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GE AK-50 User's Manual

1. 6 Flux shifter assembly mounted to the side frame eene nnns 6 Location of new hole in the flux shifter base nn 7 Locations of new holes for mounting the OFLO terminal block 7 Existing trip paddles to be removed U 8 Installing the new trip paddle pee Em ined eben s 8 A qdj sting taba alaskana uakis 8 Mounting hole drill pattern for the trip unit mounting plate canon 9 Trip unit mounting plate attached to the breaker front channel 9 Trip unit mounting bracket attached to the mounting plate 0 00 0 ccc eter sse 10 Actuator bracket attached to the left pole link enne enne 11 Drill pattern for actuator bracket mounting holes a 11 Existing EC trip devices before removal n enne nnns enne ren 12 Removal of EC tip devices 12 Parts provided for CT installation per pole nn 13 CT post mounted in the breaker back frame sse eene 13 CF installation completed 2 ee eed ROO deinen nna DER IIR 13 Phase s
2. Connections for 1 Ground Fault 20 4 1 Option Only 4 I 52 Aux I I 1 I I I 3 I 1 Flux Shift I Trip Device ERAN 1 4Wire l Load AVI 10 la Breaker Back Frame _ Left Pole 2 07 Current Sensor Neutral AA Sensor Disconnect Neutral Line Load Equipment Mounted Neutral Sensor Figure 36 Cabling diagram for ProTrip trip units with ground fault on four wire loads 25 APPENDIX DRILL TEMPLATES Appendix 1 Drill Template for Flux Shifter Mounting NWO LLOq STIOH 6 5 XATA AGIS STIOH SONGRELTTH TP 3 o aWVad WOVE 27 Appendix 2 Drill Template Trip Unit Mounting O SWTIOH G3 dd VL 03 rj SE Z 4g E s e STIOH G3ddVL 02 4 aav Trip Unit Template Appendix 3 Drill Template for Flux Shifter Mounting 29 These instructions do not cover all details variations in equipment nor do they provide for every possible contingency that may be met in connection with installation operation or maintenance Should further information be desired or should particular problems arise that are not covered sufficiently for the purchaser s purposes the matter should be referred to the GE Company GE Indu
3. 0 172 0 750 ADD 2 0 257 DIAMETER HOLES TAP 5 16 18 N C LEFT HAND LINK LEFT HAND POLE UNIT DIMENSIONS IN INCHES Figure 15 Drill pattern for actuator bracket mounting holes Removing the Existing Trip Devices AK 50 amp AKS 50 Breakers with EC or Power Sensor Trip Systems 1 Remove and discard the two screws at the base of each trip device as shown in Figure 16 Dis card the metal mounting brackets 2 Remove and discard the small Philips head screw at the top of each trip device 3 Remove and discard the four 5 i Allen head bolts securing each trip coil The coil can then be lifted off and removed Figure 17 shows one trip completely removed one with the cover removed and one still in place AK 50 amp AKS 50 Breakers with SST Trip Systems Remove the existing SST phase sensors in prepara tion for installing the new sensors AK 75 amp AK 100 Breakers with EC or Power Sensor Trip Systems Remove the existing trip devices and harnesses and discard AK 75 amp AK 100 Breakers with SST Trip Systems The new ProTrip phase sensors are visually identical to the SST sensors Remove the existing sensors and discard 12 Cover Screws 22 and Clamps Figure 16 Existing EC trip devices before removal ee A ES WU NC Bo v 1 Figure 17 Removal of trip devices Installing the Phase Sensors AK 50 amp AKS 50 Breakers Figure 18 shows the parts pr
4. AKS 50 Stationary Breakers sse eene nnns 16 AK 50 amp AKS 50 Draw Out Breakers sse 17 75 AK 100 Draw Out Breakers essen nnne nennen nnns 17 Installing the Neutral Sensor 19 SECTION 7 EQUIPMENT CONVERSION Installing Mounting Brackets Ld In RI 21 SECTION 8 TESTING AND TROUBLE SHOOTING PESIN inn hdeinieetielinnee nho RRORRRA BR IRR BRBaBBRR IB bs 23 e 23 Nuisance Tripping on Ground Fault Equipped 23 APPENDIX DRILL TEMPLATES Appendix 1 Drill Template for Flux Shifter Mounting esseeesenemnmen 27 Appendix 2 Drill Template for Trip Unit Mounting nnn 29 Appendix Drill Template for Flux Shifter Mounting can 29 LIST OF FIGURES ON AU Bb UN UJ UJ UJ UY O O UU NJ NJ N NJ N N N N N N N Fa RFP F F F P N O O O O Q N O DAN N F CO Relocation and remounting of the W and X relays enne nnne nnns 5 New X and W relay mounting brackets eene enne nnne nennt nennen 5 Flux shifter assembly 4 etica p Pat Pee eL Eee Le UO P P anash anga 6 Pattern for flux shifter mounting holes in the side frame
