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USER MANUAL

1. ze JM M 36 X Key position 4 Key number 20 Closing solenoid drive with SU control unit Fig 26 SU control drcuit 20 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 4 3 6 Shunt trip control circuit Standard DC 24 V shunt trip with control PCB Closing 6 l STOP relay l O A ST coil Ss 36 X E Key position 5 Key number 00 Without shunt trip or zero voltage release Key number 10 With shunt trip e The closing STOP signal is provided for resetting K2 on the SU control circuit It effects with priority in switching OFF by ST or UVR before switching ON Once switching ON and OFF signals are simultaneous switching OFF command will stay longer than switching ON It means that OFF command is master command e The shunt trip operates for short time period only After main contacts open switch HS 11 cuts off shunt trip coil e Manual closing of the breaker while S2 contact is closed leads to overheating of ST coil and will damage coil Fig 27a ST control circuit 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice Below non standard shunt trip with single winding directly supplied from external DC voltage X2 6 X13a 7 Breaker s aux contacts Below non standard shunt trip with double winding directly supplied from external DC voltag
2. Relevant standards 4 Railway DC acc EN50123 2 1 R LY DC acc IEEEC3714 2 China ace IEC947 2 amp GB14048 2 3 Railway amp Industry applications Military type acc MIL C 5015G see comments here 1 Without see comments here Protection options f Without 0 Forced tripping release ik Without 0 see comments here Impulse coil release 2 Without 0 3_ Impulse coil w o internal C bank 1 Auxiliary tripping device 4 Without 0 5 6 Standard Shunt Trip 2 R Shunt Trip external 110 Ydc 3 see comments here OC trip target 1 Without 0 see comments here 7 2 Ordering Quantit Jima 60 breakers per order Breaker number to Ceteleguene AAA AAA af MAA Diagram no fi m gt Unlock OnRequest options KZ Customer s reference no TF Special ratings tested by customer A Codename Opty Name coe Name ES ETT swim 1 mwdms NE 2 6 3 rapid 60073 Gerapid 20S A 4 IT E EUA EEN 5 BAU code 1 K_ BB QB BP vt y yqvt yq ooo Qqgqmqmqmu 6 arc chute type A eS E 7 5 8 impo BE 21a amp 800v E 9 ILIC code 2 E Closing solenoid supply voltage svoe aowa 7 8 AA E 2vat o9 A E 24v t E STE code 3 AAA On Request CR Main terminals layout HiH IHerzotd 222 Y 1
3. 13S yu 0z 138 yu 02 v 13S vu 03 v 138 15 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 4 3 Electrical diagrams 4 3 1 Wiring code The main circuits are not shown in the wiring diagrams for transparency The control circuit is presented as a typical circuit diagram and is a combination of numbered basic diagrams for drives trips and indicators Using the key numbers of the basic plan you can derive the number of the complete diagram Some non standard electrical circuits do not comply with the diagrams in this instruction Such circuits are coded with unique numbers i e 36 0033 In such a case an appendix to this instruction is delivered which con tains relevant electrical diagrams Coding positions Key position Breaker type Aux voltage supply ED impulse release Closing drive Aux tripping device Indicators Aux switches SELsystem EXAMPLE 36 1 O 20 20 01 1 Key number Gerapid With voltage converter With ED coil and NEKO With closing drive With UVR release With OCT trip target With 3 aux switches Without SEL system 4m igh Speed DC B Qircuit Breaker Gerapid 4207 Ine Gerapid Arc Chute Type 1x2 1000 V 2000 V 31 5 ms Iss Standard EN 50123 2 36 102020011 Serial no GE catalogue no 21A4 0025 R160 1101 0011 Customer ref no 555 555
4. E 6 kA 12 kA 8 auxiliary contacts M 230 V AC q Us 24 V DC T Type C changeover 250 V AC 50 Hz 5A 220VDC 0 3A Made in Germany August 2009 Fig 22 Example code shown on the nameplate 16 Design and specifications are subjectto change without notice Key Key Designation position number Type 1 36 Gerapid Auxiliary voltage 2 1 Voltage converter 2 DC 24 V external supply Tripping coil 3 0 Without ed trip coil 1 With ed trip coil 2 With ed trip coil and NEKO control unit Drive 4 20 Solenoid drive with SU control unit Tripping device 5 00 Without trip unit 10 With shunt trip 20 With zero voltage release Indication device 6 00 Without indicators 01 OCT trip target 02 Arc chute indicator 03 OCT arc chute indicator Auxiliary contacts 7 1 3 auxiliary contacts 2 5 auxiliary contacts 3 10 auxiliary contacts Current measurement system 8 S with SEL Indication of components Q1 Impulse ED coil Q2 Closing drive coil S1 Push button CLOSE S2 Push button OPEN type NO S3 Push button OPEN typeNC SU control PCB K1 Closing relay K2 Internal closing stop relay Shunt trip zero voltage release PCB K1 Internal closing stop relay K2 Trippingrelay HS11 Shunt trip self cut off auxiliary contact ED tripping device with internal NEKO PCB K1 Voltage monitoring relay K2 Internal closing stop relay 1 These relays are par
5. e S2 X2 6 7 is NO contact utilized for indirect releasing of the UVR by relay K2 e S2 X2 8 9 is NC contact utilized for direct releasing of the UVR If it s not used please short this connection perma nently Fig 28 UVR control circuit 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 23 4 3 8 Indicators Arc chute indicator 36 x Key position 6 Key number 00 Without indicators Key number 01 With OCT triptargetonly Key number 02 With arc chute indicatoronly Key number 03 With OCT triptarget and arc chute indicator Fig 29 OCT trip target and arc chute indicator 24 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 4 3 9 Auxiliary switch X4 N e y LO e e I I zL I I X5 o o N ceo o eo eo n e n I I T E 36 x E Key position 7 Key number 1 With 3 switc hes HS1 thru HS3 Key number 2 With 5 switches HS1 thru HS5 Key number 3 With 10 switches HS1 thru HS10 Fig 30 Auxiliary switch 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 25 4 3 10 SEL measuring system x17 X6 1 XB 2 2 X5 3 X6 4 al 1 21 X5 5 X6 6 Voltage stabilizer Self check control 17 Xx10 10 X137 X10 10 X2 3 DC 24V DC 24V x126 X5 10 6 9 Umax 5002 2 max 500Q2 3 min 300kQ a Key position 8 Key number S Wi
6. tilt and gap Pay attention to the warnings Section 1 A Remove the arc chute and adapter e See6 14 A B B Check the tilt of the main contacts e Fig 45 Use the hand lever for slowly closing the main contacts e Fig 46 Once the arcing contact touches arc runner check the air gap between main contacts The gap be tween main contacts shall have more than 1 mm 0 04 in e Incase of insufficient tilt gap replace the arcing con tact with new one See 6 2 1 and 6 2 2 for details e f required gap is not available even after component replacing please contact GE Service Team C Check the air gap of arcing contact e Close the breaker and secure the solenoid drive against unintended opening See 1 2 1 e Fig 47 Check the air gap between the arcing con tact and main arm It shall be minimum 1mm 0 04 in e Incase of insufficient gap replace the arcing contact with new one See 6 2 1 and 6 2 2 for details e f required gap is not available even after contact re placing please contact GE Service Team D Install back adapter and arc chute e See6 1 4 G H 6 1 6 Inspection ofthe screw connections Pay attention to the warnings Section 1 e Fig 41 Tighten front and backside of the arc runner screw connections 3 and 5 Use torque of 10Nm 88 in lbs e Fig 41 Tighten arc chute connections 4 Use torque of 5 Nm 44 in lbs e Fig 41 The arc runners screw connections 3 must be s
7. 1000 39 4 18071 1807 1 i000 e007 e Tuesta vea 190 93 300 018 20 v8 38073 1 1 h owes boe ux ub xD cau a cun doe ud ee Lu earn moss locaal sonra l 0010 1000 hmm Ce eres A rosca ee A ea IA O a fr Jura wa oca 1803 roo rra TA Tu eat 80219 Trova eogi sogn 3803 IN A e A AA AA A A AA es A ee A ee 87 xe mea voa woes 500078 50 018 rra 3 ER _ vossasios we oos 1803 oro rea LLL pa MS mE EE EE AAA as d 2 Los Ty To TT T 7 1 will be checked by custom ersorder 2 acc IEC 947 2 ks setting lt 12 kA H Hori zontal terminal V Verticalterminal SEL Current measurement system type SEL Legend for dimensional drawings IK Heatsink for Gerapid 600 7 All openings respectively free areas onthe top of the cubical shall be not less than 50 M Solenoid drive P Diameter 9 mm 0 35 in Countersunk screw M8 S Control box Z Connector 2009 09 02 S47183e rev 03 Design ard specifications are subjectto change without notice 29 5 2 Outlined dimensions 5 2 1 Gerapid 2607 4207 6007 with arc chute 1x_ ais o 0 2 oo oO N N P Iere ee e z e 818 z981 EZY eet E T TT t Z E j 1 LN N F E e 9 e 92 z S529 p Tey N Quo S a l cO g 9 10 gi un 05 S LOL zo sT S
8. 128521 RO2 ML o 7 ML FHz ies 7 607 4207 6007 007 with triple terminals 007 with single terminals A N A A Arc runner back side Arc runner front side 128 525 RO1 RO2 Fixed main contact 607 NA 128108 R01 207 NA 128108 R02 007 NA 128108 007 128108 RO4 ML Ix 7E7 12 128 15 516 Ro1 Set of petectonwols p x iz9sisse po Mm 2607 4207 6007 128 203 Additional ground insula ton Epmgbarep i f VA 1209 Upper domper JL f a os Lower domper ML WA eos Adapter Movable main contact 128 525 RO3 RO4 128 815 128 515R01 R02 128516 R01 RO2 ALL EFi2 128500 Ros Probe protection cop ALL AL 128529 128550 R02 128 550 A 128550 RH disons T exa 600v gt x 128550 Ri 128 550 Forced tripping release AL 1 Check the nameplate to define type 2009 09 02 S47183e rev 03 Design ard specifications are subjectto change without notice 49 6 3 2 Electrical spare parts SU control PCB ALL N A 128 700 ST control PCB LL N A 128 710 R01 VR control PCB 128 710 R02 nterface plug xternal supply 24 V DC 5 N A 1 CMD 150 24S24W GE CMD 150 48S24W GE CMD 150 110 S24W GE CMA 150 70 S24W GE gt i gt m Voltage converter gt E tandard NEKO PCB xternal NEKO 3C PCB xternal NEKO 4C PCB LL obsole
9. 9 or OZ OTOT 897 Iz VEZ M 8 Occ co e a a LD amp e oz 81S 9s 2z O02 T6 ZzZ 385 E 987 izo 9 riz 0 S LOL zo ST S 18 Fig 35 Gerapid 8007 with arc chute 2x dimensionsin mm and inches 33 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 5 2 5 Gerapid 2607 4207 with H H terminals It s possible to combine horizontal and vertical connectors Dimensions are corresponding Note with SEL option top conne ctor is vertical only 195 1 95 Gerapid 4207 PA 336 6 14 43 Fig 36 Gerapid 2607 4207 with horizontal terminals dimensions in mm and inches 34 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 5 2 6 Gerapid 2607 4207 with V V terminals It s possible to combine horizontal and vertical connectors Dimensions are corresponding P o 8 Gerapid 2607 ow amp 3 Gerapid 4207 0 55 Em 1 18 a m 28 gt 53 a 7 Fig 37 Gerapid 2607 4207 with vertical terminals di mensionsin mm andinches 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 35 5 2 7 Gerapid 6007 terminals Gerapid 6007 is available only with V V terminals 101 3 98 e e Gerapid 6007 Fig 38 Gerapid 6007 with vertical terminals dimensions i
10. Hlorizontal 4 v v B Special type B with 2 HAV Vertical 5 For SEL6kA Special type 3 wH 6 For SEL12k4 R On Request Code 15 M p o Sidewalls protection panels T Top connector 2 Top connector f Not apply Rodent proofing SEL operation temperature Code 6 Code 14 E 1 Ta 35 C D without SEL With 2 Ta 55 C Code 13 Over current release OCT ET EE Code 7 with 4 Fixed setting up to 15kA Polarized adj O4kA 12kA 0 without 2 Adjustable up to 15kA Polarized adjust 03k4 25k4 OCT Code 12 3 Fined setting up to 24k4 Polarized adjust 2kA 6kA Impulse coil with internal C bank NEKO EE Adjustable up to 24ka Polarized adjust 4k4 8k4 see comments here Control circuits supply voltage Code 8 Code 11 1 festernal 24V DC 5 4 B8 145V DC Shunt Trip external 125 Yde 2 24v 24 DC stabilizer 125 353V DC 115 240V AC Shunt Trip external 220 Yde 3 33 85V DC On request Standard Zero Voltage Release see comments here Auxiliary contacts quantity changeover type Code 9 Code 10 1 3 convertible contacts 3 9 convertible contacts R On Request with 2 5 convertible contacts 4 10 convertible contacts see comments here Design and specifications are subjectto change without notice 51 ila s as ie v a eo xo 21 32 1s 14 15 16 17 codea o o o o ej ojoj o ojoj ojoj oy o o 0 Code 20 LV DC acc IEC60947 2 On Request Gearapid SE retrofit Heavy Industry type
