Utility Relay AC-PRO Retrofit Kit User manual

AC-PRO Retrofit Kit
Retrofit Kit Instructions for
Westinghouse
DS206 THROUGH DS850
Low Voltage Breaker
Including Instructions for
AC-PRO with Modbus RTU Communications
Utility Relay Co.
Chagrin Falls, Ohio 44023
Phone: [phone] Fax: [phone]
www.utilityrelay.com
I-ACM-DS December, 2014 Rev. 10
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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, IT IS EXPRESSLY AGREED THAT
THERE IS NO WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE, AND THERE IS NO OTHER WARRANTY,
EXPRESS, IMPLIED OR STATUTORY, BY UTILITY RELAY CO., LTD.
WITH REFERENCE TO THE PRODUCT.
Should any warranty claim arise within the warranty period,
contact Utility Relay Co., Ltd. at 888-289-2864 and do the
following:
1.) Provide a complete description of the problem with the
trip unit or retrofit kit component.
2.) Provide the Serial Number located on the back or end
of the trip unit from the warranted retrofit kit.
3.) Obtain a Returned Materials Authorization number (RMA)
and return shipping instructions.
4.) Promptly return the defective material to Utility
Relay Company.
Warranty Disclaimer and Liability Limitation
As the sole and exclusive remedy, Utility Relay Co., Ltd.
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., Ltd. In
no event shall Utility Relay Co., Ltd. be liable for any
special, incidental or consequential damages.
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.
2.) Defects or damage to the Product resulting from wear,
tear, misuse, negligence, improper storage, improper
testing, impacts, or use with non-approved
accessories.
3.) Products used for any other purpose other than
originally intended by Utility Relay Company.
Visit www.utilityrelay.com for latest warranty information.
9/10/09
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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
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TABLE OF CONTENTS
Section PAGE
1.0 General .............................................1
1.1 Inspection......................................1
2.0 Initial Breaker Tests ...............................2
3.0 Remove Existing Trip Unit ...........................2
4.0 AC-PRO Installation .................................3
4.1 Amptector Configuration.........................3
4.2 Digitrip & Later Configurations.................4
5.0 Program Button ......................................5
5.1 Install Program Button Harness..................5
5.2 Making/Changing Settings........................6
6.0 Install Quick Trip Display Coupler ..................7
7.0 Current Transformers ................................7
8.0 Replace Existing Actuator ...........................8
8.1 Install Actuator/Mechanical Assembly............8
8.2 Adjust Actuator/Mechanical Reset Assembly.......9
9.0 Wiring ..............................................10
9.1 Color Codes and Connections.....................10
9.2 Current Transformer Connections.................11
9.3 Neutral Current Transformer.....................11
9.3.1 Interposing Neutral CT ..................11
9.4 Actuator Connection.............................12
9.4.1 Actuator Connection, Existing Actuator ...12
9.4.2 Actuator Connection, New Actuator ........12
10.0 Final Test ..........................................13
11.0 Communications ......................................14
11.1 Install PT Module...............................14
11.2 Install Fuse Block for PT Module................14
11.3 Communications Wiring...........................15
12.0 QT-SWITCH-ENCLOSURE Installation ....................16
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ILLUSTRATIONS
Figure
1 Front View, Breaker with Amptector ....................17
2 Front View, Breaker with Digitrip .....................18
3 Side View, Trip Unit Installation, Amptector...........19
4 Side View, Trip Unit Installation, Digitip ............20
5 Top View, BR-020-1 Bracket Installation................21
6 CT Installation, With Terminals........................22
7 New Actuator Installation..............................23
8 New Actuator Assembly..................................24
9 Side View, Neutral CT Installation, Amptector..........25
10 Side View, Neutral CT Installation, Digitrip ..........26
11 Neutral Interposing CT Terminal Block Installation.....27
12 Standard Wiring Diagram................................28
13 Wiring Diagram (5:1 Interposing Neutral CT)............29
14 Side View, PT Module Installation, Amptector...........30
15 Side View, PT Module Installation, Digitrip ...........31
16 Side View, Fuse Block Installation, Amptector..........32
17 Side View, Fuse Block Installation, Digitrip...........33
18 Communications Wiring Diagram..........................34
19 TEMPLATE: QT-SWITCH-ENCLOSURE Drilling Plan............35
20 QT-SWITCH-ENCLOSURE Installation.......................36
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AC-PRO Retrofit............................................................DS206 TO 850
Page 1
Westinghouse
DS206 TO DS850 SERIES
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.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 2
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.
b) Measure contact resistance of each pole.
c) Measure insulation resistance from pole to pole, from pole
to frame and across open contacts.
d) Check contact compression.
e) Check for sufficient finger cluster spring tension at the
rear stabs.
