AC Pro Trip Unit

ac-pro®
i-ac-pro-QT ac trip unit
instruction manual
State of the art technology for low
voltage circuit breaker retrofitting
URC Utility Relay Company

Chagrin Falls, OH 44023
Phone: 888.289.2864
w w w. u t i l i t y r e l a y. c o m
AC-PRO® With QUICK-TRIP® Instruction Manual www.utilityrelay.com
Manual Rev 1.4
Section: Page
1.0 Introduction ............................................................1 12.0 Secondary Injection Testing .................................. 17
®
2.0 UL/ULC Classification & CE Mark .........................1 12.1 AC-PRO Secondary Injection Test Set ........ 17
3.0 Trip Unit Power ......................................................1 12.2 Standard Relay Test Set ............................... 17
3.1 Current Transformer (CT) Power ...................1 12.3 LT Delay Testing Chart ................................. 18
3.2 Battery Power ................................................1 13.0 Ratings .................................................................. 19
3.3 PT Module Power ..........................................2 14.0 Warranty ................................................................ 19
3.4 Auxiliary Power ..............................................2 15.0 Time-Current Curves ............................................. 19
4.0 External Connections .............................................2 15.1 LT Trip Time .................................................. 20
4.1 Breaker Wiring Harness .................................2 15.2 ST Trip Time.................................................. 20
4.2 Security Key ...................................................2 15.3 GF Trip Time ................................................. 21
®
5.0 AC-PRO Front View .............................................3 15.4 U/B Trip Time ................................................ 21
5.1 16 Character Display .....................................4 16.0 Error Message Summary ...................................... 21
5.2 Pick-Up LED ..................................................4 16.1 Actuator Not Connected ................................ 21
5.3 Self Test LED .................................................4 16.2 Memory Error ................................................ 21
5.4 Display Contrast ............................................4 17.0 Battery Replacement ............................................. 22
5.5 UP Push Button .............................................4
5.6 DOWN Push Button .......................................4
5.7 SAVE Push Button .........................................4 Figure: Page
®
5.8 REVIEW Push Button ....................................4 4.1 AC-PRO Top View ............................................... 2
®
6.0 QUICK-TRIP System ...........................................5 4.2 Push Button “Key” ................................................. 2
® ®
6.1 QUICK-TRIP Basics .....................................5 5.1 AC-PRO Horizontal Front View ........................... 3
® ®
6.2 QUICK-TRIP Installation ..............................6 5.2 AC-PRO Vertical Left Front View......................... 3
® ®
6.3 QUICK-TRIP & Pro-Display Operation.........7 6.1 QUICK-TRIP Connections ................................... 5
® ®
7.0 Commissioning the AC-PRO ................................7 6.2 QUICK-TRIP Drilling Plan .................................... 6
7.1 Powering-Up the Trip Unit .............................7 6.3 Pro-Display Mounting ............................................ 6
7.1.1 Internal Battery ....................................7 11.1 Phase A & B, CT Phasing Test ............................. 15
7.1.2 External Power ....................................7 11.2 Phase B & C, CT Phasing Test ............................. 15
7.2 Security Key ...................................................7 11.3 U/B Test ................................................................ 16
®
7.3 CT Rating .......................................................8 12.1 AC-PRO Secondary Injection Test Set ................ 17
7.4 Long Time (LT) Pick-Up Setting ....................8 17.1 Battery Replacement ............................................. 22
7.5 Long Time (LT) Delay Setting ........................8 18.1 Typical Wiring Diagram ......................................... 23
7.6 Short Time (ST) Pick-Up Setting ...................8 18.2 Overload TCC ....................................................... 25
7.7 Short-Time (ST) Delay Setting.......................8 18.3 U/B & GF TCC ....................................................... 27
2 ®
7.8 Short Time (ST) I T ........................................8 18.4 QUICK-TRIP GF & I TCC .................................... 29
7.9 Instantaneous (I) Pick-Up Setting ..................9
7.10 Ground Fault (GF) Pick-Up Setting................9 Firmware Revision: 5.25
7.11 Ground Fault (GF) Delay Setting ...................9
2
7.12 Ground Fault (GF) I T ....................................9
7.13 Phase Unbalance (U/B) Pick-Up ...................9
7.14 Phase Unbalance (U/B) Delay .......................10
7.15 Address ..........................................................10
7.16 Reply Delay ...................................................10
®
7.17 QUICK-TRIP Ground Fault (QT GF) ............10
®
7.18 QUICK-TRIP Instantaneous (QT I) ..............10
7.19 Thermal Memory ............................................11
7.20 Exit Procedure ...............................................11
8.0 Changing Settings..................................................12
9.0 Last Trip Data Recall .............................................13
10.0 Normal Operation...................................................14
11.0 Testing ...................................................................14
11.1 Commission the Trip Unit ..............................14
11.2 LT Trip Test ...................................................14
11.3 ST Trip Test ...................................................15
11.4 I Trip Test .......................................................15
11.5 GF Trip Test ...................................................15
11.6 QT GF Trip Test .............................................15
11.7 CT Phasing Test for GF .................................15
11.8 QT I Trip Test .................................................16
11.9 U/B Trip Test ..................................................16
11.10 Erase Last Trip Data ....................................16
1.0 Introduction
UL and ULC classification is in accordance with UL1066,
CSA C22.2, IEEE C37.59-1991 as well as appropriate
The AC-PRO is a state of the art, micro-controller based trip sections of ANSI C37.17-1979 and C37.50-1989.
unit for use on three phase, 600 Volt class, AC circuit
breakers. Models are available for use on 60 Hz, 50 Hz, The AC-PRO has the CE Mark.
40 Hz, and 25 Hz systems.
AC-PRO was tested by an independent laboratory and found
The AC-PRO is a digital trip unit that uses a micro-controller in compliance with the following tests:
and a 16-character liquid crystal display (LCD).
IEEE C37.90.2-2004, RF Susceptibility
The trip unit provides over-current, as well as short time and IEEE C37.90.1-2002, Surge Withstand
instantaneous fault protection. All of the phase protection 15KV Electro-Static Discharge
functions use the true RMS currents including the Accuracy @ -20°C & +65°C
instantaneous trip function.
The AC-PRO measures the true RMS current through each 3.0 Trip Unit Power
of the breaker’s three poles. For ground fault current, the
trip unit also does a vector sum of the three phase currents
The AC-PRO can be powered in 4 different ways: CTs,
(and neutral current if applicable) and determines the
internal battery, PT module, or auxiliary power pack.
fundamental frequency component.
The trip unit also offers ground fault and phase unbalance (U/B)
tripping functions as user selectable options. The fundamental 3.1 Current Transformer (CT) Power
value of the ground fault current is used for the ground
fault trip function to eliminate nuisance ground fault trips The AC-PRO derives both signal and power from the
rd
due to multiples of the 3 harmonic. breaker phase CTs. The trip unit will power-up with less
than 10% of the rated CT tap current through a single CT
The AC-PRO uses a unique algorithm to determine if (20% for the 1/2 Amp version). This current is below the
currents greater than 12 times the CT rating have caused CT lowest pick-up setting.
saturation. The AC-PRO then corrects the effect of CT
saturation on the Short Time and Instantaneous trip
functions. 3.2 Battery Power
The AC-PRO also has two additional QUICK-TRIP protective
A 9-volt, 750 mAh, long life, lithium battery is used in the trip
settings that are intended to minimize Arc Flash Hazard. The
unit. This battery has less than 2 grams of lithium. There are
QUICK-TRIP ground fault and instantaneous trip functions are
no restrictions on transport and no special methods of
turned ON or OFF using the QUICK-TRIP Display. See Section
disposal required with this battery.
6.0 for complete details.
The battery is designed to provide two functions:
The trip unit stores the last trip data and the trip log data in a
1) Allow the user to commission (program) the trip unit
non-volatile FRAM memory for later recall. All the settings
without using the auxiliary power pack.
are stored in non-volatile EEPROM memory. Battery backup
is not required.
2) Allow the user to recall the last trip data even if the
breaker is open and without using the auxiliary power
The trip unit does not require external power to operate. Power
pack.
is derived from the current transformers (CTs). An internal
battery provides power to review and change protection
Press the “REVIEW” push button to turn the trip unit on
settings when CT power is unavailable.
under battery power.
All settings are made directly in amps or in seconds. A
When on battery power, the trip unit will automatically turn
security system reduces the risk of unauthorized tampering
off 30 seconds after the last button is pushed to conserve
with the trip unit settings.
battery energy.
The AC-PRO trip unit is manufactured under one or more of
the following patents:
**** NOTE ****
US 7,646,575 The battery is NOT involved in the protective functions of
US 7,889,472 the trip unit. The trip unit will provide protection even if the
battery is removed.
Other patents may be pending.
The battery is NOT required for the trip unit to maintain
any of its memory including the user programmed pick-up
and delay settings and the last trip data.
2.0 UL/ULC Classification & CE Mark
AC-PRO is UL and ULC classified for use on the following See Section 17.0 for battery data and instructions on
low voltage AC power circuit breakers: replacing the battery.
Westinghouse DB-50
Square D/Westinghouse DS-206, DS-416, DS-632
General Electric AK-50, AK-75
ITE KB Steel Back
ITE K-600, K-800, K-1600
FPE H-3
Page 1
Utility Relay Company
3.3 PT Module Power 4.2 Security Key
The AC-PRO trip unit is available with a communication The AC-PRO trip unit contains a security feature that only
option that has a connection for a PT module. allows someone familiar with the operation of the trip unit to
commission the trip unit or make changes to the settings. A
The PT module provides breaker 3-Phase voltage security key is required to change any of the settings.
information and also provides power for the trip unit
independently from the CTs. See the Communication The "Key" is simply a short jumper wire that is connected
Instruction Manual for more information. between the two terminals marked “KEY” on the top of the
trip unit.
3.4 Auxiliary Power Refer to Figure 4.0-1 AC-PRO top view.
Auxiliary power is optional. It can be used to change or To turn the security Key "ON":
review the trip unit settings without using the internal battery. Jumper the two terminals labeled “KEY” on the top of
the trip unit.
Plug the 24-VAC auxiliary power pack into the auxiliary
power jack on the top of the trip unit. To turn the security Key "OFF":
Remove the jumper wire.
The power pack is available from Utility Relay Company as
part number T-390. The key allows the user to commission the trip unit or to
change the settings on a trip unit by performing the steps as
outlined in Sections 7.0 and 8.0.
4.0 External Connections The “CT Rating” also has an additional security feature as
explained in Section 7.3.
The external connections are made to the top of the
AC-PRO trip unit (or the left or right side for the vertical
versions).
Battery Cover
Breaker Wiring Harness See Section 3.2 & 17.0
See Section 4.1 QT Display Jack
Security Key See Section 6.0 BATTERY
COVER
See Section 4.2
ACTUATOR
+
NEUTRAL
24 VAC QT
PHASE
KEY
PHASE
PHASE
AUXILIARY
DISPLAY Use only 9V
POWER
C
Lithium Battery
BREAKER HARNESS
BATTERY
COVER
+
Breaker Escutcheon
ACTUATOR
NEUTRAL
24 VAC QT
PHASE
KEY
PHASE
PHASE
AUXILIARY
DISPLAY Use only 9V
A
POWER Lithium Battery

