Digitrip Retrofit System for the Westinghouse DB-50 Series ...

1 Effective October, 2000IL 33-DBC-2 SAFETY PRECAUTIONSPOWER CIRCUIT BREAKERS ARE EQUIPPEDWITH HIGH SPEED, HIGH ENERGY OPERATINGMECHANISMS. THE BREAKERS AND THEIRENCLOSURES ARE DESIGNED WITH SEVERALBUILT-IN INTERLOCKS AND SAFETYFEATURES INTENDED TO PROVIDE SAFE ANDPROPER OPERATING SEQUENCES. TO PRO-VIDE MAXIMUM PROTECTION FOR PERSON-NEL ASSOCIATED WITH THE INSTALLATION,OPERATION, AND MAINTENANCE OF THESEBREAKERS, THE FOLLOWING PRACTICESMUST BE FOLLOWED. FAILURE TO FOLLOWTHESE PRACTICES MAY RESULT IN DEATH,PERSONAL INJURY, OR PROPERTY DAMAGE. Only qualified persons, as defined in the NationalElectric Code, who are familiar with the installa-tion and maintenance of power circuit breakersand their associated switchgear assembliesshould perform any work associated with thesebreakers. Completely read and understand all instructionsbefore attempting any installation, operation,maintenance, or modification of these breakers.

2 Always turn off and lock out the power sourcefeeding the breaker prior to attempting anyinstallation, maintenance, or modification ofthe breaker. Do not use the circuit breaker asthe sole means for isolating a high voltagecircuit. Follow all lockout and tagging rulesof the National Electric Code and all otherapplicable codes, regulations, and work rules. Do not work on a closed breaker or a breakerwith the closing springs charged. Trip (open) thebreaker and be sure the stored energy springsare discharged before performing any work. Thebreaker may trip open or the charging springsmay discharge, causing crushing or cuttinginjuries. For drawout breakers, trip (open), and thenremove the breaker to a well-lit work area beforebeginning work. Do not perform any maintenance: includingbreaker charging, closing, tripping, or any otherfunction which could cause significant movementof the breaker while it is on the extension so may cause the breaker to slip from therails and fall, potentially causing severe personalinjury to those in the vicinity.

3 Do not leave the breaker in an intermediateposition in the switchgear cell. Always leave itin the connected, disconnected, or (optional)test position. Failure to do so could lead toimproper positioning of the breaker andflashover, causing death, serious personalinjury, and / or property damage. Do not defeat any safety interlock. Suchinterlocks are intended to protect personneland equipment from damage due to flashoverand exposed contacts. Defeating an interlockcould lead to death, severe personal injury,and / or property Retrofit System for the Westinghouse DB-50 Series Breakers(Includes Single Position DB-50 ; Three Position, Spring Operated DB-50 ;Electrically Operated DB-50 ; and DBL-50 Fused Models)Effective October, 2000IL 33-DBC-2 Page 2 Cutler-Hammer Digitrip Retrofit Kits are available ina number of configurations that provide a widerange of features.

4 The Digitrip System starts withthe 510 Basic Kit which offers true RMS sensing,overcurrent protection, and self-testing Digitrip Retrofit Kits feature zoneinterlocking, digital alphanumeric displays, remotealarm signals, PowerNet communications, energymonitoring capabilities, power factors, andharmonic content following table provides a quick reference ofthe components supplied with each level of RetrofitKit. Before beginning the Retrofit process, take aminute to review the information contained in thetable. It is important that the Retrofitter understandwhich level of Retrofit Kit is to be installed andwhich components are included with the instructions contained in this manual cover theinstallation of all levels of Retrofit Kit. If the Kit youare installing does not contain a certain component,skip the instructions for that component andproceed to the the Retrofit process, refer to the TorqueTables at the back of this manual for specifictorque you have any questions concerning the RetrofitKit and / or the Retrofit process, contactCutler-Hammer at withComponents510 BasicZone610810910 InterlockTrip UnitRating PlugAuxiliary CurrentTransformer(CT) ModuleAuxiliaryCT HarnessSensorsSensor HarnessDirect TripActuator (DTA)Mounting Bracketsand HardwareExternalPlug1 Connector2 Connector4 Connector4 ConnectorHarnessHarnessHarnessHarnessHar nessCell HarnessBreaker MountedControl PowerTransformer (CPT)Potential Transformer(PT)

5 ModuleAuxiliary SwitchEffective October, 2000IL 33-DBC-2 Page 3 NOTE: This Retrofit Kit IS NOT DESIGNEDfor use on any model of DB-50 Breakerequipped with a Bell Alarm or BOTH a ShuntTrip AND an Under Voltage Mechanism. If theRetrofitter attempts to modify the Breaker toaccommodate this Retrofit Kit, or modify thisRetrofit Kit to accommodate the Breaker, thoseactions will be at the sole responsibility andliability of the more information, contact Cutler-Hammerat 1: General Breaker PreparationBefore attempting to remove the Breaker from theCell or perform any Retrofit Operation, be sure toread and understand the Safety Precautionssection of this manual.

6 In addition, be sure to readand understand the Instructions for the Applicationof Digitrip RMS Retrofit Kits on Power CircuitBreakers ( Retrofit Application Data - PublicationAD 33-855-1), supplied with the Digitrip Retrofit NOT ATTEMPT TO INSTALL OR PERFORMMAINTENANCE ON EQUIPMENT WHILE IT ISENERGIZED. SEVERE PERSONAL INJURY ORDEATH CAN RESULT FROM CONTACT WITHENERGIZED EQUIPMENT. VERIFY THAT NOVOLTAGE IS PRESENT BEFORE Trip the Breaker and remove it from the the Breaker to a clean, well-lit : It is the responsibility of the Retrofitter toinsure that the Breaker and all originalcomponents are in good condition. Visuallyinspect all Breaker components for signs ofdamage or wear. If any signs of damage or wearare detected for components not included in theRetrofit Kit, secure the necessary replacementparts before beginning the Retrofit force necessary to trip the Breaker shouldnot exceed three (3) : It is the responsibility of the Retrofitter toinsure that the proper, manufacturer srecommended crimping tools and terminals areused for each type of connector.

7 It is also theresponsibility of the Retrofitter to insure that allwire preparations, connections, strippings,terminations, and wiring techniques areperformed according to the latest IEEE, NEC,and / or NEMA industry standards,specifications, codes, and begin the Retrofit Process, refer to thecomponents list at the end of this manual. Lay outthe components and hardware according to thesteps outlined. The components and hardware willbe used to complete each step in the TripBell AlarmUnder VoltageMechanismEffective October, 2000IL 33-DBC-2 Page 4 Step 2: Removing the Original ComponentsRefer to the Westinghouse DB-50 InstructionManual, originally supplied with the Breaker, toperform the following Remove the bottom Finger Clusters and setthem aside for installation later in the Breakers Equipped with the OriginalElectromechanical Trip Remove the four.

8 500-13 bolts directly aboveeach of the three bottom Breaker the bolts are removed, the originalElectromechanical Trip Units will drop the Trip Units and all mounting Remove and scrap the three ElectromechanicalTrip Paddles from the Breaker Trip Bar. This willreduce the force required to trip the Breakers Equipped with an Amptector or OtherTrip Remove and scrap the Trip Mechanisms and allassociated wiring, mounting brackets 3: Installing the Copper ConnectorsA. Install a .500" flat washer on each of the (12).500-13 x " bolts supplied. Working from therear of the Breaker, insert the bolts into theholes from which the original ElectromechanicalTrip Unit mounting hardware was Install (2) copper connectors on each set " bolts. Secure the Copper Connectorsusing the (12) flat washers, (12) lock washers,and (12) nuts Kits Supplied with a PT Module one nut from each connector loose atthis time.

9 They will be used to connect the PTWires later in the Retrofit October, 2000IL 33-DBC-2 Page 5 Step 4: Installing the DTA AssemblyA. Temporarily set the DTA Assembly in place onthe right Breaker Platform and align the hole inthe DTA Assembly with the existing hole in theBreaker Using the DTA Assembly as a template, markthe position of the second DTA Assemblymounting hole. Remove the DTA Using a .219" drill bit, drill the second DTAA ssembly mounting hole in the right sideBreaker Platform. Care should be taken toinsure that no drill shavings fall into the Kits Supplied With An Auxiliary Switch the Microswitch with the holes in the Mounting Bracket, as shown, thensecure the Microswitch to the bracket using the(2).

10 138-32 x " screws, (2) flat washers, (2)lock washers, and (2) nuts the Aux. Switch Assembly with the holesin the DTA Assembly. Secure the Aux. SwitchAssembly to the DTA Assembly, as shown,using the (2) .190-32 x .375" screws, (2) flatwashers, and (2) lock washers that Aux. Switch moves to the Closed position when the DTA Reset Arm is movedtowards the following steps must be performed with theBreaker in the CLOSED position. Guard againstthe Breaker unintentionally OPENING duringthese steps. Keep hands and fingers away frommoving parts within the CLOSE the Breaker. With the Breaker in theCLOSED position, align the DTA Assemblywith the existing hole and the hole drilled inStep 4-D. The DTA Reset Arm should beunder the Breaker Cross October, 2000IL 33-DBC-2 Page 6F. Mount the DTA Assembly to the right side ofthe Breaker Platform using the DTA MountingClip, (1).