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1. L SEL operation temperature AA E AAA EM TSEL code 6 fitout SEL CE OC release Threshold KA estable upto 18kA 2 Pelarized adjust 08A 2 5 amp 29 IKSAI code 7 O Ags upto 24 kA a Pslerized adjust 4 kA 8k amp 5 Requested maris on these LIA A A ADA pp mojo PKA Jka d KAPKA Control circuits supply voltage ____extemmalaavoces i B8 i evoC O O O ea VI24 VibCstablizer A i25 383 OTIS 240V AC E NET code 8 BM s jonraques CT R Auxiliary contacts quantity convertible conos 2 JonRemes T T OR HIS code 9 9eonvertibPecontacts Pt 8 Joc tmp target TO MR OESTE Cr SY KSM code 10 Lo Lo O O Auxiliary tripping releases Who 0 shunt ip extern oO 4 AT Fruit trip extemal220 v6 5 sondado 2 Standard Zero Voltage Release 6 HIL code 11 C _____Shuntiip etemltovoc T 11 3 d Tl 44 ED impulse coil release Without O puse col with intera C bankINEKO 2 EDA code 12 mpusecoilw ointernalC bank dib J 3 Forced tripping release Mlthout J JO s 2 4 Z
2. 5peri D Codettame Opt Name Cad 1 Breaker type Gerapid 4207 I I Ll v AC g Se O p EAN AAA p fe ooo O p E E Acc A O RENE E AAA SS ee Se E p 21 ANS code 4 23 POL code O eu ftion temperature 125 ode 5 ot apply without SEL Cc wi a O Im E T o m ae ID E m a ee AUN PC SQCYOCUOC CVO ps BT 5 050 0 5 5 5 SJ LE C C BL 777 EA o ooo yA ME pne Cole ES RP NS um MD y integris 1 dc tuits supply EE pfe 34 T code 8 Ea SS z wWoneotadsqugay IIA SOO WO a liansiossrtips UU MEX LTS EI 37 rts codes IC IN E ENS A ri SS 30 Ju code 10 E 9 M EY A Auxiliary tripping device 1 C GS EE C E A Ys EEE E gera Voltage Release ETT NEN EN EU EN EN With 1 EN EW SS 43 HIL code 11 p Without gt gt Tal code 12 Forced trinpina release Wal code 13 1 46 Contacts position indicgtg 458 STA code 14 50 Protection options 5 ESCH cade 15 32 Lever for manual operating 53 HAN code 16 UU Arc chute presence siqn 557 35 Count 57 zAL code 13 5B Control connectors PE 59 60 L SST code 19 61 Relevant standards 62 63 Im IT 46 Without
3. 1 a Without Wierik J o EN Us BE ET zs Railway amp Industry applications Railway DC acc EN50123 2 Im CUS code 20 m i amp 5 Luna LEN Pe POn Request 22 Design and specifications are subject to change without notice Ve Le E B T mpo ESA oy E D a A po zm ES EJE u m 53 7 2 2 Example of order no 2 USA customer wants to buy Gerapid for DC drive application The customer used to buy Gerapid 8007 according to company special ID code GE80071x2R3 The breaker shall comply with standard IEEE C37 14 Breaking capacity of 200 kA is required and configuration as follows 1 EMT 15 16 lf 18 19 20 Correct catalogue code shall be Load current of 6000 A Nominal voltage of 800 V Available auxiliary voltage of 125 V DC With special design of main terminals as per customer drawing number GE8007terR3 Customer tested breaker in this configuration and test report and drawings were sent to GE for confirmation Breaker polarization not important Without SEL measurement system With OC release w o adjustment possibility Threshold set at 24 kA Auxiliary supply voltage of 125 V DC for controls With maximum possible number of auxiliary contacts With OC trip target Shunt trip with double winding directly supply from external 125 V DC With electrodynamic coil and
4. Hame 3 m Breaker type Gerapid 4207 E AU code 1 2 13300011 O Closing solenoid supply voltage D n Request 220 Vac ar SELGKA O STE code 3 E ___ OF Main terminals layout TI ANS code 4 Main terminals polarization Topcomecor OY POL code 5 1 E FA o A O TEL code 6 y 00x00 WELL Qver current Set ky ME quc k release OCT YE _ TIT 0 1 MA NN Zo YII_S 9 VT 8 la ee ee ea Prka 1 Without OCT ERES lads 7777774 VER 77 extemal Dem 7 Pt ZZZ el o ELA Pas e E K AT cade 7 Requested marks an A a 10 convertible contacts A VETA O E A lana ontacts dioe dd 36 chang ver type 57 His eode 9 HH OE ANA A O 5H SM code 10 ATA aS E pping deyi L 4 r 5 ka AO eee ee x A code 11 C 2 3 Winpulse cgifrelea o a 9 J 40 YF ED Al cof 12 af 5 tmpubecolw oinemalt bank 1 5 5 5 o 5 5 5 8 Car pots arlene zin 9 EN de 13 af o _ 00 854 A o9 A AAA Ap gt gt gt 2 Frotection ontions o o Pap O E 751 ECH code 15 L1 sidewalls protection panels a d U 52 Lever for manual operating h v i
5. LZ Customer s reference no gt GEBD0z1s2w3 Special ratings tested by customer Gee ee E codename Jone 7 Name 5 me e ae fT LE EE 2 foo E P Led A Ea O S So a a7 EN A TE E y 9 BAU code 1 A NY A E O ee las EE x NE 7 V E O EA 2 ER A G Lic code 2 PIA OOOO 10 A 2 O 7 11 YAA E A A YA 83 A EA EI E O A el ce AAA A E O EA A A Dd OO Tr AAA A E A A A E A A A O E A ee ation 1 es ie 23 ode5 E a A A me PAT 25 ITAL cod Ew AA gt without Seb A 36 pler curn Set fal AA E Ls El fined setting up to A Psp bays ed marks onthe scale 24 00 ka cee A Abend A be 31 ur 2004 intervals AMA uk uae o AN Akn Aka 32 fontolcivcutssuppy AAA A y fe so a 3 37 voltage fC dl SEA EE f INET code 8 Du A BA aa OE 35 Auxiliary contacts quantity Y AE convertible contacts 36 changeover type Y 214 HO 37 trtstcodes EN mera ita aa rr gt A 39 iksm code 10 Li ASA A E AAA A 40 Auxiliary tripping device DH 9 Shuntpie eternal 125 ae double coil 4 y o E lt lt MERA 42 C ee 8 43 HILI code 11 ME O EN Cad Impulse gef release a mpukecoTwihrintera C banF ERG E pes EN EN IN a 46 Eptted trippinu release io A iw al code 13 Da A E eee e erre P a tal C 1 1 1 o oOo 49 ETA code 14 A E O A Lt Protection options Wiheut o E f EA JH
6. 33 IHAN code 16 E O E O A 54 Are chute presence signal Without 55 LEM code 17 Md 56 Counter RRA Y of ZAL code 18 EN JJ Po 38 Control connectorstype a semagpdsEreroft 3 EH pe code 19 AAA A ee ae EN Term standards A E L4J m pot Cus code 20 PR Pi Request EEE PR 64 Doranestaton tensas YPF 55 io EL eee TA Fst Polish 55 7 3 Glossary a release see Shunt trip device Activating magnet see Closing drive Anti pumping device see SU control PCB Prevents reclosing after a close open operation as long as the device initiating closing is maintained in the position for closing Arc runners also arc probes arc horns Provide safe arc leading into the arc chute There are two arc runners mounted in Gerapid breaker front and back Arcing contact also pre contact arcing pre contact An arcing contact on which the arc is intended to be established to avoid wearing and burning of the main contacts It is mounted at the top of flexible band It is easy to replace Spring loaded to maintain proper contact force Auxiliary contact also make break contact a b contact changeover contact convertible contact A contact included in an auxiliary circuit and mechanically operated by the breaker Aux
7. Gerapid breaker has a very high interruption capacity combined with a current limiting characteristic The arc chute works on the basis of an asbestos free arc splitting principle A wide variety of accessories and spares are available for maintenance repair or as a possible enhancement Use the catalogue coding system described in section 7 1 to configure the breaker Each rating option or accessory has own code Closing of the circuit breaker is performed through a high power solenoid drive Code 3 During inspections opening and closing may be carried out by means of a hand lever Code 16 which is mounted onto the armature of the closing drive Overload tripping and release is obtained directly by means of the OCT release Code 7 or optionally by ED impulse release Code 12 Indirect remote tripping can be achieved by means of a shunt trip or optionally by a zero voltage release Code 11 Gerapid breakers have a compact and enclosed construction Fig 4 Gerapid is IP 00 protected All parts are mounted on thick walled non breakable and fireproof insulation panels Pre arcing contact Arc chute Main contacts Flexband Upper copper terminal Auniliary contacts Control connections 3e rt 73 Wea A A ES EE li Mechanism ED coil tripping device Lower copper terminal Closing solenoid drive OCT device Adjusting device Shunt trip Zero voltage releaser
8. 1 These relays are part of internal closing stop circuit It is a 24 V DC closed circuit through all PCBs in the box except SEL Serial connection of all relays is realized through connections 5 6 in each PCB This circuit provides priority of a tripping signal over a closing signal Additionally it prevents from closing the internal supply 24 V DC lost at UVR PCB or NEKO PCB Design and specifications are subject to change without notice 17 4 3 2 Controls supply circuit Breaker Mia E ME occu up External X3 X10 i power supply 4 1 DC 24 V 2 pee E 0001 01 A aaa l c AC 115 240V 10 i DC35 350V 10 7 e _ gt L x ll 6 eC a ED AE GND N b 2 del y 3 ee eu cte E Breaker po cc S UN nece ECCE EE External X3 X11 power supply l TE y DC 24 V 42 y y DC 24 V 5 m Key position 2 Key number 1 Voltage converter DC 35 85 V DC 88 145 V DC 125 353 V AC 115 240 V Key number 2 Interface for direct external voltage DC 24 V 596 connection Fig 23 Supply with voltage converter or with direct external 24 V DC 5 18 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 4 3 3 ED coil with external capacity bank e n this option customer p
9. Fig 4 Modular construction overview Design and specifications are subject to change without notice 3 2 Components and accessories 3 2 1 Contact system All Gerapid breakers are equipped with a two stage contact system Fig 5 consisting of a main contact and an arcing contact With this proven design the main contact is not subjected to any appreciable wear or tear The main contact is made of a silver composite material The arcing contact and link braid are made of copper and can be easily replaced The flexible bend is linked to the arcing contact by means of very tight braid arcing contact A arc runner main contacts flexible band L d Pw Contact system after 11 2003 arcing contact Quem flex braid gt are runner main contacts Contact system before 11 2003 Fig 5 Two types of the contact system 3 2 2 Arc chute Code 2 Compact and modular design of the arc system requires no additional magnetic support and allows small safety distances with high breaking capacity Because of the compact dimensions these breakers can be installed in extremely small enclosures from 500 mm 1 65 ft and offers a cost effective solution for replacements An adaptor Fig 43 is used to mount the various arc chutes for different operating voltages on the breakers The arc chutes consist of a highly durable arc proof material in which the arc plates have been integrated The arc plat
10. 2 5 convertible contacts 4 10 convertible contacts Design and specifications are subject to change without notice 51 7 2 Ordering Gerapid CIEN 1 1 eNG amp DRS7 revo 09 2008 quantity a rm Te caog TI I I I L L L IL I ILIL I I L ILI LITI Dagom On Requests J Customer s reference no Ll gt LJ gt Special ratings tested by customer a NS Code Name Opt Name Code Name Code E 1 Breaker type Gerapid 2607 Gerapid 8007R Gerapid 4207 Gerapid 10007R NE Gerapid 6007 erapid 8007DS Gerapid 8007 BAU code 1 Arc chute type 1X2 1000 V 1X3 1500 V 1X4 2000 V 2X2 S 1500 V 48V DC 60 V DC 110 V DC 125 V DC 220 V DC 250 V DC x2 2000 V x3 3000 V x4 3600 V F4 12 3600 V 10V AC 20V AC 25 VAC 30 V AC 40 V AC n Request LIC code 2 Closing solenoid supply voltage STE code 3 no rol 5 Cee Coed Cad ed dd e H H iHlorizontal H V Vjertical 2 For SEL 12 kA iH On Request VN UMS i ANS code 4 A eyes T E L 22 Main terminals polarization L Jopcomectre o o o 1 Nctappy O O0 POLI code 5 Top connector SSCS P
11. Z ex PP o 6 amp oD es ind O D O O n WN 09 op 4 HS 6 HS 7 HS 8 HS 9 HS 10 t c gt gt ves o G O e 2 J 975 O 0 0 y y O gt 0 35 Wo S Sg Ey 20 E SEL self check 9 9 Ps 8 5 p p go F HE ME um E 5 E 58 68 2 5 0 O O a Og 3 a Y 9 9 O 9 0 Tiko Ey a 1121 131415 74 10111 112 13 14 15 E Cue Zt 2t HE 0 0 x X X6 uw i Fig 21 Typical terminals wiring system external customer connections SEL 4 20 mA SEL 4 20 mA SEL 20 mA SEL 20 mA SEL 10V SEL 10 V 16 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 4 3 Electrical diagrams 4 3 1 Wiring code e The main circuits are not shown in the wiring diagrams for transparency The control circuit is presented as a typical circuit diagram and is a combination of numbered basic diagrams for drives trips and indicators e Using the key numbers of the basic plan you can derive the number of the complete diagram e WARNING Some non standard electrical circuits do not comply with the diagrams in this instruction Such circuits are coded with unique numbers i e 36 0033 In such a case an appendix to this instruction is delivered which contains relevant electrical diagrams Coding positions 1 2 3 4 5 6 7 8 Key position Breaker type Aux voltage supply ED impulse release Closi
