Effective April 2010Supersedes IL 33-A46-2 Dated 01/04Instruction Leaflet IL33-A46-3
Digitrip Retrofit System for Allis-Chalmers LA-600 F Electrically Operated Fused Breakers
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Instruction.Leaflet.IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-Chalmers LA-600 F Electrically Operated Fused Breakers
EAtOn CORpORAtIOn www.eaton.com
WARNINGPOWER 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.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 3
INTRODUCTION
Eaton Digitrip Retrofit Kits are available in a numberof configurations that provide a wide range offeatures. The Digitrip System starts with the 510Basic Kit which offers true RMS sensing,overcurrent protection, and self-testing features.Advanced Digitrip Retrofit Kits feature zoneinterlocking, digital alphanumeric displays, remotealarm signals, PowerNet communications, energymonitoring capabilities, power factors, andharmonic content measurements.
The following table provides a quick reference ofthe components supplied with each level of RetrofitKit. Before beginning the Retrofit process, take aminute to review the information contained in the
table. It is important that the Retrofitter understandswhich level of Retrofit Kit is to be installed andwhich components are included with the Kit.The instructions contained in this manual cover theinstallation of all levels of Retrofit Kit. If the Kit youare installing does not contain a certain component,skip the instructions for that component andproceed to the next.
Throughout the Retrofit process, refer to the TorqueTables at the back of this manual for specifictorque values.
If you have any questions concerning the RetrofitKit and / or the Retrofit process, contact Eaton at1-800-937-5487.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
4 EATON CORPORATION www.eaton.com
WARNING
STEP 1: GENERAL BREAKER PREPARATION
Before attempting to remove the Breaker from theCell or perform any Retrofit Operation, be sure toread and understand the Safety Precautionssection of this manual. In addition, be sure to readand understand the Instructions for the Applicationof Digitrip RMS Retrofit Kits on Power CircuitBreakers (Retrofit Application Data - PublicationAD 33-855-4), supplied with the Digitrip RetrofitKit.
DO NOT ATTEMPT TO INSTALL OR PERFORMMAINTENANCE ON EQUIPMENT WHILE IT ISENERGIZED. SEVERE PERSONAL INJURY ORDEATH CAN RESULT FROM CONTACT WITHENERGIZED EQUIPMENT. VERIFY THAT NOVOLTAGE IS PRESENT BEFORE PROCEEDING.
A. Trip the Breaker and remove it from the Cell.Move the Breaker to a clean, well-lit work area.
NOTE: It is the responsibility of the Retrofitter toinsure that the Breaker and all originalcomponents are in good condition. Visu-ally inspect all Breaker components forsigns of damage or wear. If any signs ofdamage or wear are detected for compo-nents not included in the Retrofit Kit,secure the necessary replacement partsbefore beginning the Retrofit Process.
The force necessary to trip the Breakershould not exceed three (3) lbs.
NOTE: It is the responsibility of the Retrofitter toinsure that the proper, manufacturer’srecommended crimping tools and termi-nals are used for each type of connector.It is also the responsibility of theRetrofitter to insure that all wire prepara-tions, connections, strippings, termina-tions, and wiring techniques are per-formed according to the latest IEEE, NEC,and / or NEMA industry standards, speci-fications, codes, and guidelines.
To begin the Retrofit Process, refer to the compo-nents list at the end of this manual. Layout thecomponents and hardware according to the stepsoutlined. The parts bags are labeled with thecorresponding step number. The components andhardware will be used to complete each step in theRetrofit Process.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 5
STEP 2: REMOVING THE ORIGINALCOMPONENTS
Refer to the Allis-Chalmers LA-600 F InstructionManual, originally supplied with the Breaker, toperform the following procedures.
A. If equipped, remove and save the hardwaresecuring the Manual Closing Handle to theBreaker. Remove and save the Manual ClosingHandle.
B. Remove and save the hardware securing theFront Cover to the Breaker. Remove and savethe Front Cover.
C. Remove and save the hardware securing thePrimary Disconnect Fingers (Finger Clusters) tothe bottom Breaker Studs. Remove and savethe Finger Clusters.
Fig. 1 Original Components Removed from theBreaker and Saved for Reinstallation.
