Magnum LV-Air Circuit Breaker User Manual

Model: 1812.900A

Work on medium and low voltage switchgear installations, such as setting up, connecting of cables, operation, inspection, and maintenance must only be carried out by authorized personnel.

Administrative Data

Version number: A
Date of issue: 01-03-2005
Source file: IB.2C13060H03 eff. 7/02

Introduction

1.1 General Information

The Magnum Air Circuit Breaker is a fixed or drawout air circuit breaker design utilizing an electronic tripping system. It is designed and tested for use at nominal voltages of 380-440 and 500-690 volts ac. Magnum circuit breakers are available in three physical frame sizes with continuous current ratings from 800 through 6300 A. and interrupting capacities from 42 kA to 150 kA. The three physical frame sizes share common height and depth dimensions, differing only in width. The circuit breaker nameplate provides complete rating information. All Magnum circuit breakers are 100 percent rated and are built and tested in an ISO 9002 certified facility to applicable IEC and BS standards. In addition, the Magnum circuit breaker carries full third-party KEMA certification for both short circuit and endurance test requirements.

Magnum circuit breakers use a rigid frame housing of engineered thermoset composite resins which offers high strength structural properties, excellent dielectric characteristics, and arc tracking resistance.

The drawout Magnum circuit breaker is a through-the-door design having three breaker positions with the compartment door closed: CONNECT, TEST, and DISCONNECT, and one position out of its compartment on extension rails: REMOVE. The operating mechanism is a two-step stored energy mechanism, either manually or electrically operated.

When withdrawn on captive compartment cassette extension rails, Magnum circuit breakers can be inspected, accessory items added, and minor maintenance performed. The inside of the compartment can also be inspected with the circuit breaker on its extension rails.

NOTICE: PLEASE READ AND UNDERSTAND THESE INSTRUCTIONS BEFORE ATTEMPTING TO UNPACK, INSTALL, OPERATE OR MAINTAIN THIS EQUIPMENT. STUDY THE BREAKER AND ITS MECHANISM CAREFULLY BEFORE ATTEMPTING TO OPERATE IT ON AN ENERGIZED CIRCUIT.

Figure 1-1: Family of Magnum Low Voltage Air Fixed and Drawout Circuit Breakers (800-6300 Amperes)

WARNING: MAGNUM CIRCUIT BREAKERS SHOULD NOT UNDER ANY CIRCUMSTANCES BE APPLIED OUTSIDE THEIR NAMEPLATE RATINGS. OPERATION OUTSIDE OF THESE RATINGS COULD RESULT IN DEATH, BODILY INJURY OR PROPERTY DAMAGE.

1.2 Purpose

This instruction manual is intended to cover the installation, operation, and maintenance of Magnum Air Circuit Breakers. These circuit breakers may be supplied as part of complete switchboard assemblies or as separate components. This manual applies only to the circuit breaker and its mating cassette (if drawout). Magnum circuit breakers may also be supplied as fixed mounted devices. For fixed versions, sections referring to position interlocks and the drawout mechanism will not apply.

Trip units associated with Magnum Air Circuit Breakers are addressed generally. Specific trip unit details and time-current characteristic curves are covered in separate documents specific to the trip units.

Magnum circuit breaker accessory items are discussed briefly. Field installation instructions for accessories are covered in individual instruction leaflets specific to the accessory. This information is also available from the Eaton website at www.eatonelectrical.com.

For application information, consult Eaton or see applicable Product Guides, Technical Documents, Application Publications, and/or Industry Standards.

SAFETY: All safety codes, safety standards, and/or regulations must be strictly observed in the installation, operation, and maintenance of this equipment.

WARNING: THE WARNINGS AND CAUTIONS INCLUDED AS PART OF THE PROCEDURAL STEPS IN THIS MANUAL ARE FOR PERSONNEL SAFETY AND PROTECTION OF EQUIPMENT FROM DAMAGE. AN EXAMPLE OF A TYPICAL WARNING LABEL HEADING IS SHOWN ABOVE TO FAMILIARIZE PERSONNEL WITH THE STYLE OF PRESENTATION. THIS WILL HELP TO ENSURE THAT PERSONNEL ARE ALERT TO WARNINGS. IN ADDITION, CAUTIONS ARE ALL UPPER CASE AND BOLDFACE.

1.3 Safety Features

Magnum circuit breakers and associated drawout equipment are manufactured with built-in interlocks and safety-related features. They are provided to reduce hazards to operating personnel and ensure proper operating sequences.

1.4 Safe Practices

To protect personnel associated with the installation, operation, and maintenance of this equipment, the following practices must be followed:

Only qualified electrical personnel familiar with the equipment, its operation, and the associated hazards should be permitted to work on the equipment. Additionally, only qualified personnel should be permitted to install or operate the equipment.
Always be certain that the primary and secondary circuits are de-energized or the circuit breaker is removed to a safe work location before attempting any maintenance.
For maximum safety, only insert a completely assembled breaker into an energized cell.
Always ensure that drawout circuit breakers are in one of their designed cell positions, such as Connect, Test, Disconnect, or Remove. A circuit breaker permitted to remain in an intermediate position could result in control circuits being improperly connected, leading to electrical failures.

1.5 Qualified Personnel

For the purpose of operating and maintaining low voltage power circuit breakers, a person should not be considered qualified if they are not thoroughly trained in the operation of the circuit breaker and how it interfaces with the assembly in which it is used. In addition, the individual should have knowledge of the connected loads.

For the purpose of installing and inspecting circuit breakers and their associated assembly, a qualified person should also be trained with respect to the hazards inherent to working with electricity and the proper way to perform such work. The individual should be able to de-energize, clear, and tag circuits in accordance with established safety practices.

1.6 Other Publications and Documentation

In addition to this instruction manual, other printed information and documentation is available and supplied as appropriate. This additional information can include, but not necessarily be limited to, an instruction manual for a specific electronic trip unit, instruction leaflets for accessory items, renewal parts information, necessary dimensional drawings, and a Product (application) Guide.

Figure 1-2: Typical Magnum Nameplate. Components include: A. Low voltage air circuit breaker family name, B. Breaker family designation number, C. Breaker frame size in amperes, D. Interrupting capacity rating, E. Factory Equipped Accessories.

Figure 1-3: Magnum Designation Example. Illustrates model number breakdown for frame types (MWI, MWN, MWK), interrupting capacity codes, and frame size in amperes.

WARNING: TYPE MAGNUM CIRCUIT BREAKERS ARE ROBUST AND ARE PROVIDED WITH SAFETY FEATURES. NEVERTHELESS, THE VOLTAGES, CURRENTS, AND POWER LEVELS AVAILABLE IN AND AROUND THIS EQUIPMENT WHEN IT IS IN OPERATION ARE EXTREMELY DANGEROUS AND COULD BE FATAL. UNDER NO CIRCUMSTANCES SHOULD INTERLOCKS AND OTHER SAFETY FEATURES BE MADE INOPERATIVE, AS THIS MAY RESULT IN DEATH, BODILY INJURY, OR PROPERTY DAMAGE.

Receiving, Handling and Installation

2.1 General Information

Magnum Air Circuit Breakers, when supplied as part of an assembly, may be shipped already installed in their respective breaker compartments. Receiving and handling of this equipment is addressed in an assembly instruction manual supplied with the assembled equipment. This instruction manual applies to only the circuit breakers.

2.2 Suggested Tools

A large number of different tools are not required to properly install and maintain Magnum circuit breakers. The following tools are, however, suggested:

Flat blade screwdriver
Phillips head screwdriver
3/8" socket (ratchet) wrench
10 mm socket
17 mm socket
Secondary wiring removal tool

2.3 Unpacking Circuit Breaker

Before beginning to unpack new Magnum circuit breakers, read and understand these directions. Following the directions will ensure that no damage is caused.

Shipping containers should be inspected for obvious signs of rough handling and/or external damage incurred during the transportation phase. Record any observed damage for reporting to the transportation carrier and Eaton, once the inspection is completed. All reports and claims should be as specific as possible and include the order number and other applicable nameplate information.

Every effort is made to ensure that Magnum circuit breakers arrive at their destination undamaged and ready for installation. Care should be exercised, however, to protect the breakers from impact at all times. Do not remove protective packaging until the breakers are ready for inspection, testing, and/or installation.

When ready to inspect and install the Magnum circuit breaker, carefully remove the banding straps and lift off the cardboard box. Remove any additional packing material and internally packed documentation. The circuit breaker and/or cassette are mounted to a wooden shipping pallet.

On drawout circuit breakers shipped without a cassette, two shipping clamps hook into the breaker side plates and are held to the pallet with 4 lag screws. Remove the lag screws and clamps. Save the screws and clamps for future shipment of the breaker. On empty cassettes, remove the 4 or 5 lag screws and/or machine screws which pass through the floorpan of the cassette holding it to the wooden pallet. On drawout breakers shipped in a cassette, first remove the breaker from the cassette using the levering mechanism and drawout rails. After the breaker is removed, the machine screws passing through the floorpan can be removed. On fixed breakers, remove the lag screws passing through the mounting feet which hold the breaker to the pallet.

Figure 2-1: Shipping Clamps for Drawout Circuit Breaker. Shows a shipping clamp.

Circuit breakers are designed to be easily lifted from the wooden pallet using an appropriate lifting yoke and overhead or portable lifting device.

2.3.1 Storing Circuit Breaker

If it is necessary to store a circuit breaker before installation, do so in its original shipping container. Keep the circuit breaker in a clean, dry place. Ensure there is ample air circulation and heat, if necessary, to prevent condensation. It is very important that the circuit breaker not be exposed to dirt or moisture.

NOTICE: A CIRCUIT BREAKER THAT HAS BEEN STORED FOR ANY LENGTH OF TIME SHOULD BE OPERATED A MINIMUM OF FIVE TIMES BEFORE IT IS PLACED IN SERVICE.

