digitrip retrofit system for siemens-allis rlx-1600 breakerspub/@...breaker. step 3: installing the...

ContentsDescription Page

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Step 1: General Breaker Preparation . . . . . . . . . 3Step 2: Removing the Original Components . . . 3Step 3: Installing the Sensors . . . . . . . . . . . . . . 4Step 4: Building the DTA Assembly . . . . . . . . . 4Step 5: Installing the Breaker Reset Assembly . 7Step 6: Installing the DTA Assembly . . . . . . . . . 8Step 7: Preparing the Trip Unit Assembly for

Installation on the Breaker . . . . . . . . . . 9Step 8: Mounting the Trip Unit Assembly

to the Breaker . . . . . . . . . . . . . . . . . . . 11Step 9: Installing the Auxiliary CT Module . . . 12Step 10: Installing the CPT Module . . . . . . . . . 13Step 11: Connecting the Sensor and DTA

Harnesses . . . . . . . . . . . . . . . . . . . . . . 15Step 12: Installing the External Harness and

Final Connections . . . . . . . . . . . . . . . . 16Step 13: Final Breaker Preparation . . . . . . . . . . 18Step 14: Testing the Breaker . . . . . . . . . . . . . . . 18Step 15: Mounting the Cell Harness . . . . . . . . . 19Step 16: Installing the Retrofitted Breaker in

the Cell . . . . . . . . . . . . . . . . . . . . . . . . 19Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Effective April 2010Instruction Leaflet IL 33-RXC-1

Digitrip Retrofit System forSiemens-Allis RLX-1600 Breakers

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Instruction Leaflet IL 33-RXC-1Effective April 2010


EAton CoRpoRAtIon www.eaton.com

WARNINGPOWER CIRCUIT BREAKERS ARE EQUIPPED WITH HIGH SPEED, HIGH ENERGY OPERATING MECHANISMS. THE BREAKERS AND THEIR ENCLOSURES ARE SIGNED WITH SEVERAL BUILT-IN INTERLOCKS AND SAFETY FEATURES INTENDED TO PROVIDE SAFE AND PROPER OPERATING SEQUENCES. TO PROVIDE MAXIMUM PROTECTION FOR PERSONNEL ASSOCIATED WITH THE INSTALLATION, OPERATION, AND MAINTENANCE OF THESE BREAKERS, THE FOLLOWING PRACTICES MUST BE FOLLOWED. FAILURE TO FOLLOW THESE PRACTICES MAY RESULT IN DEATH, PERSONAL INJURY, OR PROPERTY DAMAGE.

Safety Precautions

• Periodic testing of this devise is required (see Step 16: Testing the Breaker for test procedures) .

• Only qualified persons, as defined in the National Electric Code, who are familiar with the installation and maintenance of power circuit breakers and their associated switchgear assemblies should perform any work associated with these breakers .

• 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 modi-fication 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, clos-ing, 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 switch-gear 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 flash-over and exposed contacts . Defeating an interlock could lead to death, severe personal injury, and / or property damage

Section 1: IntroductionEaton 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 that offers true RMS sensing, overcurrent protection, and self-testing features . Advanced Digitrip Retrofit Kits feature zone interlocking, digital alphanumeric displays, remote alarm signals, PowerNet communications, energy monitoring capabilities, power factors, and harmonic content measurements .

Table 1 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 Table 1 . It is impor-tant that the Retrofitter understands 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 Eaton Cutler-Hammer at: 1-800-937-5487 .

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Table 1. Available Retrofit Kits

Components 510 Basic510 with Zone Interlock 610 810 910

Trip Unit

Rating Plug

Auxiliary Current

Transformer

(CT) Module

Auxiliary

CT Harness

Sensors

Sensor Harness

Direct Trip Actuator (DTA)

Mounting Brackets and Hardware

External Harness Plug 1 Connector Harness 2 Connector Harness 3 Connector Harness 4 Connector Harness

Cell Harness

Breaker Mounted Control Power Transformer (CPT

Potential Transformer (PT) Module

Auxiliary Switch

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 33-855-4), supplied with the Digitrip Retrofit Kit .

WARNINGDO NOT ATTEMPT TO INSTALL OR PERFORM MAINTENANCE ON EQUIPMENT WHILE IT IS ENERGIZED. SEVERE PERSONAL INJURY OR DEATH CAN RESULT FROM CONTACT WITH ENERGIZED EQUIPMENT. VERIFY THAT 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 area .

Note: It is the responsibility of the Retrofitter to insure that the Breaker and all original components 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 nec-essary replacement parts before beginning the Retrofit Process .

The force necessary to trip the Breaker should not exceed five (5) lbs .

Note: It is the responsibility of the Retrofitter to insure that the proper, manufacturer’s recommended crimping tools and terminals are used for each type of connector . It is also the responsibility of the Retrofitter to insure that all wire preparations, connections, strippings, terminations, and wiring techniques are performed according to the latest IEEE, NEC, and / or NEMA industry standards, specifications, codes, and guidelines .

To begin the Retrofit Process, refer to the components list at the end of this manual . Layout the components and hardware according to the steps outlined . The parts bags are labeled with the corresponding step number . The components and hardware will be used to complete each step in the Retrofit Process .

Step 2: Removing the original Components

Refer to the Siemens-Allis RLX-1600 Instruction Manual, originally supplied with the Breaker, to perform the following procedures .

A . Using a 3/16 in . Allen wrench, remove and save the bottom Finger Clusters from each Phase . They will be reinstalled later in the Retrofit Process .

B . Trace the CT wiring from the CT’s forward to the Trip Unit termi-nal block . Disconnect the CT wiring from the terminal block . Pull the CT wiring out through the rear of the Breaker . Scrap the CT wiring .

