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Applicable Machinery

HAT06, HAT08, HAT10, HAT12, HAT16, HAT20, HAT25, HAT32, HAT40, HAT50 HAS06, HAS08, HAS10, HAS12, HAS16, HAS20

Notice
Please read this instruction manual frist before using Air Circuit Breaker. Contact the head office or branch office listed on the back if you have any inquiries or technical problems. Keep this instruction handy at all times. Changing to this instruction manual may be made without previous notice due to quality improvement. Refer to our catalog for the rating items on our products.

For Operational Safety of Air Circuit Breakers

Safety Notices
Thank you for purchasing the HHI Air Circuit Breaker. These safety notices contain important information on safety. Be sure to read these notices, the product instruction manual, and other associated documents accompanying the product thoroughly to familiarize yourself with product handling, safety information, and all other precautions before installing, operating, or inspecting the product. The safety notices are divided into DANGER, WARNING, and CAUTION according to the hazard level:
A danger notice with this symbol indicates that neglecting the suggested procedure or practice could be fatal or result in serious personal injury. A warning notice with this symbol indicates that neglecting the suggested procedure or practice could result in serious personal injury and/or property damage. Note that failing to observe caution notices could result in moderate or slight injury/damage in some situations. Because safety notices contain important information, be sure to read and observe them.

Transportation Precaution
Never enter the area under the ACB when it is lifted or suspended using a lifter or chain block in case the ACB drops accidentally. The ACB is heavy. Entering such an area could cause serious injury.

Installation Precautions
Installation work must be performed by competent persons. Prior to commencing any installation work, open an upstream circuit breaker or the like to isolate all sources of power/voltage. Otherwise, electric shock may result. Tighten terminal screws securely to the specified torque. Otherwise, a fire could result. Fix the ACB (draw-out cradle) firmly on a flat lever surface using mounting screws. Otherwise, draw-out operation may cause the ACB to fall. Avoid blocking the arc gas vents of the ACB to ensure adequate arc space (insulation distance). Blocking the vents could result in failure of ACB tripping. Do not place the ACB in such an area that is subject to high temperature, high humidity, dusty air, corrosive gas, strong vibration and shock, or other unusual conditions. Mounting in such areas could cause a fire, non-tripping, or malfunction. Be careful to prevent foreign objects (debris, concrete powder, iron powder, etc.) and rainwater from entering the ACB. These materials inside the ACB could cause a fire or non-tripping. For the ACB with four poles, connect the neutral wire of a 3-phase, 4-wire cable to the N-phase pole (on the right end). Otherwise, an overcurrent may cause non-tripping and a fire.

Operation Precautions
Never touch live terminal parts. Otherwise, electric shock may result. Do not leave the ACB in the draw-out position. The ACB is heavy. Dropping the ACB could cause serious injury.

If the ACB trips open automatically, remove the cause before closing the ACB. Otherwise, a fire could result. For the ACB with the fixed block, be sure to loosen the block screws before drawing out the ACB. Otherwise, damage to the ACB may result.

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ACB

Instruction Manual

OCR Field Tests Precautions


OCR field tests must be performed by competent persons. Never touch live terminal parts. Otherwise, electric shock may result.

Maintenance and Inspection Precautions


ACB maintenance, inspection and/or parts replacement must be performed by competent persons. Prior to commencing any work on the ACB, open an upstream breaker or the like to isolate all sources of power/ voltage from both the primary and auxiliary circuits. Otherwise, electric shock may result. Prior to commencing ACB internal inspection, make sure that the ACB is open and the closing spring is released. Otherwise, fingers or tools could be pinched in the internal mechanism, causing an injury. Retighten the terminal screws periodically to the specified torque. Otherwise, a fire could result. Retighten the arcing contact mounting screws periodically to the specified torque. Otherwise, a fire or malfunction could result. Be sure to reinstall the arc chute if removed. Failure to do so or incorrect installation of the arc chute may result in a fire and burns. Do not touch ACB live parts (contacts in particular), or structural parts close to a live part immediately after opening the ACB to stop supplying power. Otherwise, remaining heat may cause burns. Do not bring your hand or face close to the arc gas vent of the arc chute while the ACB is closed. Otherwise, a burn may result from high-temperature arc gas blowing out of the arc gas vent when the ACB trips open.

Contents

1. Receiving and Handling 1.1 Storage 1.2 Directions for Transportation 2. Description of Various Parts 3. Operation 3.1 Manual Charging Type 3.2 Motor Charging Type 3.3 Slow Closing Operation 4. Draw-Out Mechanism 4.1 Moving the Breaker Body Within Draw-Out Cradle 4.2 Drawing Out the Breaker 4.3 Putting the Breaker Body Back Into Draw-Out Cradle 5. Periodic Inspection and Parts Replacement 5.1 Arc Chutes 5.2 Contacts 5.3 Operating Mechanism 5.4 Internal Accessories

6. Over-Current Protective Device 6.1 Base Current (I0) of Type AOR Multifunction Protective Device 6.2 Protective Functions and Setting Ranges of Type AOR Multifunction Protective Device

27

4 6

6.3 Operation Indication Functions of Type AOR Multifunction Protective Device 6.4 Field Test Method of Type AOR Multifunction Protective Device 7. Insulation Resistance Test and Dielectric Withstand Test 7.1 Main Circuit 46

7.2 Control Circuit (to Earth) 8. Troubleshooting Points 9. Draw-Out Mechanism of HAS Type 9.1 Moving the Breaker Body Within Draw-Out Cradle 47 48

15

9.2 Putting the Breaker Body Back Into Draw-Out Cradle 10. Circuit Diagrams of AOR 11. Circuit Diagrams of HAT 12. Appendix 12.1 Ground Fault Protection 12.2 Closing and Tripping Operation Cycles 50 52 56

HAT Series ACB Instruction Manual

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01

Receiving and Handling

Upon receipt of your breaker, check the following. If you have any questions or any problems, contact our agent nearest you. HAT series Air Circuit Breakers are completely assembled, inspected and tested both electrically and mechanically at the factory, then shipped in fully guaranteed condition in construction and operation.

1.1 Storage
While it is recommended that the breaker be used as soon as you receive it, if it is necessary to store the breaker for some time before its installation, please note the following for proper storage: 1) Store the breaker in a dry indoor location to prevent condensation due to sudden change in temperature, which is quite harmful to the breaker insulation. 2) Store the breaker in a clean place free of corrosive gases, dirt and dust. In particular, a mixture of cement dust and moisture can cause corrosion in the various metal parts of the breaker, so fully protect the breaker from such mixtures. 3) Place the breaker on a flat, level surface in its normal position. 4) Do not place the breaker directly on the floor.

1.2 Directions for Transportation


When transporting the breaker from one place to another, note the following: 1) When lifting the breaker, apply wire ropes to the lifting plates (Fig. 1. ). Take necessary care so that the tightened wire ropes may not touch the arc chutes (Fig. 1. ) and multi-protective device (Fig. 1. ). When lifting the breaker, be sure to lift it up slowly. 2) Lower the breaker onto a flat, level surface. 3) Avoid impacts and shocks to the breaker during transportation.

02

Description of Various Parts

Fig. 1. General view of HAT06~HAT40 type

Fig. 1-1. General view of HAT50 type

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ACB

Instruction Manual

1 2 3 4 5 6 7 8 9 10 11 12 13

14

15 16 17 18

19 20

21 22 23 24 25 26

27 28 29 30 31 32 33 34 35 36

Draw-out cradle Breaker body Name plate Charging handle Mechanism cover Draw-out handle (for HAT06~HAT40) Lifting lugs used to transport the breaker and install the breaker into the switchgear Position indicator Open-close indicator Spring charge indicator Push to close button: Pressing this button closes the breaker Push to open button: Pressing this button opens the breaker Position stopper release lever (HAT06~HAT40) When this lever is in the up position, the breaker is locked in each of the CONN , TEST ISOLATED and positions This lever can be turned down only when the breaker is OPEN Turning down this lever unlocks the position stopper and opens the shutter which covers draw-out handle insert hole Position padlock lever (HAT06~HAT40) Up to three padlocks may be applied to this lever to keep the breaker body locked in the CONN , TEST ISOLATED or position Padlocks themselves are not supplied (6 to 8 shackle diameter) Draw-out handle insertion hole Draw-out stopper (ref. pages 13, 1-3 and 1-4 [for HAT50]) Wiring hole for position switch Auxiliary switch assembly. The auxiliary switch assembly has five a-contacts and five b-contacts and wiring is made to the switch terminals M3.5- terminal screws are to be used (HAT50 type has three a-contacts and four b-contacts) Disconnect device for control circuits Open padlock lever (optional) The breaker may be padlocked in the OPEN position To padlock the breaker in the OPEN position, press the PUSH TO OPEN button and pull out the lever , then apply up to three padlocks to the lever Under this padlocked condition, the breaker is prevented from being closed manually or electrically To return the lever to the withdrawn position, un-padlock and press the PUSH TO OPEN button again Padlocks themselves are not supplied (6 to 8- shackle diameter) Front cover Dust plate (optional) OCR front cover Arc chute Front cover mounting screw Fixing blocks (optional); These blocks are standard equipment when the breaker is subject to the ship classification societys rules These are to be secured to the switchboard framework The breaker body is secured to the draw-out cradle by the screws only when it is in the CONN position Type AOR multifunction protective device (optional) Under-voltage trip device (optional) Close-open counter Key-lock (optional) Release lever (for HAT50) Draw-out handle fixing clip (for HAT50) Extention rail (for HAT50) To fully draw-out the breaker body from draw-out cradle, this rail is subject to draw-out rail 35 Breaker stopper (for HAT50) Draw-out rail (for HAT50) Button for draw-out (for HAT50)

HAT Series ACB Instruction Manual

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03

Operation

HAT series air circuit breakers are available either in manual charging type or in motor charging type.

3.1 Manual Charging Type


In the manual charging type, charging the closing springs and open-close control of the breaker are all done manually. The breaker is able to close only when the closing springs are charged.
Do not force down the charging handle after completion of charging. Doing so may cause a malfunction.

1) Spring charging operation. Follow the procedure given below to charge the closing springs. Pump the charging handle. The maximum stroke of the charging handle is about a 105 angle.

When the closing springs are fully charged, a metallic CLICK will be heard and no further pumping of the charging handle will be possible. When the charging handle is pumped with its maximum stroke at approx. 105 about four pumping cycles will complete the charging. , Check that the spring charged indicator (Fig. 4. ) now shows CHARGED.
Fig. 4. Front view

4 8 9 10 11 12 13 15 20 23

Charging handle Position indicator Open-closed indicator Spring charged indicator Push to close button Push to open button Position stopper release lever Draw-out handle insertion hole Open position padlock lever Front protective cover

2) Closing operation. Before closing the breaker, check the following items: The closing springs should be charged. The position stopper release lever (Fig. 4. ) should be in the up position. The shutter of the draw-out handle insertion hole (Fig. 4. ) should be completely closed. The open position padlock lever (Fig. 4. ) should not be pulled out. The specified voltage should be applied to the under-voltage trip device option or the function of the under-voltage trip device should be locked. See the description of the under-voltage trip device for the procedure in detail. Upon satisfactory confirmation of the above items, open manual operation button cover upward, if provided, and press the PUSH TO CLOSE button (Fig. 4. ). The breaker is closed. The OPEN-CLOSED indicator (Fig. 4. ) shows CLOSED and the spring charged indicator (Fig. 4. ) , shows DISCHARGED .
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ACB

Instruction Manual

3) Opening operation. Open the manual operation button cover upward if provided and press the PUSH TO OPEN button (Fig. 4. ). This trips the breaker, and the OPEN-CLOSED indicator (Fig. 4. ) shows OPEN.