D. Remove and scrap the hardware securing theStatic DC Trip Device Assembly (Trip UnitAssembly) to the right Breaker Frame. Removeand scrap the Static DC Trip Device Assemblyand associated wiring.
E. Remove and scrap the hardware securing theMagnetic Latch Release Device Assembly(original DTA) to the Breaker. Remove andscrap the Magnetic Latch Release DeviceAssembly and associated wiring.
F. Remove and scrap the CTs (Sensors), spacers,and associated wiring.
NOTE: Depending on the original configuration ofthe Breaker, it may be necessary to re-move the Fuse Carriage Assembly in orderto remove the CTs. If this is necessary,refer to the Allis-Chalmers LA-600 FManual, originally supplied with theBreaker, for removal and installationinstructions.
Fig. 2 Original Components Removed from theBreaker and Scrapped.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
6 EATON CORPORATION www.eaton.com
STEP 3: INSTALLING THE SENSORS
Fig. 3 Overview: Sensors Installed on theBreaker.
A. Slide a Sensor over each bottom Breaker Stud,as shown. Note that the Sensor Terminals areat the top and that the Sensor Nameplates facethe rear of the Breaker.
Fig. 4 Sensors Installed on the Bottom BreakerStuds.
B. Position a Sensor Spacer at the top and bot-tom of each bottom Breaker Stud, as shown.Using the (6) .190-32 × 1.25" screws, (12) flatwashers, and (6) Nylok nuts supplied securethe Sensor Spacers to the bottom BreakerStuds so they hold the Insulation Piece andSensors against the Breaker Backplate. Do notover tighten the mounting hardware.
Fig. 5 Sensor Spacers Installed on the BottomBreaker Studs.
C. Connect the ring terminals of the SensorHarness to the Sensors.
Refer to Section 12 of the Retrofit ApplicationData, supplied with the Retrofit Kit, for detailedwiring specifications.
For LA-600 F Retrofits, the following conventionsapply.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 7
D. Temporarily route the Sensor Harness, asshown, up along the left side of the BreakerBackplate towards the top of the Breaker.Final Sensor Harness routing and connectionswill be made later in the Retrofit Process.
STEP 4: INSTALLING THE AUX. CT MODULEASSEMBLY
Fig. 7 Sensor Harness Routed Towards the Topof the Breaker.
E. Using the original mounting hardware removedin Step 2-C, reinstall the Finger Clusters.
For Kits Supplied with a PT Module Only: Donot fully tighten the Finger Cluster hardware atthis time. This hardware will be used to securethe PT Wires later in the Retrofit Process.
Fig. 8 Finger Clusters Reinstalled on the BottomBreaker Studs.
Fig. 9 Overview: Aux. CT Module AssemblyInstalled on the Breaker.
A. Remove and save the mounting hardwaresecuring the top of the Breaker Backplate tothe rear Breaker Frame.
Fig. 10 Location of the Breaker BackplateMounting Hardware.
B. Align the right Aux. CT Module MountingBracket with the hole in the Breaker Backplateand rear Breaker Frame. Reinstall the mount-ing hardware removed in the previous step.
HARDWARE TOBE REMOVED
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
8 EATON CORPORATION www.eaton.com
Fig. 11 Identifying the Aux. CT Module MountingBrackets.
Once the mounting hardware is started, rotatethe mounting bracket until it is level with thetop of the Breaker. Fully tighten the mountinghardware.
RIGHT
LEFT
Fig. 12 Right Aux. CT Module Mounting BracketInstalled on the Breaker.
C. Repeat the procedure to install the left Aux. CTModule Mounting Bracket.
E. Align the bottom Aux. CT Module InsulationBarrier Assembly with the existing center holesin the right and left Aux. CT Module MountingBrackets, as shown. Secure the bottom Aux.CT Module Insulation Barrier Assembly to theAux. CT Module Mounting Brackets using the(2) .190-32 × .375" flat head, counter sunkscrews supplied.
Fig. 13 Left Aux. CT Module Mounting BracketInstalled on the Breaker.
D. Align the Insulation Barrier Mounting Bracketswith the existing holes in the bottom Aux. CTModule Insulation Barrier, as shown. Securethe mounting brackets to the Insulation Barrierusing the (4) .190-32 × .250" nylon screwssupplied.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 9
Fig. 15 Bottom Aux. CT Module InsulationBarrier Assembly Installed on the Aux. CTModule Mounting Brackets.