2.4 Lifting Circuit Breaker

CAUTION: DO NOT ATTEMPT TO LIFT CIRCUIT BREAKERS WITH ORDINARY CRANE HOOKS, ROPES, CHAINS, OR OTHER SUCH DEVICES. FAILURE TO FOLLOW THIS CAUTION COULD RESULT IN DAMAGE TO VITAL PARTS SUCH AS ARC CHUTES, BARRIERS, AND WIRING, OR THE ENTIRE CIRCUIT BREAKER.

To closely examine, install, or become more familiar with the circuit breaker, carefully lift and place the circuit breaker on a solid work surface capable of handling the circuit breaker's weight (Table 2-1) or on the captive drawout extension rails of the breaker compartment. This is accomplished by using the appropriate lifting yoke and lifter. The lifting yoke consists of two steel hooks specially shaped to hook under the integral molded lifting handles on both sides of the circuit breaker. Every effort should be made during lifting to minimize circuit breaker swing and tilt.

If the circuit breaker is to be lifted onto compartment extension rails, follow the instructions in paragraph 2.7 entitled "Installing Drawout Circuit Breaker."

Table 2-1: Basic Circuit Breaker Weights
Breaker model	Weights (kg)		Universal cassette
	Fixed 3P	Fixed 4P	Drawout 3P	Drawout 4P	3P	4P
MWN-408	48	59	48	61
MWN-412	48	61	48	61
MWN-508	49	61	48	61
MWN-512	48	61	48	61
MWN-516	50	62	48	61
MWN-520	48	61	48	61
MWN-608	48	59	48	61
MWN-612	49	61	48	61
MWN-616	50	62	48	61
MWN-620	48	61	48	61
MWI-408	48	59	48	61
MWI-412	48	61	48	61
MWI-608	56	69	50	62
MWI-612	59	74	59	74
MWI-616	51	63	51	63
MWI-620	63	79	63	79
MWI-808	58	73	58	73
MWI-812	70	88	70	88
MWI-816	NOT YET AVAILABLE
MWI-820
MWI-C08	94	118
MWI-C12	116	148
MWI-C16	108	137
MWI-C20	131	167
MWI-625			29	32
MWI-630			29	32
MWI-632			29	32
MWI-825			31	36
MWI-830			31	36
MWI-832			31	36
MWI-C25			38	45
MWI-C30			49	65
MWI-C32			63	79
MWK-232
MWI-641
MWI-841
MWI-C41
MWI-640, 64N
MWI-840, 84N
MWI-C40, C4N
MWI-E40, E4N
MWI-850, 85N
MWI-C50, C5N
MWI-E50, E5N
MWI-863, 86N
MWI-C63, C6N
MWI-E63, E6N

Figure 2-2: Rear View Showing Current Sensor Rating Through Viewing Window.

Figure 2-3: One Side of Drawout Circuit Breaker Properly Seated on Extension Rail. Shows molded rail supports and extension rail cutout.

2.5 Circuit Breaker Inspection

All circuit breakers, once removed from their shipping containers, should be visually inspected for any obvious damage. The current rating of the rating plug installed in the trip unit should match the current rating of the sensors mounted on the lower primary stabs of the circuit breaker. Check to make sure that this match exists. The rating plug rating can be viewed from the front of the circuit breaker. The sensor rating can be viewed through the viewing windows at the rear of the circuit breaker. Sensors and rating plugs can be easily changed as described in Section 6.

2.6 Adapting Cassette

Drawout circuit breaker cassettes are built and shipped in a "basic" configuration that can be adapted in the field to mate with specific circuit breakers. Specifically, the rejection interlock must be configured to the specific circuit breaker to be mated with the cassette, and the automatic secondary connections may have to be installed or upgraded. These operations are described in the following sections.

2.6.1 Rejection Interlocks

Within any one physical frame size, Magnum drawout circuit breakers come in a variety of continuous current and interruption ratings, some of which are incompatible with others. Double wide circuit breakers also come with several phase sequence options which are also incompatible. To prevent the insertion of circuit breakers with (1) inadequate interrupting capability, (2) physically incompatible primary disconnects, or (3) an incompatible phase sequence, rejection interlock key plates are provided on both the circuit breaker and cassette. The key plate on the circuit breaker is pre-assembled at the factory; however, the cassette-side rejection plate and key pattern must be assembled and installed by the switchboard builder.

CAUTION: DO NOT DISABLE REJECTION INTERLOCKS. DOING SO AND USING A LOWER CAPACITY CIRCUIT BREAKER IN AN INCOMPATIBLE CASSETTE COULD RESULT IN AN ELECTRICAL FAULT WHICH COULD RESULT IN DEATH, BODILY INJURY, AND/OR EQUIPMENT DAMAGE.

The rejection interlocks are steel pins in the floor of the circuit breaker cassette. As the circuit breaker is pushed into the structure, the mating pins on the bottom of the circuit breaker move past a set of corresponding pins in the cassette, if the circuit breaker and cassette are compatible. If the circuit breaker and the cassette are mismatched, the rejection pins will block the insertion of the circuit breaker into the cassette before the levering-in mechanism is engaged.

Before attempting to push the circuit breaker into the DISCONNECT position, compare the positioning of rejection interlock pins in the cassette with Table 2-2 and Figure 2-4 and the information supplied on the circuit breaker's nameplate. Proceed if the circuit breaker and cassette are compatible.

Table 2-2: Rejection Interlock Pin Locations
Cell for	Pin Locations
MWN-408, 412	1
MWN-508, 512, 516, 520	2
MWN-608, 612, 616, 620	3
MWI-608, 612, 616, 620	4
MWI-808, 812, 816, 820	5
MWI-C08, C12, C16, C20	6
MWI-625, 632	7
MWI-825, 832	8
MWI-C25, C32	x
MWI-640	x
MWI-64N	x
MWI-840	x
MWI-84N	x
MWI-C40	x
MWI-C4N	x
MWI-E40	x
MWI-E4N	x
MWI-850, 863	x
MWI-85N, 86N	x
MWI-C50, C63	x
MWI-C5N, C6N	x
MWI-E50, E63	x
MWI-E5N, E6N	x
MWK-225, 232	x

Figure 2-4: Cassette Rejection Interlock Pin Positioning/Installation.

2.6.2 Installing Secondary Jumpers

On drawout circuit breakers, the automatic secondary connector between the circuit breaker and cassette can be ordered either fully populated or depopulated (without terminal blocks and jumper wires installed); these parts can be ordered separately and installed by the customer. These kits can also be used to add additional secondary wiring to upgrade circuit breakers in the field.

2.7 Installing Drawout Circuit Breaker

In structures equipped for drawout circuit breakers, a bolted-in cassette with movable extension rails supports the circuit breaker. The extension rails must first be pulled all the way out. Once the rails are fully extended, the circuit breaker can be carefully placed on the extension rails.

CAUTION: IT IS IMPORTANT TO TAKE GREAT CARE WHEN PLACING A DRAWOUT CIRCUIT BREAKER ON ITS EXTENSION RAILS. IF THE CIRCUIT BREAKER IS NOT PROPERLY SEATED ON THE EXTENSION RAILS, IT COULD FALL FROM THE RAILS CAUSING EQUIPMENT DAMAGE AND/OR BODILY INJURY.

Carefully lower the circuit breaker down onto the extension rails. Be certain that the circuit breaker's four molded drawout rail supports are fully seated in the extension rail cutouts on both sides. Do not remove the lifting yoke from the circuit breaker until it is properly seated on the rails.

Once the circuit breaker is on the extension rails and the lifting yoke is removed, proceed with the rest of the circuit breaker installation. From Table 2-2, make a pin location comparison. Stop nuts should be torqued to 8-10 Ft.-Lb.

2.7.1 Circuit Breaker Positioning

The Magnum drawout circuit breaker has four normal positions:

REMOVE (Withdrawn)
DISCONNECT
TEST
CONNECT

The REMOVE position is a position outside the compartment on the cassette's drawout rails where the circuit breaker is not engaged with the levering mechanism. The DISCONNECT, TEST, and CONNECT positions are reached by means of the levering mechanism.

With the breaker solidly positioned on the cassette's extension rails and the levering-in mechanism in the DISCONNECT position, carefully and firmly push the circuit breaker into the compartment as far as it will go. The outer (recessed) portion of the circuit breaker face plate should align with the GREEN target line (labelled DISC) on the inside top left wall of the cassette.

Figure 2-5: Remove Position. No Electrical Connections Made. Breaker On Extension Rails. Remove or Inspection Position.

Figure 2-6: Disconnect Position. Only Ground Connection Made. Breaker Still Behind Door. Typical Storage Position.

Figure 2-7: Test Position. Breaker and Trip Unit Testing. Primary Connection Not Made. Secondary and Ground Connections Made.

Figure 2-8: Connect Position. Full Breaker Operation. Primary, Secondary and Ground Connections Made. Fully Racked into Cassette (Compartment).

CAUTION: MAKE CERTAIN THAT THE CIRCUIT BREAKER IS FULLY INSERTED INTO ITS COMPARTMENT BEFORE ANY ATTEMPT IS MADE TO LEVER THE CIRCUIT BREAKER. ATTEMPTING TO LEVER THE CIRCUIT BREAKER IN BEFORE IT IS FULLY POSITIONED INSIDE ITS COMPARTMENT CAN RESULT IN DAMAGE TO BOTH THE CIRCUIT BREAKER AND THE COMPARTMENT.

Figure 2-9: Cassette Label Showing Disconnected, Test and Connected Position of Recessed Cover.

2.7.2 Levering Circuit Breaker

The circuit breaker is now ready to be levered. With the circuit breaker OPEN, the levering device access door can be raised. The levering device is hand operated using a standard 3/8" square drive and ratchet, which is not provided. As long as the levering access door is raised, the circuit breaker is held trip free. Begin by rotating the levering-in screw to the full counterclockwise (DISCONNECT) position.

