Cutler-Hammer Digitrip 510 User manual

Effective October, 2000
IL 33-G2C-2
SAFETY PRECAUTIONS
POWER CIRCUIT BREAKERS ARE EQUIPPED
WITH HIGH SPEED, HIGH ENERGY OPERATING
MECHANISMS.THE BREAKERS ANDTHEIR
ENCLOSURES ARE DESIGNED WITH SEVERAL
BUILT-IN INTERLOCKS AND SAFETY
FEATURES INTENDEDTO PROVIDE SAFE AND
PROPER OPERATING SEQUENCES.TO PRO-
VIDE MAXIMUM PROTECTION FOR PERSON-
NEL ASSOCIATEDWITHTHE INSTALLATION,
OPERATION, AND MAINTENANCE OFTHESE
BREAKERS,THE FOLLOWING PRACTICES
MUST BE FOLLOWED. FAILURETO FOLLOW
THESE PRACTICES MAY RESULT IN DEATH,
PERSONAL INJURY, OR PROPERTY DAMAGE.
• Only qualified persons, as defined in the National
Electric Code, who are familiar with the installa-
tion and maintenance of power circuit breakers
and their associated switchgear assemblies
should perform any work associated with these
breakers.
Digitrip Retrofit System for the General Electric AK-50 Series Breakers:
AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50;
AK-3-50; AK-3A-50; and AKT-3A-50
• Completely read and understand all instructions
before attempting any installation, operation,
maintenance, or modification of these breakers.
• Always turn off and lock out the power source
feeding the breaker prior to attempting any
installation, maintenance, or modification of
the breaker. Do not use the circuit breaker as
the sole means for isolating a high voltage
circuit. Follow all lockout and tagging rules of
the National Electric Code and all other
applicable codes, regulations, and work rules.
• Do not work on a closed breaker or a breaker
with the closing springs charged.Trip (open) the
breaker and be sure the stored energy springs
are discharged before performing any work.The
breaker may trip open or the charging springs
may discharge, causing crushing or cutting
injuries.
• For drawout breakers, trip (open), and then
remove the breaker to a well-lit work area before
beginning work.
• Do not perform any maintenance: including
breaker charging, closing, tripping, or any other
function which could cause significant movement
of the breaker while it is on the extension rails.
Doing so may cause the breaker to slip from the
rails and fall, potentially causing severe personal
injury to those in the vicinity.
• Do not leave the breaker in an intermediate
position in the switchgear cell. Always leave it
in the connected, disconnected, or
(optional) test position. Failure to do so
could lead to improper positioning of the
breaker and flashover, causing death, serious
personal injury, and / or property damage.
• Do not defeat any safety interlock. Such
interlocks are intended to protect personnel
and equipment from damage due to flashover
and exposed contacts. Defeating an interlock
could lead to death, severe personal injury,
and / or property damage.
WARNING
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Effective October, 2000
IL 33-G2C-2
Page 2
Cutler-Hammer Digitrip Retrofit Kits are available in
a number of configurations that provide a wide
range of features.The Digitrip System starts with
the 510 Basic Kit which offers true RMS sensing,
overcurrent protection, and self-testing features.
Advanced Digitrip Retrofit Kits feature zone
interlocking, digital alphanumeric displays, remote
alarm signals, IMPACC communications, energy
monitoring capabilities, power factors, and
harmonic content measurements.
The following table provides a quick reference of
the components supplied with each level of Retrofit
Kit. Before beginning the Retrofit process, take a
minute to review the information contained in the
table. It is important that the Retrofitter understand
which level of Retrofit Kit is to be installed and
which components are included with the Kit.
The instructions contained in this manual cover the
installation of all levels of Retrofit Kit.If the Kit you
are installing does not contain a certain component,
skip the instructions for that component and
proceed to the next.
Throughout the Retrofit process, refer to the Torque
Tables at the back of this manual for
specific torque values.
If you have any questions concerning the Retrofit
Kit and / or the Retrofit process, contact
Cutler-Hammer at 1-800-937-5487.
