Eaton Digitrip Retrofit System Instruction Leaflet Download Page 22

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EATON CORPORATION www.eaton.com

Instruction Leaflet IL 33-LGH-3

Effective September 2010

Digitrip Retrofit System for the ITE

LG-3000 (Frameless) Circuit Breaker

Digitrip Retrofit Kit Installation Components for the ITE LG-3000 Frameless Series Breaker (Continued)

Step

Description

Style No.

Qty. Comment

Step 9

Rating Plug

See Pick List

Trip Unit Mounting Parts

4A35792G06

.250-20 x 1.00 Lng. Hex Bolt

.250 Flat Washer Stl.

.250 Lock Washer Stl.

.250-20 Nut Hex Stl.

Step 10

External Harness

6502C83G__

External Harness Parts

4A35792G13

.138-32 x .500 Lng. Screw Fil.

.138 Flat Washer Stl.

.138 Lock Washer Stl.

.138-32 Nut Hex Stl.

.250-20 x .375 Lng. Hex Bolt (From Step 8)

.250 Flat Washer Stl. (From Step 8)

Comm. Only

.250 Lock Washer Stl. (From Step 8)

Wire Clamp Nylon

Wire Tie Nylon

Step 13

Cell Harness

6503C57G__

Except 510 Basic

NOTE:

Due to the wide vintage of breakers and the multiple functions of the Retrofit components, some excess hard-

ware may remain when the Retrofit is complete.

Summary of Contents for Digitrip Retrofit System

Page 1: ...tep 5 8 Step 6 10 Step 7 12 Step 8 13 Step 9 14 Step 10 15 Step 11 17 Step 12 18 Step 13 19 Step 14 19 Parts List 20 Effective September 2010 Supersedes IL 33 LGH 2 Dated 10 00 Instruction Leaflet IL 33 LGH 3 Digitrip Retrofit System for the ITE LG 3000 Frameless Circuit Breaker ...

Page 2: ...cuit 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 o...

Page 3: ...nt 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 th...

Page 4: ...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 necessary replacemen...

Page 5: ...mation B Remove and save the hardware securing the pivot block to the front Breaker Frame C Mount the Aux CT Module Mounting Bracket to the front Breaker Frame as shown using the original mounting hardware and the 2 500 flat washers supplied D Remove the two 2 existing screws from the back of the Aux CT Module Cut away the grommet from the back of the Aux CT Module but leave the grommet in place o...

Page 6: ...ensor Harness connection will be made later in the Retrofit Process G Connect the wire of the DTA Extension Harness to the OP terminal of the Aux CT Module and the unmarked wire to the ON terminal Route the DTA Extension Harness through the inside of the Breaker towards the left side making sure it is clear of all moving parts within the Breaker Final routing and connection of the DTA Extension Ha...

Page 7: ...Breaker Route the harness down through the Breaker to the bottom right corner to the CPT making sure the Harness is clear of all moving parts within the Breaker Cut the Harness to a suitable length for attachment to the CPT E Strip 250 of insulation and attach a 138 ring terminal to each wire of the CPT Harness Connect the wires to the X1 and X2 terminals of the CPT F Attach the HV Wires to the CP...

Page 8: ...RIP UNIT DISPLAY IF BREAKER IS USED ON A LINE VOLTAGE OTHER THAN SHOWN THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE TRIP UNIT AND OR CONTROL POWER TRANSFORMER NP 9A10039H04 240V CONTROL POWER TRANSF TAPS H1 H4 480V H2 H4 240V H3 H4 208V WARNING THIS BREAKER CONTAINS A 50VA CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY IF BREAKER IS USED ON A LINE V...

Page 9: ... the nuts and washers securing the Breaker Secondary Contact Rack to the bottom rear of the breaker E Align the four 4 holes in the Sensor Support Brackets with the bolts used to secure the Breaker Secondary Contact Rack Secure the Sensor Assembly and Breaker Secondary Contact Rack to the Breaker as shown using the original washers and nuts just removed F Connect the ring terminals of the Sensor H...

Page 10: ... the DTA Assembly Mounting Bracket with the bolts used to secure the side cover Secure the DTA Assembly to the Closing Coil Case as shown using the original hardware just removed and the 2 625 flat washers supplied C Remove and scrap the two 2 bolts and washers on the left side of the Breaker Trip Bar D Remove and save the lock nut from the end of the Trip Shaft Insert the Trip Shaft through the c...

Page 11: ...pring from the Reset Shaft While holding the brass spacer in place on the Shaft insert the Reset Shaft into the cut out in the DTA Reset Arm Reinstall the original hardware on the Reset Shaft in the following order washer spring adjusting nut and lock nut I Align the holes in the Reset Assembly Mounting Bracket with the holes in the Breaker Cross Bar J Mount the Reset Assembly to the Breaker Cross...

Page 12: ...the lock nuts Note The Reset Shaft must not contact the floor when the Breaker is in the Closed position Close the Breaker and check for a clearance of 50 between the end of the Reset Shaft and the floor If this clearance is not present loosen and adjust the nuts on the top of the Reset Shaft until the 50 clearance is achieved If this adjustment is required the correct cage height must be verified...

