Digitrip Retrofit System for ITE K-3000, K-3000 S, K-4000 and K-4000 S Breakers

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1 Supersedes IL Dated 05/02 Digitrip Retrofit System for ITE K-3000, K-3000 S, K-4000 and K-4000 S Breakers

2 Digitrip Retrofit System for ITE K-3000, Digitrip Retrofit System for ITE K-3000, K-3000 S, K-4000, and K-4000 S Breakers CONTENTS Description Introduction... 5 Step 1: General Breaker Preparation... 6 Recommended Safety Practices... 6 Step 2: Removing the Original Components... 8 Step 3: Installing the Trip Finger, Reset Assembly, and DTA Step 4: Preparing and Installing the Pole Unit Assemblies Step 5: Adjusting the DTA and Reset Assemblies Step 6: Preparing and Installing the Trip Unit / Aux. CT Module Assembly Step 7: Installing CPT Harness and HV Wires Step 8: Installing the Sensors Step 9: Installing the Sensor and DTA Extension Harnesses Step 10: Connecting the PT Wires Step 11: Installing the External Harness and Final Wiring Step 12: Testing the Breaker Step 13: Mounting the Cell Harness Step 14: Installing the Retrofitted Breaker in the Cell Figures 1. Mechanical Trip Unit Externally Mounted Sensors Internally Mounted Sensors Overview: Original Components Removed from the Breaker Top Platform Assembly Resting on the Breaker Charging Spring Assembly Removing the Pole Unit Barrier Retaining Bar Adjusting Stud Free from the Breaker Pole Shaft Removing the Finger Clusters Location of the Original Trip Fingers Overview: Trip Finger, Reset Assembly, and DTA Installed in the Breaker Trip Finger Mounted to the Breaker Trip Shaft Drilling Plan A Reset Rod Attached to the DTA Reset Arm DTA Assembly Mounted to the Right Breaker Frame Reset Rod Installed on the Opening Spring Pin Overview: Modified Pole Units Ready for Installation Mechanical Trip Unit Removed from a Pole Unit Bottom Stud Assembly Reinstalled with the Longer Mounting Bolt Glastic Molding and Mechanical Trip Unit Removed from the Stud Assemblies Top Stud Assembly Installed in the New Glastic Molding EATON CORPORATION

3 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A 20. Bottom Stud Assembly Installed in the New Glastic Molding Laminated Sensor Shielding Installed on the Bottom Stud Assembly Adjusting Stud Installed in the Insulating Link Pole Unit Retainer Bar Reinstalled in the Breaker Overview: DTA and Reset Assemblies Installed in the Breaker Reset Rod Assembly Cage Height DTA to Trip Finger Gap Overview: Trip Unit / Aux. CT Module Assembly Ready for Installation Trip Unit / Aux. CT Module Assembly Mounting Brackets Installed on the Mounting Platform PT Module Mounted to the Trip Unit Insulation Barrier Trip Unit Insulation Barrier Mounted to the Aux. CT Module Trip Unit Installed on the Aux. CT Module Correct Installation of the Trip Unit Spacers and Support Clips Trip Unit / Aux. CT Module Assembly Installed on the Mounting Platform Correct Positioning of the Spacers Aux. CT Harness Connection Breaker Mounted CPT Installed on the Trip Unit / Aux. CT Module Assembly Mounting Platform Trip Unit / Aux. CT Module Assembly Installed on the Breaker Trip Unit Assembly with Rating Plug Installed Overview: CPT Harness and HV Wires Connected to the Breaker Mounted CPT Fuse Clips and Spade Connector Removed from the CPT CPT Harness Connected to the X Terminals of the CPT Module Load and Line Sides of the HV Wires Suggested Location for the HV Fuses Load Side HV Wires Connected to the H Terminals of the CPT Module HV Wires Connected to the Top Stud Assemblies CPT Voltage Labels Supplied with the CPT Kit Overview: Externally and Internally Mounted Sensors Installed on the Breaker Point Terminal Blocks Mounted on the Sensor Mounting Bracket Sensors Mounted on the Sensor Mounting Bracket Sensor Wires Connected to the 3-Point Terminal Blocks Mounting the Sensor Assembly to the Rear Breaker Frame Drilling Plan B Internally Mounted Sensors Installed on the Breaker Internally Mounted Sensor Wires Connected to the 3-Point Terminal Blocks Sensor Retainers Installed Over the Sensors Overview: Sensor and DTA Extension Harness Connected to the Aux. CT Module DTA Extension Harness Connected to the Aux. CT Module Terminal Block Routing of the DTA Extension Harness DTA Extension Harness Connected to the DTA Terminal Block Routing of the Sensor Harness - Externally Mounted Sensors Routing of the Sensor Harness - Internally Mounted Sensors Sensor Harness Connected to the Aux. CT Module Terminals Overview: PT Wires Connected to the Bottom Stud Assemblies PT Wires Connected to the Bottom Stud Assemblies Overview: External Harness Installed on the Breaker EATON CORPORATION 3

4 Digitrip Retrofit System for ITE K-3000, Basic Kit External Harness Shorting Plug Wiring and Installation of the Auxiliary Switch External Harness Connections at the Trip Unit External Harness Secured to the Trip Unit / Aux. CT Module Assembly Mounting Bracket Standard Retrofit Components Optional Internally Mounted Sensor Retrofit Components Tables 1. Available Retrofit Kits CPT Low Voltage Taps for Standard and Special Order CPTs (After Removing Fuse Clips) CPT High Voltage Taps for Standard and Special Order CPTs Sensor Taps Rating Torque Values for General Mounting and Screw Size Conversion Torque Values for Copper BUS Connectors WARNING POWER CIRCUIT BREAKERS ARE EQUIPPED WITH HIGH SPEED, HIGH ENERGY OPERATING MECHANISMS. THE BREAKERS AND THEIR ENCLOSURES ARE SIGNED WITH SEVERAL BUILT-IN INTERLOCKS AND SAFETY FEATURES INTENDED TO PROVIDE SAFE AND PROPER OPERATING SEQUENCES. TO PROVIDE MAXIMUM PROTECTION FOR PERSONNEL ASSOCIATED WITH THE INSTALLATION, OPERATION, AND MAINTENANCE OF 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 tests if this device is required (see Step 12 Testing the Breaker for test procedures). Only qualified persons, as defined in the National Electric Code, who are familiar with the installation and maintenance of power circuit breakers and their associated switchgear assemblies should perform any work associated with these breakers. Completely read and understand all instructions before attempting any installation, operation, maintenance, or modification of these breakers. Always turn off and lock out the power source feeding the breaker prior to attempting any installation, maintenance, or modification of the breaker. Do not use the circuit breaker as the sole means for isolating a high voltage circuit. Follow all lockout and tagging rules of the National Electric Code and all other applicable codes, regulations, and work rules. Do not work on a closed breaker or a breaker with the closing springs charged. Trip (open) the breaker and be sure the stored energy springs are discharged before performing any work. The breaker may trip open or the charging springs may discharge, causing crushing or cutting injuries. For drawout breakers, trip (open), and then remove the breaker to a well-lit work area before beginning work. Do not perform any maintenance: including breaker charging, closing, tripping, or any other function which could cause significant movement of the breaker while it is on the extension rails. Doing so may cause the breaker to slip from the rails and fall, potentially causing 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 improper positioning of the breaker and flashover, causing death, serious personal injury, and / or property damage. Do not defeat any safety interlock. Such interlocks are intended to protect personnel and equipment from damage due to flashover and exposed contacts. Defeating an interlock could lead to death, severe personal injury, and / or property damage 4 eaton corporation