510 with
Components 510 Basic Zone 610 810 910
Interlock
Trip Unit
Rating Plug
Auxiliary Current
Transformer
(CT) Module
Auxiliary
CT Harness
Sensors
Sensor Harness
Direct Trip
Actuator (DTA)
Mounting Brackets
and Hardware
External Plug 1 Connector 2 Connector 4 Connector 4 Connector
Harness Harness Harness Harness Harness
Cell Harness
Breaker Mounted
Control Power
Transformer (CPT)
Potential Transformer
(PT) Module
Auxiliary Switch
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Effective October, 2000
IL 33-G2C-2 Page 3
Beginning the Retrofit Process
Identifying the Breaker and the Retrofit Kit
Before beginning the Retrofit Process, it is
important to verify exactly which version of
G. E. AK-50 Series Breaker(s) is to be Retrofitted
and to insure that the correct Cutler-Hammer
Retrofit Kit(s) was ordered. Each Breaker must be
identified using all of the following sources that are
applicable:
1. Nameplate Information;
2. Breaker Rating;
3. Framed or Frameless;
4. Fused or Non-Fused; and if fused
5. Location of Fuses
(on Top or Bottom Breaker Stabs).
Please refer to the following chart and verify that
the first three (3) characters of the Digitrip Retrofit
Kit Code Number correspond to the Breaker being
Retrofitted. If you find that the Retrofit Kit does not
match the Breaker, do not attempt the Retrofit.
Contact your purchasing agent and have the
correct Retrofit Kit ordered for the Breaker.
Following the Icons to a Successful Retrofit
During certain parts of the Retrofit Process,
procedures may differ depending on the version
of the Breaker being Retrofitted.To enable the
Retrofitter to quickly identify the correct procedures
for the Breaker, the following Icon System has
been developed. As you are working through a
procedure and the Icons appear, simply follow
only the instructions identified by the Icon for the
Breaker being Retrofitted.
Digitrip Retrofit Breaker Breaker Rating Fuse
Kit Code ID (Amps) Configuration Icon
GMC AK-1-50 1600 N.A.
AK-1-50
G2C AK-2-50 & AK-2A-50 1600 N.A.
AK-3-50 & AK-3A-50
Frameless Breaker with NO Fuses
Framed Breaker with NO Fuses
AK-1-50
G2C AK-2-50 & AK-2A-50 1600 Horizontal
AK-3-50 & AK-3A-50
Framed Breaker with BOTTOM Mounted Fuses
GUC AKU-2A-50 1600 Horizontal or Vertical
Framed Breaker withTOP Mounted Fuses
GTD AKT-2A-50 & AKT-3A-50 2000 N.A.
Framed Breaker with NO Fuses
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Effective October, 2000
IL 33-G2C-2
Page 4
Step 1: General Breaker Preparation
Before attempting to remove the Breaker from the
Cell or perform any Retrofit Operation, be sure
to read and understand the Safety Precautions
section of this manual. In addition, be sure to read
and understand the Instructions for the Application
of Digitrip RMS Retrofit Kits on Power Circuit
Breakers (Retrofit Application Data - Publication
AD 33-855-1), supplied with the Digitrip Retrofit Kit.
NOTE:
For Breakers Utilizing a Remotely
Mounted Neutral Sensor Connected to the
Breaker via Neutral CT Disconnect Only.
The
rating of the Neutral CT Disconnect, originally
supplied with the Breaker, does not meet the
specifications / requirements of the Retrofit Kit.
The Neutral CT Disconnect must be removed
and scrapped.The remotely mounted fourth
Sensor must be wired into the system via
Secondary Disconnects.
If the Breaker being Retrofitted is NOT
equipped with Secondary Disconnects, the
Secondary Disconnects for both the Breaker
and the Cell, as well as all mounting brackets
and hardware, must be secured from the
original manufacturer of the Breaker BEFORE
beginning the Retrofit Process.
DO NOT ATTEMPTTO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENTWHILE IT IS
ENERGIZED. SEVERE PERSONAL INJURY OR
DEATH CAN RESULT FROM CONTACT WITH
ENERGIZED EQUIPMENT.VERIFYTHAT NO
VOLTAGE IS PRESENT BEFORE PROCEEDING.
A. Trip the Breaker and remove it from the Cell.
Move the Breaker to a clean, well-lit work
bench.
NOTE: It is the responsibility of the Retrofitter
to insure that the Breaker and all original com-
ponents are in good condition.Visually inspect
all Breaker components for signs of damage or
wear. If any signs of damage or wear are
detected for components not included in the
Retrofit Kit, secure the necessary replacement
parts before beginning the Retrofit Process.
The force necessary to trip the Breaker should
not exceed three (3) lbs.
To begin the Retrofit Process, refer to the compo-
nents list at the end of this manual. Lay out the
components and hardware according to the steps
outlined.The components and hardware will be
used to complete each step in the Retrofit Process.
