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Maintenance Manual

1. 1A MAX 30 sec MAX 23 sec Or or High Set 80 160 X 1B INTER 15 sec 2B INTER 15 sec up to 15X EC 1 10 or or Non Adjustable 1C MIN 5 sec 2C MIN 07 sec 2AA MAX 20 sec 80 160 X 1BB MAX 4 5 sec Or 4 9X EC 18 15 or 2BB INTER 13 sec 6 12X 1CC MIN 2 sec Or 9 15X or 2CC MIN 07 sec 80 250 X 1 X Trip device ampere rating If trip devices are set above 100 3 At lower limit of band at 22 times pickup setting for coordination purposes such settings do not increase the breaker s 4 Low set instantaneous Not available in combination with long continuous current rating time delay 2 At lower limit of band at 6 times pickup setting 86 13 1 Direct Acting Tripping Device EC 1B The type EC 1B overcurrent tripping device is a direct acting device that causes the power circuit breaker with Which it is associated to open within a predetermined time range which depends upon the magnitude of the current overload The EC 1B tripping device can be constructed to supply a variety of different types of time current charac teristics either alone or in combination These are long time delay short time delay and instantaneous and they are identified respectively by numbers 1 2 and 3 Charac teristics are further broken down within each of the first two of these general classifications into maximum intermediate
2. lt T X iu CO o o G em Q a T 5 Sa 100 AKR 9D AKS 5A 50 Types AKR 75 100 and AKS 6D 75 AKR Low Voltage Power Circuit Breakers Table of Contents Description SECTION 1 Introduction 1 1 Inspection and Maintenance 1 2 Renewal Parts Tv age SECTION 2 General Description 2 1 Frame SIZ6 xs s s ba Kw EXC RR ACERO CR 2 2 OD TALIOM uuu v o ERO state cr c 2 3 Mounting s sos ke hax ERE REC os 2 4 MID DEVICE ss torut do ns 2 5 Short Circult Ratings SECTION 3 Storage Safety and Maintenance 3 1 Storage daba eti ia ete secte aa 3 2 Safety ss tet sd o ceo E 3 3 Maintenance RE SECTION 4 Breaker Operation 4 1 Manual Closing ST 4 2 Electrical Closing 42 1 Alternate Control Circuit 4 3 Connections SS 43 1 Stationary Breaker 4 3 2 Drawout Breaker 4 4 Tripping SEED D T DD D DD 4 5 Charging and Closing Using the Malntenance Handle SECTION 5 Contact Maintenance 5 1 Slow Closing the Breaker 5 1 1 Electrical AI V 51 2 Manual M T TD 5 2 Arc Quencher Removal and Inspectlon 5 2 1 Removal and Replacement 5 3 Separatlon of Front and Back Frames
3. 5 4 Back Frame Assembly 5 5 Measuring Contact Force 5 5 1 Statlonary Arcing Contacts 5 5 2 Stationary Main and Intermediate Contacts 5 6 Measuring Contact Wlpe 5 7 Adjusting Contact Wipe 5 8 Measuring Contact Open Gap 5 9 Checking Contact Sequence 5 10 Replacement of Contacts 5 10 1 Statlonary Arcing Contacts 5 10 2 Movable Arcing Contacts 5 10 3 Movable Main and Intermedlate Contacts 5 10 4 Stationary Intermediate and Maln Contacts 5 11 Assembly and Adjustment of Crossbar O 1993 GENERAL ELECTRIC COMPANY 933 Description Page SECTION 6 Breaker Maintenance 26 6 1 ENS Precautlons A 26 6 2 T E JII 26 6 3 Breaker Mechanism Adjustments 26 GT LT 26 6 3 2 eee P 26 6 3 3 Reset Latch Bearing and Prop 26 6 4 Electrical Mechanism 28 6 4 1 Control Components 28 DA Charging MORE F x s o s 29 643 Motor Operator Unit 30 6 4 4 Spring Discharge Interlock 32 6 5 Manual Mechanism 32 6 5 1 Mechanism Part Replacement 33 6 5 2 Ratchet Pawl Replacement 35 6 5 3 Adjustments E MM lt lt oes 35 6 6 Drawout M
4. SECTION 1 Introduction Introduction These instructions provide the maintenance procedures and describe the operation of the 1600 thru 4000 amp AC 6000 amp DC frame size type AKR AKS low voltage power circuit breakers listed in Table 1 and Table 2 The proper use care and maintenance of these breakers is a prime safety consideration for the protection of personnel as Well as a means of minimizing equipment damage when faults occur Persons who apply use and service these breakers will acquire the knowledge they need by gaining the information contained in these instructions 1 1 Inspection and Maintenance Breakers should be cared for under a systematic maintenance program Taking each breaker out of service periodically for inspection and maintenance is an excellent means of establishing high service reliability It is good policy to have one or more spare breakers to install in place of breakers requiring maintenance Keeping a stock of recommended renewal parts will insure that maintenance work can be done quickly How frequently an individual breaker should be inspected will depend on the circumstances of its use It would be well to inspect any breaker at least once a year If it is frequently operated or installed in an area of high humidity or a dusty dirty atmosphere inspections should be more often Inspections might be monthly under adverse conditions Table 1 AKS 50 Designations FRAME SIZE Ampe
5. ACTUATOR BRACKET BUFFER STUD POSITION TRIP PADDLE IN MECHANISM RESET POSITION TRIP ROD 0 109 DIA IN RESET ROD POSITION ADJUSTER END Fig 68 Flux shift trip device adjustments Fig 69 SST ECS test set cat no TAK TS1 53 SECTION 8 Type SST Overcurrent Trip Device 8 4 Troubleshooting When malfunctioning is suspected the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as a Breaker tripping in proper response to overcurrents or incipient ground faults b Breaker remaining in a trip free state due to mechanical interference along its trip shaft c Inadvertent shut trip activations WARNING DO NOT CHANGE TAPS ON THE CURRENT SENSORS OR ADJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CARRYING CURRENT Once it has been established that the circuit breaker can be opened and closed normally from the test position attention can be directed to the trip device proper Testing is performed by either of two methods 1 Conduct high current single phase tests on the breaker using a high current low voltage test set NOTE For these single phase tests special connections must be employed for SST breakers equipped with Ground Fault Any Single phase input to the ground differential transformer will generate an unwanted ground fault output signal which will trip the breaker This can be nullifie
6. Fig 20 Re assembly of arcing contacts Fig 19 Upper stud details 11 Assembly and Ad screws with locking plates on crossbar finger tight and set crossbar to dimension shown making sure that all three tment of jus 5 poles of moveable arcing contacts are touching stationary Crossbar When assembling crossbar to back frame push moveable irst tacts within 032 Tighten screws as shown f A second B and finally C to 400 inch pounds Bend tabs on locking plates to secure screws Refer to Fig 21 arcing con ionary arcing il they touch stati tacts forward unt contacts on upper terminal Then lay crossbar on top of links on pole units Assemble adjusting plates as shown 4 arcing con 0 me o ie hs CC O O O _ O E LI a D gt 3 05 4 Adjustment plates After assembling crossbar always check contact wipe and open gap see Sections 5 6 thru 5 8 tacts a ionary arcing con f 1 Crossbar 2 Stati making sure slots in plates are properly oriented Fasten Fig 21 Crossbar assembly 25 SECTION 6 Breaker Maintenance Breaker Maintenance 6 1 Safety Precautions BEFORE INSPECTION OR ANY MAINTENANCE WORK IS DONE BE SURE THAT THE BREAKER IS IN THE OPEN POSITION ALL ELECTRICAL POWER BOTH PRIMARY AND CONTROL SOURCES SHOULD ALSO BE DISCONNECTED ENSURE THAT THE CLOSING SPRINGS ARE DISCHARGED 6 2 Lubrication In general the circu
7. The remote fault indication switch leads are brought out the bottom of the MicroVersaTrip programmer as shown in Fig 80 This switch lead harness is plugged into the mating connector on the breaker see Fig 81 The switch leads are brought out from the breaker through the Programmer Secondary Disconnect shown in Fig 82 The zone selective interlocking function wiring is also brought out through this disconnect See Figs 76 and 77 for the remote fault indication and zone selective interlocking cable diagrams REMOTE FAULT INDICATION CONNECTOR Fig 80 MicroVersaTrip w remote fault indication harness Fig 82 Programmer secondary connector 62 md Remote fault indicator disconnect Fig 81 Remote fault indicator disconnect 10 2 MicroVersaT rip Installation The programmer is located on the left side of the breaker s center channel as shown in Fig 81 It mounts to the bracket assembly shown in Figs 83 or 84 Referring to either Fig 83 or 84 the guide pins mate with the holes on either side of the programmer connector They provide the necessary alignment for the connector engagement The locking lever engages with the pin which is assembled to the programmer frame and secures the programmer to the mounting bracket 10 2 1 AKS 50 Installation The AKS 50 mounting bracket is shown in Fig 83 Installation is as follows a Insert the guide pins into the holes and push on the programmer This will enga
8. a REVERSE CURRENT 3 E DEVICE TRIP POTENTIAL e SOURCE Fig 4 Control connections to stationary breakers front view TRIP vaT SOURCE TRIP CLOSING SOURCE E TARAAAAA 7654321 7654321 7654321 B c STATIONARY SECONDARY DISCONNECT BLOCKS LOCATED AT TOP OF COMPARTMENT POSITIONS B AND C FURNISHED ONLY WHEN REQUIRED Fig 5 Control connections to drawout breakers front view of breaker compartment 12 4 4 Tripping In the closed position the breaker movable contacts are held in by a toggle linkage The breaker is tripped open by displacing a mechanism latch which allows this toggle linkage to collapse The trip latch is rigidly fastened to a horizontal trip shaft running from left to right through the breaker In turn the trip shaft carries paddles actuated by the manual trip button and the various other trip devices overcurrent reverse current shunt trip undervoltage open fuse lockout Viewing the breaker from the right rotating the trip shaft counterclockwise trips the breaker clockwise movement resets the mechanism latch In addition to tripping the breaker some devices hold the breaker trip free e prevent the contacts from closing even though a closing impulse is applied to the mechanism Such devices are the undervoltage bell alarm and lockout electric lockout open fuse lockout and the key operated locks These devices and the drawout mechanism interlocks must be in t
9. a Install the safety pin 3 as described in Section 5 1 2 b Remove the closing spring assembly by removing the upper and lower spring pins 1 31 c Remove the right hand bearing side plate 20 and the side plate shims 18 by removing four mounting bolts 19 thus allowing the main closing crank 25 to be removed 21 Ratchet pawls 25 Main closing crank 26 Pawl buffer stop 27 Buffer stop shims 31 Lower spring pin 33 Ant rebound spring 34 Ant rebound pawl d Remove the closing handle 22 by removing two set screws threaded in same hole e Remove the front escutcheon by removing four screws holding it to the front frame center support f Remove handle shaft extension by removing roll pin g Remove the handle return spring 29 by unhooking either end of the spring h Disconnect the top end of each pawl spring 7 i Remove the roll pin 24 thus allowing the closing handle shaft and pawl assembly 23 to be removed j Remove the ratchet wheel 17 and its assembly 16 by removing self locking screw 15 and thrust bearing 12 If shims 13 are present they must also be removed Continued next page 33 SECTION 6 Breaker Maintenance MANUAL MECHANISM Partial Front View With Handle And Escutcheon Removed 1 Upper Spring Pin 12 Thrust Bearing 24 Roll Pin 2 Safety Pin Holder 13 Shims 25 Main Closing Crank 3 Safety Pin and Chain 14 Groove Pin 26 Pawl Buffer Stop 4
10. A 50V AKS S 50V 2 AKST 50H AKST A 50H AKST S 50H 1 1600 AKSU 50 AKSU A 50 8 1 The H suffix denotes extended short circuit ratings 2 Integrally fused models This digit identifies the trip device type as follows 2 EC 1 or EC 2A Dc only s er 50 60 Hertz only 6 MicroVersaTrip N Non automatic In addition all non automatic 250 VDc breaker types carry the suffix letter D after their frame number e q AKS N 50D EC 1 8 EC 2A trip devices are the electro mechanical type ECS SST MicroVersaTrip RMS 9 and MVT Plus or MVT PM units are Solid State For detailed information on these trip devices refer to Sections 8 thru 11 7 RMS 9 9 MVT PLUS or MVT PM Table 2 AKR 75 100 Designations FRAME SIZE Gd sida BREAKER 250V Dc 900V Ac DESIGNATION DRAWOUT 50 60 Hz AKD 4000 AKR A 75 B 75 nc D o NE A MOUNTING TYPE Stationary ESCUTCHEON X d LM AKR S 7 AKR D 75H AKR F 75H AKR A 10 AKR B 10 0 ol 6000 4000 AKR C 100 oj 0 ME NEN x x lt x lt MD TE 3200 F AKR F 100 AKR S 100 a AKR W 100 SPECIAL DC BREAKERS FOR FIELD SWITCHING ARK N 75F X AKR NB75F X 4000 AKR ND 75F x AKA NF 75F X AKR NS 75F AKR N 100F X
11. out of trip settings 3 phase ammeter and trip indicators are standard as is a clear plastic cover with provisions for sealing to allow tamper resistant installation The trip unit digitally measures the current waveform in each phase to de termine the true RMS value of the current regardless of the waveshape MicroVersaTrip Plus trip units provide accu rate predictable overload and short circuit protection for dis tribution systems that include ac and dc variable speed drives rectifiers induction heating and other loads that cause high harmonic distortion as well as standard circuit They provide maximum breaker to breaker selectivity and custom load protection Short time and ground fault func tions include the flexibility of coordination with or without an lt ramp and are also available with high range instanta neous MicroVersaTrip PM Trip Unit MicroVersaTrip PM trip unit adds power management sys tem capability advanced metering and protective relays to the basic functions of the MicroVersaTrip Plus MicroVersaTrip PM trip units communicate directly on the GE POWER LEADER communications bus Power Requirements A small amount of power is necessary to energize the liquid crystal display LCD during setup for viewing breaker status and for metering displays MicroVersaTrip PM trip units re quire external 24 Vdc control power for operation The four sources of such power are the following e Flow of current Br
12. 6 6 3 2 Latch Buffer Referring to Fig 22D the center line of the trip latch 10 should pass through the center of the roller 9 The latch buffer 18 on the mechanism frame can be adjusted by loosening the retaining screws to reposition the latch with respect to the roller 6 3 3 Reset Latch Bearing and Prop Referring to Figs 22C 22D amp 24 the distance between the bearing 17 and the prop 5 should be between 015 and 032 To obtain this gap advance or retard the nuts 4A on the bottom of the rod using the reset spring 4 Fig 22B Mechanism in reset position Trip latch Cam Trip shaft Link Clevis pin Reset spring Clevis Spring adjusting nuts Reset latch Prop Roller Adjusting screw Prop Adjusting screw stop pin Bearing Prop return spring Buffer Roller Nut Fig 22C Mechanism in closed position Fig 22D Latch bearing and prop closing spring discharged 1 Feeler gage 2 Trip latch 1 Feeler gage Fig 23 Adjusting trip latch and roller Fig 24 Adjusting bearing and prop 27 SECTION 6 Breaker Maintenance 6 4 Electrical Mechanism The function of the electrical mechanism is to charge and discharge the closing springs either electrically or manually The electrical mechanism consists of a b C d Control components Charging motor Motor operator unit Spring discharge interlock Section 4 2 details the associated control circuitry for the electrical mechanism
13. AKR NB 100F X 6000 D H AKR NF 100F X __AKR NS 100F AKR Nw t00F Example AKR 5B 75 identifies a drawout substructure mounted breaker equipped with the SST trip device The EC trip devices are electro mechanical refer to GEI 86157 for detailed information Breaker Models This digit identifies N Non automatic the trip device In addition all 2 EC 1B Dc only non automatic 250V 4 ECS Dc breaker types carry the 5 SST 50 60 Hertz only suffix letter D after the 6 MicroVersaT rip 50 60 Hertz only frame number 7 RMS 9 e g AKR NB 75D 9 MVT PLUS or MVT PM AKR 75H not available for DC applications For detailed information on these trip devices refer to Sections 8 thru 11 SECTION 2 General Description General Description Type AKR low voltage power circuit breakers are used for con trolling and protecting power circuits in the low voltage range usually up to 600 volts In serving this function they are a means of safely switching loads and automatically clearing cir cuits when abnormal conditions occur Among these condi tions the more common are short circuits and sustained overloads and undervoitages The type AKR breakers are of the quick make quick break description having the feature of storing energy in a closing spring for quick release in closing In closing some energy is transferred to an opening spring to be used
14. The mounting type is identified by the second middle digit in the breaker nameplate designation as follows EC devices See Section 11 AKR 4 1 75 where 2Power Sensor devices are discontinued See publications f mounting type code letter per Table 3 GEK 7301 and GEK 7309 for detailed servicing procedures 2 5 Short Circuit Ratings Short circuit ratings vary with the applied system voltage On 240 VAC systems they are also dependent upon whether the overcurrent trip device contains an instantaneous trip element See Table 5 Table 5 Breaker Interruption Ratings 30 Interruption Rating KA RMS Symmetrical Instantaneous Trip Frame Size Amperes Short Time Rated Maximum Voltage 60 Hz AC 635 AKS 50 508 254 1600 AC 635 AKS 50H 508 254 gt AKSU 50 AKST 50H AKR 75 om Breaker Type Eh NO C O O A on N on O Oo qa Pa Cc nj ND O a a sz o O o rn A n2 200 NO e Co Co o A al C C NO e O I Cc Cn NO O Q3 al C e 00 C 7 254 35 508 254 635 AKR 75H 508 254 130 O Cc 3200 AC Co on 00 on AKR 75 fused 635 AKR 100 508 4000 AC 254 130 AKR 100 fused 200 AKS 50 2000 DC AKS 50V 300V DC 50 D 4000 DC AKR 75 300V DC 50 6000 DC AKR 100 300V DC 50 With 200 2000 amp trip coils Consult factory for application data NO e NO NO Co Gn on Co Co Ojo Cc al Cn Cn Co SECTION 3
15. phase and neutral sensors are electrically identical their tap to tap resistance should closely agree See Table 9 or Table 10 95 FLUX SHIFT PROC TRIP DEVICE BREAKER BACK FRAME T D m g 48V dc A TO SCR LEFT POLE ANODE CURRENT SENSOR HARNESS CONNECTOR AMP 201298 1 PROGRAMMER CONNECTOR AMP 201297 1 Fig 70 Cabling diagram SST without ground fault TRIP DEVICE BREAKER BACK FRAME T D m C 48V dc TO SCR LEFT POLE ANODE CURRENT SENSOR HARN CONNECTOR PROGRAMMER AMP 201298 1 CONNECTOR AMP 201297 1 Fig 71 Cabling diagram SST with ground fault on 3 wire load 56 FLUX SHIFT Ei Ti DA TRIPDEVIGEA AN 77 BREAKER AN Nm BACK FRAME T BED 4 E 1 LEFT POLE CURRENT SENSOR TO SCR ANODE NEUTRAL NEUTRAL SENSOR DISCONNECT A HARNESS PROGRAMMER CONNECTOR EQUIPMENT MOUNTED AMP 201298 1 CONNECTOR NEUTRAL SENSOR 4 AMP 201297 1 4 WIRE LOAD Fig 72 Cabling diagram SST with ground fault on 4 wire load BREAKER HARNESS GROUND FAULT DEFEAT CABLE iiri tia CONNECTOR CAT NO TGFD UNIT 4 ASS r ON B Fa 71 CURRENT Eo sensors o Fa 3 e EC or 2 ANY Sst Da Pool koje AE O BE Teje Fc Pr GROUND FAULT TH ELEMENT a ne F LS OC Do Hoo Aan ma S LOL SED Loni neutral OFS fect yy DO PR OY TS yy
16. subsequently for fast tripping Knowledge of how the breaker is designed and how it operates will enable the purchaser to make proper use of the breaker and to avoid mistakes in its operation Specific directions on adjustments and maintenance procedures will be treated later The three main functional components of a breaker are its mechanism an assembly comprising the conductive members and the interrupter The mechanism unit is designed to receive energy store it and later when called upon to do so deliver it to close the breaker contacts It must be able to reverse its commitment to close the breaker at any point upon the activation of an automatic trip device i e be Trip Free Finally it also must be able to trip open a closed breaker quicky enough to minimize arc erosion and in such a manner as to effect proper arc transfer to the arc runner The current carrying members of the breaker are assembled on the back frame which provides the mechanical support required and also the insulating structure needed The conductive members are the studs for external connections movable and stationary contact sets pivots for the movable contacts and provision for mounting the current transformers The interrupter components are in addition to the arcing contacts the arc runners mounted on the back base and the removable arc quencher assemblies In addition to these basic components a breaker may be equipped with any co
17. to the buffer stop 26 to provide a clearance of 1 64 to 1 32 inch between the pawls 21 and the buffer stop when the pawls are touching the ratchet wheel teeth extending a maximum distance from the center of rotation of the ratchet wheel 17 This measurement should be made while operating the closing handle during the four spring charging operations and before the closing springs are reassembled 3 The ratchet pawls 21 should operate freely throughout the closing strokes They should engage the ratchet wheel teeth near the end of each counterclockwise and clockwise stroke of the closing handle with a definite clicking sound indicating a free non binding operation After the clicking sound is detected the closing handle should have a minimum overtravel of vin or 3 degrees measured at the end of each handle stroke At the end of the four stroke the rebound stop 34 must move into place to properly position the ratchet wheel 4 The groove pin 14 in the front of the ratchet wheel assembly 16 must be assembled in a manner that will allow screw 15 to be tightened securely A clearance of 1 64 to 1 32 in should exist between the front of the groove pin and the rear surface of the screw head 35 SECTION 6 Breaker Maintenance 6 6 Drawout Mechanism c Remove racking cam assembly and replace with new Drawout breakers are manuafactured in five different adi styles depending on the type of equipment that the breaker d A