3.2 Motor Charging Type


In this type, a motor-operated mechanism automatically charges the closing springs. Means for remote electrical OPEN-CLOSED control of the breaker are also fitted. See page 52 for control circuit diagram. Complete manual operations are also possible for the same procedures as described in above manual charging type section. 1) Spring charging operation. Supply the specified control power voltage to the charging motor circuit. In case of AC motor, check whether the UVT is applied to specified voltage or locking function [See clause 5.4, 2)]. As soon as the closing springs are discharged, the charging motor is turned on to charge the closing springs. The charging motor is automatically stopped when the closing springs are fully charged, and the spring charged indicator (Fig. 4. ) shows CHARGED. While the charging time varies depending on the rated control voltage and the type of breaker, it is normally within a range from 2.4 to 10 seconds.
The permissible control voltage range for the charging motor is 85 to 110% of the rated voltage when AC rated, or 75 to 110% when DC rated. It is strongly recommended to supply the control power at the rated voltage. When dielectric withstand voltage test is carried out, the dielectric withstand voltage of DC 100 V, AC 100 V, and AC 220 V motors is 1500 V, but for DC 24 V, and DC 48 V motors it is 500 V.

2) Closing operation. Before closing the breaker, check the following items: The closing springs are charged. The position stopper release lever (Fig. 4. ) is in the upper position. The shutter of the draw-out handle insertion hole (Fig. 4. ) is completely closed. The open position padlock lever (Fig. 4. ) is not pulled out. The specified voltage is applied to the under-voltage trip device (optional) or the function of the under-voltage trip device is locked (see the description of the under-voltage trip device for the procedure described in page 21). Upon satisfactory confirmation of the above items, press the CLOSE button (PB CLOSE, see page 52). This energizes the latch release coil (LRC, see page 52), which, in turn, releases the charged closing springs and the breaker is immediately closed. The spring charged indicator shows DISCHARGED. With the closing springs discharged, the charging motor is immediately turned to charge the closing springs.

Even when items (2) to (5) are not satisfied, the charged closing springs are released by pressing the PUSH TO CLOSE button, but the breaker will not be placed in closed state. Be sure to perform closing operation according to each item, (2) to (5).

3) Opening operation. The shunt trip device (SHT) or under-voltage trip device (UVT) is used for remote electrical opening operation. Press the OPEN button (PB OPEN, see page 52). This trips open the breaker via the SHT or UVT.
When open-close operations are repeated with the charging motor ON, limit the number of successive open-close cycles to 15. If the OPEN-CLOSE cycle is repeated more than 15 times, allow a cooling period of at least 20 minutes between the 15th cycle and the 16th cycle.

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03

Operation

3.3 Slow Closing Operation


Avoid slow closing operation for purposes other than inspection and maintenance of the breaker. Check that 3-poles of arcing contact are touched at the same time or the main contact is touched after the arcing contact has touched, using an optional slow-close operation jig pair (2 jigs/set). 1) Remove the breaker body (Fig. 1. ) from the draw-out cradle. See the next draw-out mechanism section for how to remove the breaker body. 2) Place the removed breaker body on a workbench in such a position that its bottom is readily visible and accessible, turning it sideways or backwards. Take every precaution to avoid damage to the breaker. 3) Pump the charging handle (Fig. 4. ) to fully charge the closing springs and loosen the wing screws (Fig. 6. (Fig. 6.
32 ) 33 ).

4) When the springs are fully charged, a wider gap (marked in Fig. 6) develops between each closing spring guide and the closing spring guide shaft. Insert the jigs leaf springs into each gap (square hole), with their pins toward the outer side of the breaker. Make sure that these jigs should be fitted to both the closing spring guides. 5) Check that the conditions to close the breaker are satisfied. See items [3-1, 2)], closing operation of page 6.
Fig. 6. Bottom side view of ACB

30 31 32 33

Slow-close operation jig Frame base Closing spring guide Wing screw

6) Press the PUSH TO CLOSE button (Fig. 4. ). Although the closing mechanism moves slightly, the breaker remains open. The breaker is now ready for slow closing operation. 7) Pump the charging handle (Fig. 4. ). The moving contacts move toward the stationary contacts in unison with down strokes of the charging handle, and the breaker is closed with 3 or 4 pumping cycles. When the breaker is closed, the indicators show CLOSED and DISCHARGED, respectively. 8) Restoring the slow-close condition to normal. Press the PUSH TO OPEN button (Fig. 4. ) to open the breaker. Pump the charging handle (Fig. 4. ) to charge the closing springs. The spring charged indicator (Fig. 4. ) shows CHARGED. To irritate the SLOW CLOSING OPERATION execute from 6) to 7) again. Compress the jigs leaf springs to remove the jigs from the respective closing spring guides (Fig. 6. Attach the jigs to frame base. Only operate ACB in normal state after removing slow closing jigs.
32 ).

The jigs cannot be removed after the PUSH TO CLOSE button is pressed, in this case repeat the procedure from 6).

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04

ACB
Draw-Out Mechanism

Instruction Manual

The draw-out mechanism permits one to draw out and remove the breaker body from the draw-out cradle and to put the breaker body back into the cradle, which facilitate the inspection and parts replacement. The draw-out mechanism permits one to move the breaker body to any of the following three positions in the draw-out cradle. The switchboard panel door can be shut with the breaker body drawn out to the TEST or ISOLATED position. The auxiliary switch assembly (Fig. 1. ) mounted on the draw-out cradle works in the CONN. and TEST positions (only the CONN. position when the breaker is subject to ship classification society rules).

Operational Precautions Open the breaker before working with the draw-out mechanism. Be sure to loosen the screws of the fixing blocks (Fig. 1. ) before drawing out the breaker body. Otherwise, a malfunction may result. Do not work with the draw-out mechanism while holding the position stopper release lever (Fig. 4. ). Doing so may cause a malfunction. When you try to move the breaker body to the CONN. position, the operating force will increase. Further rotate the draw-out handle 2 or 2.5 turns to move the breaker body to the CONN. position. Typical operating force HAT06~HAT20 10 kgf HAT25 12 kgf HAT32~HAT40 25 kgf

When a metallic click sound is heard (the draw-out mechanism shaft is locked), stop turning the draw-out handle. Otherwise, a malfunction may result. Make sure the shutter (Fig. 4. ) is closed after the draw-out handle is removed. A halfway position of the breaker body may cause the breaker to fail in closing operation.

Conn. position
In this position, the main circuit and the control circuits (of the breaker) are connected to the external circuits for normal service.

Test position
In this position, the main circuit is isolated, but the control circuits are connected. This position permits such tests as CLOSE-OPEN test, control circuit function test, etc.

Isolated position
In this position, the main circuit and the control circuits are isolated. The breaker is completely de-energized in this position.

Conn. position

Test position

Isolated position

HAT Series ACB Instruction Manual

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04

Draw-Out Mechanism

4.1 Moving the Breaker Body Within Draw-Out Cradle


The draw-out handle (installed external to the breaker Fig. 1. ) is used to move the breaker body to one of the three positions (CONN., TEST, and ISOLATED) in the draw-out cradle.
When the fixing blocks (Fig. 1. ) (optional) are fitted, be sure to loosen the right and left screws of the fixing blocks before drawing out the breaker body. Otherwise, a malfunction may result.

1) Moving to test position. When the fixing blocks (Fig. 1. )are fitted, loosen and free the right and left screws. Check that the breaker is OPEN. If it is CLOSED, press the PUSH TO OPEN button (Fig. 7. ) to open the breaker. Turn down the position stopper release lever (Fig. 7. ) to open the shutter of the draw-out handle insertion hole (Fig. 7. ).
Fig. 7

6 7 8 11 13 14 15 34

Draw-out handle Position indicator Open-closed indicator Push to open button Position stopper release lever Position padlock lever Draw-out handle insertion hole Draw-out mechanism shaft

Engage the draw-out handle with the draw-out mechanism shaft (Fig. 7. to move the breaker body.

34 )

and turn the handle counterclockwise

As the breaker body is drawn out, the position stopper release lever (Fig. 7. ) automatically returns to the up position, but leave it as it is. When the main circuit is disconnected as the breaker body is being drawn out, the breaker body will be slightly pushed forward by the spring action of the primary disconnect contacts with a banging sound. While the loudness of this sound may vary from one breaker type to another, the sound itself is perfectly normal and does not affect the breaker performance.
When the breaker is drawn out to the TEST position, a metallic click will be heard, the breaker will be locked in this position, and further turning effort on the draw-out handle will be stopped. The position indicator (Fig. 7. ) now shows TEST. Do not attempt to compulsively the draw-out handle while it is locked. When the draw-out handle is inserted in the draw-out mechanism shaft, the breaker is prevented from being closed. For close-open test, remove the draw-out handle.

2) Moving to isolated position.


If the automatic closing spring release mechanism (optional) is fitted, the charged closing spring will be automatically discharged as the breaker body is moved from the TEST position to the ISOLATED position. Although this may be felt as a light shock, just continue the draw-out operation.

After the breaker body has been drawn out to the test position, turn down the position stopper release lever (Fig. 7. ) again.

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ACB

Instruction Manual

Turn the draw-out handle counterclockwise to move the breaker body. As the breaker body is drawn out, the position stopper release lever (Fig. 7. ) automatically returns to the up position, but leave it as it is.
When the breaker is drawn out to the ISOLATED position, a metallic click will be heard, the breaker will be locked in this position, and further turning effort on the draw-out handle will be stopped. The position indicator (Fig. 7. ) now shows ISOLATED. Do not attempt to forcefully turn the draw-out handle under this condition, but remove it.

3) Further withdrawal and removal of breaker body from ISOLATED position. The breaker body may be further drawn out from the ISOLATED position to remove it from the draw-out cradle for inspection, maintenance or parts replacement purposes. If the breaker is in charged condition, perform close-open operation once and release the closing spring. Lower the left and right draw-out stoppers to unlock the breaker body and slowly draw out the breaker body from the draw-out cradle until the draw-out stoppers are locked.
Do not leave the breaker body as it is. When the above operation is made in as-received condition to separate the breaker body from the cradle, take necessary measures to prevent the possible turnover due to a change of the center of gravity.

Apply wire ropes to the lifting plate (Fig.1. ) and lift the breaker body upward after unlocking the left and right draw-out stoppers. Alternatively, a lifter (available as option) may be used to remove the breaker body from the draw-out cradle.
Never enter under the breaker. The breaker weight will cause serious injuries in the event that it drops. Do not attempt to force-turn the draw-out handle while it is locked. When the draw-out handle is inserted in the draw-out mechanism shaft, the breaker is prevented from being closed. For close-open test, remove the draw-out handle.

4.2 Drawing Out the Breaker (for HAT50)


To move the breaker from the CONNECTED to TEST or DISCONNECTED position, the draw-out handle (Fig. 10-1. ) must be used. The draw-out handle is secured to the righthand side of the draw-out framework by the wing screw (Fig. 10-1.
32 ).

Loosen the wing screw (Fig. 10-1.

32 )

to remove it from the framework.

1) Drawing out from CONNECTED to TEST position. Loosen and free the right and left fixing screws (Fig. 10-1. completely. Push the right and left release levers (Fig. 10-1. Pressing the Button for Draw-Out (Fig. 1-1.
31 ) 37 )

with draw-out handle, but do not remove them

down.

