Rockwell Automation Allen-Bradley 140U User manual

1
40752-195 (1) Effective 2/2011
Installation Instructions for Bul. 140UN-Frame Circuit Breakers and Molded
Case Switches
DO NOT ATTEMPT TO INSTALL OR PERFORM MAIN-
TENANCE ON EQUIPMENT WHILE IT IS ENERGIZED.
DEATH, SEVERE PERSONAL INJURY, OR SUBSTAN-
TIAL PROPERTY DAMAGE CAN RESULT FROM
CONTACT WITH ENERGIZED EQUIPMENT. ALWAYS
VERIFY THAT NO VOLTAGE IS PRESENT BEFORE
PROCEEDING WITH THE TASK, AND ALWAYS FOL-
LOW GENERALLY ACCEPTED SAFETY PROCE-
DURES.
ALLEN-BRADLEY IS NOT LIABLE FOR THE MISAPPLI-
CATION OR MISINSTALLATION OF ITS PRODUCTS.
The user is cautioned to observe all recommendations,
warnings and cautions relating to the safety of personnel
and equipment as well as general and local health and
safety laws, codes and procedures.
The recommendations and information contained herein
are based on Rockwell experience and judgement, but
should not be considered to be all-inclusive or covering
every application or circumstance which may arise. If any
questions arise, contact Rockwell for further information
or instructions.
1. INTRODUCTION
The N-Frame Circuit Breaker (Figure 1-1) are 690VAC
maximum rated devices, 600V for UL applications, and
have integral trip units. Available current ratings are up
to 1600 Amp, 1200 for UL applications. I N-Frame Circuit
Breakers and molded case switches are listed in ac-
cordance with Underwriters Laboratories, Inc. Standard
UL-489 and satisfy the requirements of the International
Electrotechnical Commission Recommendations No. IEC
60947-2.
The Trip Units are AC only devices that employ
microprocessor based technology that provides true
RMS current sensing means for proper correlation
with thermal characteristics of conductors and equipment.
The primary function of the Trip Unit is circuit protection.
This is achieved by analyzing the secondary current
signal received from the circuit breaker current sensors and
initiating trip signals to the circuit breaker shunt trip when
pre-set current levels and time delay setting are exceeded.
Low level ground fault protection with an adjustable time
delay is supplied when appropriate trip types are selected.
In open air at 40º C, a N-Frame Circuit Breaker with a
Trip Unit will carry continuously up to 1200 amperes without
exceeding a 50º C rise at the terminals. The calibration
of the trip unit is insensitive to ambient temperatures over
a range of -20º to +55º C. However, the trip unit contains
thermal temperature protective circuitry that initiates a trip
operation for self-protection if the internal ambient tem-
perature at the printed circuit board (PCB) reaches approxi-
mately 90º C. For ambient conditions above 40º C, derat-
ing of the circuit breaker should be considered to avoid
exceeding a safe terminal temperature operation range.
Consult Allen-Bradley for recommendations.
Figure 1-1 N-Frame Circuit Breaker
Bul. 140U

2
40752-195 (1) Effective 2/2011
Molded Case Switches: The Molded Case Switch (MCS)
is similiar to the Circuit Breaker except that it has a differ-
trip at 15,000 Ampere but there is no overload short delay
or ground fault trip. As a result sections 2.6, 4.5, 6.8 and
7 are not applicable. In the remaining sections the term
circuit breaker shall also include the molded case switch.
Overload Trip: In accordance with standards require-
ments, the trip unit initiates a trip of the circuit breaker
within two hours of an overload of 135 percent, and a trip in
less time for higher overloads.
A “Thermal Memory” effect prevents the breaker from being
reenergized immediately after an overload. A “cooling off”
period of up to 5 minutes is required, which allows time for
the cabling to cool off.
Short delay/Instantaneous Trip: For short circuit con-
ditions that exceed the short delay pick-up settings, the
trip units initiate a trip after a delay prescribed by the I²t
response time delay action is provided by trip unts desig-
nated LSI and LSIG unless the instantaneous (I) setting is
selected.
Table 1.1: Trip Unit Types
Trip Unit Functions Digitrip RMS 310+ Trip Unit
LS LSI LSG LSIG MCS
Long Time Adjustable Ampere Rating
with Adjustable Long Delay • • • •
Short Time Adjustable Short Time Pick-up • •
with Short Time Delay l²t Ramp
Adjustable Short Time Delay  • •
with Adjustable short Time Pick-up
Instantaneous Fixed Instantaneous (Override) • • • • •
Ground Fault Adjustable Ground Fault Pick-up ••
Adjustable Ground Fault Time • ③ •
Using Trip unit with adjustable delay (LSI, LSIG), instantaneous pick-up is achieved when the lowest
time delay setting (l) is selected for non-IMM trip units.
Override setting fixed at frame withstand rating.
③I2t response.

