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W-VACiMB FIXED SECONDARY TERMINAL BLOCK OEM CONVERSION TYPE #1

PUSH ON TYPE TERMINAL BLOCK

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PLEASE READ

These instructions are provided so that an OEM can officially convert a

W-VACiMB Mining Breaker to an approved secondary variation. This

variation is required for some OEM’s for them to be in compliance with

end customer needs. The OEM is authorized to do the conversion per

this process and to still have the proper warranty protection.

This procedure is intended to show the necessary steps to remove the

standard secondary connector and replace it with a Push-On type

terminal block that contains the following connections (Refer to Figure

29):

o Spring Charging Circuit

Uses secondary connector pins 25 & 35.

o (1) Shunt Open Circuit (Trip Coil)

Uses secondary connector pins 31& 30.

o (1) Shunt Close Circuit

Uses secondary connector pins 4 & 14.

o Control Under Voltage Release (UVR) Circuit

Uses secondary connector pins 2 & 44.

This requires the UVR option to be installed.

o (2) Normally Open Relays

Relays are open when breaker is open.

1st Relay uses secondary connector pins 7 & 17.

2nd Relay uses secondary connector pins 9 & 19.

o (1) Normally Closed Relay

Relay is closed when breaker is open.

Uses secondary connector pins 23 & 33.

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Due to jumping connections in this procedure, the three relays will

have the same voltage/supply as the charge motor. Similarly, the UVR,

Close Coil, Charging Motor, and Trip Coil will share a common return

(See Appendix A). You may choose to not install the jumpers for more

circuit flexibility.

Use appendices A through F for additional information.

TOOLS REQUIRED

Narrow & Thin Flathead Screwdriver

o To be used on DIN-Rail Mountable Terminal Blocks

Male Pin Remover

8 mm Wrench

10 mm Wrench

Wire Strippers

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Parts List

Quantity Item Supplier Part

Number Cost

1 DIN Rail www.monti-inc.com 68B7301 $3.90 per 50

4 Red Terminal Block www.ab.com 1492-J4-RE $1.01 Each

4 White Terminal Block www.ab.com 1492-J4-W $0.93 Each

6 Gray Terminal Block www.ab.com 1492-J4 $0.96 Each

2 Four-Pole Center Jumper www.ab.com 1492-CJJ6-4 $2.25 Each

4 Gray Terminal Divider www.ab.com 1492-EBJ3 $0.66 per 50

2 End Cap www.ab.com 1492-EAJ35 $3.49 Each

3 Feet Translucent Wire Sleeving www.McMaster.com 7432K741 $8.97 per foot

5 Zip Tie www.McMaster.com 7130K19 $3.78 per 100

5 Zip Tie Holder www.McMaster.com 7566K62 $11.32 per 50

8 Inches 3M Fire & Arc Protect Tape

Roll www.McMaster.com 77255A4 $28.28 per 20 feet

1 3M Electrical Tape Roll www.McMaster.com 76455A21 $2.03 per 20 feet

Monti Contact Info: Nick LaVigne nickl@monti-inc.com 864-323-0444 104 Airport Industrial Road, Greenwood, SC 29649

Red Terminal

Block

White

Terminal Block

Grey Terminal

Block

Four-Pole

Center Jumper

DIN Rail

See Appendix C

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Gray Terminal

Divider

End Cap

Translucent

Wire Sleeving

Zip Tie

Zip Tie Holder Electrical Tape

Arc Protect

Tape

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PROCEDURE

Step 1: Locate the secondary control power wiring terminal box on the breaker.

Figure 1: Breaker side secondary Terminal Box.

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Step 2:

Insert flat head screwdriver into the two clips to release the front

cover.

Figure 2: Schematic of the how to remove the front cover on the secondary.

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Step 3:

Using the male pin remover, take out each pin. This can be

accomplished by pressing the male pin remover into a pin slot and

pushing hard to unseat the pin. Once the pin has been unseated,

push from the opposite side of the secondary connector to pull the

pin out of its slot. Repeat for ALL pins (more figures on next page).

Figure 3a: Line up the male pin remover with a pin.

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Figure 3b: Press the male pin remover in hard to unseat the pin.