Rectify any abnormalities found. Clean and lubricate the
breaker as required.
3.0 Remove Existing Trip Unit
1) Remove the breaker front cover by removing four (4)
screws.
2) Disconnect the existing wiring harness at the old trip
unit and remove the wiring harness.
3) Remove the Trip Unit and related items.
For breakers with Amptector trip units with the low
resistance actuator coil (approximately 40 Ohms or less)
the existing actuator can be reused.
For breakers with Digitrip trip units the actuator must be
replaced. See Section 8.0.
The existing CTs will be replaced in Section 7.0.
4) Temporarily replace the breaker front cover.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 3
4.0 AC-PRO Installation
4.1 Breakers with Amptector Trip Unit
Refer to Figures 1, 3 & 5 for the following:
1) Attach bracket BR-020-1 to the four (4) 1/4-20 threaded
inserts in the top of the breaker platform using four (4)
1/4-20 X 3/4 HCS screws, flat washers, lock washers and
four (4) HW-0402-2 spacers. The bracket should be
orientated so the 10-32 holes for the trip unit will be
behind the “window” in the breaker front cover. See
Figure 5.
2) Some breakers may have only two (2) 1/4-20 threaded
inserts. Using the BR-020-1 bracket as a guide, mark the
location of the two other holes. Drill and tap two (2)
1/4-20 holes where marked.
3) Attach bracket BR-0A023 to the back of the AC-PRO using
two (2) 8-32 X 3/8 Phillips screws and lock washers.
4) Temporarily attach the trip unit/bracket assembly to the
BR-020-1 bracket using two (2) 10-32 X 1/2 Phillips
screws, flat washers and lock washers. Make sure the trip
unit is "square" in the "window".
5) Place the BR-038 face plate on the outside of the breaker
front cover. Adjust the location of the BR-038 face plate
so the opening is lined up properly with the trip unit.
Mark the location of the four (4) mounting holes and drill
5/32 holes in the breaker front cover where marked.
6) Remove the trip unit/bracket assembly and attach the BR-
038 face plate to the inside of the breaker front cover
using four (4) 6-32 X 1/4 Phillips head screws.
7) Replace the trip unit/bracket assembly.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 4
4.2 Breakers with Digitrip Trip Unit
Refer to Figures 2, 4 & 5 for the following:
1) Loosely attach bracket BR-020-1 to the four (4) 1/4-20
threaded inserts in the top of the breaker platform using
four (4) 1/4-20 X 3/4 HCS screws, flat washers, lock
washers and four (4) HW-0402-2 spacers. The bracket should
be orientated so the “cut out” in the bracket will be
behind the “window” in the breaker front cover. See
Figure 5.
2) Some breakers may have only two (2) 1/4-20 threaded
inserts. Using the BR-020-1 bracket as a guide, mark the
location of the two other holes. Drill and tap two
(2) 1/4-20 holes where marked.
3) Attach the BR-0A023 bracket to the back of the AC-PRO
using two (2) 8-32 X 3/8 Phillips screws and lock washers
leave the hardware loose enough to allow for adjustment.
4) Loosely attach the trip unit and bracket assembly from
step #3 onto the BR-020-1 bracket using two (2)
10-32 X 1/2 Phillips screws, flat washers and lock
washers.
5) Adjust the position of the BR-020-1 so the trip unit is
snug to the front cover of the breaker and tighten the
mounting hardware.
6) Adjust the position of the trip unit so it is aligned with
the opening in the cover then tighten the mounting screws.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 5
5.0 Program Button
An optional program button can be used to modify the trip unit
settings instead of using the security key.
5.1 Install Program Button Harness
Refer to Figures 1 and 3 for breakers with Amptector trip units
or Figures 2 and 4 for breakers with Digitrip trip units for
the following:
1) Temporarily remove the 1/4-32 hex nut and internal tooth
lock washer from the push button on the CA-2-403 program
button harness.
2) Plug the harness connector into the “KEY” on the trip
unit.
3) Using the harness as a guide, find a suitable location for
the push button on the front of the breaker and mark for
the mounting hole.
Verify the harness can be routed to the mounting location
without pinching or cutting the wires.
4) Drill a 1/4" hole in the previously marked location.
5) Install the push button in the 1/4" hole using the 1/4-32
hex nut and internal tooth lock washer removed in Step 1.
6) Place the L-0032 “PROGRAM BUTTON” label on the front of
the breaker below the button.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 6
5.2 Making/Changing Settings
The CA-2-403 program button harness can be used instead of the
jumper wire used as the “KEY”.
To make the initial settings or to change the settings, use the
following procedures.
1) Push and hold the “PROGRAM BUTTON” push button.
