NP 7410 V1P3

Circuit Breaker Maintenance
Volume 1: Low-Voltage Circuit Breakers

Part 3: Westinghouse DB Models
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REPORT
SUMMARY

This comprehensive guide will help utilities improve their maintenance of Westinghouse DB model low-voltage circuit breakers.
It consolidates industry guidelines, applicable standards, original
equipment manufacturer recommendations, and hands-on experience
relative to these circuit breakers. Ultimately, improved maintenance
will increase reliability and reduce costs associated with corrective
maintenance and equipment downtime.
INTEREST CATEGORIES
Maintenance practices
Nuclear plant operations
and maintenance
Plant electrical systems
and equipment
Engineering and technical
support
KEYWORDS
Control equipment
Switchgear
Predictive maintenance
Preventive maintenance
Maintenance
BACKGROUND Increased awareness of circuit breaker performance trends,

reliability, and failure effects has prompted an in-depth review of maintenance
practices and standardized technical guidance. Circuit breaker failures are
costlyboth in plant downtime and in potential damage to other plant components. EPRI therefore developed this guide to establish a working-level understanding of low-voltage circuit breaker performance trends, reliability, and failure
modes from which maintenance practices can be specified. DB model low-voltage
circuit breakers were selected because of their wide-ranging uses in nuclear and
fossil power plants.
OBJECTIVE To reduce power plant operation and maintenance costs by providing practical, cost-effective preventive and corrective maintenance recommendations for Westinghouse DB model circuit breakers along with the basis for such
recom mendations.
APPROACH The project team developed a description of Westinghouse DB
model low-voltage circuit breakers installed at nuclear and fossil power plants.
Their review included operating mechanisms, overcurrent trip units, and auxiliary
features. The team then performed an in-depth examination of available operating
experience and failure data from the Nuclear Power Reliability Data System, licensee event reports, and nuclear as well as nonnuclear circuit breaker overhaul data.
Other investigations addressed current industry practices, including a review of
manufacturer recommendations and industry standards. Finally, the project team
used this collective information to develop maintenance recommendations and
detailed guidance for inspection, test, and overhaul.
RESULTS This maintenance guide focuses on Westinghouse DB model lowvoltage air circuit breakers installed at nuclear and fossil power plants. Topics
address the DB breaker and its operation, reliability and failure data, principal
degradation/failure mechanisms, maintenance recommendations, inspection and
test periodicity, detailed inspection and test guidance, renewal parts lists, and
parts procurement. In its comprehensive consolidation of industry guidelines,
standards, and recommendations, this guide presents practical information not
previously available for the maintenance technician, planner, or engineer.
The DB breaker guide is one of a series of guides on low- and medium-voltage circuit breakers. This guide is divided into three volumes, which are further divided
EPRI NP-7410s Vol. 1, Part 3
Electric Power Research Institute
into parts that correspond to a specific class, manufacturer, and model.

Volume 1, with four parts, covers low-voltage circuit breakers. Volume 2,
in three parts, discusses medium-voltage circuit breakers. Volume 3, a
stand-alone document, describes molded-case circuit breakers. Additional parts of Volume 1 as well as Volume 2 are forthcoming. Volume 3
is now available.
EPRI PERSPECTIVE Circuit breaker maintenance is an ongoing responsibility for electric power plants. Improper maintenance practices can
decrease electrical system reliability and availability. Because downtime
resulting from poor maintenance is costly, improving just a few maintenance
activities can result in significant cost savings. This guide provides prudent test and inspection methods, which, in turn, result in more-effective
use of maintenance resources. Power plant personnel using this guide
will thus be better equipped to establish an effective time-and-conditionbased maintenance program.
PROJECT
RP2814-49
Project Manager: James P. Sharkey
Nuclear Power Division / Nuclear Maintenance Applications Center
Contractor: Grove Engineering, Inc.
For further information on EPRI research programs, call
EPRI Technical Information Specialists (415) 855-2411.

NP-7410, Volume 1, Part 3
Research Project 2814-49
Final Report, December 1992
Prepared by
GROVE ENGINEERING, INC.
15215 Shady Grove Road, Suite 200
Rockville, Maryland 20850
Principal Investigators
J. W. Danahy
M. l. Denny
E. F. MciGnn
Prepared by
Nuclear Maintenance Applications Center
Operated by
Electric Power Research Institute
3412 Hiliview Avenue
Palo Alto, California 94304
EPRI Project Manager
J. P. Sharkey
Nuclear Power Division
DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS REPORT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED
BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC. (EPRI). NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE
ORGANIZATION(S) NAMED BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:
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IN THIS REPORT.
ORGANIZATION(S) THAT PREPARED THIS REPORT:
GROVE ENGINEERING, INC.
Price: $10,800.00
ORDERING INFORMATION
Requests for copies of this report should be directed to the Nuclear Maintenance Applications Center
(NMAC), 1300 Harris Blvd., Charlotte, NC 28262, (800) 356-7448. There is no charge for reports requested
by EPRI member utilities and affiliates.
Electric Power Research Institute and EPRI are registered service marks of Electric Power Research Institute, Inc.
Copyright 1992 Electric Power Research Institute. All rights reserved.
ABSTRACT
Low-voltage circuit breakers provide power and circuit protection to essential plant
equipment and systems. Increasing awareness of circuit breaker performance trends,
reliability, and failure effects has led to a need for an in-depth review of breaker
maintenance practices and standardized technical guidance.
The Nuclear Maintenance Applications Center (NM A C ) developed this guide to
establish a working-level understanding of breaker performance trends, reliability, and
failure modes from which maintenance practices could be specified. Development of
this guide involved an in-depth review of available operating experience and failure
data; which was obtained from information sources within the nuclear power industry.
In addition, non-nuclear circuit breaker overhaul data was evaluated. Investigations
were made into current industry practices, including a review of manufacturer's
recommendations and industry standards. Finally, the collective information was used
to develop maintenance recommendations and detailed guidance for inspection, test,
and overhaul.
The guide is designed to consolidate industry guidelines, applicable standards, OEM
recommendations, and industry hands-on experience pertaining to W e s t i n g h o u s e
model DB circuit breakers. Combining this information into one document will provide
utilities with a tool for the development and implementation of a practical, costeffective, and technically sound maintenance program for W estinghouse type DB lowvoltage circuit breakers.
Contents of the guide include a description of Westinghouse's m o d e l D B b r e a k e r s ,
their historical performance, failure mode identification, maintenance
recommendations, inspection and test periodicity, and maintenance guidelines.
Potential benefits of this guide include a more thorough maintenance program by
providing an organized approach and standardized maintenance practices. The guide
provides prudent testing and inspection methods, which in turn utilize maintenance
resources more effectively. Power plant personnel utilizing this guide will be better
equipped to establish an effective time- and condition-based maintenance program.
Such a program will ultimately result in increased reliability and reduced costs
associated with corrective maintenance and equipment downtime.
This guide on Westinghouse breakers is one part of a series of guides on low- and
medium-voltage circuit breakers. This maintenance guide series consists of three
volumes. Each volume is further divided into parts which correspond to a specific
class, manufacturer, and/or model.
This series of guides is intended for personnel responsible for planning, performing,
supervising, or providing technical support for circuit breaker maintenance activities.
This product is applicable to both nuclear and non-nuclear applications.
iii
FOREWORD
The Nuclear Maintenance Applications Center (NMAC) is committed to the distribution

of successful and practical maintenance solutions to its member utilities. According to
utility needs, this document will be reviewed and revised to reflect any future advances
in techniques or technology. Utility personnel are encouraged to provide comments
on this document. Proposed changes or additions may be submitted using the
following address.
Nuclear Maintenance Applications Center
Project Manager, Circuit Breakers
c/o EPRI NDE Center
1300 Harris Boulevard
Charlotte, North Carolina 28262
ACKNOWLEDGEMENTS
This guide was prepared by the Nuclear Maintenance Applications Center (NMAC),
under the Electric Power Research Institute's research project number 2814-49. To
assure an accurate and meaningful publication was developed, draft copies were sent
to individuals in the electric power industry who have an interest in the proper
maintenance of low-voltage circuit breakers. The comments and suggestions made
by these individuals provided an essential user input and resulted in a number of
meaningful and substantive changes to the document.
For any document of this scope, various people and organizations must provide
extensive assistance and information to make the publication possible. In particular,
N M A C recognizes Lesa Kopsidas and Shelley Owrutsky of Grove Engineering, Inc., for
producing and editing this document. NMAC also recognizes the following individuals
for their valuable contributions through their technical assistance, document reviews,
or support. The time and attention provided by each are gratefully appreciated.
James Canning
Power Distribution Technology
Larry P. Clark
Nebraska Public Power District
Carl Johnson
Tennessee Valley Authority
Bill Nowicki
Baltimore Gas and Electric
John Roy
Rickey D. Sparks
Tennessee Valley Authority
Graig Wenzel
Rick Whitt
vii
CONTENTS
Section
1.0
Page
Introduction
1-1
1.1
Background........................................................................................... 1-1
1.2
Purpose ................................................................................................. 1-1
1.3
Scope..................................................................................................... 1-2
1.4
Approach............................................................................................... 1-2
1.4.1 Project Approach ......................................................................... 1-2
1.4.2 Report Approach.......................................................................... 1-3
2.0
Circuit Breaker Description
2-1
2.1
General Information.............................................................................. 2-1
2.2
DB-15/25, DBF-6, and DBL-25 Circuit Breakers ................................. 2-1

2.2.1 General Description..................................................................... 2-1
2.2.2 Mounting Arrangement ................................................................ 2-2
2.2.3 Breaker Operation ....................................................................... 2-6
2.2.4 Contacts and Arc Chutes ............................................................. 2-9
2.2.5 Electrical Devices ...................................................................... 2-12
2.2.6 Overcurrent Trip Devices........................................................... 2-13
2.2.7 Options ...................................................................................... 2-17
2.3
DB-50/75, DBF-16, and DBL-50 Circuit Breakers ............................. 2-18

2.3.1 General Description................................................................... 2-18
2.3.2 Mounting Arrangement .............................................................. 2-19
2.3.3 Breaker Operation ..................................................................... 2-23
2.3.4 Contacts and Arc Chutes ........................................................... 2-27
2.3.7 Options ...................................................................................... 2-33
ix
Section
3.0
Page
Historical Performance
3.1
3-1
Analysis of Overhaul Data ................................................................... 3-1

3.1.2 Deficiencies by Breaker Subcomponent...................................... 3-2
3.2
Analysis of NPRDS Data ...................................................................... 3-6

3.2.2 Failures by Breaker Operation..................................................... 3-6
3.2.3 Failures by Breaker Model........................................................... 3-8
3.2.4 Failures by Breaker Subcomponent .......................................... 3-10
3.3
Failure Modes Analysis...................................................................... 3-14

3.3.1 Critical Functions ....................................................................... 3-15
3.3.2 Failure Analysis by Subcomponent ........................................... 3-15
3.4
Recordkeeping Guidelines ................................................................ 3-21

3.4.1 Maintenance Data...................................................................... 3-21
3.4.2 Test Data ................................................................................... 3-22
4.0
Maintenance Recommendations
4.1
4-1
Maintenance Scheduling...................................................................... 4-2

4.1.1 Time-Based Scheduling............................................................... 4-2
4.1.2 Condition-Based Scheduling ....................................................... 4-9
4.2
Subcomponent Replacement .............................................................. 4-9

4.2.1 Time-Based Replacement ........................................................... 4-9
4.2.2 Condition-Based Replacement .................................................. 4-11
4.2.3 Subcomponent Upgrades .......................................................... 4-14
4.2.4 Lubrication ................................................................................. 4-14
Section
Page
4.3
Personnel Qualification and Training ............................................... 4-16
4.4
Industry and Manufacturer Recommendations................................ 4-17
5.0
Maintenance Guidelines
5-1
5.1
Precautions ........................................................................................... 5-1
5.2
Tools and Test Equipment .................................................................. 5-2
5.3
DB-15/25 Routine Maintenance Inspections, Test,

and Adjustments................................................................................... 5-5
5.3.1 General Inspection ...................................................................... 5-5
5.3.2 Mechanical/Electrical Operation .................................................. 5-6
5.3.3 Contact Inspection and Adjustment ............................................. 5-6
5.3.4 Operating Mechanism Inspection ................................................ 5-7
5.3.5 Cleaning, Inspection, and Adjustment of
Major Subcomponents ................................................................. 5-8
5.3.6 Electrical Tests .......................................................................... 5-16
5.3.7 Overcurrent Trip Device Operation............................................ 5-17
5.3.8 Final Assembly and Inspection .................................................. 5-24
5.3.9 Maintenance Data Record ......................................................... 5-26
5.4
DB-15/25 Overhaul Guideline ............................................................ 5-31

5.4.1 Initial Test and Inspection.......................................................... 5-31
5.4.2 Disassembly .............................................................................. 5-40
5.4.3 Inspections, Tests, Cleaning, and Re-lubrication ...................... 5-45
5.4.4 Reassembly ............................................................................... 5-52
5.4.5 Post-Overhaul Inspections, Adjustments, and
QA Requirements ...................................................................... 5-56
5.4.6 Overhaul Data Record ............................................................... 5-68
5.5
DB-50/75 Routine Maintenance Inspections, Tests,

and Adjustments................................................................................. 5-75
5.5.1 General Inspection .................................................................... 5-75
5.5.2 Mechanical/Electrical Operation ................................................ 5-76
5.5.3 Contact Inspection and Adjustment ........................................... 5-76
xi
Section
Page
5.5.4 Operating Mechanism Inspection .............................................. 5-77
Major Subcomponents ............................................................... 5-79
5.6
DB-50/75 Overhaul Guideline .......................................................... 5-101

5.6.1 Initial Test and Inspection........................................................ 5-101
5.6.2 Disassembly ............................................................................ 5-111
5.6.3 Inspections, Tests, Cleaning, and Re-Lubrication ................... 5-116
5.6.4 Reassembly ............................................................................. 5-123
QA Requirements .................................................................... 5-129
5.6.6 Overhaul Data Record ............................................................. 5-141
6.0
Replacement Parts
6.1
6-1
DB-15 Replacement Parts List ............................................................ 6-1

6.1.1 DB-15 Renewal Parts List............................................................ 6-2
6.1.2 DB-15 Overhaul Parts List ........................................................... 6-4
6.2

6.3
DB-50 Replacement Parts List .......................................................... 6-10

6.3.1 DB-50 Renewal Parts List.......................................................... 6-10
6.3.2 DB-50 Overhaul Parts List ......................................................... 6-12
6.4

xii
Section
Page
6.5
Replacement Parts Procurement ...................................................... 6-19

6.5.1 Procurement Process ................................................................ 6-19
6.5.2 Alternate Sourcing Guidelines ................................................... 6-22
Appendix A
References
A-1
Appendix B
Glossary
B-1
Appendix C
Nuclear Industry Information
C-1
xiii
ILLUSTRATIONS
Figure
Page
2.2-1
Electrically Operated DB-25 Circuit Breaker ......................................................... 2-3
2.2-2
DB-25 Drawout Breaker (Rear View) .................................................................... 2-5
2.2-3
DB-15/25 Control Circuit ....................................................................................... 2-8
2.2-4
DB-25 Contact Assemblies ...................................................................................2-10
2.2-5
DB-25 Arc Chutes .................................................................................................2-11
2.2-6
Electro-Mechanical Overcurrent Trip Device.........................................................2-14
2.2-7
Amptector IIA Overcurrent Trip Device ................................................................2-16
2.3-1
Electrically Operated DB-75 Circuit Breaker .........................................................2-20
2.3-2
DB-75 Drawout Breaker........................................................................................2-21
2.3-3
DB-75 Drawout Breaker (Rear View) ....................................................................2-24
2.3-4
DB-50/75 Breaker Control Circuit..........................................................................2-26
2.3-5
DB-75 Contact Assemblies ...................................................................................2-29
3.1-1
Overhaul Data Summary Subcomponent Deficiencies ......................................... 3-3
3.2-1
Subcomponent Failures by Operation .................................................................. 3-8
3.2-2
Subcomponent Failures by Breaker Model ........................................................... 3-9
3.2-3
NPRDS Subcomponent Failures...........................................................................3-11
3.3-1
Subcomponent Deficiency Summary ....................................................................3-18
4.1-1
NRPDS Failure Detection Methods....................................................................... 4-2
5.3-1
UV Device Lubrication Points ...............................................................................5-15
5.5-1
UV Device Lubrication Points ...............................................................................5-86
6.5-1
Procurement Process ...........................................................................................6-20
xv
TABLES
Table
Page
3.3-1
General Circuit Breaker Critical Function/

Failure Mode Analysis .......................................................................................... 3-16
3.3-2
Reactor Protection Breaker Critical Function/

Failure Mode Analysis .......................................................................................... 3-17
4.0-1
Maintenance Scheduling ...................................................................................... 4-1
4.1-1
Routine Inspection, Test, and Adjustment Actions ............................................... 4-4
4.2-1
Subcomponent Time-Based Replacement........................................................... 4-10
4.2-2
Subcomponent Condition-Based Replacement.................................................... 4-12
4.4-1
Industry and Manufacturer Maintenance

Recommendations ............................................................................................... 4-19
6.1-1
DB-15 Renewal Parts........................................................................................... 6-3
6.1-2
DB-15 Overhaul Parts .......................................................................................... 6-5
6.2-1
DB-25 Renewal Parts........................................................................................... 6-7
6.2.2
6.3-1
DB-50 Renewal Parts........................................................................................... 6-11
6.3-2
6.4-1
DB-75 Renewal Parts........................................................................................... 6-16
6.4-2
xvii
Section 1.0
Introduction
1.1
Background........................................................................................... 1-1
1.2
Purpose ................................................................................................. 1-1
1.3
Scope..................................................................................................... 1-2
1.4
Approach............................................................................................... 1-2
1.4.1 Project Approach ......................................................................... 1-2
1.4.2 Report Approach.......................................................................... 1-3
1.0
Introduction
1.1
Background
In order to achieve its goal of responding to its member utilities' maintenance related
technical issues, the Nuclear Maintenance Applications Center (NMAC) performs an
annual review of maintenance issues. During this review, power plant maintenance issues
are identified and prioritized so that NMAC can focus its resources to the benefit of its
members. NMAC issue reviews during previous years have ranked circuit breakers within
the top 15 maintenance issues. In addition, increasing awareness of breaker performance
trends, reliability, and failure effects have lead NMAC's utility Steering Committee to
support NMAC's work in breaker maintenance.
Benefits of this maintenance guide include a more thorough maintenance program by
providing an organized approach and standardized maintenance practices. These guides
provide prudent testing and inspection methods, which in turn utilize maintenance
resources more effectively. Power plant personnel utilizing these guides will be better
equipped to establish an effective time and condition-based maintenance program. Such a
program will ultimately result in increased reliability and reduced costs associated with
corrective maintenance and equipment downtime.
1.2
Purpose
The purpose of this report is to define maintenance guidelines for Westinghouse Type DB
low-voltage (480/600Vac) air circuit breakers. The maintenance guidelines incorporate
recommendations from vendor manuals, industry standards, utility personnel, industry
organizations, and regulatory information, as well as the results of evaluating Nuclear
Plant Reliability Data System (NPRDS) failure reports and circuit breaker overhaul data.
To the extent practical, the topical discussions address common information by circuit
breaker model type. The purpose of this format is to present self-contained modules and
thus limit the amount of searching required by the readers.
1-1
1.3
Scope
This maintenance guide addresses the majority of Westinghouse Type DB low-voltage air
circuit breakers installed at nuclear power plants. It includes Type DB models with
continuous-current frame sizes of 225 amps, 600 amps, 1600 amps, and 2000 amps. These
frame sizes were selected based on a review of six nuclear power plants' Final Safety
Analysis Reports (FSARs), which showed that these frame sizes accounted for greater than
95% of the low-voltage air circuit breakers listed in the FSARs. This selection process was
confirmed by the NPRDS failure reports for Type DB breakers. These failure reports
showed that 97% of the reported failures occurred to breakers m these frame sizes.
Each model is described, and documented failure/degradation occurrences (whether
occurring at a nuclear power plant or elsewhere) are analyzed for the population of subject
breaker models. Issues associated with maintenance scheduling, subcomponent
replacement, and personnel training are discussed. Routine maintenance and overhaul
guidelines that reflect the results of the analyses are provided, as are replacement parts
lists and recommendations for replacement parts procurement.
Although failure data from other facilities (i.e., beyond nuclear power plant applications)
are included, this maintenance guide does not discuss low-voltage air circuit breaker
models not currently installed at nuclear power plants.
Additionally, although the data, recommendations, and maintenance guidelines apply
primarily to Type DB breakers installed at nuclear power plants, the guide is applicable to
Type DB breakers installed at fossil power plants.
1.4
Approach
1.4.1 Project Approach

This project was accomplished in five tasks:
1-2
Task 1: Circuit Breaker Description. The project team developed a

description of applicable Westinghouse Type DB circuit breaker models. The
description includes details on operating mechanisms, overcurrent trip units,
and auxiliary features (e.g., shunt trip device, undervoltage trip device,
current-limiting fuses).
Task 2: Failure Mode Analysis. The project team collected failure report
data for the relevant breaker models from NPRDS and breaker overhaul
reports. They also reviewed the failure data to identify potential age-related
failure and degradation mechanisms. The analysis identified possible
failure causes and quantified the significance of the principal degradation/
failure mechanisms.
Task 3: Maintenance Recommendations. The project team developed a

series of maintenance recommendations based on: 1) the degradation/failure
mechanisms identified in Task 2; 2) published vendor recommendations; 3)
applicable industry practices; 4) utility practices; and 5) regulatory
information. These recommendations address a broad range of issues,
including maintenance activities, tests, inspections, adjustments,
replacements and upgrades, time-based versus condition-based maintenance
and replacement, maintenance periodicities, and personnel training
requirements.
Task 4: Maintenance Guidelines. The project team developed detailed

guidelines for accomplishing the routine maintenance and overhaul
recommendations identified in Task 3, as well as component verification
testing, assembly testing, and QA requirements. As part of this process, the
team identified those tools--both common and specialized--required to
successfully complete the guidelines.
Task 5: Replacement Parts List and Procurement. The project team

developed replacement parts lists for the subject breaker models. The
replacement parts lists identify those parts that should be available for
routine maintenance and those that should be available for overhaul.
Guidelines for procuring replacement parts were developed, relying on
hands-on experience and EPRI NP-5652, "Guideline for the Utilization of
Commercial Grade Items m Nuclear Safety Related Applications," and EPRI
NP-6406, "Guideline for the Technical Evaluation of Replacement Items in
Nuclear Power Plants," as base reference reports. Strategies for alternate
vendor sourcing were also formulated.
1.4.2 Report Approach

The maintenance guide has been assembled so that each reader can locate and access
specific and complete information pertaining to a subject breaker model, generic
subcomponent type, or maintenance issue. To that end, information pertaining to more
than one breaker model or maintenance practice reappears within each relevant guide
subsection.
The maintenance guide is arranged as follows:
Section 2 presents the circuit breaker descriptions by model type.
Section 3 presents the results of the failure report analyses and offers
recordkeeping guidelines for tracking site-specific breaker/subcomponent
failures.
Section 4 presents the maintenance recommendations derived from the

analyses described above as well as hands-on experience.
1-3
1-4
Section 5 presents the maintenance and overhaul guidelines, as well as

recommended precautions and tools needed to complete the work. Each
guideline is accompanied by a data record that can be used to record data for
breaker-specific maintenance/overhaul tasks.
Section 6 presents the replacement parts lists and discussions related to

replacement parts procurement.
Appendix A lists the references used to develop this maintenance guide.
Appendix B is a glossary of circuit breaker terminology.
Appendix C is a list of nuclear industry technical information applicable to

Westinghouse Thorpe DB circuit breakers.
Section 2.0
2.1
General Information.............................................................................. 2-1
2.2
DB-15/25. DBF-6, and DBL-25 Circuit Breakers ................................. 2-1

2.2.2 Mounting Arrangement ................................................................ 2-2
2.2.3 Breaker Operation ....................................................................... 2-6
2.2.4 Contacts and Arc Chutes ............................................................. 2-9
2.2.7 Options ...................................................................................... 2-17
2.3
DB-50/75, DBF-16, and DBL-50 Circuit Breakers ............................. 2-18

2.3.1 General Description................................................................... 2-18
2.3.2 Mounting Arrangement .............................................................. 2-19
2.3.3 Breaker Operation ..................................................................... 2-23
2.3.4 Contacts and Arc Chutes ........................................................... 2-27
2.3.7 Options ...................................................................................... 2-33
2.0
2.1
General Information
This section describes the following Westinghouse type DB/DBF/DBL circuit breakers:
DB-15
DB-25
DB-50
DB-75
DBF-6
DBF-16
DBL-25
DBL-50
The designations for Westinghouse type DB/DBF/DBL circuit breakers describe the
various models as follows:
DB-15, DB-25, DB-50, and DB-75 designate standard Type DB low-voltage

air circuit breakers with interrupting capabilities of 15,000Aac (15KAac),
25KAac, 50KAac, and 75KAac, respectively.
DBF-6 and DBF-16 designate special field-discharge breakers which consist

of standard two-pole dc DB-25 and DB-50 circuit breakers, respectively, with
a set of field-discharge contacts m the center pole.
DBL-25 and DBL-50 designate standard DB-25 and DB-50 breakers with
current-limiting fuses mounted m the primary circuit on the upper studs.
For each breaker type, the model variations are presented and discussed. Subsections 2.2
and 2.3 provide general descriptions and details on the mounting arrangements, operating
mechanisms, contacts and arc chutes, electrical devices, overcurrent trip devices, as well
as options and accessories for each circuit breaker type.
2.2
DB-15/25, DBF 6, and DBL-25 Circuit Breakers
2.2.1 General Description

The Westinghouse DB-15 and DB-25 (DB-15/25) circuit breakers are three-pole (ac) or
two-pole (dc), low-voltage air circuit breakers. They are used for controlling and protecting
branch and feeder circuits in electrical distribution systems rated to 600Vac or 250Vdc.
These breakers are available in frame sizes with the following ratings:
Breaker
DB-15
DB-25
DBL-25
Continuous
225Aac
600Aac
600Aac
Interrupting
15,000Aac
25,000Aac
200,000Aac
2-1
EPRI Licensed Materlal
The DB-15 design uses a combined main and arcing contact to carry rated current. The
DB-25 has separate main and arcing contacts which provide greater contact surface to
carry the higher rated current. The DB-25 also has wider pole unit bases, wider flexible
shunts, thicker upper and lower studs, and larger insulating links than the DB-15 to
accommodate the higher current rating.
DB-15/25 circuit breakers may be equipped with a manual or an electric operating
mechanism. A mannualyoperated DB-1/25 breakers is operated by a "gun-grip" handle,
located on the front if the breaker. Electrically operated DB-15/25 breakers are equippeed
with solenoid operating mechanisms. Electrically operated DB-15/25 breakers are also
equipped with a "gun-grip" handle for manual operation.
Figure 2.2-1 shows an electrically operated, drawout DB-25 circuit breaker.
A position indicator on the breaker front cover shows the status (opened or closed) of the
breaker. The position indicator is actuated by the breaker operating mechanism.
DB-15/25 breaker may be equipped with either electromechanical or solid-state
overcurrent trip devices. These devices are described in Subsection 2.2.6.
DB-15 breaker dimensions are approximately 14"(w) x 18"(d) x 17"(h) and they weigh
between 60 and 85 lbs., depending on breaker model.
2.2.2 Mounting Arrangement

The DB-15/25 may be equipped with either a fixed or a 3-position drawout mounting
arrangement. Each arrangement is described below.
Fixed Mounting. The fixed mounting arrangement provides for bolting the breaker frame
to the supporting switchgear structure, bolting the upper and lower studs directly to
primary bus or cable connections, and connecting breaker control wiring to a terminal
board.
3-Position Drawout Mounting. The 3-position drawout mounting arrangement consists of
four flanged rollers (on the breaker), drawout rails (in the switchgear), primary disconnect
finger clusters, secondary disconnect contacts, a drawout interlock lever, a ground finger
contact, levering-in handles, and two drawout rail extensions. The levering handles and
rail extensions are accessories and not part of the breaker or switchgear.
2-2
Figure 2.2-1
Electrically Operated DB-25 Circuit Breaker
2-3
The drawout mounting arrangement allows easy removal and installation of the breaker
in the switchgear without de-energizing the primary or control circuits. The 3-position
drawout mechanism enables withdrawal to a TEST position at which the secondary
disconnect contacts remain connected, but the primary disconnects are disengaged. In this
position, the breaker may be electrically or manually operated without affecting the
associated bus.
When the breaker is in the CONNECT position, as indicated on the right side of the
breaker front cover, the primary, secondary, and ground finger contacts are engaged and
the breaker is latched to the breaker stop bracket in the switchgear.
A drawout interlock lever prevents removal of a closed breaker.
The breaker levering handle is used to disengage the breaker from the CONNECT
position to the TEST position. The TEST position is indicated on the right side of the
breaker front cover. In this position, the primary disconnects and ground finger are
disengaged and the secondary control circuits remain energized through the secondary
disconnect contacts.
The breaker is removed by installing the drawout rail extensions onto the switchgear rails
and rolling the breaker to the DISCONNECT position and onto the rail extensions.
Primary Disconnects. On drawout breakers, the primary disconnect finger clusters
connect the breaker line and load studs to the primary bus line and load. The primary
disconnects are attached to the end of the upper and lower primary circuit studs on the
rear of the pole unit bases. These finger clusters are constructed of two parallel pairs of
opposing contact fingers. The contact fingers are held in place by a surrounding bracket
and contact leaf springs. The contact springs ensure good contact with the breaker studs
and bus, and secure the finger clusters to the breaker studs.
Secondary Disconnects. Secondary disconnects, used only on drawout circuit breakers,
connect the breaker control circuit components to the external control circuits. [A
terminal board provides this function for fixed (stationary) mounted breakers.]
Each secondary disconnect is constructed of an insulating plastic body with four springtype contact fingers, which provide the contact pressure with the stationary disconnect
contacts in the cubicle. DB-15/25 breakers may be equipped with 1 to 4 (6 for DB-25)
secondary disconnect assemblies, which provide 4 to 16 (24 for DB-25) secondary contacts
depending on control circuit requirements.
The secondary disconnects allow easy removal of the breaker without disconnecting the
control wiring. With the breaker m the TEST position, the primary disconnects are
disengaged while the secondary disconnects remain connected. This allows operation and
testing of the breaker without affecting the associated bus.
Figure 2.2-2 is a rear view of a DB-25 drawout breaker showing primary and secondary
disconnects.
2-4
Figure 2.2-2
DB-25 Drawout Breaker (Rear View)
2-5
Drawout Interlock As a safety feature, a drawout interlock lever extends out of the left
side of the breaker. This lever acts on the trip bar, and when the lever strikes a leaf
spring or bracket m the breaker cubicle while levering out, it trips the breaker. This
interlock prevents electrical damage to the primary disconnects which could result if a
breaker was levered from the CONNECT to the TEST position with the contacts closed.
2.2.3 Breaker Operation

DB-15/25 breakers may be equipped with manual or electric operating mechanisms. These
mechanisms are described below.
Manual Operation The manual operating mechanism is non-adjustable and consists of an
arrangement of toggle links which open and close the breaker contacts.
There are two types of manually operated breakers- independent and dependent. The
independent manual type utilizes a closing spring to close the contacts, whereas the
dependent manual type depends solely on the rotation of the closing handle to close the
contacts.
On the independent manual breaker, rotating the closing handle clockwise raises a lift
link and the lower spring guide, which compresses the breaker closing spring. Near the
end of the closing stroke, the top of the lift link rotates the toggle linkage, which starts
the breaker closing operation. As the breaker closes, a push rod raises the toggle link and
push link, which discharges the closing spring. The closing spring pulls downward on the
pivot of the toggle linkage. This extends the toggle linkage and closes the breaker. This
closing spring provides a "quick-make" closing action, which closes the breaker contacts at
a speed that is independent of closing handle operation speed. This quick-make feature
minimizes the arcing time on the arcing contacts, thereby reducing contact damage.
Slow closing of the independent manual breaker is accomplished by slightly turning the
closing handle clockwise, simultaneously pushing the crossbar, and continuously turning
the closing handle to close the breaker.
The dependent manual breaker is operated similarly to the independent manual breaker
with the exception that there is no closing spring. The manual closing handle provides
the force for the entire closing operation. Consequently, the breaker contacts close at a
speed that is proportional to the speed at which the closing handle is rotated.
Slow closing of the dependent manual breaker is accomplished by slowly turning the
closing handle clockwise.
Electrically operated DB-15/25 breakers may be manually closed. Manual closing of an
electrically operated breaker is accomplished in the same manner as for the dependent
manual breaker.
DB-15/25 breakers may be tripped manually by pressing the manual trip button on the
front of the breaker. This button is attached to a lever that depresses the trip plate,
2-6
releasing the trip latch, which collapses the linkage that holds the contacts closed. This
allows the breaker opening springs on each pole unit to force the contacts open.
Electrical Operation. Figure 2.2-3 shows the control circuit for an electrically operated
DB-15/25 circuit breaker. The breaker is closed by energizing the closing solenoid.
The closing solenoid is mounted m the front of the circuit breaker underneath the
operating mechanism. The device consists of a stationary coil assembly and a moving
armature, which actuates the operating mechanism when the coil is energized.
Closing solenoids are available m control voltages from 12 to 250Vdc and 230 to 575Vac,
with closing currents ranging from 12A to 49A depending on the application.
The closing solenoid is energized by closing a remote control switch, which energizes the
control (or "X") relay through the secondary disconnects or control wiring terminal board.
When the control relay is energized, its contacts close, providing power to the closing
solenoid. The closing relay is held energized by a holding contact. When the breaker
closes, a release arm on the closing solenoid armature opens the relay by actuating the
control relay release lever. This, in turn, de-energizes the closing solenoid. When the
breaker is closed, the control relay cannot be energized as the relay contacts are held
trip-free by the release arm.
When the breaker is opened (or tripped), the release lever drops. This allows the control
relay to be energized when a closing operation is required. The control relay is mounted
under the left side of the breaker front frame. The relay consists of a molded base and
cover, an operating coil, a release lever, and a set of normally opened contacts. The relay
coil is rated for continuous duty.
The control relays on breakers with dc control voltage are equipped with a small arc chute
and blowout coil to help extinguish the arc drawn when the relay contacts part. This
helps to limit relay contact burning and pitting.
Electrically operated DB-15/25 breakers are tripped by energizing the shunt trip device.
This is accomplished by closing a remote control switch, which energizes the shunt trip
device coil through either the secondary disconnects or the control wiring terminal board,
and through a set of " a" contacts on the auxiliary switch. When the coil is energized, the
moving core pulls on the trip lever, which rotates the trip bar and trips the breaker.
When the breaker opens, the auxiliary switch opens and de-energizes the shunt trip
device.
The shunt trip device is mounted on the right side of the top of the breaker front frame,
just to the right of the operating mechanism. The device consists of a mounting frame, a
stationary core and coil, and a moving core or armature.
2-7
Figure 2.2-3
DB-15/25 Control Circuit
2-8
The shunt trip device is rated for intermittent duty and is non-adjustable.
Shunt trip coils are available in the same voltage ratings as the closing solenoids. Trip
currents range from 0.2A to 18A depending on the application.
2.2.4 Contacts and Arc Chutes

Contacts. The current-conducting path of each phase of the DB-15/25 circuit breaker
consists of an insulated pole unit base on which are mounted the upper stud, stationary
contacts, moving contacts, flexible shunt, and lower stud.
The contacts of the DB-15 breaker consist of just one set of moving and stationary contacts
per phase. The stationary contact is a combined main and arcing contact that is bolted to
the upper stud. The moving contact is a similar contact that is bolted to the moving
contact arm.
The DB-25 pole unit has a set of separate main and arcing contacts to accommodate the
higher rated current of the breaker.
The breaker opening springs are mounted between the pole unit base and the moving
contact arm of each pole unit. The moving contact arm is electrically connected to the
lower stud by a flexible shunt ribbon, which is bolted to the moving contact arm and the
lower stud.
An insulated operating link is connected to the moving contact arm of each phase and to
the breaker crossbar. The operating link includes a threaded stud for adjusting contact
pressure.
When the DB-15 breaker closes, the contacts of each phase close and remain closed until
the breaker IS tripped. The DB-25 differs m that when the breaker is closed, the arcing
contacts touch first, then the main contacts touch, and finally, the arcing contacts part.
When the breaker is fully closed, the main contacts will be fully closed and the arcing
contacts will be slightly parted. Figure 2.2-4 shows the DB-25 moving and stationary
contact assemblies.
Arc Chutes. Each pole unit is equipped with an arc chute. The arc chute is constructed of
several internal splitter plates, two insulated side plates, and an outside housing. The arc
chute housing material is a heat-resistant electrical insulator. The arc chute side plates
are made of a ceramic material designed to withstand and extinguish the electric arc
produced when the breaker contacts part. The splitter plates are constructed of plated
steel. Figure 2.2-5 shows two DB-25 arc chutes.
When the contacts part under loaded conditions, an arc is drawn between the parting
conductors. Heat generated by the arc causes the surrounding air to rise and move the
arc upward into the arc chute. The steel plates interrupt the arc and cool the gases
resulting from the arc. The hot gasses rise through the splitter plates and out the top of
the arc chute.
2-9
Figure 2.2-4
DB-25 Contact Assemblies
2-10
Figure 2.2-5
DB-25 Arc Chutes
2-11
2.2.5 Electrical Devices

A DB-15/25 breaker may be equipped with any combination of the following protective
electrical devices:
Undervoltage Trip Attachment

Undervoltage Time Delay Attachment.
Reverse Current Trip Attachment (2-pole dc breakers)
Undervoltage Trip Attachment. The undervoltage trip (UV) attachment (device) is

mounted on top of the front frame just to the right of the shunt trip device. The UV
device trips the breaker when the voltage decreases to 30-60 percent of normal. when the
UV device is energized, the breaker may be closed. The UV device consists of a frame,
stationary core, moving core, coil, plunger, latch, latch pin, reset lever, reset lever spring,
trip spring, and trip lever. The coil IS rated for continuous duty.
When the UV device is energized, the moving core and plunger are held against the
stationary core, and consequently the reset lever is held in the reset position. When the
voltage drops below 30-60 percent of normal, the force of the reset lever spring overcomes
the magnetic force of the coil and the reset lever is rotated, releasing the latch. When the
latch releases, the trip spring causes the trip lever to rotate and lift the trip bar, which
trips the breaker. The device is reset by the breaker crossbar actuating the reset lever
when the breaker opens.
Undervoltage Time Delay Attachment. The UV time delay attachment is an air-operated
dashpot which mounts on the front of the W device. The time delay attachment is
mounted over the moving core of the UV device. When the voltage drops sufficiently to
cause the moving core and plunger of the UV device to move, the motion is delayed by
restricting air flow through a needle valve adjustment screw on the time delay
attachment. The needle valve adjustment screw is located on the top of the attachment
and is secured by a locking nut. The UV delay interval is set for 4-7 seconds.
Reverse Current Trip Attachment. The reverse current trip attachment (device) is used
only on dc breakers, and trips the breaker when the direction of current flow is reversed.
It mounts on the lower front portion of the center pole unit base of two-pole dc breakers.
The device consists of a series coil assembly, front yoke, armature, trip finger, trip screw,
trip crank, calibration thumb nut, calibration spring, back yoke, potential coil, and a
cover.
When dc current is flowing through the series coil in the forward direction, the magnetic
force that is created by the current forces the armature against a stop. When the current
is reversed, the armature rotates away from the stop, which actuates the trip crank and
trip finger to trip the breaker. The potential coil provides the directional bias to either
add to or oppose the magnetic field in the series coil. The device may be adjusted from 5
to 25 percent reverse current by adjusting the calibration spring via the calibration thumb
nut.
2-12
When the breaker trips, the device is reset by an "a" auxiliary switch contact, which
opens to de-energize the potential coil.
2.2.6 Overcurrent Trip Devices