11. and the counter spring s force 4 Once the load current exceeds the set static response threshold the attraction flux PA 2 takes over and rapidly pulls down the flexible armature 3 During this operation the armature hits the seesaw which releases the quick latch in the mechanism The latch and contacts are opened immediately The response threshold can be easily adjusted by turning the adjustment nut with a SW6 hexagon wrench The available ranges are described in the table below Other ranges might be possible on request When supplied with the optional transparent side protec tion covers Code 15 a fixed mounted insulated knob is provided to enable OCT adjustment Fig 16 Fig 7 OCT device Default tripping bands for the OC release No OCT bond 2607 4207 6007 8007 Eques ot haa EE 4 1 Customer specific bands on request Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 3 2 5 ED impulse coil release Code 12 Fig ED impulse release requires an external protective relay for monitoring a current increase This relay must be pro vided and installed by the customer If a fault occurs an external relay signal wired into the capacitors control unit internal NEKO or external C bank causes NEKO unit to discharge its energy into ED coil Fig 8 The coil trips the breakers quick latch and opens breaker s contacts in
12. been tested After agreement with GE both parties decided to create special version of the breaker and assign to it a letter a as extension of standard name These breakers will be a retrofit units replacing old Gearapid SE type Load current of 3200 A Operating voltage of 27 50 V High power low stability source 220 V AC available for closing solenoid Terminals suitable to install SEL current measure ment syste m Plus pole connected to the TOP terminal With SEL measurement system Without OC release Low power high stability 24 V DC source available for control supply 9 With maximum possible number of auxiliary contacts Without OC triptarget Zero voltage release With ED impulse release supply directly from external C bank Without forced tripping release With contacts position indicator With side insulation panels With hand lever Without arc chute indicator Counter not avail able Special retrofit connectors for Gearapid SE breakers According to IEC 60947 2 standard User Manual must be in Polish 205R51201406101110034 ONAN C4 9 FP 19 20 21 Correct catalogue code shall be General remarks e Customer s special solution with non typical ratings Additional letter a will be assign to this configuration exclusively Later customer can use this letter to call the same configuration e itis possible to supply closing drive and controls from two separate source of power 41 2009 09 0
13. 2600 W 100 ms 8s w o NEKO installed 14s with NEKO DC 33 85 V DC 24V 5 6A permanent PCMD 150 48 S24W GE Voltage range Voltage range Current odel description DC 88 145V DC 24V x 596 6A permanent PCMD 150 110 S24W GE Voltage range Voltage range Current with plug and socket unit Aux contact HS 1 HS 10 Rated operational voltage Ue AC OCT and Arc chute indicators Rated operational current le AC 15 Rated operational current le AC 12 Ith Rated operational voltage Ue DC Rated operational current le DC 13 Minimum current voltage ratings Contact duty min value Shunt trip standard Rated voltage power Uc Pc Operating range OFF Shunt trip double winded Rated voltage power Uc Rated power for a single winding Pc UVR Uc Rated voltage Operating range OFF Operating range ON Power consumption Energie source Capacity Charging voltage Switching interval Endurance Firing signal level duration Charging signalization relay Zero voltage release EDimpulse release AC duty AC115 240V DC125 353V DC 24V 5 3A permanent 5 A 100 ms PCMA 70 S24W GE requires extrnal 24 V 5 DC 0 1 mA 6V DC DC 10V 2 mA E 21 6V 264V pue 1230 W 24 V 410 10W 300 V max 2 min with 10 consecutive operations 1000 operations with 1 operation per 180s 6 24 V 100 1000 ms AC 250V 05 A AC 120V 1A DC duty j DC 220V 0 1A DC 125V 0 3A DC 10V 3A Stan
14. 4 ZW Onrequest ens A 3 2 0 7 eee 77 En WN equested maks on the scale 600 ka roo ka eoo Aka ooo kA lopo ka tipo ka To 33 voltgde AA A 34 code 8 A MA AAA eni EA e A S a 7 0 1 1 1 E TEA E 8 HIST coge PR d 38 6 taraet a AAA Pf p wo ES A z p cod 6 4 piilse coil release decur Dy Kb Forced trinpina release With 55 LBM code 17 0 2o o d Railway amp Industry applications T code 19 bj 1 a i uu Protection options 3 0 1 0 Relevant standards Railway DC acc ENSO123 2 i 2 63 CUS code 20 1 E 65 L LN6 LER 1 ima 50 breakers per arder Breaker number to AEREA EEE TER ES ENSE TES ERES 36 102020011 PL Unlock On Request options YY Customer s reference no gt LLLA 4 Special ratings tested by customer Wy COTO a yA Mme po Yt YE po Gerapida20r 7 7 1 2 s 1 0 0 y 7 Z HOYA Le E A A n a JA TD LA YO L ALL Sy LL f EO MT E SS AN 184 20001 Closing solenoid supply N D gt 2 E P m P v AC ano wo mou Not apply 0 ojojujajun Jo D 0 ALL YEN EEE 7 N m mjolojunie A S AS tandard Zero Voltage Release 6 S LLM 0 With 1 gto am n os Los On Request 7 2 2 Example of order no 2 USA customer wants to buy Gerapid for DC drive application The c
15. E time lume ee eee ee adjustment inspection B E justment and changing Trained technician inspection B E justment might be necessary GNE du a ae inspection B E AAA oe ollie d MEE RN inspection B E Table4 Required tools Cleaning tissue Pocket lamp Hand lever Hexagon wrenc h SW 4 SW 5 SW 6 Screw wrench SW 10 SW 13 Torx wrench size 30 40 and 45 Small and medium screwdriver Pliers Wire cutter File Steel brush Safety hints Securing against falling parts Place a cloth into the lower area of the arcing contact Fig a Rememberto secure the closing drive accordi ng to Hint 3 Fig a Protecting of the ardng area against falling parts 2009 09 02 S47183e rev 03 Maintenance with zero voltage release If an optional zero voltage rele ase is in stalled it must be energized to enable closing of the breaker Only then maintenance of the arcing con tacts is possible Hint 3 To prevent the risk of injury itis recom mended to secure the breaker in the closed position with a simple mechanical interlock device Fig b A piece of tubing having 50 mm 2 in length and in ner diameter of minimum 14 mm 0 55 in works well The outer diameter of the locking rod shall be less 8 mm 0 3 in GE does not offer thislocking device Closing drive Secure tube k 7 Locking rod k Fig b Securing dosing drive against opening Design and specifications are subjectto change
16. L8 Fig 32 Gerapid 2607 6007 arc chute 1X dimensions in mm and inches 30 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 5 2 2 Gerapid 2607 4207 600 7with arc chute 2x_ Pay attention to legend warnings and safety distances pages 26 27 220 8 66 eses 98 6 02 81S 121 5 4 78 a a is SDN R 248 c og SS 3 i A E Q9 o a li 3 ee S See ee eee te CN T as io SLOL zo ST S 18 Fig 33 Gerapid 2607 6007 arc chute 2x dimensionsin mm andinches 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 31 5 2 3 Gerapid 8007 with arc chute 1x Pay attention to legend warnings and safety distances pages 26 27 Se 901 OLE 9T OT 897 126 VES 99 8 Occ AD NO auae os iz OO 1622 C89 izo 9 60 6T S87 sl 6501 SL footy T62T SGV gl 801 OMS 65 0 iz ze 818 gt ELY ez T T trt 2 aT del P izz LOL zo ST G L8E w S 0 Fig 34 Gerapid 8007 with arc chute 1x dimensionsin mm and inches 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 32 5 2 4 Gerapid 8007 with arc chute 2x Pay attention to legend warnings and safety distances pages 26 27 M t
17. ST coil s overheating and damage Fig 9 Zerovoltage release 3 2 7 Forced tripping release Code 13 Optionally the forced tripping release FT can be installed in the breaker Fig 10a This unit mechanically trips the breaker by pressing the pin against the bottom plate Force required to trip the breaker is about 30 N 7 ft lb The tripping pin position is as on Fig 10b GM p F 30 N initial position L 15mm 0 6 in tripped position L 8mm 0 3 in Fig 10a Forced tripping release Design and specifications are subjectto change without notice 7 With a correctly designed interlock in an enclosure FT pro vides safety tripping function During withdrawal operation of the trolley the breaker is tripped BEFORE its main terminals disconnect from the mains Bottom view Fig 10b Positioning of the forced tripping pin 3 2 8 Lever for manual operating Code 16 e Optionally a hand lever for manual closing and opening operation during maintenance is available This tool must not be use while breaker is energize dl e Toclose the contacts install hand lever onthe drive s rod and pull it out smoothly until latches snap Fig 11a e To open the contacts install the tool into the ring and push it hard against the drive s rod until breaker opens Fig 11b 200N 45 ft lb ring Manual closing only during maintenance Fig 11a dosing operation by using handlever Ma
18. and voltage listed in Table 1 sec tion 3 3 e During continuous operation breaker must only be loaded up to its maximum rated current Load currents in excess of breaker nameplate rating are allowable for brief periods Refer to the short time currents listed in Ta ble 1 e Donot exceed the rated operating voltage shown on the breaker s name plate e Supply voltage for the drive and the auxiliary tri pping de vices Code 8 shall be within the specified control voltage range Maxim um current values for the auxiliary tri ppi ng devices are listedin Table 2a e Plugging in or unplugging ofthe auxiliary connectors X2 1 2 X3 4 5 is only allowed with disconnected primary mains and secondary voltages 2 3 2 Adjusting the over current rdease e OCT is an over current tripping release Code 7 which trips and releases the breaker incase of overload or short circuit currents This is aninstantaneous and direct acting device e f equipped with an adjustable OCT the response thresh old can be easily adjusted Fig 3 by turning the adjust ment nut 1 with a SW6 hexagon wrench 2 e The adjustment must only be carried out after the breaker has been disconnected from the main circ uit For fixed installations breakers main terminals shall be grounded e Turning the adjustment screw clockwise increases the trip threshold turning the screw counter clockwise de creases the tripping threshold e Align the arrow and the desired
19. e Fig 41 Put arc chute 1 into adapter 2 e Fig 41 Tighten front and backside connections of the arc runners 3 including lock washer Use a torque of 10 Nm 88 in Ibs e Fig 41 Tighten front and backside of the arc chute connections 4 including flat washers Use a torque of 5 Nm A4 in Ibs e Fig 41 Put on isolation caps 6 Fig 41 Arc chute and arc runners fixing Design and specifications are subjectto change without notice 39 Fig 42 Inspection of the arc chute 6 1 4 Inspection of the contact system Pay attention to the warnings Section 1 A Remove the arc chute e Fig 41 Loosen the clamping screws 3 and 4 using SW5 hexagon wrench and take off the arch chute 1 from the adapter 2 B Remove the arc chute adapter e Fig 43 To dismantle the arc chute adapter loosen and pull out the four uprightscrews 1 using SW5 tool Pay attention that no screws or washers fall inside the breaker e Fig 43 Draw aside and lift off both parings of adapter 2 Then pull out two protective walls 3 zm 1 Fig 43 Adapter and protective walls 40 Design and specifications are subjectto change without notice Fig 44 Checking the contact system C Check the protective walls e Fig 44 The material burn out on the protective walls 5 shall not exceed 1 mm 0 04 in at any place D Check the arc runners e Fig 44 The arc runners should not be burned more
20. fForsELSka CC jS Top Bottom 5 SSCS fn Request CdR i ee IS CT EC E ANS code 4 TS E TE E 22 Main terminals polarization A EEE Cid d IT 0 23 POLL codes MN IA TS TN E 24 SEL operation temperature CEE EY y s irstil code 6 ASA AAA pem FAN Fred settng opto SRA MO LECCE OTRAS adjustable upto ska TO 2 Polarized adjust 08ka 25ha 5 __Fined setting up T E Pslrzedadustzk Sk 222222 KA code 7 Adjustable upto2aka Sa Fslrzedadustakacck E 30 pequested marks onthescole IE Ika LIS T I Jka Jka JO rei o 31 PKA TA ka Aka a 32 Contralcrcuts supply voltage eMemozavpuw T 1 wv JOTA 33 E 2 E 5 34 NET code 8 E TE EN TEE TS E es ET TT 1 ilconvertble contacts E 36 ___Sconvertiblecontacts 2 fonReqet OR 37 HIsI code 9 9comvertiblecontacts 2222 3 y 38 OC trio taraet TT E 39 KSMI code 10 MEC E E 40 auxiliary tripping releases Without O Shunt Trip external 125 Yde 4 ul B Li untrip eternal 220 Ve Pd 32 5 43 HILI code 11 ea Shunt Trip external 110 Vde C o 24 ED imoulse collrelease Without SSCS 0 TERA E 45 EDA code 12 T e T CSS 46 Forced tribvina release TT A 47 2W a code 13 A E E 48 Contact position indicator TT TA 49 STA code 14 EE a E ee 50 rtecionootons Mie D
21. is initiated after the initiation of the closing operation even if the closing command is maintained To ensure proper breaking of the current which may have been established it may be necessary that the contacts momentarily reach the closed position U UVR control PCB control circuit designed as a single PCB for RIPE the EE release device Zero voltage release also under voltage UVR r rdease An auxiliary tripping device Trips the breaker open on control volt age loss Opening time is less 75ms It is used for remote OPEN operation or control voltage supervision Interchangeable op tion with shunt trip release Activated by means of auxiliary po tential free NO or NC contact Design and specifications are subjectto change without notice 56 7 4 Troubleshooting Breaker will not CLOSE A Closing drive doesnt operate electrically but it is still possible to close the breaker manually by mean ofthe hand lever 1 Check the supply voltage of the drive X2 1 2 The voltage shall not be less than 80 of drive s rated voltage 2 Check the supply voltage of the controls X3 4 5 The voltage shall not be less than minimum input voltage required for installed voltage converter 3 Calculate the voltage drop at both supply lines and check for ade quate wire size 4 Check the polarity of the supply connections 5 Check continuity of the control connections Openthe control box WARNING Following operati
22. less 3ms ED impulse release is an optional accessory Complete set consists of ED coil and electronic control unit with C bank called NEKO The external release signal shall be 6V to 24V DC and shall be connected at terminals X2 10 11 in standard wiring sc heme Customer supplied capacitor trip unit may be used Rated voltage of 300 V and capacity of 2 000 UF is required In this case only ED coil will be installedin the breaker Firing signal voltage level is between 6V and 24V There should be no spikes on the signal of duration less 3 ms This can lead to defect of the NEKO board Maximum duration of the firing signal must not exceed 1sec Longer signal can lead to NEKO overheat It is recommended to use an auxiliary contact in serial con nection with firing circuit X2 10 11 It will automatically cut off the firing circuit after breaker opening 8 EDimpulse coil with seesaw interface 3 2 6 Auxiliary tripping devices Code 11 2009 09 02 S47183e rev 03 The breaker can be equipped with either a shunt trip ST or a zero voltage release UVR It is not possible to have both devices installed in the same breaker Both devices are interc hange able In standard configuration internal voltage converter Code 8 transforms external voltage into 24 V DC which is required by ST or UVR Both devices are tripped by a potential free contact connected as shown in section 4 2 Optionally ST can be connected directly to ex
23. marking 3 to perform adjustment I F Fig 3 Setting of the OCT unit Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 3 Technical information 3 2 Components and accessories 3 1 Introduction 3 2 1 Contact system Gerapid is a high speed DC circuit breaker This is a sin gle pole DC breaker primarily designed for use in railway power distribution systems with operating currents up to 8000 A Code 1 and operating voltages up to 3600 V Code 2 Additional applications are special industrial plants such as electrolysis mining or steel mills Gerapid breaker has a very high interruption capacity combined with a current limiting characteristic The arc chute works on the basis of an asbestos free arc splitting All Gerapid breakers are equipped with a two stage con tact system Fig 5 consisting of a main contact and an arcing contact With this proven design the main contact is not subjected to any appreciable wear or tear The main contact is made of a silver composite material The arcing contact and link braid are made of copper and can be easily replaced The flexible bend is linked to the arcing contact by means principle of very tight braid e A wide variety of accessories and spares are available for gt maintenance repair or as a possible enhancement The breaker is configured by using the catalogue coding system which is describe in section 7 1 Each rating op tion o
24. older systems the control boards may be installed Fig 55 3 Carefully lower the box cover turned 180 46 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 Fig 55 5 Pull out the zm ofthe control boards Pull out selected control board Insert new control board e Listen that both the isolation plate at the side of equi pment and the isolation plate at the side of sol dering were inserte d Screws Fig 55 7 Pay attention that no cables will be pinched between box and front cover during closing arefully replace the control box front cover g and attach the with the four screws e Put on plugs X2 X6 fix the screws of the plugs and switch on control voltage Checking the breaker e Openand Close the breaker 3 times while it is discon nected from the system in the Test position of the draw out version the installation The breaker must open and close without a time delay over 400 ms e ifthe test succeeds reconnect the breaker to the main circuit 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 47 6 2 5 Adjusting the auxiliary switch A Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock 1 OPEN the breaker 2 Disconnect power supply and pull out all the plugs from control box s terminals 3 In case of NEKO control unit inside wait 1 minute u
25. on any rough surface e The breaker s weight including arc chute is listed in Table 1 page 13 Arc chute s weight is ca 30 kG 66 Ib for 1x type and ca 60 kG 132 lb for 2x type e Storing tips e Store in original packaging e Do not store outdoors e Use protection against crush and blow e Do not store the breakerina damp area e Storing temperature range 25 C 55 C Design and specifications are subjectto change without notice 3 2 2 Installation 2 2 1 Operational environment The breaker as delivered is IPOO NEMA 1 protected It is intended to work in indoor applications without pollu tions with non conductive dust protected against high humidity and condensation Low conductivity dust de posit due to frequent condensation of humidity is accept able General environmental conditions refer to EN 50123 1 annex B and IEC 60947 class PD3 The breaker can operate at rated current within ambient temperature range of 5 C to 40 C 23 to 104 F Maxi mum operating ambient temperature is 55 C 130 F with continuous current derated by 10 The breaker can operate at altitude up to 2000m 6500 ft without derating The breaker shall not be subjected to strong vibrations Maximum vibrations of 0 5g per 30sec in vertical and horizontal directions are allowed Air shall be clean and its relative humidity shall be not more than 50 r h at the maximum temperature of 40 C 104 F Relat
26. opening 2 Check contact system area Look for any parts that may be stuck between contacts or into mechanism module 3 If the zero voltage release is installed check connec tion of S2 pushbutton If only NO type X2 6 7 is used be sure that X2 8 9 is shorted Open the control box only when UVR is installed 4 Check the wiring connections for UVR PCB 5 Check supply of the UVR control PCB X13 7 8 Contact GE Service in case the problemis not solved 2009 09 02 S47183 e rev 03 Breaker will not OPEN WARNING Below operations are done with control voltage connected Only trained specialist or GE Ser vice representative shall perform them Risk of electric shock A Shunt trip does not operate Breaker is able to CLOSE and OPEN by means of hand lever 1 Check points A2 to A5 2 Check the self cut off contact HS11 X14 1 2 3 Check the wiring connections and supply line of ST PCB X14 7 8 4 Check the continuity of shunt trip coil X14 9 10 5 Replace the ST PCB or ST coil if necessary Contact GE Service in case of problem is not solved B Zero voltage release does not operate Breaker is able to CLOSE and OPEN by means of hand lever 1 Check points A2 to A5 2 Check point B3 to B5 3 Check the continuity of UVR s coil X13 9 10 4 Replace the UVR PCB or UVR coil if necessary Contact GE Service in case the problem is not solved C ED impulse releasedoes not o
27. subjectto change without notice 6 INSPECTIONS AND MAINTENANCE 38 6 1 List of INSPECLIONS cesessseccceceeeecssssseceeeeeeeeeees 38 6 1 1 General visual inspection 39 6 1 2 General functional inspection 39 6 1 3 Inspection of the arc chute oooooooocococcccccccn nooo 39 6 1 4 Inspection of the contact system 40 6 1 5 Inspection of contacts tilt and gap 41 6 1 6 Inspection of the screw connections 41 6 1 7 Inspection ofthe mechanical components 41 6 2 List of maintenance works eese eee 42 6 2 1 Maintenance of contact system after 11 2003 43 6 2 2 Maintenance of contact system before 11 2003 44 6 2 3 Layout of control PCB inside control box 46 6 2 4 Replacement ofthe control boards 46 6 2 5 Adjusting the auxiliary switch 48 6 3 Spareparts lists nesesario eene enn 49 6 5 1 Mechanicalspare parts ssssssssss 49 6 3 2 Electrical spare parts ssssssss 50 6 3 3 Recommend materials forselected works 50 7 CUSTOMER SUPPORT eee 51 7 1 Options OVE EW sesoses sesse siss sanesas eee eene ene nen 51 rere 52 7 2 1 Example of order no 1 53 7 2 2 Example of order no 2 esere 54 7 2 3 Example of order no 3 55 T3 GIOSS ONY asan
28. trip device The NEKO control unit is not furnished and coil is connected directly to front panel of control box X2 10 11 AS Breaker External SS Po AREA C bank X2 Q1 N EC i impulse coil i i N l gm Key position 3 Key number 0 Without ED coil Key number 1 With ED coil and external C bank Fig 24 ED coil with external Capacitor trip device 18 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 4 3 4 NEKO control circuit a I C cC aS ge a rs dl o e a rae ee eres e ee eee m X 16 NEKO PCB l Ss XQ D P UH 000000 b Isolating Transformer z l OW a Th EE TE oca rs Charging Control ee X3 6 charging signalization i l 7 Le AS i Charging Voltage 313 Control Closing E STOP relay i 6 i e E mure O Cut off I X2 a contact gesesssssssssssssssesssssssssssossssssssossosesescssoseseseesessoos thie m RE nM M ur I 10 3 nput circuit for firing signa i TION ie HS10 Tripping Firing signal idid lI signd l I control ee 6V 24V by user eer I 11 41 Even ELT yee TU A etssssssess
29. 0 Hz Ua kV eff 10 10 10 15 15 10 10 10 15 15 7 10 10 15 1 7 10 laccording to EN 50124 1 1997 DD o oO CE zi a e o um o 5 lt a zu o O D hort time current 2 min A v I Io Ear o omi m ee 3 D Q D 2 N o wn oO o Z Rated short circuit making capacity ns kA 70 50 100 50 42 70 50 100 50 42 70 50 80 50 1 70 1 Rated short circuit breaking capacity Inss KA 35 1 according to EN 50123 2 Rated service short circuit breaking current Ics kA Ra a d Ead od a Er E ERN according to IEC 947 2 Short circuit current according to IEEE C37 14 kA 120 1 120 60 1 120 1 Peak current according to IEEE C37 14 kA 200 1 200 100 1 200 1 120 120 160 120 120 160 160 160 150 150 165 165 165 190 210 Table 1 Technical data of Gerapid 2607 4207 6007 8007 1 Rating tests at customer request Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 Control box terminals 1x12 pole E 400V 20A 4x15 pole AC250V 8A Closing solenoid drive Rated voltage Operating range Power consumption Gerapid 2607 4207 Power consumption Gerapid 6007 8007 Minimal CLOSING command duration min interval between two CLOSE operations Voltage range Voltage range Current Internal voltage converter for Gerapid 2607 4207 6007 8007 AC48V 230V and DC48V 220V 80 96 115 96 of rated voltage 1750W 2000 W 2600W
