Utility Relay Company AC-PRO User manual
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
•
/
Provide
a
complete
description
of
the
problem
with
the
trip
unit
or
retrofit
kit
component
.
Provide
the
Serial
Number
located
on
the
back
of
the
2
.
)
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
defective
products
back
to
Utility
Relay
Co
event
shall
Utility
Relay
Co
special
,
incidental
or
consequential
damages
.
Ltd
.
•
/
Ltd
.
In
no
•
/
Ltd
.
be
liable
for
any
•
/
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
.
Visit
www
.
utilityrelay
.
com
for
latest
warranty
information
.
12
/
02
/
05
2
.
)
3
.
)
Courtesy of NationalSwitchgear.com
TABLE
OF
CONTENTS
Section
PAGE
1.0
General
1.1
Inspection
2.0
Initial
Breaker
Tests
3.0
Remove
Existing
Trip
Unit
4.0
CT
Installation
4
.
1
Install
CTs
5.0
Actuator
Installation
5.1
Install
Actuator
5.2
Verify
Trip
Free
Operation
5.3
Adjust
Reset
of
Actuator
6.0
AC
-
PRO
Installation
7.0
Wiring
7.1
Color
Codes
and
Connections
..
.
.
7.2
Current
Transformer
Connections
7.3
Neutral
Current
Transformer
.
.
.
.
7
.
4
Actuator
Connection
.
.
.
8.0
Final
Test
9.0
Communications
9.1
Install
PT
Module
9.2
PT
Module
Installation
9.3
Communications
Wiring
.
1
1
2
2
3
3
3
3
4
4
5
6
6
6
7
7
7
8
8
Detail
View
8
9
ILLUSTRATIONS
Figure
1
Front
View
Side
View
-
Trip
Unit
Installation
Rear
View
Actuator
Pre
-
Assembly
Actuator
Installation
10
2
11
3
CT
Installation
12
4
13
5
14
Wiring
Diagram
Front
View
with
Communications
Side
View
6
15
7
16
8
PT
Module
Installation
Wiring
Diagram
with
Communications
17
9
18
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
BBC
/
ITE
MBE
Breakers
2.0
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
AC
-
PRO
Retrofit
MBE
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
Existing
Trip
Unit
l
)
Remove
the
breaker
front
cover
plate
.
2
)
Disconnect
the
harness
from
the
existing
trip
unit
.
3
)
Remove
the
existing
trip
unit
from
the
breaker
.
Page
2
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
4.0
CT
Installation
4.1
Install
CTs
The
CTs
are
mounted
behind
the
finger
clusters
on
the
lower
breaker
stabs
.
See
Figure
3
for
the
following
:
Remove
the
three
(
3
)
5
/
16
-
18
H
.
C
.
screws
and
two
(
2
)
10
-
32
socket
head
screws
to
remove
the
finger
assemblies
and
CTs
from
the
lower
stabs
.
1
)
2
)
Slide
a
CT
over
each
of
the
lower
stabs
with
the
terminals
facing
up
.
3
)
Replace
the
finger
assemblies
using
the
previously
removed
hardware
.
5.0
Actuator
Installation
5.1
Install
Actuator
Refer
to
Figures
4
&
5
for
the
following
:
Remove
the
existing
actuator
/
reset
assembly
from
the
breaker
.
1
)
2
)
Remove
the
existing
actuator
from
the
reset
assembly
and
replace
it
with
the
new
actuator
assembly
as
shown
in
Figure
4
.
3
)
Attach
the
new
actuator
assembly
to
the
existing
reset
mechanism
with
two
(
2
)
10
-
32
X
V
2
Phillips
screws
and
lock
washers
.
Insert
the
3
/
32
x
1
/
2
spring
pin
through
the
hole
in
the
end
of
the
10
-
32
reset
rod
.
4
)
5
)
Install
the
actuator
/
reset
assembly
in
the
breaker
as
shown
in
Figure
5
.
Using
the
existing
hardware
.
