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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 FEA-
TURES INTENDED TO PROVIDE SAFE AND
PROPER OPERATING SEQUENCES. TO PRO-
VIDE MAXIMUM PROTECTION FOR PERSON-
NEL 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.
Effective 10/00
Digitrip Retrofit System for the
ITE K-Line Breakers: K-1600
(Black or Red), KDON-1600
(Black or Red), and K-2000 (Red)
• 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.
IL 33-K2C-3
Page 1
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Related Manuals for Eaton digtrip 510 with zone Interlock
Summary of Contents for Eaton digtrip 510 with zone Interlock
- Page 1 IL 33-K2C-3 Page 1 Digitrip Retrofit System for the ITE K-Line Breakers: K-1600 (Black or Red), KDON-1600 (Black or Red), and K-2000 (Red) • Completely read and understand all instructions before attempting any installation, operation, maintenance, or modification of these breakers. •...
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Page 2: Table Of Contents
IL 33-K2C-3 Page 2 Digitrip Retrofit System for the ITE K-Line Breakers: K-1600 (Black or Red), KDON-1600 (Black or Red), and K-2000 (Red) CONTENTS Description Step 17: Installing the Retrofitted Breaker in the Cell ..........34 Introduction ............4 Before Beginning the Retrofit Process Figures Identify the Breaker and the Retrofit Kit .... - Page 3 IL 33-K2C-3 Page 3 21. Identification of the Line and Load Side 47. PT Wires Connected to the HV Wires ............14 Breaker Stags ..........25 22. Routing of the HV Wires ....... 15 48. Correct Position of the Insulated Tubing and HV Fuses ..........
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Page 4: Introduction
IL 33-K2C-3 Page 4 table. It is important that the Retrofitter INTRODUCTION understands which level of Retrofit Kit is to be Cutler-Hammer Digitrip Retrofit Kits are available in installed and which components are included with a number of configurations that provide a wide the Kit. -
Page 5: Before Beginning The Retrofit Process Identify The Breaker And The Retrofit Kit
IL 33-K2C-3 Page 5 Before Beginning the Retrofit Process Please refer to the following table and verify that Identify the Breaker and the Retrofit Kit the first three (3) characters of the Retrofit Kit Code Number correspond to the Breaker being It is important to verify exactly which version of ITE Retrofitted. -
Page 6: Step 1: General Breaker Preparation
IL 33-K2C-3 Page 6 STEP 1: GENERAL BREAKER PREPARATION To begin the Retrofit Process, refer to the compo- nents list at the end of this manual. Lay out the Before attempting to remove the Breaker from the components and hardware according to the steps Cell or perform any Retrofit operation, be sure to outlined. -
Page 7: Step 2: Preparing The Breaker For Retrofitting
IL 33-K2C-3 Page 7 STEP 2: PREPARING THE BREAKER FOR RETROFITTING Refer to the ITE K-Line Instruction Manual, origi- Note the orientation of the existing fuses. nally supplied with the Breaker, to perform the Follow the ITE K-1600 / 2000 Instruction following procedures. -
Page 8: Step 3: Drilling The Breaker Angles
IL 33-K2C-3 Page 8 STEP 3: DRILLING THE BREAKER ANGLES NOTE: The hole should be drilled slightly below the Breaker Cross Rail and be located so A. Working from the rear of the Breaker and using as not to interfere with the Lifting Rack a .500"... -
Page 9: Step 4: Preparing The Dta Assembly For Installation
IL 33-K2C-3 Page 9 STEP 4: PREPARING THE DTA ASSEMBLY FOR INSTALLATION FRONT VIEW EXISTING SLOT .50" Fig. 6 Overview - DTA Assembly NOTE: If an existing Breaker component does not allow the DTA to be mounted on the right .500"... -