5 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Section 1: Introduction Eaton 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 that offers true RMS sensing, overcurrent protection, and self-testing features. Advanced Digitrip Retrofit Kits feature zone interlocking, digital alphanumeric displays, remote alarm signals, PowerNet communications, energy monitoring capabilities, power factors, and harmonic content measurements. Table 1 provides a quick reference of the components supplied with each level of Retrofit Kit. Before beginning the Retrofit process, take a minute to review the information contained in Table 1. It is important that the Retrofitter understands which level of Retrofit Kit is to be installed and which components are included with the Kit. The instructions contained in this manual cover the installation of all levels of Retrofit Kit. If the Kit you are installing does not contain a certain component, skip the instructions for that component and proceed to the next. Throughout the Retrofit process, refer to the Torque Tables at the back of this manual for specific torque values. If you have any questions concerning the Retrofit Kit and / or the Retrofit process, contact Eaton at: Table 1. Available Retrofit Kits Components Trip Unit Rating Plug Auxiliary Current Transformer (CT) Module Auxiliary CT Harness Sensors Sensor Harness Direct Trip Actuator (DTA) Mounting Brackets and Hardware 510 Basic 510 with Zone Interlock External Harness Plug 1 Connector Harness 2 Connector Harness 3 Connector Harness 4 Connector Harness Cell Harness Breaker Mounted Control Power Transformer (CPT Potential Transformer (PT) Module Auxiliary Switch eaton corporation 5

6 Digitrip Retrofit System for ITE K-3000, 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 and understand the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers (Retrofit Application Data - Publication AD ), supplied with the Digitrip Retrofit Kit. WARNING DO NOT ATTEMPT TO INSTALL OR PERFORM MAINTENANCE ON EQUIPMENT WHILE IT IS ENERGIZED. SEVERE PERSONAL INJURY OR DEATH CAN RESULT FROM CONTACT WITH ENERGIZED EQUIPMENT. VERIFY THAT NO VOLTAGE IS PRESENT 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 to insure that the Breaker and all original components are in good condition. Visually inspect all Breaker components for signs of damage or wear. If any signs of damage or wear are detected for components not included in the Retrofit Kit, secure the necessary replacement parts before beginning the Retrofit Process. The force necessary to trip the Breaker should not exceed three (3) lbs. To begin the Retrofit Process, refer to the components list at the end of this manual. Layout the components and hardware according to the steps outlined. The parts bags are labeled with the corresponding step number. The components and hardware will be used to complete each step in the Retrofit Process. Note: The stock Digitrip Retrofit Kit for ITE K- 3000, K-3000 S, K-4000, and K-4000 S Breakers is supplied with externally mounted Sensors and mounting components. Due to potential interference from Cell-mounted Instrumentation Current Transformers (CTs) in some systems, optional Retrofit components may be needed to install internally mounted Sensors. For more information, or if the Breaker has been modified from its original configuration during a past upgrade, contact Eaton Technical Support at The optional Retrofit components to install internally mounted Sensors will be needed if the following is true for the Breaker being Retrofitted: 1. Instrumentation CTs are present within the Cell; AND / OR 2. the Breaker being Retrofitted is currently equipped with Mechanical Trip Units. NOTE: It is the responsibility of the Retrofitter to insure that the proper, manufacturer s recommended crimping tools and terminals are used for each type of connector. It is also the responsibility of the Retrofitter to insure that all wire preparations, connections, strippings, terminations, and wiring techniques are performed according to the latest IEEE, NEC, and / or NEMA industry standards, specifications, codes, and guidelines. Fig. 1 Mechanical Trip Unit. 6 EATON CORPORATION

7 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A This IL documents the Retrofit Procedure for Kits with externally AND internally mounted Sensors. To perform the Retrofit, follow the procedures that correspond with the type of Sensors being installed. Note: This Retrofit Kit is NOT designed for ITE K Series Bolt-in Breakers. Externally Mounted Sensors. Fig. 2 Internally Mounted Sensors. EATON CORPORATION 7

8 Digitrip Retrofit System for ITE K-3000, STEP 2: REMOVING THE ORIGINAL COMPONENTS Fig. 3 Overview: Original Components Removed from the Breaker. Refer to the appropriate ITE K-3000, K-3000 S, K-4000, or K-4000 S Instruction Manual, originally supplied with the Breaker, to perform the following procedures. Fig. 4 Top Platform Assembly Resting on the Breaker Charging Spring Assembly. D. Remove and save the clips securing the Pole Unit Barrier Retaining Bar to the Breaker Phase Partitions. Slide the Retaining Bar out of the Breaker. A. Remove the hardware securing the Arc Chute Retainer Moldings to the Breaker. Remove the Arc Chutes. Save the Arc Chutes, Retainer Moldings, and all hardware for use later in the Retrofit process. B. Remove and save the seven (7) screws securing the Outer / Inner Front Cover Assembly to the Breaker. Remove the Outer / Inner Front Cover Assembly. C. Remove and save the hardware securing the top Breaker Platform Assembly to the Breaker. Carefully slide the top Platform Assembly toward the front of the Breaker and rest it on the Charging Spring Assembly. Note: Leave all components, linkages, harnesses, and wires connected at this time. Fig. 5 Removing the Pole Unit Barrier Retaining Bar. E. Loosen the three (3) locking bolts securing each Adjusting Stud between the Insulating Links on the Pole Unit Assemblies and the Breaker Pole Shaft. Loosen each Adjusting Stud until the Insulating Links are free from the Breaker Pole Shaft. 8 EATON CORPORATION

9 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Note: For this Retrofit, only the right Trip Finger must be removed. Removal of the center and left Trip Fingers is optional. If the Retrofitter opts not to remove the center and left Trip Fingers, care should be taken to insure all harnesses and wiring installed during the Retrofit are routed so they are Clear of these Trip Fingers. Fig. 6 Adjusting Stud Free from the Breaker Pole Shaft. F. Working from the back of the Breaker, remove and save the retaining clips and flat washers securing the Finger Clusters to the Breaker Studs. Remove the Finger Clusters. CENTER TRIP FINGER RETAINING CLIP Fig. 8 Location of the Original Trip Fingers. Fig. 7 Removing the Finger Clusters. G. Remove and save the 12 bolts (four [4] per Pole Unit Assembly) securing the Pole Unit Assemblies to the Rear Breaker Frame. Lift each Pole Unit Assembly up and out of the Breaker. H. Remove and scrap the hardware securing the Trip Fingers to the Trip Shaft. Remove and scrap the Trip Fingers. EATON CORPORATION 9

