I.L. 29C103G

JWC Circuit Breakers and Molded Case Switches

nel and equipment as well as all general and localhealth and safety laws, codes, and procedures.

The recommendations and information contained hereinare based on Cutler-Hammer experience and judgment,but should not be considered to be all-inclusive or cov-ering every application or circumstance which mayarise. If any questions arise, contact Cutler-Hammer forfurther information or instructions.

1. INTRODUCTION

General InformationThe J-frame Series C circuit breaker (Figure 1-1) typesJD, JDB, HJD, and JDC are 600 Vac maximum rateddevices with inter changeable thermal-magnetic tripunits rated 250A maximum continuous current. Circuitbreaker types JW, HJW, and JWC are 660 Vac maxi-mum rated devices using interchangeable adjustablethermal/adjustable magnetic or electronic trip units ratedup to 250A continuous current. The type JDB noninter-changeable trip circuit breaker is rated 600 Vac maxi-mum with a maximum continuous current rating of250A. Refer to Table 1-1 for all available trip unit rat-

DO NOT ATTEMPT TO INSTALL OR PERFORMMAINTENANCE ON EQUIPMENT WHILE IT IS ENER-GIZED. DEATH, SEVERE PERSONAL INJURY, ORSUBSTANTIAL PROPERTY DAMAGE CAN RESULTFROM CONTACT WITH ENERGIZED EQUIPMENT.ALWAYS VERIFY THAT NO VOLTAGE IS PRESENTBEFORE PROCEEDING WITH THE TASK, ANDALWAYS FOLLOW GENERALLY ACCEPTED SAFE-TY PROCEDURES.

CUTLER-HAMMER 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-

Figure 1-1 J-Frame Model D Series C Circuit Breakerwith JT Trip Unit Installed

! WARNING

Circuit Breaker Trip Unit TypesTypes Thermal-Magnetic Amperes In

Fixed Adjustable AdjustableThermal Thermal Magnetic

of In

01 ot 507BDJJD 90HJD 100JDC JW 125 100-125

HJW 150 125-160JWC

175200 160-200225250 200-250

Not UL listed. For adjustable thermal trip units, the magnetic setting is a multiple of the maximum thermal setting.

Table 1-1 Available Trip Unit Ratings

2

2

1

1

Installation Instructions for JDB, JD, HJD, JDC, JW HJW,

Effective July 2015 Supersedes I.L. 29C103F dated April, 2007

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ings. Model D circuit breakers are listed in accordancewith Underwriters’ Laboratories, Inc. Standard UL489and satisfy the (P1) requirements of the InternationalElectrotechnical Commission Recommendations No.IEC 157-1 Model W circuit breakers satisfy the require-ments of IEC 947-2. Molded case switches are listed inaccordance with UL 489.

This instruction leaflet (IL) gives procedures for installa-tion and field testing of J-frame Series C circuit break-ers. For this publication, the term circuit breaker shallalso include the molded case switch.

2. INSTALLATION

The installation procedure consists of inspecting the cir-cuit breaker and, as applicable, installing the trip unit,accessories, interphase barriers and terminals; mount-ing the circuit breaker; connecting the line and load con-ductors; torquing terminals; and attaching terminalshields. Circuit breaker frames, trip units, accessories,mounting hardware, and unmounted terminals may besupplied in separate packages. To install the circuitbreaker, perform the following steps.

JDB circuit breakers are factory sealed for reversefeed applications under UL489. UL requires thatinternal accessories be installed at the factory inthis type of circuit breaker.

For hardware conversion kits and handle mechanismsrequired to replace existing Cutler-Hammer circuitbreakers.

If required, internal accessory installation in any type ofcircuit breaker should be done before the circuit breakeris mounted and connected. Refer to individual accesso-ry instruction leaflets.

Circuit breaker mounting hardware is supplied separate-ly.

2-1. Make sure that the circuit breaker frame is suitablefor the intended installation by comparing nameplatedata with existing ratings and system requirements.Inspect the circuit breaker for completeness, and checkfor damage before mounting. Uninstalled cover mount-ing hardware is supplied in a plastic bag with the circuitbreaker frame. (See Figure 2-1)

2-2. Remove installed cover screws and cover.

Figure 2-1 Cover Mounting Hardware

Pan Head Screws

Thread-Forming Screws

Figure 2-2 Cover Screw Installation Positions

Screw, .190-32 x 3.13 Inch, Pan Head, Cross-Recessed.Screw, No. 8 x 1.88 Inch, Pan Head, Cross-Recessed,Thread Forming.Screw, No. 6 x 1.50 Inch, Pan Head, Cross-Recessed, Thread Forming (used with 4 Pole Only)

Note: Hatched lines show additional pole and screws for 4-pole circuit breaker.

On/

Off/

NOTICE

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The circuit breaker handle must be in the tripped orOFF position to remove the cover. Instructions forinstalling the trip unit accessories are supplied withthe devices.

2-3. If not already installed, mount trip unit and acces-sories (if required) in circuit breaker frame.

