Bul. 140U Q and M-Frame Circuit Breakers and …...40752-076(1) Effective 4/02 Q and M-Frame Circuit Breakers Instruciton Leaflet for Alarm Switch and Auxiliary Switch Combinaiton

40752-076(1) Effective 4/02

Q and M-Frame Circuit BreakersInstruciton Leaflet for Alarm Switch and Auxiliary Switch Combinaiton

CONTACT WITH ENERGIZED EQUIPMENT CANRESULT IN DEATH, SEVERE PERSONAL INJURY,OR SUBSTANTIAL PROPERTY DAMAGE. DO NOTATTEMPT TO INSTALL OR PERFORM MAINTE-NANCE ON EQUIPMENT WHILE IT IS ENERGIZED.ALWAYS VERIFY THAT NO VOLTAGE IS PRESENTBEFORE PROCEEDING WITH THE TASK, ANDALWAYS FOLLOW GENERALLY ACCEPTED SAFE-TY PROCEDURES.

ALLEN-BRADLEY IS NOT LIABLE FOR THE MISAP-PLICATION OR MISINSTALLATION OF ITS PROD-UCTS.

The user is cautioned to observe all recommendations,warnings, and cautions relating to the safety of person-nel and equipment as well as all general and localhealth and safety laws, codes, and procedures.

The recommendations and information contained hereinare based on Allen-Bradley experience and judge-ment, but should not be considered to be all-inclusive orcovering every application or circumstance which mayarise. If any questions arise, contact Allen-Bradley forfurther information or instruction.

1.0 INTRODUCTION

General Information

The alarm (signal)/ lockout switch (ASL switch) (Figure1-1) is attached to a plug-in module available in the fol-lowing combinations:

· One or two ASL switches· One auxiliary switch and one ASL switch· Two Auxiliary switches and one ASL switch

The plug-in module is mounted in slots in the top of thetrip unit and occupies the accessory mounting cavity inthe circuit breaker frame. The ASL switch providesremote signaling and interlocking when the circuitbreaker trips; it consists of one or two single-pole, double-throw (SPDT) switches. Each SPDT switch hasa make (alarm) and a break (lockout) contact; it is

! WARNING

mounted so that the switch actuator arm is controlled bythe circuit breaker operating mechanism cradle.

When the circuit breaker is in the ON or Off position, thecradle holds the make contact open and the break con-tact closed. When the circuit breaker is in the trippedposition, the make contact is closed and the break con-tact is open. Any type of trip operation (for example,automatic trip, shunt trip, or undervoltage release) actu-ates the ASL switch.

The auxiliary switch(es) in the combination accessoryindicates circuit breaker contacts status, and is used forremote signaling and system interlocking purposes.Each SPDT switch has one “a” and one “b” contact.The plug-in module is mounted in slots in the top of thetrip unit; it occupies the accessory cavity in the circuitbreaker frame, and is positioned so that the switch actu-ator is operated by the crossbar. When the crossbar isin the contact-closed position, the “a” contact of each

Figure 1-1 Alarm (Signal)/ Lockout Switch Installed in L-Frame Circuit Breaker

Bul. 140U

SPDT switch is closed and the “b” contact is open.When the crossbar is in the tripped or contacts-openposition, the “a” contact is open and the “b” contact isclosed.

Table 1.1 lists electrical rating data for the auxiliaryswitch.

For this publication, the term circuit breaker shall alsoinclude molded case switch and motor circuit protector.

Depending on the model ordered, connections for theASL switch and auxiliary switch contacts are in one offour forms. The standard wiring configuration is pigtailleads exiting the rear of the base directly behind theaccessory, leads exiting the side of the base where theaccessory is mounted, and leads exiting the rear of thebase on the side opposite the accessory. The 18-inchlong pigtail leads are color coded for identification; iden-tification labels are provided for pigtail leads and termi-nal block points. For allowable locations of all acces-sories, refer to Selection Guide.

No more than three pigtail leads can be routedthrough the rear trough in the circuit breaker base.When the walking beam interlock is used with thecircuit breaker, the rear trough cannot be used foraccessory pigtail leads.

This instruction leaflet (IL) gives detailed procedures forinstalling the ASL switch and ASL switch/auxiliary switchcombination (accessory combination).

Table 1.1 Alarm (Signal)/Lockout and Auxiliary SwitchElectrical Rating Data ➀➁➂

Maximum Freq Maximum DielectricVoltage Current Withstand(V) (A) Voltage (V)

600 50/60 Hz 6 2500125 DC 0.5➃

250 DC 0.25➃

➀ Endurance - 400 electrical operations plus 5600 mechan-ical operations

➁ Pigtail wire size - No. 18 AWG (0.82 mm)➂ Terminal block is listed for use with one or two No. 18

to No. 14 AWG solid or stranded copper wires.➃ Non-inductive load

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40752-076(1) Effective 4/02

2.0 INSTALLATION

The ASL switch(es) accessory combination can befield-installed in circuit breakers Q and M-Frame.

