HS O08 ° Shost no. MANUAL FOR REPLACEMENT oF FDC-CONNECTION NO-FUSE BREAKERS WITH SPARES pogo KRB-5022 193)The spares for the FDC-connection breakers (LINE side plug-in connected and LOAD aide front-connected) used in group starter panels are a plug-in connection type when they also serve as spares for the same-model and -rating breakers used in the main switchboard. Before the existing FDC-connection breaker can be replaced with such a plug-in type spare, therefore, it is necessary to convert the LOAD side of the spare breaker (same-model/rating plug-in breaker) from the plug-in type to the front~connected type in accordancé with the conversion procedure given below. The mounting screws, terminal screws and washers fitted on the existing FDC-connection breaker are re-used, and keep them from missing. WHEN REMOVING OR MOUNTING A BREAKER, BE SURE TO TURN OFF THE BREAKER. Plug-in Connection Type FOC Connection Type {| if 1 ie iid 600A and larger frames ok a For most breakers up to 225A frame KRB-5022 (98)CONVERSION PROCEDURE For HBL-33, HBS-33, HBE-53, TO-60BA, HBS-63C, HBH-103 (15 to 60 A rated current) and H8S-103C (15 to 60 A rated current): Plug-in Terminal Converted Front-connected Terminal ™ ‘(noaD side only) (2) Contact mounting screw (5) Terminal screw (2) spring washer (6) Spring washer (3) BC disconnect contact (7) Wire grip plate (4) Square nut (8) Terminal Size of Contact Mounting Size of Terminal Screw Screw (metric, mm) (metric, mm) HBS-33 MS5x10, pan head Has-33- 6x12, pan head *1 HBE-S3 MSx10, pan head Hee-s3- M6x12, pan head *1 T0-60BA MSx16, pan head T0-60BA M6x16, pan head *1 HBS-63¢ MSx16, pan head HBS=630° M6x16, pan head *1 HBH-103 - MSx18, pan head HBH-103 - M8x16, pan head *2 HBS-103C MSx16, pan head HBS-103¢ > M6x16, pan head *1 HBL=33 -M5x18, pan head HBL-33 -M@x16, pan head *2 41 - Complete with wire grip plate and spring washer. #2 - complete with plain washer and spring washer. Og na KRB-5022 (95)1) 2) Sheat na. Remove everything ((1) to (4)) from each LOAD terminal end of the spare breaker to leave the terminal (8) only, Remove the terminal screw (5), spring washer (6) and wire grip plate (7) from each LOAD terminal end of the FDC-connection breaker to be replaced, and mount them on each LOAD terminal (8) of the spare breaker. vg KRB-5022 (96)2. For H8L~103, HBX-103, HBH-103, (75 or 100 A rated current) and HBL-103C (75 or 100 A rated current): Plug-in Terminal Converted Front-connected Terminal {LOAD side only) 7H | % Prevent turning with a flat screwdriver if turns together. a) (2) a) (4) 1) 2) M6 hexagon nut for (3) (5) Terminal screw, pan head, MBx: Spring washer (5) Spring washer BC contact bolt (7) Plain washer Tulip contact (8) Terminal Remove everything ((1) to (4)) from each LOAD terminal end of the spare breaker to leave the terminal (8) only. Remove the terminal screw (5), spring washer (6) and plain washer (7) from each LOAD terminal end of the FDC-connection breaker to be replaced, and mount them on each LOAD terminal (8) of the spare breaker. Dupo __KRB-5022 (97)3. For HBH-203 and “Hps-203 Plug-in Terminal Converted Front-connected Terminal (Loap side only) %& prevent turning with a flat screwdriver if turns together. (1) Mounting screw for (4), pan head, M8x16 (2) Spring washer (3) Plain washer (4) Plug contact (5) Terminal screw, hexagon socket head, M8x12 (6) Spring washer (7) Terminal 1) Remove everything ((1) to (4)) from each LOAD terminal end of the spare breaker to leave the terminal (7) only. 2) Remove the terminal screw (5) (use a hexagon key wrench of 8 mm across the flats) and spring washer (6) from each LOAD terminal end of the FDC-connection breaker to be replaced, and mount them on each LOAD terminal (7) of the spare breaker. 02 (98)4 ‘Shestno, 6. Por “HBL-203, TL-225- and. HBX-203 Plug-in Terminal Converted Front-connected Terminal qa) (2) a) (4) (5) w) q@ (8) o (LOAD side only) MB hexagon nut for (2) BC contact bolt Talip contact Terminal screw, hex. socket head Ml0x20 for HBi-203 and HBX-203 ; hex. head M10x19 for TL-275 - Spring washer Plain washer Terminal Breaker mounting holes, each houses a cap nut. Cover mounting screw pug __ KRB-5022 _ (99)Bo} 2) 3) Remove everything ((1) to (3)) from each LOAD terminal end of the spare breaker to leave the terminal (7) only. Remove the cover from the spare breaker by" loosening the four cover mounting screws (9), then take out the two cap nuts from the LOAD-side breaker mounting holes (8). Replace the cover as it was. Remove the terminal screw (4) (use a hexagon key wrench of 10 mm across the flats for