5. DEH 40028A Installation Instructions ProTrip M Conversion Kits For GE Types AK 50 AKU 50 AKS 50 AKT 50 AK 75 and AK 100 Low Voltage Power Circuit Breakers INTRODUCTION GE Conversion Kits are designed for upgrading existing GE low voltage power circuit breakers rather than replacing the entire breaker The Con version Kits include ProTrip Trip Units the latest technological advance in GE trip systems ProTrip Conversion Kits are designed and tested to conform to ANSI Standard C37 59 allowing the retrofitter to properly install the kit and acceptance test the breaker This publication covers installation of ProTrip Con version Kits on GE types AK 50 AKU 50 AKS 50 AKT 50 AK 75 and AK 100 low voltage power circuit breakers Each Conversion Kit contains all the components needed to convert from an existing GE type EC trip system TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION seen nennen 4 SECTION 2 BEFORE INSTALLATION 4 SECTION 3 FRONT FRAME BREAKER CONVERSION Relocating and Remounting the W and X Relays nennen 5 Installing the Flux Shifter Assembly n nn 6 Breakers with EC or Power Sensor Trip 6 Breakers with a Side Bracket U nnn nnn 7 AKU 50 Breakers Only 7
6. 3 Measure the resistance across the line and load terminals for each phase using a micro ohmme ter or millivolt tester If the resistance differs considerably from phase to phase the electrical connections may not be properly tightened or it could also indicate improper contact wipe 4 To verify that the breaker has been properly retrofitted perform a primary injection test on each phase This test will check the CTs bus wiring harness flux shifter and trip unit as a complete system a A high current low voltage power supply should be connected across each line and load terminal to simulate an overcurrent fault b Set the long time trip at 0 5 to minimize the breaker stress c When ground fault is installed the test can be performed by wiring two adjacent poles in series or by using the GE Digital Test Kit cat no TVRMS2 This will prevent the breaker from tripping because of an unbalanced cur rent flow CAUTION Do not attempt to use GE Test Kit cat no TVTS1 or TVRMS on this trip unit Trouble Shooting When malfunctioning is suspected first examine the breaker and its power system for abnormal condi tions such as the following The breaker is not tripping in response to over current conditions or incipient ground faults The breaker is remaining in a trip free state because of mechanical interference along its trip shaft The shunt trip if present is activating improp erly Nuisance Trippin
7. Breakers with ECS or SST Trip Systems a 8 Installing the Trip Paddle ER 2 b tbid ada 8 Adj stinig the Flux SHhifter e et E EE EE REC EE HERE EROR ERE ERE ELE CE E LER 8 Installing the Trip Unit Mounting Bracket nennen nennen nnne 9 EC or Power Sensor Trip System l 9 ECS or SST ip Systermz season dee dE EDD ODDS 9 SECTION 4 BACK FRAME CONVERSION Crossbar 2 HORIRORRIOIIROI enemies 11 Removing the Existing Trip Devices n n nennen rennen nens 12 AK 50 amp AKS 50 Breakers with EC or Power Sensor Trip Systems 12 AK 50 AKS 50 Breakers with SST Trip 5 12 75 6 AK 100 Breakers with EC or Power Sensor Trip Systems 12 75 AK 100 Breakers with SST Trip 12 Installing the Phase ai 13 50 amp AKS 50 Breakers nn nsn 13 5 6 1 tenir eterne 14 SECTION 5 INSTALLING THE TRIP UNIT Configuring the Tri 01 5 rir rrr rrr E HE PEE RETE E ERU ER ERE ER eeu e 15 SECTION 6 FOUR WIRE GROUND FAULT OPTION Installing the Fourth Wire Disconnect eee enne nennen ennt nnns 16 AK 50
8. lead of the phase A CT to the white lead of the phase B CT c Repeat this continuity test for the white leads of the phase A and phase C CTs d Measure the resistance across each phase sensor and compare the values measured to the values listed in Table 1 e Reconnectthe black CT leads to all of the phase sensors Ensure that this is done before continuing with performance testing of the breaker CAUTION In addition to the continuity test described in Step 1 and before performance testing of the converted breaker each phase of the breaker should be primary injected with a current level of about 10 but no more than 20 of the CT rating During the application of test current activate the trip unit screen by depressing the battery button on the trip unit face and check that the test current is displayed on the screen for each phase tested If the trip unit fails to display the test current stop the test immediately and verify the installation of the trip unit and wire harness before proceeding with any additional testing WARNING If the converted breaker is energized or tested by primary injection with a sufficiently high test current with a loose or open circuit between the CTs and the trip unit damage will occur to the trip unit wire harness 36 pin trip unit connector and CTs Failure to adhere to these instructions will void all warranties 2 Check the insulation on the primary circuit with a 1 000 volt Meggar