C . Remove and scrap the CT’s, spacers, and wiring from each bot-tom Stud .

D . On manually operated Breakers, remove and save the Charging Handle for reinstallation later in the Retrofit Process .

E . Remove and save the mounting hardware and Front Cover from the Breaker . They will be reinstalled later in the Retrofit Process .

F . Remove and scrap the existing Trip Unit, mounting bracket, and any associated wiring from the bottom right front of the Breaker .

G . Remove and scrap the existing Direct Trip Actuator (DTA), mount-ing bracket, and wiring from the bottom right front of the Breaker .

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Figure 1. Overview: Original Components Removed from the Breaker.

Step 3: Installing the Sensors

Figure 2. Overview: Sensors Installed on the Breaker (Shown with Sensor Harness Connected).

A . Working from the back of the Breaker, slide a Sensor over each bottom Stud with the terminals on the bottom and facing away from the Breaker .

B . Using the original mounting hardware, reinstall the bottom Finger Clusters removed in Step 2-A .

Figure 3. Finger Clusters Reinstalled and the Proper Orientation of the Sensors and Terminals.

Note: The Sensor Harness will be installed later in the Retrofit Process .

Step 4: Building the DtA Assembly

Figure 4. Overview: Completed DTA Assembly.

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ote:N The photos used to illustrate the steps in this procedure were taken using a fully assembled DTA Assembly . Therefore, some components are shown installed on the DTA Assembly before they are installed during this procedure .

A . Apply Loc-Tite® 242 to the threads on both ends of the DTA Shaft . On the end of the DTA shaft that exits the DTA where the nuts secure the DTA to its frame, install (1) 0 .250”-20 flange nut supplied flange first (flange facing the DTA) on the shaft . Turn the flange nut onto the shaft until the end of the DTA shaft is flush with the nut surface of the flange nut .

On the other end of the DTA shaft, install (1) 0 .250”-20 flange nut supplied nut surface first (flange facing away from the DTA) on the shaft . Turn the flange nut onto the shaft until the end of the DTA shaft is flush with the flange surface of the flange nut .

See the Loc-Tite label for curing time . Set the DTA aside until the Loc-Tite has fully cured .

Figure 5. Flange Nuts Properly Installed on the DTA Shaft.

B . Align the Support bracket with the holes in the DTA Mounting bracket as shown (see Figure 6) . Secure the Support bracket to the DTA Mounting bracket using the (2) 0 .190-32 × 0 .500” screws, (4) flat washers, (2) lock washers, and (2) nuts supplied .

Figure 6. Support Bracket Installed on the DTA Mounting Bracket.

C . Once the Loc-Tite used on the DTA shaft in Step 4-A is cured, align the holes in the Actuator Assembly with the holes in the DTA as shown on the side where the flange nut was installed flange side out (see Figure 7) . Note that the Actuator Assembly’s lever orientation is opposite to the side that the DTA Wires exit the DTA (top of the DTA) . Secure the Actuator Assembly to the DTA using the (2) 0 .164-32 × 0 .250” screws, (2) lock washers, and (2) flat washers supplied .

Figure 7. Actuator Assembly Mounted to the DTA.

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D . Align the Actuator Support bracket with the holes in the side of the DTA as shown (see Figure 8) . At this time, the Actuator Support bracket will only be mounted to the DTA using (3) 0 .164-32 × 0 .375” screws, (1) 0 .164-32 × 0 .500” screw, (4) lock washers, and (4) flat washers supplied . The other two holes in the Actuator Support bracket and DTA will be used to mount the Reset Assembly in the next step . Reference Figure 8 for the locations at which the (3) 0 .164-32 screws are to be installed .

Note: DO NOT fully tighten the four Actuator Support bracket mounting screws at this time . This will allow for adjustment of the Reset Assembly in the next step .

Figure 8. Actuator Support Bracket Mounted to the DTA with Four Screws.

E . Position the “fork” of the Reset Assembly around the DTA shaft and between the flange nut and DTA frame as shown (see Figure 9) . Then align the holes in the left side of the Reset Assembly with the open holes in the Actuator Support bracket and DTA frame . Secure the Reset Assembly to the Actuator Support bracket and DTA using the (2) 0 .164-32 × 0 .500” screws, (2) lock washers, and (2) flat washers supplied .

Figure 9. Reset Assembly Mounted to the Actuator Support Bracket and DTA.

F . Fully tighten the four screws to secure the Actuator Support bracket to the DTA .

G . Align the holes in the right side of the Reset Assembly with the top two holes in the right side of the DTA frame . Use (1) 0 .164-32 × 0 .500” screw, (1) lock washer, and (1) flat washer supplied in the top hole of the Reset Assembly to hold it in place . Do Not fully tighten the screw at this time .

Figure 10. Right Side of the Reset Assembly Mounted to the DTA Frame with One Screw.

Screw Holding Reset Assembly

0 .500” Long Screw 0 .375” Long Screws

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H . Slide the spring over the Actuator shaft .

I . Slide the Guide plate onto the Actuator shaft then align the mounting holes in the Guide plate with the holes in the right side of the Reset Assembly and DTA (see Figure 11) . Loosely secure the Guide plate to the right side of the Reset Assembly and DTA using the (1) 0 .164-32 × 0 .500” screw, (1) lock washer, and (1) flat washer supplied . Also loosely secure the Guide plate to the right side of the Reset Assembly using the (1) 0 .190-32 × 0 .500” screw, (2) flat washers, (1) lock washer, and (1) nut supplied .

Figure 11. Spring in Place on the Actuator Shaft and the Guide Plate Loosely Secured to the Reset Assembly and DTA.

