federal pioneer 25 h-2 & h-l and 50 / 65 h-2 & h-l ...il 33-fhc-3 page 2 effective 4/02 •...

IL 33-FHC-3

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Digitrip Retrofit System forFederal Pioneer 25 H-2 & H-Land 50 / 65 H-2 & H-L 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 SAFETY FEATURESINTENDED TO PROVIDE SAFE AND PROPEROPERATING SEQUENCES. TO PROVIDEMAXIMUM PROTECTION FOR PERSONNELASSOCIATED WITH THE INSTALLATION,OPERATION, AND MAINTENANCE OF THESEBREAKERS, THE FOLLOWING PRACTICES MUSTBE FOLLOWED. FAILURE TO FOLLOW THESEPRACTICES MAY RESULT IN DEATH, PERSONALINJURY, 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.

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• 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 those inthe 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, causingdeath, serious personal injury, and / or propertydamage.

• 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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Description

Introduction .......................................................... 5Step 1: General Breaker Preparation ............ 6Step 2: Removing the Original Components

and Preparing the Breaker forRetrofitting ............................................ 7

Step 3: Installing the Sensors and SensorHarness (Partial) .................................... 8

Step 4: Preparing the Aux. CT Assembly ....... 11Step 5: Installing the Breaker

Mounted CPT ...................................... 13Step 6: Installing the Trip Finger..................... 19Step 7: Installing the DTA ................................ 21Step 8: Installing the Aux. CT Module

Assembly and the Trip Unit ................ 24Step 9: Installing the External Harness

and Final Wiring .................................. 27Step 10: Testing the Breaker ............................. 29Step 11: Mounting the Cell Harness................. 30Step 12: Installing the Retrofitted Breaker

in the Cell ............................................. 30

Figures

1. Overview: Original Components Removedfrom the Breaker and Saved forReinstallation. ................................................ 7

2. Hood Assembly, Arc Chutes, Flash Barrier,Interphase Barriers, and Side Barriers Re-moved from the Breaker. ............................... 7

3. Charging Handle, Face Plate, and FloatingTrim Removed from the Breaker. .................... 8

4. Overview: Sensors Installed in the Breaker. 8

CONTENTS

5. Finger Clusters Removed from the BottomLoad Terminals (Electrically Operated). ......... 8

6. Lower Molding and Load TerminalsRemoved from the Breaker. ........................... 9

7. Sensor and Spacers Installed on a Jumper. .. 9 8. Sensors, Load Terminals, and Lower

Molding Installed on the Breaker. ................ 10 9. Finger Clusters Reinstalled on the Load

Terminals (Electrically Operated). ................ 10

10. Sensor Harness Connected to theSensors. ...................................................... 10

11. Routing of the Sensor Harness. ................... 11

12. Overview: Aux. CT Assembly and PTModule Ready for Installation. ..................... 11

13. Glass Poly Barrier Mounted to theAux. CT Module. .......................................... 11

14. PT Module Mounted to the Aux. CTModule Assembly. ....................................... 12

15. Aux. CT Module Assembly Placedon the Breaker Frame. ................................. 12

16. PT Wires Connected to the Jumper Bolts. .. 12

17. PT Wires Secured to the Sensor Harness. .. 1318. Overview: Breaker Mounted CPT

Installed in the Breaker. ............................... 13

19. Fuse Clips and Spade ConnectorRemoved from the CPT ............................... 13

20. CPT Module Installed on the MountingBracket. ....................................................... 14

21. Drilling Plan “A”. .......................................... 1422. Drilling Plan “B” ........................................... 14

23. Load and Line Sides of the HV Wires. ....... 1424. HV and CPT Wires Connected to the CPT

Module. ....................................................... 15

Digitrip Retrofit System forFederal Pioneer 25 H-2 & H-L50 / 65 H-2 & H-L Breakers

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25. Finger-Safe Covers Installed on the CPTModule. ....................................................... 16

26. Microswitch Mounted to the AuxiliarySwitch Mounting Bracket. .......................... 16

27. CPT Assembly Installed in the Breaker. .... 1628. Auxiliary Switch and CPT Assemblies

Installed in the Breaker. .............................. 16

29. Correct Engagement of the AuxiliarySwitch Arm. ................................................ 17

30. Correct Orientation of the HV WireRing Terminals. ........................................... 17

31. HV Wires Connected to Side SecuredFinger Clusters. .......................................... 18

32. HV Wires Connected to Top SecuredFinger Clusters. .......................................... 18

33. HV Fuses and Wires Secured Away fromMoving Breaker........................................... 18

34. CPT Voltage Labels supplied with theCPT Kit. ....................................................... 19

35. Overview: Trip Finger Installed in theBreaker - Long Trip Shaft. .......................... 19

36. Short Trip Shaft. .......................................... 1937. Trip Finger to be used with a Long Trip

Shaft (Style Number 9A10093G05). ........... 20

38. Trip Finger to be used with a Short TripShaft (Style Number 9A10093G06). ........... 20

39. Original Trip Finger Removed from anElectrically Operated Breaker with ShortTrip Shaft. .................................................... 20

40. Trip Finger Installed on a Long Trip Shaft. . 2041. Trip Finger Installed on a Short Trip Shaft. 2042. Overview: DTA Installed in the Breaker. .... 21

43. Drilling Plan “C”........................................... 2144. Drilling Plan “D” .......................................... 2145. Hardware to Remove from the

DTA Trip Shaft. ........................................... 2146. DTA Mounted to the Bottom Front

Breaker Channel. ........................................ 22

47. Slow Close Handle Engaged in theClosing Link. ............................................... 22

48. Reset “L” Bracket Installed on theDTA Shaft. ................................................... 22

49. Proper Cage Height Adjustment. .............. 2350. Proper Air Gap Adjustment. ....................... 23

51. Routing and Securing of the Originaland New Wiring........................................... 23

52. Overview: Aux. CT Assembly and TripUnit Installed on the Breaker. ..................... 24

53. Original Components Reinstalled on theBreaker. ....................................................... 24

54. Drilling Plan “E”. .......................................... 24

55. Aux. CT Module Mounting BracketsInstalled on the Breaker. ............................. 25

56. Aux. CT Module Assembly Installedon the Breaker and Preliminary Routingof the Sensor Harness, DTA Wires, andCPT Wires. .................................................. 25

