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Digitrip Retrofit System forFederal Pacific FPS-75(3000A) Breakers

SAFETY PRECAUTIONS

WARNING

POWER CIRCUIT BREAKERS ARE EQUIPPEDWITH HIGH SPEED, HIGH ENERGY OPERATINGMECHANISMS. THE BREAKERS AND THEIRENCLOSURES ARE DESIGNED WITH SEVERALBUILT-IN INTERLOCKS AND SAFETYFEATURES INTENDED TO PROVIDE SAFE ANDPROPER OPERATING SEQUENCES. TO PROVIDEMAXIMUM PROTECTION FOR PERSONNELASSOCIATED WITH THE INSTALLATION,OPERATION, AND MAINTENANCE OF THESEBREAKERS, THE FOLLOWING PRACTICESMUST BE FOLLOWED. FAILURE TO FOLLOWTHESE PRACTICES MAY RESULT IN DEATH,PERSONAL INJURY, OR PROPERTY DAMAGE.

• Only qualified persons, as defined in the NationalElectric Code, who are familiar with the installationand maintenance of power circuit breakers and theirassociated switchgear assemblies should performany work associated with these breakers.

• Completely read and understand all instructionsbefore attempting any installation, operation,maintenance, or modification of these breakers.

• Always turn off and lock out the power sourcefeeding the breaker prior to attempting anyinstallation, maintenance, or modification of thebreaker. Do not use the circuit breaker as thesole means for isolating a high voltage circuit.Follow all lockout and tagging rules of theNational Electric Code and all other applicablecodes, regulations, and work rules.

• Do not work on a closed breaker or a breaker withthe closing springs charged. Trip (open) the breakerand be sure the stored energy springs aredischarged before performing any work. The breakermay trip open or the charging springs may discharge,causing crushing or cutting injuries.

• For drawout breakers, trip (open), and then removethe breaker to a well-lit work area before beginningwork.

• Do not perform any maintenance: including breakercharging, closing, tripping, or any other functionwhich could cause significant movement of thebreaker while it is on the extension rails. Doing somay cause the breaker to slip from the rails and fall,potentially causing severe personal injury to thosein the vicinity.

• Do not leave the breaker in an intermediateposition in the switchgear cell. Always leave it inthe connected, disconnected, or (optional) testposition. Failure to do so could lead to improperpositioning of the breaker and flashover,causing death, serious personal injury, and / orproperty damage.

• Do not defeat any safety interlock. Suchinterlocks are intended to protect personnel andequipment from damage due to flashover andexposed contacts. Defeating an interlock couldlead to death, severe personal injury, and / orproperty damage.

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IL 33-863-4APage 2

INTRODUCTION

Cutler-Hammer Digitrip Retrofit Kits are available ina number of configurations that provide a widerange of features. The Digitrip System starts withthe 510 Basic Kit which offers true RMS sensing,overcurrent protection, and self-testing features.Advanced Digitrip Retrofit Kits feature zoneinterlocking, digital alphanumeric displays, remotealarm signals, PowerNet communications, energymonitoring capabilities, power factors, andharmonic content measurements.

Table 1 provides a quick reference of thecomponents supplied with each level of Retrofit Kit.Before beginning the Retrofit process, take a minuteto review the information contained in Table 1. It isimportant that the Retrofitter understands which

level of Retrofit Kit is to be installed and whichcomponents are included with the Kit.

The instructions contained in this manual cover theinstallation of all levels of Retrofit Kit. If the Kit youare installing does not contain a certain component,skip the instructions for that component andproceed to the next.

Throughout the Retrofit process, refer to the TorqueTables at the back of this manual for specifictorque values.

If you have any questions concerning the RetrofitKit and / or the Retrofit process, contactCutler-Hammer at: 1-800-937-5487.

510 withComponents 510 Basic Zone 610 810 910

Interlock

Trip Unit

Rating Plug

Auxiliary CurrentTransformer(CT) Module

AuxiliaryCT Harness

Sensors

Sensor Harness

Direct TripActuator (DTA)

Mounting Bracketsand Hardware

External Plug 1 Connector 2 Connector 4 Connector 4 ConnectorHarness Harness Harness Harness Harness

Cell Harness

Potential Transformer(PT) Module

Auxiliary Switch

Table 1 Available Retrofit Kits

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IL 33-863-4APage 10

STEP 16: TESTING THE BREAKER

A. Measure the force necessary to trip theBreaker at the point where the Trip AdjustingScrew Finger impacts the Breaker Trip Plate.The force necessary to trip the Breaker MUSTNOT EXCEED THREE (3) lbs.