Westinghouse DB-15/25 circuit breakers may be equipped with either a "Discriminator"
electromechanical overcurrent trip device, or a solid-state Amptector overcurrent trip
device. Both types of overcurrent trip device provide a means of automatically tripping
the circuit breaker under an overcurrent condition. This feature isolates the electrical
system at the fault location and prevents loss of power to properly operating loads.
Electro- Medical Overcurrent Trip Device. The Discriminator electromechanical
overcurrent trip device is supplied on the DB-15 breaker in ratings of 15A to 225A, and on
the DB-25 breaker in ratings of 40A to 600A. These are magnetic devices which may be
supplied with long-time delay and short-time delay, long-time delay and instantaneous
trip, or instantaneous trip only.
Figure 2.2-6 shows an electromechanical overcurrent trip device used on Type DB circuit
breakers. The electromechanical overcurrent trip device is constructed of a primary
current coil (2 turns), which passes primary current through a magnet yoke, and a moving
armature. Current flow in the primary circuit exerts a force to close the armature against
the magnet yoke. When current is sufficient to close the armature, the armature forces a
trip rod against the breaker trip bar, lifting the trip bar and tripping the breaker. The
motion of the armature is restrained by long-time delay, short-time delay, or
instantaneous trip calibration devices. These devices are described below.
Long-line Delay. When primary current exceeds the long-time delay (LTD) pick-up
setting, as indicated by the LTD pointer on the face plate of the trip device, the magnetic
force of the magnet yoke on the armature exceeds the force of the LTD calibration spring.
This allows the armature to begin to move upward toward the breaker trip bar. The
armature is attached to an air diaphragm assembly which retards the armature's motion.
The upward motion of the armature and air diaphragm causes air to enter the diaphragm
void through an adjustable calibration valve.
LTD pick-up and delay may be adjusted by turning the appropriate adjustment knobs on
the bottom of the trip device. LTD pick-up is varied by changing the length of the LTD
pick-up spring. LTD pick-up has calibrated settings at 80, 100, 120, 140, and 160 percent
of the device's coil rating. Long-time delay is varied by changing the size of the orifice in
the air diaphragm calibration valve. LTD has calibrated settings at 20 and 30 seconds.
Short-Time Delay. When primary current exceeds the short-time delay (STD) pick-up
setting, as indicated by the pointer on the face plate of the trip device, the magnetic force
is sufficient to pull the secondary armature toward the main armature. The motion of the
secondary armature opens the LTD calibration valve to a calibrated position which gives
the desired short-time delay before the main armature trips the breaker.
2-13
Figure 2.2-6
Electro -Mechanical Overcurrent Trip De vice
2-14
STD pick-up and delay may be adjusted by turning the appropriate adjustment knobs on
the bottom of the trip device. STD pick-up is varied by changing the length of the STD
pick-up spring. STD pick-up has calibrated settings at 500, 750, and 1000 percent of the
device's coil rating. STD is varied by changing the size of the orifice in the air diaphragm
calibration valve with the secondary armature against the main armature. STD has
calibrated settings at 6, 14, and 30 cycles.
Instantaneous Trip. When primary current exceeds the instantaneous pick-up setting, as
indicated by the pointer on the face plate of the trip device, the magnetic force is sufficient
to pull the secondary armature toward the main armature. The motion of the secondary
armature moves the LTD calibration valve to the full open position. This removes all
restraint and allows the main armature to trip the breaker instantly.
Instantaneous (INST) pick-up may be adjusted by turning the appropriate adjustment knob
on the bottom of the trip device. INST pick-up is varied by changing the length of the
INST pick-up spring. INST pick-up has calibrated settings at 800 and 1200 percent of the
device's coil rating.
The instantaneous trip device normally trips the breaker m less than 2 cycles or 0.034
seconds.
Solid-State Overcurrent Trip Device. Westinghouse DB-15/25 breakers may be equipped
with solid-state Amptectar overcurrent trip units. Amptector units are available in two
basic types, IA and IIA. Both devices provide adjustable overcurrent tripping. Both types
of Amptectors are available with any combination of long-time delay, short-time delay,
and instantaneous trip functions. Amptectors are available for DB-15 breakers m
ratings from 100A to 225A and for DB-25 breakers in ratings from 100A to 600A.
Amptector IA has the additional features of optional ground fault protection and
"pop-out" indicators for ground fault, overload, and short circuit. These functions are not
available on the Amptector IIA. Figure 2.2-7 shows an Amptector IIA unit.
Amptector IA model designations may be any combination of the following:
L
S
I
G
- Long Delay
- Short Delay
- Instantaneous
- Ground
An ''Amptector IA LIG" would indicate a unit with Long Delay, Instantaneous, and
Ground Fault functions.
Amptector IIA model designations are the following:
DU (Dual)
SE (Selective)
TR (Triple)
- Long Delay and Instantaneous

- Long Delay and Short Delay
- Long Delay, Short Delay, and Instantaneous
2-15
Figure 2.2-7
Amptector IIA Overcurrent Trip Device
2-16
There are a maximum of seven adjustable elements on the Amptector IA, and five on the
Amptector IIA. All adjustments are made on the face plate of the unit using a small
screwdriver. The possible adjustments are:
Long-Time Delay pick-up current (times sensor rating)
Long-Time Delay (seconds)
Short-Time Delay pick-up current (times sensor rating)
Short-Time Delay (seconds)
Instantaneous pick-up current (times sensor rating)
Ground Fault pick-up current (amperes) (IA only)
Ground Fault Delay (seconds) (IA only)
Solid-state overcurrent protection consists of one solid-state Amptector unit, three
current sensors (one per pole), and a magnetic trip actuator. The sensors are simple
current transformers that produce an output proportional to the load current. The sensors
are mounted on the rear of the breaker studs and may be provided with multiple taps.
When the sensors send a signal that exceeds the preselected value for pick-up and delay to
the Amptector unit, the Amptector sends a tripping pulse to the magnetic trip actuator.
The magnetic trip actuator is a permanent magnet device which trips the breaker. When
the breaker is opened, the breaker crossbar resets the actuator by compressing its spring
until the actuator armature touches the poles of the permanent magnet. The magnet
holds the armature m place with the actuator spring fully compressed. When the
Amptector unit sends a current pulse to the actuator, a small coil is energized to
counteract the force of the permanent magnet. This allows the armature to release from
the magnet, and the actuator spring then forces the armature against a lever on the trip
bar to trip the breaker.
2.2.7 Options
Auxiliary Switch The auxiliary switch is mounted on the top left side of the breaker
front frame, just to the left of the operating mechanism. The switch is operated by a shaft
that is linked to the breaker operating mechanism. The switch is available as a four-pole,
eight-pole, or twelve-pole, rotary type, with various combinations of "a" and "b" contacts.
The "a" contacts are the same state as the breaker main contacts; when the main contacts
are open the "a" contacts are open. The "b" contacts are the opposite state of the "a"
contacts. The switch consists of a housing and cover, switch shaft, insulation rotors,
contact fingers, contact rotors, and finger springs.
Alarm Switch Attachment. The alarm switch attachment is mounted above the shunt trip
device and may have one or two switches. The alarm switch attachment closes to energize
an alarm circuit when the breaker is opened by any means other than manual trip or
shunt trip. The device consists of a switch, guard, impact spring, clevis, crossbar, reset
link, and reset casting. The alarm switch is reset by pushing the manual trip button or
by energizing the shunt trip device.
2-17
Electric Lockout Attachment. The electric lockout device is mounted under the right side
of the breaker front frame just below the UV device. The lockout device will hold the
breaker m the trip-free condition until the device is energized. The lockout device is used
to electrically interlock two breakers and prevent both from being closed at the same time.
When the lockout device coil is energized, the breaker may be closed. The lockout device
may be de-energized once the breaker is closed and it will not trip the breaker. The device
consists of a mounting bracket, moving core, stationary core, coil, plunger, and lever.
Key Interlock Attachment. The key interlock is mounted on the right side of the breaker
on the top of the front frame. The interlock is designed so that the key cannot be removed
unless the breaker is locked in the tripped position. This interlock maintains the breaker
m a trip-free condition when the key is removed. This allows mechanical interlocking of
two or more breakers.
Model Options. Two options m the basic DB-25 design are discussed below.
The DBF-6 is a special field-discharge breaker which consists of a standard two-pole (outer
poles) dc DB-25 circuit breaker with a set of field-discharge contacts in the center pole.
The model is designed to discharge the field circuits of synchronous generators and
motors. These breakers have no overcurrent trip devices. When the breaker is opened,
the field-discharge contacts close before the main contacts open. When the breaker is
closed, the field-discharge contacts open after the main breaker contacts close. This
contact overlap prevents the field circuit from opening.
The DBL-25 is a standard DB-25 breaker with current-limiting fuses mounted in the
primary circuit on the upper studs. These special primary fuses incorporate a fuse trip
button that extends when a fuse blows. When the fuse on any phase blows, the fuse trip
button on that fuse extends and actuates a linkage, which rotates the trip bar and trips
the circuit breaker.
2.3 DB-50/75, DBF-16, and DBL-50 Circuit Breakers

2.3.1 General Description
The Westinghouse DB-50 and DB-75 (DB-50/75) circuit breakers are three-pole (ac) or
two-pole (dc), low-voltage air circuit breakers. They are used for controlling and protecting
branch and feeder circuits m electrical distribution systems rated to 600Vac or 250Vdc.
These breakers are available m frame sizes with the following ratings:
Breaker
DB-50
DB-75
DBL-50
2-18
Continuous
1600Aac
2000Aac
1600Aac
Interrupting
50,000Aac
75,000Aac
200,000Aac
The DB-50 breaker design incorporates separate main, arcing, and auxiliary contacts. The
DB-75 breaker design incorporates separate arcing, upper main, lower main, and hinge
contacts. The DB-75 also has wider pole unit bases, thicker upper and lower studs, and
larger insulating links than the DB-50 to accommodate the higher current rating.
DB-50 circuit breakers may be equipped with a manual or electric operating mechanism.
DB-75 breakers are available only with electrically operated mechanisms. The manually
operated DB-50 is operated by a"gun-grip" handle, located on the front of the breaker.
Electrically operated DB-50/75 breakers are equipped with solenoid operating mechanisms.
The electrically operated DB-50 breaker is also equipped with a "gun-grip" handle for
manual operation. Figure 2.3-1 shows a view of an electrically operated DB-75 circuit
breaker.
A position indicator on the breaker front cover shows the status (opened or closed) of the
breaker. The position indicator is actuated by the breaker operating mechanism.
DB-50/75 breakers may be equipped with either electro-mechanical or solid-state
overcurrent trip devices. These devices are described in Subsection 2.3.6.
approximately 475 Ibs.
2.3.2 Mounting Arrangement

The DB-50/75 may be equipped with either a fixed or a 3-position drawout mounting
arrangement. Each arrangement is described below.
Fixed Mounting. The fixed mounting arrangement provides for bolting the breaker frame
to the supporting switchgear structure, bolting the upper and lower studs directly to
primary bus or cable connections, and connecting breaker control wiring to a terminal
board.
3-Position Drawout Mounting. The 3-position drawout mounting arrangement consists of
four flanged rollers (on the breaker), drawout rails (in the switchgear), primary disconnect
finger clusters, secondary disconnect contacts, a drawout interlock lever, a ground finger
contact, a levering-in handle, and two drawout rail extensions (DB-50 only). The leveringin handle and the rail extensions are accessories and are not part of the breaker or
switchgear. Figure 2.3-2 shows a view of a DB-75 drawout breaker.
2-19
Figure 2.3-1
Electrically Operated DB-75 Circuit Breaker
2-20
Figure 2.3-2
DB-75 Drawout Breaker
2-21
The drawout mounting arrangement allows easy removal and installation of the breaker
in the switchgear without de-energizing the primary or control circuits. The 3-position
drawout mechanism enables withdrawal to a TEST position at which the secondary
disconnect contacts remain connected, but the primary disconnects are disengaged. In this
position, the breaker may be electrically or manually operated without affecting the
associated bus.
When the breaker is in the CONNECT position, as indicated on the right side of the
breaker front cover, the primary, secondary, and ground finger contacts are engaged and
the breaker is latched to the breaker stop bracket in the switchgear.
A drawout interlock lever prevents removal of a closed breaker.
The breaker levering handle is used to disengage the breaker from the CONNECT
position to the TEST position. The TEST position is indicated on the right side of the
breaker front cover. In this position, the primary disconnects and ground finger are
disengaged and the secondary control circuits remain energized through the secondary
disconnect contacts.
The breaker is removed by installing the drawout rail extensions onto the switchgear rails
and rolling the breaker to the DISCONNECT position and onto the rail extensions.
Primary Disconnects. On drawout breakers, the primary disconnect finger clusters
connect the breaker line and load studs to the primary bus line and load. The primary
disconnects are attached to the end of the upper and lower primary circuit studs on the
rear of the pole unit bases. The DB-50 has two finger clusters per phase and the DB-75
has four finger clusters per phase. Each finger cluster is constructed of six parallel pairs
of opposing contact fingers held in place by a surrounding bracket and contact leaf
springs. The contact springs ensure good contact with the breaker studs and bus, and
secure the finger clusters to the breaker studs.
Secondary Disconnects. Secondary disconnects, used only on drawout breakers, connect
the breaker control circuit components to the external control circuits. [A terminal board
provides this function for fixed (stationary) mounted breakers.]
Each secondary disconnect is constructed of an insulating plastic body with four spring
type contact fingers, which provide the contact pressure with the stationary disconnect
contacts in the enclosure. DB-50 breakers may be equipped with 3 to 6 secondary
disconnect assemblies, which provide 12 to 24 secondary contacts depending on control
circuit requirements. DB-75 breakers may be equipped with 4 to 8 secondary disconnect
assemblies, which provide 16 to 32 secondary contacts depending on control circuit
requirements.
The secondary disconnects allow easy removal of the breaker without disconnecting the
control wiring. With the breaker in the TEST position, the primary disconnects are
disengaged while the secondary disconnects remain connected. This allows operation and
testing of the breaker without affecting the associated bus.
2-22
Figure 2.3-3 shows a rear view of a DB-75 drawout breaker showing the primary and
secondary disconnects.
Drawout Interlock As a safety feature, a drawout interlock lever extends out of the left
side of the DB-50 breaker or the right side of the DB-75 breaker. This lever acts on the
trip bar (DB-50) or trip shaft (DB-75). When the lever strikes a leaf spring or bracket in
the breaker cubicle while levering out it trips the breaker. This interlock prevents
electrical damage to the primary disconnects which could result if a breaker was levered
from the CONNECT to the TEST position with the contacts closed.
2.3.3 Breaker Operation

DB-50 breakers may be equipped with manual or electric operating mechanisms. DB-75
breakers are equipped only with electrical operating mechanisms. These mechanisms are
described below.
Manual (DB-50 only). The operating mechanism is non-adjustable and consists of an
arrangement of toggle links which open and close the breaker contacts.
There are two types of manually operated breakers independent and dependent. The
independent manual type utilizes a closing spring to close the contacts, whereas the
dependent manual type depends solely on the rotation of the closing handle to close the
contacts.
On the independent manual breaker, rotating the closing handle clockwise raises a lift
link and the lower spring guide, which compresses the breaker closing spring. Near the
end of the closing stroke, the top of the lift link rotates the toggle linkage, which starts
the breaker closing operation. As the breaker closes, a push rod raises the toggle link and
push link, which discharges the closing spring. The closing spring pulls downward on the
pivot of the toggle linkage. This extends the toggle linkage and closes the breaker. This
closing spring provides a "quick-make" closing action which closes the breaker contacts at
a speed that is independent of closing handle operation speed. This quick-make feature
minimizes the arcing time on the arcing contacts, thereby reducing contact damage.
Slow closing of the independent manual breaker is accomplished by slightly turning the
closing handle clockwise, simultaneously pushing the crossbar, and continuously turning
the closing handle to close the breaker.
The dependent manual breaker is manually operated similarly to the independent manual
breaker with the exception that there is no closing spring. The manual closing handle
provides the force for the entire closing operation. Consequently, the breaker contacts
close at a speed that is proportional to the speed at which the closing handle is rotated
Slow closing of the dependent manual breaker is accomplished by slowly turning the
closing handle clockwise.
2-23
Figure 2.3-3
DB-75 Drawout Breaker (Rear View)
2-24
Electrically operated DB-50 breakers may be manually closed. Manual closing of an

electrically operated DB-50 breaker is accomplished in the same manner as for the
dependent manual breaker.
Slow closing of the DB-75 breaker is accomplished by inserting the maintenance operating
handle into the maintenance close cam on the front of the breaker and pushing the handle
down to close the breaker.
DB-50 breakers may be tripped manually by pressing the manual trip button on the front
of the breaker. This button is attached to a lever that depresses the trip plate, releasing
the trip latch, which collapses the linkage that holds the contacts closed. This allows the
breaker opening springs on each pole unit to force the contacts open.
DB-75 breakers may also be manually tripped by pressing the manual trip button on the
front of the breaker. This button is attached to a link that strikes a trip paddle on the
trip shaft, causing the trip shaft to rotate, releasing the trip latch, which collapses the
linkage that holds the contacts closed. This allows the breaker opening springs on each
pole unit to force the contacts open.
Electrical Operation. Figure 2.3-4 shows the control circuit for an electrically operated
DB-50 or DB-75 circuit breaker. Each type of breaker is closed electrically by energizing
the closing solenoid.
The closing solenoid is mounted in the front of the circuit breaker underneath the
operating mechanism. The device consists of a stationary coil assembly and a moving
armature, which actuates the operating mechanism when the coil is energized.
Closing solenoids are available in control voltages From 24 to 250Vdc and 230 to 575Vac,
with closing currents ranging from 4A to 20A depending on the application.
The closing solenoid is energized by closing a remote control switch, which energizes the
control (or "X") relay through the secondary disconnects or control wiring terminal board.
When the relay is energized, the circuit is completed to the closing solenoid and the relay
is held in by a holding contact. When the breaker closes, a release arm on the closing
solenoid armature hips the relay by actuating the control relay release lever. This
de-energizes the closing solenoid. When the breaker is closed, the control relay cannot be
energized since the relay contacts are held trip-free by the release arm.
When the breaker is tripped, the release lever drops. This allows the control relay to be
energized when a closing operation is required.
The control relay is mounted under the left side of the breaker front frame. The relay
consists of a molded base and cover, an operating coil, release lever, and a set of normally
opened contacts. The relay coil is rated for continuous duty.
2-25
Figure 2.34
DB-50/75 Breaker Control Circuit
2-26
The control relays on breakers with dc control voltage are equipped with a small arc chute
and blowout coil to help extinguish the arc drawn when the relay contacts part. This
helps to limit relay contact burning and pitting.
Electrically operated DB-50/75 breakers are tripped by energizing the shunt trip device.
This is accomplished by closing a remote control switch which energizes the shunt trip
device through either the secondary disconnects or the control wiring terminal board, and
through a set of "a" contacts on the auxiliary switch.
For the DB-50, when the coil is energized, the moving core pulls down on the trip lever,
which lifts the trip bar and trips the breaker. For the DB-75, when the coil is energized,
the moving core pulls on a trip shaft paddle, which rotates the trip shaft and trips the
breaker.
When the breaker opens, the auxiliary switch opens and de-energizes the shunt trip
device.
The shunt trip device is mounted on the right side of the top of the breaker front frame,
just to the right of the operating mechanism. It consists of a mounting frame, a stationary
core and coil, and a moving core or armature.
The shunt trip device is rated for intermittent duty and is non-adjustable.
Shunt trip coils are available in the same voltage ratings as the closing solenoids. Coil
current ratings range from 0.2A to 18A depending on the application.
2.3.4 Contacts and Arc Chutes

Contacts. The current-conducting path of each phase of the DB-50/75 circuit breaker
consists of an insulated pole unit base on which the upper stud, stationary contacts,
moving contacts, and lower stud are mounted.
The stationary contacts of the DB-50 breaker consist of one arcing, two main, and four
auxiliary contacts per phase. The moving contacts consist of one arcing, one main, and
one auxiliary contact per phase, each of which makes contact with all of its respective
stationary contacts. The upper contacts are the arcing contacts, the center contacts are
the main contacts, and the lower contacts are the auxiliary contacts. The stationary
arcing and main contacts are bolted to the upper stud, and the auxiliary contacts and the
moving contact arm are attached to the lower stud. All of the moving contacts are
attached to the moving contact arm.
The stationary contacts of the DB-75 breaker consist of three arcing, four upper main, four
lower main, and eight hinge contacts per phase. The moving contacts consist of one
arcing, one upper main, and one lower main contact per phase, each of which makes
contact with all of its respective stationary contacts. The upper contacts are the arcing
contacts, the center contacts are the upper and lower main contacts, and the lower
contacts are the hinge contacts. The stationary arcing, upper main, and lower main
2-27
contacts are attached to the upper stud. The hinge contacts and the moving contact arm
are attached to the lower stud. All of the moving contacts are attached to the moving
contact arm. Figure 2.3-5 shows the DB-75 moving and stationary contact assemblies.
The breaker opening springs are mounted between the pole unit base and the moving
contact arm of each pole unit. The DB-50 moving contact arm is electrically connected to
the lower stud by a flexible shunt ribbon, which is bolted to the moving contact arm and
the lower stud. The DB-75 moving contact arm is electrically connected to the lower stud
by the hinge contacts, which bear against the lower part of the moving contact arm.
An insulated operating link is connected to the moving contact arm of each phase and to
the breaker crossbar. This operating link also contains a threaded stud for adjusting
contact pressure.
When the DB-50/75 breaker closes, all of the contacts of each phase close and remain
closed until the breaker is tripped, unlike the DB-25 arcing contacts which are slightly
parted when the breaker is closed.
Arc Chutes. Each pole unit is equipped with an arc chute. The arc chute is constructed of
several internal splitter plates, two insulated side plates, and an outside housing. The arc
chute housing material is a heat-resistant electrical insulator. The arc chute side plates
are made of a ceramic material designed to withstand and extinguish the electric arc
produced when the breaker contacts part. The splitter plates are constructed of plated
steel.
When the contacts part under loaded conditions, an arc is drawn between the parting
conductors. Heat generated by the arc causes the surrounding air to rise and move the
arc upward into the arc chute. The steel plates interrupt the arc and cool the gases
resulting from the arc. The hot gasses rise through the splitter plates and out the top of
the arc chute.
2.3.5 Electrical Devices

A DB-50/75 breaker may be equipped with any combination of the following protective
electrical devices:
Undervoltage Trip Attachment

Undervoltage Time Delay Attachment
Reverse Current Trip Attachment (2-pole dc breakers)
Undervoltage Trip Attachment. The undervoltage trip (UV) attachment (device) is

mounted on top of the front frame just to the right of the shunt trip device. The UV
device trips the breaker when the voltage decreases to 30-60 percent of normal. When the
UV device is energized, the breaker may be closed. The UV device consists of a frame,
stationary core, moving core, coil, plunger, latch, latch pin, reset lever, reset lever spring,
trip spring, and trip lever. The coil is rated for continuous duty.
2-28
Figure 2.3-5
DB-75 Contact Assemblies
2-29
When the UV device is energized, the moving core and plunger are held against the
stationary core. When the voltage drops below 30-60 percent of normal, the force of the
reset lever spring overcomes the magnetic force of the coil and the reset lever is rotated,
releasing the latch. When the latch releases, the trip spring causes the trip lever to
rotate. On DB-50 breakers, the trip lever lifts the trip bar which trips the breaker. On
DB-75 breakers, the trip lever strikes a paddle on the trip shaft which rotates the trip
shaft and trips the breaker. The device is reset by the breaker crossbar actuating the
reset lever when the breaker opens.
Undervoltage Time Delay Attachment. The UV time delay attachment (device) is an
air-operated dashpot which mounts on the front of the UVW device. The time delay
attachment is mounted over the moving core of the UV device. When the voltage drops
sufficiently to cause the moving core and plunger of the UV device to move, motion is
delayed by restricting air flow through the needle valve adjustment screw. The needle
valve adjustment screw is located on the top of the delay device and is secured by a
locking nut. The UV delay interval is set for 4-7 seconds.
Reverse Current Trip Attachment. The reverse current trip attachment (device) is used
only on dc breakers and trips the breaker when the direction of current flow is reversed. It
mounts on the lower front portion of the center pole unit base of two-pole dc breakers.
The device consists of a series coil assembly, front yoke, armature, trip finger, trip screw,
trip crank, calibration thumb nut, calibration spring, back yoke, potential coil, and a
cover.
When dc current is flowing through the series coil in the forward direction, the magnetic
force that is created by the current forces the armature against a stop. When the current
is reversed, the armature rotates away from the stop, which actuates the trip crank and
trip finger to trip the breaker. The potential coil provides the directional bias to either
add to or oppose the magnetic field in the series coil. The device may be adjusted from 5
to 25 percent reverse current by adjusting the calibration spring via the calibration thumb
nut.
When the breaker trips, the device is reset by an "a" auxiliary switch contact opening to
de-energize the potential coil.
2.3.6 Overcurrent Trip Devices

Westinghouse DB-50/75 circuit breakers may be equipped with either a "Discriminator"
electromechanical overcurrent trip device, or a solid-state Amptector overcurrent trip
device. Both types provide a means of automatically tripping the circuit breaker under an
overcurrent condition. This feature isolates the electrical system at the fault location and
prevents loss of power to properly operating loads.
Electro-Mechanical Overcurrent Trip Device. The Discriminator electromechanical
overcurrent trip device may be supplied on the DB-50 breaker in ratings of 200A to 1600A
and on the DB-75 breaker m ratings of 2000A to 3000A. These are magnetic devices
2-30
which may be supplied with long-time delay and short-time delay, long-time delay and
instantaneous trip, or instantaneous trip only.
Figure 2.2-6 (previous subsection) shows an electromechanical overcurrent trip device.
The electromechanical overcurrent trip device is constructed of a primary current coil (2
turns), which passes primary current through a magnet yoke, and a moving armature.
Current flow m the primary circuit exerts a force to close the armature against the
magnet yoke. If current is sufficient to close the armature against the magnet yoke, the
armature forces a trip rod against a lever on the trip bar, or a paddle on the trip shaft,
and trips the breaker. The motion of the armature is restrained by long-time delay,
short-time delay, or instantaneous trip calibration devices. These devices are described
below.
Long-Time Delay. When primary current exceeds the long-time delay (LTD) pick-up
setting, as indicated by the LTD pointer on the face plate of the trip device, the magnetic
force of the magnet yoke on the armature exceeds the force of the LTD calibration spring.
This allows the armature to begin to move upward toward the breaker trip bar (DB-50) or
trip shaft (DB-75). The armature is attached to an air diaphragm assembly which retards
the armature's motion. The upward motion of the armature and air diaphragm causes air
to enter the diaphragm void through an adjustable calibration valve.
LTD pick-up and delay may be adjusted by turning the appropriate adjustment knobs on
the bottom of the trip device. LTD pick-up is varied by changing the length of the LTD
pick-up spring. The LTD pick-up has calibrated settings at 80, 100, 120, 140, and 160
percent of the device's coil rating. The LTD is varied by changing the size of the orifice m
the air diaphragm calibration valve. LTD has calibrated settings at 20 and 30 seconds.
Short-Time Delay. When primary current exceeds the short-time delay (STD) pick-up
setting, as indicated by the pointer on the face plate of the trip device, the magnetic force
is sufficient to pull the secondary armature toward the main armature. The motion of the
secondary armature opens the LTD calibration valve to a calibrated position which gives
the desired short-time delay before the main armature trips the breaker.
STD pick-up and delay may be adjusted by turning the appropriate adjustment knobs on
the bottom of the trip device. STD pick-up is varied by changing the length of the STD
pick-up spring. STD pick-up has calibrated settings at 500, 750, and 1000 percent of the
device's coil rating. STD is varied by changing the size of the orifice in the air diaphragm
calibration valve with the secondary armature against the main armature. STD has
calibrated settings at 6, 14, and 30 cycles.
Instantaneous Trip. Short-circuit currents above the instantaneous pick-up setting, as
indicated by the pointer on the face plate of the trip device, cause a magnetic force that is
sufficient to pull the secondary armature toward the main armature. The motion of the
secondary armature moves the LTD calibration valve to the full open position. This
removes all restraint and allows the armature to trip the breaker instantly.
2-31
Instantaneous (INST) pick-up may be adjusted by turning the appropriate adjustment knob
on the bottom of the trip device. INST pick-up is varied by changing the length of the
INST pick-up spring. INST pick-up has calibrated settings at 800 and 1200 percent of the
device's coil rating.
The instantaneous trip device normally trips the breaker m less than 2 cycles or 0.034
seconds.
Solid-State Overcurrent Trip Device. Westinghouse DB-50/75 breakers may be equipped
with solid-state Amptector overcurrent trip units. Amptector units are available in two
basic types, IA and IIA. Both devices provide adjustable overcurrent tripping. Both types
of Amptectors are available with any combination of long-time delay, short-time delay,
and instantaneous trip functions. Amptectors are available for DB-50 breakers in
ratings from 200A to 1600A and for the DB-75 breakers in ratings from 2000A to 3000A.
Figure 2.2-7 (previous subsection) shows an Amptector IIA overcurrent trip device.
Amptector IA has the additional features of optional ground fault protection and
"pop-out" indicators for ground fault, overload, and short circuit. These functions are not
available on the Amptectors IIA.
Amptector IA model designations may be any combination of the following:
L
S
I
G
Long Delay
Short Delay
Instantaneous
Ground
An "Amptector IA LIG" would indicate a unit with Long Delay, Instantaneous, and
Ground Fault functions.
Amptector IIA model designations are the following:
DU (Dual)
SE (Selective)
TR (Triple)
- Long Delay and Instantaneous

- Long Delay and Short Delay
- Long Delay, Short Delay, and Instantaneous
There are a maximum of seven adjustable elements on the Amptector IA, and five on the
Amptector IIA. All adjustments are made on the face plate of the unit using a small
screwdriver. The possible adjustments are:
Long-Time Delay pick-up current (times sensor rating)
Long-Time Delay (seconds)
Short-Time Delay pick-up current (times sensor rating)
Short-Time Delay (seconds)
Instantaneous pick-up current (times sensor rating)
Ground Fault pick-up current (amperes) IA only)
Ground Fault Delay (seconds) IA only)
2-32
Solid-state overcurrent protection consists of one solid-state Amptector unit, three

current sensors (one per pole), and a magnetic trip actuator. The sensors are current
transformers that produce an output proportional to the load current. The sensors are
mounted on the rear of the breaker studs and may be provided with multiple taps. When
the sensors send a current that exceeds a preselected value for pick-up and delay to the
Amptector unit, the Amptector sends a tripping pulse to the magnetic trip actuator.
The magnetic trip actuator is a permanent magnet device which trips the breaker. When
the breaker is opened, the breaker crossbar resets the actuator by compressing its spring
until the plunger touches the poles of the permanent magnet. The magnet holds the
plunger in place with the plunger spring fully compressed. When the Amptector unit
sends a current pulse to the actuator, a small coil is energized to counteract the force of
the permanent magnet. This allows the plunger to release from the magnet and the
actuator spring then forces the plunger against a trip lever on the trip bar (DB-50), or the
trip shaft (DB-75), to trip the breaker.
2.3.7 Options
Auxiliary Switch. The auxiliary switch is mounted on the top left side of the breaker
front frame, just to the left of the operating mechanism. The switch is operated by a shaft
which is linked to the breaker operating mechanism. The switch is available as a fourpole, eight-pole, or twelve-pole, rotary type, with various combinations of "a" and "b"
contacts. The "a" contacts are the same state as the breaker main contacts; when the
main contacts are open the "a" contacts are open. The "b" contacts are the opposite state
of the "a" contacts. The switch consist of a housing and cover, switch shaft,insulation
rotors, contact fingers, contact rotors,and finger springs.
Alarm Switch Attachment. The alarm switch attachment is mounted above the shunt trip
device and may have one or two switches. The alarm switch attachment closes to energize
an alarm circuit when the breaker is opened by any means other than manual trip or
shunt trip. The device consists of a switch, guard, impact spring, clevis, crossbar, reset
link, and reset casting. The alarm switch is reset by pushing the manual trip button or
by energizing the shunt trip device.
Electric Lockout Attachment. The electric lockout attachment (device) is mounted on the
top left side of the breaker front frame, behind the auxiliary switch. The lockout device
will hold the breaker in the trip-free condition until the device is energized. The lockout
device is used to electrically interlock two breakers and prevent both from being closed at
the same time. When the lockout device coil is energized, the breaker may be closed. The
lockout device may be de-energized once the breaker is closed and it will not trip the
breaker. The device consists of a mounting bracket, moving core, stationary core, coil,
plunger, and lever.
Rectifier Unit For ac Electric Lockout Attachment. When an electric lockout device is ac
controlled, a rectifier unit is mounted on the breaker under the UV front frame. An
auto-transformer is provided to allow hook-up of common ac voltages to the appropriate
tap. On breakers with ac closing coils, the closing rectifier is mounted under the front
2-33
frame which does not allow mounting space for the ac lockout rectifier. In this case, the
ac lockout rectifier must be mounted external to the circuit breaker.
Key Lock Attachment. The key lock is mounted on the right side of the breaker on top of
the front frame. The key may be removed with the breaker in the closed or opened
position. This interlock maintains the breaker in a trip-free condition by mechanically
blocking the trip button in the trip position when the device is in the locked position.
This allows mechanical interlocking of two or more breakers.
Model Options. Two options in the basic DB-50 design are discussed below.
The DBF-16 is a special field-discharge breaker which consists of a standard two-pole
(outer poles) dc DB-50 circuit breaker with a set of field-discharge contacts in the center
pole. The DBF-16 is designed to discharge the field circuits of synchronous generators and
motors. These breakers have no overcurrent trip devices. When the breaker is opened,
the field-discharge contacts close before the main contacts open. When the breaker is
closed, the field-discharge contacts open after the main breaker contacts close. This
contact overlap prevents the field circuit from opening.
The DBL-50 is a standard DB-50 breaker with current-limiting fuses mounted in the
primary circuit on the upper studs. These special primary fuses incorporate a fuse trip
button that extends when a fuse blows. When the fuse on any phase blows, the fuse trip
button on that fuse extends and actuates a linkage, which rotates the trip bar and trips
2-34
Section 3.0
Historical Performance
3.1
Analysis of Overhaul Data ................................................................... 3-1

3.1.1 General Discussion ..................................................................... 3-1
3.1.2 Deficiencies by Breaker Subcomponent ...................................... 3-2
3.2
Analysis of NPRDS Data ...................................................................... 3-6

3.2.1 General Discussion ..................................................................... 3-6
3.2.2 Failures by Breaker Operation..................................................... 3-6
3.2.3 Failures by Breaker Model........................................................... 3-8
3.2.4 Failures by Breaker Subcomponent .......................................... 3-10
3.3
Failure Modes Analysis...................................................................... 3-14

3.3.1 Critical Functions ....................................................................... 3-15
3.3.2 Failure Analysis by Subcomponent ........................................... 3-15
3.4
Recordkeeping Guidelines ................................................................ 3-21

3.4.1 Maintenance Data...................................................................... 3-21
3.4.2 Test Data ................................................................................... 3-22
3.0 Historical Performance

This section documents the historical performance of Westinghouse Type DB low-voltage
circuit breakers.
The historical performance is based on the analysis of overhaul data and Nuclear Plant
Reliability Data System (NPRDS) data. Breaker subcomponents with high failure rates
are identified along with the associated degradation mechanisms. The significance of the
subcomponent degradation mechanism is also identified. The failure analysis does not
include a root cause (or failure cause) analysis, as these analyses are too in depth for the
scope of this project. Finally, recordkeeping guidelines for maintenance and test data are
discussed.
3.1
Analysis of Overhaul Data
Data from the overhaul of 12 Westinghouse Type DB circuit breakers were analyzed to
determine the condition of the various breaker subcomponents. This type of data is an
important factor in assessing breaker degradation because it documents a breaker's
condition in an unfailed state. Other databases, such as the NPRDS, comprise specific
failure information and may not provide any insight into the overall breaker condition.
Overhaul data may also offer insights into long-term subcomponent degradation, through
the detailed disassembly and inspection requirements, as compared to the data available
from typical routine maintenance inspections.
The breaker model population included two type DB-15, four type DB-25, four type DB-50,
and two type DB-75. The breaker applications included non-safety related nuclear utility,
fossil utility, marine, and general industry. The data represent breakers overhauled from
September 1986 to December 1991.
3.1.1 General Discussion

The overhaul data were supplied by Power Distribution Technology, Inc. (PDT), an
independent vendor that specializes in overhauling and repairing circuit breakers. PDT
operates a Quality Assurance program that meets the requirements of 10CFR50 Appendix
B and requires the use of detailed procedures for each circuit breaker overhaul. These
procedures document the as-received condition of a breaker by recording the results of
extensive pre-overhaul and disassembly tests, inspections, and evaluations.
Approximately 100 pre-overhaul tests, inspections, and evaluations were reviewed for each
breaker during the course of preparing this guide.
The data for each breaker were assigned to a subcomponent category. The data were
reviewed to identify degradation mechanisms and deficiencies associated with each
subcomponent. These degradation mechanisms and deficiencies include loose/damaged
parts, failed parts, out-of-adjustment, out-of-calibration, poor/dirt-contaminated lubricant,
and wear/binding. Identification of the degradation mechanisms and deficiencies is a
3-1
primary means toward developing appropriate preventive and corrective maintenance

actions for each subcomponent.
The overhaul data show that a breaker subcomponent is sometimes subjected to several
degradation mechanisms. In these cases each deficiency was included in the evaluation.
Following is the analysis of these data presented by subcomponent category.
3.1.2 Deficiencies by Breaker Subcomponent
The data for each breaker were assigned to the following subcomponent categories:
1.
Operating mechanism -
Mechanical subcomponents associated

with closing, tripping, and indication.
2.
Main current-carrying subcomponents -
Main and arcing contact assemblies, and

primary disconnects.
3.
Overcurrent trip device (OCTD) -
Electro-mechanical units, solid-state logic

unit, actuator, and current transformers.
4.
Electrical control devices -
Electric switches, control relays, close

coil, undervoltage trip device, shunt trip
device, auxiliary switch, secondary
disconnects, and indicator lights.
5.
Wiring -
Control wiring for operating the breaker

and for indication.
6.
Plastic subcomponents -
Plastic insulating parts of secondary

disconnects, switch enclosures, relay
mounting bases, and switch covers.
7.
Racking mechanism -
Mechanical subcomponents associated

with disconnecting and removing, and
installing and connecting the breaker to
the bus.
8.
Arc chute -
Arc chute assembly and connections.
9.
Insulation -
Inter-phase barriers, pole unit base

moldings, and unidentified poor
insulation.
10.
Frame -
The structural supporting members to

which the breaker subcomponents are
fastened.
3-2
A total of 65 deficiencies were identified for the 12 breakers. Figure 3.1-1 illustrates the
percentage of deficiencies by subcomponent. The analysis is presented by subcomponent
category and in order beginning with the highest percentage of deficiencies.
Figure 3.1-1
Overhaul Data Summ ary
Subcomponent Deficiencies
Operating Mechanism The circuit breaker operating mechanism is a complex assembly of

levers, latches, linkages, cams, springs, shafts, and bearings. The operating mechanism
provides the force to open or close the breaker, hold the breaker closed, and release the
force to open the breaker. The operating mechanism must operate properly if the breaker
is to perform its critical functions of closing on demand, opening on demand, or opening
within a specified time interval. Operating mechanism degradation occurred in all of the
overhauled breakers and accounted for the largest percentage of deficiencies (28%).
Operating mechanism deficiencies include:
Poor/dirt contaminated lubricant.
Binding or excessive wear.
Loose or damaged parts.
3-3
Dirt contamination was identified on all 12 breakers, and this type of deficiency is
common for circuit breakers in service for greater than 10 years. The original lubricant
was a dry molybdenum disulfide mixed with oil, and it was applied with a squeeze bottle
during maintenance. As a result, the breakers were dirty with graphite disbursed
throughout the mechanism.
Four breakers had insufficient lubrication but only one experienced intermittent
mechanism binding. Sluggish operation was reported on three other breakers. Based on
the limited binding, it appears that the dry graphite may be a better lubricant than
petroleum-based grease. This may be due to the graphite not experiencing the separation
problem associated with petroleum-based grease and resulting m a pasty residue. The DB
model breaker also utilizes sleeve bearings in the operating mechanism, which may be
less susceptible to lubricant degradation than roller bearings. When operating
mechanisms become excessively dirty and exhibit sluggish operation, extensive
disassembly is required to clean and relubricate bushings, pins, and shafts.
The damaged or worn parts did not show a repeatable trend. They consisted of one bent
toggle assembly, one breaker with damaged charging and reset springs, and one worn
bearing.
Electrical Control Devices. Electrical control devices accounted for 18% of the deficiencies.
Typical deficiencies were:
High-resistance switch contacts.
Failed or damaged parts.
Shunt trip adjustment out of specification.
High-resistance switch contacts (> 0.1) occurred on five breakers and is easily corrected
by periodically cleaning the contact surfaces. The damaged parts consisted of a control
relay and a closing coil with damaged coil windings, a control relay with a cracked arc
chute, an auxiliary switch with a cracked housing, and a second auxiliary switch with
unspecified damage. Physical damage of this type can generally be identified during
routine maintenance inspections.
The shunt trip device was out of adjustment on two breakers; this adjustment can be
easily performed during routine maintenance inspections.
Overcurrent Trip Device. OCTDs accounted for 18% of the deficiencies. These consisted
of:
3-4
Setpoint out of adjustment.
Damaged or failed subcomponents.
Loose mounting.
Of the 12 overhauled breakers, two were being retrofitted from electromechanical to solidstate and, therefore, were not tested. Of the remaining ten, three were solid-state and
seven were electromechanical. The most common deficiency was setpoint drift, which
occurred on eight of ten breakers, indicating that this should be checked each
maintenance inspection. The two failed OCTDs were both of the electromechanical type.
One could not be adjusted into specification and one was replaced due to burn marks from
overheating.
Plastic Subcomponents. Plastic subcomponents exhibiting cracked, split, or broken parts
were responsible for 14% of the deficiencies. Subcomponents having damaged plastic
included:
Secondary disconnects.
Auxiliary switch covers.
Pole unit bases and links.
Damage to the secondary disconnects accounted for 44% of these deficiencies and is
typically caused by racking operations and handling. All plastic subcomponent damage
except for that affecting pole unit bases is easily detectable during routine maintenance
inspections. Pole unit base cracking is a potential age-related degradation mechanism.
This deficiency was discovered on the three phases of two breakers and can only be
detected by disassembling the contact assembly. This inspection should be accomplished
at overhaul. Additionally, spare pole unit bases should be available at overhaul.
Main Current-Carrying Subcomponents. Four of the twelve breakers required contact
adjustments and one required contact cleaning. Contact inspection and adjustment are
easily accomplished during routine maintenance.
Miscellaneous. Two of the twelve breakers had chipped or cracked arc chutes, however,
this type of damage should not affect breaker operation. Two breakers had loose or
damaged wires, which are easily detectable during routine maintenance. Breaker frame
deficiencies occurred from loose bolts for overcurrent trip devices, pole unit bases, and
closing coils. One breaker had a bent actuator arm. As this can affect breaker operation,
the entire racking mechanism should be checked during routine maintenance inspections.
Low ground readings due to excessive dirt occurred on one breaker. Insulation resistance
readings should be taken during all routine maintenance inspections for problem detection
and trending.
3-5
3.2
3.2.1
Analysis of NPRDS Data