J . Fully tighten the hardware securing the right side of the Reset Assembly to the DTA frame .

K . Adjust the position of the Guide plate to insure that the Actuator shaft has a full range of movement and does not bind when mov-ing . Fully tighten the hardware securing the Guide plate to the Reset Assembly and DTA .

Note: Insure that the Reset Arm in the Reset Assembly moves freely . If it does not move freely, slightly loosen the Nylock nuts on the Reset Arm pin until free movement is achieved .

Step 5: Installing the Breaker Reset Assembly

Figure 12. Overview: Breaker Reset Assembly Installed in the Breaker.

A . Remove and scrap the “X” washers and wrist pin from Phase 3 . This is the wrist pin that connects the Phase 3 Insulating Link to the Pole Shaft .

B . Install (1) “X” washer supplied on one end of the new Wrist Pin .

C . From the right, insert the new wrist pin through the Phase 3 Pole Shaft and Insulating Link .

D . Slide (1) 0 .375” flat washer supplied and the Breaker Reset Assembly on the left end of the wrist pin . Note that the “leg” of the Reset Assembly MUST face to the right . Secure the Breaker Reset Assembly and flat washer on the wrist pin using (1) “X” washer supplied .

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Step 6: Installing the DtA Assembly

Figure 13. Overview: DTA Assembly Installed in the Breaker.

A . Using Drilling Plan “A” and a 0 .203” bit, drill two holes in the right front side of the breaker platform .

Figure 14. Drilling Plan “A” – Right Front Side of the Breaker Platform.

B . Using Drilling Plan “B” and a 0 .219” bit, drill one hole in the right side breaker frame .

Figure 15. Drilling Plan “B” – Right Side Breaker Frame.

C . Install (1) washer, (1) spring, then (1) washer on the Breaker Reset Shaft . While holding the washers and spring in place on the shaft, align the shaft with the slot in the DTA Reset Arm .

D . Slide the Breaker Reset Shaft through the slot in the DTA Reset Arm then align the mounting holes in the DTA Assembly with the holes drilled in Steps 6-A and B . Note that the Trip Bar Shaft goes behind the Breaker Trip Bar .

Figure 16. Proper Positioning of the Breaker Trip Bar and Trip Bar Shaft.

E . Once the DTA Assembly is properly aligned, secure it to the right front side of the breaker platform using (2) 0 .250-20 × 0 .750” thread cutting screws, (2) lock washers, and (2) flat washers, and to the right side breaker frame using (1) 0 .190-32 × 0 .500” screw, (2) flat washers, (1) lock washer, and (1) nut supplied .

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Figure 17. DTA Assembly Installed in the Breaker.

F . Connect a 24 Vdc power supply to the DTA terminals: positive-to-positive and negative-to-negative . Close the breaker . Energize the DTA to trip the breaker; de-energize when the breaker trips . Make certain that the DTA resets . If the breaker fails to properly trip, adjust the Guide Plate up or down . If the DTA fails to reset, adjust the spring tension on the Reset Assembly .

Step 7: preparing the trip Unit Assembly for Installation on the Breaker

Figure 18. Overview: Trip Unit Assembly Prepared for Installation on the Breaker.

Note: While performing the following Steps A through D, only “snug” the mounting hardware used during each step . This will allow for some adjust-ment as the components are being mounted during this process . The time at which all “snugged” hardware can be fully tightened is identified .

A . Align the Trip Unit Insulation Barrier mounting “L” clips with the existing holes in the Insulation Barrier as shown . Note that the small leg of each Insulation Barrier mounting “L” is used to mount the “L” clips to the Insulation Barrier . Attach the Insulation Barrier mounting clips to the Insulation Barrier using the (4) .112-40 × 0 .250 screws, (4) lock washers, and (4) flat washers supplied .

Figure 19. Insulation Barrier Mounting “L” Clips Attached to the Insulation Barrier.

B . Align the Trip Unit with the holes in the Trip Unit mounting plate, as shown . Secure the Trip Unit to the mounting plate using the (2) .190-32 × 4 .00 screws, (4) flat washers, (2) lock washers, (2) nuts, and (2) brass spacers supplied . Note that the brass spacers are used between the bottom of the Trip Unit and the top of the Trip Unit Mounting Plate .

Figure 20. Proper Positioning of the Brass Spacers.

C . Align the left and right Trip Unit support clips with the slots in the sides of the Trip Unit and the existing tapped holes in the Trip Unit mounting plate . Attach the Trip Unit support clips to the mounting plate using the (4) .138-32 × 0 .380 screws, (8) flat washers, (4) lock washers, and (4) nuts supplied .

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Figure 21. Trip Unit Support Clips Attaching the Trip Unit to the Mounting Plate.

D . Align the holes in the “L” clips on the Insulation Barrier Assembly with the threaded holes in the Trip Unit support clips . Attach the Insulation Barrier Assembly to the Trip Unit support clips using the (2) .164-32 × 0 .500 screws, (2) lock washers, and (2) flat washers supplied .

Figure 22. Insulation Barrier Assembly Attached to the Trip Unit Mounting Clips.

E . Fully tighten all mounting hardware used in Steps A through D at this time .

F . Align a Trip Unit mounting bracket with the existing holes in each end of the Trip Unit mounting plate . Note that the turned down edge of the Trip Unit mounting plate and the straight edges of the mounting brackets should face in the same direction . Secure the mounting brackets to the mounting plate using the (4) 0 .250-20 × 0 .750” bolts, (8) flat washers, (4) lock washers, and (4) nuts sup-plied .

Figure 23. Trip Unit Mounting Brackets Secured to the Trip Unit Mounting Plate.

