I.B. 2C12060H03

Effective August 1999, Supersedes I.B. 2C12060H02 dated July, 1999

Cutler-Hammer

Instructions for Installation, Operation and Maintenance ofMagnum DS Low Voltage Power Circuit Breakers

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For application information, consult Cutler-Hammer Inc.,see applicable Product Guides, Technical Documents,Application Publications and/or Industry Standards.

SAFETY

All safety codes, safety standards and/or regulationsmust be strictly observed in the installation, operationand maintenance of this equipment.

THE WARNINGS AND CAUTIONS INCLUDED ASPART OF THE PROCEDURAL STEPS IN THIS MAN-UAL ARE FOR PERSONNEL SAFETY AND PROTEC-TION OF EQUIPMENT FROM DAMAGE. AN EXAM-PLE OF A TYPICAL WARNING LABEL HEADING ISSHOWN ABOVE TO FAMILIARIZE PERSONNELWITH THE STYLE OF PRESENTATION. THIS WILLHELP TO INSURE THAT PERSONNEL ARE ALERTTO WARNINGS. IN ADDITION, CAUTIONS ARE ALLUPPER CASE AND BOLDFACE.

PURPOSE

This instruction manual is expressly intended to coverthe installation, operation and maintenance of MagnumDS Power Circuit Breakers. These circuit breakers areusually supplied as part of low voltage metal-encloseddrawout switchgear. This manual applies only to the cir-cuit breakers and their details. Magnum DS circuitbreakers may also be supplied as fixed mounteddevices. In the case of fixed versions of Magnum DS cir-cuit breakers, certain sections of this manual, referringto such items as position interlocks and the drawoutmechanism, will not apply.

Trip units associated with Magnum DS Power CircuitBreakers will be addressed in a general manner in thismanual. Specific trip unit details and time-current char-acteristic curves are covered in separate documentsspecific to the trip units.

Magnum DS circuit breaker accessory items are dis-cussed in this manual. Field installation instructions forsuch items, however, are covered in individual instruc-tion leaflets specific to the accessory. This informationis also available from the Cutler-Hammer website atwww.cutlerhammer.eaton.com

All possible contingencies which may arise during installation operation or maintenance, and all details and variationsof this equipment do not purport to be covered by these instructions. If further information is desired by purchaserregarding his particular installation, operation or maintenance of particular equipment, contact the local Cutler-Hammer Inc. representative.

WARNING

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TABLE OF CONTENTS

SECTION 1: INTRODUCTION PAGE

1-1 General Information.............................................................................................................................................11-2 Safety Features ...................................................................................................................................................21-3 Safety Practices ..................................................................................................................................................21-4 Qualified Personnel .............................................................................................................................................31-5 Other Publications and Documentation...............................................................................................................3

SECTION 2: RECEIVING, HANDLING AND INSTALLATION

2-1 General Information.............................................................................................................................................42-2 Suggested Tools .................................................................................................................................................42-3 Unpacking Circuit Breaker...................................................................................................................................4

2-3.1 Storing Circuit Breaker ...........................................................................................................................52-4 Lifting Circuit Breaker ..........................................................................................................................................52-5 Circuit Breaker Inspection ...................................................................................................................................62-6 Installing Drawout Circuit Breaker .......................................................................................................................6

2-6.1 Rejection Interlocks ................................................................................................................................62-6.2 Circuit Breaker Positioning .....................................................................................................................72-6.3 Levering Circuit Breaker.........................................................................................................................9

2-7 Fixed Circuit Breaker.........................................................................................................................................102-8 Circuit Breaker Operation..................................................................................................................................10

SECTION 3: CIRCUIT BREAKER DESCRIPTION AND OPERATION

3-1 Introduction........................................................................................................................................................113-2 Basic Circuit Breaker Assembly ........................................................................................................................153-3 Pole Units ..........................................................................................................................................................15

3-3.1 Primary Moving Contacts .....................................................................................................................153-3.2 Primary Stationary Contacts.................................................................................................................16

3-4 Operating Mechanism .......................................................................................................................................173-4.1 Manual Operation.................................................................................................................................173-4.2 Electrical Operation ..............................................................................................................................183-4.3 Anti-Pump Feature ...............................................................................................................................18

3-5 Arc Chambers ...................................................................................................................................................183-5.1 Arc Chute .............................................................................................................................................18

3-6 Electronic Tripping System................................................................................................................................193-6.1 Microprocessor-based Trip Unit ...........................................................................................................193-6.2 Rating Plug...........................................................................................................................................213-6.3 Current Sensors ...................................................................................................................................213-6.4 Trip Actuator .........................................................................................................................................223-6.5 Mechanical Trip Flag ............................................................................................................................223-6.6 Making Current Release.......................................................................................................................223-6.7 High Instantaneous Trip Option............................................................................................................22