BREAKER HARNESS
Auxiliary Power Jack Push Button "Key"

See Section 7.1.2
Figure 4.0-1 AC-PRO® Top View Figure 4.0-2 Push Button “Key”
When the AC-PRO is installed on some breakers, the “Key”
4.1 Breaker Wiring Harness terminal block on top of the trip unit is not readily accessible.
In those cases a short harness with a “Key” push button is

The breaker wiring harness connects the trip unit to the CTs
provided. The “Key” push button is installed in the breaker
and actuator. The wiring harness plugs into the 10-pin
escutcheon so it is easily accessible.
connector on the top of the trip unit and is retained with two
screws.
To turn the security Key "ON" with the “Key” button:
Push and hold the “Key” button.
Pin Function Color Code
1 Actuator (+) Red
To turn the security Key "OFF" with the “Key” button:
2 Actuator (-) Black
Release the “Key” button.
3 Phase A (Dot) Blue
4 Phase A White
5 Phase B (Dot) Yellow
6 Phase B White
7 Phase C (Dot) Brown
8 Phase C White
9 Neutral CT (Dot) Green
10 Neutral CT White
Table 4.1 Breaker Wiring Harness Pin-Out
A neutral CT wiring harness is provided as part of the neutral

CT installation kit and is only required with ground fault on a
4-wire system. The ground fault function on a 3-wire system
does not require a neutral CT.
Page 2
5.0 AC-PRO® Front View
The front view of the horizontal version of the AC-PRO trip

unit is shown in Figure 5.0-1. The front view of a vertical
version of the AC-PRO is shown in Figure 5.0-2.
Wiring Harness Battery

Cover
CE Mark Display
Lo
9V -Lif
W ithiu atte
ng
ith m ry
AC TRIP UNIT
AC-PRO
L eB
R
AC-PRO
B-521H
WITH QUICK-TRIP TM
Pick-Up Part Number

LED Label
Contrast
H490F524
PC 01168
PICK-UP
SELF TEST OK
PUSH TO
ADJUST
DISPLAY
Option
CONTRAST
Label
1A 0 CT 60Hz
Self Test SAVE REVIEW
PUSH TO VIEW
LAST TRIP DATA
1A N CT
AND SETTINGS
LED
UTILITY RELAY COMPANY
Serial Number
UL Label (on end)
Up Review
Save Down
Figure 5.0-1 AC-PRO® Horizontal Front View
UL Label
CE Mark
Battery
Cover
Lo
9V -Lif
W th iu a tte
ng
ith m ry
Li e B
TM AC TRIP UNIT
AC-PRO WITH QUICK-TRIP
TM
Display
Pick-Up
LED
PUSH TO
ADJUST
DISPLAY
Contrast
PICK-UP CONTRAST
SELF TEST OK
Self Test
LED SAVE REVIEW
PUSH TO VIEW
LAST TRIP DATA
AND SETTINGS
Review
1A 0 CT 60Hz AC-PRO
1A N CT H490F524 B-521L
PC 01180
Up Save Down
Wiring Harness
Option Part Number
Serial Number Label
Label
(on end)
Figure 5.0-2 AC-PRO® Vertical Left Front View
Page 3
5.1 16 Character Display 5.6 DOWN Push Button
A 16-character dot matrix liquid crystal display (LCD) Use this push button to decrease the setting values during
provides information to the user. commissioning. When the “DOWN” push button is held
longer than one second, the settings are decreased in fast
The LCD is used for the following purposes: mode.
1) Entering the CT rating and making the pick-up and time When the minimum setting value is reached, the “DOWN”
delay settings with prompts from the display. push button will have no further effect on the setting value.
2) Displaying, on demand, the CT rating and the various
pick-up and delay settings.
5.7 SAVE Push Button
3) Displaying, on demand, the reason for the last trip and
the currents at the time of trip.
Use this push button to step though the settings when in the
4) Continuously displaying the actual 3-phase AC currents
commissioning mode.
on the breaker.
Holding this push button has no effect.
5.2 Pick-Up LED
5.8 REVIEW Push Button
The Pick-Up LED is normally off. It will turn on whenever the
breaker current is above the LT Pick-up setting.
Use this push button to step though the settings in the
settings review mode. Also use this push button to turn the
5.3 Self Test LED trip unit on using battery power.
Hold this push button down to review trip counts during the
settings review.
The Self Test LED is normally on. It will turn off under the
following conditions:
1) The actuator is not connected. The LCD will also

display an error message.
2) There is a checksum error in the micro-controller.

The LCD will also display an error message.
5.4 Display Contrast
The contrast level of the LCD can be adjusted by pressing

this push button.
When the contrast push button is pressed and held, the

display will begin to get either darker or lighter. To change
direction, release the push button for more than one second,
then press and the hold the push button until the desired
contrast is achieved.
5.5 UP Push Button
Use this push button to increase the setting values during

commissioning. When the “UP” push button is held longer
than one second, the settings are increased in fast mode.
When the maximum setting value is reached, the “UP” push

button will have no further effect on the setting value.
Page 4
6.0 Quick-Trip® System
QT-Display 2
on cubicle door 2 Pole Plug into
back of Pro-Display
AC-PRO QUICK-TRIP
QT-DISPLAY
R
REMOTE DISPLAY
MICRO-CONTROLLER BASED ON OFF
16 Character
display
PUSH TO
ADJUST
PICK-UP DISPLAY
CONTRAST
SELF TEST OK
Plug into Jack
PUSH TO VIEW
in back of R
QUICK-TRIP ON REVIEW LAST TRIP DATA
AND SETTINGS
QT-DISPLAY Padlocking
Cover
3
Red LED is "ON" Quick-Trip ON-OFF
with Quick-Trip turned ON selector switch
8/C Cable, shielded Plug into
with modular connectors "QT Display"
(100 foot maximum) jack Quick-Trip
ON OFF
Lo
9V -Lif
W hiu atte
ng
ith m ry
AC TRIP UNIT
AC-PRO
Lit e B
R
AC-PRO
Remote
B-521H
TM
WITH QUICK-TRIP
NC
Indication Contacts
NO for Customer Use
To QT-Display
H490F524
PC 01168
PICK-UP
PUSH TO
ADJUST
SELF TEST OK DISPLAY
Quick-Trip
CONTRAST
1A 0 CT 60Hz
SAVE REVIEW
PUSH TO VIEW
LAST TRIP DATA
On-Off Contact
1A N CT
AND SETTINGS