G . Remove the Trip Unit Cover . Install the Rating Plug . Reinstall the Trip Unit Cover using the original hardware .

Figure 24. Trip Unit with Rating Plug and Cover Installed.

H . Install the Digitrip Retrofit Label on the top of the Trip Unit .

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For Kits Supplied with a PT Module Only.

I . Align the PT Module mounting bracket with the existing holes in the Trip Unit mounting plate . Secure the PT Module mounting bracket to the Trip Unit mounting plate using the (2) .164-32 × 0 .500 screws, (4) flat washers, (2) lock washers, and (2) nuts sup-plied .

J . Remove and scrap the PT Module Nameplate extension clip . Using the original mounting hardware, relocate the PT Module Warning Nameplate as shown (see Figure 25) . Install the sup-plied new PT Module Warning label over the existing Warning Nameplate label .

Figure 25. PT Module’s Relocated Warning Nameplate and New Warning Label.

K . Align the small PT Module Insulation Barrier with the back of the PT Module and then both with the holes in the front of the PT Module mounting bracket . At the same time but from the back, align the holes in the large PT Module Insulation Barrier with the holes PT Module mounting bracket . Secure the PT Module, small Insulation Barrier, and large Insulation Barrier to the PT Module mounting bracket using the (2) .138-32 × 0 .500 screws, (4) flat washers, (2) lock washers, and (2) nuts supplied .

Figure 26. PT Module and Insulation Barriers Mounted to the PT Module Mounting Bracket and Trip Unit Assembly.

Step 8: Mounting the trip Unit Assembly to the Breaker

Figure 27. Overview: Trip Unit Assembly Mounted to the Breaker.

A . Remove the two bolts and bearing caps from each end of the breaker Racking Bar .

B . Position the Trip Unit Assembly down over the insides of the breaker Racking Bar bearing . Secure the Trip Unit Assembly to the breaker using the existing bearing caps and the (4) .250-20 × 0 .750 bolts, (4) lock washers, and (4) flat washers supplied .

Figure 28. Trip Unit Assembly Mounted to the Breaker.

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For Kits Supplied with a PT Module Only.

C . Drill and tap the top of each top Stud on the rear of the breaker, per Drilling Plan ‘C’ to accept a 0 .190”-32 screw .

Figure 29. Drilling Plan “C”: Drilling the Breaker Studs for PT Wire Connections.

D . Refer to Section 7-3, Power Flow Convention of the Retrofit Application Data, supplied with the Retrofit Kit for additional wir-ing information and to verify the Phase Convention used on this Breaker Application .

The PT Wires are marked for connection to Phases 1, 2, and 3 with corresponding numbers .

Note: Before cutting the PT Wires, verify the Phase Convention used on the Breaker Application .

Route the PT Wires from the PT Module back to the top breaker Studs . Move the PT Wire markers to a position where they will still be attached to the wires after cutting . Cut the wires to the appropriate length, strip each wire .250”, and install a .190” ring terminal on each wire .

Using the (3) .190-32 × 0 .375 screws, (3) lock washers, and (3) flat washers supplied secure the appropriate PT wire to each top Stud .

Figure 30. PT Wires Connected to the Top Breaker Studs.

E . Secure the PT Wires away from any moving parts on the breaker using the self-adhesive mounting pads and wire ties supplied .

Step 9: Installing the Auxiliary Ct Module

Figure 31. Overview: Aux. CT Module Installed in the Breaker.

A . For Kits Supplied with a CPT Module Only . There are four (4) existing holes in the left breaker frame near the front of the breaker . Enlarged all four holes using a 0 .203” drill bit (see Figure 32) .

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Figure 32. Holes to Be Enlarge to Mount the Aux. CT Module.

B . From inside the breaker, align the Aux . CT Module mounting plate with the four (4) holes in the left breaker Frame . Secure the Aux . CT Module mounting plate to the inside of the left breaker frame using the (4) .190-32 × 0 .500 screws, (8) flat washers, (4) lock washers, and (4) nuts supplied .

For Kits Supplied with a CPT Module Only . If a CPT Module was included with the Retrofit Kit, DO NOT install the lower two (2) Aux . CT Module mounting plate screws, washers, and nuts at this time . The lower two (2) mounting holes will be used to mount the CPT Module later in this Retrofit process

C . Remove and save the two (2) bottom screws from the left side of the Aux . CT Module .

D . From the inside of the breaker, align the holes in the left side of the Aux . CT Module with the bottom four (4) holes in the Aux . CT Module mounting plate . Secure the Aux . CT Module to the mounting plate using the original mounting hardware just removed in the bottom holes and (2) .190-16 × 0 .500 thread cut-ting screws, (2) lock washers, and (2) flat) supplied in the top holes .

Figure 33. Aux. CT Module Secured to the Mounting Plate.

E . After the Aux . CT Module is mounted, check to insure that the ground lug on the left side of the breaker frame is clear of the Aux . CT module and the mounting bracket . If it is not, loosen the hardware securing the ground lug to the breaker and adjust the lug until proper clearance is achieved .

For Kits Supplied with a CPT Module Only.

Step 10: Installing the Cpt Module

Figure 34. Overview: CPT Module Installed in the Breaker.

Enlarge

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A . Remove and save the (2) .190 - 32 × .250” screws securing the fuse clips and male spade connector installed on the CPT Module . Discard the fuse clips and spade connector, then rein-stall the screws in the CPT Terminals .

Figure 35. Fuse Clips and Spade Connector Removed from the CPT.

Note: The Load Side HV Wires may be longer than necessary . Before cutting the wires, be sure that sufficient length is left so that the HV Wire Fuses can be mounted in an accessible position and that the connections can be made to the correct “H” terminals on the CPT Module .