Close the compartment door and begin levering the breaker into its different positions using a clockwise ratcheting motion. The circuit breaker can be levered with the compartment door open or closed, but it is advisable to close the door prior to levering. The position of the circuit breaker within its compartment is indicated by color-coded position indicators (Red = Connect, Yellow = Test, Green = Disconnect). When the circuit breaker is levered fully to the DISCONNECT or CONNECT position, the levering shaft hits a hard stop; do not exceed 34.2 N.m. of torque or the levering mechanism may be damaged. To remove the circuit breaker from its compartment, follow the procedure just described using a counterclockwise ratcheting motion.

NOTICE: THE CIRCUIT BREAKER MECHANISM IS INTERLOCKED SUCH THAT CHARGED CLOSING SPRINGS ARE AUTOMATICALLY DISCHARGED IF THE CIRCUIT BREAKER IS LEVERED INTO OR OUT OF THE CELL. DISCHARGE TAKES PLACE BETWEEN THE DISCONNECT AND TEST POSITION.

Figure 2-10: Levering Position Indication. Shows color-coded indicators for Connect (Red), Test (Yellow), and Disconnect (Green).

2.8 Fixed Circuit Breaker

The Magnum fixed type circuit breaker differs from the drawout version in that it has no levering device, primary disconnects, and secondary disconnects. In addition, a fixed circuit breaker does not have a standard feature to hold the breaker in a trip-free position. Fixed circuit breakers can be mechanically interlocked using either the optional key interlock (which is mounted through the front panel) or with optional cable interlocks which operate on the tripper bar.

Circuit breaker terminals have holes for making bolted horizontal primary bus connections. Adapters are available for making vertical primary bus connections. Secondary connections can be made through standard terminal blocks or a special connector compatible with the drawout circuit breaker's type secondary connector. Both secondary connection devices are mounted at the top front of the circuit breaker.

The fixed circuit breaker frame has two mounting feet, one on each side, to permit the fixed circuit breaker to be securely mounted. Each mounting foot has two slotted mounting holes which are used to bolt the circuit breaker securely in place. Use either M10 or 3/8" bolts for this purpose. Refer to the dimensional drawings referenced in Section 5 (Fixed Circuit Breakers) for circuit breaker and bus stab dimensions.

Figure 2-11: Typical Fixed Magnum Circuit Breaker. Shows mounting foot.

NOTICE: REFER TO THE CIRCUIT BREAKER WEIGHTS IN TABLE 2-1 TO ENSURE THAT THE PANEL ON WHICH A FIXED CIRCUIT BREAKER IS TO BE MOUNTED IS CAPABLE OF SUPPORTING THE WEIGHT.

2.9 Circuit Breaker Operation

Circuit breakers should be operated manually and/or electrically before they are put into service. This can be done during the installation process or at a later date prior to start-up. To check circuit breaker operation, follow the operational procedures outlined in Section 3 for both manually operated and electrically operated circuit breakers.

Circuit Breaker Description and Operation

3.1 Introduction

Magnum circuit breakers are available in three physical frame sizes and in both drawout and fixed mounting configurations. A majority of features are common to both configurations and will be discussed in this section. The mounting features unique to the drawout and fixed configurations will be covered individually in Sections 4 and 5 respectively.

Controls and indicators for both drawout and fixed circuit breakers are functionally grouped on the front of the circuit breaker. The front escutcheon (faceplate) is common for the three frame sizes that cover all continuous current ratings through 6300 amperes.

Double Wide frame circuit breakers utilize six (or eight) sets of rear primary connections; these circuit breakers are available from the factory with several different phase sequences, distinguishable by the sixth character in the model number. The phase sequence is also labeled on the rear of the circuit breaker. For drawout breakers, phase sequence labels are also supplied with the cassette and must be applied by the switchgear builder. Circuit breakers with different phase sequences are not interchangeable. Drawout breakers with differing phase sequences are prevented from insertion into the cassette by properly assembled rejection key plates (see section 2.6.1).

Figure 3-1: Typical Drawout Circuit Breaker Features (Front and Rear Views). Shows components like Baffled Arc Chute Cover, Secondary Disconnects, Faceplate, Drawout Rail Supports, Integral Lifting Handle, Primary Moving Contacts, Arc Chamber, Tripper Bar, Sensor Rating Viewing Window, Levering Device Bearing Plate, Padlockable Levering Device Access Door, and Circuit Breaker Nameplate.

Figure 3-2: Typical Fixed Circuit Breaker Features (Front and Rear Views). Shows components like Baffled Arc Chute Cover, Secondary Disconnect, Faceplate, Integral Lifting Handle, Fixed Horizontal Primary Terminal, Fixed Primary Terminal (with optional Vertical Adapter), Arc Chamber, Sensor Rating Viewing Window, Mounting Foot, Circuit Breaker Nameplate, and Tripper Bar.

Figure 3-3: Typical Double-wide Standard Frame Fixed Circuit Breaker Features (Front and Rear Views). Shows components like Baffled Arc Chute Cover, Secondary Contact Connector, Faceplate, Integral Lifting Handle, Fixed Vertical Primary Terminals with Optional Vertical Adaptor, Arc Chamber, Mounting Foot, Circuit Breaker Nameplate, Phase Identification Labels, and Tripper Bar.

Figure 3-4: Typical Drawout Circuit Breaker Features (Front and Rear Views). Shows controls and indicators: Trip Flag (Pop Out Indicator), Accessory Windows, Trip Unit, Rating Plug, Contact Status (Open-Close), Spring Status (Charged-Discharged), Manual "OFF" Button, Manual "ON" Button, Manual Charge Handle, Optional Operation Counter, Padlockable Levering Device Access Door for Drawout Breaker, Color Coded-Breaker Position Indicator, Nameplate, Trip Unit Test Port, Trip Unit Cover with Mounting Screws.

3.2 Basic Circuit Breaker Assembly

Magnum circuit breakers use a rigid frame housing construction of engineered thermoset composite resins. This construction provides high strength structural properties, excellent dielectric characteristics, and resistance to arc tracking.

The 3-piece construction approach provides support while isolating and insulating power conductors:

A 2-piece engineered thermoset composite resin case encloses current paths and arc chambers. The chambers act to channel arc gases up and out of the circuit breaker during interruption.
The operating mechanism sits on the front of the case and is electrically isolated and insulated from current contact structures. It is covered by an insulating front cover.

Figure 3-5: Typical Magnum Construction (Right Side View). Shows Case and Front Cover.

3.3 Pole Units

A current carrying pole unit is individually enclosed and rigidly supported by the case. The individual chambers provide for pole unit isolation and insulation from one another. Each pole unit has one primary contact assembly, which consists of a moving portion and a fixed portion. The exact design configuration depends upon the breaker's frame size. Double-wide circuit breakers use two pole units and arc chute assemblies connected mechanically and electrically in parallel to form each phase.

3.3.1 Primary Moving Contacts

Depending upon the frame size, each primary moving contact assembly is comprised of multiple individual copper contact fingers connected to the load conductor through flexible braided connectors. Two flexible connectors are used to connect each finger to the load conductor. The number of fingers used depends upon the circuit breaker's continuous and short-circuit current ratings. On some ratings, fingers are removed and replaced with spacers.

The single contact finger performs both the main and arcing contact functions on different parts of the same finger. A highly conductive alloy pad is part of the contact finger and functions as the moving main contact, and is called the "Heel." The tip of the same contact finger functions as the moving arcing contact, and is called the "Toe."

Figure 3-6: Features of Magnum Moving Conductor Assembly. Shows Pivot Point, Single Contact Finger, Moving Arcing Contact Area (Toe), Moving Main Contact Conductive Pad (Heel), and Dual Flexible Connections.

Figure 3-7: Narrow Frame (8-finger) Moving Conductor Assembly. Shows "Toe" (Arcing Contact) and "Heel" (Main Contact).

Figure 3-8: Standard Frame (12-finger) Moving Conductor Assembly. Shows "Toe" (Arcing Contact) and "Heel" (Main Contact).

3.3.2 Primary Stationary Contacts

The primary stationary contact is a combination of two items. One is a conductive pad mounted on the line conductor which functions as the stationary main contact. The other is an arc runner, also connected to the line conductor. The integral arc runner serves a dual purpose:

Fixed arcing contact
Part of the arc chute

Figure 3-9: Partial Cross-Sectional View (Shown in Closed Position).

3.4 Operating Mechanism

The Magnum operating mechanism is based on the proven cam and spring design of the DSII power circuit breaker. It is easily accessed by removing four cover screws and the front cover. The mechanism is a two-step stored energy mechanism. Potential energy is stored to close the circuit breaker. Sufficient energy to open the circuit breaker remains available after a closing operation.

3.4.1 Manual Operation

On manually operated circuit breakers, the closing spring can only be charged manually. To manually charge the spring, insert one finger in the recess behind the charging handle and pull out. This permits a gloved hand to grasp the handle and begin charging. It takes from 5 to 7 downward strokes on the charging handle to complete the manual charging process. It is possible to manually recharge the spring immediately after closing the circuit breaker and before it has been tripped open.

Standard manually operated circuit breakers are closed and opened by hand using the Manual "ON" and Manual "OFF" buttons respectively located on the front of the circuit breaker. Performing either operation is accomplished by pressing and releasing the appropriate button. Access to these pushbuttons can be limited by the use of an optional, padlockable cover. In addition, complete access to the "ON" button can be prevented with an optional prevent close cover. The status of the springs and the primary contacts are always indicated in an indicator window just above the pushbuttons.

Electrically operated optional devices are available to automatically close or trip a manually operated circuit breaker. An electrical spring release is available to close a manually operated circuit breaker. Two optional devices, a shunt trip and an undervoltage release, are available to automatically trip (open) a manually operated circuit breaker. These optional devices can be installed easily in the field. For more details on these devices, refer to paragraph 3-8 in this manual.