12. contact y 1 nsu I 2 bo A MEN Key position 5 Closing STOP relay L Key number 00 Without shunt trip or zero voltage release Key number 10 With shunt trip e The closing STOP signal is provided for resetting K2 on the SU control circuit It effects with priority in switching OFF by ST or UVR before switching ON Once switching ON and OFF signals are simultaneous switching OFF command will stay longer than switching ON It means that OFF command is master command e The shunt trip operates for short time period only After main contacts open switch HS 11 cuts off shunt trip coil e Manual closing of the breaker while S2 contact is closed leads to overheating of ST coil and will damage coil Fig 27a ST control circuit 22 Design and specifications are subject to change without notice S47183R01E06 2012 11 21 e Below non standard shunt trip with single winding directly supplied from external DC voltage X2 6 Breaker s Za aux B e Below non standard shunt trip with double winding directly supplied from external DC voltage 1st winding 2nd winding X2 6 A2 8 dies A E L eese s de 8 3 5 6 c 8 3 5 Breaker s Qux 4 Qux L 1 3 CH Breaker s e Double winding shunt trip coil is available for external DC 110 V DC 125 V and DC 220 V e Use
13. 1 Controls layout X17 X13 X14 XI5 X12 X10 x11 ese X2 X3 X4 X5 X ee 277 rap ra Lo n O b 1234567891011 12 X3 X6 RE HE YI 1234567891011 12 13 14 15 N X10 X15 12345678910 12345678910 11 12 X17 123456789 1011 12 13 141516 17 18 Closing solenoid drive Shunt trip Zero voltage release ED coil OCT device HS 1 HS 10 OCT trip target Arc chute indicator Description Designation X2 1 Connector Auxiliary and control circuits X3 2 Connector Auxiliary and control circuits x4 3 Connector Auxiliary contacts HS1 HS5 x5 4 Connector Auxiliary contacts HS6 HS10 A6 5 Connector Current measure system SEL X10 Control board Voltage converter X11 Control board Interface for external DC 24V supply OPTION X12 Control board SU control unit X13 Control board Shunt trip control unit X14 Control board Zero voltage release X16 Control board NEKO control unit for ED coil control X17 Control board Current measure system SEL Fig 20 Control system s layout 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 15 1121 9 4 5 7 1011112113 114 15 4 2 Terminals wiring system x o e S ceo Z 2 9 E A L p co be E do oem E E S 3 O O c O oc D Q Q E gt 7p 09 Oo N co LO 22 8 3 z D 0 nf a 2 F 2 T gt gt E CE Qo
14. HS11 X14 1 2 3 Check the wiring connections and supply line of ST PCB X14 7 8 4 Check the continuity of shunt trip coil X14 9 10 5 Replace the ST PCB or ST coil if necessary Contact GE Service in case of problem is not solved B Zero voltage release does not operate Breaker is able to CLOSE and OPEN by means of hand lever 1 Check points A2 to A5 2 Check point B3 to B5 3 Check the continuity of UVR s coil X13 9 10 4 Replace the UVR PCB or UVR coil if necessary Contact GE Service in case the problem is not solved C ED impulse releasedoes not operate Breaker is able to CLOSE and OPEN by means of hand lever 1 Check points A2 to AS 2 Check the wiring connections and supply line for NEKO PCB X16 1 2 3 Check the voltage level and timing of firing signal for releasing the C bank energy X16 3 4 Voltage signal shall be between 6 24 V DC and duration of minimum 3 ms 4 Check if the NEKO is signaling C bank charging correctly X16 9 10 Relay is closed when NEKO is ready to operate 5 Check the continuity of ED coil X16 11 12 6 Replace the NEKO PCB if necessary Contact GE Service in case the problem is not solved Design and specifications are subject to change without notice 57 7 5 GE service teams Germany Netherlands MA s N uU o a GE Consumer Industrial Berliner Platz 2 6 24534 Neumu nster T 49 1804 43 34 8 F 4 494321 2
15. O 5 O O O eee TET Short circuit current according to IEEE C37 14 kA 120 1 120 60 1 120 1 EPPEEELULL cen Ll I d E b A d LE tested at customer request 1 Rating tests at customer request Table 1 Technical data of Gerapid 2607 4207 6007 8007 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 13 4x15 pole AC 250V 8A Closing solenoid drive Rated voltage AC 48V 230V and DC48V 220V Operating range 80 115 of rated voltage Power consumption Gerapid 2607 4207 1750 W 2000 W Power consumption Gerapid 6007 8007 2600 W 2600 W Minimal CLOSING command duration 100 ms min interval between two CLOSE operations 8 s w o NEKO installed 14 s with NEKO Internal voltage converter Input Voltage range DC 33 85 V for Gerapid 2607 4207 6007 8007 Output Voltage range DC 24 V 5 Current 6 A permanent Model description PCMD 150 48 S24W GE PIIIIIII SIISII ISISI III ggg gg Voltage range DC 88 145 V Voltage range DC 24 V 5 Current 6 A permanent PCMD 150 110 S24W GE Voltage range AC115 240V DC125 353V Voltage range DC 24 V 596 Current 3 A permanent 5 A 100 ms Model description PCMA 70 S24W GE Aux contact HS 1 HS 10 Rated operational voltage Ue AC 230V OC trip target code 10 Rated operational current le AC 15 1A Arc chutes indicator code 17 Conventional thermal current le AC 12 Ith 10A Rated operational voltage
16. This section is valid for breakers manufactured before 11 2003 This section refers to maintenance works A B C from Table A A Remove the arc chute and adapter See 6 2 1 A B C Changing the protective walls and arc runners Fig 48 Pull out two protective walls 3 Fig 50 Loosen screws 6a with Torx 30 and take out front wall 6 Fig 50 Loosen screw 5a with tool SW5 Fig 50 Take out the front arc runner as it s shown Fig 50 Take out the back arc runner 4 by loosening two screws 4a with tool SW5 Don t remove the protective cap 4b Fig 50 Install new front arc runner 5 and new back arc runner 4 Tighten it using torque of 10 Nm 88 in Ibs Fig 50 Install front wall 6 and adjust it by positioning the protective wall 3 Fig 48 Tighten it using torque of 10 Nm 88 in lbs Fig 48 Put in two new protective walls 3 Fig 51 Taking out the front arc runner of old design Fig 50 Changing arcing contact 44 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 D Changing the arcing contact e Fig 52 4 Replace arcing contact with new one Use old e Remove front and back arc runner See 6 2 2 C contact to lift up two washers and slip the new contact e Close the breaker and secure the solenoid drive against under these Remove old contact and rotate the new one unintended opening See 1 2 2 by 180 to its normal orientatio
17. and take out screw 7 including locking plate 8 Don t split up screw and locking plate e Fig 50 Pull out axis pin 9 Pull out arcing contact 10 and put in new arcing contact e Fig 50 Put in axis pin 9 and protect it by the locking plate 8 Tighten screw 7 with torque of 10 Nm 88 in Ibs e Fig 50 Install front arc runner 5 and back arc runner 4 Tighten it using torque of 10 Nm 88 in lbs e Fig 50 Install front wall 6 and adjust it by positioning the protective wall Tighten with torque of 10 Nm 88 in Ibs e Fig 48 Put in two protective walls 3 D Install the adapter e Fig 48 Install two protective walls 3 Use new ones if necessary Install two parings of adapter 2 and tighten screws 1 use 5 Nm 44 in lbs E Install the arc chute e Fig 49 Put in arc chute 1 into adapter 2 e Fig 49 Tighten front and backside connections of the arc runners 3 including lock washer use 10 Nm 88 in lbs e Fig 49 Tighten front and backside of the arc chute connections 4 including flat washers use 5 Nm 44 in Ibs Fig 48 Adapter and protective walls Fig 49 Arc chute and arc runners fixing 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 43 3 10 e 6 2 2 Contact system before 11 2003 Pay attention to the warnings Section 1
18. code 15 E ee ee Sefleverfortranualopercting COHAN code 16 Li ooh Oe ee A Pad fare chute presence sianal fp LEM code 17 AA 56 Counter Witeut o A A A 57 Iza code 13 A O E O A 55 control connectorstype Railway amp Industry applications Jif 0 5 5 0 0 8 085 3 58 A ee is 60 ssT code 19 A O L O A OO EE cessi CR EM A A E POSS 63 icus code 20 LO O E O o VAS Rn 6h Documentation Lanauags EMI AA GAAL 65 LL Fp ie TE E A S47183RO1E06 2012 11 21 7 2 3 Example of order no 3 Customer wants to use Gerapid as a field discharge breaker to commutate current from excitation system of synchronous machine to the discharge resistor circuit Customer has previously tested one Gerapid breaker in a special test sequence using special ratings and internal standard XXX 123 Customer requests to put on the nameplate rated parameters that have been tested After agreement with GE both parties decided to create special version of the breaker and assign to it a letter a as extension of standard name These breakers will be a retrofit units replacing old Gearapid SE type Load current of 3200 A Operating voltage of 2750 V High power low stability source 220 V AC available for closing solenoid Terminals suitable to install SEL current measurement system Plus pole connected to the TOP terminal With SEL measurement system Without O
19. for the auxiliary tripping devices are listed in Table 2a WARNING Plugging in or unplugging of the auxiliary connectors X2 1 2 X3 4 5 is only allowed with disconnected primary mains and secondary voltages 2 3 2 Adjusting the over current release OCT is an over current tripping release Code 7 which trips and releases the breaker in case of overload or short circuit currents This is an instantaneous and direct acting device If equipped with an adjustable OCT the response threshold can be easily adjusted Fig 3 by turning the adjustment nut 1 with a SW6 hexagon wrench 2 The adjustment must only be carried out after the breaker has been disconnected from the main circuit For fixed installations breaker s main terminals shall be grounded Turning the adjustment screw clockwise increases the trip threshold turning the screw counter clockwise decreases the tripping threshold Align the arrow and the desired marking 3 to perform adjustment SW 6 Fig 3 Setting of the OCT unit Design and specifications are subject to change without notice 5 3 Technical information 3 1 Introduction Gerapid is a high speed DC circuit breaker This is a single pole DC breaker primarily designed for use in railway power distribution systems with operating currents up to 8000 A Code 1 and operating voltages up to 3600 V Code 2 Additional applications are special industrial plants such as electrolysis mining or steel mills
20. internal C bank NEKO control PCBJ Without forced tripping release With contacts position indicator Without additional protection covers With hand lever With arc chute indicator Counter not available With standard terminals for controls connection According to IEEE C37 14 standard 414R0034414201011012 General remarks 54 Special wiring indicates that dedicated electrical diagram will be created for this order The diagram will be attached to the User Manual as an appendix Diagrams from the User Manual are not applicable here Customer may call any special identification code that has been used in the past This will be additional reference number and will be placed on the breaker s nameplate beside of the actual 20 digit catalogue code Modifications of main terminals according to customer s drawings are possible after agreement with GE and after positive tests results Choosing a double winded shunt trip will limit your available auxiliary contacts number to maximum 8 units Design and specifications are subject to change without notice f imax 60 breakers per order Breaker number Catalogue no Ja 1 R B OQ jJ 3 J 4 1 2 o0 1 u0 1 1 jO 1 je Diagram no A Speciolwirino gt Unlock On Request options Quantity 1
21. pages 26 27 7 09 3 66 d 6007 823 LO T e E e 180 220 P 224 only Gera i 31 3221 8418 Ie998V EEF 316 71244 455 117 911 485 719 097 0B2 22 91 o LO m ex ce e m 12091 GBE Fig 32 Gerapid 2607 6007 arc chute 1X dimensions in mm and inches 30 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 5 2 2 Gerapid 2607 4207 6007with arc chute 2x_ Pay attention to legend warnings and safety distances pages 26 27 240 1945 ieee FoR egos OLS PaO Sb Gab Fig 33 Gerapid 2607 6007 arc chute 2x dimensions in mm and inches 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 5 9 7 156 T8 7 186 220 15 10591 455 1731 1053 15 amp B6 d 6007 a E e c E m C E 485 19 09 EZ 12291 FOO 12756 153 16021 31 5 2 3 Gerapid 8007 with arc chute 1x_ Pay attention to legend warnings and safety distances pages 26 27 Re pe Lu E gt tJ T EST 220 1466 258 11016 sig POSE else TAP 3168 f1244 389 1831 455 MEN 485 18908 e ue PJ Wi ala Perse Geb Fig 34 Gerapid 8007 with arc chute 1x dimensions in mm and inches 32 Design and specifications are subject to change without notice S47183RO1E06 2012
22. 0 39 4 300 11 8 300 118 180 7 1 p m o v J v n J 2 J n n J n n dnf T j pK V VHeatsnk X 150659 1000694 300018 300 11 8 18070 Eoo oL LLL LLL A po ex V VHeatsink 80 3 15 1000694 180 7 1 1800 1807 0 A poa V VHeatsink X 80615 1000694 180 7 1 1807 0 8070 MENU GU SEM ee ee ESA AAA ee ee 8007 1x2 V VHeatsnk X 10 0 4 _ 1000 94 300 11 8 300 118 1800 J MET PAE AN p D pop orn ES O ck Spo 0 o pm wr mum rc up E AE ASE lA EE A E ho p A ex v VHeasik 803 15 1000394 1800712 1802 1807 0 2x3 V VHeatsink 980 5159 1000 9 4 18017 1 1807 1 300018 EEES qeu auque EE will be checked by customers order acc IEC 947 2 ks setting 12 kA H Horizontal terminal V Vertical terminal SEL Current measurement system type SEL Legend for dimensional drawings K Heatsink for Gerapid 6007 All openings respectively free areas on the top of the cubical shall be not less than 5096 Solenoid drive Diameter 9 mm 0 35 in Countersunk screw M8 Control box 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 29 5 2 Outlined dimensions 5 2 1 Gerapid 2607 4207 6007 with arc chute 1x_ Pay attention to legend warnings and safety distances
23. 000 V 2 1X3 1500 V 3 1X4 2000 V 2X2 2000 V 2X3 3000 V 2X4 3600 V 2X2 S 1500 V EF4 12 3600 V Heavy Industry type Military type acc MIL C 5015G Mechanical Counter Without 125 V AC 230 V AC 240 V AC On Request Without Special type B Without Special type S On Request 6 For SEL 12 kA Protection options Sidewalls protection panels Without 0 Top connector Top connector Not apply Rodent proofing SEL operation temperature Code 14 Contacts position indicator O without SEL Without O Forced tripping release Without O Over current release OCT 1 Fixed setting up to 15 kA 2 Adjustable up to 15 kA 3 Fixed setting up to 24 kA 4 Adjustable up to 24 kA Polarized adj 0 4 1 2 kA 0 Without Polarized adjust 0 8 2 5 kA OCT Polarized adjust 2 6 kA Impulse coil with internal C bank NEKO Without Polarized adjust 4 8 kA Impulse coil w o internal C bank ON DD UO Control circuits supply voltage Auxiliary tripping device 1 external 24 V DC 5 4 88 145V DC Shunt Trip external 125 V DC Without 2 24V 24V DC stabilizer 5 125 353V DC 115 240V AC Shunt Trip external 220 V DC 3 33 85V DC R On request Standard Zero Voltage Release Standard Shunt Trip 0 Shunt Trip external 110 V DC Code 9 Code 10 R On Request With 1 Without 0 Auxiliary contacts quantity changeover type 1 3 convertible contacts 3 9 convertible contacts
24. 01 490 E service g ge com GE PowerControls NL Parallelweg 10 7482 CA Haaksbergen 3153 5 73 03 03 pP 451555r 20515 E service nli amp ge com GE Power Controls Spain Marques de Comillas Uoszz5 Terrassa 4493 4635 42 F 5494 89 0945 E service e ge com GE Power Controls UK Foundry Lane Widnes T 44 1162905271 F 444 151 420 96 54 E service uk ge cam GE Power Controls Leszczynska 6 43300 Bielsko Biala 45 44625 6544 F 46 55611 6702 E service pl ge cam 2012 11 21 S47183RO1E06 France Italy Belgium GE Consumer amp Industrial 900 Yishan building C 200233 Shanghai T 86 21 2401 30 55 F 66 215423 54359 GE Consumer amp Industrial 510 East Agency RoadWest Burlington lowa 52601 1 888 4537 5765 F 1 519 753 3479 GE Power Controls France 1572 route de Guise 02100 Harly Saint Quentin T 43332350 70 66 67 F 3332350 7065 E service f ge com GE Power Controls Italy via Monte Avaro 7 24060 Chiuduno Bergamo T 3935935353521 P 359 2503535301 E service ittogae com GE Power Controls Belgium Nieuwe Vaart51 9000 Gent 535292652111 F 529 265 26 le E service b ge cam Design and specifications are subject to change without notice 58 7 6 Notes 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 59 GE Consumer amp Industrial GmbH Berliner Platz 2 6 D 24534 Neum nster Germany Phone 4 449 4321 201 0 Fax 4
25. 11 21 5 2 4 Gerapid 8007 with arc chute 2x_ Pay attention to legend warnings and safety distances pages 26 27 PA 13945 6 ce cog regag Bh Poggi Fig 35 Gerapid 8007 with arc chute 2x dimensions in mm and inches 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice TSE 220 266 15 0569 A m Ty ra Ww wy 10537 15 258 11016 153 1602 55 5 2 5 Gerapid 2607 4207 with H H terminals It s possible to combine horizontal and vertical connectors Dimensions are corresponding Note with SEL option top connector is vertical only 4 2D l 7 9 1164 P1357 116 Gerapid 4207 330 6 114 42 186 6 EE T od Fig 356 Gerapid 2607 4207 with horizontal terminals dimensions in mm and inches 34 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 5 2 6 Gerapid 2607 4207 with V V terminals It s possible to combine horizontal and vertical connectors Dimensions are corresponding 1 167 E Gerapid 4207 PESO Fig 37 Gerapid 2607 4207 with vertical terminals dimensions in mm and inches 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 21 164 157 1164 5 2 7 Gerapid 6007 terminals Gerapid 6007 is available only with V V terminals 30 11487 Co i390 QU 135901 Fig 38 Gerapid 6007 w
26. 2012 11 21 S47183RO01E06 GE Consumer amp Industrial Power Protection High Speed DC Circuit Breaker Gerapid 2607 4207 6007 8007 with arc chutes 1X2 1X4 2X2 2X3 2X4 USER MANUAL Design and specifications are subject to change without notice Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 INDEX 1 WARNINGS wu ccccccccssseesssssssescsssssssssssseccsssssscessssecessssescessnsesesssusssessseeeessssess 4 2 GENERAL USAGE CONDITIONS cont 4 2A Mansponta ton ONO SUO DING vecinita ae 4 2 NAM OOO meses utet rent tote 5 2 2 1 Operational environment 5 2 2 2 Installation and interfaces 5 C a0 E 0 5 SAN ONA VOGO AAA ea 5 2 3 2 Adjusting the over current release 5 S TECANICAGINFOR MATION scsscoasesssazassassasoassaseasoaseasonsonsonconeneesanscode 6 SAITO CO To nu NN REINO NN 6 3 2 Components and accessories ssee 6 Sito COMA CES leccion 6 Sea A SO 2 ME 6 S2 MSS eue E LU uU ee 7 3 2 4 Over current release Code lr 7 3 2 5 EDimp lsecoil release Code al 8 3 2 6 Auxiliary tripping devices Code 11 8 3 2 7 Forced tripping release Code 13 8 5 2 8 Lever for manual operating Code 16 9 3 2 9 AUNI SV IEC I COS OY chit a contatto etti 10 2 2 AO MING AAA tedesco erat 10 3 2 11 Solenoid closing drive Code 3 10 5 2 12 Current measurement system Code 6 11 32 13 Elect
27. 3 Control box inside w o SEL unit Slot Control board Z No Orientation Lp NEKO unit ED trip 128750 R1 equipment to left 3 Voltage converter 128 730 R2 R4 equipment to left SU control unit 128 700 equipment to right 6 ST UVR control unit 128710 R1 R2 equipment to left Table 5 Layout of control PCBs inside the box w o SEL EE RES E a 3 cs s T ps ra 4 4 4 Eas laia lo la la la lalo a aa Fig 54 Control box inside with SEL unit Slot control board E No fomentan NEKO unit ED trip 128 750 R1 equipment to right 2 Voltage converter 128 730 R2 R4 equipment to right 3 SU control unit 128 700 equipment to left ST UVR control unit 128 710 RI R2 equipment to right 6 SEL control unit 128 785 R1 R2 equipment to left Table 6 Layout of control PCBs inside the box with SEL e Warning The isolation plates between the control boards and at the wall of the box must always be present e Hint In older systems the control boards may be installed turned 180 Fig 55 3 Carefully lower the box cover 46 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 Fig 55 8 Carefully replace the control box front cover and attach the with the four screws re y y Bp F NE Fig 55 5 Pull out the plugs of the control boards Pull out selected control board Insert new control
28. 41 The arc chute s screw connections 4 must be secured by means of flat washer e Any other screws shall be tightening with applied torques from Table 3 D e Ensure that the screws are in good condition that thread and nest are not damaged Surface shall be free from rust Replaced any screw which does not fulfill above conditions e This check must be carried out prior to commissioning and after maintenance 6 1 7 Inspection of the mechanical components Only GE Service Team or its representative shall perform this inspection These require major disassembly and adjustment of the breaker Customer without supervision of trained specialist shall not execute these 2012 11 21 S47183RO1E06 cO0N Manual closing only during maintenance Fig 45 Closing operation by using hand lever 1 Establish contact point 2 Check the gap 1311 ee Fig 46 Inspection of the main contacts tilt 1 Close the breaker 2 Check the gap gap of min 2mm b Fig 47 Inspection of the arcing contact s air gap Design and specifications are subject to change without notice 41 6 2 List of maintenance works TYPE OF THE WORK BY WHOM WHEN REQUIRED RECOMMENDATIONS Lilia 70 Len NENNEN Trained technician runners changing Trained technician CER RSS a A Trained technician D Adjustment of the GE Service Engr As a result of the inspection C Only when replacement of the arcing contacts contact results w
29. 449 4321 201 444 60 Design and specifications are subject to change without notice S47183R01E06 11 2012 S47183RO1E06 2012 11 21
30. 460R ID GE 128730 Ra GND GND 24V INPUT 88 140V OUTPUT 24V 3 0A 6 0A Made in Germany Fig 19 2 Voltage converter 110 V 24 V DC Design and specifications are subject to change without notice 11 12 3 SU control unit see point 3 2 11 e 5 EMPTYS e 6 SELcont Fig 19 3 SU control unit 4 ST UVR control unit simple relay system It controls Fig 19 6a operation of shunt trip or zero voltage release 4 4 fone zt Fig 19 4a UVR control unit Fig 19 6b Fig 19 4c Extinguish capacitor for direct ST supply Design and specifications are subject to change without notice LOT not used rol unit see point 3 2 12 L EIRFA Y EEE DP B Ld i P D z LLL A HAM tee K EL 2 xd mm yo gt 2 3 x LJ SEL control unit T 35 E MI j 2 oy mnim re von LIIS 3 MY SEL control unit T 55 S47183R01E06 2012 11 21 3 3 Technical data tables Impulse withstand voltage 1 2 50 us Ui kV 18 18 18 30 30 18 18 18 50 50 12 18 18 50 1 12 18 ERR Power frequency withstand voltage 50 Hz Ua kVeff 10 10 10 15 15 10 10 10 15 15 ri 10 10 15 1 7 10 crew si PY PPEEPeCEEE PEELE Te Rated short circuit making capacity ls kA 70 50 100 50 42 70 50 100 50 42 70 50 80 50 1 70 1 according to EN 50123 2 Rated service short circuit breaking current Ics kA 40 50 40 40 40 50 40 40 40 50 40 1 1 T 508 50 5 5 O O
31. C release Low power high stability 24 V DC source available for control supply With maximum possible number of auxiliary contacts 10 Without OC trip target 11 Zero voltage release 12 With ED impulse release supply directly from external C bank 13 Without forced tripping release 14 With contacts position indicator 15 With side insulation panels 16 With hand lever 17 Without arc chute indicator 18 Counter not available 19 Special retrofit connectors for Gearapid SE breakers 20 According to IEC 60947 2 standard 21 User Manual must be in Polish Correct catalogue code shall be O 0 Y 0 UN E WN FP 245R51201406101110034 General remarks e Customer s special solution with non typical ratings Additional letter will be assign to this configuration exclusively Later customer can use this bue to call the same configuration e It is possible to supply closing drive and controls from two separate source of power g n 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice Diagram no 36 2120200035 lj codename opt a amp Are chute type j Po tC O C_ CC CY E LIC cade 2 NS 31 Mi LE Control circur 33 voltage i NL AE a rz 2 Z EHE E 2 onL1 PA A Quantity 1 fimo 53 breakers per arder Breaker number mme eos Te TS IE EE Unlack On Request options gt LL st tT Customer s mm no