Figure 36. Load and Line Sides of the HV Wires.

B . Temporarily position the CPT Module and the HV Fuses near the front left corner of the breaker . Route the Load Side HV Wires to the CPT Module . Mark and cut the Load Side of each HV Wire to an appropriate length for connection to the “H” terminals of the CPT . Strip approximately 0 .250” of insulation from the Load Side HV Wires and attach a 0 .190” ring terminal to each . Attach the HV Wires to the CPT “H” terminals to achieve the required volt-age (see Table 1) .

Note: The terminals to which the Load Side HV wires are connected deter-mine the voltage of the CPT . Verify that the line voltage of the circuit match-es the CPT voltage BEFORE putting the Breaker into service .

Line Side Load Side

Table 2. CPT High Voltage Taps for Standard and Special Order CPTs

Standard CPT (Style #9A10037G01 & G02)

Voltage Required CPT Terminals Used

480 volts Circuit H1 & H4

240 Volt Circuit H2 & H4

208 Colt Circuit H3 & H4

Special Order 575 Volt CPT (Style #9A10037G03 & G04)

575 volts Circuit H1 & H4

460 Volt Circuit H2 & H4

230 Colt Circuit H3 & H4

C . Connect the CPT Harness wires to the appropriate “X” terminals of the CPT Module as shown . See Table 3 for Tap information .

Table 3. CPT Low Voltage Taps for Standard and Special Order CPT (After Removing fuse Clips)

Standard CPT (Style #9A10037G01 & G02)

120 Voltage Required CPT Terminals Used

Secondary Circuit X1 & X2

Special Order 575 Volt CPT (Style #9A10037G03 & G04)

Secondary Circuit X2 & X3

D . Install the “A” and “B” Finger-Safe Covers over the CPT Terminals as shown . Secure the Finger-Safe Covers to the CPT using the (4) .098 - 28 × .375” screws supplied with the CPT Kit . Torque the screws to 8 - 10 in ./lbs .

Figure 37. Finger Safe Covers Installed on the CPT.

Finger Safe Covers

HV Wires

CTP Harness

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E . Working from inside the breaker, align the mounting holes in the CPT Module with the holes in the Aux . CT Module mounting plate . Secure the CPT Module to the Aux . CT Module mounting plate and left breaker frame using the (4) .190-32 × 0 .750 screws, (8) flat washers, (4) lock washers, and (4) nuts supplied

F . Secure the HV Fuses in their desired location within the breaker . Insure that the selected location allows the HV Fuses to clear all moving components within the breaker and will not interfere as the breaker is being racked into the Cell .

G . Install the appropriate CPT Voltage Label on the breaker Front Cover .

Figure 38. CPT Voltage Labels Supplied with the CPT Kit.

ote:N The power convention of circuit breakers is normally Top to Bottom, meaning the top breaker Studs are on the Line Side of the breaker and the bottom breaker Studs are on the Load Side .

The HV Wires from the CPT MUST BE ATTACHED to the Line Side of the breaker . If it is determined that the power flow for the breaker application is opposite the normal convention, the HV Wires must be attached to the bot-tom breaker Studs . In the case of the Line Side being the bottom breaker Studs, the HV Wires can be connected to the bottom Studs in a similar man-ner as the PT wires are connected to the breaker Studs in Step 7 .

Note: The Line Side HV Wires may be longer than necessary . Before cutting the wires, be sure that sufficient length is left so that the HV Wire Fuses are accessible and that the connections can be made to the Studs .

H . Route the HV Line Side Wires to the Phase 1 and 2 or the Phase 2 and 3 top breaker Studs . Cut each HV Wire to an appropriate length for attachment to the same hardware used to secure the PT Wires to the top breaker Studs . Strip .250” from each wire and then install a .190” ring terminal on each wire .

208VCONTROL POWER TRANSF. TAPS

H1–H4=480V H2–H4=240VH3–H4=208V

WARNINGTHIS BREAKER CONTAINS A 50VA

CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY. IF BREAKERIS USED ON A LINE VOLTAGE OTHERTHAN SHOWN. THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING.FAILURE TO DO SO WILL RESULT IN

DAMAGE TO THE TRIP UNIT AND / ORCONTROL POWER TRANSFORMER

NP# 9A10039H04


H1–H4=480V H2–H4=240VH3–H4=208V




NP# 9A10039H03


H1–H4=480V H2–H4=240VH3–H4=208V




NP# 9A10039H02


H1–H4=575V




NP# 9A10039H01

I . Remove the existing hardware securing the PT wires to the Phase 1 and 2 or Phase 2 and 3 top breaker Studs . Secure the HV Line Side Wires and the PT wires to the top breaker Studs using the hardware just removed .

Figure 39. HV Line Side Wires Connected to the Top Breaker Studs.

J . Route the CPT Harness from the CPT Module to the right side of the Trip Unit . It will be connected to the Trip Unit later in the Retrofit process .

K . Use the self-adhesive mounting pads and wire ties supplied to secure the HV Wires away from any moving breaker compo-nents .

Step 11: Connecting the Sensor and DtA Harnesses

Figure 40. Overview: Sensor and DTA Harnesses Connected to the Aux. CT Module.

A . Connect the Sensor Harness to the proper terminals of the Aux . CT Module . Refer to Section 12 of the Retrofit Application Data, supplied with the Retrofit Kit, for detailed wiring specifications . The long tan and green wires in the Sensor Harness are used for a remote Neutral Sensor on a 4W Ground Breaker . If these wires are not used in this application, they should be removed from the Sensor Harness .

B . Remove the front screw and washers from the right side of the Aux . CT Module . Connect the Sensor Harness Ground Wire (with ring terminal) to the Aux . CT Module using the screw and washers just removed .

