molded case circuit breakers A www. ElectricalPartManuals. com mastering electrical power MERLIN GERIN

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1 molded case circuit breakers 4-6A mastering electrical power

2 table of contents molded case circuit breaker introduction standard compliance ratings interrupting ratings advantages description current limiting circuit breakers lp and Ft curves trip units thermal-magnetic solid state mini test kit time current curves accessories. terminals location shunt trip undervoltage trip device auxiliary and alarm switches overcurrent trip switch motor operator rotary operating handle padlock adaptater door escutcheon label holder boot wiring diagrams main connections front connection rear connection plug-in mounting molded case switch dimensions appendix routine maintenance guidelines UL 489 test procedures international standards page ,

3 introduction, description standard compliance CJ circuit breakers are built in accordance with Underwriters Laboratories standard UL 489. The circuit breaker and its accessories, except when noted, are listed under UL files E782, E782, E7822, E635 and E374. additional tests in addition to standard tests, CJ circuit breakers meet UL standard 489 optional requirements (high available fault current). compliance with international standards Compact CJ has been designed to comply also with the international standard EC 57- as well as with the major standards : british BS 4752, german VDE 66, french NF C63-2, australian AS 284. Compact circuit breakers have been approved for marine application by American Bureau of Shipping, Bureau Veritas, Lloyd's Register of Shipping, Registro taliano Navale, Germanische Lloyd's and Det Norske Veritas. description three-pole high strength glass polyester casing 2 front accessory cover (accessory terminals located on left and right hand side behind this cover) 3 quick-make/quick break mechanism 4 handle with three positions : ON-TRPPED-OFF 5 shunt trip or undervoltage trip devices 6 auxiliary and alarm switches 7 rotary operating handle 8 motor operator 9 test receptacle is provided on each trip unit for use with the mini test kit in addition, the push to trip button can achieve a mechanical checking. rotary switches adjust continuously the protection to the requirments of the distribution system solid state trip unit containing three parts : current sensors, solid state logic unit and flux-transfer device) 2 the rating plug sets the maximum ampere rating of the circuit breaker. Rejection keying assures that the plug is used with the proper circuit breaker. When the plug is not installed, the current setting automaticaly returns to its minimum value. 3 plug-in disconnecting interlock 4 plug-in assembly 2 interrupting ratings Compact circuit breakers are listed for 3 levels of interrupting capabilities : 35, Amps at 48V for the standard breaker 42, Amps at 48V for the high interrupting breaker 5, Amps at 48V for the current limiting breaker. ratings Compact CJ are equipped with thermal-magnetic or solid state trip units. thermal-magnetic : CJ4 rating: A CJ6 rating: A solid state : Rating plugs are provided to set the maximum current setting at a value equal or lower than the basic breaker selected. CJ4 plug: A CJ6 plug: A CJ type 3-pole 6V AC standard breakers CJ 4N CJ 6N UL listed nterrupting ratings RMS Sym. Amps 24V 48V 6V 65, 65, high nterrupting breakers 35, 35, CJ 4H, 42, CJ 6H, 42, current limiting breakers 4, 4, 8, 8, CJ 4L 5, 5, 65, motor circuit protectors CJ 4HC, 42, CJ 6HC, 42, CJ 4LC 5, 5, 8, 8, 65,

4 advantages reinforced insulation Two insulation barriers separate the front face of the circuit breaker from the main contacts. This reinforced insulation allows safe operation and installation of the electrical auxiliaries. The compartment in which they are installed is independant from the compartment of the main contacts. ) integral partioning Once the front cover has been removed, to give access to the auxiliary compartments, the main circuits remain fully insulated. Furthermore, interphase partitioning allows full insulation between each pole even if the front cover has been removed. built-in terminal blocks are provided with the accessories. Consequently, intermediate terminals are not required for the connection of control wiring. They are located behind a front accessory cover. Removing this cover gives no access to direct access to live parts. nternal accessories are UL listed and are field installable. isolation function The operating handle is representative of the position of the main contacts. The OFF position can be reached only when the main contacts are fully opened. The handle will reach the OFF position only if the pin A can be engaged into the slot B of the operating mechanism. n case of unbreakable welding of any main contact due to non correct application of the circuit breaker, the mechanism will bump on this pin. field interchangeable rating plug All solid state trip units have a field installable rating plug located on the front face. The interchangeability makes rating changes simple. To avoid inadvertent errors, frames and rating plugs are keyed together and are not interchangeable with CK 2 frame rating plugs and circuit breaker. plug-in disconnecting interlock As a safety feature, in the event of disconnecting a closed breaker, a mechanical interlock will trip the breaker before the separation of the main disconnects. 3