10 Digitrip Retrofit System for ITE K-3000, STEP 3: INSTALLING THE TRIP FINGER, RESET ASSEMBLY, AND DTA B. Using Drilling Plan A, drill two (2) 0.281" holes in the right Breaker Frame. These holes will be used later in the Retrofit process to mount the DTA Assembly. TRIP FINGER RESET ASSEMBLY RIGHT BREAKER FRAME 1.19 DTA DIA. (2) Fig. 9 Overview: Trip Finger, Reset Assembly, and DTA Installed in the Breaker. A. Align the new Trip Finger with the existing holes in the Breaker Trip Shaft from which the original right Trip Finger was removed in Step 2-H. Note that the Trip Finger is to be installed on the bottom surface of the Breaker Trip Shaft. Secure the Trip Finger to the Trip Shaft using the (2) " screws, (2) lock washers, (2) flat washers, and (2) nuts supplied. Fig. 11 Drilling Plan A. C. Remove the Nylok nut from the bottom of the Reset Rod. While holding the spring and wide flat washer in place, insert the Reset Rod through the hole in the DTA Reset Arm. Reinstall the Nylok nut on the bottom of the Reset Rod. Fig. 10 Trip Finger Mounted to the Breaker Trip Shaft. Fig. 12 Reset Rod Attached to the DTA Reset Arm. D. Align the DTA Assembly, as shown, with the holes drilled in Step 3-B. Insure that the Adjusting Disk on the top of the DTA Shaft is below the Trip Finger. Apply Loc-Tite 242 to the threads then secure the DTA Assembly to inside of the right Breaker Frame using the (2) " bolts and (2) lock washers supplied. 10 EATON CORPORATION

11 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A MOUNTING BOLTS DTA Fig. 13 DTA Assembly Mounted to the Right Breaker Frame. E. Remove and scrap the cotter pin from the end of the right Opening Spring Pin. If the Breaker is equipped with an original Auxiliary Switch, temporarily remove the linkage from the Opening Spring Pin. Remove and scrap the existing spacer. F. Install the supplied steel bushing on the right Opening Spring Pin. G. If the original Auxiliary Switch linkage was removed in Step 3-E, reinstall the linkage on the Opening Spring Pin. While compressing the spring on the Reset Rod Assembly, install the top of the Reset Rod on the Opening Spring Pin, as shown. Install the supplied cotter pin in the end of the Opening Spring Pin. Fig. 14 Reset Rod Installed on the Opening Spring Pin. EATON CORPORATION 11

12 Digitrip Retrofit System for ITE K-3000, STEP 4: PREPARING AND INSTALLING THE POLE UNIT ASSEMBLIES FOR EXTERNALLY MOUNTED SENSORS Fig. 16 Mechanical Trip Unit Removed from a Pole Unit. FOR INTERNALLY MOUNTED SENSORS C. Reinstall the original bottom Stud Assemblies in each Pole Unit using 9 of the 12 original mounting bolts. The bottom, right bolts securing each bottom Stud Assembly are to be replaced with the (3) " bolts, (3) lock washers, and (3) flat washers supplied. Fig. 15 Overview: Modified Pole Units Ready for Installation. For Kits Supplied with Externally Mounted Sensors Only. A. Remove and save the bolts securing the bottom Stud Assemblies to each Pole Unit. Remove the bottom Stud Assemblies from the Pole Units. B. Remove and scrap the Mechanical Trip Units and associated hardware from each Pole Unit. Fig. 17 Bottom Stud Assembly Reinstalled with the Longer Mounting Bolt. For Kits Supplied with Internally Mounted Sensors Only. D. Set a Pole Unit Assembly, with the contacts facing down, on the work surface. Remove the eight (8) bolts securing the bottom and top Stud Assemblies to the Glastic Molding. Save the hardware that secures the top Stud Assembly. Scrap the hardware that secures the bottom Stud Assembly. 12 EATON CORPORATION

13 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A E. Lift the Glastic Molding, with the original Mechanical Trip Unit attached, up from the Stud Assemblies. Scrap the original Glastic Molding and Trip Unit. I. Align the bottom Stud Assembly and Adapter Plate with the holes in the Glastic Molding. Secure the bottom of the bottom Stud Assembly and Adapter Plate to the Glastic Molding, using the (1) " bolt, (1) " bolt (1) lock washer, and (1) flat washer supplied. Fig. 18 Glastic Molding and Mechanical Trip Unit Removed from the Stud Assemblies. F. Repeat Steps 4 - D & E for the remaining two Pole Unit Assemblies. G. Align the top Stud Assembly with the holes in the new Glastic Molding. Using the original hardware, secure the top Stud Assembly to the Glastic Molding. Fig. 20 Bottom Stud Assembly Installed in the New Glastic Molding. J. Align the supplied Laminated Sensor Shielding with the top holes of the bottom Stud Assembly. Secure the Laminated Sensor Shielding and the top of the bottom Stud Assembly, using the (1) " bolts, (1) " bolts, (2) flat washers, and (2) lock washers supplied. Fig. 19 Top Stud Assembly Installed in the New Glastic Molding. H. Align the new Adapter Plate with the holes in the bottom Stud Assembly. Note that the notched edge of the Adapter Plate must face the bottom of the Stud Assembly. Secure the Adapter Plate to the bottom Stud Assembly, as shown, using the counter sunk holes in the Adapter Plate and the (2) " flat head screws supplied. Fig. 21 Laminated Sensor Shielding Installed on the Bottom Stud Assembly. EATON CORPORATION 13

14 Digitrip Retrofit System for ITE K-3000, K. Repeat Step 4 - G through J for the remaining two Pole Unit Assemblies. For Kits Supplied with Externally or Internally Mounted Sensors. L. Set each Pole Unit Assembly in position within the Breaker. Secure each Pole Unit Assembly using the original hardware. M. Align each Adjusting Stud with the Insulating Links. Thread each Adjusting Stud into the Insulating Link until the required contact pressure and gap are achieved. Note: For information on setting the correct contact pressure and gap for the Breaker, the Retrofitter MUST refer to the ITE K-3000, K-3000 S, K-4000, or K-4000 S Instruction Manual originally supplied with the Breaker. Fig. 23 Pole Unit Retainer Bar Reinstalled in the Breaker. O. Carefully rotate the Top Platform Assembly back into its original position. Temporarily secure the Top Platform Assembly to the Breaker using the original hardware. P. Reinstall the Arc Chutes and the Arc Chute Retainer Moldings using the original hardware. Note: The Finger Clusters and the Inner and Outer Front Covers will be reinstalled later in the Retrofit process. Fig. 22 Adjusting Stud Installed in the Insulating Link. Once the correct contact pressure and gap have been achieved, tighten the three (3) locking bolts securing the threaded Adjusting Studs. N. Correctly position the Pole Unit Barriers then insert the Pole Unit Barrier Retainer Bar into the holes in the Breaker Phase Partitions. Note that the Bar must be inserted so that the retaining clips will be situated on both sides of the right Breaker Phase Partition. Secure the Pole Unit Barrier Retainer Bar using the original clips. 14 EATON CORPORATION

