Utility Relay AC-PRO User manual

AC
-
PRO
Retrofit
Kit
Retrofit
Kit
Instructions
for
GE
AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
Low
Voltage
Breaker
Instructions
for
:
Manual
Reset
Actuator
Mechanical
Reset
Actuator
Including
Instructions
for
AC
-
PR
0
+
Communications
Utility
Relay
Co
.
Chagrin
Falls
,
Ohio
44023
Phone
:
888
-
289
-
2864
Fax
:
440
-
708
-
1177
www
.
utilityrelay
.
com
I
-
ACM
-
AK
-
50
October
,
2009
Rev
.
6
Courtesy of NationalSwitchgear.com

Courtesy of NationalSwitchgear.com

LIMITED
WARRANTY
Utility
Relay
Co
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
.
Ltd
.
warrants
that
every
AC
-
PRO
and
ZERO
-
•
/
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
:
Ltd
.
at
888
-
289
-
2864
and
do
the
•
/
1
.
)
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
.
,
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
event
shall
Utility
Relay
Co
Ltd
.
Ltd
.
be
liable
for
any
special
,
incidental
or
consequential
damages
.
In
no
•
I
•
/
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
PAGE
Section
1
General
1.1
Inspection
Initial
Breaker
Tests
AK
-
1
/
2
/
2
A
-
50
Breaker
3.1
Remove
Existing
Series
Trip
Units
3.2
Shunt
/
Standard
CT
Installation
.
..
3.3
Shunt
/
Non
-
Standard
CT
Installation
3.4
2000
Amp
CT
Installation
AK
-
3
-
50
Breaker
4.1
Remove
Existing
Trip
Unit
4.2
Remove
Exiting
CT
'
s
4.3
Install
New
CT
'
s
Trip
Paddle
,
Manual
Reset
Actuator
. ...
5.1
Install
Trip
Paddle
5.2
Reset
Spring
Manual
Reset
Actuator
6.1
Install
Actuator
6.2
Install
Actuator
Half
Frame
6.3
Adjust
Manual
Reset
Actuator
6.3
.
1
Adjust
the
actuator
rod
position
relative
to
the
trip paddle
6.3
.
2
Adjust
the
location
of
the
stop
nuts
6.4
Verify
Trip
Free
Operation
Mechanical
Reset
Actuator
Assembly
7.1
Install
Mechanical
Reset
Actuator
7.2
Alternate
Installation
7.3
Adjust
Tripping
of
Mechanical
Reset
Actuator
.
..
15
7.4
Adjust Trip
Free
Operation
7.5
Adjust
Reset
of
Mechanical
Reset
Actuator
AC
-
PRO
Installation
8.1
AC
-
PRO
Left
Side
Installation
8.2
AC
-
PRO
Right
Side
Installation
8.3
AC
-
PRO
Half
Frame
Installation
Wiring
9.1
Color
Codes
and
Connections
9.2
Current
Transformer
Connections
9.3
Neutral
Current
Transformer
9.4
Actuator
Connection
10.0
Final
Test
11.0
Communications
11.1
Install
PT
Module
11.2
Install
Fuse
Block
for
PT
Module
11.3
Communications
Wiring
1.0
1
2
2.0
2
3.0
2
3
4
5
6
4.0
6
6
6
7
5.0
7
7
8
6.0
8
Full
Frame
9
10
10
11
12
13
7.0
13
14
16
17
18
8.0
18
18
19
20
9.0
20
20
21
21
21
22
.
22
22
23
Courtesy of NationalSwitchgear.com

ILLUSTRATIONS
Page
Figure
1
Front
View
2
Trip
Unit
Side View
3
Shunt
/
Standard
CT
Installation
-
AK
-
1
/
2
/
2
A
-
50
.
..
