Eaton digtrip 510 with zone Interlock, Installation, Operation And Maintenance Manual

Page 1: ...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 brea...

Page 2: ...sting the Breaker 33 Step 16 Mounting the Cell Harness 34 CONTENTS Step 17 Installing the Retrofitted Breaker in the Cell 34 Figures 1 Original Electromechanical Trip Units 7 2 Removing the Glastic Mo...

Page 3: ...ly Mounting Brackets 23 44 Connecting the Aux CT Harness 24 45 Overview Final Routing of the PT and HV Wires 24 46 Correct Position of the Insulated Tubing 25 47 PT Wires Connected to the Breaker Stag...

Page 4: ...ich 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 compone...

Page 5: ...1 Location Type Location Configuration Kit Code Non Fused K 1600 Black Top Rectangular None N A K1C K 1600 Red Top Rectangular None N A K2C K 2000 Red Top Round None N A K2D Top Mounted Horizontal an...

Page 6: ...ndition Visu ally inspect all Breaker components for signs of damage or wear If any signs of damage or wear are detected for compo nents not included in the Retrofit Kit secure the necessary replaceme...

Page 7: ...rews securing each of the three 3 copper pieces to the Breaker Pole Assemblies E Remove the Glastic Moldings with the at tached Electromechanical Trip Units from the Breaker Fig 1 Original Electromech...

Page 8: ...or the Sensor Harness can not be drilled where indicated in Drilling Plan A If this is the case with the Breaker Being Retrofitted follow the instructions in Step 3 B B For Use on Some Versions Workin...

Page 9: ...r in the Retrofit Process when connecting the PT and or HV Wires STEP 4 PREPARING THE DTA ASSEMBLY FOR INSTALLATION Fig 6 Overview DTA Assembly NOTE If an existing Breaker component does not allow the...

Page 10: ...TA Assembly as shown using the 2 164 32 625 screws 4 flat washers 2 lock washers and 2 nuts supplied Note that the non threaded holes in the Mounting Bracket are used to secure the Mounting Bracket to...

Page 11: ...tend through the hole in the DTA Reset Arm Fig 13 Overview DTA Assembly installed in the Breaker A Carefully lay the Breaker on its left side B Working from the bottom of the Breaker drill a 312 diame...

Page 12: ...ardware just removed again temporarily mount the DTA Assembly to the Breaker Fig 15 Correct Wiring Harness Position Fig 16 Spacers Installed with the DTA Assembly Return the Breaker to its upright pos...

Page 13: ...gle in Step 4 the Breaker Mounted CPT can not be installed on the DTA Assembly as detailed in the following steps The CPT will have to be mounted either in another location on the Breaker or in the Br...

Page 14: ...164 32 312 pan lock screws and 2 flat washers supplied Fig 20 Bracket Mounted to the CPT Insulation Barrier Fig 21 Identification of the Line and Load Side HV Wires NOTE The Load Side HV Wires are lon...

Page 15: ...attach a 138 ring terminal to each wire of the HV Wire Attach the HV Wires to the CPT terminals to achieve the required voltage See Table 3 Table 3 CPT Voltage Taps Fig 23 CPT Harness and HV Wires con...

Page 16: ...and 2 flat washers supplied Fig 26 Insulation Plate Mounted to the CPT J Tighten the hardware that secures the DTA Assembly to the Breaker K Attach the appropriate CPT Voltage Label in a clearly visib...

Page 17: ...turn the DTA Trip Plate until a gap of 06 is achieved between the bottom of the Breaker Trip Arm and the top of the DTA Trip Plate Fig 28 Overview DTA and Reset Adjustment A With the Breaker in its up...

Page 18: ...shown using the 2 164 32 312 pan lock screws and 2 flat washers supplied Fig 31 Mounting the DTA Insulation Plate K 2000 Breakers Only G Carefully lay the Breaker on its right side H If the Breaker is...

Page 19: ...d Assembly and the Auxiliary Switch Drive Link to the Pole Shaft Stop using the 1 250 20 1 25 bolt 4 flat washers and 1 lock nut supplied The lock nut should be installed so that the bolt Reset Rod As...

Page 20: ...s K 1600 BLACK RED K 2000 RED KDON 1600 BLACK AND RED Fig 38 Copper Connectors for the K 1600 2000 Breakers A Install a new Copper Connector with the short leg facing upwards in each of the Glastic Mo...

Page 21: ...ntact using the 4 312 18 1 12 hex cap bolts 4 lock washers and 4 flat washers supplied STEP 9 PREPARING THE TRIP UNIT ASSEMBLY Fig 38 Overview Trip Unit Assembly A Mount the Glass Poly Barrier to the...