Selector Switch Wiring
AC-PRO trip unit

on breaker 1
Figure 6.0-1
QUICK-TRIP® Connections
6.1 Quick-Trip® Basics
The QUICK-TRIP system is a manually controlled Zone When QUICK-TRIP is on, the following settings are enabled:
Selective Interlock (ZSI) system. It can reduce trip times • GF QUICK-TRIP (GF QT)
when turned on and allows selective coordination between • I QUICK-TRIP (I QT)
circuit breakers when turned off. All other settings remain in effect.
If maintenance personnel must work on energized The “QUICK-TRIP ON LED” provides positive indication that
equipment, they will first turn the QUICK-TRIP system on at the QUICK-TRIP settings are active if the LED is on.
the breaker feeding the equipment. If a fault now occurs, the
upstream breaker will trip quickly based on the QUICK-TRIP The extra contact block on the QUICK-TRIP selector switch
settings reducing the Arc Flash Hazard to personnel. can be used for local or remote indication of the QUICK-TRIP
selector switch setting.
When the work is done, the QUICK-TRIP system is turned off
and the original selective coordination is back in effect.
**** IMPORTANT ****
A qualified engineer must determine the QUICK-TRIP
The QUICK-TRIP system consists of the following
settings, calculate the incident energy levels and
components:
determine the Hazard Risk Categories (HRC).
1. AC-PRO trip unit with QUICK-TRIP.
2. QUICK-TRIP Display with a “QUICK-TRIP ON“ LED.
If an older Pro-Display without the “QUICK-TRIP ON”
3. Padlocking selector switch mounted near the
LED is plugged into an AC-PRO with QUICK-TRIP, the
QUICK-TRIP Display that is used to turn QUICK-TRIP
QUICK-TRIP settings will always be on.
on and off.
Page 5
Drill 1 11/16" diameter hole

or alternately use
1 1/4" conduit knockout punch
Outline of
QT-Display R Use 22mm switch knockout punch
Locate near QT-Display
1 1/4" 1 1/4"
Drill (2) 13/64"
diameter holes
Figure 6.2-1
QUICK-TRIP® Drilling Plan
6.2 Quick-Trip® Installation
The QUICK-TRIP system is easy to install on the front of the 4. Attach the QUICK-TRIP Display to the front of the
breaker cubicle door. cubicle door using two (2) 10-32 hex nuts, flat washers
and lock washers.
To install the QUICK-TRIP Display: 5. Connect the QUICK-TRIP Display to the AC-PRO trip
unit by plugging one end of the shielded modular
1. Find a suitable location on the cubicle door and mark cable provided into the jack on the back of the QUICK-
the location of the three (3) holes using the TRIP Display. Plug the other end of the cable into the
dimensions in Figure 6.2-1. “QT Display” jack on the top of the AC-PRO.
2. Drill two (2) 13/64” mounting holes. 6. Route the cable so it does not interfere with the
3. For the center hole, cut a 1-11/16” diameter hole using opening or closing of the cubical door or with the
a hole saw or alternately, use a 1-1/4” conduit racking of the breaker between connect and
knockout punch. disconnect positions. Use cable ties and holders to
hold the cable in position.
Breaker Cubicle Door
To install the on/off selector switch:
1. Use a 22mm switch knock-out punch to make a hole

in the cubicle door for the selector switch. The selector
switch should be located near the QUICK-TRIP
Display.
2. Attach the selector switch, padlock attachment and
contact blocks to the cubicle door.
3. Plug the cable from the switch into the back of the
QUICK-TRIP Display.
(2) 10-32 hex nuts,

flat washers &
lock washers
QT-Display R
side view
Figure 6.2-2
QUICK-TRIP Display Mounting
Page 6
6.3 Quick-Trip® & Pro-Display Operation
The QUICK-TRIP Display will display the same messages as Press the “SAVE” push button. The following will be
the display on the AC-PRO. It provides the capability of displayed:
viewing the breaker currents and reviewing the settings and
the last trip data without opening the breaker cubicle PROD: H4.90F5.26
door.
Press the “SAVE” push button to begin the commissioning
For security reasons, it is not possible to change any process.
settings from the QUICK-TRIP Display.
3) Enter the appropriate CT tap, pick-up and delay
When the display on the QUICK-TRIP Display is off, push settings using the "UP", "DOWN" and "SAVE" push
the “REVIEW” button to power the QUICK-TRIP Display buttons.
from the internal battery in the AC-PRO. The following
information will be available: 4) Remove the security key (see Section 4.2).
• Last trip data including the type of trip and the currents
• Pushing the “REVIEW” button will display the trip log Sections 7.1 through 7.20 go over the commissioning
• Continuing to push the “REVIEW” button will step process in greater detail.
through the settings
• The “SELF TEST OK” LED will indicate proper operation
****NOTE****
• The “QUICK-TRIP ON” LED will indicate the on/off status
An additional security feature is provided to avoid
of the QUICK-TRIP settings
accidentally changing the CT tap setting. See Section 7.3.
When the display on the QUICK-TRIP Display is on, the
phase currents will be displayed (if greater than 10% of the
CT tap). The following information will also be available:
• The “PICK-UP” LED will indicate if phase currents are
7.1 Powering-Up the Trip Unit
above the Long Time pick-up setting
In normal service, the AC-PRO trip unit is powered directly
• The “SELF TEST OK” LED will indicate proper operation from the breaker mounted CTs.
• The “QUICK-TRIP ON” LED will indicate the on/off status
of the QUICK-TRIP settings For commissioning, the AC-PRO trip unit can be powered-up
Pushing the “REVIEW” button will display: in either of the following two ways.
• Last trip data including the type of trip and the currents
• Pushing the “REVIEW” button will display the trip log
• Continuing to push the “REVIEW” button will step 7.1.1 Internal Battery
through the settings
Press the "REVIEW" button to power-up the trip unit using
the internal battery.
7.0 Commissioning the AC-PRO® The trip unit is designed to shut off automatically if none of
the 4 lower push buttons on the face of the unit are pressed
Before the AC-PRO trip unit is put into service, it must first for 30 seconds. It is best to have all the desired settings
be commissioned so it will function. This requires the user to readily available before commissioning the unit when using
enter all of the pick-up and delay settings into the unit. the battery.
The commissioning process normally takes less than a few If the unit shuts down before the commissioning process is
minutes to complete. completed, the process must be started again from the
beginning.
**** IMPORTANT ****
The trip unit will NOT FUNCTION as it is shipped from 7.1.2 External Power
the factory. The user must first COMMISSION the unit as
outlined in this Section to make it functional.
Apply 24 VAC to the "auxiliary power" jack located on the top
of the trip unit using the Utility Relay auxiliary power pack.
After the AC-PRO is installed on the breaker, it must be
(Utility Relay Company part number T-390).
commissioned as follows:
By applying external power, the unit will stay energized as
1)Connect the security key (see Section 4.2)
long as necessary to complete the commissioning process.
2)Push the "REVIEW" push button to power-up the trip
unit. The trip unit will alternately display the following: 7.2 Security Key
ENTER DATA The following will be displayed if the security key is not
already connected:
SERIAL # XXXXXXX
SECURITY KEY OFF
Connect the security key to continue the commissioning
process (See Section 4.2).
Page 7
7.3 CT Rating
current 6 times the LT Pick-Up setting is applied. See the
time-current curves in Figure 18.2.
After the security key is connected, the following will be
displayed: Press and hold the "UP" or "DOWN" push button as required
until the correct LT Delay setting is displayed.
CT RATING XXXXA
Press the "SAVE" push button to continue.
Where "XXXX" represents the CT rating in amps. The CT
rating can range from 50 amps to 5,000 amps in 25 amp 7.6 Short Time (ST) Pick-Up Setting
steps and 5250 amps to 6000 amps in 250 amp steps.
The CT rating entered into the trip unit must correspond to The following will be displayed:
the actual rating of the phase and neutral CT tap that the trip
unit is connected to. ST PICK-UP OFF
A security feature is provided so the CT rating will not be If the ST function is not desired, press the "SAVE" push
accidentally changed later. button and go to Step 7.9.
The CT security feature must be used to enter the initial CT If the ST function is desired, press the "UP" push button and
rating or to change the CT rating. the following will be displayed:
***To Activate the CT Security Feature*** ST PICK-UP XXXXA

In the commissioning mode and when the CT rating is
displayed: Where "XXXX" represents the ST Pick-Up in amps.
Simultaneously push and release both the "SAVE"
and "REVIEW" push buttons The ST Pick-Up setting ranges from 150% to 1200% of the
This allows the CT rating to be changed. LT Pick-Up setting in 100 amp steps (1000 amp steps for
5250 to 6000 amp CTs and 10 amp steps for 50 to 200 amp
With the security feature activated, press and hold the "UP" CTs). Press and hold the "UP" or "DOWN" push button as
or "DOWN" push button as required until the correct CT required until the correct ST Pick-Up setting is displayed.
rating is displayed.
Press the "SAVE” push button to continue.
7.7 Short Time (ST) Delay Setting
7.4 Long Time (LT) Pick-Up Setting
If the ST function is not off, then the following will be
displayed:
The following will be displayed:
LT PICK-UP XXXXA ST DELAY .XXS

Where ".XX" represents the ST Delay.
Where "XXXX" represents the LT Pick-Up setting in amps.
The LT Pick-Up setting ranges from 20% to 100% of the CT
The ST Delay settings are .07, .10, .15, .20, .30 and .40
rating. This setting is adjustable in 5 amp steps (50 amp
seconds.
steps for 5250 to 6000 amp CTs and 0.5 amp steps for 50 to
200 amp CTs).
Press and hold the "UP" or "DOWN" push button as required
until the correct ST Delay setting is displayed.
until the correct LT Pick-Up setting is displayed.
7.8 Short Time (ST) I2T
7.5 Long Time (LT) Delay Setting
The I²T function adds a ramp to the ST delay if required for
coordination purposes as shown in the Overload TCC in
Figure 18.2.
LT DELAY XX.XS If the ST function is not off, then the following will be
displayed:
Where "XX.X" represents the LT Delay band. The LT Delay
band is labeled by the number of seconds to trip at 6 times ST I SQ T XXX
the LT Pick-Up setting.
Where "XXX" represents ON or OFF.
The LT Delay setting ranges from 2.0 to 30.0 seconds in
steps of 0.5 seconds. This provides 57 LT Delay bands.
If the ST I²T ramp is desired, press the "UP" push button. If
the ST I²T ramp is not desired, press the "DOWN" push
Please note that the LT trip time is not a constant value, but
button.
is a function of breaker current. For lower currents the trip
time is longer, and for higher currents the trip time is shorter.
The trip time is only equal to the LT Delay setting when a
Page 8
7.9 Instantaneous (I) Pick-Up Setting until the correct GF Delay setting is displayed.
The following will be displayed: Press the "SAVE” push button to continue.
I PICK-UP XXXXXA 7.12 Ground Fault (GF) I2T