NOTE: For most photographs contained within
this manual, a G. E. AK-2-50 Breaker was used
as the subject. Depending on the version and
age of the Breaker being Retrofitted, some
components / views depicted in this manual
may differ from the Breaker being Retrofitted.
WARNING
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Effective October, 2000
IL 33-G2C-2Page 5
Step 2: Removing the Original
ElectromechanicalTrip Units
For All G. E. AK-50 Series Breakers Except
AK-3/3A-50, AKU-3/3A-50, and Breakers
Equipped with a Quick Close Mechanism.
Follow the G. E. AK-50 Series Instruction Manual,
originally supplied with the Breaker, to perform the
following procedures.
A. Carefully lay the Breaker over on its right side to
provide access to the bottom of the Breaker.
B. Remove and scrap the original
Electromechanical Trip Units and mounting
hardware from each phase.
C. Remove and scrap the Electromechanical Trip
Paddles and mounting hardware from the
Breaker Trip Bar.
For G. E. AK-3/3A-50, AKU-3/3A-50, and Breakers
Equipped with a Quick Close Mechanism Only.
Follow the G. E. AK-3/3A-50 Series Instruction
Manual, originally supplied with the Breaker, to
perform the following procedures.
A. Carefully lay the Breaker over on its right side to
provide access to the bottom of the Breaker.
B. Disconnect and scrap all wires connecting
the original Electronic Trip Units, Direct Trip
Actuator, and the original Sensors mounted
on the bottom studs.
C. Remove and scrap the original Sensors,
Electronic Trip Units, Direct Trip Actuator,
Reset Links, and all associated mounting
hardware.
Note: For Breakers originally fitted with a
remotely mounted Neutral Sensor, the
Neutral CT Disconnect must be removed
and discarded.
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Effective October, 2000
IL 33-G2C-2
Page 6
Step 3: Installing the Copper Adapters
A. Align the holes in the Copper Adapters with the
holes that were used to mount the original
Electromechanical Trip Units.
B. Mount a Copper Adapter to each Phase, as
shown, using the (12) .375-16 ×1.50" bolts,
(12) lock washers, and (12) flat washers
supplied.
For Kits Supplied with a PT Module Only.
As viewed from the front of the Breaker, do not
install the left mounting bolt in each Copper
Adapter.These will be used later in the Retrofit
Process to attach the PT Wires to each Phase
Frame.
C. Carefully return the Breaker to the upright
position.
Before proceeding, identify the section(s) within
the Step that apply to the Breaker being
Retrofitted.
Step 4: Installing the Sensors
Note: On Breakers equipped with a Racking
Mechanism, the Sensors and Sensor Mounting
Bracket provide adequate clearance between
the Sensors and Racking Mechanism.
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Effective October, 2000
IL 33-G2C-2 Page 7
For Top Mounted Sensors Only.
A. Align a 3-Point Terminal Block with each set
of holes in the Sensor Mounting Bracket as
shown.Secure the 3-Point Terminal Blocks to
the Sensor Mounting Bracket using the
(6) .138-32 ×.500" screws and (6) lock
washers supplied.
B. Install a Flexiform Grommet to the edges of
each wire cutout in the Sensor Mounting
Bracket.
C. Insert the three (3) wires exiting the top of the
Sensor through the opening in the Sensor
Mounting Bracket.
D. With the Sensor Nameplate at the top and
facing out, align the threaded holes in the top
of the Sensor with the holes in the Sensor
Mounting Bracket. Secure the Sensor to the
Sensor Mounting Bracket using the (4)
.250-20 ×.500" bolts, (4) lock washers, and
(4) flat washers supplied.
E. Repeat Steps B and C for the remaining
two (2) Sensors.
F. Connection of the Sensor Wires to the 3-Point
Terminal blocks is detailed in the photo.Once
the correct connection point has been
determined, cut each Sensor Wire to an
appropriate length and attach a supplied ring
terminal to each wire.
G. Align the Sensor Mounting Bracket / Sensor
Assembly with the existing holes on the top rear
of the Breaker Back Plate as shown. Secure
using the (2) .500-13 ×1.50" bolts, (4) flat
washers, (2) lock washers, and (2) nuts
supplied.
Black Red
White
Black White Red
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Effective October, 2000
IL 33-G2C-2
Page 8
For Bottom Mounted Sensors Only.