Page 13: ...upport Clips on the sides of the Trip Unit so they pinch the Trip Unit in place Secure the Trip Unit Support Clips to the Trip Unit Mounting Bracket using the 4 138 32 x 375 screws 4 lock washers and 4 flat washers supplied E Align the Glass Poly Barrier Assembly with the holes in the Trip Unit Support Brackets Secure the Glass Poly Barrier Assembly to the Trip Unit Assembly using the 2 164 32 x 3...

Page 14: ...uts that secure the Control Panel Assembly to the Breaker Control Panel Assembly Mounting Bracket Note The original copper bolts and hardware just removed can be used to mount the Trip Unit Assembly and Breaker Control Panel Assembly to the Control Panel Mounting Bracket in the next Steps However new mounting hardware is supplied that can be used in place of the original mounting hardware B Align ...

Page 15: ...Trip Unit Cover and install the Rating Plug Replace the cover Step 10 Final Connection of the Harnesses and Wiring A For Kits Supplied with a PT Module Only Refer to Section 7 3 Power Flow Convention of the Retrofit Application Data supplied with the Retrofit Kit for additional wiring information and to verify the Phase Convention used on this Breaker Application Note Before cutting the PT Wires v...

Page 16: ...and 2 nuts supplied Note For 510 Basic Retrofit Kits the External Harness is the plug pictured here It is to be plugged into the right side of the Trip Unit D Connect the Aux CT Harness to its receptacle on the Trip Unit E For Kits Supplied with a PT Module Only Connect the PT Harness to the External Harness Plug the other end into the receptacle on the PT Module F For Kits Supplied with an Auxili...

Page 17: ... normal convention the HV Wires must be attached to the Bottom Phase Frames In this case the same bolts used to attach the PT Wires to the Phase 1 and 2 or Phase 2 and 3 Phase Frames can be used to mount the HV Wires Note The Line Side HV Wires are longer than necessary and are cut during the following steps Before cutting the wires be sure that suffi cient length is left so that the connections c...

Page 18: ...f Digitrip RMS Retrofit Kits on Power Circuit Breakers Publication AD 33 855 supplied with the Retrofit Kit for detailed testing procedures and specifications For test information specific 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 Ci...

Page 19: ... 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 moveable parts within the Cell Housing Step 14 Installing the Retrofitted Breaker in the Cell Do not leave the Breaker in an intermediate position in the switchgear cell Always leave it in the CONNECTED DISCONNECTED or Optional T...

Page 20: ...nsion Harness 1 Wire Tie Nylon 10 Step 4 Breaker Mounted CPT Kit 8259A91G05 1 Ring Terminals 138 190 250 312 375 500 Each Size 2 CPT Mounting Parts 4A35792G20 1 CPT Mounting Bracket 1 190 32 x 500 Lng Screw Fil 4 CPT Only 190 Flat Washer Stl 8 190 Lock Washer Stl 4 190 32 Nut Hex Stl 4 Grommet 1 Step 5 Sensors See Pick List 3 Sensor Mounting Parts 4A35792G04 1 Sensor Mounting Bracket 1 Support Bra...

Page 21: ...Screw 2 190 Flat Washer Stl 4 190 Lock Washer Stl 2 190 32 Nut Hex Stl 2 164 32 x 312 Screw Pan Lock 2 164 Flat Washer Stl 2 138 32 x 375 Lng Screw Fil 4 138 Flat Washer Stl 4 138 Lock Washer Stl 4 112 40 x 250 Lng Screw Fil 4 112 Flat Washer Stl 4 112 Lock Washer Stl 4 PT Module 6502C82G01 1 Ring Terminals 190 250 312 375 500 Each Size 3 PT Module Mounting Parts 4A35792G11 1 Insulation Barrier 1 ...

Page 22: ...Flat Washer Stl 4 250 Lock Washer Stl 2 250 20 Nut Hex Stl 2 Step 10 External Harness 6502C83G__ 1 External Harness Parts 4A35792G13 1 138 32 x 500 Lng Screw Fil 2 138 Flat Washer Stl 4 138 Lock Washer Stl 2 138 32 Nut Hex Stl 2 250 20 x 375 Lng Hex Bolt From Step 8 3 250 Flat Washer Stl From Step 8 3 Comm Only 250 Lock Washer Stl From Step 8 3 Wire Clamp Nylon 2 Wire Clamp Nylon 2 Wire Tie Nylon ...

Page 23: ...em for the ITE LG 3000 Frameless Circuit Breaker A C B E F N D A Sensors B Trip Unit C Aux CT Module D CPT Transformer E Rating Plug F Direct Trip Actuator DTA G HV Wires H External Harness I Cell Terminal Block Assembly J Sensor Harness K Aux CT Harness L PT Extension Harness M Aux Switch N PT Module G H I J K L M ...

Page 24: ... 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 3 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 ...

Page 25: ...25 Instruction Leaflet IL 33 LGH 3 Effective September 2010 Digitrip Retrofit System for the ITE LG 3000 Frameless Circuit Breaker eaton corporation www eaton com Notes ...

Page 26: ...26 Instruction Leaflet IL 33 LGH 3 Effective September 2010 Digitrip Retrofit System for the ITE LG 3000 Frameless Circuit Breaker eaton corporation www eaton com Notes ...

Page 27: ...27 Instruction Leaflet IL 33 LGH 3 Effective September 2010 Digitrip Retrofit System for the ITE LG 3000 Frameless Circuit Breaker eaton corporation www eaton com Notes ...

Page 28: ...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 enl...

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