Figure 3c: Once unseated by the male pin remover, push on the pin

from the opposite side to get the pin out of the slot. Repeat for all

pins.

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Step 4:

Once all pins have been taken out of their slots, remove the

secondary connector and rubber tubing. Discard if desired.

Figure 4: Remove the gray rubber tubing and secondary connector, they will not be used.

Rubber Tubing Secondary Connector

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Step 5:

Separate the (14) wires needed for the secondary terminal block from

the rest of the wires and set them aside. See appendix A for a listing

of the necessary wires.

Figure 5: Separating the (14) needed wires.

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Step 6:

Pull the unnecessary wires through the hole in the top of the

breaker. These wires will be secured inside the breaker in the

proceeding steps.

Figure 6: Pull out the unnecessary wires.

14 Used Wires

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Step 7: Wrap about (22) inches of transparent protective covering around these unnecessary wires. These wires that are unused will be secured inside of the breaker.

Figure 7: Transparent protective wiring cover.

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Step 8:

If too long, cut the transparent protective wiring cover two inches

from the end of these unnecessary wires.

Figure 8: Removal of excessive wiring cover.

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Step 9: Cut an 8 inch section of the fire retardant arc protective tape.

Figure 9: Cutting an 8 inch section of arc protective tape.

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Step 10:

Wrap the arc protective tape around the exposed portion of the

unused wires. Then, secure this protective tape with the electrical

tape.

Figure 10: Wrapping the unused wires in electrical tape.

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Step 11:

Wrap the unused wires completely with electrical tape.

Figure 11: Unused wires completely covered.

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Step 12: We will now secure the unused wires inside the breaker. Place (2) cable tie holders on the inside wall of the breaker (spring side). Position them about three inches from each other and a half inch from the edge.

Figure 12: Placement of cable tie holders.

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Step 13: Insert cable ties through the inslots of the tie holders to secure the unused wires.

Figure 13: Securing of the unused wires.

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Step 14: Place another cable tie holder as shown closer to the back of the breaker to hold the end of the unused wire bundle. Zip tie the bundle to the cable tie holder.

Figure 14: Securing of the wires to avoid interference with spring.

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Step 15: The wires should be secured in this manner and any excess cable ties should be clipped.

Figure 15a (left): Use three zip ties to secure the unused wires to the inner wall.

Figure 15b (right): Wires are secured from both the closing and open spring assemblies.

In Process Quality Check: Operate the breaker mechanically and make sure no moving parts interfere with the wiring.

(3)

Zip

Ties

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Step 16:

Wrap transparent wiring cover around the (14) wires used for the

terminal blocks. The wiring cover should span roughly eight inches.

Figure 16: Wrapping of the transparent wire covering on terminal wires.

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Step 17: Clip on (4) red, (4) white, and (6) grey terminal blocks onto the DIN-Rail. Attach the (4) grey dividers onto each set of colored terminal blocks and put on the (2) end caps as shown below.

Figures 17a & 17b: Attachment of the block terminals and dividers.

End Cap

Grey Dividers

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Step 18: Squish all pieces together so there are no gaps and fasten both grey end caps to the DIN-Rail as shown by using a flathead screwdriver.

Figures 18a & 18b: Mounting and fastening of the end terminal blocks.

End Cap End Cap

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Step 19: Unfasten the bolt on the top center of the breaker that helps secure the mechanism in place using a 10 mm wrench.

Figure 19: Temporary removal of the center bolt. It will be used for mounting the DIN-Rail.

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Step 20: Unfasten this bolt on the underside of the top of the breaker ground terminal connection bolt using an 8 mm wrench.

Figure 20: Removal of the bolt.

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Step 21: Fasten the DIN-Rail and block terminals onto the top of the breaker using the bolts removed in steps 19 and 20. Remember to reconnect the grounding wire on the inside of the breaker (Figure 20).

Figure 21: Securing of the DIN-Rail and block terminals.

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Step 22: Slide the white labels on the wires back until they reach the transparent wire cover.

Figure 22: Sliding the white labels back.

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Step 23:

Remove excess wire on each wire by lining up the wire with the

screw hole of the terminal slot designated for that wire (See

Appendix A). The wires will increase in length as you go down the

DIN-Rail from left to right.

Figure 23: Snipping of the wires.