A. Following the G. E.AK-50 Series Instruction
Manual originally supplied with the Breaker,
remove and save the fuses, mounting brackets,
and hardware.
B. Again following the G.E. AK-50 Series
Instruction Manual, remove and save the
hardware that secures the .750" thick Support
Plate to the Breaker Back Plate. Remove and
scrap the Support Plate.
C. Align the holes in the new Glass Poly Support
Plate with the holes in the Breaker Plate. Note
that the cutout for the Sensors must face the
bottom of the Breaker. Secure the new Support
Plate using the original mounting hardware.
D. Align a 3-Point Terminal Block with each set
of holes in the Sensor Mounting Bracket as
shown.Secure the 3-Point Terminal Blocks
to the Sensor Mounting Bracket using the
(6) .138-32 ×.500" screws, (12) flat washers,
(6) lock washers, and (6) nuts supplied.
E. Install a Flexiform Grommet to the edges of
each wire cutout in the Sensor Mounting
Bracket.
F. Insert the three (3) wires exiting the top of the
Sensor through the opening in the Sensor
Mounting Bracket.
G. With the Sensor Nameplate at the bottom and
facing out, align the threaded holes in the top
of the Sensor with the holes in the Sensor
Mounting Bracket. Secure the Sensor to the
Sensor Mounting Bracket using the (4)
.250-20 ×.500" bolts, (4) lock washers, and
(4) flat washers supplied.
H. Repeat Steps E and F for the remaining two
(2) Sensors.
I. Connection of the Sensor Wires to the 3-Point
Terminal blocks is detailed in the photo. Once
the correct connection point has been
determined, each Sensor Wire should be cut to
an appropriate length and a supplied ring
terminal attached to each.
Black Red
White
Black White Red
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Effective October, 2000
IL 33-G2C-2 Page 9
J. Align the Sensor Mounting Bracket with the
existing holes on the bottom rear of the Breaker
Back Plate as shown. Secure using the (2)
.500-13 ×1.50" bolts, (4) flat washers, (2) lock
washers, and (2) nuts supplied.
K. Following the G. E. AK-50 Series Instruction
Manual originally supplied with the Breaker,
reinstall the original fuses, mounting brackets,
and hardware.
For AKT-2A-50 and AKT-3A-50 2,000 Amp
Breakers Only.
A. Align two (2) Sensor Adapter Brackets with
the holes in the top of the Sensor as shown
(the Sensor Terminals are located on the
bottom of the Sensor). Secure the Sensor
Adapter Brackets to the Sensor using the (2)
.250-20 ×2.75" bolts, (4) flat washers, (2) lock
washers, and (2) nuts supplied.
B. Repeat Step A for the remaining two (2)
Sensors.
C. Align the threaded holes in the Sensor
Adapter Brackets with the holes in the Sensor
Mounting Bracket. Secure the Sensor Assembly
to the Sensor Mounting Bracket using the (4)
.250-20 ×.500" bolts, (2) lock washers, and (2)
flat washers supplied.
D. Repeat Step B for the remaining two (2)
Sensor Assemblies.
E. Align the Sensor Mounting Bracket / Sensor
Assembly with the existing holes on the top
rear of the Breaker Back Plate as shown.
Secure using the (2) .500-13 ×1.50" bolts,
(4) flat washers, (2) lock washers, and (2)
nuts supplied.
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Effective October, 2000
IL 33-G2C-2
Page 10
Step 5: Installing the Aux. CT Module
A. Carefully lay the Breaker over on its left side.
B. Using Drilling Plan “A”, drill four (4) .219"
diameter holes near the bottom of the right side
of the Breaker. Note that the positioning of the
Aux. CT Module differs slightly for Breakers
equipped with a Quick Close Mechanism.
Note: Cover the region below the area to
be drilled to prevent chips from falling into
the Breaker.
C. Remove the screws installed in the right side of
the Aux.CT Module.
D. Align the holes in the right side of the Aux.CT
Module with the holes just drilled in the right
side of the Breaker. Secure the Aux.CT Module
to the Breaker using the (4) .190-16 ×.500"
thread cutting screws, (4) flat washers, and
(4) lock washers supplied.
AK Breaker AB
Without Quick Close Mech. 6.62 0.75
With Quick Close Mech. 4.38 1.00
Drilling Plan “A”
1.38" 1.38" Rear of Breaker
0.219 Dia. (4)
B
1.50"
0.75"0.75"
A
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