15 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A STEP 5: ADJUSTING THE DTA AND RESET ASSEMBLIES B. Turn the DTA Adjusting Disk down the DTA Shaft until it is fully seated against the shoulder of the DTA Shaft. Apply Loc-Tite 242 to the threads of the DTA Shaft. C. CLOSE the Breaker. Turn the DTA Adjusting Disk until a gap of 0.060" to 0.090" is achieved between the top of the DTA Adjusting Disk and the bottom of the Trip Finger. Fig. 24 Overview: DTA and Reset Assemblies Installed in the Breaker. GAP 0.06 TO 0.09" A. Loosen the lock nut on the Reset Rod. Turn the adjusting nut until a cage height of 0.828" to 0.859" is achieved. Tighten the lock nut against the adjusting nut, then verify that the cage height is still within range. Fig. 26 DTA to Trip Finger Gap. D. Return the Breaker to the OPEN position. CAGE HEIGHT " Fig. 25 Reset Rod Assembly Cage Height. WARNING TO ADJUST THE GAP BETWEEN THE DTA AD- JUSTING DISK AND TRIP FINGER, THE BREAKER MUST BE IN THE CLOSED POSITION. KEEP HANDS AND FINGERS AWAY FROM MOVING PARTS WITHIN THE BREAKER. FAILURE TO DO SO COULD RESULT IN SEVERE PERSONAL INJURY. EATON CORPORATION 15

16 Digitrip Retrofit System for ITE K-3000, STEP 6: PREPARING AND INSTALLING THE TRIP UNIT / AUX. CT MODULE ASSEMBLY Fig. 27 Overview: Trip Unit / Aux. CT Module Assembly Ready for Installation. A. Align the Trip Unit / Aux. CT Module Assembly Mounting Brackets with the holes in the ends of the Mounting Platform, as shown. Secure the Mounting Brackets to the Mounting Platform using the (4) " bolts, (4) lock washers, (8) flat washers, and (4) nuts supplied. Fig. 28 Trip Unit / Aux. CT Module Assembly Mounting Brackets Installed on the Mounting Platform. B. For Kits Supplied with a PT Module Only: Align the PT Module with the holes in the Trip Unit Insulation Barrier, as shown. Secure the PT Module to the Insulation Barrier using the (2) " screws, (4) flat washers, (2) lock washers, and (2) nuts supplied. Fig. 29 PT Module Mounted to the Trip Unit Insulation Barrier. 16 EATON CORPORATION

17 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A C. Align the Trip Unit Insulation Barrier with the holes in the back of the Aux. CT Module, as shown. Secure the Insulation Barrier to the Aux. CT Module using the (2) " screws, (2) lock washers, and (2) flat washers supplied. Fig. 31 Trip Unit Installed on the Aux. CT Module. Fig. 30 Trip Unit Insulation Barrier Mounted to the Aux. CT Module. D. Align the Trip Unit with the holes in the top of the Aux. CT Module, as shown. Loosely secure the Trip Unit to the Aux. CT Module using the (2) brass spacers, (2) " screws, (2) lock washers, and (2) flat washers supplied. Note that the brass spacers are placed between the bottom of the Trip Unit and the Aux. CT Module. E. Position the Trip Unit Support Clips on the sides of the Trip Unit so they pinch the Trip Unit in place. Secure the Trip Unit Support Clip to the sides of the Aux. CT Module using the (4) " screws, (4) lock washers, and (4) flat washers supplied then fully tighten the (2) " screws loosely installed in Step 6-D. Fig. 32 Correct Installation of the Trip Unit Spacers and Support Clips. F. Align the Trip Unit / Aux. CT Module Assembly and three (3) Spacer Plates per side, as shown, with the holes in the right side Trip Unit / Aux. CT Module Mounting Platform. Secure the Trip Unit / Aux. CT Module Assembly and the spacer plates to the Mounting Platform using the (4) " flat head screws, (4) lock washers, (4) flat washers, and (4) nuts supplied. EATON CORPORATION 17

18 Digitrip Retrofit System for ITE K-3000, Fig. 33 Trip Unit / Aux. CT Module Assembly Installed on the Mounting Platform. Fig. 35 Aux. CT Harness Connection. Fig. 34 Note: Correct Positioning of the Spacers. The Trip Unit / Aux. CT Module Mounting Platform has been pre-drilled to allow the Trip Unit / Aux. CT Module Assembly and, if applicable, the Breaker Mounted CPT to be mounted on either the right or left sides of the Platform. The instructions contained in this IL detail the standard installation. If, for some reason, the mounting locations must be switched, just use the existing holes on the opposite end of the Platform. H. For Kits Supplied with a Breaker Mounted CPT Only: Align the Breaker Mounted CPT with the holes in the left side of the Trip Unit / Aux. CT Module Mounting Platform, as shown. Secure the CPT to the Mounting Platform using the (4) " screws, (4) lock washers, (4) flat washers, and (4) nuts supplied. G. Connect the Aux. CT Harness to the Aux. CT Module and the Trip Unit receptacle. 18 EATON CORPORATION

19 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Fig. 36 Breaker Mounted CPT Installed on the Trip Unit / Aux. CT Module Assembly Mounting Platform. I. Remove and scrap the hardware securing the ends of the top Breaker Platform to the Breaker. Align the holes in the Trip Unit / Aux. CT Module Assembly Platform Mounting Brackets with the holes in the top Breaker Platform and Breaker Frame, as shown. Secure the Trip Unit / Aux. CT Module Assembly Platform to the Breaker using the (4) " screws, (4) lock washers, and (4) flat washers supplied. Fig. 38 Trip Unit Assembly with Rating Plug Installed. K. Install the Digitrip Retrofit label in a prominent location on the Outer / Inner Breaker Cover Assembly. Fig. 37 Trip Unit / Aux. CT Module Assembly Installed on the Breaker. J. Remove the Trip Unit Cover and install the Rating Plug. Reinstall the cover. EATON CORPORATION 19

20 Digitrip Retrofit System for ITE K-3000, For Kits Supplied with a Breaker Mounted CPT Only. STEP 7: INSTALLING CPT HARNESS AND HV WIRES Table 2 CPT Low Voltage Taps for Standard and 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 X2 & X3 Fig. 39 Overview: CPT Harness and HV Wires Connected to the Breaker Mounted CPT. A. Remove and save the (2) " screws securing the fuse clips and male spade connector installed on the CPT. Discard the fuse clips and spade connector, then reinstall the screws in the CPT Terminals. Fig. 41 CPT Harness Connected to the X Terminals of the CPT Module. C. Route the CPT Harness between the back of the Trip Unit and the Trip Unit Insulation Barrier, towards the right side of the Trip Unit. CPT Harness connection to the Trip Unit will be performed later in the Retrofit Process. NOTE: The Load Side HV Wires are longer than necessary and are cut during the following steps. Before cutting the wires, be sure that sufficient length is left so that the HV Wire Fuses can rest in the top, rear Breaker Channel and that the connections can be made to the correct H terminals on the CPT Module. Fig. 40 Fuse Clips and Spade Connector Removed from the CPT. B. Connect the CPT Harness wires to the appropriate X terminals of the CPT Module as shown. See Table 2 for Tap information. 20 EATON CORPORATION