32. T UVR NEKO PCBs by controlling state of contacts at points 5 6 of each 10 Replace any ST UVR NEKO if necessary 11 Replace the SU control PCB 12 Switch OFF the power at control box Check continuity and resistance of solenoid winding Replace the solenoid in case of winding breakage Contact GE Service in case the problem is not solved B Closing drive operates electrically but it is not possible to keep contacts closed 1 Check the forced tripping release if installed A permanently blocked tripping device during closing operation will cause closing failure and force contact opening 2 Check contact system area Look for any parts that may be stuck between contacts or into mechanism module 3 If the zero voltage release is installed check connection of S2 pushbutton If only NO type X2 6 7 is used be sure that X2 8 9 is shorted Open the control box only when UVR is installed 4 Check the wiring connections for UVR PCB 5 Check supply of the UVR control PCB X13 7 8 Contact GE Service in case the problem is not solved 2012 11 21 S47183RO1E06 Breaker does not OPEN WARNING Below operations are done with control voltage connected Only trained specialist or GE Service representative shall perform them Risk of electric shock A Shunt trip does not operate Breaker is able to CLOSE and OPEN by means of hand lever 1 Check points A2 to A5 2 Check the self cut off contact
33. Ue DC 110 V 220V Rated operational current le DC 13 0 5A 0 3A Minimum current voltage ratings 0 1 mA 6 V DC Contact duty min value DC 10V 2mA Operating range OFF 21 6 V 26 4 V Rated power for a single winding Pc 230 W UVR Uc Rated voltage Zero voltage release Operating range OFF Operating range ON Power consumption ED impulse release Energie source Capacity Charging voltage Switching interval max 2 min with 10 consecutive operations Endurance 1 000 operations with 1 operation per 180 s Firing signal level duration 8 24 V 100 1000 ms Charging signalization relay AC duty AC 250 V 0 5 A AC 120 V 1A DC duty DC 220V 0 1A DC 125V 0 3A DC 10V 3A Standard ambient conditions acc to EN 50123 1 Attachement B For meeting outside of this standard range please call back Table 2a Technical data of auxiliary circuits Us In SU Control CLOSE push button S1 DC 24 V approx 10 mA ST releasing push button S2 DC 24 V approx 4A UVR releasing push button S2 X2 6 7 DC 24 V approx 10 mA push button S2 X2 8 9 DC 24 V approx 450 mA ED coil tripping w o NEKO push button S3 DC 300 V 750A 3 ms ED coil tripping with NEKO Connect Firing signal at X2 10 11 DC 8 V 24 V approx 20 mA Table 2b Control circuits directional values to rate the components 14 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 4 Electrical circuits 4
34. WA code 13 o dqdh A O rales o A A Contact position indicator A ZFthout sid JL STA code 14 tet mu Protection options tho O JRodenttprooing od SCH code 15 Sidewdlsprotectonpanels o l Lever for manual operating Without Op HAN code 16 E Wt 1 J J W udj 0 0 0 0 VA Arc chute presence AT A JJJ J JJJ Jl b LBM code 17 d Counter TA ZAL code 18 e Meade a o l 58 control connectors type 60 SSTI code 19 A O O OnReguest O R Relevant standard IN AT A gt 7A E 763 licus code zo china acc IEC947 2 amp GB140482 E Torque TR Documentation Language 765 JUNG AA ermano fon Request TR 52 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 7 2 1 Example of order no 1 Line feeder breaker for LRT substation in Europe comply with EN50123 with breaking capacity of 50 kA configured as follows 9 10 11 12 13 14 15 16 17 18 19 20 Load current of 4000 A Nominal voltage of 1500 V 2x2 arc chute chosen due to high breaking capacity up to 70 kA Auxiliary supply voltage of 230 VAC for closing solenoid Vertical layout of both main terminals V V Breaker polarization not important Without SEL unit not available with special terminals With OC release adjustabl
35. With arc chute indicator only Key number 03 With OCT trip target and arc chute indicator Fig 29 OCT trip target and arc chute indicator 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 25 4 3 9 Auxiliary switch 1 2 3 4 5 7 10 11 12 13 14 15 XA v N eo lt LO op o o o o L E E TE I 1 2 3 4 9 T 10 11 12 13 14 15 X5 HS 6 HS 7 HS 8 HS 9 HS 10 Key position 7 Key number 1 With 3 switches HS1 thru HS3 Key number 2 With 5 switches HS1 thru HS5 Key number 3 With 10 switches HS1 thru HS10 Fig 30 Auxiliary switch 26 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 4 3 10 SEL measuring system Ab 1 AB Z 2 AB 3 Abd 3 ADS ABB 24 w DC 24 V sir E Sensor Signal l AL I Processing ee i d Unit al SPannundas k Voltage stabilizer Funta bani ralle Self check control 21010 2137 10 10 wes 2a y M126 DC 24 V 6 10 E9 1 max 5009 2 max 500Q 3 min 300 KQ a Key position 8 Key number S With SEL measurement system Fig 31 SEL current measurement system 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 27 5 Dimensions amp safety distances Warnings A Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric S
36. al i Po control provided l gy ayy by user j usi AY PE eh tenn eid ceca Rc E C bank and output circuit ED impulse Key position 3 Key number 2 With ED coil and internal NEKO control unit e Firing signal at X2 10 11 is processed by opto coupler Pay attention to the polarity e Closing STOP signal is provided to lock CLOSE command until capacitors are fully charged e Be sure that voltage level is between DC 8 V 24V and there are no transient spikes 5 ms on firing signal This can lead to major defect of the NEKO control unit e Maximum duration of the firing command must not exceed 1 sec Longer signal might cause NEKO failure It is recommended to use one of HS auxiliary contacts connected in series with firing circuit X2 10 It will automatically cut off the firing circuit after breaker opening Fig 25 ED coil with internal NEKO control unit 20 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 4 3 5 SU control circuit Q1 Closing drive AC 110 250V DC 48 220V Closing control circuit 36 X MEN Key position 4 Key number 20 Closing solenoid drive with SU control unit Fig 26 SU control circuit 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 21 4 3 6 Shunt trip control circuit Standard DC 24 V shunt 36 trio with control PCB K1 oe es 7 Cut off
37. al C bank Opening time is less 3ms Time to charge capacitors is 15sec Lever for manual operating also hand ever Hand lever can be used for both closing and opening manual operation It is intend for use only during maintenance M Main circuit also mains primary circuit current path All the conductive parts of the breaker included in the circuit which is intend to close or open It consists of main terminals upper and lower fixed contact flexible band and lower bus bar Main terminals also main connections Two conductive bars provided for electrical connection to external main circuit Different configurations are avaiable NEKO control PCB also ED coil control unit internal C bank control Control circuit PCB to supervise the operation of the ED coil It consists of control circuit and bank of capacitors Required to energize the ED impulse coil 56 Design and specifications are subject to change without notice OCT see Over Current release Opening operation also switching OFF OPEN operation An operation by which the breaker is brought from the CLOSED Over Current release also OCT An instantaneous and direct acting mechanical release Tripping the breaker in case of overloads and short circuits Is adjustable within predetermined range Opening time depends on short circuit conditions and shall not exceed 5ms Oct is activated be means of magnetic energy from main circuit Requires n
38. atch and quick latch of the mechanism Apply dash of Beacon EP2 grease afterwards Required tools Cleaning tissue abrasive paper manual closing lever hexagon wrenches SW5 SW6 Torx amp wrenches size 30 40 45 small and medium screwdrivers ratchet with 10 mm hex cap pliers tongs Dispose of the breakers if required Pay attention to the national and local regulations of disposal 38 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 2012 11 21 S47183RO1E06 6 1 1 General visual inspection Check out for damages or cracks of the frame the adapter or the arc chute Check out the black marks on the countersunk screws These marks shall be aligned together If any screw is loosening shall be replaced with new one using Loctite 222 Afterwards mark the screw with black line to sign Its position in nest Check out for missing screws or caps Check out for damaged labels Clean and repair Check out for corrosion In case of significant corrosion please contact GE representative for assistance Check out for distinct manifestations of flame or smoke at the frame Especially in lower area of the breaker Please document and contact GE representative for assistance Clean the breaker of dirt and dust Remove all dirt with a dry cloth No particularly high signs of abrasion rough chips should be visible anywhere Clean and degrease the copper terminals 6 1 2 General functional in
39. ate electrically but it is still possible to close the breaker manually by mean of the hand lever 1 Check the supply voltage of the drive X2 1 2 The voltage shall not be less than 80 of drive s rated voltage 2 Check the supply voltage of the controls X3 4 5 The voltage shall not be less than minimum input voltage required for installed voltage converter 3 Calculate the voltage drop at both supply lines and check for adequate wire size 4 Check the polarity of the supply connections 5 Check continuity of the control connections Open the control box WARNING Following operations are done with control voltage connected Only trained specialist or GE Service representative shall perform them Risk of electric shock 6 Check if the PCBs plugs are connected and screwed 7 Check if there is 24 V DC available at output of the voltage converter Check X10 8 9 10 6 7 8 Check the status of the red LED diode on the SU PCB Does not light power supply failure Weak light system ready to CLOSE Intensive red light system not ready to CLOSE Closing STOP circuit is active or NEKO PCB is not charged or anti pumping is active for 15 sec 9 Check if the Closing STOP circuit is not open Measure voltage at SU PCB X12 57 6 There shall be 24 V DC available for actuation of closing stop relay If there is no 24V DC check continuity of closing STOP circuit Check relays at S
40. be carried out only by qualified and suitably trained personnel and under strict observation of national and international applicable safety regulations During their operation circuit breakers must be equipped with appropriately fitted covers e g in suitable enclosures or panel boards Safety distances must be preserved Suitably trained service personnel shall only carry out certain works Non compliance with these warnings may result in death and or severe physical damage and extensive damage to equipment Prior to carrying out maintenance inspection or checks the circuit breaker must be open the both terminals must be grounded the circuit breaker must be switched off and the control plugs removed Manual activation of the breaker while energized is forbidden Manual activation must only be used for maintenance and inspection purposes when breaker power is off and grounded The circuit breaker consists of high energy moving components Do not touch the circuit breaker while it is being switched ON closing or OFF opening There is a high risk of major injury The control circuits may include capacitor banks which can be charged with dangerous voltages Work on this section must be carried out carefully 4 Design and specifications are subject to change without notice 2 General usage conditions 2 1 Transportation and storing The breaker is transported on wooden palette It is fixed by shrunken plastic fi
41. bient temperature 5 C 435 C and the model for higher temperature T55 5 C 55 C More details can be found in separate instruction for SEL usage Md d o ee Input 6 kA 6 kA 12 kA 12 kA Une V 1000 2000 4000 1000 2000 4000 T35 for ambient temperature of the breaker 5 C 35 C 23 F 95 F T55 for ambient temperature of the breaker 5 C 55 C 23 F 131 F Relating to the rated current of the breaker Output 3 2 13 Electronic control system All the control PCBs are installed in control box Fig 18 Starting from the left these are Fig 18 Control box with control units 1 NEKO control unit Fig 19 1 Code 12 internal control unit with capacitor bank Releases firing signal for ED coil X2 10 11 and provides indication of the capacitors charging X3 6 7 NEKO control unit also blocks the firing signal until C bank is fully charged 15 sec WARNING NEKO unit requires a high quality firing signal Be sure that voltage level is between 8 V 24 V DC and there are no short spikes on signal lt 3 ms This might lead to major defect of the NEKO control unit 128760R1 5 EI 36 04 Bus Fig 19 1 NEKO control unit e 2 Internal voltage converter Code 8 converts external supply voltage X3 4 5 to the internal 24V DC Required by controls except for the drive supply IN e PCMD 150 110 S24W GE ID 900593 02