4
Shunt
/
Non
-
Standard
CT
Installation
-
AK
-
1
/
2
/
2
A
-
50
5
CT
/
Copper
Detail
Assembly
-
AK
-
3
A
-
50
6 2000
Amp
CT
Installation
-
AKT
-
50
7
Trip
Paddle
Extension
,
Manual
Reset
8
Trip
Paddle
Installation
,
Manual
Reset
9
Trip
Bar
Reset
Spring
,
Manual
Reset
10
TEMPLATE
:
Actuator
Bracket
"
Left
"
Side
,
Manual
Reset
. .
33
11
TEMPLATE
:
Actuator
Bracket
"
Right
"
Side
,
Manual
Reset
.
34
12
TEMPLATE
:
Actuator
Bracket Half
Frame
,
Manual
Reset
.
..
35
13
Manual
Reset
Actuator
Installation
-
Half
Frame
. .
14
Fuse
Block
Installation
15
Front
View
Half
Frame
Breaker
16
Side
View
Half
Frame
Breaker
17
Actuator
Assembly
,
18
Mechanical
Reset
Actuator
Installation
Front
View
19
Mechanical
Reset
Actuator
Installation
Side
View
,
20
Alternate
Installation
21
TEMPLATE
:
Reset
Arm
Plate
,
Mechanical
Reset
22
TEMPLATE
:
Actuator
Base
Plate
,
Mechanical
Reset
.
23
Wiring Diagram
24
Front
View with
Communications
25
Wiring Diagram
with
Communications
24
25
26
27
28
29
30
31
32
36
37
38
39
40
41
42
43
44
45
46
47
48
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
GE
AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
Manually
or
Electrically
Operated
Breaker
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
AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
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
:
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
.
a
)
b
)
c
)
d
)
e
)
Rectify
any
abnormalities
found
.
Clean and
lubricate
the
breaker
as
required
.
3.0
AK
-
1
/
2
/
2
A
-
50
Breaker
3.1
Remove
Existing
Series
Trip
Units
On
each
pole
,
remove
the
existing
series
trip
unit
as
follows
:
Remove
the
trip
unit
cover
by
removing
the
two
(
2
)
1
/
4
-
20
X
2
1
/
2
R
.
H
.
screws
on
either
side
of
the
trip
unit
.
1
)
Remove
the
1
/
4
-
20
X
1
/
2
R
.
H
.
Phillips
screw
located
just
above
the
trip
coil
toward
the
rear
of the
breaker
.
2
)
Remove
four
(
4
)
3
/
8
-
16
X
1 1
/
4
H
.
C
.
screws
from
the
coil
.
Lift
out
the
trip
unit
/
coil
assembly
.
3
)
Page
2
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
3.2
CT
/
Shunt
Installation
-
Standard
CT
'
s
On
each
pole
,
install
the
copper
shunts
and
CT
Refer
to
Figure
3
for
the
following
:
1
)
Remove
the
paper
backing
from
the
HW
-
2910
-
1
silicone
rubber
spacer
and stick
it
to
the
center
of the
CU
-
022
front
shunt
approximately
1
3
/
4
"
from the bottom
as
shown
in
Figure
3
.
Loosely
assemble
the
CU
-
021
bottom shunt
to
the
two
(
2
)
threaded
inserts
previously
used
by
the
trip
coil
using
two
(
2
)
3
/
8
-
16
X
1
1
/
2
H
.
C
.
screws
,
heavy
flat
washers
and lock washers
.
2
)
Check
the
alignment
of
the
CU
-
021
bottom
shunt
by
setting
the
CU
-
023
shunt
post
and
CU
-
022
top
shunt
in
position
.
Use
a
1
/
2
-
13
X
2 1
/
2
H
.
C
.
screw
to
keep
the
shunt
post
in
position
.
Adjust
the
position
of
the
CU
-
021
bottom
shunt
as
required
to
align
all
mounting
holes
.
Remove
the
top
shunt
and
shunt
post
and
securely
tighten
the
two
(
2
)
CU
-
021
mounting
screws
.
3
)
Loosely
install
the
CU
-
022
top
shunt
using
two
(
2
)
3
/
8
-
16
X
1
1
/
2
H
.