21 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Fig. 42 LINE SIDE LOAD SIDE Load and Line Sides of the HV Wires. D. Position the HV Fuses in the top, rear Breaker Channel, behind the left Arc Chute. Mark and cut the Load Side of each HV Wire to an appropriate length for connection to the H terminals of the CPT. Strip approximately.250" of insulation from the Load Side HV Wires and attach a.138" ring terminal to each. Attach the HV Wires to the CPT H terminals to achieve the required voltage (see Table 3). Table 3 CPT High Voltage Taps for Standard and Special Order CPTs Standard CPT (Style #9A10037G01 & G02) Voltage Required CPT Terminals Used 480 Volt Circuit H1 & H4 240 Volt Circuit H2 & H4 208 Volt Circuit H3 & H4 Special Order 575 Volt CPT (Style #9A10037G03 & G04) 575 Volt Circuit H1 & H4 460 Volt Circuit H2 & H4 230 Volt Circuit H3 & H4 Fig. 44 Load Side HV Wires Connected to the H Terminals of the CPT Module. Fig. 43 Suggested Location for the HV Fuses. NOTE: The terminals to which the Load Side HV wires are connected determine the voltage of the CPT. Verify that the line voltage of the circuit matches the CPT voltage BEFORE putting the Breaker into service. E. Install the A and B Finger-Safe Covers over the CPT Terminals as shown. Secure the Finger-Safe Covers to the CPT using the (4) " screws supplied with the CPT Kit. Torque the screws to 8-10 in./lbs. NOTE: The power convention of Circuit Breakers is normally Top to Bottom, meaning the top Stud Assemblies (Breaker Stabs) are on the Line Side of the Breaker and the bottom Stud Assemblies are on the Load Side. The HV Wires from the CPT MUST BE ATTACHED to the Line Side of the Breaker. If it is determined that the power EATON CORPORATION 21

22 Digitrip Retrofit System for ITE K-3000, flow for the Breaker application is opposite the normal convention, the HV Wires must be attached to the bottom Stud Assemblies. In the case of the Line Side being the bottom Stud Assemblies, the bolts that secure the bottom Stud Assemblies to the Pole Units can be used for HV Wire attachment. I. Install the appropriate CPT Voltage Label in a clearly visible location on the Outer / Inner Front Breaker Cover Assembly. WARNING WARNING NOTE: The Line Side HV Wires are longer than necessary and are cut during the following steps. Before cutting the wires, be sure that sufficient length is left so that the HV Wire Fuses are accessible and that the connections can be made to the correct Stud Assemblies. F. Route the HV Line Side Wires over the top, rear Breaker Channel towards the Phase 1 and 2 or the Phase 2 and 3 top Stud Assemblies. Cut each HV Wire to an appropriate length, strip.250" from each wire, then install a.312" ring terminal on each wire. G. Completely remove one (1) bolt from each of the selected top Stud Assemblies. Slide the HV Wire ring terminals onto the bolts then install the bolts back into the top Stud Assemblies, as shown. Fully tighten the bolts. Fig. 46 THIS BREAKER CONTAINS A 50VA CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY. IF BREAKER IS USED ON A LINE VOLTAGE OTHER THAN SHOWN. THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING. FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE TRIP UNIT AND / OR CONTROL POWER TRANSFORMER 208V CONTROL POWER TRANSF. TAPS H1 H4=480V H2 H4=240V H3 H4=208V NP# 9A10039H04 WARNING THIS BREAKER CONTAINS A 50VA CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY. IF BREAKER IS USED ON A LINE VOLTAGE OTHER THAN SHOWN. THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING. FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE TRIP UNIT AND / OR CONTROL POWER TRANSFORMER 480V CONTROL POWER TRANSF. TAPS H1 H4=480V H2 H4=240V H3 H4=208V NP# 9A10039H02 THIS BREAKER CONTAINS A 50VA CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY. IF BREAKER IS USED ON A LINE VOLTAGE OTHER THAN SHOWN. THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING. FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE TRIP UNIT AND / OR CONTROL POWER TRANSFORMER 240V CONTROL POWER TRANSF. TAPS H1 H4=480V H2 H4=240V H3 H4=208V NP# 9A10039H03 WARNING THIS BREAKER CONTAINS A 50VA CONTROL POWER TRANSFORMER FOR TRIP UNIT DISPLAY. IF BREAKER IS USED ON A LINE VOLTAGE OTHER THAN SHOWN. THE CPT TAPS MUST BE CHANGED BEFORE ENERGIZING. FAILURE TO DO SO WILL RESULT IN DAMAGE TO THE TRIP UNIT AND / OR CONTROL POWER TRANSFORMER 575V CONTROL POWER TRANSF. TAPS H1 H4=575V NP# 9A10039H01 CPT Voltage Labels Supplied with the CPT Kit. Fig. 45 HV Wires Connected to the Top Stud Assemblies. H. Use the self-adhesive mounting pads and wire ties supplied to secure the HV Wires to the top, rear Breaker Channel. 22 EATON CORPORATION

23 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A STEP 8: INSTALLING THE SENSORS Fig Point Terminal Blocks Mounted on the Sensor Mounting Bracket. Externally Mounted Sensors B. Align the Sensors with the holes in the Sensor Mounting Bracket, as shown. Note that the X-1 and X-2 Sensor Wires are positioned towards the Terminal Blocks. Secure the Sensors to the Sensor Mounting Bracket using the (6) " bolts, (12) flat washers, (6) lock washers, and (6) nuts supplied. Internally Mounted Sensors Fig. 47 Overview: Externally and Internally Mounted Sensors Installed on the Breaker. For Kits Supplied with Externally Mounted Sensors Only. A. Align the three (3) 3-Point Terminal Blocks with the holes in the Sensor Mounting Bracket, as shown. Secure the Terminal Blocks to the Sensor Mounting Bracket using the (6) " screws, (12) flat washers, (6) lock washers, and (6) nuts supplied. Fig. 49 Sensors Mounted on the Sensor Mounting Bracket. C. Cut the Sensor Wires to an appropriate length for connection to the 3-Point Terminal Blocks. Strip an appropriate length of insulation from the Sensor Wires and attach a.138" ring terminal to each. Connect the Sensor Wires to the 3-Point Terminal Blocks. EATON CORPORATION 23