General Discussion
The NPRDS is an industry source of historical data used to evaluate the performance of
nuclear power plant subcomponents. The NPRDS data are collected from failure reports,
but analysis of a population of failures can reveal a clear trend which, in turn, points to
maintenance and parts replacement activities that should be conducted on in-service
breakers. The accumulation of NPRDS data concerning Westinghouse type DB lowvoltage circuit breakers yields a population of 298 reported failures between 1974 (initial
data collection) and January 1992. These reports have been analyzed for the following
factors:
1.
Failures by breaker operation

a.
Frequent operation - reactor trip breakers
Infrequent operation - all others (general application)
b.
2.
Failures by breaker model

DB-25 breakers
a.
b.
DB-50 breakers
c.
DB-75/100 breakers
3.
Failures by breaker subcomponent

a.
Racking mechanism
b.
Operating mechanism
c.
Contacts and arc chutes
Electrical
control devices and wiring
d.
Overcurrent trip devices
e.
Miscellaneous subcomponents
f.
Of the 298 reports, 18 were due to human error, and 59 were either duplicate entries or
not circuit breaker related. The remaining 221 failure reports were analyzed to identify
the subcomponent(s) responsible for the failure, resulting in 237 failures (some breakers
experienced multiple subcomponent failures). Additionally, the analyses identified the
suspected degradation mechanisms which caused each failure and the breaker average age
at failure. Details on the analyses are presented below.
3.2.2 Failures by Breaker Operation

The NPRDS failure reports were categorized by breaker operation so that the failures of
reactor trip breakers (RTBs) could be compared to all other breakers. This was done for
the following reasons.
RTBs constitute a relatively small subset of the total number of 480V air circuit breakers
at a plant but are responsible for a relatively large percentage of the failure reports (43%).
RTBs are frequently cycled at regular intervals because of testing requirements and are
subjected to approximately the same amount of testing at all nuclear power plants. There
3-6
is also a history of problems with the undervoltage trip (UV) device with Westinghouse
DB-50 circuit breakers (NRC Generic Letter 83-28 and IE Bulletin No. 85-02).
The wide spectrum of applications for infrequently operated breakers (general application)
accounts for variances in cycling frequency but, for the most part, this population consists
of breakers that feed the equipment required for normal power production and thus these
breakers are subject to infrequent cycling.
RTBs were compared to general application breakers and both groups were analyzed to
identify the predominant subcomponent failures, the corresponding degradation
mechanisms, and the average breaker age at failure.
General application breaker failures are compared to RTB failures in Figure 3.2-1. The
average breaker age at failure for general application breakers was 14.5 years. The major
degradation mechanisms were failed or damaged parts, loose parts, and dirt. The average
breaker age at failure for RTBs was much lower, at 8.5 years. The predominant failure
modes were failed or damaged parts, excessive wear, and mechanical binding.
Analysis of the RTB failure data shows the effect of frequent cycling and testing. Failures
of operating mechanisms were 8% higher m RTBs, with an average failure age of 7.4
years. The average failure age for operating mechanisms m general application breakers
was 16.1 years. The degradation mechanisms for RTB operating mechanisms were also
different. Dirt, poor lubrication, and binding caused 56% of RTB operating mechanism
failures as compared to 23% m general application breakers. Twenty-two percent of RTB
operating mechanism failures were due to binding or inadequate lubrication of the trip
bar assembly. Problems with trip bar assembly binding are discussed in NRC Generic
Letter 83-28, and the last reported trip bar failure was in 1986. This indicates that this
problem has been corrected through increased maintenance and testing. The remaining
dirt- and lubrication-related failures occurred to latches and the operating mechanism in
general. The average age at failure was 6.0 years. Cleaning and lubrication to accessible
areas of the operating mechanism should be included in routine maintenance. In general
application breakers, 50% of the operating mechanism failures were due to wear, and
failed or damaged parts, at an average failure age of 17.4 years. This IS opposed to 30%
and an average age of 9.7 years m RTBs. The comparison indicates that dirt and poor
lubrication are more significant in RTBs due to their frequent cycling, and should be
checked during maintenance inspections.
Failures of electrical control devices were 8% higher for general application breakers, with
an average failures age of 14.3 years, as opposed to 7.4 years for RTBs. There is no
apparent explanation for the age difference but it may be due to the tendency to replace
the complete RTB when a subcomponent fails rather than replacing the subcomponent.
This would mean that, with an average RTB failure age of 8.5 years, RTBs are replaced
prior to electrical devices reaching their typical average failure age. This is supported by
the degradation mechanisms of electrical control devices. For both breaker types,
damaged parts was the most common mode of degradation, however, failed parts for
general application breakers occurred three times as often as for RTBs. The only other
obvious difference between RTB and general application breaker subcomponent failures is
3-7
F igure 3.2-1
S u b c o m p o n e n t F a ilu r e s b y O p e r a t i o n
the failure frequency of OCTDs and UV devices. The UV device is installed on all RTBs,
whereas it is not commonly installed on general application breakers. Likewise, the
OCTD is installed on all general application breakers, whereas it is not normally installed
on RTBs.
3.2.3 Failures by Breaker Model

The NPRDS failure reports were also categorized by breaker model and then analyzed to
detect significant failure trends related to model types. The 221 breaker failure reports
had the following distribution:
Model
DB-25
DB-50
DB-75/100
Total Number
44
154
23
RTBs constitute 62% of the DB-50 failure reports.
3-8
Figure 3.2-2 provides a breakdown of subcomponent failures by breaker model.

Significant differences among breaker models are apparent in operating mechanism,
electrical devices, UV devices, OCTDs, arc chute, and racking mechanism failures.
Since the operating mechanisms of DB-75 and DB-50 breakers are similar, the absence of
operating mechanism failures m DB-75/100 breakers is unusual. The DB-75/100 breakers
are also subject to frequent testing and cycling due to their use as diesel generator output
breakers at several plants. The DB-75/100 operating mechanism design is similar to the
DB-50, and lubrication requirements are the same for all three models. Routine
maintenance tests and inspections for the three models should be the same.
The large (46%) number of electrical device failures associated with DB-75/100 breakers is
attributed to failures or damage to the secondary disconnects. Twenty-seven percent of
DB-75/100 failures were due to damaged (bent) secondary disconnects. This damage occurs
during racking operations and is more common in larger breakers because of their weight.
Secondary disconnects should be inspected during maintenance inspections on DB-75/100
breakers.
3-9
The large percentage of UV device failures for DB-50 breakers is attributed to the large
number of RTBs in the DB-50 population. One UV device failure was associated with both
DB-25 and DB-75/100 breakers, and none with general application DB-50 breakers. The
small percentage of OCTD failures on DB-50 breakers is also attributed to the large
number of RTBs in the DB-50 population. RTBs do not have OCTDs. General application
DB-50 breakers had an OCTD failure rate of 27%, which is consistent with the failure rate
found on DB-25 and DB-75/100 breakers.
Arc chute failure reports of cracking or chipping were much higher in DB-25 breakers.
This is attributed to the arc chute material in DB-25 breakers being ceramic while in
larger breakers it is asbestos. The asbestos material is less susceptible to damage. Most
of the DB-25 arc chute damage occurred at one plant and may be an isolated case. Arc
chutes are easily inspected during routine maintenance inspections.
The absence of racking mechanism failures in DB-25 breakers is attributed to their
smaller frame size. Larger breakers are more cumbersome and require more force to rack
in and out. This extra force makes larger breakers more susceptible to damage.
The average failure ages for the three categories of breakers were:
Model
DB-25
DB-50
DB-75/100
Failure Age
16.7
10.3
14
The lower failure age for DB-50 breakers is due to the large population of RTBs. The
average age at failure for general application DB-50 breakers was 13.2 years.
3.2.4 Failures by Breaker Subcomponent

The analysis of failures by subcomponent provides information that can be used to identify
trends in subcomponent reliability. This type of analysis is most revealing m terms of
routine maintenance and inspection activities that can prolong the functional life of a
breaker and prevent in-service failures.
Figure 3.2-3 displays the reported failures by breaker subcomponent.
The subcomponents, listed below, are defined in Subsection 3.1:
Electrical control devices
Operating mechanism
Overcurrent trip device (OCTD) (electromechanical and solid-state trip device)
Racking mechanism
Main current-carrying subcomponents
Wiring
Arc chute
Miscellaneous (frame, insulation, unknown)
3-10
Electrical control devices were further divided for the NPRDS analysis and included.
1.
Undervoltage trip (UV) assembly - the UV coil and all associated parts
required to cause the breaker to trip on undervoltage.
2.
Close coil assembly - The assembly associated with the normal electrical
closing of a breaker, including mechanical assembly and electrical coil and
armature.
3.
Shunt trip device - The device associated with normal electrical opening,
including mechanical assembly and electrical coil and armature.
Failures by the breaker to perform its normal function but for which no cause could be
determined were categorized as unknown.
The operating mechanism and electrical control devices had the highest number of
reported failures. The major degradation mechanisms for the operating mechanism were:
3-11
Dirt/poor lubricant (30%).

Subcomponent wear (23%).
Subcomponent failures (12%).
Subcomponent damage (8%).
Nine breakers failed from poor lubricant and four failed from excessive dirt. Five
lubrication failures were due to sticking trip bars- as discussed in Subsection 3.2.2, this
problem appears to have been corrected. Subcomponents that failed due to normal wear or
aging include the latch mechanism, needle bearing, and the entire operating mechanism.
Subcomponents that simply failed include trip levers, first toggle lever, and the latching
mechanism. Dirt, poor lubrication, and subcomponent wear are detectable through
routine maintenance. The average breaker age at operating mechanism failure was 11
years.
Electrical control devices accounted for 18% of the failure reports. The major degradation
mechanisms were:
Damaged parts (28%).
Dirty contacts (20%).
Failed parts (15%).
Out of adjustment or calibration (11%).
Damaged parts include nine bent secondary disconnects and three cracked plastic covers.
As stated previously, secondary disconnect damage occurs from racking operations. Dirty,
high-resistance contacts are preventable by cleaning and inspection. Failed parts
consisted of two control relay coil failures, two broken auxiliary switches, one failed alarm
switch, and one worn reverse current relay. Coil failure is difficult to predict through
routine maintenance. Visual inspection should be included in routine maintenence.
Items requiring adjustment were four control relays and one alarm switch. Adjustment or
calibration problems can be corrected during routine maintenance. The average failure
age for electrical control device failures was 12.3 years.
The UV device assembly was the next highest failure subcomponent (13%). The major
degradation mechanisms were:
Failed or worn parts (60%).
Binding or lack of lubrication (24%).
The failed or worn parts consisted of both electrical (coil) and mechanical (latch assembly)
parts. Four failures (13%) were attributed to failed wire-wound subcomponents, with an
3-12
average failure age of 10.3 years. Six failures (20%) were described in NPRDS as "UV
failures," which may be due to coil failure. The average age for these failures was 9.5
years. Whether the "UV failures" were electrical failures or not, the coil failure rate for
UV devices is higher than for any other electrical device. This higher failure rate may be
due to the UV coil being continuously energized.
Forty percent of the UV device failures were due to worn or binding parts in the UV latch
assembly. Three failures were attributed to inadequate lubrication, four were due to
binding, and five were attributed to wear. Binding of the UV latch assembly from
dirt/poor lubrication surfaced as a problem in 1983 (NRC Generic Letter 83-28) with the
recommended corrective action being increased inspection, testing, cleaning, and
lubrication. These additional actions appear to be moderately effective, since the last
occurrence of UV latch assembly binding due to inadequate lubrication was in 1985.
Binding has occurred as recently as 1991, but all occurrences since 1983 have been
detected during routine maintenance or testing. The average failure age for UV latch
assembly binding was 8.3 years. UV latch assembly binding is detectable through routine
maintenance inspections and testing. Additionally, periodic replacement should be
considered.
OCTDs were the next highest failure subcomponent, with 16% of the reported failures.
The NPRDS failure narrative was used to classify the type of OCTD as either solid-state
(Amptector ) or electromechanical. If the narrative did not indicate that it was an
Amptector unit, then the OCTD was assumed to be an electromechanical device.
Twenty-six failures occurred for electromechanical devices and eleven occurred for solidstate devices. The major degradation mechanisms for electromechanical devices were:
Out of adjustment (23%).
Dirt (15%).
Of the fourteen failed or worn parts, three failures were due to punctured diaphragms and
three could not be adjusted into specification. The remaining failures were due to wear or
unexplained. Two failures were attributed to dirt in the OCTD air valves. Both dirt
contamination and adjustment problems are detectable during routine maintenance
testing. The average age at failure for electromechanical devices was 13.1 years.
The major degradation mechanisms associated with solid-state devices were:
Out of adjustment (18%).
No specific failed parts were mentioned, indicating that the entire Amptector unit was
replaced. Since most solid-state units were not the original OCTD installed on the
breaker (the original electromechanical devices were upgraded to solid-state), no accurate
3-13
failure age data were available. Periodic testing of OCTDs should be included in routine
maintenance tests.
Racking mechanisms accounted for 7% of the failures. The major degradation mechanisms
were:
Damaged parts (47%).

Various parts of the racking mechanisms and interlocks were bent or damaged due to
repeated or incorrect racking operations. These deficiencies should be detectable during
maintenance inspections.
There were ten (4%) failure reports associated with main current-carrying subcomponents.
Contact wear, pitting, and dirt were responsible for 90% of the problems, and all are
detectable through routine maintenance. The average failure age was 8.9 years.
Wiring deficiencies also accounted for ten (4%) failures. Eight involved loose connections
and two involved damaged wires, with an average failure age of 10.6 years. These
deficiencies are also detectable during routine maintenance.
Close coils accounted for 4% of the failure reports. Of the ten failures: three were due to
the coil failing; five were due to binding from worn parts, dirt, or debris; and one was out
of adjustment. With the exception of coil failure, these deficiencies can be detected during
routine maintenance. The average age for close coil failures was 12.2 years.
Shunt trip devices also accounted for ten deficiencies (4%). These consisted of three failed
coils (open/short), two loose mountings, and five adjustment problems, with an average
failure age of 13.6 years. Loose mounting and adjustment deficiencies are detectable
during routine maintenance and inspections.
Broken arc chutes occurred on seven breakers at an average age of 20 years. Damaged
arc chutes have little impact on breaker operation unless a piece of the arc chute becomes
loose in the breaker.
Insulation and frame failures were uncommon and mostly detected during routine
maintenance activities.
3.3
Failure Modes Analysis
This section provides a failure modes analysis of the DB circuit breaker degradation
mechanisms identified in the two previous subsections. The analysis identifies the critical
functions of the circuit breaker, the major subcomponents responsible for accomplishing
the critical functions, and the degradation mechanisms identified for the subcomponents.
The significance of the degradation mechanism is then assessed based on the effect it has
3-14
on the subcomponent and the frequency at which it has appeared in the databases. Once
the significant degradation mechanisms are identified, preventive/corrective actions and
their frequencies can be established to assure that DB type circuit breakers are properly
maintained.
3.3.1
Critical Functions
Critical functions are requirements that a circuit breaker must meet successfully to satisfy
its design function. Critical functions are identified for general application circuit
breakers and RTBs. Although these breakers function similarly and have many of the
same subcomponents, critical functions are identified for RTBs because of their unique
applications. Additionally, RTBs have slightly different configurations than general
application circuit breakers.
A circuit breaker's system application will determine its specific critical functions. Table
3.3-1 identifies the critical functions, the subcomponents responsible for accomplishing
each function, and the failure effects for general application circuit breakers. Table 3.3-2
identifies these categories for RTBs. These critical functions should be verified by each
utility for its specific reactor protection system.
3.3.2 Failure Analysis by Subcomponent

Figure 3.3-1 shows the percentage of failures for each database by subcomponent. The
following subcomponents, which are discussed below, are those primarily responsible for
the breaker to perform its critical functions.
SUBCOMPONENT
Operating mechanism
Electrical control devices
Overcurrent trip device
Undervoltage trip device
Main current-carrying subcomponents
Wiring
Insulation
Shunt trip device
Close coil assembly
3-15
Table 3.3-1 General Circuit Breaker Critical Function/Failure Mode Annalysis

Critical Function
Subcomponent
Load Systern Failure Effects
Electrical System Failure Effects
Plant Failure Effects
Close on demand
Operating mechanism
Close coil assembly
Electrical closing system
Wiring
No power to load
None
Potential loss of safety system
Open on demand
Operating mechanism
Shunt trip assembly
W ing
Load remains energized
Potential higher load on emergency

generator
None
Open on overcurrent
Operating mechanism
Overcurrent trip device
Load failure from excessive currrent
Upstream breaker trips; loss of

multiple loads
Potential plant trip due to loss

of multiple loads
Open on undervoltage
Operating mechanism
Undervoltage assembly
Wiring
Load failure from low voltage
Potential higher load on emergency

generator
None
Operating mechanism
No power to load
None
Potential loss of safety system
Provide power to load
Main current-carrying
subcomponents
Provide indication of breaker status
Auxiliary switch
Wiring
No Indication
None
None
Provide electrical insulation
insulation subcomponents
No power to load
Upstream breaker trips; loss of

multiple loads
Potential plant trip due to loss

of multiple loads
Table 3.3-2 Reactor Protection Breaker Critical Function/Failure Mode Analysis

Critical Funtion
Subcomponent
Load Systern Failure Eflects
Electrical Systern Failure Effects
Plant Failure Effects
Close on demand
Operating mechanism
Close coil assembly
Electrical closing system
Wiring
No power to load
None
Plant shutdown to investigate
Open on demand
Operating mechanism
Shunt trip assembly
Undervoltage assembly
Wring
Breaker remians closed
None
Plant shutdown to Investigate
Provide power to load
Operating mechanism
Main current-carrying
subcomponents
No power to load
None
Plant shutdown to Investigate
Provide indication of breaker status
Auxillary switch
Wiring
No indication
None
Provide electrical Insulation
Insulation subcomponents
No power to load
None
Operating Mechanism. This assembly is essential to the critical functions of open and
close on demand, open on overcurrent/undervoltage, and power transmission. The major
degradation mechanisms were dirt, poor lubricant, worn parts, and failed or damaged
parts. Although worn, failed, or damaged parts accounted for 44% of the degradation
mechanisms, the NPRDS data do not indicate a significantly higher failure for one
operating mechanism part over another. Thus, dirt and lubrication are the degradation
mechanisms of consequence in preventing operating mechanism failure. Dirt
accumulation and poor lubricant are difficult to detect and correct prior to breaker failure
because correction involves complete disassembly of the operating mechanism. This is
typical of work associated with breaker overhaul. All twelve of the overhauled breakers
were classified as dirty, yet only one exhibited binding, indicating that dirt by itself may
not cause operating mechanism failure. Also, as stated previously, much of this dirt was
attributed to the graphite-based lubricant that is used. Although there were few failures
directly attributed to dirt accumulation and poor lubricant, this degradation mechanism
can cause excessive friction that results in accelerated subcomponent wear, binding, and
part failure.
Dirt, poor lubrication, binding, and wear m the mechanism accounted for 63% of operating
mechanism failures and 12% of all failure reports. The effect of dirt and poor lubrication
3-18
also appears to be dependent upon frequency of operation. Failures due to binding, wear,
dirt, and lubrication constituted 78% of RTB operating mechanism failures as compared to
45% in general application breakers. As general application breakers approach the same
number of operations, they, too, will start to develop wear and binding problems. This
may be somewhat alleviated by routine overhaul, however, subcomponents not replaced at
overhaul may be subject to the wear.
Trip bar binding and latch mechanism failure/binding were the only recurring
subcomponent problems, with four failures each. These items should be checked for proper
operation during routine maintenance and replaced if they exhibit signs of deterioration.
Electrical Control Devices. The number of failures from electrical control devices was
about the same as for the operating mechanism. Dirty, pitted, and high resistance
contacts were the most common degradation mechanisms, accounting for 22% of the total
(overhaul and NPRDS) electrical control device deficiencies. This degradation mechanism
does not generally affect breaker operation until it is in its advanced stages. Degraded
contacts should be identified during routine maintenance inspections.
Damaged secondary disconnects accounted for 20% of the total number of deficiencies in
electrical control devices. As stated previously, damage to this subcomponent is a result of
racking operations and is more prevalent in larger frame breakers. Secondary disconnects
should be inspected closely during every maintenance evolution. The most common switch
or relay failures were control relays and auxiliary switches, but these occurred relatively
infrequently. Coil and switch failures are difficult to detect beforehand and preventive
measures are limited to inspection, adjustment, and periodic replacement.
There were more instances of chipped or cracked plastic in electrical control devices in the
overhaul data. Although cracked plastic may be a common occurrence, it rarely results,
either directly or indirectly, in breaker degradation. Visual inspection of plastic
subcomponents should be included in routine maintenance inspections.
Overcurrent Trip Devices. The critical function of OCTDs is to open the breaker on
detecting an overcurrent condition. The predominant degradation mechanisms were failed
parts and being out of adjustment. These were typically detected during routine
maintenance testing. The electro-mechanical trip devices had more failures than the solidstate devices, but this may be due to the electro-mechanical devices being more common.
The percentage of failures due to parts failure or out of adjustment were about the same
for both types of devices. Testing and inspection of overcurrent trip devices should
continue to be included in routine maintenance testing.
Undervoltage Trip Devices. UV device failures were primarily attributable to RTBs (93%).
None of the overhauled breakers had a UV device installed. Routine maintenance or
testing detected 83% of the failures. Part failure was responsible for 60% of UV device
failures, with undervoltage coil failure occurring four times (13%). This is attributed to
the coil being continuously energized and to the increased inspection and testing required
for the RTBs.
3-19
Worn or binding parts in the UV device latch assembly were responsible for a significant
number of failures. Increased inspection and lubrication requirements have reduced the
occurrence of mechanism binding, but worn parts still appear to be a problem, especially
during later stages of circuit breaker life. Standard replacement of UV devices for RTBs
at overhaul should be considered.
Main Current-Carrying Subcomponents. No significant degradation mechanism trends
were associated with main current-carrying subcomponents. Contact wear, pitting, and
dirt were the most common degradation mechanisms. All of these deficiencies develop
over a period of time and are detectable by routine maintenance inspections.
Wiring. Wiring deficiencies included broken or damaged wires, loose connections, and dirt
accumulation/low insulation resistance. There were no common degradation trends. The
wiring deficiencies in the overhaul data were caused by environments more severe than
that of a nuclear power station. Wiring deficiencies are detected by thorough inspection
during routine maintenance.
Insulations. Insulation degradation does not appear to be a significant problem. Cracked
or chipped insulating links occurred m three NPRDS reports, and cracked pole unit bases
occurred in two overhauled breakers. Low grounds from excessive dirt occurred once in
both NPRDS and overhaul data. Cracked insulating links and pole unit bases may be an
age-related degradation mechanism. Insulation resistance readings should be taken
during routine maintenance to detect insulation degradation. Insulating link damage is
visible during routine maintenance, but pole unit base inspection requires contact
disassembly and should be accomplished at overhaul.
S h u n t T r i p D e v i c e . Failure of the shunt trip device does not appear to be a significant
problem. Out-of-adjustment and failed coils were the primary failure modes. Adjustment
can be checked during routine maintenance. The shunt trip coil is energized briefly
during opening operations and is not subjected to a severe duty. Preventive measures are
limited to inspection and adjustment and periodic replacement.
Close Coil Assembly. Failure of the close coil assembly does not appear to be a significant
problem. Only a few close coil failures were reported. The close coil is energized briefly
during closing operations and is not subjected to a severe duty. Several failures were
attributed to binding of the coil from worn parts, dirt, or debris. This should be checked
during routine maintenance.
Miscellaneous. The remaining subcomponents--the racking mechanism, frame, and the arc
chutes--do not directly affect the function of the breaker. Arc chutes and the frame had
few reported failures, none of which affected breaker operation. Although there were a
significant number of racking mechanism deficiencies (19), these are usually discovered
during routine maintenance or post-maintenance testing. Racking mechanisms and arc
chutes are easily inspected during routine maintenance.
3-20
3.4
Recordkeeping Guidelines
Maintenance records, which include maintenance data and test data, are an important
element of an effective routine maintenance program. Accurate maintenance records
allow maintenance personnel to establish circuit breaker condition and adjust
maintenance frequencies. Records should include all vital information and exclude any
extraneous information which may encumber the recordkeeping process, reducing the
maintenance program's effectiveness.
Two important variables when analyzing circuit breaker data are time in service and
number of breaker operations. Once a program is implemented, time in service should be
relatively easily obtainable. The number of breaker operations is more difficult to obtain
because DB type breakers are not generally equipped with operation counters. The
number of operations can be estimated or operation counters can be installed on a sample
number of breakers to establish typical operating frequency.
Maintenance data and test data are described briefly in the following subsections.
3.4.1
Maintenance Data
Maintenance data consist of the information used to document the maintenance history of
the subject equipment. These data provide records of parts replaced, corrective actions
taken, inspection dates, and inspection results. They are used to adjust maintenance
schedules and to identify renewal parts requirements.
Analyses of maintenance data may also identify a degrading condition within a breaker.
When an adjustment is repeatedly out-of-tolerance or a repeated maintenance action is
required, this may be indicative of a degrading condition elsewhere. For example, if the
shunt trip coils fail on several breakers, this may indicate that the operating mechanism
lubricant is degrading and thus requiring the shunt trip coil to be energized longer to
open the breaker.
In addition to the maintenance data already mentioned, examples of maintenance data are
listed below:
Operating mechanism condition.
Overcurrent trip device adjustments.
Shunt trip and undervoltage trip device adjustments.
Parts replaced during maintenance.
Contact condition and adjustment.
Safety interlock adjustments.
3-21
3.4.2 Test Data

Test data are used to trend specific circuit breaker parameters to document breaker
condition. Test data are trended to identify subcomponents whose material condition is in
need of maintenance, so that corrective actions can be scheduled to maintain the
equipment in its optimum state of readiness. These data also verify that the material
condition is sufficient to allow the equipment to function reliably until the next scheduled
maintenance.
Test data are trended for those degradation mechanisms which require extensive breaker
disassembly, breaker overhaul, or breaker replacement to correct. Some examples of
trendable test data are:
3-22
Insulation resistance, to detect insulation degradation.
Contact pressure measurement, to determine contact spring condition.
Analysis of breaker lubricant samples, to trend lubricant condition.
Force required to operate the trip lever/shaft, to trend lubricant condition.
Breaker opening and closing time, to trend operating mechanism condition.
Section 4.0
4.1
Maintenance Scheduling...................................................................... 4-2

4.1.1 Time-Based Scheduling............................................................... 4-2
4.1.2 Condition-Based Scheduling ....................................................... 4-9
4.2
Subcomponent Replacement .............................................................. 4-9

4.2.1 Time-Based Replacement ........................................................... 4-9
4.2.2 Condition-Based Replacement .................................................. 4-11
4.2.3 Subcomponent Upgrades .......................................................... 4-14
4.2.4 Lubrication ................................................................................. 4-14
4.3
Personnel Qualification and Training ............................................... 4-16
4.4
Industry and Manufacturer Recommendations................................ 4-17
4.0
This section provides maintenance recommendations for Westinghouse DB Type circuit

breakers. These maintenance actions offer a means to identify and correct the degraded
conditions identified in Section 3. The actions are described along with their bases and
recommended periodicities for implementation. These maintenance actions are
summarized in Table 4.0-1. Subcomponent replacement intervals are identified and
justified. Upgrades for subcomponents which have had recurring failures are discussed.
Lubrication maintenance is also addressed. Maintenance personnel training and
qualification recommendations are provided. Finally, industry and manufacturer
recommendations are presented.
Table 4.0-1 Maintenance Scheduling
Category
Safety-Related
Non-SafetyRelated
After
Experiencing an
Overcurrent
Condition
Maintenance Action
Periodicity *
Reference
Subsection
1. Routine Inspection,
Test, and Adjustment
Each Refueling
Outage (18/24
Months)
5.3, 5.5
2. Complete Overhaul
8-12 Years
5.4, 5.6
3. Lubrication (General
Application Breakers)
4-6 Years
5.3, 5.5
4. Test OCTD current

sensors
4-6 Years
5.3, 5.5
Test, Adjustment, and
Lubrication (Reactor Trip
Breakers)
200 Operations or
18 Months
Utility
Procedures
Test, and Adjustment
Every Second
Refueling Outage
(36/48 Months)
5.3, 5.5
2. Complete Overhaul
8-12 Years
5.4, 5.6
3. Lubrication
4-6 Years
5.3, 5.5
4. Test OCTD current

sensors
4-6 Years
5.3, 5.5
1. Inspection, Test, and

Adjustment
As Soon as
Possible
5.3, 5.5
*The maintenance periodicity identified in this table may be adjusted to a longer or

shorter frequency based on analysis of maintenance and test data, see Subsection 3.4.
4-1
4.1
Maintenance Scheduling
4.1.1 Time-Based Scheduling

The importance of periodic inspections for DB Type circuit breakers cannot be
overemphasized. Approximately 67% of the failures identified in the NPRDS data were
detected during routine maintenance inspections and tests. Another 20% of the NPRDS
failures were due to degradation mechanisms that develop over a period of time and can
be detected by routine maintenance inspections. Figure 4.1-1 provides a breakdown of the
methods by which failures were detected as reported m NPRDS.
For general application breakers, the manufacturer recommends a limited monthly

inspection and a thorough semi-annual inspection, with the schedule being modified
depending upon the severity of the duty performed. For reactor trip breakers (RTBs), the
manufacturer recommends a series of maintenance actions every 200 operations or
refueling outage, whichever occurs first, not to exceed 18 months. Applicable industry
standards recommend a similar inspection at intervals ranging from annually to once
every 1750 operations. Industry and manufacturer maintenance recommendations are
summarized in Subsection 4.4.
4-2
The recommended interval for performing the routine maintenance described in Section
5.0 of this guide is every refueling outage (18/24 months) for safety-related general
application circuit breakers and every second refueling outage for non-safety-related
circuit breakers. RTB maintenance intervals should be in accordance with the utility's
existing maintenance program and procedures.
These recommendations are based on analysis of NPRDS failure data and overhaul data,
and should be modified based upon inspection results as discussed in Subsection 3.4. The
number of operations and a breaker's environment may also influence maintenance
scheduling.
The inspection is relatively easy to accomplish and the recommended interval will allow
detection of developing degradations before they reach unacceptable levels. The 18/24month interval for safety-related breakers is based on their critical function. Analysis of
breaker-specific maintenance and test data may allow this frequency to be extended to
36/48 months. The 36/48-month interval for non-safety-related breakers is supported by
the NPRDS failure data. These data indicate that the shortest average breaker age at the
time of subcomponent failure was nine years.
Analysis of the failure data indicates that the items described below should be checked
during each routine maintenance interval. These items are summarized in Table 4.1-1.
Operating Mechanism. The major degradation and failure mechanisms for circuit breaker
operating mechanisms, as identified in both the NPRDS and the overhaul data, are:
Dirt accumulation.
Degraded lubricant.
Failed or damaged parts.
Worn or binding parts.
Loose parts.
Methods to detect these degradation mechanisms during routine maintenance include

visual inspection and observation of manual and electric operation. With the exception of
failed parts, these degradation and failure mechanisms are detectable during routine
maintenance. Failed parts accounted for 12% of the NPRDS operating mechanism failures
at an average age of 15 years. Inadequate lubrication accounted for 21% of the NPRDS
operating mechanism failures, and excessive dirt caused 9% of the failures. The average
failure age from dirt/lubrication was 8.4 years. One of the effects of dirt and inadequate
lubrication is excessive subcomponent wear, which caused 10 of the 43 NPRDS operating
mechanism failures.
4-3
Table 4.1-1 Routine Inspection, Test, and Adjustment Actions

Subcomponent
Maintenance Action
Operating Mechanism
Check freedom of operation

Verify operation
Visual inspection
Electrical Control Devices
Measure contact resistance

Measure insulation resistance
Electrical operation
Visual inspection
OCTD
Overcurrent testing
Visual inspection
UV Device
Test pickup and dropout

Visual inspection
Check freedom of operation
Main Current-Carrying Subcomponents
Measure contact resistance

Measure contact adjustments
Visual inspection
Wiring

Visual inspection
Racking Mechanism
Visual inspection
Check operation
Close Coil
Visual inspection
Check operation
Shunt Trip Device
Check operation
Visual inspection
Arc Chutes
Visual inspection
Primary Insulating Subcomponents

Visual inspection
Frame
Visual inspection
Trip bar and trip latch binding are two common failures. These subcomponents should be
included in routine maintenance inspections. Binding of the trip bar was identified by
NRC Generic Letter 83-28 and the recommended inspections, cleaning, and lubrication
have had a significant impact m reducing its occurrence.
4-4
The overhaul data support the importance of routine maintenance for the operating
mechanism. Of the 12 breakers overhauled, all had excessive dirt and four had
inadequate lubrication.
The above inspections should be included in the routine maintenance interval. The
inspections are consistent with the manufacturer and industry recommendations. The
maintenance interval is also consistent with detecting operating mechanism subcomponent
failure, as the NPRDS breaker average age at the time of operating mechanism failure
was 11.4 years.
Electrical Control Devices. The major degradation and failure mechanisms for electrical
control devices, as identified in the NPRDS and overhaul data, are:
Dirty/high-resistance contacts.
Failed parts.
Damaged parts.
Out-of-adjustment or calibration.
With the exception of failed coils and broken switches, these degradation mechanisms are
detectable by visual inspection, mechanical and electrical operation, and contact and
insulation resistance measurement. Failed coils and broken switches accounted for 15% of
all electrical control device failures at an average age of 14.6 years. Measurement of coil
resistance is not recommended since coil failures (open or short circuit) occur suddenly and
cannot normally be predicted by trend analysis.
Dirty/high-resistance switch contacts, which accounted for 20% of the failures, can easily
be corrected by periodic cleaning. Damaged secondary disconnects--constituting 20% of all
electrical control device failures--can be minimized by proper handling and can be detected
visually during routine maintenance inspections. The importance of periodic inspections
is supported by the overhaul data; five of the 12 overhauled breakers had high-resistance
contacts, and four of the breakers had damaged secondary disconnects. The routine
maintenance interval is sufficient since the average breaker age for detecting these
degradation mechanisms is 12.3 years and it is consistent with industry and manufacturer
recommendations.
Overcurrent Trip Device (OCTD-Electro-Mechanical. The degradation mechanisms for
electro-mechanical OCTDs are:
Failed or worn parts.
Out-of-adjustment.
Dirt.
4-5
Failed or worn parts accounted for 54% of the electro-mechanical OCTD failures. They are
best detected by overcurrent testing by primary injection during routine maintenance.
Testing of electro-mechanical OCTDs is not discussed by the manufacturer but is
recommended by several industry guides (Subsection 4.4).
The need for periodic testing is supported by the overhaul data, where five of the seven
electro-mechanical OCTDs that were tested required adjustment. The long-time delay and
short-time delay trip functions should be tested during the routine maintenance period. If
the test current is greater than 20 times the breaker frame rating, testing of the
instantaneous setpoint is not recommended due to the excessive contact pitting that is
experienced at this high current. In these instances, the instantaneous trip function
should be bench tested during circuit breaker overhauls. A more frequent interval for
instantaneous trip testing is considered unnecessary due to the number of common
subcomponents the instantaneous trip function shares with the long-time delay and shorttime delay trip functions.
Operability of the OCTD on dc breakers can be verified using an ac low-voltage, highcurrent test machine and should be checked during the routine maintenance period. A dc
low-voltage, high-current machine can be used at overhaul to accurately test the current
setpoints and time delay on dc breaker OCTDs.
A visual inspection should also be accomplished on all electromechanical OCTDs to check
for missing hardware, dirt, and corrosion.
OC15-Solid-State. The degradation mechanisms associated with solid-state OCTDs are:
Failed or worn parts.
Out-of-adjustment.
Over 50% of the failures were due to failed parts which, like electromechanical OCTDs,
are best detected by periodic testing. There are two methods for testing solid-state
devices; primary and secondary injection. Primary injection tests the current sensors,
Amptector unit, and actuator by injecting current into the primary disconnects.
Secondary injection tests the Amptector unit and actuator by injecting a low-current
signal from a test device directly into the Amptector unit. Since secondary injection
bypasses the main current-carrying assembly, operability of the current sensors is never
checked.
Current sensors appear to be a reliable subcomponent as no NPRDS failures were
attributed to them. However, it is recommended that their operation be checked
periodically by primary injection. This could be accomplished by testing, by primary
testing injection, one trip function (long- or short-time delay) mid-cycle between overhauls,
and testing all trip functions during breaker overhaul.
A visual inspection for missing hardware, correct mounting, and loose connections should
also be performed during the routine maintenance period. The need for periodic testing of
4-6
solid-state OCTDs is supported by the overhaul data, which reported that all three of the
solid-state OCTDs tested required adjustment.
Undervoltage Trip (UV) Device. The degradation and failure mechanisms associated with
UV devices are:
Failed parts.
Failed coils.
Binding.
Inadequate lubrication.
Eighty-three percent of UV device failures were detected during routine maintenance or

testing. An aggressive routine maintenance program should be able to detect and prevent
degradation due to binding, wear, or inadequate lubrication. In fact, a large number of
NPRDS failures, due to UV device binding, were discovered during the testing performed
subsequent to NRC Generic Letter 83-28.
Failed coils accounted for 13% of the UV device failures, and failure of the entire UV
device accounted for 20% of the failures. It is suspected that the majority of the UV
device failures are actually coil failures. As stated previously, predicting coil or winding
failure is difficult. The UV coil is always energized, and thermal degradation is a
potential cause of failure. Replacing the UV coil at fixed intervals should be considered.
RTB testing and maintenance should be continued at their present time intervals. NonRTB testing of UV devices should be done at the routine maintenance period. The
inspection should include checking for poor/dirt-contaminated lubricant, tight connections
and parts, signs of overheating, and the physical condition of the coil insulation material.
Operation of the UV device should also be checked along with the pickup and dropout
points, armature overtravel, and any evidence of binding. The routine maintenance
interval is consistent with industry and manufacturer recommendations and sufficiently
accommodates the breaker average age at failure of 8.6 years.
Main Current-carrying Subcomponents. Main current-carrying subcomponents did not
experience a significant number of deficiencies. The degradation mechanisms identified
are:
Contact wear.
Contact pitting.
Dirt.
Out-of-adjustment.
4-7
Although some pitting is normal, severe burning and pitting can usually be attributed to
repetitive opening under load or an overcurrent condition. Identification and prevention
of all of these degradation mechanisms is accomplished by a periodic inspection and
checking contact adjustments. This includes a visual inspection of contact surface
condition, tightening loose hardware, measuring contact resistance, and checking contact
gap and sequence. Overhaul data support this, with four of the twelve overhauled circuit
breakers requiring adjustments to the main contacts.
The routine maintenance interval is suitable for main current-carrying subcomponents, as
the average breaker age for detecting the failure mechanisms was 8.9 years. These checks
are easy to accomplish.
Wiring. Wiring deficiencies were relatively few. The degradation mechanisms identified
are loose, damaged, or oxidized connections, and damaged wire. These conditions are
detectable by visually inspecting the connections and wiring, and by measuring the
control wiring insulation resistance. The breaker average age for wiring failures was 10.6
years.
Racking Mechanism. Failed, damaged, and worn parts were the degradation mechanisms
associated with racking mechanisms. These failures were detected 83% of the time by
routine maintenance or testing. Careful visual inspection and post-maintenance
operability testing should detect racking mechanism degradations since they usually occur
while the breaker is being racked in or out for maintenance.
Close Coil. Close coil deficiencies were relatively few. The degradation mechanisms
identified are coil failures, coil binding, and adjustment. Predicting coil failure (short or
open circuit) by trend analysis is difficult because these failures occur suddenly. A careful
visual inspection for cracked phenolic subcomponents, loose laminations, dirt, corrosion,
and evidence of overheating may help to identify an impending failure. The close coil
should also be checked during several closing cycles for smooth operation with no binding.
Shunt Trip. Shunt trip device deficiencies were relatively few. The degradation
mechanisms associated with shunt trip devices are coil failure, misalignment or loose
mounting, and out-of-adjustment. Coil failure does not appear to be a significant problem
with only three failures. Adjustments were required on two of the twelve (17%)
overhauled breakers and contributed to five NPRDS failure reports. During routine
maintenance, the shunt trip device should be inspected for correct operation, insulation
condition, solid mounting, and general cleanliness. These checks may help provide early
indication of coil failure. Armature clearance should also be checked to ensure a positive
tripping action. Periodic lubrication is recommended to prevent binding.
Arc Chutes. Cracked and chipped arc chutes occurred on two of the twelve overhauled
breakers and seven NPRDS failure reports. Damaged arc chutes rarely result in breaker
failure and detection is accomplished by visual inspection.
Insulation and Frame. Deficiencies with the circuit breaker frame and insulation occurred
very infrequently and are not significant. A visual inspection of these subcomponents
4-8
along with measuring the insulation resistance of primary insulating subcomponents

should be part of normal routine maintenance.
Circuit Breaker Overhauls. Periodically, circuit breakers should be overhauled to allow
for a complete disassembly, cleaning, inspection, and lubrication of the entire circuit
breaker. Complete disassembly is required to remove dried, hardened grease and
relubricate areas inaccessible during routine inspections. Overhauls also provide a
convenient opportunity for the replacement of high-failure-rate items.
The recommended overhaul period for Westinghouse DB circuit breakers is every eight to
twelve years. This is based on NPRDS data that indicate: 1) the average age for failures
due to dirt/contaminated lubricant is 11.5 years; and 2) most failures/degradations from
failed parts occur between ten and twelve years. This interval may be adjusted by a
utility after analyzing data gathered during circuit breaker maintenance, inspections, and
overhauls.
4.1.2 Condition-Based Scheduling

