Cutler-Hammer Installation Instructions for the ND OPTIM 550 PowerNet and/or Zone Interlock Accessories (ICK 550N, ZGK550N, ZGPK550N)! WARNING CONTACT WITH ENERGIZED EQUIPMENT CAN RESULT IN DEATH, SEVERE PERSONAL INJURY, OR SUBSTANTIAL PROPERTY DAMAGE. DO NOT ATTEMPT TO INSTALL OR PERFORM MAINTE- NANCE ON EQUIPMENT WHILE IT IS ENERGIZED. ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT BEFORE PROCEEDING WITH THE TASK, AND ALWAYS FOLLOW GENERALLY ACCEPTED SAFE- TY PROCEDURES. CUTLER-HAMMER IS NOT LIABLE FOR THE MISAP- PLICATION OR MISINSTALLATION OF ITS PROD- UCTS. INSTALLATION MUST BE DONE BY A QUALIFIED ELECTRICIAN The user is cautioned to observe all recommendations, warnings, and cautions relating to the safety of personnel and equipment as well as all general and local health and safety laws, codes, and procedures. The recommendations and information contained herein are based on Cutler-Hammer experience and judgement, but should not be considered to be all-inclusive or covering every application or circumstance which may arise. If any questions arise, contact Cutler-Hammer for further information or instruction. 1.0 INTRODUCTION General Information The ND OPTIM 550 IMPACC Communications Kit(ICK), Zone Interlock(ZGK), and Zone Interlock with PowerNet(ZGPK) are plug-in modules available for field installation by authorized personnel (Figure 1-1). The plug-in modules are mounted in slots in the top of the right-hand side of the trip unit, and occupy the accessory mounting cavity in the circuit breaker assembly. The assemblies are composed of the following (Figures 1-2, 1-3 and 1-4): ICK550N: A contact assembly to feed breaker status information to the trip unit through the 12-pin connector. Figure 1-1 ND OPTIM 550 with ICK A 12-pin plug-in connector that connects to the trip unit. Containing a 4-wire pigtail connection for external use to provide 24 VDC control power to the breaker communications, and to transfer information to the IMPACC communications system. A 2-pin plug-in connector with violet wires that connects to the 2-pin connector with violet wires that extend from the trip unit. The Zone Select Interlock feature will only function with 550 Digitrip OPTIM trip units manufactured after March 1st, 2001 using the ZGK550N or the ZGPK550N field installable accessory. Any 550 Digitrip OPTIM trip units manufactured before this date will only provide the Short Delay Interlock feature using these accessories. Effective February 2001, Supersedes I.L. 29C898A dated September 2000.
Page 2 ZGK550N: A contact assembly to feed breaker status information to the trip unit through the 12-pin connector. A 12-pin plug-in connector that connects to the trip unit. Containing a 4-wire pigtail connection for external use to transfer zone interlock and ground fault information. ZGPK550N: A contact assembly to feed breaker status information to the trip unit through the 12-pin connector. A 12-pin plug-in connector that connects to the trip unit. Containing a 4-wire pigtail connection for external use to provide 24 VDC control power to the breaker communications, and to transfer information to the IMPACC communications system, zone interlock, and ground fault information. A 2-pin plug-in connector with violet wires that connects to the 2-pin connector with violet wires that extend from the trip unit. This instructional leaflet (IL) gives detailed procedures for installing the OPTIM 550 plug-in modules. Figure 1-3 ZGK Module Figure 1-2 ICK Module Figure 1-4 ZGPK Module