For Kits Supplied with a PT Module Only.
F. Remove and scrap the “PT Label Flag” fromthe PT Module. Use the original hardware toreinstall the PT Harness Connector Bracket tothe PT Module.
Fig. 16 PT Module Warning Label Bracket Re-moved from the PT Module.
G. Align the Insulation Barrier (Fish Paper) and PTModule with the existing holes in the top of theAux. CT Module, as shown. Secure the Insula-tion Barrier and PT Module to the Aux. CTModule using the (2) .138-32 × .375" threadcutting screws, (2) lock washers, and (2) flatwashers supplied.
Fig. 17 PT Module and Insulation BarrierMounted to the Aux. CT Module.
H. Connect the PT Extension Harness to the PTHarness.
Fig. 18 PT Extension Harness Connected to thePT Harness.
For All Retrofit Kits.
I. Align the Aux. CT Module Assembly with theexisting holes in the Aux. CT Module MountingBrackets. Secure the Aux. CT Module Assem-bly to the mounting brackets using the (4) .190-32 × .375" flat head, counter sunk screwssupplied. Note that the Aux. CT ModuleTerminal Block should be oriented towards theleft side of the Breaker
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
J. Align the front Aux. CT Module InsulationBarrier with the existing holes in the rear of theAux. CT Module Mounting Brackets, as shown.Secure the front Insulation Barrier to themounting Brackets using the (2) .190-32 ×.500" nylon screws supplied.
NOTE: The front and rear Aux. CT Module Insula-tion Barriers are the same and, therefore,interchangeable.
Fig. 20 Rear Aux. CT Module Insulation BarrierInstalled on the Mounting Brackets.
K. Repeat the procedure for the front Aux. CTModule Insulation Barrier.
Fig. 21 Front Aux. CT Module Insulation BarrierInstalled on the Mounting Brackets.
L. Remove and save the Cover from the Aux. CTModule Terminal Block. Route the SensorHarness along the outside of the left Aux. CTModule Mounting Bracket to the TerminalBlock.
Connect the Sensor Harness to the properterminals of the Aux. CT Module. Refer toSection 12 of the Retrofit Application Data,supplied with the Retrofit Kit, for detailed wiringspecifications. The long tan and green wires inthe Sensor Harness are used for a remoteNeutral Sensor on a 4W Ground Breaker. Ifthese wires are not used in this application,they should be removed from the SensorHarness.
Fig. 22 Sensor Harness Connected to the Aux.CT Module Terminal Block.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 11
M. Remove one of the nuts from the front TerminalBlock Cover Stud. Connect the Sensor Har-ness Ground Wire (with ring terminal) to thestud. Use the original nut to secure the groundwire.
N. Secure the Sensor Harness to the outside ofthe left Aux. CT Module Mounting Bracketusing the (1) self-adhesive mounting pad and(1) wire tie supplied.
NOTE: The Terminal Block Cover will be installedlater in the Retrofit Process after the DTAWires are connected to the TerminalBlock.
For Kits Supplied with a PT Module Only.
O. Install a PT Module Warning Label on the frontand rear Aux. CT Module Insulation Barriers sothey are clearly visible.
Fig. 24 Sensor Harness Secured to the Left Aux.CT Module Mounting Bracket.
Fig. 25 PT Warning Label Installed on the FrontAux. CT Module Insulation Barrier.
Fig. 26 PT Warning Label Installed on the RearAux. CT Module Insulation Barrier.
P. Refer to Section 7-3, Power Flow Conventionof the Retrofit Application Data, supplied withthe Retrofit Kit for additional wiring informationand to verify the Phase Convention used onthis Breaker Application.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
12 EATON CORPORATION www.eaton.com
The PT Wires are marked for connection toPhases 1, 2, and 3 with corresponding num-bers.
NOTE: Before cutting the PT Wires, verify thePhase Convention used on the BreakerApplication.
Route the PT Wires to the right side of theBreaker, then downward to a position suitablefor attachment to the bottom Breaker Studs.Move the PT Wire markers to a position wherethey will still be attached to the wires aftercutting. Cut the wires to the appropriatelength, strip each wire .250", and install a .250"ring terminal on each wire.
