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Gerapid DC OEM Module - GE Industrial Solutions

1. eee tenens 19 7 3 Trolley with Remote RACKING sees 19 Operational positions 19 Remote Rack In Procedure ees 20 Manual Rack Out Procedure ees 21 7 4 Operate the breqker lites a nba s 21 TROUBLESHOOTING AND MAINTENANCE cote teet 22 8 1 Troubleshooting aa 22 Manually operated trolley 22 Motor driven 22 8 2 22 CUSTOMER SUPPORT A erp etait 23 OnE un SS hum 23 8 2 Field Service Support eerte 23 8 3 Publications and other support 23 APPENDIX A MODULE amp TROLLEY DRAWINGS teme rods 24 APPENDIX B PRIMARY TERMINALS DRAWINGS a 26 APPENDIX C LAYOUT DRAWINGS p fa i e e 29 APPENDIX D TIGHTENING TORQUES TABLES 30 APPENDIX E ELECTRICAL DIAGRAMS 31 APPENDIX RATING TABLES uN nanas nag a h au achi ayda in 39 APPENDIX G ACCESSORIES amp INSTALLATION DRAWINGS 40 APPENDIX H FIELD TEST PROCEDURE 43 Design and specifications are subject to change
2. HS6 Dur RAL IL n MINA BREAKER AUXILIA UM Hab GERAPID TERMINAL 7 GERAPID BREAKER AUXILIARY HS6 3 ej qnicn gt Ca CAC Y28 Y29 2 132 0 D 6 ri 9 Y28 I E TAE o I Yo a GERAPID TERMINAL GERAPID BREAKER AUXILIARY N O HS7 4 GERAPID TERMINAL GERAPID BREAKER AUXILIARY COM HS 5 GERAPID TERMINAL RAPID BREAKER AUXILIARY N H GERAPID TERMINAL GERAPID BREAKER AUXILIARY HSB 7 GERAPID TERMINAL GERAPID BREAKER AUXILIARY COM HSB B GERAPID TERMINAL GERAPID BREAKER AUXILIARY N C HS8 9 GERAPID TERMINAL X RAPID BREAKER AUXILIAR HS3 10 Y50 GERAPID BREAKER AUXILIARY COM HS8 11 GERAPID TERMINAL X5 12 GERAPID BREAKER AUXILIARY HS9 12 AUX CONTACT BREAKER GPS1B 1 RACKING MOTOR CIR BREAKER AUXILIARY SWITCH AUX CONTACT BREAKER GPS1B 1 1 RACKING MOTOR CIRCUIT BREAKER AUXILIARY SWITCH Note 2 Y empb BREAKER GPS1B 1 RACKING MOTOR POWER SUPPLY Moez _ TERMINAL 1 10 _ MOTOR POWER SUPPLY IN Moez Y C Ew us DRIVE COMMAND CIRCUIT EMERGENCY RACKING STOP NORMALLY CLOSED Moez COMMAND _ EMERGENCY RACKING STOP NORMALLY CLOSED Note 7 DRIVE CO
3. d W z Te Te z Tu 9 LS Tp KZ T rex T8 2 9 T L L8 e T1 6X oe Lee DS NEP ss M TRECE SENS dv 439 Ob 6 6 84 9353 G3 Od 5w3 L6 AT ax 253 941 pA SNA Exe Ieee OL RO em CLES m FP FE f EE 7 L LSA OSA BRA BFA EPA GPA IPA OPA ESA BEA LEA JEA GEA PEA ECA ZEA LEA BZA 39509 APPENDIX Electrical Diagrams page 01 04 APN465329 Electrical diagram remote racking Fig E 1 Remote Racking Module Gerapid connections 31 Design and specifications are subject to change without notice 2011 04 26 547183 01 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX F Rating Tables zw zz i n TE id y zz i 9 i ub 2 ub 2 i 9 12 zn ug uu TES 5 ef 12 ub 5 338 HE E 5 00 2907 MNYM3 NDHISOd NOILISOd SHG NOILISOd 1f NI 3 5 425 Ee 6 66 X57 24 9GA ex TT HEN EE 3J amp li 1no NI cy 1 Z Y XS ino Iv Iv iy XOZ wl 2757 i 9115 915 B ML Mt k ceS
4. HS8 8 GERAPID TERMINAL X5 9 GERAPID BREAKER AUXILIARY N C H58 9 GERAPID TERMINAL X5 10 GERAPID BREAKER AUXILIARY N J HS9 10 GERAPID TERMINAL X5 11 APID BREAKER AUXILIARY COM HS9 11 GERAPID TERMINAL X5 12 GERAPID BREAKER AUXILIARY N C HS9 12 GERAPID TERMINAL X5 13 RACKING MOTOR CIRCUIT BREAKER AUXILIARY SWITCH 3j GERAPID TERMINAL X5 14 R R CIRCUIT BREAKER AUXILIARY SWITCH ee Yu AF SNB O oo oit oie n Y O Ol BREAKER GPS1B 1 RACKING MOTOR POWER SUPPLY TERMINAL X1 10 2222 MOTOR POWER SUPPLY ee ee ep E ee fa DRIVE COMMAND CIRCUIT EMERGENCY RACKING STOP NORMALLY CLOSED 1 _ ____ DRIVE COMMAND CIRCUIT PS EMERGENCY RACKING STOP NORMALLY CLOSED C C DRIVE COMMAND CIRCUIT RACK BREAKER IN COMMAND YB81 COMMAND CIRCUM C C RACK BREAKER IN DRIVE COMMAND CIRCUIT RACK BREAKER DUT COMMAND DRIVE COMMAND CIRCUIT RACK BREAKER GUT COMMAND 4 COUPLING SWITCH NORMALLY CLOSED UMBILICAL PLUG INTERLOCK COUPLING SWITCH NORMALLY UMBILICAL PLUG INTERLOCK 33 4 BREAKER POSITION NORMALLY OPENED UMBILICAL PLUG INTERLOCK 33 4 BREAKER POSITION NORMALLY OPENED UMBILICAL PLUG INTERLDCK 33 4 BREAKER POSITION NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 33 4 BREAKER POSITION NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 55 5 222 BREAKER PO
5. ZEA LEA 624 2156 Tele z T SX YASNA NIYIN a e L pa 1 5 T h T SL j _ L p L SL L L L L L Dh 110 C L ee CL G L ee page 01 04 APN465330 Electrical diagram manual racking Fig 5 Manual Racking Module Gerapid connections 35 Design and specifications are subject to change without notice 2011 04 26 547183 01 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX F Rating Tables NOLISOd 498 504 38 NOLISOJ 31228025101 JHL N3d0 359349 355 f NANIO IHL HUA NWOHS SIOVINOA TIY ON 2 u n OWN sf i NOILISQd 49 NOlISOd MH HALS 09 G E r 375 66 IZ lt Byd PA Swi e re T acl 1 rra L Fel e EN DI E ZOA 10 OQA OSA BGA OA GGA GA BA ep BBA BA E ERR 350705 DONTES SNIS NOLWWSOd MOM 399388 0109410 page 02 04 APN465330 Electrical diagram manual racking Fig E 6 Manual Racking Module Control diagram 547183 01 2011 04 26 Design and specifications a
6. CONTROL COMPARTEMENT BREAKER 2200 86 61 PRIMARY STABS 4 000 i H SEE DETAIL CABLE COMPARTEMENT 1050 41 39 600 23 62 1500 59 06 Fig A 4 Outline dimensions for OEM Module with 450 17 72 inches Cable Compartment 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX B Primary Terminals Drawings APPENDIX B Primary Terminals Drawings 1861 2 lis 1 OF mm TX y Seno 9a 08 62 1101 Fe 618 FF Z 29 41791 DEI 9 6 9 31 01 852 922389124 XII 2 6 ae ee 7 ee S ZXI 7LILILIX 25 6 srca tye a pr Na SL 192 99 IBS 7 28 165 21 6 RIE 11 17087 Fig B 1 2500A and 4000A Primary Terminals of OEM DC Module Units are mm inches S47183Ee rev 01 2011 04 26 Design and specifications are subject to change without notice 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX B Primary Terminals Drawings q DE UU 0 7 ee ee Ae GS Wa xu 9 9 9 LI 8 B 9 8 1 48 9 1 35 59
7. E as CS 371943N3 30 1081N03 j ey yar E 5 NOWSOd 3193990250 JHL NI N3dO 375338 E 6992 JHL NWOHS 51241802 TIY LON 0 1 gt tl A WI El ales 11 2267 af HS zt ty of 7 12 TL n ipe ale 3 p e es 74221 ELACA 402 99 FIA CGA GGA n a rt ee tore _ dX 2 t zc j NOJ 153 38804 QOO 38019 02 04 APN465329 Electrical diagram remote racking Fig E 2 Remote Racking Module Control diagram 547183 01 2011 04 26 Design and specifications are subject to change without notice 32 PIN CODING SOCKET HC B 24 5 ao 1 00 CODING PLUG HC B 24 TFL DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX E Electrical Diagrams Go od O 95 GG oo 2 O amp 465429 Electrical diagram remote racking Fig E 3 Remote Racking Module Secondary Disconnect coding 2011 04 26 547183 01 Design and specifications subject to change without notice page 03 04 33 34 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX F Rating Tables
8. Module amp Trolley Drawings TROLLEY FRONT VIEW 23 4 mL QE a E ILC SS ka o eme Eri SS E Q 2 i 4 ar E 3 P C amp B rz Lae s 7 edes VM 1 ce Lae 3 hl 1 n GB C c rd J ja 15 9 117 ie ga lt u jj ts mp PEEN 3 LL T 881 1 E 95 x 221 n _ s A Fig A 2 Primary disconnect clusters for 2508 4008 left and 5008 6008 right Gerapid breakers Units are mm inches 24 Design and specifications are subject to change without notice 547183 rev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX A Module amp Trolley Drawings FRONT VIEW S44 21 42 _ 250 982 LEFT SIDE VIEW 583 22 95 DETAIL A PRIMARY STABS 6 000 amp CONTROL COMPARTEMENT BREAKER 2200 86 61 PRIMARY 4 000 rh idi SEE DETAIL A CABLE COMPARTEMENT 1050 41 59 600 23 62 1800 70 87 Fig A 3 Outline dimensions for OEM Module with 750 mm 29 53 inches Cable Compartment FRONT VIEW 544 2142 250 982 LEFT SIDE VIEW 583 22 95 DETAIL A PRIMARY STABS 6 000
9. WIRE HARNESS END LABELS WIRE ORIGIN DESCRIPTION IL l GERAPID TERMINAL X2 1 222 GERAPID CLOSING DRIVE SUPPLY O GERAPID TERMINAL X2 2 GERAPID CLOSING DRIVE SUPPLY GROUND TERMINAL x1 15 GERAPID MOTOR RACK GROUND Wi C GERAPID TERMINAL X2 4 RAPID OLENOID CLO COMMAND GERAPID TERMINAL X2 5 GERAPID SOLENOID CLOSE COMMAND CERAPID TERMINAL X2 6 GERAPID 52 BY ST COMMAND Note T _ GERAPID IERMINAL X2 7 GERAFID 52 OPEN BY ST COMMAND Mete T CERAPID TERMINAL X2 8 GERAPID 52 OPEN BY UVR COMMAND Note T Y08 GERAPID TERMINAL 2 0 GERAPID 52 OPEN BY UVR COMMAND MoeT GERAPID TERMINAL X2 10 GERAPID 53 ED FIRING SIGNAL Note 7 GERAPID TERMINAL X2 11 53 ED FIRING SIGNAL RAPID TERMINAL X a 7 E GERAPID TERMINAL X3 1 GERAPID TERMINAL X3 2 GERAPID TERMINAL X3 3 cr GERAPID TERMINAL 3 4 GERAPID EXTERNAL CONTROL VOLTAGE SUPPLY H CERAPID TERMINAL X3 5 GERAPID EXTERNAL CONTROL VOLTAGE SUPPLY 2 gt GERAPID TERMINAL RERAPID NEKO CHARGING INDICATOR Note T GERAPID TERMINAL X3 7 GERAPID NEKO CHARGING INDICATOR Now GERAPID TERMINAL X3 8 GERAPID WITH OCT INDICATOR Note TERMINAL X3 8 RAPID OCT INDICATOR Note GERAPID TERMINAL X3 10 AE GERAPID TERMINAL X3 11 a ae ee ert GERAPID TERMINAL X3 12 RAP CH NDICATOR Note
10. GE Energy Industrial Solutions DC OEM Module For use with Gerapid DC Circuit Breaker Installation and Maintenance Instructions 2011 04 26 547183 01 Design and specifications are subject to change without notice Design and specifications are subject to change without notice 547183 rev 01 2011 04 26 INDEX Dip DIG Ir 5 GenerqaliNotesuu ou aa a Sab 5 1 2 Instruction Book Arrangement sees 5 1 3 Related Publications 5 RECEIVING HANDLING AND STORAGE trend En IHRER e end 6 2 1 RECEIVING e u u e Grins Oase Clau 6 Module and Trolley Package sees 6 Inspecting for tentes 6 E To MM 6 2 2 Handling and unpacking se 6 Module handling and unpacking sss 6 Trolley handling and UNPACKING sss 7 2 551 ahina etc tera etg tie tene od odo tette 7 Circuit BEBOKGES a e omg 7 Modules dnd oto tate taret tario tree at pde ieu 7 GENERAL DESCRIPTION hn quado ettet nde qu bd 8 3 1 General 8 3 2 Summary Description eerte cett elt 8 kusanata 8 I Ler oekS uy a uay ua uska manua uku maaa apa maa ka 8 PC COSSOMCS u ore ee ua UT 8 as aaa a an au ass 8 Breaker Com
11. Remove protective covering Check thoroughly for damage Store in a clean dry rodent free location with moderate temperature and provide protective coverings to prevent dirt water or other foreign substances from entering the equipment If dampness or condensation may be encountered in the storage location heaters must be placed inside the module breaker compartment module must be without trolley and in the front of the trolley with trolley door open to prevent condensation Approximately 250 watts of heat in each section is required Incandescent lamps can be used and located in the bottom of the breaker compartment and supported so the bulbs will not touch adjacent materials Design and specifications are subject to change without notice 7 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 4 Installing the Module General Description 3 1 General Notes This section contains a description of the GE DC OEM Module and Trolley for use with Gerapid high speed DC circuit breaker It also describes the functions of the electrical and mechanical systems 3 2 Summary Description The DC OEM Module is an individual freestanding metal enclosed switchgear section designed to be used in conjunction with the withdrawable trolley containing a Gerapid circuit breaker auxiliary contacts primary finger clusters and secondary disconnect Ratings The module is designed to be used on DC systems operating up to 800VDC and 6000
12. 1 GERAPID TERMINAL X3 3 GERAPID TERMINAL X3 4 GERAHFID EXTERNAL CONTROL VOLTAGE SUPPLY Ho GERAPID TERMINAL X 3 5 GERAPID EXTERNAL CONTROL VOLTAGE SUPPLY _________ GERAPID TERMINAL X3 6 GERAPID NEKO CHARGING INDICATOR _ Note GERAPID TERMINAL 5 GERAPID NEKO CHARGING INDICATOR Note C GERAPID TERMINAL X3 5 WITH OCT INDICATOR Note 1 ___ GERAPID TERMINAL X3 9 GERAPID WITH INDICATOR _ Note GERAPID TERMINAL X3 10 T pum ee a GERAPID TERMINAL X3 12 GERAPID AIR CHUTE INDICATOR GERAPID TERMINAL X3 13 GERAPID AIR CHUTE INDICATOR Note GERAPID TERMINAL X3 14 GERAPID TERMINAL X3 15 ue GERAPID TERMINAL 4 4 GERAPID BREAKER AUXILIARY HS2 4 GERAPID TERMINAL GERAPID BREAKER AUXILIARY HS2 5 GERAPID TERMINAL GERAPID BREAKER AUXILIARY N C HS2 GERAPID TERMINAL RAPID BREAKER AUXILIARY D GERAPID TERMINAL GERAPID BREAKER AUXILIARY COM 8 GERAPID TERMINAL GERAPID BREAKER AUXILIARY N C HS3 9 GERAPID TERMINAL X RAPID BREAKER AUXILIARY N 54 GERAPID TERMINAL 4 11 GERAPID BREAKER AUXILIARY COM HS4 1 GERAPID TERMINAL X4 12 GERAPID BREAKER AUXILIARY N C HS4 1 GERAPID TERMINAL X4 13 GERAPID BREAKER AUXILIARY HSS 1 RAPID ARF SA D A D GERAPID TERMINAL X4 14 RAPID BREAKER AUXILIAR N n GERAPID TERMINAL X4 GERAPID BREAKER AUXILIARY N C HSS 1 GERAPID TERMINAL X5 1 GERAPID BREAKER AUXILIARY
13. 125 5 4 94 825 25 32 49 1900 25 39 38 65 2 56 58 10 16 87 5 3 44 344 75 13 57 219 8 62 227 25 8 95 Fig B 2 5000A and 6000A Primary Terminals of OEM DC Module Units are mm inches 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 2 amp 5 26 100 3 941 712 25 1 98 28 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX B Primary Terminals Drawings a 212 12471 Side View 65 2 56 lt r1 lt gt EJ s87 0 00 19 gt Do Sof JjoooOo9ooQoooQo9 9oQ L5 300 k 2 Top View Fig B 3 Ground bus main connect Des to chonge without notice 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX B Primary Terminals Drawings APPENDIX C Layout drawings TOP VIEW Dimension A min 0 3 ft Dimension B min 7 ft Dimension C 0 3 ft in case of no need for rear access min 1 5 ft in case of need for rear access NOTE Minium free space over the Module s roof should be 1 5 ft Fig C 1 Minimum required distances for installing the DC OEM Module 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 29 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX C Layout Drawings APPENDIX
14. GERAPID TERMINAL X3 13 GERAPID AIR CHUTE INDICATOR GERAPID TERMINAL X3 14 2775 772222 JUI GERAPID TERMINAL X3 15 DE GERAPID TERMINAL X4 4 GERAPID BREAKER AUXILIARY HS2 4 GERAPID TERMINAL 4 5 GERAPID BREAKER AUXILIARY HS 5 GERAPID TERMINAL X4 5 RAPID BREAKER AUXILIARY N H GS GERAPID TERMINAL X4 7 GERAPID BREAKER AUXILIARY N D HS3 7 GERAPID TERMINAL X4 8 GERAPID BREAKER AUXILIARY COM HS3 8 2 1 TERMINAL X4 9 RAPID BREAKER AUXILIARY N j GERAPID TERMINAL X4 10 GERAPID BREAKER AUXILIARY HS4 10 Y35 QERAPID TERMINAL C C C RAPID BREAKER AUXILIARY HS4 GERAPID TERMINAL X4 12 GERAPID BREAKER AUXILIARY HS4 12 GERAPID TERMINAL 4 13 GERAPID BREAKER AUXILIARY HS5 13 dGERAPID TERMINAL 4 14 C C RAPID BREAKEF AUXILIARY COM H j GERAPID TERMINAL 4 15 GERAPID BREAKER AUXILIARY H55 15 GERAPID TERMINAL X5 1 GERAPID BREAKER AUXILIARY N O H56 1 GERAPID TERMINAL X5 2 RAPID BREAKER AUXILIARY COM HSS GERAPID TERMINAL X5 3 GERAPID BREAKER AUXILIARY N C HS6 3 GERAPID TERMINAL X5 4 GERAPID BREAKER AUXILIARY HS7 4 GERAPID TERMINAL X5 5 RAPID BREAKER AUXILIARY COM H GERAPID TERMINAL X5 5 GERAPID BREAKER AUXILIARY N C H57 6 GERAPID TERMINAL 5 7 GERAPID BREAKER AUXILIARY N D HS8 7 GERAPID TERMINAL X5 8 RAPID BREAKER AUXILIARY COM
15. Installation Procedure To install the Gerapid circuit breaker proceed as follows 1 Ensure that the lifting frame has been removed from the trolley See Fig 22 2 2 Place the lifting slings in position See Fig 52 1 Carefully lift the breaker and place it on the trolley 3 Slide in the breaker toward the front of the trolley until four attachment bolt holes in platform match the holes in breaker baseplate Install bolts provided and tighten with torque listed in Table D 1 The fixing kit is attached to the trolley s platform 4 Plug in all connectors to correct terminals at the front of breaker s control box Tight the connectors See Fig 52 3 WARNING Do not stand under the circuit breaker during the lifting and transport operations NOTE Do not transport the circuit breaker with arc chute installed Fig 52 1 Lifting the breaker Design and specifications are subject to change without notice 13 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 5 Installing the Breaker A ee Fig 52 2 Breaker on the trolley NOTE Do not use attachment screws longer than 1 2 in Longer screws may damage trolley s components Configuration of the Rejection Interlock It is strongly recommended to check and set up correct position of the rejection interlock immediately after breaker is installed on the trolley All trolleys have their rejection interlock set at 2500A by default If t
16. cable channel be Sr ri ire nn r connector EDIT M DETAIL 4 screws G for installing cable channel connector D COUPLING DETAIL a L gt Le Lee Le Pras im ee a L Lid G s s mw m w P E G P WS E EF Q Oo Ga ecl s s ss s s coble channel cover E 2 screws G for installing cable channel cover E Fig G 4 Installing end cover E for top cable channel 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 41 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX G Accessories and Installation Drawings Edge Strips gt 4 Qe O 4 Q O O Q O 2 gt 4 O O gt O O I O O O O WN O C T 4 LO gt O Fig G 5 Installing edge strips and side cover B or C 547183 01 2011 04 26 Design and specifications are subject to change without notice 42 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX H Field Test Procedure APPENDIX H Field Test Procedure This Appendix describes full recommended procedure for Field Testing of DC OEM Module equipped with Gerapid DC Circuit Breaker The description co
17. C37 14 Trip free capability according to ANSI C37 100 TRASSA Gerapid 6008 See Fig 35 3 v 6000 frame size Standard 200 peak interrupting current at 800VDC 3700V power frequency withstand level v Current limiting characteristic v Tested for duty type a b c and d according to ANSI C37 14 v Trip free capability according to ANSI C37 100 10 Design and specifications are subject to change without notice Main arcing contaci Arc chute Adaptor Flexband Contral connectors Control bas Aumiliany contacts Impulse ED coil release Oc release losing salarepsd drive Shunt trip i Tero valtaqe releager device Lever rain berminal Fig 355 1 Gerapid circuit breaker construction Fig 35 2 Gerapid 2508 and 4008 circuit breakers Fig 35 3 Gerapid 5008 and 6008 circuit breakers 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 4 Installing the Module Installing the Module 4 1 General Notes This chapter contains instructions for installing the GE DC OEM Module CAUTION Personnel installing this equipment must be thoroughly familiar with this instruction manual and all articles of the National Electrical Code applicable to the installation of this equipment In addition all drawings both mechanical installation and electrical must be understood and strictly followed to prevent damage to the module Enviro
18. OPEN Positions Check signal must be active The breaker must not CLOSE if it is not in TEST or CONNECTED position The trolley must not move while breaker is CLOSED The trolley must not move out of the module while Plug is connected The trolley must move out of the module 547183 01 2011 04 26 2011 04 26 547183 01 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX H Field Test Procedure Table H 4 DC Module w o Remote Racking Field Test Procedure Trolley is in WITHDRAWN position Breaker is OPEN Insert Crank Handle b into Access Slot c Trolley is in DISCONNECTED position Breaker is OPEN Insert Crank Handle b into Access Slot Connect Secondary Plug 9 Trolley is in TEST position Breaker is OPEN Remove Crank Handle b from the slot c Trolley is in TEST position Breaker is OPEN Insert Crank Handle b into Access Slot C Trolley is in CONNECTED position Breaker is OPEN Trolley is in CONNECTED position Breaker is OPEN Insert Crank Handle b into Access Slot C Trolley is in TEST position Breaker is OPEN Remove Crank Handle b from slot c Trolley is in TEST position Breaker is OPEN a Try to rack in the trolley to CONNECTED position Try to CLOSE the breaker CLOSE the breaker Check Position Check signal at this position Try to lift up Access Lever e Try to lift up Trip Lever d
19. Rack in the trolley to a position between TEST and CONNECTED Remove Crank Handle CLOSE the breaker Rack in the trolley to CONNECTED position Remove Crank Handle CLOSE the breaker Try to lift up Access Lever Try to lift up Trip Lever d Check Position Check signal at this position Rack out the trolley into a position between CONNECTED and TEST Remove Crank Handle CLOSE the breaker Rack out the trolley into TEST position CLOSE the breaker Try to lift up Access Lever e Try to lift up Trip Lever d Check Position Check signal at this position Try to manually pull trolley out of the module Disconnect Secondary Plug g Try to manually pull trolley out of the module The trolley must not move while Secondary Plug g is disconnected The breaker must not CLOSE while Crank Handle b is inserted The breaker must CLOSE Positions Check signal must be active The Access Lever must not move while breaker is CLOSED The breaker must OPEN The breaker must not CLOSE if itis not in TEST or CONNECTED position The Access Lever must not open while breaker is CLOSED The breaker must OPEN Positions Check signal must be active The breaker must not CLOSE if it is not in TEST or CONNECTED position The Access Lever must not open while breaker is CLOSED The breaker must OPEN Positions Check signal must be active The trolley must not move
20. Tables Table F 1 UL listed Gerapid Ratings according to IEEE Std C37 14 2002 Table F 2 UL listed DC OEM Module Ratings according to IEEE Std C37 20 1 2002 functional parts replaced during the listed number of operations Breakers require servicing at recommended intervals Servicing consists of adjusting cleaning lubricating tightening and similar procedures as recommended in Users Guide S47183De 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 39 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX G Accessories and Installation Drawings APPENDIX G Accessories amp Installation Drawings Accessories Table G 1 List of accessories for DC OEM Module DCOEMCRANK 700695 Crank handle for manual racking Consists of 1 handle Side cover kit for 450 mm depth cable compartment Consists of DCOEMCOVER15 700696 E LL iU v 4 pcs of edge trim strip v 16 pcs of bolting sets like in 289160 C Side cover kit for 750 mm depth cable compartment Consists of DCOEMCOVER18 700697 2 pcs ol side cover _ 4pcsof edge trim strip 20 pcs of bolting sets like in 289160 Cable channel connector for connecting top cable channels Sufficient for connecting eleven 11 OEM modules side by side Attachment requires four 4 DCOEMCONNECTOR 700698 screws M6x12 289158 per single cable duct connector Consist of v 10 pcs of cable duct connector v 10
21. available at http www geindustrial com Go to Products Circuit Breakers Gerapid Fig 11 1 DC OEM Module and Trolley with Gerapid High Speed Circuit Breaker Design and specifications are subject to change without notice 5 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 2 Receiving handling and storage Receiving handling and storage 2 1 Receiving Module and Trolley Package Every package leaving the factory is plainly marked with the case number requisition number and customers order number The Module and the trolley are shipped in separate wooden crates The contents of each shipping package are listed on the crate NOTE Breakers Trolleys and Modules ordered individually and shipped separately Module accessories If ordered are shipped separately See Fig 21 1 for crates dimensions Crates load weights are 6 5 2 6 8 0 ft 850 Ibs 3 9 2 6 5 8 ft 500 Ibs W Crate with module Crate with trolley D Fig 21 1 Typical wooden module crate for shipment Inspecting for Damage All equipment leaving the factory is carefully inspected and packed by personnel experienced in the proper handling and packing of electrical equipment Upon receipt of any equipment immediately perform q visual inspection to ascertain if any damage has been sustained in shipping or if there are any loose parts Be sure to Inspect all devices mounted inside compartments of e
22. covers Components Mounting Plate Fig 42 4 Control compartment Device mounting on control compartment door Control compartment s door should be removed before making any cutouts To remove the door open and remove grounding connection Lift the door up until the pins are free from hinges All auxiliary devices can be attached to the mounting plate provided at the back of the control compartment However it is recommend prefabricating a separate metal sheet and installing it in the control compartment using frame supports There are two cover plates that provide access to the top mounted wire way cable channel Remove the covers to use them See Fig 42 4 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 5 Installing the Breaker Installing the Breaker 5 1 General Notes Before installing operating or removing a circuit breaker refer to the Gerapid breaker instruction manual S47183De preparation inspection and test Check thoroughly for damaged or loose parts and for any dirt or foreign matter which may be in the breaker To install the breaker proceed as follows 1 Before installing a breaker check the contact areas on each primary disconnect cluster of fingers for foreign matter that may have accumulated Clean these areas if necessary Be sure that a thin film of the red lubricating grease MOBIL GREASE 28 covers the fingers areas before putting
23. information needed prior to installation site location and foundation requirements and how to anchor the equipment properly and safely It also covers information on electrical connections and mechanical construction 2011 04 26 547183 01 Chapter 5 Installing and Removing the Breaker gives step by step procedure for lifting the breaker from the floor and installing it on the trolley Information on configuring the Rejection Interlock on the trolley is included e Chapter 6 Testing and Inspection reviews items which should be field tested or inspected prior to energizing and operating the switchgear e Chapter 7 Operating the Module covers how to operate the trolley the module and the breaker This section contains information concerning drawout provisions and functions of various accessories e Chapter 8 Energizing the Module outlines the steps to be taken before and during the electrical energization of the completed equipment e Chapter 9 Maintaining the Module provides instructions for recommended preventive maintenance servicing and lubrication information for the module e Appendixes contains information covering ratings dimensional drawings electric diagrams screw and bolt torque values field testing procedures and accessories 1 3 Related Publications Detailed Users Guides and Instruction Books for the Gerapid breaker and other devices not fully described in this instruction book are
24. out of the module while Secondary Plug is connected The trolley must move out of the module END OF PROCEDURE Design and specifications are subject to change without notice 45 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX H Field Test Procedure Table H 6 High Potential Tests for the module and the trolley Step Starting Status Check Points CLOSE the breaker connectors and frame 2 2 Trolley is at CONNECTED position Apply 3 9 kV DC or 2 8 kV RMS for 60 seconds between TOP main No flashover Breaker is OPEN connector and frame Connect BOTTOM connector with frame Trolley is at CONNECTED position Apply 3 9 kV DC or 2 8 kV RMS for 60 seconds between BOTTOM flashover Breaker is OPEN main connector and frame Connect TOP connector with frame 46 Design and specifications are subject to change without notice S47183Ee rev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX H Field Test Procedure Table H 7 High Potential Tests for control and auxiliary circuits Trolley is at TEST position Apply 3 9 kV DC or 1 2 kV RMS for 60 seconds between Breaker is OPEN wiring harness and frame Connect all control wires together Disconnect all earthing wires Table H 8 Grounding Circuit Tests Step Starting Status Check Points Pass Criteria Check mounting screws of end switches no 33 1 33 2 33 3 S4F 33 4 33 5 Check door locks of the control compart
25. position unless Secondary Disconnect is connected Rack out Interlock prevents the trolley from being fully withdrawn from the Module unless the secondary disconnect is unplugged See Fig 71 6 After removing the plug both interlocks move to the right and reset This enables withdrawal operation and blocks rack in operation as shown at Fig 71 7 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 7 Operating the Module Receptacle Snap Lock SS Rack In Interlock active E release LI Rack Out Interlock Fig 71 6 Secondary Disconnect with two interlocks Rack In Interlock activated k Pork position for the plug Fig 71 7 Operation of Rack in Interlock Remote Racking A motor drive 230V 60 Hz and 250 W 0 34 Hp is available for Remote Racking option The gear motor is installed in the front bottom compartment of the trolley See Fig 34 1 Complete rack in or rack out operation lasts 8 seconds Actuator Pins of 33 1 D Racking Socket Fig 71 8 Limit switches 33 1 and 33 2 The motor is protected by 2 5A fuse element Two independent limit switches 33 1 and 33 2 switch off the motor drive s supply when the trolley reaches CONNECTED position Limit switch 33 3 stops the trolley in TEST position See Fig 71 9 All three switches are wired to block the breaker CLOSE operation if the trolley is between CONNECTED and TEST
26. without notice 3 Design and specifications are subject to change without notice 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 1 Introduction Introduction 1 1 General Notes This manual contains procedures for receiving handling storage operation and maintenance of GE s DC OEM Module called also the Module in this document with withdrawable DC OEM Trolley referred to as Trolley in this document for use with Gerapid high speed DC circuit breaker referred to as Breaker in this document The OEM Module is designed to simplify the construction of a DC switchgear assembly Typical applications for such equipment are Heavy and Light Rail Transit systems commercial IT systems Data Centers heavy industrial applications in mining and metals Other applications include equipment to supply DC motors excitation systems or high power DC testing and research facilities DC OEM Module and Trolley described in this document are UL Recognized components for use with GE s UL listed Gerapid high speed circuit breaker NOTE The personnel responsible for installing operating and servicing this equipment should be thoroughly familiar with the contents of this manual Before any installation work is performed thoroughly read and understand the material in this instruction manual A copy of the instruction manual is shipped with each module in the control compartment When requesting
27. 3 Lift up the Access Lever Fig 71 4 and push the trolley in further until racking shaft Fig 71 1 couples with socket Fig 71 8 NOTE S4F contact should indicate the coupling position if connected Y64 Y65 to any external indication device ON OFF the breaker will not possible in such case 18 Design and specifications are subject to change without notice 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 7 Operating the Module Tus to release 1 4 Door Interlock a mJ Door Key Door Locks Fig 72 3 Door locks positions 4 Insert Crank Handle into the Access Console slot Fig 72 4 and rotate the crank clockwise until trolley reaches CONNECTED position NOTE CONNECTED position is indicated by Position Indicator Fig 71 3 or by contacts of the switch 33 5 5 Remove the Crank Handle Push down the Trip Lever Fig 71 4 to make sure that both levers of the Access Console are in their maximum lower positions NOTE If the Access Lever is not at its maximum lower position closing of the breaker will not be possible Fig 72 4 Crank Handle installed 2011 04 26 547183 01 Rack Out Procedure NOTE Crank Handle is necessary for racking operations Crank Handle has to be ordered separately 1 Trolley CONNECTED Open the breaker either using OPEN command or pulling up the Trip Lever Fig 71 4 2 Lift up the