18. 2 Adjustment When this device is installed or replaced its positive ability to trip the breaker must be demonstrated Undervoltage devices trip the breaker when the armature opens This causes an extension of the armature to strike the paddle on the trip shaft An extension on the other end of the armature towards the front of the breaker extends through the device frame and limits the movement of the armature When the armature is released this extension stops against a stop which is factory set To check positive trip the armature should be held down the end of a 1 32 inch diameter wire should be inserted against the stop and the armature released If this trips the breaker the setting is correct The place to insert the wire is shown in Fig 54 Note that only the tip of the wire is to be against the stop If the undervoltage device does not have positive tripping ability the adjustment screw of the trip paddle assembly on the trip shaft may be turned in increments of half turns until the check is successful When the undervoltage device is closed and the breaker mechanism is reset there must be clearance between the trip paddle and the device armature Spring Bracket Adjusting plate and screw Shading ring Armature Coil Clamp Magnet Screws Pin Adjusting screws Locking wire Adjusting screws Trip paddle and clamp Mtg hardware D O O1 R L M New models may use
19. 5 Series Overcurrent Tripping Device EC 1 91 13 5 1 Short Time Delay Tripping 91 135 2 Long Time Delay Tripping 91 13 5 3 Instantaneous Tripping 92 13 5 4 EC 1 Adjustment 92 13 6 Positive Trip Adjustment 92 13 7 Reverse Current Tripping Device 93 13 7 1 AdjustMentS 44 94 13 7 2 Replacements e wees 94 13 8 Switchette Feature 94 13 9 Trip Device Replacement 94 SECTION 14 Electrical Characteristics 95 Table 23 Charging and Closing Operating Currents 95 Table 24 Bell Alarm Contact Rating 95 Table 25 Auxiliary Switch Contact Sequence 95 Table 26 Auxiliary Switch Contact Ratings 95 Table 27 Charging Times panda cas ews eet ses dis 95 Table 28 Shunt Trip and Undervoltage Device 96 Table 29 Lali HesistdliCO es spare nadaa 96 Table 30 Instantaneous Undervoltage Device Settings 97 Table 31 Time Delay Undervoltage Device Settings 97 THESE INSTRUCTIONS ARE INTENDED FOR USE BY QUALIFIED PERSONNEL FOR INSTRUCTION AND MAINTENANCE PURPOSES REPRODUCTION IN WHOLE OR IN PART IS NOT PERMITTED WITHOUT THE EXPRESS PERMISSION OF GENERAL ELECTRIC 3
20. Safety Pin Hole 15 Nylok Screw 27 Buffer Stop Shims 5 Closing Springs 16 Ratchet Wheel Shaft and Asm 28 Buffer Stop Support 6 Guide Rod 17 Ratchet Wheel 29 Handle Return Spring 7 Pawl Springs 18 Side Plate Shims 30 Mechanism Roller 8 Front Escutcheon 19 Side Plate Mounting Bolts 31 Lower Spring Pin 9 Front Bearing Plate 20 Bearing Side Plate 32 Output Crank 10 Bearing Plate Mounting Bolts 21 Ratchet Pawls 33 Ant Rebound Spring 11 Output Crank Roller 22 Manual Closing Handle 34 Ant Rebound Pawl 23 Closing Handle Shaft and Pawl Asm Fig 38 Manual closing mechanism charged position 34 k Remove front bearing plate 9 by removing mounting bolts 10 accessible from the front of the breaker The mechanism is now completely disassembled It is not recommended that any of the subassemblies removed during the above operation be further disassembled in the field Replacement sub assemblies should be obtained from the factory To reassemble the mechanism reverse the procedure described above and follow the adjustments given in Section 6 5 3 6 5 2 Ratchet Pawl Replacement The manual mechanism is inoperable with broken ratchet pawls Therefore the safety pin probably can t be inserted into the guide rod If this is the case the following procedure is used to replace the ratchet pawls Refer to Figs 37 amp 38 a Remove upper spring pin 1 by removing retainer ring and pushing pin through front c
21. Storage Safety amp Maintenance 3 1 Storage It is recommended that the breaker be put into service immediately in its permanent location If this is not possible the following precautions must be taken to insure the proper storage of the breaker 1 The breaker should be carefully protected against condensation preferably by storing it in a warm dry room since water absorption has an adverse effect on the insulation parts Circuit breakers for outdoor switchgear should be stored in the equipment only when power is available and the heaters are in operation to prevent condensation 2 The breaker should be stored in a clean location free from corrosive gases or fumes Particular care should be taken to protect the equipment from moisture and cement dust as this combination has a very corrosive effect on many parts CAUTION IF THE BREAKER IS STORED FOR ANY LENGTH OF TIME IT SHOULD BE INSPECTED PERIODICALLY TO SEE THAT RUSTING HAS NOT STARTED AND TO ASSURE GOOD MECHANICAL CONDITION SHOULD THE BREAKER BE STORED UNDER UNFAVORABLE ATMOSPHERIC CONDI TIONS IT SHOULD BE CLEANED AND DRIED OUT BEFORE BEING PLACED IN SERVICE 3 2 Each user must maintain a safety program for the protection of personnel as well as other equipment from the potential hazards associated with electrical equipment The following requirements are intended to augment the user s safety program but NOT supplant the user s respon sibility for de
22. T Time delay shown at 600 of 2 Time delay shown at lower X Rating plug amps Triple selective trip is 6 Time delay shown at lower current setting at lower limit limit of each band All pick S Sensor amp rating standard when long limit of each band of band up tolerances are 10 C Current setting time short time only Ground fault pick up not Is required to exceed 1200 amps 73 SECTION 11 RMS 9 and Epic MicroVersaTrip Trip Device 74 Fig 102 RMS 9 Phase Sensors Fig 103 H Option Phase Sensor Fig 104 Typical Neutral Sensor Fig 104 shows the neutral sensor The neutral sensor is re quired when integral ground fault protection is used on single phase three wire or three phase four wire systems It is inserted into the neutral conductor and therefore is sepa rately mounted in the cable or bus compartment The outputs of the phase sensors and neutral sensors are connected to a programmer circuit which sums these values The total value will remain zero as long as there is no ground current flowing See cable diagram in Fig 108 The neutral sensor is an electrical duplicate of the phase sensor Therefore when phase sensors are changed the neutral sensor must be correspondingly changed Since the neutral sensor is mounted separately from the breaker a disconnect means is required to connect its output to the breaker Fig 88 shows the breaker and equipment mounted 4th wire secondary disconnect
23. Table of Contents Description Page 8 42 Resistance Values 55 8 43 False Tripping Breakers Equipped with Ground Fault 55 8 5 SST Cabling Diagrams 55 SECTION 9 Type ECS Overcurrent Trip Device 58 9 1 ECS Cabling Diagram 59 SECTION 10 MicroVersaTrip Overcurrent Trip Device 60 10 1 Programmer Unit meme 60 10 1 1 Fault Trip indicators E 60 101 2 Remote Fault Indication 60 10 2 MicroVersaTrip Installation 62 10 2 1 AKS 50 Installation es iii 62 102 2 AKR 50 100 Installation 63 10 3 Current Sensors ERE EE 64 103 1 Replacement of Current Sensors AKS 90 rro mao emt 65 10 3 2 Replacement of Curent Sensors AKR 75 100 SA 65 10 4 Flux Shift Trip Device 65 10 5 Troubleshooti 65 105 1 Resistance Values 66 105 2 False Tripping Breakers Equipped With Ground Fault 67 106 MicroVersaTrip Cabling Diagrams 67 SECTION 11 RMS 9 Epic MicroVersaTrip 71 11 1 MAA A 71 11 1 1 Faslli E 71 11 2 RMS 9 amp Epic MicroVersaTrip Installation 71 113 Current Sensors 1 storas aas 42 11 3 1 Replacement of Current Sensors 75 11 4 Flux
24. These tests are conducted with the programmer unit disconnected from the breaker During test the unit can remain attached to the breaker or may be completely removed from it CAUTION NEVER DISENGAGE THE HARNESS CONNECTOR FROM THE PROGRAMMER UNIT ON A BREAKER ENERGIZED AND CARRYING LOAD CURRENT THIS WIEL OPEN CIRCUIT THE CUR RENT SENSORS ALLOWING DANGEROUS DAMAG ING VOLTAGES TO DEVELOP Test scope 1 Verify the time current characteristics and pickup calibration of the various trip elements 2 Verify operation of the SST target indicators on programmer units so equipped B Complete Trip Device System For these tests the programmer unit must be mounted on the breaker and connected to its wiring harness Test scope 1 All A tests previously described plus provision for optionally switching the programmer s output to activate the Flux Shift Device and verify its operation by physically tripping the breaker 2 Check phase sensor continuity In the event that any component of the SST system does not perform within the limits prescribed in test instructions GEK 64454 it should be replaced SECTION 8 Type SST Overcurrent Trip Device 8 4 2 Resistance Values For use in troubleshooting the Common to Tap resistance for SST current sensors is given in Tables 9 and 10 These values apply to both phase and neutral sensors Table 9 Sensor Resistance Values AKS 50 Breaker Resistance in ohms Fr
25. an overcurrent condition overcomes this restraining force the CN ne Si Pi TJ ZTT D T 27 ES m E A SIR ISSUE AAA 7 Left Side View Showing Short Time Delay Mechanism 13 5 2 Long Time Delay Tripping The armature 10 is restrained by the calibration spring 11 After the magnetic force produced by an overcurrent condition overcomes this restraining force the armature movement dashpot w characteris armature E im is further retarded by the flow of silicone oil in a hich produces an inverse time delay tic The mechanism is shown on Fig 126 HAS qo SS X AA A AMA A Right Side View Showing Long Time Delay Mechanism Front View Showing 1 Series coil 8 2 Magnet 9 3 Pallet 10 4 Pinion AJ 5 Escape wheel 12 6 Driving segment 13 7 S T D armature 14 Mounting Bracket S T D calibration spring Trip paddle adjusting screw L T D armature L T D or low set inst calibration spring Inst trip spring high set Spring holder Calibration clamp nut Plunger Cylinder Calibration plate Trip paddle Trip arm Clamping bracket Fig 126 Series overcurrent tripping device EC 1 91 SECTION 13 Type EC Overcurrent Trip Device 13 5 3 Instantaneous Tripping a Adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition overcomes the restraining force of
26. cal eto O O wih Sa ee IIS MALE FEMALE END END Fig 73 Cabling diagram with ground fault defeat cable inserted between breaker harness and SST programmer unit for use during single phase high current low voltage testing 57 SECTION 9 Type ECS Overcurrent Trip Device The ECS is a solid state direct acting self powered trip device system The ECS system consists of the ECS programmer unit shown in Fig 74 current sensors anda flux shifter trip device Fig 75 shows a block diagram of the system The ECS trip system essentially duplicates the SST trip system described in Section 8 except for the following 1 Programmer units are limited to combinations of Long Time Short Time and Instantaneous trip elements only The Ground Fault element is not available 2 Fault indicators trip targets are not available 3 Phase sensors are not tapped As listed in Table 11 each sensor has only a single ampere rating A different sensor is available for each of the tabulated ampere ratings which span the same range as SST see Fig 76 4 Neutral sensors are not required because there is no Ground Fault function In all other respects the ECS trip device system operates and can be treated identically to SST This includes circuitry size construction component location programmer unit set points performance characteristics operating range quality reliability and the flux shift trip device Use the same tro
27. indicated by the cabling sal p T T diagram of Fig 106 each phase sensor is connected to 4 summing circuitry in the programmer Under no fault condi C 4 wire tions on 3 wire load circuits the currents in this circuitry add to zero and no ground signal is developed This current sum CURRENT Ny will be zero only if all three sensors have the same electrical E characteristics If one sensor differs from the others i e dif L ferent rating the circuitry can produce output sufficient to A trip the breaker Similarly discontinuity between any sensor and the programmer unit can cause a false trip signal If nuisance tripping is encountered on any breaker whose RMS 9 or Epic MicroVersaTrip components have previously demonstrated satisfactory performance via the TVRMS Test Set the sensors and their connections should be closely LL scrutinized After disconnecting the breaker from all power KI T T T AR our a Check that all phase sensors are the same type am LORU AMP 1 350356 9 pere range b Verify that the harness connections to the sensors Fig 106 Cabling diagram RMS 9 amp Epic meet the polarity constraints indicated by the cabling MicroVersaTrip without ground fault diagram C c On Ground Fault breakers serving 4 wire loads check that the neutral sensor is properly connected see sneaker f An Fe PROGRAMMER cabling diagram Fig 108 In particular BACK TRIP DEVICE pose
28. onto the stationary disconnects of the enclosure 1 Secondary disconnect Fig 49 Secondary disconnects Fig 50 Secondary disconnect details 7 2 1 Replacement Replacement of the disconnects is given below Refer to Fig 50 a Unfasten disconnect body from breaker cross channel b Open tabs which hold wires on inner side C Pull contact tip loose from hollow tube d Remove contact tip by cutting wire at its base Continued next page 39 SECTION 7 Accessories 7 2 1 Cont e Push wire through hollow tube of new disconnect 7 3 1 Replacement assembly Referring to Fig 51 f Strip insulation off end of wire to about in from the GE SB 12 end s a Disconnect all leads g Place new contact tip on end of wire and crimp b Remove two mounting bolts h Pull wire through hollow tube until contact tip fits c Disengage auxiliary switch shaft 4 from triangular snugly against end of hollow tube link 2 i Crimp tab on other side of assembly to hold wire in d Orient the shaft of the new switch so that the arrow place stamped on the shaft end points towards the front of the breaker j Any hollow tubes which are not used should be pushed into the disconnect body and held in that position by placing fiber spacers over inner ends of tubes and e Push auxiliary switch shaft into square hole in link breaker open spreading tabs f Replace mounting hardware and wiring k When all wires have
29. reverse current tripping device see Fig 128 consists of a series coil 2 with an iron core mounted between two pole pieces 9 also a potential coil 7 connected across a constant source of voltage and mounted around a rotary type armature 10 Calibration spring 6 determines the armature pick up when a reversal of current occurs As long as the flow of current through the breaker is in the normal direction the magnetic flux of the series coil and the magnetic flux of the potential coil produce a torque 2A BT F 2B ki amp E9 EJ which tends to rotate the armature counterclockwise The calibration spring also tends to rotate the armature in the same direction This torque causes the armature to rest against the stop screw 12 attached to a bearing plate on the right side of the device If the current through the series coil 2 is reversed the armature 10 tends to move in the clockwise direction against the restraint of the calibration spring 6 When the current reversal exceeds the calibration setting the armature revolves clockwise causing the trip rod 3 to move upward engaging the trip paddle 1 thereby tripping the breaker Trip paddle Series coil Adjusting Nut Locking nut Trip rod Trip crank Setting sealing screw Calibration spring Potential coil Calibration nut Pole pieces Armature Counter weight Stop screw Mounting screw Screw o gt O NH WK amp D D
30. that it does not contact the trip paddle on the trip shaft until the air gap between armature and pole piece is reduced to 3 32 in or less measured at the rivet in the pole piece Also the armature must have a minimum of 1 32 in of travel beyond the point in its motion at which the breaker is tripped 89 SECTION 13 Type EC Overcurrent Trip Device a I ing justment indexi adjus Time 125 Ig E ink li ing Connecti 9 10 Ser ing tantaneous spri ins ion p Low seti 1 11 Movable nut ies coi late tment knob Calibrat 2 jus ime a Ad T 12 Instantaneous pickup adj 13 Dashpot tment screw jus d Instantaneous spr 3 4 ing 5 TES PTS 14 Operating arm Trip screw 6 15 Calibration marks Armature f Dashpot arm 8 EC 2A ice dev ipping Fig 124 Overcurrent tr 90 13 5 Series Overcurrent Tripping Device EC 1 movement is further retarded by an escapement mechanism which produces an inverse time delay characteristic The mechanism is shown on Fig 126 Each series overcurrent tripping device is enclosed ina molded case and mounted by screws and a bracket to the lower part of the pole unit base Refer to Fig 126 for the discussions below 13 5 1 Short Time Delay Tripping The armature 7 is restrained by calibrating spring 8 After the magnetic force produced by
31. the breaker cam moves down allowing the lockout device to assume its normal de energized position 1 Front of breaker 2 Pull knob for manual defeat of lockout device 3 Manual defeat linkage 4 Adjusting nuts Each electric lockout device also includes a By Pass or manual defeat linkage to permit closing the breaker when the lockout is de energized This allows startup of dead systems pull knob for this purpose is located beneath the breaker frame 1 7 1 Adjustment All lockout devices are factory adjusted If adjustments are needed referring to Fig 55 a Adjust manual defeat linkage adjusting nuts to obtain max travel of lockout tripping arm b With breaker in open and reset position and lockout coil de energized pull knob for manual defeat Check clearances between lockout trip arm and adjusting screw Clearance must be 06 to 09 Release knob lockout trip arm must move trip paddle 03 to 06 beyond point of tripping breaker Adjust screw accordingly 9 06 to 090 clearance 10 Lockout lever Mounting screws Breaker cam 5 Lockout coil 6 Lockout tripping arm 7 Adjusting screw 11 8 Trip paddle 12 Fig 55 Electric lockout device breaker closed 44 7 8 Bell Alarm Device This device provides a means for remote indication that the breaker has been tripped due to action of one ofits automatic trip devices overcurrent UV or drawout interlocks It is not activated by the manua
32. the calibration spring which can be adjusted by the calibration clamp nut 14 b Non adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition overcomes the restraining force of a non adjustable spring 13 5 4 EC 1 Adjustments Before attempting any checks or adjustments on breaker with EC trip devices the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads EC 1 Devices may have their pick up settings varied by changing the positions of the sliding calibration plates on the front of each device The clamping nut holding the plate must be loosened to make the change and then retightened If a new device is installed the adjusting screw on the tripping arm must be set to give 1 32nd of an inch overtravel in tripping The method for making this check is demonstrated in Figure 127 The rod shown is used for pushing the armature of device closed If this is done with the device mounted on a closed breaker it will simulate the action which occurs when the device reacts to an overload condition 13 6 Positive Trip Adjustment Before attempting any checks or adjustments on breaker with EC trip devices the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads The trip latch of the breaker sho
33. 100 Programmer Secondary Connector Epic MicroVersaTrip 71 SECTION 11 RMS 9 and Epic MicroVersaTrip Trip Device 11 3 Current Sensors The current sensors supply the power and signal input nec essary to operate the trip system The RMS 9 and Epic MicroVersaTrip use a phase and neutral sensor Fig 102 shows the phase sensors See Section 11 5 for cabling dia grams Fig 101 The fixed phase sensors have a polarity associated with their windings Their COMMON terminal is the right hand terminal as shown in Fig 102 A white wire with a push on terminal will be connected to this COMMON terminal All phase sen sors must be correctly wired for the programmer summing circuit to function properly The phase sensors are available with an additional winding This winding is brought out to separate flag terminals These phase sensors are used when the hi level instantaneous RMS 9 option H option is required Fig 102 shows an H option phase sensor When the H option phase sensor is installed there are four leads connected to it There is no polarity associated with the special winding connection Fig 103 shows the connections for the additional H option windings 72 TABLE 17 TRIP FUNCTIONS AVAILABLE BASIC FUNCTIONS ADD TO BASIC FUNCTIONS STD or S or H or M T G or GR Al or A2 or A3 or A Z1 or Z2 or Z E MEE e Adjustable Current Setting e Adj Long Time Pickup e Adj Long Time Del
34. 13 8 Switchette Feature The switchette is operated by the long time delay function Its purpose is to provide a set of contacts that will close before an overload occurs This device will not trip the breaker on overload it will trip on instantaneous only 94 The switchette feature is available only in type EC 1 devices The switchette is used in one pole and EC 1 trips in the other poles For the alarm to be effective in indicating the overload before the other poles trip the breaker the device must have less time delay than the other two poles this is accomplished by using a lower characteristic on the alarm device than the other poles or setting the alarm devices long time setting at 80 13 9 Trip Device Replacement Overcurrent devices on the AKS50 breakers can be replaced as follows a Separate frames as described in Section 5 3 b Referring to Fig 126 remove bolts securing the series coil 1 to the lower stud c Remove the clamping bracket 20 d Before installing the replacement device check the travel of trip arm as described in Section 11 5 4 and Fig 127 e Replace new device in reverse order f Adjust the new device as described in Section 11 5 4 When replacing an EC 1 device with an EC 2 or EC 2A device it may be necessary to replace the trip paddles on the trip shaft with slightly longer ones if paddle replacement is required new paddles are provided with the replacement trip units Pi