An electrical operator which is used to charge the closing spring automatically can be added to a manually operated circuit breaker in the field. Manually operated circuit breakers are pre-wired to accept this addition.

Figure 3-10: Electrically Operated Drawout Circuit Breaker with Front Cover Removed. Shows Secondary Wiring Points, Field Installable Accessories, Trip Unit, Electric Charging Motor, Manual Charge Handle, Operations Counter (optional), Padlockable Levering Device Access Door, and Breaker Position Indicator.

Figure 3-11: Circuit Breaker Closing Springs Being Manually Charged.

3.4.2 Electrical Operation

For electrically operated circuit breakers, the springs are normally charged through the use of an electrical operator. The springs can, however, be charged manually as just described in the previous paragraph.

Like the manually operated circuit breaker in the previous paragraph, electrically operated circuit breakers can also be manually closed and opened through the use of the front mounted Manual "ON" and Manual "OFF" buttons.

An electrically operated circuit breaker from the factory is also equipped as standard with a spring release to close the circuit breaker electrically. An optional shunt trip and undervoltage release are also available to trip (open) an electrically operated circuit breaker. Refer to paragraph 3.8 for more details on both standard and optional devices.

Figure 3-12: Electrical Motor Operator to Charge Closing Spring. Shows the Electrical Motor Operator.

3.4.3 Anti-Pump Feature

The Magnum circuit breaker has both mechanical and electrical anti-pump features. If the circuit breaker is closed on a fault condition (and trips open while the CLOSE signal is maintained), using either the mechanical pushbutton or the electrical close coil, it will not make another attempt to close until the close command is removed and reapplied. Note that if the close signal is applied prematurely (before the breaker is completely charged and latched), the close command will be ignored until it is removed and reapplied.

For electrical closing, a Latch Check Switch (LCS) option is available (see paragraph 3.8.1) which will block the application of the electrical close command until the breaker is ready to close.

3.5 Arc Chambers

The Magnum circuit breaker utilizes arc chambers to insulate and isolate individual poles from one another, from the rest of the circuit breaker, and from operating personnel. Arc chambers are molded and integral parts of the circuit breaker frame. Enclosed within each arc chamber is an arc chute which mounts over each set of primary contacts.

After the main contacts part, any remaining current is driven to the arcing contacts. Magnetic action draws the arc to the arc chute. As the arcing contacts separate, the moving arcing contacts discharge into the arc chute plates while the integral arc runner also helps to draw the arc into the arc chute.

Figure 3-13: Cross Section of Conductor and Arc Control System.

Figure 3-14: Integral Arc Runner Viewed From Top of Arc Chamber (Arc Chute Removed, Circuit Breaker Closed). Shows the Integral Arc Runner.

Figure 3-15: Magnum Arc Plate Assembly. Shows "V" Shaped Plates and Top Plate for Arcing Contact.

3.5.1 Arc Chute

The Magnum arc chute mounts down over the arcing contact. Alternating V-shaped arc chute plates attract the arc and interrupt it. The top arc plate, which is a part of the arc chute itself, also helps to attract the arc away from the moving arcing contact and up into the arc chute's V-shaped plates. Arc chute components are assembled in an insulating jacket which is removable from the top of the circuit breaker, as previously described in paragraph 2.4. Each arc chute has a baffled top cover.

3.6 Electronic Tripping System

The Magnum circuit breaker utilizes a three-part tripping system:

Microprocessor-based trip unit
Current Sensors
Trip Actuator

All three parts of the tripping system are discussed here, except that the trip unit itself is not discussed in detail. For detailed information pertaining to the different trip unit models available with Magnum circuit breakers, refer to the specific instruction leaflet dedicated to the trip units.

3.6.1 Microprocessor-Based Trip Unit

Magnum circuit breakers use any one of a family of Digitrip RMS trip units whose main features are summarized in Table 3-1. Versions of the trip unit without the "i" meet the USA National Electric Code which specifies a maximum ground fault current setting of 1200A; the trip units are otherwise identical. Note, however, that the 1150/1150i trip units are not available in the narrow frame circuit breaker.

Table 3-1: Magnum-Digitrip Trip Units
Functions	220	520i6	520Mi5+6	520MC5+6	1150i5+6
LSIG Protection	Yes 1	Yes	Yes	Yes	Yes
Disable (I)	No	Yes	Yes	Yes	Yes
GF Protection	No	Yes	Yes	Yes	Yes
GF Alarm	No	No	Yes	Yes	Yes
Display	No	No	Yes2	Yes2	Yes3
Programmable	No	No	No	No	No
Metering	No	No	Yes4	Yes4	Yes4
Power and Energy Values	No	No	No	No	Yes
Power Quality	No	No	No	No	Yes
Communication	No	No	No	No	Yes

Notes for Table 3-1:

Long and Instantaneous only.
One-line, (four characters per line) LCD display.
Three-line, (eight characters per line) LED display.
Phase, neutral, ground, and high load current only.
Available control voltages are 24/48Vdc, 120Vac and 240Vac.
Models 520, 520M, 520MC and 1150 also available with a maximum ground fault current setting of 1200A.

A functional local test of a major portion of the trip unit's electronic circuitry and the circuit breaker's mechanical tripping action can be verified through the trip unit's test receptacle. This is accomplished using a Digitrip (DS Type) Test Kit which provides a secondary injection test that simulates the current sensors. A small handheld Magnum functional Test Kit can also be used to check circuitry and mechanical tripping functions.

When the circuit breaker is shipped from the factory, the trip unit's protective functions are normally set at minimum values. For specific overload tripping characteristics and time/current curves to coordinate with a load or system, refer to the trip unit instruction book.

Figure 3-16: Pictorial Diagram of Typical Current Sensing, Processing and Tripping System. Shows Toroidal Current Sensor, Rating Plug, Trip Unit, Trip Actuator, Magnum Circuit Breaker, and Sensors.

Figure 3-17: Digitrip RMS1150 Programmable Trip Unit Installed in Magnum Circuit Breaker. Shows Pop Out Trip Flag, Auxiliary Power Module Port, Rating Plug, and Test Receptacle.

Figure 3-18: Hand Held Tester.

3.6.2 Rating Plug

All Magnum circuit breaker trip units use a fixed type rating plug. The current rating of the rating plug must match the current rating of the integrally mounted current sensors. The rating plug performs several functions:

It tells the trip unit what the rating is of the current sensors. A label on the front of the rating plug clearly indicates that the rating plug and sensors must have the same rating.
It determines the maximum instantaneous setting, which is a function of the current sensor rating.
When it is required that the maximum ground fault pickup value not exceed 1200 amperes, a properly matched rating plug accomplishes this requirement for higher ampere sensors by incorporating circuitry to identify that level by sensor rating.

If the rating plug is removed from the trip unit, the circuit breaker will trip if it is carrying current. Make certain the rating plug is secured in position with its retaining screw. Do not torque the retaining screw beyond 0.1 Nm.

Refer to Table 3-2 for a tabulation of the available rating plugs.

Table 3-2: Magnum Current Sensors and Matching Rating Plugs
Current Rating in Amperes
200	1000
250	1200
300	1250
400	1600
600	2000
630	2500
800	3000
	3150
	3200
	4000
	5000
	6300

3.6.3 Current Sensors

Three toroidally wound current sensors are installed at the rear of the circuit breaker on the lower terminals. The sensors produce an output current proportional to the load current. Under preselected conditions of current magnitude and time, the sensors furnish the trip unit with a signal and the energy required to trip the circuit breaker.

External neutral current sensors are also available for customer installation. The additional sensor is not supplied with the circuit breaker and must be ordered separately. They are wired to the trip unit through the secondary contacts of the circuit breaker.

Refer to Table 3-2 for a tabulation of the available current sensor ratings.

Figure 3-19: Replaceable Current Sensors Shown with Bottom Adapters and Cover Plate Removed. Shows a Toroidal Sensor.

3.6.4 Trip Actuator

The trip actuator is a small cylindrically shaped electromagnetic device which acts mechanically to trip the circuit breaker in response to a signal from the trip unit. In general, it is comprised of a permanent magnet, a spring-loaded rod to produce the mechanical tripping, and a lever for resetting the actuator after tripping occurs. The electronic trip unit provides a pulse which counteracts the effect of the permanent magnet, releasing the spring-loaded rod to act mechanically. The device is reset when the circuit breaker opens.

3.6.5 Mechanical Trip Flag

A red, pop-out mechanical trip indicator is an optional Magnum feature. It is located above the trip unit on the breaker's front faceplate. It operates by releasing and popping out any time the circuit breaker trips due to an overcurrent condition. Note that the mechanical trip indicator will not prevent the breaker from being reclosed. The indicator is reset manually by pushing it back in. If the indicator is not reset, the circuit breaker will operate normally, but future mechanical trip indication will be lost.

An optional overcurrent trip switch (bell alarm) that operates off the position of the mechanical trip indicator is also available. The switch is reset when the trip indicator is reset.

On optional Digitrip models with LED cause-of-trip indicators, these indicators should also be reset (by pushing momentarily) after the cause of the fault has been diagnosed; this will preserve the internal battery. On trip units equipped for communication, the LED reset function can be performed remotely using INCOM commands.

3.6.6 Making Current Release

All Magnum circuit breaker trip units have a making current release function. This safety feature prevents the circuit breaker from being closed and latched on a faulted circuit. The non-adjustable release is preset at a peak instantaneous current of 25 x In; this corresponds to an rms current of 11 x In with maximum asymmetry.

The making current release is enabled only for the first 2 cycles following a circuit breaker closing operation. The making current release will trip the circuit breaker instantaneously, release the mechanical (pop-out) indicator, and flash the instantaneous LED trip indicator, if so equipped.

3.6.7 High Instantaneous Trip Option

The high instantaneous trip option is installed in 800 to 3200 ampere Magnum circuit breakers with a 100 kA interrupting capacity. In general, the high instantaneous trip is comprised of three small air core sensors, one in each phase, which produce a signal and transmit it back to the trip unit when the 85 kA withstand rating of the circuit breaker is exceeded. The result is an instantaneous trip by the circuit breaker. This high instantaneous trip option permits the 800-3200 ampere Magnum circuit breakers to be applied where a 100 kA fault is possible, while selectivity up to 85 kA is maintained.

3.6.8 Voltage Taps

On circuit breakers with Digitrip 1150 trip units, potential taps are required to monitor the three phase voltages. Voltage taps may be placed on either the line (top) or load (bottom) terminals of the breaker at the factory. Figure 3-20 illustrates line-side voltage taps.

Figure 3-20: Line-Side Voltage Tap for 1150 Trip Unit.

Labels Legend:

OTS: Overcurrent Trip Switch
UVR: Undervoltage Release
ATR: Automatic Trip Relay (520M and 1150 Trip Units Only)
INCOM: PowerNet Communications Network
ABUS: (Future Use)
A/S: Auxiliary Contacts
NEUTRAL: Neutral Sensor Input
GFSGND: Source Ground Input
ZONE: Zone Interlocking
ST: Shunt Trip
SR: Spring Release
MOTOR: Charging Motor
LCS: Latch Check Switch

Figure 3-21: Top View Secondary Connectors. Shows Secondary Connector Labels.

3.7 Secondary Contacts and Connection Diagrams

A maximum of sixty secondary wiring connection points are available on the standard frame circuit breaker (48 on narrow frame), each dedicated to a specific function. The wiring points are finger safe with no more than two wires per terminal.

Up to two secondary contact plug-in connectors (AMP), each with 30 secondary points, are mounted on the top rear portion of the circuit breaker. The plug-in connectors are protected by a molded hood.

Figure 3-22: Secondary Connector Protective Hood. Shows the Protective hood.

How many connectors are mounted depends upon a number of considerations, such as whether the circuit breaker is electrically or manually operated and how many features are required. When the front cover of the circuit breaker is removed, the top of each plug-in connector is exposed. A label on each connector identifies the wiring points.

Drawout type circuit breakers: Compatible secondary plug-in connectors are mounted on the top front portion of the drawout cassette. These connectors match and plug into the circuit breaker mounted connectors. Contact points are wired from the cassette's plug-in connectors to cassette mounted terminal blocks. The terminal blocks are also mounted on the top front portion of the cassette. The secondary terminals have finger-proof hinged covers with small holes for probe testing.

Figure 3-23: Cassette Mounted Secondary Wiring. Shows Closed Hinged Covers with Testing Holes, Terminal Blocks, and Plug-in Connectors.

Fixed type circuit breakers: There are two secondary connection options:

Without Terminal Block
With Terminal Block

1. Without Terminal Block - If a terminal block for customer use is not required, the circuit breaker is supplied with both plug-in connectors (male and female) just described in the two previous paragraphs. The plug-in connectors are joined and attached to the top portion of the circuit breaker. The customer can plug secondary wiring with crimp-on connectors into the back of the plug-in connectors; subsequently, the connections to the circuit breaker can be quickly joined or separated as required.

2. With Terminal Block - For customers preferring to wire to a terminal block, terminal blocks with finger-proof hinged covers are added to the secondary configuration just described for a fixed circuit breaker "without a terminal block." The terminal blocks are wired to the plug-in connectors and also permanently attached to the upper rear portion of the circuit breaker.

A standard tool is available from the plug-in connector manufacturer (AMP) to facilitate the removal of secondary wiring from a plug-in connector, or contact Eaton for assistance. The connector halves must be separated to use this tool.

Figure 3-24: AMP Secondary Wiring Removal Tool.

3.7.1 Connection Diagrams

The connection diagrams for all Magnum circuit breakers using Digitrip RMStrip units are shown in Figures 3-25 through 3-30. These diagrams illustrate various configurations for narrow, standard, and double-wide frames with different Digitrip models (220, 520, 520M, 520MC, 1150) and phase arrangements (ABCABC, AABBCC).

Figure 3-25: Connection Diagram for Narrow and Standard Frame with Digitrip 220/520/520M/520MC. Includes detailed notes on wiring, functions, and optional accessories.

Figure 3-26: Connection Diagram for Standard Frame with Digitrip 1150. Includes detailed notes on wiring, functions, and optional accessories.

Figure 3-27: Connection Diagram for Double-wide Frame with Digitrip 520/520M/520MC with ABCABC Configuration. Includes detailed notes on wiring, functions, and optional accessories.

Figure 3-28: Connection Diagram for Double-wide Frame with Digitrip 520/520M/520MC with AABBCC Configuration. Includes detailed notes on wiring, functions, and optional accessories.

Figure 3-29: Connection Diagram for Double-wide Frame with Digitrip 1150 with ABCABC Configuration. Includes detailed notes on wiring, functions, and optional accessories.

Figure 3-30: Connection Diagram for Double-wide Frame with Digitrip 1150 with AABBCC Configuration. Includes detailed notes on wiring, functions, and optional accessories.

3.8 Accessory Devices

A variety of accessory devices are available for use with Magnum circuit breakers. Unless otherwise stated, they are all considered optional devices in the sense that they are not provided as standard on a manually operated circuit breaker. Available accessories are identified here and discussed in general terms. For more detailed information and/or installation instructions, refer to individual instruction leaflets dedicated to the accessories.

Magnum circuit breaker accessories are designed to fit all frame sizes. The accessories fall into one of three categories: Plug-in electrical, Internal electrical, or Mechanical.

3.8.1 Plug-in Electrical Accessories

There are four Magnum Plug-In electrical accessories. Three can be viewed for identification by name and rating through viewing windows located in the right front of the circuit breaker. All four are plug-in type and can be factory installed or field installed.

The four Plug-In accessories are:

Shunt Trip (ST)
Spring Release (SR)
Undervoltage Release (UVR)
Auxiliary Switch

Shunt Trip - The shunt trip is an optional device on circuit breakers. It opens the circuit breaker instantaneously when its coil is energized by a voltage input (Table 3-3). A total of two shunt trips can be mounted on a Magnum circuit breaker.

Table 3-3: Shunt Trip Ratings
Control Voltages	Operational Voltage Range 70-110%	Inrush Power Consumption1	Opening Time (ms)
24 Vdc	17-26 Vdc	250 W	35
48 Vdc	34-53 Vdc	250 W	35
110-125 Vdc	77-138 Vdc	450 W	35
220-250 Vdc	154-275 Vdc	450 W	35
110-127 Vac	77-140 Vac	450 VA	35
208-240 Vac	146-264 Vac	450 VA	35

1 Required for less than 35 ms

Figure 3-31: Through-the-Window Electrical Accessories. Shows Accessory Viewing Windows.

Figure 3-32: Shunt Trip with Cutoff Switch.

Figure 3-33: Shunt Trip Switch Installed.

Spring Release - The spring release is an optional device. It remotely closes the circuit breaker when the coil is energized by a voltage input (Table 3-4). The closing spring must be fully charged and the trip latch reset (not held in the tripped position) for the SR to operate. If these two conditions are not met, the close signal will be ignored until it is removed and re-applied.

An optional Latch Check Switch (LCS) can also be installed to delay application of power to the Spring Release coil until the circuit breaker is "ready to close". The LCS will not permit energization of the Spring Release until the breaker is fully charged and the trip latch is reset. Two versions of the LCS are available. One version is wired internally to the Shunt Trip coil control circuit. On the other version, the LCS switch contacts are brought out through the secondary contacts for integration into external control schemes. Note that placing the (externally accessible) LCS directly in series with the ST coil is not recommended as this will override the "anti-pump" feature of the electrical charging/closing system.

Table 3-4: Spring Release Ratings
Control Voltages	Operational Voltage Range 70-110%	Inrush Power Consumption1	Closing Time (ms)
24 Vdc	17-26 Vdc	250 W	40
48 Vdc	34-53 Vdc	250 W	40
110-125 Vdc	77-138 Vdc	450 W	40
220-250 Vdc	154-275 Vdc	450 W	40
110-127 Vac	77-140 Vac	450 VA	40
208-240 Vac	146-264 Vac	450 VA	40

1 Required for less than 200 ms

Figure 3-34: Spring Release with Optional Latch Switch.

Undervoltage Release - The undervoltage release is an optional device on both manually and electrically operated circuit breakers. It opens the circuit breaker when its supply voltage falls to between 35-60% of rated voltage. If the release is not energized to 85% of its supply voltage, the circuit breaker cannot be closed electrically or manually (Table 3-5).

Figure 3-35: Undervoltage Release.

Figure 3-36: Shunt Trip, Spring Release and Undervoltage Release Installed.

Auxiliary Switch - An auxiliary switch is an optional device providing remote electrical indication if the circuit breaker is open or closed. Up to 3 auxiliary switches can be mounted in the circuit breaker. Each switch has 2 normally open ("a") and 2 normally closed ("b") contacts for a total of 12 available contacts (Table 3-6).

Figure 3-37: Auxiliary Switch (2A/2B).

3.8.2 Internal Electrical Accessories

Other electrical accessories are mounted inside the circuit breaker. They can be factory or site installed. There are two different internally mounted accessories:

Overcurrent Trip Switch (Bell Alarm)
Motor Operator

Overcurrent Trip Switch (Bell Alarm) - An overcurrent trip switch (bell alarm) is an optional device that is used with an optional pop-out indicator. It provides an electrical indication when a circuit breaker trips as a result of the trip unit reacting to an overcurrent condition. Opening as a result of a circuit breaker's manual open button, shunt trip, or undervoltage release does not cause the overcurrent trip switch to operate. The overcurrent trip switch has (2a 2b) Form C contacts (Table 3-6).

