1. Introduction
This instruction leaflet provides procedures for the installation and field testing of R-Frame circuit breakers and molded case switches. For the purpose of this publication, the term "circuit breaker" also includes the molded case switch.
1.1 General Information
R-Frame circuit breakers feature interchangeable electronic trip units rated for a maximum of 2500A. Refer to Table 2-2 for available trip unit rating plug ratings. These breakers and switches comply with Underwriters Laboratories, Inc. Standard UL489 and the requirements of the International Electrotechnical Commission Recommendation No. IEC 60947-2. For more information, consult Selection Data 29-120R.
Figure 1-1: R-Frame Circuit Breaker Frame with Digitrip RMS Trip Unit Installed.This diagram illustrates the R-Frame circuit breaker, showing its main frame, the handle mechanism, and the integrated Digitrip RMS trip unit.
2. Installation
The installation process involves inspecting the circuit breaker, installing the trip unit and rating plug, accessories, and terminals, mounting the breaker, connecting conductors, and torquing terminals. Components may be supplied in separate packages.
⚠️ WARNING: DO NOT ATTEMPT TO INSTALL OR PERFORM MAINTENANCE ON ENERGIZED EQUIPMENT. DEATH, SEVERE PERSONAL INJURY, OR SUBSTANTIAL PROPERTY DAMAGE CAN RESULT FROM CONTACT WITH ENERGIZED EQUIPMENT. ALWAYS VERIFY THAT NO VOLTAGE IS PRESENT BEFORE PROCEEDING AND FOLLOW GENERALLY ACCEPTED SAFETY PROCEDURES.
Eaton is not liable for the misapplication or misinstallation of its products.
Users are cautioned to observe all recommendations, warnings, and cautions regarding safety of personnel and equipment, as well as all general and local health and safety laws, codes, and procedures. The information herein is based on Eaton experience but should not be considered all-inclusive. Contact Eaton for further information if questions arise.
Note: If required, internal accessory installation should be done before mounting and connecting the circuit breaker. Refer to individual accessory instruction leaflets.
2.1 Suitability Check
Ensure the circuit breaker is suitable for the intended installation by comparing nameplate data with existing equipment ratings and system requirements. Inspect the circuit breaker for completeness and check for damage before mounting.
2.2 Cover Removal and Replacement
Remove cover screws and the cover. The breaker has a Cover Interlock feature; removing the cover will cause the breaker to trip and it cannot be reset until the cover is replaced and screwed down securely.
Note: Instructions for installing the trip unit rating plug and accessories are supplied with each item.
2.3 Trip Unit, Rating Plug, and Accessories Installation
If not already installed, mount the trip unit rating plug and accessories in the circuit breaker frame.
2.4 Cover Re-installation
Re-install the cover and secure with provided pan-head screws. Torque cover screws to 24 in-lbs.
2.5 Terminal Installation
If not already installed, mount terminals as shown in Figure 2-1 or Figure 2-2. If a warning label is supplied with the terminal, place it on the upper portion of the circuit breaker cover.
Figure 2-1: Terminal Installation.This diagram shows the installation of terminals, including conductors (viewed from front and rear), securing hardware, and terminal catalog numbers (e.g., T1600RD, TA1600RD). It also notes to use supplied hardware only and not substitute. Torque values are specified: 25 lb-ft for terminals, 15 lb-ft for rear connectors.
Figure 2-2: 2500A Rear Connector Instructions.This figure provides a step-by-step guide for installing 2500A rear connectors and heat sinks. Step 1: Install One Rear Connector. Step 2: Install One Set of Heat Sinks. Step 3: Repeat Steps One and Two to Adjacent Poles.
2.6 Mounting the Circuit Breaker
To mount the circuit breaker, perform the following steps:
- For individual surface mounting, drill the mounting panel using the plan in Figure 2-3. For dead-front cover applications, cut the cover to the correct escutcheon dimensions as per Figure 2-4.
- If the circuit breaker includes factory or field-installed internal accessories, ensure accessory wiring is accessible after mounting. Note labels with accessory connection schematic diagrams are provided on the circuit breaker side; record these if labels are obscured when mounted.
- Position the circuit breaker on the mounting surface.
- Install the circuit breaker using mounting hardware (not supplied).
Figure 2-3: Circuit Breaker Mounting Bolt Drilling Plans.This diagram provides dimensions for drilling mounting holes for 3-pole and 4-pole circuit breakers, indicating bolt sizes and hole counts.
Figure 2-4: Circuit Breaker Escutcheon Dimensions for 3 and 4-Pole Circuit Breakers.This diagram shows the required dimensions for escutcheons or panel cutouts for 3 and 4-pole circuit breakers, including width, height, and bolt hole patterns.