16




Figure 41. Sensor Harness and Ground Wire Connected to the Aux. CT Module Terminals and Case.

C . Route the Sensor Harness back from the Aux . CT Module to the Sensors . Insure that the Sensor Harness is clear of all moving components within the breaker .

D . Connect the ring terminals of the Sensor Harness to the Sensors .

Refer to Section 12 of the Retrofit Application Data, supplied with the Retrofit Kit, for detailed wiring specifications .

Figure 42. Sensor Harness Connected to the Sensors.

E . Route the DTA wires to the Aux . CT Module . Insure that the DTA wires are clear of any moving components within the breaker .

F . Connect the “+” DTA Wire to the “OP” terminal of the Aux . CT Module Terminal Block and the unmarked wire to the “ON” termi-nal .

Figure 43. DTA Wires Connected to the Aux. CT Module Terminal Block.

G . Use the wire ties and clamps supplied to secure the Sensor Harness and DTA Wires so they are clear of any moving compo-nents within the breaker .

Step 12: Installing the External Harness and Final Connections

Figure 44. Overview: Harnesses Connected to the Trip Unit.

A . Plug the Aux . CT Harness into the connector on the Aux . CT Module Pigtail .

B . Route the Aux . CT Harness up through the breaker then across to the right side of the Trip Unit . Connect the Aux . CT Harness to its receptacle in the Trip Unit .

17




C . Connect the External Harness to the receptacles in the Trip Unit .

D . Attach the External Harness to the right Trip Unit Support Clip with two nylon wire clamps supplied . Use the two screws locat-ed there that attach the Support Clip to the Trip Unit Mounting Bracket .

Note: For 510 Basic Kits, the External Harness is the Shorting Plug pictured below . It is to be plugged into the corresponding receptacle in the Trip Unit .

Figure 45. 510 Basic Kit External Harness Shorting Plug.

E . For Kits Supplied with a PT Module Only: Route the PT Extension Harness between the Trip Unit and Insulation Barrier to the right side of the Trip Unit . Connect the PT Extension to the corresponding plug on the External Harness .

Figure 46. Routing and Connection of the PT Extension Harness to the External Harness.

For Kits Supplied with an Auxiliary Switch Only.

F . Cut 2 .12” off the end of the Microswitch Arm .

G . Align the holes in the Microswitch with the holes in the Auxiliary Switch mounting bracket . Secure the Microswitch to the Auxiliary Switch Mounting Bracket, as shown, using the (2) .138-32 × 1 .00 screws, (4) flat washers, (2) lock washers, and (2) .138-32 nuts supplied .

Figure 47. Microswitch Installed on the Auxiliary Switch Mounting Bracket.

F . Route the two wires with Ring Terminals from the External Harness down to the Microswitch . Connect one wire to the normally “Open” terminal and the other wire to the “Common” terminal of the Microswitch .

Mount the Auxiliary Switch Assembly behind the DTA mount-ing bracket as shown using the (2) .190-32 × .375 screws, (2) lock washers, and (2) flat washers supplied . The Microswitch Lever operates off of the Phase 3 Insulating Link as shown . The Microswitch must open and close as the breaker opens and closes .

Figure 48. Auxiliary Switch Assembly Installed on the DTA Mounting Bracket.

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For Kits Supplied with a CPT Module Only.

G . Remove the External Harness plug connected to the Trip Unit . Connect the black plug of the CPT Harness into the same recep-tacle in the Trip Unit from which the External Harness plug was removed . Reinsert the External Harness plug just removed into the female receptacle on the CPT Harness .

Figure 49. CPT Harness Connected to the External Harness.

For All Retrofit Kits.

H . Use the wire ties and clamps supplied to secure all wires and harnesses away from any moving components within the break-er .

Step 13: Final Breaker preparation

Figure 50. Overview: Breaker Ready for Testing.

A . Use the self-adhesive mounting pads and wire ties supplied to dress all wires and harnesses to keep them away from any mov-ing parts within the Breaker .

B . Reinstall the breaker Front Cover using the original hardware removed in Step 2-E .

C . If equipped, using the original mounting hardware removed in Step 2-D, reinstall the Manual Closing Handle .

Step 14: testing the Breaker

A . Measure the force necessary to trip the Breaker at where the DTA Adjusting Screw impacts the Breaker Trip Paddle . The force necessary to trip the Breaker MUST NOT EXCEED 5 lbs .

B . The Retrofit must be tested using primary injection . Refer to Section 8 of the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers (Publication AD 33-855-4, September 2001), supplied with the Retrofit Kit, for detailed testing procedures and specifications . For test information spe-cific to the Trip Unit, refer to the IL publication supplied with the Retrofit Kit (see the Pick List for the IL number) .

C . While Section 8 of the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers provides the infor-mation necessary for testing the Breaker, please keep the follow-ing notes in mind when reviewing other sections of the publica-tion .

CAUTION:WHEN ALL TESTING IS COMPLETE, THE TRIP UNIT MUST BE RESET. FAILURE TO DO SO MAY CAUSE THE BATTERY IN THE RATING PLUG TO RUN DOWN.

NOTES:

1 . For All Kits Other Than 510 Basic: If testing the Breaker with Short Delay or Ground Fault functions, be sure to either plug in the Cell Harness Assembly or use the Zone Interlock Shorting Plug . Failure to do so may result in shorter than expected trip times .

2 . For 810 and 910 Kits Only: Without any power applied to the system (neither the 120 volt power supply nor the Aux . Power Module connected), plug the External Harness into the Cell Harness and check the impedance between COM 1 and COM 2 . The impedance should be between one (1) and three (3) ohms . If the impedance is not within this range, trace the wiring and examine each connection to assure its integrity .

