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.c om Ma�ntenance Manual .E lec tri ca lP ar tM an ua ls 6 Low-Voltage VPower Ci rcuit Breakers Types·AKR-30/50 andAKRT-50 G. " f' : w "' ww :..._,.. GEK-644598 GENERAL fj ELECTRIC T Page SECTION 1 INTRODUCTION SECTION 4 10 DRAWOUT BREAKER INTERCHANGEABILITY SECTION 5 SECTION 6 ca Mechanism Operation Charging Using The Maintenance Handle INTERLOCKS 6.1 Racking Mechanism Interlock 6.2 6.3 6.4 6.5 6.6 Positive Interlock Closing Spring Interlock Disconnect Position Interlock Padlocks Key Interlock-Stationary Breaker Optional Interlocks .E lec tri 6.0 6.7 SECTION 7 ww w 7.0 7.1 7.2 7.3 7.4 7.5 11 11 11 12 13 lP Electrical Closing 7.9 7.9.1 7.10 7.1 1 7.12 ar 11 BREAKER OPERATION Manual Closing 7.8 10 5.2.1 Alt. Control Circuit 5.3 5.4 7.7 tM 10 BREAKER MAINTENANCE Lubrication Manual Handle Adjustment Drawout Mechanism Position Slow Closing the Breaker Primary Disconnects 7.5.1 Replacement 7.5.2 AdJustment Auxiliary Switch 7.6.1 Replacement 7.62 Adjustment Shunt Trip 7.7.1 Replacement 7.7.2 Adjustment Undervoltage Device 7.8.1 Replacement 7.8.2 Operational Check 7.8.3 Adjustments Static Time-Delay Undervoltage ua ls 6 6 6 6 8 8 8 9 GENERAL DESCRIPTION Frame Size Operation Fused/Non-Fused Mounting Trip Device Model Number Short Circuit Ratings 10 5.0 5.1 5.2 7.6 6 SECTION 3 3.0 STORAGE 4.0 SECTIO N 7 4 4 4 Inspection and Maintenance Renewal Parts SECTION 2 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Page Adjustments Electric Lockout Device an 1 .0 1.1 1 .2 4 .c om Table of Contents 7. 13 7. 14 7.1 5 Bell Alarm 7.1 1 .1 Operation 7.1 12 Adjustments 7.1 1 .3 Replacement Electrical Control Component 7. 12.1 Component Replacement 7.1 2.2 F and G Switch Adjustment Drawout Mechanism Buffer Assembly 7.14.1 Buffer Adjustment Trip Latch Adjustment SECTION 8 22 22 22 23 23 23 23 23 24 24 25 25 26 26 26 27 27 27 28 29 29 31 32 32 33 8.0 8.1 8.2 CONTACT MAINTENANCE Arc Chute Removal & Inspection Contact Adjustment - 33 33 15 AKA 30/30H & AKRU 30 34 8.3 Contact Adjustment - 16 16 17 17 8.4 18 18 8.7 13 15 15 18 18 18 19 20 20 21 22 22 8.5 8.6 AKA 50/SOH & AKRU 50 Contact Adjustment AKRT 50/SOH Stationary Contact Identification Contact Replacement AKA 30130H & AKRU 30 Contact Replacement - AKA 50150H, AKRU 50 & AKRT 50150H SECTION 9 9.0 9.1 9.2 9.3 36 37 38 39 39 41 FUSED BREAKER Fuse Sizes and Mounting 41 41 Special 2500 A Fuse For AKRU 50 41 Open Fuse Lockout Device 9.3.1 TypeA and B Breaker OFLO Adjustment 9.3.2 TypeD Breaker OFLO Adjustment 43 43 43 Page 10.3 10.4 SST Cabling Diagrams 1 0.5 SECTION 11 1 1 .1 1 3.5 1 3.6 1 4.0 ar 58 58 58 58 59 60 63 64 64 65 EC TRIP DEVICE Series Overcurrent Tripping Device EC-2A 1 3.1 1 Long Time-Delay And High Set Instantaneous Tripping 13.1.2 Instantaneous Low-Set Tripping 1 3.1.3 Instantaneous High-Set Tripping 70 70 72 72 72 72 72 w Series Overcurrent Tripping Device EC-1 73 Tripping 1 3.2.3 Instantaneous Tripping 1 3.2.4 EC-1 Adjustments Positive Trip Adjustments Reverse Current Tripping Device 1 3.4.1 Adjustments 1 3.4.2 Replacement Switchette Feature Trip Device Replacement SECTION 1 4 lP .E lec SECTION 13 13.2 58 Equipped with Ground Fault 65 MicroVersaTrip Cabling Diagrams 66 12.5 13.0 13.1 1 3.3 1 3.4 53 53 ca 1 2.3 12.4 MICROVERSATRIP TRIP DEVICE Programmer Unit 1 2.1.1 Fault Trip Indicators 1 2.1.2 Remote Fault Indication 1 2. 1 .3 Mi croVersaTrip Installation Current Sensors 12.2.1 Replacement of Current Sensors Flux Shifter Trip Device Troubleshooting 12.4.1 Resistance Valves 12.4.2 False Tripping-Breakers tri 12.2 51 52 52 57 SECTION 12 12.0 12.1 48 48 56 Page 73 1 3.2.2 Long Time-Delay 56 TYPE ECS OVERCURRENT TRIP DEVICE ECS Cabling Diagrams 1 1.0 45 46 tM 10.1 10.2 1 3.2.1 Short Time-Delay Tripping 45 an TYPE SST OVERCURRENT TRIP DEVICE Programmer Unit Current Sensors 1 0.2.1 Replacement of Current Sensors Flux Shift Trip Device Troubleshooting 1 0.4.1 SST Test Set 1 0.4.2 Resistance Valve 1 0.4.3 False Tripping-Breakers Equipped with Ground Fault 1 0.0 SECTION 13 45 ua ls SECTION 10 .c om f ww " 73 74 74 74 75 76 76 76 76 77 ELECTRICAL CHARACTERISTICS Table 1 6 Charging and Closing Operating Currents Fuse Selection 77 77 Table 1 7 77 Bell Alarm Contact Rating Table 1 8 Auxiliary Switch Contact Sequence Table 1 9 Auxiliary Switch Contact Ratings Table 20 Charging Times Table 21 Shunt Trip Undervoltage Device Table 22 Coil Resistance Table 23 Instantaneous Undervoltage Device Settings Table 24 Time-Delay Undervoltage Device Ratings 77 77 77 78 78 79 79 .c om SECTION 1-lntroduction A basic inspection should consist of the following: The proper use, care, and maintenance of these break ers is a prime safety consideration for the protection of personnel, as well as a means of minimizing equipment damage when faults occur. Persons who apply, use, and service these breakers will acquire the knowledge they need by gaining the information contained in these instruc tions. a. Visual Check - Look for dirt, grease or other forei material on any breaker parts. Check insulating surfac for conditions that could degrade insulating properties (cracks, overheating, etc.). Also check for loose hardware and components on the breaker and the compartment's bottom, loose or damaged control wiring and similar prob lem areas. b. Operation - Observe a few close-open operations using the operating or maintenance handle. If a breaker is seldom operated such that it remains open or closed for a period of six months or more, it is recommended that ar rangements be made to open and close it several times in succession. ua ls These instructions provide the maintenance procedures and describe the operation of the 800 thru 2000 amp frame size type AKA low voltage power circuit breakers listed in Table 1 . ' 1.1 INSPECTIO N AND MAINTENANCE d. Arc Chutes and Contacts - Inspect the condition of the arc chutes and contacts. Look for excessive burning or breakage. Check the amount of contact depression or wipe. tM Breakers should be cared for under a systematic main tenance program. Taking each breaker out of service periodically for inspection and maintenance is an excellent means of establishing high service reliability. It is good policy to have one or more spare breakers to install in place of breakers requiring maintenance. Keeping a stock of recommended renewal parts will insure that maintenance work can be done quickly. an c. Interlocks- During the Operational check verify the safety interlocks are properly working. e. Accessories- Verify that the various accessories are working properly. ar f. The performance of the solid-state current trip devices may be checked with a suitable test set. Check elec tromechanical devices for positive trip in accordance with the instructions in their Maintenance Manual, GEl 86157. ca lP How frequently an individual breaker should be in spected will depend on the circumstances of its use. It would be well to inspect any breaker at least once a year. If it is frequently operated, operated under severe load condi tions, or mstalled in an area of high humidity or a dusty, dirty atmosphere, inspections should be more often. In spections might be monthly under adverse conditions. lec tri Always mspect the breaker after a short-circuit current has been mterrupted. SAFETY PRECAUTION ww w .E BEFORE INSPECTING OR BEGINNING ANY MAINTENANCE WORK ON THE BREAKER. IT MUST BE DISCONNECTED FROM ALL VOLT· AGE SOURCES. BOTH POWER AND CON· TROL. AND BE IN THE ··oPEN' POSITION 4 1 .2 RENEWAL PARTS The AKA breakers contain a variety of parts and as semblies. Many of these are available as replacement parts when the need arises. See publication GEF 4527, Renewal Parts, for a complete listing of these parts. - .c om TABLE 1 BREAKER MODELS 2000 DC 800 1600 SOH SOH SOH SOH X X X X AKRT-(•)A 50, SOH AKRT-(•)8 50, SOH AKRT-(•)D 50, SOH AKRT-(•)S 50, SOH X AKR-2A 30 AKR-28 30 AKR-20 30 AKR-2S 30 X AKR-2A-50 AKR-28-50 AKR-20-50 AKR-28-50 X AKRU-(*)A 30 AKRU-(*)8 30 AKRU-(*)0 30 X AKRU-(*)A 50 AKRU-( *)B 50 AKRU-(")0 50 X X X X X X X X X X Th•s dlg•t ldenbf•es the tnp dev�ce type X X ua ls X X as X X X X X X X X X X X X X X X X X X X X X X X folows l : 2 - EC (DC only) 4 - ECS 5 - SST 50/60 Hertz Only 6 - M•croVersa Tnp N - Non-automabc. In adell bon, all non-automabc 250VDCbreaker types carry the suffix letter Dafter the frame number, e.g. AKR-NB-500 tri - X X X X X } ww w .E lec (*) AKR-(•)A 50, AKR-(•)8 50, AKR·(•)D 50, AKR-(•)S 50, X an 800 DC X tM 2000 AC AKR-(•)A 30, 30H AKR-(•)8 30, 30H AKR-(•)D 30, 30H AKR-(•)S 30, 30H I, ar 1 600 AC AK� lP 800 AC BREAKER DESIGNATION ca FRAME SIZE (AMPERES) MOUNTING TYPE DRAWOUT SUB· DEEP FUSED STRUCTURE STATIONARY ESCUTCHEON BREAKER AKD-8 5 .c om SECTION 2-General Description ua ls Type AKR low-voltage power circuit breakers are used for controlling and protecting power circuits in the low voltage range (usually up to 600 volts). In serving this function, they are a means of safely switching loads and automatically clearing circuits when abnormal conditions occur. Among these conditions, the more common are short circuits and sustained overloads and under voltages. The type AKR breakers are of the "quick-make, quick· break description, having the feature of storing energy in a closing spring for quick release in closing. In closing, some energy is transferred to an opening spring to be used subsequently for fast tripping. an Knowledge of how the breaker is designed and how it operates will enable the owner to make proper use of the breaker and to avoid mistakes in Its operation. Specific directions on adjustments and maintenance procedures will be treated later. tM The three main functional components of a breaker are its mechanism, an assembly comprising the conductive members, and the interrupter. FIG. 1 - Manually Operated AKR-4A-50-1 ar The mechanism unit is designed to receive energy, store it, and later (when called upon to do so) deliver it to close the breaker's contacts. It must be able to reverse its com mitment to close the breaker at any point upon the activa tion of an automatic trip device (i.e., be "Trip-Free"). Fi· nally, it also must be able to trip open a closed breaker quickly enough to minimize arc erosion and in such a manner as to effect proper arc transfer to the arc runner. lP These values represent the maximum continuous cur rent capability of the respective frames. However, each breaker carries a specific rating which is determined by the current sensor ampere rating or top setting of the trip device with which it is equipped. tri ca The current-carrying members of the breaker are as· sembled on the back frame, which provides the mechani cal support required and also the insulating structure needed. The conductive members are the studs for exter nal connections, movable and stationary contact sets, pivots for the movable contacts, and provision for mounting the current transformers. lec The interrupter components are, in addition to the arcing contacts, the arc runners mounted on the back base and the removable arc quencher assemblies. 2.1 .E In addit1on to these basic components, a breaker may be equipped with any combination of many accessones and interlockmg dev1ces. Breakers may also d1ffer m a vanety of areas as shown in Table 1 . A bnef descnpllon of these areas is g1ven below. FRAME SIZE w ww 6 - OPERATION There are Manual and Electrical breaker models. The Manual breaker, shown in Fig. 1 , has an operating handle which is used to manually charge the mechanism closing spring. The Electric breaker, shown in Fig. 2, contains an elec tric motor which charges the mechanism closing spring. External control power is required to energize this motor and its control c�rcuit. A nameplate md1cates what voltage IS required by the motor circuit. 2.3 The breakers are ava1lable 1n 5 frame s1zes 800 am peres A.C. (AKA 30'30H, AKAU 30). 1 600 amperes A.C. (AKA SO:SOH, AKAU 50), 2000 amperes AC (AKAT 50/SOH). 800 amperes D.C. (AKA 30) and 2000 amperes D.C. (AKA 50). 2.2 FUSED/NON FUSED Fused breakers are identified as either AKRU 3 0 (800 ampere frame SIZe) or AKRU 50 (1 600 ampere frame size). A fused breaker IS shown in Fig. 3. They are not inter· changeable with Non-Fused breakers, since they require deeper compartments for their fuses. .c om ua ls r tM an r··· FIG. 3 - Fused Breaker AKRU-60-30 w .E lec tri ca lP ar FIG. 2 - Electrically Operated AKR-SB-30 ww - FIG. 4 - Drawout Breaker 7 .c om SECTION 2-General Description {Cont.) 2.5 MOUNTING Type AKA breakers are designed for either drawout or stationary mounting. Drawout breakers (See Fig. 4) are equipped with features which make them easy to install in or withdraw from their associated switchgear equipment. These features are a racking mechanism (which facilitates inserting and withdrawing the breaker unit) and primary and control power disconnects which connect and part automatically. Interlocking devices are included. There are 4 types of solid-state, direct-acting, self powered trip device systems associated with AKA break ers. These systems are for AC applications only. For DC applications an electro-mechanical system is available. The trip device system is identified by the first middle digit in the breaker's nameplate designation as follows: AKA-(! )B-30 L- Trip device code number per Table 3 Stationary breakers are designed to be mounted on a framework or panel, with mechanical fasteners being used to secure the breaker frame and make power connections. If control power connections are needed, a suitable termi nal board is supplied. TABLE 3 CODE NUMBER 2 3 4 5 6 A AKD-5 AKD-6 B Substructure D AKD-8 - - ca Substructure s Stationary - AC AC AC AC 2.6 MODEL N U MBER ar Breaker Type DC EC Power Sensor' ECS SST MicroVersa Trip 'Power Sensor devices are discontinued. See publications GEK-7309 and GEK-7301 for detailed servicing procedures MOUNTING TYPE CODES Drawout APPLICATION Type AKA breakers (see Table 2) exist as either no model number of "-1" versions. For example AKA-5A-30H or AKA-5A-30H-1. lP Code TRIP DEVICE tM AKA-5 (�0 Mounting type code letter per Table 2 Letter TRIP DEVICE CODES an The mounting type is identified by the second middle digit in the breaker's nameplate designation as follows: TABLE 2 TRIP DEVICE ua ls 2.4 ' X All AKRTSOH breakers use only molded arc chutes. lec tri -- The difference between these models is their arc chute construction. The arc chutes in the no model number break ers have a two piece porcelain frame and use 2 arc chute retainers, see Fig. 5. The "-1" breaker arc chutes have a one piece molded polyester glass frame and 1 arc chute re tainer, see Fig. 6. i ww w .E .J FIG. 5 8 • - -I "1 1ct s !413-lirl - CERAMIC ARC CHUTES .. .__.: _ _ ;.,r .. .......__ I er-:3 ..4 II t,q PI ;""·���· .!. ___ FIG. 6 - MOLDED ARC CHUTES - .c om j 2.7 SHORT CIRCUIT RATINGS Short circuit ratings vary with the applied system vol tage. On 240 VAC systems they are also dependent upon whether the overcurrent trip device contains an instan taneous trip element. See Table 4. TABLE 4 - BREAKER INTERRUPTION RATINGS 800 AC AKA 30H 635 508 254 635 508 254 635 508 254 AKA 50 1600 AC AKAT 50 635 508 254 635 508 254 ca 2000 AC lP AKA SOH-1 AKAT SOH AKA 50 30 42 42 42 42 50 65 50 42 50 50 50 50 65 65 65 65 65 65 50 65 50 65 50 65 65 65 65 600 600 300VDC 200 200 - 300 VDC 25' so• 3 25 50 lec 2000 DC AKAU 30 AKAU 50 AKA 30 tri 800 1600 800 DC SHORT TIME 30 30 42 ar AKA SOH ua ls 635 508 254 635 508 254 AKA 30 KA RMS SYMMETRICAL WITHOUT WITH INSTANTANEOUS INSTANTANEOUS TRIP TRIP an BREAKER TYPE 3c/> INTERRUPTION RATING tM FRAME SIZE (AMPERES) RATED MAXIMUM VOLTAGE (60HZ AC) ww w .E 'With 40-800 Amp Trip Coils 'With 200-2000 Amp Trip Coils >consult Factory For Application Data 9 .c om SECTION 3-Storage The rejection hardware prevents the converse bf a. thru d. above. It is recommended that the breaker be put into service immediately in its permanent location. If this is not possi ble, the following precautions must be taken to insure the proper storage of the breaker: A detailed description of the rejection pin and bracket combinations used is given in Installation manual, GEl 86150. lP an ar CAUTION: IF THE BREAKER IS STORED FOR ANY LENGTH OF TIME, IT SHOULD BE INSPECTED PERIOD/CALLY TO SEE THA T RUSTING HAS NOT S TAR TED AND TO ASSURE GOOD MECHANICAL CONDITION. SHOULD THE BREAKER BE S TORED UNDER UNFAVORABLE A TMOSPHERIC CONDI TIONS, IT SHOULD BE CLEANED AND DRIED OUT BEFORE BEING PLACED IN SERVICE. tM 2. The breaker should be stored in a clean location free from corrosive gases or fumes. Particular care should be taken to protect the equipment from moisture and cement dust, as this combination has a very corrosive effect on many parts. ua ls 1. The breaker should be carefully protected against condensation, preferably by storing it in a warm dry room, since water absorption has an adverse effect on the insula tion parts. Circuit breakers for outdoor switchgear should be stored in the equipment only when power is available and the heaters are in operation to prevent condensation. ca SECTION 4- FIG. 7- DRAWOUT BREAKER REJECTION SYSTEM Drawout Breaker Interchangeability FRONT OF COMPARTMENT lec tri In general, drawout breakers of the same type an d r ating are interchangeable in their equipment compartments: drawout breakers of different frame sazes are not anter changeable. To prevent inserting the wrong type breaker into a drawout compartment. suitable "reJectaon hardware" is affixed to each breaker and ats compartment. Fagure 7 shows a typacal re1ectaon bracket whtch ahgns wath a reJec· lion pan tn the drawout rail (Fag. 8) When the wrong type breaker as tnserted anto a compartment the bracket and ptn do not mate. preventang the breaker from seattng atself tnlo .E the drawout ratls. There as one exception to the above Breakers of the same frame s•ze havtng dafferent short carcu•t ratangs may be interchanged •n one darechon only RIGHT SIDE PIN a. An AKR-30H can be anserted tnto an AKR-30 compart· w ment. b. An AKR·SOH can be anserted tnto an AKR-50 compart· ww ment. c. An AKR·SOH-1 can be anserted tnto an AKR-50 and AKR·SOH compartment. d. An AKRT·SOH can be anserted anto an AKRT-50 com partment. 10 FIG. 8 INSERTING THE BREAKER 5.2 SECTION 5-Breaker Operation ELECTRICAL CLOSING On electrically operated breakers the closing springs are charged by a gear motor. With the springs discharged, voltage applied to the control circuit will energize the motor through the G switch contacts- see Fig. 9. The motor, through the gear reduction output crank, compresses the closing springs until they are fully charged. As this fully charged position is reached, mechanically operated switches "F" and G reverse their shown position, the G switch deenergizing the motor and the "F" switch estab lishing a circuit to the "X" relay. At the same time, a mechanical prop is positioned to prevent the discharge of the fully charged closing spring. " A breaker may be equipped to operate either manually or electrically. Both types of operation result in the same fast-closing movement as far as the contact action is concerned. The variation is in the way energy is stored in the closing spring, and how it is released. " " " " " ua ls 5.1 .c om ' MANUAL CLOSING Manually operated AKA breakers are constructed with front-mounted handles. Handle operation resets the mechanism and fully charges the closing spring. A com plete charge is accomplished in either cranking the han dle through one cycle (1 35-degree swing) or three cycles (50-degree swing). Manually operated breakers manufac tured after July, 1984 can only be charged by cranking the handle through one cycle. The CLOSE button mounted on the escutcheon, is used to manually close the breaker contacts and the TRIP button is used to open them. an With the closing spring propped fully-charged, the breaker is ready for closing. This may be accomplished electrically by depressing the closing switch on the breaker (if so equipped) or by a remote closing switch. Operation of the closing switch energizes the "X" relay, which in turn energizes the closing solenoid. This removes the prop, releasing the closing springs to close the breaker. tM As the closing relay is energized, it energizes anti-pump relay "W". If the closing switch is maintained closed, the anti-pump relay will remain picked-up to prevent a second closing operation on the breaker in the event it is tripped open automatically. The closing impulse must be released and reapplied before a second closing operation can occur. lec �r 'I X cc w CC- CLOSING SOLENOID � F- CUTOFF SWITCH. cc X .E Gl ...J ww LEGEND tri CONTROL SOURCE - The closing springs on electrically operated breakers can be manually charged. The breakers can also be man ually closed. Refer to Section 5.4 for this procedure. ca lP ar I f equipped with a closing solenoid, a manual breaker may be closed remotely by a control switch or relay. Before this can be done, however, the closing spring has to be charged by hand. The closing solenoid is an op tional accessory and is not supplied unless specified in the breaker order. w TC � --------- -- --- CLOSED WHEN CLOSING SPRING IS FULLY CHARGED. G- CUTOFF SWITCH OPEN WHEN CLOSING SPRING IS FULLY CHARGE D L - AUXILIARY SWITCH M - CHARGING MOTOR PB- CLOSE PUSHBUTION ON BREAKER ESCUTHEON. OPTIONAL TC- SHUNT TRIP DEVICE W - ANTI-PUMP RE LAY X- CONTROL RE LAY - FIG. 9 - ELEMENTARY DIAGRAM FOR ELECTRICALLY OPERATED DRAWOUT BREAKER. CONTACT POSITIONS ARE SHOWN WITH BREAKER OPEN AND CLOSING SPRINGS DISCHARGED. 11 .c om ' 5.2.1 ALTERNATE CONTROL CIRCUIT The motor is energized through the 'G' cutoff switch and the K-relay contact. The motor is deenergized when the 'G' cutoff switch changes state which occurs when the closing spring is fully charged. tM REMOTE CLOSE -1 �-., A F- CUTOFF SWITCH, CLOSED WH EN CLOSING SPRING IS FULLY CHARGED (D.C. ONLY) TC G - CUTOFF SWITCH, OPEN WHEN CLOSING SPRING IS FULLY CHARGED. L- AUXILIARY SWITCH M - CHARGING MOTOR PB- CLOSE PUSHBUTTON ON BREAKER ESCUTCHEON. OPTIONAL TC - SHUNT TRIP DEVICE K - ANTI-PUMP RELAY .E lec tri ca lP t�PS LEGEN D CC - CLOSING SOLENOID ar o------o- - The anti-pump function is obtained through the nor mally closed K-relay contact in the motor circuit. If a close signal is maintained after the breaker has tripped open automatically, the K-relay Is energized preventing the motor from charging the closing spring. The closing signal must be removed for approximately 1 .3 to 2.0 seconds to allow the closing spring to charge. an With the closing spring propped fully-charged, the breaker is ready for closing. This may be accomplished electrically by depressing the closing switch on the breaker (if so equipped) or by a remote closing switch. Operation of the closing switch energizes the K-relay which in turn energizes the closing solenoid. Thi� removes the prop, releasing the closing springs to close the breaker. The 'F' cutoff switch is only installed on breakers using D.C. control voltage. ua ls Later production breakers use the electrical control circuit shown in Fig. 9A for all control voltages except 250 volts D.C. which uses the circuit shown in Fig. 9. This alternate control circuit eliminates the X-relay and CC switch shown in Fig. 9. ww w FIG. 9A. ALTERNATE ELEMENTARY DIAGRAM. CONTACT POSITIONS ARE SHOWN BREAKER OPEN AND CLOSING SPRINGS DISCHARGED. 12 ' .c om ! 5. 3 M ECAHNISM OPERATION Figure 10 shows the mechanism components in the Closed, Tripped and Reset positions. The closing spring is shown in the charged position in all of these details. lP ar tM Reset Position - The mechanism is shown in Fig. 10C. The cam, item no. 3, which is assembled to the cam shaft, item no. 4, is rotated by the charging motor, manual operating handle, or maintenance handle. The cam engages the cam roller and partially extends the toggle linkage. This allows the secondary latch to pivot against the front frame as shown leaving a gap between the trip latch and secondary latch roller. The secondary latch is now in a position to engage with both the top latch and cam roller. 10 11 ca The breaker closes when the closing spring discharges and rotates the cam against the cam roller. The toggle linkage is fully extended, pivoting the secon dary latch from the front frame and engaging it with the trip latch and cam roller as shown in Fig. 10A. 5 5.4 FIG.10C RESET Prop Cam 4. Camshaft 5. Cam Roller 10. Trip Shaft 2. 3. Trip Latch Insulated Coupling Main Shaft 14. Secondary Latch 15. Opening Spring 11. 12. 13. CHARGING USING THE MAINTENANCE HANDLE The closing spring on electrically operated breakers can be manually charged by using the maintenance handle (568B386G1) as shown in Fig. 11. The triangular socket in the maintenance handle mates with the mechanism's camshaft extension on the front right side of the breaker. Using the knob on the handle, it will probably be necessary to a lign this socket to fit on the end of the shaft. .E lec w 8. tri When the breaker is closed and the closing spring discharged, the upper cam roller is supported by the cam rather than the prop. This is the position the mechanism must be in to check contact adjustment refer to Sectior 14 FIG. 108 TRIPPED an Tripped Position - The mechanism goes from the Closed position to the Tripped position, shown in Fig. 108, when the trip shaft, item no.10, is rotated by either the manual trip button or one of the other trip devices. The trip latch, item no.11 is assembled to the trip shaft. When the trip shaft rotates, the trip latch disengages from the secondary latch roller. The secondary latch pivots, resulting in the collapse of the toggle linkage. This collapse along with the opening spring, item no.15, causes the breaker contacts to open. ua ls Closed Position- As shown in Fig.10A, the movable contacts are held against the stationary contacts by the toggle linkage. The toggle linkage is held in position through the engagement of its cam rollers, item no. 5, with the prop, item no. 2 and the secondary latch/trip latch, item nos. 14 & 11. ww . AG. 10A CLOSED FIG. 1 1- MAINTENANCE HAN DLE INSTALLED ON CAMSHAFT EXTEN SION 13 .c om , FIG. 1 2 - tM an ua ls SECTION 5-Breaker Operation {Cont.} ROLLER ENGAGED WITH CLOSING PROP lP ca tri lec .E w ww 14 (�i:) El £ Rotate the camshaft using the maintenance handle until the ratchet assembly's roller engages with the prop. Do not drive the roller against the prop with undo force. The breaker can now be closed by removing the prop from thr #" roller. This is done by manually activating the closin� solenoid's armature. Push the solenoid's armature into its windings. See Fig. 13. ar There is a ratchet assembly attached to the camshaft extension. This ratchet is normally driven by the breaker's gear motor. A roller on this ratchet engages with a prop when the closing spring is fully charged and driven over center, see Fig. 1 2. This holds the closing spring in a charged condition. G f N ERA L FIG. 1 3 - MANUAL OPERATION OF CLOSING SOLENOID . .c om ' SECTION 6-lnterlocks RACKING MECHANISM I NTERLOCK The function of the racking mechanism interlock is to prevent the breaker from moving from its CONNECTED position before it is in the OPEN position. tM The racking mechanism drive shaft is located behind the RACKING SCREW cover shown in Fig. 14. This cover must be slid to the right to gain access to the drive shaft. When the breaker is in the CLOSED position, a link en gages the RACKING SCREW cover preventing it from being opened. This link is driven by the motion of the OPEN/CLOSED indicator as shown in Fig. 15. an 6.1 ua ls AKA breakers are equipped with safety interlock devices that are required by Industry Standards and Certifying Au thorities. Interlock devices for special applications are also available as options. The standard interlock devices de scribed below are used only on drawout breakers. Station ary breakers have no required interlocks. ar FIG. 1 4-A - RACKING SCREW ca lP The TRIP button also engages with the RACKING SCREW cover in both the OPEN and CLOSED positions. Therefore, the TRIP button must be pushed in before the cover can be opened. This will open the breaker if it was closed and also remove the OPEN/CLOSED linkage dis cussed above. When the RACKING SCREW cover is open it holds the TRIP button in. This keeps the breaker tri p free so a mechanism closing cycle will not cause contact movement especially when the breaker is being racked in or out. FIG. 14-B ww w .E lec tri - 15 .c om . tM position, the crank's pin reaches the end of the slot in the linkage. Continued motion of the racking mechanism causes the linkage to rotate the lever which moves the closing solenoid armature forward. The armature linkage then releases the prop, discharging the closing spring. POSITIVE INTERLOCK The Closing Spring interlock should be adjusted to cause the closing spring to discharge when the racking mechanism is a minimum of 1 and a maximum of 2Y2 turns short of the fully racked out position. In this position the racking handle can no longer be turned. If adjustment is required, use the linkage adjusting screws shown in Fig. 17. lP 6.2 FIG. 1 6 - POSITIVE INTERLOCK ar FIG. 1 5 RACKING SCREW COVER INTERLOCK C LOSED POSITION an ua ls SECTION 6-lnterlocks (Cont.) The function of the positive interlock is to keep the breaker trip-free while it is being racked in or out between the CONNECTED and TEST positions. 6.3 lec tri ca The positive interlock is located on the breaker's left side as shown in Fig. 16. As the breaker moves between the CONNECTED and TEST positions, the positive interlock engages with a ramp cam located in the breaker compart ment. Th1s cam raises the interlock's lever assembly caus ing the trip shaft to move and preventing the trip latch from engaging with the secondary latch assembly roller. The breaker IS held trip-free and cannot be closed during this interval. CLOSING SPRING INTER LOCK .E The function of the clos1ng sprrng interlock is to dis charge the clos1ng sprrng as the breaker IS being racked out of 1ts hous1ng Th1s ehm1nates the hazard of a com pletely charged breaker be1ng discharged after the breaker is removed from 1ts compartment ww w The operat1on of the clos1ng sprrng 1nterlock IS shown m Fig. 17. The rack1ng mechan1sm arms and the crank are connected to a common shaft. As the breaker rs racked out a pin anached to the crank moves through the slot rn the linkage. The hnkage IS connected to a lever wh1ch engages with a prn on the clos1ng solenoid armature hnkage. When the rack1ng mechantsm approaches the DISCONNECT 16 Note - undue force on the racking handle at the fully racked out position will cause the lever to move past the pin on the armature linkage. This will bind u p the overall interlock. Under these cond itions, continued application of this force will deform the linkage assembly. A later lever design (shown in Fig. 17) includes a stop which pre vents the lever from moving past the pin. When the pin is against this stop, undue force may still d eform the link age assembly. . .c om 6.4 DISCONNECT POSITION I NTERLOCK The function of the Disconnect Position Interlock is to block the RACKING SCREW cover open when the racking mechanism is in the DISCONNECTED position. When the cover is held open, the TRIP button is depressed. The mechanism is held trip-free and there is no contact arm movement when the closing spring is discharged by the Closing Spring interlock. tM an ua ls The operation of this interlock is shown in Fig. 18. A crank, which is attached to the racking mechanism shaft, is connected to the blocking plate through a link. As the shaft turns, the blocking plate rotates; holding the cover open in the DISCONNECTED position, but allowing it to close in the TEST and CONNECTED positions. .E lec tri ca lP Linkage Pin Not Engaged ar Breaker Racked In - Lever And Armature w Breaker Being Racked Out - ww Lever Activates Armature Linkage FIG. 17 - FIG. 1 8 DISCONNECT POSITION INTERLOCK 6.5 PADLOCKS Provisions are made in all breakers to use padlocks to prevent the breaker from being closed. For non Type B or D breakers the padlock shackle goes through the TRIP but ton hole and out the slot in the side of the escutcheon. For Type B or D breakers the padlock shackle goes through the TRIP button hole and out the RACKING SCREW cover hole in the deep escutcheon. In either case, the shackle holds the TRIP button in keeping the mechanism trip-free. C LOSING SPR ING I NTERLOCK 17 .c om SECTION &-Interlocks (Cont.) ' 6.7 O PTIONAL INT ERLOCKS The function of the Key Interlock is to prevent an open breaker from being closed when the lock bolt is extended and its key is removed. The optional interlocks are key interlocks and door inter locks. On drawout breakers, these devices are mounted in the equipment and are part of the breaker enclosure. Pad locks may be used to lock the "inner" house in the "discon nected" position. The operation of this interlock is shown in Fig. 19. When the breaker is in the OPEN position, the end plate assembly on the main shaft pivots the lever counter-clockwise. This removes the pin on the lever from blocking the lock bolt. Extending the lock bolt rotates the linkage which moves the trip shaft, preventing the mechanism from closing the breaker. 1. Lock 2. End Plate tM 3. Pin When the breaker is in the CLOSED position, the flywheel assembly is away from the lever. The lever is spring loaded and rotates clockwise causing its pin to block the lock bolt extension. an B REAKER ua ls 6.6 KEY I NT ERLOCK-STAT IONARY Lock Bolt 5. Pin 6. Lever ca lP ar 4. r?�r=�==�-4 -;.....J:J;�-..:..+---- 3 _,.;..�I--- lec tri �::::::-::-=....:.* .:..::=::=-:: ��� 5 6 FIG. 1 9 - KEY INTERLOCK-STATIONARY B R EAKERS .E SECTION 7- Breaker Maintenance SAFETY PRECAUTION ww w WARNING: BEFORE INSPECTING OR BEGIN NING ANY MAINTENA NCE WOR K ON THE BREAKER, IT MUST BE DISCONNECTED FROM ALL VOL TAGE SOURCES, BOTH POWER AND CONTROL. AND THE BREAKER MUST BE IN THE "OPEN" POSITION. 18 7.1 LU BRICATION In general, the circuit breaker requires moderate l ubrication. The majority of the factory l ubricated bear ing points and sliding surfaces are accessible for inspec tion and if necessary, cleaning and relubricating. The on ly l ubricant used on the breaker for both electrical and mechanical areas is General Electric specification D50HD38 (Mobilgrease 28). . .c om ' SECTION 7 -Breaker Maintenance (Cont.) 7.2 3. 4. 5. 6. There are two handle adjustment linkage designs in use. The adjustment linkage connects the handle assembly to the chain drive mechanism which turns the cam shaft. The length of this linkage provides the handle adjustment. If the link is too long, the handle stroke cannot extend the closing spring enough for it to go over center. In this event, use the maintenance handle to complete the spring charg ing. The breaker can then be closed and opened prepara tory to further shortening of the link. If the link is too short, one-stroke charging is not possi ble. However, more than one stroke will charge the springs. The original linkage design used a double-ended stud in the linkage center. A hex section in this stud allowed adjust ing with an open-end wrench. When looking down on the breaker, turning the wrench clockwise lengthens the link. The opposite motion shor:tens it. The range of adjustment is 300 degrees. In the confined space available, each wrench stroke imparts 1 5 degrees movement. The best setting is approximately mid-range. ar 7. On manually-operated AKA breakers, the closing springs may be charged either by a single 1 35 degree clockwise handle stroke or up to four multiple strokes of lesser swing. The following adjustment procedures should be performed using the single-stroke method. By so doing, proper multi-stroke operation is assured. ua ls 2. Contacts - A thin fil m on the stationary and movable contact assembly pivot surfaces. Refer to Section 8. Racking Mechanism - The drive threads, jamb nut/trunnion interface, thrust washer/collar interface, and the shaft support bearings. Refer to Section 7.13. Manual Operating Handle - Lubricate the two pivot areas associated with the adjustment linkage. Also, the handle, mounting shaft/support bushing inter face. Refer to Section 7.2. Flux Shifter - Lubricate pivoting and sliding sur faces of the reset linkage. Refer to Section 1 0.3. Switchette - Lubricate the activator lever surface that contacts the switchette button. Mechanism - All accessible bearing and sliding sur faces that have been factory lubricated. Primary Disconnects - Lubricate the finger contact surface just prior to installing in switchgear or lubricate and then cover the disconnect assembly to protect from dust, dirt, etc. Refer to Section 7.5 tM 1. MANUAL HANDLE ADJUSTMENT an The areas requiring l ubrication are: The present design is shown in Fig. 20. This linkage is assembled together on a threaded stud. Adjustment is accomplished by removing the upper linkage assembly from the handle assembly and changing the linkage length by turning the upper linkage up or down the threaded stud. ww w .E lec tri ca lP Before lubricating, remove any hardened grease or dirt from the latch and bearing surfaces. After lubricating, remove all excess lubricant of dirt·or dust. The use of cotton waste to wipe bearing surfaces should be avoid ed. The cotton ravelings may bec.ome entangled under the bearing surfaces and destroy the surface of the bear ing. FIG . 20 - MANUAL HANDLE ADJUSTMENT 19 .c om SECTION 7-Breaker Maintenance (Cont.) Remember, before installing the breaker back into its compartment, the drawout mechanism must be returned to the DISCONNECT position. 7.4 SLOW CLOSING T H E B REAKER Closing the breaker slowly, while observing the action of the mechanism and contacts, is a good way of judging the correctness of mechanical and contact relationships. Some of the maintenance procedures described later will involve operating the breaker in this manner. The proce dure for slow closing is given below. Remove the hex-head bolt only, do not remove or loosen the slotted head screw shown in Fig. 21 . Removal of the slotted head will cause the closing spring to become dis engaged from the camshaft with considerable force. Verify that this screw remains tightened during the slow close operation. ua ls Maintenance or inspection should be conducted with the breaker on a workbench. The drawout mechanism must be placed in the CONNECT position. This will deactivate the various interlocks which would otherwise prevent the mechanism or contacts from closing. Engage the racking handle with the racking shaft and turn clockwise until it stops. After the bolt is removed, use the maintenance handle to rotate the ratchet assembly's roller onto the closing prop (see Charging Using The Maintenance Handle, sec tion 5.4). At this point, the closing prop must be removed by either pushing the CLOSE button on Manual breakers, or pushing the closing solenoid armature on electric breakers (see Fig. 1 3). When the closing prop is removed, continue turning the camshaft. The contacts and mechanism is in Its fully closed position, the cam will support the cam roller (refer to Fig. 10 & section 5.3) and the contacts will develop maximum depression. an D RAWOUT MECHANISM POSIT ION Push the TRIP button to release the mechanism and open the contacts. CAUTION The mechanism and contacts will open with normal speed and force. tM 7.3 - When replacing the hex-head bolt, tum the camshaft with the maintenance handle to align the mating holes in the lower spring assembly and camshaft linkage. ww w .E lec tri ca lP ar The closing spring must be isolated from the mechanism's camshaft. This is done by disconnecting the lower spring assembly from the mating camshaft linkage. Remove the hex-head bolt as shown in Fig. 21 . Remove this bolt only with the mechanism in the DISCHARGED position and the spring at its minimum extension. 20 FIG. 21 - SLOW CLOSING-LOWER SPRING ASM HARDWAR E .c om SECTION 7-Breaker Maintenance (Cont.) 7.5 P RIMARY DISCONNECTS The BOO ampere breakers use four primary disconnect fingers per phase. The 1 600 and 2000 ampere breakers use eight fingers per phase. Fig. 22 shows a line and load end disconnect assembly. The line end disconnects on fusible breakers have the spring pointing downwards, otherwise they are identical . lP ar tM an ua ls Primary disconnects are found only on drawout break ers. They provide the flexible connection between the breaker's line and load terminals and the equipment's line and load terminals. FIG. 22 - P RI MARY DISCONNECT w .E lec tri ca ASSE M B LY FIG. 23 - PARTIAL PRIMARY DISCONNECT ASM ww FIG. 24 - PARTIAL P R I MARY DISCONN ECT ASM FIG. 25- PARTIAL P R I MARY DISCONNECT ASM 21 .c om SECTION 7-Breaker Maintenance (Cont.) 7.5.1 REPLACEMENT Figs. 22, 23, 24, and 25 show the primary disconnect assembly breakdown. Refer to these illustrations when replacing the disconnects. Note the following details: ua ls Fig. 25- The position of the spacer in the breaker stud. The hole in the spacer must be positioned as shown so it will align with the holes in the clip. Fig. 24 - The engagement of the fingers with the re tainer. Also the location of the 'bowtie' spacers in the fingers, both upper and lower. Fig. 22 & 23 - The position of the upper and lower retainers and, again, the 'bowtie' spacers. ADJUSTMENT 7.6 an FIG. 27 - AUXILIARY SWITCH LINKAGE 7.6.1 REPLACEMENT The switch may be dismounted by removing the two bolts which fasten it to the mechanism frame. The replacement switch should have its crank shaft set so that the arrow head on the end of the shaft points as shown in Fig. 28 when the breaker is open. If a switch is added to a breaker having none, the ad justing link will also have to be installed. This is connected to the pin on the crank which is attached to the main shaft. It is secured by means of a cotter pin. ar The primary disconnect assembly is factory adjusted to apply a force of 85- 1 05 pounds on a 1/2 thick copper bar inserted between the upper and lower fingers. After instal lation of the disconnect assembly this force range is ob tained by tightening the locknuts to set the dimension shown in Fig. 26. Note that this dimension is measured between the top of the retainer and the underside of the washer. Also note that no bar is inserted between the fingers when setting this dimension. tM 7.5.2 AUX I LIARY SWITCH lP All electrically operated breakers and manual breakers having shunt trips are supplied with auxiliary switches. Depending upon the requirements of the breaker's applica tion, the switch may contain from two to six stages. Usually, each stage has one "'A" contact and one "B" contact. "A" contacts are opened or closed as the breaker is opened or closed. "B" contacts are the reverse of this. ca ARROWHEAD tri The auxiliary switch is mounted on the upper side of the mechanism frame as shown in Fig. 27. A crank on the main shaft operates the switch through an adjustable link which connects it to the switch crank. lec !* _l_ ,J:;:L_ :_--::-::�;�� �:-J 11 i - � � J _::_ -_ I ·: ___ --� L j ww w FIG. 26 - PRIMARY FINGER ADJUSTMENT 22 AG. 28- AUXILIARY SWITCH CRANK SHAFT POSITION �- -----... I '-- �-�-·-r 'F' �"$:.I-:.. ..-� '-=t� ? .E . \' ________... 7.6.2 ADJ USTMENT If the adjustable link Is installed, its length should be set, before installing. at 6 3J8 inches, between pin centers. After installing a new switch, its operation should be checked. Viewing the switch from above, the contacts toward the front of the breaker are nonnally the "B" con tacts. Even if a special switch is used, it is always the case that the first two stages nearest the crank have the "B" contacts to the front, and the "A" contacts towards the back. ··A" contacts are closed when the breaker is closed. "B"" contacts are closed when the breaker is open. .c om :To check the setting, arrange the breaker for "slow close" as described in Section 7.4. Through the use of a continuity tester, observe the position of the breaker con tacts when the switch's LI-LIC "A" contacts touch. At this point the breaker's arcing contacts must be within .250 "• � of closing. Adjustment is made by disconnecting the upper end of the adjustable link and varying its length as required. The shunt trip device opens the breaker when its coil is energized. An "A" auxiliary switch, which is closed only when the breaker is closed, is in series with the device coil. Connections are made to the external tripping source through secondary disconnects on drawout breakers, or to the auxiliary switch and terminal board on stationary breakers. The shunt trip is mounted to the underside of the breaker front frame as shown in Fig. 29. A second shunt trip may also be mounted to the frame (see Fig. 30) if a se cond undervoltage device isn't already installed, see Sec tion 7.8. FIG. 29 - SHUNT TRIP AND UNDERVOLTAGE MOUNTING If the breaker is disconnected, and for some reason the breaker is to be operated manually, the undervoltage device may be tied or wired down so that it will not cause tripping. The undervoltage device is mounted to the underside of the breaker front frame as shown in Fig. 29. A second undervoltage may also be mounted to the frame (see Fig. 31) if a second shunt trip isn't already installed, see Sec tion 7.7. tM 7.7.1 REPLACEMENT ua ls S H U NT TRIP an 7.7 If a second undervoltage device is added, a new buffer assembly block will be supplied; This is required for clearance, in this case, the buffer assembly must be taken off, disassembled, and remounted together with the number two undervoltage device. Before disassembling the original buffer, carefully measure the distance between the faces of the threaded members as shown in Fig. 31, and set this dimension carefully on the new assembly. Refer to the breaker wiring diagram for the coil lead connections. ar If it is necessary to replace or add one of these devices, t he easiest procedure is to remove the mounting bracket, shown in Fig. 29, from the breaker frame and remove the device from the bracket. If a replacement or new device is ordered, a mounting bracket will be supplied with the device. lP If a second shunt trip is added, this is mounted by means of an additional bracket as shown in Fig. 30. This additional bracket is fastened by two of the hex head bolts used to fasten the buffer assembly to the breaker frame. ca 7.7.2 ADJUSTMENT tri When these devices are installed or replaced, their positive ability to trip the breaker must be demonstrated. This is done by placing a 1 /32·inch shim between the ar mature and magnet of the device and manually operating the armature to trip the breaker. 7.8 .E lec If the shunt trip is not successful in this test, check the mounting fasteners to make sure they are reasonably tight. If they are, then bend the trip paddle on the trip shaft to slightly reduce the distance between the trip arm of the device and the trip paddle, and recheck for positive trip. If this bending is necessary, be careful that it is not over· done. Verify that there is a .030 ··.® · gap between the ' , trip arm and t h e trip paddle with the breaker closed. This gap is necessary to prevent nuisance tripping. 7.8.1 REPLACEM ENT If it is necessary to replace or add one of these devices, the easiest procedure is to remove the mounting bracket shown in Fig. 29, from the breaker frame and remove the device from the bracket. If a replacement or new device is ordered, a mounting bracket will be supplied with the device. � (, 0 UN DERVOLTAG E DEVICE w The undervoltage deivce tnps the breaker when its coil is de-energ tzed . The leads of the coil are connected direct ly to secondary disconnects or to a terminal board. Under normal conditions. the coil remams energized and the breaker may be closed. ww " Drop-out" of the armature, with resultant breaker tripp. ing, occurs when the voltage is reduced to less than 60 percent of the rated voltage. An open armature will render the breaker incapable of closing. The armature "picks up" and al lows c losing, if the voltage ts 85 percent or more of its nominal value. Refer to Table 23. Section 14 for the ac· tual drop out and pick up voltage ranges. FIG. 30 - 2ND SHUNT TRIP INSTALLATION 23 .c om ua ls SECTION 7-Breaker Maintenance (Cont.) an FIG. 32A - UNDERVOLTAGE DEVICE 7.8.2 OPERATIONAL CH ECK tM ar FIG. 31 - 2N D UN DERVOLTAGE DEVICE If excessive clearance or binding exists, loosen the screws holding the magnet assembly to the frame and move the magnet up or down as necessary. Tighten the screws to 27 to 32 in-lbs. 2. The air gap between the armature and magnet with the undervoltage device de-energized should be .25 inches. Check the gap by inserting a .201 ± .005 diameter gage between the armature and magnet as shown in Fig. 328. If necessary reset the air gap adjusting plate so that the gage pin fits. Tighten the adjusting plate screw to 9 to 1 1 inches and cover it with RTV. 3. Check the pick up voltage level with the undervoltage device mounted on the breaker. Refer to Table 23 for the allowable voltage ranges. The voltage measurements should be made at the breaker's secondary d isconnects and with the undervoltage coil energized. The coil should also be close to room temperature (approx. 20-240C) when taking voltage measurements. The coil resistance will in crease as its temperature increases and will change the ac tual pick up level. If necessary, the pick up level is changed by using the adjustment screw shown in Fig. 32A. Remove the locking wire, tum the screw clockwise to raise the pick up level and counterclockwise to lower. Once the pick up level is set, In stall the locking wire. Allow t�-coil to cool and then recheck the pick up level with 3 quick measurements. ca lP When the undervoltage device is used as part of a shut down circuit which opens the breaker by deenergizing the coil, the following operational check should be made. It is recommended that this check be performed every 12 mon ths or every 1 7fiJ operations for AKR 30 breakers and 500 operations for AKR fiJ I AKRT fiJ breakers. tri 1 . Check the trip latch engagement as described in Sec· tion 7.15. Trip Latch Adjustment 2. Check the torque required on the trip shaft to trip the closed breaker. The value must be 24 inch-ounces max· imum. lec 3. Check the response time required to go from zero volts across the undervoltage coil to the breaker contacts open ing. This time should be 20 to fiJ milliseconds. If steps 1 and 2 above are acceptable, but the response time is too high, refer to Section 7.8.3. .E 7.8.3 ADJUSTM ENTS It is recommended that the following checks be made at the intervals given In Section 7.8.2. ww w 1 . Hold the armature against the magnet as shown in Fig. 32A and check the following: a The rivet can tum freely. b. There is no binding between the armature pivot and the shading ring. c. There is a .CX)1 to .010 inch clearance between the rivet and armature as shown In Fig. 32A. This measurement should be made at the outer edge of the armature where Its constant radius Is closest to the rivet. OPEN GAP ADJUSTMENT 24 FIG. 328 - OPEN GAP CHECK .c om When adjusting the pick up level on instantaneous de undervoltage devices, set the gap between the armature and magnet to .030 inches using the adjustment screw as shown in Fig. 32C. After setting the pick up level, use this same adjustment screw to obtain the drop out setting. Cover the adjustment screw locknut with RTV. INSERT WIRE GAGE tS positive �� ADJUSTMENT an ua ls 4. When this device is installed or replaced, i ability to trip the breaker must be demonstrated. FIG. 320 c:!::::==d - POSITIVE TRIP CHECK If the a-c control voltage is any voltage other than tM FIG. 32C - CLOSED GAP C H ECK 2081240V ac, a control power transformer (also remotely mounted with respect to the breake" must be used. This must have a minimum rating of 100 volt-amperes. When installed, the voltage to be monitored is connected across terminals No. 1 and No. 2 of the static delay box. The coil of the tripping unit is connected across terminals No. 4 and No. 5 of the static box through the secondary disconnects of the breaker. The secondary disconnects to be used will be shown on the breaker wiring diagram. ca lP ar Undervoltage devices trip the breaker when the armature opens. This causes an extension on the armature to strike the paddle on the trip shaft. An extension of the other end of the armature. When the armature is released, this exten sion stops against a stop which is factory set. To check positive trip, the armature should be held down, the end of a 1 132-inch diameter wire should be inserted against the stop, and the armature released. If this trips the breaker, the set ting is correct. The place to insert the wire is shown in Fig. 320. Note that only the tip of the wire is to be against the stop. tri If the undervoltage device does not have positive tripping ability, the adjustment screw of the trip paddle assembly on the trip shaft may be turned in increments of half turns until the check is successful. When the undervoltage device is closed and the breaker mechanism is reset, there must be clearance between the 7.9 lec trip paddle and the device armature. STATIC TIME·DELAY UNDERVOLTAGE .E The static time-delay undervoltage system consists of a time-delay unit which controls an instantaneous under voltage device. The time-delay unit is separately mounted in the sw i tchgear and the undervoltage device is mounted on the breaker. Table S lists the catalog numbers available. w CAT. NO. ww TAKYUVT- 1 TAKYUVT-2 TAKYUVT-3 G- & ' G- r=;c\ TABLE 5 No more than one undervoltage tripping device should be used in conjunction with one static time-delay unit. The static time-delay undervoltage can also be furnished with a thermotector control unit. Overheating of motor win dings causes the thermotector, imbedded in the motor win dings, to open. This de-energizes the undervoltage device on the breaker and drops the motor load. 7.9.1 ADJUSTMENTS In the event the system fails, the following checks are recommended to determine whether the undervoltage device on the breaker of the static time delay unit is the faulty component. 1 . Check input voltages across terminals 1 and 2 on the static box. See Table 5 for these values. 2. Check output voltages on terminals 4 and 5 with the undervoltage device connected. See Table 5 for values. TI M E-DELAY U NITS APPROXIMATE STEADY STATE DC OPERATING VOLTAGE TERMINALS 4 & 5 NOMINAL DC COIL RESISTANCE (OHMS) @ 25°C 50 440 250VDC 100 1600 208/240 VAC 1 10/125 1600 CONTROL VOLTAGE TERMINALS 1 & 2 125 voc 25 .c om SECTION 7-Breaker Maintenance (Cont.) 3. Check resistance of the disconnected undervoltage device. See Table 5 for values. The undervoltage device must be calibrated through the time-delay unit after the device pick up has been adjusted. A .008 inch minimum closed gaiJ must exist between the ar mature and magnet as shown in Fig. 32C. Refer to Section 7.8.3 and Table 24. 7.1 0 ELECTRIC LOCKOUT DEVICE FIG. 33 - ELECTRIC LOCKOUT DEVICE 7.1 1 BELL ALARM an This device is used to give a remote indication of the breaker's having tripped open through the action of one of Its automatic protective devices. It will not be activated by manual tripping or the action of the shunt trip. A remotely mounted protective relay energizing the shunt trip will there fore not result in the remote alarm action. tM The electric lockout device utilizes an undervoltage device to keep the breaker from resetting its mechanism if the breaker is open and the undervoltage device coil is not energized. The breaker thus cannot be closed unless voltage is on the coli. Once the breaker is closed, loss of voltage will not trip the breaker because, in the closed posi tion, a mechanical link is used to hold down the armature of the device. See Fig. 33. This arrangement provides a means of electrically interlocking two breakers so that they cannot be closed at the same time. Each undervoltage coil may be wired in series with a "B" auxiliary switch contact on the other breaker for cross-interlock purposes. ua ls See instruction Sheet GEH-4545 for more detailed infor mation, including schematic diagrams and circuit descrip tion. ar On each breaker having an electric lockout, an arrange ment is made which will allow breaker closing with the coil de-energized. This is provided to allow "start-up" on "dead" systems. Figure 34 shows this device. The push slide shown is located in the opening in the lower part of the escutcheon. This breaker door must be opened to gain access to it. The bell alarm circuit may be turned off by pushing in the manual trip or by energizing the shunt trip. In the latter case, a normally open contact of the bell alarm switch must be wired in parallel with the "A" auxiliary switch contact in the shunt-trip circuit Closing the breaker will also tum off the alarm. lP ' ---2EM£i :,.� I ··�·· \, 1 _}. ' ..- I . tri I . I ca MAIN SHAFT CLOSED) l """ · J_ 'l� �··· I·"-� ""' ·. ' . lec /TiI I I HOLD- IN The bell alarm device may be equipped with a lockout link which will lock the breaker open until the bell alam device is reset. � .. � The bell alarm is not a standard device and is supplied only when specified on the breaker order. 7.1 1 .1 OPERATION Referring to Rg. 35: the bell alarm mechanism Is ac tivated by a crank which is assembled to the breaker's main shaft. When the breaker opens, a pin attached to this crank moves the alarm link against the switch and locklever Of provided). This activates the switch contacts. It also moves the locklever adjustment screw against the trip shaft padd le keeping the breaker trip free. . ww w .E \: FIG. 34 - ELECTRIC LOCKOUT BY-PASS 26 POINT ENGAGEME �� · � ,40 � ""' ./ FIG. 35 - BELL ALARM DETAILS .c om ' SECTION 7-Breaker Maintenance (Cont.) ADJUSTMENTS The bell alarm Is mounted on the right hand side of the breaker at the rear of front frame It is located under the mechanism's main shaft. . The bell alarm is removed by passing it through a cutout in the rear bend of the front frame, slipping it between the front frame and trip shaft and out through the bottom of the breaker as follows: 1 . Remove the 4 bell alarm mounting screws from the bottom of the front frame 2. If the crank which Is part of the main shaft has a bell alarm activating pin assembled to both sides, remove these pins. 3. 1nsert the flat of the maintenance handle between the top of the left hand side buffer block and the end plate assembly. This should eliminate any Interference from the main shaft during the bell alarm removal. 4. The trip shaft must be moved to allow the bell alarm to fit beteen It and the front frame. Remove the retaining ring holding the right hand trip shaft bearing to the mechanism frame. Slide the bearing from the frame and along the trip shaft. There will now be enough trip shaft movement to slip the bell alarm past. 5. Install the replacement bell alarm in reverse order. 6. Check the adjustments given in Section 7.1 1 2 . tM If a breaker is equipped with a bell alarm/lockout device originally, all the adjustments are made at the time of assembly. Switch operation is controlled by means of shims of insulating material placed between the switch body and the bracket to which it Is fastened. The adjust ment screw is positioned so that when the locklever is in its activated position, it holds the breaker mechanism latch in the tripped position. REPLACEMENT ua ls 7.1 1 .2 7.1 1 .3 an The mechanism i s reset by disengaging the side latch link from the upper latch link or by closing the breaker if a locklever is not provided. The side latch link, is activated only by pushing the TRIP button or operating the shunt trip. A slide attachment on the TRIP button shaft moves against the side latch link when the TRIP button is pushed. This slide attachment is factory adjusted to activate the side latch before the breaker is tripped. A second arm on the shunt trip also activates the side latch link when the shunt trip is energized. ar Check that TRIP button shaft and shunt trip operations, besides tripping the breaker, displace the side latch and prevent the bell alarm switch from operating. The other trip devices and interlocks must activate the bell alarm when they open the breaker. .E lec X- R E LAY OR K - R E LAY ELECTRICAL CONTROL COMPONENTS tri W RELAY 7.12 ca lP The bracket assembled to the TRIP button shaft must be adjusted so that it will displace the side latch when or before the shaft opens the breaker. Maintain a .030 inch minimum gap between the bracket and the side latch when the breaker is closed. A .187 inch depression of the TRIP button must not trip the breaker, but a .375 inch must trip the side latch. the breaker and A bell alarm with a lockout assembly or a bell alarm in stalled on a 2000 amp frame (AKRT 50/SOH) breaker may not work with the above procedure. If this is the case, the breaker front and back frame will have to be separated. ww w CHARGING MOTOR G SWITCH F SWITCH AG. 36A - ELECTRICAL CONTROL COMPONENTS 27 COMPONENT REPLACEMENT 1 To gain access to the electrical control components, the breaker's front escutcheon must be removed. Type B and D breakers require that both the deep molded escut cheon and the shallow steel escutcheon be removed. Before removing the front escutcheon on Type A or B breakers, a supporting block should be placed under the front frame to keep if from tlipping forward. 2 Referring to Fig. 36A, the X-relay or K-relay and F and G switches are mounted on the same bracket. This mounting bracket is fastened to the right-hand mechanism side frame by two hex-head 1/4-20 screws. Removing these screws allows the bracket to be pulled forward from between the mechanism side plates. The W-relay must also be un fastened from the left side frame to allow enough freedom for all the devices and the wiring harness to be taken from between the side frames. With the bracket removed, in dividual devices can be replaced easily. \ 4 6 4. SPRING WASHER 5. WASHER .032• 6. MOTOR DRIVE PIN an RETAINER RING WASHER .010• 3. PAWL ASM FIG. 36B - DRIVING PAWL ASSEMBLY DETAILS The holding pawl pivots on a pin which is assembled to the mechanism frame. Refer to Fig. 36C. To replace the holding pawl: 1 . Remove the front escutcheon for accessibility. 2. Using the maintenance handle, rotate the ratchet ar The charging motor is secured through three spacers to the mechanism frame. The front mounting bolt is accessi ble using a socket and universal joint through the opening in the side of the breaker's frame. The upper rear mounting bolt is accessible using a socket and universal joint over the top of the frame. The lower rear mounting bolt is ac cessible using a socket and universal joint through the opening in the frame's side by the buffer assembly. Slow close the breaker to move the flywheel assembly out of the way. 1. 2. 5 tM The closing solenoid is mounted by means of mounting bracket to the bottom of the breaker frame. The most con venient way to take off the solenoid is to remove the moun ting bracket and then disconnect the solenoid from the bracket. The pin connecting the armature to the closing link must also be removed. 3 ua ls 7.12.1 .c om SECTION 7-Breaker Maintenance (Cont.) enough to disengage the holding pawl. 3. Remove the retaining ring and washer from the pivot ca lP pin. The ratchet on the camshaft is removed by driving out tri the rol l pin which fastens it to the camshaft. Before this can be done, the charging motor must be removed and the closing spring arranged for "slow-dosing" as described lec earlier. Tum the camshaft, using the maintenance handle, until the roll pin is well started, tum the camshaft to gain enough space for the roll pin to clear the breaker frame. Before removing the ratchet note the position of the ratc het s roller or mar1( the ratchet's hub and the camshaft. ' 4. While holding the spring pressure from the holding pawl, remove the existing pawl and slip on the new pawl. 5. Install the washer and retaining ring. 6. Verify that the holding pawl engages a minimum of 4 ratchet laminations. 7. Verify that the holding pawl pivot pin is perpendicular to the mechanism frame. The hardware which assembles the pivot pin to the frame must be torqued to 250 in-lbs minimum. If this hardware must be retightened, add LOG TITE 290 to the shaft threads. 8. Install the front escutcheon. Tighten the escutcheon hardware to 80 ± 10 in-lbs. 3 When replacmg the ratchet, be sure It Is oriented with respect to the camshaft as it was originally and not di spl ac ed 180 degrees Align the mark made on the hub with the 4 shaft. .E mark on the camshaft or position the roller as It was. If the ratchet is displaced 1� degrees, the holes in the ratchet's hub wil l not completely line up with the holes in the cam w The driv1ng pawl I S assem bl ed to the charging motor's drive pin as shown 1n Fig. 36 8 . To replace the driving pawl: 1 . Remove the charging motor. 