W-VACiMB FIXED SECONDARY TERMINAL BLOCK OEM CONVERSION TYPE #2 RING-TYPE TERMINAL BLOCK 1 of 41
PLEASE READ These instructions are provided so that an OEM can officially convert a W-VACiMB Mining Breaker to an approved secondary variation. This variation is required for some OEMs for them to be incompliance with end customer needs. The OEM is authorized to do the conversion per this process and to still have the proper warranty protection. This procedure is intended to show the necessary steps to remove the standard secondary connector and replace it with a ring-type terminal block that contains the following connections: o Spring Charging Circuit Uses secondary connector pins 25 & 35. o (1) Shunt Open Circuit Uses secondary connector pins 31 & 30. o (1) Shunt Close Circuit Uses secondary connector pins 4 & 14. o Control Under Voltage Release (UVR) Circuit Uses secondary connector pins 2 & 44. This requires the UVR option to be installed. o (2) Normally Open Relays Relays are open when breaker is open. 1 st Relay uses secondary connector pins 7 & 17. 2 nd Relay uses secondary connector pins 9 & 19. o (1) Normally Closed Relay Relay is closed when breaker is open. Uses secondary connector pins 23 & 33. 2 of 41
Due to jumping connections in this procedure, the three relays will have the same voltage/supply as the charge motor. Similarly, the UVR, Close Coil, Charging Motor, and Trip Coil will share a common return (See Appendix A). You may choose to not install the jumpers for more circuit flexibility. Use appendices A through F for additional information. TOOLS REQUIRED Flathead Screwdriver Male Pin Remover 8 mm Wrench 9 mm Wrench 10 mm Wrench Wire Strippers Standard Wire Crimpers o To be used on 14 Gauge Insulated Wire Terminals 3 of 41
Parts List Quantity Item Supplier Part Number Cost 1 DIN Rail With PEM Studs www.monti-inc.com 68D7101G01 $12.60 Each 22 Insulated Eye Terminals #6 Screw, 16-14 AWG www.mcmaster.com 7113K23 $7.04 per 50 6 Two-Pole Jumpers www.mcmaster.com 7527K79 $4.55 per 25 4 #8-32 Nylock Nuts www.mcmaster.com 90633A009 $2.30 per 100 4 Spacers for #8 Bolt www.mcmaster.com 92510A133 $1.05 Each 1 Sixteen Terminal Block www.mcmaster.com 7527K75 $8.12 Each 5 Zip Tie www.mcmaster.com 7130K19 $3.78 per 100 5 Zip Tie Holder www.mcmaster.com 7566K62 $11.32 per 50 3 Feet Translucent Wire Sleeving www.mcmaster.com 7432K741 $8.97 per foot 8 Inches 3M Fire & Arc Protect Tape www.mcmaster.com 77255A4 $28.28 per 20 feet 1 3M Electrical Tape www.mcmaster.com 76455A21 $2.03 per 20 feet Monti Contact Info: Nick LaVigne nickl@monti-inc.com 864-323-0444 104 Airport Industrial Road, Greenwood, SC 29649 Eye Terminals DIN-Rail with PEM Studs Two-Pole Jumper 4 of 41
#8-32 Nylock Nuts #8 Spacers Zip Tie Holder Sixteen Terminal Block Zip Tie Translucent Wire Sleeving Electrical Tape Arc Protect Tape 5 of 41
PROCEDURE Step 1: Locate the secondary control power wiring terminal box on the breaker. Figure 1: Breaker side secondary Terminal Box. 6 of 41
Step 2: Insert flat head screwdriver into the two clips to release the front cover. Figure 2: Schematic of the how to remove the front cover on the secondary. 7 of 41
Step 3: Using the male pin remover, take out each pin. This can be accomplished by pressing the male pin remover into a pin slot and pushing hard to unseat the pin. Once the pin has been unseated, push from the opposite side of the secondary connector to pull the pin out of its slot. Repeat for ALL pins (more figures on next page). Figure 3a: Line up the male pin remover with a pin. 8 of 41
Figure 3b: Press the male pin remover in hard to unseat the pin. Figure 3c: Once unseated by the male pin remover, push on the pin from the opposite side to get the pin out of the slot. Repeat for all pins. 9 of 41
Step 4: Once all pins have been taken out of their slots, remove the secondary connector and rubber tubing. Discard if desired. Rubber Tubing Secondary Connector Figure 4: Remove the gray rubber tubing and secondary connector, they will not be used. 10 of 41