5 description current limiting circuit breakers A series association of the basic circuit breaker and of a.current limiting compartment equipped with an original system enables outstanding performances to be obtained : very hig" interrupting capability specialization of the devices according to the current to be interrupted : r-lf contact repulsion Electrodynamic forces are generated by the current flowing in parallel conductors band c. The moving contact is blown-apart by those repulsive forces, which are created by a short circuit. 4 D the basic circuit breaker interrupts currents of up to 6, Amps Dover 6, Amps, both devices operate simultaneously. This mutual assistance noticeably reduces contact wear. These performances are obtained by combination of the following techniques in the current limiting block : contact repulsion enhancement of induced magnetic field arc quenching. a b c contact and tripping coordination By means of calibrated U-shaped circuit, inertia and spring force, full opening of basic circuit breaker is ensured by tripping before reclosing of current limiting unit contacts arms. arc quenching due to the design and materials of the arc chute, a magnetic force F draws the arc into the V-shaped plates. t is then split and cooled until extinction. The combined effect of these three forces, together with the double break in series, allow very rapid interruption of any fault current.

6 ' description lp and Ft curves The limitation capability of a circuit breaker is that characteristic whereby only a current less than the prospective fault current is allowed to flow under short-circuit conditions. This is illustrated by limitation curves which give : th limited peak let-through current in relation to the RMS sym. value of the prospective short-circuit current (the short-circuit current that would flow continuously in the absence of protective equipment) ; the limited let-through energy (thermal stress) in relation to the RMS sym. value of the prospective short-c ircuit current. lsc prospective lsc peak , / ' \ respective lsc \ _L \ l limited lsc \ \ \ nstallation of current limiting circuit breakers offers several advantages : better protection Current limiting circuit breakers considerably reduce the undesirable effects of short-circuit currents in an installation. reduced mechanical effects Electrodynamic forces are reduced, thus electrical contac ts are less likely to be deformed or broken. reduced electromagnetic effects Measuring equipment situated near an electrical circuit is less affected D Ll ' l y 5 6 ' max prospective peak current J.. Jl J J. ' ' :...- ;...- A"' (J 9..l j---- b: oov lit ' V prospective short circuit current {ka RMS sym) -- f-±±± R=-rf m r=- t-- -+T t:--+-- '-""FH h- r-t fh t- 8 -j-t t-:- +- tt- t"-. - j=r f--;-2: f--+---; "Jtt -+- t--:- Hfi.:-=...;::::-f+t-' JT. E.....t..i:8f --j- -t--' r--; tr r-r- pro spective energy 3 2 =t::" r r=r!-- -= 5,=:l:.iJ _-:--...: t h----r- H...,.- J...L' t-:--::!.. t-:-f-= t-:- rh et'fi' :::E:E::t: =:R t=.::.. = ::r: F#-f t::? J jf=h"f - = _:- --+ ::; ' ' '-+ : _F f+i-+ =::±: r--...:... f--=-t :$:; R=- W JTt j---..j 5--..,..., --;- ' j t rf :--!... ±:- - :;::j:....,--, -;-- J----'-+-t- +--;-t --:-; +!-+- f.l : h r- ' -;--- f--- = ::= '- - :...J::i::' E= n= Lt.. ' ',FP=tf {/2 cycle) t- h:-t H.,-+. -r-ri- f±- :- f=: +=:-Jc':f,+tf. -=±-= t--l -, t- lr -, -=!; :-r, r-;-f+=, 2 2 ' o' ' r ' o' r-, - +, 7l!!'+-= 2_6V...,. BOV:-- p r-'- + r-- r-r t-' ti,... H -h--+- hi!eilif f-:j- -= :.. r--,= r-r- -t- - '-H ::.=r- H-ftf+ -+-J-:--+ H.. -j-- j--ct- -t-f-lf-f+l '+ J----t Hi o ' :t+h: o prospective short circuit current {ka RMS sym)

7 trip units thermal-magnetic trip unit instantaneous trip unit for motor circuit protectors nstantaneous trip circuit breakers are similar to standard circuit breakers except that they do not provide overload protection. The magnetic trip has a single adjustement for all three poles. They are equipped with a push to trip. 6 ampere rating (A) CJ CJ magnetic settings low high time current curve : page 9 type CJ 4HC, CJ 4LC CJ 6HC ampere magnetic rating (A) settings (A) time current curve : page 2 thermal-magnetic trip unit