hex. socket head), spring washer (5) and plain washer (6) from each LOAD terminal end of the FDC-connection breaker to be replaced, and mount them on each LOAD terminal (7) of the spare breaker. pug. KRB-5022 {100)5. For TL-2258, HBS-403- and HBL-403 Plug-in Terminal Converted Front-connected Terminal (LOAD side only) (1) M8 hexagon nut for (3) (2) Terminal cover (TL-225B only) (3) Plug contact bolt (4) Terminal screw, hexagon socket head, M10x20 (5) Spring washer (6) Plain washer (7) Terminal (8) Breaker mounting holes, each houses a cap nut. (9) Cover mounting screw Deore __KRB-5022 (10)1) 2) 3) After removing the nut (1) from each LOAD terminal of the spare breaker, turn each plug contact bolt (3) counterclockwise with a flat-bladed screwdriver to remove. Remove the cover from the spare breaker by loosening the four cover mounting screws (9), then take out the two cap nuts from the LOAD-side breaker mounting holes (8); for TL-225B, also remove the terminal covers (2). Replace the cover as it was. Remove the terminal screw (4) (use a hexagon key wrench of 10 mm across the flats), spring washer (5) and plain washer (6) from each LOAD terminal end of the FDC-connection breaker to be replaced, and mount them on each LOAD terminal (7) of the spare breaker. KxB-5022 (10216. For 7G-400, TL-400 and HBX-403+ Plug-in Terminal Converted Front-connected Terminal Converted 7 (LOAD side only) x use key wrench of 10 mm across the flats. (1) Nut for (2): M11 hexagon for TG-400 and TL-400 (use M10 spanner); MLO hexagon for HBX-403 . (2) Plug contact bolt (3) Terminal bolt, hex. socket head; Mllx26 for TG-400 and TL-400, Ml0x25 for H8X-403'; use hex. key wrench of 8 mm across the flats for each bolt. (4) Spring washer (5) Plain washer (6) Terminal (7) Protective cover for angle (TL-400 only) (8) Breaker mounting holes, each houses a cap nut, (9) Cover mounting screwY 2) 3) Sheatno. ff After removing the nut (1) from each LOAD terminal of the spare breaker, turn each plug contact bolt (2) counter-clockwise with a hexagon key wrench (10 mm across the flats) to remove, Remove the cover from the spare breaker by loosening the four cover mounting screws (9), then take out the two cap nuts from the LOAD-side breaker mounting holes (8), Replace the cover as it was. Remove the terminal bolt (3) (use a hexagon key wrench of 8 mm across the flats), spring washer (4) and plain washer (5) from each LOAD terminal end of the FDC- connection breaker to be replaced, and mount them on each LOAD terminal of the spare breaker. NOTE: When mounting a TL-400 breaker converted to the FDC connection type, be sure to use the protective cover (7) for the mounting angle. owgm, _KiB-5022 (104)1 Shaet no,_12 For “HBE-603, HBL-603, TG-600, TL-600, HBX-603, HBS-803, TG-800, TL-800 and HBX-803 : Plug-in Terminal Converted Front-connected Terminal b OLORO ole (1) «ay @) 4) () (6) a) (8) (a) on —Converted (LOAD side only), for HBE-603 and —HBL-603 hex. key wrench of 8 mn across the flats. Nut for (2): M11 hexagon for ‘HBE-603 and HBL-603 (use MLO spanner; M12 hexagon for all other breakers. Plug contact bolt Terminal bolt, hex. socket head, M11x26 (use hex. key wrench of 8 mn across the flats) Spring washer Plain washer Terminal bar ‘Terminal Front-connected Terminal {LOAD side only), for all breakers other than HBE-603 and HBL-603 Terminal barrier (TL-600 & TL-800) Terminal cover (TG-600, TL-600, HBS-803 , TG-800 & TL-800) Terminal bolt, hexagon head: M12x25.5 for TG-600, M12x27.5 for HBS-803 & TG-800, M12x32 for TL-600 & TL-800, M12x28 for HBX-603 , M1230 for HBX-803 - wpm KRB-5022 1105)Sa eT gt 19 Bee (10) Cover mounting screw (11) Breaker mounting holes, each houses a cap nut 1) 2) 3) 4) After ‘removing the nut (1) from each LOAD terminal of the spare breaker, turn each plug contact bolt (2) counter-clockwise with a hexagon key wrench (8 mm across the flats) to remove. Remove the cover from the spare breaker by loosening the four cover mounting screws (10), then take out, the two cap nuts from the LOAD-side breaker mounting holes (11). Also take out the retainer rings or springs. Remove the terminal bolt (3), spring washer (4), plain washer (5) and terminal bar (6) (also terminal barrier (8) for TL-600 and TL-800) from each LOAD terminal end of the FDC-connection breaker to be replaced, and mount them on each LOAD terminal (7) of the spare breaker. The terminal covers (9), when used, should also be removed and mounted on the spare breaker. Replace the cover on the spare breaker and secure it by the cover mounting screws (10). cum KRB-5022 (106)