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AC-PRO Retrofit Kit
Retrofit Kit Instructions for
Westinghouse
DS206 THROUGH DS850
Low Voltage Breaker
Including Instructions for
AC-PRO with Modbus RTU Communications
Utility Relay Co.
Chagrin Falls, Ohio 44023
Phone: 888-289-2864
Fax: 440-708-1177
www.utilityrelay.com
I-ACM-DS
December, 2014
Rev. 10
Courtesy of NationalSwitchgear.com
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Summary of Contents for Utility Relay AC-PRO Retrofit Kit
- Page 1 AC-PRO Retrofit Kit Retrofit Kit Instructions for Westinghouse DS206 THROUGH DS850 Low Voltage Breaker Including Instructions for AC-PRO with Modbus RTU Communications Utility Relay Co. Chagrin Falls, Ohio 44023 Phone: 888-289-2864 Fax: 440-708-1177 www.utilityrelay.com I-ACM-DS December, 2014 Rev. 10 Courtesy of NationalSwitchgear.com...
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- Page 3 The customer is liable and shall pay for shipment of defective products back to Utility Relay Co., Ltd. no event shall Utility Relay Co., Ltd. be liable for any special, incidental or consequential damages. Excluded from this warranty and not warranted by Utility...
- Page 4 Completely read and understand all instructions before attempting the installation and testing of this retrofit kit. Personnel are available at Utility Relay Company during normal working hours (Eastern Standard time) to answer any questions. Turn off and lockout the power source(s) supplying the breaker prior to removing the breaker and attempting any work on the breaker.
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Page 5: Table Of Contents
TABLE OF CONTENTS Section PAGE General ..........1 1.1 Inspection ........1 Initial Breaker Tests .......2 Remove Existing Trip Unit ......2 AC-PRO Installation .........3 4.1 Amptector Configuration ......3 4.2 Digitrip & Later Configurations ....4 Program Button ........5 5.1 Install Program Button Harness ....5 5.2 Making/Changing Settings ......6 Install Quick Trip Display Coupler ....7 Current Transformers ........7... - Page 6 ILLUSTRATIONS Figure Front View, Breaker with Amptector ....17 Front View, Breaker with Digitrip .....18 Side View, Trip Unit Installation, Amptector...19 Side View, Trip Unit Installation, Digitip ....20 Top View, BR-020-1 Bracket Installation....21 CT Installation, With Terminals......22 New Actuator Installation......23 New Actuator Assembly........24 Side View, Neutral CT Installation, Amptector..25 10 Side View, Neutral CT Installation, Digitrip ..26 11 Neutral Interposing CT Terminal Block Installation..27...
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Page 7: General
AC-PRO Retrofit ............DS206 TO 850 Westinghouse DS206 TO DS850 SERIES 1.0 General All possible contingencies, which may arise during the installation, operation or maintenance, and all details and variations of this equipment, are not necessarily covered by these instructions. 1.1 Inspection Carefully inspect the retrofit kit on arrival. -
Page 8: Initial Breaker Tests
AC-PRO Retrofit ............DS206 TO 850 2.0 Initial Breaker Tests Before starting the retrofit, perform a visual/mechanical inspection and an electrical test of the breaker to determine its condition. Refer to the breaker manufacturer's instruction manual and accepted test standards such as the NETA Maintenance Specifications or PEARL reconditioning standards to verify that the breaker is in acceptable mechanical and electrical operating condition. -
Page 9: Ac-Pro Installation
AC-PRO Retrofit ............DS206 TO 850 4.0 AC-PRO Installation 4.1 Breakers with Amptector Trip Unit Refer to Figures 1, 3 & 5 for the following: Attach bracket BR-020-1 to the four (4) 1/4-20 threaded inserts in the top of the breaker platform using four (4) 1/4-20 X 3/4 HCS screws, flat washers, lock washers and four (4) HW-0402-2 spacers. -
Page 10: Digitrip & Later Configurations
AC-PRO Retrofit ............DS206 TO 850 4.2 Breakers with Digitrip Trip Unit Refer to Figures 2, 4 & 5 for the following: Loosely attach bracket BR-020-1 to the four (4) 1/4-20 threaded inserts in the top of the breaker platform using four (4) 1/4-20 X 3/4 HCS screws, flat washers, lock washers and four (4) HW-0402-2 spacers. -
