Eaton Cutler-Hammer Digitrip RMS 510 User manual

AD 33-855-4
lnstructions lor the Application ol
Digitrip RMS 510,610,810, &-'
910 Retrolit Kits on Power Circuit
Breakers
Cutler-Hammer
Eif.il

Cutler-Hammer AD 33-855-4
Page 1
lnstructions lor the Applicati0n ol
Digitrip RMS 510, 610, 810, &
910 Retrolit Kits on Power Circuit
Breakers
Description
Section 1 General lnformation and
Safety Precautions............................................... 5
1.1 Safety Precautions ................................... 5
1.2 lntroduction .................... 6
1 .3 Warranty Disclaimer and Liability
Limitation.......... .............. 6
Section 2 Digitrip RMS Retrofit Kits, Rating
Plugs, and Accessories..........................,....,.,.,,.. 7
2.1 Digitrip RMS Retrofit Kits.........................7
2.2 Retrofit Kit lnstallation Requirements ......7
2.3 The Retrofit Process ................................ 8
2.4 Digitrip RMS Retrofit Kit Accessories ......8
Section 3 The Digitrip RMS Trip System ........ 11
3.1 Digitrip RMS Overcurrent Protection ..... 11
3.2 Current Sensors and Sensor Wiring
Harness ...................-.... 11
3.3 Auxiliary CT Module and Auxiliary CT
Harness ........................ 11
3.4 Digitrip RMS Trip Unit and Power
Relay Module (ATR) ................................ 1 1
3.5 Long Time Memory Function .................17
3.6 Discriminator (High lnitial Cunent
Release) ............ ............17
3.7 Digitrip RMS Dlrect Trip Actuator (DTA)
and Auxiliary Switch Kit
(See Figure 3-6). . . . . ............................ 18
3.8 Digitrip RMS Retrofit Rating Plug and
8a11ery.............. ............ 19
3.9 External Harness .......-............................ 20
3.10 Potential Transformer (PT) Module ........ 20
CONTENTS
3.1 1 Cell Harness Assembly .......................... 20
3.12 Breaker Mounted Control Power
Transformer (CPl .... .. .......................... 20
Section 4 Digitrip RMS 510 Basic Retrofit
Kits Without zone lnterlocks)..........................21
4.1 Digitrip RMS 510 Basic Retrofit Kit
Selection and Content .....,..................... 21
4.2 Digitrip RMS 510 Basic Retrofit Kit
Features ....................... 21
Section 5 Digitrip RMS 510 Retrofit Kits
(With Zone lnterlocks) .............23
5.1 Digitrip RMS 510 Retrofit Kit (With
Zone lnterlocks) Selection and
Content ........................ 23
5.2 Digikip RMS 510 Retrofit Kit
(\tVith Zone lnterlocks) Features ............. 23
Section 6 Digitrip RMS 61O Retrofit Kits.........25
6.1 Digitrip RMS 610 Retrofit Kit Selection
and Content .................25
6.2 Digitrip RMS 610 Retrofit Kit Features ... 25
Section 7 Digitrip RMS 810 & 910
Retrofit Kits................... ............27
7.1 Digitrip RMS 810 & 910 Fletrofit Kit
Selection and Content ........................... 27
7 .2 Digitrip RMS 810 & 910 Retrofit Kit
Features .......................27
7.3 Power Flow Convention ......................... 29
7.4 PowerNetCommunicationsWiring
Checkout .......... ............ 30
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Section 8 Testing Retrofitted Breakers........... 31
8.1 Dielectric and Meggar Testing ............... 31
8.2 Trip System Testing - General Notes.....31
8.3 Recommended TestAccessories ..........32
8.4 Explanation of Test Procedures .............33
8.5 Primary lnjection Testing ........................ 35
8.5..1 Primary lnjection Test Procedures... 35
8.6 Digitrip RMS Self-Testing System .......... 39
8.6.1 Self-Testing Procedures.................. 39
8.7 Testing Digitrip with the DS Breaker
Secondary lnjection Test Kit .................. 42
8.7.1 Secondary lnjection Testing ............ 43
8.7.2 Secondary lniection Test
Procedu res ...................................... 43
8.8 Circuit Breaker Checkout and Bench
Test ................... ............ 46
Section 9 Operation .... ............47
9.1 Breaker lnsertion in Switchgear Cell
and Power Up ........................................ 47
9.2 lnformation Available to Operator While
Breaker ls in Service .............................. 48
9.3 lnformation Available in the Event of
a Trip................. ............49
9.4 Resetting The Trip Unit After a Trip........50
9.5 Removing the Breaker From the
CONNECT Position ................................ 50
Section 10 Digitrip RMS Retrofit Switchgear
Assembly Applications ..............,....................... 51
1O.1 Zone lnterlocking .........51
.10.1.1 Zone Selective lnterlocking ............. 5.1
10.2 Setting Digitrip RMS Communications
Address (Digitrip RMS 810 & 910
Kits Only) ...................".. 54
10.3 ldentification of Trip Unit, Breaker, and
Switchgear Cell ............57
10.4 The Power Relay Module (ATR) .............57
1 0.5 Communications and PowerNet .........,..57
Section 11 Maintenance, Warranty, and
Service lnformation ,.....,.,..,.,,,.61
1 1.1 Preventative Maintenance Program .......61
1 1 .2 Breaker Maintenance ............................. 61
1 1 .3 Warranty Procedure ............................... 61
11.4 Digitrip RMS Trip Unit Warranty ............. 61