Page 3 2.0 INSTALLATION The OPTIM 550 plug-in modules can be fieldinstalled in ND circuit breakers under UL File E64983 by a qualified electrician. The OPTIM 550 plug-in modules are listed for factory installation under UL File E7819. Before attempting to install an OPTIM 550 plug-in module, check that the catalog number is correct as ordered and that the rating of the accessory satisfies the job requirements. The OPTIM 550 ICK, ZGK, and ZGPK are installed in the right accessory mounting cavity of a 3-pole circuit breaker with OPTIM 550 (electronic) trip unit (Figure 2-1). The OPTIM 550 plug-in modules must be installed in the circuit breaker before the circuit breaker is mounted in an electrical system. To install a plug-in module, perform the following procedures: 2-1. Switch circuit breaker to OFF position. 2-2. Disconnect and remove circuit breaker from installation and terminal connections. 2-3. Press PUSH-TO-TRIP button to trip operating mechanism and check handle moves to trip position with white colored indicator visible in escutcheon window. 2-4. Remove circuit breaker cover screws and covers. To install accessory, circuit breaker must be in tripped position. 2-5. Locate the wire tie that attaches gray and white neutral sensor wires (if furnished) to the metal accessory bracket in the right accessory slot. Cut the wire ties without cutting the wires. Locate the 12 position housing (see Figure 2-2) in the trip unit. Grasp it firmly and pull it out. Discard the housing. Finally, pull out the metal accessory bracket and discard. A circuit breaker that is mounted in an electrical system must be removed to install the accessory. To ensure correct accessory installation, the circuit breaker must be placed on a horizontal surface. General Installation! WARNING THE VOLTAGES IN ENERGIZED EQUIPMENT CAN CAUSE DEATH OR SEVERE PERSONAL INJURY. BEFORE REMOVING A CIRCUIT BREAKER INSTALLED IN AN ELECTRICAL SYSTEM, MAKE SURE THE CIRCUIT BREAKER IS SWITCHED TO THE OFF POSITION AND THERE IS NO VOLTAGE PRESENT WHERE WORK IS TO BE PERFORMED. SPECIAL ATTENTION SHOULD BE PAID TO REVERSE FEED APPLICATIONS TO ENSURE NO VOLTAGE IS PRESENT. For new circuit breaker installation, the trip unit must be installed in the circuit breaker before attempting to install the OPTIM 550 ICK, ZGK, or ZGPK. Wire Tie Accessory Identification Label CAT ICK550N ICK 550 STYLE 1484D67G03 FREQ 50/60 Hz DC VOLTS 125 VAC 10 AMPS 1.1 Plug-in Module with Pigtail Leads Figure 2-1 OPTIM 550 ICK
Page 4 Trip Unit 12 Position Housing Neutral Sensing 2 Position Housing (if Present) INCOM Communications Port Figure 2-2 Trip Unit Item Removal The ICK (black, orange, and violet wires) must go to wiring trough nearest the line end of the circuit breaker. Leads for the neutral sensor (if furnished) must go to the center trough. The ZGK (black, white/red, white/black, white/brown wires) must also go to wiring trough nearest the line end of the circuit breaker. For the ZGPK the black, orange, white/red, white/black, and white/brown wires go to the wiring trough nearest the line end of the circuit breaker, while the violet wires and the neutral sensor leads (if furnished) are routed through the center trough. 2-6. Route pigtails out the rear exit of the circuit breaker (Figure 2-7).! CAUTION Neutral Sensing 2 Position Housing (if Present) LEADS SHOULD BE FORMED AND ROUTED TO Remove 12 Position Housing Figure 2-3 Interphase Barrier Replacement CLEAR ALL MOVING PARTS WHEN ACCESSORY IS PROPERLY INSTALLED. LEADS COULD BE DAM- AGED IF IN CONTACT WITH MOVING PARTS. OPTIM 550 ICK Remove Blank Bracket INCOM Communications Port Neutral Sensing 2 Position Housing (if Present) 2-7. Install OPTIM 550 ICK as described in the following steps: a. Turn accessory mounting bracket to line up with slots in trip unit. b. Slide accessory mounting bracket into slots until retaining clip snaps into trip unit. c. Connect the 12 position housing from the ICK assembly to the pins vacated by the original 12 position housing supplied with the breaker. Note: the position housing fits in one orientation only. Wires from the switches will be coming out of the 12 position housing facing the left side of the breaker; wires connected to the 12 position housing on one end and bare on the other end come out toward the right side of the breaker (Figure 2-5).