3-7 Secondary Contacts and Connection Diagrams ...............................................................................................223-7.1 Connection Diagrams...........................................................................................................................24

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3-8 Accessory Devices ............................................................................................................................................273-8.1 Plug-In Electrical Accessories ..............................................................................................................273-8.2 Internal Electrical Accessories .............................................................................................................293-8.3 Mechanical Accessories.......................................................................................................................30

SECTION 4: DRAWOUT CIRCUIT BREAKER AND CASSETTE

4-1 General .............................................................................................................................................................334-1.1 Drawout Cassette.................................................................................................................................33

4-2 Drawout Circuit Breaker Dimensions ................................................................................................................334-3 Drawout Cassette Dimensions ..........................................................................................................................33

SECTION 5: FIXED CIRCUIT BREAKER

5-1 General .............................................................................................................................................................465-2 Fixed Circuit Breaker Dimensions .....................................................................................................................46

SECTION 6: INSPECTION AND MAINTENANCE

6-1 General .............................................................................................................................................................576-2 General Cleaning Recommendations ...............................................................................................................576-3 When to Inspect ................................................................................................................................................576-4 What to Inspect .................................................................................................................................................58

6-4.1 Arc Chute Inspection ............................................................................................................................586-4.2 Primary Contact Inspection ..................................................................................................................59

6-5 Circuit Breaker Modifications and Changes ......................................................................................................606-5.1 Rating Plug Replacement.....................................................................................................................606-5.2 Current Sensor Replacement...............................................................................................................61

SECTION 7: TROUBLESHOOTING

7-1 Introduction........................................................................................................................................................63

SECTION 8: RENEWAL PARTS

8-1 General .............................................................................................................................................................63

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FIGURES

Figure Title Page

1-1 Magnum DS Family of Low Voltage Power Circuit Breakers (800-5000 Amperes) ..................................11-2 Typical Magnum DS Nameplate ..............................................................................................................21-3 Sample Magnum DS Identification............................................................................................................31-4 Magnum DS Drawout Circuit Breaker Shown on Integral Cassette Extension Rails ................................3

2-1 Shipping Carton Being Partially Lifted from Circuit Breaker Revealing Shipping Clamp ..........................42-2 Magnum DS Circuit Breaker with Lifting Yoke Attached ..........................................................................52-3 Closeup Rear View of Current Sensor Rating Viewing Window ..............................................................62-4 Closeup of One Side of Drawout Circuit Breaker Properly Seated on Extension Rail ..............................62-5 Rejection Interlock Pin Positioning/Installation..........................................................................................72-6 Remove Position ......................................................................................................................................82-7 Disconnect Position ..................................................................................................................................82-8 Test Position ............................................................................................................................................82-9 Connect Position ......................................................................................................................................92-10 Fully Inserted Circuit Breaker....................................................................................................................92-11 Circuit Breaker Being Levered ..................................................................................................................92-12 Typical Fixed Type Magnum DS Circuit Breaker ....................................................................................10

3-1 Magnum DS Drawout 800-3200A Size (Front and Rear Views) ............................................................113-2 Magnum DS Fixed 800-3200A Size (Front and Rear Views)..................................................................123-3 Magnum DS Fixed 4000A and 5000A Size (Front and Rear Views) ......................................................133-4 Typical Magnum DS Drawout Circuit Breaker Front Cover ....................................................................143-5 Magnum DS Rigid Frame Construction (Right Side View)......................................................................153-6 Single Magnum DS Contact Finger ........................................................................................................153-7 Mangum DS Multi-Finger Configuration..................................................................................................163-8 Magnum DS 12-Finger Contact Assembly..............................................................................................163-9 Parital Cross-Sectional View of Magnum DS (Shown in Closed Position)..............................................163-10 Magnum DS Electrically Operated Drawout Circuit Breaker with Front Cover Removed ......................173-11 Magnum DS Circuit Breaker Closing Springs Being Manually Charged ................................................183-12 Field Installable Motor Operator Shown Mounted ..................................................................................183-13 Magnum DS Arc Running System ..........................................................................................................193-14 Bottom View Magnum DS Arc Chute ......................................................................................................193-15 Integral Arc Runner as Viewed From Top of Arc Chamber

(Arc Chute Removed and Circuit Breaker Closed) ................................................................................193-16 Typical Magnum DS Tripping System Diagram ......................................................................................203-17 Digitrip RMS 1150 Programmable Trip Unit Installed in Magnum DS Circuit Breaker............................213-18 Hand Held Tester ....................................................................................................................................213-19 Current Sensors Shown Mounted (Sensor Cover Plate Removed for Clarity)........................................223-20 Top View Secondary Connectors............................................................................................................233-21 Close-up of Protective Secondary Hood ................................................................................................233-22 Cassette Mounted Secondary Wiring ......................................................................................................243-23 AMP Secondary Wiring Removal Tool.....................................................................................................243-24 Connection Diagram Digitrip 220/520/520M............................................................................................253-25 Connection Diagram Digitrip 1150 ...........................................................................................................263-26 Through-the-Window Electrical Accessories ...........................................................................................273-27 Shunt Trip Device ....................................................................................................................................273-28 Spring Release Device ............................................................................................................................283-29 Undervoltage Release Device .................................................................................................................28

