Utility Relay Company AC-PRO, Instructions Manual

Page 1: ...for BBC ITE MBE Low Voltage Breaker Including Instructions for AC PRO Communications Utility Relay Co Chagrin Falls Ohio 44023 Phone 888 289 2864 www utilityrelay com 440 708 1177 Fax I ACM MBE November 2008 Rev 0 Courtesy of NationalSwitchgear com ...

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Page 3: ...ns Promptly return the defective material to Utility Relay Company 3 4 Warranty Disclaimer and Liability Limitation As the sole and exclusive remedy Utility Relay Co 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 event shall Utilit...

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Page 5: ...ctions 7 3 Neutral Current Transformer 7 4 Actuator Connection 8 0 Final Test 9 0 Communications 9 1 Install PT Module 9 2 PT Module Installation 9 3 Communications Wiring 1 1 2 2 3 3 3 3 4 4 5 6 6 6 7 7 7 8 8 Detail View 8 9 ILLUSTRATIONS Figure 1 Front View Side View Trip Unit Installation Rear View Actuator Pre Assembly Actuator Installation 10 2 11 3 CT Installation 12 4 13 5 14 Wiring Diagram...

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Page 7: ...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 well as the AC PRO...

Page 8: ...ating condition As a minimum perform the following a Close and trip operation of the breaker Measure contact resistance of each pole Measure insulation resistance from pole to pole from pole to frame and across open contacts Check contact compression Check for sufficient finger cluster spring tension at the rear stabs b c d e Rectify any abnormalities found Clean and lubricate the breaker as requi...

Page 9: ...hardware 5 0 Actuator Installation 5 1 Install Actuator Refer to Figures 4 5 for the following Remove the existing actuator reset assembly from the breaker 1 2 Remove the existing actuator from the reset assembly and replace it with the new actuator assembly as shown in Figure 4 3 Attach the new actuator assembly to the existing reset mechanism with two 2 10 32 X V2 Phillips screws and lock washer...

Page 10: ...tor Assembly 1 Re attach the rod end to the reset plate using the 10 32 X 3 4 Phillips screw and lock washer The existing reset mechanism spring should be slightly compressed If the spring is not compressed enough for proper reset the actuator may be moved by loosening the two 2 10 32 screws and adjusting the actuator position within the limits of the slotted mounting holes If moving the actuator ...

Page 11: ... using two 2 8 32 X 1 4 male female Hex standoffs and lock washers in the upper mounting bracket where the old trip unit was attached 4 Install one 8 32 X 3 8 male female Hex standoff in the lower mounting bracket where the old trip unit was attached 5 6 Attach the CA 2 400 security key harness to the BR 084 Face plate using a T 892 shroud and internal tooth lock washer 7 Attach the BR 084 Face pl...

Page 12: ...and Connections the wiring harness connector color code and For new CTs connections are as follows from top to bottom Terminal Wire Color Use 1 Red R Black B Blue L White W Yellow Y White W Brown N White W Green G White W Actuator Actuator Phase A Tap Phase A Dot Phase B Tap Phase B Dot Phase C Tap Phase C Neutral Dot 4W GF only Neutral Tap 4W GF only 2 3 4 5 6 7 8 Dot 9 10 7 2 Current Transformer...

Page 13: ...the primary rating of the existing neutral CT is the same as the phase CT taps used IMPORTANT 7 4 Actuator Connection Route the red and black wires from the actuator to the ACTUATOR terminal block on the trip unit Trim the wires to an appropriate length Use the protective sleeving on the wires Connect the red actuator wire to the terminal on the wiring harness trip unit connector Similarly connect...

Page 14: ...s and lock washers Using the PT Module bracket assembly as a guide mark the location of the two 2 mounting holes Drill and tap 2 8 32 holes where marked 3 4 Attach the PT Module bracket assembly to the breaker using two 2 8 32 X 3 8 Phillips screws and lock washers 9 2 Install Fuse Block for PT Module l Attach the 3 pole fuse block to the breaker as close to the line side stabs as possible 2 Drill...

Page 15: ...ving to protect the wires 2 Ground Input 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 left side of the AC PRO trip unit and the PT Module Use cable ties and holders to make a clean installation 4 Breaker Position Indication As an option connect an unused a contact in the breaker auxiliary contacts to the ...