Section 12 Detailed Wiring of Harnesses and
Related Components... ............ A3
'1 2.1 Sensor Harness Wiring .......................... 63
12.2 Auxiliary CT Harness Wiring.....-............. 63
12.3 Auxiliary CT Module Wirin9 .................... 63
Section 13 References ...........73
Section 14 Explanation of Time Current
Curves ............. -.....,.,.........,.,..,.. 75
14.1 Explanation of the Time Current
Curves (LSl) ...... ............75
Figures
3-1 Digitrip Retrofit System -........................... 1 3
3-2 Digivip RMS Long Time / Shofi
Time-Current Curves (LS) ...............,........ 1 4
3-3 Digitrip RMS lnstantaneous
Time-Current Curve (l).............................. 1 5
3-4a Digitrip RMS Ground Fault Protection
Time-Current Curve (G) ............................ 1 6
3-4b Digitrip RMS Ground Fault Protection
Time-Current Curve (G) .......... ..........,....... 17
3-5 Disabling the Long Time Memory
(LTM) Function.. .............. 18
3-6 Digitrip RMS Direct Trip Actuator (DTA) ... 19
4-1 Digitrip RMS 510 Basic Wirin'.................22
5-1 Digitrip RMS 510 Wiring ........ ...................24
6-1 Digitrip RMS610Wirin9...........................26
7-1 Digitrip RMS 810 & 910 Wiring ................ 28
7 -2 Power Flow Conventions ......................... 29
8-1 Pick-up Test and Time Test... ......,............32
8-2 Adapter Methods .-.........42
1 0-1 Zone Selective lnterlocking ...................... 51
1O-2 Connection Schematics for Multiple
Circuit Breakers ..............52
10-3 Connection Schematics for Multiple
Circuit Breakers ..............53
10-4 Digitrip Trip Unit Display Panel ........-....-.. 55
10-5 Terminating Resistor Location ................. 56
10-6 Terminating Resistor Location ................. 56
1 0-7 Terminating Resistor Location ................. 57
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AD 33-855-4 Page 3
10-8 Typical ATR 120 VAC Source lnput
and Dry Contact Alarm Output
Connections for Remote
Alarm lndication .............58
10-9 Typical Control Schematic Without
CC1 / CC2 Modification ........................... 59
'10-10 Typical Control Schematic Without
CC1 / CC2 Modification ........................... 59
10-11 CC1 / CC2 Modification to a
Typical Control Schematic
(Stored Energy) ..............59
10-12 CC1 / CC2 Modification to a
Typical Control Schematic (Solenoid) ...... 59
12-1 Without Ground 30 3-Wire
(Lr, LS, LSr) ....... ..............64
12-2 Wilh Ground, Without Neutral
Connection 3@ 3-Wve
(LrG, LSG, LSrG)....................................... 64
'12-3 With Ground and With Neutral
Sensor 30 4-Wire (LlG, LSG, LSIG).........65
12-4 With Ground, With External Ground
Source 30 3-Wire or 4-Wire (LlG,
LSG, LSGD .....................65
1 2-5 Auxiliary CT Harness................................ 66
'1 2-6 Auxiliary CT Module Wiring ...................... 66
12-7 Digitrip RMS 510 Basic External
Harness .......................... 67
12-8 Digitrip RMS 510 External Harness .........67
12-9 Digitrip RMS 610 External Harness ........'67
12-1 0 Digitrip RMS 810 & 91 0 External
Harness with CPT Adapter Harness ........ 68
12-11 Digitrip RMS 810 & 910 External
Harness .......................... 68
12-12 Digitrip RMS 510 Cell Harness ................69
12-13 Digitrip RMS 610 Cell Harness ................69
12-14 Digitrip RMS 810 & 910 Cell Harness ...... 70
12-15 Digitrip RMS 810 & 910 Simplified
Cell Harness..... ..............71
12-16 Digitrip RMS 810 & 910 PT Module.........71
1 4-1 Time-Current Curves........ ................,....... 76
Tables
2-1 Digitrip Rating Plugs (50 and 60 Hz)
and Their Coordination with Sensor
Connections ....................... 9
2-2 Digitrip RMS Retrofit Kit Accessories .......' 10
8-1 Primary lnjection Testing Settings
and Expected Test Results ................-....... 36
8-2 Self-Testing of the Digitrip Trip
Unit Settings and Expected Test
Resu|ts............. ................40
8-3 DS Breaker Secondary lnjection
Testing Settings and ExPected
Test Results...... ..-.............44
9-1 lnformation Available to Operator
While Breaker is in Service......................... 48
9-2 lnformation Available in the Event
of a Trip ...........................49
1 2-1 Power Flow Conventions ........................... 63
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AD 33-855-4 Page 5
SECTION 1 GENERAL INFORMATION
AND SAFEW PRECAUTIONS
1.1 Safety Precautions
The warnings included as part of the procedural
steps in this manual are for personnel safety and
protection of the equipment from damage. An
example of a typical warning is shown here to
familiarize personnel with the style of presentation.
ln addition, the following warning applies
throughout this manual. lt should be read and
understood before proceeding.
I wnnr.rrruc
POWER CIRCUIT BREAKERS ARE EOUIPPED
WITH HIGH SPEED, HIGH ENERGY OPERATING
MECHANISMS. THE BREAKERS AND THEIR
ENCLOSURES ARE DESIGNED WITH SEVERAL
BUILT-IN INTERLOCKS AND SAFETY FEA-
TURES INTENDED TO PROVIDE SAFE AND
PROPER OPERATING SEQUENCES. TO PRO-
VIDE MAXIMUM PROTECTION FOR PERSON.
NEL ASSOCIATED WITH THE INSTALLATION,
OPERATION, AND MAINTENANCE OF THESE
BREAKERS, THE FOLLOWING PRACTICES
MUST BE FOLLOWED. FAILURE TO 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 installation and maintenance of Power
Circuit Breakers and their associated
switchgear assemblies should pedorm any
work associated with these Breakers.
. 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 pedorming 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.
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1.2 Introduction
This Application Data is provided as a guide, for
authorized and qualified personnel only, in the
selection and application of Digitrip RMS Retrofit
Kits on Power Circuit Breakers.
The information, recommendations, descriptions,
and safety notations in this document are based
on Cutler-Hammer's experience and judgement
with respect to retrofitting Power Circuit Breakers.
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 this document. lf further
information is desired by the purchaser regarding a
particular installation, operation, or maintenance of
his particular equipment, contact your local Cutler-
Hammer representative or phone [phone].
1.3 Warranty Disclaimer and Liability
Limitation
The instructions for installation, testing,
maintenance, or repair herein are provided for the
use of the product in general commercial
applications and may not be appropriate for use in
nuclear applications. Additional instructions may
be available upon specific request to replace,
amend, or supplement these instructions to qualify
them for use with the product in safety related
applications in a nuclear facility.
The information, recommendations, descriptions,
and safety notations in this document are based
on Cutler-Hammer's experience and judgement
with respect to retrofitting of Power Circuit
Breakers. This information should not be
considered to be all inclusive or covering all
contingencies. lf furlher information is required,
Cutler-Hammer should be consulted.
NO WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE OR
MERCHANTABILIry OR WARRANTIES
ARISING FROM COURSE OF DEALING OR
USAGE OF TRADE, ARE MADE REGARDING
THE INFORMATION, RECOMMENDATIONS,
AND DESCRIPTIONS CONTAINED HEREIN. ln
no event will Cutler-Hammer be responsible to the
user in contract, in tort (including negligence), strict
liability or otherwise, for any special, indirect,
incidental, or consequential damage or loss
whatsoever, including but not limited to damage to
or loss of use of equipment, plant or power
system, cost of capital, loss of profits or revenues,
cost of replacement power, additional expenses in
the use of existing power facilities, or claims
against the user by its customers resulting from
the use of the information, recommendations, and
descriptions contained herein.
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AD 33-855-4 Paqe 7
SECTION 2 DIGITRIP RMS RETROFIT
KITS, RATING PLUGS, AND
ACCESSORIES
2.1 Digitrip RMS Retrofit Kits
Cutler-Hammer Digitrip RMS Retrofit Kits are
available for many Breakers produced by major
manufacturers of Power Circuit Breakers. The
Digitrip RMS Retrofit Kits are structured according
to the Digitrip RMS Trip Unit and the specific
Overcurrent Protective features provided.
The product line begins with the Digitrip RMS 510
Basic Retrofit Kit series. True RMS sensing, basic
Overcurrent Protection, and self-testing features
are standard. The Overcurrent Protection provided
is determined by the selected Long Time (L), Shon
Time (S), lnstantaneous (l), and Ground Fault (G)
Trip Functions.
The balance of the Retrofit Kits listed, Digitrip RMS
510, 610, 810, & 910 series, add increasing levels
of features to those of the RMS 510 Basic Retrofit
Kits and to each other. The features include Zone
lnterlocking, Digital Alphanumeric Displays, Re-
mote Alarm Signals, PowerNet Communications,
Energy Monitoring Capability, and Harmonic
Distortion lnformation.
Additional information on the features and content
of each Digitrip RMS Retrofit Kit is provided in
Sections 4 through 7 of this Application Guide.
2.2 Retrofit Kit lnstallation Requirements
Digitrip RMS Retrofit Kits can be applied to many
types of Power Circuit Breakers, provided the
Breakers are used on 50 or 60 Hz AC distribution
systems. Retrofits for fixed mounted or non-
drawnout Breakers should be referred to Cutler-
Hammer for evaluation.
I wnnr'rrr.rc
THE DESIGN AND CONTENT OF THE RETRO-
FIT KIT IS BASED ON THE FOLLOWING CONDI-
TIONS, WHICH MUST BE ADDRESSED BY
THE RETROFIT KIT PURCHASER, PRIOR TO
INSTALLATION. FAILURE TO ADDFESS THESE
CONDITIONS COULD RESULT IN FAILURE OF
THE EQUIPMENT TO OPERATE PROPERLY,
PERMANENT EQUIPMENT DAMAGE, AND IN
SOME INSTANCES, PERSONAL INJURY OB
DEATH.
1, The Breaker must be in good mechanical
and electrical operating condition. Breakers
that are not in good operating condition must
be repaired, reconditioned, or refurbished prior
to being retrofitted. Refer to Section 11 for
general guidelines on Breaker preventative
maintenance.
2. Rating Plug selection. One Rating Plug is
normally provided, which does not exceed the
Breaker's maximum continuous current frame
rating. lf an alternate Rating Plug is required
for the Breaker being retrofitted, it can be
ordered separately or as part of the kit. Table
2-1 provides a complete listing of all Rating
Plugs. Rating Plugs must coordinate with the
Breaker Sensor Tap being used. Together they
determine the Breaker Continuous Current
Rating (ln). Refer to Catalog 26-000 and the
Digitrip Retrofit Kit Product Guide for Retrofit
Kit ordering information.
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Page 8AD 33-855-4
3. Retrofit Kits shown with Ground Fault (G)
Protection assume a 3-phase' 3-wire
grounded system. lf the retrofit is for a
4-wire grounded system, the customer must
specify the fourthsensor when ordering the kit'
Also, provisions must be made on the Breaker
to bring the foudh sensor wiring through the
Breaker secondary contacts. Secondary
contacts and brackets, etc. are not included in
the content ot the kits.
4. Digitrip RMS 610, 81O, & 91O Retrofit Kits
require an external (customer supplied) 120
VAC source to power the Trip Unit information
functions and Alphanumeric Digital Displays,
as applicable. lf the Optional Breaker Mounted
Control Power Transformer (CPT) is utilized,
the External 120 VAC power source via the
Cell Harness assembly is not utilized for this
condition.
2.3 The Retrofit Process
During the Retrofit process, the Retrofitter must
adhere to the following guidelines to insure that the
Breaker is in good working condition, that the
Retrofit is pedormed correctly, and that the
Breaker is ready to return to service.
1 . lt is the responsibility of the Retrofitter to
insure that the Breaker and all original
components are in good condition by visually
inspecting each component for signs of
damage or wear. lf any signs of damage or
wear are detected for components not
included in the Retrofit Kit, the Retrofitter must
secure the necessary replacement parts
before beginning the Retrofit process.
2. lt is the responsibility of the Retrofitter to
carefully follow all instructions supplied with
the Retrofit kit.
3. lt is the responsibility of the Retrofitter to
insure that the Direct Trip Actuator (DTA)
Assembly has been correctly set-up,
according to the specifications given within
the instructions supplied with the Retrofit Kit.
4. lt is the responsibility of the Retrofitter to
insure that, following the Retrofit process, the
force necessary to trip the Breaker meets the
specifications given within the instructions
supplied with the Retrofit Kit.
5. lt is the responsibility of the Retrofitter to test
the Retrofitted Breaker using primary injection.
Refer to Section 8 of this manual for detailed
testing procedures and specifications. For
test information specific to the Trip Unit, refer
to the lL publication supplied with the Retrofit
Kit.
6. lt is the responsibility of the Retrofitter to
mount the Cell Harness in the cell in a location
suitable for connection with the External
Harness.
7. lt is the responsibility of the Retrofitter to
install the retrofitted Breaker in the Cell to
insure proper Breaker / Cell fit and correct
Breaker operation.
2.4 Digitrip RMS Retrofit Kit Accessories
Table 2-2 provides a listing of optional accessories
that are useful in the installation, maintenance, and
operation of your Breaker equipped with a Digitrip
RMS Retrof it Kit.
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AD 33-855-4 Paqe 9
Table 2-1 Digitrip Rating Plugs (5O and 60 Hz) and Their Coordination with Sensor Connections
Sensor
Rating
1600:5
50/60 Hz Bating Plug
Catalog Numbet & l. Rating
RP64.l64080
RP6A1 641OO
RP6A16A12O
RP6A164160
RP6A2OA1 OO
RP6MOA120
RP6MOA160
RP6A2OA2OO
1000 Amp
1200 Amp
1600 Amp
2000 Amp
800 Amp
1000 Amp
1200 Amp
1600 Amp
1600 Amp
2000 Amp
2500 Amp
3000 Amp
1600 Amp
2000 Amp
2400 Amp
3200 Amp
RP6A3OA1 60
RP6A3OMOO
RP6A3OA25O
RP6A3OA3OO
RP6A32A160
RP6432A2OO
RP6A32A24O
RP64324320
RP6A4OA2OO
RP6A4OA25O
RP6A4OASOO
RP6A4OA32O
RP6A4OA4OO
2000
2500
3000
3200
4000
Amp
Amp
Amp'
Amp
Amp
Notes:
'1 . Sensor Tap rating connected must correspond with the Rating Plug shown.
2. Breaker current rating shown is adjustable down to 50% of the value listed with Digihip RMS Long Delay Pickup Setting.
3. Rating Plugs for Digitrip 510, 610, 810, & 910 are NOT interchangeable with Rating Plugs for Digitrip 500, 600, 700, or 800.
4. A complete listing of all Rating Plugs (Retrofit, DS and SPB) is in the Cat 26-000, Second Edition, [,/]arch 1997.
RP6412AO6O
RP6412AO8O
RP6A12A1OO
RP6A12A12O
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Table 2-2 Digitrip RMS Retrofit Kit Accessories
Accessory
Description Accessory Style
or Catalog Number Function
Auxiliary Power
Module (APM) PRTAAPM Powers Digitrip RMS Trip Unit for testing
Secondary lnjection
Test Kit 8779C02G02 Tests Digitrip RMS Trjp Unit by Secondary
lnjection. Requires Adapter Harness.
Adapter Harnesses" 6503C53G0.1 Crypel) or
6503C54G01 ffype 2) and
6503C55G01
(Breaker Mounted Test Plug)
Connects Secondary lnjection Test Set
to Trip System for testing.
External Harness
(For 510 Basic Kit) 6502C83G01 Plugs into RMS Trip Unit Plug J2.
Shorts Out GrN to Gour
and S,^, to S^, - durinq Trip Unit testing.
Lithium Battery
3.0 Volt
NOTE: Sourced
from the listed
suppliers.
Type CR l/3N
Varta Batteries, lnc.,
150 Clarbrook Road,
Elmsford, NY 10523
Type DL 1/3N
Duracell,
South Broadway,
TarMown, NY 10591
[phone]
Type CR 1/3N
Sanyo Electric, lnc.,
Battery Division
200 Riser Boad
Little Ferry NJ 07643
Powers Digitrip LED
Trip lndicators (Back-up Power).
Cell Harness
Assembly 6503C57G03 Provides auxiliary power and shorts out the
Zone lnterlocks during testing, for all 610,
810. & 910 Kits with an External Harness.
.See Section 8.7
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AD 33-855-4 Page 11
SECTION 3 THE DIGITRIP RMS TRIP
SYSTEM
3.1 Digitrip BMS Overcurrent Protection
The Digitrip RMS Retrofit Kits covered by this
Application Guide are designed to replace the
existing Trip System employed on the Breaker
selected for Retrofitting.
All Digitrip RMS Retrofit Kits provide basic
Overcurrent Protection, which includes a selected
combination of Long Time (L), Short Time (S),
lnstantaneous (l), and Ground Fault Time (G) Delay
Trip Functions. Five major components comprise
the Digitrip RMS Ti'ip System: the Current Sensors;
Auxiliary CT Module; Digitrip Trip Unit; Rating Plug;
and the Direct Trip Actuator (DTA). These compo-
nents are interconnected by use of the various
wiring harnesses to make up the Digitrip RMS Trip
System. Breaker interface diagrams for Digitrip
RMS 510 through 910 are provided in Sections 4
through 7. These diagrams show the major Digitrip
RMS components and their interconnections.
Wiring diagrams for each of the wiring harnesses
are shown in Section 12.
Figure 3-1 shows the major components of the
Digitrip Retrofit System and their interconnections.
The following sections describe the function and
operation of each component.
3.2 Current Sensors and Sensor Wiring
Harness
Three single or multi-tapped Current Sensors (one
per phase) are located at the rear of the Breaker.
The Sensors pass information to the Auxiliary CT
Module and the Trip Unit about the primary current
level passing through the Breaker. All the energy
required to power the Digitrip RMS Trip System is
produced by the Current Sensors.
The Current Sensors are connected to a terminal
block strip on the Auxiliary CT Module by the
Sensor Wiring Harness. The Current Sensor Tap
ratio connected, in concert with the Rating Plug,
determines the Continuous Current Rating (ln) of
the Breaker. At rated primary current, the Current
Sensors provide 5 ampere nominal current inputs
to the Auxiliary CT Module.
3.3 Auxiliary GT Module and Auxiliary CT
Harness
The Auxiliary CT Module encloses three auxiliary
phase Current Transformers, which reduce the 5
ampere nominal inputs from the Current Sensors
to the milliampere level required for the Digitrip
RMS Trip Unit electronics. When Ground Fault (G)
protection is selected, a Ground Auxiliary Current
Transformer is also provided, which performs the
same function.
A 7-point terminal block strip is mounted to the
Auxiliary CT Module. Terminals A through G termi-
nate the inputs from the Current Sensors via the
Sensor Wiring Harness. Terminals OP and ON
connect the Trip Signal Outputs to the Direct Trip
Actuator (DTA) via the Sensor Wiring Harness or
DTA Wiring Harness. A 12-point female CT Plug-in
Block is mounted on the right hand side of the
module, which receives the male plug of the
Auxiliary CT Harness. The Auxiliary CT Harness
also has a 10-pin black plug, which plugs into the
Trip Unit to connect the Auxiliary CT lnputs to the'
Trip Unit and receives the Trip Unit trip signal
outputs. Refer to Figure 12-6 for Auxiliary CT
Module wiring.
3.4 Digitrip RMS Trip Unit and Power
Relay Module (ATR)
The 1O-Series Digitrip RMS Trip Units (510
through 910 Kits), Figure 3-1 , are designed to
permit flexibility in Retrofit applications. They are
physically repackaged versions of the original
1 OO-Series Digitrip RMS Trip Units that were used
on Cutler-Hammer DS and SPB Breakers. The
RMS Trip Units have the same features and
options and have identical characteristic curves,
adjustments, and electrical pedormance.
The Digitrip RMS Trip Unit is a microprocessor
based protective device that provides true RMS
sensing means for proper correlation with thermal
characteristics on conductors and equipment.
Digitrip RMS Trip Units are available in four mod-
els, RMS 510, 61 0, 81 0, & 91 0. These models are
available in horizontal or vertical labeling and
display orientations.
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Page 12 AD 33-855-4
The Trip Unit includes a female type receptacle
provided to accept a Rating Plug, which, in con-
ced with the Current Sensors, determines the
Continuous Current Rating (ln) of the Breaker or
the Long Delay (lr) Setting of the Breaker. Adjust-
able current protective settings are provided for
the Long Time (L), Shod Time (S), lnstantaneous
(l), and Ground Fault (G) Trip Functions selected.
Short Time (S) and Ground Fault (G) Delays are
equipped with an adjustable setting for a flat or an
l2t response. The adjustable settings are step-type,
expressed in terms of Continuous Current Rating
(ln) the maximum of the Breaker or the Long Delay
Setting (lr) of the Breaker. LEDs provide Mode of
Trip lndications for the L, S, l, and G trip functions.
Digitrip RMS Trip Units are equipped with multi-pin
disconnect plug receptacles which permit quick
connections to the Auxiliary CT Harness and, when
supplied, the External Harness.
The Power Relay Module (ATR) is provided in
Digitrip RMS Trip Unit Kits 61 0 through 91 0 only.
The ATR provides hard contact closures for remote
indication of the following Trip Unit functions:
. High Load (HL) Alarm
The HL contact closes when the current
passing through the Breaker exceeds 85%
of the Trip Unit Long Delay Pickup Setting
continuously for more than 40 seconds.
. Long Delay (LD) Trip
. Short Circuit (SC) Trip
. cround Fault (GF) Trip
o PowerNet Remote Close (CC1 and CC2)
Contact (RMS 810 & 910 Trip Units only)
All ATR contacts are rated 1 ampere at 120 VAC or
1 ampere at 28 VDC. These contacts are generally
used for illuminating indicator.lights or picking up
slave relays local to or remote from the Breaker /
Switchgear. A bridge rectifier circuit in the ATR
serves to power up the Trip Unit, the Trip Unit
Alphanumeric Display, and the INCOM Communi-
cations, when a 120 VAC source is supplied to ATR
terminals AC120 and ACCOM.
Digitrip RMS Trip Units are equipped with a recep-
tacle, located on the front of the Trip Unit, to
receive the Auxiliary Power Module (APM). The
APM is used to supply power to the Trip Unit self-
test system during Circuit Breaker testing. Adjust-
able test settings are provided which enable the
unit to be tested with or without tripping the
Breaker.
Figures 3-2 though 3-4a & 3-4b provide the pub-
lished Digitrip RMS Characteristics Curves for
Retrofit Breakers. Also provided are the available
Trip Unit settings for all trip functions. These
curves are available on onion paper as Applica-
tions Data 32-870.
F:T.il Efiective 9/01

AD 33-855-4 Page 13
WHITE
PLUG
PT MODULE
(810/910 K|TS ONLY)
WHITE
DISCONNECT
PLUG
SENSORS
AUXILIARY
SWITCH
(81 0/91 o
KITS ONLY)
>
!rl
olo
uu
l
I
$*or'to
'= al eluc
TEBI\4INAL BLOCKS
(cusTor!1ER coNNEcTroNS)
I
AUXILIABY CT HARNESS I
CELL HARNESS
20-PtN
PLUG
*.6'10 to 910 Units Only
SENSOR HARNESS
AUXILIARY CT I\iIODULE
DTA HARNESS
TRIP UNIT
Fig. 3-1 Digitrip Retrofit System
ElT.il
Fffective g/01

|-
Page 14 AD 33-855-4
CURRENT IN I\,4ULTIPLES OF THE LONG DELAY SETTING /T
05 .07 .1 2 .3.4.s .7 12 3 45 7 10 20 30 50 70 100 2oo 3oo 5oo 7oo 1000
1000
700
500
400
300
200
100
7A
50
40
30
20
1000
700
500
400
300
200
100
70
50
40
30
20
.t
.07
.05
.44
.03
.42
.01
10
a;7
o
z5
o
tJl 3
I
u2
F
1
.7
.4
3
.2
.1
.47
.05
.04
.03
.o2
.01
+
\VAILABLE I2t I
)N SHORT DE
rIME SETT NG
NDICATED BY
:'
't G)U I
6.)0 1
]HAPE
s
10
ta o
5Z
40o
3UlI
2uF
,1
.7
.5
.4
.3
.2
. .< 71n .n . 1^5 710 20 30 50 70 100 200 3oo 500/oo 1000
CURRENT IN MULTIPLES OFTHE LONG DELAY SETTING /T
Available Digitrip BMS Rating Plugs Marked 50/60 HzO
Amperes Pllg Ral ng nAmpe€sli)
AVAILABLE LONG
DELAY (IB) SETTINGS
.5. .6. .7, .8, .85, .9, .95, I
I300 200. 250,300
.100 200. 250,300. ,100
600 300 ,100,600
aoo 400,600.400
12oO 600.a00.1000 1200
t6oo a00.1000.1200.1600
2000 1000. 1200. r 600. 20!0
1600. 2000. 2'lO0
3000 1600. 2000. 2500. 3000
32oO 1600. 2000.2400.3000.3200
4!OO 2000. 2400. 3200. 4000
LDS Range - 1 009" lo 1 10"/" ol sening
LoT Range = 67% to looot ol seting shown @ 6x/.
sos = Bange goob ro 1 10o! ol selling
OThe R.rn9 Puq s br50and60 Hzapp'cl'ons
a. ,tue\hn'-,6m 20, ro r-c dmoenl lemoe'drurp\dbovF
TOTAL
CLEARING
TIME
I
MINIMUI\,1
TOTAL
CLEARING
Tll\riE ss c €use adomalic tr o.
o w tr zone nter ck ng on slrod delay uliized a.d no restra n ng
sional,the mlnimumlim€ band Mapp'es regadless ol sening
O L;ng Ime Memory run.ton automali€ ly shonens long deavl me
-++
- - .-l-]_
- rd.f
r rT
=F- AVAILABLE LONG
DELAY SETTINGS
c!^\^iNl .61 ^- lo
lA)l 12,a,i.1a.12.15.2a.2a
I
I1@
4,2.5.3
l0)x /,
1sr(8) or s2(
t\
1
^o
.3'
tt
.fl \VAILABLE FLAT RESPONSE
JHORT DELAY TII\4E SETTINGS
1. .2. .3. 4, .5 SFCOND
-l G)
I
ll
APPLICAT ON
DETERMINES
END OF CURVE
Fig. 3-2 Digitrip RMS Long Time / Shott Time-Current Curves
F:T.iI Ftfective 9/01

-
AD 33-855-4 Page 15
CURRENT lN MULTIPLES OF PLUG RATING /n
.05 .07 .1 .2 .3.4.5 .7 12 3 45 710 2A 30 sO 70 100 200 3oo 5oo 7oo 1000
1000
700
500
400
300
200
100
70
50
4A
30
20
1000
700
500
400
300
204
100
7A
50
40
30
20
10
67
o
O4
(_)
L!3
g
u2
=
F
'10
76o
5z
40o
3t! I
2uF
1
.7
.5
.4
.3
2
1
.7
.5
,3
.2
.1
.47
.05
.o4
.03
.o2
.1
.07
.05
.04
.03
.02
.01
o1 .os .07 .1 2 3.4.5 .7 12 s 45 710 20 30 50 70 100 200 3oo 5oo 700 1000
cURRENT lN MULTIPLES OF PLUG RATING /n
ffi I Available Diqilrip RMs Rating Plugs Marked 50/60 HzO
Pruq Far ng in anp*s (rn)
200.250,300
200.250, 300. .l!0
300. 400, 600
400.600.800
600 a00.100!.1200
300. 1000,1200. I600
10m. 1200. 1600. 2000
1 600. 2000. 2440
1 6m. 2000, 25m, 3000
1 600. 2000, 2400. 3000. 3200
2000,2400. 3200. 4400
or 50 and 60 Hz appLlcalions.
lmeses
m0
600
800
3200
a
I c5C cuse aulomal
l^.-""..,-."..".
| r5poffie chd.deck rhown n these cuNes apply only lo the
is ol the Trip Unn and DTA combinaiion
nherenl n lhe host b@aker musl be added
ihown he@, to povide lhe actualtotal
1_
tr 12r-
E3| frt
-.^:-r
(8)
rD
q,
+t fiAVAl LABLE INSTANTANEOUS
SETTINGS
2, 2.5, 3, 4, 5, 6, I\,41(8) or lM2(12) APPLICATION DETERI\,1INES
END OF CURVE
Fig. 3-3 Digitrip RMS tnstantaneous Time-Current Curve (l)
Etfective 9,'01 ElT.il

AD 33-855-4
Page 16
cUFRENT lN MULTIPLES OF PLUG RATING in
.2 3.4.5.7 1 2 s 45 7 10 2 3 5 .7 1
.2 3 .4.5 .7 1 2 3 4 5 7 10 2 3 5 7 1
oURRENT lN MULTIPLES OF PLUG RATING /n
5 7 '10
.os .07 .1
1000
700
500
400
300
200
1000
704
500
400
300
100
70
50
4A
20
'100
70
50
40
30
20
10
a;7
o
O4
o
uJ3
g
u2
tr
'1
.7
.5
.3
2
10
76o
40O
3r!g
2utr
1
.7
.5
.4
.3
.2
.1
.07
.05
.04
.03
.42
.01 .os .07 .1
Fig. 3-4a Digitrip RMS Ground Fault Protection Time-Current Curve (G)
E:T.il Fflective g/01

AD 33-855-4 Page 17
3.5 Long Time Memory Function
ln addition to the standard Long Delay Protection
Element, Digikip RMS 510, 610, 810, & 910 Trip
Units also have an unpowered Long Time Memory
function (LTM), which serves to protect load cir-
cuits from the effects of repeated overload condi-
tions. lf a Breaker is reclosed soon after a Long
Delay Trip and the current again exceeds the Long
Delay Setting (lr), the LTM automatically reduces
the time to trip to allow for the fact that the Load
Circuit temperature is already higher than normal,
due to the prior overload condition. Each time an
overload condition is repeated, the LTM causes the
Breaker to trip in a time progressively earlier than
the "Long Delay Time Settings". When the Load
Current returns to normal, the LTM begins to reset;
and after about 10 minutes it has reset fully. There-
fore the next Long Delay Trip Time will again be the
"Setting" value.
ln certain applications, it may be desirable to
disable the LTM function. The LTM function can be
disabled by first removing the Rating Plug from the
Trip Unit (Figure 3-5a), and then moving the LTM
Jumper found inside the Rating Plug cavity on the
Trip Unit (Figure 3.5b) to its "INACTIVE" connection
(Figure 3.5c). You can enable the LTM function
again at any time by moving the LTM Jumper back
to its original "ACTIVE" connection. The action of
the LTM is a factor to consider in pedorming
multiple Long Delay Time tests as described in
Section 8 of this manual.
3.6 Discriminator (High lnitial Current
Release)
When the Digiirip RMS Trip Unit is not equipped
with an adjustable instantaneous protection set-
ting, i.e.: types LS or LSG, a Discriminator Circuit
is provided. This circuit will prevent the Circuit
Breaker from being closed and latched-in on a
faulted circuit. The nonadjustable release is preset
at eleven (11)times the installed Rating Plug
ampere rating (ln).
The Discriminator is armed only for the first ten (10)
cycles following an initial Circuit Breaker closing
operation with a load current exceeding approxi-
mately 2O%o of the Circuit Breaker Frame or Sensor
Rating. Should the Load Current through the
Circuit Breaker drop to a value less than this, the
Discriminator will re-arm. Once armed, it will
remain armed until the Load Current passing
through the Circuit Breaker exceeds approximately
2jyo for 10 cycles. Any trip operation initiated by
the Discriminator will trip the Circuit Breaker
instantaneously. The Discriminator can be selected
by a switch selection on the front of
the Trip Unit.
Code a@ BA cA oA EFHK
100 25 30 35 40 50 60 75 100
200 50 60 7A ao 100 120 150 2AA
250 63 75 a8 100 125 150 188 254
300 75 90 105 120 150 140 225 300
400 100 120 140 160 200 240 300 400
600 150 180 210 240 300 360 450 600
800 200 240 280 320 400 4AA 600 800
1000 250 300 350 400 500 600 750 1000
1200 300 360 420 480 600 720 900 1200
1600 400 440 650 640 800 960 1200 1200
2000 500 600 700 800 1000 1200 1200 1200
2400 600 720 840 960 1200 1200 '1200 1200
3000 750 900 1050 1200 1200 '1200 1200 1200
3200 800 960 1120 1200 1200 1200 1200 1200
4000 1000 1200 1200 1204 1200 1200 1200 1200
5000 1200 1200 1200 1200 1200 1200 1200 1200
cRouND FAULT SETTTNGS larUeeneSlooo
L!
J
.D
J
a
?
a
o
z
-
k
t
o
l
)
I
Notes:
lD Except as noied, tolerances on cunent levels are !1oo/o of values
O For Testing Purposes Only;when using an exle.nalsingle phase
currentsource lo check low levelground lault currenl seitngs, il is
advisable to use lhe Auxiliary Power l\,4odule (APM). See IEST
PBOCEDURES in instruction leallet.
O The raiing plug is tor 50 Hz and 60 Hz applicalions-
O All tabulated values are based on the use ol a residual sensinq
scheme wth lhe same rated cufient sensor in all phase
and neutral conduclors.
O CuNes apply trom -20 C to +55 C ambienti lemperalures above 95
C cause aulomatic trip.
@ wittr zone intertoct<inq on qround iault utilized and no restraining
signal, the minimum time band @applies -
regardless of selting.
Fig. 3-4b Digitrip RMS Ground Fault Protection Time-Current Curve (G)
Etlective 9/01 ElT.il

AD 33-855-4
Page 18
9.7 Digitrip RMS Direct Trip Actuator (DTA) .
and Auxiliary Switch Kit (See Figure 3-6)
The Digitrip RMS Direct Trip Actuator (DTA) re-
ceives ln electrical trip pulse from the Trip Unit
via the Auxiliary CT Module and provides the
mechanical trip force to trip the Breaker.
The DTA is made up of a permanent magnet, a
disc held by the magnet, a rod acted on by a
spring, a means for tripping the Breakel and a
iesei Mechanism for mechanically resetting the
DTA. The magnet cannot pull and reset the disc
against the force of the spring acting on the rod,.
bit it can overcome the spring force when the disc
is in contact with the magnet pole piece.
A tripping pulse from the Trip Unit counteracts the
effect of the permanent magnet, allowing the
sorino to separate the disc from the magnet pole
piece"anO to actuate the DTA. The DTA strikes the
trip paOdte and trips the Breaker. As the Breaker
opens, the Breaker Mechanism moves the DTA
Reset Mechanism, which moves the disc to close
the air gap between it and the magnet pole piece'
The DTA is reset when the disc is held in contact
with the magnet pole piece, against the spring
force. lf the DTA does not reset properly, the DTA
will hold the Breaker in the trip free condition and
the Breaker will not be able to close'
For Powered Trip Units: Once an overcurrent has
occurred, the Trip Unit sends an electrical signal
to the DTA which will be monitored until the Trip
Unit is reset, keeping the Breaker in a trip free
condition.
RMS 810 & 910 Retrofit Kits include an Auxiliary
Switch Kit, which usually mounts on or near the
DTA. The Auxiliary Switch Kit consists of a
microswitch with mounting hardware and brackets'
The switch is used to provide the Trip Unit with
information on the Breaker status, i.e.: open or
closed. This status information is passed on
through the PowerNet network
HORIZONTAL TRIP UNIT
"LTM ACTIVE" "LTM INACTIVE"
VERTICAL TRIP UNIT
LTM JUMPER
STANDARD FROM FACTORY
"LTM ACTIVE"
"LTM INACTIVE"
(c)
(A)
@@@
o ,.--. o
@(J
@,-@
oo@
@ r-.- O
o\-,,'
@,-@
(B)
Fig. 3-5 Disabling the Long Time Memory (LTM) Function
ElT.il Efiective 9/01

AD 33-855-4 Page 19
3.8 Digitrip RMS Retrofit Rating Plug and
Battery
The Digitrip RMS Rating Plug fits into the Digitrip
RMS Trip Unit and determines the Breaker Con-
tinuous Current Rating, ln. The Rating Plug must
be matched to the installed Current Sensor ratio.
The Rating Plug can be used in 50 Hz or 60 Hz
applications. Each Rating Plug has fixed S1 (8) and
52 (10) values, which correspond to the Trip Unit's
highest two Short Delay Settings. Each Rating
Plug also has fixed Ml (8) and M2 (12) values,
which correspond to the Trip Unit's highest two
lnstantaneous Settings.
Each Rating Plug is equipped with a long life, 3.0
Volt lithium type back-up battery. This back-up
battery is not required for the basic Digitrip RMS
Overcurrent Protective Functions. lt is used to
maintain the Trip Unit mode of trip indication LEDS,
following a Breaker tripping operation, when no
120 VAC control power source (through the ATR) to
the Trip Unit is applied. A new battery will maintain
the mode of trip LED for approximately 60 hours
when no 120 VAC source is applied to the Trip
Unit. The battery is replaced from the front, without
having to remove the Rating Plug from the Trip
Unit. Replacement battery types are listed under
the Accessories, Section 2, of this Application
Guide.
SPB Rating Plugs are matched to the Breaker
Frames which are suitable. The Rating Plug At-
tachment is accomplished by use of a specific
Rating Plug screw size and length.
lf a Rating Plug is removed when the Breaker is in
the closed position, the Breaker may trip. There-
fore, the Rating Plug must be securely plugged in
and the Trip Cover put back on the Trip Unit to
assure that the Rating Plug stays in place"
Fig. 3-6 Digitrip RMS Direct Trip Actuator (DTA)
Etiective g/01 ElT.il