9. the National Electrical Code and all other applicable codes Do not work on a closed breaker or a breaker with the closing springs charged Trip an OPEN breaker and be sure the stored energy springs are discharged thus removing the possibility that the breaker may trip OPEN or the closing springs discharge and cause injury Trip the breaker OPEN then remove the breaker to a well lighted work area before beginning work Do not perform any maintenance that includes breaker charging closing tripping or any other function that could cause significant movement of a draw out breaker while it is on the draw out extension rails Do not leave the breaker in an intermediate position in the switchgear compartment Always leave it in the CONNECTED TEST or DISCONNECTED position Failure to do so could lead to improper positioning of the breaker and flashback SECTION 3 FRONT FRAME BREAKER CONVERSION Front frame conversion consists of the following steps 1 Separation of the front and back breaker frames for AK 50 AKU 50 AKS 50 and AKT 50 breakers Frame separation is not necessary for AK 75 and AK 100 breakers Refer to the appropriate installation and maintenance manuals supplied with the breakers and equipment for instructions on frame separation Copies of these publications may be obtained from your local GE sales office 2 Relocation and remounting the W and X relays on AK 50 AK 75 and AK 100 electrically ope
10. 00 fourth wire disconnect for AKD 5 amp AKD 6 PHASE CENTER LEFT SENSOR POLE POLE TERMINAL BOARD REAROF COMPARTMENT CK REAROF BREAKERS 75 ETC DRILL 2 0 281 DIAMETER HOLES IN COMPARTMENT 2 VIEW LOOKING REAR OF COMPARTMENT SIDE VIEW OF COMPARTMENT Figure 33 AK 100 fourth wire disconnect for AKD LEFT POLE POLE OF BRACKET REAR OF BREAKER 6 00 Ei oa DIAMETER 5 COMPARTMENT SIDE VIEW OF COMPARTMENT VIEW LOOKING REAR OF COMPARTMENT Figure 34 AK 50 amp AKS 50 fourth wire disconnect for AKD CENTER LEFT POLE POLE 6 00 i DRILL 2 0 224 DIAMETER HOLES IN COMPARTMENT REAR OF COMPARTMENT 06232 P 044 0 88 SIDE VIEW OF COMPARTMENT VIEW LOOKING AT REAR OF COMPARTMENT Figure 35 Fourth wire disconnect for AKD 5 amp AKD 6 22 SECTION 8 TESTING AND TROUBLE SHOOTING WARNING Do not change taps on the current sen sors or adjust the trip unit settings while the breaker is carrying current Failure to adhere to these instructions will void all warranties Testing Before installing a converted breaker back into service perform the following steps 1 Verify that the trip unit is securely installed by performing a continuity test on the CT wiring and the trip unit a Disconnect the black CT wires at each phase sensor b Check for continuity with a continuity tester or VOM from the white
11. ONVERSION Installing Mounting Brackets The equipment compartment contains the mating portions of the fourth wire disconnect and the neu tral sensor The same disconnect assembly is used for types AKD AKD 5 and AKD 6 switchgear Mounting brackets for AKD AKD 5 AKD 6 and AKD 8 switchgear applications are included in the conversion kit Figures 31 32 33 34 and 35 are mounting diagrams for the various applications Table 1 is a key to the numbers used in these figures to indicate various hardware items Legend Description Breaker portion of fourth wire disconnect Equipment portion of fourth wire disconnect Mounting bracket for AK 100 for AKD compartments 10 32 x 1 375 inch mounting screw Insulation 10 lock washer 10 flat washer 1 8 20 flat washer 1 8 20 lock washer 1 4 20 nut 1 4 20 x 1 25 inch mounting screw Bracket Table 1 Legend for number symbols appearing in Figures 31 35 21 PHASE SENSOR REAR or ERNAL BORA CENTER LEFT BREAKER 230 POLE POLE 1 75 7 00 100 9 75 DRILL 2 0 224 DIAMETE OF BRACKET HOLES IN COMPARTMENT SIDE VIEW OF COMPARTMENT VIEW LOOKING AT REAR OF COMPARTMENT Figure 31 AK 50 amp AKS 50 fourth wire disconnect for AKD PHASE CENTER LEFT SENSOR POLE POLE TERMINAL BOARD REAR OF 97 COMPARTMENT HOLES IN SIDE VIEW OF COMPARTMENT VIEW LOOKING AT REAR OF COMPARTMENT Figure 32 AK 75 amp AK 1
