Cutler-Hammer Digitrip OPTIM 550 Installation instructions

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I.B. 29C891B
Effective 11/98 Supersedes I.B. 29C891A dated October 1996
Cutler-Hammer
Instructions for Operation and Maintenance
of Digitrip OPTIM Trip Units
PROTECTION AND COORDINATION
COMMUNICATIONS SYSTEMS
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DSII/DSLII Power Circuit Breakers
SPB Systems Pow-R Circuit Breakers
Series C K, L, N and R Molded Case Circuit Breakers

I.B. 29C891B Page iii
Effective 11/98
All possible contingencies which may arise during installation, operation or maintenance, and all details and
variations of this equipment do not purport to be covered by these instructions. If further information is
desired by purchaser regarding his particular installation, operation or maintenance of particular equipment,
contact a Cutler-Hammer representative.
WARRANTY AND LIABILITY INFORMATION
NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR
PURPOSE OF MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF
TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONS CON-
TAINED HEREIN. In no event will Cutler-Hammer be responsible to the purchaser or user in contract, in tort (includ-
ing negligence), strict liability or otherwise for any special, indirect, incidental or consequential damage or loss what-
soever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of
power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its cus-
tomers resulting from the use of the information and descriptions contained herein.

I.B. 29C891B
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Effective 11/98
TABLE OF CONTENTS
Page
SECTION 1: INTRODUCTION
1-1 Common Terms...................................................................................................................................................1
1-2 Preliminary Comments and Safety Precautions..................................................................................................1
1-2.1 Safety Precautions .................................................................................................................................1
1-3 Product Overview ................................................................................................................................................2
1-4 Features and Functions.......................................................................................................................................5
1-4.1 Common Features of Digitrip OPTIM 750 and 1050 Trip Units..............................................................5
1-4.2 Additional Features of Digitrip OPTIM 1050 Trip Units ..........................................................................7
SECTION 2: HARDWARE DESCRIPTION AND EQUIPMENT INTERFACES
2-1 General ...............................................................................................................................................................8
2-2 General Trip Unit Details .....................................................................................................................................8
2-2.1 Trip Unit Configuration ...........................................................................................................................8
2-3 Trip Unit Packages ..............................................................................................................................................8
2-4 Series C K, L-Frame and N-Frame OPTIM Trip Units.........................................................................................9
2-4.1 K, L-Frame and N-Frame OPTIM Trip Unit Displays..............................................................................9
2-5 Series C R-Frame, SPB and DSII/DSLII OPTIM Trip Units ..............................................................................11
2-5.1 R-Frame, SPB and DSII/DSLII OPTIM Trip Unit Displays ...................................................................12
2-6 OPTIM Trip Unit Rating Plug.............................................................................................................................14
2-7 External OPTIM Trip Unit Accessories..............................................................................................................15
2-8 Specification and Protective Range Summaries ...............................................................................................15
SECTION 3: OPERATION AND FUNCTIONALITY
3-1 General .............................................................................................................................................................20
3-2 Protection and Coordination..............................................................................................................................20
3-2.1 Over-Temperature Trip.........................................................................................................................20
3-2.2 Characteristic Curve Review ................................................................................................................20
3-2.3 Protection and Curve Shaping Features ..............................................................................................25
3-2.4 Long Delay Protection ..........................................................................................................................26
3-2.5 Short Delay Protection .........................................................................................................................28
3-2.6 Instantaneous Protection......................................................................................................................30
3-2.7 Ground Fault Protection .......................................................................................................................31
3-2.8 Time-Current Curves............................................................................................................................33
3-3 System Monitoring.............................................................................................................................................33
3-3.1 Displays and LED Indicators ................................................................................................................34
3-3.2 Normal Service/Automatic Trip Current Monitoring..............................................................................34
3-3.3 Remote Signal Contacts.......................................................................................................................34
3-3.4 Power and Energy Monitoring ..............................................................................................................35
3-3.5 Power Quality (Harmonics) Monitoring.................................................................................................35
3-3.6 Power Factor ........................................................................................................................................35
3-4 Communications................................................................................................................................................35
3-4.1 IMPACC ...............................................................................................................................................36
3-5 Testing...............................................................................................................................................................36
3-5.1 Secondary Injection Testing .................................................................................................................37
3-5.2 When to Test ........................................................................................................................................37
3-5.3 Conducting Tests .................................................................................................................................37
3-5.4 Performance Testing for Ground Fault Trip Units ................................................................................38

