Download Print this page

Advertisement

Quick Links

Digitrip Retrofit System for the General Electric AK-50 Series Breakers:
AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50;
SAFETY PRECAUTIONS
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 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 installa-
tion and maintenance of power circuit breakers
and their associated switchgear assemblies
should perform any work associated with these
breakers.
Effective October, 2000
AK-3-50; AK-3A-50; and AKT-3A-50
WARNING
• 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-G2C-2

Advertisement

loading
Need help?

Need help?

Do you have a question about the Digitrip 510 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Summary of Contents for Cutler-Hammer Digitrip 510

  • Page 1 IL 33-G2C-2 Digitrip Retrofit System for the General Electric AK-50 Series Breakers: AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50; AK-3-50; AK-3A-50; and AKT-3A-50 • Completely read and understand all instructions before attempting any installation, operation, maintenance, or modification of these breakers. •...
  • Page 2 IL 33-G2C-2 Page 2 Cutler-Hammer Digitrip Retrofit Kits are available in which level of Retrofit Kit is to be installed and a number of configurations that provide a wide which components are included with the Kit. range of features. The Digitrip System starts with...
  • Page 3 Breaker, do not attempt the Retrofit. G. E. AK-50 Series Breaker(s) is to be Retrofitted Contact your purchasing agent and have the and to insure that the correct Cutler-Hammer correct Retrofit Kit ordered for the Breaker. Retrofit Kit(s) was ordered. Each Breaker must be...
  • Page 4 IL 33-G2C-2 Page 4 A. Trip the Breaker and remove it from the Cell. Step 1: General Breaker Preparation Move the Breaker to a clean, well-lit work bench. Before attempting to remove the Breaker from the Cell or perform any Retrofit Operation, be sure NOTE: It is the responsibility of the Retrofitter to read and understand the Safety Precautions to insure that the Breaker and all original com-...
  • Page 5 IL 33-G2C-2 Page 5 Step 2: Removing the Original A. Carefully lay the Breaker over on its right side to Electromechanical Trip Units provide access to the bottom of the Breaker. For All G. E. AK-50 Series Breakers Except B. Disconnect and scrap all wires connecting AK-3/3A-50, AKU-3/3A-50, and Breakers the original Electronic Trip Units, Direct Trip Equipped with a Quick Close Mechanism.
  • Page 6 IL 33-G2C-2 Page 6 Before proceeding, identify the section(s) within Step 3: Installing the Copper Adapters the Step that apply to the Breaker being Retrofitted. Step 4: Installing the Sensors A. Align the holes in the Copper Adapters with the holes that were used to mount the original Electromechanical Trip Units.
  • Page 7 IL 33-G2C- 2 Page 7 For Top Mounted Sensors Only. F. Connection of the Sensor Wires to the 3-Point Terminal blocks is detailed in the photo. Once the correct connection point has been determined, cut each Sensor Wire to an appropriate length and attach a supplied ring A.
  • Page 8 IL 33-G2C-2 Page 8 For Bottom Mounted Sensors Only. F. Insert the three (3) wires exiting the top of the Sensor through the opening in the Sensor Mounting Bracket. G. With the Sensor Nameplate at the bottom and facing out, align the threaded holes in the top of the Sensor with the holes in the Sensor Mounting Bracket.
  • Page 9 IL 33-G2C- 2 Page 9 J. Align the Sensor Mounting Bracket with the C. Align the threaded holes in the Sensor existing holes on the bottom rear of the Breaker Adapter Brackets with the holes in the Sensor Back Plate as shown. Secure using the (2) Mounting Bracket.
  • Page 10 IL 33-G2C-2 Page 10 Step 5: Installing the Aux. CT Module Note: Cover the region below the area to be drilled to prevent chips from falling into the Breaker. Drilling Plan “A” 0.75" 0.75" 0.219 Dia. (4) 1.50" Rear of Breaker 1.38"...
  • Page 11 IL 33-G2C- 2 Page 11 Before proceeding, identify the section(s) within the Step that apply to the Breaker being Retrofitted. C. Install the supplied grommet in the hole near Step 6: Installing the Sensor Harness and DTA the bottom right corner of the Breaker Back Extension Harness Plate.
  • Page 12 IL 33-G2C-2 Page 12 For Kits Supplied with a PT Module Only. Refer to Section 7-3, Power Flow Convention, of the Retrofit Application Data, supplied with the Retrofit Kit, for additional wiring information and to Connect the ring terminals of the Sensor verify the Phase Convention used on this Breaker Harness to the Sensor Terminals.
  • Page 13 IL 33-G2C- 2 Page 13 For Kits Supplied with a PT Module Only. Step 7: Installing the DTA Assembly Refer to Section 7-3, Power Flow Convention, of the Retrofit Application Data, supplied with the Retrofit Kit, for additional wiring information and to verify the Phase Convention used on this Breaker Application.
  • Page 14 IL 33-G2C-2 Page 14 B. Position the DTA Assembly near the front of the E. With the Breaker in the OPEN position and with Breaker. Route the DTA Extension Harness the Breaker Closing Springs DISCHARGED, from the Aux. CT Module under the front of the slide the Trip Finger (attached to the Breaker Breaker to the 2-Point Terminal Block mounted Trip Bar in Step 7-A) over so that it is located...
