Cutler-Hammer Digitrip 510 Manual Download Page 31

Page: 31 / 32

Effective October, 2000

Page 31

A. Sensors
B. Trip Unit
C. Aux. CT Module
D. Direct Trip Actuator (DTA)
E. CPT Kit (Optional)
F. Rating Plug
G. Copper Adaptors

H. Aux. Switch
I.

Aux. CT Harness

J. Sensor 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 the components pictured will not be
included with all kits. Please note that the 0.75

Glass Poly Plate used in top fused

Breaker Retrofits is not shown in this photo.

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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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