35. 210 e y od E D Oo a FT n gt a s y E qn E 52 3 c YN TT E c iR z 0o amp el Z Z E oco l mac n n D CQ v Sc teas i T oa e E Z 2 E hM C G 0 E LL 00 co Fig 44 amp 45 The position of the upper and lower retainers and again the bowtie spacers The primary disconnect assembly is factory adjusted to apply a force of 85 105 pounds on a 1 2 thick copper bar inserted between the upper and lower fingers After installation of the disconnect assembly this force range is obtained by tightening the locknuts to set the dimension shown in Fig 48 Note that this dimension is measured between the top of the retainer and the underside of the washer Also note that no bar is inserted between the fingers when setting this dimension Fig 48 Primary finger adjustment 7 2 Secondary Disconnects The secondary disconnects for all drawout breakers serve as connections between breaker control circuit elements and external circuits They are mounted on a horizontal cross channel at the top rear of the breaker as shown in Fig 49 These secondary disconnects allow removal of the breaker without having to detach external connections The moveable part of the secondary disconnects consists of an insulating body which holds a conducting spring loaded plunger to which a flexible lead is attached see Fig 50 As the breaker moves into its enclosure the plunger is depressed by sliding
36. 28 1 Terminal board 2 Auxiliary switch 3 F amp G switches 4 5 6 Motor 6 4 1 Control Components Referring to Fig 25 The control relay X is located on the left side of the front frame channel It may be removed by disconnecting the wiring loosening the two mounting screws and lifting it slightly to pass the top mounting screw through the keyhole mounting The entire relay should be replaced rather than changing coils and contacts The antipump relay W is located on the left side of the front channel The connections to this relay are soldered Relay replacement requires unsoldering of these connections and removing the mounting hardware When replacing relay take care in soldering connections Do not use excess amount of solder on connectors as to impair Operation of contact arms The closing solenoid is located in the lower right hand side of the motor operator unit The switchette is separately mounted in front of the solenoid 7 Closing button Anti pump relay W 8 Switchette Control relay X 9 Closing solenoid Fig 25 Control component location After replacing closing solenoid or switchette check adjustment of switchette and readjust if necessary With breaker in discharge position use a 010 feeler gage and push closing solenoid to position shown in Fig 26 Switchette must be activated at this point To adjust loosen switchette mounting screws and pivot switch until Assembly activated the
37. 50 D cto 232 coc qc gre 0 3050 E x JO uU 0 25 21 IMS Buffer washers Buffer sh Buffer stop 4 Lock nuts N ion that the buffer bolt may be rotated freely ing nuts on the buffer bolts should be locked in Q e O gt e e 2O O 2 a i D o ao cC Men m a Lov i e g g O c 5 o co i Z 5 CN U OO Z j D D gt LL S 5 q O D D E LL D Le O gt NQ c O Y C D E i other Adjust to this d ers SECTION 5 Contact Maintenance 5 9 Checking Contact Sequence On the horizontal plane the difference in the making of the arcing contacts on the same pole must be no greater than 1 16 in this difference between arcing contacts on separate poles must be 1 16 in If it is desired to advance or retard the closing of the main contacts of a pole loosen the bolts holding the adjustment plate refer to Fig 21 of that pole and slide plate to the left to advance contact closing or to the right to retard contact closing Make this adjustment on the outer poles using the center pole as a reference Upon retightening adjustment plate bolts make sure the locking tabs are turned up around bolt heads locking the bolts securely in place Contact sequence in the vertical plane should be such that when the arcing contacts are just touching the intermediate contact gap should be at least 3 16 in and the main contacts gap at least 1 4 in see Fig 14 N
38. 6 and 67 An electromagnetic actuator located on the underside of the front frame is coupled to the breaker s trip shaft via a trip rod driven by the actuator arm The actuator is a solenoid whose armature is spring loaded and held in its normal Reset position by a permanent magnet In this state the spring is compressed So long as the actuator remains in the Reset position the breaker can be closed and opened normally at will However when a closed breaker receives a trip signal from the programmer unit the actuator is energized and its solenoid flux opposes the magnet allowing the spring to release the armature this drives the trip rod against the trip shaft paddle tripping the breaker As the breaker opens the actuator arm is returned to its normal Reset position via linkage driven by a crank on the breaker s main shaft The permanent magnet again holds the armature captive in readiness for the next trip signal The trip device requires only one adjustment the trip rod length As shown in Fig 68 the clearance between the trip rod end and the trip shaft paddle is gaged by a 0 109 inch diameter rod Adjust gap to 0 109 inch 0 031 inch To adjust open the breaker and restore the breaker mechanism to its Reset position Loosen the jamb nut rotate the adjuster end until the proper gap is attained then retighten the jamb nut While operating the breaker insure that the actuator bracket does not interfere with the buff
39. 6 wire on drawout reakers Contact Sequence Table 27 CB Auxillary Switch Position Charging Times Main n b Contacts Contact Contact or Closed Tripped O Closing spring charging times are typical values The maximum 95 permitted is 5 seconds SECTION 14 Electrical Characteristics TABLE 28 Shunt Trip and Undervoltage Device Operating Currents z 13 3o 28 60 08 os Ti 250 140 280 79 5 i 8 1 9 ig 3 308 os M gt gt 120 s E 208 60 15 32 25 8 3 208 EE 2 5 i 24 35 34 22 55 240 88 NA NA s 36 o 380 s Ca 9 gt o o oN a 25 j 480 380 508 480 29 05 ss e 45 amp s 28 25 s aloe Ks aos sm 5 See Table 30 TABLE 29 Coil Resistance DC Ohms 25 Voltage Relay W Relay X 502 Ro o 450 25 4 v o 24V 80 0 60 SO E 9 2 5 2 5 6 0 2 5 5 2 5 a O 25 TABLE 30 Instantaneous Undervoltage Device Settings RATING PICKUP VOLTAGE RANGE gt asas eses a e e ENT MM 41 323 480 VDC 408 144 288 TABLE 31 Time Delay Undervoltage Device Settings UVR INSTALLED UNIT UVR ONLY MECHANISM RESET nl VOLTAGE VDC NO PICK UP PICK UP 125 VDC 77 85 50 90 95 DELAY PICK UP RANGE MINIMUM 250 VDC 208 240 VAR 125 140 90 160 165 POSSIBLE 97 These inst
40. C Short Time 1 OTHER FUNCTIONS 1 Short Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required Table 14 MicroVersaTrip Trip Characteristics Long Time Short time Current Adjustable Setting instantaneous Pickup X X Multiple Pickup Pickup Pickup Short timej Multiple Fixed Tapped of Sensor Multiple Delay Multiple Delay Multiple rt of Sensor Delay Maximum Sensors Sensors Current jof Current of Current Q of Sensor O Current Frame Rating Rating Seconds Rating Seconds Rating Seconds Rating Seconds Size Sensor eni Rating X C C X X 100 150 100 150 225 300 15 2 25 0 10 AKR 30 800 225 300 or 3 4 5 7 0 22 400 600 300 400 9 C 0 36 800 600 800 300 400 300 400 600 800 AKR 50 1600 600 800 or AKS 50 1200 1600 600 800 1200 1600 AKST 50 800 1200 800 1200 AKRT 50 2000 1600 2000 1600 2000 1200 1600 1200 1600 AKR 75 3200 12000 3200 2000 3200 1 Time delay shown at 600 of ampere setting at lower limit of each band C current setting 2 Time delay shown at lower limit of each band X sensor current All pickup tolerances are 10 Ground Fault pickup not to exceed 1200 amperes 61 SECTION 10 MicroVersaTrip Overcurrent Trip Device 10 1 2 Cont
41. D a poop Fig 128 EC 1 reverse currrent triping device 93 SECTION 13 Type EC Overcurrent Trip Device 13 7 1 Adjustments The only adjustment to be made on the reverse current device is to make sure that the trip rod has a minimum overtravel of 1 32 in beyond the point of tripping the breaker This adjustment should have to be made only when an old device is being replaced by a new one The new device will be factory adjusted so that the top end of the trip rod 3 will extend 1 2 in above the top of the device case and no additional adjustments of the trip rod should be required To obtain the proper 1 32 in overtravel close the breaker and proceed as follows 1 Loosen the locking nut 2B 2 Manually lift the trip rod and vary the position of the adjusting nut 2A this establishing the position of the adjusting nut where the breaker is just tripped NOTE Be sure to keep clear of moving breaker parts when tripping the breakers 3 With this position of the adjusting nut established advance the adjusting nut upward one and one half turns 4 Tighten the locking nut and the minimum 1 32 in overtravel of the trip rod should be obtained 13 7 2 Replacement After removing the wiring for the potential coil the reverse current device can be removed and replaced by following the procedure outlined for replacing the series overcurrent device See Section 11 9 For wiring see Fig 128
42. ECTOR EQUIPMENT MOUNTED AMP 1 350356 9 NEUTRAL SENSOR s m 4 WIRE LOAD Fig 108 Cabling diagram RMS 9 amp Epic MicroVersaTrip with ground fault on 4 wire load 4 WIRE LOAD 1 FLUX SHIFT Bian in TRIP DEVICE BREAKER AN 7h oU BACK FRAME f E RED W i m m LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT ilii EQUIPMENT MOUNTED NEUTRAL SENSOR D Lo l in LUN IT Sh a unali m HARNESS AMP 1 350356 9 CONNECTOR LOAD Fig 109 Cabling diagram RMS 9 amp Epic MicroVersaTrip with ground fault on 4 wire load breaker reverse feed fT SECTION 11 RMS 9 and Epic MicroVersaTrip Trip Device Note Location of Pin 1 Gnd Fault Inputs Selective interlock Gnd Fault Outputs Spare 24 Ret 24 VDC Fig 110 Programmer secondary connector pin locations for zone selective interlock and Epic MicroVersaTrip Trip Device 78 SECTION 12 MicroVersaTrip Plus and MicroVersatTrip PM Trip Units The MVT Plus MVT PM is a solid state direct acting self powered trip device system The system consists of the MVT Plus MVT PM programmer current sensors and a flux shifter trip device Figure 111 shows location of features on programmer See user manual GEH 5891A 12 1 Trip Unit MicroVersaTrip Plus Trip Unit MicroVersaTrip Plus trip units utilize a digital LCD display with a four button keypad to provide local set up and read
43. KR 10 AKR 100 NOTES Breaker Frame Type AKS 5 5A 50 2 25 3 4 AKST 5 5A 50 5 6 X AK 5 5A 75 AKR 5 5A 75 2 22 25 3 35 37 X 18 2 22 60 27 3 X 2 1200 1600 2000 3200 1600 2000 3000 4000 X Sensor ampere rating trip rating Pickup tolerance 10 Pickup Multiple of L Multiple of L Multiple Seconds of X Seconds Seconds Maximum 0 35 Maximum 0 30 4 5 6 8 Intermed 10 12 L Intermed 8 7 8 9 Intermed odes 11400 Minimum Time delay at lower limit of band 6L Time delay at lower limit of band Applicable time current curves GES 6033B 6034A 6035B 47 SECTION 8 Type SST Overcurrent Trip Device Fig 59 SST programmer 8 2 Current Sensors The SST system uses two types of current sensors a phase sensor and a neutral sensor Fig 61 shows a phase sensor Fig 62 shows the neutral sensors available The current sensor supplies the power and signal inputs necessary to operate the trip system Each sensor has four taps which provide field adjustment of the trip device s continuous ampere rating The SST Ground Fault trip element operates on the principle that the instantaneous values of current in the three conduc tors four on 4 wire systems add to zero unless ground current exists On SST s equipped with Ground Fault the ground trip signal is developed by connecting each phase sensor in series
44. MENT occ G KE p s Hj 18 ER 17 22 OQ o a ov o a ONO HH L Fig 94 Cabling diagram with ground fault defeat module inserted between breaker harness and MicroVersaTrip programmer unit for use during single phase high current low voltage testing PROGRAMMER UNIT BREAKER BACK FRAME T N Partial LEFT POLE CURRENT SENSOR HARNESS PROGRAMMER CONNECTOR CONNECTOR Fig 95 Partial cabling diagram H option winding connections 69 SECTION 10 MicroVersaTrip Overcurrent Trip Device PROGRAMMER REMOTE FAULT MICROVERSATRIP SECONDARY INDICATION PROGRAMMER DISCONNECT CONNECTOR EQUIPMENT BREAKER OVERLOAD SS ZE O Q SHORT CIRCUIT GROUND FAULT lt 2192 Cimim Mimim Z zZ OVERLOAD PICKUP LD PZ m gt O POLO SONOQAOFONO Be m O Q AMP AMP AMP 1 350239 9 1 350246 9 1 350242 9 1 350235 9 Fig 96 Cabling diagram remote fault indication PROGRAMMER MICROVERSATRIP SECONDARY PROGRAMMER DISCONNECT PROGRAMMER ne E HARNESS I EQUIPMENT BREAKER CONNECTOR SHORT TIME INPUT SHORT TIME OUTPUT GROUND FAULT INPUT zx GROUND FAULT OUTPUT gt AMP P 1 350239 9 1 350246 9 Fig 97 Cabling diagram zone selective interlock 70 SECTION 11 RMS 9 Epic MicroVersa Trip The RMS 9 Epic MicroVersaTrip is a solid state direct act ing se
45. O D gt 0 B 27 o UO E 23 g D Du o c E 227 i cm 89 ca E 2 SES 3 Se O c _ oS o C gt gt S 2 8 oo EU E O oo Jose co 5 Qn on D i 2 E 5 oc S Do CO the c Coo os D y T D o LLC 4 n D So x D 5 O c PEE d D 0 2 y TN EE oo Zo d i E Bos E 255 Q o jesus 2060 5 DO Qu E non SECTION 5 Contact Maintenance Later design 1 2 amp 3 Barriers Nuts Hex head bolts Side support Protective barrier Phase barrier screws Mounting bolts Q 9 4 K Original design Fig 8 Arc quencher removal e Lift arc quenchers clear of the movable arcing contact 5 3 Separation of Front and aes Back Frames f Inspect arc quenchers carefully and replace if In order to perform some repair and replacement necessary operation the front frame must be separated from the back g During replacement tighten jack screw nuts 4 first frame Proceed as follows referring to Fig 9 then the two hex head bolts that secure the channel shaped retaining bar to side sheet DO NOT OVERTIGHTEN THESE TWO BOLTS a Open the breaker manually compress the closing springs and insert the safety pin as described under SLOW CLOSING Section 5 1 Restraining the springs properly positions the main operating cam to facilitate the separation operation 16 b 1 Opening springs Flux shifter actuator bracket Side support bolts 2 Cle
46. OTE This check can best be made by means of the maintenance handle with the safety pin restraining the closing springs See Section 5 1 for this procedure If the gap is under the required minimum it is usually pos sible to form the arcing contacts and obtain the required di mensions To form the contacts place a piece of conduit approximately two feet long over the contact and form the contact either forward or backward by bending it If the proper dimensions are still not obtained the moveable arc ing contacts should be replaced If it has been necessary to make any adjustments while obtaining proper contact sequence the contact wipe must be checked and adjusted if necessary see Section 5 6 Fig 14 Measuring main contact gap 5 10 Replacement of Contacts Criteria for replacement a Arcing contacts should be replaced when eroded to a thickness of 5 64 b Intermediate contacts should be replaced when flush with main contacts 062 lead when new c Main contact very seldom needs replacement Replace when arcing contacts have been neglected causing severe erosion of mains so you can not obtain proper contact depression When replacing the arcing contact assemblies you do not have to separate the front frame from the back frame 5 10 1 Stationary Arcing Contacts a Refer to Fig 15 b Remove insulator block 1 c Slide pin 2 to side Contact assembly 3 will lift freely exposing two sprin
47. PROGRAMMER FLUX SHIFT i UNIT TRIP DEVICE BREAKER BACK FRAME LEFT POLE CURRENT SENSOR HARNESS CONNECTOR AMP 1 350356 9 l L PROGRAMMER CONNECTOR Cabling diagram MicroVersaTrip with ground fault on 3 wire load Fig 91 67 SECTION 10 MicroVersaTrip Overcurrent Trip Device BREAKER BACK FRAME T LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT y maa 4 WIRE EQUIPMENT MOUNTED NEUTRAL SENSOR BREAKER BACK FRAME LT LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT EQUIPMENT MOUNTED NEUTRAL SENSOR FLUX SHIFT TRIP DEVICE YT TAS 4 uh AN LOAD gt r lt l Ju Fe CY Y Y PROGRAMMER UNIT ee erm A eee HARNESS CONNECTOR PROGRAMMER AMP 1 350356 9 CONNECTOR FLUX SHIFT PROGRAMMER TRIP DEVICE D m D I Y m SS un A X RE ue 0 UE m ER Re A U ram mr 0 pe HARNESS CONNECTOR PROGRAMMER AMP 1 350356 9 CONNECTOR Fig 93 Cabling diagram MicroVersaT rip with ground fault on 4 wire load breaker reverse feed 68 SECTION 10 MicroVersaTrip Overcurrent Trip Device BREAKER HARNESS GROUND FAULT DEFEAT MODULE iE CONNECTOR CAT NO TVTGD9 p y ish SS S ut SS o Rem s mme ut bre a ANY MICROVERSATRIP PROGRAMMER UNIT WITH GROUND FAULT ELE
48. Shifter Trip Device e 75 si olsi AA 15 11 5 1 Resistance Values em nn 75 11 5 2 False Tripping Breakers Equipped mund Fault Ml A 76 I MAQTAMS e Eee 76 SECTION 12 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 79 12 1 Trip OWE rro ccc nen n n nn n n n ng 79 12 2 Read ThiSWNSEU M osseuse 80 12 3 Product Structura R coco 80 12 4 Trip Unit Removal and Replacement 81 12 5 Phase Current Sensors 82 12 6 Neutral Current Sensors T PIT 83 IZ Rating Plug Removal and Replacement 83 12 8 Trip Unit Functions 4 2 83 12 9 Trouble Shooting Guide 84 Description Page SECTION 13 Type EC Overcurrent Trip Device 85 13 1 Direct Acting Tripping Device EC 1B 87 13 1 1 Long Time Delay Tripping 87 13 1 2 Short Time Delay Tripping 87 13 1 3 Instantaneous Tripping High Set 87 13 1 4 instantaneous Tripplng LovSet 87 13 2 Replacement MU 87 133 Adjustments WE J en 88 13 4 Series Overcurrent Tripping Device EC 2A Morocco roo 89 13 4 1 Long Time Delay and High Set Instantaneous Tripping 89 134 2 Instantaneous Low Set Tripping 89 13 4 3 Instantaneous High Set Tripping 89 13
49. a jam nut in place of the locking wire E If the a c control voltage is any voltage other than 208 240V ac a control power transformer also remotely mounted with respect to the breaker must be used This must have a minimum rating of 100 volt amperes When installed the voltage to be monitored is connected across terminals No 1 and No 2 of the static delay box The coil of the tripping unit is connected across terminals No 4 and No 5 of the static box throughthe secondary disconnects of the breaker The secondary disconnects to be used will be shown on the breaker wiring diagram No more than one undervoltage tripping device should be used in conjunction with one static time delay unit The static time delay undervoltage can also be furnished with a thermotector control unit Overheating of motor windings causes the thermotector imbedded in the motor windings to open This de energizes the undervoltage device on the breaker and drops the motor load In the event the device fails to pick up the following checks are recommended to determine whether the magnetic device on the breaker of the static time delay unit is the faulty component 1 Stop 2 Armature 1 Check input voltages across terminals 1 and 2 on the 3 Insert wire gage static box See Table 7 for these values 2 Check output voltages on terminals 4 and 5 with the undervoltage device connected See Table 7 for values 7 6 Static Time Delay Und
50. a rating plug from a Spectra RMS breaker or a MicroVersaTrip RMS 9 MVT 4 function trip in a MicroVersaTrip Plus or MicroVersaTrip PM trip unit TABLE 20 Rating plug catalog numbers Sensor Plug Breaker Cat No Rating Amps Rating Frames TR32B1200 TR32B1600 3200 AKR75 TR32B2400 TR32B3200 TR40B1600 TR40B2000 4052500 4000 AKR100 TR40B3000 TR40B3600 TR40B4000 12 8 Trip Unit Functions MicroVersaTrip Plus and MicroVersaTrip PM trip units have specific standard and optional functions All trip units share a series of interchangeable rating plugs The standard functions for both types of trip unit are as follows e Protection Long time protection Instantaneous protection e Status Trip target e Metering display Phase current selectable among phases The optional functions available on both types of trip unit are as follows e Adjustable protection Switchable instantaneous and ground fault protection High range fixed instantaneous overcurrent protection Short time protection with or without I T Ground fault protection with or without I T Zone selective interlock with ground fault only or with both ground fault and short time Additional optional functions available only with PM style trip units are as follows PM style trip units require the presence of external control power e Configurations Communication and metering Communication and prote
51. acteristic curves The tripping time may be varied within the limits shown on the characteristic curves by turning the time adjustment screw 4 Turning in a clockwise direction increases the tripping time counterclockwise motion decreases it The dashpot arm 8 is indexed at four points MIN 1 3 2 3 MAX as indicated in Fig 124 When the Index mark on the connecting link 9 lines up with a mark on the dashpot arm the approximate tripping time as shown by the characteristic curve Is indicated The 1A and 1B characteristic devices are shipped with this setting at the 213 mark and the 1C characteristic at the 1 3 mark Standard characteristic curves are plotted at these settings Time values are inversely proportional to the effective length of the dashpot arm Therefore the linkage setting that gives the shortest time value is the one at which dimension A Fig 123 is greatest The time adjustment screw 4 may be turned by inserting a Phillips head screwdriver through the hole in the front of the case If it is desired to relate the linkage setting to the index marks on the linkage it will be necessary to remove the case This may be done by removing the two mounting screws one on each side of the case which may be taken off without disturbing the trip unit itself 13 4 2 Instantaneous Low Set Tripping The low set instantaneous pick up point may be varied by the adjustment knob 3 The calibration in this case usually ranges fr
