ABB K-Line Plus KP-32 Installation and operating instructions

IB 6.2.11.1-2C
Installation/Maintenance Instructions
Low Voltage Power Circuit Breaker
K-Line Plus®
Types KP-32, KPE-32, KP-40 and KPE-40
ABB

NOTE: This Instruction Book is provided solely for the convenience of the
purchaser, and does not purport to cover all details or variations in equipment nor
to provide for every possible contingency to be met in connection with installation,
operation, or maintenance. Should further information be desired or should
particular problems arise which are not covered sufficiently for the purchaser’s
purposes, the matter should be referred to the nearest Sales Representative.
INTRODUCTION ....................................................... 3
RECEIVING AND STORAGE.................................... 3
BASIC HANDLING .................................................... 3
CIRCUIT BREAKER RATING ................................... 3
ESCUTCHEON OPERATING FEATURES ............... 3
Circuit Breaker Nameplate .................................... 4
Manual Charging Handle....................................... 4
Manual Trip Button ................................................ 4
Circuit Breaker "OPEN" or "CLOSED" Indicator.... 4
Automatic Trip Indicator......................................... 4
Automatic Trip Alarm Contacts.............................. 4
Automatic Trip Lockout Device.............................. 4
Padlocking Device ................................................. 4
Closing Spring Charge Indicator............................ 4
Motor Disconnect Switch ....................................... 4
Electrical Close & Trip Push Buttons..................... 4
Manual Close Lever............................................... 8
Racking Mechanism .............................................. 8
CIRCUIT BREAKER INTERNAL COMPONENTS .... 8
Solid State Control Device (SSCD) ....................... 8
Shunt Trip .............................................................. 8
Close Coil .............................................................. 8
Closing Spring Charging Motor ............................. 8
Closing Spring Check Switch (CSCS) ................... 8
Auxiliary Switches.................................................. 8
Undervoltage Trip Device ...................................... 9
MPSC-2000 SOLID STATE TRIP SYSTEM.............. 9
Selecting Trip Settings......................................... 10
OPERATING SEQUENCE FOR EO BREAKERS... 10
CLOSING SPRING OPERATION ........................... 11
INSTALLATION, INITIAL TESTING & REMOVAL .. 11
Installation ........................................................... 11
Checking Breaker Operation in “TEST”............... 11
Checking Breaker Operation in “CONNECTED” . 11
Manual Closing Operation ................................... 12
Circuit Breaker Removal...................................... 12
MAINTENANCE AND ADJUSTMENTS .................. 12
Periodic Maintenance Inspection......................... 12
Arc Chutes........................................................... 12
Insulation Structure ..............................................13
MPSC-2000 Trip Device Removal & Installation..13
Electrical Components (EO only) .........................13
Contact.................................................................13
Contact Pitting......................................................13
Contact Pressure Check and Adjustment ............13
Manual Slow Close to Check Contact Pressure ..14
Operating Mechanism..........................................14
Primary Trip Latch............................................15
Tripper Bar Adjustment ....................................15
Primary Close Latch.........................................15
Shunt Trip Device.............................................15
FIELD TESTING THE MPSC-2000 TRIP SYSTEM 16
Instantaneous or Short Time Threshold Test.......16
Long Time Threshold Test ...................................16
Long Time Delay Test ..........................................17
Short Time Delay Tests........................................17
Ground Trip Delay Tests ......................................17
LUBRICATION.........................................................17
DIELECTRIC TESTS ...............................................18
RENEWAL PARTS ..................................................19
Table of Contents
FIGURES
Figure 1 - Typical Electrically Operated Breaker .......5
Figure 2 - Typical Composite Schematic (EO)...........6
Figure 3 - Contact Pressure and Adjustment...........13
Figure 4 - Shutter Detail...........................................14
Figure 5 - Primary Trip Latch Adjustment ................14
Figure 6 - Tripper Bar Adjustment............................14
Figure 7 - Primary Close Latch Adjustment .............15
Figure 8 - Shunt Trip Device Adjustment .................15
TABLES
Table 1 - Secondary Disconnect Assignments ..........7
Table 2 - Electrical Characteristics of Devices...........8
Table 3 - Undervoltage Trip Device Operating Data..9
Table 4 - MPSC-2000 Typical Delay Bands ............16

IB 6.2.11.1-2C
Page 3 ABB
INTRODUCTION
The KP-32/40 family of circuit breakers are low voltage
AC power circuit breakers featuring draw-out
construction and the MPSC-2000 microprocessor-
based trip system with RMS sensing. These circuit
breakers can be furnished with either electrically
operated (EO) or manually operated (MO)
mechanisms. On EO models, various control power
combinations are available, and numerous options are
available for both mechanism styles.
These instructions apply to the ANSI-rated “KP” series
(KP-32 and KP-40), and the extended-rated “KPE”
series (KPE-32 and KPE-40).
An electrically operated, drawout type circuit breaker is
shown in Figure 1, with a typical schematic diagram
shown in Figure 2.
These instructions should be read thoroughly before
handling, installing and/or operating the circuit breaker.
RECEIVING AND STORAGE
Immediately upon receipt of the circuit breakers,
examine the cartons to determine if any damage or loss
was sustained during transit. If injury or rough handling
is evident, file a damage claim at once with the carrier
and promptly notify the nearest District Office. The
Company is not responsible for damage of goods after
delivery to the carrier. However, the Company will lend
assistance if notified of claims.
Unpack the circuit breakers as soon as possible after
receipt. If unpacking is delayed, difficulty may be
experienced in making a claim for damages not evident
upon receipt. Use care in unpacking in order to avoid
damaging any of the circuit breaker parts. Check the
contents of each carton against the packing list before
discarding any packing material. If any shortage of
material is discovered, promptly notify the nearest
District Office. Information specifying the purchase
order number, carton number and part numbers of the
damaged or missing parts should accompany the
claim.
Circuit breakers should be installed in their permanent
location as soon as possible (see Basic Handling
below). If the breakers are not to be placed in service
for some time, it is advisable to provide adequate
means of protection. This may he done by keeping the
breaker in its original carton, covering with waterproof
paper and sealing to prevent infiltration of dirt. Where
conditions of high humidity prevail, the use of heaters is
recommended.
BASIC HANDLING
Once the circuit breaker has been unbolted and
removed from its shipping carton, it should be turned
to the upright position and placed on a flat surface to
avoid damage to breaker parts. For safety, all
handling in this position should utilize the lifting yoke
(9) shown in Figure 1.
CIRCUIT BREAKER RATING
The circuit breaker continuous current rating (in
hundreds of amps) is given by the number which
follows the type designation (e.g., KP-40 = 4000A). If
required, the breakers can be fitted with lower ampere
current sensors and trip systems, which provide
tripping below the actual continuous current rating of
the frame size.
Exceeding the continuous current rating of the circuit
breaker for extended periods may raise the
temperature of the circuit breaker beyond the limits
set forth in ANSI C37.13 thus affecting the life of the
circuit breaker insulating materials. The MPSC-2000
trip system has a tolerance band on long time of
minus zero, plus ten percent (-0, +10%) which will
allow the circuit breaker to carry its rated continuous
current but will provide tripping above that value.
Additionally, root mean square (RMS) current
calculation on the long time trip element provides
tripping based on the true heating value of the current
passing through the circuit breaker.
ESCUTCHEON OPERATlNG FEATURES
Manually and electrically operated circuit breakers are
provided with an extended escutcheon face plate.
This escutcheon provides a central area for the
controls which are mounted directly on the circuit
breaker. Figure 1 shows the controls and other
features provided on a typical electrically operated
circuit breaker. The controls for manually operated
circuit breakers are the same, except that the manual
charging handle (16) is standard and the charge
motor and its cut-off switch are not provided.
A self-aligning plate, immediately behind the
escutcheon face plate, is used to exclude dust from
the circuit breaker compartment. The escutcheon
face will protrude through the front door of the
compartment when the circuit breaker is in the “TEST”
and "DISCONNECTED" positions. In these positions,
the dustplate still functions to exclude dust.