WHEN REMOVED AND REINSTALLED, THREAD-FORMING SCREWS WILL TRY TO REFORM THETHREADS IN THE BASE. CARE SHOULD BE TAKENEVERY TIME A THREAD-FORMING SCREW IS USEDTO ENSURE THE SCREW STARTS IN THE ORIGINALTHREADS. DAMAGED THREADS CAN RESULT INIMPROPER CIRCUIT BREAKER COVER RETENTION.

2-4. Install cover, and secure with pan-head screws fol-lowed by threadforming screws, as shown in Figure 2-2.

2-5. If not already installed, mount terminals as shownin Figure 2-3. When using terminal (Catalog No.TA250KB), secure the terminal to the circuit breakerusing a 1/8-inch socket wrench and torque to 6-8 lb.-ft(8-11 N.m). After mounting the circuit breaker and

before installation of the conductors, the terminal mount-ing screw can be checked or retightened through theterminal when the conductor screw is removed. Whenusing terminal (Catalog No. T250KB), secure the termi-nal to the circuit breaker using screw and nut. Torque to7-9 lb.-in (0.8-1.0 N.m).

THE VOLTAGES IN ENERGIZED EQUIPMENT CANCAUSE DEATH OR SEVERE PERSONAL INJURY.BEFORE MOUNTING THE CIRCUIT BREAKER IN ANELECTRICAL SYSTEM, MAKE SURE THERE IS NOVOLTAGE PRESENT WHERE WORK IS TO BE PER-FORMED. SPECIAL ATTENTION SHOULD BE PAIDTO REVERSE FEED APPLICATIONS TO ENSURENO VOLTAGE IS PRESENT.

Depending on the equipment configuration, the cir-cuit breaker can be mounted using different stylesof hardware. The following steps describe how tomount the circuit breaker using standard hardware.When special hardware is needed (for example, withthe electrical operator), the instruction leafletdescribing the accessory also describes the specialmounting arrangements.

2-6. To mount the circuit breaker, perform the followingsteps:

a. For individual surface mounting, drill mounting panelusing the drilling plan shown in Figure 2-4. For panel-board mounting, only load end support mountingholes are required. For deadfront cover applications,cut out cover to correct escutcheon dimensions. (SeeFigure 2-5)

b. If circuit breaker includes factory- or field-installedinternal accessories, make sure that accessorywiring can be reached when the circuit breaker ismounted.

Labels with accessory connection schematic dia-grams are provided on the side of the circuit breaker.A note should be made of the diagrams if the labelscannot be seen when the circuit breaker is mounted.

Figure 2-3 Terminal Installation

TerminalConnectors

Collar

SocketScrew

TA250KB Terminal

Collar

Nut

T250KB Terminal

Flat-HeadScrew

NOTICE

NOTICE

! CAUTION

! WARNING

NOTICE

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Torque cover screws to 18-23 lb-in (2-2.6 N.m.).

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c. Position circuit breaker on mounting surface.

d. Install circuit breaker mounting screws and washers.Tighten screws firmly, but do not exceed 28 pound-inches (3 N.m.).

WHEN ALUMINUM CONDUCTORS ARE USED, THEAPPLICATION OF A SUITABLE JOINT COMPOUNDIS RECOMMENDED TO REDUCE THE POSSIBILITYOF TERMINAL OVERHEATING. OVERHEATING CANCAUSE NUISANCE TRIPPING AND DAMAGE TOTHE CIRCUIT BREAKER.

2-7. Connect line and load conductors and accessoryleads.

2-8. If required, install terminal shield on circuit breakercover with mounting screws provided.

2-9. After the circuit breaker is installed, check allmounting hardware and terminal connecting hardwarefor correct torque loading. Torque values for line/loadterminals are given in Table 2-1 and on the circuitbreaker nameplate.

3. MANUAL OPERATION, AND THERMAL-MAGNETIC ADJUSTMENT

Manual OperationManual operation of the circuit breaker is controlled bythe circuit breaker handle and the PUSH-TO-TRIP but-ton in the trip unit. The circuit breaker handle has threepositions, two of which are shown on the cover withraised lettering to indicate ON and OFF. On the slidinghandle barrier, ON, OFF, and trip are also shown by acolor-coded strip for each circuit breaker handle posi-tion: red for ON, white for tripped, and green for OFF.ON/OFF is also shown with the international symbols1/0. (See Figure 3-1)

Circuit Breaker ResetAfter an automatic or accessory initiated trip, or a manu-al Push-to-Trip operation, the circuit breaker is reset bymoving the circuit breaker handle to the extreme OFFposition.

In the event of a thermal trip in a thermal magnetictype trip unit, the circuit breaker cannot be resetuntil the thermal element in the trip unit cools.