Page 16: ...ip Unit U Figure 2 View OPEN TRIP CLOSE TRIP frooool o L 0010 KEY label 0 CA 2 400 Security key harness Attach with 1 T 892 Shroud Sc LW BR 084 Face Plate behind breaker front FIGURE 1 Front View Page 10 Courtesy of NationalSwitchgear com ...

Page 17: ... 32 X 3 8 Phillips screw LW HD PHASE CO c HD NEUTRAL HD BR 084 Face plate C n t M 7s 5 n U O O n Breaker Front o O 3 o go 53 B Trip Unit 9 fe s 3 o m 1 T 892 Shroud LW Connect to 2 pole KEY connector on trip unit CA 2 400 Security key harness 1 8 32 X 3 8 Male Female Hex standoff Sc LW 1 8 32 X 3 8 Phillips screw Sc LW FIGURE 2 Right Side View Trip Unit Installation Page 11 Courtesy of NationalSwi...

Page 18: ...e fuse block For PT Module included with the communications option o o mr BD BE Bd BD o o o o o o New Current Transformer Existing Current Transformers Rear View of Breaker Shown less finger clusters Shown with top stabs as line side of breaker FIGURE 3 Rear View CT Installation Page 12 Courtesy of NationalSwitchgear com ...

Page 19: ...embly 9 o Insert HW 9923 03 32 X 1 2 Spring Pin OC 1 r 1 S3 Attach Actuator Assembly to Existing Reset Mechanism using 2 HW 3304 1 10 32 X 1 2 Phillips screws LW a 1 o o IB O Ml Back View Side View FIGURE 4 Actuator Pre Assembly Page 13 Courtesy of NationalSwitchgear com ...

Page 20: ... Spring Existing Snap Ring for Reset Linkage 3 it I H I y A 300C MBE Actuator Assembly 2 10 32 X 1 2 Phillips LW Loosen 10 32 screws and adjust actuator position within limits of slots for positive reset n JO Rod End Position may be adjusted for Positive Reset if required 2 Reset Plate I Existing trip paddle o Some Parts Removed for Clarity FIGURE 5 Actuator Installation Page 14 Courtesy of Nation...

Page 21: ...rip wires in Vinyl sleeving COLOR CODE R Red B Black W White Y Yellow L Blue N Brown G Green i M RB LwTWNWGW I II I I I I I W mmmmn B 1 S 3 L ___ wKvte 10 Pole harness plug with hold down screws BEE 24 VAC AUXJUAKf PWER CM co y 8V UIHM 0WNGAH HOWE Batttty QT j o o DISPLAY U R C Ififfff lelay Company Top view of AC PRO CA 2 400 Key Harness FIGURE 6 Wiring Diagram CT Installation Page 15 Courtesy of...

Page 22: ... Unit Figure 2 View I AC PRO i M U M ri I OPEN l 3 fO PKK W Q ior nsr S as TRIP CLOSE TRIP UTILITY RELAY COMPANY o rfc OH booooj 9 L 0010 KEY label KEY CA 2 400 Security key harness Attach with 1 T 892 Shroud LW BR 084 Face Plate behind breaker front Figure 7 Front View With Communications Page 16 Courtesy of NationalSwitchgear com ...

Page 23: ...hield 2 8 32 X 3 8 Phillips screw c LW jT U BR 047 Bracket 2 8 32 X 3 8 Phillips screw LW 2 8 32 X 3 8 Nylon RHS LW PT Module Breaker Front Figure 8 Left side View PT Module Installation Page 17 Courtesy of NationalSwitchgear com ...

Page 24: ...C y 5A 125VAC C Relay 2 NO NC OPTIONAL To next AC PRO trip unit s I C Relay 1 NO Loosen screws to remove 3 P terminal block PT Module harness T 119 Mount terminal block inside breaker cubical c I JH Shield W H 1 P Xv Ji Shield T o o l Free hanging connector CA 5 24 48 Cable Connector assembly IMPORTANT Maintain proper polarity of twisted pair communication cable Blue wire is RS485 Twisted pair com...

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