2) Push the “REVIEW” button
3) Push the “SAVE” button two times.
4) Release the “PROGRAM BUTTON” push button.
5) Make any necessary changes using the “UP” or “DOWN”
buttons. Use the “SAVE” push button to move to each new
setting.
IMPORTANT: The CT rating entered in the trip unit MUST
match the actual CT taps used on the breaker.
Remember that the CT rating has an additional security feature
as explained in Section 7.3 of the AC-PRO instruction manual.
6) After making all necessary changes, press the “SAVE” push
button until the display reads “SECURITY KEY OFF”.
7) Press and release the “PROGRAM BUTTON” push button to save
the settings.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 7
6.0 Install Quick Trip Display Coupler
Refer to Figures 1 and 3 for breakers with Amptector trip units
or Figures 2 and 4 for breakers with Digitrip trip units for
the following:
1) Plug the CA-3-18 harness connector into the “QT DISPLAY”
on the trip unit and the back of the CA-3-CM Quick Trip
Display Coupler.
2) Using the harness as a guide, find a suitable location for
the CA-3-CM Quick Trip Display Coupler on the front of the
breaker and mark for the mounting hole.
Verify the harness can be routed to the mounting location
without pinching or cutting the wires.
3) Drill a 1-1/16" hole in the previously marked location.
4) Unplug the CA-3-18 harness and install the CA-3-CM Quick
Trip Display Coupler in the previously drilled hole.
5) Plug the free end of the CA-3-18 harness connector into
the CA-3-CM Quick Trip Display Coupler.
6) Place the L-0238 “Quick Trip Display” label on the front
of the breaker below the connector.
IMPORTANT: Before drilling the 1-1/16” hole, verify the
location of the Quick Trip Display Coupler will
not interfere with the optional
5
:1A interposing
CT or the PT module fuse block, if they are to
be installed.
7.0 Current Transformers
Refer to Figure 6 for the following:
1) Remove the three (3) lower finger clusters and the
existing CTs.
2) Slide the three (3) new CTs on the lower stabs with the
terminals pointing down.
3) Replace the finger clusters.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 8
8.0 Replace Existing Actuator
Skip to Section 9.0 if the existing actuator will be reused.
8.1 Install Actuator/Mechanical Reset Assembly
Actuator Assembly A-100B-DS has been pre-assembled. See Figures
7 & 8 for the following:
1) Remove the breaker front cover.
2) Remove the Bell Alarm assembly if it is on the breaker.
3) Remove the Under Voltage assembly to allow access to the
back of the actuator assembly.
4) Carefully remove and keep the trip shaft spring (anchored
to the actuator assembly). An extra spring has been
provided in case the existing spring is damaged.
5) Remove the existing actuator assembly from the breaker.
6) Carefully fit the new actuator assembly into place, making
sure the reset lever is in the correct position. Attach
the actuator assembly to the frame of the breaker using
three (3) 1/4-20 x 3/4 hex cap screws and lock washers
using holes used by the original actuator.
7) Align the actuator assembly on the breaker and tighten all
the mounting hardware.
8) Reinstall the spring saved from step 4 for the breaker’s
trip shaft.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 9
8.2 Adjust Actuator/Mechanical Reset Assembly
1) The breaker trip arm should be along side the actuator
threaded rod. The rod should not interfere with the trip
arm movement. The trip arm should move freely. It may be
necessary to bend the trip arm.
2) Close the breaker. Turn the trip adjustment screw in until
the breaker trips, then back the screw off 3-1/2 turns.
3) Next check to insure that the breaker will trip free. To
do this mark the current position of the set screw collar
HW-9607. Then loosen and unscrew it until the Reset Lever
is loose on the breaker reset pin. Close the breaker and
trip the actuator using a 9 Volt battery (Red is “+”). The
breaker should open and the actuator should not reset.
Next try to close the breaker. It should trip free and not
close.
4) With the breaker open, screw the collar back to its
original position. Check that the set screw collar is
adjusted so the reset lever has enough preload that it
will provide a reliable reset. Adjust the location of the
set screw collar if necessary and lock in position.
5) Close the breaker and trip the actuator using a 9 Volt
battery (Red is “+”). Cycle the breaker several times to
verify reliable trip and reset of the actuator.
6) Reinstall the Bell Alarm Switch assembly if so equipped.
7) Close the breaker and trip the actuator using a 9 Volt
battery (Red is “+”). Cycle the breaker several times to
verify reliable trip and reset of the actuator, and bell
alarm switch.
8) Reinstall the Under Voltage assembly if so equipped.
9) Check that all the mounting hardware and the set screw
collar for the reset are tight then reinstall the front
cover of the breaker.