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Figure Title Page

3-30 Auxiliary Switch........................................................................................................................................293-31 Overcurrent Trip Switch and Mechanical Trip Indicator ...........................................................................293-32 Motor Operator Mounted..........................................................................................................................293-33 Non-Electrical Optional Accessories in Circuit Breaker Front Cover .......................................................303-34 Cassette Lock Mounted ...........................................................................................................................303-35 Pushbutton Cover Mounted .....................................................................................................................313-36 Safety Shutters in Closed Position...........................................................................................................313-37 Safety Shutters in Open Position .............................................................................................................313-38 Cell Switch Unmounted............................................................................................................................323-39 Cell Switch Mounted ................................................................................................................................323-40 Door Escutcheon and Gasket ..................................................................................................................32

4-1 Drawout Circuit Breaker and Cassette Isometric .....................................................................................334-2 Drawout Cassette Shown with Extension Rails Fully Extended ..............................................................344-3 Drawout 800/1600 Amp Magnum DS Circuit Breaker ............................................................................354-4 Drawout 2000 Amp Magnum DS Circuit Breaker ....................................................................................364-5 Drawout 3200 Amp Magnum DS Circuit Breaker ...................................................................................374-6 Magnum DS Cassette Top and Front Views with Accessories Through 3200 Amp................................384-7 Drawout Magnum DS Cassette Top/Right Views 800-3200 Amp............................................................384-8 Compartment Door Cutout 800-3200A Dimensions ...............................................................................394-9 Drawout Magnum DS Cassette 800-2000 Amp ......................................................................................404-10 Drawout Magnum DS Cassette 3200 Amp .............................................................................................414-11 Drawout Magnum DS Cassette Front/Top Views 4000/5000 Amp..........................................................424-12 Drawout Magnum DS Cassette Side/Rear Views 4000/5000 Amp .........................................................434-13 Compartment Door Cutout Dimensions 4000/5000 Amp.........................................................................444-14 Drawout Magnum DS Cassette Primary Stabs 4000/5000 Amp .............................................................45

5-1 Closeup of Fixed Circuit Breaker’s Connection Possibilities....................................................................465-2 Fixed 800, 1600 and 2000 Amp Magnum DS Circuit Breaker (Horizontal Primary Connection).............475-3 Fixed 800 and 1600 Amp Magnum DS Circuit Breaker (Vertical Primary Connection) ...........................485-4 Fixed 2000 Amp Magnum DS Circuit Breaker (Vertical Primary Connection) ........................................495-5 Fixed 800, 1600 and 2000 Amp Magnum DS Circuit Breaker (Enclosure/Ventilation))...........................505-6 Fixed 3200 Amp Magnum DS Circuit Breaker (Horizontal Primary Connection) ....................................515-7 Fixed 3200 Amp Magnum DS Circuit Breaker (Vertical Primary Connection) ........................................525-8 Fixed 3200 Amp Magnum DS Circuit Breaker (Enclosure/Ventilation) ...................................................535-9 Fixed 4000/5000 Amp Magnum DS Circuit Breaker (Horizontal Primary Connection)............................545-10 Fixed 4000/5000 Amp Magnum DS Circuit Breaker (Vertical Primary Connection) ................................555-11 Fixed 4000/5000 Amp Magnum DS Circuit Breaker (Enclosure/Ventilation)...........................................56

6-1 Top Rear View of Circuit Breaker with One Arc Chute Removed............................................................586-2 Bottom View of Arc Chute........................................................................................................................586-3 Primary Contacts with Circuit Breaker Open (Not Used for Contact Wear Inspection) ...........................596-4 Contact Inspection Area with Circuit Breaker Open.................................................................................596-5 Use of Contact Wear Indicator with Circuit Breaker Closed ....................................................................606-6 Trip Unit Rating Plug Location .................................................................................................................616-7 Current Sensor Cover in Place Over Sensors .........................................................................................616-8 One Current Sensor Shown Removed and Disconnected.......................................................................61

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TABLES

Table Title Page

1.1 Magnum DS Ratings at 240, 480, 600 volts ..............................................................................................2

2.1 Circuit Breaker Weights .............................................................................................................................52.2 Rejection Interlock Pin Locations...............................................................................................................7

3.1 Line/Load Conductors..............................................................................................................................163.2 Magnum DS Digitrip Trip Units ................................................................................................................203.3 Magnum DS Current Sensors and Matching Rating Plugs......................................................................223.4 Shunt Trip Ratings ...................................................................................................................................273.5 Spring Release Ratings ...........................................................................................................................273.6 Undervoltage Release .............................................................................................................................283.7 Auxiliary Switch, Overcurrent Trip Switch and Cell Switch Contact Ratings............................................283.8 Motor Operator.........................................................................................................................................29