⚠️ CAUTION: OVERHEATING CAN CAUSE NUISANCE TRIPPING AND DAMAGE TO THE CIRCUIT BREAKER. WHEN ALUMINUM CONDUCTORS ARE USED, THE APPLICATION OF A SUITABLE JOINT COMPOUND IS RECOMMENDED TO REDUCE THE POSSIBILITY OF TERMINAL OVERHEATING.
2.7 Connecting Conductors
Connect line and load conductors and accessory leads. The circuit breaker is suitable for reverse feed applications. Observe the warning label on the cover before attempting to remove it.
2.8 Torque Check
After installation, check all mounting hardware and terminal connecting hardware for correct torque loading. Torque values for line/load terminals are provided in Table 2-1 and on the circuit breaker nameplates.
1.2 100 Percent Rated R-Frame Circuit Breakers
CRD and CRDC circuit breakers are suitable for continuous operation at 100 percent of the frame rating when used with supplied rear connectors B2016EDL and installed in an enclosure with minimum dimensions of 21.5 in. high x 18 in. wide x 13 in. deep. Ventilation is not required in such enclosures. If cable connections are made to these rear connectors, use only 90°C wire with ampacity based on 75°C conductors and copper or AL9CU terminals.
1.3 2500 Amp R-Frame Circuit Breakers
When installed in an enclosure with minimum dimensions of 26 in. x 18 in. x 10 in., the enclosure cover must be insulated with a barrier on the line end, having minimum dimensions of 18 in. x 8 in. x 1/32 in. When installing the R-Frame 2500 amp breaker at 80% of the full rating and inside an enclosure, it is necessary to use coated or painted buswork.
3. Manual Operation
The trip unit and rating plug must be installed before attempting to close the circuit breaker. Manual operation is controlled by the circuit breaker handle and the PUSH-TO-TRIP button. The handle has three positions indicated by raised lettering (ON and OFF) and color-coded strips (red for ON, white for tripped, green for OFF).
Figure 3-1: Circuit Breaker Manual Controls.This diagram shows the manual controls of the circuit breaker, including the handle position indicator (color-coded: Red-ON, White-TRIP, Green-OFF/Reset), the PUSH-TO-TRIP button, Trip Unit Controls, and the Rating Plug.
3.1 Circuit Breaker Reset
After an automatic, accessory-initiated, or manual PUSH-TO-TRIP operation, reset the circuit breaker by moving the handle to the extreme OFF position.
Note: Do not reclose the breaker until the cause of the trip is known and the situation rectified.
3.2 PUSH-TO-TRIP Button
The PUSH-TO-TRIP button verifies the circuit breaker's tripping function and can be used to periodically exercise the operating mechanism. It is designed for finger pressure operation.
3.3 Interchangeable Trip Units
Information for Digitrip RMS trip units is shown in Table 2-2. For additional details on interchangeable trip units, refer to the following instruction leaflets:
- Series G RMS 310+: IL01210003E
- Digitrip RMS 310: I.L. 29C883
- Digitrip RMS 510: I.L. 29-885
- Digitrip RMS 610: I.L. 29-886
- Digitrip RMS 810: I.L. 29-888
- Digitrip RMS 910: I.L. 29-889
- Digitrip OPTIM 750 or 1050: I.L. 29C891
4. Inspection and Field Testing
R-Frame molded case circuit breakers are designed for years of maintenance-free operation. The following procedures describe how to inspect and test a circuit breaker in service.
Inspection
Circuit breakers should be inspected periodically, ideally during normal equipment maintenance when no voltage is present. The inspection should include checks 4-1 through 4-9.
⚠️ WARNING: VOLTAGES IN ENERGIZED EQUIPMENT CAN CAUSE SEVERE PERSONAL INJURY OR DEATH. BEFORE INSPECTING, ENSURE THE CIRCUIT BREAKER IS SWITCHED TO THE OFF POSITION AND NO VOLTAGE IS PRESENT. PAY SPECIAL ATTENTION TO REVERSE FEED APPLICATIONS TO ENSURE NO VOLTAGE IS PRESENT.
⚠️ CAUTION: SOME COMMERCIAL CLEANING AGENTS WILL DAMAGE NAMEPLATES OR MOLDED PARTS. ENSURE CLEANING AGENTS OR SOLVENTS USED ARE SUITABLE FOR THE JOB.
- 4-1. Cleaning: Remove dust, dirt, soot, grease, or moisture using a lint-free dry cloth, brush, or vacuum cleaner. Do not blow debris into the breaker. If contamination is found, identify and eliminate the source.