30. 2 S47183e rev 03 Design and specifications are subjectto change without notice 63 64 65 LLNS 2 A Main terminals polarizqtj a Over current 27 release Oct 28 Gerapid 4207 m 3 s000V m n Request 220Vac or SELOk i A N Js POLI code 5 Ae operation tempera PS TsELI code 6 55 C t kA ay AS MAREA oo AE EA As a oun EB v LZ ZA Lm ka Y A WZ Wiis Aa OO ree EN B voltage DA fe A WU NET code 8 LOA AAA Tr A AA V3 EE changeover type A es i AA HIS code 9 AA A ECH IE E KSM code 10 o E IS E Auxiliary trippip M a A aoa ee rc EA M L EEE EE 1 Impulse coil w o internal C bank Boe ksa code 7 Without OCT tors circuits m 2 position indicgt code 14 SCH code 15 HAN code 16 AR Arc chute presence siqnal LEM code 17 E Counter Ee T code 19 ee Po CUS code 20 bs _ _ _ _ ______ CC e Documentation Lanauq Sidewalls protection panels earapid E retrofit 4 LEA amp ER n Request ES il De On Request 55 7 3 Glossary 2 a release see Shunt trip device Activating magnet see Closing drive Anti pumping device see SU control PCB Prevents reclosing after a close open operation as long as the device initiating closing is maintained in the position for closing Arc runners also arc probes arc hor
31. 6 Fig 50 Loosen screw 5a with tool SW5 Fig 50 Take out the front arc runner as it s shown Fig 50 Take out the back arc runner 4 by loosening two screws 4a with tool SW5 Don t remove the pro tective cap 4b Fig 50 Install new front arc runner 5 and new back arc runner 4 Tighten it using torque of 10 Nm 88 in Ibs Fig 50 Install front wall 6 and adjust it by position ing the protective wall 3 Fig 48 Tighten it using torque of 10 Nm 88 in Ibs Fig 48 Putin two new protective walls 3 Fig 50 Changing arcing contact Fig 51 Taking out the front arc runner of old design 44 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 D Changing the arcing contact Remove front and back arc runner See 6 2 2 C Close the breaker and secure the solenoid drive against unintended opening See 1 2 2 Secure the contact area against parts falling inside the breaker See 12 1 Fig 52 1 Initially loosen two braid s screws with tool and unboltthem finally by hand Fig 52 2 Remove the safety ring from axis pin end Fig 52 3 Pull out the axis pin from contact Fig 52 4 Replace arcing contact with new one Use old contact to lift up two washers and slip the new contact under these Remove old contact and rotate the new one by 180 to its normal orientation Fig 52 2 3 Re install the axis pin and safety ring Fig 52 5 Initia
32. Close the control box with front cover 1 by A fixing the four screws 2 Pay attention that no cables will be pinched between box and front plate e CLOSE the breaker several times Check if the auxiliary contacts are switching over correctly A cc A peee e Finally check the electrical functions in the TEST position of the draw out version after installing the breaker into the substation Gerapid in ON position Gerapid in OFF position Main contacts closed Main contacts open If re adjustment does not help please contact GE Service Aux switches not actuated Auxiliary switches actuated Team It might be required to install switch block again or to move switches to center of the block for better per 2 formance Fig 56 3 Actuating plate forauxiliary switch block 48 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 6 3 Spare parts lists Hints for parts identification 6 3 1 Mechanical spare parts NOTE Gray shaded parts are recommended for amaintenance stock as appli cable to your specific breaker configuration ee T 0 Service kit for replacing 0 arcing components 0 EGO EF4 12 2607 4207 6007 1x APN340110 RO6 Service kit for replacing arcing components After 11 2003 B x JAPNS40110 ROS EFA 12 lAPN340110 IR10 128 810 128 521R01 RO2 FERMEN ALL before 11 2003 128121 ALL 1x 128521 ro1 ALL 2x
33. Diagrams from the User Manual are not applicable here e Customer may call any special identification code that has been used in the past This will be additional reference number and will be placed on the breaker s name plate beside of the actual 20 digit catalogue code e Modifications of main terminals according to customer s drawings are possible after agreement with GE and after positive tests results e Choosing a double winded shunt trip will limit your available auxiliary contacts number to maximum 8 units 54 Design and specifications are subjectto change without notice ent 51 Relevant standards 62 63 tus code 20 Diagram no Customer s reference no 1 Breaker type 6 Arc chute type F LIC code 2 RN E 1 Top Bottom ANS code 4 Main terming gfizq POL code R tion Over cyfrent Set kA release 0C 24 0 KSA code 3 O VA marks on the scale 31 ue rine als m 45 EDA code 12 2 46 A 47 zw code 13 0 48 Er rcm gio 49 fie 14 En 51 KCH code 15 durer 3 HAN code 16 AA 55 LE M code 56 Brei 57 244 code 18 A 55T code 19 eN 6 LNG D Quantity 1 fima 5o breakers per order Catalogue no EER EGET ESSE EO ESTEE ESTESA ETE Ee OA E METH ERI EE o 4 Special wiring gt Unlock On Request options CY code
34. ED coil OCT device HS 1 HS 10 OCT trip target Arc chute indicator Description Designation X2 1 Connector Auxiliary and control circuits X3 2 Connector Auxiliary and control circuits X4 3 Connector Auxiliary contacts HS1 HS5 X5 4 Connector Auxiliary contacts HS6 HS10 X6 5 Connector Current measure system SEL X10 Control board Voltage converter X11 Control board Interface for external DC 24V supply OPTION X12 Control board SU control unit X13 Control board Shunt trip control unit X14 Control board Zero voltage release X16 Control board NEKO control unit forED coil control X17 Control board Currentmeasure system SEL Fig 20 Control system s layout 14 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 4 2 Terminals wiring system SSH Y SH SH c SH LSH opAye 9 jeubis Buy diy pe es pueuiuuo9 YAN Aq N3dO ZS pueuiuoo 1S Aq N3dO ZS pue WWOD 4SO19 IS 3d N Ajddns eAup Burso 2 es Ajddns eAup Burso 2 Ol SH 6SH 8 SH ZSH 9SH SEL self check uotiMs Jojeoipul Jojeoipui amyo 91y 190 Aq Buiddiai seyeoipu JoyeSIPU 190 YIM 6ulBseyo yueg 5 seyeolpul 40jeo put Bulb rey OMAN Ajddng e8e3jo0A 041002 eu e x3 Ajddns eBeioA jo41u02 euJo1x3 external customer Fig 21 Typical terminalswiring system connections AOL 13S AOL 138 yu 03
35. GE Consumer amp Industrial Power Protection N High Speed DC Circuit Breaker Gerapid 2607 4207 6007 8007 with arc chutes 1X2 1X4 2X2 2X3 2X4 USER MANUAL INDEX Ae WARNINGS eun ihenuxeTuunesneee 3 2 GENERAL USAGE CONDITIONS 3 2 1 Transportation and storing eeeeeeee eee 3 2 2 1 Operational environment oocccccoocccncccccccnnno 4 2 2 2 Installation and interfaces sssssss 4 A TOO 4 2 3 1 Supply and lodd ooccocoooccnccccoccnncccoccnnnno 4 2 3 2 Adjusting the over current release 4 3 TECHNICAL INFORMATION eee 5 EMT rei C 5 3 2 Components and accessories eese 5 3 2 1 Contact Systemy esie i y E EEn e EE RE RES 5 3 2 2 Arc chute Code 2 5 3 2 4 Over Current Tripping release Code 7 6 3 2 5 ED impulse coil release Code 12 7 3 2 6 Auxiliary tripping devices Code 11 7 3 2 7 Forced tripping release Code 13 7 3 2 8 Lever for manual operating Code 16 8 3 2 10 Indicators 9 3 2 11 Solenoid closing drive Code 3 9 3 2 13 Electronic control system ssssss 10 3 3 Technical data tables ooococcnncccncnnonocnncnncnnncnnons 12 4 ELECTRICAL CIRCUITS eese 14 4 1 Contr
36. OC release adjustable in range of 6 kA 12 kA with 7 marks onthe scale every 1 kA set at 9 kA 8 Auxiliary supply voltage of 230 VAC for controls 9 With 8 auxiliary contacts 10 With OC triptarget 11 With zero voltage release UVR 12 Without electrody namic tripping device 13 With forced tripping release for withdrawal operations 14 With contacts position indic ator 15 Without sidewalls protection 16 With hand lever 17 Without arc chute indicator 18 Counter not available 19 With standard control connectors 20 Testreport according to EN50123 2 standard Correct catalogue code shall be 23A40025R16011010011 General remarks e Please check the Unlock On Request options checkbox to enable en tering values which are not liste din this form Please always define the markings number and values for OC release Please choose the On Request optionto define own OC tripping range Use On Request option if available to define own not standard ratings Any other than first option for connector type are usually dedicated for retrofit purposes Please refer to special type of connectors options 2 3 4 R before choosing these Option 1 is suitable for most applications 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice Main terminals layout Main terminals polarization SEL operation tempera TSEL code 6 es Over current Adjustable up to 15k
37. a 56 S47183e rev 03 2009 09 02 1 Warnings AN Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock Warnings During operation electrical equipment carries dangerous voltages In addition circuit breaker emits hot ionized gases when switching currents especially short circuit cur rents Installing commissioning maintaining changing or refit ting of this equipment must be carried out only by qualified and suitably trained personnel and under strict observa tion ofnational and international applicable safety regula tions During their operation circuit breakers must be equipped with appropriately fitted covers e g in suitable enclosures or pand boards Safety distances must be preserved Suitably trained service personnel shall only carry out cer tain works Non compliance with these wamings may result in death and or severe physical damage and extensive damage to equipment Prior to carrying out maintenance inspection or checks the circuit breaker must be open the both terminals must be grounded the circuit breaker must be switched off and the control plugs removed Manual activation of the breaker while energized is forbid den Manual activation must only be used for maintenance and inspection purposes when breaker power is off and grounded The circuit breaker consists of high energy moving compo nents Do not touch the circuit breaker wh
38. als also control sockets plugs Fully in sulated sockets at the front cover of control box Intended for external connection to the auxiliary and control circuits E ED coil also el ectro dynamic coil An impulse coil release Ac tuating element of ED impulse release mounted on the base under the mechanism Electro Dynamic impulse release also ED tripping impulse release Release device consist of actuator ED coil and control circuit NEKO PCB with C bank This is an auxiliary release acti vated by high energy impulse of current The impulse is shaped by internal NEKO or external C bank Opening time is less 3ms Time to charge capacitors is 15sec F Forced tripping release also FTU forced tripping device unit Fully insulated direct mechanical tripping pin mounted thru the bottom of the breaker The breaker will be tripped open by pushing of this pin upward H Lever for manual operating also hand ever Hand lever can be used for both closing and opening manual operation It is in tend for use only during maintenance M Main circuit also mains primary circuit current path All the conductive parts of the breaker included in the circuit which is intend to close or open It consists of main terminals upper and lower fixed contact flexible band and lower bus bar Main terminals also main connections Two conductive bars provided for electrical connection to external main circui
39. ations Correct control PCBs or pre Wires 1 mm 1 5 mms 2 5 mm 500 V polymer insulation and control PCB pared wiring harness type upto 100 C ROHS compliant black change Plugs MSTBC 2 5 5 08 Terminations Crimp MSTBC MT 0 5 1 0 Crimp MSTBC MT 1 5 2 5 Receptacles 2 8 mm DIN 46247 withinsulation cap Dum pers change Damper 128 018 Screws amp Washers M6x25 M6x30 M8x25 M8x30 8 8 Damper 128 019 15014581 Optional Materials Transparent silicone E COLL 310ML glue Locktite Spring barcap 128 058 222 thermo paste WLP5 00 Changing of zero volt UV release 128 220 Screws amp Washers M6x25 M6x30 M8x25 M8x30 8 8 age release shunttrip Correct shunt trip 15014581 M4x10 8 8 DIN912 M4 ribbed lock washer Optional BN791 by Bossard Spring bar cap 128 058 Others Polyamide clip bands 25x100mm Materials Transparent silicone E COLL 310ML glue Locktite 222 thermo paste WLP500 grease Beacon EP3 by ESSO 1 For substitute materials please consult GE representative 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 50 2009 09 02 7 Customer support 7 1 Options overview The coding system introduced in 2008 is a catalog configuration tool based on Excel The catalogue code consists of 20 digits Each digit represents specific rated value or component Table 7 shows all available values components and accessories for the Gerapid break