6.1 Inspection Frequency...............................................................................................................................57

7.1 Circuit Breaker Troubleshooting Guide....................................................................................................63

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SECTION 1: INTRODUCTION

1-1 GENERAL INFORMATION

The Magnum DS Power Circuit Breaker is a fixed or dra-wout air circuit breaker design utilizing an electronic trip-ping system. It is designed for use in both switchboardand metal-enclosed switchgear assemblies having maxi-mum voltages of 635 volts ac. Magnum DS circuit break-ers are available in six continuous currents and framesizes from 800 through 5000 amperes. These framesizes are covered by two physical sizes with the sameheights and depths (Figure 1-1, Table 1.1). The circuitbreaker nameplate provides complete rating information.All Magnum DS circuit breakers are 100 percent rated,UL listed, and are built and tested in an ISO 9000 certi-fied facility to applicable NEMA, ANSI, IEEE and ULstandards (Table 1.1, Figures 1-2 and 1-3).

Magnum DS circuit breakers use a rigid frame housingof engineered thermoset composite resins which hashigh strength structural properties, excellent dielectriccharacteristics and arc tracking resistance.

The drawout Magnum DS circuit breaker is a through-the-door design having three breaker positions with thecompartment door closed (CONNECT, TEST, DISCON-NECT) and one position out of its compartment onextension rails (REMOVE). The operating mechanismis a two-step stored energy mechanism, either manuallyor electrically operated.

When withdrawn on captive compartment cassetteextension rails, Magnum DS circuit breakers can beinspected, accessory items added, and minor mainte-nance performed. The inside of the compartment canalso be inspected with the circuit breaker on its exten-sion rails (Figure 1-4).

Please read and understand these instructionsbefore attempting to unpack, install, operate ormaintain this equipment. Study the breaker and itsmechanism carefully before attempting to operate iton an energized circuit.

Figure 1-1 Magnum DS Family of Low Voltage Power Circuit Breakers (800-5000 Amperes)

NOTICE

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MAGNUM DS CIRCUIT BREAKERS SHOULD NOTUNDER ANY CIRCUMSTANCES BE APPLIED OUT-SIDE THEIR NAMEPLATE RATINGS. OPERATIONOUTSIDE OF THESE RATINGS COULD RESULT INDEATH, BODILY INJURY OR PROPERTY DAMAGE.

1-2 SAFETY FEATURES

Magnum DS circuit breakers and associated draw-outequipment are manufactured with built-in interlocks andsafety related features. They are provided to reducehazards to operating personnel and provide properoperating sequences.

TYPE MAGNUM DS CIRCUIT BREAKERS AREROBUST AND ARE PROVIDED WITH SAFETY FEA-TURES. NEVERTHELESS, THE VOLTAGES, CUR-RENTS AND POWER LEVELS AVAILABLE IN ANDAROUND THIS EQUIPMENT WHEN IT IS IN OPERA-TION ARE EXTREMELY DANGEROUS AND COULDBE FATAL. UNDER NO CIRCUMSTANCES SHOULDINTERLOCKS AND OTHER SAFETY FEATURES BEMADE INOPERATIVE, AS THIS MAY RESULT INDEATH, BODILY INJURY OR PROPERTY DAMAGE.

1-3 SAFETY PRACTICES

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

WARNING

Table 1.1 Magnum DS Ratings at 240, 480, 600 volts

Maximum Breaker Interrupting Short TimeAmperes Designation Rating Rating

800 MDS-408 42 kA 42 kAMDS-608 65 kA 65 kAMDS-808 85 kA 85 kAMDS-C08 100 kA 85 kA

1600 MDS-616 65 kA 65 kAMDS-816 85 kA 85 kAMDS-C16 100 kA 85 kA

2000 MDS-620 65 kA 65 kAMDS-820 85 kA 85 kAMDS-C20 100 kA 85 kA

3200 MDS-632 65 kA 65 kAMDS-832 85 kA 85 kAMDS-C32 100 kA 85 kA

4000 MDS-640 65kA 65kAMDS-840 85 kA 85 kAMDS-C40 100 kA 100 kAMDS-E40 130kA 130kA

5000 MDS-850 85 kA 85 kAMDS-C50 100 kA 100 kAMDS-E50 130kA 130kA

WARNING

Figure 1-2 Typical Magnum DS Nameplate

Magnum DSMDSC32Low Voltage AC Power Circuit Breaker3200 Amp Frame 3 Pole 50/60 HzInterrupting Ratings in Amps*Max Inst ShortVolts Trip Delay

635 100,000A 85,000A

508 100,000A 85,000A

254 100,000A 85,000A

AccessoriesMotor Operator 120VACOTS Reset 2A 2BTrip Unit Power Supply 120VAC

G.O. # Cust. P.O.IT:

Code 06/16/98 115002Cat.# MDS8323WEA 32MUA AA6N NNNXXEnclosure Requirements Dwg: 2C13090Installation and Operating Instructions: 2C12060

A

B

C

D

E

AB

Low voltage power circuit breaker family name

Breaker family designation number

C Breaker frame size in amperes

D Interrupting capacity rating

E Accessories

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1. Only qualified electrical personnel familiar with theequipment, its operation and the associated hazardsshould be permitted to work on the equipment.Additionally, only qualified personnel should be per-mitted to install or operate the equipment.

