Allen-Bradley Q and M-Frame Circuit Breakers Installation Instructions

Bul. 140U
Q-Frame Circuit Breaker
Instruction Leaflet for Installation of Q-Frame Circuit Breakers
A
WARNING
arise, contact Allen-Bradley for further information or
instructions.
1. INTRODUCTION
CONTACT WITH ENERGIZED EQUIPMENT CAN
RESULT IN DEATH, SEVERE PERSONAL INJURY, OR
SUBSTANTIAL PROPERTY DAMAGE. DO NOT
ATTEMPT TO INSTALL OR PERFORM MAINTENANCE ON EQUIPMENT WHILE IT IS ENERGIZED.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT
BEFORE PROCEEDING WITH THE TASK, AND
ALWAYS FOLLOW GENERALLY ACCEPTED SAFETY
PROCEDURES.
ALLEN-BRADLEY IS NOT LIABLE FOR THE MISAPPLICATION OR MISINSTALLATION OF ITS
PRODUCTS.
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
Allen-Bradley experience and judgement, but should not
be considered to be all-inclusive or covering every application or circumstance which may arise. If any questions
General Information
The Q-Frame circuit breaker (Fig. 1-1)
are 600 Vac maximum rated devices with
interchangeable thermal-magnetic or electronic
trip units rated 600A maximum continuous
current. The circuit breaker uses noninterchanageable
trip units and is factory sealed.
Refer to Table 1-1 for all available trip unit ratings.
This instruction leaflet (IL) gives procedures for installation and field testing of Q-Frame circuit breakers.
For this publication, the term circuit breaker shall also
include the molded case switch.
100 Percent Rated L-Frame Circuit Breakers
Q-Frame circuit breakers are suitable for conrtinuous
operation at 100 percent of the frame rating if
used with 90°C insulated wire and AL9CU terminals in an
enclosure which measures at least 24" high x 15" wide x
6" deep. The minimum required ventilation is 8 sq. in. top
front and 8 sq. in. bottom front.
2. INSTALLATION
The installation procedure consists of inspecting the circuit breaker and, as applicable, installing the trip unit and
rating plug, accessories, and terminals; mounting the circuit breaker; connecting the line and load conductors;
torquing terminals; and attaching terminal shields. Circuit
breaker frames, trip units, rating plugs, accessories,
mounting hardware, and unmounted terminals may be
supplied in separate packages. To install the circuit
breaker, perform the following steps.
Fig. 1-1
Q-Frame Circuit Breaker
Frame with Trip Unit Installed
40752-078(1) Effective 5/02
Page 2
mounting screws may be checked for correct
torque.
a
Internal accessory installation in any type of circuit
breaker should be done before the circuit breaker is
mounted and connected. Refer to individual
accessory instruction leaflets for specific installation
instructions on field installable accessories.
2-1. Compare nameplate data with existing equipment
ratings and system requirements to make sure that
the circuit breaker is suitable for the intended installation. Prior to mounting, confirm that the circuit
breaker has not been damaged during transit or initial handling.
2-2. To install trip unit and any internal accessories,
remove installed cover screws and cover.
Note: The circuit breaker handle must be in the
tripped or OFF position to remove the cover.
Instructions for installing the trip unit and
accessories are supplied with the devices.
THE VOLTAGES IN ENERGIZED EQUIPMENT CAN
CAUSE DEATH OR SEVERE PERSONAL INJURY.
BEFORE MOUNTING THE CIRCUIT BREAKER IN AN
ELECTRICAL SYSTEM, MAKE SURE 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.
Note: Depending on the equipment configuration, the
circuit breaker can be mounted using different styles
of hardware. The following steps describe how to
mount the circuit breaker using standard hardware.
When special hardware is needed (for example, with
the motor operator), the instruction leaflet describing
the accessory also describes the special mounting
arrangements.
2-6. To mount the circuit breaker, perform the following
steps:
a.
For individual surface mounting, drill mounting
panel using the drilling plan shown in Fig. 2-2.
For panelboard mounting, only load end support mounting holes are required. For deadfront
cover applications, cut out cover to correct
escutcheon dimensions, see Fig. 2-3.
b.
If circuit breaker includes factory or field
installed internal accessories, make sure
accessory wiring is accessible when the circuit
breaker is mounted.
2-3. If not already installed, mount trip unit and accessories (if required) in circuit breaker frame. Rating
plug must be installed in electronic trip units.
