TT-943 10/93a

INSTALLATION INSTRUCTIONS

Original Issue Date: 10/93

Model: 20--150 kW
Market: Industrial
Subject: Safeguard Circuit Breaker Kits Without Current Transformers
(Used with Controllers with Meters)

Introduction Disconnecting the electrical load. Hazardous voltage can

cause severe injury or death. Disconnect the generator set
The safeguard circuit breaker kit protects the generator from the load by opening the line circuit breaker or by
set in the event of an overload or short circuit. It is disconnecting the generator set output leads from the transfer
different than conventional circuit breakers in that it has switch and heavily taping the ends of the leads. High voltage
transferred to the load during testing may cause personal
a trip curve matched to the generator characteristics.
injury and equipment damage. Do not use the safeguard
When an overload or short circuit occurs, the safeguard circuit breaker in place of the line circuit breaker. The
circuit breaker opens the battery supply voltage to the safeguard circuit breaker does not disconnect the generator
voltage regulator. set from the load.

PA-255127 PA-255127-SD
PA-255128 PA-255128-SD WARNING
PA-255129 PA-255129-SD
PA-255130 PA-255130-SD
PA-255131 PA-255131-SD

Note: These kits do not include current transformers.

Accidental starting.
However, generator sets equipped with the basic Can cause severe injury or death.
relay controller without meters will require
installation and connection of current Disconnect the battery cables before
transformers. If your generator set is not working on the generator set.
equipped with current transformers, they are Remove the negative (--) lead first
when disconnecting the battery.
available as a separate accessory kit.
Reconnect the negative (--) lead last
when reconnecting the battery.
Note: Contact your local authorized distributor/dealer
for availability and selection of safeguard circuit
breakers should the unit require voltage Disabling the generator set. Accidental starting can
reconnection. cause severe injury or death. Before working on the
generator set or connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
Safety Precautions OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Observe the following safety precautions while installing Reconnect the negative (--) lead last when reconnecting the
the kit. battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
WARNING start/stop switch, or engine start command from a remote
computer.

Hazardous voltage. Moving rotor.

Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
are in place.
 Mounting and Connection
1. Place the generator set master switch in the OFF 4. Remove right-side panel of junction box by
position. removing six screws.

2. Disconnect the power to the battery charger, if 5. Locate and remove safeguard circuit breaker
equipped. knockout. See Figure 1 for location. To remove,
place wood block behind plate and strike with
3. Disconnect the generator set engine starting hammer. Remove burrs.
battery(ies), negative (--) lead first.

1
2

Section A-A Section A-A

Viewed from Engine End Viewed from Engine End EH-273000-A
20--60 kW 80--150 kW
1. Safeguard circuit breaker
2. Decal (293667) with safeguard breaker kit only

Figure 1 Safeguard Circuit Breaker Locations

6. Mount breaker to junction box with four screws

and flat washers. ON/OFF markings must be right
side up. 1

Note: If the generator set is equipped with current

transformers (controllers with meters), use
the following for installation of the safeguard
2
circuit breaker kit. If current transformers are
purchased as a separate accessory, follow
the instructions included with the current
transformer kit.
3
7. Attach terminals (X-283-3) to each lead of current
transformers.

8. Place generator output leads through current TT-943

transformers (1 turn) as shown in Figure 3.

1. Current transformers
Note: Place all current transformers with dot or HI 2. Safeguard terminal strip
markings toward the generator set (see 3. Safeguard circuit breaker
Figure 2). Figure 2 Safeguard Circuit Breaker Kit Installation

2 TT-943 10/93
 See Note A below before making delta connections.

Note: On 10-lead generators, leads T10, T11, and T12 are all
brought out together and labeled TO.

Note: Position the current transformers with the dot or HI side

CT marking toward the generator set. Current transformers
are not used on all sets.

Note: Phase Rotation: A = L1, B = L2, and C = L3.

Note: All 10- and 12-lead generator sets are reconnectable.

The 4-lead generator set is not reconnectable. Some
specially wound stators are made for a single voltage and are
also not reconnectable.

Note A: Use the delta connection shown in this illustration to

ensure correct phase sensing. Do not use the configuration
shown in the alternator technical manual.

5750-6

Figure 3 Current Transformer Connections

TT-943 10/93 3
 9. Loosen upper screws on safeguard terminal strip 13. Check that the generator set master switch is in the
with leads marked C0, C1, C2, and C3. Place OFF position.
jumper strip under terminals and tighten screws.
14. Reconnect the generator set engine starting
10. Connect safeguard circuit breaker as follows. See battery, negative (--) lead last.
Figure 4 for wiring diagram.
15. Reconnect power to the battery charger, if
Note: Safeguard terminal strip may have wires equipped.
connected in a different sequence than
shown in Figure 3. Leads connected to top
terminals have identification marked. Make
connections based on terminal identification
(not position).

a. Connect black leads of current transformers to

C0 on terminal strip.

Note: Due to screw length, it may be

necessary to place one CT lead on
upper screw of terminal strip.

b. Disconnect white lead of CT1 from terminal

strip and connect to lower relay on first pole of
breaker. Connect jumper lead from upper relay
terminal on first pole of breaker to C1 on
terminal strip.

c. Disconnect white lead of CT2 from terminal

strip and connect to lower relay terminal of
Figure 4 Wiring Diagram
second pole of breaker. Connect jumper lead
from upper relay terminal on second pole of
breaker to C2 on terminal strip. Parts List
d. Disconnect white lead of CT3 from terminal Kit: PA-255127, PA-255127-SD, PA-255128,
strip and connect to lower relay terminal on PA-255128-SD, PA-255129, PA-255129-SD, PA-255130,
third pole of breaker. Connect jumper lead from PA-255131, and PA-255131-SD
upper terminal on third pole of breaker to C3 on Qty. Description Part Number
terminal strip. 4 Washer, 0.156 x 0.375 x 0.049 in. plain X-25-9
4 Screw, 6-32 x 0.375 in. RHM X-49-2
e. Disconnect 1B from terminal strip and connect
1 Lead LW-1604-2214
to load terminal on third pole of breaker.
Connect jumper lead from line terminal on third 3 Decal, safeguard 293667
pole of breaker to terminal 70 on terminal strip. 1 Breaker, circuit (Kits PA-255127 and
PA-255127-SD) X-796-1
11. Replace right-side panel of junction box using six 1 Breaker, circuit (Kits PA-255128 and
PA-255128-SD) X-796-4
screws.
1 Breaker, circuit (Kits PA-255129 and
12. Check the surface of the junction box directly PA-255129-SD) X-796-6

beneath the safeguard circuit breaker. With 1 Breaker, circuit (Kits PA-255130 and
PA-255130-SD) X-796-2
surface clean and dry, apply safeguard circuit
1 Breaker, circuit (Kits PA-255131 and
breaker decal (kits with decal only). PA-255131-SD) X-796-3

4 TT-943 10/93