57. DTA Wires Connected to the Aux. CTModule Terminal Block. .............................. 25

58. Sensor Harness Connected to the Aux.CT Module Terminal Block. ........................ 26

59. Support Clips and Sensor Harness GroundWire Connected to the Aux. CT Module. ... 26

60. Rating Plug and Aux. CT HarnessInstalled. ...................................................... 26

61. Overview: External Harness Installedon the Breaker. ........................................... 27

62. 510 Basic Kit External Harness ShortingPlug. ............................................................ 27

63. External Harness Wires Connected tothe Auxiliary Switch. ................................... 28

64. External Harness Connections at theTrip Unit. ...................................................... 28

65. External Harness Secured to the Side ofthe Breaker. ................................................. 28

66. Retrofit Components .................................. 35

Tables

1. Available Retrofit Kits ................................... 5

2. Sensor Taps Rating .................................... 10 3. CPT High Voltage Taps for Standard

and Special Order CPTs .............................. 15

4. CPT Low Voltage Taps for Standardand Special Order CPTs .............................. 15

5. Torque Values for General Mountingand Screw Size Conversion ........................ 34

6. Torque Values for Copper BUSConnectors .................................................. 34

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INTRODUCTION

Cutler-Hammer Digitrip Retrofit Kits are available ina number of configurations that provide a wide rangeof features. The Digitrip System starts with the 510Basic Kit which offers true RMS sensing, overcurrentprotection, and self-testing features. AdvancedDigitrip Retrofit Kits feature zone interlocking, digitalalphanumeric displays, remote alarm signals,PowerNet communications, energy monitoringcapabilities, power factors, and harmonic contentmeasurements.

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 and proceedto 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 Retrofit Kitand / 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

Breaker MountedControl PowerTransformer (CPT)

Potential Transformer(PT) Module

Auxiliary Switch

Table 1 Available Retrofit Kits

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STEP 1: GENERAL BREAKER PREPARATION

Before attempting to remove the Breaker from theCell or perform any Retrofit Operation, be sure toread and understand the Safety Precautionssection of this manual. In addition, be sure to readand understand the Instructions for the Applicationof Digitrip RMS Retrofit Kits on Power CircuitBreakers (Retrofit Application Data - Publication AD33-855-3), supplied with the Digitrip Retrofit Kit.

DO NOT ATTEMPT TO INSTALL OR PER-FORM MAINTENANCE ON EQUIPMENTWHILE IT IS ENERGIZED. SEVERE PER-SONAL INJURY OR DEATH CAN RESULTFROM CONTACT WITH ENERGIZED EQUIP-MENT. VERIFY THAT NO VOLTAGE ISPRESENT BEFORE PROCEEDING.

A. Trip the Breaker and remove it from the Cell.Move the Breaker to a clean, well-lit work area.

NOTE: It is the responsibility of the Retrofitter toinsure that the Breaker and all originalcomponents are in good condition. Visu-ally inspect all Breaker components forsigns of damage or wear. If any signs ofdamage or wear are detected for compo-nents not included in the Retrofit Kit,secure the necessary replacement partsbefore beginning the Retrofit Process.

The force necessary to trip the Breakershould not exceed three (3) lbs.

NOTE: It is the responsibility of the Retrofitter toinsure that the proper, manufacturer’srecommended crimping tools and termi-nals are used for each type of connector.It is also the responsibility of the Retrofitterto insure that all wire preparations, con-nections, strippings, terminations, andwiring techniques are performed accordingto the latest IEEE, NEC, and / or NEMAindustry standards, specifications, codes,and guidelines.

To begin the Retrofit Process, refer to the compo-nents list at the end of this manual. Layout thecomponents and hardware according to the stepsoutlined. The parts bags are labeled with thecorresponding step number. The components andhardware will be used to complete each step in theRetrofit Process.

WARNING

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STEP 2: REMOVING THE ORIGINAL COMPO-NENTS AND PREPARING THEBREAKER FOR RETROFITTING

Fig. 1 Overview: Original Components Removedfrom the Breaker and Saved forReinstallation.

NOTE: Throughout this Retrofit, an electricallyoperated Breaker was used for the supportphotographs. Where the components and/ or procedures differ between the electri-cally and mechanically operated Breakers,photos of both are supplied for clarity.

NOTE: The Breakers Retrofitted in the creation ofthis IL had 21" wide Frames. If theBreaker being Retrofitted is either narroweror wider, exact locations for drilling anymounting holes must be confirmed beforedrilling. The locations may not match theDrilling Plans contained in this IL.

HOODASSEMBLYARC

CHUTESFLASHBARRIER

ARCCHUTEHOLDERS

MOUNTINGKNOBS

INTERPHASEBARRIERS

SIDE BARRIERS

Refer to the Federal Pioneer 25 H-2 & H-L or 50 /65 H-2 & H-L Instruction Manual, originally sup-plied with the Breaker, to perform the followingprocedures.

A. Remove and discard the original Trip Unit andall associated wiring and mounting hardware.

B. Remove and save the Hood Assembly.

C. Remove the Mounting Knobs and Arc ChuteHolders securing the Arc Chutes to the Breaker.Remove and save the Arc Chutes, the Holders,and the Mounting Knobs.

D. Remove and save the two (2) Side Barriers.

E. Remove the mounting hardware securing theFlash Barrier to the Breaker. Remove and savethe Flash Barrier and the mounting hardware.

F. Remove and save the Phase 1 & 2 and Phase 2& 3 Interphase Barriers.

Fig. 2 Hood Assembly, Arc Chutes, Flash Bar-rier, Interphase Barriers, and Side BarriersRemoved from the Breaker.

NOTE: Removing the Charging Handle, BreakerFace Plate, and the Floating Trim detailedin Steps “G” and “H” below, are notmandatory for the Retrofit. However,removing these components will provideadditional access to the internal Breakermechanisms during the Retrofit.

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STEP 3: INSTALLING THE SENSORS ANDSENSOR HARNESS (PARTIAL)

Fig. 4 Overview: Sensors Installed in theBreaker.

Refer to the Federal Pioneer 25 H-2 & H-L or 50 /65 H-2 & H-L Instruction Manual, originally sup-plied with the Breaker, to perform the followingprocedures.

A. Remove the hardware securing the FingerClusters (Drawout Contacts) to the bottomLoad Terminals. Remove and save the FingerClusters and mounting hardware.

B. Raise the rear of the Breaker approximately four(4) inches to provide clearance for the follow-ing steps.

Fig. 5 Finger Clusters Removed from the Bot-tom Load Terminals (Electrically Oper-ated).

G. Remove and save the Charging Handle.

H. Remove the hardware securing the BreakerFace Plate to the Breaker. Remove and savethe Face Plate, Floating Trim, and mountinghardware.