2. Remove the retaJning ring from the drive pin. Slip off ww the components. 3. Wipe off any grease or dirt from the drive pin. DO NOT LUBRICA TE. 4. Install the 28 components as shown. 6 I 5 1. MECHANISM FRAME PIVOT PIN 3. SPRING 4. WASHER .032" 2. 5. PAWL ASM WASHER .Q10• 7. RETAINING RING 6. FIG. 36C - HOLDING PAWL ASSEMBLY DETAILS 7 .c om 7.1 2.2 F AND G SWITCH ADJUSTMENT For proper electrical operation, the F and G mechani cally operated switches must operate at the proper point in the closing cycle. If these switches are to be replaced, measure the distance between the tip of the switch button and the bracket on which they are mounted. When the new switch is mounted, duplicate the measured dimension, then check for proper operation. When a normal closing operation occurs, the ratchet usually comes to a stop with an arbitrarily designated ratchet tooth No. 1 , Fig. 37, engaged by the holding pawl. This tooth is the one which is In line with an I maginary line passing through the centers of the camshaft (2) and the rivet opposite the roller on the ratchet assem bly. It Is matter of no concern If the action stops on a different tooth, but it is i m portant to positively identify tooth No. 1 by the method described. ua ls an FIG. 37 - LOCATION OF RATCHET TOOTH N0. 1 tM To check the switch action, after tooth No. 1 has been identified, turn the camshaft with the maintenance handle and count the teeth as they pass the holding pawl. By using a continuity tester, observe when the switches operate as the ratchet turns. The normally open F switch on the left will close, and the G switch will open. 1 TOOTH Electrical breakers should operate the switches while moving from tooth No. 1 0 to tooth No. 1 1 . 7.1 3 lP ar If this check shows that an adjustment is needed, the switch to be corrected can be moved closer to or farther away from the paddle which operates the switches. A very thin open-end 5/8-inch wrench will be needed to loosen or tighten the nuts which fasten the switches to the bracket. DRAWOUT MECHANISM ca The drawout mechanism shown in Fig. 38 moves the breaker through the DISCONNECTED, TEST, and CON NECTED positions. Fig. 39 shows how the d rawout mechanism is mounted to the breaker. lec tri As the ra ck i ng handle is turned, the internally threaded trunn1on moves on the screw threads, rotating the hex shaft. on the ends of which are fastened the arms which engage the f 1xed pins in the drawo ut e nclos u re . .E The trunn1on travels between the two jamb nuts on the end of t he screw. and the adjustment sleeve, which stops the trunn1on movement at the other extreme point of its travel The trunnion i s against the jamb nuts when the breaker 1 s fully racked out and against the sleeve when fu ll y racked m . The rackmg mechanism i s adjusted at the factory as sembly operat1on so that the action is stopped in either d1rect1on at t he prec1sely correct point. The jamb nuts are set so that w he n the trunn1on is against them the relation between the arms and the equipment pins they engage is ww w shown m F1g 38 The length of the sleeve, which is free to slide on the threaded shaft , IS controlled by the amount of thread engagement between the sleeve and its collar. This lengt h 1s a dJ usted to stop the trunn1on when the distance between the ends of the equipment and breaker studs is .03 2 " to . 2 1 8 After th1s adJustment is made, the sleeve and 1ts collar are locked together by the set screw. .. . 29 .c om tM an ua ls SECTION 7-Breaker Maintenance (Cont.) ww w .E lec tri ca lP ar FIG. 38 - D RAWOUT MECHANISM DETAI LS 30 FIG. 39 - RACKING MECHANISM INSTAL LED .c om SECTION 7-Breaker Maintenance (Cont.) B UFFER ASSEMBLY When the break�r is opened, the end plate assembly is driven against the opposite end of the buffer assembly. The buffer is a stop absorbing the opening energy of the mechanism. See Fig. 41 . ca lP ar tM an When the breaker is closed, the energy in the closing spring is transferred to the main s haft through the mechanism. The main shaft then drives the contacts closed. The end plate assembly on each end of the main shaft is driven against the buffer assembly shown in Fig. 40. This prevents the mechanism from overdriving the contacts. ua ls 7.1 4 ww w .E lec tri FIG. 40 - BUFFER/END PLATE R E LATIONSHIP-BR EAKER CLOSED FIG. 41 - B U F FE R/END P LATE R ELATIONSHIP-BR EAKER OPEN 31 .c om SECTION 7-Breaker Maintenance (Cont.) 7.1 4.1 NEOPRENE WASHERS BUFFER ADJUSTMENT ua ls Referring to Fig. 40, with the breaker closed and the mechanism not reset, a .005 " min. clearance must exist between the end plate assembly and the buffer nut as shown. Thi s dimension is factory set. It can be reset by Hold the nut with a tightening the buffer nut. screwdriver and tighten using a socket on the bolt head opposite the nut. When tig htening this assembly don't over compress the neoprene washers by overtightening the assembly. These washers absorb the breaker open i ng shock. 7.1 5 TRIP LATCH ADJUSTMENT ar The reset position of the trip latch is set by the adjust· ment screw shown in Fig. 43. The adjustment is correct if three and one-half turns of the adjustment screw causes a closed breaker to trip. If this check is made, the screw must then be set back, or unscrewed, three and one-half turns. tM Fig. 42 shows a buffer assembly prior to being installed in a breaker. The dimensions given establish the number of spacers that are used. an Referring to Fig. 41 , with the breaker open, a .040" maximum clearance can exist between either of the end plate assemblies and the buffer bolt heads as shown. If a larger clearance exists, close it up by unscrewing the buffer assembly i nvolved. - BUFFER ASSEMBLY ww w .E lec tri ca lP FIG. 42 t---- 1 .93 ---- 32 FIG. 43 - TRIP LATCH ADJUSTMENT 8.1 .c om SECTION 8-Contact Maintenance ARC CHUTE REMOVAL AND INSPECTION There are two types of arc chute construction used on the 800 thru 2000 ampere breakers. They are the ceramic type shown in Fig. 5 and the molded type shown in Fig. 6. The ceramic type uses a two piece porcelain frame to enclose its internal parts. The molded type uses a one piece, glass-filled polyester frame. When contacts are replaced, they must be adjusted to ensure that the proper amount of force is developed be tween the movable and stationary contacts when the breaker is closed. This is called the "wipe" adjustment. "Wipe" is the distance through which the stationary con tacts move when the breaker closes. It is measured bet ween the point of contact on a stationary contact when the breaker is open, and the position of the same point when the breaker is closed. The actual wiping motion is greater because the contacts over-travel. "Wiping" imparts a slid ing or "scrubbing" action to the contacts. The 800 ampere arc chute is different from the 1600 and ampere arc chute, which are identical. Therefore, the 800 ampere arc chute cannot be interchanged with the 1 60012000 ampere arc chute. Also note that a breaker must have either all ceramic or all molded type arc chutes install ed, do not intermix on the same breaker. an The arc chutes are held in place by retainers secured by bolts through the mechanism frame. The ceramic type uses two retainers and the molded type uses only one. To remove the arc chutes: 1 . Loosen and back off the retainer bolt locking nut from the mechanism frame. They do not have to be removed. tM The wipe adjustment influences proper arc transfer dur ing interruption of fault currents. "Transfer" of the arc is its forced sequential movement from the intermediate con tacts to the arcing contacts to the arc runner and finally to the arc quencher where it is dissipated and extinguished. It is recommended that contact wipe be checked periodically during normal maintenance inspections. 2000 ua ls Breakers subjected to frequent interruption of high cur rents may eventually require replacement of their contacts. The general rule for determining need of replacement is the loss of one-half or more of the mass of the contact tip material. Roughening or light pitting of the contact surface does not indicate loss of ability to carry or interrupt current. 2. Loosen the retainer bolts until the retainer(s) can be removed. lP ar 3. With the retainer(s) removed, lift the arc chutes off for inspection. tri To install the arc chutes: 1. Replace the arc chutes over each pole unil 2. Locate the retainer(s). 3. Tighten the retainer bolts until the arc chutes are secure. There may be some side to side motion of .the arc chutes, but there must not be any front to back motion. Torque the retainer bolts to 30 in-lbs for the molded type arc chutes and 60 to 1 00 in·lbs for the ceramic type. Do not over tighten. 4. Tighten the locknuts against the mechanism frame with 150 to 175 in-lbs torque. ww w .E lec 7.4 ca CAUTION : BEFORE DOING ANY OF THE FOL L O WING CONTA C T A DJUSTMENT AND RE PLA CEMENT WOR K, MECHANICAL L Y DIS CONNEC T THE CLOSING SPRING FROM THE MECHANISM CAM SHAFT AS DESCRIBED UN DER SLOW CLOSING THE BREAKER, SECTION Inspect each arc chute for excessive burning and erosion of the arc plates and arc runner. Also look for fractures, damage to the liner material used in the molded arc chute and damage to the insulation material used in both arc chutes. Check for any missing parts. 33 .c om SECTION 8-Contact Maintenance (Cont.) 8.2 CONTACT ADJUSTMENT AKR 30130H & AKRU 30 The following wipe adjustment procedure is applicable to all AKR-30 types: 1 . Open the breaker, remove arc quenchers. an PIVOT STUD FIG. 45 0.250• M EASUREMENT POINT WIPE ADJUSTMENT 800 AMP CONTACT STRUCTURE - ar 4. Once the gap dimension is set, verify that the torque required to just tum the adjustment nut is greater than 40 in-lbs. If less torque is required, carefully add LOCTITE 220 to the adjustment nut threads. Wipe off any excess LOC TITE. Once the LOCTITE is set, recheck the torque valve. 5. Repeat above procedure on the other pole units. t tM 2. Slow-close the breaker. The cam roller must be supported by the cam and not the prop. Refer to section 5.3. 3. Select one pole and, using a flat or wire feeler gage, measure the gap between the top contact and its pivot stud as shown in Fig. 45. As necessary, adjust the gap to 0.060 ± 0.020 inch by turning the wipe adjustment nut shown in Fig. 46. ua ls The contact structure of the AKR 30 and the AKRU 30 breakers is slightly different from the AKR 30H. Referring to Fig. 44 A & B, both structures use one moveable contact arm, and two stationary arcing contacts. However, the AKRJAKRU 30 uses three stationary main contacts and the AKR 30H uses four. ww w .E lec tri ca lP 6. Trip the breaker. 34 FIG. 46 - WIPE ADJUSTMENT N UT-800 AMP CONTACT STR UCTUR E ww .c om w .E lec tri ca lP ar tM an ua ls SECTION 8-Contact Maintenance (Cont.) FIG . 448 - A K R 30H 800 AMP CONTACT STR U CT U R ES 35 .c om SECTION 8-Contact Maintenance {Cont.) CONTACT ADJUSTMENT AKR 50150H & AKRU 50 The following procedure Is used to perform the wipe ad justment. 1 . Open the breaker, remove arc quenchers. 2. Arrange the breaker for slow-closing. The cam roller must be supported by the cam and not the prop. Refer to Section 5.3. 3. Select one pole of the breaker and place a thin sheet or strip of tough insulating material, such as mylar, over the stationary arcing and intermediate contacts. This strip should be about two inches wide and must prevent the arc ing and intermediate contacts from making contact when the breaker is closed. 6. Facing the breaker, tum the wipe adjustment stud shown in Fig. 47 clockwise until the checker indicates that the main contacts are separated. 7. Tum the stud counter-clockwise until the main con tacts just touch. a From this point, advance the stud counter-clockwise 270 degrees. This will be 4-1� flats. 9. Once the adjustment is complete, verify that the torque required to just tum the adjustment nut is greater than 40 in-lbs. If less torque is required, carefully add LOCTITE 220 to the adjustment nut threads. Wipe off any excess LOC TITE. Once the LOCTITf is set, recheck the torque valve. 10. Trip the brtrclker, remove the insulating strips. 1 1 . Repeat the above procedure on the other two poles. ww w .E lec tri ca lP ar 4. Using the ratcheting.maintenance handle, slow-close the breaker with tl}e insulation held in place. Examine the insulation to make sure it "over-hangs" below the in termediate contacts, but not enough to cover the main con tacts. 5. Attach a continuity checker (bell-set, light, or ohm meter) between the upper and lower stud. The checker should indicate continuity exists. ua ls · an The contact structure shown in Fig. 47 is used by all AKR50 breaker types. This structure uses two movable contact arms. Each arm acts against a stationary arcing, a stationary intermediate and three stationary mains. tM 8.3 36 FIG. 47 - 1 600 AMP CONTACT STR UCTURE 1 . Open the breaker. The contact structure shown in Fig. 48 is used by all AKRT 50 breaker types. This structure is similar to the AKR 50 structure. There are two movable contact arms, each acting against single stationary arcing and intermediate contacts and four (not three) stationary mains. 2. ua ls 4. Screw the driving link completely into the insulating link. 5. Back out the driving link two and one-half turns. Ex ceed this by whatever amount is necessary to properly position the link within the movable contact arms. 6. Install the coupling pin and retainer rings. · 7. Using the maintenance handle, slow-close the breaker and observe that all eight stationary main contacts move away from their stops. If this condition is not achieved, open the breaker, again remove the coupling pin and back out the driving link an additional half turn. 8. Reassemble, reclose the breaker and recheck wipe. 9. Repeat the above procedure on the other two poles. tM On the AKRT-50 the proper amount of contact wipe exists if, on a closed breaker, all of the stationary main contacts have moved away from their stops. This condition can be checked visually by removing the arc quenchers, closing the breaker and verifying that all eight stationary main contacts are "lifted off" their stops. Should wipe ad justment appear necessary, proceed as follows: Arrange the breaker for slow-closing. 3. Selecting one pole, drift out the coupling pin and detach the driving link from the movable contact arms. There are two designs used to connect the movable contact arms to the insulated link. This results in two con tact adjustment procedures depending on which design the breaker has. In the original design the two movable contact arms are pin-coupled to a metal driving link whose opposite end is threaded and screws directly into the insulating link. This arrangement omits the wrench-operated wipe adjustment stud provided on the AKR-30 and -50 frames. Instead, wipe is adjusted by detaching the driving link from the movable contact arms and then rotating it with respect to the insulat ing link. .c om CONTACT ADJUSTMENT AKRT 50/SOH an 8.4 ww w .E lec tri ca lP ar In the existing design, the metal driving link uses the same adjustment as the AKR 50. To perform the wipe adjustment on this design follow the procedure for the AKR 50, Section 8.3. FIG. 48 - 2000 AMP CONTACT STRUCTUR E 37 .c om SECTION 8-Contact Maintenance (Cont.) 8.5 STATIONARY CONTACT IDENTIFICATION ua ls The stationary arcing, intermediate, and main contacts each have a different function during current conduction and current interruption. For this reason, these contacts are made using different material compositions. Also, the different functions require that the contacts be replaced in configurations shown in Figs. 44, 47 or 48. ar tM an Fig. 49 shows the stationary contacts and how they differ from one another. The 800 amp main and arcing contacts are rectangular, but the arcing contacts have two of their corners notched. The 1 600/2000 amp main and intermediate contacts are rectangular, but the main contacts have two of their corners notched. The inter mediate contacts have all four corners notched. lec tri ca lP 1 600/2000 AMP MAIN ww w .E 1 600/2000A MP INTE R M E D IATE 38 FIG. 49 - STATIONARY CONTACT CONFIG URATION • ·'- . .l 800 AMP MAIN '� .' .� .c om 8.6 8.7 CONTACT REPLACEMENT AKR 30/30H & AKRU 30 CONTACT REPLACEMENT AKR 50/50H , AKRU 50 & AKRT 50/50H Refer to Stationary Contact Identification, Section 8.5 before replacing any stationary contacts. Refer to Stationary Contact Identification, Section 8.5, before replacing any stationary contacts. The stationary contacts are held in place by the contact springs which pivot the contacts against the contact stop, refer to Fig. 45. To replace contacts: The stationary intermediate and main contacts are replaced just like the stationary contacts on the 800 ampere breakers. Refer to steps 2 & 3 in Section 8.6 2. Release each contact spring by holding the contact, extending the spring, and removing it from the contact. The end pieces on each spring have a small hole for inser ting a spring puller. A suitable puller can be fashioned by forming a hook on the end of a length of .062 " diameter steel wire. Referring to Fig. 50, the stationary arcing contacts are replaced as follows: 1 . Remove the arc runner and the flat insulation assembled underneath the arc runner. It is secured with four screws. When removing the lower screws, use care not to damage or misplace the insulating washer found under each of these screws, see Fig. 50A. 2. Remove the arcing contact pivot. Clean off the ex isting lubrication found on the pivot area Replace with D50RD38 (MOBIL 28), see Fig. 50B. ua ls 1. Remove the arc runner. It is secured by two screws into the base and one screw into the contact stop. an A spring puller is available for this use and may be ordered under Cat. No. 286A8168G1 . 3. Clean off the existing lubrication o n the stud's pivot area. Replace with a small amount of D50HD38 (MOBIL 28) before installing new contacts. 4. Torque the upper arc runner mounting screws to 45 ± 5 in-lbs. Torque the lower screw to 35-40 in-lbs. 3. Remove the Insulating spacers, contact pin and arcing contacts, see Fig. 50C. tM 4. Reassemble the reverse of above. Make sure that the insulating spacers and insulating washers are properly in stalled. Torque the arc runner hardware to 45 ± 5 in-lbs. The movable contacts are removed as follows, referring to Fig. 46. ar The movable contacts are removed in a similar manner as the 800 ampere breaker movable contacts. Refer to Section 8.6. When removing the pivot pin from a 2000 ampere (AKRT 50/50H) contact assembly, the pivot pin from the opposite contact assembly must be slightly removed. This provides enough clearance to completely remove the pivot pin. 1 . Using a right angle tru-arc pliers, remove the tru-arc retainer on the coupling pin. Drift out the coupling pin. 3. Slip out the contact arm. lP 2. Remove the pivot pin hardware and spring from one side of the pivot pin. Carefully remove the pivot pin. 4. Place a thin film of D50HD38 lubrication on the pivot �":'""'"":""'����""':'":'7',,....,..,_�� ""�!:""!': . • . ·. _ - ·. .- · ·· . . .. .. · ww w .E lec tri ca surfaces of the new arm. Clean any existing lubrication �-'�' from the pivot pin and place a small amount of D50HD38 ;;�::, on it. 5. Install the new arm, insert the pivot pin, and replace . the pivot spring �nd hardware. Tighten the pivot pin hard- > ·� ware to 90 ± 5 1n-lbs. FIG. 50A - ARC RU N N ER STATIONARY CONTACT - 1 600/200 AMP REPLACEM ENT CONTACT STRUCTU RE 39 .c om lP ar tM an ua ls SECTION 8-Contact Maintenance (Cont.) ww w .E lec tri ca FIG. SOB - ARC RU N N ER REMOVED 40 FIG. SOC - ARCING CONTACT PIVOT REMOVED .c om SECTION 9-Fused Breakers FUSE SIZES AND MOUNTING Table 6 lists the range of fuse sizes available for these breakers. The Class L fuses are mounted as shown in Fig. 51 . Other than the SOOA size, which has a single mounting hole per tang, each L fuse tang has two holes sized for one-half inch bolts. This fuse provides a melting time-current characteristic that coordinates with 1 600A trip devices. Compared physi cally with a 2500A NEMA Class L fuse, the special fuse is more compact (shorter); its tangs are specially configured and offset to achieve the required pole-to-pole fuse spac ing ; a special primary disconnect assembly mounts directly on the outboard tang of the fuse. Considering their unique mounting provisions, when replacing these fuses the fol lowing procedure should be adhered to ( Refer to Fig. 53): a) Remove the primary disconnect assembly from the fuse tang, accomplished by first loosening the two keys via their holding screw and pulling them u pward and out. After the keys are removed, pull the disconnect assembly off the end of the fuse tang. N OT E : This removal does not disturb disconnect's clamping force adjustment. the tM Class J fuses rated 300 thru 600A have one mounting hole per tang. The 300, 350 and 400A sizes require copper adapter bars per Fig. 52. SPECIAL 2500A FUSE FOR AKRU-50 ua ls 9.1 9.2 an There are two types of fused breakers; AKRU 30, 800 ampere frame and AKRU 50, 1 600 ampere frame. Except for the open fuse lockout device and the integrally mounted fuses on the upper studs, the AKRU-30 and -50 breakers are identical to the unfused AKR-30 and -50 models. Overcurrent trip devices are the same for both types. b) Remove the upper barrier. ar c) Detach the inboard end of the fuse by removing the two 1 /2 inch - 1 3 bolts. A ratchet and socket with a short extension will be requied. d) Remove the heat sink. f) Install the new fuse by reversing the disassembly procedure. Ensure that the mating faces of the fuse and heat sink are clean. ca lP e) Remove the fuse. .E lec tri ADAPTER B ARS (COPPER) - TY PI CA L MOUNTI NG CLASS L FUSES FIG. 52 - 300 THRU 600 AMP CLASS J FUSE MOUNTING ww w FIG . 51 41 .c om SECTION 9-Fused Breakers (Cont.) ua ls CAUTION: WHEN REPLACING THE FUSE IN THE LEFT POLE (FRONT VIEW) OF THE BREAKER, NOTE PAR TI C ULARL Y THA T THIS FUSE IS MOUNTED DIFFERENTLY THAN THE OTHER TWO FUSES. A S SHOWN IN FIG . 54, FOR THIS PHASE THE FUSE IS ROTA TED 1 80 DEGREES ABOUT ITS AXIS S O THA T I TS INBOARD TA N G IS POSITIONED BENEATH THE BREAKER S TUD. THIS TANG IS OFFSET WITH RESPECT TO THE OPPOSITE END SO THA T ROTATING THE FUSE DOES NOT ALTER THE POSITION OF THE PRI MARY DISCONNECT. an 0 FOR THIS POLE ONLY, FUSE IS ROTATED 1 80 TO POSITION TANG BENEATH STUD FRONT OF BREAKER 4 . Upper Ba r r i e r 5 . Primary Di s c onnect 1 . Spe c ial Z S OOA Fu s e Z . Di s c onnect Key 0 ca B reaker 42 L 30 l I l I 50 - � AKRU 50-2500A FUSE TANG POSITIONS - ! Ampere Rating I Gould Shawmut Cat. Nos. Fuse 300 A4J - 350' A4J 350 - 400' A4J 400 I I i l Mounting adapter requ•red - see F 19 52 0 FIG. 54 300' l - Spec1al A1lru. 0 0 PRIMARY DISCONNECT ASSEMBLY (SEE FIG. 1 3) MOUNTS DIRECTLY ON OUTBOARD FUSE TANG tri .E ww w J 0 0 TABLE 6 FUSES FOR AKRU BREAKERS lec NEMA Fuse Clan 600V 60 Hz • 2500A. FUSE CAT. NO. GF9F2500 AK AK RU 50 WITH SPECIAL 2500 AMP FUSE lP FIG. 53 1 TANG BOLT• HOLES IN USE � l •� -�-� ar 3 . Heat Sink tM BREAKER STUD FUSE TANGS POSITIONED ON TOP OF BREAKER STUD 450 500 600 A4J 450 A4J 500 A4J 600 800 1 000 1 200 A48Y 800 A4BY 1 000 B G 1 600 2000 2500 A4BY 1 200BG A48Y 1 600BG A48Y 2000B G - Limiter - - - - A4BX 800 A4BX 1 000BG A4BX 1 200BG A4BX 1 600BG A4BX 2000BG A4BX 2500GE .c om SECTION 9-Fused Breakers (Cont. ) 9.3 OPEN FUSE LOCKOUT DEVICE 9.3.1 TYPE A AN D B BREAKER OFLO ADJUSTMENT an tM Type D breakers use the Open Fuse Lockout (OFLO) shown in Fig. 55. Type A and B breakers use the OFLO shown in Fig. 56. Both OFLO's work on the same design. When the fuse opens, the resulting open circuit voltage activates the OFLO's phase solenoid when the voltage level reaches approximately 90 VAC. The solenoid's arma ture then drives a tripping rod against a trip paddle which is attached to the trip shaft. This causes the breaker to open. The armature also drives the reset button forward indicat ing what phase is involved. The reset button linkage also holds the tripping rod against the trip paddle. The button must be pushed in to release the tripping rod. ua ls This device automatically trips the fuse breaker if one of the fuses opens. When this happens, the breaker is locked open until the reset button of the phase involved is pushed. The breaker should not be reclosed, of course, until the opened fuse is replaced. FIG. 55- TYPE D B R EAKER OFLO DEVICE ar To adjust the Type A and B breaker OFLO (Refer to Fig 56) : a ) Back off tripping rod s o that it will not hit the trip paddle when a solenoid is activated. lP b) Using the maintenance handle, close the breaker. d) Close the breaker. ca c) Manually close the Left pole armature. Screw tripping rod forward until it moves the trip paddle enough to open the breaker. Add two full turns. tri e) Manually close the Left pole armature again. The breaker must open and the reset button pop out. In this condition close the breaker, it should trip-free. TYPE D B R EAKER OFLO ADJUSTMENT To adjust the Type D breaker OFLO: a) With the breaker in the CHARGED position and the OFLO reset, adjust the dimension between the end of the tripping rod and the trip paddle to .062" .093". • b) With the OFLO energized, the breaker must TRIP and the R ESET button must move forward to the front plate. In this condition, the breaker must be held trip-free. lec f) Reset the OFLO, the breaker must now be able to close. 9.3.2 g) Repeat for Center and Left poles. h) Check for a . 1 25" minimum clearance between trip ping rod and trip paddle with the OFLO reset. Check for .032" m m t m u m overtravel after tripping rod trips breaker. ww w .E i) Hold tripping rod in position and ttghten its locknut. 43 � --I/ .. =I -·-==r __ -- -- ___)_. ua ls 1 tM an TRIP PADDLE ll I= .c om SECTION 9-Fused Breakers (Cont.) ar ARMATURE RESET BUTION ww w .E lec tri ca lP FIG. 56A-DETAILS 44 FIG. 568-INSTALLED TYP E A OR 8 B R EAKER O FLO DEVICE .c om SECTION 10-Type SST Overcurrent Trip Device • 1 0.1 OVOI.CWI I TAIIGET I I ua ls The SST is a solid-state, direct-acting, self-powered trip device system. The SST system consists of the SST pro grammer unit, current sensors, and a flux shifter trip de vice. Fig. 57 shows a block diagram of the system. PROGRAMMER UNIT I I I 1- CIM:IIIT I TMW I tM an Fig. 58 shows a typical SST programmer unit. The pro grammer unit provides the comparison basis for overcur rent detection and delivers the energy necessary to trip the breaker. It contains the electronic circuitry for the various trip elements. Their associated pickup and time delay ad justments (set-points) are located on the face plate. De pending on the application, programmer units may be equipped with various combinations of Long Time, Short Time, Instantaneous and Ground Fault trip elements. See Table 7 for available ratings, settings and trip characteris tics. Adjustments are made by removing the clear cover over the face plate, unscrewing (counter-clockwise) the set-point knob, moving the set-point along the slot to the new setting, and screwing the set-point knob in. Once all adjustments are made, install the clear cover to the face plate. ar FIG. 57 - SST BLOCK DIAGRAM Each target pops out when its associated trip element operates to trip the breaker. After a trip, the popped target must be reset by hand. However, neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being reclosed. ca lP The SST programmer units can be optionally equipped with trip indicators (targets). These are pop-out, me chanically-resettable plungers located across the top of the programmer's front. Units with a ground fault element employ three targets: from left to right, the first is for over load, the second for short circuit (actuated by the short time and instantaneous elements) and the third for ground fault. The latter is omitted on units without ground fault. The programmer unit is mounted to the lower right of the breaker as shown in Fig. 59. The bracket attached to the top of the programmer, see Fig. 58, engages with a bracket mounted to the underside of the breaker's front frame. TABLE 7 SST TRIP CHARACTERISTICS SST PROGRAMMER ADJUSTMENT RANGE ( Set Pointa) SIZe Frame in Ampere. • Sen.or Tap - - -- - - - - - -- ( .E lec Bnaker tri X • Trip Ratinr Type (Amperes) Sen.or Am.,.re Tapt ) ( Pic:k Lonr Time <D ) (•L) Mult1p .. or X @ Time Delay Band (Sec:onds) - or - 100. 1 50. 225. 300 AKR-30 800 GROUND FAULT Short Time ( ® Pic:kup Multip.. or L ) Multiple or L Multiple or X ) ( 300 . 400. 600, 800 ww w AKR-50 AKRT-50 CD @ 300. 400. 600. 800 - or 600. 800 . 1 200 . 1 600 1 600 2000 Pitkup toler ante 1 Pic:kup toltnnte is 11 800 , 1 200 . 1 600 , 2000 �� � 1 0'\ Maximum 22 lntermed. 10 MUiimum 4 ® @ -or - 1 .7&, 2 , 2.2&, 2.!i, 3, 4 ( Ll ) @ Time Delay Band (Sec:onda) .4, .5, .6, . 8 . 1 .0 . 1 .2 ( X ) 3, 4, 5. 6, 8, 1 0 I L ) .6 . . 7 . 8. .9, 1 .0. 1.1 (X) ® Pickup @ ( Time Delay Band (Sec:onds) ® Instantaneous Pickup Maximum 0.35 lntcrmed. 0.21 4, &, 6, 8, 10, 12 (L) Minimum 0.09& Maximum 0.30 .25, .3, .4, .&, .6, .7 (X) lntermed . 0.1 6& Minimum 0.065 .2, .25, .3, .4, .&, .6 ( X ) Tame delay shown at 60()'\ or lonl time pickup s.ettinl (6L), It lower limit of band. Time delay shown at lower limit of band. 45 ar .c om tM an ua ls SECTION 10-Type SST Overcurrent Trip Device (Cont.) tri ca lP 1 0.2 ww w .E lec FIG . 58 - SST PROG R A M M ER 46 FIG. 59 - AKR-58-30 C U R RENT SENSORS The SST system uses two types of current sensors, phase sensor and a neutral sensor. Fig. 60 shows a phast. sensor. Fig. 61 shows the neutral sensors available. The current sensor supplies the power and sig nal inputs necessary to operate the trip system . Each sensor has four taps which provide field adjustment of the trip device's continuous ampere rating. · The SST Ground Fau!t trip element operates on the principle that the instantaneous values of current in the three conductors (four on 4-wire systems) add to zero unless ground current exists. On SST's equipped with Ground Fault, the ground trip signal is developed by con nectmg each phase sensor in series with a companion pnmary winding on a ground differential transformer mounted in the programmer unit. Its secondary output is zero so long as there is not ground current. Application of the Ground Fault element on 4-wire sys· tems w1th neutral grounded at the transformer requires the add1hona1. separately mounted neutral sensor (Fig. 61 ) mserted 1n the neutral conductor: its secondary is con nected to a fourth primary windmg on the ground differen tial transformer. See Fig . 70 . This "fourth-wire" neutral sensor 1s an electncal duplicate of the phase sensor, in cludmg taps . Therefore, when taps are changed on the phase sensors. those on the neutral sensor must be cor respondingly posit1oned. When used. the neutral sensor is separately mounted ir the bus or cable compartment of the switchgear. In draw out construction. its output is automatically connected to the breaker v1a secondary disconnect blocks. See Fig. 62. .c om ua ls an MOUNTED BREAKER ca lP ar FIG. 60 - SST PHASE SENSOR WITH TAP BOARD tM REAR VIEW AKR - 50 \ lec tri 600 - 1600 A EQUIPMENT · MOUNTED • 800 A ww w .E 300 100 · 3 00 A FIG. 61 - SST NEUTRAL S ENSORS FIG. 62 - N EUTRAL SENSOR S ECONDARY DISCONNECT BLOCKS 47 .c om REPLACEM ENT O F CU R RENT SENSORS a) Disconnect the breaker harness from the tap ter minal board, removing cable ties as necessary. U n· fasten the term i nal board from the breaker base. b) At the rear of the breaker, remove the two Allen head screws to separate the stud connector from the contact pivot block. c) Loosen the clamping bolt and remove the stud connector. Li ft out the sensor and It� tap term i nal board. AKA 30/30H - 1 20 ± 10 i n· l bs AKA 50/50H - 470 ± 1 0 i n· l bs AKRT 50/50H - 470 ± 1 0 i n· l bs 1 0.3 FLUX S H I FT TRIP DEVICE T h e F l u x Shift Trip device i s a low-energy, elec· tromagnetic device which, u pon receipt of a trip s i gnal from the programmer u n it, tri ps the breaker by actuating the trip shaft. The mounting arrangement of this component is I I· l ustrated in Figs. 64 and 65. An electromagnetic ac· tuator located on the u nderside of the front frame i s coupled t o the breaker's trip shaft via a trip rod driven by the actuator arm. The actuator i s a solenoid whose armature i s spring-loaded and held in its normal (Reset) position by a permanent magnet. In this state the spring is compressed. ww w .E lec tri ca lP ar tM The sensor may be prevented from s l i pping off the sensor stud by adjacent accessories. If t h i s exists, the sensor stud m ust be removed from the breaker base. The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker. d) When rep laci n g the stud connector, tighten the Allen head screws to 250 ± 10 i n·l bs. Tighten th6 c lamping bolt as fol l ows: ua ls Referri ng t o F i g . 63, replacement o f i nd ividual SST current sensors is accomp l ished as follows: an 1 0.2.1 48 1. 2. 3. 4. Flux shift Trip Device A llen-head Screws Stud Connector FIG. 63 Current Sensor - 5. Tap Terminal B>ard 6. Progr ammer Unit 7 . Clamp Bolt 8. Sensor Stud AKR-SA-30 B R EAKER WITH SST TRIP DEVICE .c om 5. Verify all sockets are inserted to the same depth. CAUTION : IN THE EVENT THAT THE SST TRIP DE VICE MUST BE RENDERED INOPERA TIVE TO ALLOW THE BREAKER TO CARR Y CURRENT WITHOUT BENEFIT OF OVERCURRENT PROTEC TION, THE RECOMMENDED METHOD IS TO SHORTEN THE TRIP ROD BY TURNING ITS AD JUSTER END FULL Y CLOCKWISE. THIS PRE VENTS ACTUATION OF THE TRIP SHAFT PADDLE. tM The trip device requi res o n ly one adj ustment - the trip rod length. As shown fn Fig. 66, the clearance between the trip rod and the trip shaft paddle is gaged by a 0. 1 25 inch diameter rod. Adj ust gap to 0.1 25 inch ± 0.01 5 inch. To adjust, open the breaker and restore the breaker mechanism to its Reset position. Loosen the jamb nut, rotate the adj uster end until the proper gap is attai ned, then reti ghten the jamb nut to 35 ± 5 i n-lbs. 3. Insert the extractor tool over the female pin. When the extractor tool bottoms out, depress the plunger and force the wire/socket assembly out of the connector. 4. No tool is req uired to i nsert the wire/socket assembly i nto the connector. Insert the assembly u n t i l It snaps i nto place. ua ls As the breaker opens, the actuator arm-is returned to its normal (Reset) position via l i n kage d riven by a crank on the breaker's main shaft. The permanent m ag net again holds the armature captive in readiness for the next trip signal. 1 . Remove the flux shifter leads from the harness. 2. Referri ng to the cabl ing d iag rams in Section 1 0.5, the flux shifter leads are RED ifl point B and B LACK i n point E. an So long as the actuator remains i n the Reset posi tion ' the breaker can be closed and opened normally . at will. H owever, when a closed breaker rece1ves a tri p signal from the programmer unit, the actuator i s energized and its solenoid f l u x opposes t h e mag n �t, allowing the spring to release the armature; th1s d rives the trip rod agai nst the trip shaft padd le, tripp ing the breaker. ar The actuator is a sealed, factory-set device and re q u i res no mai ntenance or field adj ustment. I n case of malfunction, the complete actuator unit should be replaced. When making the electrical connector to the replacement unit, it i s recom mended that the brea ker harness be cut at some convenient point and the new actuator leads solder-sp liced thereto. tri C RANK BREAKER ) CLOSED POS I T I ON .E lec ( ca lP The preferred method is to remove the flux shifter leads from the A M P connector using the A M P extrac tion tool, Cat. N o. 3051 83 as follows: ( RESET L I NKAGE I{! H ::lla I ( w J � '"{=! bi � TRIP P A D DLE ww \ f L SIDE VIEW FRONT - VIEW 0 .... I � ,. 0 FIG. 64 - FLUX SHIFT TRIP DEVICE AND OP ERATING LINKAG ES 49 4 lP 3 .c om ar tM an ua ls SECTION 10-Type SST Overcurrent Trip Device (Cont.) ca Bottom view 1 . Actuator Trip rod adjuster end Trip paddle tri 2. 3. - ww w .E TRIP PADDLE I N " " w ( CHANISW R E S E T POS I T IO N FIG . 66 50 - Top view 4. Trip shaft 5 . Actuator ar m 6. Reset l inkage FLUX SHIFT TRIP DEVICE COMPONENTS lec FIG. 65 5 TRIP ROD ADJ USTMENT .c om TROU BLESHOOTING a) Breaker tripping in proper response to overcurrents or incipient ground faults. b) Breaker remaining in a trip-free state due to mechanical interference along its trip shaft. c) Inadvertent shunt trip activations. WARNING: DO NOT CHANGE TAPS ON THE CURRENT SENSORS OR A DJUST THE PRO GRA MMER UNIT SET KNOBS WHILE THE BREA KER IS CARRYING CURRENT. Once it has been established that the circuit breaker can be operated and closed normally from the test posi tion, attention can be directed to the trip device proper. Testing is performed by either of two methods. 1 . Conduct high-current, single-phase tests on the breaker using a high current-low voltage test set. 2. Test the components to the SST system using por table Test Set Type TAK-TS1 (Fig. 67) or TAK-TS2. The applicable test procedures are detailed i n i n struction Book GEK-64454 and are summarized in Sec tion 1 0.4.1 . The TAK-TS1 and TAK-TS2 Test Sets are portable in struments designed for field checking the time-current characteristics and pickup cal ibration of the SST's various trip elements. It can verify the ability of the Flux-Shift Trip Device to trip the breaker and, in addi tion, includes means for. continuity checking the phase sensors. A TAK-TS1 Test Set Is shown in Fig. 67. The time-current characteristics for the SST Trip Device are given in curves G ES-6033, G ES-6034 and GES-6035. ar tM N OTE: For these single-phase tests, special con nections must be employed for SST breakers equipped with Ground Fault. Any single-phase in put to the ground differential transformer will generate an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by b) using the Ground Fault Defeat Cable as shown in Fig. 71. This special test cable energizes a ll the primary windings of the differential transformer in a self-cancelling, series-parallel connection so tha t its secondary output is always zero. ua ls When malfunctioning is suspected the first step in troubleshooting is to exami ne the circuit breaker and its power system for abnormal conditions such as: an 1 0.4 ww w .E lec tri ca lP a) testing two poles of the breaker in series, or FIG. 67 - SST/ECS TEST SET, CAT. NO. TAK-TS1 51 SST TEST SET The TAK-TS1 and TAK-TS2 Test Sets are portable in struments designed for field-checking the time-current characteristics and pickup calibration of the SST's various trip elements. It can verify the ability of the Flux-Shift Trip, Device to trip the breaker and, in addi tion, includes means for continuity checking the phase sensors. A TAK-TS1 Test Set is shown in Fig. 67. The TAK-TS2 functions identically to and supersedes the TAK-TS1 device. The TAK-TS2 can also test the Ver saTrip Mod 2 trip device. 1 0.4.2 RESISTANCE VALUES For use in troubleshooting, the Common to Tap resist ance for SST current sensors is given in Table 8 . These values apply to both phase and neutral sensors. TABLE 8 - SENSOR RESISTANCE VALUES Ampere TAP 1 00 1 50 225 300 WARNING: BEFORE CONNECTING THE TEST SET an TO THE BREAKER TRIP DEVICE S YS TEM, EN SURE THA T THE CIRCUIT BREAKER IS COM· PLETEL Y DISCONNECTED FROM ITS PO WER SOURCE. ON DRAWOUT EQUIPMENT, RACK THE BREA KER TO ITS DISCONNECTED POSITION. VERIFY THAT THE BREAKER IS TRIPPED. ua ls 1 0.4.1 300 400 600 800 tM Either of two test modes may be employed: .c om SECTION 10-Type SST Overcurrent Trip Device (Cont.) Resistance In Ohms between COMMON and TAP Terminals 2.2 3.3 5.1 6.8 - 2.6 3.9 5.8 7.8 5.3 7.2 1 0.8 1 4.6 - 6.1 8.2 1 2.4 1 6.9 600 800 1 200 1 600 6.4 - 7.6 8.8 - 1 0.4 1 3.5 - 1 5.8 1 9 .4 - 22.8 CAUTION: NEVER DISENGAGE THE HARNESS CONNEC TOR FROM THE PROGRAMMER UNIT ON A BREAKER THA T IS ENERGIZED AND CARRY ING LOAD CURRENT. THIS WILL OPEN-CIRCUIT THE CURRENT SENSORS, ALLOWING DANGER OUS AND DAMAGING VOL TAGES TO DEVELOP. 800 1 200 1 600 2000 1 0.2 - 1 2.4 1 5.8 - 1 9.2 22.0 - 26.7 28.5 - 34.7 ca lP ar "A" - Programmer Unit Only. These tests are con ducted with the programmer unit disconnected from the breaker. During test, the unit can remain attached to the breaker or may be completely removed from it. Test scope: 1 . Verify the time-current characteristics and pickup calibration of the various trip elements. tri 2 . Verify operation of the SST target indicators on pro grammer units so equipped. Test scope • lec " 8 " - Complete Trio Device Svstem. For these tests, the programmer un1t must be mounted on the breaker and connected to 1ts wiring harness. .E 1 . All "A" tests prev1ously described, plus provision for optionally swrtchrng the programmer's output to activate the Flux· Shlft Tnp Device and verify its operation by physi cally tnppmg the breaker. 2. Check phase sensor continuity. ww w In the event that any component of the SST system does not perform wrthrn the limits prescnbed m test instructions GEK-64454 . 1t should be replaced . 52 I The coil resistance of the SST/ ECS Flux shifter device is approximately 1 6 ohms. .c om d) On G round Fault breakers serving 4-wire loads, check that the neutral sensor is properly connected (see cabling diagram Fig. 70). In particular, ( 1 ) Verify that the neutral sensor has the same rating and tap setting as the phase sensors. (2) Check continuity between the neutral sensor and its equipment-mounted secondary disconnect block. Also check for continuity from the breaker-mounted neutr;il secondary disconnect block through to the female harness connector (terminals L and N). (3) If the breaker's lower studs connect to the supply source, then the neutral sensor must have its LOAD end connected to the source. (4) Ensure that the neutral conductor is carrying only that neutral current associated with the breaker's load cur rent (neutral not shared with other loads). tM If nuisance tripping is encountered on any breaker whose SST components have previously demonstrated satisfactory performance via the TAK-TS1 Test Set, the sen sors and their connections should be closely scrutinized. After disconnecting the breaker from all power sources, c) Verify that the harness connections to the sensors meet the polarity constraints indicated by the cabling dia gram, i.e., white wire to COMMON, black wire to TAP. ua ls When nuisance tripping occurs on breakers equipped with the Ground Fault trip element, a probable cause is the existence of a false "ground" signal. As indicated by the cabling diagram of Fig. 69, each phase sensor is con nected in a series with a primary winding on the Ground Fault differential transformer. Under no-fault conditions on 3-wire load circuits, the currents in these three windings add to zero and no ground signal is developed. This current sum will be zero only if all three sensors have the same electrical characteristics. If one sensor differs from the others (i.e., different rating or wrong tap setting), the dif ferential transformer can produce output sufficient to trip the breaker. Similarly, discontinuity between any sensor and the programmer unit can cause a false trip signal. an FALSE TRIPPING-BREAKERS EQUIPPED WITH GROUND FAULT 1 0.4.3 a) Check that all phase sensors are the same type (am pere range). SST CABLING DIAGRAMS FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT �-- - -- - P�+o-K�H<l+- (48V. del ���� ��� �0 � ANOOE) ww w .E lec tri ca lP 1 0.5 ar b) Ensure that the tap settings on all 3-phase sensors are identical. e) lf the preceding steps fail to identify the problem, then the sensor resistances should be measured. Since the phase and neutral sensors are electrically identical, their tap-to-tap resistance should closely agree. See Table 8. HARNESS CONNECTOR LOAD (AMP 201298·1 ) PROGRAMMER CONNECTOR (AMP 201297· 1 ) FIG. 68 - CAB LING DIAG RAM - SST WITHOUT G ROUND FAULT 53 PROGRAMMER FLUX SHIFT TRIP DEVICE ,-- UNIT - -- - .c om SECTION 1 0-Type SST Overcurrent Trip Device ua ls WHITE BLACK WHITE BLACK tM LOAD an WHITE CONNECTOR PROGRAMMER (AMP 201217·1) lec tri ca lP ar FIG. 69 - CABLING DIAGRAM - SST WITH GROUND FAULT ON 3-WIRE LOAD r -UNIT - -- - ��+o-+-<�H<� (48V. de) J2!::�'-l-ok •f:..k*- (TO SCR ANODE) BLACK WHITE BLACK WHITE BLACK WHITE .E w ww 54 PROGRAMMER FLUX SHIFT TRIP DEVICE BLACK HARNESS CONNECT OR 4 -WIRE LOAD CAMP 20 1 298 • 1 1 PROGRAMMER CONNECTOR CAMP 201217- 1 ) FIG. 7 0 - CAB LING DIAG RAM - SST WITH GROUND FAULT ON 4-WI RE LOAD I "' o-t-< '"' "' �� � � "' •c� +A y ·B � '"'"' '"' NEUTRAL I o-t-< ' y � I o4-< I Ij A c� B E A II I I \\ L_ N 1t u K - M p u I \ II I L ...._ i '""' L ._ r I D FH -n I I I "'c "D F H K r ......,L N I ""'M p r - - - -, I r-, '"'"' :l '"'"' H-0-t'"' � "' 3 '.. 3 '. '"'"' � �: � : ! �: · f ti�t· � � +-r-o � f-H) II � H-a l R " � R o-+-< ., � L_J &.-- ----- �oo-..J FEMALE MALE END END tM SENSOR DISCONNECT . r--A .c om � r\. -, B I cH--( � E RAMMER U NI T : ""' ANY SST PROGRAMMER UN IT WITH GROUND FAULT ELEMENT ua ls CURRENT SENSORS PROG GROUND FAULT DEFEAT CABLE CAT. NO. TGFD an BREAKER HARNESS CONNECTOR L_J L _ _ _j ww w .E lec tri ca lP ar FIG. 71 - CABLING DIAGRAM WITH G ROUND FAU LT DEFEAT CABLE INSERTED BETWEEN BREAKER HARNESS AND SST PROGRAMMER UNIT - FOR USE DURING SINGLE-PHASE, HIGH CURRENT - LOW VOLTAGE TESTING 55 .c om SECTION 1 1 -Type ECS Overcurrent Trip Device The ECS is a solid-state, direct-acting, self-powered trip device system. The ECS system consists of the ECS programmer unit shown in Fig. 72, current sensors, and a fl ux shifter trip device. Fig. 73 shows a block diagram of the system. ua ls The ECS trip system essentially duplicates the SST trip system described i n Section 1 0 except for the following: 2. Phase sensors are not tapped. As l i sted in Table 9, each sensor has only a single ampere rating. A different sensor is available for each of the tabulated ampere ratings, which span the same range as SST, see Fig. 74. 3. Neutral sensors are not required because there is no G round Fault function. lP ar tM In all other respects the ECS Trip device system operates and can be treated identically to SST. This in cludes circuitry, size, construction, component loca tion, programmer unit set points, performance characteristics, operating range, q uality, rel iability and the flux shift trip device: Use the same troubleshooting and test procedures for single-phase, high current-low voltage tests or those employing the TAK-TS1 or TAK TS2 Test Sets. The Ground Fault test procedures, of course, do not apply. ECS pha&e sensor resistance values are given in Table 1 0. an 1 . Programmer units are ltn1ited to combinations of Long Time, Short Ti me and instantaneous tri p elements only. The Ground Fault element is not available. FIG. 72 - ECS PROGRAMMER UNIT ca The ti me·current characteristics for the ECS trip device are given in curve GE5.6032. ___ w .E lec !,_ tri • ww FIG . 73 - ECS BLOCK DIAGRAM 56 FIG 74 - ECS CURRENT SENSOR ECS PROGRAMMER ADJUSTMENT RANGE (Set Points) X • Trip Rating 1600 2000 AKRT-50 (!) ® ) Pick � (•L) { ! } Mu iple of X .6, .7, .8, .9, 1.0, 1.1 (X) @ Pickup tolerance is ±. 9% @ Pickup tolerance is ±. 10% (Seconds) Maximum 22 300, 400, 600, 800, 1200, 1600 800, 1200, 1600, 2000 Band ® Time Delay ( ® Pickup Multiple of L ) Time Delay Band @ (Seconds) Instantaneous Pickup ( ® Multiple of L ) 3, 4, 5, 6, 8, 10 (L) 100, 150, 225, 300, 400, 600, 800 800 AKR-50 Sensor Ampere Rating ua ls AKR-30 ( Short Time Long Time Intermed. 10 Minimum 4 -or- 1.75, 2, 2.25, 2.5, 3, 4 (L) Maximum 0.35 Intermed. 0.21 Minimum 0.095 4, 5, 6, 8, 10, 12 (L) an Type Frame Size (Amperes) Time delay shown at 600% of long time pickup setting (6L), at lower limit of band. Time delay shown at lower limit of band. tM Breaker in Amperes • SeDSOr Rating -- - -- -- .c om TABLE 9 ECS TRIP CHARACTERISTICS TABLE 1 0 - SENSOR R ESISTANCE VALUES Ampere Rating ar Resistance In Ohms between Terminals tri ca lP 1 00 1 50 225 300 400 600 800 1 200 1 600 2000 3.0 - 3.4 4.4 - 5.0 4.8 - 5.6 6.4 - 7.2 6.7 - 7.8 6.4 - 7.6 8.8 - 1 0.4 1 3.5 - 1 5.8 1 9.4 - 22.8 29.5 - 34.5 1 1 .1 ECS CABLING DIAGRAM ww w .E lec � A A 4 ... •• •c rf>--1-� - + -+ � I I I' •• I A I I I I I I L I I H 'a H I I f- .J ... - , v- � v 'c rr r liED - I��LAC�< M«TE '8 E (..V dcl (TO SCR ANODE I .. c IILACI< M«TE D :+-�� IILACI< M«TE IILACI< r -UNT ---� FlUX SHIFT ,._ DEVICE H K r L ..-s5 PRODIIAMR ME COHHE CTOR � 201-"11 COHIECTOR � 201217 · 1 1 - - --� FIG. 75. CABLING DIAGRAM FOR ECS TRIP D EVICE 57 .c om SECTION 1 2-MicroVersaTrip™ Trip Device FAULT TRIP INDICATORS ua ls The optional fault trip indicators are similar to the SST indicators. They are mechanical pop-out type for identify ing overload or short circuit over-currents faults when breakers are ordered without integral ground fault protec tion. They are also available to identify overload, short circuit and ground fault trips for breakers supplied with integral ground fault protection. Each target pops out when its associated trip element operates to trip the breaker. After a trip, the popped target must be reset by hand. However, neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being -closed. 1 2.1 .2 REMOTE FAULT INDICATION Remote fault indication is available in the form of a mechanical contact which may be incorporated directly into the customer's control circuitry. This is a Normally open contact which is activated when its associated target pops out. When the target is reset, the contact is returned to its open position. Each contact is rated 0.25 amp at 1 25 VDC and 1 .0 amp ( 1 0 amp in rush) at 1 20 VAC. , I - _j I I NEUTRAL I � � CIRC R 1-- SUUUING UI T 'V .E � I I L .' •2 •3 _ _ _ _ I SHORT TIU( PICKuP & DE LA Y I t SHOR T oRCUIT T ARGE T � ..ST ..... T AHE OVS PICKuP I 1 I GAQvO.IO ' Ac.\ T POC.. uP & I 0£ L A • f I I R E Gc.\ A i f O '� lltlC � A SuPI"l • _ _ _ I _ _ __. ww . .. �-- ..� �--. - - .. - .. • " .. I< o< '" .. - .._ ..,_ " - .. ......_ ...., ... .. .. _.< -- • .. ....... .... I - FIG. 76 MICROVERSATRIP BLOCK DIAG RAM 58 0VERLOAO T ARGET I f w E-�.9 I I PICKuP & OELAV -� ..... I I LOGIC OA I ""' lec I f-'----- LONG TIUE ,_ I I J SWITCH lP TAP IIOARD.I I I a'� L -----� -�=-..Jr cuR'RE'Nisffis15RI I 501.10 STATE ca c _ __. I I FLUX SHIFTER TRIP COIL tri r 1»- - - ar tM 1 2. 1 PROGRAM M E R UNIT Fig. 77 shows a typical MicroVersaTrip programmer unit. Like the SST and ECS units, the MicroVersaTrip provides the comparison basis for overcurrent detection and delivers the energy necessary to trip the breaker. It contains a programmable microelectronic processor which incorporates nine adjustable time-current func tions, three mechanical fault indicators (local and remote), a long-time pickup LED indicator (local and remote) and a zone selective interlocking function. All adjustable programmer functions are automatic and self-contained requiring no external relaying, power supply or accessories. See Table 1 1 for trip functions available and Table 12 for trip function characteristics. A detailed description of each trip function is given in publication GEA 1 0265 and GEH 4657. 1 2.1 .1 an The MicroVersaTrip is a solid-state, direct-acting, self-powered trip device system. The MicroVersaTrip system consists of the MicroVersaTrip programmer, current sensors, and a flux shifter trip device. Fig. 76 shows a block diagram of the system. T - ·-· -• ' e&At • ·- ...... .. . -· oou• .-ot.IIG ....., oou• I •• ---. c- .... •• ...., c:r...i ""' .. - ... ... -.. w .. .. .. .. ...... FIG. 7 7 M I C ROVERSAT R I P PROGRAM M ER .c om The remote fault Indication switch leads are brought out the bottom of the Mi.croVersaTrlp programmer as shown In Fig. 78. This switch lead harness is plugged Into the mating connector on the breaker, see Fig. 79. an ua ls The switch leads are brought out from the breaker through the Programmer Secondary Disconnect shown In Fig. 80. The zone selective interlocking function wir Ing Is also brought out through this disconnect. See Figs. 95 and 96 for the remote fault indication and zone selective Interlocking cable diagrams. tM FIG. 80 REMOTE FAULT INDICATOR DISCONN ECT ar 1 2.1 .3 M ICROVERSATRIPTM I N STALLATION The programmer mounts to the upper left of t h e breaker lP as shown in Fig. 81 . It mounts to the bracket assembly shown in Fig. 82. Referring to Fig. 82, the guide pins mate ww w .E lec tri ca FIG. 78 M I C ROVERSATRI P W/R EMOTE FAU LT I NDICATI O N HARNESS FIG. 79 PROG RAMMER SECONDARY CONNECTOR with the holes on either side of the programmer connector. They provide the necessary alignment for the connector engagement. The locking lever engages with the pin which is assembled to the programmer frame and secures the pro grammer to the mounting bracket There are two programmer mounting designs in use. The d ifference in the designs is in the operation of the locking lever, see Fig. 82. Installation using each design Is as follows: a Insert the g u ide pins into the holes and push on the pro grammer, engaging the connectors. b. Original design-push In the locking lever, securing the programmer. later design-the locking lever Is released, securing the programmer. c. Verify that the locking lever did engage the programmer pin. d . Connect remote fault indication harness, If equipped, see Fig. 80. To remove the programmer: a. Disconnect the remote fault Indication harness, i f equipped. b. Original designs-push I n locking lever, which will release the programmer pin. While holding the locking lever In, remove the programmer. c. later design-pull out locking lever, which w i l l release the programmer pin. Remove the programmer. 59 .c om SECTION 1 2-MicroVersaTrip™ Trip Device (Cont.) The tapped and fixed phase sensors have a polarity as sociated with their windings. Their COMMON terminal is the right hand terminal as shown in Fig. 83. A white wire with a ring terminal will be connected to this COMMON terminal. All phase sensors must be correctly wired for the program mer summing circuit to function properly. ua ls The tapped or fixed phase sensors are available with an additional winding. This winding Is brought out to separate flag terminals rather than the screw terminals. These phase sensors are used when the hi-level Instan taneous MicroVersaTrip option {'H'-option) is required. Fig. 84 shows an 'H'-option phase sensor. When the 'H' option phase sensor is installed, there are four leads connected to It; two flag terminal connections {additional winding) and two screw termi n al connections {ampere rating). There is no polarity associated with the flag ter minals. Fig. 94 shows the connections for the additional 'H'-option windings. an 1 2.2 CURRENT SENSORS The current sensors supply the power and signal in put necessary to operate the trip system. Like the SST system, the MicroVersaTrlp uses a phase and neutral sensor. Fig. 83 shows the phase sensors. Tapped and fixed phase sensors are available. The tapped sensors provide field adjustment of the trip device's continuous ampere rating. See Section 1 2.5 for cabling diagrams. tM Fig. 85 shows the neutral sensor. The neutral sensor is required when integral ground fault protection is used on single phase-three wire or three phase-four wire systems. It is inserted into the neutral conductor and therefore is separately mounted in the cable or bus compartment. ar The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these val ues. The total value will remain zero as long as there is no ground current flowing. See cable diagram in Fig. 91 . - AKR-60-30 ww w .E lec tri FIG. 81 ca lP The neutral sensor is an electrical duplicate of the phase sensor, including taps. Therefore, when taps are charged on the phase sensors, those on the neutral sensor must be correspondingly positioned. 60 FIG. 82 - M I C R OVERSATRIP'- M O U NTI NG B RACKET .c om TABLE 1 1 TRIP FUNCTIONS AVAILABLE Optional Features ADD TO BASIC FUNCTIONS BASIC FUNCTIONS OTHER FUNCTIONS X X X X X X A1-or-A2-or·A:kK·A X X X X X X X X X X X X X .5 . .6, .7. .8 . .85 . .9. .95, 1 .0 .8, . 9. 1 .0. 1 . 1 2.5. 5, 10. 21 - - .. ca (Multiple ol Sensor Cul'l"efft Rdng) (X) 1 00. 1 50, 225. 300 .E lec AKR-30 ...._ f:::� A8tlng 100, 1 50, 225. 300 , 400. 800. 800 800 or 300 . 400 800 . 800 300. 400. AKR-50 300, 400, 1 600 600 . 600 600 . 800 01 1 200, 1800 600. 800 1 200 . 1 800 (X) (C) .2. 25• .3, .35, .4• .45, .5, .6 (X) . - - .. .. - - .. - .. . .. .2 • .22• .24, . - 1 .5. 2. 2.5, 3. 4, 5. 7, 9 (X) - .2• .22. .24. - 9 (C) . - - - .. - AI<R-75 3200 1200, 1600, 1 200 . 1600 2000. 3200 2000. 3200 - - .. - - 1800 , 2000. 1600. 2000 3000. 4000 3000. 4000 - - .. - .. w 600. 1200 1600 . 2000 ww � (Seconds) 0.4 800 . 1 200. 1600. 2000 1 Time delay lholon at 6ClO"JJ. d � selli ng at lower •mil d each band 2 Time delay shown at lower •mil ol NCh band All pldwp toler.nc::es ... !: 1 C)% Ground Feull pedt141 na to axcaed 1200 � - Del8y 1 .5. 2. 2.5. 3, 4, 6, 8, 10 (X) 2000 4000 Pickup 0.10, 022. 0.36 1 .5. 2. 2.5. 3, 4, 5, 7, AKRT-50 AI<R- 1 00 Ground FIIUH Lonci nme Short-time CurTent Adjunble Setting lnatllntl.-. l s (Multiple Pickup Pickup Pickup Short-time ol Sensor (Multiple Delay PI (Multiple (Multiple Del8y CurTent ol CurTent ol CurTent ol Sensor (f) � (f) Aallng) Aallng) (Seconds) Rilling) (Seconds) Aallng) (Seconds) (X) (C) (C) (X) tri ,_ Size llulmum Aallng (Amps) (X) TJIPPed Seneora X X X TABLE 1 2 M I CROVERSATRIPTM TRIP CHARACTERISTICS (X) Filled s.n.or. Z1 -or-22-or-Z X lP 1 Short-Time Delay is required 2 Standard when Ground Fall! specified 3 Ground Faull required X X X X ua ls GROUND FAULT X X X X G-or-GR an SHORT TIME INSTANTANEOUS X X X X T tM LONG TlME X X X X L ar Adjustable Current Setting • Adj Long-Time Pickup • Adj Long-Time Delay • Long-Time Timing Ught • Remote Long-Time Timing Ught • Adj Short-Time Pickup • AdJ Short-Time Delay • Short-Time Pt Switch(.1) • Adj Instantaneous PickuD • Adj High Range Instantaneous • Adj Ground Fault Pickup -1 PH, 2·W-3PH, 314-W -Ground Return • Adj Ground Fault Delay • Trip Indication Targets -Overload & Short Circuit -local only -local and remote -0/L, SIC and Ground Fault -local only� -local and remote • Zone Selective Interlock -Ground FaultG -8hort lime(.1) • STD.-or-5-or-H-or-M 26, .28 • .30. .34 . .37 (X) . 26, .28, .3 (X) C X s � 0.10. 022, 0.36 aJrTent selling sensor aJrTent 61 .c om an ua ls SECTION 1 2-MicroVersaTrip™ Trip Device (Cont.) tM TAPPED ar COMMON TERMINAL .E lec tri ca lP FIG. 83 - M I C ROVERSATRIP'M PHASE SEN SORS "'••"'t � � '- .& • •-.G C t �a.. E :: ' � � { ww w FIG. 84 - ' H '-Optlon Phase Sensor 62 FIG. 85 - TYPICAL N EUTRAL S ENSOR .c om Since the neutral sensor is mounted separately from the breaker, a d i sconnect means is requi red to con nect its output to the breaker. Fig. 86 shows the breaker and equi pment mounted 4th wire secondary d i sconnect used with the M icroVersaTrip system. 1 2.2.1 ua ls REPLACEM ENT OF CU RRENT SENSO RS Referring to Fig. 87, replacement of MicroVersaTrip cur rent sensors is accomplished as follows: a) Disconnect the programmer harness from the ter minal board, removing cable ties as necessary. an b) At the rear fo the breaker, remove the two Allen head screws to separate the stud connector from the contact pivot block. c) Loosen the clamping bolt and remove the stud con nector. Uft out the sensor and its tap terminal board. tM BREAKER MOUNTED - R IGHT SIDE d) When replacing the stud connector, tighten the Allen head screw to 2SO ± 10 in-lbs. Tighten the clamping bolt as follows: AKR 30130H 1 20 AKR 50/SOH 470 AKRT 50/SOH 470 ± ± ± 1 0 in-lbs 10 in-lbs 10 in-lbs e) When replacing the programmer harness to the phase sensors verify that the winding polarity is maintain ed, white wire with ring terminal to COMMON terminal (right hand terminal, see Fig. 83). .E lec tri ca lP ar A The sensor may be prevented from slipping off the sen sor stud by adjacent accessories. If this exists, the sensor stud must be removed from the breaker base. The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker. EQU I PMENT MOUNTED w B ww FIG. 86 - N E UTRAL SENSOR SECON DARY DISCONNECT 63 The only difference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid winding. Refer to Section 1 0.3 for details. When replacing a MicroVersaTrip flux shifter, AMP ex traction tool Cat. No. 45582-2 2 Is required to remove the socket leads from the AMP connector. 12.4 TROUBLESHOOTING When malfunctionion is suspected, the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as: a) Breaker tripping in proper response to overcurrents or incipient ground faults. b) Breaker remaining in a trip-free state due to mechanical maintenance along Its trip shaft. WARNING: DO NOT CHANGE TAPS ON THE CUR· NOTE: For these single-phase tests, special connec tions must be employed for Micro Versa Trip breakers equipped with Ground Fault. Any single-phase Input to the programmer circuit will generate an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by a) Using the Ground Fault Defeat Cable as shown In Fig. 93. This special test cable energizes the pro grammer circuit in a self-cancelling, series-parallel connection so that Its output is always zero. 2. Test the components of the MicroVersaTrip system using portable Test Set Type TVTS1 (Fig. 88). The ap plicable test procedures are detailed in instruction Book GEK-84464. The time-current characteristics for the M icroVersaTrip Trip Device are given in curves GES8195 and GES8199. ww w .E lec tri ca lP ar RENT SENSORS OR ADJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CAR· RYING CURRENT. 1 . Conduct high-current, single-phase tests on the breaker using a high current-low voltage test set. tM c) Inadvertent shunt trip activations. Once It has been established that the circuit breakf can be opened and closed normally from the test posltior., attention can be directed to the trip device proper. Testing is performed by either of two methods: ua ls FLUX SHIFTER TRIP DEVICE an 1 2.3 64 .c om SECTION 1 2-MicroVersaTrip™ Trip Device (Cont.) PROGRAP.!t.!ER HAR N E SS FIG. 87 - M I C ROVERSATRIP C OMPON ENT .c om SECTION 1 2-MicroVersaTrip™ Trip Device (Cont.) FALSE TRIPPING-BREAKERS EQUIPPED WITH G ROUND FAULT When nuisance tripping occurs on breakers equipped with the G round Fault trip element, a probable cause is the existence of a false "ground" signal. As indicated by the cabling diagram of Fig. 90, each phase sensor is connected to summing circuitry in the programmer. U n der no-fault conditions on 3-wire load circuits, the currents in this circuitry add to zero and no gro�.md signal is developed. This current sum will be zero only if all three sensors have the same electrical charac teristics. If one sensor differs from the others (i.e., dif ferent rating or wrong tap setting), the circuitry can produce output sufficient to trip the breaker. Similarly, discontinuity between any sensor and the programmer unit can cause a false trip signal. R ESISTANCE VALUES 1 2.4.1 For use in troubleshooting the MicroVersaTrip.... current sensors, the resistance of the tapped and fixed windings is given in Tables 1 3 and 1 4 respectively. Am pere Tap 7.0-8.2 1 0- 1 2 1 5-18 20-24 20-24 27-32 42·50 58-68 42·50 lP 1 00 1 50 225 300 300 400 600 800 600 800 1 200 1 600 800 1 200 1 600 2000 ca 53-68 93-1 09 1 30- 1 54 74·88 .E lec tri 1 16-136 162· 190 210-246 TAB L E 1 4 - FIXED SENSOR R ESISTANCE VALUES Ampere Rating 1 00 ww w 1 50 225 300 400 600 800 1 200 1 600 2000 ! If nuisance tripping is encountered on any breaker whose MicroVersaTrip components have previously demonstrated satisfactory performance via the TVTS1 Test Set, the sensors and their connections should be closely scrutinized. After disconnecting the breaker from all power sources. ar Resistance in Ohms Between Common and Tap Terminals tM TABLE 1 3 - TAPPED SENSOR R ESISTANCE VALUES an FIG. 88 TEST SET, CAT. NO. TVTS1 ua ls 1 2.4.2 Resistance In Ohms Between Terminals 6 7-7.8 1 0- 1 2 15- 1 7 a) Check that all phase sensors are the same type (am pere range). b) Ensure that the tap settings on all 3-phase sensors are identical. c) Verify that the harness connections to the sensors meet the polarity constraints indicated by the cabling diagram. d) On G round Fault breakers serving 4-wire loads, check that the neutral sensor is properly connected (see cabling diagram Fig. 9 1 ) . In particular, ( 1 ) Verify that the neutral sensor has the same rating and tap setting as the phase sensors. (2) Check continuity between the neutral sensor and its equipment-mounted secondary disconnect block. Also check for continuity from the breaker-mounted neutral secondary disconnect block through to the female harness connector. (3) If The breaker's lower studs connect to the supply source, then the neutral sensor must have Its LOAD end connected to the source. See Fig. 92. 