28. A continuous The module is available in two continuous current ratings 4000 for use with 2500A and 4000A Gerapid breaker 60004 for use with 5000A and 6000A Gerapid breaker NOTE See Appendix F for complete ratings of the Module and the breaker Interlocks Module and trolley are equipped with variety of safety interlocks that minimize risk of incorrect operations The following interlocks incorporated into the module and trolley Positive Interlock preventing movement of the trolley to or from CONNECTED position when breaker is closed Negative Interlock preventing breaker closing unless the trolley is CONNECTED or TEST position Access Interlock ensures breaker opening before any manual operations Secondary Control Interlock preventing movement of the trolley from TEST position to CONNECTED position unless secondary disconnect is connected The same interlock prevents the trolley from being fully withdrawn from the module unless the secondary disconnect is unplugged Breaker Disconnected Padlock Provisions allows padlocking the trolley in DISCONNECTED position v Control Compartment Padlock Provisions allows for padlocking of the controls compartment door Rejection Interlock prevents trolley coded for particular breaker current rating from being inserted into the module that is coded to different rating Shutter Safety Padlock allows padlocking of the safety shutters in closed po
29. Access Lever Fig 71 4 and insert Crank Handle Rotate the crank counterclockwise until trolley stops Breaker is now at TEST position NOTE TEST position is indicated by Position Indicator Fig 71 3 or by contacts of the switch 33 4 Fig 71 9 3 Open the trolley s door and disconnect the Secondary Disconnect Hang it on the frame to the right Fig 71 7 Now the trolley is at the DISCONNECTED position NOTE Use the Door Key to open all Door Locks and release Door Interlock See Fig 72 3 4 Remove the crank Lift up the Access Lever Fig 71 4 and pull the trolley out from the module 7 3 Trolley with Remote Racking Operational positions The trolley has distinguished four operational positions CONNECTED POSITION A REMOTE RACKING Position Interlock Fig 73 1 CONNECTED position for the remote racking trolley Design and specifications are subject to change without notice 19 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 7 Operating the Module 1 CONNECTED position Primary Disconnects and Secondary Disconnect in full contact breaker ready for normal operation Position Interlock see Fig 73 1 keeps the trolley in this position DISCONNECTED POSITION 2 TEST position Primary Disconnect open and separated by a safe distance with shutters closed The Secondary Disconnect is in full contact The Trolley is withdrawn 4 inches and locked by Position
30. D Tightening Torques Tables All the tightening torques listed below are applicable for Module Trolley and Breaker Table D 1 Tightening torques for mechanical construction elements Screw size Hex head screws Hex head screws Self tapping Class 5 8 Class 8 8 screws pounds Inch pounds Less M3 M3 14 15 22 24 15 17 26 29 44 49 ws ew P J 362 398 620 681 885 973 1500 1650 Table D 2 Tightening torques for electric circuits connections Screwsize Auxiliary amp control Copper bus bar circuits connections Inch o Inch pounds 0655 5 M3 52 58 124 136 29 253 454 390 551 584 1240 1560 30 1 78 177 194 454 590 620 681 Design and specifications are subject to change without notice 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX E Electrical Diagrams 2S32U9J J3I 295 sjaqp SSALUDY 90 GEA PEA CZA LCA OCA BLA IA SLA SLA PLA SLA OLA BOA ZOA 904 60A n pq dez 512 CY B HS Pit a PEU 1895 934813194 995 ede es Es E L L L L sm siequunu Jejdnoo Auppucses amp amp F amp j S im F e 649 849 LARD 949 642 CAN 49 6H 643 BTW 24 SR SAN bad 179 E Lo 9020
31. ID CIRCUIT BREAKERS Chapter 2 Receiving handling and storage Removable lifting plates are provided on the top of each module as standard equipment Using a crane or overhead hoist carefully lift the module from the palette using the four lifting plates See Fig 22 1 Min 4 ft Fig 22 1 Overhead lifting of the module To preserve the external appearance of the equipment it is suggested that the lifting plates be left in place Utilize four equal length cables or slings each with a minimum load rating of twice the weight of the Module package See section 2 1 NOTE The angle between the cables and the top of the equipment must be at least 45 degrees This requires the use of chains slings at least 4 ft long If this is not possible spreader bars must be used NOTE Do not move lift or handle the module with a trolley installed Take up the slack in the lifting device very carefully and manually stabilize the module to prevent it from rotating WARNING Do not stand under the module while it is being moved Serious injury may occur if the cables or lifting device fail CAUTION Gently lower the module onto the level site location If the module is roughly handled or jarred it is possible to damage or misalign internal components Trolley handling and unpacking The trolley in its original package should be transported using forklift only To unpack the trolley remove the top cover first and then remov
32. Interlock See Fig 72 3 TEST POSITION REMOTE RACKING Secondary Disconnect u x Ta FO CEIT ee CTT Position Interlock Fig 73 3 DISCONNECTED position for remote racking trolley Remote Rack In Procedure NOTE Crank Handle is necessary for completing racking Position Interlock operations Crank Handle has to be ordered separately Fig 73 2 TEST position for remote racking trolley WARNING EMERGENCY RACKING STOP circuit 58 Y59 3 DISCONNECTED position Primary Disconnects open and must be wired to a pushbutton furnished by OEM It is separated by a safe distance with shutters closed Secondary recommended the STOP PB be installed on the control Disconnect is open Trolley is withdrawn 5 inches See Fig 72 compartment door See example Fig 73 4 Use this pushbutton for immediate interruption of racking operation and stop the trolley regardless of its position 3 amp WITHDRAWN position Trolley outside of the module NOTE Remote racking operations require control voltage and control commands to be provided See Appendix E for electrical circuit drawings Fig 73 4 EMERGENCY STOP pushbutton by OEM 20 Design and specifications are subject to change without notice S47183Ee rev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 7 Operating the Module 1 Trolley WITHDRAWN Push trolley toward the module until it
33. MMAND CIRCUIT BREAKER IN COMMAND DRIVE COMMAND CIRCUIT RACK BREAKER IN COMMAND Mote DRIVE COMMAND CIRCUIT RACK BREAKER QUT COMMAND Note DRIVE COMMAND CIRCUIT RACK BREAKER Q OMMAND N UMBILICAL PLUG INTERLOCK COUPLING SWITCH NORMALLY CLOSED _________ UMBILICAL PLUG INTERLOCK COUPLING SWITCH NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 33 4 BREAKER POSITION NORMALLY OPENED Y O UMBILICAL PLUG INTERLOCK 53 4 DBREAMER FUSION NORMALLY OPENED C C C C UMBILICAL PLUG INTERLOCK 33 4 BREAKER POSITION NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 33 4 BREAKER POSITION NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 33 5 BREAKER POSITION NORMALLY OPENED UMBILICAL PLUG INTERLOCK 33 5 BREAKER POSITION NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 33 5 BREAKER POSITION NORMALLY CLOSED gt lt gt lt 79 20 3 D 6 4 8 9 0 1 5 lt e e x D 4 T J Cni __ Note 1 IF BREAKER IS EQUIPPED WITH THIS FEATURE Note 2 IF MANUAL RACK WILL BE REPLACED BY REMOTE RACK APN465330 Electrical diagram manual racking page 04 04 Fig E 8 Manual Racking Module Wiring Harness coding Design and specifications are subject to change without notice 547183 rev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX G Accessories and Installation Drawings APPENDIX F Rating
34. STION NORMALLY OPENED C C C UMBILICAL PLUG INTERLOCK 33 5 BREAKER POSITION NORMALLY OPENED UMBILICAL PLUG INTERLOCK 35 5 BREAKER POSITION NORMALLY CLOSED UMBILICAL PLUG INTERLOCK 55 5 _ POSITION NORMALLY CLOSED Note 1 IF BREAKER IS EQUIPPED WITH THIS FEATURE APN465329 Electrical diagram remote racking 04 04 Fig E 4 Remote Racking Module Wiring Harness coding Design and specifications are subject to change without notice 547183 rev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX E Electrical Diagrams peus S2U9J9 9 895 sleqp ssauJpu OA ne ee ie min pz pm PS PR 43 bi Me od p 49005 e2U8J8J8J a 8 8 sis s E E E E F Ty sjequunu uid SR ues pa Et mop EE gt e m 2 6490 BAND LAND 942 540 EAN 210 LO ASO E NGL 619 BW SA LAY 943 Gay pay k LB F Lay i B E EH B B ER B o R E B OS S 5 BS E B S gt 8 E j Y sir IS TGS Tu ole Te 2 TS L X T2 T8 s T T Z T 1 JX mag ee ee s T To s I Z 9199933 0 iH FEF 01 dk 1080 pem cR pL LEA GEA
35. a breaker in the compartment 2 Check to see that the breakers match their respective trolley and compartment Each breaker is assigned a serial number and ratings These are shown on the breaker s nameplate The breaker may also be identified using the 20 digit PST catalog number See Fig 51 1 Gerapid x Fig 51 1 Nameplate of Gerapid breaker Breakers of the same rating are interchangeable in their equipment compartments as long as they have the same accessories equipped The trolley design is the same and universal regardless of the Gerapid breaker type intend to operate with WARNING A breaker with different rating fit into any of the trolleys If the trolley s rejection interlock does not match the breakers rating but it does match the compartment s rejection interlock it is possible to rack in an incorrect breaker into the compartment This may lead to serious damages and could result in death or serious injury for operator 2011 04 26 547183 01 5 2 Installing Gerapid Breaker Prior to Installation Prior to placing a breaker in its intended location on the trolley please check following precautions 1 Find the foil bag with breaker bolting kit no 700701 that is attached to the trolley s platform Remove it 2 Ensure that the breaker is OPEN 3 Ensure that arc chute is NOT on the breaker 4 Ensure that lifting device can carry 300 lbs and that lifting slings are min 6 ft long
36. ach section to see if any have been dislodged or damaged Gerapid circuit breakers are shipped separately in individual boxes with the breaker in the open position See Fig 21 2 Circuit breakers should be unpacked and visually inspected for damage or loose parts as soon as possible after they have been received 6 Design and specifications are subject to change without notice Remove the carton box and check plastic covers for any damages Do not remove the plastic if the breaker will be stored for long periods See Fig 21 2 and 21 3 Fig 21 2 Gerapid circuit breaker package Fig 21 3 Breaker plastic shrink wrap protection Filing a Claim If any damage 15 evident or indication of rough handling is visible file a claim for damage at once with the transportation company and notify the nearest GE Energy Sales Office immediately Information on damaged parts part number case number requisition number etc should accompany the claim 2 2 Handling and unpacking Module handling and unpacking The module shipping crate should be transported using forklift only During transport the module should remain in its original package To unpack the module start by removing the top cover then remove sidewalls and all inner supports CAUTION Never use a forklift to transport an unpacked module as the module is not bolted to the shipping palette 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAP
37. additional information from GE Energy include the complete data appearing on the equipment nameplate including requisition number The module s label is located inside the control compartment The trolleys nameplate is located on the right side of the trolley next to doors When requesting information concerning any specific item furnished with module and or trolley refer to that item by description part number its location within this manual and any applicable drawing number Any materials which may be required to meet local codes such as mats screens railings etc are not included and not furnished by GE Energy If there are any questions or requirements not covered in this manual or in the accompanying drawings please contact the local sales office of GE Energy 1 2 Instruction Book Arrangement Information and procedures in this instruction book are divided into Chapters as follows e Chapter 1 Introduction provides applicable data for the module and its components e Chapter 2 Receiving Handling and Storage describes procedures required for receiving handling and storage the module and trolley e Chapter 3 Component Description describes the module and its various components Included are the cable compartment breaker compartment and instrument compartment This section also lists the electrical and mechanical components and explains their assigned functions e Chapter 4 Module Installation provides the
38. breaker to trip open and additionally enable access to manual racking slot NOTE The Access Lever is locked in lower position when the breaker is closed sr EC T UAM EE DI PUCE Bee LEVER ID MANUALE AA EOD LIAE DARE EM ED ju WISE BOTH LEAVERS TO ACCESS MANUAL HACKING WILL BREAKER IF NOT ALREADY OPEN AND ACCESS MANUAL RACKING Access Lever rr Fig 71 4 Front door Access Interlock Trip Lever is mechanically coupled with a vertical interlock under the trolley This interlock mechanically locks the trolley in TEST or CONNECTD position When the Tri Lever is lifted up the Crank Lock stop switch S3F electrically cuts off the closing circuit of the breaker and blocks remote racking This ensures no remote command activates the trolley or closes the breaker with the Crank Handle is inserted See Fig 71 5 and wiring circuit in Appendix D Operating Rod S3F stop switch Lower position Fig 71 5 Locking rod with S3F end switch Crank Lock Secondary Control Interlock Secondary Disconnect consist of a receptacle installed in the stationary cell and removable plug which is a part of the trolley See Fig 71 6 This disconnect is equipped with Rack in Interlock preventing movement of the trolley from TEST position to CONNECTED
39. e Rejection 14 2011 04 26 547183 01 TESTING AND INSPECTION 15 6 1 General u u 15 Prior COD CS akasqan uta laaya Ato 15 Connecting Control Circuits 15 6 2 Field Testing Procedure 15 Testing the Module with Remote Racking 5 15 Testing the Module w o Remote Racking System 15 High Potential Tests d eid 15 Grounding Circuit 15 OPERATING THE MODULE t dr rh ra rbd et ud 16 7 1 Mechanisms and Interlocks sss 16 Racking Mechanism e tt 16 Access Interlocks e atra dona 16 Secondary Control Interlock sse 16 Remote RaeKITIO uu sa aaa 17 Trolley Operated Switches see 17 Padi sua sss kausaq aD ney buba ny a 17 7 2 Trolley with Manual Racking sees 18 Operational Positions ee dI d e i du 18 Racking In Procedure iecore tr cce cbe tun 18 Rack Out Procedure
40. e sidewalls and all inner supports To lift the trolley use special lifting frame available See Fig 22 2 2011 04 26 547183 01 NOTE After transportation but before installing of the breaker loosen six attachment screws and remove lifting frame from the trolley Replace and tighten these screws Lifting slots Fixing SCrews Fig 22 2 Lifting of the trolley CAUTION Never use forklift to transport unpacked trolley as it is not bolted or fixed to the shipping palette NOTE Do not lift or transport the trolley using forklift Never lift the trolley with a breaker mounted Never roll the trolley on the floor with a breaker set in place unless the breaker is properly bolted to the trolley and arc chutes properly secured to the breaker if installed 2 3 Storage Circuit Breakers Open shipping cartons and thoroughly inspect shipping materials for damage If shipping plastic is in satisfactory condition leave the breakers in their shipping cartons for storage Do not remove the circuit breaker shipping material shrink wrap at this time Store the circuit breakers in a clean dry location in an upright position If shipping plastic is damaged a plastic or canvas type cover should be provided to reduce the possibility of damage or contamination to the breakers due to dust and water For details concerning Gerapid breakers handling consult the breaker s User Guide S47183De Modules and Trolleys
41. en two 2 positions TEST and CONNECTED Clockwise rotation of the racking shaft Fig 71 1 results in Trolley movement toward the CONNECTED position Counterclockwise rotation of the racking mechanism results in trolley movement from the CONNECTED to the TEST position Racking Shaft Indicator Shaft Fig 71 1 Racking system The racking mechanism can be manually or remotely operated closed door drawout designed to prevent over travel and equipped with guides for alignment of the breaker in the module The Crank Handle has a torque clutch See Fig 71 2 This clutch protects the racking system against damages caused by applying excessive force when Trolley is in CONNECTED position Clutch Fig 71 2 Crank Handle An indicator is provided to show breaker position within the compartment See Fig 71 3 The indicator is visible from the exterior of the switchgear Fig 71 3 Position Indicator Trolley is equipped with integral wheels for moving the trolley in and out of a cubicle and sized to carry the weight without deforming or cutting into the concrete surface The wheels roll but not slide and guide the trolley to correctly align and engage the racking mechanism 16 Design and specifications are subject to change without notice Access Interlocks Front door Access Interlock see Fig 71 4 ensures tripping of the breaker before the Crank Handle can be inserted for racking Lifting up of the Trip Lever causes
42. ess Lever END OF PROCEDURE 44 Fig H 2 Access Console and Secondary Disconnect of the trolley Table H 3 DC Module with Remote i Field Test Procedure Trolley is in WITHDRAWN position Breaker is OPEN Insert Crank Handle b into Access Slot Trolley is in DISCONNECTED position Breaker is OPEN Insert Crank b into Access Slot c Connect the Plug 9 Remove Crank Handle b from Access Slot c Trolley is in TEST position Breaker is OPEN Insert Crank Handle b into Access Slot Trolley is in CONNECTED position CLOSE the breaker Trolley is in CONNECTED position Breaker is OPEN Insert Crank Handle b into Access Slot c Trolley is in TEST position CLOSE the breaker Remove Crank Handle b from Access Slot Trolley is in TEST position Breaker is OPEN Insert Crank Handle b into Access Slot c c Access Slot a Position Indicator b Crank Handle E Pa Sl 4 E 5 ae ay h Rack Out Interlock 7 7 mexmw i Rack In Interlock E NOTE Please refer to section 7 for module operating instructions and hints Try to rack in the trolley to TEST position Manually rack in the trolley to TEST position using the Crank Handle b Try to CLOSE the breaker at TEST position CLOSE the breaker Check the position indication in TEST Send a command to rack in the trolley to CONNECTED position Try to lift
43. g trolley includes motor drive installed in a bottom front compartment of the trolley See Fig 34 1 NOTE Make sure that locking plate has been removed if the trolley is manual racking type See section 4 2 Connecting Control Circuits Some of the field test procedures require control circuits to be active and energized Therefore it is necessary to connect the wiring harness of the module to a dedicated system which enables control of the module To see recommended connections please refer to Appendix H Fig H 1 CAUTION All wires which are not connected must be insulated while test is running The Remote Racking option is available only with 230 V 60 Hz control voltage For other values please contact GE Industrial Solutions representatives Supply source should be capable to carry 5 A permanent current NOTE See Appendix F for details concerning electric characteristics of auxiliary loads 6 2 Field Testing Procedure NOTE Extended descriptions of the module operating modes with illustrations are given in Chapter 7 Refer to these during Field Testing execution Testing the Module with Remote Racking System Proceed with steps 1 1 to 1 9 from Appendix H Table H 4 Testing the Module w o Remote Racking System Proceed with steps 1 1 to 1 9 from Appendix H Table H 5 2011 04 26 547183 01 High Potential Tests High potential tests to check the integrity of the insulation are not necessary if
