Cutler-Hammer Digitrip 510 User manual

Effective October, 2000

IL 33-G2C-2

SAFETY PRECAUTIONS

POWER CIRCUIT BREAKERS ARE EQUIPPED

WITH HIGH SPEED, HIGH ENERGY OPERATING

MECHANISMS.THE BREAKERS ANDTHEIR

ENCLOSURES ARE DESIGNED WITH SEVERAL

BUILT-IN INTERLOCKS AND SAFETY

FEATURES INTENDEDTO PROVIDE SAFE AND

PROPER OPERATING SEQUENCES.TO PRO-

VIDE MAXIMUM PROTECTION FOR PERSON-

NEL ASSOCIATEDWITHTHE INSTALLATION,

OPERATION, AND MAINTENANCE OFTHESE

BREAKERS,THE FOLLOWING PRACTICES

MUST BE FOLLOWED. FAILURETO FOLLOW

THESE PRACTICES MAY RESULT IN DEATH,

PERSONAL INJURY, OR PROPERTY DAMAGE.

• Only qualified persons, as defined in the National

Electric Code, who are familiar with the installa-

tion and maintenance of power circuit breakers

and their associated switchgear assemblies

should perform any work associated with these

breakers.

Digitrip Retrofit System for the General Electric AK-50 Series Breakers:

AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50;

AK-3-50; AK-3A-50; and AKT-3A-50

• Completely read and understand all instructions

before attempting any installation, operation,

maintenance, or modification of these breakers.

• Always turn off and lock out the power source

feeding the breaker prior to attempting any

installation, maintenance, or modification of

the breaker. Do not use the circuit breaker as

the sole means for isolating a high voltage

circuit. Follow all lockout and tagging rules of

the National Electric Code and all other

applicable codes, regulations, and work rules.

• Do not work on a closed breaker or a breaker

with the closing springs charged.Trip (open) the

breaker and be sure the stored energy springs

are discharged before performing any work.The

breaker may trip open or the charging springs

may discharge, causing crushing or cutting

injuries.

• For drawout breakers, trip (open), and then

remove the breaker to a well-lit work area before

beginning work.

• Do not perform any maintenance: including

breaker charging, closing, tripping, or any other

function which could cause significant movement

of the breaker while it is on the extension rails.

Doing so may cause the breaker to slip from the

rails and fall, potentially causing severe personal

injury to those in the vicinity.

• Do not leave the breaker in an intermediate

position in the switchgear cell. Always leave it

in the connected, disconnected, or

(optional) test position. Failure to do so

could lead to improper positioning of the

breaker and flashover, causing death, serious

personal injury, and / or property damage.

• Do not defeat any safety interlock. Such

interlocks are intended to protect personnel

and equipment from damage due to flashover

and exposed contacts. Defeating an interlock

could lead to death, severe personal injury,

and / or property damage.

WARNING

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Effective October, 2000

IL 33-G2C-2

Page 2

Cutler-Hammer Digitrip Retrofit Kits are available in

a number of configurations that provide a wide

range of features.The Digitrip System starts with

the 510 Basic Kit which offers true RMS sensing,

overcurrent protection, and self-testing features.

Advanced Digitrip Retrofit Kits feature zone

interlocking, digital alphanumeric displays, remote

alarm signals, IMPACC communications, energy

monitoring capabilities, power factors, and

harmonic content measurements.

The following table provides a quick reference of

the components supplied with each level of Retrofit

Kit. Before beginning the Retrofit process, take a

minute to review the information contained in the

table. It is important that the Retrofitter understand

which level of Retrofit Kit is to be installed and

which components are included with the Kit.

The instructions contained in this manual cover the

installation of all levels of Retrofit Kit.If the Kit you

are installing does not contain a certain component,

skip the instructions for that component and

proceed to the next.

Throughout the Retrofit process, refer to the Torque

Tables at the back of this manual for

specific torque values.

If you have any questions concerning the Retrofit

Kit and / or the Retrofit process, contact

Cutler-Hammer at 1-800-937-5487.

510 with

Components 510 Basic Zone 610 810 910

Interlock

Trip Unit

Rating Plug

Auxiliary Current

Transformer

(CT) Module

Auxiliary

CT Harness

Sensors

Sensor Harness

Direct Trip

Actuator (DTA)

Mounting Brackets

and Hardware

External Plug 1 Connector 2 Connector 4 Connector 4 Connector

Harness Harness Harness Harness Harness

Cell Harness

Breaker Mounted

Control Power

Transformer (CPT)

Potential Transformer

(PT) Module

Auxiliary Switch

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Effective October, 2000

IL 33-G2C-2 Page 3

Beginning the Retrofit Process

Identifying the Breaker and the Retrofit Kit

Before beginning the Retrofit Process, it is

important to verify exactly which version of

G. E. AK-50 Series Breaker(s) is to be Retrofitted

and to insure that the correct Cutler-Hammer

Retrofit Kit(s) was ordered. Each Breaker must be

identified using all of the following sources that are

applicable:

1. Nameplate Information;

2. Breaker Rating;

3. Framed or Frameless;

4. Fused or Non-Fused; and if fused

5. Location of Fuses

(on Top or Bottom Breaker Stabs).

Please refer to the following chart and verify that

the first three (3) characters of the Digitrip Retrofit

Kit Code Number correspond to the Breaker being

Retrofitted. If you find that the Retrofit Kit does not

match the Breaker, do not attempt the Retrofit.

Contact your purchasing agent and have the

correct Retrofit Kit ordered for the Breaker.

Following the Icons to a Successful Retrofit

During certain parts of the Retrofit Process,

procedures may differ depending on the version

of the Breaker being Retrofitted.To enable the

Retrofitter to quickly identify the correct procedures

for the Breaker, the following Icon System has

been developed. As you are working through a

procedure and the Icons appear, simply follow

only

the instructions identified by the Icon for the

Breaker being Retrofitted.

Digitrip Retrofit Breaker Breaker Rating Fuse

Kit Code ID (Amps) Configuration Icon

GMC AK-1-50 1600 N.A.

AK-1-50

G2C AK-2-50 & AK-2A-50 1600 N.A.

AK-3-50 & AK-3A-50

Frameless Breaker with NO Fuses

Framed Breaker with NO Fuses

AK-1-50

G2C AK-2-50 & AK-2A-50 1600 Horizontal

AK-3-50 & AK-3A-50

Framed Breaker with BOTTOM Mounted Fuses

GUC AKU-2A-50 1600 Horizontal or Vertical

Framed Breaker withTOP Mounted Fuses

GTD AKT-2A-50 & AKT-3A-50 2000 N.A.

Framed Breaker with NO Fuses

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Effective October, 2000

IL 33-G2C-2

Page 4

Step 1: General Breaker Preparation

Before attempting to remove the Breaker from the

Cell or perform any Retrofit Operation, be sure

to read and understand the Safety Precautions

section of this manual. In addition, be sure to read

and understand the Instructions for the Application

of Digitrip RMS Retrofit Kits on Power Circuit

Breakers (Retrofit Application Data - Publication

AD 33-855-1), supplied with the Digitrip Retrofit Kit.

NOTE:

For Breakers Utilizing a Remotely

Mounted Neutral Sensor Connected to the

Breaker via Neutral CT Disconnect Only.

The

rating of the Neutral CT Disconnect, originally

supplied with the Breaker, does not meet the

specifications / requirements of the Retrofit Kit.

The Neutral CT Disconnect must be removed

and scrapped.The remotely mounted fourth

Sensor must be wired into the system via

Secondary Disconnects.

If the Breaker being Retrofitted is NOT

equipped with Secondary Disconnects, the

Secondary Disconnects for both the Breaker

and the Cell, as well as all mounting brackets

and hardware, must be secured from the

original manufacturer of the Breaker BEFORE

beginning the Retrofit Process.

DO NOT ATTEMPTTO INSTALL OR PERFORM

MAINTENANCE ON EQUIPMENTWHILE IT IS

ENERGIZED. SEVERE PERSONAL INJURY OR

DEATH CAN RESULT FROM CONTACT WITH

ENERGIZED EQUIPMENT.VERIFYTHAT NO

VOLTAGE IS PRESENT BEFORE PROCEEDING.

A. Trip the Breaker and remove it from the Cell.

Move the Breaker to a clean, well-lit work

bench.

NOTE: It is the responsibility of the Retrofitter

to insure that the Breaker and all original com-

ponents are in good condition.Visually inspect

all Breaker components for signs of damage or

wear. If any signs of damage or wear are

detected for components not included in the

Retrofit Kit, secure the necessary replacement

parts before beginning the Retrofit Process.

The force necessary to trip the Breaker should

not exceed three (3) lbs.