NOTICE

NOTICE

NOTICE

Where local codes and standards permit and UL list-ing is not required, internal accessories can be fieldinstalled in sealed circuit breakers. In this case, ULlisting becomes invalid and the label should beremoved.

Before attempting to install the ASL switch oraccessory combination, check that the catalog num-ber is correct as ordered and that the rating of theaccessory(s) satisfies the job requirements.

The ASL switch (shown in kit form in Figure 2-1) andaccessory combination, is installed in the right or leftaccessory mounting cavity of a 2-, 3-, or 4-pole circuitbreaker with a fixed thermal, adjustable thermal or electronic trip unit. An auxiliary switch must be installedin the circuit breaker before the circuit breaker is mountedin an electrical system. To install the auxiliary switch, perform the following procedures:

A circuit breaker that is mounted in an electricalsystem must be removed to install the accessory.To ensure correct accessory installation, the circuitbreaker must be placed on a horizontal surface.

General Installation

THE VOLTAGES IN ENERGIZED EQUIPMENT CANCAUSE DEATH OR SEVERE PERSONAL INJURY.BEFORE REMOVING A CIRCUIT BREAKERINSTALLED IN AN ELECTRICAL SYSTEM, MAKESURE THE CIRCUIT BREAKER IS SWITCHED TOTHE OFF POSITION AND THERE IS NO VOLTAGEPRESENT WHERE WORK IS TO BE PERFORMED.SPECIAL ATTENTION SHOULD BE PAID TOREVERSE FEED APPLICATIONS TO ENSURE NOVOLTAGE IS PRESENT.

Steps 2-1 through 2-8 and 2-11 through 2-17 are forgeneral installation and apply to the ASL switch andthe accessory combination. Step 2-9 covers instal-lation of the accessory combination.

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40752-076(1) Effective 4/02

2-1. Switch circuit breaker to OFF position.

Molded case switch trip units are not equipped witha Push-to-Trip button. For molded case switches,omit step 2-3.

2-2. Disconnect and remove circuit breaker frominstallation and terminal connections.

2-3. Press PUSH-TO-TRIP button to trip operatingmechanism and check handle moves to tripposition with white colored indicator visible inescutcheon window.

2-4. Remove circuit breaker cover screws and covers.

To install accessory, circuit breaker must be intripped position

2-5. For high instantaneous trip-type (catalog suffix Kdesignation) molded case switches, findrecessed hole in either of the trip unit outer polesnormally intended for intermediate plunger(Figure 2-4). Push a fine point implement in onehole to trip the molded case switch.

2-6. Remove interphase barrier between center poleand pole in which accessory is to be mounted(Figure 2-2).

2-7. Install replacement interphase barrier (suppliedwith kit) in base (Figure 2-2).

For all combinations of accessories, leads from theinner accessory switch must go to the wiring troughnearest the line end of the circuit breaker. For a dou-ble or triple combination, leads from the outer acces-sory switch must go to the center trough. Pigtailleads exiting in this manner should be eased throughtrough as mounting bracket is inserted into trip unitretaining slots. Use center trough also for leads exit-ing the side of the circuit breaker.

2-8. Route wiring to meet installation requirements(see Figure 2-3).

! WARNING

NOTICE

NOTICE

NOTICE

Figure 2-1 Alarm (Signal)/Lockout Switch Kit

Accessory Combination Installation

2-10. Install accessory combination switch asdescribed in the following steps:

a. Remove barrier from trip unit accessorymounting slots in pole being used for acces-sory (Figure 2-4).

b. Put tip of ASL switch actuator arm throughslot in interphase barrier and under cradleextension.

c. Turn accessory combination mountingbracket to line up with slots in trip unit.

d. Slide accessory combination mountingbracket into slots until retaining clip snapsinto trip unit. For terminal block assemblies,slide terminal block into mounting slot onside of base as accessory combination isbeing positioned.

e. If required, complete routing of leads toopposite side through rear wiring trough.

f. For double auxiliary switch pigtail leads,attach wire marking labels to bundle ofthree leads for each switch. (Markers des-ignated 1 and 2 are provided if required.)

General Installation

WHEN INSTALLING CIRCUIT BREAKER MAINCOVER, MAKE SURE THAT ALL INTERNAL PARTSARE IN PLACE:

· SLIDING HANDLE BARRIER IS POSITIONED SOTHAT THE HANDLE OPENING IS ALIGNED WITHTHE HANDLE.· ALL LEADS ARE CLEAR OF THE COVER.

2-11. With circuit breaker handle in TRIPPED positionand accessory pigtail leads (if used) routed asrequired, install circuit breaker covers. Securewith pan-head cover screws. Torque to 20-22lb-in. (2.26-2.46 N.m.).

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40752-076(1) Effective 4/02

LEADS SHOULD BE FORMED AND ROUTED TOCLEAR ALL MOVING PARTS WHEN ACCESSORY ISPROPERLY INSTALLED. LEADS COULD BE DAM-AGED IF IN CONTACT WITH MOVING PARTS.