Page 22: ...all the Cover G Install the Digitrip Nameplate on the top of the Trip Unit Fig 40 PT Module Mounted to the Glass Poly Barrier C Mount the Trip Unit to the top of the Aux CT Module as shown using the 2...

Page 23: ...g Brackets taller then the standard brackets have been supplied for some older models of the KDON 1600 Black Breaker equipped with trigger fuses If the Brackets are needed but were not ordered contact...

Page 24: ...se on both the PT and HV Wires For Kits Supplied with a PT Module Only A Cut appropriate length pieces from the sup plied insulated tubing and install one 1 piece on each PT Wire Route the three 3 PT...

Page 25: ...Note that the PT Wires are marked for connec tion to Phase 1 2 and 3 NOTE Before cutting the PT Wires verify the Phase Convention used on the Breaker Application B Route the PT Wires to a position su...

Page 26: ...re longer than necessary and are cut during the following steps Before cutting the wires be sure that sufficient length is left so that the connections can be made to the correct Breaker Stabs F Remov...

Page 27: ...6 250 20 500 bolts 6 lock washers and 6 flat washers supplied C Slide the Sensor Assemblies over the top Breaker Stabs Do not secure the Sensor Mounting Angle to the Breaker at this time D Reinstall t...

Page 28: ...sociated hardware removed in Step 2 B on the bottom Breaker Stabs Refer to the ITE K 1600 2000 Instruction Manual originally supplied with the Breaker for more information G Rotate the Secondary Conta...

Page 29: ...ng Platform to the Mounting Brackets at this time E Reinstall the bottom Finger Clusters removed in Step 2 B using the original hardware F Mount the Sensor Mounting Platform to the Sensor Mounting Bra...

Page 30: ...Sensor Harness towards the left rear of the Breaker then through the hole drilled in Step 3 A or B Fig 59 Routing of the Sensor Harness E Connect the ring terminals of the Sensor Harness to the Sensor...

Page 31: ...Mounting Bracket using the 2 nylon wire clamps and the 2 138 380 thread cutting screws supplied Fig 60 Sensor Harness Connected to the Top Mounted Sensors Fig 61 Sensor Harness Connected to the Bottom...

Page 32: ...least one 1 wire tie to secure the existing wiring harness that was routed below the DTA Assembly earlier in the Retrofit Pro cess to the left side of the Breaker as shown Fig 64 Securing the Externa...

Page 33: ...ations 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 F While Section 8 of the Instructions for the Appli...

Page 34: ...SEVERE PERSONAL INJURY AND OR PROPERTY 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 MU...

Page 35: ...Lock Washer Stl 2 164 32 Nut Hex Stl 2 Aux Switch Kit 4A35899G02 1 Microswitch 1 Mounting Bracket 1 138 32 1 00 Lng Screw 2 138 32 375 Lng Screw 2 138 Flat Washer Stl 8 138 Lock Washer Stl 4 138 32 N...

Page 36: ...3 K 1600 Black Kits Copper Connector K 1600 Red 8259A13G04 3 K 1600 Red Kits Copper Connector K 2000 Red 8259A13G05 3 K 2000 Red Kits Insulation Plate 1 Mounting Bracket 1 164 32 625 Lng Screw 2 164...

Page 37: ...omm Only From Step 13 Step 12 Sensor 3 See Pick List Sensor Mounting Parts 4A35899G10 1 Sensor Mounting Bracket 1 250 20 500 Lng Hex Bolt 6 250 Flat Washer Stl 6 250 Lock Washer Stl 6 375 16 750 Lng H...

Page 38: ...380 Lng Screw T C 2 Step 16 Cell Harness 6503C57G__ 1 Except 510 Basic Step 14 Cont NOTE Due to the wide variety of Breakers and multiple functions of the Retrofit components some excess hardware may...

Page 39: ...2 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 Decimal Standard Torque Torque Size in Size in lbs ft lbs 250 1 4 20 60 5 312 5 16 18 144 12 375 3 8 16 240 20 500 1 2 1...

Page 40: ...Transformer F Rating Plug G HV Wires H Aux CT Harness I Sensor Harness J External Harness K Cell Terminal Block L Aux Switch M PT Module N CPT Harness O DTA Extension Harness P Copper Connectors C B A...

Page 41: ...Effective 10 00 Page 41 IL 33 K2C 3 Notes w w w E l e c t r i c a l P a r t M a n u a l s c o m...

Page 42: ...Effective 10 00 IL 33 K2C 3 Page 42 Notes w w w E l e c t r i c a l P a r t M a n u a l s c o m...

Page 43: ...Effective 10 00 Page 43 IL 33 K2C 3 Notes w w w E l e c t r i c a l P a r t M a n u a l s c o m...

Page 44: ...commendations 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 be con...