40. d ard ambient condition sa cc to EN 50123 1 Attachement B For meeting outside of this standard range please call back Table 2a Technical data of auxiliary circuits SU Control ST releasing UVR releasing CLOSE push button S1 push button S2 push button S2 X2 6 7 push button S2 X2 8 9 ED coil tripping w o NEKO push button S3 ED coil tripping with NEKO Connect Firing signal at X2 10 11 Table 2b Control circuits directional values to rate the components 2009 09 02 S47183e rev 03 Technical datas of control circuits Us In DC 24V approx 10mA DC 24V approx 4A DC 24V approx 10mA DC 24V approx 450 mA DC 300 V 750A 3ms Design and specifications are subjectto change without notice 13 4 Electrical circuits 4 1 Controls layout X17 X13_X14_X15 x12 X10 x11 Xl o o o x2 x 6 0 a x 6 4 i WEE JEN XA Tii D c a 4 2 x6 WEE NM E T E hy Duct o E E PJ Q 0 A LA 10 Pa t Em jo 0 i gt C 3 l 9 1345678910112 __ O Q X3 X6 1234567891011 12 18 14 15 X10 X15 12345678910 X16 X16 12345678910 11 12 X17 123456798910 11 12 13 14 15 16 17 18 Closing solenoid drive Shunt trip Zero voltage release
41. e 1st winding 2nd winding X2 6 X2 8 X13a 7 X13b 7 Breakers Breakers aux contacts aux contacts l e Double winding shunt trip coil is available for external DC 110 V DC 125 V and DC 220 V e User shall provide fused means for safe switching the voltage to the coil See table 2afor coil parameters e Auxiliary contacts used for cutting off shunt trip coils are internal breaker s components Fig 27b Special versions of shunttripwith a single and double winding coils directly suppliedfrom external DC source 22 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 4 3 7 Zero voltage release control circuit SSS 2 K2 X14 UVR PCB lo py S3 icy Ia 21 13 E S2 6 Dx ccs al 5 Closing gt K1 STOP relay 10 11 pene oon l 71 7 DC24V 8 93 ica eae UVR coil i 36 ___X E Key position 5 Key number 00 Without shunt trip or zero voltage release Key number 20 With zero voltage release e The closing STOP signal is provided for resetting K2 on the SU control circuit It effects with priority in switching OFF by ST or UVR before switching ON Once switching ON and OFF signals are simultaneous switching OFF command will stay longer than switching ON It means that OFF commandis master command
42. e M4 3Nml 26 in lbs e Carry out inspection B above e Check out settings of the main contacts and auxiliary switch Check out upper dumper of the mecha nism no cracks deformation or heavy discoloration hard consistency without punctures Check out main flexband break age shall not exceed 30 of its cross sec tion Check out wear of mini flexband shall not exceed 30 of its cross section Clean and de grease UVR latch and quick latch of the mechanism A pply dash of Beacon EP2 grease afterwards S47183e rev 03 2009 09 02 6 1 1 General visual inspection e Check out for damages or cracks of the frame the adapter or the arc chute e Check out the black marks on the countersunk screws These marks shall be aligned together If any screw is loosening shall be replaced with new one using Loc tite 222 Afterwards mark the screw with black line to sign its position in nest e Checkoutfor missing screws or caps e Check out for damaged labels Clean and repair e Check out for corrosion In case of significant corro sion please contact GE representative for assistance e Check out for distinct manifestations of flame or smoke at the frame Especially in lower area of the breaker Please document and contact GE representa tive for assistance e Clean the breaker of dirt and dust Remove all dirt with a dry cloth No particularly high signs of abrasion rough chips should be visible anywhere e Clean and degrease t
43. ec ured by means of lock washer e Fig 41 The arc chute s screw connections 4 must be sec ured by means of flat washer e Any other screws shall be tightening with applied torques from Table 3 D e Ensure that the screws are in good condition that thread and nest are not damaged Surface shall be free from rust Replaced any screw which does not fulfill above conditions e This check must be carried out prior to commissioning and after maintenance 6 1 7 Inspection ofthe mechanical components Only GE Service Team or its representative shall perform this inspection These require major disassembly and ad justment of the breaker Customer without supervision of trai ned specialist shall not execute these 2009 09 02 S47183 e rev 03 200N P Manual closing only during maintenance Fig 45 dosing operation by using handlever Fig 47 Inspection of the arcing contact s air gap Design and specifications are subjectto change without notice 41 6 2 List of maintenance works Eee e sl Trained technician inspection C runners changing Trained technician inspection C ing Trained technician inspection C tacts inspection C sults with incorrect gaps See point 6 1 5 amobond tramediectricon mepeciemee E o control board Trained technician inspection B E mechas PA irene mechanism inspection B E oma c EHE a 3 tact changing inspection C E acp RN A Wee ee ea inspection B E inspection
44. er family Detailed descriptions are available in section 3 Please contact GE Sales repre sentative in case of any questions The coding system is valid for Gerapid feeder type F rectifier type R and disconnector type DS This User Manual relates only to stan dard feeder type breakers F Not all of the options from Table 7 are compatible To avoid improper configurations use the Gerapid configuration tool for ordering This Excel amp based tool provides a quick and mistake proof configura tion with automatic generating of the proper catalogue code and set of characteristics helpful for order description Ask your GE Represen tative for details The number of this tool is APN46043 7 S47183e rev 03 Table 7 General options overview for Gerapid breakers Codes Breaker type 1 Gerapid 2607 S 2 Gerapid 4207 3 Gerapid 6007 4 Gerapid 8007 see comments here Arc chute type 1 jime 1000v 5 2 153 15004 5 3 J1n4i2000v 6 see comments here Gerapid 8007R Gerapid 10007R Gerapid 8007DS Code2 2H2 1500 EF4 12 36004 22 20004 243 3000 E 2n4 3600 Closing solenoid supply voltage Code 3 Mechanical Counter 1 48VDC 5 220 Y DC 9 125 Y AC 2 60vDC 6 250 Y DC 4 230 V AC 3 110 DC 7 110 Y AC B 240 V AC 5 4 125 DC 8 120 V AC R On Request With Main terminals layout Top Bottom Code 4 1 H H
45. for the drive sup pl jl PCMD MD 150 110 S24W GE 1D GE 128730 R4 INPUT 88 140V OUTPUT 24V 3 0A 6 0A Fig 19 2 Voltage converter 110 V 24 V DC S47183e rev 03 2009 09 02 e 3 SU control unit see point 3 2 11 cic ue Mr WOOIXY 3 e Fig 19 4c Extinguish capacitor for direct ST supply Fig 19 3 SU control unit e 5 Empty slot not used in control box e 4 ST UVR control unit simple relay system It controls operation of shunt trip or zero voltage release e 6 SEL control unit see point 3 2 12 Fig 19 4a ST control unit i we T Fig 19 6b SEL control unit T 55 Fig 19 4b UVR control unit 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 11 12 3 3 Technical data tables Gerapid 2607 Gerapid 6007 Gera pid 8007 onventional thermal current l A IEC EN 2600 4200 6000 8000 ANSI IEEE C57 14 2600 4150 ated voltage Ue V 1000 2000 2000 3000 4000 2000 2000 2000 3000 4000 1000 2000 2000 3000 4000 1000 2000 Dy IOPE a ia ES E D o IQ Sm We flo elo le orient E O fet 3 o s KS o E 9 o I p x N N o o o V hort time current 120 min A 3150 5000 7200 9600 5200 8500 12000 16000 7800 12600 18000 24000 Impulse withstand voltage 1 2 50 us Ui kV 18 18 18 30 30 18 18 18 30 30 12 18 18 30 1 12 18 laccording to EN 50124 1 1997 Power frequency withstand voltage 5
46. he copper terminals 6 1 2 General functional inspection Pay attention to the warnings Section 1 e n order to check the latch mechanism the breaker can be opened and closed with a hand lever a Te ral Fs 4 Fs A Fig 40 Using of the hand lever 2009 09 02 S47183 e rev 03 e Re energize the control circuits and switch the breaker ON and OFF several times using ST or UVR and using closing drive The contacts must close after the CLOSE command and must open following the OPEN command e The breaker mechanism must not appear sluggish nor must ON OFF be unduly delayed 6 1 3 Inspection of the arc chute Pay attention to the warnings Section 1 A Remove the arc chute e Fig 41 Take off isolation caps 6 Loosen the clamp ing screws 3 and 4 using SW5 hexagon wrench and take off the arc chute 1 from the adapter 2 B Check the arc chute e Fig 42 Check the arc chute s interior as far as pos sible for deposits 1 There should be no copper pearls on the metal plates which could partially short the plates e Fig 42 Check the general condition of the insulation plates 4 These shall not be bent or burned Also other insulation shall not be heavily damaged e Fig 42 Check the arc horns 2 The cross section shall not be reduced more than 30 96 e Fig 42 Check the splitting plates 3 These shall not be burned more than 20 mm 0 8 in C Install the arc chute
47. ile it is being switched ON closing or OFF opening There is a high risk of major injury The control circuits may include capacitor banks which can be charged with dangerous voltages Work on this sec tion must be carried out carefully 2009 09 02 47183e rev 03 2 General usage conditions 2 1 Transportation and storing e The breaker is transported on wooden palette It is fixed by shrunken plastic film A cardboard box covers the breaker on the palette Truck railway airplane and ship transport is possible In case of sea transport special pro tection against salty and humid environment is provided e The circuit breaker must always be transported to the in stallation site vertically and fully packed The packaging protects the device against damage and dust it should only be removed prior to installation e f the packaging is damaged the breaker and the arc chute must be inspected for damage Ensure that all packaging materials have been carefully removed prior to breaker installati on e For handling the unpacked breaker use canvas slings and position them below the closing drive a and below the lower terminal b Fig 3 Fig 1 Handling the breaker e Breaker and arc chute must be transported separately Never handle the breaker with arc chute installed at e Take care thatthe bottom isolation plate of the unpacked breaker is not damaged during handling Do not push the breaker back and forth
48. it conditions and provides an anti pumping safety feature OCT knob Optional side protection cover Control box Closing drive Fig 16 Solenoid closing drive and control box e After closing attempt the switch in mechanism is electri cally blocked for approximately 8 sec Lock time in creases to 14 sec if internal C bank NEKO is present This prevents premature closing following a short circuit Design and specifications are subjectto change without notice 9 3 2 12 Current measurement system Code 6 1 SEL sensor 2 SEL control The SEL current measurement system consists of the sensing component 1 and signal processing unit 2 Fig 17 SEL sensor is integrated into a specially shaped upper terminal of the breaker and is connected by a shielded cable to the signal processing unit SEL control unit is placed in the control box Fig 18 Fig 17 SEL current measurement system 10 SEL may be used for recording DC currents in selected measurement ranges of 6kA or 12kA Measurement of rated current values and of the current rise may now be made directly at the breaker The sensor includes Hall probes and delivers a propor tional signal output to the SEL control The signal processing unit transforms input signal into standard output signals shown in the table below The outputs are insulated from the main voltage The in sulation withstands voltages up to 4 kV RMS and up to 40 kV in peak T