Fig. 3 Charging Handle, Face Plate, and FloatingTrim Removed from the Breaker.

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C. Loosen the six (6) bolts and nuts securing therear Lower Molding and Load Terminals to theJumpers.

D Remove and save the mounting hardwaresecuring the Lower Molding to the right and leftsides of the Breaker.

E. While “spreading” the sides of the Breaker,remove the Lower Molding and Load Terminalsfrom the Breaker. Note that as you are remov-ing the Lower Molding, the Load Terminals willfall free.

F. Remove the original Sensors from the Jump-ers. Scrap the original Sensors and all associ-ated wiring.

Fig. 6 Lower Molding and Load TerminalsRemoved from the Breaker.

G. Install a new Sensor and two (2) spacers, asshown, on each Jumper. Note that the Sen-sors must be installed with the terminalstowards the inside of the Breaker. The combi-nation of the Sensors and spacers create a“friction fit” to hold the Sensors in place.

Fig. 7 Sensor and Spacers Installed on aJumper.

H. To reinstall the Lower Molding, align the LoadTerminals with the holes in the Lower Molding.Insert the bolts into the Lower Molding andLoad Terminals and thread two (2) to three (3)turns to keep the Load Terminals in place.

Insert the right side of the Lower Molding intoposition with the right side of the Breaker(when viewed from the rear). While “spread-ing” the left side of the Breaker, push the leftside of the Lower Molding into place.

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I. Using the original mounting hardware re-moved in Step 3-D, secure the Lower Moldingto the Breaker.

J. Tighten the six (6) original bolts and nuts untilthe Load Terminals are securely mated to theJumpers.

For Kits Supplied with a PT Module Only:Leave one (1) nut loose on each Load Terminal.These will be used later in the Retrofit Processto secure the PT Wires.

Fig. 8 Sensors, Load Terminals, and LowerMolding Installed on the Breaker.

K. Using the original mounting hardware, reinstallthe bottom Finger Clusters on the LoadTerminals in their original positions.

L. Remove what was used to elevate the back ofthe Breaker and return the Breaker to its restposition.

M. Working from the front of the Breaker, connectthe ring terminals of the Sensor Harness to theSensor Terminals. Refer to Section 12 of theApplication Data, supplied with the Retrofit Kit,for detailed wiring specifications.

For FP 25 H-2 & H-L and 50 / 65 H-2 & H-LRetrofits, the following conventions apply.

Table 2 Sensor Taps RatingFP 25 H-2 & H-L

Sensor Style No. Terminal Com. Amps

8188A79H01 X1-X2 = 400 A

X1-X3 = 800 A

8188A81H01 X1-X2 = 300 A

X1-X3 = 600 A

8184A45H01 X1-X2 = 200 A

FP 50 / 65 H-2 & H-L

Sensor Style No. Terminal Com. Amps

9A10020H01 X1 - X2 = 800 AX1 - X3 = 1,600 A

9A10021H01 X1 - X2 = 1,200 AX1 - X3 = 2,000 A

Fig. 9 Finger Clusters Reinstalled on the LoadTerminals (Electrically Operated).

Fig. 10 Sensor Harness Connected to theSensors.

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Fig. 11 Routing of the Sensor Harness.

STEP 4: PREPARING THE AUX. CT ASSEMBLY

Fig. 12 Overview: Aux. CT Assembly and PTModule Ready for Installation.

A. Align the Glass Poly Barrier with the existingholes in the back of the Aux. CT Module asshown. Secure the Barrier to the Aux. CTModule using the using the (2) .190-32 × .375"screws, (2) lock washers, and (2) flat washerssupplied.

Fig. 13 Glass Poly Barrier Mounted to the Aux.CT Module.

For Kits Supplied with a PT Module Only.

B. Align the PT Module with the existing holes inthe Glass Poly Barrier as shown. Secure the PTModule to the Glass Poly Barrier using the (2).138-32 × .500" screws, (4) flat washers, (2)lock washers, and (2) nuts supplied.

N. Route the Sensor Harness along the back ofthe Breaker towards the left side. Use theself-adhesive mounting pads and wire tiessupplied to secure the Sensor Harness awayfrom any moving parts within the Breaker.

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Fig. 14 PT Module Mounted to the Aux. CTModule Assembly.

NOTE: To ease installation, the PT Wires will beconnected to the Jumpers in the followingsteps. To accomplish this, the Aux. CTModule Assembly must be set on the topof the Breaker Frame. Until the Aux. CTModule Assembly is mounted later in theRetrofit Process, care must be taken toinsure that the Aux. CT Module Assemblyis not “knocked off” the Breaker.

C. Set the Aux. CT Module Assembly on the topof the Breaker Frame.

Fig. 15 Aux. CT Module Assembly Placed on theBreaker Frame.

D. Route the PT Wires through the cut-out in thetop and middle Breaker Frames, down towardsthe bottom left rear corner of the Breaker.

E. The PT Wires are marked for connection toPhases 1, 2, and 3 with corresponding num-bers.

NOTE: Before cutting the PT Wires, verify thePhase Convention used on the BreakerApplication.

Route the PT Wires to a position suitable forattachment to the bolts that secure the LoadTerminals to the Jumpers. These were leftloose in Step 3. Move the PT Wire markers toa position where they will still be attached tothe wires after cutting. Cut the wires to theappropriate length, strip each wire .250", andinstall a .500" ring terminal on each wire.Remove the nuts and washers from theJumper bolts left loose in Step 3-J. Using thehardware just removed, connect the PT Wiresto the Jumpers.

Fig. 16 PT Wires Connected to the JumperBolts.

F. Use the wire ties supplied to secure the PTWires to the Sensor Harness running along theinside of the left Breaker Frame.

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Fig. 17 PT Wires Secured to the Sensor Har-ness.

For Kits Supplied with a Breaker Mounted CPTand / or Auxiliary Switch Only.

STEP 5: INSTALLING THE BREAKERMOUNTED CPT

Fig. 18 Overview: Breaker Mounted CPT In-stalled in the Breaker.

A. Remove and save the (2) .190 - 32 × .250"screws securing the fuse clips and male spadeconnector installed on the CPT. Discard thefuse clips and spade connector, then reinstallthe screws in the CPT Terminals.

