GE Industrial Solutions DB-75, DBL-75, DB-100, DBL-100 User Manual

DEH–40032A 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-75,
DBL-75, DB-100, and DBL-100
power circuit breakers. Each Conversion Kit
contains all the components needed to convert
from an existing Westinghouse
electromechanical trip system.

low-voltage power

low-voltage

ProTrip™ Conversion Kits

For Westinghouse

®

Type DB-75, DBL­75, DB-100,
DBL-100 Low-Voltage Power Circuit
Breakers

TABLE OF CONTENTS

INTRODUCTION.........................................................................................................................................................1

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

SECTION 2. BEFORE INSTALLATION

..............................................................................................................4

SECTION 3. BACK FRAME BREAKER CONVERSION

Removing the Electromechanical Trip Devices......................................................................................5

Installing the Phase Sensors (CTs) ........................................................................................................6

SECTION 4. FRONT FRAME BREAKER CONVERSION

Installing the Trip Paddle ........................................................................................................................7

Installing the Trip Unit Mounting Bracket................................................................................................7

Adjusting the Flux Shifter........................................................................................................................8

Connecting the Trip Unit Wiring Harness ...............................................................................................9

Installing the Trip Unit ...........................................................................................................................10

Configuring the Trip Unit.......................................................................................................................10

SECTION 5. FOUR-WIRE GROUND FAULT OPTION................................................................................11

SECTION 6. TESTING AND TROUBLE-SHOOTING

Testing ..................................................................................................................................................12

Trouble-Shooting...................................................................................................................................12

Nuisance Tripping on Ground Fault-Equipped Breakers.........................................................12

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LIST OF FIGURES

1. Removing a trip device.....................................................................................................................................5

2. Electromechanical trip devices removed from the breaker..............................................................................5

3. Preparing the load terminals............................................................................................................................6

4. CTs installed on the breaker............................................................................................................................6

5. Trip paddle installed on the trip bar..................................................................................................................7

6. Trip unit mounting bracket................................................................................................................................ 7

7. Installing the support bracket...........................................................................................................................7

8. Trip unit mounting bracket installed on the breaker frame. ............................................................................. 8

9. Adjusting the flux shifter...................................................................................................................................8

10. Wiring harness installation on the CTs. ...........................................................................................................9

11. Trip unit attached to its mounting plate..........................................................................................................10

12. Harness connector attached to the trip unit...................................................................................................10

13. Mounting the trip unit on the breaker. ............................................................................................................ 10

14. Neutral sensor outline for a DB-75 or DB-100 breaker..................................................................................11

15. Cabling diagram for ProTrip™ trip units with ground fault on four-wire loads...............................................14

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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.

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SECTION 3. BACK FRAME BREAKER
CONVERSION

The back frame conversion of a Westinghouse DB-75 or
DB-100 breaker consists of the following steps:

1. Remove the breaker to a clean, well-lighted work
bench and place it on its left side, so that both the
bottom and back are easily accessible.

2. Remove the existing electromechanical trip devices.

3. Install the new phase sensors (CTs).

Removing the Electromechanical Trip
Devices

1. Remove and discard the four bolts holding each trip
device to a pole of the breaker, as shown in Figure 1.

2. Remove and discard the three electromechanical trip
devices, shown in Figure 2.

CAUTION: Do not remove the trip paddles from the
common trip bar. They are used to balance the trip
action and could cause nuisance tripping if removed.

Figure 1. Removing a trip device.

Figure 2. Electromechanical trip devices removed from

the breaker.

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