B. The Retrofit must be tested using primaryinjection. Refer to Section 8 of the Instructionsfor the Application of Digitrip RMS Retrofit Kitson Power Circuit Breakers (PublicationAD 33-855-2), supplied with the Retrofit Kit, fordetailed testing procedures and specifica-tions. For test information specific to the TripUnit, refer to the IL publication supplied withthe Retrofit Kit (see the Pick List for the ILnumber).

C. While Section 8 of the Instructions for theApplication of Digitrip RMS Retrofit Kits onPower Circuit Breakers provides the informa-tion necessary for testing the Breaker, pleasekeep the following notes in mind when review-ing other sections of the publication.

the wiring and examine each connection toassure its integrity.

Confirm that the PowerNet communicationwiring is correct by following the proceduresdetailed in Section 7.4 of the Instructions forthe Application of Digitrip RMS Retrofit Kits onPower Circuit Breakers. Note that for 810 and910 Kits, the impedance between COM 1 andCOM 2 should be between one (1) and three(3) ohms.

When testing is complete, disconnect theExternal Harness from the Cell Harness. FinalExternal Harness connection will be performedlater in the Retrofit Process.

WHEN ALL TESTING IS COMPLETE, THE TRIPUNIT MUST BE RESET. FAILURE TO DO SOMAY CAUSE THE BATTERY IN THE RATINGPLUG TO RUN DOWN.

NOTES:

1. For All Kits Other Than 510 Basic. If testingthe Breaker with Short Delay or Ground Faultfunctions, be sure to either plug in the CellHarness Assembly or use the Zone InterlockShorting Plug. Failure to do so may result inshorter than expected trip times.

2. For 810 and 910 Kits Only. Without any powerapplied to the system (neither the 120 voltpower supply nor the Aux. Power Moduleconnected), plug the External Harness into theCell Harness and check the impedance be-tween COM 1 and COM 2. The impedanceshould be between one (1) and three (3) ohms.If the impedance is not within this range, trace

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IL 33-863-4APage 14

Decimal Standard Torque TorqueSize (in) Size (in-lbs) (ft-lbs)

.112 4-40 10 0.8

.138 6-32 18 1.5

.164 8-32 36 3.0

.190 10-32 46 3.8

.250 1/4-20 100 8.3

.312 5/16-18 206 17.2

.375 3/8-16 356 29.7

.438 7/16-14 572 47.7

.500 1/2-13 856 71.3

Decimal Standard Torque TorqueSize (in) Size (in-lbs) (ft-lbs)

.250 1/4-20 60 5

.312 5/16-18 144 12

.375 3/8-16 240 20

.500 1/2-13 600 50

Table 1 Torque Values for General Mounting and Screw Size Conversion

Table 2 Torque Values for Copper BUS Connectors

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Page 15IL 33-863-4A

Notes

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Pittsburgh, Pennsylvania U.S.A.

Publication No. I.B. 33-863-4AFebruary 2001Printed in U.S.A./TBG00035

Cutler-Hammer

We wish to thank you for purchasing the Digitrip Retrofit System. Digitrip Retrofit Kits are designed and manufactured inAmerica with pride. All the components are engineered to fit the existing Circuit Breaker with little or no modifications to theexisting Breaker. However due to the wide variety and vintage of Breakers in use today, an occasional problem may arise.Please contact us with any questions, comments or concerns.

Phone: 1-800-937-5487 Fax. (724) 779-5899

The instructions for installation, testing, maintenance, or repair herein are provided for the use of theproduct in general commercial applications and may not be appropriate for use in nuclear applications. Additionalinstructions may be available upon specific request to replace, amend, or supplement these instructions to qualifythem for use with the product in safety-related applications in a nuclear facility.

The information, recommendations, descriptions, and safety notations in this document are based onCutler-Hammer’s experience and judgement with respect to Retrofitting of Power Breakers. This information shouldnot be considered to be all inclusive or covering all contingencies. If further information is required, Cutler-Hammershould be consulted.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULARPURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGEOF TRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONSCONTAINED HEREIN. In no event will Cutler-Hammer be responsible to the user in contract, in tort (includingnegligence), strict liability or otherwise, for any special, indirect, incidental, or consequential damage or losswhatsoever, including but not limited to damage to or loss of use of equipment, plant or power system, cost of capital,loss of profits or revenues, cost of replacement power, additional expenses in the use of existing power facilities, orclaims against the user by its customers resulting from the use of the information, recommendations, anddescriptions contained herein.

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