GE Industrial Solutions DB-15 User Manual

DEH–40030 Installation Instructions

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INTRODUCTION

GE Conversion Kits are designed for upgrading

®

existing Westinghouse
circuit breakers, rather than replacing the entire
breaker. The Conversion Kits include ProTrip™
Trip Units, the latest advance in GE trip
systems.

ProTrip Conversion Kits are designed and
tested to conform to ANSI Standard C37.59,
allowing the retrofitter to properly install the kit
and acceptance test the breaker.

This publication covers installation of ProTrip™
Conversion Kits on Westinghouse Type DB-15
low-voltage power circuit breakers. Each
Conversion Kit contains all the components
needed to convert from an existing
Westinghouse electromechanical trip system.

low-voltage power

ProTrip™ Conversion Kits

For Westinghouse

®

Type DB-15

Low-Voltage Power Circuit Breakers

TABLE OF CONTENTS

SECTION 1. GENERAL INFORMATION............................................................................................................4

SECTION 2. BEFORE INSTALLATION..............................................................................................................4

SECTION 3. DISASSEMBLING THE BREAKER

............................................................................................5

SECTION 4. INSTALLING THE CONVERSION KIT

Installing the Phase Sensors (CTs) ........................................................................................................7

Installing the Trip Paddle ........................................................................................................................9

Installing the Flux Shifter Mounting Bracket .........................................................................................10

Adjusting the Flux Shifter......................................................................................................................11

Connecting the Trip Unit Wiring Harness .............................................................................................11

Installing the Trip Unit ...........................................................................................................................12

Configuring the Trip Unit.......................................................................................................................13

Completing the Breaker Assembly .......................................................................................................13

SECTION 5. FOUR-WIRE GROUND FAULT OPTION................................................................................14

SECTION 6. TESTING AND TROUBLE-SHOOTING

Testing ..................................................................................................................................................15

Trouble-Shooting...................................................................................................................................15

Nuisance Tripping on Ground Fault-Equipped Breakers.........................................................15

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LIST OF FIGURES

1. Westinghouse DB-15 breaker ready for conversion........................................................................................5

2. Draw-out finger removal...................................................................................................................................5

3. Removing the bolts securing the existing trip units..........................................................................................5

4. Westinghouse electromechanical trip units removed from the breaker...........................................................6

5. DB-15 breaker disassembled and ready for conversion..................................................................................6

6. Assembling the CT and bus components........................................................................................................7

7. Installing the CT assemblies onto the breaker.................................................................................................7

8. Installing the CT mounting bolts.......................................................................................................................7

9. Tightening the CT assembly mounting bolts....................................................................................................8

10. Tightening the CT assembly bolt......................................................................................................................8

11. Installing the trip paddle. ..................................................................................................................................9

12. Flux shifter assembly and mounting bracket..................................................................................................10

13. Drilling the flux shifter bracket mounting hole. ...............................................................................................10

14. Mounting the flux shifter assembly.................................................................................................................10

15. Adjusting the flux shifter................................................................................................................................. 11

16. Installing the wiring harness...........................................................................................................................11

17. Trip unit attached to its mounting plate. .........................................................................................................12

18. Harness connector attached to the trip unit. ..................................................................................................12

19. Mounting the trip unit on the breaker. ............................................................................................................12

20. DB-15 breaker with conversion kit installed...................................................................................................13

21. Neutral sensor outline ....................................................................................................................................14

22. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads...............................................17

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SECTION 1. GENERAL INFORMATION

SECTION 2. BEFORE INSTALLATION

GE Conversion Kit installation is straightforward, but
does require careful workmanship and attention to these
instructions. Familiarity with the breaker is highly
desirable. Then general approach is to first remove the
existing trip devices from the breaker, then install the
ProTrip components. Following this procedure, the
converted breaker is performance tested before it is
returned to service.

The majority of trip unit kit installations do not require any
customized assembly work. However, some installations
may involve unusual mounting conditions or accessory
combinations that require minor modifications and/or
relocation of components. In most instances, this
supplementary work can be done on site.