36 ),

open the shutter which is covering the draw-out handle

insertion hole (Fig. 1-1. ) and engage the draw-out handle (Fig. 10-1. ) with the draw-out operation shaft by inserting the handle (Fig. 10-1. ) through the insertion hole (Fig. 1-1. ). Turn the draw-out handle (Fig. 10-1. ) counterclockwise; the breaker slides out. When the breaker body slides out to the TEST position, the draw-out position stoppers operate and lock the breaker body in TEST position. If locked, do not turn the draw-out handle (Fig. 10-1. ) any further. When opening and closing test, etc. are made at this position, be sure to remove the draw-out handle (Fig. 10-1. ). 2) Drawing out to DISCONNECTED position. After drawing out the breaker body to the TEST position, push up the release levers (Fig. 10-1.
31 ).

Turn the draw-out handle (Fig. 10-1. ) further counterclockwise; the breaker body slides out to the DISCONNECTED position and the draw-out position stoppers operate again to lock the breaker body in DISCONNECTED position. If locked, do not turn the draw-out handle (Fig. 10-1. ) any further. Remove the draw-out handle.
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04

Draw-Out Mechanism

If it is desired to secure the breaker body in the TEST or DISCONNECTED position, loosen the position fix screw (Fig. 10-1. 38 ), slide out the breaker fixing plate (Fig. 10-1. 39 ), tighten the breaker fixing screw (Fig. 10-1. 38 ), and position fix screw (Fig. 10-1. 37 ). Repeat these steps on the other side. The breaker fixing plates (Fig. 10-1. 39 ) should be pushed back and secured in place when not used.

3) Drawing out from DISCONNECTED position to out of the draw-out framework, the breaker body can be further drawn-out by using the extension rails (Fig. 1-1.
33 )

for making inspection, maintenance, or parts

replacement or for removing the breaker body from the framework. Draw out the breaker body to the DISCONNECTED position with the draw-out handle (Fig. 10-1. ), then remove the draw-out handle (Fig. 10-1. ). Insert the extension rails (Fig. 1-1. respectively. Push down the release levers (Fig. 10-1.
31 ), 33 )

into the end sockets of the right-and left-hand draw-out (Fig. 1-1.

35 ),

then pull the breaker body forward by holding the breaker body fixing

pieces (Fig. 10-1. ) by hands until the breaker body is stopped by the extension-rail end stoppers. The draw-out position stoppers will operate at halfway between the DISCONNECTED position and fully drawn-out position which will lock the breaker body again. In this case, unlock by pushing up the release levers (Fig. 10-1. How to take out breaker body from framework. After drawing out the breaker body to the fully drawn out position, lift the breaker body off the rails with a chainblock or the like, using the lifting holes (Fig. 1-1. ) of the breaker body.
Fig. 8
31 )

and pull out again.

4.3 Putting the Breaker Body Back into Draw-Out Cradle


1) Follow the procedure given below to put the removed breaker body back into the draw-out cradle (for HAT06~HAT40). Check that the breaker is OPEN, then check that the position indicator (Fig. 1. ) is showing ISOLATED. Check that the jigs for slow-closing operation (Fig. 6. ) is secured in the frame base (Fig. 6. are discharged. If automatic closing spring release mechanism (optional) is fitted, the charged closing springs will be automatically discharged as the breaker body is moved from the ISOLATED position to the TEST position. Although this may be felt as a light shock, just continue the insertion operation. Lift up the breaker body or use a special lifter. Push in the breaker body until the draw-out stoppers are locked so that the slide plate of the breaker body side will be engaged with the slide plate of the draw-out cradle side.
Never enter under the breaker. The breaker weight will cause serious injuries in the event that it drops.
31 ).

Check that the spring charged indicator (Fig. 1. ) is showing DISCHARGED, indicating that the closing springs

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ACB

Instruction Manual

Fig. 9

Further push in the breaker body again until the draw-out stopper is locked. This position is ISOLATED. Turn down the position stopper release lever (Fig. 10. ) to open the shutter of the draw-out handle insertion hole (Fig. 10. ), and engage the draw-out handle with the draw-out mechanism shaft (Fig. 10.
34 ).

Fig. 10

6 7 8 11 13 14 15 34

Draw-out handle Position indicator Open-closed indicator Push to open button Position stopper release lever Position padlock lever Draw-out handle insertion hole Draw-out mechanism shaft

Turn the draw-out handle clockwise to send the breaker body into the draw-out cradle. As the breaker body is moved the position stopper release lever (Fig. 10. ) automatically returns to the up position, a metallic click will be heard, the breaker will be locked in its position, and further turning effort on the draw-out handle will be stopped. The position indicator (Fig. 10. ) now shows TEST. Turn down the position stopper release lever again, and turn the draw-out handle clockwise to send the breaker into the CONN. position. The position stopper release lever automatically returns to the original position (up position), but continue the insertion operation. Mating of the primary disconnect device starts just before the CONN. position, and the draw-out handle will become heavy, but continue to turn the handle. When the breaker is sent into the CONN. position, a metallic click will be heard, the breaker will be locked in this position, and further turning effort on the draw-out handle will be stopped. The position indicator now shows CONN.. Remove the draw-out handle (Fig. 10. ).
When you try to move the breaker body to the CONN. position, the draw-out handle operating force will increase. This is because the primacy circuit contacts in the breaker begin to close and the insertion friction increases; An increase in handle operating force is not a sign of failure. Further rotate the draw-out handle 2 or 2.5 turns to move the breaker body to the CONN. position.

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04

Draw-Out Mechanism

A click sound, a measure to check if an intended breaker position is reached, may be inaudible depending on the ambient conditions. In such a case, rely on a change in draw-out handle operating force in order to check if the intended breaker position is reached. When the handle is locked and impossible to turn anyway, the breaker has reached the intended position. Do not forcefully the draw-out handle while it is locked. Doing so may cause a malfunction.

When the fixing blocks (Fig. 1. ) are fitted, fully tighten the right and left fixing screws using the draw-out handle.
Failing to firmly tighten these screws may cause a breaker malfunction in particular when the breaker is installed in such an area that is subject to strong vibration.

2) Putting the removed breaker body back into the draw-out framework, observe the following procedure (for HAT50): Insert the extension rails (Fig. 1-1. body on them. Push up the release levers (Fig. 1-1. Remove the extension rails (Fig. 1-1. Push the release levers (Fig. 1-1. draw-out operation shaft. Turn the draw-out handle (Fig. 10-1. ) clockwise. The draw-out position stoppers will operate again when the breaker body reaches the TEST position; push up the release levers (Fig. 1-1.
31 ) 31 ) 31 ) 33 )

into the end sockets of the draw-out rails (Fig. 1-1.

35 )

and place the breaker

and push breaker body into the draw-out framework manually; the draw-

out position stoppers will operate and lock the breaker body in the DISCONNECTED position.
33 ).

down, then press the Draw-Out button (Fig. 1-1.

36 ),

open the shutter which


39 )

is covering the draw-out handle insertion hole (Fig. 1-1. ), and engage the draw-out handle (Fig. 10-1.

with the

and turn the draw-out handle (Fig. 10-1. ) further clockwise.

The draw-out position stoppers will operate once again. This is the CONNECTED position. Remove the draw-out handle (Fig. 10-1. ) and tighten the right and left fixing screws (Fig. 10-1. The breaker is now ready for operation. Put the extension rails (Fig. 1-1. tightening the wing screws.
Fig. 10-1
33 ) 37 )

firmly.

and draw-out handle (Fig. 10-1. ) back to original place and fix in place by

6 26 31 32 33 34 35 36 37 38 39

Draw-out handle Fixing block Release lever Draw-out handle fixing clip Extension rail Stopper Draw-out rail Position indication mark Fixing bolt Fixing bolt Fixing plate

3) Frequency of periodic inspection. It is most appropriate that the user works out his or her own inspection plan for the breakers according to the switching frequency, the values of normal making and breaking of currents, the magnitude of fault current interrupted, service conditions and environmental conditions, otherwise it is recommended to perform a simplified inspection once every 6 months and a full inspection once a year. Be sure to draw out the breaker to the ISOLATED position or to remove the breaker body from the draw-out cradle for inspection or parts replacement purposes.

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4) Mechanical durability of the breaker. The following table shows the mechanical durability of the breaker in terms of the number of switching cycles. When the breaker switching cycles exceed those shown in the table, the possibility of failure may increase. For renewal or thorough inspection of the breaker, contact HHI.
Frame size No. of switching cycles 2500 A or smaller 10,000 3200 A or larger 5,000

5) Frequency of periodic inspection. While it is most appropriate that the user works out his or her own inspection plan for the breakers according to the switching frequency, the values of normal making and breaking of currents, the magnitude of fault current interrupted, service conditions and environmental conditions, it is recommended to perform a simplified inspection once every 6 months and a full inspection once a year.
Inspection interval based on switching cycles Switching conditions of ACB Below 630 frame (A)
Switching operation in the state of nearly 1,000 no-carrying current Switching operation in the rated current region Switching operation in overload region 25 (about 6 times the rated current) Switching operation in current interruption region Each time Each time Each time 25 10 1,000 500 100 1,000 1,000

1250 frame (A) 2500 frame (A)

Over 3200 frame (A)

Be sure to draw out the breaker to the ISOLATED position or to remove the breaker body from the draw-out cradle for inspection or parts replacement purposes. Make sure that live parts have cooled down before performing inspection work.

05

Periodic Inspection and Parts Replacement

5.1 Arc Chutes


Check each arc chute during the periodic inspection and also after a fault current is interrupted. A cracked arc chute cover or deionized grid side plate, or heavy, hard-to-remove molten contact or deionized grid pieces inside the arc chute require replacement of the arc chute. 1) Periodic inspection.
Inspection item Check visually. Dirt, dust, foreign matter Inside must be clean, free of foreign matter and dust. Blow off foreign matter and dust with a jet of compressed air. Check visually. Cracks There should be no cracks or other damage. Replace arc chute if cracked or damaged. Method / Criteria

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2) Removal and mounting. Loosen the two mounting screws captivated on an arc chute until they are free, then remove the arc chute. To mount the arc chute, set it in position and tighten the two mounting screws.
Fig. 11. Arc chute

5.2 Contacts
The pole contact assemblies are visible and accessible when the arc chutes are removed. Check them during a periodic inspection and after a short-circuit fault current is interrupted.
Fig. 12. Sideview of contact assembly

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Stationary arcing contact Stationary main contact Molded base Contact bearing Ribbon Lead Contact holder Contact spring Contact tip Operating rod Lock nut Adjusting screw Moving contact pin Main moving contact Moving arcing contact Stationary arcing contact mounting screw Moving arcing contact mounting nut

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1) Periodic inspection. (1) Arcing contacts.


Inspection item Check visually. Blackening of contact tip surfaces is due to oxidation and sub-formation, but is not a problem since it is wiped off during the closing operation. Contact tip surfaces Remove dirt, dust, grease, etc. Dress roughened surfaces with fine emery paper (#200). If thickness of contacttip is reduced to of original value after a number of dressing operations, replace both the moving and stationary arcing contacts. Check each moving arcing contact for loosening of mounting nut (M5) (Fig. 12. ). Mounting conditions Tighten screws as necessary. Check each contact tip pair for proper alignment in the closed position. Method / Criteria

(2) Main contacts. If the main contacts are toughened through wear, clean their surfaces during periodic inspection.
When dressing contact tips, be careful to not let dust fall into the breaker mechanism. After dressing, be sure to wipe and clean the tips.

