DEH–40030 Installation Instructions
g
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
2
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
3
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.
6
SECTION 4. INSTALLING THE
CONVERSION KIT
Installing the Phase Sensors (CTs)
Each of the Westinghouse® DB-15 conversion kit phase
sensors (CTs) must be assembled onto its new copper
bus before installation onto the breaker.
1. Place the CT over the post on the bottom piece of
the new bus. Place the insulated barrier in position
on top of the CT, then place the top piece of the new
bus in position, as shown in Figure 6. Place a
bolt with flat washer through the top bus and into the
tapped hole in the post of the bottom bus. Leave the
bolt finger tight for now.
2. Place the alignment pins in the breaker frame bottom
mounting holes left vacant by removal of the bolt in
step 3 (Component Removal). Position each CT
assembly over its alignment pin in the bottom of the
breaker frame, as shown in Figure 7.
1
3. Insert the provided
washers through the hole above each load terminal
from the back of the breaker, as shown in Figure 8.
Leave the bolts finger tight for now.
4. Insert the provided
flat washers through the holes above the
installed in step 3, as shown in Figure 8. Leave the
bolts finger tight for now.
/2-13 x 11/2" bolts with lock
3
/8-16 x 11/4" bolts with lock and
3
/8-16
1
/2-13 bolts
Figure 7. Installing the CT assemblies onto the breaker.
Figure 6. Assembling the CT and bus components.
Figure 8. Installing the CT mounting bolts.
7
1
5. Tighten the
in step 3 to 300 in-lb, as shown in Figure 9. Tighten
3
/8-16 x 11/4" bolts inserted in step 4 to 200 in-lb.
the
/2-13 x 11/2" CT assembly bolts inserted
6. Tighten the CT post bolts inserted in step 1 to 200 inlb, as shown in Figure 10.
WARNING: Steps 5 and 6 provide critical electrical
integrity connections. The designated bolts must be
correctly tightened for proper operation. Failure to
tighten these bolts properly will cause a breaker failure,
resulting in property damage and/or personal injury.
Figure 9. Tightening the CT assembly mounting bolts.
Figure 10. Tightening the CT assembly bolt.
8
Installing the Trip Paddle
Mount the new trip paddle on the right side of the
common trip bar, as shown in Figure 11. Insert the
provided 8-32 x
the trip bar and secure with the nut with integral lock
washer.
1
/2" screw through the existing hole in
Figure 11. Installing the trip paddle.
9
Installing the Flux Shifter Mounting Bracket
1. Before the flux shifter assembly, shown in Figure 12,
can be mounted on the breaker frame, a clearance
hole for a
lifting bar. Align the base of the flux shifter mounting
bracket with the existing holes in the breaker frame
and drill the top hole into the breaker frame, as
shown in Figure 13. The mounting bracket must be
parallel with the breaker back frame.
2. Position the flux shifter assembly, ensuring that the
1
/2"-diameter hole in the end of the reset link is
placed over the end of the crossbar arm. Use the
retaining ring provided to hold the link in place, as
shown in Figure 14.
3. Fasten the assembly to the breaker with a
3
/4" bolt and lock washer inserted through the hole in
the back of the assembly, as shown in Figure 14.
Insert a
the hole drilled in step 1 and secure with the lock
washer and nut provided.
NOTE: If an undervoltage device is present on the
breaker, it will have to be relocated.
4. Insert a 1/4-20 x 3/4" bolt through the hole in the front
of the flux shifter mounting bracket, as shown in
Figure 15. Secure with the nut and lock washer
provided.
1
/4" bolt must be drilled in the top right
1
/4-20 x
1
/4-20 x 3/4" bolt through the assembly and
Figure 13. Drilling the flux shifter bracket mounting hole.
Figure 12. Flux shifter assembly and mounting bracket.
Figure 14. Mounting the flux shifter assembly.
10
Adjusting the Flux Shifter
With the breaker in the CLOSED position, the gap
between the adjustment screw and the end of the flux
1
shifter should be
safety, OPEN the breaker before adjusting the screw with
1
/4-inch wrench. CLOSE the breaker to check the
a
adjustment.