Fig. 19 Fuse Clips and Spade Connector Re-moved from the CPT

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B. Align the CPT Module with the holes in theCPT Mounting Bracket as shown. Note thatwhen viewed from the angled end of theMounting Bracket, the “X” Terminals should betowards the left edge of the Mounting Bracket.Secure the CPT Module to the CPT MountingBracket using the (4) .190-32 × .500" screws,(8) flat washers, (4) lock washers, and (4) nutssupplied.

Fig. 22 Drilling Plan “B”

NOTE: The Load Side HV Wires are longer thannecessary and are cut during the follow-ing step. Before cutting the wires, besure that sufficient length is left so thatthe HV Wire Fuses are accessible andthat the connections can be made to thecorrect “H” terminals on the CPT.

Fig. 20 CPT Module Installed on the MountingBracket.

C. Using Drilling Plan “A” for H-2 Breakers, orDrilling Plan B for H-L Breakers, drill two (2).281" diameter holes in the bottom frontBreaker Channel. Note that it may be neces-sary to temporarily remove the fuse box orexisting wire ties and mounting pad in order todrill the Breaker Channel.

Fig. 21 Drilling Plan “A”.

Fig. 23 Load and Line Sides of the HV Wires.

LINE SIDE LOAD SIDE

“X”TERMINALS

0.281 DIA. - (2)

0.63

1.25 4.75

DRILL MOUNTING HOLES INTO CHANNELON BOTTOM / FRONT OF BREAKER

0.281 DIA. - (2)

0.63

1.25 2.75

DRILL MOUNTING HOLES INTO CHANNELON BOTTOM / FRONT OF BREAKER

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G. After the HV and CPT Wires have been con-nected to the proper terminals of the CPT,install the “A” and “B” Finger-Safe Covers overthe CPT Terminals as shown. Secure theFinger-Safe Covers to the CPT using the (4).098 - 28 × .375" screws supplied with the CPTKit. Torque the screws to 8 - 10 in./lbs.

NOTE: The “C” and “D” Finger-Safe Coverssupplied with the CPT Kit are not used inthis application and should be discarded.

Table 3 CPT High Voltage Taps for Standardand Special Order CPTs

Standard CPT (Style #9A10037G01 & G02)

Voltage Required CPT Terminals Used

480 Volt Circuit H1 & H4



Special Order 575 Volt CPT (Style #9A10037G03 & G04)




D. Set the CPT Assembly in front of the bottomfront Breaker Channel, near the holes drilled inStep C. Position the HV Fuses along the rightside of the Breaker, roughly half way betweenthe front and back of the Breaker.

E. Mark and cut the Load Side of each HV Wireto an appropriate length for connection to the“H” terminals of the CPT. Strip an appropriatelength of insulation from the Load Side HVWires and attach a .138" ring terminal to each.Attach the HV Wires to the CPT terminals toachieve the required voltage (see Table 3).

NOTE: The terminals to which the Load Side HVwires are connected determine the volt-age of the CPT. Verify that the line volt-age of the circuit matches the CPTvoltage BEFORE putting the Breaker intoservice.

Table 4 CPT Low Voltage Taps for Standardand Special Order CPTs(After Removing Fuse Clips)

Standard CPT (Style #9A10037G01 & G02)

120 Voltage Required CPT Terminals Used

Secondary Circuit X1 & X2

Special Order 575 Volt CPT(Style #9A10037G03 & G04)

Secondary Circuit X1 & X2

Fig. 24 HV and CPT Wires Connected to theCPT Module.

F. Connect the CPT Wires to the appropriate “X”terminals of the CPT Module as shown. SeeTable 4 for Tap information. Temporarily routethe CPT Wires towards the left side of theBreaker. These will be routed and connectedalong with the Sensor Harness later in theRetrofit Process.

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Fig. 26 Microswitch Mounted to the AuxiliarySwitch Mounting Bracket.

I. Align the CPT Assembly, as shown, with theholes drilled in the bottom front BreakerChannel in Step 5-C. Secure the CPT Assem-bly to the bottom front Breaker Channel usingthe (2) .250-20 × .750" bolts, (4) flat washers,(2) lock washers, and (2) nuts supplied.

Fig. 28 Auxiliary Switch and CPT AssembliesInstalled in the Breaker.

As the Auxiliary Switch Assembly is beinginstalled in the Breaker, insure that the AuxiliarySwitch Arm engages the Closing Link as shown.

Fig. 25 Finger-Safe Covers Installed on the CPTModule.

H. For Kits Supplied with an Auxiliary Switch Only:For H-2 Breakers cut 2.88" off the MicroswitchArm. For H-L Breakers cut 0.88" off theMicroswitch Arm. Align the Microswitch, asshown, with the existing holes in the AuxiliarySwitch Mounting Bracket. Secure theMicroswitch to the Mounting Bracket using the(2) .138-32 × 1.00" screws, (4) flat washers, (2)lock washers, and (2) nuts supplied.

Fig. 27 CPT Assembly Installed in the Breaker.

For Kits Supplied with an Auxiliary Switch Only:The hardware and holes used to secure CPTAssembly to the Breaker are also used tosecure the Auxiliary Switch Assembly. TheAuxiliary Switch Mounting Bracket should beplaced behind the CPT Mounting Bracket, asshown.

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The HV Wires from the CPT MUST BEATTACHED to the Line Side of the Breaker.If it is determined that the power flow forthe Breaker application is opposite thenormal convention, the HV Wires must beattached to the Bottom Load Terminals. Inthe case of the Line Side being the BottomLoad Terminals, the bolts that secure theLoad Terminals to the Jumpers can beused for HV Wire attachment.

NOTE: The Line Side HV Wires are longer thannecessary and are cut during the followingsteps. Before cutting the wires, be surethat sufficient length is left so that the HVWire Fuses are accessible and that theconnections can be made to the correctLoad Terminals.

J. Route the HV Line Side Wires up towards theappropriate Top Load Terminals. Cut each HVWire to an appropriate length, then strip .250"from each wire.

NOTE: There are two distinct types of FingerClusters that were used on FP 25 H-2 &H-L and 50 / 65 H-2 & H-L Breakers.Finger Clusters that are secured to the

Fig. 30 Correct Orientation of the HV Wire RingTerminals.

Using the original bolts and the (2) new .250"washers supplied, secure the HV Wires to theFinger Clusters and Load Terminals.

Fig. 29 Correct Engagement of the AuxiliarySwitch Arm.

NOTE: The power convention of Circuit Breakersis normally Top to Bottom, meaning the TopLoad Terminals (Breaker Stabs) are on theLine Side of the Breaker and the BottomLoad Terminals are on the Load Side.