With one hex cap screw removed and the otherloosened, insert the ring terminal of each PTWire between the Finger Cluster and Stud ofeach corresponding bottom Phase. Insert theremoved hex cap screws through the FingerCluster and PT Wire ring terminals. Fullytighten all six (6) hex cap screws securing theFinger Clusters to the bottom Breaker Studs.
Fig. 27 PT Wires Connected to the BottomBreaker Studs.
Fig. 28 PT Wires Secured to the Breaker andSensor Harness.
NOTE: The PT Module is slightly higher theBreaker Arc Chutes. As the RetrofittedBreaker is being installed in the Cell,ensure that clearance exists between thetop of the PT Module and the BreakerCell. If sufficient clearance does not exist,contact Eaton.
Q. Secure the PT Wires to the top of the Aux. CTModule, right Aux. CT Module MountingBracket, right rear Breaker Frame, and SensorHarness using the self-adhesive mountingpads and wire ties supplied.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 13
STEP 5: INSTALLING THE DTA ASSEMBLY
Fig. 29 Overview: DTA Assembly Installed in theBreaker.
A. Using the specifications contained in CuttingPlan “A”, cut the bottom front corner off of theright Arc Chute Insulation Barrier.
Fig. 31 DTA Extension Harness Connected to the2-Point Terminal Block.
For Kits Supplied with an Auxiliary Switch Only.
B. Cut 2.50" off the Microswitch Arm. Bend theMicroswitch Arm according to the specifica-tions contained in Bending Plan “A”.
Fig. 30 Cutting Plan “A”, Left Arc Chute Insula-tion Barrier.
B. Connect the DTA Extension Harness, Positiveto Positive and Common to Common, at the2-Point Terminal Block on the DTA Assembly.
REMOVE THIS AREA.438
.875
.188Fig. 32 Bending Plan “A”, Microswitch Arm.
C. Mount the Microswitch to the Auxiliary SwitchMounting Bracket, as shown, using the (2).138-32 × 1.00 screws, (4) flat washers, (2) lockwashers, and (2) .138-32 nuts supplied.
.375"
45˚
3.125"
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
14 EATON CORPORATION www.eaton.com
Fig. 33 Microswitch Installed on the AuxiliarySwitch Mounting Bracket.
D. Mount the Auxiliary Switch Assembly to theDTA Assembly, as shown, using the (1) .164-32× .375 screw, (1) .164-32 × .250 screw, (2) lockwashers, and (2) flat washers supplied. Notethat the longer screw is used to secure the topof the Auxiliary Switch Assembly.
Fig. 35 Wrist Pin to be Removed from theBreaker.
F. I insert the Wrist Pin into the Insulation Linkand Breaker Pole Shaft from the right side.Install (1) Tru-arc lock ring on the left end of thenew Wrist Pin.
E. Remove and scrap the Wrist Pin and hardwarethat connects the right Insulation Link to theBreaker Pole Shaft for Phase 3.
Fig. 36 New Wrist Pin Installed in the Breaker.
G. The DTA is mounted to the Breaker using thetwo existing holes in the right Breaker Frameand a hole in the front Breaker Frame. In somecases, the hole needed to mount the DTA tothe front Breaker Frame may not exist. In thiscase, use Drilling Plan “A” to drill the neededhole.
LONGER SCREW
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 15
Fig. 37 Drilling Plan “A”.
NOTE: Cover the region below the area to bedrilled to prevent metal shavings fromfalling into the Breaker Mechanism.
H. Position the External Harness near the top rightfront corner of the Breaker. Route the AuxiliarySwitch Wires down through the Breaker to thefront bottom right corner. With the DTA As-sembly sitting on the work surface, connect theExternal Harness Auxiliary Switch Wires to the“Common” and “Normally Open terminals onthe Auxiliary Switch.
NOTE: As the DTA Assembly is being mounted tothe right Breaker Frame, the DTA FrontMounting Bracket MUST be on the OUT-SIDE of the front Breaker Frame, the DTATrip Finger MUST be IN FRONT of the rollpin on the Breaker Trip Bar, and theAuxiliary Switch Arm, if applicable, MUSTbe IN FRONT of the Insulating Link asshown.