The status of the contacts changes when the trip indicator pops out. This permits the switch to be used as an alarm or in conjunction with a spring release to block a subsequent remote electrical closing signal.

Motor Operator - A Motor operator is an electric motor assembly internally mounted in the circuit breaker. It charges the closing springs electrically for remote or local operation. The motor operator can be factory or site installed (Table 3-7).

To convert a manually operated circuit breaker to an electrically operated circuit breaker, a motor operator kit is available.

Figure 3-38: Mechanical Trip Indicator with Associated Overcurrent Trip Switch. Shows Overcurrent Trip Switches and Mechanical Trip Indicator.

Figure 3-39: Motor Operator Kit.

Figure 3-40: Motor Operator Installed in Narrow Frame Circuit Breaker.

Table 3-5: Undervoltage Release
Control Voltages	Operational Voltage Range 85-110%	Dropout Volts 30-60%	Inrush/Continuous Power Consumption1 2	Opening Time (ms)
24 Vdc1	20-26 Vdc	7-14 Vdc	250 W/18 W	70
32 Vdc1	27-35 Vdc	10-19 Vdc	275 W/15 W	70
48 Vdc1	41-53 Vdc	14-29 Vdc	275 W/18 W	70
110-125 Vdc1	94-138 Vdc	33-75 Vdc	450 W/10 W	70
220-250 Vdc1	187-275 Vdc	66-150 Vdc	450 W/10 W	70
110-127 Vac2	94-140 Vac	33-76 Vac	450 VA/10 VA	70
208-240 Vac2	177-264 Vac	62-144 Vac	400 VA/10 VA	70
380-415 Vac2	323-457 Vac	114-249 Vac	480 VA/10 VA	70
480 Vac2	408-528 Vac	144-288 Vac	400 VA/10 VA	70
600 Vac2	510-660 Vac	180-360 Vac	400 VA/10 VA	70

1 Required for 200 ms. 2 Required for 400 ms.

Table 3-6: Auxiliary Switch, Overcurrent Trip Switch and Cell Switch Contact Ratings
Contact Rating	Inductive Load (amperes)
250 Vac	10
125 Vdc	0.5
250 Vdc	0.25

Table 3-7: Motor Operator
Control Voltages1	Operational Voltage Range 85-110%	Running Current (A. avg.)	Typical Inrush Current	Power Consumption (watts or VA)	Maximum Charging Time (seconds)
24 Vdc	20-26	12.0	300% of Running	300	5
48 Vdc	41-53	5.0	500% of Running	250	5
110-125 Vdc	94-138	2.0	600% of Running	250	5
220-250 Vdc	187-225	1.0	600% of Running	250	5
110-127 Vac	94-140	2.0	600% of Running	250	5
208-240 Vac	177-264	1.0	600% of Running	250	5

1 AC voltages are 50/60Hz

3.8.3 Mechanical Accessories

There are eleven optional mechanical type accessories:

Operations Counter
Off Key Lock
Cassette Lock
Pushbutton Cover
Prevent Close Cover
Cassette Safety Shutters
Cassette Cell Switch
Door Escutcheon
Waterproof Cover
Mechanical Interlock
Mechanical (Pop-out) Trip Indicator

Operations Counter - The operations counter is a mechanical device used to provide a record of the number of circuit breaker open-close operations. It is mounted in the lower right portion of the circuit breaker and can be viewed through the front cover.

Off Key Lock - The off key lock secures the circuit breaker in the "OFF" position. It is mounted in the lower right portion of the circuit breaker and can be viewed through the front cover. The customer supplies the key lock. The provisions available are for Kirk, Castell, or Ronis.

Figure 3-41: Cover Mounted Key Lock and Operations Counter. Shows Operation Counter and "OFF" Key Lock.

Figure 3-42: Cassette Mounted Key Lock.

Cassette Lock - A cassette mounted lock can be used in conjunction with different interlocking schemes (such as main-tie-main). The lock holds the circuit breaker trip-free in the connected position, preventing it from being closed. Up to three lock cylinders can be installed on one cassette. Eaton supplies the lock provisions only. The customer is responsible for the locks, which can be Kirk or Castell.

Figure 3-43: ON-OFF Pushbutton Lockable Cover Plate.

Pushbutton Cover - A padlockable cover is available to limit access to the "ON" and "OFF" pushbuttons. It can be installed with either or both pushbutton covers in place.

Prevent Close Cover - Complete access to the "ON" pushbutton can be prevented by adding the prevent close cover to the pushbutton cover.

Cassette Safety Shutters - Automatically operated insulating type safety shutters are available for use with the drawout cassette. When the drawout circuit breaker is levered from the CONNECT position, the shutters automatically close to cover the fixed primary contacts. When the circuit breaker is levered into the cassette, the shutters automatically open permitting primary connections to be made.

Figure 3-44: Safety Shutters in Closed Position.

Figure 3-45: Safety Shutters in Open Position.

Cassette Cell Switches - The cassette cell switches are compartment position switches for drawout circuit breakers. They are available in a 2a2b contact configuration, and mount on the right side of the cassette. Refer to the Ratings Table 3-6 for cell switch contact information. One or more cell switches can be mounted to operate at the WITHDRAWN, TEST, or CONNECT position.

Figure 3-46: Cell Switch (Drawout Position Indicator) Unmounted.

Figure 3-47: Cell Switches Mounted on Cassette.

Door Escutcheon - The door escutcheon is a molded frame used to seal the space between the circuit breaker and the compartment door cutout. It is supplied with a mounting gasket.

Figure 3-48: Door Escutcheon and Gasket.

IP54 Waterproof Cover - A hinged dome-shaped waterproof cover attaches to the metal compartment door to provide waterproof protection for the circuit breaker.

Figure 3-49: IP54 Waterproof Cover.

Mechanical Interlock - A family of mechanical interlocks are available to interlock the closing of two or three Magnum circuit breakers. The mechanical interlock holds one or more circuit breakers tripped (prevents closure) when others are closed. A lever assembly is mounted on each breaker which interfaces with the pole shaft and the tripper bar. The lever assemblies are interconnected with either cables or rods, depending upon the relative orientation of the breakers. Rods can be used only when the circuit breakers to be interlocked are vertically stacked. Cables can be used for any orientation of the breakers. Mechanical interlocks are available for both fixed and drawout circuit breakers and in both 2-way and 3-way versions. An illustration of a 2-way cable interlock mounted on two drawout circuit breakers is shown in Figure 3-50.

Figure 3-50: Cassette-Mounted 2-Way Cable Interlock.

Mechanical (Pop-Out) Trip Indicator - A red, pop-out mechanical trip indicator is an optional Magnum feature. It is located above the trip unit on the breaker's front faceplate. It operates by releasing and popping out any time the circuit breaker trips due to an overcurrent condition. Note that the mechanical trip indicator will not prevent the breaker from being reclosed.

Drawout Circuit Breaker and Cassette

4.1 General

Chapter 3 discussed topics and features common to all Magnum circuit breakers, no matter what the mounting configuration. In this section, features unique to the drawout configuration not covered elsewhere, including the drawout cassette, are covered. The installation and levering of a drawout circuit breaker were discussed in Section 2. If necessary, review that information, since it will not be repeated here.

4.2 Drawout Cassette

A drawout circuit breaker is used in combination with a fixed drawout cassette; the drawout circuit breaker is equipped with automatic primary disconnects. The cassette provides all of the necessary interfaces to the drawout circuit breaker including automatic primary and secondary connections. For the IEC circuit breaker, a cassette style using horizontal stabs and horizontal customer bus bar terminals is available as standard. The cassette terminal connections can be adapted to vertical bus bar connections with a variety of optional vertical adapters.

Mounting locations for cell (TOC) switches, safety shutters, mechanical interlocks, and key interlocks are provided on the cassette.

Figure 4-1: Drawout Circuit Breaker in Cassette.

Figure 4-2: Drawout Circuit Breaker with Automatic Primary Disconnects.

Figure 4-3: Drawout Cassette Features (Front and Rear Views). Shows Extension Rails, Extension Rail Cutout, Secondary Plug-in Connectors, Secondary Terminal Blocks, Arc Hood, Optional Cell (TOC) Switch, Optional Key Interlock, Earthing Bar, Open Safety Shutters, and Primary Terminals.

4.3 Drawout Circuit Breaker Dimensions

The Magnum drawout circuit breaker connects to the fixed primary stabs of the drawout cassette through the primary finger clusters attached to the rear of the circuit breaker. Three different frame sizes cover all Magnum circuit breakers from an overall dimensional standpoint.

4.4 Drawout Cassette Dimensions

Cassette drawings provide all the dimensional information required for all mounting configurations.

Fixed Circuit Breaker

5.1 General

Section 3 discussed topics and features common to all Magnum circuit breakers, no matter what the mounting configuration. In this section, features unique to the fixed configuration not covered elsewhere are covered. The installation of a fixed circuit breaker was discussed in Section 2. If necessary, review that information, since it will not be repeated here.

5.2 Fixed Circuit Breaker Dimensions

The standard fixed circuit breaker is supplied with horizontally mounted primary connections. Optional vertical primary adapters are available for different bus configurations.

Figure 5-1: Fixed Circuit Breaker with Available Vertical Adaptor. Shows Horizontal Connection and Optional Vertical Adapter.

Inspection and Maintenance

6.1 General

WARNING: FAILURE TO INSPECT, CLEAN, AND MAINTAIN CIRCUIT BREAKERS CAN REDUCE EQUIPMENT LIFE OR CAUSE THE EQUIPMENT NOT TO OPERATE PROPERLY UNDER FAULT CONDITIONS. THIS COULD RESULT IN EQUIPMENT DAMAGE, BODILY INJURY, OR EVEN DEATH.