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Page
SECTION 4: STARTUP AND TESTING
4-1 Introduction........................................................................................................................................................40
4-2 Wiring ................................................................................................................................................................40
4-2.1 Wiring Diagrams...................................................................................................................................40
4-2.2 Wiring Plan Drawing.............................................................................................................................40
4-2.3 Network Wiring Diagram ......................................................................................................................40
4-3 Initial Startup .....................................................................................................................................................40
4-3.1 Before Power Application .....................................................................................................................40
4-3.2 Initial Power Application .......................................................................................................................41
4-4 Testing...............................................................................................................................................................41
SECTION 5: TROUBLESHOOTING AND MAINTENANCE
5-1 Level of Repair ..................................................................................................................................................43
5-2 Troubleshooting.................................................................................................................................................43
5-3 Trip Unit Replacement.......................................................................................................................................43
5-4 Maintenance and Care ......................................................................................................................................43
5-4.1 Local Indicator Battery Check and Replacement .................................................................................53
5-4.2 Rating Plug Replacement.....................................................................................................................54
5-5 Return Procedure ..............................................................................................................................................55
5-6 Technical Assistance.........................................................................................................................................55
Appendix A Instructional References ............................................................................................................56
Appendix B Checking Zone Selective Interlocking ....................................................................................58

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LIST OF FIGURES
Figure Title Page
1-1 Series C L-Frame Molded Case Circuit Breaker with OPTIM Trip Unit .....................................................2
1-2 SPB Systems Pow-R Circuit Breaker with OPTIM Trip Unit......................................................................2
1-3 DSII Power Circuit Breaker with OPTIM Trip Unit .....................................................................................2
1-4 Family of Digitrip OPTIM Trip Unit Rating Plugs........................................................................................3
1-5 Family of Digitrip Trip Units Comparison ...................................................................................................3
1-6 Hand Held Programmer in Use..................................................................................................................4
1-7 Breaker Interface Module in Service..........................................................................................................4
1-8 Monitor and Control from Central PC ........................................................................................................5
1-9 Typical System Configurations ..................................................................................................................6
2-1 Typical OPTIM Trip Unit Circuitry (DSII Type Circuit Breaker Shown) ......................................................8
2-2 OPTIM Trip Unit Mounted in Series C L-Frame Circuit Breaker (K-Frame is Similar)...............................9
2-3 OPTIM Trip Unit Mounted in Series C N-Frame Circuit Breaker ...............................................................9
2-4 Front View of L-Frame Type OPTIM Trip Unit (K and N-Frame Designs are Similar).............................10
2-5 K, L and N-Frame Type OPTIM Trip Unit Battery Compartment.............................................................10
2-6 K, L and N-Frame Type OPTIM Trip Unit Programming Port..................................................................11
2-7 OPTIM Trip Unit Mounted in Series C R-Frame Circuit Breaker .............................................................11
2-8 OPTIM Trip Unit Mounted in SPB Circuit Breaker...................................................................................12
2-9 OPTIM Trip Unit Mounted in DSII Circuit Breaker ...................................................................................12
2-10 Front View of R-Frame, SPB and DSII/DSLII Type OPTIM Model 1050 Trip Unit
with R-Frame Rating Plug Installed .........................................................................................................13
2-11 R-Frame, SPB and DSII/DSLII Type OPTIM Trip Unit Battery Compartment .........................................13
2-12 OPTIMizer Shown Connected to Programming Port of DSII Type Circuit Breaker .................................14
2-13 Family of OPTIM Trip Unit Ratings Plugs................................................................................................14
2-14 Power Accessory Requirements for K, L and N-Frame Circuit Breakers ................................................15
2-15 Externally Mounted Potential Transformer Module (necessary for K, L and N-Frame only) ...................16
2-16 Ground Fault Alarm Indicator (necessary for K, L and N-Frame only) ....................................................16
3-1 Sample of Partial Time-Current Trip Curve .............................................................................................21
3-2 Typical Trip Curve Horizontal Movement.................................................................................................21
3-3 Typical Long Delay Time Slope Adjustment............................................................................................21
3-4 Overcurrent Protective Function Combinations.......................................................................................25
3-5 Typical OPTIM Trip Unit Time-Current Curve (10 Curve Shaping Adjustments).....................................26
3-6 Typical Long Delay Setting Adjustment...................................................................................................27
3-7 Typical Long Delay Time Adjustment (I2t) Response ..............................................................................27
3-8 Typical Long Delay Time Adjustment (I4t) Response ..............................................................................28
3-9 Typical Short Delay Pickup Adjustment...................................................................................................28
3-10 Typical Short Delay Time Adjustment, Flat Response ............................................................................29
3-11 Typical Short Delay Time Adjustment, (I2t) Response.............................................................................29
3-12 Multi-layer Ground Fault Protection Scheme Using Zone Selective Interlocking ....................................30
3-13 Typical Instantaneous Pickup Adjustment...............................................................................................31
3-14 Ground Fault Alarm LED .........................................................................................................................32
3-15 Typical Ground Fault Pickup Adjustment.................................................................................................33
3-16 Typical Ground Fault Time Delay Adjustment, Flat Response................................................................33
3-17 Typical Ground Fault Time Delay Adjustment, (I2t) Response ................................................................33
3-18 Typical Waveform and Harmonic Display................................................................................................36
3-19 Auxiliary Power Module ...........................................................................................................................38
3-20 Typical Performance Test Record Form..................................................................................................39

