Westinghouse IL 33-DAH-1 User Manual
IL 33-DAH-1
Digitrip Retrofit System for
Westinghouse DA-75 Breakers
Table of Contents
SAFETY PRECAUTIONS................................................................................................................1
Kit Components List.........................................................................................................................2
Step 1: General Breaker Preparation............................................................................................3
Step 2: Removing the Original Electromechanical Trip Units........................................................3
Step 3: Preparing the Sensors......................................................................................................4
Step 4: Installing the Sensors........................................................................................................4
Step 5: Installing the Trip Unit Mounting Platform..........................................................................5
Step 6: Preparing the Trip Unit Assembly......................................................................................6
Step 7: Installing the Trip Unit........................................................................................................6
Step 8: Installing the Trip Finger....................................................................................................7
Step 9: Installing the Reset Arm Assembly...................................................................................7
Step 10: Installing the DTA Assembly.............................................................................................8
Step 11: Installing the 2-Point Terminal Block.................................................................................9
Step 12: Installing the Breaker Mounted CPT.................................................................................9
Step 13: Final Connection of the Harnesses and Wiring...............................................................11
Step 14: Installing the Auxiliary Switch..........................................................................................14
Step 15: Testing the Breaker.........................................................................................................15
Step 16: Mounting the Cell Harness.............................................................................................15
Step 17: Installing the Retrofitted Breaker in the Cell....................................................................16
Kit Parts List...................................................................................................................................17
Torque Values for General Mounting..............................................................................................21
Torque Values for Copper BUS Connectors...................................................................................21
INDEX............................................................................................................................................25
Digitrip Retrofit System for Westinghouse DA-75 Breakers
SAFETY PRECAUTIONS
WARNING
POWER CIRCUIT BREAKERS ARE EQUIPPED
WITH HIGH SPEED, HIGH ENERGY OPERATING
MECHANISMS. THE BREAKERS AND THEIR
ENCLOSURES ARE DESIGNED WITH SEVERAL
BUILT-IN INTERLOCKS AND SAFETY
FEATURES INTENDED TO PROVIDE SAFE AND
PROPER OPERATING SEQUENCES. TO PROVIDE MAXIMUM PROTECTION FOR PERSONNEL ASSOCIATED WITH THE INSTALLATION,
OPERATION, AND MAINTENANCE OF THESE
BREAKERS, THE FOLLOWING PRACTICES
MUST BE FOLLOWED. FAILURE TO FOLLOW
THESE PRACTICES MAY RESULT IN DEATH,
PERSONAL INJURY, OR PROPERTY DAMAGE.
• Only qualified persons, as defined in the National
Electric Code, who are familiar with the installation and maintenance of power circuit breakers
and their associated switchgear assemblies
should perform any work associated with these
breakers.
IL 33-DAH-1
• Completely read and understand all instructions
before attempting any installation, operation,
maintenance, or modification of these breakers.
• Always turn off and lock out the power source
feeding the breaker prior to attempting any
installation, maintenance, or modification of
the breaker. Do not use the circuit breaker as
the sole means for isolating a high voltage
circuit. Follow all lockout and tagging rules
of the National Electric Code and all other
applicable codes, regulations, and work rules.
• Do not work on a closed breaker or a breaker
with the closing springs charged. Trip (open) the
breaker and be sure the stored energy springs
are discharged before performing any work. The
breaker may trip open or the charging springs
may discharge, causing crushing or cutting
injuries.
• For drawout breakers, trip (open), and then
remove the breaker to a well-lit work area before
beginning work.
• Do not perform any maintenance: including
breaker charging, closing, tripping, or any other
function which could cause significant movement
of the breaker while it is on the extension rails.
Doing so may cause the breaker to slip from the
rails and fall, potentially causing severe personal
injury to those in the vicinity.
• Do not leave the breaker in an intermediate
position in the switchgear cell. Always leave it
in the connected, disconnected, or (optional)
test position. Failure to do so could lead to
improper positioning of the breaker and
flashover, causing death, serious personal
injury, and / or property damage.
• Do not defeat any safety interlock. Such
interlocks are intended to protect personnel
and equipment from damage due to flashover
and exposed contacts. Defeating an interlock
could lead to death, severe personal injury,
and / or property damage.