IB 6.2.11.1-2C
Page 4
ABB
Circuit Breaker Nameplates (Figure 1, Item 4). The
circuit breaker nameplates contain information
regarding the manufacturer's name and address, type
of circuit breaker design, serial number of circuit
breaker, continuous current rating of frame size, short
circuit current rating at rated voltages, frequency, short
time current, and breaker control voltages.
Manual Charging Handle (Figure 1, Item 16). The
manual charging handle is a T-shaped lever used to
charge the closing springs by pumping approximately
ten times.
Manual Trip Button (Figure 1, Item 10). The manual
trip button, when pushed, trips the circuit breaker to
"OPEN."
Circuit Breaker "OPEN" or "CLOSED" Indicator
(Figure 1, Item 2). This indicator shows the physical
position of the circuit breaker contacts.
Automatic Trip Indicator (Figure 1, Item 15). (Not
including undervoltage, alarm switch, or lockout). The
automatic trip indicator is provided as standard
equipment on the K-Line Plus circuit breakers and is
used to indicate the operation of the overcurrent trip
device. This device is an indicator only and does not
prevent the circuit breaker from reclosing.
Upon an overcurrent trip operation, the indicator
protrudes from the front plate approximately 1/2 inch.
The automatic trip indicator should be reset after each
trip indication by pushing it back into its normal latch
position. The operator should investigate the cause of
tripping before resetting the automatic trip indicator and
subsequently reclosing the circuit breaker after an
outage which results in an operation of the indicator.
Automatic Trip Alarm Contacts (optional - not
shown). An alarm switch for remote electrical
indication, which is optional, shows when automatic
tripping has occurred. This is accomplished by adding
a precision snap switch to the automatic trip indicator
assembly. The automatic trip indicator actuates the
roller on the alarm switch which in turn causes a
normally open contact to close and a normally closed
contact to open on overcurrent trip. The alarm contact
is manually reset by pushing the trip indicator back into
its normal position.
Automatic Trip Lockout (optional - not shown). An
additional optional device may be added to the
automatic trip indicator assembly device which serves
to mechanically prevent reclosing the circuit breaker
after an automatic trip operation. When the trip
indicator is pushed in, the circuit breaker mechanism
can then be operated to close the circuit breaker
contacts.
Padlocking Device (Figure 1, Item 13). All K-Line
Plus circuit breakers are equipped with means of
padlocking the circuit breaker mechanism in a trip-tree
position. This is accomplished by the use of a locking
plate to maintain the manual trip button in a tripping
direction when the locking plate is held forward by one
or more padlocks. To obtain the condition for
padlocking the circuit breaker in the open position, the
manual trip button is pushed inward. Then the padlock
plate is pulled out and the padlock inserted into the
vertical slot. In this position, the mechanism is
maintained trip free and the contacts cannot be moved
to the closed position.
The padlocking device is also associated with the
drawout interlocking mechanism so that the circuit
breaker cannot be moved from any of its three basic
drawout positions of "CONNECTED", “TEST” or
"DISCONNECTED" with the padlocking in effect.
Closing Spring Charge Indicator (Figure 1, Item 6).
Under normal operating conditions, the closing springs
of an electrically operated breaker are automatically
charged after each tripping operation. However, there
are occasions when the springs will be in a discharged
state. Therefore, it is desirable that means be available
to indicate the condition of the closing springs. This is
accomplished by a visual indicator seen through an
aperture in the escutcheon plate. The indicator is
marked "CHARGED" and "UNCHARGED."
Motor Disconnect Switch (Figure 1, Item 14). The
motor disconnect switch (EO breakers only) is a double
pole, single-throw toggle type switch connected in
series with the charging motor circuit and is used to
disconnect the motor from the voltage source. This
switch is used: (a) when it is desirable to prevent
automatic recharging of the closing springs just prior to
taking the circuit breaker out of service for
maintenance, and (b) for control wiring dielectric test.
The motor must be disconnected for the control wiring
dielectric test and subsequently tested at the
appropriate voltage.
Electrical Close and Trip Push Buttons (Optional,
Figure 1, Item 20). The electrical close and trip push
buttons are used to electrically operate the circuit
breaker from the escutcheon. These contacts are
connected in series with their respective latch release
coils. Energizing the close latch release coil allows the
charged springs to close the circuit breaker, while
energizing the trip latch release coil allows the breaker
to open.
(Continued on page 8)

IB 6.2.11.1-2C
Page 5 ABB
1. Arc Chute
2. “OPEN” or “CLOSED” Indicator
3. MPSC-2000 Trip Device
4. Nameplates
5. Escutcheon Assembly with Self-
Aligning Dust Cover
6. Spring Charge Indicator
7. Wheels
8. Racking Handle (Optional)
9. Lifting Rig (Optional)
10. Manual Trip Button
11. Drawout Lever
12. Manual Close Lever
13. Padlock Hasp
14. Motor Disconnect Switch (EO only)
15. Automatic Trip Indicator
16. Manual Charging Handle (Optional)
17. Position Indicator Label
18. Spring Charging Motor (EO only)
19. Racking Cam Rollers
20. Electrical Trip & Close Buttons
(Optional - Not Shown)
Figure 1 - Typical Electrically Operated K-Line Plus Circuit Breaker
1
19
3
4
5 18
17
7
9
16
2
8 11
13
6
10
15 14 20
12