Confirm that the PowerNet communication wiring is cor-rect by following the procedures detailed in Section 7 .4 of the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers . Note that for 810 and 910 Kits, the impedance between COM 1 and COM 2 should be between one (1) and three (3) ohms .

When testing is complete, disconnect the External Harness from the Cell Harness . Final External Harness connection will be per-formed later in the Retrofit Process .

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Step 15: Mounting the Cell Harness

A . The Cell Harness is to be mounted in the Breaker Cell . The con-nector end is to be mounted on the right side of the Cell, in a location suitable for connection with the External Harness . The Terminal Blocks can be mounted anywhere space is available in the Cell as long as connection to the External Harness can be made .

B . Route the Cell Harness wiring to keep it away from any moving parts within the Cell Housing .

Step 16: Installing the Retrofitted Breaker in the Cell

WARNING: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 FLASH-OVER, CAUSING DEATH, SERIOUS PERSONAL INJURY, AND / OR PROP-ERTY DAMAGE.

Note: It is the responsibility of the Retrofitter to insure proper Breaker / Cell fit . When racking the Breaker into the Connected position, the Retrofitter MUST FOLLOW BOTH the manufacturer’s instructions and the customer’s safety standards and procedures for racking a Breaker into the “Connected” position .

A . With the Breaker in the Open position and the springs dis-charged, slowly rack the Breaker into the Connected position, making sure there is no interference or binding . The Breaker should rack smoothly and without mechanical interference between any Breaker and Cell parts . The Retrofitter will feel some resistance when the primary fingers connect onto the stabs of the Cell . This is normal .

However, if any unusual resistance is detected that could be abnormal interference between the Breaker and Cell parts, stop immediately and move the Breaker out of the Connected posi-tion . Examine what is causing the interference and correct the situation .

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Digitrip Retrofit Kit Installation Components for Siemens-Allis RLX-1600 Breaker RMS/R Retrofits

Step Description Qty. Comment

Step 3 Sensor 151D995G16 3

Step 4 DTA Assembly 6503C67G13 1

DTA Reset Parts 8153A22G04 1

Mounting Bracket 1

DTA Reset Assembly 1

Bracket 1

.190-32 × .500 Lng. Screw, Stl., Fil. 3

.190 Flat Washer Stl. 6

.190 Lock Washer Stl. 3

.190-32 Nut Hex Stl. 32

DTA Trip Bar Assembly 8153A22G05 1

Trip Assembly 1

Bracket 1

Spring 1

Loc-Tite® 242 1

.250-20 Flange Nut, Stl. 2

.164-32 × .375 Lng. Screw, Stl., Fil. 3

.164-32 × .500 Lng. Screw, Stl., Fil. 6



Step 5 Breaker Reset Parts 8153A22G06 1

Wrist Pin 1

“X” Washer .500 Stl. 2


Step 6 DTA Mounting Hardware 8153A22G07 1

.250-20 × .750 Lng. Screw, Stl., T.C. 2



.190-32 × .500 Lng. Screw, Stl., Fil. 1



.190-32 Nut Hex Stl. 1

Step 7 Trip Unit See Pick List 1

Rating Plug See Pick List 1

Trip Unit Assembly Parts 8153A22G08 1

Mounting Plate 1

Mounting Bracket 2

Bracket 1

Support Clip 1

Mounting Clip 2

Insulation Barrier 1

Digitrip Retrofit Label 1

.250-20 × .750 Lng. Hex Bolt Stl. 8




21




Digitrip Retrofit Kit Installation Components for Siemens-Allis RLX-1600 Breaker RMS/R Retrofits (Cont.)