Effective December, 1998
Page 2
IL 33-DAH-1
Cutler-Hammer Digitrip Retrofit Kits are available in
a number of configurations that provide a wide
which level of Retrofit Kit is to be installed and
which components are included with the Kit.
range of features. The Digitrip System starts with
the 510 Basic Kit which offers true RMS sensing,
overcurrent protection, and self-testing features.
Advanced Digitrip Retrofit Kits feature zone
interlocking, digital alphanumeric displays, remote
alarm signals, IMPACC communications, energy
The instructions contained in this manual cover the
installation of all levels of Retrofit Kit. If the Kit you
are installing does not contain a certain component,
skip the instructions for that component and
proceed to the next.
monitoring capabilities, power factors, and
harmonic content measurements.
Throughout the Retrofit process, refer to the Torque
Tables at the back of this manual for specific
The following table provides a quick reference of
torque values.
the components supplied with each level of Retrofit
Kit. Before beginning the Retrofit process, take a
minute to review the information contained in the
table. It is important that the Retrofitter understand
If you have any questions concerning the Retrofit
Kit and / or the Retrofit process, contact
Cutler-Hammer at 1-800-937-5487.
510 with
Components 510 Basic Zone 610 810 910
Interlock
Trip Unit
Rating Plug
Auxiliary Current
Transformer
(CT) Module
Auxiliary
CT Harness
Sensors
Sensor Harness
Direct Trip
Actuator (DTA)
Mounting Brackets
and Hardware
External Plug 1 Connector 2 Connector 4 Connector 4 Connector
Harness Harness Harness Harness Harness
Cell Harness
Breaker Mounted
Control Power
Transformer (CPT)
Potential Transf ormer
(PT) Module
Auxiliary Switch
Effective December, 1998
IL 33-DAH-1
Page 3
Step 1: General Breaker Preparation
Before attempting to remove the Breaker from
the cell or perform any Retrofit Operation, be sure
to read and understand the Safety Precautions
section of this manual. In addition, be sure to read
and understand the
Instructions for the Application
of Digitrip RMS Retrofit Kits on Power Circuit
Breakers
(Retrofit Application Data - Publication
AD 33-855-1), supplied with the Digitrip Retrofit Kit.
WARNING
DO NOT ATTEMPT TO INSTALL OR PERFORM
MAINTENANCE ON EQUIPMENT WHILE IT IS
ENERGIZED. SEVERE PERSONAL INJURY OR
DEATH CAN RESULT FROM CONTACT WITH
ENERGIZED EQUIPMENT. VERIFY THAT NO
VOLTAGE IS PRESENT BEFORE PROCEEDING.
A. Trip the Breaker and remove it from the Cell.
Move the Breaker to a clean, well-lit work
bench.
To begin the Retrofit Process, refer to the
components list at the end of this manual. Lay
out the components and hardware according
to the steps outlined. The components and
hardware will be used to complete each step
in the Retrofit Process.
Step 2: Removing the Original
Electromechanical T rip Units
Follow the Westinghouse DA-75 Instruction Manual,
originally supplied with the Breaker, to perform the
following procedure.
A. Remove and scrap the original
Electromechanical Trip units and all
associated hardware.
NOTE: It is the responsibility of the
Retrofitter to insure that the Breaker and
all original components are in good
condition. Visually inspect all Breaker
components for signs of damage or wear.
If any signs of damage or wear are
detected for components not included in the
Retrofit Kit, secure the necessary
replacement parts before beginning the
Retrofit Process.
The force necessary to trip the Breaker
should not exceed seven (7) lbs.
Effective December, 1998
Page 4
IL 33-DAH-1
Step 3: Preparing the Sensors
A. Place each Sensor between two Glass Poly
Insulation Plates. The connector stabs should
be positioned towards the cutouts in the
Insulation Plates as shown.
B. Secure the Glass Poly Plates on either side of
the Sensors using the (12) .250-20 × 2.00"
bolts, (24) flat washers, and (12) elastic stop
nuts supplied. Note that the bolts must be
installed so that the bolt heads will be against
the back of the Breaker and the stop nuts away
from the Breaker (same side as the screw
heads of the Sensor terminals). Do not over
tighten the bolts.
Step 4: Installing the Sensors
A. Remove and save the center bolts securing the
bottom Finger Clusters to the Breaker Stabs.
Remove the Finger Clusters.
B. Install a Sensor Assembly over each Breaker
Stab, with the Sensor terminals pointing
downward and the bolt heads outward as
shown.
C. Reinstall the Finger Clusters and secure them
using the original hardware.