WARNING: Be extremely careful when working on a
CLOSED breaker. Do not reach into the mechanism
while adjusting the flux shifter.
Optional Test – The flux shifter may be tested by closing
the breaker and applying a 9 Vdc power source to the
flux shifter leads (the red wire is positive). The breaker
should trip.
/16 inch, as shown in Figure 15. For
Connecting the Trip Unit Wiring Harness
1. Join the four-pin connector on the trip unit harness to
the four-pin connector on the flux shifter.
2. Run the CT leads through the inside of the breaker
frame, as shown in Figure 16. Connect the harness
leads to the screw terminals on each CT. The black
wire (tap) connects to the left terminal and the white
wire (common) to the right terminal.
3. Use the wire ties provided to tie the harness back
against the frame. Tie the harness to each CT
assembly, as shown in Figure 16. Ensure that the
wiring will not interfere with any moving parts.
Figure 15. Adjusting the flux shifter.
Figure 16. Installing the wiring harness.
11
Installing the Trip Unit
1. Place a lock washer and flat washer over each of the
three
through the mounting holes on the trip unit mounting
plate. From the rear of the plate, place a flat washer,
spacer, and O-ring over the screws, as shown in
Figure 17.
2. Remove the large screw from the rear of the trip unit.
Place the trip unit in position on the mounting plate,
with the 50-pin connector aligned with the opening in
the plate. Secure with the large screw, as shown in
Figure 17.
3. Insert the 50-pin female connector on the wiring
harness into the trip unit connector through the rear
of the mounting plate. Secure to the mounting plate
with the two small screws provided, as shown in
Figure 18.
4. Place the trip unit and mounting plate in position on
the support bracket mounted to the breaker. Secure
with the screws in the mounting plate into the tapped
holes in the bracket, as shown in Figure 19.
1
/4-20 x 13/8" screws provided and insert
Figure 18. Harness connector attached to the trip unit.
Figure 17. Trip unit attached to its mounting plate.
Figure 19. Mounting the trip unit on the breaker.
12
Configuring the Trip Unit
See DEH-40034 for detailed instructions for setting up
ProTrip trip units.
Completing the Breaker Assembly
On draw-out breakers, reinstall the draw-out fingers. A
completed DB-15 breaker is shown in Figure 20.
Figure 20. DB-15 breaker with conversion kit installed.
13
SECTION 5. FOUR-WIRE GROUND
FAULT OPTION
The ground fault option for four-wire installations requires
the installation of an additional current sensor on the
neutral bus in the equipment. The sensor is connected to
the trip unit through the connector provided in the wiring
harness.
1. Mount the neutral sensor on the outgoing neutral
lead, normally in the bus or cable compartment in the
equipment. Figure 21 shows the outline of the neutral
sensor.
2. Connect the neutral sensor wire harness to the
correct taps on the sensor. To maintain the same
polarity as the phase sensors, connect the white wire
to the common terminal, black to the tap.
3. Route the wires through the equipment and connect
to the two-pin connector on the trip unit wiring
harness. The wires should be tied to the breaker
frame in an easily accessible location.
Figure 21. Neutral sensor outline.
14
SECTION 6. TESTING AND TROUBLESHOOTING
WARNING: Do not change taps on the current sensors
or adjust the trip unit settings while the breaker is
carrying current. Failure to adhere to these instructions
will void all warranties.
Testing
Before installing a converted breaker back into service,
perform the following steps:
1. Verify that the trip unit is securely installed by
performing a continuity test on the CT wiring and the
trip unit.
a. Disconnect the black CT wires at each phase
sensor.
b. Check for continuity with a continuity tester or
VOM from the white lead of the phase A CT to the
white lead of the phase B CT.
c. Repeat this continuity test for the white leads of
the phase A and phase C CTs.
d. Measure the resistance across each phase
sensor and compare the values measured to the
values listed in Table 1.
e.
Reconnect the black CT leads to all of the phase
sensors. Ensure that this is done before
continuing with performance testing of the
breaker.
CAUTION:
Step 1 and before performance testing of the converted
breaker, each phase of the breaker should be primary
injected with a current level of about 10%, but no more
than 20%, of the CT rating.
WARNING: If the converted breaker is energized or
tested by primary injection with a sufficiently high test
current with a loose or open circuit between the CTs
and the trip unit, damage will occur to the trip unit, wire
harness, 50-pin trip unit connector, and CTs. Failure to
adhere to these instructions will void all warranties.
2.
Check the insulation on the primary circuit with a
1,000-volt Megger.
3.
Measure the resistance across the line and load
terminals for each phase using a micro-ohmmeter or
millivolt tester. If the resistance differs considerably
from phase to phase, the electrical connections may
not be properly tightened or it could also indicate
improper contact wipe.
4. To verify that the breaker has been properly retro-
fitted, perform a primary injection test on each phase.
This test will check the CTs, bus, wiring harness, flux
shifter, and trip unit as a complete system.
In addition to the continuity test described in
a. A high-current, low-voltage power supply should
be connected across each line and load terminal
to simulate an overcurrent fault.
b. Set the long-time trip at 0.5 to minimize the
breaker stress.
c. When ground fault is installed, the test can be
performed by wiring two adjacent poles in series
or by using the GE Digital Test Kit, cat. no.
TVRMS2. This will prevent the breaker from
tripping because of an unbalanced current flow.
CAUTION: Do not attempt to use GE Test Kit cat. no.
TVTS1 or TVRMS on this trip unit.
Trouble-Shooting
When malfunctioning is suspected, first examine the
breaker and its power system for abnormal conditions
such as the following:
• The breaker is not tripping in response to overcurrent conditions or incipient ground faults.
• The breaker is remaining in a trip-free state because
of mechanical interference along its trip shaft.
• The shunt trip (if present) is activating improperly.
Nuisance Tripping on Ground Fault-Equipped
Breakers
When nuisance tripping occurs on breakers equipped
with ground fault trip, a probable cause is the existence
of a false ground signal. Each phase sensor is connected
to summing circuitry in the trip unit. Under no-fault
conditions on three-wire load circuits, the currents add to
zero and no ground signal is developed. This current
sum is zero only if all three sensors have the same
electrical characteristics. If one sensor differs from the
others (such as by a different rating or wrong tap setting),
the circuitry can produce an output sufficient to trip the
breaker. Similarly, a discontinuity between any sensor
and the trip unit can cause a false trip signal.
The sensors and their connections should be closely
examined if nuisance tripping is encountered on any
breaker whose ProTrip trip unit has previously
demonstrated satisfactory performance. After disconnecting the breaker from all power sources, perform
the following procedure:
1. Check that all phase sensors are the same type
(current range).
2. Verify that the tap settings on all three phase sensors
are identical.
3. Verify that the wiring harness connections to the
sensors have the proper polarity (white lead to
common, black lead to tap), as shown in the cabling
diagram in Figure 22.
4. On ground fault breakers serving four-wire loads,
check that the neutral sensor is properly connected,
15
as indicated in Figure 22. In particular, check the
following:
a. Verify that the neutral sensor has the same rating
and tap setting as the phase sensors.
b. Verify continuity between the neutral sensor and
its equipment-mounted secondary disconnect
block. Also check for continuity from the breakermounted neutral secondary disconnect block
through to the trip unit wiring harness connector.
c. If the breaker’s lower studs connect to the power
source, then the neutral sensor must have its load
end connected to the source.
d. Verify that the neutral conductor is carrying only
the neutral current associated with the breaker’s
load current (the neutral is not shared with other
loads).
5. If the preceding steps fail to identify the problem,
then measure the sensor resistances. The appropriate values are listed in Table 1. Since the phase
and neutral sensors are electrically identical, their
resistances should agree closely.
Breaker CT Rating, A Resistance,
ohms
DB-15
150
225
7–15
12–20
Table 1. CT resistance values.
16
Figure 22. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads.
17
NOTES
These instructions do not cover all details or variations in equipment nor do they provide for every possible contingency
that may be met in connection with installation, operation, or maintenance. Should further information be desired or should
particular problems arise that are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the
GE Company.
General Electric Company
41 Woodford Ave., Plainville, CT 06062
DEH40030 R02 0899 © 1999 General Electric Company
g GE Industrial Systems
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