Figure 2-5 Circuit Breaker Escutcheon Dimensions

.344R(8.74)

1.562(39.67)

.781(19.84)

2.922(74.22)3.938

(100.02)

.875(22.22)

.781

.188R(4.77)

3.50(88.90)

Circuit Breaker HandleCL

Circuit Breaker HandleCL

! CAUTION

NOTICE

Figure 2-4 Circuit Breaker Mounting Bolt Drilling Plans

2, 3 Pole Breakers 4-Pole Breakers

1.375(34.37)

.688(14.47)

2.750(69.85)

1.375(34.37)

4.078(103.58)

7.250(184.15) .250-20

(M6-1.0)Tap

(4 Holes)

.250-20(M6-1.0)

Tap(6 Holes)

Circuit BreakerHandle

Circuit Breaker Handle

CL CL

CL

I.L. 29C103G

No circuit breaker should be reclosed until thecause of trip is known and the situation rectified.

PUSH-TO-TRIP ButtonThe PUSH-TO-TRIP button checks the circuit breakertripping function and is used to periodically exercise theoperating mechanism in thermal-magnetic trip units. Thebutton is designed to be operated by a small screwdriver.

Thermal-Magnetic Trip Unit AdjustmentThe magnetic element of each pole of the trip unit canbe adjusted by rotating the adjustment buttons on thefront face of the trip unit with a screwdriver. The buttonshave several settings, as indicated on the nameplate,with values in multiples of the trip unit ampere rating (In).(See Figure 3-2) To adjust the setting, rotate each but-ton clockwise until arrow on button points to desired set-ting.

4. INSPECTION AND FIELD TESTING

Series C molded case circuit breakers are designed toprovide years of almost maintenance-free operation.

The following procedure describes how to inspect andtest a circuit breaker in service.

InspectionCircuit breakers in service should be inspected periodi-cally. The inspection should include the following checks(4-1 through 4-8):

THE VOLTAGES IN ENERGIZED EQUIPMENT CANCAUSE DEATH OR SEVERE PERSONAL INJURY.BEFORE INSPECTING THE CIRCUIT BREAKER INAN ELECTRICAL SYSTEM, MAKE SURE THERE ISNO VOLTAGE PRESENT WHERE WORK IS TO BEPERFORMED. SPECIAL ATTENTION SHOULD BEPAID TO REVERSE FEED APPLICATIONS TOENSURE NO VOLTAGE IS PRESENT.

! WARNING

Table 2-1 Terminal TypesTerminal Terminal Screw AWG Metric Wire TorqueCat. No. Material Head Wire Wire Type Value

Body Type Range Range lb-in (N.m.)

T250KB Stainless Socket 4-350 MCM 25-185 Cu Only 180 (20)Steel

TA250KB Aluminum Socket 4-350 MCM 25-185 Cu/AI 275 (31)

Figure 3-1 Circuit Breaker Manual Controls

ON

TRIP

OFF(Reset)

InternationalSymbols

ONOFF

Push-To-TripButton

Thermal-MagneticTrip Unit AdjustmentButton (3 Places)

Handle Position Indicator Color Red – ONWhite – TRIPGreen – OFF (Reset)

On/

Off/

Figure 3-2 Trip Unit Magnetic Trip Adjustment Buttons

AdjustmentButtons

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MAKE SURE THAT CLEANING AGENTS OR SOL-VENTS USED TO CLEAN THE CIRCUIT BREAKERARE SUITABLE FOR THE JOB. SOME COMMER-CIAL CLEANING AGENTS WILL DAMAGE THENAMEPLATES OR MOLDED PARTS.

4-1. Remove dust, dirt, soot, grease, or moisture fromthe surface of the circuit breaker using a lint-free drycloth, brush, or vacuum cleaner. Do not blow debris intocircuit breaker. If contamination is found, look for thesource and eliminate the problem.

4-2. Switch circuit breaker to ON and OFF severaltimes to be sure that the mechanical linkages are freeand do not bind. If mechanical linkages are not free,replace circuit breaker.

4-3. With the circuit breaker in the ON position, pressthe PUSH TO-TRIP button to mechanically trip the cir-cuit breaker. Trip, reset, and switch circuit breaker ONseveral times. If mechanism does not reset each timethe circuit breaker is tripped, replace the circuit breaker.

4-4. Check base, cover, and operating handle forcracks, chipping, and discoloration. Circuit breakersshould be replaced if cracks or severe discoloration isfound.

4-5. Check terminals and connectors for looseness orsigns of overheating. Overheating will show as discol-oration, melting, or blistering of conductor insulation, oras pitting or melting of conductor surfaces due to arcing.If there is no evidence of overheating or looseness, donot disturb or tighten the connections. If there is evi-dence of overheating, terminations should be cleaned orreplaced. Before reenergizing the circuit breaker, all ter-minations and cable should be refurbished to the condi-tion when originally installed.

4-6. Check circuit breaker mounting hardware, Tightenif necessary.

4-7. Check area where circuit breaker is installed forany safety hazards, including personal safety and firehazards. Exposure to certain types of chemicals cancause deterioration of electrical connections.

4-8. The operation of circuit breakers with electronic tripunits can be field-tested periodically using the Seltronictest kit.

Field TestingAny field testing should be done in accordance withapplicable NEMA Standard.

! CAUTION

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Style 6632C43H08Printed in Dominican Republic

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Eaton Electrical, Inc.1000 Cherrington parkwayMoon Township, PA 15108-4312USATel: 1-800-525-2000www.EatonElectrical.com

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