IB 6.2.11.1-2C
Page 6
ABB
NOTES:
1. This wiring diagram includes some optional features
not found on all K-Line Plus breakers, including an
alarm switch, undervoltage trip device, LET/LEC,
and spare auxiliary switch contacts.
2. Secondary disconnect numbers begin with a letter
which indicates in which plug the disconnect
resides. The “A” plug is the right-hand plug when
viewed from the rear of the breaker.
3. The spare auxiliary switch contacts which are routed
through secondary disconnect “A” are standard on
EO breakers. Those routed through plug “B” are
optional.
Figure 2. K-Line Plus Typical Composite Schematic (Electrically Operated)
60
58
52
59
Close+
55 54
62
Close-
MOTOR DISCONNECT SWITCH
Motor-
A7
M
CC
8
COIL
61
CLOSE
7
COIL
TRIP
b
AS
Motor+
A1
b
AS
4
3
TC
1
51
2a
AS
Trip-
Control Device
5
P18
A5
P4
P20
P8
2
P6
A2
P2
P19
P22
P1
P10
Solid State
3A
1
3
A3
P17
4
Trip+
A4
2
P5
4A
1
7
P9
P3
80
191715
A14 A18A16
2321
A22A20
14 1816 20 22
A15 A21A19A17 A23
5
6
AS
a
10
AS
9
a
12
AS
11
b
14
AS
13
a
16
AS
15
b
53
65
CSCS
CSCS
64
63
56
57
NO
C
C
NO
B21
32
31
B22
B13B9 B11B7
3432 36
B15 B17 B19
38 40 42 44
19
17
18
a
AS
20
21
23
b
AS
22
AS
a
24
3533 37
28
27
25
AS
b
26
a
AS
29
30
AS
b
AS
a
39 41 43 45
B14B10B8 B12 B18B16 B20
46
b
AS
47
Standard Alarm Switch (Optional)
15
B1 B2
the UVD model and voltage.
breaker is dependent on
UVD wiring internal to the
26
13
27
14
UV
Undervoltage Trip Device (Optional)
Local Electrical Trip & Close (Optional)
Spare Auxiliary Switch Contacts (see notes)
A12
A10
r
A11 11
s
10
12 4B
4A3A
1 2
4
A4
3
A3
TRIP CLOSE
3B
9
A9
8
A8
Note: The "normal" positions shown in this
figure are the switch contact postions when the
Auto Trip Indicator is "in" (reset).
P16 P13

IB 6.2.11.1-2C
Page 7 ABB
Table 1. K-Line Plus Secondary Disconnect Assignments
Pin Description Pin Description
A1 Charge Motor + B1 Undervoltage Trip Device +
A2 Shunt Trip - B2 Undervoltage Trip Device -
A3 Close Coil + B3 (MPSC-2000 4WG or DESP) 6
A4 Shunt Trip + B4 (MPSC-2000 4WG or DESP) 6
A5 Close Coil - B5 (MPSC-2000 4WG or DESP) 6
A6 MPSC-2000 VIM B6 (MPSC-2000 4WG or DESP) 6
A7 Charge Motor - B7 Aux. Sw. "a" +
A8 Local Elec. Close + B8 Aux. Sw. "a" -
A9 Local Elec. Trip + B9 Aux. Sw. "b" +
A10 Alarm Switch 4 B10 Aux. Sw. "b" -
A11 Alarm Switch 4B11 Aux. Sw. "a" +
A12 Alarm Switch 4B12 Aux. Sw. "a" -
A13 Alarm Switch 4B13 Aux. Sw. "b" +
A14 Aux. Sw. "a" + B14 Aux. Sw. "b" -
A15 Aux. Sw. "a" - B15 Aux. Sw. "a" +
A16 Aux. Sw. "a" + B16 Aux. Sw. "a" -
A17 Aux. Sw. "a" - B17 Aux. Sw. "b" +
A18 Aux. Sw. "b" + B18 Aux. Sw. "b" -
A19 Aux. Sw. "b" - B19 Aux. Sw. "a" +
A20 Aux. Sw. "a" + B20 Aux. Sw. "a" -
A21 Aux. Sw. "a" - B21 Aux. Sw. "b" +
A22 Aux. Sw. "b" + B22 Aux. Sw. "b" -
A23 Aux. Sw. "b" - B23 (Spare) 5
A24 (Spare) 5B24 (Spare) 5
A25 (Not Used) B25 (Not Used)
supplied with the breaker for pin-out assignments.
(6) The assignments for pins B3 - B6 will differ depending on whether the DESP option has been supplied. See
the MPSC-2000 schematic supplied with the breaker.
Notes:
(1) These assignments are
provided for reference only,
and may be changed due to
special requirements. Some
pins or plugs may not be
present on all breaker
configurations. See the
breaker schematic wiring
diagram(s) for details.
(2) Note the polarity of control
devices: “+” is the send and
“-” is the return.
(3) The two terminals of each
Auxiliary Switch contact are
connected to adjacent
Secondary Disconnect pins.
For example, pins A14 and
A15 are connected to a
single “a” contact. Also, the
polarity signs are provided
on these pins for consistency
only; the Auxiliary Switch
contacts are not polarity
sensitive.
(4) The Alarm Switches can be
wired in two different ways.
See the schematic supplied
with the breaker for details
on the pin-outs.
(5) The pins marked “(Spare)”
may be used in some
breakers for special
customer wiring
requirements. Refer to the
schematic wiring diagram

IB 6.2.11.1-2C
Page 8
ABB
(Continued from page 4)
Manual Close Lever (Figure 1, Item 12). The manual
close lever is provided on all circuit breakers to provide
a safe means of closing the breaker without control
power. The lever is provided with a hole through which
a lanyard should be attached for closing the breaker at
a safe distance .
Racking Mechanism. The racking mechanism is used
to move the circuit breaker to any one of its three
positions: "CONNECTED", "TEST”, or
“DlSCONNECTED." All of these positions are
attainable with the cubicle door closed or opened. The
breaker can be closed only when the drawout lever (11,
Figure 1) is up. When up, the racking crank (8, Figure
1) cannot be turned. The circuit breaker must be in the
"OPEN" position before lever (11, Figure 1) can be
pushed down. In order to move the circuit breaker from
one position to another, the lever must be pushed down
and the crank turned; once turning begins, the lever will
stay down until another position is reached and the
lever will snap up, preventing additional turning, until
the lever is again pushed down.
When the padlocking device is locked, the lever (11) is
locked in the up postion preventing movement of the
racking mechanism.
There is a label (17, Figure 1) on the right side of the
breaker escutcheon to show breaker position when the
swichgear door is closed.
CIRCUIT BREAKER INTERNAL COMPONENTS
For electrically operated (EO) circuit breakers, the
Operating Sequence section illustrates the function of
the following devices. Electrical characteristics can be
found in Table 2.
Solid State Control Device (SSCD) - The SSCD is
mounted on the lower-left portion of the operating
mechanism of EO circuit breakers, and controls the
electrical closing functions of the breaker. The “anti-
pump” feature of the SSCD prevents a second
electrical closing until the first closing signal is
released. For example, if the breaker is closed
electrically and the signal is maintained, the SSCD will
not permit the breaker to be closed electrically again
after a trip until the electrical close signal is released.
Shunt Trip - The shunt trip is standard on EO breakers
and optional on MO breakers. When energized, it
releases the stored energy of the contact and opening
springs causing the circuit breaker to open.
Close Coil - The close coil is standard on EO breakers.
When energized, it releases the stored energy of the
closing springs causing the circuit breaker to close.
Closing Spring Charging Motor (Electrically
Operated Breakers only) - When the motor disconnect
switch is ON, the charging motor is energized
automatically by internal limit switches to charge the
closing springs electrically.
Closing Spring Check Switch (CSCS) - There are
two CSCS’s: one automatically disconnects the power
to the charging motor when the closing springs are fully
charged; the other sends spring charge information to
the SSCD.
Auxiliary Switches - The integral auxiliary switch is
standard on EO breakers and MO breakers with shunt
trip, and optional on MO breakers without shunt trip.
The standard configuration contains the four "a" and
Figure 2 - Electrical Characteristics of Control Devices
Nominal Control
Voltage
Average
Charging
Motor
Current*
Shunt Trip or
Close Coil
Current
Closing
Circuit
Voltage
Range
Shunt Trip
Circuit
Voltage
Range
Recommended
Control Fuse Size
120VAC (60 Hz) 10A 6.5A 104-127 104-127 10A
240VAC (60 Hz) 5A 1.2A 208-254 208-254 10A
48VDC 25A 3.1A 38-56 28-56 15A
125VDC 10A 1.3A 100-140 70-140 10A
250VDC 5A 0.7A 200-280 140-280 10A
* Approximate steady state values; momentary in-rush currents are approximately 6-8 times these values
Table 2