Note: When required to be removed or replaced,
stationary interphase barriers can only be installed
or removed with circuit breaker in the tripped or open
position.
2-4. After the trip unit and any internal accessories are
installed, and with the circuit breaker in the tripped
position, make sure that stationary interphase barriers are properly installed in base. Install cover and
secure with pan-head screws. Eight screws are
used for two and three pole circuit breakers. Ten
screws are used for four pole circuit breakers.
Torque to 20-22 Ib-in (2.26-2.49 N.m).
2-5. If not already installed, mount wire connecting terminals as shown in Fig. 2-1. Secure the terminals
to the circuit breaker using two pan-head slotted
screws and lockwashers. Torque to 6 to 8 Ib-ft (8.14
to 10.85 N.m). With the circuit breaker mounted
and before the conductors are installed and conductor clamping screws inserted, the terminal
40752-078(1) Effective 5/02
WARNING
Note: Labels with accessory connection schematic
diagrams are provided on the side of the circuit
breaker.
C.
Position circuit breaker on mounting surface.
d.
Install circuit breaker mounting screws and
washers. Tighten screws firmly, but do not
exceed 28 Ib-in (3 N.m.).
Page 3
Termina Lug
1
Pan-Head
Screws
and
'
Pan-Head Screws
and Lockwashers
140U-Q-TJC2
(Installed before
140U-Q-TLA2 Cable Clamoina
I
Line End
2- and 3-Pole
Circuit Breaker
3.438
(87.33)
. -
Lug
Circuit
Breaker
Handle-
1.325
(33.66)
0.250
0.188
(4.77)
2.292
(58.22)
I
(254.79)
(4-Pole)
Cover
Load End
Fig. 2- 1
Terminal Installation
Fig. 2-3
Circuit Breaker Escutcheon Cutout Dimensions
for 2-, 3-, and 4-Pole Circuit Breakers
Terminal
Shield
r..
Circuit
Breaker
Load End
2- and 3-Pole
\
I
Circuit
Breaker
screws
4-Pole
Dimensions in Inches
(Millimeters)
Fig. 2-2 2-, 3-, and 4-Pole Circuit Breaker Mounting
Bolt Drilling Plans
40752-078(1) Effective 5/02
Fig. 2-4
Installation of Terminal Shields and Warning
Label
Page 4
a
CAUTION
WHEN ALUMINUM CONDUCTORS ARE USED, THE
APPLICATION OF A SUITABLE JOINT COMPOUND
IS RECOMMENDED TO REDUCE THE POSSIBILITY
OF TERMINAL OVERHEATING. OVERHEATING CAN
CAUSE NUISANCE TRIPPING AND DAMAGE TO THE
CIRCUIT BREAKER.
2-7. Connect line and load conductors and accessory
leads.2-8.After the circuit breaker is installed, check
all mounting hardware and terminal connecting
hardware for correct torque loading. Torque values
for line/load terminals are given in Table 2-1 and on
the circuit breaker nameplate.
2-9. Install line terminal cover on circuit breaker cover
with mounting screws provided. Torque to 20-22 Ibin. (2.26-2.49 N.m).
Handle Throw Positions
Existing handle mechanisms may be modified or
replaced. Consult Allen-Bradleyr for additional
information.
Internal Accessories
Only Q-Frame accessories may be used.
External Accessories
Motor operators must be replaced.
Key interlock mounting brackets must be replaced.
Consult Allen-Bradley for additional information.
Terminal Wire Connectors
Terminals must be replaced, see Table 2-1 for
replacement types.
Other
Unless noted above, all other physical characteristics
are the same.
2-10. When step-type terminals are used, terminal
shields (supplied with terminals) must be
installed on the circuit breaker (Fig. 2-4) and
secured using retainer and screws included
with the terminal shield kit. Warning label
supplied with the kit must be attached to the
circuit breaker cover.
A
International
Symbols
Handle
Position
Indicator
Color: Red - ON
White - TRIP
Green - OFF (Reset)
-
u -ON
0 - OFF
I
WARNING
HAZARDOUS VOLTAGE CONDITIONS CAN CAUSE
DEATH OR SEVERE PERSONAL INJURY. MAINTAIN
ORIGINAL ELECTRICAL CLEARANCE AND CREEPAGE SPACINGS AT TERMINATIONS.
Panel Escutcheon Cutout Sizes
Existing cutouts must be modified to agree with
requirements shown in Fig. 2-3.