8 trip units ST 4 rating plug 2 magnetic pickup 3 test receptacle time time current curve : page ST 24S rating plug 2 long time current setting 3 short time pickup 4 test receptacle time magnetic setting long time setting time current curve : page current current ST 4... rating plug for: CJ GOON CJ 6H push to trip solid state trip unit magnetic overcurrent protection rating plug breaker current sensor plug rat ing CJ 4 4A A CJ 6 6A A magnetic pickup 2.5 to x current setting CD test rece p tacle for overcurrent testing <D override pickup : CJ4 at 4SOOA, CJ6 at 66A ST 245 for: CJ SOON CJ 6H push to trip long time ",(i}: pickup short time fi)m,ij). ='-"'9'---f-' 6. 3 current setting = lr pickup 2 3 test overcurrent protection rating plug breaker current sensor plug rat ing CJ 4 4A A CJ 6 6A A long time current setting.8 to x plug rating short time pickup 2.5 to x current setting in stantan eous CJ 4 override at 48A CJ 6 override at 66A test receptacle for overcurrent testing 7 test - + 4

9 trip units mini test kit Every trip unit is equipped with a test receptacle that can be used with a small mini test kit (battery operated). The same mini test kit can be used on CJ, CK and MP type breakers. Operations performed by this kit are only functional tests designed to electrically test the operating integrity of the trip unit, the flux transfer device and the mechanical operation of the breaker. They are not designed to calibrate the breaker. Calibration can best be done at the factory. batteries The mini test kit requires five 9 volt batteries. Alkaline batteries are recommended. dimensions : 5 2 x 3 x 2 catalog number mini test kit test procedure battery check prior to testing : press the push button, tests leads not connected, the green light should tum ON. f not, remove the test kit rear cover and check the batteries. testing : operate on "OFF load" conditions 2 record the short time or instantaneous pickup setting and set the trip unit to the minimum setting 3 close the circuit breaker 4 connect test leads into trip unit test receptacle, observing the +- markings 5 press the test kit push button, the circuit breaker will trip 6 return to initial setting.

10 .. time current curves 25 to 6 Amp \ \ \ \ \ \ \ \ ' ' != instantaneous pickup setting : 5 ' sosor i'i: ampere rating (A) CJ CJ breaker type CJ 4N CJ 4H CJ 4L CJ GOON CJ 6H +- lm = 5 to x continuous current rating ""' 2 3 4o sosor&sgg l netic settings (A) low high nterrupting ratings RMS symmetrical Amps 24V 48V 6V 65, 35, 4,, 42, 8, 5, 5, 65, 65, 35, 4,, 42, 8, multipleolcurrentsettlng (lr)

11 time current curves ST 4 trip unit.., ::. " E "' s s 7 a so current setting : \ ' \ '\ lr plug rating ' m'll gnetic : \ r sosor 8. - lm: 2.5 to x current setting (lr) breaker type CJ 4N CJ 4H CJ 4L CJ 6N CJ 6H breaker type CJ 4N CJ 4H CJ 4L CJ 6N CJ 6H override fixed at : CJ 6N-CJ 6H : 66A CJ 4N-CJ 4H-CJ 4L : 48A current sensor rating plug (A) 4A 2, 225, 25 3, 35, 4 6A 3, 35, 4 5,6 nterrupting ratings RMS symmetrical Amps 24V 65,, 5, 65,, 48V 35, 42, 5, 35, 42, 6V 4, 8, 65, 4, 8, g --- multipleolcurrentsetting (lr)

12 time current curves ST 245 trip unit,.. t: BOO ' current setting : - lr.8 to x plug rating (n) \ \ \ ' "' " \ \ so so Rgg;=. 2.5 short time pickup : \ ' ' lm = 2.5 to x current setting (lr).s.s.7.a.9.2.s sosora3$ ---- multiple of current setting (lr) ---- breaker type CJ 4N CJ 4H CJ 4L CJ 6N CJ 6H breaker type CJ 4N CJ 4H CJ 4L CJ 6N CJ 6H current sensor rating plug (A) 4A 2, 225, 25 3, 35, 4 6A 3, 35, 4 5,6 nterrupting ratings RMS symmetrical Amps 24V 48V 6V 65, 35, 4,, 42, 8, 5, 5, 65, 65, 35, 4,, 42, 8, instantaneous : CJ 6N-CJ 6H : 66A CJ 4N-CJ 4H-CJ 4L : 48A :2:$ amperes x

13 time current curves instantaneous trip for motor circuit protectors 4 and 6 Amp s s 7 a so sosorgga 2 breaker ampere interrupting ratings type rating (A) RMS symmetrical Amps 24V 48V 6V CJ 4HC 4, 42, 8, CJ 4LC 4 5, 5, 65, CJ 6HC 6, 42, 8, instantaneous pickup : CJ 6HC : 3A to 6A CJ 4HC, CJ 4LC : 2A to 4A \ thermal withstand ooo fe g Rgg multiple of current setting (lr)

14 accessories nternal accessories comply with requirements of Underwriters Laboratories Standard UL 489. Most of them as noted are listed for field installation per UL file E 782. accessories nstallation shunt trip field installable undervoltage trip field installable 2 auxiliary switches field installable aux. + alarm switches field installable 3 aux. + alarm switches field installable motor operator field installable overcurrent trip switch factory mounted terminals internal accessory terminals ar e standard and located within the breaker, beh ind the accessory cover. Each terminal may be connected by one or two stranded copper wires 8 to 4 AWG. Tightening torque : 2 lb. in. Cable strip length : 3/8" approximate. Caution: open circuit breaker and disconnect control power before removing the front accessory cover. location shunt tr ip or undervoltage tr ip terminals 3

15 accessories shunt trip The shunt trip is intermitentfy rated with a series normally open contact. AC shunt trips can be operated at 55 percent of their rated voltage, making them suitable for use with fault protection devices. minimum operating voltage : AC : 55 % of rated voltage DC : 75 % of rated voltage during 5 ms max. undervoltage trip device Undervoltage trip devices may be used as circuit interlocks. f an undervoltage condition exists, operation of the closing mechanism of the circuit breaker will not perm it the main contacts to touch, even momentarily. dropout : 35-7 % of rated voltage pickup : 85 % of rated voltage auxiliary and alarm switches Auxiliary switches consist of SPOT switches and provide remote information of the breaker status. Alarm switch provides alarm/lockout information. When the breaker is reset, the "a" contact (alarm) is open, and the" b" contact (lockout) is closed. This SPOT swi tc h is operated when the breaker is tr ipped by the trip unit, shunt trip, undervoltage trip device or "push-to-trip" button. 2 auxiliary switches (6V) cat. no aux. + alarm switch (6V) cat. no aux. + alarm switch (24V) cat. no overcurrent trip switch The auxiliary switch consists of a SPOT contact. The "b" contact open when the breaker operates through the trip unit (overcurrent or ground fault). t does not operate if tr ipping is by shunt trip, undervoltage tr ip device or push-to-trip button. This contact is used as interlock when resetting of the breaker is done remotely or automatically by means of a motor operator. catalog number voltage (V) 5/6 Hz DC control voltage - -- ' lltrip f = (l) control voltage t_trtp f button control voltage --, toff ton lock alarm : , b reset } auxiliary terminal block on motor operator shunt trip undervoltage trip device auxiliary and alarm switches overcurrent trip switch rated nrush cat. no. voltage (\{} current (A) 6 Hz DC rated sealed-in cat. no. voltage (V) current (A) 6 Hz DC control voltage --, totf ton lock talarm Q Q--- o t h ; a a b fa 5b a --, r--< L >--- --> auxiliary + alarm 3 auxiliary + alarm auxiliary alarm auxiliary alarm voltage 56 Hz DC note: not available on m.c.s current (A) 24V 6 25V.3

16 accessories motor operator The motor operator remotely operates the circuit breaker and provides a handle to manually operate it as well. ON, TRPPED and OFF positions are clearly indicated by the operating handle. Provision for padlocking is provided as standard to lock the toggle in the OFF position. When locked manual or remote closing is impossible. nterlock switches electrically disconnect the motor operator when the front transparent cover is open for local operation or padlocking and when the complete mechanism is opened for connecting internal accessories (shunt tr ip, undervoltage trip device, auxiliary switches or the motor operator) Under fault conditions the operating handle will indicate the tripped position of the breaker. Depending on the wiring, resetting can be done locally, remotely or automatically (see wir ing diagrams). note : when using an overcurrent tr ip switch (cat. no. 3743), automatic resetting is not possible after an overcurrent, i.e. short circuit or overload, but possible af ter a voluntar y tr ipping, local or remote. (field installable) voltage catalog number (V) standard synchronizing AC DC G) caution :control diagram shall be designed to interlock remote on and off orders <2l overcurrent trip swrrch is recommended to lock remote resetting after an electrical faun Cl limrr switch CV locking switch, opens when : the breaker is manually operated the breaker is padlocked the motor operator is rocked CD built-in alarm swrrch, operates when breaker trips by an electrical fault or opening coils. CA self feeding switch CS electrical interlock switch delivered with automatic source changeover M motor standard scheme (manual resetting) -r--r--r--- f (j)f ff automatic resetting after tripping -r--r--r--r !j2n : (j)!j2 ff : llil 'Y motor overcurrent auxiliary operator trip switch ell switch motor operator rated nrush fuse voltage (V) current (A) amps (A) 5/6 Hz DC operating voltage : 85- % of rated voltage max. operation frequency: 2 per minute closing time : standard : 2 ms synchronizing : 6 ms (not UL listed) opening time : 5 ms minimum operating order: ms remote resetting during opening sequence '_' [ (j)fff '_ +reset motor operator overcurrent trip switch ell... remote resetting using a resetting push button -r--r--r--r!j2n: (j)!j2dj!eset ll 'Y motor operator overcurrent trip switch ell