To begin the Retrofit Process, refer to the compo-

nents list at the end of this manual. Lay out the

components and hardware according to the steps

outlined.The components and hardware will be

used to complete each step in the Retrofit Process.

NOTE: For most photographs contained within

this manual, a G. E. AK-2-50 Breaker was used

as the subject. Depending on the version and

age of the Breaker being Retrofitted, some

components / views depicted in this manual

may differ from the Breaker being Retrofitted.

WARNING

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Effective October, 2000

IL 33-G2C-2Page 5

Step 2: Removing the Original

ElectromechanicalTrip Units

For All G. E. AK-50 Series Breakers Except

AK-3/3A-50, AKU-3/3A-50, and Breakers

Equipped with a Quick Close Mechanism.

Follow the G. E. AK-50 Series Instruction Manual,

originally supplied with the Breaker, to perform the

following procedures.

A. Carefully lay the Breaker over on its right side to

provide access to the bottom of the Breaker.

B. Remove and scrap the original

Electromechanical Trip Units and mounting

hardware from each phase.

C. Remove and scrap the Electromechanical Trip

Paddles and mounting hardware from the

Breaker Trip Bar.

For G. E. AK-3/3A-50, AKU-3/3A-50, and Breakers

Equipped with a Quick Close Mechanism Only.

Follow the G. E. AK-3/3A-50 Series Instruction

Manual, originally supplied with the Breaker, to

perform the following procedures.

A. Carefully lay the Breaker over on its right side to

provide access to the bottom of the Breaker.

B. Disconnect and scrap all wires connecting

the original Electronic Trip Units, Direct Trip

Actuator, and the original Sensors mounted

on the bottom studs.

C. Remove and scrap the original Sensors,

Electronic Trip Units, Direct Trip Actuator,

Reset Links, and all associated mounting

hardware.

Note: For Breakers originally fitted with a

remotely mounted Neutral Sensor, the

Neutral CT Disconnect must be removed

and discarded.

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Effective October, 2000

IL 33-G2C-2

Page 6

Step 3: Installing the Copper Adapters

A. Align the holes in the Copper Adapters with the

holes that were used to mount the original

Electromechanical Trip Units.

B. Mount a Copper Adapter to each Phase, as

shown, using the (12) .375-16 ×1.50" bolts,

(12) lock washers, and (12) flat washers

supplied.

For Kits Supplied with a PT Module Only.

As viewed from the front of the Breaker, do not

install the left mounting bolt in each Copper

Adapter.These will be used later in the Retrofit

Process to attach the PT Wires to each Phase

Frame.

C. Carefully return the Breaker to the upright

position.

Before proceeding, identify the section(s) within

the Step that apply to the Breaker being

Retrofitted.

Step 4: Installing the Sensors

Note: On Breakers equipped with a Racking

Mechanism, the Sensors and Sensor Mounting

Bracket provide adequate clearance between

the Sensors and Racking Mechanism.

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Effective October, 2000

IL 33-G2C-2 Page 7

For Top Mounted Sensors Only.

A. Align a 3-Point Terminal Block with each set

of holes in the Sensor Mounting Bracket as

shown.Secure the 3-Point Terminal Blocks to

the Sensor Mounting Bracket using the

(6) .138-32 ×.500" screws and (6) lock

washers supplied.

B. Install a Flexiform Grommet to the edges of

each wire cutout in the Sensor Mounting

Bracket.

C. Insert the three (3) wires exiting the top of the

Sensor through the opening in the Sensor

Mounting Bracket.

D. With the Sensor Nameplate at the top and

facing out, align the threaded holes in the top

of the Sensor with the holes in the Sensor

Mounting Bracket. Secure the Sensor to the

Sensor Mounting Bracket using the (4)

.250-20 ×.500" bolts, (4) lock washers, and

(4) flat washers supplied.

E. Repeat Steps B and C for the remaining

two (2) Sensors.

F. Connection of the Sensor Wires to the 3-Point

Terminal blocks is detailed in the photo.Once

the correct connection point has been

determined, cut each Sensor Wire to an

appropriate length and attach a supplied ring

terminal to each wire.

G. Align the Sensor Mounting Bracket / Sensor

Assembly with the existing holes on the top rear

of the Breaker Back Plate as shown. Secure

using the (2) .500-13 ×1.50" bolts, (4) flat

washers, (2) lock washers, and (2) nuts

supplied.

Black Red

White

Black White Red

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Effective October, 2000

IL 33-G2C-2

Page 8

For Bottom Mounted Sensors Only.