20-24 27-32 42-50 (4) Ensure that the neutral conductor is carrying only that neutral current associated with the breaker's load cur rent (neutral not shared with other loads). 92- 108 1 29- 151 e) If the preceding steps fail to identify the problem, then the sensor resistances should be measured. Since the phase and neutral sensors are electrically identical, their tap-to-tap resistances should closely agree. See Tables 1 3 and 1 4 . 58-68 207-243 The coil resistance of the MlcroVersaTrlp flux shifter device Is approximately 7 ohms. 65 1 2.5 CABLI N G DIAG RAMS •B •c rf)===)= -1-t-}= \ LEFT POLE I CURRENT SENSOR .. .. an I I �-- - -- - IL------k� I '- rr r J HARNESS PROGRAMMER CONNECTOR CON NECTOR (AMP 1 _3 50356-9) ar LOAD tM ..?����E � B PROGRAMMER UNIT FLUX SHIFT TRIP DEVICE ua ls •A A A A .c om SECTION 1 2-MicroVersaTrip ™ Trip Device (Cont.) lP FIG. 89. CABLI N G DIAGRAM-MIC ROVERSATRI P'• WIT H O UT G R O U N D FAULT A -� A A $ � BREAKER BAcK FRAME r A, b - A-: 1 •B •c FLUX SHIFT TRIP DEVICE ca •A � >- - -)- --):- LEFT POLE I CURRENT �- - - - - - I lec tri SENSOR PROGRAMMER UNIT I � �----��� ww w .E I 66 I_ rr r LOAD J HARNESS CONNECTOR (AMP 1 .3 50356- 9) PROGRAMMER CONNECTOR FIG. 90. CABLING D I AGRAM-M ICROVERSAT R I P'• WITH GROU N D FAU LT O N 3-WIRE LOAD •c I I I A I I SENSOR 1 DISCONNECT - -1 I an I tM LINE r- UNIT - --- ua ls :� NEUTRAL PROGRAMMER FLUX SHIFT TRIP DEVICE ¢ � --$ b ,- b, II ' �1 >---)- --}- BREAKER BACK FRAME r .c om A A 4' A •a •A ar HARNESS CONNECTOR PROGRAMMER TO N AMP 1 _350356-9 CO NEC R lP FIG. 9 1 . CABLI N G DIAGRAM-MICROVERSATRI P'M WITH G R O U N D FAU LT O N 4-WIRE LOAD 4-WIRE LOAD 111 ca 4'- I � ' -$ . b b, I � )- --)- --}- BREAKER BACK FRAME r¢ PROGRAMMER FLUX SHIFT TRIP DEVICE r - UNIT - -- - _ tri LEFT POLE I CURRENT SENSOR I '-lf-=4--+�-----+<>+-< H •111 lec 1...--....h.-""'""'- I t I I I I A NEUTRAL I SENSOR 1 DISCONNECT .E EQUIPMENT - M OU N T E D NEUTRAL SE NSOR / ww w � {t I I rt-='-'-t<>H \ 1 1N I LOAD >+�-+-�-�-+----�� v •A v •a v •c HARNE SS CONNECTOR AMP 1 -350356-9 PROG RAMMER CONNECTOR FIG. 92. CABLING DIAGRAM-MIC ROVERSATR I P WITH G R O U N D FAU LT ON 4-WIRE LOAD B REAKER REVERSE FEED 67 .c om SECTION 1 2-MicroVersaTrip™ Trip Device (Cont.) ..-f.! r , � � o-+-< o-+-< o-+-< C>-+-< _j 4 � � 7 ! 1� 0 :!0 1] � � 24 24 �8 � ++-o � �2 - "-+--0 � � 26 - - ANY MICROVERSATRIP PROGRAMMER UNIT WITH GROUND FAULT ELEMENT I O I O � 21 - 1 0 0 -22 � �.f � I O 0 19 , - - -, r -t � -E-+--0 ""t-0 � ""t-0 ... � +t-O � ++-<> tM L o-+-< � <>-+-< o-t-< o-+--< <>-+-< o-J.......< 1 - -....- - ..__ L -f L.. ar o-t-< - - - an ' o-+-< 0+-< e>-t--< o-+-< o+-< o-+-< PROGRAMMER UNIT GROUND FAULT DEFEAT MODULE CAT. NO. TVTGD9 ua ls BREAKER HARNESS CONNECTOR _ _ _j ca lP FIG. 93. CABLI N G DIAG RAM WITH GRO U N D FAU LT D EFEAT M O D U LE I N SE RTED B ETWEEN BREAKER HARNESS A N D M I C ROVERSATR IP PROGRA M M ER U N IT-FOR U S E D U R I N G S I NG LE-PHASE, HIGH C URRENT-LOW VOLTAG E TESTI NG. PROGRAMMER lec tri �- - UNIT ---- YEUOW ww w .E YELLOW 68 YEUOW YELLOW YEUOW rr r HARNESS CONNECTOR PROGRAMMER CONNECTOR LOAD FIG. 94. PARTIAL CABLING DIAGRAM: 'H'-OPTI ON W I N D I N G C O N N ECTI O N S EQUIPMENT OVERLOAD PICKUP ua ls GROUND FAULT , - - - - -1 I �+-<:>-+-Y...;;E""LL�O;..;.W;..___---l �----'1-0-+-<: �;,__1-0>-+----+1:::>-+-< I RED I I �---HD-+-� ��rc�-----��--< �+-<:>-+�R�m-----� GREEN I I I I YELLOW AMP 1·350239-9 AMP 1-350246-9 an SHORT CIRCUIT { { BREAKER MICRO-VERSA TRIP PROGRAMMER AMP 1-350242·9 L AMP 1·350235-9 tM OVERLOAD .c om REMOTE FAULT INDICATION CONNECTOR PROGRAMMER SECONDARY DISCONNECT _ _ _ __ I ...J ca lP ar FIG. 95. CABLI N G DIAGRAM-REMOTE FAULT I NDICATION PROGRAMMER SECONDARY DISCONNECT TIME { { • _ OUTPUT SHORT TIME GROUND FAULT INPUT GROUND FAULT OUTPUT { { • - • _ • w - --, I I I �-+-o-+-< <E:-t-o+-----IKJ-t-<.... ��-C>-+-< - �-+�+-< <E-+-��----i-o�< AMP 1 -350239-9 ww - �-+-o-+-< <E-f-Q-�-----i-Q-t-<._ .E lec SHORT INPUT BREAKER tri EQUIPMENT MICRQ-VERSA TRIP PROGRAMMER AMP 1 ·35024&-9 _ _ _j FIG. 98. CABLI N G DIAG RAM-ZON E SELECTIVE I NTERLOC K 69 .c om SECTION 1 3-EC Trip Device There are three basic characteristics: long time delay, short time delay and instantaneous, which can be used in various combinations to suit the application. device for these frames is the type EC-1 , see Fig. 98. tM ar lP ca FIG. 98 EC·, TRIP DEVICE tri FIG. 97 EC-2A TRIP DEVICE TABLE 1 5 EC DEVICE TRIP CHARACTERISTICS ! ! I I ' ' Pickup (!) 80- 1 60">. X I · t o--. ) .E EC-2A I EC- t I i I I w EC- I B I l.oftg Time lec Trip Device 80- 1 60">. X ( "' t o--. ) 80- 1 60"<. X I ' I S') o...y � ( l A} MAX --- l !t-38 MC �up ww 70 Deley � Ot I I C I M IN ---- 3 3-8 2 MC Ot MAX -30 MC l l!l 1 INTER - I S MC Ot I I C I MIN -S MC Ot I I B8 t lotAX � S MC II CCI MIN -2 MC Ot 2-5X. ).7X Ot 6- I OX 2·SX. ).7X Ot 6- I OX 1 X = Tnp devoce ampere rat•ng If tnp devlcea are Ml aoo--. I 00"'. lot c:oord>nabOtl PVPOeM band at 6 llmes pockup Mft•ng 3 At lower hm•t of band at 2'"1 llmes pod<up Mft>ng 4 Low-set onstantaneous Not avaolabll lt'l comoonatiO" - 10nQ lime Olley 2 At lower hm•t of Shott Time 1 1 81 INTER --.c21 7 !t- 1 8 Me ( I AI ' Trip characteristics are for the EC devices are given in Table 15. The time-current characteristics for the EC trip devices are given in the following curves: GESOOOO EC-1 GES001 0 EC-2/2A 1A-3 GES001 1 EC-2/2A 1 8-3 GES001 2 EC-2/2A 1 C-3 an AKR breakers with EC Trips are for use on DC system voltages. One EC trip device is mounted per breaker pole. This device contains its functional adjustments. The standard EC trip device for breaker frames up 2000 amps is the type EC-2A, see Fig. 97. An optional tr., ua ls Type EC overcurrent trip devices are magnetically operated, using a series coil or single conductor, and an associated magnetic structure to provide tripping force. IUCfl 12AI MAX -.23 MC 1281 INTER Ot 15 MC (2C) MIN - 07 MC Ot 12AAI MAX -.20 MC Ot (288) INTER-.13 MC . Ot (2CC) MIN - 07 MC aen.ng. do nol mcr.ue the brlaker·a ln.wrtllneoue Pldlup '-IIX. � 1 2X. II- 1 5X 0t 80-250%)( ® High Set up 110 1 5X. Non-Adtut� '-IIX. �12)(, II- 1 5X 0t 80-250'!1. X @ continuous c:u�nt rebng .c om SECTION 1 3-EC Trip Device (Cont.} - �' . ....,._. -:- ., .. . . . ··---�-.- :. :: -,."::.."'.-.- "fi • . ,. _1_ ' � I. • ua ls •. • r' , ,• tM an • · .· ·. . . , . . , . . .: . . ·,;.· . . ....',. ww w .E lec tri ca lP ar 2 - :.:. FIG. 99 OVERCURRENT TRIPPING DEVICE - EC·2A 71 ADJUSTMENT NOTE 1 3. 1 . 1 LONG TIME·DELAY AND HIGH-SET INSTANTANEOUS TRIPPING The low-set instantaneous pick-up point may be varied by the adjustment knob (3). The calibration in this case usually ranr from 80 percent to 250 percent of the series coil rating, with . . calibration plate indexed at values of 80, 1 00, 1 50, 200, and 250 percent of the rating. 1 3.1 .3 I N STANTANEOUS HIGH-SET TRIPPING The high-set instantaneous pick-up value may have one of the following three ranges: 4 to 9 times coil rating; 6 to 1 2 times coil rating or 9 to 1 5 time coil rating. The pick-up setting may be varied by turning the instantaneous pick-up adjusting screw (12). Three calibration marks (1 5) will appear on the operating arm (14) and the value of these calibration marks will be indicated by stampings on the arm as follows: (4X - 6.5X - 9X) or (6X 9X - 1 2X) or (9X - 1 2X - 1 5X). At the factory, the pick-up point has been set at the name plate value of the instantaneous trip current. (Usually expressed in times the ampere rating of the trip coil). The variation in pick up setting Is accomplished by varying the tensile force on the instantaneous spring (5). Turning the adjustment screw changes the position of the movable nut (1 1 ) on the screw. The spring is anchored to this movable nut so that when the position of the nut is changed, there is a corresponding change in the spring load. As the spring is tighten�. the pick-up point is increased. The top edge of the movable nut (1 1 ) serves as an index pointer and should be lined up with the center of the desired cal ibration mark (1 5) to obtain the proper instantaneous trip setting. The trip screw (6) on the end of the armature (7) should � set so that it does not contact the trip paddle on the trip st until the air gap between armature and pole piece is reduced 3/32 in. or less, measured at the rivet in the pole piece. Also, the armature must have a minimum of 1 /32 in. of travel beyond the point in its motion at which the breaker is tripped. Replacement of the EC-2A device is accomplished by the same procedure described for the EC-1 series trip device; how ever, in some cases, when replacing an EC-1 device with an EC-2A it will be necessary to replace the trip paddles on the trip shaft with ones which are slightly longer. When required these will be provided with the replacement trip units. tM Before attempting any checks or adjustments on breaker with EC trip devices, the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads. The trip latch of the breaker should also be checked for proper trip latch engage ment. See Section 7.15 Refer to Fig. 99 for the discussions given below. INSTANTANEOUS LOW-SET TRIPPING ua ls The Type EC-2A overcurrent tripping device is available in three forms: 1 . Dual overcurrent trip, with long-time delay and high-set instantaneous tripping. 2. Low-set instantaneous tripping. 3. High-set instantaneous tripping. The dual trip has adjustable long-time and instantaneous pick-up settings and adjustable time settings. Both forms of in stantaneous trip have adjustable pick-up settings. .c om 1 3.1 .2 SERIES OVERCURRENT TRIPPING DEVICE EC-2A an 13.1 ._ NOTE: Pick-up settings on the calibration plate of the EC-2A device are calibrated for the specific device. When replacing covers, replace on associated device. · - --- ww w .E lec tri ca lP ar By means of the adjustment knob (3), which can be manipu lated by hand, the current pick-up point can be varied from 80 to 1 60 percent of the series coil rating. The indicator and a cal ibration plate (2) on the front of the case provide a means of indicating the pick-up point setting in terms of percentage of coil rating. The calibration plate is indexed at percentage settings of 80, 1 00, 1 20. 1 40, and 1 60. As in the case of the EC-1 over-current trip, the long-time de lay tripping feature can be supplied with any one of three time-current characteristics which correspond to the NEMA standards maximum, intermediate and minimum long-time delay operating bands. These are identified as 1 A, 1 B and 1C char acteristics, respectively. Approximate tripping time for each of these. in the same order are 30, 1 5, and 5 seconds at 600 per cent of the pick-up value of current. (See time-current charac teristic curves). The tripping time may be varied within the limits shown on the characteristic curves by turning the time adjustment screw (4). Turning in a clockwise direction increases the tripping time; counterclockwise motion decreases it. The dashpot arm (8) is indexed at four points, MIN-1 13-213-MAX, as indicated in Fig. 100. When the Index mark on the connecting link (9) lines up with a mart( on the dashpot arm, the approximate tripping time as shown by the characteristic curve is indicated. The 1 A and 1 B charactenst1c dev1ces are shipped with this setting at the 213 mart( and the 1 C characteristic at the 1 13 mark. The standard charactenst1c curves are plotted at these same settings. T1me values are Inversely proportional to the effective length of the dashpot arm Therefore. the linkage setting that gives the shortest hme value IS the one at which dimension "A", Fig. 99, is greatest . The t1me adJUStment screw (4) may be turned by in sertmg a Ph1ll1ps head screwdriver through the hole in the front of the case. II it 1s des�red to relate the linkage setting to the index marks on the hnkage it will be necessary to remove the case. Th1s may be done by removing the two mounting screws. one on each s1de of the case. which may be taken off without disturbing the tnp unit itself. 72 FIG. 1 00 TIME-ADJUSTMENT INDEXING Each series overcurrent tripping device is enclosed in a molded case and mounted by screws and a bracket to the lower part of the pole unit base. Refer to Fig. 1 01 for the discussions below. 13.2.1 SHORT TIME-DELAY TRIPPING r=!fo�?'��-- 9 iii--til--- 8 The armature (1 0) is restrained by the calibration spring (1 1 ). After the magnetic force produced by an overcurrent condition overcomes this restraining force, the armature movement is fur ther retarded by the flow of silicone oil in a dashpot, which pro duces an inverse time delay characteristic. The mechanism is shown on Fig. 1 0 1 . ca lP 't-f+!--+<'�-- 4 LONG TIME-DELAY TR I PPING ar ..rt=�+t--- 5 1 3.2.2 tM ��---- 7 v-t-tNt--- 6 comes this restraining force, the armature movement is further retarded by an escapement mechanism which produces an in verse time delay characteristic. The mechanism is shown on Fig. 1 01 . an The armature (7) is restrained by calibrating spring (8). After the magnetic force produced by an overcurrent condition over- .c om SERIES OVERCURRENT TRIPPING DEVICE Ec-1 ua ls 13.2 Right Side VIew Showing Long Time Delay Mechanism .E lec tri Left Side VIew Showing Short Time Delay Mechanism Series Coil Magnet Pallet Pinion Escape Wheel Driving Segment S.T.D. Armature ww w 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 1 2. 1 3. 14. Front VIew Showing Mounting Bracket S.T.D. Calibration Spring Trip Paddle Adjusting Screw L.T.D. Armature LT.D. or Low-set lnst. Calibration Spring lnst. Trip Spring (High Set) Spring Holder C&libration Clamp Nut 1 5. 1 6. 1 7. 1 8. 1 9. 20. Plunger Cylinder Calibration Plate Trip Paddle Trip Arm Clamping Bracket RG. 1 01 SERIES OVERCURRENT TRIPPING DEVICE EC-1 73 1 3.2.4 EC-1 ADJUSTMENTS Before attempting any checks or adjustments on breaker wi� EC trip devices, the breaker mechanism and trip latch should checked to assure their proper functioning so that the breakt.. . trip shaft is free of high friction loads. The trip latch of the breaker should also be checked for proper trip latch engage ment. See Section 7.1 5 In addition to the pick-up settings and time-delay adjustments already described, overcurrent trip devices must be adjusted for positive tripping. This adjustment is made at the factory on new breakers, but must be made in the field when the breaker mech anism or the overcurrent trip devices have been replaced. Positive tripping is achieved when adjustment screw (9) Fig ure 1 01 is in such a position that it will always carry the trip pad dle on the trip shaft beyond the point of tripping the mechanism, when the armature closes against the magnet. In order to make the adjustment, first unscrew trip screws (9), Figure 1 01 until it will not trip the breaker even though the ar mature is pushed against the magnet. Then, holding the arma ture in the closed position, advance the screw until it just trips the breaker. After this point has been reached, advance the screw two additional full turns. This will give an c;>vertravel of 1 I 1 6 of an inch and will make sure that activation of the device will always trip the breaker. Adjustment screw (9), Figure 1 0 1 can best be manipulated by an extended 1 /4 inch hex socket wrench. , lec tri ca lP ar tM Before attempting any checks or adjustments on breaker with EC trip devices, the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads. The trip latch of the breaker should also be checked for proper trip latch engage ment. See Section 7. 1 5 EC-1 Devices may have their pick-up settings varied by changing the positions of the sliding calibration plates on the front of each device. The clamping nut holding the plate must be loosened to make the change, and then retightened. If a new device is installed, the adjusting screw on the tripping arm must be set to give 1 /32nd of an inch overtravel in tripping. The method for making this check is demonstrated in Figure 1 02. The rod shown is used for pushing the armature of device closed. If this is done with the device mounted on a closed breaker, it will simulate the action which occurs when the device reacts to an overload condition. POSITIVE TRIP ADJUSTMENT ua ls (a) Adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition, over comes the restraining force of the calibration spring which can be adjusted by the calibration clamp nut (14). (b) Non-adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition over comes the restraining force of a non-adjustable spring. .c om 1 3.3 INSTANTANEOUS TRIPPING an 1 3.2.3 .E FIG. 1 02 C H EC KING TRAVEL DISTANC E OF SERIES OVERCURRENT TRIPPING ww w DEVICE. 74 .c om SECTION 1 3-EC Trip Device {Cont.) REVERSE CURRENT TRIPPING DEVICE The device is enclosed in a molded case and is mounted on the right pole base similar to the series overcurrent tripping device. The reverse current tripping device (see Fig. 1 03) consists of a series coli (2) with an jron core mounted between two pole pieces (9), also a potential coli (7) connected across a constant source of voltage and mounted around a rotary-type armature ( 1 0). Calibration spring (6) determines the armature pick-up when a reversal of current occurs . as the flow of current through the breaker is in the .E lec tri ca lP ar tM an As long normal direction, the magnetic flux of the series coil and the magnetic flux of the potential coil produce a torque which tends to rotate the armature counterclockwise. The calibration spring also tends to rotate the armature in the same direction. This torque causes the armature to rest against the stop screw (12) attached to a bearing plate on the right side of the device. H the current through the series coil (2) is reversed, the ar mature ( 1 0) tends to move in the clockwise direction against the restraint of the calibration spring (6). When the current reversal exceeds the calibration setting, the armature revolves clockwise causing the trip rod (3) to move upward engaging the trip paddle (1 ), thereby tripping the breaker. ua ls 1 3.4 �Lt - - - - - - ·· ... - - -am - - --, 9 I _ , ·,I ·�· 1'rr··I' j. :}"9�··�· ... w • I t r L IL MIX. IW 6. 7. 8. 9. 1 0. 11. 12. 1 3. 14. Trip Paddle Series Coil Adjusting Nut Locking Nut Trip Rod Trip Crank Setting Sealing Screw . Calibration Spri ng Potential Coil Calibration Nut Pole Pieces Armature Counter Weight Stop Screw Mounting Screw Screw ww w I , 1. 2. 2A. 28. 3. 4. 5. FIG. 1 03 ED-1 REVERSE CURRENT TRIPPING DEVICE 75 1 3.6 ADJUSTMENTS The only adjustment to be made on the reverse current de vice is to make sure that the trip rod has a minimum overtravel of 1 /32 in. beyond the point of tripping the breaker. This adjust ment should have to be made only when an old device is being replaced by a new one. The new device will be factory adjusted so that the top end of the trip rod (3) will extend 1 /2 in. above the top of the device case, and no additional adjustments of the trip rod should be re TRIP DEVICE REPLACEMENT Overcurrent devices on AKR30 & AKR50 breakers may bA dismounted by removing clamps on the case in ua ls 1 . Loosen the locking nut. (28). justing nut (2A), this establishing the position of the adjusting nut where the breaker is just tripped. Be sure to keep clear of moving breaker parts when tM 1 3.4.2 an tripping the breakers. 4. Tighten the locking nut and the minimum 1 /32-in. over travel of the trip rod should be obtained. the front removed, may be lowered clear breakers. 2. Manually lift the trip rod and vary the position of the ad 3. With this position of the adjusting nut established, advance REPLACEMENT After removing the wiring for the potential coil the reverse cur rent device can be removed and replaced by following the pro cedure outlined for replacing the series overcurrent device. See ar FIG. 104 DISCONNECTING EC COIL Section 1 3 .6 . For wiring, see Fig. 1 03 . 1 3.5 SWITCHETTE FEATURE lP The switchette is operated by the long-time delay function. Its purpose is to provide a set of contacts that will close before an overload occurs. This device will not trip the breaker on over· load it will trip on instantaneous only. type EC-1 devices. ca The switchette feature is available only in The switchette is used in one pole and EC-1 trips in the other poles. For the alarm to be effective in indicating the overload tri before the other poles trip the breaker, the device must have less time delay than the other two poles; this is accomplished by using a lower characteristic on the alarm device than the other poles or settang the alarm devices long time setting at ww w .E lec 80%. 76 · of the breaker. You do not have to separate frames on these breaker and proceed as follows: the adjusting nut upward one and one-haH turns. the fastening hardware at the rear the breaker and withdrawing the device. EC devices, after beia ... unfastened as shown in Figures 1 04 and 1 05, and having the quired. To obtain the proper 1 /32 in. overtravel, close the NOTE: .c om 13.4.1 FIG. 1 OS DISCONNECTING EC FRAME .c om ·sECTION 14-Eiectrical Characteristics TABLE 1 6 CHARGING AND CLOSING OPERATING CURRENTS MOTOR 0 "' • • �0 - .!! t:: CII Z > r: • "" . N :o ::C G' !! .... i o a. Current (Amps) Cll . . CII :: t:: o • > a: ,.�� �..... � · ... � ��' Rated-Amps Inrush Sealed -� Open Closed 063 063 J! "S a. "' • . ... .. a i: 30 48V DC 38·56 40 10 38 . . 1 25V DC 1 Q0- 1 40 27 5 85 .024 .024 90 250V DC 2Q0-280 13 3 1 70 .01 5 .01 5 1 80 . .052 50 1 20V 25 1 04·127 5 25 090 60 208V 50 208V 25 250V 60 250V 50 250V 25 15 1 80·220 3.5 1 75 208-254 3 12 .032 .050 .029 .050 .029 .032 .01 8 . .036 1 90 . 064 .035 2.5 0.9 2.5 0.9 30 10 5 15 7 3 lec TABLE 1 8 AUXILIARY SWITCH CONTACT SEQUENCE ee .E Au11lllary Switch Position ""b "" ..•.. Contact Contact � ()pen w or Tnpped Closed 95 .036 Open Closed Closed Open Sealed Closed 4.1 4.1 1 .05 1 .05 .53 .53 . .1 4 1 .0 .15 6.85 1 .27 .45 1 75 1 90 .023 J! "S a. :10 . . ... .. u SOLENOID Rated Amps z C) � rn � = "' r.a. rn "' "' Inrush Sealed ::E � Open Closed 38 5.2 5.2 1 5A 1 00 1 .75 1 .75 6A 2.6 .35 6A .88 200 98 063 . .88 6A 2.2 .29 6A 1.1 .17 6A 1 .5 .19 6A 1 .2 .16 6A .08 6A .55 .083 3.86 .76 .60 .50 .07 1 .3 .17 6A 1 .1 .15 6A .54 .08 6A .08 .50 3.42 .64 1 77 1 96 TABLE 1 9 AUXILIARY SWITCH CONTACT RATINGS lP Contln· uoua ca 60 Hz. Ae 120 240 480 Inrush tri De 125 250 Main ContecU Open Bell Alarm Contact Rating (empern) Control Volt8ge I .052 .047 064 TABLE 1 7 BELL ALARM CONTACT RATIN G ! . Inrush 1 .0 ar 208V ww 090 95 Rated Amps an 60 1 20V RELAY "X" tM 1 20V CLOSING CONTROL ANTI·PUMP RELAY "W" ua ls I Control Voltage De 48 125 250 Ac 115 240 480 Auxlllery SwHch Interrupting Ratings (Amperes)® NonInductive Inductive 25 11 2 75 50 25 - 6.3 1.8 50 25 12 <D Limited to 20A continuous ratmg of switch on all breakers and to SA contin uous rating of # 16 wire on drawout breakers. TABLE 20 CHARGING TIMES Nominal Voltage nme (sec.) 48VDC 1.5 120VDC 250VDC 1.0 120VAC 208VAC 240VAC 0.09 77 .c om -. TABLE 21 SHUNT TRIP AND UNDERVOLTAGE DEVICE OPERATING CURRENTS SHUNT TRIP UNDER VOLTAGE Current "" Voltage ,.nge 30 240 25 380 50 14 28 70 1 40 59 95 95 95 1 75 1 75 1 75 1 90 1 90 1 90 1 90 315 480 60 380 508 480 50 380 DC DC DC DC 24 48 1 25 250 70 1 20 1 20 1 20 208 208 208 60 60 50 25 60 50 25 60 50 240 240 240 40 60 1 40 280 1 32 1 27 1 27 1 27 220 220 220 254 254 254 254 25 380 575 60 475 625 575 50 475 575 25 475 Open Cloud 8.3 4.5 2.0 1 .0 8.3 4.5 2.0 1 .0 - - 1 0.8 6.7 4.1 2.6 3. 1 1 .9 Operating (Amps) Voltage ,.nge lnruah Sealed Open CloMd .38 .19 .08 .38 .19 .08 SEE TABLE 23 3.4 4.1 5.1 1 .9 2.6 3.1 7.3 3.4 7.5 3.5 2.8 5.1 3.1 625 625 .04 .04 N/A N/A .66 .75 .31 .51 .30 .14 .37 .34 .24 .25 .10 .17 .10 .05 .12 .1 1 N/A .16 .22 .23 .1 7 .11 .16 .14 .10 3.3 2.5 4.7 3.0 lP 480 Sealed 1 2.3 7.6 4.7 3.2 3.8 2.1 3.9 4.7 5.8 2.1 2.9 410 508 508 lnruah tM I> Operlltlng ua ls r I ! ar 'i .! c 0 Current (Amps) "" u c an :g 8& Nominal Control Frequency Hz Anti-Pump Relay ··w- · N!A N/A DC 802 DC DC 240 1 19 64 1 600 DC 1 6400 476 260 6700 60 450 54 25.4 1 20V 50 450 75 1 20V 25 1 4 50 75 3.9 7.15 25 . 4 208V 60 1 4 50 216 25.4 64 208V 50 1 450 25.4 1 46 208V 25 3900 64 580 240V 60 1 4 50 25.4 1 00 240V 50 1 450 240V 25 380V 50 480V 60 480V 50 480V 25 575V 60 575V 50 575V 25 lec .E w ww 78 12 · 1 20V 1 25V I Undervolblge 3 11 · 250V 48V ! Shunt Trip ·· 5000 24V I Control Relay x tri Voltage ca TAB LE 2 2 COIL RESISTANCE-DC O H M S @ 25°C 6000 NA NA NA NA NA NA NA 300 300 300 300 300 NA NA NA NIA NA N�A N, A 25.4 64 64 64 64 33 1 46 1 46 580 370 370 32 580 100 1 600 1 00 580 1 46 3200 64 918 N/A .06 .08 .08 .06 .05 .06 .06 .05 ... ...... .c om . TABLE 23 1NSTANTANEOUS UNDERVOLTAGE DEVICE SETTI NGS PICK UP VOLTAGE RANGE COI L RATING UVR O N LY UVR I N STALLED MECHANISM R ESET 24 VDC 1 8 . 20 1 6 . 20 48 VDC 36 . 41 32 - 41 1 25 VDC 1 06 - 1 1 0 1 04 - 1 1 0 1 55 VDC 1 09 - 1 32 1 01 1 32 47 - 93 250 VDC 212 - 221 209 - 221 75 - 85 1 20 VAC 1 02 - 1 06 1 00 - 1 06 36 - 72 208 VAC 1 56 . 1 76 1 36 - 1 76 62 - 1 25 240 VAC 206 - 21 2 200 . 21 2 72 . 1 44 380 VAC 285 - 323 247 - 323 1 1 4 - 223 480 VAC 360 - 408 3 12 - 408 1 44 - 288 575 VAC 431 - 488 374 - 488 1 73 . 345 DROP OUT RANGE 7 . 8.3 14 - 1 7 ua ls 38 - 43 tM an • TABLE 24 TIME-DELAY UNDERVOLTAGE DEVICE SETTI NGS 1 25 VDC 77 - 85 UVR INSTALLED MECHANISM RESET ar PICK UP RANGE UVR O N LY VDC NO PICK UP PIC K UP 50 90 - 95 90 1 60 - 1 65 ca lP DELAY U N IT VOLTAGE 250 VDC 208/240 VAC M IN I M U M POSSIBLE ww w .E lec tri 1 25 - 1 40 DROP OUT RAN G E 79 .c om ua ls an tM ar lP ca tri lec .E w These ,nst'vtflOI"' Oc "'01 D""'P<Y' IU co..,- all o.t.,s 01 .,.,..flrOttJ , eoutpmerlf f"'()t ro oro ..•att ,.._ ........, ()( l ' ' �. ( �� .. rc o. ,.,., ,., CO"W"'eC&ot" .,., '"S'Mf•ttor" Gpitl•t•OI"' Of ..,.,,.,.,� • S."'U'a ,._,.., ,.,bm.tK>t" bl O.Sif'.a' 01 I"Duk:1 D� ut•' l)r()bl.,... , .,.. ,.. ·� � .,. ""C't c� au"<..,.,. lot ,. {)Uf'Ctt•sw s Dv' pa.ses ,. ..., .,..., '�)U',:! o. ·•'•'"'.0 ro ,... �· l'«'"< Como., ww Outside t h e U S w r • t e Con s t ruct iOn EQui pment E x port Opera t •on 4 1 1 T heo d or e F r emd Ave . A ye. N Y 10580 GEK-644598 PSE 1 285 For further 1nformat1on call or wnte your local General E lectnc Sales Off iCe or G E N ERAL General Electnc 01stnbut1on EQuipment 4 1 Woodford Avenue Pla1nv1lle. CT 06062 fj E L E C T R I C • .c om GEK-644590 Maintenance Manual Low Voltage Power Circuit Breakers ww w .E lec tri ca lP ar tM an ua ls Types AKR-30 I 50 and AKRT-50 Low Voltage Power Circuit Brea kers .c om Table of Contents Page Page 4 1 .0 1 .1 1 .2 4 4 4 I NTRODUCTION I nspection and M ai ntenance Renewal Parts 6 SECTIO N 2 G E N E RAL DESCRI PTION Frame Size Operation Fused/Non-Fused Mounting Trip Device Model N u m ber Short Circuit Ratings SECTIO N 3 3.0 3.1 3.2 10 10 10 1 0A STORAG E Safety M aintenance SECTIO N 4 DRAWOUT BREAKER I NTERCHANGEABI LITY 1 0B ar 4.0 10 SECTI O N 5 11 SECTION 6 tri .E 6.7 I NTERLOCKS Racking M echanism I nterlock Positive I nterlock Closing Spring I nterlock Discon nect Position I nterlock Padlocks Key I nterlock-Stationary Breaker Optional I nterlocks lec 6.0 6.1 6.2 6.3 6.4 6.5 6.6 SECTIO N 7 BREAKER MAI NTENANCE Lubrication M an ual H andle Adj ustment Drawout Mechanism Position Slow Closi ng the Breaker Primary Disconnects Replacement Adjustment ww w 7.0 7. 1 7.2 7.3 7.4 7.5 7.5. 1 7.5.2 2 11 11 11 12 13 lP B REAKER OPERATION M anual Closing Electrical Closi n g Alternate Control Circuit Mechanism Operation Charg i ng Using The Maintenance Handle ca 5.0 5.1 5.2 5.2.1 5.3 5.4 13 15 15 15 16 16 17 17 18 18 18 18 18 19 20 20 21 22 22 Auxil iary Switch Replacement Adj ustment Shunt Trip Replacement Adj ustment U ndervoltage Device Replacement Operational Check Adjustments Factory Settings Static Time-Delay Undervoltage Adjustments Electric Lockout Device Bell A larm Operation Adjustments Replacement Electrical Control Components Component Replacement F and G Switch Adjustment Drawout Mechan ism Buffer Assembly Buffer Adj ustment Tri p Latch Adj ustment ua ls 6 6 6 6 8 8 8 9 7.6 7.6. 1 7.6.2 7.7 7. 7. 1 7.7.2 7.8 7.8. 1 7.8.2 7.8.3 7.8.4 7.9 7.9.1 7.10 7.1 1 7.1 1 .1 7.1 1 .2 7. 1 1 .3 7. 1 2 7. 1 2. 1 7. 1 2.2 7. 1 3 7.14 7.14.1 7. 1 5 tM 2.0 2. 1 2.2 2.3 2.4 2.5 2.6 2.7 SECTIO N 7 an SECTIO N 1 SECTI O N 8 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 9.3.2 25 25 26 26 26 27 27 27 28 29 29 31 32 32 33 CONTACT MAI NTENA N C E 33 Arc Chute Removal & I nspection 33 Contact Adjustment AKR 30/30H/30L & A K R U 30 34 Co ntact Adj ustment - AKR 50/50H & A K R U 5 0 & A K R 30L C ontact Adjustment A KRT 50/5 0H Stationary Contact Identification Contact Replacement AKR 30/30H & A K R U 30 Contact Replacement - A K R 50/50H , AKRU 50 & AKRT 50/5 0H SECTIO N 9 9.0 9.1 9.2 9.3 9.3. 1 22 22 22 23 23 23 23 23 24 24 36 37 38 39 39 41 41 FUSED B REAKER 41 Fuse Sizes and Mounting Special 2500A Fuse For AKRU 50 41 43 Open Fuse Lockout Device 43 Type A and B Breaker OFLO Adjustment Type D B reaker 43 OFLO Adj ustment 1 0.5 45 45 46 48 48 51 52 52 1 1 .1 TYPE ECS OVERCURRENT TRI P D EVICE ECS Cabl ing Diag ram 56 57 58 1 2 .5 SECTION 1 3 1 5 .0 1 5. 1 1 5. 1 . 1 1 5. 1 .2 1 5 . 1 .3 1 5 .2 1 5.2.1 1 5. 2 . 2 1 5 .2.3 1 5 .2 .4 1 5.3 1 5. 4 1 5. 4 . 1 1 5.4.2 1 5.5 1 5. 6 ca lP ar M ICROVERSATRI P '" TRIP D EVICE 58 58 Programmer Unit 58 Fault Trip Indicators 58 Remote Fault Indication MicroVersaTrip� Installation 59 60 Current Sensors Replacement of Current 63 Sensors 64 Flux Sh ifter Tri p Device 64 Troubleshooting 65 Resistance Values False Tri pping- Breakers 65 Equ ipped with Ground Fault MicroVersaTrip .. Cabl ing Diag rams 66 tri 1 2.3 1 2.4 1 2.4. 1 1 2.4.2 SECTION 1 5 56 SECTION 1 2 1 2.0 1 2. 1 1 2. 1 .1 1 2. 1 .2 1 2. 1 .3 1 2.2 1 2.2.1 1 4.8 1 4.9 53 53 SECTION 1 1 1 1 .0 1 4. 1 1 4. 2 1 4.3 1 4 .4 1 4. 5 1 4. 6 1 4 .7 M ICROVERSATRI P '" P LUS AND M ICROVERSATRIP PM TRIP U N ITS Trip U n it Testing Product Structure Trip Unit Removal and Replacement Phase Current Sensors Neutral Current Sensors Rating Plug Removal and Replacement Trip Unit Functions Trouble-Shooting Guide ua ls 1 0.3 1 0.4 1 0.4. 1 1 0.4.2 1 0.4.3 1 4. 0 TYPE SST OVERCURRENT TRIP DEVICE Programmer Unit Current Sensors Replacement of Current Sensors Flux Shift Tri p Device Troubleshooti ng SST Test Set Resistance Values False Tri pping- Breakers Equ i pped with G round Fault SST Cabl ing Diag rams an 1 0.1 1 0.2 1 0.2.1 SECTION 1 4 EC T R I P DEVI CE Series Overcurrent Tripping Device EC-2A Long Time-Delay and High-Set I nstantaneous Tri p ping Instantaneous Low-Set Tripping Instantaneous H ig h -Set Tripping Series Overcurrent Tripping Device EC-1 Short Time-Delay Tri pping Long Time-Delay Tri pping Instantaneous Tri p ping EC-1 Adjustment Positive Trip Adjustment Reverse Current Tripping Device Adjustment Replacement Switchette Feature Trip Device Replacement tM 1 0.0 Page 45 SECTION 1 0 .c om Page 77 77 77 78 78 79 80 81 81 82 83 84 84 86 86 86 86 87 87 87 88 88 88 89 90 90 90 90 70 RMS-9 & EPIC M I CROVERSATRI P '"70 Programmer U n it 70 Fault T r i p Indicators 70 RMS-9 & E p i c MicroVersaTrip I nstallation 71 1 3. 2 Current Sensors 71 1 3. 2 . 1 Replacement of Current Sensors 7 4 Flux Sh ifter Trip Device 1 3 .3 74 Troubleshooting 1 3.4 74 74 1 3. 4 . 1 Resistance Values 1 3.4.2 False Trip ping-Breakers Eq u ip ped With G round Fault 75 Cabling Diagrams 1 3.5 75 ww w .E lec 1 3.0 1 3. 1 1 3.1 .1 1 3. 1 .2 3 .c om SECTION 1 -lntroduction A basic i nspection should consist of the following : The proper use, care , and mai ntenance of these break ers is a prime safety consideration for the protection of person nel , as well as a means of minimizing equipment damage when faults occur. Persons who apply, use , and service these breakers will acquire the k nowledge they need by gaining the i nformation contained i n these instruc tions. a. Visual Check - Look for dirt, grease or other foreign material on any breaker parts. Check insulati ng surfaces for conditions that could degrade i nsulati ng properties (cracks, overheating, etc . ) . Also check for loose hardware and components on the bottom of the b reaker compart ment. Loose or damaged control wiring and similar problem areas should also be checked . b. Operation - Observe a few close-open operations using the operating or maintenance handle. If a breaker is seldom operated such that it remains open or closed for a period of six months or more, it is recommended that it be opened and closed several times i n succession. ua ls These i nstructions provide the mai ntenance procedures and describe the operation of the 800 thru 2000 amp frame size type AKA low voltage power circuit breakers listed i n Table 1 . INSPECTIO N AND MAINTENANCE e . Accessories - Verify that the various accessories are working properly. f. The performance of the solid-state current trip devices may be checked with a suitable test set . Check elec tromechanical devices for positive trip in accordance with the instructions in their Maintenance Manual, G E l 86 1 57. ar Breakers should be cared for under a systematic main te nance prog ram. Taking each breaker out of service pe riodically for inspection and mai ntenance is an excellent means of establishing high service reliability. It is good policy to have one or more spare breakers to i nstall in place of breakers requiring maintenance. Keeping a stock of reco m mended renewal parts will insure that maintenance work can be done quickly. d . Arc Chutes and Contacts - I nspect the condition of the arc chutes and contacts. Look for excessive burning or breakage. Check the amount of contact depression or wipe when the breaker is closed. tM 1 .1 an c. I nterlocks - During the O perational check verify the safety i nterlocks are properly working. 1 .2 ca lP How frequently an ind ividual breaker should be in spected will depend on the circumstances of its use. It would be well to i nspect any breaker at least once a year. If it is frequently operated, operated under severe load condi tions, or i nstalled i n an area of high humidity or a dusty , dirty atmosphere, inspections should be more often. I n spections m ight be monthly under adverse conditions. lec tri Always i nspect the breaker after a short-ci rcuit current has been i nterru pted . SAFETY P RE CAUTION ww w .E BEFORE INSPECTING OR B EGINNING ANY MAINTENANCE WORK ON THE BREAKER, I T MUST BE DISCONNECTED FROM A L L VOL T A G E S O UR CES, B O TH P O WER AND CON TROL, AND BE IN THE "OPEN" POSITION. 4 R E N EWAL PARTS The AKA breakers contain a variety of parts and as semblies. Many of these are available as replacement parts when the need arises. See publication G E F 4527, Renewal Parts, for a complete listing of these parts. 800 AC AKR-(*)8 30, 30H X X AKR-(*) D 30, 30 H , 30L AKR-(*)S 30, 30H AKR-(*)A 50, 50H 1 600 AC AKR-(*)8 50, 50H 2000 AC AKRT-(*)8 50, 50H X AKR-28 30 X AKR-2S 30 X AKR-2A 50 AKR-28 50 X lP 2000 DC AKR-2D 50 800 AKRU -(*)8 30 AKRU-(*) D 30 1 600 X tri AKRU-(*)A 50 X ca AKR-2S 50 AKRU-(*)A 30 AKRU-(*)8 50 } X X AKRU-(*)D 50 X X X X X X X X X X X X X X X X X X X X X X X X .E lec (*) - This digit identifies the trip device type as follows: X X X X X X X ar AKR-2D 30 X X X AKRT-(*)S 50, 50H 800 DC X X AKRT-(*) D 50, 50H AKR-2A 30 X X AKR-(*)S 50, 50H X X X AKR-(*)D 50, 50H AKRT-(*)A 50, 50H X ua ls AKR-(*)A 30, 30H MOUNTING TYPE DRAWOUT S U BDEEP FUSED AKD-5 AKD-8 STRUCTURE STATIONARY ESCUTCHEON BREAKER an BREAKER DESIGNATION BREAKER MODELS tM FRAME SIZE (AMPERES) .c om TABLE 1 2 - EC (DC on ly) 4 - ECS ww w 5 - SST 50/60 Hertz Only 6 - MicroVersa Trip N - Non-automatic. I n ad dition, all non-automatic 250VDC breaker types carry the suffix letter D after the frame nu mber, e.g. AKR-N B-500 7 - RMS-9 9 - MVT-PLUS or MVT-PM 5 .c om SECTION 2-General Description ua ls Type AKA low-voltage power c i rc u it breakers are used for contro l l i n g and protecti n g power c ircuits in the l ow voltage range (usually up to 600 volts). I n serving this function, they are a means of safely switching loads and automatically cleari ng circuits when abnormal conditions occur. Among these conditions, the more com mon are short circu its and sustained overloads and under voltages. The type AKA breakers are of the "quick-make, quick break description, having the feature of storing energy in a closing spring for quick release in closi ng. I n closing, some energy is transferred to an opening spring to be used subsequently for fast tripping. FIG . 1 - Manually Operated AKR-4A-50-1 ar The mechanism unit is designed to receive energy, store it, and later (when called upon to do so) deliver it to close the breaker1 contacts. It must be able to reverse its com mitment to c lose the breaker at any point upon the activa tion of an automatic trip device ( i . e . , be "Trip- Free"). Fi nally, it also must be able to trip open a closed breaker qu ickly enough to minimize arc erosion and in such a manner as to effect proper arc transfer to the arc runner. tM The three main functional com pone nts of a b reaker are its mechanism, an assembly comprising the conductive members, and the i nterrupter. an Knowledge of how the breaker is designed and how it operates will enable the owner to make p ro per use of the b reaker and to avoid m istakes in its o pe ratio n . S pecific d i rections on adjust ments and mai ntenance p rocedu res will be treated later. lP These values represent the maxi m u m conti n uous cur rent capability of the respective frames . However, each breaker carries a specific rating which is determi ned by the c urrent sensor ampere rating or maxim u m setting of the trip device with which it is equip ped . tri the cu rrent transformers. ca The cu rrent-carrying members of the breaker are as sembled on the back frame, which provides the mechani cal support req uired and also the insu lating structure needed. The conductive members are the studs for exter nal connections, movable and stationary contact sets, pivots for the movable contacts, and provision for mo unting lec The interrupter components are , in addition to the arcing contacts, the arc ru n ners mounted on the back base and the removable arc quencher assemblies. .E I n addition to these basic components, a breaker may be equipped with any combination of many accessories and interlocking devices . Breakers may also differ in a variety of areas as shown in Table 1 . A brief description of these areas is given below. M outline d rawir;Jg is available for each breaker frame size showing critical dimensions. The d rawing number appears on the breaker nameplate and can be obtained from GE. FRAME S IZ E w 2.1 ww The breakers are available i n 5 frame sizes - BOO am peres A.C. (AKA 3 0/3 0 H , 30L, AKAU 30), 1 600 a m peres A . C . (AKA 50/5 0 H , AKAU 500), 2000 am peres A . C . (AKAT 5 0/50H), 800 a mperes D . C . (AKA 30) a n d 2000 am peres D . C. (AKA 50). 6 2.2 OP ERATION There are Manual and Electrical breaker models. The Manual breaker, shown in Fig. 1 , has an operating handle which is used to manually charge the mechanism closing spri ng. The Electric breaker, shown i n Fig. 2, contains an elec tric motor which charges the mechanism closing spri ng. External control power is required to energize this motor and its control circuit. A nameplate i ndicates what voltage is req uired by the motor circuit and trip and close coils. 2.3 FUSED/NON FUSED Fused breakers are identified as either AKAU 30 (800 ampere frame size) or AKAU 50 ( 1 600 am pere frame size) . A fused breaker is shown i n Fig. 3. They are not inter changeable with Non- Fused breakers, si nce they require deeper compartments for their fuses . .c om ua ls an tM Electrically Operated AKR-70-30 FIG. 3 ar - - Fused Breaker AKRU-60-30 PRIMARY 7"'"'"""' ww w .E lec tri ca lP FIG. 2 FIG. 4 - Drawout B reaker 7 2.5 MOUNTI NG Type AKA breakers are designed for either drawout or stationary mounting. Drawout breakers (See Fig. 4) are equi pped with features which make them easy to instal l in or withdraw from their associated switchgear equipment. These features are a racking mechanism (which facilitates i nserting and withdrawing the breaker u nit) and primary and control power d isconnects which connect and part automatically. I nterlocking devices are included. There are several types of solid-state, direct-acti n g , self powered trip d evice system s associated with AKA breakers. These systems are for AC applications only. For DC appl ications an electro-mechanical system is available. The trip device system is identified by the first middle d igit in the breaker nameplate designation as fol lows : AKA-( i )8-30 1.__:_ Trip device code nu mber per Table 3 Stationary breakers are designed to be mounted on a framework or panel, with mechanical fasteners being used to secure the breaker frame and make power connections. If control power connections are needed , a suitable termi nal board is supplied. TABLE 3 TRIP DEVICE APPLICATION 2 3 EC Power Sensor1 ECS SST MicroVersaTrip RMS-9 MVT-PLUS or MVT-P M DC AC AC AC AC AC AC an �0 4 5 6 7 9 2 tM Mounting type code letter per Table 2 TAB L E MOUNTING TYPE CODES For Power Sensor devices. See publications G EK-7309 and G EK-7301 for detailed servicing procedures. 1 Stationary Drawout - B - Substructure D - A K D-8 Substructure - ca s 2.6 X � The difference between these models is their arc chute construction. The arc chutes in the no model number break ers have a two piece porcel ai n frame and use 2 arc chute retainers, s ee Fig. 5. The "- 1 " breaker arc chutes have a one piece molded polyester glass frame and 1 arc chute re tainer, see Fig. 6. All AKAT50H b reakers use only molded arc chutes. .E lec tri -- MODEL N U M B E R Type AKA breakers (see Table 2 ) exist a s either no model nu mber or "- 1 " versions. For example AKA-5A-30H or AKA-5A-30H- 1 . lP AKD-5 AKD-6 A ar Breaker Type Code Letter TRIP DEVICE CODES CODE N U MBER The mo unting type is identified by the second middle d igit in the breaker's nameplate designation as follows: AKA-5 ( TRIP DEVICE ua ls 2 .4 .c om SECTION 2-General Description (Cont.) p.,:'·· ww w . - - !! ' FIG. 5 - CERAMIC A R C CHUTES 8 FIG. 6 - MOLDED A R C C H U TES SHORT CIRCUIT RATINGS Short circuit ratings vary with the applied system vol tage. On 240 VAC systems they are also dependent upon whether the overcurrent trip device contains an instan taneous trip element. See Table 4. 800 AC AKR 30H AKR 30L AKR 50 1 600 AC AKR 50H AKR 50H-1 2000 AC AKRU 30 AKRU 50 AKR 30 AKR 50 lec 800 1 600 800 DC 2000 DC 'With 40-800 Amp T r i p Coils 2With 200-2000 Amp Trip Coils ua ls 30 30 30 42 42 42 42 50 50 65 65 65 42 50 65 50 42 42 50 50 50 50 65 65 65 65 65 65 50 50 50 65 65 65 65 65 65 200 200 - 25 1 502 3 25 50 tri ARKT 50H SHORT TIME 50 50 ca AKRT 50 WITHOUT INSTANTANEOUS TRIP an AKR 30 WITH INSTANTAN EOUS TRIP tM BREAKER TYPE RATED MAXIMUM VOLTAGE {60 HZ AC) 635 508 254 635 508 254 635 508 254 635 508 254 635 508 254 635 508 254 635 508 254 635 508 254 600 600 300VDC 300VDC 3<!> I NTERRUPTION RATING KA RMS SYM M ETRICAL ar FRAME SIZE (AM PERES) BREAKER I NTERRUPTION R ATINGS lP TABLE 4 .c om 2 .7 ww w .E 3Consult Factory For Appli cation Data 9 CAUTION : 1 . ALL CONDUCTORS M UST BE ASSUMED TO BE ENER GIZED UNLESS THE I R POTENTIAL HAS BEEN M EASURED AS G ROUND AND SUITABLE G ROUNDING CONDUC TORS HAVE BEEN APPLIED TO PREVENT ENERGIZING. Many accidents have been caused by back feeds from a wide variety of sources. 2. Although interlocks to reduce some of the risks are provided, the individual's actions while performing service or maintenance are essential to prevent accidents. Each person's knowledge; his mental awareness; and has planned and executed actions often determ ine if an accident will occur. The most important method of avoiding accidents is for all associated personnel to carefully apply a thorough understanding of the specific equipment from the viewpoints of it's purpose, it's construction , it's operation and the situations which could be hazardous. ww w .E lec tri ca lP ar IF THE B REA KER IS S TORED FOR ANY LENG TH OF TIME, IT SHOULD BE INSPECTED PERIODICAL L Y TO SEE THA T R US TING HAS NOT S TA R TED AND TO ASSURE G OOD MECHANICAL CONDITION. SHOULD THE B REAKER BE STORED UNDER UNFA VORABLE A TMOSPHERIC CONDI TIONS, IT SHOULD BE CLEANED AND DRIED OUT BEFORE BEING PLACED IN SER VICE. ua ls 2 . The breaker should be stored in a clean location free from corrosive gases or fumes. Particular care should be taken to protect the equipment from moisture and cement dust, as this combi nation has a very corrosive effect on many parts. The following requirements are intended to augment the user's safety program, but NOT supplant the user's responsibility for devising a c::>m plete safety program. The following basic industry practiced safety require m ents are app l icable to all major electrical equipment such as switchgear or switchboards. General Electric neither condones nor assumes any responsibility for prac tices which deviate from the following: an 1 . The breaker should be carefully protected against condensation , preferably by storing it in a warm dry roo m , since water absorption has a n adverse effect o n the insula tion parts. Circuit breakers for outdoor switchgear should be stored in the equipment only when power is available and the compartment heaters are i n operation to prevent condensation. Each user must maintain a safety program for the protec tion of personnel, as wel l as other equipment, from the potential hazards associated with electrical equ ipment. tM I t is recommended that the breaker be put into service i m mediately in its permanent location. If this is not possi ble, the following precautions m ust be taken to insure the proper storage of the breaker: .c om 3 . 1 Safety SECTIO N 3 . 0-Storage, Safety, Maintenance 10 All personnel associated with installation, operation and maintenance of electrical equipment, such as power circuit breakers and other power handling equipment, must be thoroughly instructed, with periodic retraining, regarding power equipment in general as well as the particular model of equipment with which they are working. Instruction books, actual devices and appropriate safety and mainte nance practices such as OSHA publications, National Electric Safety Code (ANSI C2), The National Electrical Code, and NFPA 7 OB Electrical Equipment Maintenance must be closely studied and followed. During actual work, supervi sion should audit practices to assure conformance. 3. Excellent maintenance is essential for reliability and safety of any electrical equipment. Industry publications of recom menced maintenance practices such as ANSI/NFPA 70B, Electrical Equipment Maintenance, should be carefully stud ied and applied in each user's formation of planned maintenance. .c om 3 . 2 Maintenance ua ls I ndustry publications of recom mended maintenance prac tices such as ANSI/NFPA 708, E lectrical Equi pment Mai ntenance, should be carefully stud ied and applied i n each user's formation o f plan ned maintenance. Some users may require additional assistance from Gen eral E lectric in t h e p la n n i ng a n d performance of maintenance. The General Electric Company can be contracted to either undertake maintenance or to p rovide technical assistance such as the latest publications. tM One of the critical service activities, sometimes neglected, involves the calibration of various control d evices. These monitor conditions in the primary and secondary c ircuits, sometimes initiating emergency corrective action such as opening or closing circuit breakers. I n view of the vital role of these devices, it is i m portant that a periodic test p rogram be followed. As was out lined above, it is recog n ized that the interval between periodic checks will vary depending u pon environment, the type of device and the user's experience. It is the General Electric recommenda tion that, until the user has accumulated enough experience to select a test interval better suited to h is individual requirements, all significant c alibrations be checked at an interval of one to two years. Instruction books supplied by manufacturers address com ponents that would normally require service or main tenance during the useful life of the equi pment. However, they can not include every possible part that could require attention, particularly over a very long service period or under adverse environments. M aintenance personnel must be alert to deterioration of any part of the sup p lied switchgear, taking actions, as necessary to restore it to serviceable status. an Both long and short term maintenance o f a l l electrical equipment is essential for rel iability and safety. Mainte nance programs must be tuned to the specific application, well planned and carried out consistent w ith both i ndustry experience and manufacturer's recommendations. Local environment must always be considered in such pro g rams, including such variables as am bient temperatures, extreme moisture, num ber of o perations, corrosive atmo sphere or major insect problems and any other unusual or abusive condition of the application. ar The performance and safety of this equipment may be compromised by the modification of supplied parts or their replacement by non identical substitutes. All such design changes must be qualified to ANSI/IEEE Standard C37.59 . The user should methodically keep written maintenance records as an aid in future service planning and equipment reliability im provement. Unusual experiences should be prom ptly communicated to the General Electric Company. ww w .E lec tri ca lP To accom plish this, sorne items, such as "EC" direct operating trip systems for low voltage breakers, must be tested with prim ary current injection . Others can be adequately tested using test sets. Specific calibration instructions on particular devices typ ically are provided by supplied instruction books. 1 0A .c om 5.2.1 ALTERNATE CONTROL CIRCUIT USED The motor is energized through the "G" cutoff switch and the K-relay contact. The motor is deenerg ized when the "G" cutoff switch changes state wh ich occurs when the closing spring is fully charged. tM o----o- REMOTE CLOSE - 1 �-, )... LEG E N D C C - CLOSING SOLENOID F - CUTOF F SWITCH, CLOSED W H EN CLOSING S PRI NG IS FU LLY CHARGED (D.C. O N LY) G - CUTOF F SWITCH, OPEN W H EN CLOSING SPRING IS FULLY CHARGED. L - AUXI LIARY SWITCH M - CHARG I N G MOTOR PB - CLOSE PUS H B UTION O N BREAKER ESCUTCH EON. O PTIONAL TC - SHUNT TRIP DEVICE K - ANTI-PU M P R ELAY TC .E lec tri ca lP ar CONTROL SOURCE The anti-pum p function is obtained through the nor mally closed K-relay contact i n the motor c i rcuit. If a close signal is mai ntained after the breaker has tripped open automatical ly, the K-relay is energ ized preventing the motor from charg i ng the closing spring. The closing signal must be removed for approxi m ately 1 .3 to 2.0 seconds to al low the closing spri ng to charge. an With the c losi ng spring propped ful ly-ch arged, the breaker is ready for c losing. Th is may be accompl ished electrically by closing the "PB" switch on f he breaker (if so equipped) or by a remote closing switch. Operation of the closing switch energizes the K-relay, which in turn ener g izes the closing solenoid "CC". This removes the p rop, releasing the closing s prings to close the breaker. The "F" cutoff switch is only installed on breakers using D.C. control voltage. ua ls A second type of electrical control is shown in Fig . 9A for all control voltages except 250 volts D.C. which uses the circuit shown in Fig . 9. This alternate control c i rcuit eliminates the X-relay and CC switch shown in Fig. 9. ww w FIG. 9A. ALTERNATE ELEM ENTARY DIAG RAM . CONTACT POSITIONS ARE SHOWN BREAKER OPEN A N D CLOSING SPRINGS DISCHARG ED. 12 TYP #183 L7 1 2 "B" SERIES .c om 5.3 13 12 M ECHA'N ISM O PE RATIO N Figures 1 OA, 1 08 and 1 O C show the mechaniSm com .. ponents in the Closed, Trip ped and Reset positions. The closing spring is in the charged position for all of these details. I ca tri 5 II J; FIG. 1 0B TRIPPED 5.4 5 14 4 3 FIG. 1 0C RESET 2. Prop 3. Cam 4. Camshaft 5. Cam Ro l l er 6 . Secondary Latch Roller 1 0. Trip Shaft 1 1. 1 2. 1 3. 1 4. 1 5. Trip Latch I ns u lated Cou p l i n g M a i n Shaft Secondary Latch Opening Spring CHARGING USING THE MAINTENANCE HANDLE The closing spring on electrically operated breakers can be manually charged by using the mai ntenance handle (5688386G1 ) as shown in Fig . 1 1 . The triangu lar socket in the maintenance handle mates with the mechanism cam shaft extension on the front right side of the breaker. Using the knob on the handle, it will be necessary to align this socket to fit on the end of the shaft when the handle is positioned as shown. ww w .E lec 14 )1 an tM lP ar Reset Position - The mechan ism is shown i n Fig. 1 OC. The closing cam, item no. 3 , which is assembled to the cam shaft, item no. 4, is rotated by the charging motor, manual operating handle, or maintenance handle. The cam engages the cam rol ler and partially extends the toggle linkage. This allows the secondary latch item 1 4 to pivot against the front frame as shown leaving a gap between the trip latch and secondary latch roller. The secondary latch is now in a position to engage with both the trip latch and cam roller. When the breaker is closed and the closing spring d ischarged , the u pper cam rol ler item #5 is supported by the cam rather than the prop. This is the position the mechanism must be in to check contact adjustment, refer to Section 8. 11 I �-±=l"s.:.!�-"==== --,Jc-r-r� ua ls 10 · The breaker closes when the closing spring d ischarges and rotates the cam item #3 against the cam roller item #5. The togg le l i n kage is fu l ly extended, p ivot i ng the secon d ary latch from the front frame and engag i ng it with the tri p l atch and cam rol ler as shown i n Fig. 1 0A. 3 I Closed Position - As shown in Fig. 1 0A, the movable contacts are pushed against the stationary contacts by the toggle linkage. The toggle linkage is held in position through the engagement of its cam rollers, item no. 5, with the prop, item no. 2 and the secondary latch/roller item #6 and secondary latch #1 4 and trip latch #1 1 . Tripped Position - The mechanism goes from the Closed position to the Tripped posit ion, shown i n Fig. 1 08, when the trip shaft, item no. 1 0, i s rotated by either the manual trip button or one of the other trip devices. The trip l atch, item no. 1 1 is assembled to the trip shaft. When the tri p shaft rotates, the trip l atch disengages from the secondary l atch rol ler. The secondary l atch p ivots, resulting in the col l apse of the toggle l i n kage. Th i s col l apse along with the open i ng spring, item no. 1 5, shown i n Fig . 1 0 C , causes the breaker contacts to open. 2 4 5 11 14 6 FIG. 1 0A CLOSED FIG. 11 - MAINTENANCE HAN DLE I N STALLED ON CAMSHAFT EXTEN SI O N 13 .c om tM an ua ls SECTION 5-Breaker Operation (Cont.) FIG . 1 2 - R O L L E R ENGAG E D WITH CLOSING PROP Rotate the camshaft u s i n g the m ai ntena nce h a n d l e u n t i l the ratchet assem b l y roller e ng ages with the prop. Do n o t d rive the rol l e r agai nst the prop w i t h u nd o force . T h e b r e a k e r can now be closed by removi n g the prop from the rol l e r . This i s d o n e b y m a n u al l y activati ng the closing lP ar T h e r e i s a ratchet asse m b ly attached t o t h e c a m s h aft exte n s i o n . This ratchet is normally d ri ve n by the b reaker's gear motor. A rol l e r on this ratchet e n g ages with a prop when the c l o s i n g s p r i n g i s f u l l y charged and d riven over center, see F i g . 1 2 . This holds the cl osing spring i n a charged c o n d i t i o n . ww w .E lec tri ca solenoid armat u re b y push i n g t h e s o l e n o i d armatu re i n t o its w i n d i n g s . See Fig . 1 3 . 14 FIG . 1 3 - MAN UAL O P E RATION OF CLOSING SOLENOID .c om SECTION 6-lnterlocks ua ls AKR breakers are equipped with safety interlock devices that are requi red by I ndustry Standards and Certifyi ng Au thorities. I nterlock devices for special applications are also available as options. The standard interlock devices de scribed below are used only on drawout breakers. Station ary breakers h ave no required interlocks. C' Caution m ust be taken to ensure that any interlock lever is not bent and caused to not function. All interlocks should be operated to c onfirm that they function as required. RACKING MECHANISM I NTERLOCK tM The function of the racking mechanism interlock is to prevent the breaker from moving from the CONN ECTED position before the breaker is in the OPEN position. an 6.1 . RESET FIG. 1 4A - RACKING SCREW ar The racking mechanism d rive shaft is located behind the RACKING SCREW cover shown in Fig. 1 4A. This cover m ust be slid to the right to gain access to the d rive shaft as shown in Fig. 1 48 . When the RACKING SCREW cover preventing it from being o pened . This l i n k is d riven by the motion of the OPEN/CLOSED indicator as shown in Fig. 1 5. lP CAUTION! Prior to m oving rack screw cover over to attach ca racking wrench push the manual trip button above the cover. This will ensure that the breaker is open. Also read breaker position flag to confirm that breaker is open. Compartment door should be closed and latched when racking a breaker from the connect position. lec tri The T R I P button also en gages with the RAC K I N G SCREW cover in both the O P E N and CLOSED positions. Therefore , the T R I P button must be pushed in before the cover can be opened. This will open the breaker if it was closed and also depress the OPEN/C LOSED lin kage d isc ussed above. .E When the RACKI N G SCR EW cover is open it holds the TR I P button i n . Th is keeps the breaker trip-free so a mechanism closing cycle wi ll not cause contact movement especially when the breaker is being racked in or out. CAUTION! FIG. 1 4B ww w Use only the proper racking m echanism wrench for racking the breaker in or out, otherwise the trip-free interlock featu re may not function . 15 .c om ua ls SECTION 6-lnterlocks (Cont. ) ' ' �· POSITIVE/ ' POSITIVE INTERLOCK crank pin reaches the end of the slot in the linkage. Continued motion of the racking mechanism causes the linkage to rotate the lever which m oves the c losing sole noid armature forward. The armature linkage then releases the prop, d ischarg ing the closing spring . ar 6.2 FIG. 1 6 - POSITIVE INTERLOCK tM FIG. 1 5 RACKING SCREW COVER I NTER LOCK CLOSED POSITION an INTERLOCK The C losing Spring i nterlock should be adjusted to cause the closing spring to discharge when the racking mechanism is a minimum of 1 and a maxi m u m of 2V2 turns short of the fully racked out position. In this position the racking handle can no longer be turned . If adjustment is req uired, use the l i nkage adjusting screws shown in Fig. 1 7. Note: - Undue force on the racking handle at the fu l ly racked out position will cause the l ever to m ove past the pin on the armature l i n kage. This w i l l bind up the overall interlock. Under these cond itions, conti nued appl ication of this force will defo r m the l i n kage assem b ly. lP The function of the positive interlock is to keep the breaker trip-free while it is being racked in or out between the CONN ECT E D and TEST positions. C LOSING SPRING INTERLOCK lec 6.3 tri ca The positive interlock is located on the breaker left side as shown in Fig . 1 6 . As the breaker moves between the CONN ECT E D and TEST positions, the positive interlock engages with a ramp cam located in the breaker compart ment. This cam raises the interlock lever asse mbly caus ing the trip shaft to rotate and prevent the trip latch from engaging with the secondary latch assembly rol ler. The breaker is held trip-free and can not be closed d uring this interval. .E The function of the closing spring interlock is to dis charge the closing spring as the breaker is being racked out of its housing. This eliminates the hazard of a com pletely charged breaker being discharged after the breaker is removed from its compartment. ww w The operation of the closing spring interlock is shown in the two pictures for Fig. 1 7 . The racking mechanism arms and the crank are connected to a common shaft. As the breaker is racked out a pin attached to the crank moves through a slot tint he mechanism linkage. The linkage is connected to a lever which engages with a pin on the closing solenoid armature linkage. When the racking m echanism approaches the DISCONNECT position, the 16 .c om 6.4 DISCONNECT POSITION I NTER LOCK The function of the Discon nect Position I nterlock i s to block the RAC KING SCREW cover open when the racking mechanism is in the D I SCONN ECTED position. When the cover is held open, the T R I P button is depressed . The mechanism is held trip-free and there is no contact arm movement when the closing spring is discharged by the Closing Spring i nterlock. an ua ls The operation of this interlock is shown in Fig. 1 8 . A crank, which is attached to the racking mechanism shaft, is connected to the blocking plate through a link. As the shaft turns, the blocki ng plate rotates ; holdi ng the cover open in the D I SCONN ECTED position, but allowing it to close in the TEST and CONN ECTED positions. tM �" Breaker Racked I n - Lever And Armature .E lec tri ca lP ar Linkage P i n Not E ngaged Breaker Being Racked Out - ww w Lever Activates Armature Li nkage FIG. 1 8 DISCONN ECT POSITION I NTERLOCK 6.5 PADLOCKS Provisions are made on all breakers to use padlocks to prevent the breaker form being closed. For all breakers except Type B or D the padlock shackle goes through the TR I P button hole and out the slot in the side of the escutcheon. For Type B or D b reakers the padlock shackle goes through the TRI P button hole and out the RACKING SCREW cover hole in the deep escutcheo n . I n either case, the shackle holds the TRI P button in keeping the mechanism trip-free. FIG. 1 7 - CLOSING SPRING I NTERLOCK 17 .c om SECTION 6- lnterlocks (Cont.) The function of the Key Interlock is to prevent an open breaker from being closed when the lock bolt is extended and its key is removed. The operation of this interlock is shown in Fig. 1 9 . When the breaker is in the OPEN position, the end plate assem bly item #2 on the main shaft pivots the lever item #6 counter-clockwise. This removes the pin item #3 on the lever from blocking the lock bolt. Extending the lock bolt rotates the li nkage which moves the trip shaft, preventing the mechan ism from closing the breaker. When the breaker is in the C LOSED position , the fly wheel assembly item #2 is away from the lever item #6. The lever is spring loaded and rotates clockwise causing its pin to block the lock bolt extension. ua ls KEY I NTERLOCK-STATIONARY B R EAKER 6.7 OPTIONAL INTERLOCKS The optional interlocks are key interlocks and door inter locks. On drawout breakers, these devices are mounted in the equipment and are part of the breaker enclosure. an 6.6 - ' / " -� - �� ," /' �\ �-� \ , ' ( e I ; ' " '- / / ' "------ - / \ \ .E lec tri ca lP 3. P i n 4 . Lock Bolt 5. Pin 6 . Leve r ar 1 . Lock 2. End Plate tM 2 \ ---1--++--- 4 ��=�----+-- 3 ---r-i---+--!-1--- 5 6 FIG. 1 9 - K EY I NTERLOCK-STATIONARY B R EAKERS SECTION 7-Breaker Maintenance SAFETY PRECAUTION ww w WARNING : B EFORE INSPECTING OR BEGIN NIN G A N Y MAINTENA NCE W O R K ON THE BREAKER, IT MUST BE DISCONNECTED FROM ALL VOL TA G E SOUR CES, B O TH PO WER AND CONTROL, AND THE BREAKER MUST BE IN THE "OPEN" POSITION. 18 7.1 L U B RICATION In general, the c i rcuit breaker req u i res moderate l u brication. The majority of the factory l ubricated bear i n g poi nts and s l iding surfaces are accessi ble for i nspec t ion and if necessary, c leani ng and rel ubricat i ng. The on ly l u bricant used on the breaker for both electrical and mechanical areas is General Electric specification D50H D38 (D6A1 5AI Mobilgrease 28 or 32). .c om SECTION 7-Breaker Maintenance (Cont.} 7.2 3. 4. 5. 6. If the link is too long, the handle stroke cannot extend the closing spring enough for it to go over center. In this event, use the maintenance handle to complete the spring charg ing. The breaker can then be closed and opened prepara tory to further shortening of the link. If the link is too short, charging is not possible. The orig inal linkage design used a double-ended stud in the l inkage center. A hex section in this stud allowed adjust ing with an open-end wrench . When looking down on the . breaker, turning the wrench clockwise lengthens the hnk. The opposite motion shor.tens it. The range of adjustment is 300 degrees. In the conf ined space available, each wrench stroke imparts 1 5 degrees movement. The best setting is approximately mid-range. The present design is shown in Fig. 20. This l inkage is assembled together on a threaded stud. Adjustment is accomplished by removing the upper linkage assembly from the handle assembly and changing the linkage length by turning the upper linkage up or down the th readed stud. ar 7. The adjustment l i n kage co nnects the handle assembly to the chain drive mechanism which turns the cam shaft. The length of this linkage provides the handle adjustment. ua ls 2. Contacts Pivots - A t h i n fi l m on t he stat ionary and movable contact assembly pivot surfaces. Refer to Section 8. Do not lu bricate the contact tips. Racking Mechanism - The drive t h rea? s, jam b nut/tru nn ion i nterface, thru st washer/col l ar mterface, and the shaft support beari ngs. Refer to Section 7 . 