42. board e Put on plugs X2 X6 fix the screws of the plugs and switch on control voltage e Listen that both the isolation plate at the side of equipment and the isolation plate at the side of Checking the breaker soldering were inserted Open and Close the breaker 3 times while it is disconnected from the system in the Test position of the draw out version the installation The breaker must open and close without a time delay over 400 ms If the test succeeds reconnect the breaker to the main Circuit m Nil all control plugs and tighten it by the mis mr Fig 55 6 Plug in screws 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 47 6 2 5 Adjusting the auxiliary switch A Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock 1 OPEN the breaker 2 Disconnect power supply and pull out all the plugs from control box s terminals 3 In case of NEKO control unit inside wait 1 minute until capacitors discharge e Adjustment of the switches may be required if they fail to 3 J SA t COPIA provide correct position indication This condition can be m z caused by misalignment of the actuating plate 6 Fig Fig 56 1 Control box with auxiliary switch block 56 3 represented by dashed line e If only 3 or 5 switches are installed in the center of the block plate misal
43. d voltage from external source ST can have a single or double winding Solenoid drive see Closing drive ST control PCB control circuit PCB supervising the operation of shunt trip release SU control PCB control circuit PCB supervising the remote closing operation by means of solenoid drive Presents in every breaker and placed in control box Provides also anti pumping and self cut off functions Switching ON see Closing operation Switching OFF see Opening operation Trip free device A mechanical switching device the moving contacts of which return to and remain in the open position when the opening operation is initiated after the initiation of the closing operation even if the closing command is maintained To ensure proper breaking of the current which may have been established it may be necessary that the contacts momentarily reach the closed position UVR control PCB control circuit designed as a single PCB for supervising the zero voltage release device Z Zero voltage release also under voltage UVR r release An auxiliary tripping device Trips the breaker open on control voltage loss Opening time is less 75ms It is used for remote OPEN operation or contro voltage supervision Interchangeable option with shunt trip release Activated by means of auxiliary potential free NO or NC contact S47183RO1E06 2012 11 21 7 4 Troubleshooting Breaker does not CLOSE A Closing drive doesn t oper
44. e 2 2 1 Operational environment 2 3 1 Supply and load 2012 11 21 S47183RO1E06 The breaker as delivered is IPOO NEMA 1 protected It is intended to work in indoor applications without pollutions with non conductive dust protected against high humidity and condensation Low conductivity dust deposit due to frequent condensation of humidity is acceptable General environmental conditions refer to EN 50123 1 annex B and IEC 60947 class PD3 The breaker can operate at rated current within ambient temperature range of 5 C to 40 C 23 to 104 F Maximum operating ambient temperature is 55 C 130 F with continuous current derated by 10 The breaker can operate at altitude up to 2000m 6500 ft without derating The breaker shall not be subjected to strong vibrations Maximum vibrations of 0 5 g per 30sec in vertical and horizontal directions are allowed Air shall be clean and its relative humidity shall be not more than 50 r h at the maximum temperature of 40 C 104 F Relative humidity may be higher if the temperatures are lower for example 90 r h at 20 C 68 F Slight condensation might occur during variations of temperature 2 2 2 Installation and interfaces The lower and upper main terminals Code 4 must be connected directly to the main cables or bus bars WARNING The breaker must only be used in an upright operation position with the arc chute in place and fully secured After arc chute
45. e in range of 6 kA 12 kA with 7 marks on the scale every 1 kA set at 9 kA Auxiliary supply voltage of 230 VAC for controls With 8 auxiliary contacts With OC trip target With zero voltage release UVR Without electrodynamic tripping device With forced tripping release for withdrawal operations With contacts position indicator Without sidewalls protection With hand lever Without arc chute indicator Counter not available With standard control connectors Test report according to EN50123 2 standard Correct catalogue code shall be 23A40025R16011010011 General remarks Please check the Unlock On Request options checkbox to enable entering values which are not listed in this form Please always define the markings number and values for OC release Please choose the On Request option to define own OC tripping range Use On Request option if available to define own not standard ratings Any other than first option for connector type are usually dedicated for retrofit purposes Please refer to special type of connectors options 2 3 4 R before choosing these Option 1 is suitable for most applications 2012 11 21 S47183RO1E06 Quantity 1 imac so breakers per order Breaker number to Catalogue no 2 3 4 Q j j 2 j 5 R 1 6 amp jOr 1 1 0 1 o jojJ1 1 36402020011 gt Unlock On Request options mes EHI MEE EI Yi
46. eed 2 mm 0 08 in gt 300 openings at load Check for wear of the main contacts at current fixed and flexible sides shall not exceed gt 100 openings at over 1 5 mm 0 06 in of its depth current load 2 3 x In Check for wear of the arc chute plates check for deposits inside of arc chute this It is recommend to carry area shall be free of deposits out inspection of contact Check for wear of protective walls shall system after breaking of not exceed 1 mm 0 04 inl equivalent of 150MASs total Check for contact tilt and gaps let through energy D Inspection of the Customer Every 6 12 months Check the position of the countersunk screws screw bolt connections Trained technician or after every inspection in the sidewalls e of the arc runners Check for tightness or use torque tool torque e ofthe contacts in SI and Imperial units e of the arc chute M8 20 Nm 177 in lbs M6 10 Nm 88 in lbs M5 5 Nm 44 in Ibs M4 3 Nm 26 in lbs E Inspection of the GE Every 5 years Carry out inspection B above mechanic components Service technician or Check out settings of the main contacts After 5 000 openings and auxiliary switch Check out upper dumper of the mechanism no cracks deformation or heavy discoloration hard consistency without punctures Check out main flexband breakage shall not exceed 30 96 of its cross section Check out wear of mini flexband shall not exceed 30 96 of its cross section Clean and degrease UVR l
47. elease FT can be installed in the breaker Fig 10a This unit mechanically trips the breaker by pressing the pin against the bottom plate Force required to trip the breaker is about 30 N 7 ft lb The tripping pin position is as on Fig 10b P oe A ms vA wre e A F zoN _ Initial position L 15mm 06 in tripped position L 8mml 0 3 in Fig 10a Forced tripping release S47183R01E06 2012 11 21 With a correctly designed interlock in an enclosure FT provides safety tripping function During withdrawal operation of the trolley the breaker is tripped BEFORE its main terminals disconnect from the mains Bottom view Fig 10b Positioning of the forced tripping pin 3 2 8 Lever for manual operating Code 16 e Optionally a hand lever for manual closing and opening operation during maintenance is available This tool must not be use while breaker is energized e Toclose the contacts install hand lever on the drive s rod and pull it out smoothly until latches snap Fig 11a e To open the contacts install the tool into the ring and push it hard against the drive s rod until breaker opens Fig 11b fe 200n I T 45 ft lb i 2 ee TA j Je WARNING Manual closing and opening only during maintenance Fig 11a Closing operation by using hand lever 2012 11 21 S47183RO1E06 Design and specifications are subject to change with
48. er area of the arcing contact Fig a Remember to secure the closing drive according to Hint 3 securing tube drive locking rod Fig b Securing closing drive against opening Fig a Protecting of the arcing area against falling parts 42 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 6 2 1 Contact system after 11 2003 Pay attention to the warnings Section 1 This section is valid for breakers manufactured after 11 2003 This section refers to maintenance works A B C from Table 4 A Remove the arc chute e Fig 49 Loosen the screws 3 and 4 using SW5 hexagon wrench and take off the arch chute 1 from the adapter 2 B Remove the arc chute adapter e Fig 48 To dismantle the arc chute adapter loosen and pull out the four upright screws 1 using SW5 tool Pay attention that no screws or washers fall inside the breaker e Fig 48 Draw aside and lift off both parings of adapter 2 Then pull out two protective walls 3 C Changing the protective walls arc runners and arcing contacts e Fig 48 Pull out two protective walls 3 e Fig 50 Loosen screws 6a with tool SW4 and take out front wall 6 e Fig 50 Loosen screw 5a with tool SW5 and take out the front arc runner 5 e Fig 50 Take out the back arc runner 4 by loosening two screws 4a with tool SW5 Don t remove the protective cap 4b e Fig 50 Loosen
49. ers Others Conductivity grease Alvania RL3 by Shell Two protection sheets Hint Replace 128 123 or 128 150 only if recognize Optional these parts are broken Replace all the parts from Mini flexible braid 128 123 service kit APN340110 Wiring modifications Correct control PCBs or prepared wiring Wires 1 mm 1 5 mm 2 5 mm 500 V polymer and control PCB harness insulation type up to 100 C RoHS compliant black change Dumpers change Damper 128 018 Damper 128 019 Optional Spring bar cap 128 058 Changing of zero UV release 128 320 voltage release shunt Correct shunt trip trip Optional Spring bar cap 128 058 1 For substitute materials please consult GE representative Design and specifications are subject to change without notice Plugs MSTBC 2 5 5 08 Terminations Crimp MSTBC MT 0 5 1 0 Crimp MSTBC MT 1 5 2 5 Receptacles 2 8 mm DIN 46247 with insulation cap Screws amp Washers M6x25 M6x30 M8x25 M8x30 8 8 15014581 Materials Transparent silicone E COLL 310ML glue Locktite 222 thermo paste WLP500 Screws amp Washers M6x25 M6x30 M8x25 M8x30 8 8 15014581 M4x10 8 8 DIN912 M4 ribbed lock washer BN791 by Bossard Others Polyamide clip bands 25x100mm Materials Transparent silicone E COLL 310ML glue Locktite 222 thermo paste WLP500 grease Beacon EPS by ESSO S47183R01E06 2012 11 21 7 Customer support 7 1 Options overview The coding sy
50. es split the arc into partial arcs and increase the arcing voltage by multiplying the anode and cathode voltage drop Because of their high heat capacity the plates and arc chute walls absorb a large amount of the arc s energy S47183R01E06 2012 11 21 2012 11 21 S47183R01E06 3 2 3 Mechanism The Gerapid is equipped with a modular designed mechanism which is wear resistant and nearly maintenance free This mechanism ensures an extended electrical and mechanical endurance of the breaker as well as a high level of safety under all operation conditions Breaker can operate 20 000 cycles when opened by the shunt trip or zero voltage release and 1 000 operations by means of ED impulse coil or OCT releases This mechanism is mechanically latched in the CLOSED position The principle of a mechanically latched mechanism offers a big advantage compared to often used electro magnet holding system No auxiliary control power source is required to keep breaker closed The mechanism is provided with two tripping latches Fig 6 First latch called slow latch is used for opening under normal conditions like actuation of shunt trip or zero voltage release The second one quick latch de clutches the main contact arm from the mechanism and opens the contacts with an extremely short delay This is used when interrupting short circuit or overloads All safety releases operate onto quick latch latch Different main springs are used in mecha
51. hock During operation all metallic parts of the breaker except control box and closing solenoid drive may carry dangerous voltages Insulation covers are available as an option For installation of the breaker into cubicle top and side openings shall be provided in order to reduce internal pressure rise during clearing short circuit Ventilation openings in the breaker cubicle top cover shall not be less than 50 of total surface area 28 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 5 1 Safety distances Units call in mm inches Type Arc chute Main Additional Deflector Safety distances Insulated plates Safety distances Earthed plates m mp E C 2607 4207 1x2 al 10004 700 276 150 59 150 59 120 4 7 1000 39 4 300 11 8 300 11 8 300 11 8 1 v8 da uu u ou ou uu j j pt f 150a f 7001276 1500 9 150 9 1200 7 1350 53 2 450 17 7 450 17 7 200 7 9 E we s cod s ge 3E E d s c docu ch EE a ae 2 all FF 80 315 1000 39 4 18017 1 180 7 1 180 7 1 1350 53 2 450 17 7 450 17 7 300 11 8 ada i 803 15 1000 39 4 10002 1802 1807 0 PEO ee Cd A EET ee ERE o as A A Sidewals 150659 1000 594 180071 1802 18070 BENE 1000 39 4 180171 180 71 18078 _ 6007 1x2 V VHeatsnk 10004 100
52. ignment will not occur breakers built after 2003 e n the case of 10 switches or when switches are mounted at the far left position it might be needed breaker before 2003 In most cases only far left or far right mounted switches might need to be re adjusted e Check all the switches operation to establish which need to be re adjusted left or right side e OPEN the breaker e Fig 56 1 Loosen four screws 2 Move the front cover 1 slowly down The auxiliary switch block 3 is accessible now in the bottom of the compartment e Fig 56 2 Loosen screw 4 on the side left or right which needs to be re adjusted Turn the proper adjusting screw 5 clockwise until all contacts switch properly Warning Adjusting screw 5 too far in may over compress the switches pin and cause breakdown e Fig 56 1 Check the correct signalization of all switches at the connecting plug terminations X4 X5 If necessary re adjust the switches from other side e Now tighten solid the screws 4 e Fig 56 1 Close the control box with front cover 1 by 6 ll Fig 56 2 Auxiliary switch block fixing the four screws 2 Pay attention that no cables will be pinched between box and front plate e CLOSE the breaker several times Check if the auxiliary contacts are switching over correctly e Finally check the electrical functions in the TEST position of the draw out version after install
53. ilable ranges are described in the table below Other ranges might be possible on request When supplied with the optional transparent side protection covers Code 15 a fixed mounted insulated knob is provided to enable OCT adjustment Fig 16 Fig 7 OCT device Default tripping bands for the OCT release 1 2 Ne ocr band 2607 4207 6007 2007 n ista 2 15k4 3ka MEME 3 15kAa 4kAa 4 15kA SkA MN 5 2kA 6kA GHE 6 2k 7kA 7 2ka ska e esmassa 9 7 A 10 3 8 po pu se sw AAA e aa DESI 15 544 104 E aa ora 1ara PO 15744 1854 16 eka taka op ir is i54 MIN ris i2ka 24ka PS 1 Customer specific bands on request 2 Tripping accuracy 1096 Design and specifications are subject to change without notice 7 3 2 5 ED impulse coil release Code 12 ED impulse release requires an external protective relay for monitoring a current increase This relay must be provided and installed by the customer If a fault occurs an external relay signal wired into the capacitors control unit internal NEKO or external C bank causes NEKO unit to discharge its energy into ED coil Fig 8 The coil trips the breaker s quick latch and opens breaker s contacts in less 3ms ED impulse release is an optional accessory Complete set consists of ED coil and electronic control unit with C bank called NEKO The external release signal
54. iliary switch also auxiliary switch make break contact a b contact A switch block containing up to 10 auxiliary contacts Mechanically operated by the mechanism of the breaker during switching operations Auxiliary switch block is mounted in lower compartment of the control box Every contact can be either NO or NC configured by appropriate wiring Closing drive also activating magnet closing solenoid solenoid drive High power black solenoid coil mounted at the front of the breaker below the control box Use for electric and remote closing of the main contacts Power consumption is up to 2 6kW Closing time is 150ms Closing operation also switching ON CLOSE operation It is operation by which the breaker is brought from the OPEN position to the CLOSED position Closing solenoid see Closing drive Control circuit terminals also control sockets plugs Fully insulated sockets at the front cover of control box Intended for external connection to the auxiliary and control circuits ED coil also electro dynamic coil An impulse coil release Actuating element of ED impulse release mounted on the base under the mechanism Electro Dynamic impulse release also ED tripping impulse release Release device consist of actuator ED coil and control circuit NEKO PCB with C bank This is an auxiliary release activated by high energy impulse of current The impulse is shaped by internal NEKO or extern
55. ing the q breaker into the substation If re adjustment does not help please contact GE Service Team It might be required to install switch block again or to move switches to center of the block for better performance Gerapid in ON position Gerapid in OFF position Main contacts closed Main contacts open Aux switches not actuated Auxiliary switches actuated Fig 56 3 Actuating plate for auxiliary switch block 48 Design and specifications are subject to change without notice S47183RO1E06 2012 11 21 6 3 Spare parts lists 6 3 1 Mechanical spare parts NOTE Gray shaded parts are recommended for a maintenance stock as applicable to your specific breaker configuration Service kit for replacing arcing components Before 11 2003 Service kit for replacing arcing components After 11 2003 Arcing contact Arc runner back side Arc runner front side Fixed main contact Movable main contact Set of protection walls Ground insulation Additional ground insulation 2607 4207 6007 ix APN340110 ROO 8007 gf2x JAPN340110 RO9 ALL Ibefore 11 2008 a ein Lais ee ML raiz ees ML pe Veraz faze sns si6 Ro ML fe essissi Ro peor azor oo7 a izezos Rol poor iem roe or areas sos Lower damper Adapter hL S eos Forced tripping release TAL a seo 1 Check the nameplate to define type 2012 11 21 S47183RO1E06 Design and specificati
56. installation check for tightness both connections to the arc runners See drawing 49 item 3 The safety distances as listed in section 5 1 shall be maintained to grounded or insulated parts Suitable measures must be taken to protect personnel from arcs Strong external magnetic fields caused by improperly located supply conductors or stray fields from other devices can lead to a shift of the trip setting thresholds This may result in premature tripping or no tripping at all during low level short circuit current events This has to be accounted for when installing and operating the device with shielding added if appropriate The control wires must be connected to the control terminals Code 19 as shown in the schematic circuit diagrams in section 4 The protective grounding wire must be connected at the marked contact Fig 2 Fig 2 Termination for grounding wire In accordance with its type the breaker has been designed for the current and voltage listed in Table 1 section 3 3 During continuous operation breaker must only be loaded up to its maximum rated current Load currents in excess of breaker nameplate rating are allowable for brief periods Refer to the short time currents listed in Table 1 Do not exceed the rated operating voltage shown on the breaker s nameplate Supply voltage for the drive and the auxiliary tripping devices Code 8 shall be within the specified control voltage range Maximum current values
57. ith incorrect gaps See point 6 1 5 xcu te emere ILL control board Trained technician fee see e mechanism Hp 0 changing H Mechanism changing GE Service Engr As a result of the inspection BE the same time Pa d a adjustment K Auxiliary contacts Customer As a result of the inspection B E In case of improper operation of the adjustment and changing Trained technician switches adjustment might be necessary L Drive changing GE Service Engr As a result of the inspection BE Vo M Accessories changing GE Service Engr As a result of the inspection BE Table 4 Required tools Maintenance with zero voltage release Cleaning tissue Pocket lamp If an optional zero voltage release is installed it Hand lever must be energized to enable closing of the breaker Only Hexagon wrench SW 4 SW 5 SW 6 then maintenance of the arcing contacts is possible Screw wrench SW 10 SW 13 Torapuvrencdhstza 20 andas Hint 3 To prevent the risk of injury it is recommended eallcamd medum a to secure the breaker in the closed position with a simple Biers mechanical interlock device Fig bl A piece of tubing Miedos having 50 mm 2 in length and inner diameter of File minimum 14 mm 0 55 in works well The outer diameter of the locking rod shall be less 8 mm 0 3 in GE does not Steel brush offer this locking device Safety hints Securing against falling parts Place a cloth into the low
58. ith vertical terminals dimensions in mm 36 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 5 2 8 Gerapid 8007 terminals Gerapid 8007 is available only with V V terminals 10 96 e Gerapid 6004 10 36 qo 3 90 2 oy P oF CA Fig 39 Gerapid 8007 with vertical terminals dimensions in mm and inches 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 37 6 Inspections and maintenance 6 1 List of inspections TYPE OF THE BY WHOM HOW OFTEN WHAT TO DO CHECK INSPECTION A General visual Customer Every 6 12 months Check for damages or cracks of the inspection Trained technician frame adapter or arc chute Check for missing screws or caps Check for damaged labels Check for corrosion Check for distinct manifestations of flame or smoke at the frame Clean the breaker from dirt and dust Clean and degrease the copper terminals B General functional Customer Every 6 12 months Manually close and open the breaker to inspection Trained technician check the drive and mechanism Close the breaker electrically and open by trip unit s releasing to check controls C Inspection of the arc Customer Every 6 12 months Check for wear of the arc runners shall chute and contact Trained technician or after not exceed 30 of its cross section system high short circuit Check for wear of the pre arcing contact opening at gt 25 kA It shall not exc
59. lm A cardboard box covers the breaker on the palette Truck railway airplane and ship transport is possible In case of sea transport special protection against salty and humid environment is provided The circuit breaker must always be transported to the installation site vertically and fully packed The packaging protects the device against damage and dust it should only be removed prior to installation If the packaging is damaged the breaker and the arc chute must be inspected for damage Ensure that all packaging materials have been carefully removed prior to breaker installation For handling the unpacked breaker use canvas slings and position them below the closing drive a and below the lower terminal b Fig 1 Fig 1 Handling the breaker WARNING Breaker and arc chute must be transported separately Never handle the breaker with arc chute installed at Take care that the bottom isolation plate of the unpacked breaker is not damaged during handling Do not push the breaker back and forth on any rough surface The breaker s weight including arc chute is listed in Table 1 page 13 Arc chute s weight is ca 30 kG 66 Ib for 1x type and ca 60 kG 132 Ib for 2x type WARNING Store in original packaging Do not store outdoors Use protection against crush and blow Do not store the breaker in a damp area Storing temperature range 25 C 55 C S47183R01E06 2012 11 21 2 2 Installation 2 5 Usag