In preparation for the conversion, the installer should
verify that the appropriate current sensors and trip unit
have been furnished. Whenever a ProTrip kit is installed
on a breaker with a four-wire system, an associated
neutral sensor (CT) is required for separate mounting in
the equipment. Ensure that retrofitted breakers are
applied within their short-circuit ratings.

Note that all ProTrip trip units supplied with conversion
kits are equipped with long-time, short-time,
instantaneous, and defeatable ground fault (LSIGX) trip
functions. The installer should be aware of how these
functions will affect his application before installing the
conversion kit.

As a service-related consideration, the installation of a
ProTrip kit provides an excellent opportunity to perform
normal maintenance on the breaker, particularly when
the front and back frames are separated. Such
procedures are described in the installation and
maintenance manuals supplied with the breaker and
equipment.

Before starting any work, turn off and lock out all power
sources leading to the breaker, both primary and
secondary. Remove the breaker to a clean, well-lighted
work area.

WARNING: Low-voltage power circuit breakers use
high-speed, stored-energy spring operating
mechanisms. The breakers and their enclosures
contain interlocks and safety features intended to
provide safe, proper operating sequences. For
maximum personnel protection during installation,
operation, and maintenance of these breakers, the
following procedures must be followed. Failure to follow
these procedures may result in personal injury or
property damage.

• Only qualified persons, as defined in the National
Electrical Code, who are familiar with the installation
and maintenance of low-voltage power circuit
breakers and switchgear assemblies, should
perform any work on these breakers.

• Completely read and understand all instructions
before attempting any breaker installation,
operation, maintenance, or modification.

• Turn off and lock out the power source feeding the
breaker before attempting any installation,
maintenance, or modification. Follow all lock-out
and tag-out rules of the National Electrical Code and
all other applicable codes.

• Do not work on a closed breaker or a breaker with
the closing springs charged. Trip an OPEN breaker
and be sure the stored-energy springs are
discharged, thus removing the possibility that the
breaker may trip OPEN or the closing springs
discharge and cause injury.

• Trip the breaker OPEN, then remove the breaker to
a well-lighted work area before beginning work.

• Do not perform any maintenance that includes
breaker charging, closing, tripping, or any other
function that could cause significant movement of a
draw-out breaker while it is on the draw-out
extension rails.

• Do not leave the breaker in an intermediate position
in the switchgear compartment. Always leave it in
the CONNECTED, TEST, or DISCONNECTED
position. Failure to do so could lead to improper
positioning of the breaker and flashback.

4

SECTION 3. DISASSEMBLING THE
BREAKER

A Westinghouse® DB-15 breaker conversion consists of
removing certain breaker components and replacing
some of them with the new GE conversion kit
components. After the GE conversion kit is installed, the
breaker is ready for testing and return to service.

The first step is to remove the breaker to a clean, well­lighted work bench and place it upright, so that both the
front and back are easily accessible, as shown in Figure

1.

1. Remove and save the load terminal draw-out fingers
on all draw-out breakers. They can be easily
removed by inserting a flat-blade screwdriver under
the back edge of the top finger and prying the fingers
back, as shown in Figure 2.

1

2. Remove the two
terminal, as shown in Figure 3. Discard the bolts and
lock washers.

3. Remove and discard the
terminal, as shown in Figure 3. The trip units should
loosen as this bolt is removed.

/2-13 bolts above each load

3

/8-16 bolt under each load

Figure 2. Draw-out finger removal.

Figure 1. Westinghouse DB-15 breaker ready for

conversion.

Figure 3. Removing the bolts securing the existing trip

units.

5

4. Remove and discard the three electromechanical trip
units, shown in Figure 4. The disassembled breaker
is shown in Figure 5.

Figure 4. Westinghouse electromechanical trip units

removed from the breaker.

Figure 5. DB-15 breaker disassembled and ready for

conversion.

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