Digitrip Retrofit System Foor The Allis-Chalmers G-50/G-50A
Instruction Leaflet IL 33-A5C-2Effective July 2010Supersedes IL 33-A5C-1 Dated 12/98Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AContentsDescriptionPageIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Step 1: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Step 2: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Step 3: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5Step 4: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Step 5: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Step 6: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Step 7: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Step 8: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8Step 9: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Step 10: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Step 11: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Step 12: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Step 13: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Step 14: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Step 15: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Instruction Leaflet IL 33-A5C-2Effective July 2010 WARNINGPOWER CIRCUIT BREAKERS ARE EQUIPPED WITH HIGH SPEED, HIGHENERGY OPERATING MECHANISMS. THE BREAKERS AND THEIRENCLOSURES ARE SIGNED WITH SEVERAL BUILT-IN INTERLOCKS ANDSAFETY FEATURES INTENDED TO PROVIDE SAFE AND PROPER OPERATINGSEQUENCES. TO PROVIDE MAXIMUM PROTECTION FOR PERSONNELASSOCIATED WITH THE INSTALLATION, OPERATION, AND MAINTENANCEOF THESE BREAKERS, THE FOLLOWING PRACTICES MUST BE FOLLOWED.FAILURE TO FOLLOW THESE PRACTICES MAY RESULT IN DEATH,PERSONAL INJURY, OR PROPERTY DAMAGE.Safety Precautions Periodic testing of this device is required (see Step 13 Testing theBreaker for test procedures). Only qualified persons, as defined in the National Electric Code,who are familiar with the installation and maintenance of powercircuit breakers and their associated switchgear assembliesshould perform any work associated with these breakers. Completely read and understand all instructions before attemptingany installation, operation, maintenance, or modification of thesebreakers. Always turn off and lock out the power source feeding thebreaker prior to attempting any installation, maintenance, or modification of the breaker. Do not use the circuit breaker as the solemeans for isolating a high voltage circuit. Follow all lockout andtagging rules of the National Electric Code and all other applicablecodes, regulations, and work rules. Do not work on a closed breaker or a breaker with the closingsprings charged. Trip (open) the breaker and be sure the storedenergy springs are discharged before performing any work. Thebreaker may trip open or the charging springs may discharge,causing crushing or cutting injuries. For drawout breakers, trip (open), and then remove the breaker toa well-lit work area before beginning work. Do not perform any maintenance: including breaker charging, closing, tripping, or any other function which could cause significantmovement of the breaker while it is on the extension rails. Doingso may cause the breaker to slip from the rails and fall, potentiallycausing 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 improperpositioning of the breaker and flashover, causing death, seriouspersonal injury, and / or property damage. Do not defeat any safety interlock. Such interlocks are intendedto protect personnel and equipment from damage due to flashover and exposed contacts. Defeating an interlock could lead todeath, severe personal injury, and / or property damage2eaton corporation www.eaton.comDigitrip Retrofit System for theAllis-Chalmers G-50/ G-50A
Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AInstruction Leaflet IL 33-A5C-2Effective July 2010Section 1: IntroductionEaton Digitrip Retrofit Kits are available in a number of configurationsthat provide a wide range of features. The Digitrip System startswith the 510 Basic Kit that offers true RMS sensing, overcurrentprotection, and self-testing features. Advanced Digitrip Retrofit Kitsfeature zone interlocking, digital alphanumeric displays, remote alarmsignals, PowerNet communications, energy monitoring capabilities,power factors, and harmonic content measurements.Table 1 provides a quick reference of the components supplied witheach level of Retrofit Kit. Before beginning the Retrofit process,take a minute to review the information contained in