44. h all the modules and all Gerapid circuit breakers listed in Section 3 5 The OEM must correctly configure the rejection Interlock on the trolley and in the module for the specific rating of breaker being installed All breaker controls control power supply and auxiliary contacts are extended to the control compartment via the secondary disconnect and harness Negative and positive interlocks are operated from access console at the front of the trolley The access opening for the manual crank handle is there as well Secondary Disconnect Plug Console Motordrive Rejection Interlock Fig 34 1 Trolley features motorized racking shown Design and specifications are subject to change without notice 9 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 4 Installing the Module 3 5 Gerapid Breakers The GE Gerapid DC Circuit Breaker is a high speed single pole breaker used for protection of high power DC supply systems The main features of the Gerapid circuit breaker are Modular construction easy to inspect and maintain Non flammable and non toxic insulation materials High speed current limiting short circuit characteristics Up to 24kA tripping threshold for OC release High speed remote impulse release for distant faults Shunt or zero voltage releases for opening operation Powerful closing solenoid enables quick closing operation Easy and safe remote and local control of the breaker Wide variety of accessorie
45. he breaker has a different rating the rejection interlock has to be configured accordingly 1 Remove both rejection markers from default positions 2 Reattach them in to the positions which correspond to the breaker s current rating In example from 25004 to 5000A see Fig 52 4 CAUTION Make sure both rejection markers on both sides of the trolley match the breaker current rating Fig 52 4 Rejection Interlock of the trolley 14 Design and specifications are subject to change without notice S47183Eerev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 5 Installing the Breaker Testing and Inspection 6 1 General Notes After the equipment has been installed and all connections made equipment must be tested and inspected before it is put in service Although each module and each breaker have been tested at the factory a final field test must be made to be sure that the equipment has been properly installed and that all interlocks operate correctly Directions for inspection and testing breakers are given in the instruction book S47183De furnished with each breaker The extent of the tests on the equipment as a whole is given below NOTE See Appendix H for corresponding Field Test Procedure where all steps are listed in Tables H 2 H 3 and 4 Prior to Test Before any operation on the module it is required to check if corresponding trolley is remote or manual racking type Remote rackin
46. ing positions 1 CONNECTED position Primary Disconnects and Secondary Disconnect in full contact breaker ready for normal operation Position Interlock see Fig 72 1 keeps the trolley in this position Secondary Disconnect 1 r i Tm 1 1 i Position Interlock Fig 72 1 CONNECTED position of the trolley 2 TEST position Primary Disconnect separated by a safe distance and shutters closed The Secondary Disconnect is in full contact Trolley is withdrawn 5 inches and locked by Position Interlock See Fig 72 2 3 DISCONNECTED position Primary Disconnects separated by a safe distance and shutters closed Secondary Disconnect is disengaged Trolley positioned in the TEST position 4 WITHDRAWN position Trolley outside of the Module NOTE Manual racking in and racking out does not require control voltage to be present Although switching Position Interlock Fig 72 2 TEST position of the trolley Racking In Procedure NOTE Crank Handle is necessary for racking operations Crank Handle has to be ordered separately 1 Trolley WITHDRAWN Push trolley toward the module until it stops at DISCONNECTED position 2 Open the trolley s door and install Secondary Disconnect Now the trolley is at the TEST position NOTE Use the Door Key to open all Door Locks and release Door Interlock See Fig 72 3 NOTE Make sure that Receptacle Snap Lock is engaged
47. ks Fig 33 2 Front view of the module 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 4 Installing the Module Grounded steel barriers on the top sides bottom and front enclose the breaker compartment In the back a flame retardant track resistant glass filled polyester base minimizes the possibility of fault communication between compartments or to the bus Breaker compartment has primary stabs for connecting the breaker Insulated shutters cover primary stabs See Fig 33 2 NOTE See Appendix A for all dimensional drawings of the breaker Compartment Primary disconnect shutters are provided as standard feature to provide protection against contact with the energized stationary primary stabs when the trolley is removed from its compartment The shutters are constructed from fiberglass reinforced thermoset polyester A padlock can lock the shutters in the closed position See Fig 33 3 411 Shutters Padlock Fig 33 3 Safety padlock on the shutters Every module is equipped with rejection Interlock that must be properly configured by the OEM This interlock allows configurations for all current ratings It is placed on both sides of the breaker compartment See Fig 33 2 Cable Compartment The primary stabs extend into the cable compartment and are suitable for connection with ANSI type busbars Fig 33 4 shows primary terminals for 4000A and 6000 A rated modules Gro
48. ment Check end switch S3F under the trolley Grounding path resistance between main ground bus and measured point must be less 0 1 Ohm 4 1 Check the motor drive s housing Check breaker s grounding point at 2 3 Check door locks of the trolley Check handles at the front of the trolley Rack in the trolley into TEST position Connect Secondary Plug g Fig H 2 4 2 Step 4 la p 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 47 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX H Field Test Procedure Step 4 1b Design and specifications are subject to change without notice 547183 01 2011 04 26 GE Industrial Solution 41 Woodford Ave Plainville CT 06062 www geindustrial com 2010 General Electric Company All Rights Reserved 2011 04 26 547183 01 imagination at work Design and specifications are subject to change without notice S47183Ee rev 01 49
49. ned to operate during specified period and in prescribed conditions without functional part replacement Only simple preventive maintenance is recommended to be performed every two years Check the racking shaft of the trolley and grease it with molybdenum based grease such as MOLYKOTE G4700 or NYE Rheolube 373 Also grease racking socket in the structure Check the Primary Disconnect clusters Clean and apply a light coating of red Mobile 28 grease manufactured by ExxonMobil Perform testing routine as listed in Appendix H tables H3 547183 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX A Module amp Trolley Drawings Customer support 8 1 Warranty For warranty issues or other after sales service contact the GE Energy GE Resolve Customer support line at 1 888 457 5765 8 2 Field Service Support To request and schedule GE Energy Service Engineering support call 1 800 533 5885 8 3 Publications and other support Instruction Books Drawings and other technical documents can be found and downloaded from the GE Energy web site at http www geindustrial com Goto Products gt Circuit Breakers gt DC High Speed Circuit Breakers gt Gerapid 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX A Module amp Trolley Drawings APPENDIX A
50. nmental Requirements The module as provided is designed for indoor installations only and should be placed in an indoor area where clean dry air is free to circulate around and above it Since air is taken into the equipment at the bottom of each section and exhausted at the top a location with good airflow must be provided for efficient operation A minimum of 30 inches of clear space above the equipment is recommended In order to properly withdraw the trolley there should be at least 7 foot of space in the front of the module NOTE See Appendix C for sketches concerning layout Foundation Requirements The foundation requirements detailed in this chapter should be strictly adhered to Top View the floor gt 4 n KUK oT V t po 27 72 9 6 5797797797140 _ aa S il C Y ox 4 o i e LJ g ret 3 46 in Anchor Points 3551 in 41 46 in Use M12 or 7 16 grade 5 bolts Locking Plate 17 32 23 62 in Fig 41 1 Module anchor bolt hole locations The foundation must be strong enough to prevent sagging due to the weight of the completed switchgear structure and to withstand the impact loading caused by the opening of the breakers under fault conditions The impact loading 15 approximately 1 1 2 times the static load 2011 04 26 547183 01 The foundation must be flat and le
51. nsists of four chapters Connecting control commands to the module See Fig H 1 Testing the module with Remote Racking See Table H 3 Testing the module with Manual Racking See Table H 4 High potential test optional See Table H 6 SASAS Connecting control commands for testing Following control commands are available for OEM wiring Name Wire Points Description RACK BREAKER IN Y60 Y61 Moves trolley from TEST to CONNECTED position RACK BREAKER OUT Y62 Y63 Moves trolley from CONNECTED to TEST position GERAPID SOLENOID CLOSE YO4 Y05 Closes Gerapid breaker possible only in TEST or CONNECTED positions GERAPID OPEN Y06 YO7 Opens Gerapid breaker possible only in TEST or CONNECTED positions POSITIONS CHECK Y67 Y73 Signals when trolley reaches TEST or CONNECTED position EMERGENCY RACKING STOP Y58 Y59 Immediately stops the trolley regardless of position Typical external controls furnished MARKINGS OF WIRING HARNESS REMOTE RACK IN REMOTE RACK OLIT f POSITIONS KA B Hite Fig H 1 Wiring diagram for connection of control functions for the module 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 43 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX H Field Test Procedure Testing the module with Remote Racking option g Secondary Plug f Receptacle Snap Latch d Trip Lever e Acc