C
.
screws
,
heavy
flat washers
and
lock
washers
.
4
)
Slip
a
CT
(
as
shown
in
Figure
3
)
over
a
CU
-
023
shunt
post
.
5
)
Slide
the
CT
/
shunt
assembly
between
the
CU
-
022
top
shunt
and
CU
-
021
bottom
shunt
.
6
)
Make
sure
the
silicone
rubber
spacer
is still
in
the
proper
location
.
install
the
1
/
2
-
13
X
2
1
/
2
H
.
C
.
When
satisfied
,
flat
washer
and
lock
washer
.
screw
,
Securely
tighten
all
screws
.
A
universal
socket
will
be
required
for
"
B
"
phase
.
7
)
Page
3
Courtesy of NationalSwitchgear.com

AC
-
PRO
Retrofit
AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
3.3
CT
/
Shunt
Installation
-
Non
-
Standard
CT
'
s
On
each
pole
,
install
the
copper
shunts
and
CT
as
follows
(
See
Figure
4
)
:
1
)
Loosely
assemble
the
CU
-
021
bottom
shunt
to
the
two
(
2
)
threaded
inserts
previously
used
by
the
trip
coil
using
two
(
2
)
3
/
8
-
16
X
1
1
/
2
H
.
C
.
screws
,
heavy
flat
washers
and
lock
washers
.
2
)
Check
the
alignment
of
the
CU
-
021
bottom
shunt
by
setting
the
CU
-
023
shunt
post
and
CU
-
022
top
shunt
in
position
.
Use
a
1
/
2
-
13
X
2
1
/
2
H
.
C
.
screw
to
keep
the
shunt
post
in
position
.
Adjust
the
position
of
the
CU
-
021
bottom
shunt
as
required
to
align
all
mounting
holes
.
Remove
the
top
shunt
and
shunt
post
and
securely
tighten
the
two
(
2
)
CU
-
021
mounting
screws
.
Loosely
install
the
CU
-
022
top
shunt
using
two
(
2
)
3
/
8
-
16
X
11
/
2
H
.
C
.
screws
,
heavy
flat
washers
and
lock
washers
.
3
)
Slip
a
CT
and
one
(
1
)
or
two
(
2
)
silicone
rubber
washers
as
required
,
on
a
CU
-
023
shunt
post
as
shown
in
Figure
4
.
4
)
Slide
the
CT
/
shunt
/
rubber
washer
assembly
between
the
CU
-
022
top
shunt
and
CU
-
021
bottom
shunt
.
Make
sure
the
silicone
rubber
washer
is
not
pinched
between
the
shunt
post
and
shunt
.
When
satisfied
,
install
the
1
/
2
-
13
X
2
1
/
2
H
.
C
.
screw
,
flat
washer
and
lock
washer
.
5
)
Securely
tighten
all
screws
.
A
universal
socket
will
be
required
for
"
B
"
phase
.
6
)
Make
sure
the
silicone
rubber
washers
are
not
pinched
between
the
shunt
post
and
shunt
IMPORTANT
:
Page
4
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
3.4
2000
Amp
CT
Installation
Refer
to
Figure
5
for the
following
:
Loosely
assemble
the
CU
-
184
bottom shunt
to
the
two
(
2
)
threaded
inserts
previously
used
by
the
trip
coil
using
two
(
2
)
3
/
8
-
16
X
1
-
1
/
2
H
.
C
.
screws
,
heavy
flat
washers
and
lock
washers
.
1
)
Remove
the
paper
backing
from
the
HW
-
2910
-
1
silicone
rubber
spacer
and stick
it
to
the
center
of the
CU
-
184
bottom
shunt
approximately
2
"
from
the
bottom
as
shown
in
Figure
5
.
2
)
Assemble the front
shunt
by loosely
installing
the
CU
-
185
Front
Shunt
to
the
breaker
using
two
(
2
)
3
/
8
-
16
X
1
-
1
/
2
H
.