Page
3
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
5.2
Verify
Trip
Free
Operation
of
the
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
.
1
)
Disconnect
the
Rod
End
from
the
Reset
Plate
by
removing
the
10
-
32
X
3
/
4
Phillips
screw
.
2
)
With
the
rod
end
loose
,
close
the
breaker
.
Trip
the
actuator
using
18
volts
(
two
9
volt
batteries
in
series
.
)
(
The
Red
wire
is
"
+
"
)
.
3
)
With
the
rod
end
loose
the
actuator
should
not
reset
.
4
)
With
the
actuator
still
tripped
,
attempt
to
close
the
breaker
it
should
trip
free
.
IMPORTANT
:
WHEN
THE
ACTUATOR
IS
IN
THE
TRIP
POSITION
(
NOT
RESET
)
,
THE
BREAKER
MUST
TRIP
FREE
.
5.3
Adjust
Reset
of
the
Actuator
Assembly
1
)
Re
-
attach
the
rod
end
to
the
reset
plate
using
the
10
-
32
X
3
/
4
Phillips
screw
and
lock
washer
.
The
existing
reset
mechanism
spring
should
be
slightly
compressed
.
If
the
spring
is
not
compressed
enough
for
proper
reset
,
the
actuator
may
be
moved
by
loosening
the
two
(
2
)
10
-
32
screws
and
adjusting
the
actuator
position
within
the
limits
of
the
slotted
mounting
holes
.
If
moving
the
actuator
is
not
enough
to
correct
the
reset
,
the
rod
end
may
be
screwed
in
or
out
on
the
threaded
rod
.
2
)
Close
the
breaker
and
trip
the
actuator
using
18
volts
(
two
9
volt
batteries
in
series
.
)
(
The
Red
is
"
+
"
)
.
The
breaker
should
open
and
the
linkage
should
reset
the
actuator
.
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
4
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
6.0
AC
-
PRO
Installation
Refer
to
Figures
1
&
2
for
the
following
:
1
)
Attach
the
BR
-
082
bracket
to
the
back
of
the
trip
unit
using
two
(
2
)
8
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
Attach
the
BR
-
083
bracket
to
the
BR
-
082
/
trip
unit
assembly
-
using
two
(
2
)
8
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
2
)
3
)
Connect
the
CA
-
2
-
201
wiring
harness
to
the
trip
unit
"
KEY
"
terminal
block
and
tighten
the
two
(
2
)
screws
.
Attach
the
trip
unit
/
bracket
assembly
to
the
breaker
using
two
(
2
)
8
-
32
X
1
/
4
male
/
female
Hex
standoffs
and
lock
washers
in
the
upper
mounting
bracket
where
the
old
trip
unit
was
attached
.
4
)
Install
one
8
-
32
X
3
/
8
male
/
female
Hex
standoff
in
the
lower
mounting
bracket
where
the
old
trip
unit
was
attached
.
5
)
6
)
Attach
the
CA
-
2
-
400
security
key
harness
to
the
BR
-
084
Face
plate
using
a
T
-
892
shroud
and
internal
tooth
lock
washer
.
7
)
Attach
the
BR
-
084
Face
plate
to
the
previously
installed
Hex
standoffs
using
three
(
3
)
8
-
32
X
3
/
8
Phillips
screws
and
lock
washers
as
shown
in
Figure
2
.
8
)
Replace
the
front
cover
after
completing
the
wiring
connections
to
the
actuator
and
CTs
in
section
7
.
Page
5
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
7.0
Wiring
Use
the
wiring
harness
provided
to
make
the
connections
to
the
existing
actuator
and
the
new
CTs
.
See
Figure
6
for
the
wiring
diagram
.
The
wiring
harness
plugs
into
the
right
side
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
.