52. oss sections less that recommend in Table 6 Gerapid circuit breakers are not polarized Therefore the load and the supply line can be connected to either top or bottom terminal See Fig 33 4 for primary terminals views NOTE See Appendix B for primary terminals drawings and recommend bus bar dimension 12 Design and specifications are subject to change without notice Ground Bus Connection Ground bus connection terminal is located at the bottom of the module in the cable compartment See Fig 33 4 Circuit connections to a ground bus are made so that it is not necessary to open circuit the ground bus to remove any connection made to the ground bus Ground connections are provided for all removable elements to ensure that the frame and mechanism are grounded until the primary circuit is disconnected and the removable element is moved a safe distance NOTE See Appendix B for ground terminal drawings Connecting Secondary Controls Secondary disconnect plug in the module is pre wired with the harness going into control compartment All wires that should be used by OEM for completing the module and breaker control are numbered and accessible inside the Control Compartment NOTE See Appendix E for electrical schemes for connections NOTE See Appendix A for control compartment dimensions All trolley control commands and supply connections are also available thru the harness in the Control Compartment Top mounted wire way access
53. partment 8 temere tr ribera tque cerei tertie 9 Control 9 3 4 1h86 EY 9 3 5 Gerapid 10 INSTALLING THE MODULE LL L LLL La uku ee octobre reno 11 Generdl Notes ated puts ca ma Qa 11 Environmental Requirements 11 Foundation Requirements eerte 11 4 2 Module Configuration and 11 Multiple Modules Side by Side 11 Module Preparation 11 Module Rejection Interlock see 12 Main Busbars Connection sette 12 Ground Bus Connections Reste ut 12 Connecting Secondary Controls sss 12 Device mounting on control compartment 12 INSTALLING THE BREAKER a HM ROGER 13 5 1 Generali Notes scien a ns Pas vastus 13 5 2 Installing Gerapid Breaker T3 Prior to Installation sseseettettententenes 13 Installation Procedure seseeteentttettnees 13 Configuration of th
54. pcs of cable duct connector cover End covers for top cable channels Fixation requires four 4 screws M6x12 289158 DCOEMCHANCOVER 700699 per single cover Consist of 10 pcs of cable channel covers DCOEMM8x25KIT 700701 Screws for fixation of the single Gerapid breaker to the single Trolley Consist of 4 pcs of countersunk screws M8x25 G DCOEMM6x12KIT 289158 Screws M6x12 use for fixation of user components to the skeleton frame Consist of 500 pcs of screws M6x12 H Side covers fixing kit Consist of v 100fixing sets for side covers installing Module coupling kit Consist of 12 bolting sets for connecting two adjacent Module frames J DCOEMHINGES 289709 Hinges kit Single hinge requires one screw M6x12 289158 Consist of 12 pcs of hinges for doors lt 4 sg A DCOEMCRANK B DCOEMCOVER15 C DCOEMCOVER18 D DCOEMCONNECTOR b d DCOEMCHANCOVER F single M8x30 screw G single M6x12 screw H single side cover connector S single frame bolting connector J single hinge 40 Design and specifications are subject to change without notice S47183Ee rev 01 2011 04 26 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX G Accessories and Installation Drawings Installation Drawings 12 bolting elements 41 for connecting of rear middle and front columns CABLE CHANNEL
55. positions See circuit diagram E 2 Appendix E 2011 04 26 547183 01 Trolley Operated Switches Stationary part of the Module is equipped with set of trolley position switches See Fig 71 9 for location al ES 33 3 S4F 1 s ma X or a4 K m sm Q ss c p S s Fig 71 9 Position switches 33 3 S4F 33 4 33 5 Following signal switches are available with the Module Switch S4F NC dry contact available at Y64 Y65 Indicate coupling of the racking shaft with racking socket Switch 33 4 NO and NC dry contacts available at Y66 Y67 Y68 Y69 Indicate TEST position Switch 33 5 NO and NC dry contacts available at Y70 Y71 and Y72 Y73 Indicate CONNECTED position Padlocks There are three interlocks which can be padlocked Padlock s diameter shall not exceed 1 3 inch Padlocks are not included v Safety Shutters see Fig 33 3 V Console see Fig 71 10 Control Compartment see Fig 71 10 M Fig 71 10 Padlock set at Access Console left and Control Compartment right Design and specifications are subject to change without notice 17 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 7 Operating the Module 7 2 Trolley with Manual Racking Operational Positions The trolley has four separate operat
56. re subject to change without notice 36 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX E Electrical Diagrams dlelf QO 90 3 Q O QO PIN CODING SOCKET HC B 24 c 33 Oo Go Qo 95 50g PIN CODING PLUG HC B 24 TFL APN465330 Electrical diagram manual racking page 03 04 Fig E 7 Manual Racking Module Secondary Disconnect coding 2011 04 26 547183 rev 01 Design and specifications are subject to change without notice 37 38 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS APPENDIX F Rating Tables WIRE HARNESS END LABELS WIRE ORIGIN DESCRIPTION GERAPID TERMINAL X2 1 GERAPID CLOSING DRIVE SUPPLY 4 Oo WO C GERAPID TERMINAL X2 2 CLOSING DRIVE SUPPLY GROUND TERMINAL X1 15 GROUND GERAPID TERMINAL 2 4 GERAPID SOLENOID CLOSE COMMAND GERAPID TERMINAL X2 5 RAPID OLENGID CLO OMMAND GERAPID TERMINAL 2 6 GERAPID S2 OPEM BY ST COMMAND Note 1 GERAPID TERMINAL X2 7 GERAPID 52 OPEN HY ST COMMAND Note T GERAPID TERMINAL X2 8 GERAPID 52 BY UVR COMMAND Noel TOS C O GERAPID TERMINAL X2 9 GERAPID 52 BY UVR COMMAND _ 1 GERAPID TERMINAL X2 10 GERAPID 53 ED FIRING SIGNAL GERAPID TERMINAL 2 11 GERAPID 53 ED FIRING SIGNAL GERAPID TERMINAL X3 1 GERAPID TERMINAL X3
57. red thru available harness YO1 Y54 See Appendix E for details of available commands and signals Design and specifications are subject to change without notice 21 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 9 Customer Support Troubleshooting and Maintenance 8 1 Troubleshooting Troubleshooting section describes potential issues that user may experience during operation of the trolley Contact GE Energy service in case the problem is not resolved NOTE See User Manual 5471830 for breaker troubleshooting information Manually operated trolley A Cannot lift Access Lever to insert Crank Handle Check if the breaker is OPEN When CLOSED breaker s drive rod activates interlock which locks the Access Lever Check the length of four M8 mounting screws for the breaker Screws may limit the movement of the Access Lever if are longer than 25mm 1 B Cannot trip the breaker by means of Trip Lever Check the length of four M8 mounting screws for the breaker Screws may limit the movement of the Trip Lever if are longer than 25 mm 1 v Check the Forced Tripping Release pin under the breaker s base The pin should be able to be fully pressed against base If this does not work the pin may be damaged inside the breaker C Cannot move the trolley using Crank Handle Check if Crank Handle is properly and fully inserted into Access Slot The crank engages fully with the shaft only with proper orienta
58. s Crank Handle has to be ordered separately 1 Trolley CONNECTED Open the breaker either using OPEN command or pulling up the Trip Lever Fig 71 4 2 Use RACK BREAKER OUT command Y62 Y63 to start motor for rack out operation Trolley will stop at TEST position NOTE TEST position is indicated by Position Indicator Fig 71 3 or by indication of switch 33 4 Fig 71 9 3 Open the trolleys door and disconnect the Secondary Disconnect Hang it on the frame to the right Fig 71 7 NOTE Use the Door Key to open all Door Locks and release Door Interlock See Fig 73 4 4 Lift up the Access Lever Fig 71 4 and insert Crank Handle Rotate Crank Handle counterclockwise until trolley stops Now the trolley is in the DISCONNECTED position 5 Remove Crank Handle Lift up the Access Lever Fig 71 4 and pull the trolley out from the module 7 4 Operate the breaker Gerapid circuit breakers can be operated electrically and manually NOTE Manual CLOSE operation at the breaker is possible only at WITHDRAWN position of the trolley Manual closing should only be performed for maintenance Manual OPEN operation at CONNECTED or TEST positions is possible by means of Trip Lever For maintenance purposes breaker can be operated by means of dedicated hand lever at WITHDRAWN position NOTE See User Manual S47183De for breaker operation details and accessories All electric control commands and signals are wi
59. s such as counter indicators interlocks manual handle etc See Fig 35 1 for overview of the breaker construction NOTE See Appendix F for all ratings and see User Manual S47183De for breaker details and accessories Four current ratings of Gerapid circuit breakers are available for mounting on the trolley and used in the module These circuit breakers are UL Listed and type tested in accordance with IEEE ANSI C37 14 2000 Standards Continuous current ratings range from 2500 to 6000 ampere frame size All Gerapid circuit breakers of the same type and rating may be interchanged provided the breaker accessories have the same ratings 2508 See Fig 35 2 2500A frame size Standard 200kA peak interrupting current at 800VDC 3700V power frequency withstand level Current limiting characteristic Tested for duty type a b c and d according to ANSI C37 14 Trip free capability according to ANSI C37 100 Gerapid 4008 See Fig 35 2 4000A frame size Standard 200kA peak interrupting current at 800VDC 3700V power frequency withstand level Current limiting characteristic Tested for duty type a b c and d according to ANSI C37 14 Trip free capability according to ANSI C37 100 s s eS s Gerapid 5008 See Fig 35 3 5000A frame size Standard 200kA peak interrupting current at 800VDC 3700V power frequency withstand level Current limiting characteristic Tested for duty type a b c and d according to ANSI