Page 10: Dta Mounted To The Dta Mounting Angle
IL 33-K2C-3 Page 10 B. Apply Loc-Tite ® 243 to the threads then mount the DTA and the DTA Bearing Plate Assembly to the DTA Mounting Angle, as shown, using the (2) .164-32 × .312" pan lock screws, (2) .164-32 × .500" pan screws, (2) lock washers, and (4) flat washers supplied. -
Page 11: Step 5: Installing The Dta Assembly In The Breaker
IL 33-K2C-3 Page 11 E. For Kits Supplied with an Auxiliary Switch Only: STEP 5: INSTALLING THE DTA ASSEMBLY IN Cut .250" from the end of the Microswitch Arm. THE BREAKER Mount the Microswitch the to Auxiliary Switch Mounting Bracket, as shown, using the (2) .138-32 ×... -
Page 12: Installing The Dta Assembly
IL 33-K2C-3 Page 12 E. Return the Breaker to its upright position. Verify that there is clearance between the bottom of the DTA Shaft and the work bench. If not, turn the Breaker back on its side, re- move the mounting hardware securing the DTA Assembly to the Breaker. -
Page 13: Step 6: Installing The Breaker Mounted Cpt On The Dta Mounting Angle
IL 33-K2C-3 Page 13 F. Route the DTA Extension Harness up through For Kits Supplied with a Breaker Mounted CPT the Breaker, then through the existing hole in Only. the Breaker Platform. Insure that the DTA Extension Harness is clear of all moving parts STEP 6: INSTALLING THE BREAKER within the Breaker. -
Page 14: Cpt Orientation And Screw Location
IL 33-K2C-3 Page 14 A. Mount the Breaker Mounted CPT to the NOTE: The High Voltage (HV) Wires have a LOAD CPT Mounting Plate, as shown, using the Side and a LINE Side. The HV Wires must (2) .190-32 × .500" flat head screws, (2) .190- be installed in the correct orientation 32 ×... -
Page 15: Routing Of The Hv Wires
IL 33-K2C-3 Page 15 Table 3 CPT Voltage Taps Voltage Required CPT Terminals Used 480 Volt Circuit H1 & H4 240 Volt Circuit H1 & H3 208 Volt Circuit H1 & H2 Fig. 22 Routing of the HV Wires D. Carefully lay the Breaker on its left side. E. -
Page 16: Cpt Mounted To The Dta Assembly
IL 33-K2C-3 Page 16 Fig. 26 Insulation Plate Mounted to the CPT Fig. 24 CPT Mounted to the DTA Assembly J. Tighten the hardware that secures the DTA Assembly to the Breaker. K. Attach the appropriate CPT Voltage Label in a clearly visible position on the front of the Breaker. -
Page 17: Step 7: Final Dta And Reset Installation And Adjustment
IL 33-K2C-3 Page 17 STEP 7: FINAL DTA AND RESET INSTALLATION AND ADJUSTMENT Fig. 29 DTA Trip Plate Installed on the DTA Shaft C. CLOSE the Breaker. Fig. 28 Overview – DTA and Reset Adjustment WARNING: A. With the Breaker in its upright position, liberally apply Loc-Tite ®... -
Page 18: Setting The Dta Gap
IL 33-K2C-3 Page 18 Fig. 30 Setting the DTA Gap Fig. 31 Mounting the DTA Insulation Plate – E. Return the Breaker to the OPEN position. K-2000 Breakers Only NOTE: The Loc-Tite ® 243 must be allowed to G. Carefully lay the Breaker on its right side. cure for a MINIMUM of one (1) hour before the DTA is tested. -
Page 19: Reset Rod Assembly
IL 33-K2C-3 Page 19 J. Remove the lock nut and small flat washer from the threaded end of the Reset Rod OPTIONAL DRIVE Assembly supplied with the Retrofit Kit. POLE SHAFT STOP LINK TO AUXILIARY SWITCH FLAT WASHER FLAT WASHER RESET ROD BOLT ELASTIC STOP NUT... -
Page 20: Step 8: Installing The Copper Connectors
IL 33-K2C-3 Page 20 M. Adjust the nuts on the Reset Rod Assembly STEP 8: INSTALLING THE COPPER until a nominal cage height of .56" is achieved. CONNECTORS NOMINAL CAGE HEIGHT .56" Fig. 36 Adjusting the Reset Rod Assembly Fig. 37 Overview – Installation of the New Copper Connectors N. -
