Cutler Hammer, Div of Eaton Corp DK, KDB, KD, HKD, KDC Installation Instructions

I.L. 29C104C

File 29-000

Effective June 1998 Supersedes I.L. 29C104-B dated August 1997.

Cutler-Hammer

Installation Instructions for DK, KDB, KD, HKD, KDC, KW, HKW,
KWC, CKD, CHKD Circuit Breakers and Molded Case Switches

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 K-frame Series C circuit breaker (Figure 1-1) types
KD, HKD, and KDC are 600 Vac maximum rated
devices with interchangeable thermal-magnetic or elec­tronic (Seltronic) trip units rated 400A maximum continu­ous current. Circuit breaker types KW, HKW, and KWC
are 660 Vac maximum rated devices using interchange­able adjustable thermal/adjustable magnetic or electron­ic trip units rated up to 400A continuous current. The
type KDB noninterchangeable trip circuit breaker is rated
600 Vac maximum with a maximum continuous current
rating of 400A. The type DK 240 Vac maximum circuit
breaker is also a noninterchangeable trip device with trip
unit ratings from 250A to 400A. Refer to Table 4-1 on
page 8 for all available trip unit ratings. 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 C947-

2. Molded case switches are listed in accordance with
UL1087. For more information, see Frame Book 29-103.

100 Percent Rated K-Frame Circuit Breakers

CKD and CHKD circuit breakers are suitable for contin­uous operation at 100 percent of the frame rating if
used with an 90°C insulated wire and AL9CU terminals
in an enclosure which measures at least 24” high x 15”
wide x 6” deep. Ventilation is not required in an enclo­sure having these minimum dimensions. CKD and
CHKD 100 percent rated circuit breakers use electronic
trip units only.

This instruction leaflet (IL) gives procedures for installa­tion and field testing of K-frame Series C circuit break­ers. Instructions are also provided for replacement of
existing Cutler-Hammer circuit breaker types DA, LB,
LBB, HLB, JA, KA, and HKA. For this publication, the
term circuit breaker shall also include the molded case
switch.

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 person­nel and equipment as well as all general and local
health and safety laws, codes, and procedures.

Figure 1-1 K-Frame Model D Series C Circuit Breaker
Frame with KT Trip Unit Installed

WARNING

I.L. 29C104C

Page 2

Effective 6/98

2. INSTALLATION

The installation procedure consists of inspecting the cir­cuit breaker and, as applicable, installing the trip unit and
rating plug, 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, rating
plugs, accessories, mounting hardware, and unmounted
terminals may be supplied in separate packages. To
install the circuit breaker, perform the following steps.

If circuit breaker is replacing a DA, JA, KA, HKA, LB,
LBB, or HLB circuit breaker, refer to section 3 of
this instruction leaflet.

DK and KDB circuit breakers are factory sealed for
reverse feed applications under UL489. UL requires
that internal accessories be installed at the factory
in these types of circuit breakers.

If required, internal accessory installation in any
type of circuit breaker should be done before the

Figure 2-1 Cover Mounting Hardware

Flat Head, Thread

Forming Screws

Pan Head

Screws

Figure 2-2 Cover Screw Installation Positions

On

Off

Screw, .190-32 x 3.125 Inch Pan Head, Cross-Recessed.

Screw, No. 8 x 1.63 Inch, Flat Head, Cross-Recessed,
Thread Forming.

Note: Hatched lines show additional pole and screws for
4-pole circuit breaker.

Figure 2-3 Terminal Cover Installation

Terminal Cover

Dovetails

Mounting
Slots

NOTICE

NOTICE

I.L. 29C104C

Page 3

Effective 6/98

circuit breaker is mounted and connected. Refer to
individual accessory instruction leaflets.

2-1. Make sure that the circuit breaker is suitable for the
intended installation by comparing nameplate data with
existing equipment 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.

The circuit breaker handle must be in the tripped or
OFF position to remove the cover. Instructions for
installing the trip unit and accessories are supplied
with the devices.

2-3. If not already installed, mount trip unit and acces­sories (if required) in circuit breaker frame. Rating plug
must be installed in Seltronic trip units.

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. Replace cover and install pan-head screws fol­lowed by thread-forming screws as shown in Figure 2-2.

2-5. If not already installed, mount terminals as shown
in Figure 2-4. Secure the terminals to the circuit breaker
using a 7/32-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. If
Warning label is supplied with terminal, place on upper
portion of circuit breaker cover.

THE VOLTAGE 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 2-5. For panel­board mounting, only load end support mounting

NOTICE

CAUTION

WARNING

Figure 2-4 Terminal Installation

TA300K/TA350K
T300K/T350K Terminals

Circuit Breaker
Terminal Conductors

Conductor
Screws

Terminal
Mounting
Screw

TA400K, TA401K, TA402K,
T400K Terminals

Terminal Mounting Screw

NOTICE