The recommended routine maintenance interval was based on NPRDS and overhaul data,
and assumes that the breakers are not located in harsh environments. If the circuit
breakers are subjected to extremes in temperature, humidity, or radiation, the
maintenance frequency may have to be increased.
Both the routine maintenance and overhaul periodicities should be adjusted based on the
results of actual inspections and maintenance. A history should be established for each
breaker. The history should document performance of routine maintenance, conditions
observed during inspections and maintenance, and test data identified in Subsection 3.4.
Analysis of this documentation may then be used to justify increasing or decreasing the
frequency of tests or inspections for the subject breaker.
This analysis should place special emphasis on the condition on the lubricant. As
discussed in Subsection 4.2.4, lubricant condition is very dependent on age and
environment. Assessing lubricant condition may provide an early indication of the need
for more frequent circuit breaker overhauls due to excessive dirt or temperature extremes.
Additionally, any time a circuit breaker opens due to an overcurrent condition, the
breaker should be inspected as soon as possible. This inspection should focus on the
current-carrying subcomponents, insulation, arc chutes, and control wiring, since these are
the likeliest areas of potential damage.
4.2
Subcomponent Replacement
4.2.1 Time-Based Replacement

Analysis of the failure data indicates that certain Westinghouse DB breaker
subcomponents are more susceptible to failure than others and may warrant replacement
4-9
at regular intervals. Replacement of these subcomponents prior to their failure will

improve breaker reliability. The following recommendations are made for time-based
subcomponent replacement. Time-based subcomponent replacement recommendations are
summarized in Table 4.2-1.
Table 4.2-1 Subcomponent Time-Based Replacement

Subcomponent
Replacement Period
UV Device (RTB)
Each overhaul (8-12 years) or 2500

operations
Shunt Trip (RTB)
Each overhaul (8-12 years) or 2500

operations
Operating Mechanism. Failed or worn parts constituted 35% of all operating mechanism
failures, at an average age of 15.4 years. Although this is a fairly high percentage, the
NPRDS data do not indicate a significantly higher failure rate for one operating
mechanism part over another. Both the latch mechanism and the operating mechanism
had four failure reports; a failure rate that does not warrant periodic replacement. Also,
circuit breaker cleaning and relubrication during periodic overhauls should reduce failures
from excessive wear. No operating mechanism subcomponents are recommended for timebased replacement.
Electrical Control Devices. Of the 43 failure reports attributed to electrical control
devices, only seven were due to part failures with no single subcomponent having a
significantly higher failure rate. This failure rate is insignificant when the total
population of DB breakers (greater than 700) is considered. Although coil and switch
failures are difficult to predict, time-based replacement is not recommended until failure
rates and maintenance inspections show an increasing degradation trend. Although
damage to secondary disconnects continues to be a problem, this should be detected and
corrected during routine maintenance.
UV Device. The manufacturer recommends the replacement of the UV device every 2500
operations in reactor trip breakers. Ninety-three percent of the NPRDS UV device failure
reports were for reactor trip breakers. Subcomponent failure, including coils and the
entire UV device, accounted for 60% of the failures at an average age of 9.8 years. This is
considered a high failure rate. The UV coils are continually energized and thus
susceptible to thermal aging. Due to the difficulty in predicting coil failure, the critical
function of the UV assembly, and the problems associated with binding in the latch
assembly, it is recommended that UV coils be replaced during reactor trip circuit breaker
overhaul.
OCTD-Solid-State. Although 45% of solid-state OCTD failures were from failed parts, the
total number of part failures was small (5). Although the number of solid-state units
subject to NPRDS reporting is unknown, it appears they are reliable and are not a
4-10
candidate for periodic replacement. Testing during routine maintenance appears to be the
appropriate maintenance strategy.
OCTD-Electro-Mechanical. Fourteen failure reports were due to worn or failed electromechanical OCTD units, with an average breaker age at failure of 13.5 years. Most of
these failures were attributed to subcomponent wear or inability to calibrate with no
specific parts having an exceptionally high failure rate. Testing during routine
maintenance is the most appropriate maintenance strategy because of this subcomponent's
low failure rate. However, consideration should be given to upgrading to a solid-state unit
since electro-mechanical devices and their parts are no longer supplied by the
manufacturer.
Racking Mechanism. Although there was a significant number of failure reports (17) for
racking mechanism degradation, these should be detectable during routine maintenance
and post-maintenance testing. Time-based replacement of racking mechanism
subcomponents is not recommended.
Main Current-Carrying Subcomponents. NPRDS and overhaul data indicate that the
main current-carrying subcomponents do not require periodic replacement. Routine
inspections of contact condition, alignment, sequence, and gap should be sufficient to
prevent excessive degradation.
Wiring. NPRDS and overhaul data did not reveal any significant degradation mechanism
that affects control wiring. Routine cleaning, inspection, and testing during routine
maintenance appears to be a satisfactory maintenance strategy.
Close Coil. With only three coil failures, the close coil appears to be a very reliable
subcomponent. Close coils are energized for brief periods during closing operations and
are not subjected to a severe service cycle. Fixed-time replacement is not considered
necessary.
Shunt Trip. The shunt trip device also appears to be a reliable subcomponent, reported as
the cause for only ten total failures, three from failed coils. However, the manufacturer
recommends that RTB shunt trip devices be replaced every 2500 operations since the
devices act as backups to the UV devices. Based upon this, it is recommended that the
shunt trip device be replaced during reactor trip breaker overhauls.
Arc Chutes and Insulation. Arc chutes and insulation (pole unit bases and insulating
links) are extremely reliable subcomponents, caused no circuit breaker failures, and
exhibited only minor chipping and cracking. Routine maintenance inspections are the
appropriate maintenance strategy, however, complete inspection of the pole unit bases
must be accomplished during overhaul because of the disassembly required.
4.2.2 Condition-Based Replacement

Replacement of subcomponents should also be accomplished based upon the results of
periodic inspections and tests to supplement the periodic replacement schedule. The
4-11
following is a discussion of condition-based replacement guidelines; they are summarized

in Table 4.2.2.
Table 4.2 2 Subcomponent Condition-Based Replacement

Subcomponent
Replacement Condition
Operating mechanism subcomponents
Excessive wear/binding
Switch/relay contacts
Excessive pitting
Control relay
Damaged coil insulation
Auxiliary switch contacts
Excessive pitting
Secondary disconnect
Cracked/damaged
UV device
OCTD
Fails calibration
Main and arcing contacts
Excessive patting, cracks m contact

surface
Wiring
Broken wires, damaged insulation
Close coil
Damaged coil insulation, armature

binding
Shunt trip device
Racking mechanism components
Excessive wear, damaged
Arc chutes
Excessive burning, damaged parts
Pole unit bases
Cracks, burning
Insulating links
Cracks
Operating Mechanism. Worn, damaged, and failed parts are a common operating
mechanism failure mode. Subcomponent degradation is accelerated by poor lubricant
condition. The failure data do not indicate a higher failure rate for one operating
mechanism part over another. Operating mechanism subcomponent replacements are
difficult due to the required disassembly, and are typically accomplished during overhaul
but not during routine maintenance. Trending adjustment and test data combined with
visual inspection may identify poor operation and defective parts.
Electrical Control Devices. Poor contact condition was the most common degradation
mechanism associated with electrical control devices. Degraded contacts can be identified
by routine maintenance inspections and resistance tests. Cleaning the contact surface is
normally all that is required to correct the degraded condition. Contacts are replaced
when they are excessively pitted or burned. The failure data did not show any discernible
4-12
failure trend with a specific subcomponent. The more common failed subcomponents were
the control relay and auxiliary switch. Coils and switches should be inspected during
routine maintenance and replaced any time they are damaged, show signs of overheating,
or have evidence of exterior damage, such as loose laminations or cracks. Secondary
disconnects were frequently damaged due to incorrect or excessive racking operations.
They should be replaced any time they appear loose, cracked, damaged, or bent
excessively.
UV Device Assembly. Subsection 4.2.1 addresses the fixed-time replacement for RTB UV
devices. As mentioned earlier, the UV coils are susceptible to thermal aging. Inspection
and electrical operation of the UV assembly should be included in routine maintenance.
The assembly should be replaced any time the coil is damaged, shows signs of overheating,
or displays evidence of exterior damage.
OCTO-Solid-State. Solid-state OCTD failures were typically identified during routine
maintenance calibration tests. The failures were within the solid-state unit and prevented
calibration of the affected units to the proper trip setting. Solid-state subcomponent drift
or failure is not predictable. Periodic testing and replacement when unable to calibrate
appears to be the best maintenance strategy for the solid-state OCTD.
OCTD-Electro-Mechanical. Most failures of electro-mechanical OCTDs were identified
during routine maintenance when the devices could not be calibrated to the proper
setpoint. This type of failure is difficult to predict unless maintenance records suggest a
history of setpoint drift. Continued periodic testing and replacement, or upgrade to a
solid-state unit when it fails calibration, appear to be the best maintenance strategies.
Main Current-Carrying Subcomponents. Contact wear, pitting, and dirt were the most
common degradation mechanisms associated with main current-carrying subcomponents.
Measurement of contact gap, sequence, and alignment during periodic inspections should
be sufficient to detect normal and accelerated wear. Contacts should be replaced when
they exhibit excessive pitting or the proper adjustment cannot be achieved.
Wiring. The failure data did not reveal any significant degradation mechanism that
affects control wining. Typical deficiencies were broken or loose connections, and damaged
insulation. These are detectable during routine maintenance inspections.
Close Coil. Close coils have a low failure rate with coil binding and coil failure being the
predominant degradation mechanisms. They are energized for brief periods during closing
operations and are not subjected to a severe service duty. Inspection and operation should
be included m routine maintenance. The coil should be replaced any time it is damaged,
shows signs of overheating, or displays evidence of exterior damage or binding.
Shunt Trip. Subsection 4.2.1 addresses the fixed-time interval replacement for reactor trip
breaker shunt trip devices. Although the shunt trip device has a low failure rate, its
critical function m RTBs, as a backup to the UV device, warrants periodic replacement.
Inspection and operation should be included in routine maintenance. The device should be
4-13
replaced any time it is damaged, shows signs of overheating, or has evidence of exterior
damage, such as wear or cracks.
Racking Mechanism. Damage to various parts of the interlock and roller assembly
occurred from incorrect or excessive racking operations. These are detectable by routine
maintenance.
Arc Chutes and Insulation. Arc chutes and insulation have a low failure rate. Typical
failures were damaged or broken parts, which can be detected by routine maintenance
inspections. Replacement of arc chutes, pole unit bases, and insulating links should be
accomplished if any burning, cracks, or damage is detected.
4.2.3 Subcomponent Upgrades

Although failed or worn parts contributed to 37% of the failure reports, the failure
analysis did not identify any subcomponent with a significantly high failure rate to
warrant subcomponent upgrade.
Operating mechanisms suffered a significant number of failures due to worn or failed
parts (15 failures, 35%) but the source was fairly evenly spread among the mechanism
subcomponents. Also, fifteen failures out of the total population of safety-related DB
circuit breakers does not warrant an upgrade of the operating mechanism.
The UV device also experienced a significant number of failed or worn parts. Mechanical
part failures and binding problems appear to have been corrected through increased
inspection, cleaning, and lubrication requirements. Four failures were due to failed coils,
at a breaker average age at failure of 10.25 years, although it is suspected that the
number of failures may be as high as ten. Upgrading the UV coil to improve its
resistance to thermal aging may improve the reliability of the UV device, however, it may
be difficult to significantly improve a subcomponent with such a low failure rate at an
average breaker age at failure in excess of ten years.
Worn or failed parts were the predominant degradation modes for both electro-mechanical
and solid-state OCTDs. Since the relative populations of each type of device could not be
determined from NPRDS, reliability comparisons would be difficult. However, since
electro-mechanical devices and parts are no longer supplied by the manufacturer and
eleven failures were due to worn or failed parts, upgrading to solid-state devices should be
considered based on parts unavailability.
4.2.4 Lubrication
Section 3 identified dirt and inadequate lubrication in the operating mechanism and UV
device as one of the major degradation mechanisms affecting Westinghouse DB breakers.
Although failed or worn parts constitute a greater percentage of failures, dirt/lubrication
deficiencies are detectable and preventable through routine maintenance. Failed or worn
parts are difficult to detect and prevention normally consists of periodic replacement.
Also, dirt/lubrication problems contribute to accelerated subcomponent wear.
4-14
Early Westinghouse DB instruction manuals recommended the use of a lubricant

composed of molybdenum disulfide mixed with oil (Westinghouse M8577-U).
For DB-15/25 breakers, the instruction manual recommended lubricating the operating
mechanism latch-plate felt and roller, and oiling pins and slides in the closing spring
assembly every 10,000 operations. For a breaker operated 200 times a year, that means
lubricating it once every fifty years. The instruction manual for DB-50 breakers also
recommended oiling pins and slides m the closing spring assembly every 10,000
operations. There were no recommended lubrication points in the original DB-75/100
instruction manual since the operating mechanism was "factory lubricated for the life of
the breaker." Periodic lubricatior was discouraged because the addition of oil would
promote the accumulation of dust and dirt. Overhaul and NPRDS data indicate that
lubrication at these intervals would be inadequate.
The Westinghouse maintenance program manual for DB-50 RTBs provides detailed
cleaning and lubrication procedures with a recommended periodicity of every 18 months or
200 breaker operations (whichever occurs first). The recommended lubricant for the
operating mechanism, shunt trip device, and UV device is a mixture of molybdenum
disulfide and isopropyl alcohol (Westinghouse 53701GW).
The maintenance program manual recommends the following lubrication points for the
UV device:
1.
Between the latch and latch spring.
2.
The pin running through the trip spring.
3.
The latch pivot pin.
4.
The latch loop to latch-guide pin.
5.
The latch to the notched latch pin.
The lubricant should be applied to all metal-to-metal contact surfaces with the above
items. The UV device may remain installed during lubrication and should be exercised
manually during lubricant application.
The lubrication point for the shunt trip device is the linkage pin of the trip lever bracket.
The lubrication points for the operating mechanism are:
1.
Latch faces and latch mechanism.
2.
Trigger faces.
3.
Trip pan felt pad.
4-15
4.
All pins, linkage, and bearing points.
5.
Trip bar bearing/friction points.
6.
Inertia latch pivot pin.
These points are accessible without extensive disassembly of the breaker. After
lubrication, the breaker should be exercised manually four or five times. The shunt trip
device is lubricated by applying lubricant to the linkage pin on the inside and outside
mechanism surfaces.
The maintenance program manual also recommends applying a light coat of graphite
grease (Westinghouse 53701ANOOT) to auxiliary switch contacts and the auxiliary
contact hinge if these contacts are cleaned and the existing grease is removed.
The periodicity for lubrication of RTBs should be consistent with the manufacturer's
recommendations and the individual utility's experience.
The lubrication points for non-RTBs should be the same as RTBs, but the frequency may
be extended since their cycling frequency is much lower. At the midway point between
circuit breaker overhauls (4-6 years), non-RTBs should be lubricated as discussed above.
Cleaning should be limited to removal of accumulated dirt and gummy deposits. During
overhaul (8-12 years), the circuit breaker should be completely disassembled, cleaned, and
all moving parts and friction points in the operating mechanism should be lubricated in
addition to those mentioned above.
4.3
Personnel Qualification and Training
The training and qualification program a utility establishes for circuit breaker
maintenance personnel should depend on the type of maintenance to be performed. For
example, if the utility does not intend to perform its own circuit breaker overhauls, then
its training and qualification program need not include those complicated tasks.
Regardless of the program content, maintenance personnel should thoroughly understand
the basics of circuit breaker design and operation. One possible source for this training is
courses offered by breaker manufacturers and other industry organizations. These courses
are usually approximately two to five days and provide hands-on training m breaker
maintenance and overhaul. In many cases, arrangements can be made to have the course
taught on site.
Maintenance personnel qualification should be tailored to a specific type of breaker and
task. Task qualification may be divided into two groups; routine maintenance and circuit
breaker repair/overhaul. Qualification criteria for routine maintenance technicians should
include one year of basic electrical theory classroom training, two years of hands-on
experience in assisting during circuit breaker routine maintenance activities, a thorough
understanding of circuit breaker theory and operation, and training with the appropriate
4-16
vendor maintenance manuals. Qualifications similar to a Level I Quality Assurance

Inspector, as defined in ANSI N 45-2.6, are recommended.
Personnel qualified to perform circuit breaker repairs and overhaul (i.e., circuit breaker
technicians) should have two years of experience as a qualified routine maintenance
technician along with two years of experience assisting in circuit breaker repairs and
overhauls. A thorough understanding of troubleshooting techniques and procedures, and
of advanced circuit breaker theory should be demonstrated. Since circuit breaker
technicians will be tasked with evaluating test results and troubleshooting, qualifications
similar to a Level II Quality Assurance Inspector are recommended.
Qualification proficiency should also be kept current. This can be accomplished by
requiring routine maintenance technicians to perform breaker routine maintenance every
18 months. Likewise, circuit breaker technicians should be required to overhaul at least
one circuit breaker every 18 months to keep their proficiency current. As with the initial
qualification process, maintaining proficiency should be tailored to a specific type of circuit
breaker.
A continuing training program should be established for personnel to maintain
proficiency, especially when different types of breakers are involved. This training should
emphasize troubleshooting procedures, failure analysis, breaker operation, and reviews of
routine maintenance and overhaul procedures. Periodic written exams should be given
annually to document continuing proficiency.
4.4 Industry and Manufacturer Recommendations

Table 4.4.1 lists circuit breaker maintenance and test activities recommended by
Westinghouse and industry standards. Production tests listed m ANSI C37.50-1981 are
included in Table 4.4.1 to show production tests on new circuit breakers. The original DB
instruction manuals suggested a semi-annual inspection, but did not list any specific
inspection requirements. The maintenance program manual for DB-50 RTBs has specific
requirements for the recommended inspection at 18-month intervals. The RTB
maintenance manual requirements are included in Table 4.4.1 for comparison with
industry standards.
4-17

TABLE 4.4-1 INDUSTRY AND MANUFACTURER MAINTENANCE RECOMMENDATIONS
4-19
TABLE 4.4-1 INDUSTRY AND MANUFACTURER MAINTENANCE RECOMMENDATIONS

(continued)
4-21
Section 5.0
5.1
Precautions ........................................................................................... 5-1
5.2
Tools and Test Equipment .................................................................. 5-2
5.3

and Adjustments................................................................................... 5-5
5.4
5.5

and Adjustments................................................................................. 5-75
5.6
5.0
This section contains the routine maintenance guidelines and the overhaul guidelines to
maintain Westinghouse Type DB low-voltage circuit breakers. The guidelines include
performance and adjustment checks, tests, and measurements. The guidelines also include
lists for recording data to document circuit breaker condition so that corrections may be
made to improve reliability. As-found maintenance records provide valuable historical
data which aid in the refinement of the maintenance program and the understanding of
circuit breaker degradation mechanisms.
The maintenance program requires experienced, qualified personnel (Subsection 4.3),
proper tools and test equipment (Subsection 5.2), and sufficient renewal parts (Section 6).
The routine maintenance and overhaul guidelines have been developed in a step-by-step
sequence. They are presented separately for the DB-15/25 and DB-50/75 models because of
the differences between these breaker types. It is intended that each plant review these
guidelines and incorporate applicable steps into its circuit breaker maintenance and
overhaul procedures in accordance with its procedure approval policy.
5.1
Precautions
Personnel involved in circuit breaker maintenance should be aware of the potential

dangers involved. Only qualified, experienced personnel should attempt to operate or
maintain circuit breakers and the associated equipment.
5.1.1
Ensure that hands, tools, test leads, and other objects are moved away from
moving breaker parts prior to energizing the breaker control circuits.
5.1.2
When working on a breaker with the arc chutes removed, keep hands and
tools clear of the moving parts of the breaker. Severe injury or breaker
damage may result from objects left in the breaker.
5.1.3
Always be aware of the location of energized circuits, in the switchgear

cubicle and on the circuit breaker, to avoid electrical shock.
5.1.4
Do not lift a breaker by hand. Circuit breakers are heavy and awkward.
Dropping the breaker can cause personal injury and/or damage to the circuit
breaker.
5.1.5
Do not insert a breaker into its cubicle without the arc chutes being
installed.
5-1
5.2
Tools and Test Equipment
The following special tools and test equipment are required to perform the maintenance
activities described in this guide.
5.2.1
Suitable lifting equipment for safely handling circuit breakers. Some

breaker models may weigh as much as five-hundred pounds.
5.2.2
The levering handle and drawout rails or platform,supplied with the

switchgear, for proper removal of circuit breakers from switchgear cubicles.
5.2.3
A flat dolly with casters, roll cart, or other suitable means to transport
circuit breakers to the work area.
5.2.4
A portable power supply which provides an adjustable dc and dc voltage,

with a 0-440V range and current rating as required by the breaker control
components.
5.2.5
A voltmeter to measure voltage in the breaker control circuits, and to

measure millivolt drop across main contacts. A Fluke 25 Multimeter is a
suitable meter for this application.
5.2.6
A dc insulation resistance tester (Megger), with a 0-500Vdc range and a

0-1000Vdc range for measuring insulation resistance of control wiring and
primary circuits, respectively. A Biddle Megger model 210159 is a suitable
meter for this application.
5.2.7
An ohmmeter or multi-meter with 0.1W accuracy to measure switch and coil

resistances, and to verify continuity. A Fluke 25 Multimeter is a suitable
meter for this application.
5.2.8
A low-voltage, high-current, overcurrent trip device test set with an

automatic timer and a current range appropriate to allow testing of all
overcurrent trip device elements by primary injection. A Multi-Amp model
CB-8160 test set is suitable for this application for dc breakers. A MultiAmp model CB-120-DC is suitable for dc breakers.
5.2.9
An Amptector Trip Unit Test Kit, Westinghouse style number 140D481, is

suitable for testing Amptector overcurrent trip devices by secondary
injection.
5.2.10
Approved lubricant for lubricating the breaker operating mechanism and

primary and secondary disconnect contacts, as directed in the maintenance
guidelines.
5-2
5.2.11
A plant-approved electrical solvent or isopropyl alcohol, and a mild,

ammonia-based glass cleaner for cleaning insulated surfaces.
5.2.12
A plant-approved degreasing solvent, such as Varsol , for removing dirt and

grease from disassembled breaker subcomponents during overhaul.
5.2.13
Standard mechanic's tools, including socket wrenches, combination

wrenches, pliers, screwdrivers, feeler gauges, rulers, scales, go/no-go gauges,
etc.
5.2.14
Clean, lint-free rags.
5.2.15
A spring-force scale with a 50-oz. range for measuring the force to lift/rotate
the trip bar/shaft. A Chatillon model DPP-10 push/pull gauge is suitable for
this application.
5-3
THIS PAGE INTENTIONALLY LEFT BLANK
5-4
Section 5.3
DB-15/25 Routine Maintenance

Inspections, Tests, and Adjustments
5.3
DB-15/25 Routine Maintenance Inspections,

Tests, and Adjustments ....................................................................... 5-5
5.3.1 General Inspection ...................................................................... 5-5
5.3.2 Mechanical/Electrical Operation .................................................. 5-6
5.3.3 Contact Inspection and Adjustment ............................................. 5-6
5.3.4 Operating Mechanism Inspection ................................................ 5-7
Major Subcomponents ................................................................. 5-8
5.3
DB-15/25 Routine Maintenance Inspections, Tests, and

Adjustments
5.3.1 General Inspection

1.
Verify smooth drawout operation during breaker removal.
2.
Remove the circuit breaker from its cubicle.
3.
Verify the function of the following drawout device interlocks after

removing the breaker from its cubicle:
1.
Drawout interlock: For all drawout breakers, verify that the breaker
drawout mechanism cannot be operated from the CONNECT position
with the breaker contacts closed.
With the circuit breaker closed, simulate operation of the drawout
device from the CONNECT position toward the TEST position by
lifting up the breaker positioning lever. Verify that the breaker trips.
An interlock lever extends out of the left side of the breaker, and acts
on the trip bar. When the breaker is levered out, this lever strikes a
bracket in the breaker cubicle and trips the breaker.
2.
Trip-free interlock: Verify that the breaker cannot be closed while

placed between the CONNECT and TEST positions.
The breaker positioning lever on the left side of the breaker engages
the cell positioning stop bracket in the switchgear to maintain the
breaker in a trip-free state when not in the TEST or CONNECT
position. Simulate the stop bracket by holding the positioning lever
up. With the breaker opened, attempt to close the breaker and verify
that the breaker does not close.
4.
Switchgear cubicle:
WARNING: Portions of the switchgear may be energized.

1.
Inspect the general condition of the switchgear cubicle and door.

Inspect for corrosion and bent or damaged components.
2.
Clean the air filters, if present.
3.
Clean the cubicle interior.
4.
Lubricate the door with an approved grease.

5-5
5.
Inspect the general appearance of the breaker (e.g., dirt burns; broken, bent,
or missing parts; corrosion).
6.
Remove the arc chutes by removing the Amptector unit (if installed) and
then the two arc chute retaining screws, and lifting out the arc chutes.
7.
Inspect the primary insulation/pole unit bases for dirt, moisture, carbon
tracks, and cracks.
5.3.2 Mechanical/Electrical Operation

1.
Close and open the breaker manually, three times, and verify that the
breaker operates freely without binding or tripping free.
NOTE:
On breakers equipped with an undervoltage trip (UV) device or an

electric lockout device, the devices will hold the breaker in a
trip-free condition unless energized or mechanically defeated.
The UV and electrical lockout devices are energized by applying rated

voltage to the secondary disconnects that are connected to the applicable
device coil leads. See the breaker control wiring diagram for connection
points. Device voltage rating is indicated on the device label plate. If a
voltage source is not available, the device may be restrained by tying the
armature in the energized position using a tie-wire or a nylon cable tie.
2.
Verify operation of the breaker indicators and the breaker operation

counter. The counter should advance once for each close-trip cycle.
3.
Verify that the breaker closes and trips electrically. Look for sluggishness,
binding, smoking, or arcing of electrical control devices.
5.3.3 Contact Inspection and Adjustment

1.
Contact inspection: Inspect the breaker contacts for hairline cracks, pitting
roughness, galling, or discoloration which may have resulted from
overheating.
NOTE:
2.
Contact gap:
1.
5-6
Evidence of serious overheating, such as discoloration of metal

and surrounding insulation, requires corrective action and,
possibly, replacement of contacts.
Contact pressure is verified by measuring and/or adjusting the

contact gap with the breaker closed.
2.
On DB-15 breakers, contacts are adjusted to obtain a 3/32" to 1/8"

gap between the contact armature plate and the contact steel pivot
link.
Contact Gap Specification:
3.
3/32"-1/8"
(0.094"-0.125")
Arcing contacts on the DB-25 are opened when the breaker is

completely closed. For these breakers, the gap between the
stationary and moving arcing contacts should be approximately 3/32"
with the breaker closed.
Contact Gap Specification: 6/64"-7/64" (0.094"- 0 .109)"
3.
Check contact overadjustment with the breaker closed by manually pulling

the moving main contact arm away from the stationary contact. This gap
should be at least 1/64".
Overadjustment Specification: 1/64" (0.016")
CAUTION:
Do not overadjust as this will cause the contact springs to compress

to the solid position, increasing the closing force.
4.
If necessary, the contact gap and overadjustment may be adjusted by

removing the crossbar, loosening the lock nut, and screwing the insulating
link in or out on the stud connected to the moving contact arm. Be sure to
tighten the lock nuts after each adjustment.
5.
Wipe contact assemblies with a clean cloth and isopropyl alcohol. Clean
contact surfaces with a mild abrasive such as Scotch-Brite .
5.3.4 Operating Mechanism Inspection

1.
Remove the top cover on the operating mechanism to allow visual access to
the mechanism.
2.
Inspect the operating mechanism for loose or broken parts.
3.
Inspect the mechanism for missing or loose retainers, snap-rings, or bearing

retainers.
4.
Inspect for binding or excessive wear of the mechanism's mating surfaces.
5.
Inspect latch and roller surfaces for wear.
5-7
6.
Inspect the operating mechanism components for excessive dirt buildup and
corrosion.
7.
Inspect the lubrication for dirt contamination and dryness.
8.
Cycle the trip bar by hand. Check for freedom of movement, binding, or
sluggish operation.
9.
Tripping load: Determine the force required to lift the trip bar and trip the
breaker by performing the following:
WARNING: Breaker contacts open at high speed. To prevent injury or
equipment damage, ensure that hands and test equipment remain
clear of moving breaker parts.
1.
Close the breaker. Using a spring scale with a 0-50 ounce range, pull
or push up vertically on the trip bar, about 3/4" from its right end,
until the breaker trips.
NOTE:
The spring scale should be held as perpendicular to the trip

bar as possible.
Trip Load Specification: 38 oz.
10.
2.
Investigate the cause of the high force if the trip load exceeds 38
ounces.
3.
If not already marked, mark the location on the trip bar where the
trip load measurement was made.
Wipe accessible areas with a clean cloth and solvent such as isopropyl
alcohol.
5.3.5 Cleaning, Inspection, and Adjustment of Major Subcomponents

Loose dust and dirt should be removed from external surfaces using a vacuum
cleaner or low-pressure compressed air. Care should be taken to not blow dirt or
foreign objects into the mechanism area. When wiping or brushing is required, a
dry, lint-free cloth or bristle brush should be used. On gummy areas, an approved
solvent such as isopropyl alcohol should be applied to the cloth. The recommended
lubricant used on the operating mechanism, the UV device, and the shunt trip
device is a mixture of isopropyl alcohol and molybdenum disulfide. When the
alcohol evaporates, the molybdenum disulfide is left behind as a powdery film.
5-8
NOTE:
Care should be taken to not confuse the molybdenum disulfide for dust
and dirt, and mistakenly remove it during cleaning.
Inspect the components for cracks, wear damage, burning, and discoloration
associated with excessive heat.
1.
Frame assemblies: Inspect the frames for corrosion, bends, and cracked or
unfused welds.
2.
Pole unit bases:
3.
1.
Wipe accessible areas with a clean cloth and a mild, ammonia-based

glass cleaner.
2.
Inspect for cracks, burns, carbon tracks, warping, and signs of

overheating, especially around the upper and lower stud penetrations.
Arc chutes:
1.
Inspect for broken or cracked ceramic or asbestos components, dirt

and carbon deposits m the interrupter, and erosion of the splitter
plates and barriers.
Arc chutes with 40% of their original wall thickness eroded should be
replaced.
WARNING:
2.
Do not sand asbestos arc chute material. The resulting

dust is hazardous. If the material of construction for the
arc chute is unknown, do not sand.
Remove arc products from the inside of the arc chute using a cloth or
fine-grained sandpaper. Do not use a wire brush or emery cloth, as
these may embed conductive materials m the insulation.
WARNING:
Do not use compressed air on asbestos arc chutes, as

hazardous asbestos material may become airborne.
3.
Blow out the internals of non-asbestos arc chutes with clean, dry air
directed upward from the runners and out the splitter plates.
4.
Wipe the outside of each arc chute with a clean cloth and a mild,
ammonia-based glass cleaner.
5-9
4.
5.
6.
Current-limiting fuses:
1.
Check that the fuse is the proper type and size.
2.
Check for tight connections, and wipe the outside of the fuse with a
lint-free cloth. Remove any conductive deposits using an approved
electrical solvent.
3.
Check the continuity of the fuse.
Closing solenoid:
1.
Inspect the coil and leads for signs of overheating or cracked

insulation.
2.
Clean the coil with a clean cloth and alcohol, or an approved solvent.
Control relay:
Inspect for freedom of operation and insulation condition. Clean the
coil and assemblies using an approved electrical solvent. Loosen the
front cover of the relay for better access to the contacts.
7.
5-10
2.
Inspect the coil for signs of overheating. Inspect plastic components

for cracks.
3.
Verify that all moving parts operate freely. Inspect for physical
distortions and warping of the plunger core.
4.
Inspect the contacts for burning and pitting. Measure the contact
resistance. Investigate the cause of any resistance readings which
exceed 0.1W.
5.
Clean the contacts with Scotch-Brite or equivalent, mildly abrasive

material.
Undervoltage trip device:

1.
Inspect the device for correct operation, insulation condition, tight

connections, and signs of overheating.
2.
Check the device for loose hardware, proper mounting, and freedom
of movement.
3.
UV device clearance: The trip lever of the UV device should have

approximately 1/16" clearance to the trip bar.
Energize the UV device and slow close the breaker. When the
breaker is fully closed, measure the gap between the UV device trip
lever and the trip bar.
Specification: ~1/16" (0.063")
WARNING:
4.
Keep hands and tools away from all moving parts.
Verify UV device overtravel. Open the breaker manually and deenergize the UV device. Restrain the reset lever and close the
breaker manually. Slowly release the reset lever. The circuit
breaker should trip before the reset lever comes to rest.
Observe the UV device and trip mechanism for any signs of
sluggishness, binding, or hesitation. Cleaning, relubrication, or
replacement may be necessary to correct binding during this
operation.
8.
9.
10.
Fuse trip device:

1.
Inspect the device for correct operation, insulation condition, and

tight connections.
2.
Fuse trip device adjustments: Insert a 1/8" feeler gauge between the
fuse trip lever and the micarta lever. The breaker should close and
latch. When a 3/16" feeler gauge is inserted, the breaker should trip.
If necessary, adjust the trip screw attached to the fuse trip linkage.
Primary disconnects:
1.
Inspect the primary disconnects for signs of overheating, improper

wear, and broken or weak springs.
2.
Clean the disconnects with a clean cloth and a mild solvent such as
isopropyl alcohol.
3.
Apply a conductive, anti-oxidizing lubricant to the contact surfaces

just prior to installing the breaker m the switchgear.
Wiring and connections:

1.
Inspect the insulation condition and verify connections are tight.

Inspect for broken lugs, and broken or frayed wires.
2.
Replace damaged lugs or wires.
5-11
3.
11.
12.
Verify that wires are tied properly, secured, and routed away from
moving parts.
Auxiliary switch:
1.
Inspect for smooth operation. Inspect the plastic housing for cracks.
2.
Measure the resistance of all contacts. Clean the contacts and

investigate the cause of any contact resistance greater than 0.1.
Apply a light coat of graphite grease to any switch contacts removed
during contact cleaning.
Secondary disconnects:
1.
Inspect the secondary disconnects for correct operation, insulation

condition, and tight connections.
2.
Verify that all secondary disconnect contacts spring freely without

binding. Verify that the clearance between the contact hook and the
back of the disconnect molding is 0.015".
Specification: 0.015"
13.
3.
Clean the disconnects with a clean cloth and an approved solvent

such as isopropyl alcohol. Inspect plastic insulation for cracks or
damage, particularly at mounting holes.
4.

just prior to installing the breaker in the switchgear.
Shunt trip device:

1.
Inspect for correct operation, freedom of operation, insulation

condition, tight connections, and solid mounting.
2.
Restrain the UV device and close the breaker manually.
3.
With the hunt trip device de-energized, measure the clearance

between the trip bar and the trip lever of the shunt trip device.
Specification: ~1/16" (0.063")
14.
Bell alarm attachment:

1.
5-12
Inspect for correct operation, insulation condition, tight connections,

and solid mounting.
15.
2.
Verify that if the breaker is tripped by any means other than the
manual trip button or shunt trip (i.e., overcurrent trip, undervoltage
trap, etc.), the bell alarm is activated. Activation of the device is
verified by the normally opened switches changing state.
3.
Reset the bell alarm by operating the manual trip button or shunt
trip device. Manually close the breaker and trip it by means of the
trip button. Verify that the bell alarm does not activate.
Electric lockout device:

1.

and solid mounting.
2.
With the lockout device de-energized, attempt to close the breaker.

The lockout device lifting bracket should prevent the breaker from
closing by holding the trip bar in the trip-free position. Pushing
down on the lifting plate should permit the breaker to close. When
the lifting plate is released, the breaker should remain closed. Verify
that the lifting plate is not touching the trip bar when the breaker is
closed.
3.
Energize the lockout coil. The clearance between the bottom of the
trip bar and the lifting bracket should be between 1/32" and 1/16".
The lifting bracket can be moved to obtain this clearance by turning
the adjusting screw.
Lifting Bracket Clearance: 1/32"-1/16"
(0.031"-0.063")
16.
Reverse current trip attachment:

1.

and solid mounting.
2.
C lose the breaker manually. Check that the breaker will trip when
the spring stud--which attaches the spring to the bottom of the
armature--is pushed.
3.
Armature overtravel: Insert a 1/32" feeler gauge in front of the

armature. Verify that the breaker trips when the spring stud is
pushed.
Overtravel Specification:
1/32" (0.031")
6-13
17.
Breaker positioning lever: Inspect the lever for correct operation and
freedom of movement. It should not be bent or damaged, and the stop pin at
the end of the lever should be intact
18.
Subcomponent lubrication:
NOTE:
The following components should be lubricated approximately

every Six years.
1.
Operating mechanism: Lubricate accessible areas of the following

locations in the operating mechanism using a mixture of
molybdenum disulfide and isopropyl alcohol (Westinghouse 53701GW
or equivalent). Use a hypodermic syringe to apply the lubricant in
areas with close tolerances.
2.
Latch faces and latch mechanism;
Trigger faces;
Trip pan felt pad;
All pins, linkage, and bearing points; and
Trip bar bearing/friction points.
UV device:
See Figure 5.3-1. Lubricate the following locations on the UV device
using a mixture of molybdenum disulfide and isopropyl alcohol
(Westinghouse 53701GW or equivalent):
3.
Between the latch and latch spring;
The pin running through the trip spring
The latch pivot pin;
The latch loop to latch-guide pin; and
Shunt trip device:
5-14
Linkage pin on the trip lever bracket.
Figure 5.3.1
W Device Lubrication Points
5-15
5.3.6 Electrical Tests

NOTE:
1.
Refer to the appropriate plant wiring diagrams to identify the secondary

disconnect terminals where the breaker electrical control devices may be
energized.
Primary circuit insulation resistance: Measure the insulation resistance of
the primary circuits at 1,000Vdc.
Line-to-Load (Breaker opened)
Phase-to-Ground (Breaker closed)
Phase-to-Phase (Breaker closed)
Specification: 100 M
CAUTION:
2.
Do not megger the wiring of the solid-state trip unit.
Wiring insulation resistance: Measure the insulation resistance of the

control wiring to ground at 500Vdc.
3.
Contact resistance: Measure the contact resistance of each phase. Contact

resistance may be measured directly using a micro-ohmmeter. Contact
resistance also may be determined by injecting 200A through the primary
circuit and measuring the millivolt drop across the contacts. Dividing the
voltage drop by the current will yield the contact resistance.
Specification: 1 5 0
NOTE:
4.
Undervoltage pickup and dropout: Energize the UV device with an

appropriate variable voltage applied to the secondary disconnects, and close
NOTE:
5-16
This test may be accomplished concurrent with overcurrent trip

device testing.
Energize the UV coil for approximately 10 minutes prior to

testing to allow the coil to reach thermal equilibrium.
1.
Slowly reduce voltage to the UV device until the breaker trips.