Page 21: Step 9: Preparing The Trip Unit Assembly
IL 33-K2C-3 Page 21 B. Install the Glastic Molding Assemblies back STEP 9: PREPARING THE TRIP UNIT into the Breaker using the original hardware ASSEMBLY removed during Step 2-C. C. Secure each new Copper Connector to each existing Copper Contact using the (4) .312-18 ×... -
Page 22: Pt Module Mounted To The Glass Poly
IL 33-K2C-3 Page 22 B. For Kits Supplied with a PT Module Only: Mount the PT Module to the Glass Poly Barrier, as shown, using the (2) .138-32 × .500" screws, (4) flat washers, (2) lock washers, and (2) nuts supplied. -
Page 23: Step 10: Installing The Trip Unit On The Breaker
IL 33-K2C-3 Page 23 STEP 10: INSTALLING THE TRIP UNIT ON THE F. Assure that the area under the Breaker Plat- BREAKER form where the holes will be drilled is clear, then drill two (2) 0.166" diameter holes where marked. G. -
Page 24: Step 11: Final Connection Of The Pt And / Or Hv Wires
IL 33-K2C-3 Page 24 Install the Aux. CT Harness between the Trip For Kits Supplied with a PT Module and / or Unit and the Aux. CT Module. Breaker Mounted CPT Only. STEP 11: FINAL CONNECTION OF THE PT AND / OR HV WIRES Fig. -
Page 25: Correct Position Of The Insulated Tubing
IL 33-K2C-3 Page 25 Fig. 47 PT Wires Connected to the Breaker Stags For Kits Supplied with a Breaker Mounted CPT Only. E. Cut appropriate length pieces from the sup- plied insulated tubing and install one (1) piece Fig. 46 Correct Position of the Insulated Tubing on each HV Wire. -
Page 26: Hv Wires Connected To The Top
IL 33-K2C-3 Page 26 NOTE: The power convention of the ITE K-1600 / 2000 Series Breakers is normally Top to Bottom, meaning the Top Breaker Stabs are on the Line Side of the Breaker and the Bottom Breaker Stabs are on the Load Side. -
Page 27: Step 12: Installing The Sensors
IL 33-K2C-3 Page 27 ATTENTION: Before proceeding, it is necessary E. Mount the (2) threaded coupling nuts to the top to verify which Step 12 is to be rear of the Breaker, using the (2) .375-16 × followed for correct installation of .750”... -
Page 28: Overview - Installed Bottom Mounted
IL 33-K2C-3 Page 28 ATTENTION: Before proceeding, it is necessary to verify which Step 12 is to be followed for correct installation of the Sensors. This is done by refer- ring to the Icon(s) with each step. F. Reinstall the bottom Finger Clusters (removed in Step 2-B) using the original hardware. -
Page 29: Step 13: Connecting The Sensor Harness And The Dta Harness
IL 33-K2C-3 Page 29 B. Mount a Sensor Mounting Bracket to each side STEP 13: CONNECTING THE SENSOR of the Breaker Frame using the holes just HARNESS AND THE DTA HARNESS drilled and the (4) .250-20 × .500" bolts, (4) flat washers, and (4) lock washers supplied. -
Page 30: Connecting The Dta Harness
IL 33-K2C-3 Page 30 D. Route the Sensor Harness towards the left rear of the Breaker, then through the hole drilled in Step 3-A or B. Fig. 57 Connecting the DTA Harness C. Connect the Sensor Harness to the proper Fig. -
Page 31: Step 14: Connecting The External Harness And Optional Components
IL 33-K2C-3 Page 31 For Kits Supplied with a PT Module Only: STEP 14: CONNECTING THE EXTERNAL Refer to Section 7-3, Power Flow Convention HARNESS AND OPTIONAL of the Retrofit Application Data, supplied with COMPONENTS the Retrofit kit for additional wiring information and to verify the Phase Convention used on this Breaker Application. -
Page 32: Securing The External Harness