60. lock washer Use a torque of 10 Nm 88 in lbs Fig 41 Tighten front and backside of the arc chute connections 4 including flat washers Use a torque of 5 Nm 44 in lbs Fig 41 Put on isolation caps 6 Fig 41 Arc chute and arc runners fixing Design and specifications are subject to change without notice 39 D n NSS S OSOS NS SS ANN ANAS AA y ZENSA X Fig 42 Inspection of the arc chute 6 1 4 Inspection of the contact system Pay attention to the warnings Section 1 A Remove the arc chute e Fig 41 Loosen the clamping screws 3 and 4 using SW5 hexagon wrench and take off the arch chute 1 from the adapter 2 B Remove the arc chute adapter e Fig 43 To dismantle the arc chute adapter loosen and pull out the four upright screws 1 using SW5 tool Pay attention that no screws or washers fall inside the breaker e Fig 43 Draw aside and lift off both parings of adapter 2 Then pull out two protective walls 3 Fig 43 Adapter and protective walls 40 Design and specifications are subject to change without notice Fig 44 Checking the contact system C Check the protective walls e Fig 44 The material burn out on the protective walls 5 shall not exceed 1 mm 0 04 in at any place D Check the arc runners e Fig 44 The arc runners should not be burned more than 3096 of its total cross sec
61. n Fig 52 2 3 Re install the axis pin and safety ring Fig 52 5 Initially screw in braid s screws by hand Fig 52 6 Tighten these by torque of 10 Nm 88 in lbs Install back the arc runners See 6 2 2 C Check the adjustments according to point 6 1 5 C Install back adapter and arc chute See 6 2 1 D E e Secure the contact area against parts falling inside the breaker See 1 2 1 e Fig 52 1 Initially loosen two braid s screws with tool and unbolt them finally by hand e Fig 52 2 Remove the safety ring from axis pin end e Fig 52 3 Pull out the axis pin from contact Fig 52 2 Remove safety ring Fig 52 6 Tighten braid s screws with torque of 10Nm Fig 52 3 Remove axis pin 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 45 6 2 3 Layout of control PCB inside control box 6 2 4 Replacement of the control boards ime ORE LEA eto Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock 1 OPEN the breaker 2 Disconnect power supply and pull out all the plugs from control box s terminals 3 If a NEKO control unit is installed wait 1 minute until capacitors discharge Aw 3r FERES EQEQEQEQ LM y M de y Xa AIR D ME n EAD T vd st SART y M E d gt d a f E s o de 7 els es te cs Pu 3 uL D L 2 A 1 iJ P CAA M 6 n B 5 h h a Fig 5
62. ng drive Aux tripping device Indicators Aux switches SEL system EXAMPLE 36 1 0 2020 01 1 Key number Gerapid e With voltage converter Without ED and NEKO With closing drive With UVR release With OCT trip target With 3 aux switches Without SEL system Fig 22 Example code shown on the nameplate 2012 11 21 S47183RO1E06 Key Key Designation position number Type 1 56 Gerapid Auxiliary voltage 2 1 Voltage converter 2 DC 24 V external supply Tripping coil 3 0 Without ed trip coil 1 With ed trip coil 2 With ed trip coil and NEKO control unit Drive 4 20 Solenoid drive with Tripping device SU control unit 5 00 Without trip unit 10 With shunt trip 20 With zero voltage release Indication device 6 00 Without indicators 01 OCT trip target 02 Arc chute indicator 03 OCT arc chute indicator Auxiliary contacts 7 1 5 auxiliary contacts 2 5 auxiliary contacts 3 10 auxiliary contacts Current measurement system 8 S with SEL Indication of components Q1 Impulse ED coil Q2 Closing drive coil S1 Push button CLOSE S2 Push button OPEN type NO S3 Push button OPEN type NC SU control PCB K1 K2 Closing relay Internal closing stop relay 1 Shunt trip zero voltage release PCB K1 K2 Internal closing stop relay Tripping relay HS11 Shunt trip self cut off auxiliary contact ED tripping device with internal NEKO PCB K1 Voltage monitoring relay K2 Internal closing stop relay
63. nisms for different breaker frames Therefore mechanisms cannot be exchange between breakers of different frame movable main arm quick latch slow latch main contacts Shunt trip Zero voltage releaser ED coil Fig 6 Latching and tripping system 3 2 4 Over current release Code 7 The OCT release is a magnet with two magnetic circuits optimizing the twin magnetic field principle Fig 7 This technology ensures equally fast tripping in both current directions This system does not require an auxiliary control voltage to operate It is a direct acting and instantaneous tripping device The OCT consists of the holding circuit 6 the movable armature 3 and the tripping circuit 7 The holding and the tripping magnetic circuits are both excited by load current 1 Until the static overload release s response threshold has been reached the armature 3 is held in position by the holding flux DH 2 and the counter spring s force 4 Once the load current exceeds the set static response threshold the attraction flux BA 2 takes over and rapidly pulls down the flexible armature 3 During this operation the armature hits the seesaw OCT unit rotated 90 view which releases the quick latch in the mechanism The latch and contacts are opened immediately The response threshold can be easily adjusted by turning the adjustment nut with a SW6 hexagon wrench The ava
64. ns and provides an anti pumping safety feature panel control box closing drive Fig 16 Solenoid closing drive and control box e After closing attempt the switch in mechanism is electrically blocked for approximately 8 sec Lock time increases to 14 sec if internal C bank NEKO is present This prevents premature closing following a short circuit S47183R01E06 2012 11 21 knob protection 2012 11 21 S47183RO1E06 3 2 12 Current measurement system Code 6 The SEL current measurement system consists of the sensing component 1 and signal processing unit 2 Fig 17 SEL sensor is integrated into a specially shaped upper terminal of the breaker and is connected by a shielded cable to the signal processing unit SEL control unit is placed in the control box Fig 18 SEL sensor SEL control Fig 17 SEL current measurement system SEL may be used for recording DC currents in selected measurement ranges of 6 kA or 12 kA Measurement of rated current values and of the current rise may now be made directly at the breaker The sensor includes Hall probes and delivers a proportional signal output to the SEL control The signal processing unit transforms input signal into standard output signals shown in the table below The outputs are insulated from the main voltage The insulation withstands voltages up to 4 kV RMS and up to 40 kV in peak Two versions are available Standard model T35 for am
65. o external control power Position indicator also position indicating device A mechanical device mounted at the front of closing drive Indicates whether the breaker is in the open or closed position CLOSED position is marked as l OPEN position is marked as O Pre contact see Arcing contact r release see Zero voltage release SEL Current measurement system consisting of sensing element and control circuit The sensor is an insulated tube mounted on the top terminal of the breaker Utilizes two Hall s probes for sensing the current and direction The proportional voltage signal is transmitted to control circuit placed in control box The SEL control PCB is an opto isolated transducer which generates standard output signals proportional to measured current SEL control PCB a control circuit PCB Controls and transforms current measurement signal from SEL sensor Self cut off function A safety feature provided to avoid overstressing of the closing drive and shunt trip release Closing drive is automatically cut off from power source after 500ms Shunt trip coil is connected in series with auxiliary contact s which cause cut off after breaker s opening Shunt trip release also ST shunt release a release Instantaneous release energized by means of voltage signal Within 50ms trips the breaker s mechanism Use for remote OPEN operation ST can be activated by potential free contact or by directly applie
66. one CONTO SUSTO aeter nennen 11 BiB CINCO CCUG tables ccc UU DUE DURS 15 GELE CTRICAECIRCUIT econ UD EN 15 AA COMO O OU arrasan 15 4 2 Terminals wiring system ecscssesssssesssssecssseessssessssesssssecssneesssees 16 43 Electrical dICgEF as seem cem ERI REUS 17 4 5 1 Wiring Code eerte 17 43 2 Controls SUDPIY CII CUI escrita eiii 18 4 3 3 ED coil with external capacity bank 19 2 54 NEKO CONTONE CU lanus 20 ES NE SA ESTER TONE SESTE TREE NOE EN SOURS 2 ASO SHUNTED CODTFOLGI CUIDe t 22 4 5 7 Zero voltage release control circuit 24 4 3 8 IICA accetti ette ete ctas d cud 25 2 9 9 TII SUM IU Ped e E BS RENNES NER EE 26 4 35 10 SEL A etn 21 2012 11 21 S47183RO1E06 5 DIMENSIONS amp SAFETY DISTANCES sees 28 SUE ASTON E ou RN DEM ieee 29 5 2 Qutlinied DIMENSIONS escri a 30 5 2 1 Gerapid 2607 4207 6007 with arc chute 1x_ 30 5 2 2 Gerapid 2607 4207 6007with arc chute 2x_ 31 5 2 3 Gerapid 8007 with arc chute 1x s 32 5 2 4 Gerapid 8007 with arc chute 2x s 33 5 2 5 Gerapid 2607 4207 with H H terminals 34 5 2 6 Gerapid 2607 4207 with V V terminals 35 5 2 7 Gerapid 6007 TERMINAS asp tese 36 5286 Gerapid S007 ol 37 6 INSPECTIONS AND MAINTENANCE 38 SAME Un Pee ET 38 6 1 1 General visual iINSpection since 39 6 1 2 General functional inspection 39 SS nspectoim Ol the ORC CUS oec ten 39 6 1 4 Inspection of the contact s
67. ons are subject to change without notice Hints for parts identification 128 122 RO2 128 121 128 810 128 521 R01 R02 128 525 R01 RO2 128 525 ROS RO4 128 815 Alas 128 515 RO1 RO2 128 529 128 058 49 6 3 2 Electrical spare parts SU control PCB N A 128 700 Interface plug External supply 24 V DC 5 128 730 PCMD 150 24 S24W GE 128 730 PCMD 150 48 S24W GE 128 730 Voltage converter PCMD 150 110 S24W GE 128 730 PCMA 150 70 S24W GE 128 730 Standard NEKO PCB 128 750 External NEKO 3C PCB ALL obsolete 128 755 External NEKO 4C PCB _ ALL obsolete 128 755 s ue 2607 4207 for 35 C ambient 128 785 contro 2607 4207 for 55 C ambient 128 785 Connector X2 DFK PC 4 12 GF 7 62 Connector X3 X4 X5 DFK MSTB 2 5 15 GF 6 3 5 Recommend materials for selected works 50 128 018 128 019 128018 128019 Standard parts glues pastes and greases are recommended for a maintenance stock Work to do Spare parts Standard parts Misi and optional components 1 Arc chute change Correct version of arc chute 128 550 Screws amp Washers M6x16 8 8 ISO 4762 M6 toothed Rip Lock M6 conical spring DIN 6796 Arcing contact arc Correct version of the service kit APN340110 Screws amp Washers M6x16 A4 DIN 4762 M6 runners and protective consist of toothed Rip Lock Retain ring 4 DIN 6799 Disc walls change Arcing contact spring 12 5 type A DIN 2093 Two arc runn
68. option for 110 125 220 V DC external control supply Optionally it s possible to supply both devices directly to external 24 V DC 5 In this case the release signal for ST shall not be longer 100 ms The ST is used for remote actuation It is designed for short time operation with max duty cycle of 9 96 ST s supply is connected through auxiliary contacts which cut off supply voltage after opening This protects ST against overheating Design and specifications are subject to change without notice The UVR Fig 9 is used for remote actuation and in combination with an internal electronic control for voltage control The UVR releases at voltage interruption or supply voltage drop below 20 V In these cases UVR trips the breaker It is therefore possible to use this device in combination with the electronic trip unit for voltage monitoring where an unintended re start of machines after a temporary voltage breakdown is to be prevented The UVR is intended for continuous operation Its rated power is 10 W Due to its operational mode the UVR is a self monitoring device i e when the breaker is tripped upon a break of the pilot wire EMERGENCY OFF principle NOTE Manual closing of the breaker with ST installed while pushbutton OPEN is pressed and control power applied might lead to ST coil s overheating and damage Fig 9 Zero voltage release 3 2 7 Forced tripping release Code 13 Optionally the forced tripping r
69. out notice a E i rm 2 per eor 1 e A T it eOUN SD SG ie Su SN EM WARNING Manual closing and opening only during maintenance Fig 11b Opening operation by using hand lever Alternative manual closing and opening operation is possible by rotating the main shaft of the breaker mechanism which is accessible from the side Use 10 mm hexagon socket wrench to OPEN CLOSE Fig 11c WARNING Pay attention to control rotation speed of the shaft during manual opening Impede the wrench to avoid hitting it to the ground which may lead to a hand injury WARNING Manual closing and opening only during maintenance Fig 11c ON OFF operation by using a 10 mm wrench 3 2 9 Auxiliary switch Code 9 e Standard breaker can be equipped with 3 5 or 10 isolated form C invertible auxiliary contacts 1 NO NC each The movable main arm activates the contacts e The contacts are wired to 15 pin control terminals X4 and X5 with 5 switches to each terminal Fig 21 e Conventional thermal current Ith 10A Maximum electrical ratings for switches are 1 A 230 V for AC15 For DC13 are 0 5 A 110 V and 0 3 A 220 V Fig 12 Auxiliary contacts layout in control box 3 2 10 Indicators Optionally the circuit breaker can be equipped with following indicators e POSITION INDICATOR Code 14 mounted at the front of the closing drive Mechanically switched by means of drive s rod Indica
