I.L. 29C103G
JWC Circuit Breakers and Molded Case Switches
nel and equipment as well as all general and local
health and safety laws, codes, and procedures.
The recommendations and information contained herein
are based on Cutler-Hammer experience and judgment,
but should not be considered to be all-inclusive or covering every application or circumstance which may
arise. If any questions arise, contact Cutler-Hammer for
further information or instructions.
1. INTRODUCTION
General Information
The J-frame Series C circuit breaker (Figure 1-1) types
JD, JDB, HJD, and JDC are 600 Vac maximum rated
devices with inter changeable thermal-magnetic trip
units rated 250A maximum continuous current. Circuit
breaker types JW, HJW, and JWC are 660 Vac maximum rated devices using interchangeable adjustable
thermal/adjustable magnetic or electronic trip units rated
up to 250A continuous current. The type JDB noninterchangeable trip circuit breaker is rated 600 Vac maximum with a maximum continuous current rating of
250A. Refer to Table 1-1 for all available trip unit rat-
DO NOT ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT IS ENERGIZED. DEATH, SEVERE PERSONAL INJURY, OR
SUBSTANTIAL PROPERTY DAMAGE CAN RESULT
FROM CONTACT WITH ENERGIZED EQUIPMENT.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT
BEFORE PROCEEDING WITH THE TASK, AND
ALWAYS FOLLOW GENERALLY ACCEPTED SAFETY PROCEDURES.
CUTLER-HAMMER IS NOT LIABLE FOR THE MISAPPLICATION OR MISINSTALLATION OF ITS PRODUCTS.
The user is cautioned to observe all recommendations,
warnings, and cautions relating to the safety of person-
Figure 1-1 J-Frame Model D Series C Circuit Breaker
with JT Trip Unit Installed
WARNING
Circuit Breaker Trip Unit Types
Types Thermal-Magnetic Amperes I
n
Fixed Adjustable Adjustable
Thermal Thermal Magnetic
of I
n
JDB 70 5 to 10
JD 90
HJD 100
JDC JW 125 100-125
HJW 150 125-160
JWC
175
200 160-200
225
250 200-250
Not UL listed.
For adjustable thermal trip units, the magnetic setting is a multiple
of the maximum thermal setting.
Table 1-1 Available Trip Unit Ratings
Installation Instructions for JDB, JD, HJD, JDC, JW HJW,
!
1
2
1
2
I.L. 29C103G
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ings. Model D circuit breakers are listed in accordance
with Underwriters’ Laboratories, Inc. Standard UL489
and satisfy the (P1) requirements of the International
Electrotechnical Commission Recommendations No.
IEC 157-1 Model W circuit breakers satisfy the requirements of IEC 947-2. Molded case switches are listed in
accordance with UL 489.
This instruction leaflet (IL) gives procedures for installation and field testing of J-frame Series C circuit breakers. For this publication, the term circuit breaker shall
also include the molded case switch.
2. INSTALLATION
The installation procedure consists of inspecting the circuit breaker and, as applicable, installing the trip unit,
accessories, interphase barriers and terminals; mounting the circuit breaker; connecting the line and load conductors; torquing terminals; and attaching terminal
shields. Circuit breaker frames, trip units, accessories,
mounting hardware, and unmounted terminals may be
supplied in separate packages. To install the circuit
breaker, perform the following steps.
JDB circuit breakers are factory sealed for reverse
feed applications under UL489. UL requires that
internal accessories be installed at the factory in
this type of circuit breaker.
For hardware conversion kits and handle mechanisms
required to replace existing Cutler-Hammer circuit
breakers.
If required, internal accessory installation in any type of
circuit breaker should be done before the circuit breaker
is mounted and connected. Refer to individual accessory instruction leaflets.
Circuit breaker mounting hardware is supplied separately.
2-1. Make sure that the circuit breaker frame is suitable
for the intended installation by comparing nameplate
data with existing ratings and system requirements.