2. Always be certain that the primary and secondary cir-cuits are de-energized or the circuit breaker isremoved to a safe work location before attemptingany maintenance.

3. For maximum safety, only insert a completely assem-bled breaker into an energized cell.

4. Always ensure that drawout circuit breakers are inone of their designed cell positions, such as Connect,Test, Disconnect or Remove. A circuit breaker per-mitted to remain in an intermediate position couldresult in control circuits being improperly connectedresulting in electrical failures.

1-4 QUALIFIED PERSONNEL

For the purpose of operating and maintaining low volt-age power circuit breakers, a person should not be con-sidered qualified if the individual is not thoroughlytrained in the operation of the circuit breaker and how itinterfaces with the assembly in which it is used. In addi-tion, the individual should have knowledge of the con-nected loads.

For the purpose of installing and inspecting circuitbreakers and their associated assembly, a qualified per-son should also be trained with respect to the hazardsinherent to working with electricity and the proper way toperform such work. The individual should be able to de-energize, clear and tag circuits in accordance withestablished safety practices.

1-5 OTHER PUBLICATIONS AND DOCUMENTATION

In addition to this instruction manual, other printed infor-mation and documentation is available and supplied asappropriate. This additional information can include, butnot necessarily be limited to, an instruction manual for aspecific electronic trip unit, instruction leaflets for acces-sory items, renewal parts information, and necessarydimensional drawings.

Figure 1-3 Sample Magnum DS Identification

MDS C32

Figure 1-4 Magnum DS Drawout Circuit BreakerShown on Integral Cassette Extension Rails

Circuit BreakerType

MDS - Magnum DS

Interrupting Capacity

4 - 42,0006 - 65,0008 - 85,000C - 100,000E - 130,000

FrameSize

08 - 800 Amps16 - 1600 Amps20 - 2000 Amps32 - 3200 Amps40 - 4000 Amps50 - 5000 Amps

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SECTION 2: RECEIVING, HANDLING ANDINSTALLATION

2-1 GENERAL INFORMATION

Magnum DS Power Circuit Breakers, when supplied aspart of an assembly, may be shipped already installed intheir respective breaker compartments. Receiving andhandling of this equipment is addressed in an assemblyinstruction manual supplied with the assembled equip-ment. This instruction manual applies to only the circuitbreakers.

2-2 SUGGESTED TOOLS

A large number of different tools are not required toproperly install and maintain Magnum DS circuit break-ers. The following tools are, however, suggested:

• Flat bed screw driver• Phillips head screw driver• 3/8” socket (rachet) wrench• 6” socket extension with 3/8” square drive• 10mm socket• 17mm socket• Secondary wiring removal tool

2-3 UNPACKING CIRCUIT BREAKER

Before beginning to unpack new Magnum DS circuitbreakers, read and understand these directions.Following the directions will ensure that no damage iscaused.

Shipping containers should be inspected for obvioussigns of rough handling and/or external damageincurred during the transportation phase. Record anyobserved damage for reporting to the transportation car-rier and Cutler-Hammer, once the inspection is complet-ed. All reports and claims should be as specific as pos-sible and include the order number and other applicablenameplate information.

Every effort is made to ensure that Magnum DS circuitbreakers arrive at their destination undamaged andready for installation. Care should be exercised, howev-er, to protect the breakers from impact at all times. Donot remove protective packaging until the breakers areready for inspection, testing and/or installation.

When ready to inspect and install the Magnum DS cir-cuit breaker, carefully remove the banding straps and liftoff the cardboard box (Figure 2-1). Remove any addi-tional packing material and internally packed documen-tation. The circuit breaker is mounted to a wooden ship-ping pallet.

If it is a drawout type circuit breaker, clamps hook intothe circuit breaker on both sides and are screwed to thewooden pallet. Remove the screws first and then theclamps (Figure 2-1). Save the clamps for any futureshipments of the circuit breaker.

If it is a fixed type circuit breaker, screws through the cir-cuit breaker’s mounting feet into the wooden pallet areused to hold the circuit breaker securely to the pallet.Remove the screws to free the circuit breaker from thepallet.