Step 5: Separate the (14) wires needed for the secondary terminal block from the rest of the wires and set aside. See appendix A for a listing of the necessary wires. Figure 5: Separating the (14) needed wires. 11 of 41
Step 6: Pull the unnecessary wires through the hole in the top of the breaker. These wires will be secured inside the breaker in the proceeding steps. 14 Needed Wires Figure 6: Pull out the unnecessary wires. 12 of 41
Step 7: Wrap about (22) inches of transparent protective covering around these unnecessary wires. These wires that are not needed will be secured inside of the breaker. Figure 7: Transparent protective wiring cover. 13 of 41
Step 8: If too long, cut the transparent protective wiring cover two inches from the end of these unnecessary wires. Figure 8: Removal of excessive wiring cover. 14 of 41
Step 9: Cut an 8 inch section of the fire retardant arc protective tape. Figure 9: Cutting an 8 inch section of arc protective tape. 15 of 41
Step 10: Wrap the arc protective tape around the exposed portion of the unneeded wires. Then, secure this protective tape with the electrical tape. Figure 10: Wrapping the unneeded wires in electrical tape. 16 of 41
Step 11: Wrap the unused wires completely with electrical tape. Figure 11: Unneeded wires completely covered. 17 of 41
Step 12: We will now secure the unused wires inside the breaker. Place (2) cable tie holders on the inside wall of the breaker (spring side). Position them about three inches from each other and a half inch from the front edge. Figure 12: Placement of cable tie holders. 18 of 41
Step 13: Insert cable ties through the inslots of the tie holders to secure the unused wires. Figure 13: Securing of the unneeded wires. 19 of 41
Step 14: Place another cable tie holder as shown closer to the back of the breaker to hold the end of the unneeded wire bundle in place. Zip tie the bundle to the cable-tie holder. Figure 14: Securing of the wires to avoid interference with spring. 20 of 41
Step 15: The wires should be secured in this manner and any excess cable ties should be clipped. (3) Zip Ties Figure 15a (left): Used three zip ties to secure the unused wires to the inner wall. Figure 15b (right): Wires are secured from both the closing and open spring assemblies. In Process Quality Check: Operate the breaker mechanically and make sure no moving parts interfere with the wiring. 21 of 41
Step 16: Wrap transparent wiring cover around the (14) wires used for the terminal blocks. The wiring cover should span roughly eight inches. Figure 16: Wrapping of the transparent wire covering on terminal wires. 22 of 41
Step 17: Unfasten the bolt on the top center of the breaker that helps secure the mechanism in place using a 10 mm wrench. Figure 17: Temporary removal of the center bolt. It will be used for mounting the mounting bracket. 23 of 41
Step 18: Unfasten this bolt on the underside of the top-right of the breaker ground terminal connection bolt using an 8 mm wrench. Figure 18: Removal of the bolt. 24 of 41
Step 19: Fasten the DIN-Rail onto the top of the breaker using the bolts removed in steps 17 and 18. For the bolt on the right, remember to reconnect the grounding wire on the inside (Figure 18). You will not be able to access the breaker s center bolt once the terminal block is mounted on the DIN-Rail. Figure 19: Securing of the din-rail. 25 of 41
Step 20: Fasten the terminal block to the four PEM studs on the DIN-Rail using the (4) spacers and the (4) Nylon Locking Nuts. Figure 20a: Place terminal block on PEM studs Figure 20b: Place spacers and nylon locking nuts on all (4) PEM studs and tighten down. 26 of 41
Step 21: Slide the white wire labels on the wires back until they reach the transparent wire cover. Figure 21: Sliding the white labels back. 27 of 41
Step 22: Remove excess wire on each wire by lining up the wire with the center of the terminal designated for that wire. The wires will increase in length as you go down the DIN-Rail from left to right. See appendix A for the proper location of each wire to determine the appropriate length. Figure 22: Snipping of the wires. 28 of 41