C
.
screws
,
flat
washers
and lock washers
.
3
)
4
)
Attach
CU
-
186
Front
Spacer
and
CU
-
187
Front
Shunt
using
two
(
2
)
3
/
8
-
16
X
1
-
3
/
4
H
.
C
.
screws
,
flat washers and
lock
washers
.
5
)
Check
the
alignment
of the
CU
-
184
bottom shunt
by
setting
the
CU
-
188
Shunt
Post
in
position
.
Use
a
1
/
2
-
13
X
2
-
1
/
2
H
.
C
.
screw
to
keep
the
shunt
post
in
position
.
Adjust
the
position
of
the
CU
-
184
bottom shunt
as
required
to
align
all
mounting
holes
.
6
)
Slip
a
CT
(
as
shown
in
Figure
5
)
over
a
CU
-
188
shunt
post
.
Slide the
CT
/
shunt
assembly
between the
CU
-
187
top
shunt
and
CU
-
184
bottom
shunt
.
7
)
Make
sure
the
silicone
rubber
spacer
is still
in
the
proper
location
.
When
satisfied
,
install
the
1
/
2
-
13
X
2
-
3
/
4
H
.
C
.
flat washer and
lock
washer
.
screw
,
8
)
Securely
tighten
all
screws
.
A
universal socket
will
be
required
for
"
B
"
phase
.
Page
5
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
4.0
AK
-
3
-
50
Breaker
4.1
Remove
Existing
Trip
Unit
Disconnect
and
remove
the
wiring
harness
from
the
old
trip
unit
and
associated
components
.
1
)
Remove
the
trip
unit
,
all
associated
electronic
components
,
the
actuator
and
the
mounting
brackets
.
The
CT
'
s
will
be
removed
later
.
2
)
4.2
Remove
Existing
CT
'
s
Remove
the
existing
CT
'
s
on
each
pole
as
follows
:
Loosen
the
CT
post
clamp
screw
.
1
)
Remove
four
(
4
)
3
/
8
-
16
screws
holding
the
existing
CT
/
copper
detail
assembly
in
place
.
2
)
Remove
the
existing
CT
/
copper
detail
assembly
from
the
breaker
.
3
)
Remove
the
instantaneous
trip
device
from
each
copper
detail
if
so
equipped
.
4
)
Remove
the
existing
CT
'
s
from
the
copper
detail
.
5
)
4.3
Install
New
CT
'
s
Refer
to
Figure
6
for
the
following
:
Slide the
new
CT
on
the shunt
post
.
Use
a
small
amount
of
RTV
Silicone
to
hold
each
CT
in
position
.
1
)
The
CT
'
s
should be held
in
position
to
prevent
them from
rotating
and
possibly
shorting
the
terminals
.
IMPORTANT
:
Replace
the
CT
/
copper
assembly
using
the
hardware
previously
removed
.
2
)
3
)
Securely
tighten
all hardware
including
the
CT
post
clamp
screw
.
Page
6
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
5.0
Trip
Paddle
,
Manual
Reset
This
section
is for
the
manual
reset
actuator
installation
only
.
Skip
this
section
if
mechanical
reset
actuator
will
be
used
.
5.1
Install
Trip
Paddle
Refer
to
Figures
7
and
8
for
the
following
:
Remove
the
"
A
"
or
"
C
"
phase
trip
paddle
from
the
trip
bar
by
removing
the
10
-
32
clamp
screw
.
1
)
Loosely
install
the
new
BR
-
254
-
1
trip
paddle
using
the
BR
-
215
clamp
,
two
(
2
)
8
-
32
X
3
/
8
Sems
screws
and
one
(
1
)
8
-
32
X
1
/
4
set
screw
.
2
)
5.2
Reset
Spring
Refer
to
Figure
9
for the
following
:
It
is
usually
necessary
to
install
a
trip
bar
reset
spring
to
counter
the
weight
of the
trip
paddle
extension
.