Effective December, 1998
IL 33-DAH-1
(4)
Page 5
Step 5: Installing the Trip Unit Mounting
Platform
A. Using Drilling Plan “A”, drill and counter sink
two .375" holes in both the left and right
Breaker side plates.
B.
Mount the right and left Trip Unit Support Brackets
to the Breaker side plates as shown, using the
(4) .312-18 × .750" flat head screws, (4) flat
washers, (4) lock washers, and (4) nuts
supplied.
Do not tighten them completely at this time.
NOTE: The holes for mounting the DTA
(see Step 10) should also be drilled and
countersunk in the right Breaker Frame
at this time.
Drilling Plan “A”
6.50" 2.00"
1.81"
Drill 0.375" Dia. and
0.75"
0.75"
Countersink to 0.578"
Head Size (2)
Right Side Only
Drill 0.375" Dia. and
Countersink to 0.578"
Head Size
2.38"
NOTE: For ease of assembly, the 2-Point
Terminal Block (Step 11-A) can be mounted
to the inside of the right Trip Unit Support
Bracket at this time.
C. Mount the Trip Unit Mounting Platform to the
Support Brackets using the (4) .312-18 × .750"
bolts, (8) flat washers, (4) lock washers, and (4)
nuts supplied. Tighten the hardware connecting
the Mounting Platform to the Support Brackets,
and then the Support Brackets to the Breaker
side plates. Assure that the Mounting Platform
and Support Brackets are square with the Breaker.
Effective December, 1998
Page 6
IL 33-DAH-1
Step 6: Preparing the Trip Unit Assembly
A.
For Kits Supplied with a PT Module Only.
the PT Module to the Glass Poly Insulation
Barrier as shown, using the (2) .138-32 × .500"
screws, (4) flat washers, (2) lock washers, and
(2) nuts supplied.
D. Mount the Trip Unit Mounting Brackets to the
sides of the Aux. CT Module, using the (4)
.190-32 × .375" screws, (4) lock washers, and
(4) flat washers supplied, so they “pinch” the
Trip Unit in place.
Mount
E. Remove the Trip Unit cover and install the
Rating Plug. Replace the cover.
F. Install the Digitrip Nameplate on the top of the
Trip Unit.
B. Secure the Glass Poly Insulation Barrier to
the back of the Aux. CT Module using the (2)
.190-32 × .375" screws, (2) lock washers, and
(2) flat washers supplied.
C. Install the Trip Unit on the top of the Aux. CT
Module using the (2) brass spacers, (2)
.190-32 × 4.00" screws, (2) lock washers, and
(2) flat washers supplied as shown. Note that
the brass spacers are placed between the
bottom of the Trip Unit and the top of the Aux.
CT Module.
G. Connect the Aux. CT Harness to the Trip Unit
and Aux. CT Module.
Step 7: Installing the Trip Unit
A. Mount the Trip Unit / Aux. CT Module Assembly
to the Trip Unit Mounting Platform as shown,
using the (4) .250-20 × .750" bolts, (8) flat
washers, (4) lock washers, and (4) nuts supplied.
Effective December, 1998
IL 33-DAH-1
Page 7
Step 8: Installing the Trip Finger
A. Note the position of the original Trip Finger and
associated “gap” between the Trip Finger and
manual Trip Shaft. Remove the original Trip
Finger and scrap the mounting hardware.
Step 9: Installing the Reset Arm Assembly
B. Mount the new Trip Finger on the top of the
Cross Bar (with the curve upward and the notch
to the right) as shown, and the original Trip
Finger back on the bottom of the Cross Bar.
Secure using the (2) .190-32 × 1.75" bolts,
(4) flat washers, (2) lock washers, and
(2) nuts supplied.
C. Verify that the original Trip Finger has been
reinstalled in its initial position by checking the
gap (noted in Step 8-A) between the original
Trip Finger and manual Trip Shaft.
GAP
A. Remove the original Interlock Arm. Scrap the
original bolts, washers, and nuts.
B. Mount the Reset Arm Assembly to the bottom
of the Cross Bar and the original Interlock Arm
to the top of the Cross Bar in its original
position, using the (2) .190-32 × 1.75" bolts, (4)
flat washers, (2) lock washers, and (2) nuts
supplied. The Reset Arm Assembly should be
positioned so that the Reset Arm is hanging
downward as shown.
Effective December, 1998
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