2) Replacement. (1) Stationary arcing contact (see Fig. 12. ). Remove the two mounting screws (Fig. 12. ) and remove the stationary arcing contact (Fig. 12. ). Set a new stationary arcing contact in position and firmly tighten the two mounting screws.

Fig. 13. Stationary arcing contact

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Periodic Inspection and Parts Replacement

(2) Moving arcing contact (see Fig. 14).


Breaker type HAT/HAS 06, 08 HAT/HAS 10, 12 HAT/HAS 16 HAT/HAS 20 HAT 25 HAT 32 HAT 40 HAT 50 No. of moving arcing contacts per pole Two pieces (with left and right side pieces paired) Two pieces (with left and right side pieces paired) Two pieces (with left and right side pieces paired) Two pieces (with left and right side pieces paired) Two pieces (with left and right side pieces paired) Two pieces (with left and right side pieces paired) Three pieces (with left, center and right side pieces paired) Three pieces (center piece paired)

Remove the mounting nut (Fig. 12. ) and remove the moving arcing contact (Fig. 12. ). Take extra care so as not to drop the spring washer. Set a new moving arcing contact in position and firmly tighten the mounting nut.

Fig. 14. Moving arcing contact

5.3 Operating Mechanism


Fig. 15

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Stationary contact assembly Moving contact unit Operation rod Connector lever Crossbar Closing spring Closing link Tripping link Trip lever A Trip lever B Trip lever pin Closing roller Trigger lever Trigger lever Trigger link Trigger actuating lever Trigger actuating lever shaft Closing cam Closing camshaft Closing latch Closing release lever Closing release pawl Closing release plate Closing springs Ribbon lead

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1) Periodic maintenance. Check the operating mechanism in detail as much as possible. If there are detail parts that seem to require a check but are hard to check, please contact HHI.
Inspection item Operation Method / Criteria / Disposition Open and close the breaker through manual control to check the mechanical parts for normal operation. Lubrication Add a small amount of grease to each of the pins, shafts and their bearings. Avoid excessive oiling as such will result in accumulation of dirt and dust. Screws, bolts and springs Check tightening screws and bolts of each part for loosening. Tighten them if loose. Check each spring for proper engagement and damage. Correct problem by repair or replacement. Dirt and dust Dirt and dust Latching parts should be free of dirt and dust. Wipe them with a clean cloth.

5.4 Internal Accessories


Remove the front cover (Fig. 1. ) to gain access to the internal accessories. Also remove the OCR front cover (Fig. 1. ) and the mechanical part protective cover (Fig. 16. ) if necessary. To remove the front cover, remove the four front cover mounting screws (Fig. 1. ).

Safety Precautions: 1) Do not place your finger or a tool in the gap between the PUSH TO CLOSE button and the OPEN-CLOSED indicator (Fig. 16. ) since this gap is closed when the breaker is closed. 2) Never attempt to put your hand or a tool into the breaker when the closing springs are charged. Be sure to discharge the closing springs prior to internal inspection.

Fig. 16. Location of internal accessories, motor charging type

1 2 3 4 5 6 7 8 9 10

Open-closed indicator Push to close button Charging motor Charged indicator switch Latch release device (LRC) Auxiliary microswitch Magnet hold trigger (MHT) Shunt trip device (SHT) Anti-pumping hold relay (HC) Breaker front part protective cover

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1) General view of shunt trip device. Table 1, coil resistance values (reference values).
Rated voltage (V) 421 ~ 480 380 ~ 420 AC 180 ~ 250 100 ~ 150 150 ~ 230 90 ~ 125 DC 48 24 Coil resistance () 472 352 101 25 161 36 9.7 2.7

(1) Periodic inspection.


Inspection item Method / Criteria / Dispoition Push the moving core of SHT with a pointed tool, such as screwdriver tip, then slowly release the core. The result is acceptable if the core returns lightly. Operation Slowly push in the moving core after closing the breaker. The result is acceptable if breaker trips open. If the breaker trips open at less than 70% of the rated voltage after closing the breaker, the result is acceptable. Coil Terminals and mounting screws Measure the coil resistance with an ohmmeter. If it is much lower than the value shown in table 1 or there is no continuity, replace the SHT. Check terminals and mounting screws for loosening. Tighten them if loose.

Fig. 17. Shunt trip coil (bottom view)

1 2 3 4 5 6 7

Support Support mounting screw Yoke Yoke mounting screw Coil Moving core Terminal

(2) Replacement of SHT. Take out the breaker body from the draw-out cradle. Set the breaker body so that the bottom surface is visible (see Fig. 17). Remove the two wires from the SHT terminals (Fig. 17. ). Remove the two support mount screws (M5 and M4, one each) (Fig. 17. ) and take out the SHT. After checking the light movement of the moving core (Fig. 17. ) of new SHT, mount it in the breaker as it was. Connect the two wires to the SHT terminals (Fig. 17. ). Test the SHT both electrically and mechanically for normal operation.

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2) Under-voltage trip device. The coil of under-voltage trip device (UVT) uses only DC rating. This under-voltage trip device includes instantaneous trip type AUT-1BS or HATS-U and time delay trip type AUT-1BD or HATS-T having 500- time delay characteristics. The UVT function lock is a standard option (for function lock, refer to locking function of UVT (4), page 22). (1) General view of under-voltage trip device.
Fig. 18. UVT control device

1 2 3 4 5 6

UVT cover UVT cover mounting bolt Wire terminals (fasten terminal) UVT coil UVT mounting bolt (2-M5X10) Wire terminals (fasten terminal)

(2) Periodic inspection.


Inspection item Method / Criteria / Disposition The breaker is trip-free when the UVT is de-energized. Because of this, when the PUSH TO CLOSE button is depressed, the closing springs are discharged, but if the breaker is not closed, the result is acceptable. Operation If the breaker can be closed at more than 85% of the rated voltage, the result is acceptable. If the breaker can be tripped at 70 to 35% of the rated voltage after closing breaker, the result is acceptable. Measure the coil resistance with an ohmmeter. If the measured resistance is much lower than Coil resistance the value shown in the right or there is no continuity, replace the UVT. Terminals and mounting screws Check terminals and mounting screws for loosening. Retighten them if loose. Rated voltage (V) 100-470 V AC 100-200 V DC Coil resistance (ohms) 160 16

(3) Replacement of UVT. When it is necessary to replace the UVT, replace the whole UVT unit. Remove the UVT cover (Fig. 18. ). Pull out the wire terminals (fasten terminals , , and (Fig. 18. )). Remove two UVT mounting screws M5 10 (Fig. 18. ). Take out the UVT. Remove the UVT cover of a new UVT. Install the UVT on the breaker body with UVT mounting screws (Fig. 18. ). Connect the wire terminals (fasten terminals , , and (Fig. 18. )) sequentially from the right. Install the UVT cover. Install the OCR front protective cover. Test the UVT both electrically and mechanically for normal operation in the same manner described in Fig. 18.

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(4) Locking function of UVT. During the inspection and maintenance, the breaker can be closed without supplying the voltage to the UVT, locking its function. Hold the ADJ nut with a tool such as pliers, then pull it up to the position in which it stops (Refer to Fig. 19). Pull the lock lever up to the position in which the positioning stopper comes off, then rotate it in the arrowmarked direction shown in Fig. 19, and hook it on the switch actuator pin for locking (Refer to Fig. 19). This condition is the same as when the specified rated voltage is supplied, making it possible to close the breaker. Perform inspection and maintenance. After completion of inspection and maintenance, hold the ADJ nut with pliers and rotate the lock lever in the reverse direction of the arrow in Fig. 19 for unlocking. This returns the switch actuator pin to the original position. In the function lock condition, the lock lever remains protruded forward, making it impossible to install the OCR front protective cover. After checking that the function lock is released (Fig. 1. ), install the OCR front cover.
Never apply voltage to the UVT terminals - (page 52 circuit diagram) when the UVT function is locked. Doing so may cause burn-out of the equipment. Never loosen or tighten the ADJ nut. Doing so may cause a malfunction.

Fig. 19

3) Latch release device. See table 1. given in 1) (page 20) shunt trip device for the coil resistance values. (1) General view of latch release device.
Fig. 20. LRC mounting

1 2 3 4 5 6

LRC mounting screw Yoke Yoke mounting screw Moving core Coil Terminal

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(2) Periodic inspection.


Inspection item Method / Criteria Push the moving core with a pointed tool, such as screwdriver tip, then slowly release the core. The result is acceptable if the core returns lightly. Charge the closing springs and push the moving core. The result is acceptable if the closing springs are discharged. If the breaker can be closed at 85% of the rated voltage, the result is acceptable. Measure the coil resistance with an ohmmeter. If it were much lower than the value shown in table 1 or there is no continuity, replace the LRC. Check terminals and mounting screws for loosening. Tighten them if they were loosened.

Operation

Coil resistance Terminals and mounting screws

(3) Replacement of LRC. Remove the wires from the LRC terminals (Fig. 20. ). Remove one M5 LRC mounting screw (Fig. 20. ), and take out the LRC from the breaker body. After checking the light movement of the new LRC moving core (Fig. 20. ), mount it in the breaker as it was. Connect the wires to the LRC terminals (Fig. 20. ). Test the device both electrically and mechanically for normal operation in the same manner described in (periodic inspection table). 4) Auxiliary switch unit. HAT06 ~ HAT40. In the case of draw-out type, auxiliary switches operate only when the breaker body is in the CONN. or TEST position. Further, where the ship classification societys rules are applied. They operate only in the CONN. position. The auxiliary switch unit itself is mounted ON the draw-out cradle and mechanically linked to the breaker switching mechanism. (1) General view of auxiliary switch unit and contact arrangement.
Fig. 21. Aux. SW. mounting layout (for HAT06~HAT40)

1 2 3 4 5 6 7 8 9 10 11

Auxiliary switch unit Lock lever Operating lever Operating arm Actuator slide plate Shaft Shaft conn. nut Support mounting screws Switch mounting screw S/Washer Support

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(2) Periodic inspection.


Inspection item Method / Criteria Take the breaker body out of the draw-out cradle. Connect the ohmmeter or alarm (buzzer) to each switch element. Lower the lock lever (Fig. 21. ) for unlocking, and move the operating slide plate (Fig. 21. ) up and down to check each switch element for continuity. - When actuator slide plate is located in the up position, the breakers state is CLOSED. - When actuator slide plate is located at the down position, the breakers state is OPEN. Check that a-contact is ON and b-contact is OFF when breaker is closed, and that a-contact is OFF and b-contact is ON when breaker is OPEN. Check each contact for surface roughness (removing laminated phenolic plate from unit permits visual check of contacts). If contact is excessively worn or rough, replace whole switch unit. Check terminals and mounting screws for loosening. Tighten them if loose.