- 4-2. Mechanical Linkages: Switch the circuit breaker ON and OFF several times to ensure mechanical linkages are free and do not bind. If they bind, replace the circuit breaker.
- 4-3. PUSH-TO-TRIP Test: With the breaker ON, press the PUSH-TO-TRIP button to mechanically trip it. Trip, reset, and switch ON several times. If the mechanism does not reset consistently, replace the circuit breaker.
- 4-4. Physical Check: Inspect the base, cover, and operating handle for cracks, chipping, and discoloration. Replace breakers with cracks or severe discoloration.
- 4-5. Terminals and Connectors: Check terminals and connectors for looseness or signs of overheating (discoloration, melting, blistering, pitting). If no issues are found, do not disturb connections. If overheating is evident, clean or replace terminations. Refurbish all terminations and cable before re-energizing.
- 4-6. Mounting Hardware: Check circuit breaker mounting hardware and tighten if necessary.
- 4-7. Safety Hazards: Inspect the installation area for safety hazards, including personal safety and fire hazards. Certain chemicals can degrade electrical connections.
- 4-8. Digitrip RMS 310 Testing: Operation of circuit breakers with Digitrip RMS 310 trip units can be field tested using the Seltronic test kit (Catalog Number SKT2). Refer to Selection Data 29-120R.
- 4-9. Digitrip RMS 510, 610, 810, 910 Testing: Operation of circuit breakers with these trip units can be bench tested using the Auxiliary Power Module (Catalog Number PRTAAPM). Digitrip OPTIM 750 and 1050 units require a Digitrip OPTIMIZER for bench testing.
- 4-10. Series G RMS 310+ Testing: Operation of circuit breakers with Series G RMS 310+ trip units can be field tested using the G Series test kit general assembly number: 70C1056G54.
Field Testing
Any field testing should be conducted in accordance with NEMA Standards Publication AB4-1990.
Tables
Table 2-1. Terminal Types
| Catalog Number | Maximum Breaker Amps | Terminal Body Material | Hardware Type | AWG/MCM Wire Range/No. Conductors | Metric Wire Range mm² | Wire Type | Torque Values Lb-in (N.m) | Wire Lug Mtg. Hardware |
|---|---|---|---|---|---|---|---|---|
| TA1600RD | 1600 | Aluminum | English | 500-1000(4) | 300-500 | Cu/Al | 550 (62) | 300 (34) |
| T1600RD | 1600 | Copper | English | 1-600 (4) | 50-300 | Cu | 375 (42) | 300 (34) |
| TA1600RDM | 1600 | Aluminum | Metric | 500-1000(4) | 300-500 | Cu/Al | 550 (62) | 300 (34) |
| T1600RDM | 1600 | Copper | Metric | 1-600 (4) | 50-300 | Cu | 375 (42) | 300 (34) |
| B2016RD | 2000 | Copper | English | 180 (20) | ||||
| B2016RDM | 2000 | Copper | Metric | 180 (20) | ||||
| B2016RDL | 2000 | Copper | English | 180 (20) | ||||
| B2016RDLM | 2000 | Copper | Metric | 180 (20) | ||||
| B2500RD ② | 2500 | Copper | English | 180 (20) | ||||
| B2500RDM ② | 2500 | Copper | Metric | 180 (20) |
Required and shipped with 100% rated frames ①
Required and shipped with 2500 Amp frames. ②
Table 2-2. Available Trip Unit Rating Plug Ratings and Trip Unit Settings
Digitrip RMS 310 Trip Units
| Maximum Rating Plug Amperes | Adjustable Rating Plug Amperes | Adjustable Short Time Delay | Independently Adjustable Setting Time (Optional) | ||
|---|---|---|---|---|---|
| Fixed Rating Plug | Adjustable Rating Plug Range | Pick-up Time Delay @ 12t Ramp (Standard) | Time Delay Setting (Sec.) | ||
| 1600 | 800 | 800/1000/1200/1600 | 2 to 8 | X | I (No Intentional Delay) 100/200/300 M.Sec |
| 1000 | 800/1000/1250/1600 | 2 to 8 | X | I (No Intentional Delay) 100/200/300 M.Sec | |
| 1200 | 1000/1200/1600/2000 | 2 to 8 | X | I (No Intentional Delay) 100/200/300 M.Sec | |
| 1250 | 1000/1250/1600/2000 | 2 to 8 | X | I (No Intentional Delay) 100/200/300 M.Sec | |
| 1400 | 1200/1600/2000/2500 | 2 to 6 | X | I (No Intentional Delay) 100/200/300 M.Sec | |