49. ive humidity may be higher if the temperatures are lower for example 90 r h at 20 C 68 F Slight condensation might occur during variations of temperature 2 2 2 Installation and interfaces The lower and upper main terminals Code 4 must be connected directly to the main cables or bus bars The breaker must only be used in an upright operation po sition with the arc chute in place and fully secured After arc chute installation check for tightness both con nections to the arc runners See drawing 49 item 3 The safety distances as listed in section 5 1 shall be main tained to grounded or insulated parts Suitable measures must be taken to protect personnel from arcs Strong external magnetic fields caused by improperly lo cated supply conductors or stray fields from other de vices can leadtoa shift of the trip setting thresholds T his may result in premature tripping or no tripping at all dur ing low level short circuit current events This has to be accounted for when installing and operating the device with shielding added if appropriate The control wires must be connected to the control ter minals Code 19 as shown in the schematic circuit dia grams in section 4 The protective grounding wire must be connected at the marked contact Fig 2 Closing drive Fig 2 Contact for grounding wire 2 3 Usage 2 3 1 Supply and load e n accordance with its type the breaker has been de signed for the current
50. lly screwin braid s screws by hand Fig 52 6 Tighten these by torque of 10 Nm 88 in Ibs Install back the arc runners See 6 2 2 C Check the adjustments according to point 6 1 5 C Install back adapter and arc chute See 6 2 1 D E Fig 52 2 Remove safety ring Fig 52 3 Remove axis pin 2009 09 02 S47183e rev 03 Fig 52 5 Tighten braid s screws by means of hand Fig 52 6 Tighten braid s screw swith torque of 10Nm Design and specifications are subjectto change without notice 45 6 2 3 Layout of control PCB inside control box 6 2 4 Replacement of the control boards A Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock e OPEN the breaker e Disconnect power supply and pull out all the plugs from control box s terminals e ifa NEKO control unit is installed wait 1 minute un til capacitors discharge DER ee ee a get ee lo NEKO unit ED trip 128750 R1 equipmentto left E __olings converter 428730 RoR 730 R2 R4 equipmentto left 3351 1 dT cx rim Fig 54 Control box inside with SEL unit Slot Control board Z No Orientation 2 voltage converter 128730 R2 R4 egupmenttoridht L ea oa ale LOC e s SEL control unit 128785 R1 R2 equipmentto left Table6 Layout of control PCBs inside the box with SEL Attention e The isolation plates between the control boards and at the wall of the box must always be present e in
51. m 88 in lbs e Fig 50 Install front arc runner 5 and back arc run ner 4 Tighten it using torque of 10 Nm 88 in Ibs e Fig 50 Install front wall 6 and adjust it by position ing the protective wall Tighten with torque of 10 Nm 88 in lbs e Fig 48 Putintwo protective walls 3 D Install the adapter e Fig 48 Install two protective walls 3 Use new ones if necessary Install two parings of adapter 2 and tighten screws 1 use 5 Nm 44 in lbs E Install the arc chute e Fig 49 Putin arc chute 1 into adapter 2 e Fig 49 Tighten front and backside connections of the arc runners 3 including lock washer use 10 Nm 88 in Ibs e Fig 49 Tighten front and backside of the arc chute connections 4 including flat washers use 5Nm 44 in lbs 2009 09 02 S47183 e rev 03 Fig 48 Adapter and protective walls Fig 49 Arcchute and arcrunners fixing Design and specifications are subjectto change without notice 43 6 2 2 Maintenance of contact system before 11 2003 Pay attention to the warnings Section 1 This section is valid for breakers manufactured before 11 2003 This section refers to maintenance works A B C from Ta ble 4 A Remove the arc chute and adapter See 6 2 1 A B C Changing the protective walls and arc runners Fig 48 Pull out two protective walls 3 Fig 50 Loosen screws 6a with Torx 30 and take out front wall
52. n mm 36 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 5 2 8 Gerapid 8007 terminals Gerapid 8007 is available only with V V terminals 8 88 225 6 Fig 39 Gerapid 8007 with vertical terminals dimensions in mm and inches 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 37 6 Inspections and maintenance 6 1 List of inspections TYPE OF THEINSPECTION BY WHOM A General visual inspec tion B General functional in spection C Inspection of the arc chute and contact system D Inspection of the screw bolt connections E Inspection of the me chanic components Required tools Cleaning tissue abrasive paper manual closing lever hexagon wrenches SW 5 SW6 Torx wrenches size 30 40 45 small and medium screwdrivers ratchet with 10 mm hex cap pliers tongs Dispose of the breakers if required Pay attention to the national and loc al regulations of disposal 38 Customer Trained technician Customer Trained technician Customer Trained technician Customer Trained technician GE Service technician Design and specifications are subjectto change without notice HOW OFTEN Every 6 12 months Every 6 12 months Every 6 12 months or after high short circuit open ing at gt 25 kA gt 300 openings at load current gt 100 openings at over current load 2 3 x In Itis
53. name fort M nmm coe Nome col EE 7 DY A EE 1 7 1s 1000 125 Y DC Breaker number to N NS A y 2 GESDO terk3 Q 3 z m 2 E m 4 stehen Jf Fixed setting up to 24k 4 m LM Z PS COC AAA ithout SEL Pa 2 IN N N zN NN A PLZ A ZA N 32 circuits supply 4 37 voltdge HP 1 SSSSS F E Lh DCR Ro Do gt N Eqmsawywws Fy INGA code 8 jo LCC A WE A 7 36 fhanaeovertype AAA AAA AM A 5 37 Mist codes BI 7 3 LEM B9 ksm code 10 Eu mith A Auxiliary tripping device Shunt Trip external 125 Vde double coil 41 TI zo 43 HILI code 11 La MS A 77y 4 Impulse coil release Cl A C I li Railway amp Industry applications LV DC acc IEEEC37 14 Feb eed HeH Englis S47183e rev 03 2009 09 02 bo gt N 3 s c a n e 3 5 n Request 7 2 3 Example of order no 3 Customer wants to use Gerapid as a field discharge breaker to commutate current from excitation system of synchronous machine to the discharge resistor circuit Customer has previously tested one Gerapid breaker in a special test sequence using special ratings andinternal standard XXX 123 Custo mer requests to put on the nameplate rated parameters that have
54. ng system No auxiliary control power source is required to keep breaker closed The mechanism is provided with two tripping latches Fig 6 First latch called slow latch is used for opening un der normal conditi ons like actuation of shunt trip or zero voltage release The second one quick latch de clutches the main contact arm from the mechanism and opens the contacts with an extremely short delay This is used when interrupting short circuit or overloads All safety releases operate onto quick latch latch Different main springs are used in mechanisms for differ ent breaker frames Therefore mechanisms cannot be exchange between breakers of different frame movable main arm quick latch slow latch main contacts OCT unit rotated 90 view Fig 6 Latching and tripping system 3 2 4 Over Current Tripping release Code 7 The OCT release is a magnet with two magnetic circuits optimizing the twin magnetic field principle Fig 7 This technology ensures equally fast tripping in both current directions This system does not require an auxiliary con trol voltage to operate The OCT consists of the holding circuit 6 the movable armature 3 and the tripping circuit 7 The holding and the tripping magnetic circuits are both excited by load current 1 Until the static overload release s response threshold has been reached the armature 3 is held in position by the holding flux PH 2
55. ns Provide safe arc leading into the arc chute There are two arc runners mounted in Gerapid breaker front and back Arcing contact also pre contact arcing pre contact An arcing contact on which the arc is intended to be established to avoid wearing and burning of the main contacts It is mounted at the top of flexible band It is easy to replace Spring loaded to maintain proper contact force Auxiliary contact also make break contact a b contact changeover contact convertible contact A contact included in an auxiliary circuit and mechanically operated by the breaker Auxiliary switch also auxiliary switch make break contact a b contact A switch block containing up to 10 auxiliary con tacts Mechanically operated by the mechanism of the breaker during switching operations Auxiliary switch block is mounted in lower compartment of the control box Every contact can be either NO or NC configured by appropriate wiring C Closing drive also activating magnet closing solenoid sole noid drive High power black solenoid coil mounted at the front of the breaker below the control box Use for electric and re mote closing of the main contacts Power consumption is up to 2 6kW Closing time is 150ms Closing operation also switching ON CLOSE operation It is operation by which the breaker is brought from the OPEN posi tion to the CLOSED position Closing solenoid see Cosing drive Control circuit termin
56. ntil capacitors discharge e Adjustment of the switches may be required if they fail to provide correct position indication This condition can be caused by misalignment of the actuating plate 6 Fig 56 3 represented by dashed line e if only 3 or 5 switches are installed in the center of the block plate misalignment will not occur breakers built after 2003 e In the case of 10 switches or when switches are mounted at the far left position it might be needed breaker before 2003 In most cases only far left or far right mounted switches might need to be re adjusted 5 e Check all the switches operation to establish which need to be re adjusted left or right side e OPEN the breaker e Fig 56 1 Loosen four screws 2 Move the front cover 1 slowly down The auxiliary switch block 3 is acces sible now in the bottom of the compartment La 1 e Fig 56 2 Loosen screw 4 on the side left or right i which needs to be re adjusted Turnthe proper adjust ing screw 5 clockwise until all contacts switch prop erly Warning Adjusting sc rew 5 too far in may over 4 compress the switches pin and cause breakdown e Fig 56 1 Check the correct signalization of all Fig 56 1 Controlboxwith auxiliary switch block switches at the connecting plug terminations X4 X5 If Fig 56 2 Auxiliary switch block necessary re adjust the switc hes from other side e Nowtighten solid the screws 4 e Fig 56 1
57. ntrol circuit placed in control box The SEL control PCB is an opto isolated transducer which generates standard output signals proportional to measured current SEL control PCB a control circuit PCB Controls and transforms current measurement signalfrom SEL sensor Self cut off function A safety feature provided to avoid over stressing of the closing drive and shunt trip release Closing drive is automatically cut off from power source after 500ms Shunt trip coil is connected in series with auxiliary contacts which cause cut off after breaker s opening Shunt trip release also ST shunt release a rd ease Instanta neous release energzed by means of voltage signal Within 50ms trips the breakers mechanism Use for remote OPEN op eration ST can be activated by potential free contact or by di rectly applied voltage from external source ST can have a single or double winding Solenoid drive see Cosing drive ST control PCB control circuit PCB supervising the operation of shunt trip release SU control PCB control circuit PCB supervising the remote closing operation by means of solenoid drive Presents in every breaker and placed in control box Provides also anti pumping and self cut off functions Switching ON see Cosing operation Switching OFF see Opening operation Trip free device A mechanical switching device the moving contacts of which return to and remain in the open position when the opening operation