3 40752-195 (1) Eective 2/2011
Ground Fault Protection: when selected, ground fault
pick-up and time delay settings shown in Table 1.2 allow
selective ground fault coordination with other circuit protec-
tion devices.
Ground Fault Alarm: A ground fault alarm relay may be
ordered that provides a contact closure when a ground fault
trip occurs.
DC Application: N-Frame trip units are suitable for AC ap-
plication only.
Field Testing: -
ing of the trip unit when connected to test kit.
Table 1.2: Trip Unit Function and Rating Sensing
Internal Accessories: Internal accessories mount in the
breaker. A list of internal accessories and their instruction
Auxiliary Alarm
Alarm (Signal)/Lockout (ASL) Switch 40752-094
Auxiliary Switch 40752-097
Shunt Trip 40752-095
Low Energy Shunt Trip
Undervoltage Release Mechanism
(Handle Reset) 40752-096
Note: Shunt trip and undervoltage accessories, if re-
quired, must be mounted in the left pole.
Note: Trip unit versions with ground
fault protection are supplied with an auxiliary switch,
mounted in the right pole of the trip unit.
Trip Function Range/Setting Description ②
Ampere Rating Adjustable Trip Unit Ampere Rating (IR)
with IR Switch
1250 Amp ③
1200 Amp
800 Amp
Short Delay Pick-Up (Adjustable) In Multiples of amperes (In) with marks at 2-3-4-5-6-7-8-9x
Short Delay Time (Adjustable) I²t ramp configuration
Short Delay Time (Adjustable) Flat response with time delay settings at Instantaneous, 120ms and 300ms.
Trip Unit Ampere Rating Trip Unit Setting
Ground Fault 1200 Amp
Pick-Up 800 Amp
(Adjustable)
Ground Fault Time Delay Flat Response with time settings of: Inst, 120ms and 300ms
①
Occurs with short delay time adjustment set at 1.
②The Molded Case Switch has a fixed instantaneous setting.
③Not UL Listed
①

4
40752-195 (1) Effective 2/2011
This instruction leaet gives procedures for installation
and eld testing of N-frame circuit breakers and describes
the different trip unit characteristics. For this publication,
the term circuit breaker shall also include the molded case
switch.
2. INSTALLATION
The installation procedure consists of inspecting the circuit
breaker, installing the accessories and terminals and, if
required, mounting the circuit breaker, connecting the line
and load conductors and accessory wiring, and adjusting
trip settings. Circuit breakers, accessories, and terminals.
may be supplied in separate packages. To install the circuit
breaker, perform the following steps:
2.1 Inspection
Make sure the circuit breaker is suitable for the intended
installation by comparing nameplate date with existing
equipment ratings and system requirements. Inspect the
circuit breaker for completeness and check for damage
before mounting.
2.2 Accessory Installation
Note: If required, internal accessory installation in
any type of circuit breaker should be done before the
circuit breaker is mounted and connected. Refer to the
individual accessory instruction leaets listed above.
Terminals are not included.
Terminals must be purchased separately.
For bus connections use:
M12 - 1.75 bolts for Metric Style front mounted bus
connections, socket cap screws are recommended.
Torque Table (Domestic)
Figure 2-2 Conductor Extensions (Purchased Separately)
Figure 2-1 Terminal Installation
Terminal Cat.
No.
Wire Size
MCM
Cond.
Mat'l
Torq.
Lb.-in.
Torq.
Nm.vv
140U-N-TLA2 #1-500 (2) CU/AL 375 42.4
140U-N-TLA3 3/0-400 (3) CU/AL 375 42.4
140U-N-TLA4 4/0-500 (4) CU/AL 375 42.4
140U-N-TLA3
A
500-750 (3) CU/AL 450 50.9
140U-N-TLC2 2/0-500 (2) CU ONLY 300 33.9
140U-N-TLC3 3/0-5-- (3) CU ONLY 300 33.9
140U-N-TL4 3/0-400 (4) CU ONLY 275 31.1

