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1. 29 NUTS i ADJUSTMENT SLEEVE LUBRICATIO COLLAR SET SECTION 7 Breaker Maintenance Cont 7 14 BUFFER ASSEMBLY When the breaker is closed the energy in the closing When the breaker is opened the end plate assembly is spring is transferred to the main shaft through the driven against the opposite end of the b ff r assembly mechanism The main shaft then drives the contacts The buffer is a stop absorbing the opening energy of the closed The end plate assembly on each end of the main mechanism See Fig 41 shaft is driven against the buffer assembly shown in Fig 40 This prevents the mechanism from overdriving the contacts END PLATE 005 MIN FIG 40 BUFFER END PLATE RELATIONSHIP BREAKER CLOSED END PLATE 040 FIG 41 BUFFER END PLATE RELATIONSHIP BREAKER OPEN 31 SECTION 7 Breaker Maintenance Cont NE
2. INSTANTA Adj Ground Fault Pickup FAULT Ground Return X Adj Ground Fault Delay e Trip Indication Targets Overload amp Short Circuit OTHER local only X FUNCTIONS local and remote X S C and Ground Fault local only X local and remote X Zone Selective Interlock Ground Faut X X Short Time X X GROUND 1PH 2 W 3PH 3 4 W X 1 Short Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required TABLE 12 RMS 9 AND EPIC MICROVERSATRIP CHARACTERISTICS Long Time Short Time Adjustable Adjustable Ground Fault I Current Instantan Instantan High Range Setting eous eous Instantan Triple Pickup Mult Pick up Pick Up Pick Up eous Selective Mult 1 Mult Pick up w o ST with ST Mult of Trip of Sensor Rating of Mult of Mult of Mult of Frame Fixed High Sensor Max Rating Plug Current Current Rating Rating Short time Range Amp Delay Delay Frame Amp Amps Amps Setting Delay Setting Delay Plug Amps Plug Amps Rating Instantaneous Rating 12 w o RT Size Rating S x C Sec C Sec X X H de S AKR 30 is 15 235 15 2 3 5 222 10 21 7 8 00 9 5 5 2 3 5 3 35 21 AKR 30H
3. TABLE 16 Sensor Plug Breaker Cat No Rating Amps Rating Frames TR4B150 150 TR4B200 200 TR4B225 400 225 AKR30 TR4B250 250 AKR30H TR4B300 300 TR4B400 400 TR8B300 300 TR8B400 400 TR8B450 450 TR8B500 800 500 AKRSOS TR8B600 600 5 TR8B700 700 TR8B800 800 TR16B600 600 TR16B800 800 TR16B1000 1600 1000 AKR50 TR16B1100 1100 AKR50H TR16B1200 1200 TR16B1600 1600 TR20B750 750 TR20B800 800 TR20B1000 1000 TR20B1200 2000 1200 AKRT50H TR20B1500 1500 TR20B1600 1600 TR20B2000 2000 81 SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 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 Protection Long time protection Instantaneous protection e Status Trip target 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 82 Ground fault protection with or without I T Zone selective interlock with ground fault only or with both ground fault and short tim Ad
4. Fi nally it also must be able to trip open a closed breaker quickly 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 s sembled on the back frame which provides the mechani cal support required and also the insulating structure needed The conductive members are the studs for exter nal connections movable and stationary contact sets pivots for the movable contacts and provision fornmounting the current transformers The interrupter components in additionto 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 combination of many accessories and interlocking devices lt also differ in a variety of areas as shown in Table brief description of these areas is given below An outline drawing is available for each breakerframe size showingcriticaldimensions The drawingnumberappears on the breaker nameplate and can be obtained from GE 2 1 FRAMESIZE The breakers are available in 5 frame sizes 800 ampereS A Gr AKR 30 30H 301 AKRU 30 1600 amperes A C AKR 50 50H AKRU 500 2000 am peres AC 50 50H 800 amperes D C 30 and 2000 amperes D C 50 FIG 1 Manually Operated AKR 4A 50 1 mhese values repre
5. SECTION 7 Breaker Maintenance Cont 7 14 BUFFER ASSEMBLY When the breaker is closed the energy in the closing spring is transferred to the main shaft through the mechanism The main shaft then drives the contacts closed The end plate assembly on each end of the main shaft is driven against the buffer assembly shown in Fig 40 This prevents the mechanism from overdriving the contacts END PLATE When the breaker is opened the endplat assembly is driven against the opposite end of the b ffer assembly The buffer is a stop absorbing the opening energy of the mechanism See Fig 41 FIG 40 BUFFER END PLATE RELATIONSHIP BREAKER CLOSED FIG 41 BUFFER END PLATE RELATIONSHIP BREAKER OPEN END PLATE 31 SECTION 7 Breaker Maintenance Cont 7 14 1 BUFFER ADJUSTMENT Referring to Fig 40 with the breaker closed and the mechanism not reset a 005 clearance must exist be tween the end plate assembly and the buffer nut as shown This dimension is factory set It can be reset by tightening the buffer nut Hold the nut with a screwdriver and tighten using a socket on the bolt head opposite the nut When tightening this assembly don t over compress the neo prene washers by o
6. PRIMARY DISCONNECT ASSEMBLY SEE FIG 13 MOUNTS DIRECTLY ON OUTBOARD FUSE TANG FIG 54 AKRU 50 2500A FUSE TANG POSITIONS TABLE 6 FUSES FOR AKRU BREAKERS Gould Shawmut Cat Nos Breaker Type A4J 450 A4J 500 A4J 600 4 800 A4BX 800 1000 A4BY 1000BG A4BX 1000BG 1200 A4BY 120080 A4BX 1200BG 1600 A4BY 1600BG A4BX 1600BG 2000 A4BY 2000BG A4BX 2000BG Special 2500 4 2500GE Mounting adapter required see Fig 52 42 SECTION 9 Fused Breakers Cont 93 OPEN FUSE LOCKOUT DEVICE This device automatically trips the fuse breaker if one of the fuses opens When this happens the breaker is locked open until the reset button of the phase involved is pushed The breaker should not be reclosed of course until the opened fuse is replaced Type D breakers use the Open Fuse Lockout OFLO shown in Fig 55 Type A and B breakers use the OFLO shown in Fig 56 Both OFLO s work on the same design When the fuse opens the resulting open circuit voltage activates the OFLO s phase solenoid when the voltage level reaches approximately 90 VAC The solenoid s arma ture then drives a tripping rod against a trip paddle which is attached to the trip shaft This causes the breaker to open The armature also drives the reset button forward indicat ing what phase is involved The reset button linkage also holds the tripping rod against the trip paddle The button m
7. eS CONNEETOR PROGRAMMER CONNECTOR NORD AMP 201298 1 201297 1 FIG 69 CABLING DIAGRAM SST WITH GROUND FAULT ON 3 WIRE LOAD A B8 9 FLUX SHIFT TRIP DEVICE w BREAKER aS Ne N BACK FRAME PSI 48V dc TO SCR LEFT POLE ANODE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT W BLACK k HARNESS PROGRAMMER CONNECTOR FROGRAMMEF EQUIPMENT MOUNTED AMP 201298 1 201297 1 NEUTRAL SENSOR V o 4 4 WIRE LOAD FIG 70 CABLING DIAGRAM SST WITH GROUND FAULT ON 4 WIRE LOAD 54 BREAKER HARNESS GROUND FAULT DEFEAT CABLE PROGRAMMER CONNECTOR CAT NO TGFD UNIT Sat F p r7 lt lt o CURRENT SENSORS 9 lt A ea 3 any SST PROGRAMMER elo UNIT WITH Mr 3 GROUND FAULT JELEMENT C l px 3 1 AUR NR d cot 1 lt NEURAL tX SENSOR lt lt DISCONNECT PETAT Lj LA I FIG 71 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 55 SECTION 11 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
8. 1TANG BOLT 2500 FUSE 2 Disconnect Key 5 Primary Disconnect HOLES 3 Heat Sink IN USE FIG 53 AKRU 50 WITH SPECIAL 2500 AMP FUSE xe PRIMARY DISCONNECT ASSEMBLY SEE FIG 53 MOUNTS DIRECTLY ON OUTBOARD FUSE TANG FIG 54 AKRU 50 2500A FUSE TANG POSITIONS TABLE 6 FUSES FOR AKRU BREAKERS Gould Shawmut Breaker Cat Nos Type Ampere Rating Fuse Limiter 300 A4J 300 350 A4J 350 400 A4J 400 450 A4J 450 500 A4J 500 600 A4J 600 800 A4BY 800 A4BX 800 L 1000 A4BY 100080 A4BX 1000BG 1200 A4BY 120080 A4BX 1200BG 1600 A4BY 1600BG A4BX 1600BG 2000 A4BY 2000BG A4BX 2000BG Special 2500 A4BX 2500GE Mounting adapter required see Fig 52 42 SECTION 9 Fused Breakers Cont 9 33 OPEN FUSE LOCKOUT DEVICE This device automatically trips the fuse breaker if one of the fuses opens When this happens the breaker is locked open until the reset button of the phase involved is pushed The breaker should not be reclosed of course until the opened fuse is replaced Type D breakers use the Open Fuse Lockout OFLO shown in Fig 55 Type A and B breakers use the OFLO shown in Fig 56A amp 56B Both OFLO s work on the same design When the fuse opens the resulting open circuit voltage activates the OFLO phase solenoid when the voltage level reaches approximately 90 VAC the functional test in the factory is accomplished using
9. N J i2 i Co en sar ut FIG 41 BUFFER END PLATE RELATIONSHIP BRE AKER OPEN 31 SECTION 7 Breaker Maintenance Cont NEOPRENE WASHERS 7 14 1 BUFFER ADJUSTMENT Referring to Fig 40 with the breaker closed and the mechanism not reset a 005 min clearance must exist between the end plate assembly and the buffer nut as shown This dimension is factory set It can be reset by tightening the buffer nut Hold the nut with a screwdriver and tighten using a socket on the bolt head opposite the nut When tightening this assembly don t over compress the neoprene washers by overtightening the assembly These washers absorb the breaker open ing shock Referring to Fig 41 with the breaker open a 040 maximum clearance can exist between either of the end plate assemblies and the buffer bolt heads as shown If a larger clearance exists close it up by unscrewing the buffer assembly involved Fig 42 shows a buffer assembly prior to being installed in a breaker The dimensions given establish the number of spacers that are used 7 15 TRIP LATCH ADJUSTMENT The reset position of the trip latch is set by the adjust ment screw shown in Fig 43 The adjustment is correct if three and one half turns of the adjustment screw causes a FIG 42 BUFFER ASSEMBLY closed breaker to trip If this check is made the screw must then be set back or unscrewed three and one half tur s ADJUSTMENT SCREW
10. 5 to restore it to serviceable status Industry publications of recommended maintenance prac tices such as 70B Electrical Equipment Maintenance should beycarefully studied and applied in each user s formation of planned maintenance Some users may require additional assistance from Gen eral Electric in the planning and performance of maintenanc The General Electric Company can be contracted to either undertake maintenance or to provide technicabassistance such as the latest publications The performance and safety of this equipment may be compromised by the modification of supplied parts or their replacement by non identical substitutes All such design changes must be qualified to ANSI IEEE Standard C37 59 The user should methodically keep written maintenance tecords as an aid in future service planning and equipment reliability improvement Unusual experiences should be promptly communicated to the General Electric Company 10A 5 2 1 ALTERNATE CONTROL CIRCUIT USED A second type of electrical control is shown in Fig 9A for all control voltages except 250 volts D C which uses the circuit shown in Fig 9 This alternate control circuit eliminates the X relay and CC switch shown in Fig 9 The motor is energized through the G cutoff switch and the K relay contact The motor is deenergized when the G cutoff switch changes state which occurs when the closing spring is fully char
11. W W Right Side Vlew Showing Long Time Delay Mechanism Front View Showing Mounting Bracket 1 Senes Coil 8 S T D Calibration Spring 15 Plunger 2 Magnet 9 Trip Paddle Adjusting Screw 16 Cylinder 3 Pallet 10 L T D Armature 17 Calibration Plate 4 Pinion 11 L or Low set Inst Calibration Spring 18 Trip Paddle 5m Escape Wheel 12 Inst Trip Spring High Set 19 Trip Arm 6 Driving Segment 13 Spring Holder 20 Clamping Bracket 7 S T D Armature 14 Calibration Clamp Nut FIG 101 SERIES OVERCURRENT TRIPPING DEVICE EC 1 73 13 2 3 INSTANTANEOUS TRIPPING a Adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition over comes the restraining force of 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 over comes the restraining force of a non adjustable spring 13 2 4 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 The trip latch of the breaker should also be checked for proper trip latch engage ment See Section 7 15 EC 1 Devices may have their pick up settings varied by changing the positions of the sl
12. XL E 2 Nd w gt 32 SECTION 8 Contact Maintenance Breakers subjected to frequent interruption of high cur rents may eventuallyrequire replacementoftheir contacts The general rule for determining 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 notindicate loss of ability to carry or interrupt current When contacts are replaced they must be adjusted to ensure that the proper amount of force is developed be tween the movable and stationary contacts when the breaker is closed This is called the wipe adjustment Wipe is the distance through which the stationary con tacts move when the breaker closes It is measured bet ween the point of contact on a stationary contact when the breaker is open and the position of the same point when the breaker is closed The actual wiping motion is greater because the contacts over travel Wiping imparts a slid ing or scrubbing action to the contacts The wipe adjustment influences proper arc transfer dur ing interruption of fault currents Transfer of the arc is its forced sequential movement from the intermediate con tacts to the arcing contacts to the arc runner and finally to the arc quencher where it is dissipated and extinguished It is recommended that contact wipe be checked periodically during normal maintenance inspections CAUTION B
13. UPPER LATCH ADJUSTMENT SCREW SIDE LATCH LATCH ENGAGEMENT 7 POINT FIG 35 BELL ALARM DETAILS SECTION 7 Breaker Maintenance Cont The mechanism is reset by disengaging the side latch link from the upper latch link or by closing the breaker if a locklever is not provided The side latch link is activated only by pushing the TRIP button or operating the shunt trip A slide attachment on the TRIP button shaft moves against the side latch link when the TRIP button is pushed This slide attachment is factory adjusted to activate the side latch before the breaker is tripped A second arm on the shunt trip also activates the side latch link when the shunt trip is energized 7 11 2 ADJUSTMENTS If a breaker is equipped with a bell alarrr lockout device originally all the adjustments are made at the time of assembly Switch operation is controlled by means of shims of insulating material placed between the switch body and the bracket to which it Is fastened The adjust ment screw is positioned so that when the locklever is in its activated position it holds the breaker mechanism latch in the tripped position Check that TRIP button shaft and shunt trip operations besides tripping the breaker displace the side latch and prevent the bell alarm switch from operating The other trip devices and interlocks must activate the bell alarm when they open the breaker The bracket assembled to the TRIP button shaft m
14. or 4 0X 288 INTER 13 sec 6 12X or 9 15X or 2CC MIN 07 sec 80 250 x 2 1 Xe Trip device ampere rating If tnp devices are set above 100 for Such sefungs do not increase the breakers cononuous current rating 2 lower imit of band at 6 umes pickup sefting 9 At lower limit of bana at 272 times pickup setting 4 Low set instantaneous Not available in wih tong eme 70 SECTION 13 EC Trip Device Cont FIG 99 OVERCURRENT TRIPPING DEVICE EC 2A 71 13 1 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 in stantaneous tripping 2 Low set instantaneous tripping 3 High set instantaneous tripping The dual trip has adjustable long time and instantaneous pick up settings and adjustable time settings Both forms of in stantaneous 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 engage ment See Section 7 15 Refer to Fig 99 for the discussions given below 13 1 1 LONG TIME DELAY AND HIGH SET INSTANTANEOUS TRIPPI
15. SUMMING CIRCUITRY ui REGULATED 15 POWER SUPPLY FIG 76 MICROVERSATRIP BLOCK DIAGRAM 58 OVERLOAD TARGET CIRCUIT TARGET 12 1 1 FAULT TRIP INDICATORS The optional fault trip indicators are similar to the SST indicators They are mechanical pop out type f r identify ing overload or short circuit over currents faults when breakers are ordered without integral ground fault protec tion They are also available to identify overload short circuit and ground fault trips forsbreakers supplied with integral ground fault protection Each target pops out when its asSociated trip element operates to trip the breaker Aftera trip the popped target must be reset by hand However neglecting to reset does not affect normal oper tiom of any trip element or prevent the breaker from beingyclosed 12 1 2 REMOTE FAULT INDICATION Remote fault indieation is available in the form of a mechanical contact which may be incorporated directly into the Cust mer s control circuitry This is a Normally open coritactwhich is activated when its associated target pops o t When the target is reset the contact is returned to its open position Each contact is rated 0 25 amp at 125 VDG and 1 0 amp 10 amp in rush at 120 VAC oven ONT GROUND FAULT FAULT TRIP AN ANNUNCIATOR Versa Trip lt lt TO WESETONDICATOR Sena Ne FIG 7 7 MICROVERSATRIP PROGRAMMER The remote fault indication switch leads are br
16. 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 52 10 4 2 RESISTANCE VALUES For use in troubleshooting the Common to Tap resist ance for SST current sensors is given in Table 8 These values apply to both phase and neutral sensors TABLE 8 SENSOR RESISTANCE VALUES Resistance in Ohms between COMMON and TAP Terminals 6 4 7 6 8 8 10 4 13 5 15 8 19 4 22 8 10 2 12 4 15 8 19 2 22 0 26 7 28 5 34 7 The coil resistance of the SST ECS Flux shifter device is approximately 16 ohms 10 43 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 69 each phase sensor is con nected 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 addto zero and nogroundsignalis 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 dif ferential transformer can produce output sufficient to trip the breaker Similarly discontinuity between any sensor and the
17. The bell alarm is not a standard device and is supplied only when specified on the breaker order 7 11 1 OPERATION Referring to Fig 35 the bell alarm mechanism is ac tivated by a crank which is assembled to the breaker s main shaft When the breaker opens a pin attached to this crank moves the alarm link against the switch and locklever if provided This activates the switch contacts It also moves the locklever adjustment screw against the trip shaft paddle keeping the breaker trip free SWITCH LOCKLEVER ALARM LINK UPPER LATCH ADJUSTMENT SCREW SIDE LATCH LATCH ENGAGEMENT POINT FIG 35 BELL ALARM DETAILS SECTION 7 Breaker Maintenance Cont The mechanism is reset by disengaging the side latch link from the upper latch link or by closing the breaker if a locklever is not provided The side latch link is activated only by pushing the TRIP button or operating the shunt trip A slide attachment on the TRIP button shaft moves against the side latch link when the TRIP button is pushed This slide attachment is factory adjusted to activate the side latch before the breaker is tripped A second arm on the shunt trip also activates the side latch link when the shunt trip is energized 7 11 2 ADJUSTMENTS f a breaker is equipped with a bell alarm lockout device originally all the adjustments are made at the time of assembly Switch operation is controlled by means of shims of insulating material plac
18. 12 2 CURRENT SENSORS The current sensors supply the power and signal in put necessary to operate the trip system Like the SST system the MicroVersaTrip uses a phase and neutral sensor Fig 83 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 12 5 for cabling diagrams PED Lures RE FIG 81 AKR 6D 30 Locking Lever The tapped and fixed phase sensors have a polarity ass sociated with their windings Their COMMON terminal is the right hand terminal as shown in Fig 83 A white wire with a ring terminal will be connected to this COMMON terminal All phase sensors must be correctly wired for the program mer summing circuit to function properly The tapped or fixed phase sensors are available with an additional winding This windingyis brought out to separate flag terminals rather than the screw terminals These phase sensors are used when the hi level instan taneous MicroVersaTrip option H option is required Fig 84 shows an H option phase sensor When the H option phase sensor is
19. BREAKEFP MOUNTED FIG 60 SST PHASE SENSOR WITH TAP BOARD EQUIPMENT MOUNTED 300 800 SHORTING STRAP FIG 62 NEUTRAL SENSOR SECONDARY DISCONNECT FIG 61 SST NEUTRAL SENSORS BLOCKS 00 300 A 47 10 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 63 replacement of individual SST current sensors is accomplished as follows a Disconnect the breaker harness from the tap ter minal board removing cable ties as necessary Un fasten the terminal board from the breaker base b At the rear of the breaker remove the two Allen head screws to separate the stud connector from the contact pivot block c Loosen the clamping bolt and remove the stud connector Lift out the sensor and its tap terminal board The sensor may be prevented from slipping off the sensor stud by adjacent accessories If this exists the sensor stud must be removed from the breaker base The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker Flux shift Trip Device Allen head Screws Stud Connector Current Sensor A C9 d When replacing the stud connector tighten the Allen head screws to 250 gt 10 in Ibs Tighten the clamping bolt as follows AKR 30 30H 30L 120 gt 10 in Ibs 50 50H 470 10 in Ibs 50 50H 470 gt 10 in Ibs 10 3 FLUX SHIFT TRIP DEVICE T
20. BREAKER REVERSE FEED SECTION 12 MicroVersaTrip Trip Device Cont REESE GROUND FAULT DEFEAT MODULE PROGRAMMER CONNECTOR CAT NO TVTGD9 M rd o lt lt I lt a lt 0 lt 4 0 o lt 4 0 lt 0 lt o 191 MICROVERSATRIP pes HEN BC Qua pd GROUND FAULT 1 o lt 191 4 Lot o lt lt 1 o lt lt 0 lt 4o I o lt AA L L pa FIG 93 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 HARNE PROGRAMMER Y Y CONNECTOR CONNECTOR FIG 94 PARTIAL CABLING DIAGRAM H OPTION WINDING CONNECTIONS PROGRAMMER REMOTE FAULT MICRO VERSA TRIP SECONDARY INDICATION PROGRAMMER DISCONNECT CONNECTOR EQUIPMENT BREAKER g ser 13 5 15 onere H ER 13502399 13502469 1350242 9 1 360235 9 FIG 95 CABLING DIAGRAM REMOTE FAULT INDICATION Ea PROGRAMMER a DISCONNECT EQUIPMENT BREAKER CONNECTOR I SHORT TIME 5 INPUT 3 SHORT TIME OUTPUT 6 GROUND FAULT ri INPUT 2 7 GROUND FAULT f gt OUTPUT A
21. RNESS CONNECTOR PROGRAMMER AMP 201298 1 reco c Verify that the harness connections to the sensors meet the polarity constraints indicated by the cabling dia gram i e white wire to COMMON black wire to TAP d On Ground Fault breakers serving 4 W ire loads check that the neutral sensor is properly connected see cabling diagram Fig 70 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 t4he breaker mounted neutral secondary disconnectblockithrough to the female harness connector terminals L 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 neutral conductor is carrying only that n utral c rrent associated with the breaker s load cur rent neutral not shared with other loads Ifthe preceding steps failto identify the problem then the sensor resistances should be measured Since the phase and neutral sensors are electrically identical their tap to tap resistance should closely agree See Table 8 PROGRAMMER UNIT AMP 201297 1 FIG 68 CABLING DIAGRAM SST WITHOUT GROUND FAULT SECTION 10 Type SST Overcurrent Trip Device CONNECTOR AMP 201298 1 PROGRAMMER CONNECTOR
22. The time c rrent characteristics for the SST Trip Device are diven in curves GES 6033 GES 6034 and GES 6035 FIG 67 SST ECS TEST SET CAT NO TAK TS1 51 SECTION 10 Type SST Overcurrent Trip Device Cont 10 4 4 SST TEST SET The TAK TS1 and TAK TS2 Test Sets are portable in struments 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 addi tion includes means for continuity checking the phase sensors A TAK TS1 Test Set is shown in Fig 67 The TAK TS2 functions identically to and supersedes the TAK TS1 device The TAK TS2 can also test the Ver saTrip Mod 2 trip device WARNING BEFORE CONNECTING THE TEST SET TO THE BREAKER TRIP DEVICE SYSTEM EN SURE THAT THE CIRCUIT BREAKER IS COM PLETELY DISCONNECTED FROM ITS POWER SOURCE ON DRAWOUT EQUIPMENT RACK THE BREAKER TO ITS DISCONNECTED POSITION VERIFY THAT THE BREAKER IS TRIPPED Either of two test modes may be employed Programmer Unit Only These tests con ducted 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 ONABREAKERTHATIS ENERGIZED AND CARRY ING LOAD CURRENT THIS WILL OPEN CIRCUIT THE
23. a 5 i a j I HE da FIG 11 MAINTENANCE HANDLE INSTALLED ON CAMSHAFT EXTENSION 13 SECTION 5 Breaker Operation Cont x 73 E 9 er ee ee FIG 12 ROLLER ENGAGED WITH CLOSING There is a ratchet assembly attached to the camshaft Rotate the camshaft using the maintenance handle until extension This ratchet is normally driven by the breaker s the ratchet assembly s roller engages with the prop Do not gear motor A roller on this ratchet engages with a prop drive the roller against the prop with undo force The when the closing spring is fully charged and driven over Breaker can now be closed by removing the prop from the center see Fig 12 This holds the closing spririg in a roller This is done by manually activating the closing charged condition solenoid s armature Push the solenoid s armature into its windings See Fig 13 t GENERAL 7 ELEC i vt b CEREN s P 2 ES MEE PUSH ARMATURE ASM INTO SOLENOID CORE a FIG 13 MANUAL OPER E ATION OF CLOSING SOLENOID 14 SECTION 6 Interlocks AKR breakers are equipped with safety interlock devices that are required by Industry Standards and Certifying Au thorities Interlock devices for special applications are also available as options The standard interlock devices de scribed below are used only on dr
24. below the intermediate contacts but not enough to cover the main contacts ARC RUNNER STATIONARY ARCING CONTACTS STATIONARY INTERMEDIATE CONTACTS STATIONARY MAIN CONTACTS ARCING CONTACT 5 Attach a continuity checker bell set light or ohm meter between the upper and lower stud The checker should indicate continuity exists 6 Facing the breaker turn the wipe adjustment stud shown in Fig 47 clockwise until the checKer indicates that the main contacts are separated 7 Turn the stud counter clockwiseyuntil the main con tacts just touch 8 From this point advance the stud counter clockwise 270 degrees This will be 44 2 flats 9 Once the adjustmenft is complete verify that the torque required to just turn the adjustment nut is greater than 40 in Ibs Iflesstorque ismequired carefully add LOCTITE 220 or 290 to the adjustmenthut threads Wipe off any excess LOCTITE Orice the LOCTITE is set recheck the torque valve 10 Trip the Breaker remove the insulating strips 11 Rep at the above procedure on the other two poles FIG 47 1600 AMP CONTACT STRUCTURE 36 8 4 CONTACT ADJUSTMENT AKRT 50 50H The contact structure shown in Fig 48 is used by all AKRT 50breakertypes This structure is similarto the AKR 50 structure There are two movable contact arms each acting against single stationary arcing and intermediate contacts and four stat
25. 2 Magnet 9 Trip Paddle Adjusting Screw 16 Cylinder 9 Pallet 10 L T D Armature 17 Calibration Plate 4 Pinion 11 L T D or Low set Inst Calibration Spring 18 Trip Paddle 5 Escape Wheel 12 Inst Trip Spring High Set 19 Trip Arm 6 Driving Segment 13 Spring Holder 20 Clamping Bracket 7 S T D Armature 14 Calibration Clamp Nut FIG 123 SERIES OVERCURRENT TRIPPING DEVICE EDC 1 87 SECTION 15 EC Trip Device Cont 15 2 3 INSTANTANEOUS TRIPPING a Adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition over comes the restraining force of 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 over comes the restraining force of a non adjustable spring 15 2 4 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 The trip latch of the breaker should also be checked for proper trip latch engage ment See Section 7 15 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 chang
26. 4 No tool is required tominsert the wire socket assembly into the connector the assembly un til it snaps into place 5 Verify all sockets afe inserted to the same depth CAUTION N THE EVENT THAT THE SST TRIP DE VICE MUST BE RENDERED INOPERATIVE TO ALLOW THE BREAKER TO CARRY CURRENT WITHOUT BENEFIT OF OVERCURRENT PROTEC TION RECOMMENDED METHOD IS SHORTEN IHE TRIP ROD BY TURNING ITS AD JUSTER END FULLY CLOCKWISE THIS PRE VENTSACTUATION OF THE TRIP SHAFT PADDLE RESET LINKAGE FIG 64 FLUX SHIFT TRIP DEVICE AND OPERATING LINKAGES 49 SECTION 10 SST Overcurrent Trip Device Cont Bottom view Top view 1 Actuator 4 Trip shaft 2 Trip rod adjuster erid 9 Actuator arm 3 Trip paddle 6 Reset linkage FIG 65 FLUX SHIFT TRIP DEVICE COMPONENTS TRIBPADOLE IN _ MECHANISM RESET POSITION TRIP ROO IN RESET POSITION ADJUSTER AM NUT END J NU O 125 DiA ROD FIG 66 TRIP ROD ADJUSTMENT 10 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 trip free state due to mechanical interference along its trip shaft c Inadvertent shunt trip activations WARNING DO NOT CHANGE TAPS ON THE CURRENT SENSORS OR
27. AMP 201297 1 FIG 69 CABLING DIAGRAM SST WITH GROUND FAULT ON 3 WIRE LOAD eee X FLUX SHIFT PROGRAMMER TRIP DEVICE HARNESS PROGRAMMER CONNECTOR CONNECTOR AMP 201298 1 Gap 201207 1 FIG 70 CABLING DIAGRAM SST WITH GROUND FAULT ON 4 WIRE LOAD BREAKER HARNESS GROUND FAULT DEFEAT CABLE CONNECTOR CAT NO TGFD SE M rye 5 lt CURRENT o SENSORS o Eo lt S a Ee or J 12 elo UNIT WITH 9 GROUND FAULT ELEMENT E S Hojo yerrer lt No EPI WE NEUTRAL 97 T5927 I DISCONNECT et O Th MALE FEMAL END END ese c FIG 71 CABLING DIAGRAM WITH GROUND FAULT DEFEAT CABLE INSERTED BETWEEN BREAKER HARNESS AND SST PROGRAMMER UNIT FOR USE DURING SINGLE PHASE HIGH CURRENT VOLTAGE TESTING 55 SECTION 11 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 72 current sensors and a flux shifter trip device Fig 73 shows a block diagram of the system The ECS trip system essentially duplicates the SST trip system described in Section 10 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 availabl
28. Lock ex u End Plate 4 Pin 2 Lock Bolt 3 6 7 OPTIONAL INTERLOCKS Theoptional interlocks are key interlocks anddoorinter locks On drawoutbreakers these evices are mounted in the equipment and are part ofthe breaker enclosure Pad locks may be used to lock the inner the discon nected position When the breaker is in the CLOSED position the flywheel assembly is away from the lever The lever is spring loaded and rotates clockwise causing its pin to block the lock bolt extension FIG 19 KEY INTERLOCK STATIONARY BREAKERS SECTION 7 Breaker Maintenance SAFETY PRECAUTION WARNING BEFORE INSPECTING OR BEGIN NING ANYSMAINTENANCE WORK ON BREAKER IT MUST BE DISCONNECTED FROM ALL VOLTAGE SOURCES BOTH POWER AND CONTROL AND THE BREAKER MUST BE IN THE POSITION 18 7 4 LUBRICATION In general the circuit breaker requires moderate lubrication The majority of the factory lubricated bear ing points and sliding surfaces are accessible for inspec tion and if necessary cleaning and relubricating The on ly lubricant used on the breaker for both electrical and mechanical areas is General Electric specification D50HD38 Mobilgrease 28 SECTION 7 Breaker Maintenance Cont The areas requiring lubrication are 1 Contacts A thin film on the stationary and movable contact assembly pivot surfaces Refer to Section 8 2 Racking Me
29. PARTIAL PRIMARY DISCONNECT ASM The 800 ampere breakers use four primarysdisconnect fingers per phase The 1600 and 2000 ampere breakers use eight fingers per phase Fig 22 shows a line and load end disconnect assembly The line end disconnects on fusible breakers have the spring pointing downwards otherwise they are identical 3 Se S i FIG 23 PARTIAL PRIMARY DISCONNECT ASM SPACER FORWARD FIG 25 PARTIAL PRIMARY DISCONNECT ASM 21 SECTION 7 Breaker Maintenance Cont 7 5 1 REPLACEMENT Figs 22 23 24 and 25 show the primary disconnect assembly breakdown Refer to these illustrations when replacing the disconnects Note the following details Fig 25 The position of the spacer in the breaker stud The hole in the spacer must be positioned as shown so it will align with the holes in the clip Fig 24 The engagement of the fingers with the re tainer Also the location of the bowtie spacers in the fingers both upper and lower Fig 22 amp 23 The position of the upper and lower retainers and again the bowtie spacers 7 52 ADJUSTMENT 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 instal lation of the disconnect assembly this force range is ob tained by tightening the locknuts to set the dimension shown in Fig 26 Note tha
30. Referring to Fig 35 the bell alarm mechanism is ac tivated by a crank which is assembled to the breaker s main shaft When the breaker opens a pin attached to this crank moves the alarm link against the switch and locklever if provided This activates the switch contacts It also moves the locklever adjustment screw against the trip shaft paddle keeping the breaker trip free SWITCH LOCKLEVER ALARM LINK UPPER LATCH ADJUSTMENT SCREW SIDE LATCH LATCH ENGAGEMENT POINT FIG 35 BELL ALARM DETAILS SECTION 7 Breaker Maintenance Cont The mechanism is reset by disengaging the side latch link from the upper latch link or by closing the breaker if a locklever is not provided The side latch link is activated only by pushing the TRIP button or operating the shunt trip A slide attachment on the TRIP button shaft moves against the side latch link when the TRIP button is pushed This slide attachment is factory adjusted to activate the side latch before the breaker is tripped A second arm on the shunt trip also activates the side latch link when the shunt trip is energized 7 11 2 ADJUSTMENTS If a breaker is equipped with a bell alarm lockout device originally all the adjustments are made at the time of assembly Switch operation is controlled by means of shims of insulating material placed between the switch body and the bracket to which it is fastened The adjust ment screw is positioned so that whe
31. device is mounted on the breaker Table 5 lists the catalog numbers available If the control voltage is ny 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 INSERT WIRE GAGE FIG 32D POSITIVE TRIP CHECK When installed the voltage to be monitored is connected across terminals No 1 and No 2 of the static delay box The the tripping unit is connected across terminals and No 5 of the static box through the secondary disconnects of the breaker The secondary disconnects to b 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 win dings causes the thermotector imbedded in the motor win dings to open This de energizes the undervoltage device on the breaker and drops the motor load 7 9 1 ADJUSTMENTS In the event the system fails the following checks are recommended to determine whether the undervoltage device on the breaker of the static time delay unit is the faulty component 1 Check input voltages across terminals 1 and 2 on the static box See Table 5 for these values 2 Check output voltages on terminals 4 and 5 with the undervoltage dev
32. g Repeat for Center and Left poles h Check fora 125 minimum clearance between trip ping rod and trip paddle with the OFLO reset Check for 032 minimum overtfavel after tripping rod trips breaker i Hold tripping rod in position and tighten its locknut EIG 55 TYPE D BREAKER OFLO DEVICE 9 3 2 TYPE D BREAKER OFLO ADJUSTMENT To adjust the Type D breaker OFLO a With the breaker in the CLOSED position and the OFLO reset adjust the dimension between the end of the tripping rod and the trip paddle to 100 140 b With the OFLO energized the breaker must TRIP and the RESET button must move forward to the front plate In this condition the breaker must be held trip free 43 SECTION 9 Fused Breakers Cont TRIP PADDLE TRIPPING ROD SOLENOID ARMATURE RESET FIG 565A DETAILS ED LO a TREE POWER CIR en A0345858 1841188365 AEROS ATOM 13364364 dun Qu OPEN FUSE LOCKOUT FIG 56B INSTALLED TYPE BREAKER OFLO DEVICE 44 SECTION 10 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 pro grammer unit current sensors and a flux shifter trip de vice Fig 57 shows a block diagram of the system 10 1 PROGRAMMER UNIT Fig 58 shows a typical SST programmer unit The pro grammer unit provides the comparison basis for overcur rent
33. tion 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 con nections must be employed for SST breakers equipped with Ground Fault Any single phase in put to the ground differential transformer 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 or b using the Ground Fault Defeat Cable as shown in Fig 71 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 to the SST system using por table Test Set Type TAK TS1 Fig 67y or TAK TS2 The applicable test pro edures are detailed in in struction Book 64454 are summarized Sec tion 10 4 1 The TAK TS1 and 152 Test Sets are portable in struments designed fof 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 addi tion includes means for continuity checking the phase sensors A TAK TS1 Test Set is shown in Fig 67
34. tion of personnel as well as other equipmerit frofn the potential hazards associated with electrical equipment The following requirements are intended to augment the user s safety program but NOT supplantethe user s responsibility for devising a complete safety program The following basic industry practiced safety require ments are applicable to all major lectrical equipment such as switchgear or switchboards General Electric neither condones nor assumes any responsibility for prac tices which deviate from the following 1 ALLCONDUCTORS MUSTBE ASSUMED TO BE ENER GIZEDUNLESSTHEIRPOTENTIALHASBEEN MEASURED AS GROUND AND SUILABEE GROUNDING CONDUC TORS HAVE BEEN4APPLIED TO PREVENT ENERGIZING Many accidents have been caused by back feeds from a wide variety of Sources 2 Althoughrinterlocks to reduce some of the risks are provided theindividual s actions while performing service or maintenance are essential to prevent accidents Each person sknowledge his mental awareness andhas planned and executed actions often determine if an accident will occur Thernostimportant method of avoiding accidents is fer all associated personnel to carefully apply a thorough understanding ofthe specific equipment from the viewpoints of 5 purpose it s construction it s operation and the sitdations which could be hazardous All personnel associated with installation operation and maintenance of electrical equipment such as power circuit
35. 2 Check continuity between the neutraksensor and its equipment mounted secondary disconnect block Also check for continuity from the ibreaker mounted neutral secondary disconnect block through to the female har ness 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 Fig 108 4 Ensure thatthe neutral conductor is carrying only that neutral cuirrent associated with the breaker load current neutral not shared with other loads 3 If the preceding steps fail to identify the problem then the sensor resistances should be measured Since the phase and n utral sensors are electrically identical their tap t0 tap resistances should closely agree See Tableh 13 5 CABLING DIAGRAMS FLUX SHIFT TRIP DEVICE pl BREAKER BACK FRAME LEFT POLE CURRENT SENSOR PROGRAMMER HARNESS PROGRAMMER ee AMP T 350356 9 CONNECTOR FIG 105 CABLING DIAGRAM RMS 9 amp EPIC MICROVERSATRIP WITHOUT GROUND FAULT s BREAKER BACK FRAME T N LEFT POLE CURRENT SENSOR l 1 I l Y Y Y HARNESS CONNECTOR 1 350356 9 LOAD lE ot PROGRAMMER CONNECTOR FIG 106 CABLING DIAGRAM RMS 9 amp EPIC MICROVERSATRIP WITH GROUND FAULT ON 3 WIRE LOAD 75 FLUX SHIFT TRIP DEVICE AAA BACK FRAME T T T LE
36. 2000 amps is the type EC 2A see Fig 119 An optional trip device for these frames is the type EC 1 see Figud 20 Trip characteristics are for the EC devices are given in Table 17 The time current characteristics for the EC trip devices are given in the following curves GES 6000 EC 1 GES 6010 EC 2 2A 14 3 GES 6011 EC 2 2A 1B 3 GES 6012 EC 2 2A 1C 3 FIG 120 EC 1 TRIP DEVICE TABLE 17 DEVICE TRIP CHARACTERISTICS Trip Long Time Device Pickup 2 Delay 2 1 MAX adj 15 98 sec or 80 160 EC 2A 1035 18 TUE 7 5 18 sec 1C MIN adj 3 3 8 2 sec 1A MAX 30 sec or 80 160 X 10 1B INTER 15 sec or 1C MIN S sec 188 MAX 4 5 sec or 1CC MIN 2 sec 80 160 X EC 1B 15 Short Time Inatantaneous Pickup 4 9X 6 12X 9 15X or 80 250 2 2 23 sec 2B INTER 15 sec High Set or up to 15X 2C MIN 07 sec Non Adjustable 2AA MAX 20 sec or 4 9X 2BB INTER 13 sec 6 12 9 15 2 MIN 07 sec 80 250 X 2 1 X Trip device ampere rating If trip devices are set above 100 for coordination purposes such settings do not increase the breaker s continuous current rating 2 Atdoweralimit of band at 6 times pickup setting 3 At lower limit of band at 21 2 times pickup setting 4 LOw se t instantaneous Not available in combin
37. AKR 6D 30 Locking Lever The tapped and fixed phase sensors have a polarity as sociated with their windings Their COMMON terminal is the right hand terminal as shown in Fig 83 A white wire with a ring terminal will be connected to this COMMON terminal All phase sensors must be correctly wired for the program mer summing circuit to function properly The tapped or fixed phase sensors are available with an additional winding This windi g is brought out to separate flag terminals rather thanethe screw terminals These phase sensors are used when the hi level instan taneous MicroVersaTrip option H option is required Fig 84 shows an H option phase sensor When the H option phase sensor is installed there are four leads connected to it two flag terminal connections additional winding and two crew terminal connections ampere rating There is no polarity associated with the flag ter minals Fig 94 shows the connections for the additional H option windings Fig 85 s ows 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 the cable or bus compartment The outputs of the phase sensors and neutral sensor are Connected to a programmer circuit which sums these val ues The total value will remain zero as long as there is no g
38. AUXILIARY SWITCH CRANK SHAFT POSITION 7 62 ADJUSTMENT If the adjustable link is installed its length should be set before installing at 6 3 8 inches between pin centers After installing a new switch its operation should be checked Viewing the switch from above the contacts toward the front of the breaker are normally the B con tacts Even if a special switch is used it is always the case that the first two stages nearest the crank have the B contacts to the front and the A contacts towards the back A contacts are closed when the breaker is closed B contacts are closed when the breaker is open check the setting arrange the breaker for slow close as described in Section 7 4 Through the use of a continuity tester observe the position of the breaker con tacts when the switch s LI LIC A contacts touch At this point the breaker s arcing contacts must be within 250 49 of closing Adjustment is made by disconnecting the upper end of the adjustable link and varying its length as required 7 SHUNT TRIP The shunt trip device opens the breaker when its coil is energized An A auxiliary switch which is closed only when the breaker is closed is in series with the device coil Connections are made to the external tripping source through secondary disconnects on drawout breakers or to the auxiliary switch and terminal board on stationary breakers The shunt trip is mounted to the
39. Except for the open fuse lockout device and the integrally mounted fuses on the upper studs the AKRU 30 and 50 breakers are identical to the unfused AKR 30 50 models Overcurrent trip devices are the same for both types 9 1 FUSE SIZES AND MOUNTING Table 6 lists the range of fuse sizes available for these breakers The Class L fuses are mounted as shown in Fig 51 Other than the 800A size which has a single mounting hole per tang each L fuse tang has two holes sized for one half inch bolts Class J fuses rated 300 thru 600A have one mounting hole per tang The 300 350 and 400A sizes require copper adapter bars per Fig 52 FIG 51 TYPICAL MOUNTING CLASS L FUSES 9 2 SPECIAL 2500A FUSE FOR AKRU 50 This fuse provides a melting time current characteristic that coordinates with 1600A trip devices Compared physi cally with a 2500A NEMA Class L fuse the special fuse is more compact shorter its tarigs are specially configured and offset to achieve the requir d pole to pole fuse spac ing a special primary disconnect aSsembly mounts directly on the outboard tang of tlie fuse Considering their unique mounting provisions whe replacing these fuses the fol lowing procedure should be adhered to Refer to Fig 53 a Remove the primary disconnect assembly from the fuse tang accomplished by first loosening the two keys via their holding screw and pulling them upward and out After the keys are removed pul
40. When replacing the stud connector tighten the Allen head screws to 250 10 in Ibs Tighten the clamping bolt as follows 30 30H 120 10 in Ibs AKR 50 50 470 10 in Ibs AKRT 50 50H 470 10 in Ibs 10 3 FLUX SHIFT TRIP DEVICE The Flux Shift Trip device is a low energy elec tromagnetic 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 il lustrated in Figs 64 and 65 An electromagnetic ac tuator located on the underside of the front frame is coupled to thesbreaker s trip shaft via 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 9 Tap Terminal Board 6 Programmer Unit 7 Clamp Bolt 8 Sensor Stud FIG 63 AKR 5A 30 BREAKER WITH SST TRIP DEVICE So long as the actuator remains in the Reset posi tion 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 tripp ing the breaker As the breaker opens the actuator 15 returned to its normal Reset position via linkage driven b
41. all three sensorS have the same electrical charac teristics If onessensor differs from the others i e dif ferent rating or wrong tap setting the circuitry can produce outputgsufficient to trip the breaker Similarly discontinuity between any sensor and the programmer unit Gan Catise a false trip signal If nuisance tripping is encountered on any breaker Whose MicroVersaTrip components have previously demonstrated satisfactory performance via the TVTS1 Test Set the sensors and their connections should be closely scrutinized After disconnecting the breaker from all power sources a Check that all phase sensors are the same type am pere range b Ensure that the tap 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 91 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 t
42. and the value of these calibration marks will be indicated by stampings on the arm as follows 4X 6 5X 9X or 6X 9X 12 or 9X 12 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 of the trip coil The variation in pick up setting is accomplished by varying the tensile force on the instantaneous Spring 5 Tuming the adjustment screw changes the position of the movable nut 11 on the screw The spring is arichored 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 cal ibration mark 15 to obtain the proper instantaneous trip setting The trip screw 6 on the end of the armature 7 should be Set so that it does not contact the trip paddle on the trip sh until the air gap between armature and pole piece is reduced 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 Replacement of the EC 2A device is accomplished by the same procedure described for the EC 1 series trip device how ever in some cases when replacing an EC 1 device with
43. end pieces on each spring have a small hole for inserting a spring puller A suitable puller can be fashioned by forming a hook on the end of a length of 062 diameter steel wire A spring puller is available for this use and may be ordered under Cat No 286A8168G1 3 Clean off the existing lubrication on the stud s pivot area Replace with a small amount of D50HD38 MOBIL 28 before installing new contacts 4 Torque the upper arc runner mounting screws to 45 5 in lbs Torque the lower screw to 35 40 in Ibs The movable contacts are removed as follows referring to Fig 46 1 Using a right angle tru arc pliers remove the tru arc retainer on the coupling pin Drift out the coupling pin 2 Remove the pivot pin hardware and spring from one side of the pivot pin Carefully remove the pivot pin 3 Slip out the contact arm 4 Place a thin film of D50HD38 lubricatiom on the pivot surfaces of the new arm Clean any existing lubrication from the pivot and place a small amount of D5OHD38 on it 5 Install the new arm insert the pivotpinand replace the pivot eng an hardware Tighten the pivot pin hard ware to 90 5 in Ibs 6 Install the coupling pin and tr arc retainer 7 Make the contact adjustment aS per section 8 2 8 7 CONTACT REPLACEMENT 50 50H AKRU 50 amp AKRT 50 50H Refer to Stationary Contact Identification Section 8 5 before replacing any stationary contacts The stationa
44. long time setting at 80 90 15 6 TRIP DEVICE REPLACEMENT Overcurrent devices on AKR30 amp AKR50 breakers may be dismounted by removing the fastening hardware at the rear of the breaker and withdrawing the device EC devices after being unfastened as shown in Figures 126 and 127 and having the clamps on the case in the front removed may be lowered clear of the breaker You do not have to separate frames on these breakers FIG 126 DISCONNECTING EC COIL FIG 127 DISCONNECTING EC FRAME SECTION 16 Electrical Characteristics TABLE 18 Charging and Closing Operating Currents MOTOR CONTROL CLOSING 5 Current Amps RELAY X SOLENOID E e I a 2 Rated Amps 2 Rated Amps s 5 o go S c ES OX SS gt Inrush Sealed 2 Inrush l Sealed ss 5 lt 2 2 lt es s 5 gt gt Open Closed Open Closed 9 48V DC 38 56 40 10 38 30 4 1 4 1 38 52 5 2 125V DC 100 140 27 5 85 90 105 105 41 75 175 250V DC 200 280 13 170 180 53 53 200 88 88 120 60 1 0 14 2 6 35 120 50 104 127 25 5 95 95 1 0 15 98 2 2 29 120V 25 6 85 27 14 17 208 60 45 063 1 5 19 208V 50 180 220 15 3 5 175 175 5 083 177 12 16 208V
45. lt E 31 any sst PROGRAMMER lt c UNIT WIZH B hs j GROUND FAULT V ELEMENT ect ERE 3 clot fN o7 T lt lt NEUTRAL SENSOR o lt 4 o o s NN 1 FIG 71 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 55 SECTION 11 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 72 current sensors and a flux shifter trip device Fig 73 shows a block diagram of the system The ECS trip system essentially duplicates the SST trip system described in Section 10 except for the following 1 Programmer units are limited fo combinations of Long Time Short Time and instantaneous trip elements only The Ground Fault element is not available 2 Phase sensors are not tapped As listed in Table 9 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 74 3 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 in cludes circuitry size construction component loc
46. mounted with respect to the breaker must be used This must a minimum rating of 400 volt amperes INSERT WIRE GAGE FIG 32D POSITIVE TRIP CHECK 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 through the secondary disconnects of the breaker The secondary disconnects to be Sed 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 win dings causes the thermotector imbedded in the motor win dings to open This de energizes the undervoltage device on the breaker and drops the motor load 7 91 ADJUSTMENTS In the event the system fails the following checks are recommended to determine whether the undervoltage device on the breaker of the static time delay unit is the faulty component 1 Check input voltages across terminals 1 and 2 on the static box See Table 5 for these values 2 Check output voltages on terminals 4 and 5 with the undervoltage device connected See Table 5 for values 5 TIME DELAY UNITS CONTROL VOLTAGE NOMINAL DC COIL RESISTANCE APPROXIMATE STEADY STATE DC OPERA
47. the existence of a false4ground signal As indicated by the cabling diagram of Fig 90 each phase sensor is connected to summingsCircuitry in the programmer Un der no fault conditions on 3 wire load circuits the currents in this circuitry to zero and no ground signal is developed This current sum will be zero only if all three sensorsahaye the same electrical charac teristics If on sensor differs from the others i e dif ferent wrong tap setting the circuitry can produce outputisufficient to trip the breaker Similarly discontinuity between any sensor and the programmer unittean Cause a false trip signal If nuisance tripping is encountered on any breaker whose MicroVersaTrip components have previously demonstrated satisfactory performance via the TVTS1 Test Set the sensors and their connections should be closely scrutinized After disconnecting the breaker from all power sources a Check that all phase sensors are the same type am pere range b Ensure that the tap 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 91 In particular 1 Verify that the neutral sensor has the same rating and tap setting as the phase sensors 2 Check continuit
48. 1 65 65 50 50 AKRT 50 65 65 2000 AC AKRT 50H 65 65 800 AKRU 30 200 1600 AKRU 50 800 30 300VDC 25 2000 DC AKR 50 300 VDC 50 With 40 800 Amp Trip Coils 2With 200 2000 Amp Trip Consult Factory Application Data SECTION 3 0 Storage Safety Maintenance It is recommended that the breaker be put into service immediately in its permanent location If this is not possi ble 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 onthe insula tion parts Circuit breakers for outdoor switchgear should be stored in the equipment only when power is available and the compartment 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 F 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 10 3 1 Safety Each user must maintain
49. 40 165 The movable contacts are removed as follows referring to Fig 46 1 Using a right angle tru arc pliers remove the tru arc retainer on the coupling pin Drift out the coupling pin 2 Remove the pivot pin hardware and spring from side of the pivot pin Carefully remove the 3 Slip out the contact arm 4 Place a thin film of D50HD38 lubrication pivot surfaces of the new arm Clean any existing lubrication from the pivot and place a small amoufit of D50HD38 on it 5 Install the new arm insert the pivot replace the pivot spring narawara Tighten the pivot pin hard ware to 90 5 in Ib 6 Install the coupling pin and tru arc retainer 7 Make the contact adjustment per section 88 2 8 7 CONTACT REPLACEMENT AKR 30L AKR 50 50H AKRU 50 amp AKRT 50 Refer to Stationary Contact Identification Section 8 5 before replacing any stationary contacts The stationary intermediate and maint contacts are replaced just like the stationary contacts on the 800 ampere breakers Refer to steps 2 amp 3 in Section 8 6 Referring to Fig 50A 50B amp 50C the stationary arcing contacts are replaced as follows 1 Remove the rummer the flat insulation assembled underneath the aresfunner It is secured with four screws When reffioving the lower screws use care not to damage or misplac the insulating washer found under each of thes
50. 6 Inputs Selective Interlock 7 Zone 8 Outputs 11 12 Homnet 9 Spare 10 MVT PM 1 VB 4 VA 2 24 Ret 3 24 VDC NOTE LOCATION OF PIN 1 FIG 114 PROGRAMMER SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND MVT PM 79 SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units FIG 115 14 5 PHASE CURRENT SENSORS The current sensors supply the power and signahinput necessary to operate the trip system Fig 116 shows the fixed phase sensors available The sensors have apolar ity associated with their windings The common terminal of the sensor is the right hand terminal A whiteire with a push on terminal will be connected to this cotnmon terminal All phase sensors must be correctly wiredfor the programmer summing circuitry to functi n properly 80 TAPPED FIXED COMMON TERMINAL FIG 116 Thefixed 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 H option is required Fig 117 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 117 H OPTION PHASE SENSOR SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 6 NEUTRAL CURRENT SENSORS CAUTION
51. ADJUST THE PRO GRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CARRYING CURRENT Once it has been established that the circuit breaker can be operated and closed normally from the test posi tion 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 con nections must be employed for SST breakers equipped with Ground Fault Any single phase in put to the ground differential transformer 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 Q ELECTRIC mues m w ctt b using the Ground Fault Defeat Cable as shown in Fig 71 This special test cable energizes all the primary windings of the differentialitransformer in a self cancelling series parallel connection so that its secondary output is always zero 2 Test the components to the SST system using por table Test Set Type TAK TS1 Fig 67 or TAK TS2 The applicable test procedures are detailed in in struction Book GEK 64454 arid are summarized in Sec tion 10 4 1 The TAK TS1 and TAK TS2 Test Sets are portable in struments designed for field checking the time current characteristics and pickup calibration of the SST s various trip eleme
52. AKR 30 and 50 models Overcurrent trip devices are the same for both types 9 1 FUSE SIZES AND MOUNTING Table 6 lists the range of fuse sizes available for these breakers The Class L fuses are mounted as shown in Fig 51 Other than the 800A size which has a single mounting hole per tang each Class L fusetang has two holes sized for one half inch diameter bolts Class J fuses rated 300 thru 600A have one mounting hole per tang The 300 350 and 400A sizes require copper adapter bars per Fig 52 All 2 13 fuse mounting bolts should be torqued to 200 350in Ib 11 bolts which attach the C shaped fuse adapters to the breaker studs should be torqued to 300 525 in Ib FIG 51 TYPICAL MOUNTING CLASS L FUSES 9 2 SPECIAL 2500A FUSE FOR AKRU 50 This fuse provides a melting time current characteristic that coordinates with 1600 trip devices Compared physi cally with a 2500A NEMA Class L fuse the special fuse is more compact shorter itstfangsare specially configured and offset to achieve the required pole to pole fuse spac ing a special primary disconnectassembly mounts directly on the outboard tang of the f se Considering their unique mounting provisions when replacing these fuses the fol lowing procedure should be adhered to Refer to Fig 53 a Remove the primary disconnect assembly from the fuse tang accomplished by first loosening the two keys via their holding Screw and pulling them upward and
53. Cont 8 5 STATIONARY CONTACT Q IDENTIFICATION The stationary arcing intermediate and main contacts e each have a different function during current conduction and current interruption For this reason these contacts are made using different material compositions Also the different functions require that the contacts be replaced in configurations shown in Figs 44 47 or 48 Fig 49 shows the stationary contacts they differ from one another The 800 amp main and arcing contacts are rectangular but the arcing contacts have two of their corners notched The 1600 2000 amp main and intermediate contacts are rectangular but the main contacts have two of their corners notched The inter mediate contacts have all four corners notched Qy 1600 2000 AMP MAIN 800 AMP MAIN 1600 2000AMP 800 AMP ARCING INTERMEDIATE FIG 49 STATIONARY CONTACT CONFIGURATION 8 6 CONTACT REPLACEMENT AKR 30 30H amp AKRU 30 Refer to Stationary Contact Identification Section 8 5 before replacing any stationary contacts The stationary contacts are held in place by the contact springs which pivot the contacts against the contact stop refer to Fig 45 To replace contacts 1 Remove the arc runner It is secured by two screws into the base and one screw into the contact stop 2 Release each contact spring by holding the contact extending the spring and removing it from the contact The
54. Current Current 2 UM Amps Amps 5 2r A t Operating Inrush Sealed Operating Inrush Sealed z Voltage range Open Closed Voltage range Open Closed 24 DC 14 30 8 3 8 3 38 38 48 DC 28 60 4 5 4 5 SEE 719 19 125 DC 70 140 2 0 2 0 TABLE 08 08 250 DC 140 280 1 0 1 0 25 04 04 70 60 59 132 120 60 95 127 12 3 10 8 66 24 120 50 95 127 7 6 6 7 9 75 25 120 25 95 127 4 7 4 1 8S 31 10 208 60 175 220 3 2 26 9 51 17 208 50 175 220 3 8 3 1 30 10 208 25 175 220 241 1 9 14 05 240 60 190 254 3 9 3 4 5 37 12 240 50 190 254 47 41 Sx 34 ET 240 40 190 254 5 8 5 1 20 240 25 190 254 24 19 20 16 06 380 50 315 410 2 9 2 6 ox 22 08 480 60 380 508 3 4 59 23 08 480 50 380 508 7 5 7 3 PE 217 06 480 25 380 508 3 8 33 a 5 41 05 575 60 475 625 28 25 g e 16 06 575 50 475 625 5 1 4 7 14 06 575 25 475 625 341 3 0 10 05 92 TABLE 24 COIL RESISTANCE DC OHMS 25 Nominal Control Anti Pump Control Shunt Voltage Frequency Hz Relay W Relay X Trip Undervoltage 24V DC N A N A 3 64 48V DC 802 12 11 240 125V DC 5000 119 64 1600 250V DC 16400 476 260 6700 120V 60 450 54 3 9 25 4 120V 50 450 75 7 15 33 120V 25 1450 75 25 4 146 208V 60 1450 216 25 4 64 208V 50 1450 300 25 4 146 208V 25 3900 300 64 580 240V 60 1450 300 25 4 100 240V 50 1450 300 25 4 146 240V 25 6000 300 64 580 380V 50 N A NA 64 370 480V 60
55. EQUIPPED WITH GROUND FAULT When nuisance tripping occurs on breakers equipped with the Ground Fault tip element a probable cause is the existence of a false ground signal As indicated by the cabling diagram of Fig 106 each phase sensor is con nected 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 devel oped 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 the circuity can produce output sufficient to trip the breaker Simi larly 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 TestSet the sensors and their connections should be closely scrutinized After disconnecting the breakerfrom all power sources a Check that all phase sensors are the same type ampere range c Verify that the harness connections to the sensor meet the polarity constraints indicted by the cabling diagram d On Ground Fault breakers serving 4 wire I ads check that the neutral sensor is properly connected see cabling diagram Fig 107 In particular 1 Verify that the neutral sensor has the same rating as the phase sensors
56. Fig 29 from the breaker frame and remove the device from the bracket If a replacement or new evice is ordered a mounting bracket will be supplied with the device If a second shunt trip is added this is mounteg by means of an additional bracket as shown in Fig 30 This additional bracket is fastened by two of the hex head bolts used to fasten the buffer assembly to the breaker frame 7 7 2 ADJUSTMENT When these devices are installed their positive ability to trip the breaker must be demonstrated This is done by placing a 1 32 inchtshim between the ar mature and magnet of the deviceand manually operating the armature to trip the breaker If the shunt trip is not successful in this test check the mounting fasteners to make s re they are reasonably tight If they are then b nd th trip paddle on the trip shaft to slightly reduce the distanc between the trip arm of the device and the trip paddle and recheck for positive trip If this bending is necessary be careful that it is not over done Verify 15 a 030 050 gap between the trip arm and the trip paddle with the breaker closed greater than 050 is permitted and may sometimes be necessary in order to prevent nuisance tripping Re verify positive trip as final check 7 8 UNDERVOLTAGE DEVICE The undervoltage device trips the breaker when its coil is de energized The leads of the coil are connected Girectly to secondar
57. Fig 37 engaged by the holding pawl This tooth is the one which is in line with an imaginary line passing through the centers of the camshaft and the rivet opposite the roller on the ratchet assembly It is a matter of no concern if the action stops on a different tooth but it is important to positively identify tooth No 1 by the method described To check the switch action after tooth No 1 has been identified turn the camshaft with the maintenance handle andcountthe teeth as they pass the holding pawl By using a continuity tester observe when the switches operate as the ratchet turns The normally open F switch on the left will close and the G switch will open Electrical breakers should operate the switches while moving from tooth No 10 to tooth No 11 If this check shows that an adjustment is needed the switch to be corrected can be moved closer to or farther away from the paddle which operates the switches Avery thin open end 5 8 inch wrench will be needed to loosen or tighten the nuts which fasten the switches to th bracket 7 13 DRAWOUT MECHANISM The drawout mechanism shown in Fig 38 moves the breaker through the DISCONNECTED TEST and CON NECTED positions Fig 39 shows how the drawout mechanism is mounted to the breaker As the racking handle is turned the internally threaded trunnion moves on the screwathreads rotating the hex shaft on the ends of which are fastene d the arms which engage the fixed pin
58. For all breakers except Type B or D the padlock shackle goes through the TRIP button hole and out the slot in the side of the escutcheon For Type B or D breakers the padlock shackle goes through the TRIP button hole and out the RACKING SCREW cover hole in the deep escutcheon In either case the shackle holds the TRIP button in keeping the mechanism trip free 17 SECTION 6 Interlocks Cont 6 6 KEY INTERLOCK STATIONARY BREAKER The function of the Key Interlock is to prevent an open breaker from being closed when the lock bolt is extended and its key is removed Theoperation ofthis interlock is shown in Fig 19 When the breaker is in the OPEN position the end plate assem bly item 2 on the main shaft pivots the lever item 6 counter clockwise This removes the pin item 3 on the lever from blocking the lock bolt Extending the lock bolt rotates the linkage which movesthe trip shaft preventing the mechanism from closing the breaker Lock End Plate Pin Lock Bolt Pin Lever c When the breaker is in the CLOSED positionxth fly wheel assembly item 42 is away from the lever item 6 The lever is spring loaded and rotates clockwise causing its pin to block the lock bolt extension 6 7 OPTIONAL INTERLOCKS The optional interlocks are key interlocks and door inter locks On drawout breakers these devices are mounted in the equipment andare partof the breaker enclosure FIG 49
59. HESEVENT THAT THE SST TRIP DE VICE MUST BE RENDERED INOPERATIVE TO ALLOW BREAKER TO CARRY CURRENT WITHOUT BENEFIT OF OVERCURRENT PROTEC TION THE RECOMMENDED METHOD IS SHORTEN THE TRIP ROD BY TURNING ITS AD JUSTEB END FULLY CLOCKWISE THIS PRE VENTS ACTUATION OF THE TRIP SHAFT PADDLE RESET LINKAGE FIG 64 FLUX SHIFT TRIP DEVICE AND OPERATING LINKAGES 49 SECTION 10 SST Overcurrent Trip Device Cont Bottom view Top view 1 Actuator 4 Trip shaft 2 Trip rod adjuster end 5 Actuator arm 6 Reset linkage 3 Trip paddle FIG 65 FLUX SHIFT TRIP DEVICE COMPONENTS TRIP PAODLE IN MECHANISM RESET POSITION TRIP ROD IN RESET POSITION ADJUSTER JAM NUT END 0 109 031 Dia rod FIG 86 TRIP ROD ADJUSTMENT 50 10 4 TROUBLESHOOTING When malfunctioning is suspected the first step in troubleshooting is to examine the circuit breaker 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 shunt trip activations WARNING DO NOT CHANGE TAPS ON THE CURRENT SENSORS OR ADJUST THE PRO GRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CARRYING CURRENT Once it has been established that the circuit breaker can be operated and closed normally from the test posi
60. LOAD 4 WIRE LOAD 7 FLUX SHIFT PROGRAMMER TRIP DEVICE pe NIT BREAKER ARRAN BACK FRAME l LEFT POLE CURRENT SENSOR NEUTRAb NEUTRAB SENSOR DISCONNECT EQUIPMENT MOUNTED NEUTRAL SENSOR 55 PROGRAMMER AMP 1 350356 9 CTOR FIG 92 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD BREAKER REVERSE FEED SECTION 12 MicroVersaTrip RMS 9 Epic MicroVersaTrip Device Cont BREAKER HARNESS GROUND FAULT DEFEAT PROGRAMMER CONNECTOR CAT NO TVTGD9 2 x e a ANY MICROVERSATRIP PROGRAMMER U IWITH GROUND FAULT ELEMENT O OO 0 uiii 1 bo FIG 93 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 AL amp C PROGRAMMER UNIT BREAKER Z BACK S lt Partial LEFT CURRENT SENSOR YELLOW YELLOW YELLOW YELLOW O YELLOW 5 YELLOW HARNI 55 PROGRAMMER CONNECTOR CONNECTOR LOAD FIG 94 PARTIAL CABLING DIAGRAM H OPTION WINDING CONNECTIONS PROGRAMMER REMOTE FAULT MICRO VERSA TRIP SECONDARY INDICATION PROGRAMMER DISCONNECT CONNECTOR EQUIPMENT BREAKER OVERLOAD SHORT CIRCUIT GROUND FAULT OVERL
61. Maintenance Cont ARCING CONTACT PIVOT STATIONARY ARCING CONTACTS INSULATING SPACERS CONTACT PIN FIG 508 ARC RUNNER REMOVED FIG 50C ARCING CONTACT PIVOT REMOVED 40 SECTION 9 Fused Breakers There are two types of fused breakers AKRU 30 800 ampere frame and AKRU 50 1600 ampere frame Except for the open fuse lockout device and the integrally mounted fuses the upper studs the AKRU 30 and 50 breakers are identical to the unfused AKR 30 and 50 models Overcurrent trip devices are the same for both types 9 1 FUSE SIZES AND MOUNTING Table 6 lists the range of fuse sizes available for these breakers The Class L fuses are mounted as shown in Fig 51 Other than the 800A size which has a single mounting hole per tang each Class L fusetang has two holes sized for one half inch diameter bolts Class J fuses rated 300 thru 600A have one mounting hole per tang The 300 350 and 400A sizes require copper adapter bars per Fig 52 All 2 13 fuse mounting bolts should be torqued to 200 350 in Ib The 11 bolts which attach the C shaped fuse adapters to the breaker studs should be torqued to 300 525 in Ib FIG 51 TYPICAL MOUNTING CLASS L FUSES 9 2 SPECIAL 2500A FUSE FOR AKRU 50 This fuse provides a melting time current characteristic that coordinates with 1600A trip devices Compared physi cally with a 2500A NEMA Class_L fuse the special fuse is more compact shorter its
62. NB 50D 7 RMS 9 9 MVT PLUS or MVT PM gt x gt SECTION 2 General Description Type AKR low voltage power circuit breakers are used for controlling 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 circuits when abnormal conditions occur Among these conditions the more common are short circuits and sustained overloads and under voltages 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 subsequently for fast tripping Knowledge of how the breaker is designed and how it operates will enable the ownerto 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 com mitment to close the breaker at any point upon the activa tion of an automatic trip device i e be
63. NOT CHANGE TAPS ON THE CUR RENT SENSORS OR ADJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CAR RYING CURRENT PROGRAMMER FLUX YE SHIFTER ers PROGRAMMER HARNESS MICROVERSATRIP COMPONENT WITH TAPPED SENSORS 64 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 properwikesting 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 phas testsy special connec tions must be employed for breakers equipped with Ground Fault Any single phase input to the programmer circuit will generate an unwanted ground fault output ignal hich will trip the breaker This be nullified either by a Using the Ground Eault Defeat Cable as shown Fig 93 This special test cable energizes the pro grammer circuit inta self cancelling series parallel connection sogthat its out put is always zero 2 Test theacomponents of the MicroVersaTrip system using portable Test Set Type TVTS1 Fig 88 The ap plicable test procedures are detailed in instruction Book 64464 The time current characteristics for the MicroVersaTrip Trip Device are given in curves GES 6195 and GES 6199 FIG 87B 5 9 EPIC MICROVERSATRIP AND MVT PLUS OR MVT
64. 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 terminals are left open Do not short any neural current sensor terminals in a three phase three wire system as this could result in damage to or malfunction of the electrical system Fig 118 shows the neutral sensor The neural 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 Theneutral sensorisan electrical duplicate ofthe phase sensor Therefore when phase sensors are changed the neutral sensor must be correspondingly be changed FIG 118 TYPICAL NEUTRAL SENSOR 14 7 RATING PLUG REMOVAL ANDIRE PLACEMENT CAUTION Removal of the rating plug while the breaker is carrying current reduces the breaker s current carrying capacity to approximately 2596 of the current sensor rating Interchangeable rating plugS are removed with a Rating Plug Extractor Catalog Suitable equiva lents are commercially available as integrated circuit extractors Grasp the ati
65. RMS 9 amp Epic MicroVersaTrip Device Gont 74 Sincetheneutralsensoris mounted separatelyfrom the breaker a disconnect means is required to connect its output to the breaker Fig 86 shows the breaker and equipment mounted 4th wire secondary disconnect used with the RMS 9 system 13 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 87B replacement of RMS 9 Epic MicroVersaTrip current sensors is accomplished by the same procedure as the MicroVersaTrip current sensors 13 3 FLUX SHIFTER TRIP DEVICE The only difference between the RMS 9 Epic MicroVersaTrip and SST flux shifter trip devices is the solenoid winding Refer to Section 10 3 for details When replacing RMS 9 Epic MicroVersaTrip flux shifter AMP extraction tool Cat No 455822 2 is required to remove the socket leads from the AMP connector 13 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 m chanical maintenance along its trip shaft c Inadvertent shunt trip activations WARNING Do not adjust the programmer unit Set knobs while the breaker is carrying curr nt Once it has been established that the cirewit breaker can be opened and closed normally from thettest position attentio
66. SECTION 10 Type SST Overcurrent Trip Device Cont 46 FIG 58 SST PROGRAMMER Ax di FIG 59 AKR 5B 30 10 2 CURRENT SENSORS The SST system uses two types of current sensors phase sensor and a neutral sensor Fig 60 shows a phase sensor Fig 61 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 the principle that the instantaneous values of current in the three conductors 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 con necting each phase sensor in series 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 Application of the Ground Fault element on 4 wire sys tems with neutral grounded at the transformer requires the additional separately mounted neutral sensor Fig 61 inserted in the neutral conductor its secondary is con nected to a fourth primary winding on the ground differen tial transformer See Fig 70 This fourth wire neutral sensor is an electrical duplicate of the phase sensor in cluding taps Therefore when taps are changed on the phase sensors
67. Symptom Possible Cause Corrective Action 1 The trip unit display Line current is below 20 At least 20 of the cufrent sensor rating S must is blank of S MicroVersaTrip Plus be flowing throughithe breaker to activate the display If not powerthe trip unit with the Test Kit or external battery pack External 24 Vdc is absent Check thatthe control power supply is present MicroVersTrip PM and operational 2 The trip unit display Can occur on Plus style trip Power unit with the Test Kit or external flashes units when load current battery pack fluctuates near 20 of S 3 The trip unit display Thebuilt in self test has Replace the trip unit flashes ERR detected an error 4 The trip indication Trip unit is not in status Press FUNCTION until STATUS is displayed Press N target will not clear Unit does not com municate with the Monitor POWER LEADER Distribution Software or FPU Current readings are incorrect Voltage readings incorrect kW legend is flashing Overload target is flashing by itself mode Commnet wir syare Shorted or improperly connected FPU version s lower than 2 0 Tripuinit address incorrect 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 SELECT and VALUE together to clear
68. TRIPPING ROD SOLENOID ARMATURE RESET FIG 56A DETAILS GENERAL GD ELECTRIC FUSED LOW VOLTAGE POWER CIRCUIT BREAKER 3 FIG 56B INSTALLED TYPE AOR BREAKER OFLO DEVICE 44 SECTION 10 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 pro grammer unit current sensors and a flux shifter trip de vice Fig 57 shows a block diagram of the system 10 1 PROGRAMMER UNIT Fig 58 shows a typical SST programmer unit The pro grammer unit provides the comparison basis for overcur rent 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 ad justments set points are located on the face plate De pending on the application programmer units may be equipped with various combinations of Long Time Short Time Instantaneous and Ground Fault trip elements See Table 7 for available ratings settings and trip characteris tics 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 clear cover to the face plate The SST programmer units can be optionally equipped with trip indicators targets These are pop out m
69. This is a Normally open contactwhich is activated when its associated target pops out Whenrthe target is reset the contact is returned to its open position Each contact is rated 0 25 amp at 125 VDG and 1 0 amp 10 amp in rush at 120 VAC FRAT n CURRENT SETTING INSTANTANEOUS M PICKUP FIG 77 MICROVERSATRIP PROGRAMMER The remote fault indication switch leads are brought out the bottom of the MicroVersaTrip programmer as shown in Fig 78 This switch lead harness is plugged into the mating connector on the breaker see Fig 79 The switch leads are brought out from the breaker through the Programmer Secondary Disconnect shown in Fig 80 The zone selective interlocking function wir ing is also brought out through this disconnect See Figs 95 and 96 for the remote fault indication and zone selective interlocking cable diagrams over GROUND LOAD CIRCUIT FAULT FAULT TRIP ANNUNCIATOR REMOTE FAULT INDICATION CONNECTOR FIG 78 MICROVERSATRIP W REMOTE FAULT INDICATION HARNESS FIG 79 PROGRAMMER SECONDARY CONNECTOR REMOTE FAULT INDICATION DISCONNECT FIG 80 REMOTE FA
70. Time delay shown at lower limit of each band All pickup tolerances 10 Ground Fault pickup not to exceed 1200 amperes 2 22 24 26 28 30 34 37 X 1 5 2 2 5 3 2 22 24 4 5 7 9 X d 26 28 3 X X sensor current 61 SECTION 12 MicroVersaTrip Trip Device Cont soa tano b ka S xe ra TAPPED COMMON TERMINAL FIG 83 MICROVERSATRIP PHASE SENSORS SPECIAL WINDING CONNECTIONS AMPERE RATING CONNECTIONS FIG 84 H OPTION PHASE SENSOR 62 FIG 85 TYPICAL NEUTRAL SENSOR A BREAKER MOUNTED RIGHT SIDE B EQUIPMENT MOUNTED FIG 86 NEUTRAL SENSOR SECONDARY DISCONNECT Since the neutral sensor is mounted separately from the breaker a disconnect means required to connect its output to the breaker Fig 86 Shows the breaker and equipment mounted 4th wire Secondary disconnect used with the MicroVersaTrip system 12 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 87 replaeementof MicroVersaTrip cur rent sensors is accomplished as follows a Disconnect the programmer harness from the ter minal board removingycabledies as necessary b At the rear of the breaker remove the two Allen head screws to separate the stud connector from the contact pivot block Loosengthe Clamping bolt and remove the stud con nector Lift outthe sensor and its tap terminal board The sensor may be preven
71. Trip Adjustment 88 15 4 Reverse Current Tripping Device 89 15 4 4 Adjustment 90 15 4 2 Replacement 90 15 5 Switchette Feature 90 15 6 Trip Device Replacement 90 SECTION 1 Introduction These instructions provide the maintenance procedures and describe the operation of the 800 thru 2000 amp frame size type AKR low voltage power circuit breakers listed in Table 1 The proper use care and maintenance of these break ers is a prime safety consideration for the protection of personr el 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 instruc tions 1 14 INSPECTION AND MAINTENANCE Breakers should be cared for under a systematic main tenance 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 in spected will depend on the circumstances of its use H would be well to inspect any breaker at least once a years If itis frequently operated operated under severe load coindi tions or installed in an area of high humidity or a dusty di
72. Values 65 12 4 2 False Tripping Breakers Equipped with Ground Fault 65 12 5 MicroVersaTrip Cabling Diagrams 66 SECTION 13 70 13 0 RMS 9 amp EPIC MICROVERSATRIP 70 13 1 Programmer Unit 70 13 1 1 Fault Trip Indicators 70 13 1 2 RMS 9 amp Epic MicroVersaTrip Installation 71 13 2 Curfent Sensors 71 13 2 1 Replacement of Current Sensors 74 13 3 Flux Shiftef Trip Device 74 13 4 Troubleshooting 74 13 4 1 Resistance Values 74 13 4 2 False Tripping Breakers Equipped With Ground Fault 75 19 93 Cabling Diagrams 75 Page SECTION 14 77 140 MICROVERSATRIP PLUS ANB MICROVERSATRIP PM TRIP UNITS 77 14 1 Trip Unit 77 14 2 Testing 78 14 3 Product Structure 78 14 4 Trip Unit Removal andsReplacement 79 14 5 Phase Current Sensors 80 14 6 Neutral Current Sensors 81 14 7 Rating Plug Removal and Replacement 81 14 8 Trip Unit Functions 82 14 9 Trouble4Shooting Guide 83 SECTION 15 84 15 0 EC TRIP DEVICE 84 15 1 Series Overcurrent Tripping Device EC 2A 86 19 13 Long Time Delay High Set Instantaneous Tripping 86 15 4 2 instantaneous Low Set Tripping 86 1551 3 Instantaneous High Set Tripping 86 15 27 Series Overcurrent Tripping Device EC 1 87 15 2 1 Short Time Delay Tripping 87 15 2 2 Long Time Delay Tripping 87 15 2 3 Instantaneous Tripping 88 15 2 4 EC 1 Adjustment 88 15 3 Positive Trip Adjustment 88 19 4 Reverse Current Tripping Device 89 15 41 Adjustment 90 15 4 2 Replacement 90 15 5 Switchette Feature 90 15 6 Tr
73. a minimum of 4 ratchet laminations 7 Verify that the holding pawl pivot pin is perpendicular to the mechanism frame The hardware which assembles the pivot pin to the frame must be torqued to 250 in Ibs minimum If this hardware must be retightened add LOC TITE 290 to the shaft threads B Install the front escutcheon Tighten the escutcheon hardware to 80 10 in Ibs 1 MECHANISM FRAME 2 PIVOT PIN 3 SPRING 4 WASHER 032 FIG 36C HOLDING PAWL ASSEMBLY DETAILS 5 PAWL ASM 6 WASHER 010 7 RETAINING RING 7 12 2 F AND G SWITCH ADJUSTMENT For proper electrical operation the F and G mechani cally operated switches must operate at the proper point in the closing cycle If these switches are to be replaced measure the distance between the tip of the switch button and the bracket on which they are mounted When the new Switch is mounted duplicate the measured dimension then check for proper operation When a normal closing operation occurs the ratchet usually comes to a stop with an arbitrarily designated ratchet tooth No 1 Fig 37 engaged by the holding pawl This tooth is the one which is in line with an imaginary line passing through the centers of the camshaft 2 and the rivet opposite the roller on the ratchet assembly It 15 matter of no concern if the action stops on a different tooth but it is important to positively identify tooth No 1 by the method described To check the switch action afte
74. aligns with a rejec tion pin in the drawout rail Fig 8 When the wrong type breaker is inserted into a compartment the bracket and pin prevent the breaker from seating itself into the drawout rails There is one exception to the above Breakers of the same frame size having different short circuit ratings may be interchanged in one direction only a An AKR 30H can be inserted into an AKR 30 compart ment b An AKR 50H can be inserted into an AKR 50 compart ment c An AKR 50H 1 can be inserted into an AKR 50 and AKR 50H compartment d An AKRT 50H can be inserted into an AKRT 50 com partment The rejection hardware prevents the converse of a thru d above A detailed description of the rejection pin and bracket combinations used is given in Installation manual GEI 86150 10B TYPICAL REJECTION BRACKET FIG 7 DRAWOUT BREAKER REJECTION SYSTEM FRONT OF COMPARTMENT FRONT PIN IN POSITION A SLOT RAIL PIN RIGHT SIDE FIG 8 INSERTING THE BREAKER SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 9 TROUBLE SHOOTING GUIDE The following guide is provided for trouble shooting and isolating common problems possible co
75. an EC 2A it will be necessary to replace the trip paddles on the trip shaft with ones which are slightly longer When required these will be provided with the replacement trip units NOTE Pick up settings on the calibration plate of the EC 2A device are calibrated for the specific device When replacing Covers replace on associated device ps ij n FIG 100 TIME ADJUSTMENT INDEXING 13 2 SERIES OVERCURRENT TRIPPING DEVICE EC 1 Each series overcurrent tripping device is enclosed in a molded case and mounted by screws and a bracket to the lower part of the pole unit base Refer to Fig 101 for the discussions below 13 2 1 SHORT TIME DELAY TRIPPING The armature 7 is restrained by calibrating spring 8 After the magnetic force produced by an overcurrent condition over Z lt lt Left Side View Showing Short Time Delay Mechanism comes this restraining force the armature movement is further retarded by escapement mechanism which pr duces verse time delay characteristic The mechanism is shown on Fig 101 13 2 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 is fur ther retarded by the flow of silicone oil in a dashpot which pro duces an inverse time delay characteristic The mechanism is shown on Fig 101
76. any breaker whose MicroVersaTrip components have previously demonstrated satisfactory performance via the TVTS1 T st Set the sensors and their connections should be Closelyscrutinized After disconnecting the breaker from all power sources a Check that all phase sensors are the same type am pere range b Ensure that the tap 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 91 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 92 4 Ensure that the neutral conductor is carrying only that neutral current associated with the breaker s load cur rent neutral not shared with other loads e Ifthe preceding steps fail toidentify the problem then the sensor resistances should be measured Since the phase and neutral sensors are electrically identical their
77. breakers and other power handling equipment must be thoroughly instructed with periodic retraining regarding power equipment in general as well as the particular model of equipment with which they are working Instruction books actual devices and appropriate safety and mainte nance practices suchas OSHA publications NationalElectric Safety Code ANSI C2 The National Electrical Code and NFPA 7 OB Electrical Equipment Maintenance must be closely studied and followed During actual work supervi Sion should audit practices to assure conformance 3 Excellent maintenance is essential for reliability and safety of any electrical equipment Industry publications of recom menced maintenance practices such as ANSI NFPA 70B Electrical Equipment Maintenance should be carefully stud ied and applied in each user s formation of planned maintenance 3 2 Maintenance Both long and short term maintenance of all electrical equipment is essential for reliability and safety Mainte nanceprograms must be tuned to the specific application well planned and carried out consistent with both industry experience and manufacturer srecommendations Local environment must always be considered in such pro grams including such variables as ambienttemperatures extreme moisture number of operations corrosive atmo sphere or major insect problems and any other unusual or abusive condition of the application One of the critical service activities sometim
78. causes the breaker contacts to open Reset Position The mechanism is shown in Fig 10C The closing cam item no 3 which is assembled to the cam shaft item no 4 isrotated by the charging motor manual operating handle or maintenance handle The cam engages the cam roller and partially extends the toggle linkage This allows the secondary latch item 14 to pivot against the front frame as shown leaving between the trip latch and secondary latch roller The secondary latch is now in a position to engage With both the trip latch and cam roller The breaker closes when the closing springfdischarges androtates the cam item 3 against the cam roll r item 5 The toggle linkage is fully extended th secon dary latch from the front frame and engagingjit with the trip latch and cam roller as shown insFigas9A When the breaker is closed spring discharged the upper cam rollemitem 5 is supported by the cam rather than the prop This is the position the mechanism must be in to check contact adjustment refer to Section 8 FIG 10A CLOSED 10 n 4 5 FIG TRIPPED 14 5 4 3 FIG 10C RESET 2 Prop 11 Trip Latch 3 Cam 12 Insulated Coupling 4 Camshaft 13 Main Shaft 5 Cam Roller 14 Secondary Latch 6 Secondary Latch Roller 15 Opening Spring 10 Trip Shaft 5 4 CHARGING USING THE MAINTENANCE HANDLE The closing spring on electrically oper
79. circwit current has been interrupted SAFETY PRECAUTION BEFORE INSPECIING OR BEGINNING ANY MAINTENANCE WORK ON THE BREAKER IT MUST BE DISCONNECTED FROM ALL VOLT AGE SOURCES BOTH POWER AND CON TROL AND BE IN THE OPEN POSITION A basic inspection should consist of the following a Visual Check Look for dirt grease or other foreign material on any breaker parts Check insulating surfaces for conditions that could degrade insulating properties cracks overheating etc Also check for loose hardware and components on the bottom of the breaker compart ment Loose or damaged control wiring and similar problem areas should also be checked b Operation Observe a few close open operations using the operating or maintenance handle If a breaker is seldom operated such that it remiains open or closed for a period of six months or more it isrecommended that it be opened and closed several tim s if succession c Interlocks During the Operational check verify the safety interlocks are properly working d Arc Chutes and Gontacts Inspect the condition of the arc chutes and contacts Look for excessive burning or breakage Gheck the amount of contact depression or wipe when the breaker is closed e Accessories Verify thatthe various accessories are working properly f We performance of the solid state current trip devices checked with a suitable test set Check elec tromechanica
80. de energized This is provided to allow start up on dead systems Figure 34 shows this device The push slide shown is located in the opening in the lower part ofthe escutcheon This breaker door must be opened to gain access to it MAIN SHAFT BREAKER CLOSED EN dT d 2 pis m N 9 UV DEVICE FIG 34 ELECTRIC LOCKOUT BY PASS 26 I 1 5 LOCKOUT FIG 33 ELECTRIC LOCKOUT DEVICE 7 11 BELL ALARM This device is used to give a remote indication of the breaker having tripped open through the action of one of its automatic protective devices It will not be activated by manual tripping the action of the shunt trip A remotely mounted protective relay energizing the shunt trip will there fore not result in the remote alarm action The may be turnedoff by pushing in the manual trip or by energizing the shunt trip In the latter case a normally open contact of the bell alarm switch must be wir diin parallel with the auxiliary switch contact in the shunt trip circuit Closing the breaker will also turn off the alarm Th bell alarm device may be equipped with a lockout link which will lock the breaker open until the bell alarm device is reset The bell alarm is not a standard device and is supplied only when specified on the breaker order 7 11 1 OPERATION
81. 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 ad justments set points are located on the face plate De pending on the application programmer units may be equipped with various combinations of Long Time Short Time Instantaneous and Ground Fault trip elements See Table 7 for available ratings settings and trip characteris tics 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 clear cover to the face plate The SST programmer units can be optionally equipped with trip indicators targets These are pof out me chanically 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 firstis for over load the second for short circuit actuated by the Short time and instantaneous elements and the third forground fault The latter is omitted on units without ground fault SOLID STATE SWITCH FLUX SHIFT TRIP COIL qm PT re J l WHEN l USED I GROUND TARGET GROUND FAULT PICKUP amp DELAY REGULATED 4
82. force is developed be tween the movable and stationary contacts when the breaker is closed This is called the wipe adjustment Wipe is the distance through which the stationary con tacts move when the breaker closes It is measured bet ween the point of contact on a stationary contact when the breaker is open and the position of the same point when the breaker is closed The actual wiping motion is greater because the contacts over travel Wiping imparts a slid ing or scrubbing action to the contacts The wipe adjustment influences proper arc transfer dur ing interruption of fault currents Transfer of the arc is its forced sequential movement from the intermediate con tacts to the arcing contacts to the arc runner and finally to the arc quencher whereitis dissipated and extinguished It is recommended that contact wipe be checked periodically during normal maintenance inspections CAUTION BEFORE DOING ANY OF TH amp F OL LOWING CONTACT ADJUSTMENT AND RE PLACEMENT WORK MECHANICALLY DIS CONNECT THE CLOSING 5 THE MECHANISM CAM SHAFT AS DESCRIBED UN DER SLOW CLOSING THE SECTION 7 4 8 1 ARC CHUTE REMOVAL AND INSPECTION There are two types of arc chute construction used on the 800 thru 2000 ampere breakers They are the ceramic type shown in Fig 5 and the molded type shown in Fig 6 The ceramic type uses a two piece porcelain frame to enclose its internal par
83. fully charged the breaker is ready for closing This may be accomplished electrically by depressing the closing switch on the breaker if so equipped of 5y 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 closingfelay is energized it energizes anti pump relay W 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 The closing springs on electrically operated breakers can be manually charged The breakers can also be man ually closed Refer to Section 5 4 for this procedure LEGEND CC CLOSING SOLENOID F CUTOFF SWITCH CLOSED WHEN CLOSING SPRINGIS FULLY CHARGED G CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGED L AUXILIARY SWITCH M CHARGING MOTOR PB CLOSE PUSHBUTTONON BREAKER ESCUTHEON OPTIONAL TC SHUNT TRIP DEVICE W ANTI PUMP RELAY X CONTROL RELAY FIG 9 ELEMENTARY DIAGRAM FOR ELECTRICALLY OPERATED DRAWOUT BREAKER CONTACT POSITIONS ARE SHOWN WITH BREAKER OPEN AND CLOSING SPRINGS DISCHARGED 11 5 2 1 ALTERNATE CONTROL CIRCUIT Later production breakers use the electrical con
84. installed there are four leads connected to it two flag terminal connections additional winding and two screw terminal connections ampere rating There is no p larity associated with the flag ter minals Fig 94 shows the connections for the additional H option windings Fig 85 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 to a programmer circuit which sums these val ues The total value will remain zero as long as there is no ground current flowing See cable diagram in Fig 91 The neutral sensor is an electrical duplicate of the phase sensor including taps Therefore when taps are charged on the phase sensors those on the neutral sensor must be correspondingly positioned 3 3480338 JAWWWHOONd TWISNI NOLLAWD FIG 82 MICROVERSATRIP RMS 9 AND POWER LEADER MOUNTING BRACKET 60 TABLE 11 TRIP FUNCTIONS AVAILABLE Optional Features BASIC FUNCTIONS ADD TO BASIC FUNCTIONS e AdjLong Time Delay s x e Long Time Timing Light TD or S or H e Adj Long Time Pickup x LONG j i TIME x Remote Long Time Timing Light e Adj Short Time Pickup SHORT e Adj Short Time Delay TI
85. lever surface that contacts the switchette button 6 Mechanism All accessible bearing and sliding sur faces that have been factory lubricated 7 Primary Disconnects Lubricate the finger contact surface just prior to installing in switchgear or lubricate and then cover the disconnect assembly to protect from dust dirt etc Refer to Section 7 5 Before lubricating remove any hardened grease or dirt from the latch and bearing surfaces After lubricating removeall excess lubricant to stop accumulation of dirt or dust The use of cotton waste to wipe bearingysurfaces should be avoided The cotton ravelings may become entangled under the bearing surfaces and destroy the surface of the bearing 7 7 2 MANUAL HANDLE ADJUSTMENT The adjustment linkage connects the handle assembly to the chain drive mechanism which turns the cam shaft The length of this linkage provides the handle adjustment If the link istoo long the handle stroke cannotextend the closing spring enough for itto g over center In this event use the maintenance handle to complete the spring charg ing The breaker can the be closed and opened prepara tory to further shortening of the link If the link is too short charging is not possible The original linkage d sign used a double ended stud the linkage center Alhex section in this stud allowed adjust ing with an open end wrench When looking down on the breaker turning the wren
86. link which connects the Switch crank The switch can be a GE type 58 12 or Electro Switch Type 101 22 ADJUSTABLE LINKAGE FIG 27 AUXILIARY SWITCH LINKAGE 7 6 4 REPLACEMENT Either switch type may be dismounted by removing the two bolt screws Which fasten it to the mechanism frame The GE SB 12 replacement switch should have its crank shaftiset so that the arrow head on the end of the shaft points as shown in Fig 28A when the breaker is open The Electro Switch replacement should have its crank shaftsetso that the horizontal line on the end of the shaft is ds shown in Fig 28B when the breaker is open ARR W HEAD FIG 28A GE SB 12 FIG 28B ELECTRO CRANK SHAFT POSITION SWITCH CRANK SHAFT If a switch is added to a breaker having none the ad justing link will also have to be installed This is connected to the pin on the crank which is attached to the main shaft It is secured by means of a cotter pin 7 6 2 ADJUSTMENT GE SB 12 If a new adjustable link is installed its length should be set beforeinstalling at6 375 inches between pin centers After installing a new switch its operation should be checked Viewing the switch from above the contacts toward the front of the breaker are normally the B con tacts Even if a special switch is used it is always the case that the first two stages nearest the crank have the B contacts to the fro
87. not be reclosed of course until the opened fuse is replaced Type D breakers use the Open Fuse Lockout OFLO shown in Fig 55 Type A and B breakers use the OFLO shown in Fig 56A amp 56B Both OFLO s work on the same design When the fuse opens the resulting open circuit voltage activates the OFLO phase solenoid when the voltagelevelreaches approximately 90 VAC the functional test in the factory is accomplished using 120VAC The Solenoid armature then drives a tripping rod against a trip paddle which is attached to the trip shaft This causes the breaker to open The armature also drives the reset button forward indicating what phase is involved The reset button linkage also holds the tripping rod against the trip paddle The button must be pushed in to release the tripping rod 9 3 1 TYPE A AND B BREAKER OFLO ADJUSTMENT To adjust the Type and B breaker OFLO Refer to Fig 56A a Back off tripping rod so that it will not hit the trip paddle when a solenoid is activated b Using the maintenance handle close the breaker c Manually close the Left pole armature SCrew tripping rod forward until it moves the trip paddle enough to open the breaker Add two full additional turns d Close the breaker e Manually close the Left pole armature again The breaker must open and the resetibutton pop out In this condition close the breaker it should trip free f Reset the OFLO the breaker must now be able to close
88. of the dashpot arm Therefore the linkage setting that gives the shortest time value is the one at which dimension Fig 121 is greatest time adjustment screw 4 may be turned by in serting a Phillips head screwdriver through the hole in the front of the is desired to relate the linkage setting to the index4marKs on the linkage it will be necessary to remove the 5 be done by removing the two mounting screws each side of the case which may be taken off without disturbing the trip unit itself 86 15 1 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 from 80 percent to 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 15 1 3 INSTANTANEOUS HIGH SET TRIPPING The high set instantaneous pick up wale may have one of the following three ranges 4 to 94imes rating 6 to 12 times coil rating or 9 to 15 time coil rating setting may be varied by turning the instantaneousgpick up adjusting screw 12 Three calibration marks 15 will appear on the operating arm 14 and the value of th ese calibration marks will be indicated by stampings on the arm as follows 4X 6 5X 9X or 6X 9X 12X or 9X 12 15X At the factory the pick up poin
89. of the supplied switchgear taking actions asfnecessary to restore it to Serviceable status Industry publications of irecommended maintenance prac tices such as ANSI NFPA 70B Electrical Equipment Maintenance should be carefully studied and applied in each user s formation of planned maintenance Some users may require additional assistance from Gen eral Electric i _ 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 compromised by the modification of supplied parts or their replacement by non identical substitutes All such design changes must be qualified to 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 10A SECTION 4 Drawout Breaker Interchangeability In general drawout breakers of the same type and rating are interchangeable in their equipment compartments drawout breakers of different frame sizes are not inter changeable To prevent inserting the wrong type breaker into a drawout compartment suitable rejection hardware is affixed to each breaker and its compartment Figure 7 shows a typical rejection bracket which
90. of trip settings A 3 phase ammeter and trip indicators are standard as is a clear plastic cover with provisions for sealing to allow tamper resistant installa tion The trip unit digitally measures the current waveform in each phase to determine the true RMS value of the current regardless of the waveshape MicroVersaTrip Plus trip units provide accurate predictable overload and short circuit protection for distribution systems that in cludeacanddc variable speed drives rectifiers induction heating and other loads that cause high harmonic distor tion as well as standard circuit They provide maximum breaker to breaker selectivity and custom load protec tion Short time and ground fault functions include the flexibility of coordination with or without an 124 ramp and are also available with high range instantaneous MicroVersaTrip PM Trip Unit The MicroVersaTrip PM trip unit adds power mentsystem 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 FIG 110 Power Requirements A small amount of power is necessary to energize the liquid crystal display LCD during setup for viewing breaker status andformeteringdisplays MicroVersaTrip PM trip units require external 24 Vdc control power for operation The four sources of such power are the following Flo
91. operational Power the tfip 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 agrees with address at host Read the X value from the rating plug name plate and enter this with the rating plug current set point procedure 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 With the PT connection procedure enter VL N for a wye connected PT primary or VL L fora delta connected PT Indicates that the total power is metered in Clear target as indicated above Symptom 4 83 SECTION 15 Trip Device 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 119 EC 2A TRIP DEVICE The standard EC trip device for breaker frames Upst6
92. programmer unit can cause a false trip signal If nuisance tripping is encountered on any breaker whose SST components have previously demonstrated satisfactory performance via the TAK TS1 Test Set the sensors and their connections should be closely scrutinized After disconnecting the breaker from all power Sources a Check that all phase sensors are the same type am pere range b Ensure that the tap settings on all 3 phase sensors are identical 10 5 SST CABLING DIAGRAMS BREAKER BACK FRAME LEFT POLE CURRENT SENSOR LOAD FLUX SHIFT TRIP DEVICE HARNESS CONNECTOR AMP 201298 1 AMP 201297 1 Verify that the harness connections to the sensors meet the polarity constraints indicated by the e bling dia gram 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 70 In particular4 1 Verify that the neutralfsensor has the same rating and tap setting as the phasessensors 2 Check continuity between the neutral sensor and its equipment mounted secondary disconnect block Also check for continuity from the breaker mounted neutral secondary disconnectblo k through to the female harness connector terminals N 3 If the bfeaker s lower studs connect to the supply source ther the neutral sensor must have its LOAD connectedato the source 4 Ensure that
93. provide a means of indicating the pick up point setting in terms of percentage of coll rating The calibration plate is indexed at percentage settings 80 100 120 140 and 160 As in the case of the EC 1 over current trip the long time de lay tripping feature can be supplied with any one of three time current characteristics which correspond to the NEMA standards maximum intermediate and minimum long4ime delay operating bands These are identified as 1A 4B and 1C Ghar acteristics respectively Approximate tripping forse ch of these in the same order 30 15 and 5 seconds at 600 per cent of the pick up value of current charac teristic curves The tripping time be varied within4he 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 179 2 3 MAX as indicated in Fig 122 When the index mark 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 2 3 mark and the 1C characteristic at the 1 3 mark The standard characteristic curves are plotted at these same settings Time values are inversely proportional to the effective length
94. ratchet assembly attached to the camshaft extension This ratchet is normally driven by the breaker s gear motor A roller on this ratchet engages with a prop when the closing spring is fully charged and driven ov r center see Fig 12 This holds the closing spring charged condition H ARMATURE ASM INTO SOLENOID CORE HE eee eee Rotate the camshaft using the maintenance handle until the ratehet assembly roller engages with the prop Do not drive the roller against the prop with undo force The breaker can now be closed by removing the prop from the roller This is done by manually activating the closing solenoid armature by pushing the solenoid armature into its windings See Fig 13 FIG 13 MANUAL OPERATION OF CLOSING SOLENOID 14 SECT
95. s current carrying capacity to approximately 2596 of the current sensor rating This may result in undesired tripping NOTE Trip units as received may have Settings that are undesirable for the specific application Ensure that settings are appropriately adjusted before energizing 78 FIG 111 FRONT VIEW OF MICROVERSATRIP PM TRIP UNIT CAUTION FIG 112 REAR VIEW OF MICROVERSATRIP PM TRIP UNIT SECTION 14 MicroVersaTrip Plus and MicroVersaTrip Trip Units 14 4 TRIP UNIT REMOVAL AND REPLACEMENT The programmer mounts to the upper left of the breaker as shown in Fig 115 It mounts to the bracket assembly shownin Fig 82 Guide pins on the bracket 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 secures the programmer to the mounting bracket When a trip unit is replaced the locking arm snaps back into place to indi cate proper alignment WARNING Always de energize Type AKR circuit break ers before attempting to remove or replace the trip unit Because of the exposed location of the trip unit failure to observe this warning may result in equipment damage or personal injury including death FIG 113 PROGRAMMER SECONDARY CONNECTOR Socket Class No 5 Zone Zone
96. 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 be changed FIG 118 TYPICAL NEUTRAL SENSOR 14 7 RATING PLUG REMOVAL AND RE PLACEMENT CAUTION Removal of the rating plug while the breaker is carrying current reduces the breaker s current carrying capacity to approximately 25 the current sensor rating Interchangeable rating plugs arer moved with a Rating Plug Extractor Catalog No TRTOOL Suitable equiva lents are commercially avail ble as integrated circuit DIP extractors Graspsthe r amp ting plug tabs with the extractor and pull the4plug Out Be sure to grab the tabs and not the front cover Ofthe rating plug or the plug may be damaged Rejection features provided on all rating plugs to prevent application mismatches Never force a rating plug into place Refer to Table 16 to find the appropriate rating plugs foreach sensor rating and breaker frame If a teplacement rating plug has a different rating than theyplug that was removed follow the appropriate setup procedure GEH 5891A to enter the new rating Do not attempt to use a rating plug from a Spectra RMS breaker or a MicroVersaTrip Plus or MicroVersaTrip PM Trip Unit
97. shown so it will align with the holes in the clip Fig 24 The engagement of the fingers with the re tainer Also the location of the bowtie spacers in the fingers both upper and lower Fig 22 amp 23 The position of the upper and lower retainers and again the bowtie spacers 7 5 2 ADJUSTMENT 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 instal lation of the disconnect assembly this force range is ob tained by tightening the locknuts to set the dimension shown in Fig 26 766 to 797 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 26 PRIMARY FINGER ADJUSTMENT 7 6 AUXILIARY SWITCH All electrically operated breakers manual breakers having shunt trips are supplied with auxiliary switches Depending upon the requirementsof the breaker s applica tion the switch may containfrom two to six stages Usually each stage has one A eontact and one contact contacts are opened or cloS d as the breaker is opened or closed B contacts are the reverse of this The auxiliary switch is mounted on the upper side of the mechanism frame as shown in Fig 27 Acrank on the main shaft operategathe switch through an adjustable
98. stationary mains The following procedure is used to perform the wipe ad justment 1 Open the breaker remove arc quenchers 2 Arrange the breaker for slow closing 3 Selectone pole of the breaker and place a thin sheet or strip of tough insulating material such as mylar over the stationary arcing and intermediate contacts This strip should be about two inches wide and must prevent the arcing and intermediate contacts from making contact when the breaker is closed 4 Using the ratcheting maintenance handle slow close the breaker with the insulation held in place Examine the insulation to make sure it over hangs below the in termediate contacts but not enough to cover the main con tacts ARC RUNNER STATIONARY ARCING CONTACTS STATIONARY INTERMEDIATE CONTACTS STATIONARY MAIN CONTACTS MOVABLE ARCING CONTACT 5 Attach a continuity checker bell set light or ohm meter between the upper and lower stud The checker should indicate continuity exists 6 Facing the breaker turn the wipe adjustment stud shown in Fig 47 clockwise until the ch cker indicates that the main contacts are separated 7 Turn the stud counter clockwise until the main con tacts just touch 8 From this point advance the stud counter clockwise 270 degrees This will be 41 2 flats 9 Once the adjustm nt is complete verify that the torque required to just turn the adjustment nut is greater than 40 in Ibs Iflessto
99. tap to tap resistances should closely agree See Tables 13 and 14 65 SECTION 12 MicroVersaTrip Trip Device Cont 12 5 CABLING DIAGRAMS BREAKER BACK FRAME f LEFT POLE CURRENT SENSOR HARNESS PROGRAMMER CONNECTOR AMP 1 350356 CONNECTOR LOAD FIG 89 CABLING DIAGRAM MICROVERSATRIP WITHOUT GROUND FAULT B PROGRAMMER x FLUX SHIFT UNIT TRIP DEVICE LEFT POLE CURRENT SENSOR CONNECTOR AMP 1 350356 9 PROGRAMMER CONNECTOR FIG 90 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 3 WIRE LOAD c A UR FLUX SHIFT PROGRAMMER TRIP DEVICE rA BREAKER 74M BACK rp LEFT POLE CURRENT SENSOR NEUTRAL SENSOR DISCONNECT oe CONNECTOR PROGRAMMER EQUIPMENT MOUNTED Y Y 1 AMP 1 350356 9 CONNECTOR NEUTRAL SENSOR 4 WIRE LOAD FIG 91 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT 4 WIRE LOAD 4 WIRE LOAD 7 1 FLUX SHIFT PROGRAMMER TRIP DEVICE BREAKER E SN BACK FRAME f I LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT EQUIPMENT MOUNTED NEUTRAL SENSOR N XN HARNESS eB eC CONNECTOR PROGRAMMER AMP 1 350356 CONNECTOR LOAD FIG 92 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD
100. terminal A white wire with a push on terminal will be connected to this common terminal All phase sensors must be corfectly wired for the programmer summing circuitry to functiomproperly 80 TAPPED FIXED COMMON TERMINAL FIG 116 ThE fixed 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 H option is required Fig 117 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 117 H OPTION PHASE SENSOR SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 6 NEUTRAL CURRENT SENSORS CAUTION Neutral current sensors arerequired for three phase four wire systems When the trip unit is connected to a three phase three wire system the neutral sensor terminals are left open Do not short any neural current sensor terminals in a three phase three wire system as this could result in damage to or malfunction of the electrical system Fig 118 shows the neutral sensor The neural 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
101. the flux shifter leads from the AMP connector using the AMP extrac tion tool Cat No 305183 as follows CRANK BREAKER CLOSED POSITION TRIP PADDLE 1 Remove the flux shifter leads from the harness 2 Referring to the cabling diagrams Section 10 5 the flux shifter leads are RED for point Band BLACK for point E 3 Insert the extractor tool over the female pin When the extractor tool bottoms out depress the plunger and force the wire socket assembly out of the connector 4 No tool is required to insert the wire socket assembly into the connector Insert the assembly un til it snaps into place 5 Verify all socket are inserted to the same depth CAUTION INT HE EVENT THAT THE SST TRIP DE VICE MUST RENDERED INOPERATIVE TO ALLOW_THE BREAKER TO CARRY CURRENT WITHQUT BENEFIT OF OVERCURRENT PROTEC THE RECOMMENDED METHOD IS SHORTEN THE TRIP ROD BY TURNING ITS AD JUSTER END FULLY CLOCKWISE THIS PRE VENTS ACTUATION OF THE TRIP SHAFT PADDLE RESET LINKAGE FIG 64 FLUX SHIFT TRIP DEVICE AND OPERATING LINKAGES 49 SECTION 10 SST Overcurrent Trip Device Cont i Bottom view Top view 1 Actuator Trip shaft 4 2 Trip rod adjuster end 9 Actuator arm 3 Trip paddle 6 Reset linkage FIG 65 FLUX SHIFT TRIP DEVICE COMPONENTS TRIP PAODLE IN MECHANISM RESET POSITION TRIP ROD IN RESET POSITION ADJUSTER JAM NUT E
102. the primary disconnect assembly breakdown Refer to these illustrations when replacing the disconnects Note the following details Fig 25 The position of the spacer the breaker stud The hole in the spacer must be positioned as shown so it will align with the holes in the clip Fig 24 The engagement of the fingers with the re tainer Also the location of the bowtie spacers in the fingers both upper and lower Fig 22 amp 23 The position of the upper and lower retainers and again the bowtie spacers 7 5 2 ADJUSTMENT 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 instal lation of the disconnect assembly this force range is ob tained by tightening the locknuts to set the dimension shown in Fig 26 766 to 797 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 26 PRIMARY FINGER ADJUSTMENT 7 6 AUXILIARY SWITCH All electrically operated breakersyand manual breakers having shunt trips are supplied With auxiliary switches Depending upon the requirements of the breaker s applica tion the switch may contain from two to six stages Usually each stage has one A e ntact and one contact contacts are open
103. 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 101 untilit will not trip the breaker even though the ar mature is pushed against the magnet Then holding the arma ture 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 oftan ineh and will make sure that activation of the device will always trip the breaker Adjustment screw 9 Figure 101 can best be manipulated by extended 1 4 inch hex socket wrench SECTION 13 EC Trip Device Cont 13 4 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 reverse current tripping device see Fig 103 consists of a series coll 2 with an jron core mounted between two pole pieces 9 also a potential coll 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 A riy WS normal direction the magnetic flux of the series Coil and the magnetic flux of the potential coil produce a torque which ten
104. the two Allen head screws to separate the stud connector from the contact pivot block Loosen the clamping bolt and remove the stud con nector LiftsOUt thesensor and its tap terminal board The sensor may be prevented from slipping off the sen sor stud byadjacent accessories If this exists the sensor stud must be removed from the breaker base The stud assembly s secured to the base with four bolts which are accessible from the rear of the breaker d When replacing the stud connector tighten the Allen head screw to 250 10 in Ibs Tighten the clamping bolt as follows 120 10 in Ibs 50 50H 470 10 in Ibs AKRT 50 50H 470 10 in Ibs e When replacing the programmer harness to the phase sensors verify that the winding polarity is maintain ed white wire with ring terminal to COMMON terminal right hand terminal see Fig 83 SECTION 12 MicroVersaTrip Trip Device Cont 123 FLUX SHIFTER TRIP DEVICE The only difference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid winding Refer to Section 10 3 for details When replacing MicroVersaTrip flux shifter ex traction tool Cat No 455822 2 is required to remove the socket leads from the AMP connector 124 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 Brea
105. to the programmer frame and secures the pro grammer to the mounting bracket There are two programmer mounting designs in use The difference in the designs is in the operation of the locking lever see Fig 82 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 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 80 To remove the programmer a Disconnect the remote fault Indication harness if equipped b Original designs push in locking lever 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 59 SECTION 12 MicroVersaTrip Trip Device Cont 12 2 CURRENT SENSORS The current sensors supply the power and signal in put necessary to operate the trip system Like the SST system the MicroVersaTrip uses a phase and neutral sensor Fig 83 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 12 5 for cabling diagrams FIG 81
106. unit shown in Fig 72 current sensors and a flux shifter trip device Fig 73 shows a block diagram of the system The ECS trip system essentially duplicates the SST trip system described in Section 10 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 Phase sensors are not tapped As listed in Table 9 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 74 3 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 in cludes circuitry size construction component loca tion programmer unit set points performance characteristics operating range quality reliability and the flux shift trip device Use the same troubleshooting and test procedures for single phase high current low voltage tests or those employing the TAK TS1 or TAK TS2 Test Sets The Ground Fault test procedures of course do not apply ECS phase sensor resistance values are given in Table 10 The time current characteristics for the ECSetrip device are given in curve GES 6032 LONG TIME DELAY SHORT TIME PICKUP INSTANTANEOUS PICKUP CURRENT SENSOR FIG 73 ECS BLOCK DIA
107. with a B auxiliary switch contact on the other breaker for cross interlock purposes On each breaker having an electric lockout an arrange ment is made which will allow breaker closing with the coil de energized This is provided to allow start up on dead systems Figure 34 shows this device The push slid shown is located in the opening in the lower part of the escutcheon This breaker door must be opened access to it MAIN SHAFT BREAKER CLOSED UV DEVICE FIG 34 ELECTRIC LOCKOUT BY PASS 26 PUSH YIN TO DEFEAT S 2 FIG 35 ELECTRIC LOCKOUT DEVICE 7 11 BELL ALARM This device is used to give a remote indication of the breaker having trippedyopen through the action of one of its automatic protective devices It will not be activated by manual tripping or the action of the shunt trip A remotely mounted protective relay energizing the shunt trip will there fore not resultin the remote alarm action The belhalatma circuit may be turned off by pushing the manu btfip Obby energizing the shunt trip In the latter case a normally open contact of the bell alarm switch must be wired in parallel with the A auxiliary switch contact in the shunt trip circuit Closing the breaker will also turn off the alarm The bell alarm device may be equipped with a lockout link which will lock the breaker open until the bell alarm device is reset
108. 00 1600 9 1 E 921 8 10 12 L 0 095 3 Time delay shown at 600 Of long time pickup setting 6L at lower limit of 4 Time delay shown at lower limit of band TABLE 10 SENSOR RESISTANCE VALUES Resistance In Ohms between Terminals 3 0 3 4 44 5 0 4 8 5 6 64 72 6 7 78 6 4 7 6 8 8 10 4 13 5 15 8 19 4 22 8 29 5 34 5 FIG 75 CABLING DIAGRAM FOR ECS TRIP DEVICE 57 SECTION 12 MicroVersaTrip Trip Device The MicroVersaTrip is a solid state direct acting self powered trip device system MicroVersaTrip system consists of the MicroVersaTrip programmer current sensors and a flux shifter trip device Fig 76 shows a block diagram of the system 12 1 PROGRAMMER UNIT Fig 77 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 func tions three mechanical fault indicators local and remote a long time pickup LED indicator local and remote and a zone selective interlocking function All adjustable programmer functions are automatic and self contained requiring no external relaying power supply or accessories See Table 11 for trip functions available and Table 12 for trip func
109. 12 21 Replacement of Current Sensors 63 12 3 Flux Shifter Trip Device 64 12 4 Troubleshooting 64 12 41 Resistance Values 65 12 4 2 False Tripping Breakers Equipped with Ground Fault 65 12 5 MicroVersaTrip Gabling Diagrams 66 SECTION 13 70 13 0 RMS 9 8 EPIC MICROVERSATRIP 70 13 1 9 70 13 1 1 Fault Trip Indicators 70 13 1 2 5 9 amp Epic MicroVersaTrip Installation 71 13 2 OCufrent Sensors 71 13 2 1 Replacement of Current Sensors 74 19 3 Flux Shifter Trip Device 74 19 4 Troubleshooting 74 13 4 1 Resistance Values 74 13 4 2 False Tripping Breakers Equipped With Ground Fault 75 13 Sm Cabling Diagrams 75 Page SECTION 14 77 14 0 MICROVERSATRIP PLUS AND MICROVERSATRIP PM TRIP UNITS 77 14 1 Trip Unit 77 14 2 Testing 78 14 3 Product Structure 78 14 4 Trip Unit Removal and Replacement 79 14 5 Phase Current Sensors 80 14 6 Neutral Current Sensors 81 14 7 X Rating Plug Removal and Replacement 81 14 8 Trip Unit Functions 82 14 9 TroublesShooting Guide 83 SECTION 15 84 15 0 EC TRIP DEVICE 84 15 1 Series Overcurrent Tripping Device EC 2A 86 19 31 31 Long Time Delay and High Set Instantaneous Tripping 86 1521 2 Instantaneous Low Set Tripping 86 15 1 3 Instantaneous High Set Tripping 86 15 2 Series Overcurrent Tripping Device EC 1 87 15 2 1 Short Time Delay Tripping 87 15 2 2 Long Time Delay Tripping 87 15 2 3 Instantaneous Tripping 88 15 2 4 EC 1 Adjustment 88 15 3 Positive
110. 120VAC The solenoid armature then drives a tripping rod against a trip paddle which is attached to the trip shaft This causes the breaker to open The armature also drives the reset button forward indicating what phase is involved The reset button linkage also holds the tripping rod against the trip paddle The button must be pushed in to release the tripping rod 9 3 1 TYPE A AND B BREAKER OFLO ADJUSTMENT To adjust the Type A and B breaker OFLO Refer tQ Fig 56 a Back off tripping rod so that it will not hit4the trip paddle when a solenoid is activated b Using the maintenance handle close the breaker c Manually close the Left pole armature Screwtripping rod forward until it moves the trip paddle eno gh to open the breaker Add two full additional turns d Close the breaker e Manually close the Left 4pole sarmature again breaker must open and the reset button pop out In this condition close the breakef it should trip free f Reset the OFLO the breaker must now be able to close g Repeat for Center and Left poles h Check for a 4295 minimum clearance between trip ping rod and trip paddle with the OFLO reset Check for 032 minimum Overtravel after tripping rod trips breaker i Hold tripping rod in position and tighten its locknut FIG 55 TYPE D BREAKER OFLO DEVICE 9 3 22 TYPE D BREAKER OFLO ADJUSTMENT To adjust the Type D breaker OFLO a With the breaker in t
111. 15 Trip Latch Adjustment SECTION 8 8 0 CONTACT MAINTENANCE 8 1 Arc Chute Removal amp Inspection 8 2 Contact Adjustment AKR 30 30H 30L amp AKRU 30 8 3 Contact Adjustment AKR 50 50H amp AKRU 50 amp AKR 30L 8 4 Contact Adjustment AKRT 50 50H 8 5 Stationary Contact Identification 8 6 Contact Replacement AKR 30 30H amp AKRU 30 8 7 Contact Replacement AKR 50 50H AKRU 50 amp AKRT 50 50H SECTION 9 9 0 FUSED BREAKER 9 1 Fuse Sizes and Mounting 9 2 Special 2500A Fuse For AKRU 50 9 3 Open Fuse Lockout Device 9 3 1 Type A and B Breaker OFLO Adjustment 9 3 2 D Breaker OFLO Adjustment 33 33 34 36 37 38 39 39 41 41 41 41 43 43 43 Page SECTION 10 45 10 0 TYPE SST OVERCURRENT TRIP DEVICE 45 10 1 Programmer Unit 45 10 2 Current Sensors 46 10 21 Replacement of Current Sensors 48 10 3 Flux Shift Trip Device 48 10 4 Troubleshooting 51 10 4 1 SST Test Set 52 10 4 2 Resistance Values 52 10 4 3 False Tripping Breakers Equipped with Ground Fault 53 10 5 SST Cabling Diagrams 53 SECTION 11 56 11 0 TYPE ECS OVERCURRENT TRIP DEVICE 56 11 1 ECS Cabling Diagram 57 SECTION 12 58 12 0 MICROVERSATRIP TRIP DEVICE 58 12 1 Programmer Unit 58 12 1 1 Fault Trip Indicators 58 12 1 2 Remote Fault Indication 58 12 1 3 MicroVersaTrip Installation 59 12 2 Current Sensors 60 12 21 Replacement of Current Sensors 63 12 3 Flux Shifter Trip Device 64 12 4 Troubleshooting 64 12 41 Resistance
112. 2 22 0 26 7 28 5 34 7 Thecoilresistance ofthe SST ECS Flux shifter device is approximately 16 ohms 10 4 3 FALSE TRIPPING BREAKERS EQUIPPED WITH GROUND FAULT When nuisance tripping occurs on breakers equipped withthe Ground Faulttrip element a probable cause is the existence of a false ground signal As indicated by the cabling diagram of Fig 69 each phase sensor is con nected 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 dif ferential 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 breaker whose SST components have previously demonstrated satisfactory performance via the TAK TS1 Test Set the sensors and their connections should be closely scrutinized After disconnecting the breaker from all power Sources a Checkthat all phase sensors are the same type am pere range b Ensure that the tap settings on all 3 phase sensors are identical 10 5 SST CABLING DIAGRAMS c A FLUX SHIFT TRIP DEVICE
113. 2 Guide pins on the bracket 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 secures the programmer to the mounting bracket When a trip unit is replaced the locking arm snaps back into place to indi cate proper alignment WARNING Always de energize Type AKR circuit break ers before attempting to remove or replace the trip unit Because of the exposed location of the trip unit failure to observe this warning may result in equipment damage or personal injury including death FIG 113 PROGRAMMER SEGONDARY CONNECTOR Socket Class No 5 z Zone Zone 6 Inputs Selective LUE Interlock 7 Zone 8 Outputs 11 12 Homnet 9 Spare 10 1 VB 4 VA 2 24 Ret 3 24 VDC NOTE LOCATION OF PIN 1 FIG 114 PROGRAMMER SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND MVT PM 79 SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units FIG 115 14 5 PHASE CURRENT SENSORS The current sensors supply the power and signal input necessary to operate the trip system Fig 116 shows the fixed phase sensors available The sensors have apolar ity associated with their windings The terminal of the sensor is the right hand
114. 23 for the allowable voltage ranges The voltage measurements should be made at the breaker s secondary disconnects and with the undervoltage coil energized The coil should also be close to room temperature approx 20 24 when taking voltage measurements The coil resistance will in crease asits temperature increases and will change the ac tual pick up level If necessary the pick up level is changed by using the adjustment screw shown in Fig 32A Remove the locking wire tum the screw clockwise to raise the pick up level and counterclockwise to lower Once the pick up level is set in Stall the locking wire Allow the coil to cool and then recheck the pick up level with 3 quick measurements OPEN GAP ADJUSTMENT 201 005 DIA F1G 328 OPENGAPCHECK PIN pus x When adjusting the pick up level on instantaneous dc undervoltage devices set the gap between the armature and magnet to 030 inches using the adjustment screw as shown in Fig 32C After setting the pick up level use this same adjustment screw to obtain the drop out setting Cover the adjustment screw locknut with RTV 4 When this device is installed or replaced its positive ability to trip the breaker must be demonstrated ADJUSTMENT FIG 32 CLOSED GAP CHECK Undervoltage devices trip the breaker when the armature opens This causes an extension on the armature to strike the paddle on the trip shaft An extension of the other end of the arm
115. 25 386 76 60 08 250 60 50 07 1 3 17 250V 50 208254 12 3 190 190 50 08 196 1 1 15 250V 25 342 64 54 08 Table 19 Bell Alarm Contact Rating Bell Alarm Contact Control Rating amperes Voltage Contin Inrush uous 125 2 5 2 5 He 250 09 09 120 30 10 G0 HZ 240 15 5 480 7 3 Table 20 Auxiliary Switch 5 Auxiliary Switch Position Main p Contacts Contact Contact Open Tripped Closed Closed Open Table 21 Auxiliary Switch Contact Rating Auxiliary Switch Interrupting Ratings Control Amperes Voltage Inductive Inductive 48 25 Dc 125 11 6 3 250 2 1 8 115 75 50 Ac 240 50 25 480 25 12 Limited to 20A continuous rating of switch on all breakers and to 5A contin uous rating of 16 wire on drawout breakers Table 22 Charging Times Nominal Time Voltage 48VDC 1 5 125VDC 250VDC 1 0 120 1 5 208VAC 0 09 240VAC 1 3 Closing spring charging times typical values The maximum permitted is 5 seconds TABLE 23 SHUNT TRIP AND UNDERVOLTAGE DEVICE OPERATING CURRENTS SHUNT TRIP UNDER VOLTAGE gt
116. 298 1 CONNECTOR AMP 201297 1 FIG 75 CABLING DIAGRAM FOR ECS TRIP DEVICE SECTION 12 MicroVersaTrip 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 76 shows a block diagram of the system 12 1 PROGRAMMER UNIT Fig 77 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 func tions three mechanical fault indicators local and remote a long time pickup LED indicator local and remote and a zone selective interlocking function All adjustable programmer functions are automatic and self contained requiring no external relaying power supply or accessories See Table 11 for trip functions available and Table 12 for trip function characteristics A detailed description of each trip function is given in publication GEA 10265 and GEH 4657 d PROGRAMMER U UNT FLUX SHIFTER SOLID TRIP COIL STATE SWITCH wit LONG TIME PICKUP amp DELAY ice SHORT TIME PICKUP amp DELAY INSTANTANEOUS GROUND FAULT PIGKUP amp DELAY SHORT NEUTRAL
117. 64 370 480V 50 32 580 480V 25 NA N A 100 1600 575V 60 NA NA 100 580 575V 50 NA NA 64 918 575V 25 N A 146 3200 TABLE 25 INSTANTANEOUS UNDERVOLTAGE DEVICE SETTINGS COIL MAXIMUM DROP OUT RATING PICKUP VOLTAGE RANGE 24 VDC 20 7 14 48 VDC 41 14 29 125 VDC 106 38 75 155 VDC 132 47 93 250 VDC 213 75 150 120 VDC 102 36 72 208 VDC 177 62 125 240 VDC 204 72 144 380 VDC 323 114 228 480 VDC 408 144 288 575 VDC 489 173 345 TABLE 26 TIME DELAY UNDERVOLTAGE DEVICE SETTINGS DELAY PICK UP RANGE UVR INSTALLED DRE GUT UNIT UVR ONLY MECHANISM RESET RANGE VOLTAGE VDC UP PICK UP 125 VDC 77 85 50 90 95 250 VDC 298240 VAG 125 140 90 160 165 POSSIBLE 93 These instructio contingency to be 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 bg referred to the GE Company GE Electrical Distribution amp Control General Electric Company 41 Woodford Ave Plainville CT 06062 GEK 64459C 0693 PSA 1993 General Electric Company SECTION 5 Breaker Operation A breaker may be equipped to operate either manually or electrically Both types of operation result in the same fast closing movement as far as the contact action is concerned The var
118. 8 POWER SUPPLY FIG 57 55 BLOCK DIAGRAM 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 lower right of the breaker as shown in Fig 59 The bracket attached to the top of the programmer see Fig 58 engages with a bracket mounted to the underside of the breaker s front frame TABLE 7 SST TRIP CHARACTERISTICS X SST PROGRAMMER ADJUSTMENT RANGE Set Points mperes F Sensor Tap Long Time Short Time GROUND FAULT rame Breaker Size 27 Instantaneous T Type Amperes Sensor Pickup L Time Pickup Time Pickup Pickup Time Ampere Delay Delay Delay Taps Multiple Band Band 4 Multiple Multiple Band 4 of X Seconds of L Seconds of L X Seconds 100 150 225 300 3 4 5 AKR 30 800 or 6 8 10 L 300 400 600 800 Maximum Maximum Maximum 6 7 8 22 0 35 4 5 6 0 30 300 400 600 800 9 1 0 8 10 12 L 25 3 4 50 1600 or amat SoG 600 800 1200 1600 2 25 2 5 2 7 Minimum 3 4 L Minimum Minimum 0 095 0 065 800 1200 2 25 3 AKRT 50 2000 1600 2000 4 5 6 X D Pick
119. 8 N ENS Oo C9 O1 Dy won 5 55 300VDC 300VDC SECTION 3 0 Storage Safety Maintenance It is recommended that the breaker be put into service immediately in its permanent location If this is not possi ble 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 insula tion parts Circuit breakers for outdoor switchgear should be stored in the equipment only when power is available and the compartment heaters arein operation to prevent condensation 2 The breaker shouldbe 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 F 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 1 Safety Each user must maintain a safety program for the protec
120. 8 3 4 34 xo 23 08 480 50 380 508 7 5 7 3 17 06 480 25 380 508 3 5 3 3 E 11 05 575 60 475 625 2 8 2 5 x 8 16 06 575 50 475 625 81 4 7 14 06 gt 575 25 475 625 3 1 3 0 10 o TABLE 24 COIL RESISTANCE DC OHMS 25 Nominal Control Anti Pump Control Voltage Frequency Hz Relay W Relay X i Undervoltage 92 TABLE 25 INSTANTANEOUS UNDERVOLTAGE DEVICE SETTINGS RATING PICKUP VOLTAGE RANGE m m TABLE 26 TIME DELAY UNDERVOLTAGE DEVICE SETTINGS DELAY PICK UP RANGE UVR INSTALLED DROP OUT UNIT UVR ONLY Cau pick uP RESET RANGE VOLTAGE VDC h NO PICKUP PICKUP 125 VDC 77 85 90 95 250 VDC 208 240 VAC MINIMUM 125 140 160 165 POSSIBLE 93 These instructio contingency to ber i be desired or should particular problems arise which are not covered sufficiently for the purchaser s purposes the matter shoulg be referred to the GE Company Lus GE Electrical Distribution amp Control General Electric Company 41 Woodford Ave Plainville CT 06062 GEK 64459D 0596 PSA 1996 General Electric Company GEK 64459C Maintenance Manual Low Voltage Power Circuit Breakers Types AKR 30 50 and AKRT 50 Low Voltage Power Circuit Breakers Table of Contents SECTION 1 1 0 INTRODUCTION 1 1 Inspec
121. 800 Son 9 85 Gurrent 9 8 7 9 10 7 9 10 19 NA 4 45 35 140 1 1 Setting 20 inzi 15 5 6 44 at F 40 200 5 64 Fixed at 2 4 1 5 2 0 2 25 of pick i 800 7 8 1 0 of 4 9 2 5 3 0 12T 1 5 2 3 5 1 5 2 3 9 13 35 up at 21 50 1600 1600 9 95 Current 9 8 4 0 5 0 out 7 9 10 7 9 10 13 4 6 8 1 0 NA 4 45 pulled 135 1 0 1 1 Setting 20 7 0 9 0 10 15 5 6 limit 21 5 6 Fixed at 2 4 35 2 25 band 7 8 1 0 of 4 9 1 5 2 3 5 1 5 2 3 5 3 35 10 21 2004 2000 9 95 Current 9 8 7 9 10 7 9 10 13 4 6 8 1 0 4 45 35 1 0 1 1 Setting 20 15 5 6 Time del y shown Timedelayshownat X Rating plug amps Triple selective trip Time delay shown X Rating plug amps at 600 of c r lower limit of each 5 Sensor amp rating is standard when at lower limit of S Sensor amp rating rents setting at band All pickuptol C Current setting long time short eachband Ground C Current setting lower limit Of band erances 10 time onlyisrequired fault pick up not to H Short time rating exceed 1200 amps 72 N s gt amani i FIG 101 RMS 9 PHASE SENSORS FIG 102 H OPTION PHASE SENSOR FIG 103 TYPICAL NEUTRAL SENSOR Fig 103 shows the neutral sensor The neutral sensor is requiredwwhen integral ground fault protection is used onGi
122. BREAKERS SECTION 7 Breaker Maintenance SAFETY PRECAUTION WARNING BEFORE INSPECTING OR BEGIN NING ANY MAINTENANCE WORK BREAKER T MUST BE DISCONNECTED FROM ALL VOLTAGE SOURCES BOTH POWER AND CONTROL AND THE BREAKER MUST BE IN THE POSITION 71 LUBRICATION In general the circuit breaker requires moderate lubrication The majority of the factory lubricated bear ing points and sliding surfaces are accessible for inspec tion and if necessary cleaning and relubricating The on ly lubricant used on the breaker for both electrical and mechanical areas is General Electric specification D50HD38 D6A15Al Mobilgrease 28 or 32 SECTION 7 Breaker Maintenance Cont The areas requiring lubrication are 1 Contacts Pivots A thin film on the stationary and movable contact assembly pivot surfaces Refer to Section 8 Do not lubricate the contact tips 2 Racking Mechanism The drive threads jamb nut trunnion interface thrust washer collar interface and the shaft support bearings Refer to Section 7 13 3 Manual Operating Handle Lubricate the two pivot areas associated with the adjustment linkage Also the handle mounting shaft support bushing inter face Refer to Section 7 2 4 Flux Shifter Lubricate pivoting and sliding sur faces of the reset linkage Refer to Section 10 3 5 Switchette Lubricate the activator lever surface that contacts the switchette but
123. CURRENT SENSORS ALLOWING DANGER OUS AND DAMAGING VOLTAGES TO DEVELOPS Test scope 1 Verify the time current characteristics a d piekup calibration of the various trip elements 2 Verify operation of the SST target indicators on pro grammer units so equipped B Complete Trip Device System Formthese tests the programmer unit must be mounted on the breaker and connected to its wiring harness Test scope 1 A tests previously described plus provision for optionally switching thef programmer s output to activate the Flux Shift Trip Device a d verify its operation by physi cally tripping the breaker 2 Check phase sensor continuity Inthe eventthat any component of the SST system does not perform within the limits prescribed in test instructions GEK 64454 it should be replaced 52 10 4 2 RESISTANCE VALUES For use in troubleshooting the Common to Tap resist ance for SST current sensors is given in Table 8 These values apply to both phase and neutral sensors TABLE 8 SENSOR RESISTANCE VALUES Ampere TAP 100 150 225 Resistance in Ohms between COMMON and TAP Terminals 6 4 7 6 8 8 10 4 13 5 15 8 19 4 22 8 10 2 12 4 15 8 19 2 22 0 26 7 28 5 34 7 The coil resistance ofthe SST ECS Flux shifter device is approximately 16 ohms 10 4 3 FALSE TRIPPING BREAKERS EQUIPPED WITH GROUND FAULT When nuisance tripping occurs on breakers equipped wi
124. D SO THAT ROTATING THE FUSE DOES NOT ALTER THE POSITION OF THE PRI MARY DISCONNECT SECTION 9 Fused Breakers Cont FRONT OF BREAKER FOR THIS POLE ONLY FUSE TANGS FUSE IS ROTATED 180 BREAKER POSITIONED ON TOP TO POSITION TANG STUD OF BREAKER STUD BENEATH BREAKER STUD Wass I d eSeo RAA 1 Special 2500A Fuse 4 Upper Barrier TANG BOLT 2500A FUSE 2 Disconnect Key 5 Primary Disconnect HOLES 3 Heat USE FIG 53 AKRU 50 WITH SPECIAL 2500 FUSE Op x PRIMARY DISCONNECT ASSEMBLY SEE FIG 53 MOUNTS DIRECTLY ON OUTBOARD FUSE TANG FIG 54 AKRU 50 2500A FUSE TANG POSITIONS TABLE 6 FUSES FOR AKRU BREAKERS Gould Shawmut Cat Nos Type ___ AKRU 30 Ampere Rating 50 Fuse 300 A4J 300 350 A4J 350 400 A4J 400 450 4 450 500 600 Limiter A4J 500 A4J 600 L 800 1000 1200 1600 2000 A4BY 800 A4BY 1000BG A4BY 1200BG A4BY 1600BG A4BY 2000BG A4BX 800 A4BX 1000BG A4BX 1200BG A4BX 1600BG A4BX 200080 Special Mounting adapter required see Fig 52 42 2500 A4BX 2500GE SECTION 9 Fused Breakers Cont 9 33 OPEN FUSE LOCKOUT DEVICE This device automatically trips the fuse breaker if one of the fuses opens When this happens the breaker is locked open until the reset button of the phase involved is pushed The breaker should
125. DER VOLTAGE f TABLE 23 INSTANTANEOUS UNDERVOLTAGE DEVICE SETTINGS PICK UP VOLTAGE RANGE COIL UVR INSTALLED DROP OUT RATING UNR ONLY MECHANISM RESET RANGE zvoc wa 1m 73 voc a 3 4 wr 18 10 et Z 10 19 S ovo 29 21 292 AN wovac 9 9 ww P aOVAG 26 2 29 22 sovac 25 33 20 38 Ww 144 288 173 345 TABLE 24 TIME DELAY UNDERVOKTAGE DEVICE SETTINGS DELAY PICK UP RANGE UVR INSTALLED DROP OUT UNIT UVR ONLY MECHANISM RESET RANGE VOLTAGE NO PICK UP PICK UP 125 VDG 77 85 90 95 250 VDC 208 240 VAC 125 140 160 165 POSSIBLE MINIMUM 79 10 Droede gt pois ve conge y fo De met gt w insteiaton e S write Construction Equipment Export Operation re Fremd Ave Rye NY 10580 4459B PSE 1285 For further information Genera Electnc Call or write your local Distribution Equipment General Electric 41 Woodford Avenue Sales Office or Plainville CT 06062 GENERAL QA ELECTRIC GEK 64459D Maintenance Manual Low Voltage Power Circuit Breakers Types AKR 30 50 and AKRI 50 Low Voltage Power Circuit Breakers Table of Contents SECTION 1 1 0 INTRODUCTION 1 1 Inspection and Maintenance 1 2 Renewal Parts SECTION 2 2 0 GENERAL DESCRIPTION 2 1 Frame Size 2 2 Operation 2 3 Fused Non Fused 2 4 Moun
126. DEVICE 48 So long as the actuator remains in the Reset posi tion 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 tripp ing 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 66 the clearance between the trip rod 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 jam nut rotate the adjuster end until the proper gap is attained then retighten the jamb nut to 35 5 in Ibs The actuator is a sealed factory set device and re quires no maintenance or field adjustment In case of malfunction the complete actuator unit should be replaced When making the electrical connector to the replacement unit it is recommended that the brea ker harness be cut at some convenient point and the new actuator leads solder spliced together The preferred method is to remove
127. EFORE DOING OF LOWING CONTACT ADJUSTMENT AND RE PLACEMENT WORK MECHANICALLY DIS CONNECT THE CLOSING SPRING FROM THE MECHANISM CAM SHAFT AS DESCRIBED UN DER SLOW CLOSING THE BREAKER SECTION 7 4 8 1 ARC CHUTE REMOVAL AND INSPECTION There are two types of arc chute construction used on the 800 thru 2000 ampere breakers They are the ceramic type shown in Fig 5 and the molded type shown in Fig 6 The ceramic type uses a two piece4porcelain frame to enclose its intemal parts The molded type uses a one piece glass filled polyester frame The 800 ampere arc ch te is different from the 1600 and 2000 ampere arc chute Which are identical Therefore the 800 ampere arc chute cannot be interchanged with the 1600 2000 ampere atc chute Also note that a breaker must have either all ceramic all molded type arc chutes install ed do not intermix on tfhe same breaker The arc chutes are held in place by retainers secured by bolts through the mechanism frame The ceramic type uses two retainers and the molded type uses only remove the arc chutes 1 Loosen and back off the retainer bolt locking nut from the mechanism frame They do not have to be removed 2 Loosen the retainer bolts until the retainer s can be removed 3 With the retainer s removed lift the arc chutes off for inspection Inspect each arc chute for excessive burning and erosion of the arc plates and arc runner Also loo
128. ER UNIT FLUX ya TRIP DEVICE BREAKER BACK FRAME LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT HARNESS NEUTRAL SENSOR 4 WIRE LOAD CONNECTOR PROGRAMMER EQUIPMENT MOUNTED Y Y 1 850356 9 CONNECTOR FIG 91 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD 4 WIRE LOAD w 4 1 FLUX SHIFT PROGRAMMER TRIPDEVICE BREAKER BACK FRAME LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT EQUIPMENT MOUNTED 47 NEUTRAL SENSOR p p HARNESS CONNECTOR PROGRAMMER 1 350356 9 CONNECTOR FIG 92 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD BREAKER REVERSE FEED SECTION 12 MicroVersaTrip RMS 9 Epic MicroVersaTrip Device Cont BREAKER HARNESS GROUND FAULT DEFEAT MODULE RO en CONNECTOR CAT NO TVTGD9 r rd lt I o ANY MICROVERSATRIP PROGRAMMER UNIEANITH GROUND FAULT Lol ELEMENT lt D lt lt lt lt lt l L ho _ FIG 93 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 C PROGRAMMER UNIT 1 BREAKER x BACK ie
129. FT POLE PROGRAMMER CONNECTOR 1 350356 CONNECTOR EQUIPMENT MOUNTED NEUTRAL SENSOR 4 WIRE LOAD FIG 107 CABLING DIAGRAM RMS 9 amp EPIC MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD 4 WIRE LOAD FLUX SHIFT TRIP DEVIC BREAKER T T 9 1 PROGRAMMER UNIT BACK FRAME LEFT Ee E NEUTRAL 19 DISCONNECT PROGRAMMER ONNE E AMP 1 350396 9 LOAD FIG 108 CABLING DIAGRAM RMS 9 amp EPIC MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD BREAKER REVERSE FEED 76 Socket PIN No E 5 Zone Zone 6 Inputs Selective Interlock 7 Zone 8 Outputs 11 12 Homnet 9 Spare Epic 10 1 VB 4 VA 2 24 Ret 3 24 VDC NOTE LOCATION OF PIN 1 FIG 109 PROGRAMMER SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND EPIC MVT SECTION 14 MicroVersaTrip Plus MicroVersaTrip 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 110 shows location of features on programmer See user manual GEH 5891A 14 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 readout
130. GEK 644598 Meintenance Low Voltage Types AKRz30 50 and gt 5 GENERAL ELECTRIC Table of Contents SECTION 1 10 INTRODUCTION 1 1 Inspection and Maintenance 1 2 Renewal Parts SECTION 2 20 GENERAL DESCRIPTION 24 Frame Size 2 2 Operation 2 3 Fused Non Fused 2 4 Mounting 2 5 Trip Device 26 Model Number 27 Short Circuit Ratings SECTION 3 3 0 STORAGE SECTION 4 40 DRAWOUT BREAKER INTERCHANGEABILITY SECTION 5 50 BREAKER OPERATION 5 1 Manual Closing 5 22 Electrical Closing 5 2 1 Alt Control Circuit 53 Mechanism Operation 54 Charging Using The Maintenance Handle SECTION 6 60 INTERLOCKS 6 1 Racking Mechanism Interlock 62 Positive Interlock 6 3 Closing Spring Interlock 64 Disconnect Positionulnterlock 6 5 Padlocks 66 Key Interlock Stationary Breaker 6 7 Optional interlocks SECTION 7 70 BREAKER MAINTENANCE 7 1 Lubrication 7 2 Manual Handle Adjustment 7 3 Drawout Mechanism Position 7 4 Slow Closing the Breaker A5 Primary Disconnects 7 5 1 Replacement 7 5 2 Adjustment Page 4 o O O O O O O AAA oo 10 11 11 11 11 12 13 13 15 15 15 16 16 17 17 SECTION 7 7 6 7 7 7 8 7 9 7 9 1 7 10 7 11 7 12 7 13 7 14 7 15 Auxiliary Switch 7 6 1 7 6 2 Adjustment Shunt Trip 7 7 1 Replacement 7 7 2 Adjustment Undervoltage Device 7 8 1 Repl cement 7 8 2 Operatio
131. GRAM 56 FIG 72 ECS PROGRAMMER UNIT FIG 74 ECS CURRENT SENSOR TABLE 9 ECS TRIP CHARACTERISTICS X Trip Rating ECS PROGRAMMER ADJUSTMENT RANGE Set Points in Amperes Frame Size Amperes Breaker Type Sensor Ampere Rating 100 150 225 300 400 600 800 300 400 600 800 1200 1600 AKR 30 800 AKR 50 1600 AKRT 50 2000 800 1200 1600 2000 Pickup tolerance is 9 Pickup tolerance is 10 Sensor Rating Long Time Short Time ae Instantaneous Pickup L Pickup Multiple of X Time Delay Band 4 Seconds Time Pickup Delay Band 3 Multiple Seconds Multiple of L of L 3 4 5 6 8 10 L Maximum 085 Intermed 0 21 Mimmum 0 095 Maximum 22 Intermed 10 Minimum 4 5 6 8 10 12 L Time delay shown at 600 of long time pickup setting 6L at lower limit of band Time delay shown at lower limit of band TABLE 10 SENSOR RESISTANCE VALUES Ampere Resistance in Ohms Rating between Terminals 100 3 0 3 4 150 4 4 5 0 225 4 8 5 6 300 6 4 72 400 6 7 7 8 600 6 4 7 6 800 8 8 10 4 1200 13 5 15 8 1600 19 4 22 8 2000 29 5 34 5 11 1 ECS CABLING DIAGRAM LA BREAKER BACK FRAME LEFT POLE CURRENT SENSOR 48V dc TO SCR ANODE 18555544654 ta HARNE 55 PROGRAMMER CONNECTOR AMP 201
132. ING INTERLOCK The function of the closing spring interlock is to dis charge the closing spring as the breaker is being racked out of its housing This eliminates the hazard of a com pletely charged breaker being discharged after the breaker is removed from its compartm nt The operation ofthe closing spring interlock is shown in the two pictures for Fig 17 The racking mechanism arms and the crank ake connected to acommon shaft As the breaker is pin attached to the crank moves through aeslottinthe mechanism linkage The linkage is connected to a lever which engages with a pin on the closindssolenoid armature linkage When the racking mechanism approaches the DISCONNECT position the EE INTERLOCK p v FIG 16 POSITIVE INTERLOCK crank the end of the slot in the linkage Contintied motion of the racking mechanism causes the linkage to rotate the lever which moves the closing sole noid armatureforward The armature linkage then releases the prop discharging the closing spring Th Closing Spring interlock should be adjusted to cause the closing spring to discharge when the racking mechanism is a minimum of 1 and a maximum of 2 turns short of the fully racked out position In this position the racking handle can no longer be turned If adjustment is required use the linkage adjusting screws shown in Fig 17 Note Undue force on the racking handle at
133. ION 6 Interlocks AKR breakers are equipped with safety interlock devices that are required by Industry Standards and Certifying Au thorities Interlock devices for special applications are also available as options The standard interlock devices de scribed below are used only on drawout breakers Station ary breakers have no required interlocks Caution must be taken to ensure that any interlock lever is not bent and caused to not function All interlocks should be operated to confirm that they function as required 6 1 RACKING MECHANISM INTERLOCK The function of the racking mechanism interlock is to prevent the breaker from moving from the CONNECTED position before the breaker is in the OPEN position The racking mechanism drive shaft is located behind the RACKING SCREW cover shown in Fig 14A This cover must be slid to the right to gain access to the drive E shaft as shown in Fig 14B When the RACKING SCREW FIG 14A RACKING SCREW cover preventing it from being opened This link is driven by the motion of the OPEN CLOSED indicator as shown Fig 15 CAUTION Prior to moving rack screw cover over to attach racking wrench push the manual trip button above the cover This will ensure that the breaker is open Also read breaker position flag to confirm that breaker is open I Dm Compartment door should be closed and latched when racking a breaker from the connect position The TRIP button also eng
134. KEY INTERLOCK STATIONARY BREAKERS SECTION 7 Breaker Maintenance SAFETY PRECAUTION INSPECTING OR BEGIN NING ANY MAINTENANCE WORK ON MUST BE DISCONNECTED FROM ALL VOLTAGE SOURCES BOTH POWER AND CONTROL AND THE BREAKER MUST BE IN THE POSITION 71 LUBRICATION In general the circuit breaker requires moderate lubrication The majority of the factory lubricated bear ing points and sliding surfaces are accessible for inspec tion and if necessary cleaning and relubricating The on ly lubricant used on the breaker for both electrical and mechanical areas is General Electric specification D50HD38 D6A15AI Mobilgrease 28 or 32 SECTION 7 Breaker Maintenance Cont The areas requiring lubrication are 1 Contacts Pivots A thin film on the stationary and movable contact assembly pivot surfaces Refer to Section 8 Do not lubricate the contact tips 2 Racking Mechanism The drive threads jamb nut trunnion interface thrust washer collar interface and the shaft support bearings Refer to Section 7 13 3 Manual Operating Handle Lubricate the two pivot areas associated with the adjustment linkage Also the handle mounting shaft support bushing inter face Refer to Section 7 2 4 Flux Shifter Lubricate pivoting and sliding sur faces of the reset linkage Refer to Section 10 3 5 Switchette Lubricate the activator
135. LUS or AC MVT PM For Power Sensor devices See publications GEK 7309 and GEK 730f fof detailed servicing procedures 26 MODEL NUMBER Type AKR breakers see Table 2 existas either no model number or 1 versions For example AKR 5A 30H or AKR 5A 30H 1 The difference between these models is their arc chute construction The arc chutes in the no model number break ers have a two piece porcelain frame and use 2 arc chute retainers see Fig 5 The 1 breaker arc chutes have a one piece molded polyester glass frame and 1 arc chute re tainer see Fig 6 All AKRT50H breakers use only molded arc chutes FIG 6 MOLDED ARC CHUTES 2 7 SHORT CIRCUIT RATINGS Short circuit ratings vary with the applied system vol tage On 240 VAC systems they are also dependent upon whether the overcurrent trip device contains an instan taneous trip element See Table 4 TABLE 4 BREAKER INTERRUPTION RATINGS 3 INTERRUPTION RATING RATED KA RMS SYMMETRICAL FRAME MAXIMUM WITH WITHOUT SHORT TIME SIZE BREAKER VOLTAGE INSTANTANEOUS INSTANTANEOUS AMPERES TYPE 60 HZ AC TRIP 635 AKR 30 508 pus AKR 30H AKR 30L AKR 50 no AKR 50H AKR 50H 1 AKRT 50 c ARKT 50H _ AKRU 30 30 600 AKRUSQ 600 800DC _ AKR30 2000DC AK amp 50P With 40 800 Amp Trip Coil 2With 200 2000 Amp Ttip Coils 3Consult Factory For Application Data 508 508 2 zn 50
136. M CHARGING MOTOR PB CLOSE PUSHBUTTON ON BREAKER ESCUTCHEON OPTIONAL TC SHUNT TRIP DEVICE K ANTI PUMP RELAY FIG 9A ALTERNATE ELEMENTARY DIAGRAM CONTACT POSITIONS ARE SHOWN BREAKER OPEN AND CLOSING SPRINGS DISCHARGED 12 5 3 5 OPERATION Figure 10 shows the mechanism components in the Closed Tripped and Reset positions The closing spring is shown in the charged position in all of these details Closed Position As shown in Fig 10A the movable contacts are held against the stationary contacts by the toggle linkage The toggle linkage is held in position through the engagement of its cam rollers item no 5 with the prop item no 2 and the secondary latch trip latch item nos 14 amp 11 Tripped Position The mechanism goes from the Closed position to the Tripped position shown in Fig 10B when the trip shaft item no 10 is rotated by either the manual trip button or one of the other trip devices The trip latch no 11 is assembled to the trip shaft When the trip shaft rotates the trip latch disengages from the secondary latch roller The secondary latch pivots resulting in the collapse of the toggle linkage This collapse along with the opening spring item no 15 causes the breaker contacts to open Reset Position The mechanism is shown in Fig 10C The cam item no 3 which is assembled to the cam shaft item no 4 is rotated by the charging motor manual operat
137. ME e Short Time 121 Switch T INSTANTA e Adj Instantaneous Pickup x NEOUS e Adj High Range Instantaneous Adj Ground Fault Pickup GROUND 1PH 2 W 3PH 3 4 W FAULT Ground Return e Adj Ground Fault Delay e Trip Indication Targets Overload amp Short Circuit OTHER local only FUNCTIONS local and remote O L S C and Ground Fault local onlyQ local and remote e Zone Selective interlock Ground Fault 2 Short Time 1 Short Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required TABLE 12 MICROVERSATRIP TRIP CHARACTERISTICS Current Setting X X Multiple Fixed Tapped Maximum Sensors Sensors Sensor Current Rating Amps Ground Fault Adjustable Instantaneous Pickup Pickup Pickup Short time Multiple Multiple Delay Multiple Ft of Sensor Delay of Current Q of Sensor Current Rating Seconds Rating Seconds Rating Seconds C x 100 1 50 100 150 225 300 AKR 30 800 225 300 or 400 600 300 400 800 600 800 300 400 300 400 600 800 50 1600 600 800 1200 1600 600 800 1200 1600 800 1200 800 1200 50 1600 2000 1600 2000 1200 1600 1200 1600 75 2000 3200 2000 3200 1600 2000 1600 2000 100 4000 3000 4000 3000 4000 Time delay shown at 600 of ampere setting at lower limit of each band C current setting 2
138. MP AMP 1 350239 9 1 350246 9 FIG 96 CABLING DIAGRAM ZONE SELECTIVE INTERLOCK 69 SECTION 13 EC Trip Device 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 97 EC 2A TRIP DEVICE The standard EC trip device for breaker frames up 2000 amps is the type 2 see Fig 97 An optional tr device for these frames is the type EC 1 see Fig 98 Trip characteristics are for the EC devices are given in Table 15 The time current characteristics for the EC trip devices are given in the following curves GES 6000 EC 1 GES 6010 EC 2 2A 1A 3 GES 6011 2 2 18 3 GES 6012 2 2 10059 FIG 98 EC 1 DEVICE TABLE 15 EC DEVICE TRIP CHARACTERISTICS 1A MAX ed 15 38 sec o 1B INTER ed 7 5 18 sec o 1C MIN ed 33 8 2 sec 1A MAX 30 sec o 118 INTER 15 sec o 16 MIN 5 sec 188 MAX 4 5 sec o t1 MIN 2 sec 2A MAX 23 sec or 28 INTER 15 sec or 2C MIN 07 sec 2AA MAX 20 sec
139. N AND CLOSING SPRINGS DISCHARGED TYP 183L712 R SERIES 11 5 2 1 ALTERNATE CONTROL CIRCUIT USED A second type of electrical control is shown in Fig 9A for all control voltages except 250 volts D C which uses the circuit shown in Fig 9 This alternate control circuit eliminates the X relay and CC switch shown in Fig 9 The motor is energized through the G cutoff switch and the K relay contact The motor is deenergized when the G cutoff switch changes state which occurs when the closing spring is fully charged With the closing spring propped fully charged the breaker is ready for closing This may be accomplished electrically by closing the PB switch on the breaker if so equipped or by a remote closing switch Operation of the Closing switch energizes the K relay which in turn eners gizes the closing solenoid CC This removes he prop releasing the closing springs to closethe breaker he F cutoff switch is only installed on breakers using D C control voltage The anti pump function is obtained through the nor mally closed K relay contact in the motor circuit If a close signal is maintained aftettheabreaker has tripped open automatically the K relay iS energized preventing the motor from charging the cl Sing Spring The closing signal must be removed for approximately 1 3 to 2 0 seconds to allow the closing spring to charge LEGEND CLOSING SOLENOID F CUTOFF SWITCH CLO
140. ND 0 109 031 Dia rod FIG 66 TRIP ROD ADJUSTMENT 10 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 trip free state due to mechanical interference along its trip shaft c Inadvertent shunt trip activations WARNING DO NOT CHANGE TAPS ON THE CURRENT SENSORS OR ADJUST THE PRO GRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CARRYING CURRENT Once it has been established that the circuit breaker can be operated and closed normally from the test posi tion 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 con nections must be employed for SST breakers equipped with Ground Fault Any single phase in put to the ground differential transformer 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 n b using the Ground Fault Defeat Cable as Shown in Fig 71 This special test cable energizes all the primary windings of the
141. NG By means of the adjustment knob 3 which can be manipu lated by hand the current pick up point can be varied from 80 to 160 percent of the series coil rating The indicator and a cal ibration 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 and 160 As in the case of the EC 1 over current trip the long time de lay tripping feature can be supplied with any one of three time current characteristics which correspond to theQNEMA standards maximum intermediate and minimum long time delay operating bands These are identified as 1A 1B and AC char acteristics respectively Approximate tripping time for each of these in the same order are 30 15 and 5 seconds at 600 per cent of the pick up value of current See time current charac teristic Curves The tripping time may be varied within the limitS shown on the characteristic curves by turning the time adjustment screw 4 Tuming in a clockwise direction increases the tripping time counterclockwise motion decreases it The dashpot arm 8 is indexed at four points 1 3 2 3 as indicated in Fig 100 When the index mark on the connecting link 9 lines up with a mark on the dashpot the approximate tripping time as shown by the characteristic curve is indicated The 1A and 1B charactenstic are sh
142. Non automatc additon non automabc 250VDC breaker types carry the suffix letter D after the frame number e g AKR NB 50D SECTION 2 General Description Type AKR low voltage power circuit breakers are used for controlling 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 circuits when abnormal conditions occur Among these conditions the more common are Short circuits and sustained overloads and under voltages The type 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 subsequently for fast tripping Knowledge of how the breaker is designed and how it operates will enable the owner 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 s contacts It must be able to reverse its com mitment to close the breaker at any point upon the activa tion of an automatic tr
143. O 2000 2009 9 95 Current 9 8 7 9 10 7 9 10 13 4 6 8 1 0 NA 4 45 135 1 0 1 1 Setting 20 15 5 6 9 Time d lay shown at 600 of Cur rents Setting at lowerlimitof band 72 Q Time delay shown at X Rating plug amps lower limit of each S Sensor amp rating band All pick up tol C Current setting erances are 11096 Triple selective trip Time delay shown is standard when long time short time onlyisrequired at lower limit of eachband Ground fault pick up not to exceed 1200 amps X Rating plug amps S Sensor amp rating C Current setting AS H Short time rating FIG 101 RMS 9 PHASE SENSORS FIG 102 H OPTION PHASE SENSOR FIG 103 TYPICAL NEUTRAL SENSOR Fig 108 shows the neutral sensor The neutral sensor is req ired when integral ground fault protection is used on single pbase three wire or three phase four wire sys tems ltisinsertedinto the neutral conductor and therefore i separately mounted in the cable or bus compartment The outputs of the phase sensors and neutral sensor areconnected 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 107 Theneutral sensor is an electrical duplicate of the phase sensor Therefore when phase sensors are charged the neutral sensor must be correspondingly changed 73 SECTION 13
144. OAD PICKUP AMP AMP 1 350239 9 1 350246 9 1 350242 350235 9 FIG 95 CABLING DIAGRAM REMOTE FAULT INDICATION PROGRAMMER MICRO VERSA TRIP PROGRAMMER PROGRAMMER DISCONNECT EQUIPMENT BREAKER CONNECTOR SHORT TIME 7 5 INPUT 3 SHORT TIME f ri OUTPUT GROUND FAULT f INPUT 7 GROUND 4 AMP AMP 1 350239 9 1 350246 9 FIG 96 CABLING DIAGRAM ZONE SELECTIVE INTERLOCK 69 SECTION 13 RMS 9 amp Epic MicroVersaTrip The RMS 9 Epic MicroVersaTrip is a solid state di rect acting self powered trip device system TheRMS 9 system consists of the RMS 9 programmer current sen sors and a flux shifter trip device Fig 97 shows a block diagram of the system 13 1 PROGRAMMER UNIT Fig 98 shows a typical RMS 9 Epic MicroVersaTrip programmer unit Like the MicroVersaTrip the RMS 9 Epic MicroVersaTrip provides the comparison basis for overcurrent detection and delivers the energy necessary to trip the breaker It contains a programmable micro electronic processor which incorporates nine adjustable time current functions three mechanical fault indicators local and remote along time pickup LED indicator local andremote anda zone selective interlocking function All adjustable programmer functions are automatic and self contained requiring no external relaying power supply or accessories See Table 15 for trip functions available and Table 16 for trip
145. OPRENE WASHEHS 7 14 1 BUFFER ADJUSTMENT Referring to Fig 40 with the breaker closed and the WASHERS mechanism not reset a 005 clearance must exist be 3 tweenthe end plate assembly andthe buffer nutas shown c This dimension is factory set It can bereset by tightening the buffer nut Hold the nut with a screwdriver and tighten using a socket on the bolt head opposite the nut When tightening this assembly don t over compress the neo prene washers by overtightening the assembly These washers absorb the breaker opening shock Referring to Fig 41 with the breaker open a 040 maximum clearance can exist between either of the end plate assemblies and the buffer bolt heads as shown If a larger clearance exists close it up by unscrewing the buffer assembly involved Fig 42 shows a buffer assembly prior to being installed in a breaker The dimensions given establish the number of spacers that are used 7 15 TRIP LATCH ADJUSTMENT The reset position of the trip latch is set by the adjust ment screw shown in Fig 43 The adjustment is correct if three and one half turns of the adjustment screw causes a E closed breaker to trip If this check is made the screw must FIG 42 BUFFER ASSEMBLY then be set back or unscrewed three and one half turns FIG 43 TRIP LATCH ADJUSTMENT 32 SECTION 8 Contact Maintenance Breakers subjected to frequent interruption of
146. OTE Pick up settings on the calibration plate of the EC 2A device are calibrated for the specific device When replacing covers replace on associated device FIG 122 TIME ADJUSTMENT INDEXING SECTION 15 Trip Device Cont 15 2 SERIES OVERCURRENT TRIPPING DEVICE EC 1 Each series overcurrent tripping device is enclosed in a molded case and mounted by screws and a bracket to the lower part of the pole unit base Refer to Fig 123 for the discussions below 15 2 1 SHORT TIME DELAY TRIPPING The armature 7 is restrained by calibrating spring 8 After the magnetic force produced by an overcurrent condition over Left Side View Showing Short Time Delay Mechanism comes this restraining force the armature movement is further retarded by an escapement mechanism which produces an in verse time delay characteristic The mechanism is shown on Fig 123 15 2 2 LONG TIME DELAY TRIPPING The armature 10 is restrained by the calibration spring 11 After the magnetic force produ ed_by an overcurrent condition overcomes this restraining force armature movement is fur ther retarded by the flow of Silicone oil in a dashpot which pro duces an inverse time d lay characteristic The mechanism is shown on Fig 123 Right Side View Showing Long Time Delay Mechanism Front View Showing Mounting Bracket 1 S ries Coil 8 S T D Calibration Spring 15 Plunger
147. PM COMPONENTS WITH FIXED SENSORS FIG 88 TEST SET CAT NO TVTS1 12 4 1 RESISTANCE VALUES For use in troubleshooting the MicroVersaTrip current sensors the resistance of the tapped and fixed windings is given in Tables 13 and 14 respectively TABLE 13 TAPPED SENSOR RESISTANCE VALUES Resistance in Ohms Ampere Between Common Tap and Tap Terminals 7 0 8 2 10 12 15 18 20 24 20 24 27 32 42 50 58 68 42 50 53 68 93 109 190 154 74 88 116 136 162 190 210 246 TABLE 14 RESISTANCE VALUES Ampere Resistance in Ohms Rating Between Terminals 100 6 7 7 8 150 10 12 225 15 17 300 20 24 400 27 32 600 42 50 800 58 68 1200 92 108 1600 129 151 2000 207 243 The coil resistance of the MicroVersaTrip flux shifter device is approximately 7 ohms SECTION 12 MicroVersaTrip Trip Device Cont 12 4 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 90 geach phase sensor is connected to summing eircUitry in the programmer Un der no fault conditions 6 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
148. RINGgFROM MECHANISM CAM SHAFT 5 DESCRIBED UN DER SLOW CLOSING SECTION 7 4 8 1 ARC CHUTE REMOVAL AND INSPECTION There are two types of arc chute construction used the 800 thru 2000 ampere breakers They are the ceramic type shown in Fig 5 and the molded type shown in Fig 6 The ceramic type uses a two piece porcelain frame to enclose its internal parts Thesmolded type uses a one piece glass filled polyester frame The 800 ampere arc chute is diff rent from the 1600 and 2000 ampere arc chute which identical Therefore the 800 ampere arc chute cannoty be interchanged with the 1600 2000 ampere arc chute Also note that a breaker must have either all ceramic molded type arc chutes install ed do not intermix on the same breaker The arc chutes are held in place by retainers secured by bolts through the mechanism frame The ceramic type uses two retainers and the molded type uses only one Tosemove the arc chutes 1 Loosen arid back off the retainer bolt locking nut from the mechanism frame They do not have to be removed 2 Loosen the retainer bolts until the retainer s can be removed 3 With the retainer s removed lift the arc chutes off for inspection Inspect each arc chuteforexcessive burning and erosion of the arc plates and arc runner Also look for fractures damage to the liner material used in the molded arc chute and damage to the insulation mater
149. RUCTURE SPRING PIVOT PIN FIG 46 WIPE ADJUSTMENT NUT 800 AMP CONTACT STRUCTURE 34 SECTION 8 Contact Maintenance Cont ARC RUNNER CONTACT SPRING STATIONARY ARCING CONTACT STATIONARY MAIN CONTACT MOVABLE CONTACT ARM FIG 44A AKR30 AKRU30 ARC RUNNER CONTACT SPRING STATIONARY ARCING CONTACT STATIONARY MAIN MOVABEE 4 UT ARM FIG 44B AKR 30 800 AMP CONTACT STRUCTURES 35 SECTION 8 Contact Maintenance Cont 8 3 CONTACT ADJUSTMENT AKR30L AKR50 50H amp AKRU 50 The contact breaker shown in Fig 47 is used by and all AKR50 breaker types This structure uses two movable contact arms Each arm acts against a stationary arcing a stationary intermediate and three stationary mains The following procedure is used to perform the wipe adjustment 1 Open the breaker remove arc quenchers 2 Arrange the breaker for slow closing 3 Select one pole of the breaker and place a thin sheet or strip of tough insulating material such as mylar over the stationary arcing and intermediate contacts This strip should be about two inches wide and must prevent the arcing and intermediate contacts from making contact when the breaker is closed 4 Using the ratcheting maintenance handle slow close the breaker with the insulation held in place Examine the insulation to make sure it over hangs
150. SED WHEN CLOSING SPRING IS FULLY CHARGED D C ONLY G CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGED L AUXILIARY SWITCH M CHARGING MOTOR PB CLOSE PUSHBUTTON ON BREAKER ESCUTCHEON OPTIONAL TC SHUNT TRIP DEVICE K ANTI PUMP RELAY FIG 9A ALTERNATE ELEMENTARY DIAGRAM CONTACT POSITIONS ARE SHOWN BREAKER OPEN AND CLOSING SPRINGS DISCHARGED TYP 183L712 B SERIES 53 MECHANISM OPERATION Figures 10A 10B and 10C show the mechanism com ponents in the Closed Tripped and Reset positions The closing spring is in the charged position for all of these details Closed Position As shown in Fig 10A the movable contacts are pushed against the stationary contacts by the toggle linkage The toggle linkage is held in position through the engagement of its cam rollers item no 5 with the prop item no 2 and the secondary latch roller item 6 and secondary latch 14 and trip latch 11 Tripped Position The mechanism goes from the Closed position to the Tripped position shown in Fig 10B when the trip shaft item no 10 is rotated by either the manual trip button or one of the other trip devices The trip latch item no 11 is assembled to the trip shaft When the trip shaft rotates the trip latch disengages from the secondary latch roller The secondary latch pivots resulting in the collapse of the toggle linkage This collapse along with the opening spring item no 15 shown in Fig 10 C
151. SST AC 6 MicroVersaTrip AC 7 RMS 9 AC 9 MVT PLUS or AC MVT PM For PowemSensor devices See publications GEK 7309 4301 for detailed servicing procedures 26 MODEL NUMBER breakers see Table 2 exista s either no model number or 1 versions For example AKR 5A 30H or AKR 5A 30H 1 The difference between these models is their arc chute construction The arc chutes in the no model number break ers have a two piece porcelain frame and use 2 arc chute retainers see Fig 5 The 1 breaker arc chutes have a one piece molded polyester glass frame and 1 arc chute re tainer see Fig 6 All AKRT50H breakers use only molded arc chutes FIG 6 MOLDED ARC CHUTES 2 7 SHORT CIRCUIT RATINGS Short circuit ratings vary with the applied system vol tage On 240 VAC systems they are also dependent upon whether the overcurrent trip device contains an instan taneous trip element See Table 4 TABLE 4 BREAKER INTERRUPTION RATINGS INTERRUPTION RATING RATED KA RMS SYMMETRICAL FRAME MAXIMUM WITH WITHOUT SIZE BREAKER VOLTAGE INSTANTANEOUS INSTANTANEOUS SHORT AMPERES TYPE 60 HZ AC TRIP TRIP TIME 635 AKR 30 508 30 30 30 800 254 42 AC 635 AKR 30H 508 42 42 42 50 42 42 42 50 50 50 1600 65 AC 50 50 50 50 65 65 AKR 50H
152. STUD 5 _ Ws T Le ee ton FIG 20 MANUAL HANDLE ADJUSTMENT 19 SECTION 7 Breaker Maintenance Cont 7 DRAWOUT MECHANISM POSITION Maintenance or inspection should be conducted with the breaker on a workbench The drawout mechanism must be placed in the position This will deactivate the various interlocks which would otherwise prevent the mechanism or contacts from closing Engage the racking handle with the racking shaft and turn clockwise until it stops Remember before installing the breaker back into its compartment the drawout mechanism must be returned to the DISCONNECT position 7 4 SLOW CLOSING THE BREAKER Closing the breaker slowly while observing the action of the mechanism and contacts is a good way of judging the correctness of mechanical and contact relationships Some of the maintenance procedures described later will involve operating the breaker in this manner The proce dure for slow closing is given below The closing spring must be isolated from the mechanism s camshaft This is done by disconnecting the lower spring assembly from the mating camshaft linkage Remove the hex head bolt as shown in Fig 21 Remove this bolt only with the mechanism in the DISCHARGED position and the spring at its minimum extension Remove the hex head bolt only do not remove or loosen the slotted head screw shown in Fig 21 Removal of the slotted head
153. TING VOLTAGE TERMINALS TERMINALS OHMS 1 amp 2 4 amp 5 9 25 TAKYUVT 3 208 240 VAC 110 125 1600 25 SECTION 7 Breaker Maintenance Cont 3 Check resistance of the disconnected undervoltage device See Table 5 for values See instruction Sheet GEH 4545 for more detailed infor mation including schematic diagrams and circuit descrip tion The undervoltage device must be calibrated through the time delay unit after the device pick up has been adjusted A 008 inch minimum closed gap must exist between the ar mature and magnet as shown in Fig 32C Refer to Section 7 8 3 and Table 24 7 10 ELECTRIC LOCKOUT DEVICE The electric lockout device utilizes undervoltage device to keep the breaker from resetting its mechanism if the breaker is open and the undervoltage device coil is not energized The breaker thus cannot be closed unless voltage is on the Once the breaker is closed loss of voltage will not trip the breaker because in the closed posi tion a mechanical link is used to hold down the armature of the device See Fig 33 This arrangement provides a means of electrically interlocking two breakers so that they cannot be closed at the same time Each undervoltage coil may be wired in series with a B auxiliary switch contact on the other breaker for cross interlock purposes On each breaker having an electric lockout an arrange ment is made which will allow breaker closing with the coil
154. Type B or D breakers the padlock Breaker Being Racked Out shackle goes through the TRIP button hole and out the RACKING SCREW cover hole in the deep escutcheon In Lever Activates Armature Linkage either case the shackle holds the TRIP button in keeping the mechanism trip free FIG 17 CLOSING SPRING INTERLOCK 17 SECTION 6 Interlocks Cont 6 6 KEY INTERLOCK STATIONARY BREAKER The function of the Key Interlock is to prevent an open breaker from being closed when the lock bolt is extended and its key is removed The operation of this interlock is shown in Fig 19 When the breaker is in the OPEN position the end plate assem bly item 2 on the main shaft pivots the lever item 6 counter clockwise This removes the pin item 3 on the lever from blocking the lock bolt Extending the lock bolt rotates the linkage which moves the trip shaft preventing the mechanism from closing the breaker Lock End Plate Pin Lock Bolt Pin Lever D pope s When the breaker is in the CLOSED position the fly wheel assembly item 42 is away from the lever item 6 The lever is spring loaded and rotates clockwise causing its pin to block the lock bolt extension 6 7 OPTIONAL 5 The optional interlocks ar key interlocks and door inter locks On drawout breakers these devices are mounted in the equipment and are partof the breaker enclosure FIG 19 KEY INTERLOCK STATIONARY
155. ULT INDICATOR DISCONNECT 12 1 9 MICROVERSATRIP INSTALLATION The programmer mounts to the upper left of the breaker as shown in Fig 81 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 There are two programmer mounting designs in use The difference in the designs is in the operation of the locking lever see Fig 82 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 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 80 To remove the programmer a Disconnect the remote fault indication harness if equipped b Original designs push in locking lever 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 59 SECTION 12 MicroVersaTrip Trip Device Cont
156. VICE 58 121 Programmer Unit 58 12 1 1 Fault Trip Indicators 58 12 1 2 Remote Fault Indication 58 12 1 3 MicroVersaTrip Installation 59 122 Current Sensors 60 12 2 1 Replacement of Current Sensors 63 123 Flux Shifter Trip Device 64 124 Troubleshooting 64 12 4 1 Resistance Valves 65 12 4 2 False Tripping Breakers Equipped with Ground Fault 65 125 MicroVersaTrip C bling Diagrams 66 SECTION 13 70 13 0 EC TRIP DEVICE 70 131 Series Over urr nt 72 Tripping Device 2 72 13 11 Long Time Delay And High Set Instantaneous Tripping 72 13 1 2 Instantaneous Low Set Tripping 72 13 1 3 Instantaneous High Set Tripping 72 13 2 Series Overcurrent Tripping Device EC 1 73 SECTION 13 13 3 13 4 13 5 13 6 13 2 1 Short Time Delay Tripping 13 2 2 Long Time Delay Tripping 13 2 3 Instantaneous Tripping 13 2 4 EC 1 Adjustments Positive Trip Adjustments Reverse Current Tripping Device 13 4 1 Adjustments 13 42 Replacement Switchette Feature Trip Device Replacement SECTION 14 140 ELECTRICAL CHARACTERISTICS Table 16 Charging and Closing Operating Currents Fuse Selection Table 17 Bell Alarm Contact Rating Table 18 Auxiliary Switch Contact Sequence Table 19 Auxiliary Switch Contact Ratings Table 20 Charging Times Table 21 Shunt Trip Undervoltage Device Table 22 Coil Resistance Table 23 Instantaneous Undervoltage Device Settings Table 24 Time Delay Undervoltage Device Ratin
157. When replacing a MicroVersaTrip flux shifter AMP ex traction tool Cat No 4558222 is required to remove the socket leads from the AMP connector 124 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 b Breaker remaining in a trip free state due to mechanical maintenance along its trip shaft C Inadvertent shunt trip activations WARNING DO NOT CHANGE TAPS ON THE CUR RENT SENSORS OR ADJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CAR RYING CURRENT PROGRAMMER FLUX Y SHFTER PROGRAMMER RES HARNESS FIG 87A MICROVERSATRIP COMPONENT WITH TAPPED SENSORS 64 Once it has been established that the circuitzbreaker 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 test on the breaker using a high current low voltage test set NOTE Forthese single phasetestSyspecial connec tions must be employed for MicroVersaTrip breakers equipped with Ground Fault Ahny single phase input to the programmer circuit will generate an unwanted ground fault output signal which will trip the breaker This can be nullifiedyeither by a Using the Ground Ea
158. Y CONTACT IDENTIFICATION The stationary arcing intermediate and main contacts each have a different function during current conduction and current interruption For this reason these contacts are made using different material compositions Also the different functions require that the contacts be replaced in configurations shown in Figs 44 47 or 48 Fig 49 shows the stationary contacts and how they differ from one another The 800 amp main and arcing contacts are rectangular but the arcing contacts have two of their corners notched The 1600 2000 amp main and intermediate contacts are rectangular but the main contacts have two of their corners notched The inter mediate contacts have all four corners notched 1600 2000 AMP MAIN 1600 2000AMP INTERMEDIATE FIG 49 STATIONARY CONTACT CONFIGURATION 8 6 CONTACT REPLACEMENT AKR 30 30H amp AKRU 30 Refer to Stationary Contact Identification Section 8 5 before replacing any stationary contacts The stationary contacts are held in place by the contact springs which pivot the contacts against the contact stop refer to Fig 45 To replace contacts 1 Remove the arc runner It is secured by two screws into the base and one screw into the contact stop 2 Release each contact spring by holding the contact extending the spring and removing it from the contact The end pieces on each spring have a small hole for inser ting a spring puller A suitable puller ca
159. a tion programmer unit set points performance characteristics operating range quality reliability and the flux shift trip device Use the same troubleshooting and test procedures for single phase high current low voltage tests or those employing the TAK TS1 or TAK TS2 Test Sets The Ground Fault test procedures of course do not apply ECS phase sensor resistance values are given in Table 10 The time current characteristics for the ECS trip device are given in curve GES 6032 DELA SHORT TIME PICKUP DELAY Sarees CKUP REGULATED POWER SUPPLY FIG 73 ECS BLOCK DIAGRAM 56 FIG 72 ECS PROGRAMMER UNIT FIG 74 ECS CURRENT SENSOR TABLE 9 ECS TRIP CHARACTERISTICS X Trip Rating ECS PROGRAMMER ADJUSTMENT RANGE Set Points in Amperes Sensor Rating Long Time Short Time Breaker 7 EE Instantaneous Type Amperes Deor ROM ame Rating ut Band 3 Can Band 4 Mule of X Seconds of L Seconds ofL 100 150 225 3 4 5 AKR 30 800 300 400 6 8 10 L 600 800 Maximum Maximum 22 0 35 300 400 600 6 7 8 Intermed Intermed 45 6 1600 00 1200 1600 9 1 10 021 10 12 1 Minimum Minimum 4 0 095 AKRT 50 2000 800 1200 1600 2000 Pickup tolerance is 9 Time delay shown at 600 of long time pickup setting 6L at Q Pickup tolerance is 10 lowe
160. a 24 Vdc power source and a jack The LCD is energized when the jack is plugged into the rating plug test receptacle 77 SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 2 TESTING Testing of MicroVersaTrip Plus and MicroVersaTrip PM trip units may be performed with the trip unit installed in the circuit breaker the rating plug installed in the 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 Maintenance and Troubleshooting section for additional details 14 3 PRODUCT STRUCTURE MicroVersaTrip Plusand MicroVersaTrip PM trip units are removable Figures 111 and 112 contain front and rear views of a MicroVersaTrip PM trip unit Figure 112 shows the 36 pin plug that connects either trip unit to the circuit breaker and equipment circuity This plug is called the trip unit disconnect CAUTION Removal 8 trip unit from its breaker must be performed with the breaker in the OPEN or TRIPPED position Draw out breakers should be racked out first CAUTION Do notattemptto operate the breaker without its assigned trip unit Installation of an incorrect trip anit may result in unsafe operation of the breaker CAUTION Removal of the rating plug while the breaker is carrying current reduces the breaker
161. a pin which is assembled to the mechanism frame Refer to Fig 360 To replace the holding pawt 1 front escutcheon for accessibility 2 Using the maintenance handle rotate the ratchet enough to disengage the holding 3 Remove the retaining ring and washer from the pivot pin 4 While holding the spring pressure from the holding remove the existing pawl and slip on the new 5 Install the washer and retaining ring 6 Verify that the holding pawl engages a minimum of 4 ratchet laminations 7 Verify that the holding pawl pivot pin is perpendicular to the mechanism frame The hardware which assembles the pivot pin to the frame must be torqued to 250 in Ibs minimum If this hardware must be retightened add LOC TITE 290 to the shaft threads 8 Install the front escutcheon Tighten the escutcheon hardware to 80 10 in Ibs 1 MECHANISM FRAME 2 PIVOT PIN 3 SPRING 4 WASHER 032 FIG 36 HOLDING PAWL ASSEMBLY DETAILS 5 PAWL ASM 6 WASHER 010 7 RETAINING RING 7 12 2 F AND G SWITCH ADJUSTMENT For proper electrical operation the F and G mechani cally operated switches must operate atthe proper point in the closing cycle If these switches are to be replaced measure the distance between the tip of the switch button and the bracket on which they are mounted When the new switch is mounted duplicate the measured dimension then check for proper operatio
162. a safety program for thesprotec tion of personnel as well as other equipment fromthe potential hazards associated with electrical equipment The following requirements are intended to augment the user s safety program but NOT supplant 4he user s responsibility for devising a complete safety program The following basic industry practicedmsafety require ments are applicable to all major electrical equipment such as switchgear or switchboards General Electric neither condones nor assumes any responsibility for prac tices which deviate from the following 1 ALL CONDUCTORS MUSTBEASSUMEDTO BE ENER GIZED UNLESS THEIR POTENTIALHAS BEEN MEASURED AS GROUND AND S ITABEE GROUNDING CONDUC TORS HAVE BEEN APPLIED TO PREVENT ENERGIZING Many accidents have been caused by back feeds from a wide variety of Sources 2 Althoughyinterlocks to reduce some of the risks provided the individual s actions while performing service or maintenancesare essential to prevent accidents Each persons knowledge his mentalawareness and has planned and executed actions often determine if an accident will occur The most important method of avoiding accidents is forall associated personnel to carefully apply a thorough nderstanding ofthe specific equipment fromthe viewpoints Oflit s purpose it s construction it s operation and the situations which could be hazardous All personnel associated with installation operation and maintenance of e
163. ages with the RACKING SCREW cover in both the OPEN an CEOSED positions Therefore the TRIP button must be pushed before the cover can be opened This will open the breaker if it was closed and also depress the OPEN CLOSED linkage discussed above When the RACKING SCREW cover is open it holds the TRIP button in ThiSskeeps 4he breaker trip free so mechanism closing cycle will not cause contact movement especially when the Breaker is being racked in or out CAUTION Use only the proper racking mechanism wrench for racking the breaker in or out otherwise the trip free interlock feature may not function FIG 14B SECTION 6 Interlocks Cont mm FIG 15 RACKING SCREW COVER INTERLOCK CLOSED POSITION 6 2 POSITIVE INTERLOCK The function of the positive interlock is to keep the breaker trip free while it is being racked in or out between the CONNECTED and TEST positions The positive interlock is located onthe breaker leftside as shown in Fig 16 As the breaker moves between the CONNECTED and TEST positions the positive interlock engages with a ramp cam located in the breaker compart ment This cam raises the interlock lever assembly ca s ing the trip shaft to rotate and prevent the trip latch from engaging with the secondary latch assembly teller The breaker is held trip free and cannot be closedgduring this interval 6 3 CLOSING SPR
164. ame 7 SST TRIP CHARACTERISTICS X Rating SST PROGRAMMER ADJUSTMENT RANGE Set Points Amperes Sensor Long Time Short Time GROUND FAULT Breaker ww e Instantaneous Pickup 1 Time Pickup Time Pickup Time Ampere Delay Delay Taps Band Multiple Band 4 of X Seconds of L Seconds Seconds 100 150 225 300 3 4 5 AKR 30 6 8 10 L 300 400 600 800 l Maximum Maximum Maximum 6 8 22 0 35 4 5 6 0 30 300 400 600 800 9 1 Intermed ntermed 8 10 12 L Intermed AKR 50 0 or 10 0 21 0 165 600 800 1200 1600 e Minimum Minimum Minimum 0 095 0 065 800 1200 AKRT 50 1600 2000 D Pickup tolerance is 9 Pickup tolerance is 10 Time delay shown at 600 of long time pickup setting 6L at lower limit of band Time delay shown at lower limit of band 45 SECTION 10 SST Overcurrent Trip Device Cont MOUNTING BRACKET X Y ox Max FIG 58 SST PROGRAMMER 46 eS MES FIG 59 AKR 5B 30 10 2 CURRENT SENSORS 65 system uses two types of current sensors a phase sensor and a neutral sensor Fig 60 shows a phase sensor Fig 61 shows the neutral sensors available The current sensor supplies the po
165. amp AKRU 30 The contact structure of the AKR 30 and the AKRU 30 breakers is slightly different from the AKR 30H Referring to Fig 44 A amp B both structures use one moveable contact arm and two stationary arcing contacts However the AKR AKRU 30 uses three stationary main contacts and the AKR 30H uses four The following wipe adjustment procedure is applicable to all AKR 30 30H amp AKRU 30 1 Open the breaker remove arc quenchers 2 Slow close the breaker The cam roller must be sup ported by the cam and not the prop Refer to section 5 3 3 Select one pole and using a flat or wire feeler gage measure the gap between the top contact and its pivot stud as shown in Fig 45 As necessary adjust the gap to 0 060 x 0 020 inch by turning the wipe adjustment nut shown in Fig 45 amp 46 4 Once the gap dimension is set verify that the torque required to just turn the adjustment nut is greater than 40 in Ibs If less torque is required carefully add LOCTITE 220 or 290 to the adjustment nut threads Wipe off any excess LOCTITE Once the LOCTITE is set recheck the torque value up to 40 in Ibs but do not break loose 5 Repeat above procedure on the other pole units 6 Trip the breaker WIPE ADJUSTMENT NUT RETAINER OUPLINGSPIN CONTACT WIPE ADJUST GAP AT ADJUSTMENT MEASUREMENT POINT TO 060 020 0 250 MEASUREMENT POINT FIG 45 WIPE ADJUSTMENT 800A EXCEPT 30b AMP CONTACT ST
166. at the trip shaft tofque required to trip a closed breaker is no greater than 24 inch ounces Then proceed as follows PICKUP VOLTAGE The pickup level is changed by turning the adjustment screw shown in Fig 32A The Screws secured by either a locking wire or a jam nut nsidethe frame Devices with a jam nut require removal of the device to make this adjustment The picK p voltage at room temperature approx 20 24 should pe 85 or less of coil rating and should be measured at the secondary disconnects with the coil energized Note DC devices set the between the armature and magnet initially to 0 030 inch using the closed gap adjustment screw shown in Fig 320 before making pickup adjustments Be sure to secure the pickup adjustment screw with the jam nut of lockwire 24 DROPOUT VOLTAGE On AC devices the dropout level will fall within the required limits 3096 to 6096 ofthe coil rating if the pickup is set properly On DC devices the dropout level need independent adjustment This is accomplished afterthe pickup level has been established per the above procedure If required use the closed gap adjustment screw shown in Fig 32C to obtain the dropout setting A gap must remain between the armaturesand magnet on DC devices to prevent sealingsin Upon loss of voltage Secure the adjustment screw with thell cknut and apply RTV to the locknut POSITIVE TRIP Check positive trip 8 2 Adjust t
167. ated breakers can be manually charged by using the maintenance handle 568B386G1 as shown in Fig 11 The triangular socket in the maintenance handle mates with the mechanism cam shaft extension on the front right side of the breaker Using the knob on the handle it will be necessary to align this socket to fit on the end of the shaft when the handle is positioned as shown INSTALLED ON CAMSHAFT EXTENSION 13 SECTION 5 Breaker Operation Cont FIG 12 ROLLER ENGAGED WI TH GLOSING PROP There is a ratchet assembly attached to the camshaft extension This ratchet is normally driven by the breaker s gear motor roller on this ratchet engages with a prop when the closing spring is fully charged and driven center see Fig 12 This holds the closing spring imta charged condition Rotate the camshaft using the maintenance handle until the ratchet assembly roller engages with the prop Do not drive the roller against the prop with undo force The breaker can now be closed by removing the prop from the roller This is done by manually activating the closing solenoid armature by pushing the solenoid armature into its windings See Fig 13 SPUSH ARMATURE ASM INTO SOLENOID CORE V FIG 13 MANUAL OPERATION OF CLOSING SOLENOID 14 SECTION 6 Interlocks AKR breakers are equipped with safety interlock devices that are r
168. ation with long time delay 84 SECTION 15 EC Trip Device Cont FIG 121 OVERCURRENT TRIPPING DEVICE EC 2A 85 SECTION 15 EC Trip Device Cont 15 1 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 in stantaneous tripping 2 Low set instantaneous tripping 3 High set instantaneous tripping The dual trip has adjustable long time and instantaneous pick up settings and adjustable time settings Both forms of in stantaneous 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 engage ment See Section 7 15 Refer to Fig 121 for the discussions given below 15 1 1 LONG TIME DELAY AND HIGH SET INSTANTANEOUS TRIPPING By means of the adjustment knob 3 which can be manipu lated by hand the current pick up point can be varied from 80 to 160 percent of the series coil rating The indicator and a cal ibration plate 2 on the front of the case
169. ature When the armature is released this exten sion 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 diarneter wire should be inserted against the stop and the armature released If this trips the breaker the set ting is correct The place to insert the wire is showrrin Fig 32D 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 ass mbly 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 7 9 STATIC TIME DEEAY UNDERVOLTAGE The static time delay und rvoltage system consists of a time delay unit which controls an instantaneous under voltage device time delay unit is separately mounted the switchgear and theaindervoltage device is mounted on the breaker Table 5 lists the catalog numbers available INSERT WIRE GAGE FIG 32D POSITIVE TRIP CHECK If the 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 N
170. awout breakers Station ary breakers have no required interlocks 6 1 RACKING MECHANISM INTERLOCK The function of the racking mechanism interlock is to prevent the breaker from moving from its CONNECTED position before it is in the OPEN position The racking mechanism drive shaft is located behind the RACKING SCREW cover shown in Fig 14 This cover must be slid to the right to gain access to the drive shaft When the breaker is in the CLOSED position a link en gages the RACKING SCREW cover preventing it from being opened This link is driven by the motion of the OPEN CLOSED indicator as shown in Fig 15 The TRIP button also engages with the RACKING SCREW cover in both the OPEN and CLOSED positions Therefore the TRIP button must be pushed in before the cover can be opened This will open the breakef if it was closed and also remove the OPEN CLOSED linkag dis cussed above When the RACKING SCREW cover is open it holds the TRIP button in This keeps the breaker trip free so mechanism closing cycle will not cause contact movement especially wnen the breaker is being racked in or out PEU E SCREW C FIG 14 A RACKING SCREW FIG 14 B 15 SECTION 6 Interlocks Cont DITS I SCREW 15 RACKING SCREW COVER INTERLOCK CLOSED POSITION 6 2 POSITIVE INTERLOCK The function of the positive interlock is to keep the breaker trip free while it is being racked in or out b
171. board The sensor may be prevented from slipping off the sensor stud by adjacent accessories If this exists the sensor stud must be removed from the breaker base The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker Flux shift Trip Device Allen head Screws Stud Connector Current Sensor A 9 d When replacing the stud connector tightengthe Allen head screws to 250 10 in lbs Tighten 4he clamping bolt as follows AKR 30 30H 120 10 in Ibs AKR 50 50H 470 10 in Ibs 50 50H 470 10 in lbs 10 3 FLUX SHIFT TRIP DEVICE The Flux Shift Trip device isa loW energy elec tromagnetic device which pon receipt of a trip signal from the programmer Unit trips the breaker by actuating the trip shaft The mounting arrangement of this component is il lustrated in Figs 64 65 electromagnetic ac tuator located on th 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 Wspring laaded and held in its normal Reset position by a permanent magnet In this state the spring is Compressed Tap Terminal Board Programmer Unit Clamp Bolt Sensor Stud FIG 63 AKR 5A 30 BREAKER WITH SST TRIP
172. by driving out the roll pin which fastens it to the camshaft Before this can be done the charging motor must be removed and the closing spring arranged for slow closing as described earlier Turn the camshaft using the maintenance handle until the roll pin is well situated turnsthe camshaft to gain enough space for the roll pin to clear the breaker frame Before removing the ratchet note thesposition of the ratchet roller or mark the ratchet hub and the camshaft When replacing the ratchetybewsure it is oriented with respect to the camshaftas it was Originally and not displac ed 180 degrees Alignithe mark made on the hub with the mark on the camshaft or Positi n the roller as it was If the ratchet is displaced 180 degrees the holes in the ratchet hub will not completely line up with the holes in the cam shaft The driving pawl is assembled to the charging motor drive as showniin Fig 36B Toreplace the driving pawl 1 Remove the charging motor 2 Remove the retaining ring from the drive pin Slip off the components 3 ANipe off any grease or dirt from the drive pin DO NOT LUBRICATE 4 install the components as shown 28 1 RETAINER RING 2 WASHER 010 lt 3 PAWL ASM FIG 36 DRIVING PAWL ASSEMBLY DETAILS 4 SPRING WASHER 5 WASHER 032 6 MOTOR DRIVE PIN The holding pawlpivots on a pin which is assembled to the mechanism frame Refer to Fig 36C To replace the holding 4pawt 1 Remov
173. ch clockwise lengthens the link The motion shortens it The range of adjustment is 300 degrees In the confined space available each wrenchistroke imparts 15 degrees movement The best Setting isS approximately mid range The present design is shown in Fig 20 This linkage is assembled together on a threaded stud Adjustment is accomplished by removing the upper linkage assembly from the handle assembly and changing the linkage length by turning the upper linkage up or down the threaded stud REMOVE THIS UPPER LINKAGEI ASSEMBLY _ THREADED STUD FIG 20 MANUAL HANDLE ADJUSTMENT 19 SECTION 7 Breaker Maintenance Cont 7 3 DRAWOUT MECHANISM POSITION Maintenance or inspection should be conducted withthe breaker on a workbench The drawout mechanism must be placed in the CONNECT position This will deactivate the various interlocks which would otherwise prevent the mechanism or contacts from closing Engage the racking handle with the racking shaft and turn clockwise until it stops Remember before installing the breaker back into its compartment the drawout mechanism must be returned to the DISCONNECT position 7 4 SLOW CLOSING THE BREAKER Closingthe breaker slowly while observing the action of the mechanism and contacts is a good way of judging the correctness of mechanical and contact relationships Some of the maintenance procedures described later will involve operating th
174. chanism The drive threads jamb nut trunnion interface thrust washer collar interface and the shaft support bearings Refer to Section 7 13 3 Manual Operating Handle Lubricate the two pivot areas associated with the adjustment linkage Also the handle mounting shaft support bushing inter face Refer to Section 7 2 4 Flux Shifter Lubricate pivoting and sliding sur faces of the reset linkage Refer to Section 10 3 5 Switchette Lubricate the activator lever surface that contacts the switchette button 6 Mechanism All accessible bearing and sliding sur faces that have been factory lubricated 7 Primary Disconnects Lubricate the finger contact surface just prior to installing in switchgear or lubricate and then cover the disconnect assembly to protect from dust dirt etc Refer to Section 7 5 Before lubricating remove any hardened grease ordirt from the latch and bearing surfaces After lubficating remove all excess lubricant of dirt or dust The use of cotton waste to wipe bearing surfaces shouldbe avoid ed The cotton ravelings may become entangled under the bearing surfaces and destroy the surfac of the bear ing py 7 2 MANUAL HANDLE ADJUSTMENT On manually operated breakerS sthe closing springs may be charged either by a single 135 degree clockwise handle stroke or up to four multiple strokes of lesser swing The following adjustment procedures should be performed using the sin
175. cked Viewing the switch from above the contacts toward the front of the breaker are normally the B con tacts Even if a special switch is used it is always the case that the first two stages nearest the crank have the B contacts to the front and the A contacts towards the back A contacts are closed when the breaker is closed B contacts are closed when the breaker is open To check the setting arrange the breaker for slow close as described in Section 7 4 Through the use of a continuity tester observe the position of the breaker con tacts when the switch A contactstouch Atthis point the breaker s arcing contacts must be within 250 to 500 of closing Adjustment is made by disconnecting the upper end of the adjustable link and varying its length as required ELECTROSWITCH TYPE 101 Adjustment is the same as the GE SB12 except that when the switch A contacts touch the breaker arcing contacts must be within O to 250 inches of closing 77 SHUNT TRIP The shunt trip device opens the breaker when its coil is energized An A auxiliary switch which is closed only when the breaker is closed is in series with the device coil Connections are made to the external tripping source through secondary disconnects on drawout breakers or to the terminal board on stationary breakers The shunt trip is mounted on the underside of the breaker front frame as shown in Fig 29 A second shunt trip may also be mounted to
176. cts which connect and part automatically Interlocking devices are included Stationary breakers are designed to be mounted on a framework or panel with mechanical fasteners being used to secure the breaker frame and make power connections If control power connections are needed a suitable termi nal board is supplied The mounting type is identified by the second middle digit in the breaker s nameplate designation as follows AKR 5 A 30 Mounting type code letter per Table 2 TABLE 2 MOUNTING TYPE CODES Code Breaker Type Letter Drawout Stationary AKD 5 AKD 6 5 Substructure AKD 8 Substructure 2 5 TRIP DEVICE There are 4 types of solid state direct acting self powered trip device systems associated with AKF break ers These systems are for AC applications only For DC applications an electro mechanical system is available The trip device system is identified by the first middle digit in the breaker s nameplate designation as follows AKR OU 30 Trip device per Table TABLE 3 TRIP DEVICE CODES TRIP DEVICE CODE NUMBER APPLICATION EG Power Sensor ECS SST MicroVersa Trip Power Sensor devices are discontinued See publications GEK 7309 and GEK 7301 for detailed servicing procedures 2 6 MODEL NUMBER Type AKR breakers see Table 2 exist as either no model number of 1 versions For example AKR 5A 30H or AKR 5A 30H 1 The d
177. d by the current sensor ampere rating or top setting of the trip device with which it is equipped 2 2 OPERATION There are Manual and Electrical breaker models The Manual breaker shown in Fig 1 has an operating handle which is used to manually charge the mechanism closing spring The Electric breaker shown in Fig 2 contains an elec tric motor which charges the mechanism closing spring External control power is required to energize this motor and its control circuit A nameplate indicates what voltage s required by the motor circuit 2 3 FUSED NON FUSED Fused breakers are identified as either AKRU 30 800 ampere frame s ze or AKRU 50 1600 ampere frame size A fused breaker s shown in Fig 3 They are not inter changeable with Non Fused breakers since they require deeper compartments for their fuses y FIG 2 Electrically Operated AKR 5B 30 FIG 3 Fused Breaker AKRU 6D 30 SECONDARY DISCONNECTS PEE ses a OF koha NUS 2 VOX PRIMARY DISCONNECTS FIG 4 Drawout Breaker SECTION 2 General Description Cont 24 MOUNTING Type AKR breakers are designed for either drawout or stationary mounting Drawout breakers See Fig 4 are equipped with features which make them easy to install in or withdraw from their associated switchgear equipment These features are a racking mechanism which facilitates inserting and withdrawing the breaker unit and primary and control power disconne
178. daway from their stops This condition can be checked visually by removing the arc quenchers closing the breaker and verifying that all eight stationary main contacts are lifted off their stops Should wipe ad justment appear necessary proceed as follows STATIONARY INTERMEDIATE CONTACTS 1 Open the breaker 2 Arrange the breaker for slow closing 3 Selecting one pole drift out the coupling pin and detach the driving link from the movable contact arms 4 Screw the driving link completely into the insulating link 5 Back out the driving link two one half turns Ex ceed this by whatever amount is necessary to properly position the link within the movable contact arms 6 Install the coupling pin and retainer rings 7 Using the maintenance handle slow close the breaker and observe that all eight stationary main contacts move away trom their stops If this condition is not achieved open the breaker again remove the coupling pin and back outithe driving link an additional half turn 8 Reassemble reclose the breaker and recheck wipe 9 Repeat the above procedure on the other two poles In the existing design the metal driving link uses the same adjustment as the AKR 50 To perform the wipe adjustment on this design follow the procedure forthe AKR 50 Section 8 3 STATIONARY ARCING CONTACTS FIG 48 2000 AMP CONTACT STRUCTURE 37 SECTION 8 Contact Maintenance Cont 8 5 STATIONAR
179. devices for positive trip in accordance with the instructions in their Maintenance Manual GEI 86157 1 2 RENEWAL PARTS The AKR breakers contain a variety of parts and as semblies Many of these are available as replacement parts when the need arises See publication GEF 4527 Renewal Parts for a complete listing of these parts TABLE 1 BREAKER MODELS MOUNTING TYPE DRAWOUT s UB 8 STRUCTURE X X DEEP FUSED TATIONARY ESCUTCHEON BREAKER BREAKER DESIGNATION AKR A 30 30H 800 AKR B 30 AKR D 30 30H FRAME SIZE AMPERES x AKRT A 50 50H AKR A 50 50H x 1600 AKR B 50 50H X X AC AKR D 50 50H X X AKR S 50 50H X j x 2000 50 50H x X AC JAKRT D 50 50H x X x AKRT S 50 50H X AKR 2A 30 x 800 AKR 2B 30 x x DC AKR 2D 30 x x x AKR 2S 30 X AKR 2A 50 x AKR 2B 50 x x AKR 2D 50 x fi x x AKR 2S 50 x AKRU A 30 x X AKRU B 30 X X Xx AKRU D 30 X X X X AKRU A 50 X X AKRU B 50 X X x AKRU D 50 X X This digit identifies the device type as follows 2 EC DC 4 ECS 5 SST 50 60 Hertz Only 6 MicroVersa Tnp N
180. differential transformer in a self cancelling series parallel eonn ction so that its secondary output is always Zero 2 Test the components to the SST system using por table Test Set Type TAK TS1 Fig 67 52 The applicable test pro edures are detailed in in struction Book 64454 are summarized Sec tion 10 4 1 The TAK TS1 and TAK TS2 Test Sets are portable in struments 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 addi tion includes means for continuity checking the phase sensors TAK TS1 Test Set is shown in Fig 67 The time G rrent characteristics for the SST Trip Device are diven in curves GES 6033 GES 6034 GES 6035 FIG 67 SST ECS TEST SET TAK TS1 51 SECTION 10 SST Overcurrent Trip Device Cont 10 4 4 SST TEST SET The TAK TS1 and TAK TS2 Test Sets are portable in struments 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 addi tion includes means for continuity checking the phase sensors A TAK TS1 Test Set is shown in Fig 67 The TAK TS2 functions ident
181. ditional optional functions available only with PM style trip units are as follows PM style trip units require the presence of external control powef e Configurations Communication and metering Communication and protective relaying Communicationgmeteriftg and protective relaying Metering and protective relaying functions Voltage Energy kWh MWh Real power KW MW Erequency Hz lt Protective relays undervoltage overvoltage voltage unbalance current unbalance and power reversal
182. draw from their associated switchgear equipment These features are a racking mechanism which facilitates inserting and withdrawing the breaker unit and primary and control power disconnects which connect and part automatically Interlocking devices are included Stationary breakers are designed to be mounted on a framework or panel with mechanical fasteners being used to secure the breaker frame and make power connections If control power connections are needed a suitable termi nal board is supplied The mounting type is identified by the second middle digit in the breaker s nameplate designation as follows AKR 5 A 30 Mounting type code letter per Table 2 TABLE 2 MOUNTING TYPE CODES Code Breaker Type Letter Drawout Stationary A AKD 5 AKD 6 B Substructure AKD 8 Substructure 2 x FIG 5 CERAMIC ARC CHUTES 2 5 TRIP DEVICE There are several types of solid state direct acting self powered trip device systems associated with breakers These systems are for AC applications only For DC applications an electro mechanical system is available The trip device system is identified by the first middle digit in the breaker nameplate designation as follows AKR B 30 Trip device code number per Table 3 TABLE 3 TRIP DEVICE CODES CODE NUMBER TRIP DEVICE APPLICATION 2 EC DC 3 Power Sensor AC 4 ECS AC 5
183. ds 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 ofthe device if the current through the series coil 2 is reversed the ar mature 10 tends to move in the clockwise direction against the restraint of the calibration spring 6 When the current reversal exceeds the calibration setting thetarmature 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 10 Armature 11 Counter Weight 12 Stop Screw 13 Mounting Screw 14 Screw FIG 103 ED 1 REVERSE CURRENT TRIPPING DEVICE 75 13 41 ADJUSTMENTS The only adjustment to be made on the reverse current de vice is to make sure that the trip rod has a minimum overtravel of 1 32 in beyond the point of tripping the breaker This adjust ment 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 re quired To obtain the proper 1 32 in overtravel close t
184. e 2 Phase sensors are not tapped As listed in Table 9 each sensor has only a single ampere rating A different sensor is available for each of the tabulated ampere ratings which span the same ra ge as SST see Fig 74 3 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 in cludes circuitry size construction component loca tion programmer unit set points performance characteristics operating range quality reliability and the flux shift trip device Use the same troubleshooting and test procedures for single phase high current low voltage tests or those employing the TAK TS1 or TAK TS2 Test Sets The Ground Fault test procedures of course do not apply ECS phase sensor resistance values are given in Table 10 time current characteristics for the ECS trip device are given in curve GES46032 FIG 73 ECS BLOCK DIAGRAM 56 FIG 72 ECS PROGRAMMER UNIT FIG 74 ECS CURRENT SENSOR 2 Pickup tolerance is 9 2 Pickup tolerance is 10 TABLE 9 ECS TRIP CHARACTERISTICS X Trip Rating in Amperes Sensor Rating ECS PROGRAMMER ADJUSTMENT RANGE Set Points Short Time Instantaneous NON i i i Pickup Sensor Anse v 3 Multiple 100 150 225 300 600 800 Maximum 0 35 300 400 600 6 7 Intermed 4 5 6 800 12
185. e chanically 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 istfor Over load the second for short circuit actuated by he short time and instantaneous elements and the thirdfor ground fault The latter is omitted on units without ground fault FIG 57 SST BLOCK DIAGRAM 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 lower right of the breaker as shown in Fig 59 The bracket attached to the top of the programmer see Fig 58 engages with a bracket mounted to the underside of the breaker s front frame TABLE 7 SST TRIP CHARACTERISTICS X Rating in Amperes Pickup L Time SST PROGRAMMER ADJUSTMENT RANGE Set Points GROUND FAULT Instantaneous Pickup Pickup Delay Band 3 Seconds of L Multiple 100 150 225 300 300 400 600 800 400 400 600 800 600 800 1200 1600 Intermed 0 165 Minimum 0 095 Time delay shown at 600 of long time pickup setting 6L at lower limit of band Time delay shown at lower limit of band Pickup tolerance us 9 Pickup tolerance is 10 45
186. e See Table 5 for values See instruction Sheet GEH 4545 for more detailed infor mation including schematic diagrams and circuit descrip tion The undervoltage device must be calibrated through the time delay unit after the device pick up has been adjusted A 008 inch minimum closed gap must exist between the ar mature and magnet as shown in Fig 32C Refer to Section 7 8 3 and Table 24 7 10 ELECTRIC LOCKOUT DEVICE The electric lockout device utilizes undervoltage device to keep the breaker from resetting its mechanism if the breaker is open and the undervoltage device coil is not energized The breaker thus cannot be closed unless voltage is on the coil Once the breaker is closed loss of voltage will not trip the breaker because in the closed posi tion a mechanical link is used to hold down the armature of the device See Fig 33 This arrangement provides a means of electrically interlocking two breakers so that they cannot be closed at the same time Each undervoltage coil may be wired in series with a B auxiliary switch contact on the other breaker for cross interlock purposes On each breaker having an electric lockout an arrange ment is made which will allow breaker closing with the coil de energized This is provided to allow start up on dead Systems Figure 34 shows this device The push slide shown is located in the opening in the lower the escutcheon This breaker door must be opened
187. e 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 124 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 FIG 124 CHECKING TRAVEL DISTANCE OF SERIES OVERCURRENT TRIPPING DEVICE 88 15 3 POSITIVE TRIP ADJUSTMENT Before attempting any checks or adjustments 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 engage ment See Section 7 15 In addition to the pick up settings and time delay adjustments already described overcurrent trip devicesumust be adjusted for positive tripping This adjustment4S made at the factory on new breakers but must be made in the fieldtwhen the breaker mech anism or the overcurrent trip devices Have been replaced Positive tripping is achi ved when adjustment screw 9 Fig ure 124 is in such a position that it will always carry the trip pad dle on the trip shaft beyond the point of tripping the mechanism when the armature closes against the magnet In order to make
188. e working properly f The performance of the solid state current trip devices may be checked with a suitable test set Check elec tromechanical devices for positive trip in accordance with the instructions in their Maintenance Manual GEI 86157 1 2 RENEWAL PARTS The AKR breakers contain a variety of parts and as semblies Many of these are available as replacement parts when the need arises See publication GEF 4527 Renewal Parts for a complete listing of these parts TABLE 1 BREAKER MODELS MOUNTING TYPE DRAWOUT FRAME SIZE BREAKER AMPERES DESIGNATION AKD 8 STRUCTURE STATIONARY ESCUTCHEON BREAKER AKR A 30 30H AKR D 30 30H AKR B 30 30H AKR S 30 30H AKR A 50 50H AKR B 50 50H AKR D 50 50H AKR S 50 50H AKRT A 50 50H AKRT B 50 50H AKRT D 50 50H AKRT S 50 50H AKRU A 30 AKRU B 30 AKRU D 30 A 50 B 50 D 50 anos akos sraucTune X X X X X X X X X X X X X X X X X X X X X X X X X X X This digit identifies the trip device type as follows EC DC only ECS 5 SST 50 60tHertz Only 6 MicroVersa Trip N Non automatic In additiomf ll nontalitomatic 250VDC breaker types carry the suffix letter D after the frame number e g AKR NB 50D 7 RMS 9 9 MVT PLUS SECTION 2 General Description Type AKR
189. e breaker in this manner The proce dure for slow closing is given below The closing spring must be isolated from the mechanism camshaft This is done by disconnecting the lower spring assembly from the mating camshaft linkage Remove the hex head bolt as shown in Fig 21 Remove this bolt only with the mechanism in the DISCHARGED position and the spring at its minimum extension REMOVE THIS BOLT LOOSEN THIS SCREW Remove the hex head bolt only do not remov er loosen the slotted head screw shown in Fig 21 Removal of the slotted head will cause the closing spring to become dis engaged from the camshaft with considerable force Verify that this screw remains tightened during the slow close operation After the bolt is removed use the maintenance handle to rotate the ratchet assemblyarollen onto the closing prop see Charging Using Maintenance Handle sec tion 5 4 At this point the closing prop must be removed by either pushing the CLOSE button on Manual breakers or pushing the closing solenoid armature on electric breakers see Fig 13 ANhen the closing prop is removed continue turning the camshaft When the contacts and mechanism in the fully closed position the cam will support the cam roller refer to Fig 10 amp section 5 3 and the contactSqwill develop maximum depression Push the TRIP button to release the mechanism and open tHe contacts CAUTION The mechanism and contacts will open wi
190. e clearance between the trip rod and the trip shaft paddle is gaged by a 0 109inch diameter rod Adjust gap to 0 109inch x 0 031 inch To adjust open the breaker and restore the breaker mechanism to its Reset position Loosen the jam nut rotate the adjuster end until the proper gap is attained then retighten the jamb nut to 35 5 in Ibs The actuator is a sealed factory set device and re quires no maintenance or field adjustment In case of malfunction the complete actuator unit should be replaced When making the electrical connector to the replacement unit it is recommended that the brea ker harness be cut at some convenient point and the new actuator leads solder spliced together The preferred method is to remove the flux Shifter leads from the AMP connector using the AMP extrac tion tool Cat No 305183 as follows CRANK BREAKER CLOSEO POSITION TRIP PADOLE ACTUATOR 1 Remove the flux shifter leads from the harness 2 Referring to the cabling diagrams i Section 10 5 the flux shifter leads are RED for point Band for point E 3 Insert the extractor tool over the female When the extractor tool bottoms out depress the plunger and force the wire socket assembly out of the connector 4 No tool is required to insert the wire socket assembly into the connectof Insert the assembly un til it snaps into place 5 Verify all socketS are inserted to the same depth CAUTION IN T
191. e function of the closingsspring interlock is to dis charge the closing spring as the breaker is being racked out of its housing This eliminates the hazard of a com pletely charged breaker being discharged after the breaker is removed from its compartment The operation ofthe closing spring interlock is shown in the two pictures for Fig 17 The racking mechanism arms and the crankgare connected to a common shaft As the breaker is racked out a pin attached to the crank moves through a slot tint he mechanism linkage The linkage is connected to a lever which engages with a pin on the closing solenoid armature linkage When the racking mechanism approaches the DISCONNECT position the 16 ma INTERLOCK FlG 46 POSITIVE INTERLOCK crank pin reaches the end of the slot in the linkage Conti ued motion of the racking mechanism causes the linkage to rotate the lever which moves the closing sole noidarmatureforward The armature linkage then releases the prop discharging the closing spring The Closing Spring interlock should be adjusted to ca se the closing spring to discharge when the racking mechanism is a minimum of 1 and a maximum of 21 turns short of the fully racked out position In this position the racking handle can no longer be turned If adjustment is required use the linkage adjusting screws shown in Fig 17 Note Undue force on the racking handle at the fully rac
192. e screws see Fig 50A 2 Remove contact pivot Clean off the exist ing lubrication foumd on the pivot area Replace with D50HD38 268 see Fig 508 3 Remove the insulating spacers contact pin and arc ing contacts see Fig 50C 4 Reassemble the reverse of above Make sure that the insulating spacers and insulating washers are properly in Stall d Torque the arc runner hardware to 45 5 in Ibs The movable contacts are removed in a similar manner as the 800 ampere breaker movable contacts Refer to Section 8 6 When removing the pivot pin from a 2000 ampere AKRT 50 50H contact assembly the pivot pin from the opposite contact assembly must be slightly removed This provides enough clearance to completely remove the pivot pin ha Tw he b INSULATING WASHER INSULATING WASHER ARC RUNNER FIG 50D STATIONARY CONTACT 1600 2000 AMP REPLACEMENT CONTACT STRUCTURE 39 SECTION 8 Contact Maintenance Cont ARCING CONTACT PIVOT INSULATING SPACERS FIG 50B ARC RUNNER REMOVED 40 STATIONARY ARCING 5 CONTACT PIN FIG 50C ARCING CONTACT PIVOT REMOVED SECTION 9 Fused Breakers There are two types of fused breakers AKRU 30 800 ampere frame and AKRU 50 1600 ampere frame Except for the open fuse lockout device and the integrally mounted fuses on the upper studs the AKRU 30 and 50 breakers are identical to the unfused
193. e trip shaft There will now be enough trip shaft movement to slip the bell alarm past 5 Install the replacement bell alarm in reverse order 6 Check the adjustments given in Section 7 11 2 A bell alarm with a lockout assembly or a bell alarm in stalled on a 2000 amp frame AKRT 50 50H breaker may not work with the above procedure If this is the case the breaker front and back frame will have to be seperated 7 12 ELECTRICAL CONTROL COMPONENTS The operation of the electrical control components is described in Section 5 2 The location of these components is shown in Fig 36A ae CHARGING MOTOR G SWITCH Wap F SWITCH 27 SECTION 7 Breaker Maintenance Cont 7121 COMPONENT REPLACEMENT gain access to the electrical control components the breaker s front escutcheon must be removed Type B and D breakers require that both the deep molded escut cheon and the shallow steel escutcheon be removed Before removing the front escutcheon on Type or B breakers a supporting block should be placed under the front frame to keep if from tlipping forward Referring to Fig 36A the X relay or K relay and F and G switches are mounted on the same bracket This mounting bracket is fastened to the right hand mechanism side frame by two hex head 1 4 20 screws Removing these screws allows the bracket to be pulled forward from between the mechanism side plates The W relay must also be un fastened from t
194. e4pushedin before the cover can be opened This will op n the breaker if it was closed and also depress the OPEN CLOSED linkage discussed above When the RACKING SCRREW cover is open it holds the TRIP button in Thisskeeps the breaker trip free so a mechanism closing eycle will 6t cause contact movement especially when the breakers being racked in or out CAUTION Use only 4he proper racking mechanism wrench for racking the breaker in or out otherwise the trip free interlock feature may not function FIG 14B SECTION 6 Interlocks Cont FIG 15 RACKING SCREW COVER INTERLOCK CLOSED POSITION 6 2 POSITIVE INTERLOCK The function of the positive interlock is to keep the breaker trip free while it is being racked in or out between the CONNECTED and TEST positions The positive interlock is located on the breaker left Side as shown in Fig 16 As the breaker moves between the CONNECTED and TEST positions the positive interlock engages with a ramp cam located in the breaker Compart ment This cam raises the interlock lever assembly caus ing the trip shaft to rotate and prevent the trip latch from engaging with the secondary latch assembly roller The breaker is held trip free and cannot be d ring this interval 6 3 CLOSING SPRING INTERLOCK Th
195. ect used with the MicroVersaTrip system 12 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 87 replacement of MicroVersaTrip cur rent sensors is accomplished as follows a Disconnect the programmer harness from the ter minal board removing cable ties as necessary b At the rear ofgthe breaker remove the two Allen head screws to separate the stud connector from the contact pivot block C Loosen the sclamping bolt and remove the stud con nector Lift out the sensor and its tap terminal board The sensor4nay be prevented from slipping off the sen sor stud Dy adjacent accessories If this exists the sensor studamust be removed from the breaker base The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker d When replacing the stud connector tighten the Allen head screw to 250 gt 10 in Ibs Tighten the Clamping bolt as follows AKR 30 30H 120 10 in Ibs 50 50H 470 10 in Ibs AKRT 50 50H 470 10 in Ibs 30L 470 10 in Ibs e When replacing the programmer harness to the phase sensors verify that the winding polarity is maintained white wire with ring terminal to COMMON terminal right hand terminal see Fig 83 63 SECTION 12 MicroVersaTrip Trip Device Cont 123 FLUX SHIFTER TRIP DEVICE The only difference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid winding Refer to Section 10 3 for details
196. ed between the switch body and the bracket to which it is fastened The adjust ment screw is positioned so that when the locklever is in its activated position it holds the breaker mechanism latch in the tripped position Check that TRIP button shaft and shunt trip operations besides tripping the breaker displace the side latch and prevent the bell alarm switch from operating The other trip devices and interlocks must activate the bell alarm when they open the breaker The bracket assembled to the TRIP button shaft must be adjusted so that it will displace the side latcn when or before the shaft opens the breaker Maintain a 030 inch minimum gap between the bracket and the side when the breaker is closed A 187 inch depression ofthe TRIP button must not trip the breaker but a 375 inich depres sion must trip the breaker and displace the side latch W RELAY X RELAY 7 11 3 REPLACEMENT The bell alarm is mounted on the righthand Side of the breaker at the rear of front frame It is located under the mechanism main shaft The bell alarm is removed by passing it through a cutout in the rear bend of the front frame slipping it between the front frame and trip shaft and out through the bottom of the breaker as follows 1 Remove the 4 bell alarm mounting screws from the bottom of the front frame 2 If the crank which is part of the main shaft has a bell alarm activating pin assembled to both sides remove these pi
197. ed or closed 85 the breaker is opened or closed contacts are the reverse of this The auxiliary switch isemounted on the upper side of the mechanism frame as shown in Fig 27 A crank the main shaft operates the switch through an adjustable link which connects it to the Switch crank The switch can be a GE type 5 42 Electro Switch 101 22 ADUUST BLE LINKAGE FIG 27 AUXILIARY SWITCH LINKAGE 7 6 4 REPLACEMENT Either switch typemay be dismounted by removing the two bolt screws which fasten it to the mechanism frame The GEsSB 12 replacement switch should have its crank shaftset so that the arrow head on the end of the shaft points as shown in Fig 28A when the breaker is open The Electro Switch replacement should have its crank shaftsetso that the horizontal line on the end of the shaft is as shown in Fig 28B when the breaker is open ARROW HEAD nh gt FIG 28 GE 5 12 FIG 288 ELECTRO CRANK SHAFT POSITION SWITCH CRANK SHAFT If a switch is added to a breaker having none the ad justing link will also have to be installed This is connected to the pin on the crank which is attached to the main shaft It is secured by means of a cotter pin 7 6 2 ADJUSTMENT GE SB 12 If a new adjustable link is installed its length should be set before installing at 6 375 inches between pin centers After installing a new switch its operation should be che
198. ed with four screws When removing the lower screws use care not to damage or misplace the insulating washer found under each of these screws see Fig 50A 2 arcing contact pivot Clean off the ex isting lubrication found on the Pivot area Replace with D38 MOBIL 28 see Fig 50B 3 Remove the Insulating spacers contact and arc ingContacts See Fig 50C 4 Reassemble the reverse of above Make sure that the insulating spacers and insulating washers are properly in stalled Torque the arc runner hardware to 45 5 in Ibs The movable contacts are removed in a similar manner as the 800 ampere breaker movable contacts Refer to Section 8 6 When removing the pivot pin from a 2000 ampere AKRT 50 50H contact assembly the pivot pin from the opposite contact assembly must be slightly removed This provides enough clearance to completely remove the pivot pin 5 Install the new arm insert the Divot pin and replace x the Spring ane ano Tighten the pivot pin hard FIG 50 ARC RUNNER STATIONARY CONTACT 1600 200 REPLACEMENT CONTACT STRUCTURE 39 SECTION 8 Contact Maintenance Cont ARCING NTACT PIVOT INSULATING 4 f SPACERS FIG 50 RUNNER REMOVED FIG 506 ARCING CONTACT PIVOT REMOVED 40 SECTION 9 Fused Breakers There are two types of fused breakers AKRU 30 800 ampere frame and AKRU 50 1600 ampere frame
199. ee Partial LEFT POLE CURR NT SENSOR YELLOW YELLOW YELLOW YELLOW ae YELLOW d YELLOW HARNESS PROGRAMMER CONNECTOR CONNECTOR LOAD FIG 94 PARTIAL CABLING DIAGRAM H OPTION WINDING CONNECTIONS 68 PROGRAMMER REMOTE FAULT MICRO VERSA SECONDARY INDICATION PROGRAMMER DISCONNECT CONNECTOR EQUIPMENT BREAKER YELLOW OVERLOAD YELLOW SHORT CIRCUIT GROUND FAULT l OVERLOAD i PICKUP SET AMP AMP AMP AMP 1 350239 9 1 350246 9 1 350242 9 1 350235 9 FIG 95 CABLING DIAGRAM REMOTE FAULT INDICATION PROGRAMMEN MICRO VERSA TRIP PROGRAMMER PROGRAMMER DISCONNECT HARNESS 71 EQUIPMENT BREAKER CONNECTOR SHORT OUTPUT GROUND GROUND FAULT OUTPUT ic SHORT TIME Uu gt ud AMP AMP 1 350239 9 1 350246 9 FIG 96 CABLING DIAGRAM ZONE SELECTIVE INTERLOCK 69 SECTION 13 RMS 9 Epic MicroVersaTrip The RMS 9 Epic MicroVersaTrip is a solid state di rect acting self poweredtrip device system The RMS 9 system consists of the RMS 9 programmer current sen sors and a flux shifter trip device Fig 97 shows a block diagram of the system 13 1 PROGRAMMER UNIT Fig 98 shows a typical RMS 9 Epic MicroVersaTrip programmer unit Like the MicroVersaTrip the RMS 9 Epic MicroVersaTrip provides the comparison basis for overcurrent detection and delivers the energy nece
200. ent the discharge of the fully charged closing spring With the closing spring propped fully charged the breaker is ready for Closing This may be accomplished electrically by deptessing the closing switch PB on the breaker if so equipped or by a remote closing switch Operation closing switch energizes the X relay which in turn energizes the closing solenoid CC This removes the prop releasing the closing springs to close the breaker As the closing solenoid 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 it is tripped open automatically The closing im pulse must be released and reapplied before a second closing operation can occur The closing springs on electrically operated breakers can be manually charged The breakers can also be man ually closed Refer to Section 5 4 for this procedure 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 PUSHBUTTON ON BREAKER ESCUTHEON OPTIONAL TC SHUNT TRIP DEVICE W ANTI PUMP RELAY X CONTROL RELAY FIG 9 ELEMENTARY DIAGRAM FOR ELECTRICALLY OPERATED DRAWOUT BREAKER CONTACT POSITIONS ARE SHOWN WITH BREAKER OPE
201. equired by Industry Standards and Certifying Au thorities Interlock devices for special applications are also available as options The standard interlock devices de scribed below are used only on drawout breakers Station ary breakers have no required interlocks Caution must be taken to ensure that any interlock lever is not bent and caused to not function All interlocks should be operated to confirm that they function as required 6 1 RACKING MECHANISM INTERLOCK The function of the racking mechanism interlock is to prevent the breaker from moving from the CONNECTED position before the breaker is in the OPEN position The racking mechanism drive shaft is located behind the RACKING SCREW cover shown in Fig 14A This cover must be slid to the right to gain access to the drive shaft as shown in Fig 14B When the RACKING SCREW FIG 14A RACKING SCREW cover preventing it from being opened This link is driven by the motion of the OPEN CLOSED indicator asshownin Fig 15 CAUTION Prior to moving rack screw cover attach racking wrench push the manual trip button above the cov r This will ensure that the breaker is open Also read breaker position flag to confirm that breaker is open Compartment door should be closed and latchedywhen racking a breaker from the connect position The TRIP button also engages with the RACKING SCREW cover in both the OPEN and CEOSEP positions Therefore the TRIP button must b
202. erminal as shown in Fig 83 A white wire witb a ring terminal will be connected to this COMMON terminal All phase sensors must be correctly wired for the program mer summing circuit to function properly The tapped or fixed phase sensors are available with an additional winding This winding is brought out to separate flag terminals rather than the scfew terminals These phase sensors are used when the hi level instan taneous MicroVersaTrip option H option is required Fig 84 shows an H option phase sensor When the H option phase sensor is installed there are four leads connected to it two flag terminal connections additional winding and two screw terminal connections ampere rating There is no p larity associated with the flag ter minals Fig 94 showS the connections for the additional H option windings Fig 85 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 val ues The total value will remain zero as long as there is no ground Current flowing See cable diagram in Fig 91 The neutral sensor is an electrical duplicate of the phase Sensor including taps Therefore when taps are cha
203. es neglected involves the calibration of various control devices These monitor conditions in the primary and secondary circuits sometimesinitiating emergency correctiveaction such as opening or closing circuit breakers In view ofthevitalrole of these devices it is important that a periodic test program be followed As was outlined above itis recog nized 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 recommenda tionthat untiltheuserhas accumulated enoughexperience 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 b tested with primary current injection Others be adequately tested using test sets Specific calibration instructions on particular devices typically ar provided by supplied instruction books Instruction books supplied by manufact rers address components that would normally require Service or main tenance 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 deterioration of any part of the supplied switchgear taking actions 5
204. esthe front escutcheon for accessibility 2 Using the maintenance handle rotate the ratchet enough to disengage the holding pawl 3 Remove the retaining ring and washer from the pivot pin 4 While holding the spring pressure from the holding pawl remove the existing pawl and slip on the new pawl 5 Install the washer and retaining ring 6 Verify that the holding pawl engages a minimum of 4 ratchet laminations 7 Verify that the holding pawl pivot pin is perpendicular to the mechanism frame The hardware which assembles the pivot pin to the frame must be torqued to 250 in Ibs minimum If this hardware must be retightened add LOC TITE 290 to the shaft threads 8 Install the front escutcheon Tighten the escutcheon hardware to 80 10 in Ibs 1 MECHANISM FRAME 2 PIVOT PIN 3 SPRING 4 WASHER 032 FIG 36 HOLDING PAWL ASSEMBLY DETAILS 5 PAWL ASM 6 WASHER 010 7 RETAINING RING 7 12 2 F AND G SWITCH ADJUSTMENT For proper electrical operation the F and G mechani cally operated switches must operate atthe proper point in the closing cycle If these switches are to be replaced measure the distance between the tip of the switch button and the bracket on which they are mounted When the new switch is mounted duplicate the measured dimension then check for proper operation When a normal closing operation occurs the ratchet usually comes to a stop with an arbitrarily designated ratchet tooth No 1
205. etween the CONNECTED and TEST positions The positive interlock islocated on the breaker s left side as shown in Fig 16 As the breaker moves between the CONNECTED and TEST positions the positive 4nterlock engages with a ramp cam located in the breaker compart ment This camraises the interlock s lever assembly caus ing the trip shaft to move and preventing the triplatch from engaging with the secondary latch assembly roller The breaker is held trip free and cannot be closed during this interval 6 3 CLOSING SPRING INTERLOCK The function of the closing spring interlock is to dis charge the closing spring asthe breaker is being racked out of its housing This eliminates the hazard of a com pletely charged breaker being discharged after the breaker is removed from its Compartment The op ration of the closing spring interlock is Shown in Fig 17 racking mechanism arms and the crank are connected toa common shaft As the breaker ts racked out a pin attached to the crank moves through the slot in the linkage T e inkage is connected to a lever which engages With a pin the closing solenoid armature linkage When the racking mechamsm approaches the DISCONNECT 16 FIG 16 POSITIVE INTERLOCK position the crank s pin reaches the end ofthe slot in the lidKage Continued motion of the racking mechanism causes the linkage to rotate the lever which moves the closing solenoid armature forward The armature linkage then
206. evices long time setting at 80 76 13 6 TRIP DEVICE REPLACEMENT Overcurrent devices AKR30 amp 50 breakers may be dismounted by removing the fastening hardware at the rear the breaker and withdrawing the device EC devices after bei unfastened as shown in Figures 104 and 105 and having the clamps on the case in the front removed may be lowered clear of the breaker You do not have to separate frames on these breakers FIG 105 DISCONNECTING EC FRAME SECTION 14 Electrical Characteristics TABLE 16 CHARGING AND CLOSING OPERATING CURRENTS MOTOR ANTI PUMP CONTROL CLOSING Current Amps RELAY X SOLENOID Rated Amps Inrush Sealed Open Closed Nominal Control Voltage SELECTION FUSE 104 127 22 29 ECENUM 180 220 12 36 25 13 17 50 208 254 25 035 023 342 64 54 08 TABLE 17 TABLE 19 BELL ALARM CONTACT AUXILIARY SWITCH RATING CONTACT RATINGS Bell Alarm Contact Auxiliary Switch Rating amperes Interrupting Ratings Voltage Control Amperes o Voltage 120 30 240 15 480 7 Inductive Limited to 20A continuous rating of switch on all breakers and to SA contin ava gt 8 uous rating of 16 wire on drawout CONTACT SEQUENCE TABLE 20 Auxiliary Switch Position CHARGING TIMES 120VDC 250VDC 120VAC 208VAC 240VAC TABLE 21 SHUNT TRIP AND UNDERVOLTAGE DEVICE OPERATING CURRENTS SHUNT TRIP UN
207. exibility of coordination with or without an 21 ramp and are also available with high range instantaneous MicroVersaTrip PM Trip Unit The MicroVersaTrip PM trip unit adds power manage ment system 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 FIG 110 Power Requirements A small amount of power is necessary to energize the liquid crystal display LCD during setup for viewing breaker status and formetering displays MicroVersaTrip PM trip units require external 24 Vdc control power for operation The four sources of such power are the following Flow of current Breaker current sensors provide sufficient power to energize the LCD when at least 2096 of the sensor s ampere rating is flowing e 24Vdccontrolpower 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 MicroVeraTrip 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 supply 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
208. ft of as shown in Fig 100 It mounts to the bracket assembly shown in Fig 82 Referring to Fig 82 the guide pins mate with the hole on either side of the programmer Connector They provide the necessary alignment for thesconhector engagement The locking lever engages with the pin which is assembled to the programmer frame and secures the programmer to the mounting bracket Installation is as follows a Insert the guide pins into the holes and push on the programmer engaging the connectors b Thelocking lever is released securing the program mer c Verify that the lockinglever did engage the program mer pin To remove th prodrammer a Pull out locking fever which will release the program mer pin Remove the programmer 13 2 CURRENT SENSORS The current sensors supply the power and signal input necessary to operate the trip system Like the MicroVersaTrip the RMS 9 and Epic MicroVersaTrip uses a phase and neutral sensor Fig 101 shows the phase sensors See Section 13 5 for cabling diagrams EA FIG 100 AKR 7D 30 The fixed phase sensors have a polarity associated with their windings Their COMMON terminal is the right hand terminal as shown in Fig 101 A white wire with a terminal will be connected to this COMMON terminal All phase sensors must be correctly wired for the programmer summing circuit to function properly The phase sensors are available with an additional wind
209. function characteristics detailed description of each trip function is given in publication GEK97367 Nes pos are x AMPLIFIER QA gt l IAD RATING P RATING PLUG m VER a p OB T Is 1 RB FACE PLATE RATING 2 asd SWITCHE AMPLIFIER CHES OC fre RATING PLUG composite COMPARATOR e IOC TRIP FLUX INST SHIFTER SWITCH FIG 97 RMS 9 BLOCK DIAGRAM 70 13 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 short circuit over currents faults when breakers are ordered without integral groundfault protection Theyarealso availableto identify overload short circuit and ground fault trips for breakers supplied with integral ground fault protection Each target pops out when itssassOgciated trip element operates to trip the breaker Afterathip the popped target must bereset by hand However neglecting to reset does not affect normal operation oftany trip element or prevent the breaker from being Closed FIG 98 RMS 9 amp EPIC MICROVERSATRIP PROGRAMMER SECTION 13 RMS 9 Epic MicroVersaTrip Cont FIG 99 PROGRAMMER SECONDARY CONNECTOR MICROVERSATRIP 13 1 2 RMS 9 amp EPIC MICROVERSATRIP INSTALLATION The programmer mounts to the upper le
210. g the breaker in this manner The proce dure for slow closing is given below The closing spring must be isolated from the mechanism camshaft This is done by disconnecting the lower spring assembly from the mating camshaft linkage Remove the hex head bolt as shown in Fig 21 Remove this bolt only with the mechanism in the DISCHARGED position and the spring at its minimum extension REMOVE THIS BOLT DO NOT LOOSEN THIS SCREW Remove the hex head bolt only do not removeor loosen the slotted head screw shown in Fig 21 Removal of the slotted head will cause the closing spring to become dis engagedfrom the camshaft with considerable force Verify that this screw remains tightened during the slow close operation After the bolt is removed use the maintenance handle to rotate the ratchet assemblysroller onto the closing prop see Charging Using Maintenance Handle sec tion 5 4 At this point the closing prop must be removed by either pushing the CLOSE button on Manual breakers or pushing the closing solenoid armature on electric breakers see Fig 13 ANhen the closing prop is removed continue turning the camshaft When the contacts and mechanism in the fully closed position the cam will support the cam roller refer to Fig 10 amp section 5 3 and the contactSwwill develop maximum depression Push the FRIRebutton to release the mechanism and open The mechanis
211. g time protection nstantaneous protection e Status Trip target Metering display Phase current selectable among phases The optional functions available on both types of trip unit are as follows Adjustable protection Switchable instantaneous and ground fault protection High range fixed instantaneous overcurrent protection Short time protection with or without I T 82 CO Ground fault protection with or without 2 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 styletrip units require the presence of external control power e Configurations Communication and metering Communication and protective relaying Communication meteting and protective relaying Metering and protectivesrelaying 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 LE SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 9 TROUBLE SHOOTING GUIDE The following guide is provided for trouble shooting and isolating common problems possible condition It does not cover every Contact the Customer Support at 800 843 3742 if the problem is not resolved by these procedures
212. ged With the closing spring propped fully charged the breaker is ready for closing This may be accomplished electrically by closing the PB switch on the breaker if so equipped or by a remote closing switch Operation of the closing switch energizes the K relay which turn ener gizes the closing solenoid CC This removesthe prop releasingtheclosing springs to closethe breaker The F cutoff switch is only installed on breakers using D C control voltage The anti pump function is obtained through the nor mally closed K relay contact in thesmotor circuit If a close signal is maintained after the bfeaker has tripped open automatically the K relay is energized preventing the motor from charging the closing spring The closing signal must be removed for approximately 1 3 to 2 0 seconds to allow the closing spring to charge LEGEND CLOSING SOLENOID CUTOFF SWITCH CLOSED WHEN CLOSING SPRING IS FULLY CHARGED D C ONLY G CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGED L AUXILIARY SWITCH M CHARGING MOTOR PB CLOSE PUSHBUTTON ON BREAKER ESCUTCHEON OPTIONAL TC SHUNT TRIP DEVICE K ANTI PUMP RELAY FIG 9A ALTERNATE ELEMENTARY DIAGRAM CONTACT POSITIONS ARE SHOWN BREAKER OPEN AND CLOSING SPRINGS DISCHARGED TYP 183L712 B SERIES 12 Oy 53 MECHANISM OPERATION Figures 10A 10B and 10C show the mechanism com ponents in the Closed Tripped and Reset positi
213. ginal buffer carefully measure the distance between the faces of the threaded members as shown in Fig 31 and set this dimension carefully on the new assembly Refer to the breaker wiring diagram for the coil lead connections 7 81 REPLACEMENT Toreplace an undervoltage device remove the mount ing bracket shown in fig 29 from the breaker frame and remove the device from the bracket Re install in reverse order noting wire routing and securing means Set the gap between the trip paddle and device arma ture to approximately 0 030 inch as a starting point then proceed with the operational check 7 8 2 BREAKER TRIP SHAFT FRONT FRAME 2ND SHUNT TRIP MTG BRACKET FIG 30 2ND SHUNT TRIP INSTALLATION 23 SECTION 7 Breaker Maintenance Cont O MODIFIED MAINTAIN BUFFER FIG 31 2ND UNDERVOLTAGE DEVICE 7 8 2 OPERATIONAL CHECK BREAKER WITH UV DEVICE INSTALLED Check the pickup and dropout values at room tempera ture See table 25 Check the positive trip ability as follows With the armature closed close the breaker Insert a 0 032 005 inch shim wire gage or flat stock against the armature open stop see Fig 32D and release the armature breaker must trip 7 8 3 ADJUSTMENTS If the operational checks 7 8 2 indicate that aqjust ments arenecessary these procedures shotild befollowed First verify trip latch engagement as deseribed in sec tion 7 15 and verify th
214. gle stroke method By so doing proper multi stroke operation is assured There two handle adjustment linkage designs in use The adjustment linkage Connects the handle assembly to the chain drive mechanisni which turns the cam shaft The length of this linkage provides the handle adjustment If the link istoo long the handle strokecannotextend the closing spring ertough for it to go over center In this event use the maintenance handle to complete the spring charg ing The breaker can then be closed and opened prepara tory to further shortening of the link If the link 400 short one stroke charging is not possi ble However more than one stroke will charge the springs The original linkage design used a double ended stud in thelinkage center A hexsectionin this stud allowed adjust ing with an open end wrench When looking down on the breaker turning the wrench clockwise lengthens the link The opposite motion shortens it The range of adjustment is 300 degrees In the confined space available each wrench stroke imparts 15 degrees movement The best setting is approximately mid range The present design is shown in Fig 20 This linkage is assembled together on a threaded stud Adjustment is accomplished by removing the upper linkage assembly from the handle assembly and changing the linkage length by turning the upper linkage up or down the threaded stud REMOVE THIS bI Y HARDWARE gt THREADED
215. gs Page 73 77 78 78 79 SECTION 1 Introduction These instructions provide the maintenance procedures and describe the operation of the 800 thru 2000 amp frame size type AKR low voltage power circuit breakers listed in Table 1 The proper use care and maintenance of these break ers 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 instruc tions 1 1 INSPECTION AND MAINTENANCE Breakers should be cared for under a systematic main tenance 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 in spected will depend on the circumstances of its use lt would be well to inspect any breaker at least once year If itis frequently operated operated under severe load Condi tions or installed in an area of high humidity or aydusty dirty atmosphere inspections should be morezoftenxIn spections might be monthly under adverse conditions Always inspect t
216. h design is as follows a Insert the guide pins into the holes and push on the pro grammer 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 80 To remove the programmer a Disconnect the remote fault indication harness if equipped b Original designs push in locking lever which will release the programmer pin While holding the locking lever in remove the programmer Later design pull out locking lever which will release the programmer pin Remove the programmer 59 SECTION 12 MicroVersaTrip Trip Device Cont 12 2 CURRENT SENSORS The current sensors supply the power and signal in put necessary to operate the trip system Like the SST system the MicroVersaTrip uses a phase and neutral sensor Fig 83 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 12 5 for cabling diagrams B oo FIG 81 AKR 6D 30 2 Lockirg Lever The tapped and fixed phase sensors have polarity 5 sociated with their windings Their COMMON terminalis the right hand t
217. he breaker and proceed as follows 1 Loosen the locking nut 2B 2 Manually lift the trip rod and vary the position of the ad justing 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 over travel of the trip rod should be obtained 13 4 5 REPLACEMENT Atter removing the wiring for the potential coil the reverse cur rent device can be removed and replaced by following the pro cedure outlined for replacing the series overcurrent device See Section 13 6 For wiring see Fig 103 13 5 SWITCHETTE FEATURE The switchette is operated by the long time delay function Its purpose is to provide a set of contacts that will close beforevan overload occurs This device will not trip the breaker On over load it will trip on instantaneous only The switchette feature is available only in type EC 1 devices The switchette is used in one pole and 1 trips in the other poles For the alarm to be effective in indicating thexoverioad 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 d
218. he CLOSED position and the OFLO reset adjustthe dimension between the end ofthe tripping rod and the trip paddle to 100 140 b With the OFLO energized the breaker must TRIP and the RESET button must move forward to the front plate In this condition the breaker must be held trip free 43 SECTION 9 Fused Breakers Cont TRIP PADDLE TRIPPING ROD SOLENOID ARMATURE RESET FIG 56A DETAILS FIG 56B INSTALLED BREAKER OFLO DEVICE 44 SECTION 10 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 pro grammer unit current sensors and a flux shifter trip de vice Fig 57 shows a block diagram of the system 10 1 PROGRAMMER UNIT Fig 58 shows a typical SST programmer unit The pro grammer unit provides the comparison basis for overcur rent 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 ad justments set points are located on the face plate De pending on the application programmer units may be equipped with various combinations of Long Time Short Time Instantaneous and Ground Fault trip elements See Table 7 for available ratings settings and trip characteris tics Adjustments are made by removing the clear cover over the face
219. he Flux Shift Trip device 1 electro magnetic device which upon receipt of a trip signal from the programmer unit tripsithe breaker by actuat ing the trip shaft The mounting arrangement of this component is illustrated in Figs 64 and 65 An electromagnetic actuator located on the underside of the front frame is coupled to the bfeaker s trip shaft via a trip rod driven by the actu tor arm The actuator is a solenoid whose armature is Spring lo aded and held in its normal Reset position bya permanent magnet In this state the spring is compressed i 5 Tap Terminal Board 6 Programmer Unit 7 Clamp Bolt 8 Sensor Stud FIG 63 AKR 5A 30 BREAKER WITH SST TRIP DEVICE 48 So long as the actuator remains in the Reset posi tion 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 tripp ing 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 66 th
220. he breaker after a short circuit Current has been interrupted SAFETY PRECAUTION BEFORE INSPECTING OR BEGINNING ANY MAINTENANCE WORK ON THE BREAKER IT MUST DISCONNECTED FROM ALL VOLT i AGE SOURCES BOTH POWER AND CON TROL AND BE IN THE OPEN POSITION Y A basic inspection should consist of the following a Visual Check Look for dirt grease or other forei material on any breaker parts Check ins lating surfac for conditions that could degrade insulating properties cracks overheating etc Also check for loose hardware and components on the breaker and the compartment s bottom loose or damaged control wiring and similar prob lem areas b Operation Observe a few close open operations using the operating or maintenance handle If a breaker is seldom operated such that it remains open or closed for a period of six months or it is recommended that ar rangements be made to open and close it several times in succession Interlocks During he Operational check verify the safety interlocks are properly working d Arc Chutes and Contacts Inspect the condition of the arc chutes and contacts Look for excessive burning or breakage Check the amount of contact depression or wipe e Accessories Verify thatthe various accessories are working properly f The performance of the solid state current trip devices may be checked with a suitable test set Check elec tromechanical
221. he left side frame to allow enough freedom for all the devices and the wiring harness to be taken from between the side frames With the bracket removed in dividual devices can be replaced easily The closing solenoid is mounted by means of mounting bracket to the bottom of the breaker frame The most con venient way to take off the solenoid is to remove the moun ting bracket and then disconnect the solenoid from the bracket The pin connecting the armature to the closing link must also be removed The charging motor is secured through three spacers to the mechanism frame The front mounting bolt is accessi ble using a socket and universal joint through the opening in the side of the breaker s frame The upper rear mounting bolt is accessible using a socket and universal joint over the top of the frame The lower rear mounting bolt is ac cessible using a socket and universal joint throughthe opening in the frame s side by the buffer assemblySlow close the breaker to move the flywheel assembly out of the way The ratchet on the camshaft is removed by driving out the roll pin which fastens it to the camshaft Before this can be done the charging motor must be removed and the closing spring arranged for slow elosing as described earlier Tum the camshaft using the maintenance handle until the roll pin is well started turfi the camshaft to gain enough space for the roll pin to clear the breaker frame Before removing the ratchet