1 3. Manual Operating Handle - Lubricate the two pivot areas associated with the adj u stment l i n kage. Also, t he hand le, mounting shaft/su pport bush i ng i nter face. Refer to Section 7.2. F l ux Shifter - Lubricate pivoting and s l i di ng sur faces of the reset l i n kage. Refer to Sect ion 1 0.3. Switchette - Lubricate the activator lever surface that contacts the switchette button. Mechan ism - All accessible beari ng and s l i ding sur faces t hat have been factory l u bricated. Pri mary Disconnects - Lubricate the fi nger contact surface just prior to i nstal l i ng in switchgear or l u bricate and t hen cover the d i sconnect assembly to protect from d ust, d i rt, etc. Refer to Section 7.5 tM 1. MANUAL HANDLE ADJUSTMENT an The areas req u i ri ng l u brication are: ww w .E lec tri ca lP Before l u bricating, remove any h ardened grease or d i rt from the l atch and bearing su rfaces. After l u bricating, remove all excess l ubricant to stop accumulation of d i rt or d ust. The use of cotton waste to wipe bearing surfaces should be avoided. The cotton ravelings may become entangled under the bearing surfaces and destroy the su rface of the bearing . FIG . 20 - MANUAL HANDLE ADJ U STMENT 19 .c om SECTION 7-Breaker Maintenance ( Cont.) Remember, before i nstalling the breaker back i nto its compartment, the drawout mechanism m ust be returned to the D I SCONN ECT position. 7.4 S LOW CLOSING TH E B R EAKER Closing the breaker slowly, while observing the action of the mechanism and contacts, is a good way of judging the correctness of mechanical and contact re lationships. Some of the maintenance procedures described later will i nvolve operating the breaker i n th is manner. The proce dure for slow closing is given below. Remove the hex-head bolt only, do not remove or loosen the slotted head screw shown in Fig . 2 1 . Removal of the slotted head will cause the closi ng spring to become dis engaged from the camsh aft with considerable force. Verify that this screw remains tightened during the slow close operation. ua ls Maintenance or inspection should be cond ucted with the breaker on a workbench. The d rawout mechanism m ust be placed i n the CONN ECT position . This will deactivate the various i nterlocks wh ich would otherwise prevent the mechanism or contacts from closi ng. Engage the racki ng handle with the racking shaft and turn clockwise until it stops. After the bolt is removed, use the maintenance handle to rotate the ratchet assembly rol ler onto the closing p ro p (see Charg i ng Usi n g The Mai ntenance Handle, sec tion 5.4). At t h i s point, the c l os i ng prop m ust be removed by either pushing the CLOSE button on Manual breakers, or pushi ng the closing solenoid armatu re on electric breakers (see Fig. 1 3). When the closing p ro p i s removed, con t i n ue turn i ng the camshaft. When the ,contacts and mechan ism are in the fully closed position, the cam will support the cam rol ler (refer to Fig. 10 & section 5.3) and the contacts w i l l develop max i m um depression. an D RAWOUT MECHANISM POSITION Push the TRI P button to release the mechanism and open the contacts. tM 7.3 CAUTION The mechan ism and contacts w i l l o pen with normal speed and force. - When replac i n g the hex-head bolt, t u rn the camshaft with the mai ntenance handle to a l i g n the m at i n g holes i n the lower spring assembly a n d camshaft l i n kage. ww w .E lec tri ca lP ar The c l o s i n g s p r i n g m u st be i s o l ated f ro m t h e mechanism camshaft. This is done by discon necti ng the lower spring assembly from the mating camshaft linkage. Remove the hex-head bolt as shown i n Fig . 2 1 . Remove this bolt only with the mechanism i n the D ISCHA R G E D position and the spring at its m inimum exte nsion. 20 FIG. 21 - SLOW CLOSI NG-LOWER S PR ING ASM HARDWAR E .c om SECTION 7 -Breaker Maintenance {Cont.) 7.5 P R IMARY DISCONNECTS lP ar tM an ua ls Primary disconnects are found only on drawout break ers. They provide the f lexible connection between the breaker line and load terminals and the equipment line and load terminals. The 800 ampere b reake rs w it h the exception of AKR 30L use four primary d isconnect fingers per term inal. The 1 600 amp, 2000 amp and AKR 30L b reakers use eight fingers per term inal. Fig. 22 shows a line and load end d i sconnec t assembly. The line end d iscon nects on fusible breakers have the spring pointing downwards , otherwise t he are identical. FIG. 22 - P R I MARY DISCONN ECT ASM w .E lec tri ca ASSEMBLY FIG. 23 - PARTIAL P R IMARY DISCONNECT ww FIG. 24 - PARTIAL P R I MARY DISCONNECT ASM FIG. 25 - PARTIAL P R I MARY DISCONNECT ASM 21 .c om SECTION 7-Breaker Maintenance (Cont.) 7.5.1 R EP LACEMENT Figs. 2 2 , 23, 24, and 25 show the primary d isconnect assem bly breakdown. Refer to these illustrations when replacing the disconnects. Note the following details: ua ls Fig. 25 - The position of the spacer i n the breaker stud. The hole i n the spacer must be positioned as shown so it will align with the holes in the clip. Fig. 24 - The engagement of the fingers with the re tainer. Also the location of the 'bowtie' spacers i n the fingers, both upper and lower. Fig. 22 & 23 - The position of the u pper and lower retainers and , agai n, the 'bowtie' spacers. The primary disconnect assembly is factory adjusted to apply a force of 85-1 05 pounds on a 1 /2 thick copper bar i nserted between the upper and lower fingers. After i nstal lation of the disconnect assembly this force range is ob tained by tightening the locknuts to set the d i mension shown i n Fig. 26 . 766" to . 797" Note that this d imension is measured between the top of the retainer and the underside of the washer. Also note that no bar is inserted between the fingers when setting this d imension. an ADJUSTMENT FIG. 27 - AUXILIARY SWITCH LINKAG E 7.6.1 REPLACEMENT Either switch type may be d ismounted by removing the two bolt screws which fasten it to the mechanism frame. The GE S8- 1 2 replacement switch should have its cran k shaft set so that the arrow head on the end of the sh aft poi nts as shown in Fig. 28A when the breaker is open. tM 7.5.2 tri ca lP ar The Electro Switch replacement should have its crank shaft set so that the horizontal line on the end of the shaft is as shown in Fig. 288 when the b reaker is open. 7.6 lec FIG. 26 - P RIMARY FINGE R ADJUSTMENT AUXILIARY SWITCH .E All electrically operated breakers and manual breakers having shunt trips are supplied with auxi liary switches. Depending upon the requi rements of the breaker's applica tion, the switch may contain from two to six stages. Usually, each stage has one "A" contact and one " 8" contact. "A" contacts are opened or closed as the breaker is opened or closed. "8" contacts are the reverse of this. ww w The auxiliary switch is mounted on the upper side of the mechan ism frame as shown in Fig . 27. A cran k on the main shaft operates the switch through an adjustable link which connects it to the switch crank. The switch can be a G E type "S8- 1 2" or Electro Switch Type " 1 01 " . 22 FIG. 28A - GE SB- 1 2 CRANK SHAFT POSITION FIG. 288 - ELECTRO SWITCH C RANK SHAFT If a switch is added to a breaker havi ng none, the ad j usting l ink wil l also have to be i nstalled. This is connected to the pin on the crank which is attached to the main shaft. It is secured by means of a cotter pin. 7.6.2 ADJUSTM ENT GE SB- 1 2 I f a new adjustable link is installed, its length should be set, before installing, at 6.375 inches, between pin centers. After instal l i ng a new switch, its operation should be checked. Viewing the switch from above, the contacts toward the front of the breaker are normally the "8" con tacts. Even if a special switch is used, it is always the case that the first two stages nearest the crank have the "8" contacts to the front, and the "A" contacts towards the back. "A" contacts are c losed when the breaker is closed. "8" contacts are c losed when the breaker is open. .c om To check the setting, arrange the breaker for "slow close" as described in Section 7.4. Through the use of a continuity tester, observe the position of the breaker con tacts when the switch "A" contacts touch. At this point the breaker's arcing contacts must be within .250" to . 500 " of closing. Adjustment is made by disconnecting the upper end of the adjustable link and varying its length as required. E LECTROSWITCH TYP E 1 01 SHUNT TRIP The shunt trip device opens the breaker when its coi l is energ ized. An "A" auxi l i ary switch, which is closed only when the breaker is closed, is in series with the device coil . Connections are made to the external tri pping sou rce through secondary disconnects on drawout breakers, or to the terminal board on stationary breakers. The armature of the undervoltage device may be tied closed in order to permit breaker operation d uring main tenance. tM The shunt trip is mounted on the underside of the breaker front frame as shown in Fig. 29. A second shunt trip may also be mounted to the frame (see Fig. 30) if a se cond undervoltage device isn't already instal led, see Sec tion 7.8. FIG. 29 - SHUNT TRIP AN D UN DERVOLTAGE MOUNTING armature will "pick up" and allow closing if the applied voltage is 85% or more of the coil rating. It may also pick u p at a lower voltage. Refer to table 2 5 for picku p and dropout ranges. an 7.7 ua ls Adjustment is the same as the GE S B 1 2 except that when the switch "A" contacts touch, the breaker arcing contacts m ust be w ithin 0 to .250 inches of c losing. 7.7.1 REPLACEM ENT A second undervoltage may also be mounted to the frame (see Fig . 31) if a second shunt tri p isn't al ready instal led, see Section 7 . 7 . 7.7.2 ADJUSTM ENT ca lP ar If it is necessary to replace or add one of these devices, the easiest procedure is to remove the mounting bracket, shown in Fig. 29, from the breaker frame and remove the d evice from the bracket. If a replacement or new device is ordered, a mounting bracket will be s uppl ied with the device. If a second shunt trip is added, this is mounted by means of an additional bracket as shown in Fig. 30. This additional bracket is fastened by two of the hex head bolts used to fasten the buffer assembly to the breaker frame. The undervoltage device is mou nted to the underside of the breaker front frame as shown in Fig . 29. 7.8.1 REPLACEM ENT To replace an undervoltage d evice, remove the mount ing bracket (shown in fig . 29) from the breaker frame and remove the device from the bracket. Re-install in reverse order, noting wire routing and secu ring means. Set the gap between the trip paddle and device arma ture to approximately 0.030 inch as a starting point, then proceed with the operational check (7 .8.2). .E lec tri When these devices are i n stal led or replaced, their positive abil ity to trip the breaker m ust be demonstrated. This is done by placing a 1 /32-inch sh im between the ar mature and magnet of the device and manually operating the armature to trip the breaker. If the shunt trip is not successful in this test, check the mounting fasteners to make sure they are reasonably tight. If they-are, then bend the trip padd le on the trip shaft to slightly reduce the distance between the trip arm of the device and the trip paddle, and recheck for positive trip. If this bending is necessary, be careful that it is not over done. Verify that there is a .030 "-.050 " gap between the trip arm and the trip paddle with the breaker closed . A gap greater than .050" is perm itted and m ay sometimes be necessary in order to prevent n uisance tripping. Re-verify positive trip as a final check. If a second undervoltage device is added, a new buffer assembly block will be suppl ied. This is required for clearance, in this case, the buffer assembly must be taken off, disassembled, and remounted together with the number two undervoltage device. Before disassembling the orig inal buffer, carefully measure the distance between the faces of the threaded members as shown in Fig. 31 , and set this di mension carefu lly on the new assembly. Refer to the breaker wiring diagram for the coi l lead connections. UN D E RVOLTAG E DEVICE w 7.8 ww The undervoltage device trips the breaker when its coil is de-energized . The leads of the coil are connected directly to secondary disconnects or to a terminal board . U nder normal conditions, the coil remains energized and t he breaker may be closed. Dropout of the armature, with resultant breaker trip ping, occurs when the voltage is reduced to a val ue between 30% and 60% of the coil rating . An open armature will render the breaker incapable of closing . The FIG. 30 - 2ND SHUNT TRIP INSTALLATION 23 .c om SECTION 7 -Breaker Maintenance (Cont.) ua ls I FIG. 31 - 2ND UNDERVOLTAGE DEVICE .00 1 " .010" ca lP ar 7 .8 .2 OPERATIONAL CHECK (BREAKER WITH UV DEVICE INSTALLED) Check the pickup and d ropout values at room tempera ture. See table 2 5 . Check t h e positive trip abi lity a s follows: With the armature closed, close the breaker. Insert a 0.032 ± . 005 inch shim (wire gage or flat stock) against the armature open stop (see Fig. 32 D) and release the armature. The breaker must tri p . an TRIP PADDLE ASM MODIFIED BUFFER ASM tM MAINTAIN THI DIMENSION D ROPOUT VOLTAGE: On AC devices the d ropout level will fall within the req u i red limits (30% to 60% of the coil rating) if the pickup is set properly. On DC d evices, the d ropout level may need independent adjustment. This is accomplished after the pickup level has been established per the above procedure. If requ i red, use the closed gap adjustment screw shown in Fig. 32C to obtain the d ropout setting. A gap must remain between the armature and magnet on DC devices to prevent seal ing in u pon loss of voltage. Secu re the adjustment screw with the locknut and apply RTV to the locknut. POSITIVE TR I P: Check positive trip ability per 7.8.2. Adjust the trip paddle screw if necessary to assure positive t ri p . With the undervoltage d evice closed (picked u p), and the mecha nism reset, there m ust be clearance between the trip paddle and the device armature. If clearance adjustment I S necessary, re-verify positive trip ability. 7.8. 3 ADJUSTM ENTS If the operational checks (7. 8.2) indicate that adjust ments are necessary, these procedures should be followed: verify tri p latch engagement as described in sec tion 7 . 1 5 , and verify that the trip shaft torq ue requ ired to tri p a closed b reaker is no g reater than 24 inch-ounces. Then proceed as follows: PICKUP VOLTAGE: The Q.i.Q.!s!,m level is changed by turning the adjustment screw shown in Fig. 32A. The screw is secured by either a locking wire or a jam nut inside the frame. Devices with a jam nut requ ire removal of the device to make this adjustment. The pickup voltage at room tem peratu re (approx. 20-24 oq should be 85 % or less of coil rating and should be measured at the secondary d isconnects with the coil energized . Note: On DC devices set the gap .E lec tri First w between the armature and magnet initially to 0. 030 inch using the closed gap adjustment screw shown in Fig. 32C before making pickup adjustments. ww Be sure to secure the pickup adjustment screw with the jam nut o r lockwire. 24 FIG. 32A UNDERVOLTAGE DEVICE 7.8.4 FACTORY SETTINGS �rouble shooting. This section covers certain factory settings a s an aid to They are for reference only, and are not mtended to be field adjusted. They should not be consid ered criteria for acceptance or rejection. AR MATU RE LOCATI N G RIVET: The rivet shown in figu re 32A serves as a locater for the armature. A clearance of 0.001 to 0. 0 1 0 inch should exist between the rivet and armature as shown in fig. 32A. The rivet should be able to turn freely. ARMATU RE OPEN GAP : The air gap between the armature and the magnet with � he d evice d e-energized should be approximately 0.250 mches. This is, checked by inserting a 0.201 ± . 005 inch d iameter gage pin between the armature and magnet as shown in Fig. 328. .c om INSERT WIR E G A GE ua ls OPEN GAP ADJUSTM ENT an FIG. 328 - OPEN GAP CHECK POSITIVE TRIP CHECK � No more than one undervoltage tripping device should be used i n conjunction with one static time-delay unit. lP FIG. 32C - CLOSED GAP CHECK ar When installed, the voltage to be monitored is connected across term inals No. 1 and No. 2 of the static delay box. The coil of the tripping unit is connected across terminals No. 4 and No. 5 of the static box through the secondary disconnects of the breaker. The secondary disconnects to be used will be shown on the breaker wiring diagram. ADJUSTMENT STATIC TIM E-DELAY U N DERVOLTAGE ca 7.9 - tM FIG. 320 tri The static time-delay undervoltage system consists of a time-delay unit which controls an i nstantaneous under voltage device. The time-delay unit is separately mounted in the switchgear and the undervoltage device is mounted on the breaker. Table 5 1ists the catalog n umbers available. .E lec If the a-c control voltage is any voltage other than 208/240V ac, a control power transformer (also remotely mounted with respect to the breaker) m ust be used. This must have a minimum rating of 100 volt-amperes. TAB L E 5 The static time-delay undervoltage can also be furnished with a thermotector control unit. Overheating of motor win dings causes the thermotector, imbedded in the motor win d ings, to open. This de-energizes the undervoltage device on the breaker and drops the motor load. 7.9.1 ADJUSTM ENTS In the event the system fails, the following checks are recom mended to determi ne whether the undervoltage device on the breaker of the static time delay unit is the faulty component. 1. Check input voltages across terminals 1 and 2 on the static box. See Table 5 for these values. 2. Check output voltages on terminals 4 and 5 with the undervoltage device connected. See Table 5 for values. TIM E-DELAY U N ITS CONTROL VOLTAGE TERMINALS 1 & 2 APPROXIMATE STEADY STATE DC OPERATING VOLTAGE TERMINALS 4 & 5 NOMINAL DC COIL RESISTANCE (OHMS) @ 25°C 1 25 VDC 50 440 TAKYUVT-2 250VDC 1 00 1 600 TAKYUVT-3 208/240 VAC 1 1 0/ 1 25 1 600 CAT. NO. ww w TAKYUVT-1 25 .c om SECTION 7 -Breaker Maintenance (Cont.) 3. Check resistance of the disconnected undervoltage device. See Table 5 for values. See i nstruction Sheet G EH-4545 for more detai led infor mation, i ncluding schematic diagrams and circuit descrip tion. \ FIG. 33 - ELECTRIC LOCKOUT DEVICE 7. 1 1 BELL ALARM tM an Th is device is used to g ive a remote i ndication of the breaker having tripped open through the , action l of one of its automatic protective devices. It wi l l not be activated by manual tri pping or the action of the shunt trip. A remotely mounted protective relay energizing the shunt trip will there fore not result i n the remote alarm action. The bel l alarm circuit may be turned off by pushing in the manual trip or by energizing the shunt trip. In the latter case, a normally open contact of the bel l alarm switch m ust be wired in parallel with the "A" auxiliary switch contact in the shunt-trip circuit. Closing the breaker will also turn off the alarm. ar 7. 1 0 ELECTRIC LOCKOUT DEVICE The electric lockout device uti l izes an undervoltage device to keep the breaker from resetting its mechanism if the breaker is open and the undervoltage device coil is not energized. The breaker thus cannot be closed unless voltage is on the. coil . Once the breaker is c losed, loss-of voltage will not trip the breaker because, in the closed posi tion, a mechanical link is used to hold down the armature of the device. See Fig. 33. This arrangement provides a means of electrically interlocking two breakers so that they cannot be c losed at the same time. Each undervoltage coi l may be wired in series with a " B " auxiliary switch contact on the other breaker for cross-interlock purposes. On each breaker havin g an electric lockout, an arrange ment is made wh ich will al low breaker closing with the coil de-energized. This is provided to al low "start-up': on "dead" systems. Fig ure 34 shows this device. The push s lide shown is located in the opening in the lower part of the escutcheon. This breaker door m ust be opened to gain access to it. ua ls The undervoltage device must be calibrated through the time-delay unit after the device pick up has been adjusted. A .008 inch minimum closed gap m ust exist between the ar mature and magnet as shown i n Fig. 32C. Refer to Section 7.8.3 and Table 24. lP The bel l alarm device may be equipped with a lockout link which will lock the breaker open unti l the bel l alarm device is reset. /-_ ----/____ I 1 _ -/ ·-]--'\ ' "\ -.� .· .� - '• I lL - · _ 1 \ . \ -.- ! .! . . �-. ''---' _I "'- lec / / - /ll ' : 1 -� tri ( ca MA I N SHAFT ( BREAKER CLOSED) · � The bel l alarm is not a standard device and is suppl ied only when specified on the breaker order. 7.1 1 .1 OPERATION Referring to Fig. 35: the bel l alarm mechanism is ac tivated by a crank which is assembled to the breaker's main shaft. When the breaker opens, a pin attached to this crank moves the alarm link against the switch and locklever (if provided). This activates the switch contacts. It also moves the locklever adjustment screw against the trip shaft paddle keeping the breaker trip free. SWITCH ( �� � ww w .E l .....!--- UV DEVICE ...__ _ _ � FIG. 34 - ELECTRIC LOCKOUT BY-PASS 26 LATCH ENGAGEMENT POINT FIG. 35 - BELL ALARM DETAILS .c om SECTION 7-Breaker Maintenance ( Cont.) ADJ USTM ENTS The bel l alarm is mounted on the right hand side of the breaker at the rear of front frame. It is located under the mechanism main shaft. The be l l alarm is removed by passing it through a cutout in the rear bend of the front frame, slipping it between the front frame and trip shaft and out through the bottom of the breaker as fol lows: 1 . Remove the 4 bel l alarm mounting screws from the bottom of the front frame. 2. If the crank which is part of the main shaft has a bel l alarm activating pin assembled to both sides, remove these pi ns. 3. Insert the flat of the mai ntenance handle between the top of the left hand side buffer block and the end plate assembly. This should eliminate any interference from the main shaft duri ng the bel l alarm removal. 4. The trip shaft m ust be moved to allow the bel l alarm to fit beteen it and the front frame. Remove the retaining ring holding the right hand tri p shaft bearing to the mechanism frame. Slide the bearing from the frame and along the trip shaft. There will now be enough trip shaft movement to slip the bel l alarm past. 5. Install the replacement bel l alarm in reverse order. 6. Check the adjustments given in Section 7.1 1 .2 tM If a breaker is equipped with a bel l alarm/lockout device orig inally, all the adjustments are made at the time of assembly. Switch operation is control led by means of shims of insulating material placed between the switch body and the bracket to which it is fastened. The adjust ment screw is positioned so that when the locklever is in its activated position, it holds the breaker mechanism latch in the tripped position. REPLACEMENT ua ls 7.1 1 .2 7.1 1 .3 an The mechanism i s reset by disengaging the side latch link from the upper latch link or by closing the breaker if a locklever is not provided. The side latch l ink, is activated only by pushing the TRIP button or operating the shunt trip. A slide attachment on the TRIP button shaft moves against the side latch link when the TRIP button is pushed. This slide attachment is factory adjusted to activate the side latch before the breaker is tripped. A second arm on the shunt trip also activates the side latch link when the shunt tri p is energized. ar Check that TRIP button shaft and shunt trip operations, besides tripping the breaker, displace the side latch and prevent the bel l alarm switch from operating. The other trip devices and interlocks must activate the bell alarm when they open the breaker. CHARGING MOTOR ww w .E lec X - R ELAY ELECTRICAL CONTROL COMPON ENTS 7.1 2 The operation of the electrical control components i s described i n Section 5.2. The location o f these components is shown in Fig. 36A. tri W RELAY ca lP The bracket assembled to the TRIP button shaft m ust be adjusted so that it will displace the side latch when or before the shaft opens the breaker. Maintain a .030 inch minimum gap between the bracket and the side latch when the breaker is closed. A . 1 87 i nch depression of the TRIP button must not trip the breaker, but a .375 inch depres sion must trip the breaker and displace the side latch. A bel l alarm with a lockout assembly or a bel l alarm in stalled on a 2000 amp frame (AKRT 50/50H) breaker may not work with the above procedure. If this is the case, the breaker front and back frame will have to be seperated. G SWITCH F SWITCH FIG. 36A - ELECTRICAL CONTROL COMPONENTS 27 .c om SECTION 7-Breaker Maintenance (Cont.) 5 COM PONENT REPLACEMENT To gai n access to the electrical control com ponents, the breaker's front escutcheon m ust be removed. Type B and D breakers requ i re that both the deep molded escut cheon and the shal low steel escutcheon be removed. Before removing the front escutcheon on Type A or B breakers, a supporting block should be placed u nder the front frame to keep if from tipping forward. 4 an 1 . RETA I N E R R I N G 2. WASHER .01 0 " 3. PAWL ASM 4. SPRI NG WASH ER WAS H E R .032 " 6. MOTOR DRIVE PIN 5. FIG. 36B - DRIVING PAWL ASSEMBLY DETAILS The holding pawl pivots on a pin wh ich is assembled to the mechanism frame. Refer to Fig. 36C. To replace the hold ing pawl: 1 . Remove the front escutcheon for accessibility. 2. Using the maintenance handle, rotate the ratchet enough to d isengage the holdi ng pawl. 3. Remove the retaining ring and washer from the pivot pin. 4. Wh ile holding the spring pressure from the holding pawl, remove the existing pawl and slip on the new pawl. 5. Install the washer and retaining ring. 6. Verify that the holding pawl engages a minimum of 4 ratchet laminations. 7. Verify that the holding pawl pivot pin is perpendicular to the mechanism frame. The hardware wh ich assembles the pivot pin to the frame m ust be torqued to 250 in-lbs minimum. If this hardware must be retightened, add LOC TITE 290 to the shaft threads. 8. Install the front escutcheon. Tighten the escutcheon hardware to 80 ± 10 in-lbs. ca lP ar The charging motor is secured through three spacers to the mechanism frame. The front mounting bolt is accessi ble using a socket and universal joint through the opening in the side of the breaker frame. The upper rear mounting bolt i s accessible using a socket and universal joint over the top of the frame. The lower rear mounting bolt is ac cessible using a socket and universal joint through the opening in the frame side by the buffer assembly. Slow close the breaker to move the flywheel assembly out of the way. \ tM Referring to Fig. 36A, the X-relay or K-relay and F and G switches are mounted on the same bracket. This mounting bracket i s fastened to the right-hand mechanism side frame by two hex-head 1 /4-20 screws. Removing these screws allows the bracket to be pulled forward from between the mechanism side plates. The W-relay m ust also be un fastened from the left side frame to allow enough freedom for all the devices and the wiri ng harness to be taken from between the side frames. With the bracket removed, in dividual devices can be replaced easily. The closing solenoid is mounted by means of mounting bracket to the bottom of the breaker frame. The most con venient way to take off the solenoid is to remove the moun t ing bracket and then d isconnect the solenoid from the bracket. The pin connecting the armature to the closing link must also be removed. 2 ua ls 7.1 2.1 .E lec tri The ratchet on the camshaft is removed by driving out the rol l pin which fastens it to the camshaft. Before this can be done, the charging motor m ust be removed and the closing spring arranged for "slow-closing" as descri bed earlier. Turn the camshaft, using the maintenance handle, until the roll pin is well situated , turn the camshaft to gain enough space for the rol l pin to clear the breaker frame. Before removing the ratchet note the position of the ratchet rol ler or mark the ratchet hub and the camshaft. 3 When replacing the ratchet, be sure it is oriented with respect to the camshaft as it was originally and not d isplac ed 1 80 degrees. Align the mark made on the hub with the mark on the camshaft or position the roller as it was. If the ratchet is displaced 180 degrees, the holes in the ratchet hub will not completely line up with the holes i n the cam shaft. ww w The d riving pawl is assembled to the ch arg i n g motor drive pin as shown in Fig. 36B. To replace the driving pawl: 1 . Remove the charging motor. 2. Remove the retai ning ring from the drive pin. Sl i p off the components. 3. Wipe off any grease or d i rt from the drive pin. DO NOT LUBRICA TE. 4. Install the components as shown. 28 4 6 7 I I 5 1 . MECHANISM FRA M E 2. PIVOT PIN 3. SPRI NG 4 . WASHER .032 " 5. PAWL ASM 6. WAS HER .01 0 " 7. RETA I N I N G R I N G FIG. 36C - HOLDING PAWL ASSEMBLY DETAILS .c om 7 . 1 2.2 F AND G SWITCH ADJUSTME NT For proper electrical operation, the F and G mechani cally operated switches must operate at the proper point in the closing cycle. If these switches are to be replaced, measure the distance between the tip of the switch button and the bracket on which they are mounted. When the new switch is mounted , duplicate the measured d i mension , then check for proper operation. When a normal closing o peration occu rs, the ratchet usual ly comes to a stop with an arbitrarily desig nated ratchet tooth No. 1 , Fig. 37 , engaged by the holding pawl. This tooth is the one which i s i n l i ne with an i m ag inary line passing through the centers of the camshaft and the rivet o pposite the roller on the ratchet assembly. It is a matter of no concern if the action stops on a d ifferent tooth, but it is i mportant to positively identify tooth No. 1 by the method described. ua ls an FIG. 37 - LOCATION O F RATCH ET TOOTH N0. 1 tM To check the switch action, after tooth No. 1 has been identif ied, turn the camshaft with the maintenance handle and count the teeth as they pass the holding pawl. By using a continuity tester, observe when the switches operate as the ratchet turns. The normally open F switch on the left will close , and the G switch will open. 1 TOOTH Electrical breakers should operate the switches while moving from tooth No. 10 to tooth No. 1 1 . 7.1 3 lP ar If this check shows that an adj ustment is needed, the switch to be corrected can be moved closer to or farther away from the paddle which operates the switches. A very thin open-end 5/8-inch wrench will be needed to loosen or tig hten the nuts which fasten the switches to the bracket. DRAWOUT MECHANISM ca The drawout mechanism shown in Fig. 38 moves the breaker through the DISCONN ECT E D , TEST, and CON N ECTED positions. F i g . 39 shows how the drawout mechanism is mounted to the breaker. lec tri As the racking handle is turned, the internally threaded trunnion moves on the screw threads, rotating the hex shaft, on the ends of which are fastened the arms which engage the fixed pins in the drawout enclosure . .E The trunnion travels between the two jamb nuts on the end of the screw, and the adjustment sleeve , which stops the trunnion movement at the other extreme point of its travel . The trunn ion is agai nst the jamb nuts when the breaker is fully racked out and against the sleeve when fully racked in. . .I ww w The racking mechanism is adjusted at the factory as se mbly operation so that the action is stopped in either direction at the precisely correct point. The jamb nuts are set so that when the tru nnion is against them the relation between the arms and the equ ipment pins they engage is shown in Fig . 38. The length of the sleeve , which is free to slide on the threaded shaft, is controlled by the amount of thread engagement between the sleeve and its col lar. This length is adjusted to stop the trunnion when the distance between the ends of the equipment and breaker studs is .032" to . 2 1 8 " . After this adjustment is made, the sleeve and its col lar are locked together by the set screw. 29 7- Breake r Maintenan ce (Cont. ) .c om SECTION . ' ua ls -A RM A DJ US TME NT SL EE V E L UB RI CA TiO N R an C OLLA TiON tM FIG . 38 - D F!A WO U T IIIECiiA NI 30 ww w .E lec tri ca lP ar S IIf D E TA il FIG . 39 - DFfA WOUT NIECI-fA. NISNI I NS TA llED S .c om SECTION 7-Breaker Maintenance (Cont.) BUFFER ASSEMBLY When the breaker is closed , the energy in the c losing spring i s transferred to the m a i n s h aft thro u g h the mechan ism. The main shaft then drives the contacts closed. The end plate assembly on each end of the main shaft is driven against the buffer assembly shown in Fig. 40. This prevents the mechanism from overdriving the contacts. When the break�r is opened, the end plate assembly is driven against the opposite end of the buffer assembly. The buffer is a stop absorbing the opening energy of the mechanism. See Fig. 41 . ua ls 7.1 4 - BU FFER/END P LATE R E LATIONSHI P-BR EAKER CLOSED ., E N D PLATE ww w .E lec tri FIG. 40 ca lP ar tM an E N D PLATE FIG. 41 - B U FFER/EN D P LATE R E LATIO N S H I P- B R EAKER OPEN 31 .c om SECTION 7-Breaker Maintenance (Cont.) 7.14.1 NEOPRENE WASHERS B U FF E R ADJUSTMENT Referring to Fig. 40, with the b reaker closed and the m echanism not reset, a . 005" clearance m ust exist be tween the end p late assem bly and the buffer nut as shown. This dimension is factory set. It can be reset by tightening the buffer n ut. Hold the nut with a screwdriver and tighten using a socket on the bolt head opposite th e nut. When tighten ing this assem bly don't over com p ress the neo prene washers by overtightening the assem b ly. These washers absorb the breaker o pening shock. an Referri ng to Fig. 41 , with the breaker open, a .040 " m ax i m u m c learance can exi st between either of the end plate asse m b l i es and the buffer bolt heads as shown. If a larger c learance exi sts, c lose it u p by u n screwing the buffer asse m b l y i nvolved. TRIP LATCH ADJUSTMENT t---- 1 . 9 3 ---t FIG. 42 - B UFFER ASSEMBLY ww w .E lec tri ca lP ar The reset position of the trip latch is set by the adjust ment screw shown in Fig. 43. The adjustment is correct if three and one-half turns of the adjustment screw causes a closed breaker to trip. If this check is made, the screw m ust then be set back, or unscrewed, tti ree and one-half turns. tM Fig . 42 shows a buffer assembly prior to being i nstalled in a breaker. The dimensions given establish the number of spacers that are used. 7. 1 5 32 WASHERS ua ls r---- FIG . 43 - TRIP LATCH ADJ USTM ENT 8.1 .c om SECTION 8-Contact Maintenance ARC C H UTE R E M OVAL A N D I N S P ECTIO N Th ere are two types of arc ch ute const ru cti on used on the 800 thru 2000 ampere breakers. They are the ceramic type shown in Fig. 5 and the m o lded type shown in Fig . 6. The c eram ic type uses a two piece porcelain frame to enclose its internal parts. The molded type uses a one piece, glass-fil led polyester frame. When contacts are replaced , they m ust be adjusted to ensure that the proper amount of force is developed be tween the movable and stationary co ntacts when the breaker is closed. This is called the "wipe" adjustment. "Wipe" is the distance through which the stationary co n tacts move when the breaker closes. It is measured bet ween the point of contact on a stationary contact when the breaker is open, and the position of the same point when the breaker is closed . The actual wiping motion is greater because the contacts over-travel . "Wiping" i mparts a slid ing or "scrubbing" action to the contacts . Arc ch utes should not be interchanged between frame sizes or i nterru pting ratings. an The arc chutes are held i n p lace by retainers se c u red by bolts through the mechan ism frame. The cera m i c type uses two retainers and the m olded type uses o n ly one. To remove the arc c hutes: 1 . Loosen and back off the retai ner bolt locking nut from the mechanism frame. They do n ot h ave to be removed . 2 . Loosen the retainer bolts until the retainer(s) can be removed . 3. With the retai ner(s) removed , l ift the arc ch utes off for inspecti on. tM The wipe adjustment i nfl uences proper arc transfer dur ing interruption of fault currents. "Transfer" of the arc is its forced sequential movement from the intermediate con tacts to the arcing contacts to the arc runner and fi nally to the arc qu encher where it is dissipated and extinguished. It is reco m mended that contact wipe be checked periodically during normal mai ntenance i nspections. ua ls Breakers subjected to frequent interruption of high cur rents may eventually requ ire replacement of their contacts. The general rule for determining need of replacement is the loss of one-half or more of the mass of the contact tip material. Roughening or light pitting of the contact surface does not indicate loss of abi lity to carry or interrupt cu rrent. lP ar I n spect each arc ch ute for excessive b u rn i n g and eros ion of the arc plates and arc runner. Also look for fract u res, d amage to the l iner material used in the molded arc chute and d amage to the insu lation m aterial used i n both arc chutes. Check for any m issing parts. To in stall the arc ch utes: 1 . Replace the arc ch utes over each pole u n it . 2 . Locate t h e retainer(s). 3. Tighten the retainer bolts until the arc chutes are secu re. There may be some side to side m otion of the arc ch utes, but there must not be any front to back m otio n . Torq u e the retainer bolts to 30 i n - l bs for the molded type arc ch utes and 60 to 1 00 i n - l bs for the ceram ic type. Do not over tig hten . 4 . Tig hten the lockn uts agai nst the mechanism frame with 1 50 to 1 7 5 i n - l bs torque. ww w .E lec tri ca CAUTION: BEFORE DOING ANY OF THE FOL L O WI N G C O N TA C T A DJ U S TMENT AND RE PLA CEMENT WO R K, MECHANICA L L Y DIS CONNEC T THE CLOSING SPRING FROM THE MECHANISM CAM SHAFT AS DESCRIBED UN DER SLO W CLOSING THE BREAKER, SECTION 7.4 33 .c om SECTION 8-Contact Maintenance (Cont.) The contact structure of the AKR 30 and the AKRU 30 breakers is s lightly different from the AKR 30H. Referring to Fig. 44 A & B, both structures use one moveable contact arm, and two stationary arcing contacts. However, the AKR/AKRU 30 uses three stationary main contacts and the AKR 30H uses four. The following wipe adjustment procedure is appl icable to all AKR-30/30H & AKRU-30. ADJUST GAP AT MEASU R E M ENT POINT TO .060 ± .020 " 1 . Open the breaker, remove arc quenchers. t 2. Slow-close the breaker. The cam roller must be supported by the cam and not the prop. Refer to section 5.3. 5. Repeat above procedure on the other pole units. FIG. 45 - WIPE ADJUSTMENT 800A EXCEPT AKR 30L AMP CONTACT STRUCTURE ww w .E lec tri ca lP 6. Trip the breaker. 0.250 " M EASU R E M E N T POI NT ar 4 . Once the gap dimension is set, verify that the torque required to j ust turn the adjustment nut is greater than 40 in-lbs. If less torque is req u i red, carefu lly add LOCTITE 220 or 290 to the adjustment nut threads. Wipe off any excess LOCTITE. Once the LOCTITE is set, recheck the torque (value u p to 40 in.-l bs.) but d o not break loose. PIVOT STUD tM 3. Select one pole and, using a flat or wire feeler gage, measure the gap between the top contact and its pivot stud as shown in Fig. 45. As necessary, adjust the gap to 0.060 ± 0.020 i nch by turning the wipe adjustment nut shown i n Fig. 45 & 4 6 . ua ls CONTACT ADJUSTM ENT AKR 30/30H & AKRU 30 an 8.2 FIG. 46 34 - WIPE ADJUSTMENT N UT-800 A M P CONTACT STR UCTU R E .c om ar tM an ua ls SECTION 8-Contact Maintenance ( Cont.) ww w .E lec tri ca lP FIG. 44A - AKR30, AKRU30 FIG. 448 - AKR 30H 800 AMP CONTACT STR U CTURES 35 .c om SECTION 8-Contact Maintenance (Cont.) C ON TACT A D J U STM ENT AKR30L, A K R50/50H & A K R U 50 1 . Open the breaker, remove arc q uenchers. 2. Arrange the b reaker for slow-closing. 7. Turn the stud counter-clockwise unt i l the main con tacts j ust touch. 8. From this point, advance the stud counter-clockwise 270 degrees. This wi ll be 4-1 /2 flats. 9. Once the adjustment is complete, verify that the torque required to j ust turn the adjustment nut is greater than 40 in-lbs. I f less torque is requ i red, carefu lly add LOCTITE 220 or 290 to the adjustment nut threads. Wipe off any excess LOCTITE. Once the LOCTITE is set, recheck the torque valve. 10. Trip the br�ker, remove the i nsulating strips. 1 1 . Repeat the above procedure on the other two poles. ww w .E lec tri ca lP ar 3 . Select one pole of the b reaker and p lace a t h i n sheet or stri p of to u g h insu lating material , such as mylar, over the stationary arcing and i ntermed iate contacts. Th is stri p s h o u l d be about two i nches wid e and m ust p revent the arcing and intermed iate contacts from making contact when the b reaker is cl osed . 4 . U sing the ratchet i n g mai ntenance handle, slow close the b reaker with the i ns u lation held in p lace. Examine the insu lation to m ake s u re it "over-hangs" below the i ntermed iate contacts, but not enough to cover the main contacts. 6. Facing the breaker, turn the wipe adjustment stud shown in Fig. 47 clockwise unti l the checker indicates that the main contacts are separated. ua ls The following p roce d u re is used to perform the wipe adj u stment. 5. Attach a continuity checker (bell-set, light, or ohm meter) between the upper and lower stud. The checker should indicate continuity exists. an The contact breaker shown i n F i g . 47 is used by AKR30L and all AKR50 b reaker types. This structure uses two movable contact arms. Each arm acts against a stationary arc i n g , a stationary i ntermed iate and th ree stationary mains. tM 8.3 36 FIG . 47 - 1 600 A M P CONTACT STR UCTU RE There are two designs used to connect the movable contact arms to the insulated link. This results in two con tact adjustment procedures depending on which design the breaker has . In the origi nal design the two movable contact arms are pin-coupled to a metal driving link whose opposite end is th readed and screws directly i nto the insulating link. This arrangement omits the wrench-operated wipe adjustment stud provided on the AKR-30 and -50 frames. Instead, wipe is adjusted by detaching the driving link from the movable contact arms and then rotating it with respect to the insulat ing link. 2 . Arrange the breaker tor slow-closing. 3. Selecting one pole, drift out the coupling pin and detach the driving link from the movable contact arms. 4. Screw the driving l ink completely into the insulating l ink. 5. Back out the driving link two and one- half turns. Ex ceed this by whatever amount is necessary to properly position the l ink within the movable contact arms. 6. Install the coupling pin and retainer rings. 7. U s i ng the m a i ntenance hand l e , slow-close the breaker and observe that all eight stationary main contacts move away from their stops. If this condition is not achieved, open the breaker, agai n remove the coupling pin and back out the driving link an additional halt turn. 8. Reassemble, reclose the breaker and recheck wipe. 9 . Repeat the above procedure on the other two poles. tM On the AKRT -50 the proper amount of contact wipe exists if, on a closed breaker, all of the stationary main contacts have moved away from their stops. This condition can be checked visually by removing the arc quenchers, closing the breaker and verifyi ng that all eight stationary main contacts are " lifted oft" their stops. Should wipe ad justment appear necessary, proceed as fol lows: 1 . Open the breaker. ua ls The contact structure shown in Fig. 48 is used by all AKRT 50 breaker types. This structure is similar to the AKR 50 structure. There are two movable contact arms, each acting against single stationary arcing and intermediate contacts and tour stationary mains. .c om CONTACT ADJUSTMENT AKRT 50/SOH an 8.4 ww w .E lec tri ca lP ar In the existing design, the metal driving link uses the same adjustment as the AKR 50. To perform the wipe adjustment on this design follow the procedure tor the AKR 50, Section 8.3. FIG. 48 - 2000 AMP CONTACT STRUCTU R E 37 .c om SECTION 8-Contact Maintenance (Cont.) 8.5 STATI ONARY CONTACT I DE NTIFIC AT I O N ua ls T h e stationary arc i n g , i ntermediate, a n d m a i n contacts each have a d i fferent function d u r i n g cu rrent con d u ction and c u rrent i nterruption . For this reason, these contacts are made using d ifferent m aterial com positions . Also, the different functions req u i re that the contacts be replaced in configu rations shown in Figs. 44, 47 and 48. ar tM an F i g . 4 9 shows the stationary contacts and how they d i ffer from one another. The AKR 30 and 30H main and arc ing contacts are rectan gu lar, but the arc i n g contacts have two o f t h e i r corners notched . T h e A K R 3 0 L , AKR 50, AKR 5 0 H , A KRT 50 a n d A K R T 50H main and i nterm ediate contacts are rectang u lar, but the main contacts have two of their corners notched . The i ntermed iate contacts have all fou r corners n otched . 800 A M P MAI N EXCEPT AKR 30L ww w .E lec AKR 30L AND 1 600/2000A M P I NTE R M E D IATE tri ca lP AKR 30L AND 1 600/2000 AMP MAIN 38 FIG. 49 - STATIONARY CONTA CT CONFIGU RATION 800 A M P ARCING EXCEPT AKR 30L CONTACT R E P LAC E M E NT AKA 30/30H/30L & AKRU 30 8. 7 .c om 8.6 CONTACT R EP LACEMENT- AKR 30L, AKR 50/SOH , AKRU 50 & AKRT 50 Refer to Stationary Contact Identification, Section 8.5, before replacing any stationary contacts. The stationary contacts are held in place by the contact springs which pivot the contacts against the contact stop, refer to Fig . 45. To replace contacts : The stationary i ntermediate and main contacts are replaced just l i ke the stationary contacts on the BOO ampere breakers. Refer to steps 2 & 3 in Section 8.6 1 . Remove the arc runner. It is secured by two screws into the base and one screw into the contact stop. Referring to Fig . 50A, SOB & SOC, the stationary arcing contacts are replaced as follows. 2 . Release each contact spring by holding the contact, extending the spri ng, and removing it from the contact. The end pieces on each spring have a small hole for inserting a spring puller. A suitable puller can be fashioned by forming a hook on the end of a length of .062" diameter steel wire. 1 . Remove the arc runner and the flat insulation assembled underneath the arc runner. It i s secured with four screws. When removing the lower screws, use care not to damage or m i sp lace the insulating washer found under each of these screws, see Fig. SOA. 3 . Clean off the existing l u brication on the stud's pivot area. Replace with a small amount of D50H D38 (MOBIL 28) before installing new contacts. 4. Torque the upper arc runner mounting screws to 4S S i n-lbs. Torque the lower screw to 3S-40 i n-lbs. 3 . Remove the insu lating spacers, contact pin and arc i ng contacts, see Fig. 50C. 4. Reassemble the reverse of above. Make sure that the insulating spacers and insu lating washers are properly i n stal led. Torq ue the arc runner hardware to 4S ± S i n-l bs. tM ± 2 . Remove the Arcing contact pivot. Clean off the exist ing lubrication found on the pivot area. Repl ace with 050HD38 (MOBIL 28) , see Fig. SOB. an A spring puller is available for this use and may be ordered under Cat. No. 286A81 68G 1 . ua ls Refer to Stationary Contact Identif ication , Section 8.5 before replacing any stationary contacts. The movable contacts are removed as follows, referring to Fig. 46. lP 2. Remove the pivot pin hardware and spring from one side of the pivot pin. Carefu l ly remove the pivot pin. 3. Slip out the contact arm. The movable contacts are removed in a s i m i lar manner as the 800 ampere breaker movable contacts. Refer to Section 8.6. When removing the pivot pin from a 2000 ampere (AKRT 50/SOH) contact assembly, the pivot pin from the opposite contact assembly m ust be s l ightly removed. Th i s provides enough clearance to completely remove the pivot pin. ar 1 . Using a rig ht ang le tru-arc p l iers, remove the tru-arc retai ner on the coupl ing pin. Drift out the coupling pin. ca 4. Place a thin fi l m of DSOH D38 l ubrication on the pivot surfaces of the new arm. Clean any exi sting l ubrication from the pivot pin and place a small amount of DSOHD38 on it. S. Install the new arm, insert the pivot pin, and replace the pivot spring and hardware. Tighten the p ivot pin hard w are to 90 ± 5 i n-lbs. tri 6. Install the cou pling pin and tru-arc retainer. I INSULATING WASHER .E lec 7 . Make the contact adjustment as per section #8.2. ww w ARC R U N N E R FIG. 500 STATIONARY CONTACT -1 600/2000 A M P R E P LACEMENT CONTACT STR U CTUR E 39 .c om lP ar tM an ua ls SECTION 8-Contact Maintenance (Cont.) ww w .E lec tri ca FIG. SOB - ARC RU N N ER REMOVED 40 FIG. SOC - ARCING CONTACT PIVOT REMOVED .c om SECTION 9-Fused Breakers FUSE SIZES AND MO UNTING Table 6 lists the range of fuse sizes available for these breakers. The Class L fuses are mounted as shown in Fig . 5 1 . Other than the 800A size, which has a single mounting hole per tang , each Class L fuse tang has two holes sized for one half inc h d iameter bolts. - This fuse provides a melti ng time-current characteristic that coordinates with 1 600A trip devices. Com pared physi cally with a 2500A N EMA Class L fuse, the special fuse is more compact (shorter) ; its tangs are specially conf igured and offset to achieve the required pole-to-pole fuse spac ing; a special primary disconnect assembly mounts directly on the outboard tang of the fuse. Considering their unique mounting provisions, when replacing these fuses the fol lowing procedure should be adhered to ( Refer to Fig. 53) : a) Remove the primary d i sconnect assem bly from the fuse tang, acco m p l ished by first loosening the two keys via their holding screw and pulling them u pward and out. After the keys are removed , pull the d isconnect assem bly off the end of the fuse tang. NOT E : This removal d o e s n o t disturb disconnect's clamping force adjustment. the tM Class J fuses rated 300 thru 600A have one mounting hole per tang. The 300 , 350 and 400A sizes require copper adapter bars per Fig. 52. S P ECIAL 2500A FUSE FOR AKRU-50 ua ls 9.1 9.2 an There are two types of fused breakers; AKRU 30, 800 ampere frame and AKRU 50, 1 600 ampere frame. Except for the open fuse lockout device and the i ntegrally mounted fuses on the upper studs, the AKR U-30 and -50 breakers are identical to the u nfused AKR-30 and -50 models. Overcurrent trip devices are the same for both types. b) Remove the upper barrier. c) Detach the inboard end of the fuse by removing the two 1 /2 inch - 1 3 bolts. A ratchet and socket with a short extension will be requied. ar All V2-1 3 fuse mounting bolts should be torqued to 200350 in.- lb. The %-1 1 bolts whic h attach the C shaped fuse adapters to the breaker studs should be torqued to 300525 in.-lb. d) Remove the heat sink. f) I nstall the new fuse by reversing the disassembly procedure. E nsure that the mating faces of the fuse and heat sink are clea n . �DAPTER BARS (COPPER) .E lec tri ca lP e) Remove the fuse. FIG. 52 - 300 T H R U 600 AMP C LASS J FUSE MOUNTING ww w FIG. 51 - TYPICAL MOUNTING C LASS L FUSES 41 SECTION 9-Fused Breakers (Cont.) ua ls .c om CAUTION : WHEN REPLACING THE F U S E I N THE LEFT POLE (FRONT VIEW) O F THE BREA KER, NO TE PA R TI C UL A R L Y THA T THIS F U S E I S MOUN TED DIFFERENTL Y THAN THE O THER TWO FUSES. A S SHO WN IN FIG . 54, FOR THIS PHASE THE FUSE IS R O TA TED 1 80 DEGREES A B O U T I TS A XI S S O THA T I TS I N B O A R D TA N G I S POSI TIONED BENEATH THE B REAKER S TU D . THIS TA NG I S OFFSET WITH RESPECT TO THE OPPOSITE END SO THA T R O TA TING THE FUSE DOES NO T A L TER THE POSITION OF THE PRI MAR Y DISCONNECT. 0 FRONT OF B R E A K E R BREAKER STUD FOR THIS POLE O N L Y , F U S E I S ROTATED 1 80' TO POSITION TANG B E N EATH BREAKER STUD FUSE TANGS POSI T I O N E D ON TOP O F B R E A K E R STUD � L·� ·� I 1 . Sp e c ial 2 5 0 0 A Fu s e 2 . D i s c onne c t K e y 3 . Heat Sink 4 . Upp e r Bar r i e r 5 . P r i m a r y Di s c onne ct 2500A. F U S E CAT. N O . G F9F2500 A K l TANG BOLT· HOLES I N USE AK RU 50 WITH SPECIAL 2500 AMP FUSE tM FIG. 53 an � G G ar P R I MA R Y D I SCONN ECT ASSEM BLY ( S E E F I G . 53) MOUNTS D I RECTLY O N OUTBOA R D FUSE TANG FIG. 54 ca lP A K R U 50-2500A FUSE TANG POSITIONS TABLE 6 FUSES FOR AKRU BREAKERS tri Breaker Type A K R U- 30 .E lec NEMA Fuse Class 600V 60 Hz J L � 50 - - - w Special 42 � Mounting adapter required - see Fig. 52 ww • - Am pere Rating G o u l d Shawmut Cat. Nos. Fuse 300* 350* 400* A4J 300 A4J 350 A4J 400 450 500 600 A4J 450 A4J 500 A4J 600 800 1 000 1 200 1 600 2000 A4BY 800 A4BY 1 000BG A4BY 1 200BG A4BY 1 600BG A4BY 2000BG 2500 - Li miter - - - - - - A4BX 800 A4BX 1 000BG A4BX 1 200BG A4BX 1 600BG A4BX 2000BG A4BX 2500GE .c om SECTION 9- Fused Breakers (Cont.) 9.3 OPEN FUSE LOCKOUT DEVICE TYPE A A N D B B REAKER O F LO ADJUSTME NT an FIG. 55- TYP E D B R EAKER OFLO DEVICE ar 9.3 . 1 tM Type D breakers use the Open Fuse Loc kout (O FLO) shown i n Fig. 55. Type A and B breakers use the OFLO shown in Fig. 56A & 56B. Both OFLO's work on the same design . When the fuse opens, the resulting open c ircu it voltage activates the OFLO phase solenoid when the voltage level reaches approximately 90 VAC (the functional test in the factory is accom plished using 1 2 0VAC}. The solenoid armature then d rives a tripping rod against a trip paddle wh ich is attached to the trip shaft. This causes the breaker to open. The armature also d rives the reset button forward i nd icating what phase is i nvolved. The reset button lin kage also holds the trip p ing rod against the trip paddle. The button must be pushed in to release the tripping rod. ua ls This device automatically trips the fuse breaker if one of the fuses opens. When this happens, the breaker is locked open until the reset button of the phase i nvolved is pushed. The breaker should not be reclosed , of course, u ntil the opened fuse is replaced . lP To adjust the Type A and B breaker O FLO ( Refer to Fig 56A): a) Back off tripping rod so that it will not h it the trip paddle when a solenoid is activated . ca b ) Using the mai ntenance handle, close the breaker. c) Manually close the Left pole armature . Screw tripping rod forward u ntil it moves the trip paddle enough to open the breaker. Add two full additional turns. tri d) Close the breaker. TYP E D B REAKER OFLO ADJUSTMENT To adjust the Type D breaker OFLO: a) With the breaker in the CLOSED position and the OFLO reset, adjust the di mension between the end of the tripping rod and the trip paddle to .1 00" - . 1 40 " . b ) With the O FLO energized , the breaker must T R I P a n d t h e R ESET button must move forward t o the front plate . In this condition , the breaker must be held trip-free. .E lec e) Man ually close the Left pole armature again . The breaker must open and the reset button pop out. In this condition close the breaker, it should trip-free. 9.3.2 f) Reset the O FLO , the breaker must now be able to close. g) Repeat for Center and Left poles. h) Check for a . 1 25" minimum clearance between trip ping rod and trip paddle with the OFLO reset. Check for .032" minimum overtravel after tripping rod trips breaker. ww w i ) Hold tripping rod i n position and tighten its lockn ut. 43 .c om SECTION 9-Fused Breakers (Cont.) ua ls � -I/ tM an TRIP PADDLE ar ARMAT U R E R E S ET BUTION ww w .E lec tri ca lP FIG. 56A-DETAILS 44 FIG. 568-INSTALLED TYP E A OR 8 B R EAKER OFLO DEVICE .c om SECTION 1 0-Type SST Overcurrent Trip Device t 8 1 0. 1 ) - - - - - - 1 ua ls The SST is a solid-state, direct-acting, self-powered trip device system . The SST system consists of the SST pro grammer unit, current sensors, and a flux shifter trip de vice . Fig. 57 shows a block diagram of the syste m . PROGRAMMER UNIT I I I SIIDRT lctRCUIT I TARGET I tM SST BLOCK DIAG RAM - ar FIG. 57 TARGET I an Fig. 58 shows a typical SST programmer unit. The pro grammer unit provides the comparison basis for overcur rent detection and delivers the energy necessary to trip the breaker. It contains the electronic circu itry for the vario us trip ele ments. Their associated pickup and time delay ad justments (set-points) are located on the face plate. De pending on the application, programmer un its m ay be equipped with various combinations of Long Time, Short Time, I nstantaneous and G round Fault trip elements . See Table 7 for available ratings, settings and trip characteris tics. Adj ustments are made by removi ng the clear cover over the face plate, unscrewi ng (cou nter-clockwise) the set-point knob, moving the set-point along the slot to the new setting , and screwi ng the set-point knob in. Once all adj ustments are made, install the clear cover to the face plate. I I OYERlMD Each target pops out when its associated trip ele ment operates to trip the breaker. After a tri p, the popped target must be reset by hand. However, neglecti ng to reset does not affect normal operation of any trip element or prevent the breaker from being reclosed. ca lP The SST programmer un its can be optionally equipped with trip ind icators (targets ) . These are pop-out, me chan ically-resettable plungers located across the top of the programmer's front. U nits with a ground fault element employ three targets: from left to right, the first is for over load, the second for short circuit (actuated by the short time and instantaneous elements) and the th ird for ground fault. The latter is om itted on units without ground fault. The programmer unit is mou nted to the lower rig ht of the breaker as shown in Fig. 59. The bracket attached to the top of the programmer, see Fig . 58, engages with a bracket mounted to the underside of the breaker's front frame. TAB L E 7 SST TRIP CHARACTERISTICS Frame Size (Amperes) • Sensor Tap ( - - - - - - 800 .E AKR-30 ww w AKR-50 AKRT-50 CD @ 1600 2000 ) -- lec Breaker Type tri X • Trip Rating in Amperes Sensor Ampere Taps - -- Pick ( Long Time CD (•L) Multiple of X ) SSf PROGRAMMER ADJUSTMENT RANGE (Set Points) Short Time T i me Delay Band (Seconds) @ 800, 1 200, 1600, 2000 Pickup tolerance is ±. 9% Pickup tolerance is ±. 1 0% Multiple of L ) G) Time Delay Band (Seconds) ® .6, .7, .8, .9, 1 .0, 1 . 1 (X) Maximum 22 Intermed . 10 Minimum 4 @ G) -or1 . 75, 2, 2.25, 2.5, 3, 4 (L) ® Pickup Multiple of L Multiple of X ( ) ( 3, 4, 5, 6, 8, 10 (L) 100, 1 50, 225, 300 - or 300, 400, 600, 800 300, 400, 600, 800 - or 600, 800, 1 200, 1600 ( ® Pickup GROUND FAULT Instantaneous Pickup ) G) Time Delay Band (Seconds) .4, .5, .6, .8, 1 .0, 1.2 ( X ) Maximum 0.35 !ntdmed. 0.21 4 , 5 , 6, 8, 10, 12 (L) Minimum 0.095 Maximum 0 . 30 .25, .3, .4, .5, .6, .7 (X) In termed. 0.165 Minimum 0.065 I . 2, .25, .3, .4, . 5 , .6 ( X ) Time delay shown a t 600% of long time pickup setting ( 6 L ) , a t lower limit of band. Time delay shown at lower limit of band. 45 .c om ua ls SECTION 1 0-Type SST Overcurrent Trip Device (Cont.) tM an MOUNTING BRACKET -..... ar FIG. 59 - AKR-58-30 1 0.2 C U R R ENT S ENSORS tri ca lP The SST system uses two types of current sensors, a phase sensor and a ne utral sensor. Fig . 60 shows a phase sensor. Fig. 61 shows the ne utral sensors avai lable. The cu rrent sensor s u pplies the power and sig nal i n puts necessary to operate the trip system . Each sensor has four taps which provide field adjustment of the trip device's continuous ampere rating. ww w .E lec FIG. 58 - SST PROGRAMMER 46 The SST G round Fault trip element operates on the principle that the instantaneous values of cu rrent i n the three conductors (four on 4-wire systems) add to zero unless ground current exists. On SST's equipped with G round Fault, the ground trip signal is developed by con necting each phase sensor in series with a companion primary winding on a ground d iffe rential transformer mounted in the programmer unit. Its secondary output is zero so long as there is not ground current. Application of the G round Fault element on 4-wire sys tems with neutral grounded at the transformer requires the additional, separately mounted neutral sensor (Fig. 6 1 ) inserted in the neutral conductor; its secondary is con nected to a fourth primary winding on the ground differen tial transformer. See Fig. 70. This "fourth-wire" ne utral sensor is an electrical du plicate of the phase sensor, in cluding taps. Therefore, when taps are changed on the phase sensors , those on the neutral sensor m ust be cor respondingly positioned. When used, the neutral sensor is separately mou nted in the bus or cable compartment of the switchgear. I n draw out construction, its output is automatically connected to the breaker via secondary discon nect blocks . See Fig. 62. .c om ua ls an SST PHASE SENSOR WITH TAP BOARD tM - lP ar FIG. 60 BREAKEP MOU N T E D E Q U I P MENT MOUNTED ca \ lec tri 600 - 1 600 A A ww w .E 300 - eoo FIG. 61 100 - 300 - A SST N E UTRAL S ENSORS SHORTING STRAP FIG. 62 - N EUTRAL SENSOR SECONDARY DISCONN ECT BLOCKS 47 .c om REPLAC E M ENT O F C U R R ENT S E N SO R S a) D i s c o n nect the b reaker harness from the tap ter m i n a l board , rem ov i n g cable t i e s as necessary. U n fasten the term i n a l board from the b reaker base. b) At the rear o f the b reaker. remove the two A l len head s c rews to separate the stud con nector f rom the con tact p i vot b l ock. c) Loosen the c l a m p i n g bolt and remove t h e st ud connector. L i ft out the sen sor and its tap term i n a l board. AKRT 50/5 0H - 470 The mounting arrangement of this com ponent is i l l u st rated in Figs. 64 and 65. An electromagnetic actu ator located on the u n derside of the front frame is coupled to the b reaker' s trip shaft via a trip rod d riven by the actuator arm . The actuator is a solenoid whose armat u re is spring- loaded and held in its normal (Reset) position b y a permanent magnet . In this state the s p ri n g is com p ressed. ar lP ca tri .E lec w ww 48 5 . Tap Terminal Board 3 . Stud Connector 7 . Clamp Bolt 4 . Current Sensor 1 0 i n - l bs The Flux Sh ift Tri p d evice is a low-energy, electro magnetic device wh ich , u pon receipt of a trip signal from the p rogrammer u n it, trips the breaker by actuat i n g the trip shaft. 1 . Flux shift Trip Device 2. Allen- head Screws ± 1 0.3 FLUX S H I FT T R I P D EV I C E tM The sensor may be p revented from s l i p p i n g off the sensor stud by adjacent accessories. If t h i s exi sts, the sensor stud m u st be removed from the b reaker base. The stud asse m b l y is sec u red to the base with four bolts w h i c h are acce s s i b l e from the rear of the b rea ker. d) When replac i n g the stud con nector, tig hten the A l len head screws to 250 ± 1 0 in-lbs . Tighten the clamping bolt as fo llows: AKA 30/30H/30L - 1 20 ± 1 0 in-lbs AKA 50/50H - 470 ± 1 0 i n - l bs ua ls Referri n g to F i g . 63, rep l acement o f i n d iv i d u al SST c u rre nt sensors is acco m p l i shed as fo l l ows: an 1 0.2.1 6 . Programmer Unit 8 . Sensor Stud FIG . 63 - AKR-SA-30 B R EAKER WITH SST TRIP DEVICE .c om 5. Verify a l l soc kets are i n serted to the same depth. CAUTION : IN THE EVENT THA T THE S S T TRIP DE VICE M U S T BE RENDERED INOPERA T/VE TO A L L O W THE B R EA KER TO CA R R Y C U R RENT WITHOUT BENEFIT OF O VERCURRENT PROTEC TIO N, THE R E C O M MENDED METH O D IS TO SHORTEN THE TRIP ROD B Y TURNING ITS AD J U S TER END FULL Y C L O C K WISE. THIS PRE VENTS A C TUATION OF THE TRIP SHAFT PADDLE. tM The t r i p device req u i res o n l y one adj u stment - t h e tri p rod l e n g t h . A s s h ow n i n F i g . 66, t h e c l earance between the t r i p rod and the tri p s h aft p ad d l e is g aged by a 0 . 1 09 i nc h d i ameter rod . Adj u st gap to 0 . 1 09 i n c h ± 0.031 i n c h . T o adj u st , o p e n the breaker a n d restore the b reaker mechan i s m to i t s Reset pos i t i o n . Loosen the j am n ut, rotate the adj u ster end u n t i l the proper g ap is attai ned, then ret i g hten the j a m b n ut to 35 ± 5 i n-lbs. ua ls As the b reaker opens, the act u ator arm-is ret u rned to its normal ( Reset) pos i t i o n via l i n kage d riven by a c ra n k o n the b reake r' s m a i n s h aft. The permanent m ag n et again h o l d s the armat u re capt ive i n read i ness for the next trip s i g n a l . 1 . Remove t h e f l ux s h i fter leads f rom t h e h arness. 2. Refe r r i n g to the cabl i n g d i a g rams in Section 1 0.5, the flux shifter leads are RED for point 8 and BLAC K for point E. 3. I n sert the ext ractor too l over the female p i n . W h e n t h e ext ractor tool bottoms o u t , depress the p l u n g e r and force the w i re/socket asse m b l y out of the connector. 4. No too l is req u i red to i n se rt the w i re/socket asse m b l y i nto the connector. I n se rt the assem b l y un til i t snaps i nto p l ace. an So long as the act u ator rem a i n s i n the Reset posi tion, the b reaker can be c l o sed and opened n o rmal l y a t w i l l . H owever, w h e n a c l osed b reaker receives a trip s i g nal f ro m the prog ram mer u n it, t h e act u ator i s energ ized a n d i t s solenoid f l ux o p poses t h e magn �t, a l lowing the s p ri n g to re l ease the armat u re; t h 1 s d rives t h e t r i p rod agai n st t h e tri p s haft p addle, tripp ing the b reaker. ar The ac tu ator i s a sealed, factory-set dev i ce and re q u i res no m a i nten ance or f i e l d adj u stment. I n case of malfunction, the comp lete act uator unit should be rep l aced . When m a ki n g the electrical con nector to the rep l acement u n it, it is recom m ended t hat the brea ker h arness be cut at some conven ient point and the new act u ator leads sold e r-s p l iced together. BREAKER C RANK C L O S E D PO S I T I ON ) MA I N S H AFT ( RESET L I NKAGE - l -L w ww J c:1 H J�g: c < TRIP PAD DLE SIDE VIEW \ r 1 .E lec ( tri ca lP The preferred method is to remove the f l u x s h i fter leads from the A M P con nector u s i n g the A M P extrac t i o n too l , Cat. No. 3051 83 as fol lows: FRONT V IE W -- r I-� �� 0 j� � 0 FIG . 64 - FLUX S H I FT TRIP D EVICE A N D O P ERATING LINKAG ES 49 ca Bottom view lP 4 3 ar .c om tM an ua ls SECTION 1 0-Type SST Overcurrent Trip Device (Cont.) 1 . Actuator 2 . Trip rod adjuster end 3 . Trip paddle T R I P PA..lDLE I N " M ECHA NISM RESET POS I T I O N .E lec " - JAM NUT 0. 1 09 ± . 0 3 1 Dia. w rod ww FIG. 66 50 - Top view 4 . Trip shaft 5 . A ctuator arm 6 . Reset linkage FLUX S H I FT TRIP DEVIC E COMPON ENTS tri FIG. 65 5 TRIP ROD ADJUSTMENT .c om TROUBLESHOOTING a) Breaker tripping in proper response to overc u rrents or inci pient ground fau l ts. b) Breaker remai n i n g in a tri p-free state due to mechanical interference along its trip shaft. c) I n advertent shunt trip act ivat ions. WARN ING: DO N O T CHA N G E TA PS ON THE CURRENT SENSORS OR A DJUST THE PRO GRAMMER UNIT SET KNOBS WHILE THE BREA KER IS CA R R YING CURRENT. Once it has been establi shed that the c i rcuit breaker can be operated and closed normally from the test pos i tion, attention can be di rected to the trip device proper. Testing is performed by either of two methods. 1 . Conduct h i g h-cu rrent, sing le-phase tests on the breaker u s i ng a high cu rrent-low voltage test set. 2. Test the components to the SST system using por table Test Set Type TAK-TS1 (Fig. 67) or TAK-TS2. The appl icable test proced u res are detai led in i n struction Book G EK-64454 and are summarized in Sec tion 1 0.4. 1 . The TAK-TS1 and TAK-TS2 Test Sets are portable i n struments designed for field checking the ti me-cu rrent characteristics and pickup cali brat ion of the SST's various trip e lements. It can verify the abil ity of the Fl ux-Shift Tri p Device to trip the breaker and, i n add i tion, i n c l udes means for. continu ity checking the phase sensors. A TA K-TS1 Test Set is shown i n Fig. 67. The time-cu rrent characteristics for the SST Tri p Device are g iven i n c u rves G ES-6033, G ES-6034 and G ES-6035. ar tM NOTE: For these single-phase tes ts; special con nections m us t be, employed for SST breakers equipped with Ground Fault. Any single-phase in put to the ground differential transformer will generate an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by b) using the Ground Fault Defeat Cable as shown in Fig. 71. This special test cable energizes all the primary windings of the differen tial transformer in a self-cancelling, series-parallel connection so tha t its secondary output is always zero. ua ls W h e n malfu nction ing i s suspected t h e fi rst step i n troubleshoot ing is to exam i ne t h e c i rc u it breaker a n d its power system for abnormal cond itions such as: an 1 0.4 ww w .E lec tri ca lP a) testing two poles of the breaker in series, or FIG. 67 - SST/ECS TEST S ET, CAT. NO. TAK-TS1 51 .c om SECTION 1 0-Type SST Overcurrent Trip Device {Cont.) SST TEST SET The TAK-TS1 and TAK-TS2 Test Sets are portable in stru m ents des ig ned for field-checking the t i m e-cu rrent characteristics and pickup cali bration of the SST's vario u s trip elements. It can verify the abil ity of the Fl ux-Shift Trig Device to trip the breaker and, i n add i tion, incl udes m eans for continu ity ch ecking the ph ase sensors. A TAK-TS 1 Test Set is shown in Fig. 67. The TAK-TS2 funct ions identically to and s u persedes the TAK-TS1 device. The TAK-TS2 can also test the Ver saTri p Mod 2 trip device. 1 0.4.2 For use in troubleshooting, the Com mon to Tap resist ance for SST current sensors is given in Table 8. These values apply to both phase and neutral sensors. TABLE 8 - SENSOR R ESISTANCE VALUES Ampere TAP 2.6 3.9 5.8 7.8 5.3 7.2 1 0 .8 1 4.6 - 6.1 8.2 1 2 .4 1 6.9 600 800 1 200 1 600 6.4 8.8 1 3.5 1 9 .4 - 7.6 1 0 .4 1 5 .8 22.8 800 1 200 1 600 2000 1 0 .2 1 5.8 22.0 28.5 - 1 2 .4 1 9.2 26 . 7 34.7 tM 300 400 600 800 ar "A" - Programmer Unit Only. These tests are con d ucted with the programmer unit discon nected from the breaker. During test, the unit can remain attached to the breaker or may be completely removed from it. - an TO THE BREA KER TRIP DEVICE S YS TEM, EN S URE THA T THE CIRCUIT BREA KER IS COM PLETEL Y DISCONNEC TED FR O M I TS PO WER SOURCE. ON DRA WOUT EQUIPMENT, RACK THE BREA KER TO ITS DISCONNEC TED POSITION. VERIFY THA T THE B REAKER IS TRIPPED. ca lP CAUTIO N : NEVER DISENGAGE THE HARNESS CONNECTOR FROM THE PROGRAMMER UNIT ON A BREA KER THA T IS ENERGIZED AND CARR Y ING LOAD CURRENT. THIS WILL OPEN-CIRCUIT THE CURRENT SENSORS, A L L O WING DANGER OUS AND DAMAGING VOL TA G ES TO DEVELOP. Test scope: 1 . Verify the ti me-current characteristics and pickup calibration of the various trip elements. tri 2. Verify operation of the SST target indicators on pro grammer un its so equipped . Test scope : lec " B" - Complete Trip Device System . For these tests, the programmer unit m ust be mounted on the breaker and connected to its wiring harness. .E 1 . All "A" tests previously described, plus provision for optionally switching the programm er's output to activate the Flux-Shift Trip Device and verify its operation by physi cally tripping the breaker. 2. Check phase sensor continuity. ww w In the event that any com ponent of the SST system does not perform within the limits prescribed in test instructions G EK-64454, it should be replaced. 52 Resistance i n Ohms between COMMON and TAP Terminals 2.2 3.3 5.1 6.8 1 00 1 50 225 300 WARNING : BEFORE CONNECTING THE TEST SET Either of two test modes may be e mployed: R ES ISTANCE VAL U ES ua ls 1 0.4.1 The coi l resistance of the SSTI E CS Flux shifter device is approximately 16 ohms. c) Verify that the harness connections to the sensors meet the polarity constraints i ndicated by the cabling dia gram, i . e . , wh ite wire to COMMON, black wire to TAP . d) On G round Fault breakers serving 4-wire loads, check that the neutral sensor is properly connected (see cabling diagram Fig. 70). I n particular, ( 1 ) Verify that the neutral sensor has the same rating and tap setting as the phase sensors. (2) Check continuity between the neutral sensor and its equipment-mounted secondary disconnect block. Also check for continuity from the breaker-mounted neutral secondary discon nect block through to the female harness con nector (terminals L and N ) . ( 3 ) If t h e breaker's lower studs con nect t o the supply source, then the neutral sensor must have its LOAD encl connected to the source. (4) Ensure that the neutral cond uctor is carrying onl�' that neutral current associated with the breaker's load cur rent (neutral not shared with other loads). tM If n u isance tripping is e ncou ntered on any breaker whose SST components have previously demonstrated satisfactory performance via the TAK-TS 1 Test Set, the s e n s o rs a n d t h e i r c o n n e ct i o n s s h o u l d be c l o s e l y scruti nized. After disconnecting t h e breaker from all power sources, .c om When nuisance tripping occurs on breakers equipped with the G round Fault trip element, a probable cause is the existence of a false "ground" signal. As indicated by the cabling diagram of Fig. 69, each phase sensor is con nected in a series with a primary winding on the G round Fault differential transformer. U nder no-fault conditions on 3-wire load circuits, the currents in these three windings add to zero and no ground signal is developed. This current sum will be zero only if all three sensors have the same electrical characteristics. If one sensor differs from the others ( i . e . , different rating or wrong tap setti ng), the dif ferential transformer can produce output sufficient to trip the breaker. Similarly, disconti nuity between any sensor and the programmer un it can cause a false trip signal. ua ls FALSE TRIPPING-BR EAKERS EQUIPPED WITH G RO U N D FAU LT an 1 0.4.3 a) Check that all phase sensors are the same type (am pere range) . SST CABLING DIAG RAMS lP 1 0.5 ar b) Ensure that the tap settings on all 3-phase sensors are identical. e) If the preceding steps fail to identify the problem, then the sensor resistances should be measured. Since th13 phase and neutral sensors are electrically identical , their tap-to-tap resistance should closely agree. See Table 8. +A ;__ ;__ ;__ ca E I w .E lec tri LEFT POLE CURRENT SENSOR ww +C 11)===}= -1-t1 ==)= :������ � e +B I FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT �-- - - - - J--'-'==-+o-+-< �H<>-+--e ( 48V. de) (TO SCR ANODE) WHITE BLACK WHITE BLACK WHITE BLACK HARNESS CON NECTOR (AMP 201 298-1 ) LOAD PRO GRA MMER CONNECTOR (AMP 201 297-1 ) FIG. 68 - CABLING DIAG RAM - SST WITHOUT G RO U N D FAULT 53 A -�-� A A$ q, B q, c � ' b � ' II �I )===)= ==)= BREAKER BACK FRAME I PROGRAMMER I I I I I I I I I I I I I I I I (48V. de) (TO SCR ANODE) I LEFT POLE CURRENT SENSOR ,- - UNIT - -- , FLUX SHIFT TRIP DEVICE ua ls q,A WHITE BLACK WHITE BLACK an WHITE BLACK \l _ _ _ _ _ tM HARNESS PROGRAMMER CON NE CTOR (AMP 201298-1 ) CON NECTOR (AMP 201297 - 1 ) LOAD .c om SECTION 1 0-Type SST Overcurrent Trip Device j ar FIG. 69 - CABLING DIAG RAM - SST WITH G RO U N D FAULT ON 3-W I R E LOAD ,-- UNIT - -- PROGRAMMER ww w .E lec tri ca lP FLUX SHIFT TRIP DEVICE 54 HARNESS CONNECTOR (AMP 201298-1 ) PROGRAMMER CONNECTOR (AMP 201 297-1 ) 4-WIRE LOAD FIG. 70 - CABLING DIAG RAM - SST WITH G RO U N D FAU LT ON 4-WI R E LOAD .c om an ua ls ANY S S T PROG R A M M E R U N I T W I TH GROUND FA U LT ELEMENT FEMALE END MALE END ww w .E lec tri ca lP ar tM FIG. 71 - CA B LI N G DIAG RAM WITH G RO U N D FAU LT D EFEAT CABLE I N S E RTED B ETWEEN B R EAKER HARN ESS AND SST PROG RAM M E R U NIT - FOR U S E D U R I NG SING LE-PHASE, HIGH C U R R ENT - LOW VOLTAG E TESTING 55 .c om SECTION 1 1 -Type ECS Overcurrent Trip Device The ECS is a sol i d-state, d i rect-act i n g , sel f-powered trip device system . The ECS system con sists of the ECS prog ram mer u n i f shown in Fig. 72, current sensors, and a flux s h i fter trip device. Fig. 73 shows a block d i ag ram of the system. ua ls The ECS trip system essential ly d u p l i cates the SST tri p system descri bed in Sect ion 1 0 except for the fol lowing: 1. Programmer units are l i m ited fo combinations of Long Time, Short Ti me and i n stantaneo us trip elements on ly. The G ro u nd Fau lt element i s not ava i l able. an 2. Phase sensors are not tapped. As l i sted i n Table 9, each sensor has only a s i n g l e ampere rat i n g . A d i fferent sensor is avai lable for eac h of the tabulated ampere rat i n gs, which span the same ran ge as SST, see Fig. 74. lP ar I n a l l other respects the ECS Tri p device system operates and can be treated identical ly to SST. Th is i n c l udes c i rc u itry, size, construct ion, com ponent loca t i o n , pro g ram mer u n i t set poi nts, performance characteri stics, operating range, q ual ity, rel i abil ity and the f l u x s h i ft trip device. Use the same trou bl eshoot i n g a n d test p roced ures for s i n g l e-p hase, h i g h c u rrent-low voltage tests or those employing the TAK-TS1 or TAK TS2 Test Sets. The G round Fau l t test proced u res, of course, do not apply. ECS phase-sensor resistance values are g ive n i n Tabl e 1 0. tM 3. Neutral sen sors are not req u i red becau se there is no G round Fau l t fu nction. FIG. 72 - ECS P ROG R A M M E R UNIT - ECS C U R R ENT S ENSOR w tri .E lec 1)- - - - ca The time-cu rrent ch aracteristics for the ECS trip device are g iven i n c u rve G ES 6032. ww FIG. 73 56 - ECS BLOCK DIAG RAM FIG 74 Breaker Type AKR-30 Frame Size (Amperes) = Trip Rating in Amperes ECS PROGRAMMER ADJUSTMENT RANGE (Set Points) -- - - - - - - • Sensor Rating ( Sensor Ampere Rating ) Pick ( @( L) • Multiple of X 100, 1 50, 225, 300, 400, 600, 800 800 Short Time Long Time ) @ Time Delay Band (Seconds) Maximum @ ( ® Multiple of L ) 800, 1200, 1600, 2000 .6, .7, .8, .9, 1 .0, 1 . 1 (X) @ Pickup tolerance is ±. 9% @ Pickup tolerance is ±. 10% lntermed. 10 Minimum 4 -or- 1. 75, 2, 2.25, 2.5, 3, 4 (L) Maximum 0.35 In termed . 0.21 Minimum 0.095 4, 5, 6, 8, 10, 1 2 (L) an G) @ 300, 400, 600, 800, 1200, 1600 2000 ) Instantaneous Pickup Time delay shown at 600% of long time pickup setting (6L ) , at lower limit of band. Time delay shown at lower limit of band. tM AKRT-50 1600 ® Multiple of L Time Delay Band (Seconds) 3, 4, 5 , 6, 8, 10 (L) 22 AKR-50 ( Pickup ua ls X .c om TABLE 9 ECS TRIP CHARACTERISTICS TAB L E 1 0 - SENSOR R ESISTANCE VALUES lOO 3.0 4.4 4.8 6.4 6.7 6.4 8.8 1 3. 5 1 9. 4 29. 5 - 3.4 - 5.0 - 5.6 - 7.2 - 7.8 - 7.6 - 1 0.4 - 1 5.8 - 22.8 - 34.5 tri ca lP 1 50 225 300 400 600 800 1 200 1 600 2000 Resistance in Ohms between Term i nals ar Ampere Rating ww w .E lec 1 1 . 1 ECS CABLI NG DIAGRAM ;_ ;,_ ;_ � � 4' +A � BREAKER BACK FRAME LEFT POLE CURRENT SENSOR I •c +B FLUX SHIFT TRIP DEVICE 6, b b , I }= = =)= ==)= - - - I ---�- - UNIT PROGRAMMER 1-'-""'-+<>-t-<( �>t- (48V. de) �""'4-<>-t-<C �:>+-- (TO SCR ANODE) BLACK WHITE BLACK WHITE rr r _j BLACK LOAD FIG. 75. CABLING DIAG RAM FOR ECS TRIP DEVI CE 57 .c om SECTION 1 2- MicroVersaTrip ™ Trip Device 1 2.1 .1 The M ic roVersaTri p is a solid-state , d i rect-act i n g , self-powered tri p device system . T h e M icroVersaTrip system consist s of the M ic roVersaTr i p p rog ram mer, cu rrent sensors, and a flux sh ifter t r i p d evice. Fig. 76 shows a block d i ag ram of the system . CT I 1 � "�"'.!:: .J - - TAP BOARD - - - I I - LOGIC 'OR I I I I I r- 1-- ..._ '- I :n N f/, 1 t SHORT TIME PICKUP & DELAY l INSTANTANEOUS PICKUP l GROUND FAULT SUMMING - PICKUP & CIRCUITRY DELAY <1> 1 <1> 2 <1> 3 _ _ _ _ I I I I I I 1 I I I _ _ _ ww I __. FIG. 76 MICROVERSATRI P B LOCK DIAG RAM 58 tM Remote fault ind ication is available i n t h e form o f a mechanical contact which may be i ncorporated directly i nto the customer's control ci rcuitry. This is a Normally open contact which is activated when its associated target pops out. When the target is reset, the contact is returned to its open position. Each contact is rated 0.25 amp at 1 25 VDC and 1 .0 amp ( 1 0 amp in rush) at 1 20 VAC. ar I f r _ R EMOTE FAU LT IN DICATION I REGULATED 15 VDC POWER SUPPLY _ 1 2. 1 .2 I OVERLOAD I TARGET w L 1 LONG TIME PICKUP & DELAY .E I _j I lec I NCT _ I I I €I� I Each target pops out when its associated trip element operates to trip the breaker. After a trip, the popped target must be reset by hand . However, neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being dosed. lP I RE'NfsE'NsoRI I SOLID STATE SWITCH I SHIFTER TRIP COIL ca � I _ _ FLUX tri »- - ua ls PROGRAM M E R U N IT Fig. 77 shows a typical M icroVe rsa Trip p rog rammer u n it. Like the SST and ECS u n its, the M icroVersa Trip p rovides the com parison basis for overcu rrent d etection and del ivers the energy necessary to trip the b reaker. It contai ns a program mable m i c roelectronic p rocessor which incorporates nine adj ustable ti me-cu rrent func tions, th ree mechan ical fault i n d i cators (local and remote), a long-time pickup LED i n d icator (local and remote) and a zone selective i nterlocking function. All adj ustable p rog rammer fu nctions are automatic and self-contai ned req u i r i ng no external relayi ng, power su pply or accessories. See Table 1 1 for t r i p functions available and Table 12 for tri p fu nction characteristics. A detai led descri ption of each t r i p function is g iven i n p u b l i cation G EA 1 0265 a n d GEH 4657. r I L- The optional fault trip indicators are similar to the SST indicators. They are mechanical pop-out type for identify ing overload or short circuit over-currents faults when breakers are ordered without integral ground fault protec tio n . They are also avail able to identify overload, short circuit and ground fault trips for breakers supplied with i ntegral ground fault protection . an 1 2. 1 FAU LT TRIP I N DICATORS SHORT CIRCUIT TARGET ..�-.. .. .. '" - " .,_.. � "' K "' '"' "' $HQI!l PICIWI' �.t· -. .. ••• I n.� • "' GROUND TARGET "' "' -uP ' "" ' "' -011.4Y ""' ' LOIOG f>&4V - - - �· ""' !!A LONG ,_ -��p .. ?� u .l-MI FIG. 7 7 M I C ROVERSATRI P PROGRA M M ER .c om The remote fault ind ication switch leads are brought out the bottom of the M icroVersaTrip program mer as shown in Fig . 78. This switch lead harness is pl ugged i nto the mati ng con nector on the breaker, see Fig . 79. an ua ls The switch leads are brought out from the breaker through the Program mer Secondary Discon nect shown in Fig . 80. The zone selective i nterlocking fu nction wir i ng is also brought out through this d isconnect. See Figs. 95 and 96 for the remote fault ind ication and zone selective i nterlocking cable d iagrams. tM FIG. 80 REMOTE FAU LT I N D ICATOR ••• • DISC O N N ECT lP ar 1 2.1 .3 M ICROVERSATRIP™ I NSTALLATION ww w .E lec tri ca FIG. 78 MIC ROVERSATRIP W/REMOTE FAU LT I N DICATION HARN ESS FIG. 79 PROG RAMMER SECONDARY CONNECTOR The programmer mounts to the u pper left of t he breaker as shown in Fig. 81 . It mounts to t he bracket assembly shown in Fig. 82. Referring to Fig. 82, the guide pins mate with the holes on either side of the programmer connector. They provide the necessary alig nment for the con nector engagement . The locking lever engages with the pin which i s assembled to the programmer frame and secures the pro grammer to the mounting bracket There are two programmer mounting des igns in use. The d ifference in the des igns is in the operat ion of the locking lever, see Fig. 82. I nstal l ation using each design is as follows: a. I n sert the g u ide pins i nto the holes and push on the pro g rammer, engag ing the con nectors. b. Ori g i nal design -push in the locking lever, securing the programmer. Later design-the locking lever is released, securing the programmer. c. Verify t hat the locking lever did engage the programmer pin. d . Connect remote fault i ndication harness, if eq u i pped, see Fig. 80. To remove the programmer: a. Di sconnect the remote fault ind icat ion harness, if equi pped. b. Orig inal designs-push in locking lever, which w i l l release t h e programmer pin. W h i l e holding the locking lever in, remove the programmer. c. Later design-pull out locking l ever, which will release t he programmer p i n. Remove the programmer. 59 .c om SECTION 1 2- MicroVersaTriprM Trip Device (Cont.) C U R R ENT SENSORS The tapped and fixed phase sensors have a polarity as sociated with their windings. Their COMMON terminal is the right hand terminal as shown in Fig. 83. A white wire with a ring terminal will be connected to this COMMON terminal. All phase sensors m ust be correctly wired for the program mer summing circuit to function properly. The tapped or fixed phase sensors are available with an additional wi n d i ng . This wi n d i ng is b rought out to separate flag termi nals rather than the screw term i nals. These p hase sensors are used when the hi-level i nstan taneous MicroVersaTri p option ('H'-option) is req u i red. Fig. 84 shows an 'H'-option phase sensor. When the 'H' option p hase sensor is installed , there are fou r leads connected to it; two flag termi nal con nections (additional wi n d ing) and two screw terminal con nections (am pere rating). There is no polarity associated with the flag ter m i nals. Fig. 94 shows the con nections for the additional 'H'-option windings. an The cu rrent sensors su pply the power and signal in put necessary to o perate the trip system . Like the SST system , the MicroVersaTrip uses a phase and neutral sensor. Fig. 83 shows the phase sensors. Tapped and fixed phase sensors are avai lable. The tapped sensors provide field adj ustment of the trip device's contin uous ampere rating. See Section 1 2. 5 for cabl ing diagrams. ua ls 1 2.2 tM Fig . 85 shows the neutral sensor. The neutral sensor is required when integral ground fault protection is used on single phase-three wire or three phase-four wire systems. It is inserted i nto the neutral conductor and therefore is separately mou nted in the cable or bus compartment. ca lP ar The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these val ues. The total value will remain zero as long as there is no ground current flowing. See cable diagram in Fig. 9 1 . The neutral sensor is an electrical duplicate of the phase sensor, including taps. Therefore, when taps are charged on the phase sensors, those on the neutral sensor m ust be correspondingly positioned. ww w .E lec tri FIG . 81 - AKR-6D-30 60 FIG. 82 - MICROVERSATRIP® RMS-9 AND POWER LEADER MOUNTING BRACKET O�ional Features ADD TO BASIC FUNCTIONS BASIC FUNCTIONS • Adjustable Current Setti ng X X X X • Adj Long-Time Pickup X X X X LONG • Adj Long-Time Delay X X X X TIME • Long-Time Timing Light X X X X • Remote Long-Time Timing Light • Adj Short-Time Pickup X X X X X X SHORT • Adl Short-Time Delay TIME • Short-Time 12t Switch <D I NSTANTA- • Adj l nstantaneous Pickup NEOUS • Adj High Range I nstantaneous • Adj Ground Fault Pickup - 1 PH, 2W-3PH, 3/4-W -Ground Ret!Jrr:J. • Adj Ground Fault Delay • Trip I ndication Targets FAULT OTH ER X X X X X -local only tM -local only(2) -local and remote Zone Selective I nterlock X X X X ar -Ground FaultC3> X X -0/L, SIC and Ground Fault -Short Time<D X X X lP 1 Short-Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required Z1 -or-Z2-or-Z A 1 -or-A2-or-A3-or-A X X -local and remote • G-or-GR X -Overload & Short Circuit FUNCTIONS T an GROUND L ua ls STD.-or-5-or-H-or-M .c om TAB L E 1 1 TRIP FU NCTIONS AVAILABL E (X) AKR-30 Tapped Sensors tri Fixed Sensors (X) r, Sensor urrent Rating A mps) 1 00, 1 50 , 225, 300, 400, 600, 800 100, 1 50, 225, 300 or 300, 400 600, 800 800 300, 400, 600, 800 1 200, 1 600 300, 400, 600, 800 or 600, 800 1 200, 1 600 800, 1 200 1 600, 2000 1 600 AKRT-50 2000 800, 1 200, 1 600, 2000 AKR-75 3200 1 200, 1 600, 1 200, 1 600 2000, 3200 2000, 3200 AKR-100 4000 1 600, 2000, 1 600, 2000 3000, 4000 3000, 4000 w .E AKR-50 ww Long-Time Short-time Current Adjustable Setting Instantaneous (Multiple Pickup Pickup Pickup Short-time l't (Multiple Delay (Multiple Delay of Sensor (Multiple of Sensor Current of Current of Current <D ® <D Rating) Rating) (Seconds) Rating) (Seconds) Rating) (Seconds) (C) (X) (X) (C) Ground Fault Pickup (Multiple of Sensor Current Rating) Delay ® (Seconds) (X) .5, .6, .7, .8, .85, .9, .95, 1 .0 (X) .8, .9, 1 .0, 1 . 1 (C) 2.5, 5, 1 0 , 21 1 .5, 2, 2.5, 3, 4, 5, 7, 9 (C) 0. 1 0, 0.22, 0.36 1 .5, 2, 2.5, 3 , 4, 6, 8, 10 (X) 0.4 .2, .25, .3, .35, .4, .45, .5, .6 (X) 0.10, 0.22, 0.36 " " " " " " .. .. .. " .. .. " .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. lec Frame Size Maximum Rating (Amps) ca TABLE 1 2 M I C ROVERSATRIP™ TRIP C H ARACTERI ST I C S 1 Time delay shown at 600% of ampere setting at lower limit of each bafld. 2 Time delay shown at lower limit of each band. All pickup tolerances are ± 1 0% Ground Fault pickup not to exceed 1 200 amperes. 1 .5, 2 , 2.5, 3 , 4, 5 , 7, 9 (X) .. .. .2, .22, .24, .26, .28, .30, .34, .37 (X) .. .2, .22, .24, .26, .28, .3 (X) C X = = current setting sensor current 61 .c om an ua ls SECTION 1 2- MicroVersaTrip rM Trip Device (Cont.) FIG. 85 - TYPICAL N E UTRAL S ENSOR .E lec tri ca lP ar FIG. 83 - M I C ROVERSAT R I PTI'' PHASE SENSORS tM TAPPED A M P E R E RATING CONNECTIONS ww w FIG. 84 - 'H'-OPTION P HASE SENSOR 62 .c om Si nce t h e neutral sensor i s m o u n ted separately from the breaker, a d i scon nect means i s req u i red to con nect its o u t p u t to the b reaker. F i g . 86 shows the b reaker and eq u i pment mou nted 4th w i re secon dary d i scon nect u sed w i t h the M i c roVersaTri p syste m . REPLACEM ENT OF CURRENT SENSORS ua ls 1 2.2.1 Referring to Fig. 87, replacement of MicroVersaTrip cur rent sensors is accomplished as follows: a) Disconnect the program mer harness from the ter m i nal board, removing cable ties as necessary. an b) At the rear of the breaker, remove the two Al len head screws to separate the stud connector from the contact pivot block. . c) Loosen the clamping bolt and remove the stud con nector. Lift out the sensor and its tap terminal board. tM A The sensor may be prevented from s l i pping off the sen sor stud by adjacent accessories. If this exists, the sensor stud must be removed from the breaker base. The stud assembly is secured to the base with four bolts which are accessible from the rear of the breaker. B R EAKER M O U N T E D - R I G HT S I D E AKR 30/30H 1 20 ± 1 0 in-lbs AKR 50/5 0H 470 ± 1 0 i n - l bs A KRT 50/50 H 4 70 ± 1 0 i n- l bs A K R 30L 470 ± 1 0 i n-lbs e) When re plac i n g the prog ram mer harness to the p hase sensors verify that the wind i ng polarity is m ai ntai ned , white wire with ring term i nal to COMMON term inal (right hand term inal, see Fig. 83). w .E lec tri ca lP ar d) When replacing the stud connector, tighten the Allen head screw to 250 ± 1 0 in-lbs. Tig hten the clamping bolt as follows: ww B FIG. 86 - EQU I P M E NT MOU NTED N E UTRAL SENSOR SECON DARY DISCON NECT 63 .c om SECTION 1 2- MicroVersaTriprM Trip Device (Cont.) When replacing a MicroVersaTri p flux shifter, AMP ex traction tool Cat. No. 455822-2 is requ i red to remove the socket leads from the A M P connector. 1 2.4 TROUBLESHOOTI NG When malfunction ion is suspected, the fi rst step in troubleshooting is to exam ine the circuit breaker and its power system for abnormal conditions such as: a) Breaker tripping in proper response to overcu rrents or i ncipient ground fau lts. b) Breaker remai ning in a tri p-free state d ue to mechanical mai ntenance along its trip s h aft. c) Inadvertent shunt tri p activations. WARNING: DO NOT CHA NGE TAPS ON THE CUR 1 . Cond uct high-current, single-phase tests on the breaker using a high c urrent-low voltage test set. NOTE: For these single-phase tests, special connec tions must be employed for Micro Versa Trip breakers equipped with Ground Fault. Any single-phase input to the programmer circuit will generate an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by a) Using the Ground Fault Defeat Cable as shown in Fig. 93. This special test cable energizes the pro grammer circuit in a self-cancelling, series-parallel connection so that its output is always zero. 2. Test the components of the MicroVersaTri p system using portable Test Set Type TVTS1 (Fig. 88). The ap pl icable test procedu res are detailed in i nstruction Book G EK-64464. The time-current characteristics for the MicroVersaTrip Trip Device are given i n curves G ES-61 95 and G ES-6199. ca lP ar RENT SENSORS OR A DJUST THE PROGRA MMER UNIT SET KNOBS WHILE THE BREAKER IS CAR R YING CURRENT. Once it has been establ ished that the circuit breaker can be opened and closed normally from the test position, attention can be directed to the trip device proper. Testing is performed by either of two methods: ua ls The only difference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid wind i ng. Refer to Section 1 0.3 for details. an FLUX SHI FTER TRIP DEVICE tM 1 2.3 .E lec w PROGRAMMER HARNESS tri FLUX SHIFTER ww FIG. 87A - M I CROVERSATRIP® COMPONENT WITH TAPPED SENSORS 64 FIG. 878 RMS-9, EPIC MICROVERSATRIP® AND MVT-PLUS OR MVT-PM COMPONENTS WITH FIXED SENSORS - .c om SECTION 1 2- MicroVersaTrip ™ Trip Device (Cont.) 1 2.4.2 R ESISTANCE VAL U ES For use i n troubleshooting the M icroVersaTri prM cu rrent sensors, the resistance of the tapped and fixed windings is g iven i n Tables 1 3 and 1 4 respectively. Ampere Tap 1 00 1 50 225 300 300 400 600 800 600 800 1 200 1 600 800 1 200 1 600 7.0-8.2 1 0- 1 2 1 5- 1 8 20-24 lP 20-24 27-32 42-50 58-68 ca 42-50 53-68 93-109 1 30-1 54 tri 74-88 1 1 6- 1 36 1 62-1 90 2 1 0-246 lec 2000 TAB LE 1 4 - FIXED SENSOR R ESISTANC E VALUES Resistance in Ohms Between Terminals 1 00 1 50 225 300 400 600 800 1 200 1 600 2000 6.7-7.8 w .E Ampere Rating ww If n u isance tri p ping is encou ntered on any b reaker whose M icroVersaTrip com ponents have p reviously demonstrated satisfactory performance via the TVTS1 Test Set, the sensors and their con nections should be closely scrutin ized . After d isconnecting the breaker from all power sou rces. ar Resistance in Ohms Between Common and Tap Terminals tM TAB L E 1 3 - TAPPED SENSO R RESISTANC E VALUES ua ls 1 2.4.1 When n u isance tri pping occu rs on breakers eq u i p ped with the G round Fault tri p element, a p robable cause is the existence of a false "g round" signal. As ind icated by the cabling d iagram of Fig. 90, each phase sensor is connected to su m m ing ci rcuitry i n the p rog ram mer. Un der no-fau lt cond itions on 3-wire load c i rcu its, the currents in this circuitry add to zero and no g round signal is develo ped . This cu rrent sum will be zero only if all th ree sensors have the same electrical charac teristics. If one sensor d i ffers from the others ( i . e . , d if ferent rating or wrong tap setting), the ci rcuitry can prod uce output sufficient to trip the b reaker. S i m i larly, d iscontinu ity between any sensor and the p rogrammer u n it can cause a false trip signal. an FIG. 88 TEST SET, CAT. NO. TVTS 1 FALSE TRIPPING- B R EAKERS EQU I P P E D WITH G ROU ND FAU LT 1 0- 1 2 1 5- 1 7 20-24 27-32 42-50 58-68 92-108 1 29- 1 5 1 207-243 The coil resistance of the MicroVersaTrip flux shifter device is approximately 7 ohms. a) Check that all phase sensors are the same type (am pere range) . b) Ensure that the tap settings on all 3-phase sensors are identical. c) Verify that the harness connections to the sensors meet the pola rity constrai nts i nd icated by the cabl i ng diagram. d) On G rou nd Fau lt breakers serv i ng 4-wire loads , check that the neutral sensor is properly connected (see cabling diagram Fig. 91 ) . In particular, ( 1) Verify that the neutral sensor has the same rati ng and tap setting as the p hase sensors. (2) Ch eck conti nuity between the neutral sensor and its equ ipment-mou nted second ary disconnect block. Also check for conti nuity from the breaker-mou nted neutral secondary disconnect bl ock through to the female harness connector. (3) If The b reaker's lower studs con nect to the su pply sou rce, then tre :-�eutral sensor must have its LOAD end con nected to the source. See Fig . 92. (4) Ensure that th e n eutral conductor is carrying only that neutral current associated with the breaker's l oad cur rent (n eutral not shared with other loads) . e) If the preceding steps fail to identify the problem, then the sensor resistances should be measured . Since the ph ase and neutral sensors are electrically id entical , thei r tap-to-tap resistances should closely agree . See Tables 1 3 and 1 4 . 65 1 2.5 CABLI N G DIAG RAM S s A. A. .A r "f)=-=1t- 1 =)===)= :����;� � E LEFT POLE CURRENT SENSOR 4> C � -- ; "'- COM I ·ri-=-�l-----+-+ I I I t PROGRAMMER UNIT FLUX SHIFT TRIP DEVICE , -- -- -- ua ls �B �A .c om SECTION 1 2- MicroVersaTrip™ Trip Device (Cont.) --t-<>-1f-<' �-+o-+-<o an I A I I I I I I_ I '( '( '( tM HARNESS PROGRAMMER CONN ECTOR CO N NECTOR (AMP 1 -350356-9) LOAD lP ar F I G . 89. C AB LI N G D I A G RA M - M I C ROVER S ATRI PrM W I T H O U T G RO U N D F A U LT �A �c A. A. .A r "f)=-=1=)=- t1 ==)= :����;� E �I . FLUX SHIFT TRIP DEVICE PROGRAMMER U N IT , ---- - - ca s q, s I .E lec tri LEFT POLE CURRENT SENSOR I I I_ ww w rr r 66 1"-------+o+-< J LOAD PROGRAMMER CONNECTOR F I G . 90. C A B LI N G D I A G R A M - M I C ROVER S ATRI P™ W I T H G RO U N D F A U LT O N 3-WI RE LOA D .c om PROGRAMMER UNIT FLUX SHIFT TRIP DEV I CE ua ls I I r-+-+"--=+0� I I >t-<>t--t--+-----t-o-t-< f-t<>-i N 1 HARNESS PROGRAMMER CON N ECTOR CONNECTOR AMP 1 -350356-9 tM EQUIPMENT -MOUNTED '-------. r-----' NEUTRAL SENSOR 4-WIRE LOAD an {t \ �- - - - - - ar FIG. 9 1 . CABLI N G D I AGRAM- M I C ROVERSATRIP™ WITH G RO U N D FAU LT O N 4-WI RE LOAD 4-WIRE LOAD lP 111 1 ¢ -�- 4'- 1 �' b . b , I � )= = =)= ==}= PROGRAMMER UNIT �- - - - - - ca BREAKER BACK FRAME FLUX SHIFT TRIP DEVICE LEFT POLE CURRENT SENSOR I 'rt--'+-"'-f---t---+o+< f-+<>-l 1 4 II I I I A tri •111��"'-- I I NEUTRAL I SENSOR I DISCONNECT I - -1 j .E lec LOAD ww w LOAD HARNESS PROGRAMMER CONNECTOR N OR AMP 1 -350356-9 CON ECT FIG. 92. CABLING D I AG RAM-M I C ROVERSATRI P WITH GRO U N D FAU LT O N 4-W I R E LOAD BREAKER REVER S E FEED 67 r--;-- r- ' I o-+-< I o-+-< / I a-!--< 0 23 24 � 32 ...__ I I I I I I � I � � � I � I � I 28 - - 0 4-+--0 I 26 - - :� I 0 I I 0 I 0 � � �4 22 �. I 3] L --l l_ '----- ar L _j �'fl. mt I 0 I 0 1,Z / / 0 19 o-t-< o-+-< _1] I I Device (Cont.) ANY M ICROVERSATRIP PROG RA M M E R U N I T WITH GROUND FAULT ELEMENT an / I 0---1---< I a-+-< I 0---+-< I 7 8 I I I � I «-t-o I � I 8 7 o-+--< I a-+-< � I � 1 Q o-+-< I o-f- < I - , - - --, r -t 5 I o-t-< I o---t-< I - -.-1 - 4 I 0---+---< I o-+-< I o---+---< � - tM I o-t--< I PROGRAMMER U N IT GROUND FAULT DEFEAT M O D U LE CAT. NO. TVTGD9 r 1 .c om BREAKER HARNESS CONNECTOR & RMS-9 & Epic MicroVersaTrip™ ua ls SECTION 12- MicroVersaTrip™ _ _ I I I I _j ca lP FIG. 93. CABLING D IAG RAM WITH G R O U N D FAU LT DEFEAT M O D U LE I N SERTED B ETWEE N B REAKER HARN ESS A N D M I C ROVERSATRIP PROG RAMMER U N IT-FOR U S E D U R I N G S I N G LE-PHASE, H I G H CU RRENT -LOW VOLTAG E TESTI NG. q, A q, s q, c tri .A A. A. BREAKER � �4'BACK FRAME r & , b b, 1 )= -- --}= -- --}=1 �1 Partial ww w .E lec LEFT POLE CURRENT SENSOR 68 I PROGRAMMER �-- UNIT - --- YELLOW YELLOW YELLOW YELLOW YELLOW YELLOW rr r HARNESS CONNECTOR PROGRAMMER CONNECTOR LOAD FIG. 94. PARTIAL CABLING D IAGRAM: 'H'-OPTION WI N DI N G C O N N ECTI O N S EQUIPMENT SHORT CIRCUIT { { �---HJ-Ir--< MICRO-VERSA TRIP PROGRAMMER BREAKER �-+-0-+-----+-0-+--< �---HJ-Ic--< YELLOW , -- Y E LL _W _O 'E:::-t-'-.1-+-__ ___-l RED ua ls OVERLOAD REMOTE FAULT INDICATION CONNECTOR .c om PROGRAMMER SECONDARY DISCONNECT RED GREEN GREEN f BLUE 1 �---HJ-Ir--< �-+-o-+-------+-0-+--< <E'-----if-CH----1 BLUE AMP 1 -350246-9 AMP 1 -350242-9 __ _ _ AMP 1 -350235-9 _ _ I _j tM AMP 1 -350239-9 I an OVERLOAD PICKUP - - -, I I I I I I I I lP ar FIG. 95. CABLING D I AGRAM-REMOTE FAU LT I N DI CATION ca PROGRAMMER SECONDARY DISCONNECT EQUIPMENT {+ - -, �-1-C�--< E-+<J-t------t- tri SHORT TIME INPUT BREAKER MICRO-VERSA TRIP PROGRAMMER {+ - �--1--U·-+-< {+ {+ lec SHORT TIME OUTPUT _ GROUND FAULT INPUT .E GROUND FAULT OUTPUT _ �--1--o--+-< _ �--+-<1--+-< AMP 1 -350239-9 AMP 1 -350246-9 _ _ _j ww w FIG. 96. CABLING DIAGRAM-ZO N E SELECTIVE I NTERLOCK 69 ----cJ---- ar XFMR ----� flp tri ca 08 .E lec SWITCH ww w FIG. 97 - R MS-9 BLOCK DIAGRAM 70 Each target pops out when its associated tri p element operates to trip the breaker. After a trip, the popped target must be reset by hand. However, neglecting to reset does not affect normal o peration of any trip element or prevent the breaker from being closed . lP N ua ls Fig. 98 shows a typical RMS-9/Epic M icroVersaTrip® programmer unit. Like the MicroVersaTri p®, the RMS-9 Epic MicroVersaTri p® provides the comparison basis for overcurrent detection and del ivers the energy necessary to trip the breaker. It contains a programmable m icro electronic processor which incorporates nine adjustable time-current functions, three mechanical fault indicators (local and remote) , a long-time picku p LED ind icator (local and remote) and a ,zon e selective interlocking function. All adjustable programmer fu nctions are automatic and self contained req u i ring no external relaying, power supply or accessories. See Table 1 5 for trip functions available and Table 1 6 for trip function characteristics. A detailed d escri ption of each trip fu nction is given i n publi cation GEK97367. The optional fault tri p indicators are similar to the MicroVersaTrip® indicators. They are mechanical pop out type for i d entify i n g overload o r s h o rt c i rc u i t over-currents faults when breakers are ordered without integral g round fault protection. They are also available to i dentify overload , short circuit and g round fault trips for breakers supplied with i ntegral g round fault protection . an 1 3.1 PROGRAMMER U N IT 1 3.1 .1 FAULT TRIP INDICATORS tM The RMS-9/Epic M ic roVersaTri p® is a solid-state, d i rect-acting, self-powered t r i p device system. The RMS-9 system consists of the RMS-9 programmer, current sen sors, and a flux shifter tri p device. Fig. 97 shows a b lock d iagram of the system . .c om SECTION 1 3-RMS-9 & E p ic MicroVersaTri p ® TO FLUX SHIFTER FIG. 98 - RMS-9 & EPIC MICROVERSATRI P ® PROGRAMMER & Epic M icroVersaTrip® {Cont. ) .c om SECTIO N 1 3-RMS-9 1 3.2 CURRENT SENSORS ar 1 3. 1 .2 RMS-9 & EPIC MICROVERSATRIP® tM FIG. 99 - PROGRAMMER SECONDARY CONNECTOR EPIC MICROVERSATRIP ® an ua ls The current sensors supply the power and signal i nput n ec essary to o p erate the t r i p syst e m . L i ke t h e M icroVersaTrip '), t h e RMS-9 and Epic MicroVersaTrip(' uses a phase and neutral sensor. Fig. 1 0 1 shows the phase sensors. See Section 1 3 . 5 for cabling diag rams. INSTALLATION tri I nstallation is as follows: ca lP The programmer mounts to the u pper left of the breaker as shown in Fig. 1 00. It mounts to the brac ket assem b ly shown in Fig. 82. Referring to Fig. 82, the guide pins m ate with the hole on either side of the programmer connector. They provide the necessary alignment for the connector engagement. The locking lever engages with the pin which is assem b led to the program mer frame and secures the programmer to the mounting bracket. lec a. I nsert the g u ide p i ns into the holes and push on the programmer, engag ing the con nectors. b. The locki ng lever is released , securing the program mer. The fixed phase sensors have a polarity associated with their windings. Their COMMON terminal is the right hand term inal as shown in Fig. 1 01 . A white wire with a termi nal will be con nected to this COMMON terminal. All p hase sensors must be correctly wired for the programmer summing circuit to function properly. The phase sensors are avai lable with an additional winding. This winding is brought out to separate flag terminals. These phase sensors are used when the hi level instantaneous RMS-9 option (' H ' -option) is req uired . Fig . 1 0 2 shows an ' H ' -option phase sensor. When the ' H ' -option phase sensor is instal led, there are four leads con nected to it. There is no polarity associated with the special winding connection. Fig. 1 0 2 shows the connec tions for the add itional ' H ' -option windings. .E c. Verify that the locking lever did engage the program mer pin. FIG. 1 00 - AKR-70-30 To remove the programmer: ww w a. Pull out locking lever, which will release the program mer pin. Remove the programmer. 71 & .c om SECTIO N 1 3- RMS-9 Epic M icroVersaTrip ® TAB L E 1 1 TRIP FUNCTIONS AVAILABLE Optional Features ADD TO BASIC FUNCTIONS BASIC FUNCTIONS • TIME • • • SHORT • TIME • I NSTANTA- • NEOUS • • G R OU N D FAULT • • Adj Long-Time Delay Long-Ti me Timing Light X X X X X X X X X X X X X X X X X X X X X X Remote Long-Time Timing Light X Adj Short- Time Pickup Adj E;hort-Time Delay Short-Time l2t Switch(!) X Adj I nstantaneous Picku_p X Adj High Range I nstantaneous X Adj Ground Fault Pickup - 1 PH , 2·W-3PH, 3/4-W -Ground Return X X Trip Indication Targets -Overload & Short Circuit -local only FUNCTIONS -0/L, SIC and Ground Fault -local only(2) -local and remote -Ground Fault� X X X X X X X ca -Short Time<D Short-Time Delay is required Standard when Ground Fault specified Ground Fault required X lP Zone Selective I nterlock X ar -local and remote • Z1 -or-Z2-or-Z A 1 -or-A2-or-A3-or-A X Adj Ground Fault Delay OTH ER 1 2 3 X G-or-GR an • LONG Adjustable Current Setting Adj Long-Time Pickup T tM • L ua ls STD.-or-5-or-H-or-M tri TABLE 1 2 - RMS-9 AND EPIC MICROVERSATRIP® C HARACTERISTICS Short-Time Long-Time AKR-30 AKR-30H AKR-50 Max. Amp Rating Sensor Rating (Amps) (S) Delaym (Sec.) .5, .6, .7, .8, .9, .95, 1 .0, 1 .1 Fixed at 1 .0 of Current Setting 2.4, 4.9, 9.8, 20 1 600 800, 1 600 .5, .6, .7, .8, .9, .95, 1 .0, 1 .1 Fixed at 1 .0 of Current Setting 2.4, 4.9, 9.8, 20 2000 2000 .5, .6, .7, .8, .9, .95, 1 .0, 1 .1 Fixed at 1 .0 of Current Setting 2.4, 4.9, 9.8, 20 Time delay shown at 600% of cur r e n t s s e t t i n g at lower limit of band. ww 72 (X) 1 50, 400, 800 800 w AKRT-50 CD Pick up (Mull. of Current Setting) (C) .E lec Frame Size Current Setting (Mull. of Rating Plug Amps) � Time delay shown at lower limit of each band. All pic k u p tol erances are ± 1 0% . Pick up (Mull. of Current Setting) (C) Delay (Sec.) Adjustable lnstantaneo us Pick Up w/o ST (Mull. of Rating Plug Amps) Adjustable lnstantaneous Pick Up with ST (Mull. of Rating Plug Amps) 1 .5, 2, 3, 5, 7, 9, 1 0 1 .5, 2, 3, 5, 7 , 9 , 1 0, 1 3 15 (X) 12T in:r .40 1 .5, 2.0, 2.5, 3.0, 4.0, 5.0, 7.0, 9.0 12T out:·:l) . 1 0, .21 , (X) 1 .5, 2 , 3 , 5, 7, 9, 1 0 1 .5, 2, 3, 5, 7 , 9 , 1 0, 1 3 15 1 .5, 2 , 3 , 5, 7, 9, 1 0 1 .5, 2, 3, 5, 7 , 9 , 1 0, 1 3 Ground Fault High Range lnstantaneous (Mull. of Frame Short-timec� Rating) (H) Triple Selective Trip Fixed High Range Instantaneous (�_', '-� Pickup (Mult. of Sensor Amp Rating) (S) NA .2, .25, .3, .35, .4, .45, .5, .6 .4, .6, .8, 1 .0 NA .2, .25, .3, .35, .4, .45, .5, .6 .4, .6, .8, 1 .0 NA .2, .25, .3, .35, .4, .45, .5, .6 .4, .6, .8, 1 .0 .35 X = Rating plug amps S = Sensor amp rating C = Current setting 15 @ Triple selective trip i s standard w h e n I o n g - t i m e / s h o rt time only i s required. ® Time delay shown a t l o w e r l i m i t of each band. Ground fault pick up not to exceed 1 200 amps. X= S = C= H= Delay w/ 12T (Sec.) Delay @ w/o 12T (Sec.) .10, .21 , .35 .44 at 200% of pick up at lower limit of band . 1 0, .21, .35 .10, .21 , .35 Rating pl ug amps Sensor amp rating Current setting Short-time rating .c om ua ls an \ tM FIG. 1 03 - TYPICAL N EUTRAL SENSOR ar Fig. 1 03 shows the neutral sensor. The neutral sensor is required when integral ground fault protection is used on single phase-three wire or three phase-four wire sys tems. It is inserted into the neutral conductor and therefore is separately mounted in the cable or bus com partment. The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these values. The total val ue will remain zero as long as there is no ground current flowi ng. See cable diagram in Fig. 1 07. The neutral sensor is an electrical dupl icate of the phase sensor. Therefore, when phase sensors are charged the neutral sensor must be correspondingly changed . .E lec tri ca lP FIG. 1 01 - RMS-9 PHASE SENSORS ww w FIG. 1 02 - ' H'-OPTION PHASE SENSOR 73 PIN No. 5 Zone PROGRAMMER UNIT FLUX SHIFT TRIP DEVICE Selective �-- - - - �I Interlock I � � , rrr Ep ic MVT ����6�6 PROGRAMMER A C CONN ECTOR AMP 1-350356-9 EOUIPM NT MOUNTED NEUTRAL SENSOR ------v-4 -WIRE LOAD Zone In p uts + Zone Outp uts - - - 12 + ua ls I � + 11 Spare 10 vc 1 VB 4 VA 2 24 Ret 3 + 24 VDC NOTE LOCATION OF PIN #1 TIT T 1-t- l f--J � EQUIPMENT -MOUNTED NEUTRAL SENSOR LEFT POLE CURRENT ENSOR V I � (I � I 1 1 N lh I I, - �;r\J NEUTRAL A I I COM t LOAO COM I r:: 's I I ! WT RED HI E LOAD '" 18 22 H _ .A •s v •c I (f-� 19 I I ll :-:. '--i -'c'_ � v- v N 32�- - - - - �I r I 'c .E I_ EUTRA L I - )- - �)= -+ lec 1/ ,- �I PROGRAMMER UNIT FLUX SHIFT TRIP DEVICE tri BREAKER BACK FRAME LOAD ca 4-WIAE lP ar tM FIG. 1 07 - CABLING DIAGRAM - R MS-9 & EPIC M ICROVERSATRI P ® WITH GROUND FAULT ON 4-WIRE LOAD Hom net 9 an I 7 8 •+o-1 i r+-"=+>17>-tot--+---+--+-+----t<>+< \ I NLf-----f<>t) )-!<>t--+---lf---+----if-<>t-< �-o-j LOA I I 6 .c om Socket 20 24 I 21 I 17 _j HARNESS CONNECTOR AMP 1-350356·9 I_ _ I I I I _ _ _ ..... PROG RAMMER CON NE.CTOR ww w FIG. 1 08 - CABLING DIAGRAM - R M S-9 & EPIC M I CROVERSATRIP® WITH GROUND FAULT ON 4-WIRE LOAD - BREAKER REVERSE FEED 76 FIG. 1 09 - PROGRA MM ER SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND EPIC MVT .c om SECTION 1 4-MicroVersaTrip® Plus and M icroVersaTrip® PM Trip U nits ua ls The MVT-Pius/MVT-PM is a sol id-state d i rect-acting self-powered trip device system . The system consists of the MVT- Plus/MVT- PM programmer, current sensors and a flux sh ifter trip device. Figure 1 1 0 shows location of features on programmer. See user manual GEH -5891 A. ar tM MicroVersaTrip® Plus Trip Unit M icroVersaTrip® Plus trip un its util ize a digital , LCD display with a four-button keypad to provide local set-up and readout of tri p settings. A 3-phase ammeter and trip ind icators are standard, as is a clear plastic cover with provisions for seal ing to allow tamper resistant instal la tion. The trip unit digital ly measures the current waveform in each phase to determine the true RMS value of the current, regardless of the waveshape. MicroVersaTri p® Plus tri p units provide accurate, pred ictable overload and short circuit protection for d istri bution systems that in clude ac and de variable speed d rives, rectifiers, ind uction heating, and other loads that cause high harmonic distor tion as well as standard circuit. They provide maxi mum breaker-to-breaker selectivity and custom load protec tion. Short time and g round fault functions include the flexibility of coordination with or without an l2t ramp and are also avai lable with high range instantaneous. an 1 4.1 TRIP UNIT ww w .E lec tri ca lP MicroVersaTrip® PM Trip Unit The M icroVersaTrip® PM trip unit adds power manage ment system capability, advanced metering, and protective relays to the basic functions of the MicroVersaTri p® Plus. MicroVersaTrip® PM tri p units communicate d i rectly on the G E POWER LEADER'" com mun ications bus. FIG. 1 1 0 Power Requirements A small amount of power is necessary to energize the liq uid crystal disp lay (LCD) during setup , for viewing breaker status, and for metering d isplays. MicroVersaTrip® PM trip units require external 24 Vdc control power for operation . The four sources of such power are the following. • Flow of current - Breaker current sensors provide sufficient power to energize the LCD when at least 20% of the sensor's ampere rating is flowing. • 24 Vdc control power- Breakers with M icroVersaTrip® PM tri p units are supplied with external 24 Vdc power that, whenever present, energizes the LCD. Some breaker models that are configured for MicroVeraTri p Plus trip un its may b e optionally equ i p ped t o accept an external 24 Vdc supply. • Micro VersaTrip Test Kit - The MicroVersaTrip@ Test Kit, Cat No. TVRMS, contains a 24 Vdc power supply. The LCD is energized whenever the test kit jack is pl ugged into the test receptacle on the rating plug. • Micro Versa Trip battery pack - T h e p o rt a b l e M icroVersaTri p® battery pack contains a 24 Vdc power source and a jack. The LCD is energized when the jack is plugged into the rating p lug test receptacle. 77 .c om SECTION 1 4-MicroVersaTrip ® Plus and MicroVersaTrip® PM Trip Units 1 4.2 TESTING ua ls Testing of M icroVersaTrip® Plus and MicroVersaTri p® PM tri p un its may be performed with the trip unit installed in the circuit breaker, the rating plug installed in the tri p unit, and the breaker carrying current. The test set catalog nu mber is TVRMS. The test set plugs into the test socket of the rating plug. Test set TVRMS may also be used for MicroVersaTrip® RMS-9 and Epic M icroVersaTri p® trip u n its. Refer to the Mai ntenance and Troubleshooting section for additional detai ls. an 1 4.3 PRODUCT STRUCTURE Figure 1 1 2 shows the 36-pin plug that connects either trip unit to the circuit breaker and eq ui pment circuity. This plug is cal led the trip unit d isconnect. FIG. 1 1 1 - FRONT VIEW OF MICROVERSATRI P ® PM TRI P U NIT ar CAUTION: Removal of a trip unit from its breaker must be performed with the breaker in the OPEN or TRIPPED position . Draw-out breakers should be racked out first. tM MicroVersaTrip® P l u s a n d MicroVersaTrip® P M trip un its are removable. Figures 1 1 1 and 1 1 2 contain front and rear views of a MicroVersaTri p PM trip unit. lP CAUTION: Do not attem pt to operate the breaker without its assigned trip unit. Installation of an incorrect trip unit may result in unsafe operation of the breaker. ca CAUTION: Removal of the rating plug while the breaker is carrying current reduces the breaker's current-carrying capacity to approxi mately 25% of the current sensor rating. This may result in undesired tri pping. I>'>HY,_ ___ , __, """ """""'""'""' ""'"' '"'''" "" "'" """"''"" """"'"" .."""""''""'"'""" "' "'"""'""" ""' ',...""� "" - '"" '"''''"' """"-'""''"' "' ' ' "' ""'""' '""'""' ""' ' "-"""'"""'' ""1.''"''-'1>'• """ "" """' '"""""' ""' __, ...,, ......,,. ww w .E lec tri NOTE: Tri p units as received may have settings that are undesirable for the specific appl ication. Ensure that settings are appropriately adjusted before energizing. CAUTION IMI'ORTANT IN$T'AUCTIOfi$ TO£fifSIJJit I'I'IOP£111 1"flQCMMMEiti'UNCt!ON 78 FIG. 1 1 2 - R EAR VIEW OF M ICROVERSATRI P ® PM TRI P U N IT .c om SECTIO N 1 4-M icroVersaTri pTM Plus and M icroVersaTripT\1 PM Trip Un its 1 4.4 TRIP UNIT REMOVAL AND REPLACEMENT Socket The programmer m o u nts to the u p per l eft of the breaker as shown in F i g . shown i n F i g . 82. 1 1 5. Class I t m o u nts to the bracket asse m b l y No. G u i d e p i n s o n the bracket mate with the holes o n either side of the programmer connector. They g a g e m e n t . T h e locki n g lever engages with the p i n w h i c h i s assem bled to the program mer frame and secures the program mer to the mounting bracket. When a trip u n it i s Selective Always de-energ i ze Type AKR c i rc u it break observe t h i s warning may res u lt i n e q u i pment damag e or personal i n j u ry , i n c l u d i n g deat h . 11 - tM ar + Zone Inputs Zone Outputs Hom net 9 Spare 10 vc 1 VB 4 VA 2 24 Ret 3 + 24 VDC NOTE LOCATION OF PIN #1 tri ca lP + - 12 MVT-PM - 8 an Because o f the exposed locat i o n o f the t r i p u n i t , fai l u re t o 7 Interlock rep l aced , t h e locking a r m snaps back i nto place to i n d i ers before attempting to remove or replace the tri p u n i t . 6 Zone cate proper a l i g n ment. WARNI NG: + ua ls 5 prov i d e the necessary al i g n ment for the con nector e n ww w .E lec FIG. 1 1 3 PROGRAMM ER SECONDARY CONNECTOR FIG. 1 1 4 PROGRAMM E R SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND MVT-PM 79 .c om tM an ua ls SECTION 1 4-MicroVersaTrip® Plus a nd M icro Versa Trip® PM Trip Units FIG. 1 1 5 COMMON TERM I NAL FIG. 1 1 6 The fixed phase sensors are available with an additional winding. This winding is brought out to separate fla� term inals. These phase sensors are used when the hi level instantaneous ('H' -option) is required . Fig. 1 1 7 shows an ' H ' -option phase sensor. When the ' H ' -o ption phase sensor is installed, there are four leads connected to it. There is no polarity associated with the ' H ' -option windings. lP 1 4.5 PHASE C U RRENT SENSORS ar TAPPED ww w .E lec tri ca The current sensors supply the power and sig nal i n put necessary to operate the trip system Fig. 1 1 6 shows the fixed phase sensors available. The sensors have a po� ar ity associated with their windings. The com � on t� rm1 � al of the sensor is the right hand term inal. A wh 1te w1re With a push-on term inal will be connected to thi � common terminal. All phase sensors m ust be correctly w1red for the programmer summing circuitry to function properly. 80 FIG. 1 1 7 'H'-OPTION PHASE SENSOR .c om SECTIO N 1 4-MicroVersaTrip® Plus and M icroVersaTrip® PM Trip Units CAUTION: Neutral current sensors are req uired for three phase, four-wire systems . When the trip u n it is con nected to a three-phase, three-wire system, the neutral sensor termi nals are left open. Do not short any neural current sensor terminals in a three-phase, three-wire system , as this could result in damage to or malfunction of the electrical system . 1 4.7 RATING PLUG REMOVAL AND RE PLACEMENT CAUTION: Removal of the rating plug while the breaker is carrying current reduces the breaker's current-carrying capacity to approxi mately 2 5 % of the current sensor rating. ua ls 1 4.6 NEUTRAL C U RRENT SENSORS The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these values. The total value will remain zero as long as there is no g round current flowing. Rejection features are provided on all rating plugs to prevent appl ication mismatches. Never force a rating plug i nto place. Refer to Table 1 6 to find the appropriate rating plugs for each sensor rating and breaker frame. tM an F i g . 1 1 8 shows t h e neutral sensor. The neural sensor is requ i red when i ntegral g round fault protection is used on single phase-three wire or three phase-four wire systems. It is i nserted into the neutral cond uctor and therefore is separately mou nted in the cable or bus compartment. I nterchangeable rating plugs are removed with a Rating Plug Extractor, Catalog No. TRTOOL. (Suitable equiva lents are commercially available as "integ rated circuit (DI P) extractors . ") Grasp the rating plug tabs with the extractor and pull the plug out. Be sure to grab the tabs and not the front cover of the rating plug , or the plug may be damaged. The neutral sensor is an electrical d u plicate of the phase If a replacement rating plug has a d i fferent rating than sensor. Therefore, when phase sensors are chang ed , the the plug that was removed , follow the appropriate setup neutral sensor must be correspondingly be changed. procedure GEH -5891 A to enter the new rating. lec tri ca lP ar Do not attempt to use a rating plug from a Spectra RMS breaker or a MicroVersaTri p® Plus or M ic roVersaTrip"' P M Trip U n it. .E \ ww w FIG. 1 1 8 TYPICAL N EUTRAL SENSOR Cat. No. TR4B 1 50 TR4B200 TR4B225 TR4B250 TR4B300 TR4B400 TR8 B300 TR8 B400 TR8B450 TR8B500 TR8B600 TR8B700 TR8 B800 TR1 6 B600 TR1 6 B800 TR1 6 B 1 000 TR1 6 B 1 1 00 T R 1 6 B 1 200 TR1 6B1 600 TR20B750 TR20B800 TR20B1 000 TR20 B 1 200 TR20 B 1 500 TR20B1 600 TR20 B2000 TABLE 1 6 Sensor Rating, Amps Plug Rating Breaker Frames 400 1 50 200 225 250 300 400 AKR30, AKR30H, AKR30L 800 300 400 450 500 600 700 800 AKR30, AKR30H , AKR50S, AKR50H 1 600 600 800 1 000 1 1 00 1 200 1 600 AKR50, AKR50H 2000 750 800 1 000 1 200 1 500 1 600 2000 AKRT50H 81 .c om SECTION 1 4-MicroVersaTrip® Plus and M icroVersaTrip® PM Tri p Units 1 4.8 TRIP U N IT FUNCTIONS Protection - Long-time protection • - Zone-selective i nterlock, with grou nd fault only or with both g round fault and short time Add itional optional functions available only with PM style trip u nits are as follows. PM style trip u n its requ i re the presence of external control power. • - Communication and metering Status - Communication and protective relaying - Tri p target - Communication, meterin g , and protective relaying Metering display - Phase c urrent (selectable among phases) - Voltage The optional functions available on both types of trip u n it are as follows: • Metering and protective-relaying functions • Adjustable protection - Total power (kVAIM VA) - Switchable i nstantaneous and g round-fault protection - Frequency (Hz) - Protective relays (undervoltage, overvoltage, voltage un balance, current u n balance, and power reversal) ww w .E lec tri ca lP ar - High-range (fixed) i nstantaneous overcurrent protection - Short-time protection, with or without I 2T - Energy (kWh/MWh) - Real power (kW/MW) tM • Configurations - Instantaneous protection an • - G round-fault protection, with or without 1 2T ua ls M icroVersaTri p® P l us and M icroVersaTrip® PM tri p units have specific standard and o ptional fu nctions. All trip u nits share a series of i nterchangeable rating plugs. The standard functions for both types of trip unit are as follows: 82 .c om SECTIO N 1 4-MicroVersaTrip® Plus and M icroVersaTrip® PM Trip Units '- 1 4.9 TROUBLE-SHOOTI NG G U I D E Corrective Action 1 . The trip unit display is blank. Line current is below 20% of S (MicroVersaTrip Plus). External 24 Vdc is absent (MicroVersTrip® PM). At least 20% of the current sensor rating, S, must be flowing through the breaker to activate the display. If not, power the trip unit with the Test Kit or external battery pack. an Possible Cause Symptom ua ls The following g u i d e is provided for trouble-shooting and isolating common problems. It does not cover every possi ble condition . Contact the Customer Sup port at 800-843-37 42 if the problem is not resolved by these procedures. Check that the control power supply is present and operational. Power the trip unit with the Test Kit or external battery pack. Can occur on Plus style trip units when load current fluctuates near 20% of S. 3. The trip unit display flashes ERR. The built-in self test has detected an error. Replace the trip unit. 4. The trip indication target will not clear. Trip unit is not in status mode. Press FUNCTION until STATUS is displayed. Press SELECT and VALUE together to clear the target. 5. Unit does not com municate with the Monitor, POWER LEADER Distribution Software, or FPU. Commnet wires are shorted or improperly connected. ar lP ca U pdate FPU to version 2.0 or higher. Trip unit address incorrect. Check that address assigned to trip unit agrees with address at host. tri .E 7. Voltage readings are incorrect. w 8. kW legend is flashing. ww 9. Overload target is flashing by itself. Locate and repair the short or the incorrect con nection. FPU version is lower than 2.0 Rating plug value was defined incorrectly. lec 6. Current readings are incorrect. tM 2. The trip unit display flashes. Read the X value from the rating plug name plate and enter this with the rating plug current set point procedure . Do not enter the sensor rating, S. Potential transformer (PT) primary voltage was defined incorrectly. PT connection was defined incorrectly. Read the PT ordinary rating from the PT name plate and enter this value with the PT primary voltage procedure . With the PT connection procedure , enter VL-N for a wye-connected PT primary or VL-L for a delta-connected PT. Total power metering. Indicates that the total power is metered in kVA. Test Kit-initiated trip indication. Clear target as indicated above (Symptom 4). 83 .c om TABLE 23 SH U NT TRIP AND UNDERVOLTAGE DEVICE OPERATING C U R RENTS gc UNDER VOLTAGE SHUNT TRIP Current (Amps) Sealed Open Closed 8.3 4.5 2.0 1 .0 8.3 4.5 2.0 1 .0 - - 14 28 70 1 40 59 95 95 95 1 75 1 75 1 75 1 90 1 90 1 90 1 90 31 5 380 380 380 475 475 475 DC DC DC DC 60 60 50 25 60 50 25 60 50 40 25 50 60 50 25 60 50 25 30 60 1 40 280 1 32 1 27 1 27 1 27 220 220 220 254 254 254 254 41 0 508 508 508 625 625 625 1 2.3 7.6 4.7 3.2 3.8 2.1 3.9 4.7 5.8 2.1 2.9 3.4 7.5 3.5 2.8 5.1 3.1 1 0.8 6.7 4.1 2.6 3.1 1 .9 3.4 4.1 5.1 1 .9 2.6 3.1 7.3 3.3 2.5 4.7 3.0 Operating Voltage range SEE Inrush Sealed Open Closed .38 .19 .08 .04 N/A .66 . 75 .31 .51 .30 .14 .37 . 34 N/A .16 .22 .23 .1 7 .1 1 .16 .14 .10 .38 .19 .08 .04 N/A .24 .25 .10 .17 .10 .05 .12 .1 1 N/A .06 .08 .08 .06 .05 .06 .06 .05 TABLE ua ls Inrush 25 Q) 0 0> Q) ctl OJ .... ro ..., o � "iii - > ctl · c .� E an 24 48 1 25 250 70 1 20 1 20 1 20 208 208 208 240 240 240 240 380 480 480 480 575 575 575 Operating Voltage range - E o 0 c C 'Q 0� � co tM ! e > 0 z Current (Amps) Cll o - o 0 0 � a:: 0 0 "- +-' I.C) (") ce Cil (/) ' - ar > () c G> N :::l :t: lP 0 .. O cr� .. .. c 0 o_ :J :::l ·- +-' o u o � 0.. 0... 0 ·- ,_ ca TABLE 24 COIL R ESISTANCE-DC OHMS @ 25°C Frequency Hz 24V 48V 1 25V 250V 1 20V 1 20V 1 20V 208V 208V 208V 240V 240V 240V 380V 480V 480V 480V 575V 575V 575V DC DC DC DC 60 50 25 60 50 25 60 50 25 50 60 50 25 60 50 25 lec .E w ww 92 Anti-Pump Relay "W" N/A 802 5000 1 6400 450 450 1 450 1 450 1 450 3900 1 450 1 450 6000 N/A N/A N/A N/A N/A N/A N/A tri Nominal Control Voltage Control Relay "X" Shunt Trip Undervoltage N/A 12 1 19 476 54 75 75 21 6 300 300 300 300 300 N/A N/A N/A N/A N/A N/A N/A 3 11 64 260 3.9 7. 1 5 25.4 25.4 25.4 64 25.4 25.4 64 64 64 32 1 00 1 00 64 1 46 64 240 1 600 6700 25.4 33 1 46 64 1 46 580 1 00 1 46 580 370 370 580 1 600 580 918 3200 0 .c om COI L RATI NG MAXI MUM PIC K U P VOLTAGE 24 VDC 20 48 VDC 41 1 25 VDC 1 06 1 55 VDC 1 32 250 VDC 213 1 20 VDC 1 02 208 VDC 1 77 240 VDC 204 380 VDC 323 480 VDC 408 575 VDC tM TABLE 25 I N STANTAN EOUS U N DERVOLTAG E DEVICE SETTI NGS DROP OUT RANGE 7-1 4 1 4-29 ua ls 38-75 47-93 75- 1 50 36-72 an 62-1 25 489 72-1 44 1 1 4-228 1 44-288 1 73-345 TABLE 26 TIM E-DELAY U N DERVOLTAG E DEVICE SETTINGS PICK U P RANGE UVR O N LY VDC 1 25 VDC 77 - 85 250 VDC 208/240 VAG 1 25 - 1 40 UVR I NSTALLED M ECHAN I S M RESET ar DELAY U N IT VO LTAG E PICK U P 50 90 - 95 90 1 60 - 1 65 MINIMUM POSS I B LE ww w .E lec tri ca lP N O PICK U P DROP OUT RA N G E 93 .c om ua ls an tM ar lP ca tri lec .E These i n s tr u c ti o n s do n o t purport to cove r a l l d e ta i l s or variations in equipm e n t n o r to provide for every p o s s i b l e c o n ti n ge n c y to b e m e t i n c o n n e c t i o n w i th i n s tallation o p e r a t i o n o r m a i n t e n a n c e . Should fu r th e r i n fo rm a t i o n b e desired o r s h o u l d p a r t i c u l a r p r o b l e m s a r i s e which a r e n o t covered suffi c i e n tly for the purchaser's purposes , ww w the m a tter s h o u l d be referred to the GE Company. GEK-644590 0596 PSA GE Electrical Distribution & Control General Electric Company 4 7 Woodford A ve . Plainville, CT 06062 © 7 996 General Electric Company • .c om GEK-64459C Maintenance Manual Low Voltage Power Circuit Breakers ww w .E lec tri ca lP ar tM an ua ls Types AKR-30/50 and AKRT-50 .c om Low Voltage Power Circuit Brea kers Table of Contents Page Page 1 .0 1 .1 1 .2 4 4 4 INTRODUCTION I nspection and Mai ntenance Renewal Parts SECTION 2 6 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 6 6 6 6 8 8 8 9 GEN ERAL D ESCR I PTION Frame Size Operation Fused/Non-Fused Mounting Tri p Device Model N um ber Short Circuit Ratings SECTION 3 10 STORAGE Safety Maintenance 10 10 1 0A SECTION 4 10 D RAWOUT BREAKER I NTERC HANGEA B I LITY 1 0B ar 4.0 SECTION 5 11 lec I NTERLOCKS Racking Mechan ism Interlock Positive I nterlock Closi ng Spri ng I nterlock Discon nect Position I nterlock Padlocks Key I nterlock-Stat ionary Breaker Optional Interlocks .E 6.7 tri SECTION 6 6.0 6. 1 6.2 6.3 6.4 6.5 6.6 SECTION 7 BREAKER MAI NTENANCE Lu brication Man ual Handle Adj ustment Drawout Mechan i sm Pos ition Slow Clos i n g the Breaker Pri mary Discon nects Replacement Adj ustment ww w 7.0 7.1 7.2 7.3 7.4 7.5 7.5.1 7.5.2 2 11 11 11 12 13 lP BREAKER O PERATION Manual Closing Electri cal Closing Alternate Control Circuit Mechan ism Operation Charg i n g Using The Mai ntenance Handle ca 5.0 5.1 5.2 5.2. 1 5.3 5.4 7.6 7.6. 1 7.6.2 7.7 7.7. 1 7.7.2 7.8 7.8.1 7.8.2 7.8.3 7.8.4 7.9 7.9. 1 7.1 0 7. 1 1 7. 1 1 . 1 7. 1 1 .2 7.1 1 .3 7. 1 2 7. 1 2. 1 7. 1 2.2 7.13 7. 1 4 7. 1 4 . 1 7. 1 5 SECTIO N 8 8.0 8.1 8.2 13 15 15 15 16 16 17 17 18 18 18 18 18 19 20 20 21 22 22 Aux i l iary Switch Replacement Adj ustment Shunt Tri p Replacement Adj ustment Undervoltage Device Repl acement Operational Check Adj ustments Factory Settings Static Ti me-Delay Undervo ltage Adj ustments Electric Lockout Device Bel l Alarm Operation Adj ustments Repl acement Electrical Control Components Com ponent Replacement F and G Switch Adj u stment Drawout Mechanism Buffer Assembly Buffer Adj u stment Trip Latch Adj ustment tM 3.0 3.1 3.2 SECTION 7 ua ls 4 an SECTION 1 8.3 8.4 8.5 8.6 8.7 CONTACT MAI NTENANCE Arc Ch ute Removal & I nspect ion Contact Adj ustment AKA 30/30 H & AKRU 30 Contact Adj ustment AKA 50/SOH & AKRU 50 Contact Adj ustment AKRT 50/50H Stationary Contact Identification Contact Replacement AKA 30/30H & AKRU 30 Contact Replacement - AKA 50/50H , AKRU 50 & AKRT 50/SOH SECTION 9 9.0 9.1 9.2 9.3 9.3. 1 9.3.2 22 22 22 23 23 23 23 23 24 24 25 25 26 26 26 27 27 27 28 29 29 31 32 32 33 33 33 34 36 37 38 39 39 41 41 FUSED BREAKER Fuse Sizes and Mounting 41 Special 2500A Fuse For AKRU 50 41 43 O pen Fuse Lockout Device Type A and B Breaker 43 O FLO Adj ustment Type D Breaker 43 O FLO Adj ustment ,o'\W� 1 0.5 45 45 46 48 48 51 52 52 1 1 .1 TYPE ECS OVERCU RRENT TRIP D EVICE ECS Cabl ing Diagram 56 57 58 1 2.5 SECTION 1 3 1 5 .0 1 5. 1 1 5.1 .1 1 5 . 1 .2 1 5. 1 . 3 1 5.2 1 5. 2 . 1 1 5 . 2.2 1 5 .2.3 1 5 . 2 .4 1 5.3 1 5. 4 1 5 .4.1 1 5 .4.2 1 5. 5 1 5 .6 ca lP ar M ICROVERSATR I P '" TRIP D EVICE 58 58 Programmer Unit 58 Fau lt Tri p I nd icators 58 Remote Fau lt I n d ication M icroVersaTri p'" I nstallation 59 60 Cu rrent Sensors Replacement of Cu rrent 63 Sensors 64 Flux Shifter Tri p Device 64 Troubleshooti ng 65 Resistance Values False Tri pping- Breakers 65 Eq u i pped with Ground Fau lt M icroVersaTrip ·· Cabl i n g Diagrams 66 tri 1 2.3 1 2.4 1 2.4. 1 1 2.4.2 SECTION 1 5 56 SECTION 1 2 1 2.0 1 2. 1 1 2. 1 .1 1 2. 1 .2 1 2. 1 .3 1 2.2 1 2.2.1 1 4.8 1 4. 9 53 53 SECTIO N 1 1 1 1 .0 1 4. 1 1 4.2 1 4. 3 1 4.4 1 4. 5 1 4. 6 1 4. 7 M I C ROVERSATRIP . PLUS AND MIC ROVERSATRI P PM TRIP U N ITS Tri p U nit Testing Product Structure Trip U n it Removal and Replacement Phase Current Sensors Neutral Current Sensors Rating P l u g Removal and Replacement Trip Unit Functions Trouble-Shooting Guide ua ls 1 0.3 1 0.4 1 0.4. 1 1 0.4.2 1 0.4.3 1 4 .0 TYPE SST OVERCU RRENT TRIP D EVICE Programmer U n it Current Sensors Replacement of Cu rrent Sensors Flux Sh ift Tri p Device Troubleshoot i ng SST Test Set Resistance Values False Tri pping- Breakers Eq u i p ped with Ground Fau lt SST Cab l i ng Diagrams an 10.1 1 0.2 1 0.2.1 SECTIO N 1 4 EC TRIP DEVI CE Series Overcurrent Tripping Device EC-2A Long Time- Delay and Hig h-Set I nstantaneous Tri pping I nstantaneous Low-Set Tripping Instantaneous H ig h-Set Tri pping Series Overcu rrent Tripping Device EC-1 Short Time- Delay Tri pping Long Time- Delay Tri pping Instantaneous Tripping EC-1 Adjustment Positive Tri p Adjustment Reverse Current Tri pp i ng Device Adjustment Replacement Switchette Feature Trip Device Replacement tM 1 0.0 Page 45 SECTION 1 0 .c om Page 77 77 77 78 78 79 80 81 81 82 83 84 84 86 86 86 86 87 87 87 88 88 88 89 90 90 90 90 70 RMS-9 & EPIC MIC ROVERSATR I P '"70 Programmer Unit 70 Fault Trip Indicators 70 RMS-9 & Epic MicroVersaTrip I nstallation 71 Cu rrent Sensors 71 1 3 .2 1 3. 2 . 1 Replacement of Current Sensors 74 Flux Sh ifter Trip Device 1 3 .3 74 Trou bleshooting 1 3 .4 74 74 1 3 . 4 . 1 Resistance Values 1 3.4.2 False Tri pping-Breakers Eq uipped With Grou n d Fault 75 1 3.5 Cabling Diagrams 75 ww w .E lec 1 3.0 1 3. 1 1 3.1 . 1 1 3 . 1 .2 3 .c om SECTION 1 - lntroduction A basic i nspection should consist of the following: The proper use, care , and mai ntenance of these break ers is a prime safety consideration for the protection of personr.el, as well as a means of minimizing equi pment damage when faults occur. Persons who apply, use , and service these breakers will acquire the knowledge they need by gai ning the information contained i n these instruc tions. a. Visual Check - Look for dirt, grease or other foreign material on any breaker parts. Check insulati ng su rfaces for conditions that could degrade i nsulating properties (cracks, overheating, etc . ) . Also check for loose hardware and components on the bottom of the breaker compart ment. Loose or damaged control wiri n g and similar problem areas should also be checked . ua ls These instructions provide the mai ntenance procedures and describe the operation of the 800 thru 2000 amp frame size type AKA low voltage power circuit breakers listed i n Table 1 . b. Operation - Observe a few close-open operations using the operating or mai ntenance handle. If a breaker is seldom operated such that it remains open or closed for a period of six months or more, it is recommended that it be opened and closed several times in succession. INSPECTION AND MAINTENANCE e. Accessories - Verify that the various accessories are working properly. f. The performance of the solid-state current trip devices may be checked with a suitable test set. Check elec tromechanical devices for positive trip in accordance with the instructions in their Maintenance M an ual , G E l 86 1 57 . ar Breakers should be cared for under a systematic mai n te nance program. Taking each breaker out of service periodically for i nspection and maintenance is an excel lent means of establishing high service reliability. It is good policy to have one or more spare breakers to install in place of breakers req ui ring maintenance. Keeping a stock of recommended renewal parts will insure that maintenance work can be done quickly. d . Arc Chutes and Contacts - I nspect the condition of the arc chutes and contacts. Look for excessive burning or breakage . Check the amount of contact depression or wipe when the breaker is closed . tM 1 .1 an c . I nterlocks - During the O perational check verify the safety i nterlocks are properly worki ng. ca lP How freq uently an i ndividual breaker should be i n spected w i l l depend o n the circumstances of its use . I t would b e well to inspect any breaker at least once a year. If it is frequently operated, operated under severe load condi tions , or i nstalled in an area of high humidity or a dusty, d i rty atmosphere, i nspections should be more often . I n spections might be monthly under adverse conditions. lec tri Always inspect the breaker after a short-circuit current has been i nterrupted. SAF ETY PR ECAUTION ww w .E BEFORE INSPECTING OR BEGINNING ANY MAINTENANCE WORK ON THE BREAKER, IT MUST BE DISCONNECTED FROM ALL VOLT A G E S O UR CES, B O TH PO WER AND CON TROL, AND BE IN THE "OPEN" POSITION. 4 1 .2 REN EWAL PARTS The AKA breakers contain a variety of parts and as semblies. Many of these are available as replacement parts when the need arises . See publication G E F 4527, Renewal Parts, for a complete listing of these parts. AKR-(*)A 30, AKR-( *) 8 30, AKR- ( * ) D 30, AKR-( *)8 30 , 30H 30H 30H 30H X AKR-( *)A AKR-( * ) 8 AKR-(*)D AKR-( *) 8 SOH SOH SOH SOH X 800 DC 2000 DC 800 X X X X X X X X X X X X AKR-2A 30 AKR-28 30 AKR-2D 30 AKR-28 30 X AKR-2A-50 AKR-28-50 AKR-2D-50 AKR-28-50 X AKR U-(*)A 30 AKRU- ( * ) 8 30 AKRU-(*)D 30 X AKRU-(*)A 50 AKRU- ( * ) 8 50 AKRU- ( *) D 50 1 600 SOH SOH SOH SOH X ua ls 50, 50 , 50, 50 , X an AKRT-(*)A AKRT-(*)8 AKRT- ( * ) D AKRT-(*)8 2000 AC X X X X X X X tM 50, 50, 50, 50 , X X X X X X X X X X ar 1 600 AC AKD-5 lP 800 AC BREAKER DESIGNATION MOU NTING TYPE DRAWOUT FUSED DEEP SUBAKD-8 STRU CTURE STATIONARY ESCUTCHEON B R EAKER X X X X X X X X X X X X X X X ca FRAME SIZE (AMPERES) BREAKER MODELS .c om TABLE 1 X (*) - This digit identifies the trip device type as follows: - } EC (DC only) ECS SST 50/60 H ertz Only M icroVersa Trip Non-automatic. In addition, all non-automatic 250VDC breaker types carry the suff ix letter D after the frame number, e.g. AKR-N B-500 RMS-9 tri 2 4 5 6 N 7 ww w .E lec 9 - MVT-PLUS or MVT-PM 5 .c om SECTION 2-General Description ua ls Type AKA low-voltage power c i rcuit breakers are used for contro l l i ng and protecti n g power c i rc u its i n the l ow voltage range (usual l y up to 600 volts). I n serving this function, they are a means of safely switching loads and automatical l y cl eari ng c i rcuits when abnormal conditions occur. Among these conditions, the more common are short circu its and sustained overloads and u nder voltages. The type AKA breakers are of the "qu ick-make , qu ick break description, having the feature of storing energy in a closi ng spring for quick release in closi ng. I n closing, some energy is transferred to an opening spring to be used subsequently for fast tripping. FIG. 1 - Ma nually Operated AKR-4A-50-1 ar The mechanism unit is desig ned to receive energy, store it, and later (when cal led upon to do so) deliver it to close the breaker: contacts. It m ust be able to reverse its co m m itment to close the breaker at any poi nt upon the activa tion of an automatic trip device ( i . e . , be "Trip- Free"). Fi nally, it also m ust be able to trip open a closed breaker quickly enough to minim ize arc erosion and in such a manner as to effect proper arc transfer to the arc runner. tM The three main fu nctional components of a breaker are its mechanism, an asse mbly comprising the cond uctive members, and the i nterrupter. an Knowledge of how the breaker is desig ned and how it operates will enable the owner to make p roper use of the breaker and to avoid mistakes in its operation . Specific d i rections on adj ustments and mai ntenance p rocedu res will be treated later. lP These val ues represent the maxi m u m contin uous cur rent capability of the respective frames. However, each breaker carries a specific rating wh ich is determi ned by the current sensor ampere rating or maxi m u m setting of the trip device with which it is equipped. tri ca The cu rrent-carrying members of the breaker are as sembled on the back frame, which provides the mechani cal su pport required and also the i nsulating structure needed. The cond uctive members are the studs for exter nal con nections, movable and stationary contact sets, pivots for the movable contacts, and provision for mounting the current transformers. lec The i nterrupter components are, in addition to the arcing contacts, the arc runners mounted on the back base and the removable arc quencher assemblies. .E I n addition to these basic components , a breaker may be equi pped with any co mbination of many accessories and i nterlocking devices. Breakers may also differ in a variety of areas as shown in Table 1 . A brief description of these areas is given below. M outline d rawing is available for each breaker frame size showing critical d imensions. The drawing n um ber appears on the breaker nameplate and can be obtained from GE. FRAME SIZE w 2.1 ww The breakers are available in 5 frame sizes - 800 am peres A.C. (AKA 30/30H, AKAU 30) , 1 600 amperes A.C. (AKA 50/50 H , AKAU 5 0 ) , 2000 am peres AC (AKAT 50/50H), 800 amperes D.C. (AKA 30) and 2000 amperes D . C . (AKA 50) . 6 2.2 OPE RATION There are Manual and Electrical breaker models. The Manual breaker, shown in Fig. 1 , has an operati ng handle which is used to manually charge the mechanism closing spri ng. The Electric breaker, shown in Fig. 2, contains an elec tric motor which charges the mechanism closing spring. External control power is requi red to energize this motor and its control circuit. A nameplate i ndicates what voltage is required by the motor circuit and trip and close coils. 2.3 FUSED/NON FUSED Fused breakers are identified as either AKAU 30 (800 ampere frame size) or AKAU 50 ( 1 600 ampere frame size). A fused breaker is shown i n Fig. 3 . They are not i nter changeable with Non-Fused breakers, si nce they require deeper compartments for their fuses. .c om ua ls an tM FIG. 3 - Fused Breaker AKR U-60-30 tri ca lP ar FIG. 2 - Electrically Operated AKR-70-30 • • . . RACKING MECHANISM ww w .E lec ·� FIG. 4 - Orawout B reaker 7 2 .5 Type AKA breakers are designed for either drawout or stationary mounting. Drawout breakers (See Fig. 4) are equ ipped with features which make them easy to instal l i n o r withdraw from their associated switchgear equipment. These features are a racking mechanism (which facilitates inserting and withdrawing the breaker u n it) and prim ary and control power disconnects which connect and part automatically. I nterlocking devices are i ncl uded. Stationary breakers are desig ned to be mounted on a framework or panel , with mechanical fasteners being used to secure the breaker frame and make power connections. If control power connections are needed, a suitable termi nal board is supplied . The mounting type is identified by the second m iddle digit in the breaker's nameplate desig nation as follows : AKA-5 ( �0 MOUNTING TYPE CODES Breaker Type Code Stationary Drawout - A AKD-5 AKD-6 B Substructure D AKD-8 - Substructure - ca s AKA-( i )B-30 .L._Trip device code number per Table 3 TABLE 3 CODE N U MBER 2 X APPLICATION TRIP DEVICE EC DC Power Sensor1 AC AC 4 EC S 5 SST AC AC 6 MicroVersaTrip 7 RMS-9 AC MVT- PLUS or AC 9 MVT-PM 1 For Power Sensor devices. See publications G E K-7309 and G EK-7301 for detailed servicing proced ures. 2.6 MODEL N U M B E R Type AKA breakers (see Table 2 ) exist a s either n o model number or "- 1 " versions . For example AKA-5A-30H or AKA-5A-30H- 1 . � The difference between these models is their arc chute construction. The arc chutes in the no model number break ers have a two piece porcelain frame and use 2 arc chute retainers , see Fig . 5. The "- 1 " breaker arc chutes have a one piece molded polyester glass frame and 1 arc chute re tai ner, see Fig . 6 . All AKATSOH breakers use only molded arc chutes. ww w .E lec tri -- TRIP DEVICE CODES 3 lP Letter The trip device system is identified by the first m iddle digit i n the breaker nameplate designation as follows: ar TABLE 2 There are several types of soli d-state, direct-acting, self powered trip device systems associated with AKA breakers. These systems are for AC applications only. For DC appl ications an electro-mechanical system is avai lable. tM Mounti ng type code letter per Table 2 TRIP DEVICE ua ls MOUNTING an 2.4 .c om SECTION 2-General Description {Cont.) - l FIG. 5 - CERAMIC ARC CH UTES 8 FIG. 6 - MOLDED A R C CHU T ES .c om 2.7 SHORT CIRCUIT RATI NGS Short circuit ratings vary with the applied system vol tage. On 240 VAC syste ms they are also dependent upon whether the overcurrent trip device contains an i nstan taneous tri p element. See Table 4 . TAB L E 4 - B R EAKER I NTE R R U PTI ON RATI NGS 800 AC AKR 30H 635 508 254 635 508 254 635 508 254 AKR 50 1 600 AC AKRT 50 2000 AKRT 50H AKRU 30 AKRU 50 AKR 30 600 600 300V DC 300 VDC tri 800 1 600 800 DC 2000 DC AKR 50 42 42 50 65 50 42 50 42 50 50 50 65 65 65 65 65 65 50 65 50 65 50 65 65 65 65 200 200 - 25 1 2 50 3 25 50 ww w .E lec 'With 40-800 Amp Trip Coils 2With 200-2000 Amp Trip Coils 'Consult Factory For Application Data 42 50 635 508 254 635 508 254 ca AC 30 42 lP AKR 50H- 1 SHORT TIME 30 30 42 ar AKR 50H ua ls 635 508 254 635 508 254 AKR 30 an B R EAKER TYPE 3$ INTERR U PTION RATING KA RMS SYMM ETRICAL WITHOUT WITH INSTANTANEOU S I N STANTANEOUS TRIP TRIP tM FRAME SIZE (AMPERES) RATED MAXI M U M VOLTAGE (60 HZ AC) 9 3 . 1 Safety CAUTION: 1 . ALL CONDUCTORS M UST BE ASSUMED TO BE ENER GIZED UNLESS THEIR POTENTIAL HAS BEEN M EASURED AS GROUN D AND S UITABLE G ROUNDING CONDUC TORS HAVE BEEN APPLIED TO PREVENT EN ERGIZING. Many accidents have been caused by back feeds from a wide variety of sources. 2. Although interlocks to reduce some of the risks are provided, the individual's actions while perform ing service or maintenance are essential to prevent accidents. Each person's knowledge; his m ental awareness; and has planned and executed actions often determ ine if an accident will occur. The m ost im portant m ethod of avoiding accidents is for all associated personnel to carefully apply a thorough understanding of the specific equipment from the viewpoints of it's purpose, it's construction, it's operation and the situations which could be hazardous. ww w .E lec tri ca lP ar IF THE BREAKER IS S TORED FOR ANY LEN G TH OF TIME, IT SHOULD BE INSPECTED PERIOD/CA L L Y TO SEE THA T RUSTING HAS NO T S TA R TED AND TO A SSURE G OOD MECHANICAL CONDITION. SHOULD THE BREA KER BE STORED UNDER UNFA VORABLE A TMOSPHERIC CONDI TIONS, IT SHOULD BE CLEANED A ND DRIED O U T BEFORE BEING PLACED I N SERVICE. ua ls 2. The breaker should be stored in a clean location free from corrosive gases or fumes. Particular care should be taken to protect the equip ment from moisture and cement dust, as this co mbination has a very corrosive effect on many parts. The following requirements are intended to augment the user's safety program , but NOT supplant the user's responsibility for devising a c:::>m pl et e safety program . The following basic industry practiced safety require m ents are app l icable to all m ajor electrical equipment such as switchgear or switchboards. General Electric neither condones nor assumes any responsibility for prac tices which deviate from the following: an 1 . The breaker should be carefully protected against condensation, preferably by storing it in a warm dry room, since water absorption has an adverse effect on the insula tion parts. Circuit breakers for outdoor switchgear should be stored in the equipment only when power is available and the compartment heaters are in operation to prevent condensation. Each user m ust maintain a safety program for the protec tion of personnel, as wel l as other equipment , from the potential hazards associated with electrical equipment. tM I t i s recom mended that the breaker be put into service i m mediately in its permanent location. If this is not possi ble, the fol lowing precautions m ust be taken to insure the proper storage of the breaker: .c om SECTION 3 .0-Stora g e , Safety, M a i nten ance 10 All personnel associated with installation, operation and maintenance of electrical equipment, such as power circuit breakers and other power handling equipment, must be thoroughly instructed, with periodic retraining, regarding power equipment in general as well as the particular m odel of equipment with which they are working. Instruction books, actual devices and appropriate safety and m ainte nance practices such as OSHA publications, National Electric Safety Code (ANSI C2) , The National Electrical Code, and NFPA 7 OB Electrical Equipment Maintenance m ust be c losely studied and followed. During actual work, supervi sion should audit practices to assure conformance. 3. Excellent maintenance is essential for rel iability and safety of any electrical equipment. Industry publications of recom menced maintenance practices such as ANSI/NFPA 70B, Electrical Equipment Maintenance, should be carefully stud ied and applied in each user's formation of p lanned maintenance. .c om 3 . 2 Maintenance ua ls I ndustry publications of recom mended maintenance prac tices such as ANSI/NFPA 708, E lectrical Equi pment Maintenance, should be careful ly studied and applied in each user's formation of plan ned maintenance. Some users may require add itional assistance from Gen eral E l ectric in the p l a n n i n g a n d performance of maintenance. The General Electric Company can be contracted to either undertake maintenance or to provide technical assistance such as the latest publications. tM One oft he critical service activities, sometimes neglected, involves the cal ibration of various control devices. These monitor conditions in the primary and secondary c ircuits, sometimes initiating emergency corrective action such as opening or closing c i rcuit breakers. In v iew of the vital role of these devices, it is im portant that a periodic test program be followed. As was outlined above, it is recog nized that the i nterval between periodic checks will vary depending upon environm ent, the type of device and the user's experience. It is the General Electric recommenda tion that, until the user has accumulated enough experience to select a test interval better suited to h is individual requirements, all significant calibrations be checked at an interval of one to two years. I nstruction books supplied by manufacturers address com ponents that would normally req uire service or main tenance during the useful life of the equipment. However, they can not i nc lude every possible part that could require attention, particularly over a very long service period or under adverse environm ents. Maintenance personnel must be alert to d eterioration of any part of the supplied switchgear, taking actions, as necessary to restore it to serviceable status. an Both long and short term maintenance o f all electrical equipment is essential for reliabi l ity and safety. Mainte nance programs must be tuned to the specific application, well planned and carried out consistent with both industry experience and manufacturer's recommendations. Local environment must always be considered in such pro g rams, including such variables as am b ient tem peratures, extreme moisture, num ber of o perations, corrosive atmo sphere or major i nsect problems and any other unusual or abusive condition of the application. ar The performance and safety of this equipment may be compromised by the modification of supplied parts or their replacement by non identical substitutes. All such design changes must be qualified to ANSI/I EEE Standard C37.59. The user should methodically keep written maintenance records as an aid in future service planning and equipment reliability improvement. Unusual experiences should be promptly communicated to the General Electric Company. ww w .E lec tri ca lP To accom plish this, some items, such as "EC" direct operating trip systems for low voltage breakers, must be tested with primary current injection . Others can be adeq uately tested using test sets. Specific calibration instructions on particular devices typically are provided by supp lied instruction books. 1 0A .c om SECTION 4Drawout Breaker Interchangeability ua ls I n general, drawout breakers of the same type and rating are i nterchangeable in their equi pment compartments ; drawout breakers of different frame sizes are not i nter changeable. To prevent inserting the wrong type breaker i nto a drawout compartment, suitable " rejection hardware" is aff ixed to each breaker and its compartment. Figure 7 shows a typical rejection bracket which aligns with a rejec tion pin in the drawout rail (Fig. 8) . When the wrong type breaker is inserted into a compartment the bracket and pin prevent the breaker from seating itself i nto the d rawout rai ls. tM TYPICAL REJECTION BRACKET FIG. 7 - DRAWOUT B R EAKER R EJ ECTION SYSTEM ar a. An AKR-30H can be inserted into an AK R-30 compart ment. b. An AK R-50H can be inserted into an AKR-50 co mpart ment. c. An AKR-50H-1 can be inserted into an AKR-50 and AKR-50H compartment. d. An AKRT-50H can be inserted i nto an AK RT-50 co m partment. an There is one exception to the above . Breakers of the same frame size having different short circuit ratings may be interchanged in one direction only : The rejection hardware prevents the converse of a. thru d. above. FRONT OF COMPARTM E N T ww w .E lec tri ca lP A detailed description of the rejection pin and bracket co mbinations used is given in Installation manual , G E l 861 50. 1 08 R I GH T S I DE PIN F I G . 8 I NSERTING TH E B R EAKER .c om SECTIO N 1 4-M icroVersaTrip® Plus and M icroVersaTri p® PM Trip Units 1 4.9 TRO U BLE-SHOOTI NG G UI DE Corrective Action Possible Cause 1 . The trip unit display is blank. Line current is below 20% of S (MicroVersaTrip Plus). At least 20% of the current sensor rating, S, must be flowing through the breaker to activate the display. If not, power the trip unit with the Test Kit or external battery pack. External 24 Vdc is absent (MicroVersTrip '' PM). Check that the control power supply is present and operational. an Symptom ua ls The following guide is provided for trouble-shooting and isolating common problems. It does not cover every possi ble cond ition. Contact the Customer Support at 800-843-37 42 if the problem is not resolved by these procedures. Power the trip unit with the Test Kit or external battery pack. Can occur on Plus style trip units when load current fluctuates near 20% of S. 3. The trip unit display flashes ERR. The built-in self test has detected an error. 4. The trip indication target will not clear. Trip unit is not in status mode. 5. Unit does not com municate with the Monitor, POWER LEADER Distribution Software, or FPU. Commnet wires are shorted or improperly connected. Locate and repair the short or the incorrect con nection. FPU version is lower than 2.0 U pdate FPU to version 2.0 or higher. Trip unit address incorrect. Check that address assigned to trip unit agrees with address at host. Replace the trip unit. ar lP ca tri Rating plug value was defined incorrectly. lec 6. Current readings are incorrect. tM 2. The trip unit display flashes. Press FUNCTION until STATUS is displayed. Press SELECT and VALUE together to clear the target. Read the X value from the rating plug name plate and enter this with the rating plug current set point procedure . Do not enter the sensor rating, S . Potential transformer (PT) pri mary voltage was defined incorrectly. PT connection was defined incorrectly. Read the PT ordinary rating from the PT name plate and enter this value with the PT primary voltage procedure . With the PT connection procedure , enter VL-N for a wye-connected PT primary or VL -L for a delta-connected PT. 8. kW legend is flashing. Total power metering. Indicates that the total power is metered in kVA. 9. Overload target is flashing by itself. Test Kit-initiated trip indication. Clear target as indicated above (Symptom 4). ww w .E 7. Voltage readings are incorrect. 83 .c om SECTION 1 5-EC Trip Device The standard EC trip device for breaker frames up to 2000 amps is the type EC-2A, see Fig. 1 1 9. An optional trip device for these frames i s the type EC-1 , see Fig. 1 20. There are three basic characteristics: long time delay, short time delay and instantaneous, which can be used in various combinations to suit the appl ication. Tri p characteristics are for the EC devices are g iven in Table 1 7 . The time-current characteristics for the EC trip devices are g iven in the fol lowi ng curves: G ES-6000 G ES-601 0 G ES-601 1 G ES-6012 EC-1 EC-2/2A 1 A-3 EC-2/2A 1 B-3 EC-2/2A 1 C-3 ca lP ar tM an AKR breakers with EC Trips are for use on DC system voltages. One EC trip device is mounted per breaker pole. Thi s device contains its functional adj ustments. ua ls Type E C overcurrent trip devices are magnetically operated, using a series coi l or single conductor, and an associated magnetic structure to provide tripping force. FIG. 1 1 9 - EC-2A TRIP DEVICE tri FIG. 1 20 - EC-1 TRIP DEVICE TABLE 17 EC DEVICE TRIP C HARACTERISTICS Pickup CD 80·1 60% X EC-2A .E ( ± 1 0%) 80·1 60% X EC-1 Long Time lec Trip Device ( ± 1 0%) Delay ® Pickup Short Time Delay sec. or ( 1 8) INTER.-adj . 7 5- 1 8 sec. or ( 1 C) M I N .-adj . 3 3-8.2 sec. ( 1 A) MAX.-adj. 1 5-38 ( 1 A) MAX.-30 or or ( 1 C) MIN.-5 4-9X, 6-12X, 9-15X or 80-250%X sec. sec. sec. (2A) MAX.-.23 2-5X, ( 1 8) INTER.-1 5 lnatantlineoue Pickup <!l 3-7X or 4-1 0X sec. or (28) INTER.-. 1 5 sec. or (2C) MIN.-.07 sec. w (2AA) MAX.-.20 80-160% X ww EC- 1 8 ( ± 1 5%) ( 1 88) MAX.-4.5 or ( 1 CC) MIN.-2 sec. 2·5X, 3-7X sec. or 4- 1 0X or or High Set up to 1 5X, Non-Adjustable sec. 4·9X, (288) INTER.-. 1 3 (2CC) MIN.-.07 @) sec. 6·12X, 9-15X or sec. 80-250% X @) trip devices are set above 1 00% for coordination purposes, such sett1ngs do not 1ncrease the breaker's continuous current rat1ng. pickup setting. 3 At lower limit of band at 2112 times pickup setting. 4 Low-set instantaneous. Not available in combination with long time delay. 1 X = Trip device ampere rating. If 2 At lower limit of band at 6 times 84 ww .c om w .E lec tri ca lP ar tM an ua ls SECTION 1 5-EC Trip Device (Cont . ) FIG. 1 2 1 OVERC U R R ENT TRIPPING DEVICE - EC-2A 85 .c om SECTIO N 1 5-EC Trip Device (Cont . ) 1 5.1 .2 ADJ USTMENT NOTE Before attempting any checks or adjustments on breaker with EC trip devices, the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads. The trip latch of the breaker should also be checked for proper trip latch engage ment. See Section 7. 1 5 Refer to Fig. 1 2 1 for the discussions given below. 1 5. 1 .1 LONG TIME-DELAY AND HIG H-SET INSTANTAN EOUS TRI PPING 1 5.1 .3 INSTANTANEOUS HIGH-SET TRIPPING The high-set instantaneous pick-up value may have one of the following three ranges: 4 to 9 times coil rating; 6 to 1 2 times coil rating or 9 to 1 5 time coil rating. The pick-up setting may be varied by turning the instantaneous pick-up adjusting screw (1 2) . Three calibration marks ( 1 5) will appear on the operating arm ( 1 4) and the value of these calibration marks will be indicated by stampings on the arm as follows: (4X - 6.5X - 9X) or (6X 9X - 1 2X) or (9X - 1 2X - 1 5X). At the factory, the pick-up point has been set at the name plate value of the instantaneous trip current. (Usually expressed in times the ampere rating of the trip coil). The variation in pick up setting is accomplished by varying the tensile force on the instantaneous spring (5). Turning the adjustment screw changes the position of the movable nut (1 1 ) on the screw. The spring is anchored to this movable nut so that when the position of the nut is changed, there is a correspondin.g change in the spring load. As the spring is tightened, the pick-up point is increased. The top edge of the movable nut (1 1 ) serves as an index pointer and should be lined up with the center of the desired cal ibration mark (1 5) to obtain the proper instantaneous trip setting. The trip screw (6) on the end of the armature (7) should be set so that it does not contact the trip paddle on the trip shaft until the air gap between armature and pole piece is reduced to 3/32 in. or less, measured at the rivet in the pole piece. Also, the armature must have a minimum of 1 /32 i n . of travel beyond the point in its motion at which the breaker is tripped. Replacement of the EC-2A device is accomplished by the same procedure described for the EC-1 series trip device; how ever, in some cases, when replacing an EC-1 device with an EC-2A it will be necessary to replace the trip paddles on the trip shaft with ones which are slightly longer. When required these will be provided with the replacement trip units. NOTE: Pick-up settings on the calibration plate of the EC-2A device are calibrated for the specific device. When replacing covers, replace on associated device. ww w .E lec tri ca lP ar By means of the adjustment knob (3) , which can be manipu lated by hand, the current pick-up point can be varied from 80 to 1 60 percent of the series coil rating. The indicator and a cal ibration plate (2) on the front of the case provide a means of indicating the pick-up point setting in terms of percentage of coil rating. The calibration plate is indexed at percentage settings of 80, 1 00, 1 20, 1 40, and 1 60. As in the case of the EC-1 over-current trip, the long-time de lay tripping feature can be supplied with any one of three time-current characteristics which correspond to the NEMA standards maximum, intermediate and minimum long-time delay operating bands. These are identified as 1 A, 1 B and 1 C char acteristics, respectively. Approximate tripping time for each of these, in the same order are 30, 1 5, and 5 seconds at 600 per cent of the pick-up value of current. (See time-current charac teristic curves). The tripping time may be varied within the limits shown on the characteristic curves by turning the time adjustment screw (4) . Turning in a clockwise direction increases the tripping time; counterclockwise motion decreases it. The dashpot arm (8) is indexed at four points, MIN-1 /3-2/3-MAX, as indicated in Fig. 1 22. When the index mark on the connecting link {9) lines up with a mark on the dashpot arm, the approximate tripping time as shown by the characteristic curve is indicated. The 1 A and 1 B characteristic devices are shipped with this setting at the 2/3 mark and the 1 C characteristic at the 1 /3 mark. The standard characteristic curves are plotted at these same settings. Time values are inversely proportional to the effective length of the dashpot arm. Therefore, the linkage setting that gives the shortest time value is the one at which dimension "A", Fig. 1 2 1 , is greatest. The time adjustment screw (4) may be turned by in serting a Phillips head screwdriver through the hole in the front of the case. If it is desired to relate the linkage setting to the index marks on the linkage it will be necessary to remove the case. This may be done by removing the two mounting screws, one on each side of the case, which may be taken off without disturbing the trip unit itself. The low-set instantaneous pick-up point may be varied by the adjustment knob (3) . The calibration in tflis case usually ranges from 80 percent to 250 percent of the series coil rating, with the calibration plate indexed at values of 80, 1 00, 1 50 , 200, and 250 percent of the rating. ua ls The Type EC-2A overcurrent tripping device is available in three forms: 1 . Dual overcurrent trip, with long-time delay and high-set instantaneous tripping. 2. Low-set instantaneous tripping. 3. High-set instantaneous tripping. The dual trip has adjustable long-time and instantaneous pick-up settings and adjustable time settings. Both forms of in stantaneous trip have adjustable pick-up settings. INSTANTAN EOUS LOW-SET TRIPPING an SERIES OVERCURR ENT TRIPPING DEVICE EC-2A tM 1 5.1 86 FIG. 1 22 - TIME-ADJUSTMENT INDEXING .c om SECTIO N 1 5-EC Tri p D evice {Cont.) SERIES OVERCURR ENT TRIPPING DEVICE EC-1 Each series overcurrent tripping device is enclosed in a molded case and mounted by screws and a bracket to the lower part of the pole unit base. Refer to Fig . 1 23 for the discussions below. 1 5.2. 1 SHORT TIME-DELAY TRI PPING 8 I I ::::1 §_ '• 12 13 ca lP 4 ar 5 The armature (1 0) is restrained by the calibration spring ( 1 1 ) . After the magnetic force produced by an overcurrent condition overcomes this restraining force, the armature movement is fur ther retarded by the flow of silicone oil in a dashpot, which prr:> duces an inverse time delay characteristic. The mechanism is shown on Fig . 1 23 10 7 6 LONG TIM E-DELAY TRIPPING tM 9 2 1 5.2.2 an The armature (7) is restrained by calibrating spring (8). After the magnetic force produced by an overcurrent condition over- comes this restraining force, the armature movement is further retarded by an escapement mechanism which produces an in verse time delay characteristic. The mechanism is shown on Fig. 1 23 ua ls 1 5.2 Right Side View Showing .E lec tri Left Side View Showing Short Time Delay Mechanism ww w 1 . Series Coil 2. Magnet 3. Pallet 4. Pinion 5. Escape Wheel 6. Driving Segment 7. S.T.D. Armature Long Time Delay Mechanism 20 Front View Showing Mounting Bracket 8. S.T.D. Calibration Spring 9. Trip Paddle Adjusting Screw 1 0 . L.T.D. Armature 1 1 . L.T.D. or Low-set lnst. Calibration Spring 1 2. lnst. Trip Spring (High Set) 1 3. Spring Holder 1 4. Calibration Clamp Nut 1 5. Plunger 1 6. Cylinder 1 7. Calibration Plate 1 8. Trip Paddle 1 9. Trip Arm 20. Clamping Bracket FIG. 1 23 - SERIES OVERCURRENT TRIPPING DEVICE EDC-1 87 .c om SECTIO N 1 5-EC Trip Device (Cont . ) 1 5.3 1 5.2.4 EC-1 ADJ USTMENTS Positive tripping is achieved when adjustment screw (9) Fig ure 1 24 is in such a position that it will always carry the trip pad dle on the trip shaft beyond the point of tripping the mechanism, when the armature closes against the magnet. In order to make the adjustment, first unscrew trip screws (9), Figure 1 24 , until it will not trip the breaker even though the ar mature is pushed against the magnet. Then, holding the arma ture in the closed position, advance the screw until it just trips the breaker. After this point has been reached, advance the screw two additional full turns. This will give an overtravel of 1 1 1 6 of an inch and will make sure that activation of the device will always trip the breaker. Adjustment screw (9), Figure 1 23 can best be manipulated by an extended 1 /4 inch hex socket wrench. .E lec tri ca lP ar Before attempting any checks or adjustments on breaker with EC trip devices, the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads. The trip latch of the breaker should also be checked for proper trip latch engage ment. See Section 7. 1 5 EC-1 Devices may have their pick-up settings varied by changing the positions of the sliding calibration plates on the front of each device. The clamping nut holding the plate must be loosened to make the change, and then retightened. If a new device is installed, the adjusting screw on the tripping arm must be set to give 1 /32nd of an inch overtravel in tripping. The method for making this check is demonstrated in Figure 1 24. The rod shown is used for pushing the armature of device closed. If this is done with the device mounted on a closed breaker, it will simulate the action which occurs when the device reacts to an overload condition. Before attempting any checks or adjustments on breaker with EC trip devices, the breaker mechanism and trip latch should be checked to assure their proper functioning so that the breaker trip shaft is free of high friction loads. The trip latch of the breaker should also be checked for proper trip latch engage ment. See Section 7 . 1 5 I n addition to the pick-up settings and time-delay adjustments already described, overcurrent trip devices must be adjusted for positive tripping. This adjustment is made at the factory on new breakers, but must be made in the field when the breaker mech anism or the overcurrent trip devices have been replaced. ua ls (a) Adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition, over comes the restraining force of the calibration spring which can be adjusted by the calibration clamp nut (1 4) . (b) Non-adjustable instantaneous tripping takes place after the magnetic force produced by an overcurrent condition over comes the restraining force of a non-adjustable spring. POSITIVE TRIP ADJUSTMENT an INSTANTANEOUS TRIPPING tM 1 5.2.3 FIG. 1 24 CH ECKING TRAVEL DISTANCE OF SERIES OVERCURR ENT TRIPPING ww w DEVICE. 88 .c om SECTIO N 1 5-EC Tri p Device (Cont . ) R EVERSE CUR RENT TRIPPING DEVICE The device is enclosed in a molded case and is mounted on the right pole base similar to the series overcurrent tripping device. The reverse current tripping device (see Fig . 1 25) consists of a series coil (2) with an jron core mounted between two pole pieces (9), also a potential coil (7) connected across a constant source of voltage and mounted around a rotary-type armature (1 0). Calibration spring (6) determines the armature pick-up when a reversal of current occurs. tM an As long as the flow of current through the breaker is in the normal direction, the magnetic flux of the series coil and the magnetic flux of the potential coil produce a torque which tends to rotate the armature counterclockwise. The calibration spring also tends to rotate the armature in the same direction. This torque causes the armature to rest against the stop screw ( 1 2) attached to a bearing plate on the right side of the device. If the current through the series coil (2) is reversed, the ar mature (1 0) tends to move in the clockwise direction against the restraint of the calibration spring (6) . When the current reversal exceeds the calibration setting, the armature revolves clockwise causing the trip rod (3) to move upward engaging the trip paddle (1 ), thereby tripping the breaker. ua ls 1 5.4 2 --------� 2A 28 ar 3 -------*f---"-<;:--j ca lP 4 ------, lec tri 5 ----- - - - - - -1 ww w .E <+I Lt - - - - - - 52 "' 9 I I I L :u;_ SW 12 1. 2. 2A. 28. 3. 4. 5. 6. 7. 8. 9. 1 0. 11. 1 2. 1 3. 1 4. Trip Paddle Series Coil Adjusting Nut Locking Nut Trip Rod Trip Crank Setting Sealing Screw Calibration Spring Potential Coil Calibration Nut Pole Pieces Armature Counter Weight Stop Screw Mounting Screw Screw L3 ] s * -86- FIG. 1 25 ED-1 R EVERSE CURR ENT TRIPPING DEVICE 89 .c om SECTIO N 1 5-EC Trip Device (Cont . ) ADJ USTM ENTS 1 5.6 Overcurrent devices on AKR30 & AKR50 breakers may be dismounted by removing the fastening hardware at the rear of the breaker and withdrawing the device. EC devices, after being unfastened as shown in Figures 1 26 and 1 27, and having the clamps on the case in the front removed, may be lowered clear of the breaker. You do not have to separate frames on these breakers. ua ls The only adjustment to be made on the reverse current de vice is to make sure that the trip rod has a minimum overtravel of 1 /32 in. beyond the point of tripping the breaker. This adjust ment should have to be made only when an old device is being replaced by a new one. The new device will be factory adjusted so that the top end of the trip rod (3) will extend 1 /2 in. above the top of the device case, and no additional adjustments of the trip rod should be re quired. To obtain the proper 1 /32 in. overtravel, close the breaker and proceed as follows: 1 . Loosen the locking nut. (28). 2. Manually lift the trip rod and vary the position of the ad justing nut (2A), this establishing the position of the adjusting nut where the breaker is just tripped. Be sure to keep clear of moving breaker parts when tripping the breakers. 1 5.4.2 REPLACEMENT 1 5.5 lP ar After removing the wiring for the potential coil the reverse cur rent device can be removed and replaced by following the pro cedure outlined for replacing the series overcurrent device. See Section 1 5 .6. For wiring, see Fig . 1 25 . tM NOTE: 3. With this position of the adjusting nut established, advance the adjusting nut upward one and one-half turns. 4. Tighten the locking nut and the minimum 1 /32-in. over travel of the trip rod should be obtained . TRIP DEVICE REPLACEMENT an 1 5.4.1 SWITCHETTE FEATU RE - p ww w .E lec tri ca The switchette is operated by the long-time delay function. Its purpose is to provide a set of contacts that will close before an overload occurs. This device will not trip the breaker on over load it will trip on instantaneous only. The switchette feature is available only in type EC-1 devices. The switchette is used in one pole and EC-1 trips in the other poles. For the alarm to be effective in indicating the overload before the other poles trip the breaker, the device must have less time delay than the other two poles; this is accomplished by using a lower characteristic on the alarm device than the other poles or setting the alarm devices long time setting at 80%. FIG. 1 26 DISCONNECTING EC COIL 90 FIG. 1 27 DISCONNECTING EC FRAME TABLE 1 8 - Charg in g and Closin g Operatin g Currents .. ;;; .., C QI C-) ·e .. � .. Z > MOTOR > ... c Cl> N ::o ::t: cr "' .., .., ... ... : c .. ... � ..... ANTI-PUMP Current (Amps) > a: �� ,�... -�'l.� � -..t. :" <::,�.. .!!! c; .... > :::1 . c .... ·... :E O: RELAY "W" Rated-Amps Inrush Sealed Open Closed .!!! c; .... > :::1 . :E O: 48V DC 38-56 40 10 38 .063 .063 DC 1 00- 1 40 27 5 85 .024 .024 90 250V DC 200-280 13 3 1 70 .01 5 .01 5 1 80 1 20V 60 .090 .052 1 20V 50 .090 .052 1 20V 25 .047 .032 208V 60 .050 .029 208V 50 .050 .029 208V 25 .032 250V 60 .064 250V 50 .064 .036 250V 25 12 1 90 3 Table 1 9- Bell Alarm Contact Rating 2.5 0.9 10 5 3 2.5 0.9 30 15 7 tri 60 Hz. Ac 1 25 250 1 20 240 480 Closed Inrush Sealed Open Closed 4.1 4.1 1 .05 1 .05 1 00 5.2 1 . 75 .53 .53 200 .88 1 .0 1 .4 38 5.2 1- .75 . 88 2.6 .35 .15 2.2 .29 1 .27 1 .1 .17 .45 .063 1 .5 .19 .55 .083 1 .2 .16 .01 8 3.86 .76 .60 .08 .036 .50 .07 1 .3 .17 .50 .08 1 .1 .15 3.42 .64 .54 08 1 75 1 90 .023 98 1 77 1 96 z 0 i= Cl) � ::o w w u ..... Cl) 1 5A 6A 6A 6A 6A 6A 6A 6A 6A 6A 6A 6A Table 21 -Auxiliary Switch Contact Rating Auxiliary Switch Interrupting Ratings (Amperes)CD Control Voltage Conlinuous Inrush ca De lP Bell Alarm Contact Rating (amperes) Control Voltage Open Rated Amps 1 .0 ar .035 Sealed an 208-254 1 75 3.5 15 Inrush .!!! c; .... > :::1 . c .... ·... :E O: SOLENOID 6 . 85 95 tM 1 80-220 95 5 25 30 CLOSING Rated Amps c .... ... ·- 1 25V 1 04- 1 27 CONTROL RELAY "X" ua ls g c .c om SECTIO N 1 6-Eiectrical Characteristics NonInductive 48 1 25 250 115 240 480 De Ac Inductive 25 11 2 75 50 25 - 6.3 1 .8 50 25 12 G:l Limited to 20A contmuous ratmg of switch on all breakers and to 5A contin uous rating of # 1 6 wire on drawout breakers. lec Table 20 -Auxiliary Switch Contact Sequence ww w .E CB Main Contacts Auxiliary Switch Position " a" Contact "b" Contact Open or Tripped Open Closed Closed Closed Open Table 22 Charg ing Times Time (sec.) (j; Nominal Voltage 48VDC 1 25V D C 250VDC 1 20VAC 208VAC 240VAC 1 .5 1 .0 1 .5 0.09 1 .3 (j; Closing spring charg i n g t imes are typical values. The max i m u m perm itted is 5 seconds. 91 .c om TABLE 23 SHUNT TRIP AND UN DERVOLTAG E DEVICE OPERATING CURR ENTS e c UNDER VOLTAGE SHUNT TRIP DC Voltage range 30 60 1 40 280 1 32 1 27 1 27 1 27 220 220 220 254 254 254 254 410 508 508 508 625 625 625 14 28 70 1 40 59 95 95 95 1 75 1 75 1 75 1 90 1 90 1 90 1 90 315 380 380 380 475 475 475 DC DC DC 60 60 50 25 60 50 25 60 50 40 25 50 60 50 25 60 50 25 Inrush Sealed Open Closed 8.3 4.5 2.0 1 .0 8.3 4.5 2.0 1 .0 - - 1 2.3 7.6 4.7 3.2 3.8 2.1 3.9 4.7 5.8 2.1 2.9 3.4 7.5 3.5 2.8 5.1 3.1 1 0.8 6.7 4.1 2.6 3.1 1 .9 3.4 4.1 5.1 1 .9 2.6 3.1 7.3 3.3 2.5 4.7 3.0 Operating Voltage range SEE Inrush Sealed Open Closed .38 .19 .08 . 04 N/A .66 .75 .31 .51 .30 .14 .37 .34 N/A .16 .22 .23 .17 .1 1 .16 .14 .1 0 .38 .19 .08 .04 N/A .24 .25 .10 .17 .1 0 .05 .12 .11 N/A .06 .08 .08 . 06 .05 . 06 . 06 .05 TABLE ua ls 24 48 1 25 250 70 1 20 1 20 1 20 208 208 208 240 240 240 240 380 480 480 480 575 575 575 Operating 25 Q) 0> (1j c:n . Q) Clj _ o > 0_ - Clj --� E > - (1j c E o 0 c c .,_ 0 0� � (0 '+-- tM II. an ij. :r f 0 z Current (Amps) (/) Q .._ o 0 _0 � 0 � 0 L!) C"') co (/) (/) ' ·- - ar E > ·- lP 8 � - .. � � 0 Current (Amps) > " c: Cll N o. :J :J 0 (.) .... 0. � Q. 0... 0 ·- DC DC DC DC ww w .E lec 24V 48V 1 25V 250V 1 20V 1 20V 1 20V 208V 208V 208V 240V ,.----· 240V 240V 380V 480V 480V 480V 575V 575V 575V Frequency Hz 92 Anti-Pump Relay "W" N/A 802 5000 1 6400 450 450 1 450 1 450 1 450 3900 1 450 1 450 6000 N/A N/A N/A NiA NiA N/A N/A tri Nominal Control Voltage ca TABLE 24 COIL RESISTANCE-DC OHMS @ 25°C 60 50 25 60 50 25 60 50 25 50 60 50 25 60 50 25 Control Relay "X" NiA 12 119 476 54 75 75 21 6 300 300 300 300 300 N!A . NIA NiA N/A NIA NiA N!A Shunt Trip 3 11 64 260 3.9 7. 1 5 25.4 25.4 25.4 64 25.4 25.4 64 64 64 32 1 00 1 00 64 1 46 Undervoltage 64 240 1 600 6700 25.4 33 1 46 64 1 46 580 1 00 1 46 580 370 370 580 1 600 580 91 8 3200 .c om TABLE 25 I N STANTAN EOUS UNDERVOLTAG E DEVICE SETTINGS COI L RATING MAXI M U M PIC K U P VOLTAGE 24 VDC 20 48 VDC 41 1 25 VDC 1 06 1 55 VDC 1 32 250 VDC 213 1 20 VDC 1 02 208 VDC 1 77 240 VDC 204 380 VDC 323 480 VDC 408 575 VDC 489 DROP OUT RANGE 7- 1 4 1 4-29 ua ls 38-75 47-93 75- 1 50 36-72 tM an 62- 1 25 72-1 44 1 1 4-228 1 44-288 1 73-345 ar TABLE 26 TI M E-DELAY UNDERVOLTAG E DEVICE SETTINGS DELAY U N IT VOLTAG E PICK UP RANG E UVR O N LY VDC 1 25 VDC 77 - 85 50 90 - 95 250 V DC 208/240 VAC 1 25 - 1 40 90 1 60 - 1 65 UVR I NSTALLED M EC H A N ISM R ES ET PICK UP M I N I M UM POSSI B L E ww w .E lec tri ca lP NO PICK UP DROP OUT RA N G E 93 .c om ua ls an tM ar lP ca tri .E lec These in structions do not purport to cover all d e tails or variations i n equipment nor to provide for every possible con tingency to be met i n connection with i n stallation operation or maintenance. Should furth er information be desired or should particular problems arise which arc not covered sufficien tly fi:lr the purchaser's purposes, th e ww w matter should be referred to the GE Company. GEK-64459C 0693 PSA GE Electrical Distribution & Control General Electric Company 4 1 Woodford A ve., Plainville, CT 06062 © 1993 General Electric Company ELECTRICAL CLOSING On electrically operated brea kers the closing springs are charged by a gear motor. With the springs discharged, voltage appl ied to the control circuit will energize the motor through the " G " switch contacts - see Fig. 9 . The motor, through the gear reduction output crank, compresses the closing springs until they are fully charged. As this fully charged position is reached , mechanically operated switches " F" and "G" reverse their shown position, the " G " switch deenerg izing the motor and the F switch estab l ishing a circuit to the X relay. At the same time , a mechanical prop is positioned to prevent the discharge of the fully charged closing spring. " " MAN UAL CLOSI NG Man ually operated AKR breakers are constructed with front-mounted hand les. Handle operation resets the mechanism and fully charges the closing spring. A com p lete charge is accom p l ished by cranking the handle through one cycle (1 35-degree swing). The C LOSE but ton mounted on the escutcheon, is used to manual ly close the breaker contacts and the TRIP button is used to open them. With the closing spring propped ful ly-charged, the breaker is ready for closing. This may be accomplished electrically by depressing the closing switch " PB" on the breaker (if so eq u i p ped) or by a remote closing switch. Operation of the closing switch energ izes the "X" relay, which in turn energizes the closing solenoid "CC". This removes the prop, releasing the closing springs to close the breaker. As the closing solenoi d is energ ized , it energ izes anti pump relay " W " . If the closing switch is maintained closed , the anti-pump relay will remain picked-up to prevent a second closing operation on the breaker in the event it is tripped open automatically. The closing im p ulse must be released and reappl ied before a second closing operation can occur. The closing springs on electrical ly operated breakers can be manually charged . The breakers can also be man ually closed . Refer to Section 5.4 for this procedure. ca lP ar tM If equipped with a closing solenoid, a manual breaker may be closed remotely by a control switch or relay. Before this can be done, however, the closi ng spring has to be charged by hand. The closing solenoid is an op tional accessory and is not suppl ied un less spec ified i n the breaker order. " an 5.1 " ua ls A breaker may be eq u i pped to operate either manually or electrical ly. Both types of operation resu lt i n the same fast-closing movement as far as the contact action is concerned. The variation is in the way energy is stored i n t h e closing spring, and how it is released. .c om 5.2 SECTION 5-Breaker Operation tri CONTROL SOURCE LEGEND lec �r 'I x X TC ww w .E Gl ...J CC - C LOS I N G SOLENOID F - CUTOFF SWITC H , CLOSED WHEN CLOS I N G SPRING IS FULLY CHARGED. G - C UTOFF SWITC H . OPEN WHEN CLOSING SPRING IS F U L LY CHARG ED L - AUXI LIARY SWITCH M - C H A R G I N G MOTOR P B - C LOSE PUSHBUTION ON B R EAKER ESCUTHEON, OPTIONAL. TC - S H U NT TR I P DEVICE W - ANTI - P U M P R E LAY X - CONTROL R E LAY FIG. 9 - ELEMENTARY DIAGRAM FOR ELECTRICALLY OPERATED DRAWOUT B R EAKER. CONTACT POSITIONS ARE SHOWN WITH BREAKER OPEN AND CLOSING SPRINGS DISCHARGED. TYP #1 83L71 2 "R" SERIES 11 .c om 5.2.1 ALTERNATE CONTROL C I RC U IT USED equipped) or by a remote closing switch . Operation of the , closing switch energizes the K-relay, which i n turn ener gizes the closing solenoid "CC". This removes the p ro p , releasing the closing springs to close t h e breaker. The "F" cutoff switch is only i nstalled on breakers using D.C. The m otor i s energized through the "G" c utoff switch control voltage. and the K-relay contact. The motor i s deenergized when The anti-pum p funct ion is obtai ned through the nor the "G" c utoff switch changes state wh ich occurs when m a l l y c losed K-relay contact i n the m otor c i rcuit. If a the c l osing spring i s fully charged. c lose signal is m a i ntai ned after the breaker has tripped With the closing spring propped fully-charged, the open automatical ly, the K-rel ay is energ ized preventing breaker is ready for closing. Th i s m ay be accom p l ished the m otor from c harging t he c l osing spri ng. The closing electrically by closing the "PB" switch on the breaker (if so signal m ust be removed for approxi m ately 1 .3 to 2.0 seconds to al low the closing spring to c harge. -{ � - , t� PB CC - CLOSING SOLEN O I D F - CUTOF F SWITCH, CLOSED WHEN CLOSING SPRI NG IS FU LLY CHARGED (D.C. O N LY) G - CUTOFF SWITCH , OPEN WHEN CLOSING SPRI N G IS FU LLY C HARGED. L - AUXI LIARY SWITCH M - CHARG ING MOTOR PB - CLOSE PUSH BUITON O N BREAKER ESCUTCH EO N . O PTIONAL TC - S H U NT TRIP DEVICE K - ANTI-PU M P RELAY TC .E lec tri ca lP CONTROL SOURCE A. LEG E N D ar o------o- - tM REMOTE CLOSE an ua ls A second type of electrical control is shown i n Fig. 9A for all control voltages except 250 volts D .C . which uses the circuit shown in Fig . 9. This alternate control circuit elim i nates the X-relay and CC switch shown in Fig. 9. ww w FIG. 9A. ALTERNATE ELEMENTARY DIAGRAM. CONTACT POSITIONS ARE SHOWN BREAKER OPEN AND CLOSING SPRINGS DISCHARGED. TYP #1 83L7 1 2 "B" SERIES 12 .c om 5.3 13 12 M ECHAN ISM O P E RATION Figures 1 OA, 1 OB and 1 OC show the mechan iSm com .. ponents in the C losed, Tri p ped and Reset positions. The closing spring is in the charged position for all of these d etails. ua ls 10 tM lP ar Reset Position - The mechanism i s shown in Fig. 1 OC. The closing cam, item no. 3 , which is assembled to the cam shaft, item no. 4, is rotated by the charging motor, manual operating hand le, or mai ntenance handle. The cam engag es the cam roller and partially extends the togg le linkage. This allows the secondary latch item 1 4 to pivot against the front frame as shown leaving a gap between the trip latch and secondary latch roller. The secondary latch is now in a position to engage with both the trip latch and cam roller. ca s 5.4 2. 3. 4. 5. 6. 1 0. 15 -----�\ ;,---: � . . 14 5 4 \ 3 FIG. 1 0C RESET Prop Cam Camsh aft Cam Ro l l er Secondary Latch Roller Tr i p Shaft 11. 1 2. 13. 1 4. 1 5. Tri p Latch I ns u lated Cou p l i ng Main Shaft Seco ndary Latch Open i n g Spring CHARG I NG USING THE MAINTENANCE HANDLE The closing spring on electrically operated breakers can be manually charged by using the maintenance handle (5688386G 1 ) as shown in Fig. 1 1 . The triangular socket in the maintenance handle mates with the mechanism cam shaft extension on the front right side of the breaker. Using the knob on the handle, it will be necessary to align this socket to fit on the end of the shaft when the handle i s positioned as show n . ww w .E lec tri When the breaker is closed and the closing spring discharged , the u p per cam roller item #5 is supported by the cam rather than the prop. This is the position the mechanism must be in to check contact adjustment, refer to Section 8 . 14 FIG. 108 TRIPPED an - 11 Jr r I -E_-,_cl=J��·�=- =�·= d; I · The breaker closes when the closing spring d ischarges and rotates the cam item #3 against the cam roller item #5. The togg le l i n kage i s fully extended, pivoti ng the secon dary l atch from the front frame and engaging it with the trip l atch and cam rol ler as shown in Fig. 1 0A. 3 I Closed Position - As shown i n Fig. 1 0A, the movable contacts are pushed against the stationary contacts by the toggle linkage. The toggle linkage is held in position through the engagement of its cam rol lers, item no. 5, with the prop, item no. 2 and the secondary latch/roller item #6 and secondary latch #1 4 and trip latch #1 1 . Tripped Position The mechanism goes from the Closed position to the Tripped position, shown i n Fig. 1 08, when the trip shaft, item no. 1 0, i s rotated by either the manual trip button or one of the other trip devices. The trip l atch, i tem no. 1 1 is assem bled to the trip shaft. When the trip shaft rotates, the trip l atch d i sengages from the secondary l atch rol ler. The secondary l atch pivots, resu lting i n the col l apse of the toggle l i n kage. Th i s col l apse along with the open ing spring, item no. 1 5, s hown in Fig . 1 0 C, causes the br;eaker contacts to open. 2 4 s 11 14 6 FIG. 1 OA CLOSED FIG. 1 1 - MAINTENANCE HANDLE I NSTALLED ON CAMSHAFT EXTENSION 13 .c om tM an ua ls SECTION 5-Breaker Operation (Cont.) FIG . 1 2 - ROLLER ENGAG ED WITH CLOSING P ROP Rotate the camshaft using the m aintenance handle until the ratchet assembly roller engages with the prop. Do not drive the roller against the prop with undo force. The breaker can now be closed by re moving the prop from the roller. This is done by manually activating the closing solenoid armature by pushing the solenoid armature into its windings. See Fig. 1 3 . ww w .E lec tri ca lP ar There is a ratchet asse mbly attached to the camshaft extension . This ratchet is normally driven by the breaker's gear motor. A roller on this ratchet engages with a prop when the closing spring is fully charged and driven over center, see Fig. 1 2 . This holds the closing spring in a charged co ndition. 14 FIG. 1 3 - MAN UAL O P ERATION O F CLOSING SOLENOID .c om SECTION 6-lnterlocks ua ls AKR breakers are equipped with safety interlock devices that are requi red by Industry Standards and Certifying Au thoriti es. I nterlock devices for special applications are also avai lable as options. The standard interlock devices de scri bed below are used only on drawout breakers. Stati on ary breakers have no required interlocks. 6.1 RACKING MECHANISM INTERLOCK The function of the racking mechanism interlock is to prevent the breaker from moving from the CONN ECTED position before the breaker is in the OPEN position . tM The racking mechanism d rive shaft is located behind the RACKING SCREW cover shown in Fig . 1 4A. This cover must be slid to the right to gain access to the drive shaft as shown in Fig. 1 48. When the RACKING SCREW cover preventing it from being o pened. This link is driven by the motion of the OPEN/CLOSED indicator as shown in Fig. 1 5. an Caution must be taken to ensure that any interlock lever is not bent and caused to not function. All interlocks should be operated to confirm that they function as required. ar FIG. 1 4A - RAC KING SCREW lP CAUTION! Prior to moving rack screw cover over to attach racking wrench push the manual trip button above the cover. This will ensure that the breaker is open. Also read breaker position flag to confirm that breaker is open. ca Compartment door should be closed and latched when racking a breaker from the connect position. l :;mr lec tri The T R I P button also engages with the RAC K I N G S C R E W cover in both the OPEN and CLOS E D positions. Therefore, the T R I P button must be pushed in before the cover can be opened. This will open the breaker if it was closed and also depress the OPEN/CLOSED l i n kage discussed above. .E When the RACKI NG SCREW cover is open it holds th e TR I P button i n . This keeps the breaker tri p-free so a mechanism closing cycle wi ll not cause contact movement especi ally when the breaker is being racked in or out. FIG. 1 48 ww w CAUTION! Use only the proper racking mechanism wrench for racking the breaker in or out, otherwise the trip-free i nterlock featu re may not function. 15 .c om SECTION 6-lnterlocks (Cont.) / POSITIVE INTERLOCK cran k pin reaches the end of the slot i n the li nkage. Continued motion of the racking mechanism causes the li nkage to rotate the lever which moves the closing sole noid armature forward. The armature linkage then releases the prop, d ischarg ing the closing spring. ar 6.2 FIG. 1 6 - POSITIVE INTERLOCK tM FIG. 1 5 RACKING SCREW COVER INTERLOCK CLOSED POSITION • an POSITIVE I NTERLOCK ua ls ' ' �� The Closing Spring i nterlock should be adj usted to cause the closing spring to di scharge when the racking mechan ism is a m i n i m u m of 1 and a m axi m u m of 2112 turns short of the fully racked out position. I n this position the racking handle can no longer be turned. If adjustment is req u i red, use the l i nkage adj usting screws shown i n Fig. 1 7 . lP The fu nction of the positive interlock is to keep the breaker trip-free while it is being racked in or out between the CONN ECT E D and TEST positions. CLOSING SPRING INTERLOCK lec 6.3 tri ca The positive interlock is located on the breaker left side as shown in Fig . 1 6 . As the breaker moves between the CONNECTE D and TEST positions, the positive interlock engages with a ramp cam located in the breaker compart ment. This cam raises the interlock lever assem bly caus ing the trip shaft to rotate and prevent the trip latch from engaging with the secondary latch asse mbly roller. The breaker is held trip-free and cannot be closed during this interval . .E The fu nction of the closing spring interlock is to dis ch arge the closing spring as the breaker is bei ng racked out of its housing. This elimi nates the hazard of a com pletely charged breaker being discharged after the breaker is removed from its compartment. ww w The o peration of the closing spring interlock is shown in the two pictures for Fig. 1 7 . The racking mechanism arms and the cran k are connected to a common shaft. As the breaker is racked out a pin attached to the cran k moves through a slot tint he m echanism linkage. The li nkage is connected to a lever which engages with a pin on the closing solenoid armature linkage. When the racking mechanism approaches the DISCONN ECT position, the 16 Note: - Undue force on the racking handle at the fully racked out position wi l l cause the lever to m ove past the pin on the armatu re l i n kage. This will bind u p the overall i nterlock. U nder these conditions, conti nued application of this force wi l l defo r m the l i n kage assem bly. .c om 6.4 DISCONN ECT POSITION I NTER LOCK The function of the D iscon nect Position I nterlock is to block the RACKING SCREW cover open when the racking mechanism is in the D I SCONN ECTED position. When the cover is held open, the T R I P button is depressed. The mechanism is held trip-free and there is no contact arm movement wh en the closing spring is discharged by the Closing Spring interlock. tM an ua ls The operation of this interlock is shown in Fig. 1 8 . A crank, which is attached to the racking mechanism shaft, is connected to the blocking plate through a link. As the shaft turns, the blocking plate rotates; holding the cover open in the DISCONN ECTE D position, but allowing it to close in the TEST and CONN ECT E D positions . . �· Breaker Racked In - Lever And Armature .E lec tri ca lP ar Linkage Pin Not Engaged Breaker Bei ng Racked Out ww w Lever Activates Armature Linkage FIG. 1 8 DISCON N ECT POSITION INTERLOCK 6.5 PADLOCKS Provisions are made on all breakers to use padlocks to prevent the breaker form being closed. For all breakers except Type 8 or D the padlock shackle goes through the TRI P button hole and out the slot in the side of the escutcheon . For Type 8 or D breakers the padlock shackle g oes through the TRI P button hole and out the RACKING SCREW cover hole in the deep escutcheon. In either case, the shackle holds the TRI P button in keeping the m echanism trip-free. FIG. 1 7 - CLOSING S PRING I NTERLOCK 17 .c om SECTION 6-lnterlocks (Cont.) The function of the Key I nterlock is to prevent an open breaker from being closed when the lock bolt is extended and its key is removed. The o peration of this interlock is shown in Fig. 1 9. When the breaker is in the OPEN position, the end plate assem bly item #2 on the main shaft pivots the lever item #6 counter-clockwise. This removes the pin item #3 on the lever from blocking the lock bolt. Extending the lock bolt rotates the linkage which moves the trip shaft, preventing the m echanism from closing the breaker. When the breaker is in the CLOSED position, the fly wheel assembly item #2 is away from the lever item #6. The lever is spring loaded and rotates clockwise causing its pin to block the l oc k bolt extension. ua ls KEY INTERLOCK-STATIONARY B REAKER OPTIONAL INTERLOCKS 6.7 The optional interlocks are key i nterlocks and door inter locks. On drawout breakers, these devices are mounted in the equipment and are part of the breaker enclosure. an 6.6 � �� / \ : \ �� .. ·. I • I � ./ '� / I \ \ ca lP 3. P i n 4 . Lock Bolt 5. P i n 6 . Leve r ar 1 . Lock 2. End Plate tM 2 \ r/�r--=+==++-- 4 ��+-----+-- 3 ---n---t--:-1-- lec tri ��--=-=-===�3�� 5 6 FIG. 1 9 - KEY INTERLOCK-STATIONARY B R EAKERS .E SECTION 7- Breaker Maintenance SAFETY PRECAUTION ww w WAR NING : B EFORE INSPEC TING OR BEGIN NING A N Y M A I N TENA N C E WORK ON THE BREA KER, IT MUST B E DISCONNECTED FROM ALL VOL TA G E SOUR CES, B O TH P O WER A ND CONTR OL, A ND THE BREAKER MUST BE IN THE "OPEN" POSITION. 18 7.1 LUBRICATION I n general, the c i rcuit breaker req u i res moderate l u bri cation. The m ajority of the factory l u bricated bear i ng poi nts and s l id i ng surfaces are accessible for i nspec tion and if necessary, c lean ing and rel u bricating. The on ly l ubricant u sed on the breaker for both electrical and mechanical areas is General Electric spec ification D50H D38 (D6A1 5AI Mobilgrease 28 or 32). .c om SECTION 7-Breaker Maintenance (Cont.) 7.2 3. 4. 5. 6. If the link is too long, the handle stroke cannot extend the closing spring enough for it to go over center. In this event, use the maintenance handle to complete the spring charg ing. The breaker can then be closed and opened prepara tory to further shortening of the link. If the link is too short, charging is not possi ble. The original linkage design used a double-ended stud in the linkage center. A hex section i n this stud allowed adjust i ng with an open-end wrench. When looking down on the breaker, turn ing the wrench clockwise lengthens the link. The opposite motion shor.tens it. The range of adjustment is 300 degrees. In the conf ined space avai lable, each wrench stroke i m parts 1 5 degrees movement. The best setting is approximately m id-range. The present design is shown in Fig. 20. This l inkage is asse mbled together on a th readed stud. Adjustment is accomplished by removing the upper l i nkage assembly from the handle assembly and chang ing the linkage length by turning the upper l i nkage up or down the th readed stud. ar 7. The adjustment li nkage connects the handle assembly to the chain drive mechanism which turns the cam shaft. The length of this linkage provides the handle adjustment. ua ls 2. Contacts Pivots - A thin fi l m on the stationary and movable contact assembly pivot surfaces. Refer to Section 8. Do not lubricate the contact tips. Racking Mechanism - The drive threa? s, jamb n ut/trunnion interface, th rust washer/col l ar mterface, and the shaft support beari ngs. Refer to Section 7. 1 3. M anual Operating Handle - Lubricate the two pivot areas associated with the adj ustment l i n kage. Al so, the handle, mounting shaft/support bushing inter face. Refer to Sect ion 7.2. F l ux Shifter - Lubricate pivot ing and sliding sur faces of the reset l i n kage. Refer to Section 1 0.3. Switchette - Lubricate the activator lever surface that contacts the switchette button. Mechanism - All accessi ble bearing and sliding sur faces that have been factory l u bricated. Pri m ary Di sconnects - Lubri cate the fi nger contact surface j ust prior to install ing in switchgear or l u bricate and then cover the d i sconnect asse mbly to protect from dust, dirt, etc. Refer to Sect ion 7.5 tM 1. MANUAL HANDLE ADJ USTM ENT an The areas requiri ng l ubrication are: ww w .E lec tri ca lP Before l ubricating, remove any hardened g rease or d i rt from the latch and bearing surfaces. After l u bricating, remove all excess lu bricant to stop accumulation of d i rt or d ust. The use of cotton waste to wipe bearing surfaces should be avoided. The cotton ravelings may become entangled under the bearing surfaces and destroy the surface of the beari ng. FIG. 20 - MANUAL HANDLE ADJUSTMENT 19 .c om SECTION 7 -Breaker Maintenance (Cont.) Remember, before installing the breaker back i nto its compartment, the drawout mechanism must be returned to the D I SCONN ECT position. 7.4 SLOW CLOSING THE B R EAKER Closing the breaker slowly, while observing the action of the mechanism and contacts, is a good way of judging the correctness of mechanical and contact re lationships. Some of the maintenance procedures described later will involve operating the breaker in this manner. The proce dure for slow closing is g iven below. After the bolt is removed, use the mai ntenance handle to rotate the ratchet assem bly rol ler onto the closing prop (see Charg i n g Using The Mai ntenance H and le, sec tion 5.4). At this point, the closing prop m u st be removed by either pushing the C LOSE button on Manual breakers, or push i ng the closing solenoid armatu re on electric breakers (see F i g . 1 3). When the closing prop is removed, cont i n ue turning the camshaft. When the ;contacts and mechanism are in the fully closed position, the cam will support the cam rol ler (refer to Fig. 10 & sect ion 5.3) and the contacts will develop maxi m u m depression. Push the TRIP button to release the mechanism and open the contacts. CAUTION - The mechan ism and contacts wi l l open with normal speed and force. When replacing the hex-head bolt, t u rn the camshaft with the mai ntenance handle to align the mating holes i n t h e l ower spri ng assembly a n d camshaft l i n kage. ww w .E lec tri ca lP ar T h e c l o s i n g s p r i n g m u st be i s o l ated from the mechanism camshaft. This is done by disconnecti ng the lower spri ng assembly from the mating camshaft l inkage. Remove the hex-head bolt as shown in Fig . 2 1 . Re move this bolt only with the mechanism in the D I SCHA R G E D position a n d t h e spring a t its minimum extension. Remove the hex-head bolt only, do not remove or loosen the slotted head screw shown in Fig. 2 1 . Removal of the slotted head will cause the closing spring to become d is engaged from the camshaft with co nsiderable force. Verify that this screw re mains tig htened during the slow close operation. ua ls Maintenance or i nspection should be conducted with the breaker on a workbench. The drawout mechanism m ust be placed in the CONN ECT position . This will deactivate the various i nterlocks which wo uld otherwise prevent the mechanism or contacts from closing. Engage the racking handle with the racking shaft and turn clockwise unti l it stops. an DRAWO UT M ECHANISM POSITION tM 7.3 20 FIG. 2 1 - SLOW CLOSI NG-LOWER SP RING ASM HARDWA R E .c om SECTION 7- Breaker Maintenance (Cont.) 7.5 PRI MARY DISCONN ECTS The 800 ampere breakers use four primary discon nect fingers per terminal. The 1 600 and 2000 ampere breakers use eight fingers per term inal . Fig. 22 shows a line and load end discon nect assembly. The l i ne end disconnects on fusible breakers have the spring pointing downwards, otherwise they are identical . lP ar tM an ua ls Pri mary disconnects are found only on drawout break ers. They provide the f lexible connection between the breaker line and load termi nals and the equ i pment line and l oad terminals. FIG. 22 - PRIMARY DISCONN ECT ASM w .E lec tri ca ASS EMBLY FIG. 23 - PARTIAL PRI MARY DISCONNECT ww FIG. 24 - PARTIAL P R I MARY DISCONN ECT ASM FIG. 25 - PARTIAL P R I MARY DISCONN ECT ASM 21 .c om SECTION 7 -Breaker Maintenance (Cont.) 7.5.1 R EPLACEMENT Figs. 22, 23, 24, and 25 show the primary disconnect assembly breakdown . Refer to these ill ustrations when replacing the disconnects. Note the following details: ua ls Fig. 25 - The position of the spacer i n the breaker stud. The hole in the spacer must be positioned as shown so it will align with the holes in the clip. Fig . 24 - The engagement of the fi ngers with the re tainer. Also the location of the 'bowtie' spacers in the fingers, both upper and lower. Fig . 22 & 23 - The position of the upper and lower retainers and, agai n , the 'bowtie' spacers. FIG. 27 - AUXILIARY SWITCH LIN KAG E 7.6.1 REPLACEM ENT Either switch type may be d ismounted by removing the two bolt screws which fasten it to the mechanism frame. The GE SB-1 2 replacement switch should have its cran k shaft set so that the arrow head on the end of the shaft points as shown in Fig. 28A when the breaker is open. ar The primary disconnect assembly is factory adjusted to apply a force of 85-1 05 pounds on a 1 /2 thick copper bar inserted between the upper and lower fi ngers . After instal lation of the disconnect assembly this force range is ob tained by tightening the locknuts to set the di mension shown in Fig. 26 . 766" to .797" Note that this di mension is measured between the top of the retainer and the underside of the washer. Also note that no bar is inserted between the fingers when setting this dimension. an ADJ USTMENT tM 7.5.2 ARROW HEAD tri ca lP The Electro Switch replacement should have its crank shaft set so that the horizontal line on the end of the shaft is as shown in Fig. 288 when the breaker is open. 7.6 lec FIG. 26 - PRIMARY FING E R ADJ USTMENT AUXILIARY SWITCH .E All electrically operated breakers and manual breakers having shunt trips are supplied with auxili ary switches. Depending upon the requi rements of the breaker's applica tion, the switch may contain from two to six stages. Usually, each stage has one "A" contact and one "B" contact. "A" contacts are opened or closed as the breaker is opened or closed. "B" contacts are the reverse of this. ww w The auxil iary switch is mounted on the upper side of the mechanism frame as shown in Fig. 27. A crank on the main shaft operates the switch through an adjustable link which connects it to the switch crank. The switch can be a G E type "SB- 1 2 " or Electro Switch Type "1 01 " . 22 FIG. 28A - GE SB-1 2 CRANK SHAFT POSITION FIG. 288 - ELECTRO SWITCH C RA N K S HAFT If a switch is added to a breaker having none, the ad j usting link will also have to be installed. This is connected to the pin on the crank which is attached to the main shaft. It is secured by means of a cotter pin. 7.6.2 ADJUSTM ENT GE SB- 1 2 I f a new adjustable l i n k i s i nstalled , its length should b e set, before installing, a t 6.375 i nches, between p i n centers. After install ing a new switch, its operation should be checked. Viewing the switch from above, the contacts toward the front of the breaker are normally the "B" con tacts. Even if a special switch is used, it is always the case that the fi rst two stages nearest the crank have the "B" contacts to the front, and the "A" contacts towards the back. "A" contacts are closed when the breaker i s closed. B contacts are c losed when the breaker is open. " " .c om To check the setting, arrange the breaker for "slow close" as described in Section 7.4. Through the use of a conti n u ity tester, observe the position of the breaker con tacts when the switch "A" contacts touch. At this point the breaker's arcing contacts must be within .250" to . 500" of closing. Adjustment is made by disconnecting the upper end of the adj ustable link and varying its length as requ i red. ELECTROSWITCH TYPE 1 01 S H U NT TRIP The shunt trip device opens the breaker when its coil is energ ized. An "A" auxi liary switch, which i s closed only when the breaker i s closed, i s i n series with the device coi l . Connections are made to the external tripping source through secondary discon nects on drawout breakers, or to the terminal board on stationary breakers. The armature of the undervoltage device may be tied closed in order to permit breaker operation during mai n tenance. tM The shunt trip is mou nted on the underside of the breaker front frame as shown in Fig. 29. A second sh unt trip may also be mounted to the frame (see Fig. 30) if a se cond undervoltage device isn't al ready i nstal led, see Sec tion 7.8. FIG. 29 - SHUNT TRIP AND UN DERVOLTAGE MOUNTING armature will " pick u p" and allow closing if the applied voltage is 85 % or more of the coi l rating. It may also pick u p at a lower voltage. Refer to table 25 for pickup and d ropout ranges. an 7.7 ua ls Adjustment i s the same as the GE S B 1 2 except that when the switch "A" contacts touch , the breaker arcing contacts must be within 0 to .250 inches of c losing. 7.7.1 REPLACEM ENT A second undervoltage may also be mou nted to the frame (see Fig . 3 1 ) if a second shunt trip isn't already instal led , see Section 7. 7. 7.7.2 ADJ USTM ENT ca lP ar If it is necessary to replace or add one of these devices, the easiest procedure is to remove the mounting bracket, shown in Fig. 29, from the breaker frame and remove the device from the bracket. If a replacement or new device is ordered, a mounti ng bracket will be suppl ied with the device. If a second shunt trip is added, this is mounted by means of an additional bracket as shown in Fig. 30. Th is additional bracket is fastened by two of the hex head bolts used to fasten the buffer assembly to the breaker frame. The undervoltage device is mounted to the underside of the breaker front frame as shown i n Fig. 29. tri When these devices are i nstalled or replaced, their positive abil ity to trip the breaker m ust be demonstrated. This is done by placing a 1 /32-i nch shim between the ar mature and magnet of the device and manual ly operating the armat ure to tri p the breaker. .E lec If the shunt trip is not successfu l in this test, check the mounting fasteners to make sure they are reasonably tight. If they-are, then bend the trip paddle on the trip shaft to slightly reduce the distance between the trip arm of the device and the trip padd le, and recheck for positive tri p. If this bend ing is necessary, be carefu l that it is not over done. Verify that there i s a .030 "-.050 " gap between the trip arm and the trip paddle with the breaker closed . A gap greater than .050" is permitted and may sometimes be necessary in order to p revent n uisance tripping . Re-verify positive trip as a final check. U N DERVOLTAG E DEVICE w 7.8 ww The undervoltage device trips the breaker when its coil is de-energized. The leads of the coil are connected directly to secondary d isconnects or to a terminal board . Under normal conditions, the coil remains energized and the breaker may be closed . Dropout of the armature, with resultant breaker trip ping, occurs when the voltage is reduced to a val ue between 30% and 60% of the coi l rating. An open armature will render the breaker i ncapable of closing. The If a second undervoltage device is added, a new buffer assembly block wi l l be suppl ied. Th is is required for clearance, in this case, the buffer assembly m ust be taken off, disassembled, and remounted together with the number two undervoltage device. Before disassembling the origi nal buffer, carefu l ly measure the distance between the faces of the threaded members as shown in Fig. 31 , and set this di mension carefully on the new assembly. Refer to the breaker wiring diagram for the coi l lead connections'. 7.8.1 REPLACEM ENT To replace an undervoltage device, remove the mou nt ing bracket (shown in fig . 29) from the breaker frame and remove the device from the bracket. Re-i nstall in reverse order, noting wire routing and securing means. Set the gap between the trip paddle and device arma ture to approximately 0 . 030 inch as a starting point, then proceed with the o perational check (7 .8.2). BREAKER F RONT FRAME ;;: D SHUNT TR IP MT BRACKET RIGHT HAND BUFFER ASSEMBLY FIG. 30 - 2N D SH UNT TRIP INSTALLATION 23 .c om SECTION 7 -Breaker Maintenance (Cont.) DROPOUT VOLTAGE: On AC devices the dropout level will fall within the requ i red limits (30 % to 60% of the coil rating) if the picku p is set properly. On DC devices, the d ropout level may need independent adjustment. This is accompl ished after the pickup level has been established per the above procedure. If requ i red , use the closed gap adjustment screw shown in Fig. 32C to obtain the d ro pout setting. A gap must remain between the armature and magnet on DC devices to prevent sealing in u pon loss of voltage. Secure the adjustment screw with the locknut and apply RTV to the locknut. POSITIVE TRIP: Check positive trip abi lity per 7.8.2. Adjust the trip paddle screw if necessary to assure positive trip. With the u � dervoltage device closed (picked up), and the mecha msm reset, there must be clearance between the trip paddle and the device armature. If clearance adjustment is necessary, re-verify positive trip abi l ity. � 7.8.2 OPERATIONAL CHECK (BREAKER WITH UV DEVICE INSTALLED) lP ar Check the pickup and dropout values at room tempera ture. See table 25. Check the positive trip ability as follows: With the armature closed , close the breaker. Insert a 0.032 ± . 005 inch shim (wire gage or flat stock) against the armature open stop (see Fig. 32D) and release the armature. The breaker must tri p . tM FIG. 31 - 2N D UN DERV OLTAG E DEVIC E an ua ls \TRIP SHAFT ca 7.8.3 ADJUSTM ENTS If the operational checks (7. 8.2) indicate that adjust ments are necessary, these procedures should be followed: tri p latch engagement as described i n sec tion 7. 1 5, and verify that the trip shaft torque req u i red to tri p a closed breaker is no greater than 24 i nch-ounces. Then proceed as follows: PICKUP VOLTAG E: The Q.i.Q.!s.!,m level is changed by turning the adjustment screw shown in Fig. 32A. The screw is secured by either a locking wire or a jam nut inside the frame. Devices with a jam nut requ i re removal of the device to make this adjustment. The pickup voltage at room temperature (approx. 2 0-24 oq should be 85 % or less of coil rating and should be measured at the secondary d isconnects with the coil energized. Note: On DC devices set the gap .E lec tri Fi rst verify between the armature and magnet initially to 0.030 inch using the closed gap adjustment screw shown in Fig. 32C before making pickup adjustments. ww w Be sure to secu re the pickup adjustment screw with the jam nut or lockwire. 24 R I V ET .001 " .01 0 " HOLDING FIG. 32A U NDERVOLTAGE DEVICE 7.8.4 FACTORY SETTINGS �rouble shooting. This section covers certain factory settings as an aid to They are for reference only, and are not mtended to be field adjusted. They should not be consid ered criteria for acceptance or rejection. ARMATU RE LOCATING R IVET: The rivet shown in figure 32A serves as a locater for the armature. A clearance of 0.001 to 0.01 0 inch should exist between the rivet and armature as shown in fig. 32A. The rivet should be able to turn freely. AR MATU RE OPEN GAP: The air gap between the armature and the magnet with � he device ? �-energized should be approximately 0 .250 tnches. Thts ts, checked by inserting a 0.201 ± .005 inch diameter gage pin between the armature and magnet as shown in Fig. 328. .201 PIN 005 D I A ± an FIG. 328 - OPEN GAP CHECK STOP ua ls INSERT W I R E GAGE .c om OPEN GAP ADJ USTM ENT tM FIG. 320 - POSITIVE TRIP CHECK A DJUSTM ENT STATIC TIM E-DELAY U N DERVOLTAGE ca 7.9 lP FIG. 32C - CLOSED GAP CHECK ar When i nstalled, the voltage to be monitored is connected across term inals No. 1 and No. 2 of the static delay box. The coi l of the tri ppi ng unit is connected across term inals No. 4 and No. 5 of the static box through the secondary disconnects of the breaker. The secondary d isconnects to be used will be shown on the breaker wiring diagram. tri The static time-delay undervoltage system consists of a time-delay unit which controls an instantaneous under voltage device. The time-delay unit is separately mounted in the switchgear and the undervoltage device is mounted on the breaker. Table 5 lists the catalog numbers available. TAB L E 5 The static time-delay undervoltage can also be furnished with a thermotector control unit. Overheating of motor win dings causes the thermotector, imbedded in the motor win dings, to open. This de-energizes the undervoltage device on the breaker and drops the motor load. 7.9.1 ADJUSTMENTS In the event the system fails, the following checks are recommended to determine whether the undervoltage device on the breaker of the static time delay unit is the faulty component. 1. Check input voltages across term inals 1 and 2 on the static box. See Table 5 for these values. 2. Check output voltages on termi nals 4 and 5 with the undervoltage device connected. See Table 5 for values. TI M E-DELAY U N ITS CONTROL VOLTAGE TERMINALS 1 & 2 APPROXIMATE STEADY STATE DC OPERATING VOLTAGE TERMINALS 4 & 5 NOMINAL DC COIL R ESISTANCE (OHMS) @ 25°C TAKYUVT- 1 1 25 VDC 50 440 w .E lec If the a-c control voltage is any voltage other than 208/240V ac, a control power transformer (also remotely mounted with respect to the breaker) m ust be used. This must have a minimum rating of 100 volt-amperes. No more than one undervoltage tri pping device should be used i n conjunction with one static time-delay unit. TAKYUVT-2 250VDC 1 00 1 600 TAKYUVT-3 208/240 VAC 1 1 0/ 1 25 1 600 ww CAT. NO. 25 .c om SECTION 7 -Breaker Maintenance (Cont.) The undervoltage device must be cal i brated through the time-delay unit after the device pick up has been adjusted. A .008 inch minimum closed gap must exist between the ar mature and magnet as shown i n Fig. 32C. Refer to Section 7.8.3 and Table 24. 4 @J\ 7.1 0 ELECTRIC LOCKOUT DEVICE � ELECTRIC LOCKOUT DEVICE BELL ALARM an This device is used to give a remote indication of the breaker having tripped open through the action 1 of one of its automatic protective devices. It will not be act ivated by manual tripping or the action of the shunt trip. A remotely mounted protective relay energizing the shunt trip wi l l there fore not result in the remote alarm action. The bel l alarm circuit may be turned off by pushi ng in the manual trip or by energizing the shunt tri p. In the l atter case, a normal ly open contact of the bel l alarm switch must be wired in paral lel with the "A" auxiliary switch contact i n the shunt-trip circuit. Closing the breaker will also turn off the alarm. ar On each breaker having an electric lockout, an arrange ment is made which will al low breaker closing with the coi l de-energized. Th is is provided to al low "start-up': o n "dead" systems. Figure 34 shows this device. The push sl ide shown is located in the opening in the lower part of the escutcheon. This breaker door must be opened to gain access to it. 7.1 1 - tM The electric lockout device uti lizes an undervoltage device to keep the breaker from resetting its mechanism if the breaker is open and the undervoltage device coi l is not energized. The breaker thus cannot be closed unless voltage is on the. coil. Once the breaker is closed, loss-of voltage will not trip the breaker because, in the closed posi tion, a mechanical link is used to hold down the armature of the device. See Fig. 33. This arrangement provides a means of electrically i nterlocking two breakers so that they cannot be closed at the same time. Each undervoltage coil may be wired in series with a "B" aux i l iary switch contact on the other breaker for cross-interlock purposes. FIG. 33 ua ls 3. Check resistance of the disconnected undervoltage device. See Table 5 for values. See i nstruction Sheet G EH-4545 for more detai led infor mation, including schematic diagrams and circuit descrip tion. lP The bel l alarm device may be equipped with a lockout link which will lock the breaker open until the bel l alarm device is reset. ca MAI N SHAFT ( BREAKER CLOSED) I � - 1.�- \ / -----/-_ :� /_/Tl 1 - � \"--'-.___)- 1 :I ' . ·-� C> ; lec /. il ./ lL 'i \ tri � �/ I .' 7.1 1 .1 OPERATION Referring to Fig. 35: the bel l alarm mechanism is ac mai n shaft. When the breaker opens, a pin attached to this crank moves the alarm link against the switch and locklever (if provided). Thi s activates the switch contacts. It also moves the locklever adjustment screw against the trip shaft paddle keeping the breaker trip free. tivated by a crank which is assembled to the breaker's 11·1 · ---._ ww w .E r : -- HOLD- IN L I NK The bel l alarm is not a standard device and is suppl ied only when specified on the breaker order. FIG. 34 26 LATCH ENGAGEMENT POINT - ELECTRIC LOCKOUT BY-PASS FIG. 35 - BELL ALARM DETAILS .c om SECTION 7-Breaker Maintenance (Cont.) ADJUSTM ENTS The bel l alarm is mounted on the right hand side of the breaker at the rear of front frame. It is located under the mechanism main shaft. The bel l alarm is removed by passing it through a cutout in the rear bend of the front frame, slipping it between the front frame and trip shaft and out through the bottom of the breaker as fol lows: 1 . Remove the 4 bel l alarm mounting screws from the bottom of the front frame. 2. If the crank which is part of the main shaft has a bel l alarm activating pin assembled t o both sides, remove these pins. 3. Insert the flat of the mai ntenance handle between the top of the left hand side buffer block and the end plate assembly. This should elimi nate any interference from the main shaft during the bel l alarm removal. 4. The trip shaft must be moved to allow the bell alarm to fit beteen it and the front frame. Remove the retaining ring holding the right hand trip shaft bearing to the mechanism frame. Slide the beari ng from the frame and along the trip shaft. There will now be enough trip shaft movement to slip the bel l alarm past. 5. Install the replacement bel l alarm in reverse order. 6. Check the adjustments g iven in Section 7.1 1 .2 tM If a breaker is equ ipped with a bel l alarm/lockout device original ly, all the adjustments are made at the time of assembly. Switch operation is controlled by means of shims of insulating material placed between the switch body and the bracket to which it is fastened. The adjust ment screw is positioned so that when the locklever is in its activated position, it holds the breaker mechanism latch in the tripped position. REPLACEM ENT ua ls 7.1 1 .2 7.1 1 .3 an The mechanism i s reset by disengaging the side latch l i nk from the upper latch link or by closing the breaker if a locklever is not provided. The side latch link, is activated only by pushing the TRI P button or operating the shunt trip. A slide attachment on the TRIP button shaft moves against the side latch link when the TRIP button is pushed. This sl ide attachment is factory adjusted to activate the side latch before the breaker is tripped. A second arm on the shunt trip also activates the side latch l i nk when the shunt trip is energized. ar Check that TRIP button shaft and shunt trip operations, besides tripping the breaker, displace the side latch and prevent the bell alarm switch from operating. The other tri p devices and interlocks m ust activate the bel l alarm when they open the breaker. ca lP The bracket assembled to the TRIP button shaft must be adjusted so that it wi l l displace the side latch when or before the shaft opens the breaker. Maintain a .030 inch minimum gap between the bracket and the side latch when the breaker is closed. A .187 inch depression of the TRIP button must not trip the breaker, but a .375 inch depres sion m ust trip the breaker and displace the side latch . ELECTRICAL CONTROL COM PONENTS The operation of the electrical control components is described in Section 5.2. The location of these components is shown in Fig. 36A. CHARGING MOTOR ww w .E lec X-RELAY 7.1 2 tri W R E LAY A bel l alarm with a lockout assembly or a bel l alarm i n stalled on a 2000 amp frame (AKRT 50/SOH) breaker may not work with the above procedure. If this is the case, the breaker front and back frame will have to be seperated. G SWITCH FIG. 36A - ELECTRICAL CONTROL COMPONENTS 27 .c om SECTION 7-Breaker Maintenance (Cont.) 5 COM PON ENT REPLACEM ENT To gain access to the electrical control components, the breaker's front escutcheon m ust be removed. Type B and D breakers requ i re that both the deep molded escut cheon and the shal low steel escutcheon be removed. Before removing the front escutcheon on Type A or B breakers, a supporting block shou l d be placed u nder the front frame to keep if from tipping forward. 4 an 1 . RETA I N ER RING 2. WASHER .01 0 " 3. PAWL ASM 4. SPRING WAS H ER 5 . WASHER .032 " 6. MOTOR DRIVE PIN FIG. 36B - DRIVING PAWL ASSEMBLY DETAILS The holding pawl pivots on a pin which is assembled to the mechanism frame. Refer to Fig. 36C. To replace the holding pawl: 1 . Remove the front escutcheon for accessibi l ity. 2. Using the maintenance handle, rotate the ratchet enough to disengage the hold ing pawl. 3. Remove the retaining ring and washer from the pivot pin. 4. While holding the spri ng pressure from the holding pawl, remove the existing pawl and slip on the new pawl. 5. Instal l the washer and retai ning ring. 6. Verify that the holding pawl engages a minimum of 4 ratchet laminations. 7. Verify that the holding pawl pivot pin is perpendicular to the mechanism frame. The hardware which assembles the pivot pin to the frame must be torqued to 250 i n-lbs minimum. If this hardware m ust be retightened, add LOC TITE 290 to the shaft threads. 8. Install the front escutcheon. Tighten the escutcheon hardware to 80 ± 1 0 in-lbs. ca lP ar The charging motor is secured through three spacers to the mechanism frame. The front mounting bolt is accessi ble using a socket and universal joint through the opening in the side of the breaker frame. The upper rear mounting bolt i s accessi ble using a socket and universal joint over the top of the frame. The lower rear mounting bolt i s ac cessible using a socket and universal joint through the open ing in the frame side by the buffer assembly. Slow close the breaker to move the flywheel assembly out of the way. \ tM Referring to Fig. 36A, the X-relay or K-relay and F and G switches are mounted on the same bracket. This mounting bracket i s fastened to the right-hand mechanism side frame by two hex-head 1 /4-20 screws. Removing these screws allows the bracket to be pul led forward from between the mechanism side plates. The W-relay must also be un fastened from the left side frame to allow enough freedom for al l the devices and the wiring harness to be taken from between the side frames. With the bracket removed, in d ividual devices can be replaced easily. The closing solenoid is mounted by means of mounti ng bracket to the bottom of the breaker frame. The most con venient way to take off the solenoid is to remove the moun ting bracket and then disconnect the solenoid from the bracket. The pin connecting the armature to the closing l ink must also be removed. 2 ua ls 7.1 2.1 The ratchet on the camshaft is removed by driving out the roll pin which fastens it to the camshaft. Before this lec tri can be done, the charging motor m ust be removed and the closing spring arranged for "slow-closing" as descri bed earlier. Turn the camshaft, using the maintenance handle, unti l the roll pin is well situated , turn the camshaft to gain enough space for the rol l pin to clear the breaker frame. Before removing the ratchet note the position of the ratchet rol ler or mark the ratchet hub and the camshaft. When replacing the ratchet, be sure it i s oriented with respect to the camshaft as it was originally and not d isplac ed 1 80 degrees. Align the mark made on the hub with the mark on the camshaft or position the rol ler as it was. If the ratchet is displaced 1 80 degrees, the holes in the ratchet hub will not completely line up with the holes in the cam shaft. 6 I I .E ww w The d riving pawl is assem bled to the c h arg i n g motor drive pin as shown in Fig. 36B. To replace the d riving pawl: 1 . Remove the charging motor. 2. Remove the retaining ring from the drive pin. Sl ip off the components. 3. Wipe off any grease or dirt from the drive pin. DO NOT LUBRICA TE. 4. I nstal l the components as shown. 28 7 1. 2. 3. 4. MECHANISM FRAME PIVOT PIN SPRING WASHER .032 " 5. PAWL ASM 6. WASHER .01 0 " 7 . RETAI N I N G R I N G FIG. 36C - HOLDING PAWL ASSEM BLY DETAILS .c om 7.1 2.2 F AND G SWITCH ADJ USTMENT For proper electrical operation, the F and G mechani cally operated switches must operate at the proper point in the closing cycle. If these switches are to be replaced, measure the distance between the tip of the switch button and the bracket on which they are mounted. When the new switch is mounted, duplicate the measured dimension, then check for proper operation. When a normal closing operation occu rs, the ratchet usually com es to a stop with an arbitrarily desig nated ratchet tooth No. 1 , Fig. 37, engag ed by the hold ing pawl. This tooth is the one which is in line with an i mag inary line passing through the centers of the camshaft and the rivet o pposite the roller on the ratchet assem bly. It is a matter of no concern if the action stops on a d ifferent tooth, but it is im portant to positively identify tooth No. 1 by the method described . ua ls an FIG. 37 - LOCATION OF RATC H ET TOOTH N0. 1 tM To check the switch action, after tooth No. 1 has been identified, turn the camshaft with the maintenance handle and count the teeth as they pass the holding pawl. By using a continuity tester, observe when the switches operate as the ratchet turns. The normally open F switch on the left will close , and the G switch will open. 1 TOOTH Electrical breakers should operate the switches while moving from tooth No. 10 to tooth No. 1 1 . 7.13 lP ar If this check shows that an adj ustment is needed, the switch to be corrected can be moved closer to or farther away from the padd le which operates the switches. A very thin open-end 5/8-i nch wrench will be needed to loosen or tig hten the nuts which fasten the switches to the bracket. DRAWOUT MECHANISM ca The drawout mechanism shown in Fig. 38 moves the breaker through the D I SCONN ECTED, TEST, and CON N ECTE D positions. F i g . 39 shows how the drawout mechanism is mounted to the breaker. lec tri As the racking handle is turned, the internally threaded trunnion moves on the screw threads, rotating the hex shaft, on the ends of which are faste ned the arms which engage the fixed pins in the drawout enclosure. .E The trunnion travels between the two jamb nuts on the end of the screw, and the adjustment sleeve, which stops the trunnion movement at the other extreme point of its travel . The trunnion is agai nst the jamb nuts when the breaker is fully racked out and agai nst the sleeve when fully racked in. ww w The racking mechanism is adjusted at the factory as sembly operation so that the action is stopped in either direction at the precisely correct point. The jamb nuts are set so that when the trunnion is against them the relation between the arms and the equipment pins they engage is shown in Fig. 38. The length of the sleeve , which is free to slide on the threaded shaft, is controlled by the amount of thread engagement between the sleeve and its col lar. This length is adjusted to stop the trunnion when the distance between the ends of the equipment and breaker studs is .032" to .21 8 " . After this adjustment is made, the sleeve and its collar are locked together by the set screw . 29 -A Maintenanc e (Cont. ) .c om 7- Breake r RM ua ls SECTION L U B Ri R an COL L A CA Ti O N lU B RI CA TIO N tM • I ; N IS M D E TA I L S ..... ww w .E lec tri ca lP ar • I'IG . 38 - DRA WO U T MECHA 30 • • .c om SECTION 7-Breaker Maintenance (Cont.} BUFFER ASSE M B LY When the breaker is opened, the end plate assembly is " driven against the opposite end of the buffer assembly. The buffer is a stop absorbing the opening energy of the mechanism. See Fig. 41 . ca lP ar tM an When the breaker is closed, the energy in the closing spring i s transferred to the main shaft thro u g h the mechanism. The main shaft then drives the contacts closed. The end plate assembly on each end of the main shaft is driven agai nst the buffer assembly shown in Fig. 40. This prevents the mechanism from overdriving the contacts. ua ls 7. 1 4 .., E N D PLATE ww w .E lec tri FIG. 40 - BU FFER/END P LATE R E LATIONSHI P-BR EAKE R CLOSED FIG. 41 - BUFFER/END P LATE R E LATIONSHIP-B REAKER OPEN 31 .c om SECTION 7-Breaker Maintenance (Cont.) 7 . 1 4. 1 NEOPRENE WAS H E RS B U FFER ADJ USTME NT ..--- WAS H E R S ua ls Referring to !=ig. 40, with the breaker c losed and the mechanism not reset, a . 005 " c learance must exist be tween the end p late assembly and the buffer nut as shown. Th is dimension is factory set. It can be reset by t ightening the buffer nut. Hold the nut with a screwdriver and t ig hten using a socket on the bolt head opposite the nut. When tighten ing this assem b ly don't over compress the neo prene washers by overt ig htening the assem bly. These washers absorb the breaker opening shock. 7. 1 5 TRIP LATCH ADJ USTMENT �-- 1 . 93 ---1 FIG. 42 - B U FF E R ASSEMBL V ww w .E lec tri ca lP ar The reset position of the trip latch is set by the adjust ment screw shown in Fig. 43. The adj ustment is correct if three and one-half turns of the adj ustment screw causes a closed breaker to trip. If this check is made, the screw m ust then be set back, or unscrewed, tt\ ree and one- half turns. tM Fig. 42 shows a buffer assembly prior to being installed in a breaker. The dimensions given establish the nu mber of spacers that are used. an Referring to Fig. 41 , with the breaker open, a .040 " max i m u m c l earance can exist between either of the end p l ate assem b l i es and the buffer bolt heads as shown. If a larger c learance exists, c lose it u p by unscrewing the buffer assembly i nvolved. 32 FIG. 43 - TRIP LATCH ADJ USTMENT 8.1 .c om SECTION 8-Contact Maintenance ARC CHUTE REMOVAL AND INSPECTION There are two types of arc chute construction used on the 800 thru 2000 ampere breakers. They are the cerami c type shown i n Fig. 5 and the molded type shown i n Fig. 6. The ceram ic type uses a two piece porcelain frame to enclose its i nternal parts. The molded type uses a one piece, glass-fi l led polyester frame. When contacts are replaced, they must be adjusted to ensure that the proper amount of force is developed be tween the movable and stationary contacts when the breaker is closed. This is cal led the "wipe" adj ustment. "Wipe" is the distance through which the stationary con tacts move when the breaker closes. It is measured bet ween the point of contact on a stationary contact when the breaker is open, and the position of the same point when the breaker is closed. The actual wiping motion is greater because the contacts over-travel . "Wiping" imparts a sl id ing or "scrubbing" action to the contacts . The 800 ampere arc c h ute is different from the 1 600 and 2000 ampere arc chute, which are identical. Therefore, the 800 ampere arc chute cannot be i nterchanged with the 1 600/2000 ampere arc chute. Also note that a breaker must have either all ceram ic or all molded type arc ch utes i nstall ed, do not i ntermix on the same breaker. an The arc chutes are held in place by retai ners secured by bolts through the mechanism frame. The ceramic type uses two retainers and the molded type uses only one. To remove the arc chutes: 1 . Loosen and back off the retainer bolt locking n ut from the mechanism frame. They do not have to be removed. tM The wipe adjustment infl uences proper arc transfer dur ing interruption of fault currents. "Transfer" of the arc is its forced sequential movement from the intermediate con tacts to the arci ng contacts to the arc run ner and finally to the arc quencher where it is dissipated and exti nguished . It is recommended that contact wipe be checked periodically during normal maintenance inspectio ns. ua ls Breakers subjected to frequent i nterruption of high cur rents may eventually req uire replacement of their contacts . The general rule for determi ning need of replacement is the loss of one-half or more of the mass of the contact tip material. Roughening or l ig ht pitting of the contact surface does not i ndicate loss of ability to carry or i nterrupt current. 2. Loosen the retainer bolts until the retainer(s) can be removed. lP ar 3. With the retainer(s) removed, lift the arc chutes off for i nspection. To i nstall the arc chutes: 1 . Replace the arc chutes over each pole u nit. 2. Locate the retainer(s). 3. Tighten the retainer bolts until the arc chutes are secure. There may be some side to side motion of the arc chutes, but there m ust not be any front to back motion. Torque the retai ner bolts to 30 i n-lbs for the molded type arc chutes and 60 to 1 00 i n-lbs for the ceramic type. Do not over tighten. 4. Tighten the locknuts against the mechanism frame with 1 50 to 1 75 i n-lbs torque. ww w .E lec tri ca CAUTION: BEFORE DOING ANY OF THE FOL L O WING C O N TA C T A DJ U S TM E N T A N D RE P L A CEMENT WO R K, MECHANICA L L Y D I S CONNEC T THE CLOSING SPRING F R O M THE MECHANISM CAM SHAFT AS DESCRIBED UN DER SLO W CLOSING THE BREA KER, SECTION 7.4 Inspect each arc chute for excessive burning and erosion of the arc plates and arc runner. Also look for fractures, damage to the l i ner material used in the molded arc chute and damage to the insulation material used in both arc chutes. Check for any missing parts. 33 .c om SECTION 8-Contact Maintenance (Cont.) CONTACT ADJUSTM ENT AKR 30/30H & AKRU 30 The contact structure of the AKR 30 and the AKRU 30 breakers is slightly different from the AKR 30H. Referring to Fig. 44 A & B, both structures use one moveable contact arm, and two stationary arcing contacts. However, the AKRJAKRU 30 uses three stationary main contacts and the AKR 30H uses four. ADJUST GAP AT MEASUREMENT PO I N T TO .060 ± .020 " The following wipe adjustment procedure is appl icable to all AKR-30/30H & AKRU-30. 1. Open the breaker, remove arc quenchers. t 5. Repeat above procedure on the other pole units. FIG. 45 WIPE ADJUSTMENT 800 AMP CONTACT STRUCTU RE - ww w .E lec tri ca lP 6. Trip the breaker. 0.250 " M EASU R E M E NT POI N T ar 4. Once the gap dimension is set, verify that the torque requ i red to j ust turn the adjustment nut is greater than 40 in-lbs. If less torq ue is req uired, carefully add LOCTITE 220 or 290 to the adjustment nut threads. Wipe off any excess LOCTITE. Once t he LOCTITE is set, recheck the torque (value u p to 40 in.-l bs.) but do not break loose. PIVOT STUD tM 3. Select one pole and, using a flat or wire feeler gage, measure the gap between the top contact and its pivot stud as shown in Fig. 45. As necessary, adjust the gap to 0.060 ± 0.020 inch by turning the wipe adjustment nut shown in Fig. 45 & 46. UPPER CONTACT an 2. Slow-close the breaker. The cam rol ler must be sup ported by the cam and not the prop. Refer to section 5.3. ua ls 8.2 FIG. 46 - WIPE ADJUSTMENT N UT-800 AMP CO NTACT STR UCTU R E 34 .c om ar tM an ua ls SECTION 8-Contact Maintenance (Cont.) ww w .E lec tri ca lP FIG. 44A - AKR30, AKRU30 FIG. 448 - AKR 30H 800 AMP CONTACT STR U CTU R ES 35 .c om SECTION 8-Contact Maintenance (Cont.) The contact structure shown in Fig. 47 is used by all AKR50 breaker types. This structure uses two movable contact arms. Each arm acts against a stationary arcing, a stationary i ntermediate and three stationary mains. The following procedure is used to perform the wipe adj ustment. 5. Attach a conti nuity checker (bell-set, light, or ohm meter) between the upper and lower stud. The checker shou ld indicate continuity exists. 6. Facing the breaker, turn the wipe adj ustment stud shown in Fig. 47 clockwise until the checker i ndicates that the main contacts are separated. ua ls CONTACT ADJUSTM ENT AKR 50/SOH & AKRU 50 7. Turn the stud counter-clockwise unti l the main con tacts just touch. 2 . Arrange the breaker for slow-closing. 3. Select one pole of the breaker and place a th in sheet or strip of tough insulating material , such as mylar, over the stationary arcing and intermediate contacts. This stri p should be about two inches wide and must prevent the arcing and intermediate contacts from making contact when the breaker is closed. 9. Once the adj ustment is complete, verify that the torque required to j ust turn the adjustment nut is greater than 40 in-lbs. If less torque is requ i red , carefully add LOCTITE 220 or 290 to the adjustment nut threads. Wipe off any excess LOCTITE. Once the LOCTITE is set, recheck the torque valve. 1 0. Trip the breaker, remove the insulating strips. 1 1 . Repeat the above procedure on the other two poles. ww w .E lec tri ca lP ar 4. Using the ratcheting_maintenance handle, slow-close the breaker with the insulation held in place. Examine the i nsu lation to make sure it "over-hangs" below the in termediate contacts, but not enough to cover the main con tacts. 8. From this point, advance the stud counter-clockwise 270 degrees. This will be 4-1/2 flats. an 1 . O pen the breaker, remove arc quenchers . tM 8.3 36 FIG. 47 - 1 600 AMP CONTACT STR UCTU R E There are two designs used to co nnect the movable contact arms to the insulated link. This results in two con tact adj ustment procedures depending on which design the breaker has . In the origi nal design the two movable contact arms are pi n-coupled to a metal driving link whose opposite end is th readed and screws directly into the insulating link. This arrangement om its the wrench-operated wipe adj ustment stud provided on the AKR-30 and -50 frames. I nstead , wipe is adj usted by detaching the driving link from the movable contact arms and then rotating it with respect to the insu lat ing link. 2. Arrange the breaker for slow-closing. 3 . Selecting one pole, drift out the co upling pin and detach the driving link from the movable contact arms. 4 . Screw the driving link completely into the insulating link. 5. Back out the driving link two and one-half turns. Ex ceed this by whatever amount is necessary to properly position the link with in the movable contact arms. 6. I nstall the cou pling pin and retainer rings. 7. U s i n g the m a i ntenance hand l e , slow-close the breaker and observe that all eight stationary main contacts move away from their stops. If this condition is not achieved , ope n the breaker, again remove the cou pling pin and back out the driving link an additional half turn . 8. Reassemble, reclose the breaker and recheck wipe. 9. Repeat the above procedure on the other two poles. tM On the AK RT-50 the proper amount of contact wipe exists if, on a closed breaker, all of the stationary main contacts have moved away from their stops. This condition can be checked visually by removing the arc que nchers, closing the breaker and verifying that all eight stationary main contacts are " l ifted off" their stops. Should wipe ad j ustment appear necessary, proceed as follows: 1 . Open the breaker. ua ls The contact structure shown in Fig. 48 is used by all AKRT 50 breaker types. This structure is similar to the AKR 50 structure. There are two movable contact arms, each acting against single stationary arcing and intermediate contacts and four stationary mains. .c om CONTACT ADJUSTMENT AKRT 50/SOH an 8.4 ww w .E lec tri ca lP ar In the existing desig n , the metal driving l i nk uses the same adj ustment as the AKR 50. To perform the wipe adjustment on this design follow the procedure for the AKR 50, Section 8 . 3 . FIG. 48 - 2000 AMP CONTACT STR U CTU R E 37 .c om SECTION 8-Contact Maintenance (Cont.) 8.5 STATIONARY CONTACT I DENTI FICATION ua ls The stationary arcing, intermediate, and main contacts each have a different function d uring current conduction and current i nterruption. For this reason, these contacts are made using different material compositions. Also, the different functions require that the contacts be replaced in configurations shown i n Figs. 44, 47 or 48. ar tM an Fig. 49 shows the stationary contacts and how they d iffer from one another. The 800 am p main and arcing contacts are rectang ular, but the arci ng contacts have two of their corners notched. The 1 600/2000 am p main and i ntermed iate contacts are rectang u lar, but the main contacts have two of their corners notched . The i nter med iate contacts have all fou r corners notched . 8 0 0 A M P MAIN lec tri ca lP 1 600/2000 A M P MAIN ww w .E 1 600/2000AM P I N T E R M E D I AT E 38 F I G . 49 - STATIONARY CONTACT CON FIG U RATION 800 A M P A R C I N G CONTACT R EPLACEM E NT AKA 30/30H & AKRU 30 8.7 .c om 8.6 CONTACT R E P LACEMENTAKA 50/SOH , AKRU 50 & AKRT 50/SOH Refer to Stationary Contact Identification , Section 8.5 before replacing any stationary contacts. Refer to Stationary Contact Identification, Section 8.5, before replacing any stationary contacts. The stationary contacts are held in place by the contact springs which pivot the contacts agai nst the contact stop, refer to Fig. 45. To replace contacts: The stationary intermediate and main contacts are replaced j ust l i ke the stationary contacts on the 800 ampere breakers. Refer to steps 2 & 3 in Section 8.6 A spring puller is avai lable for this use and may be ordered under Cat. No. 286A81 68G 1 . 3 . Clean off the existing lu brication on the stud's pivot area. Replace with a small amount of D50H D38 (MO B I L 2 8 ) before installing new contacts. 4. Torq ue the upper arc runner mounting screws to 45 5 in-lbs. Torque the lower screw to 35-40 i n-lbs. 2. Remove the Arcing contact pivot. Clean off the exist ing l u bricati on found on the pivot area. Replace with D50H D38 (MOBIL 28) , see Fig. 50B. 3 . Remove the insulating spacers, contact pin and arc ing contacts, see Fig. 50C. 4. Reassemble the reverse of above. Make sure that the insu lating spacers and insu lating washers are properly in stalled. Torque the arc runner hardware to 45 ± 5 i n-l bs. tM ± 1 . Remove the arc runner and the flat insu lation assembled underneath the arc runner. It is secu red with four screws. When removi ng the lower screws, use care not to damage or misplace the insu lating washer found under each of these screws, see Fig. SOA. ua ls 2. Release each contact spring by holding the contact, extending the spring, and removing it from the contact. The end pieces on each spring have a small hole for inserting a spring puller. A suitable puller can be fashioned by forming a hook on the end of a length of .062" diameter steel wire . Referring to Fig. SOA, SOB & SOC, the stationary arcing contacts are replaced as fol lows. an 1 . Remove the arc runner. It is secu red by two screws into the base and one screw into the contact stop. The movable contacts are removed as fol l ows, referri ng to Fig. 46. lP 2. Remove the pivot piA hardware and spring from one side of the pivot pin. Carefu l ly remove the pivot pin. 3. Slip out the contact arm. The movable contacts are removed in a simi lar man ner as the 800 am pere breaker movable contacts. Refer to Section 8.6. When removing the pivot pin from a 2000 ampere (AKRT 50/SOH) contact assembly, the pivot pin from the opposite contact assem bly must be sl ightly removed. This provides enough c learance to completely remove the pivot pin. ar 1 . Using a right angle tru-arc pliers, remove the tru-arc retai ner on the coupling pin. Drift out the coupling pin. ca 4. Place a thin film of D50H D38 l ubrication on the pivot surfaces of the new arm. Clean any existi ng l ubrication from the pivot pin and place a smal l amount of D50HD38 on it. 5. Install the new arm, insert the pivot pin, and replace the pivot spring and hardware. Tighten the pivot pin hard ware to 90 ± 5 i n-l bs. tri 6. I nstall the coupling pin and tru-arc retainer. I INSULATING l"" INSULATING WASHER .E lec 7. Make the contact adjustment as per section #8 .2. ww w ARC R U N N E R FIG. SOD STATIONARY CONTACT -1 600/2000 A M P R E P LACE M E NT CONTACT STRUCT U R E 39 lP .c om ar tM an ua ls SECTION 8-Contact Maintenance (Cont.) ww w .E lec tri ca FIG. SOB - ARC RU N N ER REMOVED 40 FIG. SOC - ARC I N G CONTACT PIVOT REMOVED .c om SECTION 9-Fused Breakers FUSE SIZES AND MO UNTI NG Table 6 lists the range of fuse sizes available for these breakers. The Class L fuses are mounted as shown in Fig . 5 1 . Other than the 800A size, which has a single mo unting hole per tang , each Class L fuse tang has two holes sized for one-half inch diameter bolts. This fuse provides a melting time-current characteristic that coordinates with 1 600A trip devices . Com pared physi cally with a 2500A N EMA Class L fuse, the special fuse is more compact (shorter) ; its tangs are specially conf igu red and offset to achieve the required pole-to-pole fuse spac i ng ; a special primary disconnect assembly mounts directly on the outboard tang of the fuse. Considering their unique mounting provisions, when replacing these fuses the fol lowing procedure should be adhered to ( Refer to Fig . 53): a) Remove the pri mary d iscon nect assem bly from the fuse tang, acco m pl ished by fi rst loosening the two keys via their holding screw and pull ing them u pward and out. After the keys are removed , p u l l the d isconnect asse m bly off the end of the fuse tang. NOT E : This re m o va l does not disturb disconnect's clamping force adjustment. the tM Class J fuses rated 300 thru 600A have one mounting hole per tang . The 300, 350 and 400A sizes req uire copper adapter bars per Fig. 52. SPECIAL 2500A FUSE FOR AKRU-50 ua ls 9.1 9.2 an There are two types of fused breakers ; A K R U 30, 800 am pere frame and AKRU 50, 1 600 ampere frame. Except for the open fuse lockout device and the i ntegrally mounted fuses on the u pper studs, the AKRU-30 and -50 breakers are identical to the unfused AK R-30 and -50 models. Overcurrent trip devices are the same for both types. All 1f2-1 3 fuse mounting bolts should be torqued to 200350 in. lb. The %-1 1 bolts which attach the C shaped fuse adapters to the breaker studs should be torqued to 300525 in. -lb. c) Detach the inboard end of the fuse by removing the two 1 /2 inch - 1 3 bolts. A ratchet and socket with a short extension will be req uied. ar - b) Remove the upper barrier. e) Remove the fuse. f) I nstall the new fuse by reversing the di sassembly procedure. E nsure that the mating faces of the fuse and heat sink are clean . ADAPTER BARS (COPPER) .E lec tri ca lP d ) Re move the heat sink. FIG. 52 - 300 TH R U 600 A M P CLASS J FUSE MOUNTING ww w FIG . 51 - TYPICAL MOUNTING C LASS L FUSES 41 .c om SECTION 9-Fused Breakers (Cont.) 2 1 ua ls CAUTION: WHEN REPLACING THE FUSE I N THE LEFT POLE (FRONT VIEW) OF THE B REAKER, N O TE PA R TI C UL A R L Y THA T THIS F U S E I S MOUNTED DIFFERENTL Y THAN THE O THER TWO FUSES. AS SHOWN IN FIG . 54, FOR THIS PHASE THE FUSE IS ROTA TED 1 80 DEGREES A B O U T I TS A XIS S O THA T I TS I N B O A R D TA NG I S POSITIONED BENEA TH THE B REAKER S TU D . THIS TANG IS OFFSET WITH RESPECT TO THE OPPOSITE END SO THA T R O TA TING THE FUSE DOES NOT A L TER THE POSITION OF THE PRI MAR Y DISCONNECT. 0 FRONT OF B R E A K E R 3 . Heat Sink 2500A. F U S E CAT. N O . GF9F2500 AK lTANG BOLT• HOLES I N USE AKRU 50 WITH S PECIAL 2500 AMP FUSE (±) ar FIG. 53 4 . Upp e r Ba r r i e r 5 . Primary Di s c onne ct tM 1 . Sp e c ial 2 5 0 0 A Fu s e 2 . Di s c onne ct Key � L•� ·� I an BREAKER STUD FOR T H I S POLE O N LY , F U S E I S ROTATED 1 80c TO POSITION TANG B E N EATH ER STUD FUSE TANGS POSIT I O N E D ON TOP O F B R EA K E R STUD (±) 53) P R I MARY D I SC O N N E CT ASSEM BLY ( S E E F I G . MOUNTS DI RECTLY O N OUTBOARD FUSE TANG lP FIG. 54 ca AKRU 50-2500A FUSE TANG POSITIONS Breaker Type AKRU- 30 .E lec N E MA Fuse Class 600V 60 Hz tri TAB LE 6 FUSES FOR AKRU BR EAKERS J L � 50 - - - w - Special - \> ww * Mounting adapter required - see Fig. 52 42 Ampere Rating Gould Shawmut Cat. Nos. Fuse 300* 350* 400* A4J 300 A4J 350 A4J 400 450 500 600 A4J 450 A4J 500 A4J 600 800 1 000 1 200 1 600 2000 A4BY A4BY A4BY A4BY A4BY 2500 800 1 000BG 1 200BG 1 600BG 2000BG - Limiter A4BX A4BX A4BX A4BX A4BX 800 1 000BG 1 200BG 1 600BG 2000BG A4BX 2500GE .c om SECTION 9- Fused Breakers (Cont.) 9.3 OPEN FUSE LOCKOUT DEVICE TYPE A AND B B R EAKER OFLO ADJUSTMENT an FIG. 55- TYPE D B R EAKER OFLO DEVICE ar 9.3 . 1 tM Type D breakers use the Open Fuse Lockout (OFLO) shown in Fig. 55. Type A and B breakers use the OFLO shown in Fig. 56A & 568. Both OFLO's work on the same design. When the fuse opens, the resulting open c ircuit voltage activates the OFLO phase solenoid when the voltage level reaches approximately 90 VAC (the functional test in the factory is accom p lished using 1 20VAC). The solenoid armature then d rives a tri pping rod against a trip paddle which is attached to the trip shaft. This causes the breaker to open . The armature also d rives the reset button forward indicating what phase is involved. The reset button l in kage also holds the tripping rod against the trip paddle. The button must be pushed i n to release the tripping rod. ua ls This device automatically trips the fuse breaker if one of the fuses opens. When this happens, the breaker is locked open until the reset button of the phase involved is pushed . The breaker should not be reclosed, of course, until the opened fuse is replaced. lP To adjust the Type A and B breaker O FLO (Refer to Fig 56A): a) Back off tripping rod so that it will not hit the trip paddle when a solenoid is activated. ca b) Using the maintenance handle, close the breaker. c) Manually close the Left pole armature. Screw tripping rod forward until it moves the trip paddle enough to open the breaker. Add two full additional tu rns. tri d) Close the breaker. TYP E D B R EAKER OFLO ADJUSTMENT To adjust the Type D breaker O FLO : a) With the breaker in the C LOSED position and the OFLO reset adjust the dimension between the end of the tri p ping rod and the trip paddle to .1 00" - . 1 40 " . , b ) With the O FLO energized, the breaker m ust T R I P and the R ESET button m ust move forward t o the front plate. In this condition, the breaker m ust be held trip-free. lec e) Manually close the Left pole armature agai n . The breaker must open and the reset button pop out. In this condition close the breaker, it should trip-free. 9.3.2 f) Reset the OFLO, the breaker m ust now be able to close. g) Repeat for Center and Left poles. .E h) Check for a . 1 25" minimum clearance between trip ping rod and trip paddle with the O FLO reset. Check for .032" minimum overtravel after tripping rod trips breaker. ww w i) Hold tripping rod in position and tig hten its locknut. 43 .c om SECTION 9-Fused Breakers (Cont.) ua ls � --11 tM an TRIP PADDLE ar ARMAT U R E RESET BUTTON ww w .E lec tri ca lP FIG. 56A-DETAILS 44 FIG. 568-I NSTALLED TYPE A OR B B R EAKER OFLO DEVICE .c om SECTION 1 0-Type SST Overcurrent Trip Device t 8 �- - - - - - The SST is a s o l i d-state, d i rect-acti n g , self-powered trip 1 0.1 OVERLOAD I TARGET I I ua ls device syste m . The S S T system consists of t h e SST pro grammer u n it, c u rrent sensors, a n d a flux sh ifter t r i p de vice . F i g . 57 shows a block d i agram of t h e syste m . PROG RAMMER UNIT I I I I lciRCU I T SHORT I TARGET I tM an F i g . 58 shows a typical S ST prog r a m m e r u n it . T h e pro g r a m m e r u n it provides the com parison basis for overcur rent detect i o n and d e l i vers t h e e n e rgy necessary to trip the b reaker. I t contai n s the e lectronic c i rc u itry for t h e vari o u s t r i p e l e m e nts. T h e i r associated p i c k u p a n d t i m e de lay ad j u st me nts (set- poi nts) are located on t h e face plate . De p e n d i ng on the applicat i o n , prog r a m m e r u n its may be e q u i p pe d with various combi natio n s of Long Time, S hort T i m e , I nstanta n e o u s and G ro u n d Fault t r i p e l e me n t s . See Table 7 for ava i l ab l e rat i n g s , setti ngs and t r i p c h aracteris tics. Adj ustme nts are made by removing t h e clear cover over t h e face p late, u nscrewing ( c o u n te r- clockwise) t h e set- point k n o b , m o v i n g the set-po i n t a l o n g the slot t o t h e n e w sett i n g , and screwi ng the set- p o i n t k n o b i n . O n ce a l l adjustme nts are made , i n stall t h e clear c o v e r to t h e face p late . ar FIG. 57 - SST B LOCK DIAGRAM E a c h target pops out w h e n i t s associated trip e l e m e n t ope rates to t r i p t h e b reaker. After a tri p , t h e popped target m u st be reset by hand. However, neglecti ng to reset does not affect normal operation of any t r i p e l e ment o r p revent the breaker from being reclosed . e m ploy t h ree target s : from left to right, t h e f i rst is for over l o a d , the second for s h o rt c i r c u i t (actu ated by the short t i m e a n d i n stantaneous e l e ments) a n d t h e t h i rd f o r g r o u n d fault. The latte r is om itted on u n its without g r o u n d fault. The prog r a m m e r u n i t is mou nted to t h e l ower right of the breaker as shown i n Fig. 59. The bracket attached to the top of the prog r a m m e r , see Fig. 58 , engages with a bracket mou nted to the u n d e r s i d e of the breake r's front fra m e . ca lP The SST prog ram m e r u n its can be optionally eq u i p ped w i t h trip i nd i c at o rs (targets ) . These are p o p - o u t , m e c h a n ical ly-resettable p l u ng e rs located across the t o p o f t h e prog rammer's front. U n its w i t h a g r o u n d f a u l t e l e ment tri TAB L E 7 SST TRIP CHARACTER I STICS S ST PROGRAMMER ADJUSTMENT RANGE (Set Points) X • Trip Rating ( lec Frame in Amperes • Sensor Tap Breaker Type Size (Amperes) - - - - - - ) - - - - - Sensor Ampere .E Taps AKR-30 ww w AKR-50 AKRT-50 CD @ 800 ( Pick Long Time (D ) (•L) Multiple of X GROUND FAULT Short Time @ Time Delay Band (Seconds) ( ® Pickup Multiple of L ) @) Time Delay Band (Seconds) ( Pickup Multiple of L ) ( 3, 4 , 5, 6, 8, 1 0 ( L ) 100, 1 50 , 225, 300 - or - .6, .7, .8, 300, 400, 600, 800 .9, 1 .0 , - or - 1 . 1 (X) 600, 800, 1 200, 1600 Maximum 22 Intermed . 10 Minimum 4 -or1 . 75, 2 , 2.25, 2.5, 3, 4 (L) Pickup tolerance is ±.. 9% Pickup tolerance is ±.. 1 0% @ G) Multiple of X ) I @ Time Delay Band (Seconds) .8, 1 .0, 1.2 ( X ) Maximum Maximum 0 . 35 lnt..rmed . 0.21 Minimum 4, 5, 6, 8, 1 0 , 12 ( L ) 0 . 30 .25, .3, .4, .5, .6, .7 (X) Intermed. 0.165 Minimum I 0.065 0.095 .2, .25, . 3 , .4, . 5 , 800, 1 200 , 1 600, 2000 ® Pickup .4, .5, .6, 300 , 400 , 600, 800 1600 2000 ® Instantaneous .6 ( X ) Time delay shown a t 600% of long time pickup setting ( 6 L ) , a t lower limit of band. Time delay shown at lower limit of band. 45 .c om ua ls SECTION 1 0-Type SST Overcurrent Trip Device (Cont.) MOUNTING BRACKET tM an � ar FIG. 59 - AKR-58-30 1 0.2 C U R R ENT S ENSORS tri ca lP The SST system uses two types of cu rrent sensors, a phase sensor and a neutral sensor. Fig . 60 shows a phase sensor. Fig. 61 shows the neutral sensors available . The cu rrent sensor supplies the power and sig nal i n puts necessary to operate the trip syste m . Each sensor has four taps which provide field adj ustment of the trip device's continuous ampere rating. ww w .E lec FIG. 58 - SST P ROG RAMMER 46 The SST Ground Fault trip element operates on the principle that the instantaneous values of current in the three cond uctors (four on 4-wire systems) add to zero unless ground current exists. On SST's equipped with Ground Fault, the ground trip signal is developed by con necting each phase sensor in series with a companion pri mary winding on a ground differential tran sformer mounted in the programmer unit. Its secondary output is zero so long as there is not ground cu rrent. Application of the G round Fault e le ment on 4-wire sys tems with neutral grounded at the transformer requires the additional, separately mounted neutral sensor (Fig. 6 1 ) inserted in the neutral conductor; its secondary is con nected to a fourth primary winding on the ground differen tial transformer. See Fig . 70. This "fourth-wire" ne utral sensor is an electrical duplicate of the phase sensor, in cluding taps. Therefore, when taps are changed on the phase sensors, those on the neutral sensor must be cor respondingly positioned . When used, the neutral sensor is separately mou nted in the bus or cable compartment of the switchgear. I n draw out construction, its output is automatically con nected to the breaker via secondary disconnect blocks. See Fig. 62. .c om ua ls tM an ca lP ar FIG. 60 - SST PHASE S ENSOR WITH TAP BOA R D B R E A K E F' MOUNTED \ lec tri 600 - 1 600 A EQUI PME N T MOU N TED - a oo A ww w .E 300 FIG. 61 100 - 3 00 A - SST N EUTRAL S ENSORS FIG. 62 - N EUTRAL SENSOR SECONDARY DISCONNECT BLOCKS 47 a) D i sconnect t h e breaker harness from the tap ter m i n a l board , remov i n g cable t i e s as necessary. Un fasten the term i n al board from t h e breaker base. b) At the rear of the breaker. remove the two A l l e n he ad sc rews to sep arate t h e stud con n ector from t h e con tact p i vot b l ock. c) Loosen the c l a m p i n g bolt and remove the stud con nector. L i ft out the sen sor and i ts tap term i n al board . 1 0.3 connector, t i ghten t h e 1 0 i n - l bs. T i g h ten t h e 1 0 i n - l bs 1 0 i n- l bs 1 0 i n- l b s F L U X SH I FT T R I P D EV I C E T h e F l u x Sh i ft Tri p device i s a l ow-e nergy, e l ec t ro m ag n e t i c device w h i c h , upon rece i pt of a tri p s i g nal from t h e p rogram mer u n i t , t r i p s t h e breaker by act u at i n g the t r i p shaft . The m o u n t i n g arrangement of t h i s c o m ponent i s i l l u strated i n F i g s . 6 4 and 65. A n e l ectro m ag n e t i c ac t u ator l ocated on the u n derside of the front frame i s cou p l ed t o t h e breaker's t r i p shaft v i a a tri p rod d riven by t h e actuator arm. The actuator i s a solenoid whose armat u re i s s p r i n g - l oaded and held i n i t s norm a l (Reset) pos i t i o n b y a permanent mag net. I n t h i s state the s p r i n g is com p ressed . ww w .E lec tri ca lP ar tM The sensor may be p revented from s l i p p i n g off t h e sen sor s t u d b y adj acent accesso ries. I f this exists, the sensor stud m u st be removed from the breaker base. The stud asse m b l y i s secu red to the base w i t h fo u r b o l t s w h i c h are acces s i b l e from t h e rear o f t h e breaker. d) When re p l ac i n g t h e stud A l l e n head sc rews to 2 5 0 ± c l a m p i n g bo l t a s fol lows: AKR 30/30H - 1 20 ± A K R 50/50H - 470 :t: A K RT 50/50H - 470 ± ua ls Referri ng t o F i g . 63, re p l acem e nt o f i n d i v i d u a l SST c u rre nt sen sors i s acco m p l i s hed as fo l l ows: .c om R E P LAC EM ENT O F C U R R E NT S E N SO R S an 1 0. 2 . 1 48 1 . Flux shift Trip Device 2 . Allen- head Screws 3 . Stud Connector 4 . Current Sensor 5 . Tap Ter minal Board 6. Programmer Unit 7 . Clamp Bolt 8 . Sensor Stud FIG. 63 - AKR-SA-30 B R EAKER WITH SST TRIP DEVICE .c om 5. Verify a l l soc kets are i n serted to the same depth. CAUTION : I N THE EVENT THA T THE SST TRIP DE VICE M U S T BE RENDERED INOPERA TIVE TO A L L O W THE B REA KER TO CA R R Y C U R RENT WITHO U T B ENEFIT OF O VERCURRENT PROTEC TI O N, THE R E C O M M ENDED METHOD IS TO SHO R TEN THE TRIP ROD B Y TURNING ITS A D JUSTER END FUL L Y C L O C K WISE. THIS PRE VENTS A C TUA TION OF THE TRIP SHAFT PADDLE. tM T h e t r i p device req u i res o n l y one adj u stment - t h e t r i p rod l e n g t h . As shown rn F i g . 66, the c l earance between the t r i p rod and the t r i p shaft pad d l e i s gaged by a 0 . 1 09 i nc h d i ameter rod . Adj u st gap to 0. 1 09 i n c h ± 0.031 i nc h . To adj u st, o p e n the b reaker a n d restore the b reaker mecha n i s m to its Reset posi t i o n . Loosen the jam n ut , rotate the adj u ster end u n t i l the proper gap is attai ned, then ret i g hten the j a m b nut to 35 ± 5 i n - l bs. ua ls As the breaker opens, the act u ator arm-i s ret u rned to its normal ( Reset) pos i t i o n via l i n kage driven by a c ra n k on the b reaker's m a i n s h aft. The permanent mag net agai n holds the armat u re captive in read i n ess for t h e next t r i p s i g na l . 1 . Remove t h e flux s h i fter leads from the h arness. 2 . Referri ng to the cab l i n g d i ag rams in Section 1 0.5, the flux sh ifter leads are RED for point B and BLACK for point E. 3. I n se rt the extractor too l over the fe male p i n . When t h e extractor tool botto ms out, depress the p l u n ger and force the w i re/socket asse m b l y out of the connector. 4. N o tool i s req u i red to i n sert the wi re/socket asse m b l y i nto the conn ector. I n se rt the assem b l y u n t i l i t s n a p s i n to p l ace. an So long as the act u ator re m a i n s i n the Reset posi tion, the b reaker can be c l osed and opened norm a l l y a t w i l l . H owever, when a c l osed b reaker receives a t r i p s i g nal from the programmer u n i t , the act uator i s energ i zed a n d its solenoid f l ux opposes t h e magn �t. al low i n g the spri n g to re l ease the armat u re; t h 1 s d rives t h e tri p rod agai n st t h e t r i p sh aft padd l e , tri pp i n g the b reaker. ar The actu ator is a sealed, factory-set dev i ce and re q u i res no mai ntenance or field adj ustment. In case of m a l f u n c t i o n , the comp lete act u ator u n i t s h o u l d be rep l aced . When m a k i n g the e l ectri cal con nector to the rep l acement u n i t, i t is reco m m ended t h at the brea ker harness be cut at some conven ient point and the new act u ator leads solder-sp l i ced together. CRANK BREAKER C L OS E D P O S I T I ON ) RESET L I NKAGE MA I N S H AFT .E lec ( tri ca lP The preferred method is to remove the f l u x s h i fter leads from the A M P con nector u s i n g the A M P ext rac t i o n too l , Cat. No. 305 1 83 as fol l ows: ww w TR I P PA D DLE SIDE VIEW FRON T VIEW <?" 0 FIG. 64 - F L UX SHIFT TRIP DEVICE A N D O P ERATING L I N KAG ES 49 ca Bottom view lP 4 3 ar .c om tM an ua ls SECTION 1 0-Type SST Overcurrent Trip Device (Cont.) 1 . A ctuator 2 . Trip rod adj uster end 3 . Trip paddle 5 Top view 4 . Trip shaft 5 . Actuator arm 6 . Reset linkage T R I P PAJDLE IN " M EC H A N ISM RESET POS I T I O N .E lec " tri FIG. 65 - F LUX S H I FT TRIP DEVICE COMPON ENTS JAM NUT 0 . 1 09 ± .031 Dia. w rod ww FIG. 66 50 - TRIP ROD ADJUSTMENT .c om 1 0.4 TROUBLESHOOTI N G b) Breaker remai n i ng in a tri p-free state due to mechanical i nterference along i ts trip shaft. c) Inadvertent shunt trip activations. WARN I NG: DO N O T CHA NGE TA PS ON THE CURRENT SENSORS OR A DJUST THE PRO GRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CA RR YING CURRENT. Once it has been estab l i shed that the c i rc u i t breaker can be operated and c losed normally from the test posi tion, attention can be d i rected to the trip device proper. Testi n g is performed by either of two methods. 1 . Cond u ct h i g h-c u rrent, sing le-phase tests on the breaker using a h i g h c u rrent-low voltage test set. The applicable test proced u res are detai led in i n struction Book G EK-64454 and are summarized i n Sec tion 1 0.4. 1 . The TAK-TS1 and TAK-TS2 Test Sets are portable i n struments desig ned for field checking the t i me-cu rrent characteristics and pickup cali brat ion of the SST's various trip e lements. It can verify the abi l ity of the Fl ux-Sh ift Trip Device to trip the breaker and, i n addi tion, incl udes means for. cont i n u ity checking the phase sensors. A TAK-TS1 Test Set is shown in Fig. 67. The t i m e-cu rrent characteristics for the SST Tri p Device are g iven i n cu rves G ES-6033, G ES-6034 and G ES-6035. ar tM NOTE: For these single-phase tests; special con nections m ust be .. employed for SST breakers equipped with Ground Fault. Any s ingle-phase in· put to the ground differential transformer will generate an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by 2. Test the com ponents to the SST system u s i ng por table Test Set Type TAK-TS1 (Fig. 67) or TA K-TS2. ua ls a) Breaker tripping i n proper response to overcu rrents or i nc i pient ground fau lts. b) using the Ground Fault Defeat Cable as shown in Fig. 71. This special test cable energizes all the primary windings of the differential transformer in a self-cancelling, series-parallel connection so tha t its secondary output is always zero. an When malfunctioning i s suspected t h e fi rst step i n troubleshooti n g i s t o exam i ne the c i rc u i t breaker and its power system for abnormal conditions such as: ww w .E lec tri ca lP a) testing two poles of the breaker in series, or FIG. 67 - SST/ECS TEST S ET, CAT. NO. TAK-TS1 51 .c om SECTION 1 0-Type SST Overcurrent Trip Device (Cont.) SST TEST SET The TA K-TS1 and TA K-TS2 Test Sets are portable in struments desig ned for field-checking the t i me-cu rrent characteristics and pickup cali brat ion of the SST's various trip elements. It can verify the abil i ty of the Fl ux-Sh ift Trip, Device to tri p the breaker and, i n addi t i o n , incl udes means for cont i n u ity che.cking t h e phase sen sors. A TAK-TS1 Test Set is shown in Fig. 67. The TAK-TS2 functions identical ly to and supersedes the TAK-TS1 device. The TAK-TS2 can also test the Ver saTrip Mod 2 tri p device. 1 0.4.2 For use in troubleshooting, the Common to Tap resist ance for SST cu rrent sensors is given in Table 8. These values apply to both phase and neutral sensors. TABLE 8 - SENSOR R ESISTANCE VALUES Ampere TAP 1 00 1 50 225 300 2.2 3 .3 5.1 6.8 - 2.6 3.9 5.8 7.8 300 400 600 800 5.3 7.2 1 0. 8 1 4.6 - 6.1 8.2 1 2 .4 1 6.9 600 800 1 200 1 600 6.4 8.8 1 3 .5 1 9 .4 - 7.6 1 0 .4 1 5.8 22.8 800 1 200 1 600 2000 1 0.2 1 5 .8 22.0 28.5 - 1 2.4 1 9 .2 26 . 7 34 . 7 tM ar "A" - Programmer Unit O nly. These tests are con ducted with the programmer unit discon nected from the breaker. During test, the unit can remain attached to the breaker or may be completely removed from it. ca lP CAUTION : NEVER DISENGAGE THE HARNESS CONNECTOR FROM THE PROGRAMMER UNIT ON A BREAKER THA T IS ENERGIZED AND CAR R Y ING LOAD CURRENT. THIS WILL OPEN-CIRCUIT THE CURRENT SENSORS, ALL O WING DANGER OUS AND DAMAGING VOLTA GES TO DEVELOP. Test scope: 1 . Verify the time-current characteristics and pickup calibration of the various trip elements. tri 2. Verify operation of the SST target indicators on pro grammer units so equipped. - Test scope: lec "B" Complete Trip Device System. For these tests, the programmer unit must be mounted on the breaker and connected to its wiring harness. .E 1 . All "A" tests previously described, plus provision for optionally switching the programmer's output to activate the Fl ux-Shift Trip Device and verify its operation by physi cally tripping the breaker. 2. Check phase sensor conti nuity. ww w In the event that any component of the SST syste m does not perform within the limits prescribed in test instructions G EK-64454 , it should be replaced. 52 Resistance i n Ohms between COMMON and TAP Termi nals an WARNING : BEFORE CONNECTING THE TEST SET TO THE BREA KER TRIP DEVICE S YS TEM, EN SURE THA T THE CIRCUIT B REAKER IS COM PLETEL Y DISCONNEC TED FROM I TS PO WER SOURCE. ON DRA WO UT EQUIPMENT, RACK THE B R EA KER TO I TS DISCONNEC TED P OSITION. VERIFY THA T THE BREA KER IS TRIPPED. Either of two test modes may be employed: R ES ISTANCE VAL U ES ua ls 1 0.4.1 The coil resistance of the SST/ ECS Flux shifter device i s approximately 1 6 ohms. c) Verify that the harness connections to the sensors meet the polarity constraints i ndicated by the cabling dia gram, i . e . , white wire to COMMON, black wire to TAP. d) On G round Fau lt bre akers serving 4-wire loads, check that the neutral se nsor is properly connected (see cabling diagram Fig. 70) . In particular, ( 1 ) Verify that the neutral sensor has the same rating and tap setting as the phase sensors. ( 2) Check continu ity between the neutral sensor and its equ ipment-mou nted secondary disco nnect block. Also check for conti nuity from the breaker-mounted neutral secondary discon nect block through to the female harness con nector (terminals L and N ) . ( 3 ) I f the breaker's lower studs connect t o the supply source , then the neutral sensor must have its LOAD encl connected to the source. (4) Ensure that the neutral conductor is carrying only that neutral current associated with the breaker's load cur rent (neutral not shared with other loads) . tM If nuisance tripping is encountered on any breaker whose SST components have previously demonstrated satisfactory performance via the TAK-TS 1 Test Set, the s e n so rs and t h e i r c o n n e c t i o n s s h o u l d be c l o s e ly scrutin ized. After disconnecting the breaker from all power sources, .c om When nuisance tripping occurs on breakers equi pped with the G round Fault trip element, a probable cause is the existence of a false "ground" sig nal . As indicated by the cabling diagram of Fig. 69, each phase sensor is con nected in a series with a primary winding on the G round Fault differential transformer. Under no-fault conditions on 3-wire load circuits, the cu rrents in these three windings add to zero and no ground signal is developed. This current sum will be zero only if all three sensors have the same electrical characteristics. If one sensor differs from the others ( i . e . , different rating or wrong tap setti ng ) , the dif ferential transformer can produce output suff icient to trip the breaker. Similarly, discontinu ity between any sensor and the programmer unit can cause a false trip signal. ua ls FALSE TRIPPI NG-B R EAKERS EQUIPPED WITH G RO U N D FAU LT an 1 0.4.3 a) Check that all phase sensors are the same type (am pere range). SST CABLING DIAG RAMS lP 1 0. 5 ar b) Ensure that the tap settings on all 3-phase sensors are identical. e ) I f the preceding steps fai l to identify the proble m, then the sensor resistances should be measured . Since th13 phase and ne utral sensors are electrically identical, their tap-to-tap resistance should closely agree. See Table 8 . +A :����;� E � A A A r 1 1)===)= -t-t==)= I w .E lec tri LEFT POLE CURRENT SENSOR ww +C ca B +B FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT �- - - - - - 1---'-'==-+o-+-< •E-+<>-+-- (4BV. de) (TO SCR ANODE) WHITE BLACK WHITE BLACK WHITE BLACK HARNESS C ONN ECTOR (AMP 201 298- 1 ) LOAD PROGRAMME R CONNECTOR (AMP 201 297-1 ) FIG. 68 - CABLING DIAG RAM - SST WITHOUT G RO U N D FAULT 53 .c om SECTION 1 0-Type SST Overcurrent Trip Device A A A $ cp S � BREAKER BACK FRAME LEFT POLE CURRENT SENSOR I I ,- - - - cp C _-$ 4'- I � ' b �' I )= = =)= ==)= - ���>+-( �-o-ll-e (TO SCR _ - PROGRAMMER U N IT FLUX SHIFT TRIP DEVICE (48V. de) ANODE) ua ls cpA WHITE BLACK WHITE BLACK an WHITE BLACK PROGRAM MER CONNECTOR (AMP 201 297- 1 ) tM HARNESS CON N ECTOR (AMP 201 298- 1 ) LOAD ar FIG. 69 - CABLING DIAG RAM - SST WITH G RO U N D FAU LT ON 3-W I R E LOA D A A A cp A +B +C lP 1 $ --$ - 4'1 � ' b . b , I1 � )= = =)= ==}= I FLUX SHIFT TRIP DEVICE ,-- - - ca BREAKER BACK FRAME I 'A��--�-4--���-+o+< ��+1 II NEUTRAL I SENSOR 1 DISCONNECT I � -1 LI NE I .E lec I (• ..--1-<�4-o-14 1 1 N I t A tri I I I ')..+-ojf--.J---�--+--+-...!::!.:!�-+o+-< 1 ......._ __ ww w EQUIPMENT - M OU NTED NEUTRAL SENSOR "-------. ,.------' 4-WIRE LOAD 54 - PROGRAMMER UNIT FIG. 70 - CABLING DIAG RAM - SST WITH G ROUND FAU LT ON 4-W I R E LOAD - .c om an ua ls ANY SST PROGRAMMER U N I T W I TH G R O U N D FA U LT ELEM ENT FEMALE END MALE END ww w .E lec tri ca lP ar tM FIG. 7 1 - CA B L I NG DIAG RAM WITH G RO U N D FAULT DEFEAT CAB LE I N SERTED B ETWEEN B REAKER HARN ESS AND SST PROG RAM M E R UNIT - FOR USE D U R I NG SING LE-PHASE, H I G H C U R R ENT - LOW VOLTAG E TESTING 55 .c om SECTION 1 1 -Type ECS Overcurrent Trip Device The ECS is a so l id-state, d i rect-act i n g , sel f-powered trip devi ce system . The ECS system consi sts of the ECS p rog rammer u n i f shown in Fig. 72, cu rrent sensors, and a flux s h i fter trip device. F i g . 73 shows a bloc k d i ag ram of the system. ua ls The ECS t r i p system essentially d u p l icates the SST t ri p system descri bed i n Sect ion 1 0 except for the fol lowing: 1 . Prog ram m er un its are l i m ited fo combi nations of Lo ng Time, Short Time and i n stantaneo us tri p elements on ly. The G round Fau lt element i s not available. an 2 . Ph ase sen sors are not tapped. As l i sted in Table 9, each sensor has only a s i n g l e am pere rating. A d i fferent sensor is ava i lable for eac h of the tabu l ated am pere rat i n gs, wh i ch s pan the same range as SST, see F i g . 74. lP ar I n a l l other res pects the ECS Tri p device system operates and can be treated ident ically to SST. This in cl udes c i rc u i t ry, si ze , const ruct ion, component loca t i o n , prog ram m e r u n i t set p o i nts, performance characteri stics, operating range, qual ity, rel iabi l ity and the flux s h i ft t r i p device. Use the same troubleshoot i n g a n d test p roced u res for s i n g l e-phase, h i g h c u rrent-low voltage tests or th ose em ploying the TAK-TS1 or TAK TS2 Test Sets. The G round Fault test proced ures, of course, do not app ly. ECS phase- sensor res i stance val ues are g ive n i n Table 1 0. tM 3. Neut ral sensors are not req u i red because there i s n o G round Fau lt function. FIG . 72 - ECS PROG RA M M E R U N I T FIG 74 - E C S CU R RENT SENSOR w tri .E lec 1))- - - - ca The ti me-cu rrent ch aracteristics for the ECS tri p devi ce are g ive n i n c u rve G ES 6032. ww FIG . 73 - ECS B LOCK DIAG RAM 56 X CD ® ( eD (•L) Multiple of X @ Time Delay Band (Seconds) ( ® Pickup Multiple of L @ Time Delay Band (Seconds) ) ® Instantaneous ( Pickup Multiple of L ) 3, 4, 5 , 6, 8, 10 (L) Maximum 22 300, 400, 600, 800, 1200, 1600 2000 ) Short Time 800, 1200, 1600, 2000 . 6, .7, .8, . 9 , 1 .0, 1.1 (X) @ Pickup tolerance is ±. 9% @ Pickup tolerance is ±. 10% In termed. 10 Minimum 4 -or- 1 . 75, 2, 2.25, 2 . 5, 3, 4 (L) Maximum 0.35 In termed . 0.21 4 , 5 , 6, 8, 10, 1 2 (L) Minimum 0.095 an 1600 AKRT-50 Pick 100, 150, 225, 300, 400, 600, 800 800 AKR-50 ) Sensor Am �ere Ratmg Long Time Time delay shown at 600% of long time pickup setting (6L), at lower limit of band. Time delay shown at lower limit of band. tM Al{R-30 ( 1- - - - - - - - ECS PROGRAMMER ADJUSTMENT RANGE (Set Points) ua ls Frame Size (Amperes) Breaker Type = Trip Rating in Amperes • Sensor Rating .c om TABLE 9 ECS TRIP CHARACTERISTICS TAB L E 1 0 - S ENSOR R ESISTANCE VAL U ES lOO 1 50 225 300 400 600 800 1 200 1 600 2000 Resistance in Ohms between Term i nals ar Ampere Rating tri ca lP 3.0 - 3 . 4 4.4 - 5.0 4.8 - 5 . 6 6.4 - 7.2 6.7 - 7.8 6.4 - 7.6 8 . 8 - 1 0.4 1 3 .5 - 1 5 . 8 1 9.4 - 22.8 29.5 - 34 . 5 L--------�---- .E lec 1 1 . 1 ECS CABLING DIAGRAM A A A � -� 4'+A � BREAKER BACK FRAME LEFT POLE CURRENT SENSOR r I +B +C )==+==!= � , 6 - b, 1 I FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT �- - - - - , 1--'-'-""'-t-<>-t-( �<>+-- (48V de I !="""'-t-o-t-( f+<>-t-- (TO SCR ANODE) ww w I I I_ - LOAD FIG. 75. CABLING DIAGRAM FOR ECS TRIP D EVI CE 57 .c om SECTION 1 2- MicroVersaTrip TM Trip Device 1 2. 1 . 1 The M i c roVersaTri p is a solid-state , d i rect-acti n g , self- powered trip device system . The M icroVersaTri p system consists of the M icroVersaTri p p rog rammer, cu rrent sensors, and a flux sh ifter trip device. Fig. 76 shows a block d iagram of the system . I --- TAP BOARD _ _ I I I f----f--- ----- I I I I 1 LONG TIME PICKUP & DELAY r- 1-- ,__ t SHORT TIME PICKUP & DELAY ili= SUMMING CIRCUITRY f---. d> 1 02 03 _ _ _ _ ww ua ls an I I I I I I r l GROUND FAULT PICKUP & DELAY t I _ _ _ . .. ," tft!ll SHORT C I R C U IT TARGET "" tp; " "" GMOUtiO FAt.H.f l'fQ(UP GROUND TARGET I I REGULATED 15 VDC POWER SUPPLY _ _ I _. FIG. 76 MICROVE RSATRI P B LOCK DIAG RAM 58 tM I w L N I t t '- INSTANTANEOUS PICKUP � I OVERLOAD I TARGET lec I _j .E I €El,\''.J I _ LOGIC 'OR I I I I I .:!_ -.:!.�� _j I Remote fault indication is available i n the form of a mechanical contact which may be incorporated directly i nto the customer's control circu itry. This is a Normally open contact which is activated when its associated target pops out. When the target is reset, the contact is returned to its open position. Each contact is rated 0 . 25 amp at 1 25 VDC and 1 .0 amp ( 1 0 amp in rush) at 1 20 VAC. lP I RRENTSENSORI I SOLID STATE SWITCH 1 FLUX SHIFTER TRIP COIL R E MOTE FAU LT I N DICATION ca -k r I -'-� L --_ _ _ 1 2 . 1 .2 tri »- Each target pops out when its associated trip element operates to trip the breaker. After a trip, the popped target must be reset by hand. However, neglecti ng to reset does 110t affect normal operation of any trip element or prevent the breaker from being dosed . ar Fig. 77 shows a typical M icroVe rsaTr i p p rog rammer u n it. L i ke the SST and ECS units, the M icroVersaTrip p rovi des the com parison basis for overcu rrent detection and del ivers the energy necessary to trip the breaker. It contains a p rog rammable m icroelectronic processor which incorporates nine adj usta ble ti me-cu rrent func tions, th ree mechanical fault i n d i cators ( local and remote), a long-time pickup LED i n d icator ( local and remote) and a zone selective i nterlocking function. All adjustable p rog ram mer functions are automatic and self-contained req u i ring no external relaying, power supply or accessories. See Table 1 1 for trip functions avai lable and Table 12 for trip function characteristics. A detai led descri ption of each trip function is g iven i n publication G EA 1 0265 a n d G EH 4657 . NCT The optional fault trip indicators are similar t o t h e SST indicators. They are mechanical pop-out type for identify ing overload or short circuit over-currents faults when breakers are ordered without integral ground fault protec tion . They are also available to identify overload, short circuit and ground fault trips for breakers supplied with integral ground fault protection . PROG RA M M ER U N IT 1 2. 1 FAU LT TRIP IN DICATORS FIG. 7 7 M I C ROVERSATRIP PROG RAM M ER .c om The remote fault indication switch leads are brought out the bottom of the MicroVersaTrip program mer as shown in Fig. 78. This switch lead harness is plugged into the mating connector on the breaker, see Fig. 79. an ua ls The switch leads are brought out from the breaker through the Programmer Secondary Disconnect shown in Fig. 80. The zone selective i nterlocking fu nction wir ing is also brought out through this disconnect. See Figs. 95 and 96 for the remote fault indication and zone selective interlocking cable d iagrams. tM FIG. 80 REMOTE FAU LT I N DICATOR ·•· . """' "'" 1 2. 1 .3 M ICROVERSATRIP™ I N STALLATION lP ar • w .E lec tri ca FIG. 78 M I C ROVERSATRIP W/REMOTE FAU LT I N D I CATI O N HARN ESS ww DISCONNECT FIG. 79 PROGRAMMER SECONDARY CONNECTOR The programmer mounts to the upper left of t h e breaker as shown in Fig. 8 1 . It mounts to the bracket assembly shown i n Fig. 82. Referring to Fig. 82, the gu ide pins mate with the holes on either side of the prog rammer con nector. They provide the necessary alig nment for the connector engagement . The locking lever engages with the pin which i s assembled t o the program mer frame and secures the pro grammer to the mounting bracket There are two prog rammer mounting designs in use. The d i fference in the designs is in the operat ion of the l ocking lever, see Fig. 82. I nstallation using each design is as follows: a. I n sert the gu ide p i ns i nto the holes and push on the pro gram mer, e n gag i n g the con nectors. b. Orig i nal design-push in the locking lever, securing the programmer. the Later design -the locking lever i s released, securing programmer. c. Verify t hat the locking lever did engage the programmer pin. d. Connect remote fault ind icat ion harness, if eq u i pped, see Fig. 80. To remove the programmer: a. Disconnect the remote fault i ndication harness, if eq uipped. b. Original designs - push i n l ocking lever, which w i l l release the programmer p i n . W h i l e holding the locking lever i n , remove the programmer. c. Later design - p u l l out locking lever, which w i l l release the programmer pin. Remove the programmer. 59 .c om SECTION 1 2- MicroVersaTrip™ Trip Device (Cont.) C U R R ENT SENSORS The tapped and fixed phase sensors have a polarity as sociated with their windings. Their COMMON terminal is the right hand terminal as shown in Fig. 83. A white wire with a ring terminal will be connected to this COMMON terminal. All phase sensors must be correctly wired for the program mer summing circuit to function properly. The tapped or fixed phase sensors are avai lable with an additional winding. This winding is brought out to separate flag terminals rather than the screw term inals. These phase sensors are used when the hi-level i nstan taneous M icroVersaTrip option ('H'-option) is req u i red. Fig. 84 shows an 'H '-option phase sensor. When the 'H' option phase sensor is i nstal led , there are fou r leads con nected to it; two flag ter m i nal con nections (ad d itional winding) and two screw ter m i nal con nections (am pere rating). There is no polarity associated with the flag ter m i nals. Fig. 94 shows the con nections for the add itional 'H'-option w i n d i ngs. an The cu rrent sensors supply the power and signal in put necessary to operate the trip system . Like the SST system , the M icroVersaTrip uses a phase and neutral sensor. Fig. 83 shows the phase sensors. Tapped and fixed phase sensors are available. The tapped sensors provide field adjustment of the trip device's continuous ampere rati ng . See Section 1 2. 5 for cabling diagrams. ua ls 1 2.2 tM Fig. 85 shows the neutral sensor. The neutral sensor is required when i ntegral ground fault protection is used on single phase-three wire or three phase-four wire systems. It is inserted i nto the neutral cond uctor and therefore is separately mounted in the cable or bus compartment. ca lP ar The outputs of the phase sensors and ne utral sensor are connected to a programmer circuit which sums these val ues. The total value will remain zero as long as there i s no ground current flowing. See cable diagram i n Fig. 91 . The ne utral sensor is an electrical duplicate of the phase sensor, including taps. Therefore, when taps are charged on the phase sensors, those on the neutral sensor must be correspondi ngly positioned. ww w .E lec tri FIG. 8 1 - AKR-60-30 60 FIG. 82 - MICROVERSATRIP® RMS-9 AND POWER LEADER MOUNTING BRACKET .c om TAB L E 1 1 TRIP FUNCTIONS AVAI LAB LE Optional Features STD.-or-5-or-H-or-M • Adjustable Current Setti ng X X X X • Adj Long-Time Pickup X X X X LONG • Adj Long-Time Delay X X X X TIME • Lo�Time Timing_ Light X X X X • Remote Long-Time Timing Light • Adj Short-Time Pickup X X X X X X • Adi Short-Time Delay • Short-Time l2t Switch (I) INSTANTA- • Adj I nstantaneous PickUfl_ NEOUS GROUND X • Adj High Range I nstantaneous Adj Ground Fault Pickup -1 PH, 2.W-3PH, 3/4-W -Ground Re_turn. • Adj Ground Fault Delay • Trip Indication Targets OTH ER X X • FAULT X X -local only tM -local only(2) -local and remote Zone Selective Interlock X X X -Short Time<D X X ar -Ground Fault<3) X X -0/L, S/C and Ground Fault X X lP 1 Short-Time Delay is required 2 Standard when Ground Fault specified 3 Ground Fault required Z1 -or-Z2-or-Z A 1 -or-A2-or-A3-or-A X X -local and remote • G-or-G R X -Overload & Short Circuit FUNCTIONS ADD TO BASIC FUNCTIONS T an SHORT TIME L ua ls BASIC FUNCTIONS (X) Sensor Tapped Sensors tri Fixed Sensors (X) Long-Time Short-time Current Adjustable Setting Instantaneous (Multiple Pickup Short-time Pickup Pickup of Sensor (Multiple l't (Multiple (Multiple Delay Delay Current of Current of Sensor of Current <D <D ® Rating) Rating) (Seconds) Rating) (Seconds) Rating) (Seconds) (C) (C) (X) (X) fJt'���: Rating 1 00, 1 50, 225, 300 or 300, 400 600, 800 .E lec Frame Size Maximum Rating (Amps) ca TAB LE 1 2 M I C ROVERSATRI Pr"' TRIP C HARACTERI STI C S AKR-30 800 1 00, 1 50 , 225, 300, 400, 600, 800 300, 400, 600, 800 1 200, 1 600 300, 400, 600, 800 or 600, 800 1 200, 1 600 800, 1 200 1 600, 2000 1 600 AKRT-50 2000 800, 1 200, 1 600, 2000 AKR-75 3200 1 200, 1 600, 1 200, 1 600 2000, 3200 2000, 3200 AKR-1 00 4000 1 600, 2000, 1 600, 2000 3000, 4000 3000, 4000 ww w AKR-50 .5, .6, .7, .8, .85, .9, 95, 1 .0 (X) .8, .9, 1 .0, 1 . 1 ( C) 2.5, 5, 1 0, 21 1 .5, 2, 2.5, 3, 4, 5, 7, 9 ( C) 0.10, 0.22, 0.36 1 .5, 2, 2.5, 3, 4, 6, 8, 10 (X) " " " " " " " " " " " " " " " 1 Time delay shown at 600% of ampere setting at lower limit of each baRd. 2 Time delay shown at lower limit of each band. All pickup tolerances are ± 1 0% Ground Fault pickup not to exceed 1 200 amperes. Ground Fault Pickup (Multiple of Sensor Current Rating) Delay ® (Seconds) (X) .2, .25, .3, .35, .4, .45, .5, .6 (X) 0. 1 0, 0.22, 0.36 " " " " " " " " " " " " 1 .5, 2, 2.5, 3 , 4, 5, 7, 9 (X) 0.4 " " .2, .22, .24, .26, .28, .30, .34, .37 (X) " .2, .22, .24, .26, .28, .3 (X) C X � � current sensor setting current 61 .c om an ua ls SECTION 1 2- M icroVersaTrip TM Trip Device (Cont.) COMMON T ER M I NAL FIG . 85 - TYPICAL N EUTRAL SENSOR .E lec tri ca lP ar FIG. 83 - M I C ROVERSATRI Pr"' PHASE SENSORS tM TAPPED AMPERE RATING CONNECTIONS ww w FIG . 84 - 'H'-O PTION PHASE SENSOR 62 .c om S i n ce t h e neutral senso r is m o u n ted separately from the b reaker, a d i sconnect means i s req u i red to con nect its o u t p u t to the breaker. Fig. 86 s hows the b reaker and e q u i pment m o u nted 4th w i re second ary d i scon nect u sed w i t h t h e M i c roVersaTri p system. REPLACEM ENT OF CURRENT SENSORS ua ls 1 2.2.1 Referring to Fig. 87, replacement of MicroVersaTrip cur rent sensors is accompl ished as fol lows: a) Disconnect the programmer harness from the ter minal board , removi ng cable t ies as necessary. an b) At the rear of the breaker, remove the two Al len head screws to separate the stud connector from the contact pivot block. c) Loosen the c lamping bolt and remove the stud con nector. Lift out the sensor and its tap terminal board. tM A The sensor may be prevented from sli pping off the sen sor stud by adjacent accessories. If this exists, the sensor stud m ust be removed from the breaker base. The stud assembly is secured to the base with four bolts which are accessi ble from the rear of the breaker. B R EAKER MOUNTED - R I GHT S I D E AKR 30/30H 1 20 ± 1 0 in-lbs AKR 50/50H 470 ± 1 0 in-lbs AKRT 50/50H 470 ± 1 0 in-lbs e) When replac i ng the programmer harness to the phase sensors verify that the winding polarity is maintain ed , white wire with ring term inal to COMMON termi nal (right hand term inal, see Fig. 83). .E lec tri ca lP ar d) When replacing the stud connector, tighten the Al len head screw to 250 ± 10 i n-lbs. Tighten the clamping bolt as follows: ww w 8 EQU I PM E N T MOU NTED FIG. 86 - N E UTRAL SENSOR SECONDARY DISCONN ECT 63 .c om SECTION 1 2- MicroVersaTrip™ Trip Device (Cont.} When replacing a M icroVersaTrip flux shifter, AM P ex traction tool Cat. No. 455822-2 is req uired to remove the socket leads from the AM P connector. 1 2.4 TROUBLESHOOTING When malfunctionion is suspected, the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as: a) Breaker tripping in proper response to overcurrents or inci pient ground faults. b) Breaker remai ning in a trip-free state due to mechanical maintenance along its trip s h aft. c) Inadvertent shunt trip activations. WARNING: DO NOT CHA NGE TA PS ON THE CUR NOTE: For these single-phase tests, special connec tions must be employed for Micro Versa Trip breakers equipped with Ground Fault. Any single-phase input to the programmer circuit will genera te an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by a) Using the Ground Fault Defeat Cable as shown in Fig. 93. This special test cable energizes the pro grammer circuit in a self-cancelling, series-parallel connection so that its output is always zero. 2. Test the components of the MicroVersaTrip system using portable Test Set Type TVTS1 (Fig. 88). The ap pl icable test proced ures are detailed in instruction Book G EK-64464. The time-current characteristics for the M icroVersaTri p Trip Device are given in curves G ES-6 1 95 and G ES-6199. w .E lec tri ca lP ar REN T SENSORS OR A DJUST THE PROGRAMMER UNIT SET KNOBS WHILE THE BREAKER IS CAR RYING CURRENT. 1 . Conduct high-current, single-phase tests on the breaker using a high current-low voltage test set. ua ls The only d ifference between the MicroVersaTrip and SST flux shifter trip devices is the solenoid winding. Refer to Section 1 0.3 for details. Once it has been establ ished that the circuit breaker can be opened and closed normally from the test position, attention can be di rected to the tri p device proper. Testing is performed by either of two methods: an FLUX S H I FTER TRIP DEVICE tM 1 2.3 ww FIG. 87A - MICROVERSATRIP® COMPONENT WITH TAPPED SENSORS 64 FIG. 878 - RMS-9, EPIC MICROVERSATRIP® AND MVT-PLUS O R MVT-PM COMPONENTS WITH FIXED SENSORS .c om SECTION 1 2- MicroVersaTrip Trip Device (Cont.) 1 2.4.2 R ESISTANCE VALUES For use i n troubleshooting the M i croVersaTrip'M current sensors, the resistance of the tapped and fixed windings is g iven in Tables 13 and 1 4 respectively. Ampere Tap 7.0-8.2 1 00 1 50 225 300 300 400 600 800 600 800 1 200 1 600 800 1 200 1 600 2000 1 0- 1 2 1 5- 1 8 20-24 lP 20-24 27-32 42-50 58-68 ca 42-50 53-68 93- 1 09 1 30- 1 54 74-88 tri 1 1 6- 1 36 1 62-1 90 lec 2 1 0-246 TAB LE 1 4 - FIXED SENSO R R ESISTANCE VAL U ES .E Ampere Rating ww w 1 00 1 50 225 300 400 600 800 1 200 1 600 2000 If n u isance tripping is enco u ntered on any b reaker whose M icroVersaTrip components have p reviously demonstrated satisfactory performance via the TVTS1 Test Set, the sensors and their connections should be closely scrutin ized . After d isco nnecti ng the b reaker from all power sou rces. ar Resistance in Ohms Between Common and Tap Terminals tM TABLE 1 3 - TAPP E D SENSO R R ESISTAN CE VALUES When nu isance tripping occu rs on breakers equipped with the G round Fault trip element, a p robable cause is the existence of a false "g round" signal. As ind icated by the cabling d iagram of Fig. 90, each phase sensor is connected to su m m i ng ci rcu itry in the p rogrammer. Un der no-fault cond itions on 3-wi re load ci rcu its, the cu rrents i n this circu itry add to zero and no ground signal is developed . This cu rrent sum will be zero only if all th ree sensors have the same electrical charac teristics. If one sensor d iffers from the others (i .e. , d if ferent rating or wrong tap setting), the circuitry can p rod uce output sufficient to trip the breaker. S i m i larly, d iscontinu ity between any sensor and the p rogrammer unit can cause a false trip signal. ua ls 1 2.4.1 FALSE TRI PPI NG-B R EAKERS EQU I PP E D WITH G R O U N D FAU LT an FIG. 88 TEST SET, CAT. NO. TVTS 1 TM Resistance in Ohms Between Terminals 6.7-7.8 1 0- 1 2 1 5- 1 7 20-24 27-32 42-50 58-68 92- 1 08 1 29- 1 5 1 207-243 The coil resistance of the M icroVersaTrip flux shifter device i s approxi m ately 7 ohms. a) Check that all phase sensors are th e same type (am pere range) . b) E nsure that the tap settings on all 3-phase sensors are identi cal . c) Verify that the harness connections to the sensors meet the polarity constrai nts i ndicated by the cabl i ng diagram. d) On G rou nd Fault breakers serv i ng 4-wire loads, check that the neutral sensor is properly con nected (see cabling di agram Fig. 91 ) . In particu lar, ( 1 ) Verify that the neutral sensor has the same rating and tap setti ng as the phase s ensors. (2) Check conti nuity between the neutral sensor and its equi pment-mou nted secondary discon nect block. Also check for conti nuity from the breaker-mou nted neutral secondary disconnect block through to the female harness connector. (3) If The b reaker's lower studs con nect to the supply sou rce, then the neutral sensor must have its LOAD end con nected to the sou rce. See Fig. 92. (4) Ensure that th e neutral conductor is carrying only that neutral current associated with th e breaker's load cur rent (neu tral not shared with other loads) . e) If the preceding steps fail to identify the problem, then the sensor resistances should be measu red . Si nce the phase and neutral sensors are electrically identical , th eir tap-to-tap resistances should closely agree. See Tables 1 3 and 1 4 . 65 1 2.5 CABLI N G DIAG RAM S LEFT POLE CURRENT SENSOR ci> C A- A- A r 1}=-[-t -1 = =)= ==)= :������ E � s cpS � ----1-o-l--<: ; " COM .�::..:.:.:.l--..t -+--+ I I I I I I t A I I I �- - - - - - an I , PROGRAMMER U N IT FLUX SHIFT TRIP DEVICE ua ls cp A I \I _ rr r .c om SECTION 1 2- MicroVersaTrip ™ Trip Device (Cont.) _ _ _ _ _ _. tM HARNESS PROGRAMMER CONNECTOR CO N NECTOR (AM P 1 -350356- 9) LOAD lP ar FIG. 89. C A B L I N G DIAG RA M - M I C ROVERSATRI P™ WITH O UT G RO U N D FAU LT q,A q, c r 1}===)= -[-tl ==):. :������ E �I FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT �- - - - - - ca s q, s A- .A _A • I lec tri LEFT POLE CURRENT SENSOR I I L----�� I ww w .E I_ 66 rr r J LOAD PROGRAMMER CONNECTOR FIG. 90. C A B L I N G DIAGRAM-M I C ROVE RSAT R I P™ WITH G R O U N D FAU LT ON 3-W I R E LOAD r 1}=-t - t- l = =)===)= :����;� E �I LEFT POLE CURRENT SENSOR �- - - - - , I , A I I I 1 ua ls I I PROGRAMMER UNIT FLUX SH I FT TRIP DEV I CE :� NEUTRAL SENSOR DISCONNECT - -1 LINE I +C I an B +B .c om +A A A A HARNESS PROGRAMMER CON NECTOR NE R AMP 1 -350356-9 CON CTO tM 4-WIRE LOAD ar FIG. 91 . CABLI N G D IAGRAM-MIC ROVERSATR I P™ WITH G RO U N D FAU LT O N 4-WIRE LOAD 4-WIRE LOAD lP 1& , 1 1& 1 $ $- � - b . -: I �I }= = =)= ==)= PROGRAMMER r - UNIT - -- - ca BREAKER BACK FRAME I FLUX SHIFT TRIP DEVICE � ���--�-1-----+o+� �+o1 : tl tri ' I A I lec NEUTRAL I SENSOR 1 DISCONNECT I EQUIPMENT - MOUNTED NEUTRAL SENSOR ( I I �+ ,.--t-+'--"� >+ot----1'----+--+-<:>+-< IIN ww w .E L LOAD HARNESS PROGRAMMER CON NECTOR CON N ECTOR AMP 1 -350356-9 FIG. 92. CABLI N G DIAGRAM-M I C ROVERSATRIP WITH G R O U N D FAU LT O N 4-WI RE LOAD B R EAKER REVERSE FEED 67 I crt-< I o-+-< I o---t--< I o--1---< I o+-< I <>-t--< L I e>--t----< l o-t-< I o-+-< ' I o--+-< I o---t--< .!2 L _j - - -..-- 1 fo, 1 � / l Q' ], � 5 ./ -<' a 7 8 _w_ 0 �Q � 23 24 ...- 28 32 ./ � - I I I I I 0 I 0 � � I � I � I 4-o I ANY M ICROVERSATRIP PROGRAM MER UNIT WITH GROUND FAULT ELEMENT I �J I L -.___ I I I �� 0 -l L ar - -, I I TI1 I 0 - - - I 0 0 17 , r 4 � � � � I 0 19 ,___ ./ � 4 o-+--< L1---22 I a-+-< 23 I o-t-< 24 I � .. I a-+-< ..;;.1---Jj 28 I o-+---< � I o--l---< I .c om r 1 ..-� - - Device (Cont.) an \ PROGRAMMER UNIT GROU N D FAULT DEFEAT M O D U LE CAT. NO. TVTGD9 tM BREAKER HARNESS CONNECTOR & RMS-9 & Epic MicroVersaTrip™ ua ls SECTIO N 12- MicroVersaTrip ™ _ _ I I I _j ca lP FIG. 93. CABLI N G D IAG RAM WITH G R O U N D FAU LT DEFEAT M O DU LE I N SERTED BETWEEN B REAKER HARNESS AND M I C ROVERSATRIP PROG RAM MER U N IT-FOR U S E D U R I N G S I N G LE-PHASE, H I G H C U RRENT -LOW VOLTAG E TESTING. PROGRAMMER UNIT ww w .E lec tri �- - - - - - 68 YELLOW YELLOW YELLOW YELLOW YELLOW rr r HARNESS CONNECTOR PROGRAMMER CONNECTOR LOAD F I G. 94. PARTIAL CABLI N G D IAGRAM: 'H'-OPTION W I N D I N G C O N N ECTI O N S EQUIPMENT GROUND FAULT OVERLOAD PICKUP Jl 1r �----��-< BREAKER YELLOW , YELLOW �-+�+------------+<r+--< ��-c�-_���______� RED �-----1-G-t- RED GREEN GREEN �----+-i'J--1-< �-+-o--+----+-o-+--< �--t--rr-+-----i BLUE �---�-< --+-i� �-+-0-+------+-0-+--< BLUE l_ _ _ _ AMP 1 -350246-9 AMP 1 -350242-9 AMP 1 -350235-9 I I I I _ _ _j tM AMP 1 -350239-9 - - - -- -, I I I I I ua ls SHORT CIRCUIT { { MICRQ-VERSA TRIP PROGRAMMER an OVERLOAD REMOTE FAULT INDICATION CONNECTOR .c om PROGRAMMER SECONDARY DISCONNECT lP ar FIG. 95. CABLING D IAG RAM-REMOTE FAU LT I N D ICAT ION ca PROGRAMMER SECONDARY DISCONNECT EQUIPMENT {+ - -, +'---+-U-+-< tri SHORT TIME INPUT BREAKER MICRO-VERSA TRIP PROGRAMMER _ { { .E lec GROUND FAULT INPUT GROUND FAULT OUTPUT + _ �--+-ZH--< - �--hr,�-< ���--1-� ---�) + AMP 1 -350239-9 AMP 1 -35024 6-9 _ __ _j ww w FIG. 96. CAB L I N G DIAGRAM-ZON E SELECTIVE I N TERLOCK 69 ---cJ----- ar XFMR Each target pops out when its associated trip element operates to trip the breaker. After a trip, the popped target must be reset by hand. However, neglecting to reset does not affect normal operation of any trip element or prevent the breaker from being closed. ca lP N ua ls Fig. 98 shows a typical RMS-9/Epic M icroVersaTrip "' programmer unit. Like the MicroVersaTri p®, the RMS-9 Epic MicroVersaTri p@ provides the comparison basis for overcurrent detection and del ivers the energy necessary to tri p the breaker. It contai ns a programmable micro electronic processor which incorporates nine adjustable time-cu rrent functions, three mechanical fault indicators (local and remote), a long-time picku p LED indicator (local and remote) and a, zone selective interlocking function. All adj ustable programmer functions are automatic and self contained req ui ring no external relaying , power supply or accessories. See Table 1 5 for trip functions available and Table 1 6 for trip function characteristics. A detailed description of each trip function is given in publ ication GEK97367. The optional fau lt trip indicators are similar to the MicroVersaTri p® indicators. They are mechan ical pop out type for i d e ntify i n g overload or s h o rt c i rc u i t over-currents faults when breakers are ordered without i ntegral g round fault protection. They are also available to identify overload , short circuit and g round fault trips for breakers supplied with integral ground fault protection. an 1 3.1 PROGRAMMER U N IT 1 3.1 .1 FAULT TRIP I N DICATORS tM The RMS-9/Epic MicroVersaTri p® is a sol id-state, di rect-acting, self-powered tri p d evice system. The RMS-9 system consists of the RM S-9 programmer, cu rrent sen sors, and a flux shifter trip device. Fig. 97 shows a block diag ram of the system. .c om SECTION 1 3-RMS-9 & E p ic MicroVersaTri p ® tri TO +FLUX SHIFTER .E lec SWITCH ww w FIG. 97 - RMS-9 BLOCK DIAGRAM 70 FIG. 98 - RMS-9 & EPIC MICROVERSATRIP® PROGRAMMER & Epic MicroVersaTrip® (Cont . ) .c om SECTIO N 1 3-RMS-9 1 3.2 CURRENT SENSORS ar 1 3. 1 .2 RMS-9 & EPIC MICROVERSATRI P ® INSTALLATION tM FIG. 99 - PROGRAMMER SECONDARY CONNECTOR EPIC MICROVERSATRIP® an ua ls The current sensors supply the power and signal i n put nec essary to o p erate the tri p system . L i k e the M icroVersaTrip"' , the RMS-9 and Epic MicroVersaTri p ' uses a phase and neutral sensor. Fig. 1 0 1 shows the phase sensors. See Section 1 3 .5 for cabling d iagrams. tri I nstallation .is as follows: ca lP The program mer mounts to the upper left of the breaker as shown in Fig. 1 00. It mounts to the bracket assem b ly shown in Fig. 82. Referring to Fig. 82 , the guid e p ins mate with the hole on either side of the programmer connector. They provide the n ecessary alignment for the connector engagement. The locking lever engages with the pin wh ich is assem b led to the programmer frame and secures the program mer to the mounting bracket. lec a. I nsert the guide pins into the holes and p ush on the programmer, engaging the connectors. b. Th e locking lever is released , securing the program mer. c. Verify that the locking lever did engage the program mer pin. FIG. 1 00 - AKR-70-30 The fixed phase sensors have a polarity associated with their windings. Their COM MON terminal is the right hand termi nal as shown in Fig. 1 0 1 . A white wire with a terminal will be con nected to this COMMON term inal. All phase sensors must be correctly wired for the programmer summing circuit to function properly. The phase sensors are available with an additional wi nding. This winding is brought out to separate flag terminals. These phase sensors are used when the hi level instantaneous RMS-9 option ( H '-option) is required . Fig. 1 0 2 shows an ' H ' -option phase sensor. When the ' H ' -option phase sensor is i nstalled , there are four leads connected to it. There is no polarity associated with the special winding connection . Fig . 1 0 2 shows the connec tions for the additional ' H ' -option windings. ' .E To remove the program mer: ww w a. Pull out locking lever, which will release the program mer pin. Remove the programmer. 71 .c om SECTION 1 3-RMS-9 & Epic MicroVersaTrip® TAB L E 1 1 T R I P FU NCTIONS AVAILABL E Optional Features ADD TO BASIC FUNCTIONS STD.-or-S-or-H-or-M • TIME • • • SHORT • TIME • I NSTANTA- • N E OU S • • G ROUND FAULT • • X X X X X X Adj Long-Time Delay Long-Time Timing Light X X X X X X X X Adj Short-Time Pickup X X X Adj Short-Time Delay X X X X Short-Time l2t Switch<D X Adj Instantaneous Pickup X X Adj H i g h Range Instantaneous X Adj Ground Fau l t Pickup -1 PH, 2-W-3PH, 3/4-W - Ground Return -Overload & Short Circuit -local only -local and remote -local only<2> -local and remote X X X X X X X ca -Short Time<D 1 Short-Time Delay is required 2 Standard when Ground Fault specif ied 3 Ground Fault required X lP Zone Selective Interlock -Ground Fault� X ar I -0/L, S/C and Ground Fault • I X X Trip Indication Targets FUNCTIONS A 1 -or-A2-or-A3-or-A X Adj Ground Fault Delay OTH ER X X Remote Long-Time Timing Light Z1 -or-Z2-or-Z G-or-GR an • LONG Adjustable Current Setting Adj Long-Time Pickup T tM • L ua ls BASIC FUNCTIONS tri TABLE 1 2 - RMS-9 AND EPIC MICROVERSATRIP@ CHARACTERISTICS Long-Time Max. Amp Rating 800 Sensor Rating (Amps) (S) 1 50, 400, 800 .5, .6, .7, .8, .9, .95, 1 .0, 1 . 1 Fixed at .5, .6, .7, .8, .9, .95, 1 .0, 1 .1 Fixed at .E AKR-30 AKR-30H AKR-50 2000 w AKRT-50 1 600 Time delay shown at 600% of c u r rents setting at lower l i m i t o f b a n d . ww CD 72 Pick up (Mult. of Current Setting) (C) Short-Time lec Frame Size Current Setting (Mull. of Rating Plug Amps) (X) 800, 1 600 2000 .5, .6, .7, .8, .9, .95, 1 .0, 1 .1 1 .0 of Current Setting 1 . 0 of Current Setting Fixed at 1 .0 of Current Setting @ Time delay shown at lower l i mit of each band. All pick up tol erances are ± 1 0% . Delay ,l (Sec.) Pick up (Mull. of Current Setting) (C) 2.4, 4.9, 9.8, 20 2.4, 4.9, 9.8, 20 2.4, 4.9, 9.8, 20 Delay (Sec.) Adjustable lnstantaneous Pick Up w/o ST (Mull. of Rating Plug Amps) (X) Adjustable lnstantaneous Pick Up with ST (Mull. of Rating Plug Amps) (X) 1 .5, 2, 3, 5, 7, 9, 1 0 1 .5, 2, 3, 5, 7 , 9, 1 0, 1 3 12T in:�1 .40 1 .5 , 2.0, 2.5, 3.0, 4.0, 5.0, 7.0, 9.0 12T out:<?', Triple Selective Trip Fixed High Range Instantaneous .4, .6, .8, 1 .0 NA .2, .25, .3, .35, .4, .45, .5, .6 NA .2, .25, .3, .35, .4, .45, .5, .6 ,, 5 15 1 .5, 2 , 3 , 5, 7, 9, 1 0 . 1 0, .21, .35 X = Rating plug amps S = Sensor amp rating C = Current setting Ground Fault High Range lnstantaneous (Mult. of Frame Short-time, 3 Rating) (H) 1 .5, 2, 3, 5, 7 , 9 , 10, 1 3 .4, .6, .8, 1 .0 15 Pickup (Mull. of Sensor Amp Rating) (S) Delay w/ 12T (Sec.) Delay ·c w/o 12T (Sec.) .1 0, .21 , .35 .44 at 200% of pick up at lower . 1 0, .21 , .35 limit of 1 .5, 2 , 3 , 5, 7, 9, 1 0 1 .5, 2, 3, 5, 7 , 9 , 1 0, 1 3 .4, .6, .8, 1 .0 NA 15 @ Triple selective trip is s t a n d a r d w h e n l o n g - t i me/s h o rt time only i s required. ® Time delay shown at l o w e r l i m i t of each band. Ground fault pick u p not to exceed 1 200 amps. .2, .25, .3, .35, .4, .45, .5, .6 band . 1 0, .21 , .35 X = Rating plug amps S = Sensor amp rating C = Current setting H = Short-time rating .c om ua ls an tM FIG. 1 03 - TYPICAL N EUTRAL SENSOR ar Fig. 1 03 shows the neutral sensor. The neutral sensor is req uired when i ntegral grou nd fault protection is used on single phase-three wire or three phase-four wire sys tems. It is inserted into the neutral conductor and therefore is separately mounted in the cable or bus compartment. The outputs of the phase sensors and neutral sensor are connected to a programmer circ uit wh ich sums these values. The total val ue will remain zero as long as there is no ground current flowi ng. See cable d iagram in Fig. 1 07. The neutral sensor is an electrical duplicate of the phase sensor. Therefore, when phase sensors are charged the neutral sensor m ust be correspondingly changed. .E lec tri ca lP FIG. 1 01 - RMS-9 PHASE SENSORS ww w FIG. 1 02 - 'H'-OPTION PHASE SENSOR 73 & .c om SECTIO N 1 3-RMS-9 Epic M icroVersaTrip ® Device (Cont . ) Since the neutral sensor is mounted separately from the breaker, a d iscon nect means is required to connect its output to the breaker. Fig. 86 shows the breaker and equi pment mounted 4th wire secondary disconnect used with the R MS-9 system . 1 3.2.1 R EPlACEMENT OF CURRENT SENSORS 2 . Test the components of the R MS-9 system using portable Test Set Type. The applicable test procedures are detailed in i nstruction Book G E K-97367. The time-current characteristics for the R MS-9 & Epic M icroVersaTrip® Device are g iven i n curves G ES-6229 and G ES-6228. ua ls Referring to Fig. 87 B , replacement of RMS-9 & Epic MicroVersaTrip current sensors is accompl ished by the same procedure as the M icroVersaTrip® current sensors. 1 3.3 FLUX SHIFTER TRIP DEVICE an T h e o n l y d iff e r e n c e b etween t h e R M S - 9/E p i c M icroVersaTrip® and SST flux shifter trip devices i s the solenoid winding. Refer to Section 1 0. 3 for details. tM When replacing a RMS-9/Epic M icroVersaTrip@ flux shifter, AMP extraction tool Cat. No. 455822-2 is required to remove the socket leads from the AMP connector. 1 3.4 TROUBLESHOOTING ar When malfunctioning is suspected , the first step in troubleshooting is to examine the circuit breaker and its power system for abnormal conditions such as: lP a) Breaker tri p ping in proper response to overcurrents or incipient ground faults. b) B reaker remaining in a tri p-free state due to mechanical mai ntenance along its trip shaft. ca c) Inadvertent shunt tri p activations. 1 3.4.1 RESISTANCE VALUES For use in troubleshooting the R MS-9 current sensors, the resistance of the fixed windings is g iven in Table 1 5 . Once it has been establ ished that th e circuit breaker can be o pened and closed normally from the test position , attention can be d irected to the trip device proper. Test ing is performed by either of two methods: TABLE 1 5 - FIXED SENSOR RESISTANCE VALUES tri WARNING: Do not adjust the programmer unit set knobs while the breaker is carrying current. lec 1 . Conduct high-current, single-phase tests on the breaker using a high current-low voltage test set. NOTE: For these single phase tests, special connec .E tions must be employed for RMS-9 breakers equipped with Ground Fault. Any single-phase input to the programmer circuit will generate an unwanted "ground fault" output signal which will trip the breaker. This can be nullified either by ww w a) Using the Ground Fault Defeat Cable as shown in Fig. 93. This special test cable energizes the pro grammer circuit in a self-cancelling, series-parallel connection so that its output is always zero. 74 FIG. 1 04 - TEST SET, CAT. NO. TVRMS Ampere Resistance in Ohms Rating Between Terminals 1 50 400 800 1 600 2000 1 0- 1 2 27-32 58-68 1 29-1 5 1 207-243 The coil resistance of the R MS-9 & Epic MicroVersaTrip ® device is approximately 7 ohms. .c om 1 3.5 CABLING DIAGRAMS 1 3.4.2 FALSE TRIPPING - BREAKERS EQU IPPED WITH GROUND FAULT q,A I tM If n uisance tri p ping is encountered on any breaker whose RMS-9 or Epic MicroVersaTrip components have previously demonstrated satisfactory performance via the Test Set, the sensors and their connections should be closely scrutinized. After disconnecting the breaker from all power sources. ar lP c) Verify that the harness connections to the sensors meet the polarity constraints indicted by the cabling diagram . ca ( 1 ) Verify that the neutral sensor has the same rating as the phase sensors. , PROGRAMMER UNIT - ----, ,, I I _ _ _ _ _ HARNESS PROGRAMMER CONNECTOR CONNECTOR (AM P 1 -350356-9) LOAD s q, A q, c A A A r t)=-=1t- : =)= ==)= t������E �I LEFT POLE CURRENT SENSOR q, s FLUX SHIFT TRIP DEVICE PROGRAMMER UNIT , - --- -- • I lec tri (2) Check continu ity between the neutral sensor and its eq uipment-mounted secondary d isconnect block. Also check for continuity from the breaker-mounted neutral secondary d iscon nect block through to the female har ness connector. (3) If the b reaker's lower studs connect to the supply source, then the neutral sensor must have its LOAD end connected to the source. See Fig . 1 08. .E (4) Ensure that the neut ral cond uctor is carrying only that neutral current associated with the breaker load current (neutral not shared with other loads) . ww w 3) If the preceding steps fai l to identify the problem, then the sensor resistances should be measured . Since the phase and neutral sensors are electrically i dentical, their tap-tO-tap resistances should closely agree. See Table 1 5. j FIG. 1 05 - CABLING DIAGRAM - RMS-9 & EPIC MICROVERSATRIP® WITHOUT GROUND FAULT a) Check that all phase sensors are the same type (ampere range). d) On Ground Fault breakers serving 4-wire loads, check that the neutral sensor is properly connected (see cabling diagram Fig. 1 07). I n particular, FLUX SHIFT TRIP DEVICE ua ls LEFT POLE CURRENT SENSOR q, c r t)=-==)= 1- t1 ==)= t����� E � s q, s ;__ ;__ ;__ an When nu isance tripping occurs on b reakers eq uipped with the Ground Fault tip element, a probable cause is the existence of a false "ground" signal . As indicated by the cabling d iagram of Fig. 1 06, each phase sensor is con nected to summing circuitry in the programmer. U nder no-fault conditions on 3-wire load circuits, the currents in this circuitry add to zero and no ground sig nal is devel oped. This current sum will be zero only if all three sensors have the same electrical characteristics. If one sensor d iffers from the others (i .e., different rating) the circuity can produce output s ufficient to trip the breaker. Simi l a r l y , d i sc o n t i n u ity between any s e n s o r a n d t h e programmer unit can cause a false tri p signal. HARNESS CONNECTOR (AMP 1 -3503 56 -9) LOAD PROGRAMMER CONNECTOR FIG. 1 06 - CABLING DIAGRAM - RMS-9 & EPIC MICROVERSATRIP® WITH GROUND FAULT ON 3-WIRE LOAD 75 PIN No. 5 Zone PROGRAMMER UNIT FLUX SHIFT TRIP DEVICE 32 Selective �- - - - - Interlock 6 7 8 28 I � ��:+7>+o+--+--+----4 \ I f<o---j--o� )-f-<+--+-1-+-+---f-<>-k•(--k>-J I L N I -+-----+<>+< -"i LOA :� ,. EOUIPM NT MOUNTED NEUTRAL SENSOR rr1 ��ig ��� 1-350356-9 C AMP ---v--4 -WIRE LOAD R Zone - Inputs + Zone - Outputs - + 9 Spare 10 vc VA Epic MVT 1 VB 4 PROGRAMMER CONN ECTOR 2 3 NOTE LOCATION OF PIN 24 Ret + 24 VDC #1 TIT T t t� lP ar tM FIG. 1 07 - CABLING DIAGRAM - RMS-9 & EPIC M I CROVERSATRIP ® WITH GROUND FAU LT ON 4-WIRE LOAD Hom net an 12 I + ua ls 11 .c om Socket '-....! I LEFT POLE 17 CURRENT SENSOR � •II V EUTRAL NEUTRAL :I It I I : ! COM RED WHITE A I � EQUIPMENT -MOUNTED NEUTRAL SEN I (t� I L 1 1N Dl LOAD CT J � co I �� H LOAD N !-=- 'a H _I '-4 U NIT �- - - - - � I C02 I PROGRAMMER I 28 18 I 22 19 I .E lec �g���� - -1 - � J===)= s=)- r- FLUX SHIFT TRIP DEVICE tri BREAKER BACK FRAME ca 4-WIRE LOAD I �� 'c I •• - -- •• •c I A� 24 I v -J;; -J;; J _ : fffi; 23 r 17 I w ww I I I _ _ _ _ _ __, HARNESS PROG RAMMER CONNECTOR CON NECTOA AMP 1-350356-9 FIG. 1 08 - CABLING DIAGRAM - RMS-9 & EPIC MICROVERSATRIP® WITH GROUND FAULT ON 4-WIRE LOAD - BREAKER REVERSE FEED 76 I I I I I I I I FIG. 1 09 - PROGRAMMER SECONDARY CONN ECTOR PIN LOCATIONS FOR ZON E SELECTIVE I NTERLOCK AND EPIC MVT .c om SECTION 1 4-MicroVersaTrip® Plus and M icro Versa Tri p® PM Trip U nits Th e MVT-Pius/MVT -PM is a solid-state direct-acting self-powered trip device system. The system consists of the MVT-Pius/MVT-PM programmer, current sensors and a flux shifter trip device. Figure 1 1 0 shows location of features on programmer. See user manual G EH-589 1 A. an ar tM MicroVersaTrip"" Plus Trip Unit MicroVersaTri p@ Plus trip un its utilize a digital, LCD display with a four-button keypad to provide local set-up and readout of trip settings. A 3-phase ammeter and trip i nd icators are standard, as is a clear plastic cover with provisions for sealing to allow tamper resistant installa tion. The trip unit digitally measu res the current waveform in each phase to determ ine the true RMS value of the current, regardless of the waveshape. M icroVersaTri p" Plus trip u nits provide accurate, predictable overload and short circuit protection for distribution systems that in clude ac and de variable speed d rives , rectifiers, induction heatin g , and other loads that cause high harmonic distor tion as well as standard circuit. They provide maximum breaker-to-breaker selectivity and custom load protec tion . Short time and ground fault functions i nclude the flexibi lity of coordination with or without an l2t ramp and are also available with high range instantaneous. ua ls 1 4.1 TRI P UNIT ww w .E lec tri ca lP MicroVersaTrip® PM Trip U nit The M icroVersaTrip® PM trip unit adds power manage ment system capability, advanced metering, and protective relays to the basic fu nctions of the MicroVersaTrip" Plus. MicroVersaTrip® P M trip u nits communicate d i rectly on the GE POWER LEADER'" communications bus. FIG. 1 1 0 Power Requirements A small amount of power is necessary to energize the liquid crystal d is play (LCD) during setup, for viewing breaker status, and for metering displays. M icroVersaTrip® PM trip units req uire external 24 Vdc control power for operation. The fou r sources of such power are the following. Breaker current sensors provide sufficient power to energize the LC D when at least 20% of the sensor's am pere rating is flowi ng. • Flow of current • 2 4 Vdc control power- Breakers with MicroVersaTrip® • Micro Versa Trip Test Kit - The MicroVersaTripc' Test • Micro Versa Trip ba ttery pack - T h e p o rt a b l e - P M trip u n its are supplied with external 2 4 Vdc power that, whenever present, energizes the LC D . Some breaker models that are configured for MicroVeraTri p Plus trip u n its may b e optionally equ i pped t o accept an external 24 Vdc s u pp ly. Kit, Cat No. TVRMS, contains a 24 Vdc power supply. The LCD is energized whenever the test kit jack is p lugged i nto the test receptacle on the rating plug. M icroVersaTrip@ battery pack contains a 24 Vdc power source and a jack. The LCD is energized when the jack is plugged i nto the rating plug test receptacle. 77 .c om SECTION 1 4-MicroVersaTrip® Plus and MicroVersaTrip® PM Trip U nits 1 4.2 TESTING ua ls Testing of M icroVersaTrip® Plus and M icroVersaTrip® P M tri p units may be performed with the tri p unit installed in the circuit breaker, the rating plug installed in the trip unit, and the breaker carrying c urrent. The test set catalog num ber is TVRMS. The test set plugs into the test socket of the rating plug. Test set TVRMS may also be used for M icroVersaTrip® RMS-9 and Epic MicroVersaTri p® tri p units. Refer to the Maintenance and Troubleshooting section for additional details. an 1 4.3 PRODU CT STRU CTURE Figure 1 1 2 shows the 36-p in plug that connects either trip unit to the circuit breaker and eq uipment circuity. This plug is called the trip unit d isconnect. FIG. 1 1 1 - FRONT VIEW OF MICROVERSATRI P ® PM TRIP U N IT ar CAUTION: Removal of a trip unit from its breaker m ust be performed with the breaker in the OPEN or TRIPPED position. Draw-out breakers should be racked out first. tM M icroVersaTrip® Plus and MicroVersaTrip® PM tri p units are removable. Figures 1 1 1 and 1 1 2 contain front and rear views of a M icroVersaTrip PM trip unit. lP CAUTION: Do not attempt to operate the breaker without its assigned trip unit. Installation of an incorrect trip unit may result in unsafe operation of the breaker. ca CAUTION: Removal of the rating plug while the breaker is carrying cu rrent reduces the breaker's current-carrying capacity to approximately 25% of the current sensor rating. This may result in un desired tripping. CAUTION IW'Ofi;TAftt IN$TIWCTIQfiiS TO 1iN$UIII PIIOf't!l � AmC'fiON ... ...... ... . .... ,.. .... ,�,-·....,.�>�4< ,.•.,• ...,.,.. """""'"''""'"'"'""'""""- ' "' '""'""" ww w .E lec tri NOTE: Trip u n its a s received may have settings that are u ndesirable for the specific application. Ensure that settings are appropriately adjusted before energizing. 78 FIG. 1 1 2 - REAR VIEW OF M ICROVERSATRIP® PM TRIP U N IT .c om SECTION 1 4-MicroVersaTrip™ Plus and M icroVersaTrip™ PM Trip U n its 1 4.4 TRIP UNIT REMOVAL AND REPLACEMENT Socket No. 6 Selective Interlock 7 8 11 12 MVT - P M ar - + - Zone Inputs Zone Outputs - + Hom net 9 Spare 10 vc 4 VA VB 1 2 3 24 + Ret 24 VDC NOTE LOCA fiON OF PIN # 1 tri ca lP + ua ls 5 Zone tM WARNING: Always de-energize Type AKR circuit break ers before attempting to remove or replace the trip unit. Because of the exposed location of the trip unit, failure to observe this warning may result i n eq uipment damage or personal injury, including death. Class an The programmer mounts to the u pper left of the breaker as shown in Fig. 1 1 5 . It mounts to the bracket assembly shown in Fig. 82 . Guide pins on the bracket mate with the holes on either side of the programmer connector. They provide the necessary al ignment for the con nector en gagement. The locking lever engages with the pin which is assembled to the programmer frame and secures the programmer to the mounting bracket. When a trip unit is replaced , the locking arm snaps back i nto place to indi cate proper alig nment. ww w .E lec FIG. 1 1 3 PROGRAMMER SECONDARY CONNECTOR FIG. 1 1 4 PROGRAMMER SECONDARY CONNECTOR PIN LOCATIONS FOR ZONE SELECTIVE INTERLOCK AND MVT-PM 79 .c om tM an ua ls SECTION 1 4-MicroVersaTrip® Plus and MicroVersaTrip® PM Trip U nits FIG. 1 1 5 FIG. 1 1 6 The fixed phase sensors are avai lable with an add itional winding. Th is winding is brought out to separate flag term inals. These phase sensors are used when the hi level instantaneous ( ' H ' -option) is req u ired. Fig. 1 1 7 shows an ' H ' -option phase sensor. When the ' H ' -option phase sensor is instal led , there are four leads connected to it. There is no polarity associated with the ' H ' -option windings. lP 1 4.5 PHASE C U RRENT SENSORS ar TAPPED ww w .E lec tri ca The current sensors supply the power and signal input necessary to operate the tri p system Fig. 1 1 6 shows the fixed phase sensors available. The sensors have a polar ity associated with their windings. The common term inal of the sensor is the right hand terminal. A white wire with a push-on term inal will be connected to this common terminal . All phase sensors must be correctly wired for the programmer summing circu itry to function properly. 80 FIG. 1 1 7 'H'-OPTION PHASE SENSOR .c om SECTIO N 1 4-MicroVersaTrip® Plus and MicroVersaTrip® PM Trip Units CAUTION: Neutral current sensors are requ i red for three phase, four-wire systems. When the trip unit is connected to a three-phase, three-wire system, the neutral sensor terminals are left open. Do not short any neural current sensor termi nals in a three-phase, three-wire system, as this could result in damage to or malfunction of the electrical system. 1 4.7 RATING PLUG REMOVAL AND RE PLACEMENT CAUTION: Removal of the rating plug while the breaker is carrying current reduces the breaker's current-carrying capacity to approximately 25% of the current sensor rating. ua ls 1 4.6 NEUTRAL C UR RENT SENSORS The outputs of the phase sensors and neutral sensor are connected to a programmer circuit which sums these values. The total value will remain zero as long as there is no ground current flowing. Rejection featu res are provided on all rating plugs to prevent appl icat ion mismatches. Never force a rating plug into place. Refer to Table 1 6 to find the appropriate rating plugs for each sensor rating and breaker frame. tM an Fig. 1 1 8 shows the neutral sensor. The neural sensor is req uired when integral g round fault protection is used on single phase-three wire or three phase-four wire systems. It is inserted into the neutral cond u ctor and therefore is separately mounted in the cable or bus compartment. Interchangeable rating p lugs are removed with a Rating Plug Extractor, Catalog No. TRTOOL. (Su itable equiva lents are commercially available as "integrated circuit (DIP) extractors . ") G rasp the rating plug tabs with the extractor and pull the plug out. Be sure to g rab the tabs and not the front cover of the rati ng plug, or the plug may be damaged . The neutral sensor is an electrical d u plicate of the phase If a replacement rating plug has a d ifferent rating than sensor. Therefore, when phase sensors are changed, the the plug that was removed , follow the appropriate setup neutral sensor must be correspondingly be changed . procedure G EH -589 1 A to enter the new rati ng. .E lec tri ca lP ar Do not attem pt to use a rating plug from a Spectra RMS breaker or a MicroVersaTri p® P l us or M icroVersaTrip"' PM Trip Unit. ww w FIG. 1 1 8 TYPICAL NEUTRAL SENSOR Cat. No. TR48 1 50 TR48200 TR48225 TR48250 TR48300 TR48400 TR88300 TR88400 TR88450 TR88500 TR88600 TR88700 TR88800 TR1 68600 TR1 68800 TR1 681 000 TR1 681 1 00 TR 1 681 200 TR1 681 600 TR208750 TR208800 TR2081 000 TR208 1 200 TR2081 500 TR2081 600 TR2082000 TABLE 1 6 Sensor Plug Breaker Rating, Amps Rating Frames 400 1 50 200 225 250 300 400 AKR30 , AKR30H 800 300 400 450 500 600 700 800 AKR30, AKR30H, AKR50S, AKR50H 1 600 600 800 1 000 1 1 00 1 200 1 600 AKR50 , AKR50H 2000 750 800 1 000 1 200 1 500 1 600 2000 AKRT50H 81 .c om SECTIO N 1 4-MicroVersaTrip® Plus and M icroVersaTrip® PM Trip U nits 1 4.8 TRIP U NIT FUNCTIONS Protection - Long-time protection • • - Zone-selective interlock, with g round fault only or with both g round fault and short time Additional optional functions avai lable only with P M style trip un its are as follows. P M style trip u nits requ i re the presence of external control power. • - Communication and metering Status - Communication and p rotective relaying - Trip target - Communication, metering, and protective relaying M etering display • - Phase current (selectable among phases) - Switchable instantaneous and g round-fault protection - Real power (kW/MW) lP ca tri lec .E w ww 82 - Total power (kVAIMVA) - Frequency (Hz) - Protective relays (undervoltage, overvoltage, voltage unbalance, current unbalance, and power reversal} ar - High-range (fixed) instantaneous overcurrent protection - Energy (kWh/MWh} tM Adjustable protection - Short-time protection, with or without 1 2T Metering and protective-relaying functions - Voltage The optional functions avai lable on both types of trip unit are as follows: • Configurations - Instantaneous protection an • - Grou nd-fault protection, with or without 1 2T ua ls MicroVersaTrip® Plus and MicroVersaTrip® P M trip units have specific standard and optional functions. All trip units share a series of interchangeable rating plugs. The standard functions for both types of trip unit are as follows: