Utility Relay AC-PRO Retrofit Kit Instructions Manual Download Page 40 | Manualshive

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Utility Relay AC-PRO Retrofit Kit Instructions Manual Download Page 40

Courtesy of NationalSwitchgear.com

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Summary of Contents for AC-PRO Retrofit Kit

Page 1: ...206 THROUGH DS850 Low Voltage Breaker Including Instructions for AC PRO with Modbus RTU Communications Utility Relay Co Chagrin Falls Ohio 44023 Phone 888 289 2864 Fax 440 708 1177 www utilityrelay com I ACM DS December 2014 Rev 10 Courtesy of NationalSwitchgear com ...

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Page 3: ...ructions 4 Promptly return the defective material to Utility Relay Company Warranty Disclaimer and Liability Limitation As the sole and exclusive remedy Utility Relay Co Ltd will repair or replace the trip unit and or retrofit component s at no cost to the customer during the warranty period The customer is liable and shall pay for shipment of defective products back to Utility Relay Co Ltd In no ...

Page 4: ...ther applicable codes regulations and work rules Do not perform any work including charging closing or tripping or any other function that could cause significant movement of a draw out breaker while it is on the extension rails For both draw out and bolt in breakers trip open and then move the breaker to a well lighted work area with a sturdy workbench before starting the retrofit Do not work on ...

Page 5: ...ng Actuator 8 8 1 Install Actuator Mechanical Assembly 8 8 2 Adjust Actuator Mechanical Reset Assembly 9 9 0 Wiring 10 9 1 Color Codes and Connections 10 9 2 Current Transformer Connections 11 9 3 Neutral Current Transformer 11 9 3 1 Interposing Neutral CT 11 9 4 Actuator Connection 12 9 4 1 Actuator Connection Existing Actuator 12 9 4 2 Actuator Connection New Actuator 12 10 0 Final Test 13 11 0 ...

Page 6: ...llation Amptector 25 10 Side View Neutral CT Installation Digitrip 26 11 Neutral Interposing CT Terminal Block Installation 27 12 Standard Wiring Diagram 28 13 Wiring Diagram 5 1 Interposing Neutral CT 29 14 Side View PT Module Installation Amptector 30 15 Side View PT Module Installation Digitrip 31 16 Side View Fuse Block Installation Amptector 32 17 Side View Fuse Block Installation Digitrip 33...

Page 7: ...it kit on arrival If any damage is found file a claim with the carrier and contact Utility Relay Co for replacement parts Verify that this is the correct kit for the circuit breaker being retrofitted Check the contents of the retrofit kit package against the kit bill of material to make sure that all the required parts are included Thoroughly read and understand these installation instructions as ...

Page 8: ...e to pole from pole to frame and across open contacts d Check contact compression e Check for sufficient finger cluster spring tension at the rear stabs Rectify any abnormalities found Clean and lubricate the breaker as required 3 0 Remove Existing Trip Unit 1 Remove the breaker front cover by removing four 4 screws 2 Disconnect the existing wiring harness at the old trip unit and remove the wirin...

Page 9: ...oles where marked 3 Attach bracket BR 0A023 to the back of the AC PRO using two 2 8 32 X 3 8 Phillips screws and lock washers 4 Temporarily attach the trip unit bracket assembly to the BR 020 1 bracket using two 2 10 32 X 1 2 Phillips screws flat washers and lock washers Make sure the trip unit is square in the window 5 Place the BR 038 face plate on the outside of the breaker front cover Adjust t...

Page 10: ...1 bracket as a guide mark the location of the two other holes Drill and tap two 2 1 4 20 holes where marked 3 Attach the BR 0A023 bracket to the back of the AC PRO using two 2 8 32 X 3 8 Phillips screws and lock washers leave the hardware loose enough to allow for adjustment 4 Loosely attach the trip unit and bracket assembly from step 3 onto the BR 020 1 bracket using two 2 10 32 X 1 2 Phillips s...

Page 11: ...utton on the CA 2 403 program button harness 2 Plug the harness connector into the KEY on the trip unit 3 Using the harness as a guide find a suitable location for the push button on the front of the breaker and mark for the mounting hole Verify the harness can be routed to the mounting location without pinching or cutting the wires 4 Drill a 1 4 hole in the previously marked location 5 Install th...