Figure 2-1 Shipping Carton Being Partially Lifted fromCircuit Breaker Revealing Shipping Clamp

Clamp

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Circuit breakers are designed to be easily lifted from thewooden pallet using an appropriate lifting yoke andoverhead or portable lifting device (Figure 2-2).

2-3.1 STORING CIRCUIT BREAKER

If it is necessary to store a circuit breaker before instal-lation, do so in its original shipping container. Keep thecircuit breaker in a clean dry place. Ensure there isample air circulation and heat, if necessary, to preventcondensation. It is very important that the circuit break-er not be exposed to dirt or moisture.

A circuit breaker that has been stored for any lengthof time should be operated a minimum of five timesbefore it is placed in service.

2-4 LIFTING CIRCUIT BREAKER

DO NOT ATTEMPT TO LIFT CIRCUIT BREAKERSWITH ORDINARY CRANE HOOKS, ROPES, CHAINSOR OTHER SUCH DEVICES. FAILURE TO FOLLOWTHIS CAUTION COULD RESULT IN DAMAGE TOVITAL PARTS SUCH AS ARC CHUTES, BARRIERSAND WIRING OR THE ENTIRE CIRCUIT BREAKER.

To closely examine, install or just become more familiarwith the circuit breaker, carefully lift and place the circuitbreaker on a solid work surface capable of handling thecircuit breaker’s weight (Table 2.1) or on the captivedrawout extension rails of the breaker compartment(Figure 1-4 and 2-2). This is accomplished by using theappropriate lifting yoke and lifter. The lifting yoke con-sists of two steel hooks specially shaped to hook underthe integral molded lifting handles on both sides of thecircuit breaker (Figures 2-2 and 3-1). Every effortshould be made during lifting to minimize circuit breakerswing and tilt.

NOTICE

CAUTION

Table 2.1 Circuit Breaker Weights

Maximum Breaker Weights (lbs)Amperes Designation Fixed Drawout

800 MDS-408 116 138MDS-608 116 138MDS-808 127 138MDS-C08 127 138

1600 MDS-616 116 138MDS-816 127 149MDS-C16 127 149

2000 MDS-620 135 157MDS-820 135 157MDS-C20 135 157

3200 MDS-632 163 200MDS-832 163 200MDS-C32 163 200

4000 MDS-640 248 303MDS-840 248 303MDS-C40 248 303MDS-E40 248 303

5000 MDS-850 293 359MDS-C50 293 359MDS-E50 293 359

Figure 2-2 Magnum DS Circuit Breaker with Lifting YokeAttached

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If the circuit breaker is to be lifted onto compartmentextension rails, follow the instructions in paragraph 2-6entitled “Installing Drawout Circuit Breaker.”

2-5 CIRCUIT BREAKER INSPECTION

All circuit breakers, once removed from their shippingcontainers, should be visually inspected for any obviousdamage.

The current rating of the rating plug installed in the tripunit should match the current rating of the sensorsmounted on the lower primary stabs of the circuit breaker. Check to make sure that this match exists. The rat-ing plug rating can be viewed from the front of the circuitbreaker (Figure 3-4). The sensor rating can be viewedthrough the viewing windows at the rear of the circuitbreaker (Figures 2-3 and 3-1). Sensors and ratingplugs can be easily changed as described in Section 6.

If the circuit breaker is drawout, inspect the rejectioninterlocks on the floor of the cassette to make sure thecircuit breaker and cassette are compatible. This isdone by following the instructions outlined in paragraph2-6.1.

2-6 INSTALLING DRAWOUT CIRCUIT BREAKER

In structures equipped for drawout circuit breakers, abolted-in cassette with movable extension rails supportsthe circuit breaker (Figures 1-4 and 2-2). The extensionrails must first be pulled all the way out using the smallblack flag shaped handle on the end of each rail. Once

Figure 2-3 Closeup Rear View of Current SensorRating Viewing Window

the rails are fully extended, the circuit breaker can becarefully placed on the extension rails.

IT IS IMPORTANT TO TAKE GREAT CARE WHENPLACING A DRAWOUT CIRCUIT BREAKER ON ITSEXTENSION RAILS. IF THE CIRCUIT BREAKER ISNOT PROPERLY SEATED ON THE EXTENSIONRAILS, IT COULD FALL FROM THE RAILS CAUSINGEQUIPMENT DAMAGE AND/OR BODILY INJURY.

Carefully lower the circuit breaker down onto the exten-sion rails. Be certain that the circuit breaker’s four mold-ed drawout rail supports are fully seated in the exten-sion rail cutouts on both sides (Figures 2-4 and 3-1).Do not remove the lifting yoke from the circuitbreaker until it is properly seated on the rails.

Once the circuit breaker is on the extension rails and thelifting yoke is removed, proceed with the rest of the cir-cuit breaker installation.

2-6.1 REJECTION INTERLOCKS

Magnum DS 800, 1600, 2000 and 3200 ampere circuitbreakers have the same dimensions. To prevent theinsertion of drawout circuit breakers into incompatiblecassettes because of insufficient interrupting capabili-ties or incorrect frame sizes, rejection interlocks areprovided.