Loosely
install
the
BR
-
243
-
1
trip paddle
on
the
extreme
right
end of the
trip
bar
.
1
)
Use
a
BR
-
215
clamp
,
two
(
2
)
8
-
32
X
3
/
8
Sems
screws
and
one
(
1
)
8
-
32
X
1
/
4
set
screw
.
In
an
appropriate
location
,
drill
and
tap
the
breaker
frame
for
a
10
-
32
X
1
R
.
H
.
screw
to
be used
as
the
anchor
point
for
the end of
the
reset
spring
.
2
)
The
reset
spring
should
be under
slight
tension
when
the
trip
bar
is
in
the
reset
position
.
The
reset
position
is
obtained
when the
breaker
closing springs
are
just
short of the
charged
position
(
3
/
4
on
the
indicator
)
and
the
trip
bar
"
clicks
"
into
position
.
Note
:
As
a
safety
precaution
,
temporarily
unhook the
breaker
opening springs
before
installing
the
reset
spring
.
IMPORTANT
:
Page
7
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
6
.
0
Manual
Reset
Actuator
Skip
this
section
if
mechanical
reset
actuator
will
be
installed
.
Referring
to
Figure
1
,
determine
if
the
actuator
should
be
installed
on
the
left
or
right
side
of
the
breaker
.
The
best
location
depends
on
the
space
available
due
to
the
different
control
and
auxiliary
devices
on
the
breaker
.
A
left
side
installation
is
shown
in
Figure
1
.
6.1
Install
Actuator
-
Full
Frame
Cut
out
the
left
template
from
Figure
10
or
the
right
template
from
Figure
11
.
Locate
the
template
on
the
appropriate
side
of
the
breaker
as
indicated
in
Figure
8
for
the
left
hand
installation
.
Mark
and
drill
two
(
2
)
9
/
32
holes
.
1
)
Remove
the
reset
knob
from
the
actuator
.
2
)
Attach
the
actuator
to
bracket
BR
-
103
with
three
(
3
)
10
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
3
)
Replace
the
reset
knob
on
the
end
of
the
actuator
rod
and
lock
in
place
with
the
1
/
4
-
20
jam
nut
.
4
)
Attach
the
actuator
/
bracket
assembly
to
the
inside
of
the
breaker
frame
using
two
(
2
)
1
/
4
-
20
X
1
H
.
C
.
screws
,
lock
washers
,
and
hex
nuts
.
5
)
Use
(
1
)
or
(
2
)
BR
-
106
shims
between
the
BR
-
103
bracket
and
the
breaker
if
necessary
.
6
)
Locate
the
trip
paddle
so
the
actuator
rod
is
lined
up
with
the
trip
paddle
and
tighten
the
8
-
32
screws
and
set
screws
.
Page
8
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
6.2
Install
Actuator
-
Half
Frame
Refer
to
Figures
13
and
15
for
the
following
:
Cut
out
the
template
from
Figure
12
and
locate
the
template
on
the
appropriate
side
of
the
breaker
as
indicated
in
Figure
13
.
Mark
and
drill
two
(
2
)
9
/
32
holes
.
1
)
Remove
the
reset
knob
from
the
actuator
.
2
)
Attach
the
actuator
to
bracket
BR
-
103
with
three
(
3
)
10
-
32
X
3
/
8
Phillips
screws
and
lock
washers
.
3
)
Replace
the
reset
knob
on
the
end
of
the
actuator
rod
and
lock
in
place
with
the
1
/
4
-
20
jam
nut
.
4
)
Attach
the
actuator
/
bracket
assembly
to
the
inside
of
the
breaker
frame
using
two
(
2
)
1
/
4
-
20
X
1
H
.
C
.
screws
,
lock
washers
,
and
hex
nuts
.
5
)
Use
(
1
)
or
(
2
)
BR
-
106
shims
between
the
BR
-
103
bracket
and
the
breaker
if
necessary
.
Locate
the
trip
paddle
so
the
actuator
rod
is
lined
up
with
the
trip
paddle
and
tighten
the
8
-
32
screws
and
set
screws
.
6
)
Page
9
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2 A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
6.3
Adjust
Manual
Reset
Actuator
Adjust
the
actuator
rod
position
relative
to
the
trip
paddle
.
6.3
.
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
8
or
13
for
the
following
:
With
the
breaker
closed
,
and
the
actuator
reset
,
adjust
the
position
of the
actuator
rod
by
screwing
it
in
or
out
until
the end of
the rod
is
about
1
/
64
"
from
the
trip paddle
.
1
)
Trip
the
breaker
.
Trip
the
actuator
by
striking
the
reset
knob
.
Lock
the
actuator
rod
in
position by
tightening
the
10
-
32
set
screw
with
an
Allen
wrench
.
2
)
WITH THE BREAKER
CLOSED
AND
THE
ACTUATOR
RESET
,
THE END
OF
THE
ACTUATOR
ROD
MUST
BE
ABOUT
1
/
64
"
FROM
THE TRIP
PADDLE
.
IMPORTANT
:
THE
SET
SCREW
IN
THE
PLUNGER MUST
BE
TIGHTENED
TO
ENSURE
THAT THE
ACTUATOR ROD
REMAINS
IN
PROPER
ADJUSTMENT
.
Page
10
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
Adjust
the
location
of
the
stop
nuts
.
6.3
.
2
Temporarily position
the
stop
nuts
to
allow
a
very
short
actuator
rod
travel
.
1
)
With the
breaker
open
and
the
actuator
in
the
trip
position
,
attempt
to
close
the
breaker
.
2
)
do
the
following
:
Depending
on
the results
of
Step
2
,
3
)
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
.
If
the
breaker
tripped
free
:
Go
to
Step
4
.
b
)
Increase
the
actuator
rod
travel
by
turning
the
stop
nuts
away
from
the
actuator
an
additional
two
(
2
)
turns
minimum
.
4
)
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
.
Verify
that
with the
actuator
in
the
trip position
.
There
is
still
some
movement
left
in
the
trip paddle
.
6
)
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
.
THE TRIP PADDLE
MUST
BE
HELD
A
MINIMUM
OF
0.1
"
PAST
THE TRIP FREE
POINT
BY THE TRIPPED
ACTUATOR
.
IMPORTANT
:
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
11
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
6.4
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
,
increase
the
actuator
rod
travel
.
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
.
Page
12
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2 A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
7.0
Mechanical
Reset
Actuator
Assembly
Skip
this
section
if
the
manual
reset
actuator
was
installed
.
Determine
if
the
actuator
should
be
installed
on
the left
or
right
side
of the
breaker
.
The best
location
depends
on
the
space
available
due
to
the
different
control
and
auxiliary
devices
on
the
breaker
.
A
right
side
installation
is
described
in
the
following
sections
.
18
,
19
,
21
,
and
22
for the
following
:
Refer
to
Figures
17
,
7.1
Install
Mechanical
Reset
Actuator
Assembly
Cut
out
the
template
from
Figure
21
.
Locate
the
template
on
the
cross
bar
link
on
the
appropriate
side
of the
breaker
.
Mark and
drill
and
tap
two
(
2
)
1
/
4
-
20
holes
.
1
)
Mount
the
BR
-
737
shield
and
BR
-
1
A
019
reset
arm
plate
to
the
breaker
cross
bar
link
using
two
(
2
)
1
/
4
-
20
X
1
socket
head
cap
screws
and
lock
washers
.
The
shield
should
be
against
the
cross
bar
link
.
See
Figures
18
&
19
.
2
)
3
)
Cut
out
the
template
from
Figure
22
.
Locate
the
template
on
the
appropriate
side
of the
breaker
.
Mark
and
drill
two
(
2
)
11
/
32
holes
.
4
)
Loosely
attach
the
BR
-
2
A
018
trip paddle
to
the
breaker
trip
bar
using
a
BR
-
215
clamp
,
two
(
2
)
8
-
32
x
1
/
2
RH
screws
,
and lock
washers
.