| 1600 | 1250/1600/2000/2500 | 2 to 6 | X | I (No Intentional Delay) 100/200/300 M.Sec | |
| 2000 | 1600/2000/2500 | 2 to 8 | X | I (No Intentional Delay) 100/200/300 M.Sec | |
| 2500 | 2000/2500 | 2 to 7 | |||
Digitrip RMS 510, 610, 810, 910, 750 and 1050 Trip Units ②
| Maximum Rating Plug Amperes | Adjustable Long Delay (Standard) | Adjustable Short Time Delay | Instantaneous Pick-up Setting Range | |||
|---|---|---|---|---|---|---|
| Pick-up (I₁) Setting Range | Time Delay Setting Range (Sec.) | Pick-up Setting Range | Time Delay Setting (Sec.) | Using I₁ Ramp / Using Flat Response | ||
| 1600 | .5-1.0 @6 X I₁ Rating | 2 to 24 | 2 to 8 | 0.1 to 0.5 | 0.1 to 0.5 | 2 to 10 |
| 2000 | .5-1.0 @6 X I₁ Rating | 2 to 24 | 2 to 8 | 0.1 to 0.5 | 0.1 to 0.5 | 2 to 10 |
| 2500 | .5-1.0 @6 X I₁ Rating | 2 to 24 | 2 to 6 | 0.1 to 0.5 | 0.1 to 0.5 | 2 to 10 |
| 2 to 8 | 2 to 7 | |||||
① The current pick-up setting is a multiple of the fixed rating plug value or setting of the adjustable rating plug.
② Adjustable Rating Plugs are not available for Digitrip RMS 510, 610, 810, 910, 750 and 1050 Trip Units.
③ The adjustable long time pick-up adjustment permits a pick-up range of 50 to 100% of the rating plug value. This defines the I₁ rating which is both the long delay and short delay protection. A 1600A circuit breaker can provide 400A circuit protection when equipped with a Digitrip RMS 510, 610, 810, 910, 750 or 1050 Trip Unit with the adjustable long time pick-up adjustment set to 5 with an 800A rating plug. A 2000A circuit breaker can likewise provide 500A circuit protection.
④ Rating plugs for the Digitrip RMS 510, 610, 810, 910, 750 or 1050 Trip Unit are marked 50 Hz/60 Hz.
⑤ In multiples of the I₁ rating.
Table 2-3. Series G RMS 310+ Trip Units - Available Ratings & Trip Unit Settings
| Trip Unit Maximum Rating Amperes | Adjustable Long Delay (Standard) | Adjustable Short Time Delay | Independently Adjustable Setting Time (Optional) | ||
|---|---|---|---|---|---|
| Settings (1) Amperes @ Setting Range | Time Delay Setting Range (Sec.) | Pick-Up Setting Range | Time Delay Setting (Sec.) | ||
| 1600 | A-H 800A/900A/1000A/1100A/1200A/1400A/1500A/1600A = In @ 6 X I₁ Rating | 2 to 24 | 2 to 8 | 0.05-0.603 | Inst/120/300 millisecs (MS) |
| 2000 | A-H 1000A/1200A/1400A/1600A/1700A/1800A/1900A/2000A = In @ 6 X I₁ Rating | 2 to 24 | 2 to 8 | 0.05-0.603 | Inst/120/300 millisecs (MS) |
| 2500 | A-H 1600A/1700A/1800A/2000A/2100A/2200A/2400A/2500A = In @ 6 X I₁ Rating | 2 to 24 | 2 to 6 | 0.05-0.603 | Inst/120/300 millisecs (MS) |
① The current pick-up setting is a multiple of the I₁ setting.
Notes
The instructions provided are for general commercial applications and may not be suitable for nuclear applications. Additional instructions can be provided for safety-related applications in nuclear facilities upon specific request.
This booklet is for informational purposes only and is not all-inclusive. Consult an authorized Eaton sales representative for further information.
The sale of products is subject to Eaton's selling policies or contractual agreements. This literature does not enlarge or add to such contracts. The contract between the purchaser and Eaton is the sole governing document.
Eaton makes no warranties, expressed or implied, including warranties of fitness for a particular purpose or merchantability, or warranties arising from course of dealing or usage of trade, regarding the information, recommendations, and descriptions contained herein.
Eaton shall not be liable for any special, indirect, incidental, or consequential damages, including loss of use of equipment, plant, or power system, cost of capital, loss of power, or additional expenses, or claims against the purchaser by its customers resulting from the use of this information.
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