52. actual devices and appro priate safety and maintenance practices such as OSHA publica tions National Electric Safety Code ANSI C2 Tne National Electrical Code and NFPA 70B Electrical Equipment Mainte nance must be closely studied and followed During actual work supervision should audit practices to assure conformance 3 Excellent maintenance is essential for reliability and safety of any electrical equipment Industry publications of recom mended maintenance practices such as ANSI NFPA 70B Elec trical Equipment Maintenance should be carefully studied and applied in each user s formation of planned maintenance 3 3 Both long and short term maintenance of all electrical equip ment is essential for reliability and safety Maintenance pro grams must be tuned to the specific application well planned and carried out consistent with both industry experience and manufacturer s recommendations Local environment must always be considered in such programs including such vari ables as ambient temperatures extreme moisture number of operations corrosive atmosphere or major insect problems and any other unusual or abusive condition of the application One of the critical service activities sometimes neglected involves the calibration of various control devices These monitor conditions in the primary and secondary circuits sometimes initiating emergency corrective action such as opening or closing circuit breakers In view of th
53. aker whose SST components have previously demonstrated satisfactory perfor mance via the TAK TS1 Test Set the sensors and their connec tions should be closely scrutinized after disconnecting the breaker from all power sources a Check that all phase sensors are the same type ampere range b Ensure that the tap settings on all 3 phase sensors are identical 8 5 SST Cabling Diagrams c Verify that the harness connections to the sensors meet the polarity constraints indicated by the cabling diagram i e white wire to COMMON black wire to TAP d On Ground Fault breakers serving 4 wire loads check that the neutral sensor is properly connected see cabling diagram Fig 72 In particular 1 Verify that the neutral sensor has the same rating and tap setting as the phase sensors 2 Check continuity between the neutral sensor and its equipment mounted secondary disconnect block Also check for continuity from the breaker mounted neutral secondary disconnect block through to the female harness connector terminals L and N 3 If the breaker s lower studs connect to the supply source then the neutral sensor must have its LOAD end connected to the source 4 Ensure that the neutral conductor is carrying only that neutral current associated with the breaker s load current neutral not shared with other loads e If the preceding steps fail to identify the problem then the sensor resistances should be measured Since the
54. ame between COMMON Size and TAP Terminals AKS 50 5 3 6 1 7 2 8 2 10 8 12 4 14 6 16 9 6 4 7 6 8 8 10 4 13 5 15 8 19 4 22 8 10 2 12 0 15 8 18 6 22 0 25 9 28 5 33 6 AKST 50 Table 10 Sensor Resistance Values AKR 75 100 Tap Breaker Terminal AMP Resistance in ohms between COMMON terminal white lead and TAP terminal 13 4 15 7 18 3 21 5 23 5 27 6 42 1 49 5 AKR 75 AKR 100 The coil resistance of the SST ECS Flux shifter device is approximately 16 ohms 18 3 21 6 23 5 27 6 37 7 44 3 53 4 62 6 8 4 3 False Tripping Breakers Equipped with Ground Fault When nuisance tripping occurs on breakers equipped with the Ground Fault trip element a probable cause is the existence of a false ground signal As indicated by the cabling diagram of Fig 71 each phase sensor is connected in a series with a primary winding on the Ground Fault differential transformer Under no fault conditions on 3 wire load circuits the currents in these three windings add to zero and no ground signal is developed This current sum will be zero only if all three sensors have the same electrical characteristics If one sensor differs from the others i e different rating or wrong tap setting the differential transformer can produce output sufficient to trip the breaker Similarly discontinuity between any sensor and the programmer unit can cause a false trip signal If nuisance tripping is encountered on any bre
55. and minimum values of the time delay period These are coded respectively as AA BB and CC Time and current relationships for the various device characteristics are given by the curves listed in Table 18 TABLE 22 Time Current Curves Trip Trip Trip Characteristic Device Elements EC Devices Curve 1 only GES 6000A 1BB 3 GES 6003 EC 1B GES 6004 GES 6005 GES 6010 GES 6011 GES 6012 D L Long Time S Short Time 13 1 1 L ong Time Delay Tripping Referring to Fig 123 the long time delay is obtained as follows EC 2 2A Instantaneous The long time delay armature 22 is restrained by the long time delay calibration spring 15 After the magnetic force produced by the overcurrent condition overcomes this restraint the velocity of the armature movement is governed by the flow of oil through an orifice in the piston of the dashpot 17 The time required to displace the piston is inversely proportional to the force tending to close the magnetic circuit 13 1 2 Short Time Delay Tripping Referring to Fig 101 the short time delay is obtained as follows The short time delay armature 1 is restrained by a calibration spring 6 If the force tending to close the armature against the magnet 11 is great enough to overcome the spring force the speed of movement is governed by the mechanical escapement mechanism consisting of parts 2 3 4 and 5 13 1 3 Instantaneous Tripping Hi
56. ap settings on all 3 phase sensors are identical C Verify that the harness connections to the sensors meet the polarity constraints indicated by the cabling diagram d On Ground Fault breakers serving 4 wire loads check that the neutral sensor is properly connected see cabling diagram Fig 92 In particular 1 Verify that the neutral sensor has the same rating and tap setting as the phase sensors 2 Check continuity between the neutral sensor and its equipment mounted secondary disconnect block Also check for continuity from the breaker mounted neutral secondary disconnect block through to the female harness connector 3 If the breaker s lower studs connect to the supply source then the neutral sensor must have its LOAD end connected to the source See Fig 93 4 Ensure that the neutral conductor is carrying only that neutral current associated with the breaker s load current neutral not shared with other loads e If the preceding steps fail to identify the problem then the sensor resistances should be measured Since the phase and neutral sensors are electrically identical their tap to tap resistances should closely agree See Tables 15 and 16 10 6 MicroVersaTrip Cabling Diagrams PROGRAMMER UNIT FLUX SHIFT TRIP DEVICE BREAKER BACK FRAME _ LEFT POLE CURRENT SENSOR HARNESS CONNECTOR AMP 1 350356 9 PROGRAMMER CONNECTOR Fig 90 Cabling diagram MicroVersaT rip without ground fault
57. are shown breaker open and closing springs discharged TYP 568B736 B series 11 SECTION 4 Breaker Operation 4 3 Connections in all electrical connections good joint conductivity is a must When making power connections to stationary breakers the mating joint surfaces must be clean and have a smooth finish They should be parallel and firmly bolted or clamped together In addition the bus or cable conductors must have ample ampacitv to prevent overheating The outgoing connections to breaker accessories and control devices must be in accordance with the specific wiring diagram applicable to that breaker TERMINAL BOARD MOUNTED ON FRONT OF BREAKER AT UPPER LEFT CLOSE CUSTOMER CONNECTIONS CLOSING SOURCE 4 3 1 Stationary Breaker Control connections to stationary breakers are made to a terminal board mounted on the breaker Figure 4 shows typical closing and tripping connections If equipped with an overcurrent trip device which includes a ground fault element for use on 4 wire circuits an additional terminal board is provided on the breaker for connecting to the equipment mounted neutral sensor physically located in the neutral conductor 4 3 2 Drawout Breaker On drawout breakers the control circuits terminate in the breaker compartment on the stationary portion of separable secondary disconnects see fig 5 TO AUX SW a CONTACT i A ms UV A TRIP 1 SOURCE
58. arged the breaker is ready for closing This may be accomplished electrically by depressing the closing button on the breaker if so equipped or by a remote closing switch Operation of the closing switch energizes the X relay which in turn energizes the closing solenoid This removes the prop releasing the closing springs to close the breaker As the closing relay is energized it energizes anti pump relay W If the closing switch is maintained closed the anti pump relay will remain picked up to prevent a second closing operation on the breaker in the event it is tripped open automatically The closing impulse must be released and reapplied before a second closing operation can occur TRIP LEGEND CC CLOSING SOLENOID F CUTOFF SWITCH CLOSED WHEN CLOSING SPRING IS FULLY CHARGED L G CUTOFF SWITCH OPEN WHEN FULLY CHARGED L AUXILIARY SWITCH M CHARGING MOTOR PB CLOSE PUSHBUTTON ON BREAKER ESCUTCHEON OPTIONAL TC TC SHUNT TRIP DEVICE W ANTI PUMP RELAY X CONTROL RELAY Fig 3A Elementary diagram for electrically operated drawout breaker Contact positions are shown with breaker open and closing springs discharged TYP 568B736 R series 10 4 2 1 Alternate Control Circuit Later production breakers use the electrical control circuit shown in Fig 3B This circuit is similar to the circuit shown in Fig 3A except that the X relay and F switch are elimi nated T
59. ay e Long Time Timing Light SHORT TIME KI CT NEOUS B wykl T i Adj Ground Fault Pickup oe ERE I FAULT Ground Return X Le Adi Ground Faut Delay rg px x X X X X TABLE 18 MICROVERSATRIP TRIP CHARACTERISTICS Adjustable Adjustable Gronna Faul Instantan Instantan High Range eous eous Instantan Triple Current Setting Mutt Pick up Pick up Pick Up Pick Up eous Selective of Mult Mult w o ST with ST Mult of Trip Sensor Rating of of Mult of Mult of Frame Fixed High Max Rating Plug Current Current Rating Rating Short time Range Frame Amp Amps Amps Setting Delay Setting Delay Plug Amps Plug Amps Rating instantaneous Sec E D 4 UD de JUN Paes i OL IL H CE La Ae W 4 Re B be Peer LBS e HHE 75 A AH Al LLLI e Trip Indication Targets Overload amp Short Circuit local only local and remote O L S C and Ground Fault local only local and remote e Zone Selective Interlock Ground Faut Short Time OTHER FUNCTIONS 1 Short Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required Size Rating S X C C Sec X X H 5 6 Fixed at UB 1 0 of path yy Oe 1 5 2 3 5 AKR 75 3200 9 95 rent 9 7 9 10 13 T Setting 5 6 Fixed at AKR 100 4000 7 8 1 0 of 9 95 Current D Setting
60. been connected refasten the Electro Switch body of the moveable disconnect assembly to the breaker Follow the above procedure except in step d In step d orient cross channel the shaft of the new switch so that the horizontal line on the end of the shaft is horizontal when the breaker is open 7 3 Auxiliary Switch 7 3 2 Adjustment All electrically operated breakers and manual breakers hav ing shunt trips are supplied with auxiliary switches Depend ing upon the requirements of the breaker application the switch may contain two to six stages Usually each stage The auxiliary switch operating shaft must be positioned such that during breaker closing the a contacts make before or not later than the first touch of the breaker s one A contact and one B contact A contacts are open arcing contacts If before the open gap of the arcing or closed as the breaker is opened or closed B contacts contacts must not exceed inch This can be checked by are the reverse of this connecting a bell set across the a terminals and slow closing the breaker with the maintenance handle The a contact closing can be advanced or retarded by lengthening or shortening operating rod 3 Fig 51 The auxiliary switch is mounted on the upper left side of the mechanism frame as shown in Fig 51 As the crossbar 1 moves to the open or closed position it operates triangular link 2 via operating rod 3 The triang
61. bypassed also whenever the shunt trip is energized This is accomplished by latch release strap 1 which is engaged by shunt trip armature lever 12 Strap 11 is part of device latch 9 and must be formed to hook around ar mature lever 12 such that the device latch and catch disengage before the breaker opens With the breaker in reset position there must be at least 1 16 clearance between shunt trip armature 12 and breaker trip paddle 4 Crossbar side link pin Operating link Lockout adjusting screw Lockout trip paddle affixed to item 5 Trip paddle for shunt trip Trip shaft Trip rod release collar Manual trip rod Device latch Device catch Latch release strap Shunt trip armature lever Shunt trip armature Shunt trip Bell alarm switches Switch operating arm Fig 56 Bell alarm device 45 SECTION 7 Accessories 7 9 Open Fuse Lockout Device The open fuse lockout device OFLO is an anti single phasing device used on breakers employed in conjunction with current limiting fuses The device consists of an individual trip solenoid for each pole connected directly across the fuse in that phase Blowing of any fuse operates its solenoid tripping the breaker An indicator for each phase pinpoints the blown fuse The breaker remains trip free until the involved phase of the OFLO device is reset Referring to Fig 57 when a fuse blows coil 6 in that phase is e
62. ckup settings on the cover of the EC 2 EC 2A device are calibrated for the specific device When replacing covers replace on associated device SECTION 14 Electrical Characteristics Table 23 Table 27 Charging and closing operating currents Charging times Table 24 Table 28 Bell alarm contact rating Shunt trip and undervoltage device Table 25 Table 29 Auxiliary switch contact sequence Coil resistance Table 26 Auxiliary switch contact ratings TABLE 23 Charging and Closing Operating Currents MOTOR CLOSING Current Amps SOLENOID Rated Amps Rated Amps Sealed e e e C E e 250V DC 200 280 4 1 1 05 4 1 1 05 1 4 15 1 27 3 eM ME 104 127 1 0 6 85 208V 60 208V 60 A on e o on CI Co Cc Co e 208 254 035 023 Values are typical and are given only as application information and not intended to be maximum or minimum values Table 24 Bell Alarm Table 26 Auxiliary Switch Contact Rating Contact Rating Bell Alarm Contact Control Rating amperes Voltage Contin uous 125 2 5 2 5 5 7 nja SI Auxillary Switch interrupting Ratings Amperes O Non Inductive Control Voltage B 48 25 C 125 11 6 3 Tn da 250 2 1 8 AC 480 115 75 50 AC 240 50 25 480 25 12 D eura to R continuous rating of Soe switch on all breakers and to 5A contin Table 25 Auxiliary Switch id rating of 1
63. conductor and therefore is sepa rately mounted in the cable or bus compartment The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these values The total value will remain zero as long as there is no ground current flowing The neutral sensor is an electrical duplicate of the phase sensor Therefore when phase sensors are changed the neutral sensor must be correspondingly changed Fig 119 Typical neutral sensor 12 7 Rating Plug Removal and Replacement CAUTION Removal of the rating plug while the breaker is carrying current reduces the breaker s current carrrying ca pacity to approximately 25 of the current sensor rating Interchangeable rating plugs are removed with a Rating Plug Extractor Cat No TRTOOL Suitable equivalents are com mercially available as integrated circuit DIP extractors Grasp the rating plug tabs with the extractor and pull the plug out Be sure to grab the tabs and not the front cover of the rating plug or the plug may be damaged Rejection features are provided on ail rating plugs to prevent application mismatches Never force a rating plug into place Refer to Table 20 to find the appropriate rating plugs for each sensor rating and breaker frame If a replacement rating plug has a different rating than the plug that was removed follow the appropriate setup proce dure in GEH 5891A to enter the new rating Do not attempt to use
64. ctive relaying Communicaiton metering and protective relaying e Metering and protective relaying functions Voltage Energy kWh MWh Real power KW MW Total power KVA MVA Frequency Hz Protective relays undervoltage overvoltage voltage unbalance current unbalance and power reversal 83 SECTION 12 Microversatrip Plus and 12 9 Trouble Shooting Guide The following guide is provided for trouble shooting and iso lating common problems It does not cover every possible condition Contact the Customer Support at 800 843 3742 if the problem is not resolved by these procedures Symptom Nig 84 The trip unit display is blank The trip unit display flashes The trip unit display flashes ERR The trip indication target will not clear Unit does not comm municate with the Monitor POWER LEADER Distribution Software or FPU Current readings are incorrect Voltage readings are incorrect kW legend is flashing Overload target is flashing by itself Possible Cause Line current is below 2096 of S MicroVersaTrip Plus External 24 Vdc is absent MicroVersTrip PM Can occur on Plus style trip units when load current fluctuates near 2096 of S The built in self test has detected an error Trip unit is not in status mode Commnet wires are shorted or improperly connected FPU version is lower than 2 0 Trip unit address incorr
65. cts prop 4 b Insert safety pins 3 into the holes in the guide rods 2 c Release the prop by depressing closing lever 5 The safety pin now takes the full force of the spring and restrains it Now free from spring influence the breaker contacts can be inspected and moved at will to the fully closed position by means of the maintenance handle 5 1 2 Manual Breaker a Operate the breaker closing handle through 3 complete movements to charge the closing springs b Insert the safety pins into the guide rods c Continue to operate the closing handle 4th downstroke until the spring crank goes over center applying full spring force to the safety pin Closing motion now can be continued and is completely controlled by the breaker closing handle WARNING DO NOT APPLY CONTROL VOLTAGE OR RACK THE BREAKER INTO THE TEST OR CONNECTED POSITIONS WHILE THE SAFETY PINS ARE IN USE GAS Se SS 1 Maintenance 2 Guide rods 3 Safety pins 4 Prop ing springs 5 Clos In f safety p lon O Installati U 7 Fig Removal and Replacement 1 9 2 2 Arc Quencher Removal and 5 8 Ig ing to F Be sure breaker Referr ion Inspect The arc quenchers should be is open a In inspected at the regular 15 M D a I C C e D e C C x D poj o E eni 5 c Le Not D D c D 2 2 O ce ee E S E Lre g D O E DO QD o
66. d either by a testing two poles of the breaker in series or b Using the Ground Fault Defeat Cable as shown in Fig 73 This special test cable energizes all the primary windings of the differential transformer in a self cancelling series parallel connection so that its secondary output is always zero 2 Test the components of the SST system using portable Test Set Type TAK TS1 Fig 69 The applicable test procedures are detailed in Instruction Book GEK 64454 and are summarized in Section 8 4 1 The TAK TS1 Test Set is a portable instrument designed for field checking the time current characteristics and pickup calibration of the SST s various trip elements It can verify the ability of the Flux Shift Trip device to trip the breaker and in addition includes means for continuity checking the phase sensors 54 8 4 1 SST Test Set The TAK TS1 Test Set Is a portable instrument designed to field check time current characteristics and pickup claibration of the SST s trip elements It can verify the ability of the Flux Shift Trip Device to trip the breaker and includes means for continuity checking phase sensors WARNING BEFORE CONNECTING TEST SET TO BREAKER TRIP DEVICE SYSTEM ENSURE CIR CUIT BREAKER IS COMPLETELY DISCON NECTED FROM ITS POWER SOURCE ON DRAWOUT EQUIPMENT RACK BREAKER TO DISCONNECTED POSITION VERIFY BREAKER IS TRIPPED Either of two test modes may be employed A Programmer Unit Only
67. degrees of rotation through four complete cycles will cause the breaker to close During the four counterclockwise movements and the first three clockwise movements of the handle the springs are progressively charged After approximately seven degrees travel of the fourth clockwise handle movement the spring charge mechanism is driven over center and the energy stored in the closing springs is directed into the closing cam and causes the breaker to close A charge indicator numbered one to four visible through the breaker escutcheon indicates the number of complete handle movements that have been performed REMOTE CLOSE TE CONTROL SOURCE F CLOSING SPRING IS 4 2 Electrical Closing On electrically operated breakers the closing springs are charged by a gear motor With the springs discharged volt age applied to the control circuit will energize the motor through the G switch contacts see figs 3A amp 3B The mo tor through the gear reduction output crank compresses the closing springs until they are fully charged As this fully charged position is reached mechanically operated switch G reverses its shown position deenergizing the motor In the fig 3A diagram switch F reverses its position and es tablishes a circuit for the X relay At the same time a me chanical prop is positioned to prevent the discharge of the fully charged closing spring With the closing spring propped fully ch
68. e Type EC overcurrent trip devices are magnetically Operated using a Series coil or single conductor and an associated magnetic structure to provide tripping force There are three basic characteristics long time delay short time delay and instantaneous which can be used in various Combinations to suit the application AKR breakers with EC trips are for use on DC system voltages One EC trip device is mounted per breaker pole This device contains its functional adjustments Fig 120 EC 2A trip device The standard EC trip device for the AKS breaker frames is the type EC 2A see Fig 120 An optional trip device for these frames is the type EC 1 see Fig 121 The EC trip device for the 4000 and 6000 amp AKR 75 100 frames is the EC 1B shown in Fig 122 The trip characteristics for the EC trip devices are listed in Table 21 Fig 121 EC 1 trip device 85 SECTION 13 Type EC Overcurrent Trip Device Magnet 4 Short time adjustment 2 Connecting rod 5 Long time adjustment 3 Vibration damper 6 Adjustment for instantaneous pickup Fig 122 EC 1B trip device TABLE 21 EC Device Trip Characteristics Trip Device Pickup asar i1 EC 2A instantaneous Pickup 1A MAX adj 15 38 sec Or 4 9X 80 160 X 1B INTER adj 7 5 18 sec 6 12X 10 or 9 15X or 1C MIN adj 3 3 8 2 sec 80 250 X 4