222. he source See Fig 92 4 Ensure that the neutral conductor is carrying only thatneutral current associated with the breaker s load cur rent 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 13 and 14 65 SECTION 12 MicroVersaTrip Trip Device Cont 12 5 CABLING DIAGRAMS A C FLUX SHIFT PROGRAMMER TRIP DEVICE BREAKER BACK FRAME LEFT POLE CURRENT h SENSOR HARNESS PROGRAMMER CONNECTOR AMP 1 350356 9 V CONNECTOR LOAD FIG 89 CABLING DIAGRAM MICROVERSATRIP WITHOUT GROUND FAULT G FLUX SHIFT PROGRAMMER TRIP DEVICE BREAKER ADIA BACK FRAME F tT T Ny LEFT POLE CURRENT SENSOR ao T8 M js s jme Ns HARNESS CONNECTOR 1 350356 9 PROGRAMMER CONNECTOR FIG 90 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 3 WIRE LOAD 66 B C FLUX SHIFT PROGRAMMER Device BREAKER A _ BACK r LEFT POLE CURRENT SENSOR NEUTRAL NEUTRAL SENSOR DISCONNECT Y Y Y c HARNESS pp OGRAMMER EQUIPMENT MOUNTED AMP 1350356 97 CONNECTOR NEUTRAL SENSOR s 4 WIRE LOAD FIG 91 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE
223. he trip paddle screw if necessary to aSsure positive trip Withthe undervoltage device closed picked up and the mecha nism reset there m st be clearance between the trip paddle and the device armature If clearance adjustment is necessary rewetify positive trip ability PICK UP ADJUSTMENT FIG 32A UNDERVOLTAGE DEVICE 7 8 4 FACTORY SETTINGS This section covers certain factory settings as an aid to trouble shooting They are for reference only and are not intended to be field adjusted They should not be consid ered criteria for acceptance or rejection ARMATURE LOCATING RIVET The rivet shown in figure 32A serves as a locater for the armature A clearance of 0 001 to 0 010 inch should exist between the rivet and armature as shown in fig 32A The rivet should be able to turn freely ARMATURE OPEN GAP The air gap between the armature and the magnet with the device de energized should be approximately 0 250 inches This is checked by inserting a 0 201 005 inch diameter gage pin between the armature and magnet as shown in Fig 32B OPEN GAP ADJUSTMENT 201 005 DIA FIG 32B OPEN GAP CHECK n CLOSED GAP ADJUSTMENT FIG 32C CLOSED GAP CHECK 79 STATIC TIME DELAY UNDERVOETAGE The static time delay undervoltage system cohsists of a time delay unit which controls an instantaneous under voltage device The time delay unit is separately mounted in the switchgear and the undervoltage
224. high cur rents may eventually require replacement of their contacts The general rule for determining 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 When contacts are replaced they must be adjusted to ensure that the proper amount of force is developed be tween the movable and stationary contacts when the breaker is closed This is called the wipe adjustment Wipe is the distance through which the stationary con tacts move when the breaker closes It is measured bet ween the point of contact on a stationary contact when the breaker is open and the position of the same point when the breaker is closed The actual wiping motion is greater because the contacts over travel Wiping imparts a slid ing or scrubbing action to the contacts The wipe adjustment influences proper arc transfer dur ing interruption of fault currents Transfer of the arc is its forced sequential movement from the intermediate con tacts to the arcing contacts to the arc runner and finally to the arc quencher where it is dissipated and extinguished It is recommended that contact wipe be checked periodically during normal maintenance inspections CAUTION BEFORE DOING ANY THE EOL LOWING CONTACT ADJUSTMENT AND RE PLACEMENT WORK MECHANICALLY CONNECT THE CLOSING SP
225. hort Time D 1 Short Time Delay is required 2 Standard when Ground Fault specified Ground Fault required INSTANTA dj Instantanerus Pickup xixi j 1 1 A TABLE 12 MICROVERSATRIP TRIP CHARACTERISTICS 1 5 2 2 5 3 4 5 7 9 C 1 5 2 2 5 3 4 5 7 9 X 1 Time delay shown at 600 of ampere 5 at lower imit of each band C current setting 2 Time delay shown at lower imit of each band X sensor current Al pickup tolerancus are 10 Ground Faull pickup not to exceed 1200 61 SECTION 12 MicroVersaTrip Trip Device Cont TAPPED OMMON TERMINAL FIG 83 MICROVERSATRIP PHASE FIG 85 TYPICAL NEUTRAL SENSOR SENSORS SPECIAL WINDIN CONNECTIONS FIG484 H Option Phase Sensor 62 A BREAKER MOUNTED RIGHT SIDE B EQUIPMENT MOUNTED FIG 86 NEUTRAL SENSOR SECONDARY DISCONNECT Since the neutral sensor is mounted separately from the breaker a disconnect means is required to connect its output to the breaker Fig 86 shows the breaker and equipment mounted 4th wire secondary disconnect used with the MicroVersaTrip system 12 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 87 replacement of MicroVersaTrip cur rent sensors is accomplished as follows Disconnect the programmer harness from the ter minal board removing cable ties as necessary b At the rear fo the breaker remove
226. ial used in both arc chutes Check for any missing parts To install the arc chutes 1 Replace the arc chutes over each pole unit 2 Locate the retainer s 3 Tighten the retainer bolts until the arc chutes are secure There may be some side to side motion of the arc chutes but there must not be any front to back motion Torque the retainer bolts to 30 in Ibs for the molded type arc chutes and 60 to 100 in Ibs for the ceramic type Do not over tighten 4 Tighten the locknuts against the mechanism frame with 150 to 175 in Ibs torque 33 SECTION 8 Contact Maintenance Cont 8 2 CONTACT ADJUSTMENT AKR 30 30H amp AKRU 30 The contact structure of the AKR 30 and the AKRU 30 breakers is slightly different from the AKR 30H Referring to Fig 44 A amp B both structures use one moveable contact arm and two stationary arcing contacts However the AKR AKRU 30 uses three stationary main contacts and the AKR 30H uses four The following wipe adjustment procedure is applicable to all AKR 30 30H amp AKRU 30 1 Open the breaker remove arc quenchers 2 Slow close the breaker The cam roller must be sup ported by the cam and not the prop Refer to section 5 3 3 Select one pole and using a flat or wire feeler gage measure the gap between the top contact and its pivot stud as shown in Fig 45 As necessary adjust the gap to 0 060 0 020 inch by turning the wipe adjustment nut shown in Fig 45 amp 46 4 O
227. iation is in the way energy is stored in the closing spring and how it is released 51 MANUAL CLOSING Manually operated AKR breakers are constructed with front mounted handles Handle operation resets the mechanism and fully charges the closing spring com plete charge is accomplished by cranking the handle through one cycle 135 degree swing The CLOSE but tonmountedon the escutcheon is used to manually close the breaker contacts and the TRIP button is used to open them If equipped with a closing solenoid a manual breaker may be closed remotely by a control switch or relay Before this can be done however the closing spring has to be charged by hand The closing solenoid is an op tional accessory and is not supplied unless specified in the breaker order a 5 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 switch contacts see Fig 9 The motor through the gear reduction output crank compresses the closing springs until they are fully charged As this fully charged position is reached mechanically operated switches F and reverse their shown position the switch deenergizing the motor and the F switch estab lishing a circuit to the At the same time a mechanical prop is positioned to prev
228. ically to and supersedes the TAK TS1 device The TAK T S2 can also test the Ver saTrip Mod 2 trip device WARNING BEFORE CONNECTING THE TEST SET TO THE BREAKER TRIP DEVICE SYSTEM EN SURE THAT THE CIRCUIT BREAKER IS COM PLETELY DISCONNECTED FROM ITS POWER SOURCE ON DRAWOUT EQUIPMENT RACK THE BREAKER TO ITS DISCONNECTED POSITION VERIFY THAT THE BREAKER IS TRIPPED Either of two test modes may be employed A Programmer Unit Only These tests are con ducted 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 ONA BREAKER THAT IS ENERGIZED AND CARRY ING LOAD CURRENT THIS WILL OPEN CIRCUIT THE CURRENT SENSORS ALLOWING DANGER OUS AND DAMAGING VOLTAGES TO DEVELOP Test scope 1 Verify the time current characteristics and piekup calibration of the various trip elements 2 Verify operation of the SST target indicators on pro grammer 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 Trip Device and verify its operation by physi cally tripping the breaker 2 Check phase sensor continuity
229. ice connected See Table 5 for values TABLE5 TIME DELAY UNITS CONTROL VOLTAGE TERMINALS 1 amp 2 125 VDC TAKYUVT 1 2 3 APPROXIMATE STEADY STATE DC OPERATING VOLTAGE 208 240 VAC 110 125 1600 NOMINAL DC COIL RESISTANCE OHMS 9 25 C TERMINALS 4 amp 5 25 SECTION 7 Breaker Maintenance Cont S 3 Check resistance of the disconnected undervoltage device See Table 5 for values See instruction Sheet GEH 4545 for more detailed infor mation including schematic diagrams and circuit descrip tion The undervoltage device must be calibrated through the time delay unit after the device pick up has been adjusted A 008 inch minimum closed gap must exist between the ar mature and magnet as shown in Fig 32C Refer to Section 7 8 3 and Table 24 7 10 ELECTRIC LOCKOUT DEVICE The electric lockout device utilizes an undervoltage device to keep the breaker from resetting its mechanism if the breaker is open and the undervoltage device coil is not energized The breaker thus cannot be closed unless voltage is the coil Once the breaker is closed loss of voltage will not trip the breaker because in the closed posi tion a mechanical link is used to hold down the armature of the device See Fig 33 This arrangement provides a means of electrically interlocking two breakers so that they cannot be closed at the same time Each undervoltage coil may be wired in series
230. iding 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 102 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 FIG 102 CHECKING TRAVEL DISTANCE OF SERIES OVERCURRENT TRIPPING DEVICE 74 13 3 POSITIVE TRIP ADJUSTMENT Before attempting any checks or adjustments on breaker wi _ EC trip devices the breaker mechanism and trip latch should checked to assure their proper functioning so that the break trip shaft is free of high friction loads The trip latch of the breaker should also be checked for proper trip latch engage ment See Section 7 15 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 mech anism or the overcurrent trip devices have been replaced Positive tripping is achieved when adjustment screw 9 Fig ure 101 is in such a position thatyit will always carry the trip pad dle on
231. ifference between these models is their arc chute construction The arc chutes in the no model number break ers have a two piece porcelain frame and use 2 arc chute retainers see Fig 5 The 1 breaker arc chutes have one piece molded polyester glass frame and 1 arc chute re tainer see Fig 6 All AKRT50H breakers use only molded arc chutes 7 3 M Rm k i m oe 198 4 342 5 IEG P FIG 5 CERAMIC ARC CHUTES FIG 6 MOLDED ARC CHUTES 27 SHORT CIRCUIT RATINGS Short circuit ratings vary with the applied system vol tage On 240 VAC systems they are also dependent upon whether the overcurrent trip device contains an instan taneous trip element See Table 4 TABLE 4 BREAKER INTERRUPTION RATINGS 36 INTERRUPTION RATING RATED KA RMS SYMMETRICAL FRAME MAXIMUM WH WITHOUT SIZE BREAKER VOLTAGE INSTANTANEOUS INSTANTANEOUS SHORT AMPERES TYPE 60 HZ AC TRIP TRIP TIME 635 508 30 800 254 42 N gt N 58 M 50 1600 24 yop AC 65 X 59 50 50 2463 4 s s gt I 2000 AC 1 689 C 12 800 2 eo 1600 a 80000 AKR30 7 300 0 2000 5069 300 With 40 800 Amp Trip Coils With 200 2000 Amp Trip Coils 3Consu t Factory For Application Data SECTION 3 Storage It is recommended that the breaker be put into service immediately in its permanent l
232. ime Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required TABLE 12 RMS 9 AND EPIC MICROVERSATRIP CHARACTERISTICS Long Time Short Time Adjustable Adjustable Ground Fault Current Instantan Instantan High Range Setting eous eous Instantan Triple Pickup Mult Pick Up Pick Up eous Selective Mult of Mult Pick up w o ST with ST Mult of Trip of Sensor Rating of Mult of Mult of Mult of Frame Fixed High Sensor Max Rating Plug Current Current Rating Rating Short time3 Range Amp Delay Delay 65 Frame Amp Amps Amps Setting Delay Setting Delay Plug Amps Plug Amps Rating Instantaneous Rating 12 w ol2T Size Rating S X Cy Sec C Sec X X H d S Sec Sec AKR 30 150 49 1 5 2 3 5 15 2 3 5 E 17 8 0 9 5 2 3 5 5 2 3 5 3 35 21 AKR 30H 500 soot 995 9 8 7 930 7 9 10 13 19 MA A 45 35 4 0 1 1 Setting 20 ins 15 5 6 44 at 40 200 5 6 Fixed at 2 4 1 5 2 0 2 25 of pick 800 7 8 1 0 of 4 9 2 5 3 0 12T 1 5 2 3 5 1 5 2 3 5 13 35 up at 10 21 90 1600 1600 9 795 Current 9 8 4 0 5 0 out 2 7 9 10 7 9 10 13 4 6 8 10 4 45 twee 135 10 1 1 Setting 20 7 0 9 0 10 15 5 6 limit 21 of 15 6 Fixed at 2 4 35 2 25 band 7 8 1 0 of 4 9 1 5 2 3 5 1 5 2 3 5 13 35 10 21 AKRT S
233. ing This winding is brought out to separate flag terminals These phase sensors are used when the hi levelinstantaneous 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 102 shows the connec tions for the additional H option windings 71 SECTION 13 RMS 9 amp Epic MicroVersaTrip TABLE 11 TRIP FUNCTIONS AVAILABLE Optional Features ADD TO BASIC FUNCTIONS BASIC FUNCTIONS LONG TIME SHORT TIME INSTANTA NEOUS GROUND FAULT OTHER FUNCTIONS or S or H or M A1 or A2 or A3 or A Z1 or Z2 or Z e Adjustable Current Setting X X X x e Adj Long Time Pickup X X X X e AdjLong Time Delay X X X X 9 Long Time Timing Light X X x X e Remote Long Time Timing Light X e Adj Short Time Pickup X X X e Adj Short Time Delay X X 9 Short Time 121 Switch O X 9 Adj Instantaneous Pickup X X e Adj High Range Instantaneous X Adj Ground Fault Pickup 1PH 2 W 3PH 3 4 W x Ground Return x e Adj Ground Fault Delay X X 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 Fault Short Time 1 Short T
234. ing handle or maintenance handle The cam engages the cam roller and partially extends the toggle linkage This allows the secondary latch to pivot against the front frame as shown leaving a gap between the trip latch and secondary latch roller The secofidary latch is now in a position to engage with both the top latch and cam roller The breaker closes when the closing spr ng discharges and rotates the cam against the cam roller The toggle linkage is fully extended pivoting the secon dary latch from the front frame and engaging it with the trip latch and cam roller as shown in Fig 10A When the breaker is closed and the closing spring discharged the upper cam roller is supported by the cam rather than the prop This is the position the mechanism must be in to check contact adjustment refer to Sectior FIG 10A CLOSED 2 Prop 11 Trip Latch 3 Cam 12 Insulated Coupling 4 Camshaft 13 Main Shaft 5 Cam Roller 14 Secondary Latch 10 Trip Shaft 15 Opening Spring 5 4 CHARGING USING THE MAINTENANCE HANDLE The closing spring on electrically operated breakers can be manually charged by using the maintenance handle 568B386G1 as shown in Fig 11 The triangular socket in the maintenance handle mates with the mechanism s camshaft extension on the front right side of the breaker Using the knob on the handle it will probably be necessary to align this socket to fit on the end of the shaft e 3 BE OF vs
235. intenance handle between the top of the left nand side buffer block and the end plate assembly This should eliminate any interference from the main shaft during the bell alarm removal 4 The tfip shaft must be moved to allow the bell alarm to fit beteen it and the front frame Remove the retaining ring holding the right hand trip shaft bearing to the mechanism ffame Slide the bearing from the frame and along the trip shaft There will now be enough trip shaft movement to slip the belhalarm past 5ainstall the replacement bell alarm in reverse order 6 Check the adjustments given in Section 7 11 2 A bell alarm with a lockout assembly or a bell alarm in stalled on a 2000 amp frame AKRT 50 50H breaker may not work with the above procedure If this is the case the breaker front and back frame will have to be seperated 7 12 ELECTRICAL CONTROL COMPONENTS The operation of the electrical control components is described in Section 5 2 The location of these components CHARGING MOTOR G SWITCH F SWITCH 27 SECTION 7 Breaker Maintenance Cont 7121 COMPONENT REPLACEMENT To gain access to the electrical control components the breaker s front escutcheon must be removed Type B and D breakers require that both the deep molded escut cheon and the shallow steel escutcheon be removed Before removing the front escutcheon on Type A or B breakers a supporting block should be placed under the front fra
236. ionary mains There are two designs used to connect the movable contact arms to the insulated link This results in two con tact adjustment procedures depending on which design the breaker has In the original design the two movable contact arms are pin coupled to a metal driving link whose opposite end is threaded and screws directly into the insulating link This arrangement omits the wrench operated wipe adjustment stud providedon the AKR 30 and 50 frames Instead wipe is adjusted by detaching the driving link from the movable contact arms and then rotating it with respect to the insulat ing link On the AKRT 50 the proper amount of contact wipe exists if on a closed breaker all of the stationary main contacts have moved away from their stops This condition can be checked visually by removing the arc quenchers closing the breaker and verifying that all eight stationary main contacts are lifted off their stops Should wipe ad justment appear necessary proceed as follows STATIONARY INTERMEDIATE CONTACTS STATIONARY MAIN CONTACTS MOVABLE ARGING conte N ET WIPE ADJUSTMENT NUT 1 Open the breaker 2 Arrange the breaker for slow closing 3 Selecting one pole drift out the co pling pin and detach the driving link from the movable contact arms 4 Screw the driving link completely into the insulating link 5 Back out the drivingilinK two and one half turns Ex ceed this by whatever am
237. ions 7 8 1 REPLACEMENT Toreplace an undervoltage device remove the mount ing bracket shown in fig 29 from the breaker frame and remove the device from the bracket Re install in reverse order noting wire routing and securing means Set the gap between the trip paddle and device arma ture to approximately 0 030 inch as a starting point then proceed with the operational check 7 8 2 BREAKER 2ND SHUNT TRIP MTG BRACKET RIGHT HAND BUFFER ASSEMBLY HARDWARE FIG 30 2ND SHUNT TRIP INSTALLATION 23 SECTION 7 Breaker Maintenance Cont FIG 31 2ND UNDERVOLTAGE DEVICE 7 8 2 OPERATIONAL CHECK BREAKER WITH UV DEVICE INSTALLED Check the pickup and dropout values atroom tempera ture See table 25 Check the positive trip ability as follows With the armature closed close the breaker Insert a 0 032 005 inch shim wire gage or flat stock against the armature open stop see Fig 32D and release the armature The breaker must trip 7 8 3 ADJUSTMENTS If the operational checks 7 8 2 indicate that aqjust mentsarenecessary theseprocedures should be followed First verify trip latch engagement as described in sec tion 7 15 and verify that the trip shaft torque required to trip a closed breaker is no greater than 24 inch ounces Then proceed as follows PICKUP VOLTAGE The pickup level is changed by turning the adjustment screw shown in Fig 32A The screw is sec
238. ip Plus and MicroVersaTrip PM trip units are removable Figures 111 and 112 contain front and rear views of a MicroVersaTrip PM trip unit Figure 112 shows the 36 pin plug that connects either trip unit to the circuit breaker and equipment circuity This plug is called the trip unit disconnect CAUTION Removalofa trip unit from its breaker must be performed with the breaker in the OPEN or TRIPPED position Draw out breakers should be racked out first CAUTION Donotattemptto operate the breaker without its assigned trip unit Installation of an incorrect trip anit 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 capacity to approximately 25 of the current sensor rating This may result in undesired tripping NOTE Trip units as received may have Settings that are undesirable for the specific applicatio Ensure that settings are appropriately adjusted before energizing 78 FIG 111 FRONT VIEW OF MICROVERSATRIP PM TRIP UNIT CAUTION IMPORTANT INSTRUCTIONS TO ENSURE PROPER PROGAAMARER FUNCTION FIG 112 REAR VIEW OF MICROVERSATRIP PM TRIP UNIT SECTION 14 MicroVersaTrip Plus MicroVersaTrip PM Trip Units 14 4 TRIP UNIT REMOVAL AND REPLACEMENT The programmer mounts to the upper left of the breaker as shown in Fig 115 It mounts to the bracket assembly shownin Fig 8
239. ip Device Replacement 90 SECTION 1 Introduction These instructions provide the maintenance procedures and describe the operation of the 800 thru 2000 amp frame size type AKR low voltage power circuit breakers listed in Table 1 The proper use care and maintenance of these break ers 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 needby gaining the information contained inthese instruc tions 1 4 INSPECTION AND MAINTENANCE Breakers should be cared for under a systematic main tenance 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 in spected will depend on the circumstances of its use Jf wouldbe wellto inspect any breaker atleast once a year If itis frequently operated operated under severe load cendi tions or installed in an area of high humidity or a dusty dirty atmosphere inspections should be more oftenmln spections might be monthly under adverse conditions Always inspect the breaker after short
240. ip device i e be nally it also must be able to trip open a closed breaker quickly enough to minimize arc erosion and in such manner as to effect proper arc transfer to the arc runner The current carrying members of the breakersare s sembled on the back frame which provides the mechani cal support required and also the insulating structure needed The conductive members are the studs for exter nal connections movable and stationary contact sets pivots for the movable contacts and provision formounting 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 combination of many accessories and interlocking devices Breakers m y also differ in a variety of areas as shown Table gt brief description of these areas is given below 2 1 FRAME SIZE The breakers are available in 5 frame sizes 800 am peres 30 30H AKRU 30 1600 amperes 450 5 AKRU 50 2000 amperes 50 50H 800 amperes D C AKR 30 and 2000 amperes D C AKR 50 FIG R Manually Operated AKR 4A 50 1 These values represent the maximum continuous cur fent capability of the respective frames However each br aker carries a specific rating which is determine
241. ipped with this setting at the 2 3 mark and the 1C characteristic at the 1 3 mark The standard charactenstic curves are plotted at these same 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 99 is greatest The time adjustment screw 4 may be turned by in serting a Philips head screwdriver through the hole in the front of the case 1s desired to relate the linkage setting to the index 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 tnp unit itself 72 13 1 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 ranc from 80 percent to 250 percent of the series coil rating with calibration plate indexed at values of 80 100 150 200 and 250 percent of the rating 13 1 3 INSTANTANEOUS HIGH SET TRIPPING The high set instantaneous pick up value may have one of the following three ranges 4 to 9 times coil rating 6 to 12 times coil rating or 9 to 15 time coil rating The pick up setting may be varied by tuming the instantaneous pick up adjusting screw 12 Three calibration marks 15 will appear on the operating arm 14
242. ire 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 70 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 termi als L and N 3 If the breaker s lower studs connect to the supply source then the ne tral sensor must have its LOAD encl connected to thetsource 4 mEnsure that the neutral conductor is carrying only that neutral c rrent associated with the breaker s load cur rent neutral not shared with other loads 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 resistance should closely agree See Table 8 PROGRAMMER UNIT 48V dc TO SCR ANODE NESS PROGRAMMER ECTOR CONNECTOR FIG 68 CABLING DIAGRAM SST WITHOUT GROUND FAULT 53 SECTION 10 Type SST Overcurrent Trip Device 98 PROGRAMMER UNI A A FLUX SHIFT T TRIP DEVICE 4 BREAKER BACK ica 48V dc TOSCR LEFT POLE ANODE CURRENT SENSOR i l
243. is necessary re verify positive trip ability PICK UP ADJUSTMENT SHADING RING HOLDING SCREWS FIG 32A UNDERVOLTAGE DEVICE 7 8 4 FACTORY SETTINGS This section covers certain factory settings as an aid to trouble shooting They are for reference only and are not intended to be field adjusted They should not be consid ered criteria for acceptance or rejection ARMATURE LOCATING RIVET rivet shown in figure 32A serves as a locater for the armature A clearance of 0 001 to 0 010 inch should exist between the rivet and armature as shown in fig 32A The rivet should be able to turn freely ARMATURE OPEN GAP The air gap between the armature and the magnet with the device de energized should be approximately 0 250 inches This is checked by inserting a 0 201 005 inch diameter gage pin between the armature and magnet as shown in Fig 32B OPEN GAP ADJUSTMENT 201 005 DIA FIG 32 OPEN GAP CHECK PIN CLOSED ADJUSTMENT FIG 32C CLOSED GAP CHECK 7 9 STATIC TIME DELAY UNDERVOLTAGE The static time delay undervoltage system Consists of a time delay unit which controls an instagtaneous under voltage device The time delay unit is separately mounted in the switchgear and the undervoltage devices mounted on the breaker Table 5 lists the catalog numbers available If the a c control voltage is any voltage other than 208 240 ac a control power transformer also remotely
244. jec tion pin in the drawout fail Fig 8 When the wrong type breaker is inserted into a compartment the bracket and pin do not mate preventing the breaker from seating itself into the drawout rails There is one exception to the above Breakers the same frame size having different short circuit ratings may be interchanged one direction onty a An AKR 30H can be inserted into an AKR 30 compart ment b An AKR 50H can be inserted into AKR 50 compar ment AKR 50H 1 can be inserted into an AKR 50 and 5 compartment d An AKRT 50H can be inserted into an AKRT 50 com partment 10 The rejection hardware prevents the of a thru d above A detailed description of the rejection pin and bracket combinations used is given in Installation manual GEI 86150 TYPICAL REJECTION BRACKET FIG 7 DRAWOUT BREAKER REJECTION SYSTEM FRONT OF COMPARTMENT FRONT PIN IN POSITION A SLOT RIGHT SIDE FIG 8 INSERTING THE BREAKER SECTION 5 Breaker Operation A breaker may be equipped to operate either manually or electrically Both types of operation result in the same fast closing movement as far as the contact action is concerned The variation is in the way energy is stored in the closing spring and how it is released 51 MANUAL CLOSING Manually operated AKR breakers are constructed with front mounted handles Handle operation resets the mechanism and fully charge
245. k for fractures damage to the liner material used in the molded arc chute and damage to the insulation material used in both arc chutes Check for any missing parts To install the arc chutes 1 Replace the arc chutes over each pole unit 2 Locate the retainer s 3 Tighten the retainer bolts until the arc chutes are secure There may be some side to side motion of the arc chutes but there must not be any front to back motion Torque the retainer bolts to 30 in Ibs for the molded type arc chutes and 60 to 100 in Ibs for the ceramic type Do over tighten 4 Tighten the locknuts against the mechanism frame with 150 to 175 in Ibs torque SECTION 8 Contact Maintenance Cont 8 2 CONTACT ADJUSTMENT AKR 30 30H amp AKRU 30 The contact structure of the AKR 30 and the AKRU 30 breakers is slightly different from the AKR 30H Referring to Fig 44 A amp B both structures use one moveable contact arm and two stationary arcing contacts However the AKR AKRU 30 uses three stationary main contacts and the AKR 30H uses four The following wipe adjustment procedure is applicable to all AKR 30 types 1 Open the breaker remove arc quenchers 2 Slow close the breaker The cam roller must be sup ported by the cam and not the prop Refer to section 5 3 3 Select one pole and using a flat or wire feeler gage measure the gap between the top contact and its pivot stud as shown in Fig 45 As necessary adjust the ga
246. ked out position will cause the lever to move past the pin on the armature linkage This will bind up the overall interlock Under these conditions continued application of this force will deform the linkage assembly RACKING MECHANISM Racked In Lever And Armature Linkage Pin Not Engaged TT ADJUSTING SCREWS Breaker Being Racked Out Lever Activates Armature Linkage FIG 17 CLOSING SPRING INTERLOCK amp 6 4 DISCONNECT POSITION INTERLOCK The function of the Disconnect Position InterlocK is to block the RACKING SCREW cover open when the racking mechanism is in the DISCONNECTED position When the cover is held open the TRIP button is depressed The mechanism is held trip free and there 5 contact arm movement when the closing spring is discharged by the Closing Spring interlock The operation of this interlock is shown in Fig 18 A crank which is attached to the ra king mechanism shaft is connected to the blocking plate through a link As the shaft turns the blocking plate rotates holding the cover open in the DISCONNECTED position but allowing it to close in the TEST and CONNEGT ED positions al FIG 18 DISCONNECT POSITION INTERLOCK 6 5 PADLOCKS Provisions are made on all breakers to use padlocks to prevent the breaker form being closed
247. ker tripping in proper response to overcurrents or incipient ground faults b Breaker remaining in a trip free state due to mechanical maintenance along its trip shaft inadvertent shunt trip activations WARNING DO NOT CHANGE TAPS ON THE CUR RENT SENSORS OR ADJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CAR RYING CURRENT PROGRAMMER PROGRAMMER HARNESS Once it has been established that the circuit breake can be opened and closed normally from the testiposition 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 connec tions must be employed forMicroVersaTrip breakers equipped with Ground Fault Any single phase input to the programmer circuit wilhgenerate an unwanted ground fault output signal which will trip the breaker This can be nullified either by a Using the Ground Eault Defeat Cable as shown in Fig 93 This special test cable energizes the pro grammer circuit in 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 TVTS1 Fig 88 The ap plicable test procedures are detailed in instruction Book 64464 The time current characteristics for the MicroVersaTrip Trip Device are gi
248. l devices for positive trip in accordance with the instructions in their Maintenance Manual GEI 86157 1 2 RENEWAL PARTS The AKR breakers contain a variety of parts and as semblies Many of these are available as replacement parts when the need arises See publication GEF 4527 Renewal Parts for a complete listing of these parts TABLE1 BREAKER MODELS MOUNTING TYPE DRAWOUT FUSED FRAME SIZE BREAKER AMPERES DESIGNATION AKD 8 STRUCTURE STATIONARY ESCUTCHEON BREAKER AR 303H X 1 800 X X aL 003030 3 x XO wenssa ALL IAKR A50 50H x hm 00 50 50 x 005 5 X x S x lt eo0sso5H JE amroasusH x s 2000 _ x Fe 2 0 X 4 800 _ DC 2030 x e 3 ENS I E akr 2a50 x 2000 aman Cs DC am205 1 7 x es 860 AKRU B30 L7 X AKRU A 50 1600 ames e M _ 3 This digit identifies the trip device type as EE 2 EC DC only 4 ECS 5 SST 50 60 Hertz Only 6 MicroVersa T rip N Non automatig In addition all non automatic 250VDC breaker types carry the suffix letter D after the frame number e g AKR
249. l the disconnect assembly off the end ofthe fuse tang NOTE This removal does not disturb the disconnect s clamping force adjustment b Remove the upper barrier c Detach the inboard end of the fuse by removing the two 4 2 inch 13 bolts A ratchet and socket with a short extension will be requied d Remove the heat sink e Remove the fuse f Install the new fuse by reversing the disassembly procedure Ensure that the mating faces of the fuse and heat sink are clean ADAPTER BARS COPPER FIG 52 300 THRU 600 AMP CLASS J FUSE MOUNTING 41 SECTION 9 Fused Breakers Cont CAUTION WHEN REPLACING THE FUSE IN LEFT POLE FRONT VIEW OF THE BREAKER NOTE PARTICULARLY THAT THIS FUSE IS MOUNTED DIFFERENTLY THAN THE OTHER TWO FUSES AS SHOWN IN FIG 54 FOR THIS PHASE THE FUSE IS ROTATED 180 DEGREES ABOUT ITS AXIS SO THAT ITS INBOARD TANG IS POSITIONED STUD THIS TANG IS OFFSET WITH RESPECT TO THE OPPOSITE END SO THAT ROTATING THE FUSE DOES NOT ALTER THE POSITION OF THE PRI MARY DISCONNECT FRONT OF BREAKER FOR THIS POLE ONLY FUSE ZANGS FUSE IS ROTATED 180 BREAKER POSITIONED ON TOP TO POSITION TANG STUD OF BREAKER STUD BENEATH BREAKER STUD 1 Special 2500 Fuse 4 Upper Barrier YTANG BOLT 2500A FUSE 2 Disconnect Key 5 Primary Disconnect HOLES 3 Heat Sink a FIG 53 AKRU 50 WITH SPECIAL 2500 AMP FUSE
250. lectrical equipment such as power circuit breakers and other power handling equipment must be thoroughly instructed with periodic retraining regarding power equipment in general as well as the particular model of equipment with which they are working Instruction books actual devices and appropriate safety and mainte nance practices suchas OSHApublications NationalElectric Safety Code ANSI C2 The National Electrical Code and NFPA 7 OB Electrical Equipment Maintenance must be closely studied and followed During actual work supervi sion should audit practices to assure conformance 3 Excellent maintenance is essential for reliability and safety of any electricalequipment Industry publications of recom menced maintenance practices such as ANSI NFPA 70B Electrical Equipment Maintenance shouldbe carefully stud ied and applied in each user s formation of planned maintenance 3 2 Maintenance Both long and short term maintenance of all electrical equipment is essential for reliability and safety Mainte nance programs 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 pro grams including such variables as ambient temperatures extreme moisture number of operations corrosive atmo sphere or major insect problems and any other unusual or abusive condition of the application O
251. letely removed from it CAUTION NEVER DISENGAGE THE HARNESS CONNECTOR FROM THE PROGRAMMER UNIT ON A BREAKER THAT IS ENERGIZED AND CARRY ING LOAD CURRENT THIS WILL OPEN CIRCUIT THE CURRENT SENSORS ALLOWING DANGER OUS AND DAMAGING VOLTAGES TO DEVELOP Test scope 1 Verity the time current characteristics and pickup calibration of the various trip elements 2 Verity operation of the SST target indicators on pro grammer 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 programmer s output to activate the Flux Shift Trip Device afd verify its operation by physi Cally tripping the breaker 2 Check phase sensor continuity Inthe event that ny component ofthe SST system does not perform within the limits prescribed in test instructions GEK 64454 it should be replaced 52 10 4 2 RESISTANCE VALUES For use in troubleshooting the Common to Tap resist ance for SST current sensors is given in Table 8 These values apply to both phase and neutral s nsors TABLE 8 SENSOR RESISTANCE VALUES Resistance in Ohms between COMMON and TAP Terminals 5 3 6 1 7 2 82 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 4 15 8 19
252. lockwise lengthens the link The opposite motion shortens it The range of adjustment is 300 degrees In the confined space available each wrench stroke imparts 15 degrees movement best Setting issapproximately mid range The present design is shown in Fig 20 This linkage is assembled together on a threaded stud Adjustment is accomplished by removing the upper linkage assembly from the handle assembly and changing the linkage length by turning the upper linkage up or down the threaded stud T m REMOVE THIS HARDWARE 1 UPPER LINKAGE ASSEMBLY _ THREADED iSTUD 19 SECTION 7 Breaker Maintenance Cont 73 DRAWOUT MECHANISM POSITION Maintenance or inspection should be conducted with the breaker on a workbench The drawout mechanism must be placed in the CONNECT position This will deactivate the various interlocks which would otherwise prevent the mechanism or contacts from closing Engage the racking handle with the racking shaft and turn clockwise until it stops Remember before installing the breaker back into its compartment the drawout mechanism must be returned to the DISCONNECT position 7 4 SLOW CLOSING THE BREAKER Closing the breaker slowly while observing the action of the mechanism and contacts is a good way of judging the correctness of mechanical and contact relationships Some of the maintenance procedures described later will involve operatin
253. low voltage power circuit breakers are used for controlling 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 circuits when abnormal conditions occur Among these conditions the more common are short circuits and sustained overloads and under voltages The type 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 subsequently for fast tripping Knowledge of how the breaker is designed and how it operates will enable the owner 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 com mitment to close the breaker at any point upon the activa tion of an automatic trip device i e be Fi nally it also must be able to trip open a closed breaker quickly enough to minimize arc erosion and in sucH a manner as to effec
254. m and contacts will open with Normal speed and force When replacing the hex head bolt turn the camshaft withhthe maintenance handle to align the mating holes the lower spring assembly and camshaft linkage FIG 21 SLOW CLOSING LOWER SPRING ASM HARDWARE 20 SECTION 7 Breaker Maintenance Cont 7 5 PRIMARY DISCONNECTS Primary disconnects are found only on drawout break ers They provide the flexible connection between the breaker line and load terminals and the equipment line and load terminals FIG 22 PRIMARY DISCONNECT ASSEMBLY BOW TIE SPACERS RETAINER FINGERS FIG 24 PARTIAL PRIMARY DISCONNECT ASM The 800 ampere breakers with the exception of AKR 30L use four primary disconnect fingers per terminal The 1600 amp 2000 amp and AKR 30L br akers use eight fingers per terminal Fig 22 shows a line and load end disconnect assembly The line end discon nects on fusible breakers have the spri g pointing downwards otherwise the ar identical BOW TIE SPACERS RETAINER FINGERS FIG 23 PARTIAL PRIMARY DISCONNECT ASM SPACER HOLE RETAINER FIG 25 PARTIAL PRIMARY DISCONNECT ASM 21 SECTION 7 Breaker Maintenance Cont 7 5 1 REPLACEMENT Figs 22 23 24 and 25 show
255. me to keep if from tipping forward Referring to Fig 36 the X relay or K relay and F and G switches are mounted on the same bracket This mounting bracket is fastened to the right hand mechanism side frame by two hex head 1 4 20 screws Removing these screws allows the bracket to be pulled forward from between the mechanism side plates The W relay must also be un fastened from the left side frame to allow enough freedom for all the devices and the wiring harness to be taken from between the side frames With the bracket removed in dividual devices can be replaced easily The closing solenoid is mounted by means of mounting bracket to the bottom of the breaker frame The most con venient way to take off the solenoid is to remove the moun ting bracket and then disconnect the solenoid from the bracket The pin connecting the armature to the closing link must also be removed The charging motor is secured through three spacers to the mechanism frame The front mounting bolt is accessi ble using a socket and universal joint through the opening in the side of the breaker frame upper rear mounting bolt is accessible using a socket and universal joint Over the top of the frame The lower rear mounting bolt cessible using a socket and universal joint through the opening the frame side by the buffer assembly Slow close the breaker to move the flywheel assembly out of the way The ratchet on the camshaft is removed
256. mponent Replacement 732 2 F and G Switch Adjustment 7 13 Mechanism 7 14 Buffer Assembly 7 14 1 Buffer Adjustment 7 15 Trip Latch Adjustment SECTION 8 8 0 CONTACT MAINTENANCE 8 1 Arc Chute Removal amp Inspection 8 2 Contact Adjustment AKR 30 30H amp AKRU 30 8 3 Contact Adjustment AKR 50 50H amp AKRU 50 8 4 Contact Adjustment AKRT 50 50H 8 5 Stationary Contact Identification 8 6 Contact Replacement AKR 30 30H amp AKRU 30 8 7 Contact Replacement AKR 50 50H AKRU 50 amp AKRT 50 50H SECTION 9 9 0 FUSED BREAKER 9 1 Fuse Sizes and Mounting 9 2 Special 2500A Fuse For AKRU 50 9 3 Open Fuse Lockout Device 9 31 and B Breaker OFLO Adjustment 9 32 D Breaker OFLO Adjustment 36 37 38 39 39 41 41 41 43 43 43 Page SECTION 10 45 10 0 TYPE SST OVERCURRENT TRIP DEVICE 45 10 1 Programmer Unit 45 10 2 Current Sensors 46 10 21 Replacement of Current Sensors 48 10 3 Flux Shift Trip Device 48 10 4 Troubleshooting 51 10 4 1 SST Test Set 52 10 4 2 Resistance Values 52 10 43 False Tripping Breakers Equipped with Ground Fault 53 10 5 SST Cabling Diagrams 53 SECTION 11 56 11 0 TYPE ECS OVERCURRENT TRIP DEVICE 56 11 1 ECS Cabling Diagram 57 SECTION 12 58 12 0 TRIP DEVICE 58 12 1 Programmer Unit 58 12 1 1 Fault Trip Indicators 58 12 1 2 Remote Fault Indication 58 12 1 3 MicroVersaTrip Installation 59 12 2 Current Sensors 60
257. n When a normal closing operation occurs the ratchet usually comes to a stop with an arbitrarily designated ratchet tooth No 1 Fig 37 engaged by the holding pawl This tooth is the one which is in line with an imaginary line passing through the centers of the camshaft and the rivet opposite the roller on the ratchet assembly It is a matter of no concern if the action stops on a different tooth but it is important to positively identify tooth No 1 by the method described To check the switch action after tooth No 1 has been identified turn the camshaft with the maintenance handle andcountthe teeth asthey pass the holding pawl By using a continuity tester observe when the switches operate as the ratchet turns The normally open F switch on the left will close and the G switch will open Electrical breakers should operate the switches while moving from tooth No 10 to tooth No 11 If this check shows that an adjustment is needed the switch to be corrected can be moved closer to or farther away from the paddle which operates the switches A very thin open end 5 8 inch wrench will be needed toJ60sen or tighten the nuts which fasten the switches to thesbracket 7 13 DRAWOUT MECHANISM The drawout mechanism shown in Fig 38 moves the breaker through the DISCONNECTED TEST and CON NECTED positions Fig 39 shows how the drawout mechanism is mounted to the breaker As the racking handle is turned the internally threaded tru
258. n be fashioned by forming a hook on the end of a length of 062 diameter steel wire A spring puller is available for this use and may be ordered under Cat No 286A8168G1 3 Clean off the existing lubrication on the stud s pivot area Replace with a small amount of D50HD38 MOBIL 28 before installing new contacts 4 Torque the upper arc runner mounting screws to 45 5 in lbs Torque the lower screw to 35 40 in Ibs The movable contacts are removed as follows referring to Fig 46 1 Using a right angle tru arc pliers remove the trur retainer on the coupling pin Drift out the coupling 2 Remove the pivot pin hardware and spring from one side of the pivot pin Carefully remove the pivot pin 3 Slip out the contact arm 4 Place a thin film of D50HD38 lubricati n on the pivot surfaces of the new arm Clean any existing lubrication from the pivot and place a small amount of D50HD38 on it ware to 90 5 in Ib 8 7 CONTACT REPLACEMENT 50 50H AKRU 50 amp AKRT 50 50H Refer to Stationary Contact Identification Section 8 5 before replacing any stationary contacts The stationary intermediate and main contacts are replaced just like the stationary contacts on the 800 ampere breakers Refer to steps 2 8 in Section 8 6 Referring to Fig 50 the stationary arcing contacts are replaced as follows 1 Remove the arc runner and the flat insulation assembled undemeath the arc runner It is secur
259. n can be directed to the tripsdevice proper Test ing is performed by either of two methods 1 Conduct high current single phase tests the breaker using a high current lowwoltage test set NOTE For these single phase tests special connec tions must be employediforRMS 9 breakers equipped with Ground Fadlt Any single phase input to the programmer circuit will generate an unwanted ground fault output signalwhiC h will trip the breaker This can be nullified eitherby a Using the Ground Fault Defeat Cable as shown in Fig 93 This special test cable energizes the pro grammer circuit in 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 procedtires are detailed in instruction Book GEK 97367 The time current characteristics for the RMS 9 amp Epic MicroVersaTrip Device are given in curves GES 6229 and GES 6228 FIG 104 TEST SET CAT NO TVRMS 13 4 1 RESISTANCE VALUES For use in troubleshooting the RMS 9 current sensors the resistance of the fixed windings is given in Table 15 TABLE 15 FIXED SENSOR RESISTANCE VALUES Ampere Resistance in Ohms Rating Between Terminals 150 10 12 400 27 32 800 58 68 1600 129 151 2000 207 243 The coil resistance of the RMS 9 amp Epic MicroVersaTrip device is approximately 7 ohms 13 4 2 FALSE TRIPPING BREAKERS
260. n of this interlock is shown in Fig 18 A crank which is attached to the racking mechanism shaft is connected to the blocking plate through a link As the shaft turns the blocking plate rotates holding the cover open in the DISCONNECTED position but allowing it to close in the TEST and CONNECTED positions ie FIG 18 DISCONNECT POSITION INTERLOCK 6 5 PADLOCKS Provisions are made in all breakers to use padlocks to prevent the breaker from being closed For non Type Bor D breakers the padlock shackle goes through the TRIP but ton hole and out the slot in the side of the escutcheon For Type B or D breakers the padlock shackle goes through the TRIP button hole and out the RACKING SCREW cover hole in the deep escutcheon In either case the shackle holds the TRIP button in keeping the mechanism trip free 17 SECTION 6 Interlocks Cont 6 6 KEY INTERLOCK STATIONARY BREAKER The function of the Key Interlock is to prevent an open breaker from being closed when the lock bolt is extended and its key is removed The operation of this interlock is shown in Fig 19 When the breaker is in the OPEN position the end plate assembly on the main shaft pivots the lever counter clockwise This removes the pin on the lever from blocking the lock bolt Extending the lock bolt rotates the linkage which moves the trip shaft preventing the mechanism from closing the breaker i Pin Lever 26
261. n the locklever is in its activated position it holds the breaker mechanism latch in the tripped position Check that TRIP button shaft and shunt trip operations besides tripping the breaker displace the side latch and prevent the bell alarm switch from operating The other trip devices and interlocks must activate the bell alarm when they open the breaker The bracket assembled to the TRIP button shaft must be adjusted so that it will displace the side latch wh n or before the shaft opens the breaker Maintain a 030 inch minimum gap between the bracket and the side latch when the breaker is closed A 187 inch depression ofthe TRIP button must not trip the breaker but a 275 6 depres sion must trip the breaker and side latch W RELAY X RELAY is shown in Fig 36A FIG 36 ELECTRICAL CONTROL COMPONENTS 7 11 3 REPLACEMENT The bell alarm is mounted on the right4and side of the breaker at the rear of front frame It is located under the mechanism main shaft The bell alarm is removed by passing it through a cutout in the rear bend of the front frame slipping it between the front frame and trip shaft and out through the bottom of the breaker as follows 1 Remove the 4 bell alasm mounting screws from the bottom of the front frame 2 If the crank which 45 the main shaft has a bell alarm activating pin assembled to both sides remove these pins 3 Insert the flat of theima
262. nal Check 7 8 3 Adjustments Static Time Delay Undervoltage Adjustments Electric Lockout Device Bell Alarm 7 11 1 Operation 7 11 2 Adjustments 7 11 3 Replacement Electrical Control Component 7 12 1 Component Replacement 7 12 2 F and G Switch Adjustment Drawout Mechanism Buffer Assembly 7 14 1 Buffer Adjustment Trip Latch Adjustment SECTION 8 8 0 8 1 82 8 3 84 8 5 8 6 8 7 CONTACT MAINTENANCE Arc Chute Rernoval amp Inspection Contact Adjustment AKR 30 30H amp AKRU 30 Contact Adjustment AKR 50 50H amp AKRU 50 Contact Adjustment AKRT 50 50H Stationary Contact Identification Contact Replacement AKR 30 30H amp AKRU 30 Contact Replacement AKR 50 50H AKRU 50 amp AKRT 50 50H SECTION 9 9 0 9 1 9 2 9 3 FUSED BREAKER Fuse Sizes and Mounting Special 2500A Fuse For AKRU 50 Open Fuse Lockout Device 9 3 1 Type A and B Breaker OFLO Adjustment 9 3 2 Type D Breaker OFLO Adjustment Page SECTION 10 45 100 55 OVERCURRENT TRIP DEVICE 45 10 1 Programmer Unit 45 10 2 Current Sensors 46 10 2 1 Replacement of Current Sensors 10 3 Flux Shift Trip Device 48 10 4 Troubleshooting 51 10 4 1 SST Test Set 52 10 4 2 Resistance Valve 52 10 4 3 False Tripping Breakers Equipped with Ground Fault 53 10 5 SST Cabling Diagrams 53 SECTION 11 56 110 ECS OVERCURRENT TRIP DEVICE 56 111 ECS Cabling Diagrams 57 SECTION 12 58 12 0 MICROVERSATRIP TRIP DE
263. nce the gap dimension is set verify that the torque required to just turn the adjustment nut is greater than 40 in lbs If less torque is required carefully add LOCTITE 220 or 290 to the adjustment nut threads Wipe off any excess LOCTITE Once the LOCTITE is set recheck the torque value up to 40 in Ibs but do not break loose 5 Repeat above procedure on the other pole units 6 Trip the breaker WIPE ADJUSTMENT NUT RETAINER OUPLING PIN CONTACT WIPE ADJUSTMENT SCREW ADJUST GAP AT MEASUREMENT POINT TO 060 020 UPPER CONTACT PIVOT STUD 0 250 MEASUREMENT POINT 45 WIPE ADJUSTMENT 800 AMP CONTACT STRUCTURE SPRING PIVOT PIN FIG 46 WIPE ADJUSTMENT NUT 800 AMP CONTACT STRUCTURE 34 SECTION 8 Contact Maintenance Cont ARC RUNNER CONTACT SPRING STATIONARY ARCING CONTAGT STATIONARY MAIN CONTACT MOVABLE CONTACT ARM FIG 44A AKR30 AKRU30 ARC RUNNER CONTACT P SPRING STATIONARY ARCING CONTACT 1 y STATIONA MOVABLE lt CONTACT CONTACT FIG 44 AKR 30H 800 AMP CONTACT STRUCTURES 35 SECTION 8 Contact Maintenance Cont 8 3 CONTACT ADJUSTMENT AKR 50 50H amp AKRU 50 The contact structure shown in Fig 47 is used by all AKR50 breaker types This structure uses two movable contact arms Each arm acts against a stationary arcing a stationary intermediate and three