5 40752-195 (1)
Figure 2-5 Breaker Mounting bolt Drilling Plan
0.312-18
(M8-1.25) Tap
4-Places C
LCircuit
Breaker
C
LCircuit
Breaker
0.312-18
(M8-1.25) Tap
6-Places
Load End
C
LHandle
1.375
(34.92) 2.750
(69.85)
2.750
(69.85)
2.750
(69.85)
2- AND 3-POLE 4-POLE
8.625
(219.65)
14.750
(374.65)
6.125
(155.57)
Dimensions
in Inches
(Millimeters)
Figure 2-6 Circuit Breaker Escutcheon Dimensions
CIRCUIT BREAKER COVER CONSTRAINTS MOVING
PARTS. DO NOT OPERATE THE BREAKER WITHOUT
THE COVER INSTALLED.
CAUTION
C Handle
L
3.438
(87.31)
C
LBreaker
2.50 R
(6.35 R)
1.718
(43.64)
1.906
(48.41)
5.587
(141.91)
1.500
(38.10)
3.187
(80.95) 6.375
(161.92)
.188 R
(4.76 R)
FRONT COVER CUTOUT
2.3 Terminal Installation
1200A Front Connect
If not already installed, mount terminals.
The terminal cover screws must first be loosened
Figure 2-9 Securement of Cable (See caution note for bracing
instruction)
and the terminal covers removed.

6
40752-195 (1) 2/2011
VOLTAGE IN ENERGIZED EQUIPMENT CAN CAUSE
DEATH OR SEVERE PERSONAL INJURY. BEFORE
MOUNTING THE CIRCUIT BREAKER IN AN ELECTRI-
CAL SYSTEM MAKE SURE THERE IS NO VOLTAGE
PRESENT WHERE WORK IS PERFORMED. SPECIAL
ATTENTION SHOULD BE PAID TO REVERSE FEED AP-
PLICATIONS TO ENSURE NO VOLTAGE IS PRESENT.
To mount the circuit breaker, perform the following steps:
1200A Front Connect Circuit
Breakers
a. For individual surface mounting, drill mounting panel
using the drilling plan shown in Figure 2-5. For dead front
cover applications, cut out cover to correct escutcheon
dimensions, see Figure 2-6.
internal accessories, make sure the accessory wiring can
be reached when the circuit breaker is mounted.
Note: Labels with accessory connection schematic
diagrams are provided on the side of the circuit break-
er. A note should be made of the diagrams if the labels
cannot be seen when the circuit breaker is mounted.
c. Position the circuit breaker on the mounting surface.
d. Secure the circuit breaker with the supplied hardware
CAUTION
OVERHEATING CAN CAUSE NUISANCE TRIPPING
AND DAMAGE TO THE CIRCUIT BREAKER. WHEN
ALUMINUM CONDUCTORS ARE USED, THE APPLICA-
TION OF A SUITABLE JOINT COMPOUND IS RECOM-
MENDED TO REDUCE THE POSSIBILITY OF TERMI-
NAL OVERHEATING.
Connect line and load conductors and accessory leads. If
the circuit breaker includes ground fault protection, connect
the neutral current sensor and ground fault alarm unit as
.
HAZARDOUS VOLTAGE CONDITIONS CAN CAUSE
DEATH OR SEVERE PERSONAL INJURY. MAINTAIN
ORIGINAL ELECTRICAL CLEARANCE AND CREEPAGE
SPACINGS AT TERMINATIONS .
After the circuit breaker is installed and all connections are
made, check all mounting hardware and terminal connec-
tion hardware for torque loading. Torque values for line/
load terminal lugs are given on table in Figure 2-1. Torque
mounting screws to 30-35 lb-ft. (41-47 Nm).
Re-install load end and line end covers and secure with
pan head screws provided. Torque large screws to 35-45
lb.-in. (4.0-5.0 Nm) and small screws to 24-30 lb-in. (2.7-3.4
Nm). When using the terminals TA700NB1 or T700NB1,
or when prospective fault currents of cabled installations
exceed 65kA, (such as NDC applications), the conductors
are to be braced in accordance with Figure 2-9.
CAUTION
CAUTION
UNSUPPORTED CABLES CAN CAUSE MINOR PER-
SONAL INJURY OR EQUIPMENT DAMAGE UNDER
SHORT CIRCUIT CONDITIONS.
Wrap conductor cables with 3/8” nylon or equivalent
rope as shown in Figure 2-9, having a minimum tensile
strength of 2000 lbs., at 6” from terminals and every ad-
ditional 6” with 5 wraps or every additional 1” with 1 wrap.
2.6. Adjusting Trip Settings
The N-frame circuit breakers have the trip unit built in as
an integral part of the breaker. The trip unit is not field
replaceable. The various trip unit settings are described
in section 4. They should be adjusted as required
at this point.
2.4 Mounting
2.5 Connecting Line and Load Conductors