Where "XXXXX" represents the I Pick-Up in amps.
The I²T function adds a ramp to the GF delay if required for
The I Pick-Up setting ranges from 150% to 1200% of the LT coordination purposes as shown in the Ground Fault TCC in
Pick-Up setting in 100 amp steps (1000 amp steps for 5250 Figure 18.3.
to 6000 amp CTs and 10 amp steps for 50 to 200 amp CTs).
If the GF function is not off, then the following will be
Press and hold the "UP" or "DOWN" push button as required displayed:
until the correct I Pick-Up setting is displayed.
GF I SQ T XXX
If the I function is not desired and the ST function is not off,
press the "DOWN" push button until the following is
Where "XXX" represents ON or OFF.
displayed:
If the GF I²T ramp is desired, press the "UP" push button. If
I PICK-UP OFF the GF I²T ramp is not desired, press the "DOWN" push
button.
**** NOTE ****
The trip unit does not allow setting both the ST and the I Press the "SAVE” push button to continue.
functions off at the same time.
**** NOTE ****
**** NOTE **** On a 4-wire system, a neutral CT must be installed to
The AC-PRO has Close Fault (CLSFLT) protection which avoid nuisance GF trips.
provides arc flash reduction when a breaker is closed into
a fault. CLSFLT feature is a fixed instantaneous function
set (fixed) at 11 times the CT rating, and is only active for **** IMPORTANT ****
the first 180 milliseconds after the AC-PRO powers up. To implement GF protection on the main breakers and
CLSFLT cannot be disabled and is active if Instantaneous the tie breaker of a double ended substation, contact
protection is set to on or off. Utility Relay Co.

7.13 Phase Unbalance (U/B) Pick-Up
7.10 Ground Fault (GF) Pick-Up Setting
If the GF function is not desired, then press the "DOWN"
push button until the following is displayed: U/B PICK-UP OFF
GF PICK-UP OFF If the U/B function is not desired, then press the "SAVE”
push button and go to Step 7.15.
If the GF function is desired, press the "UP" push button and
the following will be displayed: If the U/B function is desired, press the "UP" push button
and the following will be displayed:
GF PICK-UP XXXXA
UB PICK-UP XX%
Where "XXXX" represents the GF Pick-Up setting in amps.
Where "XX" represents the U/B Pick-Up setting in
The minimum GF Pick-Up setting is 20% of the CT rating percentage. The minimum and maximum UB Pick-Up setting
with 10 amp steps (1 amp steps for 50 to 200 amp CTs). is 20% and 50% in steps of 5 percentage points.
The maximum value is 200% of the CT rating or 1200 amps,
whatever is lower. Press and hold the "UP" or "DOWN" push button as required
until the correct U/B Pick-Up setting is displayed.
until the correct GF Pick-Up setting is displayed. Press the "SAVE" push button to continue.
Press the "SAVE" push button to continue. **** NOTE ****

The U/B function should not be confused with the GF
function.
7.11 Ground Fault (GF) Delay Setting The U/B function is a motor protection function and
should ONLY be used on breakers feeding a large
If the GF function is not off, then the following will be 3-phase motor where currents are normally balanced.
displayed:
GF DELAY .XXS
Where ".XX" represents the GF Delay.
The GF Delay settings are .10, .20, .30, .40 and .50
seconds.
Page 9
7.14 Phase Unbalance (U/B) Delay 7.17 Quick-Trip® Ground Fault (QT GF)
If the U/B function is not off, then the following will be This setting applies only if the QUICK-TRIP Display and
displayed: selector switch are installed. See Section 6.0 for details.
UB DELAY XXS If the QT GF function is not desired, then press the "DOWN"
push button until the following is displayed:
Where "XX" represents the U/B Delay. The U/B Delay setting
ranges from 1 to 60 seconds in steps of 1 second. GF QT PICK-UP OFF
Press and hold the "UP" or "DOWN" push button as required If the QT GF function is desired, press the "UP" push button
until the correct U/B Delay setting is displayed. and the following will be displayed:

GF QT PICK-UP XXXXA
7.15 Address Where "XXXX" represents the QT GF Pick-Up setting in

amps.
+
This setting applies only to AC-PRO trip units with the The minimum QT GF Pick-Up setting is 20% of the CT rating
communication option and will not be displayed on non- with 10 amp steps (1 amp steps for 50 to 200 amp CTs).
communicating trip units. The maximum value is 200% of the CT rating or 1200 amps,
whatever is lower.
Each communicating trip unit that shares the same twisted
pair must have a unique address. Press and hold the "UP" or "DOWN" push button as required
until the correct QT GF Pick-Up setting is displayed.
ADDRESS XXX
The QT GF function has a non-adjustable short delay time
as shown in Figure 18.4.
Where "XXX" represents the trip unit address and ranges
from 1 to 127 in increments of 1. Press the "UP" or "DOWN"
push button as required until the desired address setting is
displayed.
7.18 Quick-Trip® Instantaneous (QT I)
This setting applies only if the QUICK-TRIP Display and
NOTE: Two trip units can have the same address as long as
selector switch are installed. See Section 6.0 for details.
they are not connected to the PC, Ethernet converter,
RS-232 converter or Local Communications Interface (LCI)
via the same twisted pair cable.
I QT PICK-UP XXXXXA
7.16 Reply Delay
Where "XXXXX" represents the QT I Pick-Up in amps.
+
This setting applies only to AC-PRO trip units with the The QT I Pick-Up setting ranges from 150% to 1200% of the
communication option and will not be displayed on non- LT Pick-Up setting in 100 amp steps (1000 amp steps for
communicating trip units. 5250 to 6000 amp CTs and 10 amp steps for 50 to 200 amp
CTs).
The reply delay set point is the minimum delay between the
trip unit’s receipt of a MODBUS packet and its reply. Press and hold the "UP" or "DOWN" push button as required
until the correct QT I Pick-Up setting is displayed.
The reply delay can be either 5 or 10 milliseconds. The
factory default is 5 milliseconds. The QT I function does not have an off setting. It is turned on
or off using the QUICK-TRIP ON-OFF selector switch. If the
REPLY DELAY XXMS Pro-Display with QUICK-TRIP is not installed, then this
function is always off.
Where "XXMS" represents either 5 or 10 milliseconds. Press
the "UP" or "DOWN" push button as required until the Press the "SAVE" push button to continue.
desired delay setting is displayed.
Page 10
7.19 Thermal Memory 7.20 Exit Procedure
The AC-PRO trip unit has a Thermal Memory feature for the The following will be displayed:
following protective functions:
Long Time (LT)
Short Time (ST)
SAVE IF DONE
Ground Fault (GF)
Thermal Memory can be turned on or off for the LT and ST REVIEW TO REVIEW
protective functions only.
If it is desired to review the setting, push the “REVIEW” push
Thermal Memory for the GF function is always on and button. Make any changes necessary using the “UP” or
cannot be turned off. The GF Thermal Memory feature “DOWN” push buttons. As before, use the “SAVE” push
provides protection against “sputtering” ground faults. button to move to each new setting.
Except for unusual conditions, it is recommended that If the settings are as desired, push the “SAVE” push button.
the Thermal Memory feature for LT and ST should be
turned on. The following will be displayed:
Cycling overloads that are not above the LT Pick-Up long REMOVE KEY TO
enough to cause a trip can still lead to thermal damage to
wiring and equipment. With Thermal Memory turned on a
cycling overload can still produce a LT trip to protect cables COMMISSION UNIT
and equipment even if any individual overload event did not
persist long enough to directly cause a LT trip. Remove the “key” (See section 4.2). The settings will be
saved in the non-volatile EEPROM memory.
With Thermal Memory turned off, an overload that drops
below the LT Pick-Up will reset the LT trip register. If the If the commissioning process was performed using the
current goes above the LT Pick-Up again, the LT trip register internal battery, the unit will turn itself off.
starts from zero.
If external power was used to power the trip unit during the
The above is also true for the ST function. commissioning process, the following will be displayed:
The following will be displayed: LOW CURRENT

THERMAL MEM XXX The commissioning process is complete.
Where "XXX" represents Thermal Memory ON or OFF for

the LT and ST functions.
If Thermal Memory for LT and ST is desired, press the "UP"

push button. If Thermal Memory for LT and ST is not
desired, press the "DOWN" push button. Thermal Memory
for LT and ST cannot be individually turned on or off.
Page 11
8.0 Changing Settings
**** IMPORTANT ****

While it is possible to make changes to the settings with
the breaker in service, it is strongly recommended that
the breaker must be removed from service while
making these changes since the breaker is energized
and the trip unit will not provide protection during a small
part of this process.
After the trip unit is commissioned, settings can easily be

changed in the following manner.
Connect the security key. See Section 4.2.
Power up the trip unit by pressing "REVIEW" or by applying

external power as described in Section 7.1.
Press the “REVIEW” push button. The following will be

displayed:
ENTER DATA
SERIAL # XXXXXXX
Press the "SAVE” push button.
Make any necessary changes using the "UP" or "DOWN"

push buttons. Use the "SAVE" push button to move to each
new setting.
**** IMPORTANT ****

The CT rating entered in the trip unit must match the
rating of the CT the trip unit is connected to.
A security feature protects against accidentally changing

the CT rating. See Section 7.3.
After going through all the settings, the following will be

displayed.
SAVE IF DONE
REVIEW TO REVIEW
If it is desired to review the setting, push the "REVIEW" push
button. Make any changes necessary using the "UP" or
"DOWN" push buttons. As before, use the "SAVE" push
button to move to each new setting.
If the settings are as desired, push the "SAVE” push button.

REMOVE KEY TO
COMMISSION UNIT
Remove the security key (See Section 4.2). The settings will
be saved in the non-volatile EEPROM memory.
The Settings have been changed.
Remember, if the trip unit loses power during this process,

the old settings will be retained and the process must be
repeated.
Page 12
9.0 Last Trip Data Recall

If the “REVIEW” button is pushed again and held down for
The AC-PRO has an especially useful last trip data recall
longer than 2 seconds, each type of trip is displayed along
and trip counter feature.
with the number of times that trip has occurred. If the
“REVIEW” button is pressed, but not held for 2 seconds, the
After a breaker trip, the trip unit will be able to display the
trip count is skipped and the settings are displayed.
type of trip (i.e. LT, ST, I, GF, U/B, FORCED, CLSFLT, GF
QT or I QT as applicable) along with the currents at the time
of trip. This information is saved in the non-volatile FLASH INST TRIPS: XXX
memory and is available immediately after a trip or anytime
thereafter. Push the “REVIEW” Button.
**** NOTE **** LT TRIPS: XXX

Only the complete data from the last trip is saved. The
second time the breaker trips, the new trip data is written Push the “REVIEW” Button.
over the first trip data. The trip counter is also updated at
this time. ST TRIPS: XXX
Push the “Review” push button to recall the Last Trip Data Push the “REVIEW” Button.
and settings. The following will be displayed if there was no
last trip:
GF TRIPS: XXX
NO LAST TRIP Push the “REVIEW” Button.
If there was a last trip, the following messages will
alternately display showing the cause of the trip and the U/B TRIPS: XXX
currents at the time of trip. The messages alternate at a one
second interval rate: Push the “REVIEW” Button.
LAST TRIP XXXX FORCED TRIPS: XXX
PHASE A XXXXXA **** NOTE ****

FORCED TRIPS counts apply to units with
Communications.
PHASE B XXXXXA
Push the “REVIEW” Button.
PHASE C XXXXXA
CLSFLT TRIPS: XXX
GF XXXXXA
**** NOTE ****
If Phase current is greater than 12 times the CT Rating, the See Section 7.9 for Close Fault Protection
following will be displayed: (CLSFLT) function description.
PHASE A > 12XCT Push the “REVIEW” Button.
If GF current is greater than 2 times the CT Rating, the GF QT TRIPS: XXX

following will be displayed for GF:
Push the “REVIEW” Button.
GF > 2X CT RATING
I QT TRIPS: XXX
Only those phase currents greater than 10% of the CT
Rating will be displayed. The text “XX” is the number of trips since last commissioned
or reset.
U/B YY%
By pressing the "REVIEW" push button the present settings
The U/B percentage will be displayed if on and the U/B is programmed in the trip unit can be stepped through in
greater than 4%. sequence.
The text “XXXX” is the type of tripping event (i.e. LT, ST, I, **** NOTE ****
GF, U/B, GF QT or I QT as applicable) and “XXXXX” is the Pushing the "SAVE", "UP" or "DOWN" push buttons
magnitude of the current at the time of trip for each phase. during last trip data recall has no effect because the key is
The text “YY” is the percentage of unbalance at trip. not installed.
Press the “REVIEW” push button again to view the following When pushing "REVIEW” after the last setting, the trip unit
message: will turn itself off.
HOLD <REVIEW> TO If the "REVIEW" push button is not pressed for about 30
seconds, the trip unit will also turn off.
VIEW TRIP COUNTS
Page 13
10.0 Normal Operations 11.0 Testing
Breaker Current Less than about 8% of CT Rating: A "primary injection" test is recommended as the final test of
the AC-PRO retrofit.
With all phase currents less than about 8%, the trip unit is
not receiving enough energy from the CTs to operate and It is not necessary to turn off the Unbalance (U/B) function
the display will be blank (except for the communication when doing a single-phase primary injection test.
version with a PT module).
If used, GF must be temporarily turned off when testing the
Breaker Current Less than 12.5% of CT Rating: other trip functions.
When the currents are greater than about 8% but less than
about 12.5% of the CT rating, the display will show the 11.1 Commission the Trip Unit
following:
Before proceeding with the normal primary injection tests,
LOW CURRENT the trip unit must be commissioned to make it functional. See
Section 7.0 for the commissioning procedure.
Breaker Current Greater than 12.5% of CT Rating:
It is best to use the final pick-up and time delay settings if
If the breaker current is greater than about 12.5% of the CT they are known. If not, use typical settings for the primary
rating but less than the LT pick-up value, the following will be injection test.
alternately displayed on the LCD at one second intervals:
Make sure GF is temporarily turned off. The U/B function can
be left on if desired.
PHASE A XXXXA
PHASE B XXXXA 11.2 LT Trip Test

PHASE C XXXXA be left on.
GF XXXXA To test the LT Pick-Up, increase the current until the “Pick-
Up” LED illuminates.
Where "XXXX" is the current in amps for that phase or
ground fault current. The injected current should correspond to the programmed
LT Pick-Up setting. Verify that the correct phase is indicated
Only those currents above 12.5% will be displayed. The GF on the LCD display.
current will only be displayed if the GF function is on.
To test the LT trip time, first calculate the trip time based on
Breaker Current Greater than the LT pick-up: the value of the test current that will be applied. Use the
formula in Section 15.1 or the chart in Section 12.3..
When the trip unit detects a phase overload situation, the
“PICK-UP” LED on the front of the trip unit will go on, and the **** NOTE ****
following will alternately be displayed on the LCD at one A simple shortcut is to note that the trip time (center
second intervals: of the curve) at 3 times the LT pick-up current is 4
times the LT Delay setting.
OVERLOAD For example:
If LT Pick-Up is 1600A and Delay is 10.0S, then the
PHASE A XXXXA trip time at 4800A (3 times 1600A) is 40 sec. (4 times
10 sec).
PHASE B XXXXA
PHASE C XXXXA
GF XXXXA
Where "XXXX" is the current in amps for that phase or
ground fault current.
Only those currents above 12.5% will be displayed. The GF

current will only be displayed if the GF function or QT GF
function is on.
Page 14
11.3 ST Trip Test

Figures 11.7-1 and 11.7-2 show a method to verify that the
breaker CT polarities match. The setup in Figure 11.7-1
be left on.
verifies that the CT polarities of Phase A and Phase B
2 match. The setup in Figure 11.7-2 verifies that the CT
To test the ST Pick-Up, temporarily set ST I T off and apply
polarities of Phase B and Phase C match.
a short pulse of current that is 10% or 20% less than the ST
Pick-Up setting. Continue applying short pulses of current
It is only necessary to inject a current slightly greater than
while increasing the current for each pulse until a ST trip
the GF Pick-Up setting and to verify that a GF trip does not
occurs. The first current where a ST trip occurred is the ST
occur.
Pick-Up.
To Test Set
2
To test the ST Delay, turn ST I T on again (if applicable) and
Apply current slightly greater
apply a current that is at least 10% greater than the ST Pick-
Up current.
than GF Pick-Up to the breaker line side.
The trip time should fall within the time band shown on the "A" "B" "C" If Phase A & B phasing match,
Time-Current curves. a GF trip will not occur.
**** NOTE ****

To bypass Close Fault (CLSFLT) when primary
injection testing at high currents, power the AC-PRO
prior to applying current using the URC part #T-390
power supply. See section 7.9 for CLSFLT Breaker
CTs
description.
11.4 I Trip Test Jumper load side of Phase A & B poles