I.B. 29C891B Page vii
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Figure Title Page
4-1 Typical Network Wiring Diagram .............................................................................................................42
5-1 Battery Test Pushbutton and LED Shown on Face of OPTIM Trip Unit ..................................................53
5-2 Battery Test Pushbutton and LED Shown on OPTIM Rating Plug ..........................................................53
5-3 Battery Shown Installed in Battery/Programming Port Compartment......................................................54
5-4 Battery Shown Installed Behind Rating Plug Hinged Cover ....................................................................54
5-5 Rating Plug Shown Removed (L and N-Frame Type OPTIM Trip Units) ................................................55
5-6 Rating Plug Shown Being Removed (R-Frame, SPB and
DSII/DSLII Type OPTIM Trip Units).........................................................................................................55
LIST OF TABLES
Figure Title Page
2.1 Rating Plugs Applicable to All OPTIM Trip Units.....................................................................................17
2.2 OPTIM Trip Unit/Accessory Specifications..............................................................................................18
2.3 OPTIM Trip Unit Metering Tolerances.....................................................................................................19
3.1 Digitrip OPTIM 750 and 1050 Trip Unit Capabilities................................................................................20
3.2 Digitrip OPTIM 550 Trip Unit System Capabilities Overview...................................................................22
3.3 Digitrip OPTIM 750 Trip Unit System Capabilities Overview...................................................................23
3.4 Digitrip OPTIM 1050 Trip Unit System Capabilities Overview.................................................................24
5.1 Troubleshooting Guide ............................................................................................................................43
A.1 Instructional References..........................................................................................................................56

I.B. 29C891B Page 1
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SECTION 1: INTRODUCTION
1-1 COMMON TERMS
Several commonly used terms or phrases are used
throughout this manual. They are defined here to elimi-
nate any confusion that might arise when reading the
text.
IMPACC (Integrated Monitoring, Protection and
Control Communications) – A family of communicat-
ing electrical power distribution protective devices,
meters, motor control devices, communications net-
works and protocols and software packages to provide
power distribution monitoring and control.
INCOM (Industrial Communications) – A noise
immune communications system designed specifically
for power distribution monitoring and control applications.
PONI (Product Operated Network Interface) – A
plug-in communications module that enables network
communications.
1-2 PRELIMINARY COMMENTS AND SAFETY
PRECAUTIONS
This instructional manual is intended to present specific
descriptive, operational and maintenance information
associated with Digitrip OPTIM Trip Units only. Digitrip
OPTIM Trip Units are designed to be used with the
Breaker Interface Module and OPTIMizer Hand Held
Programmer. For a general overview of the entire
Digitrip OPTIM Trip Unit System and certain specific
application possibilities, refer to Instruction Book
29C890 entitled “Instructional Overview for Use of the
Digitrip OPTIM Trip Unit System.”
Detailed instructional material relative to the installation,
use and maintenance of specific devices is included
under separate cover by a manual dedicated to each
device. A series of four manuals brings together the
wide array of capabilities offered by the most advanced
programmable trip unit system - Digitrip OPTIM. Refer
to Appendix A for all instruction material references.
Please read and understand this manual and all other
relevant manuals before proceeding with the installation
and operation of any device included in the trip unit sys-
tem. Pay particular attention to all WARNINGS and
CAUTIONS. They are intended to help insure personnel
safety and equipment protection. Refer to the WARN-
ING and CAUTION in Paragraph 1-2.1 before proceed-
ing to any other section in this manual or any other man-
ual. If further information is required by the purchaser
regarding a particular installation, application or mainte-
nance activity, a Cutler-Hammer representative should
be contacted.
1-2.1 SAFETY PRECAUTIONS
All safety codes, safety standards and/or regulations
must be strictly observed in the installation, operation
and maintenance of any device in this system.
THE WARNINGS AND CAUTIONS INCLUDED AS
PART OF THE PROCEDURAL STEPS IN THIS DOCU-
MENT ARE FOR PERSONNEL SAFETY AND PRO-
TECTION OF EQUIPMENT FROM DAMAGE. AN
EXAMPLE OF A TYPICAL WARNING LABEL HEAD-
ING IS SHOWN ABOVE IN REVERSE TYPE TO
FAMILIARIZE PERSONNEL WITH THE STYLE OF
PRESENTATION. THIS WILL HELP TO INSURE
THAT PERSONNEL ARE ALERT TO WARNINGS,
WHICH MAY APPEAR THROUGHOUT THE DOCU-
MENT. IN ADDITION, CAUTIONS ARE ALL UPPER
CASE AND BOLDFACE AS SHOWN BELOW.
COMPLETELY READ AND UNDERSTAND THE
MATERIAL PRESENTED IN THIS DOCUMENT
BEFORE ATTEMPTING INSTALLATION, OPERATION
OR APPLICATION OF THE EQUIPMENT. IN ADDI-
TION, ONLY QUALIFIED PERSONS SHOULD BE
PERMITTED TO PERFORM ANY WORK ASSOCIAT-
ED WITH THE EQUIPMENT. ANY WIRING INSTRUC-
TIONS PRESENTED IN THIS DOCUMENT MUST BE
FOLLOWED PRECISELY. FAILURE TO DO SO
COULD CAUSE PERMANENT EQUIPMENT DAMAGE.
WARNING
CAUTION