Load Terminals from the sides; and FingerClusters that are secured to the LoadTerminals from the top. The followingprocedures detail HV Wire connection forboth applications.

K. For Finger Clusters Secured to the LoadTerminals from the Sides: Crimp a .312" ringterminal to each HV Wire. Completely removethe mounting hardware from one side of theappropriate Finger Clusters. Loosen thehardware on the opposite sides of each FingerCluster. Slide the HV Wire ring terminalsbetween the Finger Clusters and the LoadTerminals as shown.

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Fig. 32 HV Wires Connected to Top SecuredFinger Clusters.

M. Use the nylon wire ties and self adhesive padssupplied to keep the HV Fuses and Wiresaway from any moving parts.

N. Install the appropriate CPT Voltage Label in aclearly visible location on the Breaker FacePlate.

Fig. 33 HV Fuses and Wires Secured Away fromMoving Breaker.

Fig. 31 HV Wires Connected to Side SecuredFinger Clusters.

L. For Finger Clusters Secured to the LoadTerminals from the Top: Crimp a .500" ringterminal to each HV Wire. Completely removeone of the two bolts securing the appropriateFinger Clusters to the Load Terminals. Alignthe HV ring terminals with the Finger ClusterMounting Holes. Using the original mountinghardware, secure the HV Wires to the appro-priate Finger Clusters.

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STEP 6: INSTALLING THE TRIP FINGER

Fig. 35 Overview: Trip Finger Installed in theBreaker - Long Trip Shaft.

NOTE: FP 25 H-2 & H-L and 50 / 65 H-2 & H-LBreakers were equipped with two differ-ent Trip Shafts: a long Trip Shaft (asshown in Figure 35) or a short Trip Shaft(as shown in Figure 36). If the Breakerbeing Retrofitted has a long Trip Shaft,use the new Trip Finger with the StyleNumber 9A10093G05. If the Breakerbeing Retrofitted has a short Trip Shaft,use the new Trip Finger with the StyleNumber 9A10093G06.

Fig. 36 Short Trip Shaft.

Fig. 34 CPT Voltage Labels supplied with theCPT Kit.

208VCONTROL POWER TRANSF. TAPS

H1–H4=480V H1–H3=240VH1–H2=208V

WARNINGTHIS BREAKER CONTAINS A 20VA

CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY. IF BREAKERIS USED ON A LINE VOLTAGE OTHERTHAN SHOWN. THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING.FAILURE TO DO SO WILL RESULT IN

DAMAGE TO THE TRIP UNIT AND / ORCONTROL POWER TRANSFORMER

NP# 8153A05H03


H1–H4=480V H1–H3=240VH1–H2=208V




NP# 8153A05H02


H1–H4=480V H1–H3=240VH1–H2=208V




NP# 8153A05H01


H1–H4=480V H1–H3=240VH1–H2=208V




NP# 8153A05H04

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For Breakers Equipped with a Short Trip ShaftOnly: Align the hole in the Trip Finger with theexisting hole near the end of the Trip Shaft.Secure the Trip Finger to the Trip Shaft usingthe (1) .190-32 × 1.25" screw, (2) flat washers,(1) lock washer, and (1) nut supplied.

Fig. 39 Original Trip Finger Removed from anElectrically Operated Breaker with ShortTrip Shaft.

B. For Breakers Equipped with a Long Trip ShaftOnly: Align the inner hole in the Trip Finger withthe existing hole near the end of the Trip Shaft.Secure the Trip Finger to the Trip Shaft usingthe (2) .190-32 × 1.25" screws, (4) flat washers,

Fig. 40 Trip Finger Installed on a Long TripShaft.

Fig. 41 Trip Finger Installed on a Short TripShaft.

Fig. 37 Trip Finger to be used with a Long TripShaft (Style Number 9A10093G05).

Fig. 38 Trip Finger to be used with a Short TripShaft (Style Number 9A10093G06).

A. For Breakers with a Short Trip Shaft Only:Remove and scrap the existing Trip Finger andmounting hardware.

(2) lock washers, and (2) nuts supplied. Notethat the screw that “pinches” the Trip Fingertogether should not be over tightened.

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STEP 7: INSTALLING THE DTA

Fig. 42 Overview: DTA Installed in the Breaker.

A. If existing holes do not already exist, usingDrilling Plan “C” for H-2 Breakers or DrillingPlan “D” for H-L Breakers, drill two (2) .281"diameter holes in the bottom front BreakerChannel. Note that it may be necessary totemporarily remove the existing wire ties andmounting pad in order to drill the BreakerChannel.

ON BOTTOM / FRONT OF BREAKERDRILL MOUNTING HOLES INTO CHANNEL

0.281 DIA. - (2)

0.63

1.883.75

Fig. 43 Drilling Plan “C”.

NUTWASHER (1)

Fig. 45 Hardware to Remove from the DTA TripShaft.

C. Align the DTA, as shown, with the existingholes or the holes drilled in Step 7-A. Securethe DTA to the bottom front Breaker Channelusing the (2) .250-20 × .625" bolts, (4) flatwashers, (2) lock washers, and (2) nuts sup-plied.

B. Remove the nut and one (1) wide flat washerfrom the end of the DTA Reset Shaft.

ON BOTTOM / FRONT OF BREAKERDRILL MOUNTING HOLES INTO CHANNEL

0.281 DIA. - (2)

0.63

1.883.56

Fig. 44 Drilling Plan “D”.

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NOTE: For the following procedures, it is recom-mended that the Retrofitter have both theBreaker’s Slow Close Handle and anappropriate block of wood available.

D. Using the Slow Close Handle, slightly movethe Closing Link forward towards the “Closed”position. Place a block of wood between oneof the Closing Links and the inner BreakerFrame. Slowly move the Slow Close Handletowards the back of the Breaker until thewood block is engaged.

Fig. 47 Slow Close Handle Engaged in theClosing Link.

E. Align the slot in the “L” Bracket with the DTAReset Shaft. Using the (1) .375-16 × 1.00"shoulder bolt, (3) flat washers, and (1) nutsupplied, loosely mount the Reset “L” Bracket,as shown, to the Closing Link. Note that extraflat washer is to be installed between the “L”Bracket and the Closing Link. On H-L Break-ers, an additional flat washer may be neededbetween the “L” Bracket and closing link toprovide proper vertical alignment.

Tighten the nut, then back it off three (3) tofour (4) turns. Apply Loc-Tite® 243 to thethreads of the bolt, fully tighten the nut, thenback the nut off one-half to one turn to allowthe “L” Bracket to pivot.