Specification: 30%-60% of rated voltage.
2.
Slowly increase voltage to the UV device until the UV device picks

up and fully closes. Verify that the breaker can be closed.
Specification: 85% of rated voltage.
5.
6.
Control circuit: Use a variable-voltage power supply to conduct this test at

the minimum and maximum rated voltages.
1.
Connect appropriate temporary control power to the breaker closing

circuit at the secondary disconnects.
2.
Close the breaker electrically by energizing the closing circuit

through the temporary control power.
3.
While continuing to apply a closing signal, trip the breaker by

pressing and releasing the mechanical trip button. The breaker
should trip and not close.
4.
Release and re-apply the closing signal. The circuit breaker should
close.
Shunt trip device:

1.
Connect temporary control power to the breaker shunt trip device

circuits at the secondary disconnects, and close the breaker.
2.
Energize the shunt trip device and verify that the breaker trips.
5.3.7 Overcurrent Trip Device Operation

CAUTION:
DBL breakers are equipped with current-limiting fuses. Remove the

fuses and install a test bus bar prior to conducting overcurrent tests to
avoid destroying the fuse.
1.
Remove the current-limiting fuses and install a test bus bar in their place.
2.
Electro-mechanical overcurrent trip devices: Electro-mechanical series

OCTDs should be tested for proper operation within the time specified by
the manufacturer's time-current characteristic trip curves for the device.
1.
Positive trip check: C lose the breaker. Insert a 1/16" diameter rod
into the long-time delay calibration deft) slot and raise the time delay
5-17
valve lever to remove all of the time delay. Insert another 1/16" rod
into the top slot of the OCTD nameplate and push the armature
against the yoke to trip the breaker.
If the breaker does not trip, adjust the trip nut at the top of the
device. When positive tripping is achieved, turn the trip nut
upwards an additional 3/4-turn to ensure proper overtravel.
2.
Perform overcurrent trip test by primary current injection: Test each

electromechanical trip element as described below and verify that
the circuit breaker trips within the limits specified by the applicable
time-current characteristic curve. The applicable time-current
characteristic curve is determined by the device nameplate
information, type, current rating, and curve number.
Perform tests with a calibrated high-current, low-voltage test set.
Accomplish tests on individual phases.
1.
Long-time delay element test: Close the breaker and apply

current to the phase under test.
Adjust the current to the desired value (300% of series coil
rating is recommended for the long-time delay test) and shut
off the test set.
Allow the OCTD to reset 30-60 seconds. Apply the test
current until the breaker trips or 300 seconds have elapsed.
Compare the trip time measured with the manufacturer's
time-current characteristic trip curve.
2.
Short-time delay element test: Close the breaker and apply

overcurrent momentarily. (Approximately 110%-150% of the
short-time pickup setting is the recommended test current.)
Note the test current value.
Adjust the current, if necessary, toward the desired value and
repeat until the desired test current is achieved.
Apply the test current until the breaker trips or five seconds
have elapsed.
5-18
3.
Instantaneous element test:

CAUTION:
Test currents greater than 20 times the breaker

continuous-current frame rating will pit the
contacts. Testing the instantaneous function by
direct injection at greater than 20 times the
breaker frame rating is not recommended.
In cases where the instantaneous setting is less than 20 times

the breaker continuous-current rating, test the instantaneous
trip element as follows.
Close the breaker and adjust the test current to approximately
110%-120% of the instantaneous trip setting.
Apply the test current until the breaker trips or one second
has elapsed.
Compare the trip time measured to the manufacturer's timecurrent characteristic trip curve.
3.
Electromechanical OCTD adjustments: The OCTD time delays and

pickup currents may be adjusted by turning the adjustment knobs at
the bottom of the device.
1.
The long-time delay is adjusted by turning the left knob at the

bottom of the device. Turning the knob clockwise increases
the delay, counterclockwise decreases the delay.
2.
Long-time pickup current is adjusted by turning the knob

located under the long-time pickup scale. Turning the knob
clockwise increases the pickup setting, counterclockwise
decreases the setting.
3.
The short-time delay is adjusted by turning the adjustment

knob under the short-time delay scale. Turning the knob
clockwise increases the delay, counterclockwise decreases the
delay.
4.
Short-time pickup current is adjusted by turning the

adjustment knob located under the short delay pickup scale.
Turning the knob clockwise increases the pickup setting,
counterclockwise decreases the setting.
5.
The instantaneous pickup setting is adjusted by turning the

right adjustment knob at the bottom of the device. Turning
5-19
the knob clockwise increases the pickup setting,

6.
3.
Retest OCTD trip elements that have been adjusted.
Solid-state overcurrent trip devices:

1.
Verify proper solid-state programmer device settings for the breaker

application.
2.
Verify that all OCTD wiring is properly connected and m good

condition.
3.
Inspect current transformers for cracked insulation and proper

connections, tap settings, and solid mounting.
4.
Check that the OCTD actuator is mounted solidly, operates freely,

and provides sufficient overtravel to trip the circuit breaker.
5.
With the breaker closed, verify that the clearance between the trip
bar and the actuator trip lever is between 1/32" and 1/8".
Specification: 1/32"-1/8" (0.031"-0.125")
6.
Perform overcurrent trip test by primary current injection:

NOTE:
On breakers with ground-fault trip features, it will be

necessary to defeat the ground-fault element prior to
testing the other trip features of the device.
To defeat the ground-fault feature of the Amptector trip unit,

connect the ground wire to the neutral terminal. This wire must be
restored to its original configuration for testing of the ground-fault
function.
NOTE:
Amptector units which do not have instantaneous trip

elements are equipped with a discriminator circuit which
will trip the breaker if the test current exceeds 12 times
the current or transformer rating. It will be necessary to
defeat the discriminator circuit to test the unit.
To defeat the discriminator circuit on an Amptector unit, install a

jumper between terminals DN and DS on the unit. This jumper must
be removed after testing the unit.
5-20
NOTE:
1.
If the Amptector unit is tested by secondary injection,

one trip function of each phase should be tested
periodically (every six years) by direct injection to assure
proper operation of the complete overcurrent trip system.
Long-time delay element testing: Close the breaker and
adjust the test current to 300% of the current transformer tap
setting.
Apply the test current until the breaker trips or 300 seconds
have elapsed
Compare trip times to the manufacturer's time-current
characteristic trip curve for the specific settings of the device
being tested.
Ensure that the test current does not exceed the short-time
delay trip pickup setting so that the short-time delay trip
element will not trip the breaker before the long-time delay
has elapsed.
2.
Short-time delay element testing: Close the breaker and

adjust the test current to approximately 110%-150% of the
short-time pickup setting.
have elapsed.
characteristic trip curve for the specific settings tested.
3.
Instantaneous trip element testing:

CAUTION:

In cases where the instantaneous setting would result in test

currents greater than 20 times the breaker frame rating, reset
the instantaneous setting to the lowest setpoint prior to
testing. Reset the instantaneous setting to the original
setpoint after testing.
5-21

has elapsed.
Trip times shall be compared to the manufacturer's
time-current characteristic trip curve for the specific settings
tested.
4.
Ground-fault test: Verify that the ground-fault element is

restored by checking that the ground wire has been returned
to the ground terminal.
With the breaker connected to the load machine, close the
breaker and slowly raise the test current. Note the current at
which the breaker trips. This is the ground-fault pickup
current.
Test each phase at a current higher than the pickup current
value and verify the ground-fault trip time.
being tested.
7.
Perform overcurrent trip test by secondary current injection: The

Amptectors Trip Unit Test Kit is a portable low-current source used
to simulate primary fault and overcurrent conditions by secondary
injection. The test kit consists of a current supply, an automatic
timer, and a test plug which inserts directly onto the test terminals
on the front of the Amptector unit. The test kit is powered from a
standard 120Vac outlet.
CAUTION:
When testing by secondary injection, the breaker must be

in the TEST or DISCONNECT position, or be removed
from its cubicle. Testing m the CONNECT position will
result in disruption of the primary circuit.
Secondary test current values are determined by using the standard

sensor output ratio of 0-5 amperes equals the full-scale rating of the
sensor (e.g., for a 600A sensor, a primary current of 240A of primary
current corresponds to 2A of secondary current).
1.
6-22
Long-time delay element testing: With the breaker in the

TEST or DISCONNECT position, connect the Amptector test
plug to the test terminals on the front of the Amptector unit.

The 11-pin test plug is polarized to ensure that it is connected
correctly.
Turn the circuit selector switch to the phase under test, close
the breaker, and apply a secondary test current which
corresponds to 300% of the current transformer tap setting
until the breaker trips or 300 seconds have elapsed.
Reset the timer and repeat the test for each phase.
being tested.
2.
Short-time delay element testing: Turn the circuit selector

switch to the phase under test, close the breaker, and apply a
secondary current which corresponds to approximately 110%
150% of the short-time pickup setting until the breaker trips
or five seconds have elapsed.
3.
Instantaneous trip test: Turn the circuit selector switch to the

phase under test, close the breaker, and apply a secondary
current which corresponds to approximately 110%-120% of the
instantaneous trip setting until the breaker trips or one
second has elapsed.
4.
Ground-fault test:
NOTE:
When testing ground fault by secondary injection,

it may be necessary to disconnect the sensor wiring
from the test terminals to prevent loss of a portion
of the ground test signal in the sensors.
5-23
Switch the circuit selector switch to the phase under test.

Switch the ground test switch to the GROUND TEST position.
Close the breaker and slowly raise the test current and note
the secondary current at which the breaker trips. This is the
secondary ground-fault pickup current.
Test again at a secondary current higher than this pickup
being tested.
8.
Solid-state OCTD settings: Amptector overcurrent trip units are

equipped with adjustable controls for long-time pickup and delay,
short-time pickup and delay, instantaneous pickup, and ground-fault
pickup and delay. Adjustment screws on the front cover of the
Amptector provide the means of adjusting the unit.
5.3.8 Final Assembly and Inspection
5-24
1.
Place a clean cloth under the contacts, to catch debris, and remove residual
arc products from the contacts using Scotch-Brite . Carbon and other
electric arc products may be deposited on contact surfaces during OCTD
testing.
2.
Install the arc chutes. It may be necessary to remove the Amptector unit
to install the arc chutes.
3.
Check the breaker visually for mechanical and electrical integrity. Look for
loose components, damaged wiring, etc.
4.
Operate the breaker manually and verify that the close and open operations
function properly. Verify that the breaker indicators accurately reflect
breaker status.
5.
Verify that the breaker cannot be closed with the UV device de-energized,
and may be closed with the UV device energized.
6.
Operate the breaker electrically through five consecutive close-open

operations without failure.
7.
Ensure that all test leads are removed from the breaker.
8.
Visually check all fasteners, retainers, and cotter pins for tightness and
complete installation.
9.
The maintenance is complete and the breaker is ready to be installed in the

switch gear.
5-25
5.3.9 Maintenance Data Record

This record lists the data that should be collected each time periodic maintenance
is performed on a circuit breaker. These data provide a record of the circuit
breaker condition as well as the final adjustment and test values. This list
corresponds to the steps in the maintenance guidelines.
Reason for Maintenance:

Breaker Type:
Frame Size:
Serial Number:
Cubicle:
Closing Voltage:
Tripping Voltage:
Maintenance Manual:
Counter Operations:
Date:
Last Maintenance (Date):
Last Overhaul (Date):
Step
Maintenance Data Record
5.3.1
General Inspection
General appearance of breaker
5.3.2
Mechanical/Electrical Operation
Operating mechanism condition
5.3.3
Contact Inspection and Adjustment
Contact inspection
Main contacts
Arcing contacts (DB-25)
5-26
Step
Contact gap
A
B
C
Contact overadjustment
A
B
C
5.3.4
Operating Mechanism Inspection
Tripping load
5.3.5
Inspection and Adjustment
7.3
UV device clearance
13.3
Shunt trip device clearance
15.3
Electric lockout device bracket clearance
16.3
Reverse current armature overtravel
5.3.6
Electrical Tests
1.
Primary circuit insulation resistance

Line-to-load
A
B
C
Phase-to-ground
A
B
C
5-27
Step

A-B
Phase -to -phase
B-C
A-C
2
Wiring insulation resistance
Contact resistance
A
B
5.3.7
3.5
UV device pickup and dropout

1.
Dropout voltage
2.
Pickup voltage
Overcurrent Trip Device Operation

Solid-state OCTD actuator clearance
Overcurrent Trip Device Test Results
Characteristic Curve
Device Type
Current Rating
5-28
Long-Time Delay Pickup
Delay
sec
Short-Time Delay Pickup
Delay
sec
Instantaneous Pickup
Step

Test Current
Allowable Time
Recorded Time
Phase A
Long Time
Short Time
Instantaneous
Ground Fault
Phase B
Long Time
Short Time
Instantaneous
Ground Fault
Phase C
Long Time
Short Time
Instantaneous
Ground Fault
5-29
5-30
Section 5.4
DB-15/25 Overhaul Guideline
5.4

5.4.1 Initial Test and Inspection.......................................................... 5-31
5.4.2 Disassembly .............................................................................. 5-40
5.4.3 Inspections, Tests, Cleaning, and Re-Lubrication ..................... 5-45
5.4.4 Reassembly ............................................................................... 5-52
QA Requirements ...................................................................... 5-56
5.4.6 Overhaul Data Record ............................................................... 5-68
5.4
5.4.1 Initial Test and Inspection

1.
General Inspection
1.
2.
3.

1.
Racking mechanism interlock: For all drawout breakers, verify that

the breaker drawout mechanism cannot be operated from the
CONNECT position with the breaker contacts closed.
device from the CONNECT position towards the TEST position by
lifting up the breaker positioning lever. Verify that the breaker trips.
An interlock lever extends out of the left side of the breaker and acts
on the trip bar. When the breaker is levered out, this lever strikes a
bracket in the breaker cubicle and trips the breaker.
2.

The breaker positioning lever, on the left side of the breaker, engages
4.
Inspect the general appearance of the breaker (e.g., dirt; burns; broken, bent,
5.
Remove the arc chutes by removing the Amptector unit (if installed) and
then loosening the two retaining screws and lift each arc chute up and out.
Inspect the arc chutes for signs of corona, burning, and cracks.
6.
Inspect the primary insulated pole unit bases for dirt, carbon tracks, and
cracks. Inspect prior to cleaning since carbon tracks may give evidence of
cracks in the insulation material.
5-31
2.
1.
NOTE:
On breakers equipped with an undervoltage trip (UV) device or

an electrical lockout device, the devices will hold the breaker in a
These devices are energized by applying rated voltage to the secondary

disconnects that are connected to the applicable device coil leads. See the
breaker control wiring diagram for connection points. Device voltage rating
is indicated on the device label plate. If a voltage source is not available,
the device may be restrained by tying the armature m the energized
position using a tie-wire or a nylon cable tie.
3.
2.

3.

1.
Contact inspection: Inspect the breaker contacts for hairline cracks, pitting,
overheating. Inspect silver plating for flaking or peeling.
NOTE:
2.

and surrounding insulation, requires corrective action and
possible replacement of contacts and spring assemblies.
Contact gap: Contact pressure is verified by measuring and/or adjusting the

1.
On DB-15 breakers, contacts are adjusted to obtain a 3/32" to 1/8"

gap between the contact armature plate and the contact steel pivot
link.
Gap Specification:
2.
5-32
3/32"-1/8"
(0.094"- 0.125")

stationary and moving arcing contacts should be approximately 3/32"

Gap Specification: ~6/64"-7/64" (0.094"-0.109")
3.
Check contact overadjustment with the breaker closed by manually pulling

the moving main contact arm away from the stationary contact. This gap
Overadjustment Specification: 1/64" (0.016")
CAUTION:
4.
4.
Do not overadjust as this will cause the contact springs to compress

to the solid position, increasing the closing force.
If necessary, the contact gap may be adjusted by removing the crossbar and
screwing the insulating link in or out on the stud connected to the moving
contact arm. Be sure to tighten the lock nuts after each adjustment.

1.
Remove the top cover on the operating mechanism to allow visual access.
2.
3.

retainers.
4.
5.
6.
Inspect the operating mechanism components for excessive dirt buildup and
corrosion
7.
8.
Cycle the trip bar by hand. Check for freedom of movement, binding, or
sluggish operation.
9.
Tripping load: Determine the force required to lift the trip bar and trip the
breaker by performing the following:
WARNING:
Breaker contacts open at high speed. To prevent injury or

5-33
1.
or push up vertically on the trip bar about 3/4" from its right end
NOTE:

bar as possible.

2.
5.
If not already marked, mark the location on the trip bar where the
force measurement was made.
Electrical Tests
NOTE:
1.

energized.
Primary circuit insulation resistance: M easure the insulation resistance of
the primary circuits at 1,000Vdc. Measure the insulation resistance of each
phase.
2.
Wiring insulation resistance:

CAUTION:
Do Not measure the insulation resistance of the wiring of a

solid-state trip programmer unit.
Measure the insulation resistance of the control wiring to ground at 500Vdc.

Specification: 100
3.

Specification: 150
5-34
NOTE:
4.
This test may be accomplished concurrent with OCTD testing.
UV device pickup and dropout:

NOTE:

1.
Energize the UV device by applying rated voltage to the secondary

disconnects with a variable voltage supply, and close the circuit
breaker.
2.
Slowly reduce voltage to the UV device until the breaker trips. The
voltage at which the breaker trips is the dropout voltage.
3.

5.
6.
Control circuit: Use a variable-voltage power supply and conduct this test at
minimum and maximum rated voltages.
1.
Connect temporary control power to the breaker charging and local

closing circuits at the secondary disconnects.
2.

through the temporary control power.
3.

should trip but not close.
4.
Release and re-apply the closing signal and the circuit breaker should
close.
Shunt trip device:

1.

circuit at the secondary disconnects, and close the breaker.
2.
5-35
6.
DBL breakers are equipped with current-limiting fuses. Remove

the fuses and install a test bus bar prior to conducting overcurrent
tests to avoid destroying the fuses.
CAUTION:
1.
Remove the current-limiting fuses and install a test bus bar in their place.
2.

the time-current characteristic trip curves for the device.
1.
Positive trip check: Close the breaker. Insert a 1/16" diameter rod
into the long-time delay calibration (left) slot and raise the time delay
valve lever to remove all of the time delay. Insert another 1/16" rod
into the top slot of the OCTD nameplate and push the armature
against the yoke to trip the breaker.
upwards an additional 3/4 turn to ensure proper overtravel.
2.

electro-mechanical trip element as described below and verify that
Perform tests with a suitable, calibrated high-current, low-voltage
test set. Tests are to be made on individual phases.
1.
Longtime delay test: Close the breaker and apply current to

the phase under test.
off the test set.
current until the breaker trips or 300 seconds elapse.
Compare the trip time with the manufacturer's time-current
characteristic trip curve.
5-36
2.
Short-time delay test: To accurately test the short-time delay,

the test set must have a memory feature to hold and display
the test current.
Close the breaker and apply current momentarily.
(Approximately 110%-150% of the short-time pickup setting is
the recommended test current.)
Adjust the current toward the desired value and repeat until
the desired test current is achieved.
have elapsed.
3.
Instantaneous test:
CAUTION:

continuous-current frame rating will pit the contacts.
Testing the instantaneous function by direct injection
at greater than 20 times the frame rating is not
recommended.
If the test current is greater than 20 times the breaker

continuous-current frame rating, the instantaneous test may
be accomplished by removing the trip unit from the breaker
and bench-testing the trip function. Current should be
injected through a test bus which runs through the magnet
coil of the device, and in this way verifies the function of the
armature.
has elapsed.
3.
Solid-state overcurrent trip devices: Solid-state OCTDs should be tested to

verify their ability to trip the circuit breaker within allowable time bands
specified by the time-current characteristic trip curve for the device.
5-37
CAUTION:
Tap settings should not be changed while the breaker is carrying

current.
1.
Verify proper solid-state programmer device settings.
2.
Verify that all device wiring is properly connected and in good condition.
3.
Inspect current transformers for cracked insulation and proper connections,

tap settings, and solid mounting.
4.

5.
Specification: 1/32"-1/8" (0.031"-0.125")
6.
Perform overcurrent trip test by primary current injection:

NOTE:

necessary to defeat the ground-fault element prior to testing
the other trip features of the device.
To defeat the ground-fault feature of the Amptector unit, connect

the ground wire to the neutral terminal. This wire must be restored
to its original configuration for testing of the ground-fault function.
NOTE:


1.

setting.
have elapsed.
5-38
Compare the trip time to the manufacturer's time-current

being tested.
has elapsed.
2.
Short-time delay element testing: Close the breaker and

have elapsed.
3.
Instantaneous trip test:

CAUTION:


has elapsed.
5-39
4.

With the breaker connected to the test machine, slowly raise
the test current and note the current at which the breaker
trips. This is the ground-fault pickup current.
Test each phase at a current higher than the pickup value and
verify the ground-fault trip time.
being tested.
8.

5.4.2 Disassembly
The disassembly instructions in this section do not identify location, orientation, or
size of spacers, shims, retainers, lock washers, and other hardware. The circuit
breaker mechanic must record this information during the disassembly process.
1.
Ancillary Items
1.
2.
5-40
Face plates:
1.
Remove the two screws that hold the small face plate to the moving
face plate.
2.
Remove the two screws that hold the moving face plate links to the
side of the mechanism. Remove the face plate.
1.
Primary disconnects are held in place by leaf spring pressure. Cover

the disconnects with a cloth (or similar item) to prevent damage. Use
a large pair of pliers to compress the springs until the metal tips on
the fingers clear the corresponding holes in the stud. The disconnects
may then be pulled clear of the studs.
2.
If installed, remove the solid-state OCTD current sensors.
3.
2.
3.
S e c o n d a r y disconnects:
1.
The secondary disconnects consist of an insulated body with

spring-type fingers to which the wiring is attached.
2.
Remove the mounting screws which hold the disconnects to the

breaker frame.
3.
Label and disconnect the wiring and remove the secondary

disconnects.
Frame Separation
1.
Remove the crossbar retainers and the crossbar.
2.
Separate the front platform from the back frame by removing the four bolts
that hold the breaker platform to the back frame and the two bolts that hold
the rear rollers to the back frame.
3.
Feed the control wire bundle through the hole in the breaker back frame.
Pole Unit Bases

The DB-15/25 breakers have three insulated pole unit bases on which the contacts
of each phase are mounted. These assemblies are bolted to the breaker back frame.
Prerequisites:
Front and back frames have been separated.
Upper and lower primary disconnects have been removed.
Remove the three bolts which secure the pole unit bases to the breaker back frame
and pull the bases forward and out of the back frame.
4.
Contact Structure
1.
Movable contact:
1.
On breakers with electromechanical OCTDs, three bolts at the

bottom of the pole unit base hold the OCTD, the lower stud, and the
steel link to the pole unit base. Loosen these bolts and remove the
OCTD and the phase barriers between each OCTD. On all other
breakers, remove the two bolts that hold the shunt, the lower stud,
and the steel link in place.
5-41
2.
6.
Remove the two screws that hold the hinge bracket to the pole unit
base and lift out the moving contact assembly.
3.
Remove the arcing contact (main contacts on DB-15) by removing the

two screws that hold it to the main contact assembly.
4.
Remove the retaining ring and pivot pin, and separate the moving
contact from the armature plate.
Stationary contacts:
1.
The arcing contact on DB-25 breakers and the main arcing contacts
on DB-15 breakers are held m place by two screws. Remove the
screws and the contacts.
2.
The main contacts on DB-25 breakers are integral to the upper stud.
The upper stud is held in place by a single bolt. Remove the bolt and
upper stud assembly.
Auxiliary components
1.
2.
5-42
2.
Auxiliary switch: The auxiliary switch is mounted on top of the breaker

front frame to the left of the operating mechanism. Its operating shaft is
linked to the closing lever of the breaker mechanism. Record the position of
the switch shaft relative to the actuator arm.
1.
Close the breaker to facilitate removal of the auxiliary switch.
2.
Disconnect the auxiliary switch linkage from the operating

mechanism by removing the retainer and then pulling the linkage off
of the closing lever.
3.
Remove the auxiliary switch cover and label and disconnect the leads
to the switch terminals.
4.
Remove the mounting screws and the switch.
Control relay: The control relay is located beneath the auxiliary switch on
the left side of the breaker.
1.
Remove the cover, and label and disconnect the wiring.
2.
Remove the two mounting stud nuts and the control relay.
3.
4.
5.
6.
7.
Closing solenoid (solenoid-operated breakers only):

1.
Label and disconnect the coil leads.
2.
Maintain the breaker in the trip-free position by pushing up on the

trip bar.
3.
Remove the retainer and partially remove the pin that connects the
first and second toggle links. This requires that the mechanism be
closed by hand two-thirds of the way so that the pin will line up with
a hole in the mechanism frame. To prevent binding, push up on the
solenoid moving core. Insert a punch through the small hole in the
left side of the frame and push the pin out until it clears the moving
core. The solenoid housing must be supported at this point.
4.
While continuing to support the solenoid, remove the four bolts that
connect the solenoid and the operating mechanism to the breaker
platform. Lift the solenoid out of the breaker.
Bell alarm device: The bell alarm device is mounted above the shunt trip
device and should be removed with the shunt trip device.
1.
Label and disconnect the leads.
2.
Disconnect the operating linkage from the breaker operating

mechanism by removing the retainers. Remove the bell alarm switch
with the shunt trip device.
Shunt trio device: The shunt trip device is mounted on the right side of the
breaker front frame just to the right of the operating mechanism.
1.
2.
Remove the two mounting screws, the shunt trip device, and the bell
alarm switch.
Undervoltage trip device: The UV device is mounted on top of the breaker

platform, just to the right of the shunt trip device.
1.
Label and disconnect the device leads.
2.
Remove the two mounting screws and the UV device.
Electric lockout device: The electric lockout device is mounted under the
right side of the breaker front frame, beneath the UV device.
5-43
1.
Label and disconnect the wiring.
2.
Disconnect the lockout arm and lever by removing the retainers.

Note the position of any spacers.
3.
Remove the electric lockout device by removing the screws which

secure it to the frame.
8.
Current-limiting fuses: Remove the fuse mounting bolts from each end of
the primary fuse and remove the fuse.
9.
Fuse trip device: The fuse trip device is located under the current-limiting
fuse for each phase.
Remove the mounting screws that secure the support bracket to the breaker
frame and fuse. Remove the device.
10.
11.
6.
Solid-state trip device (Amptector ):

1.
Remove the current sensor wiring harness mounting screws.
2.
Remove the mounting bolts for the Amptector unit and the
actuator.
3.
Lift all three current sensors, the Amptector unit, and the actuator
out of the breaker as an assembly.

1.
2.
Remove the mounting bolts and device from the center molded pole
unit base.
Operating Mechanism
Prerequisites:
All control and auxiliary devices and associated wiring have been removed,
including the closing solenoid.
1.
5-44
Electrically operated breakers: Remove the four screws which fasten the
bottom of the mechanism to the horizontal platform. Lift the operating
mechanism clear of the breaker.
2.
Manually operated breakers:

1.
Maintain the breaker in the trip-free position by pushing up on the

trip bar.
2.
first and second toggle links. This requires the middle pole unit to be
closed by hand two-thirds of the way so that the pin will line up with
a hole in the mechanism frame. Insert a punch through the small
hole in the left side of the frame and push the pin out until it clears
the moving core. The spring housing must be supported at this point.
3.
While continuing to support the spring, remove the four bolts that
connect the spring housing and the operating mechanism to the
breaker platform, and remove the spring assembly. Lift the
operating mechanism clear of the breaker.
5.4.3 Inspections, Tests, Cleaning, and Re-lubrication

1.
Ancillary Items
1.
Arc chutes:
1.
Inspect for broken or cracked ceramic or asbestos components, dirt

and carbon deposits in the interrupter, and erosion of the splitter
Arc chutes with barriers eroded to 40% of their original thickness
should be replaced.
WARNING:
2.
these may embed conductive materials in the insulation.
WARNING:
3.


5-45
4.
2.
3.
1.

2.
isopropyl alcohol.
3.

just prior to installing the breaker in the switchgear.
1.

binding. Clean the disconnects with a clean cloth and a mild solvent.
2.
Inspect plastic insulation for cracks or damage, particularly at

mounting holes.
3.
Verify that the clearance between the contact hook and the back of
the disconnect molding is 0.015".
4.
2.

Frame Assemblies
Inspect the frames for corrosion, bends, and cracked or unfused welds. Remove
rust. Prime and electroplate as necessary.
3.
5-46
Contact Structures
1.
Clean the contacts with Tarnex or silver plate cleaner. Rinse thoroughly
and dry. De-burr the contacts using sandpaper or Scotch-Brite.
2.
Inspect the condition of the plating and contact surfaces. Contact

replacement is recommended when less than one-half of the original
thickness of the contact tips remains or the contact tips are severely pitted.
Minor pitting and roughening of the contact surfaces are not causes for
replacement.
3.
Inspect the opening springs for corrosion, damage, and excessive wear.
4.
5.
Pole Unit Bases

1.
Wipe the pole unit bases with a clean cloth and a mild, ammonia-based glass
cleaner.
2.
Inspect for cracks, burns, carbon tracks, warping, and signs of overheating,
especially around upper and lower stud penetrations and threaded inserts.
Operating Mechanism
1.
Disassemble the operating mechanism carefully, recording component

arrangement by taking notes, punch marking, and scribing components to
provide assurance that they will be reassembled correctly. Begin by
removing the components from one end of each shaft and working from the
outside toward the center. Remove the parts slowly and observe the
mechanical relationships among the different components. Line drawings
that reference each spacer, retainer, bearing, and other component by size
and location on each shaft should be made. Care should be taken with
bearings to ensure that they are not damaged.
2.
During and after disassembly of the operating mechanism inspect for the
following:
1.
Broken, weak, or defective springs.
2.
Bearings--lubrication and freedom of movement.
3.
Latches for wear and fatigue cracks.
4.
Trip bar for freedom of movement.
5.
Worn or cracked pins.
6.
Alignment of pins through linkages.
7.
Welds for stress and cracks.
8.
Corrosion and plating condition.
3.
Clean all mechanism components with an approved/equivalent solvent.

Remove all traces of solvent by cleaning degreased parts with alcohol or
mild soapy water, and blow each component dry with compressed air.
4.
Re-plate all electroplated parts. Replace all worn or damaged components.
5-47
EPRI Llcensed Material
6.
Auxiliary Subcomponents
1.
2.
3.
5-48
Auxiliary switch:
1.
Inspect for correct operation, insulation condition, and cracks m the

housing and cover.
2.
Measure the resistance of all contacts. Investigate the cause of any

readings over 0.10.
3.
Disassemble the switch and clean the internals with alcohol. Replace
the contacts if they are badly burned or pitted.
4.
Apply a light coat of graphite grease (Westinghouse 53701ANOOT) to

the switch contacts.
Closing solenoid (solenoid-operated breakers):

1.
Inspect the coil and leads for signs of overheating and damaged
insulation.
2.
Measure the coil resistance. Clean the coil with a clean cloth and
alcohol or an approved solvent.
Control relay:
1.
Inspect for freedom of operation and insulation condition.

Disassemble and clean the coil and assembly of dirt, dust, grease, and
oil using an approved electrical solvent.
2.
Inspect the coil for signs of overheating. Measure the control relay
coil resistance.
3.
Inspect plastic components for cracks. If installed, inspect the control

relay's arc chute for cracks, erosion, and carbon deposits.
4.
Inspect the plunger core for physical distortions and warping.
5.
exceed 0.10. Clean the contacts with Scotch-Brite or equivalent,
mildly abrasive material.
4.
Shunt trip device:

1.
Inspect for freedom of operation and insulation condition. Disassemble

the coil and assemblies. Remove dirt and dust using a clean cloth and
alcohol.
2.
3.
Inspect the shunt coil for signs of overheating. Measure the shunt
coil resistance.
4.
To replace the shunt coil, perform the following:
5.
1.
Disconnect and label the coil leads.
2.
Remove the two screws which fasten the coil to the retaining
plate and frame.
3.
Remove the moving core and internal sleeve from the housing.
Remove the old coil and install the new coil.
Lubricate the shunt trip device by applying a few drops of approved

lubricant to the linkage on the inside and outside mechanism
surfaces.
5.
Wiring and connections: Inspect for brittle and cracked insulation, pinched
wires, loose connections, broken lugs, and broken or frayed wires. Clean
with alcohol and brushes.
6.
Phenolic covers and bases. insulated push rods. etc.: Inspect for cracks,
punctures, tracking, and excessive dirt. Replace if cracked. Clean with a
clean cloth and alcohol.
7.
UV device:
1.

Disassemble and clean the coil and assemblies of dirt, dust, grease,
and oil using a clean cloth and alcohol.
2.
Inspect the plunger core for physical distortions and warping
3.
Inspect the latch, latch pin, and trip lever for excessive wear.
4.
Inspect the UV coil for signs of overheating. Measure the coil

resistance.
5-49
5.
8.
9.
10.
5-50
Apply lubricant (molybdenum disulfide m isopropyl alcohol or

approved equivalent) liberally to the following points:
Between the latch and latch spring (The latch may be gently
pulled away to gain access to this area.);
Latch loop to latch-guide pin area;
Latch to latch pin with notch ("D" pin);
Latch pivot pin; and
Pin running through the trip spring.

1.

2.
Inspect the coil for signs of overheating. Measure the coil resistance.
3.
Verify that all moving parts operate freely. Inspect the plunger core
for physical distortions and warping.
Bell alarm device:

1.
Inspect for freedom of operation. Disassemble and clean the assembly

using a clean cloth and alcohol.
2.
Verify that all moving parts operate freely. Inspect the switch for
cracks or damage.
3.
Measure contact resistance. Replace the switch if contact resistance

is greater than 0.10.
Primary fuses:
1.
Verify that the primary fuses are the proper type and rating. Check
the continuity of each fuse.
2.
Wipe the outside of each fuse with a clean cloth and alcohol. Remove
any conductive deposits from the body of the fuse.
11.
12.
13.
14.
15.
Fuse trip device:

1.
Disassemble and clean the assembly using a clean cloth and alcohol.
defects.
2.
Reassemble and lubricate friction points with the molybdenum

disulfide/alcohol mixture or equivalent.
Solid-state OCTD actuator:

1.

assembly of dirt, dust, and grease.
2.
Measure the actuator coil resistance. Inspect the plastic components

for cracks.
3.
Verify that the permanent magnet has sufficient strength to hold the
device m the reset position while tapping the device lightly on a
bench top.
Solid-state trip current sensors:

1.
Inspect the sensors for signs of overheating, cracked insulation, and

damaged wiring.
2.
Clean the sensors and terminations by wiping with a clean cloth and
alcohol. Measure the current sensor resistance.
Electro-mechanical overcurrent trip device:

1.
Clean the assembled trip unit with an approved solvent and a small
brush. Remove all solvent with alcohol and blow the unit dry with
compressed air.
2.
Remove the reset valve and clean the valve filter.
3.
Inspect the device for rusted surfaces, bent or broken parts, missing
or stretched springs, and separated magnet laminations.
4.
Lubricate the moving parts with light-weight machine oil.
Reverse current device:

1.
Inspect for freedom of operation. Disassemble and clean the coil and
assembly of dirt, dust, grease, and oil using a clean cloth and alcohol.
Inspect for physical distortions or damage.
5-51
2.
QA Hold Point
At this point of the overhaul, a quality assurance (QA) review is required to verify that all
facets of disassembly and inspection have been completed
5.4.4 Reassembly
1.
Operating Mechanism
Carefully reassemble the operating mechanism, referring to the notes taken during
disassembly.
1.
Lubricate all pivot points, bearings, bushings, and sliding contact points
with molybdenum disulfide mixed with isopropyl alcohol. Ensure that the
following areas are lubricated:
Latch faces;
Trigger faces
Felt pad on the trip pan--the pad should be thoroughly soaked; and
All trip bar pivot points and bearing surfaces.
2.
Replace all c-clips, tru-arcs , lock-washers, and other special retainers

during reassembly.
3.
During reassembly, frequently check that all components operate freely and
agree with the notes and figures recorded during disassembly. Ensure that
all components are mounted solidly and that the mounting hardware is
tightened securely.
Hold Point
At this point of the overhaul, a supervisory review is required to verify that the operating
mechanism is assembled properly and that all operating mechanism retainers are
installed.
2.
Operating Mechanism and Closing Solenoid/Spring

1.
5-52
Install the operating mechanism onto the breaker platform. and insert the
four mounting bolts which fasten the bottom of the mechanism frame to the
horizontal breaker platform.
3.
4.
2.
Align the closing solenoid assembly (closing spring assembly on manual

breakers) to the breaker platform. The moving core plunger should be
oriented up into the breaker operating mechanism.
3.
Tighten the four frame mounting bolts.
4.
Connect the moving core plunger (push rod on manual breakers) to the
toggle linkage by installing the toggle link connecting pin and its associated
retainer.
5.
Connect the closing solenoid coil leads.
Contact Structure
1.
Stationary contacts: A ttach the upper stud to the pole unit base with the
mounting bolt. Attach the arcing contacts (main contacts on DB-15) to the
upper stud using the two mounting screws.
2.
Movable contacts:
1.
Coat all pivot points with a thin coat of graphite grease

(Westinghouse 53701ANOOT).
2.
Attach the moving arcing contacts (main contacts on DB-15) to the

main contact assembly with the two mounting screws.
3.
Connect the moving contact arm to the armature plate and hinge
bracket using the pivot pin and retaining ring.
4.
Attach the hinge bracket to the pole unit base using the two
mounting screws. Ensure that the opening spring is positioned
properly.
5.
Electromechanical OCTD (if installed): Install the phase barriers.

Attach the OCTD housing to the pole unit base with the 3/8" bolt in
the lower hole.
6.
Install the two bolts that connect the lower stud to the steel link. On
breakers with electromechanical OCTDs, the bolts connect to the
OCTD coil. On all other breakers, the bolts connect to a shunt.
Pole Unit Bases

Set the pole unit bases onto the front of the breaker back frame. Install the three
bolts and lock washers which secure each pole unit base.
5-53
Frame Sections
5.
NOTE:
6.
While joining the front and back frames, care should be exercised to
avoid damage to the trip bar arms and levers and the control wiring.
1.
While the back frame is held steady, insert the front frame and mechanism
so that the trip bar clears the trip arms of the OCTDs.
2.
Join the frames with the four mounting bolts. Attach the rear rollers.
3.
Run the wire bundle for the secondary disconnects through the hole m the
breaker back frame.
4.
Insert the breaker crossbar, the alarm switch clevis, and the associated
retaining rings.
Auxiliary switch:
1.
2.
1.
Before mounting the switch, position the crank end of the switch
operating shaft into the hole in the operating mechanism link. Set
the switch crank shaft so that the switch shaft and the breaker
contacts are in their original (pre-disassembly) positions.
2.
Install the mounting bolts. Connect and tighten all switch leads.
Install the switch cover.
Control relay:
1.
Install the control relay assembly and the mounting studs which
fasten the assembly to the breaker, and connect all leads.
2.
Align the relay release arm on the closing solenoid with the control
relay release lever.
Bell alarm device:
3.
1.
Install the device as a single unit with the shunt trip device.
2.
Attach the bell alarm device to its mounting bracket. Connect the
device's operating linkage to the operating mechanism link and
install new retainers. Connect the device's leads.
5-54
4.
Shunt trip device:

1.
Attach the shunt trip device to the breaker platform using the
mounting screws. Connect the device's wiring
WARNING:
2.
Measure the shunt trip device clearance.