7 40752-195 (1) Effective 2/2011
3. OPERATION
3.1 Manual Operation
Manual operation of the circuit breaker is controlled by the
circuit breaker handle and the Push-to-Trip button. The
circuit breaker handle has three positions, two of which
are shown on the cover raised lettering to indicate ON and
OFF. On the handle, ON, OFF, and TRIP are also shown
by a color-coded strip for each circuit breaker handle posi-
tion: red for ON, white for TRIP, and green for OFF (See
Figure 3-1). The Push-to-Trip button checks the circuit
breaker tripping function and may be used to periodically
exercise the operating mechanism.
Figure 3-1 Circuit Breaker Manual Controls
16.000
OVER ALL LENGTH
8.625
14.750
OF MTG HOLES
3.819
1.375
2.490
2.750
4.125
7.000
2.799
8.250
9.250
11.500
OF TERMIALS
REMOVABLE
TERMINAL
COVER
4X Ø.344 MTG HOLES
Ø.703 CBORE X .453 DP
.359 DP FROM BOTTOM
HANDLE
REMOVABLE
TERMINAL
COVER
3.2 Circuit Breaker Reset
After an automatic or accessory initiated trip, or a manual
Push-to-Trip operation, the circuit breaker is reset by mov-
ing the circuit breaker handle to the extreme OFF position.
CAUTION
LACK OF ILLUMINATION OF THE STATUS LIGHT DOES
NOT INDICATE THE TERMINALS OF THE BREAKER
ARE DEENERGIZED.