I.B. 29C891B
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Effective 11/98
Figure 1-1 Series C L-Frame Molded Case Circuit
Breaker with OPTIM Trip Unit
Figure 1-2 SPB Systems Pow-R Circuit Breaker with
OPTIM Trip Unit
Figure 1-3 DSII Power Circuit Breaker with OPTIM Trip
Unit
1-3 PRODUCT OVERVIEW
The Digitrip OPTIM Trip Unit is a programmable, com-
municating, microprocessor-based, low voltage trip unit.
Digitrip OPTIM Trip Units are for use with Series C K-
Frame, L-Frame, N-Frame and R-Frame Molded Case
Circuit Breakers, SPB Systems Pow-R Circuit Breakers,
and DSII/DSLII Power Circuit Breakers (Figures 1-1, 1-2
and 1-3). These circuit breakers using Digitrip OPTIM
Trip Units cover a range of rated currents from 70
amperes to 5000 amperes. The Digitrip OPTIM Trip Unit
provides true rms sensing and utilizes a non-adjustable
interchangeable rating plug to establish the continuous
current rating of the circuit breaker (Figure 1-4). Rating
plugs are interlocked to prevent use between different
circuit breaker frames.
The Digitrip OPTIM Trip Unit is an addition to the already
expansive family of Digitrip Trip Units (Figure 1-5). Three
different models are available, OPTIM 550, OPTIM 750
and OPTIM 1050. The OPTIM 1050 Trip Unit has all the
features of the OPTIM 550 and 750 Trip Units plus sev-
eral additional features. The OPTIM 1050 Trip Unit’s
additional features are:
• Monitoring power and energy
• Monitoring current harmonics
Trip Unit
Trip Unit
Trip Unit

I.B. 29C891B Page 3
Effective 11/98
Figure 1-4 Family of Digitrip OPTIM Trip Unit Rating
Plugs
Figure 1-5 Family of Digitrip Trip Units Comparison
Refer to paragraph 1-4 for feature and function details.
A Digitrip OPTIM Trip Unit System can be tailored to
meet very precise system requirements. The featured
parts of an OPTIM Trip Unit System are:
• OPTIM 550, 750 or OPTIM 1050 Trip Unit
• OPTIMizer Hand Held Programmer
• Breaker Interface Module
• Communications System and Software (IMPACC)
A Digitrip OPTIM Trip Unit System always includes any
number of OPTIM 550, 750 or OPTIM 1050 Trip Units
with one or more OPTIMizer Hand Held Programmers.
The OPTIMizer Hand Held Programmer is required with
the trip units to initially:
• Assign unique device addresses
• Select baud rates
In addition, OPTIM Trip Units are compatible with the
optional panel mounted Breaker Interface Module and
IMPACC software. When used, the Breaker Interface
Module and IMPACC software also become integral
parts of the overall Digitrip OPTIM Trip Unit System.
Together, the OPTIM Trip Units, the required OPTIMizer
Hand Held Programmer, the optional Breaker Interface
K, L, N & R R, SPB & DSII K thru DSII R thru DSII K thru DSII R thru DSII R thru DSII K thru DSII
RMS 310 RMS 510 OPTIM 550 ➀RMS 610 OPTIM 750 RMS 810 RMS 910 OPTIM 1050
RMS Sensing RMS Sensing RMS Sensing RMS Sensing RMS Sensing RMS Sensing RMS Sensing RMS Sensing
5 Functions 9 Functions 10 Functions 9 Functions 10 Functions 9 Functions 9 Functions 10 Functions
Front Front Programmable Front Programmable Front Front Programmable
Adjustable Adjustable Adjustable Adjustable Adjustable
Load Load Load Load Load
Monitoring Monitoring Monitoring Monitoring Monitoring
Diagnostics Diagnostics Diagnostics Diagnostics Diagnostics
Communications Communications Communications Communications
Power & Energy Power & Energy Power & Energy
➀Field Installed Monitoring Monitoring Monitoring
communications
available Harmonics Harmonics
Applicable Circuit Breaker Types and Trip Unit Type