.375
.281 DIA. (1)
4.00
Fig. 38 Auxiliary Switch Wires Connected tot heAuxiliary Switch.
I. Mount the DTA Assembly, as shown, to theexisting holes in the right Breaker Frame usingthe (2) .250-20 × .750 bolts, (2) lock washers,and (2) flat washers supplied.
Fig. 39 Correct Positioning of the DTA AssemblyFront Mounting Bracket and AuxiliarySwitch Arm.
J. Temporarily secure the DTA Assembly frommounting bracket, as shown, to the hole in thefront Breaker Frame using the (1) .250-20 ×1.00 bolt, (1) flat washer, (1) lock washer, and(1) nut supplied. Note that the bolt must beinserted from the inside of the Breaker FrontFrame.
NOTE: Do not tighten the hardware securing theDTA Assembly to the front Breaker Frameat this time. It will be used later in theRetrofit Process to secure the Trip UnitAssembly.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
16 EATON CORPORATION www.eaton.com
Fig. 40 DTA Assembly Front Mounting BracketTemporarily Secured to the Front BreakerFrame.
K. Compress the spring on the Reset Shaft. Withthe spring compressed, align and install theReset Assembly on the Wrist Pin installed inStep 5-F. Install (1) flat washer supplied on theWrist Pin. Install (1) Tru-arc lock ring on theWrist Pin to secure the Reset Assembly.
Fig. 41 Reset Assembly Installed on the BreakerPole Shaft Wrist Pin.
L. Route the DTA Extension Harness between theright Breaker Frame and the right Phase Barrierto the area on the Aux. CT Module Assembly.Use the self-adhesive mounting pads and wire
Fig. 42 DTA Extension Harness Secured to theRight Phase Barrier.
M. Route the DTA Extension Harness to the Aux.CT Module Terminal Block. Connect the “+”DTA Wire to the “OP” terminal of the Aux. CTModule Terminal Block and the unmarked wireto the “ON” terminal.
Fig. 45 Overview: Trip Unit Assembly Installedon the Breaker.
NOTE: This kit provides both a Right Hand and aLeft Hand Trip Unit Mounting Bracket.The Right Hand Mounting Bracket isnormally used as shown in this InstructionLeaflet. However, the Left Hand Trip UnitMounting Bracket should be used insteadof the Right Hand Bracket if the breakerhas a set of Trigger Fuses mounted in theupper, right hand position where the RightHand Bracket would normally mount.
A. Align the holes in the Trip Unit Insulation Barrierwith the holes in the Trip Unit MountingBracket, as shown. Secure the InsulationBarrier to the Trip Unit Mounting Bracket usingthe (2) .190-32 × .500 nylon screws supplied.
Fig. 46 Insulation Barrier Installed on the TripUnit Mounting Bracket.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
18 EATON CORPORATION www.eaton.com
B. Align the Trip Unit with the holes in the Trip UnitMounting Bracket, as shown. Secure the TripUnit to the Mounting Bracket using the (2).190-32 × 4.00 screws, (2) lock washers, (2) flatwashers, and (2) brass spacers supplied. Notethat the brass spacers are used between thebottom of the Trip Unit and the top of the TripUnit Mounting Bracket.
E. Align the Trip Unit Assembly with the holes forthe right Bearing Cap and the bolt used tomount the front DTA Assembly MountingBracket. Secure the Trip Unit Assembly to theBreaker using the (2) .250-20 × .750 bolts, (2)lock washers, and (2) flat washers supplied andthe hardware removed in the previous step.
F. Using the mounting hardware just removed inStep 6-D, secure the front Trip Unit Assemblymounting Bracket and front DTA AssemblyMounting Bracket to the front Breaker Frame.
Fig. 49 Trip Unit Assembly Mounted to theBreaker.
G. Remove the Trip Unit Cover. Install the RatingPlug. Reinstall the Trip Unit Cover using theoriginal hardware.
Fig. 47 Trip Unit Installed on the MountingBracket.
C. Remove and scrap the hardware securing theright Racking Shaft Bearing Cap to the rightBreaker Frame. Scrap the Bearing Cap.
Fig. 48 Bearing Cap to be Removed.
