SQUARE D Sensor Plug Replacement for Micrologic Trip Units Instructions

: June 9, 2024
: SQUARE D

Table of Contents

Retain for future use
Application Guidelines
Necessary Tools
Installation
Customer Support
References
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Download This Manual (PDF format)

**SQUARE D Sensor Plug Replacement for Micrologic Trip Units

**

Retain for future use

Rating| 100 A1| 250 A1| 400 A| 600 A| 630 A| 800 A| 1000 A| 1200 A| 1250 A| 1600 A
---|---|---|---|---|---|---|---|---|---|---
Sensor Plug Kit| S47051| S47052| S47053| S48823| S33091| S33092| S33093| S48824| S33094| S33095
Rating| 2000 A| 2500 A| 3000 A| 3200 A| 4000 A (IEC)| 4000 A| 5000| 6000 A| 6300 A|
Sensor Plug Kit| S33982| S38823| S48825| S33984| S47820| S47824| S47825| S48827| S47826

Cannot be installed into a circuit breaker with original sensor plug rated higher than 250 A. /

Application Guidelines

CAUTION

HAZARD OF EQUIPMENT DAMAGE

Do not field install sensor plugs into P-frame and R-frame circuit breakers with date codes prior to 07011.
Failure to follow this instruction can result in equipment damage.

Table

Circuit Breaker| Sensor Plug| Date Code| Sensor Plug Replacement
---|---|---|---
Master pact NT Master pact NW| All except 100 A and 250 A| All| Field- replaceable down to 50% of frame rating
100 A and / y / et 250 A| All| Replacement sensor plug must be 250 A or less
Power Pact P-Frame and R-Frame| All except 100 A and 250 A /| 07011 or after| Field-replaceable down to 50% of current rating
100 A and / y / et 250 A| 07011 or after| Replacement sensor plug must be 250 A or less
All| Before 07011| Sensor plug is NOT field replaceable

DANGER

HAZARD OF ELECTRIC SHOCK, EXPLOSION OR ARC FLASH

Apply appropriate personal protective equipment (PPE) and follow safe electrical work practices. See NFPA 70E.
This equipment must only be installed and serviced by qualified electrical personnel.
Turn off all power supplying this equipment before working on or inside equipment.
Always use a properly rated voltage sensing device to confirm power is off.
Failure to follow these instructions for installation, trip test and primary injection testing may result in the failure of some or all protective function.
Replacement/upgrading of a trip unit in the field must be done by qualified persons, as defined by the National Electric Code, who are familiar with the installation and maintenance of power circuit breakers.
Before replacing/upgrading trip unit, confirm that the circuit breaker is in good working condition. If the condition of the circuit breaker is unknown, do not proceed. For assistance in evaluating the condition of the circuit breaker, call Technical Support.
If the circuit breaker fails to function properly in any manner upon completion of the trip unit installation, immediately remove the circuit breaker from service and call Field Services.
Follow instructions shipped with circuit breaker to disconnect and reconnect circuit breaker.
Replace all devices, doors and covers before returning equipment to service.

Failure to follow this instruction will result in death or serious injury.

Necessary Tools

Screwdriver (Pozidriv® No. 2 or 3 pt., or slotted)
Torque-controlled screwdriver, set at 7 in-lbs (0.8 N•m) ± 10% (Lindstrom torque driver MAL500-2 or equivalent)
Micrologic Full-function Test Kit (part number S33595)

Installation

Record Switch Settings

Record all trip unit switch and advanced protection settings for later use.

FIG. 1 : Date Code Location

Circuit Breaker Disconnection

Disconnect circuit breaker as directed in the circuit breaker instruction bulletin shipped with the circuit breaker. The circuit breaker must be completely isolated.

For a draw out circuit breaker, place circuit breaker in the disconnected position.
For a fixed-mounted circuit breaker, all voltage sources, including auxiliary power, must be disconnected.