Page 5 d. Take the gray and white neutral sensor input wires (if furnished) from the trip unit out of the breaker side trough and, with the provided wire tie, tie them to the wire portion between the existing wire tie attached to the bracket and the 12 position housing. The wire tie should be up against the bracket (see Figure 2-5). e. Connect the violet INCOM communications input wires from the trip unit to the male-male connector from the ICK assembly. The wires should be as close to the bracket as possible to avoid the breaker cover (see Figure 2-5). f. Push the four wires (black, orange, two violet) from the ICK assembly through one of the breaker troughs on the right side of the breaker. Push the two wires for the neutral sensor (if furnished) input (gray and white) down a separate trough. OPTIM 550 ZI 2-8. Install OPTIM 550 Zone Interlock as described in the following steps: Rear Exiting Leads Figure 2-4 ICK WIring Options a. Turn accessory mounting bracket to line up with slots in trip unit. b. Slide accessory mounting bracket into slots until retaining clip snaps into trip unit. c. Connect the 12 position housing from the ZGK assembly to the pins vacated by the original 12 position housing supplied with the breaker. Note: the position housing fits in one orientation only d. Push the four wires(black, white/black, white/red, white/brown) from the ZGK assembly through the breaker trough (closest to the line end of the circuit breaker) on the right side of the breaker. Push the two wires for the neutral sensor (if furnished) input (gray and white) down the center trough on the right side of the circuit breaker OPTIM 550 ZIPN 2-9 Install OPTIM 550 Zone Interlock w/powernet as described in the following steps: a - e. Same as for 550 ICK Note: Using Enclosed Wire Tie, Attach Neutral Sensing (if present) as Close as Possible to Existing Wire Tie as Shown Note: Keep 2 Position Housing and Wires as Close to Bracket as Possible Wires Connecting to Power Supply and INCOM Communications Port Figure 2-5 OPTIM 550 ICK Connections Neutral Sensing Wires (if present)
Page 6 f. Push the black, orange, white/black, white/red, and white/brown wires through the breaker trough (closest to the line end of the circuit breaker) on the right side of the breaker. Push the two wires for the neutral sensor (if furnished) input (gray and white) and the two violet wires from the ZGPK assembly down the center trough on the right side of the circuit breaker. Modification Label General Installation! CAUTION WHEN INSTALLING CIRCUIT BREAKER MAIN COVER, MAKE SURE THAT ALL INTERNAL PARTS ARE IN PLACE: Sliding handle barrier is positioned so that the handle opening is aligned with the handle. All leads are clear of the cover. 2-10. With circuit breaker handle in TRIPPED position and accessory pigtail leads (if used) routed as required, install circuit breaker covers. Secure with pan-head cover screws. Torque to 22-24 lbin. (2.49-2.72 N.m.) 2-11. Push the wires through the included 18 inch section of heat shrink tubing. Push the tubing as far into the breaker as possible (approx. 1/4 inch). Use a heat gun or an equivalent heat source to shrink the tubing (the temperature range required to shrink the material is 250-275 degrees F). 2-12. Place accessory labels (supplied with kit) on circuit breaker (see Figure 2-6). Black (-) Negative Orange (+) Positive Violet: INCOM Communications Input Figure 2-7 Wiring Key Accessory Identification Label Figure 2-6 Preferred Mounting Locations for ICK Nameplate Labels Power * Supply * Note: Power supply should be sized for a load current of 45 ma. 2-13. Install circuit breaker. 2-14. Connect accessory leads as required (see Figure 2-7). Cutler-Hammer assumes no responsibility for malfunctioning accessories installed improperly by the customer.
Page 7 Table 2.1 OPTIM 550 Assemblies Wire Chart Wire Color Description 550 ICK Zone Interlock Zone w/ Powernet (ICK) (ZGK) (ZGPK) White/Brown White/Black White/Red GF Alarm Short Delay/Ground Output Short Delay/Ground Input Zone Select Interlock Black 24 V Negative Control ➀ Orange 24 VDC Power Supply Power White Neutral Sensor Non-Polarity ➁ Gray Neutral Sensor Polarity Violet Violet INCOM INCOM Powernet ➀ It is crucial to connect the +24 VDC power supply to the correct terminal. Improper connection can destroy the electronic protection functions of the circuit breaker. The trip unit imposes a load of 45ma. ➁ The Optim Ground Fault Trip and Ground Fault Alarm units have NS and NS wires. The Non-Ground Fault Optim 550 Units have no wires.
Page 8 Cutler-Hammer Pittsburgh, PA 15220 (ISI) Style 6614C24H03 Printed in U.S.A.