17 rotary operating handle Two versions are available : directly mounted This handle is directly mounted on the circuit breaker. t accomodates as standard up to three padlocks to lock the handle in the OFF position. However, a knockout tab can be removed to al low the locking of the handle in the ON position. Due to the trip free mechanism padlocking in such a position will not prevent the circuit breaker from tripping under overcurrent conditions. The handle will continue to indicate ON. Padlock shackle diameter : /4 to 5/l6. note: A mechanical interlock (cat. no ) links two rotary handles and constitues a manual source changeover. This device is only available for direct rotary handles. Simultaneous closing of the two breakers is prevented but simultaeous opening is possible. The breakers are normally fixed on a panel or on rail s. door-mounted type The handle is removable and can be fitted on a door-mounted mechanism. A 6" long shaft extension is supplied and can be cut to a suitable length. A cutting and drill ing jig is provided. The mechanism has the same functions as the directly mounted type and provides door interlocking preventing the door from being opened when the breaker is closed. The handle mechanism can be used in NEMA 3R and 2 enclosure applications. padlock adaptator A padlock adaptator is available to padlock the circuit breaker in the OF F position. t is similar to the one used on CE,CF and CJ type. The adaptator accomodates up to 3 padlocks. Padlock shackle diameter : /4 to 5/ 6. catalog number J directly mounted type note : door interlock can be disabled or defeated by turning the defeating screw located on the front face. t accomodates as standard up to three padlocks to lock the handle in the OFF or door escutcheon A door escutcheon provides better appearance of the door cutout. t is fixed to the door with two screws. catalog number door-mounted type rotary operating handle padlock adaptator door escutcheon label holder boot Designed for use with the extended rotary handle, this bracket eliminates play of the shaft. t is supplied as standard with the long shaft and as an option with the short shaft. ON (by removing a knockout) position. Padlocking is possible only if the coupling of the extension shaft and the door mounted mechanism is correct. boot The boot provides a light seal when a breaker is used behind a panel or door with cutout. The square part fits over the breaker cover and the middle provides a rubber cover for the toggle, improving protection to NEMA 3R. catalog number label holder A label holder can be clipped onto the front cover. t permits an easy circuit breaker identification. t comes in pack of ten. catalog number 42976

18 wiring diagrams k a_ u _ x _n_ la_ s_w_ l t _c_h_es jj L r m _e o t _ e_o_ p _ e_r_a_u_o_ n auxiliary and shunt u ndervoltage overcurrent alarm switches trip or trip device trip switch r----'----,,----.l - --_L_- --r ----r------, T----r--r-r-r----- lock out on off :->-f T T, ; T T open. : : : / >' C2 i : : - clo ed -- ton r- : r r reset. 'Tiff-. f-j- '" ', - J-_+-t _t_ -_t- -r, 2 : +, 4 ;C <D see page 5 for other wiring diagrams not available on coil clearing switch note : contacts are shown with the breaker in the open and reset position. '" " y ) P (o Pflo <' ) : fi xe d m o un t ing n y c) D possible wire exits possible internal gutters C) shunt trip terminal C-C2 undervoltage trip terminal J )f2 4)tj 2-3 auxiliary+ alarm switch cat. no au xiliary switches : -2-4, , alarm switch au xiliary switches cat. no , auxiliary+ alarm switch cat. no auxiliary switch alarm switch knock-outs. Break only these required dipending of the desired direction of wiri ng. _K5l. auxiliary switch 222> aux.s J: arm sw p l ug-n m o un t ing CJ or shunt trip

19 main connections CJ circuit breakers may be connected with bu s bars or cables on both line and load sides. The type of connections should be specified when ordering. A field modification is possible to either mount or remove the pressure type terminals. Complete instructions are given with the set of pressure type terminals and in the installation instructions provided with the breaker. Caution : modification of terminals requires removing of a front terminal cover (line side only). When the modification s completed, this cover must be replaced. front connection 8 4 Amp. with bus bars CJ circuit breaker may be connected with copper or alu minium bu s bars. tightening The bu s bars shall be secured with the screws and Belleville washers provided. Tightening torque is 275 lb-in. 6 Amp. Pressure terminal can accomodate one or two cables. An intermediary binding screw is inserted between the two cables. The looseness between the two threads allows the screw to move axially. After a few months of installation, this looseness will allow the retightening of the two cables using only the upper binding screw. note: for voltages above 24V, insulation of bus bars may be required to meet spacings between phases required by the NEG. with cables Cables can be connected by pressure type terminals with a range of : 4 Amp. terminal : cable 2/ to 6 MCM Cu or cable 4/ to 5 MCM A 6 Amp. terminal : cable 2/ to 5 MCM Cu or to 2 cables 2/ to 35 MCM Cu or to 2 cables 4/ to 5 MCM A. The cable strip length is : 3/8" Screws shall be torqued at 375 lb. in. (3/8" allen wrench). caution : for reliable electrical contact, connectors are plated, do not abrase them. The connectors are secured on breaker by screws tightened at 275 lb. in. (5/ 6" allen wrench).