70. r shall provide fused means for safe switching the voltage to the coil See table 2a for coil parameters e Auxiliary contacts used for cutting off shunt trip coils are internal breaker s components Fig 27b Special versions of shunt trip with a single and double winding coils directly supplied from external DC source 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 4 3 7 Zero voltage release control circuit Closing STOP relay 36 X LL Key position 5 Key number 00 Without shunt trip or zero voltage release Key number 20 With zero voltage release e The closing STOP signal is provided for resetting K2 on the SU control circuit It effects with priority in switching OFF by ST or UVR before switching ON Once switching ON and OFF signals are simultaneous switching OFF command will stay longer than switching ON It means that OFF command is master command e S2 X2 6 7 is NO contact utilized for indirect releasing of the UVR by relay K2 e S2 X2 8 9 is NC contact utilized for direct releasing of the UVR If it s not used please short this connection permanently Fig 28 UVR control circuit 24 Design and specifications are subject to change without notice S47183RO1EO06 2012 11 21 4 3 8 Indicators 36 _ X B Arc chute indicator Key position 6 Key number 00 Without indicators Key number 01 With OCT trip target only Key number 02
71. rnings Section 1 A Remove the arc chute and adapter e See 6 1 4 A B B Check the tilt of the main contacts e Fig 45 Use the hand lever for slowly closing the main contacts e Fig 46 Once the arcing contact touches arc runner check the air gap between main contacts The gap between main contacts shall have more than 1mm 0 04 in e Incase of insufficient tilt gap replace the arcing contact with new one See 6 2 1 and 6 2 2 for details e f required gap is not available even after component replacing please contact GE Service Team C Check the air gap of arcing contact e Close the breaker and secure the solenoid drive against unintended opening See 1 2 1 e Fig 47 Check the air gap between the arcing contact and main arm It shall be minimum 1 mm 0 04 in e In case of insufficient gap replace the arcing contact with new one See 6 2 1 and 6 2 2 for details e f required gap is not available even after contact replacing please contact GE Service Team D Install back adapter and arc chute e See 6 1 4 G H 6 1 6 Inspection of the screw connections Pay attention to the warnings Section 1 e Fig 41 Tighten front and backside of the arc runner screw connections 3 and 5 Use torque of 10 Nm 88 in lbs e Fig 41 Tighten arc chute connections 4 Use torque of 5 Nm 44 in lbs e Fig 41 The arc runner s screw connections 3 must be secured by means of lock washer e Fig
72. rovides his own solution for releasing of the ED coil by means of external capacitor trip device The NEKO control unit is not furnished and coil is connected directly to front panel of control box x2 10 11 eeseseccocssceocsssecoocscococssscocosssococssseocosssococssccocosssococssscocosssococssccccosssccocsoccccosscococsoccocossccecocssccocscscococssccecoocssocesscccoossscecooo ED impulse coil y AL L o a Poe eee eee ee eC eS e eee ree reer ecee rer reser reese errr cer rr reser reser ree rer er eres rere ese seer r ese e reese seer reser reece sree reser reese sree res rere ese r reer esr e reece sree resis Key position 3 Key number 0 Without ED coil Key number 1 With ED coil and external C bank Fig 24 ED coil with external Capacitor trip device 2012 11 21 S47183RO1E06 Design and specifications are subject to change without notice 19 4 3 4 NEKO control circuit ea AAA A A X10 11 Isolating Transformer 2 81 24 Vdc NI M e pa Charging Control charging l C bank l signalization l 7 TRE MENS Charging Voltage Control Closing d 2 A SR STOP rela d tel OT M EE ie ee EE CORR Cut off X2 contact l ETE O ngu RCRUM roe 101 Sap Input circuit for firing signal E des dg PE nece Firing sign
73. shall be 8V to 24 V DC and shall be connected at terminals X2 10 11 in standard wiring scheme Customer supplied capacitor trip unit may be used Rated voltage of 300 V and capacity of 2 000 UF is required In this case only ED coil will be installed in the breaker WARNING Firing signal voltage level is between 8 V and 24 V There should be no spikes on the signal of duration less 3 ms This can lead to defect of the NEKO board WARNING Maximum duration of the firing signal must not exceed 1sec Longer signal can lead to NEKO overheat It is recommended to use an auxiliary contact in serial connection with firing circuit X2 10 11 It will automatically cut off the firing circuit after breaker opening Fig 8 ED impulse coil with seesaw interface 3 2 6 Auxiliary tripping devices Code 11 The breaker can be equipped with either a shunt trip ST or a zero voltage release UVR It is not possible to have both devices installed in the same breaker Both devices are interchangeable In standard configuration internal voltage converter Code 8 transforms external voltage into 24 V DC which is required by ST or UVR Both devices are tripped by a potential free contact connected as shown in section 4 2 Optionally ST can be connected directly to external voltage In this case extinguish capacitors and diode is used to improve switching of the shunt trip s coil Fig 19 4c Double winding shunt trip is available with this
74. spection Pay attention to the warnings Section 1 In order to check the latch mechanism the breaker can be opened and closed with a hand lever Fig 40 Using of the hand lever Re energize the control circuits and switch the breaker ON and OFF several times using ST or UVR and using closing drive The contacts must close after the CLOSE command and must open following the OPEN command The breaker mechanism must not appear sluggish nor must ON OFF be unduly delayed 6 1 3 Inspection of the arc chute Pay attention to the warnings Section 1 A Remove the arc chute Fig 41 Take off isolation caps 6 Loosen the clamping screws 3 and 4 using SW5 hexagon wrench and take off the arc chute 1 from the adapter 2 B Check the arc chute Fig 42 Check the arc chute s interior as far as possible for deposits 1 There should be no copper pearls on the metal plates which could partially short the plates Fig 42 Check the general condition of the insulation plates 4 These shall not be bent or burned Also other insulation shall not be heavily damaged Fig 42 Check the arc horns 2 The cross section shall not be reduced more than 30 96 Fig 42 Check the splitting plates 3 These shall not be burned more than 20 mm 0 8 in C Install the arc chute Fig 41 Put arc chute 1 into adapter 2 Fig 41 Tighten front and backside connections of the arc runners 3 including
75. stem introduced in 2008 is a catalog configuration tool based on Excel The catalogue code consists of 20 digits Each digit represents specific rated value or component Table 7 shows all available values components and accessories for the Gerapid breaker family Detailed descriptions are available in section 3 Please contact GE Sales representative in case of any questions The coding system is valid for Gerapid feeder type F rectifier type R and disconnector type DS This User Manual relates only to standard feeder type breakers F Not all of the options from Table 7 are compatible To avoid improper configurations use the Gerapid configuration tool for ordering This Excel based tool provides a quick and mistake proof configuration with automatic generating of the proper catalogue code and set of characteristics helpful for order description Ask your GE Representative for details The number of this tool is APN460437 2012 11 21 S471835RO1E06 Table 7 General options overview for Gerapid breakers Relevant standards Railway DC acc EN50123 2 1 2 3 4 5 6 7 9s89 9 1 11 Gerapid 2607 Gerapid 8007R LV DC acc IEC60947 2 Gerapid 4207 Gerapid 10007R On Request LV DC acc IEEEC37 14 2 Gerapid 6007 Gerapid 8007DS China acc IEC947 2 amp GB14048 2 3 Gerapid 8007 Arc chute type Gearapid SE retrofit Railway amp Industry applications 1 1X2 1
76. tes position of the main contacts 0 means contacts are open l means contacts are closed Fig 13 Position indicator e OC TRIP TARGET Code 10 a potential free NO contact mounted at the top of the OCT Fig 14 Provides a signal when OCT trips Fig 14 OCT trip target 10 Design and specifications are subject to change without notice e ARC CHUTE INDICATOR Code 17 a potential free NO contact mounted on the sidewall Locks electrically the closing drive when arc chute is not installed on Fig 15 Fig 15 Arc chute indicator 3 2 11 Solenoid closing drive Code 3 e A high power solenoid is used to perform fast closing operation This drive is mounted at the front of the breaker and is encased in a grounded casing Fig 16 e Closing drive is supplied independently from other controls X2 1 2 directly from external power source Voltage level must be defined at order placement Rated power depends on breaker type but is between 1 8 kW and 2 6 kW e CLOSING command is enable by external potential free contact at X2 4 5 Signal duration shall be 300 ms e The closing drive system always includes a self interrupt control circuit SU PCB This circuit enables short activation with a time of 150 ms SU switches power to the solenoid and automatically disconnects it after 400 ms e The SU unit also prevents repeated drive closing due to an existing and continuous short circuit conditio
77. tion Pay particular attention to the area around arc runner bend 3 and at contact point with arcing contact 2 E Check the arcing contact e Fig 44 Wear of the arcing contact 1 must not exceed 2 mm 0 08 in of its depth Replace the arcing contact in that case If contact erosion exceeds 4 mm 0 16 in major contact system failure is possible F Check the main contacts e Fig 44 The main contacts 4 shall not show any particular signs of material erosion since the arc is ignited between the arcing contacts It means that for rated and overload currents there should be no erosion of main contacts e Erosion of main contacts can take place only in case of excessively worn highly burned arcing contact or during very high short circuit currents In that case wear must not exceed 1 5 mm 0 06 in G Install the adapter e Fig 43 Install the two protective walls 3 Use new ones if necessary Install two parings of adapter 2 and tighten screws 1 use 10 Nm 88 in lbs H Install the arc chute e Fig 41 Put arc chute 1 into adapter 2 e Fig 41 Tighten front and backside connections of the arc runners 3 including lock washer use 10 Nm 88 in Ibs e Fig 41 Tighten front and backside of the arc chute connections 4 including flat washers use 5 Nm 44 in Ibs Put on isolation caps 6 S47183RO1E06 2012 11 21 6 1 5 Inspection of contacts tilt and gap Pay attention to the wa
78. ystem 40 6 1 5 Inspection of contacts tilt and gap 41 6 1 6 Inspection of the screw connections 41 6 1 7 Inspection of the mechanical components 41 6 2 List of maintenance works ses 42 6 2 1 Contact system after 11 2003 43 6 2 2 Contact system before 11 2003 ees 44 6 2 3 Layout of control PCB inside control box 46 6 2 4 Replacement of the control boards 46 6 2 5 Adjusting the auxiliary switch s s 48 D 5 SPOIPDIHe sion uu apes as 49 6 3 1 Mechanical spare parts 49 6 52 Electrical spare D GIN tecate 50 6 3 3 Recommend materials for selected works 50 PCU TOMER SUPPORT enc 51 LL Opuons OU 51 T2 o ssec Ru MM EE 52 ya Me EGG Ole OU Ol Gel o o aida 53 1 2 2 Example OF Ordr MO Less 54 A 8 219 jo 2 8 MO 8 ALO aks ae PA 55 ER oS 6 gv E S 56 E TEOBIDISSPIOD UID temet Perret 57 o GE SENVICE TEOS ema O 58 es 59 Design and specifications are subject to change without notice 3 1 Warnings A Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock Warnings During operation electrical equipment carries dangerous voltages In addition circuit breaker emits hot ionized gases when switching currents especially short circuit currents Installing commissioning maintaining changing or refitting of this equipment must

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