Page 12: ...M BUTTON push button 5 Make any necessary changes using the UP or DOWN buttons Use the SAVE push button to move to each new setting IMPORTANT The CT rating entered in the trip unit MUST match the actual CT taps used on the breaker Remember that the CT rating has an additional security feature as explained in Section 7 3 of the AC PRO instruction manual 6 After making all necessary changes press th...

Page 13: ...ole in the previously marked location 4 Unplug the CA 3 18 harness and install the CA 3 CM Quick Trip Display Coupler in the previously drilled hole 5 Plug the free end of the CA 3 18 harness connector into the CA 3 CM Quick Trip Display Coupler 6 Place the L 0238 Quick Trip Display label on the front of the breaker below the connector IMPORTANT Before drilling the 1 1 16 hole verify the location ...

Page 14: ...move and keep the trip shaft spring anchored to the actuator assembly An extra spring has been provided in case the existing spring is damaged 5 Remove the existing actuator assembly from the breaker 6 Carefully fit the new actuator assembly into place making sure the reset lever is in the correct position Attach the actuator assembly to the frame of the breaker using three 3 1 4 20 x 3 4 hex cap ...

Page 15: ...ith the breaker open screw the collar back to its original position Check that the set screw collar is adjusted so the reset lever has enough preload that it will provide a reliable reset Adjust the location of the set screw collar if necessary and lock in position 5 Close the breaker and trip the actuator using a 9 Volt battery Red is Cycle the breaker several times to verify reliable trip and re...

Page 16: ...on Make sure the wires will not be pinched cut or chaffed by any moving parts or sharp edges Follow the reference chart on the CT Verify that the polarity is correct and the correct terminals were used 9 1 Color Codes and Connections The wiring harness connector color code and connections are as follows from left to right Terminal Wire Color Use 1 Red R Actuator 2 Black B Actuator 3 Blue L Phase A...

Page 17: ...Figure 12 If the existing 5 Amp secondary neutral CT will be retained a 5 1 Amp interposing CT must be used as shown in Figure 13 9 3 1 Interposing Neutral CT Install the 5 1 neutral CT as described below and shown in Figure 9 or 10 1 Attach the interposing CT to bracket BR 312 using a 10 32 X 2 Phillips screw flat washer Nylock nut and HW 2400 2 rubber washer The HW 2400 2 rubber washer is to be ...

Page 18: ...ator and shorten the wires and tubing as required 3 Connect the red and black wires in the wiring harness to the existing actuator using the knife disconnects and the Teflon tubing provided Maintain proper polarity 4 Replace the breaker front cover 9 4 2 Actuator Connection New Actuator 1 Route the red and black wires from the actuator to the ACTUATOR terminal block on the trip unit Trim the wires...

Page 19: ...accordance with ANSI C37 50 1989 A 3 7 each retrofitted breaker must be tested Utility Relay Company recommends the following tests at a minimum a Dielectric b Primary injection pick up and trip c Resistance measurement of main contacts and conductors d Trip free operation of actuator Courtesy of NationalSwitchgear com ...

Page 20: ...assembly to the BR 020 1 bracket using two 2 1 4 20 X 1 2 Phillips screws and lock washers 11 2 Install Fuse Block for PT Module Install the 3 pole fuse block as shown in Figure 16 and 17 1 Attach the T 305 1 3 pole fuse block to the BR 312 bracket using two 2 8 32 X 3 8 SEMS screws 2 Attach the fuse block BR 312 bracket assembly to the BR 020 1 bracket using two 2 1 4 20 X 1 2 Phillips screws and...

Page 21: ...put Connect a 18 MTW wire from the Ground terminal of the PT Module to the breaker frame 3 PT Module Harness Plug the PT Module cable into the bottom of the AC PRO trip unit and the PT Module Use cable ties and holders to make a clean installation It is very important to make sure the wires will not be pinched cut or chaffed by any moving parts or sharp edges 4 Breaker Position Indication As an op...

Page 22: ...l four 4 13 64 mounting holes 3 For the center hole drill a 1 1 8 diameter hole or alternately use a 3 4 conduit knockout punch 4 Attach the QT SWITCH ENCLOSURE to the cubicle door using four 4 10 32 x 1 2 Phillips screws flat washers lock washers and hex nuts 5 Plug the QT SWITCH ENCLOSURE cable into the back of the QUICK TRIP Display Any extra cable can be stored by inserting through the grommet...

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