8
40752-195 (1) Effective 2/2011
4-1 . Test Port - a test port is built into each
trip unit to allow use of a functional test kit.
The test kit performs a test of the Long Delay,
Short Delay, and Ground Fault functions.
4-2 . Test LED - to be used with a no trip
functional test. This LED is a dual function
light. As previously stated, the LED is used
as a no trip indicator when using the test port.
In normal modes, this LED indicates a high
load alarm. It will light if the continuous cur-
rent is 95% of the setting and must be present
for a 38 second duration.
4-3 . IR - Continuous Current Setting. In
accordance with standards requirements, the
trip unit initiates a trip of the circuit breaker
within 2 hours for an overload of 135% and
will trip as a function of 12 t for higher cur-
rents. Continuous Current Values for each
lettered setting are indicated by the chart on
the right side of the trip unit.
4-4 . tR - The number of seconds required to
trip @ 6x. For example, IR - 800A, - 2 sec
load current - 4800A (6x). The breaker will
trip in 2 seconds.
NOTE: The last two time settings vary
according to the frame as follows: 1200A -
20,24, 1250A\800A - 14,14, 1600A - 20,20.
NOTE: There is a thermal memory capacitor
that will affect the LDT time. If the breaker
has tripped on LD, this capacitor must be
discharged or it will self discharge after ve
minutes. If neither one of these choices has
been done, the LD trip time will be shorter.
4-5 . Isd - Setting in multiples of IR. For
short circuit conditions that exceed the short
delay pick-up setting, the trip unit initiates a
trip after a predetermined delay.
4-6 . The - Ig (xIn) switch is the ground fault
pick-up switch and is used on the LSIG &
LSG styles to set the ground fault pick-up as a
percentage of I (Frame current). For example,
a 1200A frame with an Ig (xIn) setting of 0.4
will provide a ground fault pick-up at 480A.
4-7 . For the LSI style, the Short Delay time is
a at response determined by the tsd/tg switch
setting of INST, 120ms or 300ms. For the LS
style, the short delay time is an 12t function.
Push to Trip
6646 C06 H01
STATUS
TEST / ALARM
6646 C05 H10
E
G
F
H
A
B
D
C
I
R6
8
7
2
3
5
4
9
I
sd (xI R
)
SHORT
9
12
20
15
24
2
4
10
7
t
R
(s)
LONG
B
C
D
E
F
G
H
I
J
A
STATUS
TEST / ALARM
6646 C05 H07
E
G
F
H
A
B
D
C
I
R120
300Inst.
t
sd (ms)
SHORT
6
8
7
2
3
5
4
9
I
sd (xI
R
)
SHORT
9
12
20
15
24
2
4
10
7
tR
(s)
LONG
B
C
D
E
F
G
H
I
J
A
Push to Trip
6646 C06 H01
Push to Trip
6646 C06 H01
STATUS
TEST / ALARM
6646 C05 H04
E
G
F
H
A
B
D
C
I
R.8 1.0
.2
.3
.6
.4
I
g(xIn)
GND
120
300Inst.
t
g(ms)
GND
6
8
7
2
3
5
4
9
I
sd (xI R
)
SHORT
9
12
20
15
24
2
4
10
7
tR (s)
LONG
B
C
D
E
F
G
H
I
J
A
STATUS
TEST / ALARM
tg(ms)
tsd
(ms)
120
K
N
Q
300
L
O
R
*Inst.
J
M
P
Inst.
120
300
Settings
6646 C05 H01
E
G
F
H
A
B
D
C
IR.8 1.0
.2
.3
.6
.4
Ig(xIn)
GND
N
P
O
Q
J
K
M
L
R
tsd /tg(ms)
SHORT / GND
*
6
8
7
2
3
5
4
9
Isd (xIR)
SHORT
9
12
20
15
24
2
4
10
7
tR(s)
LONG
B
C
D
E
F
G
H
A
Push to Trip
6646 C06 H01
12
3 4 56 8
3
8A
10
11
123
10
3 4 56
11 9
123
10
3 4 5
11 7
123
10
3 4 5
11
4. TRIP UNIT ADJUSTMENTS