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Step 24:

Use wire strippers to strip all 14 ends approximately 10 mm in length

(14 Gauge).

Figure 24: Stripping the wires.

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Step 25:

Secure each wire in position by fastening each screw as shown

using a small flathead screw driver.

Figure 25: Securing of the wires.

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Step 26: Install the (2) four-pole jumpers on the red and white terminals. Make sure to tighten all screws so all terminals have a solid connection the jumper.

Figures 26a & 26b: Installing the two jumpers.

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Step 27: Attach two cable tie holders to the top of the breaker and secure the wires with cable ties. Place the cable tie holders about two inches from each other as shown.

Figure 27: Securing of the wires used for the terminals.

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FINAL RESULT

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QUALITY CHECK

Visually inspect the breaker for defects.

Make sure all of the electrical connections are correctly secured.

Make sure all of the electrical connections are in accordance to the

wiring schematic.

Make sure all of the bolted connections that were added as a part of

this procedure are properly tightened.

Electrically test the operation of the breaker to make sure the

modifications were correctly done and that the breaker properly

operates. Electrically operate the breaker five times for a charge -

open - close type operation.

Inspect the operation of the large black closing mechanism spring to

make sure that it does not hit the modified wiring harness on the left

side of the mechanism side sheet. The spring should have 0.5” or

more clearance during opening or closing.

Make sure the front cover is properly mounted.

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Appendix A: Wiring Locations

Figure 28: Graphical locations of each wire.

Terminal Position Old CODE New CODE 2013+ Purpose

1 D1 X11:25M1:1 Motor Power Supply (Hi)

2 C9 Q1.1:9X11:7 Normally Open Relay 1 (Hi)

3 C13 Q1.1:13X11:9 Normally Open Relay 2 (Hi)

4 C7 Q1.1:7X11:23 Normally Closed Relay (Hi)

5 H4 X11:44Y6:2 UVR Return (Lo)

6 P2 X11:14U2:2 Close Coil Return (Lo)

7 F22 M1.2:22X11:35 Motor Return (Lo)

8 C2 Q1.1:2X11:30 Trip Coil Return (Lo)

9 H3 X11:2Y6:1 UVR Power Supply (Hi)

10 P1 X11:4U2:1 Close Coil Power Supply (Hi)

11 P7 X11:31U2:7 Trip Coil Power Supply (Hi)

12 C10 Q1.1:10X11:17 Normally Open Relay 1 (Lo)

13 C14 Q1.1:14X11:19 Normally Open Relay 2 (Lo)

14 C8 Q1.1:8X11:33 Normally Closed Relay (Lo)

1 2

3 4

5 6

7 8

9 10

11 12

13 14

Note: The “X11” designation refers to the secondary connector. For example, “X11:25” is the 25th

pin on the secondary connector.

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Appendix B: Reference wiring variations

Figure 29: Graphical schematic of terminal assembly.

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Appendix C: DIN Rail

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Appendix D: W-VACiMB Wiring Diagram

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Appendix E: New Overall Breaker Dimensions

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Appendix F: Wire Identification Sheet

The labels above can be copied and taped to the top of the breaker for easy

identification of each wire and its purpose.

Mo

tor

+

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

UV

R -

Clo

se C

oil

-

Mo

tor

-

Trip

Co

il -

UV

R +

Clo

se C

oil

+

Trip

Co

il +

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

Mo

tor

+

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

UV

R -

Clo

se C

oil

-

Mo

tor

-

Trip

Co

il -

UV

R +

Clo

se C

oil

+

Trip

Co

il +

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

Mo

tor

+

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

UV

R -

Clo

se C

oil

-

Mo

tor

-

Trip

Co

il -

UV

R +

Clo

se C

oil

+

Trip

Co

il +

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

Mo

tor

+

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

UV

R -

Clo

se C

oil

-

Mo

tor

-

Trip

Co

il -

UV

R +

Clo

se C

oil

+

Trip

Co

il +

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

Mo

tor

+

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay

UV

R -

Clo

se C

oil

-

Mo

tor

-

Trip

Co

il -

UV

R +

Clo

se C

oil

+

Trip

Co

il +

NO

Rel

ay 1

NO

Rel

ay 2

NC

Rel

ay