  • Page 15 IL 33-G2C- 2 Page 15 L. With Breaker in the OPEN position, remove the original .375-16 × 1.50" hex bolt from the left WARNING hand side of the Breaker Cross Bar. Mount the Guard against the Breaker unintentionally DTA Reset Arm to the Cross Bar with the bolt OPENING during the following steps.
  • Page 16 IL 33-G2C-2 Page 16 Before proceeding, identify the section(s) within B. Align the Glass Ploy Insulation with the holes in the Step that apply to the Breaker being the CPT Mounting Bracket as shown. Secure Retrofitted. the CPT to the mounting bracket using the (2) .190-32 ×...
  • Page 17 IL 33-G2C- 2 Page 17 C. Using Drilling Plan “B”, drill two (2) .312" holes C. Using Drilling Plan “C”, drill two (2) .312" holes in the bottom of the right front Breaker Bottom in the left side of the Top Breaker Channel. Channel as shown.
  • Page 18 IL 33-G2C-2 Page 18 Before proceeding, identify the section(s) within Framed the Step that apply to the Breaker being Retrofitted. Step 9: Installing the Trip Unit Frameless A. Using Drilling Plan “E”, mark and drill two (2) .312" diameter holes in the right side of the middle Breaker Channel.
  • Page 19 IL 33-G2C- 2 Page 19 Mount the Auxiliary Switch Assembly to the bottom of the right-hand Trip Unit Mounting Bracket Assembly, using the (1) .138-32 × .375" screw, (2) flat washers, (1) lock washer, and (1) B. Mount the left-hand (the larger Bracket with nut supplied.
  • Page 20 IL 33-G2C-2 Page 20 Scrap the Warning Label Plate and “L” Bracket. F. Align the holes in the “L” shaped Trip Unit Rotate the connector 90° then reconnect it to Mounting Bracket with the holes drilled in the the PT Module, as shown, using the original Breaker Channel in the applicable Step 8-A.
  • Page 21 IL 33-G2C- 2 Page 21 For Kits Supplied with a PT Module Only. NOTE: The power convention of the AK-50 Install the supplied PT Module Warning Label Series Breakers is normally Top to Bottom, to the top right of the Breaker in front of the meaning the Top Breaker Stabs are on the PT Module.
  • Page 22 IL 33-G2C-2 Page 22 E. For Kits Supplied with a Breaker Mounted Before proceeding, identify the section(s) within CPT Only. Remove the External Harness plug the Step that apply to the Breaker being installed in the bottom rear socket on the right Retrofitted.
  • Page 23 IL 33-G2C- 2 Page 23 Route the PT Wires to a position suitable for attachment to the proper Copper Adapters. Move the PT Wire markers to a position where they will still be attached to the wires after D. Secure the External Harness to the Trip Unit “L” cutting.
  • Page 24 IL 33-G2C-2 Page 24 Step 12: Testing the Breaker A. Measure the force necessary to trip the Breaker at the point where the DTA flange nut contacts E. For Kits Supplied with a PT Module Only. the Trip Finger. The force necessary to trip the Connect the plug from the PT Module to the Breaker MUST NOT EXCEED 3 lbs.
  • Page 25 IL 33-G2C- 2 Page 25 3. For 810 and 910 Kits Only. Step 14: Installing the Retrofitted Breaker in Without any power applied to the system the Cell (neither the 120 volt power supply nor the Aux. Power Module connected), plug the WARNING External Harness into the Cell Harness and check the impedance between COM 1 and...
  • Page 26 IL 33-G2C-2 Page 26 Digitrip Retrofit Kit Installation Components for the Geneal Electric AK-50 Series Breakers: AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50; AK-3-50; AK-3A-50; and AKT-3A-50 Step Description Style No. Qty. Comment Step 3 Connector Parts 8258A95G04 Copper Connector .375-16 × 1.50 Lng. Bolt Hex .375 Flat Washer Stl.
  • Page 27 IL 33-G2C- 2 Page 27 Digitrip Retrofit Kit Installation Components for the Geneal Electric AK-50 Series Breakers: AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50; AK-3-50; AK-3A-50; and AKT-3A-50 (Continued) Step Description Style No. Qty. Comment Step 4 Sensor Mounting Parts 8258A95G12 (cont.) Mounting Bracket R.
  • Page 28 IL 33-G2C-2 Page 28 Digitrip Retrofit Kit Installation Components for the Geneal Electric AK-50 Series Breakers: AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50; AK-3-50; AK-3A-50; and AKT-3A-50 (Continued) Step Description Style No. Qty. Comment Step 8 CPT Mounting Parts (continued) 8258A95G20 (cont.) .190 Flat Washer Nylon .190 Lock Washer Stl.
  • Page 29 IL 33-G2C-2 Page 29 Digitrip Retrofit Kit Installation Components for the Geneal Electric AK-50 Series Breakers: AK-1-50 (Frameless); AK-2-50; AK-2A-50; AKT-2A-50; AKU-2A-50; AK-3-50; AK-3A-50; and AKT-3A-50 (Continued) Step Description Style No. Qty. Comment Step 9 Trip Unit “L” Bracket Mounting Parts 8258A11G01 (cont.) Trip Unit “L”...
  • Page 30 IL 33-G2C-2 Page 30 Torque Values for General Mounting 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 .500 1/2-13 71.3 Torque Values for Copper BUS Connectors Decimal Standard...
  • Page 31 IL 33-G2C- 2 Page 31 A. Sensors H. Aux. Switch B. Trip Unit Aux. CT Harness C. Aux. CT Module J. Sensor Harness D. Direct Trip Actuator (DTA) K. PT Module E. CPT Kit (Optional) L. External Harness F. Rating Plug M.
  • Page 32 The information, recommendations, descriptions, and safety notations in this document are based on Cutler-Hammer’s experience and judgement with respect to retrofitting of power breakers. This information should not be considered to be all inclusive or covering all contingencies. If further information is required, Cutler-Hammer should be consulted.

This manual is also suitable for:

Digitrip 610Digitrip 810Digitrip 910