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Effective 

October, 2000

IL 33-G2C-2

SAFETY PRECAUTIONS

POWER CIRCUIT BREAKERS ARE EQUIPPED
WITH HIGH SPEED, HIGH ENERGY OPERATING
MECHANISMS. THE BREAKERS AND THEIR
ENCLOSURES ARE DESIGNED WITH SEVERAL
BUILT-IN INTERLOCKS AND SAFETY
FEATURES INTENDED TO PROVIDE SAFE AND
PROPER OPERATING SEQUENCES. TO PRO-
VIDE MAXIMUM PROTECTION FOR PERSON-
NEL 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.

• 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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Summary of Contents for Digitrip 510

Page 1: ...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...

Page 2: ...lled 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 cert...

Page 3: ...ng 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 vers...

Page 4: ...ing the Retrofit Process DO 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 THA...

Page 5: ...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 Break...

Page 6: ...m 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 t...

Page 7: ...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...

Page 8: ...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 Brac...

Page 9: ...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 Sen...

Page 10: ...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 hol...

Page 11: ...e Aux CT Module Note The long tan and green wires are for the Remote Neutral Sensor on a 4W Ground Breaker They should be removed if not required for the Retrofit C Install the supplied grommet in the...

Page 12: ...n and to verify the Phase Convention used on this Breaker Application C Install the supplied grommet in the hole near the top right corner of the Breaker Back Plate D Route the Sensor Harness towards...

Page 13: ...ness inside the Breaker towards the left front corner G Use the nylon wire ties and clamps supplied to dress all wires to keep them away from any moving parts within the Breaker H Carefully return the...

Page 14: ...Terminal Block mounted on the DTA Assembly Connect the wire of the DTA Extension Harness to the same terminal as the DTA Wire marked Connect the unmarked wire of the DTA Extension Harness to the same...

Page 15: ...p Finger to the DTA flange nut K Verify DTA trips the Breaker by applying 24 VDC to DTA terminals L With Breaker in the OPEN position remove the original 375 16 1 50 hex bolt from the left hand side o...

Page 16: ...rs 4 lock washers and 4 nuts supplied B Align the Glass Ploy Insulation with the holes in the CPT Mounting Bracket as shown Secure the CPT to the mounting bracket using the 2 190 32 625 nylon screws 2...

Page 17: ...ashers and 2 nuts supplied C Using Drilling Plan C drill two 2 312 holes in the left side of the Top Breaker Channel Note Cover the area below the location in which the holes will be drilled to preven...

Page 18: ...ed to prevent the drilling chips from falling into the Breaker A Using Drilling Plan E mark and drill two 2 312 diameter holes in the right side of the middle Breaker Channel Note Cover the area below...

Page 19: ...off the end of the Microswitch Arm Mount 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 nuts supplied Note The or...

Page 20: ...F Align the holes in the L shaped Trip Unit Mounting Bracket with the holes drilled in the Breaker Channel in the applicable Step 8 A Secure the Mounting Bracket to the Breaker Channel using the 2 250...

Page 21: ...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 Bottom Breaker Stabs B Route...

Page 22: ...ress the HV Wires and keep them away from any moving parts within the Breaker G Attach the appropriate label for the Breaker to the Breaker Cover in a clearly visible position Three 3 labels are inclu...

Page 23: ...ters Move the PT Wire markers to a position where they will still be attached to the wires after cutting Cut the wires to length strip each wire 250 and install a 380 ring terminal on each wire Connec...

Page 24: ...t Kits on Power Circuit Breakers Publication AD 33 855 1 June 1997 supplied with the Retrofit kit for detailed testing procedures and specifications For test information specific to the Trip Unit refe...

Page 25: ...ternal Harness can be made B Route the Cell Harness wiring to keep it away from any moveable parts within the Cell Housing Step 14 Installing the Retrofitted Breaker in the Cell Do not leave the Break...

Page 26: ...Screw 6 138 Lock Washer Stl 6 Flexiform Grommet 6 Inch 3 Terminal 6 Insulating Ring 9 Sensor Mounting Parts 8258A95G15 1 500 13 1 50 Lng Hex Bolt 2 500 Flat Washer Stl 4 500 Lock Washer Stl 2 500 13...

Page 27: ...r Stl 4 190 Lock Washer Stl 4 Step 6 Sensor Harness Mounting Parts 6503C83G01 1 Sensor Harness 1 DTA Extension Harness 1 Grommet 1 Wire Ties Nylon 6 Step 7 DTA Assembly 8258A95G35 1 DTA Mounting Parts...

Page 28: ...ing Bracket R H 1 Glass Poly Barrier 1 Spacer Brass 4 190 32 5 00 Lng Screw Stl 2 190 32 500 Lng Screw Stl 2 190 32 625 Lng Screw Nylon 2 190 Flat Washer Stl 10 190 Flat Washer Nylon 2 190 Lock Washer...

Page 29: ...Stl 4 250 Lock Washer Stl 2 250 20 Nut Hex Stl 2 Step 10 Aux CT Harness 6502C84G02 1 External Harness 6502C83G__ 1 Harness Mounting Parts 8258A95G10 1 164 32 750 Lng Screw 7 164 Flat Washer Stl 14 16...

Page 30: ...8 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 Torque Values for Copper BUS Connectors Decimal Standard Tor...

Page 31: ...ensor Harness K PT Module L External Harness M Cell Terminal Block Assembly NOTE This family photo includes the components to complete the Retrofit for all Breakers covered in the IL Therefore all of...

Page 32: ...on recommendations descriptions and safety notations in this document are based on Cutler Hammer s experience and judgement with respect to retrofitting of power breakers This information should not b...

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