Operation

Contact surface Terminals and mounting screws

(3) Replacement of auxiliary switch unit (Fig. 21). The auxiliary switch unit is an assembly of 10 switch elements (5 a-contacts and 5 b-contacts). Replace the whole switch unit even if a defect is partial. HAT06 ~ HAT40 (Fig. 21). Remove the one M4 shaft connecting nut (Fig. 21. ). Remove the three M5 support mounting screws (Fig. 21. ). Pull out the shaft (Fig. 21. ) from the operating arm (Fig. 21. ), and remove the auxiliary switch unit. Fit the shaft (Fig. 21. ) of the new auxiliary switch unit into the square hole in the operating arm (Fig. 21. ). Tighten the three M5 support mounting screws (Fig. 21. ). Tighten the one M4 shaft connecting nut (Fig. 21. ). Check the switch unit for normal operation in the method described above (2) periodic inspection. HAT50 (Fig. 21-a). The auxiliary switch unit comprises two rotary switch units linked to the operating mechanism. Upper rotary switch unit contains 4 poles, and lower rotary switch unit contains 4 poles, a total of 8 poles (four a and four b contacts). Some of the poles may be harmed. You should exchange with new AUX-SW-UNIT (if UVT were fitted, three a and four b contacts). Remove OCR front cover. Remove the two AUX-SW-MOV-LEVER MOUNTING NUT (Fig. 21-a. ). Remove the four AUX-SW-UNIT-MOUNTING-BOLT (Fig. 21-a. ). Disconnect AUX-SW-UNIT and AUX-SW-MOV-LEVER-UNIT (Fig. 21-a. ). Remove upper-cover/50 (Fig. 21-a. ) from disconnected AUX-SW-UNIT. Fit the removed upper-cover/50 (Fig. 21-a. ) into new AUX-SW-UNIT. Connect AUX-SW-Unit and AUX-SW-MOV-LEVER-UNIT (Fig. 21-a. ) according to the origin. Tighten AUX-SW-UNIT-MOUNTING-BOLT (Fig. 21-a. ). Tighten AUX-SW-MOV-LEVER-UNIT-MOUNTING-NUT (Fig. 21-a. ) with loctite (a sort of glue). Check the switch unit for normal operation.

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Fig. 21-a. for HAT50

1 2 3 4 5 6 7 8 9 10 11 12 13

Aux. fix base/R Aux. fix base/L Base cover Aux. contact/50 Aux. SW. mov. lever unit Guide bar bolt/50 Aux. SW. link Aux. link/A Upper cover/50 Aux. SW. mov. lever unit mounting nut Upper cover/50 mounting bolt Aux. SW. unit mounting bolt Split pin

5) Anti-pumping hold relay (HC). (1) General view of anti-pumping hold relay.
Fig. 22. Motor control unit PC board as mounted bottm view

1 2 3 4 5 6

Open spring Side-plate mounting screws (both side M5) Side plate support Wire terminals (slip-on receptacles) Motor control unit PC board 2-M4 mounting screws PC board

Fig. 23. Relay (HC)

7 8 9

Clip Relay (HC) PC board

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(2) Operation check. Open and close the breaker through electrical control to check the relay for normal operation. Do this in the following procedure. With the push-button switch (Page 52, PB CLOSE) ON, close the breaker. Immediately place the closed breaker in open condition. Even when the closing springs are CHARGED, if the breaker is not placed in re-closed condition, the result is acceptable. For resetting, turn the push-button switch (Page 52, PB CLOSE) OFF. (3) Replacement of HC. Take the breaker body out of the draw-out cradle. Place the breaker in OPEN condition. Set the breaker body so that the bottom surface may be visible (See Fig. 22). Remove the opening spring (Fig. 22. ). Remove the side-plate support mounting screws (one each for right and left) (Fig. 22. ) to take out the side plate support (Fig. 22. ). Remove the two M4 mounting screws for PC board (Fig. 22. ). Take out the clip fixing the relay (HC) (Fig. 23. ), and remove the relay (HC) (Fig. 23. ) from PC board. Insert a new relay (HC) into PC board (Fig. 22. , Fig. 23. ), and fix it with a clip. Check that the connected wire terminals (fasten terminal) are inserted securely. If required, remove them once, and insert them securely once again.

It is not necessary to remove the connected wire terminals (fasten terminal) (Fig. 22. ).

Install PC board in the original place of the breaker with two M4 mounting screws for PC board. Install the side-plate support in the original position with the right and left side-plate support tapping screws. Install the opening spring. Check the relay for normal operation.

6) Direction of ACB position padlock device. (1) Object Position padlock device is designed for the process of locking position of ACB (isolated, test or connection position) by using shackle. (2) Mounting Position padlock device protrudes at the front cover face. In case of using this device, pull out padlock lever by hand and lock it with shackle. This device is connected with handle-shutter at front cover face. So if it is pushed abnormally or handle-shutter is opened, the ACB will be tripped or will not be closed. If someone pushes the position padlock lever and does a draw-out operation through the opened handleshutter during running time, this will cause a fatal accident.
Do not push position padlock lever. This is the cause of tripping ACB during running time. Shackles must be used to lock this device. Otherwise this can cause mis-operation. Do not operate the draw-out handle during running time. Since main circuit is alive, draw-out operation will cause fatal accident.

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ACB
Over-Current Protective Device

Instruction Manual

Fig. 24. EX: AOR-1L-GS type

1 2 3 4 5 6 7 8 9 10 11

Base current select switch Long time delay trip pickup current setting dial Long time delay setting dial Short time delay trip pickup current setting dial Short time delay setting dial Instantaneous trip pickup current setting dial Pre-trip alarm time delay setting dial Pre-trip pickup current setting dial Ground fault time delay setting dial Ground fault trip pickup current setting System alarm indicator light (LED)

12 13 14 15 16 17 18 19 20 21

Long time delay tripped indicator light (LED) Pre-trip alarm indicator light (LED) Short time delay tripped indicator light (LED) Ground fault time delay tripped indicator light (LED) Instantaneous/MCR tripped indicator light (LED) Reset button Test switch Contact outputs for tripped indication Control circuit terminals Test connectors

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Over-Current Protective Device

Type AOR multifunction protective device is a CPU loaded, high-reliability, multifunctional protective device. This device is classified into types AOR-1L (for general feed circuits), and type AOR-1S (for generator protection). Refer to the following protective function combination table.

Protective function combination table

Type AOR multifunction protective device Protective function Indication function For general feeder circuits AOR-1L-AL For generator protection AOR-1S-AL

AL

AS

AI

IU

AL

AS

AI

AP

MCR

IU

CP/I

AOR-1L-AM

AL

AS

AI

AP

MCR

CP/I

AOR-1L-AS

AOR-1S-AS

AL

AS

AI

AP

MCR

AG

IU

CP/I

AOR-1L-GM

AL

AS

AI

AG

IU

AOR-1L-GL

AL

AS

AI

AP

MCR

AG

CP/I

AOR-1L-GS

AL

AS

AI

AP

MCR

AG

IU

CP/I

AOR-1D-GM

IU CP/I AL AP AS AI AG

Contact for operation indication (whole) Tripped LED indicator & contact (individual) Long time delay trip Pre-trip alarm Short time delay trip Instantaneous trip Ground fault trip Function is an option

MCR

The function check is provided in type AOR multifunction protective device with CP/I, allowing a simple field test.

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6.1 Base Current [Io] of Type AOR Multifunction Protective Device


Base current [I0]

Type AOR-1L (for general feeder)

Base current [I0] can be adjusted to 50%, 63%, 80% and 100% of the rated primary CT current [1CT] On the type AOR multifunction protective device nameplate, the following is marked: BASE CUR. I0: A

Base current [I0] can be selected by rotating the base current setting select switch (Fig. 24. ), which can be set to the predetermined scale. A proper CT is selected according to the rated current [IGEN] of generator.

Type AOR-1S (for generator)

Then, base current [I0] is adjusted so as to be equal to the rated current value [IGEN] of generator according to the input match inside AOR-1S. Accordingly, the rated current value [IGEN] of generator corresponds to base current [I0]. On the type AOR multifunction protective device nameplate, the following is marked: BASE CUR. I0: A

6.2 Protective Functions and Setting Ranges of Type AOR Multifunction Protective Device
Current setting range Time setting range

Long-time delay trip (I1,T1)

Setting dial is scaled in multiples of [I0]. There are eight discrete setting positions: NON, 0.8, 0.85, 0.9, 0.95, 1.0, 1.05 and 1.1 times I0. When [I0] is set at NON the protective function does not operate. The breaker is not tripped at less than 105%, and tripped at more than 120% of [I1] setting.

The setting dial is scaled in seconds, which is the operating time at 600% of [I1] setting. There are nine discrete setting position: 0.5, 1.25, 2.5, 5,10, 15, 20, 25 and 30 seconds. The breaker is tripped at the range from 95% to 105% [T1] setting. When [ICT] is less than 160 A, the breaker is tripped at the range from 90% to 110% [I1] setting. The setting dial is scaled in seconds, which is the operating time at current flow of 120% of [I1] setting. There are seven discrete positions: 15, 20, 25, 30, 40, 50 and 60 seconds.

AOR-1S type (for general feeder)

Setting dial is scaled in multiples of [I0]. There are seven discrete setting positions: NON, 0.8, 1.0, 1.05, 1.1, 1.15, 1.2 and 1.25, of [I0] setting. When [I1] is set at NON, the protective function does not operate.

AOR-1S type (for general)

Inst. trip (I3)

AOR-1L type (for general feeder)

Setting dial is scaled in multiples of [I0]. There are eight discrete setting positions: NON, 4, 6, 8, 10, 12, 14 and 16 times [I0]. When [I3] is set at NON, the protective function does not operate. Time setting is unnecessary. Setting dial is scaled in multiples of [I0]. There are eight discrete setting positions: NON, 4, 6, 8, 10, 12, 14 and 16 time [I0]. When [I3] is set at NON, the protective function does not operate.

AOR-1S type (for general)

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Over-Current Protective Device

Current setting range

Time setting range

Setting dial is scaled in multiples AO-1L type (for general feeder) of [I0]. There are eight discrete setting positions: NON, 2, 2.5, 3, 4, 6, 8, 10 times [I0]. When [I2] and [I3] are set at NON, the device is operated at 1000% of [I0] setting as a fail-safe function by [T2] setting.

Setting dial is scaled in milliseconds, which is the operating time at current flow higher than [I2] X 120% setting. There are seven discrete 80, 160, 240, 320, 400, 480, 560 milliseconds.

Short-time delay trip (I2, T2)

Setting dial is scaled in multiples AOR-1S type (for general) of [I0]. There are eight discrete setting positions: NON, 2, 2.5, 2.7, 3, 3.5, 4 and 4.5, 5 times [I0]. When [I2] is set at NON, the device is operated at 500% of [I0] setting as a fail-safe function.

Setting dial is scaled in milliseconds, which is the operating time at current flow higher than [I2] x 120% setting There are seven discrete setting positions: 80, 160, 240, 320, 400, 480, 560 milliseconds.

Current setting range


Setting dial is scaled in multiples Graund fault trip (IG) AOR-1L type (for general feeder) of OCR rated primary current [ICT]. Setting dial is scaled in multiples of [I ].
CT

Time setting range


Setting dial is scaled in milliseconds, which is the operating time at current flow higher than [I2] X 120% setting. There are seven discrete 80, 160, 240, 320, 400, 480, 560 milliseconds.

There are seven discrete setting positions: 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4 times [ICT].

AOR-1L type (for general feeder)

Setting dial is scaled in multiples of [I0]. There are eight discrete positions: 0.75, 0.8, 0.85, 0.9, 0.95, 1.0, 1.05, and 1.1 times [I0].

Setting dial is scaled in second which is the operating time at current flow higher than [IP] setting. There are eight discrete 60, 80, 120, 140, 160, 180, 200 seconds (definite time delay).

Pre-trip alarm (IP)

Setting dial is scaled in multiples AOR-1S type (for general) of [I0]. There are eight discrete positions: 0.75, 0.8, 0.85, 0.9, 0.95, 1.0, 1.05, and 1.1 times [I0].

There are nine discrete position at current flow 120% of [IP]: 5, 10, 15, 20, 25, 30, 35, 40, 45 seconds.

