NATIONAL SWITCHGEAR Westinghouse DB-100, Manual

Page 1: ...Breaker Instructions for Manual Reset Actuator Mechanical Reset Actuator Including Instructions for AC PRO Communications Utility Relay Co Chagrin Falls Ohio 44023 Phone 888 289 2864 www utilityrelay...

Page 2: ...Courtesy of NationalSwitchgear com...

Page 3: ...ions 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...

Page 4: ...her 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 i...

Page 5: ...cal Reset Actuator 5 1 Install Actuator 5 2 Install Trip Paddle 5 3 Adjust Mechanical Reset Actuator 5 4 Verify Trip Free Operation 5 5 Adjust Reset of Mechanical Reset Actuator 6 0 AC PRO Installatio...

Page 6: ...EMPLATE Manual Mechanical Reset Actuator 8 Trip Paddle Trip Rod Installation 9 Verify Trip Free 10 Mech Reset Actuator Breaker Closed Actuator Reset 27 11 Mech Reset Actuator Breaker Closed Actuator T...

Page 7: ...val 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 cont...

Page 8: ...tion 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 f...

Page 9: ...shers On this breaker design front of the breaker and will pull the trip paddle forward the actuator fires towards the 3 Using Figure 7 as a guide drill and tap two 2 1 4 20 holes in the locations mar...

Page 10: ...so the actuator rod is centered in the slot in the trip paddle and tighten the 8 32 screws and set screw 3 Thread the HW 9903 3 clamp on collar on the end of the actuator rod Do not lock in place at t...

Page 11: ...3 1 2 Trip the actuator by pulling on the reset knob Lock the actuator rod in position by tightening the 10 32 set screw with an Allen wrench 3 With the actuator reset adjust the position of the HW 99...

Page 12: ...the stop nuts away from the actuator an additional two 2 turns minimum This insures that the actuator rod travel is at least 0 1 past the trip free point of the trip paddle 5 Firmly lock the stop nuts...

Page 13: ...ly satisfied with the operation of the actuator 2 WHEN THE ACTUATOR IS IN THE TRIP POSITION NOT RESET THE BREAKER MUST BE TRIP FREE IMPORTANT THE TRIP PADDLE MUST BE HELD A MINIMUM OF 0 1 PAST THE TRI...

Page 14: ...ting Block using 2 8 32 X 1 2 Phillips screws and lock washers The Trip Lever should pivot freely 3 Install the mechanical reset actuator as shown in Figure 8 Attach the actuator assembly to the break...

Page 15: ...e on the trip bar so the threaded rod is centered in the hole in the trip paddle and tighten the 8 32 screws and set screw 4 Place a flat washer and two hex nuts with a lock washer on the end of the t...

Page 16: ...properly on breaker opening Refer to Figure 9 for the following With the breaker open and the actuator reset remove the reset rod or back off the two 2 10 32 hex nuts compressing the over travel sprin...

Page 17: ...tion and the breaker open reset the actuator by turning the 10 32 hex nuts and compressing the HW 9101 over travel spring until it resets the actuator Turn the 10 32 nuts an extra turn or two past the...

Page 18: ...echanism cover Drill tap two 2 8 32 holes where marked 3 Mount the bracket BR 001 to the top of the mechanism cover in the previously taped holes using two 2 8 32 X 1 4 Phillips screws and lock washer...

Page 19: ...finger clusters and retaining pins Use the split retainers provided 8 0 Wiring Use the wiring harness provided to make the connections to the CTs and the actuator See Figure 13 for the wiring diagram...

Page 20: ...wires in the wiring harness is housed inside an individual PVC tube for added physical protection and to simplify the wiring process Connect to the 10 32 lugs using the ring tongue terminals provided...

Page 21: ...connector Similarly connect the black actuator wire to other actuator terminal on the trip unit 9 0 Final Test Perform a final electrical test of the breaker as in Section 2 In accordance with ANSI C3...

Page 22: ...ion of the two 2 mounting holes Drill 2 7 32 holes where marked 2 3 Attach the PT Module bracket assembly to the breaker using two 2 10 32 X 1 2 Phillips screws and lock washers 10 2 Install Fuse Bloc...

Page 23: ...erglass sleeving 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 bottom o...

Page 24: ...ftY COMPAW rLH BR 001 Bracket 2 2 2 2 y 2 2 8 32 X 1 4 Phillips screws LW Oar i THU 91 J lOPEN I O 8 v 1 TRIP l I o y i Figure 3 6 8 9 10X eSc 1 1 View p y See Figure 3 for manual reset actuator insta...

Page 25: ...et 2 8 32 X 3 8 Phillips Screws LW Trip Unit BR 001 Bracket 2 8 32 X 1 4 Phillips Screws LW Use template from Figure 12 to drill tap 2 8 32 holes in the mechanism top cover Breaker Front FIGURE 2 Side...

Page 26: ...9903 3 1 4 20 Threaded Clamp On Collar Push To Reset Label 1 64 See Section 4 3 1 6 Trip Direction 6 Replace existing actuator rod with 1 4 20 X 6 rod BR 134 Bracket A 100 Actuator shown reset 2 1 4...

Page 27: ...02 Clevis Cotter Pin 2 10 32 X 1 2 Phil screws Sc LW BR 1A029 Reset Plate BR 1A024 Base Bracket O o A O o o 1 8 32 X 1 3 4 Threaded Stud BR 1A025 Pivot Mtg Block 3 8 LW 2 8 32 Hex Nut G IP o HW 9925 W...

Page 28: ...0 2 8 32 X 1 2 Phil screws Sc LW SH 0 o o I O o 0 0 IP O BR 1A049 ASM Trip Lever Assembly 2 8 32 X 1 2 Phil screws LW Add the following to the Actuator Pre Assembly BR 1A049 ASM Trip Lever Assembly BR...

Page 29: ...AC PRO Retrofit DB 75 100 Drill Tap 10 32 thru casting or approx 1 2 deep 1 2 1 2 z z z z z z z z z z z z z z z z z Breaker Front FIGURE 6 Contact Tie Bar Page 23 Courtesy of NationalSwitchgear com...

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Page 31: ...oles for Manual Reset Actuator Left Side of Mechanism Platform 4 4 Drill Sc Tap 1 4 20 2 Holes for Mechanical Reset Actuator 1 22 11 14 1 6 Breaker Front 5 FIGURE 7 TEMPLATE Manual Mechanical Reset Ac...

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Page 33: ...ZA BR 1A048 Pivot Arm z z z Trip Bar z z z z z Adjust the location of the 2 10 32 nuts on the trip rod assembly to get the See Section 5 2 Step 6 z z z z z BR 215 Trip Paddle Clamp z z z z 13 z dimens...

Page 34: ...ot per Section 5 4 Make adjustment where threaded rod goes into hex standoff 10 32 X 3 4 Phillips Sc LW ft I I ft BR 1A049 Trip Lever X7C X7T Trip Bar BR 1A048 Pivot Arm X X X X X X X X X X X X 2 1 4...

Page 35: ...ing Breaker in Closed Position 0 0 s 0 0 z z z z z z z z z z z IMPORTANT With the actuator in the trip position the breaker must be Trip Free can not be closed See Section 5 4 z z z z z z z z z z z z...

Page 36: ...on z z IMPORTANT With the actuator in the trip position the breaker must be Trip Free can not be closed See Section 5 4 z z z z z z z z z z z z z z z z z Actuator Tripped Breaker starting Breaker Fron...

Page 37: ...DB 75 100 AC PRO Retrofit 7 3 16 Mechanism Top Cover Plate II 8 32 TAP 2 holes for trip unit bracket 2j O 5 FIGURE 12 TEMPLATE Trip Unit Bracket Page 29 Courtesy of NationalSwitchgear com...

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Page 39: ...ional I COLOR CODE R Red B Black W White y Yellow L Blue N Brown G Green i Red black trip wires in vinyl sleeving 10 Pole harness plug with hold down screws RBLWT I I I I I I I I I I w w GW ipIpIMipll...

Page 40: ...T OK 2 2 2 2 2 BR 001 Bracket 2 D0B1BH 2 S 2 2 2 2 2 2 2 3 UTJUTY OMPAW Ov Vi r OK O L OPEN 2 8 32 X 1 4 Phillips screws LW TRIP c 2 10 32 X 1 2 Phillips screw Sc LW CA 5 24 48 Communication twisted p...

Page 41: ...ntrol 5A 30VDC 5A 125VAC SEdJB 1 NO UTILfTY RQAY COMPANY a w w NC OPTIONAL To next AC PRO trip unit Ss s C Relay 1 NO Loosen screws to remove 3 P terminal block PT Module harness A Vl T 119 Mount term...

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