IB 6.2.11.1-2C
Page 9 ABB
four "b" contacts (with three “a” and two “b” contacts
available for customer use via the secondary
disconnects). The switch is mechanically
interconnected with the circuit breaker mechanism such
that, with the circuit breaker closed, the “a" contacts are
closed and the "b" contacts are open. With the circuit
breaker open, the "a" and "b" contacts reverse
positions. This switch is located in the lower right
portion of the circuit breaker.
Optionally, EO breakers and MO breakers with shunt
trip can be fitted with a 16-pole switch, which offers an
additional four each “a” and “b” contacts for customer
use.
Undervoltage Trip Device (Optional) - The electrically
reset undervoltage trip device (UVD) is a single-phase
device which automatically trips the circuit breaker
when the supplied voltage decreases to 30 to 60
percent of the rated voltage. This device may be
furnished either for instantaneous trip operation or with
adjustable time delay tripping of 1.5-15 seconds. The
undervoltage trip device is an integral unit which may
be added to the circuit breaker either at the factory or in
the field.
See Table 3 for electrical characteristics of the UVD.
MPSC-2000 SOLID STATE TRIP SYSTEM
The MPSC-2000 electronic, microprocessor-based trip
system includes the sensors, the MPSC-2000
electronic trip device, the magnetic latch, and the
interconnecting wiring. A current sensor is integrally
mounted on each phase of the circuit breaker to supply
a value of current flowing in the trip unit which is
directly proportional to the current passing through the
primary circuit. When the value of current in the
primaries exceeds the trip unit threshold setting for a
given time in long time, short time, and/or ground, then
tripping occurs by sending a signal to the magnetic
latch. Instantaneous tripping occurs in the same
manner, but without the time delay. On three phase,
four wire, wye systems, provisions are made for input
from a separately mounted sensor to obtain a residual
connection of all four sensors for sensitivity to ground
currents.
The MPSC-2000 trip unit (Item 3 of Figure 1) is visible
on the front of the circuit breaker. It is completely self-
powered, taking the tripping energy from the primary
current passing through the circuit breaker without the
need for any additional power supply. An external 9V
battery is supplied to permit the user to access the
MPSC-2000’s menus. The battery is not required for
correct operation of the trip device. The battery will last
only about 1-2 hours of actual use, so the switch to this
battery should be left in the “off” position except when
needed.
To cope with modern power systems where harmonics
in the system can cause cable and busway
overheating, the MPSC-2000 long time trip element
samples the current in a unique algorithm, then
calculates the root mean square (RMS) value of the
system current, providing tripping when the RMS
current is above the trip threshold. Overheating in
cable and busway is thus avoided with the MPSC-2000
trip system. Short time and Instantaneous tripping
remains based on peak sensing methods, avoiding
unnecessary delay in tripping caused by the RMS
calculation.
The MPSC-2000 trip system also includes all the
connection ports and software for performing
communication duties when connected to the PRICOM
or PRICOM-PLUS communication systems. Although
a breaker might not be connected to a communication
system when it is installed, it will not require any
modification to be connected to the Network Interface
Module (NIM) in the PRICOM system at some future
time. This unique feature allows for future expansion
without incurring additional up-front expenses. The
NIM cable is connected to the nine-pin connector
adjacent to the 25-pin connector on the end of the
MPSC-2000 trip device. If the device is configured with
a Voltage Interface Module (VIM), a four pin connector
will also be adjacent to the previously mentioned
connectors. See bulletin 3.1.3-2A for additional details
about the PRICOM communication system.
Four basic elements within the MPSC-2000 trip unit
perform the protective functions: (1) long time, (2)
short time, (3) instantaneous, and (4) ground. Each of
these may be disabled or adjusted independently,
except for a few conditions which are required to
Figure 3 - Undervoltage Trip Device
Operating Data
Service Voltage
Current at
Rated
Voltage
Maximum
Pickup
Voltage
Dropout
Voltage
Range
120VAC (60 Hz) 0.5A 102 36-72
240VAC (60 Hz) 0.2A 204 72-144
480VAC (60 Hz) 0.1A 408 144-288
48VDC 0.3A 41 15-29
125VDC 0.2A 106 38-75
250VDC 0.1A 212 75-150
Table 3