24 Digitrip Retrofit System for ITE K-3000, For Kits Supplied with Internally Mounted Sensors Only. Note: If the Breaker being Retrofit has Glastic Moldings with terminals built in, these can be used to connect the Sensors instead of the Terminal Blocks installed in the following steps. Fig. 50 Sensor Wires Connected to the 3-Point Terminal Blocks. F. Cover the area below the bottom, rear Breaker Channel to prevent any metal shavings from entering the Breaker or its components. Using Drilling Plan B, drill six (6).156" holes in the rear Breaker Frame. D. Align the Sensor Assembly Support Brackets with the holes in the ends of the Sensor Mounting Bracket. Loosely secure the Support Brackets to the Sensor Assembly using the (2) " bolts, (4) flat washers, (2) lock washers, and (2) nuts supplied. Note: Since access for installing the nuts on the inside of the rear, bottom Breaker Channel is limited, the Retrofitter may want to consider drilling and tapping the rear, bottom Breaker Channel to accept screws E. Position the Sensor Assembly over the top Breaker Studs, as shown. Align the holes in the Sensor Assembly Support Brackets with the existing holes in the top corners of the rear Sensor Frame. After making sure the Sensors are centered over the Breaker Studs, secure the Sensor Assembly to the Breaker using the (2) " bolts, (2) flat washers, (2) lock washers, and (2) nuts supplied. Fully tighten the hardware securing the Sensor Assembly Support Brackets to the Sensor Assembly. Fig BOTTOM BREAKER CHANNEL Drilling Plan B DIA. (6) Fig. 51 Mounting the Sensor Assembly to the Rear Breaker Frame. G. Align a 3-Point Terminal Block with each set of holes just drilled. Secure the Terminal Blocks, as shown, using the (6) " screws, (12) flat washers, (6) lock washers, and (6) nuts supplied. H. Slide one (1) Sensor Spacer over each bottom Stud. I. Feed the Sensor Wires through the opening between the Adapter Plates and the Glastic Moldings, then towards the bottom of the Breaker. As the wires are being fed, align the Sensors with the bottom Studs. Slide the Sensors onto the bottom Studs until they are flush against the Sensor Spacers. 24 EATON CORPORATION

25 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Fig. 53 Internally Mounted Sensors Installed on the Breaker. Fig. 54 Sensor Retainers Installed Over the Sensors. J. Install a sufficient number of Sensor Spacers onto each bottom Stud so that when the Sensor Retainers are installed the Sensors will be held snugly in place. K. Slide a Sensor Retainer over each bottom Stud Assembly. Secure the tops of the Sensor Retainers, using the (3) " thread cutting screws, (3) flat washers, and (3) lock washers supplied. Secure the bottom of the Sensor Retainers, using the (6) " screws, (6) flat washers, and (6) lock washers supplied. L. Feed the Sensor Wires back out of the Breaker through the opening in the rear Breaker Frame. Be sure that the Sensor Wires are clear of any moving parts within the Breaker. M. Route the Sensor Wires to the appropriate 3-Point Terminal Blocks. Cut the Sensor Wires to an appropriate length for then strip approximately.250" of insulation from the Sensor Wires and attach a.138" ring terminal to each. Connect the Sensor Wires to the 3-Point Terminal Blocks. Fig. 55 Internally Mounted Sensor Wires Connected to the 3-Point Terminal Blocks. EATON CORPORATION 25

26 Digitrip Retrofit System for ITE K-3000, STEP 9: INSTALLING THE SENSOR AND DTA EXTENSION HARNESSES C. Route the DTA Extension Harness behind the Aux. CT Module and along the Trip Unit / Aux. CT Module Assembly to the right side of the top Breaker Platform. Then route the DTA Extension Harness down through the existing grommet in the top Breaker Platform towards the DTA Assembly. Connect the DTA Extension Harness to the corresponding terminals on the DTA 2-Point Terminal Block. Use the wire ties provided to secure the DTA Extension Harness away from any moving parts within the Breaker. Fig. 56 Overview: Sensor and DTA Extension Harness Connected to the Aux. CT Module. A. Remove and save the hardware securing the cover to the Aux. CT Module s 7-Point Terminal Block. Remove and save the cover. B. Connect the + wire from the DTA Extension Harness to the OP terminal of the Aux. CT Module Terminal Block and the unmarked wire to the ON terminal. Fig. 58 Routing of the DTA Extension Harness. Fig. 57 DTA Extension Harness Connected to the Aux. CT Module Terminal Block. 26 EATON CORPORATION

27 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Fig. 59 DTA Extension Harness Connected to the DTA Terminal Block. Fig. 60 Routing of the Sensor Harness - Externally Mounted Sensors. D. Reinstall the Finger Clusters removed in Step 2-F. Use the original retaining clips to secure the Finger Clusters. E. Connect the ring terminals on the Sensor Harness to the 3-Point Terminal Blocks to which the Sensor Wires were connected in Step 7. Refer to Section 12 of the Application Data, supplied with the Retrofit Kit, for detailed wiring specifications. For K-3000, K3000 S, K-4000, and K-4000 S Retrofits, the following conventions apply. For Kits Supplied with Internally Mounted Sensors Only: Route the Sensor Harness through the opening near the bottom left of the rear Breaker Frame (when viewed from the front), then up through the Breaker and the grommet in the top Breaker Platform to the Aux. CT Module Terminal Block on the Aux. CT Module / Trip Unit Assembly. Table 4 Sensor Taps Rating Breaker Sensor Sensor Terminal Amps Type Style No. Com. K-3000 External 4A35642H01 X1-X2= 3000 A K-3000 Internal 4A35785H01 X1-X2= 3000 A K-4000 Internal 8153A65H01 X1-X2= 4000 A F. For Kits Supplied with Externally Mounted Sensors Only: Route the Sensor Harness to the left side of the Breaker (when viewed from the front), along the outside of the left Arc Chute, then along the Aux. CT Module / Trip Unit Assembly to the Aux. CT Module Terminal Block, as shown. Fig. 61 Routing of the Sensor Harness - Internally Mounted Sensors. For All Retrofits. G. Connect the Sensor Harness to the proper terminals on the Aux. CT Module Terminal Block. Refer to Section 12 of the Retrofit Application Data, supplied with the Retrofit Kit, for detailed wiring specifications. EATON CORPORATION 27

28 Digitrip Retrofit System for ITE K-3000, Remove the top nut from the rear terminal block mounting post. Slide the ring terminal of the green ground wire from the Sensor Harness onto the rear mounting post for the Terminal Block Cover. Reinstall the nut. For Kits Supplied with a PT Module Only. STEP 10: CONNECTING THE PT WIRES Fig. 62 Sensor Harness Connected to the Aux. CT Module Terminals. H. Reinstall the 7- Point Terminal Block Cover using the original hardware. I. Use the wire ties supplied to secure the Sensor Harness away from any moving parts within the Breaker. Fig. 63 Overview: PT Wires Connected to the Bottom Stud Assemblies. A. Route the PT wires across the Trip Unit / Aux. CT Module Assembly to the left side of the Breaker, then down through the grommet in the top Breaker Platform towards the bottom Stud Assemblies. B. The PT Wires are marked for connection to Phases 1, 2, and 3 with corresponding numbers. NOTE: Before cutting the PT Wires, verify the Phase Convention used on the Breaker Application. C. Route the PT Wires to a position suitable for attachment to the shafts of the " bolts installed in Step 4-C (Externally Mounted Sensors) or Step 4-H (Internally Mounted Sensors) securing the bottom Stud Assemblies in the Pole Units. Move the PT Wire markers to a position where they will still be attached to 28 EATON CORPORATION

