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Westinghouse IL 33-DAH-1 manual

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Table of contents for the manual

  • Page 1

    T able of Contents SAFETY PREC A UTION S ............................................................................................................... . 1 Kit Components Lis t ........................................................................................................................ . 2 Step 1 : Gene r al Brea k er Prepa r atio n ...[...]

  • Page 2

    Effective December , 1998 IL 33-D AH-1 SAFETY PRECA UTIONS PO WER CIRCUIT BREAKERS ARE EQUIPPED WITH HIGH SPEED , HIGH ENERGY OPERA TING MECHANISMS. THE BREAKERS AND THEIR ENCLOSURES ARE DESIGNED WITH SEVERAL BUIL T -IN INTERLOCKS AND SAFETY FEA TURES INTENDED T O PRO VIDE SAFE AND PR OPER OPERA TING SEQUENCES. T O PRO- VIDE MAXIMUM PR O TECTION FO[...]

  • Page 3

    Effective December , 1998 IL 33-D AH-1 Page 2 Cutler-Hammer Digitrip Retrofit Kits are av ailable in a number of configurations that pro vide a wide range of f eatures. The Digitr ip System star ts with the 510 Basic Kit which off ers true RMS sensing, ov ercurrent protection, and self-testing features . Advanced Digitrip Retrofit Kits f eature z o[...]

  • Page 4

    Effective December , 1998 IL 33-D AH-1 Page 3 Step 1: General Breaker Preparation Bef ore attempting to remov e the Break er from the cell or perf or m any Retrofit Oper ation, be sure to read and understand the Saf ety Precautions section of this manual. In addition, be sure to read and understand the Instructions f or the Application of Digitrip [...]

  • Page 5

    Effective December , 1998 IL 33-D AH-1 Page 4 Step 3: Preparing the Sensors A. Place each Sensor between tw o Glass P oly Insulation Plates. The connector stabs should be positioned tow ards the cutouts in the Insulation Plates as shown. B. Secure the Glass P oly Plates on either side of the Sensors using the (12) .250-20 × 2.00" bolts, (24) [...]

  • Page 6

    Effective December , 1998 IL 33-D AH-1 Page 5 Step 5: Installing the T rip Unit Mounting Platform A. Using Dr illing Plan “A”, dr ill and counter sink two .375" holes in both the left and right Break er side plates. NO TE: The holes for mounting the DT A (see Step 10) should also be drilled and countersunk in the right Breaker Frame at thi[...]

  • Page 7

    Effective December , 1998 IL 33-D AH-1 Page 6 Step 6: Preparing the T rip Unit Assembl y A. F or Kits Supplied with a PT Module Only . Mount the PT Module to the Glass P oly Insulation Barrier as shown, using the (2) .138-32 × .500" scre ws, (4) flat washers , (2) loc k washers, and (2) nuts supplied. B. Secure the Glass P oly Insulation Barr[...]

  • Page 8

    Effective December , 1998 IL 33-D AH-1 Page 7 Step 8: Installing the T rip Finger A. Note the position of the or iginal T rip Finger and associated “gap” between the T rip Finger and manual T r ip Shaft. Remov e the original T r ip Finger and scrap the mounting hardw are. B. Mount the new T r ip Finger on the top of the Cross Bar (with the cur [...]

  • Page 9

    Effective December , 1998 IL 33-D AH-1 Page 8 Step 10: Installing the DT A Assembly A. Mount the DT A Mounting Brack et to the right Breaker side panel, as sho wn, using the holes drilled in Step 5 A and the (2) .312-18 × .750" scre ws, (2) flat washers , (2) loc k washers, and (2) nuts pro vided. B. Remov e the two n uts, flat washers , and [...]

  • Page 10

    Effective December , 1998 IL 33-D AH-1 Page 9 Step 11: Installing the 2-P oint T erminal Block A. Mount the 2-P oint T er minal Block to the pre-drilled holes in the r ight T rip Unit Suppor t Brac ket as sho wn, using the (2) .138-32 × .750" scre ws, (4) flat washers , (2) loc k washers, and (2) nuts supplied. B. Route the DT A wires from th[...]

  • Page 11

    Effective December , 1998 IL 33-D AH-1 Page 10 C . Route the CPT Har ness betw een the T r ip Unit and the Insulation Barrier to the CPT . Str ip .250" of insulation and attach a .138" ring ter minal to each wire of the CPT Harness. Connect the CPT Har ness wires to the X1 and X2 terminals of the CPT . D . P osition the fuses on the High [...]

  • Page 12

    Effective December , 1998 IL 33-D AH-1 Page 11 Step 13: Final Connection of the Harnesses and Wiring A. Feed the Sensor Harness through the hole in the left side of the A ux. CT Module. Connect the Sensor Har ness to the proper terminals on the A ux. CT Module. Refer to Section 12 of the Retrofit Application Data, supplied with the Retrofit Kit, f [...]

  • Page 13

    Effective December , 1998 IL 33-D AH-1 Page 12 D. F or Kits Supplied with a PT Module Only . Ref er to Section 7-3, P ower Flow Con vention of the Retrofit Application Data, supplied with the Retrofit Kit f or additional wiring information and to verify the Phase Con v ention used on this Breaker Application. Route the PT Wires between the Glass P [...]

  • Page 14

    Effective December , 1998 IL 33-D AH-1 Page 13 H. F eed the two wires from the DT A Extension Har ness through the opening in the left side of the A ux. CT Module. Connect the wire mar ked “+” to the “OP” ter minal and the unmarked wire to the “ON” terminal. I. Route the DT A Extension Harness between the Glass P oly Insulation Barrier [...]

  • Page 15

    Effective December , 1998 IL 33-D AH-1 Page 14 F or Kits Supplied with an A ux. Switch Only . Step 14: Installing the A uxiliary Switch A. Using diagonals, cut 2.625" off the Micros witch Ar m. B. Mount the Micros witch to the A uxiliar y Switch Mounting Brac ket, as sho wn, using the (2) .138-32 × 1.25" scre ws, (8) flat w ashers, (4) l[...]

  • Page 16

    Effective December , 1998 IL 33-D AH-1 Page 15 Step 15: T esting the Breaker A. Measure the force necessary to tr ip the Break er at the point where the DT A impacts the T rip Finger . The force necessary to tr ip the Break er MUST NO T EXCEED SEVEN (7) lbs. B. The Retrofit must be tested using primar y injection. Ref er to Section 8 of the Instruc[...]

  • Page 17

    Effective December , 1998 IL 33-D AH-1 Page 16 Step 17: Installing the Retr ofitted Breaker in the Cell Do not leave the Breaker in an intermediate position in the switc hgear cell. Alwa ys leave it in the CONNECTED , DISCONNECTED, or (Optional) TEST position. Failure to do so could lead to improper positioning of the Breaker and flashover , causin[...]

  • Page 18

    Effective December , 1998 IL 33-D AH-1 Page 17 Digitrip Retrofit Kit Installation Components for the Westinghouse DA-75 Breakers Step Description Style No. Qty . Comment Step 3 Sensors 3000/5000 4A35613H01 3 Sensor Mounting Parts 4A35618G04 1 Glass Poly Mounting Plates 6 .250 - 20 × 2.00 Lng. Hex Bolt 12 .250 Flat Washer Stl. 24 .250 - 20 Elastic [...]

  • Page 19

    Effective December , 1998 IL 33-D AH-1 Page 18 Digitrip Retrofit Kit Installation Components for the Westinghouse DA-75 Breakers (Continued) Step Description Style No. Qty . Comment Step 7 T rip Unit Assembly (From Step 6) T rip Unit Mounting Hardware 4A35618G08 1 .250 - 20 × .750 Lng. Hex Bolt 4 .250 Flat Washer Stl. 8 .250 Lock Washer Stl. 4 .25[...]

  • Page 20

    Effective December , 1998 IL 33-D AH-1 Page 19 Digitrip Retrofit Kit Installation Components for the Westinghouse DA-75 Breakers (Continued) Step Description Style No. Qty . Comment Step 12 Breaker Mounted CPT Kit 8259A91G05 1 CPT Only Ring T erminals (.138, .190, .250, .312, .375, .500) 2 Each Size CPT Only CPT Mounting Parts 4A35618G20 1 CPT Only[...]

  • Page 21

    Effective December , 1998 IL 33-D AH-1 Page 20 Wire Tie Nylon 10 Digitrip Retrofit Kit Installation Components for the Westinghouse DA-75 Breakers (Continued) Step Description Style No. Qty . Comment Step 14 Aux. Switch Kit 4A35618G02 1 Microswitch 1 Mounting Bracket 1 .164 - 32 × .500 Lng. Screw Fil. 2 .164 Flat Washer Stl. 4 .164 Lock Washer Stl[...]

  • Page 22

    Effective December , 1998 IL 33-D AH-1 Page 21 T orque V alues for General Mounting Decimal Standar d T orque T orque Size (in) Size (in-lbs) (ft-lbs) .112 4-40 10 0.8 .138 6-32 18 1.5 .164 8-32 36 3.0 .190 10-32 46 3.8 .250 1/4-20 100 8.3 .312 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 T orque V alues for Copp[...]

  • Page 23

    Effective December , 1998 IL 33-D AH-1 Page 22 A B C D E F G H J K L I A. Sensors B. T rip Unit C . A ux. CT Module D . Rating Plug E. Direct T rip Actuator (DT A) F . A ux. Switch G. PT Module H. Sensor Harness I. DT A Extension Harness J . A ux. CT Harness K. Exter nal Har ness L. Cell T er minal Bloc k Assembly CPT Kit not pictured.[...]

  • Page 24

    Effective December , 1998 IL 33-D AH-1 Page 23 Notes:[...]

  • Page 25

    Effective December , 1998 Printed in U.S.A. - K IL 33-D AH-1 Page 24 Cutler -Hammer 130 Commonwealth Drive Warrendale, P A 15086 W e wish to thank you f or purchasing the Digitr ip Retrofit System. Digitrip Retrofit Kits are designed and manuf actured in America with pr ide. All the components are engineered to fit the existing Circuit Break er wit[...]

  • Page 26

    Effective January , 1998 IL 33-D AH-1 Page 25 Symbols 2-Point T erminal Block 9 510 Basic Retrofit Kits 13 A Auxiliary Switch 14 B Breaker Mounted CPT 9 C Cell Harness 15 CPT T erminals 10 D Drilling Plan “A” 5 DT A Assembly 8 DT A Extension Harness 13 F Final Connection of the Harnesses and Wiring 11 G General Breaker Preparation 3 Glass Poly [...]