D. Remove and save nut, lock washer, and flatwasher securing the front DTA AssemblyMounting Bracket to the front Breaker frame.
BEARING CAP TOBE REMOVED
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 19
STEP 7: ADJUSTING THE DTA TRIP ANDRESET FUNCTIONS
Fig. 51 Overview: Breaker Ready for DTAAdjustment.
A. Back-off the top adjusting nut above the springon the Reset Shaft. Apply Loc-Tite® 243 to thethreads then turn the adjusting nut until a cageheight of 0.50" (1/2") between inside surfaceson the washers at the top and bottom of thespring is achieved.
NOTE: The cage height is measured at the backof the spring (facing the rear of theBreaker).
Fig. 52 Adjusting the Cage Height.
B. Refer to the wiring diagram originally suppliedwith the Breaker to determine the correctSecondary Contacts to be used to charge andclose the Breaker.
CAGEHEIGHT0.50"
Fig. 50 Trip Unit Assembly with Rating Plug andCover Installed on the Breaker.
H. Install the Digitrip Retrofit Label on the top ofthe Trip Unit.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
20 EATON CORPORATION www.eaton.com
Fig. 53 Location of the Secondary Contacts.
WARNING
TO ADJUST THE GAP BETWEEN THE DTA TRIPFINGER AND TRIP SHAFT INTERLOCK PIN,THE BREAKER MUST BE IN THE CLOSEDPOSITION. KEEP HANDS AND FINGERS AWAYFROM MOVING PARTS WITHIN THE BREAKER.FAILURE TO DO SO COULD RESULT IN SE-VERE PERSONAL INJURY.
C. Loosen the nut on the back end of the DTAShaft and apply Loc-Tite® 243 to the threads.CHARGE and CLOSE the Breaker. Whileholding the nut just loosened, turn the DTAShaft shoulder nut until a minimum gap of0.060" to 0.090" exists between the DTA TripFinger and the Trip Shaft Interlock Pin (roll pin)on the right end of the Breaker Trip Shaft.Tighten the nut on the back of the DTA Shaft.
Fig. 54 Nut to Be Loosened to Adjust the GapBetween the DTA Trip Finger and the TripShaft Interlock Pin.
Fig. 55 Adjusting the Gap Between the DTA TripFinger and the Trip Shaft Interlock Pin.
NUT TOBE LOOSENED
GAP 0.06"TO 0.09"
SHOULDER NUTTO TURN DTASHAFT
Instruction Leaflet IL 33-A46-3Effective April 2010
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D. Return the Breaker to the OPEN position andallow sufficient time for the Loc-Tite to set.
E. Connect a 24 VDC power supply to the DTAterminals; positive to positive and negative tonegative. Close the Breaker. Energize the DTAto trip the Breaker; de-energize when theBreaker trips. Make certain that the DTAresets. If the Breaker fails to properly tripinsure that a minimum gap of 0.060" to 0.090"exists between the DTA Trip Finger and the TripShaft Interlock Pin. If the Breaker fails toproperly reset or trip, readjust the DTA Assem-bly as described in the previous steps.
STEP 8: INSTALLING THE EXTERNALHARNESS AND FINALCONNECTIONS
Fig. 56 Overview: Harnesses Connected to theTrip Unit.
A. Plug the Aux. CT Harness into the connectoron the Aux. CT Module Pigtail.
B. Route the Aux. CT Harness across to the rightside of the Breaker, then forward towards theTrip Unit. Connect the Aux. CT Harness to itsreceptacle in the Trip Unit. Use the self-adhe-sive mounting pad and wire tie supplied tosecure the Aux. CT Harness to the right PhaseBarrier, as shown. Note that the Aux. CTHarness is longer then necessary. The excessshould be “coiled” as it is secured to the rightPhase Barrier.
Fig. 57 Routing and Connection of the Aux. CTHarness to the Trip Unit.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
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C. Connect the External Harness to the recep-tacles in the Trip Unit. Secure the ExternalHarness to the Trip Unit Mounting Bracket, asshown, using the (1) Panduit tie mount and (1).164-18 × .500 thread cutting screw, (1) lockwasher, and (1) flat washer supplied.
