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