29 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A the wires after cutting. Cut the wires to the appropriate length, strip each wire approximately.250", and install a.312" ring terminal on each wire. STEP 11: INSTALLING THE EXTERNAL HAR- NESS AND FINAL WIRING D. Slip the appropriate PT Wire ring terminal over each of the " screws installed in Step 4-C. Secure the PT Wires against the back of the bottom Stud Assemblies using the (3).312" flat washers, (3) lock washers, and (3) nuts supplied. Fig. 65 Overview: External Harness Installed on the Breaker. Fig. 64 PT Wires Connected to the Bottom Stud Assemblies. A. Connect the External Harness to the Trip Unit. NOTE: For 510 Basic Kits, the External Harness is the shorting plug pictured below. It is to be plugged into the right side of the Trip Unit. Fig Basic Kit External Harness Shorting Plug. B. For Kits Supplied with a PT Module Only: Connect the PT Harness to its receptacle on the External Harness. C. For Kits Supplied with an Auxiliary Switch Only: Cut 3.438" inches off the Microswitch Arm. Route the two (2) wires (with ring terminals) from the External Harness, down through the grommet in the right side of the Breaker Plat- EATON CORPORATION 29

30 Digitrip Retrofit System for ITE K-3000, form to the DTA Assembly. Connect one (1) wire to the normally Open terminal and the other wire to the Common terminal of the Microswitch. Align the Microswitch, as shown, with the existing holes in the Auxiliary Switch Mounting Bracket on the DTA Assembly. Apply Loc-Tite 242 to the threads then secure the Microswitch to the Auxiliary Switch Mounting Bracket using the (2) " screws supplied. Fig. 67 Wiring and Installation of the Auxiliary Switch. D. For Kits Supplied with a Breaker Mounted CPT Only: Remove the External Harness plug installed in the bottom rear socket of the Trip Unit. Insert the black plug of the CPT Harness into the same receptacle in the Trip Unit. Reinsert the External Harness Plug just removed into the female receptacle on the CPT Harness. Fig. 68 External Harness Connections at the Trip Unit. E. Use the self-adhesive mounting pads and wire ties supplied to dress all wires and harnesses to keep them away from any moving parts within the Breaker. F. Secure the External Harness to the right rear corner of the Trip Unit / Aux. CT Module Assembly mounting bracket using the (1) wire clamp, (1) " screw, (1) lock washer, and (1) flat washer supplied. 30 EATON CORPORATION

31 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A STEP 12: TESTING THE BREAKER A. Measure the force necessary to trip the Breaker at where the Trip Finger impacts the DTA Adjusting Disk. The force necessary to trip the Breaker MUST NOT EXCEED 3 lbs. Fig. 69 External Harness Secured to the Trip Unit / Aux. CT Module Assembly Mounting Bracket. G. Install the Outer / Inner Front Cover Assembly on the Breaker using the seven (7) original screws removed in Step 2-B. B. The Retrofit must be tested using primary injection. Refer to Section 8 of the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers (Publication AD ), supplied with the Retrofit Kit, for detailed testing procedures and specifications. For test information specific to the Trip Unit, refer to the IL publication supplied with the Retrofit Kit (see the Pick List for the IL number). C. While Section 8 of the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers provides the information necessary for testing the Breaker, please keep the following notes in mind when reviewing other sections of the publication. CAUTION: WHEN ALL TESTING IS COMPLETE, THE TRIP UNIT MUST BE RESET. FAILURE TO DO SO MAY CAUSE THE BATTERY IN THE RATING PLUG TO RUN DOWN. NOTES: 1. For All Kits Other Than 510 Basic: If testing the Breaker with Short Delay or Ground Fault functions, be sure to either plug in the Cell Harness Assembly or use the Zone Interlock Shorting Plug. Failure to do so may result in shorter than expected trip times. 2. For 810 and 910 Kits Only: Without any power applied to the system (neither the 120 volt power supply nor the Aux. Power Module connected), plug the External Harness into the Cell Harness and check the impedance between COM 1 and COM 2. The impedance should be EATON CORPORATION 31

32 Digitrip Retrofit System for ITE K-3000, between one (1) and three (3) ohms. If the impedance is not within this range, trace the wiring and examine each connection to assure its integrity. Confirm that the PowerNet communication wiring is correct by following the procedures detailed in Section 7.4 of the Instructions for the Application of Digitrip RMS Retrofit Kits on Power Circuit Breakers. Note that for 810 and 910 Kits, the impedance between COM 1 and COM 2 should be between one (1) and three (3) ohms. STEP 13: MOUNTING THE CELL HARNESS A. The Cell Harness is to be mounted in the Breaker Cell. The connector end is to be mounted on the right side of the Cell, in a location suitable for connection with the External Harness. The Terminal Blocks can be mounted anywhere space is available in the Cell as long as connection to the External Harness can be made. B. Route the Cell Harness wiring to keep it away from any moving parts within the Cell Housing. When testing is complete, disconnect the External Harness from the Cell Harness. Final External Harness connection will be performed later in the Retrofit Process. 32 EATON CORPORATION

33 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A STEP 14: INSTALLING THE RETROFITTED BREAKER IN THE CELL WARNING DO NOT LEAVE THE BREAKER IN AN INTERME- DIATE POSITION IN THE SWITCHGEAR CELL. ALWAYS LEAVE IT IN THE CONNECTED, DIS- CONNECTED, OR (OPTIONAL) TEST POSITION. FAILURE TO DO SO COULD LEAD TO IM- PROPER POSITIONING OF THE BREAKER AND FLASHOVER, CAUSING DEATH, SERIOUS PERSONAL INJURY, AND / OR PROPERTY DAMAGE. NOTE: It is the responsibility of the Retrofitter to insure proper Breaker / Cell fit. When racking the Breaker into the Connected position, the Retrofitter MUST FOLLOW BOTH the manufacturer s instructions and the customer s safety standards and procedures for racking a Breaker into the Connected position. A. With the Breaker in the Open position and the springs discharged, slowly rack the Breaker into the Connected position, making sure there is no interference or binding. The Breaker should rack smoothly and without mechanical interference between any Breaker and Cell parts. The Retrofitter will feel some resistance when the primary fingers connect onto the stabs of the Cell. This is normal. However, if any unusual resistance is detected that could be abnormal interference between the Breaker and Cell parts, stop immediately and move the Breaker out of the Connected position. Examine what is causing the interference and correct the situation. EATON CORPORATION 33