264. nd AKRT 50H main and intermediate contacts are rectangular but the main contacts have two of their corners notched The intermediate contacts have all four corners notched AKR 30L AND 1600 2000 AMP 800 AMP MAIN MAIN EXCEPT AKR 301 800 AMP ARCING EXCEPT 30L AKR 30L AND 1600 2000AMP INTERMEDIATE FIG 49 STATIONARY CONTACT CONFIGURATION 8 6 CONTACT REPLACEMENT AKR 30 30H 30L amp AKRU 30 Refer to Stationary Contact Identification Section 8 5 before replacing any stationary contacts The stationary contacts are held in place by the contact springs which pivot the contacts against the contact stop refer to Fig 45 To replace contacts 1 Remove the arc runner It is secured by two screws into the base and one screw into the contact stop 2 Release each contact spring by holding the contact extending the spring and removing it from the contact The end pieces on each spring have a small hole for inserting a spring puller A suitable puller can be fashioned by forming a hook on the end of a length of 062 diameter steel wire A spring puller is available for this use and may be ordered under Cat No 28648168061 3 Clean off the existing lubrication on the stud s pivot area Replace with a small amount of D50HD38 MOBIL 28 before installing new contacts 4 Torque the upper arc runner mounting screws to 45 5 Torque the lower screw to 35
265. ndition It does not cover every Contact the Customer Support at 800 843 3742 if the problem is not resolved by these procedures Symptom Possible Cause Corrective Action 1 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 com municate with the Monitor POWER LEADER Distribution Software or FPU Current readings are incorrect Voltage readings are incorrect kW legend is flashing Ov rload target is flashing by itself Line current is below 2096 of S MicroVersaTrip Plus External 24 Vdc is absent MicroVersTrip 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 5 l werthan 2 0 Trip unit address incorrect 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 At least 20 of the current sensor rating S must be flowing throughathe breaker to activate the display If powerthe trip unit with the Test Kit or external battery pack Check that the control power supply is present and
266. ne 8 Outputs 11 12 Homnet 9 Spare 1 VB 4 VA 2 24 Ret 3 24 VDC NOTE LOCATION OF PIN 1 FIG 109 PROGRAMMER SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND EPIC MVT SECTION 14 MicroVersaTrip Plus and MicroVersaTrip 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 110 shows location of features on programmer See user manual GEH 5891A 14 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 readout oftrip settings 3 phase ammeter and trip indicators are standard as is a clear plastic cover with provisions for sealing to allow tamper resistant installa tion The trip unit digitally measures the current waveform in each phase to determine the true RMS value of the current regardless of the waveshape MicroVersaTrip Plus trip units provide accurate predictable overload and short circuit protection for distribution systems that in cludeacand dc variable speed drives rectifiers induction heating and other loads that cause high harmonic distor tion as well as standard circuit They provide maximum breaker to breaker selectivity and custom load protec tion Short time and ground fault functions include the fl
267. ne ofthecritical 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 ofthevitalrole of these devices it is important that a periodic test program be followed As was outlined above it is recog nized 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 recommenda tion that untiltheuserhas accumulated enough experience to select a test interval better suited to his individual requirements all significant calibrations be checked atan 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 afe provided by supplied instruction books Instruction books supplied by manufatt rers address components that would normally require service or main tenance during the useful life ofthe 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 deterioration of_ any part
268. ng plug tabs with the extractor and pull the plugteut Be sure to grab the tabs and not the front coverof the rating plug or the plug may be damaged Rejection features are provided on all rating plugs to prevent application mismatches Never force a rating plug int place Refer to Table 16 to find the appropriate rating plugs for each sensor rating and breaker frame lf areplacement rating plug has a different rating than the plug that was removed follow the appropriate setup procedure GEH 5891A to enter the new rating Donotattempttousearating plug from a Spectra RMS breaker or a MicroVersaTrip Plus or MicroVersaTrip Unit TABLE 16 Sensor Plug Breaker Cat No Rating Amps Rating Frames TR4B150 TR4B200 1600 TR4B225 2000 AKR30 AKR30H TR4B250 AKR30L TR4B300 TR4B400 TR8B300 TR8B400 TR8B450 TR8B500 TR8B600 TR8B700 TR8B800 TR16B600 TR16B800 TR16B1000 TR16B1100 TR16B1200 TR16B1600 TR20B750 TR20B800 TR20B1000 TR20B1200 TR20B1500 TR20B1600 TR20B2000 AKR30 AKR30H AKR50S AKR50H AKR50 AKR50H AKRT50H 81 SECTION 14 MicroVersaTrip Plus and MicroVersaTrip PM Trip Units 14 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 Protection Lon
269. ngle phase three wire or three phase four wire sys tems Itisinserted into theneutral conductorandtherefore iSjseparately 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 107 Theneutral sensorisan electrical duplicate ofthe phase sensor Therefore when phase sensors are charged the neutral sensor must be correspondingly changed 73 eB 9 FLUXSHIFT PROGRAMMER TRIP DEVICE BREAKER BACK FRAME LEFT POLE NEUTRAL SENSOR DISCONNECT th l EOUIPMENT MOUNTED y NEUTRAL SENSOR EON OARECTOR PROGRAMMER 13502669 CONNECTOR 4 WIRE LOAD FIG 107 CABLING DIAGRAM RMS 9 amp EPIC MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD 4 WII LOAD PROGRAMMER UX SHIFT TAIP DEVICE CANL SE 114 s BREAKER BACK FRAME gt 2 LEFT POLE SENSOR PROGRAMMER ec CONNECTOR 1 350356 9 CONNECTOR LOAD FIG 108 CABLING DIAGRAM RMS 9 amp EPIC MICROVERSATRIP WITH GROUND FAULT ON 4 WIRE LOAD BREAKER REVERSE FEED 76 Socket PIN No 5 Zone Zone 6 Inputs Selective Interlock 7 Zo
270. nnion moves on the screwathreads rotating the hex shaft on the ends of which are fastened the arms which engage the fixed pins in the dfawout enclosure The trunnion travels between the two jamb nuts on the end of the screw and the adjustment sleeve which stops the trunnion movement at the other extreme point of its travel The trunnion 15 against the jamb nuts when the breaker is fully acked out and against the sleeve when fully racked ing The racking mechanism is adjusted at the factory as sembly operation 50 that the action is stopped in either direction at the precisely correct point The jamb nuts are set so that trunnion is against them the relation between the arms and the equipment pins they engage is shownhin Fig 38 The length of the sleeve which is free to slide onthe threaded shaft is controlled by the amount of thfead engagement between the sleeve and its collar This length is adjusted to stop the trunnion when the distance Detween the ends of the equipment and breaker studs is 032 to 218 After this adjustment is made the sleeve and its collar are locked together by the set screw SE 0 1 FIG 37 LOCATION NO 1
271. note the position of the ratchet s roller or mark the ratChet sthub and the camshaft When replacing the satchet bessure it is oriented with respect to the camshaft as it was originally and not displac ed 180 degrees Align th mark made on the hub with the mark the camshaft of position the roller as it was If the ratchet is displaced 180 degrees the holes in the ratchet s hub will not completely line up with the holes in the cam shaft The driving pawl is assembled to the charging motors drive pin as ishown in Fig 36B To replace the driving pawl 1 Remove the charging motor 2 Remove the retaining ring from the drive pin Slip off the components 3nWipe off any grease or dirt from the drive pin DO NOT LUBRICATE 4 Install the components as shown 28 4 SPRING WASHER 5 WASHER 032 6 MOTOR DRIVE PIN FIG 36B DRIVING PAWL ASSEMBLY DETAILS 1 RETAINER RING 2 WASHER4010 3 PAWL ASM The holding pawl pivots on pin which is assembled to the mechanism frame Refer to Fig 36C To replace the holding pawl 1 Remove the front escutcheon for accessibility 2 Using the maintenance handle rotate the ratchet enough to disengage the holding pawl 3 Remove the retaining ring and washer from the pivot pin 4 While holding the spring pressure from the holding pawl remove the existing pawl and slip on the new pawl 5 Install the washer and retaining ring 6 Verify that the holding pawl engages
272. ns 3 Insert the flat of the maintenance handle between the top of the left h nd side buffer block and the end plate assembly This should eliminate any interference from the main shaft during the bell alarm removal 4 The trip shaft must be moved to allow the bell alarm to fit beteen it and the front frame Remove the retaining ring holding the right hand trip shaft bearing to the mechanism frame Slide the bearing from the frame and along the trip shaft There will now be enough trip shaft movement to slip the alarm past 5minstall the replacement bell alarm in reverse order 6 Check the adjustments given in Section 7 11 2 A bell alarm with a lockout assembly or a bell alarm in stalled on a 2000 amp frame AKRT 50 50H breaker may not work with the above procedure If this is the case the breaker front and back frame will have to be seperated 7 12 ELECTRICAL CONTROL COMPONENTS The operation of the electrical control components is described in Section 5 2 The location of these components is shown in Fig 36A CHARGING MOTOR G SWITCH F SWITCH FIG 36A ELECTRICAL CONTROL COMPONENTS 27 SECTION 7 Breaker Maintenance Cont 7 12 1 COMPONENT REPLACEMENT To gain access to the electrical control components the breaker s front escutcheon must be removed Type B and D breakers require that both the deep molded escut cheon and the shallow steel escutcheon be removed Before
273. nt and the A contacts towards the back A contacts are closed when the breaker is closed B contacts are closed when the breaker is open To check the setting arrange the breaker for slow close as described in Section 7 4 Through the use of a continuity tester observe the position of the breaker con tacts when the switch A contacts touch Atthis point the breaker sarcing contacts must be within 250 to 500 of closing Adjustment is made by disconnecting the upper end of the adjustable link and varying its length as required ELECTROSWITCH TYPE 101 Adjustment is the same as the GE SB12 except that when the switch A contacts touch the breaker arcing contacts must be within 0 to 250 inches of closing 7 7 SHUNT TRIP The shunt trip device opens the breaker when its coil is energized An A auxiliary switch which is closed only when the breaker is closed is in series with the device coil Connections are made to the external tripping source through secondary disconnects on drawout breakers or to the terminal board on stationary breakers The shunt trip is mounted on the underside of the breaker front frame as shown in Fig 29 A second shunt trip may also be mounted to the frame see Fig 30 if a se cond m ona device isn t already installed see Sec tion 7 8 7 7 1 REPLACEMENT If it is necessary to replace or add one of these devices the easiest procedure is to remove the mounting bracket shown in
274. nt is complete verify that the torque required to just tum the adjustment nut is greater than 40 in Ibs If less torque is required carefully add LOCTITE 220 to the adjustment nut threads Wipe off any excess LOC TTE Once the LOCTITE is set recheck the torque valve 10 Trip the br aKer remove the insulating strips 1i4ZRepeat the above procedure on the other two poles FIG 47 1600 AMP CONTACT STRUCTURE 8 4 CONTACT ADJUSTMENT AKRT 50 50H The contact structure shown in Fig 48 is used by all AKRT50breakertypes This structure is similar to the AKR 50 structure There are two movable contact arms each acting against single stationary arcing and intermediate contacts and four not three stationary mains There are two designs used to connect the movable contact arms to the insulated link This results in two con tact adjustment procedures depending on which design the breaker has In the original design the two movable contact arms are pin coupled to a metal driving link whose opposite end is threaded and screws directly into the insulating link This arrangement omits the wrench operated wipe adjustment stud providedon the AKR 30 and 50 frames Instead wipe is adjusted by detaching the driving link from the movable contact arms and then rotating it with respect to the insulat ing link On the AKRT 50 the proper amount of contact wipe exists if on a closed breaker all of the stationary main contacts have move
275. nts can verify the ability of the Flux Shift Trip Device to trip the breaker and in addi tion include means for continuity checking the phase sensors A TAK TS1 Test Set is shown in Fig 67 The time current characteristics for the SST Trip Device are given in curves GES 6033 GES 6034 and GES 6035 FIG 67 SST ECS TEST SET CAT NO TAK TS1 51 SECTION 10 Type SST Overcurrent Trip Device Cont 10 4 1 SST TEST SET The TAK TS1 and TAK TS2 Test Sets are portable in struments 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 addi tion includes means for continuity checking the phase sensors A TAK TS1 Test Set is shown in Fig 67 The TAK TS2 functions identically to and supersedes the TAK TS1 device The TAK TS2 can also test the Ver saTrip Mod 2 trip device WARNING BEFORE CONNECTING THE TEST SET TO THE BREAKER TRIP DEVICE SYSTEM EN SURE THAT THE CIRCUIT BREAKER IS COM PLETELY DISCONNECTED FROM ITS POWER SOURCE ON DRAWOUT EQUIPMENT RACK THE BREAKER TO ITS DISCONNECTED POSITION VERIFY THAT THE BREAKER IS TRIPPED Either of two test modes may be employed A Programmer Unit Only These tests are con ducted with the programmer unit disconnected from the breaker During test the unit can remain attached to the breaker or may be comp
276. o 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 through the 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 fumished with a thermotector control unit Overheating of motor win dings causes the thermotector imbedded in the motor win dings to open This de energizes the undervoltage device on the breaker and drops the motor load 7 9 1 ADJUSTMENTS In the event the system fails the following checks are recommended to determine whether the undervoltage device on the breaker of the static time delay unit is the faulty component 1 Check input voltages across terminals 1 and 2 on the Static box See Table 5 for these values 2 Check output voltages on terminals 4 and 5 with the undervoltage device connected See Table 5 for values TABLE 5 TIME DELAY UNITS CONTROL VOLTAGE TERMINALS 182 YAKYOVT __ TAKYUVT 2 250VDC APPROXIMATE STEADY STATE NOMINAL DC COIL DC OPERATING VOLTAGE RESISTANCE TERMINALS OHMS 4 amp 5 25 C TAKYUVT 3 208 240 110 125 25 SECTION 7 Breaker Maintenance Cont s 3 Check resistance of the disconnected undervoltage devic
277. ocation If this is not possi ble 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 insula tion 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 SECTION 4 Drawout Breaker Interchangeability In general drawout breakers of the sametype and rating are interchangeable in their equipment compartments drawout breakers of different frame sizes are not inter changeable To prevent insertingsthe wrong type breaker into a drawout compartment suitable rejection hardware is affixed to each breaker and its compartment Figure 7 shows a typical rejection bracket which aligns with re
278. ons The closing spring is in the charged position for all of these details Closed Position As shown in Fig 10A the movable contacts are pushed against the stationary contacts by the toggle linkage The toggle linkage is held in position through the engagement of its cam rollers item no 5 with the prop item no 2 and the secondary latch roller item 6 and secondary latch 14 and trip latch 11 Tripped Position The mechanism goes from the Closed position to the Tripped position shown in Fig 10B when the trip shaft item no 10 is rotated by either the manual trip button or one of the other trip devices The trip latch item no 11 is assembled to the trip shaft When the trip shaft rotates the trip latch disengages from the secondary latch roller The secondary latch pivots resulting in the collapse of the toggle linkage This collapse along with the opening spring item no 15 shown in Fig 10 C causes the breaker contacts to open Reset Position The mechanism is shown in Fig 10C The closing cam item no 3 which is assembled to the cam shaft item no 4 isrotated by the charging motor manual operating handle or maintenance handle The cam engages the cam roller and partially extends the toggle linkage This allows the secondary latch item 1419 pivot against the front frame as shown leaving between the trip latch and secondary latch roll r The secondary latch is now in a position to engage With b
279. ose the breaker to move the flywheel assembly outtof the way The ratchet on the camshaft is removed by driving out the roll pin which fastens it to the camshaft Before this can be done the charging motor must be removed and the closing spring arranged for slow cloSinig described earlier Turn the camshaft using the maintenance handle until the roll pin is well situated turna he camshaft to gain enough space for the roll pin to clear the breaker frame Before removing the ratchet notesthe position of the ratchet roller or mark the ratchet hub and the camshaft When replacing the ratehetbe sure it is oriented with respect to the camshaft as it was originally and not displac ed 180 degrees Align the mark made on the hub with the mark on the camshaft or position the roller as it was If the ratchet is displaced 180 degrees the holes in the ratchet hub will not completely line up with the holes in the cam shaft The driving pawl is assembled to the charging motor drive pin as sHown in Fig 36B To replace the driving pawl 1 Remoyesthe charging motor 2 Remove the retaining ring from the drive pin Slip off the components 3 Wipe off any grease or dirt from the drive pin DO NOT LUBRICATE 4 Ifistall the components as shown 28 1 RETAINER RING 2 WASHER 010 3 PAWL ASM FIG 368 DRIVING PAWL ASSEMBLY DETAILS 4 SPRING WASHER 5 WASHER 032 6 MOTOR DRIVE PIN The holding pawl pivots on
280. osing the breaker and verifying that all eight stationary main contacts are lifted off their stops Should wipe ad justment appear necessary proceed as follows STATIONARY INTERMEDIATE CONTACTS STATIONARY 723 MAIN O MOVABLE ARCING CONAC ta _ WIPE ADJUSTMENT NUT 1 Open the breaker 2 Arrange the breaker for slow closing 3 Selecting one pole drift out the coupling pin and detach the driving link from the movable contact arms 4 Screw the driving link completely i to the insulating link 5 Back out the driving link two_a d one half turns Ex ceed this by whatever amount is necessary to properly position the link within the movable contact arms 6 Install the coupling pin and retainer rings 7 Using the maintenance handle slow close the breaker and observe that all eight stationary main contacts move away from their stops If this condition is not achieved openthe breaker again remove the coupling pin and back out the driving link an additional half turn 8 Reassemble reclose the breaker and recheck wipe 9 Repeatithe above procedure on the other two poles Inithe existing design the metal driving link uses the Same adjustment as the AKR 50 To perform the wipe adjustment on this design follow the procedure for the AKR 50 Section 8 3 STATIONARY CONTACTS ARC RUNNER FIG 48 2000 AMP CONTACT STRUCTURE 37 SECTION 8 Contact Maintenance
281. oth the trip latch and cam roller The breaker closes when the closing spring dischatges and rotates the cam item 3 against the cam roller item 5 The toggle linkage is fully extended pivoting th secon dary latch from the front frame and engaging it with the trip latch and cam roller as shown in Figx40A When the breaker is closed the closing spring discharged the upper cam roller temi 5 is supported by the cam rather than the prop This is the position the mechanism must be in to check contact adjustment refer to Section 8 FIG 10A CLOSED 10 11 14 5 FIG 10C RESET 2 Prop 11 Trip Latch 3 Cam 12 Insulated Coupling 4 Camshaft 13 Main Shaft 5 Cam Roller 14 Secondary Latch 6 Secondary Latch Roller 15 Opening Spring 10 Trip Shaft 5 4 CHARGING USING THE MAINTENANCE HANDLE The closing spring on electrically operated breakers can be manually charged by using the maintenance handle 568B386G1 as shown in Fig 11 The triangular socket in the maintenance handle mates with the mechanism cam shaft extension on the front right side of the breaker Using the knob on the handle it will be necessary to align this socket to fit on the end of the shaft when the handle is positioned as shown ree FIG 11 MAINTENANCE HANDLE INSTALLED ON CAMSHAFT EXTENSION 13 SECTION 9 Breaker Operation Cont FIG 12 ROLLER ENGAGED WITH CLOSING PROP There is a
282. ought out the bottom of the MicroVersaTrip programmer as shown in Fig 78 This switch lead harness is plugged into the mating connector on the breaker see Fig 79 The switch leads are brought out from the breaker through the Programmer Secondary Disconnect shown in Fig 80 The zone selective interlocking function wir ing is also brought out through this disconnect See Figs 95 and 96 for the remote fault indication and zone selective interlocking cable diagrams ovER stom T GROUND OAD CIRCUIT FAULT FAULT TRIP ANNUNCIATOR REMOTE FAULT INDICATION FIG 78 MICROVERSATRIP W REMOTE FAULT INDICATION HARNESS FIG 79 PROGRAMMER SECONDARY CONNECTOR REMOTE FAULT INDICATION DISCONNECT 80 REMOTE FAULT INDICATOR DISCONNECT 1218 MICROVERSATRIP INSTALLATION The programmer mounts to the upper left of the breaker as shown in Fig 81 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 There are two programmer mounting designs in use The difference in the designs is in the operation of the locking lever see Fig 82 Installation using eac
283. ount 15 necessary to properly position the link withinZthe movable contact arms 6 Install the coupling pin and retainer rings 7 Using the maintenance handle slow close the breaker and observetthat all eight stationary main contacts move away ffrom their stops If this condition is not achieved openithe breaker again remove the coupling pin and back o t the driving link an additional half turn 87 Reassemble reclose the breaker and recheck wipe 9 Repeat the above procedure on the other two poles existing design the metal driving link uses the same adjustment as the AKR 50 To perform the wipe adjustment on this design follow the procedure for the AKR 50 Section 8 3 STATIONARY CONTACTS ARC RUNNER FIG 48 2000 AMP CONTACT STRUCTURE 37 SECTION 8 Contact Maintenance Cont IDENTIFICATION The stationary arcing intermediate and main contacts each have a different function during current conduction and current interruption For this reason these contacts are made using different material compositions Also the different functions require that the contacts be replaced in configurations shown in Figs 44 47 and 48 N Fig 49 shows the stationary contacts and how they 8 5 STATIONARY CONTACT differ from one another The AKR 30 and 30H main and arcing contacts are rectangular but the arcing contacts have two oftheir corners notched The AKR 30L AKR 50 AKR 50H 50 a
284. out After the keyS are removed pull the disconnect assembly off the end of the fuse tang NOTE This removal does not disturb the disconnect s clamping force adjustment by Remove the upper barrier c Detach the inboard end of the fuse by removing the two 2 inch 13 bolts A ratchet and socket with a short extension will be requied d Remove the heat sink e Remove the fuse f Install the new fuse by reversing the disassembly procedure Ensure that the mating faces of the fuse and heat sink are clean ADAPTER BARS COPPER FIG 52 300 THRU 600 AMP CLASS J FUSE MOUNTING 41 CAUTION WHEN REPLACING THE FUSE IN THE LEFT POLE FRONT VIEW OF THE BREAKER SECTION 9 Fused Breakers Cont NOTE PARTICULARLY THAT THIS FUSE IS MOUNTED DIFFERENTLY THAN THE OTHER TWO FUSES AS SHOWN IN FIG 54 FOR THIS PHASE THE FUSE IS ROTATED 180 DEGREES ABOUT ITS AXIS SO THAT ITS INBOARD TANG 16 i POSITIONED BENEATH THE BREAKER TUD THIS TANG IS OFFSET WITH RESPECT TO THE OPPOSITE END SO THAT ROTATING THE FUSE DOES NOT ALTER THE POSITION OF THE PRI T 5 c c i e MARY DISCONNECT ew Pu z FRONT OF BREAKER FOR THIS POLE ONLY Nea e FUSE TANGS FUSE IS ROTATED 180 54 BREAKER POSITIONED ON POSITION TANG GET E STUD OF BREAKER STUD BENEATH BREAKER STUD SSSR N SS OY Nees gt b ade i 3 1 1 Special 2500 Fuse 4 Upper
285. p to 0 060 0 020 inch by turning the wipe adjustment nut shown in Fig 46 4 Once the gap dimension is set verify that the torque required to just tum the adjustment nut is greater than 40 in lbs If less torque is required carefully add LOCTITE 220 to the adjustment nut threads Wipe off any excess LOC TITE Once the LOCTITE is set recheck the torque valve 5 Repeat above procedure on the other pole units 6 Trip the breaker mm WIPE ADJUSTMENT NUT M RETAINER COUPLING PIN eA ADJUST GAP AT NT MEASUREMENT SCREW POINT TO 060 x 020 0 250 MEASUREMENT POINT FlG 45 WIPE ADJUSTMENT 800 CONTACT STRUCTURE SPRING E PIVOT PIN FIG 46 WIPE ADJUSTMENT NUT 800 AMP CONTACT STRUCTURE SECTION 8 Contact Maintenance Cont AN eee a CONTACT SPRING STATIONARY MAIN MOVABLE CONTACT ARM H E RUNNER H ui STATIONARY ARCING CONTACT DER URN STATIONARY CONTACT way MOVABLE CONTACT 488 f ARM ay Sa FIG 448 AKR 30H 800 AMP CONTACT STRUCTURES 35 SECTION 8 Contact Maintenance Cont 8 3 CONTACT ADJUSTMENT AKR 50 50H amp AKRU 50 The contact structure shown in Fig 47 is used by all 50 breaker types This structure uses two movable contact arms Each arrn acts against a stationary arcing a stationary intermediate and three stationa
286. 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 clear cover to the face plate The SST programmer units can be optionally equipped with trip indicators targets These are pop out chanically resettable plungers located across the top of the programmer s front Units with a ground faultelement employ three targets from left to right the first iStor Over load the second for short circuit actuated by the short time and instantaneous elements and the third forground fault The latter is omitted on units without ground fault FLUX SHIFT TRIP COIL DIFFERENTIAL TRANSFORMER UP amp DELAY SHORT INSTANTANEOUS T PICKUP a ROUND FAULT GI PICKUP amp DELAY WHEN USED REGULATED 48 VOC POWER SUPPLY a ee ae a ee FIG 57 SST BLOCK DIAGRAM 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 lower right of the breaker as shown in Fig 59 The bracket attached to the topof the programmer see Fig 58 engages with a bracket mounted to the underside of the breaker s front fr
287. r and proceed as follows 1 Loosen the locking nut 2B 2 Manually lift the trip rod and vary the position of the ad justing 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 over travel of the trip rod should be obtained 15 4 2 REPLACEMENT After removing the wiring for the potential coil the reverse cur rent device can be removed and replaced by following the pro cedure outlined for replacing the series overcurrent device See Section 15 6 For wiring see Fig 125 15 5 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 overload occurs This device will not trip the breaker on ver load it will trip on instantaneous only The switchette feature is available only in type EC 1 devices The switchette is used in one pole and EC 1 tripsin th other poles For the alarm to be effective in indicating theyoverload before the other poles trip the breaker the devige must have less time delay than the other two poles thissis accomplished by using a lower characteristic on the alarm device than the other poles or setting the alarm devices
288. r limit of band Time delay shown at lower limit of band TABLE 10 SENSOR RESISTANCE VALUES Ampere Resistance in Ohms Rating between Terminals 100 30 3 4 150 4 4 5 0 225 4 8 5 6 300 64 72 400 6 7 7 8 600 6 4 7 6 800 8 8 10 4 1200 13 5 15 8 1600 19 4 22 8 2000 29 5 34 5 11 1 ECS CABLING DIAGRAM eB eC PROGRAMMER A A FLUX SHIFT UNIT BREAKER BACK FRAME TRIP DEVICE LEFT POLE CURRENT SENSOR 48V dc TO SCR ANODE T T CONNECTOR FIG 75 CABLING DIAGRAM FOR ECS TRIP DEVICE 57 SECTION 12 MicroVersaTrip Trip Device The MicroVersaTrip is a solid state direct acting self powered trip device system MicroVersaTrip system consists of the MicroVersaTrip programmer current sensors and a flux shifter trip device Fig 76 shows a block diagram of the system 12 1 PROGRAMMER UNIT Fig 77 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 func tions three mechanical fault indicators local and remote a long time pickup LED indicator local and remote and a zone selective interlocking function All adjustable programmer functions are automa
289. r tooth No 1 has been identified turn the camshaft with the maintenance handle and count the teeth as they pass the holding pawl By using a continuity tester observe when the switches operate as the ratchet turns The normally open F switch on the left will close and the G switch will open Electrical breakers should operate the switches while moving from tooth No 10 to tooth No 11 if this check shows that an adjustment is needed the Switch to be corrected can be moved closer to or farther away from the paddle which operates the switches A very thin open end 5 8 inch wrench will be needed to JOosen tighten the nuts which fasten the switches to the bracket 7 13 DRAWOUT MECHANISM The drawout mechanism shown in Fig 38 moves the breaker through the DISCONNECTED TEST and CON NECTED positions Fig 39 shows how the drawout mechanism is mounted to the breaker As the racking handle is turned the internally threaded trunnion moves on the screw threads rotating the hex shaft on the ends of which fastened the arms which engage the fixed pins in drawout enclosure The trunnion travels between the two jamb nuts on the end of the screw and the adjustment sleeve which stops the trunnion movement at the other extreme point of its travel The trunnion is against the jamb nuts when the breaker is fully sacked Out and against the sleeve when fully racked in The racking mecha ism is adjusted at the facto
290. releases the prop discharging the closing spring The Closing Spring interlock should be adjusted to cause the closing spring to discharge when the racking mechanism is a minimum of 1 and a maximum of 2 turns short of the fully racked out position In this position the racking handle can no longer be turned If adjustment is required use the linkage adjusting screws shown in Fig 17 Note undue force on the racking handle at the fully racked out position will cause the lever to move past the pin on the armature linkage This will bind up the overall interlock Under these conditions continued application of this force will deform the linkage assembly A later lever design shown in Fig 17 includes a stop which pre vents the lever from moving past the pin When the pin is against this stop undue force may still deform the link age assembly Breaker Racked Lever And Armature Linkage Pin Not Engaged ADJUSTING SCREwS Breaker Being Racked Out Lever Activates Armature Linkage FIG 17 CLOSING SPRING INTERLOCK 6 4 DISCONNECT POSITION INTEREOCK The function of the Disconnect Position Interlock is to block the RACKING SCREW cover open when the racking mechanism is in the DISCONNECTED position When the cover is held open the TRIP button is depressed The mechanism is held trip free and there is no contact arm movement when the closing spring is discharged by the Closing Spring interlock The operatio
291. removing the front escutcheon on Type or B breakers a supporting block should be placed under the front frame to keep if from tipping forward Referring to Fig 36A the X relay or K relay and F and G switches are mounted on the same bracket This mounting bracket is fastened to the right hand mechanism side frame by two hex head 1 4 20 screws Removing these screws allows the bracket to be pulled forward from between the mechanism side plates The W relay must also be un fastened from the left side frame to allow enough freedom for all the devices and the wiring harness to be taken from between the side frames With the bracket removed in dividual devices can be replaced easily The closing solenoid is mounted by means of mounting bracket to the bottom of the breaker frame The most con venient way to take off the solenoid is to remove the moun ting bracket and then disconnect the solenoid from the bracket The pin connecting the armature to the closing link must also be removed The charging motor is secured through three spacers to the mechanism frame The front mounting bolt is accessi ble using a socket and universal joint through the opening in the side of the breaker frame upperrear mounting bolt is accessible using a socket and universal joint over the top of the frame The lower rear mounting bolt iS ac cessible using a socket and universal joint through the opening in the frame side by the buffer assembly Slow cl
292. rent Rating Delay Sensors Seconds Sensor Current Rating Amps 100 150 100 150 225 300 225 300 or 400 600 300 400 800 600 800 0 10 0 22 0 36 300 400 300 400 600 800 600 800 or 1200 1600 600 800 1200 1600 800 1200 1600 2000 1600 2000 800 1200 AKRT 50 1200 1600 1200 1600 75 3200 2000 3200 2000 3200 1600 2000 1600 2000 3000 4000 3000 4000 1 Time delay shown at 600 of setting at lower limit of each band 2 Time delay shown at lower limit of each band All pickup tolerances 10 Ground Fault pickup not to exceed 1200 amperes 2 22 24 26 28 30 34 37 X 1 5 2 2 5 3 4 5 7 9 X 2 22 24 26 28 3 X C current setting X sensor current 61 SECTION 12 MicroVersaTrip Trip Device Cont soe RAN 129 1600 com MAL A TAPPED COMMON TERMINAL FIG 83 MICROVERSATRIP PHASE SENSORS SPECIAL WINDING CONNECTIONS AMPERE RATING CONNECTIONS FIG 84 H OPTION PHASE SENSOR 62 FIG 85 TYPICAL NEUTRAL SENSOR A BREAKER MOUNTED RIGHT SIDE B EQUIPMENT MOUNTED FIG 86 NEUTRAL SENSOR SECONDARY DISCONNECT Since the neutral sensor is mounted separately from the breaker a disconnect meansais required to connect its output to the breaker Fig 86 shows the breaker and equipment mounted 4th wire secondary disconn
293. rged on the phase sensors those on the neutral sensor must be correspondingly positioned S eN VVN34O 340338 YaWwvuSonda TWISNI NOLLAWS FIG 82 MICROVERSATRIP RMS 9 AND POWER LEADER MOUNTING BRACKET 60 TABLE 11 TRIP FUNCTIONS AVAILABLE Optional Features ADD TO BASIC FUNCTIONS T G or GR 1 2 BASIC FUNCTIONS STD or S or H or M s oc SE o Long Time Timing Light X X xixi Reret Longtime x iaa Sotme baay X XXL enar Px Px x Pe TT e Adj Long Time Pickup X X X X _ LONG TIME SHORT TIME e Adj Ground Fault Pickup 1PH 2 W 3PH 3 4 W Ground Return e Adj Ground Fault Delay e Trip Indication Targets Overload amp Short Circuit local only local and remote OIL S C and Ground Fault local onlyQ local and remote e Zone Selective Interlock Ground Fault Short GROUND FAULT OTHER FUNCTIONS 1 Short Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required TABLE 12 MICROVERSATRIP TRIP CHARACTERISTICS Ground Fault Adjustable Instantaneous Pickup Short time Multiple Pt of Sensor Rating Seconds x Curr nt Setting Multipie Pickup Multiple of Sensor Current Rating x Fixed Maximum Sensors X Pickup Multiple of Cur
294. rip uses a phase and neutral sensor Fig 101 shows the phase sensors See Section 13 5 for cabling diagrams FIG 100 AKR 7D 30 The fixed phase sensors have a polarity associated with their windings Their COMMON terminal is the right hand terminalas shown Fig 101 A white wire with aterminal will be connected to this COMMON terminal All phase sensors 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 102 shows the connec tions for the additional H option windings 71 SECTION 13 RMS 9 amp Epic MicroVersaTrip TABLE 11 TRIP FUNCTIONS AVAILABLE Optional Features ADD TO BASIC FUNCTIONS G or GR 1 2 lt Z1 or Z2 or Z BASIC FUNCTIONS Adjustable Current Setting Adj Long Time Pickup e AdjLong Time Delay Long Time Timing Light e Remote Long Time Timing Light Adj Short Time Pickup e Adj hort Time Delay e Short Time 121 Switch 9 Adj Instantaneous Pickup NEOUS e Adj High Range Instantaneous
295. ro volts across the urdervaitaye coil to the breaker contacts open ing This time should be 20 to 50 milliseconds If steps 1 and 2 above are acceptable but the response time is too high refer to Section 7 B 3 7 8 3 ADJUSTMENTS It is recommended that the following checks be made at the intervals given in Section 782 1 Hold the armature against the magnet as shown in Fig 32A and check the following The rivet can tum freely b There iS binding between the armature pivot and the Shading ring c There s a 001 to 010 inch clearance between the rivet and armature as shown in Fig 32A This measurement should be made at the outer edge of the armature where its constant radius is closest to the rivet 24 ADJUSTMENT FIG 32A UNDERVOLTAGE DEVICE If excessive clearance or binding exists loosen the screws holding the magnet assembly to the frame and move the magnet up or down as necessary Tighten the screws to 27 to 32 in Ibs 2 The airgap between the armature and magnet with the undervoltage device de energized should be 25 inches Check the gap by inserting a 201 005 diameter gage between the armature and magnet as shown in Fig 32B If necessary reset the air gap adjusting plate so that the gage pin fits Tighten the adjusting plate screw to 9 to 11 inches and cover it with RTV 3 Check the pick up voltage level with the undervoltage device mounted on the breaker Refer to Table
296. round current flowing See cable diagram in Fig 91 The neutral sensor is an electrical duplicate of the phase sensor including taps Therefore when taps are charged on the phase sensors those on the neutral sensor must be correspondingly positioned owuvusdo 340438 15 FIG 82 MICROVERSATRIP MOUNTING BRACKET 60 TABLE 11 TRIP FUNCTIONS AVAILABLE onal Features BASIC FUNCTIONS ADD TO BASIC FUNCTIONS STD or S or H or M L T G or GR A1 or A2 or A3 or A Z1 or Z2 or Z e Adjustable Current Seting x x xi xf M Adj Long Time Pickup 1 I LONG Adj Long Time Delay ixixixix J d j J Long Time Timing Light 1 j J 1 l T Remote Long Time Timing Light 1 xi 1 Adj Short Time Pickup I IXIXIX 1 e WP B SHORT e Ad Short Time Delay t o l TIME D me l L NEOUS Es E T IL e Adj Ground Fault Pickup GROUND 1PH 2 W 3PH 3 4 W FAULT Ground Return Adj Ground Fault Delay e Trip Indication Targets Short Circuit OTHER ocal only FUNCTIONS local and remote OI L S C and Ground Fault Jocal onlyQ local and remote e Zone Selective interlock Ground X S
297. rqu isrequired carefully add LOCTITE 220 or 290 to the adjustmentnut threads Wipe off any excess LOCTITE Once the LOCTITE is set recheck the torque valve 10 Trip the br aker remove the insulating strips 11 Repeat the above procedure on the other two poles IPE AD MENT NUTI FIG 47 1600 AMP CONTACT STRUCTURE 36 8 4 CONTACT ADJUSTMENT AKRT 50 50H The contact structure shown in Fig 48 is used by all AKRT 50breakertypes This structure is similar to the AKR 50 structure There are two movable contact arms each acting against single stationary arcing and intermediate contacts and four stationary mains There are two designs used to connect the movable contact arms to the insulated link This results in two con tact adjustment procedures depending on which design the breaker has In the original design the two movable contact arms are pin coupled to a metal driving link whose opposite end is threaded and screws directly into the insulating link This arrangement omits the wrench operated wipe adjustment studprovided onthe AKR 30 and 50 frames Instead wipe is adjusted by detaching the driving link from the movable contact arms and then rotating it with respect to the insulat ing link On the AKRT 50 the proper amount of contact wipe exists if on a closed breaker all of the stationary main contacts have moved away from their stops This condition can be checked visually by removing the arc quenchers cl
298. rty atmosphere inspections should be more often spections might be monthly under adverse conditions Always inspect the breaker after a short circuit Current has been interrupted SAFETY PRECAUTION BEFORE INSPECTING ORBEGINNING ANY MAINTENANCE WORK ON THE BREAKER IT MUST BE DISCONNECTED FROM ALL VOLT AGE SOURCES BOTH POWER AND CON TROL AND BE IN THE OPEN POSITION A basic inspection should consist of the following a Visual Check Look for dirt grease or otherforeign material any breaker parts Check insulating surfaces for conditions that could degrade insulating properties cracks overheating etc Also check for loose hardware and components on the bottom of the breaker compart ment Loose or damaged control wiring a d similar problem areas should also be checked b Operation Observe feWw close open operations using the operating or maintenance handle If a breaker is seldom operated such that it remains open or closed for a period of six months or more it isfecommended that it be opened and closed several4imesS irf succession Interlocks During the Operational check verify the safety interlocks are properly working d Arc Chutes and Contacts Inspect the condition of the arc chutes and contacts Look for excessive burning or breakage Gheck the amount of contact depression or wipe when the breaker is closed e AcGessories Verify that the various accessories ar
299. rvoltage device Before disassembling the original buffer carefully measure the distance between the faces of the threaded members as shown in Fig 31 and set this dimension carefully on the new assembly Refer to the breaker wiring diagram for the coil lead connections 7 8 1 REPLACEMENT If it is necessary to replace or add one of these devices the easiest procedure is to remove the mounting bracket shown in Fig 29 from the breaker frame and remove the device from the bracket If a replacement or new device is ordered a mounting bracket will be supplied with the device BREAKER TRIP SHAFT FRONT FRAME 2ND SHUNT TRIP MT RIGHT HAND BUFFER ASSEMBLY HARDWARE FIG 30 2ND SHUNT TRIP INSTALLATION 23 SECTION 7 Breaker Maintenance Cont MTG HARDWARE FIG 31 2ND UNDERVOLTAGE DEVICE 7 8 2 OPERATIONAL CHECK When the undervoltage device is used as part of a shut down circuit which opens the breaker by deenergizing th coil the following operational check should be made is recommended that this check be performed every 12 mon ths or every 1750 operations for 30 breakers and 500 operations for AKR 50 AKRT 50 breakers 1 Check the trip latch engagement as described i Sec tion 7 15 Trip Latch Adjustment 2 Check the torque required on the trip Shaft to trip the closed breaker The value must be 24 inch ounces max imum 3 Check the response time required 1090 from ze
300. ry as sembly operation so that the action is stopped in either direction at the precisely correct point The jamb nuts are set so that whenpthe trunnion is against them the relation betweenithe arms and the equipment pins they engage is Fig 38 The length of the sleeve which is free to slide onthe threaded shaft is controlled by the amount of thread engagement between the sleeve and its collar This length is adjusted to stop the trunnion when the distance between the ends of the equipment and breaker studs is 1032 10 218 After this adjustment is made the sleeve and its collar are locked together by the set screw FIG 37 LOCATION OF RATCHET TOOTH NO 1 SECTION 7 Breaker Maintenance Cont LUBRICATIQN JAMB NUTS 5 A TRUNNION FIG 38 DRAWOUT MECHANISM DETAILS NEZ n SECTION 7 Breaker Maintenance Cont 7 14 BUFFER ASSEMBLY When the breaker is closed the energy in the closing When the breaker is opened the end plate assembly is spring is transferred to the main shaft through the driven against the opposite end of the buffer assembly mechanism The main shaft then drives the contacts The buffer is a stop absorbing the opening energy of the closed The end plate assembly on each end of the main mechanism See Fig 41 shaft is driven against the buffer assembly shown in Fig 40 This prevents the mechanism from overdriving the contacts Y
301. ry in order to prevent nuisance tripping Re verify positive trip as a final check 7 8 eUNDERVOLTAGE DEVICE The Undervoltage device trips the breaker whenits coil is de energized The leads of the coil are connected directly to secondary disconnects or to a terminal board Under normal conditions the coil remains energized and the breaker be closed Dropout of the armature with resultant breaker trip ping occurs when the voltage is reduced to a value between 30 and 60 of the coil rating An open armature will render the breaker incapable of closing The FIG 29 SHUNT TRIP AND UNDERVOLTAGE MOUNTING armature will pick up sand allow closing if the applied voltage is 85 _or More of the coil rating It may also pick up at a lower voltage Refer to table 25 for pickup and dropout ranges The armature of the undervoltage device may be tied closed in order to permit breaker operation during main tenance Mhe Undervoltage device is mounted to the underside of thebreaker front frame as shown in Fig 29 second undervoltage may also be mounted to the frame see Fig 31 if a second shunt trip isn t already installed see Section 7 7 If a second undervoltage device is added a new buffer assembly block will be supplied This is required for clearance in this case the buffer assembly must be taken off disassembled and remounted together with the number two undervoltage device Before disassembling the ori
302. ry intermediate and main ontacts are replaced just like the stationary contacts on the 800 ampere breakers Refer to steps 2 amp 3 in Section 8 6 Referring to Fig 50A 50B amp 50C thestationary arcing contacts are replaced as follows 1 Remove the arcerunnef and the flat insulation assembled underneath thegarcenuinner It is secured with four screws When removing the lower screws use care not to damage or insulating washer found under each of these screws see Fig 50A 2 Remove theArcing contact pivot Clean off the exist ing lubricationsfoundgon the pivot area Replace with D50HD38 28 see Fig 50B 3 Remove the insulating spacers contact pin and arc ing contacts See Fig 500 4 Reassemble the reverse of above Make sure that the insulating Spacers and insulating washers are properly in StalleGm Torque the arc runner hardware to 45 5 in Ibs The movable contacts are removed in a similar manner 85 the 800 ampere breaker movable contacts Refer to Section 8 6 When rempving the pivot pin from a 2000 ampere AKRT 50 50H contact assembly the pivot pin from the opposite contact assembly must be slightly removed This provides enough clearance to completely remove the pivot pin INSULATING WASHER INSULATING WASHER SN ARC RUNNER FIG 50D STATIONARY CONTACT 1600 2000 AMP REPLACEMENT CONTACT STRUCTURE 39 SECTION 8 Contact
303. ry mains The following procedure is used to perform the wipe ad justment 1 Open the breaker remove arc quenchers 2 Arrange the breaker for slow closing The cam roller must be supported by the cam and not the prop Refer to Section 5 3 3 Select one pole of the breaker and place a thin sheet or strip of tough insulating material such as mylar over the stationary arcing and intermediate contacts This strip should be about two inches wide and must prevent the arc ing and intermediate contacts from making contact when the breaker is closed 4 Using the ratcheting maintenance handle slow close the breaker with the insulation held in place Examine the insulation to make sure it over hangs below the in termediate contacts but not enough to cover the main con tacts ARC RUNNER 4 1 STATIONARY MAIN CONTACTS NE ae ae OVABLE ARCING Li STATIONARY INTERMEDIATE CONTACTS 5 Attach a continuity checker bell set light z r ohm meter between the upper and lower stud The checker should indicate continuity exists 6 Facing the breaker tum the adjustment stud shown Fig 47 clockwise until the checker indicates that the main contacts are separated 7 Tum the stud counter ci ckwise until the main con tacts just touch 8 From this point advance the stud counter clockwise 270 degrees This will be 4 1 2 flats 9 Once the adjustme
304. s in the dfawout nclosure The trunnion travels between the two jamb nuts on the end of the screw and the adjustment sleeve which stops the trunnion movement atAhe other extreme point of its travel The trunnion isyagaimst the jamb nuts when the breaker is fully racked out and against the sleeve when fully racked in The racking mechanism is adjusted at the factory as sembly operation so that the action is stopped in either direction at the precisely correct point The jamb nuts are set so that when4he trunnion is against them the relation between arms and the equipment pins they engage is showin Fig 38 The length of the sleeve which is free to slide_on the threaded shaft is controlled by the amount of thread engagement between the sleeve and its collar This length is adjusted to stop the trunnion when the distance between the ends of the equipment and breaker studs is 032 to 218 After this adjustment is made the sleeve and its collar are locked together by the set screw 1 TOOTH FIG 37 LOCATION NO 1
305. s the closing spring A com plete charge is accomplished in either cranking the han dle through one cycle 135 degree swing or three cycles 50 degree swing Manually operated breakers manufac tured after July 1984 can only be charged by cranking the handle through one cycle The CLOSE button mounted on the escutcheon is used to manually close the breaker contacts and the TRIP button is used to open them If equipped with a closing solenoid a manual breaker may be closed remotely by a control switch or relay Before this can be done however the closing spring has to be charged by hand The closing solenoid is an op tional accessory and is not supplied unless specified in the breaker order _ 5 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 en rgize the motor through the G switch contacts see Figy9 The motor through the gear reduction output crank compresses the closing springs until they are fully charged As this fully charged position is reached mechanically operated switches F and G reverse their shown position the G switch deenergizing the motor andsthe F switch estab lishing a circuit to the X relay At the same time a mechanical prop is positioned to prevent the discharge of the fully charged closing Spring With the closing spring propped
306. s 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 ar mature 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 rmature revolves clockwise causing the trip rod 3 to 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 10 Armature 11 Counter Weight 12 Stop Screw 13 Mounting Screw 14 Screw gt FIG 125 ED 1 REVERSE CURRENT TRIPPING DEVICE 89 SECTION 15 Trip Device Cont 15 41 ADJUSTMENTS The only adjustment to be made on the reverse current de vice is to make sure that the trip rod has a minimum overtravel of 1 32 in beyond the point of tripping the breaker This adjust ment 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 re quired To obtain the proper 1 32 in overtravel close the breake