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ACB

Instruction Manual

1) Method of changing protective function settings. The settings of type AOR multifunction protective device can be changed easily by dial operation. This section describes the basic procedures for setting the protective device. For setting details of individual protective functions see Section 2. (1) Basic procedures. Release two mounting screws from the transparent front cover, and remove the cover from the OCR front cover (Fig. 1. ).
Fig. 25

Using a small flathead screwdriver, adjust the setting switches as appropriate. The OCR has two types of setting switches: Rotary step switches and slide switches. a) Rotary step switches: Rotate the dial until the arrow points to the desired position. The setting is the same within the scale range denoted by a bold line.
Fig. 26. Inst. setting current dial

b) Slide switches: Slide the switch knob up/down to turn ON/OFF.

Switch knob

After adjustment, check the OCR for proper settings by using a filed tester or the like (HOC2, HOC3, HOC4).
Do not apply excessive force to the switches. The switches should lightly be turned or slid with the screwdriver.

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Return the transparent cover to its original position. (2) The setting of slide switch. Frequency setting (50 /60 ). The frequency can be change between 50 and 60 depending on power system. In case of OCR set at 60 in 50 system, the tolerance of OCR increases 20% more than exact setting. Tripping time characteristics (I2t ON/OFF). The STD trip timing can be changed between ramp (I2t=C: inverse-time) mode and definite-time mode. When delivered, the breaker has been set to the definite-time mode. To change the trip timing to the ramp mode, set the I2t - switch on the OCR to ON position.

50 Hz

T2 I2t On

I3 MCR

When a fault current exceeds 8 times (in case of the OCR 8 times), the base current [I0] and the ramp (I2t=C) mode will be changed to the definite time mode. Time setting tolerance of ramp characteristic: (T2 30%)

60 Hz

Off

INST

Tripping mode (INST/MCR). Changeover of INST to MCR or vice versa is allowed at the OCR type which requires control power. When delivered, INST trip timing are set to a mode specified on the order from. Using the INST/MCR mode select switch enables the tripping mode to be changed between INST and MCR. When changing the tripping mode to MCR, be sure to observe the following condition: Estimated short-circuit fault current Rated breaking capacity of the breaker (without INST). MCR is a protective function which instantaneously trips open the breaker only when a fault current exceeding I3 is applied to operate the breaker. After making operation, MCR locks the INST trip function. MCR is an option: refer to ACB catalogue ordering form.

6.3 Operation Indication Functions of Type AOR Multifunction Protective Device


The operation indication function includes contact for tripped indication (whole indication) and CP/I LED light and contact for tripped indication (individual indication).

IU

1)

IU

Contact for tripped indication (whole indication).

This contact output is one contact operating even when any one of LTD, STD, INST and GFT operates. The contact is automatically reset after 40 . The contact output is transmitted between terminals 22 and 23 of disconnecting device for control circuit (Fig. 24. ). Rating of contact for tripped indication rated voltage.
Rated voltage Rated current (resistive load) Rated current (inductive load) 250 V AC 8A 3A 30 V DC 5A 3A 125 V DC 0.5 A 0.25 A 250 V DC 0.3 A 0.15 A

2) CP/I LED light and contact for tripped indication (individual indication). Control power is required for tripped indication. Supply the following power between terminals 19 and 20 of control circuit disconnecting device (Fig. 24. ). 100 V AC to 125 V AC/5 VA or 200 V AC to 250 V AC/5 VA. 100 V DC to 125 V AC/5 W or 200 V DC to 250 V DC/5 W or 240 V DC/5 W.
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Instruction Manual

When LTD, STD/INST or GFT operates, the LED lights for tripped indication (Fig. 24. , , ) light up individually. At the same time, the contact signal ON is outputted individually between terminals - , - , - of control circuit disconnecting device (Fig.1. ).
AS, GS type 22: Common terminal 25: LTD terminal 26: STD/INST terminal 27: GFT terminal 22, 25 26, 27 AM / GM type Common LTD STD INST GFT

The LTD, STD/INST and GFT tripped indications remain ON until the reset button (Fig. 24. ) is depressed or the control power is turned OFF. By pressing the reset button or turning the control power OFF for more than one second, the ON state is reset. LED light and contacts for pre-trip alarm operation indication. The LTD pickup indication LED light (Fig. 24. ) flickers at more than pickup current value [I P]. At the same time, the contact signal ON is outputted between terminals 22-28 of control circuit disconnecting device (Fig. 24. ). The operation indication is automatically reset if the current of less than [IP] is reached. CPU malfunction indication LED lights and contact. When the analog circuit is abnormal, CPU malfunction indication LED light (Fig. 24. ) lights up, and at the same time, the contact signal ON is outputted between terminals 22-24 of control circuit disconnecting device (Fig. 24. ). If CPU malfunction indication LED light lights up: The breaker in service is not effected directly but take the following measures at earlier stages, and eliminate the trouble. Press the reset button (Fig. 24. ). If the abnormality is temporary, such as noise, the LED will go OFF. At that time, the control function returns to normal. If the LED does not go off even by a push of the reset button, some abnormality may occur. In this case, immediately contact HHI. Rating of contact for tripped indication.
Rated voltage Rated current (resistive load) Rated current (inductive load) 125 V AC 125 VA (2 A max.) 20 VA (2 A max.) 220 V DC 60 W (2 A max.) 10 W (2 A max.)

6.4 Field Test Method of Type AOR Multifunction Protective Device


1) Function check method. A simple check of operation for type AOR multifunction protective devices (AOR-1L-AS, AOR-1L-GS, AOR-1S-AS, AOR-1L-AM, AOR-1L-GM, AOR-4L-GS, AOR-4L-GM) can be made with a test switch.
To check each protective function, draw out the breaker to the ISOLATED position, or take it out from the draw-out cradle. If making a function check in the TEST position, confirm that there is no influence on the sequence.

Function check of the ground fault trip function is not possible. Function check of type AOR-4L should be made in the same manner as type AOR-1L function check. (1) Control power and tools to be prepared. Watch: Watch that can measure the seconds (such as a stopwatch). Flat-bladed screwdriver. Control power is indicated on the type AOR multifunction protective device nameplate. If making function check in the TEST position, confirm that the control power is applied across the terminals 19 and 20. 24 V DC between SP(+) - SN(-) terminals. 100 to 250 V AC, DC between S0 - S2 terminals.
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Function check method for each protective function.


Protective function

Type AOR-1L (for general feeder circuit), Type AOR-1S (for generator protection)

Long time delay trip function check

Close the breaker. When the STD INST pickup current value is less than 6 times of the base current in type AOR-1L, set each dial to NON with a flat-bladed screwdriver. Push the test switch (Fig. 24. ) to LO (current flow of 6 times the base current [I0] in type AOR-1L, and 1.2 times the base current in type AOR-1S), and at the same times, start the tripping time measurement with a watch. Also hold the test switch until the breaker is tripped. After tripping, release the test switch. It is reset to OFF (neutral) automatically. Read the tripped time. If it is nearly equal to the operation time at the current flow of 6 times [I0] for type AOR-1L and 1.2 times [I0] for type AOR-1S, it is normal.

Close the breaker. Set the INST pickup current setting dial to NON, using a flat-bladed screwdriver.

Short time delay trip function check

Push the test switch (Fig. 24. ) to HI current flow of more than 16 times the base current [I0]. If the breaker is tripped with time delay setting, it is normal.

After tripping, release the test switch. Return the INST pickup current setting dial to the original set value with a flat-bladed screwdriver.

Instantaneous time delay trip function check

Close the breaker. Push the test switch (Fig. 24. ) to HI current flow of more than 16 times the base current [I0]. If the breaker is tripped momentarily, it is normal. After tripping, release the test switch. It is reset to OFF (neutral) automatically.

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Instruction Manual

2) Characteristic check method. The tripping current value and time delay characteristics of each protective function are checked with secondary current levels converted from the set value primary current supplied to CT. Test current value can be obtained from the conversion formula shown below. Test current = (I/ICT) 5 I: ICT: 5: Set value [I1], [I2], [I3], [IP] or [IG]. Primary current of CT. Secondary current value of CT.

Example) I: [I1] 900 A ICT = 1250 A test current = (900/1250) 5 = 3.6 A. For each protective function characteristic check, draw out the breaker to the Isolated position or take it out from the draw-out cradle. If making function check in the TEST position, do as follows: Characteristic check can be easily made if HHI OCR checker (type HATS-HOC2) is used. When the test apparatus other than HHI OCR checker is used, make the characteristic check according to the following. Remove the protective cover of type AOR multifunction protective device front (see Fig. 25). It is not necessary to disconnect the test terminals (KA, KB, KC, n). Remove the OCR front cover (Fig. 1. ). Disconnect the connected test terminals and connect the solderless terminals to the same positions. As shown in table 2, connect the test equipment outputs to the test terminals (KA, KB, KC, n) of multifunction protective device for characteristic check of each protective function. Note that the internal circuit configuration is as described below when ground fault trip function is provided. Pay attention to the connection with the test terminals.

Stop applying test current immediately after the breaker trips open.

Never apply voltage to terminals TP and TN. Doing so may cause burn-out. Fig. 27

Protective function Long time delay trip, short time delay trip, instantaneous trip and pre-trip alarm Ground fault trip

Connection to test terminals Without GFT One out of KA, KB, KC and n terminal With GFT Between KA - KB Between KA - KC One out of KA, KB, KC and n terminal

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(2) Test equipment, control power source and tools to be prepared. Watch: Watch that can measure the seconds (measure ms as needed). Flat-bladed screwdriver. Control power source. No control power source is required for protection characteristic check. When the operation indication LED light and contact output check is required, use the following power source indicated on the nameplate of type AOR multifunction protective device. If making the characteristic check in the TEST position, confirm that the control power is applied across the terminals 19 and 20. Check the operation indication LED lights for long time delay trip, short time delay trip/instantaneous trip and ground fault trip by applying the control power, and reset them before proceeding to next step.

Supply the power: 24 V DC between SP~SN(-) terminals. 100-250 V AC, DC between S0~S2 terminals.

Test equipment. Prepare an adjustable setting current unit which can output a distortionless sinusoidal current. A sample test equipment circuit is shown below.
Fig. 28

Do not let TEST current flow more than the instantaneous trip pick current setting value (I31.2). Turn the test current OFF immediately when the breaker is tripped.

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Instruction Manual

Characteristic check method for each protective function.


Protective function

Type AOR-1L (for general feeder circuit), Type AOR-1S (for generator protection)

Close the breaker. Increase the test current from zero; the LTD pickup indication LED pickup indication LED light (Fig. 24. ) flickers just before the LTD pickup current setting. Further, increase the test current slowly up to the position in which the LTD pickup indication LED light turns to steady lighting; if the current value at that time is within the range of 1.05 to 1.2 times of secondary current value converted from current [I1] for type AOR-1L, and within the range of 5% of secondary current value converted from current [I1] for type AOR-1S, it is normal. Pickup current check Long time delay trip function check

Reduce the test current output to zero.

Close the breaker. When the STD/INST pickup current setting is less than 6 times of the base current in type AOR-1L, set each dial to NON with a flat-bladed screwdriver.

Trip time check

Apply secondary current corresponding to 6 times the set value [I1] current for type AOR-1L and 1.2 times the set value [I1] current for type AOR-1S. At the same time, start the trip time delay measurement with a watch. Read the tripped time delay. If the breaker is tripped within the range of set time [T1] sec 15%, it is normal. Reduce the test current output to zero. In step 2 above, return the STD/INST pickup current setting dial to the original set value with a flat-bladed screwdriver.