IB 6.2.11.1-2C
Page 10
ABB
ensure the correct functionality of the breaker. For
example, it is not possible to disable both the
instantaneous and short time elements simultaneously.
Also, the long time element cannot be disabled.
The MPSC-2000 trip unit is completely tested prior to
shipment. Since there are no mechanical devices
which may have lost adjustment during shipment, no
readjustments, other than making the required settings,
need be made prior to placement in service. The
following trip characteristics are available: long time
setting and delay bands; short time setting and delay
bands with switchable I2t characteristic, instantaneous
setting, and ground setting and delay bands with
switchable l2t characteristic. Other settings are
available for devices with a VIM installed - see IB
6.1.2.8-1A for details.
The MPSC-2000 trip unit must be properly set, as
required by the individual circuit based on a
coordination study performed for the system, in order to
provide the necessary protection. The MPSC-2000 trip
device is shipped with standard shipping settings; THE
SHIPPING SETTINGS DO NOT CORRESPOND TO
THE REQUIREMENTS OF THE SYSTEM IN WHICH
THE BREAKER IS INSTALLED. DETERMINE WHAT
THE CORRECT SETTINGS SHOULD BE FOR THE
ELECTRICAL SYSTEM IN WHICH THE BREAKER IS
INSTALLED PRIOR TO CLOSING THE CIRCUIT
BREAKER INTO THAT SYSTEM. Nuisance tripping
or inadequate protection may result from failure to
properly adjust the circuit breaker trip device. To adjust
the settings of the MPSC-2000 trip device, see the
instructions in IB 6.1.2.8-1A.
A trip operation indicator, or target, is provided on the
face of the MPSC-2000 unit. When the MPSC-2000
determines that a trip is necessary, it will both signal
the magnetic latch and display the trip target with an
orange "day-glo" color. Since the target is a
mechanical device, it does not require power to retain
its indication. This indication is resistant to shock and
vibration, and will remain as long as the breaker is
open. The target is automatically reset by the
microprocessor within about two seconds after breaker
closure (as long as at least 6% of sensor current is
flowing through the circuit breaker phases). In
situations where a circuit breaker is closed into a circuit
where a trip condition still exists, the target will be reset
instantaneously, and then display again when the
breaker re-trips. New circuit breakers unpacked from
the factory may have the target displayed as a result of
the factory testing performed on the breaker prior to
shipping. This target will reset when the circuit breaker
is closed and sufficient primary current is flowing.
Continuous monitoring of the microprocessor function
is programmed into the MPSC-2000. "Watchdog"
circuits guard against the possibility of microprocessor
disfunction due to "endless loops”. A red light emitting
diode (LED) mounted on the face of the MPSC-2000
indicates the condition of the microprocessor. Normal
operation is shown by a blink rate of one flash per
second when a minimum of approximately 6% of the
sensor current rating is flowing through the primaries.
The LED may not blink, or may blink intermittently at
current levels below 6%. Servicing is required if the
LED remains lit but does not blink, or does not
illuminate at all when current levels are above 6%.
When a trip element “picks up", indication is provided
by a fast blink rate of the self monitor LED. When this
is observed, the MPSC trip unit is in the timing mode
and breaker tripping is imminent.
Selecting Trip Settings - The settings of current
threshold and delay bands must be determined by an
analysis of the protection and coordination
requirements of the power system. Settings are made
using the menus on the LCD screen as explained in IB
6.1.2.8-1A. Unlike previous electronic trip devices, the
MPSC-2000 settings are selected in amperes (e.g.,
2400A, 480A, etc.) instead of multipliers (e.g., 3X, .6X,
etc.), thereby eliminating intermediate calculations.
OPERATING SEQUENCE FOR ELECTRICALLY
OPERATED (EO) CIRCUIT BREAKERS
With the circuit breaker racked to the TEST or
CONNECTED position, the closing springs discharged,
and the control power source energized, the following
occurs when the motor disconnect switch is placed in
the ON position (Refer to the schematic in Figure 2):
1. The "b" contact (closed when the breaker is open)
and the CSCS contact (closed when the closing springs
are discharged), allow the spring charging motor to be
energized. When the closing springs reach the fully
charged condition, the CSCS opens to deenergize the
motor.
2. Operation of the remote close control switch or
optional electrical close push button energizes the
close coil through the Solid State Control Device
(SSCD) and the breaker auxiliary switch "b" contact.
The close coil releases the close latch, the springs
discharge, and the breaker contacts close.
3. When the springs discharge, the CSCS contacts
close.
4. When the circuit breaker contacts close, all auxiliary
switch “a" contacts close and all “b" contacts open.

IB 6.2.11.1-2C
Page 11 ABB
5. With the local or remote close signal still applied, the
anti-pump feature of the SSCD “locks out” the close
coil. In doing so, the circuit breaker mechanism will not
pump should it close into a faulted circuit.
6. The circuit breaker can be tripped electrically by
operation of remote trip control or by operating the
optional local electric trip push button. When tripped in
this manner, the trip coil is energized through the
SSCD and the auxiliary switch "a" contact, which
releases the stored energy in the contact and opening
springs, thereby opening the breaker.
7. Tripping the circuit breaker opens the “a" contacts
and closes the “b” contacts of the auxiliary switch. At
that point, the motor circuit is once again complete and
the motor will charge the closing springs.
CLOSING SPRING OPERATION
The two closing springs supply the power that closes
the circuit breaker and also charge the two opening
springs during the closing operation. The closing
springs are charged by a motor in the electrically
operated breaker and charged by hand in the manually
operated breaker; however, in either type the springs
are charged the same amount and, when charged, the
spring energy is available to close the breaker, thus
referred to as "stored energy". In electrically operated
models, the closing springs are normally charged when
the breaker is opened. If charged after closing, (by
using the manual handle) the breaker may be opened
and then reclosed without recharging the springs. The
closing springs are automatically discharged when the
breaker is moved from the disconnected to the
withdrawn position. This prevents accidental discharge
and closing.
INSTALLATION, INITIAL TESTING, AND
REMOVAL
For initial installation of breakers in the "CONNECTED"
position, the supply for the primary circuit should be de-
energized. Testing of the breaker must be done in the
test position.
Installation (See Figure 1)
The circuit breaker must be in the “OPEN” position, the
racking crank (8, Figure 1) when inserted in opening is
rotated counterclockwise until the racking cam roller
(19) is rotated down into a 45" angle, and the motor
disconnect switch (14) for electrically operated circuit
breakers is in the "OFF” position. NOTE: Lever (11)
must be pushed down to permit the rotation of crank
(8).
Open compartment door and lower the right and left
hand track extensions to their fully extended position.
Use lifting yoke (9, Figure 1 ), which is inserted in holes
in the upper rear frame, and lower the circuit breaker
wheels (7) onto the track extensions. Remove lifting
yoke. Push circuit breaker into compartment until
racking cam rollers (19) stop against their guides.
If breaker will not insert fully, check to insure that the
breaker rating matches that of the intended cubicle.
Interference blocking is provided to prevent installation
of a breaker into an incorrectly rated cell.
CAUTION CAUTION CAUTION CAUTION
RAISE TRACK EXTENSIONS INTO COMPARTMENT
PRIOR TO RACKING THE CIRCUIT BREAKER.
Insert racking crank (8, Figure 1) into opening and
depress drawout lever (11). Turn crank clockwise until
automatically stopped. Breaker is now in
"DISCONNECT" position. If the cubicle door is closed
the label on the right side of the escutcheon (5) will
show “DISCONNECT".
Again depress drawout lever (11) and turn crank
clockwise until automatically stopped. Breaker is now
in “TEST” position.
Checking Circuit Breaker Operation in “TEST”
Position (Manually Operated Models) (See Figure 1)
a. Manually reset automatic trip indicator (15) if it
protrudes approximately 1/2 ". Push in to reset.
b. Charge and close circuit breaker; See “Manual
Closing Operation" below.
c. Trip by manual "TRIP" button (10).
d. Check each auxiliary device for proper operation.
Checking Circuit Breaker Operation in
"CONNECTED" Position
After completing check procedures in “TEST” position,
WARNING WARNING WARNING WARNING
DO NOT REMOVE THE INTERFERENCE
BLOCKING IN AN EFFORT TO ALLOW CIRCUIT
BREAKER RACKING. RISK TO PERSONNEL AND
SERIOUS DAMAGE TO THE CIRCUIT BREAKER
AND CUBICLE CAN RESULT.