F. Using the wide flat washer and nut removed inStep 7-B, secure the “L” Bracket to the DTAReset Shaft.

Fig. 48 Reset “L” Bracket Installed on the DTAShaft.

Fig. 46 DTA Mounted to the Bottom FrontBreaker Channel.

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I. “Close” the Breaker.

NOTE: Throughout the Trip System Setupprocedure, be sure to keep hands andfingers away from any moving partswithin the Breaker. Failure to do so couldresult in serious injury.

J. Back-off the DTA Trip Disk. Apply Loc-Tite®

243 to the threads of the DTA Shaft. Turn theDTA Trip Disk until a gap of .070 to .100 isachieved between the top of the Disk and thebottom of the Trip Finger.

CAGEHEIGHT .875"

Fig. 49 Proper Cage Height Adjustment.

Fig. 50 Proper Air Gap Adjustment.

K. Return the Breaker to the “Open” position.

L. Using the self-adhesive mounting pads andwire ties supplied, secure the original wiring tothe Breaker Channel.

M. Route the DTA Wires, the Sensor Harness, andif applicable the CPT wires as shown towardsthe top of the Breaker. Use the wire tiessupplied to secure and bundle the wires tokeep them clear of any moving parts within theBreaker.

DTATRIPDISK

TRIP FINGER

GAP.070"TO.100"

Fig. 51 Routing and Securing of the Original andNew Wiring.

G. Again using the Slow Close Handle, releasethe pressure on the Closing Link and removethe wood block. Return the Breaker to thefully “Open” position.

H. Back-off the nuts on the DTA Reset Shaft.Apply Loc-Tite® 243 to the threads of the ResetShaft. Adjust the nut below the “L” Bracket onthe Reset Shaft until a cage height of .875" isachieved. Fully tighten the nut securing theReset “L” Bracket to the Reset Shaft.

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STEP 8: INSTALLING THE AUX. CT MODULEASSEMBLY AND THE TRIP UNIT

Fig. 52 Overview: Aux. CT Assembly and TripUnit Installed on the Breaker.

NOTE: For Steps 8-A through 8-E, the originalcomponents removed and saved duringStep 2 will be reinstalled. Refer to theFederal Pioneer 25 H-2 & H-L or 50 / 65H-2 & H-L Instruction Manual, originallysupplied with the Breaker, to perform thereinstallations.

A. Reinstall the Phase 1 & 2 and Phase 2 & 3Interphase Barriers.

B. Using the original hardware, reinstall the FlashBarrier.

C. Reinstall the Side Barriers.

D. Reinstall the Arc Chutes, the Arc Chute Hold-ers, and the Mounting Knobs.

E. Reinstall the Hood Assembly.

Fig. 53 Original Components Reinstalled on theBreaker.

F. Remove and scrap the existing hardware fromthe top, front right corner of the Breaker andnear the top, left rear corner of the Face PlateBox.

NOTE: If no holes exist at these locations, useDrilling Plan “E” to drill two (2) .281" holesin the top Breaker Frame.

Fig. 54 Drilling Plan “E”.

10.25 1.50

21.00

0.50

TOP VEIW OF BREAKER

0.281 DIA. - (2)

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G. Align the right and left Aux. CT Module Mount-ing Brackets, as shown, with the holes fromwhich the hardware was just removed. Securethe Aux. CT Module Mounting Brackets to theBreaker using the (2) .250-20 × .625" bolts, (2)lock washers, and (2) flat washers supplied. Ifthe existing holes are not threaded, or if theholes were drilled during this process, use theadditional (2) .250-20 nuts and (2) flat washerssupplied to secure the Aux. CT ModuleMounting Brackets.

Fig. 55 Aux. CT Module Mounting BracketsInstalled on the Breaker.

H. Align the Aux. CT Module Assembly with theholes in the Aux. CT Module Mounting Brack-ets. Secure the Aux. CT Module Assembly tothe Brackets using the (4) .190-32 × .500" flathead screws.

I. Route the Sensor Harness and the DTA Wirestowards the Aux. CT Module Terminal Block.

For Kits Supplied with a Breaker Mounted CPTOnly: Route the CPT wires across the top ofthe Aux. CT Module, against the bottom of theGlass Poly Barrier. If necessary, use the self-adhesive mounting pad and wire tie suppliedto hold the CPT Wires in place.

Fig. 56 Aux. CT Module Assembly Installed on theBreaker and Preliminary Routing of theSensor Harness, DTA Wires, and CPTWires.

J. Remove and save the Aux. CT Module Termi-nal Block Cover and mounting hardware.

K. Connect the “+” DTA Wire to the “OP” terminalof the 7-Point Terminal Block and the un-marked wire to the “ON” terminal.

Fig. 57 DTA Wires Connected to the Aux. CTModule Terminal Block.

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L. Connect the Sensor Harness to the properterminals of the 7-Point Terminal Block. Refer toSection 12 of the Retrofit Application Data,supplied with the Retrofit Kit, for detailedwiring specifications.

Note that the Sensor Harness Ground Wire(with ring terminal) will be connected later in theRetrofit Process.

Fig. 58 Sensor Harness Connected to the Aux.CT Module Terminal Block.

M. Reinstall the 7-Point Terminal Cover.

N. Mount the Trip Unit to the top of the Aux. CTModule as shown using the (2) .190-32 × 4.00"screws, (2) lock washers, (2) flat washers, and(2) spacers supplied. Note that the brassspacers are positioned between the top of theAux. CT Module and the bottom rear of the TripUnit. Do not fully tighten the screws at thistime.

O. Mount the left and right Trip Unit Support Clipsto the sides of the Aux. CT Module and intothe bottom front slots in the Trip Unit asshown. Secure using the (4) .190-32 × .500"screws, (4) lock washers, and (4) flat washerssupplied. Use one of the left Support ClipMounting Screws to secure the Sensor Har-ness Ground Wire to the Aux. CT Module.

Secure the Trip Unit by tightening the 4.00"screws installed in Step 8-N.

Fig. 59 Support Clips and Sensor HarnessGround Wire Connected to the Aux. CTModule.

P. Remove the Trip Unit Cover and install theRating Plug supplied with the Retrofit Kit.Reinstall the Cover.

Q. Install the Aux. CT Harness between the TripUnit and the Aux. CT Module.

Fig. 60 Rating Plug and Aux. CT Harness In-stalled.

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R. Use the self-adhesive mounting pads and wireties supplied to secure the Sensor Harness,DTA Wires and if applicable, the PT Wires andCPT Wires away from any moving parts withinthe Breaker.