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Protective function

Type AOR-1L (for general feeder circuit), Type AOR-1S (for generator protection)

Close the breaker. Set the LTD/INST pickup current setting dial to NON, using a flat-bladed screwdriver.

Setting current function check

Rapidly apply the test current within 15% (type AOR-1L) and 10% (type AOR-1S) range of secondary current Short time delay trip function check converted from set value [I2] current; if the breaker is tripped, it is normal. Reduce the test current output to zero.

Close the breaker. Set the test equipment output to 1.2 times the secondary current levels converted from the set value [I2] current. Apply the test current. At the same time, start the trip time delay measurement with a watch. If the breaker is tripped, reduce the test equipment output to zero. Read the tripped time. If the tripped time is within the range of resettable time (ms) and maximum total clearing Trip time check time (ms) shown in the table below, it is normal.

Time setting (T2) () 7-step system Reset table time () Max. total clearing time () 80 55 150 160 120 240 240 190 335 320 260 425 400 330 520 480 400 610 560 460 700

Return the LTD/INST pickup current setting dial to the original set value with a flat-bladed screwdriver.

Current and trip time function check

Inst. trip function check

Close the breaker.

If the breaker is not tripped by applying the test current of -20% secondary current levels converted from the set value [I3] current and tripped by applying the test current of +20% secondary current levels, it is normal. Note: The test current should be applied for 50 .

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Instruction Manual

Protective function Close the breaker.

Type AOR-1L (for general feeder circuit), Type AOR-1S (for generator protection)

Increase the test current up to the position in which the LTD pickup indication LTD light (Fig. 24. ) flickers: if the current value at that time is within the range of 7.5% (AOR-1L) and 5% (AOR-1S) of secondary current levels converted from the set value [TP] current, it is normal.

Pre-trip alarm function check

Pickup current check

Reduce the test current output to zero.

Supply the specified control power. Trip time check Apply the test current of 1.1 times (AOR-1L) and 1.2 times of (AOR-1S) of secondary current levels converted from the set value [IP] current. At the same time, start the time measurement with a watch. - If the time at which an alarm signal is outputted across terminals AC and AP is within the range of 20% (AOR-1L) and 15% (AOR-1S) of the set value [TP] second, it is normal. - Reduce the test current output to zero.

Setting current function check

Close the breaker. Apply the test current within the range of 20% of secondary current levels converted from the set value [IG] current: If the breaker is tripped, it is normal. Reduce the test current output to zero. Close the breaker.

Ground fault trip function check

Set the test equipment output to approx. 4 times the secondary current levels converted from the set value current. Apply the test current. At the same time, start the trip time measurement with a watch. Trip time check If the breaker is tripped, reduce the test equipment output to zero. Read the tripped time. If the tripped time value is within the range of resettable time () and maximum total clearing time () shown in the table below, it is normal.

Time setting (T2) () 7-step system Reset table time () Max. total clearing time () 80 40 180 160 110 270 240 170 365 320 240 455 400 310 545 480 380 640 560 450 730

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3) Instruction manual of AOR-1D-GM type OCR. (1) Key menu structure.


Display screen (display phase current & setting values)

Fault

Set screen (set the value of protection function)

Sys

Tests

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ACB

Instruction Manual

(2) Key manual.


AOR-1D-GM key pad

It is very easy to access the menu, using key pad.

Main window. Main window consists of display, fault, setting, system and test. Push Push key and move to next window. key to view upper menu, available from all menu windows.

Display window. In main window, put the cursor at Disp? by using push key. This moves to display window. This window displays load current, setting values and system setting values. Disp? and

Load current. In display window, put the cursor at Curr? by using push key. and

This load current window monitors Ia, Ib, Ic & In.

Setting information. In display window, put the cursor at Set? by using push By pressing key. continuously, user sees each value. This moves to window of setting information. and

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System information. In display window, put the cursor at Sys? by using push key. This moves to system information window. and

Fault window. In main window, put the cursor at Fault? by using push key. and

This moves to window of trip information. This window displays the history of fault trip (up to 8 items) and the key will display trip information 1-8 sequentially.

Set window. In the main window, put the cursor at Set? by using user can change the password in sys window. After inputting input pasword according to example 1, push The set windows all appear. key. , and push .

This moves to the password check window. The default password is 0000 but the

(ex. 1) If password were 1234, change the flicker O into 4, press According to above method, set the other digits.

key and press

or

In set window, each item is represented as follows. LTD Curr: I1, LTD time: T1, STD Curr: I2, STD time: T2, INST Curr: I3, GFT Curr: Ig, GFT time: Tg, PRE-ALARM Curr: Ip, PRE-ALARM time: Tp. (This example shows how to set the value)

(ex. 2) If user wants to set I1=40%, put the cursor on I1 by using This moves to the window below.

and push

key in setting window.

Move cursor to the position of required modification. Using key, set 4 and O and push key. Then, the below screen will appear. If user moves the cursor to Y and pushes If user moves the cursor to N and pushes key, the setting is finished. key, the setting is canceled.

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Sys window. In sys window, user can set the communication port, password, CT ratio, Hz, load type and the characteristic curve of overload. In main window, move cursor to Sys? by using Password check window appears and input the password. Then the below screen will follow. This sample shows how to set the value of communication address. and press key.

(ex. 3) Put the cursor on Add? and push

key. key and select 1 and than

If communication address is 1, push push key.

Put the cursor on Y and push The setting is finished.

key.

Test window. User can easily check the functions of OCR. In main window move cursor to Test? by using Password check window appears. Input the password. Then the below screen will follow. In case of non-trip function, ACB does not operate but only OCR simulates LTD, STD & INST trip like a real fault. In case of trip function, OCR simulates LTD, STD & INST trip and gives a trip signal to ACB, then ACB operates trip mechanism. , and press key.

(ex. 4) In case of trip function, put the cursor on Trip? and push

key. key.

Select LTD among LTD, STD, INST and push

OCR simulates according to setting value: alarm and fault lamp light on and ACB is tripped.

Push

key to reset the fault in this screen.

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(3) AOR-1D-GM terminal block.


AOR-1D-GM terminal block

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Instruction Manual

(4) AOR-1D-GM connection diagrams.


AOR-1D-GM connection diagrams

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4) General directions for testing at primary current levels. When a single-phase current source is used to test the breaker, observe the following directions. Temperature test. If a single-phase test current equal to the rated current is applied to a breaker with its three poles connected in series for temperature test, the breaker will be tripped. This is because two out of the test currents in the same directions and the pickup circuit in the type AOR multifunction protective device see twice the actual current flow. Therefore, to prevent the breaker from being tripped during the temperature test, short the multifunction protective device test terminals KA, KB, KC and together. Over-current trip test. When a trip test is performed on a breaker with a test current supplied to its main circuit, in the same manner as in the temperature test, do this for each pole so that 2 out of the three poles are not in the same direction (not allowed when ground fault trip is provided) or with 2-poles.

07

Insulation Resistance Test and Dielectric Withstand Test

The insulation resistance test and dielectric withstand test for main circuit and control circuit are performed as follows:

7.1 Main Circuit


1) Dielectric with stand voltage characteristic is 3500 V AC for one minute. 2) Use a 500 V DC insulation resistance tester (Megger).

7.2 Control Circuit (to Earth)


1) Dielectric withstand voltage characteristic is 1500 V AC for one minute. For 24 V DC rating of motor charging and closing operation circuits, its characteristic is 500 V AC for one minute (control circuit terminals 1, 2, 3). Also for DC rating of the following control circuits, dielectric withstand test is impossible. Control circuit terminals 9 and 10 of under-voltage trip device (UVT), for both AC and DC ratings, and terminals 19 and 20 of type AOR multifunction protective device. 2) Use 500 V DC insulation resistance tester (Megger) for insulation resistance test.

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08

ACB
Troubleshooting Points

Instruction Manual

No.

Trouble phenomena

Expected causes

Corrective actions

The breaker cannot be closed

Mis-wiring in supply lines. UVT operated. Spring discharged.

Check the control lines with schematic diagram. Check UVT line and pickup condition in terminal 9 & 10. Charge spring.

Loosening of terminal screws. Contact. - Lack of compression force. - Roughness of compression plane. - Contamination of compression plane. Rise of ambient temperature.

Fix the terminal screws. - Regulate compression force or refer to HHI. - Grinding contact or changing. - Clean the plane. Install the venting equipment.

Overheat

Sliding between feed lever and ratchet. Defect of charging motor. - Abnormality of control source. - Defect of control circuit. - Defect of motor pinion or gear. - Defect of motor.

The breaker cannot be charged

When the return spring of feed lever is cut, change it. When abrasion has taken place in feed lever or ratchet, change it. - Supply of normal control source. - Revision of control circuit. - Change motor unit.

Abnormality of UVT. - Lack of trip force. - Residual magnetism. Abnormality of SHT. - Cut or short of coil. - Decrease of source voltage. - Lack of moving core stroke. - Defect of control circuit. Abnormality of OCR. The breaker - Defect of OCR. cannot be tripped - Cut of CT coil. Roughness of moving parts by missing greasing.

- Confirm the state of spring if any harm detected, change or fix it. - Confirm the moving operation of moving part. If any harm detected, fix it or refer to HHI. - If any contamination is attached, remove it. - Change the whole kit. - Change the coil. - Supply normal source voltage. - Refer to HHI. - Check the relay and revise the control circuit. - Refer to HHI. - Remove dust and inject grease. - Check the abrasion degree of ratchet, roller and shaft. If any trouble has taken place, refer to HHI.

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Draw-Out Mechanism of HAS Type

The draw-out mechanism permits one to draw out and remove the breaker body from the draw-out cradle and to put the breaker body back into the cradle, thereby facilitating the inspection and parts replacement. The draw-out mechanism permits one to move the breaker body to any of the following three positions in the draw-out cradle.

CONN. Position
In this position, the main circuit and the control circuits (of the bresker) are connected to the external circuit for normal service. This position permits tests such as close-open test, control circuit function test, etc.

TEST Position
In this position, the main circuit is isolated, and the control circuits are connected. This position permits tests such as close-open test, control circuit function test, etc.

REMOVAL Position
In this position, the main circuit and the control circuits are isolated. The breaker is completely de-energized in this position.

9.1 Moving the Breaker Body Within Draw-Out Cradle


The draw-out handle (Fig. 29. ) is used to move the breaker body from CONN. to TEST or from TEST to CONN. in the draw-out cradle. 1) Moving from CONN. to TEST position. Confirm ACB is in OPEN condition. If the ACB is in CLOSE position open the ACB by pressing Push to Open Button. Push down the rail hook lever (Fig. 29. , ). Fix the D/O handle(s) (Fig. 29. ) into pin (Fig. ) and pull the handle front side. Remove the D/O handle(s) (Fig. 29. ). Draw-out the breaker body until it is in TEST position. If breaker body arrives at the TEST position, it is locked automatically. 2) Moving from TEST to REMOVAL position. Push down the rail hook lever (Fig. 29. , ). Draw-out the breaker body from TEST position until it is locked automatically.