Circuit Breaker Accessory Cover Removal

Remove circuit breaker accessory cover as directed in the circuit breaker instruction bulletin, shipped with the circuit breaker.

Trip Unit Removal

Remove connector block (A) from top of trip unit, if present.
Loosen two trip unit screws (B).
Slide out trip unit (C).
FIG. 2 : Trip Unit Removal

Replace Sensor Plug

NOTE: Sensor plugs must be replaced in accordance with Table 1.

Remove sensor plug screw (B) and remove existing sensor plug (C).
Install new sensor plug (C), securing with screw (B).
FIG. 3 : Sensor Plug Replacement

Trip Unit Installation

Inspect trip unit connector pins and surfaces. If there is any damage, misaligned pins, or contamination, stop installation and contact the local sales office for factory authorized service.
Inspect trip unit mounting base on the circuit breaker. Clear any debris from area and check that all accessory wiring is properly routed for the trip unit being installed. If there is any damage or contamination, stop installation and contact the local sales office for factory authorized service.
For Master pact NW circuit breaker only: Manually depress trip unit interlock (A) and hold it in place during steps 4-6 below.
Align guide rail (B) on bottom of trip unit with guide rail slot (C) on trip unit mounting base in circuit breaker and gently slide the trip unit in until it stops.
NOTE: The trip unit mounting bases are shock mounted and therefore can flex slightly.
FIG. 4 : Trip Unit Installation

CAUTION
HAZARD OF EQUIPMENT DAMAGE
Check installation of trip unit to assure proper connections and seating.
Failure to follow this instruction can result in equipment damage or improper circuit breaker tripping.
Align the trip unit so top mounting screw (A) aligns with the top threaded insert and start the screw by turning the screw two full rotations.
Use a torque-controlled screwdriver to drive the bottom screw (B) to 7 in-lbs (0.8 N•m) ± 10%. The back of the trip unit must be seated against the trip unit mounting base.
Use a torque-controlled screwdriver to drive the top screw to 7 in-lbs (0.8 N•m) ± 10%.
NOTE: The face of the closed switch cover must be flush with adjoining mounting base surfaces. If these surfaces are not flush, stop installation and contact the local sales office for factory authorized service.
Install connector block (C) into top of trip unit.
FIG. 5 : Install Trip Unit

Circuit Breaker Accessory Cover Replacement

Replace circuit breaker accessory cover as directed in the Install Accessories section of the circuit breaker instruction bulletin shipped with the circuit breaker.

Trip Unit Installation Check

Secondary Injection Testing

Field installation of a trip unit requires secondary injection testing with a Full-Function Test Kit. This will ensure that the newly-installed trip unit is functioning properly. The test will require opening and closing the circuit breaker. Follow the procedures outlined in the instruction bulletins shipped with the circuit breaker and the Full-Function Test Kit.

Make sure the circuit breaker is isolated from all upstream and downstream devices.
Perform secondary injection testing as outlined in the instruction bulletin shipped with the Full-Function Test Kit. Verify that all applicable trip unit functions are operating properly.
Repeat step 2 with the circuit breaker in the open position.
NOTE: The test kit states that the circuit breaker should be closed when performing the test. Do not close the circuit breaker for this step.
If any test fails, do not put the circuit breaker into service and contact the local sales office for factory authorization service.

Primary Injection Testing

Primary injection testing is recommended to ensure that all trip system connections have been correctly made.

NOTE: Perform primary injection testing as outlined in the instruction bulletin: Field Testing and Maintenance Guide for Thermal Magnetic and Micrologic Electronic Trip Molded Case Circuit Breakers.

Circuit Breaker Reconnection

Reconnect circuit breaker as directed in the circuit breaker instruction bulletin shipped with the circuit breaker.

Electrical equipment should be installed, operated, serviced, and maintained only by qualified personnel. No responsibility is assumed by Schneider Electric for any consequences arising out of the use of this material.