/
,/
ThermalMagnetic
Trip Unit
Fig. 4- 1
40752-078(1) Effective 5/02
Maonetic
Adfistment
Button
(3 Places)
I
PUSH-TO-TRIP
Bunon
Circuit Breaker Manual Controls
Page 5
-
ThermalMagnetic
Trip
Unit
Magnetic Multiples of In.
PUSH-TO-TRIP
I
Amps
(In.)
1
“C Cat.
No.
2
Fig. 4-2
I
/
Trip Unit Magnetic Adjustment Buttons
a
Circuit Breaker Reset
WARNING
CONTACT WITH ENERGIZED EQUIPMENT CAN
RESULT IN DEATH, SEVERE PERSONAL INJURY, OR
SUBSTANTIAL PROPERTY DAMAGE. DO NOT
ATTEMPT TO INSTALL OR PERFORM MAINTENANCE ON EQUIPMENT WHILE IT IS ENERGIZED.
ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT
BEFORE PROCEEDING WITH THE TASK, AND
ALWAYS FOLLOW GENERALLY ACCEPTED SAFETY
PROCEDURES.
Note: When replacing an existing circuit breaker of
the types listed above, make sure the voltage,
continuous current, and interrupting rating of the
new circuit breaker are suitable.
4. MANUAL OPERATION, AND THERMALMAGNETIC TRIP UNIT ADJUSTMENT
Manual Operation
Manual operation of the circuit breaker is controlled by
the circuit breaker handle and the PUSH-TO-TRIP button
in the trip unit. The circuit breaker handle has three positions, two of which are shown on the cover with raised lettering to indicate ON and OFF. On the handle, ON, OFF,
and trip are also shown by a color-coded strip for each
circuit breaker handle position: red for ON, white for
tripped, and green for OFF (see Fig. 4-1).
40752-078(1) Effective 5/02
After a trip operation, the circuit breaker is reset by moving the circuit breaker handle to the Reset (extreme OFF)
position.
Note: In the event of a thermal (overload) trip the
circuit breaker cannot be reset immediately. In a
breaker with a thermal-magnetic type trip unit the
thermal element needs to cool (up to approximately
five minutes) before it can be reset. A circuit breaker
with a electronic RMS trip unit simulates the thermal
element with an electronic “thermal memory” that
also requires up to five minutes to “cool” before it
can be re-energized.
No circuit breaker should be reclosed until the cause
of trip is known and the situation rectified.
PUSH-TO-TRIP Button
The PUSH-TO-TRIP button operates the circuit breaker
tripping function and may be used to periodically exercise
the operating mechanism. In thermal-magnetic trip units,
the button is designed to be operated by a small screwdriver. The rating plug in electronic RMS trip units contains the PUSH-TO-TRIP button which is operated by
finger pressure. There is no PUSH-TO-TRIP button in the
molded case switch.
Thermal-Magnetic Trip Unit Adjustment
The magnetic element of each pole of the trip unit can be
adjusted by rotating the adjustment buttons on the front
face of the trip unit with a screwdriver. The buttons have
several settings as indicated on the nameplate with val-
Page 6
ues in multiples of the trip unit ampere rating (I,) as
shown in Fig. 4-2. To adjust the setting, rotate each button clockwise until arrow on button points to desired setting. The molded case switch is set at the factory (at 1OX)
and is not field adjustable.
Interchangeable Trip Units
For additional information on thermal-magnetic trip units,
refer to I.L. 29C607 (3-pole) and I.L. 29C609 (4-pole). For
electronic electronic RMS trip units, refer to I.L. 29C615.
5. INSPECTION AND FIELD TESTING
Q-Frame molded case circuit breakers are designed to
provide years of almost maintenance-free operation. The
following procedure describes how to do a limited amount
of field inspection and testing of a circuit breaker.
Inspection
Circuit breakers in service should be inspected periodically. The inspection should include the following checks
5-1 through 5-8.
a
WARNING
THE VOLTAGES IN ENERGIZED EQUIPMENT CAN
CAUSE SEVERE PERSONAL INJURY OR DEATH.
BEFORE INSPECTING THE CIRCUIT BREAKER IN AN
ELECTRICAL SYSTEM, MAKE SURE THE CIRCUIT
BREAKER IS SWITCHED TO THE OFFPOSITION
AND THAT 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.
a
CAUTION
SOME COMMERCIAL CLEANING AGENTS WILL
DAMAGE THE NAMEPLATES OR MOLDED PARTS.
MAKE SURE THAT CLEANING AGENTS OR SOLVENTS USED TO CLEAN THE CIRCUIT BREAKER
ARE SUITABLE FOR THE JOB.