69. e on the center pole to the right will simultaneously increase the wipe on both outside poles moving the adjusting plate to the left will have the reverse effect e To increase the wipe on either outside pole individually move the crossbar adjusting plate of that pole to the left to decrease the wipe move the adjusting plate to the right See Section 5 11 19 SECTION 5 Contact Maintenance Q Adjusting plate Open gap 21 2 to 2 o Clevis Pin Check force inthese areas Clevis centerpole Stationary Arcing Contact Stationary main contact Fig 11 Measuring contact force Table 6 Main Contacts Intermediate Contacts Arcing Contacts Column 1 Qty Force Force Breaker Per in in Type Pole Lbs Lbs AKS 50 DC 3 R Wipe in Qty Qty Force Inches Per Per in Pole Pole Lbs O on 5 32 to 31 43 9 32 AKR 75 DC AKR 100 AC DC The intermediate contact wipe should be at least in greater than main contact wipe 20 E Gg gt oo o C O gt D cd gt on D os EB E y ON tE D F go o DIRES c 2 Dr c me O co E O2225 OBEN Q n Ome lt BY 335 S398 OFZ oO 20D A xo of Su 5 cu n FE TD 20000 xoc OO E amp Q o o YT oco O S S 2 E ooo occ lt Of O 535 032 gt eb oO 22 q oTov as gt N5 eer s O oo C HL O Dox mots 0 Lao C ol Mm TY O D L Q 2 2 8
70. e sensors available The sensors have a polarity associ ated with their windings The common terminal of the sensor is the right hand terminal A white wire with a push on termi nal will be connected to this common terminal All phase sensors must be correctly wired for the programmer sum ming circuitry to function properly The fixed phase sensors are available with an additional winding This winding is brought out to separate flag termi nals These phase sensors are used when the hi level in stantaneous H option is required Fig 118 shows an H option phase sensor When the H option phase sensor is installed there are four leads connected to it There is no polarity associated with the H option windings AKR 9D 100 Fig 116 Fig 117 Phase Sensors 82 Fig 118 H option phase sensor 12 6 Neutral Current Sensors CAUTION Neutral current sensors are required for three phase four wire systems When the trip unit is connected to a three phase three wire system the neutral sensor termi nals are left open Do not short any neutral current sensor terminals in a three phase three wire system as this could result in damage to or malfunction of the electrical system Fig 119 shows the neutral sensor The neutral sensor is re quired when integral ground fault protection is used on single phase three wire or three phase four wire systems It is inserted into the neutral
71. e so that the front frame can be supported by a sling or hook as the bolts are being installed 17 SECTION 5 Contact Maintenance 5 4 Back Frame Assembly The breaker backframe consists of a frame assembly to which the pole units are mounted Each pole unit is connected to a common crossbar which provides for simultaneous pole unit operation by the breakers mechanism A typical backframe is shown in Fig 10 The pole units consist of a molded base which supports the line and load stud assemblies stationary and moveable contact assemblies and the actuating linkage The stationary main contact assembly 9 comprises of a spring loaded contact fingers Interlocked with these are the intermediate contact fingers 7 whose contact surface project beyond that of the main such that the intermediates make before and break after the mains BACK FRAME ASSEMBLY ig 8 9 10 11 12 13 Crossbar Pole unit Stationary arcing contact Pin stationary arcing Moveable arcing contact Pin moveable arcing aa Mating with the stationary contacts is a moveable contact assembly consisting of multiple main and intermediate con tact fingers 10 and 8 These moveable contact fingers pivot on a stationary pin 11 which fasten them to the lower contact block The insulated link 13 which is attached to the breaker crossbar 1 and moveable contact assembly gives the open and close motion to the contact arm The stationa
72. e ua l FRAMEF P LE 1 Verify that the neutral sensor has the same rating T T RED as the phase sensors laas LEFT 2 Check continuity between the neutral sensor and its POLE COM NSOR check for continuity from the breaker mounted neutral Saig equipment mounted secondary disconnect block Also ok Y K A secondary disconnect block through to the female harness connector 4 q 3 If The breaker lower studs connect to the supply I source then the neutral sensor must have its LOAD end connected to the source See Fig 109 4 Ensure that the neutral conductor is carrying only that neutral current associated vvith the breaker load cur H TS rent neutral not shared with other loads HARNESS e Ifthe preceding steps fail toidentity the problem then T y eG the sensor resistances should be measured Since the I phase and neutral sensors are electrically identical their papan ANNEES tap to tap resistances should closely agree See Table 19 CONNECTOR Fig 107 Cabling diagram RMS 9 amp Epic MicroVersaTrip with ground fault on 3 wire load ci 76 nen an me dc Dm e gt o qm gt eo PROGRAMMER U FLUX SHIFT A A TRIP DEVICE ENT BREAKER DA WM BACK FRAME f RED CN e gt WHITE LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT S M HARNESS PROGRAMMER CONNECTOR CONN
73. e vital role of these devices it is important that a periodic test program be followed As was outlined above it is recognized that the interval between periodic checks will vary depending upon environment the type of device and the user s experience It is the General Electric recommendation that until the user has accumulated enough experience to select a test interval better suited to his individual requirements all significant calibrations be checked at an interval of one to two years To accomplish this some items such as EC direct operating trip systems for low voltage breakers must be tested with primary current injection Others can be adequately tested using test sets Specific calibration instructions on particular devices typically are provided by supplied instruction books Instruction books supplied by manufacturers address com ponents that would normally require service or maintenance during the useful life of the equipment However they can not include every possible part that could require attention particularly over a very long service period or under adverse environments Maintenance personnel must be alert to dete rioration of any part of the supplied switchgear taking ac tions as necessary to restore it to serviceable status Industry publications of recommended maintenance practices such as ANSI NFPA 70B Electrical Equipment Maintenance should be carefully studied and applied in each user s forma tion of
74. eaker current sensors provide sufficient power to energize the LCD when at least 2096 of the sensor s ampere rating is flowing e 24 Vdc control power Breakers with MicroVersaTrip PM trip units are supplied with external 24 Vdc power that whenever present energizes the LCD Some breaker models that are configured for MicroVersaTrip Plus trip units may be optionally equipped to accept an external 24 Vdc supply e MicroVersaTrip Test Kit The MicroVersaTrip Test Kit Cat No TVRMS contains a 24 Vdc power sup ply The LCD is energized whenever the test kit jack is plugged into the test receptacle on the rating plug e MicroVersaTrip battery pack The portable MicroVersaTrip battery pack contains a 24 Vdc power source and a jack The LCD is energized when the jack is plugged into the rating plug test receptacle MicroVersaTrip PM Trip Unit for Metering Relaying and Communication on AKR Power Circuit Breakers SELECT Key chooses next item for display ENTER Key stores options VALUE Key selects phase to display or alter setpoint values Interchangeable rating plug for flexibility in matching load requirements LCD readout for metered values trip settings and fault trip indication FUNCTION Key selects the mode of display 79 Fia 111 SECTION 12 MicroVersafrip Plus and MicroVersaTrip PM Trip Units 12 2 Testing Testing of MicroVersaTrip Plus and MicroVersaTrip PM trip units may be perfor
75. echanism serere 36 6 7 Drawout Mechanism Lock 36 SECTION 7 Accessories 37 7 1 Primary Disconnects 37 EUN AKR IS x x x x a a Her m mmm mme 37 BT 2 AWSIABST SO s s ss aaaea 38 7 2 Secondary Disconnects 39 7 2 1 Replacement mnm 39 7 3 Auxiliary Switch 40 7 3 1 Replacement 40 1 32 AM lusttienis sisi ao GaN eee es 40 7 4 Sint TB a ns 41 7 41 Replacement 1 ns se dv ene se ve n n n nnn 41 74 2 AQUSIMEN iiio criadas dra 02 0 41 7 5 Undervoltage Device 42 7 5 1 Replacement uam x e e ween sete Hee vas 42 79 2 AGJUSIM N sus 064444040440 RARI Para Ky 42 7 6 Static Time Delay Undervoltage 43 7 7 Electric Lockout Device 44 tit Adjustment 2s bera Ee seins sieur 44 7 8 Bell Alarm Device 45 18 1 AGJUS MON E eus sedie e E ncc 45 7 9 Open Fuse Lockout Device 46 7 9 1 Goll Replacement ananasi y meer RR 46 7 9 2 Adjustments sse a her E ua 46 SECTION 8 Type SST Overcurrent Trip Device 47 8 1 Programmer Unit ooo oooooooo ee 47 8 2 Current S NSOTS sivas esse bene es weeds wees 48 8 2 1 Replacement of Current Sensors AKS 50 ias a ee Ar sri een eae P RUE 50 8 2 2 Replacement o
76. ecific application Ensure that settings are appropriately adjusted before energizing CAUTION 1 RST TRE TO BGAN Rear view of MicroVersaTrip PM Trip Unit Fig 113 12 4 Trip Unit Removal and Replacement The programmer mounts to the lower left of the breaker as shown in Fig 101 It mounts to the bracket assembly shown in Figs 83 and 84 Referring to Fig 83 the guide pins mate with the holes on either side of the programmer connector They provide the necessary alignment for the connector en gagement The locking lever engages with the pin which is assembled to the programmer frame and secure the pro grammer tot the mounting bracket When a trip unit is re placed the locking arm snaps back into place to indicate proper engagement WARNING Always de energize Type AKR circuit breakers before attempting to remove or replace the trip unit Be cause of the exposed location of the trip unit failure to ob serve this warning may result in equipment damage or per sonal injury including death Selective Interlock Fig 114 Programmer secondary connector Note Location of Pin 1 Fig 115 Programmer secondary connector pin locations for zone selective interlock and MVT PM 81 SECTION 12 Microversatrip Plus and Microversatrip PM Trip Units 12 5 Phase Current Sensors The current sensors supply the power and signal input nec essary to operate the trip system Fig 117 shows the fixed phas
77. ect Rating plug value was defined incorrectly Potential transformer PT primary voltage was defined incorrectly PT connection was defined incorrectly Total power metering Test Kit initiated trip indication Microversatrip PM Trip Units Corrective Action At least 2096 of the current sensor rating S must be flowing through the breaker to activate the display If not power the trip unit with the Test Kit or external battery pack Check that the control power supply is present and operational Power the trip unit with the Test Kit or external battery pack Replace the trip unit Press FUNCTION until STATUS is displayed Press SELECT and VALUE together to clear the target Locate and repair the short or the incorrect con nection Update FPU to version 2 0 or higher Check that address assigned to trip unit as in Chapter 2 agrees with address at host Read the X value from the rating plug nameplate and enter this with the rating plug current set point procedure in Chapter 2 Do not enter the sensor rating S Read the PT ordinary rating from the PT name plate and enter this value with the PT primary voltage procedure in Chapter 2 With the PT connection procedure in Chapter 2 enter VL N for a wye connected PT primary or VL L for a delta connected PT Indicates that the total power is metered in kVA Clear target as indicated above Symptom 4 SECTION 13 Type EC Overcurrent Trip Devic
78. el Control Voltage Nameplate Motor Cut Off Switch Unit Spacer Paddle Fig 35 Motor cutoff switch unit 6 4 4 Spring Discharge Interlock Referring to Figs 27 amp 30 the spring is discharged when the prop is pulled out from the roller This is done electrically by the closing solenoid and manually by the spring discharge interlock The spring discharge interlock drive link must be adjusted to the 03 to 06 inch dimension shown in Fig 27 This gap provides the closing solenoid linkage the initial freedom it requires to develop the force necessary to remove the prop 32 G Switch F Switch Fig 36 F amp G switch location 6 5 Manual Mechanism The manual AKR breaker is equipped with the spring charged stored energy mechanism shown in Figs 37 amp 38 The stored energy operating mechanism of a manual breaker consists basically of a closing spring assembly ratchet wheel and output crank assembly handle shaft and pawl assembly and the escutcheon mounted closing handle The closing springs 5 are charged by operating the manual closing handle 22 on the front of the breaker instead of the closing motor as is the case vvith the electrical breaker Closing this breaker is accomplished by pumping the operating handle four complete cycles first counterclockwise through 120 degrees from its normal vertical position and then clockwise back through 120 degrees from its normal vertical
79. ent Trip Device 10 5 Cont Once it has been established that the circuit breaker can be opened and closed normally from the test position attention can be directed to the trip device proper Testing is performed by either of two methods 1 Conduct high current single phase tests on the breaker using a high current low voltage test set NOTE For these single phase tests special connections must be employed for MicroVersaTrip breakers equipped with Ground Fault Any single phase input to the programmer circuit will generate an unwanted ground fault output signal which will trip the breaker This can be nullified either by a Testing two poles of the breaker in series Or b Using the Ground Fault Defeat Cable as shown in Fig 94 This special test cable energizes the programmer circuit in a self cancelling series parallel connection so that its output is always zero 2 Test the components of the MicroVersaTrip system using portable Test Set Type TVS1 Fig 89 The applicable test procedures are detailed in instruction Book GEK 64464 Fig 89 Test set cat no TVTS1 10 5 1 Resistance Values For use in troubleshooting the MicroVersaTrip current sensors the resistance of the tapped and fixed windings is given in Tables 15 and 16 respectively The coil resistance of the MicroVersaTrip flux shifter device is approximately 7 ohms 66 Table 15 Tapped Sensor Resistance Values Breaker Resista
80. entify the numbers in the parenthesis c Remove arcing contact block 3 by removing allen screws 4 and 5 d Depress main and intermediate contacts as shown in Fig 18 to relieve spring pressure on contact stop bracket 6 before removing mounting screws On AKR100 you must remove the outside moveable contact arm before trying to remove contact stop bracket mounting screws e Remove retaining ring 7 and slide pin 8 to side and withdraw the contact arm Fig 17 E not shown E 1 Main contact arm Intermediate contact arm Arcing contact block Arcing contact Allen screws Contact stop bracket Retaining ring Pivot pin Fig 17 Intermediate and main contacts assembly details 24 f Remove contact noting two spring washers on each contact pivot Upon re assembly position two spring washers into counter bore on one side of contact arm Fig 19 NOTE Left and righthand orientation of contact arms and position of intermediate contact Fig 19 g Depress main and intermediate contacts to relieve spring pressure on contact stop bracket before starting screws Tighten screws before releasing pressure Fig 18 h Re install arcing contact block by holding arcing contacts depressed Fig 20 while tightening screws i Assemble crossbar j Always check contact wipe following contact replacement See Secton 5 6 Contact stop bracket Fig 18 Relieving spring pressure E SE BONES
81. er which will release the programmer pin While holding the locking lever in remove the programmer c Later design pull out locking lever which will release the programmer pin Remove the programmer 10 3 Current Sensors The current sensors supply the power and signal input necessary to operate the trip system Like the SST system the MicroVersaTrip uses a phase and neutral sensor Fig 85 shows the phase sensors Tapped and fixed phase sensors are available The tapped sensors provide field adjustment of the trip device s continuous ampere rating See Section 10 5 for cabling diagrams The tapped and fixed phase sensors have a polarity associated with their windings The COMMON terminal ot the tapped sensor and of the AKS 50 fixed sensor is the right hand terminal as shown in Fig 85 white wire with a ring terminal will be connected to this COMMON terminal The AKR 75 100 fixed sensor uses push on terminals but the right hand terminal is still the COMMON terminal and uses a white wire All phase sensors must be correctly wired for the programmer summing circuitry to function properly Refer to the cabling diagrams in Section 10 6 AKR 75 100 Fig 85 MicroVersaTrip phase sensors 64 The tapped or fixed phase sensors are available with an additional winding This winding is brought out to separate flag terminals rather than the screw terminals These phase sensors are used when the hi level instantaneous Micr
82. er stud Adjust by loosening actuator bracket mounting screws and rotating the bracket clockwise to take up mounting hole slack Retighten screws The actuator is a sealed factory set device and requires no maintenance or field adjustment In case of malfunction the complete actuator unit should be replaced When making the electrical connection to the replacement unit it is recommended that the breaker harness be cut at some convenient point and the new actuator leads solder spliced thereto An alternate method is to untie the breaker harness and remove the old actuator leads directly from the female AMP connector on the end of the breaker harness However AMP extraction tool Cat No 305183 is required for this method CAUTION IF THE BREAKER MUST CARRY CURRENT WITHOUT OVERCURRENT PROTECTION THE SST TRIP DEVICE SYSTEM MUST BE PREVENTED FROM OPERATING THE RECOMMENDED METHOD IS TO SHORTEN THE TRIP ROD BY TURNING ITS ADJUSTER END FULLY CLOCKWISE THIS PREVENTS ACTUATION OF THE TRIP SHAFT PADDLE 51 SECTION 8 Type SST Overcurrent Trip Device D x o a6 n eK SS ona Ugo 258 O J gt ao No Fig 66 Flux shift trip device linkage attachment Actuator Actuator arm 2 3 4 Trip rod Trip rod ad ster end ju nkage Reset Actuator bracket 5 6 7 Mounting base linkages ing ith operati ICE WI Fig 67 Flux shift trip dev 52 CROSSBAR BKR OPEN e
83. ervoltage 3 Check resistance of the disconnected undervoltage device See Table 7 for values Fig 54 Positive trip check In addition to the instantaneous undervoltage tripping device mourited on the breaker the static time delay See Instruction Sheet GEH 4545 for more detailed undervoltage includes a separately mounted time delay information including schematic diagrams and circuit unit Table 7 lists the Cat Nos available description Table 7 Time Delay Units CONTROL APPROXIMATE STEADY STATE NOMINAL DC COIL VOLTAGE DC OPERATING VOLTAGE RESISTANCE TERMINALS TERMINALS OHMS CAT NO 1 amp 2 4 amp 5 25 C TAKYUVT 3 208 240 VAC nonas 43 SECTION 7 Accessories 7 7 Electric Lockout Device The Electric Lockout Device is used in conjunction with the normally closed auxiliary contacts of another breaker This device provides a convenient method to electrically interlock two or more breakers so that no two may be closed at the same time When its coil is de energized the electric lockout device holds an open breaker trip free However once the breaker is closed the breaker mechanism cam operates linkage which mechanically holds the lockout device armature closed to pre vent trippng the breaker in the event the lockout coil is de energized The lockout device is mounted on the right side of the mechanism frame viewed from the front as shown in Fig 55 When the breaker opens
84. f Current Sensors AKR TOO dd au ee ek ee ca aa a see IS 51 8 3 Flux Shift Trip Device pa o ss 51 8 4 Troubleshooting ecc x i din rre nanat 54 8 4 1 SST Test S ga pasa d cc uo de s 54 Insert to document GEK 64459D and GEK 64460A Breaker operation This is an insert to the maintenance manuals for AKR 30 50 GEK 64459D and AKR 75 100 GEK64460A The insert describes the operation of the breaker with the newly introduced electronic closing system For the AKR 30 50 insert to section 5 starting on page 11 For the AKR 75 100 insert to section 4 starting on page 10 Replacement Parts Replacement printed circuit board assembly for 48 VDC applications 10060126G1 Replacement printed circuit board assembly for all other voltage applications 10060126G2 x EE LAE T a Remote Close TRIP VG L S L SHOT o X Relay TC Y FIG E1 ELEMENTARY DIAGRAM FOR ELECTRICALLY OPERATED DRAWOUT BREAKER CONTACT POSITIONS ARE SHOWN WITH BREAKER OPEN AND CLOSING SPRINGS DISCHARGED TYP 183L712 amp 568B736 E SERIES 2 10 97 E 2 ELECTRICAL CLOSING On electrically operated breakers the closing springs are charged by a gear motor With the springs discharged voltage applied to the control circuit will energize the motor through the G switch contacts see Fig E1 The motor through the gear reduction output crank compresses the closing spring until they are fully charged As this f