34 Digitrip Retrofit System for ITE K-3000, Digitrip Retrofit Kit Installation Components for ITE K-3000, K-3000 S, K-4000, and K-4000 S Breaker RMS/R Retrofits Step Description Qty. Comment Step 3 Trip Finger Mounting Parts 4A35659G05 1 Trip Finger Lng. Screw Stl. Fil Flat Washer Stl Lock Washer Stl Nut Hex Stl. 2 Reset Assembly Mounting Parts 4A35659G06 1 Reset Assembly 1 Bushing Steel 1 Cotter Pin 1 Loc-Tite DTA Assembly 4A35659G 1 DTA Mounting Parts 4A35659G Lng. Bolt Stl Lock Washer Stl. 2 Loc-Tite Step 4 For Externally Mounted Sensors (Standard) Pole Unit Hardware 4A35659G Lng. Bolt Stl. Full Thread Flat Washer Stl Lock Washer Stl Nut Hex Stl. 3 For Internally Mounted Sensors (Optional) Pole Unit Hardware 9A10095G Lng. Bolt Stl Lng. Bolt Stl Lng. Bolt Stl Lng. Screw Stl. F. H Flat Washer Stl Lock Washer Stl Nut Hex Stl. 3 Pole Unit Components (From OEM Supplier) 1 Glastic Molding 3 Sensor Shield Laminated 3 Adapter Plate 3 Glass Poly Spacer 18 to 27 Depending on Application Sensor Retainer 3 Step 5 Loc-Tite From Step 3 Step 6 Trip Unit See Pick List 1 Rating Plug See Pick List 1 Trip Unit Sub Assembly Parts 4A35659G08 1 Insulation Barrier 1 Support Clip R. H. 1 Support Clip L. H. 1 Insulation Barrier 1 34 EATON CORPORATION

35 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Digitrip Retrofit Kit Installation Components for ITE K-3000, K-3000 S, K-4000, and K-4000 S Breaker RMS/R Retrofits Step Description Qty. Comment Step6 (cont.) Lng. Screw Fil Lng. Screw Fil Flat Washer Stl Lock Washer Stl Lng. Screw Stl. P. H Flat Washer Stl Lock Washer Stl Nut Hex Steel 2 Spacer Brass 2 Label Digitrip Retrofit 1 Wire Tie Nylon 10 Trip Unit Mounting Parts 4A35659G09 1 Mounting Platform Barrier 1 Mounting Bracket R. H. 1 Mounting Bracket L. H. 1 Spacer Plate Lng. Bolt Stl Flat Washer Stl Lock Washer Stl Nut Hex Stl Lng. Screw Stl. F. H Flat Washer Stl Lock Washer Stl Nut Hex Stl. 4 Trip Unit Assembly Parts 4A35659G Lng. Screw Stl. Fil Flat Washer Stl Lock Washer Stl. 4 Aux. CT Harness 6502C84G01 1 PT Module 6502C82G01 1 Ring Terminal (.190,.250,.312,.375, Each Size) 3 Comm. Only Breaker Mounted CPT Kit See Pick List 1 MTE Transformer 1 HV Fused Wires 2 CPT Wires 1 Mounting Hardware Kit Lng. Screw Fil. 4 CPT Only.190 Flat Washer Stl Lock Washer Stl Nut Hex Stl. 4 Ring Terminal (.138,.190,.250,.312,.375, Each Size) 2 Wire Tie Nylon 12 Warning Label (208, 240, 480, & 575 Volt - Each) 1 Step 7 Finger-Safe Cover Kit FSK4 1 Cover (A, B, C, & D Each) 1 CPT Only EATON CORPORATION 35

36 Digitrip Retrofit System for ITE K-3000, Digitrip Retrofit Kit Installation Components for ITE K-3000, K-3000 S, K-4000, and K-4000 S Breaker RMS/R Retrofits Step Description Qty. Comment Step Lng. Screw Fil. 4 (cont.) HV Fused Wires From Step 6 2 Ring Terminal (.138 &.312) 2 Each CPT From Step 6 CPT Wires 1 Only From Step 6 Warning Label (208, 240, 480, & 575 Volt - Each) 1 From Step 6 Mounting Pad - 1", Self-Adhesive 2 From Step 9 Step 8 For Externally Mounted Sensors (Standard) Sensors See Pick List 3 Sensor Assembly Parts 4A35659G11 1 Mounting Bracket 1 Mounting Clips 2 Terminal Block 3-Point Lng. Bolt Stl Flat Washer Stl Lock Washer Stl Nut Hex Stl Lng. Bolt Stl Flat Washer Stl Lock Washer Stl Nut Hex Stl Lng. Screw Stl. Fil Flat Washer Stl Lock Washer Stl Nut Hex Stl. 6 Ring Terminal Sensor Mounting Parts 4A35659G Lng. Bolt Stl Flat Washer Stl Lock Washer Stl Nut Hex Stl. 2 For Internally Mounted Sensors (Optional) Sensors See Pick List 3 Sensor Mounting Parts 9A10095G05 1 Terminal Block 3-Point Lng. Screw T. C Lng. Screw Fil Flat Washer Stl Lock Washer Stl Lng. Screw Stl. Fil Flat Washer Stl Lock Washer Stl Nut Hex Stl. 6 Ring Terminal Wire Tie Nylon EATON CORPORATION

37 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A Digitrip Retrofit Kit Installation Components for ITE K-3000, K-3000 S, K-4000, and K-4000 S Breaker RMS/R Retrofits Step Description Qty. Comment Step8 Mounting Pad - 1", Self-Adhesive 4 (cont.) Glass Poly Spacer 18 to 27 Depending on Application From Step 4 Sensor Retainer 3 From Step 4 Step 9 For Externally & Internally Mounted Sensors Sensor Harness Parts 4A35659G13 1 Sensor Harness 1 DTA Extension Harness Lng. Screw Stl. Fil Flat Washer Stl Lock Washer Stl Nut Hex Stl. 2 Wire Tie Nylon 12 Mounting Pad - 1", Self-Adhesive 4 Wire Clamp Nylon 2 Step 10 Ring Terminal (.312) 3 From Step Flat Washer Stl. 3 Comm. From Step Lock Washer Stl. 3 Only From Step Nut Hex Stl. 3 From Step 4 Step 11 External Harness 6502C83G 1 External Harness Mounting Parts 4A35659G14 1 Except 510 Basic Lng. Screw Stl. T. C. 2 Wire Clamp Nylon 2 Auxiliary Switch Kit 4A35659G02 1 Comm. Only Microswitch Lng. Screw Stl. Fil. 2 Loc-Tite From Step 3 Step 13 Cell Harness See Pick List 1 NOTE: Due to the wide variety of Breakers and the multiple functions of the Retrofit components, some excess hardware may remain when the Retrofit is complete. EATON CORPORATION 37

38 Digitrip Retrofit System for ITE K-3000, Table 5. Torque Values for General Mounting and Screw Size Conversion Decimal Size (in) Standard Size Torque (in-lbs) Torque (ft-lbs) / / / / / Table 6. Torque Values for Copper BUS Connectors Decimal Size (in) Standard Size Torque (in-lbs) Torque (ft-lbs).250 1/ / / / eaton corporation

39 Digitrip Retrofit System for ITE K-3000, Instructional Leaflet IL A A H B F D C I K E H G M O L N J Fig. 70 Standard Retrofit Components (Externally Mounted Sensors) A. Sensors B. Trip Unit C. Aux. CT Module D. Direct Trip Actuator (DTA) E. CPT Transformer F. Rating Plug G. Aux. CT Harness H. Sensor Harness I. External Harness J. Cell Terminal Block K. Aux. Switch L. PT Module M. CPT Harness N. DTA Extension Harness O. Trip Finger EATON CORPORATION 39

40 Digitrip Retrofit System for ITE K-3000, Fig. 71 Optional Internally Mounted Sensor Retrofit Components 40 EATON CORPORATION

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