9 40752-195 (1) Eective 2/2011
response determined by the tsd/tg switch set-
tings of INST, 120ms or 300ms. This switch is
a dual switch that also determines
the ground fault time settings of INST, 120ms
or 300ms. As an example, if the tds/tg switch
is set at a position J, then both short delay time
-
ond example would be to set the tsd/tg switch
The LSIG label (see balloon 8A) should be
used in conjuction with the tsd/tg switch to set
any one of nine possible combinations of short
label should be applied to the right side breaker
trip unit nameplate.
4-9 . For the LSG style, the short delay time is
is set by the tg switch. For the LS style, the
short time is an I2t function.
4-10 . Status LED - A green status light indi-
cates the operational status of the trip unit. If
the load current is approximately 20% of the
maximum current rating (In) of the breaker,
the status light will blink on and off once each
second.
4-11 . Mechanical Push to Trip.
4-12 . The Maintenance Mode and adjustable
INSTantaneous features are only available on
LSI and LSIG styles. Please refer to the label-
ing to the left of the test kit connector. The
Maintenance Mode consists of the two lowest
settings of the INST switch: 2.5x and 4.0x.
For example, a 1200A (In) NG breaker with the
switch set to 2.5x would trip instantaneously
when the current exceeded 3000A.
4-13 . The adjustable INSTantaneous (Ii) Mode
has four settings from 6x to 9x. For example, a
800A (In) NG breaker with the (Ii) switch set to
7x would trip instantaneously with the current
at or above 5600A. The last setting on the (Ii)
switch can be one of three values depending
on the frame current: 800A=28, 1200A=12,
1600A=9.
4-14 . On a breakerwithout Maintenance Mode,
the lowest labeled SDT setting is labeled INS-
Taneous. The lowest SDT setting with Mainte-
nance Mode is labeled as 50ms.
14
12
STATUS
TEST / ALARM
t
g(ms)
t
sd
(ms)
120
K
N
Q
300
L
O
R
*Inst.
J
M
P
50ms
120
300
Settings
6646 C05 H01
E
G
F
H
A
B
D
C
I
R.8 1.0
.2
.3
.6
.4
I
g(xI n)
GND N
P
O
Q
J
K
M
L
R
t
sd/
t
g(ms)
SHORT / GND
*
6
8
7
2
3
5
4
9
I
sd(xI
R
)
SHORT
9
12
20
15
24
2
4
10
7
t
R
(s)
LONG
B
C
D
E
F
G
H
I
J
A
8
12
10
2.5
7
6
I
i(xI n)
INST
4
Maintenance Mode
Push to Trip
Remote MM
6646 C06 H04
STATUS
TEST / ALARM
t
g(ms)
t
sd
(ms)
120
K
N
Q
300
L
O
R
*Inst.
J
M
P
Inst.
120
300
Settings
6646 C05 H01
E
G
F
H
A
B
D
C
I
R.8 1.0
.2
.3
.6
.4
I
g(xI n)
GND N
P
O
Q
J
K
M
L
R
t
sd/
t
g(ms)
SHORT / GND
*
6
8
7
2
3
5
4
9
I
sd(xI R
)
SHORT
9
12
20
15
24
2
4
10
7
t
R
(s)
LONG
Push to Trip
4P 4d4P 3dn/2 4P 3d
6646 C06 H02
B
C
D
E
F
G
H
A
13
14

10
40752-195 (1) Effective 2/2011
4-15 . The Remote Maintenance Mode is enabled by apply-
ing 24VDC to the two wire cable that exists the left side of the
breaker. The wires are color coded as follows: Yellow=+24V
and Black=common ground. A blue colored LED on the left side
of the breaker is the Maintenance Mode section
of the trip unit.The lighted blue LED indicates that the
lowest setting of the Maintenance Mode is enabled. This setting
corresponds to 2.5x of In. Turning the adjustable switch on the
trip unit has no affect on either the Maintenance Mode or the
INST Mode settings while the blue LED is lit. In addition to the
blue colored LED, a relay contact (C, NO) is available. The wires
for this contact exit the left hand side of the breaker and are color
coded as follows: Blue=C, and Red=NO.
4-16 . The High Load Alarm Relay option will provide a SPST
contact closure when the trip unit current equals or is greater than
95% of In for a period of 38 seconds. If the current drops below
the 95% value, the contact will open. The yellow and green wires
that exit the right side of the breaker are the common (C) and nor
-
mally (NO) of this relay.
4-17 . The Ground Fault Relay option will provide a SPST con-
tact closure immediately before the breaker will trip on a ground
fault over current detect. This closure is momentary (50ms) and
the customer must provide the necessary external circuitry in or-
der to latch this signal. The yellow and green wires that exit the
right side of the breaker are the common (C) and normally (NO)
of this relay.
NOTE: Either the high Load Alarm Relay or the Ground Fault
Alarm Relay option can be selected but not both. The High
Load Alarm Relay can only be selected with LS and LSI trip unit
styles. If the trip unit is a Ground Fault style, the Alarm A Relay,
by default, will be selected.
NOTE: The contact rating of the relay is: 2A, 30 VDC
resistive load. The coil resistance is approximately
1600 ohms. (Max switching voltage: 220 VDC, Max switching
current: 2A). The coil resistance is about 1600 ohms.
+
-
NO
NC
- +
24 VOLT DC
LEFT SIDE OF BREAKER
YELLOWBLACK
BLUE
RED