Page 11: Program Button
AC-PRO Retrofit ............DS206 TO 850 5.0 Program Button An optional program button can be used to modify the trip unit settings instead of using the security key. 5.1 Install Program Button Harness Refer to Figures 1 and 3 for breakers with Amptector trip units or Figures 2 and 4 for breakers with Digitrip trip units for the following: Temporarily remove the 1/4-32 hex nut and internal tooth... -
Page 12: Making/Changing Settings
AC-PRO Retrofit ............DS206 TO 850 5.2 Making/Changing Settings The CA-2-403 program button harness can be used instead of the jumper wire used as the “KEY”. To make the initial settings or to change the settings, use the following procedures. Push and hold the “PROGRAM BUTTON”... -
Page 13: Install Quick Trip Display Coupler
AC-PRO Retrofit ............DS206 TO 850 6.0 Install Quick Trip Display Coupler Refer to Figures 1 and 3 for breakers with Amptector trip units or Figures 2 and 4 for breakers with Digitrip trip units for the following: Plug the CA-3-18 harness connector into the “QT DISPLAY” on the trip unit and the back of the CA-3-CM Quick Trip Display Coupler. -
Page 14: Replace Existing Actuator
AC-PRO Retrofit ............DS206 TO 850 8.0 Replace Existing Actuator Skip to Section 9.0 if the existing actuator will be reused. 8.1 Install Actuator/Mechanical Reset Assembly Actuator Assembly A-100B-DS has been pre-assembled. See Figures 7 & 8 for the following: Remove the breaker front cover. -
Page 15: Adjust Actuator/Mechanical Reset Assembly
AC-PRO Retrofit ............DS206 TO 850 8.2 Adjust Actuator/Mechanical Reset Assembly The breaker trip arm should be along side the actuator threaded rod. The rod should not interfere with the trip arm movement. The trip arm should move freely. It may be necessary to bend the trip arm. -
Page 16: Wiring
AC-PRO Retrofit ............DS206 TO 850 9.0 Wiring Use the wiring harness provided to make the connections to the CTs and the actuator. See Figure 12 or 13 for the wiring diagram. The wiring harness plugs into the top of the AC-PRO. Be sure to tighten the two plug retaining screws after the wiring is complete. -
Page 17: Current Transformer Connections
AC-PRO Retrofit ............DS206 TO 850 9.2 Current Transformer Connections Each set of CT wires in the wiring harness is housed inside an individual PVC tube for added physical protection and to simplify the wiring process. Connect to the #6-32 lugs on the CTs using the ring tongue terminals provided. -
Page 18: Actuator Connection
AC-PRO Retrofit ............DS206 TO 850 9.4 Actuator Connection 9.4.1 Actuator Connection, Existing Actuator The following applies to breakers where the existing Amtector actuator will be reused. The Digitrip actuator can not be actuated by the new trip unit and must be replaced with a new actuator. Verify that the actuator operates freely and resets properly. -
Page 19: Final Test
Perform a final electrical test of the breaker as in Section 2. In accordance with ANSI C37.50-1989, A.3.7, each retrofitted breaker must be tested. Utility Relay Company recommends the following tests at a minimum: Dielectric Primary injection pick-up and trip. -
Page 20: Communications
AC-PRO Retrofit ............DS206 TO 850 11.0 Communications The following instructions are for the communications option using the AC-PRO with Modbus RTU communications: 11.1 Install PT Module The PT Module mounts behind the Trip Unit as shown in Figure 14 &... -
Page 21: Communications Wiring
AC-PRO Retrofit ............DS206 TO 850 11.3 Communications Wiring Refer to Figure 18 for the following: Voltage Input Determine the line side of the breaker. Use T-412-1 ring terminals and #14 AWG SIS wire from the 3/8-16 H.C screws (shown in Figure 6) to the 3-pole fuse block. -
Page 22: Qt-Switch-Enclosure Installation
AC-PRO Retrofit ............DS206 TO 850 12.0 QT-SWITCH-ENCLOSURE Installation The QT-SWITCH-ENCLOSURE should be installed on the front of the breaker cubicle door near the QUICK-TRIP Display. Refer to Figures 19 and 20 for the following: Using the template from Figure 19, mark the location of the five (5) holes. - Page 23 Courtesy of NationalSwitchgear.com...
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