60. sition Accessories Several accessories are available with the module and the trolley for user convenience Side Covers for cable compartment Crank Handle for trolley racking operations Cable Channel connectors and covers Attachment Hardware Kits for different components Hinges for user furnished compartment doors v v v v v NOTE See Appendix G for full list of accessories their codes and illustrations NOTE Detailed description of all accessories functions is given in Chapter 7 8 Design and specifications are subject to change without notice 3 3 The Module Breaker Compartment The module is metal enclosed construction and consists of the front breaker compartment upper controls compartment and rear cable compartment Fig 33 1 shows the location of the module compartments Dead front drawout circuit breaker compartment is a standard construction feature with all modules The breaker compartment door remains closed and latched while the breaker is racked out from the CONNECTED position through TEST position to the DISCONNECTED position See chapter 7 Control Compartment Cable Compartment Breaker Compartment Fig 33 1 Front view of the Module with Trolley inside Control Compartment Padlock Provisions Secondary Disconnect Secondary Control Interlock Primary Disconnect Shutters In front of Primary Stabs Racking Drive Socket Grounding Circuit Stab Rejection Interloc
61. stops at DISCONNECTED position 2 Open the trolleys door and install Secondary Disconnect NOTE Use the Door Key provided to open all Door Locks and release Door Interlock See Fig 73 4 NOTE Make sure that Receptacle Snap Lock is engaged 3 Lift up the Access Lever Fig 71 4 and push the trolley in further until racking shaft Fig 71 1 couples with socket Fig 71 8 NOTE S4F contact should indicate the coupling position if connected Y64 Y65 to any external indication device 4 Insert Crank Handle into the Access Console slot Fig 72 4 and rotate Crank Handle clockwise until trolley reaches TEST position NOTE TEST position is indicated by Position Indicator Fig 71 3 or by indication of switch 33 4 Fig 71 9 5 Remove Cronk Hondle Push the Trip Lever down Fig 71 4 making sure that both levers of the Access Console are in their maximum lower positions NOTE If the Access Lever is not at its maximum lower position closing of the breaker or remote rack in will not be possible 6 Use RACK BREAKER IN command Y60 Y61 to start motor for rack in operation Trolley will stop at CONNECTED position WARNING Use EMERGENCY STOP pushbutton in case of emergency situation See Fig 73 4 Tus to release Door Key Door Locks Fig 73 4 Door locks 2011 04 26 547183 01 Manual Rack Out Procedure NOTE Crank Handle is necessary for completing of racking operation
62. the installation instructions are carefully followed Each module and each trolley undergo High Potential Tests before shipment Passing of compete Factory Acceptance Test sequence is marked by sticker note See Fig 61 1 GE Powar Controls Bielskn Biala Poland M odor garaiei Loew lec Dirmak s ji No y Serial Iso vnitaga JIV UL File A fiwilohagar GE Power Cantrots giolsk Bata Sele hype Hasar a A Fig 61 1 Quality check markings after FAT tests If local codes demand this test or the purchaser wishes to make high potential tests the voltage should not exceed for the power circuit 2 8 kV RMS 3 9kV DC and for the control circuit 1 2 kV RMS Testing procedure is described in Appendix H Table H 7 Grounding Circuit Check If local codes demand this test or the purchaser wishes to make earthing system test refer to procedure described in Appendix H Table H 8 Minimum current required for checking of grounding connections is 10 A Resistance for each measured grounding connection must be less than 0 1 Ohm Design and specifications are subject to change without notice 15 DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 7 Operating the Module Operating the Module 7 1 Mechanisms and Interlocks Racking Mechanism The racking mechanism is designed for moving the trolley betwe
63. tion of the handle v Check if Crank s clutch is set at minimum 50 Nm D Cannot rack in the trolley into DISCONNECT TEST position Check point C v Check if rating Rejection Interlock of the trolley and the module match v Check if Racking Shaft is bent v Check if Indicator Shaft is jammed E Cannot rack in the trolley into CONNECTED position Check point C v Check if Secondary Disconnect is connected v Check if shutters are jammed or closed F Cannot rack out the trolley from TEST position Check if Secondary Disconnect is disconnected Check if Access Lever is lifted up Motor driven trolley NOTE Check points A thru F are also valid for motor driven trolley Refer to them in case of related issues G Cannot rack in the trolley to CONNECTED position v Check if Access Lever is in down position Check if motor thermal overload protection GPS1B is activated v Check if end switch S4F is activated v Check if end switch S3F is activated H Cannot rack out the trolley from CONNECTED position v Make sure the breaker contacts are OPEN v Check point G 22 Design and specifications are subject to change without notice 8 2 Maintenance NOTE See User Manual S47183De for complete breaker inspection and maintenance routines Expected service life of the OEM module is 20 years with MTBF exceeds 2 000 racking operations The module and trolley construction is nearly maintenance free The system is desig
64. und bus connection in the cable compartment is the same on all module types Cable compartment is provided without side covers See Fig 33 1 Painted and pre punched side covers can be ordered as separate accessories NOTE See Appendix A for all dimensional drawings of the primary terminals and cable compartment Module is also equipped with trolley operated contacts that are activated in CONNECTED and TEST position as well as with some other limit switches that are used for internal interlocks Control Compartment The secondary control plug located in the breaker compartment is prewired with a 3ft tagged wire harness brought into the controls compartment for User s connections The matching secondary disconnect plug is mounted on the trolley NOTE See Appendix A for all dimensional drawings of the Control Compartment 2011 04 26 547183 01 4000 Terminals 6000A Terminals Ground t Bus Connection Fig 33 4 Rear views of 4000A and 6000A Modules 3 4 The Trolley The module is designed to be used with Gerapid high speed circuit breaker installed on the withdrawable trolley The trolley can be ordered in two different versions with manual racking or with motor operated remote racking system Remote racking trolley equipped with motor drive can also be operated manually by the crank handle NOTE The crank handle is an accessory and has to be ordered separately Trolley structure is compatible wit
65. up Access Lever e Try to lift up Trip Lever d Use Crank Handle b to rack the trolley between TEST and CONNECTED positions Remove Crank Handle CLOSE the breaker Send a command to rack out the trolley to TEST position Try to lift up Access Lever e Send a command to OPEN the breaker Check Position Check signal in CONNECTED position Use Crank Handle b to rack out the trolley into position between TEST and CONNECTED Remove Crank Handle CLOSE the breaker OPEN and move the trolley to TEST position Send a command to rack in the trolley to CONNECTED position OPEN the breaker Use Crank Handle b to rack out the trolley to DISCONNECTED position Remove Crank Handle Try to manually pull trolley out of the module Disconnect Secondary Plug 9 Try to manually pull trolley out of the module Design and specifications are subject to change without notice The trolley must not move into TEST position while Plug g is disconnected The breaker must not CLOSE while Crank Handle b is inserted The breaker must CLOSE Positions Check signal must be active The trolley must not move Access Lever must not open while breaker is CLOSED Trip Lever must release and open the breaker The breaker must not CLOSE if it is not in TEST or CONNECTED position The trolley must not move while the breaker is closed Access Slot c must not open if breaker is CLOSED The breaker must
66. vel in all planes with maximum deviation of 0 8 inch at the length of 3 foot The module should be anchored to the floor through holes shown on Fig 41 1 using 7 16 or metric M12 grade 5 steel bolts 4 2 Module Configuration and Assembly Multiple Modules Side by Side Assembly Modules can be connected together to form switchgear lineups To bolt two modules together edge trim strips must be removed Special connection spacers must be used and are inserted into 12 hex shaped cut outs visible in the sidewalls Fig 42 1 shows the location of the front 4 connection spacer openings Location of all openings and installation tips are shown in Appendix G A Module Coupling Kit can be ordered under Cat No 289169 Each kit consists of 12 Connection spacers bolts and washers necessary to connect two adjacent modules NOTE See Appendix D for connection drawings Connection Spacers 12 per side by side Fig 42 1 Location of front module connection spacers Module Preparation Every module is suitable for operating either with manually or motor operated trolley Depending on the type of trolley being utilized a locking plate in the module may need to be removed v f motor operated trolley is going to be used with the Module remove the locking plate v f manually operated trolley is going to be used with the module keep the locking plate in place See Fig 41 1 and Fig 42 2 to locate locking plate NOTE Look for the yello
67. w warning label placed on the module s floor to find bottom guide rail and the plate Design and specifications are subject to change without notice DC OEM MODULE FOR USE WITH GERAPID CIRCUIT BREAKERS Chapter 4 Installing the Module Locking Plate Remove for motor operated trolley Fig 42 2 Locking Plate Module Rejection Interlock OEM must configure the rejection interlock in the module before its usage Four different configurations are possible 2500A 4000 5000A or 6000A In the module rejection markers must be screwed in place aligned with all current ratings except the one that module is dedicated to This should be done on the right and left side of the module Fig 42 3 illustrates a correctly configured module rejection Interlock for a 2500A rated Gerapid breaker Rejection markers must be fixed on both right and left sides of the breaker compartment aligned with ratings 4000A 5000A and 6000A Installed Breaker Rating Markers 26 Rejection Markers Fig 42 3 Rejection interlock set up for rating of 2500A NOTE Always verify that the rating on rejection interlock is not higher that the module rated current NOTE Always configure rejection interlock on both sides of the module breaker compartment Main Busbars Connection Module primary terminals are silver plated copper and are suitable to connect to copper bus bars as per IEEE Std C37 14 Table 6 Connected bus bars should not have cr

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