Inspect the circuit breaker for completeness, and check
for damage before mounting. Uninstalled cover mounting hardware is supplied in a plastic bag with the circuit
breaker frame. (See Figure 2-1)
2-2. Remove installed cover screws and cover.
Figure 2-1 Cover Mounting Hardware
Pan Head Screws
Thread-Forming Screws
Figure 2-2 Cover Screw Installation Positions
NOTICE
On/
Off/
Screw, .190-32 x 3.13 Inch, Pan Head, Cross-Recessed.
Screw, No. 8 x 1.88 Inch, Pan Head, Cross-Recessed,
Thread Forming.
Screw, No. 6 x 1.50 Inch, Pan Head, Cross-Recessed,
Thread Forming (used with 4 Pole Only)
Note: Hatched lines show additional pole and screws for
4-pole circuit breaker.
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The circuit breaker handle must be in the tripped or
OFF position to remove the cover. Instructions for
installing the trip unit accessories are supplied with
the devices.
2-3. If not already installed, mount trip unit and accessories (if required) in circuit breaker frame.
WHEN REMOVED AND REINSTALLED, THREADFORMING SCREWS WILL TRY TO REFORM THE
THREADS IN THE BASE. CARE SHOULD BE TAKEN
EVERY TIME A THREAD-FORMING SCREW IS USED
TO ENSURE THE SCREW STARTS IN THE ORIGINAL
THREADS. DAMAGED THREADS CAN RESULT IN
IMPROPER CIRCUIT BREAKER COVER RETENTION.
2-4. Install cover, and secure with pan-head screws followed by threadforming screws, as shown in Figure 2-2.
2-5. If not already installed, mount terminals as shown
in Figure 2-3. When using terminal (Catalog No.
TA250KB), secure the terminal to the circuit breaker
using a 1/8-inch socket wrench and torque to 6-8 lb.-ft
(8-11 N.m). After mounting the circuit breaker and
before installation of the conductors, the terminal mounting screw can be checked or retightened through the
terminal when the conductor screw is removed. When
using terminal (Catalog No. T250KB), secure the terminal to the circuit breaker using screw and nut. Torque to
7-9 lb.-in (0.8-1.0 N.m).
THE VOLTAGES IN ENERGIZED EQUIPMENT CAN
CAUSE DEATH OR SEVERE PERSONAL INJURY.
BEFORE MOUNTING THE CIRCUIT BREAKER IN AN
ELECTRICAL SYSTEM, MAKE SURE THERE IS NO
VOLTAGE PRESENT WHERE WORK IS TO BE PERFORMED. SPECIAL ATTENTION SHOULD BE PAID
TO REVERSE FEED APPLICATIONS TO ENSURE
NO VOLTAGE IS PRESENT.
Depending on the equipment configuration, the circuit breaker can be mounted using different styles
of hardware. The following steps describe how to
mount the circuit breaker using standard hardware.
When special hardware is needed (for example, with
the electrical operator), the instruction leaflet
describing the accessory also describes the special
mounting arrangements.
2-6. To mount the circuit breaker, perform the following
steps:
a. For individual surface mounting, drill mounting panel
using the drilling plan shown in Figure 2-4. For panelboard mounting, only load end support mounting
holes are required. For deadfront cover applications,
cut out cover to correct escutcheon dimensions. (See
Figure 2-5)
b. If circuit breaker includes factory- or field-installed
internal accessories, make sure that accessory
wiring can be reached when the circuit breaker is
mounted.
Labels with accessory connection schematic diagrams are provided on the side of the circuit breaker.
A note should be made of the diagrams if the labels
cannot be seen when the circuit breaker is mounted.
Figure 2-3 Terminal Installation
NOTICE
NOTICE
!
CAUTION
!
WARNING
NOTICE
Terminal
Connectors
TA250KB Terminal
Collar
Page 3
Collar
Socket
Screw
Flat-Head
Screw
T250KB Terminal
Nut
Torque cover screws to 18-23 lb-in (2-2.6 N.m.).
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c. Position circuit breaker on mounting surface.
d. Install circuit breaker mounting screws and washers.
Tighten screws firmly, but do not exceed 28 poundinches (3 N.m.).
WHEN ALUMINUM CONDUCTORS ARE USED, THE
APPLICATION OF A SUITABLE JOINT COMPOUND
IS RECOMMENDED TO REDUCE THE POSSIBILITY
OF TERMINAL OVERHEATING. OVERHEATING CAN
CAUSE NUISANCE TRIPPING AND DAMAGE TO
THE CIRCUIT BREAKER.
2-7. Connect line and load conductors and accessory
leads.
2-8. If required, install terminal shield on circuit breaker
cover with mounting screws provided.
2-9. After the circuit breaker is installed, check all
mounting hardware and terminal connecting hardware
for correct torque loading. Torque values for line/load
terminals are given in Table 2-1 and on the circuit
breaker nameplate.
3. MANUAL OPERATION, AND THERMALMAGNETIC ADJUSTMENT
Manual Operation
Manual operation of the circuit breaker is controlled by
the circuit breaker handle and the PUSH-TO-TRIP button in the trip unit. The circuit breaker handle has three
positions, two of which are shown on the cover with
raised lettering to indicate ON and OFF. On the sliding
handle barrier, ON, OFF, and trip are also shown by a
color-coded strip for each circuit breaker handle position: red for ON, white for tripped, and green for OFF.
ON/OFF is also shown with the international symbols
1/0. (See Figure 3-1)
Circuit Breaker Reset
After an automatic or accessory initiated trip, or a manual Push-to-Trip operation, the circuit breaker is reset by
moving the circuit breaker handle to the extreme OFF
position.
In the event of a thermal trip in a thermal magnetic
type trip unit, the circuit breaker cannot be reset
until the thermal element in the trip unit cools.
Figure 2-5 Circuit Breaker Escutcheon Dimensions
CAUTION
NOTICE
Figure 2-4 Circuit Breaker Mounting Bolt Drilling Plans
2, 3 Pole Breakers
1.375
(34.37)
4.078
(103.58)
7.250
(184.15)
C
L
.688
(14.47)
.250-20
(M6-1.0)
Tap
(6 Holes)
C
Circuit Breaker Handle
L
.250-20
(M6-1.0)
Tap
(4 Holes)
Circuit Breaker
Handle
4-Pole Breakers
2.750
(69.85)
C
L
1.375
(34.37)
!
1.562
.344R
(8.74)
3.938
(100.02)
.781
.188R
(4.77)
(39.67)
(19.84)
2.922
(74.22)
3.50
(88.90)
Circuit Breaker Handle
C
L
.781
Circuit Breaker Handle
C
L
.875
(22.22)
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No circuit breaker should be reclosed until the
cause of trip is known and the situation rectified.
PUSH-TO-TRIP Button
The PUSH-TO-TRIP button checks the circuit breaker
tripping function and is used to periodically exercise the
operating mechanism in thermal-magnetic trip units. The
button is designed to be operated by a small screwdriver.
Thermal-Magnetic Trip Unit Adjustment
The magnetic element of each pole of the trip unit can
be adjusted by rotating the adjustment buttons on the
front face of the trip unit with a screwdriver. The buttons
have several settings, as indicated on the nameplate,
with values in multiples of the trip unit ampere rating (In).
(See Figure 3-2) To adjust the setting, rotate each button clockwise until arrow on button points to desired setting.
4. INSPECTION AND FIELD TESTING
Series C molded case circuit breakers are designed to
provide years of almost maintenance-free operation.
The following procedure describes how to inspect and
test a circuit breaker in service.
Inspection
Circuit breakers in service should be inspected periodically. The inspection should include the following checks
(4-1 through 4-8):
THE VOLTAGES IN ENERGIZED EQUIPMENT CAN
CAUSE DEATH OR SEVERE PERSONAL INJURY.
BEFORE INSPECTING THE CIRCUIT BREAKER IN
AN ELECTRICAL SYSTEM, MAKE SURE THERE IS
NO VOLTAGE PRESENT WHERE WORK IS TO BE
PERFORMED. SPECIAL ATTENTION SHOULD BE
PAID TO REVERSE FEED APPLICATIONS TO
ENSURE NO VOLTAGE IS PRESENT.
!
WARNING
Table 2-1 Terminal Types
Terminal Terminal Screw AWG Metric Wire Torque
Cat. No. Material Head Wire Wire Type Value
Body Type Range Range lb-in
(N.m.)
T250KB Stainless Socket 4-350 MCM 25-185 Cu Only 180 (20)
Steel
TA250KB Aluminum Socket 4-350 MCM 25-185 Cu/AI 275 (31)
Figure 3-1 Circuit Breaker Manual Controls
Figure 3-2 Trip Unit Magnetic Trip Adjustment Buttons
Page 5
Handle Position Indicator Color
ON
TRIP
OFF
(Reset)
International
Symbols
ON
OFF
Thermal-Magnetic
Trip Unit Adjustment
Button (3 Places)
Red – ON
White – TRIP
Green – OFF (Reset)
On/
Off/
Push-To-Trip
Button
Adjustment
Buttons
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MAKE SURE THAT CLEANING AGENTS OR SOLVENTS USED TO CLEAN THE CIRCUIT BREAKER
ARE SUITABLE FOR THE JOB. SOME COMMERCIAL CLEANING AGENTS WILL DAMAGE THE
NAMEPLATES OR MOLDED PARTS.
4-1. Remove dust, dirt, soot, grease, or moisture from
the surface of the circuit breaker using a lint-free dry
cloth, brush, or vacuum cleaner. Do not blow debris into
circuit breaker. If contamination is found, look for the
source and eliminate the problem.
4-2. Switch circuit breaker to ON and OFF several
times to be sure that the mechanical linkages are free
and do not bind. If mechanical linkages are not free,
replace circuit breaker.
4-3. With the circuit breaker in the ON position, press
the PUSH TO-TRIP button to mechanically trip the circuit breaker. Trip, reset, and switch circuit breaker ON
several times. If mechanism does not reset each time
the circuit breaker is tripped, replace the circuit breaker.
4-4. Check base, cover, and operating handle for
cracks, chipping, and discoloration. Circuit breakers
should be replaced if cracks or severe discoloration is
found.
4-5. Check terminals and connectors for looseness or
signs of overheating. Overheating will show as discoloration, melting, or blistering of conductor insulation, or
as pitting or melting of conductor surfaces due to arcing.
If there is no evidence of overheating or looseness, do
not disturb or tighten the connections. If there is evidence of overheating, terminations should be cleaned or
replaced. Before reenergizing the circuit breaker, all terminations and cable should be refurbished to the condition when originally installed.
4-6. Check circuit breaker mounting hardware, Tighten
if necessary.
4-7. Check area where circuit breaker is installed for
any safety hazards, including personal safety and fire
hazards. Exposure to certain types of chemicals can
cause deterioration of electrical connections.
4-8. The operation of circuit breakers with electronic trip
units can be field-tested periodically using the Seltronic
test kit.
Field Testing
Any field testing should be done in accordance with
applicable NEMA Standard.
!
CAUTION
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Style 6632C43H08
Printed in U.S.A.
/TQC
I.L. 29C103G
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Eaton Electrical, Inc.
1000 Cherrington parkway
Moon Township, PA 15108-4312
USA
Tel: 1-800-525-2000
www.EatonElectrical.com
©2010 Eaton corporation
All Rights Reserved
Printed USA/TQC
Eective January 2010
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