Figure 11.7-1 Phase A & B, CT Phasing Test
be left on. To Test Set
Test the Instantaneous Pick-Up and trip time in the same Apply current slightly greater
manner as ST in Section 11.3. than GF Pick-Up to breaker line side.
11.5 GF Trip Test "A" "B" "C" If Phase B & C phasing match,
a GF trip will not occur.
With GF Pick-Up and Delay set to the required values,
testing any one of the three poles will provide a GF trip.
Test the GF Pick-Up and trip time in the same manner as ST

in Section 11.3.
CTs Breaker
11.6 QT GF Trip Test
To test QT GF the QUICK-TRIP Display must be connected Jumper load side of Phase B & C poles
to the AC-PRO trip unit and the QUICK-TRIP ON-OFF
selector switch must also be connected as shown in
Figure 6.0-1. Figure 11.7-2 Phase B & C, CT Phasing Test
With QT GF Pick-Up set to the required value and the If a GF trip does occur, determine which CT has the
QUICK-TRIP selector switch turned to the on position, testing reversed polarity. Reverse the secondary connections at the
any one of the three poles will provide a QT GF trip. CT to correct the reversed polarity.
Test the QT GF Pick-Up and trip time in the same manner as The breakers shown in Figures 11.7-1 & 11.7-2 have the
the normal GF function. CTs on the load side. Use exactly the same method if the
CTs are on the breaker line side or if they are staggered.
11.7 CT Phasing Test for GF If a neutral CT is used, its polarity must match the polarity of
the breaker mounted CTs. Testing for proper neutral CT
The breaker CT phasing is only important for the GF function polarity is more difficult because it is mounted remote from
and the QT GF function. If one of the breaker mounted CTs the breaker.
has reversed polarity, a nuisance GF or QT GF trip will most
likely occur. With the breaker in service on a 3-phase
system, the last trip data with a reversed polarity CT will
show the GF current as approximately two times the
phase currents.
Since primary injection testing normally tests only one phase

at a time, a breaker CT with reversed polarity will not be
detected with the normal tests. By using the following
method, a primary injection test set can be used to test for
proper CT polarity.
Page 15
11.8 QT I Trip Test 11.10 Erase Last Trip Data

To test QT I the QUICK-TRIP Display must be connected to After completing the primary or secondary injection tests, it is
the AC-PRO trip unit and the QUICK-TRIP ON-OFF selector important to erase the last trip data from the memory of the
switch must also be connected as shown in Figure 6.0-1. trip unit.
With QT I Pick-Up set to the required value and the QUICK-

TRIP selector switch turned to the on position, test all three
**** IMPORTANT ****
breaker poles in the same manner as the normal I function. Erase the last trip data from the memory of the trip unit
after completing the primary or secondary injection tests.
11.9 U/B Trip Test To erase the memory in the trip unit after completing the
primary or secondary injection tests, use the following
method:
The U/B trip function is not easy to test with a single phase,
high current test set. 1) The trip unit can be either off or powered-up.
Figure 11.9-1 illustrates a method to test the U/B trip 2) Push the "REVIEW" button to display the last trip data.
function. It requires using cable or bus to jumper the breaker
poles as shown. This generates an unbalanced current of 3) While the last trip data is flashing, push and hold both
50% or slightly more depending on how equally the current the "UP" and "DOWN" push buttons.
is split between the two poles.
4) Continue to hold the "UP" and "DOWN" buttons and
It is only necessary to inject a current equal to 20% or 30% push the "SAVE" button. Release all buttons. The
of the CT rating for this test. It is only possible to test the U/B following will be displayed:
trip time and not the U/B Pick-Up with this method.
NO LAST TRIP
**** IMPORTANT ****

Jumper 2 poles If the last trip data is not erased after the primary or
secondary injection test, the operating personnel may later
assume that the breaker interrupted a fault at some time in
the past when they recall the last trip data. The trip counter
"A" "B" "C" will also have misleading data.
Breaker
100% Current
50% Current
50% Current
Unbalance = 50%
CTs
Jumper 3 poles
Figure 11.9-1 U/B Test
Page 16
12.0 Secondary Injection Testing 12.2 Standard Relay Test Set
Although primary injection testing is the preferred method to Most standard relay test sets can also be used to secondary
test an AC-PRO installation, secondary injection testing can injection test the AC-PRO trip unit.
also be used.
The following are required:
®
• 24Vac Power supply to power up the AC-PRO trip unit
12.1 AC-PRO Secondary Injection Test so that it will accept current (URC Part # T-390)
• Relay test set with a 0 to 12 Amp range
• True RMS ammeter in the test set or externally
connected
• Method to stop the relay test set and test set timer when
the breaker trips
Test procedure:
1. Power up the AC-PRO trip unit with the 24Vac power
supply so it will except current
2. Temporarily turn off GF if on
3. Connect the output leads from the relay test set to the
Phase “A” CT terminals (it is not necessary to disconnect
the CT)
4. Proceed with pick-up and time testing of Phase “A”
5. When finished, similarly test Phase “B” & “C”
6. Turn GF on (if desired) and test by injecting current on
any one of the Phases
Figure 12.1-1 **** IMPORTANT ****

The CT circuits are internally grounded to the AC-PRO
AC-PRO® Secondary Injection Test Set case. If any of the CT wires are externally grounded, the
AC-PRO will not read current correctly.
The AC-PRO secondary injection test set
(see Figure 12.1-1) provides a quick and easy way to test Some relay test sets have a grounded current output.
the AC-PRO trip units. To secondary injection test the AC-PRO trip unit with this
type of test set, the AC-PRO trip unit must be isolated from
This test set can test 60Hz, 50Hz, 40Hz and 25Hz the test set ground.
AC-PRO trip units.
Follow the instructions provided with the test set.
Page 17
12.3 LT Delay Testing Chart
This chart provides trip times in Seconds for the LT Delay

The Time-Current Curves in Figure 18.2 along with the
settings at 3.0X, 4.0X and 6.0X where “X” is in multiples of
equations in Section 15 can be used to determine the trip
the LT Pick-Up setting.
times of the other trip functions.
The Maximum, Minimum and Nominal trip times are given
A test chart with additional LT Delay test points is available
for each LT Delay setting and the three listed test currents.
at www.utilityrelay.com.
LT Delay Trip Time Test Current LT Delay Trip Time Test Current LT Delay Trip Time Test Current
Setting Range 3.0X 4.0X 6.0X Setting Range 3.0X 4.0X 6.0X Setting Range 3.0X 4.0X 6.0X
Max 9.88 5.56 2.47 Max 56.79 31.94 14.20 Max 103.70 58.33 25.93
2.0 Nominal 8.00 4.50 2.00 11.5 Nominal 46.00 25.88 11.50 21.0 Nominal 84.00 47.25 21.00
Min 6.61 3.72 1.65 Min 38.02 21.38 9.50 Min 69.42 39.05 17.36
Max 12.35 6.94 3.09 Max 59.26 33.33 14.81 Max 106.17 59.72 26.54
Min 8.26 4.65 2.07 Min 39.67 22.31 9.92 Min 71.07 39.98 17.77
Max 14.81 8.33 3.70 Max 61.73 34.72 15.43 Max 108.64 61.11 27.16
Min 9.92 5.58 2.48 Min 41.32 23.24 10.33 Min 72.73 40.91 18.18
Max 17.28 9.72 4.32 Max 64.20 36.11 16.05 Max 111.11 62.50 27.78
Min 11.57 6.51 2.89 Min 42.98 24.17 10.74 Min 74.38 41.84 18.60
Max 19.75 11.11 4.94 Max 66.67 37.50 16.67 Max 113.58 63.89 28.40
Min 13.22 7.44 3.31 Min 44.63 25.10 11.16 Min 76.03 42.77 19.01
Max 22.22 12.50 5.56 Max 69.14 38.89 17.28 Max 116.05 65.28 29.01
Min 14.88 8.37 3.72 Min 46.28 26.03 11.57 Min 77.69 43.70 19.42
Max 24.69 13.89 6.17 Max 71.60 40.28 17.90 Max 118.52 66.67 29.63
Min 16.53 9.30 4.13 Min 47.93 26.96 11.98 Min 79.34 44.63 19.83
Max 27.16 15.28 6.79 Max 74.07 41.67 18.52 Max 120.99 68.06 30.25
Min 18.18 10.23 4.55 Min 49.59 27.89 12.40 Min 80.99 45.56 20.25
Max 29.63 16.67 7.41 Max 76.54 43.06 19.14 Max 123.46 69.44 30.86
Min 19.83 11.16 4.96 Min 51.24 28.82 12.81 Min 82.64 46.49 20.66
Max 32.10 18.06 8.02 Max 79.01 44.44 19.75 Max 125.93 70.83 31.48
Min 21.49 12.09 5.37 Min 52.89 29.75 13.22 Min 84.30 47.42 21.07
Max 34.57 19.44 8.64 Max 81.48 45.83 20.37 Max 128.40 72.22 32.10
Min 23.14 13.02 5.79 Min 54.55 30.68 13.64 Min 85.95 48.35 21.49
Max 37.04 20.83 9.26 Max 83.95 47.22 20.99 Max 130.86 73.61 32.72
Min 24.79 13.95 6.20 Min 56.20 31.61 14.05 Min 87.60 49.28 21.90
Max 39.51 22.22 9.88 Max 86.42 48.61 21.60 Max 133.33 75.00 33.33
Min 26.45 14.88 6.61 Min 57.85 32.54 14.46 Min 89.26 50.21 22.31
Max 41.98 23.61 10.49 Max 88.89 50.00 22.22 Max 135.80 76.39 33.95
Min 28.10 15.81 7.02 Min 59.50 33.47 14.88 Min 90.91 51.14 22.73
Max 44.44 25.00 11.11 Max 91.36 51.39 22.84 Max 138.27 77.78 34.57
Min 29.75 16.74 7.44 Min 61.16 34.40 15.29 Min 92.56 52.07 23.14
Max 46.91 26.39 11.73 Max 93.83 52.78 23.46 Max 140.74 79.17 35.19
Min 31.40 17.67 7.85 Min 62.81 35.33 15.70 Min 94.21 53.00 23.55
Max 49.38 27.78 12.35 Max 96.30 54.17 24.07 Max 143.21 80.56 35.80
Min 33.06 18.60 8.26 Min 64.46 36.26 16.12 Min 95.87 53.93 23.97
Max 51.85 29.17 12.96 Max 98.77 55.56 24.69 Max 145.68 81.94 36.42
Min 34.71 19.52 8.68 Min 66.12 37.19 16.53 Min 97.52 54.86 24.38
Max 54.32 30.56 13.58 Max 101.23 56.94 25.31 Max 148.15 83.33 37.04
Min 36.36 20.45 9.09 Min 67.77 38.12 16.94 Min 99.17 55.79 24.79
Page 18
13.0 Ratings 15.0 Time-Current Curves
Ambient Temperature: The Time-Current curves are shown in