IB 6.2.11.1-2C
Page 12
ABB
continue as follows: With circuit breaker in "OPEN"
position and motor disconnect switch (14) in "OFF"
position, insert racking crank (8) in opening and press
down drawout lever (11). Rotate the racking crank
clockwise until lever (11) moves up and cranking is
automatically stopped. Breaker is now in
"CONNECTED" position. Excessive cranking force
indicates misalignment or interference of parts.
Manual Closing Operation
The following manual closing procedures are
recommended (See Figure 1 )
a. Observe circuit breaker conditions on control
escutcheon.
b. If closing springs are discharged, manually charge
closing springs by means of the manual charge lever
(16).
c. If springs are charged, pull the manual close lever
(12) by means of a lanyard from a safe distance.
d. For partially charged closing springs, should closing
not occur upon pulling the manual close lever, continue
charging until closing springs are completely charged
(heard to snap and by visual indicator (6)), then pull
manual close lever (12) by means of a lanyard from a
safe distance.
Circuit Breaker Removal (See Figure 1)
a. Trip circuit breaker by any tripping means.
b. Open front compartment door.
c. Engage racking crank (8) in opening and push
drawout lever (11) down. Rotate racking crank
counterclockwise until racking mechanism
automatically stops at “TEST" position. Lower track
extensions.
d. Repeat step "C" to rack circuit breaker to
"DISCONNECT" position.
e. Depress drawout lever (11) and continue cranking
counterclockwise as far as stops will allow. (Do not
force beyond stops.)
f. Pull circuit breaker torward to fully extended position.
(Should the circuit breaker be charged, closing springs
will automatically be discharged at this point.)
g. Remove circuit breaker from tracks with lifting yoke,
then raise tracks into compartment and close door.
MAINTENANCE AND ADJUSTMENTS
SAFETY NOTES
When it is necessary that the charging springs be
charged, or the circuit breaker be closed, make sure to
stay clear of operating parts.
Breakers shouId be withdrawn to "TEST" position for
checking the breaker operation. For further inspection,
adjustments, cleaning or replacement of parts, the
circuit breaker should be withdrawn from the cell and
moved to a suitable area.
Periodic Maintenance Inspection
The safety and successful functioning of the connected
apparatus depends upon the proper operation of the
circuit breaker. Therefore, it is recommended that a
maintenance program be established that will provide
for a periodic inspection of the circuit breaker after 250
no load or load current switching operations.
It is recommended that the circuit breaker be inspected
after the first 250 operations and on a yearly basis
unless enviromental considerations and operating
experience indicate that more frequent inspections are
appropriate. The circuit breaker should also be
inspected after a short circuit or severe overload
interruption, regardless of time period or number of
operations.
Where unusual service conditions, as covered by ANSI
C37.13, exist, it is assumed that these conditions were
considered at the time of order, and that special
maintenance procedures are in place accordingly.
These maintenance instructions only cover circuit
breakers used under the Standard’s normal service
conditions.
The inspection should include opening and closing the
circuit breaker electrically and manually. The unit
should be visually inspected for loose or damaged
parts. Arc chutes, contacts and insulation structure
should be inspected as described below.
WARNING WARNING WARNING WARNING
DE-ENERGIZE BOTH PRIMARY AND CONTROL
CIRCUITS BEFORE MAKING ANY INSPECTIONS,
ADJUSTMENTS, OR REPLACEMENTS OF PARTS.
MAKE CERTAIN BREAKER IS OPEN BY
OBSERVING INDICATOR (2, FIGURE 1), AND
CLOSING SPRINGS ARE NOT CHARGED BY
OBSERVING INDICATOR (6, FIGURE 1).

IB 6.2.11.1-2C
Page 13 ABB
Arc Chutes
a. Remove the two arc chute mounting screws and
retainer moldings. Lift arc chute (1, Figure 1) up and
draw out.
b. Inspect for breakage of the arc chute frame or
retainer molding. Check for presence of foreign
particles such as chips of metal. Discoloration and
carbon build-up are normal in an arc chute that has
seen service, but the arc plates should not be
significantly worn, as indicated by severe warping of the
cut-out pattern.
Insulation Structure
Insulated parts should be checked for damage. Dust
and dirt should be removed by air or wiped with a clean,
lintless cloth. Do not use any oil based solvents. Spray
solvents vary as to type and should not be used. The
moldings at the rear of the breaker must be kept clean
to avoid dielectric problems. Wipe dust away and blow
out with clean, dry, compressed air. Additional steps
must be taken if dust accumulation continues to be a
problem.
MPSC-2000 Trip Device Removal and Installation
1. Remove the two nylon screws which retain the trip
system harness plug to the MPSC-2000 device. Retain
for re-use. If the breaker has the Voltage Interface
Module (VIM) option, disconnect the four-pin plug from
the trip unit.
2. Remove the six screws holding the breaker top shelf
and remove the shelf with the MPSC-2000 unit
attached.
3. To reinstall, reverse the above procedure. Be sure to
secure the DB-25 plug in the MPSC-2000; energizing
the breaker with this plug removed or not secured
will result in serious damage to the device and
perhaps injury to nearby personnel. In addition, the
breaker will not be able to provide circuit protection.
(NOTE: Metallic screws must not be used to retain the
trip system harness. Should a metallic screw fall into
the trip system, serious damage can result.)
Electrical Components (EO Breakers Only)
1. Rack the circuit breaker to the “TEST” position.
Make sure the closing springs are charged.
2. Operate the local (if installed) or remote electrical
close push button as applicable to close the circuit
breaker. This will confirm operation of the close coil.
3. While maintaining the close signal, trip the circuit
breaker with the shunt trip. The Solid State Control
Device (SSCD) should prevent the reclosing of the
circuit breaker until the close signal is removed and
then re-applied. SSCD replacement may be required if
it does not perform as indicated.
4. During the previous test, electrical operation of the
shunt trip and the spring charging motor is confirmed.
Malfunction of either requires repair or replacement.
Contacts
a. Remove dirt or grease on contacts with a clean,
lintless cloth.
b. Discoloration of the main contacts does not
necessarily indicate damage. However, this condition
may be removed by opening and closing the circuit
breaker under no-load conditions.
Contact Pitting
A moderate amount of pitting will not interfere with the
operation of the arcing contacts. Should it be
necessary to dress the arcing contacts to remove small
burrs, cover the mechanism with a cloth. Follow the
contour of the contacts with light wipes of a fine file and
do not attempt to eliminate pitting entirely. When
finished, remove cloth and wipe off any remaining dirt or
filings.
Should the main contacts show more than moderate
pitting, check the contact pressure.
Contact Pressure Check and Adjustment (See

IB 6.2.11.1-2C
Page 14
ABB
Figure 3)
FOR SAFETY: Keep clear of breaker operating parts
during this operation.
a. Close the breaker. Lever (11, Figure 1) must be in
the up position.
b. For each set of eight contacts on one pole, the
smallest gap "A" should be 0.105-0.110 inch. If
adjustment is required, loosen lock screw (2, Figure 3).
Turn adjustment screw (1) until 0.105-0.110 inch is
obtained on the smallest gap of the eight contacts.
Repeat this for the other two poles. Tighten lock screw
(2).
Note that if an adjustment is necessary for
"simultaneous" make, the contact pressure will increase
on those adjusted poles. Thus, a dimension of more
than the ranges listed above indicates more contact
pressure, which is acceptable.
Manual Slow Close to Check Contact Pressure (See
Figures 1, 3 and 4)
a. Remove arc chutes (1, Figure 1).
b. If the circuit breaker closing springs are discharged
as seen by the spring charged indicator (6), engage the
manual charge handle (16) with the charging lever.
Pump charging handle until the circuit breaker closing
springs are heard to snap into the charged position
(also check the indicator (6)).
c. Remove screw, shift the shutter to the left and insert
the spring retainer bracket so that its tips fit into the
closing springs and its flanges fit into the holes in the
closing spring guides.
NOTE: Shutter cannot be opened unless breaker
drawout mechanism is in the "DISCONNECT"; "TEST"
or "CONNECTED" position. The drawout lever (11)
cannot be operated when shutter is open.
d. Use a stick to hold the spring retainer bracket toward
the front of the breaker and in place while pulling the
manual close lever (12) to discharge the closing
springs. (This will partially close contacts.)
e. Insert the manual charge handle (16) into the
charging lever socket and pump to slow close the circuit
breaker.
f. To remove the spring retainer bracket, push the
manual trip button (10) to trip the circuit breaker.
Continue pumping until closing springs are again heard
to snap. Then remove spring retainer bracket. The
circuit breaker is now charged and ready to be closed.
h. To discharge closing springs, pull the manual close
lever (12) and push manual trip button (10).

IB 6.2.11.1-2C
Page 15 ABB
i. Re-install arc chutes.
Operating Mechanism
The circuit breaker mechanism is adjusted at the factory
for correct operation and should not be disturbed unless
necessary.
FOR SAFETY: Keep hands clear of all moving parts.
Serious injuries can result if a person comes in contact
with breaker parts when the breaker is being opened or
closed, or closing springs are being charged or
discharged. Use extension tools for manipulating
breaker parts.
If field testing indicates breaker malfunction, the
following items may be checked. Values shown herein
are approximate and may have to be adjusted slightly to
account for manufacturing tolerances and wear during
use.
Primary Trip Latch. Figure 5 shows the arrangement
necessary for the breaker to be in the closed position.
The spring holds the secondary trip latch down against
screw (1). The secondary trip latch holds the
secondary latch roller up, which in turn holds the
opposite end of the primary trip latch down. This
prevents the primary latch roller from moving to the left
and opening the breaker. If none of the various trip
devices are acting on the tripper bar or the auxiliary
latch tripper to open the breaker or to prevent the
breaker from closing and the breaker still will not close,
then the following adjustment should be made.
a. Turn screw (1, Figure 5) down to insure that the
secondary trip latch will hold the secondary latch roller
up.
b. With the breaker closed, turn up on screw (1) until
the breaker trips.
c. Turn screw (1) down approximately two turns.
Tripper Bar Adjustment (Figure 6). To insure that the
tripper bar and tripper are in the correct position with
the secondary trip latch, check and adjust as follows:
a. Turn screw (1, Figure 6) down to make certain the
tripper will not trip out the breaker.
b. With breaker closed, turn screw (1) up until the
breaker trips.
c. Turn screw (1) down approximately 2¾ turns.
Primary Close Latch (See Figure 7). With the circuit
breaker closing springs charged, the breaker contacts
opened, and the closing plunger (3, Figure 7) in de-
energized position, there should be about a 1/16" air
gap between the rod (1) and the secondary latch (2) at
point "A". Turn rod (1) for approximate 1/16"
dimension.

IB 6.2.11.1-2C
Page 16
ABB
Shunt Trip Device (See Figure 8).
a. Turn trip rod (2, Figure 8) down until circuit breaker
does not trip with plunger (3) held down.
b. Close circuit breaker.
c. Push plunger (3) down as far as possible and hold in
this position while turning up trip rod (2) until circuit
breaker just trips.
d. Turn rod (2) up approximately 2½ to 3 turns.
FIELD TESTING THE MPSC-2000 SOLID
STATE TRIP SYSTEM
There are two ways to evaluate the MPSC-2000 solid
state trip system: primary current injection through the
breaker main contacts; and secondary current injection
directly into the trip device. Either method will test the
trip device; primary injection has the advantage of
testing the current sensors and magnetic latch also.
The following is a procedure for performing this field
testing.
Notes:
1. Refer to time current curves TD-9651, TD-9652, and
TD-9653.
2. When checking calibration, disable the functions not
being tested, or set them at their highest threshold and
delay values. It is especially important to disable
the Ground function when testing the other
elements to prevent false tripping.
5. Reference bulletin IB 6.1.2.8-1A for instructions on
setting the MPSC-2000.
6. These procedures are written for primary injection. If
the trip device is being tested by secondary current
injection, contact ABB for special instructions and/or
test equipment.
7. The term “Range Selection” is used herein for
consistency with previous MPS-type devices, and
refers to the value of the “Rating” setting of the device.
Like the previous MPS-type devices, the MPSC-2000 is
capable of operating at two basic ratings: one equal to
the maximum frame continuous current rating of the
breaker-mounted current sensors, and one equal to
half the frame rating. For example, on an 4000A
breaker with 4000A sensors, the MPSC-2000 rating
can be set to 4000A or 2000A. When the rating is
changed, other available settings are scaled
accordingly; thus the term “Range Selection”.
Instantaneous or Short Time Threshold Test
1. Either disable the trip elements not being tested, or
set them to their highest threshold value. Set the Long
Time Delay to its maximum setting. Set the Short Time
delay to its minimum setting for Short Time tests.
2. It is recommended that the Range Selection be set
to its lowest value to minimize the current required for
this test; however, it may be set to either available
value.
3. Set the threshold and delay of the trip element being
tested (again, it is recommended that a low value be
used).
4. Test for the actual threshold by increasing test
current until the breaker trips. It is important to
increase the current fast enough so that the breaker will
not be tripped by the Long Time element prior to
completion of the test.
5. The threshold tolerance is +/- 10% on all selector
Table 4 - MPSC-2000 Typical Delay Bands
Delay Times (sec.)
Trip Element Min. Int. Max
Long Time 8-13 20-33 61-100
Short Time (DEF) 0.080-0.170 0.200-0.320 0.350-0.500
Short Time (IIT) 0.160-0.250 0.520-0.780 0.910-1.350
Ground Trip (IIT) 0.05-0.17 0.20-0.32 0.35-0.50
3. The circuit breaker
must be closed before
each test below.
4. Following each test,
check the MPSC-2000
event register to ensure
that the correct element
tripped the breaker,
especially if test results
appear to be incorrect.
WARNING WARNING WARNING WARNING
RISK TO PERSONNEL AND FIRE CAN RESULT IF
THE CIRCUIT BREAKER IS ENERGIZED WITHOUT
THE HARNESS PLUG AND SCREWS IN PLACE.