7.1
Color
Codes
and
Connections
the
wiring
harness
connector
color
code
and
For
new
CTs
,
connections
are
as
follows
from
top
to
bottom
:
Terminal
#
Wire
Color
Use
1
Red
(
R
)
Black
(
B
)
Blue
(
L
)
White
(
W
)
Yellow
(
Y
)
White
(
W
)
Brown
(
N
)
White
(
W
)
Green
(
G
)
White
(
W
)
Actuator
"
+
"
Actuator
Phase
"
A
"
Tap
Phase
"
A
"
"
Dot
"
Phase
"
B
"
Tap
Phase
"
B
"
"
Dot
"
Phase
"
C
"
Tap
Phase
"
C
"
Neutral
"
Dot
"
(
4
W
&
GF
only
)
Neutral
Tap
(
4
W
&
GF
only
)
2
3
4
5
6
7
8
"
Dot
"
9
10
7.2
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
.
Page
6
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
7.3
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
primary
rating
is
the
same
as
the
phase
CTs
.
The
AC
-
PRO
trip
unit
provided
is
configured
to
use
the
1
amp
secondary
phase
CTs
provided
and
to
use
the
existing
2
amp
secondary
neutral
CT
.
Verify
that
the
primary
rating
of
the
existing
neutral
CT
is
the
same
as
the
phase
CT
taps
used
.
IMPORTANT
:
7.4
Actuator
Connection
Route
the
red
and
black
wires
from
the
actuator
to
the
"
ACTUATOR
"
terminal
block
on
the
trip
unit
.
Trim
the
wires
to
an
appropriate
length
.
Use
the
protective
sleeving
on
the
wires
.
Connect
the
red
actuator
wire
to
the
"
+
"
terminal
on
the
wiring
harness
trip
unit
connector
.
Similarly
,
connect
the
black
actuator
wire
to
other
actuator
terminal
on
the
trip
unit
.
8.0
Final
Test
Perform
a
final
electrical
test
of
the
breaker
as
in
Section
1
.
A
primary
injection
test
is
recommended
as
the
final
test
of
the
AC
-
PRO
retrofit
.
See
Section
11
"
TESTING
"
in
the
AC
-
PRO
instruction
manual
for
complete
details
.
Page
7
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
9.0
Communications
The
following
instructions
are
for
the
communications
option
using
the
AC
-
PRO
+
:
9.1
Install
PT
Module
The
PT
Module
mounts
on
the
upper
left
of
the
breaker
as
shown
in
Figures
7
and
8
.
1
)
Attach
the
BR
-
047
to
the
PT
Module
using
two
(
2
)
8
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
2
)
Attach
bracket
BR
-
713
shield
to
the
PT
Module
using
two
(
2
)
8
-
32
X
3
/
8
nylon
R
.
H
.
screws
and
lock
washers
.
Using
the
PT
Module
/
bracket
assembly
as
a
guide
,
mark
the
location
of
the
two
(
2
)
mounting
holes
.
Drill
and
tap
(
2
)
8
-
32
holes
where
marked
.
3
)
4
)
Attach
the
PT
Module
/
bracket
assembly
to
the
breaker
using
two
(
2
)
8
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
9.2
Install
Fuse
Block
for
PT
Module
l
)
Attach
the
3
-
pole
fuse
block
to
the
breaker
as
close
to
the
line
side
stabs
as
possible
.
2
)
Drill
and
tap
two
(
2
)
8
-
32
holes
using
the
fuse
block
as
a
guide
3
)
Attach
the
3
-
pole
fuse
block
to
the
breaker
using
two
(
2
)
8
-
32
X
3
/
8
Phillips
screws
,
and
lock
washers
.
Page
8
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
9.3
Communications
Wiring
Refer
to
Figure
9
for
the
following
:
1
)
Voltage
Input
Use
#
14
SIS
wire
and
the
#
10
ring
terminals
from
the
line
side
stabs
to
the
3
-
pole
fuse
block
as
shown
in
Figure
3
.
For
line
side
on
top
breaker
stabs
.
It
is
very
important
to
maintain
the
proper
phasing
.
Use
#
18
MTW
wire
from
the
3
-
pole
fuse
block
to
the
PT
Module
.
Use
vinyl
sleeving
to
protect
the
wires
.