CAUTION: INSPECTION AND MAINTENANCE PROCEDURES SHOULD BE CARRIED OUT ONLY BY PERSONNEL FAMILIAR WITH THE HAZARDS ASSOCIATED WITH WORKING ON POWER CIRCUIT BREAKERS. ADDITIONALLY, THEY SHOULD BECOME FAMILIAR WITH THE SPECIFICS ASSOCIATED WITH TYPE MAGNUM DS CIRCUIT BREAKERS AS PRESENTED IN THIS INSTRUCTION BOOK.

Magnum Circuit Breakers are "Top of the Line" equipment, manufactured under a high degree of quality control with the best available materials and tooling for accuracy and parts interchangeability. Design tests and actual installation experience show them to have durability well beyond minimum standards requirements. However, because of the variability of application conditions and the great dependence placed upon these circuit breakers for protection and service continuity, inspection and maintenance activities should take place on a regularly scheduled basis.

Since maintenance of these circuit breakers mainly consists of keeping them clean, the frequency of scheduled inspection and maintenance depends to some degree on the cleanliness of the surroundings. Cleaning and preventive measures are part of any good maintenance program. Plant operating and local conditions can vary to such an extent that the actual schedule should be tailored to the conditions.

When the equipment is subject to a clean and dry environment, cleaning is not required as frequently as when the environment is humid with a significant amount of dust and other foreign matter.

It is recommended that maintenance record sheets be completed for the equipment. Careful and accurate documentation of all maintenance activities provides a valuable historical reference on equipment condition over time.

6.2 General Cleaning Recommendations

Circuit breaker cleaning activities should be part of an overall activity that includes the assembly in which the circuit breaker is installed. Loose dust and dirt can be removed from external surfaces using an industrial quality vacuum cleaner and/or lint-free cloth. Unless otherwise indicated, never use high-pressure blowing air, since dirt or foreign objects can be driven into areas, such as the breaker mechanism, where additional friction sources could create problems. Never use a wire brush to clean any part of the circuit breaker.

6.3 When to Inspect

Do not wait for specific scheduled periods to visually inspect the equipment if there are earlier opportunities. If possible, make a visual inspection each time a circuit breaker compartment door is opened, and especially when a circuit breaker is withdrawn on its compartment extension rails. This preventive measure could help to avoid future problems.

Industry standards for this type of equipment recommend a general inspection and lubrication after the number of operations listed in Table 6-1. This should also be conducted at the end of the first six months of service, if the number of operations has not been reached.

Table 6-1: Inspection Frequency
Breaker Frame Size	Interval (Breaker Cycles)
800 amperes and below	1750
Between 800 and 3000 amperes	500
3000 amperes and above	250

1 Breaker Cycle = one no load open/close operation

After the first inspection, inspect at least once a year. If these recommended inspections show no maintenance requirements, the period may be extended to a more economical point. Conversely, if the recommended inspection shows, for instance, a heavy accumulation of dirt or other foreign matter that might cause mechanical, insulation, or other electrical damage, the inspection and maintenance interval should be decreased.

6.4 What to Inspect

What to inspect and to what extent is dictated by the nature of the maintenance function. Routine inspections require one type of observation. Inspections following a known high-level fault require more detailed inspections.

A drawout type circuit breaker should first be withdrawn from its compartment onto the compartment's extension rails. When the inspection is complete, the circuit breaker can be levered to the TEST position to check the electrical operations of the circuit breaker. During the levering out and levering in of the circuit breaker, be aware for any signs that would indicate that this process is not working properly.

During the inspection of fixed type circuit breakers, bus systems supplying the fixed circuit breakers should be de-energized for convenience and safety.

For functional testing of the trip unit, refer to the separate detailed instruction book dedicated to the trip unit.

Once the circuit breaker has been cleaned as described in paragraph 6-2, visually inspect it for any signs of damage, missing or loose parts, and unusual wear. Be especially alert for foreign matter that must be removed. On drawout circuit breakers, inspect the primary disconnect finger clusters for signs of wear and erosion. Make appropriate corrections to anything found out of order.

6.4.1 Functional Field Testing

CAUTION: BEFORE DOING ANY WORK ON DRAWOUT TYPE CIRCUIT BREAKERS, MAKE SURE THE BREAKER IS LEVERED OUT TO THE TEST OR DISCONNECT POSITION. DURING THE LEVERING OUT AND LEVERING IN OF THE CIRCUIT BREAKER, BE AWARE OF ANY SIGNS THAT WOULD INDICATE THAT THE LEVERING PROCESS IS NOT WORKING PROPERLY. IF WORKING ON A FIXED CIRCUIT BREAKER, BUS SYSTEMS SHOULD BE DE-ENERGIZED FOR CONVENIENCE AND SAFETY. THE CIRCUIT BREAKER SHOULD BE SWITCHED TO THE OFF POSITION AND THE MECHANISM SPRINGS DISCHARGED.

Eaton recommends that the following functional tests be performed on Magnum circuit breakers as part of any maintenance procedure. The circuit breaker should be removed from service and Eaton notified if the circuit breaker fails to perform any of these tests successfully. Please be prepared to provide the number of operations the circuit breaker has to date as well as the following nameplate information: G.O.#, It, Seq, Cust. P.O., Date of Manufacture, Cat#.

Manual Operation Functional Test

Charge the breaker mechanism springs either using the charging handle or the motor operator.
Press the ON pushbutton to close the breaker manually and verify closing by noting the state of the indicating flag.
Charge the breaker mechanism springs either using the charging handle or the motor operator. If using the motor operator, disconnect power to it to prevent automatic recharging.
Press the OFF pushbutton to manually open the breaker.
Press the ON pushbutton to manually close the breaker. Is the breaker closed?
Press the OFF pushbutton to manually open the breaker. Is the breaker open?
Repeat this entire described test procedure three times.

Electrical Operation Functional Test

This test procedure is based on the assumption that the breaker is equipped with optional shunt trip and spring release accessories. If one accessory is missing, substitute the manual button to replace the accessory's function.

Charge the breaker mechanism springs either using the charging handle or the motor operator.
Close the breaker by applying rated voltage to the spring release accessory and verify closing by noting the state of the indicating flag.
Charge the breaker mechanism springs either using the charging handle or the motor operator. If using the motor operator, disconnect power to it to prevent automatic recharging.
Open the breaker by applying rated voltage to the shunt trip accessory.
Close the breaker using the spring release accessory. Is the breaker closed?
Open the breaker using the shunt trip accessory. Is the breaker open?
Repeat this entire described test procedure three times.

Trip Unit Overload Functional Test

This test uses the Digitrip 1150 self-test function, the Digitrip Test Kit, or the handheld Magnum Functional Test Kit. Review test kit instructions for the trip unit. Instruction leaflet 5720B55, section 1.2 or 1.3 applies for instantaneous test procedures or paragraph 5.2.1 "1150 Self Testing, Trip Mode" in the trip unit instruction leaflet 70C1036.

Charge the breaker mechanism springs either using the charging handle or the motor operator.
Press the ON pushbutton to close the breaker manually and verify closing by noting the state of the indicating flag.
Charge the breaker mechanism springs either using the charging handle or the motor operator. If using the motor operator, disconnect power to it to prevent automatic recharging.
Trip the breaker with a trip unit test. Verify that the trip indicator pop-out button (if so equipped) is "out" and then reset it.
Press the ON pushbutton to manually close the breaker. Is the breaker closed?
Trip the breaker with a trip unit test. Verify that the trip indicator pop-out button (if so equipped) is "out" and then reset it.
Repeat this entire described test procedure three times.
Reset the blinking red cause of trip LED on the trip unit by pressing the Reset/Battery Test pushbutton.

6.4.2 Arc Chute Inspection

When a circuit breaker experiences a high-level fault or during regularly scheduled maintenance periods, the circuit breaker's arc chutes and arc chambers should be inspected for any kind of damage or dirt. Be especially alert for signs of significant erosion of the V-shaped plates inside the arc chute.

Arc chutes fit inside the arc chambers and down over the primary contacts. Each arc chute is held in place by one top inserted screw. Begin by removing the arc chute screws and all three arc chutes. Turn each arc chute upside down to visually inspect the inside.

Since the arc chutes are removed, this is an ideal time to inspect primary contacts for wear using the circuit breaker's contact wear indicators. The details associated with primary contact inspection are presented in the next paragraph.

Figure 6-1: Top Rear View of Circuit Breaker with One Arc Chute Removed. Shows Arc Chute Removed, Baffled Cover, and Arc Chamber.

Figure 6-2: Bottom View of Arc Chute. Shows Alternating "V" Shaped Plates.

6.4.3 Primary Contact Inspection

With the arc chutes removed, visually inspect each primary contact structure for signs of wear and/or damage. The primary contacts with the circuit breaker open can be viewed by looking directly down into the arc chamber.

A contact wear indicator is provided for each primary contact and indicates whether or not the contact should be replaced. Inspection of the contacts using the contact wear indicators is conducted only with the circuit breaker closed.

WARNING: ARC CHUTES MUST ALWAYS BE SECURED PROPERLY IN PLACE BEFORE A CIRCUIT BREAKER IS INSTALLED IN A CIRCUIT BREAKER COMPARTMENT. FAILURE TO DO THIS COULD RESULT IN EQUIPMENT DAMAGE, BODILY INJURY, OR EVEN DEATH.

When the inspections are complete, position each arc chute down over its respective set of primary contacts, and secure in place with the screw removed earlier. Torque the arc chute screws to 4 to 5 Nm.

Figure 6-3: Primary Contacts with Circuit Breaker Open (Not Used for Contact Wear Inspection).

Figure 6-4: Contact Inspection Area with Circuit Breaker Open. Shows Arcing Contact (Toe), Integral Arc Runner, Stationary Main Contact, and Moving Main Contact.