IL 33-K2C-3 Page 32 E. For Kits Supplied with a Breaker Mounted CPT Only: Remove the 9-position External Harness plug from the female receptacle on the Trip Unit. Insert the black plug from the CPT Harness into the same female receptacle. Reinsert the External Harness Plug just re- moved into the female receptacle on the CPT Harness. -
Page 33: Step 15: Testing The Breaker
IL 33-K2C-3 Page 33 STEP 15: TESTING THE BREAKER F. While Section 8 of the Instructions for the Application of Digitrip RMS Retrofit Kits on NOTE: Insure that a minimum of one (1) hour has Power Circuit Breakers provides the informa- past since the final gap on the DTA was tion necessary for testing the Breaker, please set in Step 6-D. -
Page 34: Step 16: Mounting The Cell Harness
IL 33-K2C-3 Page 34 For Kits Supplied with a Cell Harness Only. STEP 17: INSTALLING THE RETROFITTED BREAKER IN THE CELL STEP 16: MOUNTING THE CELL HARNESS WARNING A. The Cell Harness is to be mounted in the Breaker Cell. The connector end is to be DO NOT LEAVE THE BREAKER IN AN INTER- mounted on the right front side of the Cell, in a MEDIATE POSITION IN THE SWITCHGEAR... - Page 35 IL 33-K2C-3 Page 35 Digitrip Retrofit Kit Installation Components for the ITE K-225 (Black or Red), K-600 (Black or Red), and KDON-600 (Black or Red) Breakers Step Description Style No. Qty. Comment Step 4 4A35899G33 DTA Assembly Parts 4A35899G05 DTA Mounting Angle DTA Trip Plate Bearing Plate Bearing Plate Mounting Bracket...
- Page 36 IL 33-K2C-3 Page 36 Step Description Style No. Qty. Comment Step 6 .190-32 Nut Hex Stl. (Cont.) .164-32 × .312 Lng. Screw Pan Lock .164-32 × .625 Lng. Screw .164 Flat Washer Stl. CPT Only .164 Lock Washer Stl. .164-32 Nut Hex Stl. .138 Flat Washer Stl.
- Page 37 IL 33-K2C-3 Page 37 Step Description Style No. Qty. Comment Step 9 Digitrip Nameplate (Cont.) Spacer Brass .190-32 × 4.00 Lng. Screw .190-32 × .375 Lng. Screw .190 Flat Washer Stl. .190 Lock Washer Stl. PT Module 6502C82G01 .138-32 × .500 Lng. Screw .138 Flat Washer Stl.
- Page 38 IL 33-K2C-3 Page 38 Step Description Style No. Qty. Comment Wire Clamp Step 14 .138 × .380 Lng. Screw T. C. (Cont.) Step 16 Cell Harness 6503C57G__ Except 510 Basic NOTE: Due to the wide variety of Breakers and multiple functions of the Retrofit components, some excess hardware may be left when the Retrofit is complete.
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Page 39: Torque Values For General Mounting And Screw Size Conversion
IL 33-K2C-3 Page 39 Table 5: Torque Values for General Mounting and Screw Size Conversion Decimal Standard Torque Torque Size (in) Size (in-lbs) (ft-lbs) .112 4-40 .138 6-32 .164 8-32 .190 10-32 .250 1/4-20 .312 5/16-18 17.2 .375 3/8-16 29.7 .438 7/16-14 47.7... -
Page 40: Retrofit Components
IL 33-K2C-3 Page 40 Fig. 67 Retrofit Components A. Sensors I. Sensor Harness B. Trip Unit J. External Harness C. Aux. CT Module K. Cell Terminal Block D. Direct Trip Actuator (DTA) L. Aux. Switch E. CPT Transformer M. PT Module F. - Page 41 IL 33-K2C-3 Page 41 Notes Effective 10/00...
- Page 42 IL 33-K2C-3 Page 42 Notes Effective 10/00...
- Page 43 IL 33-K2C-3 Page 43 Notes Effective 10/00...
- Page 44 We wish to thank you for purchasing the Digitrip Retrofit System. Digitrip Retrofit Kits are designed and manufactured in America with pride. All the components are engineered to fit the existing Circuit Breaker with little or no modifications to the existing Breaker. However due to the wide variety and vintage of Breakers in use today, an occasional problem may arise.
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