Trip Unit: Figures 18.2, 18.3 and 18.4.
-4°F (-20°C) to 150°F (65°C)
LCD Display: For all the functions except U/B, the curves are shown on
Standard Temp, Super Twist log-log graph with seconds in the vertical direction and
32°F (0°C) to 122°F (50°C) current in the horizontal direction.
Humidity: Overload and fault currents are shown as multiples of the LT

95% non-condensing pick-up setting. Ground fault current is shown as a
percentage of the CT rating.
Conformal Coating:
Acrylic conformal coating, For I and QT I pick-up settings below 150% of the CT rating,
HumiSeal type 1A33 trip unit power-up time must be added to the Instantaneous
Time-Current curve (if the trip unit is not already powered
Enclosure: up). The allowance for 3-phase time is shown as a dotted
AC-PRO trip unit: line on the upper right hand Time-Current curve in Figure
Extruded aluminum housing 18.4.
Conductive Iridite coating
Nominal overall dimensions: For QT GF pick-up settings below 120% of the CT rating, trip
6.76 X 3.84 X 2.28 inches unit power-up time must be added to the QT GF Time-
172 X 100 X 58 millimeters Current curve (if the trip unit is not already powered up). The
allowance of 1-phase time is shown as a dotted line in the
Pro-Display: QT GF Time-Current curve in Figure 18.4.
Conductive Plastic
Nominal overall dimensions: Tolerances for the Pick-Up bands are ± 10% in the current
4.45 X 3.66 X 0.94 inches 2 2
direction. Tolerance for LT, ST I T and GF I T trip times are
112.9 X 92.8 X 23.8 millimeters + 23% and -17% in the time direction.
Battery: The curves for the following time bands:

See Section 17.0 LT
ST I²T
GF I²T
are based on the following equation:
14.0 Warranty
I²T = Constant
A conditional 2-year warranty is offered with each AC-PRO
trip unit and Pro-Display. Where: I is current in amps
T is time to trip in seconds (center of the band)
Contact Utility Relay Company for full details.
The curves for the U/B function are shown on a semi-log
graph with seconds in the vertical direction and unbalance in
percent in the horizontal direction.
Tolerance for U/B function is given in

Section 15.4.
When performing trip-timing tests using a primary injection

test set, the trip time at various test currents can be
determined by calculation as explained in Sections 15.1,
15.2 and 15.3.
Page 19
15.1 LT Trip Time 15.2 ST Trip Time
For overload currents, the "I²T = Constant" equation can be 2

With I T off or for currents greater than 10 X LT Pick-Up
restated as follows:
Setting, the ST trip time is a constant equal to the ST Time
Band setting.
T = TBCLT
X² 2
With I T on and for currents less than 10 X LT Pick-Up
Setting, the ST trip time is determined by the following
Where: T = time to trip in seconds (center of the band)
equation:
X = current in multiples of the LT pick-up setting
TBCLT = the LT Time Band Constant
T = TBCST
= 36 X LT time band setting
X²
**** NOTE **** Where: T = time to trip in seconds (center of the band)
The LT Time Band Constant (TBCLT) is by definition 36 X = current in multiples of the LT pick-up
times the LT Time Band Setting in seconds. TBCST = the ST Time Band Constant
EXAMPLE #1: **** NOTE ****

CT Rating 1600A The ST Time Band Constant (TBCST) =
LT pick-up 1200A 40 for the .40S Time Band
LT time band 20.0S 30 for the .30S Time Band
Overload Current 3600A 20 for the .20S Time Band
15 for the .15S Time Band
TBCLT = 36 X LT Time Band Setting 10 for the .10S Time Band
= 36 X 20.0 7 for the .07S Time Band
= 720
EXAMPLE #2:
and X = overload current = 3600A = 3
CT Rating 1600A
LT Pick-Up 1200A
LT pick-up 1200A
ST pick-up 6000A
therefore:
ST time band .20S I²T ON
trip time = T = TBCLT or 720 = 720
Overload Current 7200A
X² 3² 9
= 80 seconds
TBCST = 20
**** IN SUMMARY **** and X = overload current = 7200A = 6

To calculate the LT trip time: LT Pick-Up 1200A
1) Calculate the LT Time Band Constant (TBCLT)
2) Calculate "X" where therefore:
X = overload current trip time = T = TBCST or 20 = 20
LT Pick-Up Setting X² 6² 36
3) Solve the equation: = .556 seconds
trip time(sec) = TBCLT
2
X
**** IN SUMMARY ****
2
To calculate the ST I T trip time:
1) Determine the ST Time Band Constant (TBCST)
2) Calculate "X" where
X = overload current
LT Pick-Up
3) Solve the equation:
trip time(sec) = TBCST
2
X
Page 20
15.3 GF Trip Time 15.4 U/B Trip Time
2
With I T off or for ground fault currents greater than 2 times U/B is calculated as follows:
the CT rating, the GF trip time is a constant equal to the GF
Time Band setting. U/B = (INL - INS) X 100%
INL
2
With I T on and for currents less than 2 times the CT rating,
the GF trip time is determined by the following equation: Where:
INL = Largest Phase current
T = TBCGF INS = Smallest Phase current
XGF²
The U/B function is defeated if any two phase currents are
Where: T = time to trip in seconds (center of the band) less than 10% of the CT rating.
XGF = ground fault current
CT rating The tolerance for the U/B Pick-Up is ± 10 percentage points.
TBCGF = the GF Time Band Constant A U/B Pick-Up of 20% would have a tolerance of 10% to
30% unbalance. A U/B Pick-Up of 50% would have a
tolerance of 40% to 60% unbalance.
**** NOTE ****
The GF Time Band Constant (TBCGF) = The U/B trip time is a definite time as shown on the U/B TCC
2.0 for the .50S Time Band in Figure 18.3
1.6 for the .40S Time Band
1.2 for the .30S Time Band The tolerance for the U/B trip time is ± 10% of the setting.
16.0 Error Message Summary
EXAMPLE #3:
CT Rating 1600A The following is a summary of the possible error messages
LT pick-up 1200A and what action is necessary to correct the problem.
GF pick-up 640A
GF time band .20S I²T ON
Ground Fault Current 800A 16.1 Actuator Not Connected
TBCGF = 0.8 When the actuator is not connected or is open circuited, the
following message will be displayed:
and XGF = ground fault current = 800A
CT Rating 1600A
= 0.5 NO ACTUATOR
therefore: All push buttons are disabled. To return to normal operation,

trip time = T = TBCGF or 0.8 = 0.8 a functioning actuator must be connected.
XGF² (0.5)² .25
= 3.20 sec
16.2 Memory Error
**** IN SUMMARY **** The micro-controller continuously monitors its memory.
2
To calculate the GF I T trip time: When a discrepancy occurs, the following message will be
1) Determine the GF Time Band Constant (TBCGF) displayed:
2) Calculate "XGF" where
XGF = ground fault current
CT Rating MEMORY ERROR
3) Solve the equation:
trip time(sec) = TBCGF All push buttons are disabled. The micro-controller must be
2 replaced. Contact Utility Relay Company for more
XGF
information.
Page 21
17.0 Battery Replacement
Older AC-PRO trip units did not have a battery cover. To

For best performance, replace the battery with the following
replace the battery on these AC-PROs, the top of the trip
9-volt lithium battery:
unit must be removed.
Energizer LA522
To replace the battery on older AC-PRO trip units without a
battery cover but in a “silver” case (clear Iridite aluminum):
A replacement battery can be purchased from:
• The breaker must be out of service and de-energized
for safety
• Utility Relay Co. Part # T-303-3
• Disconnect the breaker harness from the trip unit
• Digi-Key Part # N538
• Unscrew the nine (9) 4-40 X 3/8 Torx screws attaching
www.digikey.com
the trip unit top
• Newark Part # 68R2922
• Lift off the trip unit top
www.newark.com
• Remove the old battery
• Allied Electronics Part # 70231992
www.alliedelec.com • Check the markings on the circuit board for the proper
batter polarity
• Grainger Part # 6FXX3
www.grainger.com • Slide in the new battery while maintaining proper
polarity
Lithium battery ratings: • Replace the cover using the previously removed Torx
• Rated shelf life of ten-years screws
• 750 mAh Capacity • Reconnect the breaker harness
(Allows the review of last trip data and settings over
1000 times on battery power only) By ordering the “Battery Cover Kit”, an older AC-PRO trip
unit in the “silver” case (clear Iridite aluminum) can be
upgraded with the battery cover.
Pull tab on battery cover
to the right to remove AC-PRO trip units in the “black” case (black anodized
aluminum) cannot be upgraded with the battery cover.
BATTERY
COVER
+
ACTUATOR
NEUTRAL
24 VAC QT
PHASE
KEY
PHASE
PHASE
AUXILIARY
DISPLAY Use only 9V
A
POWER Lithium Battery

