in the way energy is stored in the closingspring, and how it is released.On electrically operated breakers the closing springs arecharged by a gear motor. With the springs discharged, voltageapplied to the control circuit will energize the motor through the"G" switch contacts- see fig. 8. The motor, through the gearreduction output crank, compresses the closing springs untilthey are fully charged. As this fully charged position isreached, mechanically operated switches "F" and "G" re verse their shown position, the "G" switch deenergizing themotor and the "F" switch establishing a circuit to the "X" relay.At the same time, a mechanical prop is positioned to preventthe discharge of the fully charged closing spring.ualsGENERALMANUAL CLOSINGWith the cl9sing spring propped fully-charged, the breaker isready for closing. This may be accomplished electrically bydepressing the closing switch on the breaker (if so equipped) orby a remote closing switch. Operation of the closing switchenergizes the "X" relay, which in turn energizes the closingsolenoid. This removes the prop, releasing the closing springsto close the breaker.tricalPartManManually operated AKA breakers are constructed withfront-mounted handles. Handle operation res ets themechanism and fully charges the closing spring. A completecharge is accomplished in either cranking the handle throughone cycle ( 135-degree swing) pr three cycles (50-degreeswing). The CLOSE button, mounted on the escutcheon, isused to close the breaker contacts and the TRIP button toopen them.As the closing relay is energized, it energizes anti-pumprelay "W". If the closing switch is maintained closed, the anti pump relay will remain picked-up to prevent a second closingoperation on the breaker in the event it is tripped openautomatically. The closing impulse must be released andreapplied before a second closing operation can occur.If equipped with a closing solenoid, a manual breaker maybe closed remotely by a control switch or relay. Before this canbe done, however, the closing spring has to be charged byhand. The closing solenoid is an optional accessory and is notsupplied unless specified in the breaker order.CONTROLSOURCEXlec r'IxccGl.Jwww.EX12 -ccTCw ----- - - - ------LEGENDCC- CLOSING SOLENOIDF -CUTOFF SWITCH, CLOSEDWHEN CLOSING SPRING ISFULLY CHARGED.G- CUTOFF SWITCH. OPEN WHENCLOSING SPRING ISFULLY CHARGEDL- AUXILIARY SWITCHM- CHARGING MOTORPB- CLOSE PUSHBUTTON ONBREAKER ESCUTHEON,OPTIONAL.TC- SHUNT TRIP DEVICEW- ANTI-PUMP RELAYX- CONTROL RELAY-Fig. 8 Elementary diagram for electrically operated drawout breaker.Contact positions are shown with breaker open and closing springs discharged.;,,' fl1!ii

.comGEI-86150-ATRIPPINGtrips the breaker; clockwise movement resets the mechanismlatch.In addition to tripping the breaker, some devices hold thebreaker trip free, i.13., prevent the contacts from closing eventhough a closing

A-Drawout AKD-6 switchgear B-Drawout substructure D-Drawout AKD-8 switchgear and substructure S-Stationary Fig. 1. AKR breaker type designation . com 3 BCS Switchgear Inc. Switchgear Circuit Breakers Parts Tech Support bcsswitchgear.com 888.599.0486 Need Help? 888.599.0486 · ;: .