Table 1. It isimportant that the Retrofitter understands which level of Retrofit Kitis to be installed and which components are included with the Kit.The instructions contained in this manual cover the installation of alllevels of Retrofit Kit. If the Kit you are installing does not containa certain component, skip the instructions for that component andproceed to the next.Throughout the Retrofit process, refer to the Torque Tables at theback of this manual for specific torque values.If you have any questions concerning the Retrofit Kit and / or theRetrofit process, contact Eaton at: 1-800-937-5487.Table 1. Available Retrofit KitsComponents510 Basic510 with ZoneInterlock610810910Plug1 Connector Harness2 Connector Harness3 Connector Harness4 Connector HarnessTrip UnitRating PlugAuxiliary CurrentTransformer(CT) ModuleAuxiliaryCT HarnessSensorsSensor HarnessDirect Trip Actuator (DTA)Mounting Brackets and HardwareExternal HarnessCell HarnessBreaker Mounted Control Power Transformer (CPTPotential Transformer (PT) ModuleAuxiliary Switcheaton corporation www.eaton.com3
Instruction Leaflet IL 33-A5C-2Effective July 2010Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AStep 1: General Breaker PreparationStep 2: Removing the Original ComponentsBefore attempting to remove the Breaker fromthe Cell or perform any Retrofit operation, be sureto read 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 - PublicationAD 33-855), supplied with the Digitrip Retrofit Kit.Follow the Allis-Chalmers G-50 / G-50A InstructionManual, originally supplied with the Breaker, toperform the following procedures.WARNINGDO NOT ATTEMPT TO INSTALL OR PERFORMMAINTENANCE ON EQUIPMENT WHILE IT ISENERGIZED. SEVERE PERSONAL INJURY ORDEATH CAN RESULT FROM CONTACT WITHENERGIZED EQUIPMENT. VERIFY THAT NOVOLTAGE IS PRESENT BEFORE PROCEEDING.A. Trip the Breaker and remove it from theCell. Move the Breaker to a clean, well-litwork bench.NOTE: It is the responsibility of the Retrofitterto insure that the Breaker and all originalcomponents are in good condition. Visuallyinspect all Breaker components for signs ofdamage or wear. If any signs of damage or wearare detected for components not included in theRetrofit Kit, secure the necessary replacementparts before beginning the Retrofit process.The force necessary to trip the Breaker shouldnot exceed three (3) lbs.To begin the Retrofit process, refer to thecomponents list at the end of this manual. Lay outthe components and hardware according to thesteps outlined. The parts bags are labeled with thecorresponding step number. The components andhardware will be used to complete each step in theRetrofit process.4EATON CORPORATION www.eaton.comA. Remove and scrap the original Electromechanical Trip Units. Save three(3) of the mounting screws for use later in theRetrofit process.
Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AStep 3: Mounting the SensorsInstruction Leaflet IL 33-A5C-2Effective July 2010D. Mount the Sensor Spacer Assemblies bypositioning them over the right side of eachBreaker Stab as shown. Note that the thickerend of the Assemblies must be positioned onthe top of the Stabs. Secure the Assemblies tothe Stabs using the (6) .250-20 1.25" bolts,(12) flat washers, (6) lock washers, and(6) nuts supplied.New SpacerAssemblySensorOriginalSpacerA. Remove and save the Allen head bolts thatsecure the Finger Clusters to the bottomBreaker Stabs. Remove and save theFinger Clusters.NOTE: Allis-Chalmers G-50 / G-50A Breakerswere originally fitted with two (2) differenttypes of Finger Clusters. This Retrofit Kitprovides the hardware necessary toaccommodate either type of Finger Cluster.The first type, Type A - Large Finger Clusters(pictured within this manual) will use only thethree (3) Sensor Spacer Assemblies suppliedwith the kit. Type B - Small Finger Clusters willuse the six (6) Sensor Spacers (saddle type)and the six (6) Retainers supplied with the kit.For Sensors Fitted with Type A - Large FingerClusters Only.B. Remove the Allen head bolts that secure theoriginal “L” Spacers and Shims to the BreakerStabs. Save the Spacers, Shims, and hardwarefor use later in the Retrofit process.Right Sideof BreakerE. Install a Sensor over each Breaker Stab. TheSensors must be installed with the terminals onthe bottom and facing away from the BreakerBack Plate.F. Reinstall the original “L” Spacers and Shims onthe Breaker Stabs using the original mountinghardware.G. Reinstall the Finger Clusters using the originalmounting hardware.C. Remove and scrap the bolts and associatedhardware that secure the Breaker Stabs to theBreaker Stab Mounting Brackets.EATON CORPORATION www.eaton.com5
Instruction Leaflet IL 33-A5C-2Effective July 2010For Sensors Fitted with Type B - Small FingerClusters Only.Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AStep 4: Installing the Trip Unit AssemblyA. Mount the Trip Unit Mounting Brackets to theInsulation Barrier as shown, using the(4) .190-32 .500" screws, (8) flat washers,(4) lock washers, and (4) nuts supplied. Notethat the two (2) small holes must be positionedto the top right.RetainerSensorSaddleSpacersB. Remove the top center screws securing thePhase 1 and Phase 3 Arc Chutes.Right Sideof BreakerH. Slide a Retainer on each Breaker Stab. TheRetainers should be positioned as close to theBreaker Back Plate as possible.I.Install a pair of Sensor Spacers on either sideof the Breaker Stabs. While sandwiching theStabs between each pair of Spacers, securethe Sensor Spacers to each other using the(6) .190-32 1.25" bolts, (12) flat washers,(6) lock washers, and (6) nuts supplied.J. Install a Sensor on each Breaker Stab. TheSensors must be installed with the terminals onthe bottom and facing away from the BreakerBack Plate.K. Reinstall the Finger Clusters using the originalmounting hardware.L. Slide the sensors and saddle spacers towardthe finger clusters. Slide the Retainer along thestabs until they are flush with the rear of thespacers. Secure by tightening the Retainerhardware.6EATON CORPORATION www.eaton.comC. Mount the Insulation Barrier Assembly by aligning the Barrier with the holes in the Phase 1and Phase 3 Arc Chutes. Secure the Barrierusing the original hardware or the (2) .250-20 1.00" bolts, (2) lock washers, and (2) flatwashers supplied.
Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AD. Mount the Trip Unit to the Insulation BarrierAssembly as shown. Secure using the(2) .190-32 4.00" screws, (4) flat washers,(2) lock washers, and (2) nuts supplied. Notethat the screws are inserted from the bottomof the Trip Unit. The extra length of the Trip Unitmounting screws can be cut off to preventinterference with any part of the Breakeror Cell.Instruction Leaflet IL 33-A5C-2Effective July 2010For Kits Supplied with a PT Module Only.Step 6: Mounting the PT Module to theDTA AssemblyA. Mount the PT Module Mounting Bracket tothe DTA Assembly as shown, using the(2) .190-32 .500" screws, (4) flat washers,(2) lock washers, and (2) nuts supplied.E. Remove the Trip Unit Cover and install theRating Plug supplied with the Retrofit Kit.Reinstall the Cover.F. Install the Digitrip Nameplate on the top ofthe Trip Unit.Step 5: Mounting the Trip Finger Assembly tothe Breaker Trip BarA. Mount the Trip Finger Assembly to the BreakerTrip Bar as shown. Secure the Trip FingerAssembly to the Breaker Trip Bar with the(2) .250-20 .750" bolts, (2) lock washers, and(2) flat washers supplied.B. Mount the PT Module and Insulation Barrier tothe Mounting Bracket as shown. Secure usingthe (2) .138-32 .500" flat head screws,(2) flat washers, (2) lock washers, and (2) nutssupplied. Note that the screws are insertedthrough the Mounting Bracket first, thenthrough the Insulation Barrier and PT Module.C. Install the supplied Warning Label as shown.EATON CORPORATION www.eaton.com7
Instruction Leaflet IL 33-A5C-2Effective July 2010Step 7: Installing the DTA AssemblyA. Remove the hardware securing the bottomright Breaker Foot to the Breaker Back Plate.NOTE: When the Breaker Foot is removed,the stability of the Breaker is reduced. Careshould be taken that the Breaker does not“tip” forward.B. Insert the original bolts through the DTAAssembly and then through the Breaker Footand Breaker Back Plate. Align, then insert boltsthrough the holes in the Breaker Back Plate.Secure using the original washers and nuts.8EATON CORPORATION www.eaton.comDigitrip Retrofit System for theAllis-Chalmers G-50/ G-50AStep 8: Installing the Aux. CT ModuleA. Remove the two (2) screws from each side ofthe Aux. CT Module. Attach the Side MountingBrackets to the Aux. CT Module as shown,using the original screws.B. Remove the two (2) screws from the rear ofthe Aux. CT Module. Secure the RearMounting Bracket to the Aux. CT Moduleusing the screws just removed and the(2) .190-16 .500" thread cutting screws,(2) lock washers, and (2) flat washers supplied.C. Mount the Aux. CT Module Assembly tothe Insulation Barrier as shown using the(4) .190-32 .625" nylon screws, (4) flatwashers, (4) lock washers, and (4) steelnuts supplied.
Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AD. Remove the hardware that secures the rightLifting Hook to the Breaker Back Plate.E. Insert the original bolts through the Lifting Hookand then through the Aux. CT Module RearMounting Bracket and Breaker Back Plate asshown. Use the original hardware to secure theLifting Hook and Aux. CT Module Assembly tothe Breaker Back Plate.NOTE: Do not tighten the bolts at this time.F. Position the Aux. CT Module Assembly ontop of the DTA Assembly as shown. Alignthe holes then secure the Aux. CT ModuleAssembly to the DTA Assembly using the(2) .190-16 .500" thread cutting screws,(2) lock washers, and (2) flat washers supplied.NOTE: The DTA Assembly “L” Bracket isslotted. If necessary the screws can beloosened and the Bracket moved to allowproper fit.G. Tighten the self-taping screws and Lifting Hookhardware to secure the Aux. CT Module.Instruction Leaflet IL 33-A5C-2Effective July 2010Step 9: Installing the Reset Arm AssemblyNOTE: It may be necessary to move theBreaker Handle slightly towards the Closedposition to allow adequate access to the boltsin the Breaker Crossbar during removal andinstallation of the Reset Arm Assembly.A. For Kits Equipped with a Shunt Trip OptionOnly. The bolts at the right end of the BreakerCrossbar secure the Shunt Trip Arm to theCrossbar. Before removing the Shunt TripArm, measure and note the gap between theadjusting screw on the Arm and the Shunt Trip.Remove and discard the Shunt Trip Arm, butsave the mounting hardware.B. For Kits Not Equipped with a Shunt Trip Option.Remove and save the hardware from the rightend of the Breaker Crossbar.C. Mount the Reset Arm Assembly to the BreakerCrossbar by aligning the holes then securingthe Reset Arm using all the original hardwareexcept two (2) flat washers which should bediscarded.EATON CORPORATION www.eaton.com9
Instruction Leaflet IL 33-A5C-2Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AEffective July 2010D. With the Breaker in the Open position, checkthat the gap between the nut and the surface ofthe Reset Arm Assembly. It should be 0.125".F. Apply Loc-Tite 242 to the threads of the DTAShaft. With the Breaker in the Open position,adjust the Flange nut to achieve a 0.06" gapbetween the Flange nut and the Trip Finger.If the gap is not correct, apply Loc-Tite 242 tothe threads of the Reset Shaft under the pivotarm and then turn the inner adjustment nut(dotted line drawing denotes the inner adjustment nut) until the correct gap is achieved.GAPGAPG. Connect a 24V DC power supply to the DTAterminals: positive ( ) to positive and negative(-) to negative. Close the Breaker manually.Energize the DTA to trip the Breaker:de-energize when the Breaker trips. Repeat theprocedure several times to insure that the tripand reset functions are working properly.E. For Kits Equipped with a Shunt Trip Only.Loosen the lock nut and turn the Shunt Tripadjusting screw on the new Reset ArmAssembly until the original gap is achieved.Tighten the lock nut.NOTE: If a Shunt Trip option was not installedon the Breaker, the Shunt Trip adjusting screwshould be removed from the Reset ArmAssembly and scrapped.10EATON CORPORATION www.eaton.com
Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AFor Kits Supplied with an Auxiliary Switch Only.Instruction Leaflet IL 33-A5C-2Effective July 2010Step 11: Connecting the Wiring and HarnessesStep 10: Installing the Aux. SwitchA. Cut 3.00" off the Microswitch Arm.B. Mount the Microswitch to the DTA Assembly asshown using the (2) .138-32 1.00" screws,(4) flat washers, (2) lock washers, and (2) nutssupplied.NOTE: If needed, adjust the microswitch bybending the arm to ensure that it opens andcloses properly with the Breaker.A. Route the DTA Wires up along the left side ofthe DTA Assembly to the Aux. CT Module.Connect the “ ” DTA Wire to the “OP” terminalon the Aux. CT Module and the unmarked wireto the “ON” terminal. Fold any excess length ofthe DTA Wires and secure using the nylon wireties provided. Tuck the excess in against the leftside of the DTA Assembly.B. For Kits Supplied with a PT Module Only.Route the PT Wires along the bottom of theBreaker towards the location of the originalElectromechanical Trip Units. Route them sothat they are clear of all moving parts withinthe Breaker.The PT Wires are marked for connectionto Phases 1, 2, and 3 with correspondingnumbers.Route the PT Wires to a position suitable forattachment to the proper Phase Frame. Movethe PT Wire markers to a position where theywill still be attached to the wires after cutting.Cut the wires to length, strip each wire 0.250",and install the correct size ring terminal forthe bolt used for the connection.EATON CORPORATION www.eaton.com11
Instruction Leaflet IL 33-A5C-2Effective July 2010Connect each PT Wire to its correspondingPhase Frame by using one (1) of the originalElectromechanical Trip Unit mounting screwssaved in Step 2.Digitrip Retrofit System for theAllis-Chalmers G-50/ G-50AD. Connect the ring terminals of the SensorHarness to the Sensors. Refer to Section 12 ofthe Retrofit Application Data, supplied with theRetrofit Kit, for detailed wiring specifications.For Kits Supplied with a PT Module Only.Refer to Section 7-3, Power Flow Convention ofthe Retrofit Applica
Allis-Chalmers G-50/ G-50A Instruction Leaflet IL 33-A5C-2 Effective July 2010 Step 1: General Breaker Preparation Before attempting to remove the Breaker from the Cell or perform any Retrofit operation, be sure to read and understand the Safety Precautions section of this manual. In addition, be sure to read
Cutler-Hammer Digitrip Retrofit Kits are available in a number of configurations that provide a wide range of features. The Digitrip System starts with the 510 Basic Kit which offers true RMS sensing, overcurrent protection, and self-testing features. Advanced Digitrip Retrofit Kits feature zone interlocking, digital alphanumeric displays, remote
Cutler-Hammer Digitrip Retrofit Kits are available in a number of configurations that provide a wide range of features. The Digitrip System starts with the 510 Basic Kit which offers true RMS sensing, overcurrent protection, and self-testing features. Advanced Digitrip Retrofit Kits feature zone interlocking, digital alphanumeric displays, remote
Cutler-Hammer Digitrip Retrofit Kits are available in a number of configurations that provide a wide range of features. The Digitrip System starts with the 510 Basic Kit which offers true RMS sensing, overcurrent protection, and self-testing features. Advanced Digitrip Retrofit Kits feature zone interlocking, digital alphanumeric displays, remote
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Cutler-Hammer Digitrip Retrofit Kits are available in a number of configurations that provide a wide range of features. The Digitrip System starts with the 510 Basic Kit which offers true RMS sensing, overcurrent protection, and self-testing features. Advanced Digitrip Retrofit Kits feature zone interlocking, digital alphanumeric displays, remote
trip Unit 1.1 Basic Digitrip RMS 610 Trip Unit The Digitrip RMS 610, illustrated in Figure 1, is a Trip Unit suitable for use in types DS and DSL Low-Voltage AC power circuit breakers and type SPB Systems Pow-R circuit breakers and Series C R-Frame molded case circuit breakers . The Digitrip RMS 610
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