CAUTION

Figure 2-4 Closeup of One Side of Drawout CircuitBreaker Properly Seated on Extension Rail

Molded RailSupports

Extension RailCutoutExtension RailCutout

Molded RailSupports

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DO NOT DISABLE REJECTION INTERLOCKS.DOING SO AND USING A LOWER CAPACITY CIR-CUIT BREAKER IN AN INCOMPATIBLE CASSETTECOULD RESULT IN AN ELECTRICAL FAULT WHICHCOULD RESULT IN DEATH, BODILY INJURYAND/OR EQUIPMENT DAMAGE.

The rejection interlocks are steel pins in the floor of thecircuit breaker cassette. As the circuit breaker ispushed into the structure, the mating pins on the bottomof the circuit breaker move past a set of correspondingpins in the cassette, if the circuit breaker and cassetteare compatible. If the circuit breaker and the cassetteare a mismatch, the rejection pins will prevent the circuitbreaker from being fully inserted into the cassette.

Before attempting to push the circuit breaker into theDISCONNECT position, compare the positioning ofrejection interlock pins in the cassette in keeping withTable 2.2 and Figure 2-5 and the information suppliedon the circuit breaker’s nameplate. Proceed if the circuitbreaker and cassette are compatible.

2-6.2 CIRCUIT BREAKER POSITIONING

The Magnum DS drawout circuit breaker has four nor-mal positions:• REMOVE (Withdrawn) (Figure 2-6)• DISCONNECT (Figure 2-7)• TEST (Figure 2-8)• CONNECT (Figure 2-9)

CAUTION

The REMOVE position is a position outside the com-partment on the cassette’s drawout rails and is not partof the levering mechanism. The DISCONNECT, TEST,and CONNECT, position are reached by means of thelevering mechanism.

With the breaker solidly positioned on the cassette’sextension rails, carefully and firmly push the circuitbreaker into the compartment as far as it will go. Therear portion of the circuit breaker’s faceplate and the for-ward front edge of the cassette should be flush whenthe circuit breaker is completely pushed into position(Figure 2-10).

MAKE CERTAIN THAT THE CIRCUIT BREAKER ISFULLY INSERTED INTO ITS COMPARTMENTBEFORE ANY ATTEMPT IS MADE TO LEVER THECIRCUIT BREAKER. ATTEMPTING TO LEVER THECIRCUIT BREAKER IN BEFORE IT IS FULLY POSI-TIONED INSIDE ITS COMPARTMENT CAN RESULTIN DAMAGE TO BOTH THE CIRCUIT BREAKER ANDTHE COMPARTMENT.

Figure 2-5 Rejection Interlock Pin Positioning/Installation

From Table 2.2, make a pin location comparison.Stop nuts should be torqued to 8-10 Ft.-Lb.

Stab I.C. Pin Locations Cell For: Size @600 1 2 3 4 5 6 7 8

(in) VAC

MDS-408 .50 42 X X

MDS-608, 616, 620 .50 65 X X X X

MDS-808, 816, 820 .50 85 X X X X X

MDS-C08, C16, C20 .50 100 X X X X X X

MDS-632 .75 65 X X X X

MDS-832 .75 85 X X X X X

MDS-C32 .75 100 X X X X X X

MDS-640 .50 65 X X X

MDS-840 .50 85 X X X

MDS-C40 .50 100 X X X X

MDS-E40 .50 130 X X X X X

MDS-850 .75 85 X X X

MDS-C50 .75 100 X X X X

MDS-E50 .75 130 X X X X X

Table 2.2 Rejection Interlock Pin Locations

1

23

4

5

67

8

CAUTION

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Figure 2-6 Remove Position

Figure 2-7 Disconnect Position

Figure 2-8 Test Position

� Breaker and Trip Unit Testing

� Primary Connection Not Made

� Secondary and Ground Connections Made

� Only Ground Connection Made

� Breaker Still Behind Door

� Typical Storage Position

� No Electrical Connections Made

� Breaker On Extension Rails

� Remove or Inspection Position

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Figure 2-11 Circuit Breaker Being Levered

CONNECT

TEST

DISCONNECT

CONNECT

TEST

DISCONNECT

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Figure 2-9 Connect Position

Figure 2-10 Fully Inserted Circuit Breaker

Fully Inserted when Flush

Levering DeviceAccess Door

� Full Breaker Operation

� Primary, Secondary and Ground Connections Made

� Fully Racked into Cassette (Compartment)

Close the compartment door and begin levering thebreaker into its different positions using a clockwiseratcheting motion. When levering the circuit breakerinto the CONNECT position, do not exceed 25 ft.lb. oftorque. The circuit breaker can be levered with thecompartment door open or closed, but it is advis-able to close the door prior to levering. The positionof the circuit breaker within its compartment is indicatedby color coded position indicators (Red = Connect,Yellow = Test, Green = Disconnect) (Figures 2-11 and3-4). To remove the circuit breaker from its compart-ment, follow the procedure just described using a coun-terclockwise ratcheting motion.