D. For Kits Supplied with a PT Module Only:Route the PT Extension Harness across to theright side of the Breaker, then forward towardsthe Trip Unit. Connect the PT Extension to thecorresponding plug on the External Harness.Use the self-adhesive mounting pad and wiretie supplied to secure the PT Extension Har-ness to the right Phase Barrier. Note that thePT Extension Harness is longer then necessary.The excess should be “coiled” as it is securedto the right Phase Barrier.
NOTE: For 510 Basic Kits, the External Harness isthe Shorting Plug pictured below. It is tobe plugged into the corresponding recep-tacle in the Trip Unit.
Fig. 58 External Harness Connected to the TripUnit. Fig. 60 Routing and Connection of the PT Exten-
sion Harness to the External Harness.
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F. For Kits Supplied with an Auxiliary Switch Only:Make sure that the External Harness’s AuxiliarySwitch Wires clear all moving parts within theBreaker as the pass from the External Harnessto the Auxiliary Switch. Use the wire tiessupplied to secure the Auxiliary Switch wiresaway from any moving parts.
For All Retrofit Kits.
G. Use the wire ties supplied to secure all wiresand harnesses away from any moving partswithin the Breaker.
STEP 9: FINAL BREAKER PREPARATION
Fig. 61 Overview: Breaker Ready for Testing.
A. Use the self-adhesive mounting pads and wireties supplied to dress all wires and harnessesto keep them away from any moving partswithin the Breaker.
B. Reinstall the Breaker Front Cover using theoriginal hardware removed in Step 2-B.
C. If equipped, using the original mounting hard-ware removed in Step 2-A, reinstall the ManualClosing Handle.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
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STEP 10: TESTING THE BREAKER
A. Measure the force necessary to trip theBreaker at where the DTA Adjusting Screwimpacts the Breaker Trip Paddle. The forcenecessary to trip the Breaker MUST NOTEXCEED 3 lbs.
B. The Retrofit must be tested using primaryinjection. Refer to Section 8 of the Instructionsfor the Application of Digitrip RMS Retrofit Kitson Power Circuit Breakers (Publication AD 33-855-4, September 2001), supplied with theRetrofit Kit, for detailed testing procedures andspecifications. For test information specific tothe Trip Unit, refer to the IL publication sup-plied with the Retrofit Kit (see the Pick List forthe IL number).
C. While Section 8 of the Instructions for theApplication of Digitrip RMS Retrofit Kits onPower Circuit Breakers provides the informa-tion necessary for testing the Breaker, pleasekeep the following notes in mind when review-ing other sections of the publication.
CAUTION
WHEN ALL TESTING IS COMPLETE, THE TRIPUNIT MUST BE RESET. FAILURE TO DO SOMAY CAUSE THE BATTERY IN THE RATINGPLUG TO RUN DOWN.
NOTES:
1. For All Kits Other Than 510 Basic: Iftesting the Breaker with Short Delay orGround Fault functions, be sure to eitherplug in the Cell Harness Assembly or usethe Zone Interlock Shorting Plug. Failureto do so may result in shorter than ex-pected trip times.
2. For 810 and 910 Kits Only: Without anypower applied to the system (neither the120 volt power supply nor the Aux. PowerModule connected), plug the ExternalHarness into the Cell Harness and checkthe impedance between COM 1 and COM2. The impedance should be betweenone (1) and three (3) ohms. If the imped-ance is not within this range, trace thewiring and examine each connection toassure its integrity.
Confirm that the PowerNet communica-tion wiring is correct by following theprocedures detailed in Section 7.4 of theInstructions for the Application of DigitripRMS Retrofit Kits on Power Circuit Break-ers. Note that for 810 and 910 Kits, theimpedance between COM 1 and COM 2should be between one (1) and three (3)ohms.
When testing is complete, disconnect theExternal Harness from the Cell Harness.Final External Harness connection will beperformed later in the Retrofit Process.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 25
STEP 11: MOUNTING THE CELL HARNESS
A. The Cell Harness is to be mounted in theBreaker Cell. The connector end is to bemounted on the right side of the Cell, in alocation suitable for connection with the Exter-nal Harness. The Terminal Blocks can bemounted anywhere space is available in theCell as long as connection to the ExternalHarness can be made.