S. Install the Digitrip Retrofit Label on the top ofthe Trip Unit.

STEP 9: INSTALLING THE EXTERNAL HAR-NESS AND FINAL WIRING

Fig. 61 Overview: External Harness Installed onthe Breaker.

A. Connect the External Harness to the Trip Unit.

NOTE: For 510 Basic Kits, the External Harnessis the shorting plug pictured below. It isto be plugged into the right side of theTrip Unit.

Fig. 62 510 Basic Kit External Harness ShortingPlug.

B. For Kits Supplied with a PT Module Only: Plugthe connector from the PT Module into itsreceptacle on the External Harness.

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C. For Kits Supplied with an Auxiliary Switch Only:Route the two (2) wires (with ring terminals)from the External Harness, down through theBreaker to the Auxiliary Switch. Connect one(1) wire to the normally “Open” terminal andthe other wire to the “Common” terminal of theAuxiliary Switch.

Fig. 63 External Harness Wires Connected to theAuxiliary Switch.

D. For Kits Supplied with a Breaker Mounted CPTOnly: Remove the External Harness pluginstalled in the bottom rear socket of the TripUnit. Insert the black plug of the CPT Harnessinto the same receptacle in the Trip Unit.Reinsert the External Harness Plug just re-moved into the female receptacle on the CPTHarness.

Fig. 64 External Harness Connections at the TripUnit.

E. Secure the External Harness to the rightBreaker Frame using the self-adhesive mount-ing pad and wire tie supplied.

Fig. 65 External Harness Secured to the Side ofthe Breaker.

F. Use the self-adhesive mounting pads and wireties supplied to dress all wires and harnessesto keep them away from any moving partswithin the Breaker.

G. If the Breaker Face Plate, Floating Trim, andCharging Handle were removed during theRetrofit, reinstall them using the original mount-ing hardware.

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STEP 10: TESTING THE BREAKER

A. Measure the force necessary to trip the Breakerat where the Trip Finger impacts the DTAAdjusting Disk. The force necessary to trip theBreaker MUST NOT EXCEED 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 (Publication AD 33-855-3, May 2001), supplied with the Retrofit Kit,for detailed 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 informationnecessary for testing the Breaker, please keepthe following notes in mind when reviewingother sections of the publication.

Confirm that the PowerNet communicationwiring is correct by following the proceduresdetailed in Section 7.4 of the Instructionsfor the Application of Digitrip RMS RetrofitKits on Power Circuit Breakers. Note thatfor 810 and 910 Kits, the impedance be-tween COM 1 and COM 2 should be be-tween one (1) and three (3) ohms.

When testing is complete, disconnect theExternal Harness from the Cell Harness.Final External Harness connection will beperformed later in the Retrofit Process.

CAUTION

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 anypower applied to the system (neither the 120volt power supply nor the Aux. Power Mod-ule connected), plug the External Harnessinto the Cell Harness and check the imped-ance between COM 1 and COM 2. Theimpedance should be between one (1) andthree (3) ohms. If the impedance is notwithin this range, trace the wiring and exam-ine each connection to assure its integrity.

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STEP 11: MOUNTING THE CELL HARNESS

A. The Cell Harness is to be mounted in theBreaker Cell. The connector end is to bemounted on the left side of the Cell, in alocation suitable for connection with theExternal Harness. The Terminal Blocks can bemounted anywhere space is available in theCell as long as connection to the ExternalHarness can be made.

B. Route the Cell Harness wiring to keep it awayfrom any moving parts within the Cell Housing.

STEP 12: INSTALLING THE RETROFITTEDBREAKER IN THE CELL

WARNING

DO NOT LEAVE THE BREAKER IN AN INTER-MEDIATE POSITION IN THE SWITCHGEARCELL. ALWAYS LEAVE IT IN THE CON-NECTED, DISCONNECTED, OR (OPTIONAL)TEST POSITION. FAILURE TO DO SO COULDLEAD TO IMPROPER POSITIONING OF THEBREAKER AND FLASHOVER, CAUSINGDEATH, SERIOUS PERSONAL INJURY, AND /OR PROPERTY DAMAGE.

NOTE: It is the responsibility of the Retrofitter toinsure proper Breaker / Cell fit. Whenracking the Breaker into the Connectedposition, the Retrofitter MUST FOLLOWBOTH the manufacturer’s instructions andthe customer’s safety standards andprocedures for racking a Breaker into theConnected position.

A. With the Breaker in the Open position and thesprings discharged, slowly rack the Breakerinto the Connected position, making surethere is no interference or binding. TheBreaker should rack smoothly and withoutmechanical interference between any Breakerand Cell parts. The Retrofitter will feel someresistance when the primary fingers connectonto the stabs of the Cell. This is normal.

However, if any unusual resistance is detectedthat could be abnormal interference betweenthe Breaker and Cell parts, stop immediatelyand move the Breaker out of the Connectedposition. Examine what is causing the interfer-ence and correct the situation.

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Digitrip Retrofit Kit Installation Components for Federal Pioneer 25 H-2 & H-L and 50 / 65 H-2 & H-L BreakerRMS/R RetrofitsStep Description Qty. CommentStep 3 Sensor See Pick List 3

Sensor Mounting Parts 9A10093G04 1Spacer 6

Sensor Harness Parts 9A10093G07 1Sensor Harness See Pick List 1Mounting Pad - 1", Self Adhesive 6Wire Tie Nylon 16

Step 4 Aux. CT Module 6503C59G__ 1Trip Unit Mounting Parts 9A10093G10 1

Trip Unit Barrier 1Aux. CT Mounting Bracket R. H. 1Aux. CT Mounting Bracket L. H. 1Support Clip RH 1Support Clip LH 1.250-20 × .625 Lng. Bolt Stl. 2.250 Flat Washer Stl. 4.250 Lock Washer Stl. 2.250-20 Nut Hex Stl. 2.190-32 × 4.00 Lng. Screw Fil. 2.190-32 × .500 Lng. Screw F. H. 4.190-32 × .500 Lng. Screw P. H. 4.190-32 x .375 Lng. Screw P. H. 2.190 Flat Washer Stl. 8.190 Lock Washer Stl. 8Spacer Brass 2Label Digitrip Retrofit 1

PT Module 6502C82G01 1Ring Terminal (.190, .250, .312, .375, .500 -Each Size) 3

PT Module Mounting Parts 9A10093G11 1.138-32 × .500 Lng. Screw P. H. 2.138 Flat Washer Stl. 4.138 Lock Washer Stl. 2.138-32 Nut Hex Stl. 2