2
)
Ground
Input
Connect
a
#
18
MTW
wire
from
the
"
Ground
"
terminal
of
the
PT
Module
to
the
breaker
frame
.
3
)
PT
Module
Harness
Plug
the
PT
Module
cable
into
the
left
side
of
the
AC
-
PRO
+
trip
unit
and
the
PT
Module
.
Use
cable
ties
and
holders
to
make
a
clean
installation
.
4
)
Breaker
Position
Indication
As
an
option
,
connect
an
unused
"
a
"
contact
in
the
breaker
auxiliary
contacts
to
the
two
position
input
terminals
on
the
PT
Module
.
This
will
provide
the
breaker
open
or
closed
information
to
the
communications
system
.
Page
9
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
BR
—
083
Bracket
(
2
)
8
-
32
X
3
/
8
Phillips
screw
Sc
LW
BR
—
082
Bracket
(
2
)
8
-
32
X
3
/
8
Phillips
screw
Sc
LW
®
©
m
m
+
(
2
)
8
-
32
X
1
/
4
Male
/
Female
Hex
standoff
Sc
LW
ACTUATOR
CO
HD
PHASE
•
mi
A
°
>
©
HD
PHASE
*
HD
B
(
2
)
8
-
32
X
3
/
8
Phillips
screw
&
LW
HD
PHASE
*
CO
c
HD
NEUTRAL
HD
BR
—
084
Face
plate
C
n
.
t
—
•
M
•
$
7
s
5
n
>
>
U
O
O
<
n
>
Breaker
Front
o
O
3
o
go
53
B
Trip
Unit
§
9
)
©
fe
§
s
3
?
'
o
$
°
m
(
1
)
T
—
892
Shroud
&
LW
®
Connect
to
2
—
pole
’’
KEY
”
connector
on
trip
unit
.
CA
-
2
-
400
Security
key
harness
(
1
)
8
-
32
X
3
/
8
Male
/
Female
Hex
standoff
Sc
LW
(
1
)
8
-
32
X
3
/
8
Phillips
screw
Sc
LW
FIGURE
2
Right
Side
View
Trip
Unit
Installation
Page
11
Courtesy of NationalSwitchgear.com
AC
-
PRO
Retrofit
MBE
#
10
,
#
14
AWG
lug
Replace
exiting
hardware
with
10
-
32
X
5
/
8
Phillips
screw
Sc
LW
#
14
AWG
SIS
wire
to
3
—
pole
fuse
block
For
PT
Module
included
with
the
communications
option
.
o
o
mr
BD
BE
Bd
BD
ooo
ooo
@
@
New
Current
Transformer
Existing
Current
Transformers
Rear
View
of
Breaker
Shown
less
finger
clusters
Shown
with
top
stabs
as
line
side
of
breaker
FIGURE
3
Rear
View
CT
Installation
Page
12
Courtesy of NationalSwitchgear.com
MBE
AC
-
PRO
Retrofit
i
Existing
5
/
16
-
18
HC
IMPORTANT
:
With
the
actuator
in
the
trip
position
,
the
breaker
must
be
’’
Trip
Free
”
(
can
not
be
closed
)
.
r
/
//
/
/
/
//
Z
/
S
/
/
//
/
/
/
T
ri
I
o
Existing
Reset
Assembly
Existing
Reset
Mechanism
Overtravel
Spring
Existing
Snap
Ring
for
Reset
Linkage
3
it
I
H I
y
A
-
300
C
-
MBE
Actuator
Assembly
(
2
)
10
-
32
X
1
/
2
Phillips
&
LW
Loosen
10
—
32
screws
and
adjust
actuator
position
within
limits
of
slots
for
positive
reset
n
JO
Rod
End
Position
may
be
adjusted
for
Positive
Reset
if
required
2
/
Reset
Plate
I
Existing
trip
paddle
o
Some
Parts
Removed
for
Clarity
FIGURE
5
Actuator
Installation
Page
14
Courtesy of NationalSwitchgear.com
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