20 main connections rear connection Rear bus bar connections are used for switchboard mount ing. According to the rear connection mounting, they provide for vertical or horizontal connection. cat. no. for N and H type 3674 for L type 3675 plug-in mounting flat When the breaker is in the connected position, the primary voltage is fed through the breaker by means of multiple finger disconnects. As a safety feature, in the event of disconnecting a closed breaker, a mechanical interlock will trip the breaker before the separation of the main disconnects. UL listed under file E 635. secondary disconnects control voltage of internal accessories is provided through secondary disconnects in the connected position only. See page 7 for the number of secondary disconnects required. cat. no. moving block 3 wires wires fixed block 3 wires wires 4294 edgewise 9

21 Compact CJ switch construction CJ molded case switches are designed identically to CJ molded case circuit breakers, except that they are not equipped with trip unit. They are listed under UL file E7822. Caution : molded case switches do not provide overcurrent protection. Molded case switches can be protected by a CJ circuit breaker. 2 ratings max. rating when protected by Merlin Gerin CB's : CJ 6NA 6A CJ SOON CJ 6H suitable for use on a circuit (max. RMS sym. amps) CJ 4NA suitable for use on a circuit (max. RMS sym. amps) at 24V at 48V at 6V at 24V at 48V at 6V accessories The following accessories of the CJ circuit breaker may be used with the CJ molded case switch : 4A page shunt trip 4 undervoltage trip device 4 2 auxiliary switches 4 auxiliary + alarm switches 4 3 auxiliary + alarm switches 4 motor operator 5 rotary operating handle 6 padlock adaptor 6 door escutcheon 6 boot 6 label holder 6 65,, 35, 42, 4, 8, CJ 4N CJ 4H CJ 4L 65,, 5, 35, 42, 5, 4, 8, 65, dimensions-installationconnections Molded case switch dimensions, installation and connection are identical to those of the corresponding circuit breaker. See page 2 to 24.

22 dimensions inch mm...28, 32 5 i-2.7 -i-2.7 f. 52,5 52, (4) mounting 58 holes nota for fixed mounted-front connected c. b.'s omy : CJ GOON, CJ 6H equipped wtth rating plug or trip unit 5 or 6A, CJ 6HC and CJ 6NA are suitable for use in a minimum cubicle space of H4 by W6 by 6 inches (3 by 4 by 6 mm) wnh a minimum ventilation of 3 square inches (2 dm') both at top and bottom. with pressure terminals with rear connections Cutting and drilling for attachenient to panel front connection rear connection Door cutout handle CJ 4 - CJ 6 fixed mounting, front or rear connection.29 r. 7 t -- -$-. with rear connection j==l=: : 4 handle and nameplate dia ;: 2, 5 _.22 dia (4 holes) dia 6 for accesss to push to trip.9 2

23 dimensions inch mm CJ [] CJ (4) insert nuts _ -- for panel..,--,._ mounting (4) holes for rail mounting f ! jj , Cutting and drilling for attachement on rails to panel Door dia CJ 4 - CJ 6 plug-in mounting l-35, ,5- (4 holes).63 ' 6 " 4,5.5 dia handle and nameplate :.. \ r---'... _.., r -.. '\ t

24 dimensions inch mm with pressure terminals with rear connections t== o CJ 4L fixed mounting, front or rear connection with rear connections Cutting and drilling for attachement to panel front connection rear connection handle and nameplate.25 dia 6 tor accesss to push to trip dia 2,5 ;. 5 23

25 dimensions inch / mm ,5 + CJ D c=j (4) insert nuts _ for panel..,-_ mounting (4) holes for rail mounting.49 dia 2,5-6.8, 73 -o , Cutting and drilling for attachement on rails to panel Door dia (4 holes) _ CJ 4L plug-in mounting J 87 handle and nameplate 24.5 dia