Close the breaker. Measure the clearance between the shunt trip
lever and the trip bar. The clearance should be approximately 1/16".
5.
UV device:
1.
Align the UV device on the platform and position the trip lever
under the trip bar.
2.
Attach the device to the breaker platform and tighten the hardware.
The UV device mounting base should be parallel to the breaker
platform. Connect the device's wiring
3.

approximately 1/16" clearance to the trip bar.
breaker is closed, the gap between the UV device trip lever and the
trip bar should be approximately 1/16".
6.
Electric lockout device: Install the lockout arm and lever, spacers, and
retainers. Install the device using the mounting screws which secure it to
the frame. Connect the device's leads.
7.
Primary fuses: Verify that the fuses are the proper type and rating. Install
the fuses onto the primary studs using the mounting bolts after completion
of the OCTD testing. Securely tighten all bolted fuse connections. Poor fuse
connections can cause breaker overheating.
8.
Fuse trip device: Insert the device and support frame under the fuse.
Install the mounting hardware which secures the device to the breaker
frame and fuse.
9.
Reverse current trip device: Install the device on the center pole unit base
using the mounting hardware, and connect the wiring.
5-55
7.
10.
Solid-state OCTD Amptector unit and actuator: Attach the actuator and
Amptector unit with the appropriate mounting hardware. Connect the
leads to both devices.
11.
Solid-state trip current sensors (Amptector ):

1.
Position the current sensors onto the DB-25 breaker's lower studs.
On DB-15 breakers, one sensor is placed on the middle bottom stud
and the other sensors are placed on the top outside studs.
2.
Connect the sensor wiring and secure the wiring connector with
mounting screws. Neatly dress all sensor wiring and tie with cable
ties as necessary.
Ancillary Items
1.
Primary disconnects: Attach the primary disconnect fingers to the upper

and lower studs. If pliers are used, cover the primary disconnect fingers
with a cloth to prevent their damage.
2.
Secondary disconnects: Install the secondary disconnects by inserting them

on the mounting bracket and installing the two mounting screws. Connect
the wiring in accordance with the wiring diagram.
3.
Face plates: Install the stationary and moving breaker face plates.
QA Hold Point
breaker deficiencies have been resolved and that the breaker has been reassembled.
5.4.5 Post-Overhaul Inspections, Adjustments, and QA Requirements

1.
Mechanical Tests and Inspections

1.
Contact gap:
1.
Contact pressure is maintained by measuring and/or adjusting the

1.
On DB-15 breakers, contacts are adjusted to obtain a 3/32" to

1/8" gap between the contact armature plate and the steel
link.
DB-15 Gap Specification:
5-56
3/32"-1/8"
(0.094"- 0. 125")
2.

stationary and moving arcing contacts should be
approximately 3/32" with the breaker closed.
DB-25 Gap Specification: 6/64"-7/64" (0.094"-0.109")
CAUTION:
2.
2.
Do not overadjust as this will cause the contact springs to

compress to the solid position, increasing the closing force.
If necessary, the contact gap may be adjusted by removing the

crossbar, loosening the locking nut, and screwing the insulating link
In or out on the stud connected to the moving contact arm. Be sure
to tighten the locking nuts after each adjustment.
Contact overadiustment: Check for overadjustment by manually pulling the

moving main contact arm away from the stationary contact. This gap
Overadjustment Specification: 1164" (0.016")
3.
Operating mechanism adjustments:

1.
Inspect for loose parts, and missing or loose retainers, snap-rings, or

bearing retainers
2.
Inspect the trip bar for freedom of movement, binding, or sluggish

operation.
3.
Tripping load: Determine the force required to lift the trip bar and
trip the breaker by performing the following.
WARNING:

equipment damage, ensure that hands and test equipment
remain clear of moving breaker parts.
or push up vertically on the trip bar about 3/4" from its right end
NOTE:

bar as possible.
5-57
Trip Load Specification:

4.
38 oz.
UV device:
1.

approximately 1/16" clearance to the trip bar when the breaker is
closed.
Energize the UV device. Slow close the breaker. When the breaker
is closed, measure the gap between the UV device trip lever and the
trip bar.
Specification: ~ 1/16" (0.063")
WARNING:
2.
Open the breaker manually and de-energize the UV device. Restrain

the reset lever and close the breaker manually. Slowly release the
reset lever. The circuit breaker should trip before the reset lever
comes to rest.
sluggishness, binding, or hesitation.
5.
Fuse trip device: Insert a 1/8" feeler gauge between the fuse trip lever and
the micarta lever. The breaker should close and latch. When a 3/16" feeler
gauge is inserted, the breaker should trip. If necessary, adjust the trip
screw attached to the fuse trip linkage.
6.
Shunt trip device: With the breaker closed and the shunt trip device deenergized, measure the clearance between the trip bar and the trip lever of
the shunt trip device.
7.

1.
2.

pushed.
Overtravel Specification: 1/32" (0.031")
5-58
2.
Electrical Tests and Inspections

NOTE:

energized.
1.

Specification: 100
CAUTION:
2.

3.

Specification: 150
NOTE:
4.
UV device pickup and dropout: Energize the UV device with an appropriate

variable voltage applied to the secondary disconnects, and close the circuit
breaker.
NOTE:
1.

5-59

2.
Slowly increase voltage to the UV device until the UV device

armature picks up and fully closes. Verify that the breaker can be
closed.
5.
1.
Connect appropriate temporary control power to the breaker charging

and closing circuits at the secondary disconnects. Close the breaker
by energizing the closing circuit.
2.

should not close.
3.
close.
6.
Shunt trip device: Close the breaker and verify that the shunt trip device
will trip the breaker when energized from the secondary disconnects.
7.
Bell alarm attachment-
8.
1.
trap, etc.), the bell alarm is activated. Activation of the device is
2.
trip device.
3.
Manually close the breaker and trip it by means of the trip button.
Verify that the bell alarm does not activate.

1.
5-60

closing by holding the trip bar in the trip-free position. Pushing
down on the lifting plate should permit the breaker to close. When
the lifting plate is released, the breaker should remain closed. Verify
that the lifting plate does not touch the trip bar when the breaker is
closed.
2.
Energize the lockout coil. The clearance between the bottom of the
trip bar and the lifting bracket should be between 1/32" and 1/16".
The lifting bracket can be moved to obtain this clearance by turning
the adjusting screw.
Lifting Bracket Clearance: 1/32"-1/16" (0.031"-0.063")
3.

CAUTION:
1.
Remove the current-limiting fuses and install the test bus bar.
2.
Electromechanical overcurrent trip devices: Test electromechanical series

OCTDs for proper operation within the time specified by the manufacturer's
time-current characteristic trip curves for the device.
1.
Positive trip check: Close the breaker and insert a 1/16" diameter
rod into the long-time delay calibration deft) slot and raise the time
delay valve lever to remove all of the time delay. Insert another
1/16" rod into the top slot of the OCTD nameplate and push the
armature against the yoke to trip the breaker.
upwards an additional 3/4-turn to ensure proper overtravel.
2.
Perform overcurrent trip test by primary current Section: Test each

time-current characteristic trip curve. The applicable time-current
characteristic trip curve is determined by the device nameplate
information, type, current rating and curve number.
1.
Longtime delay element test: C lose the breaker and apply

off the test set.
5-61

Compare the trip time measured under test with the
manufacturer's time-current characteristic trip curve.
Verify that the long-time pickup is not set too low by applying
a test current equal to 90% of the long-time pickup setting for
ten minutes and verifying that the breaker does not trip.
2.
Short-time delay element test- Close the breaker and apply

have elapsed.
Verify that the short-time delay pickup is not set too low by
applying a test current equal to 90% of the short-time delay
pickup setting for two seconds and verifying that the breaker
does not trip.
3.

CAUTION:

Testing the instantaneous function by direct injection
at greater than 20 times the frame rating is not
recommended.
If the test current exceeds 20 times the breaker continuouscurrent frame rating the instantaneous test should be bench
tested and adjusted prior to installing on the breaker.
has elapsed.
5-62
Verify that the instantaneous pickup is not set too low by

applying a test current equal to 90% of the instantaneous
pickup setting for 0.5 seconds and verifying that the
instantaneous element does not trip the breaker.
3.
3.
Electromechanical OCTD adjustments:

1.
The long-time delay is adjusted by turning the left knob at the

bottom of the device. Turning the knob clockwise increases
the delay, counterclockwise decreases the delay.
2.

3.

delay.
4.

5.

right adjustment knob at the bottom of the device. Turning
the knob clockwise increases the pickup setting,
6.

specified by the manufacturer's time-current characteristic trip curve for the
device.
1.
2.
Verify that all device wiring is properly connected and m good

condition.
5-63
3.
Inspect current transformers for proper connections, tap settings, and

solid mounting.
4.
Check that the magnetic trip device (or flux shift trip device) is
mounted solidly, operates freely, and provides sufficient overtravel to
trip the circuit breaker.
5.
Specification: 1/32"-1/8" (0.031"-0.125")
6.
Perform overcurrent trip test by primary current infection:

NOTE:


NOTE:


1.

adjust the test current equal to 300% of the current
transformer tap setting.
have elapsed.
Compare the trip times to the manufacturer's time-current
being tested.
5-64
2.
Short-time delay element testing; Close the breaker and

have elapsed.
does not trip.
3.

CAUTION:

direct injection at greater than 20 times the frame
rating is not recommended.

has elapsed.
5-65
4.

With the breaker connected to the load machine, close the
breaker and slowly raise the test current. Note the current at
which the breaker trips. This is the ground-fault pickup
current.
being tested.
8.
4.
5-66

Final Assembly and Inspection

1.
electric arc products may be deposited on the contact surfaces during OCTD
testing.
2.
Install the arc chutes. Remove the Amptector unit and set the arc chutes
down over the contacts. Install the two mounting screws on each arc chute.
Install the Amptector unit.
3.
loose components, damaged wiring etc.
4.
Operate the breaker manually and verify that the manual close and open
operations function properly.
5.
Verify that the breaker indicators accurately reflect breaker status.
6.
7.

8.
9.
10.
Apply a thin coat of conductive lubricant to the primary and secondary

disconnect fingers on the surfaces that mate with the switchgear cubicle
components.
QA Hold Point
steps have been completed and the circuit breaker is complete and ready to be placed in
service
5.
Quality Assurance Requirements

1.
All replacement parts installed as a result of maintenance shall be purchased in

accordance with plant procurement quality assurance requirements.
2.
Consumable items such as lubricants, tie-wraps, fasteners, etc., should be of

good quality and purchased from an evaluated supplier in accordance with
plant procedures.
3.
It is recommended that Quality Control (QC) inspections be performed

during breaker overhaul and that QC personnel witness all post-overhaul
adjustments and testing. QA hold points should be inserted after breaker
disassembly, after reassembly, and upon completion of final testing to verify
that all steps have been properly completed and documented.
5-67
5.4.6 Overhaul Data Record

This record lists the data that should be collected for each breaker overhauled.
These data provide a record of the pre-overhaul condition of the circuit breaker as
well as the final adjustment and test values. This list corresponds to the steps in
the overhaul guideline.
Reason for Overhaul:
Breaker Type:
Frame Size:
Serial Number:
Cubicle:
Closing Voltage:
Tripping Voltage:
Maintenance Manual:
Counter Operations:
Date:
Step
Overhaul Data Record
5.4.1
Initial Test and Inspection
1.4
2.1
3.1
Contact condition
Main contacts
Arcing contacts (DB-25)
3.2
Contact gap
A
B
C
5-68
Step
3.3
A
B
C
4.9
Mechanism tripping load
Electrical tests
5.1

Line-to -load
A
B
C
Phase-to-ground
A
B
C
Phase -to -phase
A-B
B-C
A-C
5.2
5.3
Contact resistance
A
B
C
5.4
Undervoltage pickup and dropout

2.
Dropout voltage
3.
Pickup voltage
5-69
Step
Overcurrent trip device operation
6.3.5

Device Type
Current Rating
Delay
sec
Delay
sec
Test Current
Phase A
Long Time
Short Time
Instantaneous
Ground Fault
Phase B
Long Time
Short Time
Instantaneous
Ground Fault
5-70
Allowable Time
Recorded Time
Step
Phase C
Long Time
Short Time
Instantaneous
Ground Fault
5.4.3
Inspections and Tests
6.2
Closing solenoid resistance
6.3
Control relay coil resistance
6.4
Shunt coil resistance
6.7
UV device coil resistance
6.8
Electric lockout coil resistance
6.12
Actuator coil resistance
6.13
Solid-state OCTD current sensors
A
B
C
5.4.5
Post-overhaul Inspections and Adjustments
1.1
Contort gap
A
B
C
5-71
EPRI Licensed Meterial
Step
1.2
A
B
C
1.3
1.4
UV device clearance
1.6
Shunt trip clearance
1.7
Electrical tests
2.1

Line-to-load
A
B
C
Phase-to-ground
A
B
C
Phase -to -phase
A-B
B-C
A-C
2.2
5-72
Step
2.3
Contact resistance
B
C
2.4

1.
Dropout voltage
2.
Pickup voltage
2.8
3.3.5

Device Type
Current Rating
Delay
sec
Delay
sec
Test Current
Allowable Time
Recorded Time
Phase A
Long Time
Short Time
Instantaneous
Ground Fault
5-73
Step
Phase B
Long Time
Short Time
Instantaneous
Ground Fault
Phase C
Long Time
Short Time
Instantaneous
Ground Fault
5-74
Section 5.5
DB-50/75 Routine Maintenance
Inspections, Tests, and Adjustments
5.5
DB-50/75 Routine Maintenance Inspections,

Tests, and Adjustments ..................................................................... 5-75
5.5.1 General Inspection .................................................................... 5-75
5.5.2 Mechanical/Electrical Operation ................................................ 5-76
5.5.3 Contact Inspection and Adjustment ........................................... 5-76
5.5.4 Operating Mechanism Inspection .............................................. 5-77
Major Subcomponents ............................................................... 5-79
5.5
DB-50/75 Routine Maintenance Inspections, Tests, and

Adjustments
5.5.1
General Inspection
1.
2.
3.

1.
D rawout interlock: For all drawout breakers, verify that the breaker
drawout mechanism cannot be operated from the CONNECT position
with the breaker contacts closed.
lifting up the breaker positioning lever. Verify that the breaker
trips. An interlock lever extends out of the side of the breaker and
acts on the trip bar (DB-50) or trip shaft (DB-75). When the breaker
is levered out, this lever strikes a bracket in the breaker cubicle and
trips the breaker.
2.

breaker in a trip-free state when not m the TEST or CONNECT
4.
Switchgear cubicle:
WARNING:
Portions of the switchgear may be energized.
1.
Inspect the general condition of the switchgear cubicle and door.

Inspect for corrosion and bent or damaged subcomponents.
2.
Clean the air filters, if present.
3.
Clean the cubicle interior.
5-75
4.
Lubricate the door with an approved grease.
5.
Inspect the general appearance of the breaker (e.g., dirt- burns; broken, bent,
6.
Remove the arc chutes by removing the two retaining screws and lifting out
the arc chutes and attached insulators.
7.
Inspect the primary insulation/pole unit bases for dirt, moisture, carbon
tracks, and cracks.
5.5.2 Mechanical/Electrical Operation

1.
NOTE:

electrical lockout device, the devices will hold the breaker in a
The UV and electrical lockout devices are energized by applying rated
voltage to the secondary disconnects that are connected to the applicable
device coil leads. See the breaker control wiring diagram for connection
points. Device voltage rating is indicated on the device label plate. If a
voltage source is not available, the device may be restrained by tying the
armature in the energized position using a tie-wire or a nylon cable tie.
2.

3.
5.5.3 Contact Inspection and Adjustment

1.
overheating.
NOTE:
5-76

and surrounding insulation, requires corrective action and,
possibly, replacement of contacts.
2.
Contact gap:
1.
Contact pressure is verified by measuring and/or adjusting the

2.
On DB-50 breakers, contacts are adjusted to obtain a 0.05" to 0.093"

gap between the pole unit hinge and the pole auxiliary main contact
Contact Gap Specification: 0.050"-0.093"
3.
On DB-75 breakers, use a feeler gauge to measure the gap above and
below the upper main contacts. This clearance should be at least
0.005" for both contacts, and both values should be approximately
equal.
Contact Gap Specification: 0.005"
3.
Check contact overadjustment by manually pushing the stationary arcing

contact arm away from the moving contact and measuring the gap.
DB-50 Overadjustment Specification:
1/16" (0.063")
1/32"-1/8" (0.031"-0.125)
CAUTION:

4.

5.
Slow close the breaker until one set of arcing contacts touch. Measure the
clearance between the stationary and moving arcing contacts of the
remaining phases.
Contact Sequence Specification:
6.
1/16" (0.063")
Wipe contact assemblies with a clean cloth and isopropyl alcohol. Clean
contact surfaces with a mild abrasive such as Scotch-Brite.
5.5.4 Operating Mechanism Inspection

1.
Remove the top cover of the operating mechanism to allow visual access to
the mechanism.
5-77
2.
3.

retainers
4.
5.
6.
Inspect the operating mechanism subcomponents for excessive dirt buildup

and corrosion.
7.
8.
Cycle the trip bar or trip shaft by hand. Check for freedom of movement,
binding, or sluggish operation.
9.
Tripping load- Determine the force required to lift the trip bar or rotate the
trip shaft, and trip the breaker by performing the following.
WARNING:

1.
Close the breaker. For the DB-50 breaker, use a spring scale with a
0-50 ounce range and pull or push up vertically on the trip bar, about
3/4" from its right end, until the breaker trips. For the DB-75
breaker, push or pull on an accessible trip shaft paddle until the
breaker trips. The scale should be placed approximately 1" from the
axis of the trip shaft.
NOTE:
The spring scale should be held as perpendicular to the

trip bar or trip shaft paddle as possible.
Trip Load Specification: < 31 oz.
10.
5-78
2.
If the trip load exceeds 31 ounces, investigate the cause of the high
force.
3.
If not already marked, mark the location on the trip bar or trip shaft
paddle where the trip load measurement was made.
Wipe accessible areas with a clean cloth and approved solvent such as
isopropyl alcohol.
5.5.5 Cleaning, Inspection, and Adjustment of Major Subcomponents

Loose dust and dirt should be removed from external surfaces using a vacuum
cleaner or low-pressure compressed air Care should be taken to not blow dirt or
foreign objects into the mechanism area. When wiping or brushing is required, a
dry, lint-free cloth or bristle brush should be used. On gummy areas, an approved
solvent such as isopropyl alcohol should be applied to the cloth. The recommended
lubricant used on the operating mechanism, the UV device, and the shunt trip
device is a mixture of isopropyl alcohol and molybdenum disulfide. When the
alcohol evaporates, the molybdenum disulfide is left behind as a powdery film.
NOTE:
Care should be taken to not confuse the molybdenum disulfide for dust
and dirt, and mistakenly remove it during cleaning.
Inspect the subcomponents for cracks, wear damage, burning, and discoloration
associated with excessive heat.
1.
Frame assemblies: Inspect the frames for corrosion, bends, and cracked or
unfused welds.
2.
Pole unit bases:
3.
1.
Wipe accessible areas with a clean cloth and a mild, ammonia-based

glass cleaner.
2.
Inspect for cracks, burns, carbon tracks, warping, and signs of

overheating, especially around the upper and lower stud penetrations.
Arc chutes:
1.
Inspect for broken or cracked ceramic or asbestos subcomponents, dirt

Arc chutes with 40% of their original wall thickness eroded should be
replaced.
WARNING:
2.

5-79
WARNING:
4.
5.
6.
7.
3.
4.
Current-limiting fuses (DBL-50):

1.
Check that the fuse is the proper type and size
2.
Check for tight connections and wipe the outside of the fuse with a
lint-free cloth. Remove any conductive deposits using an approved
electrical solvent.
Closing solenoid:
1.
Inspect the coil and leads for signs of overheating or cracked

insulation.
2.
Clean the coil with a clean cloth and alcohol, or an approved solvent.
Control relay:
1.

coil and assemblies using an approved electrical solvent.
2.
Inspect the coil for signs of overheating. Inspect plastic

subcomponents for cracks.
3.
Verify that all moving parts operate freely.
4.
exceed 0.10.
5.
Clean the contacts with Scotch-Brite or equivalent, mildly abrasive

material.
Undervoltage trip device:

1.
5-80

Inspect the device for correct operation, insulation condition, tight

connections, and signs of overheating.
2.
3.
Check the device for loose hardware, proper mounting and freedom
of movement.
UV device clearance: The UV device should have approximately
1/16" clearance to the trip bar or trip shaft paddle.
breaker is fully closed, measure the gap between the UV device trip
lever and the trip bar on the DB-50 breaker and between the UV
device trip lever and the trip shaft paddle on the DB-75 breaker.
WARNING:
4.
Verify UV device over travel. Open the breaker manually and deenergize the UV device. Restrain the reset lever and close the
breaker manually. Slowly release the reset lever. The circuit
breaker should trip before the reset lever comes to rest.
sluggishness, binding, or hesitation. Cleaning, relubrication, or
replacement may be necessary to correct binding during this
operation.
8.
9.
Fuse trip device (DBL-50):

1.
Inspect the device for correct operation, insulation condition, and

tight connections.
2.
Fuse trip device adjustments: Insert a 1/8" feeler gauge between the
fuse trip lever and the micarta lever. The breaker should close and
latch. When a 3/16" feeler gauge is inserted, the breaker should trip.
If necessary, adjust the trip screw attached to the fuse trip linkage.
Primacy disconnects:
1.

2.
isopropyl alcohol.
3.

just prior to installing the breaker on the switchgear.
5-81
10.
11.
12.
Wiring and connections:

1.
Inspect the insulation condition and verify connections are tight.

Inspect for broken lugs, and broken or frayed wires.
2.
Replace damaged lugs or wires.
3.
Verify that wires are tied properly, secured, and routed away from
moving parts.
Auxiliary switch:
1.
Inspect for smooth operation. Inspect the plastic housing for cracks.
2.
Measure the resistance of all contacts. Clean the contacts and

investigate the cause of any contact resistance greater than 0.10.
Apply a light coat of graphite grease to any switch contacts from
which the grease was removed during contact cleaning.
1.
Inspect the secondary disconnects for correct operation, insulation

condition, and tight connections.
2.

binding. Verify that the clearance between the contact hook and the
back of the disconnect molding is < 0.015".
Specification: < 0.015"
13.
5-82
3.
Clean the disconnects with a clean cloth and an approved solvent

such as isopropyl alcohol. Inspect plastic insulation for cracks or
damage, particularly at mounting holes.
4.

Shunt trip device:

1.
Inspect for correct operation, freedom of operation, insulation condition,

tight connections, and solid mounting.
2.
Restrain the UV device and close the breaker manually.
3.
With the shunt trip device de-energized, measure the clearance

between the trip bar and the trip lever of the shunt trip device on
DB-50s, and between the trip shaft paddle and the shunt trip lever on
DB-75s.
DB-50 Specification: 1/32"-1/8" (0.032"-0.125")
DB-75 Specification: ~3/32" (0.094")
14.
15.

1.

and solid mounting.
2.
trip, etc.), the bell alarm is activated. Activation of the device is
3.
trip device. Manually close the breaker and trip it by means of the
trip button. Verify that the bell alarm does not activate.

1.

and solid mounting.
2.

The lockout device should prevent the breaker from closing by
holding the trip bar or trip shaft m the trip-free position. Holding
the lockout armature in the closed position should permit the breaker
to close. When the armature is released, the breaker should remain
closed.
3.
With the lockout device de-energized, mark the plunger at the point
where it enters the solenoid. Energize the lockout device and mark
the plunger at the same point. De-energize the device and measure
the distance between the two marks.
16.

1.

and solid mounting.
5-83
2.
Close the breaker manually. Check that the breaker will trip when
3.
Armature overtravel: Insert a 1/32" feeler gauge m front of the

pushed.
17.
Breaker positioning lever: Inspect the lever for correct operation and
freedom of movement. It should not be bent or damaged, and the stop pin at
the end of the lever should be intact.
18.
Subcomponent lubrication:
NOTE:
1.
2.
The following subcomponents should be lubricated approximately

every Six years.
Operating mechanism: Lubricate accessible areas of the following
locations m the operating mechanism using a mixture of
molybdenum disulfide and isopropyl alcohol (Westinghouse 53701GW
or equivalent). Use a hypodermic syringe to apply the lubricant in
areas with close tolerances.
Latch faces and latch mechanisms;
Trigger faces-
Trip pan felt pad (DB-50);
All pins, linkage, and bearing points;
Trip bar or trip shaft bearing/friction points; and
Inertia latch pivot pin.
UV device (non-reactor trip):

NOTE:
5-84
~1/32" (0.031")
Reactor trip breaker (RTB) UV devices should be

lubricated m accordance with the utility's RTB
Maintenance Procedures.
See Figure 5.5-1. Lubricate the following locations on the UV device

using a mixture of molybdenum disulfide and isopropyl alcohol
(Westinghouse 53701GW or equivalent):
Between the latch and latch spring;
The pin running through the trip spring;
The latch pivot pin;
The latch loop to latch-guide pin; and
Shunt trip device (non-reactor trip):
3.
The linkage pin on the trip lever bracket (DB-50).
5.5.6 Electrical Tests

NOTE:
1.

energized.
the primary circuits at l,000Vdc.
Specification: > 100 M
CAUTION:
2.

Specification: > 100 M
3.

5-85
Figure 5.5-1
UV Device Lubrication Points
5-86
Specification: < 150

NOTE:
4.
UV device pickup and dropout: Energize the UV device with an appropriate

variable voltage applied to the secondary disconnects, and close the circuit
breaker. (See the applicable breaker technical manual for connection
points.)
NOTE:
1.

2.
Slowly increase voltage to the UV device until it picks up and fully

closes. Verify that the breaker can be closed.
6.
6.
Control circuit: Use a variable-voltage power supply to conduct this test at

1.
Connect appropriate temporary control power to the breaker closing

circuit at the secondary disconnects.
2.
3.

should trip and not close.
4.
close.
Shunt trip device:

1.

circuits at the secondary disconnects, and close the breaker.
2.
5-87
5.5.7 Overcurrent Trip Device Operation

CAUTION:

1.
Remove the current-limiting fuses and install a test bus bar m their place.
2.
Electromechanical overcurrent trip devices: Electro-mechanical series

the manufacturer's time-current characteristic trip curves for the device.
1.
Positive trip check:

1.
DB-50: Close the breaker. Insert a 1/16" diameter rod into

the long-time delay calibration deft) slot and raise the time
delay valve lever to remove all of the time delay. Insert
another 1/16" rod into the top slot of the OCTD nameplate and
push the armature against the yoke to trip the breaker.
If the breaker does not trip, adjust the trip nut at the top of
the device. When positive tripping is achieved, turn the trip
screw downwards an additional 1/2-turn to ensure proper
overtravel.
2.
DB-75: Turn the screw at the end of the tripping finger

counterclockwise, approximately 1-1/2 turns. Close the
breaker. Carefully reach under the device and pull the lower
armature closed. Hold the armature closed for at least the
long-time delay interval. If the breaker trips, reset the trip
screw so that the breaker does not trip.
Repeat until the point is reached where the breaker just trips.
Turn the trip screw clockwise, one full turn from this point.
Repeat this process to verify that the breaker trips.
2.

Perform tests with a calibrated high-current, low-voltage test set.
Accomplish tests on individual phases.
5-88
1.

off the test set.
current until the breaker trips or 300 seconds have elapsed.
2.

Adjust the current, if necessary, towards the desired value and
have elapsed.
3.
CAUTION:

In cases where the instantaneous setting is less than 20 times

the breaker continuous-current rating test the instantaneous
trip element as follows.
has elapsed.
5-89
Compare the trip time measured to the manufacturer's timecurrent characteristic trip curve.
3.
3.
5-90

1.
The long-time delay is adjusted by turning the long-time

adjusting dial on the bottom of the device. The dial has
markings from 1 to 10. Higher numbers correspond to longer
delay times. Two factory-calibrated points are indicated by
white marks on the dial. The corresponding delay times are
indicated on the device's face plate.
2.

clockwise increases the pickup setting counterclockwise
3.

delay. The short-time delay is calibrated in cycles.
4.

Turning the knob clockwise increases the pickup setting.
5.

adjustment knob located under the instantaneous pickup scale.
6.
Solid-state overcurrent trip devices:

1.
Verify proper solid-state programmer device settings for the breaker

application.
2.
Verify that all OCTD wiring is properly connected and m good

condition.
3.
Inspect current transformers for cracked insulation and proper

connections, tap settings, and solid mounting.
4.

5.
bar (DB-50) or the trip shaft paddle (DB-75) and the actuator trip
lever is between 1/32" and 1/8".
Specification: 1/32"-1/8" (0.031"-0.125")
6.
Perform overcurrent trip test by primary current injection

NOTE:


NOTE:


jumper between terminals DN and DS on the unit This jumper must
NOTE:
1.
If the Amptector unit is tested by secondary injection,

one trip function of each phase should be tested
periodically (every six years) by direct injection to assure
proper operation of the complete overcurrent trip system.
setting.
have elapsed.
being tested.
5-91
has elapsed.
2.
Short-time delay element testing: Close the breaker and adjust

the test current to approximately 110%-150% of the short-time
pickup setting.
have elapsed.
3.
Instantaneous trip element testing:

CAUTION:

In cases where the instantaneous setting would result m test

has elapsed.
4.

restored by checking that the ground wire is connected to the
ground terminal (not the neutral terminal).
Slowly raise the test current and note the current at which
the breaker trips. This is the ground-fault pickup current.
Test again at a current higher than the pickup current value
and verify the ground-fault trip time. Repeat for each phase.
5-92

being tested.
7.
Perform overcurrent trip test by secondary current injection: The

Amptector Trip Unit Test Kit is a portable low-current source used
to simulate primary fault and overcurrent conditions by secondary
injection. The test kit consists of a current supply, an automatic
timer, and a test plug which inserts directly onto the test terminals
on the front of the Amptector unit. The test kit is powered from a
standard 120Vac outlet.
CAUTION:
When testing by secondary injection, the breaker must be

in the TEST or DISCONNECT position, or be removed
from its cubicle. Testing m the CONNECT position will
result in disruption of the primary circuit.
Secondary test current values are determined by using the standard

sensor output ratio of 0-5 amperes equals the full-scale rating of the
sensor (e.g., for a 600A sensor, a primary current of 240A of primary
current corresponds to 2A of secondary current).
1.
Long-time delay element testing: With the breaker in the

TEST or DISCONNECT position, connect the Amptector test
plug to the test terminals on the front of the Amptector unit.
The 11-pin test plug is polarized to ensure that it is connected
correctly.
Turn the circuit selector switch to the phase under test, close
the breaker, and apply a secondary test current which
corresponds to 300% of the current transformer tap setting
until the breaker trips or 300 seconds have elapsed.
being tested.
2.
Short-time delay element testing: Turn the circuit selector

switch to the phase under test, close the breaker, and apply a
secondary current which corresponds to approximately 110%150% of the short-time pickup setting until the breaker trips
or five seconds have elapsed.
5-93
3.
Instantaneous trip test: Turn the circuit selector switch to the

phase under test, close the breaker, and apply a secondary
current which corresponds to approximately 110%-120% of the
instantaneous trip setting until the breaker trips or one
second has elapsed.
4.
Ground-fault test:
NOTE:
When testing ground fault by secondary injection,

it may be necessary to disconnect the sensor wiring
from the test terminals to prevent loss of a portion
of the ground test signal in the sensors.
Switch the circuit selector switch to the phase under test.

Switch the ground test switch to the GROUND TEST position.
Close the breaker and slowly raise the test current and note
the secondary current at which the breaker trips. This is the
secondary ground-fault pickup current.
Test again at a secondary current higher than this pickup
being tested.
8.
5-94

5.5.8 Final Assembly and Inspection

1.
electric arc products may be deposited on contact surfaces during OCTD
testing.
2.
Install the arc chutes and attached insulators.
3.
loose subcomponents, damaged wiring etc.
4.
Operate the breaker manually and verify that breaker operates freely with
no binding. Verify that the breaker indicators accurately reflect breaker
status.
5.
6.

7.
8.
9.
The maintenance is complete and the breaker is ready to be installed in the

switchgear.
5-95
5.5.9 Maintenance Data Record

This record lists the data that should be collected each time periodic maintenance
is performed on a circuit breaker. These data provide a record of the circuit
breaker condition as well as the final adjustment and test values. This list
corresponds to the steps in the maintenance guideline.
Reason for Maintenance:
Breaker Type:
Frame Size:
Serial Number:
Cubicle:
Closing Voltage:
Tripping Voltage:
Maintenance Manual:
Counter Operations:
Date:
Step
5.5.1
General Inspection
5.5.2
5.5.3
Contact inspection
Main contacts
Arcing contacts
5-96
Step
Contact gap
A
B
C
A
B
C
Contact sequence
A
B
C
5.5.4
5.5.5
Inspection and Adjustment
7.3
UV device clearance
13.3
Shunt trip device clearance
15.3
Electric lockout device travel
16.3
5.5.6
Electrical Tests

Line-to-load
A
B
C
5-97
Step

Phase -to -ground
A
B
C
Phase-to-phase
A-B
B-C
A-C
Contact resistance
A
B
C

1.
Dropout voltage
2.
Pickup voltage
5.5.7
3.5

Device Type
Current Rating
5-98
Delay
sec
Delay
sec
Step
Test Current
Allowable Time
Recorded Time
Phase A
Long Time
Short Time
Instantaneous
Ground Fault
Phase B
Long Time
Short Time
Instantaneous
Ground Fault
Phase C
Long Time
Short Time
Instantaneous
Ground Fault
5-99
5-100
Section 5.6
DB-5075 Overhaul Guideline
5.6

5.6.1 Initial Test and Inspection ....................................................... 5-101
5.6.2 Disassembly ............................................................................ 5-111
5.6.3 Inspections, Tests, Cleaning, and Re-lubrication .................... 5-116
5.6.4 Reassembly ............................................................................. 5-123
QA Requirements .................................................................... 5-129
5.6.6 Overhaul Data Record ............................................................. 5-141
5.6
5.6.1
1.
General Inspection
1.
2.
3.

1.
Racking mechanism interlock: Verify that the breaker drawout

mechanism cannot be operated from the CONNECT position with the
breaker contacts closed.
lifting up the breaker positioning lever. Verify that the breaker
trips. An interlock lever extends out of the side of the breaker and
acts on the trip bar (DB-50) or trip shaft (DB-75). When the breaker
is levered out, this lever strikes a bracket in the breaker cubicle and
trips the breaker.
2.
Trip interlock: Verify that the breaker cannot be closed while

4.
Inspect the general appearance of the breaker (e.g., dirt- burns; broken, bent,
5.
Remove the arc chutes by loosening the retaining screw and lifting each arc
chute and attached insulator up and out. Inspect the arc chutes for signs of
corona, burning, and cracks.
6.
Inspect the insulated pole unit bases for dirt, carbon tracks, and cracks.
Inspect prior to cleaning since carbon tracks may give evidence of cracks in
the insulation material.
5-101
2.
1.
NOTE:

electrical lockout device, the devices will hold the breaker in a
These devices are energized by applying rated voltage to the secondary
disconnects that are connected to the applicable device coil leads. See the
breaker control wiring diagram for connection points. Device voltage rating
is indicated on the device label plate. If a voltage source is not available,
the device may be restrained by tying the armature in the energized
position using a tie-wire or a nylon cable tie.
3.
2.

3.

1.
overheating. Inspect silver plating for flaking or peeling.
NOTE:
2.

and surrounding insulation, requires corrective action and
possible replacement of contacts and spring assemblies.
Contact gap: Contact pressure is verified by measuring and/or adjusting the

1.

gap between the pole unit hinge and the pole auxiliary contact with
the breaker closed.
2.
5-102
0.005" for both contacts and both values should be approximately
equal.

3.
4.
Check for overadjustment by manually pushing the stationary arcing

contact away from the moving contact and measuring the gap.
1/16" (0.063")
DB-75 overadjustment Specification:
1/32"-1/8" (0.031"-0.125")
remaining phases.
Sequence Specification: 1/16" (0.063")
CAUTION:
5.
4.



1.
Remove the top cover of the operating mechanism to allow visual access.
2.
3.

retainers.
4.
5.
6.
Inspect the operating mechanism subcomponents for excessive dirt buildup

and corrosion.
7.
8.
Cycle the trip bar or trip shaft by hand. Check for freedom of movement,
binding, or sluggish operation.
9.
Tripping load: Determine the force required to lift the trip bar or rotate the
trip shaft and trip the breaker by performing the following.
5-103
WARNING:

1.
NOTE:

trip bar or the trip shaft paddle as possible.

If not already marked, mark the location on the trip bar or trip shaft
paddle where the force measurement was made.
2.
Electrical Tests
5.
NOTE:
1.

energized
the primary circuits at 1,000Vdc. Measure the insulation resistance of each
phase.
Specification: l00 M
2.
Wiring insulation resistance:

CAUTION:
Do Not measure the insulation resistance of the wiring of a

solid-state trip programmer unit.
Measure the insulation resistance of the control wiring to ground at 500Vdc.
5-104
3.

Specification: 150
NOTE:
4.
UV device pickup and dropout:

1.
NOTE:
2.
Energize the UV device by applying rated voltage to the secondary

disconnects with a variable voltage supply, and close the circuit
breaker.
Slowly reduce voltage to the UV device until the breaker trips. The
voltage at which the breaker trips is the dropout voltage.
3.

5.
Control circuit Use a variable-voltage power supply to conduct this test at

1.
Connect temporary control power to the breaker charging and local

closing circuits at the secondary disconnects.
2.
3.

should trip but not close.
4.
Release and re-apply the closing signal and the circuit breaker should
close.
5-105
6.
Shunt trip device:

1.

circuit at the secondary disconnects, and close the breaker.
2.
6.
CAUTION:

avoid destroying the fuses.
1.
Remove the current-limiting fuses and install a test bus bar m their place.
2.

the time-current characteristic trip curves for the device.
1.
Positive trip check:

1.
DB-50: Close the breaker. Insert a 1/16" diameter rod into

the long-time delay calibration slot and raise the time delay
valve lever to remove all of the time delay. Insert another
1/16" rod into the top slot of the OCTD nameplate and push
the armature against the yoke to trip the breaker.
If the breaker does not trip, adjust the trip nut at the top of
the device. When positive tripping is achieved, turn the trip
screw downwards an additional 1/2-turn to ensure proper
overtravel.
2.

long-time delay. If the breaker trips, reset the trip screw so
that the breaker does not trip.
Repeat the process to verify that the breaker trips.
2.
5-106


information, type, current rating and curve number.
1.
Long-time delay test: Close the breaker and apply current to

the phase under test.
off the test set.
2.
Short-time delay test: To accurately test the short-time delay,

the test set must have a memory feature to hold and display
the test current.
Close the breaker and apply current momentarily.
(Approximately 110%-150% of the short-time pickup setting is
the recommended test current.)
Adjust the current toward the desired value and repeat until
the desired test current is achieved.
have elapsed.
3.
Instantaneous test:
CAUTION:

5-107
If the test current is greater than 20 times the breaker

continuous-current frame rating the instantaneous test may
be accomplished by removing the trip unit from the breaker
and bench-testing the trip function. Current should be
injected through a test bus which runs through the magnet
coil of the device, and m this way verifies the function of the
armature.
has elapsed.
3.

specified by the time-current characteristic trip curve for the device.
Tap settings should not be changed while the breaker is carrying
current.
CAUTION:
1.
2.
Verify that all device wiring is properly connected and m good condition.
3.
Inspect current transformers for cracked insulation and proper connections,

tap settings, and solid mounting.
4.

5.
Specification: 1/32"-1/8" (0.03 1"-0.125")
6.
Perform overcurrent trip test by Primary current injection

NOTE:
5-108
On breakers with ground-fault trip features, it will be necessary

to defeat the ground-fault element prior to testing the other trip
features of the device.

NOTE:


1.

setting.
have elapsed.
Compare the trip time to the manufacturer's time-current
being tested.
has elapsed.
2.

pickup setting.
have elapsed.
5-109
3.