85. g 21 and the instantaneous calibration spring is located where spring 15 is shown in Fig 26 Dashpot 17 is omitted from assembly See Fig 101 13 2 Replacement The EC 1B device is replaced as follows referring to Fig 123 1 Remove stud 23 2 Remove mounting clamp 3 Remove two screws fastening magnet 11 to lower stud 4 Device is now free of breaker Reassembly is accomplished by reversing the procedure When reassembling the magnet to the lower stud be sure to replace any spacing washers in the same location in which they were found during disassembly If this is not done misalignment and consequent malfunction may result 87 SECTION 13 Type EC Overcurrent Trip Device 13 3 Adjustments Before the EC 1B overcurrent device is calibrated at the factory the air gaps between magnet 11 and armatures 1 and 22 are set These gaps are measured at their widest point between the front edge of the armature and magnet The gap for the short time delay armature is 17 64 in and for the long time delay armature is 17 64 in Both have a plus and minus tolerance of 1 64 in The air gap setting is a factory adjustment and is not to be attempted in the field If any change occurs the calibration of the device will not be true If any calibration difficulties are experienced they may be due to the fact that the air gap setting has been altered by rough handling or shipment damage If a check of the air
86. gap measurement reveals that the setting is beyond the tolerance the device should be returned to the factory for recalibration The adjustment screw 7 is provided so that the short time mechanism will pick up the trip link 8 at the same point at which it is picked up by the long time mechanism This may be checked before the device is mounted by pulling forward on the connecting link 10 and checking visually to see that trip link 8 contacts both the set pin in the long time linkage and the end of adjustment screw 7 After the device is mounted on the breaker a final adjustment that must be made in the length of the AUS ame cy K NS Short Time Mechanism S T D armature Pallet Pinion Escape wheel Driving segment S T D calibration spring S T D trip adj Trip link Magnet Lock nut D M ont nna Fig 123 Direct acting tripping device EC 1B 88 Air gap adj Connecting rod Connecting rod Trip paddle L T D calibration spring Calibration clamp nut connecting rod 10 This is made by varying the amount of thread engagement between the connecting rod and the insulated coupling which ties onto the trip paddle 14 The approximate distance between the pivot centers on the ends of the connecting rod assembly is six inches The correct exact distance is that which will just cause tripping of the breaker when the armature is closed to a point 1 32 in sh
87. ge the connectors and release the locking lever which will move upwards b Verify that the locking lever did engagethe programmer pin c Connect remote fault indication harness if equipped see Fig 81 To remove the programmer a Disconnect remote fault indication harness if equipped b Move locking lever to horizontal position releasing programmer pin c Remove programmer 1 Guide pin 2 Locking lever disengaged position 3 Engaged position Fig 83 AKS 50 programmer mounting 10 2 2 AKR 75 100 Installation There are two programmer mounting designs in use The difference in the designs is in the operation of the locking lever see Fig 84 ORIGINAL LATER DESIGN DESIGN Fig 84 AKR 75 100 programmer mounting Installation using each design is as follows a Insert the guide pins into the holes and push on the programmer engaging the connectors b Original design push in the locking lever securing the programmer Later design the locking lever is released securing the programmer c Verify that the locking lever did engage the programmer pin d Connect remote fault indication harness if equipped see Fig 81 To remove the programmer a Disconnect the remote fault indication harness if equipped continued next page 63 SECTION 10 MicroVersaTrip Overcurrent Trip Device 10 2 2 AKR 75 100 Installation Cont b Original design push in locking lev
88. gh Set Referring to Fig 123 adjustable instantaneous tripping is accomplished by varying the amount of tensile force on the high set instantaneous spring 21 When a magnetic force greater than the restraining spring force is produced by an over current condition the armature 22 is pulled upward against the magnet 24 thus tripping the breaker by the movement of the connecting rod 13 against the trip paddle 14 The pickup value of the device may have one of the following ranges 4 to 9 6 to 12 or 9 to 15 times coil rating Three calibration marks will appear on the calibration scale 18 and the value of these calibration marks will be indicated by stampings on the scale as follows 4X 6 5X 9X or 6X 9X 12X or 9X 12X 15X depending on the desired range To set the device at a particular pickup value loosen the clamping nut 20 and slide the index pointer on the calibration washer 19 to a position which lines up horizontally with the desired pickup value on the calibration scale 18 13 1 4 Instantaneous Tripping Low Set Low set instantaneous tripping is adjustable from 80 percent to 250 percent of the continuous current rating of the device Whenever this is used it is the only characteristic of the device Instantaneous tripping used in conjunction with any other characteristic is always high set If the characteristic of the device is low set adjustable instantaneous a link is installed in place of sprin
89. gs 4 and button 5 d Install new parts in reverse order 5 10 2 Movable Arcing Contacts These contact arms should be replaced whenever the sta tionary arcing contacts are replaced a Refer to Fig 15 b Remove retaining rings 6 Slide pins to side and withdraw the contact arms Insulator block 4 Springs Pin 5 Button Contact assembly 6 Retaining rings Fig 15 Replacement of stationary and movable arcing contacts 5 10 3 Moveable Main and Intermediate Contacts a Refer to Fig 16 b Loosen crossbar bolts so link 10 can move freely c Remove retaining rings 7 from pins 8 Slide pins 8 until contact arms can be withdrawn d Remove contact arms noting two spring washers 9 on each contact pivot Upon re assembly position two spring washers into counter bore on one side of contact arm 9 Note left and right hand orientation of contact arms and position of intermediate contact e Before tightening crossbar see assembly and adjustment of crossbar Section 5 11 MECS o X 7 Retaining rings 8 Pins 9 Spring washers 10 Crossbar bolts 11 Intermediate contact Fig 16 Replacement of main and intermediate contacts i 23 SECTION 5 Contact Maintenance 5 10 4 Stationary Intermediate and Main Contacts a Separate the front frame from the back frame Refer to Section 5 3 b Remove crossbar NOTE In the steps below refer to Fig 17 to id
90. hanism closing spring External control power is required to energize this motor and its control circuit A nameplate indicates what voltage is required by the motor circuit Figure 2 shows a typical Electrical breaker Table 3 Mounting Type Codes Breaker Type Code Letter Stationary None AKD 3 S AKR 751100 25 vvide VV p AKR 100 33 wide 2 4 Trip Device There are six types of solid state direct acting self powered trip device systems associated with AKR breakers These systems are for AC applications only For DC applications an electromechanical system is available Fig 2 Electrically operated AKD type The trip device system is identified by the first middle digit in the breaker s nameplate designation as follows AKR t C 75 t trip device code per Table 4 2 3 Mounting Table 4 Trip Device Codes AKR 75 and 100 breakers are furnished in both drawout and stationary construction Drawout breakers are equipped with CODE features which make them easy to install in or withdraw from NUMBER TRIP DEVICE APPLICATION their associated switch gear equipment Stationary breakers EG are designed to be mounted in a switchboard or enclosure Power Sensor Mounting consists of bolting the breaker frame to a support EC ing structure within the switchboard or enclosure If control SST power connections are needed a suitable terminal board is MicroVersaTrip supplied RMS 9 MVT PLUS or MVT PM
91. hannel and spring support Closing spring will discharge Remove individual closing springs Remove lower spring pin 31 and remaining part of spring support When replacing closing spring assembly anew assembly is required or reassembly of the existing parts using a pressing means b Remove the left or right hand bearing side plate 20 and the side plate shims 18 by removing four mounting bolts 19 thus allowing the main closing crank 25 to be removed c Remove anti rebound pawl 34 by removing retaining ring 36 shown in Fig 39 and spring 33 d Remove retaining ring 35 Fig 40 Disconnect springs 7 remove buffer stop 26 Both pawls can now be removed See Fig 40 When reassembling verify that retaining ring 36 is properly seated e After replacing parts and before adding closing spring check adjustments given in Section 6 5 3 36 Retaining ring Fig 39 Anti rebound pawl removal 26 Buffer 35 Retaining 7 Disconnect springs stop ring Fig 40 Ratchet pawl removal 6 5 3 Adjustments Frequent adjustments to the mechanism should not be required If the mechanism has been disassembled it will be necessary to check the following adjustments 1 It may be necessary to add shims 13 to reduce the end play of the ratchet wheel shaft 16 An end play of 0 010 to 0 020 inch is recommended Shims should be obtained from the factory 2 It may be necessary to add buffer stop shims 27
92. he motor is energized through the G switch and the W relay contact The G switch deenergizes the motor when the closing springs are charged and the prop is engaged With the closing spring propped fully charged the breaker is ready for closing This may be accomplished electrically by depressing the closing switch on the breaker if so ad e ee eee m REMOTE CLOSE 3 CONTROL SOURCE PB C M dc P L NA AJ HI equipped or by a remote closing switch Operation of the closing switch energizes the W relay which in turn energizes the closing solenoid This removes the prop releasing the closing springs to close the breaker If the closing switch is maintained closed the anti pump re lay will remain picked up to prevent a second motor charge and closing operation on the breaker in the event it is tripped open automatically The closing impulse must be released and reapplied after the closing springs are fully charged be fore a second closing operation can occur The charging time is typically 1 to 3 seconds depending on voltage and the maximum time permitted is 5 seconds LEGEND CC CLOSING SOLENOID G CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGED L L AUXILIARY SWITCH M CHARGING MOTOR PB CLOSE PUSHBUTTON ON BREAKER ESCUTCHEON OPTIONAL TC SHUNT TRIP DEVICE W ANTI PUMP RELAY Fig 3B Alternate elementary diagram Contact positions
93. he reset position before the breaker can be closed 4 5 Charging and Closing Using the Maintenance Handle In the absence of control power an electric breaker can be closed manually by using the maintenance handle to charge the closing springs Referring to Fig 6 a With the breaker open and springs discharged release holding pawl slide per instruction label 2 b Install maintenance crank 1 568B386G1 to the motor gear reducer shaft on the front right side of the breaker Rat chet the maintenance crank up and down until the springs are fully charged as indicated by the distinct click as the prop is set This prevents any further charging of the closing springs After the prop is set do not apply undue force to the maintenance handle c Depress the Spring Discharge lever 3 located under the horizontal support on the front frame The springs should discharge and if the latch is properly reset the breaker will close Some style breakers because of an interlock in the switchgear can not be manually closed in the fully engaged position d Open the breaker by pushing the trip button 4 1 Maintenance crank 2 Instruction label 3 Spring discharge lever 4 Trip button Fig 6 Maintenance handle charging 13 SECTION 5 Contact Maintenance Contact Maintenance Breakers subjected to frequent interruption of high currents may eventually require replacement of their contacts The general rule for determ
94. ining need of replacement is the loss of one half or more of the mass of the contact tip material Roughening or light pitting of the contact surface does not indicate loss of ability to carry or interrupt current For proper operation of the breaker the contact structures must be correctly adjusted Various interrelated adjustment parameters are involved Specific amount of contact pressure and wipe must exist between moveable and stationary contacts The arcing intermediate and main contact assemblies must engage and disengage in a prescribed sequence and with breaker open an adequate gap must exist between the movable and stationary arcing contacts 5 1 Slow Closing the Breaker To perform contact maintenance work the breaker operating mechanism must be slow closed i e manually driven and controlled at will instead of in the high speed manner produced by spring discharge Slow closing is achieved by preventing the closing springs from acting on the mechanism The breaker is arranged for slow closing by manually charging the springs and then securing them in this compressed state by inserting a restraining safety pin see Fig 7 Following the inspection period a Recharge the closing springs b Remove the safety pins from the guide rods return them to their storage clips 14 5 1 1 Electrical Breaker Referring to Fig 7 a Attach maintenance handle 1 and charge the closing springs until the crank roller conta
95. ion is available in the form of a mechanical contact which may be incorporated directly into the customer s control circuitry This is a Normally open contact which is activated when its associated target pops out When the target is reset the contact is returned to its open position Each contact is rated 0 25 amp at 125 VDC and 1 0 amp 10 amp in rush at 120 VAC Continued page 62 OVER SAGA LORI Cann i Be 7 39x CHRENY 8 Zh E BHOUND FAULT SETTING BS s Este tre CORO Yr HO Yu i CHIME FAuULY KP E ELE current Galdar Bentor Caneng z Settiag xs E Pramo iert Time Rating LESH TIME DELAY PS e LUNG T l pekus HDS RANGE BSTANTAMEQUE Fig 79 MicroVersaTrip programmer Table 13 Trip Functions Available Optional Features BASIC FUNCTIONS ADD TO BASIC FUNCTIONS Adjustable Current Setting e Adj Long Time Pickup X e Adj Long Time Delay X X e Long Time Timing Li X X X e Remote Long Time Timing Light e Adj Short Time Pickup e Adj Short Time Dela e Short Time lt Switch T INSTANTA e Adj Instantaneous Pickup x x NEOUS e Adj High Range Instantaneous Adj Ground Fault Pickup GROUND 1 Ph 2 W 3 PH 3 W FAULT Ground Return Ad Ground Fault Delay e Trip Indication Targets Overload amp Short Circuit local only local and remote O L S C and Ground Fault tocal only local and remote e Zone Selective Interlock Ground Fault
96. it breaker requires moderate lubrication Bearing points and sliding surfaces should be lubricated at the regular inspection periods with a thin film of GE Lubricant D50HD38 D6A15A1 Mobilgrease 28 Before lubricating re move any hardened grease and dirt from latch and bearing surfaces with kerosene ALL EXCESS LUBRICANT SHOULD BE REMOVED WITH A CLEAN CLOTH TO AVOID ACCUMU LATION OF DIRT OR DUST NOTE The use of cotton waste to wipe bearing surfaces should be avoided as the cotton ravelings may become entangled under the bearing surfaces and destroy the surface of the bearing On drawout breakers the contact surface of the disconnect Studs should be cleaned and greased with GE Lubricant D50HD38 D6A15A1 Mobilgrease 28 Fig 22A Mechanism in motion before resetting as shown in Fig 22C 26 6 3 Breaker Mechanism Adjustments Electric and Manual breakers have the same basic mechanism shown in Fig 22 All the adjustments detailed below must be made with the breaker in the upright position and the mechanism in the reset position as shown in Fig 22B Reset the mechanism by manual operation using the slow close method given in Section 5 1 The roller 15 must be clear of the cam 2 see Fig 22C 6 3 1 Trip Latch Referring to Figs 22C 22D amp 23 the gap between the trip latch 10 and the roller 9 should be between 015 and 032 This adjustment can be obtained by loosening nut 19 and turning allen screw
97. l trip button or shunt trip device The bell alarm device can be equipped with an optional lockout feature which upon activation of the bell alarm prevents reclosure of the breaker until the bell alarm is reset A bell alarm without the lockout feature can be turned off reset by any of three modes a Reclosing the breaker b Depressing the manual trip button C Energizing the shunt trip device For this mode a normally open contact of the bell alarm switch must be connected in parallel with the auxiliary switch A contact in the shunt trip circuit For a bell alarm with lockout only reset modes b and c apply 7 8 1 Adjustment In Fig 56 the components of a bell alarm with lockout are shown in the breaker closed position The device is actuated by crossbar side link pin 1 which engages operating link 2 Lockout screw 3 should be adjusted so that it engages trip paddle 4 to displace trip shaft 6 when the breaker is opened This keeps the breaker trip free until the bell alarm is reset Operating the manual trip button must not actuate the bel alarm device With the manual trip button fully depressed ine trip rod release collar 7 should be positioned on trip rod 8 so that latch 9 and catch 10 disengage before the breaker opens When the manual trip button is not depressed there should be approximately a 3 16 gap between the trip rod release collar 7 and the latch 9 The bell alarm is
98. lear cover to the face plate The SST programmer units can be optionally equipped with trip indicators targets These are pop out mechanically resettable plungers located across the top of the programmer s front Units with a ground fault element employ three targets from left to right the first is for overload the second for short circuit actuated by the short time and instantaneous elements and the third for ground fault The latter is omitted on units without ground fault Table 8 SST Trip Characteristics Each target pops out when its associated trip element operates to trip the breaker After a trip the popped target must be reset by hand However neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being reclosed The programmer unit is mounted to the left side of the breaker as shown in Fig 60 The bracket attached to the top of the pro grammer see Fig 59 engages with a bracket mounted to the breaker s center channel FLUX SHIFT TRIP COIL CURRENT SENSOR OVERLOAO LONG TIME P DELAY PICK SHORT TIME DIFFERENTIAL TRANSFORMER GROUNO FAULT PICKUP amp OELAY REGULATED 48 vDC POWER SUPPLY SST PROGRAMMER ADJUSTMENT RANGE Set Point Ground Fault Pickup Multiple of X Sensor Taps X Amperes 300 400 600 800 or 600 800 1200 1600 B00 1200 2000 1600 2000 3000 1200 1600 AKR 5B 5C 5S 75 3200 2000 3000
99. lf powered trip device system The RMS 9 system consists of the RMS 9 programmer current sensors and a flux shifter trip device Fig 98 shows a block diagram of the system 11 1 Programmer Unit Fig 99 shows a typical RMS 9Epic MicroVersaTrip unit The RMS 9 Epic MicroVersaTrip provides the comparison basis for overcurrent detection and delivers the energy nec essary to trip the breaker It contains a programmable mi croelectronic processor which incorporates nine adjustable time current functions three mechanical fault indicators a long time pickup LED indicator and a zone selective inter locking function All adjustable programmer functions are automatic and self contained requiring no external relaying power supply or accessories See Table 17 for trip functions available and Table 18 for trip function characteristics A de tailed description of each trip function is given in publication GEK 97367 XFMR GROUND AMPLIFIER LFAULT TR 1 SIGNAL esq Hry RB RATING PLUG FACE PLATE i SWITCHES GF mu AMPLIFIER Ej m OC gt E 1 an LT TRIP RC Nu L RATING PLUG ST COMPARATOR TO E 2 7 COMPOSITE oc tap gs 0 INST SHIFTER AD RAS CONVER RATING PLUG TER P AMPLIFIER s Fig 98 RMS 9 Block Diagram 11 1 1 Fault Trip Indicators The optional fault trip indicators are similar to the MicroVersaTrip indicators They are mechanical pop out type for identifying overload or sh
100. lign center of worm with worm gear on racking cam will be used in The mounting code and description of then position collars firm against supports and tighten set each style is found in GEI 86151 furnished with each screws in collars breaker If replacement of racking cam is needed the i i t 4 following procedure should be used See fig 41 To replace guide support 4 R 5 i a Remove nut 1 and screw 2 a Remove screws 5 and support 6 i 4 j w guide b Loosen set screws in collar 3 b Remove guide 4 and replace with new gu c Reassemble 1 Nut 3 Set screw in collar 5 Screws Drawout Mechanism Lock 2 Screw 4 Guide support 6 Support Fig 41 Drawout mechanism 6 7 Drawout Mechanism Lock Breakers manufactured after January 1993 have a locking device installed on the drawout mechanism shaft Fig 41 This device provides a stop to prevent the shaft from rotating unless the interlock slide is depressed by the drawout wrench The racking handle cover plate when depressed re leases a pin on the shaft allowing it to rotate 36 SECTION 7 Accessories 7 1 Primary Disconnects Primary disconnects are found only on drawout breakers They provide the flexible connection between the breaker line and load terminals and the equipment line and load terminals 7 1 1 AKR 75 100 There are two types of primary disconnects found on the AKR 75 100 breakers Fig 42 shows the tubular type
101. mbination of many accessories and interlocking devices Individual breakers may differ in a variety of areas as shown in Tables 1 and2 A brief description of these areas follow An outline drawing is available for each breaker frame size showing critical dimensions The drawing number appears on the breaker nameplate and can be obtained from GE 2 1 Frame Size AKR 75 breakers are available in three frame sizes 3200 amperes A C and 4000 amperes D C There is also available for replacement or hole filler application on AKD or AKD5 switchgear a 3000 amperes A C frame AKR 100 breakers are available in two frame sizes 4000 amperes A C and 6000 amperes D C AKS 50 replacement breaker for the AK50 is available in two frame sizes 1600 amperes A C and 2000 amperes A C or D C depending on trip device These values represent the maximum continuous current capability of the respective frames However each breaker carries a specific rating which is determined by the current sensor ampere rating or tap setting of the trip device with which it is equipped Individual breaker rating data is shown in Table 5 2 2 Operation There are Manual and Electrical models The Manual breaker has an operating handle which is used to manually charge the mechanism closing spring Figure 1 shows a typical Manual breaker Fig 1 Manually operated AKD type The Electrical breaker contains an electric motor which charges the mec