BREAKER HARNESS
Figure 17.1 Battery Replacement

To replace the battery:
• The breaker must be out of service and de-energized
for safety
• Pop out the plastic battery cover by pulling the tab on
the battery cover to the right
• Pull out the old battery
• Check the markings on the circuit board for the proper
batter polarity
• Slide in the new battery maintain proper polarity
• Hook the right end of the battery cover under the AC-
PRO top and snap the cover into place
**** IMPORTANT ****

For best performance, replace the battery with an
Energizer LA522 9-volt lithium battery.
An alkaline type 9-volt battery may also be used with

much shorter life.
The breaker must be removed from service before

replacing the battery.
The replacement battery must be inserted with the

proper polarity.
Page 22
Neutral CT
Only for 4-Wire system
Phase CTs with GF "ON"
LINE LINE LINE LINE
Phase A Phase B Phase C Neutral
L W YW NW
GW
LOAD LOAD LOAD LOAD
Optional
Actuator
To QT Display
(Optional)
Manual reset,
Mechanical -Auto reset or
Electric-Auto reset actuator COLOR CODE
R = Red
B = Black
Red & black actuator W = White
wires in Vinyl Y = Yellow
sleeving R B L W YW N W G W L = Blue
N = Brown
G = Green
10-Pole harness plug
with hold-down screws
Top view
Figure 18.1
Typical Wiring Diagram
Page 23
INTENTIONALLY LEFT BLANK
Page 24
AC−PRO Trip Unit

1X 2X 4X 6X 10X 20X
1000 1000
LT Delay
Long Time (LT) Pick−Up 0.5 sec. steps
5A steps 2.0 to 30.0 sec.
20% to 100% of CT Rating @ 600% LT Pick−Up
(50A steps for CTs > 5000A)
(0.5A steps for CTs < 225A)
30s
100 100
600% LT Pick−Up
150% ST Pick−Up 2.0

s
10 10
Short Time (ST) Pick−Up
OFF & 100A steps
150% to 1200% of LT Pick−Up
SECONDS
SECONDS
1200% ST Pick−Up
(10A steps for CTs < 250A)
.40
s I 30s I 20s I 15s I 10s I 07s I
2
TO 2 TO 2 TO 2 TO 2 TO 2 TO
.
N
.
N
1 1
.
ST Delay with
N
& without I 2 T
.
N
.5 .5
.40sec
.
N
.30sec
N
.20sec
.15sec
ST I 2 T ON
.10sec
.1 .1
.07sec
ST I 2 T OFF
Instantaneous (I) Pick−Up

OFF & 100A steps
150% to 1200% of LT Pick−Up
150% 1200%
I Pick−Up I Pick−Up
.01 .01
1X 2X 4X 6X 10X 20X
Current in Multiples of Long Time Pick−Up
Overload Time Current Curve
Figure 18.2
Overload TCC
Page 25
Page 26
20% 40% 60% 80% 100% 20% 40% 60% 100% 200%
1000 1000
Unbalance (U/B) Pick−Up

OFF & 5% steps
from 20% to 50%
50% U/B 20% GF

Pick−Up Pick−Up
100 100
Ground Fault (GF) Pick−Up

OFF & 10A steps
20% U/B 20% to 200% of
Pick−Up CT Rating (1200A Max)
60 Sec
U/B Delay
10 10
.40
s
.30
SECONDS
SECONDS
s
.20
s
U/B Delay
1 Sec steps from
. 50
1 Sec to 60 Sec 200% GF
s
Pick−Up
1 Sec GF Delay
U/B Delay with &
without I 2 T
.10
1 1
sI
. 40
TO 2
s
N
. 30
GF I 2 T ON s
.50sec
.40sec
U/B = (I NL− I NS ) X 100%
.20
s
I NL .30sec
I NL= Largest phase current
I NS = Smallest phase current
.20sec
U/B is defeated if any
two phase currents are
less than 10% of the CT rating .10sec
.1 .1
GF I 2 T OFF
.01 .01
20% 40% 60% 80% 100% 20% 40% 60% 100% 200%
Current Unbalance in Percent Current in Percent of CT Rating
Unbalance Time Current Curve Ground Fault Time Current Curve
Figure 18.3
U/B & GF TCC
Page 27
Page 28
20% 40% 60% 100% 200% 20% 40% 60% 100% 200%
1000
Minimum possible
Instantaneous (I) Pick−Up
or
Quick−Trip Instantaneous
R
(QT I) Pick−Up
Allowance for 3−Phase
.1 power−up time
SECONDS
20% QT GF
Pick−Up
100
Quick−Trip Ground Fault Pick−Up
R
(QT GF Pick−Up)
OFF & 10A steps
20% to 200% of
CT Rating (1200A Max)
(1A steps for CTs < 225A) .01
20% 40% 60% 100% 200%
Current in Percent of CT Rating
Instantaneous Allowance for 3−Phase Power−Up Time
For Very Low QT−I Settings
10
1X 2X 4X 6X 10X 20X
5
SECONDS
200% QT GF
Pick−Up Quick−Trip Instantaneous
R
(QT I) Pick−Up
100A steps
150% to 1200% of
1 1 LT Pick−Up
.5 150%
QT I Pick−Up
Allowance for
1−Phase 1200%
SECONDS
power−up time QT I Pick−Up
.1 .1
.01 .01
20% 40% 60% 100% 200% 1X 2X 4X 6X 10X 20X
Current in Percent of CT Rating Current in Multiples of Long Time Pick−Up
Quick−Trip Ground Fault Time Current Curve Quick−Trip Instantaneous Time Current Curve
R R
Figure 18.4
QUICK-TRIP ® Ground Fault & Instantaneous TCC
Page 29
Page 30

AC Pro Trip Unit

Uploaded by

Copyright:

Available Formats

AC Pro Trip Unit

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

AC Pro Trip Unit

Uploaded by

Copyright:

Available Formats

ac-pro®

i-ac-pro-QT ac trip unit

URC Utility Relay Company

Manual Rev 1.4

3.3 PT Module Power 4.2 Security Key

POWER Lithium Battery

Auxiliary Power Jack Push Button "Key"

In those cases a short harness with a “Key” push button is

Table 4.1 Breaker Wiring Harness Pin-Out

A neutral CT wiring harness is provided as part of the neutral

5.0 AC-PRO® Front View

The front view of the horizontal version of the AC-PRO trip

Wiring Harness Battery

Pick-Up Part Number

Figure 5.0-1 AC-PRO® Horizontal Front View

Figure 5.0-2 AC-PRO® Vertical Left Front View

5.1 16 Character Display 5.6 DOWN Push Button

1) The actuator is not connected. The LCD will also

2) There is a checksum error in the micro-controller.

5.4 Display Contrast

The contrast level of the LCD can be adjusted by pressing

When the contrast push button is pressed and held, the

5.5 UP Push Button

Use this push button to increase the setting values during

When the maximum setting value is reached, the “UP” push

6.0 Quick-Trip® System

UTILITY RELAY COMPANY

AC-PRO trip unit

6.1 Quick-Trip® Basics

Drill 1 11/16" diameter hole

6.2 Quick-Trip® Installation

1. Use a 22mm switch knock-out punch to make a hole

(2) 10-32 hex nuts,

6.3 Quick-Trip® & Pro-Display Operation

***To Activate the CT Security Feature*** ST PICK-UP XXXXA

LT PICK-UP XXXXA ST DELAY .XXS

I PICK-UP XXXXXA 7.12 Ground Fault (GF) I2T

Press the "SAVE" push button to continue.

Press the "SAVE" push button to continue. **** NOTE ****

Press the "SAVE” push button to continue.

7.15 Address Where "XXXX" represents the QT GF Pick-Up setting in

Press the "SAVE” push button to continue.

7.19 Thermal Memory 7.20 Exit Procedure

The following will be displayed: LOW CURRENT

Where "XXX" represents Thermal Memory ON or OFF for

If Thermal Memory for LT and ST is desired, press the "UP"

Press the "SAVE” push button to continue.

8.0 Changing Settings

**** IMPORTANT ****

After the trip unit is commissioned, settings can easily be

Connect the security key. See Section 4.2.

Power up the trip unit by pressing "REVIEW" or by applying

Press the “REVIEW” push button. The following will be

Make any necessary changes using the "UP" or "DOWN"

**** IMPORTANT ****

A security feature protects against accidentally changing

After going through all the settings, the following will be

If the settings are as desired, push the "SAVE” push button.

The Settings have been changed.

Remember, if the trip unit loses power during this process,

To Activate the CT Security Feature ST PICK-UP XXXXA

Press the "SAVE" push button to continue. NOTE

IMPORTANT

IMPORTANT

NOTE LT TRIPS: XXX

PHASE A XXXXXA NOTE

NOTE

IMPORTANT

Figure 12.1-1 IMPORTANT

EXAMPLE #1: NOTE

IN SUMMARY and X = overload current = 7200A = 6

IMPORTANT