307. sent the maximum continuous cur fent capability of the respective frames However each breaker carries a specific rating which is determined by the current sensor ampere rating or maximum setting of the trip device with which it is equipped 2 2 OPERATION There are Manual and Electrical breaker models The Manual breaker shown in Fig 1 has an operating handle which is used to manually charge the mechanism closing spring The Electric breaker shown in Fig 2 contains an elec tric motor which charges the mechanism 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 and trip and close coils 2 3 FUSED NON FUSED Fused breakers are identified as either AKRU 30 800 ampere frame size or AKRU 50 1600 ampere frame size A fused breaker is shown in Fig 3 They are not inter changeable with Non Fused breakers since they require deeper compartments for their fuses FIG 2 Electrically Operated AKR 7D 30 FIG 3 Fused Breaker AKRU 6D 30 SECONDARY DISCONNECTS PRIMARY DISCONNECTS RACKING MEGHANISM FIG 4 Drawout Breaker SECTION 2 General Description Cont 2 4 MOUNTING Type AKR breakers are designed for either drawout or stationary mounting Drawout breakers See Fig 4 are equipped with features which make them easy to install in or withdra
308. ssOciated trip element operates to trip the breaker Afteratrip the popped target must beresetby hand However neglecting to reset does not affect normal operation ofanytrip element or prevent the breaker from being closed FIG 98 RMS 9 amp EPIC MICROVERSATRIP PROGRAMMER SECTION 13 RMS 9 amp Epic MicroVersaTrip Cont FIG 99 PROGRAMMER SECONDARY CONNECTOR EPIC MICROVERSATRIP 13 1 2 RMS 9 amp EPIC MICROVERSATRIP INSTALLATION The programmer mounts to the upper left of th breaker as shown in Fig 100 It mounts to the bracket assembly shown in Fig 82 Referring to Fig 82 the guide pins mate with the hole on either side of the programmer connector They provide the necessary alignment for 1he connpector engagement The locking lever engages with the pin which is assembled to the programmer frame_and secures the programmer to the mounting bracket Installation is as follows a Insert the guide pins into the hol s and push on the programmer engaging the connectors b The locking lever is released Securing the program mer c Verify that the locking lever did engage the program mer pin To remove the pragramimer a Pull out locking lever which will release the program mer pin Remove the programmer 13 2 CURRENT SENSORS The current sensors supply the power signal input necessary to operate the trip system the MicroVersaTrip the RMS 9 and Epic MicroVersaT
309. ssary to trip the breaker It contains a programmable micro electronic processor which incorporates nine adjustable time current functions three mechanical fault indicators local and remote a long time pickup LED indicator local andremote anda zone selective interlocking function All adjustable programmer functions are automatic and self contained requiring no external relaying power supply or accessories See Table 15 for trip functions available and Table 16 for trip function characteristics A detailed description of each trip function is given in publication GEK97367 XFMR GROUND AMPLIFIER AD sa ONVER T AJPATING PL 4 AMPLIFIER 5 OB m RB FACE PLATE RATING PLUG l SWITCHES AMPLIFIER C oL Lm Up TRIP 5 RATING PLUG ST COMPARATOR TO TRIP FLUX INST SWITCH SHIFTER FIG 97 RMS 9 BLOCK DIAGRAM 70 13 1 1 FAULT TRIP INDICATORS The optional fault trip indicators are similar to the MicroVersaTrip indicators They are out type for identifying overload or short circuit over currents faults when breakers are ordered without integral ground fault protection They are also availableto identify overload short circuit and gfound fault trips for breakers supplied with integralgroumd fault protection Each target pops out when itsza
310. t has been set at the name plate value Of the instantaneous trip current Usually expressed in times the ampere rating of the trip coil The variation in pick up settiAgais accomplished by varying the tensile force the instantaneous spring 5 Turning the adjustment screw changes the position ofthe movable nut 11 on the screw The spring is anch red 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 cal ibration mark 15 to obtain the proper instantaneous trip setting The trip screw 6 on the end of the armature 7 should be set so 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 Replacement of the EC 2A device is accomplished by the same procedure described for the EC 1 series trip device how ever in some cases when replacing an EC 1 device with an EC 2A it will be necessary to replace the trip paddles on the trip shaft with ones which are slightly longer When required these will be provided with the replacement trip units N
311. t proper arc transfer to the arc runner The current carrying members of the breaker 5 sembled on the back frame which provides the cal support required and also the insulating structure needed The conductive members are the studs for ext r nal connections movable and stationary contact sets pivots for the movable contacts and provisio for mo nting the current transformers The interrupter components are in additionte the arcing contacts the arc runners mounted opsthe back base the removable arc quencher assemblies In addition to these basic breaker may be equipped with any combination offmany accessories and interlocking devices Breakers may also differ in a variety of areas as shown in Table 1 A brief description of these areas is given below An outline drawing is available foreach breaker frame size showingcritical dimensions Thedrawingnumber appears on the breaker nameplate and can be obtained from GE 2 1 FRAME SIZE The breakerSyare available 5 frame sizes 800 am peres 30 30H AKRU 30 1600 amperes 0 50H AKRU 50 2000 amperes AKRT 50 50 4800 amperes D C 30 and 2000 amperes D Ca AKR 50 FIG 1 Manually Operated AKR 4A 50 1 These values represent the maximum continuous cur rent Capability of the respective frames However each breaker carries a specific rating which is determined by
312. t 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 7 6 AUXILIARY SWITCH All electrically operated breakers and manual breakers having shunt trips are supplied with auxiliary switches Depending upon the requirements of the breaker s applica tion the Switch may contain from two to six stages Usually each stage has one A contact and one B contact A contacts are opened or closed as the breaker is opened closed B contacts are the reverse of this The auxiliary switch is mounted on the upp r side of the mechanism frame as shown in Fig 27 A Crank the main shaft operates the switch through an adjustable link which connects it to the switch crank FIG 26 PRIMARY FINGER ADJUSTMENT E K p a FIG 27 AUXILIARY SWITCH LINKAGE 7 6 1 REPLACEMENT The switch may be dismounted by removing the two bolts which fasten it to the mechanism frame The replacement switch should have its crank shaft set so that th arrow head on the end of the shaft points as shown in Fig 28 when the breaker is open If a switch is added to a breaker having none the ad justing link will also have to be installed This is connected to the pin on the crank which is attached to the main shaft Its secured by means of a cotter pin ARROW HEAD e FIG 28
313. tangssare specially configured and offset to achieve th required pole to pole fuse spac ing a special primary disconnect assembly mounts directly on the outboard tang of the fuse Considering their unique mounting provisions when replacing these fuses the fol lowing procedure should bevadhered to Refer to Fig 53 a Remove the primary disconnect assembly from the fuse tang acc mplished by first loosening the two keys via their holding screw and pulling them upward and out After the keys areremoved pull the disconnect assembly off the end Of the fuse tang NOTE itis removal does not disturb the disconnect s clamping force adjustment b Remove the upper barrier c Detach the inboard end of the fuse by removing the two 1 2 inch 13 bolts A ratchet and socket with a short extension will be requied d Remove the heat sink e Remove the fuse f Install the new fuse by reversing the disassembly procedure Ensure that the mating faces of the fuse and heat sink are clean ADAPTER BARS COPPER FIG 52 300 THRU 600 AMP CLASS J FUSE MOUNTING 41 CAUTION WHEN REPLACING THE FUSE IN LEFT POLE FRONT VIEW OF THE BREAKER NOTE PARTICULARLY THAT THIS FUSE ZS MOUNTED DIFFERENTLY THAN THE OTHER TWO FUSES AS SHOWN IN FIG 54 FOR THIS PHASE THE FUSE IS ROTATED 180 DEGREES ABOUT ITS AXIS SO THAT ITS INBOARD TANG JS POSITIONED BENEATH THE BREAKER STUD THIS TANG IS OFFSET WITH RESPECT TO THE OPPOSITE EN
314. ted from slipping off the sen sor stud by adjacent accessories If this exists the sensor stud Mmust be removed from the breaker base The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker d When replacing the stud connector tighten the Allen head screw to 250 10 in Ibs Tighten the clamping bolt as follows 120 10 in Ibs 50 50 470 10 in Ibs AKRT 50 50 470 10 in Ibs e When replacing the programmer harness to the phase sensors verify that the winding polarity is maintain ed white wire with ring terminal to COMMON terminal right hand terminal see Fig 83 63 SECTION 12 MicroVersaTrip Trip Device Cont 123 FLUX SHIFTER TRIP DEVICE The only difference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid winding Refer to Section 10 3 for details When replacing a MicroVersaTrip flux shifter AMP ex traction tool Cat No 455822 2 is required to remove the socket leads from the AMP connector 124 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 b Breaker remaining in trip free state due to mechanical maintenance along its trip shaft c Inadvertent shunt trip activations WARNING DO
315. th Normal speed and force When replacing the hex head bolt turn the camshaft with the maintenance handle to align the mating holes in the lower spring assembly and camshaft linkage FIG 21 SLOW CLOSING LOWER SPRING ASM HARDWARE 20 SECTION 7 Breaker Maintenance Cont 7 5 PRIMARY DISCONNECTS Primary disconnects are found only on drawout break ers They provide the flexible connection between the breaker line and load terminals and the equipment line and load terminals FIG 22 PRIMARY DISCONNECT ASSEMBLY BOW TIE SPACERS RETAINER FINGERS 24 PARTIAL PRIMARY DISCONNECT ASM The 800 ampere breakers use four primary disconnect fingers per terminal The 1600 and 2000 ampefe breakers use eight fingers per terminal Fig 22 shows a line and load end disconnect assembly The line end disconnects on fusible breakers have the spring pointing downwards otherwise they are identical BOW TIE SPACERS RETAINER FIG 23 PARTIAL PRIMARY DISCONNECT ASM HOLE wasa RETAINER FIG 25 PARTIAL PRIMARY DISCONNECT ASM 21 SECTION 7 Breaker Maintenance Cont 7 5 1 REPLACEMENT Figs 22 23 24 and 25 show the primary disconnect assembly breakdown Refer to these illustrations when replacing the disconnects Note the following details Fig 25 The position of the spacer in the breaker stud The hole in the spacer must be positioned as
316. th the Ground Fault trip element a probable cause is the existence of a false ground signal As indicated by the cabling diagram of Fig 69 each phase sensor is con nected 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 addto 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 dif ferential 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 breaker whose SST components have previously demonstrated satisfactory performance via the TAK TS1 Test Set the sensors and their connections should be closely scrutinized After disconnecting the breaker from all power Sources a Checkthat all phase sensors arethe same type am pere range b Ensure that the tap settings on all 3 phase sensors are identical 10 5 SST CABLING DIAGRAMS BREAKER BACK FRAME LEFT POLE CURRENT SENSOR FLUX SHIFT TRIP DEVICE CONN AMP 201298 1 AMP 201297 1 c Verify that the harness connections to the sensors meet the polarity constraints indicated by the cabling dia gram i e white w
317. the current sensor ampere rating or maximum setting of the trip device with which it is equipped 2 22 OPERATION There are Manual and Electrical breaker models The Manual breaker shown in Fig 1 has an operating handle which is used to manually charge the mechanism closing spring The Electric breaker shown in Fig 2 contains an elec tric motor which charges the mechanism 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 and trip and close coils 2 3 FUSED NON FUSED Fused breakers are identified as either AKRU 30 800 ampere frame size or AKRU 50 1600 ampere frame size A fused breaker is shown in Fig 3 They are not inter changeable with Non Fused breakers since they require deeper compartments for their fuses FIG 2 Electrically Operated AKR 7D 30 FIG 3 Fused Breaker AKRU 6D 30 gt SECONDARY pu TEM DISCONNECTS r z 1 i E ee 2 PRIMARY E a i e DISCONNECTS a j 5 b ii RACKING MECHANISM FIG 4 Drawout Breaker SECTION 2 General Description Cont 24 MOUNTING Type AKR breakers are designed for either drawout or stationary mounting Drawout breakers See Fig 4 are equipped with features which make them easy to install in or with
318. the adjustment first unscrew trip screws 9 Figure 124 it trip the breaker even though the ar mature is pushed against the magnet Then holding the arma ture in the closed position advance the screw until it just trips the breaker After this point has been reached advance the screw additional full turns This will give an overtravel of 1 16 of an will make sure that activation of the device will alwaysatrip the breaker Adjustment screw 9 Figure 123 can best be manipulated by an extended 1 4 inch hex socket wrench SECTION 15 Trip Device Cont 15 44 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 reverse current tripping device see Fig 125 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 2 2 normal direction the magnetic flux of the and the magnetic flux of the potential coil produce a torque which tends to rotate the armature counterclockwise spring also tend
319. the frame see Fig 30 if a se cond undervoltage device isn t already installed see Sec tion 7 8 7 71 REPLACEMENT If it is necessary to replace or add one of these devices the easiest procedure is to remove the mounting bracket shown in Fig 29 from the breaker frame and remove the device from the bracket If a replacement new device ordered a mounting bracket will be supplied with the device If a second shunt trip is added this is mounted by means of an additional bracket as shown i Fig 30 This additional bracket is fastened by two of th hex head bolts used to fasten the buffer assembly to the breaker frame 7 7 2 ADJUSTMENT When these devices are installed Omnreplaced their positive ability to trip the breaker must be demonstrated This is done by placing a 1 32 inchsshim between the ar mature and magnet of the device and manually operating the armature to trip the breaker If the shunt trip is not successful in this test check the mounting fasteners to make s re they are reasonably tight If they are then bend the trip paddle on the trip shaft to slightly reduce thexdistance between the trip arm of the device and the paddle and recheck for positive trip If this bending 4S necessary be careful that it is not over done Verify that ther is a 030 050 gap between the trip arm and the trippaddle with the breaker closed greater than 050 is permitted and may sometimes be necessa
320. the fully racked out position will cause the lever to move past the pin on the armature linkage This will bind up the overall interlock Under these conditions continued application of this force will deform the linkage assembly 6 4 DISCONNECT POSITION INTERLOCK The function of the Disconnect Position 5 to block the RACKING SCREW cover open when theracking mechanism is in the DISCONNECTED position When the cover is held open the TRIP button is depressed The mechanism is held trip free and there 5 contact arm movement when the closing spring is discharged by the Closing Spring interlock The operation of this interlock is shown in Fig 18 crank which is attached to the r cking mechanism shaft is connected to the blockingplate through a link As the shaft turns the blocking plate rotates holding the cover open in the DISCONNECTED poasitionbut allowing it to close in the TEST and CONNECTED positions RACKING SCREW ARM Breaker Racked In Lever And Armature Linkage Pin Not Engaged ADJUSTING SCREWS FIG 18 DISCONNECT POSITION INTERLOCK 6 5 PADLOCKS Provisions are made on all breakers to use padlocks to prevent the breaker form being closed For all breakers except Type B or D the padlock shackle goes through the TRIP button hole and out the slot in the side of the ml escutcheon For
321. the ground differen tial transformer See Fig 70 This fourth wire neutral sensor is an electrical duplicate of the phase sensor in cluding taps Therefore when taps are changed on the phase sensors those on the neutral sensor must be cor respondingly positioned When used the neutral sensor is separately mounted in the bus or cable compartment of the switchgear In draw out construction its output is automatically connected to the breaker via secondary disconnect blocks See Fig 62 E gt FIG 60 SST PHASE SENSOR WITH TAP BOARD 300 800 A 100 300A FIG 61 SST NEUTRAL SENSORS REAR VIE W gt 59 MOUNTED EQUIPMENT MOUNTED SHORTING STRAP FIG 62 NEUTRAL SENSOR SECONDARY DISCONNECT BLOCKS 47 10 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 63 replacement of individual SST current sensors is accomplished as follows a Disconnect the breaker harness from the tap ter minal board removing cable ties as necessary Un fasten the terminal board from the breaker base b At the rear of the breaker remove the two Allen head screws to separate the stud connector from the contact pivot block C Loosen the clamping bolt and remove the stud connector Lift out the sensor and its tap terminal
322. the neutral conductor is carrying only that neutrakc rrent associated with the breaker s load cur rent Reutral not shared with other loads Ifthe 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 resistance should closely agree See Table 8 PROGRAMMER UNIT 48V dc TO SCR ANODE PROGRAMMER CONNECTOR FIG 68 CABLING DIAGRAM SST WITHOUT GROUND FAULT 53 SECTION 10 Type SST Overcurrent Trip Device PROGRAMMER FLUX SHIFT A TRIP DEVICE is BREAKER BACK FRAME 48V dc SCR LEFT POLE ANODE CURRENT SENSOR HARNESS CONNECTOR PROGREMIMEN AMP 201298 1 201297 T FIG 69 CABLING DIAGRAM SST WITH GROUND FAULT ON 3 WIRE LOAD 6B 2 K 4 FLUX SHIFT TRIP DEVICE BREAKER a A A BACK FRAME LEFT POLE CURRENT SENSOR 48V dc TO SCR ANODE NEUTRAL I NEUTRAL SENSOR DISCONNECT J Y HARNESS a PROGRAMMER CONNECTOR FRE EQUIPMENT MOUNTED AMP 201298 1 NNECTOR NEUTRAL SENSOR n AMP 201297 1 4 WIRE LOAD FIG 70 CABLING DIAGRAM SST WITH GROUND FAULT ON 4 WIRE LOAD 54 BREAKER HARNESS GROUND FAULT DEFEAT CABLE PROGRAMMER CONNECTOR CAT NO TGFD UNIT E we o lt CURRENT SENSORS o
323. 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 agrees with address at host Read the X value from the rating plug name plate and enter this with the rating plug current set point procedure 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 With the PT connection procedure enter VL N for a wye connected PT primary or VL L fora delta connected PT Indicates that the total power is metered in kVA Clear target as indicated above Symptom 4 83 TABLE 23 SHUNT TRIP AND UNDERVOLTAGE DEVICE OPERATING CURRENTS Current Amps Current Amps Operating Inrush Sealed o u v 36 Operating Inrush 6 2 Frequency Hz 4 5 4 5 419 1 0 1 0 04 5 20 7 127 123 108 66 24 127 76 67 5 75 25 120 25 95 127 4 7 4 1 10 208 60 175 220 3 2 2 6 51 17 208 50 175 220 3 8 3 1 wE 30 10 208 25 175 220 2 1 1 9 AE 14 05 240 60 190 254 9 9 9 4 5 5 37 12 240 50 190 254 4 7 4 1 5 34 11 240 40 190 254 5 8 5 1 Ba N A N A 240 25 190 254 24 1 9 20 16 06 380 50 315 410 2 9 2 6 22 08 480 60 380 50
324. those on the neutral sensor must be cor respondingly positioned When used the neutral sensor is separately mounted ir the bus or cable compartment of the switchgear in draw out construction its output is automatically connected to the breaker via secondary disconnect blocks See Fig 62 FIG 60 SST PHASE SENSOR WITH TAP BOARD 300 800 A IOO 3004 FIG 61 SST NEUTRAL SENSORS REAR VIEW ARR 50 BREAKEP MOUNTED EQUIPMENT MOUNTED SHORTING STRAP FIG 62 NEUTRAL SENSOR SECONDARY DISCONNECT BLOCKS 47 10 2 1 REPLACEMENT OF CURRENT SENSORS Referring to Fig 63 replacement of individual SST current sensors is accomplished as follows a Disconnect the breaker harness from the tap ter minal board removing cable ties as necessary Un fasten the terminal board from the breaker base b At the rear of the breaker remove the two Allen head screws to separate the stud connector from the contact pivot block c Loosen the clamping bolt and remove the stud connector Lift out the sensor and it5 tap terminal board The sensor may be prevented from slipping off the sensor stud by adjacent accessories If this exists the sensor stud must be removed from the breaker base The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker 1 Flux shift Trip Device 2 Allen head Screws 3 Stud Connector 4 Current Sensor d
325. tic and self contained requiring no external relaying power supply or accessories See Table 11 for trip functions available and Table 12 for trip function characteristics A detailed description of each trip function is given in publication GEA 10265 and GEH 4657 FLUX SHIFTER SOLID COIL STATE SWITCH PROGRAMMER UNIT 11 LONG TIME PICKUP amp SHORT TIME PICKUP amp DELAY INSTANTANEOUS PICKUP 72 SUMMING GROUND eus PICKUP amp mm CA DELAY REGULATED NEUTRAL 15 POWER SUPPLY FIG 76 MICROVERSATRIP BLOCK DIAGRAM 12 1 1 FAULT TRIP INDICATORS The optional fault trip indicators are similar to the SST indicators They are mechanical pop out type for identify ing overload or short circuit over currents faults when breakers are ordered without integral ground fault protec tion 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 whenyits associated trip element operates to trip the breaker Aft ma 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 beir g closed 12 1 2 REMOTE FAULT INDICATION Remote faulttindication is available in the form of a mechanical contactywhich may be incorporated directly into the customers control circuitry
326. ting 2 5 Trip Device 2 6 Model Number 2 7 Short Circuit Ratings SECTION 3 3 0 STORAGE 3 1 Safety 3 2 Maintenance SECTION 4 4 0 DRAWOUT BREAKER INTERCHANGEABILITY SECTION 5 5 0 BREAKER OPERATION 5 1 Manual Closing 5 2 Electrical Closing Alternate Control Circuit 5 3 Mechanism Operation 5 4 Charging Using The Maintenance Handle SECTION 6 6 0 INTERLOCKS 6 1 Racking Mechanism Interlock 6 2 Positive Interlock 6 3 Closing Spring Interlock 6 4 Disconnect Positiondnterlock 6 5 Padlocks 6 6 Key Interlock Stationary Breaker 6 7 Optional Interlocks SECTION 7 7 0 BREAKER MAINTENANCE 7 1 Lubrication 7 2 Manual Handle Adjustment 753 Drawout Mechanism Position 7 4 Slow Closing the Breaker 7 5 Primary Disconnects Replacement Adjustment Page 4 OO OO O O O 10B 11 T1 11 11 12 13 13 15 15 16 16 17 17 SECTION 7 7 6 Auxiliary Switch 7 6 14 Replacement 7 6 Adjustment 7 7 Shunt Trip 7 7 1 Replacement 7 4 2 Adjustment 7 8 Undervoltage Device 7 8 44 Replacement 7 8 2 Operational Check 7 8 3 Adjustments 7 8 4 Factory Settings 7 9 Static Time Delay Undervoltage 7 9 4 Adjustments 7 10 Electric Lockout Device 711 Bell Alarm 711 11 Operation 7 412 Adjustments 7 11 3 Replacement 7 122 gt Electrical Control Components 7421 Component Replacement 7422 F and G Switch Adjustment 7 43 Drawout Mechanism 7 14 Buffer Assembly 7 14 1 Buffer Adjustment 7
327. tion and Maintenance 1 2 Renewal Parts SECTION 2 2 0 GENERAL DESCRIPTION 2 1 Frame Size 2 2 Operation 2 3 Fused Non Fused 2 4 Mounting 2 5 Trip Device 2 6 Model Number 2 7 Short Circuit Ratings SECTION 3 3 0 STORAGE 3 1 Safety 3 2 Maintenance SECTION 4 4 0 DRAWOUT BREAKER INTERCHANGEABILITY SECTION 5 5 0 BREAKER OPERATION 5 1 Manual Closing 5 2 Electrical Closing 5 2 1 Alternate Control Circuit 5 3 Mechanism Operation 5 4 Charging Using The Maintenance Handle SECTION 6 6 0 INTERLOCKS 6 1 Racking Mechanism Interlock 6 2 Positive Interlock 6 3 Closing Spring I terlock 6 4 Disconnect PositiOnainterlock 6 5 Padlocks 6 6 Key Interlock Stationary Breaker 6 7 Optional Interlocks SECTION 7 7 0 BREAKER MAINTENANCE 7 1 Lubrigation 7 2 Manual Handle Adjustment 79 Drawout Mechanism Position 7 4 Slow Closing the Breaker 7 5 Primary Disconnects 25 1 Replacement 7 5 2 Adjustment Page 4 OO OO O O O O 10B 11 11 11 11 12 13 SECTION 7 7 6 Auxiliary Switch 7 61 Replacement 76 2 Adjustment 7 7 Shunt Trip 7 7 1 Replacement 7 7 2 Adjustment 7 8 Undervoltage Device 7 81 Replacement 7 8 2 Operational Check 7 83 Adjustments 7 8 4 FactoryeSettings 7 9 StatiemhimezDelay Undervoltage 7 9 1 Adjustments 7 10 Lockout Device 7 11 BellAjarm 7114 Operation 7 12 Adjustments 741 3 Replacement 742 Electrical Control Components 7 1271 Co
328. tion characteristics A detailed description of each trip function is given in publication GEA 10265 and GEH 4657 PROGRAMMER UNIT gt 74 FLUX SHIFTER SOLID TRIP COIL STATE SWITCH SHORT ciACUIT TARGET l TARGET NEUTRAL I 5 JG RCOITRY 659 Tota aren 22 1 vox 93 i POWER SUPR v L FIG 76 MICROVERSATRIP BLOCK DIAGRAM OVERLOAD TARGET 12 1 1 FAULT TRIP INDICATORS The optional fault trip indicators are similar to the SST indicators They are mechanical pop out type for identify ing overload or short circuit over currents faults when breakers are ordered without integral ground fault protec tion They are also available to identify overload short circuit and ground fault trips fombreakers supplied with integral ground fault protection Each target pops o tiwhem its associated trip element operates to trip the breaker After a trip the popped target must be reset by handXHowever neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being closed 12 1 2 REMOTE FAULT INDICATION Remote fault indication is available in the form of a mechanical contact which may be incorporated directly into the customer s control circuitry This is a Normally contact which is activated when its associated target popS out When the target is reset the contact is re
329. to gain access to it MAIN SHAFT BREAKER CLOSED 4 FIG 34 ELECTRIC LOCKOUT 55 FIG 33 ELECTRIC LOCKOUT DEVICE 7 11 BELL ALARM This device is used to give a remote indication of the breaker s having tripped open through the action of one of its automatic protective devices It will not be activated by manual tripping or the action of the shunt trip A remotely mounted protectiverelay energizing the shunt trip will there fore not resultin the remote alarm action The bellalarm circuit may turned off by pushing in the manual trip orby energizing the shunt trlp In the latter case a normally open contact of the bell alarm switch must be wired in parallel with the A auxiliary switch contact in the shunt trip circuit Closing the breaker will also tum off the alarm The bell alarm device may be equipped with a lockout link which will lock the breaker open until the bell alam device is reset The bell alarm is not a standard device and is supplied only when specified on the breaker order 7111 OPERATION Referring to Fig 35 the bell alarn mechanism is ac tivated by a crank which is assembled to the breaker s main shaft Whenthe breaker opens a pin attached to this crank moves the alarm link against the switch and locklever if provided This activates the switch contacts It also moves the locklever adjustment screw against the trip shaft paddle keeping the breaker trip free
330. ton 6 Mechanism All accessible bearing and sliding sur faces that have been factory lubricated 7 Primary Disconnects Lubricate the finger contact surface just prior to installing in switchgear or lubricate and then cover the disconnect assembly to protect from dust dirt etc Refer to Section 7 5 Before lubricating remove any hardened grease or dirt from the latch and bearing surfaces After lubricating remove all excess lubricant to stop accumulation dirt or dust The use of cotton waste to wipe bearingysurfaces should be avoided The cotton ravelings may become entangled under the bearing surfaces and destroy the surface of the bearing cie FIG 20 MANUAL HANDLE ADJUSTMENT 7 2 MANUAL HANDLE ADJUSTMENT The adjustment linkage connects the handle assembly to the chain drive mechanism which turns the cam shaft The length of this linkage provides the handle adjustment If the link is too long the handle stroke cannot extend the closing spring enough for t to center In this event use the maintenance handleto complete the spring charg ing The breaker can therfBe closed and opened prepara tory to further shortening of the link If the link is too short charging is not possible The original linkage d sign used a double ended stud in the linkage center A hex section in this stud allowed adjust ing with open end wrench When looking down on the breaker turning the wrench c
331. trol circuit shown in Fig 9A for all control voltages except 250 volts D C which uses the circuit shown in Fig 9 This alternate control circuit eliminates the X relay and CC switch shown in Fig 9 The motor is energized through the G cutoff switch and the K relay contact The motor is deenergized when the G cutoff switch changes state which occurs when the closing spring is fully charged 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 Y breaker if so equipped or by a remote closing switch Operation of the closing switch energizes the K relay which in turn energizes the closing solenoid This removes the prop releasing the closing springs to close the breaker The F cutoff switch is only installed on breakers using D C control voltage The anti pump function is obtained through the nor mally closed K relay contact in 4the motor circuit If a close signal is maintained after the breaker has tripped open automatically the K relay is energized preventing the motor from charging the closing spring The closing signal must be removed approximately 1 3 to 2 0 seconds to allow the closing spring to charge LEGEND CC CLOSING SOLENOID F CUTOFF SWITCH CLOSED WHEN CLOSING SPRING IS FULLY CHARGED D C ONLY G CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGED L AUXILIARY SWITCH
332. ts The molded type uses one piece glas filled polyester frame Arc chutes should not be interchanged between frame sizes or interrupting ratings The arc chutes are held jin place by retainers se cured by bolts thro gh tHe mechanism frame ceramic type uses two retainers and the molded type uses only one To remove the atc chutes 1 Loosen and back off the retainer bolt locking nut from th mechanism frame They do not have to be removed 2 Qoosen the retainer bolts until the retainer s can be removed 35 With the retainer s removed lift the arc chutes off for inspection Inspect each arc chute for excessive burning and erosion of the arc plates and arc runner Also look for fractures damage to the liner material used in the molded arc chute and damage to the insulation material used in both arc chutes Check for any missing parts To install the arc chutes 1 Replace the arc chutes over each pole unit 2 Locate the retainer s 3 Tighten the retainer bolts until the arc chutes are secure There may be some side to side motion of the arc chutes but there must not be any front to back motion Torque the retainer bolts to 30 in Ibs for the molded type arc chutes and 60 to 100 in Ibs for the ceramic type Do not over tighten 4 Tighten the locknuts against the mechanism frame with 150 to 175 in Ibs torque 33 SECTION 8 Contact Maintenance Cont 8 2 CONTACT ADJUSTMENT AKR 30 30H
333. turned its open position Each contact is rated 0 25 amp at 125 VDG and 1 0 amp 10 amp in rush at 120 VAC SHORT GROUNO Cmcurr FAUT FAULT TRIP ANNUNCIATOR Versa Trip Seg wa FIG 77 MICROVERSATRIP PROGRAMMER a The remote fault indication switch leads are brought out the bottom of the MicroVersaTrip programmer as shown in Fig 78 This switch lead harness is plugged into the mating connector on the breaker see Fig 79 The switch leads are brought out from the breaker through the Programmer Secondary Disconnect shown in Fig 80 The zone selective interlocking function wir ing is also brought out through this disconnect See Figs 95 and 96 for the remote fault indication and zone selective interlocking cable diagrams REMOTE FAULT INDICATION CONNECTOR FIG 78 MICROVERSATRIP W REMOTE FAULT INDICATION HARNESS FIG 79 PROGRAMMER SECONDARY CONNECTOR d art pum i REMOTE FAULT INDICATION ra DISCONNECT FIG 80 REMOTE FAULT INDICATOR DISCONNECT 12 1 3 MICROVERSATRIP INSTALLATION The programmer mounts to the upper left of the breaker asy shown in Fig 81 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
334. ult Defeat Cable as shown Fig 93 This special test cable energizes the pro grammer circuit in a self cancelling series parallel connection so 15 output is always zero 2 Test th comp nents of the MicroVersaTrip system using portable Test Set Type TVTS1 Fig 88 ap plicable test procedures are detailed in instruction Book GEK 64464 The time current characteristics for the MicroVersaTrip Trip B vice are given in curves GES 6195 and GES 6199 FIG 87B RMS 9 EPIC MICROVERSATRIP AND MVT PLUS OR MVT PM COMPONENTS WITH FIXED SENSORS FIG 88 TEST SET CAT NO TVTS1 12 4 4 RESISTANCE VALUES For use in troubleshooting the MicroVersaTrip current sensors the resistance of the tapped and fixed windings is given in Tables 13 and 14 respectively TABLE 13 TAPPED SENSOR RESISTANCE VALUES Resistance in Ohms Between Common and Tap Terminals TABLE 14 FIXED SENSOR RESISTANCE VALUES Ampere Resistance in Ohms Rating Between Terminals 100 6 7 7 8 150 10 12 225 15 17 300 20 24 400 27 32 600 42 50 800 58 68 1200 92 108 1600 129 151 2000 207 243 coil resistance of the MicroVersaTrip flux shifter device is approximately 7 ohms SECTION 12 MicroVersaTrip Trip Device Cont 12 4 2 FALSE TRIPPING BREAKERS EQUIPPED WITH GROUND FAULT When nuisance tripping occurs on Dreakers equipped with the Ground Fault trip el ment a probable cause is
335. underside of the breaker front frame as shown in Fig 29 A second shunt trip may also be mounted to the frame see Fig 30 if a se ROBUR device isn t already installed see Sec tion 7 8 7 7 1 REPLACEMENT If it is necessary to replace or add one of these devices the easiest procedure is to remove the mounting bracket shown in Fig 29 from the breaker frame and remove the device from the bracket If a replacement or new device is ordered a mounting bracket will be supplied with the device If a second shunt trip is added this is mounted by means of an additional bracket as shown in 30 This additional bracket is fastened by two of the hex head bolts used to fasten the buffer assembly to the breaker frame 7 7 2 ADJUSTMENT When these devices are installed or replaced their positive ability to trip the breaker must be demonstrated This is done by placing a 1 32 inch shim between the ar mature and magnet of the device and manually operating the armature to trip the breaker If the shunt trip is not successful inthis test check the mounting fasteners to make sure they are reasonably tight If they are then bend th trip paddle on the trip shaft to slightly reduce the distance between the trip arm of the device and the trip paddlegand recheck for positive trip If this bending is necessary be careful that it is not over done Verify that there is a 030 060 gap between the trip arm and the paddle
336. up tolerance is 9 Pickup tolerance is 10 Time delay shown at 600 of long time pickup setting 6L at lower limit of band Time delay shown at lower limit of band 45 SECTION 10 SST Overcurrent Trip Device Cont MOUNTING BRACKET NS 46 FIG 58 SST PROGRAMMER FIG 59 AKR 5B 30 10 27 CURRENT SENSORS 55 system uses two types of current sensors phase sensor and a neutral sensor Fig 60 shows a phase sensor Fig 61 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 conductors 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 con necting each phase sensor in series 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 Application of the Ground Fault element on 4 wire sys tems with neutral grounded at the transformer requires the additional separately mounted neutral sensor Fig 61 inserted in the neutral conductor its secondary is con nected to a fourth primary winding on
337. ured by either a locking wire or a jam nut nside4he frame Devices with jam nut require removal of the device to make this adjustment The picK p voltage at room temperature approx 20 24 should be 85 or less of coil rating and should be measured atthe secondary disconnects with the coil energized Notei On DC devices set the gap between the armature and magnet initially to 0 030 inch using the closed gap adjustment screw shown in Fig 32C before making pickup adjustments Be sure to s cure the pickup adjustment screw with the jam nut ofslockwire 24 DROPOUT VOLTAGE On AC devices the dropout level will fall within the required limits 3096 to 6096 ofthe coil rating is set properly On DC devices the dropout level may need independent adjustment This is accomplished after the pickup level has been established per the above procedure If required use the closed gap adjustment screw shown in Fig 320 to obtain the dropout setting A gap must remain between the armature and magnet on DC devices to prevent sealing in Upon loss of voltage Secure the adjustment screw with the4docknut and apply RTV to the locknut POSITIVE TRIP Check positive trip ability perJ 8 2 Adjust the trip paddle screw if necessary to assure positive trip Withthe undervoltage device closed picked up and the mecha nism reset there m st be clearance between the trip paddle and the device armature If clearance adjustment
338. ust be adjusted so that it will displace the side latch when or before the shaft opens the breaker Maintain 030 inch minimum gap between the bracket and the side latch when the breaker is closed 187 inch depression ofthe TRIP button must not trip the breaker but a 375 inich must trip the breaker and displace the side latch uer W RELAY X RELAY OR K RELAY FIG 36A ELECTRICAL CONTROL COMPONENTS 711 3 REPLACEMENT The bell alarm Is mounted on the right hand side of the breaker at the rear of front frame It is located under the mechanism s main shaft The bell alarm is removed by passing it through a cutout in the rear bend of the front frame slipping it between the front frame and trip shaft and out through the bottom of the breaker as follows 1 Remove the 4 bell alarm mounting screws from the bottom of the front frame 2 If the crank which Is part of the main shaft has bell alarm activating pin assembled to both sides remove these pins 3 Insert the flat of the maintenance handle between the top of the left hand side buffer block and the end plate assembly This should eliminate any Interference from the main shaft during the bell alarm removal 4 6 trip shaft must be moved to allow the bell alarm to fit beteen It and the front frame Remove the retaining ring holding the right hand trip shaft bearing to the mechanism frame Slide the bearing from the frame and along th
339. ust be pushed in to release the tripping rod 9 3 1 TYPE A AND B BREAKER OFLO ADJUSTMENT To adjust the Type A and B breaker OFLO Refer to Fig 6 a Back off tripping rod so that it will not hit the trip paddle when a solenoid is activated b Using the maintenance handle close the breaker c Manually close the Left pole armature Screw tripping rod forward until it moves the trip paddle enough to open the breaker Add two full turns d Close the breaker e Manually close the Left pole armature again The breaker must open and the reset button pop out In this condition close the breaker it sho ld trip free f Reset the OFLO the breaker must now be able to close g Repeat for Center and Lett poles h Check for a 125 minimum clearance between trip ping rod and trip paddle Withthe OFLO reset Check for 032 minimum overtravehafter tripping rod trips breaker i Hold tripping rod in position and tighten its locknut FIG 55 TYPE D BREAKER OFLO DEVICE 9 3 2 TYPE D BREAKER OFLO ADJUSTMENT To adjust the Type D breaker OFLO a With the breaker in the CHARGED position and the OFLO reset adjust the dimension between the end of the tripping rod and the trip paddle to 062 093 b With the OFLO energized the breaker must TRIP and the RESET button must move forward to the front plate In this condition the breaker must be held trip free 43 SECTION 9 Fused Breakers Cont TRIP PADDLE
340. ven curves GES 6195 GES 6199 FIG 87 MICROVERSATRIP COMPONENT FIG 88 TEST SET CAT NO TVTS1 12 4 1 RESISTANCE VALUES For use in troubleshooting the MicroVersaTrip current sensors the resistance of the tapped and fixed windings is given in Tables 13 and 14 respectively TABLE 13 TAPPED SENSOR RESISTANCE VALUES Resistance in Ohms Between Common and Tap Terminals Ampere R sistance In Ohms Between Terminals Theacoil resistance of the MicroVersaTrip flux shifter device is approximately 7 ohms SECTION 12 MicroVersaTrip Trip Device Cont 12 4 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 grou d signal As indicated by the cabling diagram of 90 each phase sensor is connected to summing circuitry in the programmer Un der 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 sensors4 have the same electrical charac teristics If one sensoradiffers from the others i e dif ferent rating or wrong tap setting the circuitry can produce output sufficient to trip the breaker Similarly discontinuity between any sensor and the programmer unit cause a false trip signal If nuisance tripping is encountered on
341. vertightening the assembly These washers absorb the breaker opening shock Referring to Fig 41 with the breaker open a 040 maximum clearance can exist between either of the end plate assemblies and the buffer bolt heads as shown If a larger clearance exists close it up by unscrewing the buffer assembly involved Fig 42 shows a buffer assembly prior to being installed breaker The dimensions given establish the number of spacers that are used 7 15 TRIP LATCH ADJUSTMENT The reset position of the trip latch is set by the adjust ment screw shown in Fig 43 The adjustment is correct if three and one half turns of the adjustment screw causes a closed breaker to trip If this check is made the screw must then be set back or unscrewed three and one half turns SCREW NEOPRENE WASHERS WASHERS FIG 42 BUFFER ASSEMBLY ADJUSTMENT FIG 43 TRIP LATCH ADJUSTMENT 32 SECTION 8 Contact Maintenance Breakers subjected to frequent interruption of high cur rents may eventually require replacement of their contacts The general rule for determining 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 When contacts are replaced they must be adjusted to ensure that the proper amount of
342. w from their associated switchgear equipment These features are a racking mechanism which facilitates inserting and withdrawing the breaker unit and primary and control power disconnects which connect and part automatically Interlocking devices are included Stationary breakers are designed to be mounted on a framework or panel with mechanical fasteners being used to secure the breaker frame and make power connections If control power connections are needed a suitable termi nal board is supplied The mounting type is identified by the second middle digit in the breaker s nameplate designation as follows AKR 5 30 Mounting type code letter per Table 2 TABLE 2 MOUNTING TYPE CODES Breaker Type Drawout Stationary AKD 5 AKD 6 Substructure AKD 8 Substructure FIG 5 CERAMIC ARC CHUTES 2 5 TRIP DEVICE There are several 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 electro mechanical system is available The trip device system is identified byathe first middle digit in the breaker nameplate designation as follows AKR B 30 Trip device code number per Table 3 TRIP DEVICE CODES CODE NUMBER TRIP DEVICE APPLICATION 2 EC DC 3 Power Sensor AC 4 EGS AC 5 SST AC 6 MicroVersaTrip AC 7 RMS 9 AC 9 MVT P
343. w of current Breaker current sensors provide sufficient power to energize the LCD when at least 2096 of the sensor s ampere rating is flowing 24Vadccontrolpower 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 MicroVeraTrip Plus trip units may be optionally equipped to accept an external 24 Vdc supply MicroVersaTrip Test Kit The MicroVersaTrip Test Kit Cat No TVRMS contains a 24 Vdc power supply 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 77 SECTION 14 MicroVersaTrip Plus MicroVersaTrip PM Trip Units 14 2 TESTING Testing of MicroVersaTrip Plus and MicroVersaTrip PMtrip units may be performed with the trip unit installed in the circuit breaker the rating plug installed in the trip unit andthebreakercarryingcurrent Thetestsetcatalog 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 Maintenance and Troubleshooting section for additional details 14 3 PRODUCT STRUCTURE MicroVersaTr
344. wer and signal inputs necessary to operate the trip system Each sensorhas 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 conductors 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 con necting each phase sensor in series 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 Application of the Ground Fault element on 4 wire sys tems with neutral grounded at the transformer requires the additional separately mounted neutral sensor Fig 61 inserted in the neutral conductor its secondary is con nected to a fourth primary winding on the ground differen tial transformer See Fig 70 This fourth wire neutral sensor is an electrical duplicate of the phase sensor in cluding taps Therefore when taps are changed on the phase sensors those on the neutral sensor must be cor respondingly positioned When used the neutral sensor is separately mounted in the bus or cable compartment of the switchgear In draw out construction its output is automatically connected to the breaker via secondary disconnect blocks See Fig 62 REAROVIEW gt 50
345. will cause the closing spring to become dis engaged from the camshaft with considerable force Verify that this screw remains tightened during the slow close operation After the bolt is removed use the m intenance handle to rotate the ratchet assembly s toller onto the closing prop see Charging Using The Maintenance Handle sec tion 5 4 At this point the closing prop must be removed by either pushing the CLOSE button on Manual breakers or pushing the closing solenoid armature on electric breakers see Fig 13 Whertthe closing prop is removed continue turning the camshaft The contacts and mechanism is tS fully closed position the cam will support the cam roller refer to Fig 10 section 5 3 and the contacts will develop maximum depression Push the TRIP button to release the mechanism and open the contacts CAUTION The mechanism and contacts will open with normal speed and force When replacing the hex head bolt tum the camshaft with the maintenance handle to align the mating holes in the lower spring assembly and camshaft linkage FIG 21 SLOW CLOSING LOWER SPRING ASM HARDWARE SECTION 7 Breaker Maintenance Cont 7 5 PRIMARY DISCONNECTS Primary disconnects are found only on drawout break ers They provide the flexible connection between the breaker s line and load terminals and the equipment s line and load terminals FIG 22 PRIMARY DISCONNECT ASSEMBLY FIG 24
346. with the breaker closed This gap is necessary to prevent nuisance tripping 7 8 UNDERVOLTAGE DEVICE The undervoltage deivce trips the breaker when its coil is de energized The leads of the coil are connected direct ly to secondary diSconnects or to a terminal board Under normal conditions the coil remains energized and the breaker maybe closed Drop out of the armature with resultant breaker tripp ing Occurs when the voltage is reduced to less than 60 percent the rated voltage An open armature will render the breaker incapable of closing The armature picks up and allows closing if the voltage is 85 percent or more of its nominal value Refer to Table 23 Section 14 for the ac tual drop out and pick up voltage ranges 7 060 FIG 29 SHUNT TRIP AND UNDERVOLTAGE MOUNTING If the breaker isdisconnected and for some reason the breaker is to be operated manually the undervoltage device may be tied or wired down so that it will not cause tripping The underyoltage device is mounted to the underside of the breaker front frame as shown Fig 29 second undervoltage may also be mounted to the frame see Fig 31 Second shunt trip isn t already installed see Sec tion 7 7 If a Second undervoltage device is added a new buffer assembly block will be supplied This is required for Clearance in this case the buffer assembly must be taken off disassembled and remounted together with the number two unde
347. y 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 66 the clearance between the trip rod and the trip shaft paddle is gaged by a 0 125 inch diameter rod Adjust gap to 0 125 inch 0 015 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 to 35 5 in Ibs The actuator is a sealed factory set device and re quires no maintenance or field adjustment In case of malfunction the complete actuator unit should be replaced When making the electrical connector to the replacement unit it is recommended that the brea ker harness be cut at some convenient point and th new actuator leads solder spliced thereto The preferred method is to remove the fluX shifter leads from the AMP connector using the AMP extrac tion tool Cat No 305183 as follows CRANK BREAKER CLOSED POSITION ACTUATOR 1 Remove the flux shifter leads from the harness 2 Referring to the cabling diagrams in Section 10 5 the flux shifter leads are RED in point B and BLACK in point E 3 Insert the extractor tool over the female pin When the extractor tool bottoms out depress the plunger and force the wire socket assembly out of the connector
348. y 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 92 4 Ensure that the neutral conductor is carrying only that neutral current associated with the breaker s load cur rent 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 13 and 14 65 SECTION 12 MicroVersaTrip Trip Device Cont 12 5 CABLING DIAGRAMS A FLUX SHIFT PROGRAMMER Device UNT __ BREAKER BACK FRAME LEFT POLE CURRENT SENSOR m e 55 PROGRAMMER 1 350356 9 CONNECTOR LOAD FIG 69 CABLING DIAGRAM MICROVERSATRIP WITHOUT GROUND FAULT B y FLUX SHIFT PROGRAMMER DEVICE BREAKER Z BACK 5 LEFT POLE RRENT SENSOR HARNESS CONNECTOR AMP 1 350356 9 PROGRAMMER CONNECTOR FIG 90 CABLING DIAGRAM MICROVERSATRIP WITH GROUND FAULT ON 3 WIRE LOAD 66 oC PROGRAMM
349. y disconnects or to a terminal board Under normal conditions the coil remains energized and the breaker may be closed Dropout of the armature with resultant breaker trip ping occurs when the voltage is reduced to a value between 3096 and 6096 of the coil rating An open armature will render the breaker incapable of closing The MOUNTING BRACKET ae FIG 29 SHUNT TRIP AND UNDERVOLTAGE MOUNTING armature will pick up and allow closing if the applied voltage is 8596 or more of the coil rating It may also pick up at a lower voltage Refer to table 25 for pickup and dropout ranges The armatute of the undervoltage device may be tied closed inorder to permit breaker operation during main tenance ithe undervoltage device is mounted to the underside of theybreaker front frame as shown in Fig 29 A second undervoltage may also be mounted to the frame see Fig 31 if a second shunt trip isn t already installed see Section 7 7 If a second undervoltage device is added a new buffer assembly block will be supplied This is required for clearance in this case the buffer assembly must be taken off disassembled and remounted together with the number two undervoltage device Before disassembling the original buffer carefully measure the distance between the faces of the threaded members as shown in Fig 31 and set this dimension carefully on the new assembly Refer to the breaker wiring diagram for the coil lead connect

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