102. med with the trip unit installed in the cir cuit breaker the rating plug installed in he trip unit and the breaker carrying current The test set catalog number is TVRMS The test set plugs into the test socket of the rating plug Test set TVRMS may also be used for MicroVersaTrip RMS 9 and Epic MicroVersaTrip trip units Refer to the Mainte nance and Troubleshooting section for additional details 12 3 Product Structure MicroVersaTrip Plus and MicroVersaTrip PM trip units are removable Figures 112 and 113 contain front and rear views of a MicroVersaTrip PM trip unit Figure 113 shows the 36 pin plug that connects either trip unit to the circuit breaker and equipment circuitry This plug is called the trip unit disconnect AS X ANE 2 SA Fig 112 Front view of MicroVersaTrip PM Trip Unit 80 CAUTION Removal of a trip unit from its breaker must be performed vvith the breaker in the OPEN or TRIPPED posi tion Draw out breakers should be racked out first CAUTION Do not attempt to operate the breaker vvithout its assigned trip unit Installation of an incorrect trip unit may result in unsafe operation of the breaker CAUTION Removal of the rating plug while the breaker is carrying current reduces the breaker s current carrying ca pacity to approximately 25 of the current sensor rating This may result in undesired tripping NOTE Trip units as received may have settings that are un desirable for the sp
103. n Terminals TRIP DEVICE AI ses P FR I B RAME U w Sy Ty SH REQ a 48V dc 150 44 5 0 1 9 D 9 BLACK O TO SCR i 225 48 5 6 LEFT POLE ANODE 300 6 4 7 2 CURRENT WHITE AKS50 400 5 18 Ja A AKS750 600 64 7 6 DO epe mo La wee Tel el 5 15 I og AMADO 1600 19 4 22 8 C BLACK g l 1 Jef Li we LIST E H 1200 13 4 15 7 0 1 BLACK K 1600 N de 2 S C g 2000 5 27 JS S eem N M 3000 37 7 44 3 Mil E 3200 42 1 49 5 Y Y i CHARNESS PROGRAMMER 4000 53 4 62 6 CONNECTOR AMP 201298 1 LOAD AMP 201297 1 Fig 77 Cabling diagram for ECS trip device 59 SECTION 10 MicroVersaTrip Overcurrent Trip Device The MicroVersaTrip is a solid state direct acting self powered trip device system The MicroVersaTrip system consists of the MicroVersaTrip programmer current sensors and a flux shifter trip device Fig 78 shows a block diagram of the system 10 1 Programmer Unit Fig 79 shows a typical MicroVersaTrip programmer unit Like the SST and ECS units the MicroVersaTrip provides the comparison basis for overcurrent detection and delivers the energy necessary to trip the breaker It contains a programmable microelectronic processor which incorporates nine adjustable time current functions three mechanical fault indicators local and remote a long time pickup LED indicator local and remote and a zone selective interlocking function All adju
104. n tighten screws Recheck Vint ie Hardware MOTOR mounting Hardware Closing Solenoid Maintenance X 03 06 Dimension Handle Shafi f required with lever in position shown Adjust H necessary Retaining Ring Drive Link Spacers E Opening Spring Bracket Mounting Hardware Operating Lever Spring Discharge interlock Mechanism Connection D Contacts Points Fig 26 Switchette adjustment 6 4 2 Charging Motor The charging motor is located on the right side of the breaker It is mounted on the motor operator as shown in Fig 27 A driving pawl is mounted eccentrically on the motor shaft see Fig 28 As the motor turns the driving pawl rotates the ratchet which charges the closing springs The ratchet is kept from reversing its direction by the holding pawl To remove the motor a On AKS 50 you must remove the side sheet b Disconnect and identify the motor leads at the closing solenoid and cutoff switch SEQ c Remove three motor mounting screws d Remove motor 1 Driving pawl e When reassembling assemble with the driving pawl Fig 28 Motor removal pointing toward the front of the breaker e See Fig 28 29 SECTION 6 Breaker Maintenance 6 4 3 Motor Operator Unit The motor drives the crank roller maintenance handle shaft until the control circuitry stops the motor and roller is against the prop The crank roller drives the cam shaft charging the spring through
105. nce in ohms Frame between Common Size 2nd Tap Terminals AKS50 CONSULT FACTORY AKST50 AKR75 AKR100 Table 16 Fixed Sensor Resistance Values Breaker Resistance in ohms Frame between Common Size 2nd Tap Terminals AKS50 AKST50 AKR100 CONSULT FACTORY 10 5 2 False Tripping Breakers Equipped with Ground Fault When nuisance tripping occurs on breakers equipped with the Ground Fault trip element a probable cause is the existence of a false ground signal As indicated by the cabling diagram of Fig 91 each phase sensor is connected to summing circuitry in the programmer Under no fault conditions on 3 wire load circuits the currents in this circuitry add to zero and no ground signal is developed This current sum will be zero only if all three sensors have the same electrical characteristics If one sensor differs from the others i e different rating or wrong tap setting the circuitry can produce output sufficient to trip the breaker Similarly discontinuity between any sensor and the programmer unit can cause a false trip signal If nuisance tripping is encountered on any breaker whose MicroVersaTrip components have previously demonstrated satisfactory performance v a the TVTS1 Test Set the sensors and their connections should be closely scrutinized after disconnecting the breaker from al power sources a Check that all phase sensors are the same type ampere range b Ensure that the t
106. ned Retighten lock nut Trip paddle Rod guide Rod Lock nut Trip solenoid Coil Link assembly Armature Arm Reset button Rod reset button Springs reset rod Spring link assembly Mounting bracket Trip shaft 1 2 3 4 5 6 7 8 9 Va MIN Fig 57 Open fuse lockout device 46 SECTION 8 Type SST Overcurrent Trip Device The SST is a solid state direct acting self powered trip device system The SST system consists of the SST programmer unit current sensors and a flux shifter trip device Fig 58 shows a block diagram of the system 8 1 Programmer Unit Fig 59 shows atypical SST programmer unit The programmer unit provides the comparison basis for overcurrent detection and delivers the energy necessary to trip the breaker It contains the electronic circuitry for the various trip elements Their associated pickup and time delay adjustments set points are located on the face plate Depending on the application programmer units may be equipped with various combinations of Long Time Short Time Instantaneous and Ground Fault trip elements See Table 8 for available ratings settings and trip characteristics Adjustments are made by removing the clear cover over the face plate unscrewing counter clockwise the set point knob moving the set point along the slot to the new setting and screwing the set point knob in Once all adjustments are made install the c
107. nergized and closes armature 8 engaging trip paddle 1 which trips the breaker In the process spring 12 discharges and pivots arm 9 counterclockwise latching armature 8 closed This motion also moves reset button 10 forward indicating which fuse has blown The latch held armature keeps the breaker trip free until the OFLO is reset Coil 6 is de energized as soon as the breaker is tripped 7 9 1 Coil Replacement To replace coil 6 proceed as follows 1 Remove five bolts mounting the device to the side plate and front frame Lower the lockout device guiding rod 3 through rod guide 2 Continue lowering the device until movement is restricted by the device wiring harness 2 Disconnect coil leads 3 Remove two screws holding the trip device to the device mounting plate 4 Bend lower end of brass coil clamp straight 5 Remove coil Install new coil and replace parts in reverse order 7 9 2 Adjustments From 1 32 to 1 16 inch armature overtravel is required when the breaker is tripped 1 8 inch minimum clearance is needed between trip paddle 1 and rod 3 with breaker in the reset position To make these adjustments loosen locknut 4 and turn rod 3 in or out to obtain the proper overtravel and clearance Retighten lock nut 4 A 1 8 inch minimum clearance should be maintained at reset button 10 To adjust loosen lock nut ahead of button and turn button until proper distance is obtai
108. oVersaTrip option H option is required Fig 86 shows an H option phase sensor When the H option phase sensor is installed there are four leads connected to it There is no polarity associated with the H option windings Fig 95 shows the connections for the additional H option windings 1 H option terminals Fig 86 H option phase sensor Fig 87 shows the neutral sensor The neutral sensor is required when integral ground fault protection is used on single phase three wire or three phase four wire systems It is inserted into the neutral conductor and therefore is separately mounted in the cable or bus compartment The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these values The total value will remain zero as long as there is no ground current flowing See cable diagram in Fig 92 The neutral sensor is an electrical duplicate of the phase sensor including taps Therefore when taps are changed on the phase sensors those on the neutral sensor must be correspondingly positioned Since the neutral sensor is mounted separately from the breaker a disconnect means is required to connect its output to the breaker Fig 88 shows the breaker and equipment mounted 4th wire secondary disconnect used with the MicroVersaTrip system 10 3 2 Replacement of Current Sensors AKR 75 100 The replacement of the AKR 75 100 MicroVersalT rip current sensors follows the
109. oard retaining hardware c Remove the lower connection strap d Sensors are secured with RTV Loosen RTV and remove sensors e If the front and back frame have not been separated replacement of the center pole sensor requires removal of the mechanism prop Refer also to Fig 24 1 Remove retaining rings 2 Disconnect spring 3 Remove bearings 4 Remove prop 50 2 Equipment mounted Fig 64 Sensor replacement T 2 3 4 Connection strap Bearing Retaining ring Prop erer ya a 1 Primary disconnects 2 Tap board Fig 65 AKR 75 100 sensor replacement 8 2 2 Replacement of Current Sensors AKR 75 100 Referring to Fig 65 the AKR 75 100 phase sensors are removed as follows a Disconnect the wiring harness and connections from the senser tap board b Remove the tap board hardware c Remove the primary disconnect assemblies from the stud d Remove the sensor and tap board e Reassemble in reverse order align projections on rear of sensor with notches in the position ring which is mounted on the stud Refer to Section 7 1 1 for torque requirements for the primary disconnect hardware 8 3 Flux Shift Trip Device The Flux Shift Trip device is a low energy electromagnetic device which upon receipt of a trip signal from the programmer unit trips the breaker by actuating the trip shaft The mounting arrangement of this component is illustrated in Figs 6
110. om 80 percent ot 250 percent of the series coil rating with the calibration plate indexed at values of 80 100 150 200 and 250 percent of the rating 13 4 3 Instantaneous High Set Tripping The high set instantaneous pick up value may have one of the following three ranges 4 to 9 6 to 12 9 to 15 times coll rating The pick up setting may be varied by turning the instan taneous pick up adjusting screw 12 Three calibration marks 15 will appear on the operating arm 14 and the value of these calibration marks will be indicated by stampings on the arm as follows 4X 6 5X 9X or 6X 9X 12X or 9X 12X 15X At the factory the pick up point has been set at the name plate value of the instantaneous trip current Usually expressed in times the ampere rating ofthe trip coil The variation in pick up setting is accomplished by varying the tensile force on the instantaneous spring 5 Turning the adjustment screw changes the position of the movable nut 11 on the screw The spring is anchored to this movable nut so that when the position of the nut is changed there is a corresponding change in the spring load As the spring is tightened the pick up point is increased The top edge of the movable nut 11 serves as an index pointer and should be lined up with the center of the desired calibration mark 15 to obtain the proper instantaneous trip setting The trip screw 6 on the end of the armature 7 should be set so
111. om closing spring by placing your maintenance handle on the shaft which extends from the spring charging mechanism and charge the closing spring until the charging mechanism roller engages with the prop Remove safety pin This must be done before power is applied to motor k Operate the breaker using the maintenance handle and spring discharge mechanism a few times Verify that the breaker is operating properly Before applying control voltage to your breaker verify that the motor cut off switches are properly adjusted Charge the closing spring as described in step j roller resting on prop Adjust the motor cut off switches shown in Fig 35 so that they are depressed to the point where the main stem of each switch is located 005 to 031 from the threaded barrel see Fig 34 Continued next page Main Stem Threaded Barre Fig 34 Motor cutoff switch adjustment 1 Cam shaft paddle 2 Guide Fig 33 Cam shaft lever and guide 31 SECTION 6 Breaker Maintenance 6 4 3 Motor Operator Unit Cont m When the control voltage is applied to your breaker the motor operator will be energized and charge the closing spring The G switch see Fig 36 of the motor cut off switch unit will stop the motor operator just before the roller engages the prop The breaker may be closed manually by depressing the spring discharge lever or electrically by energizing the closing solenoid Right Side Center Chann
112. ort circuit over current faults when breakers are ordered without integral ground fault protection They are also available to identify overload short circuit and ground fault trips for breakers supplied with integral ground fault protection Each target pops out when its associated trip element operates to trip the breaker After a trip the popped target must be reset by hand However neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being closed 11 2 RMS 9 amp Epic MicroVersaTrip Installation The programmer mounts to the lower left of the breaker as shown in Fig 101 It mounts to the bracket assembly shown in Fig 82 Referring to Fig 82 the guide pins mate with the holes on either side of the programmer connector They provide the necessary alignment for the connector engagement The locking lever engages with the pin which is assembled to the programmer frame and secures the pro grammer to the mounting bracket Installation using each design is as follows a Insert the guide pins into the holes and push on the pro grammer engaging the connectors b The locking lever is released securing the programmer c Verify that the locking lever did engage the programmer pin To remove the programmer a Pull out locking lever which will release the programmer pin Remove the programmer FIG 99 RMS 9 amp Epic MicroVersaTrip Programmer Note Location of Pin 1 FIG
113. ort of contact with the magnet A step by step procedure for making this adjustment follows 1 Before mounting the trip device set the center distance between the pivot centers of the connecting rod at six inches 2 Close the breaker and insert a feeler gage 1 32 in thick between the armature and magnet This should be done from the rear of the breaker The feeler gage should be no wider than 1 2 in and at least 4 inches long 3 Close the armature against the gage and magnet 4 If the breaker does not trip form paddle 14 to obtain positive trip 5 Check visually to make sure that the connecting rod does not restrict the engagement of the breaker trip latch when the breaker mechanism resets It should always be possible to adjust its length to a point where resetting is not interferred with and yet positive tripping by the overcurrent device is achieved E3JEJEJERESI ES SRE ER o ce U U E m Long Time amp High Set Inst Mechanism 17 Dashpot Calibration scale Calibration washer Clamping nut Inst calibration spring L T D armature Stud Magnet 13 4 Series Overcurrent Tripping Device EC 2A The Type EC 2A overcurrent tripping device is available in three forms 1 Dual overcurrent trip with long time delay and high set instantaneous tripping 2 Low set instantaneous tripping 3 High set instantaneous tripping The dual trip has adjustable long time and instantaneous pick up
114. planned maintenance Some users may require additional assistance from General Electric in the planning and performance of maintenance The General Electric Company can be contracted to either undertake maintenance or to provide technical assistance such as the latest publications The performance and safety of this equipment may be com promised by the modification of supplied parts or their re placement by non identical substitutes All such design changes must be qualified to ANSVIEEE Standard C37 59 The user should methodically keep written maintenance records as an aid in future service planning and equipment reliability improvement Unusual experiences should be promptly communicated to the General Electric Company 9 SECTION 4 Breaker Operation Breaker Operation The AKS 50 AKR 75 and AKR 100 breakers are closed by the discharging of the energy stored in the closing springs of the breaker As the closing springs are discharged the energy is directed into the closing cam of the breaker which causes the moveable breaker contacts to be forced against the stationary contacts and at the same time causes the opening springs to be charged so they may open the breaker during a subsequent opening operation 4 1 Manual Closing Manually operated breakers are equipped with a handle which extends from the escutcheon of the breaker Alternately rotating the closing handle counterclockwise then clockwise through approximately 120
115. position and then clockwise back through 120 degrees When approximately 70 degrees of the fourth clockwise stroke have been completed the closing springs which have been charged during the previous strokes to the closing handle are driven over center and the breaker closes The first stroke of the closing handle causes the ratchet pawls 21 attached to the handle shaft 23 to engage the first tooth of the ratchet wheel 17 thus beginning to charge the closing springs The subsequent closing handle strokes perform the same function as the pawls 21 engage the teeth in the ratchet wheel 17 thus rotating the ratchet wheel and output crank 32 and completely charging the closing springs This rotation of the ratchet wheel and output crank is in a countercloskwise direction from the lower position through slightly more than 180 degrees to a position just beyond dead center In this position the closing springs are free to release their energy closing the breaker at a high speed Upper spring pin 1 3 Safety pin and chain 5 Closing springs 7 Pawl springs 18 side plate shims 19 Side plate mounting bolts 20 Bearing side plate Fig 37 Manual closing mechanism 6 5 1 Mechanism Part Replacement If it is necessary to replace any of the mechanism parts the following total procedure is recommended This procedure may be halted at the step required to replace any particular part Referring to Figs 37 amp 38
116. primary stud used on replacement breakers for the older AKD AKD5 AKD6 switchgear If for any reason the primary stud must be FINGER TYPE PRIMARY DISCONNECTS replaced or removed simply disassemble nut and bolt arrangement that is crisscrossed through the tubular stud When reassembling mounting hardware apply equal amounts of torque to nuts so distortion to tubular mounting stud does not occur Torque nuts between 250 to 300 in Ibs Fig 43 shows the finger type disconnect assembly used on AKD 6 AKD 8 switchgear and substructure type breakers If replacement of primary finger is needed you must replace complete subassembly set of fingers which are factory adjusted to proper spring tension Reassemble as described above See renewal parts publication GEF 4552 for proper ordering data AKR100 AKR100 Fig 43 Finger type disconnects 37 SECTION 7 Accessories MUN l e T D 6 E d d 26 so 8 D D D 2 C x s E X x E wl el z o o co be on LATE 2 2 WU E ji G im rc E E QS EL Z c x O D O f s D o o METIO DOES zo E gaz E E aoc co e ooo gt E ES B 9 co 5 ES G gt EE ay UJ 0 8 o E cp we I qw LC OS gt o 2 g 5 vo o 5 ie LE m i a o E E oti 030 E c gt SN E p gt zo 9c 19082 MO E of 2 92 LL S a gt L Qo D 90 Ecz z gt 9 c ESC a E END O 25 0 WW QE ke
117. res DRAWOUT MOUNTING 250V Dc 600V Ac POLES AKD AKS 50 basic maintenance inspection should consist of an overall visual check plus observation of a few closing and opening operations lf a breaker is seldom operated such that it remains open or closed for a period of six months or more it is recommended that arrangements be made to open and close it several times in succession Dirt grease or other foreign material on any parts of the breaker should be removed by a thorough and careful cleaning Insulating surfaces should be checked for conditions that could degrade insulating properties During an inspection the breaker s contacts should be slow closed manually with closing springs restrained by the safety pin to observe contact alignment and to insure that all mechanism parts move freely A complete contact inspection including measurement of wipe and force should also be done To properly inspect contacts the arc quenchers must be removed At this time thoroughly inspect the inside surfaces of the arc quencher side plates and inner components 1 2 Renewal Parts The AKR breakers contain a variety of parts and assemblies Many of these parts and assemblies are available as replacement parts when the need arises See publication GEF4552 Renewal parts for a complete listing of these parts STATIONARY NOTES MOUNTING AKS A 50 AKS S 50 AKS A 5OH AKS S 50H 2 AKS 50V AKS
118. ructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter should be referred to the GE Company GE Electrical Distribution amp Control General Electric Company 41 Woodford Ave Plainville CT 06062 GEK 64460A 1993 General Electric Company
119. ry arcing contact assembly 3 is a separate set of contact fingers pins springs and pivot block The moveable arcing contact assembly 5 consists of multiple contact arms carried on two moveable pins 6 and 12 The arcing contact arms interleave the main contacts and pivot with them about pin 6 This relative motion is obtained by the insulating links 13 from the contact arms to the breaker crossbar 11 Stationary intermediate contact Moveable intermediate contact Stationary main contact Moveable main contact Pivot pins Drive pins Insulated link Fig 10 Front view of back frame assembly 18 5 5 Measuring Contact Force a Remove the arc quenchers b Separate front and back frames refer to Section 5 3 c Inspect all contacts for wear and arc erosion and if necessary replace see criteria for replacement Section 5 10 d Measure contact force only if you replace contact arms 5 5 1 Stationary Arcing Contacts Referring to Fig 11 Place a push scale on the stationary arcing contact at a point 1 3 16 from the contact pivot and depress that contact 1 4 of an inch Load on the scale should read within the range listed in Table 6 column 8 If the load is not within the range listed in column 8 replace the spring under that contact assembly 5 5 2 Stationary Main and intermediate Contacts Place a push scale on the stationary contact at a point 2 7 8 from the contact pivot and depress tha
120. same procedure used for the SST sensors refer to Section 8 2 2 10 4 Flux Shifter Trip Device The only difference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid winding Refer to Section 8 3 for details When replacing a MicroVersarTrip flux shifter AMP extraction tool Cat No 455822 2 is required to remove the socket leads from the AMP connector 10 5 Troubleshooting When malfunctioning is suspected the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as Fig 87 Typical neutral sensor a Breaker tripping in proper response to overcurrents or incipient ground faults 10 3 1 Replacement of Current gt Break bd tric treo state duet Breaker remaining in a trip free state due to Sensors AKS 50 mechanical interference along its trip shaft The replacement of the AKS 50 MicroVersaTrip current c Inadvertent shunt trip activations sensors follows the same procedure used for the SST sensors described in Section 8 2 1 The only difference is that the tap board is not a separate item but is integral with the sensor WARNING DO NOT CHANGE TAPS ON THE CURRENT SENSORS OR ADJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CARRYING CURRENT TYPICAL AKR 75 100 AKS 50 REAR MOUNTING EQUIPMENT MOUNTED MATING DISCONNECT Fig 88 Neutral sensor secondary disconnect 65 SECTION 10 MicroVersaTrip Overcurr
121. settings and adjustable time settings Both forms of instantaneous trip have adjustable pick up settings Adjustment Note Before attempting any checks or adjustments on breaker with EC trip devices the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads The trip latch of the breaker should also be checked for proper trip latch engagement See Section 6 3 1 Refer to Fig 124 for the discussions given below 13 4 1 Long Time Delay and High Set Instantaneous Tripping By means of the adjustment knob 3 which can be manipulated by hand the current pick up point can be varied from 80 to 160 percent of the series coil rating The indicator and a calibration plate 2 on the front of the case provide a means of indicating the pick up point setting in terms of percentage of coil rating The calibration plate is indexed at percentage settings of 80 100 120 140 160 As in the case of the EC 1 over current trip the long time delay tripping feature can be supplied with any one of three time current characteristics which correspond to the NEMA standards maximum intermediate and minimum long time delay operating bands These are identified as 1A 1B and 1C characteristics respectively Approximate tripping time for each of these in the same order are 30 15 and 5 seconds at 600 percent of the pick up value of current See time current char
122. st be employed for RMS 9 breakers equipped with Ground Fault Any single phase input to the programmer cir cuit will generate an unwanted ground fault output signal which will trip the breaker This can be nullified either by a Using the Ground Fault Defeat Cable as shown in Fig 94 This special test cable energizes the pro grammer circuit in a self cancelling series parallel connection so that its output is always zero 2 Test the components of the RMS 9 system using portable Test Set Type The applicable test procedures are detailed in instruction Book 97367 The time current characteristics for the RMS 9 amp Epic MicroVersaTrip Trip Device are given in curves GES 6227 and GES 6228 Fig 105 Test Set Cat No TVRMS 11 5 1 Resistance Values For use in troubleshooting the RMS 9 current sensors the resistance of the fixed windings is given in Table 19 TABLE 19 Ampere Resistance in Ohms Rating Between Terminals 10 12 27 32 58 68 129 151 207 243 The coil resistance of the RMS 9 amp Epic MicroVersaTrip flux shifter device is approximately 7 ohms 75 SECTION 11 RMS 9 and Epic MicroVersaTrip Trip Device 11 5 2 False Tripping Breakers 11 6 Cabling Diagrams Equipped With Ground Fault When nuisance tripping occurs on breakers equipped with A FLUX SHIFT E be c the Ground Fault trip element a probable cause is the exist BREAKER TRIP DEVICE ence of a false ground signal As
123. stable programmer functions are automatic and self contained requiring no external relaying power supply or accessories See Table 13 for trip functions available and Table 14 for trip function characteristics A detailed description of each trip function is given in publication GEA 10265 and GEH 4657 T PROGRAMMER UNIT __ JFLUX SHIFTER SOLID TRIP COIL STATE e SWITCH TT CURRENT SENSOR 1 GED Prap Sono OVERLOAD TARGET LONG TIME PICKUP amp DELAY SHORT TIME PICKUP amp DELAY SHORT TARGET CIRCUIT INSTANTANEOUS GROUND TARGET NEUTRAL h2 GROUND FAULT Dors EE PICKUP amp TD SESI C D E 1 15 VOC POWER SUPPLY Fig 78 MicroVersaTrip block diagram 60 10 1 1 Fault Trip Indicators The optional fault trip indicators are similar to the SST in dicators They are mechanical pop out type for identifying overload or short circuit over currents faults when breakers are ordered without integral ground fault protection They are also available to identify overload short circuit and ground fault trips for breakers Supplied with integral ground fault protection Each target pops out when its associated trip element operates to trip the breaker After a trip the popped target must be reset by hand However neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being closed 10 1 2 Remote Fault Indication Remote fault indicat
124. t accordingly Trip shaft of breaker shown in tripped position and shunt trip energized Spring Pin Frame Weight Screws Magnet Coll Clamp 9 Armature 10 Armature arm 11 Trip paddle 12 Clamp 13 Mtg bracket 14 Mtg hardware DADAS Fig 52 Shunt trip device 41 SECTION 7 Accessories 7 5 Undervoltage Device The undervoltage device UV is mounted on a bracket attached to the right side of the breaker operating mechanism viewed from front It trips the breaker when its coil is deenergized The coil leads are connected directly to secondary disconnects or to a terminal board Under normal conditions the coil remains energized permit ting the breaker to be closed When the system voltage de creases to a value between 30 and 60 percent of its nominal value the armature drops out and trips the breaker An open armature prevents the breaker from being closed The armature picks up and allows breaker closing when the sys tem voltage is 85 percent or more of its nominal value When the breaker is disconnected and is to be operated manually the undervoltage device may be tied or wired down to prevent tripping 7 5 1 Replacement Referring to Fig 53 a Disconnect coil leads b Remove mounting screws and remove device c Install new device in reverse order L Gj ES Eu PO Fig 53 Undervoltage device energized breaker reset 42 manam e yj ru Lif 7 5
125. t contact to the wipe dimension shown in Table 6 column 3 for the mains and column 6 for the intermediates Load on the scale should read within the range listed in Table 6 column 2 for the mains and column 5 for the intermediates If the load is not within the range listed replace the spring under that contact assembly 5 6 Measuring Contact Wipe Referring to Fig 11 a Remove arc quenchers b With the breaker open measure the horizontal distance from the edge of the stationary arcing contact to the retainer A dim for main and intermediate contacts measure the horizontal distance from the top of the contact to the contact arm retainer B dim c Close the breaker and repeat step b The difference between the readings determines the contact wipe See Table 6 for correct readings CAUTION FOR SAFETY REASONS BE EXTREMELY CAREFUL NOT TO TRIP THE BREAKER WHEN MEASURING CONTACT WIPE 5 7 Adjusting Contact Wipe Referring to Fig 11 a To obtain proper contact wipe and pressure on the center pole dimension C should be increased to increase wipe and decreased to decrease wipe b To change dimension C remove the clevis pin and rotate the clevis as necessary c To prevent overstressing the clevis threads dimension C should not exceed 3 16 in and space C should be filled with shims to 0 005 in of being solid d With the proper center pole wipe obtained moving the crossbar adjusting plat
126. the cam shaft paddle see Fig 31 The motor operator unit is located on the right hand side of the breaker as shown in Fig 29 Operator details are shown in Fig 30 The motor operator unit is not adjustable To replace the unit refer to Fig 27 a Slow close the breaker see Section 5 1 b Remove the motor see Section 6 4 2 The motor wiring doesn t have to be disconnected c Disconnect the wiring to the closing solenoid and solenoid switch d Remove retaining ring from closing solenoid drive link e Remove three mounting bolts one from the side two from the bottom of the charging mechanism Note the positions of the standoffs on the two bottom mounting bolts and replace in the same position when reassembling f Rotate motor operator shaft so its crank roller faces the rear of the breaker Refer to Fig 32 g Slide spring charging mechanism out toward the right of the breaker h Install new spring charging mechanism making sure the crank roller engages cam shaft guide Refer to Figs 31 and 33 Cam Shaft Pivot Cam Shaft Paddle Crank Roller Motor Operator Maintenance Handle Shaft Crank Roller gt Assembly E iu HE 0 _ HA Crank Roller Roller Prop Fig 31 Engagement of the motor operator crank roller with the cam shaft Fig 30 Motor operator unit paddle 30 i Reassemble all components and connect all wires j Remove safety pin fr
127. ubleshooting and test procedures for single phase high current low voltage tests or those employing the TAK TS1 Test Set The Ground Fault test procedures of course do not apply ECS phase sensor resistance values are given in Table 12 FLUX SHIFT TRIP COIL ICKUP DELAY INSTANTANEOUS PICKUP REGULATED 48 VOC POWER SUPPLY LONGTIME PICKUP DELAY SHORT TIME PROGRAMMER UNIT neem AA Se y ae eee CRC MD ee Oe Fig 75 ECS block diagram 58 Fig 74 ESC programmer unit Fig 76 ECS current sensor Table 11 ECS Trip Characteristics ECS PROGRAMMER ADJUSTMENT RANGE Set Points Frame Short Time Instan Breaker Size Sensor Pickup taneous Frame Amperes Ampere L Delay Pickup Delay Pickup Type Size i Multiple Band Multiple Band Multiple Type Seconds of L Seconds of L 25 3 4 AKS 4 4A 50 5 6 7 X I5 JM AK 4 4A 75 3000 Maximum Maximum AKR 4 4A 75 22 25 2 0 35 1200 1600 Intermed Intermed 4 5 6 AKR 4B 4C 4S 75 3200 2000 3000 10 0 21 8 10 12 L 3200 AK 100 EN 1600 2000 Minimum Minimum AKR 100 di 3000 4000 0 095 X Sensor ampere rating trip rating 3 Time delay at lower limit of band 6L Pickup tolerance 10 Time delay at lower limit of band Table 12 9 1 ECS Cabling Diagram Sensor Resistance Values Breaker Ampere Resistance in Ohms A OB oC FLUX SHIFT AM ah Type Rating Betwee
128. ular link rotates the The operating rod should also be aligned vertically to be auxiliary switch operating shaft parallel with the sides of the frame center channel and perpendicular to crossbar 1 This is done by shifting the position of bracket 5 1 Crossbar 4 Switch Shaft 2 Triangular link 5 Bracket 3 Operating rod 40 Fig 51 Auxiliary Switch 7 4 Shunt Trip The shunt tripping device is mounted on a bracket attached to the left side of the operating mechanism looking from the front remote switch or relay contacts are used to close the circuit of the device causing the armature 9 to engage the trip paddle 11 thereby tripping the breaker The spring 1 is used to return the armature to the neutral position after the breaker trips To prevent overheating the coil 7 is cut off by contacts of the auxiliary switch which are open when the breaker is open 7 4 1 Replacement Referring to Fig 52 a Disconnect coil leads b Remove mounting hardware and the device c Install new device in reverse order go EE E T Ci e 7 4 2 Adjustments With the shunt trip de energized and the breaker mechanism reset there must be clearance between trip paddle 11 and armature arm 10 0 03 in min A minimum 0 03 in over travel of the armature is required when the breaker is tripped If any adjustment is necessary to provide this amount of overtravel the trip lever is bent in or ou
129. uld also be checked for proper trip latch engagement See Section 6 3 1 In addition to the pick up settings and time delay adjustments already described overcurrent trip devices must be adjusted for positive tripping This adjustment is made at the factory on new breakers but must be made in the field when the breaker mechanism or the overcurrent trip devices have been replaced Positive tripping is achieved when adjustment screw 9 Figure 126 is in such a position that it will always carry the trip paddle on the trip shaft beyond the point of tripping the mechanism when the armature closes against the magnet In order to make the adjustment first unscrew trip screws 9 Figure 126 until it will not trip the breaker even though the armature is pushed against the magnet Then holding the armature in the closed position advance the screw until it just trips the breaker After this point has been reached advance the screw two additional full turns This will give an overtravel of 1 16 of an inch and will make sure that activation of the device will always trip the breaker Adjustment screw 9 Figure 126 can best be manipulated by an extended 1 4 inch hex socket wrench Fig 127 Checking travel distance of series overcurrent tripping device 92 13 7 Reverse Current Tripping Device The device is enclosed in a molded case and is mounted on the right pole base similar to the series overcurrent tripping device The
130. ully charged position is reached mechanically operated switches F and G reverse their shown position the G switch deenergizing the motor and the F switch establishing a circuit to the One Shot electronic With the closing spring propped fully charged the breaker is ready for closing This may be accomplished electrically by depressing the closing switch PB on the breaker if so equipped or by a remote closing switch Operation of the closing switch energizes the One Shot electronic witch in turn energizes the closing solenoid CC This removes the prop releasing the closing springs to close the breaker As the One Shot electronic is energized through a closing contact the X relay is energized as well The A relay will latch in and therefore prevent a second closing operation on the breaker in the event it is tripped open automatically The closing signal must be released and reapplied before a second closing operation can occur The closing springs on the electrically operated breakers can be manually charged LEGEND CC CLOSING SOLENOID F CUTOFF SWITCH CLOSED WHEN CLOSING SPRING IS FULLY CHARGED G CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGED L AUXILIARY SWITCH M CHARGING MOTOR PB CLOSE PUSH BUTTON ON BREAKER ESCUTCHEON OPTIONAL X CONTROL RELAY OS ONE SHOT ELECTRONIC PULSES THE CLOSING SOLENOID FOR 250 MSEC FIG 13 MANUAL OPERATION OF CLOSING SOLENOID
131. used with the RMS 9 system 11 3 1 Replacement of Current Sensors Referring to Fig 88 replacement of RMS 9 amp Epic MicroVersaTrip current sensors is accomplished by the same procedure as the MicroVersaTrip current sensors 11 4 Flux Shifter Trip Device The only difference between the RMS 9 Epic MicroVersaTrip and the SST flux shifter trip devices is the solenoid winding Refer to Section 8 3 for details When replacing a RMS 9 Epic MicroVersaTrip flux shifter AMP extraction tool Cat No 455822 2 is required to remove the socket leads from the AMP connector 11 5 Troubleshooting When malfunctionion is suspected the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as a Breaker tripping in proper response to overcurrents or incipient ground faults f b Breaker remaining in a trip free state due to mechanical maintenance along its trip shaft c Inadvertent shunt trip activations WARNING DO NOT ADJUST THE PROGRAMMER UNIT KNOBS WHILE THE BREAKER IS CARRYING CUR Once it has been established that the circuit breaker can be opened and closed normally from the test position attention can be directed to the trip device proper Testing is performed by either of two methods 1 Conduct high current single phase tests on the breaker using a high current low voltage test set NOTE For these single phase tests special connections mu
132. vis pin Auxiliary switch 3 Front back frame operating rod connector Phase barriers Position interlock Arc quencher retainer bolts Fig 9 Front and back frame separation details Remove the two opening springs 1 on lower part of the breaker from the outside pole units C d Remove the clevis pin 2 from the center pole unit Disconnect the programmer CT wire harness at each CT and remove any tye wraps holding leads to back frame e Disconnect the flux shifter actuator bracket from the crossbar assembly 4 f g h Remove the auxiliary switch operating rod 5 Remove outside phase barriers 6 Remove side support bolts 7 Remove position interlock on AKD AKD 5 AKD 6 type 8 Remove arc quencher retainer and bolts 9 k Remove the six nuts from the back frame using a socket wrench with an extension These include the two nuts at the top of the frame Check along the trip shaft for a mechanical interference or Connection between the overcurrent trip device and the trip paddles Remove mechanical connection if present or if interference exists use extreme care when removing or reassembling front and back frames to avoid mechanical breakage of trip devices When reassembling the front and back frames both should be positioned vertically so that the trip shaft is horizontally aligned It is recommended that the breaker back frame be fastened to a suitable mounting surfac
133. vising a complete safety program The follow ing basic industry practiced safety requirements are appli cable to all major electrical equipment such as switchgear or switchboards General Electric neither condones nor assumes any responsibility for practices which deviate from the following 1 ALL CONDUCTORS MUST BE ASSUMED TO BE ENER GIZED UNLESS THEIR POTENTIAL HAS BEEN MEASURED AS GROUND AND SUITABLE GROUNDING CONDUCTORS HAVE BEEN APPLIED TO PREVENT ENERGIZING Many accidents have been caused by back feeds from a wide variety of sources 2 Although interlocks to reduce some of the risks are provided the individual s actions while performing service or maintenance are essential to prevent accidents Each person s knowledge his mental awareness and his planned and executed actions often determine if an accident will occur The most important method of avoiding accidents is for all associated personnel to carefully apply a thorough understanding of the specific equip ment from the viewpoints of it s purpose it s construction it s operation and the situations which could be hazardous All personnel associated with installation operation and mainte nance of electrical equipment such as power circuit breakers and other power handling equipment must be thoroughly in Structed with periodic retraining regarding power equlpment in general as well as the particular model of equipment with which they are working Instruction books
134. with a companion primary winding on a ground differential transformer mounted in the programmer unit Its secondary output is zero so long as there is not ground current 48 HARK d MA Fig 60 AKS 5A 50 Application of the Ground Fault element on 4 wire systems with neutral grounded at the transformer requires the additional separately mounted neutral sensor Fig 62 inserted in the neutral conductor its secondary is connected to a fourth primary winding on the ground differential transformer See Fig 72 This fourth wire neutral sensor is an electrical duplicate of the phase sensor including taps Therefore when taps are changed on the phase sensors those on the neutral sensor must be correspondingly positioned When used the neutral sensor is separately mounted in the bus or cable compartment of the switchgear In drawout construction its output is automatically connected to the breaker via secondary disconnect blocks See Fig 63 o e T Po c x lt w E kol 0 hd Fig 61 SST phase sensors with tap board Tap AKR 75 100 Fig 62 SST neutral sensors 49 SECTION 8 Type SST Overcurrent Trip Device Neutral sensor secondary disconnect block breaker mounted 8 2 1 Replacement of Current Sensors AKS 50 Referring to Fig 64 AKS50 phase sensors are removed as follows a Remove the connections to and the wiring harness from the sensor tap board b Remove the tap b

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