See
Figure
19
.
A
-
300
C
-
AK
50
Actuator
assembly
has
been
pre
-
assembled
and
initial
settings
have
been
made
.
The
assembly
has
been
made
for
a
right
side
installation
.
If
a
left side
installation
is
desired
the
assembly
may
be
disassembled
and
re
-
assembled
as
a
mirror
image
.
See
Figure
17
for
reference
.
Final
adjustments
will
be
made
in
the
Section
7.3
.
5
)
Attach
the
actuator
assembly
onto
the
breaker
using
two
(
2
)
5
/
16
-
18
X
5
/
8
socket head
cap
screws
and lock
washers
in
the
previously
drilled holes
.
It
maybe
necessary
to
lay
the
breaker
on
it
'
s
back
to
gain
access
from the
bottom of the
breaker
.
Insure
that
the
8
-
32
threaded
rod
from
the
actuator
goes
through
the
slot
in
the
trip
paddle
.
See
Figure
18
.
Page
13
Courtesy of NationalSwitchgear.com

AK
-
1
/
2
/
2
A
-
50
&
AK
-
3
A
-
50
AC
-
PRO
Retrofit
Attach
the
rod
end
to
the
BR
-
1
A
019
reset
arm
plate
by
-
compressing
the
reset
spring
and
using
the
10
-
32
x
3
/
4
Phillips
screw
,
nut
,
and
lock
washer
.
Use
the
lower
10
-
32
hole
.
See
Figures
18
&
19
.
6
)
Tighten
the
10
-
32
hex
nut
against
the
lock
washer
and
reset
arm
.
The
rod
end
should
be
free
to
move
on
the
screw
.
Align
the
BR
-
2
A
018
trip
paddle
with
the
8
-
32
rod
going
through
it
so
that
it
does
not
touch
either
of
the
threaded
rods
and
lock
in
place
by
tightening
the
screws
including
the
set
screw
in
the
bottom
of
the
clamp
.
See
Figure
18
7
)
7.2
Alternate
Installation
of
Mechanical
Reset
Actuator
On
some
breakers
there
may
be
more
room
on
the
left
side
.
For
a
left
side
installation
the
A
-
300
C
-
AK
50
Actuator
assembly
may
be
disassembled
and
re
-
assembled
as
a
mirror
image
.
See
Figure
17
for
reference
.
For
breakers
with
a
ground
plate
on
the
left
side
(
AK
-
1
-
50
)
refer
to
Figure
20
.
Final
adjustments
will
be
made
in
the
Section
7.3
.
Cut
out
the
template
from
Figure
21
.
Locate
the
template
on
the
cross
bar
link
on
the
left
side
of
the
breaker
.
Mark
and
drill
and
tap
two
(
2
)
1
/
4
-
20
holes
.
1
)
Mount
the
BR
-
737
shield
and
BR
-
1
A
019
reset
arm
plate
to
the
breaker
cross
bar
link
using
two
(
2
)
1
/
4
-
20
X
1
socket
head
cap
screws
and
lock
washers
.
The
shield
should
be
against
the
cross
bar
link
.
See
Figures
18
&
19
.
2
)
Temporarily
remove
the
ground
plate
from
the
left
side
of
the
breaker
.
3
)
Cut
out
the
template
from
Figure
22
.
Locate
the
template
on
the
left
side
of
the
breaker
.
Mark
and
drill
two
(
2
)
11
/
32
holes
.
Counter
sink
for
5
/
16
-
18
Flat
head
screws
.
4
)
Loosely
attach
the
BR
-
2
A
018
trip
paddle
to
the
breaker
trip
bar
using
a
BR
-
215
clamp
,
two
(
2
)
8
-
32
x
1
/
2
RH
screws
,
and
lock
washers
.
See
Figure
19
.
5
)
Page
14
Courtesy of NationalSwitchgear.com