Step 7 Cont. .190-32 × 4.00 Lng. Screw Fil. 2

.190-32 × .500 Lng. Screw Nylon P. H. 2




.164-32 × .250 Lng. Screw 2



.138-32 × .380 Lng. Screw Fil. 4


.138 Lock Washer Stl., Helical 4


.112-40 × .250 Lng. Screw Fil. 4



Spacer, Brass 2

PT Module 6502C82G01 1 Comm. Only

Ring Terminal (.190, .250, .312, .375, .500) – Each Size 3

PT Harness 6502C85G01 1 Comm. OnlyFrom Step 12

PT Module Mounting Plate 1 Comm. OnlyFrom Step 12

Insulation Barrier, Small 1 Comm. Only From Step 12

Insulation Barrier, Large 1 Comm. Only From Step 12

PT Module Nameplate 1 Comm. Only From Step 12

PT Harness 1 Comm. Only From Step 12

.190-32 × .375 Lng. Screw, Stl., Fil. HD 3 Comm. Only From Step 12

.190 Flat Washer Stl. 3 Comm. Only From Step 12

.190 Lock Washer Stl. 3 Comm. Only From Step 12

.164-32 × .500 Lng. Screw, Stl., Fil. 2 Comm. Only From Step 12


.164 Lock Washer Stl. 2 Comm. Only From Step 12

.164-32 Nut Hex Stl. 2 Comm. Only From Step 12

.138-32 × .500 Lng. Screw Stl., Fil. 2 Comm. Only From Step 12


.138 Lock Washer Stl. Helical 2 Comm. Only From Step 12

.138-32 Nut Hex Stl. 2 Comm. Only

Step 8 .250-20 × .750 Lng. Hex Bolt Stl. 4 From Step 7

.250 Flat Washer Stl. 4 From Step 7

.250 Lock Washer Stl. 4 From Step 7

Step 9 Aux. CT Module 6503C59G__ 1

Aux. CT Module Mounting Parts 8153A22G09 1

Mounting Plate 1

.190-16 × .500 Lng. Screw, Stl., P. H. 4

.190-32 × .500 Lng. Screw, Stl., Fil. 4




22





Step 9 (contd.) Mounting Pad - 1”, Self-Adhesive 2 From Step 12

Wire Tie Nylon 2 From Step 12

Step 10 CPT Kit See Pick List 1 CPT Only

MTE Transformer 1 CPT Only

HV Fused Wires 2 CPT Only

CPT Wires 1 CPT Only

Mounting Hardware Kit 1 CPT Only

.190-32 × .750 Lng. Screw Stl. Fil. 4 CPT Only

.190 Flat Washer Stl. 8 CPT Only

.190 Lock Washer Stl. 4 CPT Only

.190-32 Nut Hex Stl. 4 CPT Only

Ring Terminal (.138, .190, .250, .312, .375, .500 - Each Size)

2 CPT Only

Warning Label (208, 240, 480, & 575 Volt - Each) 1 CPT Only

Wire Tie Nylon 12 CPT Only

Finger-Safe Cover Kit FSK4 1 CPT Only

Cover (A, B, C, & D Each) 1 CPT Only

.098-28 × .375 Lng. Screw Stl. Fil. 4 CPT Only

Step 11 Sensor Harness Parts 8153A22G10 1

Sensor Harness 1

Wire Tie Nylon (Panduit) 8

Clamp Nylon 2

.138-32 × .500 Lng. Screw Stl. Fil. 1




Step 12 Auxiliary CT Harness 6502C84G02 1

PT Extension Harness 6502C85G01 1 Comm. Only

External Harness 6502C83G__ 1

Harness Mounting Parts 8152A22G11 1 Comm. Only

.138-32 × .500 Lng. Screw Stl., Fil. 2 Comm. Only

.138 Flat Washer Stl. 4 Comm. Only

.138 Lock Washer Stl. Helical 2 Comm. Only


Clamp Nylon 2 Comm. Only

Wire Clamp 2 Comm. Only

Wire Tie Nylon (Panduit) 8 Comm. Only

Auxiliary Switch Kit 8153A22G02 1 Comm. Only

Microswitch 1 Comm. Only

Aux. Switch Mounting Bracket 1 Comm. Only

.190-32 × .375 Lng. Screw Stl. Fil. HD 5 Comm. Only


.190 Lock Washer Stl. 3 Comm. Only


.138-32 × 1.00 Lng. Screw Stl. Fil. 2 Comm. Only




23





Step 15 Cell Harness See Pick List 1

Note: Due to the wide variety of Breakers and the multiple functions of the Retrofit components, some excess hardware may remain when the Retrofit is complete .

Table 4. Torque Values for General Mounting and Screw Size Conversion

Decimal Size (in) Standard Size Torque (in-lbs) Torque (ft-lbs)

.112 4.40 10 0.8

.138 6.32 18 1.5

.164 8.32 36 3.0

.190 10.32 46 3.8

.250 1/4-20 100 8.3

.312 5/16-18 206 17.2

.375 3/8-16 356 29.7

.438 7/16-14 572 47.7

.500 1/2-13 856 71.3

Table 5. Torque Values for Copper BUS Connectors

Decimal Size (in) Standard Size Torque (in-lbs) Torque (ft-lbs)

.250 1/4-20 60 5

.312 5/16-18 144 12

.375 3/8-16 240 20

.500 1/2-13 600 50

24




Figure 51. Retrofit Components

A. Sensors

B. RMS/R trip Unit Assembly

C. Auxilliary Ct Module

D. Direct trip Actuator and Hardware

E. pt Module (810 & 910 Kits only)

F. Sensor Harness

G. Auxilliary Ct Harness

H. External Wire Harness

I. pt Extension Harness (810 & 910 Kits only)

J. Auxiliary Switch (810 & 910) Kit only)

K. Cell Harness

25




Notes:

26




Notes:

27




Notes:



Eaton CorporationElectrical Group1000 Cherrington ParkwayMoon Township, PA 15108United States877-ETN-CARE (877-386-2273)Eaton .com

© 2010 Eaton CorporationAll Rights ReservedPrinted in USAPublication No . IL 33-RXC-1 / TBG000316April 2010

PowerChain Management is a registered trademark of Eaton Corporation .

All other trademarks are property of their respective owners .

The instructions for installation, testing, maintenance, or repair herein are provided for the use of the product in general commercial applications and may not be appropriate for use in nuclear applica-tions . Additional instructions may be available upon specific request to replace, amend, or supplement these instructions to qualify them for use with the product in safety-related applications in a nuclear facility .

The information, recommendations, descriptions, and safety nota-tions in this document are based on Eaton’s experience and judg-ment with respect to Retrofitting of Power Breakers . This instruction-al literature is published solely for information purposes and should not be considered all-inclusive . If further information is required, you should consult an authorized Eaton sales representative .

The sale of the product shown in this literature is subject to the terms and conditions outlined in appropriate Eaton selling policies or other contractual agreement between the parties . This literature is not intended to and does not enlarge or add to any such contract . The sole source governing the rights and remedies of any purchaser of this equipment is the contract between the purchaser and Eaton .

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULAR PURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS, AND DESCRIPTIONS CONTAINED HEREIN. In no event will Eaton be responsible to the purchaser or user in contract, in tort (including negligence), strict liability or otherwise for any special, indirect, incidental or conse-quential damage or loss whatsoever, including but not limited to damage or loss of use of equipment, plant or power system, cost of capital, loss of power, additional expenses in the use of existing power facilities, or claims against the purchaser or user by its cus-tomers resulting from the use of the information, recommendations and description contained herein .

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