12. acket clock wise to take up mounting hole slack Retighten the screws 3 Optional Test The flux shifter may be tested by closing the breaker and applying a 9 Vdc power source to the flux shifter leads the red wire is positive The breaker should trip Trip Paddles J ww Figure 8 Existing trip paddles to be removed Trip Paddle Figure 9 Installing the new trip paddle Figure 10 Adjusting the flux shifter Installing the Trip Unit Mounting Bracket Q OF CRANK BEARING The new ProTrip trip unit mounts to the left side of the front channel A mounting bracket is shock mounted to a plate that is assembled to the front channel 1 4 20 TAP 3 HOLES EC or Power Sensor Trip System 1 The holes for the new mounting plate may have to be added to the front channel The drill pattern is shown in Figure 11 with a full size template in the Appendix Tap the holes for 1 4 20 screws 2 Attach the new mounting plate as shown in Figure 12 with two short 4 20 screws and lock washers on the top and the single long 1 4 20 OF CRANK BEARING screw and lock washer on the bottom Be sure to insert the spacer between the mounting plate and the breaker channel as shown 3 Attach the trip unit mounting bracket to the plate UL with two screws lock washers and flat washers VIEW as shown in Figure 13 np Sy Figure 11 Mounting hole drill pattern for the trip unit mounting R
13. bly for AKD 5 or AKD 6 equipment Figure 27 Fourth wire disconnect assembly for AKD equipment ROUTE LEADS BETWEEN EMEN l MOUNTING HOUSING MOUNTING HOUSING U MOUNTING HOUSING WHEN USED THE 4TH WIRE NEUTRAL SENSOR DISCONNECT BLOCK MOUNTS ON TOP OF TAP TERMINAL BOARD VIA ITS 2 LOWER MOUNTING SCREWS THE AKD 5 TYPE MOUNTING IS ILLUSTRATED THE ARRANGEMENT FOR AKD TYPES IS IDENTICAL EXCEPT FOR USE OF A DIFFERENT MOUNTING BRACKET Figure 28 AK 75 amp AK 100 back frame conversion 18 Installing the Neutral Sensor The neutral sensor is an electrical duplicate of the phase sensor including the taps Therefore when taps if provided are changed on the phase sensors the taps on the neutral sensor must be similarly changed For kits with fixed phase sensors be sure to use the corresponding tap on the neutral sensor Mount the neutral sensor on the outgoing neutral lead normally in the equipment bus or cable com partment Figure 29 shows mounting details for the neutral sensor for AK 50 breakers while Figure 30 covers AK 75 and AK 100 breakers 3 75 MAX 11 25 Figure 29 Outline of the neutral sensor for AK 50 breakers 19 fe pu E Sell 1 0 625 DIA HOLES 3 42 SENSOR CAT NO AMPERES TSVG830BK 1200 3000 TSVG940BK 1500 4000 DIMENSIONS IN INCHES Figure 30 Outline of the neutral sensor for AK 75 and AK 100 breakers 20 SECTION 7 EQUIPMENT C
14. eave enough of the stud exposed for the primary fin gers to engage Engage the sensor s antiturn lugs with the notch in the locking ring Before tightening the locking rings position each sensor so that its leads exit between the pole bases as shown 2 Mount the three sensor terminal boards to the rear of the back frame using the hardware pro vided 3 Form each sensor s leads downward between the pole bases Figure 21 Phase sensor installation on AK 75 amp AK 100 breakers 14 SECTION 5 INSTALLING THE TRIP UNIT 1 Remove the large screw from the rear of the trip unit Place the trip unit in position on the mount ing plate with the 50 pin connector aligned with the opening in the plate Secure with the large screw as shown in Figure 22 2 Insert the 50 pin female connector on the wiring harness into the trip unit connector through the rear of the mounting plate Secure to the mount ing plate with the two small screws provided as shown in Figure 22 3 Place the trip unit and mounting plate in position on the support bracket mounted on the breaker Secure with the three screws lock washers and flat washers through the holes in the mounting plate into the tapped holes in the bracket as shown in Figure 23 Configuring the Trip Unit See DEH 40034 for detailed instructions for setting up ProTrip trip units 15 Trip Unit Mounting Trip Unit Mounting Screw Wiring Harness C