Wire Tie Nylon From Step 3Step 5 Breaker Mounted CPT Kit See Pick List 1

MTE Transformer 1HV Fused Wires 2CPT Wires 1

Mounting Hardware Kit 1.190-32 × .750 Lng. Screw Fil. 4.190-32 × .375 Lng. Screw Fil. 2.190 Flat Washer Stl. 10.190 Lock Washer Stl. 6.190-32 Nut Hex Stl. 4Ring Terminal (.138, .190, .250, .312, .375, .500 -Each Size) 2

Comm. Only

CPT Only

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Digitrip Retrofit Kit Installation Components for Federal Pioneer 25 H-2 & H-L and 50 / 65 H-2 & H-L BreakerRMS/R RetrofitsStep Description Qty. Comment

Wire Tie Nylon 12Warning Label (208, 240, 480, & 575 Volt - Each) 1

Finger-Safe Cover Kit FSK4 1Cover (A, B, C, & D Each) 1.098-28 × .375 Lng. Screw Fil. 4

CPT Mounting Parts 9A10093G20 1CPT Mounting Bracket 1.250-20 × .750 Lng. Bolt Stl. 2.250 Flat Washer Stl. 6.250 Lock Washer Stl. 2.250-20 Nut Hex Stl. 2.190-32 × .500 Lng. Screw F. H. 4.190 Flat Washer Stl. 8.190 Lock Washer Stl. 4.190-32 Nut Hex Stl. 4

Auxiliary Switch Kit 9A10093G02 1Microswitch 1Auxiliary Switch Mounting Bracket 1.250-20 × .750 Lng. Bolt Stl. 2.250 Flat Washer Stl. 4.250 Lock Washer Stl. 2.250-20 Nut Hex Stl. 2.138-32 × 1.00 Lng. Screw Fil. 2.138 Flat Washer Stl. 4.138 Lock Washer Stl. 2.138-32 Nut Hex Stl. 2

Mounting Pad - 1", Self AdhesiveWire Tie Nylon

Step 6 Trip Finger Parts (Long Trip Shaft) 9A10093G05 1Trip Finger 1.190-32 × 1.25 Lng. Screw Fil. 2.190 Flat Washer Stl. 4.190 Lock Washer Stl. 2.190-32 Nut Hex Stl. 2

Trip Finger Parts (Short Trip Shaft) 9A10093G06 1Trip Finger 1.190-32 × 1.25 Lng. Screw P.H. 1.190 Flat Washer Stl. 2.190 Lock Washer Stl. 2.190-32 Nut Hex Stl. 1

Step 7 DTA Assembly 9A10093G__ 1DTA Mounting Parts 9A10093G08 1

.250-20 × .625 Lng. Bolt Stl. 2

.250 Flat Washer Stl. 4

.250 Lock Washer Stl. 2

Step 5(cont.)

CPT Only

From Step 3

Comm. Only

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Digitrip Retrofit Kit Installation Components for Federal Pioneer 25 H-2 & H-L and 50 / 65 H-2 & H-L BreakerRMS/R RetrofitsStep Description Qty. Comment

.250-20 Nut Hex Stl. 2Loc-Tite® 243 1

Reset Parts 9A10093G09 1L Bracket Reset 1.375-16 × 1.00 HEX BOLT 1.375-16 HEX NUT 1.375 FLAT WASHER 4Loc-Tite® 243 1

Mounting Pad - 1", Self AdhesiveWire Tie Nylon

Step 8 Aux. CT Mounting Bracket R. H. 1Aux. CT Mounting Bracket L. H. 1Support Clip R. H. 1Support Clip L. H. 1.250-20 × .625 Lng. Bolt Stl. 2.250 Flat Washer Stl. 4.250 Lock Washer Stl. 2.190-32 × 4.00 Lng. Screw Fil. 2.190-32 × .500 Lng. Screw F. H. 4.190-32 × .500 Lng. Screw P. H. 4.190-32 × .375 Lng. Screw P. H. 2.190 Flat Washer Stl. 8.190 Lock Washer Stl. 8Spacer Brass 2Label Digitrip Retrofit 1Auxiliary CT Harness 6502C84G01 1Mounting Pad - 1", Self AdhesiveWire Tie Nylon

Step 9 External Harness 6502C83G__ 1 Except 510 BasicMounting Pad - 1", Self AdhesiveWire Tie Nylon

Step 11 Cell Harness See Pick List 1

NOTE: Due to the wide variety of Breakers and the multiple functions of the Retrofit components, someexcess hardware may remain when the Retrofit is complete.

Step 7(cont.)

From Step 4

From Step 3

From Step 3

From Step 3

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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 5 Torque Values for General Mounting and Screw Size Conversion

Table 6 Torque Values for Copper BUS Connectors

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A. SensorsB. Trip UnitC. Aux. CT ModuleD. Direct Trip Actuator (DTA)E. CPT TransformerF. Rating PlugG. HV WiresH. Aux. CT Harness

I. Sensor HarnessJ. External HarnessK. Cell Terminal BlockL. Aux. SwitchM. PT ModuleN. CPT HarnessO. Trip Finger(s)

Fig. 66 Retrofit Components

AB

C

D

H

I

J

KL

M

N

O

G

F

E

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Notes

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Pittsburgh, Pennsylvania U.S.A.

Publication No. I.L. 33-FHC-3April 2002Printed in U.S.A./TBG00056

Cutler-Hammer

We wish to thank you for purchasing the Digitrip Retrofit System. Digitrip Retrofit Kits are designed andmanufactured in America with pride. All the components are engineered to fit the existing Circuit Breaker with littleor no modifications to the existing 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 qualify themfor 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 should not beconsidered to be all inclusive or covering all contingencies. If further information is required, Cutler-Hammer should beconsulted.

NO WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING WARRANTIES OF FITNESS FOR A PARTICULARPURPOSE OR MERCHANTABILITY, OR WARRANTIES ARISING FROM COURSE OF DEALING OR USAGE OFTRADE, ARE MADE REGARDING THE INFORMATION, RECOMMENDATIONS AND DESCRIPTIONSCONTAINED HEREIN. In no event will Cutler-Hammer be responsible to the user in contract, in tort (including negligence),strict liability or otherwise, for any special, indirect, incidental, or consequential damage or loss whatsoever, including butnot 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, or claims against the user by itscustomers resulting from the use of the information, recommendations, and descriptions contained herein.

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