B. Route the Cell Harness wiring to keep it awayfrom any moving parts within the Cell Housing.
STEP 12: INSTALLING THE RETROFITTEDBREAKER IN THE CELL
WARNING
DO NOT LEAVE THE BREAKER IN AN INTER-MEDIATE POSITION IN THE SWITCHGEARCELL. ALWAYS LEAVE IT IN THE CONNECTED,DISCONNECTED, OR (OPTIONAL) TEST POSI-TION. FAILURE TO DO SO COULD LEAD TOIMPROPER POSITIONING OF THE BREAKERAND FLASHOVER, CAUSING DEATH, SERIOUSPERSONAL INJURY, AND / OR PROPERTYDAMAGE.
NOTE: It is the responsibility of the Retrofitter toinsure proper Breaker / Cell fit. Whenracking the Breaker into the Connectedposition, the Retrofitter MUST FOLLOWBOTH the manufacturer’s instructions andthe customer’s safety standards andprocedures for racking a Breaker into theConnected position.
A. With the Breaker in the Open position and thesprings discharged, slowly rack the Breakerinto the Connected position, making sure thereis no interference or binding. The Breakershould rack smoothly and without mechanicalinterference between any Breaker and Cellparts. The Retrofitter will feel some resistancewhen the primary fingers connect onto thestabs of the Cell. This is normal.
However, if any unusual resistance is detectedthat could be abnormal interference betweenthe Breaker and Cell parts, stop immediatelyand move the Breaker out of the Connectedposition. Examine what is causing the interfer-ence and correct the situation.
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
26 EATON CORPORATION www.eaton.com
Digitrip Retrofit Kit Installation Components for Allis-Chalmers LA-600 F Breaker RMS/R Retrofits
Step Description Qty. Comment
Step 3 Sensor 8184A39H01 3Sensor Mounting Parts 9A10151G04 1
Mounting Bracket R. H. 1Mounting Bracket L. H. 1Mounting Bracket - Insulation Barrier 2Insulation Barrier Bottom 1Insulation Barrier Front & Rear 2.190-32 × .250 Lng. Screw Nylon P. H. 4.190-32 × .375 Lng. Screw Stl. F. H. 6.190-32 × .500 Lng. Screw Nylon P. H. 4Mounting Pad - 1", Self-Adhesive 2 From Step 3Wire Tie Nylon 2 From Step 3
.164 Lock Washer Stl. 1Panduit Cable Mount 1Mounting Pad - 1", Self-Adhesive 3 From Step 3Wire Tie Nylon 3 From Step 3
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
28 EATON CORPORATION www.eaton.com
Digitrip Retrofit Kit Installation Components for Allis-Chalmers LA-600 F Breaker RMS/R Retrofits
Step Description Qty. CommentStep 10 Mounting Pad - 1", Self-Adhesive From Step 3
Wire Tie Nylon From Step 3Step 12 Cell Harness See Pick List 1
NOTE: Due to the wide variety of Breakers and the multiple functions of the Retrofit components, someexcess hardware may remain when the Retrofit is complete.
Instruction Leaflet IL 33-A46-3Effective April 2010
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
EATON CORPORATION www.eaton.com 29
Decimal Standard Torque TorqueSize (in) Size (in-lbs) (ft-lbs)
.112 4-40 10 0.8
.138 6-32 18 1.5
.164 8-32 36 3.0
.190 10-32 46 3.8
.250 1/4-20 100 8.3
.312 5/16-18 206 17.2
.375 3/8-16 356 29.7
.438 7/16-14 572 47.7
.500 1/2-13 856 71.3
Decimal Standard Torque TorqueSize (in) Size (in-lbs) (ft-lbs)
.250 1/4-20 60 5
.312 5/16-18 144 12
.375 3/8-16 240 20
.500 1/2-13 600 50
Table 3 Torque Values for General Mounting and Screw Size Conversion
Table 4 Torque Values for Copper BUS Connectors
Digitrip Retrofit System for Allis-ChalmersLA-600 F Electrically Operated Fused Breakers
Instruction Leaflet IL 33-A46-3Effective April 2010
30 EATON CORPORATION www.eaton.com
Fig. 62 Retrofit Components
A. SensorsB. Trip UnitC. Aux. CT ModuleD. Direct Trip Actuator (DTA)E. Rating PlugF. Aux. CT HarnessG. Sensor Harness