I.B. 29C891B
Page 4
Effective 11/98
Module, and the optional IMPACC software form a sys-
tem that is capable of:
• Setting trip units
• Configuring systems
• Monitoring/protecting
• Displaying information
• Diagnosing input
• Testing trip units/circuit breakers
• Communicating on sub-networks/networks
Application of low voltage circuit breakers utilizing
OPTIM Trip Units generally fall into three primary cate-
gories:
Stand Alone Application (Individual Circuit
Breakers)
These applications are utilized to take advantage of the
superior protection and coordination features of Digitrip
OPTIM, and plan to perform monitoring at the circuit
breaker itself (Figure 1-6).
The following would be used:
• OPTIM 550, 750 and/or 1050 Trip Units
• One or more OPTIMizer Hand Held Programmers
Integrated Assembly Applications (Low Voltage
Assemblies)
These applications are utilized to provide on-gear or
remote monitoring and even testing of compatible
devices (Figure 1-7). Up to 50 OPTIM Trip Units, Digitrip
RMS 810/910 Trip Units or IQ Energy Sentinels can
communicate with one Breaker Interface Module.
The following would be used:
• OPTIM 550 (if field IMPACC kit installed)
• OPTIM 750 and/or 1050 Trip Units
• Digitrip RMS 810 and/or 910 Trip Units
• IQ Energy Sentinels
• One or more OPTIMizer Hand Held Programmers
• One or more assembly/remotely mounted Breaker
Interface Modules
Facility Wide Application (IMPACC System)
These applications are utilized to tie together more than
50 circuit breakers and/or other compatible devices. In
addition, this permits taking advantage of PC-based
software to improve diagnostics, power quality and
energy monitoring, or protective device coordination
capabilities. The system would consist of any number of
devices and software products, either within a facility or
across multiple facilities (Figure 1-8).
Figure 1-6 Hand Held Programmer in Use Figure 1-7 Breaker Interface Module in Service

I.B. 29C891B Page 5
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The following would be used:
• OPTIM 550 (if field IMPACC kit installed)
• OPTIM 750 and/or 1050 Trip Units
• Digitrip RMS 810 and/or 910 Trip Units
• Other IMPACC Compatible devices
• One or more OPTIMizer Hand Held Programmers
• One or more assembly/remotely mounted Breaker
Interface Modules
• IMPACC software/central PC
Refer to Figure 1-9 for typical system configurations uti-
lizing the OPTIM Trip Unit System and other compatible
devices. For additional IMPACC details, refer to Section
3 of Instruction Book 29C890.
1-4 FEATURES AND FUNCTIONS
Digitrip OPTIM 550, 750 and 1050 Trip Units provide a
wide range of common protection and coordination fea-
tures and functions. The Digitrip OPTIM 1050 Trip Unit
also provides power quality and energy monitoring capa-
bilities.
1-4.1 COMMON FEATURES OF DIGITRIP OPTIM
550, 750 AND 1050 TRIP UNITS
Precise system coordination is provided by an expan-
sive number of time-current curve shaping adjustments.
This is accomplished by the large number of incremen-
tal setpoints available for both current pickup and time
settings.
Programmable Protection and Coordination
Adjustments
• Long delay setting
• Long delay time with selectable I2t or I4t slopes
• Short delay setting
• Short delay time with selectable flat or I2t slopes
• Instantaneous setting
• Ground fault setting
• Ground fault time with selectable flat or I2t slopes
The trip units also have a selectable powered and
unpowered thermal memory to provide protection
against cumulative overheating should a number of
overload conditions occur in quick succession.
The trip unit information system utilizes LEDs to indicate
the trip mode following an automatic trip operation. The
LEDs are complemented by trip event information that is
stored in non-volatile memory after a trip condition. This
trip information can then be accessed via the Optimizer
Hand Held Programmer, the Breaker Interface Module,
or over the IMPACC System.
Selectable early warning alarms, such as the high load
current alarm, are capable of being indicated locally and
remotely. They are provided to help keep a system
operating and productive.
System Monitoring
All OPTIM Trip Units are capable of monitoring the fol-
lowing data:
• Steady-State value of phase and neutral or ground
currents ➀
• Minimum and maximum current values
• Average demand current
• Cause of trip
• Magnitude of fault current responsible for an automat-
ic trip operation
➀LSI version of OPTIM 550 only monitors phase
currents
Figure 1-8 Monitor and Control from Central PC

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Effective 11/98
Figure 1-9 Typical System Configurations
Master
Computer
Breaker
Interface
Module
Shielded
Twisted
Pair
SPB
Circuit
Breaker
with
OPTIM
DSII
Circuit
Breaker
with
OPTIM
Series C
R-Frame
MCCB
with
OPTIM
To Other IMPACC
Compatible Devices
PONI
OPTIMizer
Series C
N-Frame
MCCB
with
OPTIM
Series C
L-Frame
MCCB
with
OPTIM
Circuit
Breaker
with
RMS 810
or 910
Series C
F-Frame
MCCB
ES
IQ Energy Sentinel
Shielded
Twisted
Pair
PONI Module
(Required for IMPACC
Network Communications
to Master Computer)
Shielded
Twisted
Pair
➁ ➂
➃
OPTIMizer ➀
➀OPTIMizer ➀
OPTIMizer ➀
OPTIMizer ➀
Series C
K-Frame
MCCB
with
OPTIM
OPTIMizer ➀
NOTES
➀OPTIMizer Hand Held
Programmer compatible only
with OPTIM Trip Units
➁Can monitor up to 50 com-
patible devices.
➂Circuit breakers with OPTIM
Trip Units can be directly
connected to a master com-
puter, and do not have to be
connected through the BIM.
➃Universal IQ Energy Sentinel
also compatible with Breaker
Interface Module.
CONFIGURATIONS 1 + 2
Network Configuration —
Breaker Interface Module with
Master Computer as Master
Device
CONFIGURATION 1
Sub-Network Configuration —
Breaker Interface Module
Functioning as Master Device
CONFIGURATION 2
Master Computer and IMPACC
Software

I.B. 29C891B Page 7
Effective 11/98
Communications
Trip units that are capable of two way communication
operate via a network twisted pair for remote monitoring
and control. The circuit breaker, through the trip unit, is
able to respond to open and close commands via the
communication network. To close the breaker, a motor
operator accessory is required. Refer to Table A.1 in
Appendix A for motor operator instructional references.
Testing
An integral testing capability is part of all OPTIM Trip
Systems. The breaker can be tested in either the “Trip”
or “No Trip” Test Mode. System level testing is carried
out by using a Hand Held Programmer, a Breaker
Interface Module, or a remote computer. Bench level
testing requires the Hand Held Programmer only. Trip
tests with the Hand Held Programmer require an auxil-
iary power module to supply the necessary power. Trip
units continue to provide protection during test opera-
tions.
Data Access
All programming, information display and general trip
unit access is accomplished through the use of one or
more of the following:
• Hand Held Programmer
• Breaker Interface Module ➀
• Remote computer ➀
1-4.2 ADDITIONAL FEATURES OF DIGITRIP OPTIM
1050 TRIP UNITS
The Digitrip OPTIM 1050 Trip Unit provides all the basic
system protection features outlined in Paragraph 1-4.1.
In addition, Digitrip OPTIM 1050 Trip Units can provide
data on power quality (current harmonics) and permit
energy monitoring.
Energy Monitoring
• Peak demand (kW)
• Present demand (kW)
• Forward energy (kWh)
• Reverse energy (kWh)
• Total energy (kWh)
• Power factor
Power Quality
• Percentage harmonic content
• Total harmonic distortion (THD)
• Digitized waveforms (Remote computer only)
➀OPTIM 550 trip units must have field IMPACC kit
installed for use with BIM or remote computer

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SECTION 2: HARDWARE DESCRIPTION
AND EQUIPMENT INTERFACES
2-1 GENERAL
The purpose of this section is to familiarize the reader
with Digitrip OPTIM Trip Units, their nomenclature, the
way trip units are interfaced with specific equipment,
and trip unit specifications. The information presented is
divided into the following four parts:
• General Trip Unit Details
• Trip Units By Type
• Trip Unit Accessories
• Specification Summary
2-2 GENERAL TRIP UNIT DETAILS
This section describes general trip unit functioning, trip
unit hardware, circuit breaker specific details, and
required interfaces with other external equipment.
2-2.1 TRIP UNIT CONFIGURATION
A complete OPTIM Trip Unit System consists of current
sensors, electronic circuitry and a flux transfer shunt trip
device contained inside the circuit breaker (Figure 2-1).
The trip units are completely self-contained and, when the
circuit breaker is closed, no external power is required to
operate their protective systems. They operate from cur-
rent signal levels and control power is derived from the
current sensors integrally mounted in the circuit breakers.
Circuit protection is achieved by analyzing the sec-
ondary current signals received from the circuit breaker
current sensors. As signals are received and analyzed,
a trip signal to the flux transfer shunt trip is initiated
when programmed current levels and time delay set-
tings are exceeded.
2-3 TRIP UNIT PACKAGES
The features associated with the three different OPTIM
Trip Unit models (550, 750 and 1050) are outlined in
Figure 1-5.
Figure 2-1 Typical OPTIM Trip Unit Circuitry (DSII Type Circuit Breaker Shown)
A
B
C
N
G
ABC
N
01 02 03
A
N
Terminal
Block
Rating
Plug
Trip Unit
Trip
Actuator
Typical Trip Unit
Typical DSII Type
Circuit Breaker
Sensors
** Alternate ground locations
may be required to meet
installation requirements
Typical
Current
Sensor
**

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Models 750 and 1050 on K, L and N-Frame circuit
breakers are factory sealed. Model 550 equipped circuit
breakers and all R-Frame SPB and DSII circuit breakers
can be upgraded in the field.
2-4 SERIES C K, L-FRAME AND N-FRAME OPTIM
TRIP UNITS
The continuous frame rating of each circuit breaker is
selectable via rating plugs over the following range:
•K-Frame (70-400 amperes)
•L-Frame (200-600 amperes)
•N-Frame (400-1200 amperes)
The OPTIM Trip Unit applicable to the Series C K and L-
Frame molded case circuit breakers extends approxi-
mately 0.5 inches beyond the front of the breaker cover
(Figure 2-2). The OPTIM Trip Unit used with the L-
Frame is not applicable to any other circuit breaker.
The OPTIM Trip Unit applicable to Series C N-Frame
molded case circuit breaker is nearly flush mounted to
the front of the breaker cover (Figure 2-3). The OPTIM
Trip Unit used with the N-Frame is not applicable to any
other circuit breaker.
The side wiring brackets shown in Figures 2-2 and 2-3
are only necessary for Models 750 and 1050 on K, L
and N-Frame circuit breakers. Model 550 does not
need the bracket on the same frames.
2-4.1 K, L AND N-FRAME OPTIM TRIP UNIT
DISPLAYS
Readings are displayed and protective settings estab-
lished or adjusted through the use of one or more of the
following means:
•OPTIMizer Hand Held Programmer
•Breaker Interface Module
•Remote Computer/IMPACC software
OPTIM Trip Units provide the following features (Figure
2-4):
Push-To-Trip Button
A Push-To-Trip button provides a local manual means
for checking the circuit breaker’s mechanical tripping
function and periodically exercising the operating mech-
anism. It is located on the front of the trip unit.
Mode of Trip/Alarm Indicators
Four LED type indicators (long delay, short delay,
instantaneous and ground fault trip or ground fault
alarm) are provided to indicate the mode of trip after an
automatic trip. The appropriate LED is lit red when acti-
vated.
Figure 2-2 OPTIM Trip Unit Mounted in Series C
L-Frame Circuit Breaker (K-Frame is Similar)
Figure 2-3 OPTIM Trip Unit Mounted in Series C
N-Frame Circuit Breaker

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Page 10
Effective 11/98
Notice: Trip unit should be powered from an external
control power source. If control power is not
available the LEDs will temporatily operate off
the battery. Refer to the wiring diagrams list-
ed in Appendix A, Table A.1 for control power
connections.
Battery for Trip Indicators
A replaceable 3 volt lithium battery is located behind a
small access cover on the left side of the trip unit
(Figure 2-5). A test pushbutton and LED test indicator
are also provided. The test pushbutton will energize the
LED indicator if the battery is in good working condition.
Refer to paragraph 5-4.1 for battery replacement infor-
mation.
Trip Indicator Reset Pushbutton
A trip reset pushbutton is provided to turn off a mode of
trip LED indicator after an automatic trip. The reset
pushbutton is located next to the four mode of trip led
indicators.
Figure 2-4 Front View of L-Frame Type OPTIM Trip Unit (K and N-Frame Designs are Similar)
Figure 2-5 K, L and N-Frame Type OPTIM Trip Unit
Battery Compartment
➅
➀Push-to-Trip Button
➁Mode of Trip/Alarm LEDs
➂Battery Test Pushbutton/LED
➃Automatic Trip Indicator Reset
Pushbutton
➄Unit Status LED
➅INCOM Transmit LED (Model 550 requires field IMPACC kit)
➆Battery Compartment/Pro-gramming Port Access Cover
➇Rating Plug
➄
➆
➀
➃
➇ ➂ ➁

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covering the OPTIMizer Hand Held
Programmer for the recommended connection
and power application sequence.
2-5 SERIES C R-FRAME, SPB AND DSII/DSLII
OPTIM TRIP UNITS
Model 750 and 1050 OPTIM Trip Units used in Series C
R-Frame, SPB Systems Pow-R and DSII/DSLII circuit
breakers are field replaceable. Model 550 is only avail-
able on the R-Frame circuit breaker. For each of these
circuit breaker types, rating plugs are used to select the
continuous ampere rating of the circuit breaker. The rat-
ing plugs and circuit breakers are keyed with a mechani-
cal interlock to prevent incorrect installation. The contin-
uous ampere rating of each of these circuit breakers is
adjustable via the rating plugs as follows:
•Series C R-Frame (800-2500 amperes) (Figure 2-7)
•SPB Pow-R (200-5000 amperes) (Figure 2-8)
•DSII/DSLII (100-5000 amperes) (Figure 2-9)
Refer to Table 2.1 for the available rating plug values by
circuit breaker type.
Unit Status LED
The green Unit Status LED blinks with a one second on-
off duty cycle when power is applied to the trip unit and
it is functioning properly.
INCOM Transmit LED
The red transmit LED flashes red when the trip unit is
communicating over an INCOM network.
Programming Port
A custom phone type jack programming port is located
with the trip indicator battery behind the small access
cover. One end of the custom phone type cord provided
with the OPTIMizer Hand Held Programmer plugs into
the port, and permits direct programming of the trip unit
(Figure 2-6). To access the programming port, remove
the access cover by pulling down on the release tab
located in the center of the cover while pulling out on the
cover. The port will accept either end of the custom
phone cord.
Notice: When the OPTIMizer is plugged into a trip
unit, it prevents all remote IMPACC communi-
cations (if present) with that trip unit. This
action will also cause a No-Response alarm
on the Breaker Interface Module and a master
network. Refer to Instruction Book 29C892
Figure 2-6 K, L and N-Frame Type OPTIM Trip Unit
Programming Port
Figure 2-7 OPTIM Trip Unit Mounted in Series C
R-Frame Circuit Breaker
Push-To-Trip Button

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2-5.1 R-FRAME, SPB AND DSII/DSLII OPTIM TRIP
UNIT DISPLAYS
Readings are not displayed and protective settings are
not established or adjusted from the front of Digitrip
OPTIM Trip Units. These functions are carried out
through the use of one or more of the following means:
•OPTIMizer Hand Held Programmer
•Breaker Interface Module
•Remote Computer/IMPACC software
The R-Frame, SPB and DSII/DSLII OPTIM Trip Unit dis-
plays all provide the following features (Figure 2-10):
Push-To-Trip Button
A Push-To-Trip (Push-To-Open on SPB) button pro-
vides a local manual means for checking the circuit
breaker’s mechanical tripping function and periodically
exercising the operating mechanism. This pushbutton is
accessible from the front of the R-Frame, SPB and
DSII/DSLII circuit breakers.
Mode of Trip/Alarm Indicators
Four LED type indicators (long delay, short delay,
instantaneous and ground fault trip or ground fault
alarm) are provided to indicate the mode of trip after an
automatic trip. The appropriate LED is lit red when acti-
Figure 2-8 OPTIM Trip Unit Mounted in SPB Circuit
Breaker
vated. The LEDs are presented in the form of a mimic
time-current curve on the front of the OPTIM Trip Unit.
Notice: Trip unit indicators should be powered from a
control power source wired externally to the
circuit breaker or alternatively via battery locat-
ed in the trip unit. For connection to an exter-
nal control power source, refer to the wiring
diagrams listed in Appendix A, Table A.1.
Battery for Trip Indicators
A replaceable 3 volt lithium battery is located behind the
hinged cover of the rating plug (Figure 2-11). A test
pushbutton and LED test indicator are also provided.
The test pushbutton will energize the LED indicator if
the battery is in good working condition. Refer to para-
graph 5-4.1 for battery replacement information.
Trip Indicator Reset Pushbutton
A trip reset pushbutton is provided to turn off a mode of
trip LED indicator after an automatic trip. The reset push-
button is located directly under the programming port.
Notice: For SPB and DSII/DSLII circuit breakers, this
pushbutton also functions as a trip lockout
reset. It must be pressed after an automatic
trip to reset the trip unit.
Figure 2-9 OPTIM Trip Unit Mounted in DSII Circuit
Breaker
Push-To-Trip Button
Push-To-
Open
Button

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Unit Status LED
The green Unit Status LED blinks with a one second
on-off duty cycle when power is applied to the trip unit
and it is functioning properly.
INCOM Transmit LED
The red transmit LED flashes red when the trip unit is
communicating over an INCOM network. Model 550
requires the field IMPACC kit for communications.
Programming Port
A custom phone type jack programming port is located
just under the rating plug. One end of the custom phone
type cord provided with the OPTIMizer Hand Held
Programmer plugs into the port, and permits direct pro-
gramming of the trip unit (Figure 2-12). The port will
accept either end of the custom phone cord.
Notice: When the OPTIMizer is plugged into a trip
unit, it prevents all remote IMPACC communi-
cations with that trip unit. This action will also
cause a No-Response alarm on the Breaker
Interface Module and a master network. Refer
to Instruction Book 29C892 covering the
Figure 2-10 Front View of R-Frame, SPB and DSII/DSLII Type OPTIM Model 1050 Trip Unit with R-Frame Rating
Plug Installed
➀Mode of Trip/Alarm LEDs
➁Automatic Trip Indicator Reset
Pushbutton
➂Unit Status LED
➃INCOM Transmit LED
➄Programming Port
➅Rating Plug (Hinged Cover
Closed)
➂
➀➁
➅
➃
➄
Figure 2-11 R-Frame, SPB and DSII/DSLII Type
OPTIM Trip Unit Battery Compartment