Step 23: Strip all 14 wire ends using the wire stripper. Wires are 14 Gauge and should be stripped approximately 0.25 (7mm). Figure 23a: Stripping each wire. Figure 23b: All needed wires have been stripped. 29 of 41
Step 24: For each wire, place the ring to be crimped on the end of each wire, allowing a small amount of the wire to be exposed. Then crimp the ring terminal to the wire. Exposed Wire Figure 24a: Uncrimped ring terminal on stripped wire. Figure 24b: Crimping the ring terminals on. 30 of 41
Step 25: Repeat step 24 for all wires. Figure 25: All wires are the appropriate length and have ring terminals crimped on. 31 of 41
Step 26: Attach the appropriate wire to the appropriate terminal. Repeat for all wires. See attached appendix (A) for wiring locations. Figure 26: Attach each wire to its terminal. There will be two extra terminals that can be used for future needs. 32 of 41
Step 27: Take the first 8 screws out of the non-breaker side of the terminal block. Then, take (3) of the two-pole jumpers and arrange them on the terminal block so terminals 1 through 4 are connected together. Take another (3) jumpers to connect terminals 5 through 8. Screw the jumpers into place using the terminal block screws. Figures 27a & 27b: Terminals 1-4 will be jumped together. Terminals 5-8 will also be jumped together. Ensure 4 & 5 are NOT jumped together. Jump 1-4 Jump 5-8 No Jumper 33 of 41
Step 28: Attach a cable tie holder to the top of the breaker and secure the wires with a cable tie. Figure 28a: Place a cable tie holder on top of the breaker. Figure 28b: Use a zip tie to secure the wires. 34 of 41
FINAL RESULT 35 of 41
QUALITY CHECK Visually inspect the breaker for defects. Make sure all of the electrical connections are correctly secured. Make sure all of the electrical connections are in accordance to the wiring schematic. Make sure all of the bolted connections that were added as a part of this procedure are properly tightened. Electrically test the operation of the breaker to make sure the modifications were correctly done and that the breaker properly operates. Electrically operate the breaker five times for a charge - open - close type operation. Inspect the operation of the large black closing mechanism spring to make sure that it does not hit the modified wiring harness on the left side of the mechanism side sheet. The spring should have 0.5 or more clearance during opening or closing. Make sure the front cover is properly mounted. 36 of 41
Appendix A: Wiring Locations 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Figure 29: Graphical locations of each wire. Terminal Position Old CODE New CODE 2013+ Purpose 1 D1 X11:25 M1:1 Motor Power Supply (Hi) 2 C9 Q1.1:9 X11:7 Normally Open Relay 1 (Hi) 3 C13 Q1.1:13 X11:9 Normally Open Relay 2 (Hi) 4 C7 Q1.1:7 X11:23 Normally Closed Relay (Hi) 5 H4 X11:44 Y6:2 UVR Return (Lo) 6 P2 X11:14 U2:2 Close Coil Return (Lo) 7 F22 M1.2:22 X11:35 Motor Return (Lo) 8 C2 Q1.1:2 X11:30 Trip Coil Return (Lo) 9 H3 X11:2 Y6:1 UVR Power Supply (Hi) 10 P1 X11:4 U2:1 Close Coil Power Supply (Hi) 11 P7 X11:31 U2:7 Trip Coil Power Supply (Hi) 12 C10 Q1.1:10 X11:17 Normally Open Relay 1 (Lo) 13 C14 Q1.1:14 X11:19 Normally Open Relay 2 (Lo) Note: The 14 X11 designation C8 refers to the Q1.1:8 X11:33 secondary connector. For Normally example, Closed X11:25 Relay is the (Lo) 25 th pin on the secondary connector. 37 of 41
Appendix B: Wiring Diagram Figure 30: Graphical schematic of terminal assembly and breaker circuits (breaker is in the open position). 38 of 41
Appendix C: DIN-Rail with PEM Studs (Inches) 39 of 41
Appendix D: W-VACiMB Wiring Diagram 40 of 41
Appendix E: New Overall Breaker Dimensions 41 of 41
Appendix F: Wire Identification Sheet The labels above can be copied and taped to the top of the breaker for easy identification of each wire and its purpose. 42 of 41