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9.2 Putting the Breaker Body Back into Draw-Out Cradle


Follow the procedure given below to put the removed breaker body back into the draw-out cradle. Check that the breaker is OPEN. Check that the spring charged indicator is showing DISCHARGED, indicating the closing springs are discharged. Lift up the breaker body or, using a special lifter, push in the breaker body until the draw-out stoppers are locked so that the slide plate of the breaker body side may be engaged with the slide plate of the draw-out cradle side. At the REMOVAL position, after pushing down rail hook lever (Fig. 29. , ), insert breaker body until it is in TEST position. If breaker body arrives at the TEST position, it is locked automatically. To confirm the TEST position, refer to the sticker left of the draw-out cradle. Push down the rail hook lever (Fig. 29. , ). Insert the breaker body until isolating contact (Fig. 29. ) is touched. Fix the D/O handle(s) (Fig. 29. ) into pin (Fig. 29. , ) and lift up the D/O handle(s) (Fig. 29. ). If the breaker body arrives at CONN. position, it cannot be inserted any more. Confirm the CONN. position according to sticker left of the draw-out cradle. Dont forget to confirm that the state of the rail hook lever (Fig. 29. , ) is upward.

Fig. 29

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Circuit Diagrams of AOR

3-phase 4-wire 4-pole type

3-phase 4-wire 3-pole type

AOR-1L-GL / 4L- GL

AOR-1L-GM / 4L- GM

AOR-1L-GS / 4L-GS

CT1 ~ CT4: for HAT06, 08, 10, 12, 16, 20 CT5 ~ CT8: for HAT25, 32, 40, 50

CT1 ~ CT3: for HAT06, 08, 10, 12, 16, 20 CT4 ~ CT6: for HAT25, 32, 40, 50

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3-phase 3-wire 3-pole

AOR-1L-AL / 1S-AL

AOR-1L-AM

AOR- 1L-AS / 1S-AS

CT1 ~ CT3: for HAT06, 08, 10, 12, 16, 20 CT4 ~ CT6: for HAT25, 32, 40, 50

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Circuit Diagrams of HAT

11.1 Type HAT06~40

Main Circuit

Over-Current Protective Device

Under-Voltage Trip

Motor Charging Closing Circuits

DC 24 V AC, DC 100-250 V

SP-SN S0-S2

CT1-3 : CT for over-current trip for types HAT06 to HAT20. CT4-6 : CT for over-current trip for types HAT25 to HAT40. Do not use these output contacts in circuits exceeding 250 V AC or 220 V DC.

1: Fitted with circuits rated 240 V and 250 V AC. 2: For circuits of rated control voltage 125 V DC. 3: For circuits of rated control voltage 200 V to 220 V.

Main Circuit
CT: Current transformer for OCR

Spring Charge Switch Contact


3 15

Condenser Trip
U P V N

Spring charge switch contact

Condenser trip source Condenser trip

Over-Current Relay (OCR)


19 22 22 22 22 22 20 23 25 26 27 28

Motor Charging/Closing Circuits


1 3 M HC LRC 2

Trip Indication Switch


13 X1 14

Control power for terminals (CP/I) Common line for ind. contact (IU)
AL Ind. contact (CP/I) AS AI Ind. contact (CP/I)

Source Closing circuit Charging motor Hold relay Latch release coil Push button switch

Trip indication SW. Auxiliary relay (not supplied)

AG Ind. contact (CP/I) AP Pre-trip alarm (CP/I)

PB

MHT

Magnetic hold trigger

Under-Voltage Trip (UVT)


9 11 UVT 10 12

Shunt Trip (SHT)


SHT 7 8

Auxiliary Switch
31 50

Source Remote electrical tripping Under-voltage trip coil

Shunt trip coil Source

Auxiliary switch

AUX. SW. Auxiliary switch PB Push button switch

AUX. SW. Auxiliary switch

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Shunt Trip

Capacitor Trip

Trip Ind. SW.

Auxiliary SW.

Position SW.

Draw-out type: The Aux. SW. operate in the connected and test positions only. When marine classification societys rules are applied they operate in the connected position only.

M HC
LRC

Charging motor Hold relay (anti-pumping) Latch release coil (closing) Manufacturers wiring Users wiring Disconnecting device

Test position

61-62 ON 61-63 OFF 64-65 ON 64-66 OFF 67-68 ON 67-69 OFF

Connected position

71-72 ON 71-73 OFF 74-75 ON 74-76 OFF 77-78 ON 77-79 OFF

Terminal Arrangement of Control Circuit


31 33 35 37 39 41 43 45 47 49 B1 A1 B2 A2 B3 A3 B4 A4 B5 A5 32 34 36 38 40 42 44 46 48 50 2 4 8 10 12 14 16 18 20 22 24 26 28 30 1 3 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 B1 A1 B2 A2 B3 A3 B4 A4 B5 A5 32 34 36 38 40 42 44 46 48 50 1 2 3 4 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

OCR Circuit Diagram for 4-pole

(AUX. SW.)

(CONTROL CIRCUIT)

(AUX. SW.) (CONTROL CIRCUIT)

AOR-1L-GL AOR-1L-GM AOR-1L-GS AOR-1D-GM

Test S.W. Connect S.W.

71 61

72 62

73 63

(D/O Type)

(FIX Type)

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11

Circuit Diagrams of HAT

11.2 Type HAT50

Main Circuit

Over-Current Protective Device

Under-Voltage Trip

Motor Charging Closing Circuits

DC 24 V AC, DC 100-250 V

SP-SN S0-S2

Do not use these output contacts in circuits exceeding 250 V AC or 220 V DC.

1: Fitted with circuits rated 240 V and 250 V AC. 2: For circuits of rated control voltage 125 V DC. 3: For circuits of rated control voltage 200 V to 220 V.

Main Circuit
CT: Current transformer for OCR

Spring Charge Switch Contact


3 15

Condenser Trip
U P V N

Spring charge switch contact

Condenser trip source Condenser trip

Over-Current Relay (OCR)


19 22 23 25 27 28 MHT 20

Motor Charging/Closing Circuits


1 3 M HC
LRC

Trip Indication Switch


13 X1 14

Control power for terminals (CP/I) Common line for ind. contact (IU) Iind. contact (CP/I)
AL Pre-trip alarm (CP/I) AG AI Pre-trip alarm (CP/I)

Source Closing circuit Charging motor Hold relay Latch release coil

Trip indication SW. Auxiliary relay (not supplied)

AP Pre-trip alarm (CP/I)

15

Spring charge switch

Magnetic hold trigger

Under-Voltage Trip (UVT)


9 11 UVT 10 12

Shunt Trip (SHT)


SHT 7 8

Auxiliary Switch
31 46

Source Remote electrical tripping Under-voltage trip coil

Shunt trip coil Source

Auxiliary switch

AUX. SW. Auxiliary switch PB Push button switch

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ACB

Instruction Manual

Shunt Trip

Capacitor Trip

Trip Ind. SW.

Auxiliary SW.

Position SW.

Draw-out type: The Aux. SW. operate in the connected and test positions only. When marine classification societys rules are applied they operate in the connected position only.

M HC
LRC

Charging motor Hold relay (anti-pumping) Latch release coil (closing) Manufacturers wiring Users wiring Disconnecting device

Test position

61-62 ON 61-63 OFF 64-65 ON 64-66 OFF

Connected position

71-72 ON 71-73 OFF 74-75 ON 74-76 OFF

- -

Terminal Arrangement of Control Circuit


74 64 75 65 76 66 46 44 42 40 38 36 34 32 30 28 26 24 22 20 16 14 12 10 8 2 45 43 41 39 37 35 33 31 29 27 25 23 21 19 15 13 11 9 7 3 1 61 71 62 72 63 73

OCR Circuit Diagram for 4-pole

Test position SW. Connected position SW.

Test position SW. Connected position SW.

AOR-1L-GL AOR-1L-GM

(AUX. SW.)

(Control Circuit)

AOR-1L-GS AOR-1D-GM

(Draw-Out Type)

HAT50

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12

Appendix

12.1 Ground Fault Protection


1) In case of grounded or resistance ground system in the Y and Y-source transformer. (1) 3-poles ACB with GFT function in 3 4W system. External ground sensing neutral CT connected to the ground element terminals (29, 30). This means that this ACB will trip the breaker whenever CTs residual output current exceeds the setting as in a). Tripping is independent of phase currents. The lower the neutral CT ratio, the more sensitive the ground fault protection.
AG Pickup current Setting tolerance Time delay () Continuously adjustable from ICT X 0.1 ~ 0.4, ICT X (0.1-0.15-0.2-0.25-0.3-0.35-0.4) 7 steps Continuously adjustable from ICT X 0.1 ~ 0.4 20% Automatically set to AS time-delay.

(2) 4-poles ACB with GFT function in 3 4W system. On 4-wire systems, standard includes a fourth CT. A fourth CT does not sense ground current. Its only function is to sense neutral current. It is connected to vectorally subtract from the residual current of the phase sensors (see below). Ia Ib Ic In Non-Trip Trip

Ia + Ib + Ic + In 0 Ia + Ib + Ic + In 0

In case of current unbalance in system, trip also.

(3) 3-poles ACB with GFT function in 3 3W system. The principle is the same (1) 3-poles ACB with GFT function in 3 4W system. It is connected to vectorally subtract from the residual current of the phase sensors. Ia Ib Ic Non-Trip Trip

Ia + Ib + Ic 0 Ia + Ib + Ic 0

In case of current unbalance in system, trip also.

2) In case of ungrounded system in the Y and -source transformer. Since ungrounded systems produce minimal ground current, no damage occurs to the grounded equipment. These ground currents are also too low for detection by the AOR unit, therefore they serve no ground fault tripping function if applied on these systems. If you need ground function, separately install OCGR in switchgear using ZCT.

(1) Connection between neutral current transformer (optional) and OCR. When using a 3-pole breaker with the GFT function in a 3-phase, 4-wire distribution system, install a neutral current transformer (optional) to the neutral in the switchboard.

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Instruction Manual

(2) Type and rating of neutral current transformer Select the neutral current transformer, the rating of which is the same as that of the primary current transformer [ICT], according to the following table.
Breaker Rating of current transformer (A) 320/5 630/5 800/5 1000/5 1250/5 1600/5 2000/5 320/5 630/5 1250/5 1600/5 2000/5 500/5 1000/5 1600/5 2000/5 2500/5 3200/5 4000/5 5000/5

HAT06 HAT08 HAT10 HAT12 HAT16

HAT20

HAT25 HAT30 HAT40 HAT50

Class of Neutral CT: 1.0 Class.

(3) Connection Connect the transformer while observing polarity (dotted lines are to be wired by the user).
3-pole breakers (HAT06~HAT20)
Power source (or load) 3-pole breakers (HAT25~HAT50) Power source (or load)

Load (or power source)

Load (or power source)

If the CTs connect the reverse polarity, the GFT malfunctions.

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12

Appendix

12.2 Closing and Tripping Operation Cycles

Supply Power

Confirm the Diagram

No

Manual Charging

Motor Charging

No No Indicated CHARGED Check the Diagram Confirm the Position of ACB Confirm the Key-lock & Padlock Closing Operation Remove the D/O Handle Supply Rated Source to UVT Confirm the Movement of Interlock System Indicated CLOSE Refer to Conn. Diagram on Page 52~55 No Contact to HHI

No

Indicated OPEN

Tripping Operation

Check the Wiring of SHT & UVT If Necessary, Check the Resistance

Release KEY-LOCK

No

Indicated OPEN

No

Electrical Defect

No

Mechanical Defect

OK

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ACB

Instruction Manual

Repair and Inspection


Date Statement of repair Pay or free Repair shop Name of engineer Signature

Please be sure to obtain the appropriate signatures after service. Please keep this table for management, maintenance, and after-sales service.

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HHIS-WZ-LE-011-02 06,04 Designed by ADPARK

www.hyundai-elec.com

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