58. nual opening only during maintenance Fig 11b Opening operation by using hand lever Alternative manual closing and opening operation is pos sible by rotating the main shaft of the breaker mecha nism which is accessible from the side Use 10mm hexagon socket wrench to OPEN CLOSE Fig 11c WARNING Pay attention to control rotation speed of the shaft during manual opening Impede the wrench to avoid hitting it to the ground which may lead to a hand injury lt LE m 1 LL adl la a OPEN n l s G o Manual closing and opening only during maintenance Fig 11c ON OFF operation by using a 10 mm wrench 8 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 3 2 9 Auxiliary switch Code 9 e Standard breaker can be equipped with 3 5 or 10 iso lated form C invertible auxiliary contacts 1 NO NC each The movable main arm activates the contacts e The contacts are wired to 15 pin control terminals X4 and X5 with 5 switches to each terminal Fig 2 1 e Maximum electrical ratings for switches are 5 A 230V AC and 0 3 A 220 V DC Utilization category AC DC 12 and 13 Fig 12 Auxiliary contacts layout in control box 3 2 10 Indicators Optionally the circuit breaker can be equipped with following indicators e POSITION INDICATOR Code 14 mounted at the front of the closing drive Mechanically switched by means of drive s rod Indicates posi
59. ols layout eeeeee ee eene eene nennen 14 4 2 Terminals wiring system eceeeeeeeee eee nennen 15 4 3 Electrical diagrams eeeeeeeeeeeeee eere ener 16 4 3 1 Wiring code ssssssssss 16 4 3 2 Controls supply circuit oooccoconoccnnc 17 4 3 3 ED coil with external capacity bank 18 4 3 4 NEKO control circuit 19 4 3 5 SU control Gircuit ooooccccccoonoococicccnnnnnnnnnnnnos 20 4 3 6 Shunt trip control circuit occocoooocccnc 21 4 3 7 Zero voltage release control circuit 23 4 5 8 Indicators ssssssssesss 24 4 3 9 Auxiliary switch 25 4 5 10 SEL measuring system seesseesess 26 5 DIMENSIONS amp SAFETY DISTANCES 27 5 1 Safety distances Units call in mm inches 29 5 2 Outlined dimensions ccce 30 5 2 1 Gerapid 2607 4207 6007 with arc chute 1x 30 5 2 2 Gerapid 2607 4207 6007with arc chute 2x_ 31 5 2 3 Gerapid 8007 with arc chute 1x 32 5 2 4 Gerapid 8007 with arc chute 2x 33 5 2 5 Gerapid 2607 4207 with H H terminals 34 5 2 6 Gerapid 2607 4207 with V V terminals 35 5 2 7 Gerapid 6007 terminals ssssssssse 36 5 2 8 Gerapid 8007 terminalS ooooooooococcccccccccoos 37 2 Design and specifications are
60. ons are done with control voltage connected Only trained specialist or GE Ser vice representative shall perform them Risk of dectric shock 6 Checkifthe PCBs plugsare connected and screwed 7 Check if there is 24 V DC available at output of the voltage converter Check X10 8 9 10 6 7 8 Check the status of the red LED diode on the SU PCB Does not light power supply failure Weak light sy stem ready to CLOSE Intensive red light system not ready to CLOSE Closing STOP circuit is active or NEKO PCB is not charged or anti pumpi ng is active for 15 sec 9 Check if the Closing STOP circuit is not open Measure voltage at SU PCB X12 5 6 There shall be 24 V DC available for actuation of clos ing stop relay If there is no 24V DC check con tinuity of closing STOP circuit Check relays at ST UVR NEKO PCBs by controlling state of con tacts at points 5 6 of each 10 Replace any ST UVR NEKO if necessary 11 Replace the SU control PCB 12 Switch OFF the power at control box Check continu ity and resistance of solenoid winding Replace the solenoid in c ase of winding breakage Contact GE Service in case the problemis not solved B Closing drive operates electrically but itis not pos sibleto keep contacts closed 1 Check the forced tripping release if installed A per manently blocked tripping device during closing op eration will cause closing failure and force contact
61. or replace ments e An adaptor Fig 43 is used to mount the various arc chutes for different operating voltages onthe breakers The arc chutes consist of a highly durable arc proof ma terial in which the arc plates have been inte grated e The arc plates split the arc into partial arcs and increase the arcing voltage by multiplying the anode and cathode voltage drop Because of their high heat capacity the plates and arc chute walls absorb a large amount of the arc s energy Seesaw Mechanism Closing solenoid drive ED coil tripping device Lower copper terminal OCT device Adjusting device Shunt trip Zero voltage releaser Fig 4 Modular construction overview 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 5 Shunt trip Zero voltage releaser ED coil 3 2 3 Mechanism The Gerapid is equipped with a modular designed mechanism which is wear resistant and nearly mainte nance free This mechanism ensures an extended electri cal and mechanical endurance of the breaker as well as a high level of safety under all operation conditions Breaker can operate 20000 cycles when opened by the shunt trip or zero voltage release and 1 000 operations by means of ED impulse coil or OCT releases This mechanism is mechanically latched in the CLOSED position The principle of a mechanically latched mecha nism offers a big advantage compared to often used electro magnet holdi
62. perate Breaker is able to CLOSE and OPEN by means of hand lever 1 Check points A2 to A5 2 Check the wiring connections and supply line for NEKO PCB X16 1 2 3 Check the voltage level and timing of firing signal for releasing the C bank energy X16 3 4 Voltage sig nal shall be between 6 24V DC and duration of mini mum 3 ms 4 Check if the NEKO is signaling C bank charging cor rectly X16 9 10 Relay is closed when NEKO is ready to operate 5 Check the continuity of ED coil X16 11 12 6 Replace the NEKO PCB if necessary Contact GE Service in case the problemis not solved Design and specifications are subjectto change without notice 57 GE Consumer amp Industrial GmbH Berliner Platz 2 6 D 24534 Neum nster Germany Phone 49 4321 201 0 Fax 4449 4321 201 444 58 S47183 e rev 03 08 2009 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02
63. r accessory has a code number i e OCT code 7 arcing contact e Closing of the circuit breaker is performed through a ON EET high power solenoid drive Code 3 e During inspections opening and closing may be carried out by means of a hand lever Code 16 which is mounted 1 onto the armature of the closing drive e Overload tripping and release is obtained directly by means of the OCT release Code 7 or optionally by ED impulse release Code 12 Indirect remote tripping can be achieved by means of a shunt trip or optionally by a zero voltage release Code 11 e Gerapid breakers have a compact and enclosed con struction Fig 4 Gerapid is IP 00 protected All parts are mounted on thick walled non breakable and fireproof in sulation panels Flexible band E 1 lt Main contacts Pre arcing contact Arc chute Flexband Upper copper terminal Auxiliary contacts Control connections a A mak Fig 5 Two types of the contact system after 11 2003 upper and before 11 2003 low er i 1 soj 3 2 2 Arc chute Code 2 CT e Compact and modular design of the arc system re quires no additional magnetic support and allows small safety distances with high breaking capacity e Because of the compact dimensions these breakers can be installed in extremely small enclosures from 500 mm 1 65 ft and offers a cost effective solution f
64. recommend to carry out inspection of contact system after breaking of equivalent of 150MA s total let through energy Every 6 12 months or after every inspection e ofthe arc runners e ofthe contacts e ofthe arc chute Every 5 years or After 5 000 openings WHAT TO DO CHECK e Check for damages or cracks of the frame adapter or arc chute Check for missing screws or caps Check for damaged labels Check for corrosion Check for distinct manifestations of flame or smoke at the frame e Cleanthe breaker from dirt and dust e Clean and degrease the copper termi nals Manually close and openthe breaker to check the drive and mechanism Close the breaker electrically and open by trip unit s releasing to check con trols Check for wear of the arc runners shall not exceed 30 96 of its cross section Check for wear of the pre arcing con tact It shall not exceed 2 mm 0 08 in Check for wear of the main contacts at fixed and flexible sides shall not exceed 1 5 mm 0 06 in of its depth Check for wear of the arc chute plates check for deposits inside of arc chute this area shall be free of deposits Check for wear of protective walls shall not exceed 1 mm 0 04 inl Check for contact tilt and gaps Check the position of the countersunk screws in the sidewalls Check for tightness or use torque tool torque in SI and Imperial units e M8 20Nm 177 in lbs e M6 10Nm 88in lbs e M5 5Nm 44 in lbs
65. s eee ea 51 IscH code 15 LL sidewalls protection panel E 52 Lever for manual overatina Wihout TA X 53 HAN code 16 EE 0 nh L LL LLLLL L AR AR M 54 Arc chute presence po Without TA E 55 LBM code 17 ARA oo Q o qm 56 Counter TT E 57 zat code 18 MN ET E 58 Control connectors type Railway amp Industry applications Y 1 GearapidSEretrofit 3 59 r 60 ssT code 19 Pi Request E R 61 Relevant standard o Railway DC acc EN50123 2 LY DCacc IEC60947 2 fa 62 A 2 63 cus code 20 L thinaacc IEC947 2 amp 6B140982 3 On Request CR 64 Documentation Lanauace Eng en chinese M L t 65 ILNGI D o German E Lon Request 2222222 66 nn o 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 52 7 2 1 Example of order no 1 Line feeder breaker for LRT substation in Europe comply with EN50123 with breaking capacity of 50 kA configured as follows 1 Load current of 4000 A 2 Nominal voltage of 1500V 2x2 arc chute chosen due to high breaking capacity up to 70kA 3 Auxiliary supply voltage of 230 VAC for closing solenoid 4 Vertical layout of both main terminals V V 5 Breaker polarization not important 6 Without SEL unit not available with special terminals 7 With
66. sssssessscsssssssssssssssssessssssssessscssscsssessscssssssssssssssssssssocssssssesossssesssesssssssssssosssssssscssesssssssssssosssssessossescessossocsssssceseno C bank and output circuit ED impulse coil AA TONO RATON NES Key position 3 Key number 2 With ED coil and internal NEKO control unit e Firing signalat X2 10 11 is processed by opto coupler Pay attention to the polarity e Closing STOP signalis provided tolock CLOSE command until capacitors are fully charged e Be sure that voltage level is between DC 6V 24 V and there are no transient spikes lt 3 ms on firing signal This can lead to major defect of the NEKO control unit e Maximum duration of the firing command must not exceed 1 sec Longer signal might cause NEKO failure It is rec ommended to use one of HS auxiliary contacts connected in series with firing circuit X2 10 It will automatically c ut off the firing circuit after breaker opening Fig 25 ED coil with internal NEKO control unit 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 19 4 3 5 SU control circuit Q1 Closing drive AC 110 250V DC 48 220V Closing control circuit i d Ec E 2l E JE i i pl j e Heel o Closing 4 3 5 STOP relay Ka p 2 J te 4
67. t Dif ferent configurations are avaiable N NEKO control PCB also ED coil control unit interna C bank control Control circuit PCB to supervise the operation of the ED Coil It consists of control circuit and bank of capacitors Re quired to energize the ED impulse coil 2009 09 02 S47183e rev 03 AA OCT see Over Current release Opening operation also switching OFF OPEN operation An operation by which the breaker is brought from the CLOSED Over Current release also OCT An instantaneous and direct acting mechanical release Tripping the breaker in case of over loads and short circuits Is adjustable within predetermined range Opening time depends on short circuit conditions and shall not exceed 5ms Oct is activated be means of magnetic energy from main circuit Requires no external control power Position indicator also position indicating device A me chanical device mounted at the front of closing drive Indicates whether the breaker is in the open or closed position CLOSED position is marked as I OPEN position is markedas O Pre contact see Arcing contact A AAA r release see Zero voltage rd ease SEL Current measurement system consisting of sensing ele ment and control circuit The sensor is an insulated tube mounted on the top terminal of the breaker Utilizes two Halls probes for sensing the current and direction The proportional voltage signal is transmitted to co