15. emove the existing mounting plate and bracket plate Install the new mounting plate and bracket using the holes closest to the front of the breaker as described in steps 2 and 3 above If the manual indicator assembly busing on AK 50 manual breakers interferes with the mounting bracket installation then the bracket must be modi fied Cut off a 3 4 x 11 2 inch section from the right front of the plate to provide clearance Figure 12 Trip unit mounting plate attached to the breaker front channel Figure 13 Trip unit mounting attached to the mounting plate 10 SECTION 4 BACK CONVERSION The back frame conversion consists of the following operations 1 Modification of the crossbar assembly for the flux shifter installation 2 Removal of the existing trip devices 3 Installation of the phase sensors 4 Installation of the back frame harness Crossbar Modification The flux shifter reset linkage is driven by the actuator bracket as shown in Figure 3 The actuator bracket must be assembled to the left side link of the left pole as shown in Figure 14 If the actuator bracket mounting holes are not in the left side link the holes must be added Drill and tap two 1e 18 holes using the pattern in Figure 15 A full size template is provided in the Appendix 11 Left Pole _ Actuator Bracket 2 NV WI ce Figure 14 Actuator bracket attached to the left pole link
16. ensor installation on AK 75 amp AK 100 breakers sse 14 Attaching the trip unit to the mounting plate a 15 Trip unit mounted on the breaker U nnne nennt nnne nn 15 Fourth wire terminal board installation on AK 50 amp AKS 50 stationary breakers 16 Fourth wire disconnect installed on AK 50 amp AKS 50 draw out breakers 17 Fourth wire disconnect assembly for AKD 5 or AKD 6 17 Fourth wire disconnect assembly for AKD nn 17 K 75 amp AK 100 back frame conversion n nn 18 Outline of the neutral sensor for AK 50 breakers eset settee ease aca 19 Outline of the neutral sensor for AK 75 and AK 100 20 AK 50 AKS 50 fourth wire disconnect AKD n n nn 21 AK 75 AK 100 fourth wire disconnect for AKD 5 amp AKD 6 sse 21 C AKSTOO fourth wire disconnectforAKD a 21 AK 50 AKS 50 fourth wire disconnect for 22 Fourth wire disconnect AKD 5 6 AKD 6 n 22 Cabling diagram for Pr
17. erminal block must be relocated on the upper left side of the breaker Some parts and tool not provided with the kit are necessary for this task Sixstrips of 14 AWG wire Wire splice 12 butt splices Wire labels Drill and size F bit 5 16 18 tap Flathead screw driver Two 5 16 18 bolts and lock washers Drill and tap two holes for the 5 16 18 bolts Fig ure 7 shows the hole locations 4 Remove the three bolts securing the OFLO to the 5 breaker and lift off the OFLO device Remove the wires that connect the OFLO device to the terminal block 6 Cut the wires that connect to the coils where they join and label the wires Attach butt splices to all twelve open ends Connect the strands of wire to the OFLO Mount the terminal block in its new location DO NOT complete the wire connections until the flux shifter is installed 8 Install the new flux shifter assembly as described 9 above and shown in Figure 5 Connect the cables attached to the terminal block and tie them together Side View Edge View Figure 6 Location of new hole in the flux shifter base Figure 7 Locations of new holes for mounting the OFLO terminal block Breakers with ECS or SST Trip Systems 1 Remove the ECS or SST trip unit 2 Remove the existing flux shifter device and the trip unit control harness 3 Install the new flux shifter assembly as described above and shown in Figure 5 Insta
18. g on Ground Fault Equipped Breakers When nuisance tripping occurs on breakers equipped with ground fault trip a probable cause is the existence of a false ground signal Each phase sensor is connected to summing circuitry in the trip unit Under no fault conditions on three wire load circuits the currents add to zero and no ground signal is developed This current sum is zero only if all three sensors have the same electrical characteristics If one sensor differs from the others such as by a different rating or wrong tap setting the circuitry can produce an output sufficient to trip the breaker Similarly a discontinuity between any sensor and the trip unit can cause a false trip signal The sensors and their connections should be closely examined if nuisance tripping is encountered on any breaker whose ProTrip trip unit has previously demonstrated satisfactory performance After dis connecting the breaker from all power sources form the following procedure Breaker CT Rating A Resistance ohms 1 Check that all phase sensors are the same type current range 2 Verify that the tap settings on all three phase sen sors are identical 3 Verify that the wiring harness connections to the sensors have the proper polarity white lead to common black lead to tap as shown in the cabling diagram in Figure 36 4 On ground fault breakers serving four wire loads 36 43 check that the neutral sensor is properl
19. just replace the control harness Main tain the following color code white wire to common black wire to the tap f the disconnect must be added mount it as shown in Figure 25 AK 75 amp AK 100 Draw Out Breakers There are two fourth wire disconnect designs used with these breakers One design is used on breakers for GE type AKD switchgear while the other applies to breakers for GE types AKD 5 and AKD 6 equipment The only difference is the bracket used for mounting the disconnect to the breaker Figures 26 and 27 show these two designs The conversion kit contains an assembled ready to install mounting block and bracket for AKD 5 and AKD 6 installation plus an addition bracket only for type AKD equipment installations For AKD equip ment remove the bracket from the assembled dis connect and replace it with the AKD bracket The fourth wire disconnect for AK 75 and AK 100 draw out breakers mounts to the lower back frame as shown in Figure 28 f the terminal board is already present on the breaker just replace the control harness Main tain the following color code white wire to common black wire to the tap f the disconnect must be added mount it as shown in Figure 28 17 BOTH LEADS HAVE RING TERMINALS POLE UNIT MOUNTING HARDWARE REAR VIEW DISCONNECT ASSEMBLY Figure 25 Fourth wire disconnect installed on AK 50 amp AKS 50 draw out breakers Figure 26 Fourth wire disconnect assem
20. lling the Trip Paddle For breakers equipped with an ECS or SST trip sys tem the existing trip paddle is used with the new flux shifter For all other breakers the existing trip paddles must be removed and the new trip paddle installed as follows 1 Remove and discard the three trip paddles on the trip actuator bar as shown in Figure 8 2 Assemble the trip paddle and the threaded back plate by inserting two of the 10 32x 3 4 screws and lock washers provided along the top edge 3 Slip the trip paddle over the trip actuator bar approximately one inch from the side frame as shown in Figure 9 Insert the remaining 10 32 x 3 4 screw and tighten the other screws to secure the trip paddle in place Adjusting the Flux Shifter After the flux shifter and trip paddle are installed and the breaker frames are reassembled the following adjustments must be made 1 With the breaker OPEN and the mechanism charged set the gap between the trip paddle and the end of the flux shifter rod at 0 10 inch as shown in Figure 10 Use a 0 10 inch diameter rod Set the adjuster end of the trip rod and lock it in place with the jam nut Note that removal of the buffer stud will make the trip paddle easier to install and adjust 2 As the crossbar travels between the breaker CLOSED and OPEN positions the tang of the actuator bracket must clear the buffer stud If there is insufficient clearance loosen the two mounting screws and rotate the br
21. oTrip trip units with ground fault on four wire 25 SECTION 1 GENERAL INFORMATION GE Conversion Kit installation is straightforward but does require careful workmanship and attention to these instructions Familiarity with the breaker is highly desirable The general approach is to first remove the existing trip devices from the breaker then install the ProTrip components Following this procedure the converted breaker is performance tested before it is returned to service The majority of trip unit kit installations do not require any customized assembly work However some conversions may involve unusual mounting conditions or accessory combinations that require minor modifications and or relocation of compo nents In most instances this supplementary work can be done on site In preparation for the conversion the installer should verify that the appropriate current sensors and trip unit have been furnished Whenever a ProTrip kit is installed on a breaker with a four wire system an associated neutral sensor CT is required for separate mounting in the equipment Ensure that retrofitted breakers are applied within their short circuit ratings For example if the previous trip unit provided long time instantaneous protection the short time rating of the ProTrip Trip Unit will govern the application Asaservice related consideration the installation of a ProTrip kit provides an e
22. onnector Figure 22 Attaching the trip unit to the mounting plate GE Electrical Distribution amp Control Plainville CT Figure 23 Trip unit mounted on the breaker SECTION 6 FOUR WIRE GROUND FAULT OPTION The ground fault option for four wire installations requires the installation of an additional current sensor on the neutral bus in the equipment The sensor is connected to the trip unit through the connector provided in the wiring harness Installing the Fourth Wire Disconnect AK 50 amp AKS 50 Stationary Breakers The fourth wire disconnect for stationary breakers consists of a terminal board mounted to the lower front channel as shown in Figure 24 f the terminal board is already present on the breaker just replace the control harness Main tain the following color code white wire to common black wire to the tap If the terminal board must be added mount it as shown in Figure 24 The mounting holes may have to be added to the front channel 16 BLACK WHITE BREAKER MOUNTING HARDWAR DRILL 2 0 219 DIAMETER HOLES TERMINAL BOARD ASSEMBLY SECTION M M Figure 24 Fourth wire terminal board installation on AK 50 amp AKS 50 stationary breakers 50 amp AKS 50 Draw Out Breakers The fourth wire disconnect for AK 50 and AKS 50 draw out breakers mounts to the lower back frame as shown in Figure 25 f the terminal board is already present on the breaker
23. ovided for assembly of the CT on each pole 1 Mount the new copper CT post to the back frame with thetwo 3 8 16 11 2 bolts flat washers and lock washers provided as shown in Figure 19 2 Fasten the three small insulated wire fasteners to the back frame with the 4 20 13 4 screws provided as shown in Figure 20 One fastener is mounted under each CT 3 Place a CT over each copper post first applying a small amount of RTV or similar adhesive to prevent the CTs from rotating 4 Mountthe top copper bus over each CT and secure with the1 2 13x 11 2 Allen head bolts lock washers and flat washers provided 5 Insert two 3 8 16 x 11 2 bolts lock washers and flat washers through each top copper bus into the contact arm assembly 6 Tighten the 3 8 16 bolts to 200 in Ib and the 1 2 13 bolts to 300 in Ib WARNING Step 6 ensures critical electrical integrity connections The designated bolts must be correctly tightened for proper operation Failure to tighten these bolts properly will cause a breaker failure resulting in property damage and or personal injury 13 04 1 Figure 18 Parts provided for CT installation for one pole Wire Fastener Figure 20 CT installation completed 75 amp 100 Breakers 1 The ProTrip phase sensors mount on the upper breaker studs as shown in Figure 21 The sen sors held on the stud with locking rings L
24. rated breakers with EC trip devices 3 Installation of the flux shifter assembly and trip paddle 4 Installation of the trip unit mounting bracket 5 Installation of the trip unit wiring harness Relocating and Remounting the W and X Relays This step is necessary on electrically operated breakers with EC trip devices Figure 1 illustrates this process Figure 2 shows the new mounting brackets supplied with the kit 1 Remove the W relay and install the mounting bracket supplied with the conversion kit to the upper left side of the frame 2 Remove the X relay and its mounting bracket Use the new bracket supplied with the conver sion kit to remount the X relay in its existing position After Figure 1 Relocation and remounting of the W and X relays X Relav Figure 2 New X and W relay mounting brackets Installing the Flux Shifter Assembly The installation procedure for the flux shifter assembly illustrated in Figure 3 varies depending on the type of breaker and existing trip device In some cases mounting holes must be added termi nal blocks relocated or breaker side rails removed Breakers with EC or Power Sensor Trip Systems 1 Drill the flux shifter mounting holes in the left side of the breaker frame The mounting hole pattern is illustrated in Figure 4 A full size tem plate is provided in the Appendix 2 Mountthe new flux shifter to the inside of the side frame with the three screws lock wa
25. shers flat washers and nuts supplied as shown in Figure 5 Insert the screws from the outside of the side frame 1 Actuator 5 Reset linkage 2 Actuator arm 6 Actuator bracket 3 Trip rod 7 Mounting base 4 Trip rod adjuster end 8 Position switch Figure 3 Flux shifter assembly EXISTING 9 32 DIAMETER HOLES Mounting Screws 2 Flux Shifter lt Assembly 1 4 4 Figure 5 Flux shifter assembly mounted to the side frame Breakers with a Side Bracket 1 Drilla 3 4 diameter hole into the flux shifter assembly mounting base to provide the neces sary clearance for the bracket The location of the new hole is shown in Figure 6 Remove the side bracket from the frame and drill the holes according to the pattern in Figure 4 A full size template is provided in the Appendix After the holes are drilled return the side bracket to its original location Mount the new flux shifter to the inside of the side frame with the three screws lock washers flat washers and nuts supplied as shown in Figure 5 The upper two screws are inserted from the outside of the frame while the lower screw must be inserted from the inside AKU 50 Breakers Only For easier installation of the new flux shifter assembly on AKU 50 breakers the open fuse lockout OFLO may be removed from the breaker 1 2 3 Remove the three bolts attaching the OFLO to the base of the breaker The OFLO t
26. strial Systems General Electric Company 41 Woodford Ave Plainville CT 06062 nri annna man 4 400 FV ANNO 1 la Ms
27. xcellent opportunity to perform normal maintenance on the breaker par ticularly when the front and back frames are sepa rated Such procedures are described in the instal lation and maintenance manuals supplied with the breaker and equipment SECTION 2 BEFORE INSTALLATION Before starting any work turn off and lock out all power sources leading to the breaker both primary and secondary Remove the breaker to a clean well lighted work area WARNING Low voltage power circuit breakers use high speed stored energy spring operating mechanisms The breakers and their enclosures contain interlocks and safety features intended to provide safe proper operating sequences For maximum personnel protection during installation operation and maintenance of these breakers the following procedures must be followed Failure to follow these procedures may result in personal injury or property damage Only qualified persons as defined in the National Electrical Code who are familiar with the installation and maintenance of low voltage power circuit breakers and switchgear assem blies should perform any work on these break ers Completely read and understand all instructions before attempting any breaker installation operation maintenance or modification Turn off and lock out the power source feeding the breaker before attempting any installation maintenance or modification Follow all lock out and tag out rules of
28. y con 47 55 nected as indicated in Figure 36 In particular 75 88 check the following 108 127 a Verify that the neutral sensor has the same rat Table 2 CT resistance values ing and tap setting as the phase sensors b Verify continuity between the neutral sensor and its equipment mounted secondary discon nect block Also check for continuity from the breaker mounted neutral secondary discon nect block through to the trip unit wiring har ness connector c If the breaker s lower studs connect to the power source then the neutral sensor must have its load end connected to the source d Verify that the neutral conductor is carrying only the neutral current associated with the breaker s load current the neutral is not shared with other loads 5 If the preceding steps fail to identify the problem then measure the sensor resistances The appro priate values are listed in Table 2 Since the phase and neutral sensors are electrically identical their resistances should agree closely 24 Low Voltage Circuit 1 I Trip Unit 1 1 1 5 8024 1018 35034010 37036 390 381 49050 Trip Unit Y Y Y Y Y 1 350356 9 1 Connector 74 Harness Ei I 4030 201 20 1 i 4030 201 L 1 1

GE AK-50 User's Manual

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