IMPORTANT: With the reset mechanism defeated and the actuator
in the trip position (not reset), the breaker must
be trip free.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 10
9.0 Wiring
Use the wiring harness provided to make the connections to the
CTs and the actuator. See Figure 12 or 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.
Follow the reference chart on the CT. Verify that the polarity
is correct and the correct terminals were used.
9.1 Color Codes and Connections
The wiring harness connector color code and connections are as
follows from left to right:
Terminal# Wire Color Use
1 Red (R) Actuator “+”
2 Black (B) Actuator “-“
3 Blue (L) Phase “A” “Tap”
4 White (W) Phase “A” Dot
5 Yellow (Y) Phase “B” “Tap”
6 White (W) Phase “B” Dot
7 Brown (N) Phase “C” “Tap”
8 White (W) Phase “C” Dot
9 Green (G) Neutral Tap (4W & GF only)
10 White (W) Neutral "Dot" (4W & GF only)
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AC-PRO Retrofit............................................................DS206 TO 850
Page 11
9.2 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 #6-32 lugs on the CTs using the ring tongue
terminals provided.
9.3 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.
If a 1 Amp secondary neutral CT is supplied, use the wiring
diagram in Figure 12.
If the existing 5 Amp secondary neutral CT will be retained, a
5:1 Amp interposing CT must be used, as shown in Figure 13.
9.3.1 Interposing Neutral CT
Install the 5:1 neutral CT as described below and shown in
Figure 9 or 10.
1) Attach the interposing CT to bracket BR-312 using a
10-32 X 2 Phillips screw, flat washer, Nylock nut and HW-
2400-2 rubber washer.
The HW-2400-2 rubber washer is to be installed between the
CT and BR-312 bracket.
2) Attach the T-375 4-pole terminal block to the BR-312
bracket using two (2) 6-32 X 1/2 Phillips screws and lock
washers as shown in Figure 11.
3) Connect the interposing CT leads to the 4-pole terminal
block using ring terminals as shown in Figure 11.
4) Attach the bracket/terminal block/CT assembly to BR-020-1
bracket using two (2) 1/4-20 X 1/2 Phillips screws and
lock washers.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 12
9.4 Actuator Connection
9.4.1 Actuator Connection, Existing Actuator
The following applies to breakers where the existing Amtector
actuator will be reused.
The Digitrip actuator can not be actuated by the new trip unit
and must be replaced with a new actuator.
1) Verify that the actuator operates freely and resets
properly. Use a fresh 9 Volt battery to check the
electrical trip operation and polarity of the actuator.
The DC resistance of the coil must be between 24 and 40
Ohms.
2) Route the actuator wires in the harness to the actuator
and shorten the wires and tubing as required.
3) Connect the red (+) and black (-) wires in the wiring
harness to the existing actuator using the knife
disconnects and the Teflon tubing provided. Maintain
proper polarity.
4) Replace the breaker front cover.
9.4.2 Actuator Connection, New Actuator
1) 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. Cut the sleeving with a hot knife or use cable
ties on the sleeving ends to control fraying.
2) Connect the red actuator wire to the “+” terminal on the
wiring harness trip unit conector. Similarly, connect the
black actuator wire to other actuator terminal on the trip
unit.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 13
10.0Final Test
Perform a final electrical test of the breaker as in Section 2.
In accordance with ANSI C37.50-1989, A.3.7, each retrofitted
breaker must be tested.
Utility Relay Company recommends the following tests at a
minimum:
a) Dielectric
b) Primary injection pick-up and trip.
c) Resistance measurement of main contacts and
conductors.
d) Trip free operation of actuator.
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AC-PRO Retrofit............................................................DS206 TO 850
Page 14
11.0 Communications
The following instructions are for the communications option
using the AC-PRO with Modbus RTU communications:
11.1Install PT Module
The PT Module mounts behind the Trip Unit as shown in Figure 14
& 15.
1) Attach the BR-030-1 bracket to the PT Module using two
(2) 8-32 X 3/8 Phillips screws and lock washers.
2) Attach the PT Module/bracket assembly to the BR-020-1
bracket using two (2) 1/4-20 X 1/2 Phillips screws and
lock washers.
11.2Install Fuse Block for PT Module
Install the 3-pole fuse block as shown in Figure 16 and 17.
1) Attach the T-305-1 3-pole fuse block to the BR-312 bracket
using two (2) 8-32 X 3/8 SEMS screws.
2) Attach the fuse block/BR-312 bracket assembly to the
BR-020-1 bracket using two (2) 1/4-20 X 1/2 Phillips
screws and lock washers.
3) Install the three (3) T-306-2 KTK-R fuses into the fuse
block.
4) Install the three (3) T-305-5 fuse block covers by
snapping them on to the fuses.
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