IB 6.2.11.1-2C
Page 17 ABB
switch settings.
Long-Time Threshold Test
1. Either disable the trip elements not being tested or
set them to their highest threshold value.
2. It is recommended that the Range Selection be set
to its lowest value to minimize the current required for
this test; however, it may be set to either available
value.
3. Set the Long Time threshold. Set the delay to its
minimum value.
4. Test for the actual threshold by increasing test
current until the Self Monitor light begins to blink
quickly. The breaker should trip shortly thereafter, but
the test can be stopped at this point.
5. The threshold tolerance is +10%/-0% on all selector
switch settings.
Long-Time Delay Test
1. Position other trip element selectors at their highest
threshold value.
2. It is recommended that the Range Selection be set
to its lowest value to minimize the current required for
this test; however, it may be set to either available
value.
3. Set the Long Time threshold to its maximum setting.
4. Set test current so that it represents three times (3X)
the trip system Range Selection setting. Delays should
be as shown in Table 4.
Short-Time Delay Test
1. Position other trip element selectors at their highest
threshold value.
2. It is recommended that the Range Selection be set
to its lowest value to minimize the current required for
this test; however, it may be set to either available
value.
3. Set the ST Curve to DEF.
4. Set the ST Pickup to its lowest setting.
5. Set test current so that it represents four times (4X)
the ST Pickup setting. Delays should be as shown in
Table 4.
6. Set the ST Curve to IIT. (Note that the I2t function of
the MPSC-2000 Short Time element is operational only
from twice to four times the Range Selection, and that
the trip curve is fixed and does not vary with pickup
settings.)
7. Set test current so that it represents 1.5 times the ST
Pickup setting. Delays should be as shown in Table 4.
Ground Trip Delay Tests
Ground Trip Delay tests are performed by injecting
current through a single phase of the breaker, which
appears to be a ground fault to the trip device. On
breakers with 4-wire ground on double-ended
substations, a remote neutral sensor must be used to
perform this test.
1. Disable the other trip elements or set them at their
highest threshold value.
2. The Range Selector has no influence on ground
settings.
3. Set the GND PICKUP to the minimum available
ground setting, and set the GND CURVE to “IIT”.
4. Set test current so that it represents three times (3X)
the GND PICKUP setting. Delays should be as shown
in Table 4.
LUBRICATION
Only two lubricants are approved for use on the K-Line
Plus circuit breaker. Lubricated during final assembly,
the K-Line Plus circuit breaker should not require
additional lubrication during its service life when applied
in accordance with ANSI C37.13. If, however, the
breaker is applied in unusual situations defined by
ANSI C37.13, has lubrication contaminated with dirt
and debris, or has parts replaced, relubrication should
be performed as specified herein.
When mechanism cleaning and relubrication is
required, do not spray solvents down through the
mechanism to remove old lubricants, dust, and debris.
Do not use dichlorodifluoromethane on any part of the
circuit breaker. These solvents tend to wash debris into
the bearing areas of the breaker, while at the same
time removing any existing lubricant. Breaker
performance will be compromised when these cleaning
techniques are employed.
Proper relubrication requires disassembly, thorough
cleaning by wiping, then reassembly using a brush or

IB 6.2.11.1-2C
Page 18
ABB
other means for reapplying the lubricants listed.
1. Apply NO-OX-ID special grade A grease from
Dearborn Chemical Company to all mating surfaces of
moving current carrying joints. Do not apply NO-OX-ID
grease on any main or arcing contact surfaces.
Primary disconnects should be maintained by
reapplying NO-OX-ID during maintenance periods.
NO-OX-ID is available from ABB in one pint cans, part
number 713222A00.
2. Apply Anderol 757 synthetic grease manufactured by
HULS AMERICA, INC. to mechanism parts, bearings
and pins. Anderol 757 is also to be used on the
external reduction gearing of the spring charging motor.
DO NOT APPLY GREASE TO LATCH OR ROLLER
SURFACES. Anderol 757 is available from ABB in four
ounce tubes, part number 712994A00.
3. Anderol synthetic lubricant is also available as a
spray, Anderol 732. Anderol 732 is useful as a solvent
for removing old lubricant, dirt, and debris in the
mechanism. It can NOT be used as a substitute for
Anderol 757.
4. Use only the recommended lubricants. Use of other
than approved lubricants can cause breaker
misoperation at temperature extremes.
Please observe the following additional warnings:
a. DO NOT apply light machine oil, or thin spray
lubricants to lubricate any mechanism part.
b. DO NOT attempt to relubricate internal components
of the spring charging motor. It is sealed and should not
require repacking. Lubrication should only be applied
to the external reduction gearing per item 2 above.
c. DO NOT lubricate magnetic latch device or otherwise
clean or spray with any substance.
DIELECTRIC WITHSTAND TESTS ON POWER AND
CONTROL CIRCUITS
1. Dielectric withstand tests on circuit breakers may be
made to determine the ability of the insulation to
withstand overvoltages.
2. A 60-cps alternating sinusoidal voltage (rms) value
equal to the specific voltage shall be used. All voltages
used in the dielectric withstand test shall be measured
in accordance with ANSI Measurement of Voltage in
Dielectric Tests, C68.1.
3. Duration Of Test. The dielectric test voltage shall be
applied for a period of 60 seconds. The duration of the
test may be one second if a voltage 30% greater than
that specified is applied.
4. Condition Of Circuit Breaker To Be Tested.
Dielectric tests shall be made on a new, completely
assembled circuit breaker and not on individual parts.
When a circuit breaker is tested in the field or after
storage, the test voltage shall be 75% of the value
listed in ANSI C37.50, 3.5.2 (value shown below).
5. Temperature At Which Tests Are To Be Made.
Dielectric tests shall be made at any temperature
between 10 and 55 °C.
6. Magnitudes And Point Of Application Of Test
Voltage. The dielectric test shall be applied as follows:
a. With circuit sreaker in open position, apply 2200
volts (1000 volts plus twice 600 volts on new breakers;
0.75 x 2200 = 1650V on breakers that have been in
service):
i. Between live parts, including both line and load
terminals, and metal parts that are normally
grounded.
ii. Between !ive terminals and load terminals.
b. With circuit breaker in closed position, apply 2200
volts on new breaker and 1650 volts on breakers that
have been in service:
i. Between live parts and metal parts that are
normally grounded.
ii. Between terminals of different phases.
c. With circuit breaker in either open or closed position,
apply 1500 volts (1125 volts on breakers taken out of
service):
Note: Disconnect solid state trip unit, as a precaution.
i. Between control circuit and metal parts that are
normally grounded. If the circuit breaker control
circuit includes a motor, the motor MUST be
disconnected during the dielectric test on the
control circuit.

IB 6.2.11.1-2C
Page 19 ABB
d. Apply 1000 volts:
i. Between leads of new motors.
e. SPECIAL NOTES:
i. Apply 60% (instead of 75%) of the values given
in (a) through (d) above on breakers that have
interrupted a short circuit.
ii. Motors that have been in service may fail
dielectric due to a normal accumulation of debris
from the commutator. Cleaning the motor will
restore dielectric integrity.
iii. Do not perform dielectric testing on the solid
state trip system.
RENEWAL PARTS
ABB recommends only those renewal parts be stocked
that will be required to insure proper and timely
maintenance of the breaker.

IB 6.2.11.1-2C
Page 20
ABB
NOTES: