NATIONAL SWITCHGEAR Westinghouse DB-75 User manual

AC
-
PRO
Retrofit Kit
Retrofit Kit
Instructions
for
Westinghouse
DB
-
75
&
DB
-
100
Low
Voltage
Breaker
Instructions
for
:
Manual
Reset
Actuator
Mechanical
Reset
Actuator
Including
Instructions
for
AC
-
PRO
+
Communications
Utility Relay
Co
.
Chagrin
Falls
,
Ohio
44023
Phone
:
888
-
289
-
2864
www
.
utilityrelay
.
com
Fax
:
440
-
708
-
1177
Rev
.
2
August
,
2010
I
-
ACM
-
DB
-
7
5
Courtesy of NationalSwitchgear.com

Courtesy of NationalSwitchgear.com

LIMITED
WARRANTY
Utility
Relay
Co
.
,
Ltd
.
warrants
that
every
AC
-
PRO
and
ZERO
-
Hertz
trip
unit
and
related
retrofit
kit
components
(
herein
collectively
referred
to
as
"
product
"
)
shall
be
free
from
defects
in
material
and
workmanship
,
and
will
perform
as
described
in
Utility
Relay
Company
'
s
sales
literature
and
Instruction
Manuals
,
under
normal
use
and
service
for
a
period
of
(
2
)
two
years
from
date
of
invoice
.
EXCEPT
AS
SET
FORTH
HEREIN
,
WARRANTY
OF
MERCHANTABILITY
OR
FITNESS
FOR
A
PARTICULAR
PURPOSE
,
AND
THERE
IS
NO
OTHER
WARRANTY
,
EXPRESS
,
IMPLIED
OR
STATUTORY
,
BY
UTILITY
RELAY
CO
PRODUCT
.
IT
IS
EXPRESSLY
AGREED
THAT
THERE
IS
NO
LTD
.
WITH
REFERENCE
TO
THE
•
/
Should
any
warranty
claim
arise
within
the
warranty
period
,
contact
Utility
Relay
Co
following
:
1
.
)
Ltd
.
at
888
-
289
-
2864
and
do
the
•
t
Provide
a
complete
description
of
the
problem
with
the
trip
unit
or
retrofit
kit
component
.
Provide
the
Serial
Number
located
on
the
back
or
end
2
.
)
of
the
trip
unit
from
the
warranted
retrofit
kit
.
Obtain
a
Returned
Materials
Authorization
number
(
RMA
)
and
return
shipping
instructions
.
Promptly
return
the
defective
material
to
Utility
Relay
Company
.
3
.
)
4
.
)
Warranty
Disclaimer
and
Liability
Limitation
As
the
sole
and
exclusive
remedy
,
Utility
Relay
Co
will
repair
or
replace
the
trip
unit
and
/
or
retrofit
component
(
s
)
at
no
cost
to
the
customer
during
the
warranty
period
.
The
customer
is
liable
and
shall
pay
for
shipment
of
In
no
any
Ltd
.
•
r
defective
products
back
to
Utility
Relay
Co
event
shall
Utility
Relay
Co
special
,
incidental
or
consequential
damages
.
Ltd
.
Ltd
.
be
liable
for
*
/
•
r
Excluded
from
this
warranty
and
not
warranted
by
Utility
Relay
Company
in
any
fashion
,
either
expressed
or
implied
are
:
1
.
)
Any
product
which
has
been
disassembled
(
except
to
replace
batteries
)
,
repaired
,
tampered
with
,
altered
,
changed
,
or
modified
by
persons
other
than
Utility
Relay
Company
'
s
own
authorized
service
personnel
unless
repair
by
others
is
made
with
the
written
consent
of
Utility
Relay
Company
.
Defects
or
damage
to
the
Product
resulting
from
wear
,
tear
,
misuse
,
negligence
,
improper
storage
,
improper
testing
,
impacts
,
or
use
with
non
-
approved
accessories
.
Products
used
for
any
other
purpose
other
than
originally
intended
by
Utility
Relay
Company
.
2
.
)
3
.
)
Visit
www
.
utilityrelay
.
com
for
latest
warranty
information
.
9
/
10
/
09
Courtesy of NationalSwitchgear.com

HAZARD
WARNING
WARNING
:
Low
voltage
power
circuit
breakers
contain
stored
energy
spring
operating
mechanisms
.
For
maximum
personnel
protection
when
installing
and
testing
this retrofit
kit
,
the
following
procedures
must
be
followed
.
No
work
shall
be
performed
on an
energized
breaker
.
Only
qualified
persons
,
as
defined
by
the
National
Electric
Code
,
and
preferably
NETA
Certified
Technicians
,
who
are
familiar
with
the
operation
and
maintenance
of
low
voltage
power
circuit
breakers should
perform
the
installation
of
this retrofit kit
.
Completely
read
and understand
all
instructions
before
attempting
the
installation
and
testing
of
this
retrofit
kit
.
Personnel
are
available
at
Utility
Relay
Company
during
normal
working
hours
(
Eastern
Standard
time
)
to
answer
any
questions
.
Turn
off
and lockout the
power
source
(
s
)
supplying
the
breaker
prior
to
removing
the
breaker
and
attempting
any
work
on
the breaker
.
Follow all
lockout and
tagging
rules
of
the
National
Electric
Code and all
other
applicable
codes
,
regulations
and work
rules
.
Do
not
perform
any
work
including charging
,
closing
or
tripping
or
any
other
function
that
could
cause
significant
movement
of
a
draw
out
breaker
while it is
on
the
extension
rails
.
For
both
draw
out
and bolt
-
in
breakers
,
trip
open
and then
move
the breaker
to
a
well
-
lighted
work
area
with
a
sturdy
workbench
before
starting
the
retrofit
.
Do
not
work
on a
closed
breaker
or a
breaker
with
the
closing springs
charged
.
Trip
open
the breaker
and make
sure
any
stored
energy
springs
are
discharged
before
performing
any
work
.
If
this is
disregarded
,
the breaker
may
unexpectedly
trip
open
or
the
charging
springs
may
discharge
,
causing
severe
injuries
.
Under
some
circumstances it
may
be
necessary
to
charge
the
springs
and
close the breaker
to
make
/
verify
certain
retrofit
adjustments
.
In
those
instances
,
use
extreme
caution
to
stay
clear
of
any
moving
components
in
case
the
breaker
either
purposely
or
unexpectedly
trips
open
or
the
charging
springs discharge
.
Refer
to
the
latest
edition
of
the
ANSI
/
NETA
Standard
for
Maintenance
Testing Specifications
for
bolt
tightening
torque
specifications
.
9
/
9
/
09
Courtesy of NationalSwitchgear.com

TABLE
OF
CONTENTS
Section
PAGE
1
1.0
General
1.1
Inspection
2.0
Initial
Breaker
Tests
3.0
Remove
Series
Trip
Units
4.0
Manual
Reset
Actuator
4.1
Install
Actuator
4.2
Install
Trip
Paddle
4.3
Adjust
Actuator
4.3
.
1
Adjust
the
actuator
rod
position
relative
to
the
trip
paddle
4.3
.
2
Adjust
the
location
of
the
stop
nuts
4.4
Verify
Trip
Free
Operation
4.5
Attach
Label
A
-
021
-
1
5.0
Mechanical
Reset
Actuator
5.1
Install
Actuator
5.2
Install
Trip
Paddle
5.3
Adjust
Mechanical
Reset
Actuator
5.4
Verify
Trip
Free
Operation
5.5
Adjust
Reset
of
Mechanical
Reset
Actuator
6.0
AC
-
PRO
Installation
7.0
Install
CTs
8.0
Wiring
8.1
Color
Codes
and
Connections
8.2
Current
Transformer
Connections
8.3
Neutral
Current
Transformer
8.4
Actuator
Connection
9.0
Final
Test
10.0
Communications
10.1
Install
PT
Module
10.2
Install
Fuse
Block
for
PT
Module
10.3
Communications
Wiring
1
2
2
3
3
4
5
5
6
7
7
8
8
9
10
10
11
12
13
13
14
14
14
15
15
16
16
16
.
17
Courtesy of NationalSwitchgear.com

ILLUSTRATIONS
Figure
18
1
Front
View
19
2
Side
View
-
Trip
Unit
Installation
3
Manual
Reset
Actuator
4
Actuator
Pre
-
Assembly
,
Mechanical
Reset
...
.
5
Actuator
Assembly
,
Mechanical
Reset
6
Contact
Tie
Bar
7
TEMPLATE
:
Manual
&
Mechanical
Reset
Actuator
8
Trip
Paddle
/
Trip
Rod
Installation
9
Verify
Trip
Free
10
Mech
.
Reset
Actuator
,
Breaker
Closed
-
Actuator
Reset
...
27
11
Mech
.
Reset
Actuator
,
Breaker
Closed
-
Actuator
Tripped
.
28
12
TEMPLATE
:
Trip
Unit
Bracket
13
Wiring
Diagram
14
Front
View
,
With
Communications
.
.
15
Wiring
Diagram
with
Communications
20
21
22
23
24
25
26
29
30
31
32
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
Westinghouse
DB
-
75
/
100
1.0
General
All
possible
contingencies
,
which
may
arise
during
the
installation
,
operation
or
maintenance
,
and
all
details
and
variations
of
this
equipment
,
are
not
necessarily
covered
by
these
instructions
.
1.1
Inspection
Carefully
inspect
the
retrofit
kit
on
arrival
.
If
any
damage
is
found
,
file
a
claim
with
the
carrier
and
contact
Utility
Relay
Co
.
for
replacement
parts
.
Verify
that
this
is
the
correct
kit
for
the
circuit
breaker
being
retrofitted
.
Check
the
contents
of
the
retrofit
kit
package
against
the
kit
bill
of
material
to
make
sure
that
all
the
required
parts
are
included
.
Thoroughly
read
and
understand
these
installation
instructions
as
well
as
the
AC
-
PRO
trip
unit
instruction
manual
before
proceeding
with
the
retrofit
.
Page
1
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
2.0
Initial
Breaker
Tests
Before
starting
the
retrofit
,
perform
a
visual
/
mechanical
inspection
and
an
electrical
test
of
the
breaker
to
determine
its
condition
.
Refer
to
the
breaker
manufacturer
'
s
instruction
manual
and
accepted
test
standards
such
as
the
NETA
Maintenance
Specifications
or
PEARL
reconditioning
standards
to
verify
that
the
breaker
is
in
acceptable
mechanical
and
electrical
operating
condition
.
As
a
minimum
,
perform
the
following
:
a
)
Close
and
trip
operation
of
the
breaker
.
Measure
contact
resistance
of
each
pole
.
Measure
insulation
resistance
from
pole
to
pole
,
from
pole
to
frame
and
across
open
contacts
.
Check
contact
compression
.
Check
for
sufficient
finger
cluster
spring
tension
at
the
rear
stabs
.
b
)
c
)
d
)
e
)
Rectify
any
abnormalities
found
.
Clean
and
lubricate
the
breaker
as
required
.
3.0
Remove
Series
Trip
Units
On
each
pole
,
remove
the
existing
series
trip
unit
as
follows
:
1
)
Remove
two
(
2
)
3
/
8
-
16
X
3
/
4
H
.
C
.
screws
from
the
top
of
the
series
trip
unit
.
2
)
Remove
two
3
/
8
-
16
X
1
1
/
2
H
.
C
.
screws
from
the
bottom
of
the
series
trip
unit
.
3
)
After
the
screws
are
removed
,
mechanism
will
slip
out
.
the
series
trip
unit
Page
2
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
4.0
Manual
Reset
Actuator
Skip
this
Section
and
go
to
Section
5
if
the
mechanical
reset
actuator
will
be
installed
.
4.1
Install
Actuator
Refer
to
Figures
1
&
3
for the
following
:
1
)
Replace
the
existing
actuator
rod with
the
6
"
actuator
rod
provided
.
Thread
the
stop
nuts
on
the
actuator
rod
as
shown
in
Figure
3
.
Use
caution
since
the
plunger
is
spring
loaded
.
2
)
Attach
the
actuator
to
the
BR
-
134
bracket
with
three
(
3
)
10
-
32
X
3
/
8
Phillips
screws
and lock
washers
.
On
this
breaker
design
,
front of the
breaker
and
will
pull
the
trip
paddle
forward
.
the
actuator
fires
towards the
3
)
Using Figure
7
as
a
guide
,
drill
and
tap
two
(
2
)
1
/
4
-
20
holes
in
the
locations
marked
for the
manual
reset
actuator
.
4
)
Attach
the
actuator
/
bracket
assembly
to
the
breaker frame
using
two
(
2
)
1
/
4
-
20
X
1
/
2
H
.
C
.
screws
and
lock washers
in
the
previously
tapped
holes
.
5
)
Install
the
reset
knob
on
the end
of
the
actuator
rod
that
previously
had
the
rubber
tip
and
lock
in
place
with
a
1
/
4
-
20
jam
nut
and
lock washer
as
shown
in
Figure
3
.
The
rubber
tip
can
be
discarded
.
6
)
Attach
the
"
PUSH TO
RESET
"
sticker
on
the
actuator
knob
.
Page
3
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
4.2
Install
Trip
Paddle
l
)
Loosely
install
the
BR
-
287
trip
paddle
as
shown
in
Figure
3
using
the
BR
-
215
clamp
,
two
(
2
)
8
-
32
X
1
/
2
Phillips
screws
and
lock
washers
and
one
(
1
)
8
-
32
X
1
/
4
set
screw
.
2
)
Locate
the
trip
paddle
so
the
actuator
rod
is
centered
in
the
slot
in
the
trip
paddle
and
tighten
the
8
-
32
screws
and
set
screw
.
3
)
Thread
the
HW
-
9903
-
3
clamp
-
on
-
collar
on
the
end
of
the
actuator
rod
.
Do
not
lock
in
place
at
this
time
.
Trip
paddle
must
be
centered
on
the
actuator
rod
and
not
bind
when
rotating
.
IMPORTANT
:
With
actuator
reset
,
manually
rotate
the
trip
bar
to
the
trip
position
to
positively
verify
free
movemen
t
.
Page
4
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
4.3
Adjust
Actuator
Adjust
the
actuator
rod
position
relative
to
the
trip
paddle
.
4.3
.
1
This
adjustment
is
important
because
it
minimizes
the
time
the
actuator
rod
spends
traveling
through
air
before
it
engages
the
trip
paddle
.
See
Figure
3
for
the
following
:
Thread
the
actuator
rod
so
the
reset
knob
and
1
/
4
-
20
nut
are
up
against
the
actuator
plunger
as
shown
in
Figure
3
.
1
)
2
)
Trip
the
actuator
by
pulling
on
the
reset
knob
.
Lock
the
actuator
rod
in
position
by
tightening
the
10
-
32
set
screw
with
an
Allen
wrench
.
3
)
With
the
actuator
reset
,
adjust
the
position
of
the
HW
-
9903
-
3
clamp
-
on
-
collar
by
screwing
it
in
or
out
until
the
collar
is
about
1
/
64
"
from
the
trip
paddle
,
then
lock
the
collar
in
place
.
IMPORTANT
:
WITH
THE
BREAKER
CLOSED
AND
THE
ACTUATOR
RESET
,
THE
CLAMP
ON
COLLAR
MUST
BE
ABOUT
1
/
64
"
FROM
THE
TRIP
PADDLE
.
THE
SET
SCREW
IN
THE
PLUNGER
MUST
BE
TIGHTENED
TO
ENSURE
THAT
THE
ACTUATOR
ROD
REMAINS
IN
PROPER
ADJUSTMENT
.
Page
5
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
Adjust
the
Location
of
the
Stop
Nuts
.
4.3
.
2
l
)
Temporarily
position
the
stop
nuts
to
allow
a
very
short
actuator
rod
travel
.
2
)
With
the
breaker
open
and
the
actuator
in
the
trip
position
,
attempt
to
close
the
breaker
.
3
)
Depending
on
the
results
of
Step
2
,
do
the
following
:
a
)
If
the
breaker
closed
:
Manually
trip
the
breaker
and
turn
the
stop
nuts
away
from
the
actuator
for
additional
actuator
rod
travel
.
Go
back
to
Step
2
.
b
)
If
the
breaker
tripped
free
:
Go
to
Step
4
.
4
)
Increase
the
actuator
rod
travel
by
turning
the
stop
nuts
away
from
the
actuator
an
additional
two
(
2
)
turns
minimum
.
This
insures
that
the
actuator
rod
travel
is
at
least
0.1
"
past
the
trip
free
point
of
the
trip
paddle
.
5
)
Firmly
lock
the
stop
nuts
in
position
.
6
)
Verify
that
with
the
actuator
in
the
trip
position
.
There
is
still
some
movement
left
in
the
trip
paddle
.
This
is
important
so
that
the
force
required
to
stop
the
actuator
motion
is
absorbed
by
the
actuator
itself
and
not
by
the
breaker
trip
mechanism
.
IMPORTANT
:
THE
TRIP
PADDLE
MUST
BE
HELD
A
MINIMUM
OF
0.1
"
PAST
THE
TRIP
FREE
POINT
BY
THE
TRIPPED
ACTUATOR
.
THE
STOP
NUTS
MUST
BE
LOCKED
IN
POSITION
.
THE
TRIP
PADDLE
IS
NOT
AT
END
OF
TRAVEL
WITH
THE
ACTUATOR
IN
THE
TRIP
POSITION
.
Page
6
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
4.4
Verify Trip
Free
Operation
of
the Manual
Reset
Actuator
It
is
very
important
to
verify
that
with the
manual
reset
actuator
in
the
trip position
it
will
keep
the
breaker
trip
free
.
Attempt
to
close
the
breaker
without
resetting
the
actuator
.
The
breaker
should
trip
-
free
,
if
not
,
go
back
to
Section
4.3
.
2
.
1
)
Repeat
the
above
until
completely
satisfied
with the
operation
of the
actuator
.
2
)
WHEN THE
ACTUATOR
IS
IN THE
TRIP
POSITION
(
NOT RESET
)
,
THE
BREAKER
MUST
BE TRIP
-
FREE
.
IMPORTANT
:
THE TRIP
PADDLE
MUST
BE
HELD A
MINIMUM
OF
0.1
"
PAST
THE TRIP FREE
POINT
BY THE
TRIPPED
ACTUATOR
.
THE
SET SCREW
IN
THE
PLUNGER
MUST
BE
TIGHTENED
TO ENSURE
THAT THE
ACTUATOR
ROD REMAINS
IN
PROPER
ADJUSTMENT
.
4.5
Attach
Label
A
-
021
-
1
Attach
the
label that
indicates
the
importance
of
resetting
the
manual
reset
actuator
to
the
breaker
escution
or
cubicle
door
in
a
conspicuous
location
.
Page
7
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
5.0
Mechanical
Reset
Skip
Section
5
if
the
manual
reset
actuator
was
installed
in
Section
4
.
5.1
Install
Actuator
Refer
to
Figures
4
thru
11
for
the
following
:
Using
Figure
7
as
a
guide
,
drill
&
tap
two
(
2
)
1
/
4
-
20
holes
in
the
left
side
of
the
mechanism
platform
.
Use
the
two
holes
marked
for
the
mechanical
reset
actuator
.
1
)
The
mechanical
reset
actuator
assembly
has
been
partially
pre
-
assembled
as
shown
in
Figure
4
.
Use
Figure
5
for
the
remainder
of
the
actuator
assembly
as
described
in
steps
2
,
3
&
4
below
.
Attach
the
BR
-
1
A
030
Reset
Lever
to
the
BR
-
1
A
029
Reset
Plate
using
(
2
)
8
-
32
X
1
/
2
Phillips
screws
and
lock
washers
.
2
)
Attach
the
BR
-
1
A
049
Trip
Lever
assembly
to
the
BR
-
1
A
025
Pivot
Mounting
Block
using
(
2
)
8
-
32
X
1
/
2
Phillips
screws
and
lock
washers
.
The
Trip
Lever
should
pivot
freely
.
3
)
Install
the
mechanical
reset
actuator
as
shown
in
Figure
8
.
Attach
the
actuator
assembly
to
the
breaker
using
(
2
)
1
/
4
-
20
x
1
/
2
hex
cap
screws
and
lock
washers
in
the
previously
tapped
holes
.
4
)
Drill
and
tap
a
10
-
32
hole
in
the
end
of
the
breaker
contact
tie
bar
.
See
Figure
6
.
5
)
Screw
the
10
-
32
x
4
-
1
/
2
"
Threaded
Rod
onto
the
HW
-
9801
Rod
End
.
Lock
in
place
using
a
hex
nut
and
lock
washer
.
6
)
Place
(
2
)
additional
hex
nuts
,
(
1
)
lock
washers
,
(
1
)
flat
washer
,
a
HW
-
9101
over
travel
spring
and
(
1
)
flat
washer
onto
the
threaded
rod
.
The
flat
washers
should
be
located
at
the
ends
of
the
spring
.
See
Figure
10
.
7
)
Place
the
threaded
rod
through
the
hole
in
the
BR
-
1
A
030
Reset
Lever
and
attach
the
rod
end
to
the
breaker
reset
bar
using
a
10
-
32
x
3
/
4
Phillips
head
cap
screw
and
lock
washer
.
8
)
Page
8
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
5.2
Install
Trip
Paddle
Refer
to
Figure
8
for
the
following
:
1
)
Loosely
attach
the
BR
-
2
A
022
trip
paddle
to
the
breaker
trip
bar
as
shown
in
Figure
8
using
the
BR
-
215
clamp
,
two
(
2
)
8
-
32
X
1
/
2
Phillips
screws
and
lock
washers
and
one
(
1
)
8
-
32
X
1
/
4
set
screw
.
Assemble
the
trip
rod
by
screwing
the
10
-
32
x
2
-
1
/
2
"
threaded
rod
onto
the
HW
-
9801
rod
end
.
Lock
in
place
using
a
hex
nut
and
lock
washer
.
2
)
3
)
Place
the
threaded
rod
of
the
trip
rod
assembly
through
the
hole
in
the
trip
paddle
.
Then
attach
the
rod
end
to
the
BR
-
1
A
049
Trip
Lever
using
a
10
-
32
X
3
/
4
Phillips
head
screw
and
lock
washer
.
Locate
the
trip
paddle
on
the
trip
bar
so
the
threaded
rod
is
centered
in
the
hole
in
the
trip
paddle
and
tighten
the
8
-
32
screws
and
set
screw
.
4
)
Place
a
flat
washer
and
two
hex
nuts
with
a
lock
washer
on
the
end
of
the
threaded
rod
behind
the
BR
-
2
A
022
trip
paddle
.
5
)
With
the
breaker
open
,
adjust
the
location
of
the
two
hex
nuts
,
flat
washer
and
lock
washer
so
that
they
push
against
the
back
of
the
trip
paddle
and
lift
the
forward
leg
of
the
BR
-
1
A
049
trip
lever
approx
.
13
/
32
"
above
the
BR
-
1
A
048
pivot
arm
.
See
Figure
8
.
Lock
the
hex
nuts
securely
together
after
making
the
adjustment
.
6
)
The
trip
paddle
must
be
centered
on
the
threaded
rod
of
the
trip
rod
assembly
and
not
bind
when
rotating
.
IMPORTANT
:
With
the
actuator
reset
,
manually
rotate
the
trip
bar
to
the
trip
position
to
positively
verify
free
movement
.
Page
9
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
5.3
Adjust
Mechanical
Reset
Actuator
See
Figure
8
for
the
following
initial
adjustment
:
1
)
With
the
breaker
open
,
and
the
actuator
reset
,
adjust
the
position
of
the
8
-
32
threaded
rod
and
foot
by
screwing
it
in
or
out
until
the
end
of
the
foot
is
about
7
/
64
"
from
the
trip
paddle
.
Temporarily
lock
in
place
using
the
hex
nut
.
The
adjustment
will
be
changed
in
Section
5.4
.
5.4
Verify
Trip
Free
Operation
of
Mechanical
Reset
Actuator
Assembly
It
is
very
important
to
verify
that
the
trip
adjustment
of
the
mechanical
reset
actuator
assembly
will
keep
the
breaker
trip
free
if
the
actuator
fails
to
reset
properly
on
breaker
opening
.
Refer
to
Figure
9
for
the
following
:
With
the
breaker
open
,
and
the
actuator
reset
,
remove
the
reset
rod
or
back
off
the
two
(
2
)
10
-
32
hex
nuts
compressing
the
over
travel
spring
.
1
)
With
the
over
travel
spring
loose
,
trip
the
actuator
using
18
volts
(
two
9
volt
batteries
in
series
.
)
(
The
Red
wire
is
"
+
"
)
.
2
)
With
the
breaker
open
and
the
actuator
in
the
trip
position
,
attempt
to
close
the
breaker
.
3
)
Depending
on
the
results
of
Step
3
,
do
the
following
:
4
)
If
the
breaker
closed
:
Manually
trip
the
breaker
and
adjust
the
location
of
the
8
-
32
threaded
rod
and
foot
towards
the
trip
paddle
.
Make
this
adjustment
where
the
8
-
32
threaded
rod
goes
into
the
hex
standoff
.
The
foot
is
locked
in
position
with
Lctite
.
Go
back
to
Step
3
.
a
)
If
the
breaker
tripped
free
:
Go
to
Step
5
.
b
)
Page
10
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
5
)
Turn
the
8
-
32
threaded
rod
and
foot
an
additional
3
turns
towards
the
trip
lever
(
away
from
the
actuator
)
.
Lock
in
place
using
the
hex
nut
and
lock
washer
.
This
insures
that
the
actuator
rod
travel
is
at
least
3
/
32
"
past
the
trip
free
point
of
the
trip
lever
.
IMPORTANT
:
WHEN
THE
ACTUATOR
IS
IN
THE
TRIP
POSITION
(
NOT
RESET
)
,
THE
BREAKER
MUST
TRIP
FREE
.
THE
TRIP
LEVER
MUST
BE
HELD
A
MINIMUM
OF
3
/
32
"
PAST
THE
TRIP
FREE
POINT
BY
THE
TRIPPED
ACTUATOR
.
5.5
Adjust
Reset
of
Mechanical
Reset
Actuator
Assembly
1
)
With
the
actuator
still
in
the
trip
position
and
the
breaker
open
,
reset
the
actuator
by
turning
the
10
-
32
hex
nuts
and
compressing
the
HW
-
9101
over
travel
spring
until
it
resets
the
actuator
.
Turn
the
10
-
32
nuts
an
extra
turn
or
two
past
the
reset
point
.
Lock
in
place
using
the
(
2
)
hex
nuts
and
lock
washer
.
The
spring
should
be
compressed
approximately
1
/
4
"
.
Close
the
breaker
and
trip
the
actuator
using
18
volts
(
two
9
-
volt
batteries
in
series
.
)
(
The
Red
wire
is
"
+
"
)
.
The
breaker
should
open
and
the
linkage
should
reset
the
actuator
.
2
)
Cycle
the
breaker
several
times
to
verify
reliable
trip
and
reset
operation
of
the
actuator
.
The
Actuator
may
not
trip
using
just
one
9
-
volt
battery
.
To
insure
that
the
actuator
will
trip
use
two
fresh
9
-
volt
batteries
in
series
.
IMPORTANT
:
Page
11
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
6.0
AC
-
PRO
Installation
The
trip
unit
mounts
on
the
mechanism
top
cover
plate
as
shown
in
Figures
1
and
2
.
1
)
Remove
the
mechanism
top
cover
plate
by
removing
the
10
-
32
screw
from
the
front
of
the
cover
.
2
)
Using
the
template
from
Figure
12
mark
the
location
of
the
two
mounting
holes
on
the
mechanism
cover
.
Drill
&
tap
two
(
2
)
8
-
32
holes
where
marked
.
3
)
Mount
the
bracket
BR
-
001
to
the
top
of
the
mechanism
cover
in
the
previously
taped
holes
using
two
(
2
)
8
-
32
X
1
/
4
Phillips
screws
and
lock
washers
as
shown
in
Figure
2
.
4
)
Attach
the
AC
-
PRO
and
BR
-
027
shield
to
the
bracket
BR
-
001
using
two
(
2
)
8
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
The
BR
-
027
shield
should
be
behind
the
BR
-
001
bracket
as
shown
in
Figure
2
.
5
)
Replace
the
mechanism
top
cover
/
trip
unit
on
the
breaker
.
Page
12
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
DB
-
75
/
100
7
.
0
Install
CTs
The
CTs
are
mounted
behind
the
finger
clusters
on
the
lower
breaker
stabs
.
1
)
On
each
of
the
six
(
6
)
lower
finger
clusters
,
remove
the
split
retainer
from
one
end
of
each
retaining
pin
,
slide
out
the
twelve
(
12
)
retaining
pins
and
remove
the
finger
clusters
.
2
)
Slide
a
CT
over
each
of
the
lower
stabs
with
the
terminals
facing
up
.
3
)
Replace
the
finger
clusters
and
retaining
pins
.
Use
the
split
retainers
provided
.
8
.
0
Wiring
Use
the
wiring
harness
provided
to
make
the
connections
to
the
CTs
and
the
actuator
.
See
Figure
13
for
the
wiring
diagram
.
The
wiring
harness
plugs
into
the
top
of
the
AC
-
PRO
.
Be
sure
to
tighten
the
two
plug
retaining
screws
after
the
wiring
is
complete
.
Shorten
the
wires
and
tubing
as
required
and
use
the
cable
ties
and
holders
provided
to
make
a
clean
installation
.
Make
sure
the
wires
will
not
be
pinched
,
cut
or
chaffed
by
any
moving
parts
or
sharp
edges
.
Page
13
Courtesy of NationalSwitchgear.com

DB
-
75
/
100
AC
-
PRO
Retrofit
8.1
Color
Codes and
Connections
The
wiring
harness
connector
color
code and connections
are
as
follows from left
to
right
:
Terminal
#
Wire
Color
Use
Red
(
R
)
Black
(
B
)
Blue
(
L
)
White
(
W
)
Yellow
(
Y
)
White
(
W
)
Brown
(
N
)
White
(
W
)
Green
(
G
)
White
(
W
)
1
Actuator
"
+
"
Actuator
Phase
"
A
"
Tap
Phase
"
A
" "
Dot
"
Phase
"
B
"
Tap
Phase
"
B
" "
Dot
Phase
"
C
"
Tap
Phase
"
C
" "
Dot
Neutral
"
Dot
"
(
4
w
&
GF
only
)
Neutral
Tap
(
4
w
&
GF
only
)
2
3
4
5
6
7
8
9
10
8.2
Current
Transformer
Connections
Each
set
of
CT
wires
in
the
wiring
harness
is
housed inside
an
individual
PVC
tube
for
added
physical
protection
and
to
simplify
the
wiring
process
.
Connect
to
the
#
10
-
32
lugs using
the
ring
tongue
terminals
provided
.
Make
sure
that
the
same
tap
is
used
on
all
three
CTs
.
8.3
Neutral
Current
Transformer
A
neutral
CT
is
only required
on
a
4
-
wire
system
with
the
ground
fault
function
on
.
On
a
3
-
wire
system
,
a
neutral
CT
is
not
required
even
if
the
ground
fault
function
is
on
.
The
neutral
CT
and
neutral
wiring
assembly
are
provided
with
the
neutral
CT
kit
.
When
wiring
to
the
neutral
CT
,
make
sure
the
same
tap
is
used
as
the
phase
CTs
.
Page
14
Courtesy of NationalSwitchgear.com