NOTICE: WHEN MAKING A CONTACT WEAR INSPECTION, ALWAYS MAKE THE INSPECTION BY LOOKING STRAIGHT DOWN INTO THE ARC CHAMBER FOR THE PROPER PERSPECTIVE. VIEWING THE CONTACT WEAR AREA FROM AN ANGLE COULD DISTORT THE VIEW.

The contact wear indicator is the relative position of the individual contact fingers to a narrow, side-to-side ledge inside the arc chamber. The ledge is actually part of the arc chamber. When the circuit breaker is closed and the contacts are in good condition, the narrow ledge is covered by the back end of the contacts. If the back end of the contacts do not totally cover the ledge, the contacts should be replaced.

Figure 6-5: Use of Contact Wear Indicator with Circuit Breaker Closed. Shows Contact Wear Inspection Area (Ledge Not Visible Under Contacts) and Contact Wear Indicator - Contacts Closed and in Good Condition, and Contact Wear Inspection Area (Ledge Now Becoming Visible Under Contacts) and Contact Wear Indicator - Contacts Closed and Wear is Indicated.

Once the inspection is complete, be sure the arc chutes are properly replaced as previously described in paragraph 6-4.2.

6.5 Circuit Breaker Modifications and Changes

The topics discussed here will relate to those actions that can be taken in the field to change, update, maintain, or repair a Magnum circuit breaker. This information does not, however, include most accessory devices. Their installation is covered by separate instruction leaflets dedicated to the individual devices. The tasks described here do not, under ordinary circumstances, require any assistance beyond the appropriate instructional material. If further assistance is required, however, contact your Eaton representative.

6.5.1 Rating Plug Replacement

NOTICE: IF A RATING PLUG IS NOT INSTALLED IN THE TRIP UNIT, THE TRIP UNIT WILL TRIP WHEN ENERGIZED. ALSO REMEMBER THAT THE TRIP UNIT'S RATING PLUG AND THE CIRCUIT BREAKER'S CURRENT SENSORS MUST HAVE MATCHING RATINGS.

To remove the rating plug from the trip unit, open the small rating plug door located on the right side of the trip unit. The trip unit's battery cavity is also located behind this door. Use a 1/8" wide screwdriver to remove the M4 screw holding the rating plug in position. Pull the door to release the rating plug from the trip unit.

To install a new rating plug, insert the rating plug into the cavity where the other rating plug was removed. Make sure the three pins on the rating plug are aligned with the sockets in the cavity. The rating plug should fit with a slight insertion force.

CAUTION: TO PREVENT DAMAGE TO THE RATING PLUG, DO NOT FORCE IT INTO THE MOUNTING CAVITY.

Use the same 1/8" screwdriver to tighten the M4 screw and secure the rating plug in the trip unit. The maximum torque on the mounting screw is 15 in-oz. Close the rating plug door.

Figure 6-6: Trip Unit Rating Plug Location. Shows the Rating Plug.

6.5.2 Current Sensor Replacement

NOTICE: REMEMBER THAT THE TRIP UNIT'S RATING PLUG AND THE CIRCUIT BREAKER'S CURRENT SENSORS MUST HAVE MATCHING RATINGS.

The three current sensors are installed at the rear of the circuit breaker on the lower terminals. A cover with sensor rating viewing windows covers the sensors and is held in place with screws. Remove the cover by removing the screws.

If the circuit breaker is a drawout configuration, the lower primary disconnect finger clusters and the vertical adapters must first be removed from frame sizes up to 3000/3200A. On the 3000/3200A frame, both the upper and lower primary disconnects and vertical adapters must be removed. Each primary disconnect finger cluster is removed by loosening the two hex-head bolts with a 10 mm wrench. These bolts do not have to be completely removed to slide the primary disconnects off of the terminals. Remove the vertical adapters next from the circuit breaker terminals by removing the two or three 10 mm bolts holding them in place.

The current sensors are removed by pulling them off of the terminals and unplugging the wiring plugs from the sensors. Install new current sensors by connecting the wiring plugs to the sensors and sliding the sensors over the terminals. Reinstall the cover over the sensors and secure in place with the screws previously removed.

Reinstall the previously removed vertical adapters to the terminals using the removed hardware and 40 ft-lb of tightening torque. Make sure the vertical adapters are square to the rear housing. Slip the primary disconnects on to the vertical adapters. Make sure the primary disconnects are fully inserted on to the vertical adapters. Tighten the two retention bolts to 40 in-oz of torque. Properly engaged and secured retention bolts should engage the slots or holes in the vertical adapters.

Figure 6-7: Current Sensor Cover in Place Over Sensors.

Figure 6-8: One Current Sensor Shown Removed and Disconnected. Shows Vertical Adapter, Current Sensor, and Wiring Plug.

Troubleshooting

7.1 Introduction

Table 7-1 will help to determine the probable causes of simple circuit breaker problems and possible corrective actions. If problems cannot be resolved, contact the Eaton service center for more in-depth assistance.

Table 7-1 Circuit Breaker Troubleshooting Guide (continued on next page)
Symptom	Probable Cause	Corrective Actions
The circuit breaker trips open (red fault trip indicator button is out and/or fault indicator LED is lighted) when closed on a load current	Rating plug not installed and load current through the breaker	Install rating plug that corresponds to current sensors
	Repeated closing on transient (in-rush) current with thermal memory active	Wait for circuit breaker (and loads) to cool before re-closing
	An overload or fault current condition	Use status and fault indicators to help locate and remove overload or fault condition
Circuit breaker opens (fault trip indicator button is not out)	Undervoltage release operates; voltage too low or zero	Check and correct the UVR supply voltage (85-110% rated voltage)
	Shunt trip operates	Check control signal(s) to shunt trip; correct if necessary
	Trip latch is defective	Inspect latch condition and engagement before closing; consult Eaton service center
Circuit breaker cannot be opened remotely, but can be opened locally	Shunt trip control signal absent or too low	Check supply voltage exceeds 70% of rated voltage when signal is applied to shunt trip
	Shunt trip is faulty or improperly installed	Remove front cover; check voltage supplied to shunt trip; make sure shunt trip is seated and retainer snapped into place. Check for shunt trip motion; replace shunt trip if faulty
	Secondary contact wiring problem	Make sure electrical pin and socket connectors are properly seated in molded plug. Verify proper wiring
Circuit breaker cannot be opened remotely, but can be opened locally	Shunt trip control signal absent or too low	Check supply voltage exceeds 70% of rated voltage when signal is applied to shunt trip
	Shunt trip is faulty or improperly installed	Remove front cover; check voltage supplied to shunt trip; make sure shunt trip is seated and retainer snapped into place. Check for shunt trip motion; replace shunt trip if faulty
	Secondary contact wiring problem	Make sure electrical pin and socket connectors are properly seated in molded plug. Verify proper wiring
Circuit breaker cannot be opened locally	OPEN pushbutton locked	Remove lock
	Faulty mechanism or main contacts welded	Contact Eaton service center
Circuit breaker makes no attempt to close with either local (manual) or remote controls; springs do not discharge	Closing spring not fully charged (check SPRING CHARGED indicator)	Charge spring manually; check voltage to electrical operator; replace electrical operator if faulty
	If equipped with undervoltage release, undervoltage release is not energized or is faulty	Unplug undervoltage release from mounting deck and retry closing operation; if OK, check voltage supply to undervoltage release (>85%); replace undervoltage release if faulty
Circuit breaker cannot be closed remotely (can be closed locally)	Circuit breaker locked in OPEN position	Check reason for lock
	Drawout position interlock is operating; levering screw	Make sure that circuit breaker is at a position that permits closure; door is open check that shutter (door) over the levering screw is fully closed
	Circuit breaker interlocked with another circuit breaker or device	Check for presence of an interlocking scheme (cable interlock or key interlock); check to see if interlocked circuit breaker is CLOSED
Circuit breaker cannot be closed locally (but can be closed remotely)	Spring release (closing) coil supply voltage low or spring release faulty	Check power supply voltage; replace spring release if faulty
	Secondary contact wiring problem	Make sure electrical pin and socket connectors are properly seated in molded plug. Verify proper wiring
Circuit breaker does not recharge electrically but will recharge manually	Spring release closing coil signal blocked	Clear Digitrip 1150 relay contact
	Opening and/or closing pushbuttons locked	Check reason for lock
	Charging motor supply voltage absent or too low (<85%)	Check charging motor electrical circuit voltage (check under load)
	Charging motor faulty	Replace charging motor assembly
Drawout circuit breaker will not lever-in	Circuit breaker will not fully enter cell (cell rejection code plate)	Circuit breaker ratings do not correspond to the cassette requirements
	Levering-in screw not in fully DISCONNECT position at insertion	Rotate levering-in screw counterclockwise to DISCONNECT position, then insert breaker fully into cassette
	Levering-in screw in DISCONNECT position but not pushed in far enough	Push circuit breaker in as far it will go, cover should be flush with front of cassette side plate
	Protective boots covering stationary disconnects	Remove boots
	Shutter jammed or locked	Clear problem

Renewal Parts

8.1 General

All renewal parts and/or spare parts recommendations for Type Magnum DS Circuit Breakers are supplied in separate Renewal Parts Documentation, not this instruction manual. Refer to the most recent version of this documentation for specific assistance.

When ordering parts, always specify, if known, the part name and style number. If the style number is not known, it would help to refer to a pictorial and/or graphic reference. Also include the circuit breaker type, General Order number, and other information as shown on the nameplate on the front cover of the circuit breaker.

Some detailed parts shown in the figures in this manual may only be available as a part of a sub-assembly. Certain parts may not be available at all for field installation. Some parts in the figures are illustrated just to show their function and location in the assembly. The Renewal Parts Documentation indicates which parts are available and in what form. For additional information, visit the Eaton website at www.eatonelectrical.com.

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