2-6.3 LEVERING CIRCUIT BREAKER

The circuit breaker is now ready to be levered. With thecircuit breaker OPEN, the levering device access doorcan be raised (Figure 2-10). The levering device ishand operated using a standard 3/8” square drive andratchet, which is not provided (Figure 2-11). As long asthe access door is raised, the circuit breaker is held tripfree. Begin by rotating the levering-in screw to the fullcounterclockwise (DISCONNECT) position.

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2-7 FIXED CIRCUIT BREAKER

The Magnum DS fixed type circuit breaker differs fromthe drawout version in that it has no levering device, pri-mary disconnects and secondary disconnects (Figure 2-12). In addition, a fixed circuit breaker does not have astandard feature to hold the breaker in a trip-free posi-tion. To ensure the proper sequence of operationbetween two or more circuit breakers, an optional keyinterlock is mounted through the front panel (Figure 3-4).

Circuit breaker terminals have holes for making boltedhorizontal primary bus connections. Adapters are avail-able for making vertical primary bus connections.Secondary connections can be made through standardterminal blocks or a special connector compatible withthe drawout circuit breaker’s type secondary connector.Both secondary connection devices are mounted at thetop, front of the circuit breaker.

The fixed circuit breaker frame has two mounting feet,one on each side, to permit the fixed circuit breaker tobe securely mounted. Each mounting foot has two slot-ted mounting holes which are used to bolt the circuitbreaker securely in place. Use either M10 or 3/8" boltsfor this purpose. Refer to the dimensional drawings pre-sented in Section 5 (Fixed Circuit Breaker) for circuitbreaker and bus stab dimensions.

Refer to the circuit breaker weights in Table 2.1 toensure that the panel on which a fixed circuit break-er is to be mounted is capable of supporting theweight.

2-8 CIRCUIT BREAKER OPERATION

Circuit breakers should be operated manually and/orelectrically before they are put into service. This can bedone during the installation process or some later dateprior to start-up. To check circuit breaker operation, fol-low the operational procedures outlined in Section 3 forboth manually operated and electrically operated circuitbreakers.

NOTICE

NOTICE

Figure 2-12 Typical Fixed Type Magnum DS CircuitBreaker

MountingFoot

The circuit breaker mechanism is interlocked suchthat charged closing springs are automatically dis-charged if the circuit breaker is levered into or outof the CONNECT position.

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SECTION 3: CIRCUIT BREAKERDESCRIPTION AND OPERATION

3-1 INTRODUCTION

Magnum DS circuit breakers are available in both drawout and fixed mounting configurations (Figures 3-1and 3-2). A majority of features are common to bothconfigurations, and will be discussed in this section.The mounting features unique to the drawout and fixedconfigurations will be covered individually in Sections 4and 5 respectively.

Controls and indicators for both drawout and fixed circuitbreakers are functionally grouped on the front of the cir-cuit breaker. The front escutcheon (faceplate) is com-mon for the two frame sizes that cover all continuouscurrent ratings through 5000 amperes (Figure 3-4).

The larger frame circuit breakers, 4000 and 5000amperes, utilize six sets of rear primary connections(Figure 3-3). Facing the rear of the larger frame circuitbreaker, the standard phase sequencing is AA-BB-CCstarting at the right and moving left. For optional phasesequencing A-B-C-A-B-C, contact Cutler-Hammer.

Figure 3-1 Magnum DS Drawout 800-3200A Size (Front and Rear Views) - See Figure 3-4 for More Details

Baffled Arc Chute Cover

Secondary Disconnects (Contacts)

Faceplate (Front Cover)

Drawout Rail Supports

Integral Lifting Handle5

2

1

6

7

9

4

3

8

10

11

12

10

9

6

7

8

2 1

4

12

3

11 5

4

1 Primary Disconnect Finger Cluster

Arc Chamber

Primary Vertical Adaptor

Sensor Rating Viewing Window

Levering Device Bearing Plate

Padlockable Levering Device Access Door

Circuit Breaker Nameplate

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Figure 3-2 Magnum DS Fixed 800-3200A Size (Front and Rear Views) - See Figure 3-4 for More Details

Baffled Arc Chute Cover

Secondary Disconnect

Faceplate (Front Cover)

Integral Lifting Handle

Fixed Horizontal Primary Terminal 5

2

1

4

3

Fixed Primary Terminal (with Optional Vertical Adaptor)

Arc Chamber

Sensor Cover Plate with Viewing Window(Removed Providing Sensor Access)

Mounting Foot

Circuit Breaker Nameplate

6

7

8

9

10

3

9

102

1

4

5

6

7

89