11 40752-195 (1) Effective 2/2011
Figure 5-2 Connection Diagrams Ground Fault Breaker - Figure indicates normal feed installation. Neutral sensor is wired identi-
cally for reverse feed applications.
Figure 5-1 Neutral Sensor Outline
Polarity
Markings
2.188
(55.58)
2.75
(69.85)
M12-1.75 Tapped Holes
4-Places
3.12
(79.25)
1.69
(42.93)
5.80
(147.32)
4.375
(111.13)
.59
(14.98)
2.75
(69.85)
1.062
(26.97)
.50 (12.7)
White
Grey

12
40752-195 (1) Eective 2/2011
Ground fault circuit breakers detect ground fault currents
through residual sensing (they are not designed to use
source ground or zero sequence ground fault sensing
methods). If the system neutral is grounded, but no phase
to neutral loads are used, the neutral current sensor is not
necessary.
If the system neutral is grounded and phase or neutral
loads are used, then the neutral current sensor (see Figure
5-1) must be used. It should be connected to the breaker
according to Figure 5-2.
The neutral sensor has the same ratio as the breaker cur-
rent sensors.
Note: The polarity of the sensor connections is critical.
Always observe the polarity markings on the installa-
tion drawings. To insure correct ground fault equip-
National Electric Code requirements under article 230-
95(C). See section 7 for testing instructions.
6. INSPECTION AND FIELD TESTING
Inspection
Circuit breaker should be inspected periodically. This
inspection can be best done during normal equipment
maintenance periods when no voltage to the equipment
is available. The inspection should include the following
checks 6-1 through 6-8.
VOLTAGES IN ENERGIZED EQUIPMENT CAN CAUSE
SEVERE PERSONAL INJURY OR DEATH BEFORE
INSPECTING THE CIRCUIT BREAKER IN AN ELECTRI-
CAL SYSTEM. MAKE SURE THE CIRCUIT BREAKER IS
SWITCHED TO THE OFF POSITION AND THAT THERE
IS NO VOLTAGE PRESENT WHERE WORK IS TO BE
PERFORMED. SPECIAL ATTENTION SHOULD BE PAID
TO REVERSE FEED APPLICATIONS TO ENSURE NO
VOLTAGE IS PRESENT.
SOME COMMERCIAL CLEANING AGENTS WILL DAM-
AGE THE NAMEPLATES OR MOLDED PARTS. MAKE
SURE THAT CLEANING AGENTS OR SOLVENTS USED
TO CLEAN THE CIRCUIT BREAKER ARE SUITABLE
FOR THE JOB.
6.1 Remove dust, dirt, soil, grease, or moisture from the
surface of the circuit breaker using a lint-free dry cloth,
brush, or vacuum cleaner. Do not blow debris into the cir-
cuit breaker. If contamination is found, look for the source
and eliminate the problem.
6.2 Switch circuit breaker to ON and OFF several times to
be sure that the mechanical linkages are free and do not
bind. If mechanical linkages are not free, replace circuit
breaker.
6.3 With the circuit breaker in the ON position, press the
PUSH-TO-TRIP button to mechanically trip the circuit
breaker. Trip, reset, and switch circuit breaker ON several
times. If mechanism does not reset each time the circuit
breaker is tripped, replace the circuit breaker.
6.4 Check base, cover, and operation handle for cracks,
chipping, and discoloration. Circuit breakers should be
replaced if cracks or severe discoloration is found.
6.5 Check terminals and connectors for looseness or signs
of overheating. Overheating will show as discoloration,
melting, or blistering of conductor insulation, or as pitting
or melting of conductor surface due to arcing. If there is
no evidence of overheating or looseness, do not disturb or
tighten the connections. If there is evidence of overheat-
ing, terminatons should be cleaned or replaced. Before
re-energizing the circuit breaker, all terminations and cable
should be refurbished to the same condition as when origi-
nally installed.
6.6 Check circuit breaker mounting hardware, and tighten
if necessary.
6.7 Check area where circuit breaker is installed for any
Exposure to certain types of chemicals can cause deterio-
ration of electrical connections.
7. PERFORMANCE TESTING FOR GROUND FAULT
CIRCUIT BREAKERS
7.1 Code Requirements
The National Electric Code under Article 230-95-C
requires that any ground-fault protection system be
5. Ground Fault