68. t of internal closing stop circuit Itis a 24 V DC closed circuit through all PCBs in the box except SEL Serial connection of all relays is realized through con nections 5 6 in each PCB This circuit provides priority of a tripping signal over a closing signal Additionally it pre vents from closing the internal supply 24 V DC lost at UVR PCB or NEKO PCB S47183e rev 03 2009 09 02 4 3 2 Controls supply circuit Breaker geri quus T f des borg gt 7 External X3 X10 power supply 2d 7 eee m 7 8 He t e 10 gt E 9 e 8 e gt AC115 240V210 y m DC 35 350V 10 1 gt i M JN I i Ho T 3j m PE EM RR 4 n a a d Breaker TS A r3 External X3 X11 power supply EE n DC 24 V 22 NEM 9 i 8 DC24V 5 E o i 7 o GND id 5 3 S LI 4 l Lu Eta eel 36 X______ E Key position 2 Key number 1 Voltage converter DC 35 85 V DC 88 145V DC 125 353 V AC 115 240V Key number 2 Interface for direct external voltage DC 24 V 5 connection Fig 23 Supply with voltage converter or with direct external 24 V DC 5 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 17 4 3 3 ED coil with external capacity bank e inthis option customer provides his own solution for releasing of the ED coil by means of external capacitor
69. te LL obsolete 607 4207 for 35 C ambient N A 1 607 4207 for 55 C ambien LL LL gt gt n mimin eof rm xul Sie Q a Oo S 8 9 o TU al o Cy UJ Q POT o ele gt 128018 128019 co gt hunt trip 24 VDC 5 hunt trip 24 VDC 20 hunt trip 220 V DC hunt trip 125 V DC hunt trip 110 V DC ero voltage release olenoid closing drive onnector X2 onnector X3 X4 X5 gt E gt LL LL LL D gt 7128070 N A DFK PC 4 12 GF 7 62 N A DFK MSTB 2 5 15 GF gt gt gt 6 3 3 Recommend materials for selected works Standard parts glues pastes and greases are recommended for a mainte nance stock Work to do Spare parts Standard parts materials and optional components Arc chute change Correct version of arc chute Screws amp Washers M6x16 8 8 ISO 4762 M6 toothed Rip 128 550 Lock M6 conical spring DIN 6796 Arcing contact arc run Correct version of the service kit Screws amp Washers M6x16 A4 DIN 4762 M6 toothed Rip ners and protective APN 340110 consist of Lock Retain ring 4 DIN 6799 Disc spring 12 5 type A walls change Arcing contact DIN 2093 Twoarcrunners Others Conductivity grease Alvania RL3 by Shell Two protection sheets Hint Replace 128 123 or 128 150 only if recognize these Optional parts are broken Replace all the parts f rom service kit Mini flexible braid 128 123 APN340110 Wiring modific
70. ternal volt age In this case extinguish capacitors and diode is used to improve switching of the shunt trip s coil Fig 19 8 Double winding shunt trip is available with this option for 110 125 220 V DC external control supply Optionally it s possible to supply both devices directly to external 24V DC 5 In this case the release signal for ST shall not be longer 100 ms The ST is used for remote actuation It is designed for short time operation with max duty cycle of 9 96 ST s x AL a 24 m I Lom I supply is connected through auxiliary contacts which cut off supply voltage after opening This protects ST against overheating The UVR Fig 9 is used for remote actuation and in com bination with an internal electronic control for voltage control The UVR releases at voltage interruption or supply volt age drop below 20V In these cases UVR trips the breaker It is therefore possible to use this device in com bination with the electronic trip unit for voltage monitor ing where an unintended re start of machines after a temporary voltage breakdown is to be prevented The UVR is intended for continuous operation lts rated power is 10 W Due to its operational mode the UVR is a self monitoring device i e when the breaker is tripped upon a break of the pilot wire EMERGENCY OFF principle NOTE Manual closing of the breaker with ST installed while pushbutton OPEN is pressed and control power ap plied mightlead to
71. th SEL measurement system Fig 31 SEL current measurement system 26 Design and specifications are subjectto change without notice S47183e rev 03 2009 09 02 5 Dimensions amp safety distances Warnings A Danger Turn off power supplying the equipment before working inside breaker HAZARD or electric Shock During operation all metallic parts ofthe breaker except control box and closing solenoid drive may carry dangerous voltages Insulation covers are available as an option For installation of the breaker into cubicle top and side openings shall be provided in order to reduce internal pres sure rise during clearing short circuit Ventilation openings in the breaker cubicle top cover shall not be less than 50 of total surface area 2009 09 02 S47183e rev 03 Design and specifications are subjectto change without notice 27 5 1 Safety distances Units call in mm inches Type Main additional Deflector Safety distances Insulated Safety distances Earthed plates Gera pid Connection isolation action EIA EE TE TE ENEE EES eT ed ed ee C o a o e AGN ER a Fc 19d gt Ea 30 18 1000 eal 900 015 500 01 0 5000107 1356 632 456 07 2 450077500018 PC x a 80 3 15 1000 39 4 180071 1807 sory a Tas na rue 1506 9 1000 04 1807 1807 socn _ L2 na S siemens 1506 9 1000 30 4 eogi sogn 3808 2x44 sem Pa 169
72. than 30 96 of its total cross section Pay particular at tention to the area around arc runner bend 3 and at contact point with arcing contact 2 E Check the arcing contact e Fig 44 Wear of the arcing contact 1 must not ex ceed 2 mm 0 08 in of its depth Replace the arcing contact in that case If contact erosion exceeds 4 mm 0 16 in major contact sy stem fail ure is possible F Check the main contacts e Fig 44 The main contacts 4 shall not show any par ticular signs of material erosion since the arc is ig nited between the arcing contacts It means that for rated and overload currents there should be no ero sion of main contacts e Erosion of main contacts can take place only in case of excessively worn highly burned arcing contact or during very high short circuit currents In that case wear must not exceed 1 5 mm 0 06 in G Installthe adapter e Fig 43 Install the two protective walls 3 Use new ones if necessary Install two parings of adapter 2 and tighten screws 1 use 10 Nm 88 in Ibs H Install the arc chute e Fig 41 Put arc chute 1 into adapter 2 e Fig 41 Tighten front and backside connections of the arc runners 3 including lock washer use 10 Nm 88 in lbs e Fig 41 Tighten front and backside of the arc chute connections 4 including flat washers use 5Nm 44 in lbs Put on isolation caps 6 S47183e rev 03 2009 09 02 6 1 5 Inspection of contacts
73. tion of the main contacts e O means contacts are open I means contacts are closed Fig 13 e OC TRIP TARGET Code 10 a potential free NO contact mounted at the top of the OCT Fig 14 Provides a signal when OCT trips e ARC CHUTE INDICATOR Code 17 a potential free NO contact mounted on the sidewall Locks electrically the closingsing drive if arc chute is not installed on Fig 15 Position indicator Drive s rod Fig 13 Position indicator Fig 14 OCT trip target 2009 09 02 S47183e rev 03 Fig 15 Arc chute indicator 3 2 11 Solenoid closing drive Code 3 e A high power solenoid is used to perform fast closing op eration This drive is mounted at the front of the breaker and is encased in a grounded casi ng Fig 16 e Closing drive is supplied independently from other con trols X2 1 2 directly from external power source Volt age level must be defined at order placement Rated power depends on breaker type but is between 1 8 kW and 2 6 kW e CLOSING command is enable by external potential free contact at X2 4 5 Signal duration shall be 300 ms e The closing drive system always includes a self interrupt control circ uit SU PCB This circuit enables short activ a tion with atime of 150 ms SU switches power to the so lenoid and automatically disc onnects it after 400 ms e The SU unit also prevents repeated drive closing due to an existing and continuous short circu
74. ustomer used to buy Gerapid 8007 according to company special ID code GE8007 1x2R3 The breaker shall comply with standard IEEE C37 14 Breaking capacity of 200 kA is required and configuration as follows 1 Load current of 6000 A Nominal voltage of 800 V Available auxiliary voltage of 125 V DC With special design of main terminals as per customer drawing number GE8007terR3 Customer tested breaker in this configuration and test report and drawings were sent to GE for confirmation 5 Breaker polarization not important 6 Without SEL measurement syste m 7 With OC release w o adjustment possibility Threshold set at 24 kA 8 Auxiliary supply voltage of 125 V DC for controls 9 With maximum possible number of auxiliary contacts 10 With OC triptarget 11 Shunttrip with double winding directly supply from external 125 V DC 12 With electrody namic coil andinternal C bank NEKO control PCB 13 Without forced tripping release 14 With contacts position indic ator 15 Without additional protection covers 16 With hand lever 17 With arc chute indicator 18 Counter not available 19 With standard terminals for controls connection 20 According to IEEE C37 14 standard Correct catalogue codeshallbe 414R0034414201011012 FWD General remarks e Special wiring indicates that dedicated electrical diagram will be cre ated for this order The diagram will be attached to the User Manual as an appendix
75. without notice 42 6 2 1 Maintenance of contact system after 11 2003 Pay attention to the warnings Section 1 This section is valid for breakers manufactured after 11 2003 This section refers to maintenance works A B C from Table 4 A Remove the arc chute e Fig 49 Loosen the screws 3 and 4 using SW5 hexagon wrench and take off the arch chute 1 from the adapter 2 B Remove the arc chute adapter e Fig 48 To dismantle the arc chute adapter loosen and pull out the four upright screws 1 using SW5 tool Pay attention that no screws or washers fall inside the breaker e Fig 48 Draw aside and lift off both parings of adapter 2 Then pull out two protective walls 3 C Changing the protective walls arc runners and arcing contacts e Fig 48 Pull out two protective walls 3 e Fig 50 Loosen screws 6a with tool SW4 and take out front wall 6 e Fig 50 Loosen screw 5a with tool SW5 and take out the front arc runner 5 e Fig 50 Take out the back arc runner 4 by loosening two screws 4a with tool SW5 Don t remove the pro tective cap 4b e Fig 50 Loosen and take out screw 7 including lock ing plate 8 Don t split up screw and locking plate e Fig 50 Pull out axis pin 9 Pull out arcing contact 10 and putin new arcing contact e Fig 50 Put in axis pin 9 and protect it by the locking plate 8 Tighten screw 7 with torque of 10 N
76. wo versions are available Standard model T35 for am bient temperature 5 C 35 C and the model for higher temperature T55 5 C 55 C More details can be found in separate instruction for SEL usage mE SES Input 6 KA 6 kA 12 KA 12 kA B 2000 4000 1000 2000 4000 for ambient temper ature of the breaker 5 435 23 F 95 F T55 for ambient temper ature of the breaker 5 455 23 F 4131 F uN Relating to the rated current of the breaker Output Design and specifications are subjectto change without notice 3 2 13 Electronic control system All the control PCBs are installed in control box Fig 18 Start ing from the left these are EEEE gt Bei Fig 18 Control box with control units 1 NEKO control unit Fig 19 1 Code 12 internal con trol unit with capacitor bank Releases firing signal for ED coil X2 10 11 and provides indication of the capacitors charging X3 6 7 NEKO control unit also blocks the fir ing signal until C bank is fully charged 15 sec NEKO unit requires a high quality firing signal Be sure that voltage level is between 6V 24V DC and there are no short spikes on signal 3 ms This might lead to major defect of the NEKO control unit Fig 19 1 NEKO control unit 2 Internal voltage converter Code 8 converts external supply voltage X3 4 5 to the internal 24 V DC Required b controls except

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