A. Following the G. E.AK-50 Series Instruction

Manual originally supplied with the Breaker,

remove and save the fuses, mounting brackets,

and hardware.

B. Again following the G.E. AK-50 Series

Instruction Manual, remove and save the

hardware that secures the .750" thick Support

Plate to the Breaker Back Plate. Remove and

scrap the Support Plate.

C. Align the holes in the new Glass Poly Support

Plate with the holes in the Breaker Plate. Note

that the cutout for the Sensors must face the

bottom of the Breaker. Secure the new Support

Plate using the original mounting hardware.

D. Align a 3-Point Terminal Block with each set

of holes in the Sensor Mounting Bracket as

shown.Secure the 3-Point Terminal Blocks

to the Sensor Mounting Bracket using the

(6) .138-32 ×.500" screws, (12) flat washers,

(6) lock washers, and (6) nuts supplied.

E. Install a Flexiform Grommet to the edges of

each wire cutout in the Sensor Mounting

Bracket.

F. Insert the three (3) wires exiting the top of the

Sensor through the opening in the Sensor

Mounting Bracket.

G. With the Sensor Nameplate at the bottom and

facing out, align the threaded holes in the top

of the Sensor with the holes in the Sensor

Mounting Bracket. Secure the Sensor to the

Sensor Mounting Bracket using the (4)

.250-20 ×.500" bolts, (4) lock washers, and

(4) flat washers supplied.

H. Repeat Steps E and F for the remaining two

(2) Sensors.

I. Connection of the Sensor Wires to the 3-Point

Terminal blocks is detailed in the photo. Once

the correct connection point has been

determined, each Sensor Wire should be cut to

an appropriate length and a supplied ring

terminal attached to each.

Black Red

White

Black White Red

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Effective October, 2000

IL 33-G2C-2 Page 9

J. Align the Sensor Mounting Bracket with the

existing holes on the bottom rear of the Breaker

Back Plate as shown. Secure using the (2)

.500-13 ×1.50" bolts, (4) flat washers, (2) lock

washers, and (2) nuts supplied.

K. Following the G. E. AK-50 Series Instruction

Manual originally supplied with the Breaker,

reinstall the original fuses, mounting brackets,

and hardware.

For AKT-2A-50 and AKT-3A-50 2,000 Amp

Breakers Only.

A. Align two (2) Sensor Adapter Brackets with

the holes in the top of the Sensor as shown

(the Sensor Terminals are located on the

bottom of the Sensor). Secure the Sensor

Adapter Brackets to the Sensor using the (2)

.250-20 ×2.75" bolts, (4) flat washers, (2) lock

washers, and (2) nuts supplied.

B. Repeat Step A for the remaining two (2)

Sensors.

C. Align the threaded holes in the Sensor

Adapter Brackets with the holes in the Sensor

Mounting Bracket. Secure the Sensor Assembly

to the Sensor Mounting Bracket using the (4)

.250-20 ×.500" bolts, (2) lock washers, and (2)

flat washers supplied.

D. Repeat Step B for the remaining two (2)

Sensor Assemblies.

E. Align the Sensor Mounting Bracket / Sensor

Assembly with the existing holes on the top

rear of the Breaker Back Plate as shown.

Secure using the (2) .500-13 ×1.50" bolts,

(4) flat washers, (2) lock washers, and (2)

nuts supplied.

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Effective October, 2000

IL 33-G2C-2

Page 10

Step 5: Installing the Aux. CT Module

A. Carefully lay the Breaker over on its left side.

B. Using Drilling Plan “A”, drill four (4) .219"

diameter holes near the bottom of the right side

of the Breaker. Note that the positioning of the

Aux. CT Module differs slightly for Breakers

equipped with a Quick Close Mechanism.

Note: Cover the region below the area to

be drilled to prevent chips from falling into

the Breaker.

C. Remove the screws installed in the right side of

the Aux.CT Module.

D. Align the holes in the right side of the Aux.CT

Module with the holes just drilled in the right

side of the Breaker. Secure the Aux.CT Module

to the Breaker using the (4) .190-16 ×.500"

thread cutting screws, (4) flat washers, and

(4) lock washers supplied.

AK Breaker AB

Without Quick Close Mech. 6.62 0.75

With Quick Close Mech. 4.38 1.00

Drilling Plan “A”

1.38" 1.38" Rear of Breaker

0.219 Dia. (4)

1.50"

0.75"0.75"

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