CAUTION:

In cases where the instantaneous setting would result m test

currents greater than 20 times the breaker frame rating reset
has elapsed.
4.

ground terminal (not the neutral terminal).
Slowly raise the test current and note the current at which
the breaker trips. This is the ground-fault pickup current.
characteristic Rip curve for the specific settings of the device
being tested.
8.
5-110

Amptector provide the means of adjusting the unit
5.6.2 Disassembly
The disassembly instructions m this section do not identify location, orientation, or
size of spacers, shims, retainers, lock washers, and other hardware. The circuit
breaker mechanic must record this information during the disassembly process.
1.
Ancillary Items
1.
2.
3.
2.
Front face Plates:

1.
Remove the fixed face plate by removing the two mounting screws.
2.
Remove the moving face plate by removing the screws on the side of
the operating mechanism.
1.
Primary disconnects are held m place by leaf spring pressure. Cover

the fingers of the disconnects with a cloth to prevent damage. Use a
large pair of pliers to compress the springs until the metal tips on the
fingers clear the corresponding holes m the upper and lower studs.
The fingers may then be pulled clear of the studs.
2.
On DB-50 breakers, remove the solid-state OCTD current sensors if

installed. On DB-75 breakers with solid-state OCTDs, remove the
screws and brackets that hold the current sensors m place, and
remove the sensors.
1.
The secondary disconnects consist of an insulated body with

spring-type fingers to which the wiring is attached.
2.
Remove the mounting screws which hold the disconnects to the

breaker frame.
3.
Label and disconnect the wiring and remove the secondary

disconnects.
Frame Assemblies
1.
DB-50:
1.
Separate the operating links from the crossbar by removing the

retaining rings and sliding the crossbar out.
5-111
2.
3.
2.
Separate the front and back frames by removing the four bolts that
hold the breaker platform to the back frame.
3.
Feed the control wire bundle through the hole m the breaker back
frame.
DB-75:
1.
Separate the operating links from the crossbar by removing the

retaining rings and poles that hold each link to the crossbar.
2.
Disconnect the two tension bars that connect the operating

mechanism to the back frame after noting the positions of the locking
nuts.
3.
Separate the front and back frames by removing the four bolts that
hold the breaker platform to the back frame.
4.
Feed the control wire bundle through the hole m the breaker back
frame.
Pole Unit Bases

The DB-50/75 insulated pole unit bases are three separate pieces on which the
contacts of each phase are mounted. Each base is bolted separately to the breaker
back Same.
Prerequisites:
Upper and lower primary disconnects have been removed.
The frame assembly has been separated.
4.
1.
For breakers with electromechanical OCTDs, remove the four OCTD

mounting bolts and lift out each OCTD.
2.
Remove the bolts at the top, middle, and bottom of the pole unit base and
remove the pole bases from the back frame.
Contact Structure
1.
DB-50 movable contacts:

1.
5-112
Remove the three bolts from the back of the pole unit base and
remove the moving contact assembly. (If the breaker is equipped
with electromechanical OCTDs, two of the three bolts were removed
previously.) The stationary auxiliary main contacts and springs can

now be removed as well.
2.
3.
4.
5.
2.
Remove the arcing contacts by removing the two screws at the top of
the contact assembly.
3.
The moving main contacts are held m place by spring pressure. To

remove them, turn the spring locking screw, pull the springs through
the assembly, and then slide the contacts out.
DB-50 stationary contacts:

1.
Remove the arcing contacts by removing the two screws that hold the
arcing contact and spring in place.
2.
To remove the main contacts, remove the two bolts on the back of the
upper part of the pole unit base.

1.
Remove the four bolts at the bottom of each pole unit base and lift
out the moving contact assembly and opening sprigs.
2.
Remove the arcing contacts by removing the two screws at the top of
the contact assembly.
3.
Remove the two bolts that hold the auxiliary contacts in place.
4.
To remove the main contacts, note the position and loosen the contact
pivot tension nuts. Then remove the retainer and pivot pin that hold
the main contacts m place. Lift out the main contacts.

1.
Remove the four bolts that hold the arcing contacts m place, and lift
out the contacts.
2.
The stationary main contact assembly is held in place by two bolts.

To remove individual contact fingers, loosen the screws on either side
of the assembly and lift the fingers out.
1.
Auxiliary switch: The auxiliary switch is mounted on top of the breaker

front frame to the left of the operating mechanism. Its operating shaft is
linked to the closing lever of the breaker mechanism.
5-113
2.
3.
4.
5-114
1.
Remove the auxiliary switch cover and record the contact sequence.
2.
Close the breaker to facilitate removal of the auxiliary switch.
3.
Disconnect the auxiliary switch linkage from the operating

mechanism by removing the retainer and then pulling the linkage off
of the closing lever.
4.
Label and disconnect the leads to the switch terminals. Remove the
switch mounting screws and the switch.
Control relay: The control relay is located beneath the auxiliary switch on
the left side of the breaker.
1.
Remove the cover, and label and disconnect the wiring.
2.
Remove the two mounting screws and the relay.
Closing solenoid (solenoid-operated breakers only):

1.
2.
Maintain the breaker m the trip-free position by pushing up on the

trip bar or rotating the trip shaft.
3.
first and second toggle links. This requires that the middle pole unit
be closed by hand two-thirds of the way so that the pin will line up
with a hole in the mechanism frame. To prevent binding, push up on
the solenoid moving core. Insert a punch through the small hole in
the left side of the frame and push the pin out until it clears the
moving core. The solenoid housing must be supported at this point.
4.
While continuing to support the solenoid, remove the four bolts that
connect the solenoid and the operating mechanism to the breaker
platform. Lift the solenoid out of the breaker.
Bell alarm device: The bell alarm device is mounted above the shunt trip
device and should be removed with the shunt trip device.
1.
2.
Disconnect the operating linkage from the breaker operating

mechanism by removing the retainer clips. Remove the bell alarm
switch with the shunt trip device.
5.
6.
7.
8.
Shunt trio device: The shunt trip device is mounted on the right side of the
breaker front frame just to the right of the operating mechanism.
1.
2.
Remove the two mounting screws, the shunt trip device, and the bell
alarm device.
Undervoltage trip (UV) device: The UV device is mounted on top of the

breaker platform, just to the right of the shunt trip device.
1.
Label and disconnect the device leads.
2.
Remove the mounting hardware and the UV device.
Electric lockout device: The electric lockout device is mounted on the left
side of the breaker front frame, behind the auxiliary switch.
1.
Remove the electric lockout device by removing the screws which

secure it to the frame.
2.
Label and disconnect the wiring and remove the device.
Fuse trip device The fuse trip device is located under the current-limiting
fuses for each phase.
Remove the mounting screws that secure the support bracket to the breaker
frame and fuse. Remove the device.
9.
Current-limiting fuses: Remove the fuse mounting bolts from each end of
the primary fuse. Remove the fuse.
10.
Solid-state trip device (Amptector ):
11.
1.
Label and disconnect the OCTD leads. Remove the current sensor
wiring harness by removing the mounting screws.
2.
Remove the mounting bolts for the Amptector unit and the
actuator. Remove the Amptector unit and the actuator.

1.
2.
Remove the mounting bolts and the reverse current trip attachment.
5-115
6.
Operating Mechanism
Prerequisites:
All control and auxiliary devices and associated wiring have been removed,
including the closing solenoid.
1.
2.
Electrically operated breakers:

1.
Loosen the outboard bearings at the end of the trip shaft (DB-75).
2.
Remove the four screws which fasten the bottom of the mechanism to
the horizontal platform. Lift the mechanism clear of the breaker.
Manually operated breakers:

1.
Maintain the breaker m the trip-free position by pushing up on the

trip bar or rotating the trip shaft.
2.
first and second toggle links. This requires that the middle pole unit
be closed by hand two-thirds of the way so that the pin will line up
w ith a hole m the mechanism frame. Insert a punch through the
small hole m the left side of the frame and push the pin out until it
clears the moving core. The spring housing must be supported at
this point.
3.
While continuing to support the sprig, remove the four bolts that
connect the spring housing and the operating mechanism to the
breaker platform, and remove the spring assembly. Lift the
operating mechanism clear of the breaker.
5.6.3 Inspections, Tests, Cleaning, and Re-lubrication

1.
Ancillary Items
1.
Arc chutes:
1.
Inspect for broken or cracked ceramic or asbestos subcomponents, dirt

Arc chutes with barriers eroded to 40% of their original thickness
should be replaced.
5-116
WARNING:
2.
WARNING:
2.
3.
Do not sand asbestos arc chute material. The resulting dust

is hazardous. If the material of construction for the arc
chute is unknown, do not sand.

3.
4.
1.

2.
isopropyl alcohol.
3.

1.

binding. Clean the disconnects with a clean cloth and a mild solvent.
2.
Inspect plastic insulation for cracks or damage, particularly at the

mounting holes.
3.
Verify that the clearance from the contact hook to the back of the
disconnect molding is 0.015".
4.

5-117
2.
Frame Assemblies
Inspect the frames for corrosion, bends, and cracked or unfused welds. Remove
rust. Prime and electroplate as necessary.
3.
4.
5.
5-118
Contact Structures
1.
Clean the contacts with Tarnex or other silver plate cleaner. Rinse
thoroughly and dry. De-burr the contacts using sandpaper or Scotch-Brite.
2.
Inspect the condition of the plating and contact surfaces. Contact

replacement is recommended when less than one-half of the original
thickness of the contact tip remains or the contact tips are severely pitted.
Minor pitting and roughening of the contact surfaces are not causes for
replacement.
3.
Inspect the opening and contact springs for corrosion, damage, and excessive
wear.
Pole Unit Bases

1.
Wipe the pole unit bases with a clean cloth and a mild, ammonia-based glass
cleaner.
2.
Inspect for cracks, burns, carbon tracks, warping and signs of overheating,
especially around upper and lower stud penetrations and threaded inserts.
Operating Mechanism
1.
Disassemble the operating mechanism and spring assembly (on manual

breakers) carefully, recording subcomponent arrangement by taking notes,
punch marking, and scribing subcomponents to provide assurance that they
will be reassembled correctly. Begin by removing the subcomponents from
one end of each shaft and working from the outside toward the center.
Remove the parts slowly and observe the mechanical relationships among
the different subcomponents. Line drawings that reference each spacer,
retainer, bearing, and other subcomponent by size and location on each shaft
should be made. Care should be taken with bearings to ensure that they are
not damaged.
2.
During and after disassembly of the operating mechanism inspect for the
following:
Broken, weak, or defective springs;
Bearings--lubrication and freedom of movement;
6.
Latches for wear and fatigue cracks
Trip bar or trip shaft for freedom of movement;
Worn or cracked pins;
Alignment of pins through linkages;
Welds for stress and cracks; and
Corrosion and plating condition.
3.
Clean all mechanism subcomponents with an approved/equivalent solvent.

Remove all traces of solvent by cleaning degreased parts with alcohol or
mild soapy water, and blow each subcomponent dry with compressed air.
4.
Re-plate all electroplated parts. Replace all worn or damaged

subcomponents.
1.
2.
Auxiliary switch:
1.
Inspect for correct operation, insulation condition, and cracks m the

housing and cover.
2.
Measure the resistance of all contacts. Investigate the cause of any

readings over 0.1.
3.
Disassemble the switch and clean the internals with alcohol. Replace
the contacts if they are badly burned or pitted.
4.
Apply a light coat of graphite grease (Westinghouse 53701ANOOT) to

the switch contacts.
Closing solenoid (solenoid-operated breakers):

1.
Inspect the coil and leads for signs of overheating and damaged
insulation.
2.
Measure the coil resistance. Clean the coil with a clean cloth and
alcohol, or an approved solvent.
5-119
3.
4.
5-120
Control relay:
1.

Disassemble and clean the coil and assembly of dirt, dust, grease, and
oil using an approved electrical solvent.
2.
Inspect the coil for signs of overheating. Measure the control relay
coil resistance.
3.
Inspect plastic subcomponents for cracks. If installed, inspect the

control relay's arc chute for cracks, erosion, and carbon deposits.
4.
5.
resistance. Investigate the cause of any resistancereadings which
exceed 0.1. Clean the contacts with Scotch-Brite or equivalent,
mildly abrasive material.
Shunt trip device:

1.
Inspect for freedom of operation and insulation condition. Disassemble

the coil and assemblies. Remove dirt and dust using a clean cloth and
alcohol.
2.
3.
Inspect the coil for signs of overheating. Measure the shunt coil
resistance.
4.
To replace the shunt coil, perform the following:

1.
Disconnect and label the coil leads.
2.
Remove the two screws which fasten the coil retaining plate to
the frame.
3.
Remove the moving core and internal sleeve from the housing.
Remove the coil and install the new coil.
5.
Lubricate the shunt trip device by applying a few drops of approved

lubricant to the linkage on the inside and outside mechanism
surfaces.
6.
Replace RTB shunt trip devices at each overhaul.
5.
Wiring and connections: Inspect for brittle and cracked insulation, pinched
wires, loose connections, broken lugs, and broken or frayed wires.
6.
Phenolic covers and bases. insulated push rods etc.: Inspect for cracks,
punctures, tracking, and excessive dirt. Replace if cracked. Clean with a
clean cloth and alcohol.
7.
UV device:
1.
Inspect the coil for signs of overheating. Measure the UV coil

resistance.
2.

3.
Inspect the latch, latch pin, and trip lever for excessive wear.
4.
5.
Apply lubricant (molybdenum disulfide in isopropyl alcohol, or

approved equivalent) liberally to the following points:
6.
8.
Between the latch and latch spring (The latch may be gently
pulled away to gain access to this area.);
Latch loop to latch-guide pin area;
Latch to latch pin with notch ("D" pin);
Latch pivot pin; and
Pin running through the trip spring.
Replace RTB UV devices at each overhaul.

1.

2.
Inspect the coil for signs of overheating. Measure the coil resistance.
3.
5-121
9.
10.
11.
12.
13.
Bell alarm device:

1.
Inspect for freedom of operation. Clean the assembly using a clean

cloth and alcohol.
2.
Verify that all moving parts operate freely. Inspect the switch for
damage.
3.
Measure contact resistance. Replace the switch if contact resistance

is greater than 0.1.
Primary fuses:
1.
Verify that the primary fuses are the proper type and rating. Check
the continuity of each fuse.
2.
Wipe the outside of each fuse with a clean cloth and alcohol. Remove
any conductive deposits from the body of the fuse.
Fuse trip device:

1.
Disassemble and clean the assembly using a clean cloth and alcohol.
defects.
2.
Reassemble and lubricate friction points with the molybdenum

disulfide/alcohol mixture or equivalent.
Solid-state OCTD actuator:

1.

assembly using a clean cloth and alcohol.
2.
Measure the actuator coil resistance.
3.
Inspect the plastic subcomponents for cracks.
4.
Verify that the permanent magnet has sufficient strength to hold the
device m the reset position while tapping the device lightly on a
bench top.
Solid-state trip current sensors:

1.
5-122
Inspect the sensors for signs of overheating, cracked insulation, and

damaged wiring.
2.
14.
15.
Clean the sensors and terminations by wiping with a clean cloth and
alcohol. Measure the sensor resistance.
Electromechanical overcurrent trio device:

1.
Clean the assembled trip unit with an approved solvent and a small
brush. Remove all solvent with alcohol and blow the unit dry with
compressed air.
2.
Remove the reset valve and clean the valve filter.
3.
Inspect the device for rusted surfaces, bent or broken parts, missing
or stretched springs, and separated magnet laminations.
4.
Reverse current device:

1.
Inspect for freedom of operation. Disassemble and clean the coil and
assembly of dirt, dust, grease, and oil using a clean cloth and alcohol.
Inspect for physical distortions or damage.
2.
Lubricate moving parts with a light-weight machine oil.
QA Hold Point
facets of disassembly and inspection have been completed.
5.6.4 Reassembly
1.
Operating Mechanism
Carefully reassemble the operating mechanism, referring to the notes taken during
disassembly.
1.
Lubricate all pivot points, bearings, bushings, and sliding contact points
with molybdenum disulfide mixed with isopropyl alcohol. Ensure that the
following areas are lubricated:
Latch faces;
Trigger faces;
Felt pad on the trip pan--the pad should be thoroughly soaked; and
All trip bar and trip shaft pivot points and bearing surfaces.
5-123
2.
Replace all c-clips, tru-arcs , lock-washers, and other special retainers

during reassembly.
3.
Check frequently during reassembly to ensure that all subcomponents

operate freely and agree with the notes and figures. Ensure that all
subcomponents are mounted solidly and that the mounting hardware is
tightened securely.
Hold Point
At this point of the overhaul, a supervisory review is realized to verify tat the operating
mechanism is assembled properly and that all operating mechanism retainers are
installed.
2.
3.
Operating Mechanism and Closing Solenoid/Spring

1.
Install the operating mechanism onto the breaker platform and insert the
four mounting bolts which fasten the bottom of the mechanism frame to the
horizontal breaker platform.
2.
Align the closing solenoid assembly (closing spring assembly on manual

breakers) to the breaker platform. The moving core plunger should be
oriented up into the breaker operating mechanism.
3.
Tighten the four frame mounting bolts.
4.
Connect the moving core plunger (push rod on manual breakers) to the
toggle linkage by installing the toggle link connecting pin and its associated
retainer.
5.
Connect the closing solenoid coil leads.
6.
On DB-75 breakers, tighten the outboard bearings at the end of the trip
shaft, being careful to ensure that trip shaft binding does not result.
Contact Structure
1.
5-124

1.
Install the stationary main contacts and upper stud using the two
mounting bolts.
2.
Attach the stationary arcing contacts to the main contact assembly

with the two mounting screws after ensuring that the arcing contact
springs are properly positioned.
2.
3.
4.

1.
Slide the main moving contacts back into place and insert the
springs, ensuring they are locked in place.
2.

3.
Attach the arcing contacts to the main moving contact assembly with
the two mounting screws.
4.
Install the auxiliary main contacts, springs, and moving contact

hinge as an assembly, ensuring that the springs are positioned
correctly. Attach this assembly to the pole unit base with the
uppermost of the three lower bolts.
5.
On breakers with electromechanical OCTDs, install the lower stud

and the electromechanical OCTD with the remaining two bolts. On
all other breakers, attach the lower stud and the shunt between the
lower stud and the moving contact hinge with the mounting
hardware.

1.
Coat the hinge area of the stationary arcing contact with a thin coat
of graphite grease (Westinghouse 53701ANOOT).
2.
Install the stationary main contact assembly with the two mounting
bolts. Attach the arcing contact assembly with the four mounting
bolts.
DB-75 moving contacts:

1.

2.
Position the main contact hinge assembly and insert the pivot pin
and retaining ring. Tighten the contact pivot tension nuts to the
position recorded during disassembly.
3.
Attach the moving auxiliary contacts with two mounting bolts.
4.
Using the four mounting bolts, attach each moving contact assembly
and the opening springs to the pole unit bases. On breakers with
solid-state OCTDs, install the sensor mounting bracket. Install the
electro-mechanical OCTDs.
5-125
4.
Pole Unit Bases

Set the pole unit bases onto the front of the breaker back frame. Install the
fasteners which secure each pole unit base.
5.
Frame Actions
1.
2.
6.
1.
Lower the front frame assembly straight down onto the back frame
assembly. Take care to clear any mechanical interferences including
the trip bar and trip levers. Install the four bolts that join the
breaker platform to the back frame.
2.
Insert the mechanism crossbar to attach the operating links to the

operating mechanism. Install the alarm switch clevis on the
crossbar. Reattach all retaining rings.
DB-75:
1.
Lower the front frame assembly straight down onto the back frame
assembly. Take care to clear any mechanical interferences including
the trip shaft and trip levers. Install the four bolts that join the
breaker platform to the back frame.
2.
Install the tension bars that connect the operating mechanism to the
back frame. Tighten the locking nuts so that their position is the
same as that recorded during disassembly.
3.
Reattach the operating links and the alarm switch clevis to the
crossbar.
1.
5-126
DB-50:
Auxiliary switch:
1.
Before mounting the switch, position the crank end of the switch
operating shaft into the hole in the operating mechanism link. Set
the switch crankshaft so that the switch shaft and the breaker
contacts are m their original (pre-disassembly) direction and the
contact sequence is as originally recorded.
2.
Install the mounting bolts. Connect and tighten all switch leads.
Install the switch cover.
2.
3.
4.
5.
Control relay:
1.
Install the control relay assembly by installing the mounting studs

which fasten the assembly to the breaker. Connect all leads.
2.
Align the relay release arm on the closing solenoid with the control
relay release lever.
Solid-state trip current sensors (Amptector ):

1.
Position the current sensors onto the breaker lower studs. On DB-75
breakers, the sensors must be mounted with the end marked "SH" on
the top.
2.
Connect the sensor wiring and secure the wiring connector with
mounting screws. Neatly dress all sensor wiring and tie with cable
Lies as necessary.
Bell alarm device:

1.
Install the device as a single unit with the shunt trip device.
2.
Connect the device's operating linkage to the operating mechanism

link and install new retainers. Connect the device's leads.
Shunt trip device:

1.
Attach the shunt trip device to the breaker platform using the
mounting screws. Connect the device's wiring.
WARNING:
2.
Adjust the shunt trip device clearance.

Close the breaker. Measure the clearance between the shunt trip
lever and the trip bar or trip shaft paddle. The clearance should be
approximately 3/32" for DB-75 breakers, and between 1/32" and 1/8"
for DB-50 breakers.
6.
UV device:
1.
Align the W device on the platform and position the trip lever
under the trip bar or trip shaft paddle.
5-127
2.
Attach the device to the breaker platform and tighten the hardware.
The UV device mounting base should be parallel to the breaker
platform. Connect the device's wiring.
3.

1/16" clearance to the trip bar or trip shaft paddle.
breaker is fully closed, the gap should be approximately 1/16"
between the UV device trip lever and the trip bar on DB-50 breakers
and between the UV device lever and the trip shaft paddle on DB-75
breakers.
7.
5-128
7.
Electric lockout device: Install the lockout arm and lever, spacers, and
retainers. Install the device using the mounting screws which secure it to
the frame. Connect the device's leads.
8.
Primary fuses: Verify that the fuses are the proper type and rating. Install
the fuses onto the primary studs using the mounting bolts after completion
of the OCTD testing. Securely tighten all bolted fuse connections. Poor fuse
connections can cause breaker overheating.
9.
Fuse trip device: Insert the device and support frame under the fuse.
Install the mounting hardware which secures the device to the breaker
frame and fuse.
10.
Reverse current trip device: Install the device on the center pole unit and
attach with the mounting hardware. Connect the device's leads.
11.
Solid-state OCTD Amptector unit and actuator: Attach the actuator and
Amptector unit with the appropriate mounting hardware. Connect the
leads to both devices.
Ancillary Items
1.
Primary disconnects: Attach the primary disconnect fingers to the upper

and lower studs.
2.
Secondary disconnects: Install the secondary disconnects by installing them

on the mounting bracket and installing the two mounting screws. Attach
the wiring in accordance with the notes made during disassembly.
3.
Face Plates: Install the stationary and moving breaker face plates.
QA Hold Point
At this point of the overhaul, a quality assurance (QA) review is required to verity that all
breaker deficiencies have been resolved and that the breaker has been reassembled
5.6.5 Post-Overhaul Inspections, Adjustments, and QA Requirements

1.
Mechanical Tests and Inspections

1.
Contact gap:
1.
Contact pressure is maintained by measuring and/or adjusting the

2.

gap between the pole unit hinge and the pole auxiliary contact with
the breaker closed.
3.
0.005" for both contacts, and both values should be approximately
equal.
CAUTION:
4.
2.
3.


removing the crossbar, loosening the locking nut, and screwing the
insulating link in or out on the stud connected to the moving contact
arm. Be sure to tighten the lock nuts after each adjustment.
Contact overadiustment: Check for overadjustment by manually pushing the

stationary arcing contact arm away from the moving contact and measuring
the gap.
1/16"(0.063")
1/32"-1/8" (0.031"-0.125)
remaining phases.
5-129
Sequence Specification: 1/16" (0 063")

4.
Operating mechanism adjustments:

1.
Inspect for loose parts, and missing or loose retainers, snap-rings, or

bearing retainers.
2.
Cycle the trip bar or trip shaft by hand. Check for freedom of
movement, binding, or sluggish operation.
3.
Tripping load: Determine the force required to lift the trip bar or
rotate the trip shaft and trip the breaker by performing the
following.
WARNING:

equpment damage, ensure that hands and test equipment
remain clear of moving breaker parts.
NOTE:

trip bar or trip shaft paddle as possible.

5.
UV device:
1.

1/16" clearance to the trip bar or trip shaft paddle when the breaker
is closed.
Energize the UV device. Slow close the breaker. When the breaker
is fully closed, measure the gap between the UV device trip lever and
the trip bar for DB-50 breakers and between the UV device trip lever
and the trip shaft paddle on DB-75 breakers.
Specification: ~ 1/16 (0.063")
WARNING:
5-130
2.
Open the breaker manually and de-energize the UV device. Restrain

the reset lever and close the breaker manually. Slowly release the
reset lever. The circuit breaker should trip before the reset lever
comes to rest.
sluggishness, binding, or hesitation.
6.
Fuse trip device: Insert a 1/8" feeler gauge between the fuse trip lever and
the micarta lever. The breaker should close and latch. When a 3/16" feeler
gauge is inserted, the breaker should trip. If necessary, adjust the trip
screw attached to the fuse trip linkage.
7.
Shunt trip device: With the shunt trip device de-energized, measure the
clearance between the trip bar and the trip lever of the shunt trip device on
DB-50 breakers, and between the trip shaft paddle and the shunt trip lever
on DB-75 breakers.
DB-50 Specification: ~1/32"-1/8" (0.032"-0.125")
DB-75 Specification: ~ 3/32" (0.094")
8.

1.
2.

pushed.
2.
~ 1/32" (0.031")
Electrical Tests and Inspections

NOTE:
1.

energized.
5-131
CAUTION:
2.

3.

Specification: 150
NOTE:
4.
Undervoltage Pickup and dropout: Energize the UV device with an

appropriate variable voltage applied to the secondary disconnects, and close
NOTE:
1.
Energize the W coil for approximately 10 minutes prior to

Slowly reduce voltage to the W device until the breaker trips.
2.
Slowly increase voltage to the UV device until the UV device

armature picks up and fully closes. Verify that the breaker can be
closed.
5.
1.
5-132
Connect appropriate temporary control power to the breaker charging

and closing circuits at the secondary disconnects. Close the breaker
electrically by energizing the closing circuit.
2.

should not close.
3.
close.
6.
Shunt trip device: Close the breaker and verify that the shunt trip device
will trip the breaker when energized from the secondary disconnects.
7.
8.
1.
trip, etc.), the bell alarm is activated. Activation of the device is
2.
trip device.
3.
Manually close the breaker and trip it by means of the trip button.
Verify that the bell alarm does not activate.

1.

closing by holding the trip bar or trip shaft m the trip-free position.
Pushing down on the lifting plate should permit the breaker to close.
When the lifting plate is released, the breaker should remain closed.
2.
With the lockout device de-energized, mark the plunger at the point
where it enters the solenoid. Energize the lockout device and mark
the plunger at the same point. De-energize the device and measure
the distance between the two marks.
3.

CAUTION:

5-133
1.
Remove the current-limiting fuses and install the test bus bar.
2.
Electro-mechanical overcurrent trip devices: Test electro-mechanical series

OCTDs for proper operation within the time specified by the manufacturer's
time-current characteristic trip curves for the device.
1.
Positive trip check and overtravel:

1.
DB-50: Turn the trip screw upward one turn, and close the
breaker. Insert a 1/16" diameter rod into the long-time delay
calibration slot and raise the time delay valve lever to remove
all of the time delay. Insert another 1/16" rod into the top slot
of the OCTD nameplate and push the armature against the
yoke to trip the breaker. The breaker should not trip.
If the breaker does trip, continue to adjust the trip screw
upwards until the breaker does not trip. Then, turn the trip
screw down until the trip plunger moves just enough to trip
the breaker when the armature is pushed against the yoke.
When positive tripping is achieved, turn the trip screw down
an additional 1/2-turn to ensure proper overtravel.
2.

long-time delay interval. If the breaker trips, reset the trip
screw so that the breaker does not trip.
Repeat the process to verify that the breaker trips.
2.

time-current characteristic trip curve. The applicable time-current
characteristic trip curve is determined by the device nameplate
1.
5-134


off the test set.
2.

have elapsed.
does not trip.
3.

CAUTION:

If the test current exceeds 20 times the breaker continuouscurrent frame rating, the instantaneous test should be bench
tested and adjusted prior to installing on the breaker.
5-135

has elapsed.
3.
3.
5-136

1.
The long-time delay is adjusted by turning the long-time

adjusting dial on the bottom of the device. The dial has
markings from 1 to 10. Higher numbers correspond to longer
delay times. Two factory-calibrated points are indicated by
white marks on the dial. The corresponding delay times are
indicated on the device face plate.
2.

3.

delay. The short-time delay is calibrated in cycles.
4.

5.

adjustment knob located under the instantaneous pickup scale.
6.

specified by the manufacturer's time-current characteristic trip curve for the

device.
1.
2.
Verify that all device wiring is properly connected and in good

condition.
3.
Inspect current transformers for proper connections, tap settings, and

solid mounting.
4.
Check that the magnetic trip device (or flux shift trip device) is
mounted solidly, operates freely, and provides sufficient overtravel to
trip the circuit breaker.
5.
Specification: 1/32"-1/8" (0.031"-0.125")
6.
Perform overcurrent trip test by primary current infection:

NOTE:


the ground wire to the neutral terminal. This wire must be returned
NOTE:


1.
Long-time delav element testing: Close the breaker and

adjust the test current equal to 300% of the current
transformer tap setting.
5-137
have elapsed.
being tested.
ten minutes and verifying that breaker does not trip.
2.

pickup setting.
have elapsed.
does not trip.
3.
Instantaneous trip testCAUTION:

Testing the instantaneous function by direct injection at
greater than 20 times the frame rating is not
recommended.

has elapsed.
5-138

4.

ground terminal.
C lose the breaker and slowly raise the test current. Note the
current at which the breaker trips. This is the ground-fault
pickup current.
being tested.
8.
4.

Final Assembly and Inspection

1.
Place a clean cloth under the contacts, to catch debris, and remove
residual arc products from the contacts using Scotch-Brite. Carbon
and other electric arc products may be deposited on the contact
surfaces during OCTD testing.
2.
Install the arc chutes and attached insulators.
3.
Check the breaker visually for mechanical and electrical integrity.

Look for loose subcomponents, damaged wiring, etc.
4.
Operate the breaker manually and verify that the manual close and
open operations function properly.
5.
Verify that the breaker indicators accurately reflect breaker status.
5-139
6.
Verify that the breaker cannot be closed with the UV device deenergized, and may be closed with the UV device energized.
7.

8.
9.
Visually check all fasteners, retainers, and cotter pins for tightness
and complete installation.
10.
Apply a thin coat of conductive lubricant to the primary and secondary

disconnect finger surfaces that mate with the switchgear cubicle
sub components .
QA Hold Point
steps have been completed and the circuit breaker is complete and ready to be placed in
service.
5.
5-140
Quality Assurance Requirements

1.
All replacement parts installed as a result of maintenance shall be purchased in

accordance with plant procurement quality assurance requirements.
2.
Consumable items such as lubricants, tie-wraps, fasteners, etc., should be of good

quality and purchased from an evaluated supplier in accordance with plant
procedures.
3.
It is recommended that Quality Control (QC) inspections be performed

during breaker overhaul and that QC personnel witness all post-overhaul
adjustments and testing. QA hold points should be inserted after breaker
disassembly, after reassembly, and upon completion of final testing to verify
that all steps have been properly completed and documented.
5.6.6 Overhaul Data Record

This record lists the data that should be collected for each breaker overhauled.
These data provide a record of the pre-overhaul condition of the circuit breaker as
well as the final adjustment and test values. This list corresponds to the steps in
the overhaul guideline.
Reason for Overhaul:
Breaker Type:
Frame Size:
Serial Number:
Cubicle:
Closing Voltage:
Tripping Voltage:
Maintenance Manual:
Counter Operations:
Date:
Step
5.6.1
1.4
2.1
3.1
Contact condition
Main contacts
Arcing contacts
3.2
Contact gap
A
B
C
5-141
Step
3.3
A
B
C
3.4
Contact sequence
A
B
C
4.9
1.5
Electrical tests
5.1

Line-to-load
A
B
C
Phase-to-ground
A
B
C
Phase-to-phase
A-B
B-C
A-C
5.2
5.3
Contact resistance
A
B
C
5-142
Step
5.4

2.
Dropout voltage
3.
Pickup voltage
6.3.5

Device Type
Current Rating
Delay
sec
Delay
sec
Test Current
Allowable Time
Recorded Time
Phase A
Long Time
Short Time
Instantaneous
Ground Fault
Phase B
Long Time
Short Time
Instantaneous
Ground Fault
5-143
Step
Phase C
Long Time
Short Time
Instantaneous
Ground Fault
5.6.3
Inspections and Tests
6.2
Closing solenoid resistance
6.3
Control relay coil resistance
6.4
Shunt coil resistance
6.7
UV device coil resistance
6.8
Electric lockout coil resistance
6.12
Actuator coil resistance
6.13
Solid-state OCTD current sensors
A
B
C
5.6.5
Post-overhaul Inspections and Adjustments
Mechanical tests
1.1
Contact gap
A
B
C
5-144
Step
1.2
A
B
C
1.3
Contact sequence
A
B
C
1.4
1.5
UV device clearance
1.7
Shunt trip clearance
1.8
Electrical tests
2.1

Line-to-load
A
B
C
Phase-to-ground
A
B
C
Phase-to-phase
A-B
B-C
A-C
5-145
Step
2.2
2.3
Contact resistance
A
B
C
2.4

1.
Dropout voltage
2.
Pickup voltage
2.8
3.3

Device Type
Current Rating
Delay
sec
Delay
sec
Test Current
Phase A
Long Time
Short Time
Instantaneous
Ground Fault
5-146
Allowable Time
Recorded Time
Step
Phase B
Long Time
Short Time
Instantaneous
Ground Fault
Phase C
Long Time
Short Time
Instantaneous
Ground Fault
5-147
Section 6.0
Replacement Parts
6.1

6.2

6.3

6.4

6.5
Replacement Parts Procurement ...................................................... 6-19

6.5.1 Procurement Process ................................................................ 6-19
6.5.2 Alternate Sourcing Guidelines ................................................... 6-22
6.0 Replacement Parts

This section addresses replacement parts and the parts procurement processes for
Westinghouse Type DB circuit breakers. For purposes of clarity, replacement parts have
been separated into two lists; renewal parts and overhaul parts.
Renewal parts are those that should be accessible within a 24-hour period. The 24-hour
period is based on parts being hotshot delivered to the plant. If this time period is
unacceptable, the parts should be in the plant's inventory. Generally, Westinghouse
cannot supply safety-related parts in a 24-hour period. Therefore, the renewal parts
should be at a central storage area or at another plant. Renewal parts are those that may
be necessary to complete routine preventive maintenance.
Overhaul parts are those needed for overhauling a circuit breaker. They include both
standard replacement parts and parts that would be installed based on the condition of the
existing parts.
Replacement parts selection is based on the replacement parts recommendations described
in Section 4; the component's function; vendor recommendations; and engineering
experience gained from overhauling a wide range of low-voltage circuit breakers.
For consistency, style numbers and item descriptions used in the replacement parts lists
are identical to those in the applicable Westinghouse Renewal Parts Catalog.
Guidance is provided for purchasing both safety-related and commercial grade circuit
breaker replacement parts. Guidance is also provided for identifying the characteristics of
commercial grade items.
6.1 DB-15 Replacement Parts List

Style numbers and item descriptions used in the DB-15 replacement parts lists match
those in Westinghouse Renewal Parts Data Catalog 32-254. Additionally, Westinghouse
Catalog 32-254 should be referred to, as a particular part name may have several style
numbers to accommodate different applications (e.g., different voltage ratings).
Style numbers and item descriptions for many safety-related parts are different from those
included in the replacement parts lists. Identification and procurement of safety-related
parts should be accomplished in accordance with the utility's procurement policy.
Subsection 6.5 provides procurement guidelines.
6-1
6.1.1 DB-15 Renewal Parts List

Table 6.1-1 is the renewal parts list for Westinghouse DB-15 circuit breakers.
The following explains the parts list columns:
6-2
Qty for 3 pole bkr
The quantity installed in a three-pole circuit breaker.
Stock Qty
The recommended quantity to have available within 24 hours.
Style #
The part number listed in the Westinghouse parts catalog.
Description
The name of the part in the Westinghouse parts catalog.
Table 6.1-1 DB-15 Renewal Parts

Qty For 3
Pole Bkr
Stock
Qty
1529201
Stationary main and arcing contact
1529196
Moving main contact with shunt
1529200
Moving arcing contact
1581787
Opening spring
140622
Arc chutes
1491905
Finger clusters
1-4
18B1225G09
Moving secondary contact
See note 1
Control relay (X relay)
1491294
Control (X) relay right-hand stationary contact
23A3609G17
Control (X) relay left-hand stationary contact
1491295
Control (X) relay moving contacts
1 -2
13B4492G06
Auxiliary switch, 4-pole
1 -2
See note 1
Shunt trip coils
See note 1
UV device
See note t
UV device coil
1529190
Reset spring
1735766
Trip lever spring
See note 1
Operating mechanism, complete
1*
See note 1
Amptector for SS OCTD
692C703601
Actuator for SS OCTD
See note 1
Close coil
497A346G01
Fastener kit
6C1093G01
Operating link
1491764
Pole unit base
1529191
Pawl spring
1
4
1
2
See note 1
Shunt trip device
Style #
Description
Auxiliary switch cover
Drawout rollers
Amptector model
*per
Note 1 - See Westinghouse Renewal Parts Data Catalog 32-254
6-3
6.1.2 DB-15 Overhaul Parts List

Table 6.1-2 is the overhaul parts list for Westinghouse DB-15 circuit breakers. The list
identifies standard replacement parts (S) and conditional replacement parts (C) that should
be available for a circuit breaker overhaul. The standard replacement parts are those that
have displayed significant problems and, therefore, should be replaced at overhaul. The
conditional replacement parts are those that have experienced some degradation and
should be replaced based on their condition, as described m Section 4.
Table 6.1-2 columns match those m Table 6.1-1 with the following additions:
6-4
Overhaul Qty
The recommended quantity to have available at

overhaul, per breaker unless otherwise noted.
Replacement Strategy
The part replacement strategy:

S - standard replacement;
C - conditional replacement.
Table 6.1-2 DB-15 Overhaul Parts
Qty For 3
Pole Bkr
Overhaul
Qty
Replacement
Strategy
497A346G01
Fastener kit
3/5 bkrs
1491764
Pole unit base
1/10
6C1093G01
Operating link
1/5
1529190
Reset spring
1/10
1491454
Roller spring
1/5
1529191
Pawl spring
1/10
1572415
Tripping lever
1/5
1735766
Trip lever spring
1/5
126A107H01
Tripping spring (drawout only)
1/20
405D799H09
1st toggle lever
1/20
1406238
2nd toggle lever
1/20
1406237
3rd toggle lever
1 -4
4/5
1881225G09
Moving secondary contact
1/20
See note 1
Amptector unit
3/20
1529201
Stationary main and arcing contact
3/20
1529196
3/10
C
C
1529200
3/20
1581787
Opening spring
1/20
See note 1
Control relay (X relay)
1/10
1491294
Control (X) relay right-hand stationary

contact
1/10
23A3609G17
Control (X) relay left-hand stationary

contact
1/10
1491295
Control (X) relay moving contacts
1 -2
1/10
13B4492G06
1 -2
1/2
1/20
See note 1
Shunt trip coils
1/20
See note 1
UV device
1/20
C
C
See note 1
UV device coil
1/20
See note 1
Shunt trip device
1/30
C
C
Style
#
Description
Close coil

6-5
6.2
DB-25 Replacement Parts List
Style numbers and item descriptions used m the DB-25 replacement parts list match those
m Westinghouse Renewal Parts Data Catalog 32-254. Additionally, Westinghouse Catalog
32-254 should be referred to, as a particular part name may have several style numbers to
accommodate different applications (e.g., different voltage ratings).
included m the replacement parts lists. Identification and procurement of safety-related
6.2.1
DB-25 Renewal Parts List
6-6
Qty for 3 pole bkr
Stock Qty
Style #
Description

Qty For 3
Pole Bkr
Stock
Qty
1491419
Stationary main contact, upper stud
1491421
Stationary arcing contact
1491414
1491412
1809546
Opening spring
1491059
Arc chutes
1491904
Finger clusters
1 -4
18B1225G09
Secondary contact
See note 1
Control relay
1 -2
14B7132G06
1 -2
14B7132G07
See note 1
Shunt trip coil
See note 1
UV device coil
See note 1
UV device
1491294
Control relay right-hand stationary contact
23A3609G17
Control relay left-hand stationary contact
149 1 295
Control relay moving contact
See note 1
1*
See note 1
Amptectorfor SS OCTD
692C704G01
See note 1
Close coil
1809545
Pole unit base
1491410
Operating link
13D6586H02
Reset spring
1491450
Pawl spring
1491445
Trip lever spring
497A346G02
Fastener kit
See note 1
Shunt trip device
Style #
Description
Drawout roller
*per Amptector model

6-7

should be replaced based on their condition, as described in Section 4.
Table 6.2-2 columns match those in Table 6.2-1 with the following additions:
6-8
Overhaul Qty