For all combinations of accessories, leads frominner accessory switch must go to the wiring troughnearest line end of circuit breaker. For a double ortriple combination, leads from the outer accessoryswitch must go to center trough.

Alarm (Signal)/Lockout Switch Installation

2-9. Insert the ASL switch as described in the follow-ing steps:

a. Remove barrier from trip unit accessorymounting slots in pole being used for acces-sory (Figure 2-4).

b. Put tip of actuator arm through slot in inter-phase barrier and under cradle extension(see Figure 2-5).

c. Turn ASL switch mounting bracket to line upwith slots in trip unit.

d. Slide ASL switch mounting bracket intoslots until retaining clip snaps into trip unit.For terminal block assemblies, slide termi-nal block into mounting slot on side of baseas plug-in module is being positioned.

e. If required, complete routing of leads toopposite side through rear wiring trough.

f. For double ASL switch with pigtail leads,attach wire marking labels to bundle ofthree leads for each switch. (Markers des-ignated 1 and 2 are provided.)

g. For ASL/auxiliary switch accessory combi-nations with pigtail leads, attach wire mark-ing labels to bundle of three leads for eachswitch. (Markers designated A, B and C areprovided if required.)

! CAUTION

NOTICE

! CAUTION

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40752-076(1) Effective 4/02

For molded case switches, omit step c.

c. Press PUSH-TO-TRIP button -“a” contact(s) - open“b” contact(s) - closed

d. If auxiliary switch(es) fails test, make surethat auxiliary switch(es) module is properlyseated in trip unit slots. If auxiliaryswitch(es) appears to be correctly installedand the problem persists, contact Allen-Bradley.

2-15. Install circuit breaker.

2-16. Connect accessory leads as required (seeFigure 2-7).

Allen-Bradley assumes no responsibility for malfunc-tioning accessories installed improperly by the cus-tomer.

2-12. Place accessory labels (supplied with kit) on cir-cuit breaker (Figure 2-7).

Accessory labels show connection diagram for ASLswitch and/or auxiliary switch contacts. Pigtailleads are color coded red, black, and blue. Be surethat accessory terminal marking label is attachedcorrectly to leads and agrees with related leads ataccessory.

2-13. Test ASL switch(es) by connecting continuitytester or ohmmeter across pigtail leads or termi-nal block connections. Check continuity as fol-lows:

a. Circuit breaker handle OFF -Check that make contact(s) are open andbreak contact(s) are closed.

b. Circuit breaker handle ON -Check that make contact(s) are open andbreaker contact(s) are closed.

For molded case switch circuit breakers, omit step c.

c, Press PUSH-TO-TRIP button -Check that make contact(s) are closed andbreak contact(s) are open.

d. If ASL switch(es) fails test, make sure thatmodule is properly seated in trip unit slots.If problem persists, contact Cutler-Hammer.

2-14. Test auxiliary switch(es) (when supplied).Connect continuity tester or ohmmeter acrosspigtail leads or terminal block connections.Check continuity as follows:

a. Circuit breaker handle OFF -“a” contact(s) - open“b” contact(s) - closed.

b. Circuit breaker handle ON -“a” contact(s) - closed“b” contact(s) - open

NOTICE

NOTICE

NOTICE

Figure 2-2 Interphase Barrier Replacement

Replacement BarrierSupplied with ASLSwitch Kit

Remove InterphaseBarrier

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Figure 2-3 Accessory WIring Options

Rear Exiting Leads(Preferred)

Side Exiting LeadsOpposite-SideExiting Leads

Terminal Block

Figure 2-4 Trip Unit Barrier Removal

TripUnit

RecessedHole Trip Unit

Barrier

ASL SwitchActuator Arm

ASL Switch ModulePosition ASL SwitchOperating Arm UnderCradle Extension

Cradle Extension

Slot in ReplacementInterphase Barrier

ASL SwitchOperating Arm

Figure 2-5 Alarm (Signal)/ Lockout Switch Installation

40752-076(1) Effective 4/02

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40752-076(1) Effective 4/02

ASL Switchand AuxiliarySwitchOperatingArm

Auxiliary Switch

AccessoryCombinationModule PositionASL SwitchOperating ArmUnder CradleExtension

ASL Switch

CradleExtension Slot in

ReplacementBarrier

Figure 2-6 Accessory Combination Installation

ModificationLabel

PigtailConnectionDiagram(When Used)

AccessoryIdentificationLabelTerminal Block

Connection DiagramLabel (When Used)

Figure 2-7 Preferred Mounting Locations for AccessoryNameplate Labels

Pigtail Leads

Terminal Block

Blue

Red Blue

Red

Make(Alarm)

Black

Break(Lockout)

a

b

Blue

Red

Black

a

b

a

b

c

Make(Alarm)

Break(Lockout)

Red

Black

Blue

Al

Com

Lo

Leads Are Bundled andTagged “B”

Leads Are Bundled andTagged “A”

ASL Switch Auxiliary Switch

Figure 2-8 Alarm (Signal)/Lockout Switch - AuxiliarySwitch Connection Diagram

40752-076(1) Effective 4/02Printed in U.S.A./TQC

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