5-1. Remove dust, dirt, soot, grease, or moisture from
the surface of the circuit breaker using a lint-free
dry cloth, brush, or vacuum cleaner. Do not blow
debris into circuit breaker. If contamination is found,
look for the source and eliminate the problem.
40752-078(1) Effective 5/02
5-2. Switch circuit breaker to ON and OFF several times
to be sure that the mechanical linkages operate
freely and do not bind. If mechanical linkages do
not operate freely, replace circuit breaker.
Note: On molded case switches, there is no PUSHTO-TRIP feature. Omit step 5-3 when installing a
molded case switch and proceed with step 5-4.
5-3. With the circuit breaker in the ON position, press
the PUSH-TO-TRIP button to mechanically trip the
circuit breaker. Trip, reset, and switch circuit
breaker ON several times. If mechanism does not
reset each time the circuit breaker is tripped,
replace the circuit breaker.
5-4. Check base, cover, operating handle, and handle
barrier for cracks, chipping, and discoloration. Circuit breakers should be replaced if cracks or severe
discoloration is found.
5-5. Check wire connecting terminals and other type
bus bar connectors for looseness or signs of overheating. Overheating will show as discoloration,
melting, or blistering of conductor insulation, or as
pitting or melting of conductor surfaces due to arcing. If there is no evidence of overheating or looseness, do not disturb or tighten the connections. If
there is evidence of overheating, terminations
should be cleaned or replaced. Before re-energizing the circuit breaker, all terminations and cable
should be refurbished to the originally installed condition.
5-6. Check circuit breaker mounting hardware, and
tighten if necessary.
5-7. Exposure to certain types of chemicals can cause
deterioration of electrical connections. Check area
where circuit breaker is installed for any safety hazards, including personal safety and fire hazards and
take required precautionary actions.
5-8. The operation of circuit breakers with electronic
RMS trip units can be field tested periodically using
the Electronic test kit. Contact Allen-Bradley
for details.
Field Testing
Any field testing should be done in accordance with applicable NEMA Standard.
Page 7
TABLE I: AVAILABLE TRIP UNIT RATINGS
Trip Unit Types
Circuit
Breaker
Types
Thermal-Magnetic@
Amperes In
Fixed
Thermal
Adjustable
Thermal
Adjustable
Magnetic
(Instantaneous)
Electronic (RMS)(1)
Amperes In
Trip
Unit
Rating
Rating
Rating
Multiples
of In (2)
Multiples
of In (2)
Q-Frame
300
350
400
450
500
600
600
NA
300
350
400
500
600
300/400/500/600
(1) Two trip unit types are available:
LS(G) have fixed, sloping I2t short-time current configuration.
LSI(G)have separate adjustable short-time pick-up and short delay settings.
(2) For adjustable thermal trip units, the magnetic setting is a multiple of the maximum thermal setting.
For ELECTRONIC RMS trip units, the instantaneous/short-time setting is a multiple of the rating plug.
40752-078(1) Effective 5/02
Adjustable
Short
Time
2 to 8
Paae 8
w
TABLE II: TERMINAL TYPES 0008
Terminal
Cat No.
Terminal
Material
Wire
Range
Metric
Wire
Range
Wire
Type
Torque Value
Ib-in (N.m)
310-350 (2)
(MM2)
95-150
Cu/AI
275 (31. l )
Conductors
Screw
Head
Type
140U-Q-TLA2
Aluminum
2
Socket
(4)
Aluminum
2
Socket
400-500 (2)
185-240
CulAI
275 (31.1)
140U-Q-TLC2
Copper
2
Socket
250-350 (2)
120-150
Cu
275 (31.1)
(4)
Aluminum
1
Socket
410-600
120-300
CulAI
400 (45.2)
(4)
Aluminum
2
Socket
4-410 (2)
25-120
CulAI
275 (31.1)
Number
Of
0The maximum width nonstandard wire connector (tang-type) or bus bar connector that can be used without reducing electrical
clearance and creepage distances between phases is 1.690 inches.
0 No hardware or connector should be installed in a manner to reduce the electrical clearance between the underneath side of the
phase termination (line or load) and ground without the addition of supplementary insulation.
0The metric conductor sizes indicated are the minimum/maximum sizes that can be inserted in the terminal. Larger size conductors may be required to satisfy ampacity requirements for local installation rules.
@ Contact Allen-Bradley For Availability
40752-078(1) Effective 5/02
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