13 40752-195 (1) Eective 2/2011
The test shall be conducted in accordance with ap-
proved instructions provided with the equipment. A
written record of this test shall be made and shall be
available to the authority having inspection jurisdic-
tion.
7.2 UL Standards Requirements
As a follow-up to the basic performance requirements
stipulated by the N.E.C. as stated above in 7.1, UL Standard
No. 1053 requires that certain minimum instructions must
accompany each ground fault protection system. These
following statements plus a copy of the test record form
breaker.
7.3 General Test Instructions
7.3.1 The interconnected system shall be evaluated in ac-
cordance with the equipment assembler’s detail instruction
7.3.2 The polarity of the neutral sensor connection (if used)
must agree with equipment assembler’s detailed instruc-
tions to avoid improper operations following apparently
correct simulated test operations. Where a question exists,
consult the specifying engineer and/or equipment assem-
bler.
7.3.3 The grounding points of the system shall be veri-
bypass the sensors. High-Voltage testers and resistance
bridges may be used.
THERE IS A HAZARD OF ELECTRICAL SHOCK OR
BURN WHENEVER WORKING IN OR AROUND ELEC-
TRICAL EQUIPMENT. ALWAYS TURN OFF POWER
SUPPLYING BREAKER BEFORE CONDUCTING TESTS.
Note: Since the ground fault circuit breakers derive
their operating power from the phase current, and not
from the neutral current, passing current through the
neutral sensor only will not properly test the ground
fault feature.
7.3.4 Using a low voltage (0-24V), high current, AC source,
apply a test current of 125% of the ground fault pick-up set-
ting through one phase of the circuit breaker, as shown in
Figure 7-1a. This should cause the breaker to trip in less
than 1 second, and if an alarm indicatior is supplied, it
should operate. Reset the breaker and the alarm indicator.
Repeat the test on the other two phases.
7.3.5 If the system is a 4-wire system with a neutral current
sensor, apply the same current as described in paragraph
7.3.4 above through one phase of the breaker, returning
through the neutral sensor, as shown in Figure 7-1b. The
breaker should not trip and the alarm indicator, if sup-
plied, should not operate. Repeat the test on the other two
phases.
7.3.6 If the system is a 3-wire system with no neutral cur-
rent sensor, apply the same current as described in para-
graph 7.3.4 above through any two phases of the breaker,
with the connections exactly shown in Figure 7-1c. the
breaker should not trip, and the alarm indicator, if supplied,
should not operate.
Repeat the test using the other two combinations of break-
er phases.
CAUTION
FIELD TESTING SHOULD BE USED FOR FUNCTIONAL
TESTING AND NOT FIELD CALIBRATION.
ANY TEMPORARY CONNECTION MADE FOR THE
PURPOSE OF CONDUCTING TESTS SHOULD BE
RESTORED TO PROPER OPERATING CONDITIONS
BEFORE RETURNING THE BREAKER TO SERVICE.
7.3.7 The results of the test are to be recorded on the test
form provided with the equipment.
are shipped with each N-Frame ground fault circuit

14
40752-195 (1) Effective 2/2011
Figure 7-1a Connections for Ground
Fault Trip Test
Figure 7-1b Connections for Ground
Fault No-Trip Test with a Four Wire
System
Figure 7-1c Connections for
Ground Fault No-Trip Test with a
Three Wire System
Source
Low
Voltage
Source
L C R N
Load Current Limiting
Resistor
(if required)
Source
Low
Voltage
Source
L C R N
Load Current Limiting
Resistor
(if required)
Source
Low
Voltage
Source
L C R
Current Limiting
Resistor
(if required)

15 40752-195 (1) Effective 2/2011
NOTES

16
40752-195 (1) Eective 2/2011
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