Qty For 3
Pole Bkr
Overhaul
Qty
Replacement
Strategy
Style
#
Description
497A346G02
Fastener kit
3/5 bkrs
1809545
Pole unit base
1/10
1491410
Operating link
1/5
13D6586H02
Reset spring
1/10
1491454
Roller spring
1/5
1491450
Pawl spring
1/20
1572414
Tripping lever
1/5
1491445
Trip lever spring
1/5
126A107H03
Tripping spring (drawout)
1/20
See note 1
1st toggle lever
1/20
1491458
2nd toggle lever
1/20
1491463
3rd toggle lever
3/20
1491419
3/20
1491421
3/20
1491414
3/10
1491412
3/20
1809546
Opening spring
1 -4
4/5
18B1225G09
Secondary contact
1/20
See note 1
Control relay
1/10
1491294
Control relay right-hand stationary

contact
1/10
23A3609G17
1/10
1491295
Control relay moving contacts
1 -2
1/20
14B7132G06
1 -2
1/2
1/20
See note 1
Shunt trip coil
1/20
See note 1
UV device
1/20
See note 1
Amptectorfor SS OCTD
1/20
See note 1
UV device coil
1/20
See note 1
Shunt trip device
1/30
C
1
Note 1 - See Westinghouse Renewal Parts Catalog 32-254
Close coil
6-9
6.3
Style numbers and item descriptions used in the DB-50 replacement parts list match those
in Westinghouse Renewal Parts Data Catalog 32-254. Additionally, Westinghouse Catalog
32-254 should be referred to; as a particular part name may have several style numbers to

6-10
Qty for 3 pole bkr
Stock Qty
Style #
Description

Qty For 3
Pole Bkr
Stock
Qty
1611764
1611748
200B570G01
309C855G01
12
28A1391H25
Auxiliary contact
1584468
Opening spring
12
1584469
Main contact spring
1611017
Arc chutes
679C711G08
Finger clusters
1 -4
18B1225G09
Secondary contact
See note 1
Control relay
1 -2
20B8346G07
See note 1
Shunt trip coil
See note 1
UV device coil
See note 1
UV device
1491294
23A3609G17
1491295
See note 1
See note 1
Close coil
692C705G01
1*
See note 1
1611758
Operating link
1611747
Pole unit base
See note 1
Trip lever spring
1584520
Pawl spring
497A346G03
Fastener kit
See note 1
Shunt trip device
Style #
Description
Drawout roller
*per Amptector model

6-11

should be replaced based on their condition, as described in Section 4.
Table 6.3-2 columns match those in Table 6.3-1 with the following additions:
6-12
Overhaul Qty


Qty For 3
Pole Bkr
Overhaul
Qty
Replacement
Strategy
Style
#
Description
497A346G03
Fastener kit
See note 2
UV device
See note 2
Shunt trip device
1/20
See note 1
Shunt trip device
1/30
3/5 bkrs
1611747
Pole unit base
1/10
1 611758
Operating link
1/10
1589692
Roller lever
1/5
1584520
Pawl spring
1/20
See note 1
Tripping lever
1/5
See note 1
Trip lever spring
1/10
126A107H01
1/20
See note 1
1st toggle lever
1/20
1589676
2nd toggle lever
1/20
1589677
1/20
See note 1
3rd toggle lever

Amptector unit
3/20
1611764
Stationary main contact and upper stud
3/20
1611748
6/20
200B570G01
3/20
309C855G01
12
6/20
28A1391H25
Auxiliary contact
4/20
1584468
Opening spring
12
6/20
1584469
Main contact spring
1 -4
4/5
18B1225G09
Secondary contact
1/20
See note 1
Control relay
1/10
1491294

contact
1/10
23A3609G17
1/10
1491295
1/20
20B8346G07
1/2
Close coil
6-13
Table 6.3-2 DB-50 Overhaul Parts (Continued)
Qty For 3
Pole Bkr
Overhaul
Qty
Replacement
Strategy
1/20
See note 1
Shunt trip coil
1/20
See note 1
UV device
1/20
See note 1
UV device coil
Style
#
Description

Note 2 - Standard replacement for RTBs only
6-14
6.4
Style numbers and item descriptions used m the DB-75 replacement parts list match those
in Westinghouse Renewal Parts Data Catalog 32-254. Additionally, Westinghouse Catalog
32-254 should be referred to, as a particular part name may have several style numbers to

Qty for 3 pole bkr
Stock Qty
Style #
Description
6-15

Qty For 3
Pole Bkr
Stock
Qty
406D445G02
Upper stud assembly
302C063G01
406D443G01
Moving main contact
302C062Go1
12
679C711G08
Finger clusters
405D389G04
Arc chutes
1-4
18B1225G09
Secondary contact
See note 1
Control relay
1-2
20B8346G07
1-2
See note 1
Shunt trip coil
See note 1
UV device coil
See note 1
UV device
1491294
23A3609G17
1
1
1491295
See note 1
See note 1
Close coil
1*
See note 1
1.
692C706G01
497A346G04
Fastener kit
12
1809167
Upper stationary contact fingers
12
1799915
Lower stationary contact fingers
1799900
Pole base
21C5415G03
Operating link
1584520
Pawl spring
1799968
Lever spring
126A107H01
See note 1
Shunt trip device
Style #
Description
Drawout roller
*per Amptectormodel
6-16

should be replaced based on their condition, as described m Section 4.
Table 6.4-2 columns match those m Table 6.4-1 with the following additions:
Overhaul Qty


6-17
Table 6.4-2 DB-7B Overhaul Parts
Qty For 3
Pole Bkr
Overhaul
Qty
Replacement
Strategy
1
3
1
3/5
3
1
1/10
1/10
Style
#
Description
S
C
497A346G04
Fastener kit
1799900
Pole base
21C541SG03
Operating link
1799887
Roller lever
1/5
C
C
1584520
Pawl spring
1/5
Lever spring
1/10
1 799968
126A107H01
C
C
1799S91
15896756
1/20
1/20
1/20
1799907
Tripping lever
1st toggle lever
2nd toggle lever
1/20
1799884
1
3
1/20
See note 1
3/20
C
C
3rd toggle lever

Amptector unit
406D445G02
Upper stud assembly
3/20
302C063G01
3
3
3/20
3/20
C
C
406D443G01
302C062G01
Moving main contact

12
4/20
679C711G08
Finger clusters
4/5
18B1225G09
Secondary contact
1
1
1/20
See note 1
1/20
C
C
Control relay
1/2
1/10
1491294

contact
1/10
23A3609G17
1/10
1491295
1/20
See note 1
Shunt trip coil
1/20
1/20
C
C
See note 1
See note 1
UV device
UV device coil
C
C
1809167
1799915
Upper stationary contact fingers

Lower stationary contact fingers
C
C
See note 1
Shunt trip device
1
12
8/20
12
8/20
1/20
1/30
20B8346G07
Close coil

6-18
6.5
Replacement Parts Procurement
There are two types of circuit breaker parts from a replacement parts procurement
standpoint. The first type includes commodity items that are not unique to circuit
breakers and for which certain industry standards exist. Examples of these parts are
nuts, bolts, washers, and ware. The second type includes parts that are unique to circuit
breakers, such as arc chutes, shunt trip devices, and contact assemblies. Due to the
complexity and importance of circuit breakers, the original equipment manufacturer
(OEM) should be the primary source for both types of parts. This facilitates the
identification and reconciliation of any changes to an item's part number; design; or form,
fit, and function.
This section discusses the primary source renewal parts procurement process and both
alternate renewal parts procurement options. Words and phrases that have unique
meanings m the context of this section are defined in Appendix B to this guide.
6.5.1
Procurement Process
Figure 6.5-1 shows the steps involved m the procurement process. The first step is
completing a part/component safety/functional classification analysis. This analysis
determines the safety classification and corresponding procurement method for the part.
As discussed in EPRI NP-5652 and NP-6406, a part/component safety/functional
classification analysis is accomplished by reviewing the safety classification and function
of the host component, and the function of the part being evaluated. Then the evaluator
determines: 1) if the part is required for the host to perform its safety-related function; or
2) if failure of the part will prevent the host from performing its safety-related function.
A Failure Modes and Effects Analysis may be helpful in documenting and analyzing the
part failure modes and their effects on the safety-related or augmented quality function of
the parent circuit breaker. Only the function of the specific parent needs to be considered
for a part that will only be used in a specific breaker. However, because of the many
different circuit breaker applications, the most restrictive functions should be used for this
determination to preclude the likelihood of having the same part classified as both
non-safety related and safety-related in a safety-related breaker.
Completion of the functional classification will result m the part being classified as safetyrelated, augmented quality, or non-safety related.
Items classified as safety-related by both the utility and the OEM should be procured
under the utility's 10CFR50, Appendix B. Quality Assurance (QA) Program, and supplied
from the OEM's Appendix B QA Program. Replacement parts classified by the utility as
non-safety related can be procured as such from the OEM. However, some type of
augmented quality should be considered to satisfy seismic qualification and form, fit, and
function concerns.
6-19
Figure 6.5-1
Procurem ent Process
6-20
When a safety-related part either cannot be supplied by the OEM's Appendix B QA

Program or requires excessive lead times, then another route may be used. The item must
be dedicated by the utility or a third party or, in the case of commodity items, obtained
from another Appendix B supplier.
Procurement of commodity items from an alternate supplier is simple and efficient due to
the combination of the supplier's Appendix B QA Program and the industry standards
that control the manufacturing process. Difficulties may arise if the original Bill of
Material does not specify the applicable industry standard, or if the applicable standard
has been revised. In all cases, it is important to ensure that the standards invoked cover
the appropriate critical design characteristics and that the vendor supplies a Certificate of
Conformance to the invoked standards.
Dedication of commercial grade items, discussed m EPRI NP-5652, involves the
verification of selected critical design characteristics--at either the receipt inspection or the
factory--to provide reasonable assurance that the correct part was received. The difficulty
with dedicating circuit breaker parts is the process of determining or selecting the
appropriate critical design characteristics and their associated values. For example, the
size, dimensions, material, and electrical characteristics of a shunt trip device should be
verified, but obtaining design documentation for the device is difficult.
Possible sources of design information to select the critical characteristics for a part are
original purchase orders and receipt inspection documentation, original design
specifications, vendor-supplied drawings and technical manuals, and proprietary vendor
information. In some cases, the required information may be obtained by measuring and
evaluating an item that is in stock or installed in the plant. Once the critical design
characteristics are determined, the critical acceptance characteristics (verifiable and
measurable attributes that are a subset of the critical design characteristics) may be
selected and verified.
EPRI NP-5652 discusses four acceptance methods to measure and verify selected critical
acceptance characteristics. These are briefly discussed below.
Method 1, Special Tests and Inspections, consists of testing done by the utility. This
includes testing during the receipt inspection or post-installation testing to measure
critical acceptance characteristic values for dedicating the part. Method 2, Commercial
Grade Survey of Supplier, requires that the utility audit the supplier's commercial QA
program and its ability to invoke the controls necessary to verify and control certain
critical characteristics. Acceptance of the part by the utility is based on the Certificate of
Conformance supplied by the vendor. Method 3, Source Verification, requires that a
utility representative verify the part's critical characteristics at the factory. This method
is used mostly with special-order items, complex assemblies, or where the value of the
critical characteristics can only be determined from examining vendor-owned design
documents. Method 4, Acceptable Supplier/Item Performance Record, permits the utility
to dedicate a commercial grade part based on its proven performance and/or the
performance of its supplier. Various methods may be combined to facilitate the dedication
process.
6-21
Dedication using Special Tests and Inspections (Method 1) supplemented by Source

Verification (Method 3) is normally the most effective method for circuit breaker parts.
Method 2, Commercial Grade Survey, could be used for parts supplied by the OEM under
a commercial QA program. Dedication of complicated parts should include
post-installation testing.
A third-party qualifier (testing laboratory, etc.) with a utility-approved Appendix B QA
Program to dedicate circuit breaker parts is an option for items that may be too
complicated for the utility alone to dedicate. The advantage of using a third-party
qualifier is that agent is responsible for selecting and verifying the critical characteristics,
and for completing the reporting requirements under 10CFR21.
6.5.2 Alternate Sourcing Guidelines

When replacement parts are not available from the OEM due to obsolescence, an alternate
source must be found. Commodity items may be obtained from an alternate supplier, as
discussed in Subsection 6.5.1. Non-commodity items will require commercial grade
dedication and, m most cases, an item equivalency evaluation must be performed. The
equivalency evaluation should verify that there has been no change in the item's form, fit,
or function.
One source of safety-related spare parts is those items stocked for non-safety related
breakers at the nuclear power plant or a fossil plant. These parts must be upgraded to
safety-related by the commercial grade dedication process, discussed m Subsection 6.5.1.
Another possible source of spare parts is the safety-related stock at another nuclear power
plant. Depending on how the original item was procured, these parts may or may not
require dedication.
Fabrication of the item is an alternative if sufficient design information exists or can be
obtained from the part being replaced. This is only feasible for items of simple design and
construction. A third-party qualifier may also be used to fabricate the part or procure the
item from an alternate source.
6-22
Appendix A
References
Appendix A
References
1.
Danahy, J.W., Denny, M.I., and McGinn, E.F., Grove Engineering, Inc., for Nuclear
Maintenance Applications Center. GE Model AK Low Voltage Circuit Breaker
Maintenance Guide, DRAFT, April 1992.
2.
Danahy, J.W. and Denny, M.I., Grove Engineering, Inc., for Nuclear Maintenance
Applications Center. Maintenance Guide for BBC/ITE K-600 Circuit Breakers,
November 1989.
3.
Danahy, J.W. and Denny, M.I., Grove Engineering, Inc., for Nuclear Maintenance
Applications Center. Maintenance Guide for Molded Case Circuit Breakers,
November 1989.
4.
American National Standard for Low-Voltage AC Power Circuit Breakers Used in

Enclosures. ANSI/IEEE C37.13-1981.
5.
International Electrical Testing Association, Inc. Maintenance Testing

Specifications for Electrical Power Distribution Equipment and Systems. NETA
MTS-1989.
6.
Tulay, M.P., Yurich, F.J., and Schremser, F.M., Gilbert/ Commonwealth, Inc. EPRI
NP-5652, Revision A, Guideline for the Utilization of Commercial Grade Items in
Nuclear Safety Related Applications (NCIG-07), February 5, 1989.
7.
Craig, W.E., Fakhar, A.A., and Shulman, M.N., Cygna Energy Services. EPRI
NP-6406, Guideline for the Technical Evaluation of Replacement Items in Nuclear
Power Plants (NCIG-11), August 1989.
8.
American National Standard for Electrical Equipment Maintenance. ANSI/NFPA

70B-1987.
9.
American National Standard for Test Procedures for Low-Voltage AC Power Circuit
Breakers Used in Enclosures. ANSI C37.50-1981.
10.
U.S. Nuclear Regulatory Commission. Generic Implications of ATWS Events at

the Salem Nuclear Power Plant. NUREG-1000, Volume 1, April 1983.
11.
U.S. Nuclear Regulatory Commission. Required Actions Based on Generic

Implications of Salem ATWS Events. NRC Generic Letter 83-28, July 8, 1983.
12.
Title 10, Code of Federal Regulations, Part 50, "Domestic Licensing of Production
and Utilization Facilities," Appendix B. "Quality Assurance Criteria for Nuclear
Power Plants and Fuel Reprocessing Plants."
A-1
13.
U.S. Nuclear Regulatory Commission. Undervoltage Trip Attachments of

Westinghouse DB-50 Type Reactor Trip Breakers. IE Bulletin No. 85-02,
November 5, 1985.
14.
U.S. Nuclear Regulatory Commission. Deficiencies Identified During Electrical

Distribution System Functional Inspections. NRC Information Notice No. 91-29,
April 16, 1991.
15.
U.S. Nuclear Regulatory Commission. Failure of Circuit Breaker Following

Installation of Amptector Direct Trip Attachment. NRC Information Notice No.
88-54, July 28, 1988.
16.
U.S. Nuclear Regulatory Commission. Aging Assessment of Relay and Circuit

Breakers and System Interactions. NUREG/CR-4715, June 1987
17.
Westinghouse Instructions for Types DB-50 DBF-16. and DBL-50 Air Circuit
Breakers. I.B. 33-850-3D, May 1970.
18.
Westinghouse Maintenance Program Manual for Westinghouse Type DB-50 Reactor

Trip Circuit Breakers and Associated Switchgear. MPM-WOGRTSDB50-01,
Revision 0, November 20, 1986.
19.
Westinghouse Renewal Parts Data for Low-Voltage Power Circuit Breakers Types
DB, DBL, and DBF. No. 32-254, October 1985.
20.
Westinghouse Instructions for De-ion Air Circuit Breakers Types DB-15, DB-25.
DBF, and DBL-25. I.B. 33-850-1/2F December 1970.
21.
Westinghouse Instructions for De-ion Air Circuit Breakers Types DB-75 and
DB-100. I.B. 33-850-4/5, April 1958.
22.
American National Standard for Qualifications of Inspection, Examination, and

Testing Personnel for Nuclear Power Plants. ANSI/ASME N45.2.6-1978.
23.
G.E. Sliter, "Nuclear Power Plant Common Aging Terminology." Presented at the
International Power Generation Conference, October 6-10, 1991, San Diego, CA.
A-2
Appendix B
Glossary
Appendix B
Glossary
Accessories - Devices which perform

secondary functions as adjuncts or
refinements to the primary function of
Arcing Contacts - The contacts of the

circuit breaker on which the arc is drawn
after the main (and intermediate, where
used) contacts have parted.
"AH Contact ("AA" Contact) - An

electrical contact that is open when the
main device (circuit breaker or relay) is
m the standard reference position (open),
and that is closed when the device is in
the opposite position (closed).
Armature - The moving element of an

electromagnetic relay or solenoid which is
operated by control current in the coil
and to which the device's functional
appendage, contacts, plunger, lever, or
latch is attached.
Air Circuit Breaker - A circuit breaker

whose primary circuit interrupts current
in air as opposed to vacuum, oil, or gas.
Attachments - See Accessories.
Alarm Switch - A switch that actuates a

signaling (alarming) device upon the
automatic opening of its associated
switching device.
Ambient Temperature - The temperature
of the air surrounding the circuit
breaker.
Augmented Quality - Non-safety related

components which a utility has made
regulatory or design basis equipment; or,
for plant availability reasons, the utility
has implemented special controls to
assure reliability. The augmented
quality components are generally
included within the scope of the utility's
quality assurance processes.
Auxiliaries - See Accessories.
Antipump (Pump Free) Device - After an

opening operation, this device prevents
the reclosing of the circuit breaker as
long as the device that initiated the
opening is maintained in the position for
opening.
Anti-Single-Phase Tripping Device - In
response to the interruption of current in
one phase this device opens all phases of
the circuit breaker by means of a
polyphase switching device.
Arc Chute - A confined space or
passageway, lined with arc-resistance
material, into or through which an arc is
directed to extinction.
Auxiliary Relay - A relay which supplies

supplementary actions to assist another
relay or control device in performing a
general function.
Auxiliary Switch - A switch which is
mechanically operated by the operating
mechanism for indication, interlocking,
or other control functions, and reflects
the open or closed status of the circuit
breaker.
Barrier - A partition which insulates or
isolates electric circuits or electric arcs.
B-1
"B" Contact ("BB" Contact) - A contact

that is closed when the main device
(circuit breaker or relay) is in the
standard reference position (open) and
that is open when the device is in the
opposite position (closed).
Bus - A conductor or group of conductors
that serve as a common connection for
two or more circuits.
Bushing - An insulating sleeve which is
mounted on a barrier, to insulate through
a conductor from the barrier and allowing
current conduction from one side of the
barrier to the other.
Calibration - The process of adjusting the
operating characteristics of a device so
that they agree with standardized design
operating characteristics.
Circuit Breaker - A mechanical switching
device capable of: 1) carrying and
breaking currents under normal circuit
conditions; and 2) making, carrying for a
specified time, and breaking currents
under specified abnormal circuit
conditions (such as those of short circuit).
Clearance - See Minimum Clearance.
Clearing Time - The interval between the
time that the actuating quantity in the
main circuit reaches the value initiating
actuation of a release and the instant of
final arc extinction on all poles of the
primary arcing contacts.
Close-Open Operation - A close operation
followed immediately by an open
operation without purposely delayed
action.
Close Operation - The movement of the
main contacts from the normally open
position to the normally closed.
B-2
Closing Coil - A coil that actuates the

electrical closing of a circuit breaker.
Closing Operating Time - The time
interval during which the main contacts
are moving from the fully open position
to the fully closed.
Closing Relay - An auxiliary relay used
to control the closing device so that the
main closing current does not pass
through the control switch or other
initiating devices.
Closing Solenoid - A solenoid whose
motive power directly closes a circuit
breaker.
Closing Time - The interval of time
between initiation of the closing
operation and the instant when
continuity is established in all poles.
Commercial Grade - An item satisfying
all three of the following criteria. An
item not subject to design or specification
requirements that are unique to nuclear
facilities. An item used in applications
other than nuclear facilities. An item
Ordered from the manufacturer/ supplier
On the basis of specifications set forth in
the manufacturer's published product
description (for example, a catalog).
Connected Position - That position of a
drawout circuit breaker in which both
primary and secondary disconnecting
devices are in full contact with their
stationary counterparts.
Connection Diagram - A drawing which
shows the relationship and connection of
devices and accessories of a circuit.
Contacts - Two conducting parts that
interact to make or break a circut.
Contact Surface - That surface of a

contact through which current is
transferred to the co-acting contact.
Control Bus - A bus which distributes
power for operating electrically controlled
devices.
Control Relay - An auxiliary relay that
initiates or permits the next desired
operation in a control sequence.
Control Switch- A manually operated
switching device for controlling poweroperated devices.
Control Voltage - The voltage applied to
the operating mechanism of a device to
actuate it. Control voltage is usually
measured at the control power terminals
of the mechanism.
Critical Characteristics for Acceptance Identifiable and measurable attributes/
variables of a commercial grade item
which, once verified, provide reasonable
assurance that the item received is the
item specified.
Critical Characteristics for Design Those properties or attributes which are
essential for the item's form, fit, and
functional performance. Critical
characteristics for design are the
identifiable and/or measurable attributes
of a replacement item which provide
assurance that the replacement item will
perform its design function.
Current-limiting Fuse Unit - A fuse unit
that, when it is melted by a current
within its specified current-limiting
range, abruptly introduces a high
resistance to reduce the current
magnitude and duration.
Deficiency - A degraded condition of a

circuit breaker subcomponent which, if
uncorrected, ultimately would prevent
the breaker from performing a function.
Delayed Overcurrent Trip - See Delayed
Release (Trip).
Delayed Release Scrip) - A trip with
intentional delay introduced between the
instant when the activating quantity
reaches the release setting and the
instant when the release operates.
Dielectric Withstand Voltage Tests Tests that determine the ability of
insulating materials and spacings to
withstand specified overvoltages for a
specified time without flashover or
puncture.
Direct Acting Overcurrent Trip Device See Direct Release.
Direct Release - A release energized by
the current in the main circuit of the
switching device.
Drawout Feature - An option available on
circuit breakers which allows the circuit
breaker to be disconnected and removed
Tom the switchboard without deenergizing the switchboard.
Dropout of a Relay - A term for contact
operation (opening or closing) as a relay
just departs from pickup. Also identifies
the maximum value of an input quantity
which will allow the relay to depart from
pickup. See Pickup (Of a Relay).
Electro-magnetic Relay - An
electromechanical relay that operates
principally by action of an electromagnetic element which is energized by
the input quantity.
B-3
Equivalency Evaluation - A technical

evaluation performed to confirm that an
alternate replacement item (not identical
to the original) will satisfactorily perform
its design function.
Failure to Trip - The lack of a release
(trip) which should have occurred
considering the objectives of the trip
system design.
False Tripping - The occurrence of a
release (trip) which should not have
occurred considering the objectives of the
trip system design.
Fault - See Short Circuit.
Fault Interrupter - A self-controlled
mechanical switching device capable of
making, carrying, and automatically
interrupting current, but without
automatic reclosing capability.
Fuseholder - An assembly of base, fuse

clips, and necessary insulation for
mounting and connecting a fuse into the
circuit.
Ground Bus - A bus to which the grounds
from individual pieces of equipment are
connected and that, in turn, is connected
to a ground at one or more points.
Hotshot Deliver - A direct, door-to-door
express delivery.
Interlock - A device which is directly
associated with and actuated by the
operation of another device to govern its
succeeding operations or those of
associated devices.
Intermediate Contacts - Contacts m the
main circuit which part after the main
contacts have parted and before the
arcing contacts have parted.
Field Discharge Breaker - A switching

device that has main contacts for
energizing and de-energizing the field of
a generator, motor, or exciter; and has
auxiliary contacts for short-circuiting the
field through a discharge resistor at the
instant preceding the opening of the
circuit breaker main contacts. The
auxiliary contacts also disconnect the
field from the discharge resistor at the
instant following the closing of the main
contacts.
Latch - An attachment used to hold the

mechanical linkage of a circuit breaker in
the closed position.
Frame Size - The maximum continuouscurrent rating (in amperes) of a circuit

breaker for all parts except the coils of
the direct acting overcurrent trip device.
Long-Time-Delay Trip Element - The

element of a direct acting overcurrent
trip device that functions with a
purposely delayed action, usually in
seconds (2-1000 seconds), on an
overcurrent condition.
Fuse - An overcurrent protection device

with a circuit-opening fusible part that is
heated and severed by the passage of
overcurrent through it.
B-4
Load- The true apparent power

consumed by power-operated equipment
performing its normal function.
Lockout Mechanism - A device that locks
the contacts in the open position
following the completion of a
predetermined sequence of operations.
Low-Voltage Protection - See

Undervoltage Protection.
Main Contacts - Contacts which carry all

or most of the current of the main circuit.
Manual Control - Control of the main
devices, whether manually or power
operated, by an attendant.
Manual Operation - Operation by an
attendant without an additional source of
power.
Manual Trip Device - A device which is
connected to the tripping linkage and
which can be operated manually to trip a
switching device.
Mechanical Operation - Operation by
means of an operating mechanism
connected to the switch by mechanical
linkage.
Micarta- An electrical insulator
manufactured from a hard, plastic-like
material.
Minimum Clearance - Electrical-the
shortest distance between any live parts
of adjacent poles, or between any live
parts and adjacent ground parts.
Moving Contact - A conducting part
whose contact surface moves to and from
that of the stationary contact.
National Electrical Manufacturers
Association (NEMA) - An association of
electrical manufacturers who establish
specifications for manufacturing and
testing of electrical equipment.
Opening Operating Time - The time
interval during which a switch is moving
from the fully closed to the fully open
position.
Opening Time - The interval between the

time when the actuating quantity of the
release circuit reaches the operating
value and the instant when the primary
arcing contacts have parted.
Open Operation - Movement of the
contacts from the normally closed to the
normally open position.
Operating Mechanism - The part of the
mechanism that actuates all the main
circuit contacts of the switching device
either directly or by the use of pole-unit
mechanisms.
Operating Voltage - The voltage of the
system on which a device is operated.
Operation - Action of the parts of the
device to perform its normal function.
Overcurrent Protection - A form of
protection that operates when current in
the main circuit exceeds a predetermined
value.
Overcurrent Relay - A relay that operates
when the current in the main circuit
exceeds a predetermined value.
Overcurrent Trip (Release) - A release
that operates when the current in the
main circuit is equal to or exceeds a
predetermined value.
Pickup (Of a Relay) - The action of a
relay as it responds to progressive
increases of input. The minimum value
of an input quantity reached by
progressive increases which will cause
the relay to reach the pickup state from
reset.
B-5
Pole - That portion of a device associated

exclusively with one electrically
separated conducting path of its main
circuit.
Pole-Unit Melanism - See Pole.
Polyphase Switching Device - A
switching device for more than one phase.
Primary- First to operate; first in
preference; or, referring to the main
circuit as contrasted to the auxiliary or
control circuit.
Primary Arcing Contacts - The contacts
on which the initial arc is drawn and the
final current, except for the arc-shunting
resistor current, is interrupted after the
main contacts have parted.
Primary Disconnecting Devices - Selfcoupling, separable contacts provided to
connect and disconnect the main circuits
between the removable element and the
housing.
Primary Protection - First-choice relay
protection; in contrast to backup relay
protection.
Rated - An operating characteristic that
has a designated limit or limits for
application under specified conditions.
Rating - The designated limit or limits of
an operating characteristic for application
under specified conditions.
Reclosing Time - The interval between
the time when the actuating quantity of
the release (trip) circuit reaches the
operating value (the breaker being m the
closed position) and the reestablishment
of the circuit on the primary arcing
contacts on the reclosing stroke.
B-6
Relay- An electrical device designed to

respond to input conditions in a
prescribed manner and, after specified
conditions are met, to cause contact
operation or similar change in associated
electric control circuits.
Release (Trip) Coil/Mechanism - A coil
used in an electromagnetic device which
initiates the action of a release (trip).
Release Free (Trip Free) - A condition in
which the opening operation prevails over
the closing operation during specified
portions of the closing operation.
Remote Trip - A switching device that is
physically remote from the initiating
protective relay device, or source of
release power.
Renewal Parts - Those parts which must
be replaced as a result of wear or
damage.
Reset (Of a Relay) - The action of a relay
in response to decreases in input.
Routine Maintenance - Those inspections,
tests, adjustments, and cleaning activities
performed at specified frequencies and
not involving significant disassembly of
the circuit breaker. These activities
verify that the material condition of the
breaker is sufficient to allow the
equipment to function reliably until the
next scheduled maintenance.
Seal-in-Relay - An auxiliary relay that
remains picked up by one of its own
contacts, which bypasses the initiating
circuit until de-energized by some other
device.
Secondary and Control Wiring - Wiring

used with switchgear assemblies for
control circuits and for connections
between instrument transformer
secondaries, instruments, meters, relays,
or other equipment.
Secondary Arcing Contacts - The contacts
on which the arc of the arc-shuntingresistor current is drawn and interrupted.
Secondary Disconnecting Devices - Selfcoupling separable contacts provided to
connect and disconnect the auxiliary and
control circuits between the removable
element and the housing.
Selective Tripping - Delayed release (trip)
w ith selective settings that will reset
automatically if the actuating quantity
remains below the release setting for a
specified time.
Setting - A desired operating
characteristic, obtained as a result of
having set a device, stated in terms of
calibration markings or of actual
performance bench marks.
Short Circuit - An abnormal connection
(including an arc) of low impedance
between two points of different potential.
Short-Time Delay Trip Element - A
direct-acting trip device that functions
with a purposely delayed action, usually
in less than 1 second (.07 - 1 second), on
an overcurrent condition.
Short-Time Rating - The highest value of
current or voltage, or their product, that
a device can sustain without damage for
specified short-time intervals.
Shunt - A flexible, electrical conductor

consisting of braid, cable, or flat
laminations designed to conduct current
around the mechanical joint between two
conductors.
Shunt Release (Trip) - A release energized
by a source of voltage.
Shunt Trip Device - A circuit breaker
attachment that utilizes a solenoid to
rotate the trip shaft to open (trip) the
circuit breaker. The shunt trip device is
a device that is used to open an
electrically operated circuit breaker
under normal conditions.
Solid-State Relay - A static relay or relay
unit constructed exclusively of solid-state
components.
Solenoid - An assembly consisting of a
cylindrical coil and a metal core which
moves within the coil axis under the
influence of the magnetic field
established by the coil.
Switchgear - A general term covering
switching and interrupting devices and
their combination with associated control,
metering, protective, and regulating
devices; also, assemblies of these devices
with associated inter-connections,
accessories, enclosures, and supporting
structures.
Switching Device - A device that is rated
to interrupt the flow of current in a
controlled manner.
Terminal Board (Terminal Block) - An
insulating base equipped with terminals
for connecting secondary and control
wiring.
B-7
TEST Position - That position in which

the primary dis-connecting devices of the
removable element are separated by a
safe distance from those in the housing
and some or all of the secondary
disconnecting devices are in operating
contact.
Time-Current Characteristic - The
correlated values of time and current that
designate the interrupting function, or
portions thereof, of the automatic trip
device.
Time-Current Tests - Tests in which
current is applied to determine the
relation between the alternating current,
or direct current, and the time required
for the trip device to perform all or some
specified part of its interrupting function.
Travel - The amount of movement in
either direction of a responsive element.
Trip - To release in order to initiate
opening operation.
Trip Coil - See Release (Trip)
Coil/Mechanism.
Trip-Free - See Release Free.
Undervoltage Protection - A form of
protection that drops out when voltage is
less than a predetermined value to
protect against an undervoltage
condition.
Undervoltage Relay - A normally
energized relay that drops out when its
voltage is less than a predetermined
value and functions to protect against an
undervoltage condition.
B-8
Undervoltage Trip (Release) - A release

that operates when the voltage of the
main circuit is equal to or less than the
release setting.
Withstand Voltage - The specified voltage
that, under specified conditions, can be
applied to insulation without causing
flashover or puncture.
Appendix C
APPENDIX C
This appendix lists standards, guides, notices, and manuals that are generally applicable
to Westinghouse Type DB circuit breakers installed at nuclear power plants. This listing
is provided for information only; applicability to a specific plant must be determined by
the host utility.
C.1 Regulatory Information

1.
and Utilization Facilities," Appendix A, "General Design Criteria for Nuclear
Power Plants."
2.
and Utilization Facilities," Appendix B. "Quality Assurance Criteria for Nuclear
Power Plants and Fuel Reprocessing Plants."
3.
U.S. Nuclear Regulatory Commission. Generic Implications of ATWS Events at the

Salem Nuclear Power Plant. NUREG-1000, Volume 1, April 1983.
4.
U.S. Nuclear Regulatory Commission. Undervoltage Trip Attachments of

Westinghouse DB-50 Type Reactor Trip Breakers. IE Bulletin No. 85-02,
November 5, 1985.
5.
U.S. Nuclear Regulatory Commission. Deficiencies Identified During Electrical

Distribution System Functional Inspections. NRC Information Notice No. 91-29,
April 15, 1991.
6.
U.S. Nuclear Regulatory Commission. Failure of Circuit Breaker Following

Installation of Amptector Direct Trip Attachment. NRC Information Notice No. 8854, July 28, 1988.
7.
U.S. Nuclear Regulatory Commission. Aging Assessment of Relay and Circuit

Breakers and System Interactions. NUREG/CR-4715, June 1987
8.
U.S. Nuclear Regulatory Commission. Comprehensive Aging Assessment of Circuit

Breakers and Relays for NPAR Program Phase II (Draft). NUREG/CR-5762.
C.2 Industry Standards

1.
American National Standard for Nuclear Safety Criteria for the Design of
Stationary Pressurized Water Reactor Plants. ANSI/ANS-51.1-1983.
2.
American National Standard for Standard for Low-Voltage AC Power Circuit

Breakers Used m Enclosures. ANSI/IEEE C37.13-1981.
C-1
3.
American National Standard Criteria for Protection Systems for Nuclear Power
Generating Stations. ANSI/IEEE Std 279-1971.
4.
American National Standard Criteria for Class HE Power Systems for Nuclear
Power Generating Stations. ANSI/IEEE Std 308-1980.
5.
American National Standard Criteria for the Periodic Testing of Nuclear Power
Generating Station Class HE Power and Protection Systems. ANSI/IEEE Std 3381977.
6.
American National Standard Recommended Practice for Seismic Qualification of

Class 1E Equipment for Nuclear Power Generating Stations. ANSI/IEEE Std 3441982.
7.
American National Standard Guide for General Principles of Reliability Analysis of

Nuclear Power Generating Station Protection Systems. ANSI/IEEE Std 352-1975.
8.
American National Standard Application of the Single-Failure Criterion to Nuclear

Power Generating Station Class WE Systems. ANSI/IEEE Std 379-1977.
9.
American National Standard Recommended Practice for Electrical Equipment

Maintenance. ANSI/NFPA 70B-1990.
10.
American National Standard for Switchgear - Low-Voltage Power Circuit Breakers

and AC Power Circuit Protectors - Preferred Ratings, Related Requirements, and
Application Recommendations. ANSI C37.16-88.
11.
American National Standard for Trip Devices for AC and General-Purpose DC LowVoltage Power Circuit Breakers. ANSI C37.17-79.
12,
American National Standard for Switchgear - Metal-Enclosed Low-Voltage AC

Power-Circuit-Breaker Switchgear Assemblies - Conformance Test Procedures.
ANSI C37.51-89.
13.
Institute of Electrical and Electronics Engineers Standard Metal-Enclosed LowVoltage Power Circuit Breaker Switchgear. IEEE C37.20.1-87.
14.
Institute of Electrical and Electronics Engineers Standard Application Guide for

Low-Voltage AC Nonintegrally Fused Power Circuit Breakers (Using Separately
Mounted Current-Limiting Fuses). IEEE C37.27-87.
15.
Institute of Electrical and Electronics Engineers Standard for Low-Voltage AC

Power Circuit Protectors Used in Enclosures. IEEE C37.29-81.
16.
American National Standard for Switchgear - Low-Voltage AC Power Circuit

Breakers Used in Enclosures - Test Procedures. ANSI C37.50-89.
C-2
17.
Institute of Electrical and Electronics Engineers Standard for Standard for LowVoltage AC Power Circuit Breakers Used in Enclosures. IEEE C37.13-81.
18.
Institute of Electrical and Electronics Engineers Standard for Standard for LowVoltage DC Power Circuit Breakers Used in Enclosures. IEEE C37.14-79.
C.3
Westinghouse Technical Information
1.
Westinghouse Instructions for Types DB-50, DBF-16, and DBL-50 Air Circuit
Breakers. I.B. 33-850-3D, May 1970.
2.
Westinghouse Maintenance Program Manual for Westinghouse Types DB-50 Reactor

Trip Circuit Breakers and Associated Switchgear. MPM-WOGRTSDB50-01,
Revision 0, November 20, 1986.
3.
Westinghouse Renewal Parts Data for Low-Voltage Power Circuit Breakers Types
DB, DBL, and DBF. No. 32-254, October 1985.
4.
Westinghouse Instructions for De-ion Air Circuit Breakers Types DB-15. DB-25,
DBF, and DBL-25. I.B. 33-850-1/2F December 1970.
5.
Westinghouse Instructions for De-ion Air Circuit Breakers Types DB-75 and DB100. I.B. 33-850-4/5, April 1958.
6.
Westinghouse Technical Bulletin - Direct Trip Actuator Installation. NSID-TB-8804, August 9, 1988.
7.
Westinghouse Technical Bulletin - DB Breaker Maintenance. NSD-TB-92-04-RO,

May 18, 1992.
8.
Westinghouse Technical Bulletin - DB Breaker Secondary Contact Failure. NSDTB-91-03-RO, April 22, 1991.
9.
Westinghouse Technical Bulleton - W Type LS and LSG Amptectors. NSD-TB-9206-RO, June 16, 1992.
C-3
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Circuit Breaker Maintenance

Volume 1: Low-Voltage Circuit Breakers

EPRI Licensed Material

Circuit Breaker Maintenance

BACKGROUND Increased awareness of circuit breaker performance trends,

EPRI NP-7410s Vol. 1, Part 3

Electric Power Research Institute

into parts that correspond to a specific class, manufacturer, and model.

Circuit Breaker Maintenance

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

EPRI Licensed Material

EPRI Licensed Material

EPRI Licensed Material

The Nuclear Maintenance Applications Center (NMAC) is committed to the distribution

EPRI Licensed Material

EPRI Licensed Material

Power Distribution Technology

Nebraska Public Power District

Tennessee Valley Authority

Baltimore Gas and Electric

Power Distribution Technology

Tennessee Valley Authority

Power Distribution Technology

Power Distribution Technology

EPRI Licensed Material

EPRI Licensed Material

Purpose ................................................................................................. 1-1

Circuit Breaker Description

General Information.............................................................................. 2-1

DB-15/25, DBF-6, and DBL-25 Circuit Breakers ................................. 2-1

DB-50/75, DBF-16, and DBL-50 Circuit Breakers ............................. 2-18

EPRI Licensed Material

Analysis of Overhaul Data ................................................................... 3-1

Analysis of NPRDS Data ...................................................................... 3-6

Failure Modes Analysis...................................................................... 3-14

Recordkeeping Guidelines ................................................................ 3-21

Maintenance Scheduling...................................................................... 4-2

Subcomponent Replacement .............................................................. 4-9

EPRI Licensed Material

Personnel Qualification and Training ............................................... 4-16

Industry and Manufacturer Recommendations................................ 4-17

Precautions ........................................................................................... 5-1

Tools and Test Equipment .................................................................. 5-2

DB-15/25 Routine Maintenance Inspections, Test,

DB-15/25 Overhaul Guideline ............................................................ 5-31

DB-50/75 Routine Maintenance Inspections, Tests,

EPRI Licensed Material

DB-50/75 Overhaul Guideline .......................................................... 5-101

DB-15 Replacement Parts List ............................................................ 6-1

DB-25 Replacement Parts List ............................................................ 6-6

DB-50 Replacement Parts List .......................................................... 6-10

DB-75 Replacement Parts List .......................................................... 6-15

EPRI Licensed Material

Replacement Parts Procurement ...................................................... 6-19

Nuclear Industry Information

EPRI Licensed Material

EPRI Licensed Material

Electrically Operated DB-25 Circuit Breaker ......................................................... 2-3

DB-25 Drawout Breaker (Rear View) .................................................................... 2-5

DB-15/25 Control Circuit ....................................................................................... 2-8

DB-25 Contact Assemblies ...................................................................................2-10

DB-25 Arc Chutes .................................................................................................2-11

Electro-Mechanical Overcurrent Trip Device.........................................................2-14