26 appendix recommended inspection intervals Merlin Gerin circuit breakers are designed to be maintenance-free. However, all equipment with moving parts requires periodic inspection to ensure optimum performance and reliability. We recommend that the circuit breakers be routinely inspected six months after installation, followed by annual inspection. ntervals can vary depending on your particular experience. inspection of terminals Connections to circuit breaker terminals could be inspected. f there is discoloration due to overheating, the joint should be dissassembled and the surface cleaned before reinstallation. t is essential that electrical connections be made carefully in order to prevent overheating. Check for terminal tightness. cleaning Remove the dust and dirt that have accumulated on the circuit breaker surface and terminals. mechanical checks Even over long periods circuit breakers are not often required to operate on overload or short-circuit conditions. Therefore it is essential to operate the breaker periodically. To trip the breaker, push the push-totrip button. insulation resistance tests When breakers are subjected to severe operating conditions, insulation resistance test should be performed as indicated in NEMA standard publication no AB2-98. An insulation resistance test is used to determine the quality of the insulation between phases and phase to ground. The resistance test is made with a DC voltage higher than the rated voltage, to determine the actual resistance of the insulation. The most common method employs a "megger" type instrument. A V instrument will provide a more reliable test because it is capable of detecting tracking on insulated surfaces. Resistance values below megohm are unsafe and should be investigated. An insulation test should be made : between line and load terminals of individual poles with the circuit breaker contacts open. between adjacent poles and from poles to the metallic supporting structure with the circuit breaker contacts closed. The latter test may be done with the circuit breaker in place after the line and load conductors have been removed, or with the circuit breaker bolted to a metallic base which simulates the in-service mounting. electrical tests These tests require equipment for conducting pole resistance, overcurrent and instantaneous tripping, in accordance with NEMA standard publication no AB2. They are not within the scope of normal field operation. routine and maintenance guidelines mportant All tests must be made on circuit breakers which have been de-energized, and disconnected so as to prevent accidental contact with live parts. Caution Since molded case circuit breakers contain factory-sealed and calibrated elements, it is essential that the seal be not broken and the circuit breaker be not tampered with. Molded-case circuit breakers should not be field adjusted or repaired. n the case of malfunction, the circuit breaker should be replaced or repaired at the Merlin Gerin factory, or by an authorized representative. 25

27 appendix standard tests For solid state trip breaker, and uncompensated thermal breaker rated 4 C, the test sequences are : standard specifications 2% calibration at 25 C The breaker must trip within time limits which depend on the rating from 3 minutes for a 3A rated breaker, up to 3 minutes over 2A. 35% calibration at 25 C The breaker must trip within two hours (for breakers rated more than 5 A). Calibration of adjustable instantaneous trip The breaker must trip within the range of 8-2% of the maximum marked tripping current and 75-25% of the minimum marked tripping current. Overload up to 6A : fifty operations at 6% of rated current 2 and 25A : twenty-five operations at 6 % of rated current 3 to 6A : three operations at 6% followed by twenty-five operations at 2 % of rated current. The power factor shall be from.45 to.5 lagging. 26 test 2% calibration at 25 C (77 F) 35% calibration at 25 C (77 F) calibration of adjust instant trip overload tungsten lamp load % calibration at 4 C (4 F) temperature and % calibration at 25 C (77 F) endurance 2% calibration at 25 C (77 F) repeated 35% calibration at 25 C (77 F) repeated interrupting ability (Y sequence) interrupting abili!l (Z sequence) 2% trip out at 25 C (77 F) dielectric voltage withstand <D Applies only for breakersrated 55 A or less. t 25 or 2525V or less Applies only for thermal breakers rated 4o c. Temperature When connected with specified cables or bus bars (see below) and with its rated current, the temperature rises on the breaker and at its terminals does not exceed specified limits. Examples of specified wires and bus "?soc copper wire rating number size OOA..:....:._.:...:..:... Wc Gc...:..:: (..=. 6.:... o-=c_,_) or 3AWG 25A 25 MCM 4A 2 3/ AWG 6A 2 35 MCM 8A 3 3 MCM A 3 4 MCM 2A 4 35 MCM copper bus bar rating number size 6A 2 /4 X 3 2A 2 /4 X 4 25A 2 /4 X 5 or 4 /4 X 2 3A 4 /4 X 4 (2A or less : OOOA in2) UL 489 test procedures (abstract from UL 489 with revisions through April 6th, 987) sequence X y z D D D D D <D D D D D D D D D D D D D D Endurance The breaker must complete an endurance test : operations at rated current and rated voltage followed by no load operation. The power factor shall be.75 to.8 lagging. Examples: frame size A 225A 4A 6A 8A 2A 6A 2A 25A 3A number of cycles of operations with without total current current 6, 4,, 4, 4, 8,, 5, 6,, 5, 6, 5 3, 3,5 5 2, 2,5 5 2, 2,5 5 2, 2,5 5 2, 2,5 4 ',5

28 appendix nterrupting ability (Y sequence) After endurance tests and calibrations repeated, the breaker completes an. opening followed by a close-open operation (-t-co), with specified current. Examples for three pole breakers : frame rating RMS Sym. Amps (3-pole -t-co) A <D 3, 225A 3, 4A 5, 6A 6, 8A, 2A 4, 6A 2, 2A 25, 3A 35, <D Above 25V. nterrupting ability (Z sequence) A 3-pole breaker rated 24, 48 or 6V have to complete an opening operation and a close-open operation (-t-co) on each pole, at rated voltage, followed by an opening operation () using all the three poles for the frame sizes up to 2A, an additional close-open operation on the three poles is required). Examples for three pole breaker : frame rating RMS Sym. Amps each common pole -t-co -t-co to 8A 8,66, to 2A 2,2 4, 6A 4, 2, 2A 4, 25, 3A 25, 35, Dielectric After tests, the breaker must withstand for one minute a voltage of OOOV plus twice the rated voltage between : line and load terminals terminals of opposite polarity live parts and the overall enclosure. Optional tests : high available fault current Breakers having passed all the standard tests may have the UL label applied at higher values than the standard. Test sequence is as follow : o 2 % calibration o interrupting capacity : an opening operation followed by a close open operation (-t-co) on all poles are performed on the circuit breaker. The power factor over 2A shall be.5 to.2 lagging. o trip out at 25% o dielectric at twice the rated test voltage. % rated Breakers having passed all the standard tests may have the UL label applied to use the circuit breaker in an enclosure, when carrying % of its maxim m rating... The circuit breaker is submitted to addtonal temperature tests performed as in Standard tests, except that the breaker is installe in an enclosure. The dimensions and possble ventilations shall be recorded and shall be marked on the breaker. UL 489 test procedures (abstract from UL 489 with revisions through April 6th, 987) tests on accessories Shunt trip and undervoltage trip These devices are submitted to temperature, overvoltage, operation, endurance and dielectric tests. Overvoltage test t checks that the device is capable of withstanding % of its rated voltage continuously without injury (this test does not apply to a shunt trip with an "a" contact connected in series). Operation The shunt trip must operate at 75% of its rated voltage (except that shunt trip devices for use with ground fault protection shall operate at 55%). The undervoltage trip must trip the breaker when the voltage is between 35 and 7% of its rated voltage and shall seal (i.e.: the breaker cannot be turned on ON position) when the voltage is at 85% or more of its rated voltag e. Endurance The device must be capable of performing successfully for % of the number of "with current" operations of the breaker. Auxiliary and alarm switches Auxiliary and alarm switches must be submitted to temperature, overload, endurance and dielectric tests. Overload test The test consists of fifty operations making and breaking 5% of rated current at rated voltage, with a 75-8% power factor in AC and non inuductive load in DC. Endurance The switch must make and break its rated current at rated voltage, with a 75-8% power factor in AC, and non inductive load in DC for % of the number of operations "with current" for auxiliary switches, and % of this number for alarm switches. 27

29 international standards molded case circuit breaker n addition to UL 489 standard CJ breakers comply with EC 57- standard as per table below : CJ type ampere interru,pting ratings 3-pole rating (A)! RMS Sym. Amps 24V 48V 6V 24V 45V 66V U L i-cs te-cd = :-::: --= , _ E _ C 5 _ 7 standard breakers CJ 4N 4 65, 35, 4,. 85, 35,, CJ GOON 6 65, 35, 4, 85, 35,, high nterrupting breakers CJ 4H 4, 42, 8, 85, 5, 2, CJ 6 H cu.rrent limiting breakers CJ 4L 4 5, 5, 65, i 5, 5, 6, molded case switch CJ type ampere rating short circuit withstand when protected by fuses 3-pole (A) (RMS Sym. Amps) of maximum ratings (A) CJ 4NA 4, 4 CJ 6NA 6, 6 shunt trip rated voltage (V) UL 489 isted EC 57-6Hz 2 5/6Hz DC 24.:.._ ::::.. DC undervoltage trip device rated voltage (V) UL 489 listed EC 57- DC 24 DC =-24.: motor operator rated voltage (V) UL 489 isted EC 57-6Hz 2 5/6Hz 24 DC 24 DC auxiliary switches, alarm switch, overcurrent trip switch EC 57- characteristics are the same as those indicated in page 4. circuit breakers for compliance with other world standards Where compliance with EC standards is required, Merlin Gerin offers a versatile range (not UL listed) of CJ circuit breakers to meet your specific need. Units include two, three or four poles, ratings from 32 to 63A, three levels of interrupting capabilities up to 66V. An extensive range of accessories complements the product line. For further information, please contact your Merlin Gerin representative.

30 NC. 5 Highlands Pkwy. Suite 5 SMYRNA, GA 382 tel. (44) fax (44) GROUPE.SCNl/Pl R+ AC6/ E As standard spec ications and designs change from time to time. please